se VULCAN 800 Kawasaki = Motorcycle - Seruce Marusal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 con- tents for the exact pages to locate the specific topic required. Quick Reference Guide (General Information 1 [Fuel System I [CoolingSystem [Engine TopEnd [clutch @|/or] |e] joo! |r Engine Removal/installation 7| [CrankshafTransmission 8 [WheelsTires SI Final Drive 10 Brakes aul Suspension 12 Steering 13 Frame 14 {Electrical System 15) ‘Appendix SSCS Supplement-2000 ~ 2001 Models _17 Supplement-2002 ~ 2003 Models 18 Supplement-2004 Model 19- . . sbiv® senoisish salud palgaue ) ‘tao a aly sg AT} aia ees pert ee ic pice | ala “SN Lina? Gh Ad een Sa engl ig av ecnemmelgguiad) | echt ees ets 1 on 0 eu aa | Se Silay ees Sete ce Oot at ae mehae maha at cs lh 1 teres er ear —-- ——| i 4 VULCAN 800 VN800 Kawasaki Motorcycle Service ManualLIST OF ABBREVIATIONS a ‘ampere(s) ib pound(s) ABOC | after bottom dead center m meter(s) ac alternating currant min minute(s) TOC | after top dead center N newton(s) BBDC | before bottom dead center Pa pascal(s) BoC bottom dead center PS horsepower BTDC | before top deed center psi pound(s) per square inch € degree(s) Celsius i revolution pe direct current ‘om revolution(s) per minute F farad(s) Toc top dead center + degree(s) Fahrenheit TR total indicator reading ft foot. feet v volt(s) 9 cgrem(s) w vwait(s) h hour(s) a ohm(s) L liters) Read OWNER’S MANUAL before operating.PRR EE EMISSION CONTROL INFORMATION = To protect the environment in which we all live, Kawasaki has incorporated crankcase emission & (1) and exhaust emission (2) contol systems in compliance with applicable regulations of the United States Environmental Protection Agency and California Air Resources Board. Adcitionall Kawasaki has incorporated an evaporative emission contol system (3) in compliance with applicable regulations of the California Air Resources Board on vehicles sold in California oniy. 1. Crankease Emission Control System This system eliminates the release of crankcase vapors into the atmosphere. instead, the ‘vapors are routed through an oll separator to the intake side of the engine. While the engine is operating, the vapors ere drawn into combustion chamber, where they are burned along ‘with the fuel and air supplied by the carburetion system. 2. Exhaust Emission Control System ‘This system reduces the emnount of pollutants discharged inta the atmosphere by the exhaust ‘of this motorcycle, The fuel and ignition systems of this motorcycle have been carefully dasigned and constructed to ensure an efficient engine with low exhaust pollutant levels. 3. Evaporative Emission Control System \Vapors caused by fuel evaporation in the fuel system are not vented into the atmosphere. Instead, fuel vapors are routad into the running engine to be bumed, or stored in a canister when the engine is stopped, Liquid fuel is caught by 2 vapor separator and returned to the fuel tank, fe e Bg a a a a a a a a re ‘The Clean Air Act, which is the Federal law covering motor vehicle pollution, contains what is commonly referred to 3s the Act's "tampering provisions.” “Sec. 203(a) The following acts and the causing thereof are prohibited. EN SS¢ —(3)(A) forany person to remove or render inoperetive any device or element of design installed se on or in @ motor vehicle or motor vehicle engine in compliance with regulations under 3: mS this title prior to its sele and delivery to the ultimate purchaser, or for any manufacturer m tor dealer knowingly to remove or render inoperative any such device or slement of se design after such sele and delivery to the ultimate purchaser. £55 (3)(B) forany person engaged in the business of repairing, servicing, selling, leasing, or trading a motor vehicles or motor vehicle engines, or who operates a fieet of motor vehicles knowingly to remove or render inoperative any cevice or element of design installed on cr in'@ motor vehicle or motor vehicle engine in compliance with regulations under this tile following its sale and delivery to the ultimate purchaser...” a eusonna bi on (Continued on next page.)NOTE © The phrase “remove or render inoperative any device or element of design" has been generally interprated as follows: 1. Tampering does not include the temporary temoval or rendering inoperati. devices or elements of design in order to perform maintenance. 2. Tampering could include: 2. Maledjustment of vehicle Components such that the emission standards are exceeded. 1b Use of replacement parts of accessories which adversely affect the performance or durability of the motorcycle. @. Addition of components or accessories that result in the vehicle exceeding the standards. d. Permanently removing, disconnecting. or tendering inoperative any component or element of design of the emission contral systems. of WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL LAW, THE VIOLATION OF WHICH IS PUNISHABLE BY CIVIL PENALTIES NOT EXCEEDING $10,000 PER VIOLATION. ISU SARA SETS APR PEAS Re RS RS ee TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED “5 Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering £55 inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to his sale or delivery to the ultimate purchaser or while it is in use, or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person. 23 Among those acts presumed to constitute tampering are the acts listed below: SEe _eReplacement of the original exhaust system or muffler with a component not in comptiance with ES Federal regulations. ZEE eRemoval of the mutfier(s} or any internal portion of the mutfier(s). 35% @Removal of the cir box or air box cover. S25 @Modifcations to the mutfer(s) oF air intake system by cuting, diling, oF other means if such P53 modifications result in increased noise levels. ee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 understood in order to carry out maintenance and repair satisfactorily. When- ever the owner has insufficient experience or doubts his ability 10 do the work, all adjust- ments, maintenance, and repair should be car- ried out only by qualified mechanics. In order to perform the work efficientiy and to avoid costly mistakes, read the text, thor- oughly familiarize yourself with the procedures before starting work, and then do the work care- fully ina clean area. Whenever special tools or equipment are specified, do not use makeshift tools or equipment. Precision measurements can only be made if the proper instruments are used, and the Use of substitute tools may ad- versely affect safe operation. For the duration of the warranty period, we recommend that all repairs and scheduled maintenance be performed in accordance with this service manual. Any owner maintenance or repair procedure not performed in accordance with this manual may void the warranty. To get the longest life out of your vehicle: Follow the Periodic Maintenance Chart in the Service Manual. @Be alert for problems and non-scheduled maintenance. @ Use proper tools and genuine Kawasaki Mo- torcycle parts. Special tools, gauges, and testers that are necessary when servicing Kawasaki motoreyclos are introduced by the Special Too! Catalog of Manual. Genuine paris provided as spare parts are listed In the Parts Catalog. @ Follow the procedures in this manual care- fully. Don't take shortcuts. ‘© Remember to keep complete records of main- tenance and repair with dates and any new pars installed. How to Use This Manual In this manual, the product is divited into its major systems and these systems make up the manual's chapters. The Quick Reference Guide shows you all of the product's system and assists in locating their chapters. Each chapter in tum has its own comprehensive Table of Contents, For example, if you want ignition coil informa- tion, use the Quick Reference Guide to locate the Electrical System chapter. Then, use the Table of Contents on the first page of the chap- ter to find the Ignition Coil section. Whenever you see these WARNING and CAUTION symbols, heed their instructions! Always follow safe operating and maintenance practices. Mae This warning symbol identifies special instructions or procedures which, if not correctly followed, could result in per= sonal injury, of loss of life. __ CAUTION This caution symbol identifies special instructions or procedures which, if not strictly observed, could result in dam- age to or destruction of equipment. This manual contains four more symbols (in addition to WARNING and CAUTION) which will help you distinguish different types of informa tion. NOTE This note symbol indicates points of par- ticular interest for more efficient and con- venient operation. @ indicates a procedural step of work to be done. O indicates @ procedural sub-step or how to do the work of the procedural step it follows. It also precedes the text of a NOTE. Indicates a conditional step or what action to take based on the results of the test or inspec- tion in the procedural step or sub-stop it fol- lows. In most chapters an exploded view illustration of the system components follows the Table of Contents. In these illustrations you will find the instructions indicating which parts require spec- ified tightening torque, oll, grease or a locking agent during assembly,rst = adi cenGENERAL INFORMATION 1-1 General Information Table of Contents Before Servicing ssn Model Identification General Specifications. ae Periodic Maintenance Chart... Technical Information - Sealed Battery... Torque and Locking Agent. z ‘Special Tools and Sealant nmin Cable, Wire, and Hose Routing.1-2 GENERAL INFORMATION 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. To facilitate actual operations, notes, illustra- tions, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary. This section explains the items that require particular attention during the removal and reinstallation or disassembly and reassembly of general parts. Especially note the following: ay @ @ (4) (5) (6) (7) (8) (9) Dirt Before removal and disassembly, clean the motorcycle. Any dirt entering the engine will shorten the life of tne motorcycle. For the same reason, before installing @ new part, clean off any dust or metal filings, Battery Ground Disconnect the ground (-) wire from the battery before performing any disassembly operations ‘on the motorcycle. This prevents the engine trom accidentally turning over while work is being carried out, sparks from being generated while disconnecting the wires from electrical parts, as well as damage to the electrical parts themselves. For reinstallation, first connect the positive \wire to the positive (+) terminal of the battery Installation, Assembly Generally, installation or assembly is the reverse of removal or disassembly. However, ifinstal- lation or assembly sequence is given in this Service Manual, follow it. Note parts locations and cable, wire, and hose routing during removal or disassembly so they can be installed or assem- bled in the same way. It is preferable to mark and record the locations and routing whenever possible, Tightening Sequence ‘When installing bots, nuts, or screws for which a tightening sequence is given in this Service Manual, make sure to follow the sequence. When installing a part with several bolts, nuts, or ‘screws, start them all in their holes and tighten them to a snug fil, thus ensuring that the part has been installed in its proper location. Then, tighten them to the specified torque in the tightening ‘sequence and method indicated. If tightening sequence instructions are not given, tighten them evenly in a cross pattem. Conversely, to remove a part, first loosen all the bolts, nuts, or screws that are retaining the part a 1/4-tum betore removing them. Torque ‘When torque values are given in this Service Manual, use them. Either too little or too much torque may lead to serious damage. Use a good quality, reliable torque wrench, Force Common sense should dictate how much force is necessary in assembly and disassembly. If a part seems especially difficult to remove or install, stop and examine what may be causing the problem. Whenever tapping is necessary, tap lightly using a wooden ot plastic-faced mallet. Use ‘an impact driver for screws (particularly for the removing screws held by non-permanent locking agent) in order to avoid damaging the screw heads. Edges Waich for sharp edges, as they could cause injury through careless handling, especially during major engine disassembly and assembly. Use a clean piece of thick cloth when lifting the engine or tuming it over. High-Fiash Point Solvent A high-fiash point solvent is recommended to reduce fire danger. A commercial solvent com- monly available in North America is standard solvent (generic name), Always follow manufacturer and container directions regarding the use of any solvent. Gasket, O-Ring Replace a gasket or an O-ring with a new part when disassembling. Remove ary foreign matter from the mating surface of the gasket or O-ring to ensure a perfectly smooth surface to prevent oil or compression leaks. (10)Liquid Gasket, Locking Agent Clean and prepare surfaces where liquid gasket or non-permanent locking agent will be used. Apply them sparingly. Excessive amount may block engine oil passages and cause serious dam- age.GENERAL INFORMATION 1-3 Before Servicing (11)Press When using a press or driver to install a part such as @ wheel bearing, apply a small amount of oil to the area where the two parts come in contact to ensure a smooth fit. (12)Ball Bearing and Needle Bearing Do not remove a bail bearing or a needle bearing unless itis absolutely necessary. Replace any ball or needle bearings that were removed with new ones. Install bearings with the manufacturer ‘and size marks facing out, applying pressure evenly with @ suitable driver. Apply force only to the ‘end of the race that contacts the press fit portion, and press it evenly over the base component. (43)0il Seal and Grease Seal Replace any oil or grease seals that were removed with new ones, as removal generally dam- ages seals. Oil or grease seals should be pressed into place using a suitable driver, applying a force uniformly to the end of seal until the face of the seal is even with the end cf the hole, unless instructed otherwise. When pressing in an oil of grease seal which has manufacturer's marks, press it in with the marks facing out. (14)Circlip, Retaining Ring, and Cotter Pin ‘When installing circiips and retaining rings, take care to compress or expand them only enough to install them and no more. Install the circlip with its chamfered side facing load side as well. Replace any circlios, retaining rings, and cotter pins that were removed with new ones, as re- moval weakens and deforms them. If old ones are reused, they could become detached while the motorcycle is driven, leading to a major problem, (15)Lubrication Engine wear's generally at ts maximum while the engine is warming up and before all the sliding surfaces have an adequate lubricative film. During assembly, make sure to apply oil to any sliding surface or bearing that has been cleaned. Old grease or dirty oil could have lost its lubricative quality and may contain foreign particles that act as abrasives; therefore, make sure to wipe it of land apply fresh grease or cll. Some oils and greases in particular should be used only in certain applications and may be harmful if used in an application for which they are not intended. (16) Direction of Engine Riotation To rotate the crankshaft manually, make sure to do so in the direction of positive rotation. Pos- itive rotation is counterclockwise as viewed from the left side of the engine. To carry out proper is furthermore necessary to rotate the engine in the direction ot positive rotation as (17)Replacement Pans When there is a replacement instruction, replace these parts with new ones every time they are removed. Replacement parts will be damaged or lose their original function ones they are removed. There- fore, always replace these parts with new ones every time they are removed, Although the pre- viously mentioned gasket, O-ring, ball bearing, needle bearing, grease seal, oll seal, circlip, and cotter pin have not been so designated in their respective text, they are replacement parts. (18)Electrical Wires All the electrical wires are either one-color or two-color. A two-color wire is identified first by the primary color and then the stipe color. For example, a yellow wire with thin red stripes is refered to.as a “yellowed” wire; it would be a “red/yellow” wire if the colors were reversed. Unless in- structed otherwise, electrical wires must be connected to wires of the same color. Two-Color Electrical Wire (cross-section) | belor indicated on tue fire | sige (neiew fed — Shire Strands Yel low/Red —rn1-4 GENERAL INFORMATION Before Servicing (a9)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 cnes. Abrasion Crack Hardening Warp Bent Dent Scratch Wear Color change Deterioration Seizure (20)Specitications Specification terms are defined as follows: "Standards" show dimensions or performances which brand-new parts or systems have. "Service Limits" indicate the usable limits. If the measurement shows excessive Wear or dete- rorated performance, replace the damaged parts.GENERAL INFORMATION 1-5 Model Identification vn |S and Canada Models) Left Side View: At1-6 GENERAL INFORMATION Model Identification VN800-A1 (Europe ) Left Side View: VN800-A1 (Europe Modal) Right Side View: B z LES Ty Te =GENERAL INFORMATION 1-7 General Specifications tems VN800-A1, A2, A3, A, AS Dimensions: Overall ongth 2.370 mm, (CN) (US) 2 360 mm Overall wieth 825 mm Overall height 1170 mm Wheelbase 1625 mm Road clearance 160 mm ‘Seat height 710 mm Dry mass 225 kg, (CA) 2285 kg Curb mass: Front 107 kg Rear 137 kg, (CA) 137.5 kg Fuel tank capacity 1501 Performance: Minimum turning radius 29m Engine: Type Coating system Bore and suoke Displacement Compression ratio Maximum horsepower Maximum torque ‘Carburetion system Stanting system Ignition system “Timing advance Ignition timing Spatk plug Cylinder numbering method Firing order Valve timing: Inlet Open Close Duration Exhaust Open Close Duration stroke, SOHC, V 2-oylinder Liquid-cooied 88.0 x 66.2 mm 805 mt. 95 40.5 KW (66 PS) @7 000 r/min (rpm), (CN) 44.1 kW (60 PS) @7 500 r/min (rpm), (ST) 24.2 kW (33 PS) @3 000 r/min(rpm), (FR) 39.3 kWY (83 PS) @7 000 r/min (rpm) (UTAC’s norm), (us) 64 N-m (8.8 kg-m, 47.0 ft-lb) @3 300 r/min (1pm), (CN) 64.7 Nem (8.8 kg-m, 47,7 ft-lb) @3 500 r/min (pm). (ST) 55 N-m (5.6 kg-m, 405 ft-lb) @3 000 r/min (rom). (FR)(UK)(US) ——~ Carburetor, Keihin CVK 36 Electric starter Bettery and coil (transistorized) Electronically advanced (digital igniter) From 5.0" BTDC @1 000 r/min (rpm) to 37.8" BTDC @6 750 r/min (rpm) NGK CR7E or ND U22ESR-N Front to rear, 1-2 12 zeroc, = AD ~ 19° BTC 78" ABDC. 71" ABDC 280", 270" 72, BBC, 2 ~ 69 BEDC 28" ATDC, ai" ATDC. 280", 280°1-8 GENERAL INFORMATION General Specifications hems N300-A1, AZ YN800-A3,A4,A5 ibrication system Forced lubiication (wel sump) = Engine Grdo SE, SF or SG class - Vieccsity 'SAET0W/A40, 1044-50, 20W-40, or 20W-50 a Capacity 32 5 Brive Tr Primary reduetion system Tye Gear - Reduction ratio 2184 (69/38) = Chtch type Wet mult cise - “Transmission: Tyre S-speed, constant mesh. return shift a Gear ratios: 1st 2.250 (36/16) 2.599 (38/15) ane 1.800 (22/20) 1 ,¢50(83:20) rd 1.220 (22/26) 1.230 (92/26) ath 1.000 (29/29) 1.900 (2929) 8th 0.857 (24/28) 0.857 (24/28) Final dive system: we Chain drive - Reduction rato 2.875 (46/18) 2470 (42/17) Overall dive ratio 5.362 @Top gear 4.625 @ Top gear Frame: Type Tubular, double cradie - Caster (fake angle) 38° - Tral 149 mm e Front te: Tyee Tube = Size Bom0-21 48H x Rear tre: Type Tube = Size 140/90-16 71H - Front suspension; Type “Telescopic fork - Whee! travel | 180 mm - Rearsuspersion: Type ‘Swingarm (uni-trak) — Wheel travel | 100 mm - Brake Type: Front Single cise is Rear Drum = Electrical Equipment: Battery 1212 Ah = Headlight Type Semisealed beam = Bulb 12.V 60155 W (quartz-halogen) - “Talvorake light 12.V 5/21 W x 2, (CN) (US) 12VE27TWx2 | — Akermator: Tyee ‘Thige-phase AC - Rated output | 235 A/14 ¥ @8 000 rimin (opm) 7 Spectications aubjact to change without notice, and may not apply to every country (CA): California Model ICN): Canada Modat (FR): France Modal (ST): Siwiteedand Model (UK: U.K. Model (US): US. ModelGENERAL INFORMATION 1 Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart t0 keep the motorcycle in good running condition. The initial mainionance i vitally important and must not be naglected. 7 OUGNETER HEADING: FREQUENCY | Whichever comes 3000 bh ist 19 OOO be 15 000 t 0 OOO Ke | 25.000 Em, 30 000 km, OPERATION ayy Spark lug - aan al Spark pug - en6ok . Valve cenrance che Ai suction vahwe = check = ‘ir cleanersemert- dean . Throttle grip play — check” Idle seed - ag vel noses, connections = Sas = Fuel sysom = check Cone = change Ties Evaporaive emission conel system (Gal) cheat Engr oi - change ar Oi titer = epics Ol sereon «ean Aaiter hoses, connections chek at Fuel nose = replace 7 years ‘Cuteh edlt Divs shan wear Greek = Dive cain « ubieate on Drive ain slack che [800 en Brake Unig or pad weer eo I ‘Brake fluid level - check" |_month Bink fuid- change 2 years Brake hoses. comacione heck ale Brake hoes replace om [Brake master cylinder cup and dus! seal - replace 2 years T [Caliber piston seal and dust seal - renlace 2 years, | Bike play check? elelelelee [Bake Fah ante — caso elelelele [Brake camshait - jubicate 2 years Brin cabo « epics” 2 years Stern «check Tetetatel [Steering stem bearing - lubricate Front fork ol - change Tira wear = check" elele Sooke tights and pm nauk Shack slelsle. Singarm pho. una nage = brea (Generel ldbreation - perf eee ‘Nuts, bolls, and fastener tightness - check [el Te lee lel |e le le lol lee] efelelele| flee 35 bebe ele tebP Pel b 1 For higher odameter mscings repeat atthe Frequency inewal establishes here, * Replace, add, adfust, clean, oF torque if necessary. (Cal): Califora's Medel any1-10 GENERAL INFORMATION Technical Information - Sealed Battery ‘A sealed battery 6 instaled in this model. The battery is a Sealed type, and so cannot be performed the electrolyte eve! heck and topping- up. (1) Construction: Sealing plus Filter Lid (7) Terminal (lead calcium atloy) Filler plug Pole (lext-calcium allay) Negative plate (lead and leac-calcium alloy) * Special separator Positive plate (lead and Yead-calcium alloy) (W) Main Fosturos 1) Maintenance free. — It is mot necessary to check the electrolyte lavel and top-up the skecvolyte, 2) No elecrolyte leakage [As the electrolyte is retained firmly in the special seperators, there is no ‘ee electrolyte in the bettery, Jt can be used instantly after fling only the electrolyte without initial ‘charge. 4) One-push mation electrotyt filing...» Its possible to fil the electrolyte by easy one-push motion, 8) Safety construction .. f the betary internal pressure rises abnormally high, the safety valve ‘opens to release the ges inside the better to restora the normal pressure and prevent the battery from rupturng. After restoring the normal pressure, the safety valve closes and the battery is ssaled again ‘Moreover, a ceramic fitris disposed on top ofthe safaty valve under the lid to remove risk of ignition or explosion caused by fre from outside. 8) Compact and high performance. No presence of free electolvte allows the battery mede lower in height, thus resulting in enhanced volume siiciency. Morsover, gas being absorbed inside the battery oiminates the need fora ges exhaust tube. 7) Strong charge/discharge charactaristies .._It can amply withstand deep charge/discharge cyales. (il) Principle of Sealing Structure ‘A leed-acid battery operates undor the following chemical reaction: 3) Instant activation system. e (2) Discharge (+) ie) Poo: + Hon + Po z PbO: + 2HkO + PbSOW (Lead peroxide) (Sulfuric seid) (Spongylead) Charga (Lead suttate) (water) (Lead sultate) Positive active “Electrolyte ‘Negative active Positve active Electrolyte Negative active material ‘material material material Normatiyin an ordinary leac-acie batery when it comes to an end of s charge, where the lead sulfete being a discharge ‘product returns to lead perexide end spongy lead, the charge currant flewing thereafter is used exclusively to decompose Glecttolytealy wator from the electrolyte thus rasuting in generation of hycrogen gas from the negative plate end oxygen {98s from the positive plate, The Gases so generated are released out of the battery, causing the amount of siectrolyie ecreased to require occasional water replenishment. 'A maintenance fre battery, however, is £0 designed thar, when itis overcharged, even ifthe positive alate is fully charged, the negative plate remains not fuly tuned wo spongy lead. Thetefore, even winen the positive plate is overcharged generating ‘oxygen gas, the negative plate is no fully charged, hence generating no hydrogen gas. “Moraover, the oxygen gat generated from the rositve plate immediately reacts with the charged active material on the regative plate, and retuins to water, with the ultimate result of no water loss.Technical Information - Sealed Battery GENERAL INFORMATION 1-11 Po + 120: = (PbO) Negative active Osygen ganeratod Negative sctive ‘material ‘rom positive pi material {charged state) (Poo) = + MSOs PSOs + Etectroiye Negative active material (charged stare) “Thus, the negative plate is me Inside the batery i¢ absorbed by the nagetive plato, nil, ad alow the battery to be sealed. (IV) Filing the Battary with Electrolyte ‘CAUTION ‘Do nol remove the aluminum seal sheet sealing the filler ports unt just betore use. ‘Be sure to use the dedicated electrolyte container tor correct electrolyte volume. (© Check to ste thet there is no pesting, tears or holes in the sealing sheet (© Pi2ca the battery on 3 lval surtace. ‘@ Remove the sealing sheet [A] ‘When removing, check to hear an air sucking eound "Shoosh!” fom filer pos {8} NOTE OA battery whase sealing sheet has any peeling, tears, holes, oF from which the eit-sucking sound was not heard requires @ relreshing ‘charge (intial chara (© Taka the oloctiolyta container out of the vinyl beg. (© Detach the strip of caps (A] from the container NOTE (200 not discard the stip of caps because itis used as the battery lugs later. ©Do not pee! back or pierce the sealed areas (8 (@Place the electrolyte container upside down with the six sealed arees inline with the six barary filler cons. (© Push the container down strongly enough to beck the seals. Now the ‘lactrlyta should start t flow into the battery. NOTE ‘©o not tt the comainer 2s the slecwolyte ow miay be imerrupted. Water 85 not to get fully charged, Even ifthe overcharge continues, the oxygen gas generated ‘process called oxygen eyela. which keeps water loss theoretically at4-12 GENERAL INFORMATION Technical Information - Sealed Battery (@Moke sure air bubbles [4] ara coming up tram al eb filer ports, OLeave the container this way for § minutes or longer. | NOTE | of no air bubbles are coming up trom a filer pore tap the bottom of the bottle two or three times. Novar remove tho container fom the battery CAUTION Fil until the container is completely emptied. Be certain that all the electoivte has flowed out. (@Top the bottom the same way ae above if thera i any olectroyte loft in the container ‘@Nowr pull the container gently out ofthe batter: @Let the battory st for 20 minutes. During this time, the electrolyte permeates the spacial separators and the Gas generated by charnical reaction is released, ‘@Fit the stip of caps [A] tightly into the filer ports until the stip is at the same lavel as the top of the battery NOTE (©0o nat hammer. Press down evenly with both hands. ‘CAUTION ‘Once you installed the siip of eaps ater tiling the battery, never remove i, nor add any water or electrolyte. () Initial Change ‘While a sealed battery can be used after only filing with electrayte, a Battery may not be able to Sufficiertly move a siarter ‘motor to start an engine in the cases shown in the table below, vihere an inital change is required before use. Honever, it a battery shows a terminal vcliage of higher than 12.6 V alter 10 minutes of fling (Note 1), no initial change is necessary. Condition requiring initial charge ‘Charging method ‘At low temperatures (Jower than O°C) 4A x2 ~Shoue Battery has been stored in high temparature and humidity. ‘Seal has been removed, or broken ~ peeling, tear or hole. (if you did not hear the air-sucking sound "Shoosh!” as you removed the saal,) 14.A# 15 ~ 20 hours ‘Battery as old as 2 years or more after manufacture Battery menufacturing date is printed on bettery top. Empl) 1200 1000 9B TL Day Month Year _ Mtg. locaton Note 1: Terminal voltage ~ To maasure battery terminal voltage, use a digital valtmeterGENERAL INFORMATION 1-13 Technical Information - Sealed Battery (M1) Precautions 1) Ne need of topping-up No topping-up is necessary in this battery ntl it ends its life under normal use, Eorcibly prving off the sealing olug to add water is vanrdangerous. Never do that 2) Refreshing charga fan engine will not star, a hor sounds weak, Gr lemips are dim, it indicates the bettery has been discherged. Give refresh cherae for 5 to 10 houte with chargo curent shown inthe speciation (see the Electrical System chapter) ‘When 2 fast charge is Inevitably required, co i following precisely the maximum charge current and time conditions Indicated on the battery ‘CAUTION, “This battery ie designed to eustain no unusual detaroration W retresh-charged according 10 a anes may be ‘method specified above. Never ea Ilby chance an excessive amount of gee ls generated due to overcharging, the salely valve operates to keop the battery s2t0, 3). When you do not use the motoreyele for months Give a refrash charge before you store the motorcycle ar stor it with ‘once a month uring storage Battery lite IT the battery will not start the engine even after several refresh charges, the battery hes exceeded its usoful life. Replace it. (Provided, however, the vehiote's starting eyetom hae no probiom.) jegative lead removed. Give a refresh chaiae 4 ‘Keep the battery away from sparks and open lames during charging, since the battery gives off an explosive gas mixture ‘ot hydrogen and oxygen. When using a battery charger, connect the battery tothe charger before tuming on the charger. “This procedure provents sparks at the battar terminals which couls Ignite any battery gases. No fire shouid be drawn near the battery, or no terminals should have the tightening loosened. ‘The electrolyte contains sulfuric acld, Be careful nol tohave Ittouch your skin or eyes. lf touched, wash It of wit paral ‘amount of water. Got medical atention If savers. (V1) Incerchangesbitity with Ordinary Battery ‘A sealed batiey can fully display its performance only when combined wi proper vshicie electric systern. Thereiore, replace a sealed battary only on a matoreycie which was orginally equipped with a sealad battery Be caratul, ta soolod battery le inetalled or a motorcyote whic had an ordinary battery as original equipment, the sealed battory' Ife will be shortened,1-14 GENERAL INFORMATION Torque and Locking Agent The following tables list the tightening torque for the major fasteners requiring use of a non-permanent locking agent or liquid gasket Letters used in the “Remarks” column mean: L: Apply a non-permanent locking agent to the threads. : Apply an oil to the threads, seated surface, or washer. S: Tighten the fasteners following the specified sequence. SS: Apply silicone sealant. Fasten Torque Remarks: Nem [kgm | ft-ib Fuel System: Carburetor damper plate mounting bolts 1 11 | 95inb Air cleaner element cover mounting nut n 4.4. | 95 in Air cleaner housing mounting bolts n 1.1 | 95 ind Cooling System Water pump impelier nut 1" 4.1 | 95 in Water hose fitting bolts "1 44 | 95inb Radiator fan switch 18 | 18 | 130 ss Water temperature sensor 78 | 080 | 69inb ss Coolant drain plug n 4.4 | 95 ined Engine Top End: Cylinder head caver botts 12 | 1.2 | 104 ind Cylinder head nuts: 10mm 39 | 40 | 29 s amm 25 | 25 | 180 s Cylinder head bolts 12 | 4.2 | 104 intb s Cylinder nuts 25 | 25 | 180 Camshaft cap bolts 2 | 25 | 180 Camsnatt sprocket bolts 4a | 50 | 36 L Camshaft chain tensioner cap bolts 2 | 20 | 145 Camshaft chain quide bolts 1" 4.4. | 95inb t Intake manifold bolts 2 | 4.2. | 104 into Cylinder head cover damper plats bolts 12 | 12 |todinw) Ls Clutch: (Clutch hub nut 132 | 135 | 98 ° Clutch spring bolts ag | ogo | 78 inb Right engine cover bolts 42 | 12 |10¢inwb) Lb (1) Engine Lubrication System: | Engine drain plug 20 | 20 | 145 Oil pump mounting bolts 1" 14 | 95inb t Oil pump drive chain guide bolt 12 | 4.2 | 104 int i il iter 18 | 18 | 130 Gil filter plate mounting bolts 7.8 | 0.80 | 69inb Oil sereen plug 20 | 20 | 145 Oil pressure relief valve 18 | 15 | 11.0 L Oil pressure switch 1s | 45 | 11.0 ss Oil pressure switch adapter 20 | 20 | 145 Oil pipe mounting bolts (crankcase inside) 1" 14 | 95 imib L Oil pipe mounting bolts (crankcase outside) 54 | 0.55 | 48 inb L Oil passage cover screw (crankcase inside) 54 | 085 | 48inb LGENERAL INFORMATION 1-15 Torque and Locking Agent Engine Removal/installation: Engine mounting nuts Engine mounting bracket bolts Down tube mounting bolts Crankshatt/Transmission: Crankcase bolts: 10mm 6mm Conneeting rod big end cap nuts Primary gear bolt Balancer gear bolt Starter clutch gear bolt ‘Starter cluten bolts Output shatt beating stopper bolts Balancer shaft bearing stopper bolts Shift drum bearing stopper bolts ‘Transmission cover bolts External shift mechanism cover bolts Shift shaft return spring pin ‘Shift drum position lever bolt Neutral switch Shift pedal pivot bolt Shift pedal pivot nut Shift drum cam mounting screw Shift lever camp bolt Wheels/Tires: Front axle clamp bolt Front axle nut Rear axle nut Spoke nipples Final Drive: Engine sprocket nut Rear sprocket nuts Rear sprocket stud bolts Brakes: Torque link nuts Caliper mounting bolts Disk mounting botts Brake hose banjo bolts Bleed valve Brake pedal bolt Master cylinder clamp bolts Brake lever pivot bolt Brake lever pivot nut Reservoir cap screw Front brake light switch screws Suspension: Front fork clamp bolts: upper lower Front fork bottom Allen baits Rear shock absorber nuts Swingarm pivot shaft nut 44 | 48 | 33 23 23 16.5 44 45 33 39 4.0 29 s n wd 95 ind 46 47 34 187 16.0 5 fe} 6 | 70 | 51 L 69 7.0 51 L 34 35 25 L 12 1.2) | 104 in-lb | at | 95 inate n 1 95 in-Ib n 41 95 in-Ib n Vd 95 in-Ib 29 3.0 22 L n 1d 95 in-lb 15 1.5 11.0 29 3.0 22 20 | so | 22 - | - - L 12 1.2 | 104 in-lb 34 | as | 25 88 9.0 65 98 10.0 72 40 0.41 | 36 in-Ib 127 13.0 94 ° 7m | 75 | 84 = = L 34 | as | 25 a4 | 35. | 25 23 | 23 | 165 25 25 18.0 73 0.80 | 69 in-lb 23 23 16.5 1 | 4.4 | 95ind 10 0.10 Bintb 5.9 0.60 | 52 in-lb 15 0.15 | 13 indb 42 | 0.12 | t0inb 20 20 14.5 4 | 95 | 25 20 20 14.5 L 59 6.0 43 98 10.0 721-16 GENERAL INFORMATION Torque and Locking Agent Rocker arm pivot shaft nut 98 | 100 | 72 Tie-tod nuts 53 | 60 43 Steering: Handlebar clamp bolts a | 35 | 25 Handlebar holder mounting nuts 4 | 38 25 Handlebar weight mounting screws - = = 4 Steering stem head bolt 4 | 45 | 33 Steering stem nut 49 | 0.50 | 43 inib Frame: Rear frame mounting bolts 4 | 45 33 Side stand pivot bolt 44 | 45 33 Helmet hook mounting screw - - - L Electrical System: Alternator cover bolts, 12 | 12 |104inm] LA) Timing inspection cover screw 49 | 0.50 | 43inb Altemator rotor bolt 187 | 160 | 115 ° Stator coil bolts 13 | 13. | 113 ind Pickup coil bolts 29 | 0.30 | 26 inib Altemator lead clamp bolts 7.8 | 0.80 | 69 inib Spark plugs 1 | 18 | 139 Starter motor mounting bolts 1 | 44 | 98 intb Starter motor through bolts 4.9 | 0.50 | 43inib Starter motor terminal nut 1 | 44 | 98inb Starter motor cable nuts 4.9. | 0.50 | 43 inib Side stand switch mounting bolts 3.9 | 0.40 | 35 inib L. are for use with dry solvent-cleaned threads, Basic Torque for General Fasteners of Frame Parts The table, reading tightening torque to thread diameter, lists the basic torque for the bolts and nuts. Use this table for only the bolts and nuts which do not require a specific torque value. Alllof the values Threads dia. Torque mm Nm kgm Ss 34-49 035 ~ 0.50 80 = 43 into 6 59-78 [0.60 0.80 52 — 69 int 8 14-19 | 14-19 10.0 - 13.5 10 25 84 | 26 ~35 19-25 12 44 — 61 I 45-62 33 45 [ 14 73 - 96 74 = 10.0 54-72 16 115 ~ 155 11.5 - 16.0 a3 - 115 18 165 = 225 17 = 23 125 ~ 165 20 225 ~ $25 23 ~ 33 165 ~ 240GENERAL INFORMATION 1-17 Special Tools and Sealant ‘Steering Stom Bearing Driver: $7001-137 Isle Cirlip Pars: $7001-143 \Valve Spring Camprassor Assombly: §7001-241 ‘'S Piston Pin Puller Assembly: 5701-910 Fuel Lave! Gauge: 57001-1017 Sey Fork Cylinder Holder Handle’ 5701-183 Oil Pressure Gauge Adapter, PT %e 57001-1033 e1-18 GENERAL INFORMATION Special Tools and Sealant Fork Cylinder Holder Adapter: 67001-7057 Head Pipe Outer Race Press Shaft: 57001-1075 Y Oil Seal & Bearing Remover, 57001-1058 Head Pipe Outer Race Driver: 67001-1076 SS © im Protectoe: 57001-1063 Steering Stor Nut Wrench: 67001-1100 Bead Breaker Assembly: 57001-1072 Head Pibe Outer Race Driver: 57001-1106 | @ Steering Stem Bearing Drier Adapter: 57001-1074 Outer Race Remover: 57001-1107 eGENERAL INFORMATION 1-19 Special Tools and Sealant Vaive Seat Curtar, 45° - 932. 57001-1115 Vane Seat Cutter, 45" - 030: 57001-1187 Q © Valve Seat Cutter, 2° ~ 028: 87001-1119 Valve Seat Cutter 32° ~ 83: 57001-1199 © 2 Valve Soat Cutter, 60" ~ @30: 67001-1123 ‘Valve Spring Comprassor Adept © & \Velve Seat Cutter Holder Bar. 57001-1128 Valve Seat Curr Holeer, 05: 87001-1208 “Rigg Beating Driver Sot: 87001-1129 Rotor Puller, M16/M1B/M20/IM22 x 1.5: 57001-12161-20 GENERAL INFORMATION Special Tools and Sealant Fork Qutor Tube Weight 57001-1218 il Fiker Wranch: 87001-1248 “@B Front Fork Oil Seal Driver §7001-1219 Boaring Remover Shatt: 87001-1265, Se Jack: 57001-1238 Bearing Remover Head, @15 x 917: 87001-1267 & Plot Screw Adjuster, A: 67001-1239 Carburetor Drain Plug Wrench, Hex 2: 67001-1269 aL (clutch Holder: 57007-1243 Fork Oil Level Gauge: 57007-1280 ee “seGENERAL INFORMATION 1-21 Special Tools and Sealant Flywheel Holder. 87001-1913 Hand Tester: 57001-1394 ‘Compression Gauge Adepter, M10X 1.0: 87001-1317 Spark Plug Wrench, 16mim (Owner's Too!): 2110-1132 Valve Seat Cutter, 60" ~ 033: 7001-1334 Kawasaki Bond (Silicone Sealant): 66018-120 8 —) fy S&S Vacuum Gauge: $7001-1369 Kewasaki Bond (Liquid Gasket-Bisck): 92104-7003 =e, A1-22 GENERAL INFORMATION Cable, Wire, and Hose Routing 1. Clamp (LH Switch Leads) 2. Clamp (Brake Hose) 3. Damper 4. Clamps 5. Band 8. GrommetGENERAL INFORMATION 1-23 Cable, Wire, and Hose Routing Viewed from A ladiator Fan Leads, Right : Rear Brake Light Switch Leads) (Left: Side Stand Switch1-24 GENERAL INFORMATION Cable, Wire, and Hose RoutingGENERAL INFORMATION 1-25 Cable, Wire, and Hose Routing Direct the oil proseure ewitch lead to the downware. (Apaly grease to the terminal.) Clamps Clamp Alternator Leads, Pickuo Coil Leads Fun the leads inside the drive chain cover. ad1-26 GENERAL INFORMATION Cable, Wire, and Hose Routing Except for California Model A % Fusl Hose Direct the choke cabile to the upward. (De not run the choke cable below the manifold. ) Hose (Green) Do rot overtighten the band. Incart tha hace and to the brackstGENERAL INFORMATION 1-27 Cable, Wire, and Hose Routing (moH@4) 880H pueg sy: uaiyiueno rou 09 s8)04 Buo} ayy yBnowA SasOy ay UM ~| fepow eRUO}e9 codex eG SE1-28 GENERAL INFORMATION Cable, Wire, and Hose Routing Fepoyy e1U30}1¢9GENERAL INFORMATION 1-29 Cable, Wire, and Hose Routing1-30 GENERAL INFORMATION Cable, Wire, and Hose Routing |. Position the clamp bolt at cis point. Radiator Align the marks. 1. Right Engine Cover apsFUEL SYSTEM 2-1 Fuel System Table of Contents Exploded View ‘Specifications Throttle Grip and Cables ss — Free Play Inspection nnn eee Free Play Adjustment Cable Lubrication Cab uretOF neem Idle Speed Inspectio Idle Speed Adjustment. Service Fuel Level inspection.. Service Fuel Level Adjustment... Fuel System Cleanliness Inspection Carburetor Removal. ae Carburetor installation .. Carburetor Disassembly/Assembly. Carburetor Cleaning. Carburetor inspection . Alt Cleaner... Air Cleaner Housing Removal Element Removal... Element Cleaning and Inspection Fuel Tank. Fuel Tank Removal rn Fuel Tank Installation .. Fuel Tank and Cap Inspection ... Fuel Tank Cleaning... Fuel Tap Inspection Evaporative Emission Control System (Celifornia Model Oniy) . Parts Removal/{nstallation . Hose Inspection. ‘Soparator inspection... Soparator Operation Test Canister Inspection...2-2 FUEL SYSTEM Exploded View tela 3 gr CS aa | a i ST: Switzerland Model e acesExcept (CA)2-4 FUEL SYSTEM Specifications Item ‘Standard Throttle Grip and Cables: Float height Optional parts: Main jet above upper edge of float chamber 18,54 2mm #130, 132, 138, 140 Throttle en tree play 2~3mm ld Carburetor: Make, Type Keihin, CVK36. Idle speed 1000 + 50 «/min (rem). | (ST), (CA) 1300 £50 rimin (rpm) Main jet #135 Main ar jot #100 —_ Needle jet #5 - Saco neve | Pilot jet #48 _ Pilot air jot #70 Pilot sorow 1 xtums out | Startar jet #70 | Service fuel level 2021mm | (ST): Switzerland Mode! (CA): California Model ‘Special Too! ~ Fuel Level Gauge! §7001-1017 Pilot Screw Adjuster, A: 57001-1238 (Carburetor Drain Plug Wrench, Hex 8: 57001-1268Throttle Grip and Cables FUEL SYSTEM 2-5 Free Play inspection ‘© Check that he throtle grip moves smooth from full open to close, ‘and the throttle closes quickly and complately in all stoering positions by the return spring ‘kit the throttle grip does not return properiy, check the throttle cable routing, gro free play, and cazle damage. Then lubricate the throtie carla (© Fun te engine atthe idle speed, and turn the handlebar al the way to the rght ang let o ensure thal the idle speed does not change. ‘ifthe ile speed increase, check the throite cable tree play and the cable routing. (© Chock the tnrotte grip free play (Al. + Ifthe trae play is incorrect, adjust the throtle cable, Thratte Grip Free Play Standard: 2~ 3mm Free Play Adjustment ‘@Looson ths eck (A) ‘eScrew the adjusters (B] in completely so as to give the throtla grip plenty of play. ‘eur out tho decoierator cable [C] adjustor unt there is no play whan the thonte grip is completely closed. ‘Tighten the iocknut. ‘@Tum the accelerator cable [0] adjuster until tho proper amount of thot grip fee play is obtained (Tiahten the jocknut. 41F the proper amount of free play cannot be obtained by using tho ‘adjusters, use the adjusters middle ofthe throw cables. ‘@Frrst give the tvottle grin plenty of play by turning the adjusts ot the ‘rion ful ‘@Romavo the fal tank (250 Fuel Tank Removal) ‘@Loosan the locknuts (4) Turn the eestor: (8) fully nt the middlaof the throttle cables so as to give te throwte grip plenty of play, With the throtte grip compitay closed, tury the declerator cable {C] adjustar until the innor cable just bocomes tight ‘@ Tighten the iocknut Tun the accelerator cable [0] adjuster until the comect tote crip {r09 ploy is abtain Tighten the lockaut PU) Cable Lubrication \Wherever the cable Is removed, lubricate the throtte cable as follows: ‘@Apply« thin coating of grease to the cable lower ands. (@Lubricata the cablo with a ponatting rust inhibitor.2-6 FUEL SYSTEM Carburetor Idle Speed Inspection Start the angine and warm it up thoroughly. ‘@\Wih the engine idling, turn the handlebar to both sides. + 1{ handlebar movement changes the idle speed, the throttle cables may bbe improperly adjusted or incorectly routed, or damaged. Ee sure to correct any of these conditions before riding (sa Cable Routing section in General Information chapter) cables could result in an unsafe ring condition. ‘@ hook idlo spoad. JI the idl epeed is out of the spacitiad range, adjust lie Speed Standaré: 1,000 4 SOrimin (pm) (Gutzerand, US, Models) 4200: §0 r/min (pm) Idle Speed Adjustment ‘@Start the engine anc warm it up thoroughly. ‘@Tum the adjusting screw [A] until the idle speed is correct. OQpen and close the throtte 2 fow times to make sure that the idle speed is within the speciied range. Readjust if necessary. Service Fue! Level Inspection OTIS Gasoline is extremely tammable and can be explosive under certaln conditions. Tur the Ignion swiich OFF. Do natemoke. Make sure tho area le wollvontilaied and free {tom any source of flame or parks; this Incudes any appliance with a pli light ‘@Siuate tne motoreyele so that its perpendicular tothe ground. @Remove the fuel tank and air cleaner (see Fuel Tank Removal, Air CCleaner Housing Removal). fePrepare an ausliary fuel tank and connect the fuel hose to the carburetor. (@Fropare a suitable fuel hose, €@Connect the fuel level gauge [A] to the carburetor flaat chamber with the fuel hose. Special Tool ~ Fuel Level Gauge: 57001-1017 @Hoid the gauge vertically against the side of the carburator body so that the “zero” line [3] is several milimotors higher than the upper ‘2qge [C] of the float chamber. (9 Feed fuel tothe carburetor, then turn the carburetor drain plug (D] out afew turns, (© Wait unt tha fuel level in the gauge sortiesFUEL SYSTEM 2-7 ‘e'keoping the gauge vertical, slowly lower the gauge until the "zero" line is even with the upper edge of te floet chamber. NOTE 2Do not lower the "zero" line below the upper edge of the Host chamber. If the gauge is lowered and then raised again, tne uel level ‘measured shows somevchat higher than the actual fust level. Ifthe ‘gauge is lowered too far, dump the tual into 2 suitable container and star the procedure over again. Read the fuel level [E} in the gauge and compare tothe specification, ‘@Screw in the carburetor drain plug. ‘@Stop feeding and remove the fus level gauge Seif the fel level is incomect, adjust it (see Service Fuel Level Adjust ment). Service Fuel Level (above upper edge af float chamber) Standard: = 2.0 41mm Service Fuel Level Adjustment Gasoline Is extremely flammable and can be explosive under certain conditions, Turn the Ignition switch OFF. Do not smcke. Make sure the area f@ wellvenilated and tres trom any source of flame of ‘sparks; this Includes any appliance witha pilot light. ‘eRamove the carburetor, and drain the fual into @ sultable container Remove the float chamber. ‘@Ramove the pin [A] and take out the fost (1. ‘e\Whan removing and installing the pn, note the following. (Be careful nat to snap the pin holder log (Cl. ‘OWhen removing @ tap [0] the let end of the pin. (When installing it. press (E) the right end of te pin. ‘e8end the tang [A] on the float arm vary slighty to change the float height. Increasing the float height lowers the fuel level and decreasing the float height raises the fuel level Float Helght Standaré: © 16.5.4 2mm2-8 FUEL SYSTEM NOTE (©Do not push the needle rd [4] in during the Hoar height measure. ment (8). ‘@Assombie the carburetor, and rechock the fuel leva IF the fus! level cannot be adjusted by this method, the fost or the float valve (C] is damaged, Fuel System Cleanliness Inspection Ao Gasolina ie axtromely flammable and can be explosive under certain conditions. Turn the ignition switch OFF. Donat smoke. Make sure the area is well-ventilated and free from any source of tlame or sparks; this includes any appliance witha pte ight ‘@Rlomove the fuel tank (see Fue! Tank Removal) eConnect 2 suitable hose [A] 19 the fittng at the bottom of the carburetor flaat bow. (© un tho lower and of the hoce into a suitable container. (eTTurn our the drain plug [B} 2 few tums and drain the float bow ‘Special Tool ~ Carburetor Drain Plug Wrench, Hex 9: $7001-1269 (@Cchack to s00 it water or dirt comes out eTighten the drain plug, +f any water or dit appears during the above inspection, clean the fuel ssystom (soe Carburotor Cleaning and Fuel Tark Cleaning). Carburetor Removal ENN Gasoline s extremely flammable and can be explosive under certain Conditions. Turn tha ignition switch OFF. Do not smoke. Make sure ‘he area ‘s well-ventitod and tree trom any source of flame or sparks; this includes any appllance with a pilot light eRemove Seat (see Frame chapter) Fual Tank (see Fusl Tank Removal) Alt Cleaner Housing (see Air Cleaner Housing Removal) Vacuum Hose [A] £ ‘@Loaton the earburetor clamp scrow (8). @Remove the bolts (C] and carburetor hokier plate (D]. ‘@Remove the carburetor and throtte cable ends. ‘@Stutf piece of lint-free, clean cloth Into the carburetor holder to keep dirt out ofthe engineFUEL SYSTEM 2-9 Carburetor Installation ‘Fit the vecuur fing boss [A] of the cerburetor to the projection [8] of the clamp. feinstal the cerburetor holder plate and then tighten the clamp sorew (a1. (@ Route the cables, hemess, and hoses correctly (see General Informa tion chepie). ‘© Check fue leakage from the carburetor, Ps Fuel splied from the carburetor Is hazardous. (@ Adjust the folowing itams if necessary, Idle Speect Throttle Cables Carburetor Disassembly/Assembly ON Gasoline Is extremely lammable and can be explosive under certain ‘conditions. Turn the ignition switch OFF. Do not smoke. Make sur the area fe well-ventilated and trea trom any source ot flame or sparks; this inchices any appltance witha pict ight. ‘@For the US and Swiss models, remove the pilotscrew plug as follows: (OPunch @ hole in the plug end pry there with an avi or other suitable tool (© Turn inthe pilot screw and count the number of tums until jtseats fully but not tightly, and than remove the screw. This is to set the screw to ite origina position when assombling. ‘© Attar installing the upper chermber cover. check thatthe vacuum piston slides up and down smoothly without binding in the carburetor bore. ‘CAUTION During carburetor disassembly, be caretul not to damage the diaphragm. Never use a sharp edge to remove the dlaphragm. ‘@7Tuin in the pilot serew [A] filly But not tighty, and then back it out the same number of wins counted during disassembly, ‘@For the US and Swiss model, install the pilot crow plug a¢ follows: install a new plug [8] in the pilot screw hole. and apply a small amount of a bonding agent (C) to the circumference of the plug to fix the alu CAUTION ‘Do not apply too much Bonding agent tothe plug or he pilot screw self may be fixed,2410 FUEL SYSTEM @Slip the nesdle through the hole in the center of the vacuum piston, and put the spring seat (4] on the top of the needle, Tur the seet so that toes not block the hole [B] at the bottom of tha vaeuurs piston, Carburetor Cleaning “AWARNING CClean the earburotor in 2 wollventiiated area, and take care that there is no sparks or flame anywhere near the working area; this Includes ary appilance with a plist light. Because of the danger of highly flammable liquids, do not use gasoline oF low Mash-point solvents to clean the carburetor. (CAUTION Do not use compressed air on an assembled carburetor, othe oats ‘may be crushed by the pressure, and the vacuum piston diaphragms may be damaged. Remove as many rubber or plastic parts trom the carburetor as possible belora cloaning the carburetor with a cleaning solution. ‘This wil prevent damage to or deterioration othe pars. ‘The carburetor body has plestic parts thet cannot be removed. Do ‘et use a sirong carburetor cleaning soktion which could attack these parts; Instead, use a miki high flash-polnt cleaning solution sale for plastic parts. (Do not use wire or any othor hard inctrumont fe cloan carburetor parts, especialy ets, as ney may be damaged. ‘© Disassemble the carburetor. inmecse ll the metel parts in a carburetor cleaning solution (@Rinse tho pants in water. When the parts are clean. dry tham with compressed air (@Biow through the air and fuel passages with compressed air. @ Assemble the carburctor (Carburetor Inspection Gasoline is extremely lammable and can be explosive under certain ‘conaiions. Tur the Ignition switch OFF. Do not smoke. Make sure the area le well-ventilated and free trom any source of flame or ‘sparks; this Inctudes any appliance with a pllet light ‘e8etore disassembling the carburetor, check the ‘uel level (se2 Fuet Level inspection) “IF the fuel level is incorrect, inspect the rest of the carburetor before ‘coracting itFUEL SYSTEM 2-11 ‘@Remave the carburetor. ‘um the throttle cable pulley to check thatthe throttle butterfly valves [A] move smoathly and retum by spring tension, “kif the throttle valves do net move smoothly, repiace the earburstor ‘© Disassemble the carburstor. Clean the carburetor. ‘@Check that the O-rings on the flost bow! and pilot screw and the diephragm on the vacuum piston are in good condition, if any of the O-rings oF diaphragms are not in good condition, replace them. (@Check the plestc tip [A] of the float vaive needle [B]. it should be smooth, without any grooves, scratches, oF tears, ‘kif the piestic tp is damagod [C], replace the needie, (© Push the rod [D] jn the other end of the fia valve needi, end then felease it. +f the rod does not spring out, replace the need. ‘@Cheek the tapered portion [A] of the plot screw [8] for wear or damage ‘if the pilot screw is warn ar damaged on tho tanorad portion, it will revert the engine from idling smoothly. Replace i. (@Chock that the vacuum piston [A] moves smoothly in the carburetor body, The surface of the piston must net bs excessively worn. ‘if the vacuum piston does not move smoothly or if ts very loose in carburetor body, replace the carburetor2.12 FUEL SYSTEM. Air Cleaner Air Cleaner Housing Removal Remove: Sect (see Frame charter) Fuel Tank (see Fusl Tank Rernoval) Mounting Boks [A] and Surge Tenk [8] Ait Cleaner Element (sae Air Cleaner Element Removal) Mounting Bolts [A] lemove the air cleaner housing [A] from the carburetor (B). Disconnect the engine breather hese [C] and vacuum switch valve hose [D] Element Removal ‘eRomove: Nut [A] and Washer Ait Cleaner Cover [8] Element [A] (@Push a clean, fint-ftee towel into the carbuetor intake fo keep dirt oF ‘other foreign material from entering, 1 dirt oF dust Is allowed to pass through Into the carburetor, the throttle may became stuck, possibly causing accident.FUEL SYSTEM 2-13 ‘CAUTION 1 dirt gels through into the engine, excessive engine wear and possibly engine damage will occur. Element Cleaning and Inspection ‘©Remove the air cloner element (see Element Removal). @Ciean the clement by tapping it ightly to loosan dust. ‘@8iow away tre remaining dust by appiying comprested air (A from the inside to the outsie (om the clean side othe diy side). ‘@Visually check the element for tar or breaks and check the sponge ‘gasket [B] also. JeIF me clement or gasket has any wars or breaks, replace the element.2.14 FUEL SYSTEM Fuel Tank Fuel Tank Removal Gosoline is extremely fammabie and can be explcslve under certain conditions. Turn the ignition switch OFF. De not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appltance with a plit light CALTION, : ‘For California model, t gasoline, solvent, water or any other liquid ‘enter the canister, the canister’s vapor absorbing capacity ls greatly | reduced. 1 the canister does become contaminated, replace It with ‘© Turn the fue! tap [A] 10 tha ON oF RES position. Remove Fupl Hose (8) Fuel Tap Vacuum Hose [C] eFemeve Seat (see Frame chapter) ‘Mounting Beit [A] and Meter Instruments [B] (soe Eleetical System chapter) Ful Tank Mounting Bots [A] Fuel Tank Evaporative Emission Hoses (California model) Fue/ Tank Installation Read the above WARNING. Route the noses correctly (see General Information chapter). (@8e sure to install the rubber dampers [A] in placa, (@Be sure the hoses are clamped securely to prevent leaksFUEL SYSTEM 2-15 Fuel Tank and Cap Inspection ‘© Visually inspect the gesket [A] on the tank for any damage. 2 Fleplace the gasket if itis damaged. (@Fomove the fusl tank and drain it Check to see if the breather pipe (sis0 the fuel rerum pipe for the California model) in the tank is not clogged. Chack the tank cap breather also. “If the breather pipe ia clogged, blow the brestherfroo with compressed ot the tank cap breather is clogged, repizce the tank cap, CAUTION ‘Bo not apply compressed air tothe alr vent holes (Bin the tank cap. “This could gaune damage and clogging ol he labyrinth inthe cap. Fuel Tank Cleaning es Clean the tank in a wellventiated area, and take care that there are ‘no sparks oF flame anywhere near the working area. Because ofthe danger of highly lammabie liquids, de not use gasoline or low fazh- point eolvants to clean tho tank. ‘@Romove the fuel tank and drain ‘ePour some high flach-point solvent into the fusl tenk and shake the tank to remove dirt and fuel deposits. (@Pour high flash-point rolvent through the tap in all aver positions. ‘@Pour the solvent out of the tank. ‘@ Remove the fuel tap [A] from the tank by taking our the bolts [2] with washers, ‘@Clean the fuel tap iter screens in a high flash-point solvent ‘@Dry the tank and screens with compressed ar Inctall the fuel tap on the tank. ‘@lrnstall the fuel tark (soe Fuel Tank Installation) Fuel Tap Inspection ‘@Ramove the fuel tep. {©Chsck tho fuel tap iter sersons (A for any breaks or deterioration. ‘It th screens nave any breaks oF are deteriorated, they may allow dit to reach the carburetor causing poor running. Replace the fuel tp. Hil the fuel wep leks, or allows fuel to fow when itis ON or RES Position without engine running, replace the damaged gasket [8] or O-rings (Cl246 FUEL SYSTEM Evaporative Emission Control System (California Model Only) ‘The Evaporative Emission Control System routes fuel vapors from the fuel system into the running engine of stores the vepors in a canister \when the engine is stopped. Although no adjustments are raquired, 3 thorough visual inspection must be made atthe intervals specified bythe Periodic Maintenance Chart Parts Removal] installation Sa eee seer era eraser rn ames eae Sareea CAUTION itgasoline, solvent, water or any other liquid enters the canister, te canister’s vapor absorbing capactly 's greally reduced. the canister does become contaminated, replace It with a new one, (#7 prevent the gasoline ftom flowing into or out of the canister, hold the saparator perpendicular tothe ground. feConnect the hoses according to the diagram of the system, Make sure they do not set aincned cr kinked. Hose Inspection ‘eCheck that the hoses are seeurely connected. ‘@Replace any kinked, deterorated or damaged hoses, ‘Separator Inspection ‘@Dieconnect the hosas from the liquid/ vapor coparator, and remove tho separator from the motoroycle (Visually inspect the separator for racks and other damege. DIF the separator has any cracks or ie badly damegad, roplace it with 2 new one, ‘Separator Operation Test Ew ‘Gasoline is extremely lammable and can be explosive under cortain Cconaitions. Tum the ignition sich OFF. Oo not smoke. Make sure the area |s well-ventilated end tree trom any source of flame or this Includes any appliance witha plot light. ‘@Connect the hoses to the separator, and install the seperator on the motoroycle,FUEL SYSTEM 2-17 ‘@ Disconnect the breather hose ftom the seperetor, and inject ebout 20, mL ot gasoline into the separator through thie hose fiting ‘eDisconnact the fusl return hose from the fuel tank. ‘@ Run the open end of the retum hose into the container and hold it evel with the tank top. ‘eStart the engine, and let it idle, +i the gesoline in the separater comes out of the hose, the separator works well, [Fit dees ret, replace tho separator with a new one. Canister Inspection ‘@Flemove the canistor, and disconect the hoses from the eamister. ‘eVisuelly inspect the canister for cracks end othec damage. “elf tne canister has ony cracks or bad damage, replace it with a new one. NOTE (OThe canister is designed to work well through the motorcyele's He Without any maintenane if t's used under normal conditians.; bs Va a = ; 1s Ze an ae wicet te 7s : I = "= i = 7 = - = i i L - - “ = . - 7: i - a . 1. '* aCOOLING SYSTEM 3-1 Cooling System Table of Contents Exploded View Coolant Flow Chart. Specifications Coolant... Coolant Filing Pressure Testing. Reserve Tank Removal Water Pump, Mechanical Seal... Water Pump Impeller Removal... Water Pump Impeller Installation Mechanical Seal Removal... Mechanical Seal installation. Water Pump Shaft Removal . Water Pump Shaft Installation, Water Pump Inspection . Radiator, Radiator Fan Radiator, Raditor Fan Removal wna. Radiator Fan installation. _ Radiator Inspection. i Radiator Cap inspection.. 4 Thermostat, 3 ‘Thermostat Removal... ‘Thermostat Inspection . = Radiator Fan Switch, Watar Tempereture Sensor Radiator Fan Switch, Water Tempereture Sensor Removal... Radiator Fan Switch, Water Temperature Sensor Installation. Radiator Fan Switch, Water Temperature Sensor Inspection...3-2 COOLING SYSTEM Exploded ViewCOOLING SYSTEM 3-3 Coolant Flow Chart e-0me, ©, 8. Thermostat When the engine is cold, the thermostat is closed so thet the coolant flow is restricted through the air bleeder hole, 1. Radiator causing the engine to warm up more quickly. 2 Fan Switch 10, Rediotor Cop 3. Wator Temperature Sensor 11. Resorve Tork 4. Right Engine Cover When the engine is very hot, the pressure valve in the radiator 5. Water Pump impeller cap allows air and vapor to ascape into the resorve tank. 6. To Crankeare When the engine cools down, the pressure drop draws the 7. From Rear Cylinder aad vacuum valve (another small valve) open, admitting coolant |B. From Front Cylindsr Head from the reserva tank into the radiator,3-4 COOLING SYSTEM Specifications tem ‘Standard Service Limit ‘Coolant provided when shipping: Type Permanent ype of antifreeze (soft water - and ethylene glycol plus corrosion and rust inhibitor chernicals for aluminum engines and radiators) Color Green --- Mixed ratio Soft water 50%, coolant 50% --- Freezing point =35°C (31°F) --- Total amount 2.4L (reserve tank full level including radiator and engine) Radiator cap: Relief pressuire 99 ~123kPa (0.95 ~128kg fem, | 14 ~ 18 psi) ‘Thermostat: \Vaive opening temperature Vaive full opening Hit 58 ~ 62°C (136 ~ 144 °F) 8mm or more @95°C (203 °F) ‘Specia! Too! ~ Outside Ciretip Phers: 7001-184 Sealant ~ Kawasaki Bond (Silcone Sealant $6019-120COOLING SYSTEM 3-5 Coolant Coolent Level Inspection NOTE Check the level when the engine is cold (room or ambient temper- ‘ature. ‘@Sinate the motoreycle 60 that it's perpendicular to the ground (on its side stand) ‘@Chack the coolant lavel through the coolant level gauge [A] on the coolant reserve tank [8] “eit the coolant lavel js lower than the “L* (Low) level ine (C), add coolent io the “F* (Full) level ine (D]. ‘mixture of coolant and soft water. AAdsing water alone dilutes the coolant and degrades its anticorro- ‘son properties. The alluted coolant can attack the aluminum engine parts. in en emergency, soft water alone can be added. But the dlluied coolant must be returned to the corract mixture ratio within 2 tow days. WW coolant must be added often, or the reservoir tank has run ‘completely dry; there le probably leakage In the cooting system. Check he system for leaks. i ‘CAUTION For refling, add the spect Coolent Draining POSTS “To avoid burns, do not remove the radiotor cap or try to change the coolant when tie engine is sil hot. Walt unt it cools dawa, ‘Coolant on tres wlll make them sllgpery and can cause an accident {and injury. immediately wipe up or wasn away any ecotant that ‘onthe frame, engine, or other painted parts. Since coolant is harmful tothe humen body, do not use. 3 crinking @Fomave: Meter instruments (See Elactieal System chapter) Radiator Cop [ ‘@Place a container undor the drain plug [A] at tha bottom of the right cranes, ‘@Diain the coolant from the radiator and engine by removing the drain lug (@Femove the cap and pump cut the coolant using a syringe or some ‘ther suitable device.3-6 COOLING SYSTEM Coolant Filling ‘Tighten the crain plug. Torque ~ Drain Plug: 11 N-m (11 kg-m, 95 int) (9F il the rasiator up to the radiator filer neck [A] with coolant. and install the radiator cap. NOTE © Pour in the eoatant slowly so that it can expel the at irom the engine and rediator, (9F tha reserva tank upto the “F level ine with coolant, and install the cao. CAUTION Soll or distiied water must be used withthe anilreeze (see below for antifreeze) in the cooling system. hard water Is used inthe cystam, it causes ecales accumulation in the water passages, and considerably reduces the efficiency ofthe ‘cocling systam. Water and Coolant Misture Ratio (Recommended) ‘Soft Water : 50% Coolant, 2 0% Freezing Polat -as'¢(-31"F) Total Amount aL NOTE OChoose a suitable mixture ratio by refering (0 the coolant manufacturers directions. ‘@uart the engine, warm it up thoroughly until the radiator fen turns on and then stop the engine. (© Check the coolant level n che reserva tank after the engine cools down. +f the coolant level & lower than the “L* level Ine, add coolant to the *F*loval line, CAUTION ‘Do nat edd more coolant above the °F level ine. Pressure Testing ‘@ Remove the moter instruments (eee Electrical System chapter). (@Ramove the radiator cap, and install a cooling system pressure testor [AI on the filer mack. NOTE OWet the cap sealing surfaces with watar or coolant to prevent pressure leaks. (© Build up prossure in the system carafully until the preseure reaches 123 KPa (1.25 kg/em?. 18 psi)COOLING SYSTEM 3-7 CAUTION During pressure tasting, do not exceed the pressure for which te system lo designed. The maximum pressure le 123 kPa (1.25 kalom?, 18 pel) (@Waich the geuge for atleast 6 seconds, elf the pressure holds steady, the eystorn i allright. ‘lf the pressure drope soon, chock for leaks. Reserve Tank Removal @ Remove: ‘Seat (609 Frame chapter) Fuel Tank (soa Fuel System chapter) Coolant Hose [A] Feat Wheel (see Whoole/Tires chaptci) Rear Shock Absorber (S29 Suspension chapter) Bolts [A] and Reer Wheel Mud Guard (8) Bolts (A] and Reserve Tenk [6]3-8 COOLING SYSTEM Water Pump, Mechanical Seal Water Pump Impeller Removal eden: Engine Oil (see Engine Lubiication System chapter) Coolant (gee Coolant Draining) eRomove: Right Engine Cover (see Clutch chapter) Nut (A) Impeller (3) Water Pump Impeller Installation ‘@220 sure to install tha rubber coal [A] and sealing seat [3] into the lmpoller [C1 by hand until the seat bottoms out. ‘@Appiy «litle coolant to the siding surface [0] of the mechanical sel and sealing seat to give the sea initial lubrication 98 sure to Install a new O-ting [E] on the shat. Tighten the impeller nut ‘Torque ~ Water Pump impellor Nut 1 N-m (1.1 kg-m, 95 inst) Mechanical Seal Removal @Remnove: Clutch (see Clutch chapter) Water Pump Impeller (see Wete Pump impeller Removal) O-ring ‘@Pry tha mechanical soa flange [A] of with ama chisel [8] ‘@Pull the machanieal seal [A] out of the crankcase with por, CAUTION ‘Be careiul not to damage the water pump shaft and the Inner sealing surface ofthe crankcase. (Discard the mechanical seal Mechanical Seat Installation NOTE (©Since the replacement mnechanical seal hes an adhesive costed body. 40 not apply liquid gasket to the exterior surface ofthe body, ‘ePress [A] tha new mechanical seal [B] into the: hole by using = suitable socket (C] until it bottoms out, CAUTION Be careful not to damage the water pump shalt and mechanical sealCOOLING SYSTEM 3-9 Water Pump Shaft Removal Salt the crankcase (see Crankshaft/Transmission chapter). ‘@ Remove the oii [A] from the weter pump shait (8). ‘Special Tool ~ Outside Cirelip Pliers: S7001-144 ‘remove the shat from the outside ofthe crankcase to the Inside. Water Pump Shaft Installation Insert the wetar pump shaft from outside of the erankease to the inside ‘© instal the ciclip tothe shaft ‘Special Too! ~ Outside Clrclip Piers: S7OO1-188 Water Pump Inspection ‘eCheck the drainage outlet passage [A] et the bottom of the right crankcace for coolant leas. ‘it tha mechanical eal is damaged, the coolant leaks through the seal ‘and drains through the passaye. Replace the mechanical seal and impeller with new ones3.10 COOLING SYSTEM Radiator, Radiator Fan Radiator, Radiator Fan Removal ‘eRomove: Coolent (see Coolant Draining) Seat (gee Frame chapter) Fuel Tank (see Fuel Systam chapter) Horn Lead Connectors [A] Boks [8] and Hom [C] Radiator Hose [A] Radiator Fan Connector [A] Fen Switch Lead Connectors (8) Water Temperature Sensor Lead Connector [C] Radiator Hose [0] Radietor Mounting Bolts [E) Radistor Radiator Fan Mounting Sotts (4) Radiator Fan [8] Radiator Fen Installation (© Be sure to attach the ground lead [A] to the fan mounting bolt (8),COOLING SYSTEM 3-11 Radiator Inspection ‘© Check the radiator core “kIf there axe obstructions to ai Flow, remove them. If the comugated fins are deformed, carefully straighten them. If the air passages of the radiator core ere blocked moze than 20% by lunremovable obstructions or ireparably ceformed fins, replace the radiator with anew one. ‘CAUTION, ‘When cleaning the radiator with slam cleaner, be careful of the following to prevent radiator damage. 1) Keop he steam gun away more than 0.5 m rom the radiator core. 2) Hold the steam gun perpendicular to the core suriace. 3) Run the steam gun horizontally following the core fin direction. ‘Running it vertically may damage the fin. Radiator Cap Inspection (© Check the condition ofthe top [A] and bottom [B] valve seals. Sel! any one of them shons visible damage, replace the cap with a new Valve Spring [C] ‘instal the cap [A] on # cooling oyster proseure taster (8). NOTE (OWer the cap sealing surfaces with water or coolant 10 prevent pressure leaks. ‘@ Watching the pressure geuae, slowly pump the pressure tester to build Up the pressure, Tha gauga pointer must remain within the ralot pressure range in the table below at least 6 seconds. Continue to pump the tester until the relief valve opens, indicated by the gauge pointer flicks downward, Tha raliet valve must open within the specified range. Radiator Cap Rellet Pressure Standere: 93 ~ 123 kPa (0 Flt te cap cannot hold the specified pressure, or it ft holds too much ‘pressure replace it with @ new one. = 1.25 eg/emé 14 ~ 78 psp ci3-12 COOLING SYSTEM Thermostat Thermostat Removal @Remove: Coolant (see Coolant Draining) Saat (see Frame cnaptor) Ful Tank (see Fual Systam chapter) Thermostat Housing Cover Bolts (A] Thermostat Housing Cover [8] Themostet Thermostat Inspection ‘@Romove the thermostat, and inspect the thermostat valve (A] at room temperature. “+f the valve is open, replace the thermostat with a new one. (@To check valve opening temperature, suspend the thermostat [A] in a container of water ans raise tne temperature of tha water [8] Thermometer +f the measurement is out ofthe specified range. replace the thermostat with a new one. ‘Thermostat Valve Opening Temporature Standard: $8 ~ 62°C (196 ~ 164°F)COOLING SYSTEM 3-13 Radiator Fan Switch, Water Temperature Sensor Radiator Fan Switch, Water Temperature Sensor Removal CAUTION ‘The fan switch or the water temperature sensor should never be allowed to fall en a hard surface. Such a shoek to thele parts can damage them. Drain the coolant (see Coolant Draining) ‘@Remove: Fuel Tank (soe Fuel System chepter) Radiator Fan Switah Lead Connectors [A] Cover [B] and Radiator Fen Switch ‘Water Temporctura Sencor Load Connector [C] Water Temperature Sensor (0) Radiator Fan Switch, Water Temperature Sensor Installation ‘@Apply silicone sealant to the thresds of the fan switch and water Temperature sensor Sealant ~ Kawasaki Bond (Siieone Sealant): 56019-1209, (eTighton the fan switch and water temperature sensor ‘Torque ~ Ratllator Fan Switch : 18 Nem (1.8 ka-m, 12.0 fb) \Wator Temperature Sensor :7.8 N-m (0.80 kg-m, 69 In-tb) Radiator Fen Switch, Water Temperature Sensor Inspection ‘© Refer to Electrical Systam chaptar for these inspections.—— SeaeRrmaa: "ah oom bei eee? eee a ea Ane ee ~ ——Jae ae oe eS al eeENGINE TOP END 4-1 Engine Top End Table of Contents Exploded Viow > Valves Specifications Valve Cernce Aausient Clean Air System nn Valve Removal Air Suction Vane Inspaction.——— kb Valve instalation ‘Vacuum Switch Valve Test Valve-to-Guide Clearanca Mossuremert Cylinder Head Cover (Webbe Metned) 4:20 Cylinder Head Cover Removal Valve Seat Inspection nn e290 Cylinder Head Cover Installation. Cylinder Head Covor Assembly. Camshaft, Camshaft Chain Camshaft Remenel Camshaft instalation... Camshat Assembly enn Gamshaft. Camshaft Cop Wear ‘Camshatt Chain Removal Camshaft Chain Wear... ‘Camshaft Chain Tension. Camshaft Chain Tensioner Removals 12 locker Shaft, Rocker Arm Installation Cylinder Head. Cylinder Compression Measurement. Cylinder Head Removal Cylinder Head instalation Cylinder Head Cover Assembly. Valve Seat Repair. Cylinder, Pistons Cylinder Removal Cylinder inetalaton.. Piston Removal Piston Installstion.. Cylinder West Piston Wear Piston Rina, Piaton Ring Groove Wear Piston Ring End Gap. Carburetor Holden. i Carburetor Holder instalation... Mutter Muffler Removel... Muffler intalation Muffler Cover Removal i Muffler Cover instaliston.4-2_ENGINE TOP END Exploded View pty graass. \pply non-permanent locking agent. Maiat Siig @ ‘pply molybdenum disulfide grease. e IY ol ‘specifiod tightening sequence. ‘alicone saatant. Ss Nem (1.1 kgm, 95 into) \ am (12 kgm, 104 eb) a 5 20 Nem (2.0 kgm, 14.5 fb) rai Sow 4: 25 Nem (2.5 kg-m, 18.0 feb) —. TB: 39 Nem (0.0 kg-m, 28 fetb) ‘TB: 49 Nem (5.0 ko-m, 36 fet) ee \ \ 4 54-4 ENGINE TOP END. Specifications item Standard Service Limit ‘Clean Air System: ‘Vacuum switch vaive closing pressure: | Open —- Close 57 ~ 65 kPa (430 ~ 490 mmHg) ‘Camshafts ‘Cam height Intet 35.305 ~ 35.413 mm. 35.21 mm: Exhaust }35.033 ~ 35.141 mm 34.93 mm. Camshaft journal, Camshaft cap clearance |0.028 ~ 0.071 mm 0.16 mm Camshaft journal diameter }26.950 ~ 26,972 mm 26.92 mm. Camshaft bearing inside diameter 27.000 ~ 27.021 mm 27.08 mm Camshaft runout TIA 0.02 mm or less TIRO.1 mm Camshaft chain 20-link length 427.00 ~ 127.96 mm 128.9 mm Rocker arm inside diameter 16,000 ~ 16.018 mm 16.05 mm, Rocker shaft diameter 415.965 ~ 15.984 mm 15.94 mm ‘Cylinder Head : Cylinder compression (usable range) 855 ~ 1 315 kPa --- (8.7 ~ 13.4 kgficm?, 124 ~ 191 psi) © 470 r/min (rpm) Gylinder head warp --- 0.05 mm Valves: Valve clearance: Inlet Exhaust Valve head thickness: Inlet Exhaust Valve stem bend Valve stem diameter: Inlet Exhaust Valve guide inside diameter Valvelvalve guide clearance (wobble method): Inlet Exhaust Valve seat cutting angle Valve seat surface: Width Outside diameter: Inlet Exhaust Valve spring tree length Cylinder, Pistor Cylinder inside diameter Piston diameter Piston/cylinder clearance Oversize pistons and rings Piston ring/groove clearance: Top Second Piston ring groove width: Top | Second Piston ring thickness: Top & Second Piston ring end gap: Top Second 0.10 ~ 0.15 mm, 0.20 ~ 0.25 mm, 0.5 mm 0.8mm TIR 0.01 mm or less |4.975 ~ 4.990 mm. 4,955 ~ 4.970 mm 5.000 ~ 5.012 mm 0.03 - 0.12 mm 0.10 ~ 0.18 mm }45°, 32°, 60° 0.5 ~ 1.0 mm 30.9 ~ 31.1 mm. 26.9 ~ 27.1 mm 40.5 mm '88.000 ~ 88.012 mm 187.975 ~ 87.990 mm 10.010 ~ 0.037 mm 40.5 mm 0.03 ~ 0.07 mm 0.02 - 0.06 mm 1.02 ~ 1.04 mm 1.01 ~ 1.03 mm 0.97 ~ 0.99 mm, 0.25 ~ 0.40 mm 0.40 ~ 0.55 mm. 0.17 mm. 0.16 mm. 4.412 mm 1.11 mm 0.90 mm. 0.7 mm 0.9 mmENGINE TOP END 4-5 ‘Special Tool ~ Compression Gauge: 57001-221 Valve Spring Compressor Assembly: 5001-241 Piston Pin Puller Assembly: $7001-910 Valve Seat Gutter, 45° ~ $22: $7001-1115 Valve Seat Cuner, 32° ~ 028: $7001-1119 Valve Seat Cutter, 60" ~ 290: $7001-1123 Valve Seat Cutter Holdor Bar: 57001-1128 \Valve Seat Cutter, a8" ~ G30: 57001-1187 Valve Seat Cutter, 22" ~ 993: 57001-1199 Valve Spring Compressor Adopter, $22: 7001-1202 Valve Seat Cutter Holder, 0S: 57001-1208 Fork Ol! Level Geuge: 57001-1290 Compression Gaugo Adaptor, MIO X 1.0: 57001-1317 Valve Seat Cutter, 0° ~ 033: 57001-1334 Vacuum Gauge: 57001-1968 ‘Spark Phig Wrench, 16mm (Owner's Tool}: 92170-1132 NOTE (©The following valve seat cutters can be used instead of the above tools. Inlet Valves: exhaust Valves: Valve Seat Cutter, 55 °-095: $7001-1247 ((nsioad of Vaive Seat Cutter: 69-083: 57001-1994) ‘Valve Seat Cutter, 45°32: 57001-1115 (astead of Valve Seat Cutter: 45-090: 57001-1187) Valve Soat Cutter, 32-90: 57001-1120 (instead of Valve Seat Cuter: 82°28: 57001-1118)4-6 ENGINE TOP END Clean Air System Air Suction Valve Inspection ‘e Visually inspect the raad (A) for eracks, folds, warps, heat damage, or other damage, >If there is-any doubt es to the condition of the reed, replace the air suction valve as an assembly. ‘@Chook the ra03 contact areas [8] of the valve holder for grooves, scratches, eny signs of seperation from the holder, or heat damage. If there is any doubt as to the condition of the teed contact areas, replace the ait auction valve as an assomby. “If any carbon oF other foreign pansies have accumulated berween the rood and the reed contact area, wash the valve assembly with a high flesh-point solvent. ‘CAUTION ‘Do not serape off the deposits with 2 scraper as this could damage the rubber, requiring replacement ofthe suction valve assembly. Vacuun Switch Valve Test Using the vacuum gauge and a syringe, inspect the vacuum switch operation 2¢ follows: ‘@Remove the vacuum switch valve ‘@Connect the vecuurn gauge [A] and syringe [B] or fork oil evel geuge to the vacuum hosae as shown, ‘Special Tool ~ Vacuum Gauge: $7001-1359 Fork Oil Level Gauge: $7001-1290 ‘© Gredually reise the vacuum (lower the pressure) applied to the vacuum ‘switch valve, and heck the valve operation. When tha vacuum is low. ‘the vacuum switch vaive should permit airto flow. When the vacuum raises to 57 ~ 85 kPa (490 ~ 490 mm Hg), it should stop airflow. “IF the vacuum switch valve does not operate 2s described, replace it with a naw one, NOTE O70 check at flow through the vacuum switch valve, just blow through the ar cleener hose. ‘Vacuum Switch Valve Closing Pressure (Open > Close) Standaret, ST ~ 65 Pa (230 ~ 490 mmHg) 1. During Grsing loner hore Shing 95 Diaproay Valve Secondary ti tome 2. During Engine asking High Vacuum Seceraety sh carat He |ENGINE TOP END 4-7 Cylinder Head Cover Cilinder Head Cover Removal Remove. ‘Seat (eo Frame chapter) Fuel Tank Ait Cleaner Housing. and Carburetor (see Fuel System chapter) ‘Muti (fr Rear Head Cover) (soe Mutflor Removal Vacuum Switch Vaive (A] and Hose (21 Coolant Hose Clamp Boit (C] ‘Thermostat Housing [D1 Radiator Hose [E] Coolent Hose Clomp Bolts (Al and Hoses (8) Spatk Plug Cap Front Ignition Coll [C) (fot Front Heed Cover) (See Electrical System chapter) Cover Bolts (A) Gylindse Hoad Cover (8) Al Suction Valve Head Cover Gasket Cylinder Head Cover installation elf the plug pine [A] was removed, install it with the chamfered side 1B] feces upward. end apply grease to the O-rings {C} instal Pin (0) Head Cover Gasket [E] Air Suction Valve (F] (as shown) feinstall the washers with the metal side (Tighten the cover bolts. “Torque ~ Cylinder Head Cover Bolts: 12 Nm (1.2 kg-m, 104 in-to)4-8 ENGINE TOP END Cylinder Head Cover Assembly ‘@Apply a non-permanent locking agent to the threads of the damper plato bolts [1 ~ 7], and tighten thom tothe tghtaning sequence. {A] Cylinder Head Cover {8} Demper [C] Damper Plato Torque ~ Cylinder Hose Cover Dampor Piao Bolts: 12 Nem (1.2 Kg. 104 na)ENGINE TOP END 4-9 Camshaft, Camshaft Chain Camshaft Removal @Remove: Cylinder Head Gover (s¢e Cylinder Head Cover Removal) Tensioner Cap Balt (A). Washer [B] and Spring ‘CAUTION ‘Do not turn over the crenkshalt while the tensioner cap boll Iz removed. The tensioner body is loose trom trecylinder while thecap bolt is removed. Turning the crankshaft could damage the tensioner body and/or eylinder, and alse the valves because upsetting the ccamhatt chain ting (@Rstease the stopper [A] and push the push rod [8] into the tensioner body [C} ([D] Cylinder [E] Camehatt Chain Guide NOTE Temporarily, install the tensioner cep bole (A) only to prevent the tenzionos body irom falling into the crankcase. @Ramove: Camshaft Cap Botts (A] Camshaft Cap [8} ‘@Disengege the camshaft chain [C] from the camshaft sprocket [D], ‘and remove the camehatt. ‘CAUTION “The crankshatt may be Wened while the camshalt Is removed ‘Always pull the chain taut while turning the crankshaft This avoids kinking he chain on the lower (eranksnat) sprocket. & kinked chain | could damage both the chain and the sprocket Camshaft Installation Apply engine cil to all am parts and jours. = NOTE 7 (The front and rear camenatts are otferent. The rear camshaft (4 thas a groove (8 e4-10 ENGINE TOP END (@5et the front piston at TDC, Align the front piston TDC mark [A] and timing mark (8) by tuming the crankshaft counterclockwise (C] (ieft sie view). ‘© Engage the camshaft chain [A] with the camshaft sorocket [8]. CAlign the timing mark lina [C] on the cemshatt sprocket with the eylinder head upper surface (D] (install the camshaft cap and tighten the cap bolts [E]. ‘Torque ~ Camshalt Cap Bolts: 25 N-m (2.8 kg-m, 18.0 fb) install the front eamshaht chain tensioner as follows: (Remove the cap bolt installed temporarily GHold the tensioner body and push the push roc (A] until the rod touches to the chain guide [8] fight. ‘Olnstail the spring, washer {C] and cap bolt (0), Torque ~ Camshaft Chain Tensioner Cap Bolt: 20 Nem (2.0 kg-m, 18.5 tb) NOTE Cinstaling the rear eamshatt is the same as for the front camshatt But noting the following. (@Set the tear piston at TDC. (Align the rear piston TOC mate [A] and timing mark [8] by turning the crankshaft counterclockwise (C} 305" (left side view). Camshaft Assembly '@Ciean the sprocket bolt [A] and threads of the camshaft, ‘@8e sure to install the pin (B] ‘@Apoly a non-peranent locking agent tothe threads ef the bolt, and tiahten it. The sorookets are identical Torque ~ Camshatt Sprocket Bolt 49 Nom (5. kgm, 36 Rb)ENGINE TOP END 4-11 Camshaft, Camshaft Cap Wear ‘@Mezsure gach clearence between the cemshaft cap using plastigage (Press gauge) [A] ‘@Tighton tho camshaft cap bots. ‘Torque ~ Camshalt Cap Bolts: 25 N-m(2.5 ka-m, 18.0 fb) NOTE (©Do nat tin the camshatt when the plstigage fs Between tnejournal smsha‘t joumal and the and camshoft cop. ‘rit any clearance exceeds the service limit, meesure the diameter ofeach ‘camshaft journal with a micrometer CCamahelt Journal, Camshaft Cap Clearance ‘Standard: | 0.028 ~ 0.071 mm Service Limit: 0.18 mm “kf the camsha‘t journal diameter is less than the service limit, replace the camshaft with e new one and messura the clearance again, ‘Camshaft Journal Diameter Standard: 26.950 ~ 26.972 mm Service Limi: 26.82 mm ‘if the clearance stil remains out of the limit replace the cylinder head unit Camshaft Chain Removal Front Camshaft Chain: eFemove ‘Alternator Rator (see Electvical Syetom chapter) Bolts [A] ané Black Chain Guide (8) ott (C], Washer [D] and White Chain Guide [E] ‘@Disengage the camshaft chain [F] from the crankshaft sprocket and than remove the chain. Rear Camshaft Chain: eRemove Primary Gear (#90 Crankshaty/Transmission chapter} Clutch (s0@ Clutch chapter) Boks [A] end Black Chain Guide [B) White Chain Guido [C] ‘ebisengage the camstaft chain [D] trom the crenkshatt sprocket and then cernove the chain Camshatt Chain Wear ‘Hold the chain teut witha force of about & kg i some manne, and moatute 8 20-ink length, Since tw chain may wear unevenly, tke oe rss ee as oR _ +f any measurement exceeds the service iit replaco the chain. aT a GPESESG BEITYS | a | ‘Camshaft Chain 20-jink Length ‘Standard: 127.00 ~ 127.38 mm Service Limit: 126.3 mm4-12 ENGINE TOP END Camshaft Chain Tensioner Camshaft Chain Tensioner Removal @Romove: Engine (sae Engine Removal/instalation chapter) ‘Camshaft (see Camsha‘t Removal) Cylinder Head (see Cylinder Head Remove!) ‘eRomove the camshatt chain tensioner body ftom the cylinder. Camshaft Chain Tensioner installation oRefer: Cylinder Hoad installation Camshat InstallationENGINE TOP END 4-13 Rocker Shaft, Rocker Arm Rocker Shalt, Rocker Aim Removal 5 @Remove: Cylinder Head Cover (oylinder Head Cover Removal) Camshaft Cap, Rocker Shatts (A) Rocker Arms [8] and Springs (C) Rocker Shatt, Rocker Arm Installation Apply molybdenum disulfide grease tothe rocker shaft. ‘@lnsert the rocker shaft into the camsshatt cp and rocker arm so that the noteh side [A] faces to the spring sida. ‘@Align the bolt holes [B] of the camshaft cas and rocker shatt4-14 ENGINE TOP END Cylinder Head Cylinder Compression Measurement (© Warm up the engine thorughly. ‘@Stop the engine, and remove the spark plugs, ‘Special Tool ~ Spark Plug Wranch, 16mm (Owner's Tool): 92110-1132 (@ Measure the cylinder compression, ‘OUsing the starter motor, tum the engine over with the throttle fully ‘open untl tha compression gauge stops rising: the compreesion i= tha highest reading obtainable. Special Tool ~ Compression Gauge: 57001-221 [A] Compression Gauge Adapter, M10 X 1.0: 57001-1317 (6) NOTE (OBe sure the battery's uly charged. Be sure na air leaks out of the cylinder head gasket, Cylinder Compression Usable Range: 855 ~ 1315 kPa (67 ~ 13.4 kglem*, 124 ~ 191 pal) @470 emia (rom) ‘© Repat the meceuremant forthe other cylinder IF eyinder compression Is higher than the usable range, check the following: (1) Carbon build-up on the éyinder head combustion chamber and the piston crown (2) Cylinder head gasket is not the orginal pert (8) Valve stam oil seals and/or piston rings are demaged. +e1F cylinder compression is lower than the usable range, check the following: (1) Condition of the valve soat is wrong. (2) Vaive elaarance is too small. (3) Piston/cviinder clearance is excessive (8) Cylinder head is warped and/or head gasket Is damaged, (3) Piston ring/siston ring groove clearence is excessive. Cylinder Head Removal Remove: Engine (see Engine Removal/ instalation) ‘Camshaft (see Camshaft Removal) Bolts [A] and Intake Manifold [8] ‘8mm Cylinder Head Nuts [A]ENGINE TOP END 4-15 Cylinder Head Bolt (A Cylinder Head Nuts [8] 10 ram Cylinder Heact Nuts (C] Cylinder Heed Cylinder Head Instaliation NOTE ©The cemshatt cap ie machined with the cylinder hesd, $0 f 2 new oinder heed is instaled, use the cap that's supplied with the new ead. © The rear eylinder hoad has a brosther pipe ring. Be careful not to mis up the front and rear heads ‘@ Release the stopper end push the push rod into the tonsioner body [Al, and tightan the cap bolt [8] only temporary einssa: Oil Pips [C] White Chain Guide [D] Knock Pins [€] Now Gylinder Head Gasket ‘@Tighten the nead nurs'and bolt following the tightening sequence [1 ~T Torque ~ Cylinder Head Nut: 0:mm (1 ~ 4]: 39 Nem (80 kg-m, 29 Mb) 8 mm (5 ~ 6]: 25 Nem (25 ker, 18.0 ab) Cylinder Hoad Bolt [7]: 12 N-m (1.2 kgm, 104 into) ‘eTighton the 8 mm cylinder head nuts. ‘Torque ~ Cylinder Head Nuts (8 mrn:25 N-m (25 kg-m, 16.0 fb) Apply grease to the O-rings (A). ‘@ install the intake manifold, and tighten the bolts Torque ~ intake Manifold Bolts: 12 N-m (1.2 g-m, 108 in-ib) Cylinder Head Assembly ‘@install the rubber dampers [A] between the fins [B] as shown. Sthe ond of tho dampor should be recessed 3 ~ S mm [C] sside the top of he loner in4.16 ENGINE TOP END Front Cylinder Head: TA} Rubber Dampers (18) [8] 170 mm [C] 165 mm [0) 168 mm [E] 154mm (F133 mm [6] 140 mm. [H] 148 mm 1) 70mm [179 mm Rear Cylinder Head: [A] Rubber Dampers (17) [3] 40 mm {C1 38 mum {0} 36 mm @When installing the breather pipe fitting [A] in the rear cylinder head, slign the Ftng withthe mark (8) {C1 Fning Hose (0) 37 ~ 43"ENGINE TOP END 4-17 Valves Valve Clearance Adjustment NOTE Valve clearance must be cheeked and adjusted whan the engine ‘ot (at room temperature). eRemove Cylinder Head Cover (coe Cylinder Head Cover Removal) ‘Timing inspaction Cover (Engine Left Side) (@'Set the front piston at TOC (see Camshaft instalation) (© Using a thickness cougs [A]. measure the valve clearance between the rocker atm (8) and the shir (C ‘© Sot the raar piston at TDC by turning the erankshatt counterclockwise 305" (sea Camshatt installation). (@Using a thickness qauge, measure the valve clearance between the roskor arm and the shin. Valve Clearance Standard: IM: 0.10~0.15 mm. EX; 0,20 ~ 0.25 mm sit he vane clearance is not within the specified range, frst record the Glearence, and then adjust it. (@To change the valve clearance, slide the rocker arm [A] sidaways and change the shim [8]. Replace the shim with ona of different thickness. NOTE Mark and record the shim locations so that the shims cen be teinstalied in ther original positions. (@To select a new shim which brings the valve clearance within the spocitied rango, rfuc to the Valve Clearance Adjustmant Chart: ORemeasue any vane clearence that was adjusted. Readjust if necessery. CAUTION ‘Do not put ehim sleek under the shim. This may catise the shim to ‘pop out at high rpm, causing extensive engine damage. Do not grind the shim. This may cause it lo fracture, causing extonsive engine damage.4-18 ENGINE TOP END VALVE CLEARANCE ADJUSTMENT CHART INLET VALVE T PRESENT Sti anole 7 BRT Ro SRDS OTT i sera aa |e mane ole |W lila lato lal wo [ee [717] mo es | 60 "FHLGKWESS Gon) [00/0 1028 225 2 25)2 30 F 35 [3.00] a0] 253] 2 002.05] 70/ 2.7500 es |2.90|2 95] 3.00] “g]20e= 04] figo]s98|200]208]210[z16]220)226]2230]226]2-0]206]20[256]200|208|270]276]200] 2.05200] Z[oos~oos| 135/200, zos[aio 215|220]z25 220]z36|zc0|285|2s0|755|200[20s/z70|275 200/225] 200208 jeemon ‘SPECIFIED CLEARANCE/NO CHANGE REQUIRED axe ~020| [205] 210] 215[220] 225 |2.00|2.35|200]2.05] 260 [255] 2.00) .65]2.70]275 00]205]220]235]3.00] Ufezre ean] [sola eay|aas 230/a.s] ze [zs |aso[ ec |2ao|.s[z70[2 73/200 |2.00/200 295/300 joze = 030 | [zss|azo_2.25|230/235|2.40]24e|250|255|.00|205|2.70|275/2.00] 265 200/2.06/ 309 ‘am —oas| [azo|aas 20/236] 200 [2es|2.70| 2.75 200/205] 20/206/200) 1, [ese= 04a} [eas] 2z0/225[2c0 2465 |2.50 '270|2.75| 2.90298] 2.90) 266/300 lea ~oas| [220|205/200|24s/2s0|255|2 60|2.55]270|275/200| 225|250|295|200 Zl oan oso] [zss|2a0|240|300_s00|200]205/270|275|200[zas|z00|2a0[300] Blom ~ oss] [2so|z0s/200[258/200|2.652-70|2.75|200|z05|2.90] 2.95/3.0) Tana Fn [ase oso] |2s|zs0/z5s|200|203|2.70]275|200]2.05[ 290/208] 3.09] zz ee [soa Sfom=eas| [eso|zss 2a[zes z0|275|200(zos[zo0|za5 (300 [ep aee 2\ose~ 07] |2s5|200 265/270 275|2.0/208 2.20]2.85|3.00 eehte eon Blom ~o7| |2so|26s|270|276/ 290/238] 280 295| 3.00 Se ee Z[o7~om0| {265/270 275|2a0|285|2.90|2 95 3.00) 2160-1713 | 1.70 mm 5 ‘esi ~ons| [270|275/290]288/290|2.98|s.00| 3 feas— ese] ferelzsa/zas|zeelzae|se| The ahim from 1:70 to 1.85 mm thick are g [esr oss | —[220[20e [290/206 20] also available [oe ~ 1.00] [2.86|200 205/300, Becton Jeb] aera IRENE BARRE RIE Teta son=i30| [2as|300) a | 1. Measure the clearance (when engine is cold). 2. Check present shim siza, 3 Match clesrance in vertical column with prasant shim size in horizontal column. 4. Install tha shim specified whero the lines intersact. Thie shim wil give the proper claerance. Example: Present shim is 2.60 mm ‘Measured elsarance i 0.25 mm Replace 2.60 mm shim with 270 mm shim. 5. Remeasure the valve clearance and readjust if necessary. NOTE ‘OM there is no clearance, seloct 2 shim which is sovera! sizes smaller and then measure the clearance.ENGINE TOP END 4-19 VALVE CLEARANCE ADJUSTMENT CHART EXHAUST VALVE I PRESENT SHIN Ftamte SCC EE var le] s [wm [w |] [wale se reer ono wha ee ele lee le CO CR EER CC CER ER EM OE esa 09) [radu ae oof eas ole oof va lz aa ee a aoe fs ada sla soe ode nde le vee se) [adh aol ana ole ole le vse ee es ale oe oof sla sla one oe 1a rd tl associa) [iadh-aple ede ole eo ane ae soe nla ads oe oa sla ola one vfe ra. AoE ‘SPECIFIED CLEARANCE/NO CHANGE REQUIRED aece ay) aged id se ade ase aoe ae ole ole sole ope wf ad re ne el we ol spe a5] facea sa vale tle aafe ane ao ae oe sla oof wk vole rida ole ale lena. age vd aoe fe ope sofas owes sect fe vide ole alos ola 0 ae ade ed ade aif ofa eae te sa os aos nf fs ale 09] oo ala 0 reavse so] [ray aoe ade. as aoe fe ale shew ola fa facade ala al wa am Zane rae ose sofa sla oe one oz rae one ws vfe oa 0 Fiiekaane eicen) facaeMcneeds aia wale me of eas evan) faeaenemenes ar ae Plame) (sueieie ne neacademeess aes Ufo vase go] [pede os}r volz vale ana waa oofa va. 0 t Sieaceet (euewe rie nibaaaeesmed 2186-1 Lite Birra) [odene wenn oma sas = 4 oa [The ahie trop 1.70 ve 1.050un ChTsk ore] Sita: fedeaican Hla eaiiaet dicen [evento pa “lead si ecto yor, 4. Install the shim specified where the lines interssct. This shim wil give the proper clearance, Example: Present shim is 255 mm. Measured clearanca is 0.50 mm, Replace 2.58 mm shim with 2.75 mm shir, ', Remoasurs the valve clearanco-and readjust if nacessary. NOTE Off there is no elearance, select a shim which is several sizes simter and then measure the clearance.4-20 ENGINE TOP END Valve Removal le Remove the cylinder head (see Cylinder Head Removal) sing open the rocker arm, and then remove the shims. (© Mark and racerd tho shim locations so that the snime can be installed in their orginal positons. (© Using the valve spring compressor assembly, remove the valve. ‘Special Tec! ~ Valve Spring Compressor Assembly: 57001-251 (A falve Spring Compressor Adapier, 022: S7O01-1202 (ey Valve Installation ‘@ Replace the ol seal with a new one. ‘@Apply a thin com of molybdenum disulfite grease 10 the valve stem before valve installation. [Al Vaive Stem [D1 Spring [8] ON Seat [E] Retainer [Cl Spring Seat (Fl Split Keepers Valve-to-Guide Clearance Measurement (Wobble Method) a smal bore geuge s not available inspect the velve guide weer by meacuring the vaNe to valve guide clearance with the wooble mathod 2s indicated below ‘@insert a new valve [A] into the guide [B} and set a dial gauge against the stom perpendicular to ae lcse ae possite to the cyngor head mating surece. @eVvove the stom beck end forth [C] 10 measure vaive/valve guide loaranee. ‘Repeat the measuremant in adirection at aight angle to te fst “if he reading exceed the service limit, epiece the cylinder heed unit NOTE OTe reading is not actual valve/valve guide clearance because te ‘measuring paint ls above tha guide Valve/Vaive Guide Clearance (Wobble Method) Standard ‘Service Limit Iniet 0.3 ~ 0.12 mm 0.26 mm Exhaust 0.20 ~ 0.18 mm 032mm Valve Seat Inspectian ‘@Romove the valva (eee Valve Removal). €@Check the valve sesting surface [AA] between the valve [B] and vaive seat (C]. (OMeasure the outside diameter [D] of the seating patter on the valve “ki the outside diameter is too large oF too small repair the seat (see Seet Repair) \Vaive Seating Surtace Outside Diametor Standard: inlet -30.9.~ 31-1 mm Exhaust 26.9 ~ 27.1 mmENGINE TOP END 4-21 (© Measuro the seat width [E] of the portion whore there is no build-up carbon (white portion) of the valve seat with 8 verier caliver “the width is to0 wide, 190 nartow oF uneven, repair the seat (see Velve Seat Repeir). Valve Saating Surtace wien Standard: Inlet, Exhaust 0.5 ~ 4.0mm Valve Seat Repair (@ Repair the vaive seat with the vale seat cutters. ‘Special Tool ~ Vaive Seat Cutter Holder, ©5: 57001-1208 Valve Seat Cutter Holder Bar: 57001-1128 [For inlet Vaive Seat] ‘Valve Seat Culter, 45° — 052 57001-1115 Valve Seat Cute, 82° ~ 089: 57001-1168 Valve Seat Cutter, 60° 933: 57001-1338 for Valve Seat Cuter, 85° ~ 035: 57001-1247 [For Exhaust Valve Seat] Valve Soat Cutter, 45° ~ 030; 57001-1187 ‘or Valve Seat Cutter, 45° ~ 032: 57001-1115 Valve Seat Cutter, 32" ~ 028: 57001-1119 or Valve Seat Cutter, 32° — 030: 7001-1120, Valve Seat Cuter, 0° ~ 90: 57001-1125 rf the manufacturers instructions are not avaiable, use the following procedure, ett Cuter Operation Car This valve seat cutter Is developed to grind the valve for repair. “Therafore the cutter must not be used for other purposes than saat repal. 2 De fot drop of shack the valve Seat cutter, or the diamond perticios may fall ott. 3. De not fail to apply engina ol to the valve Seat cutter before grinding the seat surface. Also wash off ground pentclas sticking to the cuttar ‘with washing ol, NOTE (Do matuse-a wire brush to remove the metal particles trant the cuter, twill take off the oiemond particles. 44, Sorting the valve seat euttor holder in postion, operate tha cuts in fone hard. _Do not apply Yeo much force to the diamond portion, NOTE OPtior to grinding. apaly engine oil to the cuttor and during the ‘operation, wesh off any ground particles sticking to the cutter with washing oft 5. After use, wash it with washing oil end apaly thin layer of engine oi bbotere storing.4-22 ENGINE TOP END ‘Marks Stamped on the Cutter: ‘The marks stamped on tha back of the cuttor [A] ropresent the following, BO" irene ninsn Cutter angle [8] 3759. conan Outer diamatsr of eutter (C) ‘Operating Procedures: lean the seat area carefully (© Coat tha seat with machinists dye. (@Fit a 45° curr into the holder and slide it into the valve guide. (© Press down lightly on the handle and tun it ight or left. Grind the seating eurtaca only until itis emeoth, CAUTION Do not grind the seat too much. Gvergrinding will reduce valve ‘clearance by sinking the valve into the head, Wthe valve sinks too far ino the head, it will be impossible to-adjust the clearance, and the cylinder head must be replaced. fe Measure the outside diameter of the seating surface with & vemier caliper. kif the outside diamoter of the seating surface is too smal, repeat the 48° gring until the diameter is within the specified range Seif the outside diameter of the seating surface is too large, make the 37° grind described below. Zit the outside diameter of the seating surface is within the specified ge, maesure the seat width es described below, (@Grind tho seat at a 32" angle until the seat 0.0. is within the specified ‘ange (0To make the 32° grind, ft'a 32" cutter into the holder, and slide it into the valve guide Turn the holder one turn at a time while pressing down very lightly. ‘Check the seat after eech tum. CiAlker making the 32° giind, return to the saat ©.0. measurement step above. (@7To measure the seat Width, use a veri ealiper to measure the width ff the 45" angle portion of the seat at several places around the seat. “If the seat width is too narrow, repeat the 45¢ grind unti the seat is slightly too wide, and then ratum to the seat 0.0. measurement step above, ‘kif the seat wiety is to0 wide, make the 60" grind described below. elf the seat wicth is within the specified range, lap the velve to the seat 1a described below. (©.Grind the goat at 2 60" angle until the seat wieth is within the specified range. (OTo make the 60" arind, fit 60° cutter into the holder, and slide it into the valve guide. sngagerent by machining S'0uNd volume by 32° cuter | with a6cutte by 60' ureENGINE TOP END 4-23 (OTurn the holder, while pressing down lightly. (GAtter making the 60" grind, etum to the seat width measurement step above. (@ Lap the Valve to the saat, ence the saat width and 0.0. are within the ranges specified above, (OPut a litle coarse grinding compound on the face of the valve in a number of places around the valve head. ‘© Spin tha valve against the seat until the grinding compourd producss| 2 smrooth, matched surface on both the seat and the valve. (© Repeat the process with s fine grinding compound. (A) Lapper [B] Valve Seat [C] Valve ‘@7The seating area should be marked about in the midale of the valve face ‘If tha seat area isnot in the right place on the valve, check to be sure the valve isthe correc part. Ifitis, it may have boon rofaced too much replaco it. @ sure 10 move all grinding compound before essembly. ‘einen the engine is esaambled, be cure to adjust the vaive clearancs (200 Valve Ciearanca Adjustment)4.24 ENGINE TOP END Valve Seat Repalr [nay ‘Machines ive on seat 1 ‘Grind Toot 48" curr Porposs! make seating ar tmoath and round Y Moanure Seating Area OD. “Toot Vernae Caliper Purpow: crecemt OD, fg Snenstioes, T exits Tao ll Too ia cine Macunaes Teoh a8" Cutter Sy on seat Frposs: inereae 0.0. of sot mostaiee, t 2 Grind Toor a7 Gamer Frpose: reduce OD. of eat ares ‘espa. Paevre Sat wet Tool Verner Calor Purpose: check esinicth | ed Too narrow (Tox Toa wie Sina Macnee Took a8" Cure Syeon mat Proosa: ree wit of sat i Meabevand spec. to ings OD. Grind Tool 60" cutter Porpose: reduce sot wieth Taavare Toa Vale opr ardrg compeura Purpose: perfectly match valve dnd seat area; check Valve haa for darmapeENGINE TOP END 4-25 Cylinder, Pistons Cylinder Removal Remove: Cylinder Head (s00 Cylinder Head Removal) Cylinder Nut [AT Cylindse Cylinder Installation Install the new ovinder gesket. Sat the piston at tp position. ‘@ Apply engine oil to the ovinder bore and piston ski. instal tre cylinder [A] s0 that the tensioner mounting hole facos rearward. Tighten the evinder nut. Torque ~ Cylindor Nuts: 25 Nm (2.5 kg-m, 1.0 feb) Piston Removal (@ Remove the cylinder (see Cylinder Removal) ‘ePiace 2 ciaan cloth under the piston and remove the piston pin snap fing, (© Remove the piston pin. ‘Spectal Too! ~ Piston Pin Puller Assembly: $7001-910 [A] (© Carsfully spread the ring opening with your thumbs end then push up ‘on the eppasite side of tha ing [A] to remove it (@ Remove the 3-piece oll ring with your thumbs in the same manner Piston Installation (© De not mix up the top and second rings. (© Install the top cing [A] so that the “R* mark (8) faces up. (© Install the second ring (C] so that the “RN” mer [D] faces up.