Kawasaki ER-5 (2004) manual

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This quick reference guide will assist you in locating a desired topic 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 to locate the spe- cific topic required. Quick Reference G[...]

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ER-5 Motorcycle Service Manual All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Quality Assurance Department/Consumer Products & Machinery Company/Kawas[...]

LIST OF ABBREVIA TIONS A ampere(s) lb pound(s) ABDC after bottom dead center m meter(s) AC alternating 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 center PS horsepower BTDC before top dead center psi pound(s) per square inch °C degree(s) Celsius r revolution DC direct c[...]

EMISSION CONTROL INFORMA TION T o protect the environment in which we all live, K awasaki has incorporated crankcase emis- sion (1) and exhaust emission (2) control system s in compliance with applicable regulations of the United States Environmental Protection Agency and California Air Resources Board. Addi- tionally , Kawasaki has incorporated an[...]

T AMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair , or replacement, of any device or element of design incorporated into any new vehicle for the p urpose of noise control prior to its s[...]

Foreword This manual is designed primarily for use by trained mechanics in a properly equipped shop. However , it contains enough detail and basic in- formation to make it useful to the owner who de- sires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop proce- dures must be[...]

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GENERAL INFORMA TION 1- 1 1 General Information T able of C ontents Before Servicing ................................................................................................................ ..... 1-2 Model Identification................................................................................................................. 1-5 Gene[...]

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

GENERAL INFORMA TION 1-3 Before Servicing (10) Liquid Gasket, Locking Agent Clean and prepare surfaces where liquid gasket or non-permanent locking agent will be used. Apply them sparingly . Excessive amount may b lock engine oil passages and cause serious dam- age. (1 1) Press When using a p ress or driver to install a par t such as a wheel bearin[...]

1-4 GENERAL INFORMA TION Before Servicing T wo-Colo r Electrical (19) Inspection When parts have been disassembled, visually inspect these parts for the following conditions or other damage. If there is any doubt as to the condition of them, replace them with new ones. Abrasion Crack Hardening W arp Bent Dent Scratch Wear Color change Deterioration[...]

GENERAL INFORMA TION 1-5 Model Identification ER500-C1, D1 Left Side View ER500-C1, D1 Righ t Side View[...]

1-6 GENERAL INFORMA TION General Specifications Items EN500-C1 ∼ C2 EN500-C3 ∼ EN500-D1 Dimensions Overall Length 2 070 mm (81.5 in.) ← ← Overall Width 730 mm (28.74 in.) ← ← Overall Height 1 070 mm (42.13 in.) ← ← Wheelbase 1 430 mm (56.3 in.) ← ← Road Clearance 125 mm (4.92 in.) ← ← Seat Height 800 mm (31.5 in.) ← ← Dr[...]

GENERAL INFORMA TION 1-7 General Specifications Items EN500-C1 ∼ C2 EN500-C3 ∼ EN500-D1 Lubrication System Forced lubrication ← ← Engine Oil: Grade API SE, SF , SG or API SH or SJ with JASO MA ← ← Visco sity SAE10W-40 ← ← Capacity 3.4 L (3.6 us at) ← ← Drive T rain Primary Reduction System: Ty p e Chain ← ← Reduction Ratio 2[...]

1-8 GENERAL INFORMA TION General Specifications Items EN500-C1 ∼ C2 EN500-C3 ∼ EN500-D1 Electrical Equipment Battery 12 V 10 Ah ← ← Headlight: Ty p e Semi-seal ed beam ← ← Bulb 12 V 60/55 W (quartz-halogen) ← ← T ail/brake Light 12 V 5/21 W × 2 ← ← Alternator: Ty p e Three-phase AC ← ← Rated output 17 A × 14 V @6 000 r/min[...]

GENERAL INFORMA TION 1-9 Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the motorcycle i n good running condition. The initial maintenance is vitally important and must not be neglected. FREQUENCY Whichever comes first * ODOME TER READING × 1 000 km (× 1 000 mile) 1 6 12 18 24 30 36 INSPECT[...]

1-10 GENERAL INFORMA TION Periodic M aintenance Chart FREQUENCY Whichever comes first * ODOMET ER READING × 1 000 km (× 1 000 mile) 1 6 12 18 24 30 36 INSPECTION Every (0.6) (4) (7.5) (12) (15) (20) (24) Remarks Engine oil - change # year • • • • • • • Oil filter - replace • • • • Brake fluid - change 2 years • Brake maste[...]

GENERAL INFORMA TION 1-1 1 T orque and Locking Agent T ighten all bolts and nuts to the proper torq ue using an accurate torque wrench. An insufficiently tightened bolt or nut may become damaged or fall off, possibly resulting in damage to the motorcycle and injury to the rider . A bolt or nut which is overtightened may become damaged, strip an int[...]

1-12 GENERAL INFORMA TION T orque and Locking Agent T orque Fastener N·m kgf·m ft·lb Remarks W ater Pipe Bolts 9.8 1.0 87 in·lb L Cylinder Head Jacket Plug 9.8 1. 0 87 in·lb L Air Suction V alve Cover Bolts 11 1.1 95 in·lb Coolant Drain Plug 11 1. 1 95 in·lb Engine T op End Spark Plugs 14 1.4 10 Cylinder Head Cover Bolts 9.8 1.0 87 in·lb Ca[...]

GENERAL INFORMA TION 1-13 T orque and Locking Agent T orque Fastener N·m kgf·m ft·lb Remarks Engine Oil Drain Plug 29 3.0 22 Oil Pan Mounting Bolts 11 1.1 95 i n·lb Oil Pump Mounting Bolts 11 1.1 95 in· lb Breather Body Bolt 5.9 0.6 52 in ·lb Engine Removal/Installation Downtube Bolts 44 4.5 33 Engine Mounting B olts and Nuts 44 4.5 33 Engine[...]

1-14 GENERAL INFORMA TION T orque and Locking Agent T orque Fastener N·m kgf·m ft·lb Remarks Front Brake Light Switch Mounting Screw 1.2 0.12 10 in·lb Caliper Mounting Bolts 34 3.5 25 Caliper Bleed V alves 7.8 0.8 69 in·lb Brake Disc Mounting B olts 27 2.8 20 L Brake Pedal Bolt 8.8 0.9 78 in·lb T orque Link Nuts 34 3.5 25 Brake Cam Lever Bolt[...]

GENERAL INFORMA TION 1-15 T orque and Locking Agent T orque Fastener N·m kgf·m ft·lb Remarks Starter Clutch Allen Bolts 34 3.5 25 L Sidestand Switch Mounting Screw 3.9 0.4 35 in·lb L Sidestand Mounting Bolt 44 4.5 33 Starter Motor T erminal Locknut 6.9 0.70 61 i n·lb Starter Relay T erminal Bolt 4.9 0.50 43 i n·lb Headlight Body Screws 2.9 0.[...]

1-16 GENERAL INFORMA TION Special T ools a nd Sealants Piston Ring Pliers: 57001-1 15 Oil Pressure Gauge, 5 kgf/cm²: 57001-125 Bearing Puller: 57001-135 Bearing Puller Adapter: 57001-136 Steering Stem Bearing Driver: 57001-137 Inside C irclip Pli ers : 57001-143 Outside Circ lip Pliers: 57001-144 Bearing Puller: 57001-158 Fork Cylinder H older Han[...]

GENERAL INFORMA TION 1-17 Special T ools and S ealan ts V alve Spring Compressor Assembly: 57001-241 Bearing Puller Ad apter: 57001-317 Bearing Driver , 32: 57001-382 Piston Pin Puller Assembly: 57001-910 Fuel Level Gauge: 57001-1017 V alve Guide Arbor , 5.5: 57001-1021 Spark Plug Wrench, Hex 18: 57001-1024 Fork Cylinder Holder Adapter: 57001-1057 [...]

1-18 GENERAL INFORMA TION Special T ools a nd Sealants Bead Breaker Assembly: 57001-1072 Steering Stem Bearin g Driver Adapter , 34.5: 57001-1074 Head Pipe Outer Race Press Shaft: 57001-1075 Head Pipe Outer Race Driver , 51.5: 57001-1076 V alve G uide Reamer , 5.5: 57001-1079 Piston Ring Compressor Grip: 57001-109 5 Piston Ring Compressor Belt, 67 [...]

GENERAL INFORMA TION 1-19 Special T ools and S ealan ts Va l v e S e a t C u t t e r, 3 2 ° - 25: 57001-1 1 18 Va l v e S e a t C u t t e r, 3 2 ° - 30: 57001-1 120 Va l v e S e a t C u t t e r, 6 0 ° - 30: 57001-1 123 V alve Seat Cutter Holder , 5.5: 57001-1 125 V alve Seat Cutter Holder Bar: 57001-1 128 Bearing Driver Set: 57001-1 129 Compress[...]

1-20 GENERAL INFORMA TION Special T ools a nd Sealants Rotor Puller , M16/M18/M20/M22 × 1.5: 57001-1216 Fork O uter T ube Weight: 57001-1218 Front Fork Oil Seal Driver: 57001-1219 Jack: 57001-1238 Timing Light: 57001-1241 Clutch Holder: 57001-124 3 Oil Filter Wrench: 57001-124 9 Bearing Remover Head, 15 × 17: 57001-126 7 Carburetor Drain Plug Wr [...]

GENERAL INFORMA TION 1-21 Special T ools and S ealan ts Va l v e S e a t C u t t e r, 6 0 ° - 25: 57001-1328 Pilot Screw Adjuster Adapter , 5: 57001-1372 Pilot Screw Ad ju st e r Driv er: 57001-1373 Bearing Remover Shaft, 13: 57001-1377 Igniter Checker Assembly: 57001-1378 Harness Adapter #1: 57001-1381 Hand T ester: 57001-1394 Flywheel Holder: 57[...]

1-22 GENERAL INFORMA TION Special T ools a nd Sealants Kawasaki Bond (Silicone Sealan t): 56019-120 Kawasaki Bond (Liquid Gasket - Black) TB1 105: 92104-100 3[...]

GENERAL INFORMA TION 1-23 Cable, Wire, and Hose Routing 1. V acuum Hose 2. Air Hose 3. Fuel Hose 4. Throttle and Choke C ables 5. Fuel Filters 6. Fuel T ap 7. T o the air suction valve. 8. T o the vacuum switch valve. 9. Clamp 10. T o the fuel tap. 1 1. T o the left carburetor . 12. T o the right carburetor .[...]

1-24 GENERAL INFORMA TION Cable, Wire, and Hose Routing 1. Throttle Cables 2. Choke Cable 3. Right Handlebar Switch Leads 4. Horn 5. Clutch Cable 6. Left Handlebar Switch Leads 7. Brake H ose 8. Speedometer Cable 9. Run the cables outside. 10. Run the clutch cable inside the cross pipe. 1 1. Bands 12. Run th e ignition switch lead behind and then u[...]

GENERAL INFORMA TION 1-25 Cable, Wire, and Hose Routing 1. Handlebar Switch Harness 2. Main Harness 3. Radiator Fan Switch 4. Alternator Connector 5. Pickup C oil Connector 6. Neutral Switch Lead 7. Sidestand Switch Lead 8. Battery Negative Lead 9. Battery Positive Lead 10. Rear Brake Light Switch Connector 1 1. Starter Lead 12. Starter Circuit Rel[...]

1-26 GENERAL INFORMA TION Cable, Wire, and Hose Routing 1. Radiator 2. Thermostat Housing 3. Coolant Filter 4. Carburetor 5. Reserve T ank 6. Coolant V alve 7. Reserve T ank Overflow Hose 8. Air Cleaner Drain H ose 9. Cross P ipe 10. Damper 1 1. Radiator Cover 12. Face the white mark upward and to the radiator . 13. Face the head of the clamp screw[...]

GENERAL INFORMA TION 1-27 Cable, Wire, and Hose Routing 1. Reserve T ank 2. Reserve T ank Overflow Hose 3. Clamps[...]

1-28 GENERAL INFORMA TION Cable, Wire, and Hose Routing 1. Starter Motor 2. Positive Lead 3. Negative Lead 4. Plate 5. Pickup Coil 6. Pickup Coil Mounting Bolts 7. T ighten the starter motor negative lead terminal with the rear starter mounting bolt. 8. T o the battery negative terminal. 9. T o the starter relay . 10. Hold the lead w ith the plate.[...]

GENERAL INFORMA TION 1-29 Cable, Wire, and Hose Routing 1. #1 Ignition Coil Connectors 2. Radiator Fan Switch Connector 3. Left Handlebar Switch Connectors 4. W ater T emperature Switch Ground T ermi- nal 5. W a ter T emperature Switch 6. Battery Negative Lead 7. Igniter Connectors 8. #2 Ignition Coil Connectors 9. Radiator Fan Connector 10. White [...]

1-30 GENERAL INFORMA TION Cable, Wire, and Hose Routing 1. Fuel T ank 2. Fuel T ank Upper Drain Hose 3. Catch T ank 4. Reserve T ank Hose 5. Main Harness 6. Fuel T ank Lower Drain Hose 7. Plug 8. Reserve T ank Overflow Hose 9. Air Cleaner Drain H ose 10. Bind the edge of the hose bend 1 1. About 70 mm 12. Frame Corner 13. Cl ips 14. Band 15. Bo lt [...]

FUEL SYSTEM 2-1 2 Fuel System T able of C ontents Exploded View ................................................................................................................... ..... 2-2 Specifications ................................................................................................................. ........ 2-4 Throttle Grip and [...]

2-2 FUEL SYSTEM Exploded V iew 1. Throttle Cable (accelerator) 2. Throttle Cable (decelerator) 3. Choke Cable 4. Pilot Screw 5. Pilot (Slow) Jet 6. Needle Jet 7. Needle Jet Holder 8. Main Jet 9. Jet Needle CL: Apply cable lubricant. G: Apply grease.[...]

FUEL SYSTEM 2-3 Exploded V iew 1. V acuum Switch V alve 2. Air Cleaner Housing 3. Air Cleaner Element T1: 0.8 N·m (0.08 kgf·m, 7 in·lb) T2: 1.0 N·m (0.10 kgf·m, 9 in·lb) T3: 6.9 N·m (0.7 kgf·m, 61 in·lb) T4: 2.5 N·m (0.25 kgf·m, 22 in·lb)[...]

2-4 FUEL SYSTEM Specifications Item Standard Throttle Grip Free Play 2 ∼ 3m m( 0 . 0 8 ∼ 0.12 in.) Choke Cable Free Play 2 ∼ 3m m( 0 . 0 8 ∼ 0.12 in.) Carburetors Mark, T y pe KEIHIN CVK34 Idle Speed 1 200 ±50 r/min (rpm) Pilot S crew (Turns Out) (1 1/4 ±1/4 for refe rence) Synchronization V acuum 2.7 kPa (2 cmHg) or less difference betwe[...]

FUEL SYSTEM 2-5 Throttle Grip and Cables Throttle Cable Inspection Throttle Grip Free Play Inspection • Check throttle grip play [A] by lightly turning the throttle grip back and forth. If the free play is improper , adjust the throttle cable. Throttle Grip Free Play Standard: 2 ∼ 3 mm (0.08 ∼ 0.12 in.) • Check that the throttle g rip moves[...]

2-6 FUEL SYSTEM Throttle Grip and Cables • Check that the throttle pulley [A] stops against the idle adjusting screw [B], with the throttle grip released and stops against the carburetor stopper with the throttle grip opened. • T urn the handlebar from side to side while idling the en- gine. If idle speed varies, the cable may be poorly routed [...]

FUEL SYSTEM 2-7 Choke C able Free Play Inspection • Push the choke lever [A] all the way to the front. • Check choke cable free play [B]. ○ Determine the amount of choke cable play at the choke lever . Pull the choke lever until the starter plunger lever [C] at the carburetor touches the starter plunger [D]; the amount of choke lever lower en[...]

2-8 FUEL SYSTEM Carburetors Idle Speed Inspection Idle Speed Inspection • Start the engine and warm it up thoroughly . • With the engine idling, turn the handlebar to both sides. If handlebar movement changes the idle speed, the throt- tle cable may be improperly adjusted or incorrectly routed, or it may be damaged. Be sure to correct any of th[...]

FUEL SYSTEM 2-9 Carburetors Carburetor Removal WA R N I N G Gasoline is extremely flammable and can be ex- plosive under certain conditions. T urn the ignition switch OFF . Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. • Remove: Fuel T ank (see this[...]

2-10 FUEL SYSTEM Carburetors • Install the holder clamps [A] as shown being careful of the screw position and the screw head [B] direction. W ARNING Install the clamp screws horizontally as shown. Otherwise the screws could come in contact with the vacuum adjusting screws, resulting in an un- safe riding condition. [C] T op [D] Bottom • Check f[...]

FUEL SYSTEM 2-1 1 Carburetors • Connect fuel level gauge [A] to the rubber hose. Special T ool - Fuel Level Gauge: 57001-1017 • Hold the gauge vertically against the side of the carburetor body so that the "middle" line [B] is several millimeters higher than the bottom edge [D] of the carburetor body . • T urn the fuel ta p to the P[...]

2-12 FUEL SYSTEM Carburetors • Bend the tang [A] on the float arm very slightly to change the float height. Increasing the float height lowers the fuel level and decreasing the float height raises the fuel level. Float Height 17.0 ±2.0 m m (0.67 ±0 .08 in.) NOTE ○ Do not push the needle rod [A] in during the float height measurement [B]. • [...]

FUEL SYSTEM 2-13 Carburetors • T urn in the pilot screw and count the number of turns until it seats fully but not tightly , and then remove the screw . This is to set the screw to its original position when as- sembling. • After installing the upper chamber cover , check that the vacuum piston slides up and down smoothly without bind- ing in t[...]

2-14 FUEL SYSTEM Carburetors • Slip the jet needle through the hole in the center of the vacuum piston, and put the spring seat [A] on the top of the needle. T urn the seat so that it does not block the hole [B] at the bottom of the vacuum piston. Carburetor Separation/Assembly • Read the W ARNINGS in the Carburetor Removal. • The center line[...]

FUEL SYSTEM 2-15 Carburetors CAUTION Do not use compres sed air on an assembled car- buretor , or the floats may be crushed by the pres- sure, and the vacuum piston diaphragms may be damaged. Remove as many rubber or plastic parts from the carburetor as possible before cleaning the carburetor with a cleaning solution. This will pre- vent damage to [...]

2-16 FUEL SYSTEM Carburetors • Disassemble the carburetors. • Clean the carburetors. • Check that the O-rings on the float bowl and drain plug and the diaphragm on the vacuum piston are in good con- dition. If any of the O-rings or diaphragms a re not in good con- dition, replace them. • Check the plastic tip [A] of the float valve needle [[...]

FUEL SYSTEM 2-17 Air Clean er Element Removal • Remove: Left Side Cover (see Frame chapter) Screws [A] Nut [B] Inlet Pipe [C] • Remove the element [A]. • Push a clean, lint-free towel into the carburetor intake to keep dirt or other foreign material from entering. WA R N I N G If dirt or dust is allowed to pass through into the carburetor , t[...]

2-18 FUEL SYSTEM Air Cleaner Air Cleaner Draining A drain hose [A] is provided beneath the air cleaner hos- ing, and catches the water or oil from the bottom of the hose. Usually water or oil does not collect at the bottom of the hose. In the event that rain water is drawn in through the air cleaner , or if engine oil is blown back, drain the housi[...]

FUEL SYSTEM 2-19 Fuel T ank Fuel T ank Removal WA R N I N G Gasoline is extremely flammable and can be ex- plosive under certain conditions. T urn the ignition switch OFF . Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. • Remove the seat (see Frame c[...]

2-20 FUEL SYSTEM Fuel T ank • Remove the fuel tank [A]. • Drain the fuel tank. ○ Place a suitable container under the fuel tank. ○ T urn the fuel tap to the PRI position to drain the fuel into the container . Fuel T ank Installation • Read the WARNING in the Fuel T ank Removal section. • Check the rubber dampers [A]. If the dampers are [...]

FUEL SYSTEM 2-21 Fuel T ank Fuel T ank and T ap C leaning • Remove the fuel tank and drain it. • Pour some high flash-point solvent into the fuel tank and shake the tank to remove dirt and fuel deposits. WA R N I N G Clean the tank in a well-ventilated area, and take care that there are no sparks or flame anywhere near the working area; this in[...]

2-22 FUEL SYSTEM Fuel Hose Fuel Hose and Connection Inspection ○ Check the fuel hose periodically in accordance with the Periodic Maintenance C hart, and if the motorcycle is not properly handled, the inside the fuel line can cause fuel to leak [A] or the hose to burst. Remove the fuel tank and check the fuel hose. Replace the fuel hose if any fr[...]

COOLING SYSTEM 3-1 3 Cooling System T able of C ontents Exploded View ................................................................................................................... ..... 3-2 Specifications ................................................................................................................. ........ 3-3 Coolant Flow[...]

3-2 COOLING SYSTEM Exploded V iew 1. Radiator Fan Switch 2. W a ter T emperature Switch 3. Thermostat 4. Coolant Drain Plug T1: 2.5 N·m (0.25 kgf·m, 22 in·lb) T2: 7.8 N·m (0.8 kgf·m, 69 in·lb) T3: 1 1 N·m (1.1 kgf·m, 95 in·lb) T4: 9.8 N·m (1.0 kgf·m, 7.0 ft·lb) T5: 18 N·m (1.8 kgf·m, 13.0 ft·lb) T6: 25 N·m (2.5 kgf·m, 18.0 ft·lb) [...]

COOLING SYSTEM 3-3 Specifications Item Standard Coolant Provided when Shipping T ype (recommended) Permanent type antifreeze (soft water and ethylene glycol plus corrosion and rust inhibi tor chemicals for aluminum engines and radiators) Color Green Mixed Ratio Soft water 50%, coolant 50% Freezing Point –35°C (–31°F) T otal A mount 1 . 7L( 1 [...]

3-4 COOLING SYSTEM Coolant F low Chart Permanent type antifreeze is used as a coolant to protect the cooling system from rust and corrosion. When the engine starts, the w ater pump turns and the coolant circulates. The thermostat is a wax pellet type which opens or closes with coolant temperature changes. The thermostat continuously changes its val[...]

COOLING SYSTEM 3-5 Coolant Coolant De terioration Inspection • Visually inspect the coolant i n the reservoir tank. ○ If whitish cotton-like wafts are observed, aluminum parts in the cooling system are corroded. If the coolant is brown, iron or steel parts are rusting. In either case flush t h ec o o l i n gs y s t e m . ○ If the coolant give[...]

3-6 COOLING SYSTEM Coolant Coolant Filling • Install the drain plug [A]. Always replace the gasket with a new one, if it is damaged. • T ighten the drain plug. T orque - Cool ant Drain Plug: 1 1 N·m (1.1 kgf·m, 95 in·lb) • Fill [A] the radiator up to the bottom of the radiator filler neck [B] with coolant [C], and install the cap turning i[...]

COOLING SYSTEM 3-7 Coolant • Remove the reserve tank cap. • Fill the reserve tank up to the F level [A] with coolant and install the cap. CAUTION Do not add more coolant above the F level. • Install the fuel tank. • Install the seat. Visual Le ak Insp ection Any time the system slowly loses water , inspect for leaks. • Check the water pum[...]

3-8 COOLING SYSTEM Coolant Flushing Over a period of time, the cooling system accumulates rust, scale, and lime in the water jacket and radiator . When this accumulation is suspected or observed, flush the cool- ing system. If this accumulation is not removed, it will clog up the water passages and considerably reduce the effi- ciency of the coolin[...]

COOLING SYSTEM 3-9 W ater Pump Water P ump Removal • Drain the coolant. • Loosen the clamp and remove the radiator hose [A] from the water pump cover [B]. • Remove the four cover bolts [C]. • With the water pipe [D] attached, remove the water pump cover . • Install the right footpeg assembly . NOTE ○ The impeller and water pump shaft ha[...]

3-10 COOLING SYSTEM Wa t er P um p • Be sure to install the water pipe O-rings [A], and apply high temperature grease to them. • Install the water pump cover with the water pipe, being careful of the two knock p ins [B]. T orque - W ater Pump Cover Bolts: 1 1 N·m (1.1 kgf·m, 95 in·lb) Mechanical Seal Inspection • Visually inspect the mecha[...]

COOLING SYSTEM 3-1 1 W ater Pump Impeller Assembly • Clean the s liding surface of the mechanical seal w ith a high flash-point solvent, and apply a little coolant to the sliding surface to give the mechanical seal initial lubrica- tion. • Apply coolant to the surfaces of the rubber seal [A] and sealing seat [B], and install the rubber seal and[...]

3-12 COOLING SYSTEM Radiator , Radiator Fan W ARNING The radiator fan is connected directly to the bat- tery . The radiator fan may start even if the ignition switch is off. NEVER TOUCH THE RADIA TOR F AN UNTIL THE RADIA T OR F AN CONNECTOR IS DIS- CONNECTED. TOUCHING THE F AN BEFORE THE CONNECTOR IS DISCONNECTED COULD CAUS E INJUR Y FROM THE F AN [...]

COOLING SYSTEM 3- 13 Radiator , Radiator Fan CAUTION When cleaning the radiator with steam cleaner , be careful of the following to prevent radiator damage. 1) Keep the steam gun [A] away more than 0.5 m (20 in.) [B] from the radiator core. 2) Hold the steam gun perpendicular to the core sur- face. 3) Run the steam gun horizontally following the co[...]

3-14 COOLING SYSTEM Radiator , Radiator Fan Radiator Hose a nd Connection Inspection ○ The high pressure inside the radiator hose can cause coolant to leak [A] or the hose to burst if the line is not properly maintained. Visually inspect the hoses for signs of deterioration. Squeeze the hoses. A hose s hould not be hard and brittle, nor should it[...]

COOLING SYSTEM 3- 15 Thermostat Thermostat Removal • Remove: Coolant (Draining) Seat (see Frame chapter) Fuel T ank (see Fuel System chapter) • Unscrew the thermostat housing bolts [A]. • Separate the housing from the housing cover [B]. • Pull out the thermostat [A]. Thermostat Installation • Install the thermostat [A] into the thermostat[...]

3-16 COOLING SYSTEM Radiator Fan Switch, W a ter T emperature Switch CAUTION The fan switch or the water temperature switch should never be allowed to fall on a hard surface. Such a shock to these parts can damage them. Radiator Fan Switch Removal • Pull out the cover [A]. • Disconnect the fan switch connector [B]. • Remove the radiator fan s[...]

ENGINE T OP END 4-1 4 Engine T op E nd T able of C ontents Exploded View ................................... 4-2 Specifications .................................... 4-4 Clean Air System ............................... 4-6 V acuum Switch V alve Removal ... 4-6 V acuum Switch V alve Installation 4-6 Air Suction V alve Installation ........ 4-6 Air Su[...]

4-2 ENGINE T OP END Exploded V iew 1. Closed coil end faces downward. 2. Arrow points to the front (ER500-C1 ∼ C4). Install the piston so that the circle mark on the top of the piston come to front side of the engine (ER500-C5). 3. “N” marked side faces up. L: Apply a non-permanent locking agent. M: Apply molybdenum disulfide grease. O: Apply[...]

ENGINE T OP END 4-3 Exploded V iew T1: 13 N·m (1.3 kgf·m, 9.5 ft·lb) T2: 9.8 N·m (1.0 kgf·m, 87 in·lb) T3: 1 1 N·m (1.1 kgf·m, 95 in·lb) T4: 12 N·m (1.2 kgf·m, 8.5 ft·lb) T5: 15 N·m (1.5 kgf·m, 1 1.0 ft·lb) T6: 20 N·m (2.0 kgf·m, 14.5 ft·lb) T7: 25 N·m (2.5 kgf·m, 18.0 ft·lb) T8: 39 N·m (4.0 k gf·m, 29 ft·lb) T9: 51 N·m (5.[...]

4-4 ENGINE T OP END Specifications Item Standard Service Limit Clean Air System V acuum Switch V alve Closing Pressure Open → Close 57 ∼ 65 kPa (430 ∼ 490 mmHg) ––– Camshafts Cam Height: Exhaust 35.475 ∼ 35.591 mm (1.3967 ∼ 1.4012 in.) 35.38 mm (1.3929 in.) Inlet 35.474 ∼ 35.590 mm (1.3966 ∼ 1.4012 in.) 35.37 mm (1.3925 in.) Cam[...]

ENGINE T OP END 4-5 Specifications Item Standard Service Limit Outside diameter: Exhaust 24.0 ∼ 24.2 mm (0.945 ∼ 0.953 in.) ––– Inlet 28.3 ∼ 28.5 mm (1.1 14 ∼ 1.122 in.) ––– V a l v es p r i n gf r e el e n g t h : Inner 36.3 mm (1.429 in.) 35 mm (1.3780 in.) Outer 40.4 mm (1.591 in.) 39 mm (1.5354 in.) Cylinder , Piston Cylinde[...]

4-6 ENGINE T OP END Clean Air System V acuum Switch V alve Removal • Remove: Fuel T ank (see Fuel System chapter) • Remove the clamps [A] and take off the vacuum switch valve [B]. V a cuum Switch V alve Installation • Install the vacuum switch valve so that the air hole [A] faces downwards. Air Suction Valve Installation • Replace the gaske[...]

ENGINE T OP END 4-7 Clean A ir System Clean Air System Hose Inspection • Be certain that all the hoses are routed without being flat- tened or kinked, and are connected correctly to the air cleaner housing, silencer , vacuum switch valve, carbure- tors, and air suction valve covers. If they are not, correct them. Replace them if they are damaged.[...]

4-8 ENGINE T OP END Cylinder Head Cover Cylinder Head Cover Removal • Drain the coolant (see Cooling System chapter). • Remove: Fuel T ank (see Fuel System chapter) Choke Cable Lower End [A] Throttle Cable Lower Ends [B] Spark Plug Caps [C] V acuum Switch V alve [D] Thermostat Housing [E] • Unscrew the cylinder head cover bolts [A]. • T ilt[...]

ENGINE T OP END 4-9 Camshaft Chain T ensioner Camshaft Chain T ensioner Removal CAUTION This is a non-return type cam chain tensioner . The push rod does not return to its original position once it moves out to take up cam chain slack. Ob- serve all the rules listed below: When removing the tensioner , do not take out the mounting bolts only halfwa[...]

4-10 ENGINE T OP END Camshaft, Camshaft Chain Camshaft Removal • Remove the cylinder head cover . • Position the crankshaft at #2 piston TDC. ○ Using a wrench on the crankshaft rotation bolt turn the crankshaft clockwise until the "C" m ark line [A] on the rotor is aligned with the notch [B] in the edge of the upper hole in the alte[...]

ENGINE T OP END 4-1 1 Camshaft, Camshaft Chain • Engage the camshaft chain w ith the camshaft sprockets. ○ Pull the tension side [A] (inlet side) of the chain taut to install the chain. ○ The timing marks [B] on the inlet sprocket [C] must be aligned with the cylinder head upper surface [D]. • Pull the chain taut and fit it onto the camshaf[...]

4-12 ENGINE T OP END Camshaft, Camshaft Chain Camshaft, Camshaft Cap Wear The journal wear is measured using plastigage (press gauge), which is inserted into the clearance to be mea- sured. The plastigage indicates the clearance by the amount it is compressed and widened when the parts are assembled. • Cut strips of plastigage to journal width. P[...]

ENGINE T OP END 4-13 Rocker Shaft, Rocker Arm Rocker Shaft, Rocker Arm Removal • Remove the camshafts (see Camshaft Removal). • Unscrew the rocker shafts [A] and remove the rocker arms [B] and springs [C]. ○ Mark and record the rocker arm locations so that the rocker arm can be reinstalled in their original positions. Rocker Shaft, Rocker Arm[...]

4-14 ENGINE T OP END Oil Pipe Cylinder Head Oil Pipe Removal • Remove the oil pipe mounting bolts [A] and pull the oil pipes [B] and O-rings out of the cylinder head. Cylinder Head Oil Pipe Installation • Flush out the oil pipes with a high flash-point solvent. • Check that the O-rings are in good condition. If they are damaged, replace them [...]

ENGINE T OP END 4-15 Cylinder Head Compression Measurement • Remove the seat (see Frame chapter). • 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 the fue l tank, ignition coil and spark plugs, and attach the c[...]

4-16 ENGINE T OP END Cylinder Head Cylinder Head Removal • Remove: Cylinder Head Cover (see Cylinder Head Cover Re- moval) Exhaust Pipes and Mufflers (see Crankshaft/T ransmis- sion chapter) Cam Chain T ensioner (see Chain T ensioner Removal) Camshafts (see Camshaft Removal) Carburetors (see Fuel System chapter) • Remove the main oil pipe banjo[...]

ENGINE T OP END 4-17 Cylinder Head • Install a new cylinder head gasket with "UP" [A] marked side positioning to the right. NOTE ○ The camshaft caps are machined with the cylinder head so if a new cylinder head is installed, use the caps that are supplied with the new head. • T ighten the 10 mm cylinder head bolts following the tigh[...]

4-18 ENGINE T OP END Cylinder Head • Using compressed air , blow out any particles which may obstruct the oil passage [A] in the cylinder head. • Install the valves (see V alve Installation).[...]

ENGINE T OP END 4-19 Va l v e s V alve Clearance Inspection V alve Clearance Inspection NOTE ○ V alve clearance must be checked and adjusted w hen the engine is cold (room temperature). • Remove the cylinder head cover (see Cylinder Head Cover Removal). • Remove the cylinder head oil pipes (see Cylinder Head Oil Pipe Removal). • Unscrew the[...]

4-20 ENGINE T OP END Va l v e s • Measure the clearance of each valve by inserting a thick- ness gauge [A] between the adjusting screw [B] and the valve stem. V alve Clearance (when cold) Inlet 0.13 ∼ 0.18 mm (0.0051 ∼ 0.0071 in.) Exhaust 0.18 ∼ 0.23 mm (0.0070 ∼ 0.0090 in.) V alve Clearance Adjustment If the valve clearance is incorrect,[...]

ENGINE T OP END 4-21 Va l v e s Va l v e G ui d e R e mo va l • Remove: V alve (see V alve Removal) Oil Seal Spring Seats • Heat the area around the valve guide to about 120 ∼ 150°C (248 ∼ 302°F), and hammer lightly on the valve guide arbor [A] to remove the guide from the top of the head. Special T ool - V alve Guide Arbor , 5.5: 57001-1[...]

4-22 ENGINE T OP END Va l v e s If the width is too wide, too narrow o r uneven, repair the seat (see V alve Seat Repair). [F] Good [G] T oo Wide [H] T oo Narrow [J] Uneven V a l v eS e a t i n gS u r f a c eW i d t h Inlet 0.5 ∼ 1.0 mm (0.020 ∼ 0.039 in.) Exhaust 0.5 ∼ 1.0 mm (0.020 ∼ 0.039 in.) Measuring Valve-to- guide Clearance (Wobble [...]

ENGINE T OP END 4-23 Va l v e s Seat Cutter Operating Cares 1. This valve seat cutter is developed to grind the valve for repair . Therefore the cutter must not be used for other purposes than seat repair . 2. Do not drop or shock the valve seat cutter , or the dia- mond particles may fall off. 3. Do not fail to apply engine oil to the valve seat c[...]

4-24 ENGINE T OP END Va l v e s • Measure the outside diameter (O.D.) of the seating sur- face with a vernier caliper . If the outside diameter of the seating surface is too small, repeat the 45° grind [A] until the diameter is within t he specified range. Original Seating S urface [B] NOTE ○ Remove all pittings of flaws from 45° ground surfa[...]

ENGINE T OP END 4-25 Va l v e s • Lap the valve to the s eat, once the seat width and O.D. are within the ranges specified above. ○ Put a little coarse grinding compound on the face of the valve in a number of places around the valve head. ○ Spin the valve against the seat until the grinding com- pound produces a smooth, matched surface on bo[...]

4-26 ENGINE T OP END Va l v e s[...]

ENGINE T OP END 4-27 Cylinder , Piston Cylinder Removal • Remove the cylinder head (see Cylinder Head Removal). • Remove the main oil pipe mounting bolt. • Remove the bolts [A] and pull out the water pipe with wa- ter pump cover [B] (see Cooling System chapter). • T ake out the cylinder block so as not to damage the main oil pipe. Cylinder [...]

4-28 ENGINE T OP END Cylinder , Piston Piston Installation • Install the oil ring expander [A] in the piston oil ring groove so that the expander ends [B] butt together , never overlap. • Install the upper and lower steel rails. There i s no UP or Down to the rails. They can be installed either way . • Do not mix up the top ring and second ri[...]

ENGINE T OP END 4-29 Cylinder , Piston Piston Ring, Piston Ring Groove Wear • Check for uneven groove wear by inspecting the ring seat- ing. The rings should fit perfectly parallel to the groove sur- faces. If not, the piston must be replaced. • With the piston rings in their grooves, make several mea- surements with a thickness gauge [A] to de[...]

4-30 ENGINE T OP END Cylinder , Piston Piston Diameter • Measure the outside diameter [A] of each piston 5 mm [B] up from the bottom of the piston at a right angle to the direction of the piston pin. If the measurement is under the service limit, replace the piston. Piston Diameter Standard: 73.942 ∼ 73.957 mm (2.91 1 1 ∼ 2.91 17 in.) Service[...]

ENGINE T OP END 4-31 Carburetor Holder Carburetor Holder Installation • Install the carb uretor holders. The projection [A] faces upwards. • Install the holder clamps [A] as shown being careful of the screw position and the screw head [B] direction. WA R N I N G Install the clamp screws horizontally . Otherwise the screws could come in contact [...]

4-32 ENGINE T OP END Muffler Muffler Removal • Unscrew the muffler mounting bolt and nut [A]. • Remove the exhaust pipe holder nuts [A]. • T ake off the muffler [A]. Muffler Installation • Replace the exhaust pipe holder gaskets with new ones. • First, all the bolts and nuts to a snag fit. • Secondary , tighten the exhaust pipe holder n[...]

CLUTCH 5-1 5 Clutch T able of C ontents Exploded View ................................................................................................................... ..... 5-2 Specifications ................................................................................................................. ........ 5-4 Clutch Lever and Cable .....[...]

5-2 CLUTCH Exploded V iew 1. Starter Lockout Switch CL: Apply cable lubricant. G: Apply high temperature grease. M: Apply molybdenum disulfide grease. O: Apply engine oil. SS: Apply silicone sealant.[...]

CLUTCH 5-3 Exploded V iew T1: 1.5 N·m (0.15 kgf·m, 13 in·lb) T2: 9.3 N·m (0.95 kgf·m, 82 in·lb) T3: 1 1 N·m (1.1 kgf·m, 95 in·lb) T4: 132 N·m (13.5 kgf·m, 98 ft·lb)[...]

5-4 CLUTCH Specifications Item Standard Service Limit Clutch Lever Position Non-adjustable ––– Clutch Lever Free Play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) ––– Clutch Friction Plate Thickness 2.9 ∼ 3.1 mm (0.1 14 ∼ 0.122 in.) 2.75 mm (0.1082 in.) Friction and Steel Plate W arp 0.2 mm (0.008 in.) or less 0.3 mm (0.012 in.) Clutch Spring Fre[...]

CLUTCH 5-5 Clutch Lever and Cabl e Due to f riction plate wear and clutch cable stretch over a long period of use, the clutch must be adjusted in accor- dance with the Periodic Maintenance Chart. WA R N I N G T o avoid a serious burn, never touch the engine or exhaust pipe during clutch adjustment. Clutch Adjustment Clutch Lever Free Play Inspectio[...]

5-6 CLUTCH Clutch Lever and Cable Cable Lubrication Whenever the clutch cable is removed, lubricate the clutch cable as follows. • Apply a thin coating of grease to the cable upper and lower ends. • Lubricate the cable with a penetrating rust inhibitor .[...]

CLUTCH 5-7 Right Engine Cover Clutch Cover Removal • Drain the engine oil (see Engine Lubrication S ystem chapter). • Remove: Clutch Cable Right Footpeg Assembly Clutch Cover Bolts [A] • T urn the release lever [B] toward the front as shown, and remove the clutch cover . Clutch Cover I nstallation • Apply silicone sealant to the area [A] wh[...]

5-8 CLUTCH Right Engine Cover • Free the clutch inner cable tip from the clutch release lever [A]. • T urn the release lever toward the rear [ B] as shown in the figure. • Pull the lever and shaft assembly out of the clutch cover . Clutch Release Installation CAUTION Always install a new oil seal when the clutch release shaft is removed. • [...]

CLUTCH 5-9 Clutch Clutch Removal • Drain the engine oil (see Engine Lubrication S ystem chapter). • Remove the clutch c over (see Clutch Cover Removal). • Remove the clutch spring bolts [A], washers [B] and springs. • Remove the clutch spring plate [C] with the thrust ball bearing [D] and pusher [E]. • Remove the friction plates and steel[...]

5-10 CLUTCH Clutch ○ The grooves [A] on the friction plate surfaces are cut tan- gentially and radially , install the friction plates so that the grooves run toward the center in the d irection of the clutch housing rotation (counterclockwise viewed from the en- gine right side). CAUTION If new dry steel plates and friction plates are in- stalled[...]

CLUTCH 5-1 1 Clutch Clutch Spring Free Length Measurement • Measure the free length of the clutch spring [A]. If any spring is shorter than the service limit, it must be replaced. Clutch Spring Free Length Standard: 34.2 mm (1.346 in.) Service Limit: 33.1 mm (1.303 in.) Clutch Housing Finger Inspectio n • Visually inspect the fingers [A] of the[...]

[...]

ENGINE LUBRICA TION SYSTEM 6 -1 6 Engine Lubrication System T able of C ontents Exploded View ................................................................................................................... ..... 6-2 Engine Oil Flow Chart.............................................................................................................[...]

6-2 ENGINE LUBRICA TION SYSTEM Exploded V iew 1. Oil Filter 2. Main Oil Passage Plug 3. Oil Pump Drive Gear 4. Oil Pump 5. Oil Screen 6. Oil Pressure Relief V alve 7. Oil P ressure Switch 8. Engine Oil Drain Plug[...]

ENGINE LUBRICA TION SYSTEM 6 -3 Exploded V iew T1: 1.5 N·m (0.15 kgf·m, 13 in·lb) T2: 7.8 N·m (0.80 kgf·m, 69 in·lb) T3: 1 1 N·m (1.1 k gf·m, 95 in·lb) T4: 12 N·m (1.2 kgf·m, 8.5 ft·lb) T5: 15 N·m (1.5 kgf·m, 1 1.0 ft·lb) T6: 17 N·m (1.75 kgf·m, 12.5 ft·lb) T7: 18 N·m (1.8 kgf·m, 13 ft·lb) T8: 20 N·m (2.0 kgf·m, 14.5 ft·lb) [...]

6-4 ENGINE LUBRICA TION SYSTEM Engine Oil Flow Chart[...]

ENGINE LUBRICA TION SYSTEM 6-5 Specifications Item Standard Engine Oil Grade API SE, SF , S G or API SH or SJ JASO MA Vis c os it y SAE 10W-40 Capacity 2.8 L (when filter is not removed) 3.0 L (when filter is removed) 3.4 L (when engine is completely dry) Level Between upper and lower level lines Oil Pressure Measurement Oil pressure @4 000 r/min ([...]

6-6 ENGINE LUBRICA TION SYSTEM Engine Oil 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 . Engine Oil Level Inspection • If the oil has just been changed, start the engine and run it for [...]

ENGINE LUBRICA TION SYSTEM 6-7 Engine Oil and Oil Filter • Fill the engine with a good quality motor oil specified in the table. • Check the oil level. Engine Oil Grade: API SE, SF , SG or API SH or SJ with JASO MA Vis co s it y: SAE 10W 40 Capacity: 2.8 L (When filter is not removed) 3.0 L (Wh en filt e r is remove d ) 3.4 L (When engine is co[...]

6-8 ENGINE LUBRICA TION SYSTEM Oil Pan and Relief V alve Oil Pan Removal • Drain the engine oil (see Engine Oil Change). • Disconnect the oil pressure switch lead. • Remove the oil pan mounting bolts [A] and the oil pan from the crankcase. Oil Pan Installation • Check that the O-rings for the outlet side [A] and inlet side [B] are in good c[...]

ENGINE LUBRICA TION SYSTEM 6-9 Oil Pan and Relief V alve Relief V alve Inspection • Remove the relief valve. • Check to see if the steel ball inside the valve slides smoothly when pushing it in with a wooden or other soft rod, and see if it comes back to its seat by valve spring pressure. NOTE ○ Inspect the valve in its assembled state. Disas[...]

6-10 ENGINE LUBRICA TION SYSTEM Oil Pump Oil Pump Removal • Drain the coolant (see Cooling System chapter). • Drain the engine oil (see Engine Oil Change). • Remove the engine (see Engine Removal/Installation chapter). • Remove: W ater Pump (see Cooling System chapter) Clutch Cover (see Clutch chapter) Alternator Cover with Gear Change Link[...]

ENGINE LUBRICA TION SYSTEM 6-1 1 Oil Pump • Be sure to install the oil pump and outer oil pipe O-rings [A], and apply engine oil to them. • Install the oil pump outer oil pipe [B] and oil screen. ○ Apply a non-permanent locking agent to the oil pipe bolt and tighten it. T orque - O il Pump Outer Oil Pipe B o lt: 1 1 N ·m (1.1 kgf·m, 95 in·[...]

6-12 ENGINE LUBRICA TION SYSTEM Oil Pressure Measurement Oil Pressure Measurement NOTE ○ Measure the oil pressure after the engine is warmed up. • Remove: Right Footpeg Assembly Oil Passage Plug W ARNING If the oil passage p lug is removed while the engine is warm, hot engine oil will drain through the oil pas- sage; take care against burns. ?[...]

ENGINE REMOV AL/INST ALLA TION 7-1 7 Engine Removal/Installation T able of C ontents Exploded View ................................................................................................................... ..... 7-2 Engine Removal/Installation .................................................................................................[...]

7-2 ENGINE REMOV AL/INST ALLA TION Exploded V iew T1: 44 N·m (4.5 kgf·m, 33 ft·lb) T2: 25 N·m (2.5 kgf·m, 18 ft·lb)[...]

ENGINE REM OV AL/INST ALLA TION 7-3 Engine Removal/Installation Engine Removal • Set the motorcycle up on its center stand. • Squeeze the brake lever slowly and hold it with a band [A]. WA R N I N G Be sure to hold the front brake when removing the engine, or the motorcycle may fall over . It could cause an accident and injury . CAUTION Be sure[...]

7-4 ENGINE REMOV AL/INST ALLA TION Engine Removal/Installation • Remove: Battery Negative Lead [A] Starter Motor Lead [B] • Remove: Oil Pressure Switch Lead [A] Neutral Switch Lead [B] Sidestand Switch Lead Connector [C] • Support the engine with a stand or jack [A]. • Remove the engine mounting bolts [B]. • Remove the downtube bolts [C] [...]

ENGINE REM OV AL/INST ALLA TION 7-5 Engine Removal/Installation • Insert the rear mounting bolts from the left side of the engine. • T ighten the rear engine upper mounting bolt and nut first to eliminate the gap betwe en the engine and frame bracket, and then the rear engine lower mounting bolt and nut. • T ighten the engine mounting bracket[...]

[...]

CRANKSHAFT/TRANSMISSION 8-1 8 Crankshaft/T ransmission T able of C ontents Exploded View ................................................................................................................... ..... 8-2 Specifications ................................................................................................................. ......[...]

8-2 CRANKSHAFT/TRANSMISSION Exploded V iew 1. 8 mm Bolt (55 mm l.) 2. 6 mm Bolts (60 mm l.) 3. 6 mm Bolts (80 mm l.) 4. 6 mm Bolts (40 mm l.) 5. 8 mm Bolts (80 mm l.) 6. 8 mm Bolts (40 mm l.) 7. Neutral Switch T1: 8.8 N·m (0.9 kgf·m, 78 in·lb) T2: 1 1 N·m (1.1 kgf·m, 95 in·lb) T3: 12 N·m (1.2 kgf·m, 8.5 ft·lb) T4: 15 N·m (1.5 kgf·m, 1 1 [...]

CRANKSHAFT/TRANSMISSION 8-3 Exploded V iew G: Apply high tempera ture grease. L: Apply a non -permanent locking agent. LG: Apply liquid gasket-black. M: Apply a thin coat of molybdenum disulfide grease. O: Apply engine oil. S: Follow the specific tightening sequence. SS: Apply silicone sealant. WL: Apply soap water solution or rubbe r lubricant.[...]

8-4 CRANKSHAFT/TRANSMISSION Specifications Item Standard Service Limit Crankshaft, Connecting Rods Connecting Rod Bend ––– 0.2/100 mm (0.0079/4 in.) Connecting Rod T wist ––– 0.2/100 mm 0.0079/4 in.) Connecting Rod Big End Side Clearance 0.13 ∼ 0.38 mm (0.0051 ∼ 0.0150 in.) 0.50 mm (0.02 in.) Connecting Rod Big End Bearing Insert/cr[...]

CRANKSHAFT/TRANSMISSION 8-5 Specifications Item Standard Service Limit Crankshaft Main Bearing Insert Thickness: Brown 1.490 ∼ 1.494 mm (0.0587 ∼ 0.0588 in.) ––– Black 1.494 ∼ 1.498 mm (0.0588 ∼ 0.0590 in.) ––– Blue 1.498 ∼ 1.502 mm (0.0590 ∼ 0.0591 in.) ––– Crankshaft main bearing insert selection: Bearing Insert* Cra[...]

8-6 CRANKSHAFT/TRANSMISSION Specifications Item Standard Service Limit Shift Fork Ear Thickness 4.9 ∼ 5.0 mm (0.193 ∼ 0.197 in.) 4.8 mm (0.189 in.) Shift Fork Guide Pin Diameter 7.900 ∼ 8.000 mm (0.31 10 ∼ 3150 in.) 7.8 mm (0.307 in.) Shift Fork Dowel Pin Diameter 7.985 ∼ 8.000 mm (0.3144 ∼ 0.3150 in.) 7.8 mm (0.307 in.) Shift Drum Groo[...]

CRANKSHAFT/TRANSMISSION 8-7 Crankcase Splitting Crankcase Splitting • Remove the engine (see Engine Removal/Installation chapter). • Set the engine on a clean surface and hold the engine steady while parts are being removed. • Remove: Shift Lever (see External Shift Mechanism Removal) Starter Motor (see Electrical System chapter) W ater Pump [...]

8-8 CRANKSHAFT/TRANSMISSION Crankcase Splitting Crankcase Assembly CAUTION The upper crankcase half and th e lower crankcase half are machined at the factory in the assembled state, so the crankcase halves must be replaced to- gether as a set. • Using compressed air , blow out the oil passages [A] in the crankcase halves. • With a high flash-po[...]

CRANKSHAFT/TRANSMISSION 8-9 Crankcase Splitting • T ighten the lower crankcase-half bolts using the following 3 steps: ○ T ighten all lower crankcase-half bolts to a snug fit. Following the sequence numbers on the lower crankcase half, torque the 8 mm bolts first to about one half of the specification, and finally to the specification in the sa[...]

8-10 CRANKSHAFT/TRANSMISSION Clutch Housing/Primary Ch ain Clutch Housing/Primary Chain Removal • Remove the engine. • Remove: Cylinder Head, Cylinder and Pistons (see Engine T op End chapter) Starter Clutch Sprocket (see Electrical System chapter) Clutch (except the Clutch Housing) • Split the crankcase. • Lift up the transmission drive sh[...]

CRANKSHAFT/TRANSMISSION 8-1 1 Crankshaft/Connecting Rods Crankshaft Removal • Split the crankcase (see Crankcase Splitting). • Remove the clutch housing and the primary chain. • Remove the crankshaft with the camshaft chain and pri- mary chain. Crankshaft Installation CAUTION If the crankshaft, bearing inserts or crankcase halves are replaced[...]

8-12 CRANKSHAFT/TRANSMISSION Crankshaft/Connecting Rods Big End Cap [A] Connecting Rod [B] Weight Mark, Alphabet [C] Diameter Mark [D] • Apply engine oil to the inner surface of the upper and lower bearing inserts [A]. • Apply a small amount of engine oil to the threads [B] and seating surface [C] of the connecting rod big end cap nuts. • T i[...]

CRANKSHAFT/TRANSMISSION 8-13 Crankshaft/Connecting Rods • Measure the connecting rod twist. ○ With the big-end arbor [A] still on V blocks [C], hold the connecting rod horizontal and measure the dif ference in the height of the arbor [B] above the surface plate over a 100 mm (4 in.) length of the arbor to determine the amount of connecting rod [...]

8-14 CRANKSHAFT/TRANSMISSION Crankshaft/Connecting Rods If the clearance is within the standard, no bearing insert replacement is required. If the clearance is between 0.066 mm and the service limit (0.10 mm, 0.0039 in.), replace the bearing inserts [A] w ith inserts painted blue [B] Check insert/crankpin clearance with a plastigage. The clearance [...]

CRANKSHAFT/TRANSMISSION 8-15 Crankshaft/Connecting Rods • Select the proper bearing i nsert in accordance with the combination of the connecting rod and crankshaft coding. • Install the new insert in the connecting rod and check in- sert/journal clearance with a plastigage. Connecting Rod Big End Bearin g Insert Selection Bearing Insert Con-rod[...]

8-16 CRANKSHAFT/TRANSMISSION Crankshaft/Connecting Rods If the clearance is within the standard, no bearing insert replacement is required. If the clearance is between 0.044 mm and the service limit (0.08 mm), replace the bearing inserts [A] with i n- serts painted blue [B] Check insert/journal clearance with a plastigage. The clearance may exceed [...]

CRANKSHAFT/TRANSMISSION 8-17 Crankshaft/Connecting Rods Crankshaft Main Bearing Insert Selection Bearing Insert* Crankcase Main Bearing Bore Diameter Mark Crankshaft Main Journal Diameter Mark Size Color Part Number Journal Nos 92028-1 102 2, 3 ○ 1 Brown 92028-1274 1, 4 92028-1 100 2, 3 None None Blue 92028-1272 1, 4 ○ None 92028-1 101 2, 3 Non[...]

8-18 CRANKSHAFT/TRANSMISSION Balancer Balancer Removal • Split the crankcase (see Crankcase Splitting). • Pull the balancer shaft with the balancer gear out of the crankcase. Balancer Installation • Apply oil to the inside of the balancer shaft bearing insert. • Align the timing mark [A] on the balancer gear [B] with the timing mark on the [...]

CRANKSHAFT/TRANSMISSION 8-19 Balancer If either journal has worn past the service limit, replace the balancer shaft with a new one. If the measured journal diameters are not less than the service l imit, but do not coincide with the original diameter markings on the balancer shaft, write new marks on it. Balancer Shaft Diameter Marks None: 27.987 ?[...]

8-20 CRANKSHAFT/TRANSMISSION T ransmission External Shift Mechanism Removal • Remove: Engine Sprocket (see Final Drive chapter) Chain G uard [A] Neutral Switch Lead Connector [B] • Place an oil pan beneath the external shift mechanism cover [A]. • Remove the external shift m echanism cover bolts [B]. • Pull the cover . • Remove the cover [...]

CRANKSHAFT/TRANSMISSION 8-21 T ransmission • Apply high temperature grease to the seal lips. • Insert the shift shaft into the cover [A], and then fit the shift mechanism arm [B] to the shift drum [C]. • T ighten the cover bolts. T orque - Ext ernal Shift Mechanism Cover Bolts: 1 1 N·m (1.1 kgf·m. 95 in·lb) • Check: Engine Oil Level (see[...]

8-22 CRANKSHAFT/TRANSMISSION T ransmission T ransmission Shaft Installation • With a high flash-point solvent, clean off the outer cir- cumferences of the transmission ball bearings and needle bearings, and their bearing housings, and wipe dry . • Check to see that the set rings [A] and set pins [B] are in place in the transmission bearing hous[...]

CRANKSHAFT/TRANSMISSION 8-23 T ransmission Drive Shaft Assembly • Apply engine oil liberally to the drive shaft, gears, bear- ings and bushing. • Install the drive shaft ball bearing using the bearing driver [A]. Special T ool - Bearing Driver , 32: 57001-382 • Replace any circlips that were removed with new ones. ○ Always install circlips [...]

8-24 CRANKSHAFT/TRANSMISSION T ransmission Output Shaft Assembly • Assembly is the reverse of disassembly . Note the follow- ing. • Apply engine oil liberally to the output shaft, gears, bear- ings, bushing and O-ring. • Install the output shaft ball bearing, O-ring and collar us- ing the bearing driver . Special T ool - Bearin g Driver , 32:[...]

CRANKSHAFT/TRANSMISSION 8-25 T ransmission • The output s haft gears c an be identified by size: the largest diameter gear is 1st gear , and the smallest is 6th. Be sure that all parts are put back in the correct sequence and facing the proper direction, and that all circlips and washers are properly in place. • Proper sequence starting w ith 2[...]

8-26 CRANKSHAFT/TRANSMISSION T ransmission Shift Drum and Fork Installation • Insert the shift drum [A] into the crankcase part way , install the 3rd/4th shift fork [B] with the longer side [C] facing the neutral switch, i.e., the longer side goes onto the drum first. • Push the shift drum in the rest of the way . • Apply a non-permanent lock[...]

CRANKSHAFT/TRANSMISSION 8-27 T ransmission Shift Drum Disassembly • Remove the screw [A] and the pin plate [B]. • Pull out the shift drum cam [C]. • T ake of f the ball bearing [D]. • Pull off the dowel pin [E]. Shift Drum Assembly • Set the dowel pin into larger hole of the two which is the farthest hole [A] from the center . • Install[...]

8-28 CRANKSHAFT/TRANSMISSION T ransmission Ball and Needle Bearing Wear • Check the following ball bearings: shift drum LH, drive shaft RH, and output shaft LH. ○ Since the ball bearings are made to extremely c lose toler- ances, the wear must be judged by feel rather than mea- surement. Clean each bearing in a high flash-point sol- vent, dry i[...]

WHEELS/TIRES 9-1 9 Wheels/T ires T able of C ontents Exploded View ................................................................................................................... ..... 9-2 Specifications ................................................................................................................. ........ 9-3 Wheels (Rims) .[...]

9-2 WHEELS/TIRES Exploded V iew T1: 20 N·m (2.0 kgf·m, 14.5 ft·lb) T2: 88 N·m (9.0 kgf·m, 65 ft·lb) T3: 98 N·m (10.0 kgf·m, 72 ft·lb) G: Apply grease. R: Replacement P arts S: Follow the specific tightening sequence. WL: Apply soap and water solution or rubber lubricant.[...]

WHEELS/TIRES 9-3 Specifications Standard Item EN500-C1 ∼ C2, D1 EN500-C3 ∼ Service Limit Wheels (Rims) Rim Runout: Radial ––– ––– 0.5 mm (0.02 in.) Axial –– – ––– 0.8 mm (0.03 in.) Axle Runout/100 mm (3.94 in.) 0.1 mm (0.004 in.) or less ← 0.2 mm (0.008 in.) Wheel Balance 10 g ( 0.35 US oz) or less ← ––– Balanc[...]

9-4 WHEELS/TIRES Wheels (Rims) Front Wheel Removal • Remove the speedometer cable lower end [A]. • Loosen the front axle nut [B]. • Raise the front wheel off the ground. Special T ool - Jack: 57001- 1238 • Loosen the axle clamp bolt [A]. • Pull out the axle [B] to the right, and remove the front wheel, speedometer gear housing, and collar[...]

WHEELS/TIRES 9-5 Wheels (Rims) Rear Wheel Removal • Remove: Cotter P in [A] Rear Axle Nut [B] (loosen) • Raise the rear wheel off the ground using the center stand. • Remove: Cotter P in [A] T orque Link Nut and Bolt [B] Adjuster [C] and Brake Rod [D] Rear Axle Nut • Pull out the rear axle to the right and drop the rear wheel. • Remove th[...]

9-6 WHEELS/TIRES Wheels (Rims) • Insert a new cotter pin [A]. NOTE ○ When inserting the cotter pin, if the slots in the nut do not align with the cotter pin hole in the axel, tighten the nut clockwise [B] up to next alignment. ○ It should be within 30 degree. ○ Loosen once and tighten a gain when the slot goes past the nearest hole. • Ben[...]

WHEELS/TIRES 9-7 Wheels (Rims) Axle Inspection • Visually inspect the front and rear axle for damages. If the axle is damaged or bent, replace it. • Measure the axle runout with a dial gauge. If axle runout exceeds the service limit, replace the axle. Axle Runout/100 mm (3.94 in.) Standard: less than 0.1 mm (0.004 in.) Service Limit: 0.2 mm (0.[...]

9-8 WHEELS/TIRES Wheels (Rims) • Repeat the entire procedure as many times as necessary to achieve correct wheel balance. • Permanently install the balance weight. Balance Weight Part Number Wei gh t: g ( US o z ) 41075-1059 10 ( 0.35) 41075-1060 20 ( 0.71) 41075-1061 30 ( 1.06) NOTE ○ Balance weights are available from K awasaki dealers in 1[...]

WHEELS/TIRES 9-9 Wheels (Rims) • Check that the weight [A] and clip [B] are fully seated on the rim [C] and that the clip is hooked over the rib [D]. WA R N I N G If the balance weight has any play on the rim, the clip of the weight has been stretched. Replace the loose balance weight. Do not reuse balance weight. Unbalanced wheels can create an [...]

9-10 WHEELS/TIRES Tir e s Air Pressure Inspection/Adjustment • Measure the tire air pressure with an air pressure gauge [A] when the tires are cold (that is, when the motorcycle has not been rid den more than a mile during the past 3 hours). Adjust the tire air pressure according to the specifications if necessary . Air Press u re (when cold) Fro[...]

WHEELS/TIRES 9-1 1 Tir e s Tire Remova l CAUTION Do not lay the front 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 wheel. • T o maintain wheel balance, mark the valve stem position on the tire with c halk so that the tire ca[...]

9-12 WHEELS/TIRES Tir e s Tire Installation • Inspect the rim and the tire, and replace them if neces- sary . • Clean the sealing surfaces of the rim and tire, and smooth t h es e a l i n gs u r f a c e so ft h er i mw i t haf i n ee m e r yc l o t hi f necessary . • Remove the air valve and discard it. CAUTION Replace the air valve whenever [...]

WHEELS/TIRES 9-13 Tir e s • Position the tire on the rim so that the valve [A] is at the tire balance mark [B] (the chalk mark made during removal, or the yellow paint mark on a new tire). • Install the tire bead on the rim using a suitable commer- cially available tire changer . • Lubricate the tire beads and rim flanges with a soap and wate[...]

9-14 WHEELS/TIRES Hub Bearing Hub Bearing Removal • Remove the wheel, and take out the following. 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 w heel so that the disc does not touch the ground. Front Grease Seal [A] Circlips [B] Speedometer Gear Drive [C] Special T [...]

WHEELS/TIRES 9-15 Hub Bearing • Replace the circlips with new ones. Special T ool - Inside Circ lip Pliers: 57001-143 • Replace the grease seal with new ones. • Press in the grease seals so that the seal surface flush with the end of the hole. ○ Apply high temperature grease to the grease seal lips. Special T ool - Bearing Driver Set: 57001[...]

9-16 WHEELS/TIRES Speedometer G ear Disassembly and Assembly NOTE ○ It is recommended that the assembly be replaced rather than attempting to repair the components. • Install the speedometer gear so that it fits in the speedometer gear drive notches (see Front Wheel Installation). Lubrication • Clean and grease [A] the speedometer gear housin[...]

FINAL DRIVE 10-1 10 Final Drive T able of C ontents Exploded View ................................................................................................................... ..... 10-2 Specifications ................................................................................................................. ........ 10-3 Drive Chain ..[...]

10-2 FINAL DRIVE Exploded V iew 1. Drive Chain Joint (ER500-C4 ∼ ) T1: 1 1 N·m (1.1 kgf·m, 95 in·lb) T2: 127 N·m (13.0 kgf·m, 94 ft·lb) T3: 59 N·m (6.0 kgf·m, 43 ft·lb) T4: 98 N·m (10.0 kgf·m, 72 ft·lb) CO: Apply chain oil. G: Apply grease. L: Apply non-permanent locking agent. O: Apply oil. R: Replacement P arts[...]

FINAL DRIVE 10-3 Specifications Item Standard Service Limit Drive Chain Chain Slack 35 ∼ 40 mm (1.4 ∼ 1.6 in.) ––– 20-link Length 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) 323 mm (12.7 in.) Standard Chain Make Enuma ––– Ty p e EK520SX-O, Endless ––– EK520MVXL (ER500-C4 ∼ ) Link 106 links ––– Sprockets Rear Sprocket W ar[...]

10-4 FINAL DRIVE Drive Chain Drive Chain Sla ck Inspection Drive Chain Slack Inspection NOTE ○ Check the slack with the motorcycle setting on its c enter stand. ○ Clean the chain if i t is dirty , and lubricate it if it appears dry . • Check the wheel alignment (see Wheel Alignment Inspec- tion). • Rotate the rear wheel to find the position[...]

FINAL DRIVE 10-5 Drive Chain • Bend the cotter pin [A] over the nut [B]. • T urn the wheel, measure the chain slack again at the tight- est position, and readjust if necessary . • T ighten the torque link nut. T orque - T orque Link Nut: 34 N·m (3.5 kgf· m, 25 ft·lb) • Install a new cotter pin to the rear axle. • Check the rear brake. [...]

10-6 FINAL DRIVE Drive Chain Drive Chain W ear Inspection • Remove: Chain Cover • Rotate the rear wheel to inspect the drive chain for dam- aged rollers, loose pins and links. If there is any irregularity , replace the drive c hain. Lubricate the drive chain if it appears dry . • Stretch the chain taut by hanging a 98 N (10 kg, 20 lb) weight [...]

FINAL DRIVE 10-7 Drive Chain CAUTION The O-rings between the side plates seal in the lu- bricant between the pin and the bushing. T o avoid damaging the O-rings and resultant loss of lubri- cant, observe the following rules: Use only kerosene or diesel oil for cleaning an O -ring drive chain. Any other cleaning solution such as gasoline or trichlor[...]

10-8 FINAL DRIVE Drive Chain • Grind [A] pin head to make it flat. • Set cutting and rivetting pin [B] as shown. • Screw pin holder until it touches the l ink pin. • Be sure that the cutting pin hits center of the link pin. • Screw the handlebar [A] into the body . • T urn the pin holder w ith the wrench [B] clockwise to ex- tract the l[...]

FINAL DRIVE 10-9 Drive Chain • Fit the plate holder (A) to the link plate. • T urn the pin holder by hand until the plate holder (B) touches the other link plate. • T urn the pin holder by a wrench clockwise until two pins of link come into groove of the plate holder (A). • T ake of f the plate holder . • Set the plate holder (B) [A] and [...]

10-10 FINAL DRI VE Drive Chain • After staking, check the staked area of the link pin for cracks. • Measure the outside diameter [A] of the link pin and link plates width [B]. Link Pin Outside Diameter Standard: 5.6 ∼ 6.0 m m (0. 22 ∼ 0.24 in.) Link Plates Outside Width Standard: 17.45 ∼ 17.60 mm (0.687 ∼ 0.693 in.) If the reading excee[...]

FINAL DRIVE 10-1 1 Sprocket, Coupling Engine Sprocket Re mova l • Remove the bolts [A]. • Pull the engine sprocket cover [B]. • Flatten out the bended washer [A]. • Remove the engine sprocket nut [B] and washer . NOTE ○ When loosening the engine sprocket nut, hold the rear brake on. • Loosen the drive chain (see Slack Adjustment). • P[...]

10-12 FINAL DRI VE Sprocket, Coupling Rear Sprocket Removal • Remove the rear wheel (see Wheel/T ires chapter). • Remove the rear sprocket nuts [A]. • Remove the rear sprock et [ B ]. Rear Sprocket Installation • Install the sprocket facing the tooth number marking [A] outward. • T ighten the rear sprocket nuts. T orque - Rea r Sprocket N[...]

FINAL DRIVE 10-13 Sprocket, Coupling Coupling Bearing Removal • Remove: Coupling Grease Seal [A] • Remove the bearing by tapping from the brake drum side. Special T ool - Bearing Driver Set: 57001-1 129 [A] Coupling Bearing Installation • Replace the bearing with a new one. • Press in the bearing until it is bottomed. Special T ool - Bearin[...]

10-14 FINAL DRI VE Sprocket, Coupling Coupling Bearing Inspection a nd Lubrication NOTE ○ It is not necessary to remove the coupling bearing for inspection and lubrication. If the bearing is removed, it will need to be replaced with a new one. • Spin the bearing by hand to check its condition. If it is noisy , does not spin smoothly , or has an[...]

BRAKES 1 1-1 11 Brakes T able of C ontents Exploded View ................................... 1 1-2 Specifications .................................... 1 1-4 Brake Lever ....................................... 1 1-5 Lever Position Adjustment ........... 1 1-5 Caliper ............................................... 1 1-6 Caliper Removal .............[...]

1 1-2 BRAKES Exploded V iew T1: 7.8 N·m (0.80 kgf·m, 69 in·lb) T2: 25 N·m (2.5 kgf·m, 18.0 ft·lb) T3: 1 1 N·m (1.1 kgf·m, 95 in·lb) T4: 1.0 N·m (0.10 kgf·m, 9 in·lb) T5: 5.9 N·m (0.60 kgf·m, 52 in·lb) T6: 1.5 N·m (0.15 kgf·m, 13 in·lb) T7: 1.2 N·m (0.12 kgf·m, 10 in·lb) T8: 8.8 N·m (0.90 kgf·m, 78 in·lb) T9: 34 N·m (3.5 kgf[...]

BRAKES 1 1-3 Exploded V iew[...]

1 1-4 BRAKES Specifications Item Standard Service Limit Front Brake Brake Lever Position 4-way adjustable (to suit rider) ––– 5-way adjustable (to suit rider): ER500-C4 ∼ Brake Lever Free Play Non-adjustable ––– Pad Lining Thickness 4.5 mm (0.177 in.) 1 mm (0.04 in.) Disc Thickness 4.8 ∼ 5.2 mm (0.189 ∼ 0.205 in.) 4.5 m m (0.18 in[...]

BRAKES 1 1-5 Brake Lever Lever Position Adjustment The adjuster has 4 positions so that the brake lever posi- tion can be adjusted to suit the operator ’s hand. • Push the lever forward and turn the adjuster [A] to align the number with the Arrow mark [B] on the lever holder . ○ The distance from the grip to the released lever is mini- mum at[...]

1 1-6 BRAKES Caliper Caliper Removal • Drain the brake fluid. • Loosen the banjo bolt [A] at the brake hose lower end, and tighten it loosely . • Unscrew the caliper mounting bolts [B], and detach the caliper [C] from the disc. • Unscrew the banjo bolt and remove the brake hose [D] from the caliper . NOTE ○ If the caliper is to be disasse[...]

BRAKES 1 1-7 Caliper • Insert a wooden board [A] 5 mm thick inside the calipe r opening. • Pump the brake lever until the pistons [B] push the wooden board. • Remove the wooden board and pull out the piston by hand. • Remove the other parts of the caliper . • The pistons can be removed by compressed air as fol- lows. ○ Remove the banjo [...]

1 1-8 BRAKES Caliper • Apply brake fluid to the outside of the piston, and push the piston into the cylinder by hand. T ake care that neither the cylinder nor the piston skirt get scratched. • Replace the shaft rubber friction boot [A] and dust cover [B] with new ones if they are damaged. • Apply a thin coat of PBC (Poly Butyl Cuprysil) greas[...]

BRAKES 1 1-9 Brake Pads Brake Pad Removal • Remove the caliper with the hose installed. • Remove the clip and take off the pad pin. • Remove: Piston Side Pad [A] • Remove the other pad [A]. Brake Pad Installation • Push the caliper piston in by hand as far as it will go. • Install the anti-rattle spring in place. • Install the brake p[...]

1 1-10 BRAKES Master Cylinder Master Cylinder Re mova l • Disconnect the front brake switch wires [A]. • Remove the banjo bolt [B] to disconnect the upper brake hose end from the master cylinder [C]. There is a flat washer [D] on each side of the hose fitting. • Remove the clamp bolts [E] and take off the master cylin- der as an assembly with[...]

BRAKES 1 1-1 1 Master Cylinder Master Cylinder Assembly • Before assemb ly , clean all parts including the master cylinder with brake fluid or alcohol. CAUTION Except for the disc pads and disc, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol, for cleaning brake parts. Do not use any other fluid for cleaning these parts. Gasoline, [...]

1 1-12 BRAKES Brake Disc Brake Disc Removal • Remove the wheel (see Wheels/T i res chapter). • Unscrew the mounting Allen bolts [A], and take off the disc [B]. Brake Disc Installation • Install the brake disc on the wheel so that the marked side [A] faces out. • T ighten the mounting Allen bolts. T orque - Brake Disc Mounting Bolts: 27 N·m[...]

BRAKES 1 1-13 Brake Fluid Level Inspect ion • Check that the brake fluid level in the front brake reservoir [A] is above the lower level line [B]. NOTE ○ Hold the reservoir horizontal by turning the handlebar when checking brake f luid level. If the fluid level is lower than the lower level line, fill the reservoir to the upper level line [A] i[...]

1 1-14 BRAKES Brake F luid Bleeding the Brake Line The brake fluid has a very low compression coef ficient so that almost all the movement of the brake lever is transmit- ted directly to the caliper for braking action. Air , however , is easily c ompressed. When air enters the brake line, brake lever movement will be partially used in compressing t[...]

BRAKES 1 1-15 Brake Fluid • Install the reservoir cap. • Remove the rubber cap from the bleed valve on the caliper . • Attach a clear plastic hose to the bleed valve on the caliper , and run the other end of the hose into a con- tainer . • Bleed the air from the caliper as follows: • Repeat this operation until no more air can be seen com[...]

1 1-16 BRAKES Brake F luid W ARNING When working with the disc brake, observe the pre- cautions listed below. 1. Never reuse old brake fluid. 2. Do not use fluid from a container that has been left unsealed or that has been open for a long time. 3. Do not mix two types and brands of fluid for use in the brake. This lowers the brake fluid boiling po[...]

BRAKES 1 1-17 Brake Hose Brake Hoses and Connections Inspection • Inspect the brake hose and fittings for deterioration, cracks and signs of leakage. ○ The high pressure inside the brake line can cause fluid to leak [A] or the hose to burst if the line is not properly main- tained. Bend and twist the rubber hose while examining it. Replace the [...]

1 1-18 BRAKES Brake P edal and Cable Brake Play Inspection Brake Pedal Position Inspection • With the brake pedal [A] in the correct position, inspect the brake pedal position [B] as shown. Footpeg [C] Pedal P osition Standard: About 20 mm (0.79 in.) below footpeg (from T op of the footpeg to T op of the brake Pedal) If it is incorrect, adjust th[...]

BRAKES 1 1-19 Brake P edal and Cable Brake P edal Rem oval • Remove: Adjuster [A] Clevis P in [ B] Return Spring [C] • Remove the brake rod rear end. • Loosen the locknut and turn in the adjusting bolt to keep the pedal free from it. • Unscrew the right footpeg bracket bolts [A]. • Remove Rear Brake Light Switch Return Spring [A] Brake Re[...]

1 1-20 BRAKES Brake P an el and Drum Brake Lining Wear Inspection • Check that the brake lining wear indicator [A] points within the USABLE RANGE [B] when the rear brake is fully ap- plied. If does not, the shoes must be immediately replaced and the other brake parts examined. Cam Lever Angle Inspection • Check that the rear brake cam lever com[...]

BRAKES 1 1-21 Brake P an el and Drum Brake P anel Rem oval • Remove the rear wheel (see Wheels/T ires chapter). • Separate the brake panel [A] from the wheel. Brake Panel Installation • Installation is the reverse of removal. Note the following. • Adjust the brake pedal free play (see Brake Pedal Free Play Adjustment). Brake Panel Disassemb[...]

1 1-22 BRAKES Brake P an el and Drum • Link the brake shoes together with the springs, and push them onto the panel in the reverse of removal. • Put the dust seal over the end of the cam shaft. • Install the return spring. • Install the indicator [A] on the serration so that it points to the extreme right of the U SABLE RANGE box [B]. • F[...]

BRAKES 1 1-23 Brake P an el and Drum Brake Camshaft and Camshaft Hole Wear • Remove the brake camshaft (see B rake Panel Disassem- bly). • Measur e the sh aft dia meter [A] . ○ Use a micrometer at the point shown. If any measurement is less than the service limit, replace the camshaft. Camshaft Diameter Standard: 16.957 ∼ 16.984 mm (0.6676 [...]

1 1-24 BRAKES Brake P an el and Drum • Lubricate the brake pedal by applying a m ulti-purpose grease to the brake shaft pivot groove [A]. • Clean any excess grease from the parts before assembly . • Lubricate the brake cable (see Brake Cable Lubrication).[...]

SUSPENSION 12-1 12 Suspension T able of C ontents Exploded View ................................................................................................................... ..... 12-2 Specifications ................................................................................................................. ........ 12-4 Front Fork .....[...]

12-2 SUSPENSION Exploded V iew FO: Apply fork oil. L: Apply a non-permanent locking agent. R: Replacement P arts S: Follow he specific tightening sequence. T1: 20 N·m (2.0 kgf·m, 14.5 ft·lb) T2: 35 N·m (3.6 kgf·m, 26 ft·lb)[...]

SUSPENSION 12-3 Exploded V iew 1. Needle Bearings: Face the manufacturer ’s marks out. T3: 34 N·m (3.5 k gf·m, 25 ft·lb) T4: 88 N·m (9.0 k gf·m, 65 ft·lb) G: Apply gre ase.[...]

12-4 SUSPENSION Specifications Item Standard Service Limit Front Fork (per one unit) Fork Inner T ube Diameter 37 mm (1.46 in.) Fork Spring Setting Non-adjustable Air Pressure Atmospheric pressure (Non-adjustable) Rebound Damper Setting Non-adjustable Compression Damper Setting Non-adjustable Fork O il Viscosity SHOW A SS-8 or equivalent Fork Oil C[...]

SUSPENSION 12-5 Front Fork Fork Oil Change The oil should be changed in accordance with the Periodic Maintenance Chart. • Remove the front fork (see Fork Removal). • Hold the outer tube vertically in a vise. • Remove the cap. • Push the top plug [A] down to remove the plug retaining ring [B], and then remove the plug. • Remove: Spacer [A][...]

12-6 SUSPENSION Front Fork • Install the fork spring with the smaller diameter end [A] facing down. • Install: Fork Spring Seat Spacer • Install the front fork (see Front Fork Installation). • Repeat the same procedure for another front fork. Fork Removal • Remove: Brake Hose Clamps [A] (Left Front Fork only) Front Wheel (see Wheels/Ti re[...]

SUSPENSION 12-7 Front Fork • Hold the front fork horizontally in a vise [A]. • Stop the cylinder unit [B] from turning by using the special tools. • Unscrew the Allen bolt [C], and take the gasket out of the bottom of the outer tube. Special T ools - Fork Cylinder H older Handle: 57001-183 [D] Fork Cylinder Holder Adapter: 57001-1057 [E] • [...]

12-8 SUSPENSION Front Fork • Put the cylinder unit [A] with the spring into the inner tube [B] protruding from the inner tube, and install the cylinder base [C] onto the bottom end of the cylinder unit. ○ Install the cylinder base with the tapered end [D] up. • Install the inner tube, cylinder unit, and cylinder base as a set into the outer t[...]

SUSPENSION 12-9 Front Fork Inner T ube, Outer T ube Inspection • Visually inspect the inner tube [A] for scoring or scratches on the outer surface of it and repair any damage. • Nick or rust damage can sometimes be repaired by using a wet- stone to remove sharp edges or raised areas which cause seal damage. If the damage is not repairable, repl[...]

12-10 SUSPENSION Rear Shock Absorber Spring Preload Adjustmen t The spring preload adjuster on each rear shock absorber has 5 positions so that the spring tension can be adjusted for different road and loading conditions. • Using the hook wrench [A], turn the adjuster to adjust the spring tension. ○ The standard adjuster position for an average[...]

SUSPENSION 12-1 1 Rear Shock Absorber Bushing Wear • Visually inspect the rubber bushings [A]. If they show any signs of damage, replace them. Rear Shock A bsorber Oil Leak Inspection • Visually inspect the shock absorber for oil leakage. If the oil leakage is found on it, replace the shock absorber with a new one.[...]

12-12 SUSPENSION Swingarm CAUTION Do not tap the swingarm pivot shaft when removing or installing. Push or pull the pivot shaft while turn- ing the shaft. T apping on the shaft could damage the needle bearings in the swingarm. Swingarm Removal • Remove: Rear Wheel (see Wheels/T ires chapter) Rear Shock Absorber Lower Mounting Bolts and Nut [A]. C[...]

SUSPENSION 12-13 Swingarm Swingarm Installation • Installation is the reverse of removal. • T ighten the pivot shaft nut. T orque - Swingarm Pivot Nut: 88 N ·m (9.0 kgf·m, 65 ft·lb) • T ighten the torque link nut. T orque - T orque Link Nut: 34 N·m (3.5 kgf· m, 25 ft·lb) • Move the swingarm up and down [A] to check for abnor- mal fric[...]

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STEERING 13-1 13 Steering T able of C ontents Exploded View ................................................................................................................... ..... 13-2 Specifications ................................................................................................................. ........ 13-3 Handlebar ..........[...]

13-2 STEERING Exploded V iew T1: 44 N·m (4.5 kgf·m, 33 ft·lb) T2: Hand-tight T3: 25 N·m (2.5 kgf·m, 18 ft·lb) T4: 3.4 N·m (0.35 kgf·m, 30 in·lb) T5: 20 N·m (2.0 kgf·m, 14.5 ft·lb) T6: 29 N·m (3.0 kgf·m, 22 ft·lb) AD: Apply adhesive. G: Apply grease. L: Apply a non-permanent locking agent. S: Follow the specific tightening sequence.[...]

STEERING 13-3 Specifications Special T ools - Jack: 57001-1238 Steering Stem Wrench: 5 7001-1 100 Head Pipe Outer Race Press Shaft: 57001- 1075 Bearing Puller: 57001-158 Head Pipe Outer Race Driver , 46.5: 57001-1 106 Head Pipe Outer Race Driver , 51.5: 57001-1076 Steering Stem Bearing Driver: 57001 -137 Steering Stem Bearing Driver Adapter , 34.5:[...]

13-4 STEERING Handlebar Handlebar Removal • Remove: Clutch Cable Upper End Right and Left Handlebar Switch Housing Throttle Grip Brake Master Cylinder • Unscrew the handle bar mounting bolts [A] and remove the handlebar [B] and clamp [C]. Handlebar Installation • Install the handlebar clamps so that the arrow [A] on the clamp points to the fr[...]

STEERING 13-5 Handlebar Rear View Mirrors (Left and Rig ht) Installation • Screw the mounting area of the right rear view mirror into the holder all the way , and tighten the lower hexagonal area for tightening securely . [A] Lower Hexagonal Area for T ightening [B] Upper Hexagonal Area (Adapter) [C] Rear View Mirror (Right)[...]

13-6 STEERING Steering Steering Inspection Steering Inspection • Check the steering. ○ Lift the front wheel off the ground using the jack. Special T ool - Jack: 57001- 1238 ○ With the front wheel pointing s traight ahead, alternately tap each end of the handlebar . The front wheel should swing fully left and right from the force of gravity un[...]

STEERING 13-7 Steering • T ighten the steering stem head bolt [A] and fork lower clamp bolts [B]. T orque - Steering Stem Head B olt: 44 N·m (4.5 kgf·m, 33 ft·lb) Fork Lower Clamp Bolts: 29 N·m (3.0 kgf·m, 22 ft·lb) • Check the steering again. If the steering is still too tight or too loose, repeat the ad- justment.[...]

13-8 STEERING Steering Stem Steering Stem Removal • Remove the handlebar . Loosen the s tem head bolt [A] Remove the Front Fork [B] (see Suspension chapter) • Remove: Headlight T urn Signal Light Bracket Bolts [A] Headlight Housing Bolts [B] Meter Unit • Remove the stem head bolt [A] and lift up the steering stem head [B]. • Push up on the [...]

STEERING 13-9 Steering Stem • Install the stem cap [A], and hand tighten the stem nut [B]. T orque - S t eering S tem N ut: 4.9 N·m (0.50 kgf·m , 43 in·lb, for refere n ce ) NOTE ○ Install the steering stem nut so that the recess side [C] faces down. • Install the front fork (see Suspension chapter). NOTE ○ Tighten the fork upper champ b[...]

13-10 STEERING Steering Stem Bearing Stem Bearing Removal • Remove the s teering stem (see this chapter). • T o remove the outer races [A] pressed in the head pipe [B], insert a bar [C] into the head pipe, and hammer evenly around the circumference of the opposite race to drive it out. • Remove the lower inner race [A] (with its grease seal) [...]

STEERING 13-1 1 Steering Stem Bearing • Settle the inner races in place as follows. ○ Using the steering stem nut wrench, tighten the stem nut 20 N·m (2.0 kgf·m, 14.5 ft·lb) of torque. T o tighten the steering stem nut to the specified torque, hook the wrench on the stem nut, and pull the wrench at the hole by 11 0 N (1 1.1 kgf, 24.5 lb) of [...]

[...]

FRAME 14-1 14 Frame T able of C ontents Exploded View ................................................................................................................... ..... 14-2 Specifications ................................................................................................................. ....... 14-4 Seat ......................[...]

14-2 FRAME Exploded V iew T1: 34 N·m (3.5 kgf·m, 25 ft·lb) T2: 44 N·m (4.5 kgf·m, 33 ft·lb) T3: 25 N·m (2.5 kgf·m, 18 ft·lb) O: Apply oil. G: Apply grease.[...]

FRAME 14-3 Exploded V iew[...]

14-4 FRAME Specifications Special T ool - Jack: 57001-1238[...]

FRAME 14-5 Seat Seat Removal • Insert the ignition switch key [A] into the seat lock. • T urn the ignition switch key clockwise. • Swing open the seat and remove it. Seat Installation • Slip the hook [A] of the seat under the brace [B] on the fuel tank. • Push down [A] the rear part of the seat until the lock clicks.[...]

14-6 FRAME Side Covers Side Cover Removal • Remove the seat (see this chapter). • Remove the screw [A]. • Pull the rear part and front part of the side cover [A] evenly outward to clear the stoppers [B]. • Remove the side cover . • Remove the other side cover in the same manner .[...]

FRAME 14-7 Seat Cover Seat Cover Removal • Remove the seat (see this chapter). • Remove both side covers (see this chapter). • Unscrew the mounting bolts [A] and remove the tail grip [B]. • Remove the screws [A ]. • With the tail of the seat covers joined, bend open the seat cover [A] and pull them out backward. CAUTION Be careful not to [...]

14-8 FRAME Fenders Front Fender Removal • Remove the front wheel (see Wheels/Ti res chapter). • Remove the bolts [A] and take off the front fender [B] rear- ward. Rear Fender Removal • Remove: Seat (see Frame chapter) Battery (see Electrical System chapter) Regulator/Rectifier (see Electrical System chapter) Igniter (see Electrical System cha[...]

FRAME 14-9 Frame Frame Inspection • Visually inspect the frame [A] for cracks, dents, bending, or warp. If there is any damage to the frame, replace it. WA R N I N G A repaired frame may fail in use, possibly causing an accident. If the frame is bent, dented, cracked, or warped, replace it. Battery case Removal • Remove the R ear Fender (see Re[...]

[...]

ELECTRICAL SYSTEM 15-1 15 Electrical System T able of C ontents Parts Location.................................... 15-3 Exploded View ................................... 15-4 Specifications ................................... 15-8 ER500-C1 ∼ C2, D1 Wiring Diagram (other than Australia) ...................... 15-10 ER500-C1 ∼ , D1 Wiring Diagram[...]

15-2 ELECTRICAL SYSTEM Radiator Fan Switch Inspection ... 15-62 W ater T emperature Switch Inspection .................................. 15-63 Fuel Gauge Operation Inspection 15-63 Fuel Level Sensor Inspection....... 15-64 Fuses ..................... ............................ 15-66 30 Ampere Fuse Removal ........... 15-66 Fuse Box Fuse Removal..[...]

ELECTRICAL SYSTEM 15-3 Parts Location 1. Starter Lockout Switch 2. Horn 3. Radiator Fan Switch 4. #1 Ignition Coil 5. Spark Plugs 6. W ater T emperature Switch 7. Starter Motor 8. MF Battery 9. IC Igniter 10. Fuse Box 1 1. Alternator 12. Pickup Coil 13. Oil Pressure Switch 14. Neutral Switch 15. Sidestand Switch 16. Regulator/Rectifier 17. Main Fus[...]

15-4 ELECTRICAL SYSTEM Exploded V iew 1. Starter Lockout Switch 2. Front Brake Light Switch 3. Horns 4. City Light (other than Australia) T1: 1.2 N·m (0.12 kgf·m, 10 in·lb) T2: 3.4 N·m (0.35 kgf·m, 30 in·lb) L: Apply a non-permanent locking agent.[...]

ELECTRICAL SYSTEM 15-5 Exploded V iew 1. Regulator/Rectifier 2. Fuse Box 3. T urn Signal Relay 4. Rectifiers 5. IC Igniter 6. Starter Circuit Relay 7. Diode T1: 5.9 N·m (0.6 kgf·m, 52 in·lb)[...]

15-6 ELECTRICAL SYSTEM Exploded V iew[...]

ELECTRICAL SYSTEM 15-7 Exploded V iew 1. Ignition Switch 2. W ater T emperature Switch 3. Radiator Fan 4. Radiator Fan Switch 5. Ignition Coils 6. Spark Plugs 7. Rear Brake Light Switch 8. Alternator Starter 9. Pickup Coil 10. Starter Motor 11 . 3 0 A M a i n F u s e 12. Starter Relay 13. Sidestand Swit ch 14. Oil Pressure Switch 15. Neutral Switch[...]

15-8 ELECTRICAL SYSTEM Specifications Item Standard Service Limit Battery Ty p e Sealed Battery Capacity 12 V 10 Ah V oltage 12.6 V or more Charging System Alternator T ype Three-phase AC DC Battery Charging V oltage 14 ∼ 15 V @4 000 r/min (rpm) Alternator Output V oltage 46 ∼ 64 V @4 000 r/min (rpm) Stator Coil Resistance 0.3 ∼ 0.6 Ω (× 1[...]

ELECTRICAL SYSTEM 15-9 Specifications Item Standard Service Limit W ater T emperature S witch Connections: Rising T emperature From OFF to ON @1 10 ∼ 120°C (230 ∼ 248°F) Falling T emperature From ON to OFF @108°C (226°F) ∼ temperature less than ON ON: Less than 0.5 Ω OFF: More than 1 M Ω Special T ools - Hand T ester: 57001-1394 Spark[...]

15-10 ELECTRICAL SYSTEM ER500-C1 ∼ C2, D1 Wiring Diagram (other than Australia)[...]

ELECTRICAL SYSTEM 15-1 1 ER500-C1 ∼ C2, D1 Wiring Diagram (other than A ustralia)[...]

15-12 ELECTRICAL SYSTEM ER500-C1 ∼ , D1 Wiring Diagram (Australia)[...]

ELECTRICAL SYSTEM 15-13 ER500-C1 ∼ , D1 Wiring Diagram (Australia)[...]

15-14 ELECTRICAL SYSTEM ER500-C3 ∼ Wiring Diagram (oth er than Australia)[...]

ELECTRICAL SYSTEM 15-15 ER500-C3 ∼ Wiring Diagram (othe r than Australia)[...]

15-16 ELECTRICAL SYSTEM Precautions There are a number of important precautions that are musts when servicing electrical systems. Learn and ob- serve all the rules below . ○ Do not reverse the battery lead connections. This will burn out the diodes in the electrical parts. ○ Always check battery condition before condemning other parts of an ele[...]

ELECTRICAL SYSTEM 15-17 Precautions Male Connectors [B][...]

15-18 ELECTRICAL SYSTEM Electrical Wiring Wiring Inspection • Visually inspect the wiring for signs of burning, fraying, etc. If any wiring is in poor condition, 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 damage[...]

ELECTRICAL SYSTEM 15-19 Battery Battery Removal/Installation • Remove: Seat (see Frame Chapter) ○ Remove the battery cover [A] by taking off three screws. • Remove the negative (–) lead [A] from the battery first. • Remove the positive (+) lead [B] from the battery and pull out the battery . • When installing, connect the positive (+) l[...]

15-20 ELECTRICAL SYSTEM Battery • T ake the electrolyte container out of the vinyl bag. • Detach the seal caps [A] from the container . NOTE ○ Do not discard the seal cap because it is used as the battery plugs later . ○ Do not peel back or pierce the seals [B] on the container . • Place the electrolyte container upside down aligning the [...]

ELECTRICAL SYSTEM 15-21 Battery Initial Charge While a sealed battery can be used after only filling with electrolyte, a battery may not be able to sufficiently move a s tarter motor to start an engine in the cases shown in the table below , where an initial charge is required before use. However , if a battery shows a terminal voltage of higher th[...]

15-22 ELECTRICAL SYSTEM Battery Interchange The sealed battery can fully display its performance only when combined with a proper vehicle elec- tric system. Therefore, replace the sealed battery only on a motorcycle which was originally equipped with the sealed battery . Be careful, if a sealed battery is installed on a motorcycle which had an o rd[...]

ELECTRICAL SYSTEM 15-23 Battery NOTE ○ If the current does not flow when charging, raise the voltage initially (25 V as maximum), and let down the voltage to charge when the current starts to flow as a yardstick. If ammeter shows no change in current after 5 minutes, you need a new battery . The current, if it can flow into the battery , tends to[...]

15-24 ELECTRICAL SYSTEM Charging System Alternator Rotor/Starter C lutch Removal • Remove the engine sprocket cover (see Final Drive chap- ter). • Loosen the left footpeg mounting bolt and let the footpeg hang down. • Remove the shift pedal. • Remove the circlip and washer from the shift shaft. • Remove the left s ide cover . • Slide th[...]

ELECTRICAL SYSTEM 15-25 Charging System • Holding the rotor [A] steady , remove the Allen bolts [B] to separate the rotor and starter clutch [C]. Starter Clutch Sprocket Removal • Remove: Alternator cover (see Alternator Rotor/Starter Clutch Re- moval) Alternator rotor with Starter Clutch (see Alternator Ro- tor/Starter Clutch Removal) • Remo[...]

15-26 ELECTRICAL SYSTEM Charging System • T ighten the rotor bolt while holding the rotor steady with the flywheel holder , and turn the rotor bolt counterclock- wise to install i t. T orque - Alternator Rotor Bolt: 69 N·m (7.0 kgf·m, 51 ft·lb) Special T ool - Flywheel Holder: 57001-1313 • Apply silicone sealant to the area [A] where the mat[...]

ELECTRICAL SYSTEM 15-27 Charging System Alternator Inspection There are three types of alternator failures: short, open (wire burned out), or loss in rotor magnetism. A short or open in one of the coil wires will result in either a low output or no output at all. A loss in rotor magnetism, which may be caused by dropping or hitting the alternator ,[...]

15-28 ELECTRICAL SYSTEM Charging System Regulator/Rectifier Removal • Remove the right side cover and disconnect the regula- tor/rectifier connector [A]. • Unscrew two mounting bolts [B] and remove the regula- tor/rectifier [C] from the battery case. Regulator/Rectifier Output V oltage Inspection • Check the battery condition (see Battery sec[...]

ELECTRICAL SYSTEM 15-29 Charging System Regulator/Rectifier Inspection Rectifier circuit check • Remove the right side cover (see Frame chapter). • Disconnect the regulator/rectifier lead connector [A]. White Lead T erminal [A] Brown Lead T erminal [B] Black/Y ellow Lead T erminal [C] Y ellow 1 Lead T erminal [D] Y ellow 2 Lead T erminal [E] Y [...]

15-30 ELECTRICAL SYSTEM Charging System Regulator Circuit Check • Prepare the following: T est Light Bulb: one 12 V 3.4 W bulb Batteries: three 12 V batteries Wires: five wires of appropriate lengths CAUTION The test light works as an indicator and also a cur- rent limiter to protect the regulator/rectifier from ex- cessive current. Do not use an[...]

ELECTRICAL SYSTEM 15-31 Charging System Charging System Circuit 1. Ignition Switch 2. Alternator 3. Regulator/Rectifier 4. Battery 5. Main Fuse 30 A 6. Load[...]

15-32 ELECTRICAL SYSTEM Ignition System Ignition System Circuit 1. Diode 2. Fuse Box 3. Ignition Switch 4. Engine Stop Switch 5. Starter Button 6. Spark Plugs 7. Ignition Coils 8. T achometer 9. Ignition Fuse 10 A 10. Neutral Switch 1 1. Starter Lockout Switch 12. Sidestand Switch 13. Main Fuse 30 A 14. Battery 15. IC Igniter 16. Pickup Coil[...]

ELECTRICAL SYSTEM 15-33 Ignition System WA R N I N G The ignition system produces extremely high volt- age. Do not touch the spark plugs, ignition coils, or spark plug leads while the engine is running, or you could receive a severe electrical shock. CAUTION Do not disconnect the battery leads or any other electrical connections when the ignition s[...]

15-34 ELECTRICAL SYSTEM Ignition System Ignition Coil Removal/Installation • Remove the fuel tank (see Fuel System chapter). • Disconnect the leads and remove the ignition coils. • Install the ignition coils. Note the following. ○ Connect the primary winding leads to the ignition coiled terminals as shown. R Lead → #1 Ignition Coil T ermi[...]

ELECTRICAL SYSTEM 15-35 Ignition System NOTE ○ The hand tester cannot detect layer shorts and shorts resulting from insulation breakdown under high voltage. • Disconnect the primary leads from the coil terminals. • Measure the primary winding resistance [A] as follows: ○ Connect the hand tester between the coil terminals. ○ Set the tester[...]

15-36 ELECTRICAL SYSTEM Ignition System Spark P lug Removal/Installation • Remove the fuel tank (see Fuel System chapter). • Carefully pull the spark plug cap from the spark plug and unscrew the spark plug. • Using the 18 mm plug wrench [A]. • T ighten the spark plug. T orque - Spark Plug: 14 N·m (1.4 kgf·m, 10 ft·lb) • Fit the plug ca[...]

ELECTRICAL SYSTEM 15-37 Ignition System • T o examine the condition of the igniter , connect the igniter checker to the igniter as shown. Special T ools - Igniter Checker Set: 57001-1378 [A] Wiring Harness Adap ter , #14: 57001-1381 [C] IC Igniter [B] Battery [D] ○ Set the select knob to position “A”. NOTE ○ Follow the instructions in the[...]

15-38 ELECTRICAL SYSTEM Ignition System Starter Button O peration C heck • Remove the seats (see Frame chapter). • Set the Hand T ester [A] to the × 25 V DC range, connect it to the IC igniter [B] l ead as follows. Hand T ester (+) T erminal [C] → BK/R Lead Hand T ester (–) T erminal [D] → Frame Ground Special T ool - Hand T ester: 57001[...]

ELECTRICAL SYSTEM 15-39 Ignition System • T urn the ignition switch ON. • Shift the gears to neutral, and run the engine stop switch. • T urn the starter motor for several seconds and read the maximum value on the tester . Ignition Coil Primary Peak V oltage Standard: DC100 V or more WA R N I N G T o avoid high-voltage electrical shocks, do n[...]

15-40 ELECTRICAL SYSTEM Ignition System T roubleshooting[...]

ELECTRICAL SYSTEM 15-41 Ignition System Pickup Coil Peak V oltage Inspection • Measure the peak voltage of the pickup coil as follows: ○ Remove the left side cover . ○ Remove the pickup coil c onnector [A]. NOTE ○ T o obtain a correct measurement, the wires as well as the wire connections must be correct. T ake the volt- age measurement wit[...]

15-42 ELECTRICAL SYSTEM Ignition System NOTE ○ The actual meter reading varies with the meter used and the individual diode, but, generally speaking, the lower reading should be from zero to one half the scale.[...]

ELECTRICAL SYSTEM 15-43 Electric Starter System Electric Starter Circuit 1. Ignition Switch 2. Engine Stop Switch 3. Starter B utton 4. Starter Circuit Relay 5. Starter Circuit Relay 6. Fuse Box 7. Ignition Fuse 10 A 8. Starter Lockout Switch 9. Neutral Switch 10. Starter Motor 11 . S t a r t e r R e l a y 12. Main Fuse 30 A 13. Battery[...]

15-44 ELECTRICAL SYSTEM Electric St arter Syst em Starter Motor Removal • Remove the alternator cover . • Remove the starter chain guide screws [A] and remove the starter chain guide [B] with the guide stay [C]. • Disconnect the starter motor lead [A]. • Remove the starter motor mounting bolts [B]. • Remove the starter motor [A]. Starter [...]

ELECTRICAL SYSTEM 15-45 Electric Starter System Starter Motor Disassembly • Unscrew the starter motor through bolts [A] and pull off the gear cover [B] and the end cover [C]. • Pull the armature [D] out of the yoke housing [E], and remove the end bracket [F]. • Remove the terminal nut [A], and take the brush plate [B] off the end cover [C]. S[...]

15-46 ELECTRICAL SYSTEM Electric St arter Syst em • Make sure that the marks [A] on the covers and yoke housing align with each other . • T ighten the through bolts. T orque - St arter Motor Through Bolts: 6.9 N·m (0.7 kgf·m, 65 in·lb) Starter Chain Wear • Pull the starter chain tig ht. • Measure the length of 20 links (21 pins) with a v[...]

ELECTRICAL SYSTEM 15-47 Electric Starter System • Connect the hand tester [A] and 12 V battery [B] to the starter circuit relay [C] as shown. If the relay does not work as specified, the relay is defec- tive. Replace the relay . T esting Relay T ester Range: ×1 Ω Criteria: When battery is connected → 0 Ω When battery is disconnected →∞[...]

15-48 ELECTRICAL SYSTEM Electric St arter Syst em • Measure the diameter [A] of the commutator [B]. Replace the starter motor with a new one if the commu- tator diameter is less than the service limit. Commutator Diameter Standard: 28 m m (1.10 in.) Service Limit: 27 m m (1.06 in.) Armature Inspection • Using the × 1 Ω hand tester range, mea[...]

ELECTRICAL SYSTEM 15-49 Lighting System Headlight Circuit (Australia, ER500-C1 ∼ ,D 1 ) 1. Ignition Switch 2. High Beam Indicator Light 3. Headlight 4. Engine Stop Switch 5. Starter Button 6. Diode 7. Diode 8. Starter Circuit Relay 9. Diode 10. Headlight Circuit Relay 1 1. 10 A Ignition Fuse 12. 10 A Headlight Fuse 13. Dimmer Switch 14. Starter L[...]

15-50 ELECTRICAL SYSTEM Lighting System Headlight Circuit (Oth er than Australia, ER500-C1 ∼ C2) 1. Ignition Swit ch 2. Headlight Swit ch 3. Fuse Box 4. T aillight Fuse 10 A 5. Headlight Fuse 10 A 6. High Beam Indicator Light 7. Headlight 8. City Light 9. Dimmer Switch 10. Passing Button 1 1. Main Fuse 30 A 12. Battery[...]

ELECTRICAL SYSTEM 15-51 Lighting System Headlight Circuit (Other than Australia, ER500-C3 ∼ ) 1. Ignition Switch 2. Headlight Switch 3. Fuse Box 4. T aillight Fuse 10 A 5. Headlight Fuse 10 A 6. High Beam Indicator Light 7. Headlight 8. City Light 9. Dimmer Switch 10. Passing Button 1 1. Main Fuse 30 A 12. Battery 13. Alternator 14. Diode 15. Hea[...]

15-52 ELECTRICAL SYSTEM Lighting System • Connect the hand tester [A] and 12 V battery [B] to the starter circuit relay [C] as shown. If the relay does not work as specified, the relay is defec- tive. Replace the relay . T e sting Relay T ester Range: × 1 Ω Criteria: When battery is connec ted → 0 Ω When battery is disconnected →∞Ω R[...]

ELECTRICAL SYSTEM 15-53 Lighting System • Fit the dust cover [A] with the T op mark upward onto the bulb firmly as shown in the figure. Good [B] Bad [C] • After installation, adjust the headlight aim. Headlight Unit/Housing Removal • Remove the screws [A] on both sides. • T ake the headlight unit [B] out of the housing. • Disconnect all t[...]

15-54 ELECTRICAL SYSTEM Lighting System • Insert the new bulb by aligning the pins with the grooves in the walls of the socket so that the pin closest to the bulb base [A] is to the upper right. T ail/Brake Light Lens Removal/Installation • Be careful not to overtighten the lens mounting screws. T urn Signal Light Bulb Replacement • Refer to [...]

ELECTRICAL SYSTEM 15-55 Lighting System T urn Signal Light Circuit 1. T urn Signal Indicator Light 2. Front R ight T urn Signal Light 3. Front Left T urn Signal Light 4. T urn Signal Relay 5. T u rn Signal Fuse 10 A 6. Fuse Box 7. Rear Right T urn Signal Light 8. Rear Left T urn Signal Light 9. T urn Signal Switch 10. Ignition Switch 1 1. Main Fuse[...]

15-56 ELECTRICAL SYSTEM Radiator Fan Sys tem Fan System Circuit Inspection • Disconnect leads from the radiator fan switch [A]. • Using an auxiliary wire [B], connect the radiator fan switch leads. If the fan turns, inspect the fan switch. If the fan does not turn, inspect the following. Lead and Connectors Main Fuse and Fan Fuse Fan Motor Radi[...]

ELECTRICAL SYSTEM 15-57 Meter Unit Meter Unit Removal • Remove the headlight unit and housing. • Remove the speedometer cable upper end [ A] and the mounting nuts [B]. • Disconnect the meter connectors and take of f the meter unit [C]. CAUTION Place the meter unit so that the face is up. If a meter unit is left upside down or sideways for any[...]

15-58 ELECTRICAL SYSTEM Meter Unit T achometer Inspection • Check the tachometer circuit wiring (see Wiring Inspec- tion). If all wiring and co mponents other than the tachometer unit check out good, the unit is suspect. Check the unit as shown. ○ Remove the headlight body . ○ Remove the meter under cover [A] by removing three screws [B]. ○[...]

ELECTRICAL SYSTEM 15-59 Meter Unit T achomete r Circuit 1. T achometer 2. Fuse Box 3. Ignition Fuse 10 A 4. Ignition Switch 5. Main Fuse 30 A 6. Battery 7. IC Igniter Water T emperature Warning System Inspection The water temperature warning light goes on when the ignition switch is turned on and goes off soon after the en- gine starts running (oil[...]

15-60 ELECTRICAL SYSTEM Meter Unit W ater T emperature W arning System 1. Ignition Swit ch 2. Fuse Box 3. Ignition Fuse 10 A 4. Starter Relay 5. Main Fuse 30 A 6. W a ter T emperature W arning Light 7. Oil Pressure W arning Light 8. Rectifier 9. W a ter T emperature Switch 10. Oil P ressure Switch 1 1. Battery[...]

ELECTRICAL SYSTEM 15-61 Switches and Sensors Brake Light Switch Ispection Rear Brake Light Timing Inspection • T urn on the ignition switch. • Check the operation of the rear brake light switch by de- pressing the brake pedal. The brake light should go on as specified. If it does not, adjust the brake light timing. Brake Light Timing Standard: [...]

15-62 ELECTRICAL SYSTEM Switches and Sensors Oil Pressure S witch Connections* *: Engine lubrication system is in good condition Side Stand Switch Connections* Radiator Fan Switch Inspection • Remove the fan switch (see Cooling System chapter). • Suspend the switch [A] in a container of coolant so that the temperature-sensing projection and thr[...]

ELECTRICAL SYSTEM 15-63 Switches and Sensors Water T emperature Switch Inspection • Remove the w ater temperature switch (see Cooling Sys- tem c hapter). • Suspend the switch [A] in a container of coolant so that the temperature sensing projection and threaded portion are submerged. • Suspend an accurate thermometer [B] in the coolant so that[...]

15-64 ELECTRICAL SYSTEM Switches and Sensors Fuel Gauge Circuit 1. Ignition Swit ch 2. Fuel Gauge 3. Fuse Box 4. Ignition Fuse 10 A 5. Fuel Level Sensor 6. Battery 7. 30 A Main Fuse 8. Starter Relay Fuel Level Senso r Inspection • Remove the fuel tank (see Fuel System chapter). • Remove the fuel level sensor from the fuel tank. • Check that t[...]

ELECTRICAL SYSTEM 15-65 Switches and Sensors • Using a hand tester , measure the resistance across the terminals in the fuel level sensor lead connector [A]. If the tester reading are not as specified, or do not change smoothly according as the float moves up and down, re- place the sensor . Fuel Level Sens or Resistance Standard: Full position: [...]

15-66 ELECTRICAL SYSTEM Fuses 30 Ampere Fuse Removal • Remove the left side cover (see Frame chapter). • Disconnect the 30 ampere fuse connector [A]. • Pull out the main fuse [B] from the starter relay with a pair of needle nose pliers. Fuse Box Fuse Removal • Remove the seat (see Frame chapter). • Unlock the hook [A] to lift up the lid [[...]

APPENDIX 16-1 16 Appendix T able of C ontents T roubleshooting Guide ................................................................................................... ........ 16-2 General Lubrication ............................................................................................................. ... 16-7 Lubrication (Periodic Mainte[...]

16-2 APPENDIX T roubleshooting Guide NOTE ○ This is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties. Engine Doesn’t Start, Starting Difficulty: Starter motor not rotating: Starter lockout or neutral switch trou[...]

APPENDIX 16-3 T roubleshooting Guide Cylinder head not sufficiently tightened down No valve clearance Cylinder , piston worn Piston ring bad (worn, weak, broken, or sticking) Piston ring/groove clearance excessive Cylinder head warped Cylinder head gasket damaged V alve spring broken or weak V alve not seating properly (valve bent, worn, or carbon [...]

16-4 APPENDIX T roubleshooting Guide Brake dragging Lubrication inadequate: Engine oil level too low Engine oil poor quality or incorrect Coolant incorrect: Coolant level too low Coolant deteriorated Cooling system component incorrect: Radiator fin damaged Radiator clogged Thermostat trouble Radiator cap trouble Radiator fan switch trouble Fan moto[...]

APPENDIX 16-5 T roubleshooting Guide Abnormal Drive T rain Noise: Clutch noise: Clutch rubber damper weak or damaged Clutch housing/friction plate clearance ex- cessive Clutch housing gear worn T ransmission noise: Bearings worn T ransmission gears worn or chipped Metal chips jammed in gear teeth Engine oil insufficient Drive line noise: Drive chai[...]

16-6 APPENDIX T roubleshooting Guide Brake Doesn ’t Hold: Disc brake: Air in the brake line Pad or disc worn Brake fluid leakage Disc warped Contaminated pad Brake fluid deteriorated Primary or secondary cup damaged in mas- ter cylinder Master cylinder scratched inside Drum brake: Brake maladjusted Brake linings or drum worn Overheated W ater in [...]

APPENDIX 16-7 General Lubrication Lubrication (Periodic Mainte nance) • Before lubricating each part, clean off any rusty spots with rust remover and wipe off any grease, oil, dirt, or grime. • Lubricate the points listed below with indicated lubricant. NOTE ○ Whenever the vehicle has been operated under wet or rainy conditions, or especially[...]

16-8 APPENDIX Nut, Bolt, and Fastener Tightness Tightness Inspection • Check the tightness of the bolts and nuts listed here. Also, check to see that each cotter pin is in place and in good condition. NOTE ○ For the engine fasteners, check the tightness of them when the engine is cold (at room temperature). If there are loose fasteners, retorqu[...]

APPENDIX 16-9 Unit C onversion T able Prefixes for Units: Prefix Symbol Power mega M ×1 0 0 0 0 0 0 kilo k × 1 000 centi c ×0 . 0 1 milli m × 0.001 micro µ × 0.000001 Units o f Mass: k g ×2 . 2 0 5 =l b 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 13 =[...]

MODEL APPLICA TION Y ear Model Beginning Frame No. 2001 ER500-C1 JKAER500ACA051001, or JKAERVC1 □ 1A000001 2001 ER500-D1 JKAER500ADA051001 2002 ER500-C2 JKAERVC1 □ 2A003001 2003 ER500-C3 JKAERVC1 □ 3A005001, or JKAER500ACA067001 2004 ER500-C4 JKAERVC1 □ 4A007001, or JKAER500ACA072001 2005 ER500-C5 JKAERVC1 □ 5A009001, or JKAER500ACA082001[...]