Kawasaki Prairie 360, KVF 360 All Terrain Vehicle Service Manual

Below you will find brief information for All Terrain Vehicle Prairie 360, All Terrain Vehicle KVF 360. This document provides detailed instructions for servicing and maintaining your ATV. It is designed for use by trained mechanics, but it also contains enough basic information to be useful to owners who want to perform their own basic maintenance and repair work. The manual covers a wide range of topics, including engine maintenance, transmission, final drive, suspension, brakes, steering, and electrical system.
PDF
Document
PRAIRIE 360
KVF 360
All Terrain Vehicle
Service Manual
All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any
form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of
Quality Assurance Department/Consumer Products &amp; Machinery Company/Kawasaki Heavy Industries, Ltd., Japan.
No liability can be accepted for any inaccuracies or omissions in this publication, although every possible care has been
taken to make it as complete and accurate as possible.
The right is reserved to make changes at any time without prior notice and without incurring an obligation to make
such changes to products manufactured previously. See your dealer for the latest information on product improvements
incorporated after this publication.
All information contained in this publication is based on the latest product information available at the time of publication.
Illustrations and photographs in this publication are intended for reference use only and may not depict actual model
component parts.
&copy; 2002 Kawasaki Heavy Industries, Ltd.
Second Edition (1) : Jun. 20, 2002 (K)
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LIST OF ABBREVIATIONS
A
ABDC
AC
ATDC
BBDC
BDC
BTDC
C
DC
F
F
ft
g
h
L
ampere(s)
after bottom dead center
alternating current
after top dead center
before bottom dead center
bottom dead center
before top dead center
degree(s) Celcius
direct current
farad(s)
degree(s) Fahrenheit
foot, feet
gram(s)
hour(s)
liter(s)
lb
m
min
N
Pa
PS
psi
r
rpm
TDC
TIR
V
W
pounds(s)
meter(s)
minute(s)
newton(s)
pascal(s)
horsepower
pound(s) per square inch
revolution
revolution(s) per minute
top dead center
total indicator reading
volt(s)
watt(s)
ohm(s)
Read OWNER’S MANUAL before operating.
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EMISSION CONTROL INFORMATION
To protect the environment in which we all live, Kawasaki has incorporated crankcase emission (1) and exhaust emission
(2) control systems in compliance with applicable regulations of the California Air Resources Board.
1. Crankcase Emission Control System
A sealed-type crankcase emission control system is used to eliminate blow-by gases. The blow-by
gases are led to the breather chamber through the crankcase. Then, it is led to the air cleaner.
Oil is separated from the gases while passing through the inside of the breather chamber from the
crankcase, and then returned back to the bottom of crankcase.
2. Exhaust Emission Control System
The exhaust emission control system applied to this engine family is engine modifications that consist
of a modified carburetor and an ignition system having optimum ignition timing characteristics.
The carburetor has been calibrated to provide lean air/fuel mixture characteristics and optimum fuel
economy with a suitable air cleaner and exhaust system.
A maintenance free ignition system provides the most favorable ignition timing and helps maintain a
thorough combustion process within the engine which contributes to a reduction of exhaust pollutants
entering the atomosphere.
The Clean Air Act, which is the Federal law covering motor vehicle pollution, contains what is commonly referred to as
the Act’s &quot;tampering provisions.&quot;
&quot;Sec. 203(a) The following acts and the causing thereof are prohibited...
(3)(A) for any person to remove or render inoperative any device or element of design installed on or
in a motor vehicle or motor vehicle engine in compliance with regulations under this title prior to
its sale and delivery to the ultimate purchaser, or for any manufacturer or dealer knowingly to
remove or render inoperative any such device or element of design after such sale and delivery
to the ultimate purchaser.
(3)(B) for any person engaged in the business of repairing, servicing, selling, leasing, or trading motor
vehicles or motor vehicle engines, or who operates a fleet of motor vehicles knowingly to remove
or render inoperative any device or element of design installed on or in a motor vehicle or motor
vehicle engine in compliance with regulations under this title following its sale and delivery to the
ultimate purchaser...&quot;
NOTE
The phrase &quot;remove or render inoperative any device or element of design&quot; has been generally
interpreted as follows:
1. Tampering does not include the temporary removal or rendering inoperative of devices or
elements of design in order to perform maintenance.
2. Tampering could include:
a. Maladjustment of vehicle components such that the emission standards are exceeded.
b. Use of replacement parts or accessories which adversely affect the performance or
durability of the vehicle.
c. Addition of components or accessories that result in the vehicle exceeding the standards.
d. Permanently removing, disconnecting, or rendering inoperative any component or element
of design of the emission control systems.
WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL LAW, THE VIOLATION OF
WHICH IS PUNISHABLE BY CIVIL PENALTIES NOT EXCEEDING $10,000 PER VIOLATION.
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PLEASE DO NOT TAMPER WITH NOISE CONTROL SYSTEM
(US MODEL only)
To minimize the noise emissions from this product, Kawasaki has equipped it with effective intake and exhaust silencing
systems. They are designed to give optimum performance while maintaining a low noise level. Please do not remove
these systems, or alter them in any which results in an increase in noise level.
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Foreword
This manual is designed primarily for use by trained
mechanics in a properly equipped shop. However, it
contains enough detail and basic information to make
it useful to the owner who desires to perform his own
basic maintenance and repair work. A basic knowledge
of mechanics, the proper use of tools, and workshop
procedures must be understood in order to carry out
maintenance and repair satisfactorily. Whenever the
owner has insufficient experience or doubts his ability to
do the work, all adjustments, maintenance, and repair
should be carried out only by qualified mechanics.
In order to perform the work efficiently and to avoid
costly mistakes, read the text, thoroughly familiarize
yourself with the procedures before starting work, and
then do the work carefully in a clean area. Whenever
special tools or equipment are specified, do not use
makeshift tools or equipment. Precision measurements
can only be made if the proper instruments are used,
and the use of substitute tools may adversely affect safe
operation.
For the duration of the warranty period, we recommend that all repairs and scheduled maintenance be
performed in accordance with this service manual. Any
owner maintenance or repair procedure not performed in
accordance with this manual may void the warranty.
To get the longest life out of your vehicle:
Follow the Periodic Maintenance Chart in the Service
Manual.
Be alert for problems and non-scheduled maintenance.
Use proper tools and genuine Kawasaki Vehicle parts.
Special tools, gauges, and testers that are necessary
when servicing Kawasaki vehicles are introduced by
the Special Tool Catalog or Manual. Genuine parts
provided as spare parts are listed in the Parts Catalog.
Follow the procedures in this manual carefully. Don’t
take shortcuts.
Remember to keep complete records of maintenance
and repair with dates and any new parts installed.
•
•
•
•
•
How to Use This Manual
In this manual, the product is divided into its major systems and these systems make up the manual’s chapters.
The Quick Reference Guide shows you all of the product’s
system and assists in locating their chapters. Each chapter in turn has its own comprehensive Table of Contents.
For example, if you want ignition coil information, use
the Quick Reference Guide to locate the Electrical System
chapter. Then, use the Table of Contents on the first page
of the chapter to find the Ignition Coil section.
Whenever you see these WARNING and CAUTION
symbols, heed their instructions! Always follow safe
operating and maintenance practices.
This warning symbol identifies special instructions or procedures which, if not correctly followed, could result in personal injury, or loss of
life.
CAUTION
This caution symbol identifies special instructions or procedures which, if not strictly observed, could result in damage to or destruction
of equipment.
This manual contains four more symbols (in addition to
WARNING and CAUTION) which will help you distinguish
different types of information.
NOTE
This note symbol indicates points of particular interest for more efficient and convenient operation.
a procedural step or work to be done.
• Indicates
Indicates a procedural sub-step or how to do the work
of the procedural step it follows. It also precedes the
text of a NOTE.
Indicates a conditional step or what action to take based
on the results of the test or inspection in the procedural
step or sub-step it follows.
In most chapters an exploded view illustration of the
system components follows the Table of Contents. In
these illustrations you will find the instructions indicating
which parts require specified tightening torque, oil, grease
or a locking agent during assembly.
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GENERAL INFORMATION 1-1
General Information
Table of Contents
Before Servicing................................................................................................................................................................1-2
Model Identification ........................................................................................................................................................... 1-4
General Specifications ...................................................................................................................................................... 1-6
Special Tools and Sealant.................................................................................................................................................1-8
Unit Conversion Table.....................................................................................................................................................1-14
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1
1-2 GENERAL INFORMATION
Before Servicing
Before starting to perform an inspection service or carry out a disassembly and reassembly operation on a vehicle,
read the precautions given below. To facilitate actual operations, notes, illustrations, photographs, cautions, and detailed
descriptions have been included in each chapter wherever necessary. This section explains the items that require particular
attention during the removal and reinstallation or disassembly and reassembly of general parts.
Especially note the following:
(1) Dirt
Before removal and disassembly, clean the vehicle. Any dirt entering the engine will shorten the life of the vehicle.
For the same reason, before installing a new part, clean off any dust or metal filings.
(2) Battery Ground
Disconnect the ground (–) wire from the battery before performing any disassembly operations on the vehicle. This
prevents the engine from accidentally turning over while work is being carried out, sparks from being generated while
disconnecting the wires from electrical parts, as well as damage to the electrical parts themselves. For reinstallation,
first connect the positive wire to the positive (+) terminal of the battery
(3) Installation, Assembly
Generally, installation or assembly is the reverse of removal or disassembly. However, if installation or assembly
sequence is given in this Service Manual, follow it. Note parts locations and cable, wire, and hose routing during
removal or disassembly so they can be installed or assembled in the same way. It is preferable to mark and record
the locations and routing whenever possible.
(4) Tightening Sequence
When installing bolts, nuts, or screws for which a tightening sequence is given in this Service Manual, make sure
to follow the sequence. When installing a part with several bolts, nuts, or screws, start them all in their holes and
tighten them to a snug fit, thus ensuring that the part has been installed in its proper location. Then, tighten them
to the specified torque in the tightening sequence and method indicated. If tightening sequence instructions are not
given, tighten them evenly in a cross pattern. Conversely, to remove a part, first loosen all the bolts, nuts, or screws
that are retaining the part a 1/4–turn before removing them.
(5) Torque
When torque values are given in this Service Manual, use them. Either too little or too much torque may lead to
serious damage. Use a good quality, reliable torque wrench.
(6) 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 removing screws
held by non-permanent locking agent) in order to avoid damaging the screw heads.
(7) Edges
Watch for sharp edges, as they could cause injury through careless handling, especially during major engine
disassembly and assembly. Use a clean piece of thick cloth when lifting the engine or turning it over.
(8) High-Flash Point Solvent
A high-flash point solvent is recommended to reduce fire danger. A commercial solvent commonly available in North
America is standard solvent (generic name). Always follow manufacturer and container directions regarding the use
of any solvent.
(9) Gasket, O-Ring
Replace a gasket or an O-ring with a new part when disassembling. Remove any foreign matter from the mating
surface of the gasket or O-ring to ensure a perfectly smooth surface to prevent oil or compression leaks.
(10) Liquid Gasket, Locking Agent
Clean and prepare surfaces where liquid gasket or non-permanent locking agent will be used. Apply them sparingly.
Excessive amount may block engine oil passages and cause serious damage.
(11) Press
When using a press or driver to install a part such as a wheel bearing, apply a small amount of oil to the area
where the two parts come in contact to ensure a smooth fit.
(12) Ball Bearing and Needle Bearing
Do not remove a ball bearing or a needle bearing unless it is absolutely necessary. Replace any ball or needle
bearings that were removed with new ones. Install bearings with the manufacturer and size marks facing out, applying
pressure evenly with a suitable driver. Apply force only to the end of the race that contacts the press fit portion, and
press it evenly over the base component.
(13) Oil Seal and Grease Seal
Replace any oil or grease seals that were removed with new ones, as removal generally damages seals. Oil or
grease seals should be pressed into place using a suitable driver, applying a force uniformly to the end of seal until
the face of the seal is even with the end of the hole, unless instructed otherwise. When pressing in an oil or grease
seal which has manufacturer’s marks, press it in with the marks facing out.
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GENERAL INFORMATION 1-3
Before Servicing
(14) Circlip, Retaining Ring, and Cotter Pin
When installing circlips and retaining rings, take care to compress or expand them only enough to install them and
no more. Install the circlip with its chamfered side facing load side as well.
Replace any circlips, retaining rings, and cotter pins that were removed with new ones, as removal weakens and
deforms them. If old ones are reused, they could become detached while the vehicle is driven, leading to a major
problem.
(15) Lubrication
Engine wear is generally at its maximum while the engine is warming up and before all the sliding surfaces have
an adequate lubricative film. During assembly, make sure to apply oil to any sliding surface or bearing that has been
cleaned. Old grease or dirty oil could have lost its lubricative quality and may contain foreign particles that act as
abrasives; therefore, make sure to wipe it off and apply fresh grease or oil. 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.
(16) Direction of Engine Rotation
To rotate the crankshaft manually, make sure to do so in the direction of positive rotation. Positive rotation is
counterclockwise as viewed from the left side of the engine. To carry out proper adjustment, it is furthermore necessary
to rotate the engine in the direction of positive rotation as well.
(17) Replacement Parts
When there is a replacement instruction, replace these parts with new ones every time they are removed.
Replacement parts will be damaged or lose their original function once they are removed. Therefore, always
replace these parts with new ones every time they are removed. Although the previously mentioned gasket, O-ring,
ball bearing, needle bearing, grease seal, oil seal, circlip, and cotter pin have not been so designated in their respective
text, they are replacement parts.
(18) Electrical Wires
All the electrical wires are either one-color or two-color. A two-color wire is identified first by the primary color and
then the stripe 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. Unless instructed otherwise, electrical wires must be connected to
wires of the same color.
Two-Color Electrical
(19) Inspection
When parts have been disassembled, visually inspect these parts for the following conditions or other damage. If
there is any doubt as to the condition of them, replace them with new ones.
Abrasion
Bent
Color change
Crack
Dent
Deterioration
Hardening
Scratch
Seizure
Warp
Wear
(20) Specifications
Specification terms are defined as follows:
&quot;Standards&quot; show dimensions or performances which brand-new parts or systems have.
&quot;Service Limits&quot; indicate the usable limits. If the measurement shows excessive wear or deteriorated performance,
replace the damaged parts.
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1-4 GENERAL INFORMATION
Model Identification
KVF360–A1
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GENERAL INFORMATION 1-5
Model Identification
KVF360–A1
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1-6 GENERAL INFORMATION
General Specifications
Items
KVF360-A1
Dimensions:
Overall length
Overall width
Overall height
Wheelbase
Ground clearance:
Rear final gear case
Center of frame
Seat height
Dry mass
Curb mass:
Front
Rear
Fuel tank capacity
Performance:
Minimum turning radius
Engine:
Type
Cooling system
Bore and stroke
Displacement
Compression ratio
Maximum horsepower
Maximum torque
Carburetion system
Starting system
Ignition system
Timing advance
Ignition timing
Spark plug
Valve timing:
Inlet
Open
Close
Duration
Exhaust:
Open
Close
Duration
Lubrication system
Engine oil:
Type
Viscosity
Capacity
Drive Train:
Primary reduction system:
Type
Reduction ratio
2065
1205
1175
1250
mm
mm
mm
mm
(81.30
(47.44
(46.26
(49.21
in.)
in.)
in.)
in.)
195 mm (7.68 in.)
250 mm (9.84 in.)
890 mm (35.04 in.)
274 kg (604 lb), (US) 272.5 kg (601 lb)
154 kg (340 lb), (US) 153 kg (337 lb)
135 kg (298 lb), (US) 134 kg (295 lb)
13.5 L (3.6 US gal)
3.1 m (10.17 ft)
4-stroke, SOHC, 1-cylinder
Air-cooled
80.0 x 72.0 mm (3.15 x 2.83 in.)
362 mL (22.1 cu in.)
8.3 : 1
15.7 kW (21.4 PS) @7000 r/min (rpm), (US) 26.1 N1m (2.66 kgf1m, 19.25 ft1lb) @4500 r/min (rpm)
Carburetor, Keihin CVK34
Electric Starter &amp; Recoil Starter
DC-CDI
Electronically advanced
From 10 BTDC @1300 r/min (rpm) to 30 BTDC @5 000 r/min (rpm)
NGK DPR8EA-9
38 BTDC
58 ABDC
276
68 BBDC
28 ATDC
276
Forced lubrication (wet sump)
API SF or SG
API SH or SJ with JASO MA
SAE 10W-40
2.3 L (2.17 US qt)
Belt converter
3.122 0.635
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GENERAL INFORMATION 1-7
General Specifications
Items
Transmission:
Type
Gear ratios:
Forward:
Reverse
Final drive system:
Type
Reduction ratio
Overall drive ratio:
Forward:
KVF360-A1
2-speed plus reverse
High
Low
Shaft, 2WD/4WD
4.375 (35/8)
High
Low
Reverse
Front final gear case oil:
Type
Rear final gear case oil:
Viscosity
Capacity
Type
Capacity
Frame:
Type
Caster (rake angle)
Camber
King pin angle
Trail
Tread:
Front tire:
Rear tire:
Suspension:
Front:
Rear:
Front
Rear
Electrical Equipment:
Battery
Headlight:
Front
Rear
Type
Size
Type
Size
Type
Wheel travel
Type
Wheel travel
Brake:
Tail/brake light
Alternator:
3.548 (30/26 x 29/18 x 21/11)
5.536 (36/20 x 29/18 x 21/11)
4.613 (16/12 x 18/16 x 29/18 x 21/11)
Type
Bulb
Bulb
Type
Rated output
48.474 9.859
75.619 15.380
63.016 12.817
API SF or SG
API SH or SJ with JASO MA
SAE 10W-40
0.43 L (0.45 US qt)
MOBIL Fluid 424 or Kawa Chem Gear &amp; Wet Brake Oil
(CITGO TRANSGARD TRACTOR HYDRAULIC FLUID)
900 mL (0.95 US qt)
Double cradle, tubular steel
2.5
0.5
14.5
15 mm (0.59 in.)
890 mm (35.04 in.)
895 mm (35.24 in.)
Tubeless
AT25 x 8 – 12
Tubeless
AT25 x 10 – 12
MacPherson strut
170 mm (6.69 in.)
Swingarm
180 mm (7.09 in.)
Disc x 2
Enclosed wet multi-plate
12 V 14 Ah
Semi-sealed beam
12 V 30/30 W x 2
12 V 5/18 W
Three - phase AC
25 A, 14 V @8000 r/min (rpm)
Specifications are subject to change without notice, and may not apply to every country.
US: U.S.A. Model
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1-8 GENERAL INFORMATION
Special Tools and Sealant
Bearing Puller : 57001–135
Valve Guide Arbor,
Inside Circlip Pliers : 57001–143
Oil Pressure Gauge, 10 kg/cm2 : 57001–164
Outside Circlip Pliers : 57001–144
Compression Gauge : 57001–221
Circlip Pliers : 57001–154
Valve Spring Compressor Assembly : 57001–241
Valve Guide Reamer,
Valve Spring Compressor Adapter,
7 : 57001–162
7 : 57001–163
28.2 : 57001–243
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GENERAL INFORMATION 1-9
Special Tools and Sealant
Piston Pin Puller Assembly : 57001–910
Steering Stem Nut Wrench : 57001–1100
Fuel Level Gauge : 57001–1017
Valve Seat Cutter, 45 –
Compression Gauge Adapter, M12 x 1.25 : 57001–1018
Valve Seat Cutter, 32 –
Oil Pressure Gauge Adapter, PT 1/8 : 57001–1033
Valve Seat Cutter Holder Bar : 57001–1128
Oil Seal &amp; Bearing Remover : 57001–1058
Bearing Driver Set : 57001–1129
41.5 : 57001–1117
38.5 : 57001–1122
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1-10 GENERAL INFORMATION
Special Tools and Sealant
Piston Pin Puller Adapter : 57001–1211
Carburetor Drain Plug Wrench, Hex 3 : 57001–1269
Jack : 57001–1238
Flywheel &amp; Pulley Holder : 57001–1343
Pilot Screw Adjuster, A : 57001–1239
Socket Wrench : 57001–1363
Timing Light : 57001–1241
Hand Tester : 57001–1394
Oil Filter Wrench : 57001–1249
Flywheel Puller Assembly : 57001–1405
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GENERAL INFORMATION 1-11
Special Tools and Sealant
Drive &amp; Driven Pulley Holder : 57001–1412
Drive Pulley Wrench : 57001–1474
Drive Pulley Puller Bolt : 57001–1429
Damper Spring Compressor Set : 57001–1475
Filler Cap Driver : 57001–1454
Holder &amp; Guide Arbor : 57001–1476
Pulley Holder Attachment : 57001–1472
Spacer &amp; Holder : 57001–1477
Drive &amp; Driven Pulley Holder : 57001–1473
Socket Wrench, Hex 50 : 57001–1478
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1-12 GENERAL INFORMATION
Special Tools and Sealant
Output Shaft Holder &amp; Spacer : 57001–1479
Socket Wrench, Hex 41 : 57001–1484
Pinion Gear Holder : 57001–1480
Pinion Gear Holder : 57001–1485
Nut Holding Bolts : 57001–1481
Oil Seal Driver: 57001–1487
Socket Wench : 57001–1482
Gear Holder &amp; Socket Wrench, Hex 24 : 57001–1489
Spring Holder Set : 57001–1483
Hexagon Wench, Hex 41 : 57001–1491
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GENERAL INFORMATION 1-13
Special Tools and Sealant
Drive Pulley Measurement Tool : 57001–1498
Valve Seat Cutter, 50 - 44: 57001–1516
Actuator Lever Measurement Tool : 57001–1499
Oil Seal Driver: 57001–1517
Oil Seal Driver,
18: 57001–1505
Belt Measuring Gauge: 57001–1519
Oil Seal Driver,
48: 57001–1506
Drive Pulley Holder: 57001–1520
Valve Seat Cutter, 32 - 44: 57001–1515
Kawasaki Bond (Silicone Sealant) : 56019–120
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1-14 GENERAL INFORMATION
Unit Conversion Table
Prefixes for Units:
Prefix
Units of Length:
Symbol
mega
M
kilo
km
2
0.6214
1 000 000
m
2
3.281
=
ft
mm
2
0.03937
=
in
Power
2
k
2
1 000
centi
c
2
0.01
milli
m
2
0.001
micro
2
0.000001
Units of Mass:
=
mile
Units of Torque:
N1m
2
0.1020
=
kg1m
N1m
2
0.7376
=
ft1lb
N1m
2
8.851
=
in1lb
2
9.807
=
N1m
kg
2
2.205
=
lb
kg1m
g
2
0.03527
=
oz
kg1m
2
7.233
=
ft1lb
kg1m
2
86.80
=
in1lb
Units of Volume:
Units of Pressure:
L
2
0.2642
=
gal (US)
L
2
0.2200
=
gal (imp)
kPa
2
0.01020
=
kg/cm2
L
2
1.057
=
qt (US)
kPa
2
0.1450
=
psi
qt (imp)
kPa
2
0.7501
=
cmHg
L
L
2
2
0.8799
2.113
=
=
2
pint (US)
kg/cm
2
98.07
=
kPa
2
14.22
=
psi
2
1.333
=
kPa
0.6214
=
mph
L
2
1.816
=
pint (imp)
kg/cm2
mL
2
0.03381
=
oz (US)
cm Hg
mL
2
0.02816
=
oz (imp)
mL
2
0.06102
=
cu in
Units of Speed:
km/h
2
Units of Force:
N
2
0.1020
=
kg
N
2
0.2248
=
lb
kW
2
1.360
=
PS
kg
2
9.807
=
N
kW
2
1.341
=
HP
kg
2
2.205
=
lb
PS
2
0.7355
=
kW
PS
2
0.9863
=
HP
Units of Power:
Units of Temperature:
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PERIODIC MAINTENANCE 2-1
Periodic Maintenance
Table of Contents
Periodic Maintenance Chart.......................................2-2
Torque and Locking Agent ......................................... 2-3
Specifications ............................................................. 2-8
Periodic Maintenance Procedures ........................... 2-10
Fuel System..........................................................2-10
Throttle Lever Free Play Inspection .................. 2-10
Throttle Lever Free Play Adjustment.................2-10
Fuel System Cleanliness Inspection.................2-11
Air Cleaner Element Cleaning and Inspection..2-11
Air Cleaner Draining..........................................2-12
Fuel Hose and Connection Check.................... 2-12
Fuel Hose Replacement....................................2-12
Engine Top End .................................................... 2-13
Valve Clearance Inspection...............................2-13
Spark Arrester Cleaning....................................2-13
Converter System.................................................2-14
Actuator Lever (Engine Brake Control Lever) Assembly Inspection..............................................2-14
Drive Belt Inspection ......................................... 2-14
Drive Belt Deflection Inspection........................ 2-15
Drive Belt Deflection Adjustment.......................2-16
Engine Lubrication System...................................2-17
Engine Oil Change ............................................2-17
Oil Filter Change ............................................... 2-17
Oil Cooler Cleaning and Inspection .................. 2-17
Oil Hose and Connection Check.......................2-18
Wheels/Tires .........................................................2-18
Tire Inspection...................................................2-18
Final Drive.............................................................2-19
Variable Differential Control Lever Position Inspection.....................................................................2-19
Variable Differential Control Lever Position Adjustment...................................................................2-19
Front Final Gear Case Oil Change ................... 2-19
Rear Final Gear Case Oil Change....................2-20
Joint Boots Inspection.......................................2-20
Rear Propeller Shaft Joint Boot Inspection.......2-20
Brakes...................................................................2-21
Front Brake Pad Wear Inspection ..................... 2-21
Brake Hose and Connection Check..................2-21
Brake Hose Replacement ................................. 2-21
Brake Fluid Level Inspection ............................. 2-21
Brake Fluid Change...........................................2-22
Brake Master Cylinder Piston Assembly and Dust
Seal Replacement.............................................2-22
Caliper Piston Seal and Dust Seal Replacement2-23
Rear Brake Plates Replacement.......................2-23
Rear Brake Lever Free Play Inspection ............ 2-23
Brake Pedal Free Play Inspection.....................2-23
Rear Brake Lever and Pedal Free Play Adjustment...................................................................2-23
Steering.................................................................2-24
Steering Inspection............................................2-24
Electrical System .................................................. 2-24
Battery Inspection..............................................2-24
Spark Plug Cleaning / Inspection......................2-24
Spark Plug Gap Inspection ............................... 2-24
Drive Belt Failure Detection System Inspection2-24
Brake Light Switch Adjustment ......................... 2-24
General Lubrication...............................................2-26
Lubrication.........................................................2-26
Bolts and Nuts Tightening .................................... 2-27
Tightness Inspection..........................................2-27
Property of www.SmallEngineDiscount.com - Not for Resale
2
2-2 PERIODIC MAINTENANCE
Periodic Maintenance Chart
The scheduled maintenance must be done in accordance with this chart to keep the vehicle in good running condition.
The initial maintenance is vitally important and must not be neglected.
FREQUENCY
First
Service
After 10
hrs. or
100 km
(60 mi.)
of use
OPERATION
ENGINE
Converter drive belt wear – inspect *
Converter drive belt deflection - inspect *
Drive belt failure detection system function – inspect*
Engine brake control lever – inspect*
Air cleaner – service*
Throttle lever play – inspect
Valve clearance – inspect
Fuel system cleanliness – inspect*
Engine oil – change *
Oil filter – replace*
Spark plug – clean and gap
Spark arrester – clean
Oil cooler– clean*
Oil hoses and connections – inspect*
Fuel hoses and connections – inspect
Fuel hose – replace
CHASSIS
Joint boots – inspect*
Rear brake pedal and lever adjustment – inspect*
Rear brake plates – change*
Cables adjustment*
Bolts and nuts – tighten
Front brake pad wear – inspect*
Brake light switch – inspect*
Battery – inspect
Steering – inspect
Differential control lever play– inspect
Tire wear – inspect*
Front and rear finial gear case oil – change
General lubrication*
Front brake fluid level – inspect
Front brake fluid – change
Brake master cylinder piston assembly and dust seal
– replace
Caliper piston seal and dust seal – replace
Brake hoses and connections– inspect
Brake hose – replace
•
•
•
•
•
•
•
Regular Service
Every
10
days
or 200
km
(120
mi.) of
use
Every
30
days
or 600
km
(360
mi.) of
use
Every 90 days or
1700 km (1100 mi.)
of use, or when
BELT indicator light
comes on (100
hrs.) whichever
comes first
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
(NOTE)
•
•
•
•
•
4 years
Every
year of
use
•
•
•every 10 000 km (6 000 mi.)
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
2 years
2 years
4 years
•
*: Service more frequently when operated in mud, dust, or other harsh riding conditions, or when carrying heavy
loads or pulling a trailer.
: Clean, adjust, lubricate, torque, or replace parts as necessary.
•
NOTE
When the drive belt failure detection system is activated, inspect the drive belt.
Property of www.SmallEngineDiscount.com - Not for Resale
PERIODIC MAINTENANCE 2-3
Torque and Locking Agent
The following tables list the tightening torque for the major fasteners, and the parts requiring use of a non-permanent
locking agent or liquid gasket.
Letters used in the “Remarks” column mean:
L: Apply a non-permanent locking agent.
LB: Apply a non-permanet locking agent (Three Bond TB2471, Blue).
MO: Apply molybdenum disulfide oil solution (mixture of the engine oil and molybdenum disulfide grease in a weight
ratio 10:1).
EO: Apply engine oil.
M: Apply molybdenum disulfide grease.
SS: Apply silicone sealant (Kawasaki Bond: 56019-120).
Lh: Left-hand Threads
R: Replacement Parts
S: Follow the specific tightening sequence.
St: Stake the fasteners to prevent loosening.
Torque
Fastener
Fuel System:
Throttle Cable Locknut
Air Cleaner Duct Front Clamp Screw
Air Cleaner Duct Rear Clamp Screw
Air Cleaner Housing Mounting Bolts
Air Cleaner Intake Duct Clamp Screws
Engine Top End:
Camshaft Chain Tensioner Mounting Bolts
Camshaft Sprocket Bolts
Camshaft Cover Bolts
Bearing Retainer Bolts
Camshaft Chain Guard Bolts
Rear Camshaft Chain Guide Bolt
Cylinder Head Bolts (M11), first torque
Cylinder Head Bolts (M11), final torque
Cylinder Head Bolts (M6)
Valve Adjusting Screw Locknuts
Valve Adjusting Cap Bolts
Muffler Mounting Bolts
Converter System:
Converter Cover Bolts
Driven Pulley Nut
Ramp Weight Nuts
Spider
Drive Pulley Cover Bolts
Drive Pulley Bolt
Converter Air Duct Bolts
Recoil Starter:
Recoil Starter Mounting Bolts
Engine Lubrication System:
Engine Drain Plug
Oil Filter
Oil Pressure Switch
Oil Pressure Relief Valve
Oil Pump Cover Bolt
Oil Pump Cover Screws
Oil Pipe Bolts
N1m
kgf1m
ft1lb
1.3
1.4
4
6.9
1.4
0.13
0.14
0.41
0.7
0.14
11
12
36
61
12
8.8
14
8.8
12
8.8
9.8
25
44
12
12
8.8
26
0.9
1.4
0.9
1.2
0.9
1.0
2.5
4.5
1.2
1.2
0.9
2.7
78 in1lb
10
78 in1lb
104 in1lb
78 in1lb
87 in1lb
18
33
104 in1lb
104 in1lb
78 in1lb
20
8.8
93
6.9
275
13
93
8.8
0.9
9.5
0.7
28
1.3
9.5
0.9
78 in1lb
69
61 in1lb
203
113 in1lb
69
78 in1lb
5.9
0.6
52 in1lb
20
18
15
15
20
5.4
8.8
2.0
1.8
1.5
1.5
2.0
0.55
0.9
14
13
11
11
14
48 in1lb
78 in1lb
Remarks
in1lb
in1lb
in1lb
in1lb
in1lb
L
MO, S
S
S
S
Lh
R, Lh
L
R
SS
L
Property of www.SmallEngineDiscount.com - Not for Resale
2-4 PERIODIC MAINTENANCE
Torque and Locking Agent
Torque
Fastener
Oil Pipe Joint Nuts
Oil Cooler Mounting Bolts
Oil Cooler Fan Switch
Oil Temperature Warning Light Switch
Oil Filter Mounting Bolt
Oil Hose Banjo Bolts
Oil Pressure Switch Terminal Bolt
Engine Removal/Installation
Engine Mounting Bracket Bolts
Engine Mounting Nuts
Engine Mounting Upper Bolt
Crankshaft/Transmission:
Crankcase Bolts (M8)
Crankcase Bolts (M6)
Shift Shaft Positioning Bolt
Tie-Rod End Locknut
Tie-Rod End Bolt
Shift Lever Assembly Nut
Tie-Rod End Nut
Shift Lever Assembly Bracket Bolts
Tie-Rod End Rear Locknut
Tie-Rod End Front Locknut
Grip Hold Nut
Shift Shaft Spring Bolt
Shift Shaft Cover Bolts
Oil Line Plugs
Wheels/Tires:
Tie-Rod Adjusting Sleeve Locknuts
Wheel Nuts
Front Axle Nuts
Rear Axle Nuts
Final Drive:
(Output Bevel Gears)
Output Drive Bevel Gear Housing Bolts
Rotor Mounting Bolts
Output Drive Bevel Gear Cover Bolts
Forward/Reverse Detecting Sensor Mounting Bolts
Bearing Holder
Bevel Gear Holder Nut
Output Drive Bevel Gear Housing Bolts
Bearing Holder
Output Shaft Holder Nut
(Front Final Gear Case)
Oil Filler Cap
Oil Drain Plug
Variable Differential Control Cable Locknut
Front Final Gear Case Bolts and Nuts
Front Final Gear Case Center Cover Bolts (M8)
Front Final Gear Case Center Cover Bolts (M6)
Pinion Gear Bearing Holder
Front Final Gear Case Left Cover Bolts (M6)
N1m
kgf1m
ft1lb
29
8.8
16
16
25
29
1.5
3.0
0.9
1.6
1.6
2.5
3.0
0.15
22
78 in1lb
12
12
18
22
13 in1lb
25
42
25
2.5
4.3
2.5
18
31
18
20
8.8
25
20
9.8
20
20
20
9.8
9.8
9.8
25
8.8
23
2.0
0.9
2.5
2.0
1.0
2.0
2.0
2.0
1.0
1.0
1.0
2.5
0.9
2.3
14
78 in1lb
18
14
87 in1lb
14
14
14
87 in1lb
87 in1lb
87 in1lb
18
78 in1lb
17
37
52
196
265
3.8
5.3
20
27
27
38
145
195
26
12
8.8
15
118
157
26
137
157
2.7
1.2
0.9
1.5
12
16
2.7
14
16
20
104 in1lb
78 in1lb
11
87
116
20
101
116
29
24
17
42
24
9.8
137
9.8
3.0
2.4
1.7
4.3
2.4
1.0
14
1.0
22
17
12
31
17
87 in1lb
101
87 in1lb
Remarks
L
S, L (1)
Lh
L
L
L
L
L
L
L, S
L, S
L
S, L (4)
Property of www.SmallEngineDiscount.com - Not for Resale
PERIODIC MAINTENANCE 2-5
Torque and Locking Agent
Torque
Fastener
Front Final Gear Case Coupling Nut
Variable Front Differential Control Shift Shaft Lever
Ring Gear Bolts
Pinion Gear Bearing Holder Nut
(Rear Axle)
Bearing Holder
Bearing Holder Screws
(Rear Final Gear Case)
Oil Filler Cap
Oil Drain Plug
Rear Final Gear Case Bolts
Pinion Gear Bearing Holder
Rear Final Gear Case Right Cover Bolts (M10)
Rear Final Gear Case Right Cover Bolts (M8)
Pinion Gear Bearing Holder Nut
Brakes:
Reservoir Cap Screws
Bleed Valves
Master Cylinder Clamp Bolts
Brake Hose Banjo Bolts
Brake Lever Pivot Bolt
Brake Lever Pivot Bolt Locknut
Caliper Mounting Bolts
Caliper Holder Shaft
Caliper Holder Shaft (Allen Bolt)
Pad Mounting Bolts
Disc Mounting Bolts
Suspension:
Front Shock Absorber Clamp Bolts and Nuts
Front Shock Absorber Mounting Nuts
Rear Shock Absorber Mounting Nuts
Piston Rod Nut
Suspension Arm Pivot Bolts
Swingarm Pivot Right Shaft
Swingarm Pivot Left Shaft
Swingarm Pivot Left Nut
Steering:
Steering Stem Bottom End Nut
Steering Stem Clamp Bolts
Tie-Rod End Nuts
Steering Knuckle Joint Nuts
Front Shock Absorber Clamp Bolts and Nuts
Tie-Rod Adjusting Sleeve Locknuts
Handlebar Lower Holder Nuts
Handlebar Holder Bolts
Frame:
Rear Carrier Bolts and Nuts
Front Carrier Bolts
Front Guard Bolts
Trailer Hitch Bracket Bolts (M10)
Trailer Hitch Bracket Bolts (M8)
N1m
kgf1m
ft1lb
Remarks
20
8.8
57
127
2.0
0.9
5.8
13
14
78 in1lb
42
94
LB
St
255
16
26
1.6
188
12
M
L
29
20
42
137
49
24
157
3.0
2.0
4.3
14
5.0
2.4
16
22
14
31
101
36
17
116
S
L
L
L
L
1.5
5.9
8.8
25
5.9
5.9
25
18
23
18
37
0.15
0.6
0.9
2.5
0.6
0.6
2.5
1.8
2.3
1.8
3.8
13 in1lb
52 in1lb
78 in1lb
18
52 in1lb
52 in1lb
18
13
17
13
27
L
47
74
62
49
88
152
20
152
4.8
7.5
6.3
5.0
9.0
15.5
2.0
15.5
35
54
46
36
65
112
14
112
62
25
42
47
47
37
37
27
6.3
2.5
4.3
4.8
4.8
3.8
3.8
2.8
46
18
31
35
35
27
27
20
25
–
20
49
24
2.5
–
2.0
5.0
2.4
18
–
14
36
17
L
L
S
L
L
L
Property of www.SmallEngineDiscount.com - Not for Resale
2-6 PERIODIC MAINTENANCE
Torque and Locking Agent
Torque
Fastener
Footboard Mounting Nuts
Electrical System:
Alternator Cover Bolts
Alternator Rotor Bolts
Alternator Stator Bolts
Spark Plug
Ignition Coil Mounting Bolt
Pickup Coil Mounting Bolts
Starter Motor Mounting Bolts
Starter Motor Terminal Nut
Starter Motor Terminal Locknut
Starter Motor Bolts
Starter Motor Clutch Bolts
2WD/4WD Actuator Mounting Bolts
Engine Brake Actuator Mounting Bolts
Reverse Position Switch
Neutral Switch
Starter Relay Terminal Nuts
Igniter Mounting Bolts
Ignition Switch Nut
Oil Pressure Switch Terminal Bolt
Regulator/Rectifier Mounting Bolts
N1m
kgf1m
ft1lb
Remarks
–
–
–
L
8.8
127
14
14
8.8
5.9
8.8
4.9
6.9
3.4
34
9.8
8.8
15
15
4.9
2.3
2.7
1.5
8.8
0.9
13
1.4
1.4
0.9
0.6
0.9
0.5
0.7
0.3
3.5
1.0
0.9
1.5
1.5
0.5
0.23
0.28
0.15
0.9
78 in1lb
94
10
10
78 in1lb
52 in1lb
78 in1lb
43 in1lb
61 in1lb
30 in1lb
25
87 in1lb
78 in1lb
11
11
43 in1lb
20 in1lb
24 in1lb
13 in1lb
78 in1lb
L
L, S
Property of www.SmallEngineDiscount.com - Not for Resale
PERIODIC MAINTENANCE 2-7
Torque and Locking Agent
The tables below, relating tightening torque to thread diameter, lists the basic torque for the bolts and nuts. Use this
table for only the bolts and nuts which do not require a specific torque value. All of the values are for use with dry
solvent-cleaned threads.
Basic Torque for General Fasteners of Engine Parts
Threads dia.
mm (in.)
6 (0.24)
6 (0.24)
6 (0.24)
8 (0.31)
8 (0.31)
10 (0.39)
10 (0.39)
5 (0.20)
Mark of
bolt head
9T
7T
4T
7T
4T
7T
4T
4T
N1m
12 15
7.8 9.8
3.9 4.9
18 22
10 14
39 44
20 24
2.2 2.6
Torque
kgf1m
1.2 1.5
0.8 1.0
0.4 0.5
1.8 2.2
1.0 1.4
4.0 4.5
2.0 2.4
0.22 0.27
ft1lb
104 130 in1lb
69 87 in1lb
35 43 in1lb
13 16
87 122 in1lb
29 33
14 17
19 23 in1lb
Basic Torque for General Fasteners of Frame Parts
Threads dia.
mm (in.)
5 (0.20)
6 (0.24)
8 (0.31)
10 (0.39)
12 (0.47)
14 (0.55)
16 (0.63)
18 (0.71)
20 (0.79)
N1m
3.4 4.9
5.9 7.8
14 19
25 34
44 61
73 98
115 155
165 225
225 325
Torque
kgf1m
0.35 0.5
0.6 0.8
1.4 1.9
2.6 3.5
4.5 6.2
7.4 10.0
11.5 16.0
17.0 23.0
23 33
ft1lb
30 43 in1lb
52 69 in1lb
10.0 13.5
19.0 25
33 45
54 72
83 115
125 165
165 240
Property of www.SmallEngineDiscount.com - Not for Resale
2-8 PERIODIC MAINTENANCE
Specifications
Item
Fuel System:
Throttle lever free play
Air cleaner element oil
Engine Top End:
Valve clearance:
Exhaust
Inlet
Converter System:
Actuator lever guide shoe wear
Belt width
Belt deflection
Engine Lubrication System:
Engine oil:
Type
Viscosity
Capacity
Wheels/Tires
Tire tread depth:
Front
Rear
Standard tire:
Front
Rear
Final Drive:
Front Final Gear Case:
Gear Case Oil:
Type
Viscosity
Oil level
Capacity
Rear Final Gear Case:
Gear Case Oil:
Type
Oil level
Capacity
Brakes:
Front Brake Fluid:
Type
Front Disc Brake:
Pad lining thickness
Rear Brake Lever, Pedal
and Cables:
Rear brake lever free play
Brake pedal free play
Electrical System:
Spark plug gap
Rear brake light switch timing
Standard
Service Limit
2 ~ 3 mm (0.08 ~ 0.12 in.)
High-quality foam air filter oil
–––
–––
0.15 ~ 0.20 mm (0.0059 ~ 0.0079 in.)
0.08 ~ 0.13 mm (0.0032 ~ 0.0051 in.)
–––
–––
–––
29.8 ~ 31.0 mm (1.17 ~ 1.22 in.)
20 ~ 27 mm (0.79 ~ 1.06 in.)
API SF or SG
API SH or SJ with JASO MA
SAE10W40
1.50 L (1.59 US qt) (When filter is not removed)
1.74 L (1.84 US qt) (When filter is removed)
2.3 L (2.43 US qt) (When engine is completely dry)
–––
–––
6 mm (0.24 in.)
29.4 mm (1.16 in.)
–––
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
3 mm (0.12 in.)
4 mm (0.16 in.)
AT 25 X 8-12
Dunlop, KT121, Tubeless
AT 25 x 10-12
Dunlop, KT405C/KT127A, Tubeless
–
–
–
–
–
–
–
–
–
–
–
–
API SF or SG
API SH or SJ of JASO MA
SAE 10W-40
Filler opening bottom
430 mL (0.45 US qt)
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
MOBIL Fluid 424 or Kawa Chem Gear &amp; Wet Brake Oil
(CITGO TRANSGARD TRACTOR HYDRAULIC FLUID)
Filler opening bottom
900 mL (0.95 US qt)
–––
DOT 3 or DOT 4
–––
4.5 mm (0.18 in.)
1 mm (0.04 in.)
–––
–––
1 ~ 2 mm (0.04 ~ 0.08 in.)
15 ~ 25 mm (0.6 ~ 1.0 in.)
–––
–––
0.8 ~ 0.9 mm (0.031 ~ 0.035 in.)
On after 10 mm (0.4 in.) of pedal travel
–––
–––
Property of www.SmallEngineDiscount.com - Not for Resale
PERIODIC MAINTENANCE 2-9
Specifications
Special Tools - Carburetor Drain Plug Wrench, Hex 3: 57001–1269
Belt Measuring Gauge: 57001–1519
Flywheel &amp; Pulley Holder: 57001–1343
Pulley Holder Attachment: 57001–1472
Oil Filter Wrench: 57001–1249
Property of www.SmallEngineDiscount.com - Not for Resale
2-10 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Fuel System
Throttle Lever Free Play Inspection
that the throttle lever moves smoothly from full open to close,
• Check
and the throttle closes quickly and completely in all steering positions
•
•
by the return spring.
If the throttle lever does not return properly, check the throttle cable
routing, lever free play, and for possible cable damage. Then lubricate
the throttle cable.
Run the engine at the idle speed, and turn the handlebar all the way
to the right and left to ensure that the idle speed does not change.
If the idle speed increases, check the throttle lever free play and the
cable routing.
Stop the engine and check the throttle lever free play [A].
If the free play is not within the specified range, adjust the cable.
Throttle Lever Free Play
Standard:
2
3 mm (0.08 ~ 0.12 in.)
Throttle Lever Free Play Adjustment
the rubber cover off the adjuster at the throttle case.
• Slide
the locknut [A] and turn the throttle cable upper adjuster [B]
• Loosen
until the cable has proper amount of play.
• Tighten the locknut and reinstall the rubber cover.
Torque -
Throttle Cable Locknut: 13 N1m (0.13 kgf1m, 11 in1lb)
If the free play cannot be adjusted by using the upper cable adjuster,
remove the throttle cable pulley cover and then use the cable adjusting
nuts [A] at the lower end of the throttle cable and make the necessary
free play.
Property of www.SmallEngineDiscount.com - Not for Resale
PERIODIC MAINTENANCE 2-11
Periodic Maintenance Procedures
Fuel System Cleanliness Inspection
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.
the fuel tap to the OFF position.
• Turn
the check valve [A] at the end of the carburetor overflow
• Remove
hose.
the lower end of the carburetor overflow hose to a suitable
• Run
container.
out the carburetor drain plug a few turns and drain the fuel
• Turn
system.
Special Tool -
Carburetor Drain Plug Wrench, Hex 3: 57001–1269 [A]
to see if water or dirt comes out.
• Check
Tighten
the drain plug.
• If any water
or dirt appears during the above inspection, clean the
fuel system (carburetor, tank, fuel hose).
Air Cleaner Element Cleaning and Inspection
NOTE
In dusty areas, the element should be cleaned more frequently than
the recommended interval.
After riding through rain or muddy terrains, the element should be
cleaned immediately.
Also, if there is a break in the element material or any other damage
to the element, replace the element with a new one.
Clean the element in a well-ventilated area, and take care that
there are no sparks or flame anywhere near the working area;
this includes any appliance with a pilot light. Because of the
danger of highly flammable liquids, do not use gasoline or a
low-flash point solvent to clean the foam element.
the air cleaner element.
• Remove
Clean
the
element in a bath of high-flash point solvent using a soft
• bristle brush.
it dry in a clean towel [A]. Do not wring the element or blow
• Squeeze
it dry; the element can be damaged.
the element for damage.
• Inspect
If it is torn, punctured, or hardened, replace it.
NOTE
Replace the element after cleaning it five times or if it is damaged.
cleaning, saturate the element with a high-quality foam-air-filter
• After
oil, squeeze out the excess oil, then wrap it in a clean rag and squeeze
it as dry as possible. Be careful not to tear the element.
Property of www.SmallEngineDiscount.com - Not for Resale
2-12 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Air Cleaner Draining
A drain tube [A] is connected to the bottom of the air cleaner housing
to drain water or oil accumulated in the housing.
Visually check the drain tube if the water or oil accumulates in the
tube.
If any water or oil accumulates in the tube, drain it by taking off the
tube. After draining, be sure to install the tube and clamp firmly.
•
Fuel Hose and Connection Check
the fuel tap to the OFF position.
• Turn
Remove:
• Fuel Tank Cover (see Frame chapter)
•
•
•
•
Exhaust Cover (see Frame chapter)
Check the fuel hose [A].
If the fuel hose is frayed, cranked, or bulged, replace the fuel hose.
Check that the hose is securely connected and clamps [B] are
tightened.
If the fuel hose has been sharply bent or kinked, replace the fuel
hose.
If the clamps are loosened or damaged, replace the clamps.
When installing the fuel hose, route the hose according to Cable,
Wire, and Hose Routing section in Appendix chapter.
When installing the fuel hose, avoid sharp bending, kinking, flattening
or twisting, and route the fuel hose with a minimum of bending so that
the fuel flow will not be obstructed.
Fuel Hose Replacement
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.
the fuel tap to the OFF position.
• Turn
• Remove:
Fuel Tank Cover (see Frame chapter)
Exhaust Cover (see Frame chapter)
Clamps [A]
Fuel Hose [B]
the fuel hose [A] onto the pipe fully and install the clamps [B]
• Fit
beyond the raised rib [C].
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PERIODIC MAINTENANCE 2-13
Periodic Maintenance Procedures
Engine Top End
Valve Clearance Inspection
NOTE
Check the valve clearance only when the engine is cold (at room
temperature).
• Remove:
Left Front Wheel (see Wheels/Tires chapter)
Left Front Inner Cover (see Frame chapter)
Fuel Tank (see Fuel System chapter)
Rubber Cover
Bolts [A] and Valve Adjusting Caps [B]
• Remove:
Recoil Starter (see Recoil Starter chapter)
•
Timing Inspection Plug
Position the crankshaft at TDC of the end of the compression stroke
(see Camshaft Sprocket Installation in Engine Top End chapter).
the clearance of each valve between the end of the valve
• Measure
stem and the adjusting screw on the rocker arm with a thickness
gauge [A].
If the valve clearance is not correct, adjust it (see Engine Top End
chapter).
Valve Clearance (when cold)
Exhaust:
0.15
0.20 mm (0.0059 ~ 0.0079 in.)
0.13 mm (0.0032 ~ 0.0051 in.)
Inlet:
0.08
Spark Arrester Cleaning
To avoid burns, wear gloves while cleaning the spark arrester.
Since the engine must be run during this procedure, the
muffler will become hot.
the drain plug [A] on the muffler.
• Remove
In
an
open
area away from combustible materials, start the engine
• with the transmission
in neutral.
and lower engine speed while tapping on the muffler with a
• Raise
rubber mallet until carbon particles are purged from the muffler.
Do not run the engine in a closed area. Exhaust gases contain carbon monoxide; a colorless, odorless, poisonous gas.
Breathing exhaust gas leads to carbon monoxide poisoning,
asphyxiation, and death.
the engine.
• Stop
• Install the drain plug.
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2-14 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Converter System
Actuator Lever (Engine Brake Control Lever) Assembly Inspection
the width [A] of the guide [B].
• Measure
If the guide contact area width is greater than the service limit, replace
the actuator lever assembly.
Actuator Lever Guide Shoe Wear
Service Limit:
6 mm (0.24 in.)
Drive Belt Inspection
Inspection of the drive belt is required at least every 90 days of vehicle
use (average 12 mile/day) not to exceed 1,100 mile. More frequent
inspection is necessary if the vehicle is subjected to hard usage.
Neglect, abuse, or failure to maintain the transmission can
result in a severely worn or damaged drive belt locking up the
transmission and wheels. This can cause the operator to lose
control and have an accident resulting in injury or death.
the width [A] of the belt at several locations with a suitable
• Measure
straightedge [B] as shown.
If any measurements exceed the service limit, replace the belt.
Belt Width
Standard:
29.8
Service Limit:
31.0 mm (1.17 ~ 1.22 in.)
29.4 mm (1.16 in.)
NOTE
Use the belt measuring gauge [A] in order to make easy to inspect
the drive belt width.
Special Tool -
Belt Measuring Gauge: 57001–1519
the drive belt [B] into the belt measuring gauge.
• Fit
If the upper surface [C] of the belt sank in the upper surface [D] of
the gauge, replace the belt.
the belt [A] for abnormal wear [B].
• Check
Measure the width [C] of the belt at abnormal wear point.
If any measurements exceed 0.5 mm (0.02 in.), replace the belt.
using the belt of large abnormal wear, the drive belt failure
detection switch could be activated.
When
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PERIODIC MAINTENANCE 2-15
Periodic Maintenance Procedures
the belt for cracks, breaks, or peeling.
• Check
If necessary, replace the belt with a new one.
Belt [A]
Crack [B]
Broken [C]
Peeling [D]
Whenever
NOTE
the belt is replaced, inspect the drive and the driven
pulleys.
Drive Belt Deflection Inspection
NOTE
If the
drive belt failure detection system is activated by abnormal
belt, the drive belt failure detection switch is damaged. Make sure
to replace the torque converter cover.
the torque converter cover (see Torque Converter Cover
• Remove
Removal in Converter System chapter).
the transmission in neutral and rotate the driven pulley by hand
• Put
to make sure the belt is shifted all the way to the top of the driven
pulley.
the belt deflection [A] as shown:
• Measure
Place a straightedge [B] on top of the belt between the drive pulley
[C] and the driven pulley [D].
Use a ruler to push the belt away from the straightedge.
Push hard,
but with no more force than 59 N (6 kgf, 13 lb).
Belt Deflection
Standard:
•
20
27 mm (0.79 ~ 1.06 in.)
If the belt deflection is not within the specified range, first measure
the drive belt width (see Drive Belt Inspection). Adjust the deflection
by adding or removing spacers on the fixed sheave.
When adjusting the deflection, less is better than more. Less
deflection will maintain better performance for more time as the belt
width decreases by normal wear, which causes the deflection to
increase with usage.
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2-16 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Drive Belt Deflection Adjustment
the driven pulley (see Driven Pulley Disassembly in
• Disassemble
Converter System chapter).
If the belt deflection is more than 27 mm (1.06 in.), remove the
spacers to decrease it.
The rule-of-thumb is: 0.1 mm (0.004 in.) change in spacer thickness
equals about 1.3 mm (0.051 in.) change in belt deflection.
If the belt deflection is less than 20 mm (0.79 in.), add the spacers
[A] to increase it.
The rule-of-thumb is: 0.1 mm (0.004 in.) change in spacer thickness
equals about 1.6 mm (0.063 in.) change in belt deflection.
Spacers
Part No.
Thickness
92026-1569
0.6 mm (0.024 in.)
92026-1617
0.8 mm (0.032 in.)
92026-1565
1.0 mm (0.039 in.)
92026-1570
1.4 mm (0.055 in.)
the driven pulley (see Driven Pulley Assembly in Converter
• Assemble
System chapter).
the transmission in neutral, rotate the driven pulley to allow the
• With
belt to return to the top of the sheaves before measuring the belt
•
•
deflection.
Measure the belt deflection again and repeat the above procedures
until it is within the standard range.
Using the flywheel &amp; pulley holder and adapter, tighten the driven
pulley nut.
Special Tools - Flywheel &amp; Pulley Holder: 57001–1343
Pulley Holder Attachment: 57001–1472
Torque -
Driven Pulley Nut: 93 N1m (9.5 kgf1m, 69 ft1lb)
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PERIODIC MAINTENANCE 2-17
Periodic Maintenance Procedures
Engine Lubrication System
Engine Oil Change
the vehicle so that it is level side to side and front to back
• Support
after warming up the engine.
the engine drain plug [A] to drain the oil.
• Remove
The oil in the filter can be drained by removing the filter (see Oil Filter
•
Change).
Replace the drain plug gasket with a new one if it is damaged.
Tighten:
Torque -
Engine Drain Plug : 20 N1m (2.0 kgf1m, 14 ft1lb)
• Pour in the specified type and amount of oil.
Engine Oil
Type:
Viscosity:
Amount:
API SF or SG
API SH or SJ with JASO MA
SAE 10W-40
1.50 L (1.59 US qt) (When filter is not removed)
1.74 L (1.84 US qt) (When filter is removed)
2.3 L (2.43 US qt) (When engine is completely dry)
NOTE
Depending on the atmospheric temperature of your riding area, the
engine oil viscosity should be changed according to the chart.
Oil Filter Change
the engine oil.
• Drain
Remove
the oil filter [A] with the oil filter wrench [B].
•
Special Tool -
Oil Filter Wrench : 57001–1249
the filter with a new one.
• Replace
installing the oil filter, be careful of the following.
• When
Apply oil to the gasket [A] before installation.
Tighten the filter with the oil filter wrench.
Special Tool Torque -
Oil Filter Wrench: 57001–1249
Oil Filter : 18 N1m (1.8 kgf1m, 13 ft1lb)
Pour in the specified type and amount of oil.
Oil Cooler Cleaning and Inspection
the oil cooler [A].
• Check
If there are obstructions to air flow, remove them.
If the corrugated fins are deformed, carefully straighten them with the
blade of a thin screw driver.
CAUTION
Do not tear the cooler tubes while straightening the fins.
If the air passage of the cooler core are blocked by unremovable
obstructions or irreparably deformed fins, replace the oil cooler.
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2-18 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
CAUTION
When cleaning the oil cooler with compressed air, be careful
of the following to avoid damage to the fins.
Keep the air nozzle [A] over 0.5 m (20 in.) [B] away from the
oil cooler.
Blow air perpendicularly to the cooler core.
Never blow air at an angle against the fins but straight through
them in the direction of natural air flow.
Never shake the air nozzle at a right angle against the fins; be
sure to move it at a level with the fins.
Oil Hose and Connection Check
• Remove:
Left Side Cover (see Frame chapter)
•
•
Front Inner Covers (see Frame chapter)
Check the oil hoses [A].
If the oil hoses are frayed, cracked, or bulged, replace the oil hose.
Check that the hose is securely connected, and banjo bolts [B] and
oil pipe joint nuts [C] are tightened.
If the oil hose has been sharply bent or kinked, replace the oil hose.
Torque -
Oil Pipe Banjo Bolts: 29 N1m (3.0 kgf1m, 22 ft1lb)
Oil Pipe Joint Nuts: 29 N1m (3.0 kgf1m, 22 ft1lb)
installing the oil hose, route the hose according to Cable, Wire,
• When
and Hose Routing section in Appendix chapter.
installing the oil hose, avoid sharp bending, kinking, flattening
• When
or twisting, and route the oil hose with a minimum of bending so that
the oil flow will not be obstructed.
Wheels/Tires
Tire Inspection
the tire for damage and wear.
• Examine
If the tire is cut or cracked, replace it.
Lumps
•
or high spots on the tread or sidewalls indicate internal
damage requiring tire replacement.
Remove any foreign objects from the tread. After removal, check for
leaks with a soap and water solution.
Measure the tread depth at the center of the tread with a depth gauge
[A]. Since the tire may wear unevenly, take measurements at several
places.
If any measurements are less than the service limit, replace the tire.
Tire Tread Depth
Service Limit:
Front:
Rear:
3 mm (0.12 in.)
4 mm (0.16 in.)
Standard Tire
Front:
AT 25 x 8 - 12 DUNLOP KT121 Tubeless
Rear:
AT 25 x 10 - 12 DUNLOP KT405C/KT127A Tubeless
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PERIODIC MAINTENANCE 2-19
Periodic Maintenance Procedures
Final Drive
Variable Differential Control Lever Position Inspection
the variable differential control lever [A] towards the handlebar
• Pull
grip [B] with a spring scale until it reads 30 N (3 kgf, 7 lb) of force.
The clearance [C] between the control lever and grip should be 20
mm (0.8 in.).
If the clearance is not within the specified range, adjust the cable.
Differential Control Lever Position
Standard:
20 mm (0.8 in.)
Variable Differential Control Lever Position Adjustment
the locknut [A] of the differential control cable.
• Loosen
Turn
the
adjuster [B] until the cable has proper amount of play.
• Tighten the
locknut securely.
•
Front Final Gear Case Oil Change
up the oil by running the vehicle so that the oil will pick up any
• Warm
sediment and drain easily. Then stop the vehicle.
the vehicle so that it is level, both side-to-side and front-to-rear.
• Park
Remove
side cover (see Frame chapter).
• Place antheoil front
pan
beneath
the front final gear case and remove the
• drain plug [A].
When draining or filling the final gear case, be careful that no
oil gets on the tire or rim. Clean off any oil that inadvertently
gets on them with a high-flash point solvent.
the oil has completely drained out, install the drain plug with a
• After
new aluminum gasket, and tighten it.
Torque -
Oil Drain Plug: 24 N1m (2.4 kg1m, 17 ft1lb)
the gear case up to the bottom of filler opening with the oil
• Fill
specified below.
Front Final Gear Case Oil
Type:
API SF or SG
API SH or SJ with JASO MA
Viscosity:
SAE 10W-40
Capacity:
430 mL (0.45 US qt)
NOTE
Depending on the atmospheric temperature of your riding area, the
engine oil viscosity should be changed according to the chart.
•
Be sure the O-ring is in place, and tighten the filler cap.
Torque -
Oil Filler Cap : 29 N1m (3.0 kg1m, 22 ft1lb)
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2-20 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Rear Final Gear Case Oil Change
up the oil by running the vehicle so that the oil will pick up any
• Warm
sediment and drain easily. Then stop the vehicle.
the vehicle so that it is level, both side-to-side and front-to-rear.
• Park
an oil pan beneath the rear final gear case and remove the
• Place
drain plug [A].
When draining or filling the final gear case, be careful that no
oil gets on the tire or rim because oil will deteriorate the tire.
Clean off any oil that inadvertently gets on them with a highflash point solvent.
the oil has completely drained out, install the drain plug with a
• After
new aluminum gasket.
Torque -
•
Oil Drain Plug: 20 N1m (2.0 kg1m, 14 ft1lb)
Fill the final gear case up to the bottom of filler opening with the oil
specified below.
Rear Final Gear Case Oil
Type:
MOBIL Fluid 424 or Kawa Chem Gear &amp; Wet Brake Oil
(CITGO TRANSGARD TRACTOR HYDRAULIC FLUID)
Capacity:
900 mL (0.95 US qt)
• Be sure the O-ring is in place.
Torque -
Oil Filler Cap [B]: 29 N1m (3.0 kg1m, 22 ft1lb)
Joint Boots Inspection
inspect the front axle joint boots in accordance with the
• Visually
Periodic Maintenance Chart or if the axles are noisy during operation.
• Remove:
Guard [A]
inspect the joint boots [B].
• Visually
If the joint boot is torn, worn, deteriorated, or leaks grease, replace
the front axle assembly.
Rear Propeller Shaft Joint Boot Inspection
inspect the rear propeller shaft joint boot [A] in accordance
• Visually
with the Periodic Maintenance Chart or if the shaft is noisy during
operation.
If the joint boot is torn, worn, or deteriorated, replace the joint boot
and check the propeller shaft (see Rear Propeller Shaft Inspection in
Final Drive chapter).
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PERIODIC MAINTENANCE 2-21
Periodic Maintenance Procedures
Brakes
Front Brake Pad Wear Inspection
the lining thickness [A] of the pads in each caliper.
• Check
If the lining thickness of either pad is less than the service limit [B],
replace both pads in the caliper as a set.
Pad Lining Thickness
Standard:
4.5 mm (0.18 in.)
Service Limit:
1 mm (0.04 in.)
Brake Hose and Connection Check
the brake hose and fittings for deterioration, cracks and signs
• Inspect
of leakage.
The high
•
pressure inside the brake line can cause fluid to leak [A]
or the hose to burst if the line is not properly maintained. Bend and
twist the rubber hose while examining it.
Replace the hose if any cracks [B] or bulges [C] are noticed.
Tighten any loose fittings.
Brake Hose Replacement
the brake fluid out of the line as explained in the Brake Fluid
• Pump
Change.
the banjo bolts at both ends of the brake hose, and pull the
• Remove
hose off the vehicle.
• Immediately wipe up any brake fluid that spills.
CAUTION
Brake fluid quickly ruins painted surfaces; any spilled fluid
should be completely washed away immediately.
a new flat washer for each side of the hose fittings.
• Use
the new brake hose in its place (see Appendix chapter), and
• Install
tighten the banjo bolts.
Torque -
Brake Hose Banjo Bolts: 25 N1m (2.5 kgf1m, 18 ft1lb)
Brake Fluid Level Inspection
the reservoir horizontal, and check that the fluid level in the
• Position
reservoir is higher than the lower level line [A].
If the fluid level is lower than the lower level line, check for fluid
leakage of the brake line, and add the fluid as follows:
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2-22 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Remove the reservoir cap, and fill the reservoir to the upper level line
[A] in the reservoir with the same type and brand of the fluid that is
already in the reservoir. And then install the reservoir cap.
Change the fluid in the brake line completely if the fluid must
be refilled but the type and brand of the fluid that is already in
the reservoir are unidentified.
• Tighten:
Torque -
Reservoir Cap Screws : 1.5 N1m (0.15 kgf1m, 13 in1lb)
Brake Fluid Change
the front wheels (see Wheels/Tires chapter).
• Remove
Remove
reservoir cap and the rubber cap on the bleed valve.
• Attach a the
plastic hose to the bleed valve on the caliper, and run
• the otherclear
end of the hose into a container.
the reservoir with new brake fluid.
• Fill
Change
brake fluid as follows:
• Open thethebleed
valve [A].
Apply the brake lever and hold it [B].
Close the bleed valve [C].
Release the brake lever [D].
the fluid level in the reservoir often, replenishing it as neces• Check
sary.
NOTE
If the fluid in the reservoir runs completely out any time during fluid
changing, air will enter the line, and the system must be bled.
this operation until fresh brake fluid comes out into the plastic
• Repeat
hose or the color of the fluid changes.
Do not mix two brands of fluid. Change the brake fluid in the
brake line completely if the brake fluid must be refilled but the
type and brand of the brake fluid that is already in the reservoir
are not known.
• Tighten:
Torque -
Bleed Valves: 5.9 N1m (0.6 kgf1m, 52 in1lb)
the front wheels (see Wheels/Tires chapter).
• Install
Apply
the
brake lever forcefully for a few seconds, and check for fluid
• leakage around
the fittings.
If the brake lever has a soft or &quot;spongy feeling&quot; 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.
Brake Master Cylinder Piston Assembly and Dust Seal Replacement
to Master Cylinder section in Brakes chapter for Brake Master
• Refer
Cylinder Cup and Dust Seal Replacement.
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PERIODIC MAINTENANCE 2-23
Periodic Maintenance Procedures
Caliper Piston Seal and Dust Seal Replacement
to Calipers section in Brakes chapter for Caliper Piston Seal
• Refer
and Dust Seal Replacement.
Rear Brake Plates Replacement
to Internal Wet Brake section in Brakes chapter for Rear Brake
• Refer
Plates Replacement.
Rear Brake Lever Free Play Inspection
the rear brake lever free play [A].
• Check
Pull the rear brake lever lightly until the brake is applied.
If the play is incorrect, adjust it.
Rear Brake Lever Free Play
Standard:
1
2 mm (0.04 ~ 0.08 in.)
Brake Pedal Free Play Inspection
the brake pedal free play [A].
• Check
Depress the brake pedal lightly by hand until the brake is applied.
If the free play is incorrect, adjust it.
Brake Pedal Free Play
Standard:
15
25 mm (0.6 ~ 1.0 in.)
Rear Brake Lever and Pedal Free Play Adjustment
NOTE
Since the rear brake lever and pedal free play adjustments affect
each other, make them at the same time.
Rear Brake Lever:
Loosen the knurled locknut [A] and turn the adjuster [B] at the rear
brake lever in as far as it will go.
Tighten the locknut.
•
•
the brake lever adjuster [A] at the rear end of the brake cable
• Turn
until the rear brake lever has the correct amount of play.
Brake Pedal:
Turn the brake pedal adjuster [B] at the rear end of the brake cable
until the brake pedal has the correct amount of play.
•
the pedal a few times to see that it returns to its rest position
• Operate
immediately upon release.
the rear wheels to check for brake drag.
• Rotate
Check
braking
effectiveness.
• If there is any doubt
as to the conditions of the brake, check the brake
parts for wear or damage.
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2-24 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Steering
Steering Inspection
the handlebar left and right, and check the steering action.
• Turn
If the steering action is not smooth, or if the steering binds or catches
before the stop, lubricate the steering stem bearing.
NOTE
The cables and wires will have some effect on the steering action
which must be taken into account.
the steering action again.
• Check
If steering stem bearing lubrication does not remedy the problem,
•
inspect the steering stem for straighteness, steering stem clamps,
and tie-rod bearings.
If you feel looseness, or if the steering rattles as it turns, check the
tightness of the steering bolts and nuts.
Tighten loose bolts and nuts to the specified torque (see Exploded
View), and check the steering action again.
If the steering action does not change by tightening the bolts and
nuts, inspect the steering stem clamps, steering stem bearings, tierod bearings, and steering knuckle joints.
Electrical System
Battery Inspection
to Battery section in Electrical System chapter for Battery
• Refer
Inspection.
Spark Plug Cleaning / Inspection
the spark plug, preferably in a sandblasting device, and then
• Clean
clean off any abrasive particles. The plug may also be cleaned using
a wire brush or other suitable tool.
If the spark plug electrodes are corroded or damaged, or if the
insulator is cracked, replace the plug. Use the standard spark plug
or its equivalent.
Spark Plug Gap Inspection
the gap [A] with a wire-type thickness gauge.
• Measure
If the gap is incorrect, carefully bend the side electrode [B] with a
suitable tool to obtain the correct gap.
Spark Plug Gap
0.8
0.9 mm (0.031 ~ 0.035 in.)
Drive Belt Failure Detection System Inspection
Refer to Drive Belt Failure Detection System section in Electrical
System chapter.
Brake Light Switch Adjustment
the operation of the brake light switch by depressing the brake
• Check
pedal [A]. The brake light should go on after about 10 mm (0.4 in.)
of pedal travel [B].
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PERIODIC MAINTENANCE 2-25
Periodic Maintenance Procedures
If it does not, adjust the brake light switch [A] up or down. To change
the switch position, turn the adjusting nut [B].
Brake Light Switch Timing
Standard:
ON after 10 mm (0.4 in.) of pedal travel
CAUTION
To avoid damaging the electrical connections inside the
switch, be sure that the switch body does not turn during
adjustment.
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2-26 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
General Lubrication
Lubrication
lubricating each part, clean off any rusty spots with rust
• Before
remover and wipe off any grease, oil, dirt, or grime.
• Lubricate the points listed below with indicated lubricant.
NOTE
Whenever
the vehicle has been operated under wet or rainy
conditions, or especially after using a high-pressure spray water,
perform the general lubrication.
Cables: Lubricate with Cable Lubricant
Brake Cables
Throttle Cable
Choke Cable
• Lubricate the cables by seeping the oil between the cable and
housing.
The cable may be lubricated by using a pressure cable luber with an
aerosol cable lubricant.
the cable disconnected at the both ends, the cable should move
• With
freely [A] within the cable housing.
If cable movement is not free after lubricating, if the cable is frayed,
or if the cable housing is kinked, replace the cable.
Points:
Lubricate with Grease.
Throttle Inner Cable ENds [A]
Choke Cable Lower End
Brake Cable Ends
Slide Points:
Lubricate with Grease.
Brake Lever
Brake Pedal Pivot Shaft
Throttle Lever Shaft
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PERIODIC MAINTENANCE 2-27
Periodic Maintenance Procedures
Bolts and Nuts Tightening
Tightness Inspection
the tightness of the bolts and nuts listed here in accordance
• Check
with the Periodic Maintenance Chart. Also, check to see that each
cotter pin is in place and in good condition.
If there are loose fasteners, retorque them to the specified torque
following the specified tightening sequence. Refer to the appropriate
chapter for torque specifications. If torque specifications are not listed
in the appropriate chapter, see the Basic Torque Table (see Torque
and Locking Agent). For each fastener, first loosen it by 1/2 turn, then
tighten it.
If cotter pins are damaged, replace them with new ones.
Bolts, Nuts, and Fasteners to be checked
Wheels:
Front Axle Nuts and Cotter Pins
Rear Axle Nuts and Cotter Pins
Wheel Nuts
Brakes:
Master Cylinder Clamp Bolts
Brake Lever Pivot Bolt
Brake Lever Pivot Nut
Caliper Mounting Bolts
Brake Pedal Cotter Pin
Steering/Suspension:
Handlebar Clamp Bolts
Stem Clamp Allen Bolts
Stem Bearing Housing Bolts
Tie-Rod End Nuts and Cotter Pins
Tie-Rod Adjusting Sleeve Locknuts
Shock Absorber Mounting Bolts and Nuts
Suspension Arm Pivot Bolts
Steering Knuckle Pivots Nuts and Cotter Pins
Engine:
Engine Mounting Bolts
Engine Mounting Bracket Bolts
Exhaust Pipe Holder Nuts
Muffler Mounting Bolts
Muffler Clamp Bolt
Front Final Drive:
Gear Case Bracket Bolts
Others:
Footrest Mounting Bolts
Throttle Mounting Bolts
Carrier Mounting Bolts
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FUEL SYSTEM 3-1
Fuel System
Table of Contents
Exploded View............................................................3-2
Specifications ............................................................. 3-6
Throttle Lever and Cable............................................3-7
Throttle Lever Free Play Inspection .................... 3-7
Throttle Lever Free Play Adjustment...................3-7
Throttle Case Removal/Disassembly .................. 3-7
Throttle Case Assembly/Installation....................3-7
Throttle Cable Installation....................................3-8
Throttle Case Inspection ..................................... 3-8
Throttle Cable Lubrication ...................................3-8
Throttle Cable Inspection .................................... 3-8
Choke Lever and Cable..............................................3-9
Choke Lever and Cable Removal ....................... 3-9
Choke Lever and Cable Installation .................. 3-10
Choke Cable Lubrication...................................3-10
Choke Cable Inspection .................................... 3-10
Carburetor ................................................................ 3-11
Idle Speed Inspection........................................3-11
Idle Speed Adjustment......................................3-11
Pilot Screw Adjustment ..................................... 3-11
Service Fuel Level Inspection ........................... 3-11
Fuel Level Adjustment.......................................3-12
Fuel System Cleanliness Inspection.................3-12
Carburetor Removal .......................................... 3-13
Carburetor Installation ....................................... 3-13
Carburetor Disassembly....................................3-14
Carburetor Assembly.........................................3-15
Carburetor Cleaning.......................................... 3-16
Carburetor Inspection........................................3-17
Air Cleaner ............................................................... 3-19
Air Cleaner Element Removal...........................3-19
Air Cleaner Element Installation........................3-19
Air Cleaner Element Cleaning and Inspection..3-20
Air Cleaner Draining..........................................3-20
Air Cleaner Housing Removal...........................3-20
Air Cleaner Housing Installation........................3-21
Snorkel Duct Removal.......................................3-21
Fuel Tank..................................................................3-22
Fuel Tank Removal............................................3-22
Fuel Tank Installation.........................................3-22
Fuel Tap Removal..............................................3-23
Fuel Tap Installation .......................................... 3-23
Fuel Tank and Fuel Tap Cleaning.....................3-23
Fuel Tap Inspection ...........................................3-23
Fuel Level Gauge Removal...............................3-24
Fuel Level Gauge Installation............................3-24
Fuel Level Gauge Check...................................3-24
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3
3-2 FUEL SYSTEM
Exploded View
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FUEL SYSTEM 3-3
Exploded View
Torque
No.
1
Fastener
Throttle Cable Locknut
2:
3:
4:
5.
6:
7:
8:
9:
10:
11:
N1m
kgf1m
ft1lb
1.3
0.13
11 in1lb
Remarks
Choke lever
Choke cable
Throttle cable
Throttle lever
Jet needle
Pilot jet
Main jet
Needle jet
Pilot screw
Priming pump
O: Apply engine oil.
Gr: Apply grease.
CA: Canada model
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3-4 FUEL SYSTEM
Exploded View
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FUEL SYSTEM 3-5
Exploded View
Torque
No.
Fastener
N1m
kgf1m
ft1lb
1
Air Cleaner Duct Front Clamp Screw
1.4
0.14
12 in1lb
2
Air Cleaner Duct Rear Clamp Screw
4
0.41
36 in1lb
3
Air Cleaner Housing Mounting Bolts
6.9
0.7
61 in1lb
4
Air Cleaner Intake Duct Clamp Screws
1.4
0.14
12 in1lb
Remarks
Gr: Apply grease.
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3-6 FUEL SYSTEM
Specifications
Item
Standard
Service Limit
Throttle Case and Cable:
Throttle lever free play
2
3 mm (0.08 ~ 0.12 in.)
–––
Carburetor:
Make/Type
KEIHIN, CVK34
–––
Main jet
#155
–––
Main air jet:
#70
–––
Needle jet:
#6
–––
Jet needle
N2LQ
–––
Pilot jet
#35
–––
Pilot air jet
#150
–––
Pilot screw
1 1/2 turns out
–––
Starter jet
#90
–––
Idle speed
1300 &plusmn; 50 r/min (rpm)
–––
Service fuel level
0.5 &plusmn; 1 mm (0.02 &plusmn; 0.04 in.)
–––
above bottom edge of carburetor body
Float height
17.0 &plusmn; 2 mm (0.67 &plusmn; 0.08 in.)
–––
#155 (92063-1332) or #158 (92063-1344)
–––
#155 (92063-1332)
–––
Optional parts:
Main jet:
*Altitude:
0
500 m (0 ~ 1700 ft)
500
1400 m (1700 ~ 4700 ft)
1400
2300 m (4700 ~ 7700 ft)
#145 (92063-1017)
–––
2300
3300 m (7700 ~ 10700 ft)
#135 (92063-1014)
–––
3300
4500 m (10700 ~ 14800 ft)
#125 (92063-1069)
–––
High-quality foam air filter oil
–––
Air Cleaner:
Air cleaner element oil
*: Refer to pg. 5–23 for high altitude setting in Converter System chapter.
Special Tools - Fuel Level Gauge: 57001–1017
Carburetor Drain Plug Wrench, Hex 3: 57001–1269
Pilot Screw Adjuster, A: 57001–1239
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FUEL SYSTEM 3-7
Throttle Lever and Cable
Throttle Lever Free Play Inspection
to Throttle Lever Free Play Inspection in Periodic Maintenance
• Refer
chapter.
Throttle Lever Free Play Adjustment
to Throttle Lever Free Play Adjustment in Periodic Maintenance
• Refer
chapter.
Throttle Case Removal/Disassembly
the throttle case screws [A] and pull the case open.
• Remove
Slide
the
cable adjuster dust cover out of place.
•
• Remove the rubber cover [A].
the cable tip [A] out of the throttle lever catch with the throttle
• Pull
lever opened.
the locknut [B] and unscrew the adjuster [C].
• Loosen
Disassemble
the throttle case as follows:
• Remove the throttle
lever screw [D], lockwasher, and flat washer, and
lift the throttle lever [E] and return spring from the case.
Pull the throttle control lever [F] out of the case.
Throttle Case Assembly/Installation
the throttle case and cable before assembly/installation.
• Lubricate
certain that the return spring is correctly installed on the throttle
• Be
lever [A].
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3-8 FUEL SYSTEM
Throttle Lever and Cable
the throttle control lever so that the carburetor throttle valve is
• Swing
fully open. Turn the throttle limiter screw [A] until it is spaced about
1 mm (0.04 in.) [B] away from the throttle lever stop [C]. Tighten the
locknut [D].
NOTE
Refer to the Owner’s Manual for the function of the throttle limiter
and adjustment procedure of it.
Operation with an improperly assembled throttle case could
result in an unsafe riding condition.
the throttle lever free play (see Throttle
• Check
Inspection in Periodic Maintenance chapter).
Lever Free Play
Throttle Cable Installation
the throttle cable before installation.
• Lubricate
Route
the
cable correctly according to Appendix chapter.
•
Operation with an improperly adjusted, incorrectly routed, or
damaged cable could result in an unsafe riding condition.
the throttle cable (see Throttle Lever Free Play Inspection in
• Check
Periodic Maintenance chapter).
Throttle Case Inspection
the throttle cable disconnected from the throttle lever, the lever
• With
should move freely and return smoothly by spring.
•
If the lever is heavy, disassemble the throttle case, clean and lubricate
the throttle case.
Examine the lever and case for cracks. Replace the case assembly
if it is cracked.
Throttle Cable Lubrication
•
•
Whenever the throttle cable is removed, lubricate the cable as follows:
Apply a small amount of multi-purpose grease to the cable both ends.
Lubricate the cable with a penetrating rust inhibitor through the
pressure cable luber.
Throttle Cable Inspection
the throttle cable disconnected at both ends, the cable should
• With
move freely within the cable housing.
If the cable does not move freely after lubricating, if the cable is frayed,
or if the housing is kinked, replace the cable.
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FUEL SYSTEM 3-9
Choke Lever and Cable
Choke Lever and Cable Removal
the fuel tank (see Fuel Tank Removal).
• Remove
Remove
carburetor from the carburetor holder.
• Slide the the
dust cover [A] out of place.
• Unscrew the
starter plunger cap [B] and pull out the starter plunger.
•
the starter plunger spring compressed, and free the choke cable
• Hold
lower end [A] from the plunger [B].
• Remove:
Choke Lever Mounting Screw [A], Plane Washer, and Wave Washer
Switch Case Mounting Screws [B]
• Free the choke cable upper end [A] from the choke lever [B].
• Pull off the retaining clip [A].
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3-10 FUEL SYSTEM
Choke Lever and Cable
the cable end [A] in the grommet [B], and free the cable from the
• Fit
switch case.
• Pull the cable out of the vehicle.
Choke Lever and Cable Installation
the choke cable before installation.
• Lubricate
Install
the
washer, plain washer and screw in that order.
• Route the wave
choke cable according to Appendix chapter.
•
Operation with an incorrectly routed, or damaged cable could
result in an unsafe riding condition.
Choke Cable Lubrication
•
Whenever the choke cable is removed, lubricate the cable as follows:
Lubricate the cable with a penetrating rust inhibitor through the
pressure cable luber.
Choke Cable Inspection
the choke cable disconnected at both ends, the cable should
• With
move freely in the cable housing.
If the cable does not move freely after lubricating, if the cable is frayed,
or if the housing is kinked, replace the cable.
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FUEL SYSTEM 3-11
Carburetor
Idle Speed Inspection
the engine and warm it up thoroughly.
• Start
With
the
engine idling, turn the handlebar to both sides to check for
• any changes
in the idle speed.
If handlebar movement changes the idle speed, the throttle cable may
be improperly adjusted incorrectly routed, or damaged. Be sure to
correct any of these conditions before riding.
Operation with improperly adjusted, incorrectly routed, or
damaged cables could result in an unsafe riding condition.
idle speed with a suitable tachometer.
• Check
If the idle speed is out of the specified range, adjust it.
Idle Speed
Standard:
1,300 &plusmn; 50 r/min (rpm)
Idle Speed Adjustment
the engine and warm it up thoroughly.
• Start
Turn
the
adjusting screw [A] until the idle speed is correct.
• Open andidleclose
the throttle a few times to make sure that the idle
speed is within the specified range.
Pilot Screw Adjustment
the pilot screw if necessary.
• Adjust
Turn
the
carburetor pilot screw [A] all the way in until it seats lightly.
•
Special Tool -
Pilot Screw Adjuster, A: 57001–1239 [B]
CAUTION
Do not overtighten the pilot screw or the carburetor body will
be damaged and require replacement.
• Back the pilot screw out the specified number of turns.
Carburetor Pilot Screw Setting
Standard:
1 1/2 turns out
Service Fuel Level Inspection
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.
the vehicle on a level surface.
• Park
Remove
fuel tank cover.
• Remove the
the
check valve [A] at the end of the carburetor overflow
• hose.
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3-12 FUEL SYSTEM
Carburetor
the fuel level gauge to the open end of the carburetor
• Connect
overflow hose.
Special Tool -
•
•
Special Tool -
•
•
Fuel Level Gauge: 57001–1017
Fuel Level Gauge [A]
Zero Line [B]
Drain Plug [C]
Carburetor Body Bottom Edge [D]
Fuel Level [E]
Hold the gauge vertically against the side of the carburetor body so
that the &quot;zero&quot; line is several millimeters higher than the bottom edge
of the carburetor body.
Turn the fuel tap to the ON position to feed fuel to the carburetor and
gauge, then turn out the carburetor drain plug a few turns.
Carburetor Drain Plug Wrench, Hex 3: 57001–1269
Wait until the fuel level in the gauge settles.
Keeping the gauge vertical, slowly lower the gauge until the &quot;zero&quot;
line is even with the bottom edge of the carburetor body.
NOTE
Do not lower the &quot;zero&quot; line below the bottom edge of the carburetor
body. If the gauge is lowered and then raised it again, the fuel level
measured shows somewhat higher than the actual fuel level. If the
gauge is lowered too far, dump the fuel out of it into a suitable
container and start the procedure over again.
the fuel level in the gauge and compare it to the specification.
• Read
Tighten
drain plug and remove the fuel level gauge.
• If the fuelthelevel
is incorrect, adjust it.
Fuel Level
Standard:
0.5 &plusmn; 1 mm (0.02 &plusmn; 0.04 in.) above the bottom edge
of the carburetor body
Fuel Level Adjustment
the carburetor.
• Remove
Drain
the
• Remove thecarburetor.
Carburetor Disassembly).
• Bend the tangfloat[A](see
on
the
arm very slightly to change the float
• height. Increasing the floatfloat
height lowers the fuel level and decreasing
the float height raises the fuel level.
Float Height
Standard:
•
17.0 &plusmn; 2 mm (0.67 &plusmn; 0.08 in.)
Float Bowl Mating Surface [A]
Float Valve Needle Rod (contacted but unloaded) [B]
Float [C]
Float Height [D]
If the fuel level cannot be adjusted by this method, the float or the
float valve is damaged.
Assemble the carburetor, install it on the vehicle, and recheck the fuel
level.
Fuel System Cleanliness Inspection
to Fuel System Cleanliness Inspection in Periodic Maintenance
• Refer
chapter.
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FUEL SYSTEM 3-13
Carburetor
Carburetor Removal
Gasoline is extremely flammable and can be explosive under
certain conditions. Turn the ignition switch OFF. Do not
smoke. Make sure the area is well ventilated and free from
any source of flame or sparks; this includes any appliance
with a pilot light.
• Remove:
Fuel Tank (see Fuel Tank Removal)
Screw [A] and Washer
Throttle Cable Pulley Cover [B]
Throttle Cable Lower End [C]
Carburetor Heater Lead and Ground Lead Connectors
the clamp screws [A] on the carburetor holder and air cleaner
• Loosen
duct.
• Remove the choke cable lower end [B].
Carburetor Installation
the pilot screw before installation.
• Adjust
Align
the
• [B]. carburetor holder notch [A] with the carburetor projection
the air cleaner duct notches [A] with the carburetor projections
• Align
[B].
Torque -
Air Cleaner Duct Front Clamp Screws: 1.4 N1m (0.14 kgf1m,
12 in1lb)
the carburetor vent tube according to Appendix chapter.
• Route
Check
fuel leakage from the carburetor.
•
Fuel Spilled from the carburetor is hazardous.
If the carburetor has been disassembled, or if there is some other
reason that the fuel level may be incorrect, inspect the fuel level (see
Carburetor Fuel Level Inspection).
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3-14 FUEL SYSTEM
Carburetor
the carburetor heater lead [A] and ground lead [B] connec• Connect
tors.
the carburetor hoses according to Cable, Wire, and Hose
• Route
Routing section in Appendix chapter.
the idle speed (see Idle Speed Adjustment).
• Adjust
Check
throttle cable (see Throttle Lever Free Play Inspection in
• PeriodictheMaintenance
chapter).
Carburetor Disassembly
the carburetor (see Carburetor Removal).
• Remove
Disassemble
the carburetor top end as follows:
• Remove the upper
chamber cover screws and take off the cover [A]
and spring [B].
Pull out the vacuum piston [C] with the diaphragm.
CAUTION
During carburetor disassembly, be careful not to damage the
diaphragm. Never use a sharp edge to remove the diaphragm.
Slide the jet needle [D] out of the vacuum piston from the bottom.
It
will come out with a spring seat [E].
the pilot screw [A] and remove it with its spring, washer, and
• Unscrew
O-ring.
the carburetor bottom end as follows:
• Disassemble
Remove:
Screws [B]
Float Bowl [C]
Slide out the float pivot pin [A], remove the float [B], and drop out the
float valve needle with its hanger.
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FUEL SYSTEM 3-15
Carburetor
Remove:
Main Jet [A]
Air Bleed Pipe [B]
Starter Jet [C]
Pilot Jet [D]
Carburetor Heater [E]
Push the needle jet [A] out from the inside of the carburetor with your
finger.
Carburetor Assembly
the carburetor body upside down, and drop the needle jet [A]
• Turn
into place so that the smaller diameter end [B] of the jet goes in first.
screw in the air bleed pipe [C]. It will seat against the needle
• Carefully
jet, pushing the end of the jet into the carburetor bore.
CAUTION
Do not force the air bleed pipe or overtighten it. The needle jet
or the carburetor body could be damaged requiring replacement.
temperature conductive grease:
• Apply
Carburetor Heater [A]
the float valve needle [A] into the valve seat and hold the float
• Drop
in place with the tang hooked into the needle hanger [B].
• Slip the float pivot pin through the pivot posts and the float as shown.
If the float is improperly installed, the specified fuel level
cannot be maintained. Fuel spilled from the carburetor is
hazardous.
• Set the float height as specified.
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3-16 FUEL SYSTEM
Carburetor
the jet needle [A] into the hole in the center of the vacuum
• Insert
piston [B], and place the spring seat [C] over the needle.
the needle through the hole in the center of the vacuum piston,
• Slip
and put the spring seat [A] on the top of the needle. Turn the seat so
that it does not block the hole [B] at the bottom of the vacuum piston.
installing the upper chamber cover, check that the vacuum piston
• After
slides up and down smoothly without binding in the carburetor bore.
Carburetor Cleaning
Clean the carburetor in a well-ventilated area, and take care
that there is no spark or flame anywhere near the working
area; this includes any appliance with a pilot light. Because
of the danger of highly flammable liquids, do not use gasoline
or low-flash point solvents to clean the carburetor. A fire or
explosion could result.
CAUTION
Do not use compressed air on an assembled carburetor, the
float may be crushed by the pressure, and the vacuum piston
diaphragm may be damaged.
Remove as many rubber or plastic parts from the carburetor
as possible before cleaning the carburetor with a cleaning
solution. This will prevent damage or deterioration of the
parts.
The carburetor body has plastic parts that cannot be removed.
Do not use a strong carburetor cleaning solution which could
attack these parts, instead, use a mild high-flash point cleaning solution safe for plastic parts.
Do not use wire or any other hard instrument to clean carburetor parts, especially jets, as they may be damaged.
the carburetor (see Carburetor Disassembly).
• Disassemble
all the metal parts in a carburetor cleaning solution.
• Immerse
the parts in water.
• Rinse
When
are clean, dry them with compressed air.
• Blow thetheairparts
fuel passages with compressed air.
• Assemble theandcarburetor
(see Carburetor Assembly).
•
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FUEL SYSTEM 3-17
Carburetor
Carburetor Inspection
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.
disassembling the carburetor, check the fuel level (see Service
• Before
Fuel Level Inspection).
If the fuel level is incorrect, inspect the rest of the carburetor before
correcting it.
the carburetor (see Carburetor Removal).
• Remove
Turn
the
throttle cable pulley [A] to check that the throttle butterfly
• valve [B] moves
smoothly and return back with the spring tension.
If the throttle valve does not move smoothly, replace the carburetor.
the carburetor (see Carburetor Disassembly).
• Disassemble
Clean
the
carburetor
(see Carburetor Cleaning).
• Check the vacuum piston
[A], and the O-rings [B] on the
• float bowl, pilot screw, anddiaphragm
starter plunger cap.
If any of the diaphragm or O-rings are not in good condition, replace
them.
the plastic tip [A] of the float valve needle. It should be smooth,
• Check
without any grooves, scratches, or tears.
•
If the plastic tip is damaged [B], replace the float valve [C].
Push the rod [D] in the other end of the float valve needle and then
release it.
If it does not spring out, replace the float valve.
the tapered portion [A] of the pilot screw for wear or damage.
• Check
If the pilot screw is worn or damaged on the tapered portion, it will
prevent the engine from idling smoothly. Replace it.
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3-18 FUEL SYSTEM
Carburetor
that the vacuum piston moves smoothly in the carburetor body.
• Check
The surface of the piston must not be excessively worn.
If the vacuum piston does not move smoothly, or if it is very loose in
the carburetor body, replace both the body and the vacuum piston.
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FUEL SYSTEM 3-19
Air Cleaner
Air Cleaner Element Removal
• Remove:
Seat (see Frame chapter)
Snaps [A]
Air Cleaner Cover [B]
the rear end [A] of the air cleaner element assembly [B] to the
• Pull
upper and rear, and take it out of the air cleaner housing [C].
removing the element, stuff pieces of lint-free, clean cloth into
• After
the air cleaner duct to keep dirt out of the carburetor and engine.
If dirt or dust is allowed to pass through into the carburetor,
the throttle may become stuck, possibly causing an accident.
CAUTION
If dirt gets through into the engine, excessive engine wear and
possibly engine damage will occur.
• Remove:
Stopper [A]
Element [B]
Air Cleaner Element Installation
grease:
• Apply
Outside of Blue Urethane [A]
Inside of Grommet [B]
the following parts on the metal net [A].
• Install
Element [B]
Stopper [C]
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3-20 FUEL SYSTEM
Air Cleaner
the blue urethane [A] into the air cleaner housing and push the
• Insert
stopper [B] until it is bottomed.
Air Cleaner Element Cleaning and Inspection
to Air Cleaner Element Cleaing and Inspection in Periodic
• Refer
Maintenance chapter.
Air Cleaner Draining
• Refer to Air Cleaner Draining in Periodic Maintenance chapter.
Air Cleaner Housing Removal
• Remove:
Seat (see Frame chapter)
Air Cleaner Element (see Air Cleaner Element Removal)
Housing Mounting Bolts [A]
• Remove:
Snokel Duct [A]
Air Ducts [B]
• Remove:
Breather Hose [A]
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FUEL SYSTEM 3-21
Air Cleaner
• Through the housing [A] under the bracket [B].
the housing counterclockwise at right angle [A] and take it as
• Turn
shown.
Air Cleaner Housing Installation
[A] the notch in the duct with the ridge on the air cleaner housing.
• Align
• Tighten:
Torque -
Air Cleaner Housing Mounting Bolts: 6.9 N1m (0.7 kgf1m, 61
in1lb)
Air Cleaner Duct Rear Clamp Screw: 4 N1m (0.41 kgf1m, 36
in1lb)
Air Cleaner Intake Duct Clamp Screws: 1.4 N1m (0.14 kgf1m,
12 in1lb)
Snorkel Duct Removal
• Remove:
Seat (see Frame chapter)
Fuel Tank Cover (see Frame chapter)
Clamp [A]
Screws [B]
Snorkel Duct [C]
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3-22 FUEL SYSTEM
Fuel Tank
Fuel Tank Removal
the fuel tap to the OFF position.
• Turn
Remove:
• Screw [A]
Fuel Tap Knob [B]
Gasoline is extremely flammable and can be explosive under
certain conditions. Turn the ignition switch OFF. Do not
smoke. Make sure the area is well ventilated and free from
any source of flame or sparks; this includes any appliance
with a pilot light.
• Remove:
Seat (see Frame chapter)
Fuel Tank Cover (see Frame chapter)
Exhaust Pipe Cover (see Frame chapter)
Fuel Hose [A]
Fuel Tank
Remove the fuel tank and fuel tap from the vehicle, then be careful
with the choke cable.
Fuel Tank Installation
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.
the rubber dampers [A].
• Check
Check
the grommets [B].
• If the dampers
are damaged or deteriorated, replace them.
the projection [A] on the fuel tank into the damper grommet [B].
• Insert
When
the fuel tank, be careful with the choke cable.
• Be sureinstalling
the fuel hose is clamped to the fuel tap to prevent leakage.
•
Fuel spilled from the fuel tap is hazardous.
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FUEL SYSTEM 3-23
Fuel Tank
Fuel Tap Removal
the fuel tank and drain it (see Fuel Tank Removal).
• Remove
Remove:
• Bolts [A]
Fuel Tap [B]
Fuel Tap Installation
• Be sure the O-rings [A] are in good condition to prevent leakage.
Fuel Tank and Fuel Tap Cleaning
the fuel tank and drain it (see Fuel Tank Removal).
• Remove
some high-flash point solvent into the fuel tank and shake the
• Pour
tank to remove dirt and fuel deposits.
Clean the tank in a well-ventilated area, and take care that
there is no spark or flame anywhere near the working area;
this includes any appliance with a pilot light. Because of the
danger of highly flammable liquids, do not use gasoline or
low–flash point solvents to clean the tank. A fire or explosion
could result.
the solvent out the tank.
• Pour
Remove
the tank by taking out the bolts.
• Clean thethefuelfueltaptapfilterfromscreens
in a high-flash point solvent.
• Pour high-flash point solvent through
the tap in both ON and RES
• positions.
the tank and tap with compressed air.
• Dry
the fuel tap in the tank (see Fuel Tap Installation).
• Install
Install
the fuel tank (see Fuel Tank Installation).
•
Fuel Tap Inspection
the fuel tap filter screens [A] for any breaks or deterioration.
• Check
If the filter screens have any breaks or are deteriorated, it may allow
dirt to reach the carburetor, causing poor running. Replace the fuel
tap.
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3-24 FUEL SYSTEM
Fuel Tank
If the fuel tap leaks, or allows fuel to flow when it is OFF, replace the
damaged gasket [A] or O-rings [B].
Fuel Level Gauge Removal
• Remove the fuel tank cap.
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.
the fuel tank cover (see Fuel Tank Removal).
• Remove
Install
the
tank cap immediately.
• Pry off thefuel
gauge
discard the cap.
• Check the groovescap[B][A]inand
fuel tank boss. If the grooves are
• damaged by removing the the
cap or can not hold the cap nails, the
fuel tank must be replaced.
• Pull out the fuel level gauge [C].
Fuel Level Gauge Installation
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.
the fuel level gauge so that the 1/2 scale [A] faces the front [B].
• Install
Push
the
gauge cap over the gauge so that the notch [C] aligns
• with the 1/2newscale.
that the gauge cap nails fit securely in the grooves in the fuel
• Check
tank boss.
Fuel Level Gauge Check
the fuel level gauge from the fuel tank (see Fuel Level Gauge
• Remove
Removal).
that the float [A] moves up and down [B] smoothly without
• Check
binding. It should go down under its own weight.
If the float does not move smoothly or has visual damage, replace
the gauge.
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ENGINE TOP END 4-1
Engine Top End
Table of Contents
4
Exploded View............................................................4-2
Specifications ............................................................. 4-6
Camshaft Chain Tensioner.........................................4-8
Camshaft Chain Tensioner Removal...................4-8
Camshaft Chain Tensioner Installation................4-8
Camshaft Sprocket...................................................4-10
Camshaft Sprocket Removal.............................4-10
Camshaft Sprocket Installation..........................4-10
Rocker Arms and Shafts..........................................4-12
Rocker Arm and Shaft Removal........................4-12
Rocker Arm and Shaft Installation .................... 4-12
Rocker Arm and Shaft Inspection ..................... 4-13
Camshaft..................................................................4-14
Camshaft Removal............................................ 4-14
Camshaft Installation.........................................4-14
Cam Wear Inspection........................................4-14
Camshaft Bearing Inspection............................4-15
KACR Inspection ............................................... 4-15
Camshaft Chain and Guides....................................4-16
Camshaft Chain Removal..................................4-16
Camshaft Chain Installation .............................. 4-16
Camshaft Chain Guide Removal.......................4-16
Camshaft Chain Guide Installation .................. 4-16
Camshaft Chain Guide Wear ............................ 4-16
Cylinder Head...........................................................4-17
Cylinder Compression Measurement................4-17
Cylinder Head Removal.....................................4-17
Cylinder Head Installation ................................. 4-18
Cylinder Head Assembly...................................4-19
Cylinder Head Cleaning .................................... 4-19
Cylinder Head Warp..........................................4-20
Valves, Guides, Seats, Springs, Oil Seals...............4-21
Valve Clearance Inspection...............................4-21
Valve Clearance Adjustment ............................. 4-21
Valve Removal...................................................4-21
Valve Installation................................................4-22
Valve Visual Inspection......................................4-22
Valve Guide Removal........................................4-22
Valve Guide Installation.....................................4-22
Valve-to-Guide Clearance Measurement .......... 4-23
Valve Seat Inspection........................................4-23
Valve Seat Repair (Valve Lapping) ................... 4-24
Cylinder and Piston..................................................4-28
Cylinder Removal .............................................. 4-28
Cylinder Installation...........................................4-28
Cylinder Assembly ............................................4-29
Piston Removal..................................................4-29
Piston Installation .............................................. 4-30
Cylinder/Piston Wear.........................................4-31
Piston/Cylinder Clearance.................................4-31
Piston Ring and Ring Groove Wear..................4-31
Piston Ring Groove Width.................................4-32
Piston Ring Thickness.......................................4-32
Piston Ring End Gap Measurement ................. 4-32
Exhaust System ....................................................... 4-33
Spark Arrester Cleaning....................................4-33
Muffler Removal.................................................4-33
Exhaust Pipe Removal......................................4-33
Exhaust Pipe and Muffler Installation................4-33
Exhaust System Inspection...............................4-33
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4-2 ENGINE TOP END
Exploded View
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ENGINE TOP END 4-3
Exploded View
Torque
No.
Fastener
N1m
kgf1m
ft1lb
Remarks
1
Valve Adjusting Cap Bolts
8.8
0.9
78 in1lb
2
Cylinder Head Bolts (M11), first torque
25
2.5
18
MO, S
2
Cylinder Head Bolts (M11), final torque
44
4.5
33
S
3
Cylinder Head Bolts (M6)
12
1.2
104 in1lb
S
4
Camshaft Cover Bolts
8.8
0.9
78 in1lb
5
Engine Breather Plate Screws
4.4
0.45
39 in1lb
6. Face the round end outward.
G:
MO:
S:
O:
R:
Apply grease for oil seal and O-ring.
Apply molybdenum disulfide oil.
Follow the specific tightening sequence.
Apply engine oil.
Replacement Parts
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4-4 ENGINE TOP END
Exploded View
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ENGINE TOP END 4-5
Exploded View
Torque
No.
Fastener
N1m
kgf1m
ft1lb
Remarks
L
1
Camshaft Sprocket Bolts
14
1.4
10
2
Bearing Retainer Bolts
12
1.2
104 in1lb
3
Rear Camshaft Chain Guide Bolt
9.8
1.0
87 in1lb
4
Camshaft Chain Tensioner Mounting Bolts
8.8
0.9
78 in1lb
5
Camshaft Chain Guard Bolts
8.8
0.9
78 in1lb
6
Valve Adjusting Screw Locknuts
12
1.2
104 in1lb
7
Rocker Shaft Holder Bolts
8.8
0.9
78 in1lb
8
Muffler Mounting Bolts
26
2.7
20
G:
L:
MO:
M:
O:
R:
Apply grease for oil seal and O-ring.
Apply a non-permanent locking agent.
Apply molybdenum disulfide oil.
Apply molybdenum disulfide grease.
Apply engine oil.
Replacement Parts
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4-6 ENGINE TOP END
Specifications
Item
Rocker Arms and Shafts
Rocker arm inside diameter
Rocker shaft diameter
Camshaft:
Cam height:
Exhaust
Inlet
Cylinder Head:
Cylinder compression:
Electric starter
@630 r/min (rpm)
Cylinder head warp
Valves:
Valve clearance:
Exhaust
Inlet
Valve/valve guide clearance (wobble
Exhaust
method):
Inlet
Valve seating surface width:
Exhaust
Inlet
Valve seating surface outside diameter:
Exhaust
Inlet
Valve seat cutting angle
Valve head thickness:
Exhaust
Inlet
Valve stem bend
Valve stem diameter:
Exhaust
Inlet
Valve guide inside diameter:
Exhaust
Inlet
Valve spring free length:
Inner
Outer
Cylinder, Piston:
Cylinder inside diameter
Piston diameter
Piston/cylinder clearance
Piston ring/groove clearance:
Top
Second
Piston ring thickness:
Top
Second
Piston ring groove width:
Top
Second
Piston ring end gap:
Top
Second
Oil
Standard
Service Limit
13.000 ~ 13.018 mm (0.5118 ~ 0.5125 in.)
12.973 ~ 12.984 mm (0.5107 ~ 0.5112 in.)
13.05 mm (0.514 in.)
12.95 mm (0.510 in.)
40.693 ~ 41.801 mm (1.6021 ~ 1.6063 in.)
40.837 ~ 40.945 mm (1.6078 ~ 1.6120 in.)
40.59 mm (1.598 in.)
40.74 mm (1.604 in.)
(Usable Range)
810 ~ 1260 kPa
(8.3 ~ 12.8 kgf/cm2, 118 ~ 182 psi)
–––
–––
0.05 mm (0.002 in.)
0.15 ~ 0.20 mm (0.0059 ~ 0.0079 in.)
0.08 ~ 0.13 mm (0.0032 ~ 0.0051 in.)
–––
–––
0.07 ~ 0.14 mm (0.0028 ~ 0.0055 in.)
0.05 ~ 0.13 mm (0.0020 ~ 0.0051 in.)
0.30 mm (0.0118 in.)
0.30 mm (0.0118 in.)
0.5 ~ 1.0 mm (0.02 ~ 0.04 in.)
0.5 ~ 1.0 mm (0.02 ~ 0.04 in.)
–––
–––
34.9 ~ 35.1 mm (1.374 ~ 1.382 in.)
39.9 ~ 40.1 mm (1.571 ~ 1.579 in.)
45 , 32 , 50
–––
–––
–––
1.0 mm (0.04 in.)
1.0 mm (0.04 in.)
under 0.01 mm (0.0004 in.) TIR
0.5 mm (0.020 in.)
0.7 mm (0.028 in.)
0.05 mm (0.002 in.) TIR
6.955 ~ 6.970 mm (0.2738 ~ 0.2744 in.)
6.965 ~ 6.980 mm (0.2742 ~ 0.2748 in.)
6.94 mm (0.2732 in.)
6.95 mm (0.2736 in.)
7.000 ~ 7.015 mm (0.2756 ~ 0.2762 in.)
7.000 ~ 7.015 mm (0.2756 ~ 0.2762 in.)
7.08 mm (0.279 in.)
7.08 mm (0.279 in.)
39.05 mm (1.537 in.)
42.47 mm (1.672 in.)
36.7 mm (1.445 in.)
40.0 mm (1.575 in.)
80.000 ~ 80.012 mm (3.1496 ~ 3.1501 in.)
79.952 ~ 79.967 mm (3.1477 ~ 3.1483 in.)
0.033 ~ 0.060 mm (0.0013 ~ 0.0024 in.)
80.10 mm (3.154 in.)
79.80 mm (3.142 in.)
–––
0.04 ~ 0.08 mm (0.0016 ~ 0.0032 in.)
0.03 ~ 0.07 mm (0.0012 ~ 0.0028 in.)
0.18 mm (0.0071 in.)
0.17 mm (0.0067 in.)
0.97 ~ 0.99 mm (0.0382 ~ 0.0390 in.)
0.97 ~ 0.99 mm (0.0382 ~ 0.0390 in.)
0.90 mm (0.035 in.)
0.90 mm (0.035 in.)
1.03 ~ 1.05 mm (0.0405 ~ 0.0413 in)
1.02 ~ 1.04 mm (0.0402 ~ 0.0409 in.)
1.13 mm (0.0445 in.)
1.12 mm (0.0441 in.)
0.20 ~ 0.30 mm (0.0079 ~ 0.0118 in.)
0.30 ~ 0.45 mm (0.0118 ~ 0.0177 in.)
0.20 ~ 0.70 mm (0.0079 ~ 0.0276 in.)
0.6 mm (0.0236 in.)
0.8 mm (0.0315 in.)
1.0 mm (0.0394 in.)
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ENGINE TOP END 4-7
Specifications
Special Tools - Valve Guide Reamer, 7: 57001-162
Valve Guide Arbor, 7: 57001-163
Compression Gauge: 57001-221
Valve Spring Compressor Assembly: 57001-241
Valve Spring Compressor Adapter, 28.2: 57001-243
Piston Pin Puller Assembly: 57001-910
Compression Gauge Adapter, M12 x 1.25: 57001-1018
Valve Seat Cutter, 45 – 41.5: 57001-1117
Valve Seat Cutter, 32 – 38.5: 57001-1122
Valve Seat Cutter Holder, 7: 57001-1126
Valve Seat Cutter Holder Bar: 57001-1128
Piston Pin Puller Adapter: 57001-1211
Filler Cap Driver: 57001-1454
Valve Seat Cutter, 32 – 44: 57001-1515
Valve Seat Cutter, 50 – 44: 57001-1516
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4-8 ENGINE TOP END
Camshaft Chain Tensioner
Camshaft Chain Tensioner Removal
CAUTION
This is a non-return type camshaft chain tensioner. The push
rod does not return to its original position once it moves out
to take up camshaft chain slack. Observe all the rules listed
below:
When removing the tensioner, do not take out the mounting
bolts only halfway. Retightening the mounting bolts from
this position could damage the tensioner and the camshaft
chain. Once the bolts are loosened, the tensioner must be
removed and reset as described in &quot;Camshaft Chain Tensioner
Installation.&quot;
Do not turn over the crankshaft while the tensioner is removed.
This could upset the camshaft chain timing, and damage the
valves.
• Remove:
Fuel Tank Cover (see Frame chapter)
Exhaust Pipe Cover (see Frame chapter)
the cap bolt [A].
• Loosen
Remove
• tensioner.the mounting bolts [B] and take off the camshaft chain
Camshaft Chain Tensioner Installation
the cap bolt and O-ring.
• Remove
While compressing [A] the push rod [B], turn it clockwise [C] with a
suitable screwdriver [D] until the rod stops.
holding the rod in position with a holder plate, install the
tensioner on the cylinder block.
While
CAUTION
Do not turn the rod counterclockwise at installation. This could
detach the rod and the tensioner cannot be reinstalled.
NOTE
To make the procedure easy, use a holder plate [A] to keep the rod
from pushing out. A replacement chain tensioner (spare parts) has
a holder plate.
holder plate can be made of 0.8 mm (0.03 in.) thick aluminum
• The
plate as shown.
[B] 8.5 mm (0.33 in.)
[C] 3.5 mm (0.14 in.)
[D] 5 mm (0.20 in.)
[E] 12 mm (0.47 in.)
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ENGINE TOP END 4-9
Camshaft Chain Tensioner
a new gasket.
• Install
Install
the
body with the arrow [A] on it pointing downwards.
• Tighten thetensioner
mounting
bolts [B].
•
Torque -
Camshaft Chain Tensioner Mounting Bolts: 8.8 N1m (0.9
kgf1m, 78 in1lb)
the holder plate [C].
• Remove
Apply
grease
the O-ring, and install it on the tensioner body.
• Tighten the capto bolt.
• Turn the crankshaft 2 turns counterclockwise to allow the tensioner
• to expand and recheck the camshaft chain timing.
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4-10 ENGINE TOP END
Camshaft Sprocket
Camshaft Sprocket Removal
• Remove:
Fuel Tank Cover (see Frame chapter)
Exhaust Pipe Cover (see Frame chapter)
Left Front Inner Cover (see Frame chapter)
Recoil Starter (see Recoil Starter chapter)
Bolts [A] and Camshaft Cover [B]
the crankshaft counterclockwise with a wrench on the alternator
• Turn
rotor bolt until the mark [A] on the camshaft sprocket aligns with the
pointer [B] on the cylinder head.
sure to position the crankshaft at TDC of the end of the
compression stroke.
Remove the camshaft chain tensioner (see Camshaft Chain Tensioner Removal).
Remove the camshaft sprocket bolts [C].
Hold the crankshaft from turning with a wrench on the alternator rotor
bolt.
Remove the camshaft sprocket [D].
Be
•
•
•
Camshaft Sprocket Installation
• Remove:
Timing Inspection Plug [A]
Special Tool -
Driver - Filler Cap [B]: 57001–1454
Check that the “T” mark [A] on the alternator rotor aligns with the slot
• [B]
in the alternator cover.
Be
sure to position the crankshaft at TDC of the end of the
compression stroke.
If the “T” mark is not aligned, hold the camshaft chain taut and turn
the crankshaft with a wrench on the alternator rotor bolt.
the notching line [A] of the weight holder [B] aligns with the
• Confirm
pointer [C] on the cylinder head.
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ENGINE TOP END 4-11
Camshaft Sprocket
the camshaft sprocket under the chain, and install the sprocket on
• Fit
the weights so that the mark [A] aligns with the pointer [B].
a non-permanent locking agent to the camshaft sprocket bolts
• Apply
and tighten them, while holding the crankshaft from turning with a
wrench on the alternator rotor bolt.
Torque -
Camshaft Sprocket Bolts: 14 N1m (1.4 kgf1m, 10 ft1lb)
the camshaft chain tensioner (see Camshaft Chain Tensioner
• Install
Installation).
going any further, check the cam timing.
• Before
Turn the crankshaft counterclockwise with a wrench on the alternator
rotor bolt, until the mark on the sprocket realigns with the pointer on
the head.
CAUTION
If any resistance is felt when turning the crankshaft, stop
immediately, or you may bend the valves.
The “T” mark on the alternator rotor should align with the slot.
If the camshaft timing is not correct, remove the sprocket from the
camshaft, and install it again as detailed above.
grease to the O-ring [A], and push the cover into place.
• Apply
Tighten:
•
Torque -
•
Camshaft Cover Bolts: 8.8 N1m (0.9 kgf1m, 78 in1lb)
Install the timing inspection plug.
Special Tool -
Driver - Filler Cap: 57001–1454
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4-12 ENGINE TOP END
Rocker Arms and Shafts
Rocker Arm and Shaft Removal
• Remove:
Recoil Starter (see Recoil Starter chapter)
the crankshaft at TDC of the end of the compression stroke
• Position
(see Camshaft Sprocket Installation).
Rear Side:
Remove:
Fuel Tank (see Fuel System chapter)
Rubber Cover
Valve Adjusting Cap Bolts [A]
Valve Adjusting Cap [B]
Rocker Shaft Holder Bolts [C]
Rocker Shaft [D]
Washers
•
• Push the rocker arm [A] in the rocker case, and turn it in place.
• Remove the rocker arm [A].
Front Side:
Remove:
Right Front Inner Cover (see Frame chapter)
Converter Air Intake Duct
Cylinder Head Bolt [A]
Valve Adjusting Cap [B]
Rocker Shaft Holder Bolts [C]
Rocker Shaft [D]
Washers
Remove the rocker arm in the same manner as above.
•
•
Rocker Arm and Shaft Installation
molybdenum disulfide oil to the rocker shaft [A].
• Apply
Install:
• Rocker Arm [B]
Washers [C]
Rocker Shaft
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ENGINE TOP END 4-13
Rocker Arms and Shafts
Install the rocker shafts [A] so that the punch marks [B] facing to the
•
camshaft.
Tighten:
Torque -
Rocker Shaft Holder Bolts: 8.8 N1m (0.9 kgf1m, 78 in1lb)
Rocker Arm and Shaft Inspection
the area [A] on the rocker arm where the cam rubs.
• Inspect
If the rocker arm is scored, discolored or otherwise damaged, replace
•
•
it. Also inspect the camshaft lobes.
Inspect the end of the valve clearance adjusting screw [B] where it
contacts the valve stem.
If the end of the adjusting screw is mushroomed or damaged in any
way, or if the screw will not turn smoothly, replace it. Also inspect the
end of the valve stem.
Measure the inside diameter [C] of the rocker arm with a dial bore
gauge.
If the rocker arm inside diameter is larger than the service limit,
replace it. Also check the rocker shaft diameter [D].
Rocker Arm Inside Diameter
13.018 mm (0.5118 ~ 0.5125 in.)
Standard:
13.000
Service Limit:
13.05 mm (0.514 in.)
the diameter of the rocker shaft where the rocker arm pivots
• Measure
on it with a micrometer.
If the rocker shaft diameter is smaller than the service limit, replace
it.
Rocker Shaft Diameter
12.984 mm (0.5107 ~ 0.5112 in.)
Standard:
12.973
Service Limit:
12.95 mm (0.510 in.)
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4-14 ENGINE TOP END
Camshaft
Camshaft Removal
• Remove:
Camshaft Sprocket (see Camshaft Sprocket Removal)
Weights [A]
• Loosen the cylinder head bolts [B].
• Remove:
Bolts [A] and Bearing Retainer [B]
Pull
[C] straight out of the head.
• Screwthethecamshaft
camshaft sprocket bolt in to the end of the camshaft and
pull it with the camshaft.
Camshaft Installation
the oil passage with compressed air.
• Blow
molybdenum disulfide oil to the cam lobes [A].
• Apply
Carefully
• “down”. push the camshaft into the cylinder head with the cam lobes
• Install:
Bearing Retainer
Tighten:
•
Torque -
Bearing Retainer Bolts: 12 N1m (1.2 kgf1m, 104 ft1lb)
the notching line [A] of the weight holder [B] with the pointer [C]
• Align
on the cylinder head.
the loosened cylinder head bolts (see Cylinder Head Instal• Tighten
lation).
Cam Wear Inspection
the height of each cam lobe with a micrometer.
• Measure
If the cam height is less than the service limit for either lobe, replace
the camshaft.
Cam Height
Exhaust
Inlet
Standard
40.693
41.801 mm
(1.6021 ~ 1.6063 in.)
40.837 ~ 40.945 mm
(1.6078 ~ 1.6120 in.)
Service Limit
40.59 mm
(1.598 in.)
40.74 mm
(1.604 in.)
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ENGINE TOP END 4-15
Camshaft
Camshaft Bearing Inspection
the ball bearing which is press-fitted on the camshaft.
• Check
Since the ball bearing is made to extremely close tolerances, the wear
must be judged by feel rather than measurement. Clean the bearing
in a high-flash point solvent, dry it (do not spin the bearing while it is
dry), and oil it with engine oil.
Spin the bearing by hand to check its condition.
If the bearing is noisy, does not spin smoothly, or has any rough stops,
replace it.
KACR Inspection
The Kawasaki Automatic Compression Release (KACR) momentarily
opens the exhaust valves on the compression stroke at very low speeds.
This allows some of the compression pressure to escape, making it easy
to turn over the engine during starting.
Due to the simplicity of the mechanism, no periodic maintenance
is needed. There are only two symptoms of problems with the
KACR mechanism [A]: compression is not released during starting, and
compression is released during running.
(1) If compression is not released during starting, the weights are not
returning to their rest position.
Remove the camshaft (see Camshaft Removal).
Remove the KACR unit.
Visually inspect the spring.
If damaged, deformed, or missing, replace the spring.
Remove the spring and move the weights back and forth.
If the weights do not move smoothly, replace the KACR unit. Also
inspect the exhaust rocker arm for any damage, and replace the
rocker arm if necessary.
[A] Rest Position (compression is released)
[B] Weights
[C] Spring
•
•
•
•
(2) If compression is released while the engine is running, the weights
are not swinging out.
Remove the spring and move the weights back and forth.
If the weights do not move easily from the retracted position, replace
the KACR unit. Also inspect the exhaust rocker arm for any damage,
and replace the rocker arm if necessary.
[A] Running Position (compression is not released)
[B] Weights
[C] Spring
•
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4-16 ENGINE TOP END
Camshaft Chain and Guides
Camshaft Chain Removal
• Remove:
Camshaft Sprocket (see Camshaft Sprocket Removal)
Starter Clutch Gear (see Alternator Rotor Removal section in
Electrical System chapter)
Bolts [A] and Camshaft Chain Guard [B]
Camshaft Chain [C]
Camshaft Chain Installation
CAUTION
Always pull the camshaft chain taut while turning the
crankshaft when the camshaft chain is loose. This avoids
kinking the chain on the lower (crankshaft) sprocket. A kinked
chain could damage both the chain and the sprocket.
• Tighten:
Torque -
Camshaft Chain Guard Bolts: 8.8 N1m (0.9 kgf1m, 78 in1lb)
Camshaft Chain Guide Removal
• Remove:
Cylinder Head (see Cylinder Head Removal)
Starter Clutch Gear (see Alternator Rotor Removal section in
Electrical System chapter)
Front Camshaft Chain Guide [A]
Bolt [B] and Rear Camshaft Chain Guide [C]
Camshaft Chain Guide Installation
the front camshaft chain guide [A] into the position [B].
• Slip
• Install:
Rear Camshaft Chain Guide [C]
•
Collar [D]
Tighten:
Torque -
Rear Camshaft Chain Guide Bolt [E]: 9.8 N1m (1.0 kgf1m, 87
in1lb)
Camshaft Chain Guide Wear
inspect the rubber on the guides.
• Visually
If the rubber is damaged, cut, or is missing pieces, replace the guide.
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ENGINE TOP END 4-17
Cylinder Head
Cylinder Compression Measurement
NOTE
Use the battery which is fully charged.
up the engine thoroughly, and stop the engine.
• Warm
Remove
spark plug (see Electrical System chapter).
• Attach thethecompression
gauge [A] and adapter [B] firmly into the spark
• plug hole.
Special Tools - Compression Gauge: 57001-221
Compression Gauge Adapter, M12
•
•
2 1.25: 57001-1018
Hold the throttle wide open and crank the engine with the electric
starter or the recoil starter several times.
When the gauge stops rising, stop cranking and read the gauge.
Cylinder Compression (Usable Range)
1260 kPa (8.3
12.8 kgf/cm2,
Electric Starter:
810
182 psi) @630 r/min (rpm)
118
The following table should be consulted if the obtainable compression reading is not within the usable range.
Problem
Cylinder compression
is higher than usable
range
Cylinder compression
is lower than usable
range
Diagnosis
Carbon accumulation on piston, cylinder head,
and in combustion chamber possibly due to
damaged valve stem oil seal and/or damaged
piston oil rings (This may be indicated by
white exhaust smoke).
Incorrect cylinder head gasket thickness.
Damaged or missing compression release
cam spring
Compression release weights do not
move smoothly.
Gas leakage around cylinder head
Bad condition of valve seating
Incorrect valve clearance.
Incorrect piston/cylinder clearance
Piston seizure.
Bad condition of piston ring and/or piston ring
grooves
Compression release weights do not
move smoothly
Remedy (Action)
Remove the carbon deposits and
replace damaged parts if necessary.
Replace the gasket with a standard
part.
Replace the spring.
Replace the compression release unit.
Replace damaged gasket and check
cylinder head warp.
Repair if necessary.
Adjust the valve clearance.
Replace the piston and/or cylinder
Inspect the cylinder and liner and
replace/repair the cylinder and/or
piston as necessary.
Replace the piston and/or the piston
rings.
Replace the compression release unit
Cylinder Head Removal
• Remove:
Fuel Tank, Carburetor (see Fuel System chapter)
Exhaust Pipe and Muffler (see Exhaust Pipe and Muffler Removal)
Camshaft Sprocket (see Camshaft Sprocket Removal)
Converter Air Intake Duct
Weights [A]
Oil Pipe Bolt [B]
Oil Pipe End [C]
Engine Mounting Bolt [D]
Spark Plug Cap
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4-18 ENGINE TOP END
Cylinder Head
• Remove:
Rubber Cover
Bolts [A] and Cylinder Head Bracket [B]
• Remove:
Cylinder Head Bolts (M6) [A]
Cylinder Head Bolts (M11) [B]
Cylinder Head
Cylinder Head Installation
• Install:
Dowel Pins [A]
•
New Cylinder Head Gasket [B]
Be sure the camshaft chain guides are in place (see Camshaft Chain
Guide Installation).
molybdenum disulfide oil to the M11 bolt threads and both sides
• Apply
of the washers.
the cylinder head bolts [1~7] following the tightening se• Tighten
quence as shown.
[1, 4] L = 220 mm (8.7 in.)
[2, 3] L = 245 mm (9.6 in.)
Torque -
(First) Cylinder Head Bolts (M11) [1~4]: 25 N1m (2.5 kgf1m, 18
ft1lb)
Torque -
(Final) Cylinder Head Bolts (M11) [1~4]: 44 N1m (4.5 kgf1m, 33
ft1lb)
Torque -
Cylinder Head Bolts (M6) [5~7]: 12 N1m (1.2 kgf1m, 104 ft1lb)
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ENGINE TOP END 4-19
Cylinder Head
Cylinder Head Assembly
the rubber dampers [A] in the fin grooves.
• Insert
[B] Left Side
[C] Right Side
[D] Rear Side
[E] 73 mm (2.87 in.)
[F] 57 mm (2.24 in.)
[G] 15 mm (0.59 in.)
the groove [A] in the carburetor holder [B] on the projection [C] of
• Fit
the cylinder head.
Cylinder Head Cleaning
the cylinder head (see Cylinder Head Removal).
• Remove
Scrape
the
carbon out of the combustion chamber and exhaust port
• with a suitable
tool.
Wash
the
head
with a high-flash point solvent.
•
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4-20 ENGINE TOP END
Cylinder Head
Cylinder Head Warp
the cylinder head (see Cylinder Head Cleaning).
• Clean
Lay
a
straightedge
across the lower surface of the cylinder head.
• Use a thickness gauge
[A] to measure the space between the
• straightedge [B] and the head
at several locations.
Cylinder Head Warp
Service Limit:
0.05 mm (0.002 in.)
If the cylinder head is warped more than the service limit, replace it.
If the cylinder head is warped less than the service limit, repair the
head by rubbing the lower surface on emery paper secured to a
surface plate (first No. 200, then No. 400).
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ENGINE TOP END 4-21
Valves, Guides, Seats, Springs, Oil Seals
Valve Clearance Inspection
• Refer to Valve Clearance Inspection in Periodic Maintenanc chapter.
Valve Clearance Adjustment
the locknut [A] and turn the adjusting screw [B] until the
• Loosen
clearance is correct.
the adjusting screw from turning and tighten the locknut to the
• Hold
specified torque.
Torque -
•
Valve Adjusting Screw Locknuts: 12 N1m (1.2 kgf1m, 104 in1lb)
Recheck the clearance.
If the clearance is incorrect, repeat the adjustment procedure.
If the clearance is correct, perform the adjustment procedure on the
other valve.
grease to the O-ring [A].
• Apply
Install
• Tighten:the valve adjusting cap so that the “UP” mark facing upward.
•
Torque -
Valve Adjusting Cap Bolts: 8.8 N1m (0.9 kgf1m, 78 in1lb)
Valve Removal
• Remove:
Cylinder Head (see Cylinder Head Removal)
•
Camshaft (see Camshaft Removal)
Rocker Arms and Shafts (see Rocker Arm and Shaft Removal)
Use the valve spring compressor assembly [A] and adapter [B] to
press down the valve spring retainer.
Special Tools - Valve Spring Compressor Assembly: 57001-241
Valve Spring Compressor Adapter, 28.2: 57001-243
the split keepers.
• Remove
• Loosen the valve spring compressor and take out the valve.
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4-22 ENGINE TOP END
Valves, Guides, Seats, Springs, Oil Seals
Valve Installation
new valve is to be used, check the valve-to-guide clearance.
• IfIf athere
is too little clearance, ream the valve guide.
If there is too much clearance, install a new valve guide.
the valve seat (see Valve Seat Inspection).
• Check
After
proper
• oil seal [A]. valve seating has been confirmed, replace the valve stem
a thin coat of molybdenum disulfide grease to the valve stem
• Apply
[B], and install the valve into the guide.
the spring seat [C].
• Put
Put
and outer springs [D] in place.
• Placethetheinner
springs so that the closed coil end [E] of each spring faces
•
•
•
•
•
•
•
•
down.
Set the valve spring retainer [F] on the springs.
Use the valve spring compressor to press down the retainer.
Install the split keepers [G], and slowly remove the spring compressor.
Be sure the keepers stay in place, holding the retainer down.
Repeat the procedure for the other valve.
Install the removed parts to the cylinder head.
Install the cylinder head (see Cylinder Head Installation).
Adjust the valve clearance (see Valve Clearance Inspection).
Valve Visual Inspection
the valve
• Inspect
warpage.
•
head seating area [A] for erosion, nicks, and
If the valve head seating area is warped, replace the valve.
If the valve head seating area is eroded or nicked, it may be possible
to repair the valve on a valve refacing machine.
Inspect the stem [B] for obvious wear, discoloration, and stem end
[C] damage.
If the stem is obviously worn or discolored, replace the valve.
If the stem end is damaged, it may be possible to repair it on a valve
refacing machine.
Valve Guide Removal
• Remove:
Valve (see Valve Removal)
Valve Stem Oil Seal
Heat the area around the guide to 120 to 150 C (250 to 302 F), and
• hammer
lightly on the valve guide arbor [A] to remove the guide from
the top of the head.
Special Tool -
Valve Guide Arbor,
7 : 57001-163
Valve Guide Installation
the valve guide hole in the cylinder head.
• Clean
Lightly
the valve guide.
• Set theoilsnap
ring into the groove in the valve guide.
• Heat the cylinder
• (250 to 300 F). head around the valve guide hole to 120 to 150 C
the valve guide arbor and a hammer to drive the guide into the
• Use
head from the outside until the snap ring on the guide against the
•
•
head.
Allow the cylinder head to cool.
Ream the valve guide with the valve guide reamer [A] even if the old
guide is reused.
Special Tool -
Valve Guide Reamer,
7 : 57001-162
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ENGINE TOP END 4-23
Valves, Guides, Seats, Springs, Oil Seals
Valve-to-Guide Clearance Measurement
If a small bore gauge is not available, inspect the valve guide wear by
measuring the valve to valve guide clearance with the wobble method
as indicated below.
Insert a new valve [A] into the guide [B] and set a dial gauge against
the stem perpendicular to it as close as possible to the cylinder head
mating surface.
Move [C] the stem back and forth to measure valve/valve guide
clearance.
Repeat the measurement in a direction at a right angle to the first.
If the reading exceeds the service limit, replace the guide.
•
•
•
NOTE
The reading is not actual valve/valve guide clearance because the
measuring point is above the guide.
Valve/Valve Guide Clearance (Wobble Method)
Standard
Service Limit
Exhaust
0.07
0.14 mm
0.30 mm
(0.0028 ~ 0.0055 in.)
(0.0118 in.)
Inlet
0.05 ~ 0.13 mm
0.30 mm
(0.0020 ~ 0.0051 in.)
(0.0118 in.)
Valve Seat Inspection
the valve (see Valve Removal).
• Remove
the valve seating surface [A] between the valve [B] and valve
• Check
seat [C].
Coat the valve seat with machinist’s dye.
Push the valve into the guide.
Rotate the valve against the seat with a lapping tool.
Pull the valve out, and check the seating pattern on the valve head.
It must be the correct width and even all the way around.
the outside diameter [D] of the seating pattern on the valve
• Measure
seat.
If the outside diameter of the valve seating pattern is too large or too
small, repair the seat (see Valve Seat Repair).
Valve Seating Surface Outside Diameter
35.1 mm (1.374 ~ 1.382 in.)
Exhaust:
34.9
40.1 mm (1.571 ~ 1.579 in.)
Inlet:
39.9
NOTE
The valve stem and guide must be in good condition, or this check
will not be valid.
•
If the valve seating pattern is not correct, repair the seat (see Valve
Seat Repair).
Measure the seat width [E] of the portion where there is no build-up
carbon (white portion) of the valve seat with a vernier caliper.
If the width is too wide, too narrow or uneven, repair the seat (see
Valve Seat Repair).
[F] Good
[G] Too Wide
[H] Too Narrow
[J] Uneven
Valve Seating Surface Width
1.0 mm (0.02 ~ 0.04 in.)
Exhaust:
0.5
1.0 mm (0.02 ~ 0.04 in.)
Inlet:
0.5
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4-24 ENGINE TOP END
Valves, Guides, Seats, Springs, Oil Seals
Valve Seat Repair (Valve Lapping)
• Using the valve seat cutters [A], repair the valve seat.
Special Tools - Valve Seat Cutters:
Exhaust Valves: Valve Seat Cutter, 45 - 41.5: 57001-1117
Valve Seat Cutter, 32 - 38.5: 57001-1122
Valve Seat Cutter, 50 - 44: 57001-1516
Inlet Valves:
Valve Seat Cutter, 45 - 41.5: 57001-1117
Valve Seat Cutter, 32 - 44: 57001-1515
Valve Seat Cutter, 50 - 44: 57001-1516
Holder &amp; Bar:
Valve Seat Cutter Holder, 7: 57001-1126 [B]
Valve Seat Cutter Holder Bar: 57001-1128 [C]
If the manufacturer’s instructions are not available, use the following
procedure.
Seat Cutter Operation Care:
1. This valve seat cutter is developed to grind the valve seat for
repair. Therefore the cutter must not be used for other purposes
than seat repair.
2. Do not drop or shock the valve seat cutter, or the diamond
particles may fall off.
3. Do not fail to apply engine oil to the valve seat cutter before
grinding the seat surface. Also wash off ground particles sticking
to the cutter with washing oil.
Do
NOTE
not use a wire brush to remove the metal particles from the
cutter. It will take off the diamond particles.
4. Setting the valve seat cutter holder in position, operate the cutter
in one hand. Do not apply too much force to the diamond portion.
Prior
NOTE
to grinding, apply engine oil to the cutter and during the
operation, wash off any ground particles sticking to the cutter with
washing oil.
5. After use, wash it with washing oil and apply thin layer of engine
oil before storing.
Marks Stamped on the Cutter:
The marks stamped on the back of the cutter [A] represent the
following.
60 ........................................ Cutter angle [B]
37.5 .................................... Outer diameter of cutter [C]
Operating Procedures:
Clean the seat area carefully.
Coat the seat with machinist’s dye.
Fit a 45 cutter into the holder and slide it into the valve guide.
Press down lightly on the handle and turn it right or left. Grind the
seating surface only until it is smooth.
•
•
•
•
CAUTION
Do not grind the seat too much. Overgrinding will reduce
valve clearance by sinking the valve into the head. If the valve
sinks too far into the head, it will be impossible to adjust the
clearance, and the cylinder head must be replaced.
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ENGINE TOP END 4-25
Valves, Guides, Seats, Springs, Oil Seals
Widened Width [A] of engagement by machining with 45 cutter
Ground Volume [B] by 32 cutter
32 [C]
Correct Width [D]
Ground Volume [E] by 50 cutter
50 [F]
the outside diameter of the seating surface with a vernier
• Measure
caliper.
If the outside diameter of the seating surface is too small, repeat the
45 grind [A] until the diameter is within the specified range.
Original Seating Surface [B]
NOTE
Remove all pittings of flaws from 45 ground surface.
After grinding with 45 cutter, apply thin coat of machinist’s dye to
•
seating surface. This makes seating surface distinct and 32 and
50 grinding operation easier.
When the valve guide is replaced, be sure to grind with 45 cutter
for centering and good contact.
If the outside diameter [A] of the seating surface is too large, make
the 32 grind described below.
If the outside diameter of the seating surface is within the specified
range, measure the seat width as described below.
Grind the seat at a 32 angle [B] until the seat O.D. is within the
specified range.
To make the 32 grind, fit a 32 cutter into the holder, and slide it into
the valve guide.
Turn the holder one turn at a time while pressing down very lightly.
Check the seat after each turn.
CAUTION
The 32 cutter removes material very quickly. Check the seat
outside diameter frequently to prevent overgrinding.
After making the 32 grind, return to the seat O.D. measurement step
•
above.
To measure the seat width, use a vernier caliper to measure the width
of the 45 angle portion of the seat at several places around the seat.
If the seat width is too narrow, repeat the 45 grind until the seat is
slightly too wide, and then return to the seat O.D. measurement step
above.
•
If the seat width is too wide, make the 50 [A] grind described below.
If the seat width is within the specified range, lap the valve to the seat
as described below.
Grind the seat at a 50 angle until the seat width is within the specified
range.
To make the 50 grind, fit 50 cutter into the holder, and slide it into
the valve guide.
Turn the holder, while pressing down lightly.
After making the 50 grind, return to the seat width measurement step
above.
Correct Width [B]
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4-26 ENGINE TOP END
Valves, Guides, Seats, Springs, Oil Seals
the valve to the seat, once the seat width and O.D. are within the
• Lap
ranges specified above.
Put a little coarse grinding compound on the face of the valve in a
number of places around the valve head.
Spin the valve against the seat until the grinding compound produces
a smooth, matched surface on both the seat and the valve.
Repeat the process with a fine grinding compound.
•
•
•
[A] Lapper
[B] Valve Seat
[C] Valve
The seating area should be marked about in the middle of the valve
face.
If the seat area is not in the right place on the valve, check to be sure
the valve is the correct part. If it is, it may have been refaced too
much; replace it.
Be sure to remove all grinding compound before assembly.
When the engine is assembled, be sure to adjust the valve clearance
(see Valve Clearance Adjustment).
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ENGINE TOP END 4-27
Valves, Guides, Seats, Springs, Oil Seals
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4-28 ENGINE TOP END
Cylinder and Piston
Cylinder Removal
• Remove:
Cylinder Head (see Cylinder Head Removal)
Front Chain Guide [A]
off the cylinder [B], and remove the cylinder base gasket. If
• Lift
necessary, tap lightly around the base of the cylinder with a plastic
mallet, taking care not to damage the cylinder.
Immediately stuff a clean cloth around the piston to prevent parts or
dirt from falling into the crankcase.
Cylinder Installation
If
NOTE
a new cylinder is installed, be sure to check piston/cylinder
clearance (see Piston/Cylinder Clearance).
any remains of the old cylinder base gasket from the bottom
• Clean
of the cylinder and the top of the crankcase.
• Install:
Dowel Pins [A]
New Cylinder Base Gasket [B]
arrow [A] on the piston head must point toward the front of the
• The
engine.
piston ring openings must be positioned as shown. The openings
• The
40 [B] of angle from
of the oil ring steel rails must be about 30
•
•
•
•
the opening of the top ring.
Top Ring [C]
Second Ring [D]
Oil Ring Expander [E]
Oil Ring Steel Rails [F]
Apply engine oil to the cylinder bore and piston rings.
The rear camshaft chain guide also fit inside the tunnel.
Fit the cylinder down over the piston and rings.
Hold the rings into their groove with your fingers so that the cylinder
does not catch on them.
Push the cylinder down solidly against the crankcase.
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ENGINE TOP END 4-29
Cylinder and Piston
Cylinder Assembly
the rubber dampers [A] in the fin grooves.
• Insert
[B] Front Side
[C] Right Side
[D] Rear Side
[E] 22 mm (0.87 in.)
[F] 21 mm (0.83 in.)
[G] 31 mm (1.22 in.)
Piston Removal
the cylinder (see Cylinder Removal).
• Remove
Place
a
clean
under the piston, remove the one of the piston
• pin snap rings cloth
[A].
CAUTION
Do not reuse snap rings, as removal weakens and deforms
them. They could fall out and score the cylinder wall.
out the piston pin, and remove the piston.
• Push
If necessary, use the piston pin puller assembly [A].
Special Tools - Piston Pin Puller Assembly: 57001-910
Piston Pin Puller Adapter [B]: 57001–1211
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4-30 ENGINE TOP END
Cylinder and Piston
the top and second piston rings [A].
• Remove
Spread the ring open with your thumbs.
Push up on the opposite side with your fingers.
the oil ring upper and lower steel rails.
• Remove
the rail open with your thumbs.
• Spread
Push up on the opposite side with your fingers.
• Remove the oil ring expander.
Piston Installation
If
NOTE
a new piston is used, check piston to cylinder clearance (see
Piston/Cylinder Clearance), and use new piston rings.
The oil ring rails have no “top” or “bottom”.
the oil ring expander [A] in the bottom piston ring groove so
• Install
the ends [B] butt together.
the oil ring steel rails, one above the expander and one below
• Install
it.
Spread the rail with your thumbs, but only enough to fit the rail over
the piston.
Release the rail into the bottom piston ring groove.
not mix up the top ring and second ring.
• Do
the second ring [A] so that the “RN” mark [B] faces up.
• Install
Install
the top ring [C] so that the “R” mark [D] faces up.
•
the piston pin [A].
• Install
Oil the piston pin lightly and slide it through the side of the piston
without a snap ring.
Hold the piston in position over the connecting rod, with the arrow [B]
•
pointing forward, and slide the piston pin the rest of the way through
the connecting rod and piston.
Fit a new piston pin snap ring into the side of the piston so that the
ring opening does not coincide with the slit of the piston pin hole.
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ENGINE TOP END 4-31
Cylinder and Piston
Cylinder/Piston Wear
there is a difference in cylinder wear in different direction, take
• Since
a side-to-side and a front-to-back measurement at each of the 3
locations (total of 6 measurements) shown in the figure.
If any of the cylinder inside diameter measurements exceeds the
service limit, replace the cylinder.
20 mm (0.79 in.) [A]
40 mm (1.57 in.) [B]
10 mm (0.39 in.) [C]
Cylinder Inside Diameter
Standard:
80.000
80.012 mm (3.1496 ~ 3.1501 in.),
and less than 0.01 mm (0.0004 in.) difference
between any two measurements
Service Limit:
80.10 mm (3.154 in.), or more than 0.05 mm
(0.0020 in.) difference between any two
measurements
the piston diameter [A] of each piston 5 mm (0.20 in.) [B]
• Measure
up from the bottom of the piston at a right angle to the direction of
the piston pin.
Piston Diameter
Standard:
Service Limit:
79.967 mm (3.1477 ~ 3.1483 in.)
79.952
79.80 mm (3.142 in.)
If the piston diameter is less than the service limit, replace it.
Piston/Cylinder Clearance
the piston diameter from the cylinder inside diameter to get
• Subtract
the piston/cylinder clearance.
Piston/Cylinder Clearance
Standard:
0.033
0.060 mm (0.0013 ~ 0.0024 in.)
Piston Ring and Ring Groove Wear
for uneven groove wear by inspecting the ring seating.
• Check
The rings should fit perfectly parallel to groove surfaces. If not,
replace the piston and all the piston rings.
the piston rings in their grooves, make several measurements
• With
with a thickness gauge [A] to determine piston ring/groove clearance.
Piston Ring/Groove Clearance
Standard
Top:
0.04
0.08 mm
(0.0016 ~ 0.0032 in.)
Second:
0.03 ~ 0.07 mm
(0.0012 ~ 0.0028 in.)
Service Limit
0.18 mm
(0.0071 in.)
0.17 mm
(0.0067 in.)
If the piston ring groove clearance is greater than the service limit,
measure the ring thickness and groove width as follows to decide
whether to replace the rings, the piston or both.
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4-32 ENGINE TOP END
Cylinder and Piston
Piston Ring Groove Width
the piston ring groove width.
• Measure
Use a vernier caliper at several points around the piston.
Piston Ring Groove Width
Standard
Top:
1.03 ~ 1.05 mm
(0.0405 ~ 0.0413 in.)
Second:
1.02 ~ 1.04 mm
(0.0402 ~ 0.0409 in.)
Service Limit
1.13 mm
(0.0445 in.)
1.12 mm
(0.0441 in.)
If the width of any of the two grooves is wider than the service limit
at any point, replace the piston.
Piston Ring Thickness
the piston ring thickness.
• Measure
Use a micrometer to measure at several points around the ring.
Piston Ring Thickness
Top:
Second:
Standard
0.97 ~ 0.99 mm
(0.0382 ~ 0.0390 in.)
0.97 ~ 0.99 mm
(0.0382 ~ 0.0390 in.)
Service Limit
0.90 mm
(0.035 in.)
0.90 mm
(0.035 in.)
If any of the measurements is less than the service limit on either of
the rings, replace all the rings.
NOTE
When using new rings in a used piston, check for uneven groove
wear. The rings should fit perfect parallel to the groove sides. If
not, replace the piston.
Piston Ring End Gap Measurement
the piston ring inside the cylinder, using the piston to locate
• Place
the ring squarely in place. Set it close to the bottom of the cylinder,
•
where cylinder wear is low.
Measure the gap [A] between the ends of the ring with a thickness
gauge, where cylinder wear is low.
Piston Ring End Gap
Top:
Second:
Oil:
Standard
0.20 ~ 0.30 mm
(0.0079 ~ 0.0118 in.)
0.30 ~ 0.45 mm
(0.0118 ~ 0.0177 in.)
0.20 ~ 0.70 mm
(0.0079 ~ 0.0276 in.)
Service Limit
0.6 mm
(0.0236 in.)
0.8 mm
(0.0315 in.)
1.0 mm
(0.0394 in.)
If the end gap of either ring is greater than the service limit, replace
all the rings.
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ENGINE TOP END 4-33
Exhaust System
This vehicle is equipped with a spark arrester approved for off-road
use by the U.S. Forest Service. It must be properly maintained to ensure
its efficiency. In accordance with the Periodic Maintenance Chart, clean
the spark arrester.
Spark Arrester Cleaning
• Refer to Spark Arrester Cleaning in Periodic Maintenance chapter.
Muffler Removal
the muffler clamp bolt [A] until the clamp turns freely on the
• Loosen
muffler.
the muffler mounting bolts [B].
• Remove
• Remove the muffler [C] from the rear of the frame.
Exhaust Pipe Removal
• Remove:
Left Front Wheel (see Wheels/Tires chapter)
Front Left Inner Cover (see Frame chapter)
Exhaust Pipe Cover (see Frame chapter)
Muffler (see Muffler Removal)
Exhaust Pipe Nuts [A]
Exhaust Pipe [B]
Gasket
Exhaust Pipe and Muffler Installation
the exhaust pipe holder gasket [A] and clamp gasket [B] with
• Replace
new ones.
• Install:
Exhaust Pipe [C] and Clamp [D]
•
Muffler [E] and Dampers [F] and Collars [G]
Plane Washers [H] and Spring Washers [I]
Tighten:
Torque -
Muffler Mounting Bolts [J]: 26 N1m (2.7 kgf1m, 20 ft1lb)
If the cover was removed, install it.
Exhaust System Inspection
removing the exhaust system, check for signs of leakage at
• Before
the exhaust pipe gasket in the cylinder head and at the muffler clamp.
•
•
•
If there are signs of leakage around the exhaust pipe gasket, it should
be replaced. If the muffler-to-exhaust pipe joint leaks, tighten the
clamp.
Remove the exhaust pipe and muffler (see Exhaust Pipe and Muffler
Removal).
Inspect the gasket for damage and signs of leakage.
If the gasket is damaged or has been leaking, replace it.
Check the exhaust pipe and muffler for dents, cracks, rust and holes.
If the exhaust pipe or muffler is damaged or has holes, it should be
replaced for best performance and least noise.
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CONVERTER SYSTEM 5-1
Converter System
Table of Contents
Exploded View...................................................................................................................................................................5-2
Specifications .................................................................................................................................................................... 5-6
Torque Converter...............................................................................................................................................................5-7
Torque Converter Cover Removal..............................................................................................................................5-7
Torque Converter Cover Installation...........................................................................................................................5-7
Torque Converter Cover Disassembly........................................................................................................................5-8
Actuator Lever (Engine Brake Control Lever) Assembly Inspection..........................................................................5-8
Torque Converter Cover Assembly ............................................................................................................................ 5-8
Drive Belt.........................................................................................................................................................................5-10
Drive Belt Removal...................................................................................................................................................5-10
Drive Belt Installation................................................................................................................................................5-10
Drive Belt Deflection Inspection...............................................................................................................................5-10
Drive Belt Deflection Adjustment..............................................................................................................................5-10
Drive Belt Inspection ................................................................................................................................................ 5-10
Drive Pulley .....................................................................................................................................................................5-11
Drive Pulley Removal ...............................................................................................................................................5-11
Drive Pulley Disassembly.........................................................................................................................................5-11
Drive Pulley Inspection.............................................................................................................................................5-12
Spider Shoe Side Clearance Adjustment.................................................................................................................5-14
Drive Pulley Assembly..............................................................................................................................................5-15
Drive Pulley Installation............................................................................................................................................5-16
Driven Pulley................................................................................................................................................................... 5-18
Driven Pulley Removal.............................................................................................................................................5-18
Driven Pulley Disassembly.......................................................................................................................................5-18
Driven Pulley Inspection...........................................................................................................................................5-19
Driven Pulley Assembly............................................................................................................................................5-20
Driven Pulley Installation..........................................................................................................................................5-22
High Altitude Setting Information .................................................................................................................................... 5-23
Specifications ........................................................................................................................................................... 5-23
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5
5-2 CONVERTER SYSTEM
Exploded View
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CONVERTER SYSTEM 5-3
Exploded View
Torque
No.
Fastener
N1m
kgf1m
ft1lb
Remarks
R, Lh
1
Drive Pulley Bolt
93
9.5
69
2
Driven Pulley Nut
93
9.5
69
3
Drive Pulley Cover Bolts
13
1.3
113 in1lb
4
Ramp Weight Nuts
6.9
0.7
61 in1lb
5
Spider
275
28
203
Lh
6: Spacer for High Altitude Setting
G:
M:
Lh:
R:
Apply grease for oil seal and O-ring.
Apply molybdenum disulfide grease.
Left-hand Threads
Replacement Parts
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5-4 CONVERTER SYSTEM
Exploded View
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CONVERTER SYSTEM 5-5
Exploded View
Torque
No.
Fastener
N1m
kgf1m
ft1lb
Remarks
S
1
Converter Cover Bolts
8.8
0.9
78 in1lb
2
Engine Brake Actuator Mounting Bolts
8.8
0.9
78 in1lb
3
Coverter Air Duct Bolts
8.8
0.9
78 in1lb
S: Follow the specific tightening sequence.
G: Apply grease for oil seal and O-ring.
M: Apply molybdenum disulfide grease.
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5-6 CONVERTER SYSTEM
Specifications
Item
Standard
Service Limit
Torque Converter:
Actuator lever guide shoe wear
Drive Belt:
–––
Belt Deflection
20
Belt Width
29.8
6 mm (0.24 in.)
27 mm (0.79 ~ 1.06 in.)
31.0 mm (1.17 ~ 1.22 in.)
–––
29.4 mm (1.16 in.)
Drive Pulley:
Cover bushing inside diameter
27.985
28.085 mm (1.1018 ~ 1.1057 in.)
28.12 mm (1.107 in.)
Sheave bushing inside diameter
37.985
38.085 mm (1.4955 ~ 1.4994 in.)
38.12 mm (1.501 in.)
Shoe side clearance
0.15 ~ 0.30 mm (0.0059 ~ 0.0118 in.)
–––
Spring free length
60 mm (2.36 in.)
–––
Driven Pulley:
40.104 mm (1.5746 ~ 1.5789 in.)
Sheave bushing inside diameter
39.994
Spring free length
75.1 mm (2.96 in.)
40.13 mm (1.580 in.)
–––
Special Tools - Circlip Pliers: 57001–154
Flywheel &amp; Pulley Holder: 57001–1343
Drive &amp; Driven Pulley Holder: 57001–1412
Drive Pulley Puller Bolt: 57001– 1429
Pulley Holder Attachement: 57001–1472
Drive &amp; Driven Pulley Holder: 57001–1473
Drive Pulley Wrench: 57001–1474
Spring Holder Set: 57001–1483
Drive Pulley Measurement Tool: 57001–1498
Actuator Lever Measurement Tool: 57001–1499
Drive Pulley Holder: 57001–1520
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CONVERTER SYSTEM 5-7
Torque Converter
Excessive imbalance or operating rpm could cause torque
converter pulley failure resulting in severe injury or death.
The pulleys of the belt drive torque converter are precision
balanced components designed to operate within certain rpm
limits. Disassembly/assembly and servicing procedures of the
pulley assemblies must be followed closely. Modifications to
the engine or pulleys that increase rpm may cause failure.
CAUTION
Do not turn the ignition switch OFF position from ON position,
while the torque converter cover is removed.
If it is done, the learning control of Engine Brake Control
system works and the engine brake actuator works an error
operation.
If the
NOTE
drive belt failure detection system is activated by abnormal
belt, the drive belt failure detection switch is damaged. Make sure
to replace the torque converter cover.
Torque Converter Cover Removal
• Turn the ignition switch OFF.
NOTE
If the drive failure detection switch lead connector is disconnected
when the ignition switch is in the ON position, the drive Belt Failure
Detection System is activated in the drive belt failure mode. For
resetting the failure mode, the drive belt failure mode clearing
procedure must be done (see LED Indicator section in Electrical
System chapter).
• Disconnect:
Drive Belt Failure Detection Switch Lead Connector [A]
Engine Brake Actuator Lead Connector [B]
If the disconnecting is difficult, remove the fuel tank cover (see Frame
chapter).
• Remove:
Clamp [A]
Air Duct [B]
Torque Converter Cover Bolts [C]
Torque Converter Cover [D]
Torque Converter Cover Installation
the actuator lever assembly installation length (see Torque
• Check
Converter Cover Assembly).
the trim seal into the converter cover.
• Fit
Position point [A] as shown.
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5-8 CONVERTER SYSTEM
Torque Converter
• Check:
Drive Belt Failure Detection Switch (see Switch Inspection section
in Electric System chapter)
• Set the switch lever [A] to the ON mark side [B].
NOTE
The failure detection system is activated when the switch is in the
ON position. This is the normal running mode. Engine rpm is
limited when the switch is in the OFF position.
the No. 3 bolt temporarily.
• Tighten
Tighten
No.1 and No.2 bolts temporarily.
• Press thethecover
toward the arrow [A], and then tighten the cover bolts
• following the tightening
sequence as shown.
Torque -
Converter Cover Bolts: 8.8 N1m (0.9 kgf1m, 78 in1lb)
[B] Clamp
Torque Converter Cover Disassembly
• Remove:
Torque Converter Cover (see Torque Converter Cover Removal)
Engine Brake Actuator (see Electrical System chapter)
Circlip [A]
Spring [B]
Actuator Lever Assembly [C]
Actuator Lever (Engine Brake Control Lever) Assembly Inspection
to Actuator Lever (Engine Brake Control Lever) Assembly
• Refer
Inspection in Periodic Maintenance chapter.
Torque Converter Cover Assembly
• Install:
New Circlip
•
Spring
Actuator Lever Assembly
Engine Brake Actuator (see Electrical System chapter)
Measure the installation length [A] of the actuator lever assembly
between the cover end [B] and resin tips [C] on the actuator lever
assembly as follows:
Actuator Lever Assembly Installation Length
Standard:
149.33 ~ 150.47 mm (5.879 ~ 5.924 in.)
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CONVERTER SYSTEM 5-9
Torque Converter
Install the actuator lever measurement tool (plate [A] and rods [B]) on
the torque converter cover [C] and tighten the two cover bolts.
Special Tool -
Actuator Lever Measurement Tool: 57001-1499
Set the rod ends on the resin tips [D].
Measure the recess length [E] between the plate and rods with Vernier
calipers [F] or depth gauge.
Measurement Length [E]
Standard:
1.33 ~ 2.47 mm (0.052 ~ 0.097 in.)
If the measurement is 1.33 mm (0.052 in.) or less, use the actuator
lever assembly (13236–1385) of yellow paint.
If the measurement is more than 2.47 mm (0.097 in.), use the actuator
lever assembly (13236–1386) of green paint.
If the length is not within the specified length after the actuator lever
assembly is replaced, replace the torque converter cover, and install
the actuator lever assembly (13236–1387).
Actuator Lever Assemblies
Part Number
13236-1385
13236-1387
13236-1386
Paint Color [A]
Yellow
None
Green
Length [B]
0.4 &plusmn; 0.1 mm (0.016 &plusmn; 0.004 in.)
1.0 &plusmn; 0.1 mm (0.039 &plusmn; 0.004 in.)
1.6 &plusmn; 0.1 mm (0.063 &plusmn; 0.004 in.)
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5-10 CONVERTER SYSTEM
Drive Belt
Drive Belt Removal
• Remove the drive pulley [A] (see Drive Pulley Removal).
NOTE
Before removing, observe the direction the belt’s printed information [B] (such as manufacturer’s name and arrow marks) is facing
so that it may be reinstalled on the pulleys to rotate in the same
direction as originally installed.
• Lift the drive belt [C] off the driven pulley [D].
Drive Belt Installation
NOTE
Be sure the printed information faces the same direction so the belt
rotates in the same direction as originally installed. When installing
a new belt, install it so the printed information [A] can be read from
beside the vehicle.
is basically the reverse of removal.
• Installation
Loop
the
belt
the driven pulley.
• Install the driveoverpulley
(see Drive Pulley Installation).
•
the transmission in neutral, and rotate the driven pulley to allow
• Put
the belt to return to the top [A] of the sheaves, before measuring belt
deflection.
Drive Belt Deflection Inspection
to Drive Belt Deflection Inspection in Periodic Maintenance
• Refer
chapter.
Drive Belt Deflection Adjustment
to Drive Belt Deflection Adjustment in Periodic Maintenance
• Refer
chapter.
Drive Belt Inspection
• Refer to Drive Belt Inspection in Periodic Maintenance chapter.
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CONVERTER SYSTEM 5-11
Drive Pulley
Drive Pulley Removal
• Remove:
Torque Converter Cover (see Torque Converter Cover Removal)
the three bolts of the drive pulley cover.
• Remove
and tighten the drive pulley holder [A] and the three bolts [B]
• Install
as shown.
Special Tool -
Drive Pulley Holder: 57001–1520
• Loosen the drive pulley bolt [C].
The
NOTE
drive pulley bolt has left-hand threads.
clockwise for loosening.
Turn the wrench
the drive pulley holder [A] and drive pulley puller bolt [B],
• Using
remove the drive pulley [C] from the crankshaft.
Special Tools - Drive Pulley Puller Bolt: 57001–1429
Drive Pulley Holder: 57001–1520
Drive Pulley Disassembly
the drive &amp; driven pulley holder [A] and guide (57001–1412) [B]
• Hold
in a vise so that the upper surface on the holder is 7 mm (0.28 in.)
[C] above the vise.
Special Tools - Drive Pulley Holder: 57001-1473
Drive &amp; Driven Pulley Holder: 57001–1412
the pulley onto the pulley holder.
• Set
Remove:
• Drive Pulley Cover Bolts [A]
Drive Pulley Cover [B]
• Remove:
Spring [A]
Spacer
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5-12 CONVERTER SYSTEM
Drive Pulley
the drive pulley wrench [A] on the spider [B] and tighten the bolt
• Put
[C].
Special Tool -
•
Drive Pulley Wrench: 57001–1474
Turn the wrench clockwise and remove the spider with the movable
sheave.
The
NOTE
spider has left-hand threads. Turn the wrench clockwise for
loosening.
• Remove:
Spider [A]
Shoes [B]
Nuts [C]
Ramp Weight Pin [D]
Ramp Weight [E]
Movable Sheave [F]
Fixed Sheave [G]
Drive Pulley Inspection
If the sheave surfaces [A] appear damaged, replace the sheaves.
If the cover bushing is damaged or worn, replace the drive pulley
cover.
Cover Bushing Inside Diameter [A]
28.085 mm (1.1018 ~ 1.1057 in.)
Standard:
27.985
Service Limit:
28.12 mm (1.107 in.)
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CONVERTER SYSTEM 5-13
Drive Pulley
If the sheave bushing is damaged or worn, replace it.
Sheave Bushing Inside Diameter [A]
Standard:
37.985
38.085 mm (1.4955 ~ 1.4994 in.)
Service Limit:
38.12 mm (1.501 in.)
•
If the spider shoes [A] are damaged, replace them.
Check the spider shoe side clearance (see Spider Shoe Side
Clearance Inspection).
If the ramp weights [A] are damaged or worn, replace them.
If the pins [B] are damaged or worn, replace them.
If the rollers [A] are damaged or worn, replace the spider [B].
If the washers [C] are damaged or worn, replace the spider.
If the spring is worn or damaged, replace the spring.
Spring Free Length [A]
Standard:
60 mm (2.36 in.)
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5-14 CONVERTER SYSTEM
Drive Pulley
Spider Shoe Side Clearance Adjustment
• Remove:
Drive Pulley (see Torque Converter Removal)
Drive Pulley Cover and Spring (see Drive Pulley Disassembly)
install:
• Temporarily
Dowel Pins (2)
Drive Pulley Cover
Two Bolts (at dowel pins)
the movable sheave clockwise.
• Turn
Measure
clearance [A] between the shoe [B] and the
• post [C] onthetheresulting
movable sheave at all four arms.
Shoe Side Clearance
Standard:
0.15 ~ 0.30 mm (0.0059 ~ 0.0118 in.)
If any of the measurements are greater than the maximum, replace
all shoes with standard shoes (P/No. 49048-1080) (see Drive Pulley
Disassembly).
the movable sheave clockwise.
• Turn
the resulting clearance [A] between the shoe [B] and the
• Measure
post [C] on the movable sheave at two positions as shown.
[D] Arrow Mark
If the clearance is not within the specified range, adjust it according
to following chart.
Clearance Measurement
up to 0.15 mm (0.0059 in.)
over 0.15 to 0.30 mm
(over 0.0059 to 0.0118 in.)
(standard clearance)
over 0.30 mm (0.0118 in.)
Present Shoes
Part Number
Thickness
49048-1078
7.2 mm (0.283 in.)
49048-1079
7.3 mm (0.287 in.)
no change
49048-1080
7.4 mm (0.291 in.)
49048-1081
49048-1082
49048-1083
49048-1084
49048-1085
49048-1086
7.5
7.6
7.7
7.8
7.9
8.0
mm
mm
mm
mm
mm
mm
(0.295
(0.299
(0.303
(0.307
(0.311
(0.315
in.)
in.)
in.)
in.)
in.)
in.)
that the movable sheave [A] moves smoothly, after the shoe
• Check
side clearance adjustment.
The movable sheave must move freely towards the fixed sheave [B].
If the movable sheave does not move smoothly, readjust the shoe
side clearance.
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CONVERTER SYSTEM 5-15
Drive Pulley
Drive Pulley Assembly
the ramp weight [A] as shown.
• Install
Tighten:
•
Torque -
Ramp Weight Nuts [B]: 6.9 N1m (0.7 kgf1m, 61 in1lb)
• Check that the ramp weights swing smoothly.
• Hold the fixed sheave [A] with the drive pulley holder [B] in a vise.
Special Tool -
Drive Pulley Holder: 57001–1473
the threads of the fixed sheave and spider.
• Clean
• Install:
Movable Sheave
Spider [A] and Wear Guides [B]
Align the arrow [C] on the spider with the arrow [D] on the movable
sheave.
the guides so that the rubber side (small diameter) faces
inward.
Insert
the drive pulley wrench [A] on the spider [B] and tighten the bolt
• Put
[C].
Special Tool -
•
Drive Pulley Wrench: 57001–1474
Turn the wrench counterclockwise for tightening.
Torque -
Spider: 275 N1m (28 kgf1m, 203 ft1lb)
the spacer.
• Install
Put
the
[A] in the groove of the spider.
• Align thespring
• Install: arrows [B] on the drive pulley cover and spider.
• Dowel Pins [C]
Drive Pulley Cover
• Tighten:
Torque -
•
Drive Pulley Cover Bolts: 13 N1m (1.3 kgf1m, 113 in1lb)
Clean the surface of the sheaves with an oil-less cleaning fluid.
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5-16 CONVERTER SYSTEM
Drive Pulley
Drive Pulley Installation
the following portions with an oil-less cleaning fluid such as
• Clean
trichloroethylene or acetone.
Fixed Sheave Tapered Portion [A]
Crankshaft Tapered Portion [B]
These cleaning fluids are usually highly flammable and harmful if breathed for prolonged periods. Be sure to heed the fluid
manufacturer’s warnings.
the drive pulley and washers (3) [A] on the drive pulley bolt as
• Install
shown.
• Hold the drive pulley with the drive pulley holder [A].
Special Tool -
Drive Pulley Holder: 57001–1520
• Tighten:
Torque -
Drive Pulley Bolt [B] (New, left-hand threads): 93 N1m (9.5
kgf1m, 69 ft1lb)
the installation length [A] of the drive pulley between the
• Adjust
surface of the crankcase [B] and the collar [C] on the drive pulley
as followings.
Drive Pulley Installation Length [A]
Standard:
149.85 ~ 150.95 mm (5.900 ~ 5.943 in.)
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CONVERTER SYSTEM 5-17
Drive Pulley
Install the drive pulley measurement tool (legs [A] and plate [B]) on
the crankcase [C].
Special Tool -
Drive Pulley Measurement Tool: 57001–1498
Measure the length [D] between the plate and collar [E] with Vernier
calipers [F] or a depth gauge.
Measurement Length [D]
Standard:
14.55 ~ 15.65 mm (0.573 ~ 0.616 in.)
If the measurement is 14.55 mm (0.573 in.) or less, use the drive
pulley cover (14041–1148) of red paint.
If the measurement is more than 15.65 mm (0.616 in.), use the drive
pulley cover (14041–1149) of blue paint.
If the length is not within the specified length after the drive pulley
cover is replaced, replace the drive pulley assembly.
Drive Pulley Covers
Part Number
14041-1148
14041-1149
14041-1150
Paint Color [A]
Red
Blue
None
Length [B]
24.0 mm (0.945 in.)
25.4 mm (1.000 in.)
24.7 mm (0.972 in.)
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5-18 CONVERTER SYSTEM
Driven Pulley
Driven Pulley Removal
• Remove:
Torque Converter Cover (see Torque Converter Cover)
•
Drive Pulley (see Drive Pulley Removal)
Drive Belt (see Drive Belt Removal)
Using a flywheel &amp; pulley holder [A] and adapter [B], remove the
driven pulley nut [C] and washers. (Nut has R/H threads.)
Special Tools - Flywheel &amp; Pulley Holder: 57001–1343
Pulley Holder Attachment: 57001–1472
• Remove:
Driven Pulley
Driven Pulley Disassembly
• Hold the drive &amp; driven pulley holder [A] in a vise.
Special Tool -
Drive Pulley Holder: 57001–1473
• Screw the guide bar [B] into the holder.
Special Tool -
Spring Holder Set: 57001–1483
the driven pulley [C] on the guide bar.
• Put
• Tighten nut [D], and compress the spring with the spring holder [E].
Special Tool -
Spring Holder Set: 57001–1483
• Remove circlip [A] with circlip pliers [B].
Special Tool -
Circlip Pliers: 57001–154
• Remove nut and spring holder [C].
• Remove:
Spring Seats [A]
Spring [B]
Spring Spacer (if used, for high altitude setting)
Thrust Plate [C]
match-marks [A] and [B] on the sheaves so that it can be
• Make
installed later in the same position.
Movable Shoe [C]
Fixed Sheave [D]
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CONVERTER SYSTEM 5-19
Driven Pulley
off the molybdenum disulfide grease.
• Wipe
Remove
four pins [A] with a thin standard tip screwdriver [B].
• Remove the
the
movable sheave from the fixed sheave.
•
• Remove:
Spacer(s) [A] (for Drive Belt Deflection Adjustment)
Driven Pulley Inspection
If the sheave surfaces [A] appear damaged, replace the sheaves.
sheave with uneven wear on the belt contacting surfaces.
• Replace
[A] Sheave Surface
[B] Straight Edge
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5-20 CONVERTER SYSTEM
Driven Pulley
If the guide bushings [A] are damaged or worn, replace the movable
sheave.
Sheave Bushing Inside Diameter
40.104 mm (1.5746 ~ 1.5789 in.)
Standard:
39.994
Service Limit:
40.13 mm (1.580 in.)
seals for damage.
• Inspect
If seals are damaged, replace the movable sheave.
If the splines [A] are damaged or worn, replace the fixed sheave.
If the spring is damaged or worn, replace the spring.
Spring Free Length [A]
Standard:
75.1 mm (2.96 in.)
If the spring coils are distorted, replace the spring.
Driven Pulley Assembly
off any grease or dirt on the movable and fixed sheave, and
• Clean
dry them with a clean cloth.
• Install:
Spacers [A] (for Drive Belt Deflection Adjustment)
grease to the oil seal lips [A].
• Apply
Apply
disulfide grease to the inner surface of the
• bushingsmolybdenum
[B].
installing the new oil seal, press and insert it so that the seal
• When
surface is flush with the end of each housing in the movable sheave.
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CONVERTER SYSTEM 5-21
Driven Pulley
the match-marks on the sheaves, made when disassembled,
• Align
and the opening [A] and hole [B] will be matched easily.
molybdenum disulfide grease to the seating surface [A] of the
• Apply
pins, and insert them into the holes in the movable sheave.
the movable sheave onto the fixed sheave, and apply molybde• Draw
num disulfide grease of 1 g (0.035 oz) to all openings [A].
NOTE
Do not heap up the grease out of the openings.
that the O-rings [A] are in good condition.
• Check
If any of the O-rings are damaged, replace them.
• Apply grease to the O-rings.
• Hold the drive &amp; driven pulley holder in a vise.
Special Tool -
Drive Pulley Holder: 57001- 1473
• Screw the guide bar into the holder.
Special Tool -
Spring Holder Set: 57001-1483
the driven pulley [A] onto the guide bar.
• Put
the thrust plate [B] so that the alloy side (gray) faces the movable
• Put
sheave.
• Install:
Spring Spacer (see High Altitude Setting Information)
Spring Seat [C] 18.5 mm (0.728 in.)
Spring [D]
Spring Seat [E] 9.3 mm (0.366 in.)
Circlip [F]
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5-22 CONVERTER SYSTEM
Driven Pulley
• Tighten nut [A], and compress the spring with the spring holder [B].
Special Tool -
•
Special Tool -
•
•
Spring Holder Set: 57001-1483
Install circlip [C] with circlip pliers [D].
Circlip Pliers: 57001-154
Remove the driven pulley from the spring holder set.
Clean the surface of the sheaves with an oil-less cleaning fluid.
Driven Pulley Installation
the transmission driven shaft [A].
• Clean
Install:
• Driven Pulley
NOTE
When engaging the spline on the driven pulley with the spline [B]
on the shaft, do not damage the pulley’s spline. If any damage
occurs, remove it with a file.
the driven shaft and driven pulley ends to open the air vent
• Clean
passage. Wipe off any extra grease.
Wipe off any protruding grease [A].
• Install the washers [A] on the shaft as shown.
a flywheel &amp; pulley holder [A] and adapters [B], tighten the
• Using
driven pulley nut [C].
Special Tools - Flywheel &amp; Pulley Holder: 57001–1343
Pulley Holder Attachment: 57001–1472
Torque -
Driven Pulley Nut: 93 N1m (9.5 kgf1m, 69 ft1lb)
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CONVERTER SYSTEM 5-23
High Altitude Setting Information
Specifications
Altitude
Drive Pulley
m (ft)
Ramp Weight
Spring
0 ~ 500
P/No. 39152-1096
P/No. 92145-1465
(0 ~ 1,700)
(STD, EC)
(STD, Pink)
Driven Pulley
Carburetor
Spring Spacer
Main Jet
P/No. 92063-1332
—
(STD) #155 or
P/No. 92063-1344
#158
500 ~ 1,400
P/No. 39152-1096
P/No. 92145-1465
(1,700 ~ 4,700)
(STD, EC)
(STD, Pink)
1,400 ~ 2,300
P/No. 39152-1098
P/No. 92145-1187
(4,700 ~ 7,700)
(EC-H1)
(Gray)
—
P/No. 92063-1332
P/No. 92026-1623
P/No. 92063-1017
(STD) #155
#145
2,300 ~ 3,300
P/No. 39152-1100
P/No. 92145-1187
P/No. 92026-1623
P/No. 92063-1014
(7,700 ~ 10,700)
(EC-H2)
(Gray)
x 2 pc.
#135
3,300 ~ 4,500
P/No. 39152-1100
P/No. 92145-1187
P/No. 92026-1623
P/No. 92063-1069
(10,700 ~ 14,800)
(EC-H2)
(Gray)
x 2 pc.
#125
Refer to the Drive Pulley and Drive Pulley sections in this chapter and Carburetor section in Fuel System chapter for
the parts replacement.
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Property of www.SmallEngineDiscount.com - Not for Resale
RECOIL STARTER 6-1
Recoil Starter
Table of Contents
Exploded View...................................................................................................................................................................6-2
Recoil Starter .................................................................................................................................................................... 6-4
Recoil Starter Removal .............................................................................................................................................. 6-4
Recoil Starter Installation...........................................................................................................................................6-4
Recoil Starter Inspection............................................................................................................................................6-4
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6
6-2 RECOIL STARTER
Exploded View
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RECOIL STARTER 6-3
Exploded View
Torque
No.
1
Fastener
Recoil Starter Mounting Bolts
N1m
kgf1m
ft1lb
Remarks
5.9
0.6
52 in1lb
L
L: Apply a non-permanent locking agent.
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6-4 RECOIL STARTER
Recoil Starter
Recoil Starter Removal
• Remove:
Recoil Starter Mounting Bolts [A]
Recoil Starter [B]
Recoil Starter Installation
a non-permanent locking agent:
• Apply
Recoil Starter Mounting Bolts
• Tighten:
Torque -
Recoil Starter Mounting Bolts: 5.9 N1m (0.6 kgf1m, 52 in1lb)
Recoil Starter Inspection
• Check the starter rope for excessive wear or fraying.
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ENGINE LUBRICATION SYSTEM 7-1
Engine Lubrication System
Table of Contents
Exploded View...................................................................................................................................................................7-2
Specifications .................................................................................................................................................................... 7-4
Engine Oil Flow Chart.......................................................................................................................................................7-5
Engine Oil and Oil Filter....................................................................................................................................................7-6
Oil Level Inspection....................................................................................................................................................7-6
Engine Oil Change.....................................................................................................................................................7-6
Oil Filter Change ........................................................................................................................................................ 7-6
Oil Screen Removal ................................................................................................................................................... 7-6
Oil Screen Cleaning................................................................................................................................................... 7-7
Oil Pressure Measurement ............................................................................................................................................... 7-8
Oil Pressure Measurement ........................................................................................................................................ 7-8
Oil Pressure Relief Valve .................................................................................................................................................. 7-9
Oil Pressure Relief Valve Removal............................................................................................................................7-9
Oil Pressure Relief Valve Installation.........................................................................................................................7-9
Oil Pressure Relief Valve Inspection..........................................................................................................................7-9
Oil Pump ......................................................................................................................................................................... 7-10
Oil Pump Removal ................................................................................................................................................... 7-10
Oil Pump Installation ................................................................................................................................................ 7-10
Oil Pipe/Oil Hose.............................................................................................................................................................7-11
Oil Pipe Removal......................................................................................................................................................7-11
Oil Pipe Installation .................................................................................................................................................. 7-11
Oil Hose Removal .................................................................................................................................................... 7-12
Oil Hose Installation ................................................................................................................................................. 7-12
Oil Cooler........................................................................................................................................................................ 7-13
Oil Cooler Removal ..................................................................................................................................................7-13
Oil Cooler Installation...............................................................................................................................................7-13
Oil Cooler Disassembly............................................................................................................................................7-13
Oil Cooler Fan Switch, Oil Temperature Warning Light Switch Removal................................................................7-14
Oil Cooler Fan Switch, Oil Temperature Warning Light Switch Installation.............................................................7-14
Oil Cooler Fan Switch, Oil Temperature Warning Light Switch Inspection..............................................................7-14
Oil Cooler Inspection................................................................................................................................................7-14
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7
7-2 ENGINE LUBRICATION SYSTEM
Exploded View
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ENGINE LUBRICATION SYSTEM 7-3
Exploded View
Torque
No.
Fastener
N1m
kgf1m
ft1lb
Remarks
1
Oil Cooler Mounting Bolts
8.8
0.9
78 in1lb
2
Oil Pipe Joint Nuts
29
3.0
22
3
Oil Cooler Fan Switch
16
1.6
12
4
Oil Temperature Warning Light Switch
16
1.6
12
5
Oil Hose Banjo Bolts
29
3.0
22
6
Oil Pipe Bolts
8.8
0.9
78 in1lb
7
Oil Filter
18
1.8
13
R
8
Oil Filter Mounting Bolt
25
2.5
18
L
9
Oil Pressure Relief Valve
15
1.5
11
L
10
Oil Pressure Switch
15
1.5
11
SS
11
Oil Pump Cover Screws
5.4
0.55
48 in1lb
12
Oil Pump Cover Bolt
20
2.0
14
13
Oil Line Plugs
23
2.3
17
14
Engine Drain Plug
20
2.0
14
15
Oil Pressure Switch Terminal Bolt
1.5
0.15
13 in1lb
G:
L:
O:
SS:
R:
L
Apply grease for oil seal and O-ring.
Apply a non-permanent locking agent.
Apply engine oil.
Apply silicone sealant (Kawasaki Bond: 56019–120).
Replacement Parts
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7-4 ENGINE LUBRICATION SYSTEM
Specifications
Item
Standard
Engine Oil:
Type
API SF or SG
API SH or SJ with JASO MA
Viscosity
SAE 10W-40
Capacity
1.50 L (1.59 US qt) (when filter is not removed)
1.74 L (1.84 US qt) (when filter is removed)
2.3 L (2.43 US qt) (when engine is completely dry)
Oil Pressure Measurement:
Oil Pressure @ 4500 r/min (rpm), oil temp. 120 C
(248 F)
177 kPa (1.8 kg/cm2, 25.6 psi)
Special Tools - Oil Filter Wrench: 57001–1249
Oil Pressure Gauge, 10 kgf/cm2: 57001–164
Oil Pressure Gauge Adapter: 57001–1033
Sealant -
Kawasaki Bond (Silicone Sealant): 57001–120
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ENGINE LUBRICATION SYSTEM 7-5
Engine Oil Flow Chart
1.
2.
3.
4.
5.
6.
Oil Hose
Oil Pipe
Oil Screen
Oil Pump
Relief Valve
Oil Cooler
7.
8.
9.
10.
11.
Oil Filter
Oil Pressure Switch
Drive Shaft
Input Shaft
Crankshaft
12.
13.
14.
15.
16.
Oil Nozzle
Rocker Shaft
Camshaft
Engine Breather
Blow-by Gas (to Air Cleaner)
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7-6 ENGINE LUBRICATION SYSTEM
Engine Oil and Oil Filter
Vehicle operation with insufficient, deteriorated, or contaminated engine oil will cause accelerated wear and may result in
engine or transmission seizure, accident, and injury.
Oil Level Inspection
the vehicle so that it is level, both side-to-side and front-to-rear.
• Park
If
the
oil has just been changed, start the engine, and run it for several
• minutes
to fill the oil filter.
CAUTION
Allow the engine to idle for several minutes so that oil may
reach all parts of the engine. Racing a &quot;dry&quot; engine may cause
severe damage.
the engine and wait several minutes for all the oil to drain back
• Stop
to the sump.
the oil filler cap, wipe its dipstick [A] dry, and tighten it into
• Unscrew
the filler opening.
the oil filler cap and check the oil level. The oil level should
• Unscrew
be between the upper (H) level line [B] and lower (L) level line [C].
If the level is too high, suck the excess oil out the filler hole with a
syringe or other suitable device.
If the level is too low, add oil through the filler hole. Use the same
type and make of oil that is already in the engine.
Engine Oil Change
• Refer to Engine Oil Change in Periodic Mantenance chapter.
Oil Filter Change
• Refer to Oil Filter Change in Periodic Maintenance chapter.
Oil Screen Removal
the crankcase (see Crankshaft/Transmission chapter).
• Split
Pull
the
oil screen [A] out of the crankcase.
•
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ENGINE LUBRICATION SYSTEM 7-7
Engine Oil and Oil Filter
Oil Screen Cleaning
the oil screen [A] thoroughly whenever it is removed for any
• Clean
reason.
the oil screen with a high-flash point solvent and remove any
• Clean
particles stuck to it.
Clean the screen in a well-ventilated area, and take care that
there is no spark or flame anywhere near the working area.
Because of the danger of highly flammable liquids, do not use
gasoline or low flash-point solvents.
NOTE
While cleaning the screen, check for any metal particles that might
indicate internal engine damage.
•
Check the screen carefully for any damage, holes, broken wires, or
gasket pulling off.
If the screen is damaged, replace it.
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7-8 ENGINE LUBRICATION SYSTEM
Oil Pressure Measurement
Oil Pressure Measurement
NOTE
Measure the oil pressure after the engine is warmed up.
the front left flap and oil pressure switch, and attach the oil
• Remove
pressure gauge [A] and adapter [B].
Special Tools - Oil Pressure Gauge, 10 kgf/cm2: 57001–164
Oil Pressure Gauge Adapter: 57001–1033
Oil Pressure
Standard:
•
•
177 kPa (1.8 kgf/cm2, 25.6 psi) @ 4500 r/min
(rpm), 120 C (248 F) of oil temp.
If the oil pressure is much lower than the standard, inspect the relief
valve, oil pump, and/or crankshaft bearing insert wear.
If the oil pressure is much higher than the standard inspect the oil filter,
oil screen, and other areas of the lubrication system for clogging.
Stop the engine.
Remove the oil pressure gauge and adapter.
Take care against burns form hot engine oil that will drain
through the oil passage when the gauge adapter is removed.
• Apply silicone sealant to the oil pressure switch, and tighten it.
Sealant -
Kawasaki Bond (Silicone Sealant): 56019–120
Torque -
Oil Pressure Switch: 15 N1m (1.5 kgf1m, 11 ft1lb)
Oil Pressure Switch Terminal Bolt: 1.5 N1m (0.15 kgf1m, 13
in1lb)
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ENGINE LUBRICATION SYSTEM 7-9
Oil Pressure Relief Valve
Oil Pressure Relief Valve Removal
Crankcase disassembly (see Crankshaft / Transmission chapter).
• See
Remove
the oil pressure relief valve [A].
•
Oil Pressure Relief Valve Installation
crankcase assembly (see Crankshaft / Transmission chapter).
• See
Apply
a non-permanent locking agent to the threads of oil pressure
• relief valve,
and tighten it.
Torque -
Oil Pressure Relief Valve: 15 N1m (1.5 kgf1m, 11 ft1lb)
Oil Pressure Relief Valve Inspection
the relief valve.
• Remove
Using
a
wooden
stick, push the inner valve to make sure that the
• valve [A] moves smoothly
and that it returns to its original position by
the force of the spring [B].
NOTE
The relief valve cannot be disassembled and it must be inspected
in the assembled state.
If the valve movement is not smooth, wash the relief valve with highflash point solvent, and use compressed air to remove any foreign
particles from it.
Clean the oil pressure relief valve in a well-ventilated area,
and take care that there is no spark or flame anywhere near
the working area. Because of the danger of highly flammable
liquids, do not use gasoline to low-flash point solvent.
If the valve does not move smoothly even after washing it, replace
the relief valve. The oil pressure relief valve is precision made with
no allowance for replacement of individual parts.
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7-10 ENGINE LUBRICATION SYSTEM
Oil Pump
Oil Pump Removal
• Remove:
Alternator Rotor and Starter Clutch Gear (see Electrical System
chapter)
Oil Pump Cover Screws [A]
Oil Pump Cover Bolt [B]
Oil Pump Cover [C]
• Remove:
Inner Rotor [A]
Outer Rotor [B]
Oil Pump Installation
engine oil:
• Apply
Inner and Outer Rotors
• Install:
Inner Rotor
•
Outer Rotor
Oil Pump Cover
Tighten:
Torque -
Oil Pump Cover Bolt: 20 N1m (2.0 kgf1m, 14 ft1lb)
Oil Pump Cover Screws: 5.4 N1m (0.55 kgf1m, 48 in1lb)
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ENGINE LUBRICATION SYSTEM 7-11
Oil Pipe/Oil Hose
Oil Pipe Removal
Engine Left Side Oil Pipe:
Remove:
Engine Left Side Cover (see Frame chapter)
Oil Pipe Bolts [A]
Oil Pipe [B]
•
Engine Inside Oil Pipe:
Remove:
Cylinder Head (see Engine Top End chapter)
Alternator Rotor and Starter Clutch Gear (see Electrical System
chapter)
Rear Camshaft Chain Guide [A]
•
• Remove:
Oil Pipe Bolts [A]
Oil Pipe [B]
Oil Pipe Installation
the O-ring [A] with new ones if they are damaged.
• Replace
Apply
grease
• Tighten: to the O-rings before installation.
•
Torque -
Oil Pipe Bolts: 8.8 N1m (0.9 kgf1m, 78 in1lb)
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7-12 ENGINE LUBRICATION SYSTEM
Oil Pipe/Oil Hose
Oil Hose Removal
the engine oil (see Engine Oil Change).
• Drain
Remove:
• Front Inner Covers (see Frame chapter)
•
•
Left Side Cover (see Frame chapter)
Loosen the oil pipe joint nuts [A] and remove the oil pipes from the
oil cooler [B].
Remove:
Oil Hose Banjo Bolts [C]
Oil Hoses [D]
Oil Hose Installation
grease to the O-rings [E] on the oil pipe joint and insert them
• Apply
into the oil cooler.
the oil hoses according to Cable, Wire, and Hose Routing
• Rout
section in Appendix chapter.
installing the oil hose, avoid sharp bending, kinking, flattening
• When
or twisting, and route the oil hose with a minimum of bending so that
•
the oil flow will not be obstructed.
Tighten:
Torque -
Oil Pipe Joint Nuts: 29 N1m (3.0 kgf1m, 22 ft1lb)
the rear ends of the oil hoses [A] on the crankcase as shown.
• Install
[B] 3
•
•
[C] 6
Replace the washers on each side of the banjo bolt [D] with new
ones.
Tighten:
Torque -
Oil Hose Banjo Bolts: 29 N1m (3.0 kgf1m, 22 ft1lb)
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ENGINE LUBRICATION SYSTEM 7-13
Oil Cooler
Oil Cooler Removal
The oil cooler fan is connected directly to the battery. The oil
cooler fan may start even if the ignition switch is off. NEVER
TOUCH THE OIL COOLER FAN UNTIL THE OIL COOLER FAN
CONNECTOR IS DISCONNECTED. TOUCHING THE FAN BEFORE THE CONNECTOR IS DISCONNECTED COULD CAUSE
INJURY FROM THE FAN BLADES.
• Drain the engine oil (see Engine Oil Change).
• Remove:
Front Fender (see Frame chapter)
•
•
Oil Cooler Fan Switch Lead Connectors [A]
Oil Temperature Warning Light Switch Lead Connectors [B]
Oil Cooler Fan Motor Lead Connector
Loosen the oil pipe joint nuts [C] and remove the oil pipes from the
oil cooler [D].
Remove:
Oil Cooler Mounting Bolts [E] and Nuts
Oil Screen and Oil Cooler
Oil Cooler Installation
• Connect:
Oil Cooler Fan Switch Lead Connectors
Oil Temperature Warning Light Switch Lead Connectors
Oil Cooler Fan Motor Lead Connector
• Install:
Oil Cooler [A]
•
Screen [B]
Fame [C]
Damper [D] (as shown)
Collar [E]
Tighten:
Torque -
Oil Cooler Mounting Bolts [F]: 8.8 N1m (0.9 kgf1m, 78 in1lb)
grease to the O-rings in the oil pipe joint and insert them into
• Apply
the oil cooler.
• Tighten:
Torque -
Oil Pipe Joint Nuts: 29 N1m (3.0 kgf1m, 22 ft1lb)
Oil Cooler Disassembly
• Remove:
Oil Cooler (see Oil Cooler Removal)
Fan Assembly Mounting Bolts [A]
Fan Assembly [B]
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7-14 ENGINE LUBRICATION SYSTEM
Oil Cooler
Oil Cooler Fan Switch, Oil Temperature Warning Light Switch
Removal
CAUTION
The oil cooler fan switch or the oil temperature warning light
switch should never be allowed to fall on hard surface. Such
a shock to their parts can damage them.
• Remove:
Oil Cooler (Oil Cooler Removal)
Oil Cooler Fan Switch [A]
Oil Temperature Warning Light Switch [B]
Oil Cooler Fan Switch, Oil Temperature Warning Light Switch
Installation
grease to the O-rings of the oil cooler fan switch and oil
• Apply
temperature warning light switch.
the oil cooler fan switch and oil temperature warning light
• Tighten
switch.
Torque -
Oil Cooler Fan Switch: 16 N1m (1.6 kgf1m, 12 ft1lb)
Oil Temperature Warning Light Switch: 16 N1m (1.6 kgf1m, 12
ft1lb)
Oil Cooler Fan Switch, Oil Temperature Warning Light Switch
Inspection
• Refer to Electrical System chapter.
Oil Cooler Inspection
to Oil Cooler Ceaning and Inspection in Periodic Maintenance
• Refer
chapter.
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ENGINE REMOVAL/INSTALLATION 8-1
Engine Removal/Installation
Table of Contents
Exploded View...................................................................................................................................................................8-2
Engine Removal/Installation..............................................................................................................................................8-4
Engine Removal ......................................................................................................................................................... 8-4
Engine Installation......................................................................................................................................................8-5
8
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8-2 ENGINE REMOVAL/INSTALLATION
Exploded View
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ENGINE REMOVAL/INSTALLATION 8-3
Exploded View
Torque
No.
Fastener
N1m
kgf1m
ft1lb
1
Upper Engine Mounting Bracket Bolt and Nut
42
4.3
31
2
Upper Engine Mounting Bolt and Nut
25
2.5
18
3
Lower Engine Mounting Bracket Bolts
25
2.5
18
4
Lower Engine Mounting Bolts and Nuts
42
4.3
31
Remarks
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8-4 ENGINE REMOVAL/INSTALLATION
Engine Removal/Installation
Engine Removal
• Remove:
Engine Oil (drain)
Front Fender (see Frame chapter)
Muffler and Exhaust Pipe (see Engine Top End chapter)
Carburetor (see Fuel System chapter)
Left Footboard (see Frame chapter)
Torque Converter Air Intake Duct
Tie-rod (Shift Lever)
Engine Brake Actuator Lead Connector [A]
Drive Belt Failure Detecting Switch Lead Connector [B]
Spark Plug Cap [C]
Front Propeller Shaft [D]
Speed Sensor Connector [E]
Torque Converter Air Duct [F]
• Remove:
Alternator Lead Connector
Pickup Coil Lead Connector
Forward/Reverse Detecting Sensor Lead Connector
Reverse Position Switch Lead Connector [A]
Neutral Position Switch Lead Connector [B]
Engine Ground Lead [C]
Oil Pressure Switch Lead [D]
Oil Hoses [E]
• Remove:
Engine Mounting Upper Bolt [A]
Engine Mounting Front Bracket [B]
• Remove:
Boot [A]
Engine Mounting Bolts [B]
Engine Mounting Rear Brackets [C]
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ENGINE REMOVAL/INSTALLATION 8-5
Engine Removal/Installation
a tape to protect the frame.
• Put
Move
the engine forward to remove the drive shaft [A] from the rear
• propeller
shaft joint [B].
• Remove the engine from the left side.
Engine Installation
• Be sure the damper [A] is in place.
• Roll up the boot [A] toward the engine.
the drive shaft in the rear propeller shaft joint [A].
• Insert
Tighten:
•
Torque -
Lower Engine Mounting Bracket Bolts: 25 N1m (2.5 kgf1m, 18
ft1lb)
Lower Engine Mounting Bolts and Nuts: 42 N1m (4.3 kgf1m,
31 ft1lb)
Upper Engine Mounting Bracket Bolt and Nut: 42 N1m (4.3
kgf1m, 31 ft1lb)
Upper Engine Mounting Bolt and Nut: 25 N1m (2.5 kgf1m, 18
ft1lb)
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CRANKSHAFT / TRANSMISSION 9-1
Crankshaft / Transmission
Table of Contents
Exploded View...................................................................................................................................................................9-2
Specifications .................................................................................................................................................................... 9-6
Crankcase ......................................................................................................................................................................... 9-7
Crankcase Disassembly.............................................................................................................................................9-7
Crankcase Assembly..................................................................................................................................................9-7
Crankshaft/Balancer Shaft and Connection Rod............................................................................................................9-10
Crankshaft/Balancer Shaft Removal ........................................................................................................................ 9-10
Crankshaft/Balancer Shaft Installation.....................................................................................................................9-10
Crankshaft Disassembly...........................................................................................................................................9-10
Crankshaft Assembly................................................................................................................................................9-11
Connecting Rod Big End Seizure ............................................................................................................................ 9-12
Connecting Rod Big End Radial Clearance.............................................................................................................9-12
Connecting Rod Big End Side Clearance................................................................................................................9-12
Crankshaft Alignment...............................................................................................................................................9-13
Connecting Rod Bend/Twist.....................................................................................................................................9-14
Transmission....................................................................................................................................................................9-15
Shift Lever Removal .................................................................................................................................................9-15
Shift Lever Installation..............................................................................................................................................9-16
Transmission Removal..............................................................................................................................................9-18
Transmission Installation .......................................................................................................................................... 9-19
Shift Fork Bending....................................................................................................................................................9-21
Shift Fork/Gear and Shifter Groove Wear................................................................................................................9-21
Transmission and Shift Mechanism Inspection........................................................................................................9-21
Ball Bearing, Needle Bearing, and Oil Seal ................................................................................................................... 9-23
Ball and Needle Bearing Replacement....................................................................................................................9-23
Ball and Needle Bearing Wear.................................................................................................................................9-23
Oil Seal Inspection ................................................................................................................................................... 9-23
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9
9-2 CRANKSHAFT / TRANSMISSION
Exploded View
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CRANKSHAFT / TRANSMISSION 9-3
Exploded View
Torque
No.
Fastener
N1m
kgf1m
ft1lb
1
Camshaft Chain Guard Bolts
8.8
0.9
78 in1lb
2
Oil Line Plugs
23
2.3
17
3
Engine Drain Plug
20
2.0
14
4
Crankcase Bolts (M8)
20
2.0
14
5
Crankcase Bolts (M6)
8.8
0.9
78 in1lb
L:
M:
O:
LG:
S:
Remarks
L
S, L(1)
Apply a non-permanent locking agent.
Apply molybdenum disulfide grease.
Apply engine oil.
Apply liquid gasket (Three Bond 1215, Gray).
Follow the specific tightening sequence.
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9-4 CRANKSHAFT / TRANSMISSION
Exploded View
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CRANKSHAFT / TRANSMISSION 9-5
Exploded View
Torque
No.
Fastener
N1m
kgf1m
ft1lb
1
Grip Hold Nut
9.8
1.0
87 in1lb
2
Shift Lever Assembly Bracket Bolts
20
2.0
14
3
Tie-Rod End Bolt
9.8
1.0
87 in1lb
4
Tie-Rod End Locknut
20
2.0
14
5
Shift Lever Assembly Nut
20
2.0
14
6
Tie-Rod End Front Locknut
9.8
1.0
87 in1lb
7
Tie-Rod End Rear Locknut
9.8
1.0
87 in1lb
8
Tie-Rod End Nut
20
2.0
14
9
Shift Shaft Cover Bolts
8.8
0.9
78 in1lb
10
Neutral Position Switch
15
1.5
11
11
Reverse Position Switch
15
1.5
11
12
Shift Shaft Positioning Bolt
25
2.5
18
13
Shift Shaft Spring Bolt
25
2.5
18
G:
L:
M:
O:
MO:
Lh:
Gr:
LG:
Remarks
Lh
L
Apply grease for oil seal and O-ring.
Apply a non-permanent locking agent.
Apply molybdenum disulfide grease.
Apply engine oil.
Apply molybdenum disulfide oil.
Left-hand Threads
Apply grease.
Apply liquid gasket (Three Bond 1215, Gray)
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9-6 CRANKSHAFT / TRANSMISSION
Specifications
Item
Crankshaft, Connecting Rods:
Standard
Service Limit
Connecting rod big end radial clearance
0.008 ~ 0.020 mm (0.0003 ~ 0.0008 in.)
0.07 mm (0.003 in.)
Conencting rod big end side clearance
0.25 ~ 0.35 mm (0.0098 ~ 0.0138 in.)
0.6 mm (0.024 in.)
Crankshaft runout
Left
TIR 0.03 mm (0.0012 in.) or less
Right
TIR 0.04 mm (0.0016 in.) or less
TIR 0.08 mm (0.0032 in.)
TIR 0.10 mm (0.0039 in.)
Connecting rod bend
under 0.05/100 mm (0.002/3.94 in.)
0.2/100 mm (0.008/3.94 in.)
Connecting rod twist
under 0.15/100 mm (0.006/3.94 in.)
0.2/100 mm (0.008/3.94 in.)
Crankshaft main journal/bearing
0.025 ~ 0.052 mm
clearance
Crankshaft main journal diameter
–––
(0.001 ~ 0.002 in.)
37.989 ~ 38.000 mm
37.97 mm (1.4949 in.)
(1.4956 ~ 1.4961 in.)
Crankcase main bearing bore diameter
38.025 ~ 38.041 mm
38.07 mm (1.4988 in.)
(1.4970 ~ 1.4977 in.)
Transmission:
Shift fork ear thickness
5.9 ~ 6.0 mm (0.2322 ~ 0.2362 in.)
Shifter grooove width
6.05 ~ 6.15 mm (0.2382 ~ 0.2421 in.)
5.8 mm (0.228 in.)
6.25 mm (0.2460 in.)
Special Tools - Outside Circlip Pliers: 57001–144
Bearing Driver Set: 57001–1129
Oil Seal Driver: 57001–1517
Sealant - Kawasaki Bond (Liquid Gasket - Gray): 92104–1065
Three Bond: 1215 (Gray)
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CRANKSHAFT / TRANSMISSION 9-7
Crankcase
Crankcase Disassembly
• Remove:
Engine (see Engine Removal/Installation chapter)
Drive and Driven Pulleys (see Converter System chapter)
Starter Motor (see Electrical System chapter)
Oil Filter
Starter Clutch Gear (see Electrical System chapter)
Oil Pump (see Engine Lubrication System chapter)
Piston (see Engine Top End chapter)
Camshaft Chain (see Engine Top End chapter)
Shift Shaft Positioning Bolt [A], Washer, Spring, and Steel Ball
Damper [B]
• Remove:
Crankcase Bolts (M6) [A]
•
•
•
Crankcase Bolts (M8) [B]
Wrap the teeth on the sprocket [C] by taping for protecting the bushing
in the crankcase.
Using the pry points [D] split the crankcase halves.
Lift off the left crankcase half.
Crankcase Assembly
CAUTION
Right and left crankcase halves are machined at the factory
in the assembled state, so the crankcase halves must be
replaced as a set.
NOTE
Be certain that all parts are cleaned thoroughly before assembly.
Blow through all oil passages with compressed air to clear any
blockage in the crankcase halves and crankshaft.
Clean the engine parts in a well-ventilated area, and take care
that there are no sparks or flame anywhere near the working
area; this includes any appliance with a pilot light. Do not use
gasoline or a low-flash point solvent to clean parts. A fire or
explosion could result.
a small amount of engine oil to the transmission gears,
• Apply
bearings, and shift forks.
sure the mating surfaces of the crankcase halves are clean and
• Be
dry.
• Press and insert the new ball bearings until they are bottomed.
Special Tool -
•
•
•
Bearing Driver Set: 57001-1129
[A] Ball Bearing
[B] Ball Bearing (sealed side towards crankcase)
Press and insert the new needle bearing so that the bearing surface
is flush with the end of the hole.
[C] Needle Bearing
Apply engine oil to the bearings.
Install:
Oil Pressure Relief Valve [D] (see Engine Lubrication System
chapter)
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9-8 CRANKSHAFT / TRANSMISSION
Crankcase
• Press and insert the new ball bearings [A] until they are bottomed.
Special Tool -
•
•
Bearing Driver Set: 57001-1129
Press and insert the new needle bearing so that the bearing surface
is flush with the end of the hole.
[B] Needle Bearing
Apply engine oil to the bearings.
sure the following parts are in place in the right crankcase half.
• BeCrankshaft
and Balancer Shaft (see Crankshaft/Balancer Shaft
Installation)
Transmission Shafts and Shift Rod [A]
Spacers [B]
Oil Screen [C]
Dowel Pins [D]
• Apply liquid gasket [A] to mating surface of the left crankcase half.
Sealant -
Three Bond: 1215 (Gray)
• Install:
Oil Pump (see Engine Lubrication System chapter)
Apply
a non-permanent locking agent:
• Left Crankcase
Bolt (M8) [3]
the left crankcase bolts (M8) following the tightening se• Tighten
quence [1~7].
Torque -
•
Crankcase Bolts (M8): 20 N1m (2.0 kgf1m, 14 ft1lb)
[1] L = 85 mm (3.35 in.)
[2, 5, 6, 7] L = 75 mm (2.95 in.)
[3, 4] L = 110 mm (4.33 in.)
Tighten:
Torque -
Crankcase Bolts (M6): 8.8 N1m (0.9 kgf1m, 78 in1lb)
[A] L = 40 mm (1.57 in.)
[B] L = 65 mm (2.56 in.)
[C] L = 85 mm (3.35 in.)
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CRANKSHAFT / TRANSMISSION 9-9
Crankcase
the oil seal [A] into the crankcase [B] with the oil seal driver.
• Press
[C] 3 mm (0.12 in.)
Special Tool -
Oil Seal Driver [D]: 57001–1517
grease to the steel ball [A] and spring [B].
• Apply
Install:
• Steel Ball
•
Spring
Washer (C)
Shift Shaft Positioning Bolt [D]
Tighten:
Torque -
Shift Shaft Positioning Bolt: 25 N1m (2.5 kgf1m, 18 ft1lb)
• Check:
Crankshaft, driven shaft and output shaft turn freely.
If any of the shaft do not turn freely, split the crankcase to locate the
problem.
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9-10 CRANKSHAFT / TRANSMISSION
Crankshaft/Balancer Shaft and Connection Rod
Crankshaft/Balancer Shaft Removal
the crankcase (see Crankcase Disassembly).
• Split
Remove:
• Balancer Shaft [A]
•
Transmission Shaft Assemblys
Remove the crankshaft [B] from the crankcase using a press.
Crankshaft/Balancer Shaft Installation
left shaft [A] of the crankshaft is longer than the right shaft [B].
• The
Apply
engine oil to the both main journals and teeth of the sprocket.
• Insert the
crankshaft tapered end (the shorter end) into the right
• crankcaseright
using a press.
the punch mark [A] on the balancer shaft gear with the punch
• Align
marks [B] on the crankshaft gear as shown.
Crankshaft Disassembly
CAUTION
Since assembly of the crankshaft demands exacting tolerances, the disassembly and reassembly of the crankshaft
should only be performed by experienced mechanics with the
necessary tools and equipment.
The crankshaft left main bearing, chain sprocket, and left
crankshaft are available separately as spare parts, however,
it is recommended that the crankshaft assembly be replaced
rather than attempting to replace the components.
the crankpin out of the crank halves to separate the crank
• Press
halves, connecting rod, spacers, crankpin needle bearing, and
crankpin.
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CRANKSHAFT / TRANSMISSION 9-11
Crankshaft/Balancer Shaft and Connection Rod
Crankshaft Assembly
engine oil to the needle bearing.
• Apply
Press
halves onto the crankpin, noting the crankpin
• directiontheuntilcrank
connecting rod side clearance is within specification
(see Connecting Rod Big End Side Clearance).
Make sure oil passages of the crank and crankpin are lined up during
assembly.
that the connecting rod radial clearance is within specification
• Check
(see Connecting Rod Big End Radial Clearance).
crankshaft runout until runout is within specification (see
• Adjust
Crankshaft Alignment).
1.
2.
3.
4.
Crankpin
Spacers
Crankpin Needle Bearing
1.1 &plusmn; 0.35 mm (0.043 &plusmn; 0.014 in.)
(From web end to crankpin end)
5. Balancer Gear
6. Left Crankshaft
7.
8.
9.
10.
11.
12.
Right Crankshaft
45 &plusmn; 1
Center of Crankpin
57 25′ &plusmn; 30′
Center of Sprocket Tooth
Punch Mark
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9-12 CRANKSHAFT / TRANSMISSION
Crankshaft/Balancer Shaft and Connection Rod
Connecting Rod Big End Seizure
the case of serious seizure with damage to the crank halves, the
• Incrankshaft
must be replaced.
If the seizure was less severe, disassemble the crankshaft and
replace the crankpin, needle bearing, and connecting rod.
Connecting Rod Big End Radial Clearance
the crankshaft on V blocks, and place a dial gauge [A] against
• Set
the connecting rod big end.
[B] the connecting rod first towards the gauge and then in the
• Push
opposite direction. The difference between the two gauge readings
is the radial clearance.
If the radial clearance exceeds the service limit, the crankshaft
assembly must be replaced or disassembled and the crankpin, needle
bearing, and connecting rod big end examined or wear.
Connecting Rod Big End Radial Clearance
Standard:
0.008
0.020 mm (0.0003 ~ 0.0008 in.)
Service Limit:
0.07 mm (0.003 in.)
Connecting Rod Big End Side Clearance
the crankshaft on V blocks.
• Set
Measure
• gauge. the side clearance [A] of the connecting rod with a thickness
If the big end side clearance exceeds the service limit, the crankshaft
assembly must be replaced or disassembled and the connecting rod
and thrust washers visually inspected for wear.
Connecting Rod Big End Side Clearance
0.35 mm (0.0098 ~ 0.0138 in.)
Standard:
0.25
Service Limit:
0.6 mm (0.024 in.)
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CRANKSHAFT / TRANSMISSION 9-13
Crankshaft/Balancer Shaft and Connection Rod
Crankshaft Alignment
the crankshaft on V blocks, turn the crankshaft slowly and
• With
measure runout at each of the locations shown.
[A] 8 mm (0.315 in.)
[B] 25.5 mm (1.004 in.)
Crankshaft Runout
Left Half [C]
Standard:
TIR 0.03 mm (0.0012 in.) or less
Service Limit:
TIR 0.08 mm (0.0032 in.)
Right Half [D]
•
•
•
•
Standard:
TIR 0.04 mm (0.0016 in.) or less
Service Limit:
TIR 0.10 mm (0.0039 in.)
If runout at either location exceeds the service limit, align the
crankshaft so that runout is within the service limits.
In the case of horizontal misalignment, strike the projecting crankshaft
half with a plastic, soft lead, or brass hammer as shown.
Recheck the runout and repeat the process until the runout is within
service limits.
Vertical misalignment is corrected either by driving a wedge in
between the crank halves, or by squeezing the crank halves in a
vise, depending on the nature of the misalignment.
In the case of both horizontal and vertical misalignment, correct the
horizontal misalignment first.
Recheck big end side clearance after aligning crankshaft (see Connecting Rod Big End Side Clearance).
NOTE
If crankshaft alignment cannot be corrected by the above method,
replace the crankpin or crank halves as required.
CAUTION
Don’t hammer the flywheel at the point [A].
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9-14 CRANKSHAFT / TRANSMISSION
Crankshaft/Balancer Shaft and Connection Rod
Connecting Rod Bend/Twist
the connecting rod bend.
• Measure
Set the crankshaft in an alignment jig or in V blocks on a surface
plate.
Select an arbor of the same diameter as the piston pin and at least
100 mm (3.94 in.) long, and insert the arbor through the connecting
rod small end.
With the connecting rod held vertically, use a height gauge to measure
the difference in the height of the arbor above the surface plate over
a 100 mm (3.94 in.) length to determine the amount of connecting
rod bend.
If connecting rod bend exceeds the service limit, the connecting rod
must be replaced.
Connecting Rod Bend
Standard:
Service Limit:
Under 0.05/100 mm (0.002/3.94 in.)
0.2/100 mm (0.008/3.94 in.)
the connecting rod twist.
• Measure
With the crankshaft still in the alignment jig, hold the connecting rod
horizontally and measure the amount that the arbor varies from being
parallel with the crankshaft over a 100 mm (3.94 in.) length of the
arbor to determine the amount of connecting rod twist.
If connecting rod twist exceeds the service limit, the connecting rod
must be replaced.
Connecting Rod Twist
Standard:
Under 0.15/100 mm (0.006/3.94 in.)
Service Limit:
0.2/100 mm (0.008/3.94 in.)
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CRANKSHAFT / TRANSMISSION 9-15
Transmission
Shift Lever Removal
the shift lever in the neutral position.
• Set
Remove:
• Air Cleaner Housing (see Fuel System chapter)
•
Shift Shaft Lever Bolt [A]
Remove the shift shaft lever [B] from the shift shaft.
• Remove:
Nut [A]
Shift Lever Assembly [B]
• Remove:
Tie-Rod End Bolt [A]
Tie-Rod [B]
• Remove:
Oil Seals [A]
Collar [B]
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9-16 CRANKSHAFT / TRANSMISSION
Transmission
Shift Lever Installation
the tie-rod end [A] and tie-rod locknut [B] to bottom of the screw
• Twist
and then turn back to dimension with 77 &plusmn; 10 [C] as shown.
• Tighten the locknut against the tie-rod end:
Torque -
•
•
•
Tie-Rod End Locknut: 20 N1m (2.0 kgf1m, 14 ft1lb)
Apply molybdenum disulfide grease:
Outside of Tie-Rod End Collar [D]
Apply grease to the oil seals, and install them.
Tighten:
Torque -
Tie-Rod End Bolt [E]: 9.8 N1m (1.0 kgf1m, 87 in1lb)
the mark [A] on the shaft end with the slit [B] of the shift shaft
• Align
lever.
the shift shaft lever end [C] on the boss-center [D] of the
• Position
crankcase.
• Install:
Bracket [E]
•
Shift Lever Assembly Nut [F]
Tighten:
Torque -
Shift Lever Assembly Nut: 20 N1m (2.0 kgf1m, 14 ft1lb)
Tie-Rod End Nut [G]: 20 N1m (2.0 kgf1m, 14 ft1lb)
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CRANKSHAFT / TRANSMISSION 9-17
Transmission
• Install:
Guide [A]
Tighten:
•
Torque -
Shift Lever Assembly Bracket Bolts [B]: 20 N1m (2.0 kgf1m, 14
ft1lb)
the lever assembly in the neutral position [C] while turning the
• Set
tie-rod [D].
NOTE
Do not turn the shift shaft [E] when setting the lever assembly on
neutral position.
Turn the tie-rod until the rod [F] of the shift lever assembly contact
•
with the guide [G], and then the tie-rod can be turned until 1/8. At
that time, the clearance [H] which can be made between the rod and
the guide is 0 ~ –0.5 mm (0 ~ –0.02 in.).
This clearance is a setting range for the neutral position.
Tighten:
Torque -
Tie-Rod End Rear Locknut [I]: 9.8 N1m (1.0 kgf1m, 87 in1lb)
• Holding the rear locknut, and tighten the front locknut [J].
Torque -
Tie-Rod End Front Locknut : 9.8 N1m (1.0 kgf1m, 87 in1lb)
NOTE
The front locknut has left-hand threads.
Do not lean the tie-rod rear end after tightening the front locknut.
•
•
•
•
Right [K]
Wrong [L]
Check that the shift lever moves from right to left smoothly.
Install:
Spring [M]
Trim Seal [N]
Align the mark [O] of the grip [P] with the projection [Q] on the guide.
Tighten:
Torque -
Grip Hold Nut [R]: 9.8 N1m (1.0 kgf1m, 87 in1lb)
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9-18 CRANKSHAFT / TRANSMISSION
Transmission
Transmission Removal
the crankcase (see Crankcase Disassembly).
• Sprit
Remove:
• Shift Shaft Cover Bolts [A]
Shift Shaft Cover [B]
• Remove:
Shift Shaft Spring Bolt [A]
Shift Shaft [B]
• Remove:
Reverse Idle Shaft [A]
Spacer [B]
Reverse Drive Gear [C], Needle Bearing, and Spacer
Shifter [D]
Shift Rod [E]
• Remove:
Circlip [A]
Special Tool -
Outside Circlip Pliers: 57001-144
• Remove:
Spacer [A]
Idle Gear Assembly [B]
Washers and Spacer [C]
Low and High Gears [D]
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CRANKSHAFT / TRANSMISSION 9-19
Transmission
• Remove:
Needle Bearings [A]
Remove
the driven shaft [B] from the crankcase using a press.
•
Transmission Installation
the driven shaft in the crankcase until it is bottomed using a
• Insert
press.
• Apply engine oil to the needle bearings and install them.
the following parts on the low gear [A].
• Install
Needle Bearings [B]
Spacer [C] (P/No. 92026–1599, 48.2 x 54.3 x 1.0)
High Gear [D]
• Install:
Idle Shaft [A] with Gear Assembly [B]
•
Spacer [C]
Spacer [D] (P/No. 92026–1599, 48.2 x 54.3 x 1.0)
Install the spacer [E] so that the stepped side [F] faces outward.
• Install:
Spacer [A]
Toothed Washer [B]
Circlip
Special Tool -
Outside Circlip Pliers: 57001–144
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9-20 CRANKSHAFT / TRANSMISSION
Transmission
engine oil:
• Apply
Shift Rod and Shift Fork Ear [A]
Needle Bearing
• Install:
Shift Rod [B] with Shifter [C]
Spacer [D]
Needle Bearing [E]
• Install:
Reverse Drive Gear [A]
Spacer [B]
Reverse Idle Shaft [C]
molybdenum disulfide oil to the shift shaft [A].
• Apply
• Install:
Shift Shaft Spring Bolt [B]
•
•
Spring [C]
Guide [D]
Apply a non-permanent locking agent:
Shift Shaft Spring Bolt
Tighten:
Torque -
Shift Shaft Spring Bolt: 25 N1m (2.5 kgf1m, 18 ft1lb)
a new bushing [A] and oil seal [B] are installed in the shift shaft
• When
cover [C], press and insert the new bushing and oil seal so that there
surfaces are flush with the end of the each hole.
• Install:
Shift Shaft Cover
• Tighten:
Torque -
Shift Shaft Cover Bolts: 8.8 N1m (0.9 kgf1m, 78 in1lb)
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CRANKSHAFT / TRANSMISSION 9-21
Transmission
Shift Fork Bending
inspect the shift fork.
• Visually
If the fork is bent, replace the shift rod with a new one. A bent fork
could cause difficulty in shifting, or allow the transmission to jump out
of gear when under power.
[A] 90
Shift Fork/Gear and Shifter Groove Wear
the thickness of the shift fork ears [A], and measure the
• Measure
width [B] of the gear groove and shifter.
If the thickness of a shift fork ear is less than the service limit, the
shift rod must be replaced.
Shift Fork Ear Thickness
Standard:
5.9
Service Limit:
6.0 mm (0.2322 ~ 0.2362 in.)
5.8 mm (0.228 in.)
If the groove is worn over the service limit, the shifter must be
replaced.
Shifter Groove Width
Standard:
Service Limit:
6.05
6.15 mm (0.2382 ~ 0.2421 in.)
6.25 mm (0.2460 in.)
Transmission and Shift Mechanism Inspection
inspect:
• Visually
Gears
Dogs on Gear and Shifter
If they are damaged or worn excessively, replace them.
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9-22 CRANKSHAFT / TRANSMISSION
Transmission
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Driven Shaft
Spacer (17.3 x 30 x 2.0)
Reverse Gear (12T)
Spacer (21.2 x 29 x 1.6)
Shifter
Circlip
Washer T=1.5
Spacer (28.2 x 34.5 x 1.6)
Spacer (Hi and Low)
Spacer (48.2 x 54.3 x 1.0)
Drive Hi Gear (26T)
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
Drive Low Gear (20T)
Reverse Idle Shaft
Reverse Driven Gear (16T)
Reverse Driven Output Gear (16T)
Idle Shaft
Spacer (20.3 x 33 x 2.0)
Driven Output Gear (18T)
Driven Hi Gear (30T)
Driven Low Gear (36T)
Needle Bearing
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CRANKSHAFT / TRANSMISSION 9-23
Ball Bearing, Needle Bearing, and Oil Seal
Ball and Needle Bearing Replacement
CAUTION
Do not remove the ball or needle bearings unless it is necessary. Removal may damage them.
a press or puller, remove the ball bearing and/or needle bearing
• Using
outer race.
NOTE
In the absence of the above mentioned tools,
satisfactory results
may be obtained by heating the case to approximately 93 C
(200 F) max., and tapping the bearing in or out.
CAUTION
Do not heat the case with a torch. This will warp the case.
Soak the case in oil and heat the oil.
a press and the bearing driver set [A], install the new bearing
• Using
or outer race until it stops at the bottom of its housing.
Special Tool -
Bearing Driver Set: 57001–1129
Ball and Needle Bearing Wear
CAUTION
Do not remove the bearings for inspection.
damage them.
Removal may
the ball bearings.
• Check
Since the ball bearings are made to extremely close tolerances, the
•
wear must be judged by feel rather than measurement. Clean each
bearing in a high flash-point solvent, dry it (do not spin the bearing
while it is dry), and oil it with engine oil.
Spin [A] the bearing by hand to check its condition.
If the bearing is noisy, does not spin smoothly, or has any rough spots,
replace it.
Check the needle bearings.
The rollers in a needle bearing normally wear very little, and wear
is difficult to measure. Instead of measuring, inspect the bearing for
abrasion, color change, or other damage.
If there is any doubt as to the condition of a needle bearing, replace
it.
Oil Seal Inspection
the oil seals.
• Inspect
Replace it if the lips are misshapen, discolored (indicating that the
rubber has deteriorated), hardened or otherwise damaged.
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WHEELS / TIRES 10-1
Wheels / Tires
Table of Contents
Exploded View.................................................................................................................................................................10-2
Specifications .................................................................................................................................................................. 10-4
Wheel Alignment.............................................................................................................................................................10-5
Steering Centering Inspection..................................................................................................................................10-5
Steering Centering Adjustment................................................................................................................................10-5
Toe-in Inspection ...................................................................................................................................................... 10-6
Toe-in Adjustment.....................................................................................................................................................10-6
Wheels (Rims).................................................................................................................................................................10-7
Wheel Removal ........................................................................................................................................................10-7
Wheel Installation.....................................................................................................................................................10-7
Wheel (Rim) Inspection............................................................................................................................................10-7
Wheel (Rim) Replacement.......................................................................................................................................10-8
Tires ................................................................................................................................................................................ 10-9
Tire Removal ............................................................................................................................................................10-9
Tire Installation.........................................................................................................................................................10-9
Tire Inspection........................................................................................................................................................10-10
Front Hub ...................................................................................................................................................................... 10-11
Front Hub Removal ................................................................................................................................................ 10-11
Front Hub Installation............................................................................................................................................. 10-11
Front Hub Disassembly/Assembly..........................................................................................................................10-11
Rear Hub.......................................................................................................................................................................10-12
Rear Hub Removal.................................................................................................................................................10-12
Rear Hub Installation..............................................................................................................................................10-12
Rear Hub Disassembly/Assembly..........................................................................................................................10-12
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10
10-2 WHEELS / TIRES
Exploded View
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WHEELS / TIRES 10-3
Exploded View
Torque
No.
Fastener
N1m
kgf1m
ft1lb
Remarks
S
1
Wheel Nuts
52
5.3
38
2
Front Axle Nuts
196
20
145
3
Tie-Rod End Nuts
42
4.3
31
4
Tie-Rod Adjusting Sleeve Locknuts
37
3.8
27
5
Rear Axle Nuts
265
27
195
W: Apply water or soap and water solution.
R: Replacement Parts
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10-4 WHEELS / TIRES
Specifications
Item
Standard
Service Limit
Wheel Alignment:
Toe-in of front wheels:
0
20 mm (0 ~ 0.79 in.) at 1G
Tires:
Standard tire:
Front
AT 25
2 8-12
–––
–––
DUNLOP, KT121, Tubeless
Rear
AT 25
2 10-12
–––
DUNLOP, KT405C/KT127A, Tubeless
Tire air pressure (when cold):
Front
Rear
Maximun tire air pressure
35 kPa (0.35 kgf/cm2, 5.0 psi)
2
–––
35 kPa (0.35 kgf/cm , 5.0 psi)
–––
250 kPa (2.5 kgf/cm2, 36 psi)
–––
(to seat beads, when cold)
Tire tread depth:
Special Tool -
Front
–––
3 mm (0.12 in.)
Rear
–––
4 mm (0.16 in.)
Jack: 57001-1238
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WHEELS / TIRES 10-5
Wheel Alignment
Toe-in is the amount that the front wheels are closer together in front
than at the rear at the axle height. When there is toe-in, the distance A
(Rear) is the greater than B (Front) as shown.
The purpose of toe-in is to prevent the front wheels from getting out
of parallel at any time, and to prevent any slipping or scuffing action
between the tires and the ground. If toe-in is incorrect, the front wheels
will be dragged along the ground, scuffing and wearing the tread knobs.
Caster and camber are build-in and require no adjustment.
A (Rear ) – B (Front) = Amount of Toe-in
(Distance A and B are measured at axle height with the vehicle
sitting on the ground, or at 1G.)
Steering Centering Inspection
ride the vehicle.
• Test
If the handlebar is straight when the vehicle is traveling in a straight
line, go on to the Toe-in Inspection procedure.
Otherwise, go on to the Steering Centering Adjustment procedure.
Steering Centering Adjustment
a straightedge [A] against the rear wheel rim on one side at axle
• Hold
height.
the handlebar straight ahead, loosen the locknuts [A] [B] and
• With
turn the tie-rod adjusting sleeve [C] until the front wheel on that side
is parallel to the straightedge.
NOTE
The locknut [A] near the flattened area [D] on the tie-rod has lefthand threads. Turn the wrench clockwise for loosening.
CAUTION
Adjust the tie-rod so that the visible thread length [A] is even
on both ends of the tie-rod, or the threads could be damaged.
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10-6 WHEELS / TIRES
Wheel Alignment
the straightedge procedure on the other side of the vehicle.
• Repeat
Now the front wheels are parallel to each other and to the center line
•
of the vehicle.
Front Wheel [A]
Vehicle Center Line [B]
Parallel each other [C]
Straightedges [D]
Rear Wheels [E]
Go on to the Toe-in Inspection procedure.
Toe-in Inspection
a heavy coat of chalk or a paint line near the center of the front
• Apply
tires.
a needle nose scriber, make a thin mark near the center of the
• Using
chalk coating while turning the wheel.
the front wheels on the ground, set the handlebar straight ahead.
• With
the level of the axle height, measure the distance between the
• Atscribed
or painted lines for both front and rear of the front tires.
Subtract
of the front from the measurement of the
• rear to getthethemeasurement
toe-in.
If the toe-in is not in the specified range, go on to the Toe-in
Adjustment procedure.
Toe-in of Front Wheels
Standard:
0
20 mm (0 ~ 0.79 in.) at 1G
Toe-in Adjustment
the locknuts [A] [B] and turn the adjusting sleeves [C] the
• Loosen
same number of turns on both sides to achieve the specified toe-in.
NOTE
The locknut [A] near the flattened area [D] on the tie-rod has lefthand threads. Turn the locknut clockwise for loosening.
The toe-in will be near the specified value, if the tie-rod length [E]
is 315 &plusmn; 0.7 mm (12.4 &plusmn; 0.03 in.) on each tie-rod.
CAUTION
Adjust the tie-rod length so that the visible thread length [F] is
even on both ends of the tie-rod. Uneven thread length could
cause tie-rod damage.
the toe-in.
• Check
Tighten:
•
Torque -
Tie-Rod Adjusting Sleeve Locknuts: 37 N1m (3.8 kgf1m, 27
ft1lb)
• Test ride the vehicle.
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WHEELS / TIRES 10-7
Wheels (Rims)
Wheel Removal
the wheel nuts [A].
• Loosen
Support
the vehicle on a stand or a jack so that the wheels are off
• the ground.
Special Tool -
•
Jack: 57001-1238
Remove:
Wheel Nuts
Wheel
Wheel Installation
the tire rotation mark [A] on the tire, and install the wheel
• Check
accordingly.
The direction of the
NOTE
tire rotation [B] is shown by an arrow on the
tire sidewall.
the wheel so that the air valve [A] is toward the outside of
• Position
the vehicle.
• Tighten the wheel nuts in a criss-cross pattern.
Torque -
Wheel Nuts: 52 N1m (5.3 kgf1m, 38 ft1lb)
Wheel (Rim) Inspection
both sides of the rim for dents [A]. If the rim is dented,
• Examine
replace it.
If the tire is removed, inspect the air sealing surfaces [A] of the rim
for scratches or nicks. Smooth the sealing surfaces with fine emery
cloth if necessary.
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10-8 WHEELS / TIRES
Wheels (Rims)
Wheel (Rim) Replacement
the wheel (see Wheel Removal).
• Remove
Disassemble
tire from the rim (see Tire Removal).
• Remove the airthevalve
and discard it.
CAUTION
Replace the air valve whenever the tire is replaced. Do not
reuse the air valve.
Plastic Cap [A]
Valve Core [B]
Stem Seal [C]
Valve Stem [D]
Valve Seat [E]
Valve Opened [F]
a new air valve in the new rim.
• Install
Remove the valve cap, lubricate the stem with a soap and water
solution, and pull the stem [A] through the rim from the inside out
until it snaps into place.
CAUTION
Do not use engine oil or petroleum distillates to lubricate the
stem because they will deteriorate the rubber.
the tire on the new rim (see Tire Installation).
• Mount
Install
the
(see Wheel Installation).
• Install the wheel
air valve cap.
•
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WHEELS / TIRES 10-9
Tires
Tire Removal
the wheel.
• Remove
Unscrew
the valve core to deflate the tire.
• Use a proper
valve core tool [A].
the tire beads and rim flanges on both sides of the wheel
• Lubricate
with a soap and water solution, or water [A]. This helps the tire beads
slip off the rim flanges.
CAUTION
Do not lubricate the tire beads and rim flanges with engine oil
or petroleum distillates because they will deteriorate the tire.
the tire from the rim using a suitable commercially available
• Remove
tire changer.
NOTE
The tires cannot be removed with hand tools because they fit the
rims tightly.
Tire Installation
the rim (see Wheel (Rim) Inspection).
• Inspect
• Replace the air valve with a new one.
CAUTION
Replace the air valve with whenever the tire is replaced. Do
not reuse the air valve.
the tire for wear and damage (see Tire Inspection in Periodic
• Check
Maintenance chapter).
the tire beads and rim flanges with a soap and water
• Lubricate
solution, or water.
Do not use the lubricant other than a water and soap solution,
or water to lubricate the tire beads and rim because it may
cause tire separation.
the tire rotation mark [A] on the tire, and install the tire on the
• Check
rim accordingly.
The
tires should be installed on the rims so that each air valve is
toward the outside of the vehicle.
The direction of the
NOTE
tire rotation [B] is shown by an arrow on the
tire sidewall.
•
•
Install the tire on the rim using a suitable commercially available tire
changer.
Lubricate the tire beads again and center the tire on the rim.
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10-10 WHEELS / TIRES
Tires
the wheel rim [A] on a suitable stand [B] to prevent the tire
• Support
from slipping off.
• Inflate the tire until the tire beads seat on the rim.
Maximum Tire Air Pressure (to seat beads when cold)
Front and Rear:
250 kPa (2.5 kg/cm2, 36 psi)
Do not inflate the tire to more than the maximum tire air
pressure. Overinflation can explode the tire with possibility
of injury and loss of life.
to see that rim lines [A] on both sides of the tire are parallel
• Check
with the rim flanges [B].
•
•
•
If the rim lines and the rim flanges are not parallel, deflate the tire,
lubricate the sealing surfaces again, and reinflate the tire.
After the beads are properly seated, check for air leaks.
Apply a soap and water solution around the tire bead and check for
bubbles.
Deflate the tire to the specified pressure.
Check the tire pressure using an air pressure gauge.
NOTE
Kawasaki provides the air pressure gauge (P/N 52005-1082) with
the owner’s tool kit.
Tire Air Pressure (when cold)
Front:
35 kPa (0.35 kg/cm2, 5.0 psi)
Rear:
35 kPa (0.35 kg/cm2, 5.0 psi)
the air valve cap.
• Install
the wheel (see Wheel Installation).
• Install
Wipe
off
• operation.the soap and water solution on the tire and dry the tire before
Do not operate the vehicle with the water and soap still
around the tire beads. They will cause tire separation, and
a hazardous condition may result.
Tire Inspection
• Refer to Tire Inspection in Periodic Maintenance chapter.
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WHEELS / TIRES 10-11
Front Hub
Front Hub Removal
• Remove:
Cap [A]
Cotter Pin [B]
• Loosen the axle nut [C].
the wheel (see Wheel Removal).
• Remove
Remove
the caliper [A] by taking off the mounting bolts, and let the
• caliper hang
free.
the axle nut [B] and pull off the front hub [C] and brake disc.
• Remove
• Separate the brake disc from the front hub.
Front Hub Installation
the brake disc (see Brakes chapter).
• Install
• Tighten:
Torque -
•
Front Axle Nuts: 196 N1m (20 kgf1m, 145 ft1lb)
Insert a new cotter pin [A] and bend it over the nut [B].
When
NOTE
inserting the cotter pin, if the slots in the nut do not align
with the cotter pin hole in the axle shaft, tighten the nut clockwise
up to next alignment.
It should be within 30 degree.
Loosen once and tighten again when the slit goes past the nearest
hole.
Front Hub Disassembly/Assembly
not press the hub bolts [A] out.
• Do
If any hub bolt is damaged, replace the hub [B] and bolts as a unit.
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10-12 WHEELS / TIRES
Rear Hub
Rear Hub Removal
• Remove:
Cap [A]
Cotter Pin [B]
• Loosen the axle nut [C].
• Remove:
Wheel (see Wheel Removal)
Axle Nut [A]
Rear Hub [B]
Rear Hub Installation
• Tighten:
Torque -
•
Rear Axle Nuts: 265 N1m (27 kgf1m, 195 ft1lb)
Insert a new cotter pin [A] and bend it over the nut [B].
When
NOTE
inserting the cotter pin, if the slots in the nut do not align
with the cotter pin hole in the axle shaft, tighten the nut clockwise
up to next alignment.
It should be within 30 degree.
Loosen once and tighten again when the slit goes past the nearest
hole.
Rear Hub Disassembly/Assembly
not press the hub bolts [A] out.
• Do
If any hub bolt is damaged, replace the hub [B] and bolts as a unit.
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FINAL DRIVE 11-1
Final Drive
Table of Contents
Exploded View..........................................................11-2
Specifications ........................................................... 11-8
Output Bevel Gears..................................................11-9
Output Drive Bevel Gear Removal....................11-9
Output Drive Bevel Gear Installation.................11-9
Output Drive Bevel Gear Disassembly............11-10
Output Drive Bevel Gear Assembly ................ 11-12
Output Driven Bevel Gear Removal................11-12
Output Driven Bevel Gear Installation.............11-13
Output Driven Bevel Gear Disassembly..........11-13
Output Driven Bevel Gear Assembly .............. 11-14
Output Bevel Gears Adjustment......................11-16
Bevel Gears Inspection ................................... 11-19
Cam Damper Inspection..................................11-19
Front Propeller Shaft..............................................11-20
Front Propeller Shaft Removal........................11-20
Front Propeller Shaft Installation.....................11-20
Front Axle...............................................................11-21
Front Axle Removal.........................................11-21
Front Axle Installation......................................11-21
Front Axle Joint Boot Inspection ..................... 11-21
Front Axle Joint Boot Replacement.................11-22
Front Final Gear Case............................................11-27
Front Final Gear Case Oil Level Inspection....11-27
Front Final Gear Case Oil Change ................. 11-27
Variable Differential Control Lever Position Inspection...................................................................11-27
Variable Differential Control Lever Position Adjustment.................................................................11-27
Variable Differential Control Lever Removal....11-27
Variable Differential Control Lever Installation 11-27
Variable Differential Control Cable Installation11-28
Variable Differential Control Cable Lubrication11-28
Variable Differential Control Cable Inspection.11-28
Front Final Gear Case Removal ..................... 11-28
Front Final Gear Case Installation .................. 11-29
Front Final Gear Case Disassembly............... 11-29
Front Final Gear Case Assembly....................11-31
Oil Seal Installation..........................................11-35
Ring Gear Disassembly...................................11-35
Ring Gear Assembly ....................................... 11-36
LSD Clutch Torque Inspection.........................11-36
Pinion Gear Unit Disassembly ........................ 11-37
Pinion Gear Unit Assembly............................. 11-37
Front Final Bevel Gear Adjustment .................11-37
Bevel Gear Inspection.....................................11-41
Differential Gear Inspection.............................11-41
Rear Propeller Shaft...............................................11-43
Rear Propeller Shaft Removal.........................11-43
Rear Propeller Shaft Installation ..................... 11-43
Rear Propeller Shaft Joint Boot Inspection.....11-43
Rear Propeller Shaft Inspection...................... 11-43
Rear Axle................................................................11-44
Rear Axle Removal..........................................11-44
Rear Axle Installation ...................................... 11-44
Ball Bearing Wear ........................................... 11-44
Rear Axle Runout Inspection .......................... 11-44
Rear Final Gear Case............................................11-45
Rear Final Gear Case Oil Level Inspection .... 11-45
Rear Final Gear Case Oil Change..................11-45
Rear Final Gear Case Removal .....................11-45
Rear Final Gear Case Installation...................11-45
Rear Final Gear Case Disassembly .............. 11-46
Rear Final Gear Case Assembly .................... 11-47
Oil Seal Installation..........................................11-48
Rear Final Bevel Gear Adjustment..................11-49
Pinion Gear Unit Disassembly ........................ 11-51
Pinion Gear Unit Assembly............................. 11-51
Bevel Gear Inspection.....................................11-52
Bearing and Oil Seal..............................................11-53
Ball or Needle Bearing Inspection...................11-53
Oil Seal Inspection .......................................... 11-54
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11
11-2 FINAL DRIVE
Exploded View
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FINAL DRIVE 11-3
Exploded View
Torque
No.
Fastener
N1m
kgf1m
ft1lb
Remarks
1
Output Driven Bevel Gear Housing Bolts
26
2.7
20
2
Output Drive Bevel Gear Housing Bolts
26
2.7
20
3
Bearing Holder
137
14
101
L
4
Bevel Gear Holder Nut
157
16
116
L
5
Bearing Holder
118
12
87
L
6
Output Shaft Holder Nut
157
16
116
L
7
Rotor Mounting Bolts
12
1.2
104 in1lb
8
Output Drive Bevel Gear Cover Bolts
8.8
0.9
78 in1lb
Forward/Reverse Detecting Sensor Mounting Bolts
15
1.5
11
9
G:
L:
M:
MO:
Apply
Apply
Apply
Apply
grease for oil seal and O-ring.
a non-permanent locking agent.
molybdenum disulfide grease.
molybdenum disulfide oil.
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11-4 FINAL DRIVE
Exploded View
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FINAL DRIVE 11-5
Exploded View
Torque
No.
Fastener
N1m
kgf1m
ft1lb
Remarks
1
Variable Front Differential Control Shift Shaft Lever Bolt
8.8
0.9
78 in1lb
2
Front Final Gear Case Left Cover Bolts (M6)
9.8
1.0
87 in1lb
S, L(4)
3
Ring Gear Bolts
57
5.8
42
LB
4
Front Final Gear Case Center Cover Bolts (M6)
9.8
1.0
87 in1lb
L, S
5
Oil Filler Cap
29
3.0
22
6
Front Final Gear Case Center Cover Bolts (M8)
24
2.4
17
L, S
7
Pinion Gear Bearing Holder Nut
127
13
94
St
8
Pinion Gear Bearing Holder
137
14
101
L
9
Front Final Gear Case Coupling Nut
20
2.0
14
10
Oil Drain Plug
24
2.4
17
11
2WD/4WD Actuator Mounting Bolts
9.8
1.0
87 in1lb
12
Variable Differential Control Cable Locknut
17
1.7
12
13
Variable Differential Control Lever Bolt
3.5
0.36
31 in1lb
14
Parking Brake Lever Screw
2.2
0.22
19 in1lb
15
Front Final Gear Case Bolts and Nuts
42
4.3
31
G:
L:
M:
O:
LB:
S:
St:
L, S
L
Apply grease for oil seal and O-ring.
Apply a non-permanent locking agent.
Apply molybdenum disulfide grease.
Apply engine oil.
Apply a non-permanent locking agent (Three Bond TB2471 Blue).
Follow the specific tightening sequence.
Stake the fasteners to prevent loosening.
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11-6 FINAL DRIVE
Exploded View
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FINAL DRIVE 11-7
Exploded View
Torque
No.
Fastener
N1m
kgf1m
ft1lb
Remarks
1
Oil Filler Cap
29
3.0
22
2
Oil Drain Plug
20
2.0
14
3
Pinion Gear Bearing Holder
137
14
101
L
4
Pinion Gear Bearing Holder Nut
157
16
116
L
5
Trailer Hitch Btacket Bolts (M10)
49
5.0
36
L
6
Rear Final Gear Case Bolts
42
4.3
31
S
7
Rear Final Gear Case Right Cover Bolts (M8)
24
2.4
17
L
8
Rear Final Gear Case Right Cover Bolts (M10)
49
5.0
36
L
G:
L:
M:
MF:
S:
Apply grease for oil seal and O-ring.
Apply a non-permanent locking agent.
Apply molybdenum disulfide grease.
Apply MOBIL FLUID 424 or equivalent oil.
Follow the specific tightening sequence.
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11-8 FINAL DRIVE
Specifications
Item
Output Bevel Gear Case
Standard
Output bevel gear backlash
0.06
Service Limit
0.12 mm (0.0024 ~ 0.0047 in.)
–––
(at output drive shaft spline)
Front Final Gear Case:
Gear case oil (same engine oil):
Type
–––
API SF or SG
–––
API SH or SJ with JASO MA
Viscosity
SAE10W-40
–––
Oil level
Filler opening bottom
–––
Capacity
430 mL (0.45 US qt)
–––
LSD clutch torque:
(when variable differential control lever
15 ~ 20 N1m (1.5
2.0 kg1m, 11
14 ft1lb)
–––
is released.)
(when variable differential control lever
157 N1m (16 kg1m, 116 ft1lb) or more
–––
0.10
–––
is pulled in.)
Bevel gear backlash
0.20 mm (0.004 ~ 0.008 in.)
(at pinion gear spline)
Rear Axle Shaft
Rear axle shaft runout
TIR 1 mm (0.04 in.) or less
TIR 2 mm
(0.08 in.)
Rear Final Gear Case:
Gear case oil:
Type
MOBIL Fluid 424 or
–––
Kawa Chem Gear &amp; Wet Brake Oil (CITGO
TRANSGARD TRACTOR HYDRAULIC FLUID)
Oil level
Filler opening bottom
–––
Capacity
900 mL (0.95 US qt)
–––
0.07
–––
Rear final bevel gear backlash
0.14 mm (0.003 ~ 0.006 in.)
(at pinion gear spline)
Special Tools - Bearing Puller: 57001–135
Inside Circlip Pliers: 57001–143
Outside Circlip Pliers: 57001–144
Circlip Pliers: 57001–154
Oil Seal &amp; Bearing Remover: 57001–1058
Bearing Driver Set: 57001–1129
Socket Wrench: 57001–1363
Damper Spring Compressor Set: 57001–1475
Holder &amp; Guide Arbor: 57001–1476
Socket Wrench, Hex 50: 57001–1478
Output Shaft Holder &amp; Spacer: 57001–1479
Pinion Gear Holder: 57001–1480
Nut Holding Bolts: 57001–1481
Socket Wrench: 57001–1482
Socket Wrench, Hex 41: 57001–1484
Pinion Gear Holder: 57001–1485
Oil Seal Driver: 57001–1487
Gear Holder &amp; Socket Wrench, Hex 24: 57001–1489
Hexagon Wrench, Hex 41: 57001–1491
Oil Seal Driver, 18: 57001–1505
Oil Seal Driver, 48: 57001–1506
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FINAL DRIVE 11-9
Output Bevel Gears
Output Drive Bevel Gear Removal
• Remove:
Left Side Cover (see Frame chapter)
Forward/Reverse Detecting Sensor Lead Connector [A]
Output Drive Bevel Gear Cover Bolts [B]
Output Drive Bevel Gear Cover [C]
• Remove:
Circlip [A]
Special Tool -
Outside Circlip Pliers: 57001–144
• Remove:
Output Drive Idle Gear [B]
• Remove:
Output Drive Bevel Gear Housing Bolts [A]
Output Drive Bevel Gear Housing [B]
Output Drive Bevel Gear Installation
the output drive bevel gear housing.
• Install
Tighten:
•
Torque -
Output Drive Bevel Gear Housing Bolts: 26 N1m (2.7 kgf1m,
20 ft1lb)
the rotor [A] so that the projections [B] face outward.
• Install
• Tighten:
Torque -
•
Rotor Mounting Bolts [C]: 12 N1m (1.2 kgf1m, 104 in1lb)
Install:
Output Drive Idle Gear
New Circlip
Special Tool -
Outside Circlip Pliers: 57001–144
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11-10 FINAL DRIVE
Output Bevel Gears
grease:
• Apply
O-rings [A]
• Install:
Output Drive Bevel Gear Cover [B]
• Tighten:
Torque -
Output Drive Bevel Gear Cover Bolts [C]: 8.8 N1m (0.9 kgf1m,
78 in1lb)
• Install:
Forward/Reverse Detecting Sensor [A]
Tighten:
•
Torque -
Forward/Reverse Detecting Sensor Mounting Bolt: 15 N1m
(1.5 kgf1m, 11 ft1lb)
Output Drive Bevel Gear Disassembly
• Remove:
Output Drive Bevel Gear Housing [A] (see Output Drive Bevel Gear
•
•
Removal)
Look through the hole [B] in the housing.
Turn the bevel gear [C] until the groove of the output drive bevel gear
holder nut is seen.
the nut holding bolts [A] (4) securely into the grooves [B] of
• Tighten
the bevel gear holder nut [C] in the output drive bevel gear housing.
Special Tool -
Nut Holding Bolts: 57001–1481
[D] Output Drive Bevel Gear Housing
[E] Outer Ball Bearing
[F] Inner Ball Bearing
[G] Bearing Holder
[H] Output Drive Bevel Gear
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FINAL DRIVE 11-11
Output Bevel Gears
the output drive bevel gear housing [A] in a vise.
• Hold
Loosen
gear [B] using an Allen wrench about four rotations.
• Removetheonebevel
nut
holding
bolt, and look at through the hole.
• If the groove of the bevel gear
holder nut is not seen, loosen the other
three bolts.
the gear shaft end using a copper mallet until the grooves of
• Drive
the bearing holder nut can be seen again.
the nut holding bolts (4) securely into the groove of the
• Retighten
bevel gear holder nut in the output drive bevel gear housing.
Special Tool -
•
Nut Holding Bolts: 57001–1481
Repeat the above procedure, and remove the bevel gear from the
housing.
• Remove the bearing holder [A] using the hexagon wrench [B].
Special Tool -
Hexagon Wrench, Hex 41: 57001–1491
If the holder seems too difficult to break free, apply heat to softer the
locking agent.
• Remove:
Outer Ball Bearing [A]
Special Tool -
Oil Seal &amp; Bearing Remover [B]: 57001-1058
• Remove:
Output Drive Bevel Gear Holder Nut
Inner Ball Bearing [A]
Special Tool -
Oil Seal &amp; Bearing Remover [B]: 57001-1058
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11-12 FINAL DRIVE
Output Bevel Gears
Output Drive Bevel Gear Assembly
• Press the new inner ball bearing until it is bottomed.
Special Tool -
Bearing Driver Set [A]: 57001-1129
a non-permanent locking agent to the threads of the bearing
• Apply
holder [A] and tighten it so that the deep side [B] faces outward.
Torque -
Bearing Holder: 118 N1m (12 kgf1m, 87 ft1lb)
• Press the output drive bevel gear until it is bottomed.
a non-permanent locking agent to the threads of the bevel
• Apply
gear holder nut [A] and tighten it so that the projection side [B] faces
outward.
Special Tool Torque -
Socket Wrench: 57001-1482 [C]
Bevel Gear Holder Nut: 157 N1m (16 kgf1m, 116 ft1lb)
• Press the new outer ball bearing until it is bottomed.
Output Driven Bevel Gear Removal
• Remove:
Swingarm (see Suspension chapter) and Front Propeller Shaft (see
Front Propeller Shaft Removal) or Engine (see Engine Removal/
Installation chapter)
Output Driven Bevel Gear Housing Bolts [A]
Output Driven Bevel Gear Housing [B]
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FINAL DRIVE 11-13
Output Bevel Gears
lightly the front end [A] of the output driven bevel gear shaft using
• Tap
a plastic mallet.
The
output driven bevel gear shaft assembly comes off with the
housing.
Output Driven Bevel Gear Installation
grease:
• Apply
O-ring [A]
the output driven bevel gear shaft assembly.
• Install
Tighten:
•
Torque -
Output Driven Bevel Gear Housing Bolts: 26 N1m (2.7 kgf1m,
20 ft1lb)
Output Driven Bevel Gear Disassembly
• Remove:
Output Driven Bevel Gear Housing Assembly (see Output Driven
•
Bevel Gear Removal)
Hold the holder in a vise, and set the housing assembly [A] on the
holder.
Special Tools - Damper Spring Compressor Set [B]: 57001-1475
Holder &amp; Guide Arbor [C]: 57001-1476
• Tighten the nuts [D] and compress the damper spring [E].
• Remove:
Circlip [A]
Special Tool -
Circlip Pliers: 57001–154
• Remove:
Circlip [A]
Spring Holder [B]
Spring [C]
Cam Damper [D]
Output Driven Bevel Gear [E]
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11-14 FINAL DRIVE
Output Bevel Gears
the housing assembly [A] with the output shaft holder [B] &amp;
• Hold
spacer [C] in a vise.
Special Tool -
•
Output Shaft Holder &amp; Spacer: 57001-1479
Remove:
Oil Seal [D]
• Remove:
Output Shaft Holder Nut [A]
Special Tool -
Socket Wrench [B]: 57001-1482
• Hold the housing assembly [A] with the holder [B] in a vise.
Special Tool -
Holder &amp; Guide Arbor : 57001-1476
• Remove:
Bearing Holder [C]
Special Tool -
Socket Wrench [D], Hex 50: 57001-1478
If the holder seems too difficult to break free, apply heat to softer the
•
locking agent.
Remove:
Ball Bearing
Special Tool -
Oil Seal &amp; Bearing Remover: 57001-1058
Output Driven Bevel Gear Assembly
• Press the new ball bearing until it is bottomed.
Special Tool -
Bearing Driver Set [A]: 57001-1129
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FINAL DRIVE 11-15
Output Bevel Gears
• Hold the housing assembly [A] with the holder [B] in a vise.
Special Tool -
•
Holder &amp; Guide Arbor: 57001-1476
Apply a non-permanent locking agent to the threads of the bearing
holder [C] and tighten it.
Special Tool Torque -
Socket Wrench, Hex 50: 57001-1478
Bearing Holder: 137 N1m (14 kgf1m, 101 ft1lb)
the housing assembly [A] with the output shaft holder [B] &amp;
• Hold
spacer [C] in a vise.
Special Tool -
Output Shaft Holder &amp; Spacer: 57001-1479
the output shaft [D] in the housing.
• Insert
a non-permanent locking agent to the threads of the output
• Apply
shaft holder nut [E] and tighten it so that the projection side [F] faces
outward.
Special Tool Torque -
Socket Wrench: 57001-1482
Output Shaft Holder Nut: 157 N1m (16 kgf1m, 116 ft1lb)
•
the holder [A] in a vise, and set the housing assembly [B] on
• Hold
the holder.
Apply grease to the oil seal and press it.
Special Tool -
•
Holder &amp; Guide Arbor: 57001-1476
Install:
Output Driven Bevel Gear [C]
Cam Damper [D]
Spring [E]
Spring Holder [F]
Circlip [G]
• Install:
Guide Bars [A]
Damper Spring Compressor Set [B]
Special Tools - Holder &amp; Guide Arbor: 57001-1476
Damper Spring Compressor Set: 57001-1475
the nuts [C] and compress the damper spring.
• Tighten
Install:
• Circlip
Special Tool -
Circlip Pliers: 57001-154
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11-16 FINAL DRIVE
Output Bevel Gears
Output Bevel Gears Adjustment
The backlash and tooth contact pattern of the bevel gears must be
correct to prevent the gears from making noise and being damaged.
When replacing any one of the backlash-related parts, be sure to
check and adjust the backlash and tooth contact. First adjust the
backlash, and then tooth contact by replacing shims.
These two adjustments are of critical importance and must be carried
out in the correct sequence, using the procedures shown.
Output Bevel Gear (Backlash-related Parts)
1. Ball Bearings
2. Drive Bevel Gear Shims
3. Output Drive Bevel Gear
4. Bearing Housings
5. Output Driven Bevel Gear
6. Output Driven Shaft
7. Driven Bevel Gear Shims
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FINAL DRIVE 11-17
Output Bevel Gears
Drive Bevel Gear Shims for Tooth Contact Adjustment
Thickness
Part Number
0.15 mm (0.006 in.)
92180-1311
0.2 mm (0.008 in.)
92180-1312
0.5 mm (0.020 in.)
92180-1313
0.8 mm (0.031 in.)
92180-1314
1.0 mm (0.039 in.)
92180-1351
1.2 mm (0.047 in.)
92180-1352
Driven Bevel Gear Shims for Backlash Adjustment
Thickness
Part Number
0.15 mm (0.006 in.)
92180-1307
0.2 mm (0.008 in.)
92180-1308
0.5 mm (0.020 in.)
92180-1309
0.8 mm (0.031 in.)
92180-1310
1.0 mm (0.039 in.)
92180-1349
1.2 mm (0.047 in.)
92180-1350
Bevel Gear Backlash Adjustment
The amount of backlash is influenced by driven bevel gear position
more than by drive bevel gear position.
Remove the output drive idle gear (see Output Drive Bevel Gear
Removal).
•
up a dial gauge [A] against the output drive shaft spline groove
• Set
to check gear backlash.
To measure the backlash, turn the shaft clockwise and counterclock-
•
wise slightly so as not to move the mate gear. A rod can be inserted
through the lower hole of the housing and into contact with driven
gear. This may help to hold it still. The difference between the highest and lowest gauge reading is the amount of backlash.
If the backlash is not within the limit, replace the shim(s) at the driven
bevel gear.
Change the thickness a little at a time.
Recheck the backlash, and readjust as necessary.
Output Bevel Gear Backlash
Standard:
0.06
0.12 mm (0.0024 ~ 0.0047 in.) (at output
drive shaft spline)
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11-18 FINAL DRIVE
Output Bevel Gears
Tooth Contact Adjustment
Tooth contact location is influenced by drive gear position more than
by driven gear position.
Clean any dirt and oil off the bevel gear teeth.
Apply checking compound to 4 or 5 teeth on the output driven bevel
gear.
•
•
NOTE
Apply checking compound to the teeth in a thin, even coat with a
fairly stiff paint brush. If painted too thickly, the exact tooth pattern
may not appear.
The checking compound must be smooth and firm with the
consistency of tooth paste.
Special compounds are available from automotive supply stores for
the purpose of checking differential gear tooth patterns and contact.
Use this for checking the bevel gears.
the output driven shaft for 3 or 4 turns in the drive and reverse
• Turn
(coast) directions, while creating a drag on the drive bevel gear shaft.
the drive pattern and coast pattern of the bevel gear teeth.
• Check
The tooth contact patterns of both drive and coast sides should be
centrally located between the top and bottom of the tooth, and a little
closer to the toe of the tooth.
If the tooth contact pattern is incorrect, replace the shim(s) at the
drive bevel gear and shim(s) at the driven bevel gear, following the
examples shown. Then erase the tooth contact patterns, and check
them again. Also check the backlash every time the shims are
replaced. Repeat the shim change procedure as necessary.
NOTE
If the backlash is out of the standard range after changing shims,
correct the backlash before checking the tooth contact pattern.
Example 1: Decrease the thickness of the drive bevel gear shim(s) by
0.1 mm (0.004 in.), and/or increase the thickness of the driven bevel
gear shim(s) by 0.1 mm (0.004 in.) to correct the pattern shown below.
Repeat in 0.1 mm (0.004 in.) steps if necessary.
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FINAL DRIVE 11-19
Output Bevel Gears
Example 2: Increase the thickness of the drive bevel gear shim(s) by
0.1 mm (0.004 in.), and/or decrease the thickness of the driven bevel
gear shim(s) by 0.1 mm (0.004 in.) to correct the pattern shown below.
Repeat in 0.1 mm (0.004 in.) steps if necessary.
Bevel Gears Inspection
check the bevel gears [A] for scoring, chipping, or other
• Visually
damage.
Replace the bevel gears as a set if either gear is damaged.
Cam Damper Inspection
inspect:
• Visually
Bevel Gear Cam [A]
Cam Follower [B]
Spring [C]
Shaft [D]
Replace any part if it appears damaged.
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11-20 FINAL DRIVE
Front Propeller Shaft
Front Propeller Shaft Removal
the O-ring clamps off the grooves on the small rubber boots [A],
• Slip
and then pull the boot.
the front propeller shaft [A] rearward, and remove the front end
• Push
[B] from the front final gear case.
• Remove the front propeller shaft from the vehicle.
Front Propeller Shaft Installation
any old grease off the splines of the propeller shaft [A] and the
• Wipe
coupling [B].
the splines of the propeller shaft and the coupling.
• Inspect
If the splines are twisted or damaged in any way, replace the parts
•
•
•
•
•
•
•
as needed.
Apply molybdenum disulfide grease to all splines.
Replace the circlip [C] with a new one, if it is removed.
Wipe off any old grease on the splines of the shafts on the output
bevel gear and front final gear case.
Inspect the O-rings on those shafts for damage.
If any doubt exists, replace the O-rings with new ones.
Apply molybdenum disulfide grease to the splines of the shafts on
the output bevel gear and front final gear case.
First install the rear end, and then install the front end.
Slip the two O-ring clamps into the groove on the small rubber boot.
O-ring [D]
Boots [E]
Spring [F]
Spring Seat [G]
Front [H]
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FINAL DRIVE 11-21
Front Axle
Front Axle Removal
the front final gear case oil (see Front Final Gear Case Oil
• Drain
Change in Periodic Maintenance chapter).
• Remove:
Front Wheel (see Wheels/Tires chapter)
•
Knuckle Joint Bolt [A]
Remove the knuckle joint [B] from the knuckle [C].
• Pull the front axle [A] in a straight line out of the front final gear case.
Front Axle Installation
the old grease off the splines of the axle and the gear case oil
• Wipe
seal.
inspect the splines of the axle.
• Visually
If they are badly worn or chipped, replace the axle with a new one.
molybdenum disulfide grease to the axle splines.
• Apply
Apply
to the gear case oil seal.
• Insert grease
the
left
axle so that the teeth [A] fit in the grooves [B].
•
• Tap [A] the end of the front axle lightly and install the front axle.
NOTE
The axle shaft must not come off easily.
Front Axle Joint Boot Inspection
• Refer to Joint Boots Inspection in Periodic Maintenance chapter.
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11-22 FINAL DRIVE
Front Axle
Front Axle Joint Boot Replacement
NOTE
Only
the inboard joint can be disassembled, so replacement of
either the inboard or outboard joint boots always begins at the
inboard end.
Inboard Joint Boot Removal:
the front axle (see Front Axle Removal)
• Remove
the boot bands [A] of inside joint boot.
• Remove
Scrap the removed boot bands.
• Slide the joint boot towards the center [B] of the axle.
the retaining ring [A].
• Remove
Separate
to the axle shaft.
•
• Remove:
Circlip [A]
Ball Bearing [B]
Inside Joint Boot [C]
Outboard Joint Boot Replacement:
NOTE
If inspections of the outboard joint and boot reveal no probels, do
not remove the outboard boot. Move on to Inboard Joint Boot
Assembly.
the boot bands of outside joint boot.
• Remove
Scrap the removed boot bands [A].
out side joint [A] cannot be disassembled.
• The
Inspect
joint bearing [B].
• If the jointthedoes
not move smoothly due to wear or corrosion, replace
•
•
the front axle because the joint bearing is damaged.
Inspect whether the axle shaft spline is damaged or not.
If there is clear damage or wear on the spline, replace the axle shaft.
Clean the axle shaft by wiping off the used grease on it.
CAUTION
Do not clean the boot with the mineral oil or gasoline because
they damage the boot.
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FINAL DRIVE 11-23
Front Axle
the tape [A] on the inside splines of the axle shaft in order to
• Wind
protect the joint boot.
the special grease slightly on the inside of the boot small
• Apply
diameter, and install the joint boot on the groove of the shaft.
CAUTION
Only the special grease which is included with the boot kit can
be applied to the boots.
the special grease [B] slightly on the part of band installation
• Apply
in order to make easy to install the band [A].
• Install the small band first.
all of the special grease [A] (about 70 grams) into the
• Squeese
outboard boot [B], and slide the boot onto the outside joint [C].
• Open the edge [A] of the boot in order to equalize the air pressures.
Inboard Joint Boot Assembly:
Slide the small band [A] onto the shaft, and then slide the boot [B]
into the groove [C] on the shaft.
•
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11-24 FINAL DRIVE
Front Axle
Tighten the band, pulling the tip of band [B] with a plier and a driver,
while measuring the outside diameter of the band.
Outside Diameter of Band: 26.1 &plusmn; 0.3 mm (1.028 &plusmn; 0.012 in.)
(After tightening the outside small diameter)
[A] Vernier Calipers
When the outside diameter of the band comes to the specified value,
bend the tip of band about 90 degrees.
After bending the tip of band, stake it with a chisel [A] so that it does
not loosen.
After staking it, cut off the extra tip of the band, and bend it securely.
• Install the ball bearing [A] and new circlip [B].
about half a tube (35 grams) of the special grease [A] into
• Squeese
the inboard joint boot.
• Squeese the remaining special grease [A] into the bearing cup [B].
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FINAL DRIVE 11-25
Front Axle
• Install the inside shaft, and install the new retaining ring [A].
the axle assembly to the specified length while relieving
• Compress
the air pressure inside the inboard boot [A].
• Hold the axle at this setting.
Standard Length of Assembling:
Right Front Axle:
395 mm (15.55 in.) [A]
Left Front Axle:
403 mm (15.87 in.) [B]
the large board.
• Install
Assemble it the same as the small band, noting this setting;
Outside Diameter of Band: 69.0 &plusmn; 0.3 mm (2.717 &plusmn; 0.012 in.)
(After tightening the outside large diameter)
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11-26 FINAL DRIVE
Front Axle
the band is held at the diameter above, tap down [A] the wings
• While
of the clamp.
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FINAL DRIVE 11-27
Front Final Gear Case
Front Final Gear Case Oil Level Inspection
the vehicle so that it is level, both side-to-side and front-to-rear.
• Park
Remove
the filler cap.
•
CAUTION
Be careful not to allow any dirt or foreign materials to enter
the gear case.
the oil level.
• Check
filler opening [A].
•
The oil level should come to the bottom of the
If it is insufficient, first check the front final gear case for oil leakage,
remedy it if necessary, and add oil through the filler opening. Use the
same type and brand of oil that is already in the final gear case.
Be sure the O-ring is in place, and tighten the filler cap.
Torque -
Oil Filler Cap : 29 N1m (3.0 kgf1m, 22 ft1lb)
Front Final Gear Case Oil Change
to Front Final Gear Case Oil Change in Periodic Maintenance
• Refer
chapter.
Variable Differential Control Lever Position Inspection
to Variable Differential Control Lever Position Inspection in
• Refer
Periodic Maintenance chapter.
Variable Differential Control Lever Position Adjustment
to Variable Differential Control Lever Position Adjustment in
• Refer
Periodic Maintenance chapter.
Variable Differential Control Lever Removal
• Remove:
Plate Bolt [A]
Cable Stopper Plate [B]
Variable Differential Control Lever Bolt [C], Washer and Collar
Variable Differential Control Lever [D]
Variable Differential Control Cable Upper End
Variable Differential Control Lever Installation
• Install:
Variable Differential Control Cable Upper End
•
Variable Differential Control Lever [A]
Variable Differential Control Lever Bolt [B], Washer [C] and Collar
[D]
Cable Stopper Plate [E]
Plate Bolt [F]
Check the variable differential control lever position (see Variable
Differential Control Lever Position Inspection in Periodic Maintenance
chapter).
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11-28 FINAL DRIVE
Front Final Gear Case
Variable Differential Control Cable Installation
the variable differential control cable before installation.
• Lubrication
Route
the
cable
correctly according to Appendix chapter.
•
Operation with an improperly adjusted, incorrectly routed, or
damaged cable could result in an unsafe operating condition.
• Tighten:
Torque -
Variable Differential Control Cable Locknut [A]: 17 N1m (1.7
kgf1m, 12 ft1lb)
the variable differential control lever position (see Variable
• Check
Differential Control Lever Position Inspection in Periodic Maintenance
chapter).
Variable Differential Control Cable Lubrication
Whenever the variable differential control cable is removed, lubricate
the cable as follows:
Apply a small amount of multi-purpose grease to the cable (both
ends).
Lubricate the cable with a penetrating rust inhibitor through the
pressure cable luber.
•
•
Variable Differential Control Cable Inspection
the variable differential control cable disconnected at both ends,
• With
the cable should move freely within the cable housing.
If the cable does not move freely after lubricating, if the cable is frayed,
or if the housing is kinked, replace the cable.
Front Final Gear Case Removal
the gear case oil (see Front Final Gear Case Oil Change).
• Drain
Remove:
• Front Propeller Shaft (see Front Propeller Shaft Removal)
Right and Left Front Axles (see Front Axle Removal)
Steering Shaft (see Steering chapter)
Left Suspension Arm (see Suspension chapter)
2WD/4WD Actuator (see Electrical System chapter)
Breather Tube
Brake Joint Bolt [A]
• Remove:
Variable Front Differential Control Cable Lower End [A]
Front Final Gear Case Bolts [B] and Nuts
• Remove the front final gear case from the right side.
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FINAL DRIVE 11-29
Front Final Gear Case
Front Final Gear Case Installation
• Install the gear case bolts from the vehicle left side.
Torque -
Front Final Gear Case Bolts and Nuts: 42 N1m (4.3 kgf1m, 31
ft1lb)
the removed parts.
• Install
Fill the front final gear case with the specified oil (see Front Final
• Gear
Case Oil Change in Periodic Maintenance chapter).
Front Final Gear Case Disassembly
• Remove:
Front Final Gear Case (see Front Final Gear Case Removal)
Variable Front Differential Control Shift Shaft Lever Bolt [A] and Nut
[B]
Variable Front Differential Control Shift Shaft Lever [C]
2WD/4WD Actuator (see Electrical System chapter)
the front final gear case with the gear holder &amp; socket wrench
• Hold
[A] in a vise.
Special Tool -
Gear Holder &amp; Socket Wrench, Hex 24: 57001-1489
• Remove:
Front Final Gear Case Coupling Nut [A]
Washer [B]
Front Final Gear Case Coupling [C]
Shifter [D]
Oil Seals [E]
• Remove:
Front Final Gear Case Left Cover Bolts [A]
Front Final Gear Case Left Cover [B]
Variable Front Differential Control Shift Shaft
Spring
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11-30 FINAL DRIVE
Front Final Gear Case
• Remove:
Outer Disc [A]
Needle Bearing
• Remove:
Housing [A] and Differential Disc Assembly [B]
Inner Disc
Needle Bearing
• Remove:
Cam Plate [A]
• Remove:
Steel Balls [A]
Gasket [B]
Dowel Pins [C]
Front Final Gear Case Center Cover Bolts (M6) [D]
Front Final Gear Case Center Cover Bolts (M8) [E]
Front Final Gear Case Center Cover [F]
• Remove:
Ring Gear Assembly [A]
Shim(s) [B]
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FINAL DRIVE 11-31
Front Final Gear Case
the front final gear case right cover [A] in a vise, and remove
• Hold
the bearing holder using the socket wrench [B].
Special Tool -
Socket Wrench, Hex 41: 57001-1484
If the holder seems too difficult to break free, apply heat to softer the
locking agent.
• Remove:
Pinion Gear Bearing Holder
• Remove:
Pinion Gear Unit [A]
Shim(s)
Front Final Gear Case Assembly
• Install:
Ball Bearing [A]
Needle Bearing [B]
Press the ball bearing and needle bearing until they are bottomed.
• Install:
Circlip [C]
Special Tool -
•
Inside Circlip Pliers: 57001–143
Install:
Oil Seal [D]
Install the oil seal until it is bottomed.
check the pinion gear and ring gear for scoring, chipping, or
• Visually
other damage.
•
•
Replace the bevel gear as a set if either gear is damaged since they
are lapped as a set in the factory to get the best tooth contact.
Insert the pinion gear in the front final gear case right cover.
Install:
Ring Gear Assembly
grease to the O-ring [A] on the front final gear case center
• Apply
cover.
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11-32 FINAL DRIVE
Front Final Gear Case
• Install:
Front Final Gear Case Center Cover [A]
Tighten
the cover bolts following the tightening sequence as shown.
•
Torque -
Front Final Gear Case Center Cover Bolts (M8) [1, 3]: 24 N1m
(2.4 kgf1m, 17 ft1lb)
Front Final Gear Case Center Cover Bolts (M6) [2, 4]: 9.8 N1m
(1.0 kgf1m, 87 in1lb)
the gear backlash and tooth contact pattern (see Front Final
• Adjust
Bevel Gear Adjustment).
a non-permanent locking agent to the cover bolts, and tighten
• Apply
them to the specified torque in the tightening sequence [1 ~ 4].
a non-permanent locking agent to the pinion gear bearing
• Apply
holder [A], and tighten it so that the deep recess [B] faces outward.
Special Tool Torque -
Socket Wrench, Hex 41: 57001-1484
Pinion Gear Bearing Holder: 137 N1m (14 kgf1m, 101 ft1lb)
• Install:
Dowel Pins [A]
New Gasket [B]
Steel Balls [C]
• Install:
Cam Lever [A]
•
Needle Bearing [B]
Apply engine oil to the needle bearing.
the wear of the disc assembly as follows.
• Check
Measure the thickness of the inner disc [A].
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FINAL DRIVE 11-33
Front Final Gear Case
the width [A] of the disc assembly [B] in accordance with the
• Select
thickness of the inner disc, refer to the below table.
Thickness of Inner
Disc Assembly
2.4 mm (0.0945 in.)
1.8 mm (0.0709 in.)
1.2 mm (0.0472 in.)
Measure
Width [A] of Disc Assembly
16.7 ~ 17.3 mm (0.6675 ~ 0.6811 in.)
17.31 ~ 17.9 mm (0.6815 ~ 0.7047 in.)
17.91 ~ 18.5 mm (0.7051 ~ 0.7283 in.)
the width of the disc assembly at three locations, and
calculate average for three points.
NOTE
Be careful not to damage the facing surface [C] on the outer plates.
If the width is within the specified range, install the inner disc and disc
assembly.
If the width is not within the specified range, replace the disc
assembly.
• Install:
Inner Disc [A]
Disc Assembly [B] and Housing [C]
engine oil to the needle bearing [A].
• Apply
Install:
• Needle Bearing
Outer Disc [B]
engine oil to the variable front differential control shaft [A].
• Apply
the shaft and spring [B] in the front final gear case left cover
• Install
[C] as shown.
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11-34 FINAL DRIVE
Front Final Gear Case
the shaft counterclockwise and insert the tab [A] of the shift shaft
• Turn
into the groove [B] of the cam plate.
• Install:
Front Final Gear Case Left Cover [C]
a non-permanent locking agent to the cover bolts [1 ~ 4], and
• Apply
tighten them following the tightening sequence as shown.
Torque -
Front Final Gear Case Left Cover Bolts [1 ~ 8]: 9.8 N1m (1.0
kgf1m, 87 in1lb)
[1 ~ 4] L = 60 mm (2.4 in.)
[5 ~ 8] L = 30 mm (1.2 in.)
grease to the oil seal lip [A].
• Apply
the oil seal [B] in the coupling [C] to the specified position as
• Press
shown.
[D] 1 mm (0.04 in.)
Special Tool -
Oil Seal Driver,
18: 57001–1505
molybdenum disulfide grease to the spline [A] in the shifter [B]
• Apply
and inner surface [C] of the coupling.
the shifter and coupling on the pinion gear shaft [D].
• Install
Apply
grease
to the oil seal lip [E].
• Press the oil seal
the front final gear case so that the oil seal
• surface is flush [G][F]within the
case end.
Special Tool -
Oil Seal Driver,
48: 57001–1506
the front final gear case with the gear holder &amp; socket wrench
• Hold
[A] in a vise.
Special Tool -
Gear Holder &amp; Socket Wrench, Hex 24: 57001–1489
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FINAL DRIVE 11-35
Front Final Gear Case
• Install:
Washer [A]
Front Final Gear Case Coupling Nut [B]
• Tighten:
Torque -
Front Final Gear Case Coupling Nut: 20 N1m (2.0 kgf1m, 14
ft1lb)
the variable front differential control shaft lever [A] on the shift
• Install
shaft [B] so that the punch mark [C] on the lever aligns with the punch
•
mark [D] on the shaft as shown.
[E] 45.8 ~ 50.4 mm (1.803 ~ 1.984 in.)
Tighten:
Torque -
Variable Front Differential Control Shift Shaft Lever Bolt [F]:
8.8 N1m (0.9 kgf1m, 78 in1lb)
Oil Seal Installation
the oil seal [A] in the front final gear case left cover [B] to the
• Press
dimension as shown.
[C] 4.6 ~ 5.6 mm (0.18 ~ 0.22 in.)
Ring Gear Disassembly
• Remove:
Ring Gear Assembly (see Front Final Gear Case Disassembly)
Ring Gear Bolts [A]
Ring Gear [B]
• Remove:
Differential Gear Cover [A]
Right Side Gear (16T) [B]
Pins [C]
Spider Gear Shaft [D]
Spider Gears (10T) [E]
Left Side Gear (16T) [F]
Left Differential Gear Case [G]
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11-36 FINAL DRIVE
Front Final Gear Case
Ring Gear Assembly
the bearing [A] on the left differential gear case [B] until it is
• Press
bottomed.
engine oil [C] to the spider gears.
• Apply
molybdenum disulfide grease [D] to the spline in the side gear
• Apply
(16T) [E].
• Install:
Left Side Gear (16T)
Spider Gears (10T) [F]
Spider Gear Shaft [G] and Pins [H]
engine oil [A] to the spider gears.
• Apply
Apply
molybdenum
disulfide grease [B] to the spline in the side gear
• (16T) [C].
• Install:
Side Gear (16T)
•
Differential Gear Case Cover [D]
Ring Gear [E]
Apply a non-permanent locking agent (Three Bond: TB2471 Blue) to
the ring gear bolts [F], and tighten them.
Torque -
Ring Gear Bolts: 57 N1m (5.8 kgf1m, 42 ft1lb)
Keep
NOTE
the ring gear assembly at more than 20 C ( 68 F) for six
hours after tightening the bolts.
LSD Clutch Torque Inspection
•
•
•
If the vehicle has the following symptoms, check the LSD (Limited
Slip Differential) clutch torque.
–The handlebar is hard to turn.
–The front final gear case overheats.
–Abnormal noises come from the front final gear case when
rounding a curve.
Ensure 2WD mode.
Support the vehicle so that the front wheels are off the ground.
Remove:
One Front Wheel (see Wheels/Tires chapter)
Front Axle Nut Cotter Pin
the other-side front wheel from rotating.
• Secure
Measure
• evenly. the clutch torque using a torque wrench [A]. Turn the wrench
The clutch torque is the mean torque reading during about a quarter
turn of the wrench.
LSD Clutch Torque (When variable differential control lever is released.)
Standard:
15
20 N1m (1.5
2.0 kg1m, 11
14 ft1lb)
LSD Clutch Torque (When variable differential control lever is pulled in.)
Standard:
157 N1m (16 kg1m, 116 ft1lb) or more
If the clutch torque is out of the specified range, check the width of
the disc assembly (see Front Final Gear Case Assembly).
NOTE
The correct type of oil must be installed.
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FINAL DRIVE 11-37
Front Final Gear Case
Pinion Gear Unit Disassembly
• Remove:
Pinion Gear Unit (see Front Final Gear Case Disassembly)
open the staking of the pinion gear bearing holder nut with a
• Pry
small chisel.
the pinion gear unit [A] with the pinion gear holder [B] in a vise,
• Hold
and remove the pinion gear bearing holder nut [C].
Special Tool -
Pinion Gear Holder: 57001–1485
• Remove the ball bearing only if required.
Special Tool -
Bearing Puller: 57001–135
Pinion Gear Unit Assembly
The pinion gear and ring gear are lapped as a set in the factory to
get the best tooth contact. They must be replaced as a set.
color change, or other
inspect the bearing for abrasion,
• Visually
damage.
•
If there is any doubt as to the condition of a bearing, replace the
bearing.
Be sure to check and adjust the bevel gear backlash and tooth
contact, when any of the backlash-related parts are replaced (see
Front Final Bevel Gear Adjustment).
Press the bearing on the pinion gear until it is bottomed.
•
the pinion gear bearing holder nut [A] so that the projection [B]
• Install
faces outward.
• Tighten:
Special Tool Torque -
Pinion Gear Holder: 57001-1485
Pinion Gear Bearing Holder Nut : 127 N1m (13 kgf1m, 94 ft1lb)
• Stake [C] the nut with a punch at three positions to secure it.
Front Final Bevel Gear Adjustment
The backlash (distance one gear will move back and forth without
moving the mate gear) and tooth contact pattern of the bevel gears
must be correct to prevent the gears from making noise and being
damaged.
Above two adjustments are of critical importance and must be carried
out following the correct sequence and method.
When any one of the backlash-related parts are replaced, check and
adjust the bevel gear backlash, and tooth contact by replacing shims.
The amount of backlash is influenced by the ring gear position more
than by the pinion gear position.
Tooth contact location is influenced by the pinion gear position more
than by the ring gear position.
•
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11-38 FINAL DRIVE
Front Final Gear Case
Front Final Gear Case (Backlash-related Parts)
1. Pinion Gear Shim(s)
2. Ring Gear Right Shim(s)
3. Ring Gear Left Shim(s)
4. Front Final Gear Case Center
Cover
5. Front Final Gear Case Right
Cover
6.
7.
8.
9.
Ball Bearings
Ring Gear
Ring Gear Assembly
Pinion Gear
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FINAL DRIVE 11-39
Front Final Gear Case
1. Pinion Gear Shims for Backlash Adjustment
Thickness
0.15 mm (0.006 in.)
0.2 mm (0.008 in.)
0.5 mm (0.020 in.)
0.7 mm (0.028 in.)
0.8 mm (0.031 in.)
0.9 mm (0.035 in.)
1.0 mm (0.039 in.)
1.1 mm (0.043 in.)
1.2 mm (0.047 in.)
Part Number
92180-1325
92180-1327
92180-1326
92180-1384
92180-1328
92180-1385
92180-1337
92180-1386
92180-1338
2. Ring Gear Right Shims for Tooth Contact Adjustment
Thickness
0.15 mm (0.006 in.)
0.2 mm (0.008 in.)
0.5 mm (0.020 in.)
0.7 mm (0.028 in.)
0.8 mm (0.031 in.)
0.9 mm (0.035 in.)
1.0 mm (0.039 in.)
1.1 mm (0.043 in.)
1.2 mm (0.047 in.)
Parts Number
92180-1331
92180-1332
92180-1329
92180-1381
92180-1330
92180-1382
92180-1339
92180-1383
92180-1340
3. Ring Gear Left Shims for Tooth Contact Adjustment
Thickness
0.15 mm (0.006 in.)
0.2 mm (0.008 in.)
0.5 mm (0.020 in.)
0.7 mm (0.028 in.)
0.8 mm (0.031 in.)
0.9 mm (0.035 in.)
1.0 mm (0.039 in.)
1.1 mm (0.043 in.)
1.2 mm (0.047 in.)
Parts Number
92180-1334
92180-1336
92180-1335
92180-1387
92180-1333
92180-1388
92180-1341
92180-1389
92180-1342
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11-40 FINAL DRIVE
Front Final Gear Case
Backlash Adjustment
Check and adjust the gear backlash when any of the backlash-related
parts are replaced with new ones.
Clean any dirt and oil off the bevel gear teeth.
Assemble the front final gear case (see Front Final Gear Case
Assembly).
It is not necessary to install the variable front differential control unit.
Check the backlash during tightening of the front final gear case
center cover bolts and stop tightening them immediately if the
backlash disappears. Then, change the ring gear shim to a thicker
one.
Temporarily, install the right front axle in the gear case and hold it in
a vise so that the ring gear is lower than the pinion gear.
•
•
•
•
a dial gauge [A] so that the tip of the gauge is against the
• Mount
splined portion [B] of the pinion gear shaft.
measure the backlash, move the pinion gear shaft back and forth
• To
[C] while holding the front axle steady. The difference between the
highest and the lowest gauge reading is the amount of backlash.
Measure backlash at three locations equally spaced on the splines.
Front Final Bevel Gear Backlash
0.20 mm (0.004 ~ 0.008 in.) (at pinion gear
Standard:
0.10
spline)
If the backlash is not within the limit, replace the pinion gear shims. To
increase backlash, increase the thickness of the shim(s). To decrease
backlash, decrease the thickness of the shim(s).
Change the thickness a little at a time.
Recheck the backlash, and readjust as necessary.
Tooth Contact Adjustment
Clean any dirt and oil off the bevel gear teeth.
Apply checking compound to 4 or 5 teeth on the pinion gear.
•
•
•
NOTE
Apply checking compound to the teeth in a thin, even coat with a
fairly stiff paint brush. If painted too thickly, the exact tooth pattern
may not appear.
The checking compound must be smooth and firm, with the
consistency of tooth paste.
Special compounds are available from automotive supply stores for
the purpose of checking differential gear tooth patterns and contact.
Use one of these for checking the bevel gears.
the front final gear case (see Front Final Gear Case
• Assemble
Assembly).
It is not necessary to install the variable front differential control unit.
the pinion gear shaft [A] for one revolution in the drive and
• Turn
reverse (coast) direction, while creating a drag on the ring gear.
the ring gear and pinion gear unit to check the drive pattern
• Remove
and coast pattern of the bevel gear teeth.
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FINAL DRIVE 11-41
Front Final Gear Case
The tooth contact patterns of both (drive and coast) sides should be
•
centrally located between the top and bottom of the tooth. The drive
pattern can be a little closer to the toe and the coast pattern can be
a somewhat longer and closer to the toe.
If the tooth contact pattern is incorrect, replace the ring gear shim(s),
following the examples shown.
Then erase the tooth contact patterns and check them again. Also
check the backlash every time the shim(s) are replaced. Repeat the
shim change procedure as necessary.
If
NOTE
the backlash is out of the standard range after changing the
ring gear shim(s), change the pinion gear shim(s) to correct the
backlash before checking the tooth contact pattern.
Bevel Gear Inspection
check the bevel gears [A] for scoring, chipping, or other
• Visually
damage.
Replace the bevel gears as a set if either gear is damaged.
Differential Gear Inspection
check the differential gears [A] for scoring, chipping, or other
• Visually
damage.
Replace the differential gears as a set if either gear is damaged.
inspect the differential gear shaft [B], gear case [C], and cover
• Also,
[D] where the differential gears rub.
If they are scored, discolored, or otherwise damaged, replace them
as a set.
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11-42 FINAL DRIVE
Front Final Gear Case
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FINAL DRIVE 11-43
Rear Propeller Shaft
Rear Propeller Shaft Removal
the rear final gear case oil (see Rear Final Gear Case Oil
• Drain
Change in Periodic Maintenance chapter).
• Remove:
Swingarm [A] (see Suspension chapter)
Rear Propeller Shaft [B]
Rear Propeller Shaft Installation
the old grease off the front and rear end splines [A] of the rear
• Wipe
propeller shaft [B] and apply new molybdenum disulfide grease in
•
•
those.
Be sure to install the spring [C] on the pinion gear nut of the rear final
gear case.
Install the rear propeller shaft while aligning the splines.
Rear Propeller Shaft Joint Boot Inspection
• Refer to Joint Boots Inspection in Periodic Maintenance chapter.
Rear Propeller Shaft Inspection
the rear propeller shaft (see Rear Propeller Shaft Removal).
• Remove
that the universal joint [A] works smoothly without rattling or
• Check
sticking.
•
•
If it does rattle or stick, the universal joint is damaged. Replace the
propeller shaft with a new one.
Visually inspect the splines [B] on the propeller shaft.
If they are badly worn, chipped, or loose, replace the propeller shaft.
Also, inspect the splines on the rear end of the output shaft and the
pinion gear joint in the final gear case.
If splines are badly worn, chipped, or loose, replace the output shaft
and the pinion gear joint.
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11-44 FINAL DRIVE
Rear Axle
Rear Axle Removal
the rear final gear case oil (see Rear Final Gear Case Oil
• Drain
Change in Periodic Maintenance chapter).
• Remove:
Rear Wheels (see Wheels/Tires chapter)
•
Rear Hub (see Wheels/Tires chapter)
Rear Bottom Guard (see Frame chapter)
Trailer Hitch Bracket (see Frame chapter)
Rear Final Gear Case Left Cover
Tap [A] the right end of the rear axle [B] and pull it out from the left.
The left axle bearing comes off with the axle.
Rear Axle Installation
the rear axle from the left side with the left bearing installed,
• Install
while aligning the splines.
grease:
• Apply
O-ring [A]
Oil Seal Lips in Rear Final Gear Case Left Cover
• Install:
Rear Final Gear Case Left Cover [A]
Trailer Hitch Bracket [B] (see Frame chapter)
Ball Bearing Wear
CAUTION
Do not remove the bearing [A] for inspection. Removal may
damage it.
the ball bearing.
• Check
Since the ball bearing is made to extremely close tolerances, the wear
must be judged by feel rather than measurement.
Spin the bearing by hand to check its condition.
If the bearing is noisy, does not spin smoothly, or has any rough spots,
replace the rear axle shaft.
Rear Axle Runout Inspection
inspect the axle for damage.
• Visually
If the axle is damaged or bent, replace it.
the rear axle in an alignment jig or on V blocks, and place a dial
• Set
gauge [A] against the middle point.
the axle slowly. The difference between the highest and lowest
• Turn
dial gauge readings is the axle runout (TIR).
If the runout exceeds the service limit, replace the axle.
Rear Axle Shaft Runout
Standard:
Service Limit:
TIR 1 mm (0.04 in.) or less
TIR 2 mm (0.08 in.)
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FINAL DRIVE 11-45
Rear Final Gear Case
Rear Final Gear Case Oil Level Inspection
the vehicle so that it is level, both side-to-side and front-to-rear.
• Park
Remove
the filler cap.
•
CAUTION
Be careful not to allow any dirt or foreign materials to enter
the gear case.
the oil level.
• Check
filler opening [A].
•
•
The oil level should come to the bottom of the
If it is insufficient, first check the rear final gear case for oil leakage,
remedy it if necessary, and add oil through the filler opening. Use the
same type and brand of oil that is already in the final gear case.
Apply grease to the O-ring.
Be sure the O-ring is in place.
Torque -
Oil Filler Cap: 29 N1m (3.0 kgf1m, 22 ft1lb)
Rear Final Gear Case Oil Change
to Rear Final Gear Case Oil Change in Periodic Maintenance
• Refer
chapter.
Rear Final Gear Case Removal
• Remove:
Rear Shock Absorber (see Suspension chapter)
Rear Brake Cable Ends [A]
Vent Hose [B]
• Remove:
Rear Axle [A] (see Rear Axle Removal)
Rear Final Gear Case Bolts [B] (10)
Rear Final Gear Case [C]
Rear Final Gear Case Installation
• Install:
Rear Axle Shaft [A]
•
Dowel Pins [B]
New Gasket [C] (see Brake System chapter)
Spring [D]
Insert the pinion gear shaft of the rear final gear case in the plate
assembly.
Align the splines by rotating the axle shaft.
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11-46 FINAL DRIVE
Rear Final Gear Case
the rear final gear case bolts following the tightening se• Tighten
quence [1∼10].
Torque -
Rear Final Gear Case Bolts: 42 N1m (4.3 kgf1m, 31 ft1lb)
Rear Final Gear Case Disassembly
• Remove:
Rear Final Gear Case (see Rear Final Gear Case Removal)
Rear Final Gear Case Right Cover Bolts [A]
Rear Final Gear Case Right Cover [B]
• Remove:
Shim(s) [A]
Ring Gear [B]
• Remove:
Pinion Gear Bearing Holder [A]
Hold the rear final gear case [A] in a vise, and remove the bearing
holder using the socket wrench [B].
Special Tool -
Socket Wrench, Hex 50: 57001-1478
If the holder seems too difficult to break free, apply heat to softer the
locking agent.
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FINAL DRIVE 11-47
Rear Final Gear Case
• Remove:
Pinion Gear Unit [A]
Shim(s)
Rear Final Gear Case Assembly
check the pinion gear and ring gear for scoring, chipping, or
• Visually
other damage.
•
Replace the bevel gear as a set if either gear is damaged since they
are lapped as a set in the factory to get the best tooth contact.
Install:
Shim(s)
Pinion Gear Unit
Be sure to check and adjust the bevel gear backlash and tooth contact
when any of the backlash-related parts are replaced (see Rear Final
Bevel Gear Adjustment).
a non-permanent locking agent to the pinion gear bearing
• Apply
holder [A], and tighten it.
Special Tool Torque -
Socket Wrench, Hex 50: 57001-1478
Pinion Gear Bearing Holder: 137 N1m (14 kgf1m, 101 ft1lb)
• Inspect:
Ball Bearing [A] (see Bearing and Oil Seal section)
•
Oil Seals [B] (see Bearing and Oil Seal section)
If they are damaged, replace the rear final gear case right cover [C].
Apply grease to the oil seal lips and O-ring [D].
• Install:
Rear Final Gear Case Right Cover [A]
Apply
• them. a non-permanent locking agent to the cover bolts, and tighten
Torque -
Rear Final Gear Case Right Cover Bolts (M10) [B]: 49 N1m (5.0
kgf1m, 36 ft1lb)
Rear Final Gear Case Right Cover Bolts (M8) [C]: 24 N1m (2.4
kgf1m, 17 ft1lb)
• Install:
Rear Final Gear Case Left Cover
Rear Axle (see Rear Axle Installation)
Trailer Hitch Bracket (see Frame chapter)
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11-48 FINAL DRIVE
Rear Final Gear Case
Oil Seal Installation
the oil seals in the right and left covers to the specified positions
• Press
as shown.
[A] Left Cover
[B] Outside Oil Seal
[C] 31.5 ~ 32.5 mm (1.24 ~ 1.28 in.)
[D] Inside Oil Seal
[E] 21.3 ~ 22.3 mm (0.84 ~ 0.88 in.)
Use the oil seal driver [A] for the outside oil seals of the right and left
covers.
Special Tool -
Oil Seal Driver: 57001–1487
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FINAL DRIVE 11-49
Rear Final Gear Case
Rear Final Bevel Gear Adjustment
The backlash and tooth contact pattern of the bevel gears must be
correct to prevent the gears from making noise and being damaged.
replacing any of the backlash-related parts, be sure to check
• After
and adjust the backlash and tooth contact of the bevel gears. First,
adjust backlash, and then tooth contact by replacing shims.
The amount of backlash is influenced by the ring gear position more
than by the pinion gear position.
Tooth contact locations is influenced by the pinion gear position more
than by the ring gear position.
Rear Final Gear Case (Backlash-related Parts)
1.
2.
3.
4.
Pinion Gear
Pinion Gear Bearing Holder
Gear Case Right Cover
Ball Bearings
5. Ring Gear
6. Pinion Gear Shim(s)
7. Ring Gear Shim(s)
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11-50 FINAL DRIVE
Rear Final Gear Case
6. Pinion Gear Shims for Tooth Contact Adjustment
Thickness
0.15 mm (0.006 in.)
0.2 mm (0.008 in.)
0.5 mm (0.020 in.)
0.8 mm (0.031 in.)
1.0 mm (0.039 in.)
1.2 mm (0.047 in.)
Part Number
92180-1320
92180-1319
92180-1321
92180-1322
92180-1345
92180-1346
7. Ring Gear Shims for Backlash Adjustment
Thickness
0.15 mm (0.006 in.)
0.2 mm (0.008 in.)
0.5 mm (0.020 in.)
0.8 mm (0.031 in.)
1.0 mm (0.039 in.)
1.2 mm (0.047 in.)
Part Number
92180-1318
92180-1316
92180-1317
92180-1315
92180-1343
92180-1344
Backlash Adjustment
Clean any dirt and oil off the bevel gear teeth.
Install the pinion gear assembly with the primary shim 1.0 mm (0.039
in.) thickness.
Assemble the rear final gear case (see Rear Final Gear Case
Assembly).
Install the ring gear with the primary shim 1.0 mm (0.039 in.)
thickness.
Check the backlash during tightening the cover bolts, and stop
tightening them immediately if the backlash disappears. Then,
change the ring gear shim to a thinner one.
•
•
•
install the rear axle in the gear case and hold it with a
• Temporarily,
vise so that the ring gear is lower than the pinion gear.
a dial gauge [A] so that the tip of the gauge is against the
• Mount
splined portion [B] of the pinion gear joint.
measure the backlash, move the pinion gear shaft back and forth
• To
[C] while holding the rear axle steady. The difference between the
highest and the lowest gauge reading is the amount of backlash.
Measure backlash at three locations equally spaced on the splines.
Rear Final Bevel Gear Backlash :
•
0.14 mm (0.003 ~ 0.006
0.07
in.) at pinion gear spline
If the backlash is not within the limit, replace the ring gear shim(s).
To increase backlash, decrease the thickness of the shim(s). To
decrease backlash, increase the thickness of the shim(s).
Change the thickness a little at a time.
Recheck the backlash, and readjust as necessary.
Tooth Contact Adjustment
Clean any dirt and oil off the bevel gear teeth.
Apply checking compound to 4 or 5 teeth of the pinion gear.
•
•
NOTE
Apply checking compound to the teeth in a thin, even coat with a
fairly stiff paint brush. If painted too thickly, the exact tooth pattern
may not appear.
The checking compound must be smooth and firm, with the
consistency of tooth paste.
Special compounds are available at automotive supply stores for
the purpose of checking differential gear tooth patterns and contact.
Property of www.SmallEngineDiscount.com - Not for Resale
FINAL DRIVE 11-51
Rear Final Gear Case
the rear final gear case (see Rear Final Gear Case
• Assemble
Assembly).
the pinion gear for one revolution in the drive and reverse (coast)
• Turn
direction, while creating drag on the ring gear.
the ring gear and pinion gear unit to check the drive pattern
• Remove
and coast pattern of the bevel gear teeth.
The tooth contact patterns of both (drive and coast) sides should be
centrally located between the top and bottom of the tooth. The drive
pattern can be a little closer to the toe and the coast pattern can be
a somewhat longer and closer to the toe.
•
If the tooth contact pattern is incorrect, replace the pinion gear
shim(s), following the examples shown (see Correct Tooth Contact
Pattern in the Front Final Bevel Gear Adjustment section).
Then erase the tooth contact patterns, and check them again. Also
check the backlash every time the shim(s) are replaced. Repeat the
shim change procedure as necessary.
NOTE
If the backlash is out of the standard range after changing the pinion
gear shim(s), change the ring gear shim(s) to correct the backlash
before checking the tooth contact pattern.
Pinion Gear Unit Disassembly
• Remove:
Pinion Gear Unit [A] (see Rear Final Gear Case Disassembly)
Hold
pinion gear bearing holder nut [B] with the socket wrench
• [C] inthe
a vise, and loosen the pinion gear shaft using the pinion gear
holder [D].
Special Tools - Socket Wrench: 57001-1363
Pinion Gear Holder: 57001-1480
• Remove the ball bearing [E] as necessary.
Special Tool -
Bearing Puller: 57001-135
Pinion Gear Unit Assembly
The pinion gear and ring gear are lapped as a set in the factory to
get the best tooth contact. They must be replaced as a set.
color change, or other
inspect the bearing for abrasion,
• Visually
damage.
•
•
•
If there is any doubt as to the condition of a bearing, replace the
bearing.
Be sure to check and adjust the bevel gear backlash and tooth
contact, when any of the backlash-related parts are replaced (see
Front Final Bevel Gear Adjustment).
Press the bearing [A] on the pinion gear until it is bottomed.
Install the pinion gear bearing holder nut [B] so that the projection [C]
faces outward.
a non-permanent locking agent to the pinion gear bearing
• Apply
holder nut [A], and tighten it.
Special Tools - Socket Wrench [B]: 57001-1363
Pinion Gear Holder [C]: 57001-1480
Torque -
Pinion Gear Bearing Holder Nut: 157 N1m (16 kgf1m, 116 ft1lb)
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11-52 FINAL DRIVE
Rear Final Gear Case
Bevel Gear Inspection
check the bevel gears [A] for scoring, chipping, or other
• Visually
damage.
Replace the bevel gears as a set if either gear is damaged.
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FINAL DRIVE 11-53
Bearing and Oil Seal
Ball or Needle Bearing Inspection
Since the bearings are made to extremely close tolerances, the
clearance cannot normally be measured.
CAUTION
Do not remove any bearings for inspection except the right
rear axle bearing.
each bearing in the case or hub back and forth [A] while checking
• Turn
for plays, roughness, or binding.
If bearing play, roughness, or binding is found, replace the bearing.
the needle bearings [A] in the rear final gear case.
• Check
The rollers in the needle bearing normally wear very little, and wear
is difficult to measure. Instead of measuring, inspect the bearing for
abrasion, color change, or other damage.
If the bearing is damaged, replace the rear final gear case.
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11-54 FINAL DRIVE
Bearing and Oil Seal
Oil Seal Inspection
the oil seals [A].
• Inspect
Replace any if the lips are misshapen, discolored (indicating that the
rubber has deteriorated), hardened, or been otherwise damaged.
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BRAKES 12-1
Brakes
Table of Contents
Exploded View..........................................................12-2
Specifications ........................................................... 12-6
Brake Fluid ............................................................... 12-7
Brake Fluid Recommendation...........................12-7
Brake Fluid Level Inspection ............................. 12-8
Brake Fluid Change...........................................12-8
Brake Line Air Bleeding.....................................12-8
Master Cylinder........................................................ 12-9
Master Cylinder Removal..................................12-9
Master Cylinder Installation...............................12-9
Master Cylinder Disassembly............................12-9
Master Cylinder Assembly...............................12-10
Master Cylinder Inspection (Visual Inspection)12-10
Calipers .................................................................. 12-11
Caliper Removal..............................................12-11
Caliper Installation...........................................12-11
Caliper Disassembly........................................12-11
Caliper Assembly.............................................12-13
Fluid Seal Damage..........................................12-13
Dust Seal and Friction Boot Damage ............. 12-14
Piston and Cylinder Damage .......................... 12-14
Caliper Holder Shaft Wear Inspection.............12-14
Brake Pads.............................................................12-15
Brake Pad Removal.........................................12-15
Brake Pad Installation......................................12-15
Brake Pad Wear Inspection.............................12-15
Brake Discs ............................................................ 12-16
Disc Cleaning .................................................. 12-16
Disc Removal...................................................12-16
Disc Installation ............................................... 12-16
Disc Wear........................................................12-16
Disc Runout.....................................................12-16
Brake Hoses...........................................................12-17
Brake Hose Inspection .................................... 12-17
Brake Hose Replacement ............................... 12-17
Rear Brake Lever, Pedal and Cables.....................12-18
Brake Pedal Position Inspection......................12-18
Brake Pedal Position Adjustment .................... 12-18
Rear Brake Lever Free Play Inspection .......... 12-18
Brake Pedal Free Play Inspection...................12-18
Rear Brake Lever and Pedal Free Play Adjustment.................................................................12-18
Brake Pedal Removal......................................12-18
Brake Pedal Installation...................................12-18
Brake Cable Removal......................................12-19
Brake Cable Installation...................................12-19
Brake Cable Lubrication..................................12-19
Internal Wet Brake..................................................12-20
Internal Wet Brake Disassembly .....................12-20
Internal Wet Brake Assembly..........................12-21
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12
12-2 BRAKES
Exploded View
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BRAKES 12-3
Exploded View
Torque
No.
Fastener
N1m
kgf1m
ft1lb
1
Reservoir Cap Screws
1.5
0.15
13 in1lb
2
Brake Lever Pivot Bolt
5.9
0.6
52 in1lb
3
Brake Lever Pivot Bolt Locknut
5.9
0.6
52 in1lb
4
Master Cylinder Clamp Bolts
8.8
0.9
78 in1lb
5
Brake Switch Mounting Bolt
1.2
0.12
10 in1lb
6
Brake Hose Banjo Bolts
25
2.5
18
7
Pad Mounting Bolts
18
1.8
13
8
Bleed Valves
5.9
0.6
52 in1lb
9
Caliper Mounting Bolts
25
2.5
18
10
Caliper Holder Shaft
18
1.8
13
11
Disc Mounting Bolts
37
3.8
27
Remarks
L
B: Apply brake fluid.
L: Apply a non-permanent locking agent.
Si: Apply silicone grease.
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12-4 BRAKES
Exploded View
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BRAKES 12-5
Exploded View
Torque
No.
Fastener
N1m
kgf1m
ft1lb
Remarks
1
Variable Differential Control Lever Bolt
3.5
0.36
31 in1lb
2
Parking Brake Lever Screw
2.2
0.22
19 in1lb
L
3
Gasket Screws
–
–
–
L
G:
L:
Gr:
MF:
Apply
Apply
Apply
Apply
grease for oil seal and O-ring.
a non-permanent locking agent.
grease.
MOBIL FLUID 424 or equivalent oil.
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12-6 BRAKES
Specifications
Item
Standard
Service Limit
Brake Fluid:
Type
DOT 3 or DOT 4
–––
Pad lining thickness
4.5 mm (0.18 in.)
1 mm (0.04 in.)
Disc thickness
3.3
Disc runout
TIR 0.2 mm (0.008 in.) or less
Front Disc Brake:
3.7 mm (0.130 ~ 0.146 in.)
3 mm (0.12 in.)
TIR 0.3 mm (0.012 in.)
Rear Brake Lever, Pedal and Cables:
Rear brake pedal position
60 ~ 65 mm (2.36 ~ 2.56 in.) above footboad
Rear brake lever free play
1
2 mm (0.04 ~ 0.08 in.)
–––
Rear brake pedal free play
15
25 mm (0.6 ~ 1.0 in.)
–––
Special Tool -
–––
Inside Circlip Pullers: 57001–143
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BRAKES 12-7
Brake Fluid
When working with the disc brake, observe the precautions
listed below.
1. Never reuse old brake fluid.
2. Do not use fluid from a container that has been left unsealed
or that has been open for a long time.
3. Do not mix two types and brands of fluid for use in the brake.
This lowers the brake fluid boiling point and could cause the
brake to be ineffective. It may also cause the rubber brake
parts to deteriorate.
4. Don’t leave the reservoir cap off for any length of time to avoid
moisture contamination of the fluid.
5. Don’t change the fluid in the rain or when a strong wind is
blowing.
6. Except for the disc pads and disc, use only disc brake
fluid, isopropyl alcohol, or ethyl alcohol for cleaning brake
parts. Do not use any other fluid for cleaning these parts.
Gasoline, engine oil, or any other petroleum distillate will
cause deterioration of the rubber parts. Oil spilled on any
part will be difficult to wash off completely and will eventually
deteriorate the rubber used in the disc brake.
7. When handling the disc pads or disc, be careful that no disc
brake fluid or any oil gets on them. Clean off any fluid or oil
that inadvertently gets on the pads or disc with a high flashpoint solvent. Do not use one which will leave an oily residue.
Replace the pads with new ones if they cannot be cleaned
satisfactorily.
8. Brake fluid quickly ruins painted surfaces; any spilled fluid
should be completely washed away immediately.
9. If any of the brake line fittings or the bleed valve is opened
at any time, the AIR MUST BE BLED FROM THE BRAKE
LINE.
Brake Fluid Recommendation
Use extra heavy-duty brake fluid only from a container marked DOT3
or DOT4.
Recommended Disc Brake Fluid
Type :
DOT 3 or DOT 4
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12-8 BRAKES
Brake Fluid
Brake Fluid Level Inspection
• Refer to Brake Fluid Level Inspection in Periodic Maintenance chapter.
Brake Fluid Change
• Refer to Brake Fluid Change in Periodic Maintenance chapter.
Brake Line Air Bleeding
the front wheels (see Wheels/Tires chapter).
• Remove
the air whenever brake parts are replaced or reassembled.
• Bleed
the reservoir cap and fill the reservoir with new brake fluid.
• Remove
Slowly
pump
brake lever several times until no air bubbles can be
• seen rising upthethrough
the fluid from the hose at the bottom of the
reservoir. This bleeds the air from the master cylinder and the brake
line.
Tap
NOTE
the brake hose lightly going from the caliper to the reservoir
side and bleed the air off at the reservoir.
a clear plastic hose to the bleed valve on the caliper, and run
• Attach
the other end of the hose into a container.
the brake line and the caliper as follows:
• Bleed
Hold the brake lever applied [A].
Quickly open and close the valve [B].
Release the brake lever [C].
fluid level must be checked several times during the bleeding
• The
operation and replenished as necessary.
If
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.
If the brake lever action still feels soft or &quot;spongy&quot;, tap the brake
hose from bottom to top and air will rise up to the top part of the
hose. Slowly pump the brake lever in the same manner as above.
• Tighten:
Torque -
Bleed Valves : 5.9 N1m (0.6 kgf1m, 52 in1lb)
the front wheels (see Wheels/Tires chapter).
• Install
the brake lever forcefully for a few seconds, and check for fluid
• Apply
leakage around the fittings.
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BRAKES 12-9
Master Cylinder
Master Cylinder Removal
• Remove:
Brake Hose Banjo Bolt [A]
Master Cylinder Clamp Bolts [B]
Master Cylinder [C]
CAUTION
Brake fluid quickly ruins painted surface; any spilled fluid
should be completely washed away immediately.
Master Cylinder Installation
master cylinder clamp must be installed with the &quot;UP&quot; mark [A]
• The
upwards.
the upper clamp bolt first, and then the lower clamp bolt.
• Tighten
There will be a gap at the lower part of the clamp after tightening.
Torque -
•
Master Cylinder Clamp Bolts: 8.8 N1m (0.9 kgf1m, 78 in1lb)
Use a new flat washer on each side of the brake hose fitting, and
tighten the banjo bolt.
Torque -
Brake Hose Banjo Bolt: 25 N1m (2.5 kgf1m, 18 ft1lb)
the brake line after master cylinder installation (see Brake Line
• Bleed
Air Bleeding).
the brake for good braking power, no braking brag, and no
• Check
fluid leakage.
Do not attempt to drive the vehicle until a firm brake lever
can be obtained by pumping the brake lever until the pads are
against each disc. The brakes will not function on the first
application of the lever if this is not done.
Master Cylinder Disassembly
• Remove:
Master Cylinder (see Master Cylinder Removal)
Brake Lever Pivot Nut [A]
Brake Lever Pivot Bolt [B]
Brake Lever [C]
Dust Cover [D]
Circlip [E]
Piston [F]
Spring [G]
Special Tool -
Inside Circlip Pliers: 57001–143
CAUTION
Do not remove the secondary cup [H] from the piston since
removal will damage it.
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12-10 BRAKES
Master Cylinder
Master Cylinder Assembly
assembly, clean all parts including the master cylinder with
• Before
brake fluid or alcohol.
CAUTION
Except for the disc pads and disc, use only disc brake
fluid, isopropyl alcohol, or ethyl alcohol for cleaning brake
parts. Do not use any other fluid for cleaning these parts.
Gasoline, engine oil, or any other petroleum distillate will
cause deterioration of the rubber parts. Oil spilled on any
part will be difficult to wash off completely, and will eventually
deteriorate the rubber used in the disc brake.
care not to scratch the piston or the inner wall of the cylinder.
• Take
Apply
• cylinder.brake fluid to the removed parts and to the inner wall of the
• Tighten:
Torque -
Brake Lever Pivot Bolt: 5.9 N1m (0.6 kgf1m, 52 in1lb)
Brake Lever Pivot Bolt Locknut: 5.9 N1m (0.6 kgf1m, 52 in1lb)
Master Cylinder Inspection (Visual Inspection)
the master cylinder (see Master Cylinder Disassembly).
• Disassemble
Check
that
there
scratches, rust or pitting on the inner wall of
• the master cylinderare[A]noand
on the outside of the piston [B].
•
•
•
•
If the master cylinder or piston shows any damage, replace them.
Inspect the primary [C] and secondary [D] cups.
If a cup is worn, damaged, softened (rotted), or swollen, the piston
assembly should be replaced to renew the cups.
If fluid leakage is noted at the brake lever, the piston assembly should
be replaced to renew the cups.
Check the dust cover [E] for damage.
If it is damaged, replace it.
Check that the relief [F] and supply [G] ports are not plugged.
If the relief port becomes plugged, the brake pads will drag on the
disc. Blow the ports clean with compressed air.
Check the piston return spring [H] for any damage.
If the spring is damaged, replace it.
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BRAKES 12-11
Calipers
Caliper Removal
the front wheel (see Wheels/Tires chapter).
• Remove
Loosen
the
• loosely. banjo bolt [A] at the brake hose lower end, and tighten it
the caliper mounting bolts [B] with a socket wrench and an
• Unscrew
extension bar.
the caliper [C] from the disc.
• Detach
the banjo bolt and remove the brake hose [D] from the
• Unscrew
caliper.
CAUTION
Immediately wash away any brake fluid that spills.
NOTE
If the caliper is to be disassembled after removal and if compressed
air is not available, disassemble the caliper before the brake hose
is removed (see Caliper Disassembly).
Caliper Installation
the caliper and brake hose lower end.
• Install
Replace the washers that are on each side of hose fitting with new
•
ones.
Tighten:
Torque -
Caliper Mounting Bolts: 25 N1m (2.5 kgf1m, 18 ft1lb)
Brake Hose Banjo Bolt: 25 N1m (2.5 kgf1m, 18 ft1lb)
the fluid level in the brake reservoir.
• Check
Bleed
the
line (see Brake Line Air Bleeding).
• Check the brake
brake
for good braking power, no brake drag, and no fluid
• leakage.
Do not attempt to drive the vehicle until a firm brake lever
can be obtained by pumping the brake lever until the pads are
against each disc. The brakes will not function on the first
application of the lever if this is not done.
Caliper Disassembly
• Remove:
Caliper (see Caliper Removal)
•
Pads (see Brake Pad Removal)
Anti-rattle Spring
Using compressed air, remove the piston.
Cover the caliper opening with a clean, heavy cloth [A].
Remove the piston by lightly applying compressed air [B] to where
the brake line fits into the caliper.
To avoid serious injury, never place your fingers or palm inside
the caliper opening. If you apply compressed air into the
caliper, the piston may crush your hand or fingers.
NOTE
If compressed air is not available, do as follows with the brake hose
connected to the caliper.
Prepare a container for brake fluid.
Remove the pads and spring (see Brake Pad Removal).
Pump the brake lever to remove the caliper piston.
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12-12 BRAKES
Calipers
• Remove:
Plug [A]
• Loosen:
Caliper Holder Shaft (Allen Bolt) [A]
• Remove:
Washer [A] and Caliper Holder shaft [B]
Caliper Holder [C]
Boots [D]
• Remove:
Dust Seal [A]
Fluid Seal [B]
• Remove:
Caliper Holder Shaft [A]
Washer [B]
Caliper Holder [C]
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BRAKES 12-13
Calipers
Caliper Assembly
the fluid seal [A] with a new one.
• Replace
Apply brake fluid to the fluid seal, and install it into the cylinder by
hand.
the dust seal [B] with a new one if it is damaged.
• Replace
Apply brake fluid to the dust seal, and install it into the cylinder by
hand.
• Install the anti-rattle spring [A] in the caliper as shown.
brake fluid to the outside of the piston [A], and push it into the
• Apply
cylinder by hand. Take care that neither the cylinder nor the piston
•
•
skirt gets scratched.
Replace the rubber boots [B] and plug [C] if they are damaged.
Apply a thin coat of silicone grease to the caliper holder shafts [D]
and holder holes [E] (Silicone grease is a special high temperature,
water-resistant grease).
• Install the caliper holder plate [A].
Torque -
•
Torque -
•
Caliper Holder Shaft: 18 N1m (1.8 kgf1m, 13 ft1lb)
Install the bleed valve and rubber cap.
Bleed Valve: 5.9 N1m (0.6 kgf1m, 52 in1lb)
Install the pads (see Brake Pad Installation).
Fluid Seal Damage
The fluid seals [A] around the piston maintain the proper pad/disc
clearance. If the seals are not satisfactory, pad wear will increase,
and constant pad drag on the disc will raise brake and brake fluid
temperature.
Replace the fluid seals under any of the following conditions: (a) fluid
leakage around the pad; (b) brakes overheat; (c) there is a large
difference in inner and outer pad wear; (d) the seal is stuck to the
piston.
If the fluid seal is replaced, replace the dust seal as well. Also, replace
all seals every other time the pads are changed.
•
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12-14 BRAKES
Calipers
Dust Seal and Friction Boot Damage
that the dust seals [A] and friction boots [B] are not cracked,
• Check
worn swollen, or otherwise damaged.
If they show any damage, replace them.
Piston and Cylinder Damage
inspect the piston [A] and cylinder surfaces.
• Visually
Replace the caliper if the cylinder and piston are badly scored or
rusty.
Caliper Holder Shaft Wear Inspection
The caliper body must slide smoothly on the caliper holder shafts [A].
If the body does not slide smoothly, one pad will wear more than the
other, pad wear will increase, and constant drag on the disc will raise
brake and brake fluid temperature.
Check to see that the caliper holder shafts are not badly worn or
stepped, and that the rubber friction boots are not damaged.
If the rubber friction boot is damaged, replace the rubber friction boot.
If caliper holder shaft is damaged, replace the caliper holder shaft
and rubber friction boot as a unit.
•
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BRAKES 12-15
Brake Pads
Brake Pad Removal
the front wheel (see Wheels/Tires chapter).
• Remove
Flatten
out
bended parts of the lockwasher [A].
• Loosen the the
pad mounting bolts [B].
• Lift off the caliper
• hose left attached. by taking off the caliper mounting bolts with the
• Remove:
Pad Mounting Bolts
Pads
Brake Pad Installation
the caliper piston in by hand as far as it will go.
• Push
Be
sure
the anti-rattle spring is in place.
• Install thethatpads.
• The inboard pad [A] next to the piston has a wear protecting shim
•
[B]. Be careful not mix it up with the outboard pad.
Tighten:
Torque -
Pad Mounting Bolts: 18 N1m (1.8 kgf1m, 13 ft1lb)
Do not attempt to drive the vehicle until a full brake lever is
obtained by pumping the brake lever until the pads are against
each disc. The brake will not function on the first application
if this is not done.
Brake Pad Wear Inspection
to Front Brake Pad Wear Inspection in Periodic Maintenance
• Refer
chapter.
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12-16 BRAKES
Brake Discs
Disc Cleaning
Poor braking can be caused by oil on a disc. Oil on a disc must be
cleaned off with an oilless cleaning fluid such as trichloroethylene or
acetone.
These cleaning fluids are usually highly flammable and harmful if breathed for prolonged periods. Be sure to heed the fluid
manufacturer’s warnings.
Disc Removal
• Remove:
Front Hub (see Wheels/Tires chapter)
Brake Disc Mounting Bolts [A]
Brake Disc [B]
Disc Installation
disc must be installed with the marked side [A] facing toward the
• The
steering knuckle.
a non-permanent locking agent:
• Apply
Disc Mounting Bolts
• Tighten:
Torque -
•
Disc Mounting Bolts: 37 N1m (3.8 kgf1m, 27 ft1lb)
After installing the discs, check the disc runout. Completely clean
off any grease that has gotten on either side of the disc with a high
flash-point solvent. Do not use one which will leave an oily residue.
Disc Wear
the thickness of each disc at the point [A] where it has worn
• Measure
the most.
Replace the disc if it has worn past the service limit.
Disc Thickness
Standard:
Service Limit:
3.7 mm (0.130 ~ 0.146 in.)
3.3
3 mm (0.12 in.)
Disc Runout
up the vehicle so that the wheels are off the ground.
• Jack
Remove
the front wheels and turn the handlebar fully to one side.
• Set up a dial
against the disc [A], and measure the disc runout.
• If the runout gauge
exceeds the service limit, replace the disc.
Disc Runout
Standard:
Service Limit:
TIR 0.2 mm (0.008 in.) or less
TIR 0.3 mm (0.012 in.)
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BRAKES 12-17
Brake Hoses
Brake Hose Inspection
to Brake Hose and Connection Check in Periodic Maintenance
• Refer
chapter.
Brake Hose Replacement
• Referto Brake Hose Replacement in Periodic Maintenance chapter.
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12-18 BRAKES
Rear Brake Lever, Pedal and Cables
Brake Pedal Position Inspection
that the brake pedal [A] is in the correct position as shown.
• Check
[B] Footboard
Pedal Position [C]
Standard:
60 ~ 65 mm (2.36 ~ 2.56 in.) above footboard
If it is incorrect, adjust the brake pedal position.
Brake Pedal Position Adjustment
the locknut [A], and turn the adjusting bolt [B] until the brake
• Loosen
pedal is correctly positioned.
the locknut.
• Tighten
Check
the
• tion). brake pedal free play (see Brake Pedal Free Play Inspec-
Rear Brake Lever Free Play Inspection
to Rear Brake Lever Free Play Inspection in Periodic Mainte• Refer
nance chapter.
Brake Pedal Free Play Inspection
to Brake Pedal Free Play Inspection in Periodic Maintenance
• Refer
chapter.
Rear Brake Lever and Pedal Free Play Adjustment
to Rear Brake Lever and Pedal Free Play Adjustement in
• Refer
Periodic Maintenance chapter.
Brake Pedal Removal
• Remove:
Right Footboard (see Frame chapter)
Loosen
• Remove:the locknut and the adjusting bolt [A].
• Brake Switch Spring [B]
Cotter Pin, Washer, Pin and Brake Cable Joint [C]
Cotter Pin and Washer [D]
O-ring and Brake Pedal [E]
Spring
Brake Pedal Installation
grease:
• Apply
Brake Pedal Pivot [A]
O-ring [B]
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BRAKES 12-19
Rear Brake Lever, Pedal and Cables
• Install:
Spring [A]
Brake Pedal [B]
grease:
• Apply
O-ring [C]
• Install:
Brake Cable Joint and Pin [D]
•
•
Brake Switch Spring [E]
Washers [F]
Replace the cotter pins [G] with new ones.
Adjust the brake pedal position (see Brake Pedal Position).
Brake Cable Removal
• Remove:
Right Rear Flap (see Frame chapter)
the adjusters [A] at the rear ends of the cables, and pull the
• Unscrew
cables out of the joints [B] and cable mounts [C].
the knurled locknut [A] at the rear brake lever and screw in
• Loosen
the adjuster [B].
up the slots [C] in the brake lever, knurled locknut, and adjuster,
• Line
and then free the cable from the lever [D].
• Remove the brake lever cable from the frame.
• Remove:
Circlip [A]
Cotter Pin, Washer and Pin [B]
Brake Pedal Cable [C]
Brake Cable Installation
the brake cable front ends.
• Grease
the cotter pin with a new one.
• Replace
Route
the
brake cables according to the Cable, Wire, and Hose
• Routing section
in Appendix chapter.
Adjust
the
brake
pedal and rear brake lever.
•
Brake Cable Lubrication
•
Whenever the brake cable is removed, lubricate the cable as follows:
Lubricate the cable with a penetrating rust inhibitor.
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12-20 BRAKES
Internal Wet Brake
Internal Wet Brake Disassembly
• Remove:
Rear Final Gear Case (see Final Drive chapter)
Gasket Screws [A]
Gasket [B]
Dowel Pins [C]
• Remove:
Steel Plates [A]
Friction Plates [B]
Pins [C] and Springs
• Remove:
Cam Plate [A]
• Remove:
Steel Balls [A]
• Remove:
Brake Cam Lever Bolt and Nut [A]
Brake Camshaft [B]
Brake Cam Lever [C]
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BRAKES 12-21
Internal Wet Brake
Internal Wet Brake Assembly
[A] MOBIL FLUID 424 or equivalent oil to the brake camshaft
• Apply
and the inside of the collar.
• Insert the camshaft in the swingarm.
the punch mark [A] on the brake cam lever with the punch mark
• Align
[B] on the brake camshaft.
• Install:
Steel Balls
Brake Cam Plate [A]
Fit the cam plate and brake camshaft [B] as shown.
• Install:
Steel Pressure Plate [A] and Pins [B] (as shown)
• Install:
Friction Plates [A]
Steel Plates [B]
Springs [C]
Steel Pressure Plate [D]
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12-22 BRAKES
Internal Wet Brake
• Install:
Dowel Pins [A]
New Gasket [B]
a non-permanent locking agent to the gasket screws [C], and
• Apply
tighten them.
• Install:
Rear Final Gear Case (see Final Drive chapter)
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SUSPENSION 13-1
Suspension
Table of Contents
Exploded View.................................................................................................................................................................13-2
Specifications .................................................................................................................................................................. 13-4
Shock Absorbers.............................................................................................................................................................13-5
Front Shock Absorber Removal ............................................................................................................................... 13-5
Front Shock Absorber Installation............................................................................................................................13-5
Front Shock Absorber Inspection.............................................................................................................................13-5
Front Shock Absorber Spring Removal....................................................................................................................13-6
Front Shock Absorber Spring Installation ................................................................................................................ 13-7
Rear Shock Absorber Preload Adjustment ..............................................................................................................13-8
Rear Shock Absorber Removal................................................................................................................................13-8
Rear Shock Absorber Installation.............................................................................................................................13-8
Rear Shock Absorber Inspection ............................................................................................................................. 13-9
Rear Shock Absorber Spring Removal....................................................................................................................13-9
Rear Shock Absorber Spring Installation...............................................................................................................13-10
Rear Shock Absorber Scrapping............................................................................................................................13-11
Suspension Arms..........................................................................................................................................................13-12
Suspension Arm Removal......................................................................................................................................13-12
Suspension Arm Installation...................................................................................................................................13-12
Suspension Arm Disassembly ............................................................................................................................... 13-12
Suspension Arm Assembly.................................................................................................................................... 13-13
Swingarm ...................................................................................................................................................................... 13-14
Swingarm Removal ................................................................................................................................................ 13-14
Swingarm Installation.............................................................................................................................................13-14
Swingarm Disassembly..........................................................................................................................................13-14
Swingarm Assembly...............................................................................................................................................13-16
Swingarm Bearing Inspection ................................................................................................................................ 13-16
Swingarm Bearing Lubrication...............................................................................................................................13-16
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13
13-2 SUSPENSION
Exploded View
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SUSPENSION 13-3
Exploded View
Torque
No.
Fastener
N1m
kgf1m
ft1lb
1
Front Shock Absorber Mounting Nuts
74
7.5
54
2
Front Shock Absorber Clamp Bolts and Nuts
47
4.8
35
3
Steering Knuckle Joint Nut
47
4.8
35
4
Suspension Arm Pivot Bolts
88
9.0
65
5
Rear Shock Absorber Mounting Nuts
62
6.3
46
6
Piston Rod Nut
49
5.0
36
7
Swingarm Pivot Right Shaft
152
15.5
112
8
Swingarm Pivot Left Shaft
20
2.0
14
Swingarm Pivot Left Nut
152
15.5
112
9
G:
L:
AG:
MF:
Gr:
Apply
Apply
Apply
Apply
Apply
Remarks
L
grease for oil seal and O-ring.
a non-permanent locking agent.
grease (Amoco rykon premium grease No. 2 EP Green).
MOBIL FLUID 424 or equivalent oil.
grease.
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13-4 SUSPENSION
Specifications
Item
Standard
Service Limit
Shock Absorbers:
Spring preload setting position (Rear)
(Usable Range)
No. 2
1~5
Special Tools - Outside Circlip Pliers: 57001–144
Oil Seal &amp; Bearing Remover: 57001–1058
Steering Stem Nut Wrench: 57001–1100
Bearing Driver Set: 57001–1129
Jack: 57001–1238
Holder &amp; Guide Arbor: 57001–1476
Spacer &amp; Holder: 57001–1477
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SUSPENSION 13-5
Shock Absorbers
Front Shock Absorber Removal
• Remove:
Front Fender (see Frame chapter)
Front Inner Cover (see Frame chapter)
Cotter Pins [A]
Front Shock Absorber Clamp Bolts and Nuts [B]
Suspension Arm Pivot Bolts
• Remove:
Circlip [A]
Special Tool -
Outside Circlip Pliers: 57001–144
• While supporting the vehicle with a jack, loosen the nut [B].
Special Tool -
Jack: 57001–1238
the ball joint [C] of the shock absorber from the frame bracket
• Remove
[D].
• Remove:
Front Shock Absorber [A]
Front Shock Absorber Installation
the shock absorber into the knuckle, and align its recess [A]
• Insert
and the lower bolt hole [B] in the knuckle.
• Tighten:
Torque -
Front Shock Absorber Clamp Bolts and Nuts: 47 N1m (4.8
kgf1m, 35 ft1lb)
the ball joint into the frame bracket.
• Insert
Tighten
the nut.
•
Torque -
Front Shock Absorber Mounting Nut: 74 N1m (7.5 kgf1m, 54
ft1lb)
• Replace the circlip with a new one.
Special Tool -
•
Outside Circlip Pliers: 57001–144
Lower the vehicle and remove the jack.
Front Shock Absorber Inspection
Since the front 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 are not balanced, vehicle instability
at high speed may result.
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13-6 SUSPENSION
Shock Absorbers
Front Shock Absorber Spring Removal
• Remove:
Front Shock Absorber (see Front Shock Absorber Removal)
the holder [A] (57001-1476) and spacer [B] (57001-1477) in a
• Hold
vice as shown.
the guide arbors [C] (57001-1476) on the holder.
• Install
Insert
the
• holder. front shock absorber [D] into the center of the spacer and
Special Tools - Holder &amp; Guide Arbor: 57001-1476
Spacer &amp; Holder: 57001- 1477
the upper holder [A] (57001-1477) on upper end of the spring
• Put
guide [B] and arbors so that the recess side [C] faces downward.
the nuts [A] and press the spring until the spring seat stopper
• Tighten
is free.
• Pull up the spring seat [A] and remove the spring seat stopper [B].
• Remove:
Nuts and Upper Holder
Spring Guide [A]
Spring [B]
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SUSPENSION 13-7
Shock Absorbers
Front Shock Absorber Spring Installation
the front shock absorber [A] into the center of the spacer [B] and
• Set
holder [C] (see Front Shock Absorber Spring Removal).
Special Tools - Holder &amp; Guide Arbor: 57001–1476
Spacer &amp; Holder: 57001–1477
• Install:
Spring [A]
Spring Guide [B]
the upper holder [C] (57001–1477) on upper end of the spring
• Put
guide and arbors [D] so that the recess side faces downward.
• Tighten the nuts [E] and press the spring.
• Install the spring seat stopper [A] by the reverse of removal.
the spring seat stopper under the spring seat [A].
• Fit
Remove:
• Nuts [B]
Upper Holder
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13-8 SUSPENSION
Shock Absorbers
Rear Shock Absorber Preload Adjustment
The spring adjusting sleeve [A] on rear shock absorber has 5 positions
so that the spring can be adjusted for different terrain and loading
conditions. If the spring action feels too soft or too stiff, adjust it in
accordance with the following table.
Spring Action
Position
Spring
Force
Setting
Load
Terrain
Speed
1
Soft
Light
Smooth
Low
2 (STD)
&quot;
&quot;
&quot;
&quot;
3
4
#
#
#
#
#
5
Stronger
Hard
Heavy
Rough
High
the adjusting sleeve on rear shock absorber to the desired
• Turn
position with the wrench.
Special Tool -
Steering Stem Nut Wrench: 57001–1100
Rear Shock Absorber Removal
the vehicle on a stand or a jack so that the rear wheels are
• Support
off the ground.
Special Tool -
Jack: 57001–1238
holding the rear wheels, remove the lower and upper shock
• While
absorber mounting bolts [A], nuts, and washers.
• Remove the rear shock absorber [B].
Rear Shock Absorber Installation
• Install:
Bushings [A]
Washers [B]
• Tighten:
Torque -
Rear Shock Absorber Mounting Nuts [C]: 62 N1m (6.3 kgf1m,
46 ft1lb)
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SUSPENSION 13-9
Shock Absorbers
Rear Shock Absorber Inspection
the rubber bushings [A] in the upper and lower pivots.
• Check
If bushings are worn, cracked, hardened, or otherwise damaged,
replace them.
Rear Shock Absorber Spring Removal
• Remove:
Rear Shock Absorber (see Rear Shock Absorber Removal)
Hold
holder [A] (57001-1476) and spacer [B] (57001-1477) in a
• vice astheshown.
the guide arbors [C] (57001-1476) on the holder.
• Install
the rear shock absorber [D] into the center of the spacer and
• Insert
holder.
Special Tools - Holder &amp; Guide Arbor: 57001-1476
Spacer &amp; Holder: 57001- 1477
the upper holder [A] (57001-1477) on upper end of the spring
• Put
guide [B] and arbors [C] so that the recess side faces downward.
the nuts [A] and compress the spring to loosen the piston rod
• Tighten
nut [B].
Pull the top joint [C] upward.
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13-10 SUSPENSION
Shock Absorbers
the top joint [A] with a suitable bar [B], and loosen the piston
• Holding
rod nut with a wrench [C].
• Remove:
Top Joint
• Remove:
Nuts [A] and Upper Holder [B]
Spring Guide [C]
Spring [D]
Rear Shock Absorber Spring Installation
the piston rod nut [A] fully by hand.
• Tighten
the damper assembly [B] into the center of the spacer and
• Insert
holder (see Rear Shock Absorber Spring Removal).
Special Tools - Holder &amp; Guide Arbor: 57001-1476
Spacer &amp; Holder: 57001- 1477
• Install:
Adjusting Sleeve [C]
Spring Seat [D] (Stepped side facing upward.)
the spring [A] with the smaller end facing downward on the
• Install
spring seat.
• Install the spring guide [B] with the smaller end facing downward.
the upper holder [A] (57001-1477) on upper ends of the spring
• Put
guide [B] and arbors [C] so that the recess side faces downward.
• Tighten the nuts [D] and compress the spring.
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SUSPENSION 13-11
Shock Absorbers
the top joint [A] fully by hand.
• Tighten
Tighten
the piston rod nut [B] against the top joint.
•
Torque -
•
Piston Rod Nut: 49 N1m (5.0 kgf1m, 36 ft1lb)
Fit the top joint on the spring guide.
• Remove:
Nuts [A]
Upper Holder [B]
Rear Shock Absorber Scrapping
Since the rear shock absorber contains nitrogen gas, do not
incinerate or disassemble the rear shock absorber.
Before a rear shock absorber is scrapped, drill a hole at a point
about 15 mm (0.59 in.) [A] up from the bottom of the cylinder
to release the nitrogen gas completely. Wear safety glasses
when drilling the hole, as the gas may blow out bits of drilled
metal when the hole opens.
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13-12 SUSPENSION
Suspension Arms
Suspension Arm Removal
• Remove:
Front Wheel (see Wheels/Tires chapter)
Knuckle Joint Bolt [A]
Knuckle Joint [B] (from Knuckle)
Suspension Arm Pivot Bolts [C]
Suspension Arm [D]
Suspension Arm Installation
• Tighten:
Torque -
Suspension Arm Pivot Bolts: 88 N1m (9.0 kgf1m, 65 ft1lb)
Steering Knuckle Joint Nuts: 47 N1m (4.8 kgf1m, 35 ft1lb)
Suspension Arm Disassembly
• Remove:
Axle Guard Bolts [A] and Washers
•
Axle Guard [B]
Circlip [C]
Press out the knuckle joint [D].
CAUTION
Do not remove the knuckle joint grease seal. It is packed with
grease.
• Remove:
Rubber Bushings [A]
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SUSPENSION 13-13
Suspension Arms
Suspension Arm Assembly
the bushings [A] in the suspension arm [B] as shown.
• Position
[C] 0.4 ~ 0.6 mm (0.016 ~ 0.024 in.)
• Confirm that the knuckle joint is smooth motion after installed.
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13-14 SUSPENSION
Swingarm
Swingarm Removal
the vehicle on a stand or a jack so that the rear wheels are
• Support
off the ground.
Special Tool -
Jack: 57001–1238
• Remove:
Rear Final Gear Case (see Final Drive chapter)
Swingarm Pivot Left Nut [A]
Swingarm Pivot Left Shaft [B]
• Loosen:
Boot Clamp Screw [A]
Remove:
• Boot
Swingarm Pivot Right Shaft [B]
Swingarm [C]
Swingarm Installation
molybdenum disulfide grease to the spline of the output shaft
• Apply
[A].
• Fit the propeller shaft [B] on the output shaft.
a non-permanent locking agent:
• Apply
Swingarm Pivot Right Shaft [A]
• Tighten:
Torque -
Swingarm Pivot Right Shaft: 152 N1m (15.5 kgf1m, 112 ft1lb)
• Tighten:
Torque -
Swingarm Pivot Left Shaft [B]: 20 N1m (2.0 kgf1m, 14 ft1lb)
Swingarm Pivot Left Nut [C]: 152 N1m (15.5 kgf1m, 112 ft1lb)
• Fit the boot on the swingarm, and tighten the clamp screw.
Swingarm Disassembly
• Remove:
Collars [A]
O-ring [B]
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SUSPENSION 13-15
Swingarm
• Remove:
Oil Seal [A]
• Remove:
Tapered Roller Bearing [A]
• Remove:
Outer Race [A]
• Remove:
Ball Bearing [A]
Special Tool -
Oil Seal &amp; Bearing Remover [B]: 57001–1058
• Remove:
Oil Seal [A]
Property of www.SmallEngineDiscount.com - Not for Resale
13-16 SUSPENSION
Swingarm
• Remove:
Collar [A]
Oil Seal [B]
Swingarm Assembly
grease:
• Apply
Inside [A] of Oil Seals
MOBIL FLUID 424 or Equivalent:
• Apply
Surface of Collar [B]
the following parts as shown.
• Install
Brake Lever Oil Seal [C]
[D] = 14.5 &plusmn; 0.1 mm (0.571 &plusmn; 0.004 mm)
Collar (level with surface)
Propeller Shaft Oil Seal [E]
[F] = 25 &plusmn; 0.1 mm (0.984 &plusmn; 0.004 mm)
Ball Bearing [G] (level with surface)
Amoco Rykon Premium Grease No.2 EP Green:
• Apply
Inside of Oil Seals [A]
•
O-rings [B]
Install the following parts as shown.
Tapered Roller Bearing [C]
Oil Seal (level with surface)
O-ring
Collar [D]
Special Tool -
Bearing Driver Set: 57001-1129
Swingarm Bearing Inspection
the rear final gear case (see Final Drive chapter).
• Remove
Move
the
up and down to check for abnormal friction, and
• push and swingarm
pull it back and forth to check for bearing play.
•
If abnormal friction is felt, the bearings are damaged. Replace the oil
seals and both left and right bearings.
The play developed during use may indicate bearing damage. In this
case, remove the swingarm and inspect the bearings. Replace both
left and right bearings, if either of the bearings is damaged.
Swingarm Bearing Lubrication
the swingarm.
• Remove
a high flash-point solvent, wash the bearings clean of grease,
• Using
and dry them.
the bearings and oil seals for abrasion, color change, or other
• Inspect
damage.
grease to the outer races [A], and pack the tapered roller
• Apply
bearings [B] with the same grease.
Amoco Rykon Premium Grease No. 2 EP (green) to the inside
• Apply
of the oil seals.
• Install the swingarm (see Swingarm Installation).
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STEERING 14-1
Steering
Table of Contents
Exploded View.................................................................................................................................................................14-2
Specifications .................................................................................................................................................................. 14-4
Steering...........................................................................................................................................................................14-5
Steering Stem Removal ........................................................................................................................................... 14-5
Steering Stem Installation ........................................................................................................................................14-5
Steering Knuckle Removal.......................................................................................................................................14-6
Steering Knuckle Installation....................................................................................................................................14-7
Steering Knuckle Bearing Removal ......................................................................................................................... 14-7
Steering Knuckle Bearing Installation ...................................................................................................................... 14-7
Tie-Rod Removal......................................................................................................................................................14-7
Tie-Rod Installation .................................................................................................................................................. 14-7
Tie-Rod End Removal..............................................................................................................................................14-8
Tie-Rod End Installation...........................................................................................................................................14-8
Steering Maintenance .....................................................................................................................................................14-9
Steering Inspection...................................................................................................................................................14-9
Steering Stem Straightness ..................................................................................................................................... 14-9
Steering Lubrication ................................................................................................................................................. 14-9
Steering Stem Clamp Inspection ............................................................................................................................. 14-9
Steering Stem Bearing Inspection ........................................................................................................................... 14-9
Steering Knuckle Bearing Inspection.....................................................................................................................14-10
Tie-Rod End and Steering Knuckle Joint Inspection.............................................................................................14-10
Handlebar......................................................................................................................................................................14-11
Handlebar Removal................................................................................................................................................14-11
Handlebar Installation.............................................................................................................................................14-11
14
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14-2 STEERING
Exploded View
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STEERING 14-3
Exploded View
Torque
No.
Fastener
N1m
kgf1m
ft1lb
Remarks
1
Handlebar Holder Bolts
27
2.8
20
S
2
Handlebar Lower Holder Nuts
37
3.8
27
L
3
Tie-Rod Adjusting Sleeve Locknuts
37
3.8
27
4
Tie-Rod End Nuts
42
4.3
31
5
Steering Stem Clamp Bolts
25
2.5
18
6
Steering Stem Bearing Joint Bolts
–
–
–
7
Steering Stem Bottom End Nut
62
6.3
46
8
Front Shock Absorber Clamp Bolts and Nuts
47
4.8
35
9
Steering Knuckle Joint Nut
47
4.8
35
10
Parking Brake Lever Screw
2.2
0.22
19 in1lb
11
Variable Differential Control Lever Bolt
3.5
0.36
31 in1lb
12
Master Cylinder Clamp Bolts
8.8
0.9
78 in1lb
L
L
13: Speedometer (other than U.S.A. model)
14: Cover (U.S.A. model)
L:
G:
AD:
AG:
S:
Apply a non-permanent locking agent.
Apply greae for oil seal and O-ring.
Apply adhesive agent.
Apply grease (Amoco rykon premium grease No. 2 EP Green).
Follow the specific tightening sequence.
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14-4 STEERING
Specifications
Item
Tie-Rods:
Tie-Rod Length
Standard
Service Limit
315 &plusmn; 0.7 mm (12.4 &plusmn; 0.03 in.)
–––
Special Tools - Inside Circlip Pliers: 57001-143
Bearing Driver Set: 57001-1129
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STEERING 14-5
Steering
Steering Stem Removal
• Remove:
Fuel Tank (see Fuel System chapter)
Front Wheels (see Wheels/Tires chapter)
Cotter Pins [A]
Tie-Rod End Nuts [B] and Tie-Rod End
Steering Stem Bearing Housing Bolts [C] (right and left)
CAUTION
Do not loosen the locknuts [D] at the ends of the tie-rod
adjusting sleeve, or the toe-in of the front wheels will be
changed.
• Remove:
Handlebar Holder Mounting Nuts [A]
Handlebar Assembly
out the bended parts [A] of the lockwasher.
• Flatten
• Remove:
Steering Clamp Bolts [B], Lockwasher, and Plate
Steering Clamps [C] and Collars
Grease Seals [D] (upper and lower)
the steering stem out of the frame.
• Pull
Remove:
• Cotter Pin [A]
Steering Stem Bottom End Nut [B]
Collar [C]
Steering Stem Bearing [D]
Steering Stem Installation
grease up the seal grooves [A] in the steering stem bearing [B].
• Full
• Install:
Collar
Tighten:
•
Torque -
Steering Stem Bottom End Nut: 62 N1m (6.3 kgf1m, 46 ft1lb)
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14-6 STEERING
Steering
both ends of the cotter pin [A] as shown.
• Bend
Steering Stem Bottom End Nut [B]
a non-permanent locking agent:
• Apply
Steering Stem Bearing Joint Bolts [A]
Amoco Rykon Premium Grease No.2 EP (Green):
• Apply
Inside of Grease Seals [A]
•
•
Steering Stem [B]
Install:
Grease Seals
Steering Clamps [C] and Collars [D]
Plate [E], Lockwasher [F], and Steering Stem Clamp Bolts [G]
Tighten:
Torque -
Steering Stem Clamp Bolts: 25 N1m (2.5 kgf1m, 18 ft1lb)
Tie-Rod End Nuts: 42 N1m (4.3 kgf1m, 31 ft1lb)
the lockwasher along the bolt head.
• Bend
• Inspect the toe-in (see Wheels/Tires chapter).
Steering Knuckle Removal
• Remove:
Front Wheel and Hub (see Wheel/Tires chapter)
Brake Caliper (see Brakes chapter)
Tie-Rod End Nut and Tie-Rod End [A]
CAUTION
Do not loosen the locknuts at the ends of the tie-rod adjusting
sleeve [B], or the toe-in of the front wheels will be changed.
• Remove:
Front Shock Absorber Clamp Bolts [C] and Nuts
•
Knuckle Joint Bolt [D] and Nut
Remove the steering knuckle [E] from the front axle and front shock
absorber.
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STEERING 14-7
Steering
Steering Knuckle Installation
the spherical bearing [A].
• Inspect
If roughness, excessive play, or seizure is found, replace the knuckle
joint [B].
the shanks [C] of the knuckle joint.
• Clean
Check
the joint boot [D] is not torn, worn, deteriorated, or is
• leaking that
grease.
• Tighten:
Torque -
Steering Knuckle Joint Nut: 47 N1m (4.8 kgf1m, 35 ft1lb)
Front Shock Absorber Clamp Nuts: 47 N1m (4.8 kgf1m, 35
ft1lb)
Tie-Rod End Nut: 42 N1m (4.3 kgf1m, 31 ft1lb)
Steering Knuckle Bearing Removal
• Remove:
Steering Knuckle (see Steering Knuckle Removal)
Circlip [A]
Special Tool -
Inside Circlip Pliers [B]: 57001-143
the bearing out using a suitable bearing driver from the bearing
• Drive
driver set.
Special Tool -
Bearing Driver Set: 57001-1129
Steering Knuckle Bearing Installation
marked side of the bearing faces outward.
• The
Press
in the bearing until it is bottomed.
•
Special Tool -
Bearing Driver Set [A]: 57001-1129
• Replace the circlip with a new one.
Special Tool -
Inside Circlip Pliers: 57001-143
Tie-Rod Removal
• Remove:
Cotter Pins [A] and Tie-Rod End Nuts
Tie-Rod [B]
CAUTION
When removing the tie-rod, be careful not to bend it. Do not
loosen the locknuts [C] at the end of the tie-rod adjusting
sleeve, or the toe-in of the front wheels will be changed.
Tie-Rod Installation
right and left tie-rods are identical.
• The
Tighten:
•
Torque -
Tie-Rod End Nuts: 42 N1m (4.3 kgf1m, 31 ft1lb)
• Inspect the toe-in (see Wheels/Tires chapter).
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14-8 STEERING
Steering
Tie-Rod End Removal
the tie-rod (see Tie-Rod Removal).
• Remove
Holding
the
tie-rod flattened area [A], loosen the locknut [B] and
• unscrew the tie-rod
end [C].
NOTE
The locknut near the flattened area [D] on the tie-rod has left-hand
threads. Turn the wrench clockwise (as viewed from the joint end)
for loosening.
CAUTION
Do not remove the grease seal. It is packed with grease.
Tie-Rod End Installation
• Check that the seal lip [A] is on the shank [B].
the tie-rod ends so that the tie-rod has the correct length [A],
• Install
and both visible thread lengths [B] are equal.
Tie-Rod Length
Standard: 315 &plusmn; 0.7 mm (12.4 &plusmn; 0.03 in.)
• Tighten:
Torque -
Tie-Rod Adjusting Sleeve Locknuts: 37 N1m (3.8 kgf1m, 27
ft1lb)
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STEERING 14-9
Steering Maintenance
Steering Inspection
• Refer to Steering Inspection in Periodic Maintenance chapter.
Steering Stem Straightness
the steering stem (see Steering Stem Removal).
• Remove
Check
the
steering stem for straightness.
• Use a straightedge
along the stem.
If the steering stem is bent, replace the steering stem.
Steering Lubrication
the steering stem clamps.
• Lubricate
Remove the steering stem (see Steering Stem Removal).
Wipe all the old grease off the steering stem, bearing sleeves, and
out of the grease seals.
Amoco Rykon Premium Grease No. 2 EP (Green) to the
steering stem [A], grease seals [B], and mating surface [C] of the
clamp.
Apply
the steering stem bearing [A].
• Lubricate
Remove the steering stem bearing.
Pack the grease seal lips with grease.
Steering Stem Clamp Inspection
the steering stem clamps [A].
• Inspect
If roughness, excessive play, or seizure is found, replace both clamps.
Steering Stem Bearing Inspection
the spherical bearing [A].
• Inspect
If roughness, excessive play, or seizure is found, replace the steering
•
stem bearing.
Inspect the upper and lower grease seals [B].
If damage, wear or deterioration is found, replace the steering stem
bearing.
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14-10 STEERING
Steering Maintenance
Steering Knuckle Bearing Inspection
CAUTION
Do not remove any bearings for inspection.
the steering knuckle (see Steering Knuckle Removal).
• Remove
Examine
bearing seal [A] for tears or leakage.
• If the sealtheis torn
or is leaking, replace the bearing.
Turn
[B]
the
bearing
back and forth while checking for roughness or
• binding.
If roughness or binding is found, replace the bearing.
Tie-Rod End and Steering Knuckle Joint Inspection
each spherical bearing [A].
• Inspect
If roughness, excessive play, or seizure is found, replace the tie-rod
•
end, or steering knuckle joint.
Inspect each grease seal [B].
If damage, wear or deterioration is found, replace the tie-rod end, or
steering knuckle joint.
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STEERING 14-11
Handlebar
Handlebar Removal
• Remove:
Throttle Case
Front Brake Master Cylinder
Left-hand Switch Housing
Rear Brake Lever Assembly
Handlebar Cover Assembly
Handlebar Holder Bolts [A] and Brackets [B]
Handlebar Holders [C]
Handlebar [D]
Handlebar Installation
the handlebar lower holder [A] on the steering stem bracket [B]
• Install
so that the projections [C] face rearward.
a non-permanent locking agent to the holder nuts [A] and
• Apply
tighten them.
• Tighten:
Torque -
Handlebar Lower Holder Nuts: 37 N1m (3.8 kgf1m, 27 ft1lb)
the handlebar so that the angle of the handlebar is 0 ~ 5
• Install
degrees [A] as shown.
the brackets [A].
• Install
Tighten
the holder rear bolts [B] first and then the front bolts [C].
•
Torque -
Handlebar Holder Bolts: 27 N1m (2.8 kgf1m, 20 ft1lb)
If the holder is correctly installed, there will be no gap at the rear and
an even gaps [D] at the front after tightening.
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14-12 STEERING
Handlebar
the left switch housing [C] on the handlebar [B] so that the
• Install
opening angle is 40 [A] or less.
Do
NOTE
not open the housing more than 40 , the built-in parts in the
housing may be damaged.
• Install:
Left Switch Housing [A]
Rear Brake Lever Assembly [B]
[C] = 3 mm (0.12 in.)
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FRAME 15-1
Frame
Table of Contents
Exploded View.................................................................................................................................................................15-2
Specifications .................................................................................................................................................................. 15-8
Seat.................................................................................................................................................................................15-9
Seat Removal...........................................................................................................................................................15-9
Seat Installation........................................................................................................................................................15-9
Carriers..........................................................................................................................................................................15-10
Front Carrier Removal............................................................................................................................................15-10
Front Carrier Installation.........................................................................................................................................15-10
Rear Carrier Removal ............................................................................................................................................ 15-10
Rear Carrier Installation ......................................................................................................................................... 15-10
Fenders ......................................................................................................................................................................... 15-12
Front Fender Removal............................................................................................................................................15-12
Front Fender Installation.........................................................................................................................................15-12
Rear Fender Removal............................................................................................................................................15-12
Rear Fender Installation.........................................................................................................................................15-13
Covers ........................................................................................................................................................................... 15-14
Headlight Cover Removal.......................................................................................................................................15-14
Headlight Cover Installation ................................................................................................................................... 15-14
Front Inner Cover Removal....................................................................................................................................15-14
Front Inner Cover Installation.................................................................................................................................15-15
Fuel Tank Cover Removal......................................................................................................................................15-15
Fuel Tank Cover Installation...................................................................................................................................15-15
Left Side Cover Removal ....................................................................................................................................... 15-15
Exhaust Pipe Cover Removal ................................................................................................................................ 15-15
Guards...........................................................................................................................................................................15-17
Front Guard Removal.............................................................................................................................................15-17
Front Lower Guard Removal..................................................................................................................................15-17
Front Guards Installation........................................................................................................................................15-17
Engine Bottom Guard Removal ............................................................................................................................. 15-18
Engine Bottom Guard Installation .......................................................................................................................... 15-18
Rear Bottom Guard Removal.................................................................................................................................15-18
Rear Bottom Guard Installation..............................................................................................................................15-18
Flaps and Footboards................................................................................................................................................... 15-19
Front Flap Removal................................................................................................................................................15-19
Front Flap Installation.............................................................................................................................................15-19
Rear Flap Removal ................................................................................................................................................ 15-19
Rear Flap Installation ............................................................................................................................................. 15-19
Footboard Removal ................................................................................................................................................15-19
Footboard Installation.............................................................................................................................................15-20
Trailer Hitch Bracket ......................................................................................................................................................15-21
Trailer Hitch Bracket Removal................................................................................................................................15-21
Trailer Hitch Bracket Installation.............................................................................................................................15-21
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15
15-2 FRAME
Exploded View
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FRAME 15-3
Exploded View
Torque
No.
Fastener
N1m
kgf1m
ft1lb
Remarks
L
1
Front Carrier Bolts
–
–
–
2
Rear Carrier Bolts and Nuts
25
2.5
18
3
Front Guard Bolts
20
2.0
14
4
Trailer Hitch Bracket Bolts (M10)
49
5.0
36
L
5
Trailer Hitch Bracket Bolts (M8)
24
2.4
17
L
6: Canada, United Kingdom and Europe models
L: Apply a non-permanent locking agent.
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15-4 FRAME
Exploded View
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FRAME 15-5
Exploded View
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15-6 FRAME
Exploded View
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FRAME 15-7
Exploded View
Torque
No.
Fastener
N1m
kgf1m
ft1lb
1
Front Final Gear Case Bolts and Nuts
42
4.3
31
2
Upper Engine Mounting Bracket Bolt and Nut
42
4.3
31
3
Upper Engine Mounting Bolt and Nut
25
2.5
18
4
Lower Engine Mounting Bracket Bolts
25
2.5
18
5
Lower Engine Mounting Bolts and Nuts
42
4.3
31
6
Footboard Mounting Nuts
–
–
–
Remarks
L
L: Apply a non-permanent locking agent.
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15-8 FRAME
Specifications
Special Tool -
Outside Circlip Pliers: 57001–144
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FRAME 15-9
Seat
Seat Removal
the seat [A] by pulling the looped seat latch [B] and then
• Remove
pulling the seat up to the rear.
Seat Installation
the front seat hook [A] into the brace [B] on the frame, and put
• Slip
the stoppers [C] into the holes in the frame.
• Push down the rear part of the seat until the locks [D] with a click.
Property of www.SmallEngineDiscount.com - Not for Resale
15-10 FRAME
Carriers
Front Carrier Removal
• Remove:
Carrier Bolts [A]
Front Carrier [B]
Collars [C]
Headlight Cover [D]
Front Carrier Installation
• Install:
Collars [A]
• Install:
Front Carrier [A]
a non-permanent locking agent:
• Apply
Front Carrier Bolts, L = 65 mm (2.56 in.) [B]
Front Carrier Bolts, L = 80 mm (3.15 in.) [C]
Rear Carrier Removal
• Remove:
Rear Carrier Bolts [A]
Rear Carrier [B]
Rear Carrier Installation
• Install:
Damper [A]
Collar [B]
Rear Carrier
Property of www.SmallEngineDiscount.com - Not for Resale
FRAME 15-11
Carriers
• Tighten:
Torque -
Rear Carrier Bolts [A] and Nuts [B]: 25 N1m (2.5 kgf1m, 18
ft1lb)
Property of www.SmallEngineDiscount.com - Not for Resale
15-12 FRAME
Fenders
Front Fender Removal
• Remove:
Seat (see Seat Removal)
Fuel Tank Cover (see Fuel Tank Cover Removal)
Front Carrier (see Front Carrier Removal)
Headlight Cover (see Headlight Cover Removal)
Front Flap Lower Screws [A] (both sides)
Ignition Switch Nut [B]
• Remove:
Quick Rivets [A]
Screws [B] and Collars (both sides)
Front Fender
Front Fender Installation
• Install:
Damper [A]
Clamp Nuts [B]
Collars [C]
the projection [A] on the ignition switch into the recess in the front
• Fit
fender.
the nut [B] securely.
• Tighten
Install:
• Headlight Cover (see Headlight Cover Installation)
Front Carrier (see Front Carrier Installation)
Rear Fender Removal
• Remove:
Seat (see Seat Removal)
Rear Carrier (see Rear Carrier Removal)
Fuel Tank Cover (see Fuel Tank Cover Removal)
Battery [A] (see Electrical System chapter)
Electrical Equipments [B] with Grommet [C]
Bolts [D]
Screws [E]
Property of www.SmallEngineDiscount.com - Not for Resale
FRAME 15-13
Fenders
• Remove:
Rear Flap Lower Screws [A] (both sides)
Collars
Rear Fender
Rear Fender Installation
• Install:
Dampers [A]
Collars [B]
Grommet [C]
Rear Carrier (see Rear Carrier Installation)
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15-14 FRAME
Covers
Headlight Cover Removal
• Remove:
Front Carrier (see Front Carrier Removal)
Collars [A]
up the stopper part [B] at the inside of the front guard and
• Push
remove the headlight cover [C].
• Remove:
Circlip [A]
Special Tool -
Outside Circlip Pliers [B]: 57001-144
• Remove:
Collar [C]
Washer
Damper
Headlight Cover Installation
• Install:
Damper [A]
Collar [B]
Washer [C]
Circlip [D]
Special Tool -
Outside Circlip Pliers: 57001-144
the headlight cover on the headlight.
• Put
Push
• Install:the stopper [A] lightly and fit it inside the front guard [B].
• Rear Carrier (see Rear Carrier Installation)
Front Inner Cover Removal
• Remove:
Bracket Screws [A] and Bracket
Screws [B] and Collar
Front Inner Cover [C]
Property of www.SmallEngineDiscount.com - Not for Resale
FRAME 15-15
Covers
Front Inner Cover Installation
• Install:
Collar [A]
Brackets [B]
Fuel Tank Cover Removal
• Remove:
Seat (see Seat Removal)
•
Screws [A]
Bolts [B]
Grip [C]
Fuel Tank Cap [D]
Fuel Tank Cover [E]
Install the fuel tank cap at once.
Fuel Tank Cover Installation
• Insert the tabs [A] of the cover into the recesses (both sides).
Left Side Cover Removal
• Remove:
Quick Rivets [A]
Screws [B]
Left Side Cover [C]
Exhaust Pipe Cover Removal
• Remove:
Seat (see Seat Removal)
Fuel Tank Cover (see Fuel Tank Cover Removal)
Left Side Cover (see Left Side Cover Removal)
Quick Rivets [A] (Front Left Flap [B])
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15-16 FRAME
Covers
• Remove:
Screws [A]
Exhaust Pipe Cover [B]
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FRAME 15-17
Guards
Front Guard Removal
• Remove:
Front Carrier (see Front Carrier Removal)
Headlight Cover (see Headlight Cover Removal)
Headlight Lead Connector [A]
• Remove:
Front Guard Bolts [A]
Front Guard [B]
Front Lower Guard Removal
• Remove:
Front Lower Guard Bolts [A]
Front Lower Guard [B]
Front Guards Installation
• Install:
Front Guard [A]
• Tighten:
Torque -
•
Front Guard Bolts [B]: 20 N1m (2.0 kgf1m, 14 ft1lb)
Install:
Front Lower Guard [C]
Front Lower Guard Bolts [D]
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15-18 FRAME
Guards
Engine Bottom Guard Removal
• Remove:
Bolts [A]
Engine Bottom Guard
Engine Bottom Guard Installation
• Confirm:
Damper [A]
• Install:
Engine Bottom Guard [B]
Bolts
Rear Bottom Guard Removal
• Remove:
Bolts (M6) [A]
Bolts (M8) [B]
Rear Bottom Guard [C]
Rear Bottom Guard Installation
• Confirm:
Dampers [D]
Install:
• Rear Bottom Guards
Bolts (M8)
Bolts (M6)
Property of www.SmallEngineDiscount.com - Not for Resale
FRAME 15-19
Flaps and Footboards
Front Flap Removal
• Remove:
Quick Rivets [A]
Screws [B], Washers, and Nuts
Front Flap [C] and Flap Holder Plate
Front Flap Installation
• Install:
Front Flap [A]
Flap Holder Plate [B]
Screws, L=22 mm (0.87 in.) [C], Washers, and Nuts
Quick Rivet [D]
Screws, L=16 mm (0.63 in.) [E]
Rear Flap Removal
• Remove:
Quick Rivets [A]
Screws [B], Washers, and Nuts
Rear Flap [C] and Flap Holder Plate
Rear Flap Installation
• Install:
Rear Flap [A]
Flap Holder Plate [B]
Screws [C], Washers, and Nuts
Quick Rivet [D]
Footboard Removal
• Remove:
Screws [A], Washer, and Nut
Property of www.SmallEngineDiscount.com - Not for Resale
15-20 FRAME
Flaps and Footboards
• Remove:
Screws [A]
• Remove:
Bolts [A]
Footboard [B]
Footboard Installation
• Be sure the dampers [A] is in place.
• Confirm:
Footrest [A]
•
Center Holes of Three Holes [B] (both side)
Bolts [C] and Nuts [D]
Install:
Footboard
Bolts
Screws, Washers, and Nuts
Apply a non-permanent locking agent to the footboard mounting nuts.
Property of www.SmallEngineDiscount.com - Not for Resale
FRAME 15-21
Trailer Hitch Bracket
Trailer Hitch Bracket Removal
• Drain:
Rear Final Gear case Oil (see Rear Final Gear Case Oil Change
section in Final Drive chapter)
• Remove:
Rear Bottom Guard (see Rear Bottom Guard Removal)
Trailer Hitch Bracket Bolts (M8) [A]
• Remove:
Trailer Hitch Bracket Bolts [A]
Trailer Hitch Bracket [B]
Trailer Hitch Bracket Installation
• Install:
Rear Final Gear Case Left Cover [A] (see Rear Axle Installation
•
•
section in Final Drive chapter)
Trailer Hitch Bracket [B]
Apply a non-permanent locking agent to the trailer hitch bracket bolts.
Tighten:
Torque -
Trailer Hitch Bracket Bolts (M10) [C]: 49 N1m (5.0 kgf1m, 36
ft1lb)
Trailer Hitch Bracket Bolts (M8) [D]: 24 N1m (2.4 kgf1m, 17 ft1lb)
• Install:
Rear Bottom Guard (see Rear Bottom Guard Installation)
Fill
the final gear case up to the bottom of filler opening with the
• specified
oil (see Rear Final Gear Case Oil Change section in Final
Drive chapter).
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Property of www.SmallEngineDiscount.com - Not for Resale
ELECTRICAL SYSTEM 16-1
Electrical System
Table of Contents
Precautions...............................................................16-3
Exploded View..........................................................16-4
Specifications ......................................................... 16-10
Parts Location ........................................................ 16-11
Electrical Wiring ..................................................... 16-13
Wiring Inspection.............................................16-13
Battery....................................................................16-14
Battery Removal..............................................16-14
Battery Installation...........................................16-14
Electrolyte Level Inspection.............................16-14
Electrolyte Specific Gravity Inspection............16-14
Initial Charging.................................................16-15
Ordinary Charging...........................................16-16
Battery Test Charging......................................16-17
Charging System....................................................16-18
Alternator Cover Removal ...............................16-18
Alternator Cover Installation............................16-18
Alternator Rotor Removal ...............................16-19
Alternator Rotor Installation.............................16-20
Alternator Stator Removal...............................16-20
Alternator Stator Installation............................16-21
Regulator/Rectifier Output Voltage Inspection 16-21
Alternator Inspection ....................................... 16-21
Regulator/Rectifier Inspection ......................... 16-22
Ignition System.......................................................16-25
Spark Plug Removal........................................16-25
Spark Plug Installation.....................................16-25
Spark Plug Cleaning / Inspection....................16-25
Spark Plug Gap Inspection ............................. 16-25
Ignition Coil Removal.......................................16-26
Ignition Coil Installation ................................... 16-26
Ignition Coil Inspection....................................16-26
Ignition Coil Primary Peak Voltage Inspection 16-27
Pickup Coil Removal ....................................... 16-27
Pickup Coil Installation .................................... 16-28
Pickup Coil Inspection.....................................16-28
Pickup Coil Peak Voltage Inspection...............16-28
Alternator Rotor Inspection ............................. 16-29
Ignition Timing Test ......................................... 16-29
Electric Starter System .......................................... 16-32
Starter Motor Removal....................................16-32
Starter Motor Installation.................................16-32
Starter Motor Disassembly..............................16-32
Starter Motor Assembly...................................16-33
Commutator Cleaning/Inspection....................16-34
Armature Inspection ........................................ 16-35
Starter Motor Brush Length.............................16-35
Brush Assembly Inspection.............................16-35
Brush Plate and Terminal Bolt Inspection.......16-35
Starter Relay Inspection..................................16-36
Starter Circuit Relay Inspection.......................16-36
Starter Motor Clutch Removal.........................16-37
Starter Motor Clutch Installation......................16-38
Starter Motor Clutch Inspection ...................... 16-38
Torque Limiter Inspection................................16-38
Lighting System......................................................16-39
Headlight Beam Vertical Adjustment...............16-39
Headlight Bulb Replacement...........................16-39
Headlight Body Removal.................................16-40
Headlight Body Installation..............................16-40
Taillight Bulb Replacement..............................16-40
Oil Cooler Fan System...........................................16-43
Oil Cooler Fan Circuit Inspection .................... 16-43
Oil Cooler Fan Motor Inspection ..................... 16-43
Speedometer (Optional Part for U.S. model).........16-44
Speedometer Removal....................................16-44
Speedometer Inspection..................................16-44
LED Indicator..........................................................16-47
Drive Belt Failure Mode Memory Clearing Procedure..................................................................16-47
LED Indicator Removal....................................16-48
LED Indicator Installation ................................ 16-48
LED Indicator Inspection.................................16-48
Actuator Control System........................................16-53
2WD/4WD Actuator Removal..........................16-53
2WD/4WD Actuator Installation.......................16-53
Engine Brake Actuator Removal .....................16-53
Engine Brake Actuator Installation..................16-54
Actuator Control System Outline.....................16-54
Actuator Control System Troubleshooting.......16-56
Drive Belt Failure Detection System ...................... 16-64
Drive Belt Failure Detection System Inspection16-64
Carburetor Heater System ..................................... 16-67
Air Temperature Sensor Inspection.................16-67
Carburetor Heater Inspection..........................16-68
Switches.................................................................16-69
Brake Light Switch Adjustment ....................... 16-69
Oil Cooler Fan Switch Inspection....................16-69
Oil Temperature Warning Light Switch Inspection...................................................................16-69
Switch Inspection.............................................16-69
Drive Belt Failure Detection Switch.................16-70
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16
16-2 ELECTRICAL SYSTEM
Fuses......................................................................16-71
Fuses Removal................................................16-71
Fuse Inspection...............................................16-71
Wiring Diagram ..................................................... 16-72
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ELECTRICAL SYSTEM 16-3
Precautions
There are a number of important precautions that should be taken
when servicing electrical systems. Learn and observe all the rules
below.
Do not reverse the battery lead connections. This will burn out the
diodes in the electrical parts.
Always check battery condition before condemning other parts of an
electrical system. A fully charged battery is required for conducting
accurate electrical system tests.
The electrical parts should never be struck sharply, as with a hammer,
or allowed to fall on a hard surface. Such a shock to the parts can
damage them.
To prevent damaging electrical parts, do not disconnect the battery
leads or any other electrical connections when the ignition switch is
on, or while the engine is running.
Because of the high current, never keep the starter button depressed
when the starter motor will not turn over, or the current may burn out
the starter motor windings.
Only use an illumination bulb rated for the voltage or wattage specified
in the wiring diagram, or the handle cover could be warped by
excessive heat radiated from the bulb.
Take care not to short the leads that are directly connected to the
battery positive (+) terminal to chassis ground.
Troubles may involve one or in some cases all items. Never replace
a defective part without determining what CAUSED the failure. If the
failure was caused by some other item or items, they too must be
repaired or replaced, or the new replacement will soon fail again.
Make sure all connectors in the circuit are clean and tight, and
examine wires for signs of burning, fraying, etc. Defective wires and
bad connections will affect electrical system operation.
Measure coil and winding resistance when the part is cold (at room
temperature).
Color Codes:
BK
BL
BR
CH
DG
Black
Blue
Brown
Chocolate
Dark green
G
GY
LB
LG
O
Green
Gray
Light blue
Light green
Orange
P
PU
R
W
Y
Pink
Purple
Red
White
Yellow
Electrical Connectors:
Female Connectors [A]
Male Connectors [B]
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16-4 ELECTRICAL SYSTEM
Exploded View
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ELECTRICAL SYSTEM 16-5
Exploded View
Torque
No.
Fastener
N1m
kgf1m
ft1lb
1
Starter Motor Mounting Bolts
8.8
0.9
78 in1lb
2
Starter Motor Terminal Nut
4.9
0.5
43 in1lb
3
Starter Motor Terminal Locknut
6.9
0.7
61 in1lb
4
Starter Motor Bolts
3.4
0.3
30 in1lb
5
Starter Motor Clutch Bolts
34
3.5
25
6
Starter Relay Terminal Nuts
4.9
0.5
43 in1lb
7
Alternator Stator Bolts
14
1.4
10
8
Pickup Coil Mounting Bolts
5.9
0.6
52 in1lb
9
Alternator Cover Bolts
8.8
0.9
78 in1lb
10
Alternator Rotor Bolt
127
13
94
G:
L:
M:
O:
R:
Remarks
L
Apply grease for oil seal and O-ring.
Apply a non-permanent locking agent.
Apply molybdenum disulfide grease.
Apply engine oil.
Replacement Parts
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16-6 ELECTRICAL SYSTEM
Exploded View
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ELECTRICAL SYSTEM 16-7
Exploded View
Torque
No.
Fastener
N1m
kgf1m
ft1lb
1
Ignition Coil Mounting Bolt
8.8
0.9
78 in1lb
2
Spark Plug
14
1.4
10
3
Igniter Mounting Bolts
2.3
0.23
20 in1lb
4
Speed Sensor Mounting Bolt
8.8
0.9
78 in1lb
5
Forward/Reverse Detecting Sensor Mounting Bolts
15
1.5
11
6
2WD/4WD Actuator Mounting Bolts
9.8
1.0
87 in1lb
7
Ignition Switch Nut
2.7
0.28
24 in1lb
8
Engine Brake Actuator Mounting Bolts
8.8
0.9
78 in1lb
9
Neutral Position Switch
15
1.5
11
10
Reverse Position Switch
15
1.5
11
11.
12.
13.
14.
Actuator Controller
LED Indicator
Carburetor Heater
Air Temperature Sensor
G:
L:
S:
M:
Apply grease for oil seal and O-ring.
Apply a non-permanent locking agent.
Follow the specific tightening sequence.
Apply molybdenum disulfide grease.
Remarks
L, S
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16-8 ELECTRICAL SYSTEM
Exploded View
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ELECTRICAL SYSTEM 16-9
Exploded View
Torque
No.
Fastener
N1m
kgf1m
ft1lb
1
Oil Cooler Fan Switch
16
1.6
12
2
Oil Temperature Warning Light Switch
16
1.6
12
3
Oil Pressure Switch
15
1.5
11
4
Regulator/Rectifier Mounting Bolts
8.8
0.9
78 in1lb
5
Oil Pressure Switch Terminal Bolt
1.5
0.15
13 in1lb
Remarks
SS
6: Speedometer (other than U.S.A. model)
7: Starter Circuit Relays
8: Horn (other than U.S.A. and Canada models)
SS: Apply silicone sealant (Kawasaki Bond: 56019-120).
OP: Optional Parts for U.S.A. and Canada models
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16-10 ELECTRICAL SYSTEM
Specifications
Item
Battery:
Capacity
Electrolyte level
Specific gravity of electrolyte
Charging System:
Alternator type
Charging voltage
(Regulator/rectifier output voltage)
Alternator output voltage
Stator coil resistance
Ignition System:
Spark plug:
Spark plug gap
Spark plug cap resistance
Ignition coil:
3 needle arcing distance
Primary winding resistance
Secondary winding resistance
Primary peak voltage
Pickup coil resistance
Pickup coil peak voltage
Electric Starter System:
Starter motor:
Commutator diameter
Brush length
Switches:
Brake light switch timing
Oil cooler fan switch resistance:
Rising temperature
Falling temperature
Oil temperature warning light switch resistance:
Rising temperature
Falling temperature
Standard
Service Limit
12 V 14 Ah
Between upper and lower levels
1.270 @20 C (68 F)
–––
–––
–––
Three-phase AC
14 15 V
–––
–––
36 54 V 3 000 r/min (rpm)
0.33 0.49 –––
–––
0.8 ~ 0.9 mm (0.031 ~ 0.035 in.)
3.75 6.25 k
–––
–––
7 mm (0.28 in.) or more
0.09 0.13 3.8 5.8 k
100 V or more
110 140 3.6 V or more
–
–
–
–
–
–
28 mm (1.10 in.)
10 mm (0.39 in.)
–
–
–
–
–
–
–
–
–
–
–
–
27 mm (1.06 in.)
3.5 mm (0.14 in.)
ON after 10 mm (0.4 in.) of pedal travel
From OFF to ON at 67 ~ 73 C
(153 ~ 163 F)
From ON to OFF at 57 ~ 63 C
(135 ~ 145 F)
ON: Less than 0.5 OFF: More than 1 M
–––
–––
–––
From OFF to ON at 107 ~ 113 C
(225 ~ 235 F)
From ON to OFF at 97 ~ 103 C
(207 ~ 217 F)
ON: Less than 0.5 OFF: More than 1 M
–––
–––
Special Tools - Timing Light : 57001–1241
Flywheel Holder: 57001–1313
Hand Tester: 57001–1394
Flywheel Puller : 57001–1405
Needle Adapter Set: 57001–1457
Drive Pulley Holder: 57001–1520
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ELECTRICAL SYSTEM 16-11
Parts Location
Light/Dimmer Switch [A]
Engine Stop Switch [B]
Starter Button [C]
Reverse Power Assist Switch (Override) [D]
Rear Brake Light Switch [E]
Power Outlet Connector [F]
2WD/4WD Shift Switch [G]
Front Brake Light Switch [H]
Ignition Switch [I]
Speedometer [A] (except US model)
Neutral Indicator Light [B]
Oil Pressure and Temperature Warning Indicator Light [C]
Reverse Indicator Light [D]
Drive Belt Check Indicator Light (LED) [E]
&quot;4WD&quot; Indicator Light (LED) [F]
Headlights [A]
Fan Fuses 20A and Belt Switch Fuse 5A [B]
Ground Wire (Frame) [A]
Ignition Coil [B]
Oil Cooler Fan [C]
Spark Plug [D]
2WD/4WD Actuator [E]
Drive Belt Failure Detection Switch [A]
Carburetor Heater and Ground Terminals [B]
Drive Belt Failure Mode Reset Connectors [C]
Engine Brake Actuator [D]
Rear Brake Light Switch [E]
Speed Sensor [F]
Property of www.SmallEngineDiscount.com - Not for Resale
16-12 ELECTRICAL SYSTEM
Parts Location
Alternator [A]
Starter Motor [B]
Pickup Coil [C]
Reverse Position Switch [D]
Neutral Position Switch [E]
Ground Wire (Engine) [F]
Forward/Reverse Detecting Sensor [G]
Oil Pressure Warning Light Switch [H]
Battery [A]
Accessory Fuse 5A [B]
Air Temperature Sensor [C]
Starter Circuit Relay (Neutral) [D]
Starter Relay [E]
Starter Circuit Relay (Brake) [F]
Actuator Controller [G]
Main Fuse 30 A [H]
Tail/Brake Light [A]
Igniter [B]
Regulator/Rectifier [C]
Oil Temperature Switch [A]
Oil Cooler Fan Switch [B]
Property of www.SmallEngineDiscount.com - Not for Resale
ELECTRICAL SYSTEM 16-13
Electrical Wiring
Wiring Inspection
inspect the wiring for signs of burning, fraying, etc.
• Visually
If any wiring is defective, replace the damaged wiring.
each connector [A] apart and inspect for corrosion, dirt, and
• Pull
damage.
•
If the connector is corroded or dirty, clean it carefully. If it is damaged,
replace it.
Check the wiring for continuity.
Use the wiring diagram to find the ends of the lead which is suspected
of being a problem.
Connect the hand tester between the ends of the leads.
Special Tool -
Hand Tester: 57001–1394
Set the tester to the x 1 range.
If the tester does not read 0 , the lead
is defective. Replace the
lead or the wiring harness [B] if necessary.
Property of www.SmallEngineDiscount.com - Not for Resale
16-14 ELECTRICAL SYSTEM
Battery
Battery Removal
• Remove:
Seat (see Frame chapter)
the battery negative (–) cable [A] first,
• Disconnect
positive (+) cable [B].
• Remove:
Battery Holder Bolt [C]
•
and then the
Battery Holder [D]
Take out the battery [E].
Battery Installation
the positive cable first and then the negative cable.
• Connect
Put
a
light
coat of grease on the terminals to prevent corrosion.
• Route the battery
hose according to the Cable, Wire, and Hose
• Routing section in vent
Appendix chapter.
Electrolyte Level Inspection
electrolyte level should be between the upper and lower level
• The
lines [A].
If the level of electrolyte in any cell is below the lower level line, add
only distilled water to the cell, until the level is at the upper level line.
CAUTION
Ordinary tap water is not a substitute for distilled water and
will shorten the life of the battery.
Electrolyte Specific Gravity Inspection
battery condition by testing the specific gravity of the electrolyte
• Check
in each cell with a hydrometer.
Read the level of the electrolyte [A] on the floating scale.
If the specific gravity is below 1.200 the battery needs to be charged.
The
NOTE
specific gravity of the electrolyte varies with changes in
temperature, so the specific gravity reading must be corrected for
the temperature of the electrolyte.
Celsius: Add 0.007 points to reading for each 10 C above 20 C or
subtract 0.007 points for each 10 C below 20 C.
Fahrenheit: Add 0.004 points to reading for each 10 F above 68 F
or subtract 0.004 points for each 10 F below 68 F.
If the specific gravity of any of the cells is more than 0.050 away from
any other reading, the battery will probably not accept a charge. It is
generally best to replace a battery in this condition.
If the specific gravity of all the cells is 1.270 or more, the battery is
fully charged.
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ELECTRICAL SYSTEM 16-15
Battery
Initial Charging
Keep the battery away from sparks and open flames during
charging, since the battery gives off an explosive gas mixture
of hydrogen and oxygen.
When using a battery charger, connect the battery to the
charger before turning on the charger. This procedure prevents sparks at the battery terminals which could ignite any
battery gases.
each cell to the upper level line on the battery case with fresh
• Fill
electrolyte (specific gravity: 1.270) at a temperature of 30 C (86 F)
or less. Let the battery stand for about 30 minutes before charging.
NOTE
If the electrolyte level drops, add electrolyte to the upper level line
before charging.
•
Set the charging rate at 1/10 the battery capacity, and charge it for
10 hours. For example, if the battery is rated at 14 Ah, the charging
rate would be 1.4 Ah.
CAUTION
If the battery is not given a full initial charging, it will discharge
in a few weeks. After that it can not be charged by supplemental charging.
Always remove the battery from the vehicle for charging. If the
battery is charged while still installed, battery electrolyte may
spill and corrode the frame or other parts of the vehicle.
Do 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
accumulate, and can cause internal shorting.
If the temperature of the electrolyte rises above 45 C (113 F)
during charging, reduce the charging rate to lower the temperature, and increase charging time proportionately.
the charger off, then disconnect it from the battery.
• Turn
• Check battery voltage. Battery voltage should be 12 13 V.
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16-16 ELECTRICAL SYSTEM
Battery
Ordinary Charging
• Remove the battery (see Battery Removal).
Keep the battery away from sparks and open flames during
charging, since the battery gives off an explosive gas mixture
of hydrogen and oxygen. When using a battery charger, connect the battery to the charger before turning on the charger.
This procedure prevents sparks at the battery terminals which
could ignite any battery gases.
a charger to the battery BEFORE plugging it in or turning it
• Connect
on.
the charging rate and time according to the battery condition
• Set
previously determined, using the Battery Charging Rate/Time Table.
• Check the electrolyte level after charging.
CAUTION
Always remove the battery from the vehicle for charging. If the
battery is charged while still installed, battery electrolyte may
spill and corrode the frame or other parts of the vehicle.
Do 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
accumulate, and can cause internal shorting.
If the temperature of the electrolyte rises above 45 C (113 F)
during charging, reduce the charging rate to lower the temperature, and increase charging time proportionately.
the charger off or unplug it, then disconnect it from the battery.
• Turn
battery condition.
• Check
If the battery condition indicates that it is not fully charged, additional
charging time is necessary.
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ELECTRICAL SYSTEM 16-17
Battery
Battery Charging Rate/Time Table (12 V 14 Ah)
Battery Troubleshooting Guide
Good Battery
Plates
Suspect Battery
Action
Sediment
(+) Chocolate color
(−) gray
none, or small amount
Voltage
above 12 V
white (sulphated); + plates broken or corroded
sediment up to plates, causing
short
below 12 V
Replace
Electrolyte Level
above plates
below top of plates
Fill and test charge
Specific Gravity
above 1.200 in all cells; no two
cells more than 0.020 different
below 1.100, or difference of
more than 0.020 between two
cells
Test charge
Replace
Test charge
Battery Test Charging
is suspected of being defective, sulfated, or unable to
• Iftaketheabattery
charge, consult the table.
test charge a battery, perform the ordinary charging procedure and
• To
monitor the battery voltage and other signs as mentioned below.
Special Tool -
Hand Tester : 57001–1394
If the battery voltage suddenly jumps to over 13 V just after the start
of charging, the plates are probably sulfated. A good battery will rise
to 12 V immediately and then gradually go up to 12.5 or 13 V in about
30 min. to an hour after the start of charging.
If one cell produces no gas bubbles or has a very low specific gravity,
it is probably shorted.
If there does not appear to be enough sediment in a cell to short the
plates, but that cell has a very low specific gravity after the battery
is fully charged, the trouble may be that there is not enough acid in
that one cell. In this case only, sulfuric acid solution may be added
to correct the specific gravity.
If a fully charged battery not in loses its charge after 2 to 7 days; or
if the specific gravity drops markedly, the battery is defective. The
self-discharge rate of a good battery is only about 1% per day.
Sulfation here [A]
Sediment here [B]
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16-18 ELECTRICAL SYSTEM
Charging System
Alternator Cover Removal
• Disconnect:
Alternator Lead Conenctor [A]
Pickup COil Lead Connector [B]
• Remove:
Recoil Starter (see Recoil Starter chapter)
Torque Converter Cover (see Converter System chapter)
the three bolts of the drive pulley cover.
• Remove
Install
and
• shown. tighten the drive pulley holder [A] and the three bolt [B] as
Special Tool -
Drive Pulley Holder: 57001–1520
the drive pulley with the drive pulley holder,
• Holding
alternator rotor bolt [A].
• Remove the alternator rotor bolt and pulley.
loosen the
an oil pan under the engine left side.
• Place
Remove:
• Collar [A]
Alternator Cover Bolts [B]
Alternator Cover [C]
Alternator Cover Installation
sure all of the old gasket has been removed from the alternator
• Be
cover and the left crankcase sealing surfaces.
that the dowel pins [A] are in place, and fit a new gasket on
• Check
the crankcase.
• Check that the bearing [B] is in place.
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ELECTRICAL SYSTEM 16-19
Charging System
the grommets [A] into the notch in the cover.
• Fit
Apply
• Tighten:grease the alternator cover oil seal.
•
Torque -
Alternator Cover Bolts: 8.8 N1m (0.9 kgf1m, 78 in1lb)
that the O-ring [A] in the collar [B] is in good condition.
• Check
Apply
grease
O-ring.
• Install the collarto the
on
the
alternator cover.
•
• Hold the drive pulley with the drive pulley holder [A].
Special Tool -
Drive Pulley Holder: 57001–1520
the pulley [A] so that the holes of the pulley fit on the pins [B]
• Install
of the collar.
• Tighten:
Torque -
Alternator Rotor Bolt [C]: 127 N1m (13 kgf1m, 94 ft1lb)
• Add engine oil.
Alternator Rotor Removal
• Remove:
Alternator Cover (see Alternator Cover Removal)
Ball Bearing [A]
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16-20 ELECTRICAL SYSTEM
Charging System
• Thread the flywheel puller [A] onto the alternator rotor.
Special Tool -
•
Flywheel Puller: 57001–1405
Holding the flywheel puller, turn the rotor puller until the alternator
rotor is forced off the end of the crankshaft.
CAUTION
If the rotor is difficult to remove, turn the puller while tapping
the end of the puller. Do not strike the alternator rotor. Striking
the rotor can cause the magnets to lose magnetism.
Alternator Rotor Installation
a thin coat of molybdenum disulfide grease to the crankshaft
• Apply
[A].
• Install the starter clutch gear [B].
[A] the inside of the rotor and the end of the crankshaft.
• Clean
the rotor onto the crankshaft so that woodruff key [B] fits in the
• Fit
groove [C] in the hub of the rotor.
the alternator rotor [A] while turning the starter clutch gear [B].
• Install
Install
the torque limiter [C].
•
Alternator Stator Removal
• Remove:
Alternator Cover (see Alternator Cover Removal)
Pickup Coil [A] (see Pickup Coil Removal)
Bolts [B] and Alternator Stator [C]
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ELECTRICAL SYSTEM 16-21
Charging System
Alternator Stator Installation
• Tighten:
Torque -
•
•
Alternator Stator Bolts: 14 N1m (1.4 kgf1m, 10 in1lb)
Install:
Pickup Coil (see Pickup Coil Installation)
Fit the lead grommets into the notch on the alternator cover.
Grommets [A] for Alternator Leads
Grommets [B] for Pickup Coil Leads
Regulator/Rectifier Output Voltage Inspection
the seat (see Frame chapter).
• Remove
Check
the
condition (see Battery section).
• Warm up thebattery
to obtain actual alternator operating conditions.
• Check that theengine
ignition
switch is turned off, and connect a hand tester
• [A] to the battery terminals.
Special Tool -
Hand Tester : 57001–1394
the engine and note the voltage readings at various engine
• Start
speeds with the headlight turned on and then off. The readings should
show nearly battery voltage when the engine speed is low, and as
the engine speed increases, the readings should also increase.
Regulator/Rectifier Output Voltage
Connections
Tester Range
25 V DC
Reading
Tester (+) to
Tester (–) to
Battery (+)
Battery (–)
14
15 V
off the ignition switch, and disconnect the hand tester.
• Turn
If the regulator/rectifier output voltage is between the values given in
the table, the charging system is working normally.
If the output voltage is much higher than the values specified in the
table, the regulator/rectifier is defective or the regulator/rectifier leads
are loose or open.
If the battery voltage does not increase as the engine speed
increases, then the regulator/rectifier is defective or the alternator
output is insufficient for the loads. Check the alternator and regulator/
rectifier to determine which part is defective.
Alternator Inspection
There are three types of alternator failures: short, open, or loss in
rotor magnetism. A short or open in one of the coil wires will result in
either a low output, or no output at all. A loss in rotor magnetism, which
may be caused by dropping or hitting the alternator, by leaving it near
an electromagnetic field, or just by aging, will result in low output.
To check the alternator output voltage, perform the following procedures.
Disconnect the alternator connector [A].
Connect a hand tester as shown in the table.
Start the engine.
Run it at the rpm given in the table.
Note the voltage readings (total 3 measurements).
•
Alternator Output Voltage
Connections
Reading
Tester Range
Tester (+) to
250 V AC
One black lead
Tester (–) to
Another black
lead
@3 000rpm
36
54 V
If the output voltage is within the values in the table, the alternator
is operating correctly, and the regulator/rectifier is damaged. A much
lower reading indicates that the alternator is defective.
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16-22 ELECTRICAL SYSTEM
Charging System
the stator coil resistance as follows:
• Check
Stop the engine.
Disconnect the alternator connector.
Connect a hand tester as shown in the table.
Note the readings (total 3 measurement).
Stator Coil Resistance
Connections
Tester Range
Reading
Tester (+) to
x1
•
One black lead
Tester (–) to
Another black
lead
0.33
0.49
If there is more resistance than shown in the table, or no reading
(infinity) for any two leads, the stator has an open and must be
replaced. Much less resistance means the stator is shorted and must
be replaced.
Using the highest resistance range of the hand tester, measure the
resistance between each of the black leads and chassis ground.
Any reading less than infinity (∞) indicates a short, necessitating
stator replacement.
If the stator coils have normal resistance, but the voltage check shows
the alternator to be defective; then the rotor magnetism has probably
weakened, and the rotor must be replaced.
Special Tool -
Hand Tester : 57001–1394
Regulator/Rectifier Inspection
• Remove:
Bolts [A] and Regulator/Rectifier [B]
Connectors [C] (disconnect)
Rectifier Circuit Check:
Check conductivity of the following pair of terminals.
•
Rectifier Circuit Inspection
W/R-Y1,
W/R-Y2,
W/R-Y3
BK-Y1,
BK-Y2,
BK-Y3
Tester connection
The resistance should be low in one direction and more than ten
times as much in the other direction. If any two leads are low or high
in both directions, the rectifier is defective and must be replaced.
NOTE
The actual meter reading varies with the meter and the individual
rectifier. Generally speaking the lower reading should be from zero
to one half of the scale.
Regulator Circuit Check:
To test the regulator out of circuit, use three 12 V batteries and a test
light (12 V 3 6 W bulb in a socket with leads).
CAUTION
The test light works as an indicator and also a current limiter
to protect the regulator/rectifier from excessive current. Do
not use an ammeter instead of a test light.
• Check to be sure the rectifier circuit is correct before continuing.
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ELECTRICAL SYSTEM 16-23
Charging System
Regulator Circuit Test-1st Step:
Connect the test light and the 12 V battery to the regulator/rectifier
as shown.
Check Y1, Y2, and Y3 terminal respectively.
If the test light turns on, the regulator/rectifier is defective.
If the test light does not turn on, continue the test.
•
•
Regulator Circuit Test-2nd Step:
Connect the test light and a 12 V battery in the same manner as
specified in the &quot;Regulator Circuit Test-1st Step&quot;.
Apply 12 V to the BR terminal.
Check Y1, Y2, and Y3 terminals.
If the test light turns on, the regulator/rectifier is defective.
If the test light does not turn on, continue the test.
•
•
•
Regulator Circuit Test-3rd Step:
Connect the test light and a 12 V battery in the same manner as
specified in the &quot;Regulator Circuit Test-1st Step&quot;.
Momentarily apply 24 V to the BR terminal by adding a 12 V battery.
Check Y1, Y2, and Y3 terminals.
•
•
•
CAUTION
Do not apply more than 24 V to the regulator/rectifier. Do not
leave the 24 V applied for more than a few seconds, or the unit
will be damaged.
If the test light did not light when the 24 V was applied momentarily
to the BR terminal, the regulator/rectifier is defective.
If the regulator/rectifier passes all of the tests described, it may still
be defective. If the charging system still does not work properly after
checking all of the components and the battery, test the regulator/
rectifier by replacing it with a known good unit.
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16-24 ELECTRICAL SYSTEM
Charging System
Charging System Circuit
1. Ignition Switch
2. Alternator
3. Regulator/Rectifier
4. Battery
5. Main Fuse 30 A
6. Load
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ELECTRICAL SYSTEM 16-25
Ignition System
The ignition system produces extremely high voltage.
Do not touch the spark plug, ignition coil, or spark plug lead
while the engine is running, or you could receive a severe
electrical shock.
CAUTION
Do not disconnect the battery leads or any other electrical
connections when the ignition switch is on, or while the engine
is running. This is to prevent igniter damage.
Do not install the battery backwards. The negative side is
grounded. This is to prevent damage to the diodes and igniter.
Use the standard regulator/rectifier, or the igniter will be
damaged.
Spark Plug Removal
• Remove:
Spark Plug Cap [A]
Spark Plug [B]
Spark Plug Installation
• Tighten:
Torque -
•
•
Spark Plugs: 14 N1m (1.4 kgf1m, 10 ft1lb)
Fit the spark plug cap securely.
Pull up the spark plug cap lightly to make sure of the installation of
the spark plug cap.
Spark Plug Cleaning / Inspection
the spark plug, preferably in a sandblasting device, and then
• Clean
clean off any abrasive particles. The plug may also be cleaned using
a wire brush or other suitable tool.
If the spark plug electrodes are corroded or damaged, or if the
insulator is cracked, replace the plug. Use the standard spark plug
or its equivalent.
Spark Plug Gap Inspection
• Refer to Spark Plug Gap Inspection in Periodic Maintenance chapter.
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16-26 ELECTRICAL SYSTEM
Ignition System
Ignition Coil Removal
• Remove:
Front Right Inner Cover (see Frame chapter)
Spark Plug Cap [A]
Primary Lead Connectors [B]
Ignition Coil Mounting Bolt [C]
Ignition Coil [D]
Ignition Coil Installation
the primary leads to the ignition coil terminals as shown.
• Connect
G/W Lead ! (+) Mark [A]
BK/Y Lead ! (–) Mark
Tighten:
•
Torque -
Ignition Coil Mounting Bolt: 8.8 N1m (0.9 kgf1m, 78 in1lb)
Ignition Coil Inspection
the ignition coil.
• Remove
the arcing distance with a coil tester [A] to check the
• Measure
condition of the ignition coil [B].
the ignition coil (with the spark plug cap left attached at the
• Connect
end of the spark plug lead) to the tester in the manner prescribed by
the manufacturer and measure the arcing distance.
Ignition Coil Arcing Distance
7 mm (0.28 in.) or more
To avoid extremely high voltage shocks, do not touch the
ignition coil body or leads.
•
If the distance reading is less than the specified value, the ignition
coil or spark plug cap is defective.
To determine which part is defective, measure the arcing distance
again with the spark plug cap removed from the ignition coil. Remove
the cap by turning it counterclockwise.
If the arcing distance is as before, the trouble is with the ignition coil.
If the arcing distance is normal, the trouble is with the spark plug cap.
If a coil tester is not available, the coil can be checked for a broken
or badly shorted winding with a hand tester.
Special Tool -
The
Hand Tester : 57001–1394
NOTE
hand tester cannot detect layer shorts and shorts resulting
from insulation breakdown under high voltage.
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ELECTRICAL SYSTEM 16-27
Ignition System
the primary winding resistance [A] as follows:
• Measure
Connect the tester between the coil terminals.
Set the tester to the x 1 range.
the secondary winding resistance [B] as follows:
• Measure
Remove the plug cap by turning it counterclockwise.
Connect the tester between the spark plug lead and terminal.
Set the tester to the x 1 k
range.
Ignition Coil Winding Resistance
Primary windings : 0.09
0.13
5.8 k
Secondary windings : 3.8
If the hand tester does not read as specified, replace the coil.
To install the plug cap, turn it clockwise.
Ignition Coil Primary Peak Voltage Inspection
NOTE
Be sure the battery is fully charged.
the spark plug cap (see Spark Plug Removal), but do not
• Remove
remove the spark plug.
the primary peak voltage as follows.
• Measure
Connect a commercial peak voltage adapter [A] to the hand tester [B]
(250 V DC range).
Special Tool -
Hand Tester: 57001–1394
Recommended Tool -
Peak Voltage Adapter
Type: KEK-54-9-B
Brand: KOWA SEIKI
Connect the adapter between the G/W lead terminal of the ignition
coil [C] and the engien ground [D].
Install a new spark plug [E] into the spark plug cap, and ground it to
the engine.
To avoid extremely high voltage shocks, do not touch the spark
plugs or tester connections.
Turn the ignition switch ON, rotate the engine for 4 5 seconds with
• the
transmission in neutral to measure the primary peak voltage.
Repeat
the measurements 5 times for one ignition coil.
•
Ignition Coil Primary Peak Voltage
Standard:
100 V or more
If the reading is less than the specified value, check the following.
Ignition Coils (see Ignition Coil Inspection)
Pickup Coil (see Pickup Coil Inspection)
If the ignition coils and pickup coil are normal, see the Ignition System
Troubleshooting chart on page 16–30.
Pickup Coil Removal
• Remove:
Alternator Cover (see Alternator Cover Removal)
Pickup Coil Mounting Bolts [A]
Plate [B]
Pickup Coil [C]
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16-28 ELECTRICAL SYSTEM
Ignition System
Pickup Coil Installation
• Install:
Stator Coil Leads [A]
•
Plate [B]
Pickup Coil [C]
Tighten:
Torque -
Pickup Coil Mounting Bolts: 5.9 N1m (0.6 kgf1m, 52 in1lb)
the lead grommets into the notch on the alternator cover.
• FitGrommets
[A] for Alternator Leads
Grommets [B] for Pickup Coil Leads
Pickup Coil Inspection
the seat (see Frame chapter).
• Remove
the pickup coil lead connector [A].
• Disconnect
Measure
the
pickup coil resistance.
• Connect a hand
tester between the BK/W lead and the BL lead.
Set the tester to the x 10 range.
Pickup Coil Resistance
110
140
If the tester does not read as specified, replace the pickup coil.
Pickup Coil Peak Voltage Inspection
NOTE
Be sure the battery is fully charged.
the spark plug caps, but do not remove the spark plugs.
• Remove
Disconnect:
• Pickup Coil Wire Connector [A]
the hand tester [B] to the 10 V DC range.
• Set
the peak voltage adapter [C] to the hand tester and pickup
• Connect
coil leads in the connector.
Special Tool -
Hand Tester: 57001–1394
Recommended Tool -
Peak Voltage Adapter
Type: KEK-54-9-B
Brand: KOWA SEIKI
Connections:
Pickup Coil Connector
Bule
Black/White
•
Adapter
Red
Black
!
!
Hand Tester
(+)
(–)
Turn the ignition switch on, and rotate the engine for 4 5 seconds
with the transmission gear in neutral to measure the pickup coil peak
voltage.
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ELECTRICAL SYSTEM 16-29
Ignition System
• Repeat the measurement 5 or more times.
Pickup Coil Peak Voltage
Standard:
3.6 V or more
If the peak voltage is lower than the standard, inspect the pickup coil.
Alternator Rotor Inspection
the timing projection [A] for damage such as chipping or
• Check
grooving.
If the timing projection on the rotor is visibly damaged, replace the
alternator rotor.
Ignition Timing Test
the ignition timing inspection plug.
• Remove
a timing light [A] and a tachometer in the manner prescribed
• Attach
by the manufacturer.
Special Tool -
•
•
Timing Light : 57001–1241
Start the engine and aim the timing light at the timing mark on the
alternator rotor.
Run the engine at the speeds specified and note the alignment of the
timing marks.
Ignition Timing
Engine speed r/min (rpm)
Slot [A] aligned with:
1 000
Advanced mark [B] on alternator rotor
5 000
Advanced mark [C] on alternator rotor
NOTE
Do not mix up the timing marks with mark.
If the ignition timing is incorrect, replace the igniter and the pickup
coil.
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16-30 ELECTRICAL SYSTEM
Ignition System
Ignition System Troubleshooting
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ELECTRICAL SYSTEM 16-31
Ignition System
Ignition System Circuit
1.
2.
3.
4.
5.
2WD/4WD Shift Switch
Actuator Controller
Engine Stop Switch
Drive Belt Failure Detecting Switch
Drive Belt Failure Detecting Switch Fuse
5A
6. Reverse Power Assist Switch (Override)
7. Ignition Switch
8.
9.
10.
11.
12.
13.
14.
15.
Main Fuse 30A
Ignition Coil
Spark Plug
Pickup Coil
LED Indicator
Igniter
Reverse Position Switch
Battery
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16-32 ELECTRICAL SYSTEM
Electric Starter System
Starter Motor Removal
• Remove:
Fuel Tank Cover (see Fuel System chapter)
Starter Motor Cable [A]
Starter Motor Mounting Bolts [B]
Starter Motor [C]
CAUTION
Do not tap the end of the starter motor shaft or the motor may
be damaged.
Starter Motor Installation
installing the starter motor, clean the starter motor lugs [A] and
• When
crankcase [B] where the starter motor is grounded.
•
•
•
If the O-ring [A] shows wear or damage, or if it is hardened, replace
it with a new one.
Apply a small amount of engine oil to the O-ring.
Install:
Starter Motor
Starter Motor Cable
Tighten:
Torque -
Starter Motor Mounting Bolts: 8.8 N1m (0.9 kgf1m, 78 in1lb)
Starter Motor Terminal Nut: 4.9 N1m (0.5 kgf1m, 43 in1lb)
Starter Motor Disassembly
• Remove:
Starter Motor Bolts [A]
Left End Cover [B]
Right End Cover [C]
Yoke [D]
• To remove the brush plate assembly [A], remove the terminal nut [B].
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ELECTRICAL SYSTEM 16-33
Electric Starter System
the brush spring [A] with needle nose pliers, and pull the brush
• Hold
[B] off the holder.
Starter Motor Assembly
the O-rings.
• Replace
Install
the
brush plate assembly to the right end cover so that the
• projection [A]
on the brush plate fits into the groove on the right end
•
•
cover.
Install the O-ring, insulators [B], and washer [C] in that order on the
terminal bolt.
Tighten:
Torque -
Starter Motor Terminal Locknut [D]: 6.9 N1m (0.7 kgf1m, 61
in1lb)
the washers [A].
• Install
• Install the armature [B] between the brushes.
the yoke [A] onto the right end cover [B] aligning the marks [C]
• Install
on the yoke and right end cover.
• Install the washers [A].
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16-34 ELECTRICAL SYSTEM
Electric Starter System
• Install the plate [A] on the left end cover [B].
the mark [A] on the left end cover with the mark [B] on the yoke.
• Align
Tighten:
•
Torque -
Starter Motor Bolts: 3.4 N1m (0.3 kgf1m, 30 in1lb)
Commutator Cleaning/Inspection
the commutator surface [A] if necessary with fine emery cloth
• Smooth
[B], and clean out the grooves.
the diameter [A] of the commutator.
• Measure
Replace the starter motor with a new one if the commutator diameter
is less than the service limit.
Commutator Diameter
Standard:
28 mm (1.10 in.)
Service Limit:
27 mm (1.06 in.)
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ELECTRICAL SYSTEM 16-35
Electric Starter System
Armature Inspection
the x 1 range, measure the resistance between any two
• Using
commutator segments [A].
•
If there is a high resistance or no reading (∞) between any two
segments, a winding is open. Replace the starter motor.
Using the highest range, measure the resistance between the
segments and the shaft [B].
If there is any reading at all, the armature has a short. Replace the
starter motor.
Even
NOTE
if the foregoing checks show the armature to be good, it
may be defective in some manner not readily detectable with the
hand tester. If all other starter motor and starter motor circuit
components check good, but the starter motor still does not turn
over or only turns over weakly, replace the starter motor with a new
one.
Starter Motor Brush Length
• Measure the overall length [A] of each brush.
Starter Motor Brush Length
Standard:
10 mm (0.39 in.)
Service Limit:
3.5 mm (0.14 in.)
If any is worn down to the service limit, replace the brush plate
assembly.
Brush Assembly Inspection
the x 1 range, measure the resistance as shown.
• Using
[A] Terminal Bolt and Positive Brush
[B] Brush Plate and Negative Brush
If there is not close to zero ohms, the brush lead has an open.
Replace the brush plate assembly.
Brush Plate and Terminal Bolt Inspection
the highest range, measure the resistance as follows:
• Using
[A] Terminal Bolt and Right – Hand End Cover
[B] Terminal Bolt and Brush Plate
If there is any reading, the brush holder assembly has a short.
Replace the brush plate assembly.
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16-36 ELECTRICAL SYSTEM
Electric Starter System
Starter Relay Inspection
• Remove:
Seat (see Frame chapter)
Starter Relay [A]
the hand tester [A] and a 12 V battery [B] to the starter relay
• Connect
as shown.
If the relay does not work as specified, the relay is defective. Replace
the relay.
Testing Relay
Hand Tester Range: x 1 range
Criteria :
When battery is connected ⇒ 0
When battery is disconnected ⇒ ∞
Starter Circuit Relay Inspection
• Remove:
Seat (see Frame chapter).
Starter Circuit Relay [A] (Brake Switch Circuit)
Starter Circuit Relay [B] (Neutral Switch Circuit)
The starter circuit relays for the brake and neutral switch circuits are
identical.
the hand tester [A] and a 12 V battery [B] to the starter circuit
• Connect
relay [C] as shown.
If the relay does not work as specified, the relay is defective. Replace
the relay.
Testing Relay
Hand Tester Range: x 1
Criteria:
When battery is connected ⇒ 0
When battery is disconnected ⇒ ∞
Relay Coil Terminals [1] and [2]
Relay Switch Terminals [3] and [4]
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ELECTRICAL SYSTEM 16-37
Electric Starter System
Electric Starter Circuit
1.
2.
3.
4.
5.
Engine Stop Switch
Starter Button
Front Brake Light Switch
Parking Brake Light Switch
Rear Brake Light Switch
6.
7.
8.
9.
Starter Circuit Relay (Brake)
Neutral Switch
Starter Circuit Relay (Neutral)
Ignition Switch
10.
11.
12.
13.
Main Fuse 30A
Starter Relay
Starter Motor
Battery
Starter Motor Clutch Removal
the alternator rotor (see Alternator Rotor Removal).
• Remove
Hold
the
• clutch boltsrotor[A].with the flywheel holder and take out the starter motor
Special Tool -
Flywheel Holder: 57001–1313
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16-38 ELECTRICAL SYSTEM
Electric Starter System
• Take out the one-way clutch [A].
Starter Motor Clutch Installation
the one-way clutch so that the flange [A] fits on the recess [B]
• Install
of the race.
engine oil:
• Apply
One-Way Clutch
a non-permanent locking agent:
• Apply
Starter Motor Clutch Bolts
• Tighten:
Torque -
Starter Motor Clutch Bolts : 34 N1m (3.5 kgf1m, 25 ft1lb)
Starter Motor Clutch Inspection
• Remove:
Alternator Rotor (see Alternator Rotor Removal)
Fit
starter clutch gear into the starter motor clutch.
• If thethealternator
rotor turns counterclockwise [A] freely from the starter
clutch gear, but not clockwise [B], the clutch is operating correctly.
If the clutch does not operate correctly, or if it makes noise,
disassemble it and examine each part visually. Replace any worn
or damaged parts.
Examine
NOTE
the starter clutch gear [A]. Replace it if it is worn or
damaged.
Torque Limiter Inspection
• Remove:
Alternator Rotor (see Electrical System chapter)
Remove
the torque limiter [A] and visually inspect it.
• If the limiter
has wear, discoloration, or other damage, replace it as a
unit.
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ELECTRICAL SYSTEM 16-39
Lighting System
Headlight Beam Vertical Adjustment
the adjusting screw [A] on each headlight rim in or out to adjust
• Turn
the headlight vertically.
NOTE
On high beam, the brightest point should be slightly below horizontal with the vehicle on its wheels and the rider seated. Adjust both
headlights to the same angle.
Headlight Bulb Replacement
• Disconnect:
Headlight Lead Connector [A]
the bulb holder [B] counterclockwise and remove it from headlight
• Turn
body.
the bigger projection [A] of the bulb holder into the bigger hole
• Insert
[B] in the headlight body.
the bulb holder until it is contact the projection [A] to the stopper
• Turn
[B].
[C] Headlight Bulb
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16-40 ELECTRICAL SYSTEM
Lighting System
Headlight Body Removal
• Remove:
Headlight Cover (see Frame chapter)
Headlight Beam Adjusting Screw [A] and Washer
• Pull the lower side of the headlight body forward and remove it.
Headlight Body Installation
the tongues [A] on the headlight body into the grommets [B] in
• Insert
the bracket.
• Install:
Washer and Headlight Beam Adjusting Screw
Connect:
• Headlight Lead Connector
Taillight Bulb Replacement
• Remove:
Taillight Lens Mounting Screws [A]
Taillight Lens [B]
the bulb [A] in, turn it counterclockwise, and pull it out.
• Push
Be
sure
the socket is clean.
•
the new bulb by aligning the pins [A] with the grooves [B] in the
• Insert
walls of the socket.
the bulb in, turn it clockwise, and release it. It should lock in
• Push
position.
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ELECTRICAL SYSTEM 16-41
Lighting System
the projection [A] on taillight lens into the groove [B] in the
• Insert
taillight body.
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16-42 ELECTRICAL SYSTEM
Lighting System
Lighting System Circuit
1.
2.
3.
4.
5.
6.
7.
8.
9.
Light/Dimmer Switch
Headlight (Left)
Headlight (Right)
Oil Pressure/Temperature Warning Indicator Light
Neutral Indicator Light
Reverse Indicator Light
Reverse Switch
Neutral Switch
Oil Pressure Switch
10.
11.
12.
13.
14.
15.
16.
17.
Oil Temperature Switch
Tail/Brake Light
Front Brake Light Switch
Parking Brake Light Switch
Rear Brake Light Switch
Ignition Switch
Main Fuse 30 A
Battery
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ELECTRICAL SYSTEM 16-43
Oil Cooler Fan System
Oil Cooler Fan Circuit Inspection
the left front side cover (see Frame chapter).
• Remove
Disconnect
the leads [A] from the oil cooler fan switch.
• Using an auxiliary
wire, connect the oil cooler fan switch leads.
• If the fan rotates, inspect
the fan switch.
If the fan does not rotate, inspect the following.
Leads and Connectors
Main Fuse and Fan Fuse
Fan Motor
Oil Cooler Fan Motor Inspection
the Front Fender (see Frame chapter).
• Remove
Disconnect
the connector [A] in the fan lead.
• Using two auxiliary
supply battery [B] voltage to the fan motor.
• If the fan does notwires,
rotate, the fan motor is defective and must be
replaced.
Oil Cooler Fan Motor Leads
BL:
Battery (+)
BK:
Battery (–)
Oil Cooler Fan Circuit
1. Oil Cooler Fan
2. Oil Cooler Fan Switch
3. Oil Cooler Fan Fuse 20A
4. Main Fuse 30A
5. Battery
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16-44 ELECTRICAL SYSTEM
Speedometer (Optional Part for U.S. model)
Speedometer Removal
• Remove:
Front Fender (see Frame chapter)
Switch Housings
Brake Master Cylinder
Variable Differential Control Lever
Screws [A], Washers, and Collars
• Remove:
Nuts [A]
Bracket [B]
Rubber Damper and Speedometer
Speedometer Inspection
• Remove:
Speedometer (see Speedometer Removal)
CAUTION
Do not drop the meter unit.
[1] Battery (Red)
[2] Battery (Black)
[3] Speed Sensor Pulse (Green)
Check 1: Pointer and LCD Check
Using auxiliary wires, connect a 12 V battery to the meter terminals
as follows.
Connect the battery negative (–) terminal to terminal [2] (Black).
Connect the battery positive (+) terminal to terminal [1] (Red).
•
•
•
The pointer will be move counterclockwise past “0” and then back up
to “0”.
For the first second after power-up, the LCD display [A] will show the
software revision # (i.e. 6801: r2, etc.).
For the next four seconds, the accumulated hours will be shown.
Finally, the LCD display will change to the current odometer reading
(after a total of five seconds).
If this display function does not work, replace the meter unit.
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ELECTRICAL SYSTEM 16-45
Speedometer (Optional Part for U.S. model)
Check 2: MODE Button Operation Check
Connect the wires in the same manner as Check 1.
Pushing the mode switch [A] briefly will toggle the LCD display [B]
from “Odo” to “Trip”, or visa versa (however; pushing the switch more
often than once per second will not toggle the display).
The trip count includes tenths of a mile, whereas the odo count does
not.
The trip mode may therefore be identified by the presence of a
decimal point next to the “tenths” digit.
To clear the trip count, push and hold the switch for at least three
seconds (regardless of which mode the display is currently in) and
do not let go until you see the trip count reset to zero.
•
•
•
•
•
Check 3: Speedometer Check
Connect the wires in the same manner as Check 1.
The speed equivalent to the input frequency is indicated in the
oscillator [A], if the square wave is input into terminal [3] (Green).
Raise the input frequency of the oscillator to see the result of this
inspection.
If the value indicated by the speedometer does not increase, replace
the meter unit.
•
•
•
Check 4: Odometer Check
Connect the wires in the same manner as Check 3.
Pushing the mode switch [A], cycles the odometer [B].
Raise the input frequency of the oscillator to see the result of this
inspection.
If the value indicated by the odometer does not increase, replace the
meter unit.
•
•
•
Check 5: Trip Meter Check
Connect the wires in the same manner as Check 3.
Pushing the mode switch [A], cycles the trip meter [B].
Raise the input frequency of the oscillator to see the result of this
inspection.
If the value indicated by the trip meter does not increase, replace the
meter unit.
•
•
•
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16-46 ELECTRICAL SYSTEM
Speedometer (Optional Part for U.S. model)
Speedometer Circuit
1.
2.
3.
4.
5.
Speedometer (except US model)
Speed Sensor
Ignition Switch
Main Fuse 30A
Battery
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ELECTRICAL SYSTEM 16-47
LED Indicator
Drive Belt Failure Mode Memory Clearing Procedure
A flashing CHECK BELT warning LED (Light Emitting Diode) light
means that the drive belt needs inspection. The belt warning light will
activate every 100 key-on hours, or sooner if the belt becomes damaged
or fails.
NOTE
Follow the instruction on pages 2–14 to 2–16 of this Service Manual
to complete the necessary inspections.
After completing the inspections, follow these instructions to clear
the system memory and stop the flashing light.
off the ignition switch.
• Turn
the belt switch at the 2 pin connector [A] above the torque
• Disconnect
converter cover.
both sets of 5 pin connectors [B] which are located above
• Disconnect
the torque converter cover.
these 5 pin connectors to their opposite gray to black and
• Reconnect
black to gray.
on the ignition switch.
• Turn
the belt warning light [A].
• Observe
It should be flashing at a 0.4 second interval.
Let it flash for at least seven seconds.
NOTE
More than seven seconds is OK.
The 4WD LED light [B] will also flash only if 4WD is selected.
• While observing the belt warning light, turn off the ignition switch.
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16-48 ELECTRICAL SYSTEM
LED Indicator
the mismatched 5 pin connector sets and reconnect them
• Disconnect
normally. (Black to black, gray to gray) [A]
• Connect the belt switch 2 pin connector [B].
on the ignition switch.
• Turn
Confirm
no warning lights are flashing.
• The LEDthat
lights go on for one second.
LED Indicator Removal
• Remove:
Front Fender (see Frame chapter)
•
•
Handlebar Cover
Disconnect:
LED Indicator Lead Connector [A]
Remove:
Screws [B] and Collars
LED Indicator [C] and Bracket
LED Indicator Installation
• Install:
Bracket [A]
LED Indicator [B]
Screws [C] and Collars [D]
LED Indicator Inspection
Flashing Pattern Inspection
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ELECTRICAL SYSTEM 16-49
LED Indicator
LED
Indication Pattern
Condition
Check
BELT
and
4WD
Ignition Switch ON
Normal
1
BELT
and
4WD
Ignition Switch OFF
Normal
2
BELT
Drive Failure Detecting
Switch OFF (Belt Failure)
3
BELT
Total 100 hours of use
4
BELT
and
4WD
Drive Belt Failure Mode
Memory Clearing Procedure
5
BELT
and
4WD
Ignition Switch OFF
Memory Writing Failure
6
BELT
Memory Writing Time Limit
(one hundred thousand)
7
BELT
Memory Reading Failure
8
4WD
2WD/4WD Actuator Failure
9
4WD
Engine Brake Actuator Failure
10
4WD
Both 2WD/4WD Actuator
and Engine Brake Actuator
Failure
11
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16-50 ELECTRICAL SYSTEM
LED Indicator
Check 1
No Problem
Check 2
No Problem
Check 3
Check the drive belt (see Drive Belt Deflection Inspection and Drive
Belt Inspection in Periodic Maintenance chapter).
If it is flashed by abnormal belt, replace the belt and torque converter
cover.
After completing the inspections, do the drive belt failure mode
memory clearing procedure (see Drive Belt Failure Mode Memory
Clearing Procedure).
•
•
Check 4
Check the drive belt (see Drive Belt Deflection Inspection and Drive
Belt Inspection in Periodic Maintenance chapter).
After completing the inspections, do the drive belt failure mode
memory clearing procedure (see Drive Belt Failure Mode Memory
Clearing Procedure).
•
•
Check 5
This flashing is the indication pattern for the drive belt failure mode
memory clearing procedure.
Check 6
The LED indicator may be broken.
Do the drive belt failure mode memory clearing procedure.
If the same flashing appears, replace the LED indicator.
•
•
Check 7
The writing memory in the LED indicator is a limit (one hundred
thousand times).
Replace the LED indicator.
•
Check 8
The LED indicator may be broken.
Do the drive belt failure mode memory clearing procedure.
If the same flashing appears, replace the LED indicator.
•
•
Check 9, 10, 11
See Actuator Control System Troubleshooting.
•
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ELECTRICAL SYSTEM 16-51
LED Indicator
LED Indicator External Circuit
1. LED Indicator
2. CHECK BELT LED
3. 4WD LED
4. Reset Connector
5. Battery
6. Ignition Switch
7. Drive Belt Failure Detecting Switch
8. Igniter
9. Input (from Drive Belt Failure Detecting Switch)
10. Output (to LED Indicator)
11. Actuator Controller
12. 2WD/4WD Shift Switch
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16-52 ELECTRICAL SYSTEM
LED Indicator
Led Indicator Circuit
1.
2.
3.
4.
5.
6.
7.
8.
LED Indicator
Drive Belt Failure Indicator LED (CHECK BELT)
4WD Mode Indicator LED (4WD)
Drive Belt Failure Mode Reset Connector
Igniter
2WD/4WD Shift Switch
Acturator Controller
Engine Brake Actuator
9.
10.
11.
12.
13.
2WD/4WD Actuator
Battery
Main Fuse 30A
Ignition Switch
Drive Belt Failure Detecting Switch
Fuse 5A
14. Drive Belt Failure Detecting Switch
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ELECTRICAL SYSTEM 16-53
Actuator Control System
2WD/4WD Actuator Removal
• Remove:
Right Front Inner Cover (see Frame chapter)
Actuator Lead Connector [A]
• Remove:
Breather Hose [A]
Actuator Mounting Bolts [B]
Actuator [C]
2WD/4WD Actuator Installation
installing the pin [A], install the collar [B] on the actuator and
• When
then press the pin.
inspect the collar.
• Visually
If the collar is damaged or worn excessively, replace it.
grease to the O-ring [C].
• Apply
Insert
the
collar into the groove [D] of the shifter so that the long side
• [E] faces downward.
a non-permanent locking agent to the actuator mounting bolts,
• Apply
and tighten them following the tightening sequence [1 ~ 3].
Torque -
2WD/4WD Actuator Mounting Bolts: 9.8 N1m (1.0 kgf1m, 87
in1lb)
Engine Brake Actuator Removal
• Remove:
Actuator Lead Connector [A]
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16-54 ELECTRICAL SYSTEM
Actuator Control System
• Remove:
Actuator Mounting Bolts [A]
Actuator [B]
Engine Brake Actuator Installation
grease to the O-ring [A] and install it.
• Apply
Apply
disulfide grease to the pin [B].
• Insert molybdenum
• [D]. the pin into the collar [C] of the engine brake lever assembly
• Tighten:
Torque -
Engine Brake Actuator Mounting Bolts: 8.8 N1m (0.9 kgf1m,
78 in1lb)
Wipe off any protruding grease.
Actuator Control System Outline
The actuator controller [A] has a microprocessor that detects vehicle
speed, state of the selectable 2WD/4WD shift switch, ignition switch,
and the forward/reverse movement of the vehicle in order to control the
engine brake actuator and selectable 2WD/4WD actuator.
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ELECTRICAL SYSTEM 16-55
Actuator Control System
Actuator Control System
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16-56 ELECTRICAL SYSTEM
Actuator Control System
Actuator Control System Troubleshooting
When the actuator fails, the controller enters failure mode and the
4WD indicator light (LED) [A] is flash.
Failure Indication Pattern and Failure Part
No.
1
Failure Indication Pattern (4WD Indicator Light)
Failure Part
Selectable 2WD/4WD actuator
2
Engine brake actuator
3
Both the selectable 2WD/4WD actuator and the engine brake actuator
Malfunction Mode
No.
Malfunction Mode
1
The 2WD/4WD actuator does not
operate correctly.
2
The engine brake actuator does
not operate correctly.
3
The 4WD indicator light does not switch.
Probable Faulty Part/Location
2WD/4WD actuator
Controller power supply
Speed sensor
2WD/4WD shift switch
Controller
Engine brake actuator
Controller power supply
Speed sensor
F/R detecting sensor
Controller
2WD/4WD shift switch
Controller
LED indicator light
Check Number
1
3
4
5
6
2
3
4
7
6
5
6
8
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ELECTRICAL SYSTEM 16-57
Actuator Control System
Check 1. 2WD/4WD Actuator Inspection
Remove:
Right Front Inner Cover (see Frame chapter)
Actuator Lead Connector [A]
•
the resistance between
• Measure
actuator lead connector [A].
Special Tool -
the following terminals in the
Hand Tester: 57001–1394
Actuator Internal Resistance
4 (Red) – 6 (Black):
1 (Orange) – 3 (Blue):
2 (Yellow) – 3 (Blue):
3 ~15
3.5 ~6.5 k
630 ~3,720
If any reading is not within the specified range, replace the 2WD/4WD
actuator.
If the reading is within the specified range, inspect the position of the
actuator output shaft as following procedure.
• Remove:
2WD/4WD Actuator (see 2WD/4WD Actuator Removal)
if the output shaft [A] position is within the inoperative angle
• Check
range [F] as shown in the figure.
•
•
•
[A] Actuator Output Shaft
[B] 2WD Point
[C] 4WD Point
[D] Operative Range Angle = 109.5 deg.
[E] Angle = 45.6 deg.
[F] Inoperative Range Angle = 91.2 deg.
[G] Actuator Lead Connector
If the output shaft is in the inoperative range angle, move the shaft in
the operative range angle.
Apply the 12 V battery voltage to the actuator.
Battery (+)
Connector 4 terminal (Red)
Battery (–)
Connector 6 terminal (Black)
Stop applying the power when the output shaft comes near the 2WD
point [B].
Install the actuator (see 2WD/4WD Actuator Installation).
If the output shaft is in the operative range angle, the malfunction of
the 2WD/4WD actuator could be caused by other parts.
!
!
Check 2. Engine Brake Actuator Inspection
Remove:
Actuator Lead Connector [A]
•
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16-58 ELECTRICAL SYSTEM
Actuator Control System
the resistance between
• Measure
actuator lead connector [A].
Special Tool -
the following terminals in the
Hand Tester: 57001–1394
Actuator Internal Resistance
4 (Red) – 6 (Black):
1 (Orange) – 3 (Blue):
2 (Yellow) – 3 (Blue):
3 ~15
3.5 ~6.5 k
630 ~5,330
If any reading is not within the specified range, replace the engine
brake actuator.
If the reading is within the specified range, inspect the position of the
actuator output shaft as following procedure.
• Remove:
Engine Brake Actuator (see Engine Brake Actuator Removal)
Check
shaft [A] position is within the inoperative angle
• range [G]if theas output
shown in the figure.
•
•
•
[A] Actuator Output Shaft
[B] Angle = 51.4 deg.
[C] Starting Point
[D] Ending Point
[E] Operative Range Angle = 180 deg.
[F] Angle = 7 deg.
[G] Inoperative Range Angle = 91.2 deg.
[H] Actuator Lead Connector
If the output shaft is in the inoperative angle range, move the shaft in
the operative angle range.
Apply the 12 V battery voltage to the actuator.
Battery (+)
Connector 4 terminal (Red)
Battery (–)
Connector 6 terminal (Black)
Stop applying the power when the output shaft comes near the
starting point [C].
Install the actuator (see Engine Brake Actuator Installation).
If the output shaft is in the operative angle range, the engine brake
malfunction could be caused by other parts.
!
!
Check 3. Controller Power Supply Inspection
NOTE
Be sure the battery is fully charged.
• Remove:
Seat (see Frame chapter)
Connect:
• Controller Connector [A]
!
!
Hand Tester [B] (range: DC 25 V)
Tester (+)
Connector (BR) Terminal [9]
Tester (–)
Connector (BK/Y) Terminal [10]
Install the needle adapters on the tester leads.
Special Tools - Hand Tester: 57001–1394
Needle Adapter Set: 57001–1457
• Turn ON the ignition switch.
Controller Power Supply Voltage
Standard:
near Battery Voltage
If the reading is not battery voltage, check the wiring harness, 30 A
fuse, or ignition switch.
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ELECTRICAL SYSTEM 16-59
Actuator Control System
Check 4. Speed Sensor Inspection
NOTE
Be sure the battery is fully charged.
the vehicle on a stand or a jack so that the wheels are off
• Support
the ground.
• Remove:
Seat (see Frame chapter)
• Connect:
Controller Connector [A]
!
!
Hand Tester [B] (range: DC 25 V)
Tester (+)
Connector (P) Terminal [5]
Tester (–)
Connector (BK/Y) Terminal [10]
Install the needle adapters on the tester leads.
Special Tools - Hand Tester: 57001–1394
Needle Adapter Set: 57001–1457
ON the ignition switch.
• Turn
• Spin a rear wheel, measure the voltage.
Speed Sensor Output Voltage
Standard:
repeat from 0 to 5 V
If the reading is not standard, replace the speed sensor.
Check 5. 2WD/4WD Shift Switch Inspection
NOTE
Be sure the battery is fully charged.
• Remove:
Seat (see Frame chapter)
Connect:
• Controller Connector [A]
!
!
Hand Tester [B] (range: DC 25 V)
Tester (+)
Connector (G) Terminal [7]
Tester (–)
Connector (BK/Y) Terminal [10]
Install the needle adapters on the tester leads.
Special Tools - Hand Tester: 57001–1394
Needle Adapter Set: 57001–1457
ON the ignition switch.
• Turn
Push
• the switch to the 4WD position.
Controller Output Voltage (at 2WD/4WD Shift Switch OFF, 4WD)
Standard:
about 5 V
•
If the reading is not standard, check the 2WD/4WD shift switch or
actuator controller unit.
Push the switch to the 2WD position.
Controller Output Voltage (at 2WD/4WD Shift Switch ON, 2WD)
Standard:
0V
If the reading is not standard, check the 2WD/4WD shift switch or
actuator controller unit.
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16-60 ELECTRICAL SYSTEM
Actuator Control System
Check 6. Controller Unit Inspection
NOTE
Be sure the battery is fully charged.
• Remove:
Seat (see Frame chapter)
Connect:
• Controller Connector [A]
!
!
Hand Tester [B] (range: DC 10 V)
Tester (+)
Connector (O) Terminal [2]
Tester (–)
Connector (BK/Y) Terminal [10]
Install the needle adapters on the tester leads.
Special Tools - Hand Tester: 57001–1394
Needle Adapter Set: 57001–1457
ON the ignition switch.
• Turn
Measure
the controller output voltage for the actuators.
•
Controller Output Voltage (to Actuators)
Standard:
4.8 &plusmn; 0.2 V
If the reading is not standard, replace the actuator controller unit.
the speed sensor lead connector.
• Disconnect
Connect:
• Controller Connector [A]
Hand Tester [B] (range: DC 10 V)
Tester (+)
Connector (P) Terminal [5]
Tester (–)
Connector (BK/Y) Terminal [10]
Install the needle adapters on the tester leads.
!
!
Special Tools - Hand Tester: 57001–1394
Needle Adapter Set: 57001–1457
ON the ignition switch.
• Turn
Measure
the controller output voltage for the speed sensor.
•
Controller Output Voltage (to speed sensor)
Standard:
5 &plusmn; 0.25 V
If the reading is not standard, replace the actuator controller unit.
the 2WD/4WD shift switch lead connector.
• Disconnect
• Connect:
Controller Connector [A]
!
!
Hand Tester [B] (range: DC 10 V)
Tester (+)
Connector (G) Terminal [7]
Tester (–)
Connector (BK/Y) Terminal [10]
Install the needle adapters on the tester leads.
Special Tools - Hand Tester: 57001–1394
Needle Adapter Set: 57001–1457
ON the ignition switch.
• Turn
Measure
the controller output voltage for the 2WD/4WD shift switch.
•
Controller Output Voltage (to 2WD/4WD shift switch)
Standard:
5 &plusmn; 0.25 V
If the reading is not standard, replace the actuator controller unit.
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ELECTRICAL SYSTEM 16-61
Actuator Control System
the vehicle on a stand or a jack so that the wheels are off
• Support
the ground.
• Connect:
Controller Connector [A]
!
!
Hand Tester [B] (range: DC 25 V)
Tester (+)
Connector (W/R) Terminal [15]
Tester (–)
Connector (BK/Y) Terminal [10]
Install the needle adapters on the tester leads.
Special Tools - Hand Tester: 57001–1394
Needle Adapter Set: 57001–1457
ON the ignition switch.
• Turn
Spin
wheel as forward rotation.
• After atherearwheels
stop and one second elapses, turn OFF the ignition
• switch.
two seconds elapses, measure the controller output voltage for
• After
the engine brake actuator until the actuator stops.
Controller Output Voltage (to engine brake actuator)
Standard:
5 ~ 12 V
If the reading is not standard, check the forward/reverse detecting
sensor.
If the forward/reverse detecting sensor is normal, replace the actuator
controller unit.
the vehicle on a stand or a jack so that the wheels are off
• Support
the ground.
the engine and shift to the 4WD position.
• Run
the engine and turn OFF the ignition switch.
• Stop
Connect:
• Controller Connector [A]
!
!
Hand Tester [B] (range: DC 25 V)
Tester (+)
Connector (W/Y) Terminal [12]
Tester (–)
Connector (BK/Y) Terminal [10]
Install the needle adapters on the tester leads.
Special Tools - Hand Tester: 57001–1394
Needle Adapter Set: 57001–1457
ON the ignition switch.
• Turn
Shift
to the 2WD position.
• Measure
the controller output voltage for the 2WD/4WD actuator until
• the actuator
stops.
Controller Output Voltage (to 2WD/4WD actuator)
Standard:
5 ~ 12 V
If the reading is not standard, check the 2WD/4WD shift switch.
If the 2WD/4WD shift switch is normal, replace the actuator controller
unit.
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16-62 ELECTRICAL SYSTEM
Actuator Control System
Check 7. Forward/Reverse Detecting Sensor Inspection
Remove:
Left Side Cover (see Frame chapter)
Disconnect forward/reverse detecting sensor lead wire connector [A].
Measure the forward/reverse detecting sensor resistance.
Connect the hand tester between the BK lead and the W lead.
Set the tester to the 2 k
range.
•
•
•
Special Tool -
Hand Tester: 57001–1394
Forward/Reverse Detecting Sensor Resistance
Standard:
1.2 ~ 1.6 k
•
If the reading is not within the specified range, replace the forward/
reverse detecting sensor [B].
Using the highest resistance, measure the resistance between forward/reverse detecting sensor leads and chassis ground.
If the tester reading is less than infinity (∞) indicates a short, replace
the forward/reverse detecting sensor.
Check 8. Indicator Light (LCD) Inspection
NOTE
Be sure the battery is fully charged.
• Remove:
Seat (see Frame chapter)
• Connect:
Controller Connector [A]
Hand Tester [B] (range: DC 25 V)
Tester (+) ! Connector (G/W) Terminal [8]
Tester (–) ! Connector (BK/Y) Terminal [10]
Install the needle adapters on the tester leads.
Special Tool -
Hand Tester: 57001-1394
Needle Adapter Set: 57001-1457
ON the ignition switch.
• Turn
the switch to the 4WD position and shift the vehicle to 4WD
• Push
mode.
Controller Output Voltage (to LED Indicator)
Standard: about 5 V
If the reading is not standard, check the 2WD/4WD shift switch.
If the 2WD/4WD shift switch is normal, replace the actuator controller
unit.
Even if the reading is standard, when the 4WD light does not go on,
replace the LED indicator.
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ELECTRICAL SYSTEM 16-63
Actuator Control System
Actuator Control System Circuit
1.
2.
3.
4.
2WD/4WD Shift Switch
Igniter
Drive Belt Failure Detecting Switch
Drive Belt Failure Detecting Switch
Fuse 5A
5. Reverse Switch
6. LED Indicator
7.
8.
9.
10.
11.
12.
13.
Actuator Controller
Engine Brake Actuator
2WD/4WD Actuator
Speed Sensor
Ignition Switch
Battery
Main Fuse 30A
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16-64 ELECTRICAL SYSTEM
Drive Belt Failure Detection System
If the drive belt failue detetion system is activated by abnormal belt,
the drive belt failure detection switch is damaged. Make sure replace
the torque converter cover (see Converter System chapter).
Drive Belt Failure Detection System Inspection
• Remove:
Fuel Tank Cover (see Frame chapter)
the drive belt failure detection system according to following
• Check
chart.
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ELECTRICAL SYSTEM 16-65
Drive Belt Failure Detection System
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16-66 ELECTRICAL SYSTEM
Drive Belt Failure Detection System
Drive Belt Failure Detection System Circuit
1.
2.
3.
4.
5.
6.
2WD/4WD Actuator
LED Indicator
Drive Belt Failure Detecting Switch
Drive Belt Failure Detecting Switch Fuse 5A
Ignition Switch
Main Fuse 30A
7.
8.
9.
10.
11.
Actuator Controller
Igniter
Ignition Coil
Spark Plug
Battery
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ELECTRICAL SYSTEM 16-67
Carburetor Heater System
Air Temperature Sensor Inspection
• Remove:
Seat (see Frame chapter)
Air Temperature Sensor [A]
the battery and hand tester to the sensor.
• Connect
Red Connector [A]
White Connector [B]
12 V Battery [C]
Hand Tester [D]
Special Tool -
Hand Tester: 57001–1394
CAUTION
Use the sensor within –30 ~ 80 C (–22 ~ 176 F). If it is used
without the specified range, the sensor will be damaged.
Suspend the sensor [A] in a container of cold water of less than 8 C
• (46.4
F) so that the temperature sensing part [B] is submerged as
•
•
shown.
[C] Ice
Suspend an accurate thermometer [D] in the water.
Measure the output voltage between W/Y terminal and battery (–)
terminal (tester range: DC 25 V).
Air Temperature Sensor: less than 8 C (46.4 F)
Output Voltate:
8 ~ 16 V (near battery voltage)
If the voltage is less than DC 0.1 V, replace the sensor.
up the sensor [A] more than 22 C (71.6 F) with a hand.
• Warm
Measure
the output voltage between W/Y terminal and battery (–)
• terminal (tester
range: DC 2.5 V).
Air Temperature Sensor: more than 22 C (71.6 F)
Output Voltate:
less than 0.1 V
If the voltage is 8 ~ 16 V, replace the sensor.
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16-68 ELECTRICAL SYSTEM
Carburetor Heater System
Carburetor Heater Inspection
• Disconnect:
Carburetor Heater Lead Connector [A]
Ground Lead Connector [B]
the hand tester, measure the resistance of the heater.
• Using
Connect
• terminal. the tester between the heater terminal and the ground
If the tester does not read as specified, replace the heater.
Carburetor Heater Resistance
20
11
Carburetor Heater System Circuit
1. Carburetor Heater 12V23W
2. Air Temperature Sensor
3. Ignition Switch
4. Main Fuse 30A
5. Alternator
6. Battery
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ELECTRICAL SYSTEM 16-69
Switches
Brake Light Switch Adjustment
to Brake Light Switch Adjustment in Periodic Maintenance
• Refer
chapter.
Oil Cooler Fan Switch Inspection
• Remove:
Oil Cooler Fan Switch (see Engine Lubrication System chapter)
the fan switch [A] in a container of oil so that the temperature
• Suspend
sensing projection and threaded portion are submerged.
• Suspend an accurate thermometer [B] in the oil.
NOTE
The switch and thermometer must not touch the container sides or
bottom.
the container over a source of heat and gradually raise the
• Place
temperature of the oil while stirring the oil gently.
the hand tester, measure the internal resistance of the switch
• Using
across the terminals at the temperatures shown in the table.
If the hand tester does not show the specified values, replace the
switch.
Oil Cooler Fan Switch Resistance
Rising temperature:
73 C (153
From OFF to ON at 67
Falling temperature:
63 C (135
From ON to OFF at 57
ON: Less than 0.5
OFF: More than 1 M
163 F)
145 F)
Oil Temperature Warning Light Switch Inspection
• Remove:
Oil Temperature
•
•
Warning Light Switch (see Engine Lubrication
System chapter)
Suspend the switch [A] in a container of oil so that the temperature
sensing projection and threaded portion are submerged.
Suspend an accurate thermometer [B] in the oil.
NOTE
The switch and thermometer must not touch the container sides or
bottom.
the container over a source of heat and gradually raise the
• Place
temperature of the oil while stirring the oil gently.
the hand tester, measure the internal resistance of the switch
• Using
across the terminals at the temperatures shown in the table.
If the hand tester does not show the specified values, replace the
switch.
Oil Temperature Warning Light Switch Resistance
Rising temperature:
113 C (225
235 F)
From OFF to ON at 107
Falling temperature:
From ON to OFF at 97 ~ 103 C (207 ~ 217 F)
ON: Less than 0.5
OFF: More than 1 M
Switch Inspection
the hand tester, check to see that only the connections shown
• Using
in the table have continuity (about zero ohms).
For
the handlebar switches, ignition switch, refer to tables in the
Wiring Diagram.
If the switch has an open or short, repair or replace it with a new one.
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16-70 ELECTRICAL SYSTEM
Switches
Neutral Switch Connection
[A] Neutral Switch
Reverse Switch Connections
[B] Reverse Switch
2WD/4WD Shift Switch
Oil Pressure Switch Connections*
*: Engine lubrication system is in good condition
Drive Belt Failure Detection Switch
If the drive belt failure detection system is activated by abnormal belt,
the drive belt failure detection switch is damaged. Make sure to replace
the torque converter cover (see Converter System chapter).
Remove:
Torque Converter Cover (see Torque Converter Removal section in
Converter System)
•
[A] Drive Belt Failure Detection Switch
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ELECTRICAL SYSTEM 16-71
Fuses
Fuses Removal
• Remove:
Seat (see Frame chapter)
Fuse Cap [A]
Fuse [B]
• Remove:
Main Fuse 30A [A]
Accessary Fuse 5A [B]
• Remove:
Oil Cooler Fan Fuse 20A [A]
Drive Belt Failure Detecting Switch Fuse 5A [B]
[C] Oil Cooler
Fuse Inspection
the fuse element [A].
• Inspect
If it is blown out, replace the fuse. Before replacing a blown fuse [B],
always check the amperage in the affected circuit. If the amperage is
equal to or greater than the fuse rating, check the wiring and related
components for a short circuit.
CAUTION
When replacing a fuse, be sure the new fuse matches the
specified fuse rating for that circuit. Installation of a fuse with
a higher rating may cause damage to wiring and components.
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16-72 ELECTRICAL SYSTEM
Wiring Diagram
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ELECTRICAL SYSTEM 16-73
Wiring Diagram
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APPENDIX 17-1
Appendix
Table of Contents
Troubleshooting Guide .................................................................................................................................................... 17-2
Cable, Wire, and Hose Routing ...................................................................................................................................... 17-6
17
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17-2 APPENDIX
Troubleshooting Guide
NOTE
This is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting
for some of the more common difficulties.
Engine Doesn’t Start, Starting Difficulty:
Starter motor not rotating:
Neutral switch trouble
Starter motor trouble
Battery voltage low
Relays not contacting or operating
Starter button not contacting
Wiring open or shorted
Ignition switch trouble
Engine stop switch trouble
Fuse blown
Starter motor rotating but engine doesn’t turn over:
Starter motor clutch trouble
Recoil starter not operating
Recoil starter spring broken
Recoil starter pawl not engaging
Engine won’t turn over:
Valve seizure
Rocker arm seizure
Cylinder, piston seizure
Crankshaft seizure
Connecting rod small end seizure
Connecting rod big end seizure
Transmission gear or bearing seizure
Camshaft seizure
Balancer bearing seizure
No fuel flow:
Fuel tank air vent obstructed
Fuel tap clogged
Fuel line clogged
Float valve clogged
Engine flooded:
Fuel level too high
Float valve worn or stuck open
Starting technique faulty
(When flooded, crank the engine with the throttle
fully opened to allow more air to reach the engine.)
Fuel/air mixture incorrect:
Pilot screw and/or idle adjusting screw maladjusted
Pilot jet or air passage clogged
Air cleaner clogged, poorly sealed, or missing
Starter jet clogged
No spark; spark weak:
Spark plug dirty, broken, or maladjusted
Spark plug cap or spark plug lead trouble
Spark plug cap not in good contact
Spark plug incorrect
Pickup coil trouble
Igniter trouble
Ignition coil trouble
Battery voltage low
Ignition or engine stop switch shorted
Wiring shorted or open
Fuse blown
Compression Low:
Spark plug loose
Cylinder head not sufficiently tightened down
No valve clearance
Cylinder, piston worn
Piston ring bad (worn, weak, broken, or sticking)
Piston ring/groove 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)
Compression release cam (K.A.C.R.) sticks open
(Engine stalls when moving off)
Poor Running at Low Speed:
Spark weak:
Spark plug dirty, broken, or maladjusted
Spark plug cap or spark plug lead trouble
Spark plug cap shorted or not in good contact
Spark plug incorrect
Igniter trouble
Pickup coil trouble
Ignition coil trouble
Battery voltage low
Fuel/air mixture incorrect:
Pilot screw and/or idle adjusting screw maladjusted
Pilot jet or air passage clogged
Starter plunger stuck open
Air cleaner clogged, poorly sealed, or missing
Fuel level too high or too low
Fuel tank air vent obstructed
Carburetor holder loose
Air cleaner duct loose
Compression low:
Spark plug loose
Cylinder head not sufficiently tightened down
No valve clearance
Cylinder, piston worn
Piston ring bad (worn, weak, broken, or sticking)
Piston ring/groove 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)
Compression release cam (K.A.C.R.) sticks open
(Engine stalls when moving off)
Other:
Carburetor vacuum piston doesn’t slide smoothly
Engine oil viscosity too high
Brake dragging
Igniter trouble
Front or rear final gear case oil viscosity too high
Poor Running or No Power at High Speed:
Firing incorrect:
Spark plug dirty, broken, or maladjusted
Spark plug cap or spark plug lead trouble
Spark plug cap shorted or not in good contact
Spark plug incorrect
Pickup coil trouble
Igniter trouble
Ignition coil trouble
Drive belt failure detection switch activated
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APPENDIX 17-3
Troubleshooting Guide
Fuel/air mixture incorrect:
Main jet clogged or wrong size
Jet needle or needle jet worn
Main air jet clogged
Bleed holes of air bleed pipe or needle jet clogged
Fuel level too high or too low
Air cleaner clogged, poorly sealed, or missing
Starter plunger stuck open
Water or foreign matter in fuel
Carburetor holder loose
Air cleaner duct loose
Fuel tank air vent obstructed
Fuel tap clogged
Fuel line clogged
Compression low:
Spark plug loose
Cylinder head not sufficiently tightened down
No valve clearance
Cylinder, piston worn
Piston rings bad (worn, weak, broken, or sticking)
Piston ring/groove 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.)
Compression release cam (K.A.C.R.) sticks open
(Engine stalls when moving off)
Knocking:
Carbon built up in combustion chamber
Fuel poor quality or incorrect
Spark plug incorrect
Igniter trouble
Miscellaneous:
Throttle valve won’t fully open
Carburetor vacuum piston doesn’t slide smoothly
Brake dragging
Overheating
Engine oil level too high
Engine oil viscosity too high
Balancer mechanism malfunctioning
Front or rear final gear case oil viscosity too high
Overheating:
Firing incorrect:
Spark plug dirty, broken, or maladjusted
Spark plug incorrect
Igniter trouble
Fuel/air mixture incorrect:
Main jet clogged
Fuel level too low
Carburetor holder loose
Air cleaner poorly sealed, or missing
Air cleaner duct loose
Air cleaner clogged
Compression high:
Carbon built up in combustion chamber
Compression release cam sticks close (K.A.C.R.)
Engine load faulty:
Engine oil level too high
Engine oil viscosity too high
Drive train trouble
Brake dragging
Lubrication inadequate:
Engine oil level too low
Engine oil poor quality or incorrect
Front or rear final gear case overheating:
Insufficient oil
Bevel gears maladjusted
LSD clutches in front final gear case maladjustment
Oil cooler incorrect:
Oil cooler clogged
Oil cooler fan switch trouble
Fan motor broken
Fan blade damaged
Converter Operation Faulty:
Belt slipping:
Belt dirty, worn, or wetted
Drive or driven pulley sheave dirty or worn
Drive pulley spring broken or weak
Converter engagement speed too low:
Drive pulley spring broken or weak
Converter engagement speed too high:
Belt dirty or worn
Drive or driven pulley sheave dirty or worn
Drive pulley weight doesn’t move smoothly
Drive pulley movable sheave doesn’t move smoothly
Drive or driven pulley movable sheave bush worn
Drive pulley weight or roller worn
Shifting too quickly:
Drive pulley spring weak
Driven pulley spring weak or incorrectly installed (too
loose)
Shifting too slowly:
Belt dirty or worn
Drive or driven pulley sheave dirty or worn
Drive pulley weight doesn’t move smoothly
Drive pulley movable sheave doesn’t move smoothly
Drive pulley spring incorrect installed (too tight)
Driven pulley movable sheave doesn’t move smoothly
Gear Shifting Faulty:
Doesn’t go into gear:
Shift arm bent or seized
Gear stuck on the shaft
Shift tie-rod maladjusted
Shift tie-rod damaged
Jumps out of gear:
Shifter groove worn
Gear dogs worn
Shift block worn
Shift arm positioning bolt spring weak or broken
Shift tie-rod maladjusted
Drive shaft, output shaft, and/or gear splines worn
Overshifts:
Shift arm positioning bolt spring weak or broken
Shift tie-rod maladjusted
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17-4 APPENDIX
Troubleshooting Guide
Abnormal Engine Noise:
Knocking:
Igniter trouble
Carbon built up in combustion chamber
Fuel poor quality or incorrect
Spark plug incorrect
Overheating
Piston Slap:
Cylinder/piston clearance excessive
Cylinder, piston worn
Connecting rod bent
Piston pin, piston holes worn
Valve noise:
Valve clearance incorrect
Valve spring broken or weak
Camshaft bearing worn
Rocker arm worn
Other noise:
Connecting rod small end clearance excessive
Connecting rod big end clearance excessive
Piston ring worn, broken, or stuck
Piston seizure, damage
Cylinder head gasket leaking
Exhaust pipe leaking at cylinder head connection
Crankshaft runout excessive
Engine mounts loose
Crankshaft bearing worn
Camshaft chain tensioner trouble
Camshaft chain, sprocket, guides worn
Balancer bearing worn
Balancer gear worn or shipped
Loose alternator rotor
Abnormal Drive Train Noise:
Converter noise:
Belt worn
Drive or driven pulley sheave worn
Drive or driven pulley movable sheave bush worn
Drive or driven pulley mount loose
Driven pulley shoe worn
Drive pulley weight or roller side washer worn
Drive pulley weight or roller worn
Wear guides worn
Transmission noise:
Bearing worn
Transmission gears worn or chipped
Metal chips jammed in gear teeth
Engine oil insufficient or too thin
Front or rear final gear case noise:
Insufficient lubricant
Incorrect oil (Front final gear case)
Bevel gear bearings worn
Bevel gears worn or chipped
Bevel gears maladjusted
Worn LSD clutch friction plate (Front final gear case)
Worn LSD clutch spring (Front final gear case)
Damaged side gears or pinions (Front final gear case)
Abnormal Frame Noise:
Shock absorber noise:
Shock absorber damaged
Disc brake noise:
Pad installed incorrectly
Pad surface glazed
Disc warped
Caliper trouble
Rear brake noise:
Foreign matter in hub
Brake not properly adjusted
Other noise:
Bracket, nut bolt, etc. not properly mounted or
tightened
Exhaust Smokes Excessively:
White smoke:
Piston oil ring worn
Cylinder worn
Valve oil seal damaged
Valve guide worn
Cylinder head gasket damaged
Engine oil level too high
Black Smoke:
Air cleaner clogged
Main jet too large or fallen off
Starter plunger stuck open
Fuel level too high
Brown smoke:
Main jet too small
Fuel level too low
Air cleaner duct loose
Air cleaner poorly sealed or missing
Handling and/or Stability Unsatisfactory
Handlebar hard to turn:
Tire air pressure too low
Steering stem bearing damaged
Steering stem bearing lubrication inadequate
Steering stem bent
Damaged steering knuckle joint
Damage tie-rod end
LSD clutch maladjusted (front final gear case)
Noise when turning:
Damaged side gear or pinion (front final gear case)
Worn LSD clutch friction plates (Front final gear case)
Worn LSD clutch spring (Front final gear case)
Handlebar shakes or excessively vibrates:
Tire worn
Wheel rim warped
Rear axle runout excessive
Wheel bearing worn
Handlebar clamp loose
Steering stem clamp bolt loose
Handlebar pulls to one side:
Frame bent
Wheel maladjustment
Suspension arm bent or twisted
Steering stem bent
Front or rear tire air pressure unbalanced
Front shock absorber unbalanced
Shock absorption unsatisfactory:
Too hard:
Tire air pressure too high
Shock absorber maladjusted
Too soft:
Shock absorber oil leaking
Shock absorber spring weak
Tire air pressure too low
Shock absorber maladjusted
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APPENDIX 17-5
Troubleshooting Guide
Brake Doesn’t Hold
Front brake:
Air in the brake line
Brake fluid leakage
Brake fluid deteriorated
Primary or secondary cup trouble
Master cylinder scratched inside
Pad overworn or worn unevenly
Oil, grease on pads and disc
Disc worn or warped
Brake overheated
Rear Brake:
Brake not properly adjusted
Plates worn
Brake parts worn or damaged
K-EBC and Selectable 2WD/4WD System Malfunction:
Actuators failed
Speed sensor short or open
Forward/Reverse detecting sensor short or open
Actuator controller failed
Controller 10A fuse blown
Battery disconnected
Battery Discharged:
Battery faulty (e.g., plates sulphated, shorted through
sedimentation, electrolyte level too low)
Battery leads making poor contact
Load excessive (e.g., bulb of excessive wattage)
Ignition switch trouble
Regulator/rectifier trouble
Alternator trouble
Wiring faulty
Battery Overcharged:
Regulator/rectifier trouble
Battery trouble
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17-6 APPENDIX
Cable, Wire, and Hose Routing
1.
2.
3.
4.
5.
6.
7.
Brake Cable
Left Switch Housing
Choke Cable
Clamp
Brake Hose
Throttle Cable
Fuel Tank Vent Hose
8. LED Indicator
9. Neutral Indicator Light Lead (LG, BR)
10. Oil Pressure/Temperature Warning Indicator Light
Lead (W/G, BR)
11. Reverse Indicator Light Lead (R/W, BR)
12. Band
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APPENDIX 17-7
Cable, Wire, and Hose Routing
1.
2.
3.
4.
5.
6.
Band
Cover
Drive Belt Failure Detecting Switch Fuse 5 A
Oil Cooler Fan Fuse 20 A
Seat Bracket
Grommet
7.
8.
9.
10.
11.
Seat Latch
Cover (for U.S.A. model, Speedometer Leads)
Cover
Fold the cover.
Tie the cover with band.
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17-8 APPENDIX
Cable, Wire, and Hose Routing
1.
2.
3.
4.
Rear Brake Lever
Parking Brake Lock Lever
Variable Differential Control Lever
Variable Differential Control Cable
5. Cable Adjuster
6. Handle Holder Clamp
7. Variable Differential Operating Lever
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APPENDIX 17-9
Cable, Wire, and Hose Routing
1.
2.
3.
4.
2WD/4WD Actuator
2WD/4WD Actuator Breather Tube
2WD/4WD Actuator Lead
Band
5. Clamp
6. Do not interfere the actuator lead and tube with
tie-rod etc..
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17-10 APPENDIX
Cable, Wire, and Hose Routing
1.
2.
3.
4.
5.
6.
Oil Cooler
Oil Pipe Joint Nut
Oil Screen
Oil Pressure Switch
Oil Hose Banjo Bolts
to Air Cleaner
7.
8.
9.
10.
11.
12.
Fix oil pressure switch lead with clamp.
Clamp
Grommets
Oil Cooler Mounting Bolt
Damper
Oil Hose
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APPENDIX 17-11
Cable, Wire, and Hose Routing
1.
2.
3.
4.
Rear Final Gear Case Breather Tube
2WD/4WD Actuator Breather Tube
Front Final Gear Case Breather Tube
Band
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17-12 APPENDIX
Cable, Wire, and Hose Routing
1. Mark
2. Align the duct groove with the mark on the carburetor.
3. Carburetor Holder
4. Align the carburetor holder groove with the mark
on the carburetor.
5. Carburetor Vent Tube
6. View from Upside
7. from Cylinder Head
8.
9.
10.
11.
Engine Breather Hose
Starter Motor
Carburetor Drain Tube
Run the carburetor drain tube between the
crankcase and starter motor.
12. Align the duct groove with the mark on the carburetor.
13. Snaps
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APPENDIX 17-13
Cable, Wire, and Hose Routing
1.
2.
3.
4.
5.
Fuse
Band
Main Harness
Battery (+) Cable
Battery (–) Cable
6. Right Headlight Lead
7. Left Headlight Lead
8. Rotate head of band forward to prevent interference with rear fender.
Property of www.SmallEngineDiscount.com - Not for Resale
17-14 APPENDIX
Cable, Wire, and Hose Routing
1.
2.
3.
4.
5.
6.
White Mark
Band
Carburetor Heater Leads
Clamp on Torque Converter Cover
Frame Ground Lead
2WD/4WD Actuator Breather Tube
7.
8.
9.
10.
11.
Igniter
Regulator/Rectifier
Rear Brake Cable
Brake Pedal Light Switch
Speed Sensor Connector
Property of www.SmallEngineDiscount.com - Not for Resale
APPENDIX 17-15
Cable, Wire, and Hose Routing
1.
2.
3.
4.
5.
6.
Band.
Rear Final Gear Case Breather Tube
Brake Cable (Rear)
Brake Cable (Parking)
Torque Converter Cover Intake Duct
Circlip
Property of www.SmallEngineDiscount.com - Not for Resale
17-16 APPENDIX
Cable, Wire, and Hose Routing
1.
2.
3.
4.
5.
6.
7.
Band
Carburetor
Oil Pressure Switch
to Starter Motor
Clamp
Forward/Reverse Detecting Sensor
Batter (+) Terminal
8.
9.
10.
11.
12.
Main Fuse 30 A
Accessory Fuse 5 A
Air Temperature Sensor
Front Side
Apply grease (Amoco rykon premium grease No.
2 EP Green) to terminals of neutral and reverse
position switch.
Property of www.SmallEngineDiscount.com - Not for Resale
APPENDIX 17-17
Cable, Wire, and Hose Routing
1.
2.
3.
4.
5.
6.
7.
8.
9.
Battery Vent Hose
Band
Clamp
Starter Motor
Battery
Starter Relay
Actuator Controller
Inside
Front Side
10.
11.
12.
13.
14.
15.
16.
17.
Battery (+) Cable
Battery (–) Cable
Starter Circuit Relay (Brake)
Starter Circuit Relay (Neutral)
Actuator Controller
Main Fuse 30 A
Accessory Fuse 5 A
Starter Relay
Property of www.SmallEngineDiscount.com - Not for Resale
17-18 APPENDIX
Cable, Wire, and Hose Routing
1.
2.
3.
4.
5.
6.
Variable Differential Control Cable
Throttle Cable
Front Brake Hose
Choke Cable
Rear (Parking) Brake Cable
Clamp
Property of www.SmallEngineDiscount.com - Not for Resale
">
Hello! I've read through the Kawasaki Prairie 360 service manual. This comprehensive document provides detailed instructions and specifications for servicing and maintaining this all-terrain vehicle. I'm ready to answer your questions regarding repair and maintenance procedures.
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Key features

Engine maintenance
Transmission
Final drive
Suspension
Brakes
Steering
Electrical system
Frequently asked questions

API SF or SG, API SH or SJ with JASO MA, SAE 10W-40
2.3 L (2.17 US qt)
MOBIL Fluid 424 or Kawa Chem Gear & Wet Brake Oil (CITGO TRANSGARD TRACTOR HYDRAULIC FLUID)
900 mL (0.95 US qt)
The manual provides detailed instructions on how to adjust the rear brake pedal and lever. See the Periodic Maintenance section of the manual for more information.
User questions

Patricia C.

How should the camshaft chain tensioner be handled during removal and installation?
The camshaft chain tensioner is a non-return type. When removing it, do not loosen the mounting bolts halfway, as retightening from that position can cause damage. It must be fully removed and reset during installation. Crucially, do not turn the crankshaft while the tensioner is removed to avoid disrupting cam timing and damaging valves.
Patricia C.

How is correct cam timing set during installation or reassembly?
To set correct cam timing, align the mark on the camshaft sprocket with the pointer on the cylinder head, and the 'T' mark on the alternator rotor with the slot in the alternator cover. If resistance is felt while turning the crankshaft, stop immediately to prevent bending the valves.
Patricia C.

What steps are important when installing the camshaft chain?
During installation, always pull the camshaft chain taut while turning the crankshaft, especially if it is loose, to prevent kinking on the lower (crankshaft) sprocket, which can damage both the chain and sprocket. Ensure the camshaft chain guides are correctly in place.
James O.

What maintenance guidelines apply to the drive belt?
The drive belt requires inspection at least every 90 days of vehicle use, or more frequently if the vehicle is subjected to hard usage. If measurements exceed the service limit, or if the belt shows cracks, breaks, or peeling, it must be replaced.
Patricia C.

What components need to be removed to access the camshaft chain?
To remove the camshaft chain, typically remove the camshaft sprocket, starter clutch gear, and camshaft chain guard, in addition to the chain itself.
Patricia C.

How should camshaft chain guides be inspected for wear?
Visually inspect the rubber on the camshaft chain guides. If the rubber is damaged, cut, or has missing pieces, the guide should be replaced.
Patricia C.

What is the function of the camshaft (timing) chain in an engine?
The camshaft chain, also known as a timing chain, is a crucial component in an engine's top end. It works with guides and a tensioner to ensure proper cam timing, which is essential for the engine's good running condition.
What type of engine oil should I use in my KVF 360?

How much engine oil does my Prairie 360 hold?

What kind of final drive oil should I use in my KVF 360?

How much final drive oil does my Prairie 360 hold?

How do I adjust the rear brake pedal and lever on my Prairie 360?

Patricia C.

Patricia C.

Patricia C.

James O.

Patricia C.

Patricia C.

Patricia C.

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