KLX450R (2011) - Bike KAWASAKI - Free user manual and instructions

Brand	Kawasaki
Model	KLX450R (2011)
Product Type	Off-road motorcycle
Engine Displacement	449 cc
Engine Type	4-stroke, single cylinder, DOHC
Cooling System	Liquid-cooled
Fuel System	Keihin FCR40 carburetor
Transmission	5-speed, constant mesh, return shift
Final Drive	Chain drive
Front Suspension	48 mm inverted fork, fully adjustable
Rear Suspension	Uni-Trak with piggyback reservoir, adjustable
Front Brakes	Single 250 mm disc, 2-piston caliper
Rear Brakes	Single 240 mm disc, 1-piston caliper
Seat Height	940 mm (37.0 in)
Ground Clearance	325 mm (12.8 in)
Fuel Capacity	8.0 L (2.1 US gal)
Weight (curb)	118 kg (260 lb)
Oil Capacity (with filter)	1.1 L (1.16 US qt)
Spark Plug	NGK CR8E or equivalent
Battery	12V, maintenance-free
Maintenance Interval	Oil change every 15 hours, valve check every 30 hours
Key Functions	Electric start, choke, engine stop switch

Frequently Asked Questions - KLX450R (2011) KAWASAKI

What type of oil should I use for the KLX450R?

Use a high-quality 10W-40 or 10W-50 4-stroke motorcycle oil that meets API SG or higher. For optimal clutch performance, use oil specifically labeled for wet clutch applications.

How often should I change the oil?

Change the oil every 15 hours of riding under normal conditions. If riding in severe conditions (sand, mud, racing), change it more frequently. Always replace the oil filter every other change.

What is the correct tire pressure for the KLX450R?

Recommended tire pressure is 15 psi (1.0 bar) for front and 15 psi (1.0 bar) for rear for typical off-road use. Adjust based on terrain and rider preference.

How do I adjust the chain slack?

Chain slack should be 40-50 mm (1.6-2.0 in) at the midpoint of the lower chain run. Loosen the rear axle nut, turn the adjuster bolts evenly on both sides, then retighten the axle nut to 65 N·m (48 ft·lb).

What spark plug does the KLX450R use?

The standard spark plug is an NGK CR8E (or equivalent). The gap should be set to 0.7-0.8 mm (0.028-0.031 in). Replace every 30-50 hours of riding.

Why won't my KLX450R start?

Common causes include: empty fuel tank, clogged fuel line or carburetor, dead battery (if electric start), or dirty spark plug. Ensure the kill switch is in the 'Run' position and the choke is engaged when cold.

How often should I clean the air filter?

Clean the air filter after every ride in dusty conditions, or every 5-10 hours of riding. Use foam filter cleaner and re-oil with air filter oil. Replace the filter if damaged.

What is the recommended valve adjustment interval?

Check and adjust valve clearances every 30 hours of riding. Intake clearance should be 0.10-0.15 mm (0.004-0.006 in), exhaust clearance 0.15-0.20 mm (0.006-0.008 in) when cold.

Can I use ethanol-blended fuel in the KLX450R?

It is recommended to use unleaded gasoline with no more than 10% ethanol (E10). Higher ethanol content can cause carburetor corrosion and performance issues. Always empty the carburetor if storing the bike for more than a month.

How do I winterize my KLX450R?

Add fuel stabilizer to a full tank, run the engine for 10 minutes, then drain the carburetor. Remove the battery and store it on a trickle charger. Clean and lubricate the chain, and store the bike in a dry place.

USER MANUAL KLX450R (2011) KAWASAKI

Exterior view of a white Kawasaki D4 motorcycle with visible suspension and wheelbase (no text or symbols)

Motorcycle Service Manual

Quick Reference Guide

General Information 1
Periodic Maintenance 2
Fuel System 3
Cooling System 4
Engine Top End 5
Engine Right Side	6
Engine Lubrication System	7
Engine Removal/Installation	8
Crankshaft/Transmission	9
Wheels/Tires	10
Final Drive	11
Brakes	12
Suspension	13
Steering	14
Frame	15
Electrical System	16
Appendix	17

This quick reference guide will assist you in locating a desired topic or procedure.

• Bend the pages back to match the black tab of the desired chapter number with the black tab on the edge at each table of contents page.
• Refer to the sectional table of contents for the exact pages to locate the specific topic required.

Motorcycle Service Manual

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

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

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

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

LIST OF ABBREVIATIONS

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

COUNTRY AND AREA CODES

AU	Australia	EUR	Europe
CA	Canada	US	United States
CAL	California

EMISSION CONTROL INFORMATION

To protect the environment in which we all live, Kawasaki has incorporated crankcase emission (1) and exhaust emission (2) control systems in compliance with applicable regulations of the United States Environmental Protection Agency and California Air Resources Board. Additionally, Kawasaki has incorporated an evaporative emission control system (3) in compliance with applicable regulations of the United States Environmental Protection Agency.

1. Crankcase Emission Control System

This system eliminates the release of crankcase vapors into the atmosphere. Instead, the vapors are routed through an oil separator to the intake side of the engine. While the engine is operating, the vapors are drawn into the combustion chamber, where they are burned along with the fuel and air supplied by the fuel injection system.

2. Exhaust Emission Control System

This system reduces the amount of pollutants discharged into the atmosphere by the exhaust of this vehicle. The fuel, ignition and exhaust systems of this vehicle have been carefully designed and constructed to ensure an efficient engine with low exhaust pollutant levels.

3. Evaporative Emission Control System

The evaporative emission control system for this vehicle consists of low permeation fuel hoses and a fuel tank.

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

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

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

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

NOTE

○ The phrase “remove or render inoperative any device or element of design” has been generally interpreted as follows.

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

a. Maladjustment of vehicle components such that the emission standards are exceeded.
b. Use of replacement parts or accessories which adversely affect the performance or durability of the motorcycle.
c.Addition of components or accessories that result in the vehicle exceeding the standards.
d. Permanently removing, disconnecting, or rendering inoperative any component or element of design of the emission control systems.

WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL LAW, THE VIOLATION OF WHICH IS PUNISHABLE BY CIVIL PENALTIES NOT EXCEEDING \$10 000 PER VIOLATION.

TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED

Federal law prohibits the following acts or the causing thereof. (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.

Among those acts presumed to constitute tampering are the acts listed below.

• Replacement of the original exhaust system or muffler with a component not in compliance with Federal regulations.
• Removal of the muffler or any internal portion of the muffler.
• Removal of the air box or air box cover.
• Modifications to the muffler or air intake system by cutting, drilling, or other means if such modifications result in increased noise levels.

Foreword

This manual is designed primarily for use by trained mechanics in a properly equipped shop. However, it contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work. A basic knowledge of 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 Motorcycle parts. Special tools, gauges, and testers that are necessary when servicing Kawasaki motorcycles are introduced by the Service Manual. Genuine parts provided as spare parts are listed in the Parts Catalog.
• Follow the p 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 symbols, heed their instructions! Always follow safe operating and maintenance practices.

DANGER

DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury.

WARNING

WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION

CAUTION indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

NOTICE

NOTICE is used to address practices not related to personal injury.

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

NOTE

○ This note symbol indicates points of particular interest for more efficient and convenient operation.

• Indicates a procedural step or work to be done.
  ○Indicates a procedural sub-step or how to do the work of the procedural step it follows. It also precedes the text of a NOTE.
  ★Indicates a conditional step or what action to take based on the results of the test or inspection in the procedural step or sub-step it follows.

In most chapters an exploded view illustration of the system components follows the Table of Contents. In these illustrations you will find the

instructions indicating which parts require specified tightening torque, oil, grease or a locking

agent during assembly.

General Information

Table of Contents

Before Servicing 1-2

Model Identification.... 1-7

General Specifications.... 1-8

Unit Conversion Table 1-11

1-2 GENERAL INFORMATION

Before Servicing

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

Especially note the following:

Battery Ground

Before completing any service on the motorcycle, disconnect the battery cables from the battery to prevent the engine from accidentally turning over. Disconnect the ground cable (−) first and then the positive (+). When completed with the service, first connect the positive (+) cable to the positive (+) terminal of the battery then the negative (−) cable to the negative terminal.

Edges of Parts

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

DISASSEMBLY ASSEMBLY GB020248 $

Illustration of hands holding a cylindrical engine block with a no-handled hand symbol nearby (no text or labels)

Solvent

Use a high-flash point solvent when cleaning parts. High-flush point solvent should be used according to directions of the solvent manufacturer.

Solvent GB02005B S

Cleaning vehicle before disassembly

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

Line drawing of a motorcycle with hands operating the engine compartment (no text or symbols)

Before Servicing

Arrangement and Cleaning of Removed Parts

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

Technical line drawing of a mechanical assembly with gears and components (no text or symbols)

Storage of Removed Parts

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

Technical line drawing of a mechanical assembly with gears, bolts, and housing (no text or symbols)

Inspection

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

Line drawing of a hand holding a cylindrical object with motion lines, next to a small black dot and a curved line (no text or symbols)

Replacement Parts

Replacement Parts must be KAWASAKI genuine or recommended by KAWASAKI. Gaskets, O-rings, Oil seals, Grease seals, circlips, cotter pins or self-locking nuts must be replaced with new ones whenever disassembled.

Genuine Parts Kawasaki 08020108 S

Assembly Order

In most cases assembly order is the reverse of disassembly, however, if assembly order is provided in this Service Manual, follow the procedures given.

Line drawing of hands operating a mechanical device with gears and a tool (no text or symbols)

1-4 GENERAL INFORMATION

Before Servicing

Tightening Sequence

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

Tightening Torque

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

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

Force

Use common sense during disas sembly and assembly, excessive force can cause expensive or hard to repair damage. When necessary, remove screws that have a non-permanent locking agent applied using an impact driver. Use a plastic-faced mallet whenever tapping is necessary.

Gasket, O-ring

Hardening, shrinkage, or damage of both gaskets and O-rings after disassembly can reduce sealing performance. Remove old gaskets and clean the sealing surfaces thoroughly so that no gasket material or other material remains. Install new gaskets and replace used O-rings when re-assembling

Liquid Gasket, Non-permanent Locking Agent

For applications that require Liquid Gasket or a Non-permanent Locking agent, clean the surfaces so that no oil residue remains before applying liquid gasket or Non-permanent locking agent. Do not apply them excessively. Excessive application can clog oil passages and cause serious damage.

Technical diagram of a mechanical assembly with numbered components and a hand holding a lever

Line drawing of a hand using a tool to measure a cylindrical object, with no visible text or symbols.

Line drawing of a mechanical component being inserted into a housing (no text or symbols)

Line drawing of two hands adjusting a flange with a sun symbol (no text or labels)

GB02016B $

Before Servicing

Press

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

Technical line drawing of a mechanical assembly with hands and a tool, no visible text or symbols

Ball Bearing and Needle Bearing

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

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

Technical diagram of a mechanical assembly with two components and a central bearing (no text or symbols)

Oil Seal, Grease Seal

Do not remove pressed oil or grease seals unless removal is necessary. Replace with new ones whenever removed. Press new oil seals with manufacture and size marks facing out. Make sure the seal is aligned properly when installing.

GB020198 S

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

Grease GB02046B51 C

Circlips, Cotter Pins

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

Line drawing of hands using a tool to draw or mark a cylindrical object (no text or symbols present)

1-6 GENERAL INFORMATION

Before Servicing

Lubrication

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

Line drawing of hands assembling a mechanical gear with a labeled oil dropper (no text or symbols on the diagram itself)

Direction of Engine Rotation

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

Technical line drawing of a mechanical component with no visible text or symbols

Electrical Leads

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

Y / R GB02023B S

Instrument

Use a meter that has enough accuracy for an accurate measurement. Read the manufacture's instructions thoroughly before using the meter. Incorrect values may lead to improper adjustments.

Line drawing of a hand using a multimeter to test electrical components (no text or symbols visible)

Model Identification

KLX450A8F Left Side View

Side profile of a Kawasaki Drimester motorcycle with visible suspension and wheelbase (no text or symbols on the body)

KLX450A8F Right Side View

Side profile of a Kawasaki 4-wheeled off-road motorcycle with visible tracks and wheels (no text or symbols on the bike body)

Frame Number Engine Number

Close-up of a motorcycle's front wheel and engine compartment, showing internal components and a marked arrow (no text or symbols)

Close-up of a mechanical assembly with a textured component and a directional arrow (no visible text or symbols)

1-8 GENERAL INFORMATION

General Specifications

Items KLX450A8F ~ ABF
Dimensions
Overall Length	2 180 mm (85.83 in.), (AU) (EUR) 2 175 mm (85.63 in.)
Overall Width 820 mm (32.3 in.)
Overall Height	1 255 mm (49.41 in.), (AU) (EUR) 1 250 mm (49.21 in.)
Wheelbase 1 480 mm (58.27 in.)
Road Clearance	320 mm (12.6 in.), (AU) (EUR) 315 mm (12.4 in.)
Seat Height	940 mm (37.0 in.), (AU) (EUR) 935 mm (36.8 in.)
Dry Mass (KLX450A8F) 115 kg	(254 lb)
Curb Mass	(KLX450A9F ~ ABF) 126 kg (278 lb)
Fuel Tank Capacity 8 L (2.1 US gal)
Performance
Minimum Turning Radius	-
Engine
Type	4-stroke, single cylinder, DOHC 4 valve
Cooling System	Liquid-cooled
Bore and Stroke	96.0 × 62.1 mm (3.78 × 2.44 in.)
Displacement	449 cm ^3 (27.4 cu in.)
Compression Ratio	12.0 : 1
Carburetion System	Carburetor, KEIHIN FCR-MX40
Starting System	Electric starter, Primary kick
Ignition System	Digital AC-CDI
Timing Advance
Ignition Timing	BTDC 10.2° @1 800 r/min (rpm)
Spark Plug	NGK CPR8EB-9
Valve Timing:
Intake:
Open	BTDC 38°
Close	ABDC 66°
Duration	284°
Exhaust:
Open	BBDC 68°
Close	ATDC 36°
Duration	284°
Lubrication System	Forced lubrication (semi-dry sump)
Engine Oil:
Type	API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2
Viscosity	SAE 10W-40
Capacity	1.3 L (1.4 US qt)
Drive Train
Primary Reduction System:
Type	Gear
Reduction Ratio	2.727 (60/22)
Clutch Type	Wet, multi disc

General Specifications

Items KLX450A8F ~ ABF
Transmission:Type 5-speed, constant mesh,Gear ratios:1st 2.167 (26/12)2nd 1.533 (23/15)3rd 1.188 (19/16)4th 0.950 (19/20)5th 0.810 (17/21)Final Drive System:Type Chain driveReduction Ratio 3.846 (50/13)Overall Drive Ratio 8.492 @Top gear	return shift
FrameType Tubular, semi-double cradleSteering AngleCaster (rake angle)TrailFront tire:SizeMake/TypeRear tire:SizeMake/TypeRim size:FrontRearFront suspension:Type Telescopic fork (up sidedown)Wheel travelRear suspension:Type Swingarm (New Uni-trak)Wheel travelBrake type:Front and RearEffective disc diameter:Front (effect. dia.)Rear (effect. dia.)	42° to either side27.7°, (AU) (EUR) 28°122 mm (4.80 in.)80/100-21 51M, (AU) (EUR) 80/100-21 M/C 51PBRIDGESTONE M401, Tube type, (AU) (EUR) ED03, Tube type110/100-18 64M, (AU) (EUR) 120/90-18 M/C 65PBRIDGESTONE M402, Tube type, (AU) (EUR) ED04, Tube type21 × 1.6018 × 2.15down)305 mm (12.0 in.)315 mm (12.4 in.)Single disc225 mm (8.86 in.)215 mm (8.46 in.)
Electrical EquipmentBatteryHeadlight:Type Semi-sealed beamBulb	12 V 6 Ah12 V 35 W

1-10 GENERAL INFORMATION

General Specifications

Items KLX450A8F	~ ABF
Tail Light LEDMagneto:Rated Output 2.0 A / 14 V

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

Unit Conversion Table

Prefixes for Units:

Prefix Symbol Power
mega M × 1 000 000kilo k × 1 000centi c × 0 . 0 1milli m × 0 . 0 0 1micro μ × 0.000001

Units of Mass:

kg	×	2.205	=	lb
g	×	0.03527	=	oz

Units of Volume:

L	×	0.2642	=	gal (US)
L	×	0.2200	=	gal (imp)
L	×	1.057	=	qt (US)
L	×	0.8799	=	qt (imp)
L	×	2.113	=	pint (US)
L	×	1.816	=	pint (imp)
mL	×	0.03381	=	oz (US)
mL	×	0.02816	=	oz (imp)
mL	×	0.06102	=	cu in

Units of Force:

N	×	0.1020	=	kgf
N	×	0.2248	=	lb
kgf	×	9.807	=	N
kgf	×	2.205	=	lb

Units of Length:

km	×	0.6214	=	mile
m ×	3.281	=	ft
mm	×	0.03937	=	in

Units of Torque:

N·m	×	0.1020	=	kgf·m
N·m	×	0.7376	=	ft·lb
N·m	×	8.851	=	in·lb
kgf·m	×	9.807	=	N·m
kgf·m	×	7.233	=	ft·lb
kgf·m	×	86.80	=	in·lb

Units of Pressure:

kPa ×	0.01020 =		kgf/cm ^2
kPa ×	0.1450 =		psi
kPa	×	0.7501	=	cm Hg
kgf/cm ^2	×	98.07	=	kPa
kgf/cm ^2	×	14.22	=	psi
cm Hg	×	1.333	=	kPa

Units of Speed:

km/h

×

0.6214

=

mph

Units of Power:

kW	×	1.360	=	PS
kW	×	1.341	=	HP
PS	×	0.7355	=	kW
PS	×	0.9863	=	HP

Units of Temperature:

Periodic Maintenance

Table of Contents

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

Torque and Locking Agent.... 2-4

Specifications 2-9

Special Tools 2-11

Periodic Maintenance Procedures..... 2-12

Fuel System.... 2-12

Fuel Hose and Connection Inspection.... 2-12

Throttle Grip Free Play Inspection 2-12

Throttle Grip Free Play Adjustment 2-12

Hot Starter Lever Free Play Inspection.... 2-13

Idle Speed Inspection 2-13

Idle Speed Adjustment.... 2-14

Air Cleaner Element Cleaning and Inspection.... 2-14

Fuel Inspection.... 2-16

Fuel Tank, Filter and Tap Cleaning.... 2-17

Fuel Tap and Filter Inspection..... 2-17

Cooling System.... 2-17

Coolant Level Inspection.... 2-18

Coolant Deterioration Inspection.. 2-18

Radiator Hoses and Connections Inspection.... 2-19

Engine Top End 2-19

Vacuum Switch Valve Test 2-19

Valve Clearance Inspection ..... 2-20

Valve Clearance Adjustment...... 2-21

Cylinder Head Warp Inspection ... 2-23

Cylinder Wear Inspection 2-23

Piston/Cylinder Clearance 2-24

Piston, Piston Ring and Piston Pin Replacement.... 2-24

Spark Arrester Cleaning.... 2-24

Engine Right Side 2-25

Clutch Lever Free Play Check..... 2-25

Clutch Lever Free Play Adjustment 2-26

Friction and Steel Plates Inspection.... 2-26

Engine Lubrication System...... 2-26

Engine Oil Change.... 2-26

Oil Filter Change 2-27

Breather Hose Inspection 2-28

Crankshaft/Transmission 2-29

Crankshaft Inspection 2-29

Wheel/Tires 2-29

Air Pressure Inspection/Adjustment 2-29

Tires Inspection.... 2-30

Spoke Tightness Inspection...... 2-30

Rim Runout Inspection.... 2-31

Wheel Bearing Inspection...... 2-31

Final Drive.... 2-32

Drive Chain Slack Inspection ..... 2-32

Drive Chain Slack Adjustment ..... 2-32

Drive Chain Wear Inspection ..... 2-33

Drive Chain Lubrication.... 2-34

Sprocket Wear Inspection...... 2-34

Rear Sprocket Warp Inspection... 2-35

Brakes.... 2-35

Brake Lever and Pedal Position Adjustment 2-35

Brake Fluid Level Inspection...... 2-36

Brake Fluid Change.... 2-37

Brake Pad Wear Inspection ..... 2-39

Brake Master Cylinder Cup and Dust Seal Replacement .... 2-39

Caliper Piston Seal and Dust Seal Replacement.... 2-41

Brake Hose and Connection Check.... 2-44

Brake Hose Replacement...... 2-44

Suspension 2-45

Front Fork Inspection 2-45

Front Fork Oil Change (each fork leg) 2-45

Rear Shock Absorber Inspection . 2-54

Rear Shock Absorber Oil Change 2-54

Swingarm and Uni-Trak Linkage Inspection.... 2-59

Swingarm and Uni-Track Linkage Pivot Lubricate 2-59

Steering 2-59

Steering Inspection 2-59

Steering Adjustment 2-59

Stem Bearing Lubrication.... 2-61

Frame 2-61

Frame Inspection 2-61

Electrical System 2-62

Spark Plug Cleaning and Inspection.... 2-62

Cable Inspection 2-62

Lubrication 2-62

Nut, Bolt, and Fastener Tightness Inspection.... 2-63

Tightness Inspection.... 2-63

Periodic Maintenance Chart

The maintenance must be done in accordance with this chart to keep the motorcycle in good running condition.

Periodic Inspection

FREQUENCY		Traveled Distance km (mi)					See Page
		Every 100 (60) or 2.5 hr	Every 500 (300) or 7.5 hr	Every 1 000 (600) or 15 hr	Every 1 500 (900) or 30 hr	Every 2 000 (1 200) or 60 hr
OPERATION
ENGINE	Spark plug-clean, gap † Every 500 km (300 mi)	2 - 6 2
	Spark plug-inspect †		● ●	● ●			2 - 62
	Clutch cable-adjust Every 100 km (60 mi) 2 - 2 6
	Clutch and friction plates-inspect †	●	● ●	● ●			2 - 26
		After 2 000 km (1 200 mi), every 1 000 km (600 mi)
	Throttle cable-adjust	Every 100 km (60 mi)					2 - 12
	Air cleaner element-clean †	●	● ●	● ●			2 - 14
		After 2 000 km (1 200 mi), every 1 000 km (600 mi)
	Carburetor-inspect and adjust	●	● ●	● ●			2 - 13
	Cylinder head, cylinder-inspect			●		●	2 - 23
	Valve clearance-inspect †	●		●		●	2 - 20
		After 2 000 km (1 200 mi), every 1 000 km (600 mi)
	Hot starter cable-adjust	Every 100 km (60 mi) 2 - 1 3
	Spark arrester-clean	Every 6 000 km (3 750mi)					2 - 24
	Vacuum switch valve-inspect †			●		●	2 - 19
	Kick pedal and shift pedal-clean	●	● ●	● ●			-
	Engine sprocket-inspect †	●	● ●	● ●			2 - 34
	Coolant-inspect †	●	● ●	● ●			2 - 18
	Radiator hoses and connections-inspect †	●	● ●	● ●			2 - 19
	Crankshaft-inspect			●		●	2 - 29
	Breather hose-inspect	●	● ●	● ●			2 - 28
CHASSIS	Brake adjustment-inspect †	●	● ●	● ●			2 - 35
	Brake pad wear-inspect †	●	● ●	● ●			2 - 39
	Brake fluid level-inspect †	●	● ●	● ●			2 - 36
	Brake hoses, connections-inspect †	●	● ●	● ●			2 - 44
	Spoke tightness and rim runout-inspect †	●	● ●	● ●			2 - 30
	Wheel bearing-inspect †	●	● ●	● ●			2 - 31
	Frame-inspect and clean	●	● ●	● ●			2 - 61
	Drive chain wear-inspect †	●	● ●	● ●			2 - 33
	Drive chain-inspect and adjust	●	● ●	● ●			2 - 32
	Drive chain-lubricate	●	● ●	● ●			2 - 34
	Wheels/tires-inspect	●	● ●	● ●			2 - 30

Periodic Maintenance Chart

FREQUENCY		Traveled Distance km (mi)					See Page
		Every 100 (60) or 2.5 hr	Every 500 (300) or 7.5 hr	Every 1 000 (600) or 15 hr	Every 1 500 (900) or 30 hr	Every 2 000 (1 200) or 60 hr
OPERATION
CHASSIS	Rear sprocket-inspect †	● ●	● ● ●				2 - 35
	Front fork-inspect and clean	● ●	● ● ●				2 - 45
	Cable-inspect	● ●	● ● ●				2 - 62
	Fuel hose, connections-inspect †		● ●	● ●			2 - 12
	Fuel system-clean	● ●	● ● ●				2 - 17
	Steering play-inspect †	● ●	● ● ●				2 - 59
	Steering stem bearing-grease			●		●	2 - 61
	Swingarm and Uni-Trak linkage pivots-grease		● ●	● ●			2 - 59
	Swingarm and Uni-Trak linkage pivots-inspect †		● ●	● ●			2 - 59
	Nuts, bolts, fasteners-inspect †	● ●	● ● ●				2 - 63
	Rear shock absorber-inspect	● ●	● ● ●				2 - 54
	Chassis parts-lubricate	● ●	● ● ●				-

†: Replace, add, adjust, clean or torque if necessary.

Periodic Replacement Parts

FREQUENCY OPERATION	Traveled Distance km (mi)					See Page
	Every 100 (60) or 2.5 hr	Every 500 (300) or 7.5 hr	Every 1 000 (600) or 15 hr	Every 1 500 (900) or 30 hr	Every 2 000 (1 200) or 60 hr
Engine oil-change	Every 1 000 km (600 mi)					2 - 26
Piston and piston ring-replace	Every 1 500 km (900 mi)					2 - 24
Piston pin-replace	Every 1 500 km (900 mi)					2 - 24
Oil filter-replace	Every 1 000 km (600 mi)					2 - 27
Brake fluid-change	Every 2 years					2 - 3 7
Brake master cylinder cup and dust seal-replace	Every 2 years					2 - 39
Brake caliper piston seal and dust seal-replace	Every 2 years					2 - 41
Brake hoses-replace	Every 4 years					2 - 44
Front fork oil-change			●		●	2 - 45
Rear shock oil-replace			●		●	2 - 54
Fuel hose-replace	Every 4 years					2 - 12

2-4 PERIODIC MAINTENANCE

Torque and Locking Agent

Tighten all bolts and nuts to the proper torque using an accurate torque wrench. If insufficiently tightened, a bolt or nut may become damaged, strip an internal thread, or break and then fall out. The following table lists the tightening torque for the major bolts and nuts, and the parts requiring use of a non-permanent locking agent or liquid gasket.

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

Letters used in the "Remarks" column mean:

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

HL: Apply high-locking agent.

L: Apply a non-permanent locking agent to the threads.

Lh: Left-hand Threads

MO: Apply molybdenum disulfide oil.

S: Tighten the fasteners following the specified sequence.

Si: Apply Silicone grease.

R: Replacement Parts

2T: Apply 2-stroke oil.

T: First, tighten the stem locknut with 39 N·m (4.0 kgf·m, 29 ft·lb) of torque, then loosen it and retighten it with 4.9 N·m (0.50 kgf·m, 43 in·lb) of torque.

Fastener	Torque			Remarks
	N·m kgf	·m ft·lb
Fuel System
Throttle Pulley Cover Bolt 3.4 0.35 30 in·lb
Throttle Cable Mounting Bolts	6.9	0.70	61 in·lb
Vacuum Switch Valve Bracket Bolts	9.8	1.0	87 in·lb
Fuel Tap Knob Screws	0.80	0.080	7.0 in·lb
Rear Frame Mounting Bolts	34	3.5	25
Cooling System
Water Pump Cover Bolts	9.8	1.0	87 in·lb
Coolant Drain Plug	7.0	0.70	62 in·lb
Water Pump Impeller Bolt	9.8	1.0	87 in·lb
Right Engine Cover Bolts	9.8	1.0	87 in·lb
Radiator Hose Clamp Screws	3.0	0.30	27 in·lb
Engine Top End
Cylinder Head Cover Bolts	9.8	1.0	87 in·lb
Cylinder Head Bolts (M10)	59	6.0	44	S, MO
Cylinder Head Bolts (M6)	12	1.2	106 in·lb	S
Cylinder Bolt	12	1.2	106 in·lb
Camshaft Cap Bolts	9.8	1.0	87 in·lb	S, MO
Camshaft Sprocket Bolts	12	1.2	106 in·lb	L
Carburetor Holder Clamp Screws	2.0	0.20	18 in·lb
Plug	20	2.0	15	L
Rear Camshaft Chain Guide Bolt	15	1.5	11
Oil Pump (Scavenge) Cover Bolts	9.8	1.0	87 in·lb
Chain Tensioner Mounting Bolts	9.8	1.0	87 in·lb
Chain Tensioner Cap Bolt	5.0	0.51	44 in·lb
Water Hose Fitting Bolts	9.8	1.0	87 in·lb
Oil Line Plug	3.0	0.31	27 in·lb	L
Decompressor Plug Plate Bolt	9.8	1.0	87 in·lb

Torque and Locking Agent

Fastener	Torque			Remarks
	N·m kgf	m ft·lb
Vacuum Hose Fitting 8.8 0.90 78 in·lb L
Cylinder Head Pipe Mounting Bolt	9.8	1.0	87 in·lb
Exhaust Pipe Cover Bolts	12	1.2	106 in·lb
Rear Muffler Mounting Bolt	20	2.0	15
Front Muffler Mounting Bolt (First)	9.8	1.0	87 in·lb
Front Muffler Mounting Bolt (Final)	20	2.0	15
Exhaust Pipe Holder Nuts	20	2.0	15
Muffler End Mounting Bolts	10	1.0	89 in·lb
Spark Arrester Mounting Bolts	10	1.0	89 in·lb
Engine Right Side
Primary Gear Nut	98	10	72	Lh,R
Clutch Cover Bolts	9.8	1.0	87 in·lb
Right Engine Cover Bolts	9.8 1.0	87 in·lb
Clutch Spring Bolts	8.8 0.90	78 in·lb
Clutch Hub Nut	98	10	72	R
Ratchet Guide Bolt	8.8 0.90	78 in·lb
Kick Pedal Bolt	25	2.5	18	L
Ratchet Plate Mounting Bolt	9.8	1.0	87 in·lb	S
Ratchet Plate Mounting Screw	6.4	0.65	56 in·lb	L,S
Gear Set Lever Nut	8.8 0.90	78 in·lb
Shift Drum Cam Bolt	24	2.4	18	L
Engine Lubrication System
Engine Oil Drain Plug (M10) (Main)	20	2.0	15
Engine Oil Drain Plug (M6) (Sub)	7.0	0.71	62 in·lb
Oil Pump (Scavenge) Cover Bolts	9.8	1.0	87 in·lb
Oil Pump (Feed) Cover Bolts	9.8	1.0	87 in·lb
Right Engine Cover Bolts	9.8	1.0	87 in·lb
Piston Oil Nozzle	5.0	0.50	44 in·lb
Oil Filter Cover Bolt	9.8	1.0	87 in·lb
Oil Screen (Feed) Mounting Bolts	9.8	1.0	87 in·lb
Oil Pressure Relief Valve	15	1.5	11	HL
Breather Fitting	15	1.5	11	L
Oil Filler Cap	-	-	-	Hand-tighten
Engine Removal/Installation
Upper Engine Mounting Bolts (M10)	49	5.0	36
Middle Engine Mounting Nut (M10)	49	5.0	36	R
Lower Engine Mounting Nut (M10)	49	5.0	36	R
Upper Engine Bracket Bolts (M8)	29	3.0	21
Middle Engine Bracket Nuts (M8)	29	3.0	21	R
Swingarm Pivot Shaft Nut	98	10	72	R
Crankshaft/Transmission
Crankcase Bolts (M6)	12	1.2	106 in·lb	S
Crankcase Bolts (M7)	15	1.5	11	S

Torque and Locking Agent

Fastener	Torque			Remarks
	N·m kgf	m ft·lb
Gear Set Lever Nut 8.8 0.90 78 in·lb
Engine Oil Drain Plug (M6)(Sub)	7.0	0.71	62 in·lb
Engine Oil Drain Plug (M10)(Main)	20	2.0	15
Shift Drum Cam Bolt 24 2.4 18 L
Piston Oil Nozzle 4.0 0.41 35 in·lb
Bearing Retaining Screws	15	1.5	11	L
Balancer Weight Mounting Nut	52	5.3	38
Gear Position Switch Screws	2.9	0.30	26 in·lb	L
Wheels/Tires
Spoke Nipples	2.2 0.22	19 in·lb
Front Axle Nut	79 8.0	58
Front Axle Clamp Bolts	20	2.0	15	AL
Rear Axle Nut	110	11.2	81.1
Final Drive
Rear Sprocket Nuts	34 3.5	25	R
Engine Sprocket Nut	127	13.0	93.7
Brakes
Front Master Cylinder Clamp Bolts	8.8	0.90	78 in·lb	S
Brake Hose Banjo Bolts	25 2.5	18
Brake Pad Bolt	17 1.7	13
Caliper Bleed Valve	7.8	0.80	69 in·lb
Caliper Mounting Bolts	25 2.5	18
Front Brake Disc Mounting Bolts	10	1.0	89 in·lb	L
Brake Lever Pivot Bolt Locknut	5.9	0.60	52 in·lb
Brake Lever Pivot Bolt	5.9	0.60	52 in·lb	Si
Brake Reservoir Cap Screws	1.5	0.15	13 in·lb
Front Brake Light Switch Screw	1.2	0.12	10 in·lb
Brake Hose Banjo Bolts	25 2.5	18
Rear Master Cylinder Mounting Bolts	10	1.0	89 in·lb
Rear Master Cylinder Push Rod Locknut	17	1.7	13
Caliper Bleed Valve	7.8	0.80	69 in·lb
Brake Pad Bolt	17 1.7	13
Rear Brake Pad Bolt Plug	2.4	0.24	21 in·lb
Caliper Holder Shaft	27	2.8	20	Si
Brake Pedal Mounting Bolt	25	2.5	18	G,L
Rear Brake Disc Mounting Bolts	23	2.3	17	L
Brake Reservoir Cap Bolts	1.5	0.15	13 in·lb
Suspension
Base Valve Assembly	28 2.9	21
Front Fork Top Plug 30 3.1 22
Front Fork Clamp Bolts (Upper)	20	2.0	15	AL
Front Fork Clamp Bolts (Lower)	20	2.0	15	AL
Steering Stem Head Nut	98	10	72

Torque and Locking Agent

Fastener	Torque			Remarks
	N·m kgf	m ft·lb
Locknut/Adjuster Assembly	29 3.0	21
Adjuster Assembly 55 5.6 41 L
Front Axle Clamp Bolts	20	2.0	15	AL
Swingarm Pivot Shaft Nut	98	10	72	R
Rocker Arm Pivot Nut	59	6.0	44	R
Tie-rod Mounting Nut (Front, Rear)	59	6.0	44	R
Rear Shock Absorber Mounting Nut (Upper)	39 4.0	29	R
Rear Shock Absorber Mounting Nut (Lower)	34 3.5	25	R
Air Bleed Bolt	6.5	0.66	58 in·lb
Steering
Handlebar Clamp Bolts	25	2.5	18	2T
Steering Stem Head Nut	98	10	72
Steering Stem Nut	4.9	0.50	43 in·lb	T
Front Fork Clamp Bolts (Upper)	20	2.0	15	AL
Front Fork Clamp Bolts (Lower)	20	2.0	15	AL
Frame
Rear Frame Mounting Bolt	34	3.5	25
Upper Footpeg Bracket Bolts	54	5.5	40	L
Sidestand Nut	29	3.0	21	R
Electrical System
Spark Plug	13	1.3	115 in·lb
Starter Motor Terminal Nut	5.9	0.60	52 in·lb
Starter Motor Mounting Bolts	9.8	1.0	87 in·lb
Crankshaft Sensor Bolts	7.0	0.71	62 in·lb
Stator Bolts	4.0	0.41	35 in·lb	L
Flywheel Nut	98 10	72
Magneto Cover Bolts	9.8	1.0	87 in·lb
Timing Inspection Cap	-	-	-	Hand-Tighten
Flywheel Nut Cap	-	-	-	Hand-Tighten
Torque Limiter Cover Bolts	9.8	1.0	87 in·lb
Starter Motor Terminal Locknut	6.9	0.70	61 in·lb
Starter Motor Through Bolts	3.4	0.35	30 in·lb
Breather Fitting	15	1.5	11	L
Head Light Bracket Screws	1.4	0.14	12 in·lb
Gear Position Switch Screws	2.9	0.30	26 in·lb	L

2-8 PERIODIC MAINTENANCE

Torque and Locking Agent

Basic Torque for General Fasteners

Threads dia. Torque
(mm) N·m kgf·m ft·lb
5	3.4 ~ 4.9	0.35 ~ 0.50	30 ~ 43 in·lb
6	5.9 ~ 7.8	0.60 ~ 0.80	52 ~ 69 in·lb
8	14 ~ 19	1.4 ~ 1.9	10.0 ~ 13.5
10	25 ~ 34	2.6 ~ 3.5	19.0 ~ 25
12	44 ~ 61	4.5 ~ 6.2	33 ~ 45
14	73 ~ 98	7.4 ~ 10.0	54 ~ 72
16	115 ~ 155	11.5 ~ 16.0	83 ~ 115
18	165 ~ 225	17.0 ~ 23.0	125 ~ 165
20	225 ~ 325	23 ~ 33	165 ~ 240

Specifications

Item Standard Service Limit
Fuel SystemThrottle Grip Free PlayHot Starter Lever Free PlayAir Cleaner Element Oil	2 ~ 3 mm (0.08 ~ 0.12 in.)0.5 ~ 1.0 mm (0.02 ~ 0.04 in.)High quality foam air filter oil	- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
Cooling SystemCoolant:Type (recommended)Color GreenMixed RatioFreezing PointTotal Amount	Permanent type antifreezeSoft water 50% and coolant 50%-35 °C (-31 °F)1.05 L (1.11 US qt)	- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

2-10 PERIODIC MAINTENANCE

Specifications

Item Standard Service Limit
Standard Tire:Front:Size 80/100-21 51M - - -(AU) (EUR) 80/100-21 M/C 51PMake BRIDGESTONE - -(AU) (EUR) ED03, Tube - -(AU) (EUR)120/90-18 M/C 65P - -(AU) (EUR) ED04, Tube - -(AU) (EUR) ED04, Tube - -(AU) (EUR) ED04, Tube - -(AU) (EUR) ED04, Tube - -(AU) (EUR) ED04, Tube - -(AU) (EUR) ED04, Tube - -(AU) (EUR) ED04, Tube - -(AU) (EUR) ED04, Tube - -(AU) (EUR) ED04, Tube - -(AU)(AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUR) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD), (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD)	(AU) (EUR) 80/100-21 M/C 51P-(AU) (EUR) ED03, Tube - -(AU) (EUR)120/90-18 M/C 65P - -(AU) (EUR) ED04, Tube - -(AU) (EUR) ED04, Tube - -(AU) (EUR) ED04, Tube - -(AU) (EUR) ED04, Tube - -(AU) (EUR) ED04, Tube - -(AU) (EUR)ED04, Tube - -(AU) (EUR) ED04, Tube - -(AU) (EUR) ED04, Tube - -(AU) (EUR) ED04, Tube - -(AU) (EUR) ED04, Tube - -(AU) (EUR) ED04, Tube - -(AU) (EUR) ED04, Tube - -(AU) (EUR) ED04, Tube - -(AU) (EUR) ED04, tube - -(AU) (EUR) ED04, tube - -(AU) (EUR) ED04, tube - -(AU) (EUR) ED04, tube - -(AU) (EUR) ED04, tube - -(AU) (EUR) ED04, tube - -(AU) (EUR) ED04, tube - -(AU) (EUR) ED04, tube - -(AU) (EUR) ED04, tube - -(AU)(AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD)	- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
Rear:Size 110/100-18 64M - -(AU) (EUR)120/90-18 M/C 65P - -(AU) (EUR)120/90-18 M/C 65P - -(AU) (EUR)120/90-18 M/C 65P - -(AU) (EUR)120/90-18 M/C 65P - -(AU) (EUR)120/90-18 M/C 65P - -(AU) (EUR)120/18 64M - -(AU) (EUR)120/90-18 M/C 65P - -(AU) (EUR)120/90-18 M/C 65P - -(AU) (EUR)120/90-18 M/C 65P - -(AU) (EUR)120/90-18 M/C 65P - -(AU) (EUR)120/90-18 M/C 65P - -(AU) (EUR)120/90-18 M/C 65P - -(AU) (EUR)120/90-18 M/C 65P - -(AU) (EUR)120/90-18 M/C 65P - -(AU) (EUR)120/90-18 M(C 65P - -(AU) (EUR)120/90-18 M/C 65P - -(AU) (EUR)120/90-18 M/C 65P - -(AU) (EUR)120/90-18 M/C 65P - -(AU) (EUR)120/90-18 M/C 65P - -(AU) (EUR) 120/90-18 M/C 65P - -(AU) (EUR)120/90-18 M/C 65P - -(AU) (EUR)120/90-18 M/C 65P - -(AU) (EUR)120/90-18 M/C 65P - -(AU) (EUR)120/90-18 M/C( 65P - -(AU) (EUR)120/90-18 M/C 65P - -(AU) (EUR)120/90-18 M/C 65P - -(AU) (EUR)120/90-18 M/C 65P - -(AU) (EUR)120/90-18 M/C 65P - -(AU) (EUR) (EUR)120/90-18 M/C 65P - -(AU) (EUR)120/90-18 M/C 65P - -(AU) (EUR)120/90-18 M/C 65P - -(AU) (EUR)120/90-18 M/C 65P - -(AU) (EUR)120/90- (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD) (AUD)
Final DriveDrive Chain SlackDrive Chain 20 Link LengthRear Sprocket Warp	52 ~ 58 mm (2.0 ~ 2.3 in.)317.5 ~ 318.2 mm (12.50 ~ 12.53 in.)0.4 mm (0.016 in.) or less	- - - -323 mm (12.7 in.)0.5 mm (0.020 in.)
BrakesBrake Lever Free PlayBrake Fluid:Type:FrontRearBrake pad lining thickness:FrontRear	(to suit rider)DOT3 or DOT4DOT43.8 mm (0.15 in.)6.4 mm (0.25 in.)	- - - -- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

TIR: Total Indicator Readings

Special Tools

Inside Circlip Pliers: 57001-143

Line drawing of a pair of pliers (no text or symbols)

Steering Stem Nut Wrench: 57001-1100

Technical line drawing of a adjustable wrench (no text or symbols present)

Jack: 57001-1238

Technical line drawing of a mechanical support structure (no text or symbols)

Spark Plug Wrench, Hex 16: 57001-1262

Technical line drawing of a mechanical tool or support structure (no text or symbols)

Filler Cap Driver: 57001-1454

Technical line drawing of a mechanical tool with two separate views of a gear or nut assembly (no text or symbols)

Top Plug Wrench, 49 mm: 57001-1653

Technical line drawing of a wrench tool (no text or symbols on the diagram itself)

2-12 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Fuel System

Fuel Hose and Connection Inspection

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

- Check the fuel hose.

★Replace the fuel hose if any fraying, cracks [B], bulges [C] or ozonic cranks [D] are noticed.

- Check that the hose [A] is securely connected and clamps [B] are tightened correctly.

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

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

Throttle Grip Free Play Inspection

- Check throttle grip free play [A] by lightly turning the throttle grip [B] back and forth.

★If the free play is improper, adjust the throttle cable.

Throttle Grip Free Play

Standard: 2 \~ 3 mm (0.08 \~ 0.12 in.)

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

★If the throttle grip does not return properly, check the throttle cable routing, grip free play, and cable damage. Then lubricate the throttle cable.

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

★If the idle speed increase, check the throttle cable free play and the cable routing.

Throttle Grip Free Play Adjustment

- Loosen the locknuts [A] [B] at the upper end of the throttle cable.

- Screw both throttle cable adjuster [C] [D] to give the throttle grip plenty of play.

- Turn out the decelerator adjuster [C] until there is no play when the throttle grip is completely closed.

- Tighten the locknut [A].

- Turn the accelerator cable adjuster [D] until 2 \~ 3 mm (0.08 \~ 0.12 in.) of throttle grip play is obtained.

- Tighten the locknut [B].

D A C B A 0505077851 C

Technical diagram of a mechanical assembly with labeled components A and B, likely for automotive or industrial inspection.

Close-up of a black trawler handle with labeled parts (A and B), no visible text or symbols beyond labels

C A B D 03058470

Periodic Maintenance Procedures

WARNING

Operation with an improperly adjusted, incorrectly routed or damaged cables could result in an unsafe riding Condition. Follow the service manual to make sure to correct any of these conditions.

Hot Starter Lever Free Play Inspection

• Slide the clutch lever dust cover [A] back.
• Check the hot starter lever play [B] when pulling the start lever [C] lightly.

Hot Starter Lever Free Play

Standard: 0.5 \~ 1.0 mm (0.02 \~ 0.04 in.)

★If the free play is improper, adjust the hot starter cable.

A B C 65058471 P

• Slide the adjuster cover [A] back.
• Loosen the locknut [B] and turn the adjuster [C] to obtain the proper lever free play.
• Tighten the locknut securely.
• Check that the hot starter lever moves smoothly from full open to close, and the lever closes quickly and completely in all steering positions by the return spring.
  ★If the hot starter lever does not return properly, check the hot starter cable routing, free play and cable damage. Then lubricate the hot starter cable.

C B A 0008472 F

Idle Speed Inspection

NOTICE

This motorcycle is designed for competition use only. Therefore, the radiator does not incorporate a cooling fan. Prolonged idling of the engine with no airflow through the radiator can cause coolant loss and engine overheating resulting in possible engine damage. Any riding conditions that increase engine temperature will further reduce idling time before coolant loss occurs. These conditions include high ambient temperature, sandy or muddy terrain, or other conditions causing high engine loads at low speeds. Furthermore, warming the engine up excessively before operation, or leaving idling with the hot engine temperature after operation results in the engine overheating, too.

2-14 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

• Start the engine and warm it up thoroughly.
• With the engine idling, turn the handlebar to both sides [A].
  ★If handlebar movement changes the idle speed, the throttle cable may be improperly adjusted or incorrectly routed, or it may be damaged. Be sure to correct any of these conditions before riding (see Cable, Wire, and Hose Routing section in the Appendix chapter).

WARNING

Operation with an improperly adjusted, incorrectly routed or damaged cables could result in an unsafe riding Condition. Follow the service manual to make sure to correct any of these conditions.

• Check the idle speed, using the engine revolution tester [A] for high accuracy.
  ★If the idle speed is out of specified range, adjust it.

Idle Speed:

Standard: 1 800 ±50 r/min (rpm)

A A RENTHAAT RENTHAAT 03058473 P

A 03058474

Idle Speed Adjustment

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

A B C

Air Cleaner Element Cleaning and Inspection

NOTE

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

Periodic Maintenance Procedures

WARNING

Gasoline and low-flash point solvents can be flammable and/or explosive and cause severe burns. Clean the element in a well ventilated area, and take care that there is no spark or flame anywhere near the working areas. Do not use gasoline or low-flash point solvents to clean the element.

- Remove:

Front Left Side Cover (see Element Removal in the Fuel System chapter)

Air Cleaner Element (see Element Removal in the Fuel System chapter)

• Stuff a clean, lint-free towel into the carburetor so no dirt is allowed to enter the carburetor.
• Wipe out the inside of the air cleaner housing with a clean damp towel.

NOTICE

Check inside of the intake tract and carburetor for dirt. If dirt is present, clean the intake tract and carburetor thoroughly. You may also need to replace the element and seal the housing and intake tract.

- Separate the element [A] from the frame [B].

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

A B GS05024851 C

Line drawing of hands washing a bowl in a tray, labeled with point A (no text or symbols on the diagram itself)

2-16 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

• Squeeze it dry in a clean towel [A]. Do not wring the element or blow it dry; the element can be damaged.
• Check all the parts of the element for visible damage.
  ★If any of the parts of the element are damaged, replace them.

A 0505026851 C

- After cleaning, saturate the element with a high-quality foam-air-filter oil, squeeze out the excess, then wrap it in a clean towel and squeeze it as dry as possible.

○Be careful not to tear the sponge filter.

- Assemble the element.

- Remove the towel from the carburetor.

- Apply grease to all connections and screw holes in the air cleaner housing and intake tract.

- Install the element onto its frame, and coat the element lip and lip seat with a thick layer of all-purpose grease to assure a complete seal.

Line drawing of two hands inserting a mesh into a bowl (no text or symbols)

- Install the air cleaner element so that its tab [A] faces left side and its projections [B] align with the holes [C] in the housing.

- Tighten the wing bolt [D]

- Install the seat (see Seat Installation in the Frame chapter).

C B A D GC07045BS1 C

Fuel Inspection

WARNING

Gasoline is extremely flammable and can be explosive under certain conditions. Always stop the engine and 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.

Periodic Maintenance Procedures

• Turn the fuel tap to the OFF position.
• Place a suitable container beneath the carburetor drain hose [B].
• Loosen the drain plug [A] from the bottom of the float bowl and check for water or dirt in the fuel.
  ★If any water or dirt comes out, clean the carburetor, fuel filter, fuel tap and fuel tank.
• Tighten the drain plug securely.

A B G3058477 P

Fuel Tank, Filter and Tap Cleaning

WARNING

Gasoline and low-flash point solvents can be flammable and/or explosive and cause severe burns. Clean the fuel tank in a well-ventilated area, and take care that there are no sparks or flame anywhere near the working area. Do not use gasoline or low-flash point solvents to clean the fuel tank.

• Remove the fuel tank and drain it (see Fuel Tank Removal in the Fuel System chapter).
• Pour some high-flash point solvent into the fuel tank and shake the tank to remove dirt and fuel deposits.
• Pour the solvent out of the tank.
• Remove the fuel filter from the tank by taking out the bolts.
• Clean the fuel filter screens in a high-flash point solvent. After cleaning, install the fuel filter.
• Pour high-flash point solvent through the tap in all lever positions.
• Dry the tank, filter and tap with compressed air.
  • Install the filter in the fuel tank.
• Install the tap and fuel tank.

Fuel Tap and Filter Inspection

• Remove the fuel filter from the fuel tank.
• Check the fuel filter screens [A] for any breaks or deterioration.
  ★If the fuel filter screen have any breaks or is deteriorated, it may allow dirt to reach the carburetor, causing poor running. Replace the fuel filter.
• Remove the fuel tap.
• Check the fuel tap for fuel leaks.
• If the fuel tap leaks, or allows fuel to flow when it is at OFF position, replace the fuel tap.

Close-up of a mechanical component with labeled section A, showing no visible text or symbols beyond the label.

Cooling System

WARNING

Coolant can be extremely hot and cause severe burns, is toxic and very slippery. Do not remove the radiator cap or attempt to change the coolant when the engine is hot; allow it cool completely. Immediately wipe any spilled coolant from tires, frame, engine or other painted parts. Do not ingest coolant.

2-18 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Coolant Level Inspection

NOTE

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

• Lean the motorcycle slightly to the left until the radiator cap is level to the ground so that the radiatorcap is located uppermost in order to exhaust the air accumulated in the radiator.
• Remove the radiator cap [A].

NOTE

○ Remove the radiator cap in two steps. First turn the cap counterclockwise to the first stop and wait there for a few seconds. Then push down and turn it further in the same direction and remove the cap.

• Check the coolant level. The coolant level [A] should be at the bottom of the filler neck [B].
  ★If the coolant level is low, add coolant through the filler opening to the bottom of the filler neck. Install the cap.

MPS BY KONALINE HEAVY REEAST HADE A P5068163 LP

A B GD04016BS1 C

Recommended coolant:

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

Water and coolant mixture ratio:

1:1 (soft water 50%, Coolant 50%)

Total amount:

1.05 L (1.11 US qt.)

1:1 0500008S1 C

Coolant Deterioration Inspection

• Visually inspect the coolant.
  ★If whitish cotton-like wafts are observed, aluminum parts in the cooling system are corroded. If the coolant is brown, iron or steel parts are rusting. In either case, flush the cooling system.
  ★If the coolant gives off an abnormal smell, check for a cooling system leak. It may be caused by exhaust gas leaking into the cooling system.

Periodic Maintenance Procedures

Radiator Hoses and Connections Inspection

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

★Replace the hose if any fraying, cracks [C] or bulges [D] are noticed.
- Check that the hoses are securely connected and clamps are tightened correctly.

Torque - Radiator Hose Clamp Screws: 3.0 N·m (0.30 kgf·m, 27 in·lb)

Close-up mechanical assembly showing labeled components (A) and mounting points, no readable text or symbols present.

D O B C G304027BS1 C

Engine Top End

Vacuum Switch Valve Test

U.S.A., California and Canada Models

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

• Remove the vacuum switch valve (see Vacuum Switch Valve Removal in the Engine Top End chapter).
• Connect a vacuum gauge [A] and syringe [B] or fork oil level gauge to the vacuum hoses as shown.

Air Flow [C]

Special Tool - Fork Oil Level Gauge: 57001-1290

- Gradually raise the vacuum (lower the pressure) applied to the vacuum switch valve, and check the valve operation. When the vacuum is low, the vacuum switch valve should permit air to flow. When the vacuum raises to the level shown below, the valve should stop air flow. When the vacuum is high enough, air cannot flow through the valve.

Spring [A]

Diaphragm [B]

Valve [C]

Low Vacuum [D]

Secondary Air Flow [E]

Air Suction Valve [F]

A B C GE04069BS1 C

D A B F E C GE04070BS1 C

2-20 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

★If the vacuum switch valve does not operate as described, replace it with a new one.

NOTE

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

Vacuum Switch Valve Closing Pressure (open → close) Standard: 48 \~ 59 kPa (360 \~ 440 mmHg)

High Vacuum [A]

Secondary air cannot flow [B].

A B 0E04071951 C

Valve Clearance Inspection

NOTE

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

- Remove:

Cylinder Head Cover (see Cylinder Head Cover Removal in the Engine Top End chapter) Crankshaft Cap [A] Timing Inspection Cap [B]

Special Tool - Filler Cap Driver: 57001-1454

Technical diagram of a mechanical component with labeled parts A and B, showing internal components and alignment indicators.

- First, bring the piston to the top-dead-center of its compression stroke to inspect the valve clearance (the position at the end of the compression stroke), when the cam lobe faces outside of the camshaft (see Camshaft Installation in the Engine Top End chapter).

○Place a wrench over the flywheel nut and turn it counterclockwise to align the TDC mark [A] with the center of the groove [B] of the inspection hole.

B A 65078138 P

- Using a thickness gauge [A], measure the clearance between each cam lob and valve lifter for all four valves.

○For the purpose of adjusting the valve clearances, record the measured values.

Close-up of a mechanical assembly with visible gears and shafts (no text or symbols)

Valve clearance: between cam and valve lifter Standard:

Exhaust 0.20 \~ 0.25 mm (0.0079 \~ 0.0098 in.)

Intake 0.10 \~ 0.15 mm (0.0039 \~ 0.0059 in.)

★If the valve clearance is not within the specified range, adjust it.

Periodic Maintenance Procedures

Valve Clearance Adjustment

• Remove the camshaft caps [A] (see Camshaft Removal in the Engine Top End chapter).
• Remove the camshafts [B] (see Camshaft Removal in the Engine Top End chapter).
• Remove the valve lifters [C] of the applicable valve.
• Remove the shims [D] from the top of the spring retainer.

A B C D G507069851 C

NOTE

○Mark and record the locations of the valve lifters and shims so that they can be reinstalled in their original positions.

• Clean the shim to remove any dust or oil.
• Measure the thickness of the removed shim [A].
• Select a new shim thickness calculation as follows.

$$ A = (B - C) + D $$

$$ [ A ] \text { Replace Shim Thickness } $$

$$ [ B ] \text { Measured Valve Clearance } $$

$$ [ C ] \text { Specified Valve Clearance } $$

$$ [ D ] \text { Present Shim Thickness } $$

Example

$$ (0. 3 1 \mathrm{mm} - 0. 1 0 \sim 0. 1 5 \mathrm{mm}) + 2. 6 0 \mathrm{mm} = 2. 8 1 \sim 2. 7 6 \mathrm{mm} $$

○Exchange the shims for the 2.775 or 2.800 size shim.

NOTICE

Don't use the shims for another models. This could cause wear of the valve stem end, and valve stem damage.

IN R IN L EX R EX L GS07008BS1 C

Close-up of a hand using a micrometer to measure a curved metal part, labeled with point A (no text or symbols on the instrument itself)

2-22 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Adjustment shims

Thick-ness	P/No. Mark			Thick-ness	P/No. Mark
2.00 92	025-1870 0	2.55	92025-1881			55
2.05 92	025-1871 5	2.575	92025-1985	58
2.10 92	025-1872 10	2.60	92025-1882	60
2.15 92	025-1873 15	2.625	92180-1059	63
2.20 92	025-1874 20	2.65	92025-1883	65
2.25 92	025-1875 25	2.675	92180-1194	68
2.30 92	025-1876 30	2.70	92025-1884	70
2.35 92	025-1877 35	2.725	92180-1195	73
2.375 92	180-1058 38	2.75	92025-1885	75
2.40 92	025-1878 40	2.775	92180-1196	78
2.425 92	025-1982 43	2.80	92025-1886	80
2.45 92	025-1879 45	2.85	92025-1887	85
2.475 92	025-1983 48	2.90	92025-1888	90
2.50 92	025-1880 50	2.95	92025-1889	95
2.525 92	025-1984 53	3.00	92025-1890	00

5 5

0507011B51 C

NOTICE

Be sure to remeasure the clearance after selecting a shim. The clearance can be out of the specified range because of the shim tolerance.

○ If there is no valve clearance, use a shim that is a few sizes smaller, and remeasure the valve clearance.

- When installing the shim, face the marked side [A] toward the valve lifter [B]. At this time, apply engine oil to the shim or the valve lifter to keep the shim in place during camshaft installation.

NOTICE

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

Do not grind the shim. This may cause it to fracture, causing extensive engine damage.

• Apply engine oil to the valve lifter surface and install the lifter.
• Install the camshaft (see Camshaft Installation in the Engine Top End chapter).
• Recheck the valve clearance and readjust if necessary.
• Install the cylinder head cover (see Engine Top End chapter), timing inspection cap, and the crankshaft cap.

Special Tool - Filler Cap Driver: 57001-1454

Close-up mechanical assembly photo with labeled parts A and B, showing engine cylinder and valve components

Periodic Maintenance Procedures

Cylinder Head Warp Inspection

• Remove the cylinder head (see Cylinder Head Removal in the Engine Top End chapter).
• Lay a straightedge [A] across the lower surface of the head at several different points, and measure warp by inserting a thickness gauge between the straightedge and the head.
  ★If warp exceeds the service limit, repair the mating surface. Replace the cylinder head if the mating surface is badly damaged.

Cylinder Head Warp

Service Limit: 0.05 mm (0.002 in.)

• Remove the valves (see Valve Removal in the Engine Top End chapter).
• Scrape the carbon out of the combustion chamber and exhaust port with a scraper [A] or a suitable tool.
• Clean the cylinder head, using high-flash point solvent.
• Blow out any particles which may obstruct the oil passage in the cylinder head using compressed air.
• Install the valves (see Valve Installation in the Engine Top End chapter).

Cylinder Wear Inspection

NOTE

○Measure the cylinder inside diameter when the cylinder is cold (room or ambient temperature).

• Visually Inspect the inside of the cylinder for scratches and abnormal wear.
  ★If the cylinder is damaged or badly worn, replace it with a new one.
• Since there is a difference in cylinder wear in different directions, take a side-to-side and a front-to-back measurement shown in the figure.
  ★If any of the cylinder inside diameter measurements exceeds the service limit, the cylinder must be replaced with a new one since the PLATING cylinder cannot be bored or honed.

[A] 10 mm (0.39 in.)

[B] 30mm(1.2in.)
[C] 50mm(2.0in.)

Cylinder Inside Diameter

Standard: 96.000 \~ 96.012 mm (3.7795 \~ 3.7800 in.)

Service Limit: 96.10 mm (3.783 in.)

Mechanical component with highlighted section A, no visible text or symbols

Close-up of a mechanical component with visible cavities and mounting holes (no text or symbols)

A B C G507067851 C

2-24 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Piston/Cylinder Clearance

The piston-to-cylinder clearance is measured whenever a piston or cylinder is replaced with a new one. The standard piston-to-cylinder clearance must be adhered to whenever the cylinder is replaced.

If only a piston is replaced, the clearance may exceed the standard slightly. But it must not be less than the minimum, in order to avoid piston seizure.

The most accurate way to find the piston clearance is by making separate piston and cylinder diameter measurements and then computing the difference between the two values. Measure the piston diameter as just described, and measure the cylinder diameter at the very bottom of the cylinder.

Piston/Cylinder Clearance

Standard: 0.020 \~ 0.042 mm (0.00079 \~ 0.0017 in.)

Piston, Piston Ring and Piston Pin Replacement

- Refer to the Cylinder and Piston Section in Engine Top End chapter.

Spark Arrester Cleaning

This vehicle is equipped with a spark arrester. It must be properly maintained to ensure its efficiency.

NOTICE

The spark arrester must be installed correctly and functioning properly to provide adequate fire protection.

WARNING

Hot exhaust system parts can cause serious burns. The exhaust system becomes very hot soon after the engine is started. To avoid burns, be sure the exhaust system is cold before cleaning the spark arrester.

- Remove;

Muffler End Mounting Bolts [A] Muffler End [B]

A A B A A GB07B165 P

Periodic Maintenance Procedures

- Remove:

Spark Arrester Mounting Bolts [A] Spark Arrester [B]

A B A 63078166 P

• With a wire brush, remove the carbon off the inside of the spark arrester [A] and muffler.
• Inspect the spark arrester.
  ★If the spark arrester is damaged, replace it with a new one.
• Replace the gasket [B] to the new one.
• Install the spark arrester into the rear end of the muffler.

Torque - Spark Arrester Mounting Bolts: 10 N·m (1.0 kgf·m, 89 in·lb)

• Install the muffler end.

Torque - Muffler End Mounting Bolts: 10 N·m (1.0 kgf·m, 89 in·lb)

B A G007B167 P

Engine Right Side

WARNING

The engine and exhaust system get extremely hot during normal operation and can cause serious burns. Never touch the engine or exhaust chamber during clutch adjustment.

Clutch Lever Free Play Check

• Slide the clutch lever dust cover [A] and adjusting bolt cover [B] out of place.
• Check that the clutch cable upper end is fully seated in the adjusting bolt [C].
• Check that the clutch lever [D] has 8 \~ 13 mm (0.3 \~ 0.5 in.) of play [E].
  ★If it does not, adjust the lever play.

B A C G508129 P

E D GS06B132

2-26 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Clutch Lever Free Play Adjustment

• Slide the clutch lever dust cover out of place.
• Turn the adjuster [A] so that the clutch lever will have 8 \~ 13 mm (0.3 \~ 0.5 in.) of play.

NOTE

○ Be sure that the outer cable end at the clutch lever is fully seated in the adjusting bolt at the clutch lever, or it could slip into the place later, creating enough cable play to prevent clutch disengagement.

• If it cannot be done, loosen the lower locknut [A] at the lower of the clutch cable, and turn the upper locknut [B] so that clutch lever has 8 \~ 13 mm (0.3 \~ 0.5 in.) of play.
• After the adjustment is made, tighten the locknut, and start the engine and check that the clutch does not slip and that it release properly.

Close-up of mechanical components with labeled section A (no readable text or symbols)

B A

Friction and Steel Plates Inspection

• Removetheclutch plate (Gutcks) Removal in the Engine Right Side chapter).
• Visually inspect the friction and steel plates to see if they show any signs of seizure, or uneven wear.
  ★If any plates show signs of damage, replace the friction plates and steel plates as a set.
• Measure the thickness of the friction plates [A] with vernier calipers.
  ★If they have worn past the service limit, replace them with new ones.

A GF00080251 C

Friction Plate Thickness

Standard: 2.92 \~ 3.08 mm (0.115 \~ 0.121 in.)

Service Limit: 2.6 mm (0.10 in.)

• Place each friction plate or steel plate on a surface plate, and measure the gap between the surface plate [A] and each friction plate or steel plate [B] with a thickness gauge [C]. The gap is the amount of friction or steel plate warp.
  ★If any plate is warped over the service limit, replace it with a new one.

Friction and Steel Plates Warp

Standard:

Friction Plate 0.15 mm (0.0059 in.) or less

Steel Plate 0.2 mm (0.008 in.) or less

Service Limit:

Friction Plate 0.3 mm (0.01 in.)

Steel Plate 0.3 mm (0.01 in.)

B A C GF130107S1 C

Engine Lubrication System

Engine Oil Change

- Warm up the engine thoroughly so that the oil will pick up any sediment and drain easily. Then stop the engine.

Periodic Maintenance Procedures

• Remove the engine oil drain plugs on the bottom of the engine, and let the oil drain completely.
  Drain Plug (Sub) [A]
  DrainPlug(Main)[B]

NOTE

○ Hold the motorcycle upright so that the oil may drain completely.

• Replace the gaskets at the drain plugs with a new one.
• After the oil has completely drained out, install the drain plugs with the gaskets, and tighten them.

Torque - Engine Oil Drain Plug (M6)(Sub): 7.0 N·m (0.71 kgf·m, 62 in·lb)

Engine Oil Drain Plug (M10)(Main): 20 N·m (2.0 kgf·m, 15 in·lb)

- Fill the engine with a good quality motor oil specified below.

B A G5096123 P

Recommended Engine

Type Castrol "R4 Superbike" SAE 5W-40 or API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2

Viscosity SAE 10W-40

Capacity 1.06 L (1.12 US qt.) (when filter is not removed)

1.08 L (1.14 US qt.) (when filter is remove) 1.3 L (1.4 US qt.) (when engine is completely dry)

SAE 10W-50 SAE 10W-40 SAE 10W-30 -20 -10 0 10 20 30 40 (°C) -4 14 32 50 68 86 104(°F) GS09013BSI C

NOTE

○ Do not add any chemical additive to the oil. Oils fulfilling the above requirements are fully formulated and provide adequate lubrication for both the engine and the clutch.
○ The oil viscosity may need to be changed to accommodate atmospheric conditions in your riding area.

- Check the oil level (see Engine Oil Level Inspection in the Engine Lubrication System chapter).

Oil Filter Change

• Drain:
  Engine Oil (see Engine Oil Change)

- Remove:

Oil Filter Cover Bolts [A] Oil Filter Cover [B]

A B GS09B124 P

2-28 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

- Remove the Oil Filter [A].

Close-up of a mechanical component with labeled parts (A) and no visible text or symbols beyond the label.

• Install the spring [A] to the right engine cover.
• Apply grease to the grommet [B].
• Be sure to install the filter with the grommet facing outside as shown.

NOTICE

Inside out installation stop oil flow, causing engine seizure.

CE12 A B GS098126 P

• Replace the oil filter cover O-rings [A] with a new one.
• Replace the oil filter with new ones.
• Apply grease to the O-rings.
  • Install the oil filter cover.

Torque - Oil Filter Cover Bolt: 9.8 N·m (1.0 kgf·m, 87 in·lb)

- Pour in the specified type and amount of oil (see Engine Oil Change).

Close-up of a mechanical assembly with labeled component A, showing gears and a housing (no readable text or symbols)

Breather Hose Inspection

• Be certain that the breather hose are routed without being flattened or kinked and is connected correctly.
  ★If it is not, correct it.
• Inspect the breather hoses [A] for damage or sings of deterioration.
• This hose should not be hard and brittle, nor should be soft swollen.
  ★Replace it if any cracks or swelling is noticed.

Close-up mechanical assembly showing internal components and labeled parts (no readable text or symbols)

Periodic Maintenance Procedures

Crankshaft/Transmission

Crankshaft Inspection

Connecting Rod Big End Side Clearance

• Remove the cylinder head (see Cylinder Head Removal in the Engine Top End chapter).
• Remove the cylinder (see Cylinder Removal in the Engine Top End chapter).
• Remove the piston (see Piston Removal in the Engine Top End chapter).
• Measure the connecting rod big end side clearance at right side of big end using a thickness gauge [A].

Close-up mechanical component with labeled section A (no readable text or symbols beyond label)

Connecting Rod Big End Side Clearance

Standard: 0.25 \~ 0.35 mm (0.0098 \~ 0.014 in.)

Service Limit: 0.6 mm (0.02 in.)

★If the clearance exceeds the service limit, replace the crankshaft assembly.
- Make sure that the crankshaft rotates smoothly after assembling the engine.

Wheel/Tires

Air Pressure Inspection/Adjustment

• Using tire air pressure gauge [A], measure the tire pressure when the tires are cold.
  ★Adjust the tire air pressure to suit track conditions and rider preference, but do not stray too far from the recommended pressure.

Track Condition	Tire Pressure
When the track is wet, muddy, sandy or slippery, reduce the tire pressure to increase the tire tread surface on the ground.When the track is pebbly or hard, increase the tire pressure to prevent damage or punctures, through the tires will skid more easily.	80 kPa (0.8 kgf/cm2, 11 psi)↑↓100 kPa (1.0 kgf/cm2, 14 psi)

A 0J05010351 C

Periodic Maintenance Procedures

Tires Inspection

As the tire tread wears down, the tire becomes more susceptible the puncture and failure.

• Remove any imbedded stones or other foreign particles from the tread.
• Visually inspect the tire for cracks and cuts, replacing the tire in case of bad damage. Swelling or high spots indicate internal damage, requiring tire replacement.

WARNING

Some replacement tires may adversely affect handling and cause an accident resulting in serious injury or death. To ensure proper handling and stability, use only the recommended standard tires for replacement, inflated to the standard pressure.

Diagram of tire track and suspension system (no text or labels)

NOTE

○Check and balance the wheel when a tire is replaced with a new one.

Standard Tire (U.S.A., California, and Canada Models)

Front:

Size: 80/100-21 51M

Make: BRIDGESTONE

Type: D401, Tube

Rear:

Size: 110/100-18 64M

Make: BRIDGESTONE

Type: M402, Tube

Standard Tire (Australia and Europe Models)

Front:

Size: 80/100-21 M/ C 51P

Make: BRIDGESTONE

Type: ED03, Tube

Rear:

Size: 120/90-18 M/C 65P

Make: BRIDGESTONE

Type: ED04, Tube

Spoke Tightness Inspection

• Check that all the spokes are tightened evenly.
  ★If spoke tightness is uneven or loose, tighten the spoke nipples evenly.

Torque - Spoke Nipples: 2.2 N·m (0.22 kgf·m, 19 in·lb)

- Check the rim runout.

WARNING

A missing spoke places an additional load on the other spokes, which will eventually cause other spokes to break, creating the potential for an accident resulting in serious injury or death. Immediately replace any broken spoke(s).

Line drawing of a hand using a tool to adjust or install a mechanical component (no text or symbols visible)

Periodic Maintenance Procedures

Rim Runout Inspection

- Place the jack under the frame so that the front/rear wheel off the ground.

Special Tool - Jack: 57001-1238

- Inspect the rim for small cracks, dents, bending, or warping.

★If there is any damage to the rim, it must be replaced.

- Set a dial gauge against the side of the rim, and rotate the rim to measure the axial runout [A]. The difference between the highest and lowest dial readings is the amount of runout.

- Set a dial gauge against the outer circumference of the rim, and rotate the rim to measure radial runout [B]. The difference between the highest and lowest dial readings is the amount of runout.

★If rim runout exceeds the service limit, check the wheel bearings first. Replace them if they are damaged. If the problem is not due to the bearings, correct the rim warp (runout). A certain amount of rim warp can be corrected by recentering the rim. Loosen some spokes and tighten others within the standard torque to change the position of different parts of the rim. If the rim is badly bent, however, it must be replaced.

Rim Runout (with tire installed)

Standard:

Axial TIR 1.0 mm (0.039 in.) or less

Radial TIR 1.0 mm (0.039 in.) or less

Service Limit:

Axial 2 mm (0.08 in.)

Radial 2 mm (0.08 in.)

A B GJ04061051 C

Wheel Bearing Inspection

- Raise the front/rear wheel off the ground.

Special Tool - Jack: 57001-1238

- Spin the wheel lightly, and check for roughness, binding or noise.

★If roughness, binding, abnormal noise is found, replace the hub bearing.

- Turn the handlebar until the handlebar doesn't move to either side.

- The wheel edge is moved to one direction gripping the edge of the wheel by both hands and the play of the wheel bearing is checked.

★If the play is found, replace the bearing.

Close-up of a hand adjusting a bicycle tire with a white plastic component (no visible text or symbols)

Close-up of hands adjusting a bicycle tire wheel, showing mechanical components and tire structure (no text or symbols visible)

2-32 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Final Drive

Drive Chain Slack Inspection

• Raise the rear wheel off the ground, rotate the rear wheel to find the place where the chain is tightest (because it wears unevenly).
• Check the wheel alignment (see Wheel Alignment Inspection in the Final Drive chapter), and adjust it if necessary (see Drive Chain Slack Adjustment).

NOTE

○Clean the drive chain if it is dirty, and lubricate it if it appears dry.

- Rotate the rear wheel to find the position where the chain is tightest.

- Measure the space (chain slack) [A] between the chain and the swingarm at the rear of the chain slipper as shown.

★If the drive chain slack exceeds the standard, adjust it.

- Rotate the rear wheel to find the position where the chain is tightest. - Measure the space (chain slack) [A] between the chain and the swingarm at the rear of the chain slipper as shown. ★If the drive chain slack exceeds the standard, adjust it.

Chain Slack

Standard: 52 \~ 58 mm (2.0 \~ 2.3 in.)

A QS12041BS2 C

Drive Chain Slack Adjustment

• Loosen the left and right chain adjuster locknuts [A].
• Remove the cotter pin [B] and loosen the axle nut [C].
  ★If the chain is too tight, back out the left and right chain adjusting bolts [D] evenly, and push the wheel forward until the chain is too loose.
  ★If the chain is too loose, turn both chain adjusting bolts evenly until the drive chain has the correct amount of slack. To keep the chain and wheel properly aligned, the notch on the left chain adjuster should align with the same swingarm mark [E] as the right chain adjuster notch [F].
  ★Check the wheel alignment.

E F C B D A GS12B113 P

WARNING

Misalignment of the wheel will result in abnormal wear and may result in an unsafe riding condition. Be sure the wheel is properly aligned.

• Tighten both chain adjuster locknuts securely.
• Tighten the axle nut.
  Torque - Rear Axle Nut: 110 N·m (11.2 kgf·m, 81.1 ft·lb)
• Rotate the wheel, measure the chain slack again at the tightest position, and readjust if necessary.
• Install a new cotter pin [A] through the axle nut and axle, and spread its ends.

A GK04001851 C

Periodic Maintenance Procedures

NOTE

○ When inserting the cotter pin, if the slots in the nut do not align with the cotter pin hole in the axle shaft, tighten the nut clockwise [A] up to next alignment.
○ It should be within 30 degree.
○ Loosen one and tighten again when the slot goes past the nearest hole.

A

GJ04034BS1 C

WARNING

A loose axle nut can lead to an accident resulting in serious injury or death. Tighten the axle nut to the proper torque and install a new cotter pin.

- Check the rear brake.

NOTE

○ In wet and muddy conditions, mud sticks to the chain and sprockets resulting in an overly tight chain, and the chain may break. To prevent this, adjust the chain to 58 \~68 mm (2.28 \~2.68 in.) of slack whenever necessary.

Drive Chain Wear Inspection

• Rotate the rear wheel to inspect the drive chain for damaged rollers, and loose pins and links.
  ★If there is any irregularity, replace the drive chain.
  ★Lubricate the drive chain if it appears dry.

[A] Bushing
[B] Roller
[C] Pin
[D] Pin Link
[E] Roller Link
[F] O-ring

- Stretch the chain taut by hanging a 98 N (10 kgf, 20 lb) weight [A] on the chain.

- Measure the length of 20 links [B] on the straight part [C] of the chain from the pin center of the 1st pin to the pin center of the 21st pin. Since the chain may wear unevenly, take measurements at several places.

Chain 20-link Length

Standard: 317.5 \~ 318.2 mm (12.50 \~ 12.53 in.)

Service Limit: 323 mm (12.7 in.)

★If any measurements exceed the service limit, replace the chain. Also, replace the front and rear sprockets when the drive chain is replaced.

C D A F E B GS12031BSI C

C A ? 1st B 21st GK040608S1 C

2-34 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

WARNING

A chain that breaks or jumps off the sprockets could snag on the engine sprocket or lock the rear wheel, severely damaging the motorcycle and causing it to go out of control. Inspect the chain for damage and proper adjustment before each ride. If chain wear exceeds the service limit, replace it with the standard chain.

Standard Chain

Make: DAIDO

Type: D.I.D 520MXV

Link: 114 Links

Drive Chain Lubrication

The chain should be lubricated with a lubricant which will both prevent the exterior from rusting and also absorb shock and reduce friction in the interior of the chain.

★If the chain is especially dirty, it should be washed in diesel oil or kerosene, and afterward soaked in a heavy oil. Shake the chain while it is in the oil so that oil will penetrate to the inside of each roller.
- An effective, good quality lubricant specially formulated for chains is best for regular chain lubrication.
- If a special lubricant is not available, a heavy oil such as SAE90 is preferred to a lighter oil because it will stay on the chain longer and provide better lubrication.
- Apply oil to the sides of the rollers so that oil will penetrate to the rollers and bushings.
● Wipe off any excess oil. Oil applied area [A]

GK04030351 C

Sprocket Wear Inspection

• Visually inspect the front and rear sprocket teeth for wear and damage.
  ★If they are worn as illustrated or damaged, replace the sprocket.

[A] Worn Tooth (Engine Sprocket)
[B] Worn Tooth (Rear Sprocket)
[C] Direction of Rotation

A B C OK05017851 C

NOTE

○If a sprocket requires replacement, the chain is probably worn also. When replacing a sprocket, inspect the chain.

Periodic Maintenance Procedures

Rear Sprocket Warp Inspection

• Using the jack, raise the rear wheel off the ground. Special Tool - Jack: 57001-1238
• Set a dial gauge [A] against the rear sprocket [B] near the teeth as shown and rotate [C] the rear wheel to measure the sprocket runout (warp). The difference between the highest and lowest dial gauge readings is the amount of runout (warp).
  ★If the runout exceeds the service limit, replace the rear sprocket.

Rear Sprocket Warp

Standard: 0.4 mm (0.016 in.) or less

Service Limit: 0.5 mm (0.02 in.)

A B C GS12024851 C

Brakes

Brake Lever and Pedal Position Adjustment

WARNING

An improperly adjusted brake could drag and cause the brake to overheat, damaging the brake assembly and possibly locking the rear wheel, resulting in loss of control. Always maintain the proper brake adjustment.

• Adjust the front brake lever [A] to suit you.
• Slide the brake lever dust cover [B] out of place.
• Loosen the adjuster locknut [C] and turn the adjuster [D] to either side.
• After adjustment, tighten the locknut.

A B C D GL04004BS1 C

NOTE

○Usually it is not necessary to adjust the pedal position, but always adjust it when the master cylinder is disassembled or pedal position is incorrect.
● Measure the length indicated in the figure.

Length [A]

Standard: 68.5 ±1 mm (3.09 ±0.04 in.)

★If it is not specified length, the brake pedal may be deformed or incorrectly installed.
★If it is not within the specified length, adjust the push rod in the master cylinder as follows.

Close-up mechanical assembly with labeled component A and bolted joint (no readable text or symbols)

2-36 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

○Loosen the push rod locknut [A].
○Replace the cotter pin with a new one.
○Remove:

Cotter Pin [B]

Washer

Joint Pin [C]

○Turn the bracket [D] to obtain the specified length.
○Tighten the locknut.

Torque - Rear Master Cylinder Push Rod Locknut: 17 N·m (1.7 kgf·m, 13 ft·lb)

Brake Fluid Level Inspection

- Check the brake fluid level in the front or rear brake reservoir [A].

NOTE

○Hold the reservoir horizontal when checking brake fluid level.

• The front or rear reservoir must be kept above the lower level line [B].
  ○If the fluid level in front or rear reservoir is lower than the lower level line, fill the reservoir to the upper level line. Inside the reservoir is stopped end showing the upper level line [C].

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

WARNING

Mixing brands and types of brake fluid can reduce the brake system's effectiveness and cause an accident resulting in injury or death. Do not mix two brands of brake 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 unidentified.

A D B C 0513044851 C

A B GS13036BS1 C

C A 0513037851 C

A B 0513043851 C

A C D GS138466 P

Periodic Maintenance Procedures

Brake Fluid Change

In accordance with the Periodic Maintenance Chart, change the brake fluid. The brake fluid should also be changed if it becomes contaminated with dirt or water. Furthermore, the brake fluid should be changed to bleed the air quickly and completely whenever the brake line parts are removed.

WARNING

When working with the disc brake, observe the precautions listed below.

1. Never reuse old brake fluid.
2. Do not use fluid from a container that has been left unsealed or that has been open for a long time.
3. Do not mix two types and brands of fluid for use in the brake. This lowers the brake fluid boiling point and could cause the brake to be ineffective. It may also cause the rubber brake parts to deteriorate.
4. Don't leave the reservoir cap off for any length of time to avoid moisture contamination of the fluid.
5. Don't change the fluid in the rain or when a strong wind is blowing.
6. Except for the disc pads and disc, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol for cleaning of the brake parts. Do not use any other fluid for cleaning these parts. Gasoline, engine oil, or any other petroleum distillate will cause deterioration of the rubber parts. Oil spilled on any part will be difficult to wash off completely and will eventually deteriorate the rubber used in the disc brake.
7. When handling the disc pads or disc, be careful that no disc brake fluid or any oil gets on them. Clean off any fluid or oil that inadvertently gets on the pads or disc with a high-flash point solvent. Do not use one which will leave an oily residue. Replace the pads with new ones if they cannot be cleaned satisfactorily.
8. Brake fluid quickly ruins painted surfaces; any spilled fluid should be completely wiped up 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.

Recommended Disc Brake Fluid

Type:

Front DOT3 or DOT4

Rear DOT4

2-38 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

NOTE

○The procedure to change the front brake fluid. Changing the rear brake fluid is the same as for the front brake.

- Level the brake fluid reservoir.

- Remove the screws [A], reservoir cap [B] and diaphragm [C].

- Remove the rubber cap [A] on the bleed valve [B].

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

- Change the brake fluid as follows:

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

1. Open the bleed valve [A]

2. Apply the brake and hold it [B]

3. Close the bleed valve [C]

4. Release the brake [D]

○Fill the reservoir with fresh specified brake fluid.

NOTE

The fluid level must be checked often during the changing operation and replenished with fresh brake fluid. If the fluid in the reservoir runs out any time during the changing operation, the brakes will need to be bled since air will have entered the brake line.

A B C 0513118051 C

A B 0513119851 C

A B 0513120851 C

A C B D GS13121BS2 C

Periodic Maintenance Procedures

• Remove the clear plastic hose.
• Tighten the bleed valves, and install the rubber caps.

Torque - Caliper Bleed Valve: 7.8 N·m (0.80 kgf·m, 69 in·lb)

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

• After changing the fluid, check the brake for good braking power, no brake drag, and no fluid leakage.
  ★If necessary, bleed the air from the lines (see Bleeding the Brake Line in the Brakes chapter).

WARNING

Mixing brands and types of brake fluid can reduce the brake system's effectiveness and cause an accident resulting in injury or death. Do not mix two brands of brake 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 unidentified.

Brake Pad Wear Inspection

• Remove the brake pad (see Brake Pad Removal in Brakes chapter).
• Check the lining thickness and condition of the pads in each caliper.
  ★If either pad is damaged, replace both pads in the caliper as a set.
  ★If the lining thickness [A] of either pad is less than the service limit [B], replace both pads in the caliper as a set.

Lining Thickness

Standard:

Front 3.8 mm (0.15 in.)

Rear 6.4 mm (0.25 in.)

Service Limit:

Front 1 mm (0.04 in.)

Rear 1 mm (0.04 in.)

Close-up of a mechanical assembly with labeled parts A and B, showing hands operating a component.

Mechanical assembly diagram showing interconnected components labeled A and B (no readable text or symbols beyond labels)

Brake Master Cylinder Cup and Dust Seal Replacement

• Remove the front master cylinder (see Front Master Cylinder Removal in the Brakes chapter).
• Remove the reservoir cap and diaphragm, and pour the brake fluid into a container.
• Unscrew the locknut and pivot bolt, and remove the brake lever.
• Pull the dust cover [A] out of place, and remove the circlip [B].

Special Tool - Inside Circlip Pliers: 57001-143

• Remove the washer [C].
• Pull out the piston [D], secondary cup [E], primary cup [F], and return spring [G].

GS13042B51 C

Periodic Maintenance Procedures

NOTICE

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

- Remove the rear master cylinder (see Rear Master Cylinder Removal in the Brakes chapter).

NOTE

- Do not remove the push rod clevis for master cylinder disassembly since removal requires brake pedal position adjustment.

• Remove the reservoir cap and diaphragm, and pour the brake fluid into a container.
• Slide the dust cover [A] on the push rod [B] out of place, and remove the circlip [C].

Special Tool - Inside Circlip Pliers: 57001-143

• Pull out the push rod with the piston stop [D].
• Take off the piston [E], secondary cup [F], primary cup [G], and return spring [H].

NOTICE

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

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

NOTICE

Except for the disc pads and disc, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol for cleaning of the brake parts. Do not use any other fluid for cleaning of 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.

• Apply brake fluid to the removed parts and to the inner wall of the cylinder.
• Take care not to scratch the piston or the inner wall of the cylinder.

• Apply silicone grease (ex. PBC grease).
  Brake Lever Pivot Bolt Brake Lever Pivot Contact Push Rod Contact (Rear) Dust Covers

• Tighten:
  Torque - Brake Lever Pivot Bolt: 5.9 N·m (0.60 kgf·m, 52 in·lb)
  Brake Lever Pivot Bolt Locknut: 5.9 N·m (0.60 kgf·m, 52 in·lb)

Labeled diagram of a mechanical spring assembly with numbered parts from H to B

GL07057BS2 C

Periodic Maintenance Procedures

Caliper Piston Seal and Dust Seal Replacement

• Loosen the brake pad pin [A] and banjo bolt [B], and tighten them loosely.
• Remove:

Front Caliper Mounting Bolts [C]

Banjo Bolt

Brake Hose [E]

Front Caliper [D] (see Front Caliper Removal in the Brakes chapter)

Brake Pads (see Brake Pad Removal in the Brakes chapter)

- Separate the caliper holder [A] from the caliper [B] and remove the anti-rattle spring.

C E D B A 0513122851 C

A B 05128087 P

• Using compressed air, remove the pistons. One way to remove the pistons is as follows.
  ○Cover the caliper opening with a clean, heavy cloth [A].
  ○Remove the pistons by lightly applying compressed air [B] to the hose joint opening.

WARNING

The piston in the brake caliper can crush hands and fingers. Never place your hand or fingers in front of the piston.

Close-up of hands assembling a mechanical component with labeled parts A and B (no readable text or symbols beyond labels)

○Pull out the piston [A] by hand.
- Remove the dust seals [B] and fluid seals [C].

NOTE

○ If compressed air is not available, do as follows for both calipers coincidentally, with the brake hose connected to the caliper.
○Prepare a contai ner for brake fluid, and perform the work above it.
○ Remove the spring and pads (see Brake Pad Removal in the Brakes chapter).
○Pump the brake lever until the pistons come out of the cylinders, and then disassembly the caliper.

C B A 05138068 P

2-42 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

• Remove the rear caliper (see Caliper Removal in the Brakes chapter).
• Remove the pads (see Brake Pad Removal in the Brakes chapter).
• Separate the caliper holder [B] from the caliper [A].

A B 05138080 P

• Using compressed air, remove the piston.
  ○Cover the caliper opening with a clean, heavy cloth [A].
  ○Remove the piston by lightly applying compressed air [B] to where the brake line fits into the caliper.

WARNING

The piston in the brake caliper can crush hands and fingers. Never place your hand or fingers in front of the piston.

• Pull out the piston [A] by hand.
• Remove the dust seal [B] and fluid seal [C].
• Clean the caliper parts except for the pads.

NOTICE

For cleaning of the parts, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol.

- The bleed valve was removed, install the bleed valve and rubber cap.

Torque - Bleed Valve: 7.8 N·m (0.80 kgf·m, 69 in·lb)

• Replace the fluid seal(s) [A] with new ones.
  ○Apply brake fluid to the fluid seal(s), and install them into the cylinders by hand.
• Replace the dust seal(s) [B] with new ones.
  ○Apply brake fluid to the dust seal(s), and install them into the cylinder by hand.
• Apply brake fluid to the outside of the pistons [C], and push them into each cylinder by hand.

A B 05138079 P

B C A 05138078 P

- Install the anti-rattle spring [A] in the caliper as shown.

A A GL05005851 C

Mechanical assembly diagrams showing two views of a mechanical component with labeled parts (A), no readable text or symbols present.

- Replace the shaft rubber friction boot [A] and dust boot [B] if they are damaged.

- Apply a thin coat of PBC (Poly Butyl Cuprysil) grease to the caliper holder shafts [C] and holder holes (PBC is a special high temperature, water-resistance grease).

B C A C SL05006BS1 C

B C A G513B103 P

• Install the pads (see Brake Pad Installation in the Brakes chapter).
- Install the caliper (see Caliper Installation in the Brakes chapter).
- Wipe up any spilled brake fluid on the caliper with wet cloth.

2-44 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Brake Hose and Connection Check

• Inspect the brake hose and fittings for deterioration, cracks and signs of leakage.
  The high pressure inside the brake line can cause fluid to leak [A] or the hose to burst if the line is not properly maintained. Bend and twist the rubber hose while examining it.
  ★Replace the hose if any cracks [B] or bulges [C] are noticed.
  ★Tighten any loose fittings.

Brake Hose Replacement

NOTICE

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

• When removing the brake hose, take care not to spill the brake fluid on the painted or plastic parts.
• When removing the brake hose temporarily secure the end of the brake hose to some high place to keep fluid loss to a minimum.
• Immediately wash away any brake fluid that spills.
• Remove each banjo bolts [A] and washers [B].
• Replace the washers with new ones.

B C A 0L10010151 C

For Front Brake

- Remove: Bolts [A] Brake Hose Clamps [B]

A B G5138275 P

B A

Periodic Maintenance Procedures

For Rear Brake

- Remove: Master Cylinder [A] Hose Clamps [B] Caliper Cover [C]

A B C GS13B467 P

• When installing the hoses, avoid sharp bending, kinking, flattening or twisting, and route the hoses according to Cable, Wire, and Hose Routing section in the Appendix chapter.
• Tighten the banjo bolts on the hose fittings. Torque - Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb)
• Fill the brake line after installing the brake hose (see Brake Fluid Changing).

Suspension

Front Fork Inspection

• Holding the brake lever, pump the front fork back and forth manually to check for smooth operation.
• Visually inspect the front fork for oil leakage, scoring or scratches on the outer surface of the inner tube [A].
  ★If necessary, repair any damage.
• Nick or rust damage can sometimes be repaired by using a wet-stone to remove sharp edges or raised areas which cause seal damage.
  ★If the damage is not repairable, replace the inner tube. Since damage to the inner tube damages the oil seal, replace the oil seal whenever the inner tube is repaired or replaced.
• If the fork is not smooth, confirm the cause.

NOTICE

If the inner tube is badly bent or creased, replace it. Excessive bending, followed by subsequent straightening, can weaken the inner tube.

Close-up of a bicycle tire and chain components with labeled parts (A), no readable text or symbols beyond labels

Front Fork Oil Change (each fork leg)

- Loosen the front fork upper clamp bolts [A].

Close-up of a mechanical assembly with labeled component A (no readable text or symbols beyond label)

2-46 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

• Loosen the fork top plug [A].
  Special Tool - Top Plug Wrench, 49 mm [B]: 57001-1653
• Remove:
  Front Wheel (see Front Wheel Removal in the Wheels/Tires chapter)
  Front Brake Caliper (see Caliper Removal in the Brakes chapter)
  Brake Hose Clamps (see Brake Hose Replacement)

HAT B A 051482046 P

• Loosen the front fork lower clamp bolts [A].
• Remove the front fork.
  With a twisting motion, work the fork leg [B] down and out.

A B 05148299 P

NOTE

○ Set rebound and compression damping setting to the softest settings before disassembling to prevent the needle of adjusters from damaging. Record the setting before turning the adjuster.

- Thoroughly clean the fork before disassembly.

NOTICE

Be careful not scratch the inner tube and not to damage the dust seal.

Avoid scratching or damaging the inner tube or the dust seal. Use a mild detergent and sponge out dirt with plenty of water.

- Using the top plug wrench [A], remove [B] (subtank) from the outer tube and slowly slide down the outer tube [C].

Special Tool - Top Plug Wrench, 49 mm: 57001-1653

heforktopplug B A C GS148300 P

Periodic Maintenance Procedures

- Place a drain pan under the front fork and drain fork oil [A].

NOTE

○ Pump the fork tube several times to discharge the fork oil.

- Raise the outer tube and temporarily install the fork top plug [A] (subtank) to the outer tube [B] with the top plug wrench [C].

Special Tool - Top Plug Wrench, 49 mm: 57001-1653

Close-up of a metallic pipe fitting with a labeled component (A) and a circular symbol, no readable text or symbols present.

A C B 05148302 P

• Hold the axle holder [A] with a vise.
  ○Protect the axle holder with a rag when using a vise.
• Remove the cap.
• Loosen the adjuster assembly [B] completely.

WARNING

Clamping the axle holder part too tight can damage it which will affect riding stability. Do not clamp the axle holder part too tight.

A B GS148J03.P

- Compress the outer tube by hands and install the top plug wrench [A] between the axle holder bottom [B] and locknut [C].

Special Tool - Top Plug Wrench, 49 mm: 57001-1653

A C B G3148304

WARNING

The fork spring applies pressure to the adjuster assembly and can eject the special tool with substantial force if the tool is not properly and securely placed. Be sure the tool is fully in place as shown in the photo, and keep fingers away to avoid getting them pinched between the tool, adjuster assembly and axle holder.

2-48 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

- Hold the locknut [A] with a wrench [B] and remove the adjuster assembly [C].

- Remove the push rod [A].

- With the outer tube compressed by hands, remove the topplugwrench[A].

NOTICE

Removing the locknut and pushin g the piston rod thread into the cylinder unit will damage the oil seal. Do not remove the locknut from the piston rod.

- Remove the fork leg from the vise.

- Loosen the fork top plug (subtank) [A] with the top plug wrench [B].

Special Tool - Top Plug Wrench, 49 mm: 57001-1653

- Remove: Cylinder Unit [A] Spacer [B] Fork Spring [C]

NOTICE

Disassembling the cylinder unit can lead to trouble. Do not disassemble the cylinder unit.

B A C 05148305 P

Close-up of a hand holding a metal pipe fitting with a labeled component (A), no visible text or symbols on the object itself.

Close-up of a mechanical component with labeled point A and reference number 05148307 (no readable text or symbols beyond labels)

A B 05148308 P

Technical diagram of three mechanical tools labeled A, B, and C, showing internal components without any text or symbols.

Periodic Maintenance Procedures

- Holding the top plug wrench [A] with a vise, loosen the base valve assembly [B] on the subtank [C].

Special Tool - Top Plug Wrench, 49 mm: 57001-1653

A B C

- Remove the base valve assembly [A] from the subtank [B].

NOTE

○ Slowly compress the piston rod until it stops so that the base valve assembly can be removed easily.

A B GS14BD11 P

NOTICE

Disassembling the base valve assembly can lead to trouble.

Do not disassemble the base valve assembly.

- Drain the fork oil [A] from the cylinder unit [B] by pumping the piston rod several times.

A B GS14B312

- Hold the front fork inverted position for more than 20 minutes to allow the fork oil to fully drain.

Technical line drawing of a mechanical assembly or support structure (no text or symbols)

- Clean the threads [A] of subtank and base valve assembly.

Close-up of two mechanical components with labeled parts (A and 05148313), no readable text or symbols beyond labels

2-50 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

- With the piston rod in fully compressed position, pour the specified amount of fork oil [A].

Recommended Oil: KHL15-10 (KAYABA01) or equivalent

Recommended Quantity: 189 ml (6.4 US oz.)

NOTE

○ Plug the two oil holes on the subtank [B] with fingers.

- Pump [A] the piston rod [B] slowly several times to expel air.

- Replace the O-rings [A] on the base valve assembly with new ones.

- Apply specified fork oil to the O-rings [A] [B] and bushings [C] on the base valve assembly.

- With the piston rod held immorable in fully compressed position [A], gently install the base valve assembly [B] to the subtank.

- Screw in the base valve assembly in the subtank when the piston rod extends.

NOTE

○ When it is hard to screw in the base valve assembly, pull down the piston rod a little.

A B G2148314 P

A B 05148315 P

B A C GS148316 P

A GS148317 P

B 05148318 P

Periodic Maintenance Procedures

● Holding the top plug wrench [A] with avise. Special Tool - Top Plug Wrench, 49 mm: 57001-1653
- Holding the subtank [B] with the top plug wrench, torque the base valve assembly [C].

Torque - Base Valve Assembly: 28 N·m (2.9 kgf·m, 21 ft·lb)

A B C

• Protect the piston rod end [A] with a rag [B] to prevent fork damage.
• Discharge the extra oil off the cylinder unit by pumping [C] the piston rod to full stroke.

NOTICE

Be careful not to bend or damage the piston rod when the piston rod is stroked. Service carefully because oil flies out from the oil hole of the cylinder unit.

B A C G GS148020 P

NOTE

○ Set the compression damper setting to the softest.
○ Check the piston rod sliding surface for damage.
○Apply fork oil to the piston rod sliding surface.

- Drain the extra oil from the subtank oil hole [A].

Close-up of a metallic cylindrical mechanical component with labeled section A, mounted on a frame (no text or symbols beyond label)

- With the cylinder unit in horizontal position, move [A] the piston rod [B] by hand to inspect it if operating smoothly. - If the piston rod is not extend, remove the base valve assembly and perform the air bleeding (pour the specified amount fork oil and discharge an excess of oil).

A B GS148322 P

2-52 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

• Completely wipe of the fork oil from the spring [A], spacer [B] and cylinder unit [C].
• Insert above-mentioned parts into the fork.

Technical diagram of three mechanical components labeled A, B, and C, showing internal spring-like structures (no text or symbols beyond labels)

- Temporarily tighten the fork top plug [A] (subtank) using the top plug wrench.

Special Tool - Top Plug Wrench, 49 mm [B]: 57001-1653

A B 05148325 P

• Clamp the axle holder with a vise.
  ○Protect the axle holder with a rag when using a vise.

WARNING

Clamping the axle holder part too tight can damage it which will affect riding stability. Do not clamp the axle holder part too tight.

- Compress the outer tube by hands and install the top plug wrench [A] between the axle holder bottom and locknut.

Special Tool - Top Plug Wrench, 49 mm: 57001-1653

WARNING

The fork spring applies pressure to the adjuster assembly and can eject the special tool with substantial force if the tool is not properly and securely placed. Be sure the tool is fully in place as shown in the photo, and keep fingers away to avoid getting them pinched between the tool, adjuster assembly and axle holder.

- Insert the push rod [A] into the piston rod.

Close-up of a hand holding a metal pipe fitting with a labeled component (A), no visible text or symbols on the main subject.

Close-up of a mechanical clamp or fixture with a labeled component (A) and no visible text or symbols on the main subject.

Periodic Maintenance Procedures

• Replace the O-ring and gasket on the adjuster assembly with new ones and apply specified fork oil to the O-ring.
• Turn the locknut [A] counterclockwise until it contacts with the adjuster assembly [B].
• With the locknut held immovable using a wrench, tighten the adjuster assembly to the specified torque.

Torque - Locknut/Adjuster Assembly: 29N·m (3.0 kgf·m, 22 ft·lb)

- With the outer tube compressed by hands, remove the top plug wrench.

- Apply a non-permanent locking agent to the threads of a adjuster assembly.

- Tighten the adjuster assembly [A]. Torque - Adjuster Assembly: 55 N·m (5.6 kgf·m, 41 ft·lb)

A B 05148329 P

Close-up of a mechanical tool with labeled component A, no visible text or symbols beyond the label

- Loosen and remove the fork top plug (subtank) form the outer tube and slowly slide down the outer tube.

Special Tool - Top Plug Wrench, 49 mm: 57001-1653

- Pour [A] the specified amount of fork oil into the outer tube.

Recommended Oil: KHL15-10 (KAYABA01) or equivalent

Recommended Quantity: 335 mL (11.3 US oz.)

Close-up of a mechanical component with a cylindrical shaft and a tube, labeled 'A' pointing to a white cylindrical part (no text or symbols on the main subject)

Close-up of a motorcycle's front wheel and grip mechanism, showing pressure gauge and labeled parts A and B (no readable text or symbols beyond labels)

- Raise the outer tube and temporarily tighten the fork top plug (subtank).

Special Tool - Top Plug Wrench, 49 mm [A]: 57001-1653

- After installing the front fork, torque the top plug [B].

Special Tool - Top Plug Wrench, 49 mm: 57001-1653

The torque of fork top plug is specified to 30 N·m (3.1 kgf·m, 22 ft·lb) however, when you use the top plug wrench (special tool) [A], reduce the torque to 90% of the specified value [27 N·m (2.8 kgf·m, 20 ft·lb)] due to the distance [B] between the center of the square hole, where the torque wrench is fitted, and that of the octagonal hole of the wrench.

This torque value [27 N·m (2.8 kgf·m, 20 ft·lb)] is applicable when you use a torque wrench whose length gives leverage of approximately 310 mm between the grip point to the center of the coupling square.

B A GN04254B51 C

2-54 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Rear Shock Absorber Inspection

• Bounce [A] the rear of the motorcycle up and down and check for smooth suspension stroke.
• Remove the rear frame (see Rear Frame Removal in the Frame chapter).
• Check for a broken or collapsed spring.
• Check the shock for a bent shaft or oil leaks.
  ★If the shock does not smoothly or damaged, replace or repair defective parts.

Close-up of a white aircraft wing with a hand adjusting the blade, showing a directional arrow labeled 'A' (no text or symbols on the wing itself)

Rear Shock Absorber Oil Change

The oil should be changed in the rear shock absorber at least once per racing season. The frequency for best performance must be based upon riding conditions and rider ability.

• Remove the rear shock absorber from the frame (see Rear Shock Absorber Removal in the Suspension chapter).
• Remove the shock absorber spring (see Spring Replacement in the Suspension chapter).
• Point the valve [A] away from you. slowly release nitrogen gas pressure by pushing down the valve core with a screw driver.

Close-up of two cylindrical industrial components with labeled parts (A), no visible text or symbols on the main body.

WARNING

The shock contains high-pressure nitrogen gas that when suddenly released can eject oil and internal shock parts at high velocity, causing serious injury. To avoid injury, do not point the reservoir valve toward your face or body when releasing nitrogen gas pressure since an oil mist is often released with the nitrogen. Always release nitrogen gas pressure before disassembling the rear shock absorber to prevent explosive separation of parts.

• Adjust the gas reservoir damping adjusters [A] to the softest position.
• Remove the air bleed bolt [B] and pump the rear shock to drain the oil out the rear shock body.
  • Install the air bleed bolt.

Close-up of a mechanical component with labeled parts A and B, no readable text or symbols beyond labels

Periodic Maintenance Procedures

• Using the suitable tool [A] and press, push the reservoir cap [B] in 10 mm (0.39 in.).
• Remove the circlip [C] from the gas reservoir.

A B B C SW05063851 C

- Pull the gas reservoir cap [B] out of the gas reservoir using the pliers [A].

A B GW050108SI C

- Pry or tap [A] at the gaps [B] in the stop [C] with suitable tools to free the stop from the rear shock body [D].

Diagram illustrating a mechanical or electrical setup with labeled components A, B, C, D and directional arrows indicating motion or movement.

• Slide the stop up the top of the piston rod then lightly tap around the seal with a suitable rod and mallet, and push the seal assembly 10 mm (0.39 in.) down.
• Remove the circlip [A].
• Lightly move the piston rod back and forth, and pull out the piston rod assembly.
• Pour the oil out of the rear shock body.

A GW05045851 C

• Visually inspect the piston [A], O-ring [B], and oil seal assy [C].
• If the piston, O-ring and oil seal assy are badly scored, rusty or damaged, replace them.

B A C GS148107 P

2-56 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

• Using the grinder, shave off the stopper portion [A] of the rod.
• Remove:
  Nut [B]
  Washer [C]
  Piston [D]
  • Install the new piston and tighten the locknut.
  ○Discard a washer or two.

- Pour KYB K2-C (SAE 5W or Bel-Ray SE2 #40) oil into the gas reservoir to 60 \~ 70 mm (2.63 \~ 2.76 in.) [A] from the gas reservoir upper end.

D C B A GS14B106 P

A 6W050104S1 C

• Check that the bladder [A] on the gas reservoir cap is not partially collapsed.
  ★If it is, push down the valve core with a screwdriver.
• Check the bladder for sign of damage or crack.
  ★If necessary, replace it with a new one.

NOTICE

Do not use a damaged or partly ally collapsed bladder, because it may burst, gently reducing rear shock performance.

• Apply grease to the lip [B] of the bladder and install the reservoir cap [C].
• Push the bladder into the gas reservoir slowly until it just clears the circlip groove. Wipe out any spilled oil.

NOTICE

Ensure that no air remains in the system.

• Check the circlip for weakening, deformity and flaws.
  ★If necessary, replace it with a new one.

NOTICE

If weakened, deformed or flawed circlip is used, the gas reservoir cap may not hold when injecting the nitrogen gas. This would allow oil and internal parts to explode out of the reservoir.

C A B GM050888S1 C

Periodic Maintenance Procedures

- Mount the circlip [A] in the groove in the gas reservoir.

- Pull up the gas reservoir cap [A] against the circlip. The end of the gas reservoir cap must align [B] with the end of the gas reservoir [C].

WARNING

Pressurized nitrogen gas can explode out of the shock reservoir cap if the circlip is not properly installed, allowing oil and internal parts to burst out of the reservoir with great force and cause serious injury. To avoid injury, be sure to install a new circlip in the proper position. If the end of the gas reservoir cap and the end of the gas reservoir are not aligned, the circlip is not correctly fitted in the groove in the gas reservoir or the circlip is deformed and should be replaced with a new one.

- Pour KYB K2-C (SAE 5W or Bel-Ray SE2 #40) oil into the rear shock body to 55 mm (1.77 in.) [A] from the lower end of the rear shock body [B].

A SW05057851 C

A B C GW05011BS1 C

A B GM05068BS2 C

2-58 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

- Insert the piston end [A] of the piston rod assembly into the rear shock body [C] slowly. Do not insert the seal assembly [B] yet. Pump the piston rod until all the air is forced out of the rear shock body.

• Push the seal assembly into the rear shock body until it just clears the circlip groove.
• Check the circlip.
  ★If it is deformed or damaged, replace it with a new one.
• Fit the circlip [A] into the groove in the rear shock body [B].

NOTICE

If the circlip is not a certain fit in the groove in the rear shock body, the piston rod assembly may come out of the shock absorber when injecting the nitrogen gas or riding the motorcycle.

• Pull up the piston rod assembly [C] against the circlip.
• Force the stop [D] into the rear shock body by lightly tapping around the edge of the stop with a mallet.
• Fully extend the piston rod assembly.

- Install the suitable oil cup [A] to the air bleed bolt hole, and fill the specified oil into the cup.

- Purge the air from between the gas reservoir [B] and rear shock body [C] by slowly pumping the piston rod [D] in and out.

- Install the air bleed bolt securely. Torque - Air Bleed Bolt: 6.5 N·m (0.66 kgf·m, 58 in·lb)

- Fully extend the push rod assembly.

• Inject nitrogen gas to a pressure of 50 kPa (0.5 kgf/cm², 7 psi) through the valve on the gas reservoir.
• Check the rear shock body and gas reservoir for oil and gas leaks.
  ★If there are no leaks, inject the nitrogen gas up to the 980 kPa (10 kgf/cm², 142 psi) pressure.

WARNING

High pressure gas is dangerous and can explode, causing serious injury. To avoid injury, have a qualified mechanic pressurize the shock reservoir with nitrogen gas only. Do not use air or other gases, since they may cause premature wear, rust, fire hazard or substandard performance.

• Install the spring and spring guide.
• Adjust spring preload. Reinstall the rear shock absorber.
• Install the parts removed.

B A C 0W05087851 C

D A C B 6W05089BS1 C

A B C D 0W05105BS1 C

Periodic Maintenance Procedures

Swingarm and Uni-Trak Linkage Inspection

• Check the uni-trak component parts for wear periodically, or whenever excessive play is suspected.
• Using the jack under the frame, raise the rear wheel off the ground.

Special Tool - Jack: 57001-1238

- Push and pull on the swingarm [A], up and down, to check for wear.

★A small amount of play on the swingarm is normal and no corrective action is needed. However, if excessive play is felt, remove the uni-trak parts from the frame and check for wear.

Close-up of a hand adjusting a bicycle wheel rim with a cable, showing tire and chain components (no text or symbols visible)

Swingarm and Uni-Track Linkage Pivot Lubricate

- Refer to the Swingarm Bearing Installation and Rocker Arm Bearing Installation in Suspension chapter.

Steering

Steering Inspection

• Using the jack, raise the front wheel off the ground.
  Special Tool - Jack: 57001-1238

- With the front wheel pointing straight ahead, alternately nudge each end of the handlebar. The front wheel should swing fully left and right from the force of gravity until the fork hits the stop.

★If the steering binds or catches before the stop, check the routing of the cables, hoses, and harnesses.

★If the steering feels tight, adjust or lubricate the steering.

- Feel for steering looseness by pushing and pulling the forks.

★If you feel looseness, adjust the steering.

Close-up of hands assembling a bicycle tire with visible wheel rim and tire, no text or symbols present

Steering Adjustment

- Using the jack, raise the front wheel off the ground. Special Tool - Jack: 57001-1238

2-60 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

- Remove: Handlebar Pad [A] Headlight [B] (see Headlight Removal/Installation in the Electrical System chapter)

- Remove: Handlebar Clamp Bolts [A] Handlebar Clamps [B] Handlebar [C] (from holder)

- Loosen the front fork upper clamp bolts [A], and remove the steering stem head nut [B] and steering stem head [C].

- Turn the steering stem nut [A] with the steering stem nut wrench [B] to obtain the proper adjustment. ★If the steering is too tight, loosen the stem nut a fraction of a turn; if the steering is too loose, tighten the nut a fraction of a turn.

Special Tool - Steering Stem Nut Wrench: 57001-1100

NOTE

○ Turn the stem nut 1/8 turn at a time maximum.

- Install the steering stem head. - Tighten the following: Torque - Steering Stem Head Nut: 98 N·m (10 kgf·m, 72 ft·lb) Upper Front Fork Clamp Bolts: 23 N·m (2.3 kgf·m, 17 ft·lb)

NOTE

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

- Check the steering again. ★If the steering is too tight or too loose, repeat the adjustment as mentioned above.

BENTHA A

A B C GS15B170 P

A B C A 00158171 P

A B GS15B172 P

Periodic Maintenance Procedures

• Install the handlebar [B] on the handlebar holder so that the protruded scales of the both side adjust to the same width [A].
• Route the hose according to Cable, Wire, and Hose Routing section in the Appendix chapter.
• Apply 2-stroke oil to the threads of the handlebar clamp bolts.
• Install the handlebar clamp so that center [D] of the handlebar clamps [C] and handlebar bridge [E] align.

Torque - Handlebar Clamp Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb)

Front [F]

• After tighten, make sure space [A] [B] of the ahead and back are same width.
• Install the handlebar pad and number plate.

F A A B C D E C GS15026851 C

B B A A GB158173 P

Stem Bearing Lubrication

• Remove the steering stem (see Steering Stem, Stem Bearing Removal in the Steering chapter).
• Using a high-flash point solvent, wash the upper and lower tapered rollers in the cages, and wipe the upper and lower outer races, which are press-fitted into the frame head pipe, clean off grease and dirt.
• Visually check the outer races and the rollers.
  ★Replace the bearing assemblies if they show wear or damage.
• Pack the upper and lower tapered roller bearings [A] in the cages with grease, and apply a light coat of grease to the upper and lower outer races.
  • Install the steering stem, and adjust the steering (see Steering Adjustment).

Technical line drawing of a mechanical assembly with labeled components (no readable text or symbols)

Frame

Frame Inspection

• Clean the frame with steam cleaner.
• Visually inspect the frame and rear frame for cracks, dents, bending, or warp.
  ★If there is any damage to the frame, replace it.

WARNING

A repaired frame may fail in use, possibly causing an accident resulting in injury or death. If the frame is bent, dented, cracked, or warped, replace it.

Technical line drawing of a mechanical bracket assembly (no text or symbols)

2-62 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Electrical System

Spark Plug Cleaning and Inspection

• Remove:
  Seat (see Seat Removal in the Frame chapter)
  Fuel Tank (see Fuel Tank Removal in the Fuel System chapter)
  Spark Plug Cap

- Clean the plug hole [A], using the compressed air [B].

- Remove the spark plug [A], using the spark plug wrench [B].

Special Tool - Spark Plug Wrench: 57001-1262

Owner's Tool - Spark Plug Wrench, 16 mm: 92110-0005

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

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

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

★If the gap is incorrect, carefully bend the side electrode [B] with a suitable tool to obtain the correct gap.

Spark Plug Gap

Standard: 0.8 \~ 0.9 mm (0.03 \~ 0.04 in.)

• Install the spark plug.

Torque - Spark Plug: 13 N·m (1.3 kgf·m, 115 in·lb)

- Fit the plug cap securely.

○Pull the spark plug cap [A] to make sure the installation of the spark plug cap.

A B GS178260 P

Technical diagram of a mechanical assembly with labeled parts A and B, likely for assembly or inspection purposes.

B A Q517051051 C

Close-up of a mechanical assembly with hoses and a central component labeled 'A', no visible text or symbols beyond the label.

Cable Inspection

Lubrication

• Before lubricating each part, clean off any rusty spots with rust remover and wipe off any grease, oil, dirt, or grime.
• Lubricate the points listed below with indicated lubricant.

NOTE

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

Periodic Maintenance Procedures

Points: Lubricate with Grease.

Clutch Inner Cable Upper and Lower Ends [A] Hot Start Inner Cable Upper End Throttle Inner Cable Upper End

A GC04010151 C

Cables: Lubricate with Rust Inhibitor.

Throttle Cables Clutch Cable Hot Starter Cable

Line drawing of hands holding a tool with a spray bottle (no text or symbols)

• With the cable disconnected at the both ends, the cable should move freely [A] within the cable housing.
  ★If cable movement is not free after lubricating, if the cable is frayed [B], or if the cable housing is kinked [C], replace the cable.

A B C G0040201S2 C

Nut, Bolt, and Fastener Tightness Inspection Tightness Inspection

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

NOTE

○ For the engine fasteners, check the tightness of them when the engine is cold (at room temperature).

2-64 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

★If there are loose fasteners, retorque them to the specified torque following the specified tightening sequence. Refer to the Torque and Locking Agent section of the General Information chapter for torque specifications. For each fastener, first loosen it by 1/2 turn, then tighten it.

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

Nut, Bolt and Fastener to be checked

Wheels:

Spoke Nipples

Front Axle Nut

Front Axle Clamp Bolt

Rear Axle Nut Cotter Pin

Rear Axle Nut

Final Drive:

Chain Adjuster Locknut

Rear Sprocket Nuts

Brakes:

Front Master Cylinder Clamp Bolts

Brake Lever Pivot Nut

Front Caliper Mounting Bolts

Brake Pedal Bolt

Rear Brake Joint Cotter Pin

Rear Master Cylinder Mounting Bolts

Rear Caliper Mounting Bolts

Suspension:

Front Fork Clamp Bolts

Front Fender Bolts

Rear Shock Absorber Mounting Bolts, Nuts

Swingarm Pivot Nut

Steering:

Steering Stem Head Nut

Handlebar Clamp Bolts

Engine:

Throttle Cable Adjuster Locknuts

Engine Mounting Bolts, Nuts

Shift Pedal Bolt

Muffler Mounting Bolts

Exhaust Pipe Holder Nuts

Clutch Cable Adjuster Locknut

Clutch Lever Pivot Nut

Others:

Footpeg Cotter Pins

Rear Frame Bolts

Fuel System

Table of Contents

Exploded View 3-2

Specifications 3-6

Special Tool 3-7

Throttle Grip and Cable 3-8

Free Play Inspection 3-8

Free Play Adjustment.... 3-8

Throttle Cable Replacement 3-8

Throttle Cable Lubrication 3-9

Throttle Cable Inspection 3-9

Hot Starter Cable Removal 3-10

Hot Starter Cable Installation 3-10

Hot Starter Lever Free Play Inspection.... 3-10

Hot Starter Lever Free Play Adjustment 3-11

Hot Starter Cable Lubrication.... 3-11

Hot Starter Cable Inspection.... 3-11

Carburetor 3-12

Idle Speed Inspection 3-12

Idle Speed Adjustment.... 3-12

Service Fuel Level Inspection 3-12

Service Fuel Level Adjustment 3-13

Carburetor Removal.... 3-14

Carburetor Installation.... 3-16

Fuel Inspection 3-17

Carburetor Disassembly 3-17

Carburetor Cleaning 3-20

Carburetor Inspection 3-21

Carburetor Assembly 3-22

Air Cleaner.... 3-28

Air Cleaner Housing Removal 3-28

Air Cleaner Housing Installation.... 3-28

Element Removal.... 3-28

Element Installation.... 3-29

Element Cleaning and Inspection 3-29

Fuel Tank 3-30

Fuel Tank Removal 3-30

Fuel Tank Installation 3-30

Fuel Filter Removal 3-30

Fuel Filter Installation 3-30

Fuel Tank, Filter and Tap Cleaning 3-31

Fuel Tap and Filter Inspection.... 3-31

3-2 FUEL SYSTEM

Exploded View

Exploded view diagram of a mechanical assembly with numbered parts and labeled components (R, CL, G, 1-22)

Exploded View

No.	Fastener	Torque			Remarks
		N·m kgf	m ft·lb
1	Throttle Pulley Cover Bolt	3.4	0.35	30 in·lb
2	Throttle Cable Mounting Bolts	6.9	0.70	61 in·lb

1. Hot Starter Cable
2. Throttle Cables
3. Throttle Grip
4. Carburetor Cap
5. Throttle Valve Plate
6. Throttle Valve
7. Jet Needle
8. Throttle Pulley Shaft
9. Choke Knob
10. Idle Adjusting Screw
11. Pilot Jet
12. Main Jet
13. Needle Jet
14. Starter Jet
15. Float
16. Leak Jet
17. Throttle Sensor
18. Hot Start Plunger

19. Slow Air Jet
    CL: Apply cable lubricant.
    G: Apply grease.
    2T: Apply 2-stroke oil.
    R: Replacement Parts

20. Acceleration Pump Diaphragm

3-4 FUEL SYSTEM

Exploded View

Technical diagram of automotive engine components with numbered parts and exploded views

Exploded View

No.	Fastener	Torque			Remarks
		N·m kgf	m ft·lb
1	Vacuum Switch Valve Bracket Bolts	9.8	1.0	87 in·lb
2	Fuel Tap Knob Screws	0.80	0.080	7.0 in·lb
3	Rear Frame Mounting Bolts	34	3.5	25

1. Fuel Tank Cap
2. Fuel Tank
3. Fuel Tap
4. Element
5. Frame
6. Holder
7. Air Cleaner Duct
8. Air Cleaner Housing
9. Rear Frame
10. U.S.A., California, and Canada Models
    AD: Apply adhesive cement.
    G: Apply grease.
    O: High-quality foam air filter oil.
    R: Replacement Parts

3-6 FUEL SYSTEM

Specifications

Item Standard
Throttle Grip and Cable
Throttle Grip Free Play	2 ~ 3 mm (0.08 ~ 0.12 in.)
Hot Starter Lever Free Play	0.5 ~ 1.0 mm (0.02 ~ 0.04 in.)
Carburetor
Make/Type KEIHIN FCR-MX40
Starter Jet #55
Leak Jet #50
Main Jet #145
Throttle Valve Cutaway 1.5
Jet Needle NLZU, (EUR) (AU) NCVU
Jet Needle Clip Position	(EUR) (AU) 2th groove from the top
Slow Jet #45
Slow Air Jet	#100
Pilot Air Screw (turns out)	2 1/2, (EUR)(AU) 2 (reference)
Service Fuel Level(below the bottom edge of the carb. body)	6.5 ±1 mm (0.26 ±0.04 in.)
Float Height	8 ±1 mm (0.3 ±0.04 in.)
Air Cleaner
Air Cleaner Element Oil	High quality form air filter oil

Special Tool

Fuel Level Gauge, M18 × 1.0: 57001-122

Technical line drawing of a mechanical device with a curved handle and threaded connector (no text or symbols)

3-8 FUEL SYSTEM

Throttle Grip and Cable

If the throttle grip has excessive free play due to cable stretch or misadjustment, there will be a delay in throttle response. Also, the throttle valve may not open fully at full throttle. On the other hand, if the throttle grip has no play, the throttle will be hard to control, and the idle speed will be erratic. Check the throttle grip play periodically in accordance with the Periodic Maintenance Chart, and adjust the play if necessary.

The throttle cable routing is shown in Cable, Wire, and Hose Routing Section in the Appendix chapter.

Free Play Inspection

- Refer to the Throttle Grip Free Play Inspection in the Periodic Maintenance chapter.

Free Play Adjustment

- Refer to the Throttle Grip Free Play Adjustment in the Periodic Maintenance chapter.

Throttle Cable Replacement

- Slide out the dust cover [A] and cable housing dust cover [B].

- Unscrew the screws [A]. - Separate the throttle cable housing [B].

- Free the tips [A] from the grip [B].

B A 00048103

Close-up mechanical diagram showing labeled components A and B with annotations, likely from a technical manual or assembly.

Close-up of a mechanical device with labeled parts A and B, showing internal components and wiring.

Throttle Grip and Cable

• Remove the exhaust pipe (see Muffler Removal in the Engine Top End chapter).
• Unscrew the bolt [A].
• Remove the throttle pulley cover [B].

A B 02048106

• Loosen the mounting bolts [A].
• Remove the cables [B] from the carburetor.
• Free the tips [C] from the pulley.
• Pull out the cables from the frame.

C O B A GC04018BSI C

• Lubricate the cable.
• Apply grease to the tips of the cables.
• Install the throttle cable lower ends [A].
  • Install the mounting bolts [B] to the holder as shown.
  • Install the throttle pulley cover.

A B O GC04019B51 C

Torque - Throttle Cable Mounting Bolts: 6.9 N·m (0.70 kgf·m, 61 in·lb)

Throttle Pulley Cover Bolt: 3.4 N·m (0.35 kgf·m, 30 in·lb)

• Install the throttle cable in accordance with the Cable, Wire, and Hose Routing section in the Appendix chapter.
  ● After the installation, adjust each cable properly.

WARNING

Operation with incorrectly routed or improperly adjusted cables could result in an unsafe riding condition. Be sure the cables are routed correctly and properly adjusted.

Throttle Cable Lubrication

• Whenever the throttle cable is removed or in accordance with the Periodic Maintenance Chart, lubricate the these cables (see Lubrication in the Periodic Maintenance chapter).
  ○Apply a thin coating of grease to the cable upper or lower ends.
  ○Use a commercially available pressure cable lubricator to lubricate these cables.

Throttle Cable Inspection

- Refer to the Cable Inspection in the Periodic Maintenance chapter.

3-10 FUEL SYSTEM

Throttle Grip and Cable

Hot Starter Cable Removal

• Slide the clutch lever dust cover [A] back.
• Loosen the locknut [B].
• Turn in the adjuster [C] fully.

• Remove the cable end [D] from the hot starter lever [E].

• Remove: Fuel Tank (see Fuel Tank Removal)

• Unscrew the plunger cap bolt [A] and remove the cable end.

• Disassemble the cable end from the plunger [A]. Spring [B] Plunger Cap Assy [C]

- Remove: Clamps [A] (Open) Hot Starter Cable [B]

C B D E A GO04B107 P

Close-up of automotive engine components with hoses and a labeled component (A), no readable text or symbols beyond the label.

A B C 0048109 P

A B 0004022851 C

Hot Starter Cable Installation

• Install the hot starter cable in accordance with the Cable, Wire and Hose Routing section in the appendix chapter.
• After the installation, adjust the cable properly.

WARNING

Operation with incorrectly routed or improperly adjusted cables could result in an unsafe riding condition. Be sure the cables are routed correctly and properly adjusted.

Hot Starter Lever Free Play Inspection

- Refer to the Hot Starter Lever Free Play Inspection in the Periodic Maintenance chapter.

Throttle Grip and Cable

Hot Starter Lever Free Play Adjustment

- Refer to the Hot Starter Lever Free Play Inspection in the Periodic Maintenance chapter.

Hot Starter Cable Lubrication

- Whenever the hot starter cable is removed or in accordance with the Periodic Maintenance Chart, lubricate the these cable (see Lubrication in the Periodic Maintenance chapter).

Hot Starter Cable Inspection

- Refer to the Cable Inspection in the Periodic Maintenance chapter.

Carburetor

Since the carburetor regulates and mixes the fuel and air going to the engine, there are two general types of carburetor trouble: too rich a mixture (too much fuel), and too lean a mixture (too little fuel). Such trouble can be caused by dirt, wear, maladjustment, or improper fuel level in the float chamber. A dirty or damaged air cleaner can also alter the fuel to air ratio.

Idle Speed Inspection

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

Idle Speed Adjustment

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

Service Fuel Level Inspection

WARNING

Gasoline is extremely flammable and can be explosive under certain conditions. Always stop the engine and 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.

• Turn the fuel tap to the OFF position.
• Remove the fuel tank (see Fuel Tank Removal).
• Remove the carburetor, and hold it in true vertical position on a stand. The fuel hose and carburetor cable do not have to be removed to inspect the fuel level [A].
• Put the fuel tank on a bench, and connect the fuel tap to the carburetor using a suitable hose.
• Remove the drain plug from the bottom of the float bowl, and screw a fuel level gauge [B] into the plug hole.

Special Tools - Fuel Level Gauge, M18 × 1.0: 57001-122

D C A B QC06122BS2 C

• Hold the gauge vertically against the side of the carburetor body so that the "zero" line [C] is several millimeters higher than the bottom edge [D] of the carburetor body.
• Turn the fuel tap to the ON position to feed fuel to the carburetor.
• Wait until the fuel level in the gauge settles.
• Keeping the gauge vertical, slowly lower the gauge until the "zero" line is even with the bottom edge of the carburetor body.

NOTE

☐ Do not lower the "zero" line below the bottom edge of the carburetor body. If the gauge is lowered and then raised again, the fuel level measure 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.

Carburetor

- Read the fuel level in the gauge and compare it to the specification.

Service Fuel Level (below the bottom edge of the carb. body)

Standard: -6.5 ±1 mm (-0.26 ±0.04 in.)

★If the fuel level is incorrect, adjust it.
- Turn the fuel tap to the OFF position and remove the fuel level gauge.
• Install the drain plug on the bottom of the float bowl.

Service Fuel Level Adjustment

WARNING

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

• Remove the carburetor, and drain the fuel into a suitable container.
• Remove the float bowl (see Carburetor Disassembly).
• Drive out the pivot pin [A] and remove the float [B] with valve needle [C].

- Bend the tang [A] on the float arm very slightly to change the float height. Increasing the float height lowers the fuel level and decreasing the float height raises the fuel level.

Float Height

Standard: 8 ±1 mm (0.3 ±0.04 in.)

A B C 0008540 P

Close-up of a hand holding a tool with labeled component A, showing two black plastic clips (no text or symbols on the clips themselves)

Carburetor

NOTE

○Float height [A] is the distance from the float bowl mating surface [B] of the carburetor body (with the gasket removed) to the top of the float [C]. Measure the height with the carburetor upside down.
○Do not push the needle rod [D] in during the float height measurement.

B D C A 000088051 C

• Assemble the carburetor, and recheck the fuel level.
  ★If the fuel level cannot be adjusted by this method, the float or the float valve is damaged.

Carburetor Removal

WARNING

Gasoline is extremely flammable and can be explosive under certain conditions. Always stop the engine and 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.

• Turn the fuel tap lever [A] to the OFF position.
  ○Slide off the clamp [B] and pull the fuel hose [C] off the tap.

• Remove the fuel tank (see Fuel Tank Removal).

• Disconnect the throttle sensor connector [A].

A B C 00048542 P

Close-up of a mechanical assembly with labeled component A (no readable text or symbols)

Carburetor

- Loosen the clamp screw [A] fully.

- Remove: Engine Mounting Bracket Bolts [B] Right Engine Mounting Bracket [C]

- Remove:

Seat (see Seat Removal in the Frame chapter) Side Covers (see Side Cover Removal in the Frame chapter)

Muffler (see Muffler Removal in the Engine Top End chapter)

Fuel Tank (see Fuel Tank Removal)

Starter Motor (see Starter Motor Removal in the Electrical System chapter)

Battery (see Battery Removal in the Electrical System chapter)

Igniter (see Igniter Removal in the Electrical System chapter)

Tail Light Connector (see Tail Light Removal in the Electrical System chapter)

Rear Frame Bolts [A]

- Pull out the rear frame [B] with the air cleaner housing from the carburetor.

- Unscrew the hot start plunger cap bolt [A].

- Remove the hot start plunger.

- Unscrew the throttle pulley cover bolt [A].

- Remove the throttle pulley cover [B].

Mechanical assembly diagram with labeled components A, B, and C, showing mechanical connections and parts.

Mechanical assembly diagram showing components labeled A and B, no readable text or symbols present

Close-up of a mechanical assembly with hoses and a labeled component (A), no readable text or symbols beyond the label.

A B 00268547 P

Carburetor

• Loosen the mounting bolts [A].
• Pull out the end of the throttle cables [B].
• Free the tips [C].
• Remove the carburetor to the right side of the frame.
• Drain the fuel from the float bowl by removing the drain plug. After draining, install the drain plug securely.
• After removing the carburetor, push a clean, lint-free towel into the carburetor holder and the air cleaner duct to keep dirt or other foreign material from entering.

WARNING

If dirt or dust is allowed to pass through into the carburetor, the throttle may become stuck, possibly causing accident. Replace the air cleaner element according to the maintenance chart.

NOTICE

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

Carburetor Installation

• Install:
  Throttle Cables (see Throttle Cable Replacement) Hot Start Plunger (see Hot Starter Cable Installation)

- Tighten:

Torque - Throttle Pulley Cover Bolt: 3.4 N·m (0.35 kgf·m, 30 in·lb)

Throttle Cable Mounting Bolts: 6.9 N·m (0.70 kgf·m, 61 in·lb)

- When installing the carburetor into the carburetor holder, fit the projection [A] of the carburetor with the groove [B] on the holder.

○Fit the claw [A] of the clamp onto the groove [B] of the intake duct.

- Tighten the clamps securely.

- Route the air vent and overflow hoses properly (see Cable, Wire, and Hose Routing Section in the Appendix chapter).

NOTICE

Always keep the hoses free of obstruction, and make sure they do not get pinched by the chain or shock absorber.

• Connect the throttle sensor connector.
• After installing the carburetor, do the following.
  ○Turn the fuel tap to the ON position, and check for fuel leakage from the carburetor.

WARNING

Fuel spilled from the carburetor is hazardous.

C O B A GC0401B951 C

Mechanical component diagram with labeled parts A and B, showing mechanical assembly and mounting details

A B GC00124851 C

Carburetor

○Adjust the following items if necessary:

Throttle Cable (see Throttle Grip Free Play Adjustment in the Periodic Maintenance chapter)

Idle Speed (see Idle Speed Adjustment in the Periodic Maintenance chapter)

Fuel Inspection

- Refer to the Fuel Inspection in the Periodic Maintenance chapter.

Carburetor Disassembly

• Remove the carburetor, and drain the fuel into a suitable container (see Carburetor Removal).

• Remove all vent hoses [A] and fuel hose [B].

• Unscrew the screw [A].

• Pull out the fuel hose fitting [B].
• Unscrew the carburetor cap bolts [A].
• Remove the carburetor cap [B].
• Unscrew the throttle valve link screw [A].
• Pull out the throttle valve assembly [B].

Technical diagram of a mechanical device with labeled components A and B, showing internal components and wiring.

Close-up of a mechanical component with labeled parts A and B (no readable text or symbols beyond labels)

Technical diagram of a mechanical component with labeled parts A and B, showing alignment or assembly relationships.

Technical diagram of a mechanical assembly with labeled parts A and B, likely for assembly or maintenance reference.

3-18 FUEL SYSTEM

Carburetor

- Disassemble the throttle valve assembly; jet needle holder [A] (unscrew), spring [B], retainer [C], jet needle with circlip [D], O-ring with throttle valve plate [E], and throttle valve [F].

- Remove the choke knob/starter plunger assembly [A] from the carburetor.

- Remove the throttle pulley shaft [A] with the spring [B], steel washer [C], plastic washer [D], and throttle valve link [E].

Turn the throttle pulley shaft [A] clockwise while holding down the acceleration pump lever [B] and clear the idle stop screw [C] to the stopper [D] of the pulley.

- Turn in the pilot air screw [A] fully but not tightly and count the number of turns (Australia and Europe models). ○Record this number as the manufacture-set number of turns out. - Unscrew the pilot air screw (Australia and Europe models).

NOTE

○Do not remove the pilot air screw plug (U.S.A, California, and Canada models).

F D B A C E 00068264 P

Close-up of a mechanical component with labeled parts (A), no readable text or symbols beyond the label

Technical diagram of mechanical assembly with labeled parts A, B, C, D, and E

Mechanical assembly diagram with labeled parts A, B, C, D and directional arrow indicating rotation or movement

Close-up of a mechanical component with labeled parts (A and Z), no readable text or symbols beyond labels

Carburetor

• Unscrew the screws [A].
• Remove the acceleration pump cover [B] from the carburetor.

- Remove the spring [A], diaphragm [B], and the O-rings [C].

A B 0008558 P

A B C C

- Remove the following parts from the carburetor body.

[A] Idle Adjusting Screw
[B] Screws
[C] Clamps
[D] Float Bowl
[E] Leak Jet
[F] O-ring
[G] Pin
[H] Float
[I] Main Jet
[J] Needle Jet
[K] Starter Jet
[L] Pilot Jet
[M] Pilot Air Jet

M L K J I H G F E D C A C B B GC06127BS2 C

- Pull out the push rod [A] of the acceleration pump.

Close-up of a mechanical component with labeled point A (no readable text or symbols beyond label)

Carburetor

• Remove:
  E-clip [A]
  Washer [B]
• Pull out the acceleration pump lever assembly [C] as a set.

C B A 60048543 P

• Remove the throttle sensor mounting bolt [A].
• Before removing the throttle sensor [B], mark [C] the carburetor body and sensor so that it can be installed later in the same position.

A B C

Carburetor Cleaning

WARNING

Gasoline and low-flash point solvents can be flammable and/or explosive and cause severe burns. Clean the carburetor in a well-ventilated area, and take care that there are no sparks or flame anywhere near the working area; this includes any appliance with a pilot light. Do not use gasoline or a low-flash point solvent to clean the carburetor.

• Make sure the fuel tap is in the OFF position.
• Remove the carburetor (see Carburetor Removal).
• Drain the fuel in the carburetor.
• Disassemble the carburetor (see Carburetor Disassembly).

NOTICE

Do not use compressed air on an assembled carburetor, the float may be deformed by the pressure. 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. Do not use a strong carburetor cleaning solution which could attack the plastic parts; instead, use a mild high-flash point cleaning solution safe for plastic parts. Do not use wire or any other hard instrument to clean carburetor parts, especially jets, as they may be damaged.

Carburetor

• Immerse all the metal parts in a carburetor cleaning solution.
• Rinse the parts in water.
  ● After the parts are cleaned, dry them with compressed air.
• Blow through the air and fuel passages with compressed air [A].
• Assemble the carburetor, and install it on the motorcycle.

Close-up of a hand using a pliers to adjust or install a mechanical component (no visible text or symbols)

Carburetor Inspection

WARNING

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

• Remove the carburetor (see Carburetor Removal).
• Before disassembling the carburetor, check the fuel level (see Service Fuel Level Inspection).
  ★If the fuel level is incorrect, inspect the rest of the carburetor before correcting it.
• Turn the throttle pulley to check that the throttle valve [A] moves smoothly and returns by spring pressure.
  ★If the throttle valve does not move smoothly. Replace the throttle valve or pulley spring.
• Disassemble the carburetor (see Carburetor Disassembly).
• Clean the carburetor (see Carburetor Cleaning).

- Check the tapered portion [A] of the pilot air screw [B] for wear or damage.

★If the pilot air screw is worn or damaged on the tapered portion, it will prevent the engine from idling smoothly. Replace the carburetor.

Close-up of a mechanical component with a hand holding a tool, showing internal structure and part A (no text or symbols visible)

B A GC08014451 ©

Carburetor

• Remove the float valve needle.
• Check the plastic tip [A] of the float valve needle [B] for wear.
  ★If the needle is worn as shown right [C], replace the valve needle.
• Push the rod [D] in the valve needle, then release it.
  ★If the rod does not come out fully by spring tension, replace the valve needle.
  Push and release [E]

A B C D E 000014351 C

• Remove the starter jet.
• Check the slow jet for any damage.
  ★If the slow jet is damaged, replace it with a new one.
• Remove the throttle valve and jet needle.
• Inspect the outside of the throttle valve and plate for scratches and abnormal wear.
  ★If it is badly scratched or worn, replace the throttle valve or plate.
• Inspect the inside of the carburetor body for these same faults.
  ★If it is badly scratched or worn, replace the entire carburetor.
• Check the jet needle for wear.
• For the throttle sensor inspection, see the Electrical System chapter.
  ★A worn jet needle should be replaced.
• Clean the fuel and air passages with a high-flash point solvent and compressed air.

Carburetor Assembly

• Clean the disassembly parts before assembling.
  ○Clean the fuel and air passages with a high-flash point solvent and compressed air [A].

Close-up of a mechanical component with labeled parts A and a circular marker, likely from an engineering or manufacturing context.

- Set up the acceleration pump lever assembly as shown.
Acceleration pump lever [A]
Spring [B]

Push Rod Holder [C]

Adjusting Screw with Spring [D]

○Fit the spring end on the stopper [E] of the push rod holder.

A B C D E 9008567 P

Carburetor

- Install the return spring [A] to the acceleration pump lever [B].

A B 0048568 P

- Install the acceleration pump lever assembly to the carburetor body.

○Fit the end [A] of the return spring into the recess [B] on the carburetor body.

Close-up mechanical component with labeled parts A and B (no readable text or symbols)

• Install: Washer [A] E-clip [B]

Mechanical assembly diagram showing internal components labeled A and B (no readable text or symbols beyond labels)

- Apply thin coat silicone grease to the shaft.

- Fit the hook [A] of the return spring onto the stopper [B] of the throttle cable pulley.

A B GC068571 P

- Insert the throttle cable pulley shaft [A] and install the steel washer [B], nylon washer [C] and valve link [D].

A B C D

3-24 FUEL SYSTEM

Carburetor

○Fit the end [A] of the return spring into the recess [B] of the carburetor body.

- Turn the pulley counterclockwise [A] while holding down the acceleration pump lever [B] and clear the stopper [C] of the pulley from the throttle stop screw head [D].

- Install the push rod [A] into the push rod holder [B].

● Assembly: Throttle Valve [A] Jet Needle [B] Circlip [C] Retainer [D] Spring [E] Jet Needle Holder [F] O-ring [G] Throttle Valve Plate [H]

○Assemble the valve plate so that the hole side [I] down ward.

• Apply a non-permanent locking agent to the link screw.
• Insert the throttle valve assembly.
  ○Insert the link rollers [A] on the throttle link into the slits [B] of the throttle valve.
• Tighten the screw.

A B 0068573 P

Mechanical assembly diagram with labeled parts A, B, C, D and directional arrow indicating rotation or movement

A B 0008675

H G B I A F E D C GG00089B51 C

B A 0008576 P

Carburetor

• Apply a grease to the O-ring [A].
• Fit the stopper [B] of the throttle sensor onto the projection [C] on the throttle cable pulley shaft.
  ○Install the throttle sensor so that the marks aligns and check it position (see Throttle Sensor Inspection in the Electrical System chapter).

C B A 0008577 F

• Install:
  O-ring [A]
  Carburetor Cap [B]
  Bolts (tighten)

Close-up of a mechanical component with labeled parts A and B, showing a finger interacting with a housing or fixture.

• Install:
  Starter Jet [A]
  Pilot Jet [B]
  Baffle Plate [C]
  Needle Jet [D]
  Main Jet [E]

Labeled diagram of a hand holding a mechanical component with five labeled parts (A–E) pointing to different parts.

• Replace the O-ring with new one (Australia and Europe models).
  • Install (Australia and Europe models):
  Pilot Air Screw [A]
  Spring [B]
  Washer [C]
  O-ring [D]

D B C A 0006500 P

Turn in the pilot air screw fully but not tightly, and the back it out the counted number of turn (see Carburetor Disassembly).

• Hanging the float valve [A] on the tang [B] of the float [C].
• Fit the float valve into the valve seat.
• Insert the pin [D].

Labeled mechanical assembly diagram showing components A, B, C, and D with connecting rods

3-26 FUEL SYSTEM

Carburetor

• Install:
  Leak Jet [A]
• Replace the O-ring with new one.
• Fit the O-ring [B] onto the groove of the float chamber.

Close-up of a mechanical component with labeled parts A and B, showing internal components without any readable text or symbols.

• Install:
  Float Bowl
• Tighten the screws with hose clamps [A] and cable holder [B] as shown.

A A B GC08143B51 C

- Replace the O-rings with new ones.

- Fit the O-rings [A].

- Install:

Diaphragm [B]

Spring [C]

Acceleration Pump Cover

○Install the diaphragm so that its mark facing [D] outward.

- Tighten the bolts.

Labeled mechanical component diagram showing hand and gear assembly with points A, B, C, D

• Install the choke knob/starter plunger [A].

Close-up of a mechanical component being adjusted with a tool, no visible text or symbols

• Replace the O-rings [A] with the new ones.
  • Install the fuel hose fitting [B].
• Tighten the screws.

A B 000845 P

Carburetor

• Install all hoses [A].
  • Install the carburetor (see Carburetor Installation).

A A GORDUAT

• If turn the adjusting screw of the acceleration pump, follow the procedures below.
  ○Adjust the acceleration pump timing.
  ○Select an arbor [A] of the same diameter as the throttle valve height [B] and insert it under the throttle valve.
  Throttle Valve Height - 1.25 mm (0.0492 in.)

A B

○Turn in the adjusting screw [A] fully.
○Check the push rod holder [B] play.
Turn the adjusting screw counterclockwise gradually to adjust with the push rod holder moving forward or backward till no free play is available.
Push Rod [C]

A B C GC08094BS1 C

Air Cleaner

Air Cleaner Housing Removal

• Remove:
  Side Covers (see Side Cover Removal in the Frame chapter)
  Seat (see Seat Removal in the Frame chapter)
  Muffler (see Muffler Removal in the Engine Top End chapter)
  Rear Fender (see Rear Fender Removal in the Frame chapter)
  Rear Frame Bolts [A]

- Remove the hoses [B] from the air cleaner housing.

- Loosen the air cleaner duct clamp [C].

- Remove the rear frame.

- Unscrew the bolts [A].

- Remove the air cleaner housing [B].

Technical diagram of a vehicle's internal components with labeled parts A, B, and C

A B

Air Cleaner Housing Installation

- Installation is the reverse of the removal.

- Tighten:

Torque - Rear Frame Mounting Bolts: 34 N·m (3.5 kgf·m, 25 ft·lb)

Element Removal

- Remove:

Screw [A]

Front Left Side Cover [B]

KIX450R A B 00078299 P

- Remove:

Wing Bolt [A]

Element [B]

- Stuff a clean, lint-free towel into the carburetor so no dirt is allowed to enter the carburetor.

- Wipe out the inside of the air cleaner housing with a clean damp towel.

Close-up of a mechanical component with labeled parts A and B, no readable text or symbols beyond labels

NOTICE

Check inside of the intake tract and carburetor for dirt. If dirt is present, clean the intake tract and carburetor thoroughly. You may also need to replace the element and seal the housing and intake tract.

Air Cleaner

Element Installation

- When installing the element, coat the lip of the element with a thick layer of all purpose grease [A] to assure a complete seal against the air cleaner element base. Also, coat the base where the lip of the element fits.

- Apply grease to all connections and screw holes in the air cleaner housing and intake tract.

- Take out the towel from the carburetor securely.

• Install the element so that its tab [A] faces leftside and fit the frame projections [B] to the holes of the holder [C].

- Tighten the wing bolt [D].

- Install the seat (see Seat Installation in the Frame chapter).

A GC07046851 C

C B A D 0C070458SI C

Element Cleaning and Inspection

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

Fuel Tank

Fuel Tank Removal

WARNING

Gasoline is extremely flammable and can be explosive under certain conditions. Always stop the engine and 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.

• Turn the fuel tap lever [A] to the OFF position.
• Slide out the clamp [B] and pull the fuel hose [C] off the fuel tap [D].

• Remove the bolt [E].

• Remove: Seat (see Seat Removal in the Frame chapter) Bolts [A]

• Remove the fuel tank mounting bolt [B] and unhook the band [C].
• Pull out the fuel tank breather hose [D] from the steering stem.
• Remove the fuel tank [E] together with the radiator shrouds.
• Drain the fuel.

Fuel Tank Installation

• Check the rubber dampers [A] on the frame.
  ★If the dampers are damaged or deteriorated, replace them.
• Be sure the fuel hose is clamped to the fuel tap to prevent leaks.
• Insert the fuel tank breather hose outlet end into the steering stem hole.

Fuel Filter Removal

• Remove the fuel tank and drain it (see Fuel Tank Removal).
• Remove the mounting bolts [A] and take out the fuel filter [B].

A D B C GC098296 P

B D E C Kawasaki A 00098297

Close-up of mechanical components with labeled parts (A) and connectors, no readable text or symbols beyond the label.

A B 90098299

Fuel Filter Installation

• Replace the O-ring with a new one.
• Be sure to clamp the fuel hose to the tap and fuel filter to prevent leaks.

Fuel Tank

Fuel Tank, Filter and Tap Cleaning

- Refer to the Fuel Tank, Filter and Tap Cleaning in the Periodic Maintenance chapter.

Fuel Tap and Filter Inspection

- Refer to the Fuel Tap and Filter Inspection in the Periodic Maintenance chapter.

Cooling System

Table of Contents

Exploded View 4-2

Coolant Flow Chart.... 4-4

Specifications 4-6

Special Tool 4-7

Coolant 4-8

Coolant Level Inspection 4-8

Coolant Deterioration Inspection 4-8

Coolant Draining 4-8

Coolant Filling 4-9

Air Bleeding 4-10

Cooling System Pressure Testing 4-11

Cooling System Flushing 4-11

Reserve Tank Removal 4-12

Water Pump 4-13

Water Pump Cover Removal 4-13

Water Pump Cover Installation 4-13

Impeller Removal 4-14

Impeller Installation 4-14

Water Pump Inspection 4-14

Oil Seal and Bearing Removal 4-14

Oil Seal and Bearing Installation 4-15

Radiator 4-16

Radiator Removal 4-16

Radiator Installation 4-17

Radiator Inspection 4-17

Radiator Cap Inspection 4-17

Filler Neck Inspection.... 4-18

Hose Inspection 4-18

Hose Installation 4-18

4-2 COOLING SYSTEM

Exploded View

Technical diagram of a mechanical assembly with numbered components and exploded views, likely from an engineering or manufacturing context.

Exploded View

No.	Fastener	Torque			Remarks
		N·m kgf·m ft·lb
1	Water Pump Cover Bolts	9.8	1.0	87 in·lb
2	Coolant Drain Plug	7.0	0.70	62 in·lb
3	Water Pump Impeller Bolt	9.8	1.0	87 in·lb
4	Right Engine Cover Bolts	9.8	1.0	87 in·lb
5	Radiator Hose Clamp Screws	3.0	0.30	27 in·lb

1. Water Pump Cover
2. Impeller
3. Right Engine Cover
4. Right Radiator
5. Left Radiator
6. Radiator Cap
7. Reserve Tank Hose
8. KLX450A9F Model \~
   HG: Apply high-temperature grease.
   R: Replacement Parts

4-4 COOLING SYSTEM

Coolant Flow Chart

Technical diagram of a mechanical assembly with numbered components and directional arrows indicating flow or movement.

Coolant Flow Chart

1. Radiator Cap
2. Radiators
3. Reserve Tank Hose
4. Reserve Tank
5. Reserve Tank Over Flow Hose
6. Cylinder Head Jacket
7. Cylinder Jacket
8. Impeller
9. Hot Coolant
10. Cold Coolant

Permanent type antifreeze is used as a coolant to protect the cooling system from rust and corrosion. When the engine starts, the water pump turns and the coolant circulates.

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

The radiator cap has two valves. One is a pressure valve which holds the pressure in the system when the engine is running. When the pressure exceeds 112.3 \~ 141.7 kPa (1.145 \~ 1.445 kgf/cm², 16.28 \~ 20.55 psi), the pressure valve opens and releases the pressure to the reserve tank. As soon as pressure escapes, the valve closes, and keeps the pressure at 112.3 \~ 141.7 kPa (1.145 \~ 1.445 kgf/cm², 16.28 \~ 20.55 psi). When the engine cools down, another small valve (vacuum valve) in the cap opens. As the coolant cools, the coolant contracts to form a vacuum in the system. The vacuum valve opens and allows the coolant from the reserve tank to enter the radiator.

4-6 COOLING SYSTEM

Specifications

Item Service Limit
CoolantTypeColor GreenMixed Ratio Soft water 50% Freezing Point -35°C (-31°F)Total Amount 1.05 L (1.11 US qt.)	Permanent type antifreeze (soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators)coolant 50%
RadiatorCap Relief Pressure	112.3 ~ 141.7 kPa (1.145 ~ 1.445 kgf/cm2, 16.28 ~ 20.55 psi)

Special Tool

Bearing Driver Set:

57001-1129

Isometric line drawing of a mechanical device with multiple circular components and a central opening (no text or symbols)

4-8 COOLING SYSTEM

Coolant

Check the coolant level each day before riding the motorcycle, and replenish coolant if the level is low. Change the coolant in accordance with the Periodic Maintenance Chart (see Periodic Maintenance chapter).

WARNING

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

Coolant Level Inspection

- Refer to the Coolant Level Inspection in the Periodic Maintenance chapter.

Coolant Deterioration Inspection

- Refer to the Coolant Deterioration Inspection in the Periodic Maintenance chapter.

Coolant Draining

- The coolant should be changed periodically to ensure long engine life.

WARNING

Coolant can be extremely hot and cause severe burns, is toxic and very slippery. Do not remove the radiator cap or attempt to change the coolant when the engine is hot; allow it cool completely. Immediately wipe any spilled coolant from tires, frame, engine or other painted parts. Do not ingest coolant.

- Remove the radiator cap [A].

NOTE

○ Remove the radiator cap in two steps. First turn the cap counterclockwise to the first stop and wait there for a few seconds. Then push down and turn it further in the same direction and remove the cap.

- Remove: Bolt [A] Engine Guard [B]

Close-up of a mechanical component with labeled parts (A) and no visible text or symbols

Technical diagram of a mechanical assembly with labeled parts A and B, likely from an engineering or manufacturing context.

Coolant

- Place a container under the coolant drain plug [A], and drain the coolant from the radiator and engine by removing the drain plug on the water pump cover. Immediately wipe or wash out any coolant that spills on the frame, or engine.

- Inspect the old coolant for visual evidence of corrosion and abnormal smell (see Coolant Deterioration Inspection in the Periodic Maintenance chapter).

- Remove:

Bolts [A]

Reserve Tank Cap [B]

- Turn over the reserve tank, and pour the coolant into the suitable container.

Close-up mechanical component with labeled point A (no readable text or symbols beyond label)

Technical diagram of a mechanical assembly with labeled parts A and B, likely from an engineering or manufacturing context.

Coolant Filling

NOTICE

Use coolant containing corrosion inhibitors made specifically for aluminum engines and radiators in accordance with the instruction of the manufacture's. Soft or distilled water must be used with the antifreeze (see below for antifreeze) in the cooling system. If hard water is used in the system, it causes scale accumulation in the water passages, and considerably reduces the efficiency of the cooling system.

Recommended Coolant

Type:	Permanent type antifreeze (soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators)
Color:	Green
Mixed ratio:	Soft water 50%, Coolant 50%
Freezing point:	-35°C (-31°F)
Total amount	1.05 L (1.11 US qt.)

- Install the drain plug.

○Replace the gasket with a new one.

Torque - Coolant Drain Plug: 7.0 N·m (0.70 kgf·m, 62 in·lb)

Coolant

• Fill the radiator up to the bottom of the radiator filler neck [B] with coolant [A], and install the cap, turning it clockwise about 1/4 turn.
  ○Lean the motorcycle slightly to the right until the radiator filler neck is level to the ground so that the filler neck is located uppermost in order to exhaust the air accumulated in the radiator.

A B 0004018851 C

NOTE

Pour in the coolant slowly so that it can expel the air from the engine and radiator. The radiator cap must be installed into two steps. First turn the cap clock wiseto the first stop. Then push down on it and turn it the rest of the way.

• Check the cooling system for leaks.
• Fill the reserve tank up to the "F" (full) level line [A] with coolant and install the cap.
• Start the engine and warm it up thoroughly.
• Check the coolant level in the reserve tank several times while the engine is cooling down, and replenish as necessary.
  ★If the coolant level is lower than the "L" level line [B], add coolant to the "F" level line.

NOTICE

Do not add more coolant above the "F" level line.

A B

Air Bleeding

Before putting the motorcycle into operation, any air trapped in the cooling system must be removed as follows.

• Start the engine, warm up the engine thoroughly, and then stop the engine. Wait until the engine cools down.
• Remove the radiator cap.
• Check the coolant level (see Coolant Level Inspection in the Periodic Maintenance chapter).
  ★If the coolant level is low, add coolant up to the bottom of the filler neck.
  • Install the radiator cap.
• Check the cooling system for leaks.

Coolant

Cooling System Pressure Testing

NOTICE

During pressure testing, do not exceed the pressure for which the system is designed to work. The maximum pressure is 141.7 kPa (1.445 kgf/cm ^2 , 20.55 psi).

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

NOTE

○ Wet the adapter cap sealing surfaces with water or coolant to prevent pressure leaks.

• Build up pressure in the system carefully until the pressure reaches 141.7 kPa (1.445 kgf/cm², 20.55 psi).
• Watch the gauge for at least 6 seconds. If the pressure holds steady, the cooling system is all right.
• Remove the pressure tester, replenish the coolant, and install the radiator cap.
  ★If the pressure drops and no external source is found, check for internal leaks. Check the cylinder head gasket for leaks.

Cooling System Flushing

Over a period of time, the cooling system accumulates rust, scale, and lime in the water jacket and radiator. When this accumulation is suspected or observed, flush the cooling system. If this accumulation is not removed, it will clog up the water passages and considerably reduce the efficiency of the cooling system.

• Drain the cooling system.
• Fill the cooling system with fresh water mixed with a flushing compound.

NOTICE

Avoid the use of a flushing compound which is harmful to the aluminum engine and radiator. Carefully follow the instructions supplied by the manufacture of the cleaning product.

• Warm up the engine, and run it at normal operating temperature for about ten minutes.
• Stop the engine, and drain the cooling system after the coolant cools down.
• Fill the system with fresh water.
• Warm up the engine and drain the system after the coolant cools down.
• Repeat the previous two steps once more.
• Fill the system with a permanent type coolant, and bleed the air from the system (see Air Bleeding).

A B C GD05013BS1 C

4-12 COOLING SYSTEM

Coolant

Reserve Tank Removal

• Remove: Seat (see Seat Removal in the Frame chapter) Left Side Cover (see Left Side Cover Removal in the Frame chapter)
• Remove: Bolts [A] Cap [B]
• Drain the coolant to the suitable container.
• Remove: Hose [C]

A B C 50058079 P

Water Pump

Water Pump Cover Removal

• Remove engine guard (see Coolant Draining).
• Unscrew the drain plug [A], and drain the coolant (see Coolant Draining).
• Loosen the clamp screw [B], and remove the water hose [C] from the water pump cover.
• Unscrew the cover bolts [D].

- Using the pry points [A], remove the pump cover [B].

D C B D A 0008210 P

A B 0D06B211 P

Water Pump Cover Installation

• Replace the pump cover gasket [A] with a new one.
• Check to see that the dowel pins [B] are in place in the mating surfaces of the right engine cover.

Close-up mechanical component with labeled points A and B, no readable text or symbols beyond labels

A B C D A 5008213 P

• Install the water pump cover.
  ○Replace the drain plug gasket with a new one.
• Tighten:

Torque - Water Pump Cover Bolts [A]: 9.8 N·m (1.0 kgf·m, 87 in·lb)

Coolant Drain Plug [B]: 7.0 N·m (0.70 kgf·m, 62 in·lb)

• Insert the water hose [C] into the water pump cover.
• Tighten:

Torque - Radiator Hose Clamp Screws [D]: 3.0 N·m (0.30 kgf·m, 27 in·lb)

• Fill the cooling system (see Coolant Filling).
• Bleed the air from the cooling system.
• Check the coolant level and add the coolant.

4-14 COOLING SYSTEM

Water Pump

Impeller Removal

• Drain: Coolant (see Coolant Draining)
• Remove: Water Pump Cover (see Water Pump Cover Removal) Impeller Bolt [A] Impeller [B]

A B

Impeller Installation

• Install: Impeller [A]
• Tighten: Torque - Water Pump Impeller Bolt [B]: 9.8 N·m (1.0 kgf·m, 87 in·lb)
  • Install: Water Pump Cover (see Water Pump Cover Installation)

A B

Water Pump Inspection

• Visually check the impeller [A].
  ★If the surface is corroded, or if the blades [B] are damaged, replace the impeller.

Mechanical component diagram with labeled points A and B, no readable text or symbols beyond labels

• Check the drainage outlet passage [A] at the bottom of the right engine cover for coolant leaks.
  ★If the oil seal is damaged, the coolant leaks through the seal and drains through the passage. Replace the oil seals.

Close-up of a mechanical component with labeled point A and arrow indicator (no readable text or symbols)

Oil Seal and Bearing Removal

• Remove: Impeller (see Impeller Removal) Right Engine Cover (see Right Engine Cover Removal in the Engine Right Side chapter) Circlip [A] Water Pump Shaft [B]

A B G006B218 P

Water Pump

• Insert a bar [A] into the water pump shaft hole from the outside of the right engine cover, and remove the ball bearing [B] by tapping [C] evenly around the bearing inner race.
• Remove the spacer [D].
• Remove the ball bearing [E] and oil seal [F] from the right engine cover in the same way as ball bearing removal.
• Insert a bar [A] into the water pump shaft hole from the inside of the right engine cover, and remove the oil seal [B] by tapping [C] evenly around the seal lips.

F E D C A B 0000059851 C

C A B GD06060851 C

Oil Seal and Bearing Installation

NOTICE

If the oil seal or ball bearing is removed, replace all of them with new ones at the same time

• Be sure to replace the oil seals.
• Apply plenty of high-temperature grease to the oil seal lips.
• Press in the new oil seal [A] using a bearing driver set from the outside of the right engine cover so that the seal bottom surface is flush with the end face [B] of the right engine cover.
• Press in the new oil seal [C] using a bearing driver set from the outside of the right engine cover so that the oil seal surface is flush [D] with the surface of the right engine cover.

Special Tool - Bearing Driver Set: 57001-1129

- Press the ball bearings [A] together with the spacer [B] into the hole until the face of the bearing is even [C] with the end of the hole.

Special Tool - Bearing Driver Set: 57001-1129

C B D A G006061851 C

A B A C G006062BS1 C

4-16 COOLING SYSTEM

Radiator

Radiator Removal

- Drain the coolant (see Coolant Draining)

- Remove: Radiator Shrouds

- Loosen: Clamp Screws [A] Clamps [B]

- Remove: Radiator Hoses [C] Bolt [D] Left Radiator Screen [E]

- Remove: Bolts [A] Left Radiator [B]

- Loosen: Clamp Screws [A] - Remove: Radiator Hoses [B] Bolt [C] Right Radiator Screen [D]

- Remove: Bolts [A] Right Radiator [B]

Labeled mechanical components diagram showing parts A, B, C, D, E on a vehicle body assembly

A B GD07B206 P

Labeled mechanical diagram showing components A, B, C, and D with numbered annotations

Technical diagram of a mechanical assembly with labeled components A and B, likely from an engineering or automotive context.

Radiator

Radiator Installation

• Fit the projections [A] of the screen in the holes [B] of the radiator.
  Torque - Radiator Hose Clamp Screws: 3.0 N·m (0.30 kgf·m, 27 in·lb)
• Route the radiator and breather hoses correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter).
• Fill the cooling system with a permanent type coolant.

A B CD078209 P

Technical diagram showing mechanical components labeled A and B with a hand interacting, likely from an automotive or automotive diagnostic context.

Radiator Inspection

• Check the radiator core.
  ★If there are obstructions to air flow, remove them.
  ★If the corrugated fins are deformed, carefully straighten them with the thin blade of a screwdriver [A].

NOTICE

Do not tear the radiator tubes while straightening the fins.

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

NOTICE

When cleaning the radiator with steam cleaner, be careful of the following to prevent radiator damage. Keep the steam gun [A] away more than 0.5 m (1.64 ft) [B] from the radiator core. Hold the steam gun perpendicular to the core surface. Run the steam gun following the core fin direction [C].

A 00070368SI ©

Technical diagram showing a bolt and heat exchanger with labeled components A, B, and C, including a prohibition symbol.

Radiator Cap Inspection

• Check the condition of the valve seals [A], and the top and bottom valve spring [B] of the radiator cap.
  ★If any one of them shows visible damage, replace the cap.

A B GD070008S1 C

4-18 COOLING SYSTEM

Radiator

• Wet the top and bottom valve seals with water or coolant to prevent pressure leaks.
• Install the cap [A] on a cooling system pressure tester [B].
• Watching the pressure gauge, slowly pump the pressure tester to build up the pressure. The gauge hand must remain within the relief pressure range in the table below at least 6 seconds. Continue to pump the tester until the relief valve opens, indicated by the gauge hand flicking downward. The relief valve must open within the specified range.

Technical diagram of a mechanical assembly with labeled parts A and B, showing hands and components.

Radiator Cap Relief Pressure

Standard: 112.3 \~ 141.7 kPa (1.145 \~ 1.445 kgf/cm², 16.28 \~ 20.55 psi)

★If the cap cannot hold the pressure, or if the relief pressure is too high or too low, replace the cap with a new one.

Filler Neck Inspection

• Check the radiator filler neck for signs of damage.
• Check the condition of the top and bottom sealing seats [A] in the filler neck. They must be smooth and clean for the radiator cap to function properly.

Close-up of a mechanical component with labeled part A, showing internal structure and no readable text or symbols.

Hose Inspection

- Refer to the Radiator Hoses and Connections Inspection in the Periodic Maintenance chapter.

Hose Installation

• Install the hoses being careful to follow the performed bends (see Cable, Wire, and Hose Routing section in the Appendix chapter). Avoid sharp bending, kinking, flattening, or twisting.
• Tighten the hose clamps securely.

Torque - Radiator Hose Clamp Screws: 3.0 N·m (0.30 kgf·m, 27 in·lb)

Engine Top End

Table of Contents

Exploded View.... 5-2

Specifications 5-6

Special Tools and Sealant.... 5-9

Clean Air System (U.S.A., California, and Canada Models) 5-12

Vacuum Switch Valve Removal ... 5-13

Vacuum Switch Valve Installation 5-13

Cylinder Head Cover 5-14

Cylinder Head Cover Removal .... 5-14

Cylinder Head Cover Installation. 5-14

Camshaft Chain Tensioner 5-15

Camshaft Chain Tensioner Removal.... 5-15

Camshaft Chain Tensioner Installation.... 5-15

Camshaft 5-17

Camshaft Removal 5-17

Camshaft Installation 5-18

Camshaft Chain Removal...... 5-20

Camshaft Chain Installation...... 5-20

Camshaft and Camshaft Cap Wear.... 5-21

Camshaft Runout 5-21

Cam Wear 5-21

Cylinder Head.... 5-22

Cylinder Compression Measurement 5-22

Cylinder Head Removal 5-23

Cylinder Head Installation...... 5-24

Cylinder Head Cleaning 5-25

Cylinder Head Warp.... 5-25

Valves.... 5-26

Valve Clearance Inspection ..... 5-26

Valve Removal.... 5-26

Valve Installation 5-26

Valve Guide Removal 5-27

Valve Guide Installation 5-27

Valve/Valve Guide Clearance Measurement (Wobble Method) 5-28

Valve Seat Inspection 5-29

Valve Seat Repair 5-29

Cylinder and Piston 5-34

Cylinder Removal 5-34

Piston Removal 5-34

Cylinder and Piston Installation.... 5-34

Cylinder Wear 5-36

Piston Wear 5-36

Piston/Cylinder Clearance 5-36

Piston Ring/Ring Groove Clearance 5-36

Piston Ring Groove Width.... 5-37

Piston Ring Thickness 5-37

Piston Ring End Gap Measurement.... 5-37

Piston, Piston Pin, Connecting Rod Wear Inspection.... 5-38

Carburetor Holder 5-39

Carburetor Holder Installation..... 5-39

Muffler.... 5-40

Muffler Removal 5-40

Muffler Installation.... 5-40

Spark Arrester Cleaning.... 5-40

Exhaust System Inspection...... 5-41

5-2 ENGINE TOP END

Exploded View

Exploded view diagram of a vehicle engine assembly with numbered parts and labeled components

Exploded View

No.	Fastener	Torque			Remarks
		N·m	kgf·m ft·lb
1	Cylinder Head Cover Bolts	9.8	1.0	87 in·lb
2	Cylinder Head Bolts (M10)	59	6.0	44	S, MO
3	Cylinder Head Bolts (M6)	12	1.2	106 in·lb	S
4	Cylinder Bolt	12	1.2	106 in·lb
5	Camshaft Cap Bolts	9.8	1.0	87 in·lb	S, MO
6	Camshaft Sprocket Bolts	12	1.2	106 in·lb	L
7	Carburetor Holder Clamp Screws	2.0	0.20	18 in·lb
8	Plug	20	2.0	15	L
9	Rear Camshaft Chain Guide Bolt	15	1.5	11
10	Oil Pump (Scavenge) Cover Bolts	9.8	1.0	87 in·lb
11	Chain Tensioner Mounting Bolts	9.8	1.0	87 in·lb
12	Chain Tensioner Cap Bolt	5.0	0.51	44 in·lb
13	Water Hose Fitting Bolts	9.8	1.0	87 in·lb
14	Oil Line Plug	3.0	0.31	27 in·lb	L
15	Decompressor Plug Plate Bolt	9.8	1.0	87 in·lb
16	Vacuum Hose Fitting	8.8	0.90	78 in·lb	L
17	Cylinder Head Pipe Mounting Bolt	9.8	1.0	87 in·lb

1. Closed coil end faces down.
2. Circle Mark
3. Top Ring
4. Oil Ring
5. U.S.A., California, and Canada Models

EO: Apply engine oil.

G: Apply grease.

L: Apply a non-permanent locking agent.

M: Apply molybdenum disulfide grease.

MO: Apply molybdenum disulfide oil.

R: Replacement Parts

S: Follow the specific tightening sequence.

SS: Apply silicon sealant.

5-4 ENGINE TOP END

Exploded View

Technical diagram of a mechanical assembly with numbered components and labeled parts

Exploded View

No.	Fastener	Torque			Remarks
		N·m	kgf·m ft·lb
1	Exhaust Pipe Cover Bolts	12	1.2	106 in·lb
2	Rear Muffler Mounting Bolt	20	2.0	15
3	Front Muffler Mounting Bolt (First)	9.8	1.0	87 in·lb
	Front Muffler Mounting Bolt (Final)	20	2.0	15
4	Exhaust Pipe Holder Nuts	20	2.0	15
5	Muffler End Mounting Bolts	10	1.0	89 in·lb
6	Spark Arrester Mounting Bolts	10	1.0	89 in·lb

1. KLX450A8F Model
   R: Replacement Parts

Specifications

Item Standard Service Limit
Camshafts
Cam Height:
Exhaust	36.443 ~ 36.557 mm (1.4348 ~ 1.4392 in.)	36.34 mm (1.431 in.)
Intake	37.143 ~ 37.257 mm (1.4623 ~ 1.4668 in.)	37.04 mm (1.458 in.)
Camshaft Journal, Camshaft Cap Clearance	0.020 ~ 0.061 mm (0.00079 ~ 0.0024 in.)	0.15 mm (0.0059 in.)
Camshaft Journal Diameter	22.959 ~ 22.980 mm (0.90390 ~ 0.90472 in.)	22.93 mm (0.9028 in.)
Camshaft Journal Inside Diameter	23.000 ~ 23.020 mm (0.90551 ~ 0.90630 in.)	23.08 mm (0.9087 in.)
Camshaft Runout	TIR 0.02 mm (0.0008 in.) or less	TIR 0.1 mm (0.004 in.)
Cylinder Head
Cylinder Compression:
Kick Starter	(Usable range) 450 ~ 750 kPa (4.59 ~ 7.65 kg/cm2, 65.2 ~ 109 psi) @ 5 kicks.	- - -
Electric Starter	(Usable range) 450 ~ 750 kPa (4.59 ~ 7.65 kg/cm2, 65.2 ~ 109 psi) @ 420 r/min (rpm)	- - -
Cylinder Head Warp	- - -	0.05 mm (0.002 in.)
Valve
Valve Clearance:
Exhaust	0.20 ~ 0.25 mm (0.0079 ~ 0.0098 in.)	- - -
Intake	0.10 ~ 0.15 mm (0.0039 ~ 0.0059 in.)	- - -
Valve Stem Bend	TIR 0.01 mm (0.0004 in.) or less	TIR 0.05 mm (0.002 in.)
Valve Stem Diameter:
Exhaust	5.455 ~ 5.470 mm (0.2148 ~ 0.2154 in.)	5.44 mm (0.214 in.)
Intake	5.465 ~ 5.480 mm (0.2152 ~ 0.2157 in.)	5.45 mm (0.215 in.)
Valve Guide Inside Diameter:
Exhaust	5.500 ~ 5.512 mm (0.2165 ~ 0.2170 in.)	5.58 mm (0.220 in.)
Intake	5.500 ~ 5.512 mm (0.2165 ~ 0.2170 in.)	5.58 mm (0.220 in.)
Valve/valve Guide Clearance (wobble method):
Exhaust	0.09 ~ 0.16 mm (0.0035 ~ 0.0063 in.)	0.36 mm (0.014 in.)
Intake	0.06 ~ 0.14 mm (0.0024 ~ 0.0055 in.)	0.33 mm (0.013 in.)
Valve Seat Cutting Angle	45°, 32°, 60°	- - -
Valve Seating Surface Outside Diameter:
Exhaust	29.4 ~ 29.6 mm (1.16 ~ 1.17 in.)	- - -
Intake	34.4 ~ 34.6 mm (1.35 ~ 1.36 in.)	- - -
Valve Seating Surface Width:
Exhaust	0.8 ~ 1.2 mm (0.03 ~ 0.047 in.)	- - -
Intake	0.5 ~ 1.0 mm (0.02 ~ 0.039 in.)	- - -

Specifications

Item Standard Service Limit
Valve Spring Free Length:
Exhaust:
Outer	36.2 mm (1.43 in.)	34.6 mm (1.36 in.)
Intake	32.4 mm (1.28 in.)	30.9 mm (1.22 in.)
Intake:
Outer	39.3 mm (1.55 in.)	37.8 mm (1.49 in.)
Inner	36.0 mm (1.42 in.)	34.5 mm (1.36 in.)
Cylinder and Pistons
Cylinder Inside Diameter	96.000 ~ 96.012 mm (3.7795 ~ 3.7800 in.)	96.10 mm (3.783 in.)
Piston Diameter	95.970 ~ 95.980 mm (3.7783 ~ 3.7787 in.)	95.82 mm (3.772 in.)
Piston/Cylinder Clearance	0.020 ~ 0.042 mm (0.00079 ~ 0.0017 in.)	-- --
Piston Ring/Ring Groove Clearance:
Top	0.04 ~ 0.08 mm (0.002 ~ 0.003 in.)	0.18 mm (0.0071 in.)
Piston Ring Groove Width:
Top	1.03 ~ 1.05 mm (0.0406 ~ 0.0413 in.)	1.13 mm (0.0445 in.)
Piston Ring Thickness:
Top	0.970 ~ 0.990 mm (0.0382 ~ 0.0390 in.)	0.90 mm (0.035 in.)
Piston Ring End Gap:
Top	0.25 ~ 0.35 mm (0.0098 ~ 0.014 in.)	0.6 mm (0.02 in.)
Oil	0.15 ~ 0.50 mm (0.0059 ~ 0.020 in.)	0.8 mm (0.03 in.)
Piston Pin Diameter	18.991 ~ 19.000 mm (0.74768 ~ 0.74803 in.)	18.96 mm (0.7465 in.)
Piston Pin Hole Diameter	19.004 ~ 19.010 mm (0.74819 ~ 0.74842 in.)	19.08 mm (0.7512 in.)
Connecting Rod Small End Inside Diameter	19.019 ~ 19.030 mm (0.74878 ~ 0.74921 in.)	19.07 mm (0.7508 in.)

TIR: Total Indicator Readings.

5-8 ENGINE TOP END

Specifications

Cam Height

GE110122S1 C

Cam Height [A]

Camshaft Runout

Technical line drawing of a mechanical component with a pressure gauge (no text or symbols)

Valve Stem Diameter

A B GE15049BS1 C

Valve Stem Diameter [A] 45° [B]

Valve Stem Bend

GE150112S1 C

Dial Gauge [A]

Special Tools and Sealant

Compression Gauge, 20 kgf/cm²: 57001-221

Technical line drawing of a pressure gauge with no text or symbols

Valve Spring Compressor Assembly: 57001-241

Line drawing of a mechanical clamp or spring with a bolt and handle (no text or symbols)

Valve Guide Arbor, 5.5: 57001-1021

Line drawing of a cylindrical mechanical component with textured end (no text or symbols)

Valve Guide Reamer, 5.5: 57001-1079

Technical line drawing of a mechanical tool or rod with no visible text or symbols

Piston Ring Compressor Grip: 57001-1095

Technical line drawing of a mechanical component with cylindrical body and flange (no text or symbols)

Valve Seat Cutter, 45° - 25: 57001-1116

Isometric line drawing of a cylindrical mechanical part with concentric rings and textured top surface (no text or symbols)

Valve Seat Cutter, 32° - 25: 57001-1121

Technical line drawing of a cylindrical mechanical part with concentric rings and textured top surface (no text or symbols)

Valve Seat Cutter, 32° - 38.5: 57001-1122

Isometric line drawing of a cylindrical mechanical part with concentric rings and textured top surface (no text or symbols)

Valve Seat Cutter Holder, 5.5: 57001-1125

Line drawing of a cylindrical mechanical component with a protruding rod (no text or symbols)

Valve Seat Cutter Holder Bar: 57001-1128

Simple line drawing of a cylindrical rod (no text or symbols)

5-10 ENGINE TOP END

Special Tools and Sealant

Valve Seat Cutter, 55° - 35: 57001-1247

Isometric line drawing of a conical object with a circular top and textured base, no text or symbols present.

Spark Plug Wrench, Hex 16: 57001-1262

Technical line drawing of a mechanical tool or support structure (no text or symbols)

Fork Oil Level Gauge: 57001-1290

Technical line drawing of a mechanical assembly with cylindrical components and a spring-like extension (no text or symbols)

Compression Gauge Adapter, M10 × 1.0: 57001-1317

Line drawing of a U-shaped mechanical component with two connectors (no text or symbols)

Piston Ring Compressor Belt, 95 108: 57001-1358

Pure mechanical component diagram without any text, numbers, or symbols

Filler Cap Driver: 57001-1454

Technical line drawing of a mechanical tool with three views: a handle, a gear-like component, and a flat plate (no text or symbols)

Valve Seat Cutter, 45° - 40: 57001-1496

Simple line drawing of a circular mechanical part with concentric rings and a central hole (no text or symbols)

Valve Seat Cutter, 55° - 38.5: 57001-1497

Simple line drawing of a circular mechanical component with a textured top and central hole (no text or symbols)

Valve Guide Driver: 57001-1564

Technical line drawing of two mechanical components with threaded ends, one showing internal structure and the other a rod-like extension (no text or symbols)

Piston Pin Puller: 57001-1568

Technical line drawing of a mechanical device with components and part views (no text or symbols)

Special Tools and Sealant

Valve Spring Compressor Adapter, 24: 57001-1586

Technical line drawing of a mechanical component (no text or symbols)

Valve Guide Driver Attachment D: 57001-1659

Technical line drawing of a mechanical component with a cylindrical shaft and a separate circular part (no text or symbols)

Liquid Gasket, TB1216B: 92104-1064

Line drawing of a cylindrical tool with a pointed tip and flanged end (no text or symbols)

5-12 ENGINE TOP END

Clean Air System (U.S.A., California, and Canada Models)

Technical diagram of an engine assembly with numbered components and directional arrows indicating motion or flow.

1. Air Cleaner
2. Carburetor
3. Vacuum Switch Valve
4. View from A
5. Intake Air
6. Exhaust Gas
7. Secondary Air

Clean Air System (U.S.A., California, and Canada Models)

Vacuum Switch Valve Removal

• Remove:
  Fuel Tank (see Fuel Tank Removal in the Fuel System chapter)
• Slide out the clamp [A].
• Remove the hose [B] from the cylinder head pipe [C].

A B C GE048154

• Slide out the clamps [A] and take off the hoses [B] from the vacuum switch valve.
• Remove the bolts[C] and take off the vacuum switchvalve [D].

A D C A B GE 048159

Vacuum Switch Valve Installation

- Installation is the reverse of removal.

5-14 ENGINE TOP END

Cylinder Head Cover

Cylinder Head Cover Removal

• Remove:
  Fuel Tank (see Fuel Tank Removal in the Fuel System chapter) Spark Plug Cap
• Remove the cylinder head cover bolts [A] and remove the cylinder head cover [B].

A B GE09B104 P

Cylinder Head Cover Installation

• Wipe off any oil, dirt, and dust from the cylinder head matching surface.
• Apply silicon sealant [A] to the cylinder head as shown. Sealant - Liquid Gasket, TB1216B: 92104-1064

Close-up of a mechanical assembly with labeled component A, no visible text or symbols

• Replace the head cover gasket.
  • Install the head cover gasket [A] on the cylinder head.
  • Install the spark plug hole gasket [B].

Close-up mechanical assembly showing internal components with labeled parts (A, B), no readable text or symbols beyond labels

- Make sure that the upper chain guide [A] is bottomed.

NOTICE

Unless the upper chain guide is bottomed, the camshaft chain could push the cylinder head cover upward, leading to an oil leak.

• Install the head cover from the motorcycle left side.

Cross-sectional view of a mechanical component with labeled point A (no text or symbols beyond label)

• Install the head cover bolt washers [A] with the metal side upwards.
• Tighten the cover bolt [B].

Torque - Cylinder Head Cover Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)

- Install the spark plug cap. ○Pull up the spark plug cap lightly to make sure of the installation of the spark plug cap.

A B

Camshaft Chain Tensioner

Camshaft Chain Tensioner Removal

NOTICE

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 "Camshaft Chain Tensioner Installation".

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

• Remove the starter motor (see Starter Motor Removal in the Electrical System chapter).
• Loosen the cap bolt [A]
• Remove the tensioner mounting bolts [B], and remove the chain tensioner body [C].

C B A B GE108.131 P

Camshaft Chain Tensioner Installation

• Remove the tensioner cap bolt and O-ring.
• While compressing the push rod [A], turn it clockwise with a suitable screwdriver until the rod stopped.

Close-up of hands using a mechanical tool to adjust a component (no visible text or symbols)

NOTICE

Do not turn the rod counterclockwise at installation. This could detach the rod and the tensioner cannot be reinstalled.

- While holding the rod in position with a suitable push rod holder plate [A] install the tensioner on the cylinder block.

Unit: mm 3.5 7 12 8.5 GE10014BSI C

5-16 ENGINE TOP END

Camshaft Chain Tensioner

• Replace the chain tensioner gasket with a new one.
• Tighten:

Torque - Chain Tensioner Mounting Bolts [A]: 9.8 N·m (1.0 kgf·m, 87 in·lb)

• Take out the holder plate [B].
• Install the O-ring and tighten the cap bolt.

Torque - Chain Tensioner Cap Bolt: 5.0 N·m (0.51 kgf·m, 44 in·lb)

- Install the starter motor (see Starter Motor Installation in the Electrical System chapter).

A B A

Camshaft

Camshaft Removal

- Remove:

Cylinder Head Cover (see Cylinder Head Cover Removal)

Timing Inspection Cap [A]

Crankshaft Shaft Cap [B]

Special Tool - Filler Cap Driver: 57001-1454

- First, bring the piston to the TDC of the compression stroke.

- Place a wrench over the flywheel nut and turn it counterclockwise to align the TDC mark [A] with the center of the groove [B] of the inspection hole.

- Remove:

Camshaft Chain Tensioner (see Camshaft Chain Tensioner Removal).

Camshaft Cap Bolts [1 \~ 8] (sequence numbers)

Camshaft Caps [A] (together with the oil pipes [B])

- Plug the oil passage and camshaft chain tunnel with a clean cloth for prevent the oil pipe from dropping into the crankcase.

○While keeping parallel, remove the camshaft caps and oil pipes.

- Remove:

Positioning Rings [A]

- Disengage the Camshafts [B] from camshaft chain [C].

- Staff a clean cloth into the camshaft chain tunnel to keep any parts from dropping into the crankcase.

NOTICE

The crankshaft may be turned while the camshafts are removed.

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

A B

B A 0518304 P

Technical diagram of a mechanical assembly with numbered components labeled A and B

C A B GE 118006

5-18 ENGINE TOP END

Camshaft

- Remove: Bolts [A] Auto-Decompressor [B] (with the sprocket)

- Remove: Circlips [A]

Camshaft Installation

• Assemble the auto-decompressor weights [A] and spring [B] to install it to the sprocket [C].
• Replace the circlips [D] with new ones, and install them.
• Apply a non-permanent locking agent to camshaft sprocket bolts.
• Fit the recess [E] of the weight and projections [F] of the camshaft, and install it.

Torque - Camshaft Sprocket Bolts [G]: 12 N·m (1.2 kgf·m, 106 in·lb)

• Apply molybdenum disulfide oil to the ball bearing, all cam and journal surfaces of the camshaft.
• If the camshaft is replaced with a new part, apply a thin coat of molybdenum disulfide grease to the cam and journal surfaces.
• First, bring the crankshaft to the TDC (of either the compression or exhaust stroke).
  ○Place a wrench over the flywheel nut and turn it counterclockwise to align the TDC mark [A] with the center of the groove [B] of the inspection hole.

A B GE118307 P

Close-up of a mechanical gear with labeled component A, showing teeth and central bore (no text or symbols beyond labels)

GE11232B51 C

B A 118009

Camshaft

• Engage the camshaft chain with the camshaft sprockets.
  ○Pull the tension side (exhaust side) of the chain taut to install the chain.
• The timing marks on the sprocket must be aligned with the cylinder head upper surface.
• Pull the chain taut and fit it onto the camshaft sprocket.
• Starting with the timing mark on the front of the exhaust sprocket, count to the 1st pin. Feed the exhaust camshaft thought the chain and align the 29th pin with the timing mark on the intake camshaft sprocket.

EX IN A B D F E C GE11152BW2 0

1st Pin [A]

2nd Pin [B]

29th Pin [C]

Mark (exhaust) [D]

Punch Mark (intake) [E]

Upper Cylinder Head Surface [F]

• Be sure to install the positioning rings [A] and dowel pins [B].
• Plug the oil passage and camshaft chain tunnel with a clean cloth for prevent the any parts from dropping in the crankcase.

Mechanical assembly diagram showing two labeled components A and B connected to internal gears (no text or symbols beyond labels)

Camshaft

• Apply grease to the rubber portions of the oil pipes.
• Assemble:
  Camshaft Caps [A]
  Oil Pipes [B]
• While keeping parallel, install them.

Mechanical component with labeled parts A and B, no visible text or symbols

• Uniformly tighten all bolts and after the camshaft has settled, uniformly tighten all the bolts.
  ○Following the sequence numbers on the camshaft caps. Tighten the cap bolts [1 \~ 8] after applying molybdenum disulfide oil to the thread of them.

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

- Install the camshaft chain tensioner (see Camshaft Chain Tensioner Installation), then, check the camshaft chain timing.

Technical diagram of a mechanical assembly with numbered components for identification

NOTICE

After this procedure, if any resistance is felt while turning over the crankshaft, stop immediately, and check the camshaft chain timing. V alves will be bent if the timing is not properly set.

- Install the cylinder head cover (see Cylinder Head Cover Installation), timing inspection cap, and the balancer shaft cap.

Special Tool - Filler Cap Driver: 57001-1454

Camshaft Chain Removal

• Remove:
  Camshaft (see Camshaft Removal)
  Flywheel (see Flywheel Removal in the Electrical System chapter)
  Oil Pump (Scavenge) Cover Bolts [A]
  Lower Chain Guide [B]
  Front Chain Guide [C]
• Remove the camshaft chain [D] from the crankshaft sprocket.

Mechanical gear assembly diagram with labeled components A, B, C, D

Camshaft Chain Installation

- Hang the camshaft chain [A] to the crankshaft sprocket.

- Install:

Front Chain Guide [B]

Lower Chain Guide [C]

- Tighten:

Torque - Oil Pump (Scavenge) Cover Bolts [D]: 9.8 N·m (1.0 kgf·m, 87 in·lb)

- Install:

Flywheel (see Flywheel Installation in the Electrical System chapter)

Camshaft (see Camshaft Installation)

A B C D 02118314

Camshaft

Camshaft and Camshaft Cap Wear

• Measure each clearance between the camshaft journal and camshaft cap using plastigauge (press gauge) [A].
• Install the camshaft caps (see Camshaft Installation).

NOTE

○ Do not turn the camshaft when the plastigauge is between the journal and camshaft cap.

★If any clearance exceeds the service limit, measure the diameter of each camshaft journal with a micrometer.

Camshaft Journal, Camshaft Cap Clearance

Standard: 0.020 \~ 0.061 mm (0.00079 \~ 0.0024 in.)

Service Limit: 0.15 mm (0.0059 in.)

★If the camshaft journal diameter is less than the service limit, replace the camshaft with a new one and measure the clearance again.

Camshaft Journal Diameter

Standard: 22.959 \~ 22.980 mm (0.90390 \~ 0.90472 in.)

Service Limit: 22.93 mm (0.9028 in.)

★If the clearance still remains out of the service limit, replace the cylinder head unit.

Camshaft Runout

• Remove the camshaft (see Camshaft Removal).
• Set the camshaft in a camshaft alignment jig or on V blocks.
• Measure the runout with a dial gauge at the specified place as shown.
  ★If the runout exceeds the service limit, replace the camshaft.

Camshaft Runout

Standard: TIR 0.02 mm (0.0008 in.) or less

Service Limit: TIR 0.1 mm (0.004 in.)

Close-up of a mechanical component with a labeled section (A) and a hand holding a small object, no readable text or symbols present.

Pure technical diagram of a mechanical component with no text, numbers, or symbols

Cam Wear

• Remove the camshaft (see Camshaft Removal).
• Measure the height [A] of each cam with a micrometer.
  ★If the cams are worn down past the service limit, replace the camshaft.

Cam Height

Standard:

Exhaust 36.443 \~ 36.557 mm (1.4348 \~ 1.4392 in.)

Intake 37.143 \~ 37.257 mm (1.4623 \~ 1.4668 in.)

Service Limit:

Exhaust 36.34 mm (1.431 in.)

Intake 37.04 mm (1.458 in.)

GE11G122S1 C

Cylinder Head

Cylinder Compression Measurement

• Start the engine.
• Thoroughly warm up the engine so that the engine oil between the piston and cylinder wall will help seal compression as it does during normal running.
• Stop the engine.
• Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System chapter)
• Remove the spark plug [A] with spark plug wrench [B] (or owner's tool).

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

Owner's Tool -Spark Plug Wrench: 92110-0005

• Attach the compression gauge [A] and the adapter hose [B] firmly into the spark plug hole.
• With the throttle fully open, turn the engine with the kick-starter or the starter motor until the compression gauge stops rising; the compression is the highest reading obtainable.

Special Tools - Compression Gauge: 57001-221 Compression Gauge Adapter, M10 × 1.0: 57001-1317

Cylinder Compression

Usable Range: 450 \~ 750 kPa (4.59 \~ 7.65 kgf/cm², 65.2 \~ 109 psi) @ 5 kicks (kickstarter)

Usable Range: 450 \~ 750 kPa (4.59 \~ 7.65 kgf/cm², 65.2 \~ 109 psi) @ 420 r/min (rpm)(Electric Starter)

Technical diagram of a car engine bay with labeled components A and B, showing internal components and wiring.

Close-up mechanical assembly photo with labeled parts A and B, showing components like radiator and valve assembly

• Install the spark plug.
Torque - Spark Plug: 13 N·m (1.3 kgf·m, 115 in·lb)
- Pull the spark plug cap lightly to make sure the installation of the spark plug cap.

Cylinder Head

Problem Diagnosis	Diagnosis Remedy (Action)
The cylinder compression is higher than the usable range	Carbon accumulation on piston and in cylinder head (combustion chamber) is suspected due to damaged valve stem or piston oil rings.	Remove the carbon deposits and replace damaged parts if necessary.
	Incorrect cylinder head gasket thickness.	Replace the gasket with a standard one.
	Damaged auto-decompressor spring or decompressor do not move smoothly.	Replace the spring or auto-decompressor.
The cylinder compression is lower than the usable range	Exhaust gas leakage around cylinder head.	Replace the damaged gasket and check cylinder head warp.
	Incorrect seating surface of valve.	Repair seating surface if possible.
	Valve clearance is too narrow.	Adjust the valve clearance.
	Piston/cylinder clearance is too wide.	Replace the piston and/or cylinder
	Piston seizure.	Inspect the cylinder and piston; repair or replace them if necessary.
	Bad condition of piston ring and/or piston ring grooves.	Replace the piston and/or the piston rings.
	Auto-decompressor do not move smoothly.	Replace the auto-decompressor.

Cylinder Head Removal

- Remove:

Fuel Tank (see Fuel Tank Removal in the Fuel System chapter)

Starter Motor (see Starter Motor Removal in the Electrical System chapter)

Camshaft Chain Tensioner (see Camshaft Chain Tensioner Removal)

Cylinder Head Cover (see Cylinder Head Cover Removal)

Camshaft (see Camshaft Removal)

Exhaust Pipe (see Muffler Removal)

Carburetor (see Carburetor Removal in the Fuel System chapter)

Vacuum Switch Valve [A] (see Vacuum Switch Valve Removal)(equipped models)

Clamp Screw [B]

Water Hose [C]

B C A GE148243 P

- Remove:

Engine Bracket Bolts [A]

Engine Bracket [B]

- Remove the 6 mm cylinder head bolts [C] and loosen the cylinder bolt [D].

○This prevents the 6 mm bolts from becoming damaged.

Technical diagram of an engine component with labeled parts A, B, C, and D

5-24 ENGINE TOP END

Cylinder Head

• Remove the vacuum switch valve hose [A] and vacuum hose [B] from the cylinder head (equipped models).
• Remove the 10 mm cylinder head bolts following the tightening sequence [1 \~ 4] as shown.

A 2 3 B 1 4 2 P

• Tap lightly up with a plastic mallet [A] to separate the cylinder head [B] from the cylinder.
• Remove the cylinder head gasket.

Technical diagram of a mechanical assembly with labeled parts A and B, likely from an engineering or automotive context.

Cylinder Head Installation

• Fit the projection [A] of the front camshaft chain guide [B] in the groove [C] of the cylinder.
  ○Insert the guide end [D] into the recess [E] of the crankcase securely.

Technical diagram showing labeled mechanical components with annotations A, B, C, D, and E

• Install:
  Dowel Pins [A]
  New Cylinder Head Gasket [B]

• Install the cylinder head.

The camshaft caps are machined with the cylinder head; therefore, if a new cylinder head is installed, use the caps that are supplied with the new head.

A B

- Apply molybdenum disulfide oil to the both sides [A] of the 10 mm cylinder head bolt washer and thread [B] of the 10 mm cylinder head bolts.

A B GE14072BS1 C

Cylinder Head

• Tighten the 10 mm cylinder head bolts in the numbered sequence [1 \~ 4].
  Torque - Cylinder Head Bolts (M10): 59 N·m (6.0 kgf·m, 44 ft·lb)

Labeled mechanical component diagram with numbered parts and reference number

- Tighten:

Torque - Cylinder Bolt [A]: 12 N·m (1.2 kgf·m, 106 in·lb) Cylinder Head Bolts (M6) [B]: 12 N·m (1.2 kgf·m, 106 in·lb)

- Install:

Camshaft (see Camshaft Installation)

Cylinder Head Cover (see Cylinder Head Cover Installation)

Engine Bracket [C] (see Engine Installation in the Engine Removal/Installation chapter)

Technical diagram of an engine bay with labeled components A, B, and C

- Connect the Water hose, and tighten the hose clamp screw.

- Install:

Vacuum Switch Valve (see Vacuum Switch Valve Installation)(equipped models)

Carburetor (see Carburetor Installation in the Fuel System chapter)

Starter Motor (see Starter Motor Installation in the Electrical System chapter)

Exhaust Pipe (see Muffler Installation)

Fuel Tank (see Fuel Tank Installation in the Fuel System chapter)

Cylinder Head Cleaning

- Refer to the Cylinder Head Warp Inspection in the Periodic Maintenance chapter.

Cylinder Head Warp

- Refer to the Cylinder Head Warp Inspection in the Periodic Maintenance chapter.

Valves

Valve Clearance Inspection

- Refer to the Valve Clearance Inspection in the Periodic Maintenance chapter.

Valve Removal

- Remove the cylinder head (see Cylinder Head Removal). - Remove the valve lifter and the shim from the valve.

NOTE

○Use the valve spring compressor assembly and the adapter to press down the valve spring retainer.

Special Tools - Valve Spring Compressor Assembly: 57001-241 [A]

Valve Spring Compressor Adapter, 24: 57001-1586 [B]

Close-up of a mechanical component with labeled parts A and B, showing internal cavities and wiring (no readable text or symbols beyond labels)

Valve Installation

NOTICE

Do not lap the valve to the valve seat, using the grinding compound. It will come off oxide film treated surface of the valve.

• Visually inspect the valve surface.
  ★If the surface is damaged, replace it.
• Replace the oil seal [C] with a new one.
• Apply a thin coat of molybdenum disulfide grease to the valve stem [A] before installing the valve.
• Check to make sure that the valve moves up and down smoothly.
• Check to make sure that the valve and the valve seat are making proper contact.
• Install the inner valve spring [D] and outer valve spring [E] so that the closed coil end faces the spring seat [B].
• Compress the valve springs to install the split keepers [G] in order to secure the spring retainer [F] in place.

Special Tools - Valve Spring Compressor Assembly: 57001 -241

Valve Spring Compressor Adapter, 24: 57001-1586

• The shim [H] must be installed with its thickness indication facing up towards the retainer.
  ○Apply high temperature grease to the shim or to the retainer to prevent the shim from falling off when the camshaft is being installed.
• Apply engine oil to the valve lifter [l] surface, then install the lifter.

I H G F D E C O B A GE15113BS2 C

Valves

Valve Guide Removal

- Remove:

Valve (see Valve Removal)

Oil Seal

Spring Seat

- Heat the area around the valve guide up to 120 \~ 150°C (248 \~ 302°F).

NOTICE

Do not heat the cylinder head with a torch. This will warp the cylinder head. Soak the cylinder head and heat the oil.

- Hammer lightly on the valve guide arbor [A] to remove the guide.

Special Tool - Valve Guide Arbor, 5/5: 57001-1021

A GE150708S1

Valve Guide Installation

• Apply a thin coat of oil to the outer surface of the valve guide.
• Heat the area around the valve guide up to 120 \~ 150°C (248 \~ 302°F).

NOTICE

Do not heat the cylinder head with a torch. This will warp the cylinder head. Soak the cylinder head and heat the oil.

- Assemble the valve guide driver [A] and valve guide driver attachment D [B].

Special Tools - Valve Guide Driver, 4.5: 57001-1564 Valve Guide Driver Attachment D: 57001-1659

• When install the exhaust valve guide, using the attached washer (t = 2.0) [C].
• Using the valve guide driver, press and insert the valve guide in until the valve guide driver surface [D] touches the head surface.

[E] Exhaust 11.1 \~ 11.3 mm (0.437 \~ 0.445 in.)

[F] Intake 13.1 \~ 13.3 mm (0.516 \~ 0.524 in.)

A B C D E F GE15114BSI C

Valves

- Ream the valve guide with valve guide reamer [A], even if the old guide is reused.

Special Tool - Valve Guide Reamer, φ5.5: 57001-1079

Close-up of a mechanical component with a labeled section (A) and mounting holes, showing internal cavities and shafts (no readable text or symbols)

Valve/Valve Guide Clearance Measurement (Wobble Method)

○If a small bore gauge is not available, inspect the valve guide wear by measuring the valve/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 the stem back and forth [C] to measure the valve wobble.
• Repeat the measurement in a direction at a 90° angle to the first measurement.
  ★If the reading exceeds the service limit, replace the guide.

NOTE

○ The reading is greater than the actual valve/valve guide clearance because the measurement is taken outside of the guide.

Valve/Valve Guide Clearance Measurement (Wobble Method)

Standard:

Exhaust 0.09 \~ 0.16 mm (0.0035 \~ 0.0063 in.)

Intake 0.06 \~ 0.14 mm (0.0024 \~ 0.0055 in.)

Service Limit:

Exhaust 0.36 mm (0.014 in.)

Intake 0.33 mm (0.013 in.)

Technical diagram of a mechanical or electrical component with labeled parts A, B, and C

GE15010451 C

Valves

Valve Seat Inspection

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

Valve Seating Surface Outside Diameter

Standard:

Exhaust 29.4 \~ 29.6 mm (1.16 \~ 1.17 in.)

Intake 34.4 \~ 34.6 mm (1.35 \~ 1.36 in.)

- Check the seating surface width of the valve seat.

○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.

Good [F]

Valve Seating Surface Width

Standard:

Exhaust 0.8 \~ 1.2 mm (0.03 \~ 0.047 in.)

Intake 0.5 \~ 1.0 mm (0.02 \~ 0.039 in.)

★If the width is too wide [G], too narrow [H] or uneven [J], repair the seat (see Valve Seat Repair).

Valve Seat Repair

- For the instructions on how to use the valve seat cutter [A], follow the operation manual provided by the to manufacturer.

Special Tools - Valve Seat Cutter Holder, 5.5 : 57001-1125 [B]

Valve Seat Cutter Holder Bar: 57001-1128

B A C D E F G H J GE150117S2 C

Close-up of a mechanical component with labeled parts A and B, showing internal cavities and shafts (no readable text or symbols beyond labels)

Exhaust: Valve Seat Cutter, 45° - φ35: 57001- 1116

Valve Seat Cutter, 32°-φ35: 57001-1121

Valve Seat Cutter, 55° -φ35: 57001-1247

Intake: Valve Seat Cutter, 45°-φ40: 57001-1496

Valve Seat Cutter, 32° - φ38.5: 57001-1122

Valve Seat Cutter, 55° - φ38.5: 57001-1497

★If the tool manufacturer's instructions are not available, operate in accordance with the following procedure.

Valves

Seat Cutter Operation Care

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

NOTE

○Do not use a wire brush to remove the metal particles from the cutter. It will take off the diamond particles.

1. Setting the valve seat cutter holder in position, operate the cutter in one hand. Do not apply too much force to the diamond portion.

NOTE

○Prior to grinding, apply engine oil to the cutter and during the operation, wash off any ground particles sticking to the cutter with washing oil.

1. 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]

37.5φ …… Cutter Outer Diameter [C]

C B C A B 0E15011851 C

Repair 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.

NOTICE

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.

A B C D E F GE150119S1 C

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 55° cutter 55° [F]

Valves

• Measure the outside diameter of the seating surface with a vernier caliper.
  ★If the outside diameter of the seating surface is too small, repeat the 45^ grind until the diameter is within the specified range.
  Original Seating Surface [B]

○Remove all pittings of flaws from 45° ground surface.

○Alter grinding with 45° cutter, apply thin coat of machinist's dye to 45° [A] seating surface. This makes seating surface distinct and 32° and 55° 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.

B A GE150121S1 C

A B GE150122S1 C

NOTICE

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 55° [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 55° angle until the seat width is within the specified range.

To make the 55° grind, fit a 55° cutter into the holder, and slide it into the valve guide.

○Turn the holder, while pressing down lightly.

○After making the 55° grind, return to the seat width measurement step above.

Correct Width [B]

GE150123S1 C A B

Valves

• 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.
• When the engine is assembled, be sure to adjust the valve clearance (see Valve Clearance Adjustment in the Periodic Maintenance chapter).

Valves

Valve Seat Repair

graph TD
    A["START"] --> B["Machinist's dye on seat"]
    B --> C["45° Grind"]
    C --> D["Measure Seating Area O.D."]
    D --> E{Tools: Venire Caliper\nPurpose: check seat O.D.\nagainst spec.}
    E --> F["Results"]
    F --> G["Too small"]
    F --> H["OK"]
    F --> I["Too big"]
    G --> J["45° Grind"]
    H --> K["Measure Seating Width"]
    I --> L["32° Grind"]
    J --> M["Too narrow"]
    K --> N["OK"]
    L --> O["Too wide"]
    M --> P["45° Grind"]
    N --> Q["55° Grind"]
    O --> R["55° Cutter\nPurpose: reduce seat width\nto specification."]
    P --> S["FINISHED"]
    Q --> S

5-34 ENGINE TOP END

Cylinder and Piston

Cylinder Removal

• Remove:
  Cylinder Head (see Cylinder Head Removal) Front Camshaft Chain Guide [A] Cylinder Bolt [B]
• Tap lightly up with a plastic mallet to separate the cylinder from the crankcase.
• Remove the cylinder base gasket.

A B

Piston Removal

• Remove the cylinder (see Cylinder Removal).
• Place a clean cloth under the piston and remove the piston pin snap ring [A] from one end of the piston pin.

NOTICE

Do not reuse snap rings, as removal weakens and deforms them. They could fall out and score the cylinder wall.

• Remove the piston pin, using a piston pin puller.
  Special Tool - Piston Pin Puller Assembly: 57001-1568 [A]
• Remove the piston.

Close-up of a mechanical piston assembly with labeled component A, resting on a textured cloth (no text or symbols beyond label)

Close-up of a mechanical component with a labeled section A, showing internal parts and no readable text or symbols.

• Carefully spread the ring opening with your thumbs and then push up on the opposite side of the ring [A] to remove it.
• Remove the oil ring in the same procedure.

A GE18131851 C

Cylinder and Piston Installation

NOTE

○ The oil ring rails have no "top" or "bottom".

• Install the oil ring expander [A] in the bottom piston ring groove so the ends [B] butt together.
• Install the oil ring steel rails, one above the expander and one below it.
  ○Spread the rail with your thumbs, but only enough to fit the rail over the piston.
  ○Release the rail into the bottom piston ring groove.

B A GE18044BS1 C

Cylinder and Piston

- Install the top ring [A] so that the "R" mark [B] faces up.

NOTE

○ If a new piston or cylinder is used, check piston to cylinder clearance (see Piston/Cylinder Clearance), and use new piston rings.

A B GE16042851 C

- Apply engine oil to the inside wall of the small end of the connecting rod.

- Face the circle mark [A] on the top of the piston must point toward the front [B] of the engine.

B A GE16132BSI C

- Fit a new piston pin snap ring into the side of the piston so that the ring opening [A] does not coincide with the slit [B] of the piston pin hole.

When installing the piston pin snap ring, compress it only enough to install it and no more.

B A GE16133851 C

NOTICE

Do not reuse snap rings, as removal weakens and deforms them. They could fall out and score the cylinder wall.

- Install:

Dowel Pins [A]

New Cylinder Base Gasket [B]

Close-up of an engine cylinder assembly with labeled parts (A and B), no visible text or symbols beyond labels

- The piston ring openings must be positioned as shown in the figure. The openings of the oil ring steel rails must be 20^ of angle from the opening of the oil ring expander.

Circle Mark [A]

Top Ring [B]

Upper Oil Ring Steel Rails [C]

Oil Ring Expander [D]

Lower Oil Ring Steel Rail [E]

A EX IN B EX IN C 20° D EX IN E EX IN 20° GE16134851 C

Cylinder and Piston

• Apply engine oil to the cylinder bore.
  ● Determine the position of the piston ring ends.
• Install the cylinder while compressing the piston rings with your fingers or the special tool [A].

Special Tools - Piston Ring Compressor Grip: 57001-1095

Piston Ring Compressor Belt, 95 108 57001-1358

• Drive the front chain guide in.
  • Install the removed parts.

Cylinder Wear

- Refer to the Cylinder Wear Inspection in the Periodic Maintenance chapter.

Piston Wear

• Using a micrometer, measure the outside diameter [A] of each piston 8.5 mm (0.33 in.) [B] up from the bottom of the piston at a right angle to the direction of the piston pin.
  ★If the pistons outside diameter is smaller than the service limit, replace the piston.

Piston Diameter

Standard: 95.970 \~ 95.980 mm (3.7783 \~ 3.7787 in.)

Service Limit: 95.82 mm (3.772 in.)

Close-up mechanical assembly showing hoses, gears, and a labeled component (no readable text or symbols)

A B OE10135851 C

Piston/Cylinder Clearance

- Refer to the Piston/Cylinder Clearance in the Periodic Maintenance chapter.

Piston Ring/Ring Groove Clearance

• Check for uneven groovewear by inspecting the ring seating.
  ★The rings should fit perfectly parallel to groove surfaces. If not, replace the piston and all the piston rings.
• With the piston rings in their grooves, make several measurements with a thickness gauge [A] to determine piston ring/groove clearance.

Piston Ring/Ring Groove Clearance

Standard:

Top

0.04 \~ 0.08 mm (0.002 \~ 0.003 in.)

Service Limit:

Top

0.18 mm (0.0071 in.)

A GE1B1368S1 C

★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.

Cylinder and Piston

Piston Ring Groove Width

- Measure the groove width at several points around the piston with a vernier caliper.

Piston Ring Groove Width

Standard:

Top 1.03 \~ 1.05 mm (0.0406 \~ 0.0413 in.)

Service Limit:

Top 1.13 mm (0.0445 in.)

★If any of the groove widths exceeds the service limit, replace the piston.

Piston Ring Thickness

- Measure the thickness at several points around ring with a micrometer.

Piston Ring Thickness

Standard:

Top 0.970 \~ 0.990 mm (0.0382 \~ 0.0390 in.)

Service Limit:

Top 0.90 mm (0.035 in.)

★If any of the measurements is less than the service limit on either of the rings, replace the rings as a set.

NOTE

○ When using new rings in a used piston, check for uneven groove wear. The rings should fit perfectly parallel to the groove sides. If not, replace the piston.

Piston Ring End Gap Measurement

• Place the piston ring [A] inside the cylinder, using the piston to locate the ring squarely in place. Place the piston ring close to the bottom of the cylinder, where cylinder wear is minimal
• Measure the gap [B] between the ends of the ring using a thickness gauge.
  ★If the ring end gap exceeds the service limit, replace the ring.

Piston Ring End Gap

Standard:

Top	0.25 ~ 0.35 mm (0.0098 ~ 0.014 in.)
Oil	0.15 ~ 0.50 mm (0.0059 ~ 0.020 in.)

Service Limit:

Top	0.6 mm (0.02 in.)
Oil	0.8 mm (0.03 in.)

A B GE10055BSI C

Cylinder and Piston

Piston, Piston Pin, Connecting Rod Wear Inspection

• Visually inspect the snap rings [A] still fitted in place.
  ★If the rings show weakness or deformation, replace the rings. Also if the pin hole groove shows excessive wear, replace the piston.
• Measure the diameter of the piston pin [B] with a micrometer.
  ★If the piston pin diameter is less than the service limit at any point, replace the piston pin.
• Using a cylinder gauge, measure the diameter of both of piston pin holes [C] in the piston and the inside diameter of the connecting rod small end [D].
  ★If either piston pin hole diameter exceeds the service limit, replace the piston.
  ★If the connecting rod small end inside diameter exceeds the service limit, replace the connecting rod.

Piston Pin Diameter

Standard: 18.991 \~ 19.000 mm (0.74768 \~ 0.74803 in.)

Service Limit: 18.96 mm (0.7465 in.)

Technical diagram of a mechanical assembly with labeled parts A, B, C, D and a circular component with curved arrow indicating rotation.

Piston Pin Hole Diameter

Standard: 19.004 \~ 19.010 mm (0.74819 \~ 0.74842 in.)

Service Limit: 19.08 mm (0.7512 in.)

Connecting Rod Small End Inside Diameter

Standard: 19.019 \~ 19.030 mm (0.74878 \~ 0.74921 in.)

Service Limit: 19.07 mm (0.7508 in.)

Carburetor Holder

Carburetor Holder Installation

• Install the carburetor holder [A] with the marked [B] side facing toward the cylinder head outside.
  ○Install the holder clamp [C] with its screw head [D] facing left side.

CARB SIDE A B C D GE17012851 C

Torque - Carburetor Holder Clamp Screws: 2.0 N·m (0.20 kgf·m, 18 in·lb)

- Fit the recess [A] of the holder into the projection [B] of the cylinder head.

A B GE17013BSI C

Muffler

WARNING

The muffler can become extremely hot during normal operation and cause severe burns. Do not remove the muffler while it is hot.

Muffler Removal

• Loosen the muffler clamp bolt [A].
• Remove the exhaust pip holder nuts [B].
• Remove the exhaust pipe [C] and muffler clamp.

Technical diagram of a mechanical assembly with labeled parts A, B, and C

• Remove:
  Right Side Cover (see Side Cover Removal in the Frame chapter)
• Remove the muffler mounting bolts [A].
• Remove the muffler [B] from the back.

Technical diagram of a heavy-duty truck with labeled components A and B, showing structural parts and engine assembly.

Muffler Installation

• Replace the holder gasket [A] with a new one.
• Check the gasket [B] at the clamp and replace it if it is damaged. Make sure that the gasket is placed securely outside the exhaust pipe.
• First, tighten the exhaust pipe holder nuts and rear muffler mounting bolt temporary.
• Second, pull the muffler backward and tighten the front muffler mounting bolt temporary.

Torque - Front Muffler Mounting Bolt (First) : 9.8 N·m (1.0 kgf·m, 87 in·lb)

- Third, tighten the rear muffler mounting bolt and exhaust pipe holder nuts in order to the specified torque.

Torque - Rear Muffler Mounting Bolt : 20 N·m (2.0 kgf·m, 15 ft·lb)

Exhaust Pipe Holder Nuts : 20 N·m (2.0 kgf·m, 15 ft·lb)

• Fourth, tighten the exhaust pipe clamp bolt securely.
• Lastly, tighten the front muffler mounting bolt to the specified torque.

Torque - Front Muffler Mounting Bolt (Final) : 20 N·m (2.0 kgf·m, 15 ft·lb)

- Thoroughly warm up the engine, wait until the engine cools down, and then retighten the exhaust pipe holder nuts, and the clamp bolt securely.

A B GE18079BS1 C

Spark Arrester Cleaning

- Refer to the Spark Arrester Cleaning in the Periodic Maintenance chapter.

Muffler

Exhaust System Inspection

- The exhaust system, in particular the silencer, is designed to reduce exhaust noise and conduct the exhaust gases away from the rider while minimizing power loss. If carbon has built up inside the silencer, exhaust efficiency is reduced, causing engine performance to drop.

★If the silencer is badly damaged, dented, cracked or rusted, replace it. Clean the spark arrester if the exhaust noise becomes too loud or engine performance drops.

Engine Right Side

Table of Contents

Exploded View.... 6-2

Specifications 6-6

Special Tools 6-7

Clutch Lever and Cable 6-8

Clutch Lever Free Play Inspection 6-8

Clutch Lever Free Play Adjustment 6-8

Clutch Lever Installation.... 6-8

Clutch Cable Removal 6-8

Clutch Cable Installation 6-9

Clutch Cable Inspection and Lubrication 6-9

Clutch Cover and Right Engine Cover 6-10

Clutch Cover Removal 6-10

Clutch Cover Installation 6-10

Right Engine Cover Removal.... 6-10

Right Engine Cover Installation.... 6-11

Release Shaft Removal 6-11

Release Shaft Installation 6-12

Clutch 6-13

Clutch Removal 6-13

Clutch Installation.... 6-13

Clutch Plate Assembly Free Play Inspection/Adjustment 6-16

Friction and Steel Plates Wear, Damage Inspection.... 6-16

Friction and Steel Plate Warp Inspection 6-16

Clutch Spring Free Length Inspection.... 6-16

Clutch Housing Finger Damage 6-17

Friction Plate/Clutch Housing Clearance 6-17

Clutch Hub Spline Damage.... 6-17

Primary Gear 6-18

Primary Gear Removal 6-18

Primary Gear Installation 6-18

External Shift Mechanism.... 6-19

External Shift Mechanism Removal 6-19

External Shift Mechanism Installation 6-19

External Shift Mechanism Inspection.... 6-20

Kickstarter.... 6-22

Kick Pedal Assy Removal 6-22

Kick Pedal Assy Installation 6-22

Kick Pedal Assy Disassembly.... 6-22

Kick Pedal Assy Assembly.... 6-22

Idle Gear Removal 6-22

Idle Gear Installation 6-23

Kickshaft Removal 6-23

Kickshaft Installation 6-23

Kick Shaft Assembly Disassembly/Assembly 6-24

Exploded view diagram of a mechanical assembly with numbered components for identification

Exploded View

No.	Fastener	Torque			Remarks
		N·m	kgf·m ft·lb
1	Primary Gear Nut 98 10 72 Lh,R
2	Clutch Cover Bolts 9.8 1.0 87 in·lb
3	Right Engine Cover Bolts 9.8 1.0 87 in·lb
4	Clutch Spring Bolts	8.8	0.90	78 in·lb
5	Clutch Hub Nut	98 10 72	R

1. Primary Gear
2. Push Rod Holder
3. Release Lever Shaft
4. Clutch Lever
5. Clutch Cable
6. Clutch Hub
7. Clutch Housing
8. Clutch Spring Plate
9. Friction Plates (Width of the lining blocks are wide.)
10. Friction Plates (Width of the lining blocks are narrow.)
11. Steel Plates

CL: Apply cable lubricant.

EO: Apply engine oil.

G: Apply grease.

HG: Apply high-temperature grease.

Lh: Left-hand Threads

M: Apply molybdenum disulfide grease.

MO: Apply molybdenum disulfide oil.

R: Replacement Parts

Exploded view diagram of a mechanical assembly with numbered parts and labeled components (e.g., gears, springs, springs, motors)

Exploded View

No.	Fastener	Torque			Remarks
		N·m	kgf·m ft·lb
1	Ratchet Guide Bolt	8.8	0.90	78 in·lb
2	Kick Pedal Bolt 25 2.5 18 L
3	Ratchet Plate Mounting Bolt	9.8	1.0	87 in·lb	S
4	Ratchet Plate Mounting Screw	6.4	0.65	56 in·lb	L,S
5	Gear Set Lever Nut	8.8	0.90	78 in·lb
6	Shift Drum Cam Bolt	24	2.4	18	L

1. Kick Pedal

2. Kickshaft Idle Gear

3. Ratchet Gear

4. Kick Gear

5. Shift Pedal

6. Ratchet Plate

7. Ratchet Assembly

8. Gear Set Lever

9. Shift Drum Cam

10. Shift Shaft

G: Apply grease.

L: Apply a non-permanent locking agent.

MO: Apply molybdenum disulfide oil.

R: Replacement Parts

St: Stake the fasteners.

Specifications

Item Standard Service	Limit
Clutch LeverClutch Lever Free Play (Lever pointed end)	8 ~ 13 mm (0.3 ~ 0.5 in.)	- - -
ClutchFriction Plate ThicknessFriction Plate WarpSteel Plate WarpClutch Spring Free LengthFriction Plate/Clutch Housing ClearanceClutch Plate Assembly Length	2.92 ~ 3.08 mm (0.115 ~ 0.121 in.)0.15 mm (0.0059 in.) or less0.2 mm (0.008 in.) or less49.2 mm (1.94 in.)0.20 ~ 0.60 mm (0.0079 ~ 0.024 in.)34.9 ~ 35.5 mm (1.37 ~ 1.40 in.)	2.6 mm (0.10 in.)0.3 mm (0.01 in.)0.3 mm (0.01 in.)46.7 mm (1.84 in.)0.8 mm (0.03 in.)- - -

Special Tools

Outside Circlip Pliers:

57001-144

Line drawing of a pair of needle tips (no text or symbols)

Gear Holder, m2.0:

57001-1557

Technical line drawing of a gear and shaft component (no text or symbols)

Clutch Holder:

57001-1243

Technical line drawing of a mechanical clamp or bracket component (no text or symbols)

Completely blank white image with no visible content, text, or symbols.

6-8 ENGINE RIGHT SIDE

Clutch Lever and Cable

Due to friction plate wear and clutch cable stretch over a long period of use, the clutch must be adjusted in accordance with the Periodic Maintenance Chart.

WARNING

The engine and exhaust system get extremely hot during normal operation and can cause serious burns. Never touch the engine or exhaust chamber during clutch adjustment.

Clutch Lever Free Play Inspection

- Refer to the Clutch Lever Free Play Check in the Periodic Maintenance chapter.

Clutch Lever Free Play Adjustment

- Refer to the Clutch Lever Free Play Adjustment in the Periodic Maintenance chapter.

Clutch Lever Installation

- Install the clutch lever [A] so that it incline 20^ ± 5^ [B] more than the horizontal line [C], and position it from the edge of the gripto 170 mm (6.69 in.) [D].

A D B C GR110048S1 C

Clutch Cable Removal

- Loosen the adjusting nuts [A] fully at the lower end of the clutch cable.

Close-up of mechanical components with hoses and springs, no visible text or symbols

- Slide the adjuster cover [A] and clutch lever dust cover [B] back.

- Screw the adjuster [C] at the clutch lever fully.

- Line up the slots [D] in the clutch lever and adjuster and then free the cable from the lever.

A B C D GR118013 P

Clutch Lever and Cable

- Free the clutch inner cable tip [A] from the pull rod [B].

NOTICE

Do not remove the clutch release shaft unless it is absolutely necessary. If removed, release shaft oil seal must be replaced with a new one.

- Pull the clutch cable out of the frame.

A B GR11B014 P

Clutch Cable Installation

• Run the clutch cable correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter).
• Adjust the clutch cable (see Clutch Lever Free Play Adjustment in the Periodic Maintenance chapter).

Clutch Cable Inspection and Lubrication

- During a periodic inspection or when the cable has been removed, inspect and lubricate the cable (see Lubrication in the Periodic Maintenance chapter).

Clutch Cover and Right Engine Cover

Clutch Cover Removal

• Drain the engine oil (see Engine Oil Change in the Periodic Maintenance chapter).
• Remove the brake pedal (see Brake Pedal Removal in the Brakes chapter).
• Remove the clutch cover bolts [A] and right engine cover bolts [B], remove the clutch cover [C].

A B C

Clutch Cover Installation

• Replace the clutch cover gasket with a new one.
• Be sure to install the dowel pins.
• Apply a non-permanent locking agent to the brake pedal bolt.
  • Install the clutch cover [A].

Torque - Clutch Cover Bolts [B]: 9.8 N·m (1.0 kgf·m, 87 in·lb) Right Engine Cover Bolts [C]: 9.8 N·m (1.0 kgf·m, 87 in·lb) Brake Pedal Bolt: 25 N·m (2.5 kgf·m, 18 ft·lb)

C B A D 201604 P

Right Engine Cover Removal

• Drain:
  Engine Oil (see Engine Oil Change in the Periodic Maintenance chapter)
  Coolant (see Coolant Draining in the Cooling System chapter)
• Remove:
  Right Engine Guard [A]
  Kick Pedal [B] (see Kick Pedal Removal)
  Brake Pedal [C] (see Brake Pedal Removal in the Brakes chapter)
  Exhaust Pipe [D] (see Muffler Removal in the Engine Top End chapter)

Technical diagram of a mechanical assembly with labeled parts A, B, C, and D

- Remove:

Water Hose [A]

Right Engine Cover Bolts [B]

Right Engine Cover [C]

C A B G048043 F

Clutch Cover and Right Engine Cover

Right Engine Cover Installation

- Three dowel pins [A] are installed at the mating surface between the crankcase and the right engine cover.

- Apply grease to the O-rings [B], and install them to the crankcase.

○Install the lower O-ring so that the tapered side facing outside.

- Replace the engine cover gasket with a new one.

- Apply a high-temperature grease to the oil seal lip of the crankshaft of the right engine cover.

- Apply a grease to the kick shaft oil seal lips and kick shaft spline.

- When installing the cover doesn't go well, the cover is installed according to the following procedures.

○Fit the water pump shaft [A] and groove [B] of the balancer shaft while turning the water pump shaft.

Mechanical assembly diagram showing gears and housing components (no text or labels visible)

Mechanical assembly diagram showing labeled components A and B (no readable text or symbols beyond labels)

- Tighten:

Torque - Right Engine Cover Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)

- Insert the water hose [A] into the water pump cover [B], and tighten it with the clamp [C].

• Install the kick pedal (see Kick Pedal Assy Installation).

- Install the engine oil drain plugs surely (see Engine Oil Change in the Periodic Maintenance chapter).

- Pour in the specified type and amount of oil (see Engine Oil Change in the Periodic Maintenance chapter).

- Pour in the specified type and amount of coolant (see Coolant Filling in the Cooling System chapter).

- Check the rear brake for good braking power and no brake drag.

A C B GRO4B046 P

Release Shaft Removal

- Remove:

Clutch (see Clutch Removal)

Magneto Cover (see Magneto Cover Removal in the Electrical System chapter)

Magneto (see Magneto Removal in the Electrical System chapter)

- Remove the clutch cable upper end (see Clutch Cable Removal).

- Remove the tip [A] of the clutch cable (see Clutch Cable Removal).

- Remove the tip [B] of the short cable [C] from the pull rod [D].

A D B C GB04B047

Clutch Cover and Right Engine Cover

• Turn the release lever shaft [A] and remove the short cable [B] from the lever.
• Pull the lever and shaft assembly [C] out of the crankcase.

C A B SP0450-48 P

Release Shaft Installation

• Apply grease to the oil seal lips.
• Apply engine oil to the bearing in the hole of the crankcase.
• Apply molybdenum disulfide grease to the part where the push rod comes in contact.
• Insert the release shaft straight into the hole of the crankcase.

NOTICE

When inserting the release shaft, be careful not to remove the spring of the oil seal.

- Install the removed parts.

Clutch

Clutch Removal

• Drain the engine oil (see Engine Oil Change in the Periodic Maintenance chapter).
• Remove the clutch cover (see Clutch Cover Removal).
• Remove:
  Clutch Spring Bolts [A]
  Clutch Springs
  Clutch Spring Plate [B]

- Remove:

Adjusting Washer [A]

Needle Bearing [B]

Push Rod Holder [C]

Push Rod

Friction Plates [D]

Steel Plates [E]

• Fix the clutch hub [A] with the clutch holder [B]. Special Tool - Clutch Holder: 57001-1243

- Loosen the clutch hub nut [C] counterclockwise.

- Remove:

Washer

Clutch Hub

Toothed Washer [A]

Clutch Housing [B]

Close-up of a mechanical clutch assembly with labeled parts A and B (no readable text or symbols beyond labels)

Labeled mechanical assembly diagram showing components A, B, C, D, and E with a hand interacting with the component.

Mechanical assembly diagram with labeled components A, B, and C, likely for engine or transmission system analysis.

Close-up of a mechanical clutch assembly with labeled parts A and B (no readable text or symbols beyond labels)

Clutch Installation

• Check the clutch plate assembly free play (see Clutch Plate Assembly Free Play Inspection/Adjustment).
• Apply molybdenum disulfide oil to the inside of the clutch housing gear.
  • Install the clutch housing [A].
• Do not forget to install the toothed washer [B] before installing the clutch hub [C].

Technical diagram of a mechanical assembly with labeled components A, B, and C

Clutch

- Install the washer so that stamp mark [A] facing the outside.

- Tighten the clutch hub nut [A] with the clutch holder [B]. Special Tool - Clutch Holder: 57001-1243

Torque - Clutch Hub Nut: 98 N·m (10 kgf·m, 72 ft·lb)

- Install the friction plates and steel plates, starting with a friction plate [A] and alter nating them. Finishing with a friction plate.

○Install the friction plates so that the width of the lining blocks [B] at the plates of the both ends are wider than the other plates.

○Apply engine oil to the new friction plates when it shall be installed.

NOTICE

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

- Apply molybdenum disulfide grease to the rubbing portion [A] of the push rod holder.

- Install the push rod [B] and push rod holder.

- Apply molybdenum disulfide grease to the needle bearing [C] and adjusting washer [D], and install them.

Close-up of a mechanical gear assembly with central bore and mounting holes (no visible text or symbols)

Close-up mechanical assembly showing gear and housing components (no visible text or symbols)

Mechanical assembly diagram showing gear and cam mechanism with labeled parts A and B

Mechanical assembly diagram with labeled components A, B, C, D and numbered parts

Clutch

- Tighten:

Torque - Clutch Spring Bolts [A]: 8.8 N·m (0.90 kgf·m, 78 in·lb)

- Install the clutch cover (see Clutch Cover Installation).

- Check the pull rod positions [A].

○Pulling [B] the pull rod [C] lightly upward by hand and measure the portion of the pull rod coming out.

Pull Rod Position

Standard: 9.2 \~ 14.4 mm (0.36 \~ 0.567 in.)

★If the rod position is not within the standard, select the correct thickness of adjusting washer(s) according to the tables shown.

Adjusting Washers

Thickness Part Number
1.5 mm 92200-1548
1.0 mm 92200-0045

Pull Rod Position and Adjusting Washer Selection

Installed Washer		Position Length
Washers Thickness	Qty	Less than 9.2 mm		9.2 mm to 14.4 mm		More than 14.4mm
		Change Washer Thikness	Qty	Change Washer Thikness	Qty	Change Washer Thikness	Qty
1.0 1		NG OK				1.5 1
1.5 1 1.0 1				OK		1.0 2
1.0 2 1.5 1				OK		NG

- Remove the push rod holder assy as necessary and reinstall the clutch.

Mechanical assembly diagram showing a clutch with labeled components (A), no readable text or symbols present.

Close-up mechanical diagram showing labeled parts A, B, and C with arrows indicating connection or movement

Clutch

Clutch Plate Assembly Free Play Inspection/Adjustment

- Assemble the following parts.

Clutch Hub [A]

Friction Plates [B]

Steel Plates [C]

Friction Plates [D]

Spring Plate [E]

Spring [F]

Bolts [G]

○Friction Plates [B] have lining blocks that are wider than other plates. These plates install both end of the all plates.

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

- Measure the clutch plate assembly [H].

Clutch Plate Assembly Length

Standard: 34.9 \~ 35.5 mm (1.37 \~ 1.40 in.)

★If clutch plate length is not within the standard, select the correct length of adjusting plates according to the table shown.

Thickness Part Number
1.2 mm (0.047 in.) 13089-1010
1.6 mm (0.063 in.) 13089-1095
2.0 mm (0.079 in.) 13089-1005

○Do not use the steel plate of 1.2 mm (0.047 in.) and 2.0 mm (0.079 in.) thickness at the same time.

Friction and Steel Plates Wear, Damage Inspection

- Refer to the Friction and Steel Plates Inspection in the Periodic Maintenance chapter.

Friction and Steel Plate Warp Inspection

- Refer to the Friction and Steel Plate Inspection in the Periodic Maintenance chapter.

Clutch Spring Free Length Inspection

- Measure the free length [A] of the clutch springs.

★If any clutch spring is shorter than the service limit, it must be replaced.

Clutch Spring Free Length

Standard: 49.2 mm (1.94 in.)

Service Limit: 46.7 mm (1.84 in.)

A B D C B E G F H QR05034BS2 C

A GF0030351 C

Clutch

Clutch Housing Finger Damage

• Visually inspect the clutch housing fingers [A] that come in contact with the friction plate tangs.
  ★If they are damaged or if there are groove cuts in the areas that come in contact with the tangs, replace the housing. Replace the friction plates if their tangs are damaged as well.

Technical line drawing of a mechanical gear assembly with no visible text or symbols

Friction Plate/Clutch Housing Clearance

• Measure the clearance between the tangs [A] on the friction plate and the fingers [B] of the clutch housing.
  ★If this clearance is excessive, the clutch will be noisy.
  ★If the clearance exceeds the service limit, replace the friction plates.

Friction Plate/Clutch Housing Clearance

Standard: 0.20 \~ 0.60 mm (0.0079 \~ 0.024 in.)

Service Limit: 0.8 mm (0.03 in.)

A B GR050105S1 C

Clutch Hub Spline Damage

• Visually inspect the areas of the clutch hub splines that come in contact with the teeth of the steel plates.
  ★If there are notches worn into the clutch hub splines [A], replace the clutch hub. Replace the steel plates if their teeth are damaged as well.

Technical line drawing of a mechanical gear assembly with labeled point A (no text or symbols beyond label)

Primary Gear

Primary Gear Removal

• Remove:
  Right Engine Cover (see Right Engine Cover Removal) Clutch (see Clutch Removal)
• Temporarily install the clutch housing [A].
• Using the gear holder [B], secure the primary gear and loosen the primary gear nut.

Special Tool - Gear Holder, m2.0: 57001-1557

• Remove the clutch housing.
• Remove the primary gear nut [C], washer, primary gear [D] and oil pump drive gear.
  ○Primary gear nut is left-hand threads.

Primary Gear Installation

• Insert the oil pump drive gear [A] and primary gear [B] to the crankshaft.
  • Install the washer [C] as shown.

A B C D 18068027

A B C QR000070S1 C

• Replace the primary gear nut [A] with a new one.
• Using the gear holder [B], secure the clutch gear and the bottom of the primary gear; then, tighten the primary gear nut.
  ○Primary gear nut is left-hand threads.

Torque - Primary Gear Nut: 98 N·m (10 kgf·m, 72 ft·lb)

Special Tool - Gear Holder, m2.0: 57001-1557

- Install: Clutch (see Clutch Installation) Right Engine Cover (see Right Engine Cover Installation)

Mechanical assembly diagram showing gear and housing components (no readable text or symbols)

External Shift Mechanism

External Shift Mechanism Removal

- Remove: Shift Pedal Bolt [A] Shift Pedal [B]

Mechanical assembly diagram showing labeled components A and B (no readable text or symbols beyond labels)

- Remove: Right Engine Cover (see Right Engine Cover Removal) Clutch Housing (see Clutch Removal) Circlip [A] Oil Pump Driven Gear [B]

- Pull out the shift shaft [C]. - Remove the bolt [D] and screw [E], take off the shift ratchet assembly [F] with ratchet plate [G].

G D F C E A B GR078032 P

- Remove the bolt [A] and shift dram cam [B]. - Remove the nut [C], and take off the gear set lever [D].

Mechanical gear assembly with labeled components (A, B, C, D), no readable text or symbols beyond labels

External Shift Mechanism Installation

- Install the gear set lever [A]. ○Fit each end of the spring [B] or original positions. ○Do not forget to install the color and washer [C]. - Tighten the gear set lever nut [D].

A B C D 08078034 P

Torque - Gear Set Lever Nut: 8.8 N·m (0.90 kgf·m, 78 in·lb)

- Holding the gear set lever [A] with the (−) driver [B] and install the shift dram cam [C]. ○Apply a non-permanent locking agent to the shift dram cam bolt. ○Fit the groove [D] on the pin [E]. - Align the roller of the gear set lever with the slot of the shift dram cam.

Mechanical gear assembly diagram with labeled components A, B, C, D, and E

External Shift Mechanism

• Set up the shift ratchet assembly as shown in the figure. Ratchet [A]
  Pawls [B]
  Pins [C]
  Springs [D]

○Assembly the shift ratchet so that groove [E] of the pawl facing the crankcase side [F].

Technical diagram of a mechanical or hydraulic component with labeled parts A through F and directional arrow

• Then install the ratchet assembly [A] to the ratchet plate [B] as shown in the figure.
  • Install the ratchet assembly to the shift drum cam.
• Apply a non-permanent locking agent to the ratchet plate mounting screw.
• Tighten the screw first, and tighten the bolt.
• Tighten:

Torque - Ratchet Plate Mounting Screw: 6.4 N·m (0.65 kgf·m, 56 in·lb)

Ratchet Plate Mounting Bolt: 9.8 N·m (1.0 kgf·m, 87 in·lb)

A B C A B QR0701BBS1 C

• Apply grease to the collar [C] and install it.
• Before installing the shift shaft, apply high temperature grease to the oil seal lips and shift shaft splines.
• Insert the shift shaft [A].
• Replace the circlip [B] with a new one.
• Install:

Oil Pump Driven Gear [C]

Circlip

Clutch (see Clutch Installation)

Right Engine Cover (see Right Engine Cover Installation)

• Install the shift pedal so that the split portion [A] on the pedal and punch mark [B] on the shift align.
• Tighten:

Mechanical gear assembly with labeled components A, B, and C (no text or symbols beyond labels)

Mechanical assembly diagram showing components labeled A and B (no readable text or symbols)

External Shift Mechanism Inspection

• Check the shift shaft [A] for bending or damage to the splines.
  ★If the shaft is bent, straighten or replace it. If the splines are damaged, replace the shift mechanism.
• Check the return spring [B] for cracks or distortion.
  ★If the spring is damaged in any way, replace it.
• Check the shift lever [C] for distortion.
  ★If the shift lever is damaged in any way, replace the shift shaft.

A B C GR078037 P

External Shift Mechanism

• Check the ratchet assembly for damage.
  ★If ratchet [A], pawls [B], pins [C] or springs [D] are damaged in any way, replace them.

B C D A GR070218SI C

• Check the gear set lever [A] and its spring [B] for cracks or distortion.
  ★If the lever or spring is damaged in any way, replace them.

B A GR07Q23BSI C

• Visually inspect the shift drum cam [A].
  ★If it is badly worn or if it shows any damage, replace it.

Technical diagram of a mechanical assembly with labeled parts (no text or symbols present)

Kick Pedal Assy Removal

- Remove: Mounting Bolt [A] Kick Pedal Assy [B]

Technical diagram of a mechanical assembly with labeled parts A and B, showing components like engine and valve parts.

Kick Pedal Assy Installation

• Install the kick pedal assy [A] at the angle shown. 17 \~ 27 mm (0.67 \~ 1.1 in.) [B]
• Apply a non-permanent locking agent to the kick pedal bolt.
• Tighten: Torque - Kick Pedal Bolt: 25 N·m (2.5 kgf·m, 18 ft·lb)

Close-up mechanical assembly showing labeled parts A and B (no text or symbols beyond labels)

Kick Pedal Assy Disassembly

• Remove the kick pedal assy.
• Remove: Plug Screw [A] Spring [B] Steel Ball [C] Detente Screw [D] Oil Seal [E]

A B C D E GB08017851 C

Kick Pedal Assy Assembly

• Apply grease to the steel ball, oil seal lip, spring, and the sliding portion of the lever.
• After tightening the screws stake it with a punch.

Idle Gear Removal

- Remove: Clutch Cover (see Clutch Cover Removal) Clutch Housing (see Clutch Removal) Circlip [A] Idle Gear [B]

Mechanical gear assembly with labeled components A and B (no text or symbols beyond labels)

Kickstarter

Idle Gear Installation

• Apply engine oil to the inside of the idle gear.
• Replace the circlip [A] with a new one.
• Install the idle gear [B] facing embossed letter [C] to the outside.
• Install the circlip.

C A B

Kickshaft Removal

• Remove: Right Engine Cover (see Right Engine Cover Removal) Clutch Housing (see Clutch Removal)
• Pull the end [A] of the kick spring [B] out of the hole in the crankcase.
• Turn the kickshaft counterclockwise [C] and pull out the kickstarter assembly [D].
• Remove the bolt [A], take off the ratchet guide [B].

Mechanical gear assembly diagram with labeled components A, B, C, D

Mechanical gear assembly with labeled components A and B (no text or symbols beyond labels)

Kickshaft Installation

• Install the ratchet guide [A]. Torque - Ratchet Guide Bolt: 8.8 N·m (0.90 kgf·m, 78 in·lb)
• Apply molybdenum disulfide grease to the end of the kickshaft.
• Insert the kick shaft assembly [B] into the crankcase. ○Securely engage the stopper portion [C] of the ratchet gear with the guide.
• Insert the spring end [D] into the hole [E].
• Install: Clutch Housing (see Clutch Installation) Right Engine Cover (see Right Engine Cover Installation)

Mechanical gear assembly diagram with labeled components A, B, C, D, and E

Kickstarter

Kick Shaft Assembly Disassembly/Assembly

● The kick shaft assembly consists of the following parts.

[A] Kick Gear
[B] Circlip
[C] Washer
[D] Spring
[E] Ratchet Gear
[F] Kick Shaft
[G] Kick Spring
[H] Spring Guide

• Check the kick shaft assembly parts for damage.
  ★Any damaged parts should be replaced with new ones.
• Apply molybdenum disulfide oil to the inside of the kick gear and ratchet gear.
• Apply grease to the inside of the spring guide.
• When assembling the ratchet gear [A] onto the kick shaft [B], align the punch mark [C] on the ratchet gear with the punch mark [C] on the kick shaft.
• Replace the circlips that were removed with new ones.

Special Tool - Outside Circlip Pliers: 57001-144

B D B C A H E C F G C OR0001BB51 C

A B C GR08B046 P

Engine Lubrication System

Table of Contents

Exploded View 7-2

Lubrication System Chart 7-4

Specifications 7-6

Special Tools 7-7

Engine Oil and Oil Filter 7-8

Engine Oil Level Inspection 7-8

Engine Oil Change 7-8

Oil Filter Change 7-9

Oil Screen 7-10

Oil Screen (Scavenge) Removal 7-10

Oil Screen (Scavenge) Installation 7-10

Oil Screen (Feed) Removal 7-11

Oil Screen (Feed) Installation 7-11

Oil Screen (Scavenge) Cleaning 7-11

Oil Screen (Feed) Cleaning 7-12

Oil Pressure Relief Valve 7-13

Oil Pressure Relief Valve Removal 7-13

Oil Pressure Relief Valve Installation 7-13

Oil Pressure Relief Valve Inspection.... 7-13

Oil Pump 7-14

Oil Pump (Scavenge) Removal 7-14

Oil Pump (Scavenge) Installation 7-14

Oil Pump (Feed) Removal 7-15

Oil Pump (Feed) Installation 7-15

Oil Pump Inspection 7-16

Oil Pressure 7-17

Oil Pressure Measurement 7-17

7-2 ENGINE LUBRICATION SYSTEM

Exploded View

Exploded view diagram of a mechanical assembly with numbered components and labeled parts (e.g., E0, R, G, HL)

Exploded View

No.	Fastener	Torque			Remarks
		N·m kgf·m ft·lb
1	Engine Oil Drain Plug (M10) (Main)	20	2.0	15
2	Engine Oil Drain Plug (M6) (Sub)	7.0	0.71	62 in·lb
3	Oil Pump (Scavenge) Cover Bolts	9.8	1.0	87 in·lb
4	Oil Pump (Feed) Cover Bolts	9.8	1.0	87 in·lb
5	Right Engine Cover Bolts	9.8	1.0	87 in·lb
6	Piston Oil Nozzle	5.0	0.50	44 in·lb
7	Oil Filter Cover Bolt	9.8	1.0	87 in·lb
8	Oil Screen (Feed) Mounting Bolts	9.8	1.0	87 in·lb
9	Oil Pressure Relief Valve	15 1.5	11		HL
10	Breather Fitting	15	1.5	11	L
11	Oil Filler Cap	-	-	-	Hand-tighten

1. Oil Filter Cover
2. Inner Rotor (feed)
3. Outer Rotor (feed)
4. Oil Screen (Feed)
5. Oil Screen (Scavenge)
6. Oil Pump Idle Gear
7. Oil Pump Gear
8. Oil Level Gauge
9. Breather Hose
10. Drain Hose
11. Inner Rotor (Scavenge)
12. Outer Rotor (Scavenge)

EO: Apply engine oil.

G: Apply grease.

HL: Apply high-locking agent.

L: Apply a non-permanent locking agent.

M: Apply molybdenum disulfide grease.

R: Replacement Parts

7-4 ENGINE LUBRICATION SYSTEM

Lubrication System Chart

Technical diagram of a mechanical assembly with numbered components and flow paths indicating fluid or movement paths.

Lubrication System Chart

Technical diagram of a mechanical transmission system with numbered components and directional arrows indicating flow or movement.

1. Oil Screen (feed)
2. Oil Pump (feed)
3. Oil Pressure Relief Valve
4. Right Engine Cover Oil Passage (from Feed Oil Pump to Oil filter)
5. Oil Filter
6. Right Engine Cover Oil Passage (from Oil filter to Crankshaft)
7. Crankshaft
8. Piston Oil Nozzle
9. Left Crankcase Oil Passage (from Oil filter to Transmission Oil Passage)
10. Cylinder Oil Passage (from Crankcase Oil Passage to Cylinder Head Oil Passage)
11. Oil Pipes
12. Oil Screen (scavenge)
13. Oil Pump (scavenge)
14. Balancer Weight
15. Fitting
16. Breather Hose
17. To Air Cleaner Housing
18. Drain Hose
    A: Crank Room Oil
    B: Transmission Room Oil
    C: Blowby Gas

7-6 ENGINE LUBRICATION SYSTEM

Specifications

Item Standard
Engine OilTypeViscosity SAE 10W-40CapacityOil Change - when filter is not removedOil Change - when filter is removedwhen engine is completely dryOil Level (after warm-up or driving)	API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA21.06 L (1.12 US qt)1.08 L (1.14 US qt)1.3 L (1.4 US qt)Upper level
Oil Pressure Measurement(oil temperature 90°C, engine speed 4 000 rpm)	39 ~ 98 kPa (0.4 ~ 1.0 kgf/cm2, 5.6 ~ 14 psi)

Special Tools

Oil Pressure Gauge, 5 kgf/cm²: 57001-125

Line drawing of a pressure gauge with attached tubing (no text or symbols)

Outside Circlip Pliers: 57001-144

Line drawing of a pair of needle tips (no text or symbols)

Oil Pressure Gauge Adapter, M10 × 1.25: 57001-1182

Technical line drawing of a threaded bolt component (no text or symbols)

Oil Pressure Cap: 57001-1656

Technical line drawing of a mechanical component with a flanged circular base and central hole (no text or symbols)

7-8 ENGINE LUBRICATION SYSTEM

Engine Oil and Oil Filter

WARNING

Vehicle operation with insufficient, deteriorated, or contaminated engine oil will cause accelerated wear and may result in engine seizure, accident, and injury. Check the oil level before each use and change the oil and filter according to the periodic maintenance chart.

The engine oil level indicated in the right engine cover oil level gauge is very sensitive to the motorcycle's position and engine rpm at time of shut down. Because of the semi-dry sump lubrication system with separate oil chambers in the crank room and transmission room, under certain conditions oil can accumulate in the crank room and give a false low reading at the oil level gauge, which indicates oil volume in the transmission room.

Engine Oil Level Inspection

• Situate the motorcycle so that it is vertical.
• Check that the engine oil level is between the upper [A] and lower levels [B] in the gauge.

NOTE

○ Situate the motorcycle so that it is perpendicular to the ground.
○ If no oil appears in the gauge, tip the motorcycle slightly to the right until oil is visible then return to an upright position. If no oil appears even when tipped at an extreme angle, remove both drain bolts to empty any oil that may be in the transmission and crankcase, reinstall the drain bolts and refill with the specified amount of oil.
○ If the motorcycle has just been used, wait several minutes for all the oil to drain down.
○ If the oil has just been changed, start the engine and run it for several minutes at idle speed. This fills the oil filter with oil.
○Do not run the engine at high engine speed. Stop the engine, then wait several minutes until the oil settles.

NOTICE

Racing the engine before the oil reaches every part can cause engine seizure.

★If the oil level is too high, remove the excess oil through the filler opening, using a syringe or some other suitable device.
★If the oil level is too low, add the correct amount of oil through the oil filler opening. Use the same type and make of oil that is already in the engine.

NOTE

○If the engine oil type and make are unknown, use any brand of the specified oil to top off the level rather than running the engine with the oil level low. Then at your earliest convenience, change the oil completely.

Engine Oil Change

- Refer to the Engine Oil Change in the Periodic Maintenance chapter.

A B

Engine Oil and Oil Filter

Oil Filter Change

- Refer to the Oil Filter Change in the Periodic Maintenance chapter.

7-10 ENGINE LUBRICATION SYSTEM

Oil Screen

Oil Screen (Scavenge) Removal

• Remove the oil pump (scavenge) cover (see Oil Pump (Scavenge) Removal).
• Pull out the oil screen [A] from the crankcase.

Close-up mechanical assembly showing internal components and a labeled section (A), no readable text or symbols present.

Oil Screen (Scavenge) Installation

• Clean the oil screens thoroughly whenever it is removed for any reason.
• Clean the oil screens with a high-flash point solvent and remove any particles stuck to them.

WARNING

Gasoline and low-flash point solvents can be flammable and/or explosive and cause severe burns. Clean the screens 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 the screens.

NOTE

○ While cleaning the screens, check for any metal particles that might indicate internal engine damage.

• Check the screen [A] carefully for any damage, holes, broken wires, gasket pulling off.
  ★If the screen is damaged, replace it.

Technical diagram of a square component with internal grid pattern, labeled A, no text or symbols present

• Apply engine oil to the rubber portion [A] on the oil screen.
• Install the oil screen facing the carved line [B] to the outside.
• Install the oil pump (scavenge) cover (see Oil Pump (Scavenge) Installation).

A B 0007001851 C

Oil Screen

Oil Screen (Feed) Removal

• Split the crankcase (see Crankcase Disassembly in the Crankshaft/Transmission chapter).
• Remove: Bolts [A] Oil Screen [B]

Close-up of an engine cylinder head with labeled components (A and B), no visible text or symbols beyond labels

Oil Screen (Feed) Installation

• Replace the O-ring [A] with a new one.
• Apply grease to the O-ring, and install it.

Close-up of a mechanical component with labeled parts (A and B) and no visible text or symbols beyond labels

- Install the oil screen [A], and tighten the bolts [B] Torque - Oil Screen (Feed) Mounting Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)

Close-up mechanical assembly showing internal components with labeled parts A and B (no readable text or symbols beyond labels)

Oil Screen (Scavenge) Cleaning

• Remove the oil screen (see Oil Screen (Scavenge) Removal).
• Clean the oil screen with a high-flash point solvent and remove any particles stuck to them.

WARNING

Gasoline and low-flash point solvents can be flammable and/or explosive and cause severe burns. Clean the screens 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 the screens.

7-12 ENGINE LUBRICATION SYSTEM

Oil Screen

• Check the screen [A] carefully for any damage, holes, broken wires gasket pulling off.
  ★If the screen is damaged, replace it.
• Install the oil screen (see Oil Screen (Scavenge) Installation).

Oil Screen (Feed) Cleaning

• Remove the oil screen (see Oil Screen (Feed) Removal).
• Clean the oil screen with a high-flash point solvent and remove the particles stuck.
• Blow away the particles by applying compressed air [A] from the inside to the outside (from the clean side to the dirty side).

WARNING

Gasoline and low-flash point solvents can be flammable and/or explosive and cause severe burns. Clean the screen 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 the screen.

Technical diagram of a square component with internal grid pattern, labeled A (no text or symbols beyond label)

Mechanical component diagram showing a motor with a labeled arrow (no text or symbols on the diagram itself)

NOTE

○ While cleaning the screens, check for any metal particles that might indicate internal engine damage.

• Check the screen carefully for any damage, holes, and broken wires.
  ★If the screen is damaged, replace the oil screen.

Oil Pressure Relief Valve

Oil Pressure Relief Valve Removal

- Remove:

Right Engine cover (see Right Engine Cover Removal in the Engine Right Side chapter)

Clutch (see Clutch Removal in the Engine Right Side chapter)

- Remove the oil pressure relief valve [A].

Mechanical gear assembly with labeled component A (no readable text or symbols)

Oil Pressure Relief Valve Installation

- Apply high-locking agent to the threads of oil pressure relief valve, and tighten it.

Torque - Oil Pressure Relief Valve: 15 N·m (1.5 kgf·m, 11 ft·lb)

Oil Pressure Relief Valve Inspection

- Remove the relief valve (see Oil Pressure Relief Valve Removal).

- Using a wooden stick, push the inner valve to make sure that the valve [A] moves smoothly and that it returns to its original position by the force of the spring [B].

NOTE

○ The relief valve cannot be disassembled and it must be inspected in the assembled state.

★If the valve movement is not smooth, wash the relief valve with high-flash point solvent, and use compressed air to remove any foreign particles from it.

Technical diagram of a mechanical component with labeled parts A and B

G0080602S1 C

WARNING

Gasoline and low-flash point solvents can be flammable and/or explosive and cause severe burns. Clean the oil pressure relief valve 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 the oil pressure relief valve.

★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.

7-14 ENGINE LUBRICATION SYSTEM

Oil Pump

Oil Pump (Scavenge) Removal

- Drain:

Engine Oil (see Engine Oil Change in the Periodic Maintenance chapter) Coolant (see Coolant Draining in the Coolant System chapter)

- Remove:

Shift Pedal (see External Shift Mechanism in the Engine Right Side chapter) Flywheel (see Flywheel Removal in the Electrical System chapter)

- Remove:

Oil Pump Cover Bolts [A] Lower Camshaft Chain Guide [B] Oil Pump Cover [C]

- Remove:

Inner Rotor [A] Outer Rotor [B]

Mechanical gear assembly diagram with labeled components A, B, and C

Mechanical gear assembly diagram showing two labeled components A and B (no text or symbols beyond labels)

Oil Pump (Scavenge) Installation

• Install the dowel pins [A] to the crankcase.
• Apply engine oil to the each oil pump rotor and sliding surface of the oil pump shaft.
  • Install: Outer Rotor [B] Inner Rotor [C]
  ○While turn the oil pump shaft, install the oil pump so that the left and right oil pump shaft may mesh in the crankcase.

• Install: Oil Pump Cover [A] Lower Camshaft Chain Guide [B]

- While pushing the oil pump cover, tighten the oil pump cover bolts [C].

Torque - Oil Pump (Scavenge) Cover Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)

A B C

Mechanical assembly diagram with labeled components A, B, and C

Oil Pump

Oil Pump (Feed) Removal

- Remove:

Right Engine Cover (Right Engine Cover Removal in the Engine Right Side chapter)

Clutch (Clutch Removal in the Engine Right Side chapter)

Circlip [A]

Oil Pump Driven Gear [B]

Shaft [C]

Oil Pump Idle Gear [D]

- Remove:

Oil Pump Cover Bolts [A]

Oil Pump Cover [B]

- Remove:

Inner Rotor [A]

Outer Rotor [B]

B A D C 0508251

Mechanical gear assembly diagram with labeled components A and B (no readable text or symbols beyond labels)

Close-up mechanical component with labeled parts A and B, no readable text or symbols beyond labels

Oil Pump (Feed) Installation

• Install the dowel pins [A] to the crankcase.
• Apply engine oil to the each oil pump rotor and sliding surface of the oil pump shaft.
• Install:

Outer Rotor [B]

Inner Rotor [C]

• While turn the oil pump shaft, install the oil pump so that the left and right oil pump shaft may mesh in the crankcase.
  • Install the oil pump cover [A].
• While pushing the oil pump cover, tighten the oil pump cover bolts [B].

Short Bolts [C]

Torque - Oil Pump (Feed) Cover Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)

A B C

Mechanical gear assembly diagram with labeled components A, B, and C

7-16 ENGINE LUBRICATION SYSTEM

Oil Pump

• Apply molybdenum disulfide grease to the oil pump idle gear shaft [A].
• Install the oil pump idle gear [B] facing the stepped side [C] to the outside.
• Replace the circlip [D] with a new one.
  • Install the oil pump driven gear [E] and circlip.

Mechanical gear assembly diagram with labeled components A, B, C, D, E

Oil Pump Inspection

• Remove the oil pump.
• Visually inspect the oil pump body, outer rotors and the inner rotors.
  ★If the oil pump is any damaged or unevenly worn, replace the rotors, cover, or body, or the crankcase.

Oil Pressure

Oil Pressure Measurement

- Remove:

Exhaust Pipe (see Muffler Removal in the Engine Top End chapter)

Right Engine Cover Bolt [A]

Oil Filter Cover Bolt [B]

Oil Filter Cover [C]

- Install the O-rings to the oil pressure cap.

Special Tool - Oil Pressure Cap: 57001-1656

• Install the oil pressure cap.

- Attach the oil pressure gauge adapter [A] and oil pressure gauge [B].

Special Tools - Oil Pressure Gauge Adapter, M10 × 1.0: 57001-1182

Oil Pressure Gauge, 5 kgf/cm²: 57001-125

• Start the engine and warm up the engine thoroughly.
• Run the engine at the specified speed, and read the oil pressure gauge.
  ★If the oil pressure is much lower than the standard, check the feed oil pump.
  ★If the reading is much higher than the standard, check the oil filter first, and oil passages for dirt or clogging.

Oil Pump Pressure (oil temperature 90°C, @4 000 rpm) Standard: 39 \~ 98 kPa (0.4 \~ 1.0 kgf/cm², 5.6 \~ 14 psi)

NOTE

○ Warm up the engine thoroughly before measuring the oil pressure.

- Stop the engine and remove the oil pressure cap, oil pressure gauge adapter and gauge.

WARNING

Hot oil can cause severe burns. Beware of hot engine oil that will drain through the oil passage when the oil pressure gauge adapter is removed.

• Install the oil filter cover.

Torque - Oil Filter Cover Bolt: 9.8 N·m (1.0 kgf·m, 87 in·lb) Right Engine Cover Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)

- Install the exhaust pipe (see Muffler Installation in the Engine Top End chapter).

A C B 0128054 P

A B 0128055 F

Engine Removal/Installation

Table of Contents

Exploded View 8-2

Special Tool 8-4

Engine Removal/Installation 8-5

Engine Removal 8-5

Engine Installation.... 8-8

8-2 ENGINE REMOVAL/INSTALLATION

Exploded View

Technical diagram of a mechanical assembly with numbered components and labeled parts (R, 1-7)

Exploded View

No.	Fastener	Torque			Remarks
		N·m kgf	·m ft·lb
1	Upper Engine Mounting Bolts (M10)	49	5.0	36
2	Middle Engine Mounting Nut (M10)	49	5.0	36	R
3	Lower Engine Mounting Nut (M10)	49	5.0	36	R
4	Upper Engine Bracket Bolts (M8)	29	3.0	21
5	Middle Engine Bracket Nuts (M8)	29	3.0	21	R
6	Swingarm Pivot Shaft Nut	98	10	72	R

1. KLX450A8F Model
   R: Replacement Parts

8-4 ENGINE REMOVAL/INSTALLATION

Special Tool

Jack:

57001-1238

Technical line drawing of a mechanical support structure (no text or symbols)

Engine Removal/Installation

Engine Removal

- Place the jack [A] under the frame to support the motorcycle.

Special Tool - Jack: 57001-1238

WARNING

When the swingarm pivot shaft is removed the swingarm and rear wheel assembly will become detached and allow the frame to fall to the floor, creating the potential for injury. Removing the engine requires the swingarm pivot to be removed, so support the bottom of the frame with a jack or other appropriate stand.

- Squeeze the brake lever slowly and hold it with a band [A].

WARNING

Motorcycle may fall over unexpectedly resulting in an accident or injury. Be sure to hold the front brake when removing the engine.

NOTICE

Be sure to hold the front brake when removing the engine, or the motorcycle may fall over. The engine or the motorcycle could be damaged.

- Drain:

Engine Oil (see Engine Oil Change in the Periodic Maintenance chapter)

Coolant (see Coolant Draining in the Cooling system chapter)

- Remove the mounting bolt [A] and remove the engine guard [B].

- Remove:

Seat (see Seat Removal in the Frame chapter)

Side Covers (see Side Cover Removal in the Frame chapter)

Fuel Tank (see Fuel Tank Removal in the Fuel System chapter)

Mechanical assembly diagram showing a motor and gear assembly mounted on a platform (no visible text or symbols)

Close-up of a mechanical component with labeled parts (A) and no visible text or symbols beyond the label.

Close-up of a mechanical component with labeled parts A and B, showing no readable text or symbols.

8-6 ENGINE REMOVAL/INSTALLATION

Engine Removal/Installation

- Remove:

Radiator (see Radiator Removal in the Cooling System chapter)

Muffler (see Muffler Removal in the Engine Top End chapter)

Air Cleaner Housing with Rear Frame (see Air Cleaner Housing Removal in the Fuel System chapter)

Starter Motor (see Stater Motor Removal in the Electrical System chapter)

Carburetor (see Carburetor Removal in the Fuel System chapter)

Clutch Cable Lower End [A]

Drive Chain (see Drive Chain Removal in the Final Drive chapter)

Shift Pedal (see External Shift Mechanism Removal in the Engine Right Side chapter)

Vacuum Switch Valve (see Vacuum Switch Valve Removal in the Engine Top End chapter)(equipped models)

Close-up of a mechanical component with labeled parts (A) and no visible text or symbols beyond the label.

- Remove:

Bolts [A]

Rear Brake Pedal [B]

Master Cylinder [C]

A B C UH048413 P

- Pry open the clamps [A].

- Disconnect:

Magnet Lead Connector [B]

Ignition Coil Lead Connector [C]

- Remove:

Breather Hose [D]

Spark Plug Cap

Ignition Coil (Ignition Coil Removal in the Electrical System chapter) [E]

Upper Engine Bracket Bolts [F]

Upper Engine Mounting Bolts and Nuts [G]

Upper Engine Brackets [H]

B A C E F H G D 045414 LP

- Remove:

Engine Guard [A]

Middle Engine Bracket Bolts and Nuts [B]

Middle Engine Mounting Bolt and Nut [C]

Middle Engine Brackets (Left and Right) [D]

Lower Engine Mounting Bolts and Nuts [E]

A B C D E G048415 P

Engine Removal/Installation

• Remove the swingarm pivot shaft nut [A] to pull out the swingarm pivot shaft [B].
  ○Pull out the swingarm pivot shaft half way from right side to free the engine.
• Remove the engine from the vehicle to right side.
• Clear the engine rear portion from the swingarm and then remove the engine.

A B QN45816 P

Engine Removal/Installation

Engine Installation

• Install the engine.
  ○First, insert the front portion of the engine, and then install the rear portion.
• Install the swingarm pivot shaft, all engine bracket and mounting bolts temporarily.
  ○Swingarm pivot shaft insert from the right side.
  ○Insert the middle and lower engine mounting bolts from the left side.
• Replace the swingarm pivot shaft nut and lower engine mounting nut with new ones.
• First tighten the pivot shaft nut, next tighten the lower engine mounting nut.

Torque - Swingarm Pivot Shaft Nut: 98 N·m (10 kgf·m, 72 ft·lb)

Lower Engine Mounting Nut (M10): 49 N·m (5.0 kgf·m, 36 ft·lb)

• Replace the middle engine mounting nut and bracket nuts with new ones.
• Tighten the following.
  ○Tighten the M10 bolts and nut first.

Torque - Upper Engine Mounting Bolts (M10): 49 N·m (5.0 kgf·m, 36 ft·lb)

Middle Engine Mounting Nut (M10): 49 N·m (5.0 kgf·m, 36 ft·lb)

Upper Engine Bracket Bolts (M8): 29 N·m (3.0 kgf·m, 21 ft·lb)

Middle Engine Bracket Nuts (M8): 29 N·m (3.0 kgf·m, 21 ft·lb)

○Install the shim to the inside of the right upper engine bracket (KLX450A8F Model).

• Install the removed parts (see Appropriate chapter).
• Run the cables, hoses, and leads according to the Cable, Wire, and Hose Routing section in the Appendix chapter.

- Fill: Engine Oil (see Engine Oil Change in the Periodic Maintenance chapter) Coolant (see Coolant Filling in the Cooling System chapter)

- Adjust: Throttle Cable (see Throttle Grip Free Play Adjustment in the Periodic Maintenance chapter) Clutch Cable (see Clutch Lever Free Play Adjustment in the Periodic Maintenance chapter) Drive Chain (see Drive Chain Slack Adjustment in the Periodic Maintenance chapter)

- Adjust the idling (see Idle Speed Adjustment in the Periodic Maintenance chapter).

- Check the operation of the clutch lever.

- Check the brake effectiveness.

Engine Removal/Installation

WARNING

After servicing, it takes several applications of the brake pedal before the brake pads contact the disc, which could result in increased stopping distance and cause an accident resulting in injury or death. Do not attempt to ride the motorcycle until a firm brake pedal is obtained by pumping the pedal until the pads are against the disc.

Crankshaft/Transmission

Table of Contents

Exploded View.... 9-2

Specifications 9-4

Special Tools and Sealant 9-5

Crankcase 9-6

Crankcase Disassembly 9-6

Crankcase Assembly 9-8

Crankshaft/Connecting Rod 9-15

Crankshaft Removal 9-15

Crankshaft Installation 9-15

Crankshaft Disassembly 9-15

Crankshaft Assembly 9-15

Crankshaft Inspection 9-16

Connecting Rod Bend.... 9-17

Connecting Rod Twist 9-18

Torque Limiter 9-19

Torque Limiter Removal/Installation.... 9-19

Torque Limiter Inspection.... 9-19

Transmission 9-20

Transmission Shaft Removal 9-20

Transmission Shaft Installation 9-20

Transmission Shaft Disassembly 9-20

Transmission Shaft Assembly 9-21

Shift Fork Bending 9-22

Shift Fork/Gear Groove Wear 9-23

Shift Fork Guide Pin/Shift Drum Groove Wear 9-23

Gear Damage 9-23

Balancer 9-24

Balancer Removal.... 9-24

Balancer Installation.... 9-24

Bearings/Oil Seals 9-25

Bearing Replacement 9-25

Bearing Inspection 9-25

Oil Seal Inspection.... 9-26

9-2 CRANKSHAFT/TRANSMISSION

Exploded View

Exploded view diagram of a mechanical assembly with labeled components such as gears, springs, and linkages

Exploded View

No.	Fastener	Torque			Remarks
		N·m	kgf·m	ft·lb
1	Crankcase Bolts (M6)	12	1.2	106 in·lb	S
2	Crankcase Bolts (M7)	15	1.5	11	S
3	Gear Set Lever Nut 8.8 0.90 78 in·lb
4	Engine Oil Drain Plug (M6)(Sub)	7.0	0.71	62 in·lb
5	Engine Oil Drain Plug (M10)(Main)	20	2.0	15
6	Shift Drum Cam Bolt	24	2.4	18	L
7	Piston Oil Nozzle	4.0	0.41	35 in·lb
8	Bearing Retaining Screws	15	1.5	11	L
9	Balancer Weight Mounting Nut	52	5.3	38
10	Gear Position Switch Screws	2.9	0.30	26 in·lb	L

1. Copper Washer
   EO: Apply engine oil.
   G: Apply grease.
   HG: Apply high-temperature grease.
   L: Apply a non-permanent locking agent.
   LG: Apply liquid gasket.
   R: Replacement parts
   S: Tighten the fasteners following the specified sequence.

9-4 CRANKSHAFT/TRANSMISSION

Specifications

Item Standard Service Limit
Connecting Rods
Connecting Rod Big End Radial Clearance	0.002 ~ 0.014 mm(0.00008 ~ 0.0006 in.)	0.06 mm (0.002 in.)
Connecting Rod Big End Side Clearance	0.25 ~ 0.35 mm(0.0098 ~ 0.014 in.)	0.6 mm (0.02 in.)
Crankshaft Runout	TIR 0.03 mm (0.001 in.) or less	TIR 0.08 mm (0.003 in.)
Connecting Rod Bend	-- --	TIR 0.2 mm (0.08 in.)/100 mm (3.94 in.)
Connecting Rod Twist	-- --	TIR 0.2 mm (0.08 in.)/100 mm (3.94 in.)
Transmission
Shift Fork Ear Thickness	4.9 ~ 5.0 mm (0.193 ~ 0.197 in.)	4.8 mm (0.19 in.)
Gear Shift Fork Groove Width	5.05 ~ 5.15 mm (0.199 ~ 0.203 in.)	5.25 mm (0.207 in.)
Shift Fork Guide Pin Diameter	5.9 ~ 6.0 mm (0.232 ~ 0.236 in.)	5.8 mm (0.228 in.)
Shift Drum Groove Width	6.05 ~ 6.20 mm (0.238 ~ 0.244 in.)	6.3 mm (0.25 in.)

TIR: Total Indicator Readings

Special Tools and Sealant

Outside Circlip Pliers: 57001-144

Line drawing of a pair of needle pliers (no text or symbols)

Bearing Driver Set: 57001-1129

Isometric line drawing of a mechanical device with multiple circular components and an open lid (no text or symbols)

Crankshaft Jig: 57001-1174

Technical line drawing of a mechanical component with no visible text or symbols

Crankcase Splitting Tool Assembly: 57001-1362

Technical line drawing of a mechanical clamp or bracket assembly (no text or symbols)

Liquid Gasket, TB1216: 92104-1063

Line drawing of a cylindrical tool with a pointed tip and flanged end (no text or symbols)

Crankcase

Crankcase Disassembly

• Remove the engine from the frame (see Engine Removal in the Engine Removal/Installation chapter).
• Set the engine on clean surface while parts are being removed.
• Remove:

Magneto Cover (see Magneto Cover Removal in the Electrical System chapter)

Cylinder Head Cover (see Cylinder Head Cover Removal in the Engine Top End chapter)

Cylinder Head (see Cylinder Head Removal in the Engine Top End chapter)

Cylinder (see Cylinder Removal in the Engine Top end chapter)

Piston (see Piston Removal in the Engine Top End chapter)

Right Engine Cover (see Right Engine Cover Removal in the Engine Right Side chapter)

Clutch (see Clutch Removal in the Engine Right Side chapter)

Primary Gear (see Primary Gear Removal in the Engine Right Side chapter)

Balancer (see Balancer Removal)

Oil Pumps (see Oil Pump (Scavenge)(Feed) Removal in the Engine Lubrication System chapter)

Kick Shaft Assembly (see Kick Shaft Removal in the Engine Right Side chapter)

Kick Shaft Idle Gear (see Idle Gear Removal in the Engine Right Side chapter)

External Shift Mechanism (see External Shift Mechanism Removal in the Engine Right Side chapter)

Flywheel (see Flywheel Removal in the Electrical System chapter)

- Remove the output shaft sleeve [A] and the O-ring [B].
○Do not reuse the O-ring.

- Remove:

Gear Position Switch Screws [A] Gear Position Switch [B]

Close-up of a mechanical component with labeled parts A and B, showing internal components and mounting holes (no readable text or symbols beyond labels)

Technical diagram of a mechanical component with labeled parts A and B, likely for assembly or maintenance reference.

Crankcase

- Remove:

Gear Position Switch Finger [A]

Spring [B]

- Remove:

Circlip [A]

Balancer Drive Gear [B]

Special Tool - Outside Circlip Pliers: 57001-144

- Remove:

Circlip [A]

Special Tool - Outside Circlip Pliers: 57001-144

- Remove the crankcase bolts [A].

- Pry the points [A] with a screwdriver to split the crankcase halves apart evenly. There are two dowel pins on the crankcase mating surface. Pull off the left crankcase half.

Close-up of a mechanical component with labeled parts A and B (no readable text or symbols beyond labels)

Close-up mechanical gear assembly with labeled components A and B (no readable text or symbols beyond labels)

Close-up mechanical component showing a bearing assembly with a labeled section A (no readable text or symbols)

Mechanical assembly diagram showing internal components with no visible text or symbols

Close-up of mechanical components with labeled points A, showing alignment and mounting details (no readable text or symbols)

9-8 CRANKSHAFT/TRANSMISSION

Crankcase

• The crankcase may also be split, using the crankcase splitting tool assembly.
  ○Install the jig [A] between the crankshaft flywheels.
  Special Tool - Crankshaft Jig: 57001-1174

Close-up mechanical assembly showing internal components and a labeled section (A), no readable text or symbols present.

○Attach the crankcase splitting tool [A] to the left crankcase. Special Tool - Crankcase Splitting Tool Assembly: 57001 -1362

○ Tighten the center bolt [B] of the crankcase splitting tool to split the crankcase halves.
○Remove the left crankcase half.

B A 01048435 P

• Remove:
  Oil Screen (Feed) [A] (see Oil S screen (Feed) Removal in the Engine Lubrication System chapter) Shift Rods [B] (see Transmission Shaft Removal) 2 Shift Forks [C] (see Transmission Shaft Removal) Shift Dram [D] (see Transmission Shaft Removal) Transmission [E] (see Transmission Shaft Removal)
• Remove the crankshaft [F] from the right crankcase half (see Crankshaft Removal).

E F C B D A C G104B436 P

NOTICE

Do not remove the bearings and the oil seals unless it is necessary. Removal may damage them.

Crankcase Assembly

NOTICE

Right and left crankcase halves are machined at the factory in the assembled state, so if replaced, they must be replaced as a set.

• Remove the old gasket from the mating surfaces of the crankcase halves and clean them off with a high-flash point solvent.
• Using compressed air, blow out the oil passages in the crankcase halves.

WARNING

Gasoline and low-flash point solvents can be flammable and/or explosive and cause severe burns. Clean the engine parts in a well-ventilated area, and take care that there is no spark or flame anywhere near the working areas. Do not use gasoline or low-flash point solvents to clean parts.

Crankcase

• Support the crankcase bearing boss with a suitable retainer [A].
• Using a press and the bearing driver set [C], install a new bearing [B] until it bottoms out.
  Special Tool - Bearing Driver Set: 57001-1129

NOTICE

Support the crankcase bearing boss when the bearing is pressed, or the crankcase could be damaged.

• Press the new transmission shaft bearing [A] in the left crankcase half, so that the sealed side [B] faces outside of the engine.
  Special Tool - Bearing Driver Set: 57001-1129

• Press the new drive shaft bearing [A] in the right crankcase [B] half, so that the stepped side [C] faces inside of the engine.
  Special Tool - Bearing Driver Set: 57001-1129

• Press the new crankshaft bearings [A] in the left and right crankcase half [B], so that the stepped side [C] faces inside of the engine.
  Special Tool - Bearing Driver Set: 57001-1129

• Press the shift drum needle bearing [A] and shift shaft needle bearing [B] in the left crankcase half, so that bearing surface flush with the crankcase surface [C].
  Special Tool - Bearing driver Set: 57001-1129

A B C G1040008S1 C

A B G1041948SI C

B A C G104195BSI C

B A C G104196851 C

B A C C G1041978SI C

9-10 CRANKSHAFT/TRANSMISSION

Crankcase

• First, press the inside release shaft needle bearing [A] until its top comes 19.5 mm [B] from the surface using the bearing driver set.
• Next, press the oil seal [C] until it reach to the inside needle bearing with the bearing driver set.

Special Tool - Bearing driver Set: 57001-1129

B C A 0104268051 C

- Next, press the outside release shaft needle bearing [A] until the surface of the bearing is even with the crankcase surface [B].

Special Tool - Bearing driver Set: 57001-1129

B A 0104287851 C

• Replace the oil seals, if removed.
• Press the oil seals [A] of the output shaft, shift shaft, and pull rod so that oil seal lip [B] face to the engine outside and oil seal surface flush with the left crankcase surface [C].
• Apply high-temperature grease to the oil seal lip. Special Tool - Bearing driver Set: 57001-1129

G104288BS1 C

• Apply a non-permanent locking agent to the retaining screws.
• Tighten the bearing retaining screws [A]. Torque - Bearing Retaining Screws: 15 N·m (1.5 kgf·m, 11 ft·lb) Piston Oil Nozzle [B]: 4.0 N·m (0.41 kgf·m, 35 in·lb)

A A A G1048437 P

A B A A A 01048438 P

Crankcase

• Apply engine oil to the transmission gears, bearings, shift forks, shift drum and crankshaft bearing.
• Install the drive shaft [A] and output shaft [B] in the right crankcase [C] as a set.

A B C 01048429 P

- Install: Shift Drum [A] (see Transmission Shaft Installation) Shift Rods [B] (see Transmission Shaft Installation) Shift Forks [C] (see Transmission Shaft Installation)

A B C C G104B440 P

• Install: Crankshaft [A] Dowel Pins [B]

Technical diagram of a mechanical assembly with labeled parts A and B, showing gear and shaft components.

- Replace the O-ring [A] with a new one. - Install the Oil Screen (Feed). Torque - Oil Screen (Feed) Mounting Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)

Close-up of an engine component with labeled parts (A), showing internal gears and shafts without any readable text or symbols.

- With the connecting rod positioned at the bottom-dead-center, install the crankshaft jig [A]. Special Tool - Crankshaft Jig: 57001-1174

Mechanical assembly component with gears and housing, labeled A (no readable text or symbols)

9-12 CRANKSHAFT/TRANSMISSION

Crankcase

- Apply liquid gasket to the mating surface [A] of the left crankshaft half.

Sealant - Liquid Gasket, TB1216: 92104-1063

NOTE

○ Make the application finish within 30 minutes when the liquid gasket to the mating surface of the left crankcase half is applied.

- Moreover fit the case and tighten the case bolts just after finishing the application of the liquid gasket.

- Using a plastic mallet [A], press [B] the rear portion of the crankcase, and tap the area around the crankshaft of the left crankcase. While maintaining the mating surfaces of the right and left crankcase halves constantly parallel, mate the crankcase halves evenly.

NOTE

○ Constantly check the alignment of the two crankcase halves, and the position of the transmission shafts, and shift drum. The front and rear of the crankcase must be pushed together evenly.

- Remove the crankshaft jig [C].

- Tighten the crankcase bolts, starting with the periphery of the crankshaft, then outward.

- Replace the copper washer [B] with a new one.

○Tighten the crankcase bolt together with the clamp [A].

Torque - CrankcaseBolts (M6): 12 N·m (1.2 kgf·m, 106 in·lb) Crankcase Bolts (M7): 15 N·m (1.5 kgf·m, 11 ft·lb)

NOTE

○After tightening the crankcase bolts, wipe up the liquid gasket seeping out around the mating surface, especially around the area.

- Make sure that the crankshaft, driveshaft, and the output shaft, rotate smoothly (in the neutral position).

★If the crankshaft will not turn, probably the crankshaft is not centered; tap the appropriate end of the crankshaft with a mallet [A] to reposition it.

Technical line drawing of an internal combustion engine casing with mounting holes and a control panel (no text or labels)

A B C

A B G104290851 C

Close-up mechanical assembly showing internal gears and shafts (no visible text or symbols)

Crankcase

• Install the gear set lever [A].
  ○Fit each end [B] of the spring or original positions.
  ○Do not forget to install the collar and washer [C].
• Tighten the gear set lever nut [D].

Torque - Gear Set Lever Nut: 8.8 N·m (0.90 kgf·m, 78 in·lb)

A C D B G1045866

• To install the shift drum cam [A], use the driver [B] to bring the gear set lever [C] to the bottom of the crankcase.
• Mate the shift drum pin [D] into the shift drum hole.
  ○Fit the groove [E] of the shift drum cam on the shift drum pin.
• Apply non-permanent locking agent to the shift drum cam bolt and tighten it.

Torque - Shift Drum Cam Bolt: 24 N·m (2.4 kgf·m, 18 ft·lb)

Technical diagram of an engine cylinder with labeled components A, B, C, D, E and a hand pointing to the component.

• Check to see that gears shift smoothly from 1st to 5th gear, and 5th to 1st while spinning the output shaft.
• Set the shift drum in the neutral position.
• Replace the O-ring [A] on the output shaft with new one and apply grease it.
• Install the O-ring on the grinding faces of the output shaft while expanding the O-ring by the hand.
• Apply grease to the inside of the output shaft collar [B].
• Insert the collar with the oil groove ends [C] facing in.

Mechanical assembly photo with labeled parts A, B, and C, showing mechanical components and alignment indicators

• Install the balancer drive gear [A] so that the stepped portion [B] of the balancer drive gear and crankshaft are aligned.
• Replace the circlip with a new one, and install it.

Special Tool - Outside Circlip Pliers: 57001-144

Close-up of a mechanical gear assembly with labeled parts A and B (no text or symbols beyond labels)

9-14 CRANKSHAFT/TRANSMISSION

Crankcase

- Replace the circlip [A] with a new one, and install it to the output shaft.

Close-up of mechanical components with a labeled section A, showing gears and shafts (no readable text or symbols)

Crankshaft/Connecting Rod

Crankshaft Removal

• Disassemble the crankcase (see Crankcase Disassembly).
• Using the hand pull out the crankshaft [A] from the right crankcase [B].

Mechanical gear assembly with labeled parts A and B (no text or symbols beyond labels)

Crankshaft Installation

- Apply high-temperature grease to the outer side of the crankshaft bearings and use the bearing driver set [C] to face the steppedside[A] to the engine inside and drivethe bearing to the bottom of the crankcase [B]. While driving the bearing in, make sure to use a holder to support the boss area.

Special Tool - Bearing Driver Set: 57001-1129

• Install the crankshaft to the right crankcase.
- Apply engine oil to the connecting rod big end bearing.

B C A H105020BSI C

Crankshaft Disassembly

Since assembly of the crankshaft demands exacting tolerances, the disassembly and reassembly of the crankshaft can only be done by a shop having the necessary tools and equipment.

★If it should be necessary to disassemble the crankshaft, use a press to remove the crankpin.

Crankshaft Assembly

Since the assembly of the crankshaft demands exacting tolerances, the disassembly and reassembly of the crankshaft can only be done by a shop having the necessary tools and equipment.

- Carefully align the oil passage hole in the right flywheel [A] with the one in the crankpin [B] at rebuilding of the crankshaft as shown.

C B A Sect. C - C C G105144B51 C

• Reassemble the crankshaft according to the standard tolerances in Specifications.
  ○Connecting rod bend, twist.
  ○Connecting rod big end radial clearance.
  ○Cold-fitting tolerance between crankpin and flywheels.
  ○Side clearance between the connecting rod big end and one of flywheels.
  ○Crankshaft runout.

Crankshaft/Connecting Rod

Crankshaft Inspection

Connecting Rod Big End Radial Clearance

• Set the crankshaft on V blocks, and place a dial gauge [A] against the connecting rod big end.
• Push [B] the connecting rod first towards the gauge and then in the opposite direction. The difference between two gauge readings is the radial clearance.

Connecting Rod Big End Radial Clearance

Standard: 0.002 mm \~ 0.014 mm (0.00008 \~ 0.0006 in.)

Service Limit: 0.06 mm (0.002 in.)

★If the radial clearance exceeds the service limit, crankshaft should be either replaced or disassembled and crankpin, needle bearing, and connecting rod big end should be examined for wear.

Connecting Rod Big End Side Clearance

- Measure the connecting rod big end side clearance [A].

Connecting Rod Big End Side Clearance

Standard: 0.25 \~ 0.35 mm (0.0098 \~ 0.014 in.)

Service Limit: 0.6 mm (0.02 in.)

★If the clearance exceeds the service limit, replace the crankshaft assembly.

Crankshaft Runout

- Set the crankshaft in a flywheel alignment jig or on V blocks, and place a dial gauge as shown and turn the crankshaft slowly. The maximum difference in gauge reading is the crankshaft runout.

Crankshaft Runout

Standard: TIR 0.03 mm (0.001 in.) or less

Service Limit: TIR 0.08 mm (0.003 in.)

★If the runout at either point exceeds the service limit, replace the crankshaft assembly with a new one or align the crankshaft so that the runout falls within the service limit. 8.5 mm (0.33 in.) [A]

- First correct the horizontal misalignment by striking the projecting crank half [A] with a plastic, soft lead, or brass hammer as shown.

- Recheck the runout with a dial gauge and repeat the process until the runout falls within the service limit.

B A 0105018851 C

A 0105134851 C

G105135851 C

A 0105136851 C

Crankshaft/Connecting Rod

- Next, correct the vertical misalignment by either driving a wedge [A] in between the crank halves or by squeezing them in a vice, depending on the nature of the misalignment.

NOTICE

Do not hammer the crank half at the point [B].

★If flywheel misalignment cannot be corrected by the above method, replace the crank pin or the crankshaft itself.

A B G105004BS2 C

Connecting Rod Big End Seizure

★In case of serious seizure with damaged flywheels, the crankshaft must be replaced.
★In case of less serious damage, disassemble the crankshaft and replace the crankpin, needle bearing, and connecting rod.

Connecting Rod Bend

• Remove the connecting rod.
• Select an arbor [A] of the same diameter as the connecting rod big end, and insert the arbor through the connecting rod big end.
• Select an arbor of the same diameter as the piston pin and more than 105 mm long, and insert the arbor [B] through the connecting rod small end.
• On a surface plate, set the big-end arbor on a V block [C].

- With the connecting rod held vertically, use a height gauge to measure the difference in the height of the arbor above the surface plate over a 100 mm length to determine the amount of connecting rod bend.

★If connecting rod bend exceeds the service limit, the connecting rod must be replaced.

Connecting Rod Bend

Service Limit: TIR 0.2/100 mm (0.08/3.94 in.)

B A C 100 mm G1050406S1 C

9-18 CRANKSHAFT/TRANSMISSION

Crankshaft/Connecting Rod

Connecting Rod Twist

- With the big-end arbor [A] still on the V block [C], hold the connecting rod horizontally and measure the amount that the arbor [B] varies from being parallel with the surface plate over a 100 mm length of the arbor to determine the amount of connecting rod twist.

★If connecting rod twist exceeds the service limit, the connecting rod must be replaced.

Connecting Rod Twist

Service Limit: TIR 0.2/100 mm (0.08/3.94 in.)

A B C 100mm 0105040751 C

Torque Limiter

Torque Limiter Removal/Installation

- Remove:

Torque Limiter Cover Bolts [A]

Torque Limiter Cover [B]

Torque Limiter [C]

NOTICE

Do not disassemble the torque limiter. The torque limiter will not function if this is done.

- Install the torque limiter cover so that the arrow mark [A] faces upward.

Mechanical assembly diagrams showing gear and housing components (no text or symbols)

Close-up mechanical assembly with labeled component A (no readable text or symbols)

Torque Limiter Inspection

• Remove the torque limiter and visually inspect it.
  ★If the limiter has wear, discoloration, or other damage, replace it as a set.

Gear [A]

Shaft [B]

Spring [C]

Pinion [D]

Shim [E]

A B C D E

G110003BSI C

Transmission

Transmission Shaft Removal

• Disassemble the crankcase halves (see Crankcase Disassembly).
• Pull out the shift rods [A] allowing the shift fork guide pins to free from the shift drum [B].
• Remove the shift forks [C].
• Remove the shift drum.

A B A C

- Pull out the drive shaft [A] and output shaft [B] together with their gears meshed.

Mechanical assembly diagram with labeled parts A and B, showing gears and shafts in a mechanical assembly.

Transmission Shaft Installation

• Apply engine oil to the sliding portion of the transmission shafts, gears, and ball bearings.
• Install the drive shaft [A] and output shaft [B] in the right crankcase [C] with their gears meshed.
  • Install the shift drum.

A B C G1068095 P

• Apply a small amount of engine oil to the shift fork fingers and fit each shift fork into the groove of the proper gear.
• The shift forks can be identified by their shape or mark. Install them noting the direction shown.
  ○Install each shift forks with its mark [A] facing the engine left side.

Marks:

43 (Drive shaft)

47 (Output shaft)

Mechanical gear assembly with labeled components (no readable text or symbols)

- Assembly the crankcase (see Crankcase Assembly).

○Fit each shift fork guide pin into the corresponding groove in the shift drum.

○Apply a small amount of engine oil to the shift rods and slide them into the shift forks.

○Assembly the crankcase (see Crankcase Assembly).

Transmission Shaft Disassembly

• Remove the transmission shafts.
• Remove the circlips, washers, then gears.
  Special Tool - Outside Circlip Pliers: 57001-144
• Do not reuse the removed circlips.

Transmission

Transmission Shaft Assembly

• Apply engine oil liberally to the transmission shaft, gears and bearings.
• Replace any circlips that were removed with new ones.
  ○Always install the circlips [A] so that the opening [B] is aligned with a spline groove [C], and install toothed washers. To install a circlip without damage, first fit the circlip onto the shaft expanding it just enough to install it, and then use a suitable gear to push the circlip into place.

Special Tool - Outside Circlip Pliers: 57001-144

• The drive shaft gears can be identified by size; the smallest diameter gear is 1st gear, and the largest is 5th. Be sure that all parts are put back in the correct sequence, facing the proper direction, and that all circlips and the washers are properly in place.
• The output shaft gears can be identified by size; the largest diameter gear is 1st gear, and the smallest is 5th. Be sure that all parts are put back in the correct sequence, facing the proper direction, and that all circlips and washers are properly in place.

A B C G1131148S1 C

Transmission

Technical diagram of a mechanical assembly with numbered components and labeled parts, including gear and ring features.

1. Circlip

2. 5th Gear (21 T)

3. 4th Gear (19 T)

4. Toothed Washer

5. 1st Gear (12 T)

6. 3rd Gear (19 T)

7. 2nd Gear (15 T)

8. Drive Shaft

9. 5th Gear (17 T)

10. Bushing

11. Output Shaft

12. 1st Gear (26 T)

13. 4th Gear (20 T)

14. Collar

15. 3rd Gear (16 T)

16. 2nd Gear (23 T)

- Check each gear spins or slides freely on the transmission shaft without binding after assembly.

Shift Fork Bending

- Visually inspect the shift forks, and replace any fork that is bent. A bent fork may cause difficulty in shifting, or allow the transmission to jump out of gear when under power. 90° [A]

A 0113235851 C

Transmission

Shift Fork/Gear Groove Wear

- Measure the thickness [A] of the shift fork ears, and measure the width [B] of the gear grooves (with which the fork engages).

Shift Fork Ear Thickness

Standard: 4.9 \~ 5.0 mm (0.193 \~ 0.197 in.)

Service Limit: 4.8 mm (0.19 in.)

Gear Groove Width

Standard: 5.05 \~ 5.15 mm (0.199 \~ 0.203 in.)

Service Limit: 5.25 mm (0.207 in.)

★If the thickness of a shift fork ear is less than the service limit, the shift fork must be replaced.
★If the gear groove is worn exceeding the service limit, the gear must be replaced.

Shift Fork Guide Pin/Shift Drum Groove Wear

- Measure the diameter of each shift fork guide pin [A], and measure the width [B] of each shift drum groove.

Shift Fork Guide Pin Diameter

Standard: 5.9 \~ 6.0 mm (0.232 \~ 0.236 in.)

Service Limit: 5.8 mm (0.228 in.)

Shift Drum Groove Width

Standard: 6.05 \~ 6.20 mm (0.238 \~ 0.244 in.)

Service Limit: 6.3 mm (0.25 in.)

★If the guide pin on any shift fork is less than the service limit, the fork must be replaced.
★If any shift drum groove is worn exceeding the service limit, the drum must be replaced.

Gear Damage

• Visually inspect the gear dogs [A] and gear dog holes [B].
  ★Replace any damaged gears or gears with excessively worn dogs or dog holes.
• Visually inspect the gear teeth [C] on the transmission gears.
  ★Replace lightly damaged gear teeth with an oilstone. The gear must be replaced if the teeth are badly damaged.
  ★When gearis repaired or replaced, the driving gear should also be inspected and repaired or replaced if necessary.

A B A 0113236851 C

A B B G113372851 C

B C A 0113238851 C

9-24 CRANKSHAFT/TRANSMISSION

Balancer

Balancer Removal

- Remove:

Right Engine Cover (see Right Engine Cover Removal in the Engine Right Side chapter) Magneto Cover (see Magneto Cover Removal in the Electrical System chapter)

Flywheel (see Flywheel Removal in the Electrical System chapter)

- Install the flywheel [A] temporary and hold it steady with the flywheel holder [B], loosen the balancer weight mounting nut [C].

Special Tool - Flywheel Holder: 57001-1313

- Remove:

Balancer Weight Mounting Nut Balancer Weight [D] Balancer Gear [E]

- Pull out the balancer shaft from the right crankcase.

Balancer Installation

- Insert the balancer shaft from the right crankcase.

- Install the balancer gear so that the stepped portion [A] on the balancer shaft and punch mark [B] on the balancer gear align.

- Align the punch mark [A] on the balancer drive gear and punch mark [B] on the balancer gear.

- Install the balancer weight so that the punch mark [A] on the balancer and punch mark [B] on the balancer gear.

- Install the flywheel temporary and hold it steady with the flywheel holder, tighten the balancer weight mounting nut.

Torque - Balancer Weight Mounting Nut: 52 N·m (5.3 kgf·m, 38 ft·lb)

Technical diagram of a mechanical assembly with labeled parts A, B, C, D, and E

B A

Mechanical gear assembly with labeled components A and B (no readable text or symbols beyond labels)

B A G1130478

Bearings/Oil Seals

Bearing Replacement

NOTICE

Do not remove the ball bearings unless it is necessary. Removal may damaged them.

- Remove the ball bearing and/or needle bearing outer race using a press or puller.

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.

NOTICE

Do not heat the case with a torch. This will warp the case. Soak the case in oil and heat the oil.

- Install the new bearing until its outer race stops at the bottom of the case using a press and the bearing driver set [A].

Special Tool - Bearing Driver Set: 57001-1129

A

G1140605S1 C

Bearing Inspection

NOTICE

Do not remove the bearings for inspection. Removal may damage them.

- Inspect the ball bearings.

○Since the ball bearings are made to extremely close tolerances, the wear must be judged by feel rather than measurement. Clean each bearing in a high-flash point solvent, dry it (do not spin the bearing while it is dry), and oil it with engine oil to it.

○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.

Diagram of hands operating a ball bearing with a pointer and circular symbol (no text or labels)

G1130149S1 C

9-26 CRANKSHAFT/TRANSMISSION

Bearings/Oil Seals

- Check the needle bearing.

- The rollers in a needle bearing normally wear very little, and wear is difficult to measure. Instead of measuring, inspect the bearing for abrasion, color change, or other damage.

★If there is any doubt as to the condition of a needle bearing, replace it.

Oil Seal Inspection

- Inspect the oil seal.

★Replace the oil seal if the lips are deformed, discolored (indicating that the rubber has deteriorated), hardened or otherwise damaged.

Wheels/Tires

Table of Contents

Exploded View 10-2

Specifications 10-4

Special Tools 10-5

Wheels (Rims) 10-6

Front Wheel Removal 10-6

Front Wheel Installation 10-6

Rear Wheel Removal 10-8

Rear Wheel Installation 10-9

Wheels Inspection.... 10-10

Spoke Tightness Inspection.... 10-10

Rim Runout Inspection.... 10-10

Axle Inspection.... 10-10

Tires 10-11

Tire Removal.... 10-11

Tire Installation.... 10-12

Air Pressure Inspection/Adjustment 10-13

Hub Bearings.... 10-14

Hub Bearing Removal.... 10-14

Hub Bearing Installation.... 10-14

Hub Bearing Inspection.... 10-14

Hub Bearing Lubrication 10-15

Exploded View

Exploded view diagram of a mechanical assembly with numbered components and labeled parts (e.g., AL, HG, WL)

Exploded View

No.	Fastener	Torque			Remarks
		N·m kgf·m ft·lb
1	Spoke Nipples 2.2 0.22 19 in·lb
2	Front Axle Nut 79 8.0 58
3	Front Axle Clamp Bolts	20	2.0	15	AL
4	Rear Axle Nut	110	11.2	81.1

1. Spokes
2. Front Tire
3. Rims
4. Front Axle
5. Rear Tire
6. Rear Axle

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

HG: Apply high temperature grease.

WL: Apply soap and water solution, or rubber lubricant.

Specifications

Item Standard Service Limit
Wheels (Rims)
Rim Runout:
Axial	TIR 1.0 mm (0.039 in.) or less	TIR 2 mm (0.08 in.)
Radial	TIR 1.0 mm (0.039 in.) or less	TIR 2 mm (0.08 in.)
Axle Runout/100 mm (3.94 in.)	0.1 mm (0.004 in.) or less	0.2 mm (0.008 in.)
Rim Size:
Front 21 × 1.60 - - -
Rear 18 × 2.15 - - -
Tires Air Pressure
Front and Rear	100 kPa (1.0 kgf/cm2, 14 psi)	- - -
Tires
Standard Tire:
Front:
Size	80/100-21 51M(AU) (EUR) 80/100-21 M/C 51P	- - -
Make	BRIDGESTONE	- - -
Type	M401, Tube(AU) (EUR) ED03, Tube	- - -
Rear:
Size	110/100-18 64M(AU) (EUR)120/90-18 M/C 65P	- - -
Make	BRIDGESTONE	- - -
Type	M402, Tube(AU) (EUR) ED04, Tube	- - -

Special Tools

Inside Circlip Pliers: 57001-143

Line drawing of a pair of pliers (no text or symbols on the image itself)

Rim Protector: 57001-1063

Line drawing of six curved metal clips with circular bases, no text or symbols present

Bead Breaker Assembly: 57001-1072

Line drawing of a pliers tool with no text or symbols on the tool itself

Bearing Driver Set: 57001-1129

Isometric line drawing of a mechanical device with multiple circular components and an open casing (no text or symbols)

Jack: 57001-1238

Technical line drawing of a mechanical support structure (no text or symbols)

10-6 WHEELS/TIRES

Wheels (Rims)

Front Wheel Removal

• Using the jack [A] under the frame, and stabilize the motorcycle.
  Special Tool - Jack: 57001-1238
• Apply the rear brake to rear wheel does not turn.

Mechanical assembly diagram showing a motor with labeled component A, mounted on a platform (no readable text or symbols)

• Unscrew the axle nut [A].
• Loosen the left and right axle clamp bolts [B].
• Place a commercially available jack under the engine to raise the front wheel off the ground.
• Remove the axle [C], and pull out the wheel. Take off the collars and caps [D] from each side of the front hub.

D B A 4.8.046541

NOTICE

Do not lay the wheel on the ground with the disc facing down. This can damage or warp the disc. Place blocks under the wheel so the disc does not touch the ground.

B C BJ048549 P

- Insert a wood wedge between the disc brake pads this prevents them from being moved out of their proper position, should the brake lever be squeezed accidentally.

Front Wheel Installation

• Apply grease to the seals.
• Fit the projection [A] on the cap to the groove [B] on the collar.
• Install the caps and collars on the left and right side of the hub.

A B GJ04136851 C

Wheels (Rims)

- Install the speedometer gear housing so that the projections [A] fit in the drive notches [B].

Close-up of a hand holding a mechanical component with labeled parts A and B (no text or symbols beyond labels)

● Fit the collar on the right side of the hub.

- Fit the speedometer gear housing stop [A] on the fork leg clamp flat face [B].

Technical diagram of a mechanical assembly with labeled components A and B

• Insert the axle [A] from right side.
  ● Tighten the right [B] axle clamp bolts temporally.
• Tighten the axle nuts [C].
• Tighten the left axle clamp bolts [D].

Torque - Front Axle: 79 N·m (8.0 kgf·m, 58 ft·lb) Left Axle Clamp Bolts: 20 N·m (2.0 kgf·m, 15 ft·lb)

A B D C GJ04199851 C

NOTE

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

10-8 WHEELS/TIRES

Wheels (Rims)

• Remove the jack.
• Before tightening the right clamp bolts on the right fork leg, pump the forks up and down [A] 4 or 5 times to allow the right fork leg to find a neutral position on the front axle.

NOTE

○Do not apply the front brake during this process to stop the motorcycle from rolling forward. Put a block [B] in front of the wheel to stop it from moving.

- Tighten the right axle clamp bolts.

Torque - Right Axle Clamp Bolts: 20 N·m (2.0 kgf·m, 15 ft·lb)

NOTE

○ Tighten the two clamp bolts alternately two times to ensure even tightening torque.
- Check the front brake for good braking power and no brake drag.

WARNING

After servicing, it takes several applications of the brake lever before the brake pads contact the disc, which could result in increased stopping distance and cause an accident resulting in injury or death. Do not attempt to ride the motorcycle until a firm brake lever is obtained by pumping the lever until the pads are against the disc.

Rear Wheel Removal

- Using the jack under the frame so that the rear wheel is raised off the ground.

Special Tool - Jack: 57001-1238

- Remove

Cotter Pin [A] Axle Nut [B]

• Pull out the axle [C], and remove the chain adjuster.
• Disengage the drive chain from the rear sprocket toward the left.
• Move the rear wheel back with the rear caliper installed.
  ● Take off the collar and cap from the each side of the rear hub.

NOTICE

Do not lay the wheel on the ground with the disc facing down. This can damage or warp the disc. Place blocks under the wheel so the disc does not touch the ground.

- Insert a wood wedge between the brake pads. This prevents them from being moved out of their proper position, should the brake pedal be squeezed accidentally.

A B GJ048552 P

A B C GJ048553 P

Wheels (Rims)

Rear Wheel Installation

• Install the groove [A] of the brake holder [B] onto the projection [C] of the swingarm.
• Install the rear wheel while holding the disc cover [D].

B C A D GJ048554 P

• Fit the projection on the cap to the groove on the collar.
• Install the collars [A] on the left and right side of the hub. ○The collars are identical.

Mechanical gear assembly diagrams showing two views of a mechanical component with labeled parts (A), no readable text or symbols present.

• Engage the drive chain with the rear sprocket, and install the rear wheel.
• Insert the axle from the left side of the wheel, and install the axle nut.
• Check the drive chain slack (see Drive Chain Slack Inspection in the Periodic Maintenance chapter).
• Tighten the axle nut.
  Torque - Rear Axle Nut: 110 N·m (11.2 kg·m, 81.1 ft·lb)
• Install the new cotter pin [A] and spread its end.

Technical diagram showing a mechanical component with labeled connection point A and a separate electrical component.

SK04001BS1 C

NOTE

○ When inserting the cotter pin, if the slots in the nut do not align with the cotter pin hole in the axle shaft, tighten the nut clockwise [A] up to next alignment.
○ It should be within 30 degree.
○ Loosen one and tighten again when the slot goes past the nearest hole.

WARNING

A loose axle nut can lead to an accident resulting in serious injury or death. Tighten the axle nut to the proper torque and install a new cotter pin.

• Install the disc cover.
• Check the rear brake for good braking power and no brake drag.

A

GJ04034BS1 C

WARNING

After servicing, it takes several applications of the brake pedal before the brake pads contact the disc, which could result in increased stopping distance and cause an accident resulting in injury or death. Do not attempt to ride the motorcycle until a firm brake pedal is obtained by pumping the pedal until the pads are against the disc.

Wheels (Rims)

Wheels Inspection

• Place the jack under the frame so that the front/rear wheel is raised off the ground.
  Special Tool - Jack: 57001-1238
• Spin the wheellightly, and check for roughness or binding.
  ★If the roughness or binding is found, replace the hub bearings.
• Visually inspect the front and rear axles for damage.
  ★If the axle is damaged or bent, replace it.

Spoke Tightness Inspection

- Refer to the Spoke Tightness Inspection in the Periodic Maintenance chapter.

Rim Runout Inspection

- Refer to the Rim Runout Inspection in the Periodic Maintenance chapter.

Axle Inspection

• Visually inspect the front and rear axle for damages.
  ★If the axle is damaged or bent, replace it.
• Place the axle in V blocks that are 100 mm (3.937 in.) [A] apart, and set a dial gauge on the axle at a point halfway between the blocks. Turn the axle to measure the runout. The difference between the highest and lowest dial readings is the amount of runout.
  ★If the runout exceeds the service limit, replace the axle.

Axle Runout/100 mm (3.94 in.)

Standard: 0.1 mm (0.004 in.) or less

Service Limit: 0.2 mm (0.008 in.)

0J04139851 C

Tires

Tire Removal

NOTICE

Do not lay the wheel on the ground with the disc facing down. This can damage or warp the disc. Place blocks under the wheel so the disc does not touch the ground.

• Remove the wheel from the motorcycle (see Wheels Removal).
• To maintain front wheel balance, mark [A] the valve stem position on the tire with chalk so that the tire can be reinstalled in the same position.
• Remove the valve cap [B].
• Take out the valve core [A] to let out the air.
• Remove the valve stem nut [B].

A B GJ05029851 C

A B GJ050308S1 C

• Loosen the bead protector nut [A].
• Lubricate the tire beads and rim flanges on both sides with a soap and water solution or rubber lubricant. This helps the tire beads slip off the rim flanges.

A ©J05B011 P

NOTICE

Never lubricate with mineral oil (engine oil) or gasoline because they will cause deterioration of the tire.

• Break the beads away from both sides of the rim with the bead breaker [A].
  Special Tool - Bead Breaker Assembly: 57001-1072

A SJ05031851 C

Tires

- Step on the side of the tire opposite valve stem, pry the tire off the rim with the tire iron [A] of the bead breaker protecting the rim with rim protectors [B].

Special Tools - Rim Protector: 57001-1063

Bead Breaker Assembly: 57001-1072

NOTICE

Take care not to inset the tire irons so deeply that the tube gets damaged.

• Remove the bead protector and tube when one side of the tire is pried off.
• Pry the tire off the rim.

Tire Installation

NOTE

○ The Tires should be installed so that the ID serial NO. [A] faces to left side.

• Inspect the rim and tire, and replace them if necessary.
  • Install the tube band and tube.
• Apply a soap and water solution, or rubber lubricant to the rim flange and tire beads.

- Position the front tire on the rim so that the valve [A] is at the tire balance mark [B] (the chalk mark made during removal, or the white paint mark on a new tire. see Removal).

• Insert the valve stem into the rim, and screw the nut on loosely.
• Fit the rim protectors and use tire irons to install the tire bead.

NOTE

To prevent rim damage, be sure to place the rim protectors at any place the tire irons are applied.

• Pry one side of the tire back onto the rim. Fit the bead protector into the tire.
• Pry the other side of the tire onto the rim, starting at the side opposite the valve.
• Take care not to insert the tire irons so deeply that the tube is damaged.
• Install the other side of the tire bead onto the rim in the same manner.
• Check that the tube is not pinched between the tire and rim.

B A 0J050104S1 C

A EN22 • XXX• 60/100-24 514 mm MOTCROSS-MACOL J005083851 C

Close-up of a tire wheel with labeled points A and B, showing mechanical components and mounting hardware (no readable text or symbols beyond labels)

Tires

• Tighten the bead protector nut [A] and valve stem nut [B], and put on the valve cap [C].
• Check and adjust the air pressure after installing.

A B C QJ058012

Air Pressure Inspection/Adjustment

- Refer to the Air Pressure Inspection/Adjustment in the Periodic Maintenance chapter.

Hub Bearings

Hub Bearing Removal

- Remove the wheel (see Wheel Removal).

NOTICE

Do not lay the wheel on the ground with the disc facing down. This can damage or warp the disc. Place blocks under the wheel so that the disc does not touch the ground.

• Remove the oil seals and circlips.
  Special Tool - Inside Circlip Pliers: 57001-143

- Remove the hub bearing by tapping evenly around the bearing inner race as shown.

[A] Bar
[B] Distance Collar
[C] Hub Bearing

A B C GJ06013BS1 C

Hub Bearing Installation

• Before installing the wheel bearings, blow any dirt or foreign particles out of the hub [A] with compressed air to prevent contamination of the bearings.
• Replace the bearings with new ones.
• Lubricate them and install them using the bearing driver set [B] so that the marked or shielded sides face out.
  ○Press in the bearings until they are bottomed.

Special Tool - Bearing Driver Set: 57001-1129

A B 0J08009BS1 C

• Replace the circlips and oil seals with new ones.
• Press in the oil seals [A] so that the seal surface is flush [B] with the end of the hole.
• Apply high temperature grease to the oil seal lips.

Special Tool - Bearing Driver set: 57001-1129 [C]

A B C GJ08008851 C

Hub Bearing Inspection

NOTE

- It is not necessary to remove any bearings for inspection. If any bearings are removed, they will need to be replaced with new ones.

• Spin [A] it by hand to check its condition.
  ★If it is noisy, does not spin smoothly, or has any rough spots, it must be replaced.
• Examine the bearing seal [B] for tears or leakage.
  ★If the seal is torn or is leaking, replace the bearing.

B A GJ08002BS1 C

Hub Bearings

Hub Bearing Lubrication

NOTE

○ Since the hub bearings are packed with grease and sealed, lubrication is not required.

Final Drive

Table of Contents

Exploded View.... 11-2

Specifications 11-4

Drive Chain.... 11-5

Drive Chain Slack Inspection 11-5

Drive Chain Slack Adjustment 11-5

Wheel Alignment Inspection 11-5

Wheel Alignment Adjustment.... 11-5

Drive Chain Wear Inspection 11-5

Drive Chain Lubrication.... 11-5

Drive Chain Removal 11-5

Sprockets.... 11-9

Engine Sprocket Removal 11-9

Engine Sprocket Installation 11-9

Rear Sprocket Removal.... 11-9

Rear Sprocket Installation.... 11-10

Sprocket Wear Inspection.... 11-10

Rear Sprocket Warp Inspection 11-10

11-2 FINAL DRIVE

Exploded View

Technical diagram of a mechanical assembly with numbered components for identification and assembly reference.

Exploded View

No F	Fastener	Torque			Remarks
		N·m kgf	m ft·lb
1	Rear Sprocket Nuts	34	3.5	25	R
2 Engine Sprocket Nut 127 13.0 93.7

1. Engine Sprocket Cover
2. Engine Sprocket
3. Output Shaft
4. Chain Slipper
5. Swingarm
6. Chain Guide
7. Locknut
8. Adjusting Bolt
9. Chain Adjuster
10. Drive Chain
11. Rear Sprocket
12. Upper Chain Guide Roller
13. Lower Chain Guide Roller
    G: Apply grease.
    L: Apply a non-permanent locking agent.
    O: Apply oil.
    R: Replacement Parts

11-4 FINAL DRIVE

Specifications

Item Standard Service Limit
Drive Chain
Chain Slack	52 ~ 58 mm (2.0 ~ 2.3 in.)	- - -
Chain 20-link Length	317.5 ~ 318.2 mm (12.50 ~ 12.53 in.)	323 mm (12.7 in.)
Standard Chain:
Make	DAIDO	- - -
Type D.I.D. 520MXV - - -
Length 114 Links	- - -
Link Pin Outside Diameter	5.5 ~ 5.8 mm (0.22 ~ 0.23 in.)	- - -
Link Plate Outside Width	16.50 ~ 16.70 mm (0.650 ~ 0.657 in.)	- - -
Sprocket
Rear Sprocket Warp	0.4 mm (0.016 in.) or less	0.5 mm (0.020 in.)

Drive Chain

Drive Chain Slack Inspection

- Refer to the Drive Chain Slack Inspection in the Periodic Maintenance chapter.

Drive Chain Slack Adjustment

- Refer to the Drive Chain Slack Adjustment in the Periodic Maintenance chapter.

Wheel Alignment Inspection

- Check that the rear end [A] of the left chain adjuster aligns with the same swing arm mark [B] as the right chain adjuster.

WARNING

Misalignment of the wheel will result in abnormal wear and may result in an unsafe riding condition. Be sure the wheel is properly aligned.

Mechanical assembly diagram showing a component with labeled parts A and B, no readable text or symbols present.

Wheel Alignment Adjustment

This procedure is the same as Drive Chain Slack Adjustment (see Drive Chain Slack Adjustment in the Periodic Maintenance chapter).

Drive Chain Wear Inspection

- Refer to the Drive Chain Wear Inspection in the Periodic Maintenance chapter.

Drive Chain Lubrication

- Refer to the Drive Chain Lubrication in the Periodic Maintenance chapter.

Drive Chain Removal

- Using a suitable tool, replace the drive chain.

Recommended Tool - DID Chain Joint "ZJ" MakeDAIDO KOGYO

NOTICE

Read the Tool Instruction Manual before replacing the chain.

- Remove:

Body [A]
Pin Holder [B]
Positioning Pin [C]
"U" Holder [D]
Plate Holder [E]
Cutting and Riveting Pin [F]
Part for Riveting [G]
Part for Cutting [H]

D C A B E G F H OK48124 P

11-6 FINAL DRIVE

Drive Chain

• Grind [A] the heads of the link pin to make it flat.
• Set the cutting and riveting pin [C] in the pin holder [B] as shown in the figure.

Technical diagram showing structural change with labeled components A, B, and C, including a magnified view of the component being adjusted.

• Set the "U" holder and body, align the positioning pin [A] with the "A mark" [B].
• Turn the pin holder [C] clockwise until the cutting and riveting pin touches the link pin.
• Be sure that the cutting and riveting pin hits center of the link pin.

A B C OK048135 P

• Hold the body with a wrench [A].
• Turn the pin holder clockwise [B] with another wrench and remove the link pin.
• Do the same procedure for removal of the other link pin.

A B DK04B136

Drive Chain Installation

• Engage the new drive chain to the old drive chain and change the position of the chains by pulling the old chain.
• Remove the old drive chain from the new drive chain.
• Replace the link pin [A], link plate and grease seals [B] [C] with new ones.
• Apply grease to the link pin and grease seals.
• Install the grease seals on the link pin and insert it in the ends of the drive chain.
• Install the link plate so that the mark [D] faces out.
• Set the cutting and riveting pin [B] and plate holder [C] on the pin holder [A] as shown in the figure.

B A C D OK04090B51 C

A B C OK048123 P

Drive Chain

• Set the "U" holder and body, align the positioning pin [A] with the "A mark" [B].
• Hold the body with a wrench [C].
• Turn the pin holder clockwise [D] with another wrench and press in the link plate on the link pin.
• Remove the "U" holder and body.

A B C D G048137 P

- Set the cutting and riveting pin [B] in the pin holder [A] as shown in the figure.

A B OK48129 P

• Set the "U" holder and body, align the positioning pin [A] with the "B mark" [B].
• Turn the pin holder [C] clockwise until the cutting and riveting pin touches the link pin.

A B C

• Hold the body with a wrench [A] and turn the pin holder clockwise [B] with another wrench until the cutting and riveting pin touches the link plate.
• Do the same procedure for removal of the other link pin.

Mechanical assembly diagram showing a shaft and gear mechanism with labeled parts A and B (no text or symbols beyond labels)

Drive Chain

• After riveting, check the ends of the riveted pins for cracks.
• Measure the outside diameter [A] of the link pin and width [B] of the link plates.

Link Pin Outside Diameter

Standard: 5.5 \~ 5.8 mm (0.22 \~ 0.23 in.)

Link Plate Outside Width

Standard: 16.50 \~ 16.70 mm (0.650 \~ 0.657 in.)

★If the reading is not the specified length, cut and rejoin the chain again.
- Check that the rollers move smoothly.
- Adjust the drive chain slack after installing the chain (see Drive Chain Slack Adjustment in the Periodic Maintenance chapter).

A B QK04091BS1 C

Sprockets

Engine Sprocket Removal

- Remove:

Engine Sprocket Cover Bolts [A]

Engine Sprocket Cover [B]

Drive Chain Guide [C]

A B C GK05R288 P

- Remove:

Drive Chain [B] (free of engine sprocket)

- Flatten the bended sprocket washer [A].

- Remove the engine sprocket nut [C] and sprocket washer, and pull off the engine sprocket [D].

B A C D GK058299 P

Engine Sprocket Installation

• Install the engine sprocket so that the flatten side faces [A] inside.
• Replace the sprocket washer with a new one.
  • Install the sprocket washer and sprocket nut.

Torque - Engine Sprocket Nut: 127 N·m (13.0 kgf·m, 93.7 ft·lb)

• Bend the one side of the sprocket washer on the nut.
  • Install the engine sprocket cover.

Torque - Engine Sprocket Cover Bolts : 9.8 N·m (1.0 kgf·m, 87 ft·lb)

Close-up of a hand holding a gear mechanism with chains and gears (no visible text or symbols)

Rear Sprocket Removal

- Remove the rear wheel (see Rear wheel Removal in the Wheels/Tires chapter).

NOTICE

Do not lay the wheel on the ground with the disc facing down. This can damage or warp the disc. Place blocks under the wheel so that the disc does not touch the ground.

- Unscrew the rear sprocket bolts [A], and remove the rear sprocket [B].

Close-up of a mechanical gear assembly with labeled points A and B (no text or symbols beyond labels)

11-10 FINAL DRIVE

Sprockets

Rear Sprocket Installation

• Install the rear sprocket [A] so that the marked side [B] faces out.
• Replace the rear sproket nuts with new ones.
  ● Install the rear sprocket bolts and tighten the nuts.

Torque - Rear Sprocket Nuts: 34 N·m (3.5 kgf·m, 25 ft·lb)

A B CK0085292 P

Sprocket Wear Inspection

- Refer to the Sprocket Wear Inspection in the Periodic Maintenance chapter.

Rear Sprocket Warp Inspection

- Refer to the Rear Sprocket Warp Inspection in Periodic Maintenance chapter.

Brakes

Table of Contents

Exploded View 12-2

Specifications 12-6

Special Tools 12-7

Brake Lever, Brake Pedal 12-8

Brake Lever Adjustment.... 12-8

Brake Pedal Position Adjustment.... 12-8

Brake Pedal Removal 12-8

Brake Pedal Installation 12-8

Brake Fluid 12-9

Fluid Level Inspection 12-9

Fluid Change.... 12-9

Bleeding the Brake Line.... 12-10

Caliper 12-12

Caliper Removal 12-12

Caliper Installation 12-12

Caliper Disassembly 12-13

Fluid Seal Damage 12-13

Dust Seal and Cover Damage 12-13

Piston Cylinder Damage 12-13

Caliper Holder Shaft Wear 12-13

Brake Pad Removal 12-14

Brake Pad Installation 12-14

Brake Pad Inspection.... 12-14

Master Cylinder 12-15

Front Master Cylinder Removal 12-15

Front Master Cylinder Installation 12-15

Rear Master Cylinder Removal.... 12-16

Rear Master Cylinder Installation.... 12-16

Front Master Cylinder Disassembly 12-16

Rear Master Cylinder Disassembly.... 12-16

Master Cylinder Assembly 12-16

Master Cylinder Inspection (Visual Inspection) 12-17

Brake Disk 12-18

Brake Disc Removal 12-18

Brake Disc Installation 12-18

Brake Disc Inspection 12-18

Brake Hose.... 12-19

Brake Hose Removal/Installation 12-19

Brake Hose Inspection.... 12-19

Technical diagram of automotive suspension components with numbered parts and exploded views

Exploded View

No.	Fastener	Torque			Remarks
		N·m kgf·m ft·lb
1	Front Master Cylinder Clamp Bolts	8.8	0.90	78 in·lb	S
2	Brake Hose Banjo Bolts	25	2.5	18
3	Brake Pad Bolt	17	1.7	13
4	Caliper Bleed Valve	7.8 0.80	69 in·lb
5	Caliper Mounting Bolts	25	2.5	18
6	Front Brake Disc Mounting Bolts	10	1.0	89 in·lb	L
7	Brake Lever Pivot Bolt Locknut	5.9	0.60	52 in·lb
8	Brake Lever Pivot Bolt	5.9	0.60	52 in·lb	Si
9	Brake Reservoir Cap Screws	1.5 0.15	13 in·lb
10	Front Brake Light Switch Screw	1.2 0.12	10 in·lb

1. Front Brake Reservoir
2. Brake Lever
3. Brake Lever Adjuster
4. Locknut
5. Brake Hose
6. Clamps
7. Front Caliper
8. Brake Pad
9. Piston
10. Front Disc
11. Australia Models
12. KLX450A9F Model \~
    BF: Apply brake fluid.
    L: Apply a non-permanent locking agent.
    R: Replacement Parts
    S: Tighten the fasteners following the specified sequence.
    Si: Apply silicone grease.

Technical diagram of automotive brake system components with numbered parts and labeled parts (R, S, B, C, etc.)

Exploded View

No.	Fastener	Torque			Remarks
		N·m kgf	m ft·lb
1	Brake Hose Banjo Bolts	25	2.5	18
2	Rear Master Cylinder Mounting Bolts	10	1.0	89 in·lb
3	Rear Master Cylinder Push Rod Locknut	17	1.7	13
4	Caliper Bleed Valve	7.8	0.80	69 in·lb
5	Brake Pad Bolt	17 1.7 13
6	Rear Brake Pad Bolt Plug	2.4	0.24	21 in·lb
7	Caliper Holder Shaft	27 2.8 20			Si
8	Brake Pedal Mounting Bolt	25	2.5	18	G,L
9	Rear Brake Disc Mounting Bolts	23	2.3	17	L
10	Brake Reservoir Cap Bolts	1.5	0.15	13 in·lb

1. Brake Hose
2. Rear Master Cylinder
3. Brake Pedal
4. Rear Caliper Cover
5. Rear Caliper
6. Piston
7. Brake Pads
8. Rear Disc
   BF: Apply brake fluid.
   G: Apply high temperature grease.
   L: Apply a non-permanent locking agent.
   R: Replacement Parts
   Si: Apply Silicone grease.

Specifications

Item Standard Service Limit
Brake adjustmentLever Play Adjustable (to suit rider)	-- --
Brake FluidRecommended Disc Brake Fluid:TypeFrontRear DOT4	DOT3 or DOT4	-- --
		-- --
Brake PadsLining thickness:Front 3.8 mm (0.15 in.) 1 mm (0.04 in.)Rear 6.4 mm (0.25 in.) 1 mm (0.04 in.)
Brake DiscThickness:FrontRearRunout	2.85 ~ 3.15 mm (0.112 ~ 0.124 in.)3.85 ~ 4.15 mm (0.152 ~ 0.163 in.)TIR 0.25 mm (0.0098 in.) or less	2.5 mm (0.10 in.)3.5 mm (0.14 in.)TIR 0.3 mm (0.01 in.)

Special Tools

Inside Circlip Pliers: 57001-143

Line drawing of a pair of pliers (no text or symbols on the image itself)

Jack: 57001-1238

Technical line drawing of a mechanical support structure (no text or symbols)

12-8 BRAKES

Brake Lever, Brake Pedal

Brake Lever Adjustment

- Refer to the Brake Lever and Pedal Position Adjustment in the Periodic Maintenance chapter.

Brake Pedal Position Adjustment

- Refer to the Brake Lever and Pedal Position Adjustment in the Periodic Maintenance chapter.

Brake Pedal Removal

- Remove: Cotter Pin [A] Joint Pin [B] Washer [C]

- Remove the mounting bolt [D] and take off the brake pedal [E] and return spring.

A C D B E QL04020851 C

Brake Pedal Installation

- Replace O-rings with new one and apply high temperature grease to the O-rings.

- Apply high temperature grease to the shaft portion and a non-premanent locking agent to the thread of the brake pedal mounting bolt, and install the pedal with return spring onto the frame.

○Install the return spring direction [A] as shown.

Torque - Brake Pedal Mounting Bolt: 25 N·m (2.5 kgf·m, 18 ft·lb)

- Check the brake pedal position.

• Install the joint pin, washer and a new cotter pin.

○Bend the ends [A] of the cotter pin.

Close-up of a mechanical assembly with labeled component A (no readable text or symbols)

Technical line drawing of a mechanical clamp or clamping device with labeled component A (no text or symbols beyond label)

Brake Fluid

WARNING

When working with the disc brake, observe the precautions listed below.

1. Never reuse old brake fluid.
2. Do not use fluid from a container that has been left unsealed or that has been open for a long time.
3. Do not mix two types and brands of fluid for use in the brake. This lowers the brake fluid boiling point and could cause the brake to be ineffective. It may also cause the rubber brake parts to deteriorate.
4. Don't leave the reservoir cap off for any length of time to avoid moisture contamination of the fluid.
5. Don't change the fluid in the rain or when a strong wind is blowing.
6. Except for the disc pads and disc, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol for cleaning of the brake parts. Do not use any other fluid for cleaning these parts. Gasoline, engine oil, or any other petroleum distillate will cause deterioration of the rubber parts. Oil spilled on any part will be difficult to wash off completely and will eventually deteriorate the rubber used in the disc brake.
7. When handling the disc pads or disc, be careful that no disc brake fluid or any oil gets on them. Clean off any fluid or oil that inadvertently gets on the pads or disc with a high-flash point solvent. Do not use one which will leave an oily residue. Replace the pads with new ones if they cannot be cleaned satisfactorily.
8. Brake fluid quickly ruins painted surfaces; any spilled fluid should be completely wiped up 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.

Fluid Level Inspection

- Refer to the Brake Fluid Level Inspection in the Periodic Maintenance chapter.

Fluid Change

- Refer to the Brake Fluid Change in the Periodic Maintenance chapter.

Bleeding the Brake Line

The brake fluid has a very low compression coefficient so that almost all the movement of the brake lever or pedal is transmitted directly to the caliper for braking action. Air, however, is easily compressed. When air enters the brake lines, brake lever or pedal movement will be partially used in compressing the air. This will make the lever or pedal feel spongy, and there will be a loss in braking power.

WARNING

Air in the brake lines diminish braking performance and can cause an accident resulting in injury or death. If the brake lever or pedal has a soft or "spongy" feeling mushy when it is applied, there might be air in the brake lines or the brake may be defective. Do not operate the vehicle and service the brake system immediately.

NOTE

○ The procedure to bleed the front brake line is as follows. Bleeding the rear brake line is the same as for the front brake.

• Remove the reservoir cap, and check that there is plenty of fluid in the reservoir.
• With the reservoir cap off, slowly pump the brake lever several times until no air bubbles can be seen rising up through the fluid from the holes at the bottom of the reservoir.
• Bleed the air completely from the master cylinder by this operation.
• Install the reservoir cap.
• Attach a clear plastic hose to the bleed valve on the caliper, and run the other end of the hose into a container.

- Bleed the brake line and the caliper as follows:

○ Repeat this operation until no more air can be seen coming out into the plastic hose.

1. Pump the brake lever until it becomes hard, and apply the brake and hold it [A].

2. Quickly open and close the bleed valve while holding the brake applied [B].

3. Release the brake [C].

NOTE

☐ The fluid level must be checked often during the bleeding operation and replenished with fresh brake fluid as necessary. If the fluid in the reservoir runs almost out any time during bleeding operation, the bleeding operation must be done over again from the beginning since air will have entered the line.

○ Tap the brake hose lightly from the caliper to the reservoir for easier bleeding.

- Remove the clear plastic hose.

- Tighten the bleed valves, and install the rubber caps.

- Remove the clear plastic hose. - Tighten the bleed valves, and install the rubber caps.

Torque - Caliper Bleed Valve: 7.8 N·m (0.80 kgf·m, 69 in·lb)

B A C QL09G34BS2 C

Brake Fluid

• Check the fluid level.
• After bleeding is done, check the brake for good braking power, no brake drag, and no fluid leakage.

WARNING

After servicing, it takes several applications of the brake lever or pedal before the brake pads contact the disc, which could result in increased stopping distance and cause an accident resulting in injury or death. Do not attempt to ride the motorcycle until a firm brake lever or pedal is obtained by pumping the lever or pedal until the pads are against the disc

Caliper

Caliper Removal

Front Brake

• Loosen the banjo bolt [A] so as not to spill brake fluid.
• Remove the caliper mounting bolts [B].
• Remove the banjo bolt and take off the brake hose from the caliper [C].
• If the caliper is to be disassembled after removal and if compressed air is not available, remove the piston using the following steps before disconnecting the brake hose from the caliper.

○Remove the pads.

○Pump the brake lever to remove the piston.

B A C QL05163B51 C

Rear Brake

• Unbolt the caliper guard bolts [A] and remove the caliper guard [B].
• Unbolt the disc guard bolts [C] and remove the disc guard [D].

B A D C 068145 P

• Loosen the banjo bolt [A] so as not to spill brake fluid.
• Loosen the brake pad bolt plug[B], and pad bolt [C] before the caliper removal if the caliper is to be disassembled.

C A B D GL058146 P

NOTE

○ If the caliper is to be disassembled after removal and compressed air is not available, disassemble the caliper before brake hose removal (see Caliper Disassembly).

• Remove the rear wheel (see Rear Wheel Removal in the Wheels/Tires chapter).
• Unscrew the banjo bolt and remove the brake hose [D] from the caliper (see Brake Hose Replacement in the Periodic Maintenance chapter).

NOTICE

Immediately wipe up any brake fluid that is spilled.

Caliper Installation

• Tighten the brake pad bolts if it was removed.
  Torque - Brake Pad Bolt: 17 N·m (1.7 kgf·m, 13 ft·lb)

Front Brake

• Install the caliper and tighten the bolts.
Torque - Caliper Mounting Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb)

Rear Brake

• Before install the caliper, install the rear wheel (see Rear Wheel Installation in the Wheels/Tires chapter).
  • Install the brake hose lower end.
  ○Replace the washers that are on each side of hose fitting with new ones.

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

Caliper

• Bleed the brake line (see Bleeding the Brake Line).
• Check the brake for good braking power, no brake drag, and no fluid leakage.

WARNING

After servicing, it takes several applications of the brake lever or pedal before the brake pads contact the disc, which could result in increased stopping distance and cause an accident resulting in injury or death. Do not attempt to ride the motorcycle until a firm brake lever or pedal is obtained by pumping the lever or pedal until the pads are against the disc

Caliper Disassembly

- Refer to the Caliper Piston Seal and Dust Seal Replacement in the Periodic Maintenance chapter.

Fluid Seal Damage

The fluid seal around the piston maintains the proper pad/disc clearance. If this seal is not in good condition, 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 left and right pad wear; (d) the seal is stuck to the piston. If the fluid seal is replaced, replace the dust seal as well. Also, replace all seals every other time the pads are changed.

Dust Seal and Cover Damage

- Check that the dust seals and covers are not cracked, worn, swollen, or otherwise damaged.

★If they show any damage, replace them.

Piston Cylinder Damage

- Visually inspect the piston and cylinder surfaces.

★Replace the cylinder and piston if they are badly scored or rusty.

Caliper Holder Shaft Wear

The caliper body must slide smoothly on the caliper holder shafts. 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 disc and brake fluid temperature.

- Check too see if the caliper holder shafts are not badly worn or stepped, or the rubber friction boot is not damaged.

★If the shafts or rubber friction boot are damaged, replace the shafts, rubber friction boot, and the caliper holder.

Caliper

Brake Pad Removal

Front Brake Pad

• Unscrew the pad bolt [A].
  • Take the piston side pad [B].
• Push the caliper holder toward the piston, and then remove another pad [C] from the caliper holder.

A B C GL068000 P

Rear Brake Pad

- Remove: Plug [A]

Mechanical assembly diagram showing a bracket with labeled component A (no readable text or symbols)

● Unscrew the pad bolt [A].
• Take the piston side pad [B].
- Push the caliper hold toward the piston, and then remove another pad [C] from the caliper holder.

C B A GL062101 P

Brake Pad Installation

• Push the caliper pistons in by hand as far as they will go.
• Install the piston side pad first, and then another pad.
  ○Fit the pad end [A] into the groove [B] of the anti-rattle spring securely.
• Tighten the brake pad bolt.

Torque - Brake Pad Bolt: 17 N·m (1.7 kgf·m, 13 ft·lb) Rear Brake Pad Bolt Plug: 2.4 N·m (0.24 kgf·m, 21 in·lb)

- Check the brake for good braking power, no brake drag, and no fluid leakage.

A B 01.048102 P

WARNING

After servicing, it takes several applications of the brake lever or pedal before the brake pads contact the disc, which could result in increased stopping distance and cause an accident resulting in injury or death. Do not attempt to ride the motorcycle until a firm brake lever or pedal is obtained by pumping the lever or pedal until the pads are against the disc.

Brake Pad Inspection

- Refer to the Brake Pad Wear Inspection in the Periodic Maintenance chapter.

Master Cylinder

NOTICE

Brake fluid quickly ruins painted or plastic surfaces; any spilled fluid should be completely wiped up immediately.

Front Master Cylinder Removal

• Remove the banjo bolt [A] to disconnect the upper brake hose [B] from the master cylinder [C].
• When removing the brake hose, temporarily secure the end of the brake hose to some high place to keep fluid loss to a minimum.

A B C

- Unscrew the clamp bolts [A], and take off the master cylinder [B] as an assembly with the reservoir and brake lever.

Technical diagram of a mechanical assembly with labeled parts A and B, likely for assembly or maintenance instructions.

Front Master Cylinder Installation

- Install the master cylinder so that the reservoir cap [A] is horizontally.

Close-up of a bicycle hand handle with labeled component A (no text or symbols beyond label)

- The master cylinder clamp must be installed with the arrow mark [A] upward. ○Tighten the upper clamp bolt [B] first, and then the lower clamp bolt [C]. There will be a gap at the lower part of the clamp after tightening.

Torque - Front Master Cylinder Clamp Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb)

• Replace the washers that are on each side of hose fitting with new ones.
• Tighten the brake hose banjo bolt.

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

• Bleed the brake line (see Bleeding the Brake Line).
• Check the brake for good braking power, no brake drag, and no fluid leakage.

B A C UP GL07035BS1 C

Rear Master Cylinder Removal

• Remove the cotter pin [A].
• Pull off the joint pin [B] with washer.

NOTE

○ Pull off the joint pin while pressing down the brake pedal.

• Unscrew the master cylinder mounting bolts [C], and remove the master cylinder [D].
• Unscrew the brake hose banjo bolt [E].
• When removing the brake hose, temporarily secure the end of the brake hose to some high place to keep fluid loss to a minimum.

Rear Master Cylinder Installation

• Replace the cotter pin with a new one.
• Replace the washers are on each side of hose fitting with new ones.
• Tighten the following:

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

Rear Master Cylinder Mounting Bolts: 10 N·m (1.0 kgf·m, 89 in·lb)

• Bleed the brake line (see Bleeding the Brake Line).
• Check the brake for good braking power, no brake drag, and no fluid leakage.
• Check the brake pedal position (see Brake Lever and Pedal Position Adjustment in the Periodic Maintenance chapter).

Front Master Cylinder Disassembly

- Refer to the Brake Master Cylinder Cup and Dust Seal Replacement in the Periodic Maintenance chapter.

Rear Master Cylinder Disassembly

- Refer to the Brake Master Cylinder Cup and Dust Seal Replacement in the Periodic Maintenance chapter.

Master Cylinder Assembly

- Refer to the Brake Master Cylinder Cup and Dust Seal Replacement in the Periodic Maintenance chapter.

E C D O A B OL07088851 C

Master Cylinder

Master Cylinder Inspection (Visual Inspection)

- Disassemble the front and rear master cylinders. - Check that there are no scratches, rust or pitting on the inner wall of each master cylinder [A] and on the outside of each piston [B].

★If a 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 replace to renew the cups.

★If fluid leakage is noted at the brake lever, the piston assembly should be replaced to renew the cup.

- Check the dust covers [E] for damage.

★If they are damaged, replace them.

- Check that the relief [F] and supply [G] ports are not plugged.

★If the small relief port becomes plugged, the brake pads will drag on the disc. Blow the ports clean with compressed air.

- Check the piston return springs [H] for any damage.

★If a spring is damaged, replace it.

[J] Front Master Cylinder [K] Rear Master Cylinder

F J G A H C B D E QL07021B S

K A H C B D E F G GL07022B 5

Brake Disk

Brake Disc Removal

• Remove the wheel (see Front/Rear Wheel Removal in the Wheels/Tires chapter).
• Unscrew the mounting bolts [A], and take off the disc [B].

Close-up of a mechanical brake assembly with labeled components A and B (no text or symbols beyond labels)

Brake Disc Installation

• Install the disc on the wheel so that the marked side [A] faces out.
• Apply a non-permanent locking agent to the threads of the brake disc bolts [B].
• Tighten:

Torque - Front Brake Disc Mounting bolts: 10 N·m (1.0 kgf·m, 89 in·lb)

Rear Brake Disc Mounting bolts: 23 N·m (2.3 kgf·m, 17 ft·lb)

Close-up mechanical assembly diagram showing gears and shafts with labeled points A and B (no readable text or symbols)

Brake Disclnspection

• Visually inspect the disc [A].
  ★If it is scratched or damaged, replace the disc.
• Measure the thickness of each disc at the point [B] where it has worn the most.
  ★Replace the disc if it has worn past the service limit.

B A GL08024B51 C

Thickness

Standard:

Front 2.85 \~ 3.15 mm (0.112 \~ 0.124 in.)

Rear 3.85 \~ 4.15 mm (0.152 \~ 0.163 in.)

Service Limit:

Front 2.5 mm (0.10 in.)

Rear 3.5 mm (0.14 in.)

- Place a jack under the motorcycle so that the front/rear wheel is raised off the ground.

Special Tool - Jack: 57001-1238

- Set up a dial gauge against the disc [A] as illustrated.

○For the front disc, turn the handlebar fully to one side.

- Measure the disc runout while rotating the wheel slowly [B].

★If the runout exceeds the service limit, replace the disc.

Runout

Standard: TIR 0.25 mm (0.0098 in.) or less

Service Limit: TIR 0.3 mm (0.01 in.)

A B QL08029851 C

Brake Hose

Brake Hose Removal/Installation

- Refer to the Brake Hose Replacement in the Periodic Maintenance chapter.

Brake Hose Inspection

- Refer to the Brake Hose and Connection Check in the Periodic Maintenance chapter.

Suspension

Table of Contents

Exploded View.... 13-2

Specifications 13-6

Special Tools 13-7

Front Fork 13-8

Air Pressure 13-8

Rebound Damping Adjustment.... 13-8

Compression Damping Adjustment 13-9

Oil Change (each fork leg) 13-9

Front Fork Removal 13-9

Front Fork Installation 13-10

Front Fork Disassembly (each fork leg) 13-11

Front Fork Assembly 13-15

Adjuster Assembly Inspection.... 13-20

Base Valve Assembly Inspection 13-20

Cylinder Unit Inspection 13-21

Inner Tube Inspection 13-21

Guide Bush Inspection.... 13-21

Dust Seal/Oil Seal Inspection 13-21

Spring Tension 13-22

Rear Suspension (Uni-Trak) 13-23

Rear Shock Absorber: 13-23

Rebound Damping Adjustment.... 13-23

Compression Damping Adjustment 13-23

Spring Preload Adjustment 13-24

Spring Tension 13-25

Rear Shock Absorber Removal 13-26

Rear Shock Absorber Installation 13-26

Spring Replacement 13-26

Rear Shock Absorber Disassembly (Oil Change).... 13-27

Rear Shock Absorber Assembly.... 13-27

Rear Shock Absorber Scrapping 13-27

Swingarm.... 13-28

Swingarm Removal 13-28

Swingarm Installation.... 13-29

Swingarm Bearing Removal 13-29

Swingarm Bearing Installation 13-29

Swingarm Bearing, Sleeve Inspection 13-30

Drive Chain Guide, Guide Roller, Chain Slipper Wear.... 13-30

Tie-Rod, Rocker Arm.... 13-31

Tie-Rod Removal 13-31

Tie-Rod Installation 13-31

Rocker Arm Removal.... 13-31

Rocker Arm Installation.... 13-32

Tie-Rod and Rocker Arm Bearing Removal 13-32

Tie-Rod and Rocker Arm Bearing Installation.... 13-33

Needle Bearing Inspection.... 13-33

Uni-Trak Maintenance 13-34

Uni-Trak Linkage Inspection 13-34

Tie-Rod and Rocker Arm Sleeve Wear 13-34

Tie-Rod and Rocker Arm Mounting Bolt Bend 13-34

13-2 SUSPENSION

Exploded View

Exploded view diagram of a mechanical assembly with numbered parts and labeled connectors

Exploded View

No.	Fastener	Torque			Remarks
		N·m kgf	·m ft·lb
1	Base Valve Assembly 28 2.9 21
2	Front Fork Top Plug	30	3.1	22
3	Front Fork Clamp Bolts (Upper)	20 2.0	15 AL
4	Front Fork Clamp Bolts (Lower)	20 2.0	15 AL
5	Steering Stem Head Nut	98	10	72
6	Locknut/Adjuster Assembly 29 3.0 21
7	Adjuster Assembly	55 5.6 41	L
8	Front Axle Clamp Bolts	20	2.0	15	AL

1. Screw

2. O-ring

3. Piston Rod

4. Rebound Damping Adjuster Rod

5. Subtank

6. Cylinder Unit

7. Outer Tube

8. Spacer

9. Fork Spring

10. Bushings

11. Washer

12. Oil Seal

13. Retaining Ring

14. Dust Seal

15. Inner Tube

16. O-ring

17. Gasket

18. Steering Stem Head

19. Steering Stem

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

L: Apply a non-permanent locking agent to the threads.

R: Replacement Parts

Exploded view diagram of a mechanical assembly with numbered parts and labeled components

Exploded View

No.	Fastener	Torque			Remarks
		N·m kgf	f·m ft·lb
1	Swingarm Pivot Shaft Nut 98 10 72 R
2	Rocker Arm Pivot Nut	59	6.0	44	R
3	Tie-rod Mounting Nut (Front, Rear)	59	6.0	44	R
4	Rear Shock Absorber Mounting Nut (Upper)	39	4.0	29	R
5	Rear Shock Absorber Mounting Nut (Lower)	34	3.5	25	R
6	Air Bleed Bolt	6.5	0.66	58 in·lb

1. Swingarm Pivot Shaft

2. Swingarm

3. Rocker Arm

4. Tie-Rod

5. Rear Shock Absorber Cylinder

6. O-ring

7. Bladder

8. Cap

9. Circlip

10. Valve Cap

11. Locknut

12. Adjusting Nut

13. Spring

14. Spring Guides

15. Circlip

16. Piston Rod Assembly

17. Piston

18. O-ring

19. Oil Seal

20. Stopper

21. Rear Shock Absorber

G: Apply grease.

L: Apply a non-permanent locking agent.

R: Replacement Parts

2T: Apply 2-stroke oil.

Specifications

Item Standard Service Limit
Front Fork
Air Pressure Atmospheric pressure – Rebound Damping Adjustment(from the seated position adjuster turned fully clockwise)Compression Damping Adjustment(from the seated position adjuster turned fully clockwise)Oil Viscosity KHL15-10 (KAYABA 01) or oil Quantity:Outer (Outer/Inner Tubes)Inner (subtank)Fork Spring Free Length	– –9 clicks counterclockwise 18 clicks(Adjustable Range)11 clicks counterclockwise 22 clicks(Adjustable Range)335 mL (11.3 US oz.)189 mL (6.4 US oz.)460 mm (18.1 in.)	(Adjustable Range)– – –(Adjustable Range)300 ~ 380 mL(10.1 ~ 12.8 US oz.)– – –451 mm (17.8 in.)
Rear Suspension (Uni-Trak):Rear Shock Absorber
Rebound Damping Adjustment(from the seated position adjuster turned fully clockwise)Spring Preload Adjustment(Adjusting nut position from the center of the mounting hole upper)Rear Shock Spring Free Length	9 clicks counterclockwise 22 clicks123.5 mm (4.86 in.)260 mm (10.2 in.)	(Adjustable Range)(Adjustable Range)121.5 ~ 138.5 mm(4.783 ~ 5.453 in.)255 mm (10.0 in.)
Gas Reservoir
High Speed CompressionDamping AdjustmentLow Compression Damping Adjustment(from the seated position adjuster turned fully clockwise)Gas PressureTie-Rod, Rocker ArmSleeve Outside Diameter:Tie-rod	1-1/4 turn out11 clicks counterclockwise 22 clicks1 000 kPa ( 10 kgf/cm^2 , 145 psi)	(Adjustable Range)0 ~ 2 turn out(Adjustable Range)– – –

Special Tools

Oil Seal & Bearing Remover: 57001-1058

Technical line drawing of mechanical components including shafts, bolts, and fasteners (no text or symbols)

Steering Stem Nut Wrench: 57001-1100

Technical line drawing of a mechanical wrench (no text or symbols on the tool itself)

Hook Wrench R37.5, R42: 57001-1101

Technical line drawing of two mechanical wrenches (no text or symbols on the tools themselves)

Bearing Driver Set: 57001-1129

Isometric line drawing of a mechanical device with multiple circular components and a rectangular opening (no text or symbols)

Jack: 57001-1238

Technical line drawing of a mechanical support structure (no text or symbols)

Bearing Remover Shaft, 9157001-1265

Technical line drawing of a mechanical component with no visible text or symbols

Bearing Remover Head, 1/5 × 17φ 57001-1267

Technical line drawing of a mechanical connector or fitting (no text or symbols)

Fork Oil Seal Driver, 48: 57001-1509

Technical line drawings of two mechanical bracket components (no text or symbols)

Top Plug Wrench, 49 mm: 57001-1653

Line drawing of a mechanical wrench with hexagonal base and loop handle (no text or symbols)

13-8 SUSPENSION

Front Fork

Air Pressure

The standard air pressure in the front fork legs is atmospheric pressure. Air pressure in the fork legs increase with normal use, so the fork action stiffens during operation. Release air pressure form the fork legs prior to each race through the pressure relief screw located in each front fork cap.

- Place the jack under the frame so that the front wheel off the ground.

Special Tool - Jack: 57001-1238

- Remove the screws [A] at the top of the front fork top plugs to let the air pressure equalize.

Close-up mechanical component with labeled point A, showing internal components and a bolted joint (no readable text or symbols)

NOTE

○Do not use the sidestand when adjusting the air pressure.

○Adjust the air pressure when the front forks are cold.

- Replace the O-ring with a new one.

- Install the screw.

Rebound Damping Adjustment

- Place the jack under the frame so that the front wheel off the ground.

Special Tool - Jack: 57001-1238

- Clean the bottom of the fork tubes.

- Remove the caps on the bottom of the fork tubes.

- To adjust rebound damping, turn the adjuster [A] on the front fork cylinder valve with the blade of a screwdriver until you feel a click. Adjust the rebound damping to suit your preference under special condition.

Close-up of a mechanical component with a labeled bolt and arrow, no readable text or symbols present.

NOTE

○ The left and right fork legs must have the same shock damping.

Seated positions adjuster turned fully clockwise [A].

Rebound Damping Adjuster Setting

Standard: 9 clicks [B]

Softer (Counterclockwise) [C]

Harder (Clockwise) [D]

*: Number of turns counterclockwise usable range - 18 clicks or more.

Counterclockwise from the fully seated position.

- Put the caps into the bottom of the fork tubes.

C ← D B * 18 17 16 13 12 11 10 9 8 7 6 5 4 3 2 1 ← 2 A GW04521BS1 C

Front Fork

Compression Damping Adjustment

- Place the jack under the frame so that the front wheel off the ground.

Special Tool - Jack: 57001-1238

- To adjust compression damping, turn the adjuster [A] on the front fork top plugs with the blade of a screwdriver until you feel a click. Adjust the compression damping to suit you preference under special condition.

NOTE

○ The left and right fork legs must have the same shock damping.

Seated positions: adjuster turned fully clockwise [A].

Compression Damping Adjuster Setting

Standard: 11 clicks [B] Softer (Counterclockwise) [C] Harder (Clockwise) [D]

*: Number of turns counterclockwise usable range - 22 clicks or more. Counterclockwise from the fully seated position.

Close-up mechanical component with labeled point A, showing internal components and a textured surface (no readable text or symbols)

C ← → D B * 22 21 20 13 12 11 10 9 8 7 6 5 4 3 2 1 (°) A GM04445BS1 C

Oil Change (each fork leg)

- Refer to Front Fork Oil Change in the Periodic Maintenance chapter.

Front Fork Removal

- Unscrew the bolts [A], and remove the front brake hose clamps [B].

Close-up of bicycle wheel components with labeled parts A and B, likely for safety or repair instructions

- Remove: Front Wheel (see Front Wheel Removal in the Wheels/Tires chapter) Master Cylinder Camp Bolts [A]

- Remove the caliper [B] from the fork leg to be removed, and restthe caliper on some kind of stand so that it doesn't dangle.

- Remove: Bolts [C] Fork Protector [D]

Technical diagram of a mechanical assembly with labeled components A, B, C, and D

13-10 SUSPENSION

Front Fork

- Loosen the upper [A], and lower [B] fork clamp bolts.

- Remove the front fork.

With a twisting motion [A], work the fork leg [B] down and out.

Front Fork Installation

- Install the fork so that the distance between the top end of the outer tube and the upper surface of the steering stem head is specified dimension.

[A] 8 mm (0.31 in.)

- Route the cables and hose according to the Cable, Wire, and Hose Routing section in the Appendix chapter.

- Install the front wheel (see Front Wheel Installation in the Wheels/Tires chapter).

- Tighten the fork clamp bolts.

Torque - Front Fork Clamp Bolts (Upper): 20 N·m (2.0 kgf·m, 15 ft·lb)

Front Fork Clamp Bolts (Lower): 20 N·m (2.0 kgf·m, 15 ft·lb)

NOTE

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

- Tighten:

Torque - Front Caliper Mounting Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb)

- Check the front brake operation after installation.

Mechanical assembly diagrams showing two views (A and B) of a mechanical component with no visible text or symbols

Close-up of hands performing a manual task with labeled parts A and B, showing a tool interacting with a mechanical component.

Mechanical assembly diagram showing components with no visible text or symbols

Front Fork

Front Fork Disassembly (each fork leg)

- Loosen the front fork upper clamp bolts [A].

- Loosen the fork top plug (subtank) [A] with the top plug wrench [B].

Special Tool - Top Plug Wrench, 49 mm: 57001-1653 [B]

- Remove the front fork (see Front Fork Removal).

A GB04B567

THA B A GB048568 P

NOTE

○ Set rebound and compression damping setting to the softest settings before disassembling to prevent the needle of adjusters from damaging. Record the setting before turning the adjuster.

- Thoroughly clean the fork before disassembly.

NOTICE

Be careful not scratch the inner tube and not to damage the dust seal.

Avoid scratching or damaging the inner tube or the dust seal. Use a mild detergent and sponge out dirt with plenty of water.

- Using the top plug wrench [A], remove the fork top plug [B] (subtank) from the outer tube and slowly slide down the outer tube [C].

Special Tool - Top Plug Wrench, 49 mm: 57001-1653

B A C 08048569 P

13-12 SUSPENSION

Front Fork

- Place a drain pan under the front fork and drain fork oil [A].

NOTE

○Pump the fork tube several times to discharge the fork oil.

- Raise the outer tube and temporarily install the fork top plug [A] (subtank) to the outer tube [B] with the top plug wrench [C].

Special Tool - Top Plug Wrench, 49 mm: 57001-1653

• Hold the axle holder [A] with a vise.
  ○Protect the axle holder with a rag when using a vise.
• Loosen the adjuster assembly [B] completely.

WARNING

Clamping the axle holder part too tight can damage it which will affect riding stability. Do not clamp the axle holder part too tight.

- Compress the outer tube by hands and install the top plug wrench [A] between theaxle holder bottom [B] and locknut [C].

Special Tool - Top Plug Wrench, 49 mm: 57001-1653

WARNING

The fork spring applies pressure to the adjuster assembly and can eject the special tool with substantial force if the tool is not properly and securely placed. Be sure the tool is fully in place as shown in the photo, and keep fingers away to avoid getting them pinched between the tool, adjuster assembly and axle holder.

Close-up of a metallic pipe fitting with labeled component A, no readable text or symbols present

A C B 08048571 P

A B 08048572

A B C G048573 H

Front Fork

- Hold the locknut [A] with a wrench [B] and remove the adjuster assembly [C].

- Remove the push rod [A].

- With the outer tube compressed by hands, remove the topplugwrench[A].

NOTICE

Removing the locknut and pushing the piston rod thread into the cylinder unit will damage the oil seal. Do not remove the locknut from the piston rod.

• Remove the fork leg from the vise.
• Loosen the fork top plug (subtank) [A] with the top plug wrench [B].

Special Tool - Top Plug Wrench, 49 mm: 57001-1653 [B]

- Remove:

Cylinder Unit [A]

Spacer [B]

Fork Spring [C]

NOTICE

Disassembling the cylinder unit can lead to trouble. Do not disassemble the cylinder unit.

Medical or lab procedure image showing labeled mechanical components with annotations A, B, and C

Close-up of a hand holding a metal tool with a labeled component (A), no visible text or symbols on the object itself.

Close-up of a mechanical assembly with labeled component A (no readable text or symbols beyond label)

A B 08548577 P

Technical illustration of three mechanical tools labeled A, B, and C, showing internal components without any text or symbols.

13-14 SUSPENSION

Front Fork

- Remove the dust seal [A] and the retaining ring [B].

NOTICE

Be careful not to scratch the inner tube.

- Grasp the outer tube and stroke [A] the inner tube several times. The shock to fork seal separates the inner tube from the outer tube.

- Remove the following parts from the inner tube.

[A] Guide Bushes
[B] Washer
[C] Oil Seal
[D] Retaining Ring
[E] Dust Seal

- Holding the top plug wrench [A] with a vise, loosen the base assembly [B] on the subtank [C].

Special Tool - Top Plug Wrench, 49 mm: 57001-1653

- Remove the base valve assembly [A] from the subtank [B].

NOTE

○ Slowly compress the piston rod until it stops so that the base valve assembly can be removed easily.

NOTICE

Disassembling the base valve assembly can lead to trouble.

Do not disassemble the base valve assembly.

A B SM48579 P

Close-up of hands holding a metallic cylindrical object with an arrow and letter A indicating upward motion (no text or symbols on the object itself)

C B A E D G048561 P

Labeled mechanical assembly diagram showing a hand operating a cylindrical component with parts A, B, and C marked.

A B

Front Fork

- Drain the fork oil [A] from the cylinder unit [B] by pumping the piston rod several times.

A B

Front Fork Assembly

- When the fork tubes are not disassembled, hold the fork inverted position for more than 20 minutes to allow the fork oil to fully drain.

Technical line drawing of a mechanical assembly or support structure (no text or symbols)

- Replace the following with new ones:

Dust Seal [A]

Retaining Ring [B]

Oil Seal [C]

Guide Bushes [D]

• Place an oil coated plastic bag [E] over the end of the inner tube to protect the oil seals.
  The inner tube guide bush groove has a sharp edge [F] that can out the sealing lip of the seals as they as are pushed down over the inner tube.
• Install in order these parts on the inner tube.
• When assembling the new outer tube guide bush [A], hold the washer against the new one, and tap the washer with the fork oil seal driver [B] until it stops.

Special Tool - Fork Oil Seal Driver, φ48: 57001-1509

- After installing the washer, install the oil seal by using the fork oil seal driver.

Special Tool - Fork Oil Seal Driver, φ48: 57001-1509

• Install the retaining ring to the outer tube.
• Push the dust seal into the outer tube, and put the spring band on the dust seal.

D D C B A E F GW040115S1 C

A B SM04042051 C

13-16 SUSPENSION

Front Fork

- Clean the threads [A] of subtank and base valve assembly.

- With the piston rod in fully compressed position, pour the specified amount of fork oil [A].

Recommended Oil: KHL15-10 (KAYABA01) or equivalent

Recommended Quantity: 189 ml (6.4 US oz.)

NOTE

○ Plug the two oil holes on the subtank [B] with fingers.

- Pump [A] the piston rod [B] slowly several times to expel air.

- Replace the O-rings [A] on the base valve assembly with new ones.

- Apply specified fork oil to the O-rings [A] [B] and bushings [C] on the base valve assembly.

Close-up of mechanical components with labeled parts A and a small circular component (no readable text or symbols)

A B

A B 0M48538 P

B A C 00048539 P

Front Fork

• With the piston rod held immorable in position [A], gently install the base valve assembly [B] to the subtank.
• Screw in the base valve assembly in the subtank when the piston rod extends.

NOTE

○ When it is hard to screw in the base valve assembly, pull down the piston rod a little.

fully compressed A 08048540 P

B 0048541 P

• Holdingthetopplugwrench[A]withavis
• Holding the subtank [B] with the top plug wrench, torque the base valve assembly [C].

Special Tool - Top Plug Wrench, 49 mm: 57001-1653

Torque - Base Valve Assembly: 28 N·m (2.9 kgf·m, 21 ft·lb)

A B C

• Protect the piston rod end [A] with a rag [B] to prevent fork damage.
• Discharge the extra oil off the cylinder unit by pumping [C] the piston rod to full stroke.

NOTICE

Be careful not to bend or damage the piston rod when the piston rod is stroked. Service carefully because oil flies out from the oil hole of the cylinder unit.

fork B C A (00485.4) F

NOTE

○ Set the compression damper setting to the softest.
○ Check the piston rod sliding surface for damage.
○Apply fork oil to the piston rod sliding surface.

13-18 SUSPENSION

Front Fork

- Drain the extra oil from the subtank oil hole [A].

- With the cylinder unit in horizontal position, move [A] the piston rod [B] by hand to inspect it if operating smoothly. - If the piston rod is not extend, remove the base valve assembly and perform the air bleeding (pour the specified amount fork oil and discharge an excess of oil).

- Completely wipe of the fork oil from the spring [A], spacer [B] and cylinder unit [C]. - Insert above-mentioned parts into the fork.

- Temporarily tighten the fork top plug [A] (subtank) using the top plug wrench. Special Tool - Top Plug Wrench, 49 mm: 57001-1653 [B]

- Clamp the axle holder with a vise. - Protect the axle holder with a rag when using a vise.

WARNING

Clamping the axle holder part too tight can damage it which will affect riding stability. Do not clamp the axle holder part too tight.

Close-up of a metallic mechanical component with labeled section A, no visible text or symbols beyond the label

A B 08548545 P

Technical diagram of three mechanical components labeled A, B, and C, showing internal spring-like structures (no text or symbols beyond labels)

A B 08048543 P

Front Fork

- Compress the outer tube by hands and install the top plug wrench [A] between the axle holder bottom and locknut. Special Tool - Top Plug Wrench, 49 mm: 57001-1653

WARNING

The fork spring applies pressure to the adjuster assembly and can eject the special tool with substantial force if the tool is not properly and securely placed. Be sure the tool is fully in place as shown in the photo, and keep fingers away to avoid getting them pinched between the tool, adjuster assembly and axle holder.

- Insert the push rod [A] into the piston rod.

Close-up of a mechanical component with labeled section A, no visible text or symbols beyond the label

Close-up of a mechanical clamp or tool with a labeled component (A) and no visible text or symbols on the main subject.

- Replace the O-ring and gasket on the adjuster assembly with new ones and apply specified fork oil to the O-ring. - Turn the locknut [A] counterclockwise until it contacts with the adjuster assembly [B]. - With the locknut held immovable using a wrench, tighten the adjuster assembly to the specified torque.

Torque - Locknut/Adjuster Assembly: 28 N·m (2.9 kgf·m, 21 ft·lb)

- With the outer tube compressed by hands, remove the top plug wrench.

- Apply a non-permanent locking agent to the threads of adjuster assembly.

- Torque the adjuster assembly [A]. Torque - Adjuster Assembly: 55 N·m (5.6 kgf·m, 41 ft·lb)

A B 08048532 P

Mechanical assembly with a metal rod and labeled component A (no readable text or symbols)

Front Fork

• Loosen and remove the fork top plug (subtank) form the outer tube and slowly slide down the outer tube.
  Special Tool - Top Plug Wrench, 49 mm: 57001-1653
• Pour [A] the specified amount of fork oil into the outer tube.

Recommended Oil: KHL15-10 (KAYABA01) or equivalent

Recommended Quantity: 335 mL (11.3 US oz)

- Raise the outer tube and temporarily tighten the fork top plug (subtank).

Special Tool - Top Plug Wrench, 49 mm: 57001-1653

● After installing the front fork, torque the top plug [A].

Special Tool - Top Plug Wrench, 49 mm: 57001-1653 [B]

Close-up of a mechanical component with a cylindrical shaft and a tube, labeled 'A' pointing to a white cylindrical part (no text or symbols on the main subject)

Close-up of a motorcycle's front wheel and grip mechanism, showing pressure gauge and lever (no text or symbols visible)

The torque of fork top plug is specified to 30 N·m (3.1 kgf·m, 22 ft·lb), however, w hen you use the top plug wrench (special tool) [A] reduce the torque to 90% of the specified value [27 N·m (2.8 kgf·m, 20 ft·lb)] due to the distance [B] between the center of the square hole, where the torque wrench is fitted, and that of the octagonal hole of the wrench.

This torque value [27 N·m (2.8 kgf·m, 20 ft·lb)] is applicable when you use a torque wrench whose length gives leverage of approximately 310 mm between the grip point to the center of the coupling square.

B A GM04254851 C

Adjuster Assembly Inspection

• Inspect the adjuster assembly [A] and push rod [B] for damage.
  ★If they are damaged, replace them with new ones.
• Replace the gasket [C] and O-ring [D] on the adjuster assembly with new ones.

C D A B G048556 P

Base Valve Assembly Inspection

• Inspect the threads portion [A], bushing [B] and spring [C] of base valve assembly [D] for damage.
  ★If they are damaged, replace base valve assembly with new one.
• Replace the O-rings [E] with new ones.

A C E D E B E E 0048557 P

Front Fork

Cylinder Unit Inspection

• Inspect the piston rod [B] of cylinder unit [A] for scratches or bending.
  ★If it has scratches or is bent, replace cylinder unit with a new one.

B A GB048558 P

Inner Tube Inspection

• Visually inspect the inner tube [A], repair any damage.
• Nick or rust damage can sometimes be repaired by using a wet-stone to remove sharp edges or raised areas which cause seal damage.
  ★If the damage is not repairable, replace the inner tube. Since damage to the inner tube damages the oil seal, replace the oil seal whenever the inner tube is repaired or replaced.

Technical line drawing of a mechanical assembly with a vertical shaft and base mount (no text or symbols)

- Temporarily assemble the inner [A] and outer tubes [B], and pump them back and forth manually to check for smooth operation.

NOTICE

If the inner tube is badly bent or creased, replace it. Excessive bending, followed by subsequent straightening, can weaken the inner tube.

B A GWO4168BS1 C

Guide Bush Inspection

- Visually inspect the guide bushes [A], and replace them if necessary.

A GW04011951 C

Dust Seal/Oil Seal Inspection

- Inspect the dust seal [A] for any signs of deterioration or damage.

★Replace it if necessary.

- Replace the oil seal [B] with a new one whenever it has been removed.

B A SW040120S1 C

Front Fork

Spring Tension

• Since a spring becomes shorter as it weakens, check its free length [A] to determine its condition.
  ★If the spring of either fork leg is shorter than the service limit, it must be replaced. If the length of a replacement spring and that of the remaining spring vary greatly, the remaining spring should also be replaced in order to keep the fork legs balanced from motorcycle stability.

Fork Spring Free Length

Standard: 460 mm (18.1 in.)

Service Limit: 451 mm (17.8 in.)

Technical line drawing of a coiled spring with dimension lines and a circular gauge labeled A (no text or symbols beyond basic geometry)

Rear Suspension (Uni-Trak)

Rear Shock Absorber:

The rear suspension system of this motorcycle is New Uni-trak. It consists of a rear shock absorber, swing arm, tie-rod and rocker arm.

To suit to various riding conditions, the spring preload of the shock absorber can be adjusted or the spring can be replaced with an optional one. Also the damping force can be adjusted easily so changing oil viscosity unnecessary.

Rebound Damping Adjustment

• Turn the rebound damping adjuster [A] on the rear shock absorber lower end with the blade of a screwdriver until you feel a click.
  ★If the damper setting feels too soft or too stiff, adjust it in accordance with the following table:

Close-up of a mechanical component with labeled parts (A) and no visible text or symbols beyond the label.

Seated position: adjuster turned fully clockwise [A].

Rebound Damping Adjuster Setting

Standard: 9 clicks [B] Softer (Counterclockwise) [C] Harder (Clockwise) [D]

*: Number of turns counterclockwise usable range - 22 or more. Counterclockwise from the fully seated position.

C B * 22 21 20 13 12 11 10 9 8 7 6 5 4 3 2 1 A GM05273BS1 C

NOTE

○Adjustment of the rebound damping adjuster for the rear suspension will slightly affect the compression damping force. Always make any damping adjustments in small steps and test their effects before using them in competition.

Compression Damping Adjustment

There are two adjustments you can make to the rear shock absorber gas reservoir.

High Speed Compression Damping Adjuster [A] Low Speed Compression Damping Adjuster [B]

A B 08058254 P

13-24 SUSPENSION

Rear Suspension (Uni-Trak)

- Adjust the high speed compression damping, turn the high speed compression damping adjuster with a 17 mm wrench.

★If the damping feels too soft or too stiff, adjust it in accordance with the following table.

High Speed Compression Damping

Standard: 1 1/4 turns out [B]

Softer (counterclockwise) [C]

Harder (clockwise) [D]

* : Number of turns counterclockwise usable range - 2 or more.

[A] Counterclockwise from the fully seated position.

- Adjust the low speed compression damping, turn the low speed compression damping adjuster with a flat-head screwdriver.

★If the damping feels too soft or too stiff, adjust it in accordance with the following table.

Low Speed Compression Damping

Standard: 11 clicks [B]

Softer (counterclockwise) [C]

Harder (clockwise) [D]

* : Number of turns counterclockwise usable range - 22 clicks or more.

[A] Counterclockwise from the fully seated position.

NOTE

○ Adjustment of the rebound damping adjuster for the rear suspension will slightly affect the compression damping force. Always make any damping adjustments in small steps and test their effects before using them in competition.

Spring Preload Adjustment

- Remove:

Seat (see Seat Removal in the Frame chapter) Side Covers (see Side Cover Removal in the Frame chapter)

Rear Frame (see Rear Frame Removal in the Frame chapter)

Carburetor Holder Clamp Screw (loosen) Muffler (see Muffler Removal in the Engine Top End chapter)

Rear Frame Mounting Bolts [A]

Rear Frame [B] with Air Cleaner Housing

- Using the jack under the frame, raise the rear wheel off the ground.

Special Tool - Jack: 57001-1238

graph TD
    A["Hexagon"] --> B["A"]
    A --> C["C"]
    A --> D["D"]
    A --> E["*"]
    E --> F["Circle with arrow"]
    style A fill:#f9f,stroke:#333
    style B fill:#ccf,stroke:#333
    style C fill:#cfc,stroke:#333
    style D fill:#fcc,stroke:#333
    style E fill:#ffc,stroke:#333
    style F fill:#cff,stroke:#333

C B * 22 21 20 13 12 11 10 9 8 7 6 5 4 3 2 1 A 0W05274051 C

A B

Rear Suspension (Uni-Trak)

- Using the hook wrenches [A], loosen the locknut [B] on the rear shock absorber.

Special Tool - Hook Wrench R37.5, R42: 57001-1101

A B

- Using the stem nut wrench [A], turn the adjusting nut [B] as required. Turning the adjusting nut downward marks the spring action harder and upward softer.

Special Tool - Steering Stem Nut Wrench: 57001-1101

Mechanical assembly diagram showing a hand adjusting components labeled A and B on a vehicle chassis

Spring Preload Adjustment

(Adjusting nut position at the lower surface [A] from the center of the mounting hole)

Standard: 123.5 mm (4.86 in.)

Adjustable Range 121.5 \~ 138.5 mm (4.783 \~ 5.453 in.)

Mechanical assembly diagram showing internal components and labeled parts (no readable text or symbols)

• Tighten the locknut securely.
• After adjusting, move the spring up and down to make sure that the spring is seated.
• Install the parts removed.
• Tighten the rear frame mounting bolts.

Torque - Rear Frame Mounting Bolts: 34 N·m (3.5 kgf·m 25 ft·lb)

Spring Tension

• Since the spring becomes shorter as it weakens, check its free length [A] to determine its condition.
  ★If the spring length is less than the service limit, replace the spring with a new one.

Shock Absorber Spring Free Length

Standard: 260 mm (10.2 in.)

Service Limit: 255 mm (10.0 in.)

Diagram of two coiled springs with a meter labeled A, no text or symbols present

13-26 SUSPENSION

Rear Suspension (Uni-Trak)

Rear Shock Absorber Removal

- Remove:

Seat (see Seat Removal in the Frame chapter)

Side Covers (see Side Cover Removal in the Frame chapter)

Muffler (see Muffler Removal in the Engine Top End chapter)

Rear Frame with Air Cleaner Housing

- Using the jack under the frame, raise the rear wheel off the ground.

Special Tool - Jack: 57001-1238

NOTICE

When pulling out the mounting bolts, lift the rear wheel slightly. Forcing or tapping on a bolt could damage the bolt, sleeve, and bearing

• Remove the tie-rod rear mounting bolt and nut, and turn it downward.
• Remove the rear shock absorber lower mounting bolt [A] and nut.
• Remove the rear shock absorber upper mounting bolt [B], nut, and pull out the rear shock absorber [C] down and out.

B C A 0058259 P

Rear Shock Absorber Installation

• Pack the rocker arm needle bearings with grease.
• Apply plenty of 2-stroke oil to the threads of the tie-rod front mounting bolts.
• Replace the rear shock absorber mounting nuts and tie -rod mounting nut with new ones.
• Tighten the following:

Torque - Rear Shock Absorber Mounting Nut (Upper): 39 N·m (4.0 kgf·m, 29 ft·lb)

Rear Shock Absorber Mounting Nut (Lower): 34 N·m (3.5 kgf·m, 25 ft·lb)

Rear Frame Mounting Bolts: 34 N·m (3.5 kgf·m, 25 ft·lb)

Tie-Rod Mounting Nut (Front): 59 N·m (6.0 kgf·m, 44 ft·lb)

• Install the removal parts.

Spring Replacement

In addition to the standard spring, heavy and light springs are available. If the standard spring is improper for your purpose, select a proper one according to the rider's weight or course conditions.

• Remove the rear shock absorber (see Rear Shock Absorber Removal).
• Clean the threaded portion on the upper of the rear shock absorber.
• Hold the lower of the rear shock absorber with a vise.

Rear Suspension (Uni-Trak)

- Using the hook wrenches [C], loosen the locknut [B] and turn the adjusting nut [A] all way up.

Special Tool - Hook Wrench R37.5, R42: 57001-1101

C B A GM051958SI C

• Remove the rear shock absorber from the vise.
• Slide down the rubber bumper [A].
• Remove the spring guides [B] from the shock absorber and lift off the spring [C].

Close-up of a mechanical spring assembly with labeled parts A, B, and C (no text or symbols beyond labels)

• Exchange the spring for an optional part. Install the spring so that closed coil large diameter end [A] faces upward.
  • Install the spring guide.
• Adjust the spring preload (see Spring Preload Adjustment).
• Install the rear shock absorber.
• Install the parts removed.

Technical line drawing of a coiled spring with dimension label (no text or symbols beyond basic geometry)

Rear Shock Absorber Disassembly (Oil Change)

- Refer to the Rear Shock Absorber Oil Change in the Periodic Maintenance chapter.

Rear Shock Absorber Assembly

- Refer to the Rear Shock Absorber Oil Change in the Periodic Maintenance chapter.

Rear Shock Absorber Scrapping

WARNING

When heated, pressurized gas may explode and cause serious injury or death. Since the rear shocks contains gas, do not incinerate them. Before discarding a rear shock, remove the air valve to prevent the possibility of explosion.

• Remove the shock absorber (see Rear Shock Absorber Removal).
• Remove the valve cap [A] and release the nitrogen gas completely from the gas reservoir.
• Remove the valve.

WARNING

Pressurized gas can cause injury. Do not point the valve toward your face or body.

Close-up of two cylindrical mechanical components with labeled section A, no visible text or symbols on the main body.

13-28 SUSPENSION

Swingarm

Swingarm Removal

• Place the jack [A] under the frame so that the rear wheel is off the ground.
  Special Tool - Jack: 57001-1238

- Remove

Rear Wheel (see Rear Wheel Removal in the Wheels/Tires chapter)

Clamps [B]

Brake Pedal [C] (see Brake Pedal Removal in the Brakes chapter)

Disc Protector [D]

- Remove:

Bolts [A] and Nuts [B]

Chain Guide Plate [C]

Chain Guide [D]

Technical diagram of a mechanical assembly with labeled parts A, B, C, and D

- Unscrew the rocker arm pivot nut [A] and pull out the rocker arm pivot bolt [B].

NOTICE

When pulling out the mounting bolts, lift the swingarm slightly. Forcing or tapping on a bolt could damage the bolt, sleeve, and bearing.

- Unscrew the nut [A].

- Pull out the swingarm pivot shaft [B], and remove the swingarm [C].

A B C D GB068262 P

Mechanical linkage diagram with labeled components A and B, showing mechanical joints and links

A B C GM068264 P

Swingarm

• Unscrew the screws [A]
• Separate the chain slipper [B] from the swingarm.

A B GB068265 P

Swingarm Installation

• Apply plenty of grease to the inside of the needle bearings, sleeves, and oil seals.
• Replace the swingarm pivot shaft nut with a new one.
• Tighten the following:

Torque - Swingarm Pivot Shaft Nut: 98 N·m (10 kgf·m, 72 ft·lb)

Rocker Arm Pivot Nut: 59 N·m (6.0 kgf·m, 44 ft·lb)

- Refer to the Wheels/Tires, Final Drive, and Brakes chapters for wheel installing.

Swingarm Bearing Removal

• Remove:
  Swingarm (see Swingarm Removal)
  Collars [A]
  Grease Seals [B]
  Sleeves [C]
  Needle Bearings [D]

- Remove the needle bearings [E] using the oil seal & bearing remover.

Special Tool - Oil Seal & Bearing Remover: 57001-1058

A B C D E F G H I J K L M N O P Q R S T U V W X Y Z A B C D E GM06082851 C

Swingarm Bearing Installation

• Replace the needle bearings and, grease seals with new ones.
• Apply plenty of grease to the sleeves, grease seals [C], and needle bearings [A] [B].

NOTE

○ Install the needle bearings so that the manufacturer's marks face out.
○ Install the grease seals so that the deep groove side of the rip in-ward.

1. 5mm B A C C 1 mm GW08034BS1 C

Special Tool - Bearing Driver Set: 57001-1129

• Install the needle bearings and grease seals position as shown.
  ○The installation procedure is the same as the counter side.

Swingarm

Swingarm Bearing, Sleeve Inspection

NOTICE

Do not remove the bearings for inspection. Removal may damage them.

• Inspect the needle bearings installed in the swingarm.
  The rollers in a bearing normally wear very little, and wear is difficult to measure. Instead of measuring, visually inspect the bearing for abrasion, discoloration, or other damage.
  ★If the needle bearing, and sleeve show any sings of abnormal wear, discoloration, or damage, replace them as a set.

Drive Chain Guide, Guide Roller, Chain Slipper Wear

- Visually inspect the drive chain guide [A] and replace it if excessively worn or damaged.

- Visually inspect the upper and lower chain guide rollers [A] and replace them if excessively worn or damaged.

- Visually inspect the chain slipper [A] on the swingarm [B] and replace it if worn or damaged.

Close-up of a mechanical component with labeled parts (A and arrow), no readable text or symbols present.

Close-up of mechanical components with no visible text or symbols

A B 8068260 P

Tie-Rod, Rocker Arm

Tie-Rod Removal

• Using the jack under the frame, raise the rear wheel off the ground.
  Special Tool - Jack: 57001-1238
• Unscrew the nut [A] and remove the guide roller [B].

NOTICE

When pulling out the mounting bolts, lift the rear wheel slightly. Forcing or tapping on a bolt could damage the bolt, sleeve, and bearing.

• Remove the tie-rod rear mounting bolt [A].
• Remove the tie-rod front mounting bolt [B], and then take out the tie-rod [C].

Mechanical chain assembly with labeled points A and B (no readable text or symbols beyond labels)

A B C

Tie-Rod Installation

• Apply plenty of grease to the inside of the oil seals.
• Apply plenty of 2-stroke oil to the threads of the tie-rod front and rear mounting bolts.
• Tighten the tie-rod front and rear mounting nuts.

Torque - Tie-Rod Mounting Nuts (Front, Rear): 59 N·m (6.0 kgf·m, 44 ft·lb)

Rocker Arm Removal

- Using the jack under the frame, raise the rear wheel off the ground.

Special Tool - Jack: 57001-1238

NOTICE

When pulling out the mounting bolts, lift the rear wheel slightly. Forcing or tapping on bolt could damage the bolt, sleeve, and bearing.

• Remove the rear shock absorber lower mounting bolt [A].
• Remove the tie-rod rear mounting bolt [B].
• Remove the rocker arm pivot bolt [C].
• Remove the rocker arm [D].

C B D A DW07B002 P

13-32 SUSPENSION

Tie-Rod, Rocker Arm

Rocker Arm Installation

• Apply plenty of grease to the inside of the rocker arm, needle bearings, oil seals and grease seals outside of the sleeve.
• Apply plenty of 2-stroke oil to the threads of the tie-rod rear mounting bolts.
• Tighten:

Torque - Rear Shock Absorber Mounting Nut (Lower): 34 N·m (3.5 kgf·m, 25 ft·lb)

Rocker Arm Pivot Nut: 59 N·m (6.0 kgf·m, 44 ft·lb)

Tie-Rod Mounting Nuts (Rear): 59 N·m (6.0 kgf·m, 44 ft·lb)

Tie-Rod and Rocker Arm Bearing Removal

- Remove:

Tie-Rod(see Tie-Rod Removal)

Rocker Arm (see Rocker Arm Removal)

Collars [A]

Sleeves [B]

Oil Seals [C]

Grease Seals [D]

• Remove the needle bearings [E], using the bearing remover head and bearing remover shaft.
• Remove the needle bearing [F], using the oil seal & bearing remover.

Special Tools - Bearing Remover Head: 57001-1267

Bearing Remover Shaft: 57001-1265

Oil Seal & Bearing Remover: 57001-1058

A B C F D E F G H I J K L M N O P Q R S T U V W X Y Z A B C D E F G H I J K L M N O P Q R S T U V W X Y Z

Tie-Rod, Rocker Arm

Tie-Rod and Rocker Arm Bearing Installation

• Replace the needle bearing, grease seals and oil seals with new ones.
• Apply plenty of grease to the oil seal and needle bearings [A].

NOTE

○ Install the grease seals so that the deep groove side of the rip out-ward.

• Install the needle bearings [A], [B] and grease seals [C] position as shown.
  ○Install the needle bearings and grease seals position as shown.
  ○The installation procedure is the same as the counter side.

1 mm (0.04 in.) [D] Rear Shock Absorber [G]

4.5 mm (0.18 in.) [E] Tie-rod [H]

4.25 mm (0.167 in.) [F] Rocker Arm [l]

A B G I D E H C E A F GM07035BW2 C

Needle Bearing Inspection

★If there is any doubt as to the condition of either needle bearing, replace the bearing and sleeve as a set.

13-34 SUSPENSION

Uni-Trak Maintenance

Uni-Trak Linkage Inspection

- Refer to the Swingarm and Uni-Trak Linkage Inspection in the Periodic Maintenance chapter.

Tie-Rod and Rocker Arm Sleeve Wear

• Pull out the sleeves [A] of the tie-rod and rocker arm.
  ● Measure the outside diameter of the sleeve.
  ★If the sleeve is worn past the service limit, replace the sleeve.

Sleeve Outside Diameter

Standard:

Tie-rod 19.987 \~ 20.000 mm (0.7888 \~ 0.78740 in.)

Rocker Arm:

[Large] 19.987 \~ 20.000 mm (0.78688 \~ 0.78740 in.)

[Small] 15.995 \~ 16.000 mm (0.62972 \~ 0.62992 in.)

Service Limit:

Tie-rod 19.85 mm (0.781 in.)

Rocker Arm:

[Large] 19.85 mm (0.781 in.)

[Small] 15.85 mm (0.624 in.)

A A 0N07036851 C

A GW07037851 C

Tie-Rod and Rocker Arm Mounting Bolt Bend

A bent bolt causes vibration, poor handling, and instability.

- To measure the bolt runout, remove the bolt, place it in V blocks, and set a dial gauge to the bolt at a point halfway between the blocks. Turn [A] the bolt to measure the runout. The amount of dial variation is the amount of runout.

★If runout exceeds the service limit, replace the bolt.

Bolt Runout

Standard: Under 0.1 mm (0.004 in.)

Service Limit: 0.2 mm (0.008 in.)

A 0M07038851 C

Steering

Table of Contents

Exploded View 14-2

Special Tools 14-4

Steering 14-5

Steering Inspection 14-5

Steering Adjustment.... 14-5

Steering Stem, Stem Bearing Removal 14-5

Steering Stem, Stem Bearing Installation 14-7

Stem Bearing Lubrication.... 14-8

Stem Bearing Wear, Damage 14-8

Stem Warp 14-8

Handlebar 14-9

Handlebar Removal 14-9

Handlebar Installation 14-9

Technical diagram of a mechanical assembly with numbered parts and labeled connectors

Exploded View

No.	Fastener	Torque			Remarks
		N·m kgf	m ft·lb
1	Handlebar Clamp Bolts	25	2.5	18	2T
2	Steering Stem Head Nut	98	10	72
3	Steering Stem Nut	4.9	0.50	43 in·lb	T
4	Front Fork Clamp Bolts (Upper)	20	2.0	15	AL
5	Front Fork Clamp Bolts (Lower)	20	2.0	15	AL

1. Handlebar Clamp
2. Handlebar
3. Handlebar Holder
4. Steering Stem Head Bracket
5. Upper Tapered Roller Bearing
6. Head Pipe
7. Lower Tapered Roller Bearing
8. Steering Stem
   AD: Apply adhesive cement.

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

G: Apply grease.

R: Replacement Parts

2T: Apply 2-stroke oil.

T: First, tighten the stem locknut with 39 N·m (4.0 kgf·m, 29 ft·lb) of torque, then loosen it and retighten it with 4.9 N·m (0.50 kgf·m, 43 in·lb) of torque.

14-4 STEERING

Special Tools

Bearing Puller: 57001-135

Technical line drawing of a mechanical assembly with bolts and a base plate (no text or symbols)

Steering Stem Bearing Driver: 57001-137

Technical line drawing of a cylindrical mechanical component with a textured end (no text or symbols)

Steering Stem Bearing Driver Adapter, 34.5: 57001-1074

Isometric line drawing of a cylindrical mechanical component (no text or symbols)

Head Pipe Outer Race Press Shaft: 57001-1075

Technical line drawing of a mechanical component with threaded ends and a shaft (no text or symbols)

Head Pipe Outer Race Driver, 51.5: 57001-1076

Technical line drawing of a mechanical component with a flanged top and central hole (no text or symbols)

Head Pipe Outer Race Driver, 54.5: 57001-1077

Technical line drawing of a mechanical component with a flanged top and central hole (no text or symbols)

Steering Stem Nut Wrench: 57001-1100

Technical line drawing of a mechanical wrench (no text or symbols on the tool itself)

Head Pipe Outer Race Remover ID > 37 mm: 57001-1107

Technical line drawing of a mechanical clamp or bracket component (no text or symbols)

Jack: 57001-1238

Technical line drawing of a mechanical support structure (no text or symbols)

Bearing Puller: 57001-1575

Technical line drawing of a mechanical clamp or bracket component (no text or symbols)

Steering

Steering Inspection

- Refer to the Steering Inspection in the Periodic Maintenance chapter.

Steering Adjustment

- Refer to the Steering Adjustment in the Periodic Maintenance chapter.

Steering Stem, Stem Bearing Removal

- Remove:

Front Wheel (see Front Wheel Removal in the Wheels/Tires chapter) Front Fender Bolts [A] Front Fender [B]

B A ISO48100 P

- Remove:

Handlebar Pad [A]

Headlight [B] (see Headlight Removal/Installation in the Electrical system chapter)

Speedometer [C] (see Meter Unit Removal/Installation in the Electrical System chapter)

Breather Hose [D] (Pull out)

B C A HOTHA D

- Remove the bolt [A] to remove the brake hose [C] from the holder [B].

C B A GN04B102 P

- Remove:

Handlebar Clamp Bolts [A]

Handlebar Clamps [B]

Handlebar [C] (see Handlebar Removal)

- Remove the front fork upper clamp bolts [D]

- Remove the steering stem head nut [E] and washer.

- Remove the steering stem head [F].

Labeled mechanical assembly diagram with points A through F pointing to components

14-6 STEERING

Steering

- Remove: Front Fork Lower Clamp Bolts [A] Front Forks [B]

Technical diagram of a mechanical assembly with labeled parts A and B, likely from an engineering or manufacturing context.

- Pushing up on the stem base [A], and remove the steering stem nut [B], with the steering stem nut wrench [C], then remove the steering stem [D] and stem base.

Special Tool - Steering Stem Nut Wrench: 57001-1100

Labeled mechanical assembly diagram showing a hand operating a component with parts A, B, C, and D marked.

- Take off the upper stem bearing inner race (tapered roller bearing) [A].

A GN04002BS1 C

- Drive out the bearing outer races from the head pipe. ○Remove the outer races pressed into the head pipe, using the head pipe outer race remover [A], and hammer the head pipe outer race remover to drive it out.

Special Tool - Head Pipe Outer Race Remover ID > 37 mm: 57001-1107

A 0007010551 C

NOTE

○ If either steering stem bearing is damaged, it is recommended that both the upper and lower bearing (including outer races) should be replaced with new ones.

- Remove the lower stem bearing inner rase (tapered roller bearing) [A] with its grease seal from the stem using bearing puller.

Special Tools - Bearing Puller: 57001-1575

Bearing Puller: 57001-135

A GN04011851 C

Steering

Steering Stem, Stem Bearing Installation

• Replace the bearing outer race with new ones.
  ○Apply grease to the outer races, and drive them into the head pipe at the same time using the head pipe outer race press shaft [A] and the head pipe outer race drivers.

Special Tools - Head Pipe Outer Race Press Shaft: 57001-1075

Head Pipe Outer Race Driver, φ54.5: 57001 -1077 [B]

Head Pipe Outer Race Driver, 51.5: 57001-1076 [C]

• Replace the lower inner races with new ones.
  ○Apply grease to the lower tapered roller bearing [A], and drive it onto the stem using the steering stem bearing driver [B] and adapter [C].

Special Tools - Steering Stem Bearing Driver: 57001-137

Steering Stem Bearing Driver Adapter, 34.5:57001 - 1074

• Apply grease to the upper tapered roller bearing, and install it in the head pipe.
• Install the stem through the head pipe and upper bearing, install the stem cap and hand-tighten the stem nut while pushing up on the stem base.
• Install the stem head and washer, and tighten the stem head nut lightly.
• Settle the bearing in place as follows;
  ○ Tighten the stem nut to 39 N·m (4.0 kgf·m, 29 ft·lb) of torque. (To tighten the steering stem nut to the specified torque, hook the wrench [A] on the stem nut, and pull the wrench at the hole by 22.2 kg force [B] in the direction shown.)

Special Tool - Steering Stem Nut Wrench: 57001-1100

○Check that there is no play and the steering stem turns smoothly without rattles. If not, the steering stem bearings may be damaged.
○Again back out the stem nut a fraction of a turn until it turns lightly.
Turn the stem nut lightly clockwise until it just becomes hard to turn. Do not overtighten, or the steering will be too tight.

Torque - Steering Stem Nut: 4.9 N·m (0.50 kgf·m, 43 in·lb)

A C B GN05040251 C

B C A GN04012BSI C

A 90° B GN03G605S1 C

Steering

- Install the front fork (see Front Fork Installation in the Suspension chapter).

NOTE

○ Tighten the fork upper clamp bolts first, next the stem head nut, last the fork lower clamp bolt.

- Tighten:

Torque - Steering Stem Head Nut: 98 N·m (10 kgf·m, 72 ft·lb)

Front Fork Clamp Bolts (Upper): 20 N·m (2.0 kgf·m, 15 ft·lb)

Front Fork Clamp Bolts (Lower): 20 N·m (2.0 kgf·m, 15 ft·lb)

NOTE

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

- Install the parts removed (see the appropriate chapter).

WARNING

If the handlebar does not turn to the steering stop it may cause an accident resulting in injury or death. Be sure the cables, harnesses and hoses are routed properly and do not interfere with handlebar movement (see Cable, Wire, and Hose Routing section in the Appendix chapter).

- Check and Adjust: Steering Front Brake Clutch Cable Throttle Cable

Stem Bearing Lubrication

- Refer to the Stem Bearing Lubrication in the Periodic Maintenance chapter.

Stem Bearing Wear, Damage

- Using a high-flash point solvent, wash the upper and lower tapered rollers in the cages, and wipe the upper and lower outer races, which are press-fitted into the frame head pipe, clean off grease and dirt.

- Visually check the outer rase and the rollers.

★Replace the bearing assembly if it show damage.

Stem Warp

- Whenever the steering stem is removed, or if the steering cannot be adjusted for smooth action, check the steering stem for straightness.

★If the steering stem shaft is bent [A], replace the steering stem.

Technical line drawing of a mechanical component with labeled point A (no text or symbols beyond label)

Handlebar

Handlebar Removal

- Remove:

Clutch Holder [A]

Engine Stop Switch [B]

Clamps [C]

Left Handlebar Grip [D]

D A B C GRO08290 P

- Remove:

Throttle Grip Assy [A] (see Throttle Cable Replacement in the Fuel System chapter)

Master Cylinder [B] (see Front Master Cylinder Removal in the Brakes chapter)

Clamps [C]

Handlebar Pad [D]

A B C D 04068291 P

- Remove:

Handlebar Clamp Bolts [A]

Handlebar Clamps [B]

Handlebar [C]

A B C G068292 P

Handlebar Installation

- Apply adhesive cement to the inside of the left handlebar grip.

- Install the left handlebar grip so that the projection [A] on the grip face to the upward.

Close-up of a mechanical component with labeled point A and alphanumeric code (00068293 P) on the handle (no readable text or symbols beyond labels)

- Install the clutch lever [A] so that it incline 20^ ± 5^ [B] more than the horizontal line [C] and position it from the edge of the grip to 170 ~mm (6.69 in.) [D].

A D C B GR110048SI C

14-10 STEERING

Handlebar

• Apply grease to the throttle cable upper end and clutch cable upper end.
• Apply a 2-stroke oil to the throttle grip inner wall [A].

A 120mm GN00034051 C

• Install the throttle grip assy so that the grip [A] is in as far as it will go.
• Position the throttle grip assy so that the parting line [B] of the throttle case vertically, and tighten the screws.
• Install the front master cylinder (see Front Master Cylinder Installation in the Brakes chapter).

A B GN08036851 C

• Install the handlebar [B] on the handlebar holder so that the protruded scales of the both side adjust to the same width [A].
• Apply 2-stroke oil to the thread of the handlebar clamp bolts.
• Install the handlebar clamp so that center [D] of the handlebar clamp [C] and handlebar bridge [E] align.

Torque - Handlebar Clamp Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb)

Front [F]

• After tighten, make sure space [A] [B] of the ahead and back are same width.
• Instal the clamps [C].

F A A B I D E C C GS15026BS1 C

B B C C A GN068294 P

Frame

Table of Contents

Exploded View.... 15-2

Frame 15-5

Frame Inspection 15-5

Rear Frame Removal 15-5

Rear Frame Installation.... 15-5

Engine Guard Installation.... 15-6

Seat 15-7

Seat Removal 15-7

Seat Installation 15-7

Side Cover 15-8

Right Side Cover Removal.... 15-8

Right Side Cover Installation.... 15-8

Left Side Cover Removal 15-8

Left Side Cover Installation 15-9

Fender 15-10

Front Fender Removal 15-10

Rear Fender Removal.... 15-10

Rear Flap Removal 15-10

Reflector Installation 15-10

Footpegs and Brackets.... 15-11

Footpeg Removal.... 15-11

Footpegs Installation.... 15-11

15-2 FRAME

Exploded View

Technical diagram of a mechanical assembly with labeled parts including gears, linkages, and actuators

Exploded View

No.	Fastener	Torque			Remarks
		N·m	kgf·m ft	lb
1	Rear Frame Mounting Bolt	34	3.5	25
2	Upper Footpeg Bracket Bolts	54	5.5	40	L
3	Sidestand Nut 29 3.0 21 R

G: Apply grease.
L: Apply a non-permanent locking agent.
R: Replacement Parts

Technical diagram of a mechanical assembly with labeled parts and exploded views, including blades, parts, and internal components.

1. CA Model
   R: Replacement Parts

Frame

Frame Inspection

- Refer to the Frame Inspection in the Periodic Maintenance chapter.

Rear Frame Removal

- Remove:

Seat (see Seat Removal) Right and Left Side Cover (see Side Cover Removal) Battery Cables [A] and Holder [B] (see Battery Removal in the Electrical System chapter) Starter Motor Cable [C] Starter Relay Connector [D] Starter Relay [E] Main Relay [F] Tail Light Lead Connector [G] Igniter [H] Reserve Tank (see Reserve Tank Removal in the Cooling System chapter) Muffler (see Muffler Removal in the Engine Top End chapter) Rear Fender (see Rear Fender Removal)

Labeled mechanical component diagram with numbered parts A through G

H G009B038 P

• Loosen the air cleaner duct clamp screw (see Air Cleaner Housing Removal in the Fuel System chapter).
• Unscrew the rear frame mounting bolts [A].
• Remove the rear frame [B] with air cleaner housing [C].

A B C

A B A G0056036 P

- Remove:

Bolts [A] Air Cleaner Housing [B]

Rear Frame Installation

• Install the air cleaner housing.
- Tighten:
Torque - Rear Frame Mounting Bolts: 34 N·m (3.5 kgf·m, 25 ft·lb)
• Install the removal parts.

15-6 FRAME

Frame

Engine Guard Installation

• Install the engine guard as shown.

Engine Guards [A]

Collar [B]

Bolts [C]

Engine Guard [D]

Bolts [E]

Technical diagram of a mechanical assembly with labeled components A, B, C, D, and E

Seat

Seat Removal

• Remove the bolts [A].
• Pull the seat [B] out from the back.

Close-up of a white car's side panel with labeled points A and B (no text or symbols beyond labels)

Seat Installation

• Stick the pad on the inside of the seat.
• Fit the hooks [A] of the seat under the flange collar [B] and brackets [C].

A B C 000AB15

○Install the brackets [A] of the seat to inside [B] of side cover.

- Tighten the seat mounting bolts.

Close-up of a car's front compartment showing internal components and a tool, labeled A and B (no readable text or symbols)

15-8 FRAME

Side Cover

Right Side Cover Removal

- Remove: Bolts [A] Side Cover [B]

A B

Right Side Cover Installation

• Stick the pad [A] on the inside of the right side cover [B].
• Insert the inside rib [C] between rear fender and rear frame.

A B C G008007BS1 C

- Insert the tab [A] of the right side cover into the air cleaner housing [B], and install the bolts.

A B 0008141 P

Left Side Cover Removal

- Remove: Air Cleaner Cover [A] Quick Fastener [B]

B A G0068142 P

- Remove: Bolts [A] Washer [B] Left Side Cover [C]

C B A 90068143 P

Side Cover

Left Side Cover Installation

- Install:

Left Side Cover

Washer

Bolts

Air Cleaner Cover [A]

Quick Fastener

Close-up of a hand holding a black plastic component with a tool, partially open to reveal internal components (no visible text or symbols)

Fender

Front Fender Removal

- Unscrew the bolts [A] and remove the front fender [B].

A B

Rear Fender Removal

- Remove:

Seat (see Seat Removal)

Reserve Tank (see Reserve Tank Removal in the Cooling System chapter)

Regulator/Rectifier (see Regulator/Rectifier Inspection in the Electrical System chapter)

- Unscrew the bolts [A] and remove the rear fender [B].

A B 9008304 F

Rear Flap Removal

● Unscrew the screws [A] and remove the rear flap [B].

A B 0008305 P

Reflector Installation

- Install the reflector so that the projection [A] fits to the groove [B] of the bracket.

A B 0008020B51 C

Footpegs and Brackets

Footpeg Removal

- Remove:

Cotter Pin [A]

Washer [B]

Pin [C]

Spring [D]

Footpeg [E]

Upper Bolt [F]

Lower Bolt [G]

Footpeg Bracket [H]

Footpegs Installation

• Apply a non-permanent locking agent to the bracket lower bolts.
• Tighten the upper bracket bolt [A].

Torque - Upper Footpeg Bracket Bolts: 54 N·m (5.5 kgf·m, 40 ft·lb)

C F E D H B A G 0014010851 C

A O- 9014011851 C

- Install:

Footpeg [A]

Cotter Pin [B]

- Bend the longer side [C] of the cotter pin as shown.

A B C 9014012851 C

Electrical System

Table of Contents

Exploded View.... 16-2

Specifications 16-8

Special Tools and Sealant.... 16-9

Wiring Diagram (Other than Australia

Models).... 16-11

Precautions.... 16-12

Electrical Wiring.... 16-13

Wiring Inspection 16-13

Battery 16-14

Battery Removal 16-14

Battery Installation 16-14

Precautions.... 16-14

Interchange.... 16-15

Charging Condition Inspection..... 16-15

Refreshing Charge.... 16-16

Flywheel Magneto 16-17

Magneto Cover Removal...... 16-17

Magneto Cover Installation 16-18

Flywheel Removal.... 16-18

Flywheel Installation.... 16-19

Stator Removal 16-20

Stator Installation.... 16-20

Flywheel Inspection 16-20

Charging Voltage Inspection...... 16-22

Regulator/Rectifier Inspection..... 16-22

Starter Motor Clutch 16-24

Starter Motor Clutch Removal/Installation.... 16-24

Starter Motor Clutch Inspection ... 16-24

Starter Motor Clutch Disassembly 16-24

Starter Motor Clutch Assembly.... 16-24

Ignition Timing 16-25

Ignition Timing Inspection 16-25

Ignition System.... 16-26

Crankshaft Sensor Removal..... 16-26

Crankshaft Sensor Installation..... 16-26

Safety Instructions 16-26

Ignition Coil Removal.... 16-26

Ignition Coil Inspection...... 16-27

Spark Plug Cleaning and Inspection.... 16-27

Spark Plug Gap Inspection 16-28

Igniter Removal.... 16-28

Igniter Inspection.... 16-28

Throttle Position Sensor Resistance Inspection...... 16-33

Throttle Position Sensor Position

Adjustment 16-34

Crankshaft Sensor Inspection..... 16-34

Electrical Starter System 16-36

Starter Motor Removal...... 16-36

Starter Motor Installation...... 16-36

Starter Motor Disassembly...... 16-36

Starter Motor Assembly 16-37

Carbon Brush Inspection 16-37

Commutator Inspection, Cleaning 16-38

Armature Inspection.... 16-38

Brush Lead Inspection 16-38

Terminal Bolt Inspection...... 16-39

Starter Relay Inspection...... 16-39

Lighting System.... 16-41

Headlight Aiming Inspection ..... 16-41

Headlight Beam Vertical Adjustment 16-41

Headlight Bulb Replacement ..... 16-41

Headlight Removal/Installation .... 16-42

Tail Light Removal.... 16-43

Tail Light Installation.... 16-43

Meter Gauge.... 16-45

Meter Unit Removal/Installation... 16-45

Meter Unit Disassembly/Assembly.... 16-45

Switch Inspection.... 16-45

LCD Segment Inspection...... 16-47

Switches and Sensors.... 16-49

Speed Sensor Removal.... 16-49

Speed Sensor Installation...... 16-49

Speed Sensor Inspection...... 16-49

Throttle Position Sensor Removal/Installation.... 16-50

Switch Inspection.... 16-50

Gear Position Switch Removal .... 16-50

Gear Position Switch Installation . 16-51

Gear Position Switch Inspection.. 16-52

Main Relay.... 16-53

Main Relay Inspection.... 16-53

Fuses.... 16-54

Main Fuse 20 A Removal...... 16-54

Main Fuse 20 A Inspection ..... 16-54

Exploded View

Technical diagram of automotive suspension system components with numbered parts for identification

Exploded View

No.	Fastener	Torque			Remarks
		N·m kgf	m ft·lb
1	Spark Plug	13	1.3	115 in·lb

1. Ignition Coil
2. Spark Plug Cap
3. Starter Button
4. Engine Stop Switch
5. Starter Lockout Switch
6. Battery
7. Main Relay
8. Igniter
9. Main Harness
10. Regulator/Rectifier

Exploded View

Exploded view diagram of a mechanical assembly with numbered components and labeled parts (R, G, L, SS)

Exploded View

No.	Fastener	Torque			Remarks
		N·m kgf	m ft·lb
1	Starter Motor Terminal Nut	5.9	0.60	52 in·lb
2	Starter Motor Mounting Bolts	9.8	1.0	87 in·lb
3	Crankshaft Sensor Bolts	7.0	0.71	62 in·lb
4	Stator Bolts	4.0	0.41	35 in·lb	L
5	Flywheel Nut	98	10	72
6	Magneto Cover Bolts	9.8	1.0	87 in·lb
7	Timing Inspection Cap	-	-	-	Hand-Tighten
8	Flywheel Nut Cap	-	-	-	Hand-Tighten
9	Torque Limiter Cover Bolts	9.8	1.0	87 in·lb
10	Starter Motor Terminal Locknut	6.9	0.70	61 in·lb
11	Starter Motor Through Bolts	3.4	0.35	30 in·lb
12	Breather Fitting	15	1.5	11	L

1. Starter Relay
2. Starter Motor
3. Magneto
4. Stator
5. Magneto Cover
   G: Apply grease.
   L: Apply a non-permanent locking agent.
   M: Apply molybdenum dislfide grease.
   R: Replacement Parts
   SS: Apply silicone sealant.

Exploded View

Technical diagram of automotive engine components with numbered parts for identification

Exploded View

No.	Fastener	Torque			Remarks
		N·m kgf	m ft·lb
1	Head Light Bracket Screws	1.4	0.14	12 in·lb
2	Gear Position Switch Screws	2.9	0.30	26 in·lb	L

1. Meter Unit
2. Headlight
3. Speed Sensor
4. Tail Light
5. Gear Position Switch
6. Australia Models
   HG: Apply high-temprerature grease.
   L: Apply a non-permanent locking agent.

Specifications

Item Standard Service Limit
BatteryType Sealed Battery (wet) -- -Model YTZ7S (F) -- -Capacity 12 V 6 Ah -- -
MagnetoCrankshaft Sensor Resistance Magneto Output Voltage Stator Coil Resistance	190 ~ 290 Ω (at 20°C (68°F)) in the text in the text	-- -- -- -- --
Ignition SystemIgnition Timing Ignition Coil:3 Needle Arcing Distance Primary Winding Resistance Secondary Winding Resistance Spark Plug:Type Gap IC Igniter	10.2° BTDC @1 000 r/min (rpm)7 mm (0.26 in.) or more0.28 ~ 0.38 Ω (at 20°C (68°F))7.65 ~ 10.35 kΩ (at 20°C (68°F))NGK CPR8EB-90.8 ~ 0.9 mm (0.03 ~ 0.04 in.)in the text	-- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- --
Electric Starter SystemStarter Motor:Brush Length Commutator Diameter	10 mm (0.39 in.)28 mm (1.10 in.)	6.5 mm (0.26 in.)27 mm (1.06 in.)
Throttle position sensorInput Voltage Output Voltage:when engine is idle speed	around 5 V0.58 ~ 0.78 V	-- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- --

Special Tools and Sealant

Inside Circlip Pliers: 57001-143

Line drawing of a pair of pliers (no text or symbols on the image itself)

Rotor Puller, M16/M18/M20/M22 × 1.5: 57001-1216

Technical illustration of a mechanical assembly with threaded components and a cylindrical component (no text or symbols)

Timing Light: 57001-1241

Technical line drawing of a handheld electronic device with coiled cable and connector (no text or symbols)

Spark Plug Wrench, Hex 16: 57001-1262

Technical line drawing of a T-shaped tool with a cylindrical end and two protruding pins (no text or symbols)

Flywheel Holder: 57001-1313

Technical line drawing of a mechanical clamp or tool with a circular base and threaded handle (no text or symbols)

Hand Tester: 57001-1394

Technical line drawing of a mechanical housing or enclosure with internal components and mounting holes (no text or symbols)

Throttle position sensor Setting Adapter #1: 57001-1400

Technical line drawing of a mechanical connector with two connectors and wires (no text or symbols)

Peak Voltage Adapter: 57001-1415

Pure electrical circuit lines without any symbols

Filler Cap Driver: 57001-1454

Technical line drawing of a mechanical tool with two separate views (no text or symbols)

Needle Adapter Set: 57001-1457

Two types of screwdrivers shown in line drawings (no text or symbols)

16-10 ELECTRICAL SYSTEM

Special Tools and Sealant

Flywheel Puller, M28 × 1.0: 57001-1471

Technical line drawing of a mechanical component with a hexagonal nut and cylindrical body (no text or symbols)

Liquid Gasket, TB1211F: 92104-0004

Line drawing of a cylindrical tool with a pointed tip and multiple tubes, no text or symbols present

Wiring Diagram (Other than Australia Models)

Speed Sensor Bk R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R S High LOW 12V35/35W Head Light 12V35/35W Meter Unit R/BK BK/Y BK/Y BK/Y R/BK BK/Y BL-BK/Y Bl-BK/Y Bl-BK/Y Bl-BK/Y Bl-BK/Y Bl-BK/Y Bl-BK/Y Bl-BK/Y Bl-BK/Y Bl-BK/Y Bl-BK/Y Bl-BK/Y Bl-BK/Y Bl-BK/Y Bl-BK/Y Bl-BK/Y Bl-BK/Y Bl-BK/Y Bl-BK/Y Bl-BK/Y Bl-BK/Y BL-BK/Y BL-BK/Y BL-BK/Y BL-BK/Y BL-BK/Y BL-BK/Y BL-BK/Y BL-BK/Y BL-BK/Y BL-BK/Y BL-BK/Y BL-BK/Y BL-BK/Y BL-BK/Y BL-BK/Y BL-BK/Y BL-BK/Y BL-BK/Y BL-BK/Y BL-BK/Y Bl-BK/Y BL-BK/Y BL-BK/Y BL-BK/Y BL-BK/Y BL-BK/Y BL-BK/Y BL-BK/Y BL-BK/Y BL-BK/Y BL-BK/Y BL-BK/Y BL-BK/Y BL-BK/Y BL-BK/Y BL-BK/Y BL-BK/Y BL-BK/Y BL-BK/Y Bl-Bk/Bk/Bk/Bk/Bk/Bk/Bk/Bk/Bk/Bk/Bk/Bk/Bk/Bk/Bk/Bk/Bk/Bk/Bk/Bk/Bk/Bk/Bk/Bk/Bk/Bk/Bk/Bk/Bk/Bk/Bk/Bk/Bk/Bk/Bk/Bk/Bk/Bk/Bk/Bk/Bk/Bk/Bk/Bk/Bk/Bk/Bk/Bk/Bk/Bk/Bk/ Ignition Coil Spark Plug Gear Position Switch Crank-shaft Sensor Flywheel Magneto Throttle Position Sensor Regulator/Rectifire R/BR/BR/BR/BR/BR/BR/BR/BR/BR/BR/BR/BR/BR/BR/BR/BR/BR/BR/BR/BR/BR/BR/BR/BR/BR/BR/BR/BR/BR/BR/BR/BR/BR/BR/BR/BR/BR/BR/BR/BR/BR/BR/BR/BR/BR/BR/BR/BR/BR/BR/Br/BR/Br/Br/Br/Br/Br/Br/Br/Br/Br/Br/Br/Br/Br/Br/Br/Br/Br/Br/Br/Br/Br/Br/Br/Br/Br/Br/Br/Br/Br/Br/Br/Br/Br/Br/Br/Br/Br/Br/Br/Br/Br/Br/Br/Br/Br/Br/Br/Br/Br/Br/BR/Crank/Selfer Control Motor Battery 12V6Ah Bnnter Relay 12V6Ah Bnnter Relay 12V6Ah Bnnter Relay 12V6Ah Bnnter Relay 12V6Ah Bnnter Relay 12V6Ah Bnnter Relay 12V6Ah Bnnter Relay 12V6Ah Bnnter Relay 12V6Ah Bnnter Relay 12V6Ah Bnnter Relay Bnnter Relay Bnnter Relay Bnnter Relay Bnnter Relay Bnnter Relay Bnnter Relay Bnnter Relay Bnnter Relay Bnnter Relay Bnnter Relay Bnnter Relay Bnnter Relay Bnnter Relay Bnnter Relay Bnnter Relay Bnnter Relay Bnnter Relay Bnnter Relay Bnnter Relay Bnnter Delay 12V6Ah Bnnter Delay 12V6Ah Bnnter Delay 12V6Ah Bnnter Delay 12V6Ah Bnnter Delay 12V6Ah Bnnter Delay 12V6Ah Bnnter Delay 12V6Ah Bnnter Delay 12V6Ah Bnnter Delay 12V6Ah Bnnter Delay 12V6Ah BL-0 Black-Black-Blue-Blue-Blue-Blue-Blue-Blue-Blue-Blue-Blue-Blue-Blue-Blue-Blue-Blue-Blue-Blue-Blue-Blue-Blue-Blue-Blue-Blue-Blue-Blue-Blue-Blue-Blue-Blue-Blue-Blue-Blue-Blue-Blue-Blue-Blue-Blue-Blue-Blue-Blue-Blue-Blue-Blue-Blue-Blue-Blue-Blue-Blue-Blue-Blue-Blue-Black-Black-Black-Blue-Blue-Blue-Blue-Blue-Blue-Blue-Blue-Blue-Blue-Blue-Blue-Blue-Blue-Blue-Blue-Blue-Blue-Blue-Blue-Blue-Blue-Blue-Black-Black-Black-Black-Blue-Blue-Blue-Blue-Blue-Blue-Blue-Blue-Blue-Blue-Blue-Blue-Blue-Blue-Blue-Blue-Black-Black-Black-Black-Black-Blue-Blue-Blue-Blue-Blue-Blue-Blue-Blue-Blue-Blue-Blue-Blue-Black-Black-Black-Black-Black-Black-Black-Black-Black-Black-Black-Black - Black - Black - Black - Blue - Blue - BR - Brown - G - Green - GY - Gray - LB - Light Blue - LG - Light Green - O - Orange - P - Pink - PU - Purple - R - Red - W - White - Y - Yellow

16-12 ELECTRICAL SYSTEM

Precautions

There are numbers of important precautions that are musts when servicing electrical systems. Learn and observe all the rules below.

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.
○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. Poor wires and bad connections will affect electrical system operation.
○Measure coil and winding resistance when the part is cold (at room temperature).
Electrical Connectors

[A] Connectors

A A GP000101S1 C

[B] Connectors

B B GP00010251 C

Safety Instructions:

WARNING

The ignition system produces extremely high voltage. Do not touch the spark plug, ignition coil or high tension lead while the engine is running, or you could receive a severe electrical shock.

Electrical Wiring

Wiring Inspection

• Visually inspect the wiring for signs of burning, fraying, etc.
  ★If any wiring is poor, replace the damaged wiring.
• Pull each connector [A] apart and inspect it for corrosion, dirt, and damage.
  ★If the connector is corroded or dirty, clean it carefully. If it is damaged, replace it.
• Check the wiring for continuity.
  ○Use the wiring diagram to find the ends of the lead which is suspected of being a problem.
  ○Connect an ohmmeter between the ends of the leads.
  ○Set the meter to the x 1 Ω range, and lead the meter.
  ★If the meter does not read 0 Ω the lead is defective. Replace the lead or the wiring harness if necessary.

Pure electrical circuit lines without any symbols

• Remove the seat (see Seat Removal in the Frame chapter).
• Disconnect the negative (−) cable [A] and then positive (+) cable [B].

NOTICE

Be sure to disconnect the negative (−) cable first.

• Remove the battery holder bolts [C] and holder [D].
• Remove the battery.

A B C D GP06B148 P

Battery Installation

• Visually inspect the surface of the battery container.
  ★If any signs of cracking or electrolyte leakage from the sides of the battery.
• Put the battery into the battery case.
  • Install the battery holder and tighten the bolts.
• Connect the positive cable [A] to the (+) terminal first, and then the negative cable [B] to the (−) terminal.
• Apply a light coat of grease on the terminals to prevent corrosion.
• Cover the (+) terminal with the cap.

B A GP08B149 P

Precautions

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

2) Refreshing charge.

Give refresh charge for 5 to 10 hours with charge current shown in the specification (see Refreshing Change).

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

NOTICE

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

If by chance an excessive amount of gas is generated due to overcharging, the relief valve releases the gas to keep the battery normal.

3) When you do not use the motorcycle for months.
Give a refresh charge before you store the motorcycle and store it with the negative cable removed. However, check the battery's state of charge at every 6 months to be sure it meets the minimum 12.4 V specification and charge it to 100 % state of charge.

4) Battery life.

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

Battery

DANGER

Batteries produce an explosive gas mixture of hydrogen and oxygen that can cause serious injury and burns if ignited. Keep the battery away from sparks and open flames during charging. 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. The electrolyte contains sulfuric acid. Be careful not to have it touch your skin or eyes. If touched, wash it off with liberal amount of water and seek medial attention for more severe burns.

Interchange

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

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

Battery Date Inspection

• Remove the battery (see Battery Removal).
• Check the manufactured date stamp [A].

Day [B]

Month [C]

Year [D]

MFG Code [F]

NOTE

○ Do refresh charge with the battery that passes one month or more.

Charging Condition Inspection

○Battery charging condition can be checked by measuring battery terminal voltage with a digital voltmeter [A].

• Remove the seat (see Seat Removal in the Frame chapter).
• Disconnect the battery terminals.

NOTICE

Be sure to disconnect the negative (−) cable first.

- Measure the battery terminal voltage.

NOTE

○Measure with a digital voltmeter which can be read one decimal place voltage.

★If the reading is 12.4 V or more, refresh charge is not required, however, if the read is below the 12.4 V, refresh charge is required.

Terminal Voltage (V) [A]

Battery Charge Rate (%) [B]

Refresh charge is required [C]

Good [D]

0 1 0 9 0 6 X X B C D E A GP08106851 C

Diagram showing hands using a multimeter to test electrical components with labeled terminals and a switch

GP08010851 C

GP08071BSI C

Battery

Refreshing Charge

• Remove the battery (see Battery Removal).
• Do refresh charge by following method according to the battery terminal voltage.

WARNING

This battery is sealed type. Charge with current and time as stated below.

Terminal Voltage: 12 \~ less than 12.4 V

Standard Charge 0.6 A × 5 \~ 10 h (see following chart)

Quick Charge 3 A × 1 h

NOTICE

If possible, do not quick charge. If quick charge is done unavoidably, do standard charge later on.

Terminal Voltage: less than 12 V

Charging Method: 0.6 A × 20 h

NOTE

○ Increase the charging voltage to a maximum voltage of 25 V if the battery will not accept current initially. Charge for no more than 5 minutes at the increased voltage then check if the battery is drawing current. If the battery will accept current decrease the voltage and charge by the standard charging method described on the battery case. If the battery will not accept current after 5 minutes, replace the battery.

Battery [A]

Battery Charger [B]

Standard Value [C]

Current starts to flow [D].

• Determine the battery condition after refresh charge.
• Determine the condition of the battery left for 30 minutes after completion of the charge by measuring the terminal voltage according to the table below.

Criteria	Judgement
12.8 V or higher	Good
12.0 ~ lower than 12.8 V	Charge insufficient → Recharge
lower than 12.0 V	Unserviceable → Replace

graph TD
    A["Measurement System"] --> B["V-A"]
    B --> C["Capacitor A"]
    B --> D["Capacitor B"]
    D --> E["Ground"]
    F["Input Signal"] --> G["2.5 V, 16 A"]
    H["Ground"] --> I["Ground"]

Flywheel Magneto

Magneto Cover Removal

- Remove:

Left Radiator Shroud

Bolt [A]

Left Radiator Screen [B]

Left Radiator Mounting Bolts [C]

- Push the left radiator backward [D].

- Pry open the clamps [A].

Technical diagram of a mechanical assembly with labeled components A, B, C, and D

Close-up of a mechanical component with a labeled connection point A (no readable text or symbols beyond the label)

- Drain the engine oil from the crank room oil sump (see Engine Oil Change in the Periodic Maintenance chapter).

- Pull the stopper [A] to the this side to remove the magneto lead connector [B].

- Disconnect the magneto lead connector from the main harness.

A B GP21B053

- Remove:

Torque Limiter [A] (see Torque Limiter Removal/Installation in the Crankshaft/Transmission chapter)

Bolt [B]

Left Engine Guard [C]

Breather Hose [D]

Mechanical assembly diagram showing components labeled A, B, and C with no readable text or symbols

- Remove the shift pedal (see External Shift Mechanism Removal in the Engine Right Side chapter).

- Remove:

Magneto Cover Mounting Bolts [A].

Magneto Cover [B]

Mechanical assembly diagram showing a motor and gear assembly with labeled parts (A, B), no readable text or symbols beyond labels.

16-18 ELECTRICAL SYSTEM

Flywheel Magneto

Magneto Cover Installation

• Replace the gasket [A] with a new one.
• Be sure to install the dowel pins [B].

- Apply silicone sealant to the area [A] to the magneto lead grommet.

Sealant - Liquid Gasket, TB1211F: 92104-0004

A B GP218065 P

Close-up of mechanical components with labeled parts (A and P), no readable text or symbols beyond labels

• Tighten: Torque - Magneto Cover Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)
• Run the gear position switch lead [A] and magneto lead according the Cable, Wire, and Hose Routing section in the Appendix chapter. Clamps [B]
• Connect the lead connector.
  • Install the removed parts.

A B GP21B057

Flywheel Removal

• Remove the magneto cover (see Magneto Cover Removal).
• Hold the flywheel steady, with the flywheel holder [A], and remove the nut [B].

Special Tool - Flywheel Holder: 57001-1313

- Remove the flywheel holder.

Mechanical gear assembly with labeled components A and B (no readable text or symbols beyond labels)

Flywheel Magneto

• Screw the rotor pullers [A] onto the flywheel.
• Remove the flywheel from the crankshaft by turning in the puller and tapping the head of the bolt lightly with a hammer, while holding the puller body steady. There is a woodruff key in the crankshaft tapered portion.

Special Tools - Flywheel Rotor Puller: 57001-1471 Rotor Puller, M16/M18/M20/M22 × 1.5: 57001-1216

NOTICE

If the flywheel is difficult to remove, turn the puller shaft using a wrench while tapping the head of the puller shaft with a hammer. Do not attempt to strike the grab bar or the flywheel itself. Striking the bar or the flywheel can cause the bar to bend or the magnets to lose their magnetism.

Flywheel Installation

• Using a high-flash point solvent, clean off any oil or dirt that may be on the crankshaft taper [A] or in the hole [B] in the flywheel. Dry them with a clean cloth.
• Fit the woodruff key [C] securely in the slot in the crankshaft.
  • Install the flywheel following procedures.

NOTE

○ Confirm the flywheel fit or not to the crankshaft before tightening it with specified torque.

○Install the flywheel and tighten it with 54 N·m (5.5 kgf·m, 40 ft·lb) of torque.

○Remove the flywheel nut.

○Check the tightening torque with rotor puller.

★If the flywheel is not pulled out with 20 N·m (2 kgf·m, 15 ft·lb) of drawing torque, it is installed correctly.
★If the flywheel is pulled out with under 20 N·m (2 kgf·m, 15 ft·lb) of drawing torque, clean off any oil dirt or flaw of the crankshaft and flywheel tapered portion, and dry them with a clean cloth. Then, confirm that it is not pulled out with above torque.
- Holding the flywheel steady, with the flywheel holder, and tighten the flywheel nut.

Special Tool - Flywheel Holder: 57001-1313

Torque - Flywheel Nut: 98 N·m (10 kgf·m, 72 ft·lb)

- Install the magneto cover (see Magneto Cover Installation).

Mechanical assembly diagram showing gear and shaft components (no readable text or symbols)

Close-up of mechanical gears and shafts with labeled components (A, B, C), no readable text or symbols beyond labels

Flywheel Magneto

Stator Removal

- Remove:

Magneto Cover (see Magneto Cover Removal)

Stator Bolts [A]

Crankshaft Sensor Bolts [B]

Wiring Holder [C]

Wiring Grommet [D]

- Remove the stator [E] and crankshaft sensor [F] as a set.

D B C F E A GP21B061 P

Stator Installation

• Route the wires according to the Cable, Wire, and Hose Routing section in the Appendix chapter.
• Apply a non-permanet locking agent to the stator bolts.
  • Install the stator and tighten it.

Torque - Stator Bolts: 4.0 N·m (0.41 kgf·m, 35 in·lb)

• Install the crankshaft sensor and wiring holder [A].
  ○Run the magneto leads under the holder and sensor.

Torque - Crankshaft Sensor Bolts: 7.0 N·m (0.71 kgf·m, 62 in·lb)

- Apply silicone sealant around the circumference of the wiring grommet.

Sealant - Liquid Gasket, TB1211F: 92104-0004

• Set the stator wiring grommet [B] securely in the notch [C].
• Install the magneto cover (see Magneto Cover Installation).

Flywheel Inspection

• There are three types of magneto problems: short, open (wire burned out), or loss in flywheel. 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 flywheel, which may be caused by dropping or hitting the flywheel by leaving it near an electromagnetic field, or just by aging, will result in low output.
• Check the magneto output voltage, do the following procedures.
  ○Remove the left radiator shroud.
  ○Pull the stopper [A] to the this side and remove the magneto lead connector [B].

B A C GP218062 P

A B GP218063

Flywheel Magneto

○Connect the hand tester [A] to the connector [B] as shown in the table 1, using the needle adapter set [C].
○Start the engine.
○Run it at the rpm given in the table 1.
○Note the voltage readings (total 2 measurements).

Special Tools - Hand Tester: 57001-1394

Needle Adapter Set: 57001-1457

Table 1 Magneto Output Voltage

Tester Range	Connections		Reading @4 000 rpm
	Tester (+) to Tester (-) to
50 V AC	Yellow/Green lead	Ground	29 V or more
50 V AC	White lead	Red lead	25 V or more
50 V AC	Blue lead	Ground	26 V or more

★If the output voltage shows the value in the table, the magneto operates properly.
★If the outputvoltageshowsa much lowerreading than that given in the table indicates that the magneto is defective.
- To check the stator coil resistance as follows.
○Stop the engine.
○Connect the hand tester as shown in the table 2.
○Note the readings (total 2 measurement).

Table 2 Stator Coil Resistance

Tester Range	Connections		Reading
	Tester (+) to	Tester (−) to
× 1 Ω	Yellow lead	Ground	1.6 ~ 2.3 Ω
× 1 Ω	White lead Red	lead	20 ~ 50 Ω
× 1 Ω	Blue lead	Ground	1.3 ~ 2.0 Ω

★If there is more resistance than shown in the table, or no hand tester reading (infinity) the stator has an open lead and must be replaced. Much less than this resistance means the stator is shorted, and must be replaced.
- Using the highest resistance range of the hand tester, measure the resistance between each leads and chassis ground.
★Any hand tester reading less than infinity ( ) indicates a short, necessitating stator replacement.
★If the stator coils have normal resistance, but the voltage check showed the magneto to be defective; then the flywheel have probably weakened, and the flywheel must be replaced.

A B C E - Konsinkt GP218064

Flywheel Magneto

Charging Voltage Inspection

• Check the battery condition (see Charging Condition Inspection).
• Warm up the engine to obtain actual magneto operating conditions.
• Remove the seat (see Seat Removal in the Frame chapter).
• Connect the hand tester [A] as shown in the table.

Special Tool - Hand Tester: 57001-1394

A - +

Charging Voltage

Tester Range	Connections		Reading
	Tester (+) to Tester (-) to
25 V DC	Battery (+)Terminal	Battery (-)Terminal	Battery voltage to 14.4 ±0.5 V

• Start the engine, and note the voltage readings at various engine speeds. The readings should show nearly battery voltage when the engine speeds is low, and, as the engine speed rises, the readings should also rise. But they must be kept under the specified voltage.
• Stop the engine and disconnect the hand tester.
  ★If the charging voltage is kept between the values given in the table, the charging system is considered to be working normally.
  ★If the charging 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 charging voltage does not rise as the engine speed increases, the regulator/rectifier is defective or the magneto output is insufficient for the loads. Check the magneto and regulator/rectifier to determine which part is defective.

Regulator/Rectifier Inspection

• Remove the left side cover (see Side Cover Removal in the Frame chapter).
• Disconnect the connector [A].
• Remove:
  Nut [B] Regulator/Rectifier [C]

SH072-DA A B C GP21B067 P

Flywheel Magneto

- With the Kawasaki hand tester, measure the internal resistance in both directions between the terminals.

Special Tool - Hand Tester: 57001-1394

★If the reading is not the specified value, replace the regulator/rectifier.

Internal Resistance (20°C) Unit: kΩ

Use only Hand Tester 57001-1394 for this test. An ohmmeter other than the Hand Tester may show different readings. If a megger or a meter with a large-capacity battery is used, the regulator will be damaged.

E C B L GP09018851 C

Charging System Circuit (Other than Australia Models)

BK/Y BL Y/G BL Y Y/G R/BK BK/Y W/R ① ② ③ W/R ④ ⑤ R ⑥ + - BK

GP09210BW2 C

1. Frame Ground
2. Flywheel Magneto
3. Regulator/Rectifier
4. Starter Relay
5. Main Fuse 20A
6. Battery 12V 6Ah

16-24 ELECTRICAL SYSTEM

Starter Motor Clutch

Starter Motor Clutch Removal/Installation

- Refer to the Flywheel Removal/Installation.

Starter Motor Clutch Inspection

- Remove:

Torque Limiter (see Torque Limiter Removal/Installation in the Crankshaft/Transmission chapter) Magneto Cover (see Magneto Cover Removal)

- Turn the starter motor clutch gear [A] by hand. The starter motor clutch gear should turn clockwise [B] freely, but should not turn counterclockwise [C].

★If the starter motor clutch does not operate as it should or if it makes noise, go to the next step.

- Disassemble the starter motor clutch, and visually inspect the clutch parts.

★If there is any worn or damaged part, replace it.

Close-up of a mechanical gear assembly with labeled components A, B, and C (no readable text or symbols beyond labels)

NOTE

○Examine the starter motor clutch gear as well. Replace it if it worn or damaged.

Starter Motor Clutch Disassembly

- Remove:

Flywheel (see Flywheel Removal)

Snap Ring [A]

Circlip [B]

Starter Motor Clutch [C]

Special Tool - Inside Circlip Pliers: 57001-143

C B A SP078004 P

Starter Motor Clutch Assembly

- When installing the circlip, fit the projections [A] of the circlip into the slits [B] of the starter motor clutch.

Special Tool - Inside Circlip Pliers: 57001-143

B A GP078005

Ignition Timing

Ignition Timing Inspection

- Remove the timing inspection cap [A]. Special Tool - Filler Cap Driver: 57001-1454

Close-up mechanical component with labeled parts (A and -1), no readable text or symbols beyond labels

- Attach the timing light [A] to the ignition coil lead in the manner prescribed by the manufacturer. Special Tool - Timing Light: 57001-1241

- Start the engine and aim the timing light at the ignition timing mark [B] on the flywheel.

- Run the engine at the speedsspecified and note the alignment of the ignition timing marks.

A B GP22B013 F

○Check the engine speed, using the engine revolution tester [A] for high accuracy.

A GP22B012

Ignition Timing

Engine speed[r/min (rpm)]	Hole groove aligns with:
1 000	Line mark on flywheel

★If the ignition timing is incorrect, check the crankshaft sensor (see Crankshaft Sensor Inspection).
★If the crankshaft sensor are normal, check the igniter (see Igniter Inspection).
• Install the timing inspection cap.

16-26 ELECTRICAL SYSTEM

Ignition System

Crankshaft Sensor Removal

- Refer to the Stator Removal.

Crankshaft Sensor Installation

- Refer to the Stator Installation.

Safety Instructions

WARNING

The ignition system produces extremely high voltage. Do not touch the spark plug, ignition coil or high tension lead while the engine is running, or you could receive a severe electrical shock.

Ignition Coil Removal

- Remove:

Fuel Tank (see Fuel Tank Removal in the Fuel System chapter)

Bolt [A]

Left Radiator Screen [B]

Left Radiator Mounting Bolts [C]

- Push the left radiator backward [D].

- Pry open the clamps [A].

- Disconnect the ignition coil primary lead connector [A].

- Pull the plug cap off the spark plug.

- Unscrew the mounting bolts [B], and remove the ignition coil [C].

C B A D TSP18634

Close-up of a car radiator component with labeled connection point A (no text or symbols beyond label)

C A B GP108607 P

Ignition System

Ignition Coil Inspection

Measuring Arcing Distance

The most accurate test for determining the condition of the ignition coil is made by measuring arcing distance using the coil tester for the 3-needle method.

• Remove the ignition coil.
• Connect the ignition coil (with the spark plug cap left installed on the spark plug lead) [A] to the tester [B], and measure the arcing distance.

WARNING

To avoid extremely high voltage shocks, do not touch the coil body or lead.

★If the distance reading is less than the specified value, the ignition coil or spark plug cap is defective.

3 Needle Arcing Distance

Standard: 7 mm (0.26 in.) or more

• To determine which part is defective, measure the arcing distance again with the spark plug cap removed from the ignition coil lead.
  ★If the arcing distance is subnormal as before, the trouble is with the ignition coil itself. If the arcing distance is now normal, the trouble is with the spark plug cap.

Measuring Coil Resistance

If the arcing tester is not available, the coil can be checked for a broken or badly shorted winding with an ohmmeter. However, an ohmmeter cannot detect layer shorts and shorts resulting from insulation breakdown under high voltage.

• Remove the ignition coil (see Ignition Coil Removal).
• Measure the primary winding resistance [A].
  ○Connect an ohmmeter between the coil terminals.
  ○Set the meter to the x 1 Ω range, and read the meter.
  ● Measure the secondary winding resistance [B].
  ○Pull the spark plug cap off the lead.
  ○Connect an ohmmeter between the spark plug lead and the ground lead terminal.
  ○Set the meter to the x 1 kΩ range, and read the meter.

Ignition Coil Winding Resistance

Primary windings: 0.28 \~ 0.38 Ω (at 20°C (68°F)) Secondary windings: 7.65 \~ 10.35 kΩ (at 20°C (68°F))

★If the meter does not read as specified, replace the coil.
★If the meter reads as specified, the ignition coil windings are probably good. However, if the ignition system still does not perform as it should after all other components have been checked, test replace the coil with one known to be good.
- Check the spark plug lead for visible damage.
★If the spark plug lead is damaged, replace the coil.

Spark Plug Cleaning and Inspection

- Refer to the Spark Plug Cleaning and Inspection in the Periodic Maintenance chapter.

A B GP101998S1 C

GP102748SI C

Ignition System

Spark Plug Gap Inspection

- Refer to the Spark Plug Cleaning and Inspection in the Periodic Maintenance chapter.

Igniter Removal

• Remove the right side cover (see Side Cover Removal in the Frame chapter).
• Disconnect the main harness connector [A].
• Pull out the igniter [B].

B A GP108608 P

Igniter Inspection

NOTICE

When inspecting the IC Igniter observe the following to avoid damage to the IC Igniter.

Do not disconnect the IC Igniter while the engine is running.

This may damage the IC Igniter.

Ignition Coil Primary Peak Voltage Check

• Disconnect the spark plug cap from the spark plug, but do not remove the spark plug.
• Connect the good spark plug [A] to the spark plug cap, then touch the engine with it.

NOTE

○Measure the voltage with each lead connected correctly. The correct value may not be obtained if disconnected.
○Maintain the correct value of compression pressure for the cylinder (Be sure to measure the voltage with the spark plug install to the cylinder head).

- Connect the peak voltage adapter [B] between the terminal of primary lead (orange) and ground connection of the unit with the lead of the ignition coil [C] connected.

○Set the tester to DC 250 V range.

Special Tools - Hand Tester: 57001-1394

Peak Voltage Adapter: 57001-1415

Type: KEK-54-9-B

Needle Adapter Set: 57001-1457

Labeled photo of an automotive electrical testing setup with multimeter and wiring connections

F E C A G B D GP10425BS1 C

Connection: Adapter Positive → Ground Lead [D]

Adapter Negative → Orange Lead [E]

IC Igniter [F]

Needle Adapter [G]

Ignition System

• Shift the gear to the neutral position.
• Crank the engine by kicking the kick pedal and by pushing the starter button several times to measure the peak voltage of the primary ignition coil.

Ignition Coil Primary Peak Voltage

Standard: 128 V or above (Kick starter)

110 Vorabove (Electricstarter)

WARNING

Electrical equipment can cause serious electrical shock. To avoid being shocked, do not touch the metal portion of the probe when measuring voltage.

★If the voltage is less than the specified value, check the ignition coil (see Ignition Coil Inspection).
★If the ignition coil is good, check the other parts (see the flow chart in this section).
★If the all parts are good, replace the igniter.

Ignition System

graph TD
    A["Faulty ignition (Malfunctioned engine)"] --> B["Battery Inspection"]
    B -->|Good| C["Wiring and connect portion of the ignition system inspection"]
    B -->|No good| D["Charge or replace battery."]
    C -->|Good| E["Spark plug inspection"]
    C -->|No good| F["Repair"]
    E -->|Good| G["Spark plug cap inspection"]
    E -->|No good| H["Replace"]
    G -->|Good| I["Ignition coil primary peak voltage inspection"]
    G -->|No good| J["Replace"]
    I -->|Good| K["Voltage is specified but faulty ignition"]
    I -->|No good. Voltage is none or almost| L["Defective ignition"]
    K --> M["Replace"]
    L --> N["Inspect"]
    N --> O["1. Adapter connection is incorrect or adapter is directive."]
    N --> P["2. Engine stop switch"]
    N --> Q["3. Crankshaft sensor peak voltage"]
    N --> R["4. Exciter coil peak voltage"]
    N --> S["5. Throttle Sensor Inspection"]
    L --> T["Inspection"]
    T --> U["1. Speed of cranking engine is slow. (Increase force of kicking engine.)"]
    T --> V["2. Lower resistance in the tester. (Use KAWASAKI Hand Tester)"]
    T --> W["3. Lacking of sampling (Sampling few times)"]
    T --> X["4. Crankshaft sensor peak voltage"]
    T --> Y["5. Throttle Sensor Inspection"]
    U --> Z["IC Igniter is defective"]
    V --> Z
    W --> Z
    X --> Z
    Y --> Z
    Z -->|All good| AA["Replace the malfunctioned parts or inspect in proper way"]
    Z -->|All good| AB["Replace the malfunctioned no good parts"]
    AA --> AC["SP104018 F"]

Ignition System

Crankshaft Sensor Peak Voltage Check

• To check the peak voltage, do the following procedures.
  ○Disconnect the magneto lead connector from the main harness.

NOTE

○Measure the voltage with each lead connected correctly. The correct value may not be obtained if disconnected.
○ Maintain the correct value of compression pressure for the cylinder (Be sure to measure the voltage with the spark plug installed to the cylinder head).

○Set the hand tester to DC 2.5 V range.
○Connect the peak voltage adapter [A] to the tester and the terminals of the magneto lead connector [B].

Special Tools - Hand Tester: 57001-1394

Peak Voltage Adapter: 57001-1415

Type: KEK-54-9-B

Connection: Adapter Positive → Green/White Lead

[C]

Adapter Negative → White/Yellow

Lead [D]

○Crank the engine by kicking the kick pedal and by pushing the starter button several times with the transmission gear in neutral to measure the peak voltage of the crankshaft sensor.

Crankshaft Sensor Peak Voltage

Standard: 1.1 V or above (Kick starter)

2 V or above (Electric starter)

WARNING

Electrical equipment can cause serious electrical shock. To avoid being shocked, do not touch the metal portion of the probe when measuring voltage.

★If the voltage is less than the specified, check the crankshaft sensor (see Crankshaft Sensor Inspection).
★If the crankshaft sensor is good, check the other parts (see the flow chart in this section).
★If the all parts are good, replace the igniter.

D B C A DC2.5V GP10426BSI C

16-32 ELECTRICAL SYSTEM

Ignition System

Exciter Coil Peak Voltage Check

• Disconnect the magneto lead connector from the main harness.
• To check the peak voltage, do the following procedures.

NOTE

○Measure the voltage with each lead connected correctly. The correct value may not be obtained if disconnected.
○Maintain the correct value of compression pressure for the cylinder (Be sure to measure the voltage with the spark plug installed to the cylinder head.)

○Set the hand tester to DC 50 V range.

○Connect the peak voltage adapter [A] to the tester and the terminals of the magneto lead connector [B].

Special Tools - Hand Tester: 5701-1394

Peak Voltage Adapter: 57001-1415

Type: KEK-54-9-B

Connection: Adapter Positive → White Lead [C]

Adapter Negative → Red Lead [D]

○Crank the engine by kicking the kick pedal and by pushing the starter button several time with the transmission gear in neutral to measure the peak voltage of the exciter coil.

Exciter Coil Peak Voltage

Standard: 36 V or Above (Kick starter)

33 V or above (Electric starter)

★If the voltage is less than the specified, check the exciter coil (see Flywheel Inspection).
★If the exciter coil is good, replace the igniter.

Throttle position sensor Inspection

• Remove the fuel tank transiently (see Fuel Tank in the Fuel System chapter).
• Disconnect the throttle position sensor lead connector [A].

D B C A DC50V QP10427BS1 C

Close-up of a mechanical component with labeled parts (A) and no visible text or symbols beyond the label.

Ignition System

- Connect the throttle position sensor setting adapter [A] between throttle position sensor lead connector [B] and main harness connector [C].

Special Tools - Hand Tester: 57001-1394

Throttle Position Sensor Setting Adapter

1: 57001-1400

- Set the hand tester [D] to the DC 10 V range, and connect it to the adapter leads.

Hand Tester (+) → Blue Lead

Hand Tester (−) → Black/Blue Lead

• Temporary install the fuel tank.
• Start the engine.
• Check the sensor input voltage with the engine running.

Throttle Position Sensor Input Voltage

Standard: around 5 V

★If it is not within the specified voltage, replace the igniter.
★If it is within the specified voltage, go to the next step.
- To check the output voltage, do the following procedures.
○Connect the digital voltmeter [A] as follows.

Tester (+) → Yellow/White Lead

Tester (−) → Black/Blue Lead

○Start the engine.

○Measure the throttle position sensor output voltage with the engine idling speed.

Throttle Position Sensor Output Voltage

Standard: 0.58 \~ 0.78 V (when engine is idle speed)

★If it is not within the specified voltage range, adjust the throttle sensor position (see Throttle Position Sensor Position Adjustment).
★If the throttle position sensor position is good, inspect the other parts (see the previous flow chart).
★If the all parts are good, replace the igniter.

Throttle Position Sensor Resistance Inspection

• Disconnect the throttle position sensor lead connector from the main harness.
• Set the hand tester to the × 100 Ω range, and connect it to the throttle position sensor lead connector.

Throttle Position Sensor Resistance

Connections: Blue Lead ← → Black Lead

Service Limit: 4 \~ 6 kΩ

★If the reading is out of the range, replace the throttle position sensor.
★If the reading is within the specified range, check the other parts (see the previous flow chart).
★If the all parts are good, replace the igniter.

C A B D DX/BL Y/N 3L GP104298SI C

A DX/BL Y/W BL GP10430BSI C

Ignition System

Throttle Position Sensor Position Adjustment

• Check the idle speed, using the engine revolution tester for high accuracy and adjust the idle speed specified (see Idle Speed Inspection in the Periodic Maintenance chapter).
• Disconnect the throttle position sensor lead connector and connect the throttle position sensor setting adapter between throttle position sensor lead connector and main harness connector.

Special Tools - Hand Tester: 57001-1394

Throttle Position Sensor Setting Adapter

1: 57001-1400

- Set the hand tester to the 2.5 V DC range.

Hand Tester (+) → Yellow/White Lead

Hand Tester (−) → Black/Blue Lead

- Temporary install the fuel tank.

- Start the engine.

- Check the sensor output voltage at the idle speed.

Throttle Position Sensor Output Voltage

Standard: 0.58 \~ 0.78 V (when engine is idle speed)

- Adjust the position of the throttle position sensor so the voltage is within the specified voltage, and tighten the sensor bolt.

Crankshaft Sensor Inspection

• Remove:
  Magneto Lead Connector (see Magneto Cover Removal).
• Set the hand tester [A] to the × 100 Ω range and connect it to the Green/White [B] and White/Yellow [C] Leads in the connector.

Special Tool - Hand Tester: 57001-1394

★If there is more resistance than the specified value, the coil has an open lead and must be replaced. Much less than this resistance means the crankshaft sensor is shorted, and must be replaced.

Crankshaft Sensor Resistance

Standard: 190 \~ 290 Ω (at 20 °C (68 °F))

• Using the highest resistance range of the tester, measure the resistance between the crankshaft sensor leads and chassis ground.
  ★Any tester reading less than infinity ( ) indicates a short, necessities replacement of the crankshaft sensor assembly.

B C A QP10428BS1 C

Ignition System

Ignition System Circuit (Other than Australia Models)

Electrical wiring diagram with numbered components and labeled connections, including meters, resistors, and a terminal block.

GP10432BH3 C

1. Frame Ground
2. Ignition Coil
3. Spark Plug
4. Frame Ground
5. Gear Position Switch
6. Flywheel Magneto
7. Crankshaft Sensor

8. Throttle Position Sensor

9. Starter Relay

10. Main Fuse 20 A
11. Battery 12 V 6 Ah
12. IC Igniter
13. Engine Starter Button
14. Engine Stop Switch
15. Starter Lockout Switch

16-36 ELECTRICAL SYSTEM

Electrical Starter System

Starter Motor Removal

- Remove:

Exhaust Pipe (see Muffler Removal in the Engine Top End chapter)

Starter Motor Terminal Nut [A]

Starter Motor Mounting Bolts [B]

- Pull out the starter motor to right side.

Close-up mechanical assembly showing labeled parts A and B (no readable text or symbols beyond labels)

Starter Motor Installation

NOTICE

Do not tap the starter motor shaft or body. Tapping the shaft or body could damage the motor.

- Clean the starter motor mounting surface [A] and the crankcase surface [B] (mating surface with starter motor mounting).

• Replace the O-ring [A] with a new one.
• Apply engine oil to the O-ring.

Torque - Starter Motor Mounting Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)

Starter Motor Terminal Nut: 5.9 N·m (0.60 kgf·m, 52 in·lb)

• Install the starter motor.

Technical diagram of a mechanical assembly with labeled components A and B, showing connections and part numbers like GP118526.

Close-up of a mechanical component with labeled section A (no readable text or symbols beyond label)

Starter Motor Disassembly

• Remove the starter motor (see Starter Motor Removal).
• Remove:

Starter Motor Assembly Bolts [A] Both End Covers [B]

- Pull the armature out of the yoke.

A B SP118530 P

B C A GP118531 P

- Remove the terminal locknut [A] and then remove the brush with the brush plate [B] from the end cover [C].

Electrical Starter System

Starter Motor Assembly

• Replace the O-ring with a new one.
• Apply a thin coat of high-temperature grease to the oil seal [A] and the needle bearing [B].
• Fit the toothed washer [C] into the end cover.
  Thin Washer [D] Thick Washer [E]

B A C D E SP118532

- Install the brush plate [A] and tighten the terminal locknut [B].

Torque - Starter Motor Terminal Locknut: 6.9 N·m (0.70 kgf·m, 61 in·lb)

- Fit the tongue [C] on the brush plate into the end cover groove.

Cross-sectional view of a mechanical component with labeled parts A, B, and C (no text or symbols beyond labels)

- Insert the armature [A] between the brushes.

Thin Washer [B] Thick Washer [C]

B C A GP118534

- Align the marks [A] of the yoke [B] and end covers [C].

Torque - Starter Motor Through Bolts: 3.4 N·m (0.35 kgf·m, 30 in·lb)

A B C GP118535 P

Carbon Brush Inspection

• Measure the length [A] of each brush.
  ★If any one is worn down to the service limit, replace the carbon brush holder assembly [B].

Carbon Brush Length

Standard: 10 mm (0.39 mm)

Service Limit: 6.5 mm (0.26 in.)

A B SP11B536 P

16-38 ELECTRICAL SYSTEM

Electrical Starter System

Commutator Inspection, Cleaning

- Smooth the commutator surface [A] if necessary with fine emery cloth [B], and clean out the grooves.

B A 011081051 C

● Measure the outer diameter [A] of the commutator [B].

★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.)

A B GP110807S1 C

Armature Inspection

• Using the × 1 hand tester range, measure the resistance between any two commutator segments [A].
  ★If there is a high resistance or no reading ( ) between any two segments, a winding is open and the starter motor must be replaced.
• Using the × k hand tester range, measure the resistance between the segments and the shaft [B].
  ★If there is any reading at all, the armature has a short and the starter motor must be replaced.

A B GP11080851 C

Special Tool - Hand Tester: 57001-1394

NOTE

○Even if the foregoing checks show the armature to be good, if 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.

Brush Lead Inspection

- Using the x 1 Ω hand tester range, measure the continuity between the following:

Terminal Bolt and Positive (+) Brush [A]

Brush Plate and Negative (−) Brush [B]

★If there is not close to zero ohms, the brush lead has an open. Replace the terminal bolt assembly and the brush holder assembly.

Special Tool - Hand Tester: 57001-1394

A B GP118637 P

Electrical Starter System

Terminal Bolt Inspection

- Using the highest hand tester range, measure the resistance as shown.

Terminal Bolt and Brush Plate [A]

Terminal Bolt and Negative Brush Holder [B]

Terminal Bolt and End Cover [C]

★If there is any reading, the brush holder assembly and/or terminal bolt assembly have a short. Replace the brush holder assembly and the terminal bolt assembly.

Special Tool - Hand Tester: 57001-1394

Mechanical component with two measurement dials labeled A and C connected to a central hub (no text or symbols on the main body)

Mechanical component with a digital display and connection lines (no visible text or symbols)

Starter Relay Inspection

• Remove the seat (see Seat Removal in the Frame chapter).
• Disconnect the connector [A].
• Disconnect the starter motor cable [B] and batterypositive (+) cable [C] from the starter relay [D].

Technical diagram of a mechanical assembly with labeled parts A, B, C, and D

• Connect the hand tester [A] and 12 V battery [B] to the starter relay [C] as shown.
  ★If the relay does not work as specified, the relay is defective. Replace the relay.

Starter Relay Inspection

Tester range: × 1 Ω

Standard: When battery is connected → 0 Ω

When battery is disconnected → ∞ Ω

A C B GP1019B51 C

Special Tool - Hand Tester: 57001-1394

Electrical Starter System

Electric Starter Circuit (Other than Australia Models)

⑨ ⑧ ⑦ W/R Y/R BK/Y BK/W Y/R BR Bk/Y BK/W Y/R BR Bk/W ① ② ③ ④ ⑤ BK/W A B C D E F G H I J K L M N O P ⑥

GP11122BW3 C

1. Frame Ground
2. Starter Motor

3. Starter Relay

4. Main Fuse 20 A

5. Battery 12 V 6 Ah

6. IC Igniter

7. Engine Starter Button

8. Engine Stop Switch
9. Starter Lockout Switch

Lighting System

Headlight Aiming Inspection

• Inspect the headlight beam for aiming.
  ★If the headlight beam points too low or high, adjust the vertical beam.

Headlight Beam Vertical Adjustment

- Turn the vertical adjuster [A] on the headlight with the screwdriver in or out to adjust the headlight vertically.

NOTE

○ ON high beam, the brightest points should be slightly below horizontal with the motorcycle on its wheels and the rider seated. Adjust the headlight to the proper angle according to local regulations.

Headlight Bulb Replacement

• Remove:
  Headlight Assy (see Headlight Removal/Installation) Headlight Bulb Dust Cover [A]
• Open the clamp [B] and free the headlight lead [C].

- Remove: Headlight Connector [A]

- Remove: Hook [A] Headlight Bulb [B]

NOTICE

When handling the quartz-halogen bulb, never touch the glass portion with bare hands. Always use a clean cloth. Oil contamination from hands or dirty rags can reduce bulb life or cause the bulb to explode.

Close-up of a white car's headlight with a circular lens and labeled component A (no text or symbols beyond label)

A B C GP128747 P

Close-up of a mechanical component with labeled section A, showing internal structure and wiring (no readable text or symbols)

Close-up of a mechanical component with labeled parts A and B, no readable text or symbols beyond labels

NOTE

○ Clean off any contamination that inadvertently gets on the bulb with alcohol or soap and water solution.

• Replace the headlight bulb.
• Fit the projections [A] of the bulb in the hollow [B] of the headlight.
• Install the hook [C].

C B A GP12B750 P

• Fit the dust cover [A] firmly so that the headlight lead [B] faces downward [C] as shown.
• After installation, adjust the headlight aim (see Headlight Aiming Inspection in the Periodic Maintenance chapter).

B A C GP12BT51 P

Headlight Removal/Installation

- Remove the mounting bolts [A].

A GP12B752

• Disconnect the headlight connector [A].
• Remove the headlight assy.

Close-up of mechanical components with labeled parts (A and B) and no visible text or symbols

- Installation is the reverse of removal. ○Fit the projections [A] of the steering stem into the grommets [B] of the headlight assy.

Close-up of a mechanical assembly with labeled parts A and B, showing no visible text or symbols beyond labels.

Lighting System

Tail Light Removal

• Remove the seat (see Seat Removal in the Frame chapter).
• Disconnect the tail light lead connector [A].

Close-up of a mechanical component with wires and connectors, labeled point A (no readable text or symbols beyond label)

• Unhook the tail light lead [A] from the clamps [B].
• Unscrew the bolts [C] and remove the tail light [D].

C D A B GP12B756 P

Tail Light Installation

- Installation is the reverse of removal, note the following. - Route the harness and leads correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter).

Lighting System

Headlight/Tail Light Circuit (Other than Australia Models)

① HIGH ② LOW ③ ④ ⑤ ⑥ ⑦ ⑧ ⑨ ⑩ GP12334BW3 0

1. Headlight
2. Frame Ground
3. Flywheel Magneto
4. Regulator/Rectifier

5. Starter Relay

6. Main Fuse 20 A

7. Battery 12 V 6 Ah
8. Tail Light
9. Main Relay
10. IC Igniter

Meter Gauge

Meter Unit Removal/Installation

• Remove the headlight assy (see Headlight Removal/Installation).
• Remove the mounting nuts [A].
• Slide the boots [B] and disconnect the meter connector [C].
• Installation is reverse of removal.

A C B GP178306

Meter Unit Disassembly/Assembly

• Remove:
  Screws [A]
  Lower Meter Cover [B]

Close-up of a mechanical component with labeled points A and B, showing internal structure and mounting holes (no readable text or symbols beyond labels)

• Remove:
  Screws [A]
  Meter Assy [B]

Interior view of an electronic device housing with labeled components (A and B), no readable text or symbols beyond labels

- Assembly is reverse of Disassembly.

Switch Inspection

- Starting the engine causes all the LCD segments (the letters and numbers of the liquid crystal display) [A] illuminate for 3 seconds.

★If they do not illuminate, check the LCD segments (see LCD Segment Inspection).

A 88 ampb OFF/LOCK TEMP A/B GP17929851 C

16-46 ELECTRICAL SYSTEM

Meter Gauge

• Check that the display [A] shifts between ODO and CLOCK each time the ODO/CLOCK button [B] is pushed.
  ★If the display does not shift, replace the meter unit.

B 8 mph OFF/LOCK OFF/AN A QP17930051 C

• Check that the display [A] shifts between TRIP-A and TRIP-B each time the TRIP A/B button [B] is pushed.
  ★If the display does not shift, replace the meter unit.

8 mph 0.01 A B 0.01 A QP17931851 C

• Push the ODO/CLOCK button [A] to display the clock.
• Keeping the TRIP A/B button pushed, turning ON the ODO/CLOCK button [B] enables the hours and the minutes of the clock to be set [C]. Verify that the time can be set here.
  ★If the time cannot be set, replace the meter unit.

A B C 0 mmH 13 i GP17932851 C

Clock Setting

• Press the ODO/CLOCK button [A] to show the clock in the odometer display.
• Keep the ODO/CLOCK button pressed and turn the TRIP A/B button [B] ON to enable the display to assume the Hour/Minute setting mode [C] in which the numbers flash, thus enabling you to set the time on the clock.
  ○Starting with the Hour/Minute setting mode, each pressing of the ODO/CLOCK button changes the setting modes as follows:

Hour/Minute Setting Mode → Hour Setting Mode → Minute Setting Mode

12:23 A B C 8:12 QP17934851 C

Meter Gauge

In the Hour/Minute setting mode, the numbers that represent the hours and the minutes flash. In the Hour setting mode, the numbers that represent the hours flash [A]. And in the Minute setting mode, the numbers that represent the minutes flash [B].

12:23 12:23 A B GP17935851 C

• In the Hour setting mode and the Minute setting mode, set the time by pressing the TRIP A/B button [A] to increase the number of Hours and Minutes.
• Then, change to the Hour/Minute setting mode and press the TRIP A/B button to complete the time setting process.

NOV/LINE OFF/LINE 8.8 mmH OFF/LINE A GPI 179368SI C

LCD Segment Inspection

- Remove:

Headlight Assy (see Headlight Removal/Installation) Meter Unit (see Meter Unit Removal/Installation)

• Check that all the LCD segments (the letters and numbers of the liquid crystal display) illuminate for 3 seconds after connecting pins [4] and [8] of the meter connector [A] to the battery [B], then connecting pin [2] and battery (+) terminal together. Next, check that all the LCD segments become unlit when pin [2] is disconnected.
  ★If there is any problem, replace the meter unit.
  ★If there are no problems, inspect the power wiring.

NOTE

○ In case that the Liquid Crystal Display (LCD) malfunctions, e.g., display freezing, wait for 30 seconds or more after disconnecting it from the battery.

The LCD will function normally after reconnected.

A ④ ② ⑧ B + - GP17933BSI C

Meter Gauge

Meter Circuit (Other than Australia Models)

Electrical wiring diagram showing connections between a meter, resistors, and a terminal block with labeled components.

1. Speed Sensor
2. Meter Unit
3. Frame Ground
4. Starter Relay

5. Main Fuse 20 A

6. Battery 12 V 6 A

7. IC Igniter
8. Main Relay
9. Engine Starter Button
10. Starter Lockout Switch

Switches and Sensors

Speed Sensor Removal

- Disconnect the speed sensor connector [A] and remove the sensor lead from the clamp.

- Remove the bolts [A] and open the clamps [B], take off the sensor lead.

- Remove the front wheel with the speed sensor (see Front Wheel Removal in the Wheels/Tires chapter).

Speed Sensor Installation

- Install the front wheel with the speed sens or (see Front Wheel Installation in the Wheels/Tires chapter).

- Install the sensor cable [A] into the clamps [B] and connect the connector [C].

Speed Sensor Inspection

• Remove the speed sensor (see Speed Sensor Removal).
• Connect the speed sensor connector [A] with the battery [B], 10 kΩ resistor [C] and hand tester [D] as shown.
• Set the tester to the DC 25 V range.
  Special Tool - Hand Tester: 57001-1394

Close-up of mechanical components with labeled section A (no readable text or symbols beyond label)

A B A B GP108336

Kawasaki B A C B GP10B37

A C D B GP18355BSI C

Switches and Sensors

• Turn [A] the rotor of the speed sensor.
  ○Then the tester indicator should flick [B].
  ★If the tester indicator does not flick, replace the speed sensor.

A B D025V GP18096B 5

Throttle Position Sensor Removal/Installation

- Refer to the Carburetor Disassembly/Assembly in the Fuel System chapter.

Switch Inspection

- Using the hand tester, check to see that only the connections shown in the table have continuity (about zero ohms).

Special Tool - Hand Tester: 57001-1394

★If the switch has an open or short, repair it or replace it with a new one.

Engine Stop Switch Connections
Color	BK/Y	BK/W
OFF
RUN	○—	○

Starter Button
Color	Y/R	BR
Push	○	○
Release

Starter Lockout Swith
Color	W	Y/R
Clutch Lever
Pulled in	○——○
Released

QP18352BN3 C

OP18353BN3 C

Gear Position Switch Removal

- Remove:

Left Radiator Shroud

Bolt [A]

Left Radiator Screen [B]

Left Radiator Mounting Bolts [C]

- Push the left radiator backward [D].

Technical diagram of a mechanical assembly with labeled components A, B, C, and D

Switches and Sensors

• Pry open the clamps [A].
• Disconnect the gear position switch connector.

Close-up of a car radiator component with mounting bracket and fan (no visible text or symbols)

• Remove:
  Shift Pedal (External Shift Mechanism Removal in the Engine Right Side chapter) Screws [A] Gear Position Switch [B]

B A GP18B340 P

- Remove:

O-ring [A] Gear Position Switch Finger [B] Spring [C]

A B C GP18B341 P

Gear Position Switch Installation

• Insert the spring into the hole in the shift drum.
• Insert the switch finger [A] so that the small diameter [B] is toward hole side.
• Apply grease to the O-ring.
• Clean the contact points on the position sensor.
• Apply a non-parmanent locking agent to the gear position switch screws.
• Tighten:

Torque - Gear Position Switch Screws: 2.9 N·m (0.30 kgf·m, 26 in·lb)

A B GP18010351 C

- Install the other removed parts.

Switches and Sensors

Gear Position Switch Inspection

NOTE

○ Be sure the transmission mechanism is good condition.

• Remove the left radiator shroud.
• Disconnect the gear position switch lead connector [A].

- Set the hand tester [A] to the ×1 kΩ or ×100 Ω range and connect it to the terminals in the gear position switch lead connector [B] and ground.

[C] Internal Circuit
[D] Green/Red Lead
[E] Black Lead

Special Tool - Hand Tester: 57001-1394

Gear Position Switch Resistance

	Connections
Gear Position	[D] Terminal - Ground [E] Terminal - Ground
1st	3.00 ~ 3.32 kΩ	11.64 ~ 12.86 kΩ
Neutral	1.70 ~ 1.89 kΩ	10.35 ~ 11.43 kΩ
2nd	1.07 ~ 1.19 kΩ	9.71 ~ 10.73 kΩ
3rd	0.695 ~ 0.769 kΩ	9.33 ~ 10.31 kΩ
4th	0.430 ~ 0.476 kΩ	9.07 ~ 10.0 kΩ
5th	0.248 ~ 0.274 kΩ	8.88 ~ 9.82 kΩ

★If the tester reading is not as specified, replace the gear position switch with a new one.

Close-up of a mechanical component with labeled point A and alphanumeric code (GP188042) on the base, no readable text or symbols beyond labels.

E C D B 1st N 2nd 3rd 4th 5th A OP18459BS2 C

Main Relay

Main Relay Inspection

• Remove the seat (see Seat Removal in the Frame chapter).
• Remove the main relay [A].

Close-up of a car engine bay with visible components and a labeled section (A), no readable text or symbols present.

• Check conductivity of the following numbered terminals by connecting the hand tester and one 12 V battery to the main relay as shown.
  ★If the tester does not read as specified, replace the main relay.

5 1 3 2 QP18354BSI C

Main Relay Inspection (with the battery disconnected)

Tester Connection Tester Reading (Ω)
3-5	∞
1-2	Not∞*

*: The actual reading varies with the hand tester used.

Main Relay Inspection (with the battery connected)

Battery Connection (+) (-)	Tester Connection	Tester Reading (Ω)
1-2 3-5 0

(+): Apply positive lead.
(-): Apply negative lead.

• Remove the seat (see Seat Removal in the Frame chapter).
• Disconnect the starter relay connector [A].
• Removethemainfuse[B]fromthestarter

B A relay GP200130

Main Fuse 20 A Inspection

• Removethe fuse (see MainFuse20A Rem spect the fuse element.
  ★If the fuse element is blown, replace the fuse.
  Housing [A]
  Fuse Element [B]
  Terminal [C]
  Blown Element [D]

Oval A and B - C D GP200001S1 C

NOTICE

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 ad components.

Appendix

Table of Contents

Cable, Wire, and Hose Routing 17-2

Troubleshooting Guide 17-25

17-2 APPENDIX

Cable, Wire, and Hose Routing

Technical schematic diagram of a mechanical device with numbered components and exploded views

Cable, Wire, and Hose Routing

1. Starter Button Lead
2. Throttle Cables
3. Marked (AAA) cable is accelerator side.
4. Bands
5. Brake Hose
6. Engine Stop Switch Lead
7. Starter Lockout Switch Lead
8. Hot Starter Cable
9. Clutch Cable
10. Harness/Cable Guide
11. Starter Lockout Switch Connector (Green)
12. Engine Stop Switch Connector (White)
13. Starter Button Lead Connector (Black)
14. Meter Unit Lead
15. Run the throttle cables and Leads between the meter bracket and upper mounting.
16. Meter Unit Connector (Black Cap)
17. Headlight Connector (Black)
18. Clamp (Fix the leads by twisting the clamp.)
19. Front side of the harness/cable guide.
20. Inside of the harness/cable guide.
21. Speed Sensor Lead Connector (Gray)

17-4 APPENDIX

Cable, Wire, and Hose Routing

Technical diagram of a mechanical assembly with numbered components for identification and assembly reference.

Cable, Wire, and Hose Routing

1. Hot Starter Cable
2. Main Harness
3. Clamps
4. Run the throttle cables over the main harness.
5. White Tape
6. Throttle Cables
7. Blue Tape
8. Clamps
9. Band
10. Clutch Cable
11. Run the clutch cable outside of the fuel hose.
12. Fuel Hose
13. Clamp (Face the tab to the underside.)
14. Magneto Lead
15. Transmission Position Sensor Lead
16. If the magneto lead and transmission position sensor lead have the play, do no play by pulling down them.
17. Run the hot starter cable and clutch cable over the radiator hose.
18. Right Side
19. Ignition Coil Ground Lead
20. View from A-A
21. Ground Lead
22. Left Side

17-6 APPENDIX

Cable, Wire, and Hose Routing

Technical schematic diagram of a mechanical device with numbered components for identification and assembly reference.

Cable, Wire, and Hose Routing

1. Throttle Cables
2. Clamp
3. Harness/Cable Guide
4. Speed Sensor Lead Connector (Gray)
5. Fix the connector on the bracket.
6. Clamp (Put the sensor grommet into the clamp, and then fix it by crushing the clamp.)
7. Speed Sensor Lead
8. Run the harnesses to inside of the clamp.
9. Run the switch lead to inside of the throttle cables.

17-8 APPENDIX

Cable, Wire, and Hose Routing

Technical diagram of a mechanical assembly with numbered components for identification

Cable, Wire, and Hose Routing

1. Headlight Connector (Black)
2. Speed Sensor Lead Connector (Gray)
3. Meter Unit Connector (Black Cap)
4. Starter Lockout Switch Connector (Green)
5. Engine Stop Switch Connector (White)
6. Starter Button Lead Connector (Black)
7. Clamps
8. White Tape
9. Clamps
10. Blue Tape
11. Main Harness
12. Clamps
13. Run the harnesses under the frame pipe.
14. Igniter Connector (Black)
15. Bands
16. Starter Relay Connector (Red)
17. Tail Light Lead Connector (White)
18. Main Relay Connector (White)
19. Regulator/Rectifier Lead Connector (Green)
20. 50 mm (2.0 in.)
21. Throttle Position Sensor Lead Connector (White)
22. Ground Lead
23. Magneto Lead Connector (Gray)
24. Ignition Coil Lead Connector (Black)
25. Transmission Position Sensor Lead Connector (White)
26. Clamp (Fix only the main relay lead.)

17-10 APPENDIX

Cable, Wire, and Hose Routing

Technical diagram of a vehicle's internal components with numbered parts, including suspension and assembly parts.

Cable, Wire, and Hose Routing

1. Battery Negative (−) Cable (Black)
2. Starter Relay Connector (Red)
3. Starter Relay
4. Black Cap
5. Battery Positive (+) Cable (Red)
6. Starter Motor Cable (White)
7. Tail Light Lead
8. Clamps (Fix the tail light lead by twisting the clamps.)
9. Tail Light Lead Connector (White)
10. Main Relay
11. Main Relay Connector (White)
12. Regulator/Rectifier
13. Regulator/Rectifier Lead Connector (Green)
14. Run the regulator/rectifier lead to the inside of the front left side cover mounting bracket of the air cleaner housing.
15. Run the main harness and starter motor cable under the frame pipe.
16. Run the tail light lead to the most bottom of grooves on the U shaped bracket.
17. To Main Relay
18. To Regulator/Rectifier
19. Bracket
20. Bracket
21. Clamps (Tightened together with the bracket.)
22. Clamp (Fix only the main relay lead.)
23. Run the tail light lead to inside of the main relay lead.
24. Run the starter motor cable to inside of the main relay lead.
25. Place the band at the hollow of the battery holder.

17-12 APPENDIX

Cable, Wire, and Hose Routing

Technical diagram of a mechanical device with numbered components for identification

Cable, Wire, and Hose Routing

1. Starter Motor Cable (White)
2. Run the starter motor cable over the harness.
3. Tighten together the battery negative (−) cable and starter mounting bolt.
4. Connect the starter motor cable to the starter motor terminal bolt.
5. Meter Unit Connector (Black Cap)
6. Headlight Connector (Black)
7. Harness/Cable Guide
8. Starter Lockout Switch Connector (Green)
9. Engine Stop Switch Connector (White)
10. Starter Button Lead Connector (Black)
11. Speed Sensor Lead Connector (Gray)
12. Band
13. Blue Tape
14. Clamp (Fix the starter motor cable and battery negative (−) cable by the clamp near the carburetor side.)
15. Battery Negative (−) Cable
16. Run the battery negative (−) cable over the harness.

17-14 APPENDIX

Cable, Wire, and Hose Routing

Technical schematic diagram of a vehicle brake system with numbered components and labeled parts

Cable, Wire, and Hose Routing

1. Brake Lever
2. Front Brake Master Cylinder
3. Front Brake Hose
4. Clamp
5. View from A-A
6. Clamps
7. Front Brake Caliper
8. Front Brake Disc
9. Brake Pedal
10. Rear Brake Master Cylinder
11. Rear Brake Hose
12. Clamps
13. Rear Brake Caliper
14. Rear Brake Caliper Guard
15. Rear Brake Disc
16. Rear Brake Disc Guard
17. Cotter Pin

17-16 APPENDIX

Cable, Wire, and Hose Routing

Technical schematic diagram of a mechanical assembly with numbered components and labeled parts

Cable, Wire, and Hose Routing

1. Breather Hose
2. Fuel Hoses
3. Run the breather hose over the fuel hoses.
4. Clamp
5. Stretch to the arrow mark without loosing the hose when mounting the fuel tank. (Keep the gap of the chain guide roller and hoses)
6. Breather Hose
7. Face the painted portion to left side.
8. Clamps (Face the tabs to left side.)
9. Air Cleaner Housing
10. Boot (Install the boot as shown in the figure.)
11. Chain Guide Roller
12. Vent Hoses
13. Drain Hose (Run the drain hose leftmost of the bracket.)
14. View from A
15. View from B
16. Run the breather hose under the radiator fitting.

17-18 APPENDIX

Cable, Wire, and Hose Routing

Technical diagram of a mechanical assembly with numbered components and exploded views, likely from an engineering or manufacturing context.

Cable, Wire, and Hose Routing

1. Reserve Tank Hose
2. Hot Starter Cable
3. Clutch Cable
4. Clamp
5. Clamps
6. Run the reserve tank hose under the throttle cables and main harness.
7. Regulator/Rectifier Lead Connector (Green)
8. Starter Motor Cable (White)
9. Main Harness
10. Clamp
11. Throttle Cables

Cable, Wire, and Hose Routing

U.S.A., California and Canada Models

Technical diagram of a mechanical device with numbered components and labeled parts, including internal views and directional arrows.

Cable, Wire, and Hose Routing

1. Vacuum Switch Valve Hose
2. Cylinder Head Cover
3. Front of the engine
4. White paint
5. Insert the vacuum switch valve hose to the white painted portion of the pipe.
6. Clamps (Face the tabs to the upper of the engine.)
7. Clamp (Face the tab to the upper of the engine.)
8. Face the white painted portion to the upper of the engine.
9. Clamp (Face the tab to the upper of the engine.)
10. View from A
11. Clamp (Install the clamp as shown in the figure.)
12. Vacuum Hose
13. Clamp (Face the tab to the upper of the engine.)

17-22 APPENDIX

Cable, Wire, and Hose Routing

Technical diagram of a mechanical device with numbered components and exploded views, likely for assembly or maintenance instructions.

Cable, Wire, and Hose Routing

1. Radiator Hose
2. Clamps (Install the clamp as shown in the figure.)
3. Radiator Hose
4. Clamps (Install the clamp as shown in the figure.)
5. Face the white painted portion to the right side of the engine.
6. Water hose
7. Face the white painted portion to the right side of the engine.
8. View from the rear side of the engine.
9. To Water Pump Cover
10. Water Hose
11. Stoppers
12. Radiator Hose

17-24 APPENDIX

Cable, Wire, and Hose Routing

Technical diagram of a mechanical assembly with numbered components for identification

1. Clamp (Install the clamp as shown in the figure.)
2. Fuel Hose
3. Carburetor
4. Clamp (Install the clamp as shown in the figure.)
5. Clamp (Run the vent hoses through the clamp on the backward of the crankcase.)
6. Vent Hoses

Troubleshooting Guide

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:

Starter lockout switch trouble

Starter motor trouble

Battery voltage low

Starter relay not contacting or operating

Starter button not contacting

Wiring open or shorted

Engine stop switch trouble

Fuse blown

Starter motor rotating but engine doesn't turn over:

Starter clutch trouble

Engine won't turn over:

Valve seizure

Connecting rod small end, big end seizure

Transmission gear or bearing seizure

Camshaft seizure

Starter idle gear seizure

Kick shaft return spring broken

Kick ratchet gear not engaging

No fuel flow:

No fuel in tank

Fuel tank cap air vent obstructed

Fuel tap clogged

Fuel tap turned off

Fuel line clogged

Carburetor float valve clogged

Engine flooded:

Fuel level in carburetor float bowl too high

Float valve worn or jammed with foreign matter

Starting technique faulty (When flooded, crank the engine with the hot start opened to allow more air to reach the engine.)

Fuel/air mixture incorrect:

Pilot screw and/or idle adjusting screw mal-adjusted

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 gap maladjusted

Spark plug cap or high tension wiring trouble

Spark plug cap shorted or not in good contact

Spark plug incorrect heat value

Faulty IC igniter

Crankshaft sensor trouble

Ignition coil trouble

Engine stop switch shorted

Neutral switch trouble

Wiring shorted or open

Flywheel damage

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, deformed, worn, or carbon accumulation on the seating surface)

Decompression trouble

Poor Running at Low Speed:

Spark weak:

Battery voltage low

Spark plug dirty, broken, or gap maladjusted

Spark plug cap or high tension wiring trouble

Spark plug cap shorted or not in good contact

Spark plug incorrect heat value

Faulty IC igniter

Crankshaft sensor trouble

Flywheel damaged

Ignition coil trouble

Wiring connector not in good contact

Fuel/air mixture incorrect:

Pilot screw maladjusted

Pilot jet, or air passage clogged

Needle Jet, or air passage clogged

Air cleaner clogged, poorly sealed, or missing

Starter plunger stuck open

Hot start stuck open

Fuel level in carburetor float bowl too high or too low

Fuel tank cap air vent obstructed

Fuel tap clogged

Carburetor holder loose

Air cleaner duct loose

Troubleshooting Guide

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, deformed, worn, or carbon accumulation on the seating surface)

Decompression trouble

Other:

Faulty IC igniter

Engine oil level to high

Engine oil viscosity too high

Brake dragging

Drive train trouble

Engine overheating

Clutch slipping

Vacuum Switch Valve trouble (equipped models)

Poor Running or No Power at High Speed:

Firing incorrect:

Spark plug dirty, broken, or gap maladjusted

Spark plug cap or high tension wiring trouble

Spark plug cap shorted or not in good contact

Spark plug incorrect heat value

Faulty IC igniter

Crankshaft sensor trouble

Flywheel damage

Ignition coil trouble

Wiring connector not in good contact

Fuel/air mixture incorrect:

Starter plunger stuck open

Hot start stuck open

Main jet clogged or wrong size

Jet needle or needle jet worn

Air jet clogged

Fuel level in carburetor float bowl too high or too low

Needle Jet, or air passage clogged

Air cleaner clogged, poorly sealed, or missing

Air cleaner duct loose

Water or foreign matter in fuel

Carburetor holder loose

Fuel tank cap 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 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, deformed, worn, carbon accumulation on the seating surface.)

Decompression trouble

Knocking:

Carbon built up in combustion chamber

Fuel poor quality or incorrect

Spark plug incorrect heat valve

Faulty IC igniter

Crankshaft Sensor trouble

Other:

Throttle valve won't fully open

Brake dragging

Air cleaner clogged

Water or foreign matter in fuel

Clutch slipping

Overheating

Engine oil level too high

Engine oil viscosity too high

Drive train trouble

Crankshaft bearing worn or damage

Vacuum Switch Valve trouble (equipped models)

Engine Overheating:

Firing incorrect:

Spark plug dirty, broken, or maladjusted

Spark plug incorrect

Faulty IC igniter

Fuel/air mixture incorrect:

Main jet clogged or wrong size

Fuel level in carburetor float bowl too low

Carburetor holder loose

Air cleaner clogged, poorly sealed, or missing

Air cleaner duct loose

Hot start stuck open

Compression high:

Carbon built up in combustion chamber

Engine load faulty:

Clutch slipping

Engine oil level too high

Engine oil viscosity too high

Troubleshooting Guide

Brake dragging

Drive train trouble

Lubrication inadequate:

Engine oil level too low

Engine oil poor quality or incorrect

Coolant incorrect:

Coolant level too low

Coolant deteriorated

Cooling system component incorrect:

Radiator clogged

Radiator cap trouble

Water pump not rotating

Water pump impeller damaged

Clutch Operation Faulty:

Clutch slipping:

No clutch lever play

Clutch cable maladjusted

Clutch inner cable sticking

Friction plate worn or warped

Steel plate worn or warped

Clutch spring broken or weak

Clutch release function trouble

Clutch hub or housing unevenly worn

Clutch not disengaging properly:

Clutch lever play excessive

Clutch spring compression uneven

Engine oil deteriorated

Engine oil viscosity too high

Engine oil level too high

Clutch housing seized

Clutch release function trouble

Clutch hub nut loose

Clutch plate warped or rough

Clutch hub spline damaged

Gear Shifting Faulty:

Doesn't go into gear; shift pedal doesn't

return:

Clutch not disengaging

Shift fork bent, worn, or seized

Shift return spring pin loose

Shift return spring weak or broken

Shift shaft lever broken

Pawl guide plate broken

Shift pawl broken

Shift pawl spring tension lose

Gear seized

Gear set lever operation trouble

Shift drum broken

Jumps out of gear:

Shift fork ear worn, bent

Gear groove worn

Gear dogs and/or dog holes worn

Shift drum groove worn

Gear set lever spring weak or broken

Shift fork guide pin worn

Drive shaft, output shaft, and/or gear splines worn

Overshifts:

Gear set lever spring weak or broken

Pawl guide plate worn

Abnormal Engine Noise:

Knocking:

Faulty IC igniter

Carbon built up in combustion chamber

Fuel poor quality or incorrect

Spark plug incorrect heat value

Overheating

Piston slap:

Cylinder/piston clearance excessive

Cylinder, piston worn

Connecting rod bent

Piston pin, piston pin hole worn

Valve noise:

Valve clearance incorrect

Valve spring broken or weak

Camshaft bearing or cam face worn

Valve lifter worn

Other noise:

Connecting rod big end, small 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, chain guide worn

Primary gear worn or damaged

Decompressor spring broken

Magneto flywheel loose

Vacuum switch valve damaged (equipped models)

Abnormal Drive Train Noise:

Clutch noise:

Clutch housing finger and friction plate tang worn

Clutch housing gear worn

Metal chips jammed in clutch housing gear teeth

Transmission noise:

Bearings worn

Transmission gears worn or chipped

Metal chips jammed in gear teeth

Engine oil insufficient, low viscosity

Kick ratchet gear not properly disengaging from kick gear

Kick shaft idle gear worn or chipped

Troubleshooting Guide

Drive chain noise:

Drive chain maladjusted

Drive chain worn

Rear and/or engine sprocket worn

Drive chain lubrication insufficient

Rear wheel misaligned

Abnormal Frame Noise:

Front fork noise:

Oil insufficient or too thin

Spring weak or broken

Front fork air pressure high

Rear shock absorber noise:

Shock absorber trouble

Spring weak or broken

Disc brake noise:

Pad surface glazed

Disc warped

Caliper trouble

Pad installed incorrectly

Master cylinder damaged

Other noise:

Bracket, nut, bolt, etc., not properly mounted or tightened

Abnormal Exhaust Color:

White smoke:

Piston oil ring worn

Cylinder worn

Valve oil seal damaged

Valve guide worn

Engine oil level too high

Black smoke:

Air cleaner element clogged

Main jet too large or fallen off

Starter plunger stuck open

Fuel level in carburetor float bowl too high

Brown smoke:

Main jet too small

Fuel level in carburetor float bowl too low

Air cleaner duct loose

Air cleaner poorly sealed or missing

Handling and/or Stability

Unsatisfactory:

Handlebar hard to turn:

Cable, hose, wire routing incorrect

Steering stem nut too tight

Steering stem bearing damaged

Steering stem bearing lubrication inadequate

Steering stem bent

Tire air pressure too low

Handlebar shakes or excessively vibrates:

Tire worn

Swingarm pivot bearings worn

Rim warped, or not balanced

Spokes loose

Wheel bearing worn

Handlebar holder bolt loose

Steering stem head nut loose

Front, rear axle runout excessive

Handlebar pulls to one side:

Frame bent

Rear wheel misalignment

Swingarm bent or twisted

Swingarm pivot shaft bent

Steering maladjusted

Steering stem bent

Front fork bent

Right and left front fork oil level uneven

Suspension operation trouble:

(Too hard)

Tire air pressure too high

Front fork oil excessive

Front fork oil viscosity too high

Rear shock absorber adjustment too hard

Front fork bent

Front fork air pressure too high

(Too soft)

Front fork oil insufficient or leaking

Front fork oil viscosity too low

Rear shock absorber adjusted too soft

Front fork, rear shock absorber spring weak

Rear shock absorber oil or gas leaking

Tire air pressure too low

Brake Doesn't Hold:

Air in brake system

Pad, disc worn

Brake fluid leakage

Contaminated pad

Brake fluid deteriorated

Brake master cylinder cups damaged

Master cylinder scratched inside

Disc warped

Battery Trouble:

Battery discharged:

Charge insufficient

Battery faulty (too low terminal voltage)

Battery lead making poor contact

Load excessive (e.g., bulb of excessive wattage)

Magneto trouble

Wiring faulty

Regulator/rectifier trouble

Battery overcharged:

Magneto trouble

Regulator/rectifier trouble

Battery faulty

MODEL APPLICATION

Year Model Beginning Frame No.
2008 KLX	450A8F	JKALXGA1□8A000001 or JKALX450AAA000001
2009 KLX	450A9F	JKALXGA1□9A010001 or JKALX450AAA010001
2010 KLX	450AAF	JKALXGA1□AA013001 or JKALX450AAA013001
2011 KLX	450ABF

☐:This digit in the frame number changes from one machine to another.