Ninja250R~ GPX250R

Moto!rcycle Service Manual

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~n,g,il1e TD:P' End I&.i

~C~lu_t_Ch_, ~~~'1IH

L__'E_n__:~s~in~.e~. ~L~u~b:r_ic_· ,a_t_lio_," :n_' _S_·ys_t_e_ITl_:· _~~.

E,n,gine Remlovallln:staUati,onlli

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'WheelsITi:res

'11Ii

~~~--------------------------~

IBrakes

~S_~t_e_e_n_·ri_g~~~ __ ~ 1IIi

~'F·_·· ~~ ~I···.m:~ll

_,rame __

T1h,I~ qu.ic,krefe~ence ~i'de. wHl;mi5,~ yol.! j,n loo.ISting a desl'1'edtdpic o;r prooeduf'e.

"Send' the ~'9u" b~ to match .tt;~' 'blll(:1I: tab of the' $sited chililt:er' l11umbEr wilh the black~b on trl.e edgt at :eiIiGn, ~able

tif contents pa~, ' '

,,:Re(ei 'to "thi '~tln"l 'tabl!! ofCOli'ltEnts fOil' th:e e,~ pages, to, I:opatethe ,speclvic tWit ~QIli,jl'<ed,

Ninia250R GPX250R

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·'awasa··.·,1

Motorcycle Service Manuall Supplement

AU righ~ r4!l~iVed:, NQ part!> of this pui)liC<:l1!qoln may be· reproducoo, stored ina retrieval $¥stam"o:r transm'itted in any form er by any means, ejectronic rnoon,an:~cal photocopyi'ng, Ireco~ing or ,ottw· w:isE!, withrOUt the prior written perlniSi,io"; 'of OualiW Assurance Department/CeJ.l'l.sumer ~Pli"Qdudll &.

CQmponenj! G'ro1yp/Kawasald Heavy lndastries, U:d., Japae, . . ' .'

No rHability can be aeeeptedIor any in!8IOOuracies or omisSions. i;ntJhis puJbI.ica~j,on, allJ1;ouQh .eve,ry uossi b Ie care has beel'li ta ke,1'II to make it as COlTlple1e., and iI'.U::CUIr,are -as possiblle,

T~e right is I'EIserved to· make, ,change.s ~t any time. with-gut prior norti'Qe 'fnd, 'W~thQut iI'lAUH~ir:[g,,:ail cibligatiOln to l!1l<!ke $Uch ~ha;nges t;a pr.c~!.!ct~. man~"da~wred prev~.o'us.iy, See your MQt(ltcyel~· d?alier

far the latest: inform.a'll1or'lon.prod!)ct improV€m>eints incorporated after this PublicaJ;ion. .

AJ I iniorm.ation eonta i fleD i n th ls publ jcaf~:o n :~s 'based on the lattest P'r,or;iuct m!'lfOrm:atio,n .altlai~ab~:e at the time oi publi~,t~'ol1. 111~,~ystrations :aiild pf.lotograpl1fs in 1lf1isc' public1;lil:l~ofl are inter!l;tedforr~ferenee' ruse,.cH'IliY and mary nO'I>~epiCil: ?ch)i111 mod,el oornpbntmt p·,u1S.

1..1$1 OF ABBREVIAll0NS·

"If;. J~.aD1C AC ATOp saDe BOC BTDC "e

.DC F

.',ampere( !I)

.8 tmr bottom dead eerrter alternating current

afi:1'If tt;lP d.ead c'er:'lt;er be·fore bottom dea::d center botto m, dead center

pefo're top dead cern.er degree'(s! C.erciys

direct current

T;aracl(s)

degree'Is,) FallrenheHt 'f09t, f¢et

gram(s)

hovr(s)

!Ii"ter(s)

Ib

m min IN Pa PS

psl

r rpiTJr TOC TIR V

W

n

poo I'Id {:S/ mete-rltl' minuteis) rHmtot'!(s) IpascaHsl horsepower

poundis) persquare Inch revolution

reVQliYtiron~s) per minute top dead center

tetal lndlcator reading vo.ltl.s}

wat.t(s)

ohm(s}

U.K. model 01111'11'

,-

ljIjI~iRNilNG CQNU~NS .ASBE&TOS

T1tiis wau1ing may app·ly to, any ·uJ the following cQWPoflents or <jITII· assern blV 'cot'! ta,in i 1'19 orle. or mOire o·f these t:(Jmp~;m~f1t~:-·

Brake Shoes.of Pa!fs Clljtth Fri~i.pn 'Mat~rilll G!jsli(eh

I n Sid lators.

SAI"IETY ~NSTRUCTIONS

.Ope,rate if po~sible- out of d"OfS- or ln a weill ve·ntilll~ad plaee.

.,P'.ref~ra:bly use hand .tools or :Iow ~Deed tOOII.5 squ ipped. I f t'1Jf(:l!l.$S~ry, w~th !!['1 app'rop ria'ie dlJ~' sxtraction facilitY. Iff high speed to:ols are ,",s'!3d. they shou.ld alWilV's oil so ~uipIPl;!d.

ii,llf; possibi:"e, damp!J'n· be'for4;l c,yttlng or dr-ililing •

• [lam Pl!i:rl duSt an;;:!1 p,1 ace it i n p-ro~efly cI:osf)d' r~~!lPtaQI I)' ,Il'flIa d li,pal.e of i t ~af~1 y ;

B.r;llnln~ Btb.n~! d~". I. <i..n",rou. . ~o·~ .. ,!ih

FOil.,., "r.rl' ir'J1;ruOti'~f.i~

IRead! OWNER'S. MANUAL before qperating.

EMISSnON' CONTR;OL INFORM,Al'iON

To' prcite~t the efrlviro,nme'l:1t in whic:hwe ',alill Jiive, Kaw0I5aki has lneorpcreted GrankCalifl .emission (1) imd~xballst ¢missiof! t2JCOritro!1 'syste'ms in compllance WIth <!Pil'llicable reg,. l.:I~ationsQf the Uhit'e~ S'tciltes Environm-eih!a,1 PrQtei:.tio'~ ,AgencyaJnd Califbtnia Air R,e,W(kcesBoard. A:ddHtjonally~ K'awasaki has 'inCQi'porated <JIll, .evaporat,lve.emissioR control ;s,¥'S.ten'! (3)' i 11 eomrpH,~ n ee wH:h ajpr;H1cabte!:e,g~I<ltiQ:r:l$ of th~ 'Gal i tom ia Ai r R e$P1J n;:BS Board

o'm!~\eblcreH.pld~n CaiHQrhla on,ly. . ,

1.Cr1)iflkCasa Emissio~ ContrQI'Sys,te(m.

This system elimlnaites the' release of. cnm~c;3se VilI:PQr.s into the s'trmos:ph'ere. II1I~tea,dl, the v.apors .are routed thrOlugh an oil s.epat,a1tor tcthe Intaks ~rde, Of the ~ogine. Wnile the engirH3',"'ls Op>eH~twng, the vap.ors are dir.awll intocambustlQn chamber, wl1eilie they ar,e 'burnedalooQ,with, the iua'i and aiir:s!uppliecl"by ,the cerburetlon s,y~t~m.

2. Exhaust E mis'Si1Qn Control System ,. ,

Tni's, syste:m reduces the amount or pollutants disch.u:gediirl"liO tll,e, atmosphere by the exha:lJst of this: motorcvcle. The iJI.H!,1 and igrnit:iol'l systems of tbis motorcycle, have, been careful! II designied and c Q!l$tru~t@d~ to ensure ,an efficient engine wi th low ElllChsiust

PQHutsra ~e'V~I:s. '

'3. Ev.apo'ratiVeIEmisSiQ~CQnHoJ System

vapor~ c~used tlv fue~ eV~PQ;'a'ljonJ in the fuel system are 110t velflted into the atmosphS-reo Instea.d,fQe'~ vaPors are rou't;«:l into the rllJnil'l~ng en,gine ito be burn'ed, or sto~.ect in a canis.'ter wnernhe engi:ne is s'topped. Uq~ld fuel iSC;3ughtb.V a vapQf sep'ar'atQr<lr1d1 re1;!,nned tn the. iu.e~ tan'k ..

The Ciean .Ak Act; which ts the Federal> law ,covering motor vehi,d~ po!hui'Ofl, tC9ntain$' what is ccommol"ll:y reter;recl 1.0 as','!line Act.~s "tsmper'ingl'lrovisions,"

""$1l'C. 203(a) T~ e foil owl tlQ',aa;ts' .alnd the causin.g. ther~otaJe p roh ibi ted ....

~3) (A} IOir ialny pef.}On'to remove or rendl!!r!ll1oper.<mive .af'lydevk:e or element 0,1 des!lgn

, inllcl:aflleo on 01' ina! maWr' ve'hicle or motor vehicle engine in campU'ance with regutat'i OilS III nde:r th i,s mle pdo r to ltsssle 'lI I"d d ei ivery' to' the lJIilit i mate pl:lroh,aser, orror aJl~V manuf~~:H·er'or dealer krl'o.winlgl~Y to remov~ or render inc~e'rat~v~ .any :§iuch device (l'r eh~me!1it 6fdesigll aft~rslueW1 !i3lle arid dleliveryw tl1~ ultimate purcJra~r.

Ul){B) 'ten any l~ier5'O!1l, :enooQed h, the 'business qf repairing,seryi,eJng, selling. leasi,n~or trad~nlg mQtCM vehic,Jes Qr mfNtor vehilcle 'e~lgines, or who ope~a:tes s'fliwtcd mQi\:or vehicles, knowingly to, remove. or render ii1Operafiv~ any dwice Qr e~emeot of desiLgn installed on erIna rnotor vehicle er motor vel'lic~e'el'lglne, in eom'plia;nCiec with regu'ladons uncer this '1itle foHowing, its sa:.leand deli\il'!l:I'Y to 'me ultimate pu reil aser." "

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Nore

e Ph!: phrase · ... remove ,or render inopera:tive any dBV;C8 orejement' of design'"' has. been getJ.e.'f8IJV in terpre.te'tifJ!J 'fall (JW$,:'

"1. T"'8mpering doe$ (lor include the temporary of renderIng inoperatitlfJ of. devices (If elemtJna; crf design in oraer to perform ril{1intcf}ancl':,

,2,. Tam;m'finii CQtild include.::

8., Malarijusrmfint:o.fvtNl'iC/8 tompommrs s,uGh that theemlssi'6h u.j3rNlardUte l!x.Geed~, b- Uffe of rep/at:.ement liftrts or .~cct1${jdes which a~versl1Jy alftlc:.~ the peilorm,afli:80f .dui~bHity of-the motor:cycfe,

G, Add/tiono{ l!;o.mpol1;mts Of o¥t;:f!$So.des thiJttesult..in t/Je vf!hid~ ,exce.(Jqing the $tClncJards:.

(1. Pcrm;<}'fIcnti'l removing, discoaneorfng, or renc!'et{ng. Inopi1r.fJtivs any cemponeftt or etet1:le.f1t ,0 f design r!)l the' emIssion con tro! 5Ystem.~.

WE RECOMMEND' THAT .A·l.L DEALERS OBSIEA.\IE THESE IP!l~OVISIlONS Of fEDERAl!.. L.AW, il'tiE V~OILATIO:N OF WHICH liS PUNISHABLE BY CIVIIL PENALTIES ~Oli IEXGEEDING$·10~.O PER VI.OL~'TmN.

Fedjera,i law 'pit-O;hioiU t.he to~'~owiI1l9 acts. o.r tha :c;;JllIIsing tbe.t@rf: (U The ramoval or r!'lrid~rl:n!'l h]jQP~r:~tiv!E! by any person ether th;an w:or purposes oil' mailTltenam:'e:; r~pair, or rf!plam~ment, of any de\l'~,ce or element oef d'estg~ ~,ncQrporatedi into any new '\I!!3'nide, for the, P~fPOse-O't' .l11oise, contr.ol pr ior '1:0 its sah,~. or de:llverv to tb e ulti mate purchaser or. wh i Ie it is in use,or ~2) 1:hause of th,!;! v6'hiote aft-.er suc;n devi.ce Q,r element of desIgn has been removed or rendered inoperativ,e by aAY person,

ArncHligtih:Ose' a(l;t""Spresi;ln!l;!d·tocQnstilU~E! t<lJf1I'!perilog <;ifethl;!'oicn; listed below: .Replaee1mel'lt of :the originall ·e,S!:t'i;1lus;t. system or ml.l'tH~r witrn a ccom.ponelU run -. in Icpm·

pi iance W~ th IFooleral regU la:ri ons,

• Rel;n.o't~1 Qhiherru.iUI;erh) or any il'!tern:a~ j;)o<rtionof the -rnOffUe(!s·) . .. Removal oHhll~ 'iI~ r bQX 01" '''iirb.Qx cQverc.

-MOddficarionstp.the m,l!lffl.ar(S-jor air inta~e:system by Gutting, drimng, or other means. if .sy·,ch modffications re"sl.!l!t in irlcreasea noise l~veLs.

Foreword

Tbls service manuall supplement contains only the information ull1ique' to -the models covered, It must be used with the base' servi.ce manual listed b~lo.w.. Read both this sl.lp~l"lejnei1t and the ba_se manu.al for catnphna rnformatiOl1 on proper service! procedures for the mods Is covered by this manual,

Part.Nutnber

Ninja. 250R (GP'l . .2501Ft1

99924-1066,-01

This manual is designed primarily' for use by trained mechanics in a properly e'qiJ~PPfiti shop, However, it eontalios enou.gh detail; and basic Information tomake lit useful to "the Qwner who desires to perform his own basic maintenance and rep<!~r work. A basic knowledge of mechanics, ·the proper use of toels, ami. W(Jrkshop prQ!;:a~.ures must be understood in orderto carry out ma~'nteni3nc'e and repak s;at~sfaatorHY. Whenever the owner has insufficient e.x.periel'lce or doubts hls abillty to do the work, alii; adiustments, m~~nte.nanc,e,. and repair should be carried out only by Qual,ified mechilinics.

I·h order to perform the work efficiently alnd ltoavoid eostlv mistakes, read the text., thoroughly famWadze yourself with the procedures before' starting work, and then do the work care1\Jlly in 1j clean area, Whefiever si:Il~.dall toots or equipment arespecHie:a, do 'nol use m~:l<rElsh~:ft' 'tools cr equipment, Prefli:sion msasu rements can only bee made i.f the proper instruments are. used, and the US~ of substttute tools may adversely affect safe operation;

For thel d,Llration of the warranty peri.ad, we recommend that all repairs and scheduled maintenance be performed in accordance with th is' 'se'N ice. rna nuai. Any owner melntenancs or r'epairprocedlIte notperiormed in accQ,rdal'lce with thts 'manual may "'Qiid,the vvarranty.

To get the longfM'lt. life out· O'f your Motor" cycle; .

• iF 0 II ow the Pertodic MaIntenance Chart. in·tJhe service manual.

-Be ale,rtfor problems and non-scheduled tna!intenance,

-Use proper tools and genuine Kawasaki Motorevcte parts. Spr;roial tOQI$; gauge~, and testi'irs that ,are necessary when seNi'cing Kawa:saki mo'tcm;:ydes-are i ntroducad bY the Sped.al Tool M1!11'i lJ!BL. Grercli tl i ne parts p rev j dad as spa reo .parts . are listed iin the Parts Catalog.

• Follow the procedures ~n this rnanusl caJefully.

Obl1 't ta:l< e. shortcuts.

-A:emembEl'r 1:0' keep- co'mplet€ records of malw te!1ance a:nd, rep,air with dale-s alridi any "new parts jiista~.led.

,~ ••••••• _ .,Ii Ii ~ a .••••• i·.I;ii IF 11'. ~! ! ! ! !'_!! ! ! •• __ ;; a ;; ii·;I,.,I;,1 •••• 1.1 ••••• i,;

!!!!! ••• '!' ,"' ••••••• , •••• i iiliil, .. illi ••••• iI'I'oIil •••• " "'''' ..

lin prepari!lg this manual, we diVided the· product into its maja'r systems. These systems, became' the manUtall's chapters, All information fo.r a particular system from adjll:stment thtough disassembly and lnspecncn is lwaited in a s~nghl chapter.

The Quick Re-ierenc:,e Gl,Ilide shows you al~ of 'the p.wduct's sys:tem and . assis,1;S in Iloeating ·their chapt~r.s. E~ICh d1apUl"1' in tut'.t'I has its own comprehensive T{lble, of ContentS.

The Periiooic Ma,if'lHmance :Chart is, located in th.e General Illnformat:i,on chapter, The' chart gives: a. time schedule' for tequked m.a,intel1a·I1C¢ operations;

. If you want spark plug ~nfonnation. f·or .eKa;mp~e.gD to the Periodic Mailltef'l.:ance' Chart first. The chan tells )I'OUI !'now frequf!'Mly 1:0 c~ean,md ,gap the pllug. NeX"Ii, US"e the Quick. Re·fatence Gu:We·ta locate the Electrica,l System chapter, . Then, use the Tabl:eoif Cor'11ents on, tile' firSt p'~ge: of the c1'1apll3r· to, find the spark plug section.

Whe'nlW~r you see these WARNING and CAUTIOiN svrnbols, heed their lnsrruetioral Always. follow S<llfe olPeratingand m.aintenance practices.

I WARNIN6 •

aThis warni:l'Ig wrmbol ,idBllti1~es spechtl ins.truc· tion$" or prc.cedlii'ilS which, if not: GOrt9C1lly i'ollow:edo; could resllllit ln person1al injury. or loSJ I}f )118.

9 Thli~ eeutlen symbol ide!11iifi~ special instructioas or p~u:res which, "i"f nm :$;tfij}tl'v looserved. eQuid l'i9$ul,t in di!miil~to ~r des.il:l'lt:lction of'eq'lJ!ipmQI:'!'t~

This. manual c.ontain~ five more ~ymbo'l~ (in ,~ddit~on to WARNI.NG and CAunON) wh:ich will help Y{;IU distingudsh different types of informatioif'l.

NOTE

c Ttris note s yrnbe;I indicates points, ol fJ~'!1icuI8,(, interet;t to r morfJefficien.r: and convenient opf!NJti(;n.

-Indicates a procedlJraJ step or work to be done. Q Indicates a proced~ral sUlb-step' or how 1:0 do the work. of the prQcooufalistep lt follows. It also precedes the- teXi!: of a WARNING" CAlrn'ONI, or NOTE.

'*Indicates a 'cooditliomd s.te'p or wnat actlon to take. based on the results of tne test or inspeetlon in; tne' prooethiral step or sub,-'$,tepi 'ut funows:

~lllndi,~altes ij, conditional :slub"step of what action to "take bas~d upon 1he results of the condttiona' step it folJoV!,'s.

In most ,ci'1<aptienan exp~.oded view iIIu,stlr:atioif'i of the system com ponents folllo\IYS the Table of Contents, In these~ lllustratlera yO!<l will Hod the instructlons indicatin-g which carts require sPflGified tightening torque, oil, gr·ease 61" a lookihg agent durinq assembly.

I;·

I •• ,'ii .• "" i ••• i .tliil' '11' '~"'!!. '! ii •• ,. ili,t; I"" !!.""'!

••••••• ,1 I ' I ••• II!' •• !!!'III' ! ~ .. "' ••• ,;, i ii i .,i •• 'Iifijj II!'!'. ~ ! ••••• i oi i ,i iii ii ~ it! iilf! •

B'IHor,estarting to 'service a motorcycle, careful reading of the applicable section is recommended 'to elirnlnate Ul!nri!ocessary wOirlk.· PI1Oil:ogr,aphs, diiagram:;;,. notss, cautions, warn iln~m and detailed descripflons hi'IV€ been included wherever necessary. Nevertiheless, even a detailed account has limitations, -~ certain amount of bask knowledge Is also requ ired for successful work .• ,

E,s:paoially' 110te the' followingl; ~1) Dirt

Before removal and disassembly, eleanthe motorcycle. Any dirtel1l;ter<ing the engine or other psrts w~ I ~ work alS an abrasive and s~ortern t!he life of the motorevele, Forthe sat:r1a rsssen, before i'nstai~ling a hew p.art, dean off any dust or metal: -filingS.

(21 Battery Ground

Remor\l'e the gr,ound 1-) lead from the battery before performung arw diS'assembly operations 011 :lIhe m oitorcyul e, Th i s prevents:

(a) :the possibi:l ity of accidentally turninqthe engine over while partlallv d~sassemblled" (b) s'park,s ateleetrical connectlons which willi occur when they are disconnected.

(c) damage toelectrical Pilrts~

(3/Tightening Sequernoo

Generally, Wh!'lil install ing a pan whhs.eve.ral bolts, nuts, 01' screws, thev shoulld all be started 'In their holes and tightened toa sl1ug fit. Then ti'ghten themevenlyin across pattern. This is to avoid (:Hst.ortklf'l of the palt'tarll;ji/of' -c.aus1ngga_s or or! Ile~kage<' COllwerneht w,hen loosenlngl the bolts, nuts, or.llcrews,firs1l loosen al:l of them by about a quarter oftum a!nd then remove them.

Whore the:re is a tight,eni'ng seQuence indica:tlion in ·this $elrvice ManlLlal,the bol1S, nuts, Or screws-must be t~ghtened 'in the order-and method indicated.

(4) Torque

The torque. values given in this Service Manual should always be adhered tel', Either too little or too much 'torque ma,y lead to serious damage. Use a -good q!.lallity, r,eliable torque wrench, (5) Force

COlflrmon sense should di'ctale how much toree <Is necessary ill' assemblv and d~!:la$Sembly. Iii a oart seems especiailly difficult to remove' or install, stopandexarnlne what may be causing tile problem. Wihen,avertapping ls nec'~ssary, tap lightly uslnqa wooden or plastic faced mallet. Use an imp-act driver for scr(:!ws (parti,c,ul.a1rl,y tor the removal 01' screws .held by a Ilor:king -age'F1t) in

order to avoid damaging' the screw heads, . .

(6) Edges

Watoh fot sharped'gesi especia,ll", duririg major en.gin~ d~sasserlilb~y and assembly. Protect your hands with glovM'or sJMcEl 0,' thIck doth when l~ftl'(11g't'heen9ine or' turninqlt Oller.

(':n High Flash-point SoJ.v'ent

A nigh flash.potnt solvent is rec-ommended to reduce fire danger. A commercial solvent com.rnonlv availabh,t knNorth America is Stoddard solvent (ge~eric nemel, AI:ways "fol1low menuractlmHand contalner di reetlons regardiing the use of any solvent,

(8) G;;I.ske't, O-ring

Do not reuse a gasket or a·ring OnCE! i:t hss beenin service, The mating surfaces around the Q<)ISket should befree of foreign'! mattlu and perfectly smoo~n to avoid o~11 or compression leaks, (91 Li-qlJidGaskat, Non'pe'l'fT'lan.ent Locking Agent

IFollow rnanufaetu rer's di reetlons for cleaning and p1reparing surfaces where these compou nds w~11 be used, Apply :~palringiy. Excess:ive amounts may block engine oil passages and 'cause serious Q!ama.ge. An Q)(8mplleofa non-permsnent !.ockin9 agent commonly availa!Jh! in North America is l.octite l.ock'n Se(!1 (Bille).

(10) Pres'S

A part installed using a press or driver .• such as a wlleel bearing, should first hsceeted with o,il on its outer orlrmer circum'fferenoe so 1lhat it will ,go jnto.piace smoothlv,

~1 H 'Ball Be,arjng

When installing a ball hsarinq, the beari.l1Ig racI'! which isaffected by fi'ictio't'li should be pu;st'lool by a suitable drIver. This preven1!ss.ever,e stress on the balls and races, and prevents races: and balls from being dented. 'Press a balilbearing unt] tt stopsat the stop i~ the hole or on theshaft,

GENERAL INIFQRMAllON 1-3

! 12) 'Oil Sea~ and Grease Seal

Relpllsce ,a,ny oH O~ gre,ase seals that were removed with new ones, ,",srem9v,ali !Jenera!~ydlamagtls seals .

. When pressing in s; Si~fal whilqh has ina·inufa.c.tMrer~s: marks, pr~s~ it in wi'llh the marks'fach'ig! out . .Seal.s sheu ~ dbe ~p re&sed l n to place us-in ga,? u~lab.1 ~ driver. W h ieh eentaetsexe ri'l V wii'th the: .SJde.of seal, lHl1U the: face ofthe ee~~ is eve;i1 whh the 19n,<1·.0* the ho.le .•

113) Seal G ui de

. A sea,l -gu i de .i s requ ~ ~ed "1'0 r :eli! rtaki oil or grease sQal.s:du r~o g install atl onto" avoid claim a ~ to th!l'

SEMll IIp·s.. Befo,re a snaft passe:s through ·a sea'!;, .a~ply a Hnl;;! coH, pref'e.r.abily high temperature! gr.ease on the lips-to reduce rubber to metal, fdction.

f t41 t1rclip, Retainimlg R~,ng

Replace· 8'I1Y circllps a!nd retaining' rirngS, that we're mmovsd with new-ones, as removal Wei'l,K-e'f1S and .detorms 1hem. Wlhen~nstamlilQ circHps andret.alin'~ng rin.!ji, 1ake esre to compresso'r expand -them only en'oughl to in5tal~ them and nO'n'lnffl.

CUll UJibrlcatioll '

Engine· we&r""i~ geriEl'rall1 vat Us malMl'i rn urn wh he the '&ngli n e 1$ warm~ n 9 up <),Il d bell;! re all 't)hi;l rubbing ~ulrfa~es have an' a.dteq.uart'iJ: I Uibrlic-BIti.virf\i'lim. DiLHingaSS.emp!ly, oil or g'rela~9 iwhich~Eln!l: mOire su11:abie:1 sir-Quid be "a:ppliie.d to aWl", rlubblrig surface wMth heslest j·ts lubridat~ve 1Hm. Old gteMe enid dirty oil shoyll:d ,be' eleanlikl".oU. Deterior.a~ted gre:a.se.has 10's,t li,ts Il!Ibr~cart1fve .Ql,u;d~ty and

. '.. . .. - .

may contain abrasive for:eigl1palr1icl:e:s.

Do.n·'t use j:ust atn.v o:i~ or grei¥lEh Som~ oHs Bilild gre.ases ~n parrticular' sl1oul.d ~, us~c! only in certain appllo8tio!l1s;and may 00' harmjfulif used i"n an application ]Of whic:hi 1hey al;e not irnended. This menual makeS' ref~renoe to mo~ybd~lnum. d.isulfide '9lr'9!8Sa IMoS:z ), in lhe,assem~,iy 011 certi'llinengine and {:h~ssJ$. parts.. Alwary$. cheek manufact:u1rer recQmmendiati}ons befure IJsil!lg sueh -special lubricants,

(16) EI'ectdcal Wires

Ai,! the. electdcal wires are eith'ers~ngle~colororr two.:oolorand, with onlly a. few excsptlens, munbe 'Connected t.o wires of the same .. color. On Srr:i'Y oftll9 'MQ-{::olor wires 1here i~r a g.r'ealer amount of one color aada ~esser amountef a~ooon~ color', 'SiP .~ :tWo-color wtre ~sidentified' by first the primary color a.nd then ths ~eporldi'l-ry collar. 'fQlr example, 81 yellow wire with thi'h red stripe-S i;sre-rer:re'dt"{l'as a "yellow/~e.d" wire; i'l: would\: bea "redlv~lIow" wire if the colors were reversed 'to make red the main color . ... .

- ." " .. _' - ~ - ... - - . . '_ - . . . .".

N!;Ilneof W~re CqlCH

Wi re'strands

Yelfow/red

Yellow

Red

(1 n Repiaceme!t'lt Parts·

When thera is: ,a replaoe.mentil!listructiprI, repl:aoe, thesa .pans wrt~ new 'o~es e-very time. th~y ~tOO: ~l'hovedl.These replacement parts willi be dam:agedor lose thFeir original fUr!ctifig:n oM!,!refnQved.

( 1 m I nspeetion .

When p:a;rts. have b(i)e'hi dir~Il$S.embred, visually inspect thest1. parts TOt thiidiOHawi1filg ~QJ1Iiditidh~or

oth er darn age. I f the re is .any d.ou bt as tOI tn a c;('.in(Hti 01"1 01 the m~ . repl ace:'~h em wH:h.' hew ones.

Ab.rasion Crack Hardeining W~tP

Bent Dent Scratch W~alr

ColQr Gnange o eteri ot-afion Seizure

(1-9) Service: Data

. Numbers of servles .data ln-thls 'UIXt have Tol!lowingm.eaninlgs:

~~Stardards"; 'Show dimensions O'rperiormancoo which brand,11U!W parts or .systems have. "Sen.rtce ~imits":: .Indie~rte, the usable' Iljm~ts. lf the measaremem snoW$ e)(C(!S!'l~lIff wear or dieler[,orrated performal')ce,rep,lace the d~lmaged petts.

GENERAL IN FORJMATIQ!N ,.',

,Genera:1 linformatiQn Table" afConte:nt:s

B~i(J't!e'Servic'i ngJ . • • . . .. • • • • • •• •• • , • • • • • • • •.. • • •. '" • . • • • • • • • , .• • •. '

MQd!i!~ Idernific3tion •..•.•.... , .•. , ..•.. , ........• ' .

Genera,l Spec~ticaitiOl1ls .....•....•• , • ,. e •••••••• '" ••••••••••••••••••••••

Wirif;ig, C.able" or How Rcfl..!tir.ul., ...................• , .. , ....•..

Toique and lod~.ing A:gent ...•. , ..........•..•• , ,

Periodic M,ai nt.6'nan:Ci;! Chart. . . . .. • . .. • . . . . . . .. . . . .. . . ,. , ., , , . .' . . . •

':2, -14 ~ -e,

1i~11 1~15

1:-2' GENERAL ,INFORMA,TUJN

., ' •• ' •• , ' ••• IIIL····!!!"!!'t'I!!!II •••••••• liiiii,ii •••• , •••••• , !.·!!"I".,' itl!iljlil

Modell [Identifications

_. ~. -

.'t!! ••• ' .. 1 .... '!!.!.! •• '.!I'II., •••• I II iiiti ii II j II i" i i •••••• '! ~ I ~ !!'!I!I' II! I'! !';!i!l!l'" 'I,i'." iii •••• ,.

EX250·F2 lOS ModeJ)

GIilNI!RAL IN'FORMATIO.N 1-3

EX250·F2 (EIHOlpeanOIi Gener.al' Model)

"1111'1 I Ii I 1111 I I I 1'1111;1 ~II'!I!!I'I I I I I 1II'!I"'!!!'!!! I!! .. ",,!!,~, ••••••• , .. ,.Lii,i iii ... iIi i i a i ~liliLI,1 a 1.1 I I Ij. !l!iIi!li

O:tmansio.mo:

OVef~n lengtb Olj,'ei'<'d I wid.th {)vetall. heig'nt Wheel[Y~lie' Road clearance .. Seat hei,9,hrt

![)fY w!'!ig;lit

Co rb we,ig!ht:

1,2:5 m 1rom 50 km/h 2.8'm

EX26~·F2

Front Rear

.2,035mm 7'10 mm 1005 mm 1400 mm 155mm I~mm

'~3!ZlrlK.~h ~'r1~!3:!5 kg 76 K9'

85 kg, G 86.5 kg 1EhO L

iPerforE\l'l~nC8r:

Braking distalilrui

Min imuiril. 'tUrnin9 radius

Engine; Type

COl,o.llln§ system

B:o~r~ and SUo kJe DiSiplaoomeF!l!t Compression r-a'l:~o Maximum Ihomepower

4'SlIirQke, DOH C ,2'.cyfind:fW LlQ uld-coe led

62.0 x 41,2mIf!

248,mL

"2:4-

Malx.2:7.9 kW (3B, PSi@UOOOr/in]lrl (rpm.!, @-, ® 27,9 kW m8PS1 '@1200!) r/min (rpm:l,

24,5 tilorn (2.5 kg·rfil,18. 1 j=l>,ibj @l1t1000 r/mln {rpm),

@-

Carbli!retors, i(eihjrn CVK30 x 2 e~e.(u:F:i!;l $tarter

B!gtrety· and cpf~ (·tr~n_!liSt9riZijd) ElectrolflicaHy a.~,va~~

l~fQml:0~ :BTDC :@J300:rJmin (rpm~ 10 4'-2~" B f,DC ~.45.0·O r /rni 111 (rpm).

~ FrtHT! S,"BTDC:@1300 rjmin. :(Irpm) to

42P aloe @4500rlmin frpmJ ·NGrK CSHA ,or ND U24FS·t,

@ til' NGKCRBH$A or NO.U2.4.FSR"U NOIf( CR7:HSA or NcO 22FSr·L,

@@ NG'K;. C,R7HS or ND rlJi2·2IFSF('·U Left to ri>g:M, 1"2

OSirbut"etio'l'Il sy:s:t.eim Sta rti.n; sySil::eJI11 19I1litiornsy:st~ Timing: adv.u:'!qe ~gl'litj()n :tt~ming

Spark plug· STD

Opti.on

hems

GENERAIL INFORMATION 1·5

Standard

Firing order

Valve timing: Inlet.

Open Close Duration Exhaust Opell

Close Duration

Lu brIcation system

EnghH! Oi1: Grade·

Viscosity Gapaci~y

Dri,veTraill::

Primary reduetlon system: Type

1·2

30Q BTDe 70oAB.DC 2:809

70· 68D·C 30Q ABD"C .2·80"

Forcecllubri.cati'llin (witt sump) S E or SF class

SAE 1OW·40, 1OW~50. 20040, Qr2OW·50 1.9 L

Gear

Clutch type Transmission: Tvpe

Reduction ratio ·3 .. 086 (11./23) We'!: multi disc

6-S'peed. const@rIt mesh, return shift 2.600 ~39J15}

Gear ratio: 1!i1.

2nd 3rd 4th 6,th·

6th

Finilll drives"lst·em: Type

R.edl.lctio'fl ratlo Over.all drive ratlo

1.189 t34{t91' 1.409 (31122) 1.160 (29/25) 1.000 j.27j:271 0.892 (25128) Chain drive

3 .. 21'4 (45/1:4) :13:.859 @Top gear

IFrame:

Type

Caster (rake angle-) Trail

front tire: Tvpe·

Size

Rea;r tire. Type

Sile

F.ront suspension: Ty:pe

Wheel travel;

Rear suspension: Type

Wheel tra\i'~ I

Brake type: Front

Rear

Tubul.iJr. diamond 27<>

83mm

Tubeless mOO/oo·16 50s l{iibel~~s 130f;BO·~6 645 Telescopic fork 140 mm

Swing arm (Uni·l'rak) 130mm

S:inglle, disc

Sin~le.d~sc

(Continued on next page .. )

1~ .GENEjR~l INFORM!ATU)N

EleetriCai Equlpl'l1!imt:

Battery

He;adligh:t: Type

Bulb

12. V aAh Semi-seal·ed beam

12 V 60/55 W (quarn·,ha,logen)'

U!, V 8/27 W x 2, @® 12 V 5/2'1 W ~·2' Three-pha.5e AC

17 A @~OOOD r/mil1l. [rpm], 14 V Short:~jlrcuit

.. .

EX250·F2

Tal l/br~kel ig~t

Altemsltor: Type

Rated O!1tPlJlt

Valtage regyl.atotr: Type

S:p;~iifications are ·subject to, ohange witilflOllt fiotiee.ilind may not ap,pl.v to every country.

Australia Model UK Model California Model US Model

1I!lI!!I!lII,.IIIIIIII,., •• ;; i;; ., .... ! .. '!''''.IIIIIFIII!''' I""" O!llO ........ "!II."!,! I! !t"l'''!!! f 1IIII'iI!"* i io io ..... ,0 ..

! I 11.;t' ~iI • ~ II Ii i ., , "!!' .. !!! ! '1,111 ••• I .,.'.' '., !,~.! ! III I .'111 IIII I .' •••• i ,

1. froM: Sr .• 1M Fluid Re1er..oi,

2. BI'lIc!! HI;ISII

3. .SpeRdomllter C&ble

4. iI11rgnlje C4b<le IIDlit:!;l~!!r'I,tor I

,5. ThrottleCllbl1l {Accelerator}

6. CI.Irt,cI!I C.b~,

7. Cl1ok(l Cable D, !Mnll!' IiJnit

G.E.NER,AL. INiFORMAt~ON 1-1

Clamp

1. IRearBri~Matter Cv~iml:et

2. Bral!iIl'Hose

3,. $p'eedcil'lle'tef cable 4.i!'hrotde Cable tde~I,Qh!tor) 5, Th~ec.abhl (~eletBtor) 6~ CliitcbClible

1. Cliloke,Catlle

8. To M~' Unit

9. Carb,uretor ,,~t~IJ'IntRe~.vciir 'J!lnk; H~ 1.1. nilrmlfB,Qlt Hou~I"(! 12'.Sp.r:1i: fitlY I,jads

I

/

1'~1 U

l (

1. Ba~;ry

2. FueJ Tank Drain Hose i B!II.ttery· Y91i1'i1: Ho1e

4.Coohn~ RQ&elllolr Tank VQm H0tiQ 1:1. QOolairlt Resenroirfl'ink

,6. Maii'l: Hli.fneS1:

7. Frame Tube'

S. Regulact.or/FIiOOMler

9. Alterl)lirt(M' .• Pickup Coil L.e{ld£ 1(.1. Neutr~[ Switch. Ibel;Id

11. S~dtt Sgnd SWi,tdl.. '1.11d

12. To ~ Ftel"YNept!¥i lJI~mil'll!l 1.3. .S'taner R.layConne.CilOr

14. Batwry Ground Cable' Ui·.Jlln.:tign Bel)!

16.81'-11 It;! SWil!eh Connel:ti.ir 17 . Starter MomrClible

GENERAL INFORMATION 1-9

Do riot fl1ake any l<li~ here,

1,. ~'~l1Iiti,o!ll Switdt

2. 'l'ilniti,oll·SwiltClil Lead

3.. T.o Ript thmdlebal' S,wi,.tm 4. T~!r" Sigmill CQfllilect(lr~'

S. To. #1; .I'!lnition :Ooi I

6. H,orll 'la:ad

"7. Far~ ~tor l!!:id

8. WIRer fempQraWn! -hli!~t !LelKil

9. Winer TemPefittUre Sa~S!O\r- . 'G!'Qi)nd 'keftd

10. T:o !Left Handl!lblirSwitlllfl

,21. Stilrt.e.f lRe,la:yCQ:rmIACWI!'

: 2~. E1!rfil!le, LtgktSWit,clh Qljint~Or 2'3:. ReguIMo~IRe.ctif~CoIi'I~1 ~" N.,':'ttclili s.witi;h Lead

25 .. 'Side .S~d',Swil¢hi&ad 26. !I~¥~r Coi\l~b!!'S

211'. MIIII.:f Harfle~S!i

28. iJ'.amiglrlt, Turl'l Signal Li,~llt C(lnl'lilGtol

29. Herl!l

,30. ~S!:ia!!'JI L.eads.

n fan SW.iwh L.e~

12. IFan SwiNt! G~O!llnd Lead ~~. ml Preuul'e Switch uBi:) 14:, To -#1 Lpi~ion 'Col'i

15. M~er C:OIl,IiIQC1prs

16.. Het1dliljht ',ConnEu:toir

n. Ci;<v Liight: CCil'ln~,ctor

1'8. A'~I~l!Imnor, PickuJp COIU Leads 11ik fa, Batterv Groil.ndTermi,1'iB1 20,. Jl:lnctiOl'! B.G)! (:Orln!lcton

t .: FlQutrl' Hose wlttl· Red Mlairik

2. Cli$!1'lp'

3. BiHtlilf.!r HOle with BI~l:I' Made

4. Fiu~1 T:Bnk. Ovlld~ow Draffin HQ$e S.FueJ Vjlpor FlOw

1ii •. RllIrge HOIfli with G~I!!'!i1l'..tllilk '1. 'AI:r Gliilner iHi:lI.islmgl

B. ca~i!$;tei'

9. Si~(IiI';8tQr (Rlfttlrn PI.! mpl - 1G. W~Pip!H:

111'.. D~liphr.agm!

1:1t V8.;u1llm. Pull!' HOfe with Whi:w

Mark

'l:t AlternQtgr~CQ-Y!lr 14. Cl)ni,M.r"Ufiening

,Ii .. Lef't:·Ra~ l,g'n~16n'"CQil

16: To Vacuum. Joint. ~I:! "Co<!stinl

, Ii! nrii:liie'r of, b'1!tt.Han:d arln:l~lm!i!' fl: '1"0 V,iKib!um, Jo~rit .onR'igijt-HlLiid .

caj.bI:i~e"1ior -

i ", .. Ii !Ii I I I I I __ 'II!!! ~;.JI"L •••••• ''' •••• , •• , ... '" I I I I I 1''IdI!'~!!!!!!!''' •••••• ,oi,.;; a i ~;t-;!Ii! I II I·;!,-!"!'!·!'·

TheiQllowin.g tebles 11:51 the. tighteninlg to"rQu€, for the malo~ faste'ners reClUI'iring use of a. 1!'ldn: permanent Ilocking age~t or li:ql,llid gasket.

lett!ers ~sed. In the "R.~iTnarlb;." column m!1!an:

G : Apply greas,e!.

IL : App~y non-perm:i'lnent lockinQtag~ni. to the threads. IlG; Apply I,~quid gas'k,et to the threads.

o Apply .Q~~ to the threads and. seated surface .

. S ,ighten the f.a,5terrersfollow'~n9Ithe sp·ecR~ie.d seq uenc(e.

SS· A~H)~Y silioone OO'ala~n jPN 56.019-1'20) to the threads.

St Stake, the fa.s~eners to pr'e\1el1lt loowning.

Torque

Fuel System;

Swltcn, hQ!iJSil'lg.cl.amp ::liCrflWS

C;ool ingSV$oom:

Water temper.<lil;UFlf! sensor ThEw'mQ1s,ta:;t l(l l,an SWitch

C091~;IIi1t drs,in pl~'9 (cylinder) Coolant drain pl.u'g! (w.ater plump)

Engine li',op End~

Cviin~~r headco\l'~r belts Cylinder neacill:lolts 18 rnm) Cyii.r:lde,F boil's (.6 mml Chain.gu ide bott (upp:er) Chaingu~de boit (iower~ C'amshaftsP1COGke1 bol'U

Vaiye <ldlustililJ9sc~ew locknuts Ga.mshaft beariilQ cap lbol:ts Camshaft .;;kI~in tensloner bolts CCh'lla,!lt·dr.ain plug ~~ylinder)

Clutch:

Clut-eh spring bolts C~Lltch hubnut

3.4 '0.35:
7.8 0.80
''1,'8 0.80
7.8 0.80
7.8 0.,80
9.8 " .0
25 2,5
12 1.,2
25 2,5
27 2,8
15 1,5
18 1;8
12 1 ,.2
],8 (i. em
8.8- 0.90
·lao 1 3J3 ft·lb

691n-lb 6,9'in-lb 69 ~n·lb 69hlb

87 1n-lb lB~h~lb 104 ~n·lb

tB.O 210 11,0 \3.0 104

1e:hlb 98

30

ss

s s

L t, O~

s L

1-12 GENERAL liNFOR,M.ATION

Torque Remarks:
N-m kg,~m ft-Ib
·20 2<0 14.5
20 2·0 14.5
15 i.s U., .0
us 1.5 11.0 SS
15 1.5 11.0 L
L
20 2.0 "14.5
12 1.2· ·1'04 ln-Ib
L
32 3,3 24
32 3,3 24
,69 7.0 51
12 1.2 104 in-lb L
15 1.5 11.0
L
:L
25 2.5 ·"·RO
20 2.0 14.5- L
27 2.8 20 0
34 3.5 :25 l
~:2 1.2 104 ln-lb
27 2,8 20
20 2'.0 14.5
88 9.0 65
no 1 1.0 80
9.8 1-,,0- 87 in-Ib
67 6.8 49
L
32 3.3 2,4
7.8 0.80 69 in-lb
32 3.3 24
32 3.3 24
2'5 2'.5 18.(1 Enlline Ll!!lbrieadon Sys1em:

E:ngil1e drain plu91 Oil filter bolt

Oil paSsage plu:9 Oil pressure switch

OU pressure relief vahle

Oil pump mounting AII'ein bolts Engine oil hose ban~o, bolts Engin,e Qij I! pipe banjo· bolts

(er snkcase LHj Oil breather bolts

Engine R:emQv,alll nST8!llation i El"igiine mQui'lting nuts Cylinder head bracket bolts

Crank$hafttT ransrni'S$io nl:

Alternator rotor bolt Alternator stator Allel1' holts N.Elulra.1 SiNltch

Shift drum beariliil'gJ holder Ana-ill bolts Shift drum pine plat~ S(;-reV\l

Shift drum positioning bolt 1!E;Ktemalshift meensnisrr: return

sp,rlng pin

Connecting rod big: end cap nyts, Starter clsteh A!II.en .baas Crankcase bolts H:lI rnrnl Crflnkcase- bO~tSi(,8 mm]

Engine drain plug

Wheals/Tires:

F Font axlenut Rear rude nut

If i,nal. D'ri'o'8':

Engine sprocket bolts Re'sr sprocket .nUI:S. IRear .sprocket stud ends T9rque I~nk nuts

Bnlle .. ,·!

Bleed valves, Tor-que !.ink nuts

Caliper. mounting bolts·~Front} (Read

Re.ar master cylinder. clevls locknut· Brake pedal mmmtiil,9 bah

Disc rl'H}urilting Allen bohs

B.rake hose banjo bolts

Bn:ike ~ever piV-Oil bolt ~'oc:knUlil:

Frant master cylinder clamp bolts R:ear m<'l'Stercyli nder" n1loum,jng b.Qhs Fm·nil: brake if.lul~d resenroir

cap screws.

Rear brake fluid rt'!S€'tvorr bolt.

S1[JfP9n$iionrS::

Front fOllk drain bolts

front fotl<: ol amp DO ~ts (upper)

~Iowed fr,ant f'ark bonem Allerrl bolts. R-e,arshock absorber mOL:Jnting nuts. Tie-rod nuts

Rocker ,arm pivot shaft ntlt SWkilQ arm .p[eliOt sh;a1t nUlt

Ste.ering:

Stooringsf:em head b:oill Haridl'e b~r dli1l'n")p bah.s Handlle holder mountiing bolts

!frame:

Sides,talfld bracKet bolts

Electrical SY5iwm; Spark:p,lugs

Ahemator rotor ·bolt Altemator stator bolts Tl1!erm.OM:atic fan switch Water temperature sensor N e,utral :SW Rt!;:h

O~ ~ pre$sure Swj,tc;h SwitehlfMHlsing Clam ps.c!r~s n.ililught ~~nse screws Tai~4igh1t mounil:1'ng nuts

FrQnt turn sli!Jna~ U.ght i'nbuh1i~rlg! nUlt$ Sp-eedonH~1;er moumir:lQ scr,eYVs

Tprque
N,~rn kg-m ft·lb
18 1 .8 1'3: . .0
8.8 0.90 78. tn·to
2l 2·.3 1!6.5
25 2.5 1'8.0.
·5.9 '0.610 52 ln-lh
8.8 0.90 78 in-lb
;2'3 2.3 1.6.5
·15 0.1'5 13 iin·lb
. ,
5.9 '0.60 ,5:2 i":n"lb
7.,,8 O.BO 6:9 in·lb
2:0 2,0 14.5
29, 3;0 22
2.0 2.0 14.$
44 4.5 33.
44, 4.5 33,
44 4.:5 33'
8S 9.0 t'}.51
47 4.8 3~
23: 2.3 16"[S
2:3 2'.3 '16.,5
441 4.5 33
13 1.3 1 ~3 111-lb
69 1 . .0 51
12 1.2 1 04 iri·lb;
7.8 0.80 69 in"11J
1.8 0,80 69 in-Ib
'1:5 US 1 i.o
15, [5 1 1i.0
.3.4 0,36 30 in-lib
1 .0 0,' 0 9 in-lib
5.9' 0.60 52 jrl-~b
5.9 0.60 52 il1l"tb 8rG

55·

55

L

L

L.

1·14 GENERAL fNFOIRMATlO'N

The table below, relating ·ticghtening torque to thread diameter, Usi:s the basic torque for the bolts and nlllts:. Use this table fer only the bolts' and Pl4Lts which do not require a specifLc torque value, All ·of the values are for use wilth dry oolvent·cleaoed tfclre<ads"

Bas~c TorquatoI' General Fasteners

Torque Thr!!ad!!l di(l.

{mm] N-m kg·m fit-Io

Ir----------------r--------------,~----~--------_+--~---

5 S..4 - 4.9 0.3.5 ~ 0.50 30 - 43 irHb

6 0.9'-7.8 O.60-Q.aO 52-69in·[b

Be ~14 - 19 1.4 ~ 1.9 10.0 -13.5

'10 25 --34 2.6 - 3.,5 19.0 - 25

12 44 - 6·1 4,.5 ~ 6.2 33 - 45

14 i3 - 98 7.4- 10.0 54:-72

16 115 - 155 n .5, - 16.0 83 - 115-

1'S 16,5 - 225 17.0 - '23.0 l'25 - 1165

20 225 - 32,5 23 - 3,3 165 -. 240

(lENERAl INFORMATION t·15;

.I .. !! ~!!!!! ! ... "! ~ "! "".'! II II ~ III!'!, II II II II II II II, ... ' II II II II II II II II II II II II II 'I"r. ~,.!",; '.!!" II II II II,. "!" .... "" II ..

The ij.(:ihed~led main1·erjatic.e mustbedorteln accordance with ~his' chart to. keep the motortYL:lltdn good n.mnir1g condJ]tijPfi, The: lniitial maintenance is viitalllly important: a'lid must not b@ nelitElct~d.

FREQUENCY

OPERATION

Ca rbu ret()"rsynch re ~ rz·ait io n -c l'U,'C;k t

. _ .. • • .. • • {2-8}
• .. • .. • • • nn)
Ii • • • 2-4
• • • ,. I • iii I ~i5-201
• • • • 4"7
iii (2"~6t ,
'. • i.
S·cleaning!; I. !2~ 16)
II .. , . • j2~91
.. • . ' .. '" • ' . 2·6
month .. • .. ' • I .. ' . ' . 06--Ql
I • • .. e' • • • {U;·35)
• .. I • • .. • 1 1..5,
mont~, .. • .' I • ., '" • (11"1 1)
,2 years • 1=11-H~
• .. • " • ~ .. "5~41
.. ' . • • • .. .: {l3·4J
.. • • • • • 00"5)
. ' I • • • 16-.2
.. I • • • .. .. 9·3
year .. .. • e (6,·61
• :. I • • (16·61
:
• • • • • • t16~71
'. 12·3
'. • • 11i2-10J
012'-' 11
2 years .. (3-5).
year • • • .' (3-111
I 2 yealrs ., (1'3-l:))
2 'v~arsl 0 l·S)
2 y,ear,s' (11"6)
.4 years (11·l4)
4.year:s:
Every 300 km fUl-6)
Every' 800 Jkm n(4) Air cleaner e Lemen;'!:· -clea n t

Fuei sy,st'eh1··cneck t

EvaporativlE! e!l1'l;i:~~on control system @ -ehsck' t

88ftteryelec'!:rolyte·level··clcieck t

Brak.e"· light switch ".c: hed!::. +

8rake; fluid l~vi3I··c~eclk t

Ciutch··adjusi!:

Nuts, Dolts,and fa!~hmers: tightnesIH::-hfX:k t

Tiire weaf-·chaok. t

Oi I fi Iter -replaee

:G e nera I lu b rical:ion--pe'rform

Front forlk o~I-'t~ange

'Swingarm pivot, l!Ji'li·,trak

lil1ikage-l~bdcate .

Ril~:Hator ho~es, conhec:tipns -cheek t

M!;!ster cylindtar .cw:pa~d.dl.l~t sea I· -reptace

Cal~pef P~St{JI1L seel.and d~s!l: seal·-.repl·ace.

FUElI hose--replaee

D r~vec.n:a i n-lu brieata

~ ; For high.er odometer readi:ngs, Ire:pe~! at ihefre-qt;lency il11terval es;tablished t1~ra ..

t, : Re-phloe, add, ,adJust, de.al1,or·'!:o rqll·El if~!3Ce:ssarY ~ .

'if:§) : Califon:';i.! vahide' only

('X>l;,xxj: ft!3terer.ce ,Page io the. Base Manual

FUEL SYSTEM. 2·1'

Fuel Sy,stem

E)jiPl~ded View, . , , . _ , , , .. " , - - .. - , , . , . $!rl~t:~fidation!. . . . :,' ., . . . . . ., , , -, , " . Speci; a 1 lIools " . . , , , • ,. ' . , . ., . , . , , . , . Thr~tlE! Grtp snd Ca.b~e$. , .. , . __ ... , .. , ,

ThrQule Gr~'F,PI~iV In~peclion . , . , , . , . Throttl e Gablll Ad~u!'>tmeni"., . . , , , . •• Throttle C;a,ble LlIbfieatkm . .. ... -, . .. • , Threttle.Csble ~n~-pemklh ... ) .' , , •. , ,

Cho:ke C,abl~, .. , • , , , , • . , . . . , ' . . , , - _ , , Chok:eC'lbl~ Frll~'PI~y' fnw~ct'Ton. , .. , ,

CMike Gab~E! ILupri,c(ltkHl • , .,. , . , • , , . O.hokt;: Cab1e,lnspec~ioJf"l . " , . , _.,- - , .•

Carlbl!Jr#tprs , " . .. . . , " . • , • ~ •. , . • ., , . . , . .

ldle Speed I i"I~peftiotl, ; .. ; ; ... _ •.. , .. h::U~,Sr..i~d Acnustl'lnent: , • . ,

Hign AI:htw;1e P~rfQrnfHI!'I,te

Ad1umnent ,jUS,ruodel) •. , , _ .•...

G~,rlbu retor S1i!:f1ch ron ~ Zl!It!Orl

lnspeetlen • . '. ' " . ., , • . ,- " .. ,. .. _ Cai61:.>1~I~tQr &yt1l~ht';:lf]izatiorl , , , .• " , . , F~~I L~vel inspection .. , , .. , , ., ; . _ . FLlI~1 ~e\fel Adj_ustmernt. , .. ,. _ ••• , , •... f; \,Iffl Sy~te'rn ,CI,e,a-nri i n~~' Ill'Isp"i~ti.l;iri. ,_ - . Carburetor Assembly Removal. , .. , .. _ , C~~hurl!'itC;r AS$~ m~i 'I I nstallarlon

Nm€$ , • , " ,. . .. - , .,.. - __, . . , ' , ' ,

C,wbjJ~tor,&epel~(lJHm . , .. , " , , , , ' , • Carb.ur€'tor!.[!SlilHabQrl, .... , , , Carouretor Disas$~wnbly and

A~'~ernl:)ly Notes . . . " . • . . .. " , . " • Carburetor Cleaning .... ' .. _ , " - . ;, .. , , CoIrb,u,rffWr'l ns,peqtion , . . " . . , • • ' ••

Air GI·Eliilfler. , , ... , •• ', - , " , .. , ' , .. ; , ..

Air Cleilnef E.lement: Ra-rnoll.ai , , . , ' ..

Ai r 'Cl()"nllr E lemenlt I ~§ta I ~a.t'iort. "', .. , . _ Air CI.earier E lsmant CI~!lir\ilng • . , . • • • • AirC~eaner Ele!m~rlt Insp~Cl,jon

and IFI~pl~oemenl:, , " , .. , , ..• , ., _

24

z·!:) ;2·5 2·5

..

trYel Tank " .. , .... , .••• ' , •..... co ,

tf'J_I~'1 Tanl;:: Fhlmo,\te.l, .. 0 " ••• ' , ,

Fuel Tank 11.IlS,t~il~~ijjln NQle~ , ., , . ,

ruell T'i!n'k; am;lTap CI,e,miOQ .,' , . "

F .uell1ra'P Ins p!;lc,tion.. , , .,' • • • • • ' . • .

Fuel Tank sind cap lo,peet.lon •• ' , 1 f- • ,

E'faporOiti 'I!~ E m l~$lon C(J:n~rQI Sy\;t:e;1'n

(USealif()m~<I \I~hld'e Onl\,,~' ....• ' .. , : .

Par:u, RemO'ililJ/h1S'lal I aliot!, NO~$, ••••• Hose II nspactlon , '; . , . . . . , . . " • • _, ~efJar,a!t'or tIns p.l!ctio![l , • _ , • • a • , • • • • " ,'S~pO'il'ator Qperation n,s;t" ...••.•. , , C\'lrJ i ste r I nspectkrn , . . ., . . . , , .. . . , , Fu~,l Till1k, a'~d Gap l~n,s~Il$:U9n

Is!!€! Fuel Tan~ seetlon]. . . , , . . • ; • ,

2·6 2.£ Hi

II

..

"

.' : :Base Manual

".

II·

;M,.

..

-ij-.

'.

~~~~~:~~~:~:::~ :::: ::: :::::: :::::::::::: ::: :::::: :::::

· '·S. "'-E!M .2.R

FUEL . 'Tal'" '.

' ... J~.'~::f.t:i$.:. ~_'.; .. '.'.r.~"';;oi'i iii.,i .""',,",iliri" i.~"~'ilili iii .~' ••••• J •• ,,,!,,II •••• ,. -'l:'.'.' •• ! ~

'SPeciflcefians.

II! i i l!~ i i ~,i iii ilrt~~~''''.'.,.~. ~'!' • .!J~"'~-:;' !.or.! !'~! .!I'~, •• II.:~.! I'."!!""!'.'!!! ~ ~ ~ !'''!'.";.~'!.!.! '!C .. ! !'!! !'I "" .. ..-:~;II'.

Jtlle)$p.ec=d· Sij:~~.~f

'1a'OQ ;fl00 r/triiP hpml;

- ~jl~i:h:,u:liiig,.6.'~ifbrni~··lirindell

. -:: :? - ~ - .• ~.... .". ~, -_. . ...

.car~tir~J:SpecifiMti:Q~s '

Make, .type: 'Kj:lirb:in, c\i!<:SO

r&i"':~!ltl' #100'.

MlI,in'sitJ:'l!t:r· #-100} ® 'fl8'r:i

Nile.dl:8:I~t.; .~. ,

-~IJ!AA!jj~~ ~jk:' Wl6.1

P.iI~ f~t'J~IQ~J~i.: ~8;

'~I.C#l'if ~p MQW jlir Aiitr~ ~

Pi;I9;.'t ~et~·UQ.6'1~ Q!.!d:. . 2, . i;W' (Q) .:::,

'S·~il·(~:.f~·· . . .i#§2~ -,.

:S~~il;eJli!ei' J~,e!-

!~.iqirJ~~l)'Ut~~r t:k!dY/tlcttt9'1ii':ildg~)~.

'0.$ .nn'l ,b¢Q'(!f~ '; ;5mrn ab'6ve.

'flOat ~hi~i·ght·~ ",7 ;1;1' ;t;,:Z.r:fl1'l1t

HighAltiwd~·bar.bu~mH.~pecifi~tjClnS i'@@ )

~i~ tat: ,~~2.: -

J_Pli(oV~~;#3S

,QP!tJ~~;J\'P.atif Ma'irqel, Piilort~J'"

#100:,.'102, ;o~, fut '~@'#3~"

•• ~ .• ' •••• ' •••• "' ••• ·.;~·I ••• Q."t •• ~ ••• ,""~ ••• ~" ~ ••• '!' ~ •••• to •• """.!'. ~ .""'~ .,~ ~ .c~ ... ' .. ~~ .,!I .... ~~ ••••• 'tI'.

'Sp,eoiaii 'foois-

. , .

• !!;o!l~!~~ !!. ' •••• ; •• ! •••••• "". ~ •••••••••• ~ ••• ,~ •••••••• ·.r ~ ioii ~ ~.~":t !t",

A?P~~~jth ~,oomrhon:h,at1d 't.'O,ob" ih'e fO:)l~~rn~"more. ~p'e.¢~a,~! zed] ';t6c;)'h ~I\e" r;eqUlfecl i!f;1~,ic_Qmp.I~-'ftl!lI·.~·yst!lm;

!'>erl';I,t:it'llSj' '. .' ..

'~~:"' ...

. ". _.

.~ .. ~ I ".'

.'''IIlI~'., •••• ..,~ .. "' ••••• l. ;illlfil ~ •• ~. ~, •• iI;.\iI •• ~"'to ••• ill., ~ •••••••• j •••• J •• L •••••••••• ,., •••

Throttle Grip and(Cllble

rntqttf~. ($r:ip Play l(Js:pe'ctiClfJ

.ch.e"C}t ~h{p.JiI~~ gd~ - i~~(;( .'~Jay'by IFgl')it!v '>t4rmlri-g ··f;he. ij'l'r~;tnci -g,ri'p b:ack4nq (Qtt,~"

'iI11rotil:le. G.ri pf.r,e-e. 'Play·

2 ""'3 mm

'*:l1' the thif.;:ittJe·'. grht :f~ee ;p~'ay; 15 i:I;l,t:'iir-re'f~~;;l:~JLl&t',tbe'

f:h~O;tjje c:ah~~s;:" "., - . " r:

< '.

•••• , •• ii ii ii ~ .. ~ •• ' ••••• ' •••••• "'I ••• ~ ~ ""' ' '., ~ ••• 1 ',. ii. ii. ~ I,. ii ••••• <1, ••••• IIj

Air Cleaner

... !.jo .. ii ii ii .,ii ii "",i ii •• ~,~'iIj ••••• ~' I •••• ~ ,., .,., •••••• L ••••• , •• 11 •••• ii Ii,.,. ii i i. ~·ili1li I •••• Ii

Ajr' Cleaner Ele.men t Remf} Ital .ft~m(l"'~ the followin.g parts, 'Seat bee fr.ame "t1apl:er}

r-t~e~ T;ml;; Brllc:ket Bulb

• Mo:v:e ~hl~ ltan k 'b racket forwan;j 10 Pt! II the r U I:J ber c~,~d out ',II th~ ~I~anqr h·~ll'sil1g.

A .. Tank Bracket

B. Ti<l.tik iE!rack.et Boits

C. Rubber B'a'l1Id

-Removc.tihi.d.ir cleaner llof.lsirlg. Cil~).

-Pull UIt; element b:Q!dcr·Qut of- place,

-1\111 out tM alr de~iier element, .

A. Element

B. Element Holder

.PI:J~IJ· a clean, lint-free to.w.::~ i!'lt.Q the air cleaner l'lousir.Jg to keep dirt or other foreign material from en1!::r.~Il·g,

Nfdlrt Dr dus:t is '1IlllQwiid tI:} P!lSS thri;lygh kiW ttl;;) carburetors, tbll thloUl\l \lal ... ~ may ~me stiu:k, ponibly cau$in!lan "aecident.

~'l,J EL svsr EM 2-5

GJlf d ir'ig.iu tihrg ugh ~"to the ongi l'Ie .e"'te'i,~~e: ~!nD!ne

1II!",e.ar ,aind ~j~i.My '~"'gitle d~magl! w~1I (I~mH. .

Air CJe<lfu:r ~/ement IQstifJlfifJtf,rJr_J

o EI elTljlirl t il1l,sti'il;l:tior'l ~. til):: revers¢. of r~mo\l'al, Now tift o· to 1.lowin.g,

•. B.e5I:m~ to fill thtLelernenl h:Cild~I' in the. gr90Ve at the boltgm of the t;:as~.

A. Holder

B. Elernent

e Set tho' h Qu&in[!t· cap wWh the arfilJW mar k fach1~ for'·

W<l'r('L' .... .

elnstall thefuel tank. (see Fuel, TJ:!lkinSblllacl~Orl),

Throttle"Cable ·Adjustmen t

J~,e;l'er to, theBase ~nual onuti'l'IgthetolloWfng.

-After adrU\i~1 og the upper e,n:,j of 'Ut~ accelerat .. kCil:b.!e,. nghlefl~(jc ~(lck!~·lIItaMPrlst· the adj~.*lr.

A. Lo.".k.1)~ t . a. AdjusWr

T.h!,l}.tile,¢abf~.L/Jtrti(J~tion~

. Wnen.eve.t: ~he U~ro~itl:~::,~ab!f. ~s. ·jf(·mo~r:d, .• Hid ~,. jl+~9~d,ilncf ,Wi th, ·'Hi e l'~ri'of:H$ ,.",1';J.' n tI!'~4!trice ~.~af,t (~kt Gqt:iAral 'hrf1jt-fn,Jt~Q;t;I, ~rh~p'1e:rl. perforrrflhe A'6IfowTilS_

.ApplY ~,thjni,,·:o()~;iTn:-g.· Or\gr6an~ ~oNie thfottl.e e.~b~e .L<3w(ir .ch·~ ..

Tlir.oUle ·iC.~blle . Lu bricafi:(ll'l

-.: ...

rfwo-tt/.:¢ ·fJ~bje b?Sf)fJf;:tfan

"Y(t.Jb· :i\1e! F~r!)t:tM< ~.~\}~Rd~ %?~yf@'ct~d': ~r . ~oth ,e:til.~~,~ f~,e.·. ·;;ab·l~ ~h9Y I,d . tn.Ql'~· fre~~ Y' Wftfi I r' U'le cC<lib.b3. ftd,I[l'~1 f\'(~"

!'!'~"!,.!! .... ,~ ......• , ••• _"!'. ~'.,oi. ..... :-:- ••• :" '"' .•••• iliin. ii ii .... io ~ ~ i.ll 1·1 ~ ...... ' ........ ,. ~ •• ,,., ••••• , •••••• ,w ••

'Choke C1Jble.,PtefYPlay 'n~per:;litm

«=h ~~X· Jh.il£ thf' 6b;~!k~ l-ever' r~"~Llt't1J~PJr<ope;rF'lf. jrid th~t:

.00dn'llef c:atlte~ ~I..idei $IT) 00 !.Ii IY,' . .

:.'H:: ,~thM·() )s~m 'if . 'rr'r.egulari iy, . :ch ~>lk' th~ dh ok!] :C:iJ.bll;: as

:f8iJlo~~i' . . . " .

• beti\~rnil\ie.. '~h~ ~;m(JWit 'Qr' chni<:t ,;.ahle: play. :'it! the:.· ·:6hQke ·il'MW,PI;.I~J the".clij)ke l€wr. uwdl l.h~) ·imriel·· :p.t~ t:1:g~rl ~Y(:r. .at:tk~,,,afbvrelp. F ~!\l~:fC~;t~,~'~ U~ hj;~.5~t£ ( plprtger; ~t1~ amol,fl'l;rQfic:,ho;:..ke I~N¢r ;trili~~1 :~~ the J,ij'1011Itlr. 'of It!'l.ok e t)il51e.· pf~~\1

*If 'fr~eRI3y i~ I'tOit '(j~rreq, .adj,lBr_ ~~e-:··~hok~ o:a;blre,

I .... ".:;-. _. ,

Pfi,Q,~iI.:Ca\)j!!I. 'F~ "1'<IlI)' 2.~<3Im)in

()b}Jke(;t#f)Ie."Arij{JgtmrN):r

"L;tlQg~~ . the I Ot1kn'ljt ,at th:e<adjiil.~~l'!g .~ut ;(;jf ~e ,'{;holilce.

I'jI.tir.~/~l']d < tLidi '\ht: ~'d':llS t.ii:W'h u,j.J,ur.J,i;rI" th·.; ·(",<I!bie·t1:as the pr.QP;er'iJ.m,6y,~t.:of r¥~Y"

(:.tu;ike'{);if/fe' Lu:i)rit;;a'.\iiJl'/.

W1U~'l1evet' "¢hf.·· ti~,~kt bl;lli:;'" r~i'rlOV"j)'d., l!'lib rh;;a~l} trtee ,::e:i~ol!;~ "a~;re '~s:f,oQI o·w~~·

.LI,I ~r kate :tlii~,~.bt6 .w?:i!t.a. ,R~{IletraHr:rg rl.;!$.t:inhi bftor ,

Ch,6KQ Cable' )n.~;;:jer:tl(jij:

·.Wi!h·th.l'l'.c·heke, 'pb!e q;r·sc;';ml"ll;.t;i{:}f.:.a~ 'tb(ebo:th '~Fd~i th e, tabl e" shqUl~ mOli'e fr¢'i.I'Y' w~tn:i:n '·r.~eJOahle b',ouqifi!g,.

eh:QlSe '¢:able Insp&:Ct!Pii'

'I. ChQk~H:::~IjJe

'+f (:;8:b:l:e ·~q\'e.~'~n"~: is,,f'io! 'fr~e a(re,r. 'lu~F~~fI,ltirl"~)see Cmoke. table Urtmroa.ti,@nr, if the c::abje'ls. fr-·'FI"~d, or. ifthli;'ho"llSJitd·g. i:$'~ iii i1eJJ,. r~'p'lj'c~ed. ~h:El-"()ilb\I~;

"',;,. iii. iJ i 1i'!"_1ii i i .,ii,., •• ,., •• iI •• , •• i i ,. iii iilriiill i.i i ~~. i .~lil"" iI Wi ••• 1, .. '"111.1 1,,,Ij ••• i;!I'L!

Idls;S~cf h)S'P8..c;ii'en

" .S~'(:fh~ eJliine 4~d,'w1.fW··jt up: th'nrfuPfllJy" ,

.~f)i· the -e;n@ii'if( i:clHrJ!Kt ~u:m 'the il1t.n,flJ ~b.,r t.? bp,ttl ··.~Td9·!;;

'!Iri~' 'd:4Qdl~ba.r!rkClV~i;11:~:M d)lln;gccS !D,e id,k ~p~.f.(j'; t~~ ttl [<1tl~e- ,~ilble m i3:)! ~~'J~p!rOPQd}! al:lj!.J~Jf'd'. 9.'r~·lo~or"rr(",·t.- : 11' rou hR~, . or, i ~tA.ay Vbe da!p~~~; . B6 .~~ rot t6 'c,ouret:tl al~y·.;.i: the~~,~orn ~Hi o'n,f~"O:re rt~ it'l\*,

c6t!lrl'llipn.:wl~ 1!m,p!o!pE!i!1 'f l!dJuS;~, i!IiI'S1>Fr,~ct)y rQotl:l~:i or ae dilmailill.i··Qahllf ,cQUIi:!.I!e~jJith"I!t'l\'tili'i·saf21'idil1g ".ct"!

iI:It!I~. -

';;:h~ik, J.dre~~e'~d,

~ff£H:i· i.jIIJ<~P:~~cI 'f~" 6l!tt -r i)fJh~;'~p'"~~lfI.&:d ·!~n;ge,.~jlt~t rf.~

Idle .Spl!ed:·

f'3QQ;!:100,,""I1l\irl, (rpm' ~1Ji'Q(i! f1~' rbuifl . (rpfii,j

lf418-S~dAdil1$lmf?tt~

.Tlfm ,.'thil'·a:~j",i·I~n..g screw lH:lt.il idl;e "~pe'~,4 h':OI'!r~.,,!,

i!!Dp.en· <1l1d d08e·'thw·tih:ro-rtiea,1i'ew ti'm('l"~,tQ m.a.ke sure ~h'1ttt .thee "idltl 5peed"1~·~lt:~:~n ·'i~:e:$pe.cfji_ie.(rr.al!lge. ·1Rie. adj LJ it)f: Mcew"ry',.

C$rfjur~ tt!J.(Syrr.chrbnfz:ation. In$peetion

.Warm.~ ihe 'engi IUL . .

-Ch~·k .. i~M,..,·s:oeed and iHHust i::f nm::..,"~""

-1mn 1.heftleJ~irPR~ .. r:-.Qs!Jkm,_

OGjilsoliilie ii' e*jirl!l'ij'iely ftamim'atllealnd Gimb~: e.)(l1liQ~fvQ 1,I.l'Ider !:~rtllirn ·(:(in.ditiO!\s,. TIH~ -tiII~e igl)Jitiofllwwt!;t:I. e F F" DQ "In:$mGke'~ ,Malt.i:· ,~(Jro' ctt,!& :a~ i'~ We'll. l'l!nti lated ;:1illd free:trom "flV: $.tnir~' of ~18!iT1~ 'Qr spark;: thi~'incltudeJ-lIl!ly a ppLi'anoe wHliI ii, J;li.IOlt I illhf •

• ~u~l i,hi) V<lcuu,tri hQ'3es ~~,t of the Y,~JCi.JLJrn h~$~_tj.h,!ng~.

,at 1tlJIli f~~J Bpi an ,\1 ~he C'JorbUir.~tQ.i fnJer ei(lrielhiElo[, '

.• ,0 tj~(elf v1:C,Ul.Hl1I .gi!ugt: $et'( specl a I' l.Ooi-:s:j"()O i.i j 98)' to

:Lh:~ Y~C~lllm ho~a~, .

.SWr"f'Jh;e '''(It'Jg~rne '~nd i.~Ii;nQ riilt!a~ur.e, the'"'engine liit1l.kp,

_"'<!cl,l:[]irn;" v • • .' ~ .

:>\} t,the. 'jn take 'VaCL;lIWITl diff'e,rerI(Je'b~t'Wecn ~t1,y tWo cv:lln};l7ne"'f,~ed~ .the limj"tts}(1)'l~hrClt'iile the (l<l!rtiuret?r !fllJwtfl'y :va I ~es ($(l(l; . Bijtte(:fl'y Valve SynGhn:m l~lrtmJ,

El1IgiiteN~if!.li~ :&..Yiittff9i¥it;.~ifiQij.

~e~it.h~o 2,,1 .~~J2Jii .jri'bI~~r~' i:tiff~r~liipe,l'ie1We~n b~~'9.Y.~iri#e~ ,

,.:Remm .. e the> V'ii.(l(iL;lt'fl ga'lj:ge, t>oFll1eq thli! vtleu~'ro '~?~s:

to th~ vatUum Ili'o~efit(ill~., .

C"arburetor SVl1drl.pnlz8tfo~

. '~V"

.1:l~rn ·the. adjU'slting~or~w tQ ,WII'i¢-hf"oniz0 Ih~

ijtit,te:ri] Y vilJ\";es;; ,

I WARN!NG •

q~II!iQti 111$' !~ (I:!I!:ttemeIV.flalmmabIQ . .;mt!1 can lie 'W!:.I~Jo~Hr.e .. u,oder ~t!lin :cOnaIiJi:Q('Is·. T~~, ·'thll +gnltliOnsw'hth o FIF. [Yo no:!: smoke.. . Make,~~'~· ''IIll~'!lf~ it' \111;111 \ie~~!lla,ted and fFIUrfr,OIn' any .sou,rce of :fIla'me .er ~pa:fk.s; this i ncl udes anY!lIPPliliince wiilili, ilpifQil·.light~ " .

'~Pr~pare;·.a r'ubbe:r hose (t:i~mm in diameter <);h.d<lholilt3'OQ:

mridongj, , '

-CO[lrl!')ct fue:! l:e~~ll MU~ ($pe.~iili r~Q.lY tQ the.

U.r~tJfrelo(ffmn bOW] wlith Jh¢.fuel hose,

.~ol,dth~,._g1!:.uge.· ¥@r>tic;allya&ai~!st tHy side: .. Gil' the ¢<lit· O,l:J ~~tQr ~Q,dy:.go thatrh~ !"ze ro,' 'I.j ~e. i~. ~eyer~J mt~J i,~ nyeter,5>f1Im{!r :than ·the·bo ~tqm ~4~!~ Qf th:e C;l!rbl,lr~'nGr

body,' . -,

Ui,ml thefy~1 ta~·.;to the I'll: IpO!l'.i:ti:oI'I>·~:O teed fu!:\1 to i:h,~ ,c4fbureoor r' d1ej;J turn out .th e. c.a~b·u retor dra,jo pi ~g ,rfre\!(; tu rns, . .

'_'i;!{ai r 'li;!fiIIii~!h ~ fUll! I ~oq~1 ;in" ·tjrn~ gaugt! settles,

.I:\:ee:.p}~g the"g4ilg~ ¥~Mc;iI •. ~! ov,:-Iy i:qwe,j:- ih e ,ga!l,ge )JnJi r bbe "'~(:!r-o" T\ltie:.i~.'~'i!e_1t1I w.ith the'Qqtrortr ~di~ :of th~ carbu ret~'1r bo~:y~

NOTE

'o!')p mjr j(Jo/e'f·:flJe·· .. ziffo" Nne/;J?k.lw'tfieJiqttom .' ¢t ,th_e' Gi!tb.ute:ror'I:.ro.W, ff !f)f! 1fou{jiJ_ i$ 'lgWf;lf'9d and tM(i raised ,s;pJiJ, ,th~, ruM l~ ~U;Q~ sho~ sirhewh~t higher {hOlf/: " the' ,act_aai . fr;Jt!J/ le;mi. " lithJ "_~;p;~ ;; If)WlJrOO 100 f81', dl)mp ·'(lI8 1i:1e! out ol'lt iht~\Wit;We

~on't<i'iI'U'r and s:ci1rr the {N'OCet/Uf(NJver:i!rp¥it.. ' ,

._ Rea~ the f(j.cIi k""cJ l'n~ th(!> .Hi.l,Ig£; 'andc(1~nl'andt to the 9pec1fic::a:tMrLScrcw'in thc{'carhuretor drain. plug •

• 'TWflil: fhe 'fu.el i:Jp i:o,!h~·oN po.sili'on ;md rf!:movl:,the fui?1 le)1~II'_g<lu f!,'iL '

:.LtJ8'pe¢t. !he' 'fulf~1 ~.eveJ . .tn ~h (I .oth Dr(,.;irb:uretor~ In the :~~mim.?LnnH"

·',i,-lf th~. fuel lie:V:ell ls inct)rr!X:t,'a:dJu~l-i~ .(,5:<::6 F(J~: :L,~v:e:l AdJu~_tmitn--t,), ..

'1. Fuel Lwei'Gar;lW: 57QtleHO; 7

Z, FUiel Lwei '

fJU91 1I,I',el,

OS, ±1 mm, I!~o.v-e. 1h~ ,bono"", ,[ld.~i! 9f 6e.thuretiJt 'body

Pl,Jei,- U!~el A djuMtniU!t

.~~adnh~ WARN'liNG jrrthe Foe I Leier rn"p-€cu~h?nl-. '[:)r:t1.n~hefue:1 rilit Q1f the :C,arbure;lQrs i:nt.(dl.'~Uf!a!ble

.: . . . . ~ .' .

coetalner .

·.,R:emoye ·the,fioaJ. bowl by talkil'lg out .the screws

W~~Iii. I oc kwa~hen, ' .

.SUd~·Out t'I~e pivOT. pin ,al'ld r.ernoye/thJillrnoat. .Benrclche tang qr]J Jhc flo,<Jit ann' \I~ry '~Ii~liilly' tD 6hal:lge 'the .tloJ~heig~lt: hrcrea:i.irrg th:~ 'f[Qi[~ f¥:ight loW?.r~' t'he. ri:JliJ ~ll.v€1 and:.;!!lOlcrc,!!lliHng tire 1il!:>a,fht:.igtd ra~se~irh;e.' f~~~ tev.eL

.A~i;~,r;'ri b~e.~fic, ;car:bl~ retor: ,fi:@ t¢¢tieqN, tf\1 e.fuel, ~c\,CjI, litll th e . triliel: !evc I j;'Hlri~;rLbe ~d~fls.t.e~' by th uS')n~lh:_[](cI,

J'he of! 6;ii dr 't.H eildoat l;iaJ\!c· i~:dfl:_magC:d. .

.;.- • •• : ',' _. ,l'o

1, 1"10;';"1 bowlnWltktlg s!wffaQ!o.· ::t Fl'o;it ·\fal".~ Aeedi.~ rod

-3 '. F 1!.<)3j:

'4,. f!iQ'~l: H~igh,t

OGaKilipei;9; e.Ktremetv 'fllamm.ai6111 and· nan b.e expl~s>;j .... 1I. ~..ndli:r Ci'!tti!IIi1"co~iiiitiQn~., 'TU:r~, Ule igtiMa~ i!ivWolil:b'FF. ,:~ 'l)Iot '511(10~~. M~~iEi'c~!I.lrIi'c1l!ji·~i~'li)'ii5 ~ell'~e~:~ia~~~a'~:d':~~\li~gJ!li ~nv :~l!I,rge:otf,flf(nte\o:r :$P~rls'~ ~~i~ i~~~u·t;!~,,·;a-:",¥ .iiJl"R!l:anQe: wl~h :a:""pifo) li'ght~

· •. C~)"tln;eet 4 sul u!lle h(},s(l·h:) thie' :f'it;tcllg',at'th edJottom oRe~o;;.h'<l';jirbur.ernr flmrt bow'r:

.Ri:~I'I, the-lowerendset theboses lnt1lo a suhable con-

1- ·taj'!'J·e>r.,

.ati,G~k t!) .$e~ i f'~v<"ler 0 (d!i'n' (COn-Wi 'OU~;

.Pfi'gh·~n ~~§e cll'atJ:r·.p:lug/~r'rd turn tlhe·:ftj,-elljp to ON' p'OSr'~idn ,

+11" 'iH)y 'WaWI·.Qf dirt )J1pearcLl:dj.l.r~':iK"jjlil~ah?v~imp~.c.· Hon, d~,a't1 tilt fti'eI'~Y~I~rn (ser; Caibmetor C~.ealriTl1g

~nd Flier n,~k'~I1-J Tnp CjQq:~ing), ' ,

~rb,{Jhtrof':A$sert')jj,/v ('iemo'rlal .JR~mC)vei~,~ fpfJ6WI~g p;'!m~ !P.as~'t:I ger ah d· RTd.'¢t!;s "S([l:a~~

l.eft ,atld BI_gIlI' iK . .~

Left and R,i-gh,t,S RUbb(f!<Birld 'a~(j ··~:!.lJ.U~ll\I'Y

Aj r € I eOii'1ief f-i'(;us~ ifi glYhi~ n1lttl1K Bol,t~ Re;lf fen d'e(.R1 oy.ri,dnlg B'olt~ .

Rear Fender FrontS~ct~OI) MOUITl:iltli g:Bioits,

.R,earEi"mke. Rhser\!o.ir '

(Roe m,ovl}.·th ~ tl'I.Q,lH1t:H:1gho!1 .<H1Jil· p'iitll lh~reSief'!{:)ir -eut of pi a v.:: .. }

C-obIO:rJdt~servoj(tank:

.$,1 i:~~' ifuc SP(I~g" oafi"ds' ,off the: a'ifcleanef 'dw~fu" ;.ru iii \l:l'~ air clfitMJ h:6us~n g.nl"arw<!I't'L

~~J p the' c~rbo r:et'6rS,ClJ,;I t,

eSlip Jh& tip:. of" vhe[ chokeinner .. "hie t)~'f M~VI1l" I.eve;r,> ijlirii ~u)~ l.mi;);;~91.ieut..

A. C~Qk(fJnn~'1' C,:"'DI~

B. €hQKe; .Lever·

.$I.~ p. ~ tb{, i.lps of. the, 'rh rQ;tt.l,e hUI\!F cabies. ou t of the ·~uJk~t6C.or:t'f~lle!ec,1.f!b.tU1!lWr as%em)b!yr.;irrfb~iJJ.

oGaw.~i 1110 is ,eX,1rori'i9lyfla.mmiil~1I ~ntl· Can be 'oICplosill11 under c8r~h'fl· CGAdld"OMs.. T,Ui!Ii"Io the lig"nitiCin s.w'itc.h Of,F.. 10,0 not $m!>k,e., Make ~liIrle.ilfle: .IIrD i~ wer:l. lIlenti·ratlid .and .frw_.boma:n.y :&Our'ce;Qf fi:amll or·sparl{.;

tbi~ !-fU:llu~!iI'~ ""Y aIilPJi,,",~ with, III pi~ot light, .

-After tern o'Ving: xh;ec,arb LJ reters, stli!1ff pieces ii)f ,fi'rrHree, clejrl,doth,>in:tcHth(nx'iJb~rel.O'r hoMeH and the intake d.ucts:to 'keep tho ,dirt out of !l~e e,nglhe an,d f]Jr de1lJner.,

PII((jilt ,QI' dm:qs ,alhtwQ!;f 'w PiI~~ t.hr'Qugh i'ntclthQ, ,ear:~,bu~etor:s.. tJli~' ihr-ottfjl m~y: ~c:~e 'swck, p!i)s:s.ibJy Callisirig,8_!'IIl,$li~I!,i1J:"

:G'I!f 'diil O!'!t9 ·ih~(I'Qh ,i!i1!tQ 1lIl~ Bir:t.!iJM., :f!:l{~~$i'l'~,'«~g-in~ w~:rJA:d ~PQs~ibJY'~~Jliii1ieAama~ wIll O!l:CU r"

Car/J.uretQr :;lJ.:M:embly, tnstflilarjon -NuJeS-

.Aft~r in~tamn'g V~e (':tltl:ll.lre~o~~, perform th~ fQiI9w~~g,

OCheck fu el,leaka:S!l from rh~ cwr:tlJ.:lfet(!i~s. " .

O·Adij Ll'.S ~ tPl~ 't9Ii6)f.'lng: iter)~.;1 f 'lJe.ce~{~~r·;

Id~e~p~ed '

0ar:Lrl'l rete,l' ~y n eM ronizati on

l'h r.o ttlecili:ilc '

Choke cable

CafhUfflf!Oi'$ep81ation ,

,.Re rTImrc, th~,',carbu retor a~S-emb:1 y .

.Remow I.h¢fP'liO'W1hS- parts t'oeiQrt' carbLW(iwr ~elPi~ ,.~th~p.

Cb Q k~'l.e\"¢ r:Spk'i n 1,1 ,and, (fa Qk'~ L'e'ver :C:%r;lf\.uf._~tr:'f ~ ~(~ I'\tl~g P!at,(i~.

.'" Chqke Lever, , 2",Cho.k,e LeVer Sprlnrg

j" ~QunJit1gPI.:LW [UP'P,(if) 4., Coas,(ftlR EjJrt~h,er'5Y$~m .$.. No. 11 tarb'ut:¢tQ:f'(LH)

6. 'No, :2 Carbllr>eil9r U~Jf)

7. ~dlt\ Adu;u5ting Sot,ew H,oldl~t ~, ,Mb.ut'f,t~ng':Plate (Lower) ,

..

Cat:b ttre 'tor if(stall/} ti'on

~Wner\ iiln"lIinrg ,ihl'! {;arbl,Jr~I.O'r" be ca .. ~f.ui illt ;rh,e, , f:o.fl.o~v~n' s :i tems,

c(;bw~,'(()' ~e(\~:(,h~{ the Ocrirlg~'.arc :in P~<!CE;.,

,A.)':Hi'ngs IlL ,~H1i nJj

.'flle ter\tcl' li~e.i:o(( dw ec.JirbureJ;or bonis must be. parq:H~!ib,t)ih.·hQr.i2:0I'll;±n'l' aJ):d vei'tf'paily" lf lhey .,,·re. ~o t, 19'6~!;!n t~'e~-rnou n ml~g Sfrei.V~· ~id . "<\1 i;Ein vlu~" ;r;;"r· ~~~r~t"(>!'l; Qr! a ftat surfa:~e.. .Rcetigh·~en th-e mOl,ll1lling\ scr'_ws •

• Aflcr .assem bH I1i ~ th e- choke mecha:n ism ~ -ehec k to ~c.e.' t~·<i\t. ti'll(l cheke i~'I'J~r, ~rli:les ti.gI1 t to lefJ smoo ~t).J 'r' w:i'tftouta~f1o[m:j~ 'frlJ tl'cm_

Gj;iuel mhituH: U..i:ibl:e:· :CPJJldlre~l;Ih if theSJfllftll.r does ~.o1:·m~: :prbpe!ly- i!~ 'in-:"f~Sl PQ~i.iji[)ln 'j;dtl'lr: 'dill! .·dlo:h!iI knob Itt ·retiJmed.

.Visuai I 'f" $.yltlch Nlirn.E~(flhe th:ronl e. Oiutiter'fly]' ~'aly'C.~. (:(:he·c..k . to>sM' \j]'at a_pl thmid~';.al~~> open 'lnd dow ~lfiO~(th~'y W~!Yo~1" b·illdi.~g·Wh~ PIJ[lljirrg thil fuller, ~Vi~l.!illl.Y check the. clearance MtWe.e n tn e tl1rici"ilh~ va I Ire .a~d (r1ii.~·Jrl.mrritpr hpre, in each ca(~Urerof:

A, 6p.!;lnte M~~SI~ng.scr"i':w 13:; (;1 eil;ntrJ[~e .

(M~h~re is .. a .diffelt:ncc i;Jctw\'!~wJ,\:anS' tW9 c.arb-\H:(.'.ttJr9" turn the !ialotnoe". MJlb [cj.n.g se r;c';'" G~1 tee oNai n l1he 5<1.(ilj5'

(:1 ~ir'~l1c<~. . .'.

GDliId nil Cill'bu retor ~i~II~!em.bly., b~' C"lIf!iifi.1l not ttl ij~~~ t'h~ liIiul'i..agm, iN;~~~t tI,; a ~J:I a fp eijge"W r'il~vli .~~'i~lj~bMagm, .

• l"p in~!:'I~1 ),he n;~m~ jeJjN.HV the Garbu.i'ej'Ot :boil}, up,si deodi(in.v n, and drop bhle n"'ed I e' Jet in ((:) pld~" to lhiit the·"~mia~ler'"d'anie·ter·en.t,] of t"ij,~ j~~"g~e~ijn tint:

A. F j;nJ!)g:Piipe:

B. Spdn"g"

C. V~tti.f1:g~

i!). CafJhlirol()' !Body

Ol[i~f<liJ th'~ thr;;*'e COnlloitl,lng pJatc~. arid ~wring .~~ si1p)'Itl,

A,Pi:d\e: !l" rl~11!

.Ne,edlli Jet:

Vacuum Pls.ton.

,ec<ttiliu.lly~ 'sera\", ~h' thG·ne.cdJe j~t holder]'lkb:le~d P'iiPe.),,.

I'~ 'wal seat agai hs~ the needle· 1M, pusihing; rhe{!!hdi of ,the'j'el lato ikn: carburetor-bore:

1 V~wu m P~stoll i~ Jet. Needlie

.c

3 •. "5pH ng Seat 4., 'Spring

• Re:rriQ'I"e the p'i lot ~"Cr~ W$:nrom .the carbu reters a$' follows,

oF6r~he' USrnodel, ~ern.o,ve the, ;:pil.ots.cmw prllg as, :foIM)w.s;

P~ifl¢:h'< .;d:roie (h th epllU:g 'll.l1d pry' i ut wi th ¥fl .1!o\i~. :o:r

"'other }5.ui:bbl[e· tM~. . .~

qlurn( if I' the! .p.IJ!&t s,c!,.;;.w·"'I::Id·lUit:frlt:lheyn1.lm~r()ftu'm\i, WJltJl uO:eat.. -f~iHY· .but ,npt~ti'ghtJlY; <lJ~~ thlei1 remoye the ·s{;re.;v. This' is: 'W. sd!h~ sc;t$w' io Us' "riginal.~o~it;f{jil

~h~rn:~~rnblf!i'iti~ '.' . . '. . ,

A. Pi,jot''sCre'W C. Heat13bwl

B.; PhJg'(UBmiJJide,1 cml!ll.

- . ._ ....

QTum in .,the' piLot,c.<rew'ftIJHy but nr?t ii:ghlH.y, ael'!:i then b.atktE ·.:iuUtht&ame- humber ,o:f:ttfir~g :(.\oOhISC dmi'ng ·cj!i;~~s~b'.fy.'· . . . "., ... ...

Qfor the US model; ~nstaH the pilot screw pl~g, 'a$ ,·fo·IIIZIW:

~ f1~ttJl a, ;new pll u~ in tbe pi I.ot screw hole, .31f1 d'lp [;ity ",. small <1r)l.o"lflt, of ;l! bondln!! 'Igellf to the circ:u,n;h. 'l'6!'~'ncrg.f.the pli:ig te 11'::( th~~liug:.

oon., nllt liD ~c~ . t~e: nMd,llI'jet b:oh:le~· or'· ovllrti~~teii1 It.

Tha 11i;~~11l :leta:r the- .carhtHetllr . body·cQI.lId be>

:d.mt.(ged· re,..~ i ri 1'19 rOl1pl'acemEIn.t. .

, .:<

.-Slbp ·th~jer ne;ed [b·ti!irovih ·th~h:QI~ in. the }~:eol.er·pf th~. . ~at';uYlitripis-wn', ;;t~d~ ~u\rb~,:wiish~f ana ~Pflt!l!'r.se~t.bn ~h~,t~~ p,(th~fne.ed;kt Tu.6:1·th1l:'S()tI,t so Jh.¥t.1Jt.~.oes.~~.q~ hld(l~ t.iflf. '~hplr .~t ·;t~e .betto~'::o f ,'.:he.I'o,c l!:Utn pj~ ten,

1, ApplY·a hondingagCt1it. 2"PlVg

3. :Iri~h~r.ew

4. Ca.rb~:retor body

1F'U~t SYSTEM· '~-5

o()Q. I~tlle 'OOr:l1lpl'&3li1d.aif on iili'll '$Hmbled e«rbUI"EI"tt.lr. t~1 ~oa'$ may be ()I'u~lied by th,!! pr,e,~p~Q, aJild title ~Cl.lilm ipiiwn di{ljphr"Qmsmav Iboa"dBJrnlQ!!d.

°A~molle i'lJ Manly *ulbtief or· pI'asti'i!: para· from thQ tilrtJU:fetM(I$ 'pQS$ible be:fo:rG "Cr~ihg the'carbl.lretorc witib a· cleani nil' .s"''''.don. lhis wliU' Pr.eve,'nlt :di!mage or deteriior8ifion of dice Plrts,

O'The' earbllr.-mr body hat PI_tile parts thai cannot be' IHlmo·ved. DO Not !iliA! , str~ng. aarin!l'(ltof~fli!!'liflig IDlut!on- willet! could atMCk t;h~ .pith"; i,,,Stead.. 0"' II rnJldih!gfI, fi'Mfl-point· oIeanil1D .i!oiu~ion . ~fll fio'" plaSith:::

pa,r<t:'.. .

0DO 'n~'·i.isl wirli .{:Ir .anY othoet hafdln-l'tti:lrtumt to ·il.IU8ml, . c;lirbui'l;!tor pa~" ~$pEicialiv le,ts" Id thoy .may be "malipd .

• Dis.assefliible··the car~uretors .

• 'mrnei'se· all the metal p.aru, in' <1 car:biiretor <cleaning

~Ollli:ti,OD. .

.Rln~e the parts.In water:

.When_the parts. are "Jean; dry them w(th car:np're~s;e'd alr, :.Slow thrP,ygh theajrand ruc,l pa~~~,g.es Wr~h' compressed

air,. .

~sem h!-e the carbu rsto rs,

CarbunUpr liupectioR

WARNING •.

,

0Ga~q.li!1l1 i~ tj(t!,ehl.l!fly·fla II\lmiible' '~lrid Coailll be IIXlplol, ... e' ul'!der ced,i" oonditli:m!l. Tum the. igh!ition s,\IIIitd'i OF F. Do not !8Iil'iQke. 'Make $J)UI the Ifeil is willi vllntilated' and froll frolm any ~l,Ir(le offllli'riB oT$pa:rks; 'l~i$-lnCl'~il'$ any ap:pliance with a pilot liighil:.

~ RemQY~ t~e C~rb>~iretorS:.. >.

-Se fo.r.e: dis~.~e'm ~I.i mg the 9Jrbure.~Qr~~ . check .- tne . fue I

le1t('!J [see F~el Level ill&ptlc.tf0!1}. .

.,f the fuel ~~\l"e~ is incoueCt, in'~p$ct tH~ Fest ofihe

carburetor before co-rrecti1mg it. .

.sli(Je th,e; choke [ever right. to left it- to. check thil~ the' st'arter plungers mov~ smoothlv ilndrefllfl'lw'ith

sprlrig.rension, .

*I!f.ttw starter plungers do not wor.kproperIY,.r(:place

j:he'carbu re tor). ' .

.Tum lli~thrpttlle ,c.a:.b~e pulley to check that the ,throttl~ butter·H,y valves move .~flH:iot:lh.ty arrd return by

spdng:.ten!llon. .

.*J'f :th~'·tl1imula val~es·do I)OJ fl1or:e. sm1?()t[lly, Repl''''(;1l

the carbu [eto~. .

o[)o not appiy too, much bonding ~g,~n,t: to the plwg Dr tbf;lP!lOUCfllW j,uelit; from btIingfi)!:ed.

"Whei1lr.~movln,g the .c,03lsting. enriehersvstem, (.H15crew the ri:mu<l,tl1flg:. ~ir~w~; and ref1ll0Ve the cover" s.pdn:g,. O-:l;~n:g,¥'IddlaJ .. h'r'agm •

1. Ca_roureJtor (LH)

2. Mounting Screw: 3.¢~ver. .

4 •. Spr~!l~

5. Diaphragm

6. Co~sting En,rtcher Body

7. f1,fgl)oting prat~

Carburet.or Chjanlng

I WARNING _

6CI4j-an ·th~ earburetol't'lpa w.el'l·V(lntill)~diatea., and·tak,8 care, that tll'-J8 ~~ ·!tIO $~r:k'!or fta~II~.a!'lywhli!rjnear tbe w."ikln~f Irla; i;:tii~ include.s ~ny !ilppilan£ewli~b: a ,pif,ot I~liht, .~ et tho dlitt9llr Of 1!i~!itl~yflalJl!lll'IaWIL !,q~~ds,. db no'VW-l!.:ilasol~l'Ie' or ~ow fl~!/fI!1PoIntKlI'iewts tG c;ll8l1ri die 'Carlw,~~r8;

A. thtotW~Val\"!l-:S

.OJ~ass~rn ble,~hl:!c,arbu ~~to~ . .cleanr the t.arbwr~rors.,

.-cfli('jdLth~t ttle.O~hlIIg5 0111 tt:le: float b.owi :and: d!rai'r1,plug [n.d .lh~ ·.di;apnr<tgil"i on 'he 'va';::~.Utn pht(It'!.a:r~ irl.,r!('IQd c:cr!l.dit.iqt1 .

'*Ii f ,;l;11Y JJf.~e (hi ng~ qr:;d ia;phragriis.:ar!'!:!lfot '1r. gOQ.d~ .conG1:i:td'oh; ~ep,k.l!ce the.1ll , -

Khee.k. the O-fi~\g ili')'dI dt<lJ).~'Fa.!l.mr:oJ coa~ttng ·:ei)·r~th6r ~)f5tem.

-If .anY' O.fUl(', (h,dngliQr dj<l:phragmos. a>[(!t ·tfotirl'good

cMd~tlQq.> repJ:tw·them, . ..

ilChebk:lbe p~a-sllt tip' 9f :Ulci f1 ~aC.'i"Jve. Il~(l'dlt-.. ~ t ~h:941 d .be. 'Sm.C\u!.~fcl "wlii~:t>u.t'anIY. gircibves~ ~cr,~ft:,h'e~,or tears ..

~fcib:e., p~aiti.t=. ti1P isod,am ag~d,.. r~p~<}cf~ the' .~:\*d!~. ,~tlstf~, ih'~' t~d' i'r! 'tM' O~~f!(t ~il1ria 'elf ihCl fl(J:a~·.Yat'Vi

~:il~'d'ie alia 'thc"'~e:~~~~ it. .

~fflt ~.o~f(lQi:·$pr:.in g oil'!". ~e:pl~~e t{le.'ne.e~ Ie... _ .

~helCk tb? t~tt~nHI 'P.ot'll~oln 9'if;.tq:iV",ilof:SlCre1(,,\:ifQt w:f$_;i{

_\" j.. : ~... .

or ~~niilk'ge ..

P.i1~fS)':r.ew.

, .

. ,

'2.-, TiI,per~, ~r{'iQi1

L Red

:2 .. Val .... '(1 ,Nef:rdle

~*nf'~n~i: r;lHO.E. ,s~TeJ'i 'i;s: ~OH'I or da.ti1'age,d q~ r,~~ 4i1pe r~<;J ·p.or~hfr1i. }t ~ij.l.~re"';\)rit' (hie e'l)gi.~e· fr-otTl 'i~Hp~:

=).n1oothly.,Refjl;tN',.it: .

'·.c·het~ :tli~! t~e; vatu.um. PJ~t'(m;~.?v\\'~~ ~~ @{J~t~ II'; .e iil __ lhtl> '9-iI!fP.Wf~tqt l!qqey.. The ~ur,f~e ·.Qf th1;l, PJ5:tP:I1-:rl'll(l'li'~: Iii Qt ,bl;!:

c1«(:li5.sAveIV·wOHJi. .

~it ih~ ia::C;utlth·pr~ibt1,:.dO'e-s IlQ,t ~l).qv;e '{m.o'Qthly, ur if:,iC t{ veiY. 'lde,St. Tn' hrJi!:-l t(l~Qr I:i:Od.y;· lelS lace :tb'e CarbUret~i\

•••• , •• iii ~ ';'~I;;; 1'1 I I I I' I I I I I I I~ll I I!! !i'~'I' I! I I I I I~ 11!!,!!! ~I!! "'.!!!!.r!I i.!! ~ ~ i,. ~ I I I I I <1,1 I I I I Ij

,.", !;!I" iii .,i i Li"LIi i I I ~'~l~' I I I I I ~I ! I I ! ~ 1_"'" ! !! ! ! !,., ~ .,. !. ! ! , ••• ! i ~.io;. ii i i a ~:iliili i I I I I ~j

Aft Cleaner E/e_mMt Remo '>tf}1 .~l,em(l"'El tnt:'; fO:llowing parts. 'Seat [see Hame- Ghapt'Cr j

f w~~hll k Bracket Hol ts

.Mo:Vf tHe tank .'bmck"et f()rwar~ to pull the rubber 'bil.nd outol' ~h(l cleaner ifQllsing ..

A . .'[lm k Br",~1ket

B. Tank .Bradk.et Bults

c. Rt.l.bber, B'ailld

P'I.)EL SV:STEM 2.~

o U dirt~ts tihrQLlgh ~!iltQ the Ilnllil1l~.e)(te:ui·~tl: e'ni!!tle

wear and P:05~Jblv 'ellgitlll doillli;lge win o~c .. r . .

~ . ". . . .

Air Clean"fJ( ~/emfJm 1f!$t~lfl'Jtf,D(J

OEI~rn!;::llt ifl'5t;i'110l:tio·n_ b th:t1 reverse of removal. Now the- .. to I ~oWiil1.g;

•. ae~ure to fit th~ -; ~lernent hOlder inthe !!r90"'~ at the bottom 0'[ the PS~.

A..lf'k."lldew B.lEleme.nt

.. Remov(ute .air cleaner hou~i~g. (<L~). -&'lull thl'i eh~rlrn.E)l1it h9!dt1I,.Qljt of place. .Pull Ollt the a.~r de~ner element,

B. Element Holder

.Se~ the' hQus<iH~ cap Willn th~ a.ril'ow ~ark fach'iS f-p;f.

w<l;rd,' .....

• Pl:lsb a cl E.'l~n! lint-free lo.we~ iot.Q the air eleaner hQUS i t:\:g Ul ke~p d i r~ or other fore~g!1 m<"!wria,i f'Fmn ellts;:r.fll·g;

olt dilt or dun is <1I1~iowed tp. P!lS$ through Inw th:tl: carb~nlton. dI~ tiUQttl1l \lal ... ~ may beio:eme st~!ek, ponibJly eausing .. an·'OICCident.

.·A.ir (:Jt}ane:rEJement .(Jj?!J~nlf!rl NaTE

. ,Din dti'sqr%1ffffk;i. :rI)1e: ~/ewmt ,:s{Iril!ltI,:~. e.'f~im; .!"Q~ frp)]u:enrly, than' tf:re:-tei;il~rnen,d~tliijte'r9.(jj. '

", _ , _ ~.:. ' _ • ~~ • _i ..... • • '. -. "';' ,.' •

,PAtte/" fia!n~· :tj'I'fpl!Jf!i. <lIJjrt. "Df" QrJ:",4!l:1iJ{f!l .t{)a(#, t~

. e~em~t,'$It,r;JqI(/iJeir¥JiJlfWfliiI;Jmt1e1flit8l:Y.. .

.~ReitiJ6'ffl J~e ~[l'. C,Je.?f!~i; ~:J~~tJ~#t (;e,~ Al~ CJ\~j!.Qer

.~IEfrintrM R:ernol'iilj" '. ~ , •

;-Clean f4:1e, 2~.ell);enl.: ;j~l'(a> b'a.th .h i.lffi ·f.lta$i~":'p,(I~r)~· (s6i.~ent, ,an a 'th e~l .clJ~ . :i t' wiih' compres:>M' iii r.or o.y.1>h1l k ~ng K.

II W~~~JN9: I

'6:~ 11j:lit use. Jjji$ql il.\e '9'( 1I'(:Qw ifl .. sh~p.QfMtQl"'jnt to ~~l~1) .t~l:e ~,~ri!, ·",,_·nr~ 91- ~plp$'j:jri'.~Uild r(lt~d1;'.

.Aft!;l.~ Sie.[J:tri n ~;:sa~l!r:~Je- the 'SP~n:g€'1i Itfitw;i)1;iJ) iSE' ,tJat~ . 'SAB~,'3;O (:M!, ;'~.y,e~ze ~04't th~' ·~xces.~, th_ en -·W;eap Hilt].j e;I;ean ,r4g arid;;sqlH';e.Z-e.ii as ury .as pbssiMe-. B_~,~;iJfelul

/ '"; - - ",., . ' .... : '.~ ~) , ,. ._-

. n ot :~p et¢ar ime- ~JltJ nsf 'fiilMr.

Air·CJeanerE1emenUnspedtiqn.

i}liJ'd ffeplaceffll.rrn

~.Retl1r01.;t:' J}\~ .air (!ie;fi&r" ~l~~'~rct Ge.r ·'Ah· ;C~!fan~t El~meiijt'Rewi,a"'\l:IL

;fC.l~rltt:ltl7iliJ tl\~.i~\~w .eJ ernen t.fsee ;Aj r CI~ane·r: E;k me n f

CI,e~oing), ,. .

jolJ;i~,J aj:1 (i:n~J:) ~t )h~e~ef1'l.~-l'It;fl:ll~te~r" o~ ·~re.<ic~~, ch~i ~ tlil e 'cl¢f:ta<'!ltll t lij)~ (]e.r .apd WHt !!i6~eiH:)c.

~rrt h!l-s any N{MS()tbrea\Jb,~ "ep:I-a6t;Jfh,ee!ema~JI:,

·,~ti the ·hordeir. ;('}f <t~:e' SEreEil)" are (:Jr$furt.Odr¢pl·ll1;;~:ithe:iD . . \QWh'enre;p:iiicii~g\ t.he~Alder 0,< '>Crccn,~;~mu\q:~ the dip

,c:~·ltanerhQ!{~rngand·.s.c.parah!' it~ ,.

':,.~p\ea!.e:cl t !eal'i i tits- '-Q!pe1tl1s ;tb,el?¥ln:~ (,1' the ·,(oam 'j ~" tih'e ~relrl~'ll., R~pr;ffi6"e":the efkmenl ilCOOfJJ'i:ng -uo iliic .. P-eri..'·odic," !'if~iifl¥·n-~h9e.: Ch~r{{s~e ~Gencir:ill. l;nfGitmatfbo: d~;l.PfeO"

Bte/J.rti.er.O/.(Jnspf'j(l"tjoi)

-v R@mo ~'e>di~' ~r~g1i(,~h~ ,end' of' ~h'~ cl~iin tube :0f1 • .the 9PtlQ ti'lqt ··tl;:f. 'kk 'citeah'ltr ~,~itS~hg ;4t')d dr~h~ .9il Jl.du:iT1bl~)tii~:tn-t'lt1I{l, tfJl'lf:>

., ~ ,

,

),·,.Ai~·pt.lneJ HOIiI"lt;lg 1;( 1~l'lig'-'

~r! . ~:_~'¥..~ ~'~ e i.! ~ ~.~:~.",,,!,,,,!,!!!.!! I ~~ .. .(,,",-m,;M ~'-Y !'ij .... i' .• 1·1. s-"i,1Ii 1,.,., •• ,Ii:" ~+ ••••. ","i ii,"~. a Ii .. ii. ~ ...

~ust·TaAk

.6aaSQ!li'n~ )s)l!!Ii?tt,lIm~J~ '~I .. mm,lIpl~· i<l'M t~,!'1"b"e·;.~Jl:IPI95il.e' ~J1I~' urlfilfn, CJ)li'KlitlQo:J' 1'!l11i;JAli:le ~lrl)i_tiQn ,~it~h .·iQ;F·F~ ~. fiQ1-.sfQo~. M~~ .,s.u,e. )If!l_ _i~ WeQ ",V~~'tl~a~e:t(ari:d, fl!t9. f~!ri' ,,"'iV' ~Du,~t:~·~t'~lB;til~'9r:'sP8r~;< lbi!* irncl.u(je$1rnYilpprllll'll)!l1 with· iii ;~!Iort; HUM.

',:Rcmav@ lh~{QH¢.'WJrjg'p~ri[::;,

. "-~·ia·~J~~.'tl~ri1l~ .~~.pi;l;r); ,

.$ide{foyei'$:' (se;e, ff~t1ie..thOlP~_r1; . 'ui~per 'Faiiii(g Aile ~ B>ilb"" f.:U¢i·l<l:rI kS:vack;et !aJ<lI.~

i'\. JJ.pped"';j,~r"i~ghA: Ueo j~otl-$ 'B. ·F!il!e.ll)lllt"fl,"r~c'~a~t j:~Qlts

.T?r~ me: t:u~l.t.atl ~;tb'e o~~,.r.o~f~:on" .Tllt(lfe:'fank tlu:tthtJ r:~a~ of·lhe-lrOlirneG.

.Pu~l t~e ,hj~ off'··1t:.e ~tap. ".

QfcQr .QlifQJr:niil ·,/e.rii!:;~s, Unto i:\realhc.r .:a:t:ld 1'jJ:ej .tllXU!ft'\ in9sesh.'l~ sL he: ~diioonhee~e:cl. fr,oij! vth~/tq,(lIi:_cFfhiil"lg» hef6r:-e' 'lan'lk r,;e,m·qv~1. PJlIg theJueYire'lWJrr-ij;J t~l~·,g. .. T'ill'~. pifeye:c\t-o gjs9'ly",e.ffti;tri . .ffowjng· rotti)h~j;,atl:t~r~)' <

.;pr,<!i~:tti'6 fuiiij. ta~k i{r(~~e5sa}Yo,. qA:fran~,~·~'urmh[{.Jtil1jit;6~t\!;~d~r ~hf'{ue;1 :fuJlk: ,. oT~nti ths~ f~1 yap' (9· ~h"~ R~E;~p~ ~CoO ',W qr:a'ir tfl~cJud

Yfl to Jh& ~Qhb!llf:1t ;.

. FuiJ:l tank tmd Tap .Cieal)in,y h

,.;Rimo\'1t eh e :tueI • tan k ~f;1 dfJw<lin tt ~~e~ Fue l- l':!ioi; R.c,mo¥<)I) ,

._Po(;lj;·some high/f;la~'~p(Jj:nlt :SQi ... ~hVi!litb ~h.e. fuel ~rik ~",d\Sfij_ke ~e'fu:rak'";tO r~JTlci"e! ';qtrt at'l~ f~fe~ dep0'l~,

'O€;Ie.iO\ ~e.'ta~k ina w~n .... entna .. :edaf\QlI .. andl·take ;Cill~; th!!t' ,th-ere' 1$ ho spark· (lr 4r~m!ll~ "il;lI~wl:uilrj) .. :!"8!tr . ~. woil::ifl!l' are~,. Bacause 'l!If'~t~8 '~~I!'w. at .IMpJJ:ry .'fill~· \ 'mabie .. 'li,qu!!d~,~dQ" ,n~,:Lts~ gasoliM'i"9r' i[QW fJiiih'PQhn .. soi~A.t9;~~ .<t~an''tJje ·~"k~

'e,P<;.>ur ·fhb sl>lvell"l rfut:m·m~t:ta~k ..

~e,~,o~i ihiLf~"e.r ·tfP'·fiPirri:, th'l£;'WtlK by't;tl;;Jn~rotJt:'dte" 'lif)it~ whU rlyJQ'M ~her:$::. ..

~.c[ ea'p" ~iM:'f'4>e~J . tri;~ i~1 te r S'creen~' fn a h~1i:h flaS:l:1-p61inrt.

"i!"9lve!r'Il.; .

·.p'bur: hj~tl; mash-pDiflt SQtverut tturougL itiw. tap':ir;r ~I~

[e,l/ee!' P9~~ tjp~;~.

.Dr·y; ~'Me'~tan:k"ai'id trap winh' 'C9,!11·pr:essed\1-ii:i

.(.ilti1~..tllt[ Jht,"L1p·.irl tJie'.,i:airr~:,\5·C!'¢' Fu,ei ·Tap. fti~.taJJ:Hj:Qn} .. .:I"n~til.l:ilhc.fueJ.:t~nk (~e-e'Fi:(el"Ti!)'1~·II'I~h~J'(ti()nl.

Fut91 ,n~p I.nS/I!fNJ;tiM ,

"Remt;v~~;!i're'-::;fud :tanL .. nd dra]"11 "it t$ee' fU0~ T.atlllo;

~emovan· ,

.~e.~QI.'~! \h.e: fih)j,:{:a,p bt~~ki!tJg out i~A boJh W~lh',l\yIQ1,

~<\!];bp"'''

;e;Che:ek; 'wli 'f~JEfI~ tint f[I~.N·' j;veens:f6r ;UW brea.~s: or Jete;f~ or.a"ti ott.

Fuel Ta'p

.. ,"",~.

' .... £ ;.' ." :t"·

'.'

.~.

. _'.,. ," .

,

". '.' ~.' ",

1." f.ln.er :'?,; ·9"~·lIg J .. 'G<l~k£t

. jt,1f..ph ci 'fu el~l5r sn.;4n} J;aJllJe~' any Pr1i!fk ~ Qf fr:e· Jd~ ~i<o' Ja~ed •. il.t'IJa.~· aJlqwd'rlf'rtcQ reaeh 't:h{ carbiwetor:/ e:~L)!>;illjt

'.p:b9(r~n h.tJlg", R.e:pl~ce th./futl'l :~fl" .. ' .

• I'f_ ~h~,.fu·e:1 t(];P t~k~;;"'Qf·allo.w,9' fr.llei] >tQ.,j]QW w~er!'lt ofs QN: 'Of ~I;~S without. the ,engi'rll;! nmninJg" .. r:,~:rjl,lt~ the .. damaged g<l:s.ket~;( P"ri Il(l:;,

~F.uel Ttmk.,-t.md eap I i'JSpectjoff

.Vi5~iOlJi'i" j'l; ~pe.;:.t, '~~: :~~~e!5 on :th~ .~J'i ~";fr\l d~,a:p ~.:b<r ai)\(~am~:

,"!R~~laC'e t:l:\:e .g'J:~keto: if 'th ey: <ir:C, d~"ixraged, .

• iFie:rrtQv:e, .the·h~{l{it·"ff9m :ihr 'fY,el Nell ~~, ";ifI,d o:p:e f) the

·tank·cap. . . "

.c"iri,-e6k-.to {5ee .if the, bte<lth<l!'pJpe' tal-so the f!ii:e!1 reludt plpe. foil' t;fMI JJs\ taH(ornla -vebtole.} lf1:[ne 1"1ln'k.ar.e··m,o'[ <;iLoggeq,. ,t;:hBtK:th~ ~t'lk CAP' b,((l1l:ther xtb9-'

#l-1t to"i t:a·tik b)'&il.}Rf( ~ip~. ,i~ +i(lgge.~~_n~,mQlIeVtb£:' t'a'n~" ao4 ~"alia J' :~hd 'Jfith'<blQw~b~ bre!wh.et fjf~~/·Mth .. ~Q!rrIPte$iSl!d~l t,

,:*tr rille"bph'wlp ·b~e<L the".].? cJ ()8¥ed, ~f<e ~I;tc~ it"

eVilPotilthie _Emj~jon~e-l1uWt)1 :~:YS~m {us £:.:!li"fulAi.a \(eh.~'ia '~Ill'tl

The [,vapo:r.a1ive·:[ mj~~i (,Jim :~tjtltr.9t SY"Stem- r:eut~"l\ Jtie.1 vapors. nrom: -ttlie. t.~ei~y.sttlll'l-kt,to, iheiunnir.g Mg[n.e 'or ~t.orl!~ ,.the .vapots ·~tl .. ·a: c~n!i 'ioo:r' Wh(Wi! t'h;() (I) i,.~l1e·. i'l: ,s.top-"" ped· .. AIITIb9't~gi\ 1)0 a.dJU~Jm,Q<bl~ a:r\'t .t'Cq~ii'ti-t(_a"tlipreltJ~ 'vi$"!i.al l.l)~pt~,U;qn· rn.\Jst be . rn~O}d·6~;!.it (b'e :i i;i·teit\'~k ip~~T-i\!¢d 'b\('~'e P-eFiodil1' Mrii!j~mw(?~thif:t.

O(3"jso)linff lse~ttt'!~W"fl!):mmDI;lIe .a_4:'I;d,,~n: bQ-~xplo$iv<l< _.,.n~i~i~l!i~ .oo"riditi6ns. Ttlii:i\.tle-'·lpUion -Mi~ 'o.FF. D~6 "nl)t~ ,make.. .Mllktl .9!Ulre, the, ah!!I'I. 'It wetl ,v(m'tili!lted an,d' hQ~' 'from .anYSO'!.HC8 9f fiamll> or :$pa,r·Ii::!i~ ;tHi~:}!il,Ctl:ldes snyapPi iafi!!'»wtib'IlI'Piilolligt1't:.

'~

olt '1I«Io1i1i'SEI,' '$01Vi!!IIt':""_a~~r'of- 'a'IYY Q.t:iIIQr I.iq li!i~birit&I'1:;tfu,-(l! '~!1iis,~l'. ltfui.'t3!ii<il!18r's,· v~p:or >ab:.:Gftlii1g, 'cs;pacity I;~ gt:e-afly 'r«lJ.:I@d. If 'tlile-~ ci:m-jS;t~r ~s'· bl)60"ine' 001)1, ,ta;min~d Mplace.- It wi~Jill II n,ew 9!1!~~

.. To Dire"(ll1td:he .g<lsGlinclr-01'll' fllJw~ng .iWlhl thee .cal,iS1ier 'Cw~rom' l(lwing :Cl,l-li·C:f th~ ca~hrer:,f:ltlild'-It~(!:. $cp,,~a-tor

w~pe~dl;(;!Jt,rr -$() thjf gro,Uod: .

~O!j'Fl5Jt: 1be lids'~~ 'JC!t:ofk!irur·:to 'ii'i;e -dragr,a~ o:f ~he }Y.~,tero, ~~k~e ~bri' th~y QO fiQfg$!t~pj~CJ~f'~'-~rM'1'~ed_,

. Hose_JlJtpec,rA"gn

·.che'!!k IhJi.,t;Jhe. 'IiiJjii~~'M:& s~59_0l.i.y~ It;_QIifI'l~ded,

.:~~p!:1i;~ 'ar(li fi;il1~~~j,.~e.~:!!9rate~ 9:( ~i'nrl'il'?ed hpse~,

Sii/lJad(o.[ 1ns'p($tiph .'

,"D[~\':;o'l'Ill~ct:$~~flQ\e5-1t$MI theJi'.~ujtJ[jya:P0( .yci~:Jjr'*.tQt, ·.<l:.[d~iAtl\i'¢- IhVs~p;fr:at(\i'tr6m::th~_irrf0~;6r¢y de: ,.A()s.uiIlY Tns~t:l¢t~< t,he }i)~4mt~~ (fit' ~/asi,5 "Eii:I~ .. "QlJl~r:

j;hlJn'<ig~, .

'*!! tI!.~ ~e'l?ii~atpr' ~hq:Si a~ yl <t;],ci~ :b( bM3 da..!~1:a~~,~~p~ae~e:ir \ifril'Jil;.::l.lrew- @~te.,

;',.;'. . '. "

GGa)(J!illle·'ls· ex}rerrr«t( fi~rI1ma~f!l ~~d~CII'" b, Q~p'l~ille und'er l;:,ilittai·t! ¢l'iditionl~ T,U!rri' ,'the. Jgnitlof'i MACb Of,F." Do'not ·smok~.. !Make, 'sure" ttl,e,iirea;' 1$ .. weU "";til~aB.d .ailJld.fi-tll!: ,fl'.Qr;n'IIi(J¥ sOUr(:e- Qf"fhUrie c(JNPlIfk: tiI'I,b. in:d~.~: an't·;appliJ"'~. ~i~b::a p.il.,o:1 tiQbt.

et,Ol~tiC?~t" 1i.~e, h~'% tb J!it:· S(F:~r~1Ojjj, :~t:ul_' i~:~tJJI. t'Il~ Wf'ar:,a:tb r ~ll',nfut Ol<;l'tQle:yck .

• p~~~9nl;l~Et . ~h¢ b.r;eXth;ei· h:Q~t:f,tPn) )b;~ .. 'se P'<J;litIJ\J)'\ .ijf(O l:nj&t,~ j;~,P[n ~q·f'YI,. .6f~~o~rie 't~.i"C1 ·tl1e· ~ePilfa-~_or

lib rougH tlllthose fi tl~i'I g. . . .

.01s£l:ui'neil.bttie::1iljeI1l'eiuIOrJ :~I)~,fr.om '~he-¥u:et tai'll:::.,

.. Ru;n d'lc' open end' (lrlh~-re;t~rn ·.Ilme :i"il··tb· the eo:n-tii:1'Ie'r Lt),y.eil 'wj:ttj the -t;aJbk't~l.1;p"

':s;fai·i, die ~I:l:glncl. a(l.cl: 1~:d~.trJ if,

~ff ~e-.~*I~h'e_'h~h~:~:!9!~a;a:~r.. C@fit~ ,{jut ·9f- t.~lOh0i5~~~ t.he,:,~~i%ira:J6f ~~'iii~t~: yi'~U,. IHl-,~~,il},Q:t\ .rifP~.i:6~, tb~' ~.epjr;a,ti)r Wl~ti ·<l'~tteWQrre.;

,t::~jitef' tn~pedrojj ..

.Rertw""(\'th·c 'Canis.tiNf and di&c!Qi'lncct .the. ~~os-e:" 'from tbe'C;)A r~ter.

'¥fSI!.i~11y r.n~pj'ld ~-e .!j:anis.l~r fQr(:r-<!~J<~ ;)I~:d: o.thel;

,d:iirn.<1:gk.. .

*1 f t'ht<.u:aMs ¢r- 'h~ iliiy '¥rac!-i. jm" Qij4cl.'a:~a'.;fo} T~fjl~~J t.

With ':au1.~~: O~'IL

NOTE

~'t11~~ ~~;~ie(' i$ ~g-n~' !'Q,_. ~oik~ '~r' :(htp.l.!if1 ,tbiJ. -lfIqU)fi;:YW:$"~ life_ :#irhmtt :<f(J¥ 'p·l#fl'/tim.atwH,' if' it: (Sc:''u8et)

q.ri~i: nG",;m~a/)t:QI1{iitions. . . ;. ,

. ~.. .. . .,.' .~ .

t. hel.'Tank,

f Ca~b I;Ilnito r- 3.,AkClea;~er:H~,Q,sfrri.

4;· UALjjdII/~pof' ;S;ep~:r~nQr 5~ t@n~~!ei' '. •

f,>, !!r\'f;;'tr~m);f6'i€'!~I,,4);j1

1, Ftlel Riet:)i:Ff;J,Hos;e:( ~e~,)

.~t. . :QSf'{Gr'eetl),

9.. ::r HOStdei~;re)'

:1,(J.,' C~p' ..

'l i'., Vi~llli~m,Hose: ~Whne)

'COOLING SVSTEM 3,1

Table of: Contents

~x.plodted View .. SpE.'cjfieaHoh~ ... Seal!iint. . ., . . .

Cooling SV~iI..efi!'l •• coofant. . .. . . .

,Cr)Q I~,rirt iDtilefiQr~tion . Coo lant Level I nspect Lo.n coo11.,mt IDrainirn9· , , CMIMilrt FiIHniQ ....

"

. ~

!' • ~

"

Ai r 1131 eed~ng,. . " . • Vhual Leak Inspec·tlon ..

F ~,!,;i~ h11l9 • " • , , . • • , i • • • , , I')i~a~:se rn bly and Al:sern bly Prec .• iutiQ.nti

W;ilter fum p •... " . " .

lPu rrrp Cover Re,rr1th!lIl. . • • . " . !P1ump Cover InstaUatiqn N,ot~ PU.m:p ~m~lIer Inspeetito!'l ... Wate:r PilImp, Remo\l'OII ..••.. W~:t.er PumplnslaIJatkm Notes ..

Radiator; Ha(i.iator F,at) ..•.• , ...•.

R,<ld iMqr, A"adia'fO r Fan R ern(Wa I ~.liIdiatm installation NOte. IR:adiatsr ~t'i<5pedion,. " . " . Hadiator CleM1~f1Ig .•• " •• Radiator Gap lmp{!ctiOn . .

ifladiat:er Hose, Ft'~~l3fIlOit Tanl:t Tul:i;e lnspectlon

'.

'.

·ft

..

..

{It.

".

it

"

...

+ - _."j. i- - ~

iRadiator Hose, Pi·PIlO·, IRj)~~r"'Otkr T!l)'1k TuM ~nMiilliition N.ote5 .

ThEifrM.ostat .. ,: .. • , , •• ,.,.."..., Thermost"at Removal . . . . . . . ..

.. ". )

ThermOstat HO~$~ngt R~rJ].o.;i~.1 , ,.

Thetmostat I ns~eclion . " . . . . . .

TlIlei'I'I'I oo.~tic fO\n SW~tch, Wawr r em pa~at\;lr!l Sensor'. " Wate~ rem perMy',re. :$el'lS'Qr' Re moval

Iran Swi 1ir;:~ R-emov~i • .

..

l nstallation !NoteS II napeetion , , 'I • ,

~. ~

• -·1

~ .,. i i iI i i.,.,. iii i a.a, ~ i,li a i a ";iliili i i. i'i i Ii'i iii i i ~,., i i,i iii."; ~ Ii. II •• ~~ p..p. •• !'I !'!!''I'! P.! !!'.'I'!I!!!!!

Standall'd

11"~m

r--------

()ri!lina~ Coolant

Type:

Perman"eli1t"1lype of "intiT~ooze (oo'l't water arid 'ethyle'rne gtycol plus corrcsleuand rust~t:lhlbi;to:r "!Ghe.m~c"al!i lot fcI~LJminl!lm en,g~nesand radiators)

"Green

Soft water"50%, cQPlanf5rO% -::S7"C(-35"'F)

"1 . .0 L .( 'rese"rvoit tank fij ~ ~ 1€\Je~ j m;.lu(j:jing r:a,Qiairot and engirHl:)

Color~

M"i xedratie:

Free:;::ir19 polnt:

Total amount:

R,a,diatotCapi ReHer pressu re:

73.5 ~" 10'3 kPa

'(0.75 -1.06 kgJ~m:;". 11 _o15 psI~

Thermostat

Va~ve olperling temperature:

Val!ve Iu]! open ~i-ft:

810,5 -83.,Sn:: ("177 - lB2"FI 6 mmor more,@95"C !203"F)

Sealant

.,1 ~ Ii~J~'1 I 11.11 "111,.. I. I I. I.t! I I I. I ~~!I! I.!!! ~ t!.!l!'!!! .J.~!!, ••••••• , ••••• ,., ••••••• ,.;, •• ii •• ii ii io.

3-4 COOLING SYSTE:M

!. ! .. ", I ••• ,I' ••• Ii ,I i i Ii iJ. II II " ."'!'OJ! II I'll' • it il!iiI iI II " .,. II II II ~. II II I II ,,"'II ~;; .,. II II II .,. II II ~ .... ! II I'." ~ ii II "'.

Coolling Sys1fjA'!

"~'I. II • .,11 II ,I ••••••• II •• 111. "! !·If 1.11 iIIi i ii., II II ••• ,~ II!! !'! 111 .. iI i ••• '". II .... II II II .. "!!'! !II !Ii II. Ii ti,i, ... "

The water cooling systliili'fI iSl31 pnissurrzed forcedcr~cu lation type. When the' ,engrirle load varies. this system controls tlie engine tempe.r,ature. withln narrow limilts where the engine operates most effrciet'ltty. .I~1n th~s way the engiine performs sti'lbly ln varlous riding conditions, and is veiry dI,J reble,

When the engine i~(;old~.lhe thermostat is closed" ,,0 that the cool.a,nt flow is. restdeted through the f.mall ho~e,c.aming .the 'engine to w.,rm 'LJ_P mOll'eqil.i~~k~Y"

1. Wa,te.r PUnl' P

2. Water jacket

.3, Water pipe (Cylin;;ler) 4, .cylifllde,t head

5. W,ater pipe (Cylinder head)

6. Wa·ter tomperatnre sensor

7. Thermostat: 8 . Radiator cap

9. Thermnstatlc 1fanswitch lO.CQ.Qling fan

11_ Radiator

Coolant Lef(~lln$pecri9n

.Situate the. motorcvcle.sc that a j~ perpendlcutar to the ground (on irs center stand),

• R.em ave th e sea es, i(')n kne:cgr~ p Pad, and I eft 5i de Coover. .Ched( the level ~hmugf1 tbecoolant lev(!l ga.·uge on the reservoir tank. Tile coolant leve~ should be between the FUn. L an d 11i'n,E, LOW ma,rh,

Coolant

Coolant Der:erioration

-Visually .ih·$pect the ccotant lnl the rcservolr tank.

01"f Wihithl1cotton-like wafts arc observed, aluminum pants uri! !he cooling system are corroded. If vrne toolaillt is brown, iron Dr nee'! parts are rusting, ln either case,

ffus~ the~OQnng svstem, .

Clf ~hecouLm~ gives orf an abnormal smell when. "hangi~ng. check for a cooling .. system leak II t may be caused by exhaust g3i~' le;!king iiH,O d'l,e. coollugsvstem.

NOTE

ODe SUriHO fnspsct the roo/an t .. :r the f8.1ifJrvoll' tlil'lk. rf the' coollmt is 'ch'ecked by remollin,g rhe radiator GS/J, the sfr i1I(Jst De. bJf!fKi from me coofing ,system, .

NOTE

.6Check the l~~j whlJfl the. ·eilgirre i~ c.Dld (room or ambirmt tempemirure).

oDo n~t ,meek tflt: JeW by removing t/ler;ap. If

the cap is remand, air may 9'1 into tlif'coolan,t,. and lower c(JQlllIg (1ffici.ency.

'" J

3-6 COOIL.U'~G SYSTEM

CeqhUilt Filling

'J. R!l~e~Ci~'r lank Tube

2. R,itd~aror liose - lQ Ettlgihe J. CCiOlarft Lev:el

4;. RadLMQr lYo:>e- To R,)d~<HQ:r

NJOTlE

'OPour in the t:{JQl<Vlt slow;y M th~t if .(Com '~)(J)el NIl/'air fmmhe rmgiTffl.' ami radi'a.tot:.

o The nWiatof' cap must be'ltl$t~1t8d in fiWO. stlf:fJ$.Fi~r ·wm t~ cap·. clf}.Ck WJ~ r:om.e. flm stap. mUll puoli ·,down on lr,nd tile .rw"r of tl1~ iW~·y.

.Fi~1 the re~5eJt" .. oir ·.~ank JlP tel. th~' FULL mark wifl~ 'coolant, and rn~tail the tap'.

'o&>fi: 0:1 diltill.ed! w~, mlut be· utld with 1)llill antii\reeze bea below mr'.antifrl!l!ze)it1c the oooliifl9<syswm.

pit' h~rd W~t is uUld in title ~Y$'tJlm, it ~U$es.~lh acc.LU'l)tll~i(l!,! lin th.!!. Wuell~'I!!!IIS, ~nd· c:ons~derij1bly rHUCI[I~ the ~fi~cI,ln cv Q1i'ihegooling. ,yatem.

NOlE

oCho(m a suitable mixfure RftIQ by referdng w the COQ!Wit mrmufiif;turet'$ dlr8Clions,

OriginlllCooi!anl TVP8

Perl'l1fi.111'!lliIt tV11)e IIntH:reul! for :idlil:mililum en!litnBand ra.dlatnr grelln

50'ft wmr67%. '!XIcllan:t ·43 ~ -3It:C j...;22P F)

1..0 1... (up to "Fill II "mil~Ii:)

Culm

Milx.ed ... alio FrllQzi~'9 FlOlint '11"0181 <IIrrnQunl

Air Blee.ding

iBefor~ nu ttiJlg the motor,cyde ~A toe QP$ral~ CI~ ,any -ai r tr,il:pped i'n thecooH,ng ~y&;tetl1 m~M .be removed as fQ.r~9~5,

.Rem.9'V~·.the, r<id,ator cap ..

-Fill W\1 radlil')tor uri 'to the ~ad~it{lr mid I'n'Gck w1tl:1 toolallI'

A • FillerNeck

EL Coo!arnt Lev~i

.Cl1(j(,r.:··~Mc:oolin~r ~yst,e.1I11 fpr l'e'aK~'_

.s!tiin·ln'E:: 'eQginc, warm H.u.p th()rou!lhIYJ.<!f1dllh~n5top it

.Ch e~k ;llIe, coolant I~".~ I i nthe reservol f' tin It ~Jter itoe engine ceels. a·own.

"'Mth¢ coolant level is' low, addcoolaat up·to ,tlhe Fu~1 mark til rough the ,we Sf rvol r tan k(lp.elli ng;,

Vi:$uifil L~iJk Itispection

AJ1Y ti~e the sy.~WtTil C~10W[ly It¥.ies waeer, [MiPflct for le:a!i~_

.cti~r.;; the, water !-"(]rnp RlQdy drainage :9ur~~l P.1S~(l;ge..for

(ooilatYr I eaik§. ",.. . .

*If the mec·l'itarik.il seal is .da.mage~, the ,,(;Qo.~arl!. le:ak~ thr~ugh -tbe sea! $"1) d ,0 Fal ~l;S" Ufroll $h . the JP.a$~ag~, Re;pl(l>l;'C the water pump ~nit.

*U' there are. Ii 0 apparen t leaks, p ressure test the svstem.

A. Drain<J.g€ OLJtiet Pa~sage

.at ~lC' bot~orn of th~p~lm!;p l:iOdly

DDliIr.i~l9 p!'lIssyre. ~HDg, da IlQt,_reed the' p:1.a~$ute fOll w1:l11dl, th~ lYSti!rn j$ design4<i!l. The ma!l!iiml.u:npres!l}l,Ire I~ 12:31tPSI (11.2;5 kglill1!n2 ,18i:1:!iIl.

.Remol"~ the radiator ~ap, and lnstall it COQl'iiig svstern

p,re-siure: w~ten_;i:! rh~n.adi,al:Qir· f~II<);f' .n~c k. .

~'W()"t th!l"c;.~f.i ,~e~nlng ~urfQ:~es wiitm wat.e:r or ceolant to prrevl1.flt PI'i:;!>iIL!lf{ Ileak~,

.'l3~illd up pressure ln th;~ "f.tem· ,cardul~y un<til the pressure ·rea(h~~l 03 kPa (J.OS kg! em 2, 1:5 psl],

-Watch the' gauge for atleast.e SE!C()ll'Idii. If the PJ"t-ssur~ ho!1 ds steady. 'the s'f~t~m ls alii ri:g"ht.

Pres;:nnl':· Te~ti[lil

1. P"n~~5u re Tester 2:. Ada;ptew

3. Rad~ator

.Rel!lllo1,'e the prMslllre tester, r(lpk~!lhih ttHl coolant, and i n ~ta:a the r:;l.d~!fm rmlp,

*~W the pressu re dre ps an d n 0 ~.x De: mal sou rce ~:5 foun.d, chej;·k for ilf1lternill leaks_ Dwplc·ts in th"engfne o.i! in·dic~t~ilflcu:~,n.al IC~1ka'ge. Check. ~h€ cylinder head gasket.

and the cvllndcr Iiner O·ri.n.g leak, . ~

Ffusf/irtf}

Q\(et a period of tirae tile> o);ol.]ng::'ly~w:rn accumulates Irllst, scale, and lime in t~e' wa~er jacket a,na radiater, When· this J!tcurnulia~ion 15 swpeded or nbssrved, flush U\e cooling 5;y~wrn, I f Ihi~ ac,c,u~·LiI a ti.of1' i~· not·r!3imoy~.~) it wil:l.c!og· up tb~ w.a;tcr pass<Jig~~l1!d cqn.s;ldj,Hahly reduce the ~mc'ieiu;y of the cooilf1s·'vstem .

• Dra.irl thl;!!.cQoll.l'Ig ~y_$te'm.

~.f'il~~tfIe ~96lirig $y~~.Gn1I with ffe~h water mfxed with :,,,

1111~hihg compotJnQ" .

0AIIOid the. ~\I'Ul' of.gfh.n.iJlfing eoM:pol,ln!l.which harmfu;1 to ct.if,Ii!l'li:l,Il!t'Iil1llUnl!J'lgine ;!I;~drHd iBtor.. Cllrllifully iu!lmv tbll i:l!i~tI~:pns ,s!:!ppl~!I!J by ih~, ,nian ufaQ.'t.urot of ·the clq.a:nii'l9 P'.o~uce,.

COQI..IINiG SYSTE,M ,3·7

"Wil'rrn up tMen gi ne, an d. F"WJl ~ t a.t norm <II eperstl ng

temperature for abeut ten rainutes •

.. St\:lP <the engine,and.drain the coo~ing s;ys,t;e1in, •. FHI .the svstem w~th fr~sl:l water,

-Warm up.the el.1gihe;1in,~ draIn the gyst;frni. '. R,e p€iI t the pr(')vfoLJs· two stepsonce more.

"Fill th"e,~,ysfe.m wiJli .~.pe·rm~n,~ht tyPt:l ~po~atnJ' ,,~d

bl eed the an r from th!.l svstern, .

Disassem bly ,8t;'1d Assemb1y Precaution,

•• I !,~! ~ •• ,"', •••• , ••• i •• ,~. i .".1 1.1 .,.~ ••• ' .. " lli!!"!!! -!!I'! ••• , ...... UI~" i,i,."i i i ii~I" •• ~ i.!irli ~ ••• 'Ij ••

"Pr'ior to··dJS~~~Eimb!y Of ,Gool,ii"lg" w~l-enl p.a:t(~ {radlator, pump, sensors, etc), wil~t.uIlitH coolant ceols.down ·dnll dr.aifn, cqot~,nt. ... .

• A"ft<3r '.'!~~Gmbiing and fvHillt1, (he! svstern with co<l:lant, bleed 'air From !he systerrL '

.. ~ .• !. ~ ~'I!! !)"!'''!'!! •• ,. ii. ,;,. ii ii;; iii"; i ~ •.• ' •••• , .. ~ ••• HI! ~.! ,J. "' ••• '.'.'! ••• ,.,.;' •• ,Ii" ••• ,.,., ••• i:oi .. i i iii.

Water Pump

Pump Caver (iemov_af

.Drain th~ ~Qol<'t!l1- by r<!m~ying the drain plf:.lg lIit the WAter pun'!p"

.Rem'g"e '!he~ -shifr .I,~ve:f bolt ·an,d pull ~h:e iew·r ouz @f

-the shift Sh4ft.

.Remove the etlil!ineslPrQ"Cket'cov~L

-Remove the Water p~pe bol!s and puH ~he",)ip.esdfjf .th.e pump coy~'r.

'Re'tTIlQve .. tl1i.e. c,()ver bolts and remove the W;lter pllimp ociyer ..

A. Wa ter ~~pe, B.· .Pump. COWl

c.o . .cover Bol ts., Do F'irpeBolts

Pump COlle,.lnst;;1!lation Note

.Repia(:c the p'lllmD .c9"erga.~k~t·wim new one.

3.-8: COOt tNG .sYSTEM

A. rum p Cover

Pump Impel1~r Insp€crion • Visuralll!y dl~ck: the itnlP~llli~r.

*H C~i.(j surface is corraded, Or if Hie brade~.are darli\1.g~~, re pi Me the water ptlfnjp unit,

Water Pump RernovE)1

.DraJntne citlglne oil \s.e~ Engine on 'and/or F""Ult.et cnJin'~ irfl the· !Engine Ll-J bl'rcatidn· Sys.tl'nl ch<l;~:ter}.,

.pril.rn the coolant; '. .

·Removetl:Je '~~ifl Jever holt and pull 'tile lever out ~J:f

the s hift shaft,

'.RehlOV.€. the >t;'ngine sprocket cover,

.• Remove the wa1er pire~, hom th El pu rn p,

.R,~m@!Je the pump n:iQ~~ti!1g bolns" and pull the lmrnp unit out Oft"tlIii criit)kq~e;

A. PUIIll:1P Mounllrig BoIlS

Wa:ter Pump tnstfjlliltion Notes

.check thatthe O-rin.g IsgOoii to:r;difiol'l, anda_piSly .<1 .sI1Ti\11 ani ou n tofengl he oil to the O·\r~ ijg •

• 'Tum the wafer puRi'p shaft u:M:il thc:~tit un the ~hafl ls aligned with t~", 'no,tch (In the. ell pump shaft i'n the ,cran kC<lc~·e ..

A. Oli Pu mp Shaft

B. Water Pu mp Sh aft

C. O·ril)&:

•• I·.HI ••• , .. .Ii •• ~ .. ii io ., , ••• !',!,,'!.~! !'~!" 1"111" .,,. •• ~,~J.' •• , ••••••••• ""'!,I!" ~'~" ~'.,i iI. Ii

R,adiator,Rad:iator IFarn

...... iii ~. IiJ"i"i i •• "'l!! !'!'''!!,!'IIi!l! •••• "!II" "iIIIr1i" ~,ii iii .<ili i i .i ••• !!I ~. "' ii !'.'. ~

Aa.d.iar:or, fi~dia:(o.r Fan Remo'Val

.-Removo Ihe r:air~ng' (5iee Fa.iring Re'ITII(JI'·a! in Frarrl€

c~;apt.erJ. .

.Remove the fuel tank . • Drai n the, cos lianli,

.Di~t(Hlnect the fan motor COrlHl,~~toW before ~emQvM o.f ti':l e F-<l;di ator or r.acli:alo:r fan,

I WARNING I

OTh,e 'radiator 'f:a~' an"d f·an· !iWitl)h~i'1l coiil~d dii~v to t1l8' baftllry·. 'The 1' .. ~illtQr fa,n mayrt,art I'Ullin if d~9 i91lition ,witch i~Qff" NEVEIR TOUCH THE RAD'I" AlOR FA!I!/JI UN'TI L THiEl IEIN!IGINE' COMPLETELY

COOLS 01fF. TOUCHING THE FAN BEIFORE.1"I"IE !lNGI:NE COOLS CQULD CAliJSE IIN!JURV' F·R·OM i!HE, :FAN BLA.D1ES.

A. Fan Motor Connector B< Fan Switch

.Di~c{)nnecnh€ fa:nswitt:J1. con·miec:tor.

.U;i()seil (he h'osc p~Jrnps and p.u.ltl (Iff tlw·I·<l,dillJof.ho~e! (".in .0 nth ,ide.

A. HOSo:O;l;IT!IP (Left) c. I,iose Clamp (Ri~ht)

B, FHI~r M,I;IIUtltfng B;('its

'fRefllOVe the bo~t and free the clutch cable. d;ilrnp~ .El.i.!I{omye~r the ground wi,.(t, COI:1:nee:wr, then remove

iht r-adiator mOllnting Ibull~ and take the radiator off (he Frame',

.Separ,ate· th,!!; "filler ;1M radil}t(lT hose :~'mmlhe radlator. -Separate the radiator fan from the radiator.

A. lRildf<~tor

B. lRadi.~tor Fare;

.") - .

C. F,Ul MPtJtfl.ling .BoilS

Radiator instaNation Note

.Be $~Itre to In~tall the fa,~ 5whch gmund wiY:e, ~1.fl the one of me fan muunting botts,

Hadiator .lnspf}ction .Ch eck thi,~ radl <l tor core,

·.If there are obstruetlons to air flow, r.emovrthctrl. *1 fdltC' corru ga ted f.i ~t~ arc d.€forl:1lQ"{IJ ,c3!refu~J y~,~raightl1l1

them with the bladie of'il thln $Cre:w druver,

A. Thin Screwdr.lhier

3·10 COOUNrGSYSTEM

- '" -.. ". .

OWbenlcleatli!1@ tliit i'!'U;li!'lt.or w.ith ~.ea'ln· ~lIiafle~', be ~refli!1 'Qff~ i9lrpwing ~ Jlrvol.d .m~ to .tIi!~ filll5. oklJl!P' th![l ,ai'r !1~z;t1! Qliet OS m (2.0 11l.~ away 'from t.hQ

rldinor. .

OBlowliIl, perpendi:i:uhirily to dlit r8diiiltOr ~O!'ie.

0f\1ellel' blow a:l.r· .It. an '1III1Ieiallaiil'lsttb~ finl but itraillht d),rough, ttunnln' the til recttonof natural' .alr flrow.

QN'II~r~lW!ke ,the ,~If nome· aU' rig"t aJ'lrgleagai'~Jt th. firn's,lHI, 'UN! to 11119"' it at Ji h~vel with 1Iiheflin9.

OIK

. < P~'fP en dl cu I ~!r)

-Run bh.~&un 11))rI2ol").lally f6Uowtng the cere, f~n di~~· ti oifil ,

~I f the Ali: "pa:\,~age~pf ti1(! rad:ial:orr e~r(U:lil'e· bklCkcd more th~h 10%. by unremovabJ~ o.b$tnJrcdon's, Clr Irr!i!r'<l-r~bly deforme:dL filI1S, replace ·1iI~~ r",dbwr wifrn .01.. newoIO~, ~hiC<: '" In e I<!di atcrf IhH' n~oCk to rs~gns:6Jdamiige. !lChcC~~ the cond:iti¢n ofr :the toparild bottom, ~eaWirig seats itll~h.e lfHler neck, To~y must :be· smooth and clean

for lhe radiiahJt Cal'dl'l funct~on prtfPerly~ .. .

Radiator CaP inspeerio(J

.che~~ 'the (.(mCdiiti~11 of .the" valve sprin.g, ~f1~ the. ~(}P' and bottom v<lil \lei. seats 'of 'jtb y mdj <Ito r(ap,

*If any onc of Ut-eri1 shows vi'~~bl~ d<tim"'!l~r. replace the -cap,

Radiator' ~ p

.~.

1, Toj:rSell.1

'2,. l3"oU-,;m Sea!1

.Wet the ~ap ~e:a.l.ing :5t!r+;l!Ce~ with w~t.Ei'rtJr C~OLlrrti to ph:iv:ent pres~ure I eak.s..,

.I'tH,'alii i:he Ci3iP'\lli!l a cooling ~y~lern rp're,·~~r:e .' tester. .Wotll:h r ng~h~ pre$~u Fe gauge.. pltmp. the pre"u re rem~r to build tip the ·pte~$tlte.The ·Gap.tlI1:List rda~n' the pressure 111 I:e,!)t {i' se~~ I':! d'5< AI so the 'D~rpmLJSl open at. \fie, p ressurc ,shown t n thetab~e"

BadiatQf C!)P! IReli8f Press!.lli'e' 'Ba ~ '123k:PB

(0.95 :.. iL25 li;gfcml. 1A ""_;,,.8 ~H

." _". ..

'!itl!' the" cap cannot holt! the specified pn~~S,!-l~. .or (if it hold5 tOg' much pir~~Ulre;. t~pl~oe it with :iJ.. r'I~I1iW one .•

t

'I

I

A. R<,diator H o.~):j\

:B.~ C:hfrtip~ .

AMS!l'Iili~Qr

'B, Co;tlrJ!ector

G" Th((rmo$.tat H!)j:f$~h'g ,tUl;zm;$i ~~ ~'q:lli ..

'··.RemQY~ '~h& :'tlier:tf1ost~l~ h(j~ir.rg :b'9r~~., ~hd D!I:U the ~n';(~ir f1lg 6,~ 1f Of th fl· f~aq;re,:

:liF;.eJriove th~tlhettrllmtal ,c,pJ;;ef' ,'~jm;J .p'Wlll Jl~:t <tmrit th EfrtrrbSJal :i f.1l~.c~W:

.! • . - ~ • . ~

th~{}tQ1o"s.t;jt I.ri~p.:t!e.tfbn

;-:.~ern6;lic .lhJt ~~I·e;p,b.W:t,.,ari;d h;l~:~),e;.;:t j'*'e t.h0r,m9.$ta:t \1,(1:1 ifo at. f"Odrn .tem f'ler .. .tuf~i.

*J( tQ"f \i;l'ly~< i'S Q!!~n" .rfl'i·~~CC. ,df~ v:afv~ o/Hh a"neW"onc, np, 'c~~g~ . 'l"al:v!J: .crpAoin::g 't¢rarer'~Wire;. 'stl5p#:~d the . . ~h (JrmN~a t ;ill)1. d .an . aceu rJ-t.e~therm~trl.e~~i~· tll:a (dnfOli n:@r

·of:waber. . . .

.• Plft.etf;(e:c.OtFrta~rni~r: o:\!e~ II. source oj' l:tea,t,.afl\'rWOliduili~v r!l:isfJ -, i:h~, ·f«t1O'pc,ra.l.11l1 re of: ~hre water wh~i te s tinlng the>

wMer gen'd\,!,'· .

Thl;!rm osta t . ;. mUj).t~b~ ,~'m plttely ffuQtrl,oir'g~"d'

'.':-..:.,

.Wa'ti;:h ·tho{ V;fllY'lk A~,sqo.rf'j~'thevahr,".:sl<lhi:~to QI.\€tli', .'

nQtQ·tli~'le.m;p€(ilM:~,. ,. . '.-

*,-r it·iS- tiin Dof the ~etvJ(;e. lir;'lrf(· ral'l:gC. j,e-p1aot ·the" tlte."r-

~'I~:!i.t:, . . ,- . 'c·.·· ,>.. ," '" -.-,.' ,. ,

Thermostat V'lIlve bp.eAi(m~Tinnp8Iitilil.llr~~ 80 li - 83 :5D,C (177 - l.B2~ FI

."rii i i. iii ilr •••• , •.•••• J ••••••••••• ""'!' ••••• ;~ ••• , ••••• I!. 1."',. ~I\'. ~. ~ ~ ii ii i .....• :.,., •••• ,.

Tliu!1'JiI'! 05tatic F'an: .. Sw.itcl:les· Water' Temp8Jatl:l re'Se"_$t):r

,(gi!lli!l

~'bll" l,ur -switCh. Cfthe'. water ·tem.peratulrl!"·~Bmr ~ti(lYk:! nem. b!;I allowed, to filil~ en <If·htli''d "s.udac«>' Sucb"a sh:e:Ck ~Q''H;IHe par4s cat:l.I)l!!!J9.tb~m.

.J~;ern!}ve, t;he. t:11i",rmos!U1t' MO(js)'ng {~~O\._rhe~.~bH11!):

H0wsfng Rernova~). .

.R(\tnOV0~: t.i"a-e .. 'seni~or li"t).m ~M thtlfl'lilOS.krt h@o.sin~;

-Remove Ure 5e~sodii'€lm ~~.>;thermostarh.otl';II'l~, .

COOLliNG 'SYSTEM 3·13

fan Switch ABifJovlJl ~nrain theecelanr. _Remmi[) the fairiittg.

-Remove thi3 fan ~w~I(:~'h cot\ntcto.l, U~cti! remove trne fan. ~witt:h .

installation Note

.Ap.ply .iI liqui,~ ga~ke·t CQHliP.QUfld· to the threads before, lJl,o~ntrng th~ sensor.

I!Tign~en th'!': IN·aler temperature sensor a!nd the faIT! ~wltch'~ ~he specified torqub (~ee EXJ.llo~ecl V~ewii1g}.

Inspeotion

Refer to. the EleC:tr~~41 .sy5H;~11" clY~'pter ..

A. w."'ter TemperatureSenses

Table of Conten1s,

it::xpl,d<:Ioo' Vi~VI', • , •... '" ••• ' " • , , .. , , ••

Spoorfi,bilt~OI7lS·. • • " ,'. " " • " • • • • , • . , " " ,

-SpIlci,a,1 T O,Qi s , , , . , , , • , . . . • • , . . , . • • . .

. Sealant . , , . . , " , ". > • • •.• ' , , > , • " • , ., ••

Cy~ir.ldet Head Co,,,,er " , , ..• " ..

qvlintfElr Head' Gttver He,mtl"'<l~ ..... , •. CyVilldflf Head Cover

1'r1st~lI:ati9fi'1 NQte~

C:;im~aft CJ:'"l'IinTensicWiElr.. , , •. , " .• , .•• , , Chain Tensio'ner Fhmno'iiaI . , " .• , , •• , • Chah) Te'n&~onl11' IlflSti<lll~fion," • , •.••• , C!lml~hajftChain lIiens~oner DrS1Hl5emb~y , . 'CaiMhaft Ch(li n T ensloner Msem bly. . . ,

Camshaft, Catlr'l~ha:frt Chaip, Rock.er AHO ...• , Cams:1:1,afr, Rocker Ann, FleUrlova~

qnisih an Iinstal hn.~on(! nic!llJdi n 9.

Ch,ain Timing Procedu"l3"1 C'limshaft and Sp~O(!iK:ect

'A5<SHmblv NO.iEl;5, •• , , " , • , • , .• , •• Cam sh aft 011 9 e.r~n~ ~ f15pectiqri . . " . . Camsh~ft·Ch .. in wea.r ~ ... , .. , .. ,' •.

Gl'1I11~hMt Chalm, GUllde··W'el'lf •••..•.••

Gv~ i nder }Iead,. . ,. . , . . " " . . •• • . . ,.. , . ~ Compression MejhUfeinent •.•••• " .•• Cyl1nder Head 'Re'!'nlo.va,~ •.•• ,.'" • "' ., , Cylinder Head in~taHaHo:n Notes: , , . ,. , . Cyllind~r Heo;id Disa~$elt!ibl'l' and

A~~·embly (Valve Mech~lJi.sm

R ~m 01I.;l!,1· ~,ndl INstil I hlt~ on '.. . , . • , , cynnder H~",d W!!rp" , , . " . , . , .,' ... , Cv~ifilder. HeM Cleaning ......•• , • " ••

Valve' . , .•.• " .• ' " ' , . , .... , . " , , .. , ,

Va~~~ ttear.wioo Insl>e'C;tion •••• ' , •• , • V~Iv€ Clf~faro'l,nce- Adjustment . . . , , . . , . Val \I'll' S.fi~t I nspectlon , , . . ., . . ., . . , .

Va~\oI6' S{J(!t. R(lpair··· .. , , , ., , .

rygeas!Jring )I.I'\le4;o ·G'ukle

Clearance. fWobb,le Method). . , • . . . .

..

4,6 4.·6

"

"

4} 4,7 H!

..

Cyli rider. Pi~ton ..,.. " . ., " . . " ,'. . . . .

CyHnder Rewtio"Yall , • " . , .' •• , ••• ' ,.' , Cylinder In~taHat:ion Notes .. , ... ; , , , Piston Ril!TIov:aL , .. . , . . , . , . . . . , • • , Piston ~tlsta.I~Lati on N9tl;l ; ., . . . " ; ., .. • Pistol'! Rin~, Piston Rirlg

m'·OOVol]W~~L , .. , . ' . ".' .... , .' ..

Piston Riofl End G.iilP ..•.•.• , , , •••• Gyl i nder I n$~dE:! Dia,m.et~r ., , . . , . , . • . ,Pis,torl Dillmet!lr ,..,. , • , , , , . , • . . .

e,prihg •. Honili[l ...• , , . , , . , : ' .

Gi!fburetor..Holder, .. " . '" , '" . " , •.•

C"rkillji'ij-tolr HQ~ der IIiI~taliati[Jn , , i • • • • •

Muffler. , ......•.. ,. , • '. , • " ., ...• ' , " •

Muffler Remo-v,aL " .. " ... , , , •. , , • Muffler 1f1$t<l~lmiQn , s " ••• ,' •••••• E)(h,tlu."t Syst!em Iltl~p~ctioh .. ; , •• " • ,

".

..

.*

"

'11

..

*

~

._' I:NGilNE T--, c,'--c .

OF' END

B~.,~.~~ .. ~ q~'!'.~ .'~i •••• !'·'III ~--

. pi oded Vie ".-

................. '."'" ::~ : :::: ,., ......•

.......

·!'II ••••

\

\ Ai-

\ l~®

_S":_fY·~ ,

fjJ~=P @CO'

E:NGINiE. lOP END ~

'l, Cylilld4l[J Haad Boh~ . Z, C(lgh~Rt Ilfa~!l, ill.oll

SS:: A"pply ~iliCa~'U!, se.al.ani.

L :A~pI,y [lOn·peiiJlIinent lockin!l8~rft :tQ, the ·lh"ii-ad~. M :AIP.~Vill thin cva.t of mply~e.nulm disulfi&: Sjj'e-~e." o : ApPly IUllline ·oil.

1'1; :7,8 N-m lOBO kg-!!!!, 00 in"'ll:I) 12: iU3: N -rn (1:0 k9-m •. 81 in·lb I, Ta: 12.INH11l U,2I(g-m,.104 in,lbt T 4!·:1!;i NI.l1iiI 11;li' kg"m. 1, fl:-lb~' i5: 16 INH~l i1 ,8 kg'l!'li,13;O ft·l!bl 1':a;25 IN,·m (:2.5kgcm, 1.S1ft"IM T7: Z1 N·m 12.8 kg..m, 200 fHbI-

44 ENOlIN.E TOP END

1Ii,.hli Ii j;. ..... IIU' •••••• '. II i ii ij ii •••••• ,'!'!I! ••••• 11..11.'" i ••• ~ _ •• ~ .. ~! !! •••••••••••••••• j •• J.!. I

Refer to ~hB SMa Ml;ln~al. noting the following.

Item

Sm'ndllrd

Servia limit

Carmh~t:

Cam height~ lnlet ExtHUJst

CyUndet Head:

Cylinder compre.ssion (Usabl,e rangEr)

Valves:

Vajvespdng ir€'e-I,eogth:

Inner Outer Valve head th ick ness:

lnner Exhaust

cYlinder. iP'iton:

Oversize piston and! rl n gs IPiston ring/groove cleara:nC'e:

Top Second Piston ring groove width; Top 'SecQ,nd P'iston ring end gap: Top

Second

30.5'3 - 31~67 mm 30.53 -31~.67 rnrn

'000 - 1500 kPa

(10.0 ~ 15.3 kg/cm2, 14:2 - 218 psi,)

30.7 rnm 35.0mm

0.6,5 mm 0.70 mm

+0.5 min,

0;03-0,07 mm 0.02- 0.06 mm

0.82· ~ 0.84 mm 0.81 - 0.83 mm 0,30 - 0.45 mm 0.30 - 0.4.5 mrn

30.43.mm 30,.43 mm

29.1 mm 33.4mm

0.,3 film' O.5mlm

'0.17 mrn 0 .. 16 rnrn

0;,92 mm 0,91 min O.8mm O.8mm

Car-'l He~ght ~~-----r~--~r-+-

Speo:l.d, Tools

.... '!'.r.!.!!. !!'!o!IIl!!! !lI!' •.•••• 1 .. iliI, •••• "~'II"" iii .. iilii iii ~ .'.111!~"!!!!' •• ,~ ~ ~ ~ "!'i! ILl. i !J •• I! i!.! ill

ConlPie-~iliCl:"1 G<m9il; 51001·221

AdapMr: '57001i~1225

GIJJkm:;' 57001,·1224

VO'Jlvl! Sfi.t; Cutt~r$;

(45" - ~24.5: 5}I)(II1.'1113) (3-2:" Ex, - 4122;: 57001-12061 (32" In. - 9125": 5700H 1181 167.5'Q -·q..22: 57001·12,01)

! ~!! 1.'II!lII" II!!I!!I!"'I II iii I i Iii. i 1Ii.,i .'i ••••• , ... , ••••• !!.! 1:11111,,11. iI-:lilllll ~ Ii LI~' ii iii,. ii Ii'"

Sealamt

!''''I!II •• lilli. II i!"iliii!i i ii~ ii.1i Ii ill, "J."'.' II, .,~ _""'!!I' II """liiliih,i,ii iii ii i ii. II. II. "! l!f!'!1

~~: ltit.I~. i ............. I'.; .• ~ •• I • lEI." "0:"' .,., •••• .; .. ~ .•••• i I •• _ io,!!! !.! !IJ"'!I!~'" ijloio ~ .••••• ,~"_'!!'I!'" .......

QvUl1.der -H .. d COyer

~ji!!! 11'1 "'.II .. ,.iI •• · ••• '.Ii ! •. 11' .. ,.;.;i;.ilI i a ••• "'_"'!! I. I" rlil' ~~iii io ••• ~ -It'.'" 11.1.11 .

CytJn(/et Hea(j Cover Rcmov~1

-Or-aj't~ the, ~oolant hs.e Cooi~n.LDr.aitling 10 the toqlilOg

irs,rem I;:I'i<lpler). . c , " -

.R:emove th;~ fotlow'il'lg p<,n$.

U p pe~Facir~i;,g (see F:rame:chiipter .T~l t,hh te~ t'] F~,el Tank b,ee. F~e,1 S¥~,tem'dtapter'ln illh ~e'x{l Right~H<\('Id Igni~kll'l CQil

.. R~Il1¢v~ th e, I;:Y Ilndi:!f li¢!~ coyer holts and ,I~ft the .head,{O~ilr.,

-Pull Ihi, water' pip'e O.lJl" of" th~e, cvlin:dler head and tfitl'cve th~ c¥Ui1der h~ct:, co·y~r frt)r:rl. t,ne, vl}~k:lci r~ght

slde, ' ,

Ai. .wa~ilr Pip(!! ;[:,. 191'ii:tro:n toIl

B. 'Cyfi.nder fle<)d: Covel'

CvllfJder Head Cover Instafi;rrion No t~$

'-,R,e.place the head co'ver-'gaiiket. with a new"qil~f [f the

g<i~ke-Hs' d<l maged., " .

• ~A\Ppl'1's i 11 t: one :s~al(\n ~ 'to the: ¢Y I rl'lder nead, as \It{}\vl'(i,

SiliflDJ.lll,S~I,~M ,Appliedi Ar~a (ll

.. ~

'1, CYIJnder Head .2; Appi),sIHcone',5ealJtl.t here .

• St~c.k ~ih~ ga.skfi~ PMtially to the cover with 4li iiiquid ga~ke~ fQr,'install,atiQJ) pon\leOie.nce;

.• Che.tkt~it. t~'e: Q:;t~ilg is'goJd' (lo)ndhfoh, and 'inf>tltl~' the

W;l:tQf,pi.pe as.shown. '

A. W:der P:ipe

B. a-Ring'

C. Hook

• Tigh ten. u.)'ecYH ndh he.ad' eovee bolts to -the 'SpedHeod,

tor.ql!e !s~c :i:;xpipl.diedView). ..

••••••••• iii, •• 1II .. i; •••. Ii ~ ~ ~ I 10,,1 i i ,;. i. "I",,"' ••• ", ••••• ,"!.'''! ~ ~ .,., .. ii ~ •••• ~ ~ • _ ••••• !' ••• ~ .~,

;." •• ~ .,';'.l, ••• 1iI •• '.J.,';;, ," ••••••. 0 ~ •• ".'~.""':.''' ••• I. " •• , " •••• !II ~ ••••

Cfl.iir!' T~n$h:mer RemD,V;lf

.,~~moye the· 'ter'rsio;ner- mo\intilng .b6H:s 51nc;l tab 9U~

the chai.rot t€ f15i,(j:Il'~f " .. .

A. T enslon ¢r

B, Mount:iil g a.QI ts

(1)0' not tllfllL the engi",,,' w,lIli~."the-, 'cal1uli:af:t philin :teI1l5i;~er ii .r8flltl!l!I.I~. E ngllile d:aW!8{I:iI (:Qllild ni$ul t,

Chain' Tensi'oner Installa.rirm

.• LOQ~fl 'the lock scre~, ~rfd5crew ,oUf"aibout '2. Mm. .Drop the baH ~.ol1J'retair;!insw·mbIY onto thepushrod, ,.P·~lsh t~e PL!~ roc! ~p lnto tlire'! t:ensloner bQ~Y' he"lJ

. ve.rtlcally,- ' .

-Whe:n me ~LJjS:h rod ~S fA as 'fair-· as h w'ill g~l·turl"l ilr;,th-e

!Ioc:k; ~CN.w. .

1. Lock Screw '2. Push Rod

3. B.aWar1d Rebi'!'"ler Assembly

·4-. CHing -

S. Spring:(Teoskmer-j

. 0.' S"f'!'i ng {Sal'!' alii d Ret<Lj'f'ier}

ENGI'It-4~ 'fOp· ENP. 407 .,~~ $ur~th'~: O.riin~l is in place [n the. iensloner bodv,

.1 n qal!' tn e·~11.S loner t:6 tlliJe :¢"nU:1 kcas\i"

.Afle'r ifl$.t;~II~trl;l n of th C' tilli'l~iln}~f, unscrew the: lock 5cr~ about 2 mrn arrd then tight~i. Lt. \Ahth the boh I<}O~~; t~e stiff" '~pdriginside takes up .uw slick . .. autornatlcallv.

'Cams/l-a fr Chain Tensloher DisaSsembiv

-Remove the camshaft chain tansloner [see Cilrn~h<Lft

Ch<!,i:~1 T~.o.si.ot>1{\r Removal ):., .

• ;;I~emQv¢ tnt; spr'ing (Ball <i!l1d·R.etalner),

':Remove th~,~cm!'W lo,.eldng'the pl.l~l1: rod in iplac~.> -CareFully I:'il.!ll"~he push r;ocj out of' the' t;¢mioner·bodv.

Do noldror"'ih~ b~1 an1~{~ta.rire{a~5e·ffiibIY,

.Siid·i ·.d\~· ba~j and re~~iri~t ~5·5.f.mb~Y and :(110$: ~p;tlng

t,. emi'onet) ,0 Ff the-'ru'~h rod.' , .

Camshaft Chain Tens/one,- AS-!fembly

-.Slip the ·.$I):ring (Tensioned into the' push rod mad compressit down ftlll stroke:

.TtilFn irfthe'lock screw .

• prop :rhe . ball. and retainer as,s.e:mbly.,orito·the p1!l~h rod, and ~Lip, ~he. ~prfl'"!g {B,an aild Re:i~iri~r.l ClVll!r 'lh:e push rod,

••• lili. ii illilil'i Ii ii·i!o~". ~.ii~.! I'.'!'II •• It! 11.' , ••• i;1i. Ii iI·.iti ii i i •• ,. ii ••• iii i i iii •••• ~ !!'!!"""!!! "" •

• , ••• , •• ~r~! !!''!!I!I !'.J!II'!!. !III!II •• ' ... ~ •• 11111 ••• "" .. Iii oilii. ii .... ! ~. ;',,!I~. Li~",!, it!.!'I1 ••• il!l ••••. Ii.; ...... iIj.

.Catmha.tt Racket.Arrn R~mowJI

.R.emove the cyl.irnde~. head. cQv~r' [see Cy Ii nder Head

Cover;Reltiqvall): .

• Position 'tnect"nk~hah (cam is not pUih·tJh\> "v<!:I!/~) at

fofIQwi~g.. . .

OT'i;J(i1the' crankshaft counterclockwise 'wi'liie watchingthe movement of.tne #2 cylinder'sinlet val ... es,

'oWh en the val ves have J\lIs. din lshed "openi t1.g and cl 051 ng (.rnd'lo;i;ng ~ow~n'ward~ Jodrerurning u,pW,,;rds)",

OltHiri We: 'J;:r<lrnhhaft ~n ,the ·same: dlret:d(1fI uMilthe "2T"m<lJ~k on the alt~m~tor rotor 'i"s aligned with the n c!tc~{ in. in e in spec:tf;on wind ow in the a[ tern ator cover

(Compr;.e~.si.6n StrokeTIDC). ".

(~T~m ~~ecrank$ha'ft cl.oC:kwjse,ab~out 90?

.Remove the camshaft chain ·:t¢nston:er {$il"l~ 'Camshaft Chain Tensloner Removal) .

• Remove the camshaft t(lP cha.ii:'l guide. holts, and rc:move the guide,

,1'1 f.::;.

• Removethe qmsflu:ft Citp holts, ·.and; remove (he ·caps .an d! c-.arn~ha.ft;s.

OCov~r~h@·chah.'i turiHel with a clearcJ doth.

A. Camshaft Caps 6:. Carnshilfts

C. Rocker Arm s

ENGINE TQP END' ~9

.ADplyefl~ne(lilw theeamshaft c.Olp •

.checik crankshaft posu.ttion~o see that-the Number.: 2' piston b $till,~~ TDC,~i1d reatJ,jusUfnectm:ry, engage the ~3Jrnshafi: ch;l!i!:l w~i'I the: cams-haft sprockets .as shown,

A, Tilmlrl~ Mark !Not<h)

B. TDC M}"rk {f\ljljirnbeir 2. Pisroh)

.p~1:I the wni$i()h~i.de: (eXh<l!U5t ~j,[J~) 'Of the chain taut and i~l~ta;lil thechainon ~h~rsprocket.

QP'Cis.ition the ~'lJrish,af~sprQck.cts so that threttmin:g marks angn with the cy I h,dier he-ad! ~ask et sl;frfaceas shown.

1. Ex h a.ust CiHIl~11 aft Sp rm::ke. f 2, InllG;t Camsl1a'ft s.pi'[Jcket

$. No $l.a,ck

G(:OIJ nt the' camshaft ch ai n Pink pin "sa>. shown to v~ri'fy that :thesprQcket~ arc, posltioned correctlv. .~!1nall ,the(:.;.lm~h.aa Cil.p~ in the '6m"r-)~d IQcat:i~}\5 A3 Sh£jWT:[ rm,~h,e n!ll!l,r~ G~'~(lw. l.ecatlen numbers <Ire.

mawlked .en the each cap. . ,

.Pick th e - rocker arm. off the cylinder head; o,\jark the eaeh roder·armsorigil!lal rocation.

NOTE

oDo n qt drop' the I'f?qker arm in :'rt!e- chain ·tqrmlJl at th';j oytifJiJ.er h~ar;i.' .

camshaft lnst1J}la't:ion·

(inoluding Chain Timing Pr;o.cedure)

.Appl:y elll!l~nC' (li'l to '<lll cam p<lrt~. If the c3cllil:sll.ah.{s) and/or !t;.Y'iindc;f head are replaced with newones; .. ilpply .4 thtn coat of .a,.r;T!ol!ybd,enlu:lt1 JisulTidc grew,(- on t!j1,e' Ii1 ew I>.am, I).an su rf<J~s.

NO:rE

c TfUit e'xnoo;St· ·G8fflS/}Bft is Intra/led .EX mark onrf/rJ sprocket <IfId intf}t cifmsfrl}ft· is: IN marl<.

A., camshaft Sprocket B. Bolt

C Mark

'D. EX tatn5haft.

A, Ci.msnartCarps

E!. 'LocJt~on N~m,l\)ers

C. Gamsh a fts·

OThti cam! ~1it C~P$ are' ~l'lChined WI~~h.' thif cylilil.der· he'1lCI. ss, if a ~~p ii' ~,nmned' it! the wrong locatioin;,tJhe· 'c'am:iiMfl' my '5ei~~ ibeglly~e ,of 'jmiproper aU ciellirlillITIce

inthe bearings.' '.

e

.fir~t t'lght~n d(fwl1' the fw.o cilmshatt ,"'IP holh. '(Number 1 and Number '2 bolts inth,digure) e'v'enly' Uv ~Ga'tlhre C<In'lshHl.rt$ In pl<'lt;~". then to.r.qtH,~" .. altt:.Q.I't!'i,to the 'sp~~fit.a'tiQftt (~¢e Explod[!J Vtew) , foHQw.in.g Un': ~pEU)r fled tigh,teni n ill sequenee,

Cams.hafr and SprocketAsSembly Notes

.Th~ in.le} <l..nd exhaust sprochH, and the- i'nl.e~ and ej("n"u:st~Gam~h~fu an;'. identit';ll.

-!B'oth 5prd(KCb should.be ill~t;~lledwi!;h IIw i~dc ofth~ lfi.arlt fa:t~lIIg' ·the rightst:dlc onh(i engine" 'arrell for the exhau~.f sh ,tl'it: <').1 lgn th 1;:'£.1< rna rk an rrt:>~p rocket wi!i'! the. camshaft bolt hole an~l for ~n~e.t~ha.ft, alignl the IN Alar k on the- othe r sprocket wj til lt ~,hafl bolt ·n ole,

'Ap'pIV a locking a~ent to the. camshaft sprocket bolts and tiglH~iI'l the~ to the specifled totqueIsee E.xplodeJ

View),_ .

• [fanew (:annshafti~ to be U~Cd, apply", thin oo<l,t ofa tn61ybde n u IITli d i su Ifi de . grca'il'l (0 ,. ti:l~ earn ~Lfrf<li~e>,

A. EX Cilm~haf;! Be. IN Ca mshaft

C. Dmsl1aft Sprock@ts D~ IN and EX Marks

Camshaft Oil Clearance fnspflc'(;on

The ~twmal wear-is 'meaSured l,ist~g !plati~g~.· {p~~m ~:u~e);t, wh ~~h is i nserted i rilDthe clearance to:· be rneasu red., The p:I'!1stJg1l:geind k:~ tes the d carance by th.e am.Qunt it ls tQrnlpr~5s'ed and widened W~ie,ril the-parts are assernb led .

.cut5tr~p,5 of plasH.gage to.journal w~dt~·. P!ace'i1 wip on ,e<lch·oj()urnalpq,ral:lef to the ,oamll~att with the cam~h<lfr imt<llied ln rrhe correct pe,itl.Oti and 50 mat the pja~t.tgage wi.ll 01;! compreS~ed .q.etwceri lhe ~aUrl'liaJ and camshaft cap,

1, rb~tiigage~trlp

-In.tall the c;am~hift C;l!PS, tigi'ltelfli[l!l"the bol:g in the. c,orr:e:r:! ~~quMce to the slPcdfled torque (~eehp!I!.Hled Vie\v),

r.tciTI;::

~'Po' i?~t JU(l! .rt'j:? t:,~mfIJ.3t:r:. 'Wh'f'l ~he pJ(;$l~g~ri1f f,!l:

b~~whh t{!<ejiIil/!rpii- fl.nd r::qmsft_<8ft e8/;i, .

otRft"flf[lVe1.hei ·can:n:baf:t caps .aR~i'r.l;! ,dna, m,e<l$tire, iRe pta~~igJge widtn :M 'd'eie#nine '.the de;J,fJ'o"(l~ b~twe\iln :eOlc.h 1 ()Uft1:aI.,. 'll1d til e· -c,~trrf;l\.ilft cap, M easJr~ ~he, "Wide{t p.Qri.jG Ii. ("j:r: th e:';p I <l$;t;;i@M.;.

1\ rJa~;tig;{g~~\~j.dtb M~1~ u r,e~'~n'r

'*i¥ th~ c!eiif.;frilCe Thx.c:eed~ th¢·.,erv1c,::eiimH;;.eR1ate't'he ;.Cilslt;'lsha'fi ~wi~Md.~neWOl;1e and mea~lJr.e the ·dl':~f<!l'U;if:' ~gai:it.

'*!1f 'th'V (J~a&M )HJT f6o\';ii,it~ Q!I,i't .&t·tt!e.·I1fhli,Je.j'l:Wt1e;· f~e\:Y(111{j~r·he:<t,_(j Jlntr.·:

Cafll~lr!l!ft· BewfnllOH eiearamie;

St!tnd~rd.' 4·~3Q''''_'''O:·Qn ·,!'II,m

c:a_rrnf:J#ft ChaM G;#iqm, W:e,f"

~ 'Yjsti,').I~ If .~n'5r.£ti:thll toh~ ~r .b~Jhe ;gjifme\,

,.ir'jf~h-e .f!li~iM( '1i-" 4,a.mjg.e:a; \6i" .01'. J'$ tJ11"6sing. p~~c.:e:s',

f~pl~~{li\~·£ulcles., . . .

'1, B~'\i'bJte~

.1.rr@i")t Ch.;iri·(jo'iO(f ,3 .. ~·~~~iIi.r Ch,ar~, i5~, i:d~

~ ii i .. ..:., •••• '!''!'''!!'.!. ~ 1!., ~ ~! ~ !'!lHIi. iii i,.' •• ,"." ~ .". !I!!!!I OP.lliii, Ii i •· .. 01 •.•• , ••••••• r !',!! ••

CyUrni1e.r'Haad

... [0' ••••• '",., •• "'lIi,i'Ii .• ;, ••• III,.' ••• ! !'J11 iti ~if.1i ii ii ...... ii ....• , •• !')1 ~ PI •• i •••............. ,.~,!,!.! !I'.~'oIi

COmp(IJS8.J.QI:) Measureir.Jrint

Q R~fer tQ ,11,. 4"H i~ the ~se Man!.!~~ holing :ljfit~'YQh lo~i:ng .

• :"fhrqu,gh~y' ·......-atiri up::' '"tfi'e ,e{agi ~lii SQ th.;J;t"ceb :!line 01 l, 'be'W'~I~ tn;epMQ:n and 't{y:lio~~i wall \'Y'~I~ ~~~p seilJ .: qol1tp~essiOi1.;J,s it does {l.u:dl"lg normal; I'unning .

• ·Stop:fh" en$iM, ~rehio\!~e- thl.ls~~rk pr~.gil, and f1J€.l iao;k, 4nd' <lind,:!. ci.)mpre~sitlri ~uge {~P"''t;; iahdijlJfittl1ly hi to 'the ~'PJ.rkp,lug hole. ,~ .' . .

'I. Compres:oi'On Gauge: :570CllcZn :'L'.<\daple.r: 576"01 -1.22!l

3.. G<l~ktt;: 57001.1224

ca!o/~a;ft Cir[#,fv 'Wea;"(

'}l)[!1~ $f'-9h~i111'la~tJlI\ith" 'l, fq-rp;!'qf ~jJbOllt Xkg.'in'1iQm.e

"t (- . "" -~. , . . .-. . -: ,- -::: . - .' - :,. .. ~ .

'«nJ~rt~r:~. a~,di ~m~:a~u:r~'a ·~~-Hirilk;.I;~~.~~~M; Si t)qi ·the: ~ha~n' • . ~<Joy. w~qr .unevel1l:y;. -t~ik~,. r:neaStlretnient~ at~".erjl

p'!ace;~, '

.. ~;ff ~anymea~~rem~l'lt e;;;c.eeJ·~ thee se~\I'k-e IllTIrt, :rep.I'~l.(;;e

the G..hait'i.. ~

e.~n:i$tliin. eih,ariil'2fl4inlt Unglli!

" ~ '"{". ,. ~ . ~

Stalililllr.d: 121:J:r",:, triA l'i1~.

'SerV'ite iLlm tt,'l28Jl' Inl'll.

Ch~ili1:·b.e~bi MQ'a'lir~IJ!.103i.hf

.U5~J~ithtl:J?:rl~r ,tl)QP~(!. r(ll~:t&th,~ Mgip'eov~~i' Wi.th_l~,he , thl'pUl~ ,f~n~(·orFtJ ~[f~~}~e ';:O~Pf~~I~Il,<~uge$~'ps ~Ji$I~l'iIg; th,e, w,!lJi pr~S~~O~:l\ IS' the highest, 'roo:dH'Ig' obtaI!)'

able~ . -" ,

":iJRep.e;i,jj the.' !)\Ie:;usu~emenrior the. ot~e~ '6tJtbi.lilri

ey:ijnd¥I';C~rill\i*~~f9.~ ,(tlJ~~I~ i=&~~1 9.(10,..:0 1500 ~Pa, 410'~/ll)<i':b('P:1fr! I, 61IJ,·i0~' '15<3 ikg!' G'm~": "142. ''':'\21 B IPM I

:. ~~.·i~<. .. ~ .. , > . ;~- .I!: ; ._ ... _ ~~

*M';, t;yJ(nd}jf c:~tJI!prf~~~'(in) 1St hi:)~h:¢f Ihtut ht:c' stap~~~

:V1:l:liLH~/Cb~l(;ktJtne~Qfl:ow:in:Ji'. ' '. _ . '

'-1., ;Ca.~b OR~~rr:.:fI)J'iP. 0'1\1 tf:i e. p;[.ston o.rd;lie ~ i'~t'tltlIr ~!¥ad' a,rnd

:t~y-I fn'Jert tJ;cad., '

- ;"'Ie,,ah, ,Af' ,jihy c.ar8ml, 1_QrJ th~ pl:~r~in hml,d a>rig Gyli ~H;Le,~];'~!.l

,~:. ,t;;vl~rrder 'hti~: ,gp,~'~e.t,/@yllri'~et- ilia:~:e~ :~.>k~r :- 'ti~c #qly ,th¢:"prtir!.e:r ~s~ket;: fqf '~'~c;¥Jtn;a~~J\~:;t;d,fJ;ri,~ ,'[~a5e': . T~I¢ ~&,C!: qf g¥~ e,ts' <:if 'rh~ i:r¢.o;t(~~~'t J.bJ:!~kjj'~}~ . wi:I.I:.6h~~~: thct:fc,9 mfir,e~~iti,n,

3, ¥4[ye" stem q[I·~gi.lJ ~ Ofr1(fr. bt'9.f:I:, rirm _', ~PI(l, C~rbdlJ " 'a~((Jm.:tlJatLu'r:i' "in ~iw t~!i1~~tI!lfrO~)' c~,~,tnh'<!-r:s" ,'TI'ay he e~qJ~d -~y' damage-d ",a~,v~ ,~item o~ I. ,?~\iI:S' 'il1~lo.r. "d:a~', ,aged pi.st~n 9tt r~'tIigs, Tf'iis:r:n'fi be. inoi'(:.iJt~h'{Whh~

exh~Utst smoke," , '

'~'I f CJyUit~dc&t:npri~~i,~n" i~' 'I Q~pr.tb~tlI:~he ':~~r¥ ~qllln m iJ~ e~~cR,lilJer f6~1 tfw.j ng;:

,1,< G~~ IMkag'e,',.'aroUri'd the,: '~'.lr'itii4~r heaq' ~ !l'erJi¢:e,fh~

• ~ .. _ '_' ." ., .-.-:<. t ,." .." . -...

~d8irn;tJl~' 'gBl*el' ~N;~'J)M(;.~, )tb~ ,.c¥lil'l~* h,(M~o/

~tarp,· ,

::2" t@ ~\di't j,OI1l ,o'f< the -\"'il\i\(~':seat ling"

-- ""-_ t : . .:. - . '-::- - - ",

.3:" Val·v.e ctear,a,ti1c:e - 'iL';Jc' ",~J"e ,r,eql!J~fe!5. a.~· wt;lus:ualiy

aJIflJ:s~n)~I)~ 10 G;~tacL~'1 p,tQP:erClte:aif<!nq~" J;h~'- ... :alr~£ rIT~ i I"'€ ~Nr.d, . ~.,,' Mt !l;''af'n~coii' 'I'et~~ -;

,,~ \"" """ ",,<>,"IiJ'I_ ,',' ,,<,,J 1>' "P- ' Yt

*"rf:s'lon'l~·¥lr'1#~;_"i;: le,,(in¥e;; ~i~rQIiI \~i;';JJ~ ~ '~ ... rll.:ltol~ rifl~:p:i,si;.9n 'lfu~k·;g,i:oft\i~) ,

cYllnaelllfiiJaJI ;Rrem6vaf

.;Rernuve; thtddri:6Wit1g_IMrt5~ , , , ,

F,a i rillg fsoo F'a'i/~g,'R{lnl®\ia I i i1l'F~afl;1e, &J~ pt:er1 Cj;)uJOln~,.I~r:;at~ir1lg J~~e,,,GbQiiL:[)e .Drai~,ing' -rn dbolin~g S'Y,>t<>n:l !;,h~Pt~r)

fiJi 't:M(k:',b~~, Py~l' TaJiJik~~;~oJl/¥1 lh l\f(j.1 s.:y~~~m ,eh4pt;t'ii)

B$.~H<$jjC!t htie, R~~:t~l!c:i~, ~}~fatQ~ FJ(n ,~c'mp.va{ lin

. ',C~()lini §~Y~l'$m:chiDtekl .f\'Iufllier(M.ejl1'i'l:r;fle'r-:R~mQ~al} :C~mshijtt';Qha~'~ Tin~1DAl~t ,"

t:eh~ RJ~rt:' E,~ gi'Q$Bt~~,~.t w<~tb, ;r~~ i~ti?nQ()iJf

,. R~lril'O'lle: the th rmostst hou,l n:g_ bohs, ~aJi.d (r~e the

hOll~ft'lg. ' '

"Rem p,'(!,e JJ) e-.G\.yll t'I der; bll<!d ~cpV~lr, '.'Rfi1bplie, die, oan'::ts;hafL-

" •. g:ehb~'te: th~ 'h~ijrr tOl'mitili(t 2h;~Jo' w{~~ bQh :t~DR,!3th ,i1t'nd t'<ilke l!h'fiiAiB!l~l)ff-a]l:~<Wrr,n~ef}jtla:d.

,'fu,ll!th~ 'frqnr.. 'citli}hf!ifL,~~ifii1: gut~e, ~~ff tAe,:~y!ljig~'~f he;.,~'~

~~i tw

", ~. :'"

"

"

t, <;VJiOd~~ :MI4<id: sbi~,l>,(¢fl; m!l1'} ~:2. '(y.I{n(1ed:Je~d ~oltin~~: min.)

:J': ;c,iw ('ri~fQi\i~:~h:ltlLl ~]j'.l'e;,r)

" R'ern clVe'J:he Qfrlilw t1 bi)I!~J @ ,bgh.

-.;Se:fQr~ H;:mo,v:irrg the: cyl:fo~(%r tJ·cad",ho,l:d .thc'CarlbM~:~o'r: to °tb e ~iF ,j'1 ~it(lei' du\::;;f wH'~ ,(j!, '~r(j:ngs,",(

"_I?'~r~'qfl< t~~::'i'yJtJ'{J.;lf hej-'~J ~rtd ref1r6.\I~:>t,l¥il c.y.~iri'der lfea~ 'gj.~ k.e(,

'fJ#ltr1a8r.'hi~fj_ IfistaNfifiQf) Notes"

;;"W1~r).' '~t;!~b~jii!'lgo',the ~¥rrnder' head; ~,y.!Ulrdul, or tJMie

hIJQJti_t1git~in~,' ,

6R:ei~J~t,e J;,he' ,cyJLti{f~r h--e<).d ~\ket wrt,~ a "~ejW; :'fme .. i0ngh~~rt JM!\ \sy:rln;Q~~r'hJdd p.6ftd¢8) ~I[JB· (if!6J {,:r,th~ ~p~clif:ii.d~riJH~ XSf'ec~xpldQetl vJ'~W)~

oAfter qy!Jlnder heatli ~mta'III(ltlf,Jt1, [nstall !.h~ front (dm~lilaft"'~J1ai:n gU'Wea~ shown.

1" tillau to. Guide 2. No SI1lJCk

3 .. Fa heal'

dTightilnfbe :re;lw ~~'m~haft ehaln guiid.\) bolt (!lIPllcrjo 1'1'

tn~~pedfjed torque' (~'ee Explodc~ Vie\l,o} .

01'igh tell th e oi ~ hose 15,11'1 jo bQI t 10 the speclfledtorq UI:l (see Ex.pit)ded View),

CyNnd.er-Head Dis8ssembly ant/Assembly'

rV~lve M~cfl.a'fJi$m RemQVal:afu) Installation} .U'5E v;thr;e spri~g' compresser <Ii~s.embly(speoii"l H.ol)· ~6 pre~5" dow!l the va l'I'e s'p!'i ng retal ncr, and remove 'the 5pHt keepers,

I. Valve Sp rill~.Comprc$~Qr Asscmbl y.: 57001 . .]41i

2. Adapter: :57001:1202 .

.iH('iIt th e area arou n~ the ". .... 1 \(e gu id e to abcu t 120 - Ho"c {24.S. "". 30:tF).;.andl hi'imrner ·lugh~I.'1 Oil va I ve , guide .<JiIJlbOf {speciaJI tool} to r~tl1ovo thC),gulde from the top of t.ne head.

Val..,!;! Guide Remowal

1. Valve GlJiYf~ A thor: 5.7901-1203

.V,,"~~'e Guide lnstatlatlon:

~oAp,piY cl I 10 th eva I ve gu iide ottWr ~u rf<l.Qe· before

i ril$t<111 at-~o t'1.

0Ht\;ll the area aroundthe valve g~h;le'hole to abmJ(12!O -;"'''.15UoC {24S ":""30I"F}. . .

COfive.:he "'~IV'e' g~l.de ~n from the t-OR ofthe.ihta:d y~in;g

the val"'!!! guidle arbor, The. t.lal'ige·,~wps t:me gyfde from

goiHg tn tM~'M, .

olf!faITI the vali".!) guidc"f"Wi.[h a .. vi1llli-egi:Jide· reamer (s;pecfal to Clt)cv~n Hi' tihe oil gu: idle is re-tis~di.

L Villve Gtl'ide. 'R~amer': 57001" n04· .Var:ve' I r:i5t<ll~ation.

CClhe&k to ~oo that the valve move, ~moZYilh~y up, and down In thie.gufde.,

(:Check tosee that the valv,e. sean, properly in .the tIlalve seat .. If lit doe, net, rep a ~r tnE;e",aIVj) ~ea:t.; .

L V~I\'~ Stem :2, Spring Seat 3.0HSeal

:4. ~ n ner ?pri I'Ig $. QiLJte.r 51' ring

Ii V~~ye Spr"ing ~et,tiner 7. S pril[lg .sf::<l!t

8 .. CIQ~ed EnciLCQH 9\. SpHi: Kee'p,er

.QApp~y a thin coat of molybdenum clistllfid,e engine ,a~se:r:ribly gn~~~e to. ~he valve~tem !bi.fol'€_ valve instailla.t!iofl ;

bi3(l_scLire' tcl'ih5t<lU the ~111I!["~er ~nt;l outer ~r~i~~.se~h under th 0 ~ nlner 11 rid.;Ol,ltC"( 'sPFillg;~.

olnstal] the ~pring~ so that the··do5.ed ccllehd ,~ facing

'~w:ar"dlthe valve' seat tdo~nwards)., .

Cylinder He.a.d Waip

-Lay a ~tr<\i ~1i1 tM ge. ~~r..{)SiS th e l'9w~r sJ,J!ti;('ie of th e~ lie~d ilt ·s,e.veral, different polnt;~·. and measure' warp bY in sert in i! iii thick f1es;"gJuge bctl,/eeln . ~~resiraJigf;Jtedge'

and tne head, .. .

'1df warp exceeds die' ser .. lee ~irnitJ repair the maling

·s~rJa.Ge. Rc,pl.ace Ih~ cyHndel' ~ead if the. mating

s,tnface ·is l!Jadly ,{JaJmJlI~ed,

'Cvlinder IHead w'arp Service bimit:

Cy/lnder Head C!eanlng'

-Before i;wta~i~lion, below th,~ oil pfl$5age~ Glean w'iOO cor p ressed alr,

'4-8 EI\IGI.N:E TOP ·END.

• Mea$·l.J.tethfi N u ifI'ilb·w 1_c;y.H nderexhausr ya.l"Ye~ i rI ihfo 'Same mapner"

-Turn' the ~ran!<.$'ha:f't· V~OQI:OlJi~(~tdo..;;.~ .. ffs~ .l;.intii theiirlSipe c ~iorr 'Wio'dQw projectlon 'on 'th,@ att~l'in<l:tor CO .. '@I' .a~ig~~ wrth ~he',2T mark. (In the,~it'~(:na,~()t rotor. r ·'MOa$i;lt.e· tl!e Numb"er- 2 cyli.nder'5 (IYlet and exhaust va{ve. clearances jn . the same t'r!il'rlner as {tit, the, ~nlYll~(:r

1 .~ylind@r.. .

. '1 , . Exhaust Valves ,~, {~l,etV.alves

3-, NU'miber 2 Cyl'i.ndcr 4;, N urn bet lcyl'i ~ d1;r

/Q\ .Rr.·.·.······· <.;:::::1<", . //~

1>

-.H tbeva:lv!l clearance i~: lr'H:,orrlll'cl, U'Lf 'o'al'l'(d:leataoce

must- be adju.~.ted,· '. . .

VaitV6' d!ear<:tnce '1l,djutJtmeftt

o'Whel;l adj4~.ti;ijg tl1~ e;X~a_l!,s:t ~al:ve~r:eara(lce~remQye, ~hc" J'oaowi~g_p.a.rts '[Dill sert th¢ Vil.llJ~ a!ihl_5:.rer (,speCial'

~ool.l. .' .

Rilidii:l'i:or and R!ldia,t;or fan M!;Itor Right and len. rz,n!it.1~ (j,mc'ket5 a~J,or1g

'wifh Ignition Cbilis .

:.-L(j(J~ej1 'th'~ valvtl·;idjj),j~thlg screw Locknut :by I,Isl,ng the

y,ilve a~juste:r' (specjial ,tOol),. ..

,-I nser t the. Itdc~n~e%· gaUlge~ (~pedal ):Q~t;·. .id j clis't" gal:.l:ge) 'betwileil'i the cam lobe, ani! t~emckef arm .

·.r!-lm the. adtu:s~jriig'scre\:V! willi th~ gauge'.l:Ir'!;g$ ilf11h6"

clearance. . . . ..' ~

1. Fdr Inlet' Valve Adjustment

2, Fjlt EXh~u~t Yalve AdJ~~tqJ¢nt'

-Apply oll to. the. nut 5ea:ting; surface,'

'.l'fgbtei'i ~he h)ckh.ut· bY the ... a,lveadj!Ust,ertemp.or·arily~ .,.tigl'i'~ei;ithe jo~knut: to ,the, .spe~ltled torque (I? ~

Force) wMle .pr':ev~titf~g t!'ll) adiu~1jilg ~(;I'ew from . tlJ rfi iog witht.h.e .jocktl)j ~ by ~·~~rlg.ap Llsh,pull oga,uge.

'EN~ I N..E:·fQ.P BN D :4·9

.R!ifh·SJ;ai( theJ,e:fllQliJed;l'a:rt~. .

.. j::'~H ~bi§.emgine. wfth<.eJo~aot 'ilod' 'bli):OO a,lr' hi·the(;ooii·t:1'g~.

}h~~m (see 0dolfng .sy)t~m cha~it0r)", v, .

W,~.p~~~ Jr~sp8!;ti~(f .. .

·.;Rif~l1'Q\ .. e ;tbe l'fIJ".~· ~(:~'ll'J::V[ihtl(l!!r' He~d< D;l~l~~r(jtp;ly< anti

A~~1lh')bly) .. lICi:)aJ'~liVS,~;i!'t.\Vitfi·i!i;!thiTril~C~.);ly~,e;.

·.r~~b~the;",itlli¢ ·3nro';tti<;. gl) ide. . .

.R6t:t:tt}. :i:h:G;""~I:~~ '$@tri~t/J:he. ~~,at wi~h-\!.:I:a,p,pitJ~ ,!Qol' . • ~~i th~ \iJI\I(j'-(Idn;'j~d\;:heC'k the"~.eatirJli! pailern'un.·-tl1J·e

~ . ... ~. , ... ~.. - - , - { .. ', ~ ~ ~.. , .

vJlf,,·t;l 'heai;f ft m!1~t~be ·~hti' corr.ec-t'widl'h' and even .alr

th'C! way. !lm"rr~.

y;tj~ii~ ~.tltliI'SM_rfa'_~e W.i~th·

IllIilet· OJl~~.'O 1tJ1Iri'

E~~~~5~ O~~',""l;O)hm

No;riE .

:fJniJt Llabl8.:sr:nn and QJ.li(Je,r:1!Mib~· iil·.gl/J.l)il c.f!J/}(Jitirm or

tills .Ch;H~k wil1t)(}t hlJ vi/itt .

iHf i*,'9' ~i!:Ne;...sealtlr\g 'p'ri;t.t'e;m !~ n'tll 'n>l:re..;tl eepillit l:h,~. ~<eit' l'See ).(;dJo'.e:=shat R~j;l·"ir).,

... ~ ~~, .. . ' "' ~

1. ViI:I've,

>2. V<iciveS~at

,~, .. ~~.aiHlgAtt:a·b'.lit%:id~ ::cl'~<lmeter>:.

:4,. .s~t:hrg,.!\ir~'(\';Wjthij

1 •

Good

100 Wide

o

Uneven

.M(la~ute .the.o!;usidt: dl.lIm:e,te..r (If the 'y.iltirl!l pjnei'll (In

1:he "':all'(~e,at, .. . .

'-,I!lif th,e {Jul$i.de clfiltneter (If the va!\'~ sllarin~ pauern is" too I.arge'or iQ'o~man, repail! the ~eat- ($fte VaIY~ 5ea~ R~p.air).

Valve SAJ.a!tl nu suriilce Outsi.dll Diamet!lr

'!mlilet iE)!:hal.l$t

22.91- 2~.1l 11I'I:1n 20,3 ~ 20;S I1IJm

VaJw.Seat Repair

.clean thll ~'i'lind~r head tl"l:O(Du:ghlly ($ee: Cylinder Head

Uea!liogi. . .,

·.U~e the following pro~edure and. too~s to repalr the val ve S~<lt.

U:l;~d V!!lve Seat CtiJtllU

45~' - ql241.!)" 57:DIH"n 13:

IN 3~!;l~ ~!,l..o '51001·1'118

:61 ;5" -¢22·.o 5'7001·11207

45~: - ~4;5 51,001-1;13:

EX 3Zo, - ¢~2.0 57001·1206

: 67 . .5" - ¢22.G 510D1"12{)7

l);sed:H!Zlh:ler and Ba,r Holder -1J5

~r

51001·1208 57001·112B

*Ifthe m ~ilyf,~l;tu rer's. i,,·,tr!W¢tk'.F1' are-hot ;;lvaiJijl;rle, .use

ihdQl'low i ngp'r"ycetj'u re, '.

ENGIINE TOP END 4-1'7

S![Iat· Cu,ti;l!rOpijratin 1I C.Ellle:

T .. This valve seat cutter ls developed to grind the v alveseat-for repa.ir, Therefore·rjle ,CLJnc~' mliu notbe used foJ' other plIJrpos.es, than sear repOli!',

2. ,ott hot drop or ,hock.lhe·v,il\!'.e,H!Jc.t cutter, qf tbed~amonqi rZirtic~li5 mOlY filH off,

3. ·0.0 not, fail! -to ~pply engine oil :tQ:.th~ v'~Ne S~<lt wtt~r before grinding the s~a1! s.~:rfac:e. AI~Q w1l:s;_h off groun·d. particles stickih$ to theeutter with w.a"Sh i~g oil.

INon

O[)D not U$~ a wire' brush to~o ve thB meMI pfil"tk/~ tram .me cutte.... It will take arf the diamond P:9rtilitffS.,

4. S!!UirT~ fhe. val"e,seat cmtiGf holder is positio.n, ope-~w' the. iJ.ltt~r in tine, nlnd. Do rilota,pplcy .too

much' force to the diaIDol"lid porti.6n, /

NOTE

oPrior W grindif1:fJ; ,apply. '~ngifle 011 ,to the cutrer and during, the oper.~:r/on,. wasil off IiOY gf01Jfld-.rUJ"ttcles srick Ing fa tbt!!. wirer with wilSflfng oil_

1. Gutter

1. O.mer 'Holder 3. Bar

5, After- use, wash Lt wil.h \V~~hit1lg oil ;'II'i1d apply thjn,

laye:r ofc,n~ine 0 i I befort) storTn:g·. , ..

Marks,.Starn pod on"1lh QC~tte'r;

The: m~t~;5 s.tatlJl:p,ed. .o~' the b;iCf<, of the .. ' cut!.'!pl" ~e,PJ~serit the following.

6"0" ••• ' •••..... , CUI.~er.~ngre,

31 Sq;, . " . ' ... '." Oul.er diamerer of cutter

~-

I

p.

((''-''-----"1

I. Ld~lpe~

2, Valve $e;lr.

ENGINE JOIP END 4,19

li;1easlJrirtg V1th';e-fO Gw'dfJ Cleata,hot;, (Wobble Method)

If 11 small bore gilUg~ isnot.available, ~ns~eci the varve g!lj'ldB wear by mcasU!dn.g the valve to valve guide, dearr:antle with~he wobble method, ii1i' indlcated. beno:w •

• 1 nserra new \I;ll\q;: i nto the gt;rid_t; 1l,g.1i nsr th e stem per" p.e!lldkLl!<llt to ltas closeas possfble to If)e ,cyHllIder ne;l!d mating sJirfacc.

-Move the: ~teiii back,and f9rt~ tomeasure \illlv'e)va.lvc

gu'ide -Cle'aro:nte. ' , " .

• Repeat the measuremern in, a' ·dirE;l;;;tion at ,a right ,anglle

to thdim, '

".I f r.hcC read rng exceed. th e. serv fee Hmi t, rep'l ;!,(;';l the g:uide .•

i'!\IOTE

'(/The reqding IS not tictti81ItaiVlfJ'/lV-liiW;l' ,guide iJl~\9rpniH!

bectftrse N~e m~$Uffn!ipOi-nt' is's/)ol(e toe guiQi:. '

Inl.eli OJJ3-CUOmrn 0.24 mm

ti-d"musT 0.0"8 - o. 15 mm '0;29, mm

4~20 EN,GINE. TOP I!:N:O

( START _)

I

t

MilChilii~r~ dye on scat

1001 Vernier Catiper

rurpQ~c:thet k5eat,O,D~ ''"''''' ... I----~~~~---_~

ag,;f~M spec.

+

t

I TO(lhmii~1 I

,

Toot Il'urpo,,:

."15° Gutter

make $~at·i n g JJ.ea 5(1lj}(};Vn . <! nd 'TOll n d

t

Tool:

P~rpn~e':

, '

45o.0Jtter

~ncrew~e G.D. Qf seat Jrea to spec,

ill-ka,sYru Seating Ama -0,0,

0K I

' ,

_t

rvl~tR lnist 's 'Qy.e on seat

,I

I

'.

Tuol;:

Purpose:

3_2°Cuucr

reduce 9, D.of ,eal area tospec,

TOQI; PW~p(l)e;

Vemr:erCal i per .ch (lCkSlOOt 'IN id th <lgJins.u '1 p 8'4 .

•

I loo ll<!rF<Ow ~

t

'.

Ok

I

Tool:

Purpose:

45~ Cuner

in(r~!1iS~ 'width of )E!<i!t area. beyO<t"Jd spec, to increase. OJ).

I Tqo'wide. 11

_,

Ma;thini~~'s p ye uti. se at

67.5" ,Griir;i,d

fool: 1:\irp9!l<M

"67.5° Cutter reduce ~eat width to spec,

Toels: Valve lapper) 'grunding

compound ,

F\iirpQ5~; p~Hec;tly nliltt:!l1i va.l\ie .~nd~(lat ~rea;chi!ck valve head for dam<Jige

I

( F~N ISHED )

t

••••••••• ".L ••••• , ••••• ,i ••.... , •••• 'j!, i •• .,.,. a a a Iii ... ~. ill .'Ii. iI i~' i ••.• I~ I~ •• ! f!'tL! •• ! !!!! !,"!'!! ~ !!,I~

•• J •••••• iI ,!!h.!.! ,!.!.!, !'I! ""'!!.! o!!'~'. ~ "'., •••••• ;~ •• ,~ .J"' •••• , ~,. ~ •• L., •••• ,., ••• ~ .' •••• '. ~ •• I."!!

Cvlinder Rf!m(}ltaj

.;Relno",(': the follow[ng ,parts bcforeeylind.er a nd.plston r(,;I119"'o'<110

PO$iti8n th.e crraflkshaft at G6t:npreissi~1l '~t:r;Qk.e. T[)~ for the NrU!rnber"2 p:1~t~in) <Ilr1~ then lJ~rn !hc G.lockwi5~ about 90",

iFai ring

lFu~~ Tank

Coolan t "0 r1:lLn in,!,!

Radiator

Muffler

C;'IrbUrc'[9r {PuHI the re;i;rwMd) Cilrnls.~'1::1fU:::h ai n Tell"siori er

RBjl:f c.a!~rshrilft.Ch~!ln '~Mide SoJt (Upper) Cy firlr:ler H e.'!{H;:ove~

Cy I ~"n.d~'r" Head

.Rernolle·l:he water pipe mcuntlng boltarrdtake.offthe

pu.pe tmm the warer pllllr'lp.. .

• Remove: ~he o:;ylinder, ·;jIlClid then r'l>r!no1i'e.tlh .. Water Ihor.e ffo;m lh~ cy I i r;]rder.

1. WatN' Pil.'le.

2. MOJjntingSxilt }, W<l!.te-t Ho~'e

4, Mounti,hg BQI'n~

~:

ENGJ'NE TOP END ,4F21

Piston Removal

.R.en.1o\'.~ Ih~ pi'S.Will pin ~ri1Jilp rir1g:fru;n1I the·m.mul.le. of· each pis t6f1 .

oBc sure to plaice a' clean dO.th lil'ld~:r the 'piston to prevent the ~nap Tin~ from fa!lI:ing lnto thecrankcase.

A, Sh.ap Ring

.Remove the pis-ton by 'p~~5h~ng~I:8 p;ist.(lil P~!l out the .slde ·that the' ~nlr",p ring was' removed, U~e 'pi:,t,on pi~ puilier assemihly (weei",[ Jool), if the pi[ll ~s.-ti~mt.

Cvlih~r Ihstal/{itioll Notes

.Ap~~y a erngiin,<l oil 10 t!I;~ cvlirid~.rbor~~1 pi~tori rings, and plston skirt,

.Re:p.I."ce the) cyU~ililqicr Ib~segaskh wi"th <I. r1If';W one ..

• Snip,pi)tQn base ,(~ped01l!I ~,?olJ a:; shown it nre,:;:,essa:~y to hold 'IPi.stol1 level.

4·22 'ENGIINE fOP ENO

.Wlh(llrn the ,tor, seC;.onu and oll rin!lsfor C;<lrM\;iHy ~~r~d. the. whCl.goperli nil w~th y.QLJ rthumb s.and die:t'i l1~m yp' <j,ti! the. Glp'p.O!l it: side :Qf the ring t(} ram(,)'I~i it.

P/sion Installation Not.e

.ihe.ilirrow on lhe·l.o~ of the plston must pcint toward

front. ..

EL Piston

if\Vm,en inst4:mnil"il pHto.n p.il'ls·nap' rji]~J compress it only ~1l.mBh~o iri5t;il111 !Ianel no more;

ClOp !lot reu:~e. snap ring". ~n r"mQII"~1 well[li'.em~ and ddorm5,' 'tliu!!i!!>n~y Iloul~d filII Qluaric! $'cQr, the cyii:lldler wan •

• P6$lt~olrr Me&! pHtcth ring ~ (hilt the o:penihg in the top rini ~nd pil rIng: st,ool rails·.are f"'t-jng'fowafd!~, and t~ie; second Fingi'ild 'oll r~ng exp",]nd'G:F'op(mi~(g~ f~cc the rear. Tl'ne: 'open,ing~ of ti?~ o~1 ril'ig steel ralls ml:ls't bG about 3(1 ~4(}"' 'Of ang~e fromthe openlagof the 'top ring,

4

~. Top Ring·

2., Second R·ing

3.. Oil Rhrng Steel R,lili "t m Ring EiJiJandler

5. Arrow Mark '6, Snap Ring 7. Pi~ton Pin

. 0!nstall . the -ol I ri ~~g Ill'!) P er and lower steel rai I s; Th~n; i s rIO LIP or OOWN to the rails. They C1JJfl be ip~l,d!",d· either ""'14 y.

Piston Ring, PisJon PUny Groove Wear

~IC hee k fOr u n.e\'·einl gr.:)ov~ wear by inspect i n"" ther~lrng

~ ... I • - , 1::;1

seaung.

*T!lle rlil'lg~~~'mlld fit p~rfe';I.ly p,ha1lhll to t~egrobve

surface s. 1 f not, the pl~IOM' must I:Hl. repla~el\:L •

• W~th the p i·~t()nrl hg; hi th0ir grooves, make several ro('asuremel'lr~ with:;l:. thl{;kne5~ gaL1gc to determine

piaton rin!JjgroQve clearance. .

LPi~to!n, Rin!! GI~OQlIe Cleanm.ci!

Stanthud 0.02 .~. O.Q6mm

~ ... ic!l Umi,~ (),te mm

E:NG1NE TOP END 4·23

1. Pi.torl Ring

2. G.ap

. Cylinder Inside DkiJmeter

-Since there h a difference In.cylinder wear i:rl different .d~redi(m'. take <I. side-to-side and a front-to-back mea'S~renie'llt at NC;:~ of tllle 3 19~ .. ti{')j]:s (~Qtalof ,ii

measurements] shown ln nnefigllre. .

j\H c:ny [If the cyIRIl(:j'e;t tnslde dlatJ'!leter m'flasJur!llt'rie1tlt~ exceedsthe .:se,vic.e l1'imh .• the 'c~flil"ldl}[ wi,lI n;l!ve to be boredto o!llcrsjze.apd theil honed,

A. Thtckness Gatlgc

Piston Ring End Gap

• F'1<lee the .p i SVl!ll r i!lJg i I1iside th e c.y Ii n8.er, using the pl~tQI1i to ~oc;;tte the ri~g s.qll.arely irl place: .. Se~ i~ ~dose. to the bottom of the rylh1:der, whf);rCGvllil1idel' wear ls'

low, ,. .

.M~asure· t~e g.<I!P betwe.¢n 1h,eends ~f the ring with a .

. rhiic:;ikn~ss g«~ ge,' .

Top,.s~ol1dj Oil

SUUii.&rdl I)~J) - OAli.rnm t),2~ 0'.8 mm

SetllicelLfmit 0.80 JhiJtl 1.1 mm

alm'sUll ({i'~ &.1:a~Q;:q:;I '~t~f !'IcifiJO:riW, Q~ ifl;EI ~r,(i~', ,caidd ~al'i1la ~d ~onta~t :'ol(i~.h ,'lh~ V<l:.I1){Ui!i, <;Idj!Jsti I'i~, ,;*t'~'$;,"ffS~Lt)'!~' f~, 'i'U''1'!I'tI~~f~ i~~i,61r ¢<irrt~!tjQo.,

••• , • .,.~. "," ",".,.!!!! !"I 1,1 .'i ~ _tl,ii i i" .,.,_ "L" •• ~ !'I"!II'! ·iIi· ·.L~ iii ili •• , •••• , ••.••••• 0' ••

•• ~ .......• ' •••• "., •• ! !.!'! ..... 1'1' •• L. ~.'I ••• ilii'~".,. Ii ••••••• ~.! .'!!'!!! ~ •• ''''II'!!. j(iliilllli,i Ii iii" ••• ' •.••• OJ

.(!At.! ffler:RftmOVil"

,.Lo0~~11 thtl· mlfffle~' damp' b oHunti.l . the' dampmrM

Jree'!iY'f.itll·the rilufn~t;' , ,

~'Reiuovt=l th,~ 'mil ff~er : fnQu'riti ng boit amd nu to'1:t Bhf rear

f:tiQJ,pet :b~~,ck et~ll,tldtah 6f(~a(h mu'mei~, ,

• g,epej'r tfre, ~~me p.tQqedu,r~ on ,the: dJn ~r sid!i'Of ~Ibe, Vt!hi,de,.

-Tale, qff each in~ffl~r-;

• ReIl1iQ\{J!"fhe fQ I ~\}Wi.nIH)arts,

Low~ Pairing,(.~.e FII'oi.m~,c,l1a'Ptetj lC9W~ FaJ.r;ir1g $"ttly

E.::d'i>litlst P'i pe HQtder.s,

Split. K~e.per,~' .. , ,

,~N II. !I~ee)( 1l'\ltM, plpfl:~b'w~rt:l {hf (fr:O;f:i~L .,R:e;m!p~e ~h#, ex hil:ti~,f p ,pe ,h Oh.'lllfS ,a~dga*ets,

'o.!3e C1i1",ful l'Iot, to touch the ,radiatodilfll. 'durinll W01l~'

'TheA~~nure Q"si~¥ de[Qrmm. '

Muffler In~tl)j'i;Mjl)n

Q1R:MIl.r to f~'e"B"l:!ie' Manual ndtil:ig the ,foi.l,owi Ilg"

o.Th,e :leH-rniuid.rri~ffl~d'las aA ,J.: ti!'l<'l!rk and ~he"~'ghhh.1t(M trluHler'a Rn:.a~k; Be careful not,tQ mfx t~e()1llip.

A L'Mark

Clutch

Table of Contents

CLUTCH ·5-'

Specific.ati:ons ;, ..• ' ;, .. , . , , " , , .. , , ... , . , , . , ... , , . , . , .. , , .. , , . , , .

Exploded View. "' , , , ". 0 0 • '. ~ ••••• , '00' 00.0 00 5·-2

.S·pecm al Too hi! I .~ I • ,; Ii • • ~ ,~ • • 1m! • ~ • ~ ! iI Ii Ii i i ~ • • • " • • ~ • • ! -t' I ~ iI '1, Ii iI " •

~Sea .ant " ~ , ! ! ! ~ " ! • Ii I ••• " ••• " ••• !! , ! ! I t I ~ ~ i • Ii ••• III I .• ! + ... I I II iii

Clutch 0 0 0 0 0 0 , 0 •• , , , , , 0 0 0 0 0 0 0 0 0 0 ••• , , ., ••• 0 0 • 0 •••• , 0 • , •••• , • ;

CJ,utch Adius.tment Check ,' 0 0 0 o. 0 , • , , • , • 0 • , 0 0 • 0 0 0 •• 0

C~utch Adjustment . " , , .. 0 •• 0 0 •• 0 • 0 •• 0 •• , •• , 0 0 • 0 0 ... '.

Cilutch Cover iR emovel. ••. , ••••• 0 , o. 0 •••••••••• I 0 0 • 0 0 • o •• 0 0 Clutch Cover I nstaJlllat:io1l'l Note, ••••••• 0 0 0 0 0 " , 0 • 0 0 ., ••••••• Clutch Release Lever ,(Shaft:~ RerrFQVal •. 0 0 0 0 0 • , •••• , •••••••• 0 Clutch Rel,ease Lever (Shaft") linsullatiofi NO'tes 0 • 0 0 0 '. 0 0 , ••••••

Clutch RemovaL , ' . , . , , , ' ,

Cil.utch lnstellatlon Notes. " .....• , •••••••• " .......•..•• , , •

Frictli.on PI,ate We~r; DamaQ~ lnspeetlon " , , ...•

F riction 0 r . Siliee~ iP la,ita Ws,rp I nspeetto n, . . . . . . . . . . . .. . . . . • . . , , Clutch Spring Free length Measurement, r •••••• , ••• 0 ••• 0 •••••

Clutch Housinq Fi_rI'ger Inspection ; , .. , 0 " 0 0 0 , ••• , , " ,

Cilltch HubSpllne Inspectiion " " .

Base M aoua I

·5-3 5-3 5-3.

5-3 .5-3

;"

'!t.'

5 2: CLUT1:H .

. - .. " " , , ,., " -

~~~i~'ed View _ " ..

• • •.• iI, ... ·,:., i·~ •••• '!'''I' ! ! ••• iliili iii i ~ ., •••• ! ! !"'I! ~ .. ~ •• ,

~.~.!' ~" .. ~ ..... 1 •• e. ~.~·IIII·.' ... ..,"'.; ••••• ~.,It •• · .... ~ •• 11 •••• ,~ 11 ... ~,.~" •••. ,1I.t! ... , ••• ,;.-'" •.•••• ' ...... .,"" ••••• ,.,it i •• .ttll

• :gp:ec_i.:fic~i¢Jins:

crutch:

Clu·kh lever· play

Ch~tQh S-p.rillg· fre:f!.leflQ'lfh

. .. . ~

::i'-:3mm ··:l2,.a·mtJ!

2,,9 ~·3·. 1m.rn

. .' ,. ~ ~ .. ' .

3\7 mrn "2,;.8.JlOtp O.3,m_m

f;ric.itJ:p)'11 pl['jte;l:tlill~ne~%.

p fktiOit'i ·ap'd'·.~~.~'J p.1:ate..~r.p

.. OJ , •••• '.~ ••• ' •••• , ••• Ii. ~I.t " ••.• , ,., ••• , __ ••• ' .. , •• Ii •• , ••• Ii iII .. ~ ,., ••• , ..

A~~H;\g WId;! pj'fr'!rj')O,ih ~'<!nd.to9fs,thd¢~lQwing ~.or.G}; .~pe(;}aiiz~q too'l is requjred :for ~omp~ete c!~!t,ch·j;er.V:idtig .

. ' . ~ -: .

C!~tCJi IH9jde.~ :5101)1-1 243

G,i]-a l~~ tJ~ t(Jt. h.Qld~r ma;y be.~se(l t:n stead ·cd IhE!c;'~U1Ch hD~.de[ (~I"I~ciaUo~r P'N 57001·.30:5).

••• ,.'! ...... '!! ••• ~ iii. iii .'.,." •••••• ' •••• ~~ _ .. Iii;'. ~!! 'IV~i'_'I! ••• ii;;!ti. ii;, •••• _!'!' ~ ~! ~ + .... , •••• ,.,., •••••

!i-4 CLUTCH

••• ,., •••• Itl. 1i ••• !!1! ••• ! '!"!!! •••••• ,;."ii Ii ii ii ;!o,Ii'Ii •• ~'I;,I •••••••• I!'P.!!! "!!_ ••• ,.".;' •••• H., •• " ii ii ....

Chit:ch

••• !ljl!!!! ~L."." i .... 1i i iI iI,I.' ••• 1.11i •• III 'I!.!. !!I'!!. I "!'!!'!', ••• '!' ••• Ii • Iii i Ii a ilirli ••• .,iIi ~ •• i !ljLI ••••• 'II''!!!

Due ro the friction plate ·\\o1eat' and rclutoh cable stretch over a~ollg period of Id se, nhf. (I utdlr In ust be adjusted In \l!ctordaJtlIec with the Perlndic Mainl.enan.cc/ Ch.:ut.

I WARNING I

OT g. <!V(l<!d !I ser EOU$ ~~rn. !iI(Ii~(Ii~ t!;ll.u;::h the e!1!i~ne" Of ex· h8U~tpi~ dl,l'~li 1'111 clutch .adjustment.

Clutch Adjustment Check

.,Pul~ t:~H3 cJ~t:~b I~v.~r "J~st·e·I'I()l.Iigh·.to· take up thefree p.lay;

. -.M easu re the .g~.p be IWecn t he, II ever ·and tile rever bracket,

1. c:11J tch Lever Free- PI <lY 2 "-' S mm

1. A"djlJlHer .

3. Lockriirt

.. If the: ·,gap:f, too wide, the dutch t'Ili<1Yl)lot release ful!I,y. 'If the gap is, too narrow, the dut.c:h maynot engAge fully; ln .either case; .adjust th~ c.!utdi.

Clutch A dluctmen t

.Loo~¢r]t the knurledlocknut at the clu ~ch I~Wf .

• Turn Ih"e adjuster se that me, clutch lever will have 2.~ 3 I:!lmofpby ..

• Tighten the IOC;l;.IUiL

*If lteannot be done, use the adju~li"r'lg nu is at the lower end of the cable,

"LM'>.en the lower cable adjt.l'~ti[.lg nuts, at the clutch cover ;is far as they wll ~ go.

A. DW~t:.C{wer

B. !\cJ:j_u:~ting Nuts

C;:. CllHQn C~ble D. Clutch Co.yet

.Luos·en tile i;:lltlfle'd lotkl'ltit <It thl3- clutch lever.

.T'I:H,r:i in the >fjJajU"ster. 50 rnr"(l.t 5 \".6 mm of threads life visible.

1, locktiu~ ~" M)lHte~

.,Puill the. cl urch o~ter cab le t i gFit and t.is;rnten the bwer cable ~clj~~Hng riu t~ag<!in1i$ t the' bracket.

-At this' lim(t.,. 'chCGik rim: the. ·clutch, release lever- to clutch cabl:eoangle is 1m ~ got}" ..

A. so """9QO

B. R.elease. lever

.Turn th e ad jl:l ster a t t~ e, t::k:illc!h lever un iii in e free pi a y

ls correct,

iIrlif·Jmf· plutqh :,c'~n!'l(,i'l pi! adj~.steii:l: by )l!ih -method,

·imp~q.HC%i:l ttuJ:iz.~\ jlxvt:>" .. . . y

'.1)I~~eil the kn'urle,t:!'lockI1llJl fit tne,d·lllU:i:! lever

N(OT~'

. cB~ "svre; ·fha.' iI'Upw·t¥- piJbl,., enrJ'?tt/J.€$' dl1trifdf!'t~r # flil~i '~~~rl1f! f!;j:#' .;J'iiif;!stet 'iJ:t't/i(!.'ctutcf) :r~ve-ri. o.r"it tMitI :slrp' tnso. pt~· law, :c~ang W:ioogh ~able

~hJw" til p.~ventdil:'ti!hdifel'l$I~~~.r. . ..

·-After- the' .ildl u~,lment i5. rn",de", start. ih~' ~~gnt:l e- .and .{;.~eck th1l't the:td!!;l:tdl does .Mt~ltp and tnat.ii··roJe.a.36'S pro,Deelv.

Clutch Caver R:ttM01I.81

.{)~'!~" t:n.~ engrf:i:~9i'I' (s.~e. I;rtg'l'6-r- tiil c;ha~Ef~, illli Engine

l~pri~t:.i.9Jrn" 5ystE!:"i1i th·ii:iPt.~r), .

• Lo-6stli the r)~t~. ilfldsHdp ~he lower errd' oHIiIII), clt:ltth1 ca.ble·ttlgiye th e 'db·le. pi e nty of pJay.

.• Lj)o~.en the knurled ·'Iockil:tut. at the cIMwh·le".er:>,9:~cl ~(;rew ii 1rI] i;h e. ad I~gter. •.

-Une tip tb~ 1I16.(s in t!tte t;;t:u:i~ll lever,. k~~u"rled 1~~kl1l.wt,. ilni <l.dj.u~~~r, '~nd :the.n· fr:efO the qbJi' WOIi'I) th~ 1N':I\r.,

A. Adjl:i~ter:

B.'"Sfot.

eReqlpWl t~:c oll~U.h· ~b:l~ Iq~e,re~d ~fror'I'i(~tbe re~¢.a~

levee,L

"Turn the. reie\a~c' IMecr c·Q.lmhlr.Cl'j,oky.,iil¢ .abour $09 .• • Rempy~ the: t!l:It~hi 6q.,·,.'e, ~l;lllS and" take off Sh:", ~r.).;er;

Clutch Co vitr In$tall8.tian 'Veto;.

.~er:l.ao,~ t.l,'le ¢lllWh cover :gal!Jj;~t· w~{h 'it rn!w one.

"'Apply sJU9'c;ln;e ·sea.t<H1tp;i;(Hal!y tQ the:cr~n'~QS(l h:a!vesf!'latiog, ~,"'rt<1"C;1t oOli1)he 'f"Fq'n~ :and F.;:ar ~ii:ks ef rtl!;q;:ove)' m~I.iI!'I~.

'1. SHicolle.S:oa[ant .ApplkSd A~~

Clutch .Release ·Leller '1Sn'a f:t) Removal !l!!RemQve,1the cl uteh eever.

-'fum ~he release lever f()!I'ward as:'~hoW'Q" ·\ltTa;~ce th{)· p~n; o:ff :or til"", r-e!e~5e ~!fnaft..

.Pl~U there!eil~e .:5 h aft;ou[ of thewver,

Clutch ReJeIJS6: Lever (Sh.aft) In9talJ'itJDEl NDM' ;R~le~s¢ l~~r" ins,t~I-~~tiij~' IS .tll-e.· ~e:vt:";~~ '~i f~;';~.v~L .h{sp;ec,u tb:e: 0:111 '$.e:a.l.<a;nd h:,pl?l~~: i:f >i¢.ge5l5;lll"Y.

o 1JQ I'io~ t~:rn~ve:th~ cliJWI:J ~d~ase ~e'ver ;ndshah .li.5s.e.maIY unrefi.s.lf. b .,bfi6h.lwtY 'H!cei;~fY. ·t( iemoved, th~q.i ~~eat r~l?~ii!,·e:m~1.1t 'm}ljl he'; Fe:q:Ulre>d.

Clut.ch Iilfjmolifij .,R"et'l')o.ve ,the cllrif,zh' caver,

,.B.emoMe, the.', c.1 !.ltd'! wr~ n g 'bQI ts, wa'Sh€r~, 'and >pr~'ligs~. then~alk~';t)ff -th~: ',cli:(iclh ~prtrig pJ?te ,with 'Vmtl b"e;alrT~g , antf 'pu~l'!~(

A, 'Clinei'! Spdng !Bofts B, Wa.~h~~

t; B~arririg

.R~moite' th~ ~fiikti{ii DI~w~ :'ilJ)d 5izC(\ll.pr'lte~ as d. set, .Rei:noV¢' th~ ,qClt~.h 'hu~ 'nut. Wn~[1 ~i)l[)S;~,i'iIt'lg;1ihedlUb n uJ" Li~E!! ,t,h'~ );;Iutcih' if;i u 5 ho~d~r {~p~ia~ too.~)'tti' ke,e'p til ~,h~~II~t~h h!Jb ¥tom wr~i ng.as,~htl'fri'.

A.R.ight, fOQt,peg",

B. H'(l~de1r::- j:10Ql,~J,o.5,

IC.' Hub Njjt,. D.. CJ~wli !iLl)

.~~j,mG"I.e, fP(l, lihr.o~1'::,.wa,sh#~1 ,d~t~~ hf(b .• : chJ~ ho.u~i"g, he~dl (tbeari I'i~, (;Qllari and spM~r.

i)l1t:c:h·7nS:taliatio:n NfJt9!1:'

'<i~'~h "i"r:i$,t~!J~t:i6n Is the fev~r~e ·Of rertioYaI. ,P.a.~, -,!HimtIQ<n to·th~l~rhJwijn,g it.~!l'IS"

1. Spa£!1!I' 2~ C1r~lip :t conar

,4', Ne~d!I~:ae)).t.i'hg 5., ,R.ele%,e ~e.v.er ~

~i 'Pi-n '

i" Clutrh Hcill!)i~'tfi-g g.', Ow td\ Hub ' 9 ~ 'Frictldil\l~ 'P:i>ite

• ~i '

tti t [uJeh ~l1~,te, '11 , 'W~sh:er

'l2;, Hub' Nu~ '13., PiU~~'~r

4:4:, B,ei!ifii1g . 15. Spring ~l,j1:e

~ 6, c'iu~h ,S,pfi ng "7, Bt~l( ,.

4i~h~rl.[l J;h~ ,!;~ll.r;:er 'Wi:tl'n -the, chi!mft,fe~' ~id~f<l4Jn,&, lnwllrds, '

(Jj'i!shrr ,I:h.cc tpHar i:jttqhe; .. ~¥~~d ~[nHJ'l~i~e hr'>:v<l!¥

GWherdn:staliing tlil~ el~llch housing, mesh (he (}t~ ourntr drt'i€ 'g~ar with the oil pump ge<lJ so that the pump gear.' is t,urnli1g,

~Di5C,ard,tbieLr5ed hub nut" and~n5l<!~1 a.new h~:t,

olnstall the dutch hu b !hoh:ier 1spec i:<lJ too I; 5 'ipm ,305) 10 ke.ep the dut,ch hub, from turning.and tISh1C!WI',the dukh hUb 'n~it to ttLe ~peclficidwr\TUe !se~ ExplQdc_d Vie:w5L

Olnsia llthe lr~t Holt plat6i llnd ~t~1 platce$. starting, I'll it~1

~ fric~io'f1 plate'al'Jiait.e~fJ'atlf1g1Jhern. .-

OThfl: gr,oo>"e~ OF! thi~ f~~()ti,on pilate surface~ are C~l tr!l.t:'Igen,tia!Uy aM radla~IYi Lnstall the frletlen plates', sO" fhi'\t the groo,vcs rtlntow:.ird~he'G(lflt:er.1n rme direction -ef clutch housing rotatlon ,(Mtlnt.~rclockw~se viewed from th~H~f1g~rM:l ri;ght side). -

2. Dit1e.ct~on of Rotation

CLUTCHi5-1'

orightet'!, the clut.ch spring bolls 'to the -specifled [u)'quc (~-e9 EXP~bd()d V.iew).,

rrictltJn P{-ate-Wear, D.amage lnspecrion .Vi5iJaUyifl~'pe;cl the friction .olates 10 see if they. show iil'lY si'gns 'of ~~i;imet Gver,hea(Eins> or Uneven we-arc, *1 f ';l!lY pi iit:M show .. Iglns .ofcl;:!ITla&",,' rep~ ace the Jrictio:1\l

p~ate's andsteel plate. as a set. '

.M casu re the til! ~G:kne$s efthe fr:lctio n p,ra te$ at .s.€'l~l'al points.

'*If any of :the ,measurements ls [ess than the service lim ft, If.e pi acethe 1Tri:ctioH pia (.0;,

1, rriiGtion Plate

Fril;1iOIl Phne ifhickrU3l1$

'Standard:

Seflliee i!.imitl

2;JI! "'" 3 /1 m!'!]! 2-,Omm,

Oliff nllW dry steulptl!til~!ldd ff,iC'tio~ pmllt@.~ !u'ejlrlst(lned" 'lIIpply e~gillle all to'thell!:ri'I{1e~ of eac~ plart!.lto~'Qid ~I~tch Iplatll~eilru reo

QFit't~~,~pr~ngJ!late back-into place, ;lJi.gnlng the rnark 0[1 thepl,ate with ~hemarkon'the dutch h",b,

GMi~alignl)lent of t~e:$,pfih9 pl:a'~~ can¢atlse cliltoh, dr~ill ~wnillJn it i.s: disengaged ~. 0 r ",ltlltCliI ~I ipping~

Friction or Steel PfareWarp Inspection

.Place e<\~h rri,,,tion pl!iI.te 'or' steel pl1lJte on asurface plate, and measure the g.,p bll~ween Jthe"~l!lirface :plate .and easnfrictson piJt.e or steel p!IOitc'. The gap is the ,<lClU1L:J11lt offi'iciio.mQr,ste~~ plate. w.;trp.

*If<llny pbte i~ warp(ldo:ve~ 'the ~e:rvk:~' liITilut, repJliM'!' l:t 'IN it~' a hew :one.,

5·8 Cl.UTCH

IFrIction 81~d Steel 'P~1ite Wj'jrp

···SU!nd8wl;l~ Servlc~ uinu:

I !kItS than '0.2 rnm O.3m!fl

ClutG.ti'Sptlng F((J~ Length Mft){JsMremeor .Shir.;eth·e ·s.pwjllg:,h~c.Qme$.· shorter aslt weaken~, ~'Iii~k its free I e~gth to de torm i n e ~i~JCond~ti(ln ..

*If <Ihy of 1t~e~prfog~ ~$ srnbr~~r th~n I~rn;e serv!ce; HmH,.it nn'!J5~ ile repla~e"d,

C~u"'tchSpr!ln,g Free le1ilsth M~1:u:elil'lent

C11I:iii:1iI Sprlngt F)'ee length

Stl)ltldard = 3.2.6mm

!Sen'ice Limit: 31.7mm

Cfutt;h' .HousIng F frige_r inspt!ctkJfl

.V'isu,ally imp~ctt the fijngefs of the iluwh housimg where

(hC tat~!lS o f th e' frlcilon ~ales h 11 them, .

1)'1f-t:heyar.e.bad1y wornccir if there arl{grooveSCl~,1 where the ~~IiIg-; hT't. rep lace' ~h e . hous l.rrg. . Ai ~O.. rep two Litle iH<:thm plates·if ~~'~ir- tangsare da:I'n<llged.

B ... Frlctlon Plate Tang

C-JtJtch Hub Spline Insp.e.ctlon

.Vi~!.Ialhiinsp.ect where the teeth (In ~he :5te~~ 1j:Jlilte~: wear against the~pl.irms of the clutch hUb.

*1 ~ there ar.e notches worn lnto the, splines, replace !be, clutch hub" AISQ/<repbc\,! tli;,e ~t·~1!L plateslf tht'iiir temh are .d~trIaged"

A. CILl~d1 Hub S!pllne

ENGINE LUBiFUCA'TICU'lIl 'S¥&T'EM '·1

Eng!ine Lubrlcatlon System

Tabl,e of Contents

E x'p~loded V iiew' ..•...... c •••. , ••• ~ ••••••••••••••••••••••••••••••

Speclfica,tlIQns~' , .. " " .. , , .. , ......•... '" ...••

Sp.ecla.!Tooh , .. " .. , " .. , , , .. , , .. , , .

Se.alafFt. . . . . . . . . . . . . . , , . . . . . . , . . . ., . , . . . . , . , .. , . . , , . . ., , . • ,

Eng, .. !'! on and. Filter , , , '" . , . ,

Et'lgi~t1e 'Oil L.eve:11 nspsction .• " ••...... , •.••••.•..• " ..• , ...• Engi:!le Oilano/or Filter ChaiFlge' ••••••• , , • ; •••••••••• , , ••• , Oi IF Ut.er 'aM MOLJot! I1g Bolt ReMoval .•...•. ' •...•. ,' . " , ••.

OH Filte-r and MOLHlting Bolt IMtallat~(li'1 N:Oles , ..• ' .• , .

Bypass Vallv~ Disal.sS~mbly , , , , , '.'

,

Bypass Valv.e Assembily , , ,. , , , .. , , .

BYpasS VallvilGlll'arl:ing and I n !iP:e<:tion. .. . . . . . ,. • . . • . . . ,. • . , . . R:elllfif V:alv.e R.emoval .....•... , .••. , .•. " , ..•• , .•...... " .•..

:ReHefValve Installation! Note' " .. , , .. " " ,,' ...•

Oil Pump .....• ' .•.. t •• , .•• t •• , t •••••••• a. , • , ., , •••••• t ••••••• ,

Oil 'Flu mp Remo\f~~ ,.. .,. . . ,. . . . . • • • ,. . • . • ., . ~ . . . . . ., " . ., .. . . . .

Oil Pump Insto;lliathm NOlet! •... " , •.•••• , .•.••. , .•. , • , .. ,

Oil f'!,.lrflP Disa~i'r\blv. , , , ...•. , ..• , •.... '.' ..•. , •.. , .

Oil Pump Ass~n'lbly, .. , , , , , ......• , " . , , .

Oil PresSIJn'! Measurement , , , .

o i I Pum pln5p'ooUOI! . . , . . . . ' . . . , ' . . . ., , . . . . . . . . • . . ., . . . ., .

ReHer~ Va,~ve In~pe(;:I'ion , .•.. , , , •.. ,', , ......• , .

..

..

II

·6-2

,Ii

*

ft.

*

*

-;.'+;.ifo, ••••.•• ~~' ••••.• ~,,,,,,, ..... , •• ~"."'_Ii Ii i i ......... 'i 1i.1i • .,,",. i i ••• ".'.' ••••• , .... '.' •••• .:. ..... ' •• ' ••• , ••

E~ploded View

- .~...... .

.,.; •• "+01',.11 •• '1 •• i.I~. I. i,.:.. .. 1 ... 1.·. ·.'1?1i ii .... ~ .. ,. io io .r .. '''!''' io ..... ii,,,, ••• , .... ~ ~,. io ••••••• ~....; .' •• ' •••

~@(b) ~

.\.: .

i ••

. ! __ J

@.@~

JR .. ".~ ..... " .

. ~

; , 'Dill Ripe,

2;. Qi~Pa,$Ilge'~.P'i.pe ::1': 01)lP!IsSllM 'PI~g 4.0~1 Elie~"et . s: m:l¢~¢~

$, 'Oilr F'ilm· Btllt

'1: ()iIPr~.:r~, :s,."iiJdl

L.: . ,: Ai).[li:v· non ~rm~ei1t ]ockilBg agatlt ~10 ftI~ tt.'r,e&di. (r; A:pP!V @(tgi,M' Qir~ ,. ,. ,.. '. ~ . . .

SS:.t Ap~,lyJII,t~on:~f':ijI~J:ain 'W:.th.lf'tJiH!!'ild~.

T1 ;' t? N~m' (,1 ;! kg::Iti,·_ 0.4 Im':lb! . ".'

nt:mM\h.m (:~:5 kO,!'I1;~ 1'1.0; ft'ib)

T3:,.20;N-m •. (i.O k~"mi.14;$ fMbj

•••• I , .. !!.!!~, ~! ~ •• '!!!. "" •••••••••• , •••• Ii "', ••• " i';'. iii", iii iI .,.,~.! iI iI E ~!!~, ~!!! .,"'!!! ~,,,,,.

E"'lIineOil f~ow Chart

! •• ~,." ••••• '.'1iI ~ iI ~ ~ •• t ~ ,t!!!! '!'!!!! +,!!!! ~ '!" •••• ~ ••••• ~ .•••• oj.", •• ii ii .. ~,I ii ~ ~ •• _" ••

,..- "\ I,. -t

{~-""' ...••.• '.' .'.~'.~ '.".~'.'.'~

.. !I ...

t. -»:

I! ""!-,.,

II •. ,,~~

-t r-

1. Oil :PU'ill'1)

2" lByp~~~ Va'lve. 3" OHlF.iUe~

4. Hala('lcer Shaft 5, er:n ksh a ft. . 6, Drive Stl1lrfr

7, Ou tput Shaft

'8. Oi I f>orc:ss~I're :Switch -9_ Ex·hawi~t C4rT1shaH

lO. [nlet Cam~haJt

6-4 EINGINE,· LIJBRICATtON SYSTEM

11 ~ Gil flow I'rom ou P.UIlIlP 12. ReHef Valve

L

Hem

Grade

... ::

t!j,r[ or'SFafass,

I:Sl:AE .1 oW 4,0, 1 QVlf5,Q,t';roW4Q, OJ 2OW50

I ,".. .••.• .

I 1,5 L (!oM~en.fifter'fs;mlot rernov~t

.~ .~. ~ .

lJ~ L.;tw~en f.rlt~r·+s't$l)l()ve~)

B'!l1~ee~ J)pp~r ~l1d.lbwe:r j'o/ill~S

4~O::·- 59D k~j ,(4.4~ltQ .~gtctrli·,f;!.3-j?5 p~9

M:or~:th~h 3.43'·kiP~ t3~'5 )cgfem;l: ~ 4S,:8:ps~)'

V{scos~tv Ae.qlIked· amount

~. . . ,,e.' .

LWE!!:

Rell.ef v,'aJ.y.e opi~nlhg,p.~r:fl:

aU Pj,'es_sure @4;OJlO Nmin {rpJ:n,t; ~itterop.. ~O"(r (1 ~4'R'F')

'!!!;·"i~.ii'_" ii ii ii ~.~ .. i .~.I.~ ~'~' ~ . ,.;"'.: too.,1i .li ~_'_.\;i i .",i11 I,!!' ••• _ 1'1 I ~'li!II'!''''',''1IJ! ! ~ .J"'.!!'.

$'f$c.lal,:i"OOilJ:

~~ ~'!i.i'!! .. .., ! !! !'~!o ~. ~'oil~ i ~ .,.,.' •• 'ii '!i.1 •• , .. ,.,.,.,~,,,:,.,~,. ".j~,~ ~ ~ ~""}!I! ! ~ ,,!,.,.~.,~,";r~. ~"iI!"".~ .' ... .., •• ~,"',~ ,.

! •• ~ "'1 •• !"'+'.·L~ ••• ,.i.~ •• '. ~ •• I''''. '. i iI iI i i Lil .'iI •••• '''!!_ ••••.•••• , ••••••• ' •• JoO .' ••••••• ,., •• , ••••• ' ••• 11]

.'ii ii." ii, •• ,." ii ii ., ..... ,,, •••• '",., ••••••• , ••• , •• , •• "'.,~!!!! ~'~ '!!'.! ~! 'I!! ~ \!!!!!! ~ !'jo~ ..... t.!!! ~'''~'!! I ~ ~'I I.

Al~ng. ,w)tb ~Q~mi)!'iI Mn'd t(ji;iIS~. t,h(:rf~H~w,idlg rlm~' W~~jali~t~:· lo~J~" ;ar;e l'~4lJked 'f~f ~6'nirp'let~:,il!J(1;gitJe

i'~tiHc<lHQ'n' ~yst~m Sef'i''i'cillfg, . .

OUI PltluiJre. !GElu!PlAdapt9r: 5:10of .. Ha3

. ..

6-6 IENmNE LUB,RICATION .sVSTEM

........ , e ~. !'I' I ••• "'tI", I , I e "'1111" ;;;'",riii i i ,. ~ e! "!!"I' •••• 'i"" j i i ••

••• L ••••• J. III ••. 111"" •••• ~I.' •• " •• "'''''' 1;1; ••• I, .. ;;; io •• "no _'I'~' ~. !II:'" .·.Ii i iii.,,,, ~ .. e e

I WARNING.

CMotorcycll'l oper,atlo,JII wi1h i"~yffi,cient, detetiorat.ed. er c01:lt81'11'1inated engine Q'll will calise sC(;~18rat:ed W!al and m"v rssult lin IIngi!1\18 or tran5il'1ill,siOl!l s8i~li!re. accident, 'aI!Id injiJ ry •

Engine Oll Levellnspe.ctitN)

• lf the oi.l has just been d'lllngeo, start the engi,.n,e, and run it for 'Several minutes at idle speed. This fftlls the eli! fi,lter with oil. Stop the engi,ne" then walt several minutes until theoi] serrles.

CRacing the enginQ before, the oil re;lches every ,plitt can causeen!lilil6 ~lIizl.!re"

.'if the motorcvcle hal ju~t been used, walt -s\weral mlnutesfcr .1,11 the oll to. drain down .

• Situ-ate the motorcycle 50 ·ihat it 15 perpend lcular to the ground, and check rho Ei[igJne oil level throl1gh tile oil level golLi ~E,.

*lhe oil level should (arne IIJP be~ween the lU'ppef and (ower I ever nt\e~.

*If the pi! leve! i~ 1.00 high; mm'o\l~'the e~CCS$ of!, U$.]I1!! a syrinso'or s.()me ether suitable device.

-If the o iii level is ~QO low; addthe.cQrrect an1oi:H'!t of 0'11 thrQulgh the oil filliN opening. Use 'the sametype and make of oil"that is already in the f~ni&ine.

NOTE

Qlf .the flflf)infl oil type 8nd make are unkm;lwn, l,J,se any bland of tile $pecifl,d oil' to' top up ihe I~i(r;'i' in pre: terence to .running the Mgi(i'e wIth the oil fi:wel' low; Thefj, at Y;QI_H' ;]tJrfiestctlh venillnceJ change tntil all complereb/~

A. Upper Level

B. Lower Level

,0. Oi~ Fi Iler Opening C<1.p

qf the engineoiirl !leu extre'mely low en if th, 'Qil pi,! nip or oUl Ip.aI$IIU'S clog up .or' otherwhlit dQ not 'wnctiotll properly. the alii pre5SIJIre wllrn,iing light wiJII Illig'liIt. tf -th is Illigh!l: stavs c-1lI wlilen the.eng,iine is IU nnilng above idle spe.ed, strop the' eng.ine imm8dia:~ly and fi~al the ,G:IIUSl'l',

Engine Oil and/or Filter Change:

illWarm- up the engine ~I) that the oil will pic-k up any'

~edilmet1't and drain easily, Then st,opEhc engine .

'.With the motorcvcle up on it;> center ~~ndlplace an oil pan beneath 'the Cl'lgitHl;

-Remove the englne drain: plug, and let the Qil drain ccrnp letelv ,

A. D~rail1 Plug

,,-If the oil niter Is to be chang(ld, replace it wltha new' one (see Oil Fulter and Moun('ing Bolt Removal and

I nstallatlon i'kite'~). ,

-Check thegasket 111 the drain' p~!.)g for damage. *Repiace the gasket wlth a new one if it rs damaged .. -After the Gi{ has completely drained out, lnstall the" 'drain p,lugwlth the' gasket, ',J[ld' tighten it W U}e speelfied torque (see Ex piO,ded vh~wl.

-Fill the eng! ne 'w i th a gon~ qu a~ ~ty m otor oj 1 5peGi'fied

in the table. '

-cneck the oil level,

EI~!lilrUI' OU

Grade: SIE Qr SiF cillin

'Visco~it'l: ~A E '1 OW 40 , 1 OW50, 20W40, or; 2QW5Qi' R;aqui led A,mount

When 'fih,er is not: remoliled '; When, filter i~ r'liImoved:

1.5 L 1;9 t

Oil.Filter and MoumingBoJi: fi'8maval

-With the mOloroy~le up en it, c,eilt~rstfLOd, p',llace .anoi'l

pan .ti¢f1e~ith th e 'e ngfjl~~ . ,

.Woscr(:w the ,vi!1 fiher flHH.lIr!'tlng bolt and drop out jhe filter.

-like aff·rhe c:jil fef1lc~, and then holdTrlg the filter st£adYl~urn Ure mo!.)!')tln~ ho!! to wowk the' fi~cer free :l!nd take the filter offllhe bolt.

-Re!T1G lie the' flat washc rand sl2fi fig, then pull thefi Iter

oov:e:r ·off the bolt. .

.ihe 011 m'ter ltYp"a~s val\:le if\.~5semh~cd hi the m6w1tin.g

bort.

Oil Fifter and Mounting Bolt Installation Notes -Ch\!(;K,tniiUhe O-ring<i ar~ in good cundiUon.

*If tne'('H,e olam.agoo, replace t~em w~th new (IlriJ(l~·.

1, MQuntirrg'BpJ~ rindu~lti1g·e~~;P<l~S Valve) ~, Q'ling

I Filter,CQve[ 4 .. Q-ring ..

5. Spring 6.w>!~b~r

7. 011 Filter

8., Fi Iter Co vet

.Apply oill to )he': mOIJt'lii ng'onlt, 'turn iLJH:Lnh.d or the rfl9umilng beltto wClrk the m~et into place, S.c careful "that th (,\'fiji ter gromm.~t5 do nqCsilp out ;0.1' p'lilce, .

.~fl~wll the oil 'fHter and filter Gowr then ti!i/nren .the' moun11ing bolt to the specified torque. (${.<0 Expl,Qded

View), . .

.Addtngine. QH (~~,Oil L(tv,d Inspe;ctiofilj."

Bypass Valve D:1$aS'M~mb{y

-Remov:!! the oil filter. Oil dralningi.s. riot nec,e5~lr!''''" _Dri~'c.l~;e~eta.i.nl~g pin out of the f1liter rIlQuntillg bo~t. -Dr9P. our-she $pd~l)Igandthe byp;tiss \taJlv~ steelball,

Bypass" V ... /v~ Assembly

.10 rep th~ bYP<lss ... ",1 ve steel b~lIr i nto the fi lter meun t~llg. b.o~t

-Ptllt the sprin~ inte -the nl(ll1m~n;ll; bull 'and compress it

O'eyo f1Id the ~r:rm I ~ he I e .. · .

• D r i ve tlh'Elte:ta lhi ng pin in to . the small hole to h old the spring.

-Instal! 'nlle .orl I'm it.

IflyP!JSS V~/ve CIMning and. .Inspect/on .ltemQve th~ ol I f Iter.

.Oisa~i-1)im·ble the: byp.a·S·5 v1j.~".e,

tCleall~~e bypass ' v alve .p.arlS in ~ high liIash-point solv'enrt.

I WA~NING' II

OC!~m the parti: lin Eli well·vontihltoo i,rea,.and ·mke carll th.atthereis PO "~park Of flame a"ywtu!U! l:Ielir ,the worklngElte:8i. B8C;II.!'!ilili of the d:1!l'iIget" of h~!lh!y fl1!rrf. mabie I'iquids, do .,ot, use ga$Qli'll'El or low Uashi·J!l'oint ~1'leJiflt.

-vi su a I,ly un spect th e by P1!5<5.· v<\ly,~parl" *if there h<litily "{~amagcJ part, r>t?pl~~~ It.

Relief Valve Ff-e/tmval .Rem p\"e~hD cJ utch cover.

.U!'DSOf,eW l:t"n:~ oil p~e5.~Ure reUef v"llI€ from ,the .c,r~nk.· cas{i.

S·SENG.II NE. L.UBIRICATlON·gYSTEM

Rldie! Val'llf! fnsralfatio.n Note

.• Appily a nOrl"perm!anen't. IQ.;;kiif1g .. ~(ltit'.i),n th"~ valve threads, aniJ t,lghten the '<!lIve to ~he spetifi~d !.?rqu(. (s.eeExr~Qded View);·

"!'!!t •• II Ii., •••• iIl.";i i iii. iii i .,.J.,f •• ! !'!'''!'!I ~ !' •••• Ii~.1i ~i';' i i •• , •• , •••.• "" ••• '. '. II. ~~;!j",lili ii iiii ojo io

on Pump

! ••• ~ ,,;.,' ,.!!. '!-!!'!!! 'I'!f:lli. Illit'. i i ii,li iii .,. , •• ~ "~I ••• !.!!!. It ••• I.".'. iii .'., ••••

Oll PMrnp Re.moi!.al

-Remove the Cllutch Gover \5ee<Ci utch Cover. RemoN'an 'in

(:lute!] ch<llPW)"· .

"RemG~re the clutch (see Clutch Removal in: Cll!;ltt>h

ctlOlPtei:j, .

• 'R~mo"e· tihe oilpu!1lip m.Qun~i,~g AH'en bolts"

Off Pump lnsUJIJa.tI'on Notf!s

.• Fi;l1 the oil pump with engiM oil for ioWal I ubtki:diOJ"l, .t;pply a non-pesma rl.ent lock i I"Ig ag~ nt to the threads

.ofih.e pump AII(Hl bolts,

'.When il:TstJI.ll.irl"g lni!!. ?il pump. note ~~e po~itiorl of thewater Rump shaft slctand turn the oUi pump ,haft ~Q ·th.at the ·p~Ofet"tkl~l I'~[s "into ·th~ skit,

,A. lNa.t,c1[ Pump Shan B·, CHIPllll1l'lp Sh;lft

all P' .. rmp P is <fStembIy lIlR,elnQVe the oilpump,

.Rc'linov.j] jh~, c<irclip with circfiip {111m (specrallcool) on lhepurnp$haft end,

.T:~.b.: off the gearfrot'fl the ·shaft,

.UnstrlOW the oil p·u'mp t:(1lie"~(;rews"~l~d takeoff the ()~ver,

.Pull ~he, oll "pomp shaftt washer, p~ln.inner ro'tm" and outer reter from -the pump.

A. Ord.ip O. Gea:r

C. Pump O>vef D,Pin

E. Washer H. Inner Rtlt"ur

F, NI1 I. OmerRotor

G. Pump"Shaf~·, J, .PurnpBody

Off Pump Assembly Note

.Aner comipletirng the (Iii ptm~", il"ssernbly, cbeek th0il ti~.e.rQ~~.~ shaft and-rotor tLirlfir ~mon~mry,

NOTE

Q/t reUe.f viilvc. qpfmifI(J ·Pf'(MSUff! m~iJ$I,I.r;t!ment is nece, t>W!ty, meesuJe the all p~.re. .. b"~(o:~ t~ i(tnglne h; watm6l(/ .I)j).

errgi'lie 1 s coht

o!RemQve the oil pam.:g.e pLug;, Oinstall the oll pressure gauge

tQo.I~I, .