Kawasaki KX250F (2004) manual

KX250F Motorcycle Service Manual[...]

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This quick reference guid e will assist you in locating a desired topi c or pro- cedure. •Bend the pages back to match the black tab of the desired chapter num- ber with the black tab on the edge at each table of contents page. •Refer to the sectional table of contents for the exact pages t o locate t he spe- cific t opic required. Quick Refere[...]

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KX250F 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, recordi ng or otherwise, without the prior written permission of Quality Assurance Department/Consumer Products & Machinery Company/Ka[...]

LIST O F A BBREVIA TIONS A ampere(s) lb pound(s) ABDC after bottom dead center m meter(s) AC alternati ng current min minute(s) AT D C after top dead center N newton(s) BBDC before bottom dead center Pa pascal(s) BDC bottom dead cent er PS horsepower BTDC before top dead center psi pound(s) per square inch °C degree(s) Celsius r revo lution DC dir[...]

Foreword This m anual is designed pri marily f or use by trained mechanics in a properly equipped shop. However , it contains e nough detail and basic in- formation to make it useful to the owner who de- sires to perform his own basic maintenance and repair w ork. A basic knowledge of mechanics, the proper use of tools, and workshop proce- dures mu[...]

NOTE ○ This note symbol indi cates points of par- ticula r interest for more efficient and con- venien t operatio n. • Indicates a procedural step or work to be done. ○ Indicates a procedural sub-step or how to do the work of t he procedural step it follows. It also precedes the text of a NOTE. Indicates a conditional step or what action to t[...]

GENERAL INFORMA T ION 1-1 1 General Information T abl e o f Content s Bef ore S ervici ng ...... ...... .... ...... ...... .... ....... .... ...... ...... .... ....... .... ...... ...... .... ...... ....... .... ...... ... .... . 1-2 Model Identification. ...... ...... .... ...... ...... ..... ...... ...... ...... ...... ..... ...... ........ .....[...]

1-2 GENERAL INFORMA TION Before Servicing Before starting to perform an inspecti on service or carry out a disassembly and reassembly opera- tion on a motorcycle, read the precautions given bel ow . T o facilitate actual operat ions, notes, illustra- tions, photographs, cautions, and detailed descriptions have been included in each chapter wher eve[...]

GENERAL INFORMA TION 1-3 Before Servicing Stor age of R emo ved Pa rts After al l the parts including subass embly pa rts have been cleaned, st ore the part s in a clean area. P ut a clean cloth or plastic sheet over the parts to protect from any foreign materials that may collect before re-assembly . Inspection Reuse of worn or damaged parts may l[...]

1-4 GENERAL INFORMA TION Before Servicing Ti ghteni ng T orque Incorrect torque applied to a bolt, nut, or screw may lead to serious damage. T ighten fasteners to the specified torque using a good quality torque wrench. Often, the tightening sequenc e is followed twic e-initi al tightening and final tightening with torque wrench. Force Use c ommon [...]

GENERAL INFORMA TION 1-5 Before Servicing Ball Bearing and Needl e Bear ing 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 r ace as shown. Pres[...]

1-6 GENERAL INFORMA TION Before Servicing Electric al Wires A two-color wi re is identi fied fir st by the pri mary color and then the stripe color . Unless instructed otherwise, el ectrical wires must be connected to those of the same color .[...]

GENERAL INFORMA TION 1-7 Model Identification KX250–N1 Left Side Vi ew KX250–N1 Right Side View[...]

1-8 GENERAL INFORMA TION General S pecificatio ns Items KX250–N1 Dimensions: Overall length 2 170 mm (85.43 in.) Overall width 840 m m (33.1 in.) Overall height 1 270 mm (50 in.) Wheelbase 1 475 mm (8.07 in.) Road clearance 340 mm (13.4 in.) Seat height 960 m m (37.8 in.) Dry mass 92.5 kg (204 lb) Curb mass: Front 49.9 kg (1 10 lb) Rea r 52.6 kg [...]

GENERAL INFORMA TION 1-9 General Specifications Items KX250–N1 T r ansmission: Ty p e 5-speed, constant mesh, return shift Gear ratios: 1st 2.142 (30/14) 2nd 1.785 (25/14) 3rd 1.444 (26/18) 4th 1.200 (24/20) 5th 1.052 (20/19) Final drive system: Ty p e Chain drive Reduction ratio 3.692 (48/13) Overall drive ratio 13.020 @ T op gear Frame: Ty p e [...]

1-10 GENERAL INFORMA TION Unit Conversion T able Prefixes for U nits: Prefix Symbol Power mega M × 1 000 000 kilo k × 1 000 centi c ×0 . 0 1 milli m × 0.001 micro µ × 0.000001 Units of Mass: kg × 2.205 = lb g × 0.03527 = oz Units of V olume: L × 0.2642 = gal (US) L × 0.2200 = gal (imp) L × 1.057 = qt (US) L × 0.8799 = qt (imp) L × 2.1 [...]

PERIODIC MAINTENANCE 2-1 2 Periodic Maintenance T abl e o f Content s Periodic Maintenance Chart ... ...... ..... 2-2 T orque and Locking Agent .......... ...... . 2-4 Spec ifica tion s . ...... ....... .... ...... ...... .... .. 2-8 Spec ial T o ols ...... ....... ...... .... ...... .... .... 2-10 Periodic Maintenance Procedures..... 2-1 1 Fuel Sy[...]

2-2 PERIODIC M AINTENANCE Periodic Maintenance Ch art The maintenance must be done in accordance with this chart to keep the motorcycle in good running conditio n. FREQUENCY Each Ever y 3 Ever y 6 Every 12 See OPERA TION race races races race s Page Spark plug – c lean, gap † • 2-54 Clutch – adjust • 2-22 Clutch and fricti on plates - ins[...]

PERIODIC MAINTENANCE 2-3 Periodic Maintenance Chart FREQUENCY Each Every 3 Every 6 Every 12 See OPERA TION race races races races Page Front fork – inspect and clean • 2-44 Front fork oil – change • 2-44 Rear shock oil – replace • 2-46 Cable – inspect • 2-55 Fuel hose – replace Every 4 years 2-1 1 Fuel hose, connections - inspect [...]

2-4 PERIODIC M AINTENANCE T orqu e and Locking Age nt T ighten all bolts and nuts to the proper torque using an accurate torque wrench. If insuf ficiently tightened, a bolt or nut may become damaged, strip an internal thread, or br eak and then fall out. The following table lists the tightening toque for t he major bolts and nuts, and the parts req[...]

PERIODIC MAINTENANCE 2-5 T o rque and Locking Agent T orque Fastener N·m kgf·m ft ·lb Remarks Cylinder Bolt M6 12 1.2 104 in·lb S Exhaust P ipe Cover Screws 12 1.2 104 in·lb Exhaust Pipe Holder Nuts 21 2.1 15 S Muffler Mounting Bolts 21 2.1 15 S Engine Right Side: Primary G ear Nut 98 10 72 Lh Shi ft Drum Cam Bolt 24 2.4 17 L Clutch Spring Bol[...]

2-6 PERIODIC M AINTENANCE T orqu e and Locking Age nt T orque Fastener N·m kgf·m ft·lb Rem arks Piston Oil Nozzl e 2.5 0.25 22 in·lb L Crankcase Bolts 9.8 1.0 87 in·lb S Engine Oil D rain Plug (for crank room oil sump) 7.0 0.7 61 in·lb (for transmission room oil sump) 15 1.5 11 Output Shaft B earing Retaining Screw 6.4 0.65 56 in·lb L Drive [...]

PERIODIC MAINTENANCE 2-7 T o rque and Locking Agent T orque Fastener N·m kgf·m ft ·lb Remarks Pus h Rod Nut 28 2.85 20.6 Swingarm Pivot Shaft Nut 98 10 72 Rear Shock Absorber M ounting Nuts: (Upper) 39 4.0 29 (Lower) 34 3.5 25 Air Bl eed Bolt 6.4 0.65 56 in·lb T i e-Rod Mounting Nut (Front, Rear) 83 8.5 61 Rocker Arm Pi vot Nut 83 8.5 61 Steeri[...]

2-8 PERIODIC M AINTENANCE Specifications Item Standard Servic e Lim it Fuel System: Throttle grip free play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) --- Hot start lever free play 0.5 ∼ 1.0 mm (0.02 ∼ 0.04 in.) --- Air cleaner element oil High quality foam air filter oil --- Cooling System: Coolant: T ype (recommended) Permanent type antifreeze Color Gree[...]

PERIODIC MAINTENANCE 2-9 Specifications Item Standard Service Limit Wheels/T ires: Rim Runout: Axial Under 1.0 mm (0.039 in.) 2 mm ( 0.08 in .) Radial Under 1.0 m m (0.039 in.) 2 mm (0.08 in.) Front and rear tires air pressure 100 kPa (1.0 kgf/cm², 14 psi) Standard tire: Front: Siz e 80/100-21 51M -- - Make BRIDESTONE Ty p e M601, T ube (EU) M201,[...]

2-10 PERIODIC MA INTENANCE Special T ools V alve Spring Co mpressor Assemb ly : 57001–241 Steerin g Stem Nut Wrenc h : 57001–1 1 00 V alve Spring Compressor Adapter , 20 : 57001–1 1 54 Jack : 57001–123 8 Spark P lug Wrench, M16 : 57001–126 2 Fork Oil Level Gauge : 57001–1 290 Pilo t Scre w Adjuste r , C : 57001–1 292 Pilot Screw Ad ju[...]

PERIODIC MAINTENANCE 2-1 1 Periodic Ma intenance Procedures Fuel System Fuel H ose and Con nect ion Inspe ction ○ The fuel hoses are designed to be used throughout the motorcycle’ s l ife w ithout any maintenance, however , if the motorcycle is not properly handled, the inside t he fuel li ne can cause fuel to leak [A] or the hose to burst. •[...]

2-12 PERIODIC MA INTENANCE Periodic M aintenance Pro cedures If the thrott le grip free play cannot be adjusted with the adjusters at the upper end of the throttle cables, use the cable adjusters [A] at the carburetor . • Make the necessary fr ee play adjustment at t he lower ca- ble adjusters, tighten the locknuts [B]. If the thrott le grip free[...]

PERIODIC M AINTENANC E 2-13 Periodic Ma intenance Procedures • Check th e idle speed, using the engine revolution tester [A] for high accuracy . If the idle speed is out of specified range, adjust it. Idle Spee d: Standard: 2 000 ± 50 r/min (rpm) Idle Speed Adjustment • First, tur n i n the air screw [A] using the pilot screw ad- juster [A], u[...]

2-14 PERIODIC MA INTENANCE Periodic M aintenance Pro cedures • Remove: Seat (see Frame chapter) Win g Bolt [A] Air Cleaner E lement [B] • Stuf f a clean, lint-free towel into the carburetor so no dirt is allowed to enter the c arburetor . • Wipe out the inside of the air c leaner housing wi th a clean damp towel. CAUTION Check inside of the i[...]

PERIODIC M AINTENANC E 2-15 Periodic Ma intenance Procedures • Apply grease to all con nections and screw holes i n the air cleaner housing and intake tract. • Install the element onto its frame, and coat the element lip and lip seat w ith a thick layer of all-purpose grease to assure a compete seal. • Install the air cleaner element so that [...]

2-16 PERIODIC MA INTENANCE Periodic M aintenance Pro cedures • Check the coolant level. The coolant level [A] should be at the bot tom of the filler neck [B]. If the coolant level is low , add coolant through the fi ller opening to the bottom of the filler neck. Install the cap. Recommended coolant: Pe rmanen t type of antifre eze (sof t water an[...]

PERIODIC M AINTENANC E 2-17 Periodic Ma intenance Procedures Engine T op End V alve C learan ce Ins pectio n NOTE ○ V alve clearance must be checked and adjusted when the engine is cold (at room temperature) . • Remo ve: Cylinder Head Cover (see Engine T op End chapter) T iming Inspection Cap [A] Flywheel C ap [B] • Fist, bring the piston to [...]

2-18 PERIODIC MA INTENANCE Periodic M aintenance Pro cedures NOT E ○ Mark and recor d t he l ocations of the valve lifters and shims so that they can be reinstal led in their original positions. • Clean the shim to remove any dust or oil. • Measure the thickness of t he removed shim [A]. • Select a new shim thickness calculation as follows.[...]

PERIODIC M AINTENANC E 2-19 Periodic Ma intenance Procedures CAUTION 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 sm aller , and remeasure the valve clearance. • When i nstalling t he shim[...]

2-20 PERIODIC MA INTENANCE Periodic M aintenance Pro cedures Cylinder W ear Inspection NOT E ○ Measure the cylinder insi de diameter when the cylinder is cold (room or ambient temperature). • V isually Inspe ct the insi de of the cylinder for scratches and abnormal wear . If the cylinder is damaged or badly worn, replace it with a new one. • [...]

PERIODIC M AINTENANC E 2-21 Periodic Ma intenance Procedures Exhaust System • The exhaust system, in particular the silencer , is designed to reduce exhaust noi se and conduct the exhaust gases away from the rider while minimizi ng power loss. If car- bon has built up inside the silencer , exhaust efficienc y is reduced, causing engine performanc[...]

2-22 PERIODIC MA INTENANCE Periodic M aintenance Pro cedures • Apply silicone sealant to the circumference [A] of the si - lencer pi pe. • Install the m uffler (see Engine T op End chapter). Engine Right S ide W ARNING T o avoid a serious burn, never touch the hot engine or exhaust chamber during clutch adjustment. Clutch Adjustment Clutch Leve[...]

PERIODIC M AINTENANC E 2-23 Periodic Ma intenance Procedures • Slide the adjuster cover [A] back. • If it cannot be done, loosen the l ocknut [B] at the middle of the clutch cable, and turn the adjusting nut [C] so that clutch lever has 2 ∼ 3 mm (0.08 ∼ 0.12 in.) of play . • After the adjustment is made, tighten the locknut, and start the[...]

2-24 PERIODIC MA INTENANCE Periodic M aintenance Pro cedures • Remove the engine oil drain plugs on the bottom of the engine, and let the oil drain completely . Drain Plug (for crank room oil sump) [A] Drain Plug (for transmission oil sump) [B] NOT E ○ Hold the motorcycle upright so that the oil may dr ain completely . • Replace the gaskets a[...]

PERIODIC M AINTENANC E 2-25 Periodic Ma intenance Procedures • Using t he pry point [A], remove the water pump c over [B]. • Re move the oil filter [A]. • Replace the oil filter with a new one. • Apply grease to the grommet. • Be sure to install the filter with t he grommet [A] facing inside as shown. CAUTION Inside–out installation sto[...]

2-26 PERIODIC MA INTENANCE Periodic M aintenance Pro cedures Oil S creen Cleanin g • Split the crankcase (see Crankshaft/T ransmission chap- ter). • Remove the oil sc reen [A]. • Clean the oil scr eens with a high-flash point solvent and remove any par ticles stuck to them. W ARNING Clean the screen in a well-ventilat ed area, and take care t[...]

PERIODIC M AINTENANC E 2-27 Periodic Ma intenance Procedures Connecting Rod Big End Side C learance • Measure the connecting rod big end side clearance [A]. Connecting Rod Big End Side Cle arance Standard: 0.25 ∼ 0.35 mm ( 0.0 098 ∼ 0.0 138 in. ) Service Limit: 0.55 mm ( 0.0217 in.) If the cl earance exceeds the service limit, replace the cra[...]

2-28 PERIODIC MA INTENANCE Periodic M aintenance Pro cedures • 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 misalign- ment. CAUTION Do not hamm er the crank half at the point [B]. If flywheel misalignment cannot be corrected by the [...]

PERIODIC M AINTENANC E 2-29 Periodic Ma intenance Procedures Tire s In spe ction As the ti re tread wear s down, the tire becomes more sus- ceptible the puncture and failure. • Remove any imbedded stones or other foreign particles from t he trea d. • Visual ly inspect the tire for cracks and cuts, replaci ng the tire in case of bad damage. Swel[...]

2-30 PERIODIC MA INTENANCE Periodic M aintenance Pro cedures Rim Runout Insp ection • Place the jack under the frame so that the front/rear wheel off the ground. Specia l T o ol - Jack : 57001– 1238 • Inspect the rim for small cracks, dents, bending, or warp- ing. If there is any damage to the rim, it must be replaced. • Set a dial gauge ag[...]

PERIODIC M AINTENANC E 2-31 Periodic Ma intenance Procedures Final Drive Drive C hain Wear Inspection • Rotate the rear w heel to inspect the drive chain for dam- aged rollers , and loose pins and links. If there is any irregularity , replace t he drive chain. Lubricate the drive chain if it appears dry . [A] Bus hin g [D] Pin Link [B] Roller [E][...]

2-32 PERIODIC MA INTENANCE Periodic M aintenance Pro cedures • 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 lubrica tion. • Apply oil to the sides of the rollers so that oil will penetrate to the rollers and bushings. • Wipe off any[...]

PERIODIC M AINTENANC E 2-33 Periodic Ma intenance Procedures Brakes Brak e Lever and P edal Adju stme nt W A RNING Always maintain proper brake adjustment. If ad- justment is improper , the brake could drag and overheat. This could dam age the brake assembly and possibly lock the wheel resulting in l oss of control. • Adjust the front brake lever[...]

2-34 PERIODIC MA INTENANCE Periodic M aintenance Pro cedures Brake Flu id Level Inspection • Check the brake fl uid level in t he front or rear brake reser- voir [A ]. NOT E ○ Hold the reservoir horizon tal when checking brake fluid level . • The front or rear reservoir m ust be kept above the lower level lin e [B]. ○ If the fluid level in [...]

PERIODIC M AINTENANC E 2-35 Periodic Ma intenance Procedures Brake Flu id Change In accordance with the Periodic Maint enance Chart, change the brake fluid. The br ake f luid should also be changed if it becom es contaminated with dirt or water . Furthermore, the brake fluid should be changed to bleed the air quickly and completely w henever the br[...]

2-36 PERIODIC MA INTENANCE Periodic M aintenance Pro cedures NOT E ○ The procedure to change the front brake fluid. Chang- ing the rear brake fluid is the same as for the f ront brake. • Level the brak e fluid reservoir . • Remove the sc rew [A], r eservoir cap [B] and diaphragm [C]. • Remove the rubber cap [A] on the bleed valve [B]. • A[...]

PERIODIC M AINTENANC E 2-37 Periodic Ma intenance Procedures • Remove the clear plastic hose. • T ighten the bleed valves, and install the rubber caps. T o rque - Caliper Blee d V alve: 7. 8 N·m (0.8 kgf·m, 69 in·lb) Brake Rese rvoir Cap Scr ews: 1.5 N·m (0.1 5 kgf ·m, 13 in·lb) • After c hanging the fluid, check the brake for good brak[...]

2-38 PERIODIC MA INTENANCE Periodic M aintenance Pro cedures Brake Mas ter Cylinde r C up and Dust Seal Replace ment • Remove the front master cylinder (see Brake 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 [...]

PERIODIC M AINTENANC E 2-39 Periodic Ma intenance Procedures • Apply brake fluid to the removed parts and to the inner wall of the cylinder . • T ake care not t o scratch the piston or the inner wall of the cylinder . • Apply s ilicone grease (ex. PBC grease). Brake Lever Pivot Bolt Brake Lever Pivot Cont act Push Rod Contact (Rear) Dust Cove[...]

2-40 PERIODIC MA INTENANCE Periodic M aintenance Pro cedures ○ Pull out the pi ston [A] by hand. • Remove the dust seals [B] and fluid seals [C]. NOT E ○ If compressed air is not available, do as foll ows for both calipers coinci dentally , with the brake hose con nected to t he caliper . ○ Prepare a container for brake fluid, and perform t[...]

PERIODIC M AINTENANC E 2-41 Periodic Ma intenance Procedures • 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 brak[...]

2-42 PERIODIC MA INTENANCE Periodic M aintenance Pro cedures • Replace the shaft rubber friction boot [A] and dust boot [B] if t hey 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). • Install the pads (see Brakes[...]

PERIODIC M AINTENANC E 2-43 Periodic Ma intenance Procedures • Remove each banjo bolts [A] and washers [B]. • Replace t he w ashers with new ones. For Front Brake • Remo ve Bolts [A] B r a k eH o s eC l a m p s[ B ] For Rear Brake • Remo ve: Master Cyl inder [A] Hose Clamps [B] Caliper Cover [C] • When installi ng the hoses, avoid sharp b[...]

2-44 PERIODIC MA INTENANCE Periodic M aintenance Pro cedures Suspension Front For k Inspectio n • Holding the brake lever , pump the front fork back and forth manually to check for smooth operation. • V isually inspect t he front fork for oil leakage, scoring or scratches on the outer surface of the inner tube [A]. If necessary , repair any dam[...]

PERIODIC M AINTENANC E 2-45 Periodic Ma intenance Procedures • Use wrenches [A] on the rod nut [B] and t he top plug [C] to loosen the t op plug. • Remove the top plug from the push rod. • Lift t he fork spring [D] and its top spring seat [E] out of the outer tube. • T ake the rebound damping adjuster rod [A] out of the push rod. • Hold t[...]

2-46 PERIODIC MA INTENANCE Periodic M aintenance Pro cedures • Purge the air from the fork cylinder by gently moving the piston rod [A] up and down ten times. • Purge the air from between the inner and out er tubes by pumping the outer tube [A] up and down. • After purging the air from the assembly , let it sit for about five minutes so that [...]

PERIODIC M AINTENANC E 2-47 Periodic Ma intenance Procedures W A RNING Do not to point the reservoir valve toward your face or body when releasing nitrogen gas pressure. An oil m ist is often released with the nitrogen. Always release nitrogen gas pressure before disassem- bling the rear shock absorber to prevent explosive separation of part s. •[...]

2-48 PERIODIC MA INTENANCE Periodic M aintenance Pro cedures • Slide the stop up the top of the piston r od then lightly tap around the seal with a suitable rod and mallet, and push the seal assembly 10 mm (0.39 in.) down. • Remov e t he circlip [A]. • Lightly move the piston rod back and forth, and pull out t h ep i s t o nr o d a s s e m b [...]

PERIODIC M AINTENANC E 2-49 Periodic Ma intenance Procedures • Push the bladder into the gas reservoir slowly until it just clears t he circli p groove. Wipe out any spilled oil. CAUTION Ensure that no air remains in the system. • Check the circlip for w eakening, deformity and flaws. If necessary , replace it with a new one. CAUTION If w eaken[...]

2-50 PERIODIC MA INTENANCE Periodic M aintenance Pro cedures • Pour KYB K2-C (S AE 5W or Bel-Ray S E2 #40) oil i nto the rear shock body to 55 m m (1.77 in.) [A] from the lower end of the rear shock body [B]. • Insert the piston end [A] of t he piston rod assembly into the rear shock body [C] slowly . Do not insert the seal assembly [B] yet. Pu[...]

PERIODIC M AINTENANC E 2-51 Periodic Ma intenance Procedures • Install the suitable oil cup [A] to the air bleeder bolt hole, and fill the specifie d oil into th e cup . • Purge the air f rom between the gas reservoi r [B] and rear shock body [C] by slowly pumping the push rod [D] i n and out. • Install the air bleeder bolt securely . T or qu[...]

2-52 PERIODIC MA INTENANCE Periodic M aintenance Pro cedures Steering Steerin g Inspection • Using the jack, raise the front wheel off the ground. Specia l T o ol - Jack : 57 001–12 38 • With the front wheel pointing straight ahead, alternately nudge each end of the handlebar . The front wheel should swing f ully left and right from the force[...]

PERIODIC M AINTENANC E 2-53 Periodic Ma intenance Procedures • Loosen the front fork upper clamp bolts [A], and remove the steering stem head nut [B] and steering stem head [C]. • T urn the steering stem locknut [A] with the steering stem nut wrench [ B] to obtain the proper adjustment. If the steering is t oo tight, loosen the stem locknut a f[...]

2-54 PERIODIC MA INTENANCE Periodic M aintenance Pro cedures • Install the handlebar clamp [A] so that the cut side [B] on the clamp points at the front. • T ighten the handlebar clamp bolts [C]. T o rque - Handlebar Clamp Bo lts: 25 N·m ( 2.5 kgf ·m, 18 ft·lb) ○ T ighten the clamp bolts, rear first and then the front. If the handlebar cla[...]

PERIODIC M AINTENANC E 2-55 Periodic Ma intenance Procedures • Remove the spark plug [A], using the spark plug wrench [B]. Spec ial T ool - S park Plug Wrench : 5 7001–1 262 Owner ’ s T ool - Spark Plug Wrenc h, 16 mm: 921 10–0002 • Clean the spark plug, prefer ably in a sandblasting device, and then clean off any abrasive particles. The [...]

2-56 PERIODIC MA INTENANCE Periodic M aintenance Pro cedures Points: Lubricate with Grease. Clutch Inner Cable Upper and Lower Ends [A] Hot Start Inner Cable Upper End Throttle Inner Cable Upper End Cables: Lubricate with R ust Inhibitor . Throttle Cables Clutch Cable Hot Start Cable • With the cable disconnected at the both ends, the c able shou[...]

PERIODIC M AINTENANC E 2-57 Periodic Ma intenance Procedures Nut, Bolt , and Fast ener T ightness Insp ection Tigh tnes s I nspe ction • Check the tightness of the bolt s and nuts listed here in accordance with the Periodic Maintenanc e Chart. Also, check to see that each cotter pin is i n place and in good condition. NOTE ○ For the engine fast[...]

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FUEL SYSTEM 3-1 3 Fuel System T abl e o f Content s Exploded View ..... ........... ................ ........... .............. ............. .............. ............. ............ ...... ..... 3 -2 Spec ifica tion s . ...... ....... .... ...... .... ...... ....... .... ...... ...... .... ...... ..... ...... ...... .... ...... ..... ...... .....[...]

3-2 FUEL SYSTEM Exploded View[...]

FUEL SYSTEM 3-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Throttle pulley cover bolt 3.4 0.3 30 in·lb 2 Throttle cable locknut 7.0 0.7 61 in·lb 3 H ot start plunger cap bolt 1.0 0.1 10 in·l b 4. Throttle Cables 5. Th rottle Grip 6. Carburetor Cap 7. Th rott le V alv e Plat e 8. Throttle V alve 9. Jet Needle 10. Throttle P u[...]

3-4 FUEL SYSTEM Exploded View[...]

FUEL SYSTEM 3-5 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 R ear frame mounting bolts 34 3.5 25 2 A ir cleaner duct clamp screw 2.0 0.2 17 in·lb 3 Fuel tap plate mounting screws 0.8 0.08 7i n · l b 4. Fuel T ank Cap 5. Fuel T ank 6. Fuel T ap 7. Element 8. Frame 9. Holder 10. Air Cle aner Duct 1 1. Air Cleaner Housing 12. Rea[...]

3-6 FUEL SYSTEM Specifications Standard Item KX250-N1 Service Limit Carburetor: Make/T ype KEIHI N FCR37 --- Starter Jet #68 --- Leak Jet #60 --- Main jet #178 --- Throttle valve cutaway #1.5 --- Jet needle OBEKS --- Jet needle cl ip position 3r d groove from the top --- Slow jet #40 --- Slow Ai r Jet #100 --- Pilot Air Screw (turns out) 21 / 4 ---[...]

FUEL SYSTEM 3-7 Special T ool s Fuel Level Gauge, M18 × 1.0 : 57001-1 22[...]

3-8 FUEL SYSTEM Throttle Gr ip a nd Cable If the throt tle grip has excessi ve free pl ay due to cable stretch or misadjustment, there will be a delay in throttl e re- sponse. Also, the throttl e valve may not open fully at full throttle. On the other hand, if the thrott le grip has no play , the throttle will be hard to control, and the idle speed[...]

FUEL SYSTEM 3-9 Throttle Grip and Cable • Remove the rear frame assy (see Frame chapter). • Remove t he carburetor and move it to the right side of the frame. • Unscrew the bolt [A]. • Remove the throttle pulley cover [B]. • Loosen the locknuts [A]. • Remove the cables [B] from the carburetor . • Free the tips [C] from the pulley . ?[...]

3-10 FUEL SYSTEM Throttle Gr ip a nd Cable Hot Start C able Removal • Remove: Dust Cover [A] (Slide out) Locknut [B] (Loosen) • T urn in the adjuster [C] full y . • Remove the cable end [D] from the hot start lever [E]. • Remove: Carburetor (Inlet side out ) • Unscrew the plunger cap bolt [A] and remove the cable end. • Cut t he band [B[...]

FUEL SYSTEM 3-1 1 Throttle Grip and Cable Hot Start Lever Free Play Inspection • Refer to the H ot Start Lever Free Play Inspectio n in Peri- odic M aintenance Hot Start Lever Free Play Adjustment • Refer to the H ot Start Lever Free Play Inspectio n in Peri- odic M aintenance Hot Star t Cabl e Lubri cat ion • Whenever the hot start cable is [...]

3-12 FUEL SYSTEM Carburetor Since the carburetor regulates and mixes the fuel and air going to the engine, there are two general t ypes of carbure- tor trouble: too rich a mixture (too much fuel), and too lean a m ixture (too little fuel). Such trouble can be caused by dirt, wear , maladjustment, or improper fuel level in the float chamber . A dirt[...]

FUEL SYSTEM 3-13 Carburetor • Hold the gauge vertical ly against the side of the carbure- tor body s o that the "zero" line [C] is several m illimeters higher than the bottom edge [D] of the carburetor body . • T urn the fuel tap to the ON position t o feed fuel to the carburetor . • W ait until the fuel level in the gauge settles. [...]

3-14 FUEL SYSTEM Carburetor • Bend the tang [A] on t he float arm very slightly to change the float height . Increasing the float height l owers the fuel level and decreasing the float height raises the fuel level. Float Height Standa rd: 8 ± 1 mm (0.315 ± 0.039 in. ) NOT E ○ Float height [A] i s the distance from the float bowl mat- ing surf[...]

FUEL SYSTEM 3-15 Carburetor • Disconnect the throttle sensor connector [A]. • Loosen the clamp screws [A], and remove the carburetor from the carburet or holder [B] and then pull it out of the end of t he air cleaner duct [ C]. If necessary , do the followin g procedure. • Remo ve: Seat Side Covers Silencer Rear Frame Bolt [A] • Pull out th[...]

3-16 FUEL SYSTEM Carburetor • Loosen the locknut [A]. • Pull out the end of the throttle cables [B]. • Free the tips [ C]. • Remove the carburetor 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, lin[...]

FUEL SYSTEM 3-17 Carburetor • Route the air vent and overflow hoses properly (see Ap- pendix chapter). CAUTION 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. ○ T urn the fuel tap [...]

3-18 FUEL SYSTEM Carburetor • Unscrew the scr ew [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]. • Disassemble the throttle valve assembly; jet needle holder [A] (unscrew), sprin[...]

FUEL SYSTEM 3-19 Carburetor • Remove the t hrottle pulley shaft [ A] wit h the spr ing [B], steel washer [ C], plasti c washer [D] and throttle val ve link [E]. ○ T urn the throttle pulley shaft [A] clockwise while holding down the accelerat ion pump lever [B] and clear the idle stop screw [C] t o the stopper [D ] of the pulley . • T urn in t[...]

3-20 FUEL SYSTEM Carburetor • Remove the following parts from the carburetor body . [A] Idle Adjusting S crew [B] Screws [C] Clamps [D] Float Bowl [E] Leak Jet [F] O-r ing [G] Pi n [H] Float [I] M ain Jet [J] Needle Jet [K] Sta rter Jet [L] Pilot Jet [ M ]P i l o tA i rJ e t [N] Stopper Screw [O] Fuel Hose Fitting [P] O-r ings • Pull out the pu[...]

FUEL SYSTEM 3-21 Carburetor • Remove the throttle sensor mounting bolt [A]. • Before removing the throttle sensor [B], mark [C] the car- buretor body and sensor so that it can be installed later in the s ame posit ion. Carb ureto r Cl eaning W A RNING Clean the carburetor in a well-ventilated area, and take care that there i s no spark or flame[...]

3-22 FUEL SYSTEM Carburetor Carbur etor Inspection W ARNING Gasoline is ext remely flammable and can be ex- plosive under certai n 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 carburet or . • Be[...]

FUEL SYSTEM 3-23 Carburetor • Re move the start er jet. • Check the slow jet for any damage. If the slow jet is damaged, replace it with a new one. • Remove the thrott le 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 [...]

3-24 FUEL SYSTEM Carburetor • Install the accel eration pump lever assembly to the car- buretor body . ○ Fit the end [B] of the return s pring into the r ecess [A] on the carburetor body . • Inst all: W asher [A] E-c lip [B] • Apply thin coat silicone grease to the shaft. • Fit the hook [A] of the return spri ng onto the stopper [B] of th[...]

FUEL SYSTEM 3-25 Carburetor • T urn the pulley c ounterclockwise [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 r od [A] into the push rod holder [B]. • Apply a grease to the O-ri ng [A]. • Fit the stopper [B] of the throttle sensor ont[...]

3-26 FUEL SYSTEM Carburetor • Inst all: O-ri ng [A ] Carburetor Cap [B] Bolts ( tighten) • Inst all: Starter Jet [A] Pilot Jet [ B] Baffle Plate [C] Needle Jet [D] Mai n Jet [E ] • Replace t he O- ring with new one. • Inst all: Pilot Air Screw [A] Spring [B] W asher [C] O-ri ng [D ] ○ T urn in the pilot air screw fully but not tightly , a[...]

FUEL SYSTEM 3-27 Carburetor • Install: Float Bowl • T ighten the bolts with hose clamps [A] and cable holder [B] as shown. • Replace t he O-r ings with new ones. • Fit the O-rings [A]. • Install: Diaphragm [B] Spring [C] Accelerati on Pum p Cover ○ Install the diaphragm so that its mark facing [D] outward. • T ighten the bolts. • In[...]

3-28 FUEL SYSTEM Carburetor • If turn the adjusting screw of the acceleration pump, follow the procedure 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 V alve Height – 1.25 mm (0.0492 in.) ○ T urn in the adjusting s[...]

FUEL SYSTEM 3-29 Air Cleaner Air Cleaner Housi ng Removal • Remo ve: Side Covers (see Frame chapter) Seat (see Frame chapter) Silencer (see Engine T op End chapter) Bolts and Rear Fender [A] (see Frame chapter) Screws and Rear Flap [B] (see Frame chapter) Rear Frame Bolts [C] • Loosen the air cleaner duct clamp [D]. • Remove the rear frame. ?[...]

3-30 FUEL SYSTEM Air Cleaner • Install the element so that its tab [A] faces upward and fit the element projections [B] t o the holes of the housing [ C]. • T ighten the wing bolt [D]. • Install the seat (see Frame chapter). Element Cleani ng and Inspect ion • Refer to the Air Cleaner El ement Cleaning an d Inspection in Periodic Maintenanc[...]

FUEL SYSTEM 3-31 Fuel T ank Fuel T ank Removal W A RNING Gasoline is extremely flammable and can be ex- plosive under certain conditions. Always stop the engine and do not smoke. M ake sure the area is well-ventilat ed and free from any source of flame or sparks; this includes any appliance with a pilot light. • Remo ve: Seat (see Frame chapter) [...]

3-32 FUEL SYSTEM Fuel T ank Fuel T ap Removal • Remove the fuel tank and drain it. • Remove the mount ing bolts [A] and take out the fuel tap [B]. Fuel T ap Installa tion • Be sure the O-ring is in good condition to prevent leaks. • Be sure to clamp the fuel hose to the t ap to prevent leaks. Fuel T ank and T ap Cleaning W ARNING Clean the [...]

COOLING SYSTEM 4-1 4 Cooling System T abl e o f Content s Exploded View ..... ........... ................ ........... .............. ............. .............. ............. ............ ...... ..... 4 -2 Spec ifica tion s . ...... ....... .... ...... .... ...... ....... .... ...... ...... .... ...... ..... ...... ...... .... ...... ..... ......[...]

4-2 COO LING SYSTEM Exploded View[...]

COOLING SYSTEM 4- 3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 W ater pump cover bolts 9.8 1.0 87 in·lb L( 1 ) 2 W ater pump cover bolts (with washer) 7.0 0.7 61 in·lb L( 1 ) 3 Coolant drain plug 7.0 0.7 61 in ·lb 4 W ater pump impeller bolt 7.0 0.7 61 in·lb 5 Right engine cover bolts 9.8 1.0 87 in·lb 6 Cooling hose clamp [...]

4-4 COO LING SYSTEM Specifications Item Service Limit Coolant Ty p e Permanent type antifreeze for aluminum engines and radiators Color Green Mixed ratio Soft water 50%, antifr eeze 50% Freezing point -35°C (-31°F) T otal amount 1 . 2L( 1 . 2 7U Sq t . ) Radiator Cap relief pressure 93 ∼ 123 kPa (0.95 ∼ 1.25 kgf/cm², 13 ∼ 18 psi)[...]

COOLING SYSTEM 4-5 Special T oo l Bearing Dri ver S et : 57001–1129[...]

4-6 COO LING SYSTEM Coolant Check the coolant level each day before riding the motor- cycle, and replenish coolant if the level is low . Change the coolant i n accordance with the Periodic Maintenance Char t (see Periodic Maintenance chapter). W ARNING T o avoid burns, do not remove the radiator cap or try to inspect the coolant level or change t h[...]

COOLING SYSTEM 4- 7 Coolant Coolan t Filling CAUTION Use coolant contai ning corrosion inhibitors made specifically for aluminum engi nes and radiator s in accordance w ith the i nstruction of the manufac- tur e’ s. So ft o r dis til led w ater mu st be use d w ith the antifreeze (see below for antifreeze) i n the cooling system. If hard water is[...]

4-8 COO LING SYSTEM Coolant Cooling System Pressure T e sting CAUTION During pressure testing, do not exceed the pres- sure for which the system is designed to work. The maximum pressure is 123 kPa (1.25 kgf/cm², 18 psi). • Remove the radiator cap, and install a cooling system pressure tester [A] and adapt er [B] on the radiator filler neck [C].[...]

COOLING SYSTEM 4- 9 W ater Pump Water P ump C ove r Remo val • Drain the engine oil from the oil filter oil chamber . ○ Unscrew the dr ain plug [ A] • Drain the coolant (see Coolant Draining). ○ Unscrew the dr ain bolt [ B]. • Unscrew the water pi pe bolt [A], and disconnec t the water pipe [B]. • Unscrew the cover bolts [C]. • Using [...]

4-10 C OOLING SYSTEM Wa t e r P u m p • Fill the cooling system (see Coolant Filling). • Bleed the air from the cooling system. • Check the engine oil level and add the engine oil. Impe ller Rem oval • Drain: Coolant (see Coolant Draining) Engine Oil (see above) W ater Pump Cover • Remove the impeller bolt [A] and take out the impeller [B[...]

COOLING SYSTEM 4-1 1 W ater Pump Water Pump Gear Removal • Remo ve: W ater Pump Cover (see this chapter) Impeller (see this chapter) Right Engine Cover (see Engine R ight Side chapter) • Pull out the water pump shaft [A] toward inside of the right engine cover . W a t e rP u m pG e a rI n s t a l l a t i o n • T o prevent the oil seal lips fr[...]

4-12 C OOLING SYSTEM Wa t e r P u m p • Apply plenty of high t emperature grease to the oi l seal lips. • Press in the oil seals direction as shown. ○ Press in the new oil seal using a press and suitable t ools so that t he seal surface is flush with the surface of the right engine cover . Flat S ide [A] W ater Pump Oi l Seal s [B] Crankshaft[...]

COOLING SYSTE M 4-13 Radiator Radiator R emoval • Drain the coolant ( see Coolant Draining) • Drain the engine oil from the oil filter oil chamber (see W ater Pump Removal) • Remo ve: Radiator Shrouds (see Fuel System chapter) Fuel T ank (see Fuel System chapter) • Loosen: Clamp S crews [A] • Remo ve: Radiator Hoses [B] Bolts [C] Right Ra[...]

4-14 C OOLING SYSTEM Radiator • Remove: Bol ts w ith Clam ps [A] Left Radiator with Hoses [ B] Radiato r Installation • H o l dt h ec l u t c hc a b l ew i t hc l a m p s . • Fit the projections [A] of the screen in the holes [B] of t he radiator . T orque - Radiator Hose Clamp Screws: 1.5 N·m (0.15 kgf·m , 13 in·lb) Radiator Mounting Bolt[...]

COOLING SYSTE M 4-15 Radiator Radiator Cap Inspe ction • Check t he 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, repl ace the cap. • Wet the top and bottom valve seals with water or coolant to prevent pressure leaks. • Install the cap [A] on a cooli ng [...]

[...]

ENGINE T OP END 5-1 5 Engine T op End T abl e o f Content s Exploded View ..... ........... ................ ... 5-2 Spec ifica tion s . ...... ....... .... ...... ...... .... .. 5-6 Spec ial T o ols & Seal ants . ...... ...... .... .. 5-9 Cylinder Head Cover ............ ............ . 5-1 1 Cylinder Head Cover Removal .... 5-1 1 Cylinder Head[...]

5-2 E NGINE TOP END Exploded View[...]

ENGINE T OP END 5-3 Exploded View T orque No. Fastener N·m kgf ·m ft·lb Remarks 1 Auto decompressor bolt 12 1.2 104 in·lb 2 Cylinder head cover bolts 9.8 1.0 87 in·lb 3 Cylinder head bolts M6 12 1.2 104 in·l b S 4 Camshaft cap bolts 12 1.2 104 in·lb S 5 Carburetor holder clamp screws 2.0 0.2 17 in·lb 6 Plug 20 2.0 14 L 7 Lower camshaft chai[...]

5-4 E NGINE TOP END Exploded View[...]

ENGINE T OP END 5-5 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Chain t ensioner mounting bolts 9.8 1.0 87 in· lb 2 Chain tensioner cap 20 2.0 14.5 3 Cylinder head bolts M6 12 1.2 104 in·lb S 4 Cylinder bolt M6 12 1.2 104 in·lb S 5 Exhaust pipe cover screws 12 1.2 104 in·lb 6 Exhaust pipe holder nuts 21 2.1 15 S 7 Muffler mo[...]

5-6 E NGINE TOP END Specifications Item Standard Servi ce Lim it Camshafts: Cam H eight: Exhaust 33.941 ∼ 34 .057 mm 33.84 m m (1.3363 ∼ 1.3408 in.) (1.3322 in.) Inlet 34.642 ∼ 34.758 mm 34.54 mm (1.3639 ∼ 1.3684 in.) (1.3598 in.) Camshaft Journal Clearance 0.020 ∼ 0.062 mm 0.15 mm (0.0008 ∼ 0.0024 in.) (0.0059 in.) Camshaft Journal D i[...]

ENGINE T OP END 5-7 Specifications Item Standard Servi ce Limit V alve Seat Surface Outside Diameter: Exhaust 24.62 ∼ 24.82 m m --- (0.9693 ∼ 0.9772 in.) Inlet 30.62 ∼ 30.82 mm --- (1.2055 ∼ 1.2134 in.) V alve Seat Surface Width: Exhaust 0.5 ∼ 1.0 mm --- (0.0197 ∼ 0.0394 in.) Inlet 0.5 ∼ 1.0 mm --- (0.0197 ∼ 0.0394 in.) V alve Sprin[...]

5-8 E NGINE TOP END Specifications Cam Height Cam Hei ght [A] Camshaft Runout V alve S tem Diame ter V alv e S tem Diame ter [ A] 45° [B] Va l v e S t e m B e n d Dial Gauge [A][...]

ENGINE T OP END 5-9 Special T ools & Sealan ts Compression Gauge, 20 kgf/cm² : 57001–22 1 V alve Spring Compressor As sembly : 57001–24 1 Piston Ring Compressor Grip : 57001–10 95 Piston Ring Compressor Belt, 67 ∼ 79 : 57001–10 97 Va l v e S e a t C u t t e r, 4 5 ° – 27.5 : 57001–11 14 V alve S eat Cutte r , 32° – 28 : 57001[...]

5-10 ENGINE TOP END Special T ools & Sealants V alve S eat Cutte r , 45° – 35 : 57001–1 116 V alve S eat Cutte r , 60° – 28 : 57001–132 8 Spark Plug Wrench, Hex 16 : 57001–126 2 Compression Gaug e Adapt er , M 10 × 1.0 : 57001–131 7 V alve Seat Cutter Holder , 4.5 : 57001–133 0 V alve Guide A rbor , 4.5 : 57001–1 331 V alve G[...]

ENGI NE TOP END 5 -1 1 Cylinder Head Cover Cylinder Head Cover Remova l • Remo ve: Fuel T ank (see Fuel System chapter) Spark Plug Cap [A] • Remove t he cylinder head cover bolts [B] and remove t he cylinder head cover [C]. Cylinder Head Cover Installati on • Apply silicon sealant [A] to the cylinder head as shown. Sealant - Three Bond TB121 [...]

5-12 ENGINE TOP END Camshaft Chain T ensioner Camshaft Ch ain T ensioner Removal CAUTION This is a non-return type camshaft chain tensioner . The push rod does not return to its original position once it moves out to take up camshaft chain slack. Observe all the rules l isted below: When removing the tensioner , do not take out the mounting bolts o[...]

ENGINE T OP END 5-13 Camshaft Camshaft Removal • Remo ve: Cylinder Head Cover (see Cylinder Head Cover Re- moval) T iming Inspection Cap [A] Flywheel C ap [B] • First, bring t he piston to the TDC (of either the compres- sion or exhaust stroke). ○ Place a wrench over the flywheel nut and turn it counter- clockwise to align the TDC mark [A] wi[...]

5-14 ENGINE TOP END Camshaft • Remove: Bolt [A] Auto Decompressor [B] Spring Camshaft Installation • Inst all: Spring [A] Auto Decompressor [B] Bolt [C] T orque - Auto Decompressor Bolt: 12 N·m ( 1.2 kgf·m, 10 4 in·lb) • Apply molybdenum disulfide oil to the ball bearing, all cam and journal surfaces of the cam shaft. • If the camshaft i[...]

ENGINE T OP END 5-15 Camshaft 1st P in [A] Punch Marks (exhaust) [D] 2nd Pin [B] Punch Marks (inlet) [E] 28th Pin [C] Upper Cylinder Head S urface [F] • Be sure to install the positioning rings [A] and dowel pins [B]. • Install t he camshaft caps in their original posit ions by fac- ing their triangle marks [A] face to face as shown in the phot[...]

5-16 ENGINE TOP END Camshaft • Uniformly tighten a ll bolts and after the camshaf t has set- tled, uniformly tighten all the bol ts. ○ Bolts [A] are long. ○ Following the sequence numbers on the camshaft caps, tighten the cap bolts [1 ∼ 4]. T orq ue - Camshaft Cap Bolt s: 12 N·m (1.2 kg f·m, 104 in ·lb) • Install the camshaft chain ten[...]

ENGINE T OP END 5-17 Camshaft Camshaft Chain Removal • Remo ve: Camshaft (see Camshaft Removal) Magneto Flywheel (see Electrical System) Lower Camshaft Chain Guide Bolt [A] Lower Chain Guide [B] • Remove the camshaft chain [C] from the crankshaft sprocket. Camshaft Chain Installati on • Use the (–) driver [A] to bring the lower chain guide [...]

5-18 ENGINE TOP END Cylinder Head Cylinder Compression Measurement • Start the engine. • Thoroughly warm up the engine so that the engine oil be- tween the piston and cylinder wall will help seal compres- sion as it does during normal running. • Stop the engine. • Remove: Fuel T ank (see Fuel System chapter) • Remove the spark plug [A] wi[...]

ENGINE T OP END 5-19 Cylinder Head Cylinder Head Removal • Remo ve: Fuel T ank (see Fuel System chapter) Camshaft Chain T ension er (see Camshaft Chain T en- sioner R emoval) Cylinder Head Cover (see Cylinder Head Cover Re- moval) Camshaft (see Camshaft Removal) Nut [A] Bolt [ B] (loos en) Exhaust Pipe [C] Clamp Screw [D] Radiator Hose [E] • Re[...]

5-20 ENGINE TOP END Cylinder Head • Remove the 10 m m cylinder head bolts [A]. • T ap lightly up with a plastic mallet [A] to separate the cylin- der head [B] f rom the cylinder . • Move back the carburetor [A] and hold it. • Pull the cylinder head upward [B]. ○ Do not damage the r adiator core. ○ Clear the f ront chain guide. • Remov[...]

ENGINE T OP END 5-21 Cylinder Head • Replace all the 10 mm cylinder head bolt w ashers with new ones. ○ The 10 mm cylinder head bolt washers are copper-plated, and they could leak oil if reused. • Apply molybdenum disulfide oil to the following areas. 10 mm Cylinder Head Bolt Was her , both sides [A] • T ighten the 10 mm cylinder head bolts[...]

5-22 ENGINE TOP END Va l v e s V alve Clear ance Inspectio n ○ Refer to the Engine T op End in the Periodic Maintenance chapter . V alve Removal • Remove th e cylinder head (see Cylinder Head Rem oval). • Remove the valve lifter and the shim from the valve. NOT E ○ Use the valve spring compressor assembly and the adapter to press down the v[...]

ENGINE T OP END 5-23 V alves V alve Guide Removal • Remo ve: V alve (see V alve R emoval) Oil Seal Spring Seat • Heat the area around the valve guide up to 120 ∼ 15 0 ° C (248 ∼ 302 °F). CAUTION Do not heat the cylinder head with a t orch. This w ill warp the cylinder head. Soak the cylinder head and heat the oil. • Hammer l ightly on t[...]

5-24 ENGINE TOP END Va l v e s • Ream the valve guide with v alve guide reamer [A], even if the old guide is reused. Specia l T oo l - V alve Guide Reame r , 4.5: 57001–133 3 V alve/V alve Guide Clearance Measurement (Wobble Method ) ○ If a small bore gauge is not available, inspect the valve guide wear by measuring the val ve/valve guide cle[...]

ENGINE T OP END 5-25 V alves V alve Seat Inspection • Remove the v alve (see V alve Removal). • Check the valve seat ing surface [A] between t he valve [B] and valve seat [C]. • Measure the outside diameter [D] of the seating pattern on the valve seat. If the outside di ameter is too l arge or too small, repair t he seat. (see Seat Repair ) V[...]

5-26 ENGINE TOP END Va l v e s Seat Cutter Operation Care: 1. This valve seat cutter is developed to gr ind the vale for repair . Therefore the cutter must not be used for ot her purposes than seat repair . 2. Do not drop or shock the valve seat cutter , or the dia- mond particles may fall off. 3. Do not f ail to apply engine oil to the valve seat [...]

ENGINE T OP END 5-27 V alves • Measure the outside diameter of the seating surface with a vernier caliper . If the outsi de diameter of the seating surface is too small, repeat the 45° grind until the diameter is within the spec- ified range. Original Seating Sur face [B] ○ Remove all pittings of flaws from 45° ground surface. ○ Alter grind[...]

5-28 ENGINE TOP END Va l v e s • The seating are a should be marked about in the middle of the valve face. If the seat area is not in the right pl ace on the valve, check to be sur e the valve is the correc t part. If it i s, it may have been refaced too much; replace it. • When the engine is assembled, be sure to adjust the valve clearance (se[...]

ENGINE T OP END 5-29 V alves V alve Seat Repair[...]

5-30 ENGINE TOP END Cylinder and Pis ton Cylinde r Remov a l • Remove: Cylinder Head (see Cylinder Head Removal) Front C amshaft Chain Guide [A] Cylinder Bolt [B] • T ap lightly up with a plasti c m allet to separate the cyli nder from the crankcase. • Remove the cylinder base gasket. Piston Removal • Remove the cylinder (see this Cylinder [...]

ENGINE T OP END 5-31 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 t o cylin- der clearance (see Piston/Cylinder Clearance), and use new pi ston ri ngs. • Apply engine oil to the inside wall of the small end of the connecting r od. • Face [...]

5-32 ENGINE TOP END Cylinder and Pis ton • Apply engine oil to the cylinder bore. • Determine t he position of the piston ring ends. • Install the cylinder while compressing the piston rings with your fingers or the special tool [A]. Specia l T oo l - Pis ton Ring Co mpressor Grip: 570 01–109 5 Piston Ring Compressor Bel t, 67 to 79 : 57001[...]

ENGINE T OP END 5-33 Cylinder and Piston Piston Ring Thickness • Measure the thickness at several points around ring with am i c r o m e t e r . Piston Ring Thickness (T op) Standard: 0.77 ∼ 0.79 m m (0.0 303 ∼ 0.03 1 1 in.) Service Limit: 0.70 m m (0.0276 in.) If any of the measurements is l ess than the service limit on either of the rings,[...]

5-34 ENGINE TOP END Carburetor Holder Carbur etor Hol der Instal latio n • Install the c arburetor holder [A] with the marked [B] s ide facing toward the cylinder head outside. ○ Install the holder clamp [C] with its screw head [D ] facing left side. T o rque - Carburetor Holder C lamp Sc rew: 2 .0 N·m (0.2 kgf·m, 104 in·lb) • Fit the proj[...]

ENGINE T OP END 5-35 Muffler W A RNING T o avoid a serious burn, do not remove the m uffler when the engine is still hot. W ait until the muffler cools down. Muffler Removal • Loosen the muffler clamp bolt [A]. • Remove the exhaust pip holder nut [B]. • Remove the exhaust pipe [C]. • Remo ve Seat (see Frame chapter) Right Side Cover (see Fr[...]

[...]

ENGINE RIGHT SIDE 6-1 6 Engine Right S ide T abl e o f Content s Exploded View ..... ........... ................ ........... .............. ............. .............. ............. ............ ...... ..... 6-2 Spec ifica tion s . ...... ....... .... ...... .... ...... ....... .... ...... ...... .... ...... ..... ...... ...... .... ...... ..... [...]

6-2 ENGINE RIGHT SIDE Exploded View[...]

ENGINE RIGHT SIDE 6-3 Exploded View T orque No. Fastener N·m kgf·m ft ·lb Remarks 1 Primary gear nut 98 10 72 LH 2 Clutch cover bolts 9.8 1.0 87 in·lb L( 1 ) 3 Clutch cover bolt ( with washer) 7.0 0.7 61 in·lb L 4 Right engine cover bolts 9.8 1.0 87 in·lb 5 Clutch spring bolts 9.8 1.0 87 in·lb 6 Clutch hub nut 98 10 72 7. Primary Gear 8. Pus[...]

6-4 ENGINE RIGHT SIDE Exploded View[...]

ENGINE RIGHT SIDE 6-5 Exploded View T orque No. Fastener N·m kgf·m ft ·lb Remarks 1 Ratchet guide bolt 8.8 0.9 78 in·lb L 2 Kick pedal bolt 25 2.5 18 L 3 Shift pedal bolt 9.8 1.0 87 in·lb 4 Ratchet plate mounting bolt 9.8 1.0 87 in·lb 5 Ratchet plate mounting screw 6.4 0.65 56 in·lb L 6 Gear set lever nut 8.8 0.9 78 in·lb 7 Shift drum cam b[...]

6-6 ENGINE RIGHT SIDE Specifications Item Standard Servi ce L imit Clutch Lever Clutch Lever Free Play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) --- Clutch: Fricti on Plate Thickness 2.72 ∼ 2.88 mm 2.62 mm (0.1031 in.) (0.107 ∼ 0.1 13 i n.) Steel Plate Thickness 1.5 ∼ 1.7 m m 1.4 mm (0.055 in.) (0.059 ∼ 0. 067 in.) Friction Plate War p 0. 15 mm (0.007[...]

ENGINE RIGHT SIDE 6-7 Special T oo l Clutch Hol der : 57001–12 43 Gear Holder : 57001–155 7[...]

6-8 ENGINE RIGHT SIDE Clutch Lever and Cable Due to f riction plate wear and clutch cable stretch over a long period of use, t he clutch must be adjusted i n accor- dance with the Periodic Maintenance Chart. W ARNING T o avoid a serious burn, never touch the hot engine or exhaust chamber during clutch adjustment. Clutch Lever Free Play Inspecti on [...]

ENGI NE RIGH T SIDE 6 -9 Clutch Lever and Cable • Free the cable from the cable holder [A]. • Free the clutch inner cable tip [B] from the clutch release lever [C]. CAUTION Do not remove the clutch release shaft unless it is absolutely necessary . If rem oved, release shaft oil seal must be replaced with a new one. W • Pull the clutch cable o[...]

6-10 ENGINE RIGHT SIDE Clutch Cover and R ight Engine Cover Clutch Cover Removal • Drain the engine oil ( see Periodic M aintenance chapter). • Set the stand attached. • Remove the brake pedal (see Brakes chapter). • Remove the clutch cover bolts [A] and remove the clutch cover [B]. Clutch Cover Installat ion • Apply a non-permanent locki[...]

ENGINE RIGHT SIDE 6-1 1 Clutch Co ver and Right Engine Cov er • When installing the cover doesn’t go well, the cover is installed according to the following procedures. ○ The cover is installed while turning [A] the impeller [B]. • Install: W ater Pum p Cover (see Cooling System chapter) • Apply a non-permanent locking agent to two w ater[...]

6-12 ENGINE RIGHT SIDE Clutch Clutch Removal • Drain the engine oil ( see Periodic M aintenance chapter). • Remove the clutch cover (see Clutch Cover Removal). • Remove the c lutch spring bolts [A], spring, and cl utch pressure plate [B]. • Remove the push rod holder assy [A], friction plates [B] and steel plat es [C]. • Remove steel ball[...]

ENGI NE RIGHT SID E 6-1 3 Clutch • Install the toothed w asher [A]. • T ighten the cl utch hub nut [B]. T orque - Clutch Hub Nut: 98 N·m (10 kgf·m, 72 ft·lb) NOTE ○ Use the clut ch holder [C] to prevent the clu tch hub from rotati ng. Spec ial T ool - Clutch Holder : 57 001–1243 • Install the friction plates and steel plat es, starting[...]

6-14 ENGINE RIGHT SIDE Clutch • Check the release shaft lever positions [A]. ○ Pushing [B] the rel ease shaft lever [ C] light ly f rontward measure the distance between the lever and cable bracket [ D]. Releas e Shaft Lever Posi tion Stand ard: 36.7 ∼ 44.5 mm If the lever position is not wit hin the standard, select the correct thickness of [...]

ENGI NE RIGHT SID E 6-1 5 Clutch Clut c h Hou sing Fin ger Dam age • Visual ly inspect the clutch housing fi ngers [A] that come in contact with the friction plate tangs. If they are damaged or if there are groove cuts it the areas that come in contact with the tangs, replace the housing. Replace the friction plates if their tangs are damaged as [...]

6-16 ENGINE RIGHT SIDE Primary Gear Primar y Gear Remov al • Remove: Right Engine Cover • R e m o v et h ec l u t c h( s e eC l u t c hR e m o v a l ) . • T emporari ly install the clutch housing [A]. • Using the gear holder [B], secure the primary gear . Specia l T o ol - Ge ar Holde r: 57001–1557 • Remove the cl utch housing. • Remo[...]

ENGI NE RIGHT SID E 6-1 7 External Shift Mech anism External Shift M echanism Removal • Remo ve: Shift Pedal Bolt [ A] Shift P edal [B] • Remo ve: Right Engine Cover (see this chapter) Clutch Housing (see this chapter) • Pull out the shift shaft [A]. • Remove the screw [B] and bolt [C], t ake off the shift ratchet assembly [D] with ratchet [...]

6-18 ENGINE RIGHT SIDE External Shift Mechani sm • Set up the shift ratchet assembly as shown in the figure. Ratchet [A] Pawls [B] Pins [C] Springs [D] Crankcase Side [E] • Then install the ratchet assembly [A] to the ratchet plate [B] as shown i n the figure. Crankcase Side [C] • Install the ratchet assembly to the shift drum cam. • Apply [...]

ENGI NE RIGHT SID E 6-1 9 External Shift Mech anism • Check the ratchet assembly for damage. If ratc het [A], pawls [B], pins [C] or springs [D] are dam - aged in any way , replace them. • Check the gear set lever [A] and its spr ing [B] for cracks or distor tion. If the lever or spring is damaged in any way , replace them. • Visual ly inspec[...]

6-20 ENGINE RIGHT SIDE Kickstarter Kick Peda l Assy Removal • Remove: Mounting Bolt [A] Kick Pedal Assy [B] Kick Pedal Assy Installation • Install the kick pedal assy [A] at the angle shown. 14 ∼ 24 mm [B] • Apply a non-per manent locking agent to the mounting bolt. • T ighten the mounting bolt. T orque - Kick Ped al Mounting bolt: 25 N·[...]

ENGI NE RIGHT SID E 6-2 1 Kickstarter Idle Gear Installation • Apply engine oil to the inside of the idle gear . • Install the washer [A]. • Fit the idle gear [B] with the boss [C] facing toward the engine side. Kickshaft Removal • Remo ve: Right Engine Cover (see Right Engine Cover Removal) Clutch Housing (see Clutch Removal) Idle Gear [A][...]

6-22 ENGINE RIGHT SIDE Kickstarter Kickstarter Assembly Disassembly/Assembly • The kickstarter assembly consists of the following parts. • Check the kicks tarter assembly parts for d amage. Any damaged parts should be replaced with new ones. A. Ki ck G ear E. Ra tchet Gear B. Ci rclip F . K ick Sh aft C. W asher G. Kick Spring D. Sp ring H. Spr[...]

ENGINE LUB RICA TION SYSTEM 7-1 7 Engine Lubrication System T abl e o f Content s Exploded View ..... ........... ................ ........... .............. ............. .............. ............. ............ ...... ..... 7-2 Lubricati on System Chart ..... .... ...... ..... ........ ...... ........ ...... ....... ...... ........ ...... ......[...]

7-2 ENGINE LUBRI CA TION SYSTEM Exploded View[...]

ENGINE LUB RICA TION SYSTEM 7-3 Exploded View T orque No. Fastener N·m kgf·m ft·l b Rema rk s 1 Engine oil drain plug M10 (for transmission room oil sump) 15 1.5 11 2 Engine oil drain plug M6 (for crank room oil sump) 7.0 0.7 61 in·l b 3 Engine oil drain plug M6 (for oil filte r oil chamber) 7.0 0.7 61 in·lb 4 Oil Pump mounting bolts 7.0 0.7 6[...]

7-4 ENGINE LUBRI CA TION SYSTEM Lubrication System Ch art[...]

ENGINE LUBRICA TION SYSTEM 7- 5 Lubricat ion System Chart 1. Oil Screen (scavenging) 2. Oil Screen (feed) 3. Oil Pump (scavenging) 4. Oil Pump (feed) 5. Right Crankcase Oil Passage (from Scavenging Oil Pump to T ransmission Oil Shower Passage) 6. Right Engine Cover O il Passage (from Feed Oil Pump to Oil Filter Oil Chamber) 7. Oil Filter 8. Oil Fil[...]

7-6 ENGINE LUBRI CA TION SYSTEM Specifications Item Standard Engine Oil: Grade Castrol “R4 Superbike” 5W-40 API SH or SJ w ith J ASO MA Vi sc o s i ty SAE 10W-30, 10W-40, or 10W-50 Capacity Oil change – when filter is not removed 1 . 3L( 1 . 4U Sq t ) Oil change – when filter is removed 1.35 L (1.43 US qt) when engine is completely dry 1 . [...]

ENGINE LUB RICA TION SYSTEM 7-7 Special T ool s Oil Pre ssure Gauge, 5 kgf /cm² : 57001–12 5 Outside C irclip P liers : 57001–14 4 Gear Holder : 57001–155 7 Oil Pressure Gauge Adapter , M6 × 1.0 : 57001–157 9[...]

7-8 ENGINE LUBRI CA TION SYSTEM Engine Oi l and Oil Filter W ARNING Motorcycle operation with insufficient, deteri- orated, or contaminated engine oil will cause accelerated wear and may result in engine or trans- mission seizure, accident, and injury . The engine oil level indicated in the clutch cover oil level gauge is very sensi tive to the mot[...]

ENGINE LUBRICA TION SYSTEM 7- 9 Engine Oil and Oil Filter Oil Filt er Change ○ Refer to the Engine Lubricati on System in the Periodic Maintenance chapter . Oil Scree n R emov al • Separate the crankcase (see Crankshaft/T r ansmission chapter). • Remove the oil screens [A] from the crankcase. Oil Screen Installation • Clean the oil screens [...]

7-10 ENGINE LUBRICA TION SYSTEM Oil Pump Oil P ump Rem oval • Drain: Engine Oil (see Periodic Maintenance chapter) Coolant (see Periodic Maintenance chapter) • Remove: Brake Pedal (see Brakes chapter) Kick Pedal (see Engine Right Side chapter) Wat e r P i p e B o l t [A ] W ater Pipe [B] (pull out) W ater Pump Cover [C] Right Engine Cover Bolts[...]

ENGINE LUBRICA TION SYSTEM 7-1 1 Oil Pump • Remove the i nner [A] and outer [B] rotor s of the scaveng- ing oil pump. • Disassembly the feed oil pump assembly . Oil Pump Cover [A ] Inner Roto r [B] Outer Rotor [C] Pin [D] Oil Pump Body [E] Oil Pump Gear [F] Oil Pump Install ati on • Apply molybdenum disulfid e grease to the shaft of the oil p[...]

7-12 ENGINE LUBRICA TION SYSTEM Oil Pump • Install the outer rotor [A]. • Install t he dowel pin [B] and dowel pin [C]. • Install the scavenging and feed oil pump assemblies [D]. • Apply a non- permanent locking agent to the oil pum p mounting bolts. • T ighten the oil pump mounting bolts. T orque - Oil Pump Mounting Bolts: 7.0 N·m (0. 7[...]

ENGINE LU BRICA TION SYSTEM 7-13 Oil Pressure Oil Pre ssure Mea surement • Remove the oil drain plug (for oil filter oil chamber) [A]. • Attach the oil pressure gauge adapter [A]. • Attach the oi l pressure gauge [B]. Spec ial T oo ls - O il Press ure Gau ge Adapt er: 5700 1–1579 Oil Pres sure G auge: 57001–125 • Start the engine and wa[...]

[...]

ENGI NE REMO V AL/I NST ALLA TION 8-1 8 Engine Removal/Installation T able of Co ntent s Exploded View ..... ........... ................ ........... .............. ............. .............. ............. ............ ...... ..... 8-2 Spec ial T o ol ...... ....... .... ...... ...... .... ...... ..... ...... ...... .... ...... ....... .... .....[...]

8-2 E NGINE REMOV A L/I NST ALLA TIO N Exploded View[...]

ENGINE REMOV AL/INST ALLA TI O N 8-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Upper engine mounting bolt, nut (M10) 49 5.0 36 2 Middle engine mounting bolt, nut (M10) 49 5.0 36 3 Lower engine mounting bolt, nut (M10) 49 5.0 36 4 Upper engine bracket bolts, nuts (M8) 29 3.0 22 5 Middle engine bracket bolts (M8) 29 3.0 22 6 Swi[...]

8-4 E NGINE REMOV A L/I NST ALLA TIO N Special T ool Jack: 57001–123 8[...]

ENGINE REMOV AL/INST ALLA TI O N 8-5 Engine R emoval/Ins tallation Engine Removal • Place the jac k [A] under the frame to support the m otor- cycle. Spec ial T ool - Ja ck: 5700 1–1238 W A RNING For engine removal, the swingarm pivot shaft must be pulled out, causing the swingar m and rear wheel assembly to becom e detached. T o prevent the mo[...]

8-6 E NGINE REMOV A L/I NST ALLA TIO N Engine Remo val/Installa tion • Loosen: Carburetor Clamp Bolts [A] • Remove: Inlet D uct [B] with Rear Frame (see Frame chapter) Carburetor [C] (hanging it) Clutch Cable Lower End [D] (see Engine Right Side chapter) Drive Chain [ E] ( cut out ) • Remove: Bolts [A] Rear Brake Pedal [B] Master Cyl inder [C[...]

ENGINE REMOV AL/INST ALLA TI O N 8-7 Engine R emoval/Ins tallation • Pull out the c arburetor hoses [A] and breather hose [B] from the clamp [C]. • Remove the swing arm pivot shaft [D]. ○ Pull out the swing arm pivot shaft half way from right side to f ree the engine. • Remove the engine from the vehicle to right side. ○ Clear t he engine[...]

8-8 E NGINE REMOV A L/I NST ALLA TIO N Engine Remo val/Installa tion • Install the removed parts (see Appropriate chapter). • Run the cables, hoses, and leads according to the Cable, Wire and Hose Routing section of the Appendix chapter . • Fill: Engine Oil (see Periodic Maintenance chapter) Coolant (see Periodic Maintenance chapter) • Adju[...]

CRANKSHAFT/T RANSMISSION 9-1 9 Crankshaft/T r ansmission T able of Co ntent s Exploded View ..... ........... ................ ........... .............. ............. .............. ............. ............ ...... ..... 9-2 Spec ifica tion s . ...... ....... .... ...... .... ...... ....... .... ...... ...... .... ...... ..... ...... ...... .... [...]

9-2 C RANK SHAFT/TRANSMISSION Exploded View[...]

CRANKSHAFT/T RANSMISSION 9-3 Exploded View T orque No. Fastener N·m kgf·m ft·l b Remarks 1 Crankcase bolt s 9.8 1.0 87 in· lb S 2 Gear set lever nut 8.8 0.9 78 in· lb 3 Neutral swit ch 12 1.2 104 in·lb 4 Engine oil drain plug (for crank room oil sump) 7.0 0.7 61 in· lb 5 Engine oil drain plug (for transmission room oil sump) 15 1.5 11 6 Shif[...]

9-4 C RANK SHAFT/TRANSMISSION Specifications Item Standard Ser vice Limit Connecting R ods: Connecting rod big end radial clearance 0.002 ∼ 0.014 mm 0.06 mm (0.0024 in.) (0.00008 ∼ 0.0006 in.) Connecting rod big end side clearance 0.25 ∼ 0.35 mm 0.55 m m (0.0217 in.) (0.0098 ∼ 0.0138 in.) Crankshaft runout TIR 0.08 mm TIR 0.03 mm (0.0012 in[...]

CRANKSHAFT/T RANSMISSION 9-5 Special T ool s Bearing Puller : 57001–13 5 Outside C irclip P liers : 57001–14 4 Bearing Dri ver S et : 57001–1129 Crankshaf t Jig : 57001–1174 Crankcase Spli tting T ool Ass embly : 57001–136 2 Kawasaki Bond (Liquid Gasket – Gray) : 92104–106 3[...]

9-6 C RANK SHAFT/TRANSMISSION Crankcase Crankcase Di sassembly • Remove the engine from the frame (see Engine Re- moval/Install ation chapter) • Set the engine on clean surface while parts are being re- moved. • Remove: Magneto Cover (see Electrical System chapter) Cylinder H ead C over (see Engine T op End chapter) Camshaft Chain T ensioner [...]

CRANKSHAFT/TR ANSMISSION 9-7 Crankcase • Remove the crankcase bolts [A]. • Install the jig [A] between the crankshaft flywheels [B]. Spec ial T ool - Cran kshaft Jig : 57 001–1 17 4 • Attach the crankcase splitting tool [A] t o the left crankcase. ○ Adjust the gap between the split ting tool arm and bolt, using the col lar or nut [B]. Spe[...]

9-8 C RANK SHAFT/TRANSMISSION Crankcase Crankcase Assembly CAUTION Right and left crankcase hal ves are m achined at the factory in the assembled state, so if replaced, they must be re placed as a set. • Remove the old gasket from the mating surfa ces of the crankcase halv es and clean them off w ith a high–flash point sol vent. • Using com p[...]

CRANKSHAFT/TR ANSMISSION 9-9 Crankcase • Press the new drive shaft bearing [A] in the left and right crankcase half, so that the sealed side [B] faces outside of the engine. • Press the new output shaft bearing s [A] in the left and right crankcase half [B], so that the s tepped side [C] faces inside of the engine. Spec ial T ool - Be aring Dri[...]

9-10 CR ANKSHA FT/TRANSMISSION Crankcase • Apply engin e oil to the trans mission gears , bearings, shif t forks, shift drum and crankshaft bearing. • Install the drive shaft [A] and output shaft [B] in the right crankcase [C] as a set. • Inst all: Shift Drum [A] (see T ransmission Installati on) Shift Forks [B] (see T ransmission Installatio[...]

CRANKSHAFT/TRAN SMISSION 9-1 1 Crankcase • Using a plast ic hammer [A], press [B] the rear portion of the crankcase, and tap [C] the area around the crank- shaft of the left crankcase. While maintaining the m ating surfaces of the right and left crankcase halves constantly parallel, mate the crankcase halves evenly . NOTE ○ Constantly check t h[...]

9-12 CR ANKSHA FT/TRANSMISSION Crankcase • Install the gear set lever [A]. ○ Fit each end of the spring [B] or original positions. ○ Do not forget to install the colar and washer [C]. • T ighten the gear set l ever nut [D]. T orque - Gear Set Leve r Nut: 8.8 N·m (0.9 kgf·m, 78 in·lb) • T o install the shi ft drum cam [A], use the driv [...]

CRANKSHAFT/T RANSMISSION 9-13 Crankshaft Crankshaft Removal • Disassemble the crankcase (see Crankcase Disassem- bly). • Remove the transmission shaft (see this chapter). • Using the hand press [A], remove the crankshaft [B] from the right c rankcase [C]. If the bearing stay on the crankshaf t when splitting the crankcase, or removing t he cr[...]

9-14 CR ANKSHA FT/TRANSMISSION Crankshaft Crankshaft Assembly Since the assembly of the crankshaft demands exact ing tolerances , the disassembly and reassembl y of the crank- shaft can only be done by a shop having the necessary tools and equipment. • Reassemble the crankshaf t accor ding to the standard tol- erances in Specifications. ○ Conne[...]

CRANKSHAFT/T RANSMISSION 9-15 T ransmissio n T ransmissi on Shaft Removal • Disassemble the crankcase halves (see Crankcase Dis- assembly). • Pull out th e oil screens. Crank R oom Side Oil Screen [A] T ransmission Room Side Oil S creen [B] • Pull out the shif t rods [A] allo wing the shift f ork guide pins to free from the shift drum [B]. ?[...]

9-16 CR ANKSHA FT/TRANSMISSION T ran smission • Apply a small amount of engine oil to t he shift fork fi ngers and fit each shift fork into the groove of the proper gear . • The shift forks can be identi fied by their shape or mark. Install them noting the direction shown. ○ The dr ive shaft fork [A] is the shortest, and install it with its m[...]

CRANKSHAFT/T RANSMISSION 9-17 T ransmissio n • The output shaft gears can be identified by size; the largest diameter ge ar is 1st gear , and the smallest i s 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. ○ Install the collar [A] with the [...]

9-18 CR ANKSHA FT/TRANSMISSION T ran smission • Check each gear spins or slides freely on the transmission shaft without binding after assembly . Shif t Fork Bendi ng • V isually inspect the shift forks, and replace any fork that is bent. A bent fork may cause dif ficulty in s hifting, or allow the transmission to jump out of gear when under po[...]

CRANKSHAFT/T RANSMISSION 9-19 Bearings/Oil Seals Bearin g Replaceme nt CAUTION Do not remove the ball bearings unless it is neces- sary . 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, satisfac- tory result s may be obtained by he[...]

9-20 CR ANKSHA FT/TRANSMISSION Bearings/Oil Seals • Check the needle bearing. ○ The roller s in a needle bearing normally wear very little, and wear is diffi cult to measure. Instead of measuri ng, inspect the bearing for abrasion, color change, or other damage. If there is any doubt as to the c ondition of a needle bear- ing, replace it. O i l[...]

WHEELS/TIRES 10-1 10 Wheels/T ires T able of Co ntent s Exploded View ..... ........... ................ ........... .............. ............. .............. ............. ............ ...... ..... 10-2 Spec ifica tion s . ...... ....... .... ...... .... ...... ....... .... ...... ...... .... ...... ..... ...... ...... .... ...... ..... ...... .[...]

10-2 WHEELS/TIRES Exploded View[...]

WH EELS/ TIRES 10-3 Exploded View T orque No Fastener N·m kgf·m ft·lb Remarks 1 S poke Nipple 2.2 0.22 19 in·lb 2 Front Axle Nut 79 8.0 58 3 Front Axle Clamp Bolts 20 2.0 14.5 AL 4 R ear Axle N ut 11 0 11 . 0 80 5. Spokes 6. Front T ire 7. Rims 8. Front Axle 9. Swingarm 10. Rear T ire 1 1. Rear Axle AL: T ighten the two clamp bolts alternately [...]

10-4 WHEELS/TIRES Specifications Item Standard Service Lim it Wheels (Rims): Rim r unout: Axial 1.0 mm (0.039 in.) or less 2 mm (0.08 i n.) Radial 1.0 mm (0.039 in.) or less 2 mm (0.08 in.) Axle runout/ 100 mm 0.1 mm (0.004 in.) 0.2 mm (0.008 in.) Ti res Air Pressure: Front and Rear 100 kPa (1.0 kgf/cm², 14 psi) --- Tir e s : Standard tire: Front:[...]

WHEELS/TIRES 10-5 Special T ool s Inside Ci rclip P liers : 57001–14 3 Rim Protector : 57001–10 63 Bead Bre aker Ass embly : 57001–10 72 Bear ing Drive r Set : 57001–1129 Jack : 57001–123 8[...]

10-6 WHEELS/TIRES Wheels (Rims) Front Whe el Removal • Using the jack [A] under the frame, and stabilize the mo- torc ycl e. Specia l T oo ls - J ack: 570 01–123 8 • Loosen the left and right axle clamp bolts [A]. • Unscrew the axl e nut [B] . • Place a stand under the engine to raise the front wheel off the ground. • Remove the axle [C[...]

WH EELS/ TIRES 10-7 Wheels (Rims) • Remove the jack. • Before tightening the 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 t his process to stop the motorcycl e from rolli ng forward. Put a bloc[...]

10-8 WHEELS/TIRES Wheels (Rims) • Remove Cotter Pin [A] Axle Nut [B] • Pull out the axle [C]. • Move the rear wheel back with the rear caliper installed. • T ake off t he collar and cap from the each side of the rear hub. CAUTION Do not lay t he wheel on the ground with the disc facing down. This can damage or warp the disc. Place blocks un[...]

WH EELS/ TIRES 10-9 Wheels (Rims) • Check the drive chain slack (see Final Drive chapter). • T ighten the axle nut . T or que - Rear Axle Nut: 1 10 N·m (1 1 kg·m, 80 f t·lb) • Install the new cotter pin [A] and spread its end. NOTE ○ When inser ting the cotter pin, if the slots in the nut do not align with the cotter pin hole in the axle[...]

10-10 WHEELS/TIRES Wheels (Rims) Axle Inspection • V isually 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. T urn the ax le to measure the runout. The differ ence b[...]

WHEELS/TIRES 10-1 1 Tire s Tire Rem oval CAUTION 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 di sc does not touch the ground. • Remove the wheel from the motorcycle (see W heels Re- mova l) . • T o m aintain front wheel balance, mark [A] the valve stem posit[...]

10-12 WHEELS/TIRES Tir e s • Step on the side of the tire opposite valve s tem, pry the tire off the rim wi th the tire iron [A] of the bead breaker protecti ng the rim with rim protectors [B]. Specia l T oo ls - R im Prot ector: 57001–10 63 Bead Breaker Asse mbly: 5 7001–1072 CAUTION T ake care not to inset the tire irons so deeply that the [...]

WHEELS/TIRES 10-13 Hub Bearings Hub Bearing Removal • Remove the w heel (see W heel Removal). CAUTION 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. Spec ial T ool - Insi de Circlip Pl ie[...]

[...]

FINAL DRIVE 1 1 -1 11 Final Drive T able of Co ntent s Exploded View ..... ........... ................ ........... .............. ............. .............. ............. ............ ...... ..... 1 1-2 Spec ifica tion s . ...... ....... .... ...... .... ...... ....... .... ...... ...... .... ...... ..... ...... ...... .... ...... ..... ...... .[...]

1 1-2 FINAL DRIVE Exploded View[...]

FINAL DRIVE 1 1-3 Exploded View T orque No Fastener N·m kgf·m ft·lb Remarks 1 R ear Sprocket Nuts 34 3.5 25 2 E ngine Sprocket Cover Bolts 9.8 1.0 87 in·lb 3. Engine Sprocket 4. Output Shaft 5. Chain Slipper 6. Swingarm 7. Chain Guide 8. Locknut 9. Adjusting Bolt 10. Chain Adjuster 1 1. Drive Chain 12. Rear Sprocket 13. Upper Chain Guide Roller[...]

1 1-4 FINAL DRIVE Specifications Item Standard Servi ce Lim it Drive C hain: Chain slack 52 ∼ 62 mm (2.05 ∼ 2.44 in.) --- Chain 20-link length 317.5 ∼ 318.2 m m (12.50 ∼ 12 .53 i n.) 323 mm (1 2.72 in.) Standard Chain: Mak e: DAIDO --- T ype: D.I.D 520DMA2 --- Length: 11 4 L i n k s --- Sprocket Engine sprocket diameter 55.48 ∼ 55.68 m m [...]

FINAL DRIVE 1 1 -5 Special T ool s Outside C irclip P liers : 57001–14 4 Jack : 57001–123 8[...]

1 1-6 FINAL DRIVE Drive Chain Drive Chain Slack I nspection • Raise the r ear wheel of f 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 Inspec- tion), and adjust it if necessary (see Wheel Alignment Ad- justment). NOT E ○ Clean the d[...]

FINAL DRIVE 1 1-7 Drive Chain NOTE ○ When inser ting the cotter pin, if the slots in the nut do not align with the cotter pin hole in the axle shaft, ti ghten 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. W A RNING If the axle nut is not se[...]

1 1-8 FINAL DRIVE Drive Chain Drive Ch ain Remo val • Remove the cli p [A] from the master link using plier s, and free the drive chain from the rear sprocket. • Remove the drive chain from the chassis. Drive Cha in Instal lation • Fit the drive chain back onto the sprockets with the ends at the rear sprocket. • Install the master link [A] [...]

FINAL DRIVE 1 1-9 Sprockets Engine Sprocket Removal • Remo ve: Engine Sprocket Cover Bolts [A] Engine Sprocket Cover [B] Drive Chain Guide [C] • Remo ve: Drive Chain [A] (free of engine sprocket) • Remove the circlip [B], and pull off the engine sprocket [C]. Special T ools - Outside Circlip Pli ers: 57001 –144 Engine S procket Inst allati [...]

1 1-10 FINA L DRIVE Sprockets Rear Sprocket W arp In spection • Refer to the Rear Sprocket Wrap Inspection in Periodic Maintenance chapter .[...]

BRAKES 12-1 12 Brakes T able of Co ntent s Exploded View ..... ........... ................ ........... .............. ............. .............. ............. ............ ...... ..... 12-2 Spec ifica tion s . ...... ....... .... ...... .... ...... ....... .... ...... ...... .... ...... ..... ...... ...... .... ...... ..... ...... ...... .......[...]

12-2 BRAKES Exploded View[...]

BRAKES 12-3 Exploded View T orque No. Fastener N·m kgf ·m ft·l b Remarks 1 Front master cylinder clamp bolts 8.8 0.9 78 in·lb 2 B rake hose banjo bolts 25 2.5 18 3 B rake pad bolt 18 1.8 13 4 Caliper bleed valve 7.8 0.8 69 in·l b 5 C aliper mounting bolts 25 2.5 18 6 B rake disc mounting bolts 9.8 1.0 87 in·l b L 7 B rake lever pivot bolt loc[...]

12-4 BRAKES Exploded View[...]

BRAKES 12-5 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Brake hose banjo bolts 25 2.5 18 2 Rear m aster cylinder mounting bolts 9. 8 1.0 87 in·lb 3 Rear master cylinder push rod locknut 18 1.8 13 4 Caliper bleed val ve 7.8 0.8 69 in·lb 5 Brake pad bolt 18 1.8 13 6 Rear brake pad b olt plug 2.5 0.25 22 in·lb 7 Caliper holder s[...]

12-6 BRAKES Specifications Item Standard S ervic e Lim it Brake adjustment: Lever play Adjustable (to suit rider) --- Brake Fluid: Recommended disc brake fluid: --- T ype Front DOT3 or DOT4 --- Rear DOT4 Brake Pads: Lining thickness: Front 3.8 mm (0.150 in.) 1 mm (0.04 in.) Rear 6.4 mm (0.252 in.) 1 mm (0.04 in.) Brake Disc: Thickness: Front 2.85 ?[...]

BRAKES 12-7 Special T ool s Inside Ci rclip P liers : 57001–14 3 Jack : 57001–123 8[...]

12-8 BRAKES Brake Lev er , Brake Pedal Brake Lever Play Adjustment • Refer to the Brake Lever Play Adjustment in Period ic Maintenance chapter . Brake Pedal Position /Pedal Play Adjustment • Refer to Brake Pedal P osition/Pedal Play Adjustment in Periodic M aintenance chapter . Brake Peda l Removal • Remove: Cotter Pin [A] Joint Pin [B] W ash[...]

BRAKES 12-9 Brake Fluid W A RNING When working wi th the disc brake, observe the pre- cautions listed below . 1. Never reuse old brake fluid. 2. Do not u se fluid f rom a container t hat 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 bo ilin[...]

12-10 BRAKES Brake Fluid Bleedi ng th e Bra ke Li ne The brak e fluid has a very low compression coefficient so that almost all the movement of the br ake lever or pedal is transmitted directly to the c aliper for braking action. Air , however , is easily compressed. When air enters t he brake lines, brake lever or pedal movement will be partially [...]

BRAKES 12-1 1 Brake Fluid • Check t he fl uid level. • After bleeding is done, check the brake for good braking power , no brake drag, and no fluid leakage. W A RNING Do not attempt to drive the motorcycle until a full brake lever or pedal is obt ained by pumping the brake lever or pedal until the pads are against the disc. The br ake will not [...]

12-12 BRAKES Caliper Calip er 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 usin[...]

BRAKES 12-13 Caliper Caliper Inst allati on • T ighten the brake pad bolts if it was removed. T orque - Brak e Pad Bolts: 1 8 N·m (1.8 kgf·m, 13 ft·lb) Front Brake: • Install the caliper and tighten the bolts. T o rque - Caliper Mounting Bolts: 25 N·m (2.5 k gf·m, 18.0 ft·lb) Rear Brake: • Before install the caliper , install the rear w[...]

12-14 BRAKES Caliper Calipe r Hol der S haft Wear The caliper body m ust slide smoothly on t he caliper holder shafts. If the body does not slide smoothly , one pad will wear more than the other , pad wear will increase, and con- stant drag on t he disc will r aise brake and brake fluid tem- perature. • Check too see if the caliper holder shafts [...]

BRAKES 12-15 Caliper Brake Pad Install ation • 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 . • T ighten the brake pad bolt. T or que - Brake Pad Bolt: 18 N· m (1.8 k gf·m, 13 ft·lb) • C[...]

12-16 BRAKES Master Cylinder CAUTION Brake fluid quickly ruins painted or plastic sur- faces; any spilled fluid should be completely wished up immediatel y . Front Master Cylin der Removal • Remove the banjo bolt [A] to disconnect the upper brake hose [B] from the master cylinder [C]. • When removing the brake hose, te mporarily secure the end [...]

BRAKES 12-17 Master Cylinder Rear Mast er Cylin der Rem oval • Remove the cot ter 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 re- move the master cylinder [D]. • Unscrew the brake hose banjo bolt [E]. • When r[...]

12-18 BRAKES Master Cylinder Master Cylinder Inspection (V isual 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 [...]

BRAKES 12-19 Brake Disk Brake Disc Inspe ction • Visual ly inspect the disc [A]. If it is scratched or damaged, replace the disc. • Measure the thickness of each disc at the poi nt [B] wher e it has worn the most. Replace the disc if it has worn past the service limit. Thickness Front Rear Standard: 2.85 ∼ 3.15 mm 3.85 ∼ 4.15 mm (0.112 ∼ [...]

12-20 BRAKES Brake Hose Brake Hose Removal/Insta llation • Refer t o the Brake Hose Replac ement i n Periodic Main- tenance chapter . Brake Hose Insp ectio n • Refer to the Brake Hose and C onnection Check in Peri- odic Maintenance chapter .[...]

SUSPENSION 13-1 13 Suspension T able of Co ntent s Exploded View ..... ........... ................ ... 13-2 Spec ifica tion s . ...... ....... .... ...... ...... .... .. 1 3-6 Spec ial T o ols ...... ....... ...... .... ...... .... .... 13-7 Fro nt For k . ...... .... ....... .... ...... ...... .... .... 13-9 Air Pres sure .. ....... .... ...... .[...]

13-2 SUSPENS ION Exploded View[...]

SUSPENSION 13-3 Exploded View T orque No Fastener N·m kgf·m ft ·lb Remarks 1 Front f ork top plug 29 3.0 22 2 Lower front fork clamp bolts 20 2.0 14.5 AL 3 U pper front fork bolts 20 2.0 14.5 AL 4 Steering stem head nut 79 8.0 58 5 Push rod nut 28 2.85 20.6 6 Front a xle clamp bolts 20 2.0 14.5 AL 7 Front fork cylinder valve assembly 54 5.5 40 L[...]

13-4 SUSPENS ION Exploded View[...]

SUSPENSION 13-5 Exploded View T orque No Fastener N·m kgf·m ft·lb Rema rk s 1 S wingarm pivot shaft nut 98 10 72 2 R ocker arm pivot nut 83 8.5 61 3 Tie-ro d m ounting nut (front, rear) 83 8.5 61 4 Rear shock absorber mounting nut (upper) 39 4.0 29 5 R ear shock absorber mounting nut (lower) 34 3.5 25 6 A ir bleed bolt 6.5 0.65 56 in·lb 7. Pivo[...]

13-6 SUSPENS ION Specifications Item Standard Ser vice L imit Front Fork: Air pressure Atmospheric pressure -–– Rebound damping adjustment (Adjustable Range) 1 1 clicks counterclockwise 16 clicks (from the seated positi on adjus ter turned fully clockwise) 12 clicks counterclockwise (EU) Compression damping adjustment (Adjustable Range) 8 click[...]

SUSPENSION 13-7 Special T ool s Oil Seal & Bear ing Remov er : 57001–10 58 Steer ing Stem Nut Wrench : 57001–1100 Hook Wrench : 57001–1101 Bearing Dri ver S et : 57001–1129 Fork Outer T ube Weight : 57001–12 18 Jack : 57001–123 8 Bear ing Remov er Shaft, 9: 57001–126 5 Bear ing Re mover He ad, 15 × 17 : 57001–126 7 Fork O il Le[...]

13-8 SUSPENS ION Special T ools Fork C ylinder Holder : 57001–157 3[...]

SUSPENSION 13-9 Front Fork Air Pressure The standard air pressur e in the front fork legs is atmo- spheric pressure. Air pressure in the fork legs increase with normal use, so the fork acti on stif fens during opera- tion. Release air pressure form the f ork legs prior to each race through the pres sure relief scr ew located in each front fork cap.[...]

13-10 SUSPENSIO N Front Fork Seated positions adjuster turned fully clockwise [A]. Compression Damping Adjuster Setting Stand ard: 8 c licks [B] 1 1 clicks (European Model) [C] Softer (Counterclockwise ) [D] Harde r ( Clockwi se) [ E] *: Number of turns counterclockwise usable range – 16 clicks or more. Counterclockwise from the fully seated posi[...]

SUSPENSION 13-1 1 Front Fork • Place a stand or other suitable support [A] under the front wheel. • While holding the push rod nut with a 19 mm wrench, loosen the front fork top plug [A] from the top of the push rod. • Remove th e fork top plug with the f ork spring seat [C] and fork spring [B]. • Fill t he front fork to the top of the inne[...]

13-12 SUSPENSIO N Front Fork • Hold the push rod with your hand fully up. • Insert the fork spring [A] into the fork tube. • Install the fork spring seat [A] on the fork spring [B]. • Check both top plug O-ring [C] for damage and replace them if necessary . • While holding the push rod nut [A] with a 19 mm wrench [B], tighten the top plug[...]

SUSPENSION 13-13 Front Fork • Remo ve: Front wheel (see Wheels/T ires chapter) Bolts [A] • Remove the caliper [B] fro m the fork l eg to be r emoved, and rest the caliper on som e kind of stand so that it doesn’t dangle. • Loosen the upper [A], and lower fork clamp bolts [B]. • Remove t he front fork. ○ With a twisting motion [A], work [...]

13-14 SUSPENSIO N Front Fork Front For k Install ation • If the fork leg was disassembled, check the fork oil level. • Install the fork so that the distance [B] between the top end [A] of the outer tube and the upper surface [C] of the steering stem head is specified dimension. [B] = 8 m m (0.59 in.) • Route the cables and hose according to t[...]

SUSPENSION 13-15 Front Fork • Use wrenches [A] on the rod nut [B] and top pl ug [C] loosen the push rod nut. • Remove the top plug from the push rod. • Lift t he fork spring [D] and its top spring seat [E] out of the outer tube. • T ake the rebound damping adjuster rod [A] out of the push rod. • Hold the fork tube [A] upside down over a c[...]

13-16 SUSPENSIO N Front Fork • Remove: Circlip [A] O-ri ng [B ] Nut [C] Collar [D] Holder [E] • Clean the bottom of the inner tube. • Remove the cap on the bottom of the inner tube. • Hold the front fork horizontally in a vise. • Stop the cylinder unit [A] from turning by using the fork cylinder holder [B]. Unscrew the cylinder valve asse[...]

SUSPENSION 13-17 Front Fork • Separate the i nner tube [A] from the outer tube [B] as follows: ○ Slide up the spri ng band [C] . ○ Slide up t he dust seal [D]. ○ Remove the retaining ring [B] from the outer tube [A]. ○ Grasp the outer t ube and stroke the inner tube up and down several times. The shock to fork seal separates the inner tub[...]

13-18 SUSPENSIO N Front Fork • 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 T ool - Fork O il Seal Driver , 48: 5700 1–1509 • After inst alling the washer , install the oil seal by using t he fork oil seal driver . Special T[...]

SUSPENSION 13-19 Front Fork • Fit the circlips [A] onto the groove of the push rod [B]. • Install the Collar [C], Holder [D], and Nut [E] • Replace t he O-ring [F] with a new one. • Install the spring guide [A] so that the thinner portion end [B] is down. • Screw on the push rod nut [C] fully . • Insert the rebound damping adjuster rod [...]

13-20 SUSPENSIO N Front Fork Inne r T ube Inspect ion • V isually inspect the inner tube [A], repair any damage. • Nick or r ust 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, replac e t he inner tube. Since damage to the inner tube damages th[...]

SUSPENSION 13-21 Rear Sus pension (Uni-T rak) Rear Shock Ab sorber: The rear suspension system of this motorcycle i s New Uni-trak. It consists of a rear shock absorber , swing arm, tie-rod and rocker arm. T o suit to various riding condi tions, the spring preload of the shock absorber can be adjusted or the spring can be replaced with an optional [...]

13-22 SUSPENSIO N Rear Su spe nsion ( Uni-T r ak) Seated position : adjuster turned fully clockwise [A]. Rebound Da mping Adjus ter Setting Stand ard: 1 1 clicks [B] Softer (Counterclockwise ) [C] Harde r ( Clockwi se) [ D] *: Number of turns counterclockwise usable range – 16 clicks or more. Counterclockwise from the fully seated position. NOT E[...]

SUSPENSION 13-23 Rear Sus pension (Uni-T rak) Spring Preload Adjustment (Adjusting nut position at the lower s urface [A] from the center of the mounting hole) Standard: 1 13 mm (4.45 in.) Adjustable Range 109 ∼ 129.5 mm (4.2 9 ∼ 5.098 in.) • T ighten the lock nut securely . • After a djusting, move the spring up and down to make sure that [...]

13-24 SUSPENSIO N Rear Su spe nsion ( Uni-T r ak) Spri ng 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 acc ording to the rider ’s weight or course condi tions. • Remove Side Covers Seat Silencer (Engine T op End chapter) Rear Frame[...]

SUSPENSION 13-25 Rear Sus pension (Uni-T rak) Rear Shock Absor ber Scr apping W A RNING Since the reservoir tank of the rear shock absorber contains nitrogen gas, do not incinerate the reser- voir tank without firs t releasing the gas or it may explode. • Remove the shock absorber (see Rear Shock Absorber Remo val ). • Remove the valve cap [A] [...]

13-26 SUSPENSIO N Swingarm Swingarm Removal • Place the jack [A] under the frame so that the rear wheel is off the ground. Specia l T o ol - Jack : 57 001–12 38 • Remove Rear W heel (see Wheels/T ires chapter) Clamps [B] Brake Pedal [C] (see Brakes chapter) Caps [D] Disc Protector [E] • Remove: Bolts [A] Chain Guide Plate [ B] Chain Gui de [...]

SUSPENSION 13-27 Swingarm Swin garm Ins tallat ion • Apply plenty of grease to the inside of the needle bear- ings, sleeves, and oil seals. • T ighten the following: T orque - Swin garm Pivot Sha ft Nut: 9 8 N·m (10.0 kgf·m, 7 2 ft·lb) Rocker Arm Mounting Nut: 83 N·m (8.5 kgf·m, 61 ft·lb) • Refer to the Wheels/T ires, Final Drive, and B[...]

13-28 SUSPENSIO N Swingarm • V isually inspect the chain slipper [A] on the swingarm [B] and replace it if worn or damaged. • V isually inspect the upper and lower chain guide rollers [A] and replace them if excessively w orn or damaged. Swinga rm Be aring, Sleeve Inspection CAUTION Do not remove t he bearings for inspection. Re- moval may dama[...]

SUSPENSION 13-29 Tie-Rod, Rocker Arm Tie- Rod Rem ova l • Using the jack under the frame, raise the rear wheel off the ground. Spec ial T ool - Ja ck: 5700 1–1238 • Unscrew the nut [A] and remove the guide roller [B]. CAUTION When pulling out the mounting bolts, lift the rear wheel slightly . For cing or tapping on a bolt could damage the bol[...]

13-30 SUSPENSIO N 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 outsi de of the sleeve. • Be sure seated the washers. • T ighten the fol lowing: T orque - R ear Shock Absorbe r Lower Mounting Nut: 34 N·m (3. 5 kgf·m, 25 ft·lb) Rocker Arm Piv[...]

SUSPENSION 13-31 Tie-Rod, Rocker Arm • Install the needle bearings [A], [B], grease seals [C], and oil s eals [ D] position as s hown. ○ The i nstallation procedure i s the same as the counter side. Front [E] Rea r Shock A bsor ber [H] Rig ht Side [F ] T ie-rod [I] Left Side [G] Rock er Arm [J] Needle Bearing Inspecti on If there i s any doubt [...]

13-32 SUSPENSIO N Uni-T rak Maintenance Uni-T ra k Linka ge Ins pec tion • Refer to the Uni-T rak Linkage Inspection in Periodic Main- tenance chapter . Tie-Rod and Rocker Arm Sleeve W ear • 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 ser vice limit, repl[...]

STEE RIN G 14 -1 14 Steering T able of Co ntent s Exploded View ..... ........... ................ ........... .............. ............. .............. ............. ............ ...... ..... 14-2 Spec ial T o ols ...... ....... ...... .... ...... .... ....... ...... .... ...... ...... .... ....... .... ...... ...... .... ....... .... ...... ...[...]

14-2 STEERING Exploded View[...]

STEERING 14-3 Exploded View T orque No. Fastener N·m kgf·m ft ·lb Rema rk s 1 H andlebar clamp bol ts 25 2.5 18.0 S 2 S teering stem head nut 78 8. 0 58 3 S teering stem locknut 4.9 0. 5 43 in·lb T 4 U pper front fork clamp bolts 20 2.0 14.5 AL 5 Low er front fork clamp bolts 20 2.0 14.5 AL 6. Handlebar Clamp 7. Handlebar 8. Handlebar Holder 9.[...]

14-4 STEERING Special T ools Bearing Puller : 57001–135 Steering Stem Be aring Driv er : 57001–137 Steering St em Beari ng Driver Adap ter : 57001–107 4 Head Pipe Out er Race Pre ss S haft : 57001–107 5 Head Pipe Outer R ace Driver : 57001–107 6 Head Pipe Oute r Race Driver : 57001–1 077 Steer ing Stem Nut Wrench : 57001–1100 Head Pip[...]

STEERING 14-5 Steering Stee ring Inspec tion • Refer t o the Steering Inspection in Periodic Maintenance chapter . Steering Adj ustment • Refer to the Steering Adjustment in Per iodic M aintenance chapter . Steeri ng Stem, Stem Bearing Removal • Remo ve: Front Wheel (see Wheels/T ires chapter) Front Fork (see Suspension chapter) Front Fender [...]

14-6 STEERING Steering • T ake off the upper stem bearing inner r ace (tapered ro ller bearing) [A]. • Drive out the bearing outer races from the head pipe. ○ Remove the outer races pressed into the head pipe, us ing the head pipe outer race remover [A], and hammer the head pipe outer race remover to drive it out. Specia l T oo l - Head Pipe [...]

STEERING 14-7 Steering • Replace the lower inner races with new ones. ○ Apply grease to t he lower tapered roller bearing [A], and drive it onto t he stem using the steering stem be aring driver [B] and adapter [C]. Spec ial T ool - S teering Stem Bea ring Driv er : 570 01–137 Steeri ng Stem B earing Driv er Adap ter: 57001–107 4 • Apply [...]

14-8 STEERING Steering • Install the parts removed (see the appropriate chapter). W ARNING Do not impede the handlebar turning by rout ing the cables, wires and hoses improperly (see the Gen- eral Information chapter). • Check and Adjust : Steering Front Brake Clutch C able Throttle Cable[...]

STEERING 14-9 Steering Maintenance Stem Beari ng Lubri cation • Refer to t he Stem Bear ing Lubrica tion in Periodic Mainte- nance chapte r . Stem B ear ing Wear , D a mag e • Using a high flash-point solvent, wash t he upper and lower tapered rollers in the cages, and wipe the upper and lower outer races, which are press-fitted into the frame [...]

14-10 STEERING Handlebar Handle bar Removal • Remove : Clutch Holder [A] (see Clutch chapter) Engine Stop Switch [B] Clamp [C] (Discard) Left Handlebar Grip [D ] • Remove: Throttle G rip Assy [A] (see Fuel System chapter) Master Cylinder [B] ( see Brakes chapter) • Remove: Handlebar Clamp B olts [A] Handlebar Clamp [B] Handlebar [C] Handle ba[...]

STEERING 14-1 1 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]. • 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 horizontal parting line [B] of the throt tle case wi[...]

[...]

FRAME 15-1 15 Frame T able of Co ntent s Exploded View ..... ........... ................ ........... .............. ............. .............. ............. ............ ...... ..... 15-2 Fra me . ...... .... ...... ....... .... ...... .... ...... ....... .... ...... ...... .... ...... ..... ...... ...... .... ...... .... ....... ...... . .. ...[...]

15-2 FRAME Exploded View[...]

FRAME 15-3 Exploded View To r q u e No. Fastener N·m kgf·m ft·lb Remarks 1 Upper rear frame mounting bolt 34 3.5 25 2 Lower rear frame mounting bolts 34 3.5 25 G: Apply grease . R: Replacement Parts[...]

15-4 FRAME Frame Frame Inspectio n • Refer to the Frame Inspection i n Peri odic Maint enance chapter . Rear Frame Removal • Remove: Seat (see Seat Removal) Right & Left Side Cover (see Side Cover Removal) Silencer (see Engine T op End chapter) Rear Fender (see Fender Removal) Rear Flap (see Fl ap Removal) • Unscrew the rear frame mountin[...]

FRAME 15-5 Seat Seat Removal • Unscrew the bolts [A]. • Pull the seat [B ] out from the back. Seat Installa tion • Fit the hooks [A] of the seat under the flange collar [B] and bra ckets [ C].[...]

15-6 FRAME Side Cover Side Cov er Rem ova l • Unscrew the bolts [A] and remove the side cover . Side C ove r Insta llation • Stick the pads [A] on the inside of the right side cover [ B]. ○ Bend this parts [C] and stick it to the upper surface of the rib. ○ Install the dampers [D]. • Insert the t abs [A] of t he cover into the air cleaner[...]

FRAME 15-7 Fender Front Fend er Removal • Unscrew the bolts [A] and remove the front fender [B]. Rear Fender R emoval • Remo ve: Seat • Unscrew the bolts [A] and remove the rear fender [B]. Rear Flap Removal • Unscrew the screws [A] and remove the rear flap [B].[...]

[...]

ELECTRICAL SYSTEM 16-1 16 Electrical System T able of Co ntent s Exploded View ..... ........... ................ ........... .............. ............. .............. ............. ............ ...... ..... 16-2 Spec ifica tion s . ...... ....... .... ...... .... ...... ....... .... ...... ...... .... ...... ..... ...... ...... .... ...... .....[...]

16-2 ELECTRICAL SY STEM Exploded View[...]

ELECTRICAL SYSTEM 16-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 N eutral switch 12 1.2 104 in·lb 2 Flywheel nut 49 5.0 36 3 S tator bolts 7.0 0.7 61 in·lb 4 S park plug 13 1.3 11 5 i n · l b 5 M agneto cover bolts L35 9.8 1.0 87 in·lb L 6 M agneto cover bolts L30 9.8 1.0 87 in·lb 7 N eutral lead terminal screw 1.3 0.13 1[...]

16-4 ELECTRICAL SY STEM Specifications Item Standard Magneto: Crankshaft sensor resistance: 80 ∼ 120 Ω Magneto output voltage: in the text Stator coil resistance: in t he text Ignition System: Igniti on timing: (Disconnect the throttle sensor lead) 8° BTDC @ 2 000r/min (rpm) Igniti on coil: 3 needle arcing distance 7 mm ( 0.26 in.) or m ore Pr[...]

ELECTRICAL SYSTEM 16-5 Special T ool s Timing Light : 57001–12 41 S p a r kP l u gW r e n c h ,H e x1 6: 57001–12 62 Hand T ester : 57001–13 94 Throttle Sensor Setting Adapter : 57001–14 00 Need le Adapt er Set : 57001–145 7 R o t o rP u l l e r: 57001–156 5 Rotor Holder : 57001–156 7[...]

16-6 ELECTRICAL SY STEM Wiring Diagram[...]

ELECTRICAL SYSTEM 16-7 Precautions There are numbers of important precautions that are musts when servicing electri cal systems. Learn and ob- s e r v ea l lt h er u l e sb e l o w . ○ 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. ○ T r o[...]

16-8 ELECTRICAL SY STEM Electrical Wiring Wiri ng Inspecti on • V isually inspect the wiring for signs of burning, frayi ng, 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, repla[...]

ELECTRICAL SYSTEM 16-9 Flywheel Magneto Magneto Cover Removal • Drain the engine oil f rom the c rank room oil sump (see Periodic Maintenance chapter). • Push down the stopper [A]. • Remove the magneto lead connector [B]. • Disconnect the magneto lead connector with neutral switch lead connector [C] from the main harness. • Remove the shi[...]

16-10 ELECTRICAL SYSTEM Flywheel Magneto • Screw the rotor puller [A] into the flywheel. • Remove the flywheel f rom t he crankshaft by turning in the puller center bol t and tapping t he head of the bolt lightly with a hammer , while holding the puller body steady . There is a woodruff key in the crankshaft t apered portion. Specia l T oo l - [...]

ELECTRICAL SY STEM 16-1 1 Flywheel Magneto Stato r In stall ation • Route the wires according to the Cable, Wiring, and Hose Routing section in the Appendix chapter . • Install the stator and tight en it. T orque - Stator Bolts: 7.0 N·m (0.7 kgf·m, 61 in·lb) • Install the crankshaft sensor and wiring holder [A]. ○ Run the magneto leads u[...]

16-12 ELECTRICAL SYSTEM Flywheel Magneto T ab le 2 Stator Coil Resist ance Connections T ester Range T est er (+) to T ester (–) to Reading Black /Red lead Red/Wh ite lea d 27.2 ∼ 40. 8 Ω ×1 Ω Y ellow/Wh ite lead Y ellow lead 1.7 6 ∼ 2.6 4 Ω If there is more resistance than shown in the table, or no hand tester reading (infinity) the s[...]

ELECTRICAL SYSTEM 16-13 Ignition Timing Ignition T iming Inspe ction • Remove the timing inspection cap [A]. • Attach the timing light [A] to the ignition coil lead in the manner prescribed by the manufacturer . Spec ial T ool - Timing Lig ht: 57001–124 1 • Start the engine and aim the timing light at the i gnition timing m ark [B] o n the [...]

16-14 ELECTRICAL SYSTEM Ignition System Safety Instructions: W ARNING The ignition system produces extremely high volt- age. Do not touch the spar k plug, high tension coil, or spark plug lead w hile the engine is running, or you could receive a severe electrical shock. Ignition Coil Removal • Remove: Fuel T ank (see Fuel System chapter) • Disc[...]

ELECTRICAL SYSTEM 16-15 Ignition System 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 fro m insulation breakdown under high voltage. • Remove t he ignition co il. • Measure th[...]

16-16 ELECTRICAL SYSTEM Ignition System • Disconnect the m ain harness connector [ A]. • Unscrew the m ounting bolts [B] and remove the C.D.I Unit [C]. C.D.I Unit Inspection CAUTION When inspecting the C.D.I. unit observe the follow- ing to avoid damage to the C .D.I. unit. Do not disconnect the C.D.I . unit while the engine is running. This m [...]

ELECTRICAL SYSTEM 16-17 Ignition System • Shift the gear to the neutral posi tion, then free the engine stop swit ch. • Crank the engine by kicking the pedal several t imes to measure the peak voltage of the primary ignition coil. Peak V olt age 1 76 V or above W A RNING Do not touch the metal portion of the probe in case of measuring the volta[...]

16-18 ELECTRICAL SYSTEM Ignition System[...]

ELECTRICAL SYSTEM 16-19 Ignition System Crankshaft Sensor Peak V oltage Check: • T o check the peak voltage, do the following procedures. ○ Disconnect the connector of the magneto lead connector from the main harness. NOTE ○ Measure the voltage with each lead connected cor- rectly . The cor rect value may not be obtained if disconnected. ○ [...]

16-20 ELECTRICAL SYSTEM Ignition System Exciter Coil Peak V oltage Check: • Disconnect the connector of the magneto lead connector from the main harness. • T o check the peak voltage, do the following procedures. NOT E ○ Measure the voltage with each lead connected cor- rectly . The corr ect v alue may not be obtained if disconnected. ○ Mai[...]

ELECTRICAL SYSTEM 16-21 Ignition System Throttle Sensor Output/Input V oltage Check • Remove the carburetor lead connector [A]. • Connect the throttl e sensor setting adapter [A] between carburetor lead connector [B] and main harness connec- tor [C]. Special T ool - Throttle Sensor Setting Ada pter : 57001–140 0 • Set t he tester [D] to the[...]

16-22 ELECTRICAL SYSTEM Ignition System Engin e Stop S witch Electric Current Che ck: • Open the cl amp [A]. • Disconnect the engine stop switch lead connector [B]. • Start the engine. • Ground the stop switch black/white lead of the main har- ness side while the engine is running. If does not stop the engine, replace the C.D.I Unit. Cranks[...]

ELECTRICAL SYSTEM 16-23 Throttle Sensor Throttle Sensor Inspection NOTE ○ If the variable rheostat is not available, refer to th rottle sensor output/i nput voltage check in the C.D.I Unit in- spection. ○ When inspecting the throttle sensor the throttle valve of the carburetor shall be completel y closed and remain the throttle cable connected.[...]

16-24 ELECTRICAL SYSTEM Neutral Switch Neutral Switch Inspection • Slide out the dust cover [A]. • Disconnect the connector [B]. ○ Unscrew the screw . • Using a hand tester , c heck to see that only the con- nections shown in the table have continuit y (about zero ohms). If the switch has an open or short, repair it or replace it with a new[...]

APPENDIX 17-1 17 Appendix T able of Co ntent s Cable , W ire, a nd Ho se R outi ng . .... ....... ...... .... ...... .... ...... ....... .... ...... ...... .... ....... .... ...... ...... .... .. 17- 2 T roubleshooti ng G uide ............... ......... .............. ............ ......... .............. ........... .......... ............. 17-8[...]

17-2 APPENDIX Cable, Wire, and Hose Routing[...]

APPENDIX 17-3 Cable, Wire, and Hose Routing 1. Throttle Cables 2. Clamp 3. Engine Stop Switch Lead 4. Hot Start Cabl e 5. Clutch Cable 6. Main Harness 7. C.D.I. Unit 8. Throttle Cable (acceler ator cable) 9. Throttle Cable (deceler ator cable) 10. Clamp (Hold the thrott le cable .) 1 1. C.D.I. Uni t Bracket[...]

17-4 APPENDIX Cable, Wire, and Hose Routing 1. Clutch Cable 2. C.D.I. Unit 3. Main Harnes s 4. Clamps (Run the clutch cable.) 5. Clamps (Run the clutch cable.) 6. Run th e clutch cable insi de of the mag- neto l ead. 7. Hot Start Cable 8. Engine Stop S witch Lead 9. Clamp (Hold t he hot start cable, engine stop switch lead, and main harness.) 10. C[...]

APPENDIX 17-5 Cable, Wire, and Hose Routing 1. Clutch Cable 2. C.D.I. Uni t 3. Main H arness 4. Bolt (together with ground lead terminal) 5. Neutral Switch Lead Connector 6. Magneto Lead 7. Clamp 8. Run t he magneto lead outside of the clutch cable. 9. Engine Stop Swi tch 10. Clamp (Hold the hot s tart cable, engine stop switch lead and main harnes[...]

17-6 APPENDIX Cable, Wire, and Hose Routing 1. Radiator O verflow Hose 2. Clamp 3. Hot Start Cable 4. Fuel Hose 5. Breather Hose 6. Clamp 7. Breather Hose 8. Viewed A 9. Left R adiator 10. Right Radi ator 1 1. Radiator Hose (to cylinder head) 12. Radiator Hose (to water pump) 13. Radiator Hose (to water pump) 14. Joint Pipe 15. Lower Engine Bracket[...]

APPENDIX 17-7 Cable, Wire, and Hose Routing 1. Brake Lever 2. Front Brake Master Cylinder 3. Front Brake Hose 4. Clamp 5. Viewed 6. Clamps 7. Front Brake Caliper 8. Front Brake Di sc 9. Brake P edal 10. Rear Brake Master Cylinder 1 1. Rear Brake Hose 12. Clamps 13. Rear Brake Cali per 14. Rear Brake C aliper Guard 15. Rear Brake Disc 16. Rear Brake[...]

17-8 APPENDIX T roub leshooting Guide This is not an exhaustive list, giving every possible cause f or each problem listed. it is meant simply as a rough guide to assi st t he troubleshooti ng for some of the more common dif ficult ies. Engine Doesn’t Start, Starting Difficulty: Engine won’t turn over: Va l v e s e i z u r e Va l v e l i f t e [...]

APPENDIX 17-9 T ro ubleshooting Guide V alve not seating properl y (valve bent, de- formed, worn, or carbon accumulation on the seating surface) Decompression trouble Oth er: Faulty CDI unit Engine oil level to high Engine oil viscosity too high Brake dragging Drive train trouble Engine overheating Clutch slipping Poor Runni ng or N o Power at High[...]

17-10 APPENDIX T roub leshooting Guide Clutch inner cable sticking Friction plate w orn or warped Steel plate worn or war ped Clutch spring broken or w eak 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 o[...]

APPENDIX 17-1 1 T ro ubleshooting Guide 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 V alve oil seal dam aged Va l v e g u i d e w o r n Engine oil l evel too hi gh Black smoke: Air cleaner element clogged Main je t t oo lar [...]

MODEL APPLIC A T ION Y ear Model Beginning Frame No. 2004 KX250–N1 JKAKXMNC □ 4A000001 or JKAKX250NNA000001 □ :This digit in the frame number changes from one machine to another . Part No.999 24-1324 -02 Printed in Japan[...]