Quick Reference Guide ·L J
----.JD
_G_e_n_e_r_ al_l_n_ fo_r_ m_a_t_ io_n_____
I Fuel System L - - ._
_
_
I Engine Top End L . -_
_
_
_
Engine Right Side Engine Removal/Installation Engine Bottom End/Transmission
Final Drive Brakes Suspension Steering This quick reference guide will assist you in locating a desired topic or procedure.
eSend the pages back to match the black tab of the desired chapter number with the black tab on the edge at each table of contents page. eRefer to the sectional table of contents for the exact pages to locate the specif ic topic or procedure requ ired.
Frame Electrical System Appendix
.:II Ell
_
Engine Left Side
Wheels/Tires
.:w K:iI
_
Kawasaki
KLF300
All Terrain Vehicle Service Manual
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PLEASE DO NOT TAMPER WITH NOISE CONTROL SYSTEM
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(US Model onlyl
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To minimize the noise emissions from this product, Kawasaki has equipped it with ~ effective intake and exhaust silenc ing systems. They are designed to give optimum perS~ formance while maintaining a low noise level. Please do not remove these systems, or alter ~ them in any which results in an increase in noise level.
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This w,arning may apply to any of the following components or any assembly containing one or
more of these components: Brake Shoes or Pads Clutch Friction Material
Gaskets Insulators WARNING CONTAINS ASBESTOS
SAFETY INSTRUCTIONS
-Operate if possible out of doors or in a well ventilated place. .Preferably use hand tools or low speed tools equipped, if necessary, with an appropriate dust extraction facility. If high speed tools are used, they should always be so equipped . • If possible, dampen before cutting or drilling . • Dampen dust and place it in properly closed receptacle and dispose of it safely.
Breathing asbestos dust is dangerous to health Fol low safety instructions
LIST OF ABBREVIATIONS A
ampere(s)
Ib
pound(s)
ABDC
after bottom dead center
m
meter(s)
AC
alternating current
min
minute(s)
ATDC
after top dead center
N
newton(s)
BBDC
before bottom dead center
Pa
pascal (s)
BDC
bottom dead center
PS
horsepower
BTDC
before top dead center
psi
pound(s) per square inch
°C
degree(s) Celsius
r
revolution
DC
direct current
rpm
revolution(s) per minute
F OF
farad(s)
TDC
top dead center
degree(s) Fahrenheit
TIR
total indicator reading
ft
foot, feet
V
volt(s)
g
gram(s)
W
watt(s)
h
hour(s)
S1
ohm(s)
L
liter(s)
Read OWNER'S MANUAL before operating
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Foreword This manual is designed primarily for use by trained mechanics in a properly equipped shop. However, it contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily. Whenever the owner has insufficient experience or doubts his ability to do the work, all adjustments, maintenance, and repair should be carried out only by qualified mechanics. In order to perform the work efficiently and to avoid costly mistakes, read the text, thoroughly familiarize yourself with the procedures before starting· work , and then do the work carefully in a clean area . Whenever special tools or equipment are specified, do not use makeshift tools or equipment. Precision measurements can only be made if the proper instruments are used, and the use of substitute tools may adversely affect safe operation. For the duration of your warranty period, especially, we recommend that all repairs and scheduled maintenance be performed in accordance with this service manual. Any owner maintenance or repair procedure not performed in accordance with this manual may void the warranty. To get the longest life out of your vehicle: - Follow the Periodic Maintenance Chart in the Service Manual. -Be alert for problems and non-scheduled maintenance. -Use proper tools and genuine Kawasaki vehicle parts. Special tools, gauges, and testers that are necessary when servicing Kawasaki vehicles are introduced by the Special Tool Manual. Genuine parts provided as spare parts are listed in t he Parts Catalog. -Follow the procedures in this manual carefully. Don't take shortcuts. _ Remember to keep complete records of maintenance and repair with dates and any new parts installed.
How to Use this Manual In preparing this manual, we divided the product into its major systems. These systems became the manual 's chapters. All information for a particular system from adjustment through disassembly and inspection is located in a single chapter. The Quick Reference Guide shows you all of the product's systems and assists in locating their chapters. Each chapter in turn has its own comprehensive Table of Contents. The Periodic Maintenance Chart is located in the General Information chapter. The chart gives a time schedule for required maintenance operations. If you want spark plug information, for example, go to the Periodic Maintenance Chart first. The chart tells you how frequently to clean and gap the plug. Next, use the Quick Reference Guide to locate the Electrical System chapter. Then, use the Table of Contents on the first page of the chapter to find the Spark Plug section. Whenever you see these WARNING and CAUTION symbols, heed their instructions! Always follow safe operating and maintenance practices.
I WARNING. oThis warning symbol identifies special instructions or procedures which, if not correctly followed, could result in personal injury, or loss of life.
oThis caution symbol identifies special instructions or procedures which, if not strictly observed, could result in damage to or destruction of equipment. This manual contains five more symbols (in addition to WARNING and CAUTION) which will help you distinguish different types of information. NOTE o This note symbol indicates points of particular interest for more efficient and convenient operation.
elndicates a procedural step or work to be done. o lndicates a procedural sub-step or how to do the work of the procedural step it follows. It also precedes the text of a WARNING, CAUTION, or NOTE. *Indicates a conditional step or what action to take based on the results of the test or inspection in the procedural step or sub-step it follows.
GENERAL INFORMATION 1-1
10 General Information Table of Contents
Before Servicing . . . . . . . . . . . . . . . . • . . . . . . . . . . . . . . . . . . . . . . . . • .
1·2
Model Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4
General Specifications ..............................•. . . . . . .
1·6
Torque and Locking Agent. . . . . . . . . . . . . ... . . . .. . . .. . . . . . .. . ..
1·8
Periodic Maintenance Chart. . . . . . . • . . . . . . . . . . . . . . . . . . . . . . . . . .
1·10
'-2 GENERAL INFORMATION
Before Servicing Before eliminate criptions tations, a
starting to service a vehicle, careful reading of the applicable section is recommended to unnecessary work. Photographs, diagrams, notes, cautions, warnings, and detailed deshave been included wherever necessary. Nevertheless, even a detailed account has limicertain amount of basic knowledge is also required for successful work.
Especially note the following: (1) Dirt Before removal and disassembly, clean the vehicle. Any dirt entering the engine or -other parts will work as an abrasive and shorten the life of the vehicle. For the same reason, before installing a new part, clean off any dust or metal filings. (2) Battery Ground Remove the ground (-) lead from the battery before performing any disassembly operations on the vehicle. This prevents: (a) the possibility of accidentally turning the engine over while partially disassembled. (b) sparks at electrical connections which will occur when they are disconnected. (c) damage to electrical parts. (3) Tighten ing Sequence Generally, when installing a part with several bolts, nuts, or screws, start them all in their holes and tighten them to a snug fit. Then tighten them evenly in a cross pattern. This is to avoid distortion of the part and/or causing gas or oil leakage. Conversely when .loosening the bolts, nuts, or screws, first loosen all of them by about a quarter of turn and then remove them. Where there is a tightening sequence indication in this Service Manual, the bolts, nuts, or screws must be tightened in the order and method indicated. (4) Torque When torque values are given in this Service Manual, use them. Either too little or too much torque may lead to serious damage . Use a good quality , reliable torque wrench. (5) Force Common sense should dictate how much force is necessary in assembly and disassembly. If a part seems especially difficult to remove or install, stop and examine what may be causing the problem. Whenever tapping is necessary, tap lightly using a wooden or plastic-faced mallet. Use an impact driver for screws (particularly for the removal of screws held by a locking agent) in order to avoid damaging the screw heads. (6) Edges Watch for sharp edges, especially during major engine disassembly and assembly. Protect your hands with gloves or a piece of thick cloth when lifting the engine or turning it over. (7) High-Flash Point Solvent A high-flash point solvent is recommended to reduce fire danger. A commercial solvent commonly available in North America is Stoddard solvent (generic name). Always follow manufacturer and container directions regarding the use of any solvent. (B) Gasket, O-Ring Do not reuse a gasket or O-ring once it has been in service. The mating surfaces around the gasket should be free of foreign matter and perfectly smooth to avoid oil or compression leaks. (9) Liquid Gasket, Non-Permanent Locking Agent Follow manufacturer's directions for cleaning and preparing surfaces where these compounds will be used. Apply spar ingly. Excessive amounts may block engine oil passages and cause serious damage. An example of a non-permanent locking agent commonly available in North America is Loctite Lock ' n Seal (Blue) . (10) Press A part installed using a press or driver, such as a whee l bearing, should first be coated with oil on its outer or inner circumference so that it w ill go into place smoothly . (11) Ball Bearing When installing a ball bearing, the bearing race which is affected by friction should be pushed by a su itable driver. This prevents severe stress on the balls and races, and prevents races and balls from being dented . Press a ball bearing until it stops at the stop in the hole or on the shaft.
GENERAL INFORMATION 1-3 (12) Oil Seal and Grease Seal
(13)
(14)
(15)
(16)
Replace any oil or grease seals that were removed with new ones, as removal generally damages seals. When pressing in a seal which has manufacturer's marks, press it in with the marks facing out. Seals should be pressed into place using a suitable driver, which contacts evenly with the side of seal, until the face of the seal is even with the end of the hole. Seal Guide A seal guide is required for certain oil or grease seals during installation to avoid damage to the seal lips. Before a shaft passes through a seal, apply a little high temperature grease on the lips to reduce rubber to metal friction. Circlip, Retaining Ring Replace any circlips and retaining rings that were removed with new ones, as removal weakens and deforms them. When installing circlips and retaining rings, take care to compress or expand them only enough to install them and no more. Lubrication Engine wear is generally at its maximum wh il e the engine is warming up and before all the rubbing surfaces have an adequate lubricative film. During assembly, oil or grease (whichever is more suitable) should be applied to any rubbing surface which has lost its lubricative film. Old grease and dirty oil should be cleaned off. Deteriorated grease has lost its lubricative quality and may contain abrasive foreign particles. Don't use just any oil or grease. Some oils and greases in particular should be used only in certain applications and may be harmful if used in an application for which they are not intended. This manual makes reference to molybdenum disulfide grease (MoS,) in the assembly of certain engine and chassis parts. Always check manufacturer recommendations before using such special lubricants. Electrical Wires All the electrical wires are either single-color or two-color and, with on ly a few exceptions, must be connected to wires of the same color. On any of the two-color wires there is a greater amount of one color and a lesser amount of a second color, so a two·color wire is identified by first the primary color and then the secondary color. For example, a yellow wire with thin red stripes is referred to as a "yellow/ red" wire; it would be a "red/ yellow" wire if the colors were reversed to make red the main color. Wire (cross-section)
e:
~~ ....
r '"
Name of Wire Color
Red Wire strands Yellow/ red f--
Yellow Red
(17) Replacement Parts When there is a replacement instruction , replace these parts with new ones every time they are removed. These replacement parts will be damaged or lose their original function once removed. (18) Inspection When parts have been disassembled, visually inspect these parts for the following conditions or other damage. If there is any doubt as to the condition of them, replace them with new ones. Abrasion Crack Hardening Warp Scratch Wear Bent Dent Color change Deterioration Seizure (19) Specifications Specification terms are defined as follows. "Standards" show dimensions or performances which brand-new parts or systems have. "Service limits" indicate the usable limits. If the measurement shows excessive wear or deteriorated performance, replace the damaged parts.
14 GENERAL INFORMATION Model Identification
KLF300-A 1 Left Side View:
KLF300-A 1 Right Side View:
GENERAL INFORMATION 1-5 KLF300-A2 Left Side View
KLF300-A2 Right Side View
1-6 GENERAL INFORMATION General Specifications
Items
KL F300-A 1, A2
Dimensions: Overall length Overall width Overall height Wheelbase Ground clearance Seat height Dry weight Curb weight : Front Rear Fuel tank capacity
1,B50 mm 1,100mm 1,045 mm 1,200 mm 195 mm 750mm 226 kg, @ © 223 kg 109.5 kg, @ © 10B.5 kg 126.5 kg, @ 124.5 kg B.2 L
©
Performance : Minimum turning radius
3.0 m (Locked axle mode) 2.6 m (Differential mode)
Engine: Type Cool i ng system Bore and stroke Displacement Compression ratio Maximum horsepower Maximum torque Carburetion system Starting system I gn ition system Timing advance Ignition timing Spark plug Valve timing:
Inlet
Exhaust
Lubrication system Engine oil: Grade Viscosity Capacity
Open Close Duration Open Close Duration
4-stroke, SOHC, 1·cylinder Air cooled 76.0 x 64.0 mm 290 mL B.6 15.4 kW (21 PS) @7,OOO r/min (rpm). @ © 22.6 N-m (2.3 kg-m , 16.6 ft-Ib) @6,OOO r/min (rpm). @ © Carburetor, Keihin CVK32 Electric starter Battery and coil (Transistorized) Electronically advanced From 10° BTDC @1,300 r/min (rpm) to 400 BTDC @4,OOO r/min (rpm) NGK BBES, BRBES BTDC 65° ABDC 272° 62° BBDC 30° ATDC 272° Forced lubrication (wet sump) SE or SF class SAE 10W-30 , 10W-40, 1OW-50, 20W-40, 20W-50 1.7 L
2r
©®
(Continued on next page.)
®: U.K. Models
© : Canadian Models
@:
U.S. Models
GENERAL INFORMATION 1-7 Items
KLF300-A 1, A2
Drive Train: Primary reduction system: Type Reduction ratio Primary Clutch type Secondary Transmission: Type Gear ratios: 1st 2nd 3rd 4th 5th Reverse Final drive system: Type Reduction ratio Overall drive ratio Type Final gear case oil : Capacity
Gear 2_888 (78127) Auto centrifugal, wet Auto multi disc, wet 5-speed plus reverse, constant mesh, return shift 3_090 (34/11) 1_928 (27/14) 1_368 (29/19) 1_000 (23123) 0_769 (20/26) 3_072 (26/11 x 26/20) Shaft 4_886 (20/16 x 43/11) 10_858 @Top gear API GL-5 Hypoid gear oil SAE 90 (above 5° C, 41 ° F) or SAE 80 (below 5°C, 41°F) 0_3 L
Frame: Type Caster (rake angle) Camber Trail Tread Front tire: Type Size Rear tire: Type Size Suspension : Front Rear Brake type:
Type Wheel travel Type Wheel travel
Front Rear
Electrical Equipment: Battery Headlight: Type Bulb Taillight Type Alternator: Rated output Voltage regulator: Type
Double tubular 4° 0.8° @lG 17 mm 830mm Tubeless 22 x 9_00-10 Tubeless 24 x 11.00-10 Double wishbone-link 115 mm Torque tube-link 120 mm Drum (Hydraulic) Drum (Mechanical) 12 V 19 Ah Semi-sealed beam 12 V 60W 12V8Wx2 Three-phase AC 23.5 A@9,000 r/ min (rpm), 14 V Short-circuit
Specifications are subject to change without notice, and may not apply to every country.
1-8 GENERAL INFORMATION
............................................................................ Torque and Locking Agent The following tables list the tightening torque for the major fasteners requiring use of a non-permanent locking agent or liquid gasket.
Use the basic torque table below for only the bolts and nuts which do not require a specific torque value. All of the values are for use with dry solvent-cleaned threads. Basic Torque for General Fasteners Torque
Th read dia. (mm)
Letter used in the "Remarks" colu mn means: L : App ly a non-permanent lockingagentto the threads. o : App ly an oil to the threads and seated surface. S : Tighten the faste ners fo ll owing the specified se-
5 6 8 10 12 14 16 18 20
quence.
St : Stake the fasteners to prevent loosening,
N-m
kg-m
3.4 - 4.9 5_9 - 7_8 14 -19 25 - 34 44 -61 73 -98 115 '- 155 165 - 225 225 - 325
0.35 - 050 0_60 -0_80 1.4 - 1.9 2.6 - 35 4.5 - 6_2 7.4-10_0 11.5 - 16_0 17.0 - 23 23 - 33
ft-Ib 30 - 43 in- Ib 52 - 69 in-Ib 10_0 - 135 19_0-25 33 - 45 54 -72 83 -115 125 -165 165 -240
Torque Fastener Engine Top End: Cylinder Head Bolts:
6mm 8mm
Cylinder Bolt Valve Clearance Adjusting Screw Locknuts Camshaft Sprocket Bolt Camshaft Chain Guide Pivot Bolt Engine Left Side: Starter Clutch Allen Bolts Engine Right Side: Oil Drain Plug Primary Clutch Hub Nut Secondary Clutch Hub Nut Secondary Clutch Spring Bolts Engine Removal/Installation: Engine Mounting Bolts: 8 mm 10mm Engine Mounting Bracket Bolts Engine Bottom End/Transmission: Oil Pipe Banjo Bolts Shift Drum Stopper Bolt Shift Drum Pin Plate Bolt Shift Shaft Return Spring Pin Clutch Release Cam Pin Balancer Gear Nut Balancer Drive Gear and Oil Pump Drive Gear Nut Wheels/Tires: Wheel Nuts Front Hub Nuts
N-m
kg-m
ft-Ib
12 29 12
1.2
104 in-Ib
3.0
22
1_2
104 in-Ib
1.2
104 in-Ib
4.2 1.0
30
9.8 49
5.0
36
29 125
3.0
22
13.0
78
8.0
94 58
12
1.2
104 in-Ib
25 34 25
2.5 3.5 2.5
18.0
20 12 12
2.0 1.2 1.2
17 17 83
12 .41
Remarks
S S
87 in-Ib L
o o
25 18.0
1.7 1.7 8.5
14.5 104 in-Ib 104 in-Ib 12.0 12.0
L L
61
o
78
8.0
58
o
34 34
3.5 3.5
25 25
GENERAL INFORMATION 1-9
N-m
Torque kg-m
25 12 98 88 (93) 78 25
2.5 1.2 10.0 9.0(9.5) 8.0 2.5
72
St
65 (69) 58 18.0
0 0
20
2.0
14.5
25 20 78
2.5 2.0 8.0
18.0 14.5 58
0, St
29
3.0
22
L
25 29 20 6.9
2.5 3.0 2.0 0.70
18.0 22 14.5 61 in-Ib
11 5.9 7.8 7.8
1.1 0.60 0.80 0.80
95 52 69 69
20 29 145 25 20 29
2.0 3.0 15.0 2.5 2.0 3.0
14.5 22 110 18.0 14.5 22
Suspension: Shock Absorber Mounting Bolts Suspension Arm Pivot Bolts: 10mm 12 mm
34 34 88
3.5 3.5 9.0
25 25 65
Steering: Handlebar Holder Bolts Stem Clamp Allen Bolts Stem Bottom End Nut Stem Bearing Housing Bolts Tie-rod End Nuts Tie-rod Adjusting Sleeve Locknuts Knuckle Arm Pivot Nuts
20 20 29 20 41 29 41
2.0 2.0 3.0 2.0 4.2 3.0 4.2
14.5 14.5 22 14.5 30 22 30
59 27
6.0 2.8
43 20
-
-
-
Fastener Final Drive: Front Gear Case Bolts (8 mm) Output Shaft LH Bearing Housing ,B olts LH Bearing Holder Drive Gear Nut: 14 mm (when 16 mm) Driven Gear Nut Driven Gear Shaft Oil Sea l Housing Nuts Front Gear Case Plug (Odometer Gear Holder: Option) Propeller Shaft Housing Nuts Axle Shaft Pipe Bolts Pinion Gear Nut Ring Gear and Differential Gear Housing Bolts Final Gear Case Cover Bolts Final Gear Case Filler Cap Final Gear Case Drain Plug Differential Shift Fork Holder Screws Brakes: Master Cylinder Clamp Bolts Brake Lever Pivot Nut Wheel Cylinder Bolts Shoe Adjuster Bolts Brake Panel Mounting Bolts: Front Rear Rear A xle Nuts B rake Hose Banjo Bolts Brake Pipe Nipple Brake Pedal Nut
Electrical System : Alternator Rotor Bolt Spark Plug Neutral and Reverse Indicator Switch Mounting Screws
ft-Ib
Remarks
18.0 104 in-Ib
in-Ib in-Ib in-Ib in-Ib
S
S
L
1-10 GENERAL INFORMATION Periodic Maintenance Chart
The scheduled maintenance must be done in accordance with this chart to keep the vehicle in good running condition. The first service is vitally important and must not be neglected.
First Service
Regular Service
• = Clean, adjust, lubricate, tighten, or
replace parts as necessary.
Chassis : Brake adjustment - check' Brake wear - check ' Brake fluid level - check Brake fluid - change Master cylinder cup and dust seal - replace Wheel cylinder piston seal and dust seal - replace Brake hose - replace Cable adjustment' Steering play - check Final gear case oil - change' General lubrication " Bolts and nuts - tighten Battery - check Engine: Clutch adjustment' Valve clearance - check Fuel system cleanliness - check' Air cleaner - service' Engine oil - change' Oil filter - change' Spark plug - clean and gap Spark arrester - clean
• •
• •
•
• 2 years 2 years 2 years
• • •
•
• •
•
• • • • • • •
• •
• •
•
• • • • • •
'Service more frequently when operated in mud, dust, or other harsh riding conditions.
•
FUEL SYSTEM 2-1
Fuel System Table of Contents Exploded View . . . . . . . . . . . . • . . . . . • . . . .
2-2
Fuel System Cleanliness Inspection . . • . . . 2-10
Specifications
.... . ... . . . . . . . . . . . . . . . .
2·3
Carburetor Removal . . . . . . . . . . . . • . . . 2-10
. _ .. __ .. _ ......• _ . . . . . . . _
2-3
Carburetor Installation
2-10
2-4
Carburetor Disassembly
2-10
Special Tool
Throttle Case and Cable . . . . . . . . Throttle Lever Free Play Inspection . . . . ..
204
Carburetor Assembly . . . . . . . .... . ... . 2·11
Throttle Cable Adjustment . . __ .... ___ .
2-4
Carburetor Cleaning . . . . . . . . ... . . . . . 2-12
Throttle Case Removal/Disassembly. . . . ..
2-4
Carburetor Inspection . ... ... . . . . . . . . 2-12
Throttle Case Assembly/Installation. . . . ..
2-4
Air Cleaner . _ . . . . . . __ .. _ . _ ... _ ...•... 2-13
Throttle Cable Removal .... __ . ______ .
2-5
Air Cleaner Element Removal . . . . . . • ... 2-13
Throttle Cable Installation . _ ... _ .... _.
2-5
Air Cleaner Element Installation . ... • ... 2-14
Throttle Case and Cable Lubrication
2·5
Air Cleaner Removal . . . . . . . . . . . . . . . . 2-14
Throttle Case Inspection .
2-6
Air Cleaner Installation .. . . . . . . . . .... 2-14
Throttle Cable Inspection.
2-6
Air Cleaner Element Cleaning . .... . .... 2-14
Choke Lever and Cable . . . . . . . . . . . . . . . .. .
2-6
Air Cleaner Element Inspection
Choke Lever and Cable Removal . . . . . . . .
2-6
and Replacement . . . . . . . . . . . . . . . . 2·15
Choke Lever and Cable Installation
2-7
Fuel Tank. _ .... __ .. __ . .• . . . . . . . . . ... 2-15
Choke Lever and Cable Lurbication
2-7
Fuel Tank Removal .. . _ . . . . . . . . . . . . . 2-15
Choke Cable Inspection. . . . . . . . . . . • ..
2-8
Fuel Tank Installation . . . . . • . . . . . . . . . 2-15
. . . . . . . . . . . . . . . . . . . . . . . . ..
2-8
Fuel Tap Removal
Carburetor Pilot Screw Adjustment. . . . ..
2-8
Fuel Tank Inspection .... _ . _ ... . .... 2-16
Idle Speed Adjustment _ . _ . . . . . . . . . ..
2-9
Fuel Tank and Tap Cleaning .... _ .. • . _ . 2-16
Fuel Level Inspection ... . . . . . . . . . . ..
2 ·9
Fuel Tap Inspection .... _ . . . . . . _ •.. . 2-16
Fuel Level Adjustment . . . . . .. .. . . . ..
2-9
Carburetor
.....
. ... _ . _ •.. _ .. • . .. 2-16
2-2 FUEL SYSTEM
Exploded View
~J
A : Apply adhesive.
FUEL SYSTEM 2-3 Specifications
Item
Standard
Throttle Lever Free Play Carburetor:
2-3mm
Make!Type
Keihin/ CVK32
Main Jet (Option)
# 130(# 125,128,132,135)
Main Air Jet
# 100
Jet Needle
N27Q
Needle Jet
#6
Pilot Jet (Option)
# 38 (# 35,40)
Pilot Air Jet
# 140
Pilot Screw
2'/, turns out
Starter Jet (Option)
# 55 (# 58 , 60)
Service Fuel Level (from the bottom edge of carburetor body) Float Height Air Cleaner Element Oil: Grade Viscosity
............................................................. ...... ......... Special Tool Alo ng with comm on ha nd tools, th e following more specialized too l is required for complete fue l system servicing.
Fuel Level Gauge: 57001·1017
0_5 mm below - 1.5 mm above 17.0 ±2 mm SE class SAE30
24 FUEL SYSTEM Throttle Case and Cable
Throttle Lever Free Play Inspection -Check t hrottle lever free play. *If free play is not within spec ifications, adjust the
throttle cable (see Throttle Cable Adjustment).
Throttle Lever Free Play
Standard:
2-3mm A. Throttle Case Screws
o Pul1 the cable tip from the throttle lever catch. a loosen the locknut and unscrew the adjuster.
A. Throttle Lever Free Play B. Adjuster
C. Locknut
Throttle Cable Adjustment
A. Cable Tip
D. Throttle Lever Bolt
B. Locknut C. Ad ju ster
E. Limiter Screw F. Grommet
-Slide the cable adjuster dust cover out of place . eTurn the adjuster until throttle lever free play is correct.
Turning the adjuster "out" (lengthening the adjuster) will reduce free play. -Slide back the dust cover.
eDisassemble the throttle case. ORemove the throttl e lever bolt, lockwasher, and flat washer, and lift the throttle lever and return spr ing from the case. The control lever pivot bushing comes
NOTE
OLoosen the locknut and unscrew the throttle limiter screw. o Pull the throttle control lever out of the case.
off with the lever. Olf the throttle cable cannot be adjusted by using the
adjuster at the throttle case, use the adjuster at the carburetor. Do not forget to securely tighten the adjuster mounting nuts.
Throttle Case Assembly/Installation Throttle Case Removal/Disassembly eRemove the throttle case. oRemove the throttle case screws and pull the case open.
oSlide the cable adjuster dust cover out of place, and take off the grommet.
-Throttle case assembly/installation is the reverse of removal/disassembly. Note t he fo llowing. _Lubricate the throttle case and cable before assemb ly/ installation (see Throttle Case and Cable Lubrication). eBe certain that the return spring is correctly installed
on the throttle lever.
FUEL SYSTEM 2-5 -Loosen the mounting nuts at the cable lower end adjuster and free the cable from the bracket. eNote cable routing for proper installation, and pull the cable from the vehicle.
-. Throttle Cable Installation
A. Return Spring Hook
eThrottie cab le install ation is the reverse of removal. Note the following. eLubricate the throttle cable before installation (see Throttle Case and Cable Lubrication). eRoute the cab le as shown.
eTighten the throttle lever bolt to 6.9 N-m (0.7 kg-m, 61 in·lb) of torque . eSwing the throttle co ntrol lever so that the carburetor throttle valve is fully open. Turn the throttle limiter screw until it is spaced about 1 mm away from the throttle lever stop.
I WARNING. COperation with an improperly assembled throttle case could result in an unsafe riding condition.
eAdjust the throttle cable (see Throttle Cable Adjustment). A. Throttle Cable
Throttle Cable Removal eRemove the front fender (see Front Fender Removal in the Frame chapter). eRemove and disassemble the throttle case to free the upper end of the cable from the case (see Throttle Case Removal/ Disassembly) . eSlip the cable lower end out of the pUlley.
I WARNING. <::Operation with an improperly adjusted, incorrectly
routed, or damaged cable could result in an unsafe riding condition.
eAdjust the throttle cable (see Throttle Cable Adjustment).
Throttle Case and Cable Lubrication Whenever the throttle case is disassembled, or in accordance with the Periodic Maintenance Chart, per-
A. Cable End
form the following. eApply a thin coating of multi-purpose grease to the throttle control lever pivot area and the throttle cable ends.
2~
FUEL SYSTEM
A. Apply grease. *If the lever bends, disassemble the throttle case, and clean and iubricate the throttle case (see Throttle Case and Cable Lubrication). -Examine the lever and case for cracks. Replace the case assembly if it is cracked.
Throttle Cable Inspection -With the throttle cable disconnected at the both ends, the cable should move freely within the cable housing.
A. Apply grease.
_Lubricate the throttle cable by seeping the oil between the cable and cable housing.
Cable Lubrication
*If cable movement is not fre e after lu brication (see Throttle Case and Cable Lubrication), if the cable is · frayed, or if the cable housing is kinked, replace the cable.
Choke Lever and Cable
Throttle Case Inspection
Choke Lever and Cable Removal
-With the throttle cable disconnected from the throttle lever, the lever should move freely and return smoothly by spring.
-Remove th e carburetor (see Carburetor Removal). -Unscrew the starter plunger cap and pull out the starter plunger.
FUEL SYSTEM 2-7 ePull the choke lever off the housing, and free the choke cable upper end from the lever. Th.ere i!l the wave washer between the lever and the housing. eNote the choke cable routing for proper installation,
and pull the cable from the vehicle.
Choke Lever and Cable Installation -Choke cable installation is the reverse of removal. Note the following. eLubricate the choke cable before installation (see Choke Cable Lubrication). Do not lubricate the choke lever. eFit the choke cable upper end to the catch on the
A. Starter Plunger Cap
choke lever as shown.
eHold the starter plunger spring compressed, and free the choke cable lower end from the plunger.
A. Choke Cable Upper End
eRoute the choke cable as shown. A. Cable End
B. Starter Plunger
_Unscrew the choke lever mounting screw and take off
the lockwasher and fl at wa sher.
A. Choke Cable
Choke Lever and Cable Lubrication Whenever the choke cable removed, lubricate the choke cable as follows and do not lubricate the choke lever : wave washer betwee n the lever and the housing.
A. Choke Lever
B. Lever Mounting Screw
2-8 FUEL SYSTEM Carburetor
Carburetor Pilot Screw Adjustment eRemove the car~uretor (see Carburetor Removal ). eTurn the carbu retor pilot screw all the wa y in until it
seats lightly.
[CAUTIO~] 000 not overtighten the pilot screw or the carburetor body will be d~maged and require replacement.
A. Do not grease.
B. Wave Washer
-Lubricate the choke cable by seeping the oil between the cable and cable housing.
Cable Lubrication
A. Pilot Screw eBack the pilot screw out the specified number of turns. Carburetor Pilot Screw Setting
Standard:
Choke Cable Inspection -With the choke cable disconnected at the both ends, the cable should move freely within the cable housing.
Idle Speed Adjustment -Adjust the pilot screw if necessary (see Carburetor Pilot Screw Adjustment) . -Start the engine and warm it up thoroughly. eTurn the idle adjusting screw to obtain the slowest
smooth idle speed.
*If cable movement is not free after lubricating (see Choke Cable Lubrication), if the cable is frayed, or if the cable housing is kinked, replaced the cable.
A. Idle Adjusting Screw
FUEL SYSTEM 2·9 Fuel Level Adjustment
Fuel Level Inspection
I WARN ING ' OGasoline is extreme ly flammable and can be explosive
under certain conditions.
Turn the ignition switch
OFF. Do not smoke. Make sure the area is well ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light.
.Park the vehicle on a level surface. -Connect the fuel level gauge (special tool) to the open end of the carburetor overflow tube.
-Remove the carburetor (see Carburetor' Removal). -Drain the carburetor into a suitab le container, -Remove the float bowl by taking out the screws with lockwashers. -Slide out the pivot pin and remove the float.
-Bend t he tang on the float arm very slighty to change the float height. Increasing the float height lowers the fuel level and decreasing the float height raises the fuel level. Float Height Standard:
A. Fuel Level Gauge: 57001·1017 B. Carburetor body bottom edge
17.0 mm
C. Drain Plug
-Hold the gauge vertically against the side of the car·
A. Tang
buretor body so that the "zero" line is several milli·
meters higher than the bottom edge of the carburetor body. -Turn the fuel tap to the ON position to feed fuel to the carbu retor and gauge, then turn out the carburetor drain plug a few turns .
-Assemble the carburetor, install it on the vehicle, and
recheck the fuel level. *If the fuel level cannot be adjusted by this method, the float or the float valve is damaged,
-Wait until the fuel level in the gauge settle. eKeeping the gauge vertical, slowly lower the gauge until
the "zero" line is even with the bottom edge of the car-
Float Height Measurement·Keihin Carburetor
buretor body. NOTE ODo not lower the nzerou line below the bottom edge of
the carburetor body, If the gauge is lowered and then raise it again, the fuel level measured shows somewhat higher than the actual fuel level.
If the gauge is
2
@
lowered too far, dump the fuel out of it into a suitable container and start the procedure over again. -Read the fue l level in the gauge and compare it to the specification,
-Tighten the drain plug and remove the fuel level gauge . *If the fuel level is incorrect, adjust it (see Fuel Level Adjustment). Float height Fuel Level 0.5 ±1 mm above the bottom edge of the carburetor body
1. Float bowl mating surface 2. Float valve needle rod (contacted but unloaded) 3. Float
2-10 FUEL SYSTEM
Fuel System Cleanliness Inspection
IWARNING I
Carburetor Installation ec:arburetor Installation is the reverse of removal. Note the following. eRoute the carburetor vent hose as shown.
oGasoline is extremely flammable and can be explosive under certain conditions. Turn the ignition switch OFF. Do not smoke. Make sure the area is well ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. eRun the lower end of the carburetor overflow tube to a suitable container. eTurn out the carburetor drain plug a few t urns and drain the fuel system.
A. Carburetor Vent Hose -Check fuel leakage from the carburetor.
I WARNING. oFuel spilled from the carburetor is hazardous. A. Drain Plug e<:heck to see if water or dirt comes out. eTighten the drai n pi ug. *If any water or dirt appears during the above in· spection, clean the fuel system (see Carburetor Cleaning and Fuel Tank and Tap Cleaning).
eAdjust the pilot screw (see Carburetor Pi lot Screw Adjustment). elf the carburetor has been disassembled, or if there is some other reason that the fuel level may be incorrect, inspect the fuel level (see Carburetor Fuel Level Inspection). eAdjust the idle speed (see Idle Speed Adjustment). eAdj ust the throttle cable (see Throttle Cable Adjustment) .
Carburetor Removal eRemove the fuel tank (see Fuel Tank Removal).
IWARNING I OGasoline is extremely flammable and can be explosive under certain conditions. Turn the ignition switch OFF. Do not smoke. Make sure the area is well ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. eSlip the throttle cable lower end out of the carburetor pulley (see Throttle Cable Removal). eLoosen the clamps on the carburetor holder and the air cleaner duct. ePul1 the air cleaner duct off the mouth of the carburetor. ePull the carburetor out the carburetor holder. eUnscrew the starter plunger cap and free the lower end of the carburetor choke cable from the carburetor (see Choke Cable Removal).
Carburetor Disassembly -Remove the carburetor (see Carburetor Removal). -Remove the carburetor top end as fo llows. -Remove the upper chamber cover screws and take off the cover and spring. ePul1 out the vacuum piston with the diaphragm.
a During carburetor disassembly, be careful not to damage the diaphragm. Never use a sharp edge to remove diaphragm .
-Slide the jet needle out of the vacuum piston from the bottom. It will come out with a spring seat.
FUEL SYSTEM 2-11 Carburetor Assembly ecarburetor assembly is the reverse of disassembly. Note the following. eTurn the carburetor body upside-down, and drop the needle iet into place. The smaller diameter end of the jet goes in first.
A. Vacuum Piston B. Spring Seat
c.
let Needle
_Remove the carburetor bottom end as follows. -Unscrew the pilot screw and remove it with its spring, washer, and O-ring. eRemove the float bowl screws and take off the float bowl and D-ring. -Slide out the float pivot pin, remove the float, and drop out the float needle v'llve with its hanger.
A. Small End
-Carefully screw in the air bleed pipe. It will seat against the needle iet, pushing the end of the iet into the carburetor bore.
000 not force the air bleed pipe or overtighten it. The
needle jet or the carburetor body could be damaged requ iring replacement.
eDrop the float valve needle into the valve seat and hold the float in place with the tab hooked into the needle hanger. A. Float Pivot Pin B. Main let
c.
Air Bleed Pipe D. Pilot 1et
-Unscrew the main jet, pilot jet, and air bleed pipe. ePush the needle iet out from the inside of the carburetor with your finger.
A. Needle Hanger
A. Needle let
eSlip the float pivot pin through the pivot posts and the float. The float stop tab must be on the correct side as shown.
2-12 FUEL SYSTEM
I WARNING. Olf the flo'at is improperly installed, the specified fuel level cannot be maintained. Fuel spilled from the carburetor is hazardous.
-Set the floa t he ight as specified (see Fuel Level Adjustment) . -Slip th e needle through the hole in the ce nter of the vacuum piston, and put the spring seat on the top of the need le. Turn the seat so that it does not block the hol e at the bottom of th e vacuum piston.
ORemove as many rubber or plastic parts from the car· buretor as possible before cleaning the carburetor with a cleaning solution. This will prevent damage or deterioration of the parts. OThe carburetor body has plastic parts that cannot be removed. DO NOT use a strong carburetor cleaning solution which could attack these parts; instead, use a mild high flash·point cleaning solution safe for plastic parts.
-Di sassemble the carburetor (see Carburetor Disassem· bl y). -Immerse all the metal parts in a carb ur etor cleaning sol utio n. -Rinse the parts in water . -When the parts are clean, dry them with compressed air. -Blow t he ai r and fuel passages wit h co mpressed air. -Assemble th e carbureto r (see Carburetor Asse mbl y).
Carburetor Inspection
A. Spring Seat
B. Ho le
-After installing the upper chamber cover, check that the vacuum pisto n slides up and down smoothl y without binding in the carburetor bore.
-Before removing the carburetor, check th e fuel level (see Fuel Leve l Inspection). *If the fu el level is incorrect, inspect the rest of the carburetor before correcting it. -Remove the carburetor (see Carbureto r Removal). -Turn the thro ttle cable pulley to check th at the throttle butterfly va lve moves smoothl y and returns back with the spring tension . *If th e throttl e valve does not move smooth ly, replace t h e carburetor.
Carburetor Cleaning
I WARNING' OClean the carburetor in a well·ventilated area, and take care that there is no spark or flame anywhere near the working area; this includes any appliance with a pilot light. Because of the danger of highly flammable liquids , do not use gasoline or low flash-point solvents to clean the carburetor. A fire or explosion could result.
A. Throttle Butterfly Valve
000 not use compressed air on an assembled carburetor, the floats may be crushed by the pressure, and the vacuum piston diaphragms may be damaged.
-Disassemble th e carburetor (see Carbu retor Disassem· bly). eelean the car buretor (see Carburetor Cl eani ng). eeheck that t he O-rings o n the float bo wl, drai n plug, pilot sc rew, and carburetor ho lder, and the di ap hragm o n th e vacu um piston .
FUEL SYSTEM 2·13
A. O-rings
B. Diaphragm
A. Tapered Portion
*If the pilot screw is worn or damaged on the tapered portion, it will prevent the engine from idling smoothly. Replace it. -Check that the vacuum piston moves smoothly in the
carburetor body. The surface of the piston must not be excessively worn. ,/
*If the vacuum piston does not move smoothly, or if it is very loose in the carburetor body, replace both the
body and the vacuum piston.
A. O-ring *If any of the O-rings or diaphragm are not in good condition, rep lace th em.
e<:heck the plastic tip of the float valve needle. It should be smooth, without any grooves, scratches, or
............................................................................ Air Cleaner
........................................................................... .
tears.
Air Cleaner Element Removal eRemove the seat (see Seat Removal in the Frame chapter). eRemove the air cleaner cover by tak ing out the screws and then lifting the cover. The baffle plate comes out with the cover.
A. Tip
B. Rod
*If the plastic tip is damaged, replace the needle . • Push in the rod in the other end of the float valve needle and then release it. *If it does not spring out, replace the needle . -Check the tapered portion of the pilot screw for wear or damage.
A. Screws
B. Baffte Plate
2-14 FUEL SYSTEM -Uft the air cleaner element straight up and o ut. The element holder will come free with it.
A. Bolts
A. Gasket
B. Element
B. Clamp
C. Holder
Air Cleaner Installation
Air Cleaner Element Installation
-Air cleaner installation is the reverse of removal. Note the following. elf the drain was removed, twist it into place on the bottom of the air cleaner.
-Element installation is the reverse of removal. Note the following. -Set the element holder in place, as shown, with its lower edge in the slot in the bottom of the air cleaner.
A. Drain A. Slot -Smear a little grease on the foam gasket. -Slide the air cleaner element into place with the foam gasket toward the engine.
Air Cleaner Element Cleaning the air cleaner element (see Air Cleaner Element Removal).
eRe move
WARNING. Air Cleaner Removal eRemove the seat (see Seat Removal in the Frame
chapter). eTake out the bolts holding the air cleaner to the frame. eLoosen the clamp on the duct to the air cleaner mouth. • Pull the air cleaner out of the frame.
OClean the element in a well·ventilated area, and take care that there is no spark or flame anywhere near the working area; this includes any appliance with a pilot light. Because of the danger of highly flammable liquids. do not use gasoline or low flash-point solvents to clean the element. A fire or explosion could result .
FUEL SYSTEM 2-15 ePeel the air cleaner element off the plastic frame inside it.
Fuel Tank u
.
.
.
. . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Fuel Tank Removal eRemove the front fender (see Front Frender Removal in the Frame chapter). -Tu rn the fuel tap to the OFF position. -Pull the fuel hose off the tap.
IWARNING. oGasoline is extremely flammable and can be explosive under certain conditions. Turn the ignition switch OFF. Do not smoke. Make sure the area is well ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. A. Element
B. Frame
C. Screen
-Wash the element in a bath of high flash-point solvent and then squeeze it dry.
-Remove the bolt with lockwasher and flat washer from the rear end of the tan k.
!CAUTlO~] 0 00 not wring or twist the element as it may tear. -Saturate the element with SAE30 motor o il, or a commercially available air cleaner oil, and squeeze out the excess. eWrap the element in a clean, dry cloth and squeeze it as dryas possible. -Pull the element back over the plastic frame. -Inspect the element before installing it (see Air Cleaner Element Inspection and Replacement and Air Cleaner Element Installation).
Air Cleaner Element Inspection and Replacement eRemove the air cleaner element (see Air Cleaner Element Removal). eelean the· air cleaner element (see Air Cleaner Element Cleaning) . -Visually check the element for tears or breaks in the foam. Check the foam gasket also, and the plastic frame and screen . *If the . element or gasket have any tears or breaks, replace the element. *If the plastic frame and/or screen are damaged or distorted, replace the damaged one.
A Bolt
-Tilt the tank out the rear of the frame. -Drain the fuel tank. OArrange a suitable container under the fuel tank. a Turn the fuel tap to the RES position to drain the fuel into the conta iner.
Fuel Tank Installation NOTE ORepeated cleaning opens the pores of the foam in the element. Replace the element after cleaning it five times or if it is damaged.
eFuel tank installation is the reverse of removal. Note the following . -Read the WARNING in the Fuel Tank Removal section. eeheck the rubber dampers on the frame top-tubes and on the rear end of the fuel tank.
2-16 FUEL SYSTEM Fuel Tank and Tap Cleaning -Remove the fuel tank and drain it (see Fuel Tank Removal). -Pour some high flash·point solvent into the fuel tank and shake the tank to remove dirt and fuel deposits.
WARNING. oelean the tank in a well·ventilated area, and take care that there is no spark or flame anywhere near the working area; this includes any appliance with a pilot
light.
Because of the danger of highly flammable
liquids, do not use gasoline or low flash -point solvents to clean the tank. A fire or explosion could result.
A. Dampers *If the dampers are damaged or deteriorated, replace them. -Be sure the fuel hose is clamped to the fuel tap to prevent leaks.
Fuel Tap Removal _Remove the fuel tank and drain it (see Fuel Tank Removal). -Remove the bolts with nylon flat washers and take out the fuel tap and spacer.
-Pour the solvent out the tank. -Remove the fuel tap from the tank by taking out the bolts with nylon washers. -Clean the fuel tap flIter screens in a high flash-point solvent. -Pour high flash-point solvent through the tap in both ON and RES positions. -Dry the tank and tap with compressed air. -Install the tap in the tank ( see Fuel Tap Installation). -Install the fuel tank (see Fuel Tank Installation).
Fuel Tap Inspection -Check the fuel tap filter screens for any breaks or deterioration.
A. Bo lts
B. Spacer
Fuel Tap Installation eFuel tap installation is reverse of removal. following.
Note the
eBe sure the O-rings are in good condition to prevent
A. Screens
leaks. -Be sure to clamp the fuel hose to the tap to prevent leaks. eSe sure the nylon washers are in good condition to
prevent leaks. 000 not use steel washers in place of the nylon washers, because they will not seal the bolts properly and fuel will leak.
*If the fuel tap screens have any breaks or are deteriorated, it may allow dirt to reach the carburetor, causing poor running. Replace the fuel tap. *If the fuel tap leaks, or allows fuel to fiow when it is OFF, replace the damaged gasket or a-rings.
ENGINE TOP END 3-1
Engine Top End Table of Contents Exploded View . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . .. . . . .
Special Tools . . . . . . . . . . . . . . . . . • . . . . . Cylinder Head .... Cylinder Head Removal Cylinder Head Installation .. .. . . . .. . Cy linder Head Cleaning . . . . . . . . . . . .
Cylinder Head Warp ... . ..... . Va lves, ,G uides, Seats, Springs, Oil Seals
.... .
Valves .... . . . . . . . . . . . . . . _ . Valve Clearance Check . . . . . . . . . Va lve Clearance Adjustment . . . . . . . . . Va lve Removal . . .... . . . . . . .. . . . . Valve In stallation .... . . . . . . . . .. . . Va lve Visual In spection . . . . . . . .... .
Va lve Head Thickness . . . . . . . . .... . Valve Stem Bend
. . . . . . . . . . . .... .
Valve Stem Diameter . ... . ... . .... . Valve Guides .. . . . . . . . . . . . . . . . ... . Valve Guide Inside Diameter . ... . Va lve Guide Removal. . . . . . . . . . .. . . Va lve Guide Installation . . . . . . . . . Valve Seats . . . . . . . . . . . . . . . ... . . . Valve Seat Inspection . . . . . . . . . . . . Valve Seat Repair . . . . . . . Valve Springs ... . . . . . . . . . . . . . . . Valve Spring Removal / Installation . ... Valve Spring Free Length . . . . . . . . . .
. .
. .
Va lve Stem Oil Seals . . . . . . . . . . . . . . . . Va lve Stem Oil Seal Removal . . . . . . . . Valve Stem Oil Seal Installation . . . . . . .
Camshaft Sprocket .... . . . . . . . . . . . . . . . Camshaft Sprocket Removal . .. . .. .. . Camshaft Sprocket Installation .. . .. . . Camshaft, Rocker Arms and Shafts . . . . . . . . Rocker Arms and Shafts . . . . . . . Rocker Arm and Shaft Removal .. Rocker A rm and Shaft Installation . .. Rocker Arm Inspection Rocker Shaft Diameter ... .. . . . . .. .
3·2 34 3·6 3-7 3-7 3-7 3-8 3·8 3·8 3-8 3·8 3-9 3-9 3-10 3-10 3·11 3-11 3-11 3-11 3-11 3-11 3-12 3-12 3-12 3-13 3·16 3·16 3·1 6 3 ·16 3-16 3·16 3-16 3-16 3-17 3-17 3-17 3-17 3-18 3-18 3-18
Camshaft . . . . . . . . . . . . . . . . . . . . . . . Camshaft Removal. . . . . . . . . . . . . . . Camshaft Insta llation .. . . . . . . . . .. . Cam Wear Inspection . . . . . . . . . . . . . Camshaft Bearing Inspection . . . . . . . . Camshaft Chain, Guides and Tensioner . . . . . Camshaft Chain . . . . . . . . . . . . . . . . . .. Camshaft Chain Removal . . . . . . . . . . Camshaft Chain Installation .... . . . . . Camshaft Chain Wear . . . . . . . . . . . . . Camshaft Chain Guides . ... .. . . Camshaft Chain Guide Removal . . Camshaft Chain Guide Installation. Camshaft Chain Gu ide Wear . . . . . . . . Camshaft Chain T ensioner.
. . . . . . . . . .
.
Camshaft Chain Tensioner Removal ... . Camshaft Chain Tensioner Installation . . . Camshaft Chain Tensioner Wear ... ... . Cylinder, Piston and Rings . . . . . . . . . . . .. . Cylinder Removal / Installation .. . . . . . . . Cylinder Removal .. . . . . . . . . . . . . . Cylinder Install ation . . . . . . . ... .. . Piston and Ring Removal / Installation . ... Piston and Rin g Removal .. . . . . . . . . Piston and Ring In stallation . . . . . . . . Cylinder, Piston and Ring Maintenance . ..
. . . . . . .
Compression Measurement .... . . . . . . Cylinder/ Piston Wear . . . . . . . . . . . .. . Piston / Cylinder Clearance .... .. . . . . Cylinder Boring and Honing . . . . . . . . . Piston/Cylinder Seizure .. . . . . . . . . • . Piston Cleaning . . . . . . . . . . . . . . . . . Piston Ring and Ring Groove Wear . ... . Piston Ring End Gap . ... . . . . . . . . . . Exhaust System Spark Arrester Spark Arrester Cleaning . . Exhaust Pipe and Muffler . . Exhaust Pipe and Muffler Removal . .. . . Exhaust Pipe and Muffler Installation . . . Exhaust System Inspection.
3-19 3.1 9 ' : ' 3-19':' 3·19 3·19 3-20 3·20 3-20 3-20 3-20 3-20 3-20 3-20 3-21 3·21 3-21 3 ·21 3-22 3-22 3-22 3·22 3-22 3-23 3-23 3-24 3-25 3·25 3·26 3-27 3-27 3-28 3-28 3·28 3·28 3-29 3-29 3-29 3-29 3-29 3-30 3-30
3-2 ENGINE TOP END Exploded View
o
l : Apply a non-permanent locking agent. M : Apply a molybdenum disulfide grease. n : 29 N·m (3.0 kg·m, 22 ft·lb) for used parts. 34 N·m (3.5 kg·m, 25 ft·lb) for new parts. T2: 12 N-m (1.2 kg·m, 104 in·lb) T3: 41 N·m (4.2 kg·m, 30 ft·lb) T4: 9.8 N·m (1.0 kg·m, 87 in·lb)
ENGINE TOP ENO 3-3
T2
M
T4
34 ENGINE TOP END Specifications
Cylinder !-lead: Item
Standard
Cylinder Head Warp
Service Li m it 0.05 mm
Valve, Guides, Seats, Springs, Oil Seals: Item Valve Clearance:
Standard IN .
0.10 - 0.15 mm
EX.
0. 15 - 0.20 mm
Valve Seating Surface Angle Valve Head Thickness:
45°
----
IN.
0.80 - 1.20 mm
0.5mm
EX.
0.80 - 1.20 mm
0.7 mm
Valve Stem Bend Valve Stem Diameter:
Service Limit
0.02 mm TIR
0.05mm TIR
IN .
6.965 - 6.980 mm
6.95 mm
EX.
6.950 - 6.970 mm
6.94 mm
Valve Guide Inside Diameter
7.000 - 7.015 mm
7.08mm
Va Ive Seati ng Width
0.5 -1.0 mm
--
IN.
35.7 - 36.3 mm
EX.
29.7 -30.3 mm
---
Valve Seating Surface Diameter:
Valve Spring Free Length : Inner
32.4 mm
31.1 mm
Outer
37 .3 mm
35.8 mm
Camshaft, Rocker Arms and Shafts: Item
Standard
Service Limit
Rocker Arm Inside Diameter
13.000 - 13.018 mm
13.05 mm
Rocker Shaft Diameter
12.976 - 12.994 mm
12.95 mm
Cam Height
40.876 - 40.984 mm
40.78 mm
ENGINE TOP END 3-5
Camshaft Chain, Guides and Tensioner: Item Camshaft Chain Length/20-l ink Camshaft Chain Guide Groove Depth: Front Rear
Standard
Service Limit
160.00 -160.56 mm
162.4 mm
No groove No groove
2.0mm 1.5 mm
Cylinder, Piston, Rings: Item Cylinder Compression Cylinder Inside Diameter
Piston Diameter Piston/Cylinder Clearance Piston Ring/Groove Clearance Top Second Piston Ring Groove Width: Top Second Oil Piston Ring Thickness: Top & Second Piston Ring End Gap: Top & Second
Standard 795 - 1,240 kPa (8.1 - 12.6 kg/cm 2 , 115 - 179 psi) 76.000 - 76.012 mm, and less than 0.01 mm difference between any two measurements 75.950 - 75.965 mm 0.035 - 0.062 mm
Service Limit
76.10 mm, or more than 0.05 mm difference between any two measurements 75.81 mm
0.03 - 0.07 mm 0.02 - 0.06 mm
0.17 mm 0.16 mm
1.22 -1.24 mm 1.21-1.23mm 2.51 - 2.53 mm
1.32 mm 1.31 mm 2.61 mm
1.170 -1.190 mm
1.10mm
0.20 - 0.35 mm
0.7mm
3-6 ENGINE TOP END
Special Tools
Piston Pin Puller Assy: 57001-910 (use Adapter "C": 57001-914)
Along with common hand tools, the following more specialized tools are required for complete engine top
end servicing,
o
U
Valve Guide Reamer: 57001-162
o #4 Seat Cutter: 57001 -1116
Valve Guide Arbor: 57001-163
Compression Gauge: 57001-221 with Adapter Hose: 57001-1159
#5SeatCutter: 57001-1117 #9 Outside Cutter: 57001-1121 #10 Outside Cutter: 57001-1122 #12 Inside Cutter: 57001 -1124
Cutter Holder: 57001-1126
Bar: 57001-1128
Valve Spring Compressor Assy: 57001-241
ENGINE TOP END 3·7 Cylinder Head Installation
Cylinder Head
_Blowout the oil passage with compressed air.
Cylinder Head Removal eRemove the following parts. Fuel Tank Carburetor
Exhaust Pipe and Muffler Crankshaft Sprocket ePull the spark plug cap off the spark plug. eRemove the cylinder head bracket bolts and nuts, and take off the brackets.
A. Compressed Air
-Install a new cylinder head gasket.
A. Cylinder Head Brackets
eRemove the cylinder base bolt. eLoosen the cylinder head bolts completely and remo ve all the bolts. A. Cylinder Head Gasket B. O·rings
C. Dowel Pins
eBe sure the dowel pins and O-rings are in place . eSlip the cylinder head into position. Be sure the hook of the front camshaft chain guide hangs on the cylinder catch, and is between the cylinder and the cylinder head.
A.8 mm Cylinder Head Bolts B. 6 mm Cylinder Head Bolts
C. Cylinder Base Bolt
-Remove the cylinder head. OLift the head clear of t he dowel pins in the cyl inder. oS lide the head out of the frame.
A. Chain Guide Hook
B. Catch
3-8 ENGINE TOP END eTighten the cylinder head bolts in a criss-cross pattern as shown, in two steps.
-Use a thickness gauge to measure the space between the straightedge and the head.
Cylinder Head Bolt Torque First Torquing 8 mm Bolt: 6 mm Bolt: Final Torquing 8 mm Bolt: 6 mm Bolt:
Cylinder Head Warp Service Limit: 0.05 mm
15 N-m (U kg-m, 11.0 ft-Ib) 5_9 N-m (0.60 kg-m, 52 in-Ib) 29 N-m (3_0 kg-m, 22 ft-Ib) 12 N-m (1_2 kg-m, 104 in-Ib)
eTighten the cyli nder base bolt to the specified torque (see Exploded View). elnstall the cylinder head brackets, and tighten the bolts to the specified torque (see Exploded View in the Engi,n e Removal/Installation chapter). eThe remainder of Cylinder Head Installation is the reverse of removal. A. Straightedge
Cylinder Head Cleaning eRemove the cylinder head (see Cylinder Removal). eRemove the valves (see Valve Removal). eWash the head with a high flash-point solvent.
Head
B. Thickness Gauge
*If the cylinder head is warped more than the service limit, replace it. *If the cylinder head is warped less than the service limit, repair the head by rubbing th e lower surface on emery paper secured to a surface plate (first No. 200, then No. 400).
_Scrape the carbon out of the combustion chamber and exhaust port with a suitable tool. elnstall the valves (see Valve Installation). elnstall the cylinder head (see Cylinder Head Installation).
Valves, Guides, Seats, Springs, Oil Seals Valves: Valve Clearance Check
Cylinder Head Warp eClean the cylinder head (see Cylinder Head Cleaning)_
-Lay a straightedge across the lower surface of the cylinder head at the positions shown.
NOTE
OCheck the valve clearance only when the engine is cold Icool to the touch}.
ENGINE TOP END 3-9 -Remove the fuel tank (see Fuel Tank Removal in the Fuel System chapter). -Take out the bolts and remove the valve adjusting caps with O-rings.
A. Thickness Gauge B. Adjusting Screw
C. Locknut
Valve Clearance Adjustment A. Valve Adjusting Caps
-Unscrew the left engine cover guard screws, and take off the guard. -Remove the timing inspection plug and cover center plug. _Turn the crankshaft counterclockwise with a wrench on the alternator rotor bolt, and watch the intake valve. When the intake valve opens and closes, keep turning the crankshaft counterclockwise until the T mark on the alternator rotor aligns with the slot, as shown.
-Check the valve clearance (see Valve Clearance Check). *If the valve clearance is not correct, continue with the following procedure. - Loosen the locknut and turn the adjusting screw until the clearance is correct. *If it is not possible to open the clearance far enough, the valve may have been sunk too far into the head during valve seat repair. It may be possible to grind the end of the stem slightly to gain clearance. Valve Stem Griding
Minimum after grinding 4.0 mm
Do not grind off more than 0.2 mm -Hold the adjusting screw from turning and tighten the locknut to the specified torque (see Exploded View). eRecheck the clearance. *If the clearance is incorrect, repeat the adjustment procedure. *If the clearance is correct, perform the adjustment procedure on the other valve.
Valve Removal A.Slot B. T Mark
C. Timing Inspection Plug D. Cover Center Plug
_Measure the clearance of each valve between the end of the valve stem and the adjusting screw on the rocker arm with a thickness gauge. *If the valve clearance is not correct, adjust it (see Valve Clearance Adjustment).
Valve Clearance (when cold) Intake: Exhaust
0 .10 - 0.15 mm 0.15-0.20mm
-Remove the cylinder head (see Cylinder Head Removal). eRemove the follow ing parts from the cylinder head. Camshaft Rocker Arm and Shafts -Use the valve spring compressor assy (special tool) to press down the valve spring retainer. eRemove the spl it keepers. eLoosen the valve spring compressor and take out the fo llowing parts: Valve Spring Retainer Outer Spring Inner Spring ePush out the valve . eRepeat the procedure for the other valve .
3-10 ENGINE TOP END -Repeat the procedure for the other valve. elnstall the removed parts to the cylinder head. -Install the cylinder head (see Cylinder Head Installa· tion). -Check and adjust the valve clearance as needed (see Valve Clearance Check and Valve Clearance Adjust· ment).
Valve Visual Inspection elnspect the valve head seating area for erosion, nicks, and warpage. A. Valve Spring Compressor Assy: 57001·241 B. Split Keepers
Valve Installation elf a new valve is to be used, check the valve-te-guide clearance (see Valve Stem Diameter, Valve Guide Inside Diameter). *If there is too little clearance, ream the valve guide (see Valve Guide Installation). *If there is too much clearance, install a new valve guide (see Valve Guide Removal and Valve Guide Installation ). -Check the valve seating (see Valve Seat Inspection). eAfter proper valve seating has been confirmed, replace the valve stem oil seal (see Valve Stem Oil Seal Removal and Valve Stem Oil Seal Installation). -Smear the valve stem end with a thin coat of molybdenum disulfide engine assembly grease, and push the valve into the guide. .Put the inner and outer springs in place. oPlace the springs so that the closed coil end of each spring faces down.
A. Stem End
B. Stem
C. Seating Area
*If the valve head seating area is warped, replace the valve. *If the valve head seating area is eroded or nicked, it may be possible to repair the valve on a valve refacing machine. Follow the refacing machine manufacturer's instructions. elnspect the stem for obvious wear, discoloration, and stem end damage. *If the stem is obviously worn or discolored, replace the valve. *If the stem end is damaged, it may be possible to repair it on a valve refacing machine (see Valve Stem Grinding). eGo on to Valve Head Thickness, Valve Stem Bend, and Valve Stem Diameter. Valve Head Shape
~~
A. Closed Coil End _Set the spring retainer on the springs. _Use the valve spring compressor to press down the valve spring retainer. elnstall the split keepers, and slowly remove the spring compressor. Be sure the keepers stay in place, holding the retainer down .
Valve Head Thickness
l
\ 45°
ENGINE TOP END 3-11
Valve Head Thickness eMeasure the thickness of the valve head. *If the valve head thickness is less than the service limit, replace th e valve. Valve Head Thickness Intake Standard:
0.80 - 1.20 mm
Service Limit: 0.5 mm
Exhaust
Standard: 0.80 - 1.20 mm Service Limit: 0.7 mm
Valve Guides: Valve Guide Inside Diameter -Use a small hole gauge and a micrometer to measure the inside diameter of the valve guide at four places down the length of the gu ide. *If any measurement is greater than the service limit, replace the va lve guide (see Va lve Guide Removal and Valve Guide Installation). Valve Guide Inside Diameter 7.000 - · 7.015 mm Standard: Service Limit: 7.0Bmm
Valve Stem Bend -Support the valve in V blocks at each end of the stem. Valve Stem Bend
ePosition a dial gauge perpendicular to the stem. -Turn the valve and read the variation on the dial gauge. *If the stem bend is greater than the service limit, replace the valve. Valve Stem Bend Standard: Service Limit:
0.02 mm TlR 0.05mm TIR
Valve Guide Removal eRemove the cylinder head (see Cylinder Head Removal). eRemove the valve (see Valve Removal). -Remove the valve stem oil seal (see Valve Stem Oil Seal Removal). eHeat the area around the guide to 120° to 150°C (250° to 300°F) . eFit the valve guide arbor (special tool) into the guide from the combustion chamber side of the head. eDrive the guide out of the head by hammering lightly on the arbor.
1
Valve Stem Diameter _Measure the diameter of the valve stem in two direc tions at right angles, at four different positions on the stem. *If any single "measurement is less than the service limit, replace the valve . Valve Stem Diameter Intake Standard: Service Limit: Exhaust Standard: Service Limit:
6.965 - 6.980 mm 6.95 mm 6.950 - 6.970 mm 6.94 mm
A. Valve Guide Arbor: 57001·163
3-12 ENGINE TOP END
Valve Guide Installation
Valve Seats:
-Clean the valve guide hole in the cylinder head. -Lightly oil the valve guide.
-Remove the valve (see Valve Removal).
-Set the circlip onto the valve guide groove. -Heat the cylinder head around the valve guide hole to
120° to 150°C (250° to 300°F). -Use the valve guide arbor and a hammer to drive the
guide into the head from the outside until the circlip on the guide seats aga inst the head.
Valve Seat Inspection -Coat valve seat with machinist 's dy e.
ePush the valve into the guide. eRotate the valve against the seat with a lapping tool. .Pull the valve out, and check the seating pattern on the
valve head. It must be the correct width and even all the way around.
-Allow the cylinder head to cool. eReam the valve guide with the valve guide reamer
(special tool) even if the old gu ide is reused. Valve Seating Width Standard: 0 .5 - 1.0 mm
NOTE OThe valve stem and guide must be in good condition or this check will not be valid.
*If the valve seating pattern is not correct, repair the
seat (see Valve Seat Repair) . eMeasure the outside diameter of the seating pattern on the valve seat. *If the outside diameter of the valve seating pattern is too large or too small, repair the seat (see Valve Seat
A. Valve Guide Reamer: 57001-162
Repair).
-Check valve seating (see Valve Seat Inspection). -Install the valve stem oil seal (see Valve Stem Oil Seal Installation). -Install the valve (see Valve Installation ). -Install the cylinder head (see Cylinder Head Installation).
Valve Seating Surface Outside Diameter
Intake : Exhaust :
35.7 - 36.3 mm 29.7 - 30.3 mm
Valve Seating Pattern
@
Good
Too Wide
Too Narrow
Uneven
1. Valve 2. Valve Seat 3. Seating Area Outside diameter
4. Seating Area Width
ENGINE TOP END 3-13
Valve Seat Repair
Valve Seat Cutter
.Clean the cylinder head thoroughly (see Cylinder Head Cleaning) . • Use the following procedure and tools to repair the valve seat.
Used Valve Seat Cutters Intake Valve
®
45° -¢41.5
@ 32° -¢38_5 @ 60° -¢41.0
57001-1117 57001-1122 57001-1124
Exhaust Valve
® ® @
45° -¢35 _0 32° -¢35_0 60° -¢41.0
57001-1116 57001-1121 57001-1124 1. Cutter 2_ Cutter Holder 3_ Bar
Used Holder and Bar Holder - ¢ 7.0 Bar
57001 -1126 57001-1128
Seat Cutter Operating Cares: 1. This valve seat cutter is developed to grind the valve seat for repair. Therefore the cutter must not be used for other purposes than seat repair. 2. Do not drop or shock the valve seat cutter, or the dia· mond particles may falloff. 3. Do not fail to app ly engine oil to the valve seat cutter before grinding the seat surface. Also wash off ground particles st icking to the cutter with washing o il.
5. After use, wash it with washing oil and apply thin layer of eng ine oil before storing.
Marks Stamped on the Cutter: The marks stamped on the back of the cutter represent the follow ing. CD ....... _.. __ . _Cutter number, selected from CD to 0 45° _. __ ......... __ Cutter angle 24.5¢ . _ ... ___ .. _ ... Outer diameter of cutter KSOO ... . .. • .. _ . _ .. Manufactured lot number Cutter
Outer Diameter of Cutter
NOTE
OA wire brush must not be used to remove the ground particles from the cutter. That will cause the diamond particles to fall off.
Ang le of Cutter
4. Setting the valve seat cutter hol der in position, operate the cutter in one hand. Do not apply too much force to the diamond portion.
NOTE
OPrior to grinding, apply engine oil to the cutter and during the operation, wash off any ground particles sticking to the cutter with washing oil.
Operating Procedures: -Clean the seat area carefull y, -Coat the seat with machinist's dye. -Fit a 45° cutter to the holder and slide it into the valve guide . -Press down lightly on the handle and turn it right or left. Grind the seating surface only until it is smooth.
3-14 ENGINE TOP END Valve Seat Repair
(
START
)
t
I
Machinist's dye on seat
t
45° Grind Tool:
45° Cutter make seating area
Purpose:
smooth and round
t Measure Seating Area O.D. Tool Purpose:
Vern ier Caliper check seat O.D. again st spec.
,
I Reiults
I
t
,
Tool small
I
I
OK
I
I
45°Cutter
Purpose:
increase 0.0. of seat area to spec.
I
,
45° Grind Tool:
t t
Too big
Machinist's dye on seat
32° Grind Tool:
32°Cutter
Purpose:
reduce 0.0. of seat area
to spec. Measure Seat Width Tool:
Vern ier Caliper
Purpose:
check seat width against spec. Re+ts
t
I Too narrow I
I
t Tool: Purpose:
t OK
I
I
t Too wide
I
t
,
45° Grind
Machinist's
45° Cutter increase width of seat
dye on seat
area beyond spec. to increase 0.0.
60° Grind Tool : Purpose:
60° Cutter reduce seat width to spec.
Lap Valve Tools:
Valve lapper, grinding compound
Purpose:
l
perfectly match valve and seat area; check valve head for damage
,
FINISHED
)
ENGINE TOP END 3-15
[CAUTlO~] 000 not grind the seat too much . Overgrinding will reduce valve clearance by sinking the valve into the head. If the valve sinks too far into the head, it will be impossible to adjust the clearance, and the cylinder head must be replaced..
Valve Seat Repair
Widened width of engagement by machining
with 45° cutter
Volume ground by 32° cutter
Vo lume ground by 60° cutter
eTo measure the seat width, use a vernier caliper to measure the width of the 45° angle portion of the seat at several places around the seat (see Valve Seat In· ,pection ). *If the seat width is too narrow, repeat the 45° grind un til the seat is slightly too wide, and then return to the seat O .D. measurement step above. *If the seat width is too wide, make the 60° grind described below. *If the seat width is within the specified range, lap the valve to the seat as described below. eGrind the seat at a 60° angle until the seat width is within the specified range. oTo make the 60° grind, f it a 60° cutter to the holder, and slide it into the valve guide. aTurn the holder, while pressing down lightly. DAfter making the 60° grind, return to the seat width measurement step above. eLap the valve to the seat, once the seat width and 0.0. are within the specified range. aPut a little coarse grind ing compound on the face of the valve in a number of places arou nd the valve head. a$pin the valve against the seat until the gr inding compound produces a smooth, matched surface on both the seat and the valve. ORepeat the process with a fine grindi ng compound.
Valve Lapping
eMeasure th e outside diameter of the seating surface with a vernier caliper (see Valve Seat Inspection). *If the outside diameter of the seating surface is too small, repeat the 45° grind until the diameter is within the specified range. *If the outside diameter of t h e seating surface is too large, make the 32° grind described below. *If the outside diameter of the seat in g surface is within the specified range, measure the seat width as described below. eGrind the seat at a 32° angle until th e seat 0.0. is within the specifi ed range. aTo make the 32° grind, fit a 32° cutter to the holder, and sl ide it into the va lve guide. aTurn the holder one turn'at a t ime while pressing down very lightly . Check the ,eat after each turn.
[CAUTIO~ I aThe 32° cutter removes material very quickly. Check the seat outside diameter frequently to prevent overgrinding. OAfter making the 32° grind, return to the seat 0 .0. measurement step above.
1. Lapper 2. Va lve Seat 3. Valve
eThe seating area should be marked about in the middle of the valve face . * If the seat area is not in the right place on the valve, check to be sure the valve is the correct part. If it is, it may have been refaced too much; replace it. eBe sure to remove all grinding compound before assembly. eWhen the engine is assembled, be sure to adjust the ~alve clearances (see Valve Clearance Adjustment).
3-16 ENGINE TOP END
Valve Springs: Valve Spring Removal/Installation eThe valve springs are removed and installed dur ing valve removal and installation (see Valve Removal and Va lve
.Push the seal clip down over the seal until it seats in the groove in the seal. elnstall the valve (see Valve Installation).
Installation) .
Camshaft Sprocket
Valve Spring Free Length eMeasure the valve spring free length with a vernier
caliper. *If the free length is less than the service limit, replace the spring. Valve Spring Free Length Inner Standard: Service Limit: Outer Standard: Service Limit:
32.4mm 31.1 rnm 37.3 mm 35.8 rnm
Camshaft Sprocket Removal eRemove the fue l tank (see Fuel Tank Removal in the Fuel System chapter). -Unscrew the left engine cover guard screws, and take off the guard. -Remove the cover center plug. -Remove the bolts and take off the camshaft cover. olt may be necessary to pry the cover off with a screwdriver. There are prying gaps under the screw hole bosses.
Valve Stem Oil Seals: Valve Stem Oil Seal Removal eRemove the valve (see Valve Removal). eRemove the seal clip with a small screw driver or other pointed tool. ePull the valve stem oil seal off the end of the valve gu ide. The inner and outer spring seats can be removed
from the head.
A. Camshaft Cover
-Turn the crankshaft with a wrench on the alternator rotor bolt until the "LF300" mark on the camshaft sprocket aligns with the pointer on the cylinder head.
t A. Oil Seal B. Clip
B. Cylinder Head Vent Hose
C. Inner Spring Seat D. Outer Spring Seat
Valve Stem Oil Seal Installation NOTE
aFar best res'-!'ts, do not reuse old valve stem oil seals, espec;ally if valves are replaced. eSe sure the end of the valve guide is clean. eBe sure the inner and outer spring seats are in place.
eOil the inside of the seal and slip it over the end of the guide.
A. Pointer
B. "LF300" Mark
ENGINE TOP END 3-17 -Remove the camshaft chain tensioner (see Camshaft .Chain Tensioner Removal). -Remove the camshaft sprocket bolt. o Hold the crankshaft from turning with a wrench on the alternator rotor bolt. -Slide the sprocket off the shoulder on the camshaft and out from under the chain. -Support the chain on a screwdriver or other tool stuck in the hole in the head.
-Screw in the bolt and tighten it to the specified torque (see Exploded View), while holding the crankshaft from turning with a wrench on the alternator rotor bolt. -Install the camshaft chain tensioner (see Camshaft Chain Tensioner Installation). -Sefore going any further, check the cam timing. oTurn the crankshaft counterclockwise with a wrench on the alternator rotor bolt, until the "LF300" mark on the sprocket realigns with the pointer on the head .
Camshaft Sprocket Installation -Remove the timing inspection plug, and check to see that the "T" mark on the alternator rotor aligns with the slot.
olf any resistance is felt when turning the crankshaft, stop immediately, or you may bend the valves.
oThe "T" mark on the alternator rotor should align with the slot. *If the camshaft timing is not correct, remove the sprocket from the camshaft, and install it again as detailed above. -Smear a little engine oil on the camshaft cover D-ring, and push the cover into place. -Put in the camshaft cover bolts and tighten them securely. -Install the timing inspection plug, cover center plug, and guard. -Install the fuel tank (see Fuel Tank Installation in the Fuel System chapter). A. Slot B, T Mark
C. Timing Inspection Plug D. Cover Center Plug
Camshaft, Rocker Arms and Shafts
*If the "T" mark is not aligned, hold the camchain taut and turn the crankshaft with a wrench on the alternator rotor bolt. -Fit the sprocket under the chain and slip it over the shoulder on the camshaft so that the "LF300" mark on the sprocket aligns with the pointer on the cylinder head.
A. Pointer
B. "LF300" Mark
............................................................................ Rocker Arms and Shafts: Rocker Arm and Shaft Removal -Remove the camshaft sprocket (see Camshaft Sprocket Removal). -Take out the screw and remove the rocker shaft retainer.
A. Rocker Shaft Retainer
3-18 ENGINE TOP END eTake out the bolts and remove the valve adjusting caps. eLoosen all the cylinder head bolts to free the cylinder head from the tension . • Pull out the rocker shafts and remove the rocker arms .
Rocker Arm Inspection -Inspect the area on the rocker where the cam rubs.
A. Rocker Wear Area A. Rocker Arm
B. Adjusting Screw
B. Shaft
Rocker Arm and Shaft Installation -Rocker arm and shaft ins tall ation is the reverse of removal. Note the following. eBefore installation of the rocker arms and shafts, turn the camshaft so that the cam lobes point to the "down".
*If the rocker arm is scored, discolored or otherwise damaged, replace it. Also inspect the camshaft lobes (see Cam Wear Inspection). - Insp ect the end of the valve clearance adjusting screw where it con tacts the valve stem. *If the end of the adjusting screw is mushroomed or damaged in any way , or if the screw will not turn smooth ly, rep lac e it. Also inspect the end of the valve stem (see Valve Visual Inspection). eMeasure the ins ide diameter of the rocker arm with a dial bore gauge. *If the rocker arm inside diameter is larger than the service limit, replace it. Also check the rocker shaft diameter (see Rocker Shaft Diameter). Rocker Arm Inside Diameter
Standard: Service Limit:
13.000 - 13.018 mm 13.05 mm
Rocker Shaft Diameter A. Cam Lobes
B. Down
eMeasure the diameter of the rocker shaft where the rocker arm pivots on it with a mi crometer. *If the rocker shaft diameter is smaller than the service limit, replace it. Also check the rocker arm in side
dialjleter (see Rocker Arm Inspection). eTighten all the cylinder head bolts as following the specified sequence and torquing (see Cylinder Head Installation). -After installation, be sure to check and adjust the valve clearance (see Valve Clearance Ad justme nt ).
Rocker Shaft Diameter
Standard: Service Limit:
12.976 -12.994 mm 12.95 mm
ENGINE TOP END 3·19
Camshaft: Camshaft Removal eRemove the camshaft sprocket (see Camshaft Sprocket Removal). eTake out the screws and remove the bearing retainer.
A. Cam Lobes
A. Bearing Retainer
ePull the camshaft straight out of the head. oScrew the camshaft sprocket bolt into the end of the camshaft and pull it with the camshaft.
Cam Wear Inspection eMeasure the height of each cam lobe with a micrometer. *If the cam height is less than the service limit for either lobe, replace the camshaft. eGo on to Camshaft Bearing Inspection.
Cam Height Standard: Service Limit :
40.876 - 40.984 mm 40.78 mm
Camshaft Installation _Camshaft installation is the reve rse of removal. Note
the following. eBlow the oil passage with compressed air.
Cam Height
Camshaft Bearing Inspection -Check the ball bearing which is press·fitted on the camshaft. oSince the ball bearing is made to extremely close
A. Compressed Air
eCarefully push the camshaft into the cylinder head with the cam lobes"dow n" .
tolerances, the wear must be judged by feel rather than measurement. Clean the bearing in a high flash·point solvent, dry it (do not spin the bearing while it is dry), and oil it with engine oil. OSpin the bearing by hand to check its condition. *If the bearing is noisy, does not spin smoothly, or has any rough spots, replace it.
3-20 ENGINE TOP END
............................................................................. Camshaft Chain, Guides and Tensioner
.............................................................................
Camshaft Chain 20-Link Length 20·l in k Length
Camshaft Chain: Camshaft Chain Removal
¢
eRemove the camshaft sprocket (see Camshaft Sprocket Removal). eRemove the starter chain and sprockets (see Starter Chain and Sprocket Removal in the Engine Left Side chapter). -Take out the screw and remove the camshaft chain guard below the left hand end of the crankshaft.
o
5 kg
*If the 20 link length of the camshaft chain is greater than the service limit, replace it.
Camshaft Chain 20-Link Length Standard: 160.00 - 160.56 mm Service Limit: 162 .4 mm
Camshaft Chain Guides : Camshaft Chain Guide Removal
A. Chain Guard -Remove the camshaft chain.
eRemove the cylinder head (see Cylinder Head Removal). eRemove the starter chain and sprockets (see Starter Chain and Sprocket Removal in the Engine Left Side chapter) . ePull up the front chain guide. eRemove the pivot bolt and take off the rear chain guide.
Camshaft Chain Installation ecamshaft chain installation is the reverse of removal. Note the following.
OAlways pull the camshaft chain taut while turning the crankshaft when the camshaft chain is loose. This avoids kinking the chain on the lower (crankshaft) sprocket. A kinked chain could damage both the chain and the sprocket.
eSe sure the camshaft chain guard holes fit onto the pins on the crankcase.
A. Front Chain Guide
B. Rear Chain Guide
Camshaft Chain Guide Installation Camshaft Chain Wear eHold the camshaft chain so that it may be pulled tight. eMeasure the length of 20 links (21 pins) with a vern ier caliper.
-Camshaft chain guide install ation is the reverse of removal. Note the following . eThe front camshaft chain guide is marked "UP" on the top end.
ENGINE TOP END 3-21 Camshaft Chain Guide Groove Depth
r
.00'
,
eThe front guide bottom end fits into a notch in the crankcase.
Camshaft Chain Tensioner: Camshaft Chain Tensioner Removal
o
eLoosen the lockbolt in the top of the camshaft chain tens ioner. Do not remove it yet. eTake out the tensioner mounting bolts and remove the camshaft chain tensioner.
0 00 not turn the engine while the camshaft chain tensioner is removed. Engine damage could result.
eTighten the rear guide pivot bolt to the specified torque (see Exploded View ).
Camshaft Chain Guide Wear eVisually inspect the rubber on the guides. *If the rubber is damaged, cut, or is missing pieces, replace the guide. eMeasure the depth of the groove in the guides. *If either camshaft chain guide is worn beyond the service limit, replace it.
Camshaft Chain Guide Groove Depth Front Rear
Standard: Service Limit: Standard: Service Limit:
No groove 2.0 mm No groove 1.5 mm
A. Lockbolt
B. Mounting Bolts
-Remove the lockbolt. e<:arefully pull the push rod out of the tensioner bod y. Do not drop the ball and retainer assembly or the spring. eSlide the ball and retainer assembly and the spring off the push rod .
3-22 ENGINE TOP END Camshaft Chain Tensioner Installation
Camshaft Chain Tensioner Wear
-Slip the spring over the push rod and compress it down past the hole. elnsert a piece of wire in the hole to hold the spring in place.
eVisually inspect the push rod, the ball and retainer
assembly, and the tensioner body.
A
A. Push Rod B. Spring C. Ball and Retainer Assembly A. Spring B. Wire
.c.
D. Tensioner Body E. O-ring
Push Rod eSlide the push rod in and out of the tensioner body without the spring or ball and retainer assembly. *If the parts show any damage, or if the push rod does not slide smoothly in the tensioner body, replace the camshaft chain tensioner.
eDrop the ball and retainer assembly onto the push rod . ePush the push rod into the tensioner body. _When the push rod is in as far as it will go, screw in the lockbolt with its washer to lock the push rod . • Push out the wire to release the spring.
Cylinder, Piston and Rings Chain Tensioner (push rod is locked)
3
Cylinder Removal/I nstallation: Cylinder Removal eRemove the cylinder head (see Cylinder Head Removal). eRemove the cylinder head gasket, O-rings, and dowel pins. ePry up the cylinder with a suitable tool to free the cyli nd er from the crankcase. eLift the cy lind er off. elmmediately stuff a c lean cloth around the piston to prevent parts or dirt from fa ll ing into the cran~case .
1. Lockbolt 2. Push Rod 3. Ball and Retainer Assembly
4. Spring 5. O-ring
Cylinder Installation NOTE
eSe sure the O-ring is in place in the tensioner body. _After installing the tensioner, loosen the lockbolt and then tighten it. With the bolt loosened, the spring inside takes up any slack automatically.
a new cylinder is installed, be sure to check piston/ cylinder clearance before starting (see Piston/Cylinder
Olf
Clearance).
ENGINE TOP END 3-23 eBlow out the oil passage with compressed air to be sure it is not blocked. -Clean any remains of the old cylinder base gasket from the bottom of the cyl inder and the top of the crankcase. -Remove the cloth from around the piston. -Be sure the dowel pins are in place in the crankcase.
Piston Rings
~
Front
Arrow
"
~~
~ ~~
1. 2. 3. 4.
A. Dowel Pins
B. Cylinder Base Gasket
Top ring Second ring Steel rail, oil ring Expander, oil ring
eFit the cylinder down over the piston and rings. OHoid the rings into their groove with your fingers so that the cylinder does not catch on them.
-Install a new cylinder base gasket. -Turn the crankshaft until the piston is at BDC. OHoid the camshaft chain taut. oTurn the crankshaft until the piston is all the way down. -Turn the piston rings so that the gaps are in the specified positions.
Piston Ring Gap Positions Ring
Gap Position
Top
Forward
Second
Rear
O il Expander
Forward
Top Oil Rail
30° Left of Forward
Bottom O il Rai l
30° Right of Forward
-Oil the piston rings and smear some oil inside the cylinder bore. -Hold the cylinder in position above the case and push the camshaft chain up through the tunnel. -The camshaft chain guides also fit inside the tunnel.
A.Piston Rings
ePush the cylinder down solidly against the crankcase. -I nstall the cylinder head (see Cy linder Head Installation).
Piston and Ring Removal/Installation: Piston and Ring Removal -Remove the cylinder (see Cylinder Removal). -Remove one of the piston pin snap rings.
3-24 ENGINE TOP END
Piston and Ring Installation NOTE
a new piston is used~ check piston to cylinder clearance (see Piston/Cylinder Clearance)1 and use new piston rings.
Olf
elnstall the oil ring expander in the bottom piston ring
groove so the ends butt together.
Oil Ring Expander Installation A. Piston Pin Snap Ring
.Push out the piston pin, and remove the piston. o lf necessary, use the piston pin puller assy. (special tool).
-Install the oil ring steel rails, one above the expander and one below it. oSpread the rail with your thumbs, but only enough to fit the rail over the piston. oRelease the rail into the bottom piston ring groove. A. Piston Pin Puller Assy: 57001·910 B. Adapter "C": 57001·914
NOTE
oThe oil ring rails have no "topU or "bottom".
eRemove the top and second piston rings. oSpread the ring open with your thumbs. oPush up on the opposite side with your fingers.
A. Spread.
-Install the second and top rings in that order. -Install the top and second rings so that each liN" marked side faces up.
B. Push up.
eRemove the oil ring upper and lower steel rails. OSpread the rail open with your thumbs. OPush up on the opposite side with your fingers. -Remove the oil ring-expander.
A. "N" Mark
ENGINE TOP END 3-25 Top and Second Rings
Cylinder, Piston and Ring Maintenance: Compression Measurement "N" mark Top ring
Up
"N" mark 2nd ring
• 'nstall the piston pin . oOi l the piston pin lightly and slide it through the side of the piston without a snap ring. OHoid the piston in position over the connecting rod , with the arrow pointing forward, and slide th e piston pin the rest of the way through the connecti ng rod and pisto n.
eBefore measuring compression, do the following: OCheck cylinder head bolt torque (see Cylinder Head Installation). o Be sure the battery is full y charged (see Battery Condition in the Electrical System chapter). oWarm up the engine (if the engine will run ). o During warm-up, check for leaks around the cylinder head gasket . • Remove the spark plug. .Set the compression gauge and adapter hose (special too ls) into the spark plug hol e. .Hold the throttle wide open and crank the engine with the starter. .When the gauge stops rising, stop cranking and read th e gauge .
-
,r
A. Compression Gau ge: 57001-221 B. Adapter Hose: 57001·1159
Cylinder Compression
Standard:
795 - 1,240 kPa (S.l -12.6 kg/em', 115 - 179 psi)
A. Arrow pointing forward.
Olnstall a new pisto n pin snap ring.
!CAUTIO~] 0 00 not reuse the snap ring which was removed. Removal weakens and deforms th'e snap ring. It could fall out and score the cylinder wall.
.'nsta" the cylinder (see Cylinder Insta llatio n) .
*I f the compression is withi n the speci fied range, the piston rings, cyl inder and va lves are probab ly in good co nd itio n. *I f the com pression is hi gher than the specified range, see the Compression Too High tab le. *If the co mpression is belo w the specified range, sq uirt a little oil into t he spark plug hole and repeat the compressio n measurement. -(llf the co mp ression does not chan ge very much , the piston rings are probably OK. See the Wet Compression - No Change tab le. -(llf the co mpression increases, the piston rings are not seal ing properly . See the Wet Compression - Increase tab le.
3-26 ENGINE TOP END Compression Too High Possible Problems Carbon build up on piston head and cylinder head
Cylinder head or base gasket too thin
References
Solutions Remove carbon
Piston Cleaning and Cylinder Head Cleaning
Check possible oil leaks to combustion chamber
Valve Stem Oil Seal Inspection, Valve Stem Diameter, Valve Guide Inside Diameter, and check piston oil ring for visible damage.
Replace gaskets
Cylinder Head Removal, Cylinder Head Installation, Cylinder Removal, and Cylinder Installation
Wet Compression - No Change Possible Problems
Solutions
I mproper valve clearance
Check clearance
Worn valve seats
Check seats
Burned valve
Check valves
Cylinder head leak
Check head gasket Check head flatness
References Valve Clearance Check, and Valve Clearance Adjustment Valve Seat Inspection, and Valve Seat Repair Valve Visual Inspection, and Valve Head Thickness Cylinder Head Removal, and Cylinder Head Installation Cylinder Head Warp
Wet Compression - Increase Possible Problems
References
Solutions
Too much piston-tocylinder clearance
Check clearance
Worn piston rings, and ring grooves
Check piston and rings
Cylinder/Piston Wear eMeasure the cylinder inside diameter.
oUse a dial bore gauge to measure front·to-back and side-ta-side at the points shown below. Cylinder Inside Diameter Standard: 76.000 - 76 .012 mm, and less than 0.01 mm difference between any two meas.urements Service Limit: 76.10 mm, or more than 0.05 mm difference between any two measurements
Cylinder/Piston Wear, Piston/ Cylinder Clearance, and Cylinder Boring and Honing Piston Ring and Ring Groove Wear, and Piston Ring End Gap (top and second only).
*If any of the cylinder inside diam~ter measurements is greater t han the service limit, the cylinder must be bored oversize and then honed (see Cylinder Boring and Honing) . However, if the amount of boring necessary would make the cylinder inside diameter greater than the bore limit, the cylinder must be replaced.
NOTE
the cylinder has been bored oversize, use the Oversize Cylinder Inside Diameter table.
Olf
ENGINE TOP END 3·27 Oversize Cylinder Inside Diameter Standard
Service Limit Standard plus 0.1 mm, or more than Measure at bottom of cylinder for 0.05 mm difference between any two baseline standard diameter measurements
Bore Limit 77.0 mm
Oversize Piston Diameter Standard
Service Limit
75.950 - 75.965 mm plus 0.5 or 1.0 mm as stamped in piston head
Standard size minus 0.15 mm
Cylinder Diameter Measurement
*If the piston diameter is less than the service limit, replace it. NOTE Olf
the cylinder has been bored oversize, use the
Oversize Piston Diameter table. 10mm
E9
20mm
Piston/Cylinder Clearance
40mm
eMeasure the piston diameter at the point shown with a micrometer.
-Measure the piston diameter (see Cylinder/Piston Wear). eMeasure the cylinder inside diameter with a dial bore gauge at the bottom of the cylinder. -Subtract the piston diameter from the cylinder inside diameter to get the piston/cylinder clearance. *If the piston/cylinder clearance is less than the specified range, use a smaller piston or increase the cylinder inside diameter by honing (see Cylinder Boring and Honing). *If the piston/cylinder clearance is greater than the specified range, use a larger piston or bore to the next larger oversize (see Cy lind er Boring and Honing).
Piston Diameter Standard: Service Limit:
75.950 - 75.965 mm 75.81 mm
Piston/Cylinder Clearance Standard:
0.035 - 0.062 mm
Piston Diameter Measurement
Cylinder Boring and Honing -When boring and honing a cylinder, fo llow the boring and honing too l manufacturer's instructions. Note the following . -Before boring a cylinder, measure the diameter of the piston to be used. Bore and hone the cylinder to obta in the standard piston/ cylinder clearance specified. _Cylinder inside diameter must not vary by more than 0.01 mm at any point. -Do not measure the cyli nd er inside d iameter immediately after boring or honing, because the boring and honing operations heat the cylinder. Heat affects cylinder size.
3·28 ENGINE TOP END
Piston/Cylinder Seizure e ln case of seizure, remove the cylinder (see Cylinder Removal). _Visua ll y inspect the cylinder and piston damage. *If there is only light damage, smooth the piston with #400 emery cloth. Remove small aluminum deposits from the cylinder with #400 emery cloth or light honing. *If the damage is severe, the cylinder must be bored oversize and an oversized piston installed.
A. Thickness Gauge
Piston Cleaning eRemove the piston and piston rings (see Piston and Ring Removal).
[CAUTlO~J ONever clean the piston head with the engine assembled. Carbon particles will fall between the piston and cylinder and damage the crankshaft bearings. I
*If the piston ring groove clearance is greater than the service limit, measure the ring thickness and groove width as follows to decide whether to replace the rings, the piston or both. eMeasure the piston ring groove width. OUse a vernier caliper at several points around the piston .
esc rape the carbon off the piston head. cUse the scraping tool carefully . Do not gouge the piston head. -Clean the piston ring groove with a broken piston ring or other suitable tool.
Piston Ring Groove Width Top Standard: Service Limit: Second Standard: Service Limit: Oil Standard: Service Limit:
OBe careful not to widen the ring grooves or the piston must be replaced.
*If the width of any of the three grooves is wider than the service limit at any point, replace the piston. eMeasure the piston ring thickness. oUse a micrometer to measure at several points around the ring.
1.22 -1.24 mm 1.32 mm 1.21 -1 .23 mm 1.31 mm 2.51 - 2.53 mm 2.61 mm
Piston Ring Thickness (Top & Second) Standard: 1.170 -1.190 mm 1.10 mm Service Limit:
Piston Ring and Ring Groove Wear -Visually inspect the piston rings and ring grooves. *If the piston rings are worn unevenl y or damaged, replace t hem. *If the ring grooves are worn unevenly or damaged, replace both the pi ston and piston rings. eMeasure the clearance between the top and second rings and their grooves. o lnstall the rings in their grooves. OUse a thickness gauge to measure the clearance at several points around the piston.
*If any of the measurements is less than the service limit on either of the rings, replace the entire set of rin gs. NOTE OWhen using new rings in a used piston, check for uneven groove wear. The rings should fit perfectly parallel to the groove sides. If not, replace the piston.
pjston Ring End Gap (top and second only) Piston Ring/Groove Clearance Top Standard: 0.03 0.17 Service Limit: Second Standard: 0.02 Service Limit: 0.16
- 0.07 mm mm - 0.06 mm mm
eRemove the piston rings (see Piston and Ring Removal). ePush each ring (one at a time) into the bottom end of the cylinder. OUse the piston to push it in to be sure it is square. eMeasu re the gap between the ends of the ring with a th ickness gauge. .
ENGINE TOP END 3-29
A. Piston Ring
B. Thickness Gauge
A. Drain Plug B. Spark Arrester
c.
Mounting Bolt
*If the end gap of either ring is greater than the service limit, replace the entire set of rings.
WARNING. Piston Ring End Gap (Top & Second) Standard: 0.20 - 0.35 mm Service Limit: 0.7mm
000 not run the engine in a closed area. Exhaust gases contain carbon monoxide; a colorless, odorless, poisonous gas. Breathing exhaust gas leads to carbon monoxide poisoning, asphyxiation, and death . oNever run the engine with the spark arrester removed. Hot carbon particles may start a fire. NOTE
· •• i ••••••••••• • ••••••••••••••••••••••• • •••••••••• • •••• • •• • •••••• •• •••••••••••
Exhaust System Spark Arrester: This vehicle is equipped with a spark arrester approved for off·road use by the U.s. Forest Service. It must be properly maintained to ensure its efficiency. In accordance with the Periodic Maintenance Chart, clean the spark arrester.
ORun the engine with the spark arrester installed during cleaning. This keeps the exhaust pressure higher and makes carbon panicles purge easier. eStop the engine . elnstall the drain plug. eRemove the spark arrester mounting bolt from the muffler. ePull the spark arrester out of the muffler. eScrape carbon deposits off the spark arrester and slide it back into the muffler. elnstall the mounting bolt and tighten it securely.
Spark Arrester Cleaning
I WARNING. aTa avoid burns, wear gloves while cleaning the spark arrester. Since the engine must be run during this procedure, the muffler will become hot.
OThe spark arrester must be installed correctly and functioning properly to provide adequate fire protection. eRemove the drain plug on the rear muffler. eln an open area away from combustible materials, start the engine with the transmission in neutral. eRaise and lo wer engine speed while tapping on the muffler with a rubber mallet until carbon particles are purged from the muffler.
Exhaust Pipe and Muffler: Exhaust Pipe and Muffler Removal e Loosen the muffler clamp bolt until the clamp turns freely on the muffler. -Take out the muffler mounting bolts. Do not lose the coll ars. OFor extra clearance, first remove the rear fender assembly (see Rear Fender Removal in the Frame chapter). eRemove the muffler from the rear of the frame. eTake off the exhaust pipe holder nuts at the cylinder head. -Work the exhaust pipe out of the frame and remove it. -Remove the exhaust pipe ho ld er and split coll ar. -Remove the exhaust pipe gasket from the cylinder head.
3-30 ENGINE TOP END OPosition the exhaust pipe in the exhaust port.
oSlide the holder into place on the studs. oThread on the nuts, but do not tighten them yet. eFit the gasket into the muffler so that the chamfered
side of the gasket faces to the front.
A. Mounting Bolts
A. Chamfer eSl ip the muffler in to place from tlie rear of the frame, so that it fits over the exhaust pipe.
aBe sure that the collars are in place in the rubber dampers in the muffler. OHoid the muffler up and put in the mounting bolts, but do not tighten them yet. eTighten the exhaust pipe holder nuts evenly and A. Holder Nuts
B. Clamp
securely. _Tighten the muffler mounting bolts securely_
eTighten the muffler clamp bolt securely. elf the rear fender was removed, install it (see Rear
Fender Installation in the Frame chapter).
Exhaust Pipe and Muffler Installation -Smear a little grease on a new exhaust pipe gasket and stick it in to the exhaust port in the cylinder head. _Slip the exhaust pipe holder over the exhaust pipe.
Exhaust System Inspection
eAttach the exhaust pipe loosely to the cylinder head.
eBefore removing the exhaust system, check for signs of
OTape the sp lit collar in place as shown.
leakage at the exhaust pipe gasket in the cylinder head and at the muffler clamp . *If there are signs of leakage around the exhaust pipe gasket, it should be replaced. If the muffler-to-exhaust pipe joint leaks, tighten the clamp. eRemove the exhaust system (see Exhaust Pipe and Muffler Removal). el nspect the gasket for damage and signs of leakage. *If the gasket is damaged or has been leaking, replace it. -Check t he exhaust pipe and muffler for dents, cracks, rust and holes. *If the ex haust pipe or muffler is damaged or holes, it should be replaced for best performance and least noise.
A. Split Keeper
B. Holder
ENGINE LEFT SIDE 4-1
Engine Left Side Table of Contents
Exploded View ...... .. . ... . _ ................... . ....... .. . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Left Engine Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Left Engine Cover Removal. . . . . . . . . . . . . . . . . . . . . . . . Left Engine Cover Installation. . . . . . . . . . . . . . . . . . . . . . Alternator Rotor and Stator (see Electrical System chapter) Pickup Coil (see Electrical System chapter) Starter Clutch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starter Clutch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .
... ... ... ... ...
4-2 4-3 4-3 4-4 4-4 4-4
....... .......
4-4 4-4
.... .... .... .... . . ..
Starter Clutch Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . Starter Clutch Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . Starter Chain and Sprockets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starter Chain and Sprocket Removal. . . . . . . . . . . . . . . . . . . Starter Chain and Sprocket Installation ........... _ . . . . .
... ... ... ... ...
.. .. .. .. ..
4-5 4-5 4-5 4-5 4-5
Starter Chain Wear . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . . . . .
4-6
4·2 ENGINE LEFT SIDE Exploded View ................................. . ..........................................
Engine No. 017644 and up
L : Apply a non-permanent locking agent. Tl : 49 N'm (5.0 kg·m. 36 ft·lb)
ENGINE LEFT SIDE 4-3
Specifications
Item
Standard
Starter Chain 20-Link Length
155.8-156.1 mm
Special Tool Along with common hand tools, the following more special ized tool is req uired for complete engine left
side servicing. Flywheel Holder: 57001-308
NOTE OThe flywheel holder (57001-1313) can be used instead of the flywheel holder (57001-308).
Service Limit 158.0 mm
4-4 ENGINE LEFT SIDE Left Engine Cover Left Engine Cover Removal .Place an o il pan be neath the engine left side . eDi scon nect the al ternator co nnector and pickup coi l
co nn ector. eRemove the left engine cover. o Remove the differential shift lever case. oUnsc rew the cover mounting bolts.
A. Grommet for Alternator Lead B. Grommet for Pickup Coil Lead
-Tighten the front gea r case 8 mm mounting bolt to t he specified to rque (see Exp loded View in the Final Dri ve chapter). eAdd engine o il (see En gine Oil and Oil Filter Change in the Engine Right Side chapter).
A. Left Engine Cover Mounting Bolts B. Differe ntia l Shift Lever Case
Starter Clutch Left Engine Cover Installation -Left engi ne cover installation is the reverse of removal. Note the following. eBe su re all of the o ld gasket has been removed fro m the left engin e cover and the left hand crankcase seali ng surfaces. -Check the dowel pi ns are in place, and fit a new gasket o n the cra nkc ase.
Starter Clutch Removal
A. Dowe l Pins
A. Flywheel Holder: 57001-308
eFit th e lead gromme ts into the notch es on the left e ngin e cove r.
eTake out the one-way clutch.
-Remove the alternator rotor (see Alternator Rotor Removal in the El ectrical System chapter). eH o ld the roto r with t he flyw hee l holder (special tool) and take out the All en bolts.
ENGINE LEFT SIDE 4·5 NOTE
OExamine the staner chain sprocket as well. Replace it if it is worn or damaged.
• A. One-way Clutch
Starter Clutch Installation -Starter clutch installation is the reverse of removal. Note the following.
A. Inspect surface.
eApply a non-permanent locking agent to the threads of
the Allen bolts which hold the starter clutch to the flywheel. -Tighten the Allen bolts to the specified torque (see Exploded View) .
Starter Chain and Sprockets
Starter Chain and Sprocket Removal Starter Clutch Inspection eRemove the left engine cover (see Left Engine Cover Removal ). eTurn the alternator rotor.
eRemove the alternator rotor (see Alternator Rotor Removal in the Electrical System chapter). -Take out the screw and remove the sprocket guide.
A. Sprocket Guide A. Turn freely.
B. Turn with starter chain sprocket. .Pull both sprockets off simultaneously with the chain.
*If the alternator rotor turns counterclockwise freely from the starter chain sprocket, but not clockwise, the clutch is operating as it should. *If the clutch does not operate as its should, or if it makes noise, disassemble it (see Starter Clutch Removal), examine each part visually, and replace any worn or damaged parts.
Starter Chain and Sprocket Installation -Starter chain and sprocket installation is the reverse of removal. Note the following. -The protruding side of the small sprocket must face in.
4-6 ENGINE LEFT SIDE
A. Toward engine.
eThe protruding side of the large sprocket must face out.
Starter Chain Wear eHold the starter chain taut with a force of about 5 kg in some manner, and measure a 20·link length. Since the chain may wear unevenly, take measurements at several places. *If any measurement exceeds the service limit, replace
the chain.
Starter Chain 20·Link Length Standard: Service limit:
155.8 - 156.1 mm 158.0 mm
Starter Chain Measurement
1st
2nd 20·!ink Length
21st
ENGINE RIGHT SIDE 5-1
Engine Right Side Table of Contents Exploded View . ... .. .. . . . . . . . . . ... . Specifications . .. . . . . . . . . . . . . ... .. . .
Special Tool s . . . . . . . . . . . . . . . . _ . ... . Right Engine Cover . . . . . . . . . . . . . . ... . Right Engine Cover Removal . .... .. .
Right Engine Cover Installation . .... .
Clutches .. . . . . . . . . . . . . . . . . . . . . . . . Clutch Adjustment . . ... .... . . .. . . . Clutch Adjustment .... • . ....•... Clutch Removal . . . . . . . . . . . . . .. . . Clutch Removal . . . . . . . . . . . .•. . CI utch In stallation . .... . . . . . . . . . Clutch Inspection . .. . . . . . . . . . . ...
. . . .
Primar y Clutch Housi ng Wear ...... . Primary Clutch Shoe Lining Wear . . .. One-way Clutch Inspection . . . . . . . . Friction Plate Wear and Damage . . . . . Friction Plate and Steel Plate Warp . . . Secondary Clutch Housing Finger Damage . . . . . . . . . . . . . . Secondary Clutch Hub Spline Damage . Secondary Clutch Spring Wear . .. . ..
. . . .
5·2 5·3 5·3 5·4 5·4 5·4 5-4 5·4 5·4 5·5 5·5
Primary Gear Installation. . . . . . . . . .
5-9
Secondary Gear Install atio n. . . . . . . . . Primary and Secondary Gear Damage . .
5·9 5-9
Gear Backlash. . . . . . . . . . . . . . . . ..
5·10
Primary Gear /Crankshaft Wear. . . . .
5-10
Secondary Gearl Collar Wear. . . . . . ..
5·10 5·11 5·11 5·11 5·11 5·12 5·12 5·12 5·13 5·13 5·13 5·13 5·13 5·13 5·14 5·14 5·14 5·14 5·14
Lubrication System . . . . . . . . . .. .. . ... . Engine Oil and Filter . . . . . . . . . . . . . . . Engine Oil Level Inspection . . . . . .. . . Engine Oil and Filter Change . ... . .. .
5·6
Oil Pump . . . . . . . . . . . ..... . .. .. . .
5·7 5·7 5·7 5·7
Oil Pump Removal. . . . . . . .. . . . . . .
5·8 5·8
Oil Pump Inspection . . . . . . . . . . . . .
Oil Pump Installation . .. ... . . . . . . . Oil Pump Disassembly . . . . . . . . . . . .
Oil Pump Assembly . . . . . . . . . . . . . . Oil Screen . . . . . . . . . . . . . . ... . ... . Oil Screen Removal . . . . . . . . . . . . . .
. . .
Clutch Release . . . . . . . . ... . . . . . . . . Clutch Release Removal . .. .. . . ... . Clutch Release Installation . .. . . . . . . Clutch Release Wear . ..
5·8 5·8 5·8 5·9 5·9 5·9 5·9
Primary Reduction . . . . . . . . . . . . . . . . . .
5-9
Primary Gear Remova l. . . . . . . . . . . .
5-9
5-9
Seco ndar y Gear Removal . . . . . . . . . .
Oil Screen Installation . . . . . . . . . . . , Oil Screen Cleaning and In spection . .. . Oil Filter Bypass Valve . . . . . . . . ... , .. Bypass Valve Removal . . . . . . . . .. . . Bypass Valve Installation . .. .. , Bypass Va lve Cleaning and Inspection . .
5-2 ENGINE RIGHT SIDE Exploded View
M : Apply a molybdenum disulfide grease. Q : Apply an oil to the threads and seated surface. T1: 125 N-m (13.0 kg·m. 94 ft-Ibl T2: 12 N-m (1.2 kg-m. 104 in-Ibl T3: 78 N-m (8.0 kg-m. 58 ft-Ibl T4: 29 N-m (3.0 kg-m. 22 ft-Ibl
ENGINE RIGHT SIDE 5-3 Specifications Clutches : Item
Standard
Service Limit
Primary Clutch Housing I nside Diameter
125_0 - 125_2 mm
125_5 mm
Primary Clutch Shoe Groove Depth
1_0 mm
0.5mm
Friction Plate Thickness
2.92 - 3.08 mm
2.8mm
Friction Plate Warp
Under 0.15 mm
0.3mm
Steel Plate Warp
Under 0.2 mm
0.3 mm
Clutch Spring Free Length
30.38 mm
28.8 mm
Primary Clutch:
Secondary Clutch:
Primary Reduction: Standard
Service Limit
Gear Backlash
0.02 - 0.11 mm
0.14 mm
Primary Gear I nside Diameter
27.000 - 27.021 mm
27.03 mm
Crankshaft Diameter
26.959 - 26.980 mm
26.94 mm
Secondary Gear Inside Diameter
25.000 - 25.021 mm
25.03 mm
Secondary Gear Collar Diameter
24.970 - 24.985 mm
24.95 mm
Item
Lubrication System: Item Engine Oil:
Service Limit
Standard Grade
SE or SF class
--
Viscosity
SAE 10W-30, 10W-40, lOW-50, 20W-40,20W-50
--
Capacity:
1.7L
--
Special Tools
Gear Holder: 57001-1015
Along with common hand tools, the following more specialized tools are required for complete engine right side serv icin g. Flywheel Holder: 57001-308 NOTE oThe flywheel holder 157001-1313) can be used instead of the flywheel holder 157001-308).
5-4 ENGINE RIGHT SIDE Right Engine Cover
Right Engine Cover Removal eDrain the engine oil (see Engine Oil and Oil Filter Change). eRemove the right footpeg . -Take out the bolts and remove the right engine cover. oThe clutch release assembly comes out with the right engine cover.
Right Engine Cover Installation eBe sure all of the old gasket has been removed from the right engine cover and the right hand crankcase sealing
surfaces. ec:heck that the following items are in place: Dowel pins Clutch release cams and ball assembly
A. Compressed Air
-Install the right engine cover and tighten the screws securely. eAdjust the clutch (see Clutch Adjustment). elnstall the right footpeg. eFili the engine with oil (see Engine Oil and Oil Filter Change).
Clutches Clutch Adjustment:
Clutch Adiustment A. Dowel Pins B. Clutch Release Cams and Ball Assembly
aRemove the clutch release adjusting screw cover.
oThe projected portion of the ball assembly must be faced in.
A. Clutch Release Adjusting Screw Cover A. Projected Portion OAp ply a molybdenum disulfide grease to the pivot of the outer cam. eFit a new right engine cover gasket. eUsing compressed air, blowout any particles which may obstruct the oil passage on the right engine cover.
aloosen the clutch release adjusting screw locknut. aTurn the adjusting screw clockwise until it becomes hard to turn. aTurn the adjusting screw counterclockwise until it becomes hard to turn.
eTighten the locknut without changing the adjusting screw position.
ENGINE RIGHT SIDE 5-5
A. Adjusting Screw
B. Locknut
elnstall the clutch release adjusting screw cover.
A. Recess
eTake out the primary clutch hub assembly, in'ner race, and one-way clutch : Dinner race can easily be removed by turning clockwise.
Clutch Removal: Clutch Removal eRemove the right engine cover (see Right Engine Cover Removal ). -Using the gear holder (special tool), hold the primary gear and secondary gear to keep them from turning, and remove the primary clutch hub nut.
A. Turn clockwise. B. Inner Race
C. One-way Clutch
.Remove the secondary clutch hub and clutch plate assembly as a set. .Remove the secondary clutch housing and sleeve. There is the spacer behind the sleeve . • To remove the secondary clutch plates, unscrew the clutch spring bolts and take off the spring plate and springs.
A. Gear Holder: 57001-1015 B. Primary Clutch C. Secondary Clutch
D. Ball Bearing E. Pusher
elf the seconday clutch will be removed, remove the
pusher and ball bearing from the secondary clutch spring plate, and loosen the secon dary clutch hub nut at this time . • -;-'.'''-, Llle secondary clutch until the recess on the secondary clutch housing comes against the primary gear, and pull out the primary clutch housing with the hub.
A. Spring Plate
B. Secondary Clutch Hub
5-6 ENGINE RIGHT SIDE
Clutch Installation • Primary and secondary clutch instaltation is the reverse
of removal. No te the following. -Assemble the secondary clutch plates. o lnstall the friction plates and steel plates to the clutch hub, starting with a friction plate and alternating them.
.cross tighte n the secondary cl utch sp ring bolts evenly to th e specified torque (see Explo ded View) . e Be sure that the clutch whee l spli nes fit onto th e cl utch hub splines. When t he cl utch wheel is installed correctly, there is no gap be tween the clutch whee l an d the nex t friction plate, and clutch plates have no play.
( CAUTlO~J Olf new dry steel plates and friction plates are installed,
apply engine oil to the surfaces of each plate to avoid clutch plate seizure.
o lnstall the clutch wheel so that the mark on the clutch wheel is aligned with the mark on the clutch hub.
A. Clutch Wheel B. Friction Plate
C. No gap
-Fit the one-wa y clutch in to the primary clutch housing. OFit the projec tion on the cage into the groove o n the
hou sing first, and then install the one·way clutch A. Align th e marks. B. Clutch Wheel
C. Clutch Hu b
completely.
Olnsta ll the c lutch spring plate with the springs an d spring bolts temporarily, and fit the cl utc h hub an d plate assemb ly in to t he cl utch housi ng aligning the
friction plate tangs with the cl utch housing fi ngers and clutch hub spli nes wit h the dri ve shaft spli nes.
A. Projection
B. Groove
eTighten the primary an d secondary clutch hub nuts to A. Align the friction plate tangs with the clutch hou sing
fingers. B. Align the clutch hub splines with the drive shaft spli nes.
t he specified torque (see Exploded View). OApp ly a small amou nt of oil to the threads an d the
seating surfaces of the primary and secondary clutch hub nu ts.
ENGINE RIGHT SIDE 5-7
Clutch Inspection: Primary Clutch Housing Wear eMeasure the inside diameter of the clutch housing where the shoes wear against it. o Use calipers and measure at several points as shown. *If an y measurement is greater than the service limit, replace the primary clutch housing.
v
One-way Clutch Inspection
f
eRemove the right engine cover (see Right Engine Cover Removal). -Turn the primary clutch housing by hand. When viewed from the right side of the engi ne, the primary clutch housing shou ld turn counterclockwise freely, but should not turn clockwise.
Primary Clutch Housing Inside Diameter Standard: Service Limit:
125.0 -125.2 mm 125.5 mm
Primary Clutch Shoe Lining Wear -Visuall y inspect the primary clutch shoe lining for uneven wear, discoloration, or missing frict ion material, cracks, or other damage. *If any of the linings are damaged, replace the shoes as a
set. A. Turn freely.
B. Locked.
*If the one-way clutch does not operate as it should or if it makes noise, go to the next step. -Remove the primary clutch (see Clutch Removal). Visually inspect the clutch parts: one-way clutch, inner race, and outer race at the primary clutch housing. *If there is any worn or damaged part, replace it.
A. Primary Clutch Shoe Linings
eMeasure the shoe groove depth. o Use a depth gauge, and measure at several po in ts as shown. *If any measurement is less than the service limit, replace all shoes as a set. Primary Clutch Shoe Groove Depth Standard: Service Limit:
1.0mm 0.5mm
A. 1nner Race B. One·way Clutch
c. Ou ter Race
5-8 ENGINE RIGHT SIDE Friction Plate Wear and Damage -Visually inspect the friction plates for uneven wear, discoloration, or missing friction material, cracks, or other damage.
*If any of the friction plates are damaged, replace
.
~-.
eMeasure the thickness of the friction paltes at several
Secondary Clutch Housing Finger Damage eVisually inspect the fingers of the clutch housing where the housing of the friction plates hit them. *If they are badly worn or if there are grooves cut where the tangs hit, replace the housing. Also, replace the friction plates if their tangs are damaged.
points.
Friction Plate Thickness
Standard: Service Limit:
2.92 - 3.08 mm 2.8mm
Friction Plate Thickness
A. Clutch Housing Finger
*It any of the measurements is less than the service limit, replace the friction plate.
Friction Plate and Steel Plate Warp
Secondary Clutch Hub Spline Damage -Visually inspect where the teeth on the steel plates wear against the splines of the clutch hub. *If there are notches worn into the splines, replace the clutch hub. Also, replace the steel plates if the ir teeth are damaged.
-Lay each plate on a surface plate.
-Hold one side down and use a th ickness gauge to measure the gap between the other side of the plate and the surface plate . • *If any of the clutch plates is warped beyond the service limit, replace it.
Friction Plate and Steel Plate Warp
Standard:
Under 0.15 mm (Friction Plate) Under 0.2 mm (Steel Plate)
Service Limit:
0.3mm
A. Clutch Hub Spline
Secondary Clutch Spring Wear eMeasure the spring free length. *If measurement is less than the service limit, replace it. Clutch Spring Free Length A. Friction Plate B. Steel Plate
C. Thickness Gauge
Standard: Service Limit:
30.38 mm 28.8 mm
ENGINE RIGHT SIDE 5-9
Clutch Release: Clutch Release Removal eRemove the right engine cover (see Right Engine Cover Removal). eRemove the clutch release adjusting screw cover from the outsid e of the right engine cover. -Unscrew the locknut and adjusting screw. eTake off the flat washer and O·ring. ePull the clutch release lever and spring out of the right engi ne cover. eRemove the E·ring, and pull the clevis pin from the clutch release lever clevis.
*If the Coring is damage, deteriorated, compressed, or hardened, replace it. If the cam area is damaged, or if the ball assembly is worn visibl y, replace the damaged part. Also inspect the clutch release lever spring for damage. Replace it if necessary.
........................................................................... .. Primary Reduction
.............................................................................
Primary Gear Removal eTh e primary gear is removed during primary clutch
removal (see Clutch Removal).
Primary Gear Installation A. Clutch Release Lever B. Clevis C. Pin
D. E·ring E. Spring
eThe primary gear is installed during primary clutch installation (see Clutch Installation).
Secondary Gear Removal eThe secondary gear is removed during clutch removal
ePul1 the release cams and ball assemb ly from the shift shaft.
(see Clutch Removal) .
Secondary Gear Installation Clutch Release Installation
eThe secondary gear is installed installation (see Clutch Installation).
during clutch
eclutch release installation is the reverse of removal.
Primary and Secondary Gear Damage Clutch Release Wear eVisually inspect the O-ring at the clu tch adjusting screw, the cam area, and the ball assembly.
A. Cam Area
eVisually inspect the teeth on the primary and secondary gears. *If heavy damage is found, replace the damaged gear. *If light damage is found, repair it with an oil-stone.
5-10 ENGINE RIGHT SIDE Gear Backlash eRemove the right engine cover (see Right Engine Cover Removal). -Set a dial gauge against the teeth on one gear, and move the gear back and forth whi le holding the other gear steady. The difference between the highest and the lowest gauge readings is the amount of backlash. *If the amount of backlash exceeds the service limit, replace both gears.
Gear Backlash Standard : Service Limit:
0.02 -0.11 mm 0.14 mm *If the inside diameter of the primary gear is greater than the service limit, replace it. *If the outside diameter of the crankshaft is less than the service limit, replace it.
Primary Gear Inside Diameter
Standard:
27.000 - 27.021 mm
Service Limit:
27.03 rnm
Crankshaft Diameter
Standard: Service Limit:
26.959 - 26.980 mm 26.94 mm
A. Move back and forth lightly. B. Hold steady.
Secondarv Gear/Collar Wear eMeasure the in side diameter of the secondary gear. eMeasure the outside diameter of the collar mounting on the drive shaft.
Primary Gear/Crankshaft Wear eMeasure the inside diameter of the primary gear. eMeasure the outside diameter of the crankshaft.
1r
*If the inside diameter of the secondary gear is greater than the service limit, replace it. *If the outside d iameter of the coll ar is less than the service limit, replace it.
ENGINE RIGHT SIDE 5-11 Secondary Gear Inside Diameter
Engine Oil and Filter Change
Standard: 25.000 - 25.021 mm 25.03 mm Service Limit: Secondary Gear Collar Diameter
-Warm up t he engine, then shu t if off. -Set a pan beneath t he engi ne and remove the oil drain plug.
Standard: Service Limit:
24.970 - 24.985 mm 24.95 mm
Lubrication System Engine Oil and Filter:
Engine Oil Level Inspection -Park the vehicle so that it is level, both side-to-side and front-to-rear. -If the o il has just been changed, start the engine and run it for several minutes to fill the oi l fi lter.
A. Oi l Drain Plug
-Remove the oil filter. oTake out the oi l filter cover bolts.
OAllow the engine to idle for several minutes so that oil may reach all parts of the engine. Racing a "dry" engine may cause severe damage.
-Stop the engine and wait several minutes for all the oil to drain back to the sump. echeck the level of the oil in the window gauge in the lower part of the ri ght engine cover. .The o il leve l should be between the lines next to the gauge.
A. Oil Filter Cover Bolts o Remove the oi l filter cover. o Pull out the o il filter; the filter mountin g pin wil l probab ly come out with it.
A. Gauge
B. Leve l Lines
*If the level is too hi gh, suc k the excess oil out the filler hole with a sy ringe or other suitable device. *If the level is too low, add oil throu gh the filler hole. Use the same type and make of oil that is already in the engi ne.
A. Oil Filter
B. Filter Mounting Pin
5-12 ENGINE RIGHT SIDE o Pull the filter off the pin. elnstall the new filter. a Be sure both filter grommets are in place. lightly and push the filter onto the pin.
Oil them
A. Oil Pump Guard
B. Oil Pump Gear
ePull the oil pump gear from the oi l pump. eTake out the screws and remove the oil pump.
A. Grommets
OPut the filter with pin into the filter cavity. The larger end of the pin goes in first. OCheck that the filter cover O·ring is in place. Olnstall the o il filter cover and tighten the bolts secu rely . elnstall the oil drain plug with a new aluminum gasket, and tighten it to the specified torque (see Exploded View). eFili the engine with the specified oil and quantity.
A. Screws
Engine Oil Grade: Viscosity: Capacity:
SE or SF class SAE 10W-30, 10W-40, 10W-50, 20W-40, or 20W-50 1.7 L
Oil Pump Installation elnstallation is the reverse of removal. Note the following. eSe sure the dowel pins under the oi l pump are in place.
eBe sure the O·ring is In place, and install the filler cap.
Oil Pump:
Oil Pump Removal eRemove the primary clutch (see Clutch Removal) . -Take out the screws and remove the oil pump guard.
A. Dowel Pins
ENGINE RIGHT SIDE 5-13 eFill the pump with engine oil before installation.
ePull the pin out of the pump shaft, and pull off the shaft.
Oil Pump Assembly eOi l pump assembly is the reverse of disassembly. Note the following. eSe sure the dowel pi n is in place in the pump body. eBefore installing the oil pump, be sure the gear and rotors turn freely.
Oil Pump Inspection A. Oi l
eVisual ly inspect the oil pump body, rotors, and cover. * If there is any damage or uneven wear, rep lace the oil pump assembly.
Oil Pump Disassembly eRemove the o il pump (see Oil Pump Removal). eTake out the oil pump cover screw.
Oil Screen:
Oil Screen Removal eRemove the right engine cover (see Right Engine Cover Removal). ePul1 the screen out of the crankcase.
A. Screw eTake off the oi l pump cover. eD rop the rotors out of the oil pump body.
A. Oil Screen
Oil Screen Installation A. Rotors B. Oil Pump Body
C. Oil Pump Cover D. Dowel Pin
eOil screen installation is the reverse of removal. Note the followi ng. e(lean the screen thoroughly whenever it is removed for any reason.
5-14 ENGINE RIGHT SIDE Oil Screen Cleaning and Inspection
-Drop out the spring and the bypass valve piston.
eelean the oil screen with high flash-point solve nt and remove any particles stuck to it.
I WARNING. OClean the screen in a well·ventilated area, and take care that there is no spark or flame anywhere near the working area. Because of the danger of highly flammable liquids, do not use gasoline or low flash-point solvents.
Bypass Valve Installation -Drop the bypass valve piston closed end first into the filter mounting pin. ePut the spring into the mounting pin and compress it beyond the small hole. eDrive the retaining pin into the small hole to hold the spri ng. elnstall the oil filter (see Engine Oil and Filter Change).
Bypass Valve Cleaning and Inspection eelean the bypass va lve parts in a high flash-point solvent.
WARNING. NOTE aWhile cleaning the screen, check for any metal particles
that might indicate internal engine damage. -Check the scree n carefully for any damage: holes, broken wires, gasket pulling off. *If the screen is damaged, replace it.
Oil Filter Bypass Valve: Bypass Valve Removal eRemove the oil filter (see Engine Oil and Filter Change . Oil draining is not necessary). eDrive the retaining pin out of the filter mounting pin.
A. Filter Mounting Pin
B. Retaining Pin
oelean the parts in a well-ventilated area, and take care that there is no spark or flame anywhere near the working area. Because of the danger of highly flammable liquids. do not use gasoline or low flashpoint solvents.
eVisually inspect the bypass valve parts. *If the sp ring is bent or distorted, rep lace it. If the piston is worn, replace all of the bypass valve parts.
ENGINE REMOVAL/INSTALLATION 6·'
Engine Removal/Installation Table of Contents
Exploded View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • .
6·2
Engine Removal / I nstallation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6·3
Engine Removal . . . . . . . . . . • . . . . . . . . . . . . . . . . . . . . . • . . . . . .
6·3
Engine Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6·3
6-2 ENGINE REMOVAl/INSTALLATION Exploded View
T1 : 25 N-m (2.5 kg-m, 18.0 ft·lb) T2: 34 N-m (3.5 kg-m, 25 ft-Ib)
ENGINE REMOVAl/INSTALLATION 6-3
Engine Removal/lnstallation
Engine Removal eDrain the engine oil (see Engine Oil and Fi lter Change in the Engine Right Side chapter). eRemove the following parts. Front Fender and Rear Fender Fuel Tank Carburetor
Exhaust Pipe and Muffler Differential Shift Lever Case Shift Pedal eDisconnect the followi ng cable and leads from the engine. Reverse Cable Starter Motor Lead Alternator Leads Pickup Coil Leads Spark Plug Lead Battery Ground Lead
A. Mounting Bolts
B. Bracket Bolts
eFree the cy linder head vent hose and carburetor vent
hose from the frame. eLoosen the propeller shaft dust cover front clamp. eRemove the engine mounting bolts and bracket bolts.
Olt may be necessary to support the engine while sliding out the engine mounting bolts.
eLift the engine up to free the engine from the mounts, pull the engine to the right si de of the frame, and free the engine from the propeller shaft.
Engine Installation eEngine installation is the reverse of removal. Note the
A. Differential Shift Lever Case B. Battery Ground Lead
A. Mounting Bolts B. Bracket Bolts
following. eApply grease to the sp lines at the front end of the propeller shaft and fit the propeller shaft front end to the front driven gear shaft rear end. OFar extra clearance, first slide back the rear ax le and propeller shaft (see Front Gear Case Removal in the Final Drive chapter).
C. Dust Cover Clamp A. Apply grease.
64 ENGINE REMOVAl/INSTALLATION eTighten the engine mounting bolts and bracket bolts to the specified torque (see Exploded View) . eRoute the vent hoses as shown.
A. Cylinder Head Vent Hose
A. Carburetor Vent Hose
eFil1 t he engine with engine oil (see Engine Oi l and Filter Change in the Engine Right Side chapter). eAdju st the reverse cable (see Reverse Cable Adjustment in the Engine Bottom End/Transmission chapter).
ENGINE BOTTOM END/TRANSMISSION 7-1
Engine Bottom End/Transmission Table of Contents Exploded View
... . • ..... • . . . . . . . • ..
Specifications . . . . . . • . . . . • . . . . . . . . . . Special Tools . . . . . . . .. . . . . . . . . . . . • . . Crankcase Splitting .. . . . . . . . . . . .. . . . . . Crankcase Disassembly . . . . . •... •.. Crankcase Assembly . . . . . . . • . . • . . . Crankshaft and Connecting Rod ... . .. . .. . Crankshaft Removal . . . . . . . • . . .. .. Crankshaft Installation .... . • . . . . . . Crankshaft Disassembly. . . . . . . . . . .. Crankshaft Assemb ly _ . . . . . . . . . • . .. Connecting Rod Bend /Twist . . . . . • . .. Connecting Rod Big End
7-2 7-4 7-4 7-5 7-5 7-5 7 -6 7 -6 7·6 7·6 7-6 7-7
Radial Clearance. . . . . . . . . . • . . .. Connecting ,Rod Big End
7-8
Side Clearance. . . . . . . . . . . . . . .. Crankshaft Alignment. . . . . . . . . . . .. Co nnecting Rod Big End Seizure . . . . .. Transmission . . . . . . . . . . . . . . . . . . . . . .. Transmission External Shift Mechanism ... External Shift Mechanism Removal External Shift Mechanism Installation . . . . . . . . . . __ . • . . . . External Shift Mechanism Inspection. . . . . . . . . . . . . . Shift Drum Stop Lever Removal . . . . . . S hift Drum Stop Lever Installation . . . . Shift Drum Stop Lever Inspection . . . . .
7-8 7-8 7-9 7-9 7-9 7-9 7-10 7-10 7-10 7-10 7-10
Reverse Knob and Cable . . . . . . . . . . . . . Reverse Knob Free Play inspection .... Reverse Cable Adjustment . . . . . . . . . . Reverse Knob and Cable Removal . . . . . Reverse Knob and Cable Installation .. . Reverse Cable Lubrication . . . . . . . . . . Reverse Cable Inspection . . . . . . . . . . . Transmission Shafts, Shift Drum, Forks ... Transmission Removal . . . . . . . . . . . . . Transmission Installation. . . . . . . . . Transmission Shaft Disassembly . . .... Transmission Shaft Assembly . . . . . ... Shift Fork Bending . . . . . . _ . . Shift Fork/Gear Groove Wear . . . . . . . . Shift Fork Guide Pin /Shift Drum Groove Wear .. .... . . . . . . . . . . . Gear Dog/Gear Dog Hole and Recess Damage. . . . . . . . . . . Balancer .. Balancer Drive Removal . . . . . • . . . . . . Balancer Drive Installation .. _ . . . . Balancer Removal . . . . . . . . _ . . . .... Balancer Installation . . . . . . . . . . . . . . Ball and Needle Bearings . . . . . . . .. ... . _ . Ball and Needle Bearing Replacement .. . . . . . . . . . . . .... Ball and Needle Bearing Wear . . . . . . . .
7·11 7·11 7·11 7·11 7·11 7-12 7-12 7-12 7-12 7-12 7-13 7-14 7-14 7-14 7 -14 7-15 7-15 7-15 7-16 7-16 7-16 7-16 7-16 7-16
II
7-2 ENGINE BOTTOM END/TRANSMISSION
............................................................................. Exploded View
.............................................................................
L : Apply a non-permanent lock ing agent. LG: Apply a liquid gasket. o : Apply an oil to the threads and seated surface. T1 : 78 N-m (8.0 kg·m. 58 ft-Ib) T2: 83 N·m (8.5 kg-m. 61 ft·lb) T3: 20 N-m (2.0 kg-m. 14.5 ft·lb) T4: 17 N·m (1.7 kg·m. 12.0 ft·lb) T5: 12 N-m (1 .2 kg·m.104 in·lb)
ENGINE BOTTOM END/TRANSMISSION 7-3
~
i'l/
T5
r~"
~
-L
T5 "
jY~ -
/
c:J -
74 ENGINE BOTTOM END/TRANSMISSION Specifications Crankshaft, Connecting Rod: Item
Standard
Service Limit
Connecting Rod Bend
Under 0.05/100 mm
0.2/100 mm
Connecting Rod Twist
Under 0.05/100 mm
0.2/100 mm
Connecting Rod Big End Radial Clearance
O.OOS - 0.020 mm
0.07 mm
Connecting Rod Big End Side Clearance
0.25 - 0.35 mm
0.6mm
Left Half
Under 0.03 mm T1R
O.OSmm TIR
Right ;Half
Under 0.04 mm T1R
0.10mmTIR
Item
Standard
Service Limit
Shift Fork Ear Thickness
4.4 -4.5 mm
4.3mm
Gear Shift Fork Groove Width
4.55 - 4.65 mm
4.Smm
Crankshaft Runout:
Transmission:
Shift Fork Guide Pin Diameter
5.9 - 6.0 mm
5.Smm
Shift Drum Groove Width
6.05 - 6.20 mm
6.3mm
Bearing Driver Set: 57001·1129
Special Tools
Along with common hand tools , th e following more specialized tools are required for complete engine bottom end / transmission servicing.
Circlip Pliers: 57001·144
Crankshaft Jig: 57001·1174 Oil Seal Guide: 57001·264
Flywheel Holder: 57001·308
e
Socket Wrench : 57001·1214
NOTE oThe flywheel holder 157001·1313} can be used instead of the flywheel holder 157001-30B}.
ENGINE BOTTOM END/TRANSMISSION 7-5 Crankcase Splitting
Crankcase Disassembly eRemove the engi ne (see Engine Removal in the Engine
Removal/Installation chapter). eRemove the following parts. Piston Starter Motor
Oil Filter Front Bevel Gear Case Front Bevel Drive Gear Output Shaft LH Bearing Housing Shift Drum Stop Lever Neutral and Reverse Switch Clutches Oil Pump External Shift Mechanism Alternator Rotor Camshaft Chain and Guides eRemove the gaskets and dowel pins on the outside of the eran kcase. -Remove the banjo bolts and take off the oil pipe.
A. Pry at these gaps. o Lift off the left crankcase half.
Crankcase Assembly NOTE aBe certain that all pans are cleaned thoroughly before assembly. OBlow through all oil passages with compressed air to clear any blockage.
A. Banjo Bolts eRemove the crankcase bolts.
A. Compressed Air
_Separate the crankcase halves. o Pry at the gaps at the front and rear of the crankcase to split the case halves apart.
A. Compressed Air
7-6 ENGINE BOTTOM END/TRANSMISSION 08e sure all transmission shafts, shift forks, and the shift drum are in place in the right crankcase half.
I WARNING' OClean the engine parts in a well·ventilated area, and take care that there are no sparks or flame anywhere near the working area; this includes any appliance with a pilot light. Do not use gasoline or a low flash·point solvent to clean parts. A fire or explosion could result.
Crankshaft Installation ePosition the right crankcase half so that the RH main bearing housing is seated on a suitable press fixture . ePress the crankshaft into the RH main bearing. Olnsert the crankshaft jig (special tool) between the crankshaft halves, opposite the crankpin, to prevent crankshaft distortion during installation.
eApply a small amount of engine oil to the transmission gears, bearings, and shift drum. eBe sure the mating surfaces of the crankcase halves are clean and dry. eBe sure the crankcase dowel pins are in position.
A. Crankshaft Jig: 57001-1174
eThe remainder of Crankshaft Installation is the reverse of Crankshaft Removal.
A. Dowel Pi ns
Crankshaft Disassembly NOTE
eApply a liquid gasket to the mating surface of the right crankcase half. -Fit the left crankcase half on the right crankcase half, an d tigh ten the cran kcase bol ts securel y. eRotate the shift drum to the neutral position. e<:heck to see that the crankshaft, drive shaft, and output shaft all turn freely. *If any of the shafts do not turn freely, split the crankcase to locate the problem. eThe remainder of Crankcase Assembly is the reverse of disassembly.
OSince assembly of the crankshaft demands exacting tolerances, the disassembly and reassembly of the crankshaft should only be performed by experienced mechanics with the necessary tools and equipment. oThe crankshaft left main bearing, chain sprocket, and left crankshaft are available separately as spare pan, however, it is recommended that the crankshaft assembly be replaced rather than attempting to replace the components.
ePress the crankpin out of the crank halves to separate the crank halves, connecting rod, crankpin needle bearing, and crankpin.
Crankshaft and Connecting Rod Crankshaft Removal
Crankshaft Assembly
eRemove the balancer drive gear (see Balancer Drive Removal). eSplit the crankcase (see Crankcase Disassembly) . eRemove the transmission (see Transmission Removal). eRemove the crankshaft from the right crankcase half with a press.
e<:heck that the connecting rod radial clearance is within specifications (see Connecting Rod Big End Radial Clearance) . ePress the crank halves onto the crankpin until connecting rod side clearance is within specifications (see Connecting Rod Big End Side Clearance).
ENG INE BOTTOM END/TRANSMISSION 7-7 Crankpin Oil Passage Alignment
Connecting Rod Bend
Vi ew A
A
ePress the camshaft chain sprocket into the crankshaft as shown. The chamfered side of it faces to the ball bearing.
Camshaft Chain Sprocket Installation
1
OSelect an arbor of the same diameter as the piston pin and at least 100 mm long, and insert the arbor through the connecting rod small end. OWith the connecting rod held vertically, use a height gauge to measure the difference in the height of the arbor above the surface plate over a 100 mm length to determine the amount of connecting rod bend. *If connecting rod bend exceeds the service limit, the connecting rod must be replaced.
Connecting Rod Bend Standard: Under 0.05/100 mm 0 .2/100 mm Service Limit: eMeasure connecting rod twist. OWith the crankshaft still in the alignment jig, hold the connecting rod horizontall y and measure the amount that the arbor varies from being parallel with the crankshaft over a 100 mm length of the arbor to determine the amount of connecting rod twist.
1. Direction of Crankpin Center
Connecting Rod Twist
100mm
eAdjust crankshaft runout until runout is within specifications (see Crankshaft Runout).
*If connecting rod twist exceeds the service limit, the connecting rod must be replaced.
Connecting Rod Bend/Twist eMeasure connecting rod bend. OSet the crankshaft in an alignment jig or in V blocks on a surface plate.
Connecting Rod Twist
Standard: Service Limit:
Under 0.05/100 mm 0.2/100 mm
7-8 ENGINE BOTTOM END/TRANSMISSION Connecting Rod Big End Radial Clearance -Check big end radial clearance. oSet the crankshaft on V blocks, and place a dial gauge against the connecting rod big end.
Connecting Rod Big End Radial Clearance
*If big end side clearance exceeds the service limit, the crankshaft assembly must be replaced or disassembled and the connecting rod and thrust washers visually inspected for wear.
Connecting Rod Big End Side Clearance Standard: 0.25 - 0 .35 mm Service Limit: 0.6mm
Crankshaft Alignment -Check crankshaft alignment by measuring runout. OWith the crankshaft on V blocks, turn the crankshaft slowly and measure runout at each of the locations shown. o Push the connecting rod first towards the gauge and then in the opposite direction. The difference between the two gauge read ings is the radial clearance. *If the rad ial clearance exceeds the service limit, the crankshaft assembly must be replaced or disassemb led and the crankpin, need le bearing, and connecting rod big end examined for wear.
Crankshaft Runout
~,
,
9mm
Connecting Rod Big End Radial Clearance Standard: Service Limit:
0.008 - 0.020 mm 0 .07mm
Connecting Rod Big End Side Clearance eMeasure big end side clearance. o lnsert feeler gauges between the big end and either crank half to determine clearance.
Connecting Rod Big End Side Clearance
T
*If runout at either location exceeds the service lim it, align the crankshaft so that runout is with in the service limits.
Side Clearance Crankshaft Runout Left Half Right Half
Standard: Service Limit: Standard: Serivce Limit:
Under 0.03 mm TI R 0.08 mmTIR Under 0.04 mm TI R 0 .10 mm TIR
eAlign the crankshaft. 01n the case of horizontal misalignment, strike the projecting crankshaft half with a plastic, soft lead, or brass hammer as shown.
ENGINE BOTTOM END/TRANSMISSION 7·9 Flywheel Horizontal Misalignment
Connecting Rod Big End Seizure -In case of serious seizure with damage to the crank halves, the crankshaft must be replaced. If the seizure was less severe, disassemble the crankshaft and replace the crankpin, needl e bearing, and connecting rod (see Crankshaft Disassembly) .
............................................................................ Transmission Transmission External Shift Mechanism: External Shift Mechanism Removal eRecheck the runout and repeat the process until the runout is within service limits. OVertical misalignment is corrected either by driving a wedge in between the crank halves, or by squeezing the cr4nk halves in a vise, depending on the nature of the misalignment.
eRemove the clutches (see Clutch Removal in the Engine Right Side chapter). eTake off the clutch release cam and ball assembly. eRemove the bolt and take off the shift pedal. -Move the shift mechanism arm out of its position on the end of the shift drum, and pull out the shift mechanism shaft.
Flywheel Vertical Misalignment
A. Pull out the mechanism shaft. B. Return Spring C. Clutch Release Cam -Remove the shift drum positioning lever bolt and take off the lever with its spring.
O' n case of both horizontal and vertical misalignment, correct the horizontal misalignment first. oRecheck big end side clearance after aligning crankshaft (see Connecting Rod Big End Side Clearance). NOTE
crankshaft alignment cannot be corrected by the above method, replace the crankpin or crank halves as required.
Off
A. Shift Drum Positioning Lever B. Spring C. Return Spring Pin D. Clutch Release Cam Pin
7-10 ENGINE BOTTOM END/TRANSMISSION External Shift Mechanism Installation eExternal shift mechanism installation is the reverse of
removal. Note the following. e<:heck the shift drum positioning lever swings smoothly after tightening the pivot bolt. eSe sure the shift mechanism arm collar and clutch release cam are in place.
CCheck the shift shaft for bending or damage to the spline. "'If the shaft is bent, straighten or replace it. If the spline is damaged, replace the shaft. CCheck the springs for breaks or distortion. *If the springs are damaged in any way, replace them.
OCheck the shift mechanism arm for distortion. * If the shift mechanism arm is damaged in any way, replace the lever. OCheck the return spring pin and/or cam pin is not loose. -trlf it is loose, unscrew it, apply a non-permanent locking
agent to the threads, and tighten it to the specified torque (see Exploded View).
Shift Drum Stop Lever Removal A.Coliar
S. Clutch Release Cam
eUse the oil seal guide (special tool) to protect the seal during shift mechanism installation.
A. Oil Seal Guide: 57001-264
eRemove the front gear case (see Front Gear Case Removal in the Final Drive chapter). ePull the shift drum stop lever off the crankcase with its spring.
A. Shift Drum Stop Lever
B. Spring
ePosition the shift shaft return spring ends on either side of the return spirng pin.
External Shift Mechanism Inspection eExamine the shift mechanism for any dama2e.
Shift Drum Stop Lever Installation -Shift drum stop lever installation is the reverse of removal.
Shift Drum Stop Lever Inspection e<:heck the shift drum stop lever for distortion. *If the shift drum stop lever is damaged in any way, replace the lever.
A. Splines
S. Springs
C. Lever
e<:heck the spring for break or distortion. *If the spring is damaged in any way, replace the spring.
ENGINE BOTTOM END/TRANSMISSION 7-11
Reverse Knob and Cable: Reverse Knob Free Play Inspection -Check the reverse knob free play when the transmission is in neutral. e lf free play is not within specifications, adjust the reverse cable (see Reverse Cable Adjustment).
Reverse Knob and Cable Removal -Remove the screws and take off the reverse knob assembly with the cable.
Reverse Knob Free Play
Standard:
2 - 3mm
A. Screws
B. Cable Holder .
ePull the cable holder out the assembly, and free the reverse cable upper end from the assemb ly. aLoosen the mounting nuts and take off the cable adjuster from its bracket. eFree the cable from the vehicle. A. Reverse Knob
B. Free Play
Reverse Knob and Cable Installation
Reverse Cable Adjustment
e lnstallation is the reverse of removal. Note the fo ll owing. -When the reverse lever was removed, mount the lever on the shift drum stop lever shaft so that the slot of the lever aligns with the mark on the front gear case.
aLoosen the mounting nuts at the adjuster of the reverse cable, and slide the adjuster until t he reverse knob has the proper amount of play. -Tighten the mounting nuts after adj ustment.
A. Mounting Nuts
A. Adjuster
B. Mounting Nuts
B. Align mark with slot .
*If the reverse lever is difficult to install in the above position, reinstall the lever aligning the slot with just forward tooth of the shaft serration. _Route the reverse cable as shown. eAdjust the reverse cable (see Reverse Cable Adjustment).
7-12 ENGINE BOTTOM END/TRANSMISSION *If cable movemen t is not free after lubricating (see Reverse Cable Lubrication), if the cable is frayed, or
if the housing is kinked, replace the cable.
Transmission Shafts, Shift Drum, Forks: Transmission Removal -Split the crankcase (see Crankcase Disassembly). -Pull out the shift rods and take out the forks . • Pull out the transmission shafts at the same time. eT 0 remove the shift drum, remove the shift drum
positioning lever and shift drum bearing stopper.
A. Reverse Cable
Reverse Cable Lubrication Whenever the reverse cable is removed, lubricate the reverse cable as follows. eLubricate the reverse cable by seep in g the oil between the cable and cable housing. eApply a small amount of multi-purpose grease to the
cable lower end. Cable Lubrication
A. Shift Drum Positioning Lever
B. Bearing Stopper
Transmission Installation -Set the transmission shafts, and fit them into the right crankcase half at the same time. OAppJy a small amount of engine oil to the transmission
gears, bearings, and shaft journals.
Reverse Cable Inspection -With the reverse cable disconnected at the both ends, the cable should move freely within the cable housing.
-Fit each shift fork into the groove of the proper gear so that the shift fork guide pin is in the proper groove on the shift drum. oApply a small amount of engine oil to the shift fork fingers. oThe forks for the output shaft are identical.
ENGINE BOTTOM END/TRANSMISSION 7-13 -Install the shift rods. OApply a small amount of engine oil to the shift rods. olnsert the shorter shift rod through the drive shaft fork, and the longer rod through the output shaft forks.
A. Short
Transmission Shaft Disassembly eRemove the transmission shafts (see Transmission Removal) . -Using the circlip pliers (special tool), remove the circlip and disassemble the transmission shafts completely.
B. Long A. Circlip Pliers: 57001-144
Transmission Gears
Drive Shaft 4th
Reverse
Output Shaft 2nd
\
Reverse Shaft
A. Short
B. Long
-Assemble the crankcase (see Crankcase Assembly).
7·14 ENGINE BOTTOM END/TRANSMISSION Transmission Shaft Assembly
Shift Fork/Gear Groove Wear
eAssembly is the reverse of disassembly. Note the following. eReplace any circlips that were removed with new ones. eAlways install circlips so that the opening is aligned with a spline groove.
eMeasure the thickness of the ears on each shift fork, and measure the width of the shift fork grooves on transmission gears.
Shift Fork Ear Thickness Standard: 4 .4 - 4.5 mm Service Limit: 4.3mm
Circlip Installation
Gear Shift Fork Groove Width Standard: 4.55 - 4.65 mm Service Limit: 4 .8mm l
*If the thickness of a shift fork ear is less than the service limit, the shift fork must be replaced. *If a gear shift fork groove is worn over the service limit, the gear must be replaced.
e The transmission gears can be identified by size; Drive shaft gears - the smallest diameter gear is 1 st
gear, and the largest is 5th . Output shaft gears -the largest diameter gear is 1st gear, and the smail est is 5th.
Shift Fork Bending eVisually inspect the shift forks, and replace any fork that is bent. A bent fork could cause difficulty in shifting, or allow the transmission to jump out of gear when under power.
Shift Fork Guide Pin/Shift Drum Groove Wear eMeasure the diameter of each shift fork guide pin, and measure the width of each shift drum groove.
Shift Fork Guide Pin Diameter Standard: 5 .9 - 6 .0 mm Service Limit: 5 .8mm
Shift Drum Groove Width Standard: 6.05 - 6.20 mm Service Limit: 6.3mm
ENGINE BOTTOM ENO!TRANSMISSION 7-15 Balancer
Balancer Drive Removal -Remove the clutches (see Clutch Removal in the Engine Right Side chapter). eRemove the left engine cover (see Left Engine Cover Removal in the Engine Left Side chapter). -Fit the flywheel holder (special tool: P/N 57001-308) to the alternator rotor. eRemove the balancer gear nut and gear while holding the crankshaft from turning.
A. Shift Fork Guide Pin
A. Balancer Gear
C. Oil Pump Drive Gear
A. Shift Drum Grooves
B. Balancer Drive Gear
*If the guide pin on any shift fork is less than the service limit, the fork must be replaced. *If any shift drum groove is worn over the service limit, the drum must be replaced.
-Flatten the side of the toothed washer where it is bent up against the nut mounting the balancer drive gear and oil pump drive gear.
eRemove the nut with the socket wrench (special tool),
Gear Dog/Gear Dog Hole and Recess Damage -Visually inspect the gear dogs, gear dog holes and/or recesses. Replace any gears that have damaged or
and take off the oil pump drive gear and balancer drive gear.
excessively worn dogs, dog holes, or recesses.
A. Recess
B. Dog
C. Dog Hole
A. Socket Wrench: 57001·1214
7-16 ENGINE BOTTOM END/TRANSMISSION
Balancer Drive Installation
eBend the tab over the nut.
eBalancer drive installation is the reverse of removal. Note the following. eMesh the balancer gear with the balancer drive gear so
that the punch mark on the balancer gear aligns with the punch mark on the drive gear.
Balancer Removal eRmove the balancer drive gear (see Balancer Drive
Removal). -Split the crankcase (see Crankcase Splitting). _Lift the balancer out of the right hand crankcase half.
Balancer Installation _Balancer installation is the reverse of removal.
Ball and Needle Bearings A. Align punch marks.
Ball and Needle Bearing Replacement eUsing a press or puller, remove the ball bearing and/or
-Position the toothed washer on the crankshaft. of it the claw of the washer into the groove of the oil pump drive gear.
needle bearing.
NOTE Din the absence of the above mentioned tools, saris·
factory results may be obtained by heating the case to approximately 93°C (200°F) max., and tapping the bearing in or out.
000 not heat the case with a torch. This will warp the case. Soak the case in oil and heat the oil.
-Using a press and the bearing driver set (special tool: PIN 57001·1129), install the new bearing until it stops at the bottom of its housing, A. Fit claw into groove.
B. Chamfer
-Apply oil to the threads and seating su rface of the balancer drive and oil pump drive gear mounting nut.
-Install the nut so that the chamfered side of the nut faces in .
-Tighten the nut to the specified torque (see Exploded View). *If none of the toothed washer tabs align, tighten the nut further just enough to align one of the tabs with a slot in the nut. Tab
o
Ball and Needle Bearing Wear _Check the ball bearings. oSince the ball bearings are made to extremely close to lerances, the wear must be judged by feel rather than measurement. Clean each bearing in a high f1ashpoint solvent, dry it (do not spin the bearing while it is dry), and oil it with engine oil. oSpin the bearing by hand to check its condition . *If the bearing is noisy, does not spin smoothly, or has any rough spots, replace it. -Check the needle bearings. oThe rollers in a needle bearing normally wear very little, and wear is difficult to measure. Instead of measuring, inspect the bearing for abrasion, color change, or other damage. *If there is any doubt as to the condition of a needle bearing, rep lace it.
WHEELsrrlRES
8-'
Wheels/Tires Table of Contents
Exploded View .. . .. .. ..... . ...... . ... .. ...•...... .. ....... Specifications ... . .. . ......... . . . ......... . .. . .......... . . . Special Tools ... .. ........... . ............. . ..... ... . ... .. . Wheel Alignment ...... .. .................... . .... . . ...... . Steering Centering Inspection ............................ . Steering Centering Adjustment ...... .... .. . .... ..... . .... . Toe-in Inspection ......... ....... .... .. . . ....... .. . . .. . Toe·in Adjustment .................................... . Wheels (Rims) . ....... . .... . ............. . ................ . Wheel Removal ........... . ...... . ... . ........ .... ... . . Wheel Installation ........................ . ....... .. ... . Wheel Inspection . ...... . •.......... . . .. .. ...... •... .• .. Wheel Replacement .................... . ............ . •.. Tires ............... . ... . ...... . ............ ... ...... . •.. Tire Removal. . . ........... . .. .. ......... . .. . .. . . ..... . Tire Installation ......................... . . ....... .. ... . Tire Inspection .....•...... ... ... . .. ..... .. ... ... . .. • .. Front Hub Bearings .................. . ...•.... ... ........•.. . Front Hub Bearing Removal .... . .. . ........• .. ...•. ... •.. Front Hub Bearing Installation ... ... ... . . . .. .. .... .. .. ... . Front Hub Bearing Inspection ........................ .. .. .
8·2 8·2 8·3 8·3 8·3 8·3 8-4 8·5 8·5 8·5 8·5 8·6 8·6 8·6 8·6 8·7 8·8 8-8 8-8 8-9 8·9
DI
8-2 WHEELS/TIRES Exploded View
T1
T1 G : Apply grease. T1 : 34 N-m (3.5 kg·m. 25 ft·lb)
Specifications Wheel Alignment Caster 4 0 (non-adjustable) 0 Camber: 0.8 (non-adjustable) Toe-in 27 mm Tire Payload: 182 kg (400 Ib) Standard Tires
Front
22 x 9.00·10 Dunlop KT761. Knobby/Trail Tubeless Rear 24 x 11.00·10 Dunlop KT765. Knobby/Trail Tubeless Tire Air Pressure (when cold) Front 21 kPa (0.21 kg/em 2 • 3 psi) Rear 21 kPa (0.21 kg/em 2 • 3 psi) Maximum Tire Air Pressure (to seat beads, when cold)
Front Rear
137 kPa (1.4 kg/em 2 • 20 psi) 137 kPa (1.4 kg/em 2 • 20 psi)
WHEELS/TIRES 8-3
............................................................................. Special Tools
Wheel Alignment
Jack: 57001-1238
Toe-in is the amount that the front wheels are closer together in front than at the rear at the axle height. When there is toe-in, the distance A is greater than B as shown. The purpose of toe-in is to prevent the front wheels from getting out of parallel at any time, and to prevent any slipping or scuffing action between the tires and the ground. If toe-in is incorrect, the front wheels
will be dragged along the ground, scuffing and wearing the tread knobs. Caster and camber are built-in and require no adjustment.
Toe-in of Front Wheels
B Front of Vehicle
!/ Tire Irons: 57001-1073
'" i=-
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F= ' .-
-
'" -=
'" Air Pressure Gauge: 52005-1082
Bearing Driver Set: 57001-1129
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A
A A - B = Amount of Toe-in (Distance A and B are measured at hub height)
Steering Centering Inspection -Test ride the vehicle. *If the handlebar is straight when the vehicle is traveling in a straight line, go on to the Toe-in Inspection procedure.
*Otherwise, go on to the Steering Centering Adjustment procedure.
Steering Centering Adjustment -Support the vehicle so that the front wheels are off the ground and the front axles about the same height as the rear axle. eHold a straightedge against the rear wheel rim on one
side at axle height.
8-4 WHEELS/TIRES eRe peat the straightedge procedure on the other side of the vehicle. Now the front wheels are parallel to each other and to the center line of the vehicle.
eCo on to the Toe·in Inspection procedure.
Toe-in Inspection eSupport the veh icle on a stand or the jack (special tool: 57001-1238) so that the front wheels are off the ground. eApply a heavy coat of chalk near the center of the A. Straightedge
B. Jack: 57001·1238
eWith the handlebar straight ahead, loosen the locknuts
front tires.
_Using a needle nose scriber, make a thin mark near the center of the chalk coating while turning the whe~l.
and turn the tie·rod adjusti ng sleeve the same number
of turns on both sides until the front wheel on that side is parallel to the straightedge. NOTE
oThe outside locknut on the tie·rod has left·hand threads. Turn the wrench clockwise for loosening.
eKeeping the front wheels off the ground, set the handlebar straight ahead. eAt the level of the axle height, measure the distance between the scribed lines for both front and rear of the front tires.
A. Outside Locknut: left·hand threads B. Adjusting Sleeve C. Inside Locknut Steering Centering
I
r
2 -Subtract the measurement of the front from the measurement of the rear to get the -toe-in. *If the toe-in is not in the specified range, go on to the Toe-in Adjustme nt procedure.
e<.:heck the toe-in (see Toe·in Inspection). eTighten the tie-rod locknuts to the specified torque (see Exploded View in the Steering chapter). eTest ride the vehicle. .
of Front Wheels Standard: 27 mm
Toe~n
WHEELS/TIRES 8-5
Toe-in Adjustment eLoosen the locknuts and turn the adjusting sleeves the same number of turns on both sides to ach ieve the spec ified toe- in .
Wheels (Rims)
Wheel Removal eSupport the vehicle on a stand or the jack (special tool: 57001-1238) 50 that th e wheels are off the gro und. ePull off the wheel cap. eTake off the wheel nuts holding the wheel to the hub.
Wheel Installation eMount the wheelan the studs. ePosition the whee l so that the valve stem is toward the
outside of the vehicle. -Check the tire rotation mark on the front and rear tires, and install them on the rim accordingly_
A. Adjusting Sleeve
B. Locknuts
C. Front
NOTE
OThe outside locknut on the tie-rod has left-hand threads. Turn the locknut clockwise for loosening. OThe toe-in will be near the specified value, if the tie-rod length is 380 mm between the tie-rod ends.
Tie-rod Length Adjustment
A. Rotation Mark
o Far the front whee ls, align the "shoe check hole" and
"shoe adjust hole" on the rim with the holes on the drum respectively. oTighten the whee l nu ts in a criss-cross pattern to the
specified torque (see Exploded View).
1. Front 2 . Left-hand Thread 3. Tie-rod Length
e<:heck the toe-in (see Toe-in Inspection). eTighten the tie-rod locknuts to the specified torque (see Exploded View). eTest ride the vehicle.
A. Valve Stem
8-6 WHEELS/TIRES
Wheel Inspection eExamine both sides of the rim for dents. If the rim is dented, replace it. Rim Dent
<0\\ \ \ II , , I I 1/7r;
00 ~
~
Dent
\
'in
eMount the tire on the new rim (see Tire Installation).
'/)
.;:,
c:
000 not use engine oil or petroleum distillates to lubricate the stem because they will deteriorate the rubber.
elnstall the wheel (see Wheel Installation).
';J :J
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Tires
elf the tire is removed, inspect the air sealing surfaces of the rim for scratches or nicks. Smooth the sealing surfaces with fine emery cloth if necessary.
Tire Removal eRemove the wheel (see Wheel Removal ). _Unscrew the valve core to deflate the tire. o Use a proper valve core tool.
A. Sealing Surfaces
Wheel Replacement eRemove the wheel (see Wheel Removal). eDisassemb le the tire from the rim (see Tire Removal). elnstall a new valve stem in the new rim. ORemove the valve cap, lubricate the stem with a soap and water solution, or water and pull the stem through the rim from the inside out until it snaps into place.
A. Pull.
A. Valve Core Tool eLubricate the tire beads and rim flanges on both sides of the wheel with a soap and water solution, or water. This helps the tire beads slip off the rim flanges.
A. Apply lubricant.
WHEELS/TIRES 8-7
000 not lubricate the tire beads and rim flanges with engine oil or petroleum distillates because they will deteriorate the tire.
eWork around the rim with the tire irons a little at a time, while continuing to hold the bead opposite the irons in the center well of the rim.
eBreak the tire beads away from both sides of the rim with a tire tool.
I;
A. Tire Irons: 57001·1073 eLift the second bead up into the center well and use the same procedure as in removing the first bead.
Tire Installation elnspect the rim (see Wheel Inspection). e<:heck the tire for wear and damage (see Tire Inspec· tion). eLubricate the tire beads, rim flanges, and the tire irons (special tools) with a soap and water so lution, or water. eKneel on the side of the tire, forcing the tire bead into the center well of the rim.
Rim Center Well _,--r~~~~..,..,,~valve Stem
I WARNING. 000 not use the lubricant other than a water and soap solution, or water to lubricate the tire beads and rim because it may cause tire spearation. et:heck the tire rotation mark on the front and rear tires, and install them on the rim accordingly. OThe tires should be installed on the rims so that each valve stem is toward the outside of the vehicle. NOTE
OThe direction of the tire rotation is shown by an arrow on the tire side wall.
Well
eLubricate two tire irons with a soap and water, or water and pry the bead.
eBy hand, slide as much of the first bead as possible over the rim flange, starting at the side opposite the valve stem. oAs the bead goes onto the rim, force the bead into the center well of the rim to ease installation. eUse the tire irons to install the rest of the bead. eUse the same procedure to install the second bead. eLubricate the tire beads again, center the tire on the rim, and inflate the tire until the tire beads seat on the rim.
I WARNING I 000 not inflate the tire to more than 137 kP. (1 .40 kg/cm 2 • 20 psi). Overinflation can cause the tire to explode, causing personal injury.
000 not scratch the air sealing surfaces of the tire or rim. Scratches or nicks on the sealing surfaces will allow the tire to deflate.
e<:heck to see that the rim lines on both sides of the tire are parallel with the rim flanges.
8-8 WHEELS/TIRES Front Hub Bearings
Front Hub Bearing Removal .Pull off the wheel cap. eRemove the cotter pin and loosen the hub nut.
A. Rim Line
.If the rim lines and the rim flanges are not parallel, deflate the tire, lubricate the sealing surfaces again, and reinflate the tire . • After the beads are properly seated, check for air leaks. olnflate the tire to 35 kPa (0.35 kg/em', 5 psi). Apply a soap and water solution around the tire bead and check for bubbles. eDeflate the tire to spedfied pressure (see Specifications). • Install the wheel (see Wheel Installation). -Wipe off the soap and water solution on the tire, and dry out the tire before operation.
I WARNING. 0 00 not operate the vehicle when the water and soap still exist around the tire beads. They will cause the tire separation, and a hazardous condition may result.
Tire Inspection .Examine the tire for damage and wear. a lf the tire is cut or cracked, replace it. o Lumps or high spots on the tread or sidewalls indicate internal damage requiring tire replacement. ORemove any foreign objects from the tread. After removal, check for leaks with a soap and water solution. OCheck the shape of the tread knobs. If no vertical side is left on the drive side of the knobs, replace the tire.
A. Hub Nut .Pull off the wheel with the hub assembl y, and pullout the collar .
WARNING. OBrake linings contain asbestos fi~er. Inhalation of asbestos may cause serious scarring of the lungs and may promote other internal injury and illness, including cancer. Observe the following precautions when handling brake linings : 1. Never blow brake lining dust with compressed air. 2. If any components are to be cleaned, wash them with detergent, then immediately discard the cleaning solution and wash your hands. 3. Do not grind any brake lining material unless a ventilation hood is available and properly used.
eRemove the grease seals, bearings and spacer pipe.
Tire Wear
Vertical Sides Worn Away
/-----rJ/
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I
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~
.
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A. Collar
B. Grease Seal
WHEELS!TIRES 8-9 OPosition the hub assembly on wooden blocks to allow bearing removal.
Olnsert the spacer pipe into the hub assembly. o Drive out the remaining bearing and grease seal by tapping on the spacer pipe with a suitable driver. eDeburr the spacer pipe as needed.
Front Hub Bearing Installation e ln stallation
is the reverse of removal.
Note the
following. eDrive either bearing into the hub assembly with the
bearing driver set (special tool:
PIN 57001 -1129).
A. Wooden Block
OPry the spacer pipe toward one side.
eApply grease to the lips of the grease seals. eTighten the hub nut to the specified torque (see Exploded View). A. Spacer Pipe
ODrive the bearing out by tapping on the exposed portion of the spacer pipe end with a hammer and metal rod. The grease seal is tapped out with the bearing.
Front Hub Bearing Inspection eRemove the hub assembly (see Front Hub Bearing Removal). eTurn each bearing back and forth while checking for roughness or binding. *If roughness or bind in g is found, replace the bearing. eExamine the bearing seal for tears or leakage. *If the seal is tarn or is leaking, replace the bearing.
A. Metal Rod
FINAL DRIVE 9-1
Final Drive Table of Contents Exploded View .. . ...•... ......• .... Specifications . . . . . . . . .. . . . . .. ... . . Special Tools .... .. . . . . . . . . . . . . . . . . ' Final Gear Case Oil . . . . . . . . . . . . . . . . .. . Final Gear Case Oil Level Inspection ...
Final Gear Case Oil Change. . . . . . . . Front Bevel Gears and Cam Damper . . . . . . . ' Front Gear Case Removal. . . . . . . . . .. Front Gear Case Installation. . . . . . . .. Front Drive Gear Removal/ Installation . . . . . . . . . . . . . . . . . . Front Driven Gear and Cam Damper Removal ... .. ... . ... . .
9-2 9-4 9-5 9-6
Axle Shaft Installation . ... . ... .. . 9-17 Axle Shaft Inspection . ... . . . . . . __ . 9-18 Ball Bearing Inspection . . . . . . . . . . . . 9-18 Oi l Seal Inspection ...... . . . . . . . . . . 9·18
9·6
Final Bevel Gears and Differential Gears . . . . . 9 ·18 Pinion Gear Disassembly . . . . .... ... 9 · 18 Pinion Gear Assembly . . . . . . . . . . . . . 9-19 Ring Gear and Differential Gear
9-6 9·6 9·6 9·8 9-9 9-9
Front Driven Gear and Cam Damper Installation
.. . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . _ ... 9·19 Ring Gear and Differential Gear
9-9
Assemb ly . . . . . . . . . . . . . . . . . . . 9-20 Final Bevel Gear Adjustment .... . ... Bevel Gear Inspection . . . . .. . . . . . .. Differential Gear Inspection . . . . . . . .. Tapered Roller Bearing Inspection . .. . .
9·20 9·25 9-25 9-25
9-10
Ball Bearing Inspection . . . . . . . . . . . . 9·25
Bevel Gear Inspection . . . . . . . . . . . .. 9 ·14
Oil Seal Inspection . . . . . . . . . . . . . . . 9-25
Front Bevel Gear Adjustment
8all Bearing Inspection . . . . . . . . . . . . 9-14 Tapered Roller Bearing Inspection . . . . . 9·14 Oil Seal Inspection . . . . . . . . . . . . . . . 9·14 Cam Damper Inspection . ... , . . . . . . . 9·14
Propeller Shaft _ .. _ .. _ ..... _ . . . . . . . . . 9-14 Propeller Shaft Removal . _ ... .. .... 9-14 Propeller Shaft Installation . . . . . . . . . . 9·15 Propeller Shaft Lubrication . . . . . . . . . 9·15 Prope ller Shaft Joint and Pin ion Joint Inspection . . . . . . . . . , . . . . . 9-15 Propeller Shaft Inspection . . . . . . _ ... 9·15
Rear Axle Shafts . . . . . . . . . . . . . . . . . . . . 9-16 Rear Ax le and Propell er Shaft
Removal . . . . . . . _ . . . . . . . . . . . . 9-16 Rear Axle and Propeller Shaft Installa tion. .
. _ .. _ _ . _ 9-16
Axle Shaft Remova l . .... _ ..•..... 9-17
Differential Shift Mechanism
. . . . . . . . . . . . 9·25
Shift Lever Case and Cable Removal .... 9-25 Shift Lever Case and
Cable Installation . . . . . . . . . . . . . . 9-26 Shifter and Shift Fork Removal .... . _. 9-26 Shifter and Shift Fork Installation . _ ... 9-26 Differential Cable Adjustment . . . . . . . . 9·27 Differential Cable Lubrication . . . . . . . . 9·28 Differential Cable Inspection . . . . . . . . 9-28
Shifter and Shift Fork Inspection . . ... 9-28
F
9-2
INAL DRIVE .......... ......... ................... .... . ...... ..............
E~·~;~~~~
View .................................................... . ........................
Engine No. 013932 and up.. 16mm
14mm
@
16mm @
a 8mm
@
-
@
Option
FINAL DRIVE 9-3
G
G
o
~
G : Apply grease. L : Apply a non-permanent locking agent. o : Apply an oil to the threads and seated surface. St : Stake the fastener. T1 : 25 N-m (2.5 kg-m, 18.0 ft·lb) T2: 88 N-m (9.0 kg·m, 65 ft-Ib) T3: 98 N-m (10.0 kg-m, 72 ft·lb) T4: 12 N-m (1.2 kg-m, 104 in-Ib) T5: 20 N-m (2.0 kg·m, 14.5 ft-Ib) T6: 78 N-m (8.0 kg·m, 58 ft-Ib) T7: 29 N-m (3.0 kg·m, 22 ft-Ib) T8: 6.9 N-m (0.70 kg-m, 61 in·lb) T9: 93 N-m (9.5 kg-m, 69 ft-Ib)
94 FINAL DRIVE Specifications
Standard
Item Final Gear Case Oil: Type
API GL-5 Hypoid gear oil SAE 90 (above 5°C, 41° F) or SAE80 (below 5°C,41°F)
Capacity
0.3 L
Bevel Gear Bearing Preload
0.3 - 0.6 N-m (0.03 - 0.06 kg-m, 2.6 - 5.2 in-Ib)
Bevel Gear Backlash :
Front
0.06 - 0.10 mm (at bearing preload nut)
Rear
0.08 - 0.25 mm (at ring gear tooth)
FINAL DRIVE 9-5 ...............................................................·· · ·····v .... ·
Special Tools
Oil Seal & Bearing Remover: 57001·1058
A[ong with common hand too ls, the following more specialized tools are required for complete final drive servicing.
Circlip Pliers: 57001 ·143 Bearing Driver Set: 57001·1129
Circlip Pliers: 57001·144
Bevel Gear Holder: 57001·1193
Bearing puller: 57001·158
Hexagon Wrench: 57001·1194
Driven Gear Holder: 57001·1215 Oil Seal Guide: 57001·264 (Two guides are required)
Gear Holder: 57001·1015
o
9-6 FINAL DRIVE Final Gear Case Oil
Final Gear Case Oil Level Inspection .Park the vehicle so that it is level, both side-ta-side and front-to rear. eRemove the filler cap.
rCAUTlO~] a Be careful not to allow any dirt or foreign materials to enter the gear case. A. Drain Plug echeck the oil level. The oil level sho uld come to th e bottom of the filler opening.
WARNING
I
OWhen draining or filling the final gear case, be careful that no oil gets on the tire or rim. Clean off any oil that inadvertently gets on them with a high flash-point solvent.
eAfter the oil has completely drained out, install the drain plug with a new aluminum gasket, and tighten it to the specified torque (see Exploded View). eFi l1 the final gear case up to the bottom of filler opening with the oil specified below.
Final Ga.r Case Oil Type:
A. Filler Opening
SAE90 (above SoC, 41°F) SAE80 (balowSoC, 41°F)
Capacity: *If it is insufficient, first check the final gear case for oil leakage, remedy it if necessary, and add oil through the filler opening. Use the same type and brand of oil that is already in the final gear case. eBe sure the O-ring is in place, and tighten the filler cap to the specified torque (see Exploded View).
API GL-5 Hypoid gear oil
0.3 L NOTE
Q
N
GL-5" indicates a quality and additive rating. HGL_6
H
rated hypoid gear oils can also be used.
eBe sure the O·ring is in place, and tighten the filler cap to the specified torque (see Exploded View).
Front Bevel Gears and Cam Damper
Final Gear Case Oil Change -Warm up the oil by running the vehicle so that the oil w ill pick up any sediment and drain easily. Then stop the vehicle. • Park the vehicle so that it is level, both side-ta-side and front-to-rear . • Place an oil pan beneath the final gear case, and remove the drain plug.
Front Gear Case Removal eLoosen the clamp screw at the front of the propeller shaft dust cover . eSupport the rear of the frame so that the rear wheels are off the ground.
-Remove t he pivot bolts at the front of the left and right suspension arms.
FINAL DRIVE 9-7 eRemove the upper mounting bolts and nuts at the left and right rear shock absorbers. ePu ll the rear axle and propeller shaft toward the rear to free the propeller shaft front end from the front drive gear shaft rear end.
A. Front Gear Case B. Cable Brackets
A. Pivot Bolt B. Upper Mounting Bolt
C. Dust Cover Clamp
ePlace an oil pan beneath the engine left side. eRemove the shift pedal clamp bolt and take off the pedal from the shaft. eRemove the reverse lever clamp bolt and take off the lever from the shaft. eRemove the oil sea l housing mounting nuts and take off the housing.
eRemove the drive gear and output shaft LH bearing housing to complete the removal of the front gear case gasket. OSh ift the transmission gears in any gear position. ORemove the right engine cover (see Right Engine Cover Removal in the Engine Right Side chapter). OUsing the gear holder (special tool: PIN 57001 -101 5)' hold the primary and secondary gears to keep them from turn ing (see Clutch Removal in the Engine Right Side chapter). OUnscrew the drive gear nut and take off the drive gear and shim(s).
A. Drive Gear Nut
A. Oil Seal Housing
B. Mounting Nuts
eRemove the front gear case mounting bolts and take off the case. The differential shift lever case, differential cable bracket, and reverse cable bracket come off with the mounting bolts.
C. Differential Shift Lever Case
B. LH Bearing Housing
ORemove the bolts holding the output shaft LH bearing housing and pu ll out the bearing housing. o Remove the gasket and dowel pins from the crankcase. eTo remove the output shaft LH bearing from its housing, remove the bearing holder using the hexagon wrench (special tool) and drive out the bearing with the bearing driver set (special too l: PIN 5700 1-11 29) if necessary.
9-8 FINAL DRIVE eApply grease to the oil seals on the front gear case, and
use the oil seal guides (special tools) to protect the oil seals during case installation.
A. Hexagon Wrench: 57001-1194 B. Bearing Holder
A. Oil Seal Guides: 57001-264
Front Gear Case Installation eFront gear case installation is the reverse of removal.
Note the following. -The front drive gear and driven gear
are~ lapped
as a set
in the factory to get the best tooth contact. They must be replaced as a set. eBe sure to check and adjust the bearing preload and the
eTighten the front gear case 8 mm bolts to the specified torque (see Exploded View). eApply a high temperature grease to the oil seal and
beve( gear backlash and tooth contact, when any of the parts which influence these items are replaced (see
install the oil seal housing to the front gear case. Be sure the Q·ring is in place in the groove on the housing.
Front Bevel Gear Adjustment). -Install the LH bearing, bearing housing, and drive gear.
Olf the LH bearing was removed, drive the bearing into the bearing housing. Olnstall the bearing holder so that the flat side of it faces out, and tighten it to the specified torque (see Exploded View). OStake the bearing holder after torquing with a punch .
OWhen staking the holder, be careful not to apply shock
to the bearing. Such a shock could damage the bearing.
A. Apply grease .
B. O-ring
Ol nstall the LH bearing and housing to the crankcase, and tighten the housing bolts to the specified torque (see Exploded View). The front gear case gasket should be installed after finishing the front bevel gear adjustment.
Ol nstall the shim(s) and drive gear onto the output shaft. OA pply an oil to the threads and seated surface on the
drive gear nut, and tighten it to the specified torque
(see Exploded View).
eTighten the oil seal housing nuts to the specified torque
(see Exploded View). eApply grease to the splines at the front end of the propeller shaft and fit the propeller shaft to the drive gear shaft.
FINAL DRIVE 9-9 -Bend back the toothed washer tabs and remove the beari ng preload nut. .Pull the tapered roller bearings and housing out of the shaft.
Dlf necessary, use the bearing puller (special tool: PIN 57001·158). -Using the driven gear holder (special tool), remove the driven gear nut and take off the driven gear, damper cam follower, and spring. The spring seat is press-fitted onto the shaft.
A. Apply grease.
-Tighten the following fastener to the spe<;ified torque (see Exploded View in the Suspension chapter) . Rear Shock Absorber Mounting Bolts and Nuts Rear Suspension Arm Pivot Bolts -Adjust the reverse cable (see Reverse Cable Adjustment
in the Engine Bottom/Transmission chapter). _Add engine oil as if necessary (see Engine Oil Level Inspection in the Engine Right Side chapter).
Front Drive Gear Removal/Installation _The front drive gear is removed and installed during front gear case removal and installation (see Front Gear Case Removal and Installation ).
A. Driven Gear B. Damper Cam Follower C. Spring
D. Spring Seat E. Driven Gear
Holder:
57001-1215
eTa remove the ball bearing press·fitted onto the front gear case, use the oil seal and bearing remover (special tool).
Front Driven Gear and Cam Damper Removal eRemove the front gear case (see Front Gear Case Removal) .
• Pull the driven gear and cam damper assembly out of the front gear case. The shim(s) comes off with the assembly.
A. Oi l Seal and Bearing Remover: 57001 ·1058
Front Driven Gear and Cam Damper Installation
A. Bearing Preload Nut B. Bearing Housing
C. Shim(s)
eFront driven gear and cam damper installation is the reverse or removal. Note the following, eThe front drive gear and dr iven gear are lapped as a set in the factory to get the best tooth contact. They must be replaced as a set.
9·10 FINAL DRIVE eBe sure to check and adjust the bearing preload and the bevel gear backlash and tooth contact, when any of the parts which influence these items are replaced (see Front Bevel Gear Adjustment). eReplace the driven gear nut with a new one. eApply an oil to the threads and seated surface on the front driven gear nut, and t ighten it to the specified torque (see Exploded View).
Drive Gear Shims (* : Standard)
Front Bevel Gear Adjustment
Driven Gear Shims (* : Standard)
In order to prevent one gear from moving away from the other gear under load, the tapered roller bearings must be properly preloaded. Aslo the backlash (d istance one gear will move back and forth without moving the other gear) and tooth contact pattern of the bevel gears must be correct to prevent the gears from making no ise and being damaged. Above three adjustments are of critical importance and must be carried out in the correct sequence and method.
Thickness (mm)
Part Number
0.15 0.20 0.7 0.8 0.9 1.0' 1 .1 1.2 1.3
92025·1573 92025·1574 92025·1534 92025·1535 92025·1536 92025·1537 92025·1575 92025·1538 92025·1533
Thickness (mm)
Part Number
0.1 0.15 0.5 0.8 1.0' 1.2
92025·1697 92025·1698 92025·1699 92025·1700 92025·1701 92025·1702
Front Bevel Gear Adjustment Procedure
I
Preload the driven gear bearings.
,
I
I
Preload adjustment eAssemble the bearing housing, and tighten the bearing preload nut to adjust the bearing preload.
I
Adjust gear backlash.
,,
I
[CAUTlO~] OTo start with, tighten the bearing prelpad nut so that the bearings are just SNUG with NO play but also with NO preload. OAn over-preload on the bearings could damage the · bearings.
I
I
Adjust tooth contact pattern.
,
I
I
I
Assemble the front gear case completly.
I
eApply engine oil to the bearings, and turn the gear shaft more than 5 turns to allow the bearings to seat. Bearing preload is eMeasure the bearing preload. difined as the force or torque which is needed to start the gear shaft turning.
NOTE When the any of the backlash·related parts are rep laced, or the bearing preload nut is loosened; even if the purpose is not to replace the parts, be sure to check and adjust the bearing preload and the bevel gear backlash and tooth contact by replacing shims.
OPreload can be measured either with a spring scale or with a beam-type torque wrench. When measured with a spring scale, the preload is designated by force (N, kg), and when measured with a torque wrench, it is designated by torque (N'm, kg·m, in·fbi.
FINAL DRIVE 9-11 Backlash·Related Parts
1 . Front Gear Case 2. Ball Bearing
3. Driven Gear Shaft 4. Dri ve n Gear 5. Ball Bearing
6. Bearing Housing 7. Drive Gear Shim(s) 8. Drive Gear 9. Dri ve n Gear Shim(s)
10. Drive n Gear Bearing Housing
11. Tapered Roller Bearing Parts which influence the bearing preload only
12. Tapered Roll er Bearing
*13. Bearing Preload Nut
Using Spring Scale: Hook t he spring scale on the handle at a point 180 mm apart from the center of the gear shaft. Hold the bearing housing in a vise so that the gear shaft axis is vertical. App ly force to the handle horizontally and at a right angle to it.
*Whenever the nut is loosened, even if the purpose is not to rep lace the parts.
Using Torqu e Wrench:
A. Torque Wrench
*If th e preload is out of the specified range, loosen o r
A. Spring Scale B. Hole
C. Driven Gear Holder: 57001·1215 D. 180 mm
tighten the bearing preload nut. To decrease preload, loosen the bearing preload nut. To increase preload ,
tighten the nut.
9-12 FINAL DRIVE *Change the tightening torque of the nut a little at a time. eRe..check the bearing preload , and re-adjust as necessary.
OTo hold the drive gear steady, hold the shift drum at the full-turned position.
Preload for Driven Gear Bearings Using spring scale: Using torque wrench:
1.7 - 3.3 N (0.17 - 0.33 kg) 0.3 - 0 .6 N-m (0.03 - 0 .06 kg-m,
2.6 - 5.2
in~bl
Backlash adjustment
eelean any dirt and oil off the bevel gear teeth. elnstall the drive gear with the standard shim (see the shim tables), and tighten the nut to the specified torque (see Exploded View). OApply an oil to the threads and seated surface on the nut.
-Install the driven gear and cam damper assembly to the front gear case with the standard shim (see the shim tablesL and tighten the mounting nuts to the specified torque (see Exploded View) without the oil seal housing. -Install the front gear case to the crankcase, and tighten the 8 mm case bolts to the specified torque (see Exploded View). OCheck the backlash during the tightening of the case mounting bolts, and stop tightening them immediately if the backlash disappears . Then, change the shim to a thinner one. -Set up a dial gauge against a bearing preload nut of the driven gear shaft to check gear backlash.
A. Turn
B. Neutral Detent
*If the backlash is not within the limit, replace the shim(s) at the driven gear. To increase backlash, decrease the thickness of the shim(s). To decrease backlash, increase the thickness of the shim(s) . *Change the thickness a little at a time. eRe-check the backlash, and re-adjust as necessary .
Front Bevel Gear Backlash Standard:
0.06 -0.10 mm (at bearing preload nut)
Tooth contact adjustment -Clean any dirt and oil off the bevel gear teeth. eApply checking compound to 4 or 5 teeth on the driven gear.
NOTE
A. Dial Gauge
B. Move.
eTo measure the backlash, move the driven gear back and forth while holding the drive gear steady . The difference between the highest and lowest gauge readings is the amount of backlash.
OApply checking compound to the teeth in a thin, even coat with a fairly stiff paint brush. If painted too thickly, the exact tooth pattern may not appear. OThe checking compound must be smooth and firm, with the consistency of tooth paste. OSpecial compounds are available from automotive supply stores for the purpose of checking differential gear tooth patterns and contact. Use this for checking the bevel gears.
_Turn the driven gear for 3 or 4 revolutions in the drive and reverse (coast) directions, while creating a drag on the drive gear.
FINAL DRIVE 9-13 e<:::heck the drive pattern and coast pattern of the bevel gear teeth. The tooth contact patterns of both drive and coast sid es should be centrally located between th e top and bottom of the tooth, and a little closer to the toe of the tooth. * If the tooth contact pattern is incorrect, replace the shim(s) at the drive gear and shim(s) at the driven gear, following the examples shown. Then erase the tooth contact patterns, and check them agai n. Also check the backlash every time the shims are replaced. Repeat the shim change procedure as necessary.
Correct Tooth Contact Pattern Drive Gear
Bottom
. I
~~
'"''#/
NOTE
Olf the backlash is out of the standard range after changing shims correct the backlash before checking the tooth contact pattern.
Bottom
i
,
Toe
~'"
Bottom
~_ ~,
Driven Gear ______ Bottom
\
~
Heel Incorrect Tooth Contact Patterns Example 1: Increase the thickness of the drive gear shim (s) by 0.05 mm, and/or decrease the thickness of the driven gear shim (s) by 0.05 mm to correct the pattern shown below. Repeat in 0.05 mm steps if necessary.
Example 2: Decrease the thickness of the drive gear shim(s) by 0.05 mm, and /or increase the thickness of the driven gear shim(s) by 0.05 mm to correct the pattern shown below. Repeat in 0.05 mm steps if necessary.
Drive Gear Drive Gear Bottom
~/". ' Toe
Top
,---
Bottom Toe TOe Driven Gear
Bottom
9
Bottom
~
Driven Gear
T
\
Heel
op
e
.......--"':; Bottom
Bottom
~ Top
Heel
9-14 FINAL DRIVE
Bevel Gear Inspection _V isuall y check the bevel gears for scoring, chipping, or
Propeller Shaft
other damage. *Replace the bevel gears as a set if either gear is damaged.
Propeller Shaft Removal eRemove the rear axle and propeller shaft (see Rear
Axle and Propeller Shaft Removal). eRe mo ve the propeller shaft housing mounting nuts and
Ball Bearing Inspection -Since the ball bearings are made to extremely close tolerances, the wear must be judged by feel rather
ta ke off the housing with the propeller shaft. spring comes off with the propeller shaft.
The
than measurement. Clean each bearing in a high f1ashpoint solvent, dry it (do not spin the bearing while it is dry), and oil it with ·engine oil. eSpin the bearing by hand to check its condition. *If the bearing is noisy, does not spin smoothly. or has any rough spots, replace it.
Tapered Roller Bearing Inspection -V isuall y inspect the bearing for abrasion, color change, or other damage. *If there is any doubt as to the condition of a bearing, replace it.
A. Propeller Shaft Housing
C. Spring
B. Mounting Nuts
Oil Seal Inspection -Inspect the oil seals. *Replace it if the lips are misshapen, disco lored (in·
dicating that the rubber has deteriorated), hardened, or been otherwise damaged.
eRemove the circlip with the circlip pliers (special tool: PIN 57001-143), and pull out the propeller shaft assembly from the housing.
Cam Damper Inspection eVisuall y inspect the damper cam (driven gear), cam follower, spring, and shaft.
*Replace the part if it appears damaged.
, rM A. Circlip
eRemove the circlip with the circlip pliers (special tool:
PIN 57001-144), and pull out the propelier shaft from A. Cam (driven gear) B. Cam Follower
C. Spring D. Shaft
the propeller shaft joint. the joint.
The washer comes off with
FINAL DRIVE 9-15
A. Circlip
B. Propeller Shaft Joint
A. Apply grease.
Propeller Shaft Installation
Propeller Shaft Joint and Pinion Gear Joint Inspection
.Propeller shaft installation is the reverse of removal.
_Visually inspect the internal splines of the propeller
Note the following. eLubricate the propeller shaft before installation (see
Propeller Shaft Lubrication). -Tighten the propeller shaft housing mounting nuts to the specified torque (see Exploded View).
shaft sliding joint. *If they are badly worn or chipped, replace the joint
with a new one . • Visually inspect the splines of the pinion gear joint.
*If they are badly worn or chipped, replace the joint
with a new one.
Propeller Shaft Lubrication eLubricate the propeller shaft joint.
OWipe the old grease off the propeller shaft joint and pinion gear joint, and apply grease to the splines on them.
A. Splines
Propeller Shaft Inspection e(;heck that the universal joint works smoothly without rattling or sticking.
*If it does not, the bearing of the universal joint is A. Apply grease.
eLubricate the propeller shaft.
oWipe the old grease off the splines on the propeller shaft, and apply grease to them.
damaged. Replace the propeller shaft with a new one. .Visually inspect the grease seal and cap for the universal joint. *If there is any signs of deterioration, damage, or loosen,
replace the propeJler shaft. *If the grease leakage is noted, replace the propeller
shaft.
9-16 FINAL DRIVE -Loosen the clamp screw at the fro nt of the propeller shaft dust cover. -Support the vehicle with the frame so that the rear axle are free from loads. eRemove the lower mounting bolts of the left an d right rear shock absorbers. -Remove the suspension arm pivot bolts and nuts mounting to the rear axle, and free the rear axle with
the propeller shaft from the vehicle.
A. Universal Joint B. Grease Seal
C. Center Bearing D. Splines
A. Dust Cover Clamp B. Lower Mounting Bolt
C. Pivot Bolts
NOTE Olf the final gear case is full of oil, place the rear axle so that the correct side of it is up. If the rear axle is
A. Grease Cap
B. Splines
upside down or sideways, the oil will be drained out of the case through the vent hose.
_Inspect the center bearing. oSince the ball bearings are made to extremely close
tol erances, the wear must be judged by feel rather than
Rear Axle and Propeller Shaft Installation
measurement.
eRear axle and propeller shaft in stallation is the reverse
oSpin the bearing by hand to check its condition. *If the bearing is noisy , does not spin smoothly, or has any rough spots, replace the propeller shaft. eVisuall y inspect the splines on the propeller shaft. *If they are badly worn or chipped, replace the propeller shaft. Also, inspect the splines on the front driven gear shaft.
of removal. Note the following. eApply grease to the splines at the front end of the propeller shaft and fit the propeller shaft to the drive gear shaft.
Rear Axle Shafts
Rear Axle and Propeller Shaft Removal elf the final gear case is to be disassembled, drain the final gear case oi l (see Final Gear Case Oil Change). eRemove the following parts. Rear Wheels
Rear Drums Rear Brake Panels
A. Apply grease.
FINAL DRIVE 9-17 eTighten the following bolts and nuts to the specified torque (see Exploded View in the Suspension chapter). Shock Absorber Lower Mounting Bolts Suspension Arm Pivot Bolts and Nuts eRoute the fin al gear case vent hose as shown.
A. Oil Seal and Bearing Remover: 57001-1058
Axle Shaft Installation
elf the final gear case oil was drained, fill the case with oil (see Final Gear Case Oil Change).
eAxle shaft installation is the reverse of removal. Note the following. eUsing a press and the bearing driver set (special tool: PIN 57001-1129), install the oil seals and ball bearings until they stop at the bottoms of their housings. eSe sure the differential shifter and collar are in place when installing the left axle shaft.
Axle Shaft Removal eRemove the rear axle· and propeller shaft (see Rear Axle and Propeller Shaft Removal). eRemove the axle shaft pipe mounting bolts, and take off the left and right axle ·shaft pipes with shafts. The aluminum gasket comes off with each shaft pipe.
A. Differential Shifter
B. Collar
eApp ly grease to the oil seals on the axle shaft pipes.
A. Axle Shaft Pipes
.Pull the collar off the left axle shaft. eTa remove the ball bearings press-fitted onto the axle shaft pipes, use the oil seal and bearing remover (special tool). Also remove the oil seal behind each bearing using the same special tool.
A. Apply grease.
9-18 FINAL DRIVE eTighten the axle shaft pipe mounting bolts to the specified torque (see Exploded View) .
Oil Seal Inspection -Inspect the oil seals. *Replace any if the lips are misshapen, discolored (in~ dicating that the rubber has deterioratedL hardened, or been otherwise damaged.
Axle Shaft Inspection -Inspect the condition of the splines at each end of the axle.
............................................................................. Final Bevel Gears and Differential Gears
Pinion Gear Disassembly eRemove the rear axle and propeller shaft (see Rear
Axle and Propeller Shaft Removal). ePull the pinion gear assembly off the final gear case. The sh im (s} comes off with the assembly. OPry at the gaps at the left and right of the pinion gear bearing housing flange.
A. Splines
*If the splines are twisted or damaged in any way,
replace the rear axle.
Ball Bearing Inspection elnspect the axle shaft pipe ball bearings. oTurn each bearing back and forth while checking for roughness or binding.
A. Pinion Gear Assembly
B. Shim(s}
.Pry open the staking of the pinion gear nut with a small ch isel. _Unscrew the pinion gear nut using the bevel gear holder (special tool) to keep the pinion gear assembly as shown, and remove the pinion gear nut, flat washer,
shim(s), and pinion gear joint. The O·ring is between the pinion gear joint and the bearing.
A. Bearing Seal
*If roughness or binding is found, replace the bearing. eExamine the bearing seal of the ax le shaft pipe bearing for tears or leakage. *If the seal is torn or is leaking, replace the bearing.
A. Bevel Gear Holder: 57001-1193 B. Pinion Gear
FINAL DRIVE 9·19 ePut! the pinIon gear out of the bearing housing. ePry the oil seal off the bearing housing, and remove the tapered roller bearing inner race .
ePull the ring gear and differential gear hous.ing out of the case.
Pinion Gear Assembly ePinion gear assembly is the reverse of disassembly. Note the following. eThe pi nion gear and ring gear are lapped as a set in the factory to get the best tooth contact. They must be replaced as a set. eSe sure to check and adjust the pinion gear bearing preload and the bevel gear backlash and tooth contact, when an y of the parts which influence these items are replaced (see Final Bevel Gear Adjustment). o When the pinion gear nut is loosened, even if the propose is not to replace the parts, check and adjust the bearing preload. eReplace the pinion gear nut with a new one. eApply an oil to the threads and seated surface on the pinion gear nut, ·and tighten them to the specified torque (see Exploded View). eStake the head of the pinion gear nut with a punch, to secure the pinion gear nut in place after finishing the bearing preload adjustment.
OWhen staking the nut. be careful not to apply shock to the pinion and their bearing. Such a shock could damage the pinion and/or bearings.
,.
.~ ,tit
..
,
~
~ "~f
~ "
--~'.
A. Ring Gear B. Differential Gear Housing
eRemove the bolts and separate the rin g gear and differential gear housing cover from the housing. The differential left side gear comes off with the housing cover.
Ring Gear and Differential Gear Disassembly eRemove the rear axle and propeller shaft (see Rear Axle and Propeller Shaft Removal) . eRemove the pinion gear assembly (see Pinion Gear Disassembly). eRemove the axle shafts (see Axle Shaft Remova l). eUnscrew the final gear case cover bolts, and pull off the gear case cover. The shim(s) comes off with the cover.
A. Housing Cover B. Left Side Gear
A. Final Gear Case Coyer
C. Right Side Gear D. Pinion Gears
eDrive the retaining pin out of the differential gear hou sing, and pull the pinion gear shaft off the housing. The pinion gears and right side gear can be removed from the housing. The copper th rust washer is behind each gear.
9-20 FINAL DRIVE eBe sure to check and adjust the pinion gear bearing pre~
load and the bevel gear backlash and tooth contact, when any of the parts which influence these items are replaced (see Final Bevel Gear Ad justment) . eApply a non -permanent locking agent to the threads of the ring gear and differ-ential gear housing assembly bolts, and tighten them to the specified torque (see Exploded View) . -Using a press and the bearing driver set (special tool: PIN 57001-1129), install the ball bearings until they stop at the bottom of their housings. eTighten the fin al gear case cover bolts to the specified torque (see Exploded View).
A. Thrust Washer
eTo remove the ball bearings press-fitted onto the final gear case and case cover, use a press and bearing driver set (special tool: PIN 57001 ·11 29).
OBe careful not to scratch the sealing surfaces of the final gear case and case cover during the bearing removal and installation. A scratched sealing surface may allow oil to leak.
Final Bevel Gear Adjustment In order to prevent one gear from moving away from the other gear under load, the tapered roller bearings must be properly preloaded. Also the backlash (distance one gear will move back and forth without moving the other gear) and tooth contact pattern oJ the bevel gears must be correct to prevent the gears from making noise and being damaged. Above three adjustments are of critical importance and must be carried out fo ll owing the correct sequence and method.
Final Bevel Gear Adjustment Procedure
I
Preload the pinion gear bearings.
I
,
I
Adjust gear backlash.
II'
I
~
I
Adjust tooth contact pattern.
, A. Sealing Surfaces
Ring Gear and Differential Gear Assemblv eRing gear and differential gear assembly is the reverse of disassembly. Note the following. eThe ring gear and pinion gear are lapped together at the factory to get the best tooth contact. They must be replaced as a set.
I
I
/
Assemble the final gear case completly.
I
When anyone of the backlash-related parts are replaced or the pinion gear nut is loosened; even jf the purpose is not to rep1ac.e the parts, check and adjust the bearing preload and the bevel gear backlash and tooth contact by replacing shims. The amount of backlash is influenced by the ring gear position more than by the pinion gear position. Tooth contact location is influenced by pinion gear position more than by ring gear position.
FINAL DRIVE 9·21 Backlash-Related Parts
1. Pinion Gear Bearing Housing
2. 3. 4. 5. 6. 7. 8. 9. 10.
Pinion Gear Shim(s) Final Gear Case Tapered Roller Bearing Final Gear Case Cover Ring Gear Ball Bearing Differential Gear Housing Ring Gear Shim(s) Pinion Gear
Parts which influence the bearing
preload only 11. 12. 13. *14.
Tapered Roller Bearing Pinion Gear Joint Preload Adjustment Shim(s) Pinion Gear Nut
*Whenever the nut is loosened, even if the purpose is not to replace the parts .
Shims for Preload Adjustment
Thickness (mm) 0 .1 0.15 0.2 0.3 0.5 0.6 0.7 0.8 0.9 1.0 1.2 1.3
Ring Gear Shims for
Pinion Gear Shims for
Backlash Adjustment Part Number
92025-1287 92025-1656 92025-1288 92025-1289 92025-1290 92025-1291 92025-1292 92025-1293 92025-1294 92025-1295 92025-1657 92025-1282
Thickness (mm) 0.1 0.15 0.5 0.8 1.0* 1.2 (* : Standard)
Part Number
92025-1709 92025-1710 92025 -1711 92025-1712 92025-1713 92025-1714
Tooth Contact Adjustment
Thickness (mm) 0.1 0.15 0.5 0.8 1.0* 1.2
(* : Standard)
Part Number
92025-1703 92025-1704 92025-1705 92025-1706 92025 -1707 92025-1708
9-22 FINAL DRIVE Using Spring Scale: Hook the spring scale on the hand le at a point 200 mm apart from the center of the gear shaft. Hold the bearing housing in a vise so that the gear shaft axis is vert ical. Apply force to the handle horizontally and at a right angle to it.
Preload adjustment eAssemble the pinion gear bearing housing, and t ighten the pinion gear nut to the specified torque (see Exploded View). Do not install the oi l seal unt il the correct bearing preload is obtained.
OTa start with, choose a shim or shims so that the bearings are just SNUG with NO play but also with NO preload. GAn over-preload on the bearings could damage the bearings.
eApply final gear case oil to the bearings, and turn the gear shaft more than 5 turns to allow the bearings to seat. eMeasure the bearing preload. Bearing preload is defined as the force or torque which is needed to start the gear shaft turning. NOTE
A. Spring Scale B. Hole
OPreload can be measured either with a spring scale or a beam-type torque wrench. When measured with a
C. Bevel Gear Holder: 57001-1193 D.200mm
spring scale, the preload is designated by force (N, kg), and when measured with a torque wrench, it is designated by torque (N·m, kg-m, in-fbi.
Preloading Bearings (A) Before Tightening
(B) After Tightening
"'_---~~~~~ffiI-- No clearance Initial Clearance
Under no preload
1. Washer 2. Shim(s)
Under preload
FINAL DRIVE 9-23 Using Torque Wrench:
A. Dial Gauge
B. Hold
c.
Move
A. Torque Wrench
*If the preload is out of the spec ified range, replace th e shims under the flat washer. To increase preload, decrease th e thickness of the shim(s). To decrease preload , increase the thickness of the shim(s). CChange th e thickness a littl e at a tim e. eRe-check the bearing preload, and re-adju st as necessary.
eTa measure the backlash, move the ring gear back and forth whil e hold ing the pinion gear steady. The dif· ference between the highest and the lowest gauge read ing is the amou nt of back lash. *If the backlash is not w.ithin the limit, rep lace th e ring gear shims. To increase backlash, decrease the thickn ess of the sh im (s) . To decrease backlash, increase the thickness of the shim(s) . CChan ge the thickness a litt le at a time. eRe-check the backlash, and re-adjust as necessary.
Final Bevel Gear Backlash Preload for Pinion Gear Bearings Using spring scale: Using torque wrench:
1.5 -3.0 N (0.15 - 0.30 kg) 0 .3 -0.6 N·m (0.03 - 0.06 kg·m, 2.6 - 5.2 in·lb)
Standard:
0.08 - 0.25 mm (at ring gear tooth)
Tooth contact adjustment eelean any dirt and oil off th e bevel gear teeth. eApply checking compound to 4 or 5 teeth on the pinion gear.
NOTE Backlash adjustment eelean any dirt and o il off the bevel gear teeth. e lnstall the pinion gear assembly with the stand ard shim (see th e sh im t ables), and tighten the propeller shaft pipe mounting nuts to the specified torque (see Exploded View) without t he propeller shaft housing. e lnstall t he ring gear and differential gear housing to the final gear case, and put the stan dard shim (see the sh im tables) onto the ring gear. ePut on the final gear case cover and t ighte n the cover mounting bolts to the specified torque (see Exploded View) . OCheck t he backlash durin g the t ightening of the cover mounting bo lts, and stop tighte nin g them imm ediate ly if the backlas h disappears. Then, change the ring gear sh im to a thinner one. eSet up a dial gauge against a ring gear tooth to check gear backlash.
OApply checking compound to the teeth in a thin, even coat with a fairly stiff paint brush. If painted too thickly, the exact tooth pattern may not appear. OThe checking compound must be smooth and firm~ with the consistency of tooth paste. OSpecial compounds are available from automotive supply stores for the purpose of checking differential gear tooth patterns and contact. Use one of these for checking the bevel gears.
elnstall the shi m(s) and pinIOn gear assem bl y, and tighten the mounting nuts to th e speci fied torqu e (see Exp loded View). elnstall the ring gear and differential gear housing to t he final gear case, and put the shim (s) onto the ring gear. ePut o n the fi nal gear case cover and tigh ten the cover mounting bolts to the specified torque (see Exploded View).
9·24 FINAL DRIVE Correct Tooth Contact Pattern
Ring Gear Bottom
Pinion Gear
Top
Toe
Heel
Bottom
I ncorrect Tooth Contact Patterns
Example 1: Decrease the thickness of the pinion gear shim (s) by 0.05 mm to correct the pattern shown below. Repeat in 0.05 mm steps if necessary.
Ring Gear
-+-------- :~ ------Pinion Gear
I
Bottom
Heel Toe
Toe
Bottom
Bottom Example 2: Increase the thickness of the pinIOn gear
shim(s) by 0.05 mm to correct the pattern shown below. Repeat in 0.05 mm steps if necessary.
Bottom
Heel Pinion Gear
/ Heel
~'~ ~-Bottom Top
Bottom
FINAL DRIVE 9-25 eTurn the pinion gear for one revolution in the drive and reverse (coast) direction, while creating a drag on the ring gear . eRemove the ring and pinion gear assemblies to check the drive pattern and coast pattern of the beve l gear teeth. The tooth contact patterns of both (d rive and coast) sides should be centrally located between the top and bottom of the tooth. The drive pattern can be a little closer to the toe and the coast pattern can be a somewhat longer and closer to the toe. *If the too th contact pattern is incorrect, replace the pinion gear shim(s). following the examples shown . Then erase th e tooth contact patterns, and check them aga in. Also chec k the backlash every time the shim(s) are· replaced . Rep eat the shim change procedure as necessary.
Oil Seal Inspection elnspect the o il seal. *Replace it if the lips are misshapen, discolored (indicating that the ru bber has deteriorated)' hardened, or been otherwise damaged.
Differential Shift Mechanism Shift Lever Case and Cable Removal
NOTE
eRemove two front gear case bolts holding the differential shift lever case.
O ff the backlash is out of the standard range after
changing t he pinion gear shim(s), change the ring gear shim(s) to correct the backlash before checking the tooth contact pattern.
Bevel Gear Inspection eVisuall y check the bevel gears for scoring, chipping, or other damage. *Rep lace the bevel gears as a set if either gear is damaged.
Differential Gear Inspection eVisually check the different ial gears for scoring, chipping, or other damage. *Replace the differential gears as a set if either gear is damaged. Also, inspect the thrust washers, differential pinio n gear shaft, and gear housing where the diffe renti al gears rub. If they are sco red, discolored, or otherwise damaged, replace them.
A. Differential Shift Lever Case C. Cable Bracket B. Remove these bolts . ePry open the cable bracket and free the cable from it. eLoosen the mounting nuts and take off the cable adjuster fro m its bracket. ePull th e cable tip out of th e catch o n the lever and free t he case and cable from th e vehicle .
Tepered Roller Bearing Inspection eVi suall y inspect t he bearings for abras ion, color change, or other damage. *If there is any doubt as to the condition of a bearing, replace it.
Ball Bearing Inspection elnspect the final gear case ball bearings. 05ince the ball bearings are made to extremely close to lerances, the wear must be jud ged by feel rather than meas urement. Clean each bearing in a high flash·po in t solvent, dry it (do not spin the bearing while it is dry). and o il it with engi ne oil. OSpi n the bearing by hand to check its condition . *If t he bearing is no isy, does not spin smoothly, or has any ro ugh spo ts, replace it.
A. Mounting Nuts B. Adjuster
C. Cable Tip
9-26 FINAL DRIVE -Separate the cable from the case. ORemove the screws and take off the plate. oPull the cable housing out of the case and free the cable tip from the catch on the shift lever. Do not lose the
rubber seals.
A. B. C. D.
A. Cable Tip B. Rubber Seals
Differential Shift Fork Lever Left Suspension Arm Shock Absorber Lower Mounting Bolt Left Axle Shaft and Pipe
C. Do not loosen this pivot bolt. ePull the differential shifter off the shift fork ears.
000 not loosen the shift lever pivot bolt. Loosening the pivot bolt upsets the position of the special designed collar under the lever. and could cause malfunctioning
of the lever action.
Shift Lever Case and Cable Installation _Shift lever case and cable installation is the reverse of removal. Note the following. eLubricate the differential cable (see Differential Cable Lubrication) . eTighten the front gear case 8 mm bolt to the specified torque (see Exploded View). eAdjust the differential cable (see Differential Cable Adjustment).
A. Differential Shifter B. Shift Fork
C. Shift Fork Holder
eUnscrew the shift fork holder screws and pull off the holder with the gasket. Now, the shift fork can be
Shifter and Shift Fork Removal eDrain the final gear case oil (see Final Gear Case Oil Change). -Support the vehicle with the frame so that the rear axle are free from loads. eRemove the following parts. Differential Shift Fork Lever Rear Left Wheel Rear Left Drum and Panel Left Suspension Arm Left Shock Absorber Lower Mounting Bolt Left Axle Shaft
removed.
Shifter and Shift Fork Installation _Shifter and shift fork installation is the reverse of removal. Note the following.
eApply grease to the shift fork shaft .
FINAL DRIVE 9·27
A. Cable Housi ng B. Holder C. Cable Bracket
A. Apply grease.
-Tighten the shift fork holder screws to the specified torque (see Exp loded View). -Adjust the differential cable (see Differential Cable Adjustment).
D. Differential Shift Lever (in "LOCK" position)
-Rotating the rear whee ls, shift the rear ax le into the
locked·axle mode by turning the shift fork shaft clockwise.
Differential Cable Adjustment Whenever the differential cable is removed and the differential shift lever play is excessive, adjust the differential cable. -Push the different ial shift lever down all the way to the "LOCK" position. -Unhook the shift fork lever return spring. -Remove the sh ift fork lever nut and take off the lever.
A. Shift Fork Shaft
B. Turn clockwise.
-Fit the cable tip in to t he catch on the shift fo rk lever and mount the lever o nto the shaft pu lli ng the cable taut.
A. Shift Fork Lever B. Return Spring
C. Cable Adjuster D. Mounting Nuts
_ Loosen the cable adjuster mounting nuts.
-Sl ide the cable housing forward until the front end of it seats fully in to the holder on the case, tighten the cable adjuster mounting nuts without changing the position of the cable hous ing and clamp the open end of the cable bracket to secure the cable housing in place.
A. Shift Fork Lever
B. Pull the cable taut.
9-28 FINAL DRIVE eHook the shift fork lever return spring.
Differential Cable Lubrication Whenever the differential cable is removed, lubricate the differential cable as follows . -Lubricate the differential cable by seeping the oil between the cable and cable housing.
Cable Lubrication
Shifter and Shift Fork Inspection _Visually inspect the dogs on the shifter and different ial gear housing, and the shifter groove, and shift fork.
*If they are damaged or worn excessivel y, replace them.
-Apply a thin coating of mUlti-purpose grease to the differential sh ift lever pivot area and the differential cable ends.
A. Dogs
B. Shift Fork
C. Groove
-Check that the shifter slides smoothly on the axle shaft. *If it does not slide smoothly, repair the splines on th e sh ifter and axle shaft or replace them if necessary.
A. Apply grease.
Differential Cable Insepction -With the differential cable disconnected at the both ends, the cable should move freel y within the cable housing. *If cable movement is not free after lubricating (see Differential Cable Lubrication), if the cable is frayed , or if the housing is kinked, replace the cable.
A. Shifter
BRAKES 10-1
Brakes Table of Contents
Exploded View Specifications Special T oo l
. . . . . . . . . • . . . . • . .. . .. .. _ . . . . . . . . ... .•. . . . . .
. . . . . . . . . . . . . . .. ... . . . .
Brake Adjustment .. . . . . . . . . . . . . . . . . . . Front Brake Lever Free Play Inspection
10-2 10-4 10-4 10-5 10-5 10-5
Brake Shoe Adjustment Free Play Inspection . . . . . . ... . . .
Rear Brake Pedal Free Play Adjustment . . . . . . . . . . . . . . . .. .
Cam Lever Angle Adjustment . .. . . .. . Brake Fluid ................... . . .. . . Brake Fluid Recommendation . ... . • . . Brake Fluid Level Inspection ... . ... .
Brake Fluid Changing . . . . . . . . . . • . . Brake Line Air Bleeding . . . . . . . . ... .
Master Cylinder and Wheel Cylinders .... . . . Master Cylinder Remova l . . . . . . . . . . . Master Cylinder Installation .... .. . . .
Master Cylinder Disassembly . .... . . . . Master Cylinder Assembly
. . ... . ... . ........ . . .
Wheel Cylinder Installation . .. ... . . . .
Wheel Cy li nder Disassembly ... . .. .. . Wheel Cylinder Assembly ........•.. Master Cyli nder Inspection . ... .. ... . Whee l Cylinder Inspection . . . . . .. . . . Brake Lever Lubr ication
.......... .
10-6 10-6 10-7 10-7 10-7 10-8 10-8 10-9 10-10 10-10 10-10 10-11 10·11 10-11 10-11 10-11 10-11 10·11 10-12 10-12
10·12 10·12
Brake Hose Installation. . . . . . . . . . ..
10-12
Brake Hose Inspection. . . . . . . . . . . ..
10-13
Brake Drums . _ . _ .. .. .. _ ... _ . . . . • • ..
10-13
Front Brake Drum Removal/Installation . ... . .. . . .. . Rear Brake Drum Removal . .. . . . . . . .
Rear Brake Pedal
Wheel Cyli nder Removal
Brake Hoses ..... _ . . . . .. . . . . .. ..••.. Brake Hose Removal. . .. . . . . . • • . . .
Rear Brake Drum Installation . . . . . . . .
Front or Rear Drum Disassembly/ Assembly Note ... ..... ..... .• • Brake Drum Wear ....... • ......•. Rear Brake Drum Seal Wear . . . . . . . . . Brake Panel Assemblies .. . . . . . . . . . . . . . .
10·13 10·13 10-13 10-13 10·14 10·14 10·14
Front Brake Panel Removal/Disassembly
10·14
Front Brake Panel
Assembly/Installation
10·15
Rear Brake Panel Removal/Disassembly
10·15
Rear Brake Panel Assembly/Installation . . . . . . .. . . . Brake Shoe Lining Wear . . . . . . . . . . . . Brake Shoe Spring Inspection . . . . . . . . Brake Camshaft and Camshaft Hole Wear ... . .. . . . . . . Brake Panel Lubrication . . . . . . . . . . . .
Brake Pedal Brake Brake Brake Brake
and Cables . . . . . . . . . . . . . . . . Pedal and Cable Removal . .. . .. . Pedal and Cable Installation .. . . . Cable Inspection . . . . . . . . . . . . Pedal and Cable Lubrication . _ . _.
I 10·15 10.16~ 10-16~
10-16 10·16 10-17 10-17 10-18 10·1B 10-1B
10-2 BRAKES
........ E·················· __ ~ploded ........ _.. View .. __
u u __ u ••• u u u . u . u •• u . u
.................
.... ........ . ............ ........... ..........................
~
T1
@
I
lJ:'
~ d)~~: I
•
T4
$
I @J~
t @~ ~@ ~ @~~~@~
:---'"""1 ___' .. Frame No JKALFSA1DG JKALFSA lDG:04250 and up or LF300A-004250 09409 and up or and up
~
. pply adhesive A'A G 'A pply grease . S,. I : Apply silic . Tl : 25 N.m (2 one grease. 5 T2: 20 N-m (2. kg·m, lS ft-Ibl 0 T3: 11 N-m (1. kg·m, 14.5 ft-Ibl T4: 5.9 N-m (~~~g-m, 95 in-Ibl T5: 7.S N.m (O.SO kg-m, 52 in-Ibl T6: 145 N-m (150kg-m, 69 in·lbl T7: 29 N.m (30 ' kg-m, 110 ft-Ibl . kg-m, 22 ft-Ibl
BRAKES 10-3
G
10-4 BRAKES Specifications
Brakes: Item
Standard
Service Limit
Front Brake Lever Free Play
25 -30 mm
Rear Brake Pedal Free Play
20 - 30mm
- --
Rear Brake Cam Lever Angle
80 - 90°
--
Brake Fluid:
Grade
D.O.T.3
--
Brand
Recommended as below.
--
Brake Drum Inside Diameter
160.000 - 160.160 mm
160.65 mm
Brake Shoe Lining Thickness
4.0mm
Rear Brake Camshaft Diameter
16.957 - 16.984 mm
16.83 mm
Rear Brake Camshaft Hole Diameter
17.000 - 17.027 mm
17.15 mm
2.0mm
Recommended Brake Fluid Type
D.O.T.3
Brand Atlas Extra Heavy Duty Shell Super Heavy Duty Texaco Super Heavy Duty Wagner Lockheed Heavy Duty Castro I Girling·Universal Castro I GT (LMA) Castro I Disc Brake Fluid
Special Tool Jack: 57001 ·1238 Along with common hand tools, the following more speciali zed tools are required for complete brake servicing.
Circlip Pliers: 57001 ·143
BRAKES 10-5 Brake Adjustment Front Brake Lever Free Play Inspection ePull the front brake lever fully until the front brake is dragged firmly. This is the free play.
~=r@ ~
'\ ~_J ,
A. Shoe Check Hole
B. Lining Thickness
":.. _ _ - _ - _ _ _ 0#
Brake Shoe Lining Thickness Standard:
Service Limit:
A. Brake Lever Free Play
*If the front brake lever free play is incorrect, adjust the brake shoe to drum clearance for both front wheels (see Brake Shoe Adjustment). *If the free play cannot be corrected by adjusting the brake shoes, there might be air in the brake lines and the air bleeding must be necessary (see Brake Line Air Bleeding).
4.0mm 2.0mm
*If any lining thickness is less than the service limit, replace both shoes as a set. eApply a brake several times. elnsert a thin screwdriver through the hole marked "SHOE ADJUST", and turn the brake shoe adjusting wheel in the direction shown below to expand the shoe.
Front Brake lever Free Play Standard:
25 -30mm
-Operate the lever a few times to see that it returns to its rest position i'mmediately upon release. eRotate the front wheels to check for brake drag. -Check braking effectiveness. *If there is any doubt as to the conditions of the brake,
A. Shoe Adjust Hole
B. Turn adjusting wheel.
check the brake parts for wear or damage. -Continue turn ing the adjusting wheel until a firm drag is felt when attempting to rotate the wheel. eTurn back the adjusting wheel until the wheel just turns free and then turn back three clicks rrore to provide running clearance.
Brake Shoe Adjustment eSupport the vehicle on a stand so that the front wheels are off the ground. ePull the rubber cap out of the wheel. eThrough the inspection hole marked "SHOE CHECK", inspect the brake shoe lining thickness at· several points.
000 not adjust the brake shoes too close to the drum. The brake will drag, heat up and lock. The lining will be charred and rendered useless.
10-6 BRAKES eApply a brake several times and rotate the wheel to check for brake drag. -Repeat the previous step one more time for the other shoe.
Rear Brake Pedal Free Play Inspection
*If the rear brake pedal free play is incorrect and each lining wear
indicator
points within
the USABLE
RANGE, adjust the rear brake pedal free play (see Rear Brake Pedal Free Play Adjustment). e()perate the pedal a few times to see that it returns to its rest position immediately upon release. eRotate the rear wheels to check for brake drag. -Check braking effectiveness. *If there is any doubt as to the cond iti ons of the brake, check the brake parts for wear or damage.
-Depress the rear brake pedal lightly by hand. This is the free play.
Rear Brake Pedal Free Play Adjustment Rear Brake Pedal Free Play Standard:
20 -30mm
-Support the vehicle on a stand or the jack (special too l: 57001-1238) so that t he rear wheels are off the ground. -Loosen the locknut and turn the brake pedal position adjusting bolt until the brake cable equal izer stops by the frame bracket.
A. Brake Pedal Free Play A. Adjusting Bolt B. Locknut
e<:heck each brake lining wear indicator points with in the USABLE RANGE when the brake is fully applied. *If does not, the brake shoes must be immediately re· placed and the other brake parts examined.
A. USABLE RANGE
B. Wear Indicator
C. Equalizer D. Bracket
-Shift the rear ax le to the unlocked·axle mode. -Turn the adjuster at the rear end of the cable until a light drag is felt when attempting to rotate the wheel.
A. Adjuster
BRAKES 10-7 eRepeat the above step one more time for the ot her cable.
Cam Lever Angle Adjustment eRemove the bolt and nut, and take off t he cam lever. eMount the cam lever at a new position so that t he cam lever has a proper angle when the brake is full y app lied.
NOTE
Olf the rear brake cables cannot be adjusted by using the adjusters at the rear ends of the cables, use the adjusters at the equalizer. Do not forget to securely tighten the adjuster mounting nuts.
eAdjust the brake pedal position to suit you by turning the brake pedal adjust ing bolt. eTighten the locknut. eTurn both adjusters at the rear ends of th e brake cables until the brake pedal has the correct amount of play. The adj usters must be turned in the same direction and the same number of t urns . Th is will keep the eq ualizer in th e stra ight ahead positio n. -Check the cam lever comes to the proper angl e with the brake cable when t he brake is full y applied.
Cam Lever Angle Standard:
Cam Lever Angle Standard:
eAdju st the rear brake pedal free play (see Rear Brake Pedal Free Play Adjustment).
WARNING' OWhen remounting the cam, be sure that the position of the ind icator on the serrated shaft is not altered. OA change in cam lewr angle is caused by wear of internal brake parts. Whenever the cam lever angle is adjusted, also check for drag and proper operation, taking particular note of the brake lining wear indicator position . Din case of doubt as to braking effectiveness, disassemble and inspect all internal brake parts. Worn parts could cause the brake to lock or fail.
*If does not, adjust t he cam lever angle (see Cam Lever Angle Adj ustment).
WARNING' 0
OSince a cam lever angle greater than 90 reduces braking effectiveness. cam lever angle adjustment should not be neglected.
Brake Fluid Brake Fluid Recommendation Recommended fluids are given in the table below. If none of the recommended fluid s are available, use extra heavy-du ty brake fluid only from a contai ner mar ked D.O.T.3.
-o A. Cam Lever Angle (80 - 90°)
Recommended Brake Fluid Type D.O.T.3 Brand Atlas Extra Heavy Duty Shell Super Heavy Duty Texaco Super Heavy Duty Wagner Lockheed Heavy Duty Castrol Girting-Universal Castrol GT (LMA) Castrol Disc Brake Fluid
10-8 BRAKES
WARNING
I
oNever reuse old brake fluid.
000 not use fluid from a container that has been left unsealed or that has been open for a long time. 000 not mix two types and brands of fluid for use in the brake. This lowers the brake fluid boiling point and could cause the brake to be ineffective. It may also cause the rubber brake parts to deteriorate. ODon't leave the reservoir cap off for any length of time
to avoid moisture contamination of the fluid. ODon't add or change the fluid in the rain or when a
strong wind is blowing. Olf any of the brake line fittings or the bleed valve is opened at any time, the AIR MUST BE BLED FROM THE BRAKE.
!CAUTlO~] OBrake fluid quickly ruins painted surfaces; any spilled fluid should be completely wiped up immediately.
Brake Fluid Level Inspection .Position the reservoir horizontal, and check that the fluid level in the reservoir is higher than the lower revel.
A. Upper Level Line
eApply a brake forcefully for a few seconds, and check for fluid leakage around the fittings.
I WARNING I Olf the brake lever has a soft or "sponge feeling" when it is applied, there might be air in the brake line or the brake may be defective. Since it is dangerous to operate the vehicle under such conditions, bleed the air from the brake line immediately.
Brake Fluid Changing
A. Lower Level
*If the fluid level is lower than the lower leve l, check for the flu id leakage of the brake line, and add the fluid as follows. ORemove the reservoir cap, and fill the reservoir to the upper level line in the reservoir with the same type and brand of the fluid that already is in the reservoir. And then install the reservoir cap.
I WARNING I OChange the fluid in the brake line completely if the fluid must be refilled but the type and brand of the fluid that already is in the reservoir are unidentified .
eRemove the front wheels (see Wheel Removal in the Wheels/Tires chapter). eRemove the reservoir cap, and remove the rubber cap on the bleed valve. eAttach a clear plastic hose to the bleed valve on the wheel cylinder, and run the other end of the hose into a con tai ner . -Open the bleed valve (counterclockwise to open). and pump the brake lever until all the fluid is drained from the line. e<:lose the bleed valve. eRepeat the above 4 steps one more time for the other side. eFi li the reservoi r with fresh brake fluid. eOpen the bleed valve, apply the brake by the brake lever, close the valve with the brake held applied, and then quickly release the lever. Repeat this operation until the brake line is filled and fluid starts coming out of the plastic hose. NOTE oReplenish the fluid in the reservoir as often as necessary to keep it from running completely out.
eRepeat the above 2 steps one more time for the other side. eBleed the air from the lines (continue with Brake Line Air Bleeding).
BRAKES 10-9 eTighten the bleed valves to the specified torque (see Exploded View). elnstall the front whee ls (see Wheel Installation in the Wheels/Tires chapter). Filling up Brake Line
NOTE OThe fluid level must be checked several times during the bleeding operation and replenished as necessary. If the fluid in the reservoir runs completely out any time during bleeding, the bleeding operation must be done over again from
the beginning since air will have
entered the line. -Connect a clear plastic hose to the bleed valve at the wheel cylinder, running the other end of the hose into a container . • With th~ reservo ir cap off, slowly pump the brake lever
several times until no air bubbles can be see rising up through the fluid from the holes at the bottom of the reservoir. Th is bleeds the air from the master cylinder end of the line. ePump the brake lever a few times until it becomes hard and then, holding the lever squeezed, quick ly open (turn counterclockwise) and close the bleed valve. Then release the lever. Repeat this operation untiL no more air can be seen com ing out into the plastic hose. -Repeat the previous step one more time for the other sid e. eWhen air bleeding is finished, check that the fluid is filled to the upper level line marked in the reservoir.
,..
.
1. 2. 3. 4.
Open the bleed valve . Apply the brake lever and hold it. Close the bleed va lve. Then release the brake lever suddenly.
Brake Line Air Bleeding eRemove the front wheels (see Wheel Removal in the Wheels/Tires chapter). eRemove the reservoir cap, and check that there is plenty of fluid in the reservoir.
A. Upper Level Line
e ln stall the reservoi r cap. eTighten the bleed valves to the specified torque (see Exploded View). eApply the brake lever forcefully for a few seconds, and check for fluid leakage around the fittings. e ln stall the front wheels (see Wheel Installation in the Wheels/Tires chapter).
10-10 BRAKES Bleeding Brake Line
A. Banjo Bolt B. Master Cylinder
-.
C. Clamp Bolts
eRemove the clamp bol ts and take off the master cylinder.
@.,
,
Master Cylinder Installation eMaster cylinder installation is the reverse of removal. Note the following. eThe master cylinder clamp must be installed with the UP mark faced upwards. eTorque the upper clamp bolt first, and then the lower clamp bolt (see Exploded View). There will be a gap at the lower part of the clamp after tightening.
1. Hold the brake lever applied. 2. Quickly open and close the bleed valve. 3. Release the brake lever.
............................................................................. Master Cylinder and Wheel Cylinders
Master Cylinder Removal ePull back the dust cover, and remove the banjo bolt to disconnect the upper brake hose from the master cylinder. There is an aluminum washer on each side of the hose fitting . elmmediately wipe up any brake fluid that spills.
OBrake fluid quickly ruins painted surfaces; any spilled fluid should be completely wiped up immediately.
A. Tighten upper clamp bolt first. B. UP mark
-Use a new flat washer on each side of the brake hose fitting, and tighten the banjo bolt to the specified torque (see Exploded View). eBleed the brake line after master cylinder installation (see Brake Line Air Bleeding). -Check that the brake line has proper fluid pressure and no fluid leakage.
BRAKES 10-11 Master Cylinder Disassembly
Wheel Cylinder Installation
eRemove the master cylinder (see Master Cylinder Removal). -Remove the reservoir cap and diaphragm, and empty out the brake fluid. eRemove the locknut and pivot screw, and remove the brake lever. -Slide the dust cover out of its place. -Remove the retainer with the circlip priers (special tool: PIN 57001·143) and pull the piston with secondary cup, and take off the primary cup and spring.
-The wheel cylinders are installed during front brake panel assembly (see Front Brake Panel Assembly/ Installation).
Wheel Cylinder Disassembly .Remove the wheel cyl inder (see Wheel Cylinder Removal). -Pull the dust covers out of the cylinder. .Pull the pistons and cups out of the cylinder.
NOTE ODo not remove the secondary cup from the piston since
removal will damage them. Master Cylinder
.'" A. Dust Covers B. Pistons 1. Spring 2. Primary Cup 3. Secondary Cup
C. Cups
4. Piston 5. Dust Cover
Master Cylinder Assembly eMaster cylinder assembly is the reverse of disassembly. Note the following. eBefore assembly, clean all parts including the master cylinder with brake flu id or alcohol, and apply brake fluid to the removed parts and the inner wall of the cylinder.
OUse only brake fluid. isopropyl alcohol, or ethyl alcohol, for cleaning brake parts. Do not use any other fluid for cleaning these parts. Gasoline, motor oil, or any other petroleum distillate will cause deterioration of the rubber parts. Oil spilled on any part will be difficult to wash off completely, and will eventually deteriorate the rubber used in the brake.
Wheel Cylinder Assembly -Wheel cylinder assembly is the reverse of disassembly. Note the fol lowing. -Before assembly, clean all parts including the wheel cylinder with brake fluid or alcohol, and apply brake fluid to the removed parts and the inner wall of the cylinder.
DUse only brake fluid, isopropyl alcohol, or ethyl alcohol, for cleaning brake parts. Do not use any other fluid for cleaning these parts. Gasoline, motor oil, or any other petroleum distillate will cause deterioration of the rubber parts. Oil spilled on any part will be difficult to wash off completely, and will eventually deteriorate the rubber used in the brake .
-Lubricate the brake lever (see Brake Lever Lubrication).
Master Cylinder Inspection (Visual Inspection) Wheel Cylinder Removal eThe wheel cylinders are removed during front brake panel disassembly (see Front Brake Panel Removal / Disassembly).
-Check that there are no scratches, rust or pitting on the inside of the master cylinder and on the outside of the piston. * If the master cylinder or piston shows any damage, replace them . -Inspect the pr imary cup and secondary cup.
10-12 BRAKES *If a cup is worn, damaged, softened (rotted), or
Brake Hoses
swollen, replace the piston assembly.
*If fluid leakage is noted at the brake lever, the piston assembly shou ld be replaced to renew the cup. -Check the dust cover for damage. *If it is damaged , replace it. -Check that. the relief and supply ports are not plugged . *If the small relief port becomes plugged , blow the ports clean with compressed air. -Check the piston return spring for any damage. *If the spring is damaged, replace the piston assembly.
............................................ . ....................... ! ........
Brake Hose Removal -Remove the banjo bolts at both ends of the brake hose, and pull the hose off the vehicle. There is a copper washer on eac h side of the hose fitting. eTo remove the metal pipe, unscrew the metal pipe
nipple and pull out the reta iner.
NOTE
OThe cups and spring are pan of the piston assembly. Replace the piston assembly if anyone of the cups or
the spring requires replacement.
Wheel Cylinder Inspection (Visual Inspection) e<:heck that there are no scratches, rust or pitting on the
inside of the wheel cylinder and on the outside of the pistons. *If the wheel cylinder or piston shows any damage, replace the cylinder. -Inspect the cups. *If a cup is worn, damaged, softened (rotted), or swoll en, replace the cylinder. *If flu id leakage is noted at the dust covers, the cylinder should be replaced to renew th e cup. -Check the dust covers for damage.
A. Metal Pipe Nipple
B. Retainer
-Immediately wipe up any brake fluid that spills.
{CAUTION
*If these are damaged, replace them.
I
OBrake fluid quickly ruins painted surfaces; any spilled
fluid should be completely wiped up immediately.
Brake Lever Lubrication Whenever the master cylinder is disassembled, and in accordance
with
the
Periodic
Maintenance
Chart,
perform the following . _Lubricate the brake lever by applying a light coating of si licone grease to the brake lever pivot screw and the contact with the piston.
A. App ly grease.
Brake Hose Installation elf the hose protector was removed, in sta ll it to the
fram e bracket by applying an ad hesive to it.
A. Hose Protector
BRAKES 10·13 eUsing a new copper washer for each side of the hose fitti ngs, tighten the banjo bolts to the specified torque (see Exploded View). eTighten the metal pipe nipple to the specified torque (see Exp lo ded View) . eBleed the air from the brake line (see Brake Line Air Bleeding).
Brake Hose Inspection eThe high pressure inside the brake line can cause fluid to leak or the hose to burst if th e line is not properly maintained. Bend and twist the rubber hose whil e examining it. *Replace it if any cracks or bulges are noticed. eThe metal pipe which feeds the brake fluid to the 2-way joint is made of plated steel, and will rust if the plating is damaged . *Replace the hose if it is rusted, cracked (especial ly check the fittings), or if the plating is badly scratched.
I WARNING' OBrake linings contain asbestos fiber. Inhalation of asbestos may cause serious scarring of the lungs and may promote other internal injury and illness, including cancer. Observe the following precautions when handling brake linings: 1. Never blow brake lining dust with compressed air. 2. If any components are to be cleaned, wash them with detergent, then immediately discard the cleaning solution and wash your hands. 3. Do not grind any brake lining material unless a ventilation hood is available and properly used.
Rear Brake Drum Installation eRear brake drum installation is the reverse of removal. Note the following. eApply a low-temperature grease to the brake drum seal lip. An example of a low-temperature grease is NOK TOPAS J L152. Brake Drum Seal Lubrication
Grease
Brake Drums
Front Brake Drum Removal/Installation eThe front brake drums are removed and installed during front hub bearing removal and installation (see Front Hub Bearing Removal and Front Hub Bearing Installation in the Wheels/Tires chapter).
Rear Brake Drum Removal eRemove the rear wheels (see Wheel Removal in the Wheels/Tires chapter) . eRemove the cotter pins and loosen the axle nuts. Hold the axle from turning by applying the rear brake while loosening the axle nuts.
eTighten the axle nut to the specified torque (see Exploded View).
Front or Rear Drum Disassembly/ Assembly Note eDo not press the drum bolts out. *If the drum bolt is damaged, replace the drum and bolts as a unit.
3
A. Axle Nut
ePu ll each brake drum off the end of the axle.
1. Front Drum 2 . Drum Bolts
3. Rear Drum
10-14 BRAKES
.............................................................................
Brake Drum Wear eMeasure the inside diameter of the drum. DUse calipers and measure at several points.
Brake Panel Assemblies
Front Brake Panel Removal/Disassembly eRemove the front brake drum (see Front Brake Drum Removal).
WARNING
I
OBrake linings contain asbestos fiber . Inhalation of asbestos may cause serious scarring of the lungs and may promote other internal injury and illness, including cancer. Observe the following precautions when handling brake linings: 1. Never blow brake lining dust with compressed air. 2. If any components are to be cleaned, wash them with detergent, then immediately discard the cleaning solution and wash your hands. 3. Do not grind any brake lining material unless a ventilation hood is available and properly used. *If any measurement is greater than the service limit, replace the drum. *If the drum is worn unevenly or scored, lightly turn the drum on a brake drum lathe or replace it. Do not turn the drum beyond the service limit.
eRemove the brake shoe springs.
Brake Drum Inside Diameter Standard : Service limit :
160.000 -160.160 mm 160.65 mm
Rear Brake Drum Seal Wear Whenever the braking efficiency of the rear brake has decreased, perform the following. eRemove the drain plug at the bottom of the rear brake panel and check to see if any water comes out.
A. Brake Shoe Springs
eRemove the retainers and take off the brake shoes. oPush the shoe hold-down spring and twi st the pin to remove them. NOTE
OHold the brake shoes with a clean cloth to protect the linings from grease or dirt.
A. Drain Plug
*If any water drains, the rear brake drum seal is damaged and must be immediately replaced. Also, inspect the other brake parts.
A. Shoe Hold-down Spring
BRAKES 10-15 eRemove the banjo bolt to disconnect the the brake hose from the wheel cylinder. aluminum washer on each side of the Olmmediately wipe up any brake fiuid
lower end of There is an hose fitting. that spills.
[CAUTlO~] OBrake fluid quickly ruins painted surfaces; any spilled fluid should be completely wiped up immediately.
eTighten the following bolts to the specified torque (see Exploded View). Wheel Cylinder Mounting Bolts Shoe Adjuster Mounting Bolts Brake Panel Mounting Bolts Brake Hose Banjo Bolt .Lubricate the brake panel parts (see Brake Panel Lubrication). eBleed the brake line (see Brake Line Air bleeding) after brake panel installation. eAdjust the brake shoe to drum clearance (see Brake Shoe Ad justme nt).
Rear Brake Panel Removal/Disassembly .Remove the rear brake drum (see Rear Brake Drum Removal).
WARNING
A. Brake Hose Banjo Bolt
eRemove the brake panel mounting bolts, and take off the brake panel assembly.
I
OBrake linings contain asbestos fiber. Inhalation of asbestos may cause serious scarring of the lungs and may promote other internal injury and illness, including cancer. Observe the following precautions when handling brake linings: 1. Never blow brake lining dust with compressed air. 2. If any components are to be cleaned, wash them with detergent, then immediately discard the cleaning solution and wash your hands. 3. Do not grind any brake lining material unless a ventilation hood is available and properly used . • Unscrew the adjuster at the rear end of the rear brake cable, and pull the cable out of the join t. Do not lose the joint and spring. eRemove the brake panel mounting bo lts and plate, and take off the brake panel assembly and O·ring . • Hold the brake shoes, one in each hand with a clean cloth to protect the linings from grease and dirt. .Pu ll up on the shoes to remove them from the panel. eRe move the spr in gs to separate the two shoes . • Mark the cam and lever so that they can "be aligned the same way during assemb ly. eRemove the brake cam lever and wear indicator. .Pu II the brake cam o ut from the inside. Do not lose the dust seal.
A. Brake Panel Mounting Bolts B. Wheel Cylinder
C. Shoe Ad ju ster
• Remove the bolts and take off the brake shoe adjuster. eRemove the bolts and take off the wheel cylinder .
Front Brake Panel Assembly/Installation • Front brake panel assembly/ instal lation is the reverse of removal/disassembly. Note the following.
Rear Brake Panel Assembly/Installation eRear brake panel assembly/ installation is the reverse of removal. Note the fo ll owing . eLubricate the rear brake panel parts (see Brake Panel Lubrication) . • Install the wear indicator so that it points to the bottom end of the usable range projection. eTighten the brake panel mounting bolts to the specified torque (see Exploded View). oApp ly grease to the O·ring and fit it onto the end of the axle pipe . OThe projected portion of the plate must be faced in.
10-16 BRAKES
ODo not use a solvent which will leave an oily residue or the shoes will have to be replaced .
Brake Shoe Spring Inspection -Visually inspect the brake shoe springs for breaks or distortion.
*If the springs are damaged in any way, replace them.
A. Projected Portion
eAdjust the rear brake pedal free play (see Rear Brake Pedal Free Play Adjustment).
Brake Camshaft and Camshaft Hole Wear eMeasure the camshaft diameter.
*If any measurement is less than the service limit, replace the camshaft.
Brake Shoe Lining Wear eMeasure the lining thickness. oUse a caliper or scale, and measure at several points as Brake Camshaft Diameter
shown.
Standard : Service Limit :
16.957 -16.984 mm 16.83 mm
eMeasure the inside diameter of the camshaft hole in the brake panel. OUse a small hole gauge in several directions insi?e the hole, and then measure the small hole gauge with a micrometer. *If any measurement is larger than the service limit, replace the brake panel.
Brake Camshaft Hole Inside Diameter
Standard: Service Limit:
17.000 -1 7.027 mm 17.15 mm
Brake Shoe Lining Thickness
Standard: Service Limit:
4.0mm 2.0mm
*If any measurement is less than the service limit, replace both shoes as a set.
*If the lining thickness is greater than the service limit, do the following before install ing the shoes. eFile or sand down any high spots on the surface of the lining. -Use a wire brush to remove any foreign particles from the lining. -Wash off any oil or grease with an oilless solvent.
Brake Panel Lubrication Whenever the brake panel assembly is disassembled, perform the following. eelean all old grease out of the brake panel parts with a cloth. eFor the front brake panel, apply a high-temperature grease to the following. Brake Panel and Brake Shoe Contact Points Wheel Cylinder Piston Ends Brake Shoe Adjuster Ends
BRAKES 10-17
A. App ly grease .
A. Ad justers
-For the rear brake panel, apply a high-temperature grease to the following. Brake Shoe Anchor Spring Ends Camshaft Groove Cam Surfaces
-Remove the brake pedal and lever. o Unhook the return spring. o Remove the cotter pin and nu t, and pull off the brake pedal and lever. Do not lose the O-rings.
B. Equalizer
Brake Pedal and Cables Brake Pedal and Cable Removal -Remove the brake cables. o Unscrew the adjusters at the rear ends of the cables, and pull the cable out of the joints and cable mounts. Do not lose the joints and springs . A. Return Spri ng
B. Cotter Pin
eRemove the parking bra ke levers. OUnhook return spring.
ORemove the clamp bolt and pull off the upper and lower levers. Do not lose the O·rings and caps.
A. Adjuster B. Joint
C. Spring
Oloosen the mounting nuts, pull the front adjusters of the cables off the mounts, and free the front ends of the cables from the equalizer .
A. Upper Lever
B. Lo wer Lever
10-18 BRAKES Brake Pedal and Cable Installation -Brake pedal and cable installation is the reverse of removal. Note the following. -Lubricate the brake pedal, cables, and/or parking brake lever (see Brake Pedal and Cable Lubrication). -Install the brake pedal so that the punch mark on the pedal is aligned with the mark on the shaft of the lever. elnstall
the upper and lower parking brake levers
aligning the punch marks on both levers.
Brake Pedal and Cable Lubrication eelean all old grease out of the brake parts with a cloth. -Apply a multi-purpose grease to the following: Brake Pedal Pivot Shaft Parking Brake Lower Lever Shaft
A. Align marks.
-Route the rear brake vent hoses as shown .
A. Apply grease
B. O-rings
-Clean any excess grease from the parts before assemb ly. -Lubricate the brake cable by seep ing the oil between the cable and cab le housing. Cable Lubrication
A. Rear Brake Vent Hose
B. Brake Cables
-Adjust the rear brake pedal free play (see Rear Brake Pedal Free Play Adjustment) .
Brake Cable Inspection -With the brake cable disconnected at the both ends, the cable should move freely within the cable housing. *If cable movement is not free after lubricating (see Brake Pedal and Cable Lubrication), if the cable is frayed, or if the cable housing is kinked, replace the cable.
-Oil the follow ing lightly: Brake adjusters
SUSPENSION 11-1
Suspension Table of Contents
Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . .
11 ·2
Suspension .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-3
Shock Absorber Spring Force Adjustment.. . .. .. .. . . . .. ... . .
11·3
Shock Absorber Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-3
Shock Absorber Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11·3
Suspension Arm Removal. . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . .
11·3
Suspension Arm Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-4
Suspension Arm Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11 ·4
Shock Absorber and Suspension Arm Inspection . . . . . • . . . . . . . .
11-4
m
"-2
SUSPENSION
Exploded View
G
T1
~~
ff
G : Apply grease. ~~ ~~ @:l Tl : 34 N-m (3.5 kg-m, 25 ft-Ib) T2: 88 N-m (9.0 kg·m, 65 ft-Ib)
SUSPENSION 11-3 e<:heck to see that a pair of adjusting sleeves (front two
Suspension
adjusting sleeves or rear two) are turned to the same relative position.
Shock Absorber Spring Force Adjustment The spr in g adjusting sleeve on each shock absorber has 5 positions so that the spring can be adjusted for different terrain and loading conditions. If the spring action feels too soft or too stiff, adjust it
in accordance with the following table.
WARNING. Olf a pair of adjusting sleeves (front two adjusting sleeves or rear MO) are not adjusted equally, handling may be
impaired and a hazardous condition may result.
Spring Action
Position
1 2 (sTD)
3 4 5
Spring Force
Stronger
Setting Soft
Load Light
Terrain Good
Speed Low
11111 Hard
Heavy
Bad
High
Shock Absorber Removal esupport the veh icle on a stand so that the front and/or rear wheels are off the ground. -Remove the upper and lower shock absorber mounting bolts and/or nuts. eHolding the wheels, pull out the mounting bolts and then shock absorbers. o Remove the rear wheels (see Wheel Removal in the Wheels/Tires chapter) to remove the lower mounting bolts of the rear shock absorbers easy.
A. Adjusting Sleeve A. Shock Absorber Mounting Bolts eTurn the adjusting sleeve on each Sh.DCk absorber to the
des ired position with a hook spanner.
Shock Absorber Installation -Shock absorber instal lation is the reverse of removal. Note the following. -Tighten the upper and lower shock absorber mounting bolts to the specified torque (see Exploded View) .
Suspension Arm Removal
A. Adjusting Sleeve
B. Hook Spanner
eRemove the front and/or rear wheels (see Wheel Removal in the Wheels/ Tires chapter). -To remove the front suspension arms, first remove the following parts. Brake Drums and Panel Assembl ies Steering Knuckles Shock Absorber Lower Mounting Bolts Brake Hose Clamps from Upper Arms
114 SUSPENSION eTa remove the rear suspens ion arms, first remove the
final gear case guard. eRemove the suspension arm pivot bolts and take the suspension arms off the frame.
Suspension Arm Installation eSuspension arm installation is the reverse of removal. Note the following. eLub ricate the suspension arm pivots of the front upper
and center arms (see Suspension Arm Lubrication ). _Tighten the suspension arm pivot bolts and shock absprber lower mounting bolts to the specified torque (see Exploded View).
Suspension Arm Lubrication eLubricate the suspension arm pivots of the front upper
and center suspension arms. oRemove the front suspension arms. oWipe all the o ld grease out of the sleeves, bushings, and
grease seals. oA pply fresh grease to the sleeves and grease seal lips. A. Upper Arm
C. Center Arms
B. Lower Arm
Shock Absorber and Suspension Arm Inspection eV isuall y inspect the rubber bushings in the upper and lower mountings of the shock absorbers, and the ends of the rear and front lower suspension arms. *If they are worn, cracked, hardened, or otherwise damage, replace them with new ones.
A. Left Arm
B. Center Arms
A. Right Arm
B. Center Arms
STEERING 12-1
Steering Table of Contents
Ex ploded View. ' .' . . . . • . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12-2
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12-3
Handlebar Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12-3
Handlebar Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12-3
Handlebar G rip Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12-3
Handlebar G rip Installation .. . . .. ... _ .. . . .. _ . . . . . . . . . . . . . .
12-4
Steeri ng Stem Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12-4
Steering Stem Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12-4
Steering Knuckle and Ti e·rod Removal . . . . . . . . . . . . . . . . . . . . . .
12-5
Steering Knuckle and Tie·rod Installation . . . . . . . . . . . . . . . . . . . .
12-5
Steering Knuck le Stopper Adjustment . . . . . . . . . . . . . . . . . . . . . .
12-6
Steering Inspection. .. .. .. . . . . . . . .. . .. .. . .. . .. . . .. . . . .. .
12-6
Steering Stem Warp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12·6
Steering Stem Bearing, Tie·rod Bearing, and Steering Knuckle Upper and Lower Joint Inspection . . . . . . . . .
12-6
Steeri ng Lu brication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12-7
12-2 STEERING E~-~;~~~~'~i'~:"""""""""""""""""" '"
..............
A : Apply adhesive. G : Apply grease. Lh: Left-Hand Threads T1 : 20 N-m (2 T2' 29 N ( '0 k g·m, 14.5 ft-Ib) . -m 30kg·m, 22 ft-Ib) T3:41 N- (' m 42 kg-m, 30 ft-Ib)
STEERING 12-3
Steering Handlebar Removal -Remove the fuel tank (see Fuel Tan k Removal in the Fuel System chapte r). -Remove the fol lowing parts from
the handlebar.
LH Switch Housing Throttle Case Front Brake Master Cylinder -Remove the stem head cover screws and ignition
switch ring nut, .and take off the cover. A. Parallel
B. Gap
C. No Gap
eTighten the holder rear bolts first and then the front bolts. When the holder is correctly instal!ed, there will be even gap at the front and no gap at t he rear after tighten ing.
Handlebar Grip Removal -Remove the screw and take off the plug.
A. Screws
B. Ring Nut
-Remove the handlebar holder bolts and lift off the handl ebar.
A. Plug
_Slide a thin drift between the grip and the hand lebar.
A. Handlebar Holders
Handlebar Installation eHandlebar installation is the reverse of removal. Note
the following. -I nstall the handlebar so that the angle of the handlebar matches the angle of the steering stem as shown.
A. Drift
12-4 STEERING eApply a small amount of Kawasaki Electric Contact Cleaner or equivalent into the opening next to the drift. ePull the drift out and quickly slide the grip off the handlebar. Twist the grip as you pull.
Handlebar Grip Installation eApply an adhesive which is recommended by the manufacturer for bonding rubb er to metal, to the
inside of the grip. eSlide the grip into position on the handlebar.
A. Clamp Allen Bolts
Steering Stem Removal eRemove the following parts. Front Fender Fuel Tank Handlebar eRemove the following parts from the stem head. Reverse Knob with Cable Headlight with Brackets Ignition Switch
Neutral and Reverse Indicator Light Sockets
A. Tie-rod End Nuts
B. Mounting Bolts
ePull the steering stem out of the frame. eTa remove the steering stem bearing, remove the cotter pin and remove the nut from the bottom end of the steering stem.
A. Headlight B. Ignition Switch
~
C. Reverse Knob
I
D. Neutra l and Reverse Lights
I
I
eRemove the cotter pin and remove the tie-rod end nut from each tie-rod at the steer ing stem.
000 not loose the locknuts at both end of the tie-rod adjusting sleeve, or the toe-in of the front wheels will be changed. eRemove the mounting bolts of the steering stem bearing housing. eRemove the steering stem clamp Allen bolts, and take off the clamps and grease seals.
A. Steering Stem Bearing
Steering Stem Installation -Steering stem installation is the reverse of removal. Note the following.
STEERING 12-5 eLubricate the steering stem clamp and stem bearing (see Steering Lubrication). elnstall the steering stem clamps so that the ribs on both grease seals fit into the grooves on the steering stem clamps. elnstall the grease seal facing the end forward to prevent the entry of dirt. eAlign the marks on the steering stem clamps (The mark made during removal).
aDo not loosen the locknut at both ends of the tie-rod adjusting sleeve. or the toe-in of the front wheels will be changed. eRemove the cotter pins and remove the steering knuckle upper and lower joints nuts. eTap the steering knuckle to remove the knuckle joints.
[~AUTlO~J 000 not loosen the locknut of the steering knuckle stopper bolt, or the bolt will turn and the steering knuckle stopper adjustment may be necessary.
Steering Knuckle and Tie-rod Installation eSteering knuckle and tie-rod installation is the reverse of removal. Note the following. eelean the studs of the steering knuckle upper and lower joints and the tapered holes of the knuckle, or the tapers will not fit snugly.
A. Ribs
B. Grooves
eTighten the stem bottom end nut, stem bearing housing mounting bolts, stem clamp Allen bolts, and tie· rod end nuts to the specified torque (see Exploded View). elnspect the toe-in if necessary (see Toe-in Inspection in the Wheels/Tires chapter).
Steering Knuckle and Tie-rod Removal eRemove the following parts from the steering knuckle. Wheel with Hub Assembly Brake Panel Assembly with Brake Hose eRemove the cotter pin and remove the tie-rod end nut at the steering knuckle. A. Clean. elnstall the suitable nut on the tie·rod end and tap the nut to remove the tie-rod.
A. Steering Knuckle B. Tie-rod End Nut
eThe left and right tie-rods must be installed as shown. The tie-rod painted yellow is for the left tie-rod.
C. Joint Nuts A. Left Tie-rod
B. Yellow Paint Mark
12-6 STEERING
A. Right Tie-rod
A. Steering Knuckle Stopper Bolt
eTighten the steering knuckle upper and lower joint nuts and tie-rod end nuts to the specified torque (see Exploded View)_ elnspect the toe-in if necessary (see Toe-in Inspection in the Wheels/Tires chapter). eAdjust the steering knuckle stopper if necessary (see Steering Knuckle Stopper Adjustment).
eTurn the handlebar left to right, and check the steering action. *If the steering action is not smooth, or if the steering binds or catches before the stop, lubric~te the steering.
B. Locknut
Steering Inspection
NOTE
OThe cables and wires will have some effect on the steering action which must be taken into account.
Steering Knuckle Stopper Adjustment eTurn the handlebar left or right until the edge of the
stem stop bracket touches with the frame bracket. oTurn the handlebar left if the right steering knuckle stopper will be adjusted and turn the handlebar right if the left stopper will be adjusted.
e<:heck the steering action again. *If the steering lubrication does not remedy the problem, inspect the steering stem warp and/or steering
stem clamps, stem bearing and tie-rod bearings. *If you feel looseness, or if the steering is turned with
the rattle, check the tighteness of the bolts and nuts of the steering parts. eTighten loose bolts and nuts to the specified torque (see Exploded View). and check the steering action again. *If the steering action does not change by re-tightening the bolts and nuts, inspect the steering stem clamps,
stem bearing, tie-rod bearings, and steering knuckle upper and lower joints.
oWhen replacing the stem ciamps, replace both ciamps as a set.
Steering Stem Warp eRemove the steering stem. -Check the steering stem for straightness.
OUse a straightedge along the stem. *If the steering stem is bent, replace the steering stem.
A. Stem Stop Bracket
-Loosen the locknut and turn the steering knuckle
stopper bolt so that the head of it touch with the bracket on the lower suspension arm.
eTighten the locknut securely.
Steering Stem Bearing, Tie-rod Bearing, and Steering Knuckle Upper and Lower Joint Inspection elnspect each spherical bearing for roughness, excessive play, or seizure. *If roughness, excessive play, or seizure is found, replace the steering stem bearing, tie-rod, or suspension arm.
STEERING 12-7
Steering Lubrication eLubricate the steering stem clamp. o Remove the steering stem. oWipe all the old grease out of the steering stem, grease seals, and clamps. o ,A_pply grease to the steering stem and pack the grease seal grooves between the lips with grease.
A. Steering Stem B. Grease Seals
C. Clamps
-Lubricate the steering stem bearing.
o Disassemble the steering stem bearing. OWipe all the old grease out of the steering stem and bearing grease seal. oPack the grease seal groove between the lips with
grease.
A. Grease Seals
FRAME 13-1
Frame Table of Contents
Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seat Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seat Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . Front and Rear Fenders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Fender Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Fender Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Fender Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Fender Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Frame Exchange. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Suggested Parts Removal Order . . . . . . . . . . . . . . . . . . . . . . . . . . . . Suggested Parts Installation Order. . . . . . . . . . . . . . . . . . . . . . . . . . Decals ... . . . ...... ..... . ... . .. ..... . . . ... . .. . .. , . . . . . . . . . Decal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Decal Application. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13·2 13·4 13-4 13-4 13·4 13·4 13·5 13-5 13·5 13-6 13-6 13-6 13·6 13·6 13-6
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13-2 FRAME
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FRAME 13-3
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13-4 FRAME Front and Rear Fenders
Seat
Seat Removal
Front Fender Removal
ePull the seat lock lever up.
eRemove the front carrier and guard.
o Remove the front carrier and front guard mounting
bolts, and take off the carrier and guard. The bolts holding the carr ier with the front fender have the flanged collars.
A. Pull.
eLift the rear of the seat, slide it toward the rear
A. Mounting Bolts
sl ightly, and lift it off the vehicle.
eRemove the seat (see Seat Removal). eRemove the fuel tank covers.
ORemove the mounting screws, flanged collars, and nuts,
Seat Installation
and pull off the tail cover.
eSe sure the rubber dampers are in place on the bottom
of the seat. eSl ip the hook on the bottom of the front end of the seat under the brace on the frame.
A. Tail Cover
A.Hook
B. Upper Cover
B. Brace OUnscrew the fuel tank cap, remove the mounting bolts
and flanged collars, and take off the upper cover. eRemove the front fender side covers .
• Push the rear of the seat down so that the seat locks on the bottom of the rear of the seat lock on the catches.
ORemove the mounting screws and nuts, and take off
the sid e covers.
FRAME 13-5
A. Side Cover
A. Mounting Bolts
eRemove the front fender.
oRemove the front fender mounting bolts and flanged collars, four screws and nuts of the mud flaps, and take
off the front fender.
eRemove the seat (see Seat Removal). eRemove the rear fender. oPull off the storage cover. ORemove the rear fender mounting bolts and flanged
collars and take off the rear fender.
A. Mounting Bolts B. Remove these screws (both left and right sides). A. Mounting Bolts eTa remove the mud flaps, take out the screws and nuts.
e To remove the mud flaps, take out the screws and nuts.
Front Fender Installation aFront fender installation is the reverse of removal.
Rear Fender Removal
Rear Fender Installation
eRemove the rear carrier. ORemove the rear carrier mounting bolts and take off
eRear fender installtion is the reverse of removal. Note
the rear carrier. Th e bolts from the lower side of the
eBe sure the rubber plug is in place in the bottom of the storage case.
fender have the flanged collars and dampers.
the following.
13-6 FRAME
Decal Application
Frame Exchange
eelean the surface where the decal is to be applied with acetone or paint thinner.
Suggested Parts Removal Order
I WARNING.
eTo exchange the frame, remove the parts in this order.
Seat Front and Rear Fenders Fuel Tank Muffler and Exhaust Pipe Battery and Case Air Cleaner Front Suspension and Steering Rear Suspension and Rear Axle Engine with Carburetor
Electrical Components
Frame Fittings
OThese fluids are usually highly flammable and harmful if breathed for prolonged periods. Be sure to heed the fluid manufacturer's warnings.
ePeel away the end of the decal backing and stick the exposed part of the decal onto the vehicle. eWhen you are sure the decal is in the right place, peel the rest of the backing off, holding the decal stretched above the surface where it is to be applied. eWorking from the end which was stuck down first, press the rest of the decal against the surface, little by little, w ith a squeegee or sim ilar artist's tool.
Suggested Parts Installation Order eT 0 install the parts on the new frame, reverse the order of removal.
Decals
Decal Removal eHeat the decal gently with a heat gun, heat lamp, or hair drier. eBe very careful not to wrinkle the decal or get air
bubbles under it. elf air bubbles do get under the decal, use the following procedure.
OPrick the bubble with a fine needle or slit it with a modeling knife.
A. Peel slowly. ePeel up the end of the decal and slowl y pull it off, heating the decal as you go. eelean off the adhesive left on the vehicle surface with acetone or paint thinner.
I WARNING. oThese fluids are usually highly flammable and harmful if breathed for prolonged periods. Be sure to heed the fluid manufacturer's warnings.
A. Slit bubble. oUse the squeegee to push the air out of the hole in the bubble, and stick the decal tightly to the surface. -When the entire decal has been applied, go over it several times with the squeegee to burnish it.
ELECTRICAL SYSTEM 14·1
Electrical System Table of Contents Precautions . . . . . . . . . . . . . . . . . . . . . . . . . 14·2 KLF300·A1, A2 Wiring Diagram ... . .. . .... 14·3 Exploded View . . . . . . . ... . . . . . . • . . . . . . 14·4 Specifications .. . . . . . . . . . . . . . . . . . . . ... 14~6 Special Tools .... •... . . . . . . . . . , • •.... 14-6 Battery ..... ... . . . . . . . . . . . . . . , ..... 14·7 Precautions . . . . . . . . . . . . . . . . . . . . .. 14-7 Battery Removal /Insta llation . . . . . . . . . . 14-7 Battery Removal . . . . . . . . . . . .. ... 14-7
Part Removal . . . . . . . . .. .••.... 14-19 Starter Motor Removal ... . . . . . . . . . 14-19
Battery Installation . . . . . . . . . . . . . . . 14-8
Starter Motor Brush Spring Tension . . . . 14-22
Electrolyte . . . . . . . . . . . . . . . . . . . . . . 14·8
Starter Motor Commutator Inspection . . . . . . . . . . 14·22 Starter Motor Armature Inspection .... 14-23
Electrolyte Level Inspection .. _ . .. ... 14-8
Battery Charging . . . . . . . . . . . .•..... 14-8 Battery Condition .. ... . .... . . . . . . 14·8 Battery Initial Charging . . . . . . • . . . . . 14-9 Battery Ordinary Charging ....•. . ... 14-9 Battery Test Charging . . . . . . . . • .... 14-10 Chargi ng System . . . . . . . . . . . . . . . • . . . . . 14-11 Part Removal Alternator Alternator Alternator Alternator
, . . . . . . . . . . . . . . . . . . . . 14·11 Rotor Removal . . . . . . . . .. 14-11 Rotor Installation . .. .. ... . 14-11 Stator Removal . . . . . . . . .. 14·11 Stator Installation ... . .... 14-11
Charging System Checkout . . . . . . . . . . . . 14-11 Charging System Operational Inspection
.... . . ... . 14-11 Stator Coil Resistance . . . . . . . . . ... . 14·12 Rectifier Circuit Inspection . . . . . . . . . 14·12 Regulator Circuit Inspection . .... . . . . 14·12
Ignition System . . . . . . . . . . . . . . . . . . . . . 14-14 Safety Instruction s . . . . . . . . . . . . . . . . . 14·14
Part Removal . . . . . . . . . . . . . . . . . . . . . 14-14 Engine Stop Switch Removal . . . . . . . . 14-14 Engine Stop Switch Installation . . . . . . . 14·14 Ign ition Coil Removal . . . . . . .. .... . 14·14 Ignition Coil Installation . . . . . . . ... . 14·15
Spark Plug Removal . . . . . • . . . .' .... 14-15 Spark Plug Installation .... • ... . .... 14-15 Pickup Coil Removal . . . . . . . . . . . . . . 14-15 Pickup Coil Installation . . . • . . . . . . . . 14-15 Ignition System Checkout . . . . . . . . . . . . 14-15 Ignition Timing Test . . . . . . . . . . . . . . 14·15 Engine Stop Switch Inspection . . . . . . . 14·16
Ignition Coil Inspection . . . . . . . . . . . . 14-16 Spark Plug Cleaning and Inspection .... 14-17 Spark Plug Gap . . . . . . . . . . . . . . . . . 14-17 IC Ignitor Inspection . . . . . . . . . . . . . . 14-17 Pickup Coil Inspection . . . . . . . . . . . . . 14·18 Alternator Rotor Inspection . . . . . . . . . 14·18 Electric Starter System . . . . . . . . . . . . . . . . 14·19
Starter Motor Installation . .... . ... . . 14·19 Starter Motor Disassembly . . . . . . . . .. 14·19
Starter Motor Assembly . . . . . . . . . . . . 14-20 Starter Button Removal ... .. . . . . . . . 14·22 Starter Button Installation .... . .... . 14-22
Starter System Checkout . . . . . . . . . . . . . 14-22 Starter Motor Brush Length . . . . . . . . . 14-22
Brush Assembly Inspection . . . . . . . . . . 14-23 Starter Relay Inspection . . . . . . . . . . . 14-24 Starter Circuit Relay Inspection . . . . . . 14-24 Starter Button Inspection . . . . . . . . . . . 14-25
Lighting System . . . . . . . . . . . . . . . . . . . . . 14-25 Headlight Beam Headlight Beam Vertical Adjustment .... 14-25 Bulb Replacement. . . . . . . . . . . . . . . . . . 14-25 Headlight Bulb Replacement .... . .... 14-25 Taillight Bulb Replacement . .. . . .... 14-26 Neutral and Reverse Indicator
Light Bulb Replacement . . . . . . . . . . . 14-26 Part Removal . . . . . . . . . . . . . . . .. .... 14-26 Light Switch Removal . . . . . . . . • . . . . 14-26 Light Switch Installation . . . . . . ..... 14-27 Neutral and Reverse Switch Removal . . . . . . . . . . . . . . . 14-27 Neutral and Reverse
Switch Installation . . . . . . . . . . . . . 14-27 Lighting System Checkout . . . . . . . . . . . . 14-27 Light Switch Inspection . . . . . . • . . . . . 14-27 Neutral and Reverse Switch Inspection.
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. . . . . . . . 14·27
Ignition Switch . . . . . . . . . . . . . . . .•. .. . 14-28 Ignition Switch Removal . . . . . • . . . . . 14-28 Ignition Switch Installation . . . . . .... 14·28 Ignition Switch Inspection .. .. . . . . . . 14·28
Electrical Wiring . . . . . . .. . . . . . . . . . . . . . 14-28 Wiring Inspection . . . . . ... .. . . ... . 14-28
14-2 ELECTRICAL SYSTEM
Precautions There are a number of important precautions that are musts when servicing electrical systems. Learn and observe all the ru les below. 000 not reverse the battery lead connections. This will burn out the diodes in the electrical parts. OAlways check battery condition before condemning other parts of an electrical system. A fully charged battery is a mu st for conducting accurate electrical system tests. oThe electrical parts should never be struck sharply. as with a hammer, or allowed to fall on a hard surface. Such a shock to the parts can damage them . a Ta prevent damage to electrical parts, do not disconnect the battery leads or any other electrical connections when the ignition switch is on l or th e
engine is funning. o Becau se of the large amount of current, never keep the starter switc h pushed when the starter motor will not turn over, or the current may burn out the starter moto r windings. 0 00 not use a indicator bulb rated for other than voltage or wattage specified in the wiring diagram , as the indicator panel could be warped by excessive heat radiated from the bulb. OTake care not to short the leads that are directly connected to the battery positive (+) terminal to the chassis grou nd. o Troubles may in volve one or in some cases all items. Never replace a defective part without determining what CAUSED t he failure. If the failure was brough on by some other item or items, they too must be repaired or replaced, or the new replacement will soon fail agai n. o Make sure all connectors in the circuit are clean and tight, and exam ine wires for signs of burning, fra ying, etc. Poor wires and bad connections will affect electrical system operation . o El ectrical Connectors Female Connectors
Male Connectors
OColor Codes:
BK
Black Blue Brown Chocolate CH DG Dark green G Green GY Gray LB Light blue LG Light green o Orange Pink P Purple PU Red R White W Yellow Y OMeasure coil and winding resistance when the part is cold (at room temperature). BL BR
ELECTRICAL SYSTEM 14-3
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14-6 ELECTRICAL SYSTEM Specifications
Item Battery: Electrolyte Level Electrolyte Volume Specific Gravity of Electrolyte Charging System: Regulator/rectifier Output Voltage Charging Coil Resistance Ignition System: Arcing Distance Ignition Coil: Primary Winding Resistance Secondary Winding Resistance Type Spark Plug:
Standard Between level lines 1.15 L 1.2S0 @20°C (6S0 F)
----
Battery voltage - 15 V 0.2 -O.S n
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7 mm or more 1.S - 2.S n 10 - 16 kn NGK BSES NGK BRSES 0.7 -O.S mm 390 - 590 n
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Gap Pickup Coil Resistance Electric Starter System: Starter Motor: Brush Length Brush Spring Tension
Special Tools
12.0 -12.5 mm 6S0 - 920 g
Circlip Pliers: 57001·144
Along with common hand tools, the following more specialized tools are required for comp lete electrical system servicing.
Spark Plug Wrench : 57001-110
Service Limit
Flywheel Holder: 57001-308
6mm
--
ELECTRICAL SYSTEM 14-7 Timing light: 57001-1241
Rotor Puller: 57001-1099
NOTE oThe flywheel holder (57001-13131 can be used instead of the flywheel holder (57001-30B). oThe rotor puller (57001-1216) can be used instead of the rotor puller (57001-1099).
Battery Precautions: Coil Tester: 57001-1242
Following a few simple rules will greatly extend the life of the battery. oWhen the level of the electrolyte in the battery is low, add only distilled water to each cell, until the level is at the upper level line marked on the outside of the
battery.
Hand Tester: 57001-983
Ordinary tap water is not a substitute for
distilled water and will shorten the life of the battery. ONever add sulphuric acid solution to the battery. This will make the electrolyte solution too strong and will ruin the battery within a very short time. OAvoid quick-charging the battery. A quick-charge will damage the battery plates. ONever let a good battery stand for more than 30 days without giving it a supplemental charge, and never let a discharged battery stand without charging it. If a battery stands for any length of time, it slowly selfdischarges. Once it is discharged, the plates sUlphate (turn white), and the battery will no longer take a charge. OKeep the battery well-charged during cold weather so that the electrolyte does not freeze and crack open the battery. The more discharged the battery becomes, the more easily it freezes. OAlways keep the battery vent hose free of obstruction, and make sure it does not get pinched, crimped, or melted shut by contact with the hot muffler. If battery gases cannot escape through this hose, they will explode the battery. ODON'T INSTALL THE BATTERY BACKWARDS. The negative side is grounded.
Battery Removal/I nstallation: Battery Removal eRemove the seat (see Seat Removal in the Frame chapter). -Disconnect the battery negative (-) cable.
14-8 ELECTRICAL SYSTEM Battery Charging:
Battery Condition -Before charging, check battery condition by testing the
specific gravity of the electrol yte in each cel l. DDrawa little fluid from the cel l with a hydrometer. DRead the level of the electrolyte on the fioating scale. This is the specific gravity of the electrolyte.
Hydrometer
A. Negative Cable B. Positive Cable
C. Rubber Band
eDisconnect the battery positive (+) cable. eUnhook the rubber band and remove the battery from the battery case. Do not lose the damper under t he battery.
Read here
Battery Installation eBattery installation is the reverse of removal. Note the
following. -Connect the positive (+) cable first and then the negative cable.
eRoute the battery vent hose observing the label for the hose routing.
Electrolyte:
-Look for sediment and white sulfation inside the cells on the bottom of the plates.
Electrolyte Level Inspection eVisually check the electrolyte level in the battery.
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A. Level Lines
*If the level of electrolyte in any cell is below the lower level line on the battery case, add distilled water only to that cell.
eSee the Battery Troubleshooting Guide in Battery Test Charging. *If the specific gravity is below 1.200, the battery needs to be charged.
ELECTRICAL SYSTEM 14-9 NOTE OThe specific gravity of the electrolyte varies with changes in temperature, $0 the specific gravity reading must be corrected for the temperature of the electro· Iyte. oCelsius: Add 0.007 points to reading for each 10°C above 20°C or subtract 0.007 points for each 10°C below 20°C. OFahrenheit: Add 0.004 points to reading for each 10°F
above 68°F or subtract 0.004 points for each 10°F below 68°F.
*If the specific gravity of any of the cells is more than 0.050 away from any other read ing, the battery will probably not accept a charge. It is gene rally best to replace a battery in this condition. *If the specific gravity of all the cells is 1.280 or more the battery is fully charged.
Olf the temperature of the electrolyte rises above 45°C (11SoF) during charging, reduce the charging rate to lower the temperature, and increase charging time proportionately.
-Turn the charger off, then disconnect it from the battery. e<:heck battery vo ltage. Battery voltage should be 1213 V. e<:heck the specific gravity of each cell with a hydrometer (see Battery Cond ition). *If the voltmeter or hydrometer readings are below those specified, additional charging is necessary before the battery can be installed.
Battery Initial Charging Before being placed in service, a new battery should be given an initial charging. e<:ut off the sealed end of the battery vent hose and remove the filler caps. eFili each cell to the upper level line on the battery case with fresh electrolyte at a temperature of 30°C (86°F) or less. Let the battery stand for about 30 minutes before charging. NOTE Olf the electrolyte level drops, add electrolyte to the upper level line before charging.
eLeaving the caps off the celis, connect the battery to a charger, set the charging rate at 1/10 the battery capacity, and charge it for 10 hours. For example J if the battery is rated at 18 Ah, the charging rate would be 1.8 A.
WARNING' OKeep the battery away from sparks and open flames during charging, since the battery gives off an explosive gas mixture of hydrogen and oxygen. When using a battery charger, connect the battery to the charger before turning on the charger. This procedure prevents sparks at the battery terminals which could ignite any battery gases.
[CAUTIO~] 000 not use a high rate battery charger, as it typically employed at automotive service stations, unless the charging rate can be reduced to the level required. Charging the battery at a rate higher than specified may ruin the battery. Charging at a high rate causes excess heat which can warp the plates and cause internal shorting. Higher-than -normal charging rates also cause the plates to shed active material. Deposits will accumulate, and can cause internal shorting.
Battery Ordinary Charging eRemove the battery from the vehicle.
OAlways remove the battery from the vehicle for charging. If the battery is charged while still installed, battery electrolyte may spill and corrode the frame or other parts of the vehicle.
e<:lean off the battery using a baking soda·and·water solution. OMix one heaping tablespoon of baking soda in one cup of water. o Be careful not to get any of the cleaning solution in the battery. oThe terminals mu st be especiall y clean. elf any of the cells are low, fill them to the LOWER level line with distilled water only. The electrolyte will ex pand during charging, and the level will rise. e<:onnect a charger to the battery BEFORE plugging it in or turning it on.
WARNING. OKeep the battery away from sparks and open flames during charging, since the battery gives off an explosive gas mixture of hydrogen and oxygen. When using a battery charger, connect the battery to the charger before turning on the charger. This procedure prevents sparks at the battery terminals which could ignite any battery gases.
-Set the charge rate and time acco rding to the battery condition previously determined (see Battery Condition), using the table .
14-10 ELECTRICAL SYSTEM Battery Charging Rate/Time Table (12V 19Ah) 1.28
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1.24 1.20 1.16 1.12 1.08 1.04 1.00
1.140
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at 3A charge rate
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Hours of Charging Time at Rates Shown
Battery Test Charging 000 not use a high rate battery charger, as is typically
employed at automotive service stations, unless the charging rate can be reduced to the level required. Charging the battery at a rate higher than specified may ru in the battery. Charging at a high rate causes excess heat which can warp the plates and cause internal shorting. Higher-than -normal charging rates also cause the plates to shed active material. Deposits will accumulate, and can cause internal shorting. olf the temperature of the electrolyte rises above 4SOC (11S0F) during charging, reduce the charging rate to lower the temperature, and increase charging time proportionately.
eTurn t he charger off or unplug it, then disconnect it from the battery. e<:heck battery condition (See Battery Condition). *If the battery condition indicates that it is not fully charged, additional charging t ime is necessary.
elf the battery is suspected of being defective, sulfated, or unable to take a charge, consult the table. eTo test charge a battery, perform the ordinary charging procedure and mon itor the battery voltage and other signs as mentioned below. *If the battery voltage sudde nly jumps to over 13 V just after the start of charging, the plates are probably su lfated. A good battery will rise to 12 V immediately and then gradually go up to 12.5 or 13 V in about 30 min. to an hour after the start of charging. *If one cell produces no gas bubbles or has a very low specific gravity, it is probably shorted. *If there does not appear to be enough sediment in a cell to short the plates, but that cell has a very low specific gravity after the battery is fully charged, the trouble may be that there is not enough ac id in that one cell. In this case only, su lfuric acid solution may be added to correct the specific gravity . *If a fully charged battery not in use loses its charge after 2 to 7 days; or if the specific gravity drops mark· edly, the battery is defective. Th e self·disc harge rate of a good battery is only about 1% per day.
Battery Troubleshooting Guide
Plates Sediment Voltage Electrolyte Level Specific Gravity
Good Battery (+) chocolate color H gray none, or small amount above 12 V above plates above 1.200 in all cells; no two cells more than 0.020 different
Suspect Battery white (sulphated); + plates broken or corroded
Action Replace
sediment up to plates, causing short below 12 V
Replace Test charge
below top of plates
Fill and test charge
below 1.100, or difference of more than 0.020 between two cells
Test charge
ELECTRICAL SYSTEM 14-11
............................................................................. Charging System
.............................................................................
Part Removal: Alternator Rotor Removal eRemove the left engine cover (see Left Engine Cover Removal in the Engine Left Side chapter). eHold the alternator rotor from turning with the flywheel holder (special tool)' and remove the rotor bolt. -Thread in the rotor puller (special tool) and turn the rotor puller until the rotor is forced off the end of the cran kshaft.
-Clean the inside of the rotor and the end of the crankshaft thoroughly or the taper will not fit snugly. -Fit the rotor onto the crankshaft so that the woodruff key fits in the groove in the hub of the rotor. eTighten the alternator rotor bolt to the specified to rque (see Exploded View).
Alternator Stator Removal eRemove the left engine cover (see Left Engine Cover Removal in the Engine Left Side chapter). -Remove the pickup coil (see Pickup Coil Removal). eUnscrew the mounting screw and take off the wiring holder. eUnscrew the mountin g screws and pull the stator out the left engine cover.
A. Flywheel Holder: 57001-308 B. Rotor Puller: 57001-1099
!CAUTlO~] Olf the rotor is difficult to remove and a hammer is used to tap the rotor puller. be careful not to strike the rotor itself. Striking the rotor can cause the magnets to lose their magnetism.
A. Alternator Stator Mounting Screws B. Pickup Coil C. Wiring Holder
Alternator Stator Installation
Alternator Rotor Installation eAlternator rotor installation is the reverse of removal. Note the following.
eAlternator stator installation is the reverse of removal.
Charging System Checkout: Charging System Operational Inspection -Check battery condition (see Battery Condition).
NOTE
A. Key
B. Groove
C. Clean.
OAlways check battery condition before condemning other pans of the charging system. The battery must be fully charged in order to conduct accurate charging system tests.
14-12 ELECTRICAL SYSTEM _Warm up the engine to bring the components up to their normal operating temperatures. eMeasure regulator/rectifier output voltage at various engine speeds with the headlight turned on and then turned off. OConnect a voltmeter across the battery terminals. *The readings should show nearly battery yoltage when the engine speed is low, and as the engine speed rises, the readings should also rise. But they must stay within the specified range. *If the output voltage is much higher than the specification, the regulator/rectifier is defective, or the regulator/rectifier leads are loose or open.
Rectifier Circuit Inspection _Remove the regulator/rectifier.
*If the output voltage does not rise as the engine speed increase, then the regulator/rectifier is defective or the alternator output is insufficient for the loads.
RegulatorlRectifier Output Voltage Battery Voltage - 15 V A. Regulator/Rectifier
Stator Coil Resistance -Disconnect the alternator connector. _Measure the stator coil resistance. <:Connect the multimeter between the yellow leads. OSet the meter to x 1 n range, and read the meter.
-Zero the ohmmeter, and connect it to the regulator/ rectifier terminals. _Check the resistance between the terminals following the table. *The resistance should be low in one direction and more than ten times as much in the other direction. If any two leads are low or high in both directions, the rectifier is defective and must be replaced.
NOTE
Stator Coil Resistance
0.2 -0.8
Q
oThe actual meter reading varies with the meter used and the individual rectifier, but, generally speaking the lower reading should be from zero to the one - second of the scale.
Regulator/Rectifier Terminal
B (Battery) Terminal
M (Monitor) Terminal G (Ground) Terminal
*If the meter does not read as specified, replace the alternator stator. *If the coil has normal resistance, but the yoltage inspect showed the alternator to be defective; then the rotor magnets have probably weakened, and the rotor must be replaced.
Al A2 A3 (Alternator) (Alternator) (Alternator)
ELECTRICAL SYSTEM 14-13 Rectifier Circuit Inspection No . 1
A1
2
A2 A3
3 4
5 6
r-2I
Connections Meter (+) to Meter (-) to
r2.1.-
Meter Range
=
B
Regulator Circuit Test-2nd Step
A1 A2 A3
o-
x 10 n
Y2 scale
or
G
x lOa
A1 A2
B
:
r2Q.
Reading
*If the test light turns on, the regulator/ rectifier is defective. Replace it. *If the test light does not turn on, continue the test. eMomentarily app ly 12 V to the voltage monitoring terminal. e<:heck A 1, A2, and A3 terminals respectively.
n
Regu Iator / Recti fi er
A3 A1
G
A2
12
= Test Light
A3
+ Regulator Circuit Inspection eRemove the regulator/ rectifier. ePrepare the test tools shown. Tools for Regulator Circuit Test Test light -+ Bulb rated 12 V and 3 - 6 W Batteries Two 12 V batteries Test wires S auxiliary wires e<:onnect the test light and the 12 V battery to the regulator/ rectifier as shown. e<:heck A 1, A2, and A3 terminals respectively . Regulator Circuit Test-1st Step
Regulator/ Rectifier
12 V Battery
*If the test light turns on, the regulator/rectifier is defective. Replace it. *If the test light does not turn on, continue the test. eMomentarily apply 24 V to the voltage monitoring terminal by add ing a 12 V battery. e<:heck A 1, A2, and A3 term inals respectively.
000 not apply more than 24 V to the regulator/rectifier and do not leave the 24 V applied for more than a few seconds, or the unit will be damaged. Regulator Circuit Test-3rd Step 12 V Battery
,...--,
,...--,
Regu la tor/ Rec tifi er
Test Light 8
+
=Al
12 V Battery
Test Light
ICAUTlO~ I oThe test light limits the current flow through the regulator/rectifier. Do not use an ammeter or multimeter in its place.
+ 12 V Battery
14-14 ELECTRICAL SYSTEM *If the test light did not light when the 24 V was applied
eRemove the switch lever screw and take out the lever.
momentarily to the voltage monitoring terminal, the regulator/rectifier is defective. Replace it.
*1 f the regulator/rectifier passes all of the tests described, it may still be defective. If the charging system still does not work properly after checking all of the components and the battery, test the regulator/ rectifier by replacing it with a known good unit.
Ignition System Safety Instructions:
A. Switch
B. Remove these screws.
I WARNING. OThe ignition system produces extremely high voltage. Do not touch the spark plug, high tension coil. or spark
eRe move the wIring clamp screw and starter button holder screw, and pull the switch free of the case.
plug lead while the engine is running, or you could receive a severe electrical shock.
Engine Stop Switch Installation -Clean any corrosion or dirt off the contacts.
000 not disconnect battery leads or any other electrical connections when the ignition switch is on, or while the engine is running. Doing so could cause Ie ignitor damage.
0 00 not install the battery backwards or the Ie ignitor could be damaged. The negative side is grounded.
Part Removal: Engine Stop Switch Removal The engine stop switch is inside the LH switch housing. The switch and its component parts are not ava ilable separately. However, the switch may be removed for cleaning.
Be very careful not to lose any
parts or the entire LH switch housing will have to be replaced. eTake out the screws that clamp the LH switch housing to the handlebar.
A. Clean. ePush the switch part, down into the case. elnstall the wiring clamp and starter button holder. ePut the switch lever in place and fasten it with a screw and washer.
eAssemble the LH switch housing on the handlebar and tighten the screws securely.
Ignition Coil Removal eRemove the front fender (see front Fender Removal in
the Frame chapter). eRemove the fuel tank (see Fuel Tank Removal in the Fuel System chapter). ePull the spark plug lead off the spark plug. eDisconnect the green/white lead and yellow/red lead from the coil. A. Screws
eTake off the nuts and remove the coil.
ELECTRICAL SYSTEM 14-15
Pickup Coil Removal eRemove the left engine cover (see Left Engine Cover
Removal in the Engine Left Side chapter). -Unscrew the mounting screw and take off the wiring holder. -Unscrew the mounting screws and take off the pickup coil.
A. Ignition Coil
Ignition Coil Installation elgnition coil installation is the reverse of removal. Note
the following. eThe + and - markings next to the primary coil termi-
nals on the ignition coil body indicate the polarity of the terminals. The polarity of the spark plug lead is as shown when the primary leads are connected as indicated in the figure. But both the primary wires
A. Pickup Coil
Pickup Coil Installation ePickup coil installation is the reverse of removal.
can be connected with either terminal on the ignition
coil without changing the engine performance.
Ignition System Checkout: Polarity of Ignition Coil
For any ignition system problems, always check the ignition timing first (if the engine will run).
H
eRemove the ignition timing inspection plug. -Attach a timing light (special tool: PIN 57001-1241) and a tachometer · in the manner prescribed by the manufacturer. eStart the engine and aim the timing light at the timing mark on the alternator rotor. eRun the engine at the speeds specified and note the alignment of the timing marks.
Ignition Timing Test
iI I
~~ o
L____
8 ~- green / white lead --=J~ (i) . Connect Connect
yellow/red lead
Spark Plug Removal _Carefully pull the spark plug cap from the spark plug and unscrew the spark plug. o lf necessary, use the spark plug wrench (special tool:
PI N 57001-110).
Spark Plug Installation _I nstallation is the reverse of removal. Note the following. -Tighten the spark plug to the specified torque (see Exploded View).
A. Timing Inspection Hole B. Slot
C. F Mark D. Advanced Marks
14-16 ELECTRICAL SYSTEM Ignition Timing
Engine speed rlmin (rpm) 2,100 and below 4,200 and above
Slot aligned with: F mark on flywheel Advanced marks on flywheel
-Connect the ignition coil (with the spark plug cap left installed at the end of the spark plug lead) to the tester in the manner prescribed by the manufacturer and measure the arcing distance. Ignition Coil Arcing Distance
*If the ignition timing is incorrect, replace the Ie
7 mm or more
ignitor.
I WARNING' OTo avoid extremely high voltage shocks, do not touch the ignition coil body or leads.
Engine Stop Switch Inspection eDisconnect the connectors from the LH switch housing. eUsing an ohmmeter, check to see that only the can· nections shown in the table have conti nuity (about zero ohms). *If the switch has an open or short, disassemble it and clean it (see Engine Stop Switch Removal). Test it again. If it still does not wo rk, replace the LH switch housing,
Engine Stop Switch Connections
IYI
Y/ R
BR
*If the distance reading is less than the specified value, the ignition coil or spark plug cap is defective. eTo determine which part is defective, measure the arcing distance again with the spark plug cap removed from the ignition coil. *If the arcing distance is subnormal as before, the trouble is with the ignition coil itself. If the arcing distance is now normal, the trouble is with the spark plug cap.
Measuring coi l res istance:
If the arcing tester is not availab le, the coil can be checked for a broken or badly shorted wind ing with an ohmmeter. However, an ohmmeter cannot detect layer
shorts and shorts resulting from insulation breakdown under high vo ltage. eMeasure the primary winding resistance. OC:onnect the mu ltimeter between the co il terminal and the coil core.
Ignition Coil Inspection Measuring arcing distance: -Measure the arcing distance with a Kawasaki coil tester (special tool: PN 57001-1242) to check the condition of the ignition coil.
OSet the meter to the x 1 n range, and read the meter. eMeasure the. secondary wind ing resistance. o Pull the spark plug cap off the lead. CConnect the multi meter between the spark plug lead and the coil core. aSet the meter to the x 1 kn range, and read the meter.
NOTE
OSince a tester other than the Kawasaki coil tester may produce a different arcing distance, the Kawasaki coil
tester is recommended for reliable results.
Ignition Coil Winding Resistance
Primary Windings: Secondary Windings:
1.8 - 2.8 n 10 - 16 kn
ELECTRICAL SYSTEM 14-17 Ignition Coil Winding Resistance
Spark Plug Gap
CD
@
o
(:) Q)
0
1. Measure primary winding resistance. 2. Measure secondary winding resistance. 3. Ignition coil
*If the meter does not read as specified, replace the coil. *If the meter reads as specified, the ignition coil windings are probably good. However, if the ignition system still does not perform as it should after all other components have been checked, test replace the coil with one known to be good. -Check the spark plug lead for visible damage. *If the spark plug lead is damaged, replace t he co il.
~~~~~~ 0.7 - 0.8 mm 1. Terminal 2. Insulator 3. Cement
4 . Gasket
5. Center Electrode 6. Side Electrode
IC Ignitor Inspection Spark Plug Cleaning and Inspection -Clean the spark plug, preferably in a sandblasting device, and then clean off any abrasive particles. The plug may also be cleaned using a high flash-point solvent and a wire brush or other suitable tool. If the spark plug electrodes are corroded or damaged, or if the insulator is cracked, replace the plug. Use the standard spark plug or its eq uival ent.
-Set the multimeter to the x 1 kn range and make the measurements shown in the table. *If the meter readings do not correspond to the table, replace the IC ignitor.
NOTE OSince a tester other than the hand tester of Kawasaki may show different readings, the hand tester of Kawasaki is recommended for reliable results.
Spark Plug Gap -Measure the gap with a wire-type thickness gauge. If the gap is incorrect, carefull y bend the outer electrode with a suitable tool to obtain the correct gap.
Spark Plug Gap 0.7 -O.Bmm
A. IC Ignitor
14-18 ELECTRICAL SYSTEM Internal Resistance of Ie Ignitor'"
Tester (+) Lead
"0
"'"
...J
1
Battery
Ig. Coil
Ground
PC (+)
PC (-)
A
E
A
Ig. Coil
----------
C
Ground
A
--------
PC (+)
B
Battery
=kn
~
*
PC (-)
=kn
=kn on
B
-------
E
D
------
B
on
D
~
s f"
=kn
A
B
E
-------
A
B C D E
Value 1.8 - 2.6 kn 200 - 1 ,000 kn 3-4.2kn 2.3 - 3.2 kQ 80 - 150 kQ
Measured with hand tester 57001-983. A tester other than the hand tester of Kawasaki may show slightly different readings.
Ie Ignitor Terminals
Pickup Coil Resistance 390 -590 Q *If the meter does not read as specified, replace the
pickup coil. Battery ---H-l
II+I--Ig. Coil I-U---Ground
PC (+) ---!H--l
I-U--PC (-)
Alternator Rotor Inspection _Check the timing projection for damage such as chipping or grooving.
Pickup Coil Inspection eMeasure the pickup coil resistance.
OConnect the multi meter between the black lead and the blue lead. OSet the meter to the x 10
n range, and read the meter.
A. Tim ing Projection
*If the timing projection on the rotor is visib ly damaged, replace the alternator rotor.
ELECTRICAL SYSTEM 14-19 elf the O-ring shows any damage or if it is hardened, replace it with a new one . • Push the starter motor into the case, guiding the sprocket onto the shaft at the same time.
Electric Starter System Part Removal: Starter Motor Removal eRe move the left engine cover (see Left Engine Cover Removal in the Engine Left Side chapter). -Remove the starter motor cable. oSlide back the rubber cover. oTake off the nut and washers, and pull off the cable. eRemove the starter motor retaining bolts.
A. Starter Motor Sprocket
B. Engine Side
NOTE o The protruding side of the sprocket must face in.
A. Bolts
B. Starter Motor Cable
eGentl y pry the starter motor out of the engine case,
[CAUTION!
Starter Motor Disassembly eRemove the starter motor (see Starter Motor Removal). eTake out the long screws with lock washers.
000 not tap the end of the starter motor shaft or the motor may be damaged.
Starter Motor Installation -Starter motor installation is the reverse of removal. Note the following. _Clean the starter motor mounting lugs and the crank· case where the lugs touch it, for good electrical contact.
A. Right End Cover
A. Crankcase Surface
B.O·ring
B. Left End Cover
elf only the brushes are to be removed, pull off only the right end cover. -Grasp the brush springs with needle nose pliers, and pull them off the brush plate. eRaise the brush plate to allow the brushes to clear the end of the commutator.
14-20 ELECTRICAL SYSTEM .Push on the armature to remove the left end bearing
plate. Be careful not to drop the thrust washers. eln order to lubricate the gear set bearing, remove the
circlip with the circlip pliers (special tool) .
A. Brush Plate
B. Springs
-Slip the brushes out of the brush holders on the brush plate. -Free the brush plate by working the brush leads out of the slots in the plate. eTa remove the positive brushes, first take off the
A. Circlip Pliers.: 57001-144
teminal nut with its steel and fiber washer ..
Starter Motor Assemblv -Starter motor assembly is the reverse of removal. Note
the following. elf the gear set was removed, grease the shaft, gears, and
bearing plate.
A. Terminal Bolt -Push the terminal bolt out toward the inside. -Pull the brush leads to remove the brush assembly. -To remove th e gear set, pull the left end cover off. Be careful not to drop the gears.
A. Grease .
• Put the thrust washers onto the armature shaft.
-Put the bearing plate into the yoke so that the bearing protrudes toward the armature and the notch aligns
A. Left End Cover
B. Bearing Plate
with the key in the yoke . .
ELECTRICAL SYSTEM 14-21 elnstall the brush springs. OPut the spring down over the post on the brush plate so that it is wou ld clockwise. OTwist the "curl" end of the spring clockwise and slip it
into the slot in the brush holder. OPush the spri ng down onto the post until it seats against the step.
A. Notch B. Key
C. Thrust Washers D.O·ring
eBe sure the large O-ring is in place, and push the left end cover into the starter yoke so that the notch on the
'nternal gear aligns with the key in the yoke. ePush the negative brushes into the holders immediate ly clockwise from where the brush leads are mounted to the brush plate.
A. Step -Drop the thrust washers over the end of the armature
shaft. el nstall the right end cover so that the long vertical tab
on. the brush plate aligns with the key slot in the cover.
A. Brush Lead Mounting
B. Slots
eHold the brush plate over the end of the starter and push the positive brush leads through the slots in the brush plate. ePush the brush plate into place with the tab in the notch as shown.
A. Tab B. Key Slot
OAs a furt her check, these marks shou ld al ign on the outs ide of the starter.
B. Notc h
C. Thrust Washers
A. Align marks.
14-22 ELECTRICAL SYSTEM eTighten the long screws to the specified torque (see Exploded View).
Starter Button Removal The starter button is inside the LH switch housing. The starter button and its component parts are not available separately. However, the starter button may be removed for cleaning. Be very carefu l not to lose any parts or the entire switch housing will have to be replaced. eRemove the engine stop switch (see Engine Stop Switch Removal). ePull the starter button free of the LH switch housing.
A. Bru sh Length
*ff the
brushes are shorter than the service limit, replace
them.
Starter Motor Brush Spring Tension elf a brush spring tension measuring device is available, the tension shou ld be as specified.
A. Starter Button Contacts
_Spray the starter button contacts with contact cleaner.
A. Brush Spring
Starter Button Installation _Starter button install ation is the reverse of removal.
Starter Motor Brush Spring Tension
680 - 920 9
*If the tension is less than the lower limi t specified, replace the spri ng. *If the brush springs are able to sna p the brushes firmly into place, they ma y be considered serviceable. If they cannot, replace them .
Starter System Checkout: Starter Motor Brush Length eMeasure the overall length of each brush.
Starter Motor Commutator Inspection Starter Motor Brush Length
Standard: Service Limit:
12.0 - 12.5 mm 6mm
-I nspect the surface of the commutator. *If it is grooved dirty, polish it with a piece of very fine sandpaper. *If the grooves are dirty, clean them carefully .
ELECTRICAL SYSTEM 14-23 *If the resistance is less than infinite, shorted. Replace the starter motor.
~he
armature is
Brush Assembly Inspection -Measure the resistance between the two positive brushes. oUse a multimeter set to the x 1
n range.
Starter Motor Armature Inspection eMeasure t he resistance between each segment and all
the others. o Use a muJtimeter set to the x 1
n range.
A. Positive Brushes
A. Segments * If the resistance is too high or even infin ite, the armature winding has an open circuit. Replace the
starter motor. eMeasure the resistance between the commutator and the armature shaft. DUse a multi meter set to the xl kn range.
B. Yoke
*If the resistance is greater than 0 n, replace the positive brush assembly. eMeasure the resistance between the pos it ive brushes and the starter yoke. o Use a multimeter set to the xl kn range. *If the resistance is less than infinite. the positive brush assembly is shorted to ground. Replace the . positive brush assembly. -Measure the resistance between the negative brushes. DUse a multimeter set to the x 1 n range.
A. Negative Brushes
B. Pos itive Brush Ho lders
14-24 ELECTRICAL SYSTEM *If the res istance is greater than 0 Q, rep lace the negative brush assembly. eMeasure the res istance between the pos itive brush holders and the plate. o Use a mu lt im eter set to the x 1 kn range . *If the res istance is less than inf inite, replace the
Starter Circuit Relay Inspection -Remove the starter circuit re lay that is mounted on the rear of the battery case.
negative brush assem bly.
Starter Relay Inspection eRemove the rear fender (see Rear Fender Removal in th e Frame chapter) . e Disconn ect the black lead to th e starter mo to r.
A. Starter Circui t Relay
-Connect an ohmmeter and one 12 V battery to the re lay as show n. *If the relay does not work as specified, the relay is defective.
C. Small Plu g
A. Lead t o St arter Moto r B. Larger Termi na ls
eMeasure the continuity of the relay when activated.
Testing Relay Meter range : Criteria:
oCo nnect a multi me ter across the larger term inals of
t he re lay. OSet the meter to the x 1
n range .
x 1 n range When battery is connected .... 0 When battery is disconnected .... 00
n
n
CCheck that the transmi ssion is in neutral. oTurn on the ignition switch.
OPush the starter button and read the meter. * If the relay does not click or if the meter reads more than 0 n) the relay is defective. Replace it . *If the relay clicks once but the meter does not read 0 fl, the re lay is defective. Rep lace it. * If t he relay does not click at all, proceed with the fo llowing. _Disconnect the small plug in the relay. -Co nnect a mu ltimeter across the pins in the re lay pl ug. -Set the meter to the x 1 n range) and read the meter . * If th e 'meter does not read close to 0 n, the relay is defective. Re place it. * If the met er reads close to 0 fl, t he re lay may be good. Check the vo ltage to the relay fro m the starter bu tt on . -Connect a mu ltimeter across the brown and black leads in the co nnector from the main harness. -Set t he meter to the 25 V DC range. - Turn on the ignit ion switch, push the starter button , and read the meter. *If the meter reads battery voltage, the circ ui t is good. If the re lay would not click in t he previous tests, it is defective. Replace it. *If the meter reads much less than battery voltage or no voltage at all, the circuit is bad. Check the following. Starter Button Starter Circuit Re lay Wiring
Testing Relay
®
®
Q)
CD
Ohmmeter
Q Relay
@)<%I
tID
CD
+ 1 2 V Battery
CD
and <%I
Q) and @)
Relay Coi l Termi nals Relay Switch Terminals
ELECTRICAL SYSTEM 14-25
Starter Button Inspection eDisconnect the connectors from the LH switch housing. eTurn the engine stop switch to the RUN position. -Using an ohmmeter, c heck to see that the connections
eSlide back the dust cover and remove the bulb holder and bulb from the headlight unit. oTurn the holder counterclockwise and pull it out.
shown in the table continuity (about zero ohms).
*If the starter button has an open or short, disassemble it and clean it (see Starter Button Removal). Test it again. If it stil l does not wo rk, replace the LH switch housing. Starter Button Connections
I~I
VIR
BK
1-
............................................................................. Lighting System
............................................................................. Headlight Beam:
Headlight Beam Vertical Adjustment eLoosen the headlight mounting knobs and move the headlight up or down to adjust the headlight vertically.
eSe sure the socket is clean . elnsert the new bulb by aligning the tangs with the catches in the headlight unit. .Push the holder in, turn it clockwise, and release it. It should lock in position. eSlide back the dust cover completely as shown in the label behind the unit. The c'TOP" mark on the cover must point up.
A. Headlight Mounting Knobs eTighten the mounting knobs. A. "TOP" Mark
Bulb Replacement:
Headlight Bulb Replacement
elnstall the removed parts in the reverse order of removal noting the following.
eRemove the headlight mounting knobs, and take the headlight unit off the housing. eoisconnect the bulb socket from the headlight unit.
eBe sure the flanged collars are in place in the rubber dampers in the headlight housing. elnstal l the headlight unit so that the "TOP" mark on the lens points up.
A. Knobs
A. "TOP" Mark
B. Headlight Unit
14-26 ELECTRICAL SYSTEM
Taillight Bulb Replacement eRemove the taillight mounting bolts.
Neutral and Reverse Indicator Light Bulb Replacement -Remove the steering stem head cover screws and ignition switch ring nut, and take off the cover . • Push each bulb down, turn it counterclockwise, and pull it out.
A. Mounting Bolts
-Turn the socket counterclockwise and pull it out . • Push the bulb in, turn it counterclockwise, and pull it out.
eBe sure the socket is clean. eAligning the new bulb's pins with t he grooves in the walls of the socket, push the bulb in, turn it clockwise, and release it.
A. Socket
eBe sure the socket is clean . elnsert the new bulb by al igning the pins with the grooves in the walls of the socket. .Push the bulb in, turn it clockwise, and release it. It should lock in position. elnsert the socket by aligning the tangs with the catches in the housing so that the triangular mark points up, and turn it clockwise to lock in position.
A. Pins
B. Grooves
eFit the rubber boot in the place. eReplace the stem head cover and screw on the ignition switch ring nut and cover holding screws.
Part Removal: Light Switch Removal
A. Triangular Mark
The light switch is inside the LH switch hous in g. The switch and its component parts are not available separately. However, the switch may be removed for cleaning. Be very careful not to lose any parts or the entire LH switch housing will have to be replaced.
ELECTRICAL SYSTEM 14-27 eTake out the screws which clamp the LH switch housing to the handlebar.
Neutral and Reverse Switch Removal eRemove the front gear case (see Front Gear Case Removal in the Final Drive chapter). eDisconnect the neutral and reverse switch connector. eRemove the screws an d take off the switch.
A. Screws A. Neutral and Reverse Switch eDisconnect the connector from the LH switch housing, and free the LH switch housing from the frame. eTake out the screws inside the housing, and remove the clamps.
Neutral and Reverse Switch Installation eNeutral and reverse switch installation is the reverse of removal. Note the following. -Clean any corrosion or dirt off the contacts. eApply a non-permanent locking agent to the threads of the switch mounting screws.
Lighting System Checkout: Light Switch Inspection eDisconnect the connector from the LH switch housing. eUsing an ohmmeter, check to see that only the connections shown in the table have contin uity (about zero ohms). *If the switch has an open or shQrt, disassemble it and clean it (see Li ght Switch Removal). Test it again. If it still does not work , rep lace the LH switch housing. A. Screws
B. Switch Contacts
eTake out the switch mount ing screw, and remove the switch. eSpray the swi tch contacts with contact cleaner while snapping the switch on and off. o Reassemble the switch in the reverse order of disassembl y.
Light Switch Installation eLight switch installation is the reverse of removal. Be su re to put a ll the wire clamps in.
Light Switch Connections
I~I
BR
R
Neutral and Reverse Switch Inspection eDisconnect the connector from the neutral and reverse switch. eUsing a ohmmeter, check to see that the connections shown in the table have continuity (about zero ohms). *If the switch wi ll not close, it may be removed for cleaning (see Neutral and Reserve Switch Removal), or the entire switch may be replaced.
14-28 ELECTRICAL SYSTEM Neutral and Reverse Switch Inspection Gear Position
G
Ground
eDisconnect the wire leads.
R
1 st through 5th Neutral
I
Reverse
Ignition Switch Installation elgnition switch installation is the reverse of removal.
Note the followi ng. eRemove the neutral and reverse switch (see Neutral and
eAlign the notches in the bracket and rubber damper
Reverse Switch Removal) . • Push in the pin in the shift drum stopper and then release it. *If it does not spring out, it can be disassembleo'for repair. Disassemble the shift drum stopper and check the contact pin and spring. Replace the damaged part.
with the protrusion on the side of the ignition switch.
Ignition Switch Inspection eDisconnect the ignition switch leads . • Using an ohmmeter, check to see that only the connections shown in the table have continuity (about
zero ohms). *If the switch has an open or short, rep lace it with new one.
Ignition Switch Connections
White
Brown
OFF ON OFF
A. Pin
B. Spring
............................................................................. Electrical Wiring
.............................................................................
I gnition Switch
Wiring Inspection Ignition Switch Removal -Remove the steering stem head cover screws and ignition switch ring nut, and take off the cover.
.Pull the rubber damper off the ignition switch, and drop the switch out the bottom of the bracket.
eVisually inspect the wiring for signs of burning, fraying, . etc. *If any wiring is poor, replace the damaged wiring. -Pu ll eac h connector apart and inspect it for corrosion,
dirt, and damage. *If the connec tor is corroded or dirty, clean it carefully. If it is damaged, replace it. -Check the wiring for continuity.
oU,e the wiring diagram to find t he ends of the lead which is suspected of being a problem. OC:o nnect an ohmmeter between the ends of the lead s. OSet t he meter to the x 1 n range, and read the meter.
*If the meter does not read 0
n,
the lead is defective.
Replace the lead or the wiring loom if necessary.
A. Rubber Damper
B. Bracket
APPENDIX 15-1
Appendix Table of Contents
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .
15-2
General Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15-5
Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . .
15-5
Bolt and Nut Tightening. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15-5
Tightness Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . .
15-5
Unit Conversion Table. . . . . . . . . . . . . . . . . . . . . . . • . . . . . . . . . . . • • . .
15-6
15-2 APPENDIX Troubleshooting Guide NOTE
OThis is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties.
No valve clearance Cylinder, piston worn Piston rings bad (worn, weak, broken, or sticking) Piston ring/land clearance excessive Cylinder head gasket damaged Cylinder head warped Valve spring broken or weak Valve not seati ng properly (valve bent, worn, or carbon accumulation on the seating surface)
Poor Running at low Speed Spark weak
Engine Doesn't Start, Starting Difficulty Starter motor not rotating Neutral switch trouble Starter motor trouble Battery voltage low Relays not contacting or operating
Starter button not contacting Wiring open or shorted
Ignition switch trouble Engine stop switch trouble Fuse blown
Starter motor rotating but engine doesn't turn over Starter motor clutch trouble Engine won't turn over
Valve seizure Rocker arm seizure
Cylinder, piston seizure Crankshaft seizure Connecting rod small end seizure Connecting rod big end seizure Transmission gear or bearing seizure Camshaft seizure Balancer bearing seizure No fuel flow Tank air vent obstructed Fuel tap clogged Fuel line clogged Float valve clogged Engine flooded Fuel level too high Float valve worn or stuck open Starting technique faulty (When flooded, crank with the throttle fully open to allow more air to reach the engi ne.)
Spark plug dirty, broken, or maladjusted Spark plug cap or spark plug lead trouble Spark plug cap shorted or not in good contact Spark plug incorrect IC ignitor trouble Pickup co il trouble Ignition coil trouble Battery voltage low
Fuel/air mixture incorrect Pilot screw and/or idle ad justing screw maladjusted Pilot jet, or air passage clogged Starter plunger stuck open Air cleaner clogged, poorly seated, or missing Fuel level too high or too low Fuel tank air vent obstructed Carburetor holder loose Air cleaner duct loose
Compression low Spark plug loose Cylinder head not sufficiently tightened down No valve clearance Cylinder, piston worn Piston rings bad (worn, weak, broken, or sticking) Piston ring/land clearance excessive Cylinder head gasket damaged Cylinder head warped Valv e spring broken or weak Valve not seating properly (valve bent, worn, or carbon accumulation on the seating surface) Other Vacuum piston doesn't slid e smoothly Engine oil viscosity too high Brake dragging Final gear case oil viscosity too high
No spark; spark weak Spark plug dirty, broken, or maladjusted Spark plug cap or high tension wiring trouble Spark plug cap not in good contact Spark plug incorrect Pickup coi l trouble IC ignito r trouble Ignition coil troub le Battery voltage low Ignition or engine stop switch shorted Wiring shorted or open
Compression low Spark plug loose Cylinder head not sufficiently tighte ned down
Poor Running or No Power at High Speed Firing incorrect Spark plug dirty, broken, or maladjusted Spark plug cap or spark plug lead trouble Spark plug cap shorted or not in good contact Spark plug incorrect Pickup coil trouble IC ignitor trouble Ignition coil t rouble
Fuel/air mixture incorrect Main jet clogged or wrong size Jet needle or needle jet worn
APPENDIX 15-3 Air jet clogged Bleed hole of air bleed pipe or needle jet clogged Fuel level too high or too low Air cleaner clogged, poorly seated, or missing Starter plunger stuck open Water or foreign matter in fue l Carburetor holder loose Air cleaner duct loose Fuel tank air vent obstructed Fuel line clogged Fuel tap clogged
Compression low Spark plug loose Cylinder head not sufficiently tightened down No valve clearance Cylinder, piston worn Piston fing s bad (worn, weak, broken, or sticking) Piston ring/ land clearance excessive Cylinder head gasket damaged Cylinder head warped Valve spring broken or weak Valve not seating properly (valve bent, worn or carbon accumulation on t he seating surface.) Knocking Carbon built up in combustion chamber Fuel poor quality or incorrect Spark plug incorrect IC ignitor trouble Miscellaneous Throttle valve won't fully open Vacuum piston doesn't slide smoothly Brake dragging Clutch slippi ng Overheating Engine oil level too high Engine oil viscosity too high Final gear case oil viscosity too high
Overheating Firing incorrect Spark plug dirty, broken, or maladjusted Spark plug incorrect IC ignitor trouble Fuel/air mixture incorrect Main jet clogged Fuel level too low Carburetor holder loose Air cleaner poorly sealed, or missing Air cleaner duct loose Air cleaner clogged Compression high Carbon built up in combustion chamber Engine load faulty Clutch slipping Engine oil level too high Engine oil viscosity too high Drive train trouble Brake dragging Lubrication inadequate Engine oil leve l too low Engine oil poor quality or incorrect
Clutch Operation Faulty Clutch slipping Friction and/or steel plates worn or warped Clutch housi ng or shoe linings overworn or worn unevenly Clutch spring broken or weak Clutch release maladjusted Clutc h release mechanisrp trouble Clutch hub or housing unevenly worn Clutch not disengaging properly Friction and/or steel plates warped or too rough Clutch spring compression uneven Clutch shoe spring broken or weak Engine oil deteriorated Engine oil viscosity too high Engine oil level too high Clutch housing frozen on crankshaft or drive shaft Clutch release mechanism trouble
Gear Shifting Faulty Doesn't go into gear; shift pedal doesn't return CI~tch not disengaging Shift fork(s) bent or seized Gear(s) stuck on the shaft Sh ift return spring weak or broken Shift mechanism arm spring broken Shift return spring pin loose Shift drum positioning lever bind in g on pivot bolt Shift mechanism arm broken Shift drum damaged Jumps out of gear Shift fork(s) worn Gear groove(s) worn Gear dogs, dog recesses, and /or dog holes worn Shift drum groove(s) worn Shift drum positioning lever spring weak or broken Shift fork guid e pin(s) worn Shift mechanism arm spring weak or broken Drive shaft, output shaft, and / or gear splines worn Overshifts Sh ift drum positioning lever spring weak or broken Shift mechanism arm spring weak or broken
Abnormal Engine Noise Knocking IC ignitor troub le Carbo n built up in combustion chamber Fuel poor quality or incorrect Incorrect spark plug heat range Overheating Piston slap Cylinder/piston clearance excessive Cylinder, piston worn Connecting rod bent Piston pin, piston holes worn Valve noise Valve clearance incorrect Valve spring broken or weak Camshaft bearing worn Other noise Connecting rod small end clearance excessive Connecting rod big end clearance excessive
154 APPENDIX Piston ring(s) worn, broken or stuck Piston seizure damage Cylinder head gasket leaking Exhaust pipe leaking at cylinder head connection Crankshaft runout excessive Engine mount(s) loose Crankshaft bearings worn Primary gear worn or chipped Camshaft chain tensioner trouble Camshaft chain, sprocket, 19uides worn Balancer bearing worn Balancer gear worn or chipped
Abnormal Drive Train Noise Clutch noise Clutch housing and/or hub damaged Transmission noise
Bearings worn Transmission gears worn or chipped Metal chips jammed in gear teeth Engine oil insufficient or too thin Drive train noise Bevel gear bearings worn Propeller shaft bearing worn Front bevel gear cam damper damage Bevel gears worn or chipped Bevel gears maladjusted Insufficient lubricant
Abnormal Frame Noise Shock absorber noise Shock absorber damaged Brake noise Brake linings overworn or worn unevenly Drum worn unevenly or scored Brake spring(s) weak or broken Foreign matter in hub Brake not properly adjusted Other noise Brackets, nuts, bolts, etc. not properly mounted or tightened Exhaust Smokes Excessively White smoke Piston oil ring worn Cylinder worn Valve oil seal damaged Valve guide wo rn Cylinder head gasket damaged Engine oil level too high Black smoke Air cleaner clogged Main jet too large or fallen off Starter plunger stuck open Fuel level too high Brown smoke Main jet too small Fuel level too low Air cleaner duct loose Air cleaner poorly sealed or missing
Handling and/or Stability Unsatisfactory Handlebar hard to turn Steering stem bearing damaged Steering stem lubrication inadequate Steering stem bent Tire air pressure too low Handlebar shakes or excessively vibrates Tire(s) worn Rim(s) warped Rear axle ru nout excessive Wheel bearing(s) worn Handlebar mount(s) loose Steering ste m nut and/or stem clamp bolt(s) loose Handlebar pulls to one side Frame bent Wheel maladjustment Steering stem bent Front or rear tire ai r pressure unbalanced Front or rear shock absorber unbalanced Shock absorption unsatisfactory Too hard: Tire air pressure too high Shock absorber maladjusted Too soft: Shock absorber oi l leak ing Shock absorber spring weak Tire air pressure too low Shock absorber maladjusted
Brake Doesn't Hold Air in the brake lin e Brake fluid leak Brake fluid deteriorated Primary or secondary cup trouble Master or wheel cylinder scratched inside Brake not properly adjusted Linings overworn or worn unevenly Drum worn unevenly or scored Oil, grease on linin g and drum Dirt, water between lining and drum Overheated Battery Discharged Battery faulty (e.g., plates sulphated, shorted th rough sedimentation, electrolyte leve l too low) Battery leads making poor contact Load excessive (e.g., bulb of excessive wattage) Ignition switch trouble Regulator/Rectifier trouble Alternator trouble Wi rin g faulty Battery Overcharged Regulator/ Rectifier trouble Battery trouble
APPENDIX 15-5
General Lubrication
Lubrication eBefore lubricating each part, clean off any rusty spots with rust remover and wipe off any grease, oil, dirt, or
grime. eLubricate the points listed below with indicated lubricant. NOTE
OWhenever the vehicle has been operated under wet or rainy conditions, or especially after using a highpressure spray water, perform the general lubrication.
Cables: Lubricate with Motor Oil
Brake Cable, Throttle Cable Choke Cable
Reverse Cab Ie Differential Shift Cable
Slide Points: Lubricate with Grease
Brake Cable End, Throttle Cable End, Reverse Cable Lower End Differential Shift Cable End,
Brake Lever Brake Pedal Pivot Shaft Throttle Lever Shaft
Bolt and Nut Tightening
Tightness Inspection -Check the tightness of the bolt' and nut, li,ted here. Also, check to see that each cotter pin is in place and in good condition. *If there are loose fasteners, retorque them to the ,pecified torque following the 'pecified tightening sequence. Refer to the appropriate chapter for torque specifications. If torque specifications are not Iisted in the appropriate chapter, see the basic torque table (see Torque and Locking Agent in the General Information chapter). For each fastener, first loosen it by ySturn, then t ighten it. *If cotter pins are damaged, replace them with new ones. 801ts, Nuts, and Fasteners to be checked
Wheels: Front Hub Nuts and Cotter Pin, Rear Axle Nuts and Cotter Pins Wheel Nut,
Brakes: Ma,ter Cy lin der Clamp Allen Bolts Brake Lever Pivot Screw Nut Brake Pedal Nut and Cotter Pin Brake Cable Equalizer Cotter Pins Steeing/Suspension: Handlebar Clamp Bolt, Stem Nut and Cotter Pin Stem Clamp Allen Bolt, Stem Bearing Hou,ing Bolt, Tie·rod End Nut' and Cotter Pins Tie·rod Adjusting Sleeve Locknut, Shock Ab,orber Mounting Bolt, and Nut, Suspension Arm Pivot Bolts and Nuts Steering Knuckle Pivot Nuts and Cotter Pins Engine: Engine Mounting Bolts Engine Mounting Bracket Bolt, Exhau,t Pipe Holder Nuts Muffler Mounting Bolt, Muffler Clamp Bolt Shift Pedal Bolt Others: Footpeg Mounting Bolt, Grab Rail Mounting Bolt, Throttle Ca,e Clamp Screw, Carrier Mounting Bolts
15-6 APPENDIX ..... ........... ..... ......................... .......................... ..... Unit Conversion Table
Units of Length:
Prefixes for Units: Prefix mega kilo eenti milli micro
Symbol M k e m
x x x x x
1,000,000 1,000 0_01 0_001 0_000001
2_205 0_03527
x x
x
x
0 _6214 3.281 0.03937
mile ft in
kg-m ft-Ib in- Ib
Units of Torque:
Units of Mass: kg
x
m mm Power
J1
g
km
N-m N-m N-m
x x x
0.1020 0.7376 8.851
kg-m kg-m kg-m
x x x
9.807 7.233 86.80
N-m ft-Ib in-Ib
0.01020 0.1450 0.7501 98.07 = 14.22 = 1.333
kg/em' psi em Hg
0.6214
mph
=
Ib oz Units of Pressure:
Units of Volume: L L L L L L mL mL mL
gal (US) gal (imp) qt (US) qt (imp) pint (US) pint (imp) oz (US) oz (imp) cu in
0.2642 0.2200 = 1.057 0.8799 2.113 1.816 0.03381 0.02816 0.06102
x x x x x x x x x
kPa kPa kPa
x x x
kg/em ' kg/em ' em Hg
x x x
kPa psi kPa
Units of Speed : km/h
Units of Foree:
x
=
Un its of Power :
N N
x x
0.1020 0.2248
kg Ib
kW kW
x x
1.360 1.341
PS HP
kg kg
x x
9.807 2.205
N Ib
PS PS
x x
0.7355 0.9863
kW HP
Units of Temperature:
9 rC+40) -40= OF 5
OF ·40
-20
I I
·4 :0
:I ,I
·40
-2 0 :
°c
-17 . 8
40= °C
6B
32 20
: 40
60
I
I I
I
0
:
4.4
,
104 60
I I, I
100:
I'
I
120
!I
40
20 26.7
212
176 140
I
60 48.9
160
Ii 71.1
: 180
'I
I
BO
200
I
93.3
100
I
I
I, I
: 120
116
OF
2B 4
240 i, 260
,: 220
I, I :
246
I
280:
I, i; : 140
136
300
I I
320
I 160
°c
Kawasaki
KLF 300 BAYOU 300
All Terrain Vehicle Service Manual Supplement
Quick Reference Guide
General Information Fuel System Engine Top End Engine Left Side Engine Right Side
41 51
~E=n~g=i=n=e=R=e=m==o=v=al=/l=n=s=ta=I=la=t=io=n=======611 ~E=n=g=i=n=e=B=o=tt=o=m=E=n=d=lT=r=a=n=s=m=i=s=s=io=n==7I
~W=h=e=e=ls=lT==ir=es==================81 ~F=in=a=I=D=r=iv=e===================9. Brakes
10.
Suspension .
11.
Steering
12.
Frame
13.
Electrical System
14 •
I Appendix
15 •
Supplement - 1989 - 1997 Models 16 • This quick reference guide will assist you in locating a desired topic or procedure. -Send the pages back to match the black tab of the desired chapter number with the black tab on the edge at each table of contents page. -Refer to the sectional table of contents for the exact pages to locate the specific topic required.
Supplement - 1998 - 1999 Models 17 • Supplement - 2000 - 2002 Models 18 • Supplement - 2003 - 2006 Models 19 •
LIST OF ABBREVIATIONS A
ampere(s)
Ib
pound(s)
ABDC
m
meter(s)
AC
after bottom dead center alternating current
min
minute(s)
ATDC
after top dead center
N
newton(s)
BBDC
before bottom dead center
Pa
pascal (s)
BDC
bottom dead center
BTDC °C
before top dead center
PS psi
horsepower pound(s) per square inch
degree(s) Celsius
revolution
DC
direct current
r rpm
revolution(s) per minute
F
farad(s)
TDC
top dead center
of
degree(s) Fahrenheit
TIR
ft g
foot, feet gram(s)
V
total indicator reading volt(s)
W
h
hour(s)
n
L
liter(s)
watt(s) ohm(s)
US Model only
~~~~~~~~~~~~~~~~~~~~~~~~~$~~ ~
m
PLEASE DO NOT TAMPER WITH NOISE CONTROL SYSTEM
W.
To minimize the noise emissions from this product, Kawasaki has equipped it with effective intake and exhaust silencing systems. They are designed to give optimum performance while maintaining a low noise level. Please do not remove these systems, or alter them in any which results in an increase in noise level. .
~
~
~
~
~ ~
~ ~ .....
~
~
~~~~~~~~~~~~~~~~~~~~~~~~~~~~ This warning may apply to any of the following components or any assembly containing one or
more of these components:Brake Shoes or Pads Clutch Friction Material
Gaskets Insulators WARNING CONTAINS ASBESTOS Breath ing asbestos dust is dangerou s to health Follow safety
instructions
SAFETY INSTRUCTIONS -Operate if possible out of doors or in a well ventilated place. .Preferably use hand tools or low speed tools equipped, if necessary. with an appropriate dust
extraction facility . If high speed tools are used , they should always be so equipped. elf possible, dampen before cutting or drilling. eDam pen dust and place it in properly closed receptacle and dispose of it safely.
Read OWNER'S MANUAL before operating
Foreword This service manual supplement contains only the information unique to the models covered. It must be used with the base service manual listed below. Read both this supplement and the base manual for complete information on proper service procedures for the models covered by this manual. Base Manual
Part Number
KLF300 Service Manual
99924-1057 -02
This manual is designed primarily for use by trained mechanics in a properly equipped shop. However, it contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily. Whenever the owner has insufficient experience or doubts his ability to do the work, all adjustments, maintenance, and repair should be carried out only by qualified mechanics. In order to perform the work efficiently and to avoid costly mistakes, read the text, thoroughly familiarize yourself with the procedures before starting work, and then do the work carefully in a clean area. Whenever special tools or equipment are specified, do not use makeshift tools or equipment. Precision measurements can only be made if the proper instruments are used , and the use of substitute tools may adversely affect safe operation. For the duration of the warranty period, we recommend that all repairs and scheduled maintenance be performed in accordance with this service manual. Any owner maintenance or repair procedure not performed in accordance with this manual may void the warranty. To get the longest life out of your vehicle: • Follow the Periodic Maintenance Chart in the Service Manual. • Be alert for problems and non-scheduled maintenance. • Use proper tools and genuine Kawasaki Vehicle parts. Special tools, gauges, and testers that are necessary when servicing Kawasaki vehicles are introduced by the Service Manual. Genuine parts provided as spare parts are listed in the Parts Catalog. • Follow the procedures in this manual carefully. Don't take shortcuts.
• Remember to keep complete records of maintenance and repair with dates and any new parts installed.
How to Use This Manual In this manual , the product is divided into its major systems and these systems make up the manual's chapters. The Quick Reference Guide shows you all of the product's system and assists in locating their chapters. Each chapter in turn has its own comprehensive Table of Contents. For example, if you want ignition coil information, use the Quick Reference Guide to locate the Electrical System chapter. Then, use the Table of Contents on the first page of the chapter to find the Ignition Coil section. Whenever you see these WARNING and CAUTION symbols, heed their instructions! Always follow safe operating and maintenance practices.
A WARNING This warning symbol identifies special instructions or procedures which, if not correctly followed, could result in personal injury, or loss of life. CAUTION This caution symbol identifies special instructions or procedures which, if not strictly observed, could result in damage to or destruction of equipment. This manual contains four more symbols (in addition to WARNING and CAUTION) which will help you distinguish different types of information. NOTE
o This
note symbol indicates points of particular interest for more efficient and convenient operation.
• Indicates a procedural step or work to be done. Olnd icates a procedural sub-step or how to do the work of the procedural step it follows. It also precedes the text of a NOTE.
* Indicates a conditional step or what action to take based on the results of the test or inspection in the procedural step or sub-step it follows. In most chapters an exploded view illustration
of the system components follows the Table of Contents. In these illustrations you will find the instructions indicating which parts require specified tightening torque, oil, grease or a locking agent during assembly.
GENERAL INFORMATION 1-1
General Information Table of Contents •
Before Servicihg ....... . . .. . . . .... . . ....... .. . ... .. ... . .... . Model Identification . .. .. . . .. . . .. .. ....... .. . . ... ...... .. . . . General Specifications .. ... . . .... .... . . . . .... . . ... .. . . ...... . Periodic Maintenance Chart ...... .. . .. . . .... . . .. .. . .. . . ..... . . Torque and Locking Agent .. . . . . . ... .. .... . . ... .. .... . . ..... .
1-7
Wiring, Cable, or Hose Routing . ... .. . . .. .... ..... ..... . . . . ... .
1-10
* : Base Manual
1-2
1-4 1-6
'-2
GENERAL INFORMATION
•• ••••••••• • ••••••••••••••••••••• ••••• • ••••• • •• ••••• ••••• •••••••••••••••••• ,0
Model Identification
............................................................................. KLF300-Bl (US model)
GENERAL INFORMATION 1-3 KLF300-Bl (Australia model!
14 GENERAL INFORMATION General Specifications
®:
®:
Australia model
UK model
@: US model
@: Canada model Item
KLF300-Bl
Dimensions: Overall length Overall width Overall height Wheelbase G rou nd clearance Seat height Dry weight Curb weight: Front Rear Fuel tank capacity
1910 mm 1115mm, ® 1160mm 1035 mm 1210 mm 195 mm 750 mm 223 kg, ® ® 226 kg lOB kg, ® ® 109.5 kg 125 kg, ® ® 126.5 kg 9 L, ® B.2 L
Performance: Minimum turning radius
2.9 m (Locked axle mode) 2.6 m (Differential mode)
Engine: Type Cooling system Bore and stroke Displacement Compression ratio Maximum horsepower Maximum torque
4-stroke, SOHC, l-cylinder Air cooled 76.0 x 64.0 mm 290 mL B.6 15.4 kW (21 PSI @7000 r/ min (rpm), @ 22.6 N-m (2.3 kg-m, 16.6 ft-Ib) @6000 r/ min (rpm),
@Carburetion system Starting system Ignition system Timing advance Ignition timing Spark plug Valve timing:
Inlet
Exhaust
Lubrication system Engine oil : Grade Viscosity Capacity
(Continued on next page.)
Open Close Duration Open Close Duration
Carburetor, Keihin CV K32 Electric starter & recoil starter Battery and coil (transistorized) Electronically advanced From 10° BTDC @1300 r/min (rpm) to 40° BTDC @4000 r/min (rpm) NGK BBES, ®@ NGK BRBES 27° BTDC 65° ABDC 272° 62° BBDC 30° ATDC 272° Forced lubrication (wet sump) SE, SF or SG class SAE 10W-30, 10W40, lOW-50, 20W-40, or 20W-50 1.7 L
GENERAL INFORMATION 1-5 Item
KLF300-Bl
Drive Train: Primary reduction system: Type Gear Reduction ratio 2.888 (78/27) Primary Clutch type: Auto centrifugal, wet Secondary Auto multi disc, wet Transmission: Type 5-speed plus reverse, constant mesh, return shift 3.090 (34/11) Gear ratio: 1st 1.928 (27/14) 2nd 1.368 (26/19) 3rd 1.000 (23/23) 4th 0.769 (20/26) 5th 3.072 (26/11 x 26/20) Reverse Final drive system : Type Shaft Reduction ratio 4.886 (20/16 x 43/11), ®® 5.584 (20/14 x 43/11) Overall drive ratio 10.858, ®® 12.409 @Topgear Final gear case oil : Type API G L-5 Hypoid gear oil SAE 90 (above 5·C, 41· F) or SAE 80 (below 5·C, 41· F) Capacity 0.3 L Frame: Type Caster (rake angle) Chamber Trail Tread Front tire: Rear tire : Suspension:
Type Size Type Size Front Rear
Brake type:
Front Rear
Type Wheel travel Type Wheel travel
Front Rear
Electrical Equipment: Battery Headlight: Type Bulb Taillight Alternator: Type Rated output Voltage regu lator: Type
Double tubular 3.0· 1.0·@1G 13 mm 834mm 844mm Tubeless 22 x 9.00-10 Tubeless 24 x 11.00-10 Double wishbone-link 125 mm Torque tube-link 120mm Disc (Hydraulic) Drum (Mechanical) 12 V 14 Ah Semi-sealed beam 12 V 65/60 W, ® Option 12V8Wx2, ® Three-phase AC 23.5 A @9000 r/min (rpm), 14 V Short-circuit
Specifications are subject to change without notice, and may not apply to every country.
1-6 GENERAL INFORMATION Periodic Maintenance Chart The scheduled ·maintenan~e must be done in accordance with this chart to keep the vehicle in good running condition. The first service is vitally important and must not be neglected.
First Service • = Clean, adjust, lubricate, tighten, or
replace parts as necessary .
Regular Service
AM':% .~.~~ :~
of use
'"
l?
Engine: Air cleaner--service* Clutch adjustment* Valve clearance--check Fuel system cleanliness--check * Engine oil--change* Oil filter--replace* Spark plug-clean and gap Spark arrester--clean Chassis: Rear brake adjustment--check* Rear brake lining wear--check* Front brake pad wear--check * Brake fluid level--check Brake fluid--change Cable adjustment* Battery--check Steering play--check General lubrication* Bolts and nuts--tighten Final gear case oil--change* Master cylinder piston assembly and dust seal--replace Caliper piston seal and dust seal--replace Brake hose--replace
•
•
• • • • • •
• • • • • • •
~
i:-""" «! ~'"
C\;)
4'
05
~
i:-""" i:-""" «! ~'" 0'" ~'" l?
l?
~
i:-
«!()-J'
• •
• • •
• •
• •
•
•
• • • •
•
• • •
See Page
2-7 5-3 3-6 (2-10) (5-11 ) (5-11) (14-17) 3-11 (10-6) (10-6) 10-7 (10-8) (10-8) ** 14-6 ( 12-6) 15-4 15-4 (9-6)
2 years (10-11) 2 years 2 years
* : Service more frequently when operated in mud , dust, or other harsh rid ing conditions. ** : Refer to 2, 7,9, and 10 chapters. (xx-xx) : Reference Page in the Base Manual
10-6 10-9
GENERAL INFORMATION 1-7
Torque and Locking Agent The following tables list the tightening torque for the major fasteners requiring use of non-permanent locking agent or liquid gasket. Letters used in the "Remarks" column mean: L : Apply non-permanent locking agent to the threads. 0: Apply oil to the threads and seated surface. S : Tighten the fasteners following the specified sequence. St: Stake the fasteners to prevent loosening. ®: UK model
Parts Fuel System: Throttle lever bolt Fuel tap plate mounting screws Engine Top End: Spark plug Cylinder head bolts:¢8 (used bolts) ¢8 (new bolts) Cylinder head bolts: ¢6 Cylinder bolts Valve adjusting screw locknuts Camshaft sprocket bolt Camshaft chain guide pivot bolt Engine Left Side: Alternator rotor bolt Starter clutch Allen bolts Recoil starter flange nut Engine Right Side: Oil drain plug Primary clutch hub nut Secondary clutch hub nut Secondary clutch spring bolts: (used bolts) (new bolts) Oil pipe banjo bolts Engine Removal/I nstallation: 8mm Engine mounting bolts: 10 mm Engine mounting bracket bolts
N-m
Torque kg-m
6.9 0.8
0.7 0.08
61 in-Ib 7 in-Ib
27 29 34 12 12 12 41 9.8
2.8 3 .0 3 .5 1.2 1.2 1.2 4.2 1.0
20 22 25 104 in-Ib 104 in-Ib 104 in-Ib
59 49 8 .3
6.0 5.0 0 .85
43 36 74 in-Ib
29 125
3.0 13.0
22 94
78 12 15 20
8.0 1.2 1.5 2.0
58 104 in-Ib 11.0 14.5
25 34 25
2.5 3.5 2 .5
18.0 25 18.0
ft-Ib
Remarks
S S S S
30 87 in-Ib
L
0 0
S
H! GENERAL INFORMATION Parts
N-m
Engine Bottom End/Transmission: Oil drain plug Oil pipe banjo bolts Neutral switch mounting screw Shift drum stopper bolt Shift drum pin plate bolt Shift shaft return sprin9 pin Clutch release cam pin Oil pressure relief valve Balancer gear nut Balancer drive gear and oill pump drive gear nut
29 20
Torque kg-m 3.0 2.0
ft-Ib 22 14.5
-
-
-
12 12 17 17 15 120 145
1.2 1.2 1.7 1.7 1.5 12.0 15.0
104 in-Ib 104 in-Ib
34 34 145 27
3.5 3.5 15.0 2.8
25
2.5
12 98
1.2 10.0
93 7B 25
9.5 B.O 2.5
20 25 25 7B 29
2.0 2.5 2.5 B.O 3.0
25 29 20 6.9
2.5 3.0 2.0 0.70
Disc mounting bolts
7.B 25 25 37
O.B 2.5 2.5 3.8
Brake lever pivot bolt
5.9
0.6
8rake lever pivot bolt locknut Front master cylinder clamp bolts Front brake fluid reservoir cap screws
5.9 B.8
0.6
Wheels/Tires: Wheel nuts Front hub nuts Rear axle nuts Toe-in locknuts Final Drive: 8mm Front gear case bolts: Output shaft LH bearing housing bolts LH bearing holder
Drive gear nut:
16mm
Driven gear nut Driven gear shaft oil seal housing nuts Front gear case plug (Speedometer gear holder: ' Option for other than Propeller shaft housing nuts
®
.® )
Axle shaft pipe bolts Pin ion gear nut Ring gear and differential gear housing bolts Final gear case cover bolts Final gear case filler cap Final gear case drain plug Differential shift fork holder screws Brakes: Bleed valves Brake hose banjo bolts Caliper mounting bolts
1.0
0.9 0.1
Remarks
L
12.0 12.0
L L
11.0
L
87 110
a a
25 25 110 20 18.0 104 in-Ib
72 69 58 18.0
St
a a
14.5 18.0 18.0 58 22 18.0 22 14.5 61 in·lb 69 in-Ib 18 18 27 52 in·lb 52 in-Ib 78 in-Ib 9 in-Ib
0, St L
GENERAL INFORMATION 1-9
Parts Rear drum drain bolts Brake panel mounting bolts Rear brake pedal mounting bolt Rear axle nuts Suspensions: Shock absorber mounting bolts Suspension arm pivot bolts : 12 mm Rear suspension arm (rod): 10 mm Steering: Handlebar clamp bolts Stem clamp Allen bolts Stem bottom end nut Stem bearing housing bolts Tie-rod end nuts Tie-rod adjusting sleeve locknuts Knuckle joint nuts Electrical System: Spark plug Alternator rotor bolt Neut ral and reverse indicator switch mounting screws Starter circu it relay term inal nuts Taillight assembly mounting screws
N-m
Torque kg-m
ft-Ib
29 29 29 145
3.0 3.0 3.0 15.0
22 22 22 110
34 88 34
3 .5 9.0 3.5
25 65 25
20 25 29 20 41 27 41
2.0 2 .5 3.0 2.0 4.2 2.8 4.2
14.5 18.0 22 14.5 30 20 30
27 59
2.8 6.0
20 43
-
0.45 0.8
-
4.4 7.8
Remarks
L
L
L
39 in-Ib 69 in-Ib
The table below, relating tightening torque to thread diameter, lists the basic torque for the bolts and nuts. Use th is table for only the bolts and nuts which do not require a specific torque val ue. All of the varues are for use with dry solvent-cleaned threads. General Fasteners: Torque
Threads dia . (mm) N-m
kg-m
ft· lb
5
3.4 - 4.9
0.35 - 0.50
30 - 43 in-Ib
6
5.9 - 7.8
0.60 - 0.80
52 - 69 in-Ib
8
14 - 19
1.4 - 1.9
10.0 - 13.5
10
25 - 34
2.6 - 3.5
19.0 - 25
12
44 - 61
4.5 - 6.2
33 -45
14
73 - 98
7.4-10.0
54-72
16
115 - 155
11 .5 - 16.0
83 - 115
18
165 - 225
17.0 - 23.0
125 - 165
20
225 - 325
23 -33
165 - 240
1-10 GENERAL INFORMATION Wiring, Cable, or Hose Routing ViewQ
View Q (other than UK model)
5
L~.
/
Cooling Fan Installation (UK model)
ViewP
To Fan Switch (BL, BR)
Clamp
10
Strap
~ Front Strap
ViewR
18 Fuel Tank Bracket Refer to View W.
@ @
o
Straps
Tube B Tube C
GENERAL INFORMATION 1-11 ViewS
Front
Front
Clamps
@ Fuel Tank Bracket Tube A
Air Cleaner Housing Brackets
1. Viny l Cover
2. Main Harness 3. Accessary Connectors (for Auxiliary Light, R, BK/Y) 4. Cooling Fan Connectors (BR, BK/ Y) from
Main Harness 5. To Neutral and Reverse Indicator Lights (LG, BR, R/W) 6. To Headlight (R/Y, R/BK, BK/Y) 7 . To Ignition Switch (BR, W) 8. To Left-Ha nd Switch 9 . Cooling Fan 10. Fan Motor Vent Hose 11. Cooling Fan Leads (BL, BK/Y) 12. Cooling Fan lOA Fuse (BR) 1 3 . Electric Starter Cable 14. Neutral and Reverse Switch Leads 15. Alternator and Pickup Coil Leads 16. Engine Ground Lead 17. Engine Ground Terminal and Clamp
18. 19. 20. 21. 22 . 23. 24. 25. 26 . 27. 28. 29.
30. 31. 32. 33 . 34. 35.
Neutral and Reverse Switch Connectors Alternator Connector Pickup Coil Connector IC Igniter Connectors Battery Ground Cable Fuse 30A Battery Positive Cable Starter Relay Igniter Starter Circuit RelaY Battery Vent Hose Main Harness Positioning Mark - white tape (Aline with bolt hole position) Ignition Coil Leads Electric Starter Terminal Engine Breather Hose Reverse Cable Regulator/Rectifier Connector Taillight Connectors
1-12 GENERAL INFORMATION ViewU
Strap
ViewT View V
~ ! Front
36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46. 47.
Fuel Tank Vent Hose Brake Hose Choke Cable Throttle Cable Final Gear Case Breather Hose Joint for Carburetor Vent Hose Right Rear Brake Panel Vent Hose Brake Cables Carburetor Vent Hose Differential Shift Lever Case Differential Cable Left Rear Brake Panel Vent Hose
I
GENERAL INFORMATION 1·13 ViewW
the throttle cable to the right side of the steerin g stem.
Strap Tube C
47 47
Clamp
Clamp
o
FUEL SYSTEM 2-1
Fuel System Table of Contents Exploded View .. . . . . . . . . . . • . . . . . ...
2·2
Fuel System Cleanliness Inspection . . . .
Specifications . . . . . . . . . . • . . . . . . . . . ..
24
Carburetor Removal. . . . . . . . . . . . . .
Special Tools . . . . . . . . . . . . . • • • . . . . . .
24
Carburetor Installation . . . .. .•. . ...
Throttle Case and Cable . . . . . ... . . .... .
2·5
Carburetor Disassembly . .. . .. .. .. .
Throttle Lever Free Play Inspection .. .
•
Carburetor Assembly . .. . . . . . .... .
Throttle Cable Adjustment . . ...... .
•
Carburetor Cleaning . . . . . . . . . . . . . .
Throttle Case Removal/Disassembly . . .
• •
Throttle Case Assembly/Installation . . .
•
Carburetor Inspection . . . . . . . . . . . .
• • • • • •
Air Cleaner .. .... .. . . . . . . . . . . . . . . . .
2·7
Air Cleaner Element Cleaning . . . . . . .
2·7
Throttle Cable Installation .. ...... .
• •
Throttle Case and Cable Lubrication .. .
2-5
Water Inspection .. . . . . . . . . . . . .
2·8
Throttle Case Inspection . .. . . . .... .
•
Fuel Tank ..... . . . . . . . . . . . . . . . . . . .
2-9
Throttle Cable Inspection . . . . . . . .. .
•
Fuel Tank Removal . . . . . . . . . . • . ..
2-9
2-5
Fuel Tank Installation Notes . .. . . .. .
2-10
Choke Lever and Cable Removal . ... .
2·5
Fuel Tap Removal . . . . . . . . . . . • . ..
Choke Lever and Cable Installation . . . .
2·6
Fuel Tank Inspection . .. .... ... .. .
Choke Lever and Cable Lubrication .. .
2-6
Fuel Tank and Tap Cleaning ....•...
• • •
Choke Cable Inspection . . . . . . . . . . .
2-6
Fuel Tap Inspection .. . . . . . . . . . . . .
•
Carburetor .. . . . . . . . . . . . . . . . . . .. .. .
2-6
Fuel Level Gauge Removal . . . . . . . . .
2-10
Carburetor Pilot Screw Adjustment . .. .
2-6
Fuel Level Gauge Installation Notes .. .
2-10
Idle Speed Adjustment . . . . . . . . . . . .
2·7
Fuel Level Gauge Check .. .. . . . . . . .
2-11
Fuel Levell nspection ... . . . . . . . . . .
•
Fuel Tank Damper Installation .. . . . . .
2·11
Fuel Level Adjustment . ... . . . . . . . .
•
Throttle Cable Removal . . . . . . . . . . .
Air Cleaner Housing Dust and/or
I
Choke Lever and Cable . . . . . . . . . . . . .
•
Base Manual
2-2 FUEL SYSTEM ~~~;~~~~ ·V;~~·· " ·"··· " · · "··· ··· " · · "· " · · " ···"· · ··"·" "··
o
@) ~
_ _LI _ _
®~
2
~
.
~
~ .
~
~I
~)' >. .
~~l
1. 2. 3. 4. 5. 6. 7. A G
T1: 6.9 N·m (0.70 kg-m, 61 in-Ibl T2: 0.8 N·m (0.08 kg-m, 7 in-Ibl
L_ D -
.
~=======
-
I'
Choke Lever Throttle Cable Choke Cable Throttle Case Starter Jet Pilot Jet Main Jet : Apply adhesive : Apply grease. . o : Apply oil. Oe: Apply cleaner element oil R : Replacement Parts .
G
-
---
'
FUEL SYSTEM 2·3
~
I
I I
~
I
I
~
I
I
~
I
I I
I I
'<::¢
: I
~@Ah: I
I --~
I
,
~
24 FUEL SYSTEM
Specifications Refer to the Base Manual noting the following. Item Carburetor Specifications Make, type: Main jet: Main air jet: Needle jet: Jet needle mark : Pilot jet (slow jet) : Pilot air jet (slow air jet): Pilot screw (turns out): Starter jet : Service fuel level (from carburetor body bottom edge) : Float height: Engine Speed (for reference) Optional Parts Main jet: Pilot jet (slow jet): Starter jet:
Special Tools ORefer to the Base Ma nu al noting the following addi· tio nal too ls. Pilot Screw Adjuster "A": 57001·1239
Standard Keihin, CVK32 #128 # 100 #6 N27Q # 38 # 140 2'/, # 55 0.5 mm below - 1.5 mm above 17 ±2 mm 1300 ±100 r/ min (rpm) # 122,125,130,132 # 35, # 40 # 58, # 60
FUEL SYSTEM 2-5 Throttle Case and Cable
Throttle Case and Cable Lubrication
o Refer to the Base Manual noting the following . • Lubricate the throttle case and cable in accordance with the Periodic Maintenance Chart, or whenever the case and cable are removed (see General Information
chapter and General Lubrication in the Appendix chapter). OUse the pressure cable luber to lubricate the throttle cable.
A. Cable End
B. Starter Plunger
-Unscrew the choke lever mounting screw and take off the plane washer and the wave washer.
Choke Lever and Cable
Choke Lever and Cable Removal
A. Lever Mounting Screw
B. Choke Lever
• Unscrew the starter plunger cap and pull out the starter plunger. • Remove the choke lever and free the choke cable upper
end from the lever. .Pull off the retaining ring and free the choke cable housing from the switch housing.
A. Starter Plunger Cap
A. Retaining Ring -Hold the starter plunger sp ring compressed, and free the choke cable lower end from the plunger.
.Pull the cable out of the vehicle.
2-6 FUEL SYSTEM Choke Lever and Cable Installation -Choke cable installation is the reverse of removal.
Note the following. _ Lubricate the choke cable (see General Lubrication in the Appendix chapter) and grease the wave washer before installation . elnstall the wave washer, plane washer, and screw in that order.
.. ........................................................................... Carburetor Carburetor Pilot Screw Adjustment • Loosen the carburetor holder clamp screws.
A. Clamp Screws (Front and Rear)
1. Screw 2. Plane Washer
3. Wave Washer
-Tilt the carburetor to the right of the vehicle for easy access to the pilot screw.
_Route the choke cable according to the Wiring, Cable, or Hose Routing section in the General Information chapter.
Choke Lever and Cable Lubrication • Lubricate the wave washer and the flat washer of the choke lever, and the choke cable in accordance with the Periodic Maintenance Chart, or whenever the lever and cable are removed (see General Information
chapter and General Lubrication in the Appendix chapter). OUse the pressure cable luber to lubricate the choke cable.
A. Pilot Screw
eTurn the pilot screw in until it seats lightly, and back it out 21/8 turns.
Carburetor Pilot Screw Setting Standard:
Choke Cable Inspection -With the choke cable disconnected at both ends, the cable should move freely in the cable hou sing.
e Reposition the carburetor properly and tighten the clamp screws securely. OF it the carburetor ridge into the groove on the duct.
FUEL SYSTEM 2-7 NOTE
Idle Speed Adjustment eAdjust the pilot screw if necessary (see Carburetor
Pilot Screw Adjustment). -Start the engine and warm it up thoroughly. eTurn the idle adjusting screw to obtain the slowest smooth idle speed.
OWith engine idling, turn the handlebar to each side. If handlebar movement changes idle_speed, the throttle cable may be incorrectly routed, or it may be damaged.
Air Cleaner A clogged air cleaner restricts the engine's air intake, increasing fuel consumption, r~ducing engine power, and causing spark p lug fouling.
I WARNING I OA clogged air cleaner may allow dirt and dust to enter the carburetor and stick the throttle open. This could cause an accident. A. Idle Adjusting Screw
*If the engine idle is still not stable, adjust the pilot screw to obtain the slowest smooth idle speed using the pilot screw adjuster "A" (special tool) .
[~AUTIO~.l o A clogged air cleaner may allow dirt and dust to enter the engine causing excessive wear and possibly engine damage. The air cleaner element must be cleaned periodically (see the Periodic Maintenance Chart in the General Informatio n chapter). In dusty areas, the element should be cleaned more frequently than the recommended interval. After riding through rain or on muddy terrain, the element should be cleaned immediately,
Air Cleaner Element Cleaning • Remove the seat . • Pull up the snaps and remove the air cleaner cover.
A. Pilot Screw Adjuster "A": 57001-1239
WARNING
I
OOperation with an improperly adjusted. incorrect routed, or damaged cable could result in an unsafe riding condition . a Te avoid a serious burn, never touch a hot engine or an exhaust pipe during carburetor adjustment.
_Open and close the throttle a few ti mes to make sure that the idle speed does not change. Readjust if necessary.
A. Air Cleaner Cover
B. Snaps
2-8 FUEL SYSTEM e Loosen t he clamp screw, remove the ele ment fix ing sc rew, then pull the air cleaner element up out of the air cleaner housing.
A. Element
B. Metal Net
elnspect the element for damage. If it is torn o r punctured, replace it. elf the element is not obv iou sly damaged, clean it in a bath of high -flash point solve nt, and squeeze it dry. A. Screws
B. Elemen t
• Push a clean, lint-free towel into t he air cleaner ho using to kee p dirt or other foreign material from entering.
I WARNING. o If dirt or dust is allowed to pass through into the carburetor, the throttle may become stuck open, possibly causing an accident.
o If dirt gets through into the engine, excessive engine wear and possibly engine damage will occur.
eRemove the element stoppe r from the rear end of the element bo dy by removi ng the screw.
I WARN.ING • Oelean the element in a well-ventilated area, and take ample care that there are no sparks or flame anywhere near the working area; this includes any appliance with a pilot light. Do not use gasoline or a low-flash point solvent to clean the element. A fire or explosion could result. eAfter cleaning, saturate the element with SE or SF class SAE 30 oil, squeeze o ut the excess, t hen wrap it in a clean rag and sq ueeze it as dryas possib le. Be careful, not to tear the ele me nt. NOTE o Special oils for foam air cleaner elements can be used. OReplace the element after cleaning it five times or if it is damaged.
Air Cleaner Housing Dust and/or Water Inspection e Push open the two drain hoses on t he bottom of the a ir cleaner housing to expel dust and /o r water accumulated inside .
A. Screw
B. Stopper
.Pu ll t he element off th e body, then off t he inner metal net.
A. Drai n Hoses
FUEL SYSTEM 2-9 elnstall the fuel tank ca p at once. _Remove the fuel ta nk front cover by pullin g it up and
Fuel Tank
turning it to e ith er side between th e fron t carrier and the steering stem .
Fuel Tank Removal -Remo ve the sea t (see Frame chapter in this manual). eR emove the fuel tank rear cove r.
A . Front Cover
A. Rear Cover
B. Screws
eTake off t he fue l tank cap.
[ WARNING
-Remove the breather and vent hoses fro m the cla mp on
I
t he rear of the fuel tank . e Remove the following bolts.
OGasoline is extremely flammable and can be explosive under certain conditions. Turn the ignition switch OFF. Do not smoke. Make sure the area is well ventilated and free from any source of flame or sparks ; this includes any appliance with a pilot light .
• Remove th e fuel tank top cover .
A. Fuel Tank Mounting Bolts (3) B. Front Fend er Mounting Bo lts (2)
eTurn the fuel tap to t he OFF position . ePul1 the fuel hose off the tap. A . Screws B. Tank Cap
C. Top Cover
-Bend the front fender tabs o utward and remove the
f uel tank .
2-10 FUEL SYSTEM
Fuel Tank Installation Notes eFuel tank installation is the reverse of removal. Note the following.
WARNING
I
OGasoline is extremely flammable and can be explosive under certain conditions. Turn the ignition switch
eRemove the fuel tank upper cover by taking off the two mounting screws. -Install the fuel tank cap immediately. _Pry off the gauge cap and discard the cap. -Check the grooves in the fue l tank boss. If the grooves are damaged by removing the cap or can not hold the cap nails, the fuel tank must be replaced.
OFF. Do not smoke. Make sure the area is well ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light.
-Check the rubber dampers on the frame top-tube.
A. Gauge Cap
B. Grooves
-Pu ll out the fuel level gauge.
A. Dampers
*If the dampers are damaged or deteriorated, replace them . • Be sure the fuel hose is clamped to the fuel tap to prevent leakage.
I WARNING I o Fuel spilled from the fuel tap is hazardous.
-Install the breather and vent hoses on the fuel tank and secure them with the clamp (see Wiring, Cable, or Hose Routing section in the General Informat ion chapter).
A. Fuel Level Gauge
Fuel Level Gauge Installation Notes Fuel Level Gauge Removal -Remove the fuel tank cap.
Olnstallation is the reverse of removal. lowing.
Note the fol -
I
I WARNING I
WARNING
OGasoline is extremely flammable and can be explosive under certain conditions . Turn the ignition switch OFF. Do not smoke. Make sure the area is well ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light.
OGasoline is extremely flammable and can be explosive under certain conditions. Turn the ignition switch OFF. Do not smoke. Make sure the area is well ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light.
FUEL SYSTEM 2-11 elnstall the fuel level gauge so that the Y:z scale faces the front. e Push the new gauge cap over the gauge so that the notch align s with the V2 scale.
Fuel Tank Damper Installation eApply an adhesive which is recommended by the manufacturer for bonding rubber to metal to the inside of the rubber dampers and install them as ·shown. eFace each split of the dampers inward of the vehicle.
Damper Installation
A. Front
C. Notch
B. Y, Scale
eCheck that the gauge cap nail s fit securely in the grooves in the fuel tank boss.
1. Rubber Dampers
2. 10 - 15 mm 3 . Splits
Fuel Level Gauge Check -Remove the fuel level gauge Fuel Level Gauge Removal) . -Check that the float moves without binding. It sho uld weight. *If the float does not move damage, replace the gauge.
A. Fuel Level Gauge B. Float
c.
from the fuel tank (see up and down smoothly go down und er its own smoothly or has visual
Up and Down Smoothly.
ENGINE TOP END 3-1
Engine Top End Table of Contents Exploded View .. . .. . • .. . ... .. •..... Specifications ... . .. .. ... . . .. . . .... . Special Tools . . . . . . . . . . . . . . . . • . . . . . Cylinder Head . . . . . . . . . . . . . . . . . . . . . . Cylinder Head Removal . ... . . . . . . . . .
Cylinder Head Installation Notes . . .... . Compres~.ion
Releasing Lever Removal
3-2 34 34 34 34
Camshaft Bearing Inspection . . . . . . . .
• • •
Camshaft Chain, Guides, and Tensioner .... .
3-9
Camshaft Installation . . . . . . . . . . . . . Cam Wear Inspection . . .. . ... .. . . .
Camshaft Chain . . .. ... . . . . . . . . . . . .
3-5 3-5
Camshaft Chain Removal .. ... • ....
3-5 3-6
Camshaft Chain Guides . . . . . . . . . . . . . .
Camshaft Chain Installation . . . . . . . . .
Camshaft Chain Wear .. ... . ....... ,
Compression Releasing
Lever Installation . . . . . . . . . . . • . . .
Cylinder Head Assembly Note ... . .. .. Cylinder Head Cleaning . . . . . . . . . . .. Cylinder Head Warp . . . . . . . . . . . .... Valves, Guide, Seats, Springs, Oil Seals ....
. . . .
Camshaft Chain Guide Removal . . ... .
•
•
• • • •
• •
Camshaft Chain Guide Installation . .. .
•
Camshaft Chain Guide Wear . . . . . . . .
•
Valve Clearance Check . . . . . . . . ... .
3-6 3·6 3-6
Valve Clearance Adjustment . . . . . . . .
•
Tensioner Installation . .. .. . . . . . .
Valve Removal . . . . . . . . . . . . . . . . .
•
Camshaft Chain Tensioner Wear . . . .. .
•
Cylinder, Piston and Rings . . . . . . . . . . . . .
3-10
Cylinder Removal/Installation . . . . . . . . .
•
Cylinder Removal . . . . . . . . . . . . . . .
•
Valves ..... . . . . . . . . . . . . . . . . . . . .
Camshaft Chain Tensioner .. .. . . . . . . . . Camshaft Chain Tensioner Removal .. . Camshaft Chain
Valve Head Thickness .. . . . . . . . . . . .
• • •
Valve Stem Bend ...... . , . ...... .
•
Cylinder Installation Note . . . . . . . . . .
Valve Stem Diameter . . . . . . . . . . . . .
•
Cylinder Assembly Note ...... . ... .
Valve Installation . . . . . . . .. . . . . •.
Valve Visual Inspection . . . . . . . . . . .
Piston and ring Removal/Installation . ... . Piston and Ring Removal . . . . . . . . . .
•
3-7 3-7
Valve Guide Inside Diameter . . . • . . . .
•
Piston and Ring Installation .. .. . ... .
Valve Guide Removal . . . . . . . . .. .. .
•
Cylinder, Piston and Ring Maintenance . . .
Valve Guide Installation ... .. . . . . . .
3·7
Valve Seats .. . . . . . . . . . . . . . . . . . . . . Valve Seat Inspection . . . . . . . . . • . . . Valve Seat Repair . . . . . . . . . . . . . . . , Valve Springs . .. . . .. . . . . . . . . . . . . . Valve Spring Removal/Installation ... . Valve Spring Free Length . . . . . . . . . .
Valve Stem Oil Seals . .... .. . .... . , Valve Stem Oil Seal Removal . . . . . . , Valve Stem Oil Seal Installation ... . . Camshaft Sprocket . . . . . . . . . . . . . . . ..
. . . .
Camshaft Sprocket Removal . . . . . . . .
Camshaft Sprocket Installation ..... Camshaft, Rocker Arms and Shafts .... . .. Rocker Arms and Shafts . . ...... . ... Rocker Arm and Shaft Removal ..... Rocker Arm and Shaft Installation ...
. . . . .
Rocker Arm Inspection . . . . . . . • . . .
Rocker Shaft Diameter·. .... .. .. • .. Camshaft . . . . . . . . . . . . . . . . . . . . .. . Camshaft Removal. .. .. . .. . , .. , ..
• • • • • •
• • •
•
•
Cylinder/Piston Wear . . . . . . . . . . . . .
•
Piston/Cylinder Clearance . . . . . . . . . .
•
Piston/Cylinder Seizure . . . . . . . . .. . Piston Cleaning ... . . . . . . . . . . . . . . Piston Ring and Ring Groove Wear . .. .
Piston Ring End Gap . . . . . . . . . . . . . Exhaust System .. . . . . . . . . . . . . . . . . . . Spark Arrester ... . . . . . . . . . . . . . .. . Spark Arrester Cleaning . . . . . . . . . . . Exhaust Pipe and Muffler ... . . . . . . . . .
• • • • • 3-11 3-11 3·11 3·12
Exhaust Pipe and Muffler Removal Note . . . . . . . . . .
3-12
Exhaust Pipe and Muffler Installation ..
3·12
Exhaust System Inspection ... . . . . . . Carburetor Holder . . . . . . . . . . . . . . . . . . .
• • •
Compression Measurement . . . . . . . . .
3·10 3-10 3-10
Cylinder Boring and Honing ... . ... .
3-7 3-7 3·8 3-8 3-8 3-8
3-9
3-10 3-10 3-10
Valve Guides .. . . . . . . . . . . . . . . . . . .
Valve Stem Grinding . ... . ... . ... .
3-9 3-9
Carburetor Holder Installation . .. . . . .
•
Base Manual
• 3·12 3-12
3-2 ENGINE TOP END
............................................................................. Exploded View
.............................................................................
1. Manual Compression Release l : Apply non-permanent locking agent. M : Apply molybdenum disulfide grease. Q : Apply engine oil. R : Replacement Parts T1 : 29 N-m (3.0 kg-m, 22 fHb) for used parts 34 N-m (3.5 kg-m, 25 ft~b) for new parts T2: 12 N-m (1.2 kg-m, 104 in~b) T3: 41 N-m (42 kg-m, 30 ft~b) T4: 9 .8 N-m (1 .0 kg-m, 87 in~b)
3-4 ENGINE TOP END
............................................................................. Specifications Refer to the Base Manual noting the following. Cylinder Compression (Usable range, with compression release operated) Using Recoil Starter
825 - 1280 kPa (8.4 - 13.0 kg/em' .119 - 185 psi) Using Electric Starter
795 - 1240 kPa (8.1 -12.6 kg/em' .115 - 179 psi)
CyHnder Head Cylinder Head Removal • Remove the follow in g parts. Front Fender (see Frame chapter) Fuel Tank (see Fuel System chapter in this text) Carb uretor (see Fuel System chapter in the Base Manual) Exhaust Pipe and Muffler (see Base Manual) Camshaft Sprocket (see this chapter) Spark Plug Cap Cylinder Head Breather Hose and Hose Clamp eRemove the cylinder head bracket mounting bolts,the cylinder head mounting bolt, and nut, then take off the brackets,
Special Tools Refer to the Base Manual noting the fo llowing additional tool.
Bearing Driver Set: 57001-1129
A. Cylinder Head Bracket Mounting Bolts B. Cylinder Head Breather Hose and Hose Clamp C. Cylinder Head' Mounting Bolt and Nut
-Remove the cylinder base bolt. _ Loosen th e cylinder head bolts completely starting with the 6 mm bolts and remove all the bolts.
A. 6 mm Cylinder Base Bolt B. 6 mm Cylinder Head Bolts C. 8 mm Cylinder Head Bolts -Lift the cylinder head clear of the dowel pins in the cylinder and slide the cylinder head out of the f rame.
ENGINE TOP END 3-5 Cylinder Head Installation Notes eRefer to the Base Manual noting the following. elnstall a new cylinder heaa gasket. elnspect the new head gasket, and if the seal coating
.Pull out the lever along with the washer and return
spring.
breaks away, replace the gasket.
1
1. Cylinder Head Gasket
*If the cylinder head or the cylinder head bolts are new ones, tighten the 8 mm bolts to 34 N-m (3.5 kg-m, 25 fHb) of torque. eFirst tighten the three cylinder head bracket mounting bolts, then tighten the cylinder head mounting bolt and nut to the specified torque (see Cylinder Head Removal),
Compression Releasing Lever Removal
[CAUTlO~:l
A. Oil Seal B. Return Spring
C. Washer
Compression Releasing Lever Installation eReplace the oil seal in the cylinder head. Use a suitable bearing driver from the bearing driver set (special tool: PN 57001-1129) when installing the oil seal. elnstall the return spring on the compression releasing
o Do not remove the compression releasing lever unless it
lever as shown.
is absolutely necessary. If removed, the oil seal replacement may be required.
eRemove the front fender (see Frame chapter in this manual) . • Remove the bolt holding the compression releasing lever.
A. Return Spring
A. Bolt
C. Front
B. Compression Releasing Lever
eOil the lever shaft and install the washer and lever assembly. eTighten the bolt securely.
3-6 ENGINE TOP END Cylinder Head Assembly Note
• Remove the timing in spection plug.
elnsert the rubber dampers in the fin grooves starting with the first groove from the top.
eTurn the crankshaft counterclockwise with a wrench on the alternator rotor bolt, and watch the intake valve. When the intake valve opens and closes, keep turning the crankshaft counterclockwise until the T mark on the alternator rotor aligns with the slot, as shown.
Rubber Damper Installation
2
20mm
2
,-.
5 mm
".
2
1
2. Ru b ber Dam pers
1. Cylinder Head
A. Timing Inspection Plug B. Slot
C. T Mark
Valves, Guides, Seats, Springs, Oil Seals eMeasure the clearance of each valve between the end of the valve stem and the adjusting screw on the rocker arm with a thickness gauge. *If the valve clearance is not correct, adjust it (see Valve
Valves: Valve Clearance Check NOTE
Clearance Adjustment).
OCheck the valve clearance only when the engine is cold (cool to the touch). • Remove the front fender (see Frame chapter in this
manual). eRemove the fuel tank (see Fuel Tank Removal in the Fuel System chapter) . eTake out the bolts and remove the valve adjusting caps with O-fings.
A. Valve Adjusting Caps
B. Front
Valve Clearance (when cold)
Intake: Exhaust:
0.10 - 0.15 mm 0.15 - 0.20 mm
A. Thickness Gauge B. Adjusting Screw
C. Locknut
ENGINE TOP END 3-7 elnstall the valve adjusting caps so that the UP mark is on top.
A. Valve Guide Reamer: 57001-162
A. UP Mark
eCheck valve seating (see Valve Seat Inspection). eDiscard the valve stem oil seal and install the new oil seal (see Va lve Stem Oil Seal Installation). elnstall the va lve (see Valve Installation). elnstall the cylinder head (see Cylinder Head Installation).
Valve Stem Griding eThe end of the valve stem may be ground slightly to remove damage or to gain valve clearance after valve job. eFoliow the valve refacing machine manufacturer's instructions.
............................................................................ Camshaft Sprocket
Valve Stem Griding
Camshaft Sprocket Removal Minimum after
grinding 4.0 mm
Do not grind off more than 0.2 mm
• Remove the front fender (see Front Fender Removal in the Frame chapter). eRemove the fuel tank (see Fuel Tank Removal in the Fuel System chapter). eRemove the ignition timing inspection plug and the recoil starter (see Recoil Starter Remova l in the Engine Left Side chapter) . eRemove the bolts and take off the camshaft cover. Olt may be necessary to pry the cover off with a screwdriver. There are prying gaps under the screw hole bosses.
Valve Guides:
Valve Guide Installation eClean the valve guide hol e in the cylinder head. e Lightly oil the valve guide. eHeat the cylinder head around the va lve guide hole to 120° to 150°C (250° to 300° F) . • Use the valve guide arbor and a hammer to drive the guide into the head from the outside until the guide flange seats against the head. eAliow the cylinder head to cool. • Ream the valve guide with the valve gu id e reamer (special too l) even if the old guide is reused.
A. Camshaft Cover
B. Gap
,;
3-8 ENGINE TOP END eTurn the crankshaft with a wrench on the alternator
-Fit the sprocket under the chain and slip it over the
rotor bolt until the "LF300" mark on the camshaft
shoulder on the crankshaft so that the "LF300" mark
sprocket aligns with the pointer on the cylinder head .
on the sprocket aligns with the pointer on the cylinder
head.
A . Pointer A. Pointer
B. "LF300" Mark
B. "LF300" Mark
• Remove the camshaft chain tensioner (see Camshaft
Chain Tensioner Removal) . - Remove the camshaft sprocket bolt while holding the crankshaft from turning with a wrench on the alternator rotor bolt.
-Slide the sprocket off the shoulder on the camshaft and out from the chain. -Support the chain on a screwdriver or other tool stuck
in the hole in the head.
-Screw the bolt in and tighten it to the specified torque (see Exploded View), wh ile holding the crankshaft from turning with a wrench on the alternator rotor
bolt. -Install the camshaft chain tensioner (see Camshaft Chain Tensioner Installation). _Before go ing any further, check the cam timing. o Turn the crankshaft counterclockwise with a wrench
on the alternator rotor bolt, until the "LF300" mark on the sprocket aligns with the pointer on the head.
[i:AuT,o~1 Camshaft Sprocket Installation -Remove the timing inspection plug, and check to see that the "T" mark on the alternator rotor aligns with
the slot.
o If any resistance is felt when turning the crankshaft, stop immediately, or you may bend the valves. OThe liT" mark on the alternator rotor should align with
the slot. *If the camshaft timing is not correct, remove the sprocket from the camshaft, and install it again as
detailed above. _Smear a little engine oil on the camshaft cover Q·ring
and push the cover into place so that the UP mark faces up. -Put in the camshaft cover bolts and tighten them securely. -Install the timing inspection plug, and the recoi l starter.
-Install the fuel tank (see Fuel Tank Installation in the Fuel System chapter).
A.
nmi~g In~pectiQ!1
Plug B. Alternator Rotor Bolt
C. Slot
D. T Mark
*If the liT" mark is not aligned, hold the camshaft chain taut and turn the crankshaft with a wrench on the alternator rotor bolt.
Camshaft, Rocker Arms and Shafts Rocker Arms and Shafts: Rocker Arm and Shaft Removal _ Remove the camshaft sprocket (see Camshaft Sprocket Removal).
ENGINE TOP END 3-9 eTake out the screw and remove the rocker shaft retainer. eRemove the compression releasing lever (see Compression Releasing Lever Removal).
o Do not turn the engine while the camshaft chain tensioner is removed. Engine damage could result.
A. Rocker Shaft Retainer
A. Lockbo lt
eTake out th e bolts and remove the valve adj usting caps.
- Remove the lockbolt. -Carefully pull the push rod out of the tensioner body. Do not drop the ball and retainer assembly or the
-Loosen all the cylinder head bolts to free the cylinder head from the stress (see Cylinder Head Removal). ePull out the rocker shafts and remove the rocker arms.
B. Mounting Bolts
spring.
-Slide the ball and retainer assembly and the spring off the push rod.
Camshaft Chain Tensioner Installation eSlip the spring over the push rod and compress it down
past the hole. elnsert a piece of wire in the hole to hold the spring in
place.
A. Rocker Arm
B. Shaft
Camshaft Chain, Guides, and Tensioner Camshaft Chain Tensioner: Camshaft Chain Tensioner Removal
A. Spring B. Wire
C. Push Rod
_ Loosen the lockbolt in the top of the camshaft chain tensioner. Do not remove it yet. eTake out the tensioner mounting bolts and remove the camshaft chain tensioner.
-Drop the ball and retainer assembly onto the push rod. -Push the push rod into the tensioner body.
3-10 ENGINE TOP END -When the push rod is in as far as it wi ll go, screw in the lock bolt with its washer to lock the push rod . • Pull out the wire to release the spring.
Piston and Ring Removal/Installation:
Piston and Ring Installation Refer to the Base Manual noting the following. elnsta ll the second and top rings in that order.
Chain Tensioner (push rod is locked)
1
elnstall the top and seco nd rings so that each "N" marked side faces up .
1 Top and Second Rings
-_.""" mark Top ring Up
1. Lockbolt 2. Push Rod 3. Ball and Retainer Assembly
eSe sure the
O~ring
4. Spring 5. O-Ring
UN" mark
2nd ring
is in place in the tensioner body.
eAfter installing the tensioner, loosen the lock bolt and
then tighten it. With the bolt loosened, the spring inside takes up any slack automatically.
Cylinder, Piston and Rings
Cylinder, Piston and Ring Maintenance:
Compression Measurement eBefore measuring compression, do the following:
Cylinder Installation Note ORefer to the Base Manual noting the following. -Install a new cylinder base gasket. o lnspect the new base gasket and if the seal coating breaks away, replace the gasket.
Cylinder Assembly Note elnsert the rubber dampers in the fin grooves starting with the first groove from the top.
o Be su re the battery is fully charged (see Battery Condition in the Electrical System chapter in this Manual). OWarm up the engine (if the engine will run). ODuring warm-up, check for leaks around the cylinder head gasket. e Remove the spark plug. -Set the compression gauge and adapter hose (special tools) into the spark plug hole . • Pull up the recoil starter until the compression is felt. Then, push up the compression releasing lever each time to start the engine.
Rubber Damper Installation
20mm
CD
1. Rubber Dampers 2. Cylinder
A. Compression Releasing Lever
ENGINE TOP END 3-11 e Hold the throttle wide open and crank the engine with the recoil starter, or the electric starter. eWhen the gauge stops rising, stop cranking and read the gauge.
Exhaust System Spark Arrester: This vehicle is equipped with a spark arrester approved for off-road use by the U.S. Forest Service. It must be properly maintained to ensure its efficiency. In accordance with the Periodic Maintenance Chart, clean the spark arrester.
Spark Arrester Cleaning
I WARNING
I
OTo avoid burns, wear gloves while cleaning the spark arrester. Since the engine must be run during this procedure, the muffler will become hot.
A. Compression Gauge: 57001-212 B. Adapter Hose: 57001-1159
Cylinder Compression (Usable Range) with Recoil Starter 825 - 1280 kPa (8.4 -13.0 kglem', 119 -185 psi) , or with Electric Starter 795 - 1240 kP• . (8.1 - 12.6 kg/em', 115 - 179 psi)
*If the compression is within the specified range, the piston rings, cylinder and valves are probably in good condition. *If the compression is higher than the specified range, see the Compression Too High table in the Base Manual. *If the compression is below the specifi ed range, check the cylinder head bolt torq ue (see Cylinder Head Installation in this manual). *If the compression is still below the specified range, squ irt a little o il into the spark plug hole and repeat the compression measurement. * If the compression does not change very much, the piston rings are probably OK. See the Wet Compression - No Change tab le in the Base Manual. *If the compression increases, the piston rings are not sealing properly. See the Wet Compression - Increase table in the Base Manual.
OThe spark arrester must be installed correctly and functioning properly to provide adequate fire protection. e Remove the drain plug on the rear muffler. eln an open area away from combustible materials, start the engine with the transmission in neutral. eRaise and lower engine speed while tapping on the muffler with a rubber mallet until carbon particles are purged from the muffler.
A. Drain Plug B. Spark Arrester
C. Mounting Bolt
WARNING
I
0 00 not run the engine in a closed area. Exhaust gases contain carbon monoxide; a colorless, odorless, poisonous gas. Breathing exhaust gas leads to carbon monoxide poisoning, asphyxiation, and death. ONever run the engine with the spark arrester removed. Hot carbon particles may start a fire.
3-12 ENGINE TOP END NOTE
Muffler Clamp Installation
ORun the engine with the spark arrester installed during cleaning. This keeps the exhaust pressure higher and makes carbon particles purge easier. eStop the engine. elnstall the drain plug. eRemove the spark arrester mounting bolt from the muffler. ePull the spark arrester out of the muffler. -Scrape carbon deposits off the spark arrester and slide it back into the muffler. elnstall the mounting bolt and tighten it securely.
Exhaust Pipe and Muffler: Exhaust Pipe and Muffler Removal Note ORefer to the Base Manual noting the following . • Remove the rear fender (see Frame chapter in this manual) to access the muffler clamp.
1 . Gasket Stopper of Clamp 2. Exhaust Pipe
3 . Gasket
eTighten the exhaust pipe holder nuts evenly and securely. eTighten the muffler mounting bolts securely. eTighten the muffler clamp bolt securel y.
Exhaust Pipe and Muffler Installation ORefer to the Base Manual noting the following. eFit a new gasket into the muffler so that the chamfered side of the gasket faces to the front.
Carburetor Holder Carburetor Holder Installation el nstall the carburetor holder so that the projection faces upward.
Carburetor Holder Installation
A. Chamfer
eTemporarily install the muffler clamp on the muffler so that the gasket sto pper faces the rear. eSlip the muffler into place from the rear of the frame, so that it fits ove r the exhaust pipe. a Be sure that the collars are in place in the rubber dampers in the muffler. o Hold the muffler up and put in the mounting bolts, but do not tighten them yet. elnsert the muffler clamp over the exhaust pipe so that the gasket stopper of the clamp contacts the end of the exhaust pipe.
1. Projection
eTighten the bolts to a snug fit, then tighten them evenly.
ENGINE LEFT SIDE 4-1
Engine Left Side Table of Contents
@]I Exploded View . ....... . ............... . .. ...... ... . .... . . .
4-2 * 4-3 4-3 4-3 4-3 4-4 4-6 4-6 4-6 4-6 4-7
Specifications ....... . .. ....... . ................... . . . ... . . Special Tool . . .................... . . . . ................... . Recoil Starter . . . ... . . .. ..... . . .. .. . . .. . . .. . . . .. .. . ....... . . Recoil Starter Removal .. .. .... . . .. . .. ... ... . .... ...... . . Recoil Starter Disassembly ...... . ... . ... ..... ...... . .... . Recoil Starter Assembly Notes . ... . .. .. . . .... . ........... . Recoil Starter Cleaning .. . ........ . . .. . .. ... ..... .... ... . Recoil Starter Inspection .. ... .. ...... _...... . .. . . ....... . Left Engine Cover . ......... . ....... .. ... . . ...... . .. .. . .... . Left Engine Cover Removal. . ... ... . .. . . .. ......... . .. . . . . Left Engine Cover Installation Notes . . . . ...... . . ........... . Alternator Rotor and Stator (see Electrical System chapter in this Manual) Pickup Coil (see Electrical System chapter in the Base Manual) Starter Clutch . . .... . .................. . ... . . . ...... . ..... . * Starter Clutch Removal ... .. ..... ... ...... .. .. . .. .. . .. .. . * Starter Clutch Installation ............................... . * Starter Clutch Inspection .. ....... . .. . .. .. ...... .. . .. . .. . * Starter Chain and Sprockets . . ... . .... . ... ....... . .. . ...... .. . 4-7 Starter Chain and Sprocket Removal. ...... . . ......... . . . . . . * Starter Chain and Sprocket Installation . .. ... . .. .. ... . ...... . * Starter Chain Wear ....... . ... . .. .... .. . ......... .. .. . . . * Torque Limiter Inspection .. ............ . ... . .... . ... .. . . 4-7
*
Base Manual
4-2 ENGINE LEFT SIDE E~;;~d~~-,i------"-"""""""" ................... ~~~............ ................................. . ........................... ..........
T2
1. G L
Torque L'Imlter . . . Apply h'Ig h temp : Apply non-perm erature grease . ; Ap PI Y engine oil.anent Ioc k mg ' agent . T1 O . . 59 N-m (60 k T2; 34 N-m (3 '5 g-m, 43 ft-Ib) T3 .' 83 . kg-m ' 25ft ·Ib) . N-m (0.85 kg-m, 74 in-Ib}
©
ENGINE LEFT SIDE 4·3
Special Tool Refer to the Base Manual noting the following additional tool. Hook Wrench: 57001·1101
• A. Reel B. Handle Cap
C. Locking Pliers
eHold the reel in one hand wh il e removing the locking
pliers with the other. ePull the rope in through the rope hole in the housing and hold it in the notch in the reel. NOTE
ODD not let the rope wedge between the reel and the housing.
Recoil Starter
Recoil Starter Removal eRemove the recoi l starter by taking out the mounting bolts.
A. Hold rope in notch . eSlowly allow recoil spring tension to unwind the reel. eRemove the fr iction plate by taking off the flange nul.
A. Bolts
Recoil Starter Disassembly eRemove the recoil starter (see Recoil Starter Removal). ePull the handle out 100 - 200 mm. Clamp the rope in place with locking pliers. e Remove the handle cap. ePry the knot out of the handle and untie it. Pull the handle off the rope.
A. Friction Plate
B. Flange Nut
44 ENGINE LEFT SIDE
I WARNING. o Be careful that the spring does not fly loose and does not injure you. It is under great pressure.
oTum the reel one-quarter tum counterclockwise past the rest position where no tension can be felt. Now. slowly lift the friction plate straight up out of the housing.
e Remove the friction plate and friction plate spring. e Remove the pawl and pawl spring.
4
\ 1. 2. 3. 4. 5.
Pawl Pawl Spring Friction Spring Friction Plate Flange Nut
A. Strike bench.
e Remove the reel noting the following.
I WARNING. o Be careful that the spring does not fly loose and does not injure you. It is still under great pressure. o Tum the reel one.quarter tum counterdockwise past the rest position where no tension can be felt. Now, slowly lift the friction plate straight up out of .the housing.
RecoilStarter Assembly Notes eAssembly is the reverse of disassembly. Note the following. elf the recoil spring was removed, install it as shown. If it is not installed correctly, the starter not operate properly . .
will
NOTE
I WARNING.
o There should be no spring tension on the reel when removing the reel. Lift the reel slightly. If tension is felt, push the reel back into pla<;e and gently "wiggle" it until the reel may be easily removed.
o The recoil spring must be put under great pressure during installation. Wear gloves to avoid injury.
elf necessary, remove the recoil spring as follows. OPlace the starter housing facing down on a bench. oStrike the bench sharply to safely remove the. spring.
eHook the outer end of the recoil spring onto the housing tab. e Reel the recoil spring clockwise into the housing from outside to inside.
ENGINE LEFT SIDE 4-5
•
A. Hook reco il spring end onto the tab.
A. Turn reel to wind rope.
-Set the reel into place so that the hook on the spring catches on the tab in the reel. NOTE
OPush the recoil spring against the housing securely to prevent the spring from slipping off during installation.
-Lightly grease the spring.
A. Al ign hook and tab.
-Grease the pawl spring and pawl and install them as shown . eGrease the friction plate and install the friction plate
and spring being careful of the spring hook position.
A. Grease recoil spring.
elf the rope was unwound from the reel , it must be wound clockwise for correct starter operation. -Wind the rope four turns around the smaller diameter of the reel and half turn around the larger diameter.
NOTE
o Turn the reel counterclockwise to wind the rope clockwise. This prevents the rope from twisting.
A. Pawl B. Pawl Spring C. Friction Plate
D. Friction Plate Spring Hooks E. Grease here.
4-6 ENGINE LEFT SIDE eTighten the flange nut to the specified torque (see Exploded View). eTurn the reel four turns clockwise to preload the spring. o The rope should protrude about 350 mm when the reel notch aligns with the hole as shown.
A. Hole B. Notch
Left Engine Cover
Left Engine Cover Removal eRemove the recoil starter (see Recoil Starter Removal) . eHolding the recoil starter pulley steady with the hook wrench (special tool), loosen the alternator rotor bolt.
C. About 350 mm
A. Alternator Rotor Bolt B. Hook Wrench: 57001-1101
Recoil Starter Cleaning eDisassemble the recoil starter (see Recoil Starter Disassembly) . elmmerse only the metal parts in a bath of high-flash point s~lvent.
WARNING. OClean the starter in a well-ventilated area, and take care that there are no sparks or flame anywhere near the working area; this includes any appliance with a pilot light. Do not use gasoline or a low-flash point solvent to clean the starter. A fire or explosion could result.
eRemove the alternator rotor bolt, the pulley and the key. The pulley may be pulled out easily. ePlace an oil pan beneath the engine left side . e Remove the seat and disconnect the alternator connector and pickup coil connector. eRemove the left engine cover. o Remove the differential shift lever case. o Unscrew the left engine (Over mounting bolts (8).
o Do not clean any non-metallic parts in the solvent as they may be damaged_ OUse compressed air to dry the cleaned components.
Recoil Starter Inspection e Ciean the recoil starter (see Recoil Starter Cleaning). eExamine the starter pawl for chips or excessive wear. _Check the starter rope for excessive wear or fraying. -Check the condition of the recoil spring, and friction plate spring. o lnspect the springs for breaks, rust, distortion, or weakened condition .
A. Left Engine Cover Mounting Bolts B. Differential Shift Lever Case C. Lever Case Mounting Bolts
ENGINE LEFT SIDE 4-7
Left Engine Cover Installation Notes ORefer to the Base Manual noting the following.
eGrease the left engin e cover oil seal.
-Check that the pu lley O·ring is in good condition. -Clean the pulley boss and apply oil to the O·ring and the boss . • Push the pulley into the left engine cover oi l seal.
- Fit the key in the groove between the pulley and shaft. -Insert the alternator rotor bolt.
1. Torque Limiter
A. Grooves
B. Key
-Using the hook wrench (special tool), tighten the alternator rotor bolt to the specified torque (see Ex· ploded View).
A. Hook Wrench: 57001·1101
............................................................................. Starter Chain and Sprocket
Torque Limiter Inspection eRemove the torque limiter and visually inspect it.
*If the limiter has wear, discoloration, or other damage, replace it as a unit.
ENGINE RIGHT SIDE 5-1
Engine Right Side Table of Contents
Exploded View ......... • . . . • . . . . . . .
5·2
Primary Gear Installation
Specifications .. . . . . . . . . . . . . . . . . . . . .
5·3
Secondary Gear Removal
Special Tools ......... . . . . . ... . .. . . Right Engine Cover . . . .... . . .. . . . . .. .
• •
Secondary Gear Installation . . . . . .. . . Primary and Secondary Gear Damage ..
• • • •
Right Engine Cover Installation .. .. . .
• •
Primary Gear/Crankshaft Wear . . . . . . .
Clutches ...... . ... . . . . . . . . . . . . .. .
5-3
Secondary Gear/Collar Wear ....... .
• • •
Clutch Adjustment . .... • . . . •. . ....
5·3
Lubrication System . . . . . . . . . . .. . . . .. .
5·3
Clutch Adjustment . .. . ..... . . . . .
5-3
Engine Oil and Filter . . . .... ...• •. . .
Clutch Removal . . . . . . ... . . . . . . . . .
5-3
Engine Oil Level Inspection . . .. .. .. .
• •
Clutch Removal . . ....• .. .•... . .
•
Engine Oil and Filter Change ... .• • ..
•
Clutch Installation . . .. . .... .. ..•.
5-3
Oil Pump ... . .. . ... . . ... . . . . •• . .
5-3
Oil Flow Inspection . ... . . . . . • . • . .
5-3
Right Engine Cover Removal . . . . . . . .
Gear Backlash . . .. .... . .. . .. . .. .
Oil Pump Removal. . . .... . ... . . •.
•
Primary Clutch Shoe Lining Wear . ... .
• • •
Oil Pump Installatio n . .. ... ... • .•.
•
One-Way Clutch Inspection ..... . .. .
•
Oil Pump Disassembly .... . . . •.••.
Oil Pump Inspection .... . . .. . ..•.
• • •
Oil Screen . ; . . . . . . . . . . . . . . . . . .. .
•
Oil Screen Removal . . . ... . ... .. . .
•
Oil Screen Installation . . . . . . . . . . . .
•
Clutch Inspection . . .. . . . . . . . . . .. . . Primary Clutch Housing Wear . . . . . . .
Friction Plate Wear and Damage .. .. . . Friction Plate and Steel Plate Warp . .. .
• •
Oil Pump Assembly . . .... .. .•. . ••
Secondary Clutch Housing
Finger Damage . .. . . . . . . . . . . . .
•
Secondary Clutch Hub Spline Damage ..
Oil Screen Cleaning and Inspection . .. .
•
Clutch Release . . . . . . . . . . . . . . . • . . .
• • •
Oil Filter Bypass Valve . .. . ......... .
•
Clutch Release Removal . . . ... ... . .
•
Bypass Valve Removal . . . . . . . . . . . .
Clutch Release Installation .. .. . ... .
•
Bypass Valve Installation .. ... . ... .
Clutch Release Wear. .. ... . . . . . . . .
•
Bypass Valve Cleaning and Inspection ..
Balancer . . . . . . . . . . . . . . . . . . . . . • . . .
5-3
Secondary Clutch Spring Wear . . .. .. .
Primary Reduction . . . . . . . . .. . . . . .. . . Primary Gear Removal .. . . . . . . . . . .
• •
•
Base Manual
• • •
5-2 ENGINE
RIGH~___~~~.~ ...............................
•....................... ;;i;;;;;;; vi;:;; .....•.............................................® ....... ~ 1@ ~
. ~~ M
~
.
~
~/ . ~
:~o ~ ~ 1 o~®~~
@6' fiT I:) Ii)
M
.
.
~
~I~
~· ~l.
M
:;
/l(~
·~ IV ."
.
v~
~
, o . ··/·~o ~ 0 /
"
I bdenum M . Apply moy . disulfide grease. I engine OIl. ft Ib) . o : App y (130 kg-m. 94 sed bolts 25 N-m. 'n Ib) for u T1: 1 (1 . 2 kkg·m, I T2:12N-m m 104 11 .0ft .lb ) f or new bolts 15 N·m (1.5 g- '58 ft-Ib) T3: 7B N -m (B.O ~g-~, 22 ft-Ib) T4: 29 N-m (3.0 g-m' 14.5 ft-Ib) T5 : 20 N-m (2.0 kg· ,
'"
ENGINE RIGHT SIDE 5-3
Clutch Removal: Clutch Installation
Specifications Refer to the Base Manual noting the following. o The engine oi l of SAE 10W-30 can also be used.
o Refer to the Base Manual noting the following. *If the c lu tch spring plate or the clutch spring bolts are new ones, tighten the spring bolts evenly to 15 N-m (1.5 kg-m, 11.0 fHb) of torque.
Balancer
Clutches Clutch Adjustment: Clutch Adjustment • Remove the clutch release adjusting screw cover.
Refer to Engine Bottom End/Transmission in the Base Manual for the information. o Balancer punch mark alignment is needed at balancer gear installation .
Lubrication System Oil Pump: Oil Flow Inspection eRun the engine at idle speed.
I WARNING
I
a During oil flow inspection, do not open the throUle valve. Hot oil will squirt out of the banjo bolt, and may cause a serious burn. A. Clutch Release Adjusting Screw Cover B. Screws
e Loosen the main oil pipe banjo bolt on the left crankcase as shown J and check that the oil seeps out around the banjo bolt .
• Loosen the locknut. eTurn the clutch release adjusting screw clockwise until it becomes hard to turn, then turn the screw back counterclockwise until it become hard to turn.
A. Main Oil Pipe Banjo Bolt
A. Locknut
B. Adjusting Screw
eTighten the locknu t without changing the adjusting screw position. elnstall the adjusting screw cover.
eTighten the banjo bolt to the specified torque (see Exploded View). eStop the engine. eWipe up any oil that spills oh the engine or the frame . *If the oil does not flow out, inspect the oil filter and the oil pump. *If the oil filter and the oil pump are not at fault, inspect the rest of the lubrication system .
ENGINE REMOVAL/INSTALLATION 6-1
Engine Removal/Installation Table of Contents Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Removal/I nstallation .... . ... .. ... .. . .... .. ... . ..... . . Engine Removal . . ... . .. . ... . .. ..... . .. ...... . ...... .. Engine Installation Note . .. .. . ... ... . _ . . . . . . . . . . . . . . . . . .
* : Base Manual
. . . .
6-2 6-2
* 6-2
6-2 ENGINE REMOVAL/INSTALLATION Exploded View T1 : 25 N-m (2.5 kg·m, 18.0 ft·lb) T2: 34 N·m (3.5 kg·m, 25 ft·lb)
. @
,
/ ( ®
Engine Removal/Installation
Engine Installation Note Refer to the Base Manual, noting the following. eF irst tighten the upper three bracket bolts, then tighten the lower bracket bolt and nut to the specified torque (see Exploded View).
A. Three Bracket Bolts B. Lower Bracket Bolt and Nut
ENGINE BOTTOM END/TRANSMISSION 7·1
Engine Bottom End/Transmission Table of Contents Exploded View .. . ... • .• • ..••..•....
7·2
Reverse Cable Adjustment . . . . . . . . . .
•
Specifications . .... . .. . . . . . . . . .. .. . .
74
Reverse Knob and Cable Removal. ... .
•
Special Tools . .. . . . . . . . . ... . . . . . . . .
74
Reverse Knob and Cable Installation . . .
74
Sealant . . . . . . . . . . . . . . . .. ... . . . . . .
74
Reverse Cable Lubrication . . . . . . . . . .
7·5
Reverse Cable Inspection . . . . . . . . . .
•
Crankcase Disassembly . ... . . .. . . . .
• •
Transmission Shafts, Shift Drum, Forks . . .
7·5
Crankcase Assembly . . . . . . . . . . . . . .
•
Transmission Removal . . . . . . . . . . . .
•
Crankshaft and Connecting Rod . . . . . . . . . .
74
Transmission Installation . . . . . . . . . .
•
Crankshaft Removal. . . . . . . . . . . . . .
• • •
Transmission Shaft Disassembly . . . . . .
•
Transmission Shaft Assembly . . . . . . . .
7·5
Crankcase Splitting . . . . . . . . . . . • . . . . . .
Crankshaft Installation . . . . . . . . ... .
Crankshaft Disassembly . . . . . . . . . . . Crankshaft Assembly . . . . . . . . • . . . .
Connecting Rod Bend/Twist . ..... . .
Sh ift Fork Bending ..........•. . .
• •
Shift Fork/Gear Groove Wear Sh ift Fork Guide Pin/
Connecting Rod Big End Radial Clearance . . . . . . . ... ... .
• •
Shift Drum Groove Wear . . . . . . . . .
•
•
Gear Dog/Gear Dog Hole and Recess Damage . . . . . . . . . . . . . . .
•
•
Oil Pressure Relief Valve . . . . . . . . . . . . . .
7-6
Crankshaft A lignment . . . . . . . . . . . .
74
Oil Pressure Relief Valve Inspection· . .
7·6
Connecting Rod Big End Seizure . . .. .
•
Balancer .. . . . . . . . . . . . . . . . . . . . . . . .
Transmission . . . . . . . . . . . . . . . . . . . . . .
74
Balancer Drive Removal . . . . . . . . . . .
• •
Transmiss ion External Shift Mechanism . . .
•
Balancer Drive Installation . . . . . . . . .
•
External Shift Mechanism Removal. .. .
•
Ba lancer Removal . . . . . . . . . . . . . . .
Connecting Rod Big End Side Clearance . . . . . .
External Shift Mechanism Inspection ..
• •
Sh ift Drum Stop Lever Removal. .... .
•
Shift Drum Stop Lever Installation ... . Shift Drum Stop Lever Inspection . .. .
• •
Reverse Knob and Cable . . . . • . . . . . . . .
74
Reverse Knob Free Plav Inspection . ...
•
External Shift Mechanism Installation . .
Balancer Installation ... . . . . . . . .. .
Ball and Needle Bearings . . . .. . . •• ... •..
• • •
Ball and Needle Bearing Replacement . . . . . . . . . . . . . . . .
Ball and Needle Bearing Wear .....•• .
•
Base Manual
• •
[II
7-2 ENGINE BOTTOM END/TRANSMISSION
............................................................................. . Exploded View
.............................................................................
e" ~.L .?ID ~U ~'/'11">'Y/ ;'I a ~ ,g
1'\,
1
KLF300-B2-
~~ ~// ~~--
3
•
1.60lts 6,65 2.601t6,85 3.601ts6,35
G
:App I y
grease
L :App ly non-permanent locking agent LG:Apply 1 iquid gasket o :Apply engine oi I
R :Replacement Parts T1:145N·m(15. Okg·m. 110ft·lb) T2:120N·m(12 . Okg·m, 87ft·lb) T 3 : 20 N . m (2. 0 kg· m, 1 4. 5 ft· 1 b) T4:17N·m(1. 7kg·m, 12. Oft· lb ) T5:12N · m(1 . 2kg·m, 104in ·l b) T6:29N·m(3. Okg·m, 22ft·lb) T7:15N·m(1. 5kg'm, 11. Oft·lb)
7-4 ENGINE BOTTOM END/TRANSMISSION Specifications Refer to the Base Manual noting the following. Crankshaft, Connecting Rod: Connecting rod big end radial clearance: 0.08 - 0.020 mm (service limit: 0.07 mm) Cold fitting tolerance between
Crankshaft and Connecting Rod Crankshaft Alignment Refer to the Base Manual noting the following. .Put the crankshaft on V blocks when measuring runout.
crankpin and crank webs:
0.08 - 0.108 mm
Crankshaft Runout
Special Tools ORefer to the Base Manual noting the additional tool.
43mm
9mm
*If runout at either location exceeds the service limit, align the crankshaft so that the runout is within the service limits.
Sealant
Crankshaft Runout Left Half Standard: Service Limit: Right Half Standard: Service Limit:
Under 0.03 mm T1R 0.08 mm T1R Under 0.04 mm T1R 0.10 mm TIR
Kawasaki Bond (Liquid Gasket - Silver): 92104'()02 eApply this liqu id gasket to the cran kcase mating surface .
Transmission Reverse Knob and Cable: Reverse Knob and Cable Installation Olnstallation is the reverse of removal. Note the fol· lowing. elf the reverse lever was removed, mount the lever on the sh ift drum stop lever shaft so that the slot in the lever aligns with the mark on the front gear case.
ENGINE BOTTOM END/TRANSMISSION 7-5
Transmission Shafts, Shift Drums, Forks: Transmission Shaft Assembly -Assembly is the reverse of disassembly. following.
Note the
-Replace any circlips that were removed with new ones.
-Always install circiips so that the opening is aligned with a spline groove.
Circlip Installation
A. Mounting Nut
B. Align mark with slot.
*If the reverse lever is difficult to install in the position
described above, install it rotated one tooth counterclockwise.
eThe transmission gears can be identified by size; Drive shaft gears - the smallest diameter gear is 1 st gear, and the largest is 5th. Output shaft gears - the largest diameter gear is 1 st
gear, and the smallest is 5th. 1. Mark
2. Reverse Lever
eRoute the reverse cable according to the Wiring, Cable,
or Hose Routing section in the General Information
chapter. -Adjust the reverse cable (see Reverse Cable Adjust· ment).
Reverse Cable Lubrication • Lubricate the reverse cable in accordance with the Periodic Maintenance Chart, or whenever the cable is removed (see General Information chapter and General
Lubrication in the Appendix chapter).
7-6 ENGINE BOTTOM END/TRANSMISSION
Oil Pressure Relief Valve Oil Pressure Relief Valve Inspection • Split the crankcase (see Base Manual). • Remove the relief va lve [AI from the right crankcase. • Check to see if the steel ball [BI inside the valve slides sm oothly when pushing it in w ith a wooden or other soft rod, and see if it comes back to its seat by va lve spring [CI pressure.
c
I~_, A
NOTE Olnspecl Ihe valve in its assembled slale, Disassembly and assembly may change Ihe valve performance. *If any rough spots are found during above inspection, wash the valve clean with a high flash-p oint solvent and blowout any foreign particles that may be in the valve with compressed air.
WARNING' OCle.n the oil pressure relief valve in a wellventilated area, and take care that there are no sparks or flame anywhere near the working area. Because of the danger of highly flammable liquids, do not use gasoline or low flash-point solvents.
*If cleaning does not solve the problem, rep lace the relief valve as an assembly. The relief va lve is precision made w ith no allowance for replacement of individual parts. • App ly a non-permanent locking agent to the threads of the relief valve, and tighten it. Torque- Oil Pressure Relief Valve: 15 N-m (1.5 kg-m, 11.0 It-Ibl
WHEELS/TIRES 8·1
Wheels/Tires Table of Contents Exploded View ........................... . ...... .. ....... . Specifications ...... .. . . ........ . .. .. .... . .. .............. . Special Tools ........................................... . . . Wheel Alignment .... . .......... . .. . ..... .... ... ... ..... ... . Steering Centering Inspection ................... . .... . ... . Steering Centering Adjustment ...... . .. .. .... ....... . . . .. . Toe·in Inspection ................................. . ... . Toe·in Adjustment . .. . .. . . .. .. ... . . .. . .... ...... .. . .. . . Wheels (Rims) ......... . ..... . .. . .. . ........ . . . ........ . .. . Wheel Removal .......... . .. .. . .......... . .. .......... . Wheel Installation . .. .. . . ... .. ..... .... ........ .. ..... . . Wheel Inspection . .... . .......... .. .. .................. . Wheel Replacement .. . .. ... .. . . ..... . ..... . .... .. . ..... . Tires ........... . . .. . . . ...... .. , .. .. ..... . . . . . '" ....... . Tire Removal. .... . .......................... .. .... . .. . Tire Installation .......... . : ........................... . Tire Inspection ........ . ..• .......... ... .... . . . . . .. .. . . Front Hub .... .... .. .. ........... ... .... ... . . ... .. . .. .... . Front Hub Removal ... . . . ..... . ......... . ... .. . .. ..... . Front Hub Installation Notes ..................... . ...... . Front Hub Disassembly/Assembly Note ............. . .... . . . Front Hub Bearing Removal Note ............ .. .......... . . Front Hub Bearing Installation Notes .... . ................. . Front Hub Bearing Inspection ............................ . Rear Hub ......... ... . . .. . .. . ... .. ... . .. . .... . . . . . .. ... ... . Rear Hub Installation ........ ...... ......... . .. ........ . *:
Base Manual
8·2 8·3 8·3 84 84 84 8-5 8-5 8-6 8-6 8-6 8-7 8-7 8-8 8-8 8-8 8-10 8-11 8-11 8-11 8-11 8-11 8-12 8-12 8-12 8-12
~
8-2 WHEELS!TIRES Exploded View
........................................................ .................... G : R : W : T1 : T2: T3 : T4:
':,
Apply grease. Replacement Parts Apply water, or soap and water solution. 34 N·m (3.5 kg·m, 25 ft·lb) 27 N·m (2.8 kg·m, 20 ft·lb) 41 N·m (4.2 kg·m, 30 ft-lb) 145 N·m (15.0 kg·m, 110 ft·lb)
Front Wheel
®
~~@ .,
....',
- ""®
Rear Wheel
@®
@
WHEElS/TIRES 8·3
Specifications Wheel Alignment 3° (non.,adjustable) Caster: 1° (non.,adjustable) @ 1G Camber: Toe-in: 27mm Standard Tires Front:
Rear:
22 x 9.00·10 Dunlop KT761. Knobby/Trail Tubeless 24x 11.00·10 Dunlop KT765. Knobby/Trail Tubeless
Tire Air Pressure (when cold)
Front: Rear:
21 kPa (021 kg/em' .3 psi) 21 kPa (021 kg/em' • 3 psi)
Maximum Tire Air Pressure (to seat beads, when cold)
Front: Rear:
140 kPa (1.4 kg/em' • 20 psi) 140 kPa (1.4 kg/em' • 20 psi)
Maximum Vehicle Load:
182 kg (400 Ib)
Special Tools Refer to the Base Manual noting the following additional tools. Jack: 57001-1238
Air Pressure Gauge: 52005-1082
OThis tool may be used instead of the common tool.
o Be sure to use this gauge for low pressure tire instead of the conventional air pressure gauge (52005-1003).
Q------.l!~
84 WHEELS/TIRES eHold a straightedge against the rear wheel rim on one
Wheel Alignment
side at axle height.
Toe-in is the amount that the front wheels are closer
together in front than at the rear at the axle height. When there is toe-in, the distance A is gre;~.ter than Bas shown. The purpose of toe-in is to prevent the front
wheels from getting out of parallel at any time, and to prevent any slipping or scuffing action between the tires and the ground. If toe-in is incorrect, the front wheels
will be dragged along the ground, scuffing and wearing the tread knobs. Caster and camber are built-in and require no adjustment.
Toe~n
of Front Wheels
A. Straightedge
B. Jack: 57001-1238
B Front of Vehicle
'7
'\
"f-
D
'7
......
l
/,
eWith the handlebar straight ahead, loosen the locknuts and turn the tie-rod adjusting sleeve the same number
_..
~
f-
of turns on both sides until the front wheel on that side is parallel to the straightedge.
-~
i"='
(~
'"
~
A
A
NOTE
OThe yel/ow locknut on the tie-rod has left-hand threads. Turn the wrench clockwise for loosening.
A - B = Amount of Toe-in (Distance A and B are measured at axle height)
Steering Centering Inspection eTest ride the vehicle. *If the handlebar is straight when the vehicle is traveling in a straight line, go on to the Toe-in inspection procedure.
*Otherwise, go on to the Steering Centering Adjustment procedure.
Steering Centering Adjustment eSupport the vehicle so that the front wheels are off the ground and the front axles about the same height as the rear axle.
A. B. C. D.
Front Yellow Locknut: left-hand threads Adjusting Sleeve Inside Locknut
WHEELS!TIRES 8-5 eKeeping the front wheels off the ground, set the handlebar straight ahead .
Steering Centering
• At the level of the axle height, measure the distance
between the scribed lines for both front and rear of the 4
1. Front Wheels 4. Straightedge 2. Vehicle Center Line 5. Rear Wheels 3. Parallel to each other.
front tires.
eSubtract the measurement of the front from the measurement of the rear to get the toe-in.
*If the toe-in is not in the specified range, go on to the Toe-in Adjustment procedure. Toe-in of Front Wheels
eRepeat the straightedge procedure on the other side of the vehicle. Now the front wheels are parallel to each
Standard:
27 mm
other and to the center line of the vehicle. -Go on to the Toe-in Inspection procedure.
Toe-in Adjustment e Loosen the locknuts and turn the adjusting sleeves the same number of turns on both sides to achieve the specified toe-in.
Toe-in Inspection eSupport the vehicle on a stand or the jack (special tool: 57001-1238) so that the front wheels are off the ground. eApply a heavy coat of chalk near the center of the front tires. -Using a needle nose scriber, make a thin mark near the
center of the chalk coating while turning the wheel.
A. Front B. Locknuts
C. Adjusting Sleeve
NOTE
o The yellow locknut on the tie-rod has left-hand threads. Turn the locknut clockwise for loosening.
o The toe-in will be near the specified value, if the tie-rod length is 367 mm between the tie-rod ends.
8-6 WHEELS/TIRES Tie-Rod Length Adjustment
Wheel Installation .Position the whee l so that the air valve is toward the outside of the vehicle. _Check the tire rotation mark on the front and rear tires, and install the wheels accord in gly.
NOTE OThe direction of the tire rotation is shown by an arrow on the tire sidewall.
1. Front
2. Tie-Rod Length
-Check the toe-in (see Toe-in Inspection). -Tighten the toe-in locknuts to the specified torque (see Exploded View) . -Test ride the vehicle. A. Rotation Mark (Arrow)
.............................................................................
B. Rotation Direction
Wheels (Rim)
.................................................. ...........................
Wheel Remo.val eLoosen the wheel nuts.
-Support the vehicle on the jack (special tool) or a stand so that the wheels are off the ground.
-Mount the wheelan the studs. eTighten the wheel nuts in a criss-cross pattern to the specified torque (see Exploded View).
A. Stand or Jack: 57001-1238
-Take off the wheel nuts and remove the wheel.
A. Valve Stem
WAEELSITIRES 8-7 Wheel Inspection
Air Valve
• Examine both sides of the rim for dents. If the rim is dented, replace it.
Rim Dent
3) -- - - 1
.....
-if the tire is removed, inspect the air sealing surfaces of the rim for scratches or nicks.
1. Plastic Cap 2. Valve Core 3. Stem Seal
4. Valve Stem 5. Valve Seat 6. Valve Opened
Smooth the sealing
surfaces with fine emery cloth if necessary. elnstall a new air valve in the rim.
Rim Inspection
a Remove the valve cap, lubricate the stem with a soap and water solution, and pull the .stem through the rim from the inside out until it snaps into place.
1. Sealing Surfaces 1. Pull the stem.
Wheel Replacement e Remove the wheel (see Wheel Removal). eDisassemble the tire from the rim (see Tire Removal). ORemove the air va lve and discard it.
0 00 not use engine oil or petroleum distillates to lubricate the stem because they will deteriorate the rubber.
OReplace the air valve whenever the tire is replaced. o Do not reuse the air valve.
eMount the tire on the rim (see Tire Installation). elnstall the wheel (see Wheel Installation).
8-8 WHEELS!TIRES eKneel on the side of the tire, forcing the tire bead into
Tires
the center well of the rim.
Tire Removal
Rim Removal
e Remove the wheel (see Wheel Removal). -Unscrew the valve core to deflate the tire.
o Use a proper
valve core tool.
Valve Stem
OOO OD Well
-Lubricate two tire irons (special tool) with a soap and
water solution, or water, then pry the bead.
[CAUTlO~]
A. Valve Core Tool
o Do not scratch the air sealing surfaces of the tire or eLubricate the tire beads and rim flanges on both sides of the wheel with a soap and water solution, or water.
rim. Scratches or nicks on the sealing surfaces will allow the tire to deflate.
This helps the tire beads slip off the rim flanges.
!CAUTION!
eWork around the rim with the tire irons a little at a time, whi le continuing to hold the bead opposite the irons in the center well of the rim.
a Do not lubricate the tire beads and rim flanges with engine oil or petroleum distillates because they will deteriorate the tire.
eBreak the tire beads away from both sides of the rim with a bead breaker. Breaking Tire Bead
1. Tire Irons: 57001·1073
e Lift the second bead up into the center well and use the same procedure as in removing the first bead.
Tire Installation 1. Bead Breaker 2. Apply lubricant.
elnspect the rim (see Wheel Inspection). eReplace the air valve with a new one (see Wheel Re· placement).
WHEELS/TIRES 8-9
[CAUTION! o Replace the air valve whenever the tire is replaced . 0 00 not reuse the air valve. -Check the tire for wear and damage (see Tire Inspec-
tion) . • Lubricate the tire beads, rim flanges, and the tire irons
-By hand, slide as much of the first bead as possible over the rim flange .
• As the bead goes onto the rim, force the bead into the renter well of the rim to ease installation.
Bead Installation
(special tools) with a soap and water solution, or water.
I WARNING. o Do not use the lubricant other than a water and soap solution, or water to lubricate the tire beads and rim because it may cause tire separation.
1. Tire Beads
2. Center Well
-Use the tire irons {special tools} to install the rest of the bead. 1. Apply lubricant. Bead Installation -Check the tire rotation mark on the front and rear tires, and install them on the rim accordingly.
oThe tires should be installed on the rim so that each air valve is toward the outside of the vehicle. NOTE
o The direction of the tire rotation is shown by an arrow on the tire sidewall.
1. Tire Irons: 57001-1073
-Use the same procedure to install the second bead. eLubricate the tire beads again and center the tire on the rim.
A. Rotation Mark {Arrow}
B. Rotation Direction
-Support the wheel rim on a suitable stand to prevent the tire from slipping off.
8-10 WHEELS/TIRES Tire Air Pressure Front and Rear: 21 kPa (021 kg/em 2 • 3.0 psi) -Check the tire pressure using the air pressure gauge for low air pressure (special tool).
I---@ 1. Rim
2. Suitable Stand
elnflate the tire until the tire beads seat on t he rim.
Maximum Tire Air Pressure (to seat beads when cold) Front and Rear: 140 kPa (1.4 kg/em 2 • 20 psi)
A. Air Pressure Gauge: 52005-1082 elnstall the wheel (see Wheel Installation). -Wipe off the soap and water so lution, or water on the tire, and dry the tire before operation .
WARfIIlfIIG • 0 00 not inflate the tire to more than the maximum tire air pressure. Overinflation can explode the tire with possibility of injury and loss of life.
eCheck to see that the rim lines on both sides of the tire are parallel with the rim flanges.
I WARNING. 0 00 not operate the vehicle with the water and soap. or water still around the tire beads. They will cause tire separation, and a hazardous condition may result.
Tire Inspection eExamine the tire for damage and wear. Olf the tire is cut or cracked, replace it. o Lumps or high spots on the tread or sidewalls indicate internal damage requiring tire replacement. o Remove the any fore ign objects from the tread . After removal, check for leaks with a soap and water solution. oCheck the shape of the tread knobs. If no vertical side is left on the drive side of the knobs, replace the tire. Tire Inspection
Vertical Sides Worn Away 1. Rim Line
/_-~t
2. Rim Flange
elf the rim lines and the rim flanges are not parallel, deflate the tire, lubricate the sealing surfaces again, and reinflate the tire. eAfter the beads are properly seated, check fo r air leaks. Olnflate the tire to 35 kPa (0.35 kg/em 2 , 5 psi). Apply a soap and water solution around the tire bead and check for bubbles. eDefiate the tire to the specified pressure.
/ /
~ "" \
/' 1:-----..
I ;; I ~ ~_.. J. . I. . _+_
\
. \
WHEELS!TIRES 8-11 eGrease the lips of the hub end seal.
Front Hub
Front Hub Removal • Remove the cotter pin and loosen the hub nut.
Hub End Seal Lubrication
Grease
A. Hub Nut
B. Cotter Pin
eTighten the hub nut to the specified torque (see Exploded View). elnsert a new cotter pin (see Front Hub Removal).
ePull off the wheel (see Wheel Removal). eRemove the cal iper by taking off the mounting bolts, and let the caliper hang free. eRemove the hub nut and pull off the front hub.
Front Hub Disassembly/Assembly Note eDo not press the hub bolts out.
Front Hub Installation Notes
*If the hub bolt is damaged, replace the hub and bolts as a unit (see Front Hub Installation).
e Be sure to install the D·ring on the knuckle shaft after greasing the O-ring.
Front Hub Installation
Front Hub Bearing Removal Note eRemove the front hub. eRemove the grease seals, bearings and spacer pipe as follows. OPull out the collars on both sides. o Remove the grease seals using a suitable hook.
4
1. Front Hub 2 . Hub End Seal 3. D-Ring
4. Knuckle Shaft 5. Hub Bolts A. Collar
B. Grease Seal
8-12 WHEELS!TIRES o Pry the spacer pipe toward one side.
Front Hub Bearing Inspection
o Drive the bearing out by tapping on the exposed portion of the spacer pipe end with a hammer and
metal rod.
NOTE
OSince the bearings are packed with grease and sea/ed, they can not be lubricated.
e Remove the hub assembly (see Front Hub Removal). eTurn each bearing back and forth while checking for roughness or binding. *If roughness or binding is found, replace the bearing. eExamine the bearing seal for tears or leakage. *If the seal is torn or is leaking, replace the bearing.
Rear Hub Rear Hub Installation eGrease the axle splines.
eTighten the rear axle nut to the specified torque (see Exploded View). elnsert a new cotter pin.
1. Metal Rod Olnsert the spacer pipe into the hub assembly. ODrive out the remaining bearing by tapping on the spacer pipe with a suitable driver. eDeburr the spacer pipe as needed.
Front Hub Bearing Installation Notes elnstallation is the reverse of removal.
Note the fol-
lowing. eDrive either bearing into the hub assembly with the bearing driver set (special tool) until it bottoms out. The marked side of the bearing faces outboard . A. Ax le Splines
A. Bearing Driver Set: 57001·1129 eGrease the lips of the grease seals.
B. Cotter Pin
FINAL DRIVE 9-1
Final Drive Table of Contents Exploded View .....•... . . .. • .... ...
9·2
Specifications . . . . . . . . . ... .. . . .. . . . .
•
Special Tools . ......• ..• . . . • • • .....
94 94
Sealant . . . . . . . . . . . . . . .. . . . . . . . .. .
Final Gear Case Oil . . . . . . . . . . . ... ... . Final Gear Case Oil Level Inspection . . . Final Gear Case Oil Change . .. .. ... . Front Bevel Gears and Cam Damper . .. . .. . Front Gear Case Removal . . . . . . . . . . Front Gear Case Installation
• • • • • •
Rear Axle and
Installation . . . . . . . . . . . . . . . . . .
Ri n9 Gear
Differential Gear Assem~ly ... . .. . Final Bevel Gear Adjustment . .. . . . . .
•
Ball Bearing Inspection . ... . . . . . . . .
Cam Damper Inspection . . .. . . . . . . .
Propeller Shaft . ... .... . . . . . . .... . •. Propeller Shaft Removal ... .. .... • . Propeller Shaft Installation ... . .... . Propeller Shaft Lubrication . . . . . . . . . Propeller Shaft Joint and Pinion Joint Inspection . . . . . • . . . .
Propeller Shaft Inspection .. .. . . • ... Rear Axle Shafts .. .. .. . . . . . . . . . . _ .. .
• • •
Bevel Gear Inspection . . . . . . . . . . . . . Differential Gear Inspection . ..... . . Tapered Roller Bearing Inspection . .. . Ball Bearing Inspecti on . . . . . . . . . . . . Oil Seal Inspection . ... . . . . . ..... .
Differential Shift Mechanism .. .. . ... .. . . Shift Lever Case and Cable Removal .. .
• • •
•
• •
• 94
•
Cable Installation . . . . . . .. . . .. .
•
Shifter and Shift Fork Removal .. ... . Shifter and Shift Fork Installation . .. . Differential Cable Adjustment ... ... .
• • •
Differential Cable Lubrication . ... .. .
94
• •
Differential Cable Inspection . . .... . .
94
Shifter and Shift Fork Inspection .. .. .
•
• • • •
Shift Lever Case and
•
Rea r A xle and
Propelle r Shaft Removal .....• _ . .
• • •
and
Differential Gear Disassembly . ....
•
•
Oil Seal Inspection . . . . . . . . . . . . . . .
• •
•
Ring Gear and
Beve l Gear Inspection . .. . . . . . . . . . . T ape red Roller Bearing Inspection . .. .
Ball Bearing Inspection . . . . . . . .. .. .
Pinion Gear Assembly . . . . . . . . . . . .
•
• •
Front Bevel Gear Adjustment . . . . . . .
•
Pinion Gear Disassembly . . . . . . . . . . •
Front Drive Gear and Cam Damper Installation . ... . . . . . . . .
Axle Shaft Inspection . . . . . . . . .. . . . Oil Seal Inspection . . . . . . . . . . . . . . .
Front Driven Gea r and Cam
Damper Removal. . .. . ... .. . . . .
94
Final Bevel Gears and Differential Gears ... .
Fro nt Drive Gear Removal!
•
Propeller Shaft Installation . .. . . . . Axle Shaft Removal . ..........• . . Axle Shaft Installation ... . . ...... .
•
Base Manual
• •
9-2 FINA L DR IVE Exploded View
G : Apply grease. L : Apply non-permanent locking agent. o : Apply hypoid gear oil to the threads and seated surface. R : Replacement Parts SS : Apply silicone sealant. St : Stake the fastener . T1 : 25 N-m (2.5 kg-m , 18.0 ft·lb) T2 : 93 N-m (9.5 kg-m, 69 ft·lb) T3: 98 N-m (10.0 kg·m, 72 ft·lb) T4 : 12 N-m (1.2 kg·m, 104 in-Ib) T5: 20 N-m (2.0 kg·m, 14.5ft-lb) T6: 78 N-m (8.0 kg-m, 58 ft-Ib) T7: 29 N-m (3.0 kg·m, 22 ft-Ib) T8: 6.9 N-m (0.70 kg-m, 61 in-Ib)
I
®
~
=v,./
UK model,
~
Optional Parts for other than UK model
-~
~
~
~ ~~ .~ @
~-1
1. Front Gear Case 2. Drive Gear 3. Driven Gear
4. 5. 6. 7. 8.
Propelier Shaft Axle Shaft Pipe (Right) Axle Shaft (Right) Axle Shaft Pipe (Left) Axle Shaft (Left)
9. Final Gear Case
®
FINAL DRIVE 9·3
@
G
9-4 FINAL DRIVE Special Tools o Refer to the Base Manual noting the following additional tool.
Sealant
..............................................................................
Kawasaki Bond (Silicone Sealant): 56019-120
1. 2. 3. 4.
App ly silicone sealant. Axle Shaft Pipes Final Gear Case Final Gear Case Cover
Differential Shift Mechanism
Differential Cable Lubrication o Lubricate the differential cable in accordance with the Periodic Maintenance Chart, or whenever the cable is removed (see General Information chapter and General
Lubrication in the Appendix chapter). OUse the pressure cable luber to lubricate the cable.
Rear Axle Shafts
Axle Shaft Installation o Refer to the Base Manual noting the following. eApply silicone sealant (PN 56019-120) to the mating surface between the axle shaft pipes, the final gear case, and cover as shown.
BRAKES 10-1
Brakes Table of Contents Exploded View. . . . . . . . . . . . . . . . . . . ..
10·2
Master Cylinder Inspection . . . . . . . . .
Specifications. . . . . . . . . . . . . . . . . . . . ..
10-4
Brake Lever Lubrication . . . ... . . . . .
Special Tools. . . . . . . . . . . . . . . • . . • . .. Brake Adjustment. . . . . . . . . . . . • . . . • ..
10-4 10·5
Discs . . . . . . . . . . . . . . ... . ... . ... .. . Disc Installation Notes . . . . . . . . . . . .
Front Brake Lever
Disc Wear . . . . . . . . . . . . . . . . . . . . .
10-5
Free Play Inspection
Rear Brake Pedal
•
Free Play Inspection
Rear Brake Pedal Free Play Adjustment . . . . . . . . . . . Cam Lever Angle Adjustment . . . . . . . Parking Brake Cable Lubrication . . . . . Parking Brake Cable Inspection . . . . . .
Brake Fluid . . .. .. ..... .. . ... ... . . .
Brake Hose Installation Notes . . . . . . .
10·5 10·5
Bake Drums . . . . . . . . . . . . . . . . . . . . . . . Rear Brake Drum Removal . . . . . . . . .
• •
Calipers . .. ... .. ... . .. ... ... . . . . . . Caliper Removal . .... .. . . . . . . . . . Caliper Installation Notes . . . . . . . . . .
Caliper Disassembly Notes . . . . . . . . . Caliper Assembly Notes . . . . . . . . . . Caliper Fluid Seal Damage . . . . . . . . . Caliper Dust Seal and Cover Da'm age . . Caliper Piston and Cylinder Damage . . Caliper Holder Shaft Wear . . . . . . . . . Brake Pads .. ..... . .. ... ...... . .. . Brake Pad Removal .. . ..... . _ . . .
. . . . . . . .
Brake Pad Instal lation Notes . . . . . . . . Brake Pad Wear Inspection . . . . . . . . . Master Cylinder and Wheel Cylinders . . . . . . . Master Cylinder Removal . . . . . . . . . . Master Cylinder Installation . . . . . • .. . Master Cylinder Disassembly . . . . . .. .
Master Cylinder Assembly . . . . . . . . . .
Brake Hose Inspection . . . . . . . . . . . .
•
Brake Fluid Level Inspection . . . . . . . . Brake Line Air Bleeding _ . _ . . . . . . . .
Brake Hoses . ... . . . . . . . . . . .. ' .' . . . . . Brake Hose Removal . . . . . . . . . . . . .
• •
Brake Fluid Recommendation .. . . . . .
Brake Fluid Changing .. .. . . . . . . . . .
Disc Cleaning . .. . . . . . . . . . . . . . . . Disc Warp In spection . . . . . . . . . . . . .
Rear Brake Drum Installation . . . . .. . Brake Drum Wear . . . . . . . . . . . . .. .
•
Rear Brake Drum Disassembly! Assembly Note . . . . . . . .. . . ... . 10·10 Brake Panel Assemblies . . . . . .. " . . . . . . . . 10·10 Rear Brake Panel Removal ! Disassembly . .. . . . . . . . . .. .. . .
Rear Brake Panel Assembly/ Installation . . . . . . . . . . . . . . . . . . Brake Shoe Lining Wear . ... .. .. . . . Brake Shoe Spring Inspection . . . . . . . Brake Camshaft and
Camshaft Hole Wear .. ..•••... •• Brake Panel Lubrication . .. . . . . . . . .
Brake Pedal and Cables . . . . . . . . . . .....• Brake Pedal and Cable Removal ..... . Brake Pedal and Cable Installation . . . . Brake Cable Inspection . .. . . . . . . . . .
• •
Brake Pedal and Cable Lubrication . .. .
•
•
•
10·9
Rear Brake Drum Seal Wear . . . . . . . . . 10·10
• • 10·5 10·5 10·5 10·5 10·6 10·6 10·6 10·6 10·6 10·7 10·7 10·7 10·7 10·7
• 10·7 10·8 10-8 10·8 10·8 10·9 10·9 10·9 10·9 10·9 10·9
•
Base Manual
• •
• • • • • • •
• •
[!QI
10-2 BRAKES
Exploded View
A : Apply adhesive. G : Apply grease. l : Apply non-permanent locking agent. o : Apply oil. Si : Apply silicone grease . T1: 25 N-m (2.5 kg-m. 18 ft·lb) T2 : 20 N·m (2.0 kg·m, 14.5 ft·lb) T3: 8.8 N-m (0.90 kg-m, 78 in-I b) T4: 5.9 N·m (0.60 kg·m, 52 in·lb) T5: 7.8 N·m (0.80 kg-m, 69 in·lb) T6: 145 N-m (15.0 kg·m , 110 ft-Ib) T7: 29 N-m (3.0 kg·m, 22 ft-Ib) T8 : 1.0 N·m (0.10 kg-m, 9 in-Ib) T9: 37 N·m (3.8 kg·m, (27 ft·lb)
BRAKES 10-3
,
G
~.
@G
10-4 BRAKES Specifications Refer to the Base Mariual noting the following.
Standard
Item
Service Limit
DOT3 or 4
- --
Brake lever free play
Non-adjustable
- --
Pad lining thickness
4.5 mm
1 mm
Disc thickness
3.3 -3.7 mm
3.0 mm
Disc runout
0.2 mm or under
0.3 mm
Brake Fluid Grade Front Disc Brake:
Rear Drum Brake: Cam lever angle
80° - 90°
Drum inside diameter
160.000 - 160.160 mm
Special Tools Refer to the Base Manual noting the following. Jack: 57001-1238 OThis tool may be used instead of the common tool.
- -160.65 mm
BRAKES 10-5 Brake Adjustment
Front Brake Lever Free Play Inspection Disc or disc pad wear is automatically compensated for and has no effect on brake lever action . So there are no parts that require adjustment on the front brake. However if the brake lever has a soft, or "spongy
feeling," check the brake fluid level in the master cylinder and bleed the air from the brake line (see Bleeding the Brake in the Base Manual).
elf the caliper is to be disassembled after removal and if compressed air is not available, remove the piston using the following procedure. If both calipers are to be disassembled, be sure to do this procedure to both at the same time. o Remove the pads. o Temporarily reconnect .the brake hose to the caliper. The banjo bolt need not be torqued. o Pump the brake lever to remove the caliper piston. o lmmediately wipe up any brake fluid that spills. o Disconnect the brake hose from the caliper.
NOTE
OCheck the brake fluid level in accordance with the Periodic Maintenance Chart.
Caliper Installation Notes Parking Brake Cable Lubrication • Lubricate the parking brake cable in accordance with the Periodic Maintenance Chart, or whenever the cab le is removed (see Genera l Information chapter and General Lubrication in the Appendix chapter), OUse the pressure cable luber (special tool: PN 56019021) to lubricate the cable .
-Connect the brake hose to the caliper putting a new
flat washer on each side of the brake hose fitting . the fluid level in the reservoir and bleed the brake line (see Bleeding the Brake Line in the Base Manual). eCheck the brakes for good braking power, no brake drag, and no fluid leakage. eCh~ck
Parking Brake Cable Inspection eWith the brake cab le disconnected at both ends, the cable should move freely in the cable housing (see General Lubrication in the Appendix chapter).
Caliper Disassembly Notes -Using compressed air, remove the piston. o eaver the caliper opening with a clean, heavy cloth.
ORemove the .piston by lightly applying compressed air to where the brake line fits into the caliper.
Calipers
Caliper Removal
WARNING
eRemove the front wheels (see Wheel Removal in the Wheels/Tires chapter). eSeparate the brake hose from the caliper by taking off the banjo bolt. -Remove the caliper mounting bolts and take off the calipers.
A. Mounting Bolts B. Caliper
I
OTo avoid serious injury, never place your fingers or palm inside the caliper opening. If you apply compressed air into the caliper, the piston may crush your hand or fingers.
C. Front
1. Apply compressed air.
2. Cloth
10-6 BRAKES Anti-Rattle Spring Installation
Caliper Assembly Notes
I WARNING I OExcept for the disc pads and discs; use only disc brake fluid, isopropyl alcohol. or ethyl alcohol. for cleaning brake parts.
Do not use any other fluid for cleaning
these parts. Gasoline, motor oil, or any other petroleum distillate will cause deterioration of the rubber parts. Oil spilled on any part will be difficult to wash off completely, and will eventually deteriorate the rubber used in the disc brake.
-Apply brake fluid to the outside of the piston and piston rod , and the fluid seal, then push the piston into the cylinder by hand. Take care t hat neither the cylinder nor the piston sk irt gets scratched. elnstall the dust sea l around the front caliper piston. Check that the dust seal is properly fitted into the grooves in the piston and cal iper.
1. Anti-Rattle Spring
Caliper Fluid Seal Damage The fluid seal around the piston maintains the proper pad/disc clearance. If the seal is not satisfactory, pad wear will increase, and constant pad drag on the disc will raise brake and brake fluid temperature.
_ Replace the fluid seals under any of the following conditions: (a) fluid leakage around the pad; (b) brakes overheat; (c) there is a large difference in inner and
outer pad wear; (d) the seal is stuck to the piston. If the fluid seal is replaced, replace the dust seal as we ll. Also, replace all sea ls every other time the pads are
changed.
Caliper Dust Seal and Cover Damage -Check that the dust seals and covers are not cracked worn, swo llen , or otherwise damaged. _If they show any damage, replace them.
Caliper Piston and Cylinder Damage -Visually in spect the piston and cylinder surfaces.
*Replace the caliper if the cylinder and piston are badly scored or rusty.
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Caliper Brake Pad Brake Pad Caliper Holder Shafts Dust Cover Piston Anti-Rattle Spring Dust Seal Fluid Seal Friction Boot
Caliper Holder Shaft Wear The caliper body must sl ide smoothl y on the caliper holder shafts. If the body does not sl ide smooth ly, one pad will wear more than the other, pad wear will increase, and constant drag on the disc will raise brake and brake fluid temperature.
-Check to see that the caliper holder shafts are not badly worn or stepped, and that the rubber friction boots are not damaged.
eApply a th in coat of silicone grease to the caliper
holder shafts and holder holes.
(Silicone grease is a
special high temperature, water-resistant grease). -Install the anti-rattle spring in the calipers as shown.
*If the rubber friction boot is damaged, replace the rubber friction boot.
*If the caliper shaft is damaged, replace the caliper assembly.
BRAKES 10-7 WARNING
Brake Pads
I WARNING
I
OWhen handling the disc pads, be careful that no disc brake fluid or any oil gets on them. Clean off any fluid or oil that inadvertently gets on the pads with a highflash point solvent. Do not use one which will leave an oil residue. Replace the pads with new ones if they cannot be cleaned satisfactorily .
Brake Pad Removal -Remove the front wheel (see Wheel Removal in Wheels/Tires chapter). - Lift off the cal iper by taking off the mounting bolts . • Push the cal iper holder toward the piston side and then remove the pads.
I
o Do not attempt to drive the vehicle until a full brake lever is obtained by pumping the brake lever until the pads are against each disc. The brake will not function on the first application if this is not done .
Brake Pad Wear Inspection In accordance with the Periodic Maintenance Chart, inspect the brake pads for wear . • Remove the front whee ls in order to check the front brake pads. -Check the lining th ickness of the pads in each caliper. The pad thickness can be checked with the pad installed. *If the lining thickness of either pad is less than the service limit, replace both pads in the caliper as a set.
Pad Lining Thickness
Standard: Service limit:
4.5mm 1 mm
Front Brake Pad
1. Pad
2. Caliper Holder
1. Service Limit
2. Lining Thickness
Brake Pad Installation Notes -Before installation, clean the pads with a high-flash point solvent.
I WARNING I OWhen handling the disc pads or disc, be careful that no disc brake fluid or any oil gets on them. Clean off any fluid or oil that inadvertently gets on the pads or disc with a high-flash point solvent. Do not use one which will leave an oily residue. Replace the pads with new ones if they cannot be cleaned satisfactorily.
.Push the cal iper piston in by hand as far as it will go, and then install the pads.
Master Cylinder and Wheel Cylinders o Since the whee l cylinder is not on the model, the information of the wheel cylinder is omitted.
Brake Lever Lubrication Whenever the master cylinder is disassembled, or in accordance with the Periodic Maintenance Chart, per· form the following.
10-8 BRAKES e Lubricate t he brake lever by appl ying a light coati ng of silicone grease to th e brake lever pivot screw and th e contact with the piston.
-After installi ng the discs. check the disc runout. Co mpl etely clea n off any grease th at has gotte n on either side of th e d isc with a hi gh-flash point so lve nt. Do no t use one which will leave a n oil y resid ue.
Disc Wear eMeasure the th ickness of each di sc a t the point where it has worn the most . *Replace th e disc if it has worn pas t t he service lim it.
A. Apply grease.
Discs
I WARNING I OWhen handling the discs, be careful that no disc brake fluid or any oil gets on them. Clean off any fluid or o il that inadvertently gets on the discs with a high-flash point solvent. Do not use one which will leave an oily residue.
1. Brake Disc 2. Measuring Area
Disc Installation Notes
Front Disc Thickness
eTighten the disc mountin g Allen bol ts to the specified torque. The disc must be installed with th e chamfered hole side facing toward the front hub . The marked side must face o utward .
Standard: Service Limit:
3.3-3.7 mm 3.0mm
Disc Cleaning Poor brak ing can be ca used by o il on a di sc. O il o n a di sc must be cleaned off wit h a'1 oilless cleanin g fluid such as trich loroethylene o r aceto ne .
WARNING
A. Marked Side
I
OThese cleaning fluids are usually highly flammable and harmful if breathed for prolonged periods. Be sure to heed the fluid manufacturer's warnings.
BRAKES 10-9
Disc Warp Inspection
Brake Hose Inspection
e Jack up the vehicle so that the wheels are off the ground.
The high pressure inside the brake line can cause fluid to leak or the hose to burst if the line is not properly maintained. eBend and twist the rubber hose while examining it. *Replace it if any cracks or bulges are noted.
eFor front disc inspection, remove the front wheels, and
turn the handlebar fully to one side. eSet up a dial gauge against the disc as shown, and measure disc runout.
*If runout exceeds the service limit, replace the disc.
A. Front Brake Hose A. Brake Disc
B. Turn the disc by hand.
Disc Runout
Standard: Service Limit:
0.2 mm or under O.3mm
Brake Drums
Since the front brake drums are not on the model, the information of the front brake drum is omitted.
Rear Brake Drum Installation Refer to the Base Manual noting the following.
Brake
-Do not overgrease the inside seal lip of the brake drum seal.
Hoses
Brake Hose Removal Refer to the Base Manual noting that there is no metal pipe nipple and retainer on the model.
Brake Hose Installation Notes • Using a new copper washer for each side of the hose
fitting, tighten the banjo bolt to the specified torque (see Exploded View in this manual). eRun the brake hose according to the Wiring, Cable, and Hose Routing section in the General
Information
chapter. eBleed the air from the brake line (see Brake Line Air Bleeding in the Base Manual).
A. Brake Drum Seal
10·10 BRAKES Brake Drum Seal Lubrication
Grease
'-----<:- -----1 Do not grease here.
1. Rear Brake Oru m 2. Drum Bolt
Rear Brake Drum Seal Wear Refer to the Base Manual noting the following. eTighten the brake drum drain bolt to the specified torque (see Exploded View).
Brake Panel Assemblies . Since the front brake panels are not on the model, the information is omitted.
A. Drain Bolt
Rear Brake Drum Disassembly/Assembly Note eOo not press the drum bolt out.
*If the drum bolt is damaged, replace the drum and bolts as a unit .
SUSPENSION 11 ·1
Suspension Table of Contents Exploded View ... ...... .. .. .. . .. . .. . . .... .. . ........ . .... .
11-2
Specifications .. ....... . ... .. . . . ....... . . . .... . ...... ... .. .
11-3
Special Tools . .. . . ... ... . .. .. . .... .... .... .. . .. ....... .... .
11-3
Suspension . .. . . ... ... ....... .. . . . ... ...... . ........ ..... .
11-4
Shock Absorber Spring Force Adjustment .... . .... .. ..... .. .
11-4
Shock Absorber Removal .. . . . . . ..... ......... ..... . ... . .
*
Shock Absorber Installation .... . .... .. .. ... .... . ... . ... . .
*
Shock Absorber Assembly Note . . ... . ..... ... . . .. .. ..... . .
11-4
Front Suspension Arm Removal ... . .. ....... .......... .. . .
11-4
Rear Suspension Arm (Rod) Removal. ..... . . ......... . .... .
11-4
. Rear Suspension Arm (Rod) Installation ...... .. .. .. ...... . . .
11-5
Front Suspension Arm Disassembly ... .. ... . .... .. .. .. .. . . .
11-5
Front or Rear Suspension Arm Assembly Notes ....... . ...... .
11-5
Shock Absorber and Suspension Arm Inspection
*
Base Manual
*
[!II
11·2 SUSPENSION Exploded View
~(@-------(W
l
: Apply non-permanent locking agent. R : Replacement Parts W : Apply water, or soap and water solution .
, T1: 34 N·m (3.5 kg·m. 25 ft·lb) T2: 88 N·m (9.0 kg·m. 65 ft·lbl
t
I @------""@
SUSPENSION 11-3 Specifications Refer to the Base Manual noting the fo llowin g. Front Shock Absorber Spring Preload
Standard setting position: No.2
R""r Shock Absorber Spring Preload Standard setting position: No.2
Special Tools
Jack: 57001-1238
ORefer to the Base Manual no tin g th e following additi onal tool s.
Wrench (Owner's tool): 92110-1040, or Steering Stem Nut Wrench (special tool): 57001-1100
Inside Circlip Pliers : 57001-143
Bearing Driver Set: 57001·1129
11-4 SUSPENSION
Shock Absorber Assembly Note
Suspension
• Lubricate the rubber dampers with a soap and water solution when installing the rubber dampers.
Shock Absorber Spring Force Adjustment Refer to the Base Manual noting the following. o The spring adjusting sleeve on the front and rear shock absorbers have 5 positions so that the spring can be adjusted for different terrain and loading conditions. elf the spring action feels too soft or too stiff, ad just it in accordance with the following table. o Turn the adjusting sleeve on each shock absorber to the desired position with a wrench (Owner's tool or special tool: 92110-1040 or 57001-1100)
[CAUTIO~] o Do not lubricate the rubber dampers with engine oil or petroleum distillates because they will deteriorate the rubbers.
ePress the rubber dampers in using a suitable bearing driver in the bearing driver set (special tool: PN 57001-1129).
Spring Action Position
Spring Force
1
2 (sTD) 3 4 5
Setting
Load
Terrain
Speed
Soft
Light
Good
Low
j 1 1
Stronger
Hard
Heavy
Front Suspension Arm Removal
J Bad
1
High
e Remove the follow in g parts. Tie-Rod (see Tie-Rod Removal) Knuckle (see Knuckle Removal)
'1!:---;O/
~~
~ /
"
~
~
="
~~
/
~ ...v®«9Y
~~
®
~'-...~@~®
/
/~ A. Adjusting Sleeve (Rear Shock shown)
1. Knuckle
eCheck to see that each pair of adjusting sleeves (front two adj usting sleeves or rear two) are turned to the same relative position.
2. Tie-Rod
eRemove the upper suspension arm. eRemove the lower suspension arm by taking off the pivot bolts. eRepeat the same procedure on the other side of the vehicle.
WARNING' o If a pair of adjusting sleeves (front two adjusting sleeves or rear two) are not adjusted equally, handling
Rear Suspension Arm (Rod) Removal
may be impaired and a hazardous condition may
Refer to Suspension Arm Removal in the Suspension chapter in the Base Manual.
result.
.
SUSPENSION 11-5
Rear Suspension Arm (Rod) Installation
Front or Rear Suspension Arm Assembly Notes
o Suspension arm Installation is the reverse of removal. Note the following.
-When installing the rubber dampers into th e arm,
elnstall the center arms noting the installation direction.
lubricate th e outer surface of the dampers with a soap and water solution.
Center Arm Installation
o Do not lubricate the rubber dampers with engine oil or petroleum distillates because they will deteriorate the rubbers.
~I • •
ePosition the dampers in the arm as shown using a suitable bearing driver in the bearing driver set (special tool: PN 57001-1129) .
I
®
Front Suspension Arm Bushing Installation
1. Slotted hole faces the front. 2. Longer bracket faces the front.
Front Suspension Arm Disassembly • Remove the front suspension arm (see Front Suspension Arm Removal). eRemove the rubber bushings using a press and a suitable bearing driver in the bearing driver set (special tool: PN 57001-1129). eHolding the suspension arm with a vise, remove the
circlip and unscrew the knuckle joint.
t:--@ ,
1. Rubber Bushings 2. Circlip
3. Knuckle Joint
0 00 not remove the knuckle joint grease seal. packed with grease .
It is
1. Arm 2. Bushing
3.0.15 - 0.85 mm
STEERING 12-1
Steering Table of Contents Exploded View . ... ........ •... . ... . . ...... . .. ... . . .... ... .
12-2
Specification ................................. .... .... .... .
12-3
Steering ................... •.. ............... . . . ... . . .. ...
12-3
Handlebar Removal .... ......... .. ......... .. ..... ... .. .
*
Handlebar Installation .. .... .. ... .... .. . . . . ........ ... .. .
12·3
Handlebar Grip Removal .............. . ... . ............. . Steering Stem Removal ..... . .... ... . . .......... . .. . '. . . . .
* * *
Steering Stem Installation .. .. ....... . .... . . .......... . . . .
12-3
Tie·Rod Removal ... . .................... .. .. ... .. .. .. .
12-3
Handlebar Grip Installation ............ .. ............. . .. .
Tie-Rod End Installation Notes ... ...... ..... .. . . .. ....... .
12-4
Steering Knuckle Removal ... ...... . .... . . . . ..... . . . ... . .
12-4
Steering Knuckle I nstallation Notes . ... . .. .. . .. ...... . .... .
12·5
Steering Knuckle Stopper Adjustment .. ...•. ... ..•.. .......
* * *
Steering Inspection .. ......................... ... .... .. . Steering Stem Warp .. . . . ........ ...... ..... ... . ........ . Steering Stem Bearing, Tie-Rod Bearing, and
* .
Steering Knuckle Upper and Lower Joint Inspection .......•.
*
Steering Lubrication ...... . ... . ... .. ... .... . .......... . .
12-5
Base Manual
[gI
12-2 STEERING
E~~i~d;;d-v'i'~"""" '''''' '' ''''''' ' ........................ _... . ..................... ~......... A:A pp Iy adhesive G 'AppIy grease . . . Replacement P W ' A I arts . pp y. water ' or soap and water sol utlon.
R:
T1 : 20 N-m (2 0 k g m
T2: T3: T4: T5:
29 N-m (3'0 41 N.m (4 ' 25 N-m (2·2 5 88 N-m (9'0 .
k · , 14.5 ft-Ib) g-m, 22 ft·lb) kg·m, 30 ft-Ib) kg-m, 18.0 ft~b) kg·m , 65ft·Ib)
~a§§§)
__.JI®c;)l
~
.STEERING 12-3
Steering Stem Installation
Specification
Refer to the Base Manual noting the following. o When replacing the stem clamps, replace both clamps as a unit. el nstall the grease sea l facing the end rearward to
Steering Angle Right:
Left:
48
48
0
prevent the entry of dirt.
0
Steering
Handlebar Installation eHandlebar installation is the reverse of removal. Note
the following. elnstall the handlebar so that the angle of the handlebar matches the angle of the steering stem as shown.
A. Ribs and Grooves
B. Ends
eAlign the relief marks on the steering stem clamps.
A. Parallel
eTighten the holder rear bolts first and then the front bolts. When the holder is correctly installed, there will be even gap at the front and no gap at the rear after tightening,
A. Marks
• Rou te the cables, the wires, and the brake hose according to the Wiring, Cable, or Hose Routing section in the General Information chapter.
Tie-Rod Removal A. Front B. Even Gap
C. No Gap
e Remove the following parts. Front Fender (see Frame chapter in this text) Front Wheel (see Wheels/Tires chapter in this text)
12-4 STEERING _ Remove the following parts to free the tie-rod from the stress.
Front Shock Absorber (see Base Manual) Front Suspension Arm Pivot Bolts (upper)
Tie-Rod End Installation Notes -Check that the seal lip is on the shank. -Oil the bolt body. Tie-Rod End Installation
o A. Upper Suspension Arm Pivot Bolts B. Shock Absorber
1. Seal Lip 2. Shank _ Remove the cotter pin and the tie-rod end nut at the steering knuckle . • Remove the cotter pin and the tie-rod end nut at the steering stem. -Install a suitable spare nut on the tie-rod end and tap the nut to remove the tie-rod.
3. Apply oil
Steering Knuckle Removal -Remove the following parts. Front Wheel Hub (see Wheels/Tires chapter in this text) Tie-Rod (see Tie-Rod Removal) Stone Guard • Remove the cotter pins, then remove the steering knuckle upper and lower joint nuts.
o Do not loosen the locknut of the steering knuckle stopper bolt. or the bolt will turn and the steering knuckle stopper adjustment may be necessary.
A. Tap the spare nut.
OWhen removing the tie-rod, be careful not to bend it. o Do not loosen the locknuts at the end of the tie-rod adjusting sleeve. or the toe~n of the front wheels will be changed. aDo not remove the grease seal. It is packed with grease.
A. Steering Knuckle Stopper Bolt
STEERING 12-5 -Tap the steering knuckle and remove it.
Knuckle Joint Installation
Good
Not good
o
o
A. Tap the steering knuckle.
Steering Knuckle Installation Notes o The installation is the reverse of removal. Note the following. -Clean the sealing surfaces, and the tapered holes.
1. Shanks
2. Seal Lips
-Tighten the knuckle joint nuts to the specified torque (see Exploded View).
Steering Lubrication Refer to the Base Manual noting the following. -Grease the steering stem clamp mating surface, too .
A. Sealing Surfaces
B. Tapered Holes
_Clean the shanks of the knuckle joint. _Check that the grease seal does not have tear, wear, deterioration, or grease leakage. _Check that the seal lip is on the sealing surface of the
shanks as shown .
FRAME 13·1
Frame Table of Contents Exploded View ........................................... . Seat ..... .. . . . . .... .. ... . ... .. ..... .. ... •.. .. ..... . .... .. Seat Removal .. .......... . ..... .. .... . ... .. . . .. . ... .. . Seat Installation ... ..... .. . . . .. . ..... .. ........... .... . Front and Rear Fenders .. . . .. ....... ..... . .. .... .... ...... . .
13-2 13-4 13-4 13-4 13-4
Front Fender Removal ... . . . ............ .. ......... . .. . . Front Fender Installation Notes .. .. ••• .. . . . .... ... ........ Front Carrier Removal ..... . ......... . . ... ..... . ..... . . . Rear Fender Removal ...........•....................... Rear Fender Installation Notes ........................... .
13-4
Rear Carrier Removal .................................. . Frame Exchange ........ .......... .. . ... ... ... ...... . ..... . Suggested Parts Removal Order. .......................... . Suggested Parts Installation Order. ... ... . . ....... .. .. . .... . Decals .................................................. . Decal Removal ... . ....... .. . . .... .. .. ........ . ...... . . Decal Application . ...... ...... . .. ........... . . .. ...... .
13-6
* : Base Manual
13-5 13-5 13-5 13-6
*
* * * *
*
13-2 FRAME Exploded View
............................................................................. Front Carrier
1. 2. 3. 4. 5. 6. 7.
Bolts, Washers, 8 x 16 Flanged Bolts, 8 x 20 Flanged Bolts, 6 x 16 Bolts, Washers, 8 x 16 Bolts, Washers, 6 x 18 Bolts, Washers, 8 x 14 Bolts, Washers, 8 x 18
,
,,, ,: ,
~
-
: @ - - - - Australia Model
Canada Model KLF300-B6-
~---
Rear Carrier
KLF300-B 1,B2,B6 -
,, ,
Europe Model KLF300-B4-
r-.
UK Model KLF300-B3-
,,
(/ ~~
.:"'%::-
,, I
='1/",,,/
,"'''''''-,.-r
KLF300-B3-
KLF300·B3r----------- --,
,
,
~--- -- ----- --- -~
'. ')
FRAME 13-3
~
®
(ij - '
8
8. Screws 6 x 14 9. Black Screws 6 x 18 ~~. Bolts, Washers 6 x 18 . Bolts, Washers 6 x 20
~. ~
@-'ff~
'"
&1. - <$><>d~ •
- y~® .~
@
rK!-~~??~B}-
134 FRAME
.............................................................................
..............................................................................
Seat
Front and Rear Fenders
••••••••••••••••••••••••••••••••••••••••••••••••••••••• 0.0 ••• ••••••••• •• ••• 0 '
Seat Removal
Front Fender Removal
-Pull the seat lock lever up .
- Remove the follow ing parts. Seat (see Seat Removal) Fuel Tank Tail Cover (with Two Screws) Fuel Tank Cap
WARNING' o Gasoline is extremely flammable and can be explosive under certain conditions. Turn the ignition switch OFF.
Do not smoke.
Make sure the area is well
ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light.
Fuel Tank Upper Cover (with Two Screws) Front Carrier (see Front Car rier Removal) Fuel Tank Side Cover (just pull it out)
A. Pull.
-Lift the rear of the seat, slide it toward th e rear slightly, and lift it off the veh icle.
Seat Installation -Slip the seat hook under the brace o n the frame, and put the stoppers in to the holes in the frame. A. Fuel Tank Side Cover B. Fuel Tank Upper Cover with Two Screws C. Fuel Tank Tail Cover with Two Screws
-Install the fuel tank cap at once. ORe move the mounting screws and take off the side covers.
A. Brace B. Seat Hook
C. Stoppers D. Holes
-While pushing the rear part of the seat down, push the seat lock lever down until the lock clicks.
A. Side Cover
B. Screws
FRAME 13-5 e Remove the front fender mounting bolts and flanged collars, fo ur screws and nuts of the mud flaps.
Front Carrier Removal
eJ ust remove the following six bolts.
A. Mounting Bolts A. Mounting Bolts B. Remove these screws (both right and left sides).
Rear Fender Removal eRemove the four mounting bolts of the fender front
part.
eRe move the follow ing parts. Seat (see Seat Removal) Eight Rear Fender Mounting Bolts including the Bolts in the Storage.Case
A. Six Mounting Bolts
B. Storage Case
A. Mounting Bolts
eTake off the front fender along with the carrier.
Front Fender Installation Notes o Installation is the reverse of removal. eFit the tabs on the front fe nder cover and the fuel tank side cover in place.
A. Two Mounting Bolts in the Storage Case
elnstall the mounting screws, bolts, nu ts, and flanged
collars in the original positions (see Exploded View).
eTake off the rear fender along with the carrier.
13-6 fRAME
Rear Fender Installation Notes • Rear fender installation is the reverse of removal. Note
the following. _ Be sure the rubber plug is in place in the bottom of the storage case .
-Fit the front fender tabs into the slits in the rear fender. elnstall the mounting screws, bolts, nuts, and flanged
collars in the original positions (see Exploded View).
Rear Carrier Removal - Just remove the following eight bolts.
A. Carrier Mounting Bolts (8)
ELECTRICAL SYSTEM 14-1
Electrical System Table of Contents
Precautions . . . . . . . . . . . . . . . . . . . . . . .
•
Exploded View .......... ..... •..... KLF300-B1 Wiring Diagram ... .. ...... . Specifications . . ..... .. . . . . . . ... ... . Special Tools .... .. . . . .•. . .. . • ..... Battery ..... . . . .... . .... . .. • .....
14-2 14-4 14·5 14·5 14·6
Part Removal . . . . . . . . . . . . . . . . . . . .
Precautions . . ...... . ... ... . .... .
•
Battery Removal/Installation . . .... ... . Battery Removal ... .. ......•....
14·6
Starter Button Installation ... .. .. . .
Battery Installation . .... . . . . . . . . . .
14-6
Starter System Checkout . . . . ... ... . . Starter Motor Brush Length ........ .
Electrolyte ... .. .... . .. .. ...• .... Electrolyte Level inspection . .. .... .
Battery Charging .... . . . . . . . . . • .... Battery Condition ...... . .... . .. . Battery Initial Charging .. ....•.... Battery Ordinarily Charging.....• . .. Battery Test Charging . . . . . . . . . ... . Charging System ...... . .. .. ...... .. . Part Removal . . . . . . . . . . . . . . . . . . . . Alternator Rotor Removal . . . . . .. . .
Alternator Rotor Installation ....•... Alternator Stator Removal . . . . . . . . . Alternator Stator Installation . . . . . . . .
Charging System Checkout . . . . . . . ... . Charging System
Ignition· Coil Removal .. . . . . . . . . . . Ignition Coil Installation . . . . . . . . . . .
Spark Plug Removal or Installation ... . Pickup Coil Removal ..... .... ... . Pickup Coil Installation . . . . . • . . . . . Ignition System Checkout . ..... • •.... Ignition Timing Test . . . . . . . . . . .. . Ignition Coil Inspection . . . . . . . . . . .
Spark Plug Cleaning and Inspection ... . Spark Plug Gap . . . . . . . . . . . .. . . . . IC Igniter Inspection . . . . . . . . •... . Pickup Coil Inspection . . .... . •.... Alternator Rotor Inspection . . . . . . . .
Starter Motor Commutator Inspection . . Starter Motor Armature Inspection . . . .
Brush Assembly Inspection ...... .. .
•
Starter Relay Inspection . . ... . . . . . .
14·6
Starter Circuit Relay Inspection . . . . . .
•
14-6 14-6 14-6 14-6
• •
14·8
14·8
. . . . .
Starter Motor Brush Spring Tension . . .
14·6 14·6
Stator Coil Resistance Inspection . ... .
Ignition System ..... . . ... ... .... .•. Safety Instructions ..... ... ... .. .. Part Removal . . . . . . . . . . . . . . . . . . . Engine Stop Switch Removal ... .... Engine Stop Switch Installation .....
Starter Button Removal . .. ... . . .. .
• •
•
Regulator Circuit Inspection . . . . . . . .
Starter Motor Removal . . . . . . . . . . • •
Starter Motor Installation ... . ... .. . Starter Motor Disassembly ........ . Starter Motor Assembly .. .. . .. . • •.
•
Operational Inspection . . . . . . . . . . Rectifier Circuit Inspection . .. . . . . . .
Electric Starter System . .. ... ". . . . . . . . . .
• •
Starter Button Inspection . .. . . .. .. .
Lighting System ....... .. .. ........ Headlight Beam . . ....... .. ... . ... Headlight Beam Vertical Adjustment .. Bulb Replacement. ..... . ...... ... Headlight Bulb Replacement ....... Taillight Bulb Replacement ..... ... Neutral and Reverse Indicator Light Bulb Replacement ... ....... .... Part Removal . ... . ....... ....... Light Switch Removal .... .. . .. . . Light Switch Installation .... .. . . ..
• •
14·8 14·8 14·9
• •
14·9 14·9 14·5
• •
14·9
• •
. . . .
Neutral and Reverse
• • • • •
Switch Installation ..... . . ..... .
•
Ignition Switch . . . . . . . . . . . . . . . . . . . . .
14·11
•
14·8
• • • • • • • • • • • • • • • •
. 14·11 . 14·11 . 14·11 • . • . • .
Neutral and Reverse Switch Removal ..
14-8
14·10
Ignition Switch Removal or Installation . . . . . . .. . . . . . . . . . . 14·11 Switches . . . . . . . . . . . . . . . . . . • . . . . . . 14·11 Neutral and Reverse Switch Inspection . ... . . . . . . .. . 14-11 Ignition Switch, Light Switch, Engine Stop Switch, Starter Button, and Fan Switch Inspection ..... 14-11 Cooling Fan System (UK Model) .. . ....... ..... . . . .. . 14-12 Cooling Fan Installation ......•.... 14·12 Fan Motor Inspection . . . . . . . . . . . . . 14·12 Electrical Wiring . .. . . . . . . . . . . . . .... . Wiring Inspection ... .. • . . . . . . . . .
*
Base Manual
• •
[HI
14-2 ELECTRICAL SYSTEM
............................................................................. Exploded View
.............................................................................
~~
~g
@
" ()
®
@
~
.~
/~
3
eg
(Do not apply oil)
"-
®
® T1 : T2 : T3: T4 :
59 N-m (6_0 kg-m, 43 ft-Ib) 27 N-m (2_8 kg-m, 20 ft-Ib) 4.4 N-m (0_45 kg-m. 39 ft-Ib) 7_8 N-m (0_80 kg-m, 69 in-Ib)
ELECTRICAL SYSTEM 14-3
g;l
_
I~I
LJ~
IjJI~ ~
i
I
~~ !
ld
,
l
1. 2. 3. 4. 5. 6. 7.
Pickup Coil Regulator/Rectifier Neutral and Reverse Switch Starter Relay Starter Circuit Relay IC Igniter Ligh~ Switch and Engine Stop Switch
8. Igmtlon Switch
9. Cooling Fan Switch
-
I
______ -.J
............................................................................. Wiring Diagram .............................................................................
=l~
Ig"lIIon SwitCh
A
~ 9
Reve". IndiCator LI9hl12V3W
"., A""'''" L,,'n
,12V65/60W _
~
r-
~
3: Sp.rk Plug
i i
. .. _j' ___ _ _ _ __ _"-_ Q?
~..:!i
"
R
-------,
8K/Y _
--J
US model KLF300-B4-
I
---BL - - - - 0
,- -
~
_
L
11--'
.,,"
RtT_ ------c.pII" _ _....
-
L:= " V:,II.,= II
/I 8" 1_ _ _ _ .. I
J
"""" 0,""
:II
". ".
l ;;<--0<.-- ..'"
I HUdllytll
~
i~
"'lJ ~"1 "' ,,' 1", ~::...-J' :, ,~~·f :~ -~~:~""' ,!~ I.....
Accessory Terminals
o
r-
m
an " '8R~8R ,.~,.~ ':'B~ L
r- - -
~..:~
m
"J
" ----=- " -+-1-+-1-
H
COli
~
R,guletorl Rectlfl'r
•
II
~
PICkUp
~:i~li
, " "
Neutral I ndicator Ught12VlW
.j,.
UK, Australia model fKLF300-81 - 83) Altlmeto.
.H
.,....
US, Canada model fKLF300-81 _)
..
,
'
,,_
,'.''''
.. ~ ..
-
' ~Il--'
•
D
.
~8l-
Fin
II
.,,_
:1'1' 1
I
::=J
:
AceelSo.y
r Te rmln llS
~
'"
~-
-
~
H'
Ru~l
511r\e, Blltton
l~FF
1.1
Eniline Slop Switch Light Switch
0'"
~
ILO
["f":. :C
"v.w., '
II
. ~ " -"1 _.. . ~
:
'
- "" --.. ,".......;;;
::ii;
---1
UK model only
r----
Taillight
R
•
L
,
_______
- --l
LO;:.'
Color Code Black Blue Brown Green Gray Light Blue Light Green 0 Orange P Pink R Red W White Y Yellow
BK BL BR G GY LB LG
(98051·1043D,10a8A,1225B)
ELECTRICAL SYSTEM 14-5
Specifications
Special Tools
Refer to the Base Manual noting the following.
Refer to the Base Manual noting the following. TIming Light: 57001·1241
Battery 12 V 14 Ah Capacity: 1.28 @20°C (68°F) Specific gravity: Electrolyte volume: 0.9L
OThis tool may be used instead of the common tool.
Charging System Battery charging coil resistance: 0.1 - 0.7
n
Ignition System
Spark plug cap resistance: 3.75 - 6.25 kn Ie igniter resistance: in this text Ignition coil resistance (with the spark plug cap removed) Primary winding: 1.8 - 2.8 n Secondary winding: 10 - 16 kn
Coil Tester: 57001-1242 Ignition Coil Winding Resistance
OThis tool may be used instead of the Kawasaki Electrotester (PN 57001-980). "
CD
o o
Spark Plug Wrench (Owner's Tool): 92110-1109
1. Measure primary winding resistance. 2. Measure secondary winding resistance. 3. Ignition Coil
Flywheol Puller: 57001-1191
14-6 ELECTRICAL SYSTEM Battery
Charging System
Battery Removal/Installation: Battery Installation
Part Removal: Alternator Rotor Removal
Refer to the Base Manual noting the following. -Install the battery so that the terminal side faces the front. • Route the battery vent hose and wiring according to the Wiring, Cable, or Hose Routing section in the General Information chapter.
eRemove the left engine cover (see Left Engine Cover Removal in the Engine Left Side chapter). eThread the flywheel puller (special tool: 57001·1191) and rotor puller (special tool: 57001-1099) onto the alternator rotor. eHolding the flywhee l puller, turn the roto r pu ller until the alternator rotor is forced off the end of the crankshaft.
I WARNING' o Keep the battery vent hose outlet away from the frame and brake system components. Battery electrolyte will corrode and weaken them. Do not let the vent hose become folded, pinched, or melted by the exhaust system. An unvented battery will not keep a charge and it may crack from built-up gas pressure.
Olf the rotor is difficult to remove and a hammer is used to tap the rotor puller. be careful not to strike the rotor itself. Striking the ro.t or can cause the magnets to lose their magnetism.
Alternator Rotor Installation eAlternator rotor installation is the reverse of rem oval. Note the following. eelean the inside of the rotor and the end of the crankshaft thoroughly or the taper will not fit sn ugly. -Fit the rotor onto the crankshaft so that the woodruff key fits in the groove in the hub of the rotor. -Install the left engine cover (see Left Engine Cover Installation in the Engine Left Side chapter) . -Clean the alternator rotor bolt, tighten the alternator rotor bolt to the specified torque (see Exploded View).
Battery Charging: Battery Condition o Refer to the Base Manual noting the fo ll owing. *If the specific grav ity is below 1.200, the battery needs to be charged.
Battery Ordinary Charging o Refer to the Base Manual noting the following. -Set the charging rate and time according to the battery condition previously determined (see Battery Condit ion), using the table.
Battery Charging RatelTime Table (12V 14Ah) 1.28 ~ Fully Charged
1.24
at 1 A charge rate at 2A charge rate at 3A charge rate at 4A charge rate
10
5
I
2
7
5
3
1
15 0
3
4
2 3 Hours of Charging Time at Rates Shown
, 9
20 21 I
10.5
0
5
6
4
7 5.3
ELECTRICAL SYSTEM 14-7 Charging and Lighting Circuit
ON
BR
BR
OFF
Q)
w
w
w
BR
BK/Y
a:
B G
®
r1
6 Pin Connector
-!l
@ I
~
r'\ ,"
~
>
;;:
"
+
-
d R/BK
IL-_-r...r::i
R/BK BR
BR
~_---I~
R
7'T BK/Y
R/B~ mL...:B::.:K1::.Y~)C:r-=B::.:K:.;/Y~
~
OFF
o""-.J,~ HI
0
ILO @
r-~~l
I
A ~
@
L-
R/Y R
R V'-'
1. Ignition Switch 2. Reverse Indicator Light 3. Neutral Indicator Light 4. Neutral and Reverse Switch
5. Alternator
A. Headlight Connectors, Ignition Switch Connectors, and
Light Switch Connector
6. 7. 8. 9. 10.
Regulator/Rectifier Diodes Thyristers Control Unit 30A Fuse
A. Regulator/Rectifier
11. 12. 13. 14.
BK/Y
Battery Light Switch Headlight Taillight
14-8 ELECTRICAL SYSTEM
Charging System Checkout: Stator Coil Resistance Inspection eRemove the seat (see Frame chapter) . eDisconnect the a lternator connector. eMeasure the stator coil resistance. OConnect the hand tester (special too l: PN 57001-1394) between the yellow leads. OSet the hand tester to x 1 n range, and read the tester.
e Pull the spark plug lead off the spark plug. eDisconnect G/W lead and Y/R lead from the coil. eTake off the nuts and remove the coil.
Stator Coil Resistance
0.1 -0.7
n
Front
B. Front
A. Ignition Coil
¢=J Ignition Coil Installation Refer to the Base Manual noting the following. 1. Alternator Connector
*If the tester does not read as specified, replace the alternator stator. *If the coil has normal resistance, but the voltage inspect showed the alternator to be defective; then the rotor magnets have probably weakened, and the rotor must be replaced.
A. Front B. Y/R Lead
C. G/W Lead
Polarity of Ignition Coil
(-)
Ignition System Part Removal: Ignition Coil Removal . e Remove the fuel tank (see Fuel System chapter in this manual).
!I
1 9~ o
l _____
8 ~-=-J~ G) .
green/white lead Connect Connect yellow/red lead
ELECTRICAL SYSTEM 14-9
Spark Plug Removal or Installation
Ie Igniter Inspection
- Remove or install the spark plug using the spark plug wrench (e.g. owner's tool) from the vehicle right side. -Tighten the spark plug to the specified torque (see Exploded View).
o Refer to the Base Manual noting the following. -Set the hand tester (special tool) to the x 1 kU range.
Ie Igniter Range xl kU G/W
".J• 0
Y/R
I 0
>
"
·0 0~o
BK/W
Zt;
,0 00
i§ t-u
BL (BK/W)
A. Spark Plug Wrench (Owner's Tool): 92110-1109
Unit: kU
Resistance*
Tester Positive (+) Lead Connection G/W
~ 330 0.8 8.0 50500 0.8 8.0
Y/R
BK/W
BL
(BK/W)
=
=
=
=
215
60500 30300
215
~
30 300
~ 1.212.0 70550 1.2 12.0
~ 30 300
30 300
0
0
~
• Measure with the Kawasaki Hand Tester (PN 57001 1394). A tester other than the Kawasaki Hand Tester may show slightly different readings.
Ie
Igniter Terminal
Ignition System Checkout:
Ignition Timing Test eRemove the ignition timing inspection plug.
-Attach the timing light (special tool: PN 57001-1241) and a tachometer in the manner prescribed by the manufacturer. _Start the engine and aim the timing light at the timing light mark on the alternator rotor. • Run the engine at the speeds specified and note the alignment of the timing marks.
Y/R
~
(BK/W)
G/W
~~
BL BK/W
A. Advanced Mark B. F Mark
C. Top Mark D. Timing Inspection Hole
A. IC Igniter Connectors
14-10 ELECTRICAL SYSTEM Ignition System Circuit ~---------------BK/Y --------------~
.----Y/R--11;::===t--, BK BL
rLf
ON
ON
-
;;: L?
~ ~FF~-'
U@ '" '"
(5)FF
~Q)
r
-o<~
®
®
r
>-L?
(j)-
1
~ ~ ~ r-'
1. Battery 2. 30A Fuse 3. Ignition Switch 4. Engine Stop Switch
Electric Starter System
5. 6. 7. 8.
Pickup Coil Igniter Ign ition Coil Spark Plug
Refe r to the Base Manual, noting the fo llowing. Electric Starter Circuit
CD
~-----W---~~~--W-~
*\
OFF
TON a:
~ a:
~
4
a:
:
a:
~
I
p"'---" '" ;~;"'
-'" >~
a:
'" > OFF
T 1. Ignition Switch 2. Starter Circuit Relay 3. 30 A Fuse
®
RUN
o 4. Starter Button 5. Engine Stop Switch 6. Neutral Switch
7. Starter Motor 8. Starter Relay 9. Battery
ELECTRICAL SYSTEM 14·11
Ignition Switch, Light Switch, Engine Stop Switch, Starter Button, and Fan Switch Inspection
Lighting System Headlight Beam:
Headlight Beam Vertical Adjustment eLoosen the headlight mounting knobs and move the headlight up or down to adjust the headlight vertically.
-Refer to the Base Manual noting the following. -Remove the fuel tank front cover (see Fuel Tank Removal in the Fuel System chapter in this manual). -Unfasten the upper strap of the vinyl cover and open the velcro.
A. Headlight Mounting Knobs
A. Strap
B. Vinyl Cover
-Tighten the mounting knobs .
............................................................................. Ignition Switch
............................................................................. Ignition Switch Removal or Installation GRefer to the Base Manual noting that the rubber damper and the bracket are not on the model.
Switches A. Ignition Switch Terminals: BR, W B. Light Switch, Engine Stop Switch, and Starter Button
Neutral and Reverse Switch Inspection
Connector
GRefer to the Base Manual noting the following. -Remove the seat.
Neutral and Reverse Switch Inspection Gear Position
G
Ground
R
Ignition Switch Connections
1 st through 5th
W
Neutral
Reverse
OFF (
ON
C
BR
I
J
14-12 ELECTRICAL SYSTEM Wire Connections
Light Switch Connections BR
R
R/Y
R/BK
OFF LO
BL +-> Battery (+) BK/Y +-> Battery (-)
oThe fan should rotate counterclockwise when it is viewed from the rear.
HI
Engine Stop Switch Connections
Y/R
BR
OFF RUN To Starter Button
Starter Button Connections BK
Y/R
Pushed Released
1. Rotation Direction To Engine Stop
*If the fan does not rotate at this time, the fan is defective and must be replaced. Fan Switch Inspection (U K Model) BR ON
[ WARNING.
BL
OFF
c
o Be careful not to touch the fan blades to avoid injury . *If the fan rotates, inspect the fan switch or the wiring (see Electrical Wiring section in the Base Manual and Switches section in this manual). Cooling Fan System BK/Y BR
~
Cooling Fan System (UK Modell
'"
@~
Cooling Fan Installation -Install the cooling fan and connect the leads according to the Wiring, Cable, or Hose Routing section in the General Information chapter.
a:
(?)
'"
~
+ Fan Motor Inspection -Unfasten the upper strap of the vinyl cover and open the velcro (see Switches section) . • Disconnect the fan lead connectors. -Using two auxiliary wires, supply 12 V battery power to the fan.
~BRj ®L
> ~
BL~ BL
CD 1. Battery 2. 30 A Fuse 3. lOA Fan Fuse
-'"
4. Fan Switch 5 . Cooling Fan
@
APPENDIX 15-1
Appendix Table of Contents Considerations for Various Riding Conditions.................... . Carburetor ................ .. ... . .. ... .... . ...... . .. . .. . . Spark Plug ..... .. . ... ......... . ..... .. .. ..... ......... . . Spark Plug Inspection ...... . ... . . ... ........... ... . .. . . . Troubleshooting Guide . .. .. . .... . ... . ... .. . .. .............. . General Lubrication ....... .. . . ........... .. .... . . ... ...... . Lubrication .. ..... ........ ............. .... ....... .. . . Bolt and Nut Tightening ................. .... . .. ............ . Tightness Inspection . ..... . . . . . ... . ........ . . . . . .. . .... . Unit Conversion Table .. . .................... . ....... ... ... . .
* : Base Manual
15-2 15-2 15-2 15-3 15-3
15-4 15-4 15-4 15-4
*
15-2 APPENDIX
Considerations for Various Riding Conditions
Spark Plug
This vehicle has been designed and manufactured to operate under a wide range of riding conditions. However, it is not feasible to anticipate all of the conditions under which this vehicle might be used. Extremes of temperature, altitude, and riding usage may make
changing some carburetor parts or the spark plug desirable to maintain the vehicle in peak operating condi-
tion.
Carburetor: Sometimes an alteration may be desirable for good performance under different riding conditions when proper mixture is not obtained after the carburetor has
been properly adjusted, and all parts cleaned and found to be functioning properly. If the engine still exhibits symptoms of overly rich or
Reach
Plug gap
lean carburetion after all maintenance and adjustments are correctly performed, the main jet can be replaced
with a smaller or larger one. A smaller numbered jet gives a leaner mixture and a larger numbered jet a richer mixture.
1. Terminal 2. Insulator 3. Cement
4. Gasket 5. Center Electrode 6. Side Electrode
Spark Plug: The spark plug ignites the fuel and air mixture in the combustion chamber. To do this effectively and at the proper time, the correct spark plug must be used, and
A spark plug for higher operating temperatures
the spark plug must be kept clean and the gap adjusted. Tests have shown the plug listed in the General Information chapter to be the best plug for general use. Since spark plug requirements change with the igni-
sometimes may be needed for severe conditions, such as continuous high-speed riding, or towing heavy loads.
tion and carburetion adjustments and with riding conditions, whether or not a spark plug of the correct heat
Such a plug is designed for better cooling efficiency so that it will not overheat and thus is often called a "colder" plug. If a spark plug with too h;gh a heat range is used - that is, a "cold " plug that cools itse lf too well,
range is used should be determined by removing and inspecting the plug. When a plug of the correct heat range is being used, the electrodes will stay hot enough to keep all the carbon burned off, but cool enough to keep from damaging the engine and the plug itself. This temperature is about 400 - 800°C (750 - 1 ,450° F) and can be
coating the ceramic in sulator or bridging across the gap. Such a short will prevent an effective spark. Carbon
judged by noting the condition and color of the ceramic insulator around the center electrode. If the ceramic is
can heat up red-hot and cause preignition and knocking,
clean and of a light brown color, the plug is operating at the right temperature.
- the plug will stay too cool to burn off the carbon, and the carbon will collect on the electrodes and the ceramic insulator. The carbon on the electrodes conducts electricity,
and can short the center electrode to ground by either
build-up on the plug can also cause other troubles. It which · may eventually burn a hole in the top of the piston.
APPENDIX 15-3 Spark Plug Condition
Oil fouling
Carbon fouling
Spark
Plug
Normal operation
Overheating
Standard Spark Plug Threads
Inspection
• Remove the spark plug and inspect the ceramic insulator. *Whelher or not the right temperature plug is being used can be ascertained by noting the condition of the ceramic insulator around the electrode. A light brown color indicates the correct plug is being used. If the ceramic is black, it indicates that the plug is firing at too Iowa temperature, so the next hotter type should be used instead. If the ceramic is white, the plug is operating at too high a temperature and it should be replaced with the next colder type.
Diameter:
12 mm
Pitch:
1.25 mm
Reach:
19.0 mm
NOTE o The heat range of the spark plug functions like a thermostat for the engine.
Using the wrong type of
spark plug can make the engine run too hot (resulting in engine damage) or too cold (with poor performance, misfiring and stalling).
[i;AUTIO~] a lf the spark plug is replaced with a type other than the standard plug, make certain the replacement plug has the same thread pitA:h and reach (length of threaded portion) and the same insulator type (regular type or projected type' as the standard plug. a lf the plug reach is too short, carbon will build up on the plug hole threads in the cylinder head, causing overheating and making it very difficult to insert the correct spark plug later. o If the reach is too long, carbon will build up on the exposed spark plug threads causing overheating, preignition, and possibly burning a hole in the piston top. In addition, it may be impossible to remove the plug without damaging the cylinder head. Plug Reach
Too Short
Correct Reach
Troubleshooting Guide Refer to the Base Manual, noting the following.
Engine Doesn't Start, Starting Difficulty Recoil starter not operating Recoil starter springs broken Recoil starter pawl not engaging
Overheating Cooling fan won't turn over (U K model) Cooling fan fuse broken Cooling fan switch trouble Cooling fan motor broken Cooling fan damaged Cooling fan broken
Brakes Don't Hold
Carbon builds up here
Front Brake Air in the brake line Brake fluid leak Brake fluid deteriorated Primary or secondary cup trouble Master cyl inder scratched inside Brake not properly adjusted Pad overworn or worn unevenly Oil, grease on pads and disc Disc worn or warped Brake overheated
154 APPENDIX Rear Brake
Brake not properly adiusted Linings Qverworn or worn unevenly Drum worn unevenly or scored
Oil, grease on lining and drum Dirt, water between lining and drum Overheated
Bolt and Nut Tightening
Tightness Inspection Refer to the Base Manual noting the following. Bolts, Nuts, and Fasteners to be checked
Brakes: Brake Lever Pivot Bolt Brake Lever Pivot Nut Caliper Mounting Bolts
General Lubrication
Lubrication Refer to the Base Manual noting the following. Cables: Lubricate with Motor Oil Brake Cables Throttle Cable Choke Cable Reverse Gear Cable Differential Shift Cable • Lubricate the cables by seeping the oil between the cable and housing. o The cable may be lubricated by using a pressure cable luber with an aerosol cable lubricant.
Cable Lubrication
Cable: Lubricate with Grease Speedometer Cable (option)
1. Brake Lever Pivot Bolt 2. Brake Lever Pivot Nut 3. Caliper Mounting Bolts
SUPPLEMENT - 1989 - 1997 MODELS 16-1
Supplement - 1989 - 1997 Models This supplement chapter contains only the information unique to the models covered. Read both this manual's front part (up to p. 15-4) and this chapter for complete information on proper service procedures.
Table of Contents
General Information ....... . . ........................ ............................................................16-2 Model Identification .. . ......................... .. .......... .. ........................................... 16-2 General Specifications .......................... ..... .............. .......................................... 16-4 Fuel System.... ................................... .. ...... ................................... ............ 16-16 Exploded View ........... .............................. ... .....................................................16-16 Specifications ......... .... ................ .. ........... ................................... ..................... 16-16 Engine Top End ........ .. ....... ............. .. ..... .. ......... .. .........................................16-17 Specifications.. .. ................................................... ................. 16-17 Piston, Piston Rings.. .. ....................................................................... 16- 17 Engine Right Side ................. .......................... ........ ... ........... .............................. 16-17 Exploded View ..................................................................................................16-17 Frame............................... .................... .... ........... ................... .. ........... 16-18 Exploded View .............. .. ................................................................................16-18 Electrical System. . .................. ........................... .. .......... ............................ 16-18 Exploded View...... ....................... .. .... ....... .. ............................ ............... 16-18 Battery .. .. .................... ............. .......... .. .......... ............. ....... .. ................. 16-19 Ignition System.... ........................ ................ ................. .. ........ 16-20 Switches ............. ........................ ........ ........... .. . .. .... 16-20 Icing Circuit (KLF300-B8 -, UK model) ................ . ....................... 16-21 Wiring Diagram.. .. .......... .. .. .. .. .......... .. ............. ...... ..................... ...... ..... 16-22
16-2 SUPPLEMENT - 1989 - 1997 MODELS
General Information Model Identification
KLF300-B2:
KLF300-B3/B3A:
KLF300-B4:
SUPPLEMENT - 1989 - 1997 MODELS 16-3 KLF300-B5:
KLF300-B6:
KLF300-B7:
16-4 SUPPLEMENT - 1989 - 1997 MODELS General Specifications (KLF300-B2) (A): Australia model (C): Canada model
(B): UK model (U): US model
Item Dimensions: Overall length Overall width Overall height Wheelbase Ground clearance Seat height Dry weight Curb weight:
KLF300-B2 1910 mm 1115 mm, (A) 1160 mm 1065 mm 1210 mm 195mm 750mm 223 kg, (A)( B) 226 kg 10B kg, (A)(B) 109.5 kg 125 kg, (A)(B) 126.5 kg 9 L, (B) B.2 L
Front Rear
Fuel tank capacity Performance: Minimum turning radius
2.9 m (Locked axle mode) 2.6 m (Differential mode)
Engine: Type Coo ling system Bore and stroke Displacement
4-stroke, SOHC, 1-cylinder Air cooled 76.0 x 64.0 mm 290mL
Compression ratio
B.6
Maximum horsepower Maximum torque
14.3 kW (19.5 PSI @ 6500 rl min (rpm) , (U) 22.6 N-m (2.3 kg -m, 16.6 ft-Ib) @ 5500 rl min (rpm),
Carburetion system Starting system Ignition system Timing advance Ignition timing
Carburetor, Keihin CVK32 Electric starter & recoil starter Battery and coil (transistorized) Electronically advanced From 10" BTDC @ 2000 rl min (rpm) to 30" BTDC @ 3200 rl min (rpm) NGK DBEA, (A)(8)(C) NGK DRBES-L 21 " BTDC 59" ABDC 260" 56" BBDC 24" ATDC 260" Forced lubrication (wet sump) SE, SF or SG class SAE 10W-30, 10W-40, 1 OW-50, 20W-40, or 20W-50 1.7 L
(U) -
Spark plug Valve timing:
Inlet
Exhaust
Lubrication system Engine oil:
Grade Viscosity Capacity
Open Close Duration Open Close Duration
SUPPLEMENT - 1989 - 1997 MODELS 16-5 KLF300-B2
Item Drive Train: Primary reduction system: Clutch type: Transmission:
Type Gear ratio:
Type Reduction ratio Primary Secondary
1st 2nd 3rd 4th 5th Reverse
Final drive system: Overall drive ratio Final gear case oil:
Type Reduction ratio Type Capacity
Frame: Type Caster (rake angle) Camber Trail Tread: Front tire: Rear tire: Suspension:
Type Size Type Size Front Rear
Brake type:
Front Rear
Electrical Equipment: Battery Headlight: Type Bulb Taillight Type Alternator: Rated output
Front Rear
Type Wheel travel Type Wheel travel
Gear 2.888 (78/27) Auto centrifugal, wet Auto multi disc, wet 5-speed plus reverse, constant mesh, return shift 3.090 (34/11 ) 1.928(27/14) 1.368 (26/19) 1.000 (23/23) 0.769 (20/26) 3.072 (26/11 x 26/20) Shaft 4.886 (20/16 x 43/11). (A)(B) 5.584 (20/14 x 43/11) 10.858, (A)(B) 12.409@Topgear API GL-5 Hypoid gear oil SAE 90 (above 5"C, 41"F) or SAE 80 (below 5"C, 41 "F) 0.3 L Double tubular 3.0" 1.0"@ 1 G 13mm 834mm 844mm Tubeless 22 x 9.00-10 Tubeless 24 x 11 .00-1 0 Double wishbone-link 125 mm Torque tube-link 120mm Disc (Hydraulic) Drum (Mechanical) 12V14Ah Semi-sealed beam 12 V 65/60 W, (B) 12V8W x 2, (B)Three-phase AC 23.5 A@ 9000 r/min (rpm), 14 V
Specifications are subject to change without notice, and may not apply to every country.
16-6 SUPPLEMENT - 1989 - 1997 MODELS General Specifications (KLF300-B3/B3A) (A): Australia model (C) : Canada model
(B): UK model (U): US model
Item
KLF300-B3/ B3A [(A) only]
Dimensions: Overall length Overall width Overall height Wheelbase Ground clearance Seat height Dry weight Curb weight: Front Rear Fuel tank capacity
1910 mm 111 5 mm, (A) 11 60 mm 1065 mm 1210 mm 195 mm 750mm 226 kg, B3A(A) 228 kg 109.5 kg, B3A(A) 111 kg 126.5 kg, B3A(A) 127 kg 9 L, (B) 8.2 L
Performance: Minimum turning radius
2.9 m (Locked axle mode) 2.6 m (Differential mode)
Engine: Type Cooling system Bore and stroke Displacement Compression ratio Maximum horsepower Maximum torque
4-stroke, SOHC, 1-cylinder, piston reed valve Air cooled 76.0 x 64.0 mm 290 mL 8.6 14.3 kW (19.5 PS) @ 6500 rl min (rpm) , (U) 22.6 N-m (2.3 kg-m, 16.6 ft -Ib) @ 5500 rl min (rpm).
(U) Carburetion system Starting system Ignition system Timing advance Ignition timing Spark plug Valve timing:
Inlet
Exhaust
Lubrication system Engine oil: Grade Viscosity Capacity
Open Close Duration Open Close Duration
Carburetor, Keihin CVK32 Electric starter & recoil starter Battery and coil (transistorized) Electronically advanced From 10" BTDC @ 2000 rl min (rpm) to 30" BTDC @ 3200 rl min (rpm) NGK D8EA, (A)(B)(C) NGK DR8ES - L 21" BTDC 59" ABDC 260" 56" BBDC 24" ATDC 260" Forced lubrication (wet sump) SE, SF or SG class SAE 1OW-30, 1OW-40, 1OW-50, 20W-40, or 20W-50 1.7 L
SUPPLEMENT - 1989 Item
Clutch type:
Type Reduction ratio Primary Secondary
Transmission:
Type Gear ratios: 1 st 2nd 3rd 4th 5th Reverse Final drive system: Type Reduction ratio Overall drive ratio Final gear case oil: Type Capacity
Frame: Type Caster (rake angle) Camber Trail Tread:
Rear tire: Suspension:
Type Size Type Size Front Rear
Brake type:
1997 MODElS 16-7
KLF300-B3/B3A [(A) only]
Drive Train: Primary reduction system:
Front tire:
~
Front Rear
Electrical Equipment: Battery Headlight: Type Bulb Taillight A lternator: Type Rated output
Front Rear
Type Wheel travel Type Wheel travel
Gear 2.888 (78/27) Auto centrifugal. wet Auto multi disc, wet 5-speed plus reverse, constant mesh, return shift 3.090 (34/11) 1.928(27/14) 1.368 (26/19) 1.000 (23/23) 0.769 (20/26) 3.072 (26/11 x 26/20) Shaft 4.886 (20/16 x 43/11), (A)(B) 5.584 (20/14 x 43/11) 10.858, (A)(B) 12.409 @ Top gear API GL-5 Hypoid gear oil SAE 90 (above 5"C, 41"F) or SAE 80 (below 5"C, 41"F) 0.3 L Double tubular 3.0" 1.0"@ 1 G 13 mm 834mm 844mm Tubeless 22 x 9.00-10 Tubeless 24 x 11 .00-1 0 Double wishbone-link 125 mm Torque tube-link 120 mm Disc (Hydraulic) Drum (Mechanical) 12V14Ah Sem i-sea led beam 12 V 65/60 W, (B) 12V8W x 2,(B)Three- phase AC 23.5 A@ 9000 r/min (rpm), 14 V
Specifications are subject to change without notice, and may not apply to every country.
16-8 SUPPLEMENT - 1989 - 1997 MODELS General Specifications (KLF300-B4) (A): Australia model (E): Europe model
(B): UK model (U): US model
(C): Canada model
Item
KLF300-B4
Dimensions: Overall length Overall width Overall height Wheelbase Ground clearance Seat height Dry weight Curb weight: Front Rear Fuel tank capacity
1910 mm 1115 mm, (A)(E) 1160 mm 1065 mm 1210 mm 195mm 750mm 226 kg, (A) 228 kg 109.5 kg, (A) 111 kg 126.5 kg, (A) 127 kg 9 L, (B) 8.2 L
Performance: Minimum turning radius Engine: Type Cooling system Bore and stroke Displacement Compression ratio Maximum horsepower Maximum torque
2.9 m (Locked axle mode) 2.6 m (Differential mode) 4-stroke, SOHC, 1 -cylinder Air cooled 76.0 x 64.0 mm 290mL
8.6 14.3 kW (19.5 PS) @6500r/ min (rpm), (U) 22.6 N-m (2.3 kg-m, 16.6 ft-Ib) @ 5500 rl min (rpm) ,
(U)Carburetion system Starting system Ignition system Timing advance Ignition timing Spark plug Valve timing:
Lubrication system Engine oil:
Inlet
Open Close Duration Exhaust Open Close Duration
Grade Viscosity Capacity
Carburetor, Keihin CVK32 Electric starter & recoil starter Battery and coil (transistorized) Electronically advanced From 10· BTDC @ 1300 rl min (rpm)to 30· BTDC @ 4000 rl min (rpm) . NGK D8EA, (A)(C) NGK DR8ES-L, (B)(E) NGK DR7EA 21 · BTDC 59· ABDC 260· 56· BBDC 24· ATDC 260· Forced lubrication (wet sump) SE, SF or SG class SAE 10W-30, 10W-40, lOW-50, 20W-40, or 20W-50 1.7 L
SUPPLEMENT - 1989 - 1997 MODELS 16-9 Item
KLF300-B4
Drive Train: Primary reduction system: Clutch type:
Type Reduction ratio Primary Secondary
Transmission:
Type Gear ratios: 1 st 2nd 3rd 4th 5th Reverse Final drive system: Type Reduction ratio
Overall drive ratio Final gear case oil:
Type Capacity
Frame: Type Caster (rake angle) Camber Trail Tread: Front tire: Rear tire: Suspension:
Type Size Type Size Front Rear
Brake type:
Front Rear
Electrical Equipment : Battery Headlight: Type Bulb Taillight Type Alternator: Rated output
Front Rear
Type Wheel travel Type Wheel travel
Gear 2.888 (78/27) Auto centrifugal, wet Auto multi disc. wet 5-speed plus reverse. constant mesh. return shift 3.090 (34/11) 1.928(27/14) 1.368 (26/19) 1.000 (23/23) 0.769 (20/26) 3.072 (26/11 x 26/20) Shaft 4.886 (20/16 x 43/11). (A)(B)(E) 5.584 (20/14 x 43(11) 10.858. (A)(B)(E) 12.409 @ Top gear API GL-5 Hypoid gear oil SAE 90 (above 5'C. 41'F) or SAE 80 (below 5'C, 41'F) 0.35 L Double tubular 3.0' 1.0' @ 1 G 13 mm 834mm 844mm Tubeless 22 x 9.00-10 Tubeless 24 x 11 .00-10 Double wishbone-link 125 mm Torque tube-link 120mm Disc (Hydraulic) Drum (Mechanical)
12V14Ah Semi-sealed beam 12 V 65/60 W 12V8Wx2 Three-phase AC 23.5 A@9000 r/min (rpm). 14 V
Specifications are subject to change without notice. and may not apply to every country.
16-10 SUPPLEMENT - 1989 - 1997 MODELS General Specifications (KLF300-B5) (A) : Australia model (E): Europe model
(B): UK model (U): US model
(C) : Canada model
Item
KLF300-B5
Dimensions: Overall length Overall width Overall height Wheelbase Ground clearance Seat height Dry weight Curb weight Front Rear Fuel tank capacity
1910 mm 1115 mm, (A)(E) 1160 mm 1065 mm 1210 mm 195 mm 750 mm 226 kg, (A) 228 kg, (B)(C)(E) 227 kg 109.5 kg, (A) 111 kg 126.5 kg, (A) 127 kg, (B)(C)(E) 127.5 kg 9 L, (B) 8.2 L
Performance: Minimum turning radius
2.9 m (Locked axle mode) 2.6 m (Differential mode)
Engine: Type Cooling system Bore and stroke Displacement Compression ratio Maximum horsepower Maximum torque
4-stroke, SOHC, 1-cylinder Air cooled 76.0 x 64.0 mm 290 mL 8.6 14.3 kW (19.5 PS) @ 6500 r/ min (rpm). (U) 22.6 N-m (2.3 kg-m, 16.6 ft -Ib) @ 5500 r/ min (rpm),
(U) Carburetion system Starting system Ignition system Timing advance Ignition timing Spark plug Valve timing :
Inlet
Exhaust
Lubrication system Engine oil: Grade Viscosity Capacity
Open Close Duration Open Close Duration
Carburetor, Keihin CVK32 Electric starter & recoil starter Battery and coil (transistorized) Electronically advanced From 10" BTDC @ 1300 r/ min (rpm)to 30" BTDC @ 4000 r/ min (rpm) NGK D8EA, (A)(C) NGK DR8ES-L, (B)(E) NGK DR7EA 21 " BTDC 59" ABDC 260" 56" BBDC 24" ATDC 260" Forced lubrication (wet sump) SE, SF or SG class SAE 10W-30, 10W-40, 10W-50, 20W-40, or 20W-50 1.7 L
SUPPLEMENT - 1989 - 1997 MODELS 16-11 Item
KlF300-8S
Drive Train : Primary reduction system: Clutch type:
Type Reduction ratio Primary Secondary
Transmission:
Type Gear ratios: 1st 2nd 3rd 4th 5th Reverse Final drive system: Type Reduction ratio
Overa ll drive ratio Final gear case oil :
Type Capacity
Frame: Type Caster (rake angle) Camber Trail Tread: Front tire: Rear tire: Suspension:
Type Size Type Size Front Rear
Brake type:
Front Rear
Electrical Equipment: Battery Headlight: Type Bulb Taill ight A lternator: Type Rated output
Front Rear
Type Wheel travel Type Wheel travel
Gear 2.888 (78/ 27) Auto centrifugal, wet Auto multi disc, wet 5-speed plus reverse, constant mesh, return shift 3.090 (34/11 ) 1.928(27/14) 1.368 (26/19) 1.000 (23/23) 0.769 (20/26) 3.072 (26/ 11 x 26/20) Shaft 4.886 (20/ 16 x 43/11), (A)(B)(C)(E) 5.584 (20/14 x 43/ 11) 10.858, (A)(B)(C)(E) 12.409@Topgear API Gl-5 Hypoid gear oil SAE 90 (above 5"C, 41 "F) or SAE 80 (below 5"C, 41 "F) 0.35 L Double tubular 3.0" 1.0" @ 1 G 13 mm 834mm 844mm Tubeless 22 x 9.00-10 Tubeless 24 x 11 .00-10 Double wishbone-link 125 mm Torque tube-link 120 mm Disc (Hydraulic) Drum (Mechanical) 12V14Ah, (B)(C)(E) 12V19Ah Semi-sealed beam 12 V 65/ 60 W 12V8W x2 Three-phase AC 23.5 A @ 9000 r/ min (rpm), 14 V
Specifications are subject to change w ithout notice, and may not apply to every country.
16-12 SUPPLEMENT - 1989 - 1997 MODELS General Specifications (KLF300-B6/B7) (A): Australia model (E): Europe model
(B): UK model (U): US model
(C): Canada model
Item
KLF300-B6/B7
Dimensions: Overall length Overa II width Overall height Wheelbase Ground clearance Seat height Dry weight Curb weight: Front Rear Fuel tank capacity
1910 mm 1115 mm, (A)(E) 1160 mm 1065 mm 1210 mm 195 mm 750mm 226 kg, (A)(B)(E) 229 kg, (C) 227 kg 109.5 kg, (A)(B)(E) 110 kg 126.5 kg, (A)(B)(E) 129 kg, (C) 127.5 kg 9L
Performance: Minimum turning radius
2.9 m (Locked axle mode) 2.6 m (Differential mode)
Engine: lype Cooling system Bore and stroke Displacement Compression ratio Maximum horsepower Maximum torque
4-stroke, SOHC, 1-cylinder, piston reed valve Air cooled 76.0 x 64.0 mm 290 mL 8.6 14.3 kW (19.5 PS) @6500r/min (rpm). (U) 22.6 N-m (2.3 kg-m, 16.6 ft-Ib) @ 5500 r/min (rpm),
(U)Carburetion system Starting system Ignition system liming advance Ignition timing Spark plug Valve timing:
Inlet
Exhaust
Lubrication system Engine oil: Grade Viscosity Capacity
Open Close Duration Open Close Duration
.
Carburetor, Keihin CVK32 Electric starter & recoil starter Battery and coil (transistorized) Electronically advanced From 10" BlOC @ 1300 r/min (rpm)to 30" BlOC @ 4000 r/min (rpm) NGK D8EA, (A)(C) NGK DR8ES-L, (B)(E) NGK DR7EA 21" BlOC 59" ABDC 260" 56" BBDC 24" AlDC 260" Forced lubrication (wet sump) SE, SF or SG class SAE 1 OW-30, 10W-40, 1OW-50, 20W-40, or 20W-50 1.7 L
SUPPLEMENT - 1989 - 1997 MODELS 16-13 Item
KLF300-B6/B7
Drive Train: Primary reduction system: Clutch type: Transmission:
Type Reduction ratio Primary Secondary
Type
Gear ratios: 1 st 2nd 3rd 4th 5th Reverse
Final drive system:
Overall drive ratio Final gear case oil:
Type Reduction ratio
Type Capacity
Gear 2.888 (78/27) Auto centrifugal. wet Auto multi disc, wet 5-speed plus reverse, constant mesh, return shift 3.090 (34/11) 1.928(27/14) 1.368 (26/19) 1.000 (23/23) 0.769 (20/26) 3.072 (26/11 x 26/20) Shaft 4.886 (20/ 16 x 43/11), (A)(B)(C)(E) 5.584 (20/14 x 43/11) 10.858, (A)(B)(C)(E) 12.409 @ Top gear API GL-5 Hypoid gear oil SAE 90 (above 5°C, 41 °F) or SAE 80 (below 5°C, 41°F) 0.35 L
Frame: Type Caster (rake angle) Camber Trail Tread: Front tire: Rear tire: Suspension:
Type Size Type Size Front Rear
Brake type:
Front Rear
Front Rear
Type Wheel travel Type Wheel travel
Double tubular 3.0· 1.0·@ 1 G 13 mm 834 mm 844mm Tubeless 22 x 9.00-10 Tubeless 24 x 11 .00-1 0 Double wishbone-link 125 mm Torque tube-link 120mm Disc (Hydraulic) Drum (Mechanical)
Electrical Equipment: Battery Headlight: Taillight Alternator:
Type Bulb Type Rated output
12 V 14 Ah, (A)(B)(C)(E) 12 V 19 Ah Semi-sealed beam 12 V 65/60 W 12V8W x2 Three-phase AC 23.5 A @ 9000 r/ min (rpm) , 14 V
Specifications are subject to change without notice, and may not apply to every country.
16-14 SUPPLEMENT - 1989 - 1997 MODELS General Specifications (KlF300-B8/B8A/B9/B10) (A) : Australia model (E) : Europe model
(B): UK model (U): US model
(C) : Canada model
Item
KlF300-B8/B8A/B9/B10
Dimensions: Overall length Overall width Overall height Wheelbase Ground clearance Seat height Dry weight Curb weight: Front Rear Fuel tank capacity
1910 mm 1115 mm, (A)(B)(E) 1160 mm 1065 mm 1210 mm 195 mm 750mm 226 kg, (A)(B) (E) 229 kg, (C) 227 kg 109.5 kg, (A)(B)(E) 110 kg 126.5 kg, (A)(B)(E) 129 kg, (C) 127.5 kg 9L
Performance: Minimum turning radius
2.9 m (Locked axle mode) 2.6 m (Differential mode)
Engine: Type Cooling system Bore and stroke Displacement
4-stroke, SOHC, 1-cylinder, piston reed valve Air cooled 76.0 x 64.0 mm 290 mL
Compression ratio
8.6
Maximum horsepower Maximum torque
14.3 kW (19.5 PS) @ 6500 r/ min (rpm). (U) 22.6 N-m (2.3 kg-m, 16.6 ft-Ib) @ 5500 r/ min (rpm). (U) Carburetor, Keihin CVK32 Electric starter & recoil starter Battery and coil (transistorized) Electronically advanced From 10· BTDC @ 1300 r/ min (rpm)to 30· BTDC @ 4000 r/ min (rpm) NGK D8EA (A)(C) NGK DRBES-L, (B)(E) NGK DR7EA 21 · BTDC 59· ABDC 260· 56· BBDC 24· AlOC 260· Forced lubrication (wet sump) SE, SF or SG class SAE 1OW-30, 1OW-40, 1 OW-50, 20W-40, or 20W-50 1.7 L
Carburetion system Starting system Ignition system Timing advance Ignition timing Spark plug Valve timing:
Inlet
Exhaust
Lubrication system Engine oil : Grade Viscosity Capacity
Open Close Duration Open Close Duration
SUPPLEMENT -1989 - 1997 MODELS 16-15 Item
KLF300-B8/B8A/B9/B10
Drive Train: Primary reduction system: Clutch type: Transmission:
Type Reduction ratio Primary Secondary
Type Gear ratios: 1st 2nd 3rd 4th 5th Reverse
Final drive system:
Overall drive ratio Final gear case oil:
Type Reduction ratio
Type Capacity
Frame: Type Caster (rake angle) Camber Trail Tread: Front tire: Rear tire: Suspension:
Type Size Type Size Front Rear
Brake type:
Front Rear
Electrical Equipment: Battery Headlight: Type Bulb Taillight Alternator: Type Rated output
Front Rear
Type Wheel travel Type Wheel travel
Gear 2.888 (78/27) Auto centrifugal, wet Auto multi disc, wet 5-speed plus reverse, constant mesh, return shift 3.090 (34/11) 1.928(27 / 14) 1.368 (26/19) 1.000 (23/23) 0.769 (20/26) 3.072 (26/11 x 26/20) Shaft 4.886 (20/16 x 43/11), (A)(B)(C)(E) 5.584 (20/14 x 43/11) 10.858, (A)(B)(C)(E) 12.409 @Top gear API GL-5 Hypoid gear oil SAE 90 (above 5"C, 41"F) or SAE 80 (below 5"C, 41·F) 0.35 L Double tubular 3.0· 1.0·@ 1 G 13mm 834mm 844mm Tubeless 22 x 9.00-10 Tubeless 24 x 11.00-10 Double wishbone-link 125mm Torque tube-link 120mm Disc (Hydraulic) Drum (Mechanical) 12V14Ah, (A)(B)(C)(E) 12V19Ah Semi-sealed beam 12 V 25/25 W x 2 12V8W x2 Three- phase AC 23.5 A@ 9000 rlmin (rpm), 14 V
Specifications are subject to change without notice, and may not apply to every country.
16-16 SUPPLEMENT - 1989 - 1997 MODELS
Fuel System Exploded View
Specifications
Item
Standard
Service limit
Keihin, CVK32 #130, #125 (KLF300- B9 -) #100 #6 N36X, N74T (KLF300-B9 -) #38 #140 2~ turns out, 2% (KLF300-B9 -) #58, #65 (KLF300-B9 -) 0.5 mm (below) - 1.5 mm (above) 17 ±2 mm
---
Carburetor: Make, type Main jet Main air jet Needle jet Jet needle Pilot jet Pilot air jet Pilot screw Starter jet Service fuel level Float height Optional parts: Main jet Pilot jet Starter jet
#125,128,132,135 #120,122,128,130 (KLF300-B9-) #35,40 #60,62 #68, 70 (KLF300- B9 -)
---
-----------
---------------
SUPPLEMENT - 1989 - 1997 MODELS 16-17
Engine Top End Specifications
Item
Standard
Camshaft: Cam height Cylinder. Piston: Cylinder inside diameter Piston diameter Piston / cylinder clearance Piston ring / groove clearance: Top Second Piston ring thickness Piston ring groove width: Top Second
40.642 - 40.782 mm
40.54mm
76 .000 - 76 .012 mm 75.96Q - 75.975 mm 0.025 - 0.052 mm
76.10mm 75.81 mm
0.03 - 0.07 mm 0.02 - 0.06 mm 0.97 - 0.99 mm
0.17 mm 0 .16 mm 0.90 mm
1 .02 - 1.04 mm 1 .01 - 1 .03 mm
1.12mm 1.11 mm
Piston. Piston Rings
Engine Right Side
Top and Second Rings
Exploded View L:
Apply non-permanent locking agent.
n: 15 N-m Top ring
T1
"N" mark
2nd ring
Service Limit
(1.5 kg-m.ll.0ft-fb)
-- -
16-18 SUPPLEMENT - 1989 - 1997 MODELS
Frame
Electrical System
Exploded View
Exploded View
KLF300-88KLF300-88-
i
r - - --- -- ------------- ,
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L
/ /
"
/
______
KLF300-88~
_
_____
_
____
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-
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/ / /
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Australia Mo del KLF300-81, 82, 86Europe Model KLF300-84UK Model KLF300-83-85 L
____
____
______
______
~
KL3BOS-1W4 C
SUPPLEMENT - 1989 - 1997 MODELS 16-19
KLF300-BBAEurope Model'
,, ,, , ,, ,, ,,
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KLF300-B3AAustralia Mod'el
L
Battery
Battery Ch ar91n9 . Rate /TIme . Table (12 V 1 9 Ah)
.~
1.265 1.24 1.20
'"
1.16
.='
1.1
>
"·u
Fully Charged
~
Q.
If)
at 3A charge rate Hours of Ch arglng . Time at Rates Shown
I -
-
_-I
16-20 SUPPLEMENT - 1989
1997 MODELS KLF300-BSA -, Europe Model:
Ignition System
Ie Igniter Resistance·
Tester Positive ( + ) Lead Connection
Range Unit: x kO
Ie Igniter- Resistance·
Range
Tester Positive (+) Lead Connection
x 1 kO
..
R/W
2.5 50 -200 -11
50 150
G/W
G/W
-
00
00
00
00
Y/R
5 - 15
-
1 - 10
00
1 - 10
BK/W
1 - 5
1 - 10
-
00
(BK/W) 1 - 5
1 - 10
0
-
00
R/W
G/W (BK/W) BK/W
50 75 55 80 50 -300 -220 -320 -200 -200
0
(BK/W)
-
Y/R
75 -300
BL
50 150
BL
Y/R
BK/W
00
x 1 kQ
-
Y/R
50 150
..
BL
G/W
BL
Unit" x kO
-
00
00
3 -12
5 -22
2.5 -11
2.5 -11
-
1.8 -7
0 .4 -1.6
0.4 -1.6
00
-
00
00
(BK/W)
0.3 1.3 2.2 50 -200 -8.4 -1.5 -5.5
-
0
BK/W
2.2 0.3 1.3 50 -200 -8.4 -1.5 -5.5
0
-
Measure with the Kawasaki Hand Tester (PN 57001 -1394). A tester other than the Kawasaki Hand Tester may show slightly different readings.
Tester Negative (- ) Lead Connection
Measure with
the
Kawasaki
Hand Tester
(PN
57001 -1394). A tester other than the Kawasaki Hand Tester may show slightly different readings. Tester Negative (-) Lead Connection
Ie Igniter Terminal
YiR
~
(BK/W)
G/W
Ie Igniter Terminal
~~
BL BK/W
Horn Button Connections
BK/W
Push
BK/Y
R/W
BK/W
G/W
~
(BK/W)
Switches
YIR
BL
SUPPLEMENT - 1989 - 1997 MODELS 16-21 Icing Circuit (KLF300-B8-, UK model)
-
Control Unit Inspection • Remove the control unit. .Set the hand tester to the x 1 kO range and make the measurements shown in the table. If the tester readings are not as specified, replace the control unit.
*
Control U nit Resistance
1
2
3
1
-
7- 28
00
2
00
-
00
4
r
@
A Thermostatic Sensor
B. Thermostat
5
6.5-28 17-80 00
00
-
9.5-40
24150
3
6-26 9 .5-40
4
4.4-19 1.4-6
00
-
6.5-28
5
13-60 10-45
00
6.5-28
-
': Tester Negative (-) Lead Connection
*If the tester does not read as specified, replace the sensor. Carburetor Thermostatic Sensor Resistance (Reference only)
Standard:
3.0 - 7.2 kO @12' C (53.6' F)
Carburetor Heater Inspection • Disconnect the carburetor heater connector. • Using the hand tester, measure the resistance of the heater. .Connect the tester between the heater terminal and carburetor ground. If the tester does not read as specified, replace the heater.
* 3
Carburetor Heater Resistance Standard:
Carburetor Thermostatic Sensor Inspection • Remove the carburetor thermostatic sensor . • Suspend the sensor in a co ntainer of water so that the temperature sensing projection and threaded portion are submerged . • Using the hand tester, measure the internal resistance of the sensor across the terminal and the body at the temperatures shown in the table.
NOTE
o The sensor and thermostat must not touch the container sides or bottom.
i
Unit: kO
Tester Positive (+) Lead Connection
.
JI
J
11 ..... 20
0
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Switch
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16-26 SUPPLEMENT - 1989 - 1997 MODELS Wiring Diagram KLFlOO-8SA -, Europe Model
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SUPPLEMENT -1998 -1999 MODELS 17-1
Supplement - 1998 ~ 1999 Models Table of Contents Foreword .. ... ..... ........ ..... ..... ..... ..... .... . ...... .... ..•. ..... .... ..... .. ...•... ... .. ...... ........ .... ... .. .......... ..... ..... How to Use this Manual..... ... ... ... ... ... ... .... .......... ....... ..... ..... .. .•. ... .... ..•.. ... ... .... .. ....•..... .. .. ...... General Information.............................. ...... .. ......... ...... .... .. ........... .. ... ................. .. ........ ... ... .... General Specifications. .. ... .. ... .... ...... ........ ....••... ... ..•...... ....•.... .... ..... ......... ... ..... ......... .. ..... .... Final Drive .... ..... .......... ........ ...... ...... ..... .... ... ...... .... .... .... .... ..•... .. ... .... .. ...•.... ..•.. ... .. ....... ...•.... ... Exploded View (KLF300-B12 - ) ...................................................... ...• ..... .•....... .... ........... ... Brakes ..... ..... ........ .... .. ..... ...................................................... ... .. ... .•.... ... .. ... .......... ...•..... .... .... Exploded View (KLF300-B 12, Canada Model) .. ... ........ ... .... .. ..... ..... .... ... ....... .... .. ....... ....... .. Electrical System...... . ... ............ ... ........ ....... ...... ....... ..... ... ......... ..... ...... ........ ...... ..... .. ...... ... ..... Exploded View (KLF300-B12) ................................................ .... .. .... .. ...... ........... ................ Charg ing System (KLF300-B12 - ).... .......... .. ....... ............. .. ......... ... ... ..... ... ........... ....... .. .... .. Regulator/Rectifier Output Voltage Inspection ................................. ....... ............... ... .. ... ... Alternator Inspection .... ...... ...... ... ...... ...... ............ ... ... ............. ... . ..... ...... .. .... .... ... ....... .. ...... Regulator/Rectifier Inspection .................................................................. ... ........ .............. Wiring Diagram (KLF300B-11, U.S.A/Canada/Austraria Models)........ ...... ........ ..... ...... ....... Wiring Diagram (KLF300B-12, U.S.A/Canada/Austraria Models) ....... ................................ Wiring Diagram (KLF300B-11 , U.KlEurope Models) ..... ........ .. ............ ........ .......... .............. Wiring Diagram (KLF300B-12, U.KlEurope Models) .......... .... .... .. .. ...... ...... ...... ....... .. .... ... ...
17-2 17-2 17-3 17-3 17-6 17-6 17-7 17-7 17-8 17-8 17-9 17-9 17-10 17-11 17-14 17-16 17-18 17-20
17-2 SUPPLEMENT -1998 - 1999 MODELS Foreword How to Use this Manual This "Supplement 1998 - 1999 Models" designed to be used in conjunction with the front part of this manual (up to 16-26) and/or Base manual KLF300 Service Manual - Part No. 99924-1057-01. The specifications and maintenance procedures descried in this chapter are only those that are unique to the KLF300B11 - B12 models. Complete and proper servicing of the KLF300B11 - B12 models therefore requires mechanics to read both this chapter and the front of this manual.
SUPPLEMENT -1998 -1999 MODELS 17-3 General Information General Specifications Item
KLF300B11/B12
Dimensions
Overall Length
1 910 mm
Overall Width
1 115 mm, (A) (B) (E) 1 160 mm
Overall Height
1065mm
Wheelbase
1210 mm
Ground Clearance
195 mm
Seat Height
750 mm
Dry Weight
226 kg , (A) (B) (E) 229 kg, (C) 227 kg
Curb Weight: Front
109.5 kg, (A) (B) (E) 110 kg
Rear
126.5 kg, (A) (B) (E) 129 kg , (C) 127.5 kg
Fuel Tank Capacity
9L
Performance
Minimum Turning Radius
2.6 m (Differential mode) 2.9 m (Locked axle mode)
Engine
Type
4-stroke, SOHC, 1-cylinder
Cooling System
Air-cooled
Bore and Stroke
76.0 x 64.0 mm
Displacement
290 mL
Compression Ratio
B.6
Maximum Horsepower
14.3 kW (19.5 PS) @ 6500 rl min (rpm), (U) -
Maximum Torque
22 .6 N·m (2.3 kgf·m , 16.6 ft·lb) @5 500 rl min (rpm). (U)-
Carburetion System
Carburetor, Keihin CVK32
Starting System
Electric starter & recoil starter
Ignition System
Battery and coil (transistorized)
Timing Advance
El ectronically advanced
Ignition Timing
From 10° BTDC @1 300 rl min (rpm) to 30° BTDC @4 000 rlmin (rpm)
Spark Plug
NGK DBEA, (A) (C) NGK DRBES-L, (B) (E) DR7EA
Valve Timing: Inlet: Open
21 ° (BTDC)
Close
59° (ABDC)
Duration
260°
Exhaust: Open
56° (BBDC)
Close
24° (ATDC)
Duration
260°
Lubrication System
Forced lubrication (wet sump)
17-4 SUPPLEMENT -1998 -1999 MODELS General Information Item
KLF300B11/B12
Engine Oil: Grade
SE, SF or SG class
Viscosity
SAE 10W-30 10W-40, 1OW-50, 20W-40, or 20W-50
Capacity
1.7 L
Drive Train Primary Reduction System: Type
Gear
Reduction Ratio
2 .888 (78/27)
Clutch Type: Primary
Auto centrifugal, wet
Secondary
Auto multi disc, wet
Transmission: Type
5-speed plus reverse , constant mesh, return shift
Gear Ratio: 1st
3.090 (34111)
2nd
1.928 (27/ 14)
3rd
1.368 (26/19)
4th
1.000 (23/23)
5th
0.769 (20/26)
Reverse
3.072 (26/ 11 x 26/20)
Final Drive System: Type
Shaft
Reduction ratio
4.886 (26/16 x 43/11) (A) (8) (C) (E) 5.584 (20/14 x 43/11)
Overall Drive Ratio:
10.858 (A) (8) (C) (E) 12.409 @Top gear
Final Gear Case Oil: Type
API GL-5 Hypoid gear oil SAE90 (above 5°C, 41 °F) or SAE80 (below 5°C, 41 °F)
Capacity
0.35 L
Frame Type
Double tubular
Caster (Rake Angle) Chamber
3.0° 1.00 @1G
Trail
13 mm
Tread Front
834 mm
Rear
844 mm
Front Tire : Type
Tubeless
Size
22 x 9.00-10
Rear Tire: Type
Tubeless
Size
24 x 11 .00-10
SUPPLEMENT -1998 -1999 MODELS 17-5 General Information Item
KLF300B11/B12
Suspension: Front Type
Double wishbone-link
Wheel Travel
125 mm
Rear Type
Torque tube-link
Wheel Travel
120 mm
Brake Type: Front
Disc (Hydraulic)
Rear
Drum (Mechanical)
Electrical Equipment
Battery
12 V 14 Ah (A) (B) (C) (E) 12 V 19 Ah
Headlight: Type
Semi-sealed beam
Bulb
12 V 25/25 W (RH/LH)
Taillights: Bulb
12 V 8 W (RH/LH)
Tail/Brake Lights: Bulb
(C) 12 V 18/5 W (RH/LH), KLF300-B12
Alternator: Type
Three-phased AC
Rated Output
23.5 A @9 000 r/min (rpm), 14 V
Specification subject to change without notice, and may not apply to every country. AS: Australian Model EU: European Model UK: U.K. Model US: U.S.A. Model
17-6 SUPPLEMENT -1998 -1999 MODELS Final Drive Exploded View (KLF300-B12 -)
G
HK020 39 Bn c
1. Rropeller Shaft G: Apply grease. T1 : 25 N·m (2.5 kg·m , 18.0 ft·lb)
SUPPLEMENT -1998 -1999 MODELS 17-7 Brakes Exploded View (KLF300-B12, Canada Model)
S j }----\ 1":\;------{T2 @~--I::f
HL020288W3
1. Brake Switch Si: Apply silicone T1 : 1.0 N·m (0.10 T2 : 5.9 N·m (0.60 T3: 1.2 N·m (0.12 T4: 8.8 N·m (0.90
grease. kgf.m, 9 in.lb) kgf·m, 52 in·lb) kgf·m, 10 in·lb) kgf·m, 78 in·lb)
C
17-8 SUPPLEMENT -1998 -1999 MODELS Electrical System Exploded View (KLF300-B12)
2
1. Regu lator/Rectifier 2. Tail/Brake Light (Canada Model) 3. Bulb (12 V 18/5 W) 4. 7.8 N·m (0.8 kgf·m, 69 in·lb)
SUPPLEMENT -1998 -1999 MODELS 17-9 Electrical System Charging System (KLF300-B12-) Regulator/Rectifier Output Voltage Inspection • Remove the seat (see Frame chapter) . • Check the battery condition (see Battery section) . • Warm up the engine to obtain actual alternator operating conditions. • Check that the ignition switch is turned off, and connect the hand tester to the battery terminal. Special Tool- Hand Tester: 57001-1394
• Start the engine, and note the voltage readings at various engine speeds with the headlight turned on and then turned off. The readings shou ld show nearly battery voltage when the engine speed is low, and as the engine speed rises , the readings should also rise . But they must be kept under the specified voltage. Regulator/Rectifier Output Tester Range 25 V DC
Connections Tester (+) to
Tester (-) to
Battery (+)
Battery (-)
Reading 14 - 15 V
• Turn off the ignition switch to stop the engine, and disconnect the hand tester. If the regulator/rectifier output voltage is kept between the values given in the table, the charging system is considered to be working normally. *11 the output voltage is much higher than the values specified in the table, the regulator/rectifier is defective or the regulator/rectifier leads are loose or open. II the battery voltage does not rise as the engine speed increases, then the regulator/ rectifier is defective or the alternator output is insufficient for the loads. Check the alternator and regulator/rectifier to determine which part is defective.
*
*
17-10 SUPPLEMENT -1998 -1999 MODELS Electrical System Alternator Inspection There are three types of alternator failures: short, open (wire burned out), or loss in rotor magnetism . A short or open in one of the coil wires will result in either a low output, or no output at all. A loss in rotor magnetism , which may be caused by dropping or hitting the alternator, by leaving it near an electromagnetic field, or just by aging, will result in low output. • To check the alternator output vo ltage, do the following procedures. ODisconnect the alternator connector [A] . OConnect the hand tester as shown in the table. OStart the engine. O Run it at the rpm given in the table . ONote the voltage readings (total 3 measurements). Regulator/Rectifier Output Voltage Tester Range 250 V AC
Connections
Tester (+) to
Tester (-) to Another black One black lead lead
Reading 39 - 59 V
* If the output voltage shows the value in the table, the alternator operates properly and the regulator/rectifier is damaged. A much lower reading than that given in the table indicates that the alternator is defective. • Check the stator coil resistance as follows . OStop the engine. ODisconnect the alternator connector. OConnect the hand tester as shown in the table. ONote the readings (total 3 measurement). Stator Coil Resistance Tester Range
x 1
n
Connections Reading Tester (+) to Tester (-) to Another black One black lead 0.33 - 0.49 lead
n
*If there is more resistance than shown in the table , or no hand tester reading (infinity) for any two leads, the stator has an open lead and must be replaced. Much less than this resistance means the stator is shorted, and must be replaced . • Using the highest resistance range of the hand tester, measure the resistance between each of the black leads and chassis ground. *Any hand tester readi ng less than infinity (oo) indicates a short, neceSSitating stator replacement. * If the stator coils have normal resistance , but the voltage check showed the alternator to be defective; then the rotor magnetism has probably weakened, and the rotor must be replaced . Special Tool - Hand Tester: 57001-1394
SUPPLEMENT -1998 -1999 MODELS 17-11 Electrical System Regulator/Rectifier Inspection Front Fender (see Frame chapter) Connectors [A] (disconnect) Bolts [B] and Regulator/Rectifier [C]
Rectifier Circuit Check • Check conductivity of the following pair of terminals . Rectifier Circuit Inspection W/R-Yl, W /R-Y2 , W /R-Y3
Tester connection f - - - - - - - ' - - - --'-- - -- ---l BK-Yl , BK-Y2, BK-Y3 *The resistance should be low in one direction and more than ten times as much in the other direction. If any two leads are low or high in both directions, the rectifier is defective and must be replaced.
o The
HP09006BS 1 C
NOTE
actual meter reading varies with the meter used and the individual rectifier, but generally speaking the lower reading should be from zero to one half the scale.
Regulator Circuit Check To test the regulator out of circuit, use three 12 V batteries and a test light (12 V 3 - 6 W bulb in a socket with leads).
CAUTION The test light works as an indicator and also a current limiter to protect the regulatorlrectifier from excessive current. Do not use an ammeter instead of a test light.
• Check to be sure the rectifier circuit is normal before continuing. Regulator Circuit Test-1st Step • Connect the test light and the 12 V battery to the regulator/rectifier as shown. • Check Y1 , Y2, and Y3 terminal respectively. *If the test light turns on, the regulator/rectifier is defective. Replace it. *11 the test light does not turn on , continue the test.
®: I I
I
HP09018BSI
C
17-12 SUPPLEMENT -1998 -1999 MODELS Electrical System Regulator Circuit Test-2nd Step • Connect the test light and the 12 V battery in the same manner as specified in the "Regulator Circuit Test-1 st Step". • Apply 12 V to the SR terminal. • Check Y1, Y2, and Y3 terminal respectively. If the test light turns on, the regulator/rectifier is defective. Replace it. *11 the test light does not turn on, continue the test.
=-
I
*
' - - - - - ' HP09019BS I
Regulator Circuit Test-3rd Step • Connect the test light and the 12 V battery in the same manner as specified in the "Regulator Circuit Test-1st Step". • Momentarily apply 24 V to the SR terminal by adding a 12 V battery. • Check Y1 , Y2 , and Y3 terminals respectively.
C
=+-.@: I I
I
CAUTION Do not apply more than 24 V to the regulator/rectifier and do not leave the 24 V applied for more than a few seconds, or the until will be damaged.
* If the test light did not light when the 24 V was applied *
momentarily to the SR terminal , the regulator/rectifier is delective. Replace it. If the regulator/rectifier passes ali of the tests described, it may still be defective. If the charging system stili dose not work properly after checking all of the components and the battery, test the regulator/rectifier by replacing it with a known good unit.
L......_--'
HPOU208S1
C
SUPPLEMENT -1998 -1999 MODELS 17-13 Electrical System Charging System Circuit
CD
~~R~B:~~~ II
I
I
__________________ '1 II ® >"-
II
"" a>
>- >>>->-3::~~~:;:
>- >- >-
~
wllj~~
P
'" '"'" '" '" '"
'" '" 3::
>->->- .................... ~
I
'"
~ "'
TT
'"
o::::::..:::~ OJ
OJ
c:c
I I I I I I I
CD
0
CD IIP090UB1I3
1. 2. 3. 4. 5. 6.
Ignition Switch Alternator Regulator/Rectifier Battery Main Fuse 30 A Load
C
17-14 SUPPLEMENT -1998 -1999 MODELS Electrical System Wiring Diagram (KLF300B-11, U.S.AlCanadaiAustraria Models)
Au str al ia
Model
only
( u. s. A. I Canada Model
r---- I Coo l ing Switch
-
Option )
-
Ignition
,
-
Switch
~
Fan
FuseSA Coo l ing
~
__
__
_
Headlight
12 V25 / 2S " ( RH)
Opt ion
- -
- - -
@
, ~
- - - - -
--,
:
to
,
~
~
~~
I I
~
/ BK-c>cJ-R
K/ ¥-!>D-. K I
' I' -CJ
B K / y-t>£=:J-B K / Y -
Y-
R/ y
R/ y
-CJ
R/Y
~
~ lj2/ ~.t----' I ;;-.-~;l I
Switch
~~ ,.. -."'<>0<,.. ---' W 1
Fa n
~
L
Neutral / Rev erse
~
:-BK /Y-{>' : '----C~
J---, I
I
••
I~~!k
Light ; - - -
L!..!.Y 62 /-.! 0 .!....J
~
~
U
, ,
~
oo=E
,~~~,~ ~I~PN
,-
I BK---t>CJR / B K KI 'I----{:>Q< KI R/ Y ----CJ<} RI Y -
H eadl ight
~
~
12V25 /2 51'1 ( L H)
L.ft
H,"dI.b"
G)Light / Dilllller
S.'to"
Switch
f7\
~ H orn
~
~
,
~~ ~
~
ffim ,~: o~ ~ ~~!j:;; ~ ~~b :S~ :;~: L
OFF : H II : ~ __ L-ol
:
..1 ,
ri~
:p: :1r:
T-
G) En gine Stop Switch (';\ 0Starte r Button
~
m* ~
.
I
L.J
Button
P"k,p C,II
I Alternator
f4\ ~
L _ _ _ _ _ .J
CD ®
Austral ia
Model
LEFT HAN DLEBAR S" IT CH
,
LI ht / Dir.... er Color
, I,
OFF
Enl;n. Stop S.itch
RI SK
Color
OFF
LO
HI
CONNECT IONS
Swi teh
B'
only
BR
' I,
Starter Colo r Release
Pu s h
'UN
Bu tton BK
, I'
~
..,
I 1111UUIS C
SUPPLEMENT -1998 - 1999 MODELS 17-15 Electrical System
CDR eve r s e
I nd
r
L i g ht
1 2 V 3. 4 W
®N e u t r a I
I n die a tor
L i g ht
1 2 V 3. 4 W
j
cat
0
Option(U.S.A.Modelon l y) r
-
-
--
-
,
-----..,
r
Ta i I/Brake Light 12V
I
I
L
___ _
8/27WX2
_ _ _ _ _ _ _ _ _ _ _ .J
Tail
light
aWX2
12V
, - - - I B l--CJ
r- BKI Y-c:J<:J-B KI' 'Y~j:t§ , - R --c:J
,>
~
-
Ignition
COl I
~
~;
-
~ i~~i
(, )
~
~ ,>
~ ~
(- )
Battery 12V19AH
lb __ ::!J
0
12V14AH(U.
Starter
Starter
s.
A. II
"del) 0
Relay
Circuit Rei a y
Regulator ! Recti f ie r
Starter
Motor
Color Code Black Blue BR Brown
BK Bl
Spark Plug
' • • 1" . . . . ,IC N co .. Eel, •••
Color
OFF ON
I
BR
W
n UIR H
REH U E SI I ICH COUECTIHS
PO lition
G e. r
,"
,
t ~
f. UI h
lG
Ground
R/'
""
Neutral Reverse
CH DG G GY lB lG 0
P PU
R
(9805 1 -1668A) (98 05 1 - 1669A )
•Y
Chocolate lh rk Green
Green
Gco Licht Blu e Licht Green
Oran
•
Pink Purp l e
R.d White Ye I low
(9805 1 - 1 670A) .lRl868AIS
C
17-16 SUPPLEMENT -1998 - 1999 MODELS Electrical System Wiring Diagram (KLF300B-12, U.S.AlCanadalAustraria Models)
I gnition
Switch
Cool ing
fl
Fan
S.i teh F use5A
Cool ing
Neutral / Rever s e
Switch
~~
Fan
:::
~
~~ ~
I ~
Head light 12V25 / 25W
00]
1 SK--l>CJ-' I S K - R / BK~R / BK---K I ¥---{>O- B K / Y---' SK I Y{>C}-SK I Y-
RI Y --c:J<}- ' / Y
Opt ion
R! Y
f/\!3/ - ---,---, I ;---:{:;l I }- BK / V-[::> : I __ ..r---, I Y----c:]
I!~~k
~
o
( R H)
Light : - __
~~ /~O~
::J
-D
Y
l
M ~~
,
~
~ ~
,J
~BK I Y
" - - - - - - ---:::: Tl.I
I
@:I
ISpeedomete r L igh"t
.
R---i.>1---J
L
_~
R D
BK / Y~K I
11 2 V 3. 4 YI
Y
I
tA:str~lia -1II~;j -;;"1 yJ ( OPtion ) U. s. A. / Canada Mode
ls
~
m# ~
CEE
/ BK~R / B K K I 'I----{>C]o KI Y -
R / Y~R / Y
-
Headl ight 1 2V25/25W ( l H)
:11
>:0::<11::..: ...... a:: ...... m ...... o::a ~
~
~
Austral ia
~~
~
,
~
~
~
~
~
~
~
~
~
~
~
~
Mode l
only
LEFT HANDLEBAR S"I TCH CONNEC T IONS Light / O inllner Switch ,/Y Color R IR / BK BR
En lin e
Color
OFF lO
OFF
HI
'UN
Slop
S . itcll
BR
<;.
Y/ ,
.,
Sta r ter Butt on Color Y/ , SK R e lease
Push
II L175781S
C
SUPPLEMENT -1998 -1999 MODELS 17-17 Electrical System
G)Reverse
Indicator Light
lZV3.4W
(DN e u t r a I
I n die a tor
Li g ht
I 2 V 3 . 4 If
Canada
Model
onl y
,
r
Canada lIodei
(Option) Canada Model only
only
j----, Front Brake
r -
-
-.,
Rea r
I
light
Accessary Term i nal
I
------r-r:~ r
Bra k e l i gh t.
Switch
Switch
Ta i J / Brake
Light
lZV 8/27WX2
____________
J
L
~ ~~ ~ ';;;
O~ -ltD
I
~
~
I
I
,-
,
- -~
Ta i l l i g h t 12V 81 X2
~
~
r-
1
BL-D B K I Y--CJ
R---c::kJ-- R
-
..,
•
~
)
Q. r
11l
~
~
n,
~n ~~
~~
I g ni tion
'0 SM
,
~
~
~
~
~
~
~
~ Co i I
0
._<
(+)
(- )
Battery
i~~i l!: __ ::!J
o
12V19AH
12V14AH(U.
s.
A. Model)
Re lay
Starter
Starter Circuit Relay
Starter
Motor
Co lor
BK BL BR
Spark Plug
CH
IU"
' OI
" 'I e. o... HI IO U
Color
OFF ON
BR
"
HU1Ul
G• • ,
,"
•
HVEHE SII' eM
P" s i t i .. n th . . ",h
'"
Neutral
Reverse
LG
cowuel
Ground
IO~S
RI.
.- . " (9805 1-17578 )
(98051-1758B) (98051-11598)
Code
Bl ack Blu e Brown Chocolate
OG Di r k Oraon G Green GY Gray LB Li c ht 8 1u. LG Licht Oroon 0
P PU
R
•Y
Orange Pink Purple
Rod White Ye I low IIRI757BW5 C
17-18 SUPPLEMENT -1998 - 1999 MODELS Electrical System Wiring Diagram (KLF300B-11, U.KlEurope Models)
Coo Ii" g
F,"
S. i 'h
(DReverse
Indicator
Light
12V3.4W
(DNeutral
In dicator
l ight
12V3,4111
I gnition
©=:: ===Er::v~'""~.~~0-)+~=~
Neutral /Reverse
Switch
Sw i tch
F use SA
®
y-++h
/BK-l>CJ-R/BK--K ( 'f--C:::D-B K / Y
RI Y -c::J
Headl ight
IlV2S /25 W (L H)
Pickup
Coi I
Alter n
Left Handlebar Switch (DLight/Dimmer
Swi teh
(DEngine Stop Switch
CD
® CD
(DStarter
Button
LE FT HAND LEBAR SWITCH CONNEC T IONS light / Dimmer Co I or
R/Y
R
Switch
En,ine
R/BK
Color
BR
OFF
OFF
HI
RU N
La
Stop
BR
Sw i tch
Y/R
--
Starter Button Color VIR BK Release
Push
~-=>
1111671A15
C
SUPPLEMENT - 1998 -1999 MODELS 17-19 Electrical System
,-------ICarburetor
UK Model - - - - - - - - -- Sensor
Thermo
I Cnntrol
1 1 1 1 1
l~ I:
1
Heater
,-
1
BKl
I I I
Accessary
-
-iii
r®
!::Io:: 1
l~l 0::
""'<>:: .......
~
"""""'I~!iIi ~~:
~
Li g ht s
T8 i r
I2V
1
,, ' - - ~
-'""""""'
L
Terminal
;;;1
12V23W
~
BWX2
-BK I Y-D
Heater
1
Relay
1 1
I
~
BK /Y I
Carburetor
1
Un i t
1~~~ ~ BK/{[E/R~H~~ -BK
1
-..,
..... lI: ......................
"--BK/Y LI-i>D--I
1
-
I I
1
-
L
- -
I I
,
~ ~
~ ~ 1
~
l!:: __ ::!J ;:;:::1
- - - - - - - - - - - - - - ..,
I
'-,
1
1
~
If
r
1 1
1
1
1
'--n -,·n ' mr II #if' ~t: * I
1
~
~~
~
~»-;;;;::.
II TI Regulator i
,
,
~
;;;j
>
St.t.,
J
Circu i t Relay
~::;:"""' ' ' ' ' I
T~1'i' T
I
~ ~~"~""~,,
I gnition
Spa r k
....
Starter
_- - -- -
COl I
Color
OFF ON
BR
I W
GY
Il •• , I"
l
P o. i t ion
~ ~ ~
Rei ay
Mo t
un.a
lh.6U,h St h
~, 0 w.m
0
Color Code BK B I a c k Bl B I u e BR B row n CH Chocolate
r
DG G
Gr e e n
GY
G"
lB lG
Plug
HUIUl
~
12V\9AH
- --
ION I T I ON Sl lle H eO N"E crrOiS
~
(-)
~
1 J
~
Battery
~
Starter
1
Y/ R
('I
~
~~ r .............. ~~ 1 1
~~/;--
~
l!:: __ ::!J
1
0:.
Igniter
Rectifier
I
~
,
~lJ
I
~
~
•
~
1
1
,
0 OM
.-
~
1
-
·,•
~<
Si lleR CO •• HIIO H$
lG
IGr oun d
. /1
I
Neu tra I Rel/erse
O. r k
Gr .o~
l i ,ht 81"e
l i .h t
Gr •• n
0
Orange
P PU
Pink Purpl e
I Y
White
• 'od
Ye I low
( 98051 -167 1A ) (98051-1672A)
IIRI871AIS
C
17-20 SUPPLEMENT -1998 -1999 MODELS Electrical System Wiring Diagram (KLF300B-12, U.KlEurope Models)
Cool; "g F,"
S.;, h
(DReverse
Indica t or
Li gh t
12V3 . • 'II
0Neutral
In d ic a t o r
Light
12V3.4II1'
Ign i tion Sw itch
©=:: ===~\.:C:'~:""~()-~=~l
Q
Fuse 5A
: ':~'~: I':"
&=n-c=-n (' H }®/BK-{>c}-' / BK~ ' I V -c:J<}- ' I V"
Option
' I v CJ<}- ' I V
I,~/~"~R / ~~~ I
I
.. .1- RI V
I','."
L.!1
V~ 5!... 6 ~
1
~~ >
,
~
~~
11-fr=~~~bJ=b;;;;~~~~~~~~~g
---C2j
HK / -V----[>· , lIg ht.--
~M
s1
' / BK-f>C}-' / BK K I ¥-!>CJ-lI K I 'I--
K I 't-{:::>CJ-B K I
Neut ral / Reverse Switch
<}-BK / V
-c>8-----
R
SP"d,m.t'~/ V-c=}
-
li g h t 12V3 . 4 1
®
I " -{>C}-, I BK-r-rK / 't--[:::::O--B K / Y
' I V -c:J<}- R/ V
Headl ight
12V2S / 25W ( l H)
Pickup
C oi I
Alternator
Left Handlebar (D l i g h t / 0 i m mer ®Eng i ne
0S tar LEFT
L i ght / Dimlller Colo r R/ y R
OFF LO HI
Stop
t e r
Switch
Sw i t c h Switch
But to n
HANDLEBAR SWITCH CONNECT IO NS Enl;n. Stop S.;tch Starter Switch
RI SK
8R
Color OFF
BR
VI R
But ton
Colo r
Y/ R I BK
Rll l el511
.L
Pus h 1
RUN
11 Ll7B0815 C
SUPPLEMENT -1998 -1999 MODELS 17-21 Electrical System
r------I ,Carburetor
Model
~
12V23W
'-
~
BK/y
BKl liT w
.-BK
I
Accessary Terminal
"IW," IR--;:j f;;~
-BK/Y
Carbu r etor
IL
~
Un i
Cnntro I
~I~11
Lw-l>C}-w
Hea ter
--------,
Thermo Sensor
J [
UK
L
_ _ CCI
a:::~a:::
r _
"::::::"\U~II ~s~~::
_
_ _
Rei a y
_
I I
I I
__
l!:: __ ::!J
___ ,
+-I-__,,
L ____
lights 12V g"x2
Tail
.~~
:&~~R~:(~Y~tt§j I I
I I
J
L
~a::1
- - - - - - - - - - - - --..,
;;~
I
>
I
~ ~
w, I
Starter Regulator ! Rectifier
Relay
I I L-_ _ _-----' I I gn i ter
J
Color
rr===f-l~~~=:~~=~=-=_=_=_t=_=_J ~
lj
Starter
Motor
BK BL
Ignition Coi I
~"~t,,~~,, Spark
BR
Brown
CH OG G
Chocolat e
GY
lB lG
Plug
IG NITI ON SI IH H CONNECT IO NS
Color
8R
w
GY
NE U TRAl
Geu
'
REVERSE
Pos ition
HITCH
LG
CONNECTIONS
GrounG
R/ W
OFF ON
Code
Black Blue
0
P PU
D or k
L
i, "t
are. n
Orange P ink Purpl e
Neutral
R R,d
Reverse
W Y
(98051-17608) (98051-176IB)
Gr e e n
Gr e e n G ray L ie nt Blue
White Ye I I 0"
11R1760SIS
C
SUPPLEMENT - 2000 - 2002 MODELS 18-1
Supplement - 2000 - 2002 Models Table of Contents Foreword.............. ........... ......... ...... ........ ...... ........ ....... .... .... ........ ..... ... ... .... .. .•... ....... .. ..... ....... How to Use this Manual......... ...... ..... ... ...... ........ ....... ..... ..... ... .... .... ... ... ...... .... ...... ... .. ..... ... ... General Information....................................... .......... .. ............. ....... .......... ..... .............. ............ Model Identification ............. ..... ..... ...... ... .. ... ...... ......... ... ...... ....... ......... ....... ........... ... ............ General Specification.................................................................. ................... ..... ... .. ............ Torque and Locking Agents ... .................... ........ ... .... .. ....... ......... ..... .... ............ ...... ... ....... .... Periodic Maintenance Chart.................. ... ... ...... ... .... .. .... ..... ...... . ...... ..... ... .. ..... ...... .... ...... .... Wiring, Cable, and Hose Routing ................. ............. ..... .. ............ ......... ................ ..... ......... Fuel System... ...... ..... ........ ..... ....... ......... ......... ..... .... .......... .... ....... ... ..... .... .... ....... ......... ... ....... Exploded View................................. .............. ......... ..... .... ..... ........ .......... ............................. Specification... .... .... .... ............... .. .... ....... ... ... ..... .... ...... ......... ........ .......... ..... .. .... ...... .... ...... .. Engine Top End . ... ..... .... ........................ .............. ... .... ....... ..... ........ ....... ... ..... ...... .... ... .... ....... Exploded View...... .................. . ........ ...... ........ ......... .. .. ..... ..... ........ .. ........ ........... ........ ... ....... Brakes .................................................................................................................................... Exploded View (KLF300-B13 - ) ...................................................... .................................... Frame.......... ............. ................................................................. ........................................ ... .. Exploded View (KLF300-B13 -, UK/Australia Models) ..... .. .............. ..... .... ... .... ................... Electrical System. .... .............. ..... ... ........... ............ ....... ........ ...... ...... ............... ....... . ..... ... .... .... Exploded View (KLF300-B 13 - ) ............... ..... ......................... .... ... .......... ............ ......... ... .... KLF300-B13 - B15 Wiring Diagram (U.S.A Model).................................... ........... ........ ...... KLF300-B13 - B15 Wiring Diagram (Canada Model)....................... .. .... .. ... .. .. ............... .. ... KLF300-B 13 - B 15 Wiring Diagram (Australia Model) . .... ....... ....... ... ............ ... .......... ... ... ... KLF300-B13 - B15 Wiring Diagram (U.K Model) ........ .... ................... ....... ..... ....... .............. KLF300-B13 - B15 Wiring Diagram (Europe Model)...........................................................
18-2 18-2 18-3 18-3 18-4 18-6 18-7 18-8 18-9 18-9 18-9 18-10 18-10 18-11 18-11 18-12 18-12 18-13 18-13 18-14 18-16 18-18 18-20 18-22
18-2 SUPPLEMENT - 2000 - 2002 MODELS Foreword How to Use this Manual This "Supplement 1998 - 1999 Models" designed to be used in conjunction with the front part of this manual (up to 17-20) and/or Base manual KLF300 Service Manual - Part No. 99924-1057-01. The specifications and maintenance procedures descried in this chapter are only those that are unique to the KLF300B13 - B15 models. Complete and proper servicing of the KLF300B 13 - B 15 models therefore req uires mechanics to read both this chapter and the front of this manual.
SUPPLEMENT - 2000 - 2002 MODELS 18-3 General Information Model Identification KLF300-B13 Left Side View
KLF30D-B13 Right Side View
18-4 SUPPLEMENT - 2000 - 2002 MODELS General Information General Specification Item Dimensions: Overall length Overall width Overall height Wheelbase Ground clearance Seat height Dry weight Curb weight: Front Rear Fuel tank capacity Performance: Minimum turning radius
KLF300-B13-B15
1910 mm 1115 mm, (EU, UK, AS) 1160 mm, 1065 mm 1210 mm 195mm 750mm 226 kg, (EU, UK, AS) 229 kg 109.5 kg, (EU, UK, AS) 110 kg 126.5 kg, (EU, UK, AS) 129 kg 9L
Inlet
Exhaust
Lubrication system Grade Engine Oil :
Viscosity Capacity
1160 mm
2.9 m (Locked axle mode) 2.6 m (Differential mode)
Engine: Type Cooling system Bore and stroke Displacement Compression ratio Maximum horsepower Maximum torque Carburetion system Starting system Ignition system Timing advance Ignition timing Spark plug Valve timing:
(B15 ~ )
Open Close Duration Open Close Duration
4-stroke, SOHC, l -cylinder Air cooled 76.0 x 64.0 mm 290 mL 8.6 14.3 kW (19.5 PS) @6500 r/min (rpm), (US)22.5 N· m (2 .3 kg· m, 16.6 ft · lb) @ 5500 r/min (rpm), (US) Carburetor, Keihin CVK32 Electric starter & recoil starter Battery and coil (transistorized) Electronicallyadvenced From 10° BTDC @1300 r/min (rpm) to 30° BTDC @ 4000 r/mim (rpm) NGK DR8EA, (EU , UK) DR7EA 21 ° BTDC 59° ABDC 260° 56° BBDC 24° ATDC 260° Forced lubrication (wet sump) SE, SF or SG class (B15 ~ ) API SF or SG API SH or SJ with JASO MA SAE10W-30, 10W-40, lOW-50, 20W-40, or 20W-50 (B15~ ) SAE5W-30, 10W-40, 1OW-50, 20W-40 or 20W-50 1.7L
SUPPLEMENT - 2000 - 2002 MODELS 18-5 General Information
Item Drive Train: Primary reduction system:
Clutch type: Transmission:
Type Gear ratio
Final drive system:
Overall drive ratio: Final gear case oil:
Frame: Type Caster (rake angle) Chamber Trail Tread
Front tire: Rear tire: Rim Size: Suspension:
Type Size Type Size Type Size Front Rear
Front Rear Electrical Equipment: Battery Headlight: Type Bulb Reverse light Tail/Brake lights Type Alternator: Rated output Voltage regulator: Type
KLF300-B13-B15 Type Reduction ratio Primary Secondary 1st 2nd 3rd 4th 5th Reverse Type Reduction ratio
Type
Gear 2.888 (78/27) Auto centrifugal, wet Auto multi disc, wet 5-speed plus reverse, constant mesh, return shift 3.090 (34/11) 1.928 (27/14) 1.368 (26119) 1.000 (23/23) 0.769 (20/26) 3.072 (26/11 x 26/20) Shaft 4.886 (20/16 x 43/1), (EU , UK, AS) 5.584 (20/14 x 43/11) 10.858 @Top gear, (EU, UK, AS) 12.409 @ Top gear API GL-5 Hypoid gear oil SAE90 (above 50 C, 41 ° F) or 0 SAE80 (below 50 C, 41 F) 0.35 L Double tubular 3.0 0 1.0 @ 1G 13mm 834 mm 844 mm Tubeless AT 22 x 9.00-10 Tubeless AT 24 x 11.00-10 10 x 7.0 10 x 8.5 Double wishbone-link 125 mm 0
Front Rear
Type Wheel travel Type Wheel travel
Brake type:
12 V 14 Ah (EU, UK, AS) 12 V 19 Ah Semi-sealed beam 12 V 25/25 W L & R (EU , UK) 12 V 10 W 12V8/27Wx2 Three-phase AC 23.5 Al14 V @9000 r/min (rpm ) Short-circuit
Specifications are subject to change without notice, and may not apply to every country. EU: Europe Model, UK: U.K. Model, AS: Australia Model, US: U.S.A. Model
18-6 SUPPLEMENT - 2000 - 2002 MODELS General Information Torque and Locking Agents
Parts
Torque N-m
Kg-m
ft-Ib
Alternator rotor bolt
59
6.0
43
Starter clutch Allen bolts
34
3.5
25
Recoil starter flange nut
8.3
0.85
74 in-Ib
Remarks
Engine Left Side:
L : Apply non-permanent locking agent to the threads.
L
SUPPLEMENT - 2000 - 2002 MODELS 18-7 General Information Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the vehicle in good running condition. The first service is vitally important and must not be neglected.
First Service .=Clean, adjust, lubricate, tighten, or replace parts as necessary.
Engine:
* Clutch adjustment * Air cleaner--service
Valve clearance--check Fuel system cleanliness--check
*
Throttle lever play --check Engine oil--change Oil filter--replace
*
*
Spark plug-·clean and gap Spark arrester--clean Chassis:
* Rear brake lining wear--check * Front brake pad wear--check * Rear brake adjustment--check
Brake fluid level--check Brake fluid--change Cable adjustment Battery--check
*
Steering play--check
*
General lubrication Bolts and nuts--tighten
Regular Service
A~'''"~~:~:~~
of use
•• •• •• ••
".,
a-
«7o0'11-~'o
"., a-
0
«l0'11-~'o
•• •
•• •• •• • •• • • • • •• •
"., a-
".,
000
«l0'11-~'o
«la-,,OJ
•• •• • •
See Page
2·7 5-3 3-6 (2-10) (2-4) (5-11 ) (5-11) (14-17) 3-11 (10-6) (10-6) 10-7
•
•
(10-8) (10-8)
** 14-6 (12·6) 15-4 15-4
•
(9-6)
2 years
(10·11)
Caliper piston seal and dust seal--replace
2 years
10-6
Brake hose--replace
2 years
10·9
Final gear case oil--change
*
Master cylinder piston assembly and dust seal--replace
* :Service more frequently when operated in mud, dust, or other harsh riding conditions .
* *: Refer to 2, 7, 9, and 10 chapters.
(xx-xx): Reference Page in the Base Manual
18-8 SUPPLEMENT - 2000 - 2002 MODELS General Information Wiring, Cable, and Hose Routing Breather Tube Assembly (California Model)
7
6
4
6
LF300B0 1W4 C
1. Clamp 2. Clamp 3. Clamp 4. Tube (10 Cylinder Head) 5. Joint 6. Tube (to Air Cleaner Assembly) 7. Air Cleaner Assembly 8. Cylinder Head 9. Cap
10. Carburetor 11 . Install the clamp ® so that the clearances between the tube and near parts are more than 5 mm .
SUPPLEMENT - 2000 - 2002 MODELS 18-9 Fuel System Exploded View
California Model Kl3801
W2 C
Specifications Item
Standard
Service Limit
Carburetor: Make, type
Keihin, CVK32
- --
Main jet
#125
Main air jet
#100
- -- --
Needle jet
#6
-
Jet needle
N74T
Pilot jet
#38
Pilot air jet
#140
-- -- --
Pilot screw
2 1/8 turns out
- --
Starter jet
#65
- --
--
-
Service fuel level (from carbu retor 0.5 mm (below) - 1.5 mm (above) body bottom edge) (CA) 1.5 mm (above) - 0.5 (below)
- --
Float height
17 ±2 mm
-
Idle speed
1 300 ±100 r/min (rpm ,)
-
---
(CA) 1 300 ±50 r/min (rpm) Optional parts: Main jet
#120, 122, 128, 130
Pilot jet
#35, 40
Starter jet
#68, 70
CA: Californian Model
-- -- --
18-10 SUPPLEMENT - 2000 - 2002 MODELS Engine Top End Exploded View
,---
- ---
I
-- ~
Cal ifornia Model
XUII02
1. Manual Compression Release L : Apply non-permanent locking agent. M : Apply molybdenum disulfide grease.
o : Apply engine oil. R : Replacement Parts T1 : 29 N-m (3.0 kg-m, 22 ft-Ib) for used parts 34 N-m (3.5 kg-m, 25 ft-Ib) for new parts T2: 12 N-m (1.2 kg-m, 104 in-Ib)
.s
C
SUPPLEMENT - 2000 - 2002 MODELS 18-11 Brakes Exploded View (KLF300-B13 -)
S i \-----1 Vr-----{T2
2
HL020UBIJ
1. 2. Si: T1: T2: T3: T4:
Brake Switch Boot Apply silicone 1.0 N·m (0.10 5.9 N·m (0.60 1.2 N·m (0.12 8.8 N·m (0.90
grease. kgf·m , 9 in·lb) kgf·m , 52 in·lb) kgf·m, 10 in·lb) kgf·m, 78 in.lb)
C
18-12 SUPPLEMENT - 2000 - 2002 MODELS Frame Exploded View (KLF300-B13 -, UK/Australia Models)
eo
H002043B12
1. Shovel Holder
C
SUPPLEMENT - 2000 - 2002 MODELS 18-13 Electrical System Exploded View (KLF300-B13-)
A }-----1
B
HPOl062BU
1. Bulb (27/8 W) 2. Bulb (10 W) T1: 7.8 N·m (0.8 kgf·m , 69 in·lb) A: Europe/Australia/UK Models (UK Model Apply for KLF300-B13-) B: UK/Europe Models
C
18-14 SUPPLEMENT - 2000 - 2002 MODELS Electrical System KLF300-813 - 815 Wiring Diagram (U.S.A Model) (DRe,erle Indicator ®Nlutrl ' Neutral/R".r •• Iinilion Switch S. i 'C h
Indic;ator
Fr Li ,
Hlldl i ,hi
12V25/25W (RH) CIllR/BK--t>D-R /BK- R/BK~R/BK---R/Y --{>O-R/Y R/Y -{>C]-- R/Y BK/Y ---c:J<} BK/Y.- I- BK/Y-D
~ ~
I
"-
m '" m '"
1
I
Y
Y
~
~
~
R/B K---{:>C}-R/BK l- IR/Y--c:>D-- R/Y IBK/Y ---CJ<}BK/Y CIll Hlldli,hl
12V25/25W (L H)
~ '" '" ,a::Dla::,~
a:::
~~
'"m
~1D,.m
~~~
~,
"''''
# ~
I
'"
m m
[ L-------'Pic:kup Coil
AI t.rnalor
LIft Hlndl,bar Switch CDLI,ht/ Olmm.r
Switch
QUE"'ln. Stop Switch @Start.r Button
LEFT HANDLEBAR l(rht/Dlmmor 50 It. h Color R/Y R R/BK BR OFF LO HI I
I~
'------!
SUPPLEMENT - 2000 - 2002 MODELS 18-15 Electrical System
Idle.tor
Licht
12V3.4W
Idlcltol
Licht
12V3.4W
Rlar Br ake Lilht
Front Br,lt ,
OJ
Lieht Switch
2)~
~ H .,
I~ .,
«
~1 .,
.,
., .,'"
~Tail /Brak,
~
~~
., '"
~
Accesl.', Terminal
Switch
L ic hte
\ a
.rR---c:::J
., ';' '"
8/27WX2
L~
r- BK / Y ~ BK /Y
~
I
/
BL---D
2V
'--
W-
c /
C$
~
~
~
~
n
~
-~
~
c
-c _0
"'~
~
n.
i!il!!ilIII!I
.,,,, "''-
II}
Bat lery 12V14AH
'enlllDn
c ,I
I
Starter C Ire u I t
Rl lul,tor/
Stlrt,r R,la,
Ril,y
Rlctlfi,r
Co lor Cod,
M
I,nit"
BK Blaok BL Blo,
p Co i I
St 'rt, r
Motor ,
BR
Bro wn
CH
Chocolate
hr. a"l. G 6rt.n
DB
Splrk PIUI
HDLEBAR SW ITCH CONNECTIONS It, h
En, ' n
BK BR
Color
-
. .-;>
OFF RUN
It.,
BR
I . . ITID' •• lTc r CD.neTI.n
Stul,r Button Y/R Color Y/R BK
Swllc'
R,I, II.
Pu."
I I I
Color
OFF ON
BR
W
IEur_AL I REYERIE •• ITCN CO,.EeTIOI.
a •• , P .. ltI,n
La
9r •• nll
R/W
Ur . . . . 5 ..
'"N,utra'
BY
GrlY
LB LG
Lilli!
o P PU
III ..
Lis ., Gr . . .
Orin" Pink Purpl.
R R,d
Rlv,r ••
W Wh It, Y l,ll .. (98051-1860A) lnOClllllAJ C
18-16 SUPPLEMENT - 2000 - 2002 MODELS Electrical System KLF300-813 - 815 Wiring Diagram (Canada Model) Op tion
1- - - - - - - - - - - - - - 1
, i t ion
--l
Fin S., teb
I"dle .tor Lie
0N,utral
Indicator
S. it c h
S.II, h
.-
.-
R/Y-{>O--R/YBK/Y-cJ
~
.....
., ., '" '"
CD ®
., IE
,.
t
Front l i I ht !
I
Y Y
Lie
H.utrII/Rt¥,r ••
~'n
Caal II
(DR"'rlt
CJ:':
.....
1
'"I
~ .....
'"I
r
.,
ClIIE
L
Y
Y
~~~
(jD;
/BK--C>CJ--RI BK R/y---t>CJ--RI Y
B KI Y---c::::J<:J---B KIY
~ '" ,a:::
He.dli,hl 12V25/25W
IE
'"
ID a:: ........ ::.:: ~ID>-m
.,'"
~
(L H)
Jrrh'iJ
OFF'
'~ __HI'L-·l "
®
CD Le ft
Hlndllb,r
® Switch
(DLilht/Dimm.r Swlleh
illEn,ln. Stop S.lleh
CDS •• rttr
Button
#1 ~~~
AI t.rnttor
~
,......
., '"
~>:
~ * ~
'"
Pickup Call
~
>- :
SUPPLEMENT - 2000 - 2002 MODELS 18-17 Electrical System
t.r
Licht
12V3,4W
t.r
Licht
12V3,4W
Re i ' Lilhl
~
Front Br.k. Licht Swlt .. h
~
~~ ~
.,
Terminll
IC
m
m
~~ i
,.,
~
m
i
ACCls""
.
m
~
Br,k. SWi t ch
BL ~ BL r- BK/Y ~ BK/Y
.,
---
II
12V
8 / 27W X 2
"!
e
1\
- R ----D
m
T, II / Bra k. llcht .
'-
W-
fC:"\
.• ... -. ~
~
~
Q
~~
:E
~'
11l
>
>
"'
~ ~
..n
a::
"'
C!' :.::
n
~
~
~ ~
'" >
1+1 I-) Bttt.r,. 12V19AH
I, nit Ion
Stut., R.I.,
Col I
Slarter Circuit
R'lul.tor/ R,Cllfl.f
I
R. J.)'
,n it, ·J
Color Cod •
• I I
Start.r Motor SPlrk
Plu,
BK BL BR CH
BIIOk Blu. Brown Chacal_1I
DG G BY
Gr •• n Gr"
LB
lIH' 11111
LG '"ITIOI .WIT el COllECT IOU
Color
OFF ON
BR I W
'E~l'AL
a•• r 111
l RE'EIIE 'WITCH CO"EeTla ••
PD. 1 t I all
"""'
su
LG 18, .. ,,4 R/W I
N.utral
R.v., ••
o P PU R
-'
Darll; Grltn
LI,1Il
Gr .. .
Orlnl' Pin k Purple
\I
R. d Whit.
Y
y,llow
(98051-1861A) LfUOIUU
18-18 SUPPLEMENT - 2000 - 2002 MODELS Electrical System KLF300-813 - 815 Wiring Diagram (Australia Model) ladle.tor
Lie
0Ntutr,1
Indlc.tor
Ltc
N. u t r a I /R. , • r I S.I tch l enition
Cool I", Fin
W=
H,.dllrht
BL - - - - - - , BL---!:>D__
,~ '"I
12V25/25W (RH)
@,
/BK--f>D-R / B K - -RIB K-{>c:J-RI B K R/Y--f>D-R/YR/Y-t>CJ-- R/Y BK/Y--CJ
•
Frol Bnl
'n ' ij
Cool inl Fan Sw I t co h
Option
(DRIV.r ••
~
~~ ~~ H~ ~
~~
III:':
,
~
~........
.......
I
I
'"
'" '" '" ~
'"
ca
-"CD
L
It j )--.---R/B-::{::l \ :-" - R/Y----C:> t
,.... .......
J----B/Y---~
Iwork Lllhl
,
I I
r- -~-:::J
Li~V_65/6~~~
@'r)-- R--t>B- R Speedometer
Li I h-I 12V3.4W
L
BK/Y --C!<:J-BKI Y
~~~
®
R/BK---c>D R/BK R/Y-!>CJ- R/Y BK/Y---CJ<} BK/Y
,-11. ~
I~
Htadlllhi 12V25/25W
>< '" ........ 1E 1D1E , : . : ~ID>-m
«
(L H)
III
I
b
~Loi OFF:
~
~~~
:~'
HI'
§~12V
CD
So I I c h
®Enllnl Stop Switch
0SlIrt.r Button
..
>- >-:
~ * J><
"'
G
l.5AAllorn.lor
rr-h
Left Hlndl.b.r Switch
CD L II hi 10 I mmer
>- >-:
J'
Pickup Coil
:11: CD L -UJHorn
__ ~·l
CD
Horn
'" ~'"'
Bullon LEFT HANOLEBH Licht/Dimmer Swllch Color R/Y R R/BK BR
OFF LO HI ~
SUPPLEMENT - 2000 - 2002 MODELS 18-19 Electrical System
or
L II hi
12V3 . 4W
or
Lie hi
12V3.4W
Rear
Brake Lilht S. it c h
Fro n t
Brat, Lilht
6
Sw i t c h
ti
.,~ .,'"
~~ ~~ i .,
.,~ .,'"
~l ~
i
Accesli.ry
Terminal
., .,'" ~
.,'"
~
.----
.------B L--c:J
Tai I/Brlt. Licht 12V 8/21WX2
'-
------rr.-------~----------------_+~_r----rt----------W -
(t)
H
8.tt,rl 12V19AH
,n
I I I Ion Coli St.rt.r Circuit
R"ul.tor/ R,ctlfl.r
SlIrt.r RallY
R,II,
lin It. r
Color Code St.rt.f Motor
Spark
Plul
BK BL BR CH
Blick BI u 0 Sf awn Chocolat,
DG
Duk Grn.
G
.EBAR SWI TCH CONNECTIONS h
hll'"
BR
Co lor
.,
OFF
II)
RUN
St.,
Stlrt,r Button Y/R Colar Y/R BK
S_lha.
BR
R.I ....
_L
p" h
"lIT I 01 '11 Tel CDIIUT tall
Ca I 0
OFF ON
J
BR I
W
IEUTIAL l REvellE 'W ITe" CO"EeTIOI,
e •• r lit
P"III,. Ur ••• 111 5111
LO 18, .... 11 R/W I
N.utr.1 RIVlr ••
I (98D51-1862A)
are,n
GY
Gr BY
LB LO o
LI,u Blue LI.hl areen Or
In,.
P
PI nk
PU
Purplo
R Rod W Wh It 0
Y
V,llow LfJDD80UI C
18-20 SUPPLEMENT - 2000 - 2002 MODELS Electrical System KLF300-B13 - B15 Wiring Diagram (U.K Model)
CD R,VlrI.
Indicator
Lilt,
N,u t f l l
'ndlcator
li, ~
0
I,nition Switcb
Cool inl
Fan
©==::===~C"~~==~l
Swich
Fuse
Coolin.
Fan
Heldll,ht
toe
SA
KO
~ ~ ~~
(R H)
(ID;
/BK-t>CJ-R/BK R/Y---t>CJ-R/Y BK/Y-CJ<]-BK/Y r- -
R/BK{>C}-R/BKR/Y -!>D-R/YBK/YCJ<::]-BK/Yl
I
It j )-i--R/;K-=C;:l I \ }--- R/Y- ---£:> j - B K/Y -.."----'
Iwork
Li-; h l r - -
[1_2~65/~~!J
1/2W
------:>~ ! ~~
= - _ B_L
12V25/25W
Opt Ion
C.rb
Neutr.I/R,Ylrs. S. i t c h
>
9
~ ~ '"
I I
-~-~
-<}-BK/Y-l-++---1
--r>B--R
sP"dom'I'~~Y~BK/yL4-+~---+-+~1-~-+~---~-~~-~ . LII h I 12V3.4W
(ID;
/ BK-t>CJ-R/BKR/Y---t>CJ-R/Y BK/Y-CJ<]-BK/Y-
H.ldlllni
12V25/25W (L H)
1 PI ckup Col
H0 r n 12V1.5A lift
Handl.bar
Switch
(D li,ht/Dimmtr S.llch ®Enllnl Stop Switch
Horn Button
0S1.rt.r Bultoll
Spa LEFT HANDLEBAR SWll EI,I •• Lllhl/Dlmmor S.I ten
Color OFF LO HI
R R/BK BR I
RIY
I
Colo OFF
RUN
====~~-=2=OO=O~-~2~~~~~~~1 002 MODELS 18-21 ~E_~le~c~tr~ic~a~I~S~Y~SlEt~e~m~==========S=UU~PPLEMENT
=
" u, .. ""
or
L
• 4W ;(hI12V3 , 4W
Carburetor
Thermo
SenBor
•
,.
'"
K/R~~,.~~~ '" '" ~
BK/mE BK/Y B
~W
W
Ca,bu' ttor He.t,r l 2V23
BK
.[Pl >fl
BK~/~Y====--~-+~--
BKl 1 ~~ .. ,., ""'1lJilil " -, ::!J W
Tai!/Br.kl LI I h t I 12V 8/27WX2
><
'"
HI.ter R,I.,
~
I
I
I
I
~
LI • h I OW
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enltion Cui
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~
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kup Coil
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..
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Y Y,llow
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18-22 SUPPLEMENT - 2000 - 2002 MODELS Electrical System KLF300-813 - 815 Wiring Diagram (Europe Model) Ignition
Switch
Neutrai/R e yersl 5.1 Ie h
Fuse
5A.
BL-I:>CJ-- Bl - - - ----'
Cool inl Fin
H,adlirht
12V25/25W (R H)
Op I Ion
OOJ
"'
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.-
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(!)sta rt.r Button
LEFT HANDLEBAR SWI el ,lI.. Lllht/Dlmmer S.I t c h Color R/Y R RI'BK BR Colo OFF OFF LO HI RUN
SUPPLEMENT - 2000 - 2002 MODELS 18-23 Electrical System
(DR".r ••
Indi cator
Lilill
12V3.4W
0H,utral
Indic ator
Lilh!
t2V3.4W Ace •••• ry
$I
~B"k' LICh~.ar
H
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~:
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.
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RelaY
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) Co I I
St.rter Mo tor
BK BL
BR
Spark Plug
CH . DG G
AR
Ll,ht
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W-
SWITCH CONNECTIONS
IGNITION .W ITC" COllECTIONS
Start.r Bunon
Co lor
BR I Y/R
Color
OFF
I
R,I, •• ,
I
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RUN
~
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BK
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I I
W
I I
OY
IEUTRAl • REYEalE .W ITCH CO.'ECTIO.' Stat POll I hll
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La ED,I", StD, S.lld
Black B I",
o
Orin ••
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Pin k
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Purpl,
Neutral
R W Y
RId Wh I t
Re,., ••
I (9BOSI-IB6H)
I
Y'llow LfaGGIIOIU C
SUPPLEMENT - 2003 - 2006 MODELS 19-1
Supplement - 2003 - 2006 Models Table of Contents Foreword ......... ... ........ ............. ............ .... ... ....... ..... ..... ........ .......... ............. .......... ....... ........... How to Use this Manual........................... ................. ... ..... ......... ....... ....... .. .. .... ... .... ............. General Information.............. .... ... .. ............................... .......................................................... General Specifications........... ............ ........ .. .. .......... ....... .... .............. ........ .......... ........... ...... Fuel System......................... .. .... ........... ........................ .......................... ....... ......... .. .............. Specifications........... .. .. ... ...... ........ .... .................... .. ...... ...... ....................... .......... .... ............ Engine Right Side.................... ............. ........ ............... .......... ............... ........ .. ........ .. ... ........... Specifications............ ............... .. ....... ..... ............................. .. ............. ...... ............ ...... .......... Engine Oil and Oil Filter................... .............. ... .. ........ .... ...... .............. ........ ............... ........ .. WheelslTires................................ .. ........ ....... ....... .......... .......... .............. ......... ... ..................... Front Hub.... .......................... .. ....... .... ..... ........................ ....... ..... ................. ......... ..... .... ...... Front Hub Installation ............. .. ... .. ........ ................................... ......... ............................... . Rear Hub ............................................................................................................................. Rear Hub Installation ........................ ....... ................ ............ .. .... ....... .... ...... ........ .. .. .......... Brakes................................... ... ......... ..... ..... .. ....... ...................... ............ .......... ........ .... .......... Exploded View...................................... ....... ...... .. ... .. ................ .. .......... ............................... Frame... ..................... .......... .................... ........ ................ ....... ..... ...... ...... ....... .......... ........ ...... Exploded View .... ......... .. .. ......................................................... :..... .. ... .. .. .... .... ..... ............... Electrical System............... ................. .. .... .. .. ........ .......... ............. ........... ............ ....... ........... .. Exploded View............................................... .. .............. ............ .. .... .. .... .......... ........ .. .. ........ Wiring Diagram (U.S.A. Model) .............. ...... ... ...................................... ........... ....... ............ Wiring Diagram (Australian Model)......... .. ......... ...... ....... ......... .............. .......... .... .... ...... ...... Wiring Diagram (European Model) .......... ........... .. ............ .......... .. .......... ........... .. ................ Wiring Diagram (U.K. Model).............................................. .................... ..... ............ ............
19-2 19-2 19-3 19-3 19-6 19-6 19-7 19-7 19-7 19-8 19-8 19-8 19-8 19-8 19-9 19-9 19-10 19-10 19-11 19-11 19-12 19-14 19-16 19-18
19-2 SUPPLEMENT - 2003 - 2006 MODELS Foreword How to Use this Manual This "Supplement 2003 - 2006 Models" designed to be used in conjunction with the front part of this manual (up to 18-23) and/or Base manual KLF300 Service Manual - Part No. 99924-1057-02. The specifications and maintenance procedures descried in this chapter are only those that are unique to the KLF300-B16 - B6F models. Complete and proper servicing of the KLF300-B16 - B6F models therefore requires mechanics to read both this chapter and the front of this manual.
SUPPLEMENT - 2003 - 2006 MODELS 19-3 General Information General Specifications Item
KLF300-B16 - B6F
Dimensions Overall Length
1 910 mm
Overall Width
1 160 mm
Overall Height
1 065 mm
Wheelbase
1 210 mm
Ground Clearance
195 mm
Seat Height
750 mm
Dry Weight
226 kg , (AS, EU, UK) 229 kg
Curb Weight: Front
109.5 kg, (AS, EU , UK) 110 kg
Rear
126.5 kg , (AS, EU , UK) 129 kg
Fuel Tank Capacity
9 L
Pertormance Minimum Turning Radius
2.9 m (Locked axle mode) 2.6 m (Differential mode)
Engine Type
4-stroke, SOHC, 1-cylinder
Cooling System
Air cooled
Bore and Stroke
76.0 x 64.0 mrn
Displacement
290 cm 3
Compression Ratio
8.6
Maximum Horsepower
14.3 kW (19.5 ps) @6 500 r/min (rpm) , (US)-
Maximum Torque
22.5 N·m (2.3 kgf·m, 16.6 ft·lb) @5 500 r/min (rpm), (US)-
Carburetion System
Carburetor, Keihin CVK 32
Starting System
Electric starter & recoil starter
Ignition System
Battery and coil (transistorized)
Timing Advance
Electronically advanced
Ignition Timing
From 10° BTDC @1 300 r/min (rpm) to 30° BTDC @4 000 r/min (rpm)
Spark Plugs
NGK DR8EA, (EU , UK) DR7EA
Valve Timing: Inlet: Open
21 ° BTDC
Close
59° ABDC
Duration
260°
Exhaust: Open
56° BBDC
Close
24° ATDC
Duration
260°
Lubrication System
Forced lubrication (wet sump)
19-4 SUPPLEMENT - 2003 - 2006 MODELS General Information Item
KLF300-816 - 86F
Engine Oil: Type
API SE, SF or SG API SH or SJ with JASO MA
Viscosity
SAE10W40
Capacity
1.7 L
Drive Train
Primary Reduction System: Type
Gear
Reduction Ratio
2 .888 (78/27)
Clutch Type : Primary
Auto centrifugal, wet
Secondary
Auto multi disc, wet
Transmission: Type
5-speed plus reverse, constant mesh , return shift
Gear Ratios: 1st
3.090 (34111)
2nd
1.928 (27/14)
3rd
1.368 (26/19)
4th
1.000 (23/23)
5th
0.769 (20/26)
Reverse
3.072 (26/ 11 x 26120)
Final Drive System: Type
Shaft
Reduction Ratio
4.886 (20/16 x 43/1), (AS, EU , UK) 5.584 (20/14 x 43/11)
Overall Drive Ratio
10.858 @Top gear, (AS, EU , UK) 12.409 @Top gear
Final Gear Case Oil: Type
API GL-5 Hypoid gear oil SAE90 (above 5°C, 41 °F) or SAE80 (below 5°C, 41 °F)
Capacity
0.35 L
Frame
Type
Double tubular
Caster (Rake Angle) Chamber
3.0° 1.00 @1G
Trail
13 mm
Tread: Front
834 mm
Rear
844 mm
Front Tire : Type Size Rear Tire:
Tubeless AT 22 x 9-10
Type
Tubeless
Size
AT 24 x 11 -10
SUPPLEMENT - 2003 - 2006 MODELS 19-5 General Information KLF300-B16 - B6F
Item
Rim Size: Front Rear
10 x 7.0 10 x 8.5
Suspension: Front: Type
Double wishbone-link
Wheel Travel
125 mm
Rear: Type
Torque tube-link
Wheel Travel
120 mm
Brake type: Front
Disc (hydrau lic) L & R
Rear
Drum (mechanical} L & R
Electrical Equipment
Battery
12 V 14 Ah, (AS, EU, UK) 12 V 19 Ah
Headlight: Type
Semi-sealed beam
Bulb
12 V 25/25 W L & R
Reverse Light
(EU, UK) 12 V 10 W
Tail/Brake Lights
12 V 8/27 W x 2
Alternator: Type
Three-phase AC
Rated Output
23.5 Al14 V @9 000 r/min (rpm)
Voltage Regulator: Type
Short-Circuit
Specification subject to change without notice, and may not apply to every country. AS: Australian Model EU: European Model UK: U.K. Model US: U.S.A. Model
19-6 SUPPLEMENT - 2003 - 2006 MODELS Fuel System Specifications Item
Standard
Service Limit
Carburetor Make, Type
Keihin ,CVK32
- --
Main Jet
#125
Main Air Jet
#100
- -- --
Needle Jet
#6
- --
Jet Needle
N74T
- --
Pilot Jet
#38
- --
Pilot Air Jet
# 140
- --
Pilot Screw
2 118 turns out
- --
Starter Jet
#65
-
Service Fuel Level (from Carburetor 0.5 mm (above) - 1.5 mm (below) Body bottom Edg e)
--
- --
Float Height
17 ±2 mm
- --
Idle Speed
1 300 ±100 rl min (rpm), (CA) 1 300 ±50 rl min (rpm)
- --
Main Jet
#120,#122 , #128, #130
Pilot Jet
#35 , #40
- -- --
Starter Jet
#68, #70
- --
Optional Parts:
CA: California Model
SUPPLEMENT - 2003 - 2006 MODELS 19-7 Engine Right Side Specifications Item
Standard
Service Limit
Engine Oil
Type
API SE, SF or SG
- --
API SH or SJ with JASO MA Viscosity
SAE 10W-40
- --
Capacity
1.7 L
- --
Engine Oil and Oil Filter Recommended Engine Oil Type: API SE, SF or SG
SAE 20W 50 SAE 20W 40
API SH or SJ with JASO MA
SAE lOW 50
Viscosity:
SAE 10 W-40
SAE lOW 40
Capacity:
1.7 L
SAE lOW 30
NOTE ODepending on the atmospheric temperature of your riding area, the engine oil viscosity should be changed according to the chart.
( SAE 5W 30
, -",
~
I I
c·c) 20 , , , ", ", "", " "'", ,
-. 20
,
0
40
I &4(°F)
HU09002BSI
,
19-8 SUPPLEMENT - 2003 - 2006 MODELS WheelsfTires Front Hub Front Hub Installation eTighten:
A
Torque· Front Hub Nuts: 34 N·m (3.5 kgf·m, 25 ft-lb)
e Insert a new cotter pin [A].
NOTE
o When
inserting the cotter pin, if the slots in the nut do not align with the cotter pin hole in the axle, tighten the nut clockwise fBJ up to next alignment. O ft should be within 30 degree. OLoosen once and tighten again when the slot goes past the nearest hole.
HJ070078S1
C
e Bend the cotter pin [A] over the nut [B].
~
I
r----
~
A Il J07008B$ 1
Rear Hub Rear Hub Installation e Refer to the above figures in the Front Hub Installation. eTighten: Torque · Rear Axle Nuts: 145 N·m (15.0 kgf·m, 110 ft·lb)
elnsert a new cotter pin [A].
NOTE
o When inserting the cotter pin, if the slots in
the nut do not align with the cotter pin hole in the axle, tighten the nut clockwise fBJ up to next alignment. O lt should be within 30 degree. OLoosen once and tighten again when the slot goes past the nearest hole. e Bend the cotter pin [A] over the nut [B].
C
SUPPLEMENT - 2003 - 2006 MODELS 19-9 Brakes Exploded View T3
~
o
~ /®-~
~>
i~'j
I-®
~ .~
~ i~
~~ ~
l
~~ "
0'
•
HL02007BU C
L: R: Si: T1: T2: T3: T4: T5: T6: T7:
Apply non-permanent locking agent. Replacement Parts Apply silicone grease. 1.0 N·m (0.10 kgf·m, 9 in·lb) 1.2 N-m (0.12 kgf·m , 10 in·lb) 5.9 N·m (0.60 kgf·m , 52 in·lb) 7.8 N·m (0.80 kgf·m, 69 in·lb) 8.8 N.m (0.90 kgf·m , 78 in·lb) 25 N·m (2.5 kgf·m, 18 ft·lb) 37 N·m (3.8 kgf·m , 27 ft·lb)
19-10 SUPPLEMENT - 2003 - 2006 MODELS Frame Exploded View
~002013 B .~
1. Australian and U.K. Models 2. European and U.K. Models
C
SUPPLEMENT
2003 - 2006 MODELS 19-11
Electrical System Exploded View
7
KP02031BU t
1. Ignition Switch 2. Light Switch and E . 3. Cooling Fan SWitc~glne Stop Switch 4. Australian Model 5. Other than USA M
6 . U.K. Model . . .
odels
7. Optional Parts 8. KLF300-B1 7 T1: 7.8 N·m (0 .80 kgf.m, 69 in.lb)
19-12 SUPPLEMENT - 2003 - 2006 MODELS Electrical System Wiring Diagram (U.S.A. Model)
KLF300-B17rv
Neutra I/Reverse Switch
-
oo=F
-
Headl ight
12V25/25W ( R H)
----c>CJ- RI B K - R/BK-l>C}R / B K -CJo , I VV----r:>e:J-< , I VV -c:J
I" ,I
R/
~Q ,
0 ~
~
~
I
Opt ion
~(J-~-t--- RI ,-;-=r:;l I I
L
1- B K / ¥---[:> I __ I-R/V -L~ I'Iork Light ,--
~
~
I
~
~
,
J
<:J--BK I V
~2!65 / 6~W_ ~
::--D-
I - -~ - - -= R---[::1----J Option
-
R
\~---,
I
:
I 5peedometer 12V3.41'1
C
I
LBK I V{::::j
------
®
.---J
,-
~
R / BK ----[>[:=J-R I B B K I 'f----[>O-B K I VR I Y ----cJ<:} R / V -
12V2S / 25W ( L H)
Hand lebar
G)Light / Oimmer GDEngine
G)Starter
Stop
~
~
~
~
~
Headl ight
Left
~
-.>-. . . <>:: ,:c::"""" 1%1 . . . . 1%1
,
~
~ ~
~
~
~
~
,
~
# ~
~
Switch
Switch Switch
Button
' - - - - - - - - ' Pickup
Coi I
Alternator
WZL0021 Al5
C
SUPPLEMENT - 2003 - 2006 MODELS 19-13 Electrical System
(DRevers e
Indicator Li ght 1 2 V 3 .
®
In dicator
Ne u tral
Li ght
Front Li ght
1 2 V3 .
...
Rear L i &: h t
Swi tch
t: M ~
m
~
~
~
m
~- ~~ ,
~
~
~
~
m
~
m
~
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m
~
m
~
8j
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~
m
Ta i IIBrake li ,hts 12V S / 27'11'X2
~~
~
m
Term inal
,,-
I
~
~
m
~~
~
Accessarv
e
Bra k e
CD CD
,
Bra k e
Switch
~
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r - - Bl Bl r- BK / Y-c:::J<}- BK I Y -R - D < J - R
~
8j 8j
m
1
..,
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.- < :)
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-
....... ...J
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",I,;;
l!:: __ ::!J
Starter
Starter Ci r cuit
-
Rei ay
~~~,~,~ Spark
~
~:/
,
~
I
,
~
M
Starter
Relay
Color Code BK B lack Bl Blue
Mo tor
PIUI
BR
B r o. n
CH
Chocolate
DO
G
,u" ,n
U I H. CGU H IlOO I
Color
OFF ON
BR
I
•
UUIIH ,
GI • • I It
REVERSE $l ITe M CO NNE CT i o n
Po s itio n
t h".,h
LG
Ground
R/ 'II
5H
Neutral Reve r se
Dirk
Gt een
Green
GY
Gn
LB LG
l; '~t
S lu _
l; '~t
G",n
0
Oran~e
P PU
Pink Purple
R
R.,
Y
'll'h i te Ye I low
• ( 98052 - 1 13 1 A) (98 052 -0021A)
ItR002 1A1S
c
19-14 SUPPLEMENT - 2003 - 2006 MODELS Electrical System Wiring Diagram (Australian Model)
KLF300-B17rv
Cool ing Sw i tch
Neutr .. I / Reverse
Fan
Switch Fuse5A
Headlight
12V2S / 25W ( RH )
Option
CID
/
B K--[>{J-R / B K
RIB K-C>D-R / B K
K I ¥--!>CJ-B K I, R/Y -D
BK/V-c>D-SK / Y
'I, -CJ
f/\!3/ - """'--e---' I ;---~;l I I
I!~~k
f--BK / Y--[> : __ ..1----, I ,----L] l i ght ; - __
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Speedometer L i ghot 12.V3.4Yf
BK / V---D<:J--BK / Y
C!rE
I BK---[>CJ-R / B K K / 'f----[::::O-B K / Y
R( Y ----D
~
Head light 12V25 / 25W
~
=
mm
( L H)
L.ft
""dI.b"
'i'Li,n t/ Dimmer ~ 0Engine
(DStarter
Stop
S.;'oh
Switch Switch
~S!=jS:::~::;b
OFF:
0 9"
~~1~~nl . 5A
T-
L
Button
i
HI'
:~
::;;:
L. __ L-ol
CD CD
Pickup
Co i I
Alternator
,~_L1 :
66 : II
CD LU.J """
Button
LEFT HAN DLEBAR SW I TCH CONN ECTIONS
' I' ,
Light / Dimmer Co l or
OFF
Switch BR
RISK
Ent i n"
Color
OFF
BR
I, Starter 'I,
Button
S. i tch
Y
Co l or
Release Pus h
LO
HI
Stop
'UN
<;-
8K
12L0022AIS C
SUPPLEMENT - 2003 - 2006 MODELS 19-15 Electrical System
G)Reve r se
Indicator
Light
12V3 .4W
0Neutral
Indi cator
light
12V3 .4W
Rear Brake
ft"~: Front Brake
CD
@
M '8~~ " ~
~
~~
..... "'"
Accessary
~~ B 1 T ~
r;v
m
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Terminal
light
T a i I / B r ake 12V
BL---c::J
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m
-B KI
y-cJ
r' ----CJ
~
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Light
Switch
m
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8 / 2 HI'X2
J) ~
•
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:/
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~
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n,
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~
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(+)
(-)
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Ignition Co j I Starter
Starter
Rei a y
Circuit Re lay
Co lor
BK BL
Spark Plug
BR
CH OG G GY
-
,U",OI II ITC. COOOl'I,OOl
Color OFF ON
BR
•
NEUTRAL
6e. ,
•
1'0 .
REVERSE j
...
t i on
t~''''ft
SlilCH CO U ECllon
LG
Ground
,I,
'"Neutra I Reverse
(98052-11321.)
(98052-0022A)
LB LG
Code
Black
Blu e Brown Chocolate Dirk Green
Green
G" Lil ht Blue
LiJ;t.t a'ccn
0
Oran
P PU
P ink
, •Y
•
Purple
R,d White Ve I low 12R0022A15 C
19-16 SUPPLEMENT - 2003 - 2006 MODELS Electrical System Wiring Diagram (European Model)
KLF300-B17 rv Ignition S. it c h
Fuse
Cool ing
SA
L __~
Fan
BL
( RH)
I BK --l>D-' I " - . - . I ' ,--{>C]--. I " f- BK I '--{>C]--BK I , • I , --c:J
B K I Y --[>c::J-- 8 K
1',
'l
Option :--BK/V-{>"
~~ '
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R
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-D
Headlight
12V2S / 25W ( L H)
Handlebar
G)Light / Dimmer G)Engine
0Starter
Switch
Switch
~
~
~
m
,
~
m
jrrh'JJ' ~jr '~5A ~~~ ~;;:::;
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Left
~ ~
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CD
P'
Horn
Button
Alternator
k
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C
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Stop Switch Button
ULOG23AWS C
SUPPLEMENT - 2003 - 2006 MODELS 19-17 Electrical System
0Reverse
Indicat o r
l ight
12V3 , 4".
0Neutral
Indicator
Light
12V3 , 4W Rear
Brake
Light
Switch Fro n t
Brake
~ ~~
Li ght
Switch
00
M fl ~
~
m
m
m
~ ~~ ~~ ~
,
~
~~
~
~
~
Accessary Termi na I
I
r
m
~
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m
m
El Tai I / Brake
~
lights
~;;;
12V
m
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~
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i 1 'I ----------~--+_t_----_+~----------t_+_----_+~----~_+-------R/~ R /.~ m
m
j
::::::::::::::::::::::~~::i::::::::::::~~========~~====~~====~J-~~~~==-~B~R~~BR ~ " Reverse
Light
12 V 1 OW
,
~
~
~
~ ~ m
,
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)
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m
(.)
(-)
Battery 12V19AH
77 I gn It Ion Co i I
Stater
Starter
Rei ay
Circuit Relay
Regulator / Rectifier
-.J
I g nit e r
M Color
Starter Motor
"
eH
Chocolate
BL BR
Spark Plug
I G~ITlII N
Color
OFF ON
HI TCH
BR
COHHECIIOHS
•
GY
HEUIU L I
Geo. I ..
HOEHH
Position
tn ,eUlh h I!
SIlltH
lG
COUECIIONS
Grou~GI R / 'Ir
I
Neutral Reverse
Cod e
BI a c k Blue
00 0 GY LB LG 0
Brown
o. r ~
Gr e e n
Gr e e n G ray L i ,h t
Blye
L iE h t
Gr e e n
Orange
P Pink PU Purple R Rod
• y
White Ye I low
(98052-1133A) ( 98052 -0 023A )
nR0023AII5 G
19-18 SUPPLEMENT - 2003 - 2006 MODELS Electrical System Wiring Diagram (U.K. Model) (DReverse
Indicator
Light 12V3 .4".
0Heutral
Ind icator
L ight
12V3 .4'11'
KLF300-B17 ;-v
Fuse
5A
Cooling Fan
Head light
12V2S / 25W ( RH)
/BK-{>CJ-' /BK-
®B-;;-=C;l
K I I'--{>C]--e KI R / Y -c:::rc:J- R / Y
Option
I.~/ ':::'_-1- , I :----s K/
I
I
__
j'll'.o_rk
r
Y----[::> I
' I Y
Lightr- -
L.!.1V~5!...6~
--{:2j -
<:}-BK / Y--+++'
-c>8-
R
SP"do,.t'~/Y-c=}
1-
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®
~
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~
'2
».
Headl ight
12V2S / 25W ( l H)
>-;1::
O
Swi tch
J_112yH~~;A OFF"~~OH_~o~':P-" 'b6~ ~ :L lli 'tj---l CD CD CD Horn
Button
Pickup Coil Alternator
Left Handl ebar Switch (D l ight / O immer Switch ®Engi ne
Stop
(DSt arter
Switch
Button
LEFT HANDLEBAR SW ITCH CONNECTIONS
,
L i ght / O i mller Co lor ,/Y
Switch RI SK BR
Enline
Color
OFF LO
OFF
HI
'UH
..- ..-
Stop
BR
Sw i tch
Y/ ,
Starter
Co lor R II I II a S II
But ton 8K
Y/ ,
Push
I
SUPPLEMENT - 2003 - 2006 MODELS 19-19 Electrical System
Carburetor
Thermo
Sensor
Uni t
Cnntrol
@
Accessary
-/
~
~l~~~
~I
.
' ~'"
BK/~[(gr'~H~~ "--BK/Y BK•/Y ~ -BK BKl Carburetor
-
,---
~
ro
Tai IIBrake
"
~
BL'"
~
~
Relay
-
I I
~
:!J
~
81 81
(~
, - - - ' I W-cJ<:]-, I . r--B '---D
~~
"
12V 8/2711lx2
Bl
-, -----D
Heater
I I
lights
f"'- ""
"'""""'Il!~1 ~~ ~
~
,~
l~l
12V23W
~
~
w---c>D--w
Heater
Terminal
,
~
~
l i ght 1 2 V lOW
Reverse
~
ro
..,
.~
~<
I
0 O~
lf~
11 . . -i 00'--r-II T m~ #~" I
I)C>-~
Regu lator / Reet ifi er
g
ro
1»
Stater
Circuit
~
~
ro
~, ~ ~
ro
(- ) Battery 12V19AH
'" !z
~~
IT! "
Starter
Rei a y
~~
I gniter
~ Starter
Color
Code BI ack BI
Motor
COl I
BK u e Bl BR Br own CH DGG Green GY lB lG0
Choco I at e Da rk
:0.~~~'" Spa r k
,
~
Relay
§§=~Y // W, Ignition
~ ;
~ __ :!J
~ )<:j~ ~~~~ ~~ Hlff/n I
I
I ~
Gr eo n
G ray
PI ug
I GH I T I ON
Color
OFF ON
SI I TCH CONHE CT IONS
BR
• GY
H€ U IRA t
Ge. r lot
'
UYEMSE
Posit i on
th ' O ~ l h
SI I ICH
lG
COU EC IIONS
Ground
' I.
5t h
Neutral Reverse
L ic ht
B l ue
L i lht
Green
Orange
P PU
,
Purple
• y
Whit e Ye I low
Pin k
'od
(98052-1134A) (98052-0024A)
W2R002HI5
c
KLF300 BAYOU Kawasaki 4X4
All Terrain Vehicle Service Manual Supplement
Quick Reference Guide ~G__ e_n_e_ra_I_I_n_fo_r_m_a_t_i_o_n_____________1_11 ~F_u_e_I_S~ys_t_e_m_________________2_11
3_11
~E_n~g~in_e__ To~p~E_n_d______________
~E_n~g~in_e__ Le_f_t_S_id_e______________4_11
~E_n~g~in_e__ R~ig~h_t_S_id_e_____________5_11
II 7 II 8 II
~E_n---,g=-i_n_e_R_e_m_o_v_a_I/_1n_s_t_a_lI_a_ti_o_n______ 6 Engine Bottom EndlTransmission WheelslTires
L - - -_ _ _ _ _ _ _ _
~F_i_n_a_I_D_r_iv_e_____________________9~1I Brakes
10 11
Suspension
11 11
Steering
12 11
Frame
13 11
II 15 II 1990 - 1994 Models 16 II 1995 - 1998 Models 17 II
Electrical System Appendix Supplement This quick reference guide will assist you in locating a desired topic or procedure. -Bend the pages back to match the black tab of the desired chapter number with the black tab on the edge at each table of contents page. -Refer to the sectional table of contents for the exact pages to locate the specific topic required.
Supplement -
Supplement - 1999 Model
14
18 •
Supplement - 2000 - 2002 Models 19 . Supplement - 2003 - 2006 Models 20 •
LIST OF ABBREVIATIONS A
ampere(s)
Ib
pounds(s)
ABDC
after bottom dead center
m
meter(s)
AC
alternating current
min
minute(s)
ATDC
after top dead center
N
newton(s)
BBDC
before bottom dead center
Pa
pascal(s)
BDC
bottom dead center
PS
horsepower
BTDC
before top dead center
psi
pound(s) per square inch
°C
degree(s) Celcius
r
revolution
DC
direct current
rpm
revolution(s) per minute
F of
farad(s)
TDC
top dead center
degree(s) Fahrenheit
TIR
total indicator reading
ft
foot, feet
V
volt(s)
9
gram(s)
W
waU(s)
h
hour(s)
n
ohm(s)
L
liter(s)
Read OWNER'S MANUAL before operating.
i
EMISSION CONTROL INFORMATION
I
To protect the environment in which we all live, Kawasaki has incorporated crankcase emission (1) and exhaust emission (2) control systems in compliance with applicable regulations of the California Air Resources Board. 1. Crankcase Emission Control System A sealed-type crankcase emission control system is used to eliminate blow-by gases. The blow -by gases are led to the breather chamber through the crankcase. Then, it is led to the air cleaner. Oil is separated from the gases while passing through the inside of the breather chamber from the crankcase, and then returned back to the bottom of crankcase. 2. Exhaust Emission Control System The exhaust emission control system applied to this engine family is engine modifications that consist of a modified carburetor and an ignition system having optimum ignition timing characteristics. The carburetor has been calibrated to provide lean air/fuel mixture characteristics and optimum fuel economy with a suitable air cleaner and exhaust system. A maintenance free ignition system provides the most favorable ignition timing and helps maintain a thorough combustion process within the engine which contributes to a reduction of exhaust pollutants entering the atomosphere. The Clean Air Act, which is the Federal law covering motor vehicle pollution, contains what is commonly referred to as the Act's "tampering provisions." "Sec. 203(a) The following acts and the causing thereof are prohibited ... (3)(A) for any person to remove or render inoperative any device or element of design installed on or in a motor vehicle or motor vehicle engine in compliance with regulations under this title prior to its sale and delivery to the ultimate purchaser, or for any manufacturer or dealer knowingly to remove or render inoperative any such device or element of design after such sale and delivery to the ultimate purchaser. (3)(B) for any person engaged in the business of repairing , servicing , selling, leasing, or trading motor vehicles or motor vehicle engines, or who operates a fleet of motor vehicles knowingly to remove or render inoperative any device or element of design installed on or in a motor vehicle or motor vehicle engine in compliance with regulations under this title following its sale and delivery to the ultimate purchaser... "
NOTE o The phrase "remove or render inoperative any device or element of design" has been generally interpreted as follows: 1. Tampering does not include the temporary removal or rendering inoperative of devices or elements of design in order to perform maintenance. 2. Tampering could include: a.Maladjustment of vehicle components such that the emission standards are exceeded. b.Use of replacement parts or accessories which adversely affect the performance or durability of the motorcycle. c.Addition of components or accessories that result in the vehicle exceeding the standards. d.Permanently removing, disconnecting, or rendering inoperative any component or element of design of the emission control systems. WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL LAW, THE VIOLATION OF WHICH IS PUNISHABLE BY CIVIL PENALTIES NOT EXCEEDING $10,000 PER VIOLATION.
PLEASE DO NOT TAMPER WITH NOISE CONTROL SYSTEM (US MODEL only)
To minimize the noise emissions from this product, Kawasaki has equipped it with effective intake and exhaust silencing systems. They are designed to give optimum performance while maintaining a low noise level. Please do not remove these systems, or alter them in any which results in an increase in noise level.
Foreword This service manual supplement contains only the information unique to the models covered. It must be used with the base service manual listed below. Read both this supplement and the base manual for complete information on proper service procedures for the models covered by this manual. Base Manual
Part Number
KLF300 Service Manual
99924-1057 -02
This manual is designed primarily for use by trained mechanics in a properly equipped shop. However, it contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily. Whenever the owner has insufficient experience or doubts his ability to do the work, all adjustments, maintenance, and repair should be carried out only by qualified mechanics. In order to perform the work efficiently and to avoid costly mistakes, read the text, thoroughly familiarize yourself with the procedures before starting work , and then do the work carefully in a clean area. Whenever special tools or equipment are specified , do not use makeshift tools or equipment. Precision measurements can only be made if the proper instruments are used , and the use of substitute tools may adversely affect safe operation . For the duration of the warranty period, we recommend that all repairs and scheduled maintenance be performed in accordance with this service manual. Any owner maintenance or repair procedure not performed in accordance with this manual may void the warranty. To get the longest life out of your vehicle: • Follow the Periodic Maintenance Chart in the Service Manual. • Be alert for problems and non-scheduled mai ntenance. • Use proper tools and genuine Kawasaki Vehicle parts . Special tools, gauges, and testers that are necessary when servicing Kawasaki vehicles are introduced by the Service Manual. Genuine parts provided as spare parts are listed in the Parts Catalog. • Follow the procedures in this manual carefully. Don't take sho rtcuts.
• Remember to keep complete records of maintenance and repair with dates and any new parts installed.
How to Use This Manual In this manual , the product is divided into its major systems and these systems make up the manual's chapters. The Quick Reference Guide shows you all of the product's system and assists in locating their chapters. Each chapter in turn has its own comprehensive Table of Contents. For example, if you want ignition coil information , use the Quick Reference Guide to locate the Electrical System chapter. Then , use the Table of Contents on the first page of the chapter to find the Ignition Coil section . Whenever you see these WARNING and CAUTION symbols , heed their instructions! Always follow safe operating and maintenance practices.
A WARNING This warning symbol identifies special instructions or procedures which, if not correctly followed , could result in personal injury, or loss of life.
CAUTION This caution symbol identifies special instructions or procedures which, if not strictly observed, could result in damage to or destruction of equipment. This manual contains four more symbols (in addition to WARNING and CAUTION) which will help you distinguish different types of information.
NOTE
o This note symbol indicates points of particular interest for more efficient and convenient operation. • Indicates a procedural step or work to be done. Olndicates a procedural sub-step or how to do the work of the procedural step it follows . It also precedes the text of a NOTE.
* Indicates a conditional step or what action to take based on the results of the test or inspection in the procedural step or sub-step it follows. In most chapters an exploded view illustration
of the system components follows the Table of Contents. In these illustrations you will find the instructions indicating which parts require specified tightening torque, oil , grease or a locking agent during assembly.
GENERAL INFORMATION 1-1
General Information Table of Contents Before Servicing ....................... . .................. .
*
Model Identification ....................................... .
1-2
General Specifications ............................... . ...... .
1-4
Torque and Locking Agent .................................. .
1-6
Wiring, Cable, and Hose Routing .............. .. ....... . ...... .
1-10
Periodic Maintenance Chart.................................. .
1-14
* : Base Manual
1-2 GENERAL INFORMATION Model Identification
KLF300-C1 (US model)
GENERAL INFORMATION 1-3 KLF300-C1 (UK model)
1-4 GENERAL INFORMATION General Specifications
®: Australia model ©: Canada model
®: UK moclel @:
KLF300-C1
Item Dimensions: Overall length Overall width Overall height Wheelbase Ground clearance Seat height Dry weight Curb weight: Front Rear Fuel tank capacity Performance: Minimum turning radius Engine: Type Cooling system Bore and .stroke Displacement Compression ratio Maximum horsepower Maximum torque
1 860 mm 1100 mm 1 105 mm 1200 mm 225mm 805mm 257 kg, ® ® 260 kg 137 kg, ® ® 138.5 kg 128 kg, ® ® 129.5 kg 11 L, B 8.2 L 2.9 m 4-stroke, SOHC, l-cylinder Air cooled 76.0 x 64.0 mm 290mL 8.6 14.7 kW (20 PS) @6 SOO rim in (rpm). @ 23.6 N-m (2.4 kg-m, 17.3ft-lb) 5500r/min (rpm).
@-
Carburetion system Starting system Ignition system Timing advance Ignition timing Spark plug Valve timing:
Inlet
Exhaust
US model
Open Close Duration Open Close Duration
Lubrication system Engine oil: Grade Viscosity Capacity Drive Train: Primary reduction system: Type Reduction ratio Clutch type: Primary Secondary
Carburetor, Keihin CVK32 Electric starter & recoil starter Battery and coil (transistorized) Electronically advanced From 10° BTDC @2 000 rim in (rpm) to 30° BTDC @3 200 r/min (rpm) NGK D8EA, ® ® © NGK DR8ES-t_ 21° BTDC 59° ABDC 260° 56° BBDC 24° ATDC 260° Forced lubrication (wet sump) SE or SF class SAE 10W-30, 10W-40, lOW-50, 20W-40, or 20W-50 2.2 L
Gear 2.888 (78/27) Auto centrifugal, vyet Auto multi disc, wet
GENERAL INFORMATION 1-5 Item
KLF300-C1
Transmission: Type Gear ratio:
Final drive system:
1st 2nd 3rd 4th 5th Reverse
Type Reduction ratio
Overall drive ratio Front final gear case oil Rear final gear case oil:
High Low
Type Capacity Type Capacity
Frame: Type Caster (rake angle) Camber Trail Tread Front tire: Rear tire: Suspension:
Type Size Type Size Front Rear
Brake type:
Front Rear
Type Whee I travel Type Wheel travel
Front Rear Electrical Equipment: Battery Headlight: Type Bulb Taillight Alternator: Type Rated output
10-speed plus reverse, constant mesh, return shift 3.090 (34/11) 1.928 (27/14) 1.368 (26/19) 1.000 (23/23) 0.769 (20/26) 3.072 (26/11 x 26/20) Shaft (four wheel drive) 5.416 (33/33 x 20/16 x 39/9) 6.910 (37/29 x 20/16 x 39/9) High: 12.037 Low: 15.357 API GL-5 Hypoid gear oil for LSD SAE140 or SAE85W-14Q
0.25 L API GL-5 Hypoid gear oil SAE 90 (above 5°C, 41°F) or SAE 80 (below 5°C, 41°F) 0.2 L Double tubular 1.0° 0° @1 G 5mm 844mm 840mm Tubeless AT 24 x 8-11 Tubeless AT 24 x 10-11 Double wishbone 110mm Torque tube 120mm Disc (Hydraulic) x 2 Drum (Mechanical, on Rightside) 12 V 14 Ah Sem i-sealed beam 12 V 25/25 W x 2 12V8Wx2 Th ree-phase AC 23.5 A @9 000 r/min (rpm), 14 V
Specifications are subject to change without notice, and may not apply to every country
1-6 GENERAL INFORMATION
............................................................................ T or.que and Locking Agent ............................................................................ The following tables list the t ightening torque for the major fasteners requiring use of a non-permanent locking agent or liquid gasket. Letter used in the "Remarks" column means : L : Apply a non-permanent locking agent to the threads. LG: Apply liquid gasket to the threads. Lh: Left-hand threads. M : Apply a molybdenum disulfide grease. o : Apply an oil to the threads and seated surface. S : Tighten the fasteners following the specified sequence. St : Stake the fasteners to prevent loosening. Se : Nut or bolt seating surface Th: Threads
The table below, rel·ating tightening torque to thread diameter, lists the basic torque for the bolts and nuts. Use this table for only the bolts and nuts which do not require a specific torque value. All of the values are for use with dry solvent-cleaned threads.
Basic Torque for General Fasteners Torque
Thread dia. (mm)
N-m
kg-m
ft-Ib
5 6 8 10 12 14 16 18 20
3.4 - 4.9 5.9 -7.8 14 - 19 25 -34 44 - 61 73 - 98 115 - 155 165 - 225 225 - 325
0.35 - 0.50 0.60 -0.80 1.4 - 1.9 2.6 - 3.5 4.5 - 6.2 7.4-10.0 11.5 -16.0 17.0 - 23 23 - 33
30 - 43 in-Ib 52 - 69 in-Ib 10.0 -13.5 19.0 - 25 33 - 45 54 -72 83 -115 125 -165 165 - 240
N-m
Torque kg-m
Fuel System: Throttle lever bolt Fuel tap plate mounting screws
6.9 0.8
0.7 0.08
61 in-Ib 7 in-Ib
Engine Top End: Spark plug Cylinder head bolts: 8 (used bolts) 8 (new bolts) Cylinder head bolts: 6 Cylinder bolts Valve adjusting screw locknuts Camshaft sprocket bolts Camshaft chain guide pivot bolt
14 29 34 12 12 12 41 9.8
1.4 3.0 3.5 1.2 1.2 1.2 4.2 1.0
10.0 22 25 104 in-Ib 104 in-Ib 104 in-Ib 30 87 in-Ib
Engine Left Side: Alternator rotor bolt Starter clutch Allen bolts Recoil starter flange nut
59 49 8.3
6.0 5.0 0.85
43 36 74 in-I b
Engine Right Side: Oil drain plug Primary clutch hub nU,t Secondary clutch hub nut Secondary clutch spring bolts: (used bolts) (new bolts) Oil pipe banjo bolts Oil pressure relief valve
29 125 78 12 15 20 15
3.0 13.0 8.0 1.2 1.5 2.0 1.5
22 94 58 104 in-Ib 11.0 14.5 11.0
Engine Removal/I nstallation: Engine mounting bolts: 8mm 10mm Engine mounting bracket bolts
25 37 25
2.5 3.8 2.5
18.0 27 18.0
Parts
ft-Ib
Remarks
S S S S
L
o (Se, Th)
a
L S
GENERAL INFORMATION 1-7 Torque
Parts
Remarks
N -m
kg -m
ft-Ib
Oil drain Plug
29
3.0
22
Oil Pipe Banjo Bolts
20
2.0
14.5
Sub-transmission case bolts: 8 mm
25
2.5
18.0
LH bearing housing bolts (engine output)
12
1.2
104 in-Ib
LH bearing housing bolts (engine output)
120
12.0
87
Engine output shaft nut
120
12.0
87
Oil pipe cap screws (drive shaft)
7.8
0.8
69 in -Ib
Bearing holder (drive shaft)
120
12.0
87
Drive shaft slotted nut
180
18.5
135
25
2.5
18.0
120
12.0
87
Front oil seal housing bolts (output shaft)
11
1.1
95 in-Ib
Rear oil seal housing bolts (output shaft)
8.8
0.9
78 in-Ib
Output shaft slotted nut
180
18.5
135
Shift rod bolt
7.8
0 .8
69 in-Ib
Tie-rod lever bolt
7.8
0.8
69 in-Ib
Neutral switch mounting screw
-
-
-
Shift drum stopper bolt
12
1.2
104 in-Ib
Shift drum pin plate bolt
12
1.2
104 in-Ib
Shift shaft return spring pin
17
1.7
12.0
L
Oil pressure relief valve
15
1.5
11 .0
L
Balancer gear nut
120
12.0
87
0
Balancer drive gear and oil pump drive gear nut
145
15.0
110
0
34
3.5
25
Front hub nuts
145
15.0
110
Rear axle nuts
145
15.0
110
8.8
0.9
78 in-Ib
10mm
37
3.8
27
8mm
25
2.5
18.0
Oil filler cap
29
3.0
22
Oil drain plug
20
2.0
14.5
Pinion gear bearing housing nuts
25
2.5
18.0
Engine Bottom End/Transmission
Sub-transmission:
Bearing housing nuts (drive shaft) Needle bearing nut (drive shaft)
L (3 bolts)
o (Se, Th) o (Se, Th) o (Se,Th) o (Se, Th) o (Se, Th) o (Se, Th)
L
Wheels/Tires: Wheel Nuts
Final Drive: Front Final Drive: Front axle cap bolts Front final gear case mounting bolts and nuts:
L (2 bolts)
1-8 GENERAL INFORMATION Torque
Parts
Remarks
N-m
kg-m
ft-Ib
120
12.0
87
o (Se, Th)
10mm
47
4.8
35
S
8mm
25
2.5
18.0
S
Ring gear bolts
49
5.0
36
Differential case torx bolts
32
3.3
24
Oil filler cap
29
3.0
22
Oil drain plug
20
2.0
14.5
Propeller shaft housing nuts
34
3.5
25
Ax Ie pipe nuts
34
3.5
25
Speedometer gear holder screw
7.8
0.8
69 in-Ib
Ring gear thrust plug nut
54
5.5
40
Pinion gear bearing holder set plug
7.8
0.8
69 in-Ib
Pinion gear bearing holder
120
12.0
87
o (Se, Th)
Pinion gear nut
69
7.0
51
St,O (Se,Th)
10mm
47
4.8
35
8mm
25
2.5
18.0
Bleedvalves
7.8
0.8
69 in-Ib
Brake hose banjo bolts
25
2.5
18
Parking lever lock mounting screw
-
-
-
Caliper mounting bolts
25
2.5
18
Caliper pad mounting Allen bolts
18
1.8
13.0
Caliper shafts
18
1.8
13.0
Caliper shafts
23
2.3
16.5
Disc mounting bolts
37
3.8
27
Brake pipe nipples
20
2.0
14.5
Brake lever pivot bolt
5.9
0.6
52 in-Ib
Brake lever pivot bolt locknut
5.9
0.6
52 in-Ib
Front master cylinder clamp bolts
8.8
0.9
78 in-Ib
Front brake fluid reservoir cap screws
1.0
0.1
9 in-Ib
Rear drum drain bolts
29
3.0
22
Brake panel mounting bolts
34
3.5
25
Rear axle nuts
145
15.0
110
34
3.5
25
Pinion gear slotted nut Ring gear cover bolts:
L
Rear Final Drive:
Rear gear cover bolts:
Brakes:
L
L
L
Suspensions: Shock absorber mOl:Jnting nuts Suspension arm pivot bolts:
12 mm
88
9.0
65
Rear suspension arm (rod):
10mm
34
3.5
25
49
5.0
36
Steering knuckle joint
L
GENERAL INFORMATION 1-9
Parts
Torque N-m
kg-m
ft-Ib
8.8 20 25 29 20 41
0.9 2.0 2.5 3.0 2.0 4.2
78 in-Ib 14.5 18.0 22 14.5
27 49 34 52
2.8 5.0 3.5 5.3
36 25 38
Spark plug
14
Alternator rotor bolt
59
1.4 6.0
10.0 43
0.45 0.8
-
Remarks
Steering: Steering stopper nut Handlebar clamp bolts Stem clamp Allen bolts Stem bottom end nut Stem bearing housing bolts Tie-rod end nuts Tie-rod adjusting sleeve locknuts Tie-rod arm bolts Tie-rod arm locknuts Steering knuckle arm nuts
30 20 L
Electrical System:
Neutral and reverse indicator switch mounting screws Starter circuit relay terminal nuts Taillight assembly mounting screws
4.4 7.8
39 in-Ib 69 in-Ib
L
1-10 GENERAL INFORMATION Wiring, Cable, and Hose Routing
I----®
Strap
_Straps V-:::::;;;;~~--
ViewR
Fuel Tank Bracket
1. Left-Hand Switch Leads 2. Neutral and Reverse Indicator Light Leads (LG, HR, R/W) 3. Ignition Switch Leads (BR, W) 4. Choke Cable 5. Vinyl Cover 6 . Left Headlight Leads 7. Right Headlight Leads 8. Main Harness 9. Neutral and Reverse Switch Leads 10. Alternator and Pickup Coil Leads 11. Engine Ground Lead 12. Engine Ground Terminal and Clamp 13. Electric Starter Cable
¢=jt o
o
Straps
Tube B
@
Tube C
GENERAL INFORMATION 1-1 1
ViewS
~@ @ ~~~-@ Front
Front
~
.
Air Cleaner Housing Brackets
~ -----@
W
-
-, I
B : UK Model
14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28.
IC Igniter Connectors Accessory Connectors Battery Ground Cable Fuse 30A Battery Positive Cable Starter Relay Igniter Starter Circuit Relay Battery Vent Hose Ignition Coil Leads Electric Starter Terminal Engine Breather Hose Main Harness Position Mark - white tape Regulator/Rectifier Connector Taillights
1-12 GENERAL INFORMATION
Clamps
_ _-;.:,..;+_ _ _ _ _ _ Front
Straps - - - - - f L } ) ) - . 25. Put in the engine breather hose here.
29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40.
Throttle Cable Fuel Tank Vent Hose Reverse Cable Parking Brake Cable Upper Brake Hose Front Final Gear Case Vent Hose Rear Axle Vent Hose Brake Panel Vent Hose Carburetor Vent Hose Brake Cable Ignition Switch Lower Brake Hose (brake caliper)
GENERAL INFORMATION 1-13
"-- - - @
C1amp---~tfB
Straps
Tube A Front
Tube B -----.r'-----
TubeC
Clamp Tube B
Straps
T A
~@ Front
Scetion AA
Clamp Front Suspension Arm
1-14 GENERAL INFORMATION
Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the vehicle in good running condition. The first service is vitally important and must not be neglected.
Regular Service
First Service
• = Clean, adjust, lu bricate, tighten, or replace parts as necessary.
AherlA~~~~ 0' ~ '!-..~
of use
~
<:)
0'~
~
Engine: Air cleaner--service* Clutch adjustment* Valve clearance--check Fuel system c1eanliness--check* Engine oil--change* Oil filter--replace* Spark plug--c1ean and gap
• • • • • • •
• •
• • • •
• • •
~f13 '!-..~
~
<:)
0'~
~
~03 '!-..~
~
~
~.::i;.
• • • • •
Spark arrester--c1ean
<:)
~~
~
~
0'~
~
See Page
2-7 5-3 3-6 (2-1 0) 5-3 (5-11 ) 14-5 3-11
•
Chassis: Joint boots--check* Rear brake adjustment--check* Rear brake lining wear--check* Front brake pad wear--check* Brake fluid level--check Brake fluid--change Cable adjustment* Battery--check Steering--check General lubrication* Bolts and nuts--tighten Front and rear final gear case oil --change* Master cylinder piston assembly and dust seal--replace Caliper piston seal and dust seal--replace Brake hose--replace
• • • • •
• •
9-7,20 12-4 10-5 (10-6)
• • •
•
10-8 (10-8) (10-8) **
•
14-6 ( 12-6)
•
15-7 15-8 9-10,23
•
2 years (10-11) 2 years
10-7
2 years
10-10
* : Service more frequently when operated in mud, dust, or other harsh riding conditions. **: Refer to 2, 7, and 10 chapters. (xx-xx): Reference Page in the Base Manual
IS.
FUEL SYSTEM 2-1
Fuel System Table of Contents Exploded View . . . . . . . . . . . . . . . . . . . . .
2-2
Fuel System Cleanliness Inspection ... .
*
Specifications . . . . . . . . . . . . . . . . . . . . . .
2-4
Carburetor Removal. . .. . . . . . . . . . .
*
Special Tools . . . . . . . . . . . . . . . . . . . . . .
2-4
Carburetor Installation .. . ..... ... .
*
Throttle Case and Cable ...... . . . . . . . . .
Carburetor Disassembly . . . . . . . . . . .
*
Throttle Lever Free Play Inspection .. .
2-5 *
Carburetor Assembly . . . . . . . . . . . . .
*
Throttle Cable Adjustment . . . . . . . . .
*
Carburetor Cleaning . . . . . . . . . . . . . .
*
Throttle Case Removal/Disassembly .. .
*
Carburetor Inspection . . . . . . . . ... .
*
Throttle Case Assembly/Installation .. .
*
Air Cleaner ..... . . . . . . . . . . . . . . . . . . .
2-7
Throttle Cable Removal .... ... ... .
*
Air Cleaner Element Cleaning ...... .
2-7
Throttle Cable Installation .... .. .. .
*
Air Cleaner Housing Dust and/or
Throttle Case and Cable Lubrication .. .
Water Inspection . . . . . . . . . . . . . .
2-8
Throttle Case Inspection . . . . . . .. .. .
2-5 *
Fuel Tank . . . . ..... .. . . . . . . . ... .. .
2-9
Throttle Cable Inspection .... . .... .
*
Fuel Tank Removal .. . . . . . . . . . .. .
2·9
Choke Lever and Cable . . . . . . . . . . . . . . . .
2-5
Fuel Tank Installation Notes . . . . . . . .
Choke Lever and Cable Removal . ... .
2-5
Fuel Tap Removal . . . . . . . . . . . . . . .
2-9 *
Choke Lever and Cable Installation . .. .
2-6
Fuel Tank and Tap Cleaning . ...... .
*
Choke Cable Lubrication . . . . . . . .. .
2-6
Fuel Tap Inspection . . . . . . . . . . . . . .
*
Choke Cable Inspection .... . ..... .
2-6
Fuel Level Gauge Removal . . . . . . . . .
2-9
Carburetor. . . . . . . . . . . . . . . . . . . . ... .
2-6
Fuel Level Gauge Installation Notes .. .
2·10
Carburetor Pilot Screw Adjustment ... .
2-6
Fuel Level Gauge Check . . . . . . . . . . .
2·10
Idle Speed Adjustment . . . . . . . . . . . .
2-7 *
Fuel Tank Damper Installation ...... .
2-10
Fuel Level Inspection .. . . . . . . . . . . . Fuel Level Adjustment . . . . . . . . . . . .
*
Base Manual
2~2
FUE1. SYSTEM
~~~
E~~~~~~·V:························
................... ....................:::::::::::::::::::::::::::::::::
1. Choke Lever 2.. Throttle Cable 3. Choke Cable 4. Throttle Case 5. Starter Jet 6. Pilot Jet 7. Main Jet A'A pply adhesive. o . Apply grease : Apply oil. . Oe: R : Apply Replacecleaner element oil ment Parts .
G:
. N-m (0.70 T1'. 69 T2: 0.8 N-m (0.08 kg-m, 6~ in-Ib) kg-m, 7 m-Ib)
o
_I
FUEL SYSTEM 2-3
European Model
2-4 FUEL SYSTEM Specifications Refer to the Base Manual noting the following. Item Carburetor Specifications Make, type: Main jet: Main air jet: Needle jet: Jet needle mark: Pilot jet (slow jet): Pilot air jet (slow air jet): Pilot screw (turns out): Starter jet: Service fuel level (from carburetor body bottom edge) : Float height: Engine Speed (for reference) Optional Parts Main jet: Pilot jet (slow jet): Starter jet:
Special Tools
o Refer to the Base Manual noting the following additional tools. Pilot Screw Adjuster "A": 57001-1239
Standard Keihin, CVK32 #125 #50 #6 N36W #38 #140 21/8 #58 0.5 mm below - 1.5 mm above 17 ±1 mm 1 300 ±100 r/min (rpm) #120, 122, 128, 130 #35,#40 #60,62
FUEL SYSTEM 2-5 Throttle Case and Cable
Throttle Case and Cable Lubrication
o Refer to the Base Manual noting the following . • Lubricate the throttle case and cable in accordance with the Periodic Maintenance Chart, or whenever the case and cable are removed (see General Information chapter and General Lubrication in the Appendix chapter). o Use the pressure cable luber to lubricate the throttle cable.
A. Cable End
B. Starter Plunger
.Unscrew the choke lever mounting screw and take olf the plane washer and the wave washer.
Choke Lever and Cable
Choke Lever and Cable Removal
A. Lever Mounting Screw
B. Choke Le.ver
• Unscrew the starter plunger cap and pull out the starter plunger. • Remove the choke lever and free the choke cable upper end from the lever . • Pull off the retaining ring and free the choke cable housing from the switch housing.
A. Starter Plunger Cap A. Retaining Ring • Hold the starter plunger spring compressed, and free the choke cable lower end from the plunger.
• Pull the cable out of the vehicle.
2-6 FUEL SYSTEM Choke Lever and Cable Installation -Choke cable installation is the reverse of removal. Note the following. -Lubricate the choke cable (see General Lubrication in the Appendix chapter) before installation. -Install the wave washer, plane washer, and screw in that order.
Carburetor Carburetor Pilot Screw Adjustment - Loosen the carburetor holder clamp screws.
A. Clamp Screws (Front and Rear)
1. Screw 2. Plane Washer
3. Wave Washer
-Tilt the carburetor to the right of the vehicle for easy access to the pilot screw.
-Route the choke cable according to the Wiring, Cable, and Hose Routing s~ction in the General Information chapter.
Choke Cable Lubication -Lubricate the choke cable in accordance with the Periodic Maintenance Chart, or whenever the lever and cable are removed (see General I nformation chapter and General Lubrication in the Appendix chapter). o Use the pressure cable luber to lubricate the choke cable.
A. Pilot Screw
-Turn the pilot screw in until it seats lightly, and back it out 21/8 turns.
Carburetor Pilot Screw Setting Standard:
Choke Cable Inspection -With the choke cable disconnected at both ends, the cable should move freely in the cable housing.
- Reposition the carburetor properly and tighten the clamp screws securely . o Fit the carburetor ridge into the groove on the duct.
FUEL SYSTEM 2-7 NOTE
Idle Speed Adjustment e Adjust the pilot screw if necessary (see Carburetor Pilot Screw Adjustment). eStart the engine and warm it up thoroughly. eTurn the idle adjusting screw to obtain the slowest smooth idle speed.
OWith engine idling, turn the handlebar to each side. If handlebar movement changes idle speed, the throttle cable may be incorrectly routed, or it may be damaged.
Air Cleaner A clogged air cleaner restricts the engine's air intake, increasing fuel consumption, reducing engine power, and causing spark plug fouling.
I WARNING' OA clogged air cleaner may allow dirt and dust to enter the carburetor and stick the throttle open. This could cause an accident. A. Idle Adjusting Screw
*If the engine idle is still not stable, adjust the pilot screw to obtain the slowest smooth idle speed using the pilot screw adjuster "A" (special tool) .
OA clogged air cleaner may allow dirt and dust to enter the engine causing excessive wear and possibly engine damage. The air cleaner element must be cleaned periodically (see the Periodic Maintenance Chart in the General In dusty areas, the element Information chapter). should be cleaned more frequently than the recommended interval. After riding through rain or on muddy terrain, the element should be cleaned immediately.
Air Cleaner Element Cleaning e Remove the seat. ePull up the snaps and remove the air cleaner cover.
A. Pilot Screw Adj uster "A"; 57001-1239
I WARNING' oOperation with an improperly adjusted, incorrect routed, or damaged cable could result in an unsafe riding condition. OTo avoid a serious burn, never touch a hot engine or an exhaust pipe during carburetor adjustment.
eOpen and close the throttle a few times to make sure that the idle speed does not change. Readjust if necessary.
A. Air Cleaner Cover
B. Snaps
2-8 FUEL SYSTEM e Loosen the clamp screw, remove the element fixing screw, then pull the air cleaner element up out of the air cleaner housing.
A. Element
A. Element
B. Metal Net
elnspect the element for damage. If it is torn or punctured, replace it. elf the element is not obviously damaged, clean it in a bath of high-flash point solvent, and squeeze it dry. B. Screws
I WARNING. ePush a clean, lint-free towel into the air cleaner housing to keep dirt or other foreign material from entering.
I WARNING. Olf dirt or dust is allowed to pass through into the carburetor, the throttle may become stuck open, possibly causing an accident.
Olf dirt gets through into the engine, excessive engine wear and possibly engine damage will occur.
eRemove the element stopper from the rear end of the element body by removing the screw.
OClean the element in a well-ventilated area, and take ample care that there are no sparks or flame anywhere near the working area; this includes any appliance with a pilot light. Do not use gasoline or a low-flash point solvent to clean the element. A fire or explosion could result. eAfter cleaning, saturate the element with SE or SF class SAE 30 oil, squeeze out the excess, then wrap it in a clean rag and squeeze it as dryas possible. Be careful not to tear the element. NOTE OSpecialoils for foam air cleaner elements can be used. oReplace the element after cleaning it five times or if it is damaged.
Air Cleaner Housing Dust and/or Water Inspection ePush open the drain hose on the bottom of the air cleaner housing to expel dust and/or water accumulated inside.
A. Screw
B. Stopper
ePull the element off the body, then off the inner metal net.
A. Drain Hose
FUEL SYSTEM 2-9 Fuel Tank Installation Notes
Fuel Tank
e Fuel tan k installation is the reverse of removal. Note the following.
Fuel Tank Removal eRemove the seat (see Frame chapter in this manual). eTake off the fuel tank cap.
I WARNING' oGa~oline
is extremely flammable and can be explosive under certain conditions. Tum the ignition switch OFF. Do not smoke. Make sure the area is well ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light.
eMove the fuel tank top cover to the rear, then lift the cover.
WARNING' oGasoline is extremely flammable and can be explosive under certain conditions. Tum the ignition switch OFF. Do not smoke. Make sure the area is well ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. e Check the rubber dampers on the frame top-tube. *If the dampers are damaged or deteriorated, replace them. e Be sure the fuel hose is clamped to the fuel tap to prevent leakage.
WARNING' o Fuel spilled from the fuel tap is hazardous.
Fuel Level Gauge Removal e Remove the fuel tank cap.
I WARNING' A. Top Cover
el nstall the fuel tank cap at once. eRemove the breather and vent hoses from the clamp on the rear of the fuel tank. eRemove the four tank mounting bolts. eTurn the fuel tap to the OFF position. ePul1 the fuel hose off the tap. eBend the front fender tabs outward and remove the fuel tank.
A. Fuel Tank
oGasoline is extremely flammable and can be explosive under certain conditions. Turn the ignition switch OFF. Do not smoke. Make sure the ·area is well ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. eRemove the fuel tank upper cover by taking off the two mounting screws. elnstall the fuel tank cap immediately. ePry off the gauge cap and discard the cap. -Check the grooves in the fuel tank boss. If the grooves are damaged by removing the cap or can not hold the cap nails, the fuel tank must be replaced.
A. Gauge Cap B. Grooves
C. Fuel Level Gauge
2-10 FUEL SYSTEM -Pull out the fuel level gauge.
Fuel Level Gauge Installation Notes 01 nstallation is the reverse of removal. lowing.
Note the fol-
\
®
WARNING. OGasoline is extremely flammable and can be explosive under certain conditions. Turn the ignition switch OFF. Do not smoke. Make sure the area is well ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light.
-I nstall the fuel level gauge so that the Y2 scale faces the front. -Push the new gauge cap over the gauge so that the notch aligns with the 12 scale.
A. Fuel Level Gauge B. Float
c.
Up and Down Smoothly.
Fuel Tank Damper Installation -Apply an adhesive which is recommended by the manufacturer for bonding rubber to metal to the inside of the rubber dampers and install them as shown. -Face each split of the dampers inward of the vehicle.
A. Front B. 12 Scale
C. Notch
-Check that the gauge cap nails fit securely in the grooves in the fuel tank boss.
Fuel Level Gauge Check _ Remove the fuel level gauge Fuel Level Gauge Removal) . -Check that the float moves without binding. It should weight. *If the float does not move damage, replace the gauge.
from the fuel tank (see up and down smoothly go down under its own smoothly or has visual
1. Rubber Dampers 2.10 -15 mm 3. Splits
ENGINE TOP END 3-1
Engine Top End Table of Contents Exploded View . . . . . . . . . .. . . . . . . . . . .
3-2
Camshaft Installation . . . . . . . . . . . . .
Specifications .... . ..... ... . . . . . . . . .
3-4
Cam Wear Inspection . . . . . . . . . . . . .
Special Tools . . . . . . . . . . . . . . . . . . . . . .
3-4
Camshaft Bearing Inspection .... . .. .
* * *
Cylinder Head . . . . . . . . . . . . . . . . . . . . . .
3-4
Camshaft Chain, Guides, and Tensioner . .. . .
3-9
Cylinder Head Removal . . . . . . . . . . . . .
3-4
Camshaft Chain . .. . . . . . . . . . . . . . . . .
Cylinder Head Installation Notes . . . . . . .
3-5 3-5
Camshaft Chain Removal . . . . . . . . . .
* * * * * * * *
Compression Releasing Lever Removal Compression Releasina
Camshaft Chain Installation . . . . . . . . . Camshaft Chain Wear .... .. . . . . . . .
Lever Installation .. . . . . . . . . . . . . .
3-5
Camshaft Chain Guides . . . . . . . . . . . . . .
Cylinder Head Assembly Note .. . ..... .
3-6
Camshaft Chain Guide Removal ..... .
Cylinder Head Cleaning . . . . . . . . . . . . .
Camshaft Chain Guide Installation ... .
Cylinder Head Warp . . . . . . . . . . . . . . . . Valves, Guide, Seats, Springs, Oil Seals .... .
* * 3-6
Valves . . . . . . . . . . . . . . . . . . . . . . . . .
3-6
Camshaft Chain Tensioner. . . . . . ..... . Camshaft Chain Tensioner Removal .. .
Valve Clearance Check . . . . . . . .... . Valve Clearance Adjustment .. . . . . . .
3-6
Valve Removal .... .. . . . . . . . . . . . . Valve Installation . . . . . . . . ... ... . Valve. Visual Inspection . . . . . . . . . . . Valve Head Thickness . . . . . . . . .... . Valve Stem Bend . . . . . . . . . . . . . . . . Valve Stem Diameter .... . . .. .... . Valve Stem Grinding . . . . . . . . . ... . Valve Guides . . . . . . . . . . . . . . . . . . . . Valve Guide Inside Diameter . . . . . . . . Valve Guide Removal . . . . . . . . . . . . . Valve Guide Installation . . . . . . . . . . . Valve Seats . . . . . . . . . . . . . . . . . . . . . . Valve Seat Inspection . . . . . . . . . . . . . Valve Seat Repair . . . . . . . . . . . . . . . Valve Springs . . . . . . . . . . . . . . . . . . . . Valve Spring Removal/Installation ... . Valve Spring Free Length . . . . . . . . . . Valve Stem Oil Seals . . . . . . . . . . . . . . . Valve Stem Oil Seal Removal . . . . . . . . Valve Stem Oil Seal Installation . . ... . Camshaft Sprocket . . . . . . . . . . . . . . . . . . Camshaft Sprocket Removal . . . . . . . . Camshaft Sprocket Installation ..... . Camshaft, Rocker Arms and Shafts . .. ... . . Rocker Arms and Shafts . . . . . . . . . . . . . Rocker Arm and Shaft Removal . . . . . . Rocker Arm and Shaft Installation ... . Rocker Arm Inspection . . . . . . . • . . . Rocker Shaft Diameter .... . . . . . . . . Camshaft . . . . . . . . . . . . . . . . . . . . .. . Camshaft Removal. . . . . . . . . . . . . . .
* * * * * * * 3-7 3-7 * * 3-7 * * * * * * * * * 3-7 3-7 3-8
Camshaft Chain Guide Wear . . . . . . . .
3-9 3-9
Camshaft Chain Tensioner Installation . . . . . . . . . . .
3-9
Camshaft Chain Tensioner Wear ..... .
*
Cylinder, Piston and Rings . . . . . . . . . . . . . Cylinder Removal/Installation . . . . . . . . .
3-10
Cylinder Removal ............... .
* *
Cylinder Installation Note . . . . . . . . . .
3-10
Cylinder Assembly Note . . . . . . . . . . . Piston and ring Removal/Installation .. .. .
3-10
3-10
Piston and Ring Removal ..... . .. .. .
*
Piston and Ring Installation .... . ... .
3-10
Cylinder, Piston and Ring Maintenance .. ,
3-10
Compression Measurement . . . . . . . . .
3-10
Cylinder/Piston Wear . . . . . . . . . . . . .
Piston Ring End Gap . . . . . . . . . . . . .
* * * * * * *
-Exhaust System .. . . . . . . . . . . . . . . . . . .
3-11
Spark Arrester . . . . . . . . . . . . . . . . . . .
3-11
Spark Arrester Cleaning . . . . . . . . . . .
3-11
Exhaust Pipe .... . . . . . . . .. . . . . . . . .
3-12
Exhaust Pipe Removal Note . . . . . . . .
3-12
3-8
Exhaust Pipe Installation . . . . . . . . . .
3-12
3-8 3-8 * * * * *
Exhaust System Inspection . . . . . . . . .
*
Carburetor Holder . . . . . . . . . . . . .... .. . Carburetor Holder Installation ... .. . .
3-12
Piston/Cylinder Clearance ..... . ... . Cylinder Boring and Honing .. ..... . Piston/Cylinder Seizure . . . . . . . . . . . Piston Cleaning . . . . . . , . . . . . . . . . . Piston Ring and Ring Groove Wear ... .
*
Base Manual
3-12
[]I
3-2 ENGINE TOP END Exploded View
.@
R
1. Manual Compression Release L : Apply non-permanent locking agent. M : Apply molybdenum disulfide grease. D : Apply engine oil. R : Replacement Parts T1: 29 N-m (3.0 kg-m, 22 ft-lb) for used parts 34 N-m (3.5 kg-m, 25 ft-lb) for new parts T2: 12 N-m (12 kg-m, 104 in-lb) T3: 41 N-m (42 kg-m, 30 ft-lb) T4: 9.8 N-m (1.0 kg-m, 87 in-lb)
ENGINE TOP END 3-3
3-4 ENGINE TOP END
Specifications Refer to the Base Manual noting the following. Camshaft Cam Height: Inlet, Exhaust: 40.642 - 40.782 mm (Service Limit: 40.54 mm) Cylinder Compression (Usable range, with compression release operated) Using Recoil Starter 825 - 1 280 kPa (8.4 - 13.0 kg/cm 2 , 119 - 185 psi) Using Electric Starter 795 - 1 240 kPa (8.1 -12.6 kg/cm 2 , 115 - 179 psi) Cylinder, Piston: Cylinder inside diameter: 76.000 -76.012 mm (Service Limit: 76.010 mm) Piston diameter: 75.960 - 75.975 mm (75.81 mm) Piston/cylinder clearance: 0.025 - 0.052 mm Oversize piston and rings: +0.5 and +1.0 mm Piston ring/groove clearance Top: 0.03 - 0.07 mm (0.17 mm) Secondary: 0.02- 0.06 mm (0.16 mm) Piston ring thickness: Top, second: 0.97 - 0.99 mm (0.90 mm) Piston ring groove width: Top: 1.02 -1.04 mm (1.12 mm) Second: 1.01-1.03 mm (1.11 mm)
Cylinder Head Cylinder Head Remova/ • Remove the following parts. Front Fender (see Frame chapter) Fuel Tank (see Fuel System chapter in this text) Carburetor (see Fuel System chapter in the Base Manual) Exhaust Pipe (see Exhaust Pipe Removal) Camshaft Sprocket (see this chapter) Spark Plug Cap Cylinder Head Breather Hose and Hose Clamp • Remove the cylinder head bracket bolts, the cylinder head mounting bolt, and nut, then take off the brackets.
A. Cylinder Head Bracket Mounting Bolts B. Cylinder Head Breather Hose and Hose Clamp C. Cylinder Head Mounting Bolt and Nut
• Remove the cylinder base bolt. • Loosen the cylinder head bolts completely starting with the 6 mm bolts and r.emove all the bolts.
Special Tools Refer to the Base Manual noting the following additional tool. Bearing Driver Set: 57001-1129
A.8 mm Cylinder Head Bolts B. 6 mm Cylinder Head Bolts C. 6 mm Cylinder Base Bolt • Lift the cylinder head clear of the dowel pins in the cylinder and slide the cylinder head out of the frame.
ENGINE TOP END 3-5 Cylinder Head Installation Notes - Refer to the Base Manual noting the following. -Install a new cylinder head gasket. -Inspect the new head gasket, and if the seal coating breaks away, replace the gasket.
- Pull out the lever along with the washer and return spring.
1. Cylinder Head Gasket
*If the cylinder head or the cylinder head bolts are new ones, tighten the 8 mm bolts to 34 N-m (3.5 kg-m, 25 ft-lb) of torque. -First tighten the upper three br.acket mounting bolts, then tighten the lower bracket bolt and nut ):0 the specified torque (see Cylinder Head Removal and Exploded View).
Compression Releasing Lever Removal
o Do not remove the compression releasing lever unless it is absolutely necessary. If removed, the oil seal replacement may be required.
A. Oil Seal B. Return Spring
C. Washer
Compression Releasing Lever Installation - Replace the oil seal in the cylinder head. Use a suitable bearing driver from the bearing driver set (special tool: PN 57001-1129) when installing the oil seal. -Install the return spring on the compression releasing lever as shown.
-Remove the front fender (see Frame chapter in this manual). - Remove the bolt holding the compression releasing lever.
A. Return Spring
C. Front A. Bolt B. Compression Releasing Lever
-Oil the lever shaft and install the washer and lever assembly. -Tighten the bolt securely.
3-6 ENGINE TOP END Cylinder Head Assembly Note elnsert the rubber dampers in the fin grooves starting with the first groove from the top. Rubber Damper Installation
e Remove the timing inspection plug. e Turn the crankshaft counterclockwise with a wrench on the alternator rotor bolt, and watch the intake valve. When the intake valve opens and closes, keep turning the crankshaft counterclockwise until the T mark on the alternator rotor aligns with the slot, as shown.
o 2. Rubber Dampers
1. Cylinder Head
Valves, Guides, Seats, Springs, Oil Seals Valves: Valve Clearance Check
A. Timing Inspection Plug B. Slot
C.- T Mark
e Measure the clearance of each valve between the end of the valve stem and the adjusting screw on the rocker arm with a thickness gauge. *If the valve clearance is not correct, adjust it (see Valve Clearance Adjustment).
NOTE
oCheck the valve clearance only when the engine is cold (cool to the touch). eRemove the fuel tank (see Fuel Tank Removal in the Fuel System chapter). eTake out the bolts and remove the valve adjusting caps with O-rings.
A. Valve Adjusting Caps
B. Front
Valve Clearance (when cold) 0.10 - 0.15 mm Intake: Exhaust: 0.15 - 0.20 mm
A. Thickness Gauge B. Adjusting Screw
C. Locknut
ENGINE TOP END 3-7 -Install the valve adjusting caps so that the UP mark is on top.
A. Valve Guide Reamer: 57001-162
A. UP Mark
-Check valve seat (see Valve Seat Inspection). -Discard the valve stem oil seal and install the new oil seal (see Valve Stem Oil Seal Installation). -Install the valve (see Valve Installation). -Install the cylinder head (see Cylinder Head Installation).
Valve Stem Griding -The end of the valve stem may be ground slightly to remove damage or to gain valve clearance after valve job. -Follow the valve refacing machine manufacturer's instructions.
............................................................................• Camshaft Sprocket
Valve Stem Griding
Camshaft Sprocket Removal Minimum after grinding 4.0 mm
Do not grind off more than 0.2 mm
-Remove the front fender (see Front Fender Removal in the Frame chapter). -Remove the fuel tank (see Fuel Tank Removal in the Fuel System chapter). - Remove the ignition timing inspection plug and the recoil starter (see Recoil Starter Removal in the Engine Left Side chapter). -Remove the bolts and take off the camshaft cover. olt may be necessary to pry the cover off with a screwdriver. There are prying gaps under the screw hole bosses.
Valve Guides: Valve Guide Installation -Clean the valve guide hole in the cylinder head. - Lightly oil the valve guide. -Heat the cylinder head around the valve guide hole to 120° to 150°C (250° to 300°F) . - Use the valve guide arbor and a hammer to drive the guide into the head from the outside until the guide flange seats against the head. -Allow the cylinder head to cool. - Ream the valve guide with the valve guide reamer (special tool) even if the old guide is reused.
A. Camshaft Cover
B. Gaps
3-8 ENGINE TOP END -Turn the crankshaft with a wrench on the alternator rotor bolt until the "LF300" mark on the camshaft sprocket aligns with the pointer on the cylinder head.
- Fit the sprocket under the chain and slip it over the shoulder on the crankshaft so that the "LF300" mark on the sprocket aligns with the pointer on the cylinder head.
A. Pointer A. Pointer
- Remove the camshaft chain tensioner (see Camshaft Chain Tensioner Removal). - Remove the camshaft sprocket bolt while holding the crankshaft from turning with a wrench on the alternator rotor bolt. -Slide the sprocket off the shoulder on the camshaft and out from the chain . -Support the chain on a screwdriver or other tool stuck in the hole in the head.
Camshaft Sprocket Installation - Remove the timing inspection plug, and check to see that the "T" mark on the alternator rotor aligns with the slot.
A. Timirig Inspection Plug B. Slot
B. "LF300" Mark
B. "LF300" Mark
C. T Mark
-Screw the bolt in and tighten it to the specified torque (see Exploded View), while holding the crankshaft from turning with a wrench on the alternator rotor bolt. - Install the camshaft chain tensioner (see Camshaft Chain Tensioner Installation). - Before going any further, check the cam timing. oTurn the crankshaft counterclockwise with a wrench on the alternator rotor bolt, until the "LF300" mark on the sprocket aligns with the pointer on the head.
o If any resistance is felt wilen turning tile crankshaft, stop immediately, or you may bend the valves.
o The "T" mark on the alternator rotor should align with the slot. *If the camshaft timing is not correct, remove the sprocket from the camshaft, and install it again as detailed above. - Smear a little engine oil on the camshaft cover O-ring and push the cover into place so that the UP mark faces up. -Put in the camshaft cover bolts and tighten them securely. - Install the timing inspection plug, and the . recoil starter. - Install the fuel tank (see Fuel Tank Installation in the Fuel System chapter).
Camshaft, Rocker Arms and Shafts Rocker Arms and Shafts:
*If the "T" mark is not aligned, hold the camshaft chain taut and 'turn the crankshaft with a wrench on the alternator rotor bolt.
Rocker Arm and Shaft Removal - Remove the camshaft sprocket (see Camshaft Sprocket Removal).
ENGINE TOP END 3-9 eTake out the screw and remove the rocker shaft retainer. e Remove the compression releasing lever (see Compression Releasing Lever Removal).
o Do not turn the engine while the camshaft chain tensioner is removed. Engine damage could result.
A. Rocker Shaft Retainer
A. Lockbolt
eTake out the bolts and remove the valve adjusting caps. e Loosen all the cylinder head bolts to free the cylinder head from the stress (see Cylinder Head Removal). ePull out the rocker shafts and remove the rocker arms.
eRemove the lock bolt. eCarefully pull the push rod out of the tensioner body. Do not drop the ball and retainer assembly or the spring. eSlide the ball and retainer assembly and the spring off the push rod.
B. Mounting Bolts
Camshaft Chain Tensioner Installation eSlip the spring over the push rod and compress it down past the hole. elnsert a piece of wire in the hole to hold the spring in place.
A. Rocker Arm
B. Shaft
Camshaft Chain, Guides, and Tensioner Camshaft Chain Tensioner: Camshaft Chain Tensioner Removal
A. Spring B. Wire
e Loosen the lockbolt in the top of the camshaft chain tensioner. Do not remove it yet. eTake out the tensioner mounting bolts and remove the camshaft chain tensioner.
eDrop the ball and retainer assembly onto the push rod. ePush the push rod into the tensioner body.
C. Push Rod
3-10 ENGINE TOP END eWhen the push rod is in as far as it will go, screw in the lock bolt with its washer to lock the push rod. ePull out the wire to release the spring. Chain
T~nsioner
(push rod is locked)
L
Piston and Ring Removal/Installation: Piston and Ring Installation Refer to the Base Manual noting the following. elnstall the second and top rings in that order. elnstall the top and second rings so that each "N" marked side faces up.
Top and Second Rings "N" mark
Top ring
4. Spring 1. Lockbolt 5. O-Ring 2. Push Rod 3. Ball and Retainer Assembly eBe sure the O-ring is in place in the tensioner body. eAfter installing the tensioner, loosen the lockbolt and then tighten it. With the bolt loosened, the spring inside takes up any slack automatically.
Cylinder, Piston and Rings Cylinder Installation Note o Refer to the Base Manual noting the following. elnstall a new cylinder base gasket. o Inspect the new base gasket and if the seal coating breaks away, replace the gasket.
Cylinder Assembly Note elnsert the rubber dampers in the fin grooves starting with the first groove from the top.
2nd ring
Cylinder, Piston and Ring Maintenance: Compression Measurement eBefore measuring compression, do the following: oBe sure the battery is fully charged (see Battery Condition in the Electrical System chapter in this Manual). oWarm up the engine (if the engine will run). oDuring warm-up, check for leaks around the cylinder head gasket. e Remove the spark plug. eSet the compression gauge and adapter hose (special tools) into the spark plug hole. ePull up the recoil starter until the compression is felt. Then, push up the compression releasing lever each time to start the engine.
Rubber Damper Installation
20mm
1. Rubber Dampers 2. Cylinder
A. Compression Releasing Lever
ENGINE TOP END 3-11 eHold the throttle wid~ open and crank the engine with the recoil starter, or the electric starter. eWhen the gauge stops rising, stop cranking and read the gauge.
Exhaust System Spark Arrester: This vehicle is equipped with a spark arrester approved for off-road use by the U.S. Forest Service. It must be properly maintained to ensure its efficiency. In accordance with the Periodic Maintenance Chart, clean the spark arrester.
Spark Arrester Cleaning
I WARNING I OTo avoid burns, wear gloves while cleaning the spark arrester. Since the engine must be run during this procedure, the muffler will become hot.
A. Compression Gauge: 57001-212 B. Adapter Hose: 57001-1159
Cylinder Compression (Usable Range) with Recoil Starter 825 - 1280 kPa (8.4 -13.0kg/cm 2 , 119 -185 psi) , or with Electric Starter 795 - 1240 kPa (8.1 - 12.6 kg/cm 2 ,115 - 179 psi)
*If the compression is within the specified range, the piston rings, cylinder and valves are probably in good condition. *If the compression is higher than the specified range, see the Compression Too High table in the Base Manual. *If the compression is below the specified range, check the cylinder head bolt torque (see Cylinder Head Installation in this manual). *If the compression is still below the specified range, squirt a little oil into the spark plug hole and repeat the compression measurement. *If the compression does not change very much, the piston rings are probably OK. See the Wet Compression - No Change table in the Base Manual. *If the compression increases, the piston rings are not sealing properly. See the Wet Compression - Increase table in the Base Manual.
o The spark arrester must be installed correctly ·and functioning properly to provide adequate fire protection. eRemove the drain plug on the rear muffler. eln an open area away from combustible materials, start the engine with the transmission in neutral. eRaise and lower engine speed while tapping on the muffler with a rubber mallet until carbon particles are purged from the muffler.
A. Drain Plug B. Spark Arrester
C. Mounting Bolt
WARNING. not run the engine in a closed area. Exhaust gases contain carbon monoxide; a colorless, odorless, poisonous gas. Breathing exhaust gas leads to carbon monoxide poisoning, asphyxiation, and death. oNever run the engine with the spark arrester removed. Hot carbon particles may start a fire.
000
3-12 ENGINE TOP END NOTE
oRun the engine with the spark arrester installed during cleaning. This keeps the exhaust pressure higher and makes carbon particles purge easier. eStop the engine. elnstall the drain plug. e Remove the spark arrester mounting bolt from the muffler. ePull the spark arrester out of the muffler. eScrape carbon deposits off the spark arrester and slide it back into the muffler. elnstall the mounting bolt and tighten it securely.
e Temporarily install the muffler clamp on the muffler so that the gasket stopper faces the rear. e lnsert the muffler clamp over the exhaust pipe so that the gasket stopper of the clamp contacts the end of the exhaust pipe. Muffler Clamp Installation
Exhaust Pipe: Exhaust Pipe Removal Note eRefer to the Base Manual noting the following. eFirst, take off the exhaust pipe holder nuts at the cylinder head. eRemove the mud guard to loosen the muffler clamp bolt until the clamp turns freely on the muffler.
o 1. Gasket Stopper of Clamp 2. Exhaust Pipe
3. Gasket 4. Front
eTighten the exhaust pipe holder nuts evenly and securely. e Tighten the muffler clamp bolt securely.
A. Muffler Clamp Bolt eWork the exhaust pipe out of the frame and remove it.
Carburetor Holder
Exhaust Pipe Installation
Carburetor Holder Installation
elnstallation is the reverse of removal. Note the following. eFit a new gasket into the muffler so that the chamfered side of the gasket faces to the front.
e lnstall the carburetor holder so that the projection faces upward . Carburetor Holder Installation
1. Projection
A. Chamfer
e Tighten the bolts to a snug fit, then tighten them evenly.
ENGINE LEFT SIDE 4-1
Engine Left Side Table of Contents
[II Exploded View ........................................... . Specifications ............................................ . Special Tool ............................................. . Reco iI Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Recoil Starter Removal ................................. . Recoil Starter Disassembly .............................. . Recoil Starter Assembly Notes ........................... . Recoil Starter Cleaning ................................. . Recoil Starter Inspection ................................ . Left Engine Cover ......................................... . Left Engine Cover Removal. ............................. . Left Engine Cover Installation Notes....................... . Alternator Rotor and Stator (see Electrical System chapter in this Manual)
4-2 * 4-3 4-3 4-3 4-3 4-4
4-6 4-6
4-6 4-6 4-7
Pickup Coil (see Electrical System chapter in the Base Manual) Starter Clutch ............................................ . Starter Clutch Removal ................................. . Starter Clutch Installation ............................... . Starter Clutch Inspection ............................... .
* * * *
Starter Chain and Sprocket Installation ..................... . Starter Chain Wear .................................... . Torque Limiter Inspection .............................. .
4-7 * * * 4-7
Sub-Transmission Lever. .................................. .
4-7
Sub-Transmission Lever Removal ......................... . Front Propeller Shaft .................................... .
4-7 4-7
Sub-Transmission Case .......... ... .. , ................... .
4-7
Starter Chain and Sprockets ................................. . Starter Chain and Sprocket Removal. ...................... .
* : Base Manual
4-2 ENGINE LEFT SIDE Exploded View
®
@
~
~/
,
@@
1. Torque Limiter G : Apply high temperature grease. L : Apply non-permanent locking agent. o : Apply engine oil. Lh: Left-Hand Threads R : Replacement Parts Rh: Right-Hand Threads T1 : 59 N-m (6.0 kg-m, 43 ft-Ib) T2 : 49 N-m (5.0 kg-m, 36 ft-Ib) T3: 8.3 N-m (0.85 kg-m, 74 in-Ib) T4: 7.8 N-m (0.8 kg-m, 69 in-Ib
,
1/ ~/.
ENGINE LEFT SIDE 4-3
Special Tool Refer to the Base Manual noting the following additional tool. Hook Wrench: 57001-1101
e
A. Reel B. Handle Cap
C. Locking Pliers
eHold the reel in one hand while removing the locking pliers with the other. e Pull the rope in through the rope hole in the housing and hold it in the notch in the reel. NOTE
oDo not let the rope wedge between the reel and the housing.
fJecoil Starter Recoil Starter Removal eRemove the front propeller shaft cover (see Front Propeller Shaft Removal in the Final Drive chapter) and the recoil starter by taking out the mounting bolts.
A. Hold rope in notch. eSlowly allow recoil spring tension to unwind the reel. eRemove the friction plate by taking off the flange nut.
A. Starter Bolts
B. Propeller Shaft Cover
Recoil Starter Disassembly e Remove the recoil starter (see Recoil Starter Removal). ePull the handle out 100 - 200 mm . Clamp the rope in place with locking pliers. eRemove the handle cap . • Pry the knot out of the handle and untie it. Pull the handle off the rope.
A. Friction Plate
B. Flange Nut
4-4 ENGINE LEFT SIDE
I WARNING' o Be careful that the spring does not fly loose and does not injure you. It is under great pressure. OTurn the reel one-quarter turn counterclockwise past the rest position where no tension can be felt. Now, slowly lift the friction plate straight up out of the housing.
e Remove the friction plate and friction plate spring. e Remove the pawl and pawl spring.
4
\ 1. 2. 3. 4. 5.
Pawl Pawl Spring Friction Spring Friction Plate Flange Nut
A. Strike bench.
e Remove the reel noting the following.
I WARNING' o Be careful that the spring does not fly loose and does not injure you. It is still under great pressure. o Turn the reel one-quarter tum counterclockwise past the rest position where no tension can be felt. Now, slowly lift the friction plate straight up out of the housing.
NOTE
o There should be no spring tension on the reel when removing the reel. Lift the reel slightly. If tension is felt, push the reel back into place and gently "wiggle" it until the reel may be easily removed.
elf necessary, remove the recoil spring as follows. o Place the starter housing facing down on a bench. OStrike the bench sharply to safely remove the spring.
Recoil Starter Assembly Notes eAssembly. is the reverse of disassembly. Note the following. elf the recoil spring was removed, install it as shown. If it is not installed correctly, the starter will not operate properly.
WARNING' o The recoil spring must be put under great pressure during installation. Wear gloves to avoid injury.
e Hook the outer end of the recoil spring onto the housing tab. e Reel the recoil spring clockwise into the housing from outside to inside.
ENGINE LEFT SIDE 4-5
CD
1. Hook recoil spring end onto the tab.
A. Turn reel to wind rope. eGrease the reel and set the reel into place so that the hook on the spr·ing catches on the tab in the reel.
NOTE
OPush the recoil spring against the housing securely to prevent the spring from slipping off during installation.
e Lightly grease the spring.
A. Align hook and tab.
B. Grease here.
eGrease the pawl spring and pawl and install them as shown. eGrease the friction plate and install the friction plate and spring being careful of the spring hook position.
A. Grease recoil spring.
elf the rope was unwound from the reel, it must be wound clockwise for correct starter operation. eWind the rope four turns around the smaller diameter of the reel and half turn around the larger diameter.
NOTE
o Turn the reel counterclockwise to wind the rope clockwise. This prevents the rope from twisting.
A. Pawl B. Pawl Spring C. Friction Plate
D. Friction Plate Spring Hooks E. Grease here.
4-6 ENGINE LEFT SIDE -Tighten the flange nut to the specified torque (see Exploded View). -Turn the reel four turns clockwise to preload the spring.
Left Engine Cover
Left Engine Cover Removal - Remove the recoil starter (see Recoil Starter Removal). -Holding the recoil starter pulley steady with the hook wrench (special tool), loosen the alternator rotor bolt.
A. Turn clockwise
A. Alternator Rotor Bolt
B. Hook Wrench: 57001-1101
Recoil Starter Cleaning - Disassemble the recoil starter (see Recoil Starter Disassembly). -Immerse only the metal parts in a bath of high-flash point solvent.
WARNING' OClean the starter in a well-ventilated area, and take care that there are no sparks or flame anywhere near the working area; this includes any appliance with a pilot light. Do not use gasoline or a low-flash point solvent to clean the starter. A fire or explosion could result_
- Remove the alternator rotor bolt, the pulley and the key. The pulley may be pulled out easily. - Place an oil pan beneath the engine left side. - Remove the following parts. Seat Sub-Transmission Shift Lever Assembly Left Engine Cover Mqunting Bolts (8) - Take off the left engine cover. - If necessary, remove the rear fender (see Frame chapter) and pull out the alternator connectors to complete the left engine cover removal.
ODo not clean any non-metallic parts in the solvent as they may be damaged.
oUse compressed air to dry the cleaned components.
Recoil Starter Inspection -Clean the recoil starter (see Recoil Starter Cleaning). - Examine the starter pawl for chips or excessive wear. - Check the starter rope for excessive wear or fraying. - Check the condition of the recoil spring, and friction plate spring. o Inspect the springs for breaks, rust, distortion, or weakened condition.
A. Left Engine Cover Mounting Bolts B. Sub-Transmission Shift Lever Assembly
ENGINE LEFT SIDE 4-7 Left Engine Cover Installation Notes o Refer to the Base Manual noting the following. -Grease the left engine cover oil seal. -Check that the pulley O-ring is in good condition. - Clean the pulley boss and apply oil to the O-ring and the boss. -Push the pulley into the left engine cover oil seal. -Fit the key in the groove between the pulley and shaft. -Insert the alternator rotor bolt.
1. Torque Limiter
Sub-Transmission Lever
............................................................................. Sub- Transmission Lever Removal A. Grooves
B. Key
-Take off the sub-transmission lever by removing the following bolts and nut.
-Using the hook wrench (special tool), tighten the alternator rotor bolt to the specified torque (see Exploded View).
A. Bolts
B. Nut
A. Hook Wrench: 57001-11 01
Front Propeller Shaft
Refer to the Final Drive chapter.
Starter Chain and Sprocket Sub-Transmission Case
Torque Limiter Inspection -Remove the torque limiter and visually inspect it. *If the limiter has wear, discoloration, or other damage, replace it as a unit.
Refer chapter.
to
the
Engine
Bottom
End/Transmission
ENGINE RIGHT SIDE 5-1
Engine Right Side Table of Contents
Exploded View . . . . . . . . . . . . . . . . . . . . .
5-2
Primary Gear Installation
*
Specifications . . . . . . . . . . . . . . . . . . . . . .
Secondary Gear Removal
*
Special Tools .... . . . . . . . . ... . . . . . . .
5·3 *
Secondary Gear Installation . . . . . . . . .
*
Right Engine Cover . . . . . . . . . . . . . . . . . .
*
Primary and Secondary Gear Damage ..
*
Right Engine Cover Removal . . . . . . . .
*
Gear Backlash . . . . . . . . . . . . . . . . . .
*
Right Engine Cover Installation .... . .
*
Primary Gear/Crankshaft Wear . . . . . . .
*
Clutches . . . . . . . . . . . . . . . . . . . . . . . . .
5-3
Secondary Gear/Collar Wear . . . . . . . .
*
Clutch Adjustment . . . . . . . . . . . . . .. .
5-3
Lubrication System . . . . . . . . . . . . . . . . . .
5-4
Clutch Adjustment . . . . . . . . . . . . . .
5-3
Engine Oil and Filter .... . . . . . . . . .. .
*
Clutch Removal . . . . . . . . . . . . . . . . . .
5·3 *
Engine Oil Level Inspection . . . . . . . . .
*
Engine Oil and Filter Change . . . . . . . .
*
Oil Pump . . . . . . . . . . . . . . . . . . . . . . .
5-4
Clutch Inspection . . . . . . . . . . . . . . . . .
5-3 *
Oil Flow Inspection . . . . . . . . . . . . . .
5-4
Primary Clutch Housing Wear . . . . . . .
*
Oil Pump Removal. . . . . . . . . . . . . . .
*
Primary Clutch Shoe Lining Wear .... .
*
Oil Pump Installation . . . . . . . . . . . . .
*
One-Way Clutch Inspection . . . . . . . . .
*
Oil Pump Disassembly . . . . . . . . . . . .
*
Friction Plate Wear and Damage . . . . . .
*
Oil Pump Assembly . . . . . . . . . . . . . .
*
Friction Plate and Steel Plate Warp ... .
*
Oil Pump Inspection ..... . . ..... .
*
Oil Screen .. . ..... ... .. . . . . . . . . .
*
Clutch Removal . . . . . . . . . . . . . . . . Ch"tch Installation . . . . . . . . . . . . . . .
Secondary Clutch Housing Finger Damage . . . . . . . . . . . . . . .
*
Oil Screen Removal .... . .. . ..... .
*
Secondary Clutch Hub Spline Damage ..
*
Oil Screen Installation . . . . . . . . . . . .
*
Secondary Clutch Spring Wear ... ... .
Oil Screen Cleaning and Inspection ... .
*
Clutch Release . . . . . . . . . . . . . . . . . . .
* 5-3
Oil Filter Bypass Valve . . . . . . . . . . . . . .
*
Clutch Release Removal . . . . . . . . . . .
5-3
Bypass Valve Removal . . . . . . . . . . . .
*
Clutch Release Installation . . . . . . . . .
Bypass Valve Installation . . . . . . . . . .
*
Clutch Release Wear . . . . . . . . . . . . . .
5-3 *
Bypass Valve Cleaning and Inspection ..
*
Balancer . . . . . . . . . . . . . . . . . . . . . . . . .
5-4
Primary Reduction . . . . . . . . . . . . . . . . . .
*
Primary Gear Removal . . . . . . . . . . . .
*
*
Base Manual
5-2 ENGINE RIGHT SIDE Exploded View
Remove this oil pipe when the optional oil cooler is used. ~ ,-------I
~~,
T5
I
----;;>t~ @ I
I
l : M : D : T1 : T2: T3: T4: T5: T6:
Apply non-permanent locking agent. Apply molybdenum disulfide grease. Apply engine oil. 125 N-m (13.0 kg-m, 94 ft-lb) 12 N-m (1.2 kg-m, 104 in-Ib) for used bolts 15 N-m (1.5 kg-m, 11.0 ft-Ib) for new bolts 78 N-m (8.0 kg-m, 58 ft-Ib) 29 N-m (3.0 kg-m, 22 ft-Ib) 20 N-m (2.0 kg-m, 14.5 ft-Ib) 15 N-m (1.5 kg-m, 11.0ft-lb)
I I
ENGINE RIGHT SIDE 5-3
............................................................................ Specifications ............................................................................ Refer to the Base Manual noting the following. Engine oil: Grade: Viscosity: Capacity:
SE or SF class SAE10W-30 can also be used 2.2 L
Relief valve opening pressure: 430- 590 kPa (4.4 - 6.0 kg/cm 2 , 63 - 85 psi)
............................................................................ Clutches
............................................................................ Clutch Adjustment: Clutch Adjustment eRemove the clutch release adjusting screw cover.
Clutch Removal: Clutch Installation e Refer to the Base Manual noting the following. *If the clutch spring plate or the clutch spring bolts are new ones, tighten the spring bolts evenly to 15 N-m (1.5 kg-m, 11.0 ft~b) of torque.
Clutch Release: Clutch Release Removal eRemove the clutch release adjusting screw cover from the outside of the right engine cover. eUnscrew the upper adjusting screw and locknut. eRemove the right engine cover (see Right Engine Cover Removal in the Base Manual). eRemove the following parts from the right engine cover . E-Ring and Spring Clutch Pusher .Pull the release cams and ball assembly off the release shaft.
Clutch Release Installation eBe careful of the installation direction of the clutch pusher, the release cams, and the release bearing. eScrew the upper adjusting screw fu lIy in the release cam B.
A. Clutch Release Adjusting Screw Cover B. Screws eLoosen the locknut for the upper adjusting screw. eTurn the clutch release adjusting screw clockwise until it becomes hard to turn, then turn the screw back counterclockwise until it becomes hard to turn .
A. Locknut
1. E-Ring 2. Clutch Pusher 3. Upper Adjusting Screw
eLoosen the lower adjusting screw locknut and set the lower adjusting screw so that the eccentric pin is as close the upper adjusting screw as possible. eTighten the locknut.
B. Upper Adjusting Screw
eTighten the locknut without changing the adjusting screw position. elnstall the adjusting screw cover.
4. Re lease Cam A 5. Release Bearing 6. Release Cam B
1. Upper Adjusting Screw 2. Eccentric Pin 3. Lower Adjusting Screw
5-4 ENGINE RIGHT SIDE
Clutch Release Lever Installation -Grease the splines (A) of the clutch release lever (B), -Install the clutch release lever on the shift shaft (C) so that the lever points toward the center (D) of the secondary clutch,
.. ..... ....................................................................... . '
Balancer Refer to Engine Bottom End/Transmission in the Base Manual for the information. oBalancer punch mark alignment is needed at balancer gear installation.
Lubrication System Oil Pump: Oil Flow Inspection - Run the engine at idle speed.
I WARNING' ODuring oil flow inspection, do not open the throttle valve. Hot oil will squirt out of the banjo bolt, and may cause a serious burn. -Install the right engine cover. - Loosen the locknut for the upper clutch release adjusting screw. -Turn the adjusting screw counterclockwise until it becomes hard to turn, and then turn it further 12 to 1 turn to the same direction.
- Loosen the main oil pipe banjo bolt on the left crankcase as shown, and check that the oil seeps out around the banjo bolt.
A. Main Oil Pipe Banjo Bolt A. Locknuts B. Upper Adjusting Screw
C. Lower Adjusting Screw
- Loosen the locknut for the lower clutch release adjusting screw. -Turn the lower adjusting screw clockwise and then counterclockwise (about 12 turn) until it becomes hard to turn on either direction, and then stop 'it in the middle position. -Tighten the locknut. -Turn the upper clutch release adjusting screw clockwise two or three turns, and then turn it counterclockwise until it becomes hard to turn. -Tighten the locknut. -Install the adjusting screw cover.
-Tighten the banjo bolt to the specified torque (see Exploded View). -Stop the engine. -Wipe up any oil that spills on the engine or the frame. *If the oil does not flow out, inspect the oil filter, the relief valve, and the oil pump. *If the oil filter, the relief valve, and the oil pump are not at fault, inspect the rest of the lubrication system.
ENGINE REMOVAL/INSTALLATION 6-1
Engine Removal/Installation Table of Contents Exploded View ........................................... . Engine Removal/Installation ................................. . Engine Removal ......... . ............................ . Engine I nstallation Note ................................ . Another Way of Engine Removal/Installation Notes ........... .
* : Base Manual
6-2 6-3 6-3 6-3 6-3
~
6-2 ENGINE REMOVAL/INSTALLATION Exploded View
.............................................................................
(fi) ~~
~4ft
CID
T1 : 25 N-m (2.5 kg-m, 18.0 ft-Ib) T2: 37 N-m (3.8 kg-m, 27 ft-Ib)
ENGINE REMOVAL/INSTALLATION 6-3 Engine Removal/Installation
Engine Removal eDrain the engine oil (see Engine Right Side chapter in the Base Manual). eRemove the following parts. Front Fender and Rear Fender (see Frame chapter) Fuel Tank (see Fuel System chapter) Carburetor (see Fuel System chapter in the Base Manual) Exhaust Pipe (see Engine Top End chapter) Sub-Transmission Assembly (see Engine Bottom End/ Transmission chapter)
Engine Installation eEngine installation is the reverse of removal. Note the following. eTighten the engine mounting bolts and bracket bolts to the specified torque (see Exploded View). eFirst tighten the upper three bracket bolts, then tighten the lower bracket bolt and nut to the specified torque (see Exploded View).
-i
'\..
A. Three Bracket Bolts B. Lower Bracket Bolt and Nut
A. Sub-Transmission Assembly eDisconnect the following cables, hoses, and leads from the engine. Carburetor Vent Hose Cylinder Head Vent Hose. Oil Hoses Parking Brake Cable Reverse Cable Starter Motor Lead Neutral Leads Pickup Coil Leads Spark Plug Lead Battery Ground Lead eRemove the engine mounting bolts and bracket bolts. eRemove the engine from the vehicle left side.
eGrease the splines at the front end of the propeller shaft. elnstall the front end of the propeller shaft on the subtransmission output shaft while gently turning the rear wheels in order to fit the splines. eRun the following cables, hoses, and leads according to the Wiring, Cable, and Hose Routing section in the General Information chapter. Throttle Cable Choke Cable Reverse Cable Parking Brake Cable Carburetor Vent Hose Cylinder Head Vent Hose Leads eAdjust the following parts (see each appropriate chapter). Throttle Cable Reverse Cable (see Engine Bottom End/Transmission chapter) Parking Brake Cable eFili the engine with engine oil (see Engine Right Sjde chapter). eAdjust the carburetor idle screw.
Another Way of Engine Removal/Installation Notes NOTE
1 . Mounting Bolts 2. Bracket Bolts
3. Sub-Transmission Case 4. Dust Cover Clamp Screw
oThe engine can be removed with the sub-transmission and the rear propeller shaft left installed. But it may be a two-man operation.
6-4 ENGINE REMOVAL/INSTALLATION e Refer to Engine Removal/Installation procedure above noting the following. e Remove the following parts. Left Footpeg Front Propeller Shaft (see Final Drive chapter) Rear Propeller Shaft Joint Boot Front End Engine Mounting Bolts and Bracket Bolts e Move the engine forward with the sub-transmission left installed to free it from the rear propeller shaft. eRemove the engine from the vehicle left side.
1. Splines 2. Rear Propeller Shaft Joint Boot
e When installing the engine, note the following. OA person should insert the rear end of the subtransmission output shaft in the rear propeller shaft while holding the engine. Another person should turn the rear wheels by hand to fit the splines.
ENGINE BOTTOM ENDITRANSMISSION 7-1
Engine Bottom End ITransmission Table of Contents Exploded View .... . ..... . . . . . . ... ... . Specifi.c ations . . . . . . . . . . . . . . . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . . Sealant . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankcase Splitting . . . . . . . . . . .... . . . . . . Crankcase Disassembly .. . . . . . . . . . . . . Crankcase Assembly . . . . . . . . . . . . . . . . Crankshaft and Connecting Rod .... . . . . . . . . Crankshaft Removal. . . . . . . . . . . . . . . . Crankshaft Installation . . . . . . . . : ..•.. Crankshaft Disassembly . . . . . .... ... . Crankshaft Assembly . . . . . . . . . . . . . . . Connecting Rod Bend/Twist . . . . . . . . . . Connecting Rod Big End Radial Clearance . . . . . . . . . . . . . . . . Connecting Rod Big End Side Clearance . . . . . . . . . . . . . . . . . Crankshaft Alignment . . . . . . . . . . . . . . Connecting Rod Big End Seizure . . . . . . . Transmission ... . . . . . . . . . . . . . . . . . : .. . Transmission External Shift Mechanism . ... . External Shift Mechanism Removal. .... . External Shift Mechanism Installation .. . . External Shift Mechanism Inspection ... . Shift Drum Stop Lever Removal. . . . . . . . Shift Drum Stop Lever Installation . . . . . . Shift Drum Stop Lever Inspection . . . . . . Reverse Knob and Cable . . . . . . . . . . . . . . . Reverse Knob Free Play Inspecti on . . . . . . Reverse Cable Adjustment . . . . . . . . . . . . Reverse Knob and Cable Removal. . . . . . . Reverse Knob and Cable Installation .... . Reverse Cable Lubrication . . . . . . . . . . . . Reverse Cable Inspection . . . . . . . . . . . . Transmission Shafts, Shift Drum, Forks .... . Transmission Removal . . . . . . . . . . . . . . Transmission Installation . . . . . . . . . . . . Transmission Shaft Disassembly . . . . . . . . Transmission Shaft Assembly .... . . . . . . Shift Fork Bending . . . . . . . . . . . . . . . . Shift Fork/Gear Groove Wear . . . . . . . . . Shift Fork Guide Pin/Shift Drum Groove Wear . . . . . . . . . . . . . . . . . . . Gear Dog/Gear Dog Hole and Recess Damage. _ . .. .... . .. .. . . .
7·2
7-5 7-5 7·6
7-7 7-7
* 7·7 * * * *
* * * 7-7
* 7-7 * * * * * * 7-7
* 7-7 7-7 7-8 7-8
* 7-8
Balancer . . . . . . .. . . . . . . . . . . . . . . . . . . Balancer Drive Removal . . . . . . . . . . . . Balancer Drive Installation Note . . . . . . . Balancer Removal . . . . . . . . . . . . . . . . Balancer Installation . . . . . . . . . . . . . . Sub-Transmission Lever . . . . . . . . . . . . . . . . Sub-Transmission Case ... ... .... . . . . . . . Sub-Transmission Shift Fork Removal . . . . . . . . . . . . . Sub-Transmission Shift Fork Installation . . . . . . . . . . . Sub-Transmission Case Removal . . . . . . . Sub-Transmission Case Installation . . . . . Sub-Transmission Case Disassembly .... Sub·Transmission Case Assembly . . . . . . Sub-Transmission Drive Shaft Disassembly . . . . . . . . . . ... .. ... Sub-Transmission Drive Shaft Assembly . . . . . . . . . . . ... . . . . . . Sub-Transmission Drive Shaft Bearing Housing Disassembly . . . . . . . . . . . . Sub-Transmission Drive Shaft Bearing Housing Assembly . . . . . . . . . . . . . . Sub-Transmission Bevel Gear Adjustment . . . . . . . .. ... .. .... Bevel Gear Inspection . . . . . . . . . .. ... Cam Damper Inspection . . . . . . . . . . .. Ball and Needle Bearings . . . . . . . ..... . . . . . Ball and Needle Bearing Replacement . . . . . . . . . . . . . . . . . Ball and Needle Bearing Wear . . . . . . . . . Oil Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Seal Inspection . . . . . . . . . . . . . . . .
* 7-8
* * * *
7-8
.
7-9
* 7-8
* * 7-9 7-9
. 7-9 . 7-9 . 7-10 . 7-11 . 7-12 . 7-12 . 7-13 . 7-13 . 7-13 . 7-13 . 7-16 . 7-16 * .
* . * . . 7-16 . 7-16 Oil Pressure Relief Valve . . . . . . . . . . . . . .. . 7-17 Oil Pressure Relief Valve Inspection .... . 7-17
* 7-8
. . . . . . .
*
Base Manual
[II
7-2 ENGINE BOTTOM ENDITRANSMISSION
/
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Remove this oil pipe when the optional oil G : Apply grease. L : Apply non-permanent locking agent. LG : Apply liquid gasket. o : Apply engine oil. R : Replacement Parts T1 T2 T3 T4 T5 T6
: : : : : :
145 N-m (15.0 kg-m. 110 ft-Ib) 120 N-m (12.0 kg-m. 87 ft-Ib) 20 N-m (2.0 kg-m. 14.5 ft-Ib) 17 N-m (1.7 kg-m.12.0 ft-Ib) 12 N-m (1.2 kg-m. 104 in-Ib) 29 N-m (3.0 kg-m.22 ft-Ib)
,/~o~l:.r ~ ~e~. __ -, I T3 I
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ENGINE BOTTOM . ENO/TR ANSMISSION
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T7: 25 N-m (2 m 18: 120 N-m (;5 kt , 18.0 ft-Ib) 2 T9: 7.8 N-m (0 8·k kg-m, 87 ft-Ib) T10: 180 N ·( g-m, 69 in·lb) T1 1.. 11 N-m -m(11 18.5 k k 9-m,135ft-lb) T12: 8.8 N-m (09 g-m,95 in-Ib) T13: 15 N-m (1 kg-m, 78 in-Ib) . kg-m,11.0ft-lb)
5
R
7-3
7-4 ENGINE BOTTOM END/TRANSMISSION r - - - - - - - I "
-
-
-
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-
-
-
-
-
- -
-
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Oil Cooler
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ENGINE BOTTOM END/TRANSMISSION 7-5
Specifications
Circlip Pliers: 57001·144
Refer to the Base Manual notin g the following. Crankshaft. Connecting Rod: Connecting rod big end radial clearance: 0.008 - 0.020 mm (service limit: 0.07 mm) Cold fitting tolerance between crankpin and crank webs: 0.089 - 0.112 mm Sub· Transmission Bevel gear backlash (at drive shaft slotted nut groove) 0.04 - 0.09 ml1;l Shift fork ear thickness 4.4 - 4.5 mm (service limit: 4.3 mm) Shifter groove 4.55 - 4.65 mm (service limit: 4.8 mm) Shift fork guide pin diameter 4.9 - 5.0 mm (service limit: 4.8 mm) Shift fork lever groove 5.1 - 5.2 mm (service limit: 5.3 mm)
Socket Wrench: 57001·1214
Reverse Knob: Reverse knob free play 3-4mm
Special Tools Along with common hand tools, the following more specialized tools are required for comp lete engine bottom end/transmission servicing. Crankshaft Jig: 57001·1174
Oil Seal Guide: 57001·264
Bearing Driver Set: 57001 · 1129
7-6 ENGINE BOTTOM END/TRANSMISSION Jack: 57001·1238
Oil Seal and Bearing Remover: 57001·1058
Hexagon Wrench: 57001·1194
Pinion Gear Holder: 57001·1281
Socket Wrench: 57001·1282
........................................................................•... Sealant Kawasaki Bond (Liquid Gasket· Silver): 92104'{)02
- Apply this liquid gasket to the crankcase mating Gear Holder: 57001·1015
surface.
ENGINE BOTTOM END/TRANSMISSION 7-7
Crankcase Splitting
Transmission
Crankcase Disassembly
Reverse Knob and Cable
Refer to the Base Manual noting the following. -Remove the sub-transmission gear case instead of the front bevel drive gear to disassemble the crankcase.
Reverse Cable Adjustment -Remove the front propeller shaft cover (see Engine Left Side chapter). -Loosen the mounting nuts at the adjuster of the reverse cable, and slide the adjuster until the reverse knob has the proper amount of play. - Tighten the mounting nuts after adjustment.
Crankshaft and Connecting Rod A. Adjuster
Crankshaft Alignment
B. Mounting Nuts
Refer to the Base Manual noting the following. -Put the crankshaft on V blocks when measuring runout.
Reverse Knob and Cable Removal Crankshaft Runout
9mm
-Remove the screws and take off the reverse knob assembly with the cable installed (see Base Manual). -Pull the cable holder out the assembly and free the reverse cable upper end from the assembly. -Remove the following parts to free the cable lower end. Front Propeller Shaft (see Final Drive chapter) Cable Holder Reverse Lever Bolt
*If runout at either location exceeds the service limit, align ·the crankshaft so that the runout is within the service limits.
Crankshaft Runout Left Half Standard: Service Limit: Right Half Standard: Service Limit:
Under 0.03 mm TlR 0.08 mm TIR Under 0.04 mm TlR 0.10 mm TIR
A. Cable Holder
B. Reverse Lever Bolt
-Remove the front fender (see Frame chapter) and the fuel tank (see Fuel System chapter) to free the cable from the vehicle.
7-8 ENGINE BOTTOM END/TRANSMISSION
Reverse Knob and Cable Installation
Transmission Shaft Assembly
Refer to the Base Manual noting the following. The reverse lever of this model has a D-shaped hole and no alignment mark. Install the lever on the reverse shaft shown. eRoute the reverse cable according to the Wiring, Cable, and Hose Routing section in the General Information chapter. eAdjust the reverse cable (see Reverse Cable Adjustment).
eAssembly is the reverse of disassembly. Note the following. eReplace any circiips that were removed with new ones. eAlways install circiips so that the opening is aligned with a spline groove. Circlip Installation
Reverse Cable Lubrication elubricate the reverse cable in accordance with the Periodic Maintenance Chart, or whenever the cable is removed (see General Information chapter and General lubrication in the Appendix chapter).
Transmission Shafts, Shift Drums, Forks
Transmission Installation Refer to the Base Manual noting the following. aThe shift forks are not identical. elnstall the shift forks as shown.
NOTE
eThe transmission gears can be identified by size; Drive shaft gears - the smallest diameter gear is 1st gear, and the largest is 5th. Output shaft gears - the largest diameter gear is 1st gear, and the smallest is 5th.
Balancer
aBe careful not to confuse the shift forks.
Balancer Drive Installation Notes Shift Fork Installation
,---CD
Refer to the Base Manual, noting the following. eApply oil to the seating surface and threads of the balancer drive gear and oil pump drive gear slotted nut. eTighten the slotted nut to the specified torque (see Exploded View). *If none af the toothed washer tabs align, tighten the nut further just enough to align one of the tabs with a slot in the nut.
2
1. 2. 3. 4.
Drive Shaft Shift Fork (I.D. No. 73) Output Shaft Shift Fork (I.D. No. 74) Output Shaft Shift Fork (I.D. No. 72) Shift Rod
1. Slot 2. Tab
3. Claw
ENGINE BOTTOM END/TRANSMISSION 7-9 Sub- Tr.ansmission Shift Fork Installation
Sub-Transmission Lever Refer to the Engine Left Side chapter subtransmission lever information.
elnstall the shift fork with the identification number facing forward as shown above. eGrease the O-rings. eApply engine oil to the shift fork and shift rod. eBe sure to install the shift fork guide pin in the shift fork lever and install the shift fork ears in the shifter groove in the sub-transmission case. eTighten the following bolts to the specified torque (see Exploded View). Shift Rod Bolt Tie-Rod Lever Bolt
Sub-Transmission Case Sub-Transmission Shift Fork Removal eRemove the following parts. Rear Fender {see Frame chapter} Tie-Rod Lever Sub-Transmission Shift Fork Holder
Sub- Transmission Case Removal eDrain the engine oil {see Engine Right Side chapter in the Base Manual}. eRemove the following parts. Rear Fender {see Frame chapter} Left Footpeg and Guard Shift Pedal Sub-Transmission Shift Fork Holder (see SubTransmission Shift Fork Removal). Oil Pipe and Oil Pipe Cap
A. Holder Bolts {4} B. Tie-Rod Lever Bolt
eRemove the shift rod bolt and the rubber cap. ePry out the shift rod to remove the shift fork and the sh ift fork lever.
A. Shift Pedal B. Sub-Transmission Case
1. Rubber Cap 2. Shift Rod 3. Identification No. 75
4. Shift Fork Lever 5. Shift Fork
C. Left Guard
D. Left Footpeg
eSupport the rear part of the frame on blocks or the jack {special tool: PN 57001-1238} so that the suspension arms are free from loads. eRemove the following parts. Wiring Straps for Brake Cables and Vent Hoses Brake Pedal Adjuster and Parking Brake Lever Adjuster on Rear Brake Panel Rear Shock Upper Mounting Bolts and Nuts Suspension Arm Pivot Shaft Rear Propeller Shaft Joint Boot Clamp Screw eMove the propeller shaft and rear axle to the rear just enough to free the propeller shaft from the subtransmission shaft.
7-10 ENGINE BOTTOM END/TRANSMISSION O(Jsing the gear holder (special tool: PN57001-1015), hold the primary and secondary gears to keep them from turning (see Engine Right Side chapter in the Base Manual). OUnscrew the drive bevel gear nut and take off the drive bevel gear and shim(s}.
A. Propeller Shaft Front End
*If necessary, check the bevel gear backlash (see SubTransmission Bevel Gear Adjustment). eRemove the oil seal housing for the sub-transmission output shaft. eBend open the toothed washer tabs on each of the subtransmission shaft slotted nuts. eRemove the drive shaft and output shaft slotted nuts using the socket wrench (special tool). eApply front brake to hold shafts steady.
1. Drive Bevel Gear Nut 2. Left-Hand Bearing Housing
ORemove the bolts holding the output shaft left-hand bearing housing and pull out the bearing housing. oRemove the gasket and dowel pins from the crankcase. eTo remove the output shaft left-hand bearing from its housing, remove the bearing holder using the hexagon wrench (special tool) and drive out the bearing with the bearing driver set (special tool: PN 57001-1129) if necessary.
A. Slotted Locknuts B. Socket Wrench: 57001-1282
eRemove the following parts. Front Propeller Shaft (see Final Drive chapter) Left Engine Cover (see Engine Left Side chapter) Reverse Cable Lower End (see Reverse Cable Removal) Sub-Transmission Case Mounting Bolts (First 8 mm, then 6 mm bolts) eTake off the sub-transmission case. eRemove the drive" bevel gear and output shaft left-hand bearing housing from the crankcase to remove the subtransmission case gasket as follows. ORemove the right engine cover (see Engine Right Side chapter in the Base Manual).
CD
1. Hexagon Wrench: 57001-1194 2. Bearing Holder
Sub- Transmission Case Installation eSub-transmission case installation is the reverse of removal. Note the following.
ENGINE BOTTOM END/TRANSMISSION 7-11 NOTE OCheck and adjust the bevel gear backlash and tooth contact when any of the backlash-related pans are replaced.
eApply a high temperature grease to the oil seal and ·install the oil seal housing in the sub-transmission case. Be sure the O-ring is in place in the groove on the housing.
eDo not install the sub-transmission case gasket yet if the bevel gear adjustment is .to be done. Otherwise, install a new gasket. ""Install the left-hand bearing and housing on the crankcase and tighten the housing bolts to the specified torque (see Exploded View). eApply oil to the seating surface and threads of the bearing holder and install the holder with the flat side facing out. elnstall the shim(s) and drive bevel gear on the engine output shaft. -Check and adjust the bevel gear backlash and tooth contact when any of the backlash-related parts are replaced (see Sub-Transmission Bevel Gear Adjustment). eAssemble the sub-transmission case (see Sub-Transmission Case Assembly). eApply a non-permanent locking agent to the following 8 mm bolts. eTighten the 8 mm bolts to the specified torque (see Exploded View) and then tighten the 6 mm bolts.
1. Apply grease.
1. Apply non-permanent locking agent to the threads. eApply oil to the seating surface and threads of the drive and output shaft slotted nuts. eTighten the slotted nuts to the specified torque (see Exploded View). *If none of the toothed washer tabs align, tighten the nut further just enough to align one of the tabs with a slot in the nut.
® 1. Slot 2. Tab
3. Claw
eTighten the following parts to the specified" torque (see Exploded View). Oil Seal Housing Nuts Oil Pipe Cap Screws Oil Pipe Banjo Bolts elnstall the following parts. Front Propeller Shaft (see Final Drive chapter) Rear Propeller Shaft (see Final Drive chapter) Reverse Cable (see Reverse Cable Installation) eAdjust the reverse cable (see Reverse Cable Adjustment). eAdd engine oil as necessary (see Specifications in the text and Engine Right Side chapter in the Base Manual).
Sub- Transmission Case Disassembly eRemove the sub-transmission case (see SUb-Transmission Case Removal). The slotted nuts on the subtransmission drive shaft and output shaft should be removed during case removal. eRemove the following parts in the order shown. Bearing Holder for Sub-Transmission Drive Shaft Front Oil Seal Housing for Sub-Transmission Output Shaft Sub-Transmission Output Shaft Output Gears and Cam Damper Sub-Transmission Drive Shaft Assembly
7-12 ENGINE BOTTOM END/TRANSMISSION Sub-Transmission Case Assembly
A. Bearing Holder for Sub-Transmission Drive Shaft B. Front Oil Seal Housing
eAssembly is the reverse of disassembly. Note the following. eUse a high-flash point solvent to clean the case and all the gears and shafts. eApply engine oil to the gears and the shafts where they turn in the case. eAssemble the sub-transmission drive shaft (see SubTransmission Drive Shaft). eAssemble the sub-transmission drive shaft bearing housing (see Su boT ransmission Drive Shaft Bearing Housing Assembly). elnstall the ball bearings using a bearing driver from thc bearing driver set (special tool: PN 57001-1129) which contacts bearing outer race. elnstall the bearing holder for the sub-transmission drive shaft so that the grooves al ign with the bolt holes in the casc.
A. Cam Damper eTo remove the ball bearings press-fitted In the sub-
A. Bearing Holder
B. Grooves
transmission gear case, use the bearing driver set (special tool). eGrease the front oil seal. eTighten the following parts to the specified torque (see Exploded View). Bearing Housing Nuts (drive shaft) Front Oil Seal Housing Bolts (output shaft) -Temporarily, install the toothed washers, washers, and slotted nuts. elnstall the sub-transmission case on the engine. eTighten the slotted nuts to the specified torque (see Exploded View). Do not bend over a washer tab yet.
A. Bearing Driver Set: 57001-1129
Sub-Transmission Drive Shaft Disassembly eDisassemble the sub-transmission drive shaft as necessary (see Sub-Transmission Drive Shaft Disassembly). eDisassemble the sub-transmission drive shaft bearing housing as necessary (see Sub-Transmission Drive Shaft Bearing Housing Disassembly).
eRemove the sub-transmission drive shaft unit (see SubTransmission Case Disassembly). eHold the largest diameter gear and driven bevel gear of the unit with a vise and unscrew the needle bearing nut. eUse aluminum plates to prevent damage to the gears.
ENGINE BOTTOM END/TRANSMISSION 7-13
@
CD
1. Aluminum Plate 3. Driven Bevel Gear 2. Largest Diameter Gear 4. Needle Bearing Nut
A. Bearing Holder B. Hexagon Wrench: 57001-1194
eRemove the gears and the shifter.
eDrive out the bearing with the bearing driver set (special tool: PN 57001-1129).
Sub-Transmission Drive Shaft Assembly eReplace the circlip that was removed with a new one. eAlways install the circlip so that the opening is aligned with a spline groove.
Sub-Transmission Drive Shaft Bearing Housing Assembly elnstall the bearing holder (drive) with the flat side facing out. eApply engine oil to the seating surface and threads of the bearing holder. eTighten the bearing holder to the specified torque (see Exploded View).
Circlip Installation
eApply engine oil to the seating surface and threads of the needle bearing nut and tighten the nut to the specified torque (see Exploded View).
Sub-Transmission Bevel Gear Adjustme'lt In order to prevent one gear from moving away from the other gear under load, the backlash and tooth contact pattern of the bevel gears must be correct to prevent the gears from making noise and being damaged. When replacing anyone of the backlash-related parts, be sure to check and adjust the backlash and tooth contact. First adjust the backlash, and then tooth contact by replacing shims. These two adjustments are of critical importance and must be carried out in the correct sequence, using the procedures shown. Sub-Transmission Bevel Gear Adjustment Procedure
Sub-Transmission Drive Shaft Bearing Housing Disassembly e Remove the bearing housing (see Sub-Transmission Case Disassembly) . e Hold the bearing housing with a vise and unscrew the bearing holder using the hexagon wrench (special tool). e Use aluminum plates to prevent damage to the housing.
Assemble the sub-transmission gear case completly. -
7-14 ENGINE BOTTOM END/TRANSMISSION Sub-Transmission Backlash-Related Parts
/®
r
Drive Bevel Gear Shims
Thickness (mm) 0.15 0.20 0.7 0.8 0.9 1.0 (primary) 1.1 1.2 1.3
Driven Bevel Gear Shims
Part Number 92025-1573 92025-1574 92025-1534 92025-1535 92025-1536 92025-1537 92025-1575 92025-1538 92025-1533
1. Sub-Transmission Case 2. Drive Bevel Gear 3_ Sub-Transmission Drive Shaft 4. Driven-Bevel Gear 5. Ball Bearing 6. Left-Hand Bearing Housing
Thickness (mm) 0.1 0.15 0.5 0.8 1.0 (primary) 1.2
Part Number 92025-1897 92025-1898 92025-1899 92025-1900 92025-1901 92025-1902
7. Drive Bevel Gear Shim(s) 8. Spacer 9. Driven Bevel Gear Shim(s) 10. Driven Gear Bearing Housing 11. Ball Bearing
ENGINE BOTTOM ENDITRANSMISSION 7-15 Bevel Gear Backlash Adjustment eTemporarily, install the sub-transmission case on the crankcase. eThe following parts are not required to install. Propeller Shafts Sub-Transmission Case Gasket Sub-Transmission Output Shaft Shift Fork Holder Oil Pipe Cap Bearing Holder a-Ring eDo not lock the drive shaft slotted nut yet. eClean any dirt and oil off the bevel gear teeth. elnstall the drive bevel gear with the primary shim (see the shim tables). eApply oil to the seating surface and threads of the engine output shaft slotted nut and tighten it to the specified torque (see Exploded View). eAssemble the driven bevel gear with the primary shim (see the shim tables). elnstall the sUb-transmission case on the crankcase, and tighten the 8 mm case bolts to the specified torque (see Exploded View). eCheck the backlash during the tightening of the case mounting bolts and stop tightening them immediately if the backlash disappears. Then, change the shim to a thinner one. eSet up a dial gauge against the drive shaft slotted nut groove to check gear backlash.
1. Turn 2. Neutral Detent
3. Clutch
*If the backlash is not within the limit, repface the shim(s) at the drive bevel and/or driven bevel gear. ~hange the thickness a little at a time. e Re-check the backlash, and re-adjust as necessary. Sub-Transmission Bevel Gear Backlash Standard:
0.04 - 0.09 mm (at drive shaft slotted nut groove)
Tooth contact adjustment e Clean any dirt and oil off the bevel gear teeth . e Apply checking compound to 4 or 5 teeth on the driven bevel gear. NOTE oApply checking compound to the teeth in a thin, even coat with a fairly stiff paint brush. If painted too thickly, the exact tooth pattern may not appear. oThe checking compound must be smooth and firm with the consistency of tooth paste. oSpecial compounds are available from automotive supply stores for the purpose of checking differential gear tooth patterns and contact. Use this for checking the bevel gears.
A. Move
B. Dial Gauge
eTo measure the backlash, turn the shifter clockwise and counterclockwise while holding the drive bevel gear steady. The difference between the highest and lowest gauge readings is the amount of backlash. oTo hold the drive bevel gear steady, another man may turn the shift drum a little from the neutral position and hold it at the position shown using a wrench_
e Turn the driven bevel gear for 3 or 4 turns in the drive and reverse (coast) directions, while creating a drag on the drive bevel gear. - Check the drive pattern and coast pattern of the bevel gear teeth. The tooth contact patterns of both drive and coast sides should be centrally located between the top and bottom of the tooth, and a little closer to the toe of the tooth. * If the tooth contact pattern is incorrect, replace the shim(s) at the drive bevel gear and shim(s) at the driven bevel gear, following the examples shown. Then erase the tooth contact patterns, and check them again. Also check the backlash every time the shims are replaced. Repeat the shim change procedure as necessary.
7·16 ENGINE BOTTOM END/TRANSMISSION NOTE o/f the backlash is out of the standard range after changing shims, correct the backlash before checking the tooth contact pattern.
Example2: Decrease the thickness of the drive bevel gear shim(s) by 0.05 mm, and/or decrease the thickness of the driven bevel gear shim(s) by 0.05 mm to correct the pattern shown below. Repeat in 0.05 mm steps if necessary .
Correct Tooth Contact Pattern
1
Heel
t~~ot~m
,
~!wm
TO~
TO~
Toe Toe
Toe
Bottom-fTOP
Toe
1-
1. Drive Gear 2. Driven Gear
~~
1. Drive Gear 2. Driven Gear
Bottom
Top
Heel
Heel
Bevel Gear Inspection eVisually check the bevel gears for scoring, chipping, or other damage. *Replace the bevel gears as a set if either gear is damaged.
Cam Damoer Insoection Incorrect Tooth Contact Patterns
Example 1: Increase the thickness of the drive bevel gear shim(s) by 0.05 mm, and/or increase the thickness of the driven bevel gear shim(s) by 0.05 mm to correct the pattern shown below. Kepeat in 0.05 mm steps if necessary.
eVisually inspect the damper cam (sub-transmission 0l:ltput shaft), cam follower, spring, and shaft. *Replace the part if it appears damaged.
Heel
2\~~ttom TOP~ Toe
/
A. Spring B. Cam
D. Shaft
, Toe
Bottom~ ~oP 1. Drive Gear 2. Driven Gear
C. Cam Follower
Heel
Oil Seal
Oil Seal Inspection elnspect the oil seals. *Replace it if the lips are misshapen, discolored (indicating that the rubber has deteriorated), hardened or otherwise damaged.
ENGINE BOTTOM END/ TRANSMISSION 7-17 Oil Pressure Relief Valve Oil Pressure Relief Valve Inspection • Split the crankcase (see Base Manual). • Remove the relief valve [A] from the right crankcase. • Check to see if the steel ball [B] inside the valve slides smoothly when pushing it in with a wooden or other soft rod, and see if it comes back to its seat by valve spring [C] pressure.
NOTE Olnspect the valve in its assembled state, Disassembly and assembly may change the valve performance.
*If any rough spots are found during above inspection , wash the valve clean with a high flash-point solvent and blow out any foreign particles that may be in the valve with compressed air.
I WARNING . OClean the oil pressu re relief valve in a wellventilated area, and take care that there are no sparks or flame anywhere near the working area. Because of the danger of highly flammable liquids, do not use gasoline or low flash-point solvents.
*If cleaning does not solve the problem , replace the relief valve as an assembly. The relief valve is precision made with no allowance for replacement of individual parts . • Apply a non-permanent locking agent to the threads of the relief valve, and tighten it Torque- Oil Pressure Relief Valve : 15 N-m (1.5 kg-m, 11.0 ft-Ib)
WHEELSITIRES 8-1
Wheels/Tires Table of Contents Exploded View ........................................... Specifications ............................................ Special Tools ............................................. Wheel Alignment .......................................... Steering Centering Inspection ................. ..... ......
. . . . .
Steering Centering Adjustment ........................... . Toe-in Inspection ..................................... . Toe-in Adjustment .................................... . Wheels (Rims) ............................................ . Wheel Removal ....................................... . Wheel Installation ..................................... . Wheel Inspection ...................................... . Wheel Replacement .................................... . Tires ............................................ '" .... . Tire Removal. ........................................ . Tire Installation ....................................... . Tire Inspection ....................................... . Front Hub ......... ...................................... . Front Hub Removal ................................... . Front Hub Installation Notes .......... , ................. . Front Hub Disassembly/Assembly Note .................... . Front Wheel Bearing Removal/Installation .................. . Rear Hub ................................................ . Rear Hub Installation .................................. . Rear Hub Disassembly/Assembly Note ..................... .
*
Base Manual
8-2 8-3 8-3 8-4 8-4 8-4 8-5 8-5 8-6 8-6 8-6 8-7 8-7 8-8 8-8 8-8 8-10 8-11 8-11 8-11 8-11 8-11 8-11 8-11 8-12
[]]I
8-2 WHEELS/TIRES Exploded View
............................................................................. G : Apply grease. R : Replacement Parts W : Apply water, or soap and water solution. T1 : 34 N·m (3.5 kg·m, 25 ft-Ib) T2: 27 N-m (2.8 kg·m, 20 ft-lb) T3: 41 N-m (4.2 kg-m, 30 ft-lb) T4 : 145 N-m (15.0 kg-m, 110 ft-Ib) Front Wheel
Rear Wheel
WHEELS/TIRES 8-3 Specifications Wheel Alignment 1° (non-adjustable) Caster: Camber: 0° (non-adjustable) Toe-in: 20 mm
@
1G
Standard Tires Front: AT 24 x 8-11 Dunlop KT962, Knobby/Trail Tubeless Rear: AT 24 x 10-11 Dunlop KT962, Knobby/Trail Tubeless Tire Air Pressure (when cold) 35 kPa (0.35 kg/cm 2 , 5 psi) Front: Rear: 28 kPa (028 kg/cm 2 , 4 psi) Maximum Tire Air Pressure (to 'seat beads, when cold) 250 kPa (2.5 kg/cm 2 , 36 psi) Front: Rear: 250 kPa (2.5 kg/cm2, 36 psi) Maximum Vehicle Load: 195 kg (430Ib)
Special Tools Refer to the Base Manual noting the following additional tools. Jack: 57001·1238
Air Pressure Gauge: 52005-1082
aThis tool may be used instead of the common tool.
aBe sure to use this gauge for low pressure tire instead of the conventional air pressure gauge (52005-1003).
~~\ \ \
\
\
Bearing Driver Set: 57001-1129
8-4 WHEELS/TIRES e Hold a straightedge against the rear wheel rim on one side at axle height.
Wheel Alignment
Toe-in is the amount that the front wheels are closer together in front than at the rear at the axle height. When there is toe-in, the distance A is greater than Bas shown. The purpose of toe-in is to prevent the front wheels from getting out of parallel at any time, and to prevent any slipping or scuffing action between the tires and the ground. If toe-in is incorrect, the front wheels will be dragged along the ground, scuffing and wearing the tread knobs. Caster and camber are built-in and require no adjustment.
Toe-in of Front Wheels
Front Side
A. Straightedge
B. Jack: 57001-1238
~-----------B------------~
c
D eWit;h the handlebar straight ahead, loosen the locknuts and turn the tie-rod adjusting sleeve the same number of turns on both sides until the front wheel on that side is parallel to the straightedge.
A NOTE
A - B = Amount of Toe-in (Distance A and B are measured at axle height) (Distance C and D should be equal)
OThe white locknut on the tie-rod has left-hand threads. Turn the wrench clockwise for loosening.
Steering Centering Iilspection eTest ride the vehicle. *If the handlebar is straight when the vehicle is traveling in a straight line, go on to the Toe-in inspection procedure. *Otherwise, go on to the Steering Centering Adjustment procedure.
Steering Centering Adjustment eSupport the vehicle so that the front wheels are off the ground and the front axles about the same height as the rear axle.
A. Front B. White Locknut: left-hand threads C. Adjusting Sleeve
WHEELSITIRES 8-5 Steering Centering
1. Measure the distance between lines.
CD 1. Front Wheels 4. Straightedge 5. Rear Wheels 2. Vehicle Center Line 3. Parallel to each other. - Repeat the straightedge procedure on the other side of the vehicle. Now the front wheels are parallel to each other and to the center line of the vehicle. -Go on to the Toe-in Inspection procedure.
-Turn the wheels until the marks on the front tires.are at the rear side and at the same level as the axle. -Measure the distance between the scribed lines at the rear side. -Subtract the measurement of the front from the measurement of the rear to get the toe-in. At the same time the distances C and D should be equal (see Illustration Toe-in .of Front Wheels). *If the toe-in is not in the specified range, go on to the Toe-in Adjustment procedure. Toe-in of Front Wheels Standard:
20 mm
Toe-in Inspection -Support the vehicle on a stand or the jack (special tool: 57001-1238) so that the front wheels are off the ground. -Apply a heavy coat of chalk near the center of the front tires. -Using a needle nose scriber, make a thin mark near the center of the chalk coating while turning the wheel.
Toe-in Adjustment -Loosen the locknuts and turn the adjusting sleeves the same number of turns on both sides to achieve the specified toe-in.
A. Front B. Locknuts -Keeping the front wheels off the ground, set the handlebar straight ahead. -Set the wheels so that the marks on the tires are at the front side and at the level of the axle height. -At the level of the axle height, measure the distance between the scribed lines.
C. Adjusting Sleeve NOTE
oThe white locknut on the tie-rod has left-hand threads. Turn the locknut clockwise for loosening. o The toe-in will be near the specified value, if the tie-rod length is 305 mm between the tie-rod ends.
8-6 WHEELS!TIRES TIe-Rod Length Adjustment
Wheel Installation ePosition the wheel so that the air valve is toward the outside of the vehicle. -Check the tire rotation mark on the front and rear tires, and install the wheels accordingly.
NOTE
o The direction of the tire rotation is shown by an arrow on the tire sidewall.
1. Front
2. Tie-Rod Length
eCheck the toe-in (see Toe-in Inspection). eTighten the tie-rod locknuts to the specified torque (see Exploded View). eTest ride the veJiicle.
..............................................................................
1. Rotation Mark (Arrow) 2. Rotation Direction
Wheels (Rim) Wheel Removal e Loosen the wheel nuts. eSupport the vehicle on the jack (special tool) or a stand so that the wheels are off the ground.
eMount the wheel on the studs. eTighten the wheel nuts in a criss-cross pattern to the specified torque (see Exploded View).
'" \ \
A. Stand or Jack: 57001-1238
eTake off the wheel nuts and remove the wheel.
WHEELSITIRES 8-7
Wheel Inspection
Air Valve
eExamine both sides of the rim for dents. If the rim is dented, replace it. Rim Dent
CD ®_ r.-t-t0 ---1 ®
elf the tire is removed, inspect the air sealing surfaces of the rim for scratches or nicks. Smooth the sealing surfaces with fine emery cloth if necessary. Rim Inspection
1. Plastic Cap 2. Valve Core 3. Stem Seal
4. Valve Stem 5. Valve Seat 6. Valve Opened
elnstall a new air valve in the rim . oRemove the valve cap, lubricate the stem with a soap and water solution, and pull the stem through the rim from the inside out until it snaps into place.
1. Sealing Surfaces 1. Pull the stem.
Wheel Replacement eRemove the wheel (see Wheel Removal). eRemove the tire from the rim (see Tire Removal). oRemove the air valve and discard it.
o Replace the air valve whenever the tire is replaced. 000 not reuse the air valve.
000 not use engine oil or petroleum distillates to lubricate the stem because they will deteriorate the rubber.
eMount the tire on the rim (see Tire Installation). elnstall the wheel (see Wheel Installation).
8-8 WHEELS/TIRES
Tires
-Kneel on the side of the tire, forcing the tire bead into the center well of the rim.
Tire Removal
Rim Removal
-Remove the wheel (see Wheel Removal). -Unscrew the valve core to deflate the tire. o Use a proper valve core tool.
Well
- Lubricate two tire irons (special tool) with a soap and water solution, or water, then pry the bead. 1. Valve Core Tool
-Lubricate the tire beads and rim flanges on both sides of the wheel with a soap and water solution, or water. This helps the tire beads slip off the rim flanges.
o Do not scratch the air sealing surfaces of the tire or rim. Scratches or nicks on the sealing surfaces will allow the tire to deflate. -Work around the rim with the tire irons a little at a time, while continuing to hold the bead opposite the irons in the center well of the rim.
o Do not lubricate the tire beads and rim flanges with engine oil or petroleum distillates because they will deteriorate the tire. -Break the tire beads away from both sides of the rim with a bead breaker. Breaking Tire Bead
1. Tire Irons: 57001-1073 - Lift the second bead up into the center well and use the same procedure as in removing the first bead.
Tire Installation 1. Bead Breaker 2. Apply lubricant.
-Inspect the rim (see Wheel Inspection). -Replace the air valve with a new one (see Wheel Replacement).
WHEE LSITIRES 8-9
o Replace the air valve whenever the tire is replaced. not reuse the air valve.
000
-Check the tire for wear and damage (see Tire Inspection) . - Lubricate the tire beads, rim flanges, and the tire irons (special tools) with a soap and water solution, or water .
- By hand, slide as much of the first bead as possible over the rim flange. - As the bead goes onto the rim, force the bead into the center well of the rim to ease installation.
Bead InStallation
I WARNING I o Do not use the lubricant other than a water and soap solution, or water to lubricate the tire beads and rim because it may cause tire separation.
1. Tire Beads
2. Center Well
- Use the tire irons (special tools) to install the rest of the bead. 1. Apply lubricant. Bead Installation
-Check the tire rotation mark on the front and rear tires, and install them on the rim accordingly. oThe tires should be installed on the rim so that each air valve is toward the outside of the vehicle. NOTE
o The direction of the tire rotation is shown by an arrow on the t;re sidewall.
ROTATION
1. Rotation Mark (Arrow)
1. Tire Irons: 57001 -1073
2. Rotation Direction
- Use the same procedure to install the second bead. - Lubricate the tire beads again and center the tire on the rim. - Support the wheel rim on a suitable stand to prevent the tire from slipping off.
8-10 WHEELS!TIRES Tire Air Pressure 35 kPa (0.35 kg/cm 2 , 5 psi) 28 kPa (0.28 kg/cm 2 , 4 psi)
Front: Rear:
-Check the tire pressure using the air pressure gauge for low air pressure (special tool).
/
~-I®
1. Rim
\ &
2. Suitable Stand \
\
'
-Inflate the tire until the tire beads seat on the rim.
Maximum Tire Air Pressure (to seat beads when cold) Front and Rear:
1. Air Pressure Gauge: 52005-1082
250 kPa (2.5 kg/cm 2 , 36 psi)
-Install the wheel (see Wheel Installation). -Wipe off the soap and water solution, or water on the tire, and dry the tire before operation.
WARN.ING • 000 not inflate the tire to more than the maximum tire air pressure. Overinflation can explode the tire with possibility of injury and loss of life.
-Check to see that the rim lines on both sides of the tire are parallel with the rim flanges .
I WARNING. 000 not operate the vehicle with the water and soap, or water still around the tire beads. They will cause tire separation, and a hazardous condition may result.
Tire Inspection -Examine the tire for damage and wear. Olf the tire is cut or cracked, replace it. OLumps or high spots on the tread or sidewalls indicate internal damage requiring tire replacement. oRemove the any foreign objects from the tread. After removal, check for leaks with a soap and water solution. oCheck the shape of the tread knobs. If no vertical side is left on the drive side of the knobs, replace the tire. Tire Inspection Vertical Sides Worn Away 1. Rim Line
/---~J---l
2. Rim Flange
-If the rim lines and the rim flanges are not parallel, deflate the tire, lubricate the sealing surfaces again, and reinflate the tire. -After the beads are properly seated, check for air leaks. Olnflate the tire to 45 kPa (0.45 kg/cm 2 , 6.4 psi). Apply a soap and water solution around the tire bead and check for bubbles. -Deflate the tire to the specified pressure.
~~
/
\
/
\
/ /
,
~
//
I
-+-
'\
WHEELS/TIRES 8-11 eTighten the hub nut to the specified torque (see Exploded ViewL elnsert a new cotter pin and bend it over the nut.
Front Hub
Front Hub Removal e Remove the cotter pin and loosen the hub nut.
/
CD
CD
1. Cotter Pi n 1. Hub Nut
2. Cotter Pin
ePuli off the wheel (see Wheel Removal). eRemove the caliper by taking off the mounting bolts, and let the caliper hang free. eRemove the hub nut and pull off the front hub.
Front Hub Disassembly/Assembly Note eDo not press the hub bolts out. *If any hub bolt is damaged, replace the hub and bolts as a unit.
1. Hub Bolts A. Hub Nut
Front Hub Installation Notes eGrease the axle splines.
Front Wheel Bearing Removal/Installation This model has a wheel bearing in the steering knuckle. Refer to Knuckle Bearing Removal/Installation in the Steering chapter.
............................................................................ Rear Hub
Rear Hub Installation
1. Grease the splines.
eqrease the axle splines. eTighten the rear axle nut to the specified torque (see Exploded View). elnsert a new cotter pin .
8-12 WHEELSITIRES
1. Axle Splines
2. Cotter Pin
Rear Hub Disassembly/Assembly Note eDo not press the hub bolts out. *If any hub bolt is damaged, replace the hub and bolts as a unit.
1. Hub Bolts
FINAL DRIVE 9-1
Final Drive Table of Contents Exploded View . . : . . . . . . . . . . . . . . . . . . .. Full Time 4 Wheel-Drive Mechanism. . . . . . . .. Specifications. . . . . . . . . . . . . . . . . . . . . . .. Special Tools. . . . . . . . . . . . . . . . . . . . . . .. Front Propeller Shaft. . . . . . . . . . . . . . . . . .. Front Propeller Shaft Removal. . . . . . . .. Front Propeller Shaft Installation Notes. . . . . . .. . . . . . .. Front Axle . . . . . . . . . . . . . . . . . . . . . . . . .. Front Axle Joint Boot Inspection. . . . . .. Front Axle Removal . . . . . . . . . . . . . .. Front Axle Installation Notes . . . . . . . .. Front Axle Joint Boot Replacement. . . .. Front Final Gear Case . . . . . . . . . . . . . . . . .. Fornt Final Gear Case Oil Level Inspection. . . . . . . . . . . . . . . . . . .. Front Final Gear Case Oil Change . . . . . . . Front Final Gear Case Removal . . . . . . . . Front Fillal Gear Case Installation Notes ..... . . . . . . . .. . Front Final Gear Case Disassembly . . . . . . Front Final Gear Case Assembly. . . . . . . . Differential Unit and Ring Gear Disassembly. . . . . . . . . . . . . . . . . . . Differential Unit and Ring Gear Assembly. . . . . . . . . . . . . . . . . . . . . LSD Clutch Torque Inspection .. . .... .. LSD Clutch Plates Inspection . . . . . . . . .. Pinion Gear Unit Disassembly .... ... .. Pinion Gear Unit Assembly .. . . . . . . . . . Fornt Final Bevel Gear Adjustment . . . . . . Bevel Gear Inspection . . . . . . . . . . . . . . . Differential Gear Inspection . . . . . . . . . . Tapered Roller Bearing Inspection ... ...
9-2 9-4 9-5 9-5 9-7 9-7 9-7 9-7 9-7 9-7 9-8 9-8 9-9 9-9 9-10 9-10 9-11 9-11 9-11 9-12 9-12 9-13 9-13 9-14 9-14 9-14 9-19 9-19 9-19
Rear Propeller Shaft . . . . . . . . . . . . . . . . . . . . Rear Propeller Shpft Removal . . . . . . . . . Rear Propeller Shaft Installation . . . . . . . . Rear Propeller Shaft Joint Boot Inspection .. . . . . . . ..... .. . Rear Propeller Shaft Joint Boot Replacement . . . . . . . . . . . . . . . . . . Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Axle Unit Removal . . . . . . . . . . . . . Rear Axle Unit Ihstallation Notes .... .. . Rear Axle Unit Disassembly . . . . . . . . . . Rear Axle Unit Assembly . . . . . . . . . . . . Rear Axle Bearing Inspection .... .. .. .. . Rear Final Gear Case . . . . . . . . . . . . . . . . . . . Rear Final Gear Case Oil Level Inspection . . . . . . . . . . . . . . . . Rear Final Gear Case Oil Change ..... . . . Rear Final Gear Case Removal . . . . . . . . . Rear·Final Gear Case Installation Notes .. . Rear Final Gear Case Disassembly . . . . . . . Rear Final Gear Case Assembly Notes ... . Rear Final Bevel Gear Adjustment . .. .. . Pinion Gear Disassemblx . . .. . .. .... . Pinion Gear Assembly Note . . . . . . . . . . . Bevel Gear Inspection . . . . . . . . . . . . . . . Oil Seal . . . . . . . . . . . . ... . . . . . . . ... .. . Oil Seal Inspection . . . . . . . . . . . . . . . . . Ball Bearing or Needle Bearing . . . . . . . . . . . . . Ball or Needle Bearing Replacement .... . Ball or Needle Bearing Inspection ...... .
9-19 9-19 9-19 9-20 9-20 9-21 9-21 9-22 9-22 9-22 9-23 9-23 9-23 9-23 9-24 9-24 9-24 9-24 9-26 9-27 9-28 9-28 9-28 9-28 9-28 9-28 9-28
~
9-2 FINAL DRIVE
Circlip
® Front Propeller Shaft .
FINAL DRIVE 9-3 Circlip ~
®
Rear Propeller Shaft
I
t I ["'®
~v
lj-------,
~ I~ ~::G
,
B: UK ModeJ
~ ®
i Q)
hront Carrier
/'
T1 : 8.8 N-m (0.9 kg-m, 78 in-Ib) T2 : 37 N-m (3.8 kg.m, 27 ft-Ib) T3 : 25 N-m (2.5 kg-m, 18.0 ft-Ib) T4 : 29 N-m (3.0 kg-m, 22 ft-Ib) T5 : 20 N-m (2.0 kg-m, 14.5 ft-Ib) T6 : 120 N-m (12.0 kg-m, 87 ft-Ib) T7 : 47 N-m (4.8 kg-m, 35 ft-Ib) T8 : 49 N-m (5.0 kg-m, 36 ft-Ib) T9 : 32 N-m (3.3 kg-m, 24 ft-Ib) T10: 34 N-m (3.5 kg-m, 25 ft-lb) T11: 7.8 N-m (0.8 kg-m, 69 in-Ib) T12: 54 N-m (5.5 kg-m, 40 ft-Ib) T13: 69 N-m (7.0 kg-m, 51 ft-Ib) G : Apply grease. L : Apply non-permanent locking agent. o : Apply hypoid gear oil. R : Replacement Parts SG : Specified Grease St : Stake the fastener.
9-4 FINAL DRIVE
............................................................................ Full Time 4 Wheel- Drive Mechanism
............................................................................
iJ
Front
Front Final
10
Sub-Transmission
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
Engine Output Shaft Bevel Gears (Sub-Transmission) Sub-Transmission Shifter Drive Shaft (Sub-Transmission) Output Shaft (Sub-Transmission) Rear Propeller Shaft Bevel Gears (Rear Final) Rear Axles Front Propeller Shaft Bevel Gears (Front Final) LSD Clutches Differential Gears Front Axles
~
'----
Rear Final
FINAL DRIVE 9-6 Outside Circlip Pliers: 57001-144
Specifications Front final gear case: Gear case oil Grade: Viscosity: Oil level: Amount: LSD clutch torque: Outside friction plate thickness: Inside friction plate thickness: Pinion gear bearing preload: Bevel gear backlash: Rear final gear case: Gear case oil Grade: Viscosity: Oil level: Amount: Rear final bevel Gear backlash:
API GL-5 hypoid gear oil for LSD (Limited Slip Differential gears) SAE140 or SAE85 W-140 filler opening level 025 L 7.8 -13.0 N~ (0.8 -1.3 kg-m, 69 -113 in-lb)
Pinion Gear Holder: 57001-1281
2.3 -2.4 mm (Service limit: 2.1 mm) 2.7 -2.8 mm (Service limit: 2.4 mm) 0.3 - 0.6 N~ (0.03 - 0.06 kg~, 2.6 - 52in-lb) 0.09 - 020 mm (at ring gear tooth)
Socket Wrench: 57001-1283
API GL-5 hypoid gear oil when above 5°C (41°F) SAE90 when below 5°C (41°F) SAE80 filler opening bottom 0.2 L
0.07 - 0.17 mm (at pinion gear.spline) Ring gear thrust plug: % turn out Ring gear thrust plug gap (for reference): 0.3 - 0.5 mm
Bearing Puller: 57001-158
.............................................................................. Special Tools Along with common hand tools, the following more specialized tools are required for complete final drive servicing.
Socket Wrench: 57001-1268 Dial Gauge Holder: 57001-1049
o
9-6 FINAL DRIVE Pinion Gear Holder: 57001-1285
Bearing Driver Set: 57001-1129
Jack: 57001-1238
Bevel Gear Holder: 57001-1193
Hexagon Wrench: 57001-1284
Inside Circlip Pliers: 57001-143
Front Fork Oil Seal Driver: 57001-1104
Oil Sea.1 & Bearing Remover: 57001 -1058 Bearing Driver: 57001-382
FINAL DRIVE 9-7
............................................................................ Front Propeller Shaft
Front Axle
Front Propeller Shaft Removal
Front Axle Joint Boot Inspection
eRemove the front propeller shaft cover using the socket wrench (special tool: 57001-1268).
eVisuaily inspect the front axle joint boots in accordance with the Periodic Maintenance Chart (see General Information chapter) or if the axles are noisy during operation.
A. Front Propeller Shaft Cover B. Mounting Bolts eRemove the circlip with the outside circlip pliers (special tool: PN 57001-144). ePuil back the propeller shaft sliding joint. The spring comes off with the joint.
A. Front Axle Joint Boots
*If the joint boot is torn, worn, deteriorated, or leaks grease, replace the joint boots as a set and check the universal joints (see Front Axle Joint Boot Replacement).
Front Axle Removal eRemove the following parts. Steering Knuckle (Steering Knuckle Removal in the Steering chapter) Front Axle Cap Bolts
A. Propeller Shaft Sliding Joint
B. Circlip
eRemove the propeller shaft from the vehicle. ePuil out the universal joints.
Front Propeller Shaft Installation Notes e lnstallation is the reverse of removal. Note the following. eWipe the old grease off the splines of the propeller shaft, the propeller shaft joint, and the universal joints. elnspect the splines of the prop~lIer shaft, the sliding joint, and the universal joints. *If the splines are twisted or damaged in any way, replace the shaft, the sliding joint, or the universal joints. eApply grease to them. eReplace the circlip with a new one. eAlign the yoke angle of the front propeller shaft and the output shaft.
A. Front Axle Cap Bolts
ePuil the front axle out of the front final gear case.
9-8 FINAL DRIVE
Front Axle Installation Notes -Installation is the reverse of removal. Note the following. -Wipe the old grease off the splines of the axle and the cap oil seal, and grease them. -Visually inspect the splines of the axle. *If they are badly worn or chipped, replace the axle with a new one. -Be sure to install the space'r in the recess of the front final gear case.
- Remove the following parts in the order shown. 1. Larger Retaining Ring (to split the outboard and inboard shafts) 2. Smaller Retaining Ring 3. Ball Bearing 4. Inboard Joint Boot
Inboard Joint DiSassembly
@
1. Spacer -Tighten the cap bolts to the specified torque (see Exploded View).
CD
® @
-Unlock the boot bands for the outboard joint boot and remove the boot. oThe outboard joint can not be disassembled . . oReplace the inboard and outboard joint boots. -Check the universal joints. *If any joint does not work smoothly without rattling or sticking, the joint bearing is damaged. Replace the axle with a new one. - Visually inspect the splines on the shaft. *If they are badly worn or chipped, replace the axle. oAssembly is the reverse of disassembly. Note the following. - Clean off the joint parts.
Front Axle Joint Boot Replacement -Remove the front axle (see Front Axle Removal). -Unlock the boot bands for the inboard joint boot and move the boot toward the outboard joint. ONever clean the boots with mineral oil or gasoline because they will deteriorate the boot .
• P\lck the outboard joint with about 40g of the special grease . • Pack the inboard joint with about 2Sg of the special grease at fi rst.
OBe sure to use the special grease in the boot set.
A. Boot Bands
B. Move the boot
- Install the larger retaining ring so that the opening is aligned with one of the projections.
FINAL DRIVE 9-9
®
1. Retaining Ring 2. Opening
3. Outer Race
1. Pull
-Pack the inboard joint with the rest of the grease (about 20g). -Fit the joint boot lips onto the grooves on the axle. oPosition the joint boot as shown.
2. Tangs
Front Final Gear Case
............................................................................. Front Final Gear Case Oil Level Inspection 21 mm
82mm
78 mm
48 mm
~
ePark the vehicle so that it is level, both side·to-side and front-to rear. eRemove the filler cap.
OBe careful not to allow any dirt or foreign materials to enter the gear case.
Outboard Joint Boot
Inboard Joint Boot
ec:heck the oil level. The oil level should come to the bottom of the filler opening.
eSlightly open the larger diameter end of the joint boot to equalize the air pressure inside the boot.
A. Filler Opening
ec:lamp the boot band and bend the tangs securely to hold down the end of the band.
*If it is insufficient, first check the front final gear case for oil leakage, remedy it if necessary, and add oil through the filler opening. Use the same type and brand of oil that is already in the final gear case. -Be sure the O-ring is in place, and tighten the filler cap to the specified torque (see Exploded View).
9-10 FINAL DRIVE Front Final Gear Case Oil Change
Front Final Gear Case Removal
eWarm up the oil by running the vehicle so that the oil will pick up any sediment and drain easily. Then stop the vehicle. ePark the vehicle so that it is level, both side-to-side and front-to-rear. eRemove the gear case skid plate. ePlace an oil pan beneath the front final gear case and remove the drain plug.
eDrain the gear case oil (see Front Final Gear Case Oil Change). eRe move the following parts. Front Propeller Shaft (see Front Propeller Shaft Removal) Right Front Axle (see Front Axle Removal) Front Final Gear Case Bolts and Nuts
A. Drain Plug
A. Gear Case Bolts
B. Front
WARNING
I
OWhen draining or filling the final gear case, be careful that no oil gets on the tire or rim. Clean off any oil that inadvertently gets on them with a high-flash point solvent.
B. Right Front Axle
eLoosen the right and left suspension arm pivot bolts on front and upper. elt may be necessary to support the case while sliding out the case bolts.
eAfter the oil has completely drained out, install 'the drain plug with a new aluminum gasket, and tighten it to the specified torque (see Exploded View). eFill the gear case up to the bottom of filler opening with the oil specified below.
Front Final Gear Case Oil Grade: API GL.o hypoid gear oil for LSD (Limited Slip Differential gears) SAE140 or SAE85 W-140 Viscosity: Amount: 0.25 L A. Gear Case Bolts
NOTE
C. Front
B. Suspension Arm Pivot Bolts
O"GL-5" indicates a quality and additive rating. eBe sure the O-ring is in place, and tighten the filler cap to the specified torque (see Exploded View). elnstall the gear case skid plate.
eRe move the vent hose from the gear case. eRemove the left front axle cap bolts and pull out the front final gear case from the vehicle right side.
FINAL DRIVE 9·11 Front Final Gear Case Installation Notes
e Take out the ring gear and differential unit.
e lnstallation is the reverse of removal. Note the following. • After installing the gear case vent hose, install the gear case bolts and nuts. eTighten the following bolts and nuts to the specified torque (see Exploded View) . Front Axle Cap Bolts Suspension Arm Pivot Bolts Front Final Gear Case Bolts and Nuts eApply a non-permanent locking agent to the threads of the two case bolts on the front side. eFili the front final gear case with the specified oil (see Front Final Gear Case Oil Change).
Front Final Gear Case Disassembly eRemove the front final gear case (see Front Final Gear Case Removal). e Remove the bearing housing nuts . e Take out the pinion gear unit.
A. Differential Unit
B. Ring Gear
Front Final Gear Case Assembly
A. Pinion Gear Unit
B. Bearing Housing Nuts
e lnspect the following parts. Ball Bearings (see Ball or Needle Bearing section) Oil Seal (see Oil Seal section) e Visually check the pinion gear and ring gear for scoring, chipping, or other damage. * Replace the bevel gears as a set if either gear is damaged since they are lapped as a set in the factory to get the best tooth contact. e lnstall the following parts in the order shown. Defferential Unit and Ring Gear (see Differential Unit and Ring Gear Assembly) Ring Gear Shim Ring Gear Cover Pinion Gear Unit (see Pinion Gear Unit Assembly)
e Remove the ring gear cover bolts, starting with the smaller bolts.
A. Ring Gear Shim
A. Smaller Bolts B. Pry Points
C. Larger Bolts
Olnstall the pinion gear unit with the ring gear side of the case facing down. oAlign the air vent passage shown with the hose nipple.
9-12 FINAL DRIVE oThe clutch plates, springs, spring shims, and side gears come out.
Differential Unit and Ring Gear Assembly e Assembly is the reverse of removal. lowing.
Note the fol-
NOTE
aBe sure to install the right and left side parts of the unit in the original position. A. Air Vent Passage
B. Hose Nipple
oTighten the following fasteners to the specified torque (see Exploded View). Ring Gear Cover Bolts (first tighten 10 mm, then 8 mm) Pinion Gear Bearing Housing Nuts OAdjust the following items (see Front Final Bevel Gear Adjustment) Front Final Gear Back-Lash Front Final Gear Tooth-Contact
e lnspect the clutch plates (see Clutch Plate Inspection) and the other differential unit parts. Replace any damaged parts. e Measure and record the thickness of the original clutch spring shim(s). e Apply the specified gear oil to the differential unit parts. e Note direction and position of the friction plate and the clutch spring.
Differential Unit and Ring Gear Disassembly e Re move. the differential unit and ring gear (see Front Final Gear Case Disassembly). NOTE
not interchange the right and left side parts in the differential unit.
000
e Remove the following differential unit. Ring Gear Differential Caps
parts to
disassemble the
1. Clutch Spring Shim(s) 2. Clutch Spring 3. Outside Friction Plate
A. Ring Gear Bolts C. Differential Cap B. Mark here for assembly later.
4. Steel Plate 5. Inside Friction Plate
eTemporarily assemble the differential unit and inspect the clutch torque (see LSD Clutch Torque Inspection). e lnstall the front axles to center the steel plates. eTighten t he following bolts to the specified torque (see Exploded View). Differential Case Torx Bolts (Apply non-permanent locking agent) Ring Gear Bolts
FINAL DRIVE 9-13 oAlso, check the clutch plates and replace them as necessary (see Clutch Plates Inspection). oTo increase clutch torque, increase the thickness of the shim(s). OChange the thickness a little at a time. e Re-check the clutch torque and re-adjust as necessary.
Clutch Spring Shim(s) Part Number
Thickness (mm)
C. Mark D. Dowel Pin
A. Front Axle B. T orx Bolts
1.0 1.2 1:4 1.6 1.8
92025-1908 92025-1909 92025-1910 92025-1911 92025-1912
LSD Clutch Torque Inspection eRemove the differential unit and ring gear (see Front Final Gear Case Disassembly). eRemove the ring gear from the differential unit. elnsert both front axles in the unit. eHold one of the front axles with a vise. elnstall the hUb nut on the other axle. eMeasure the clutch torque using a torque wrench. Turn the wrench evenly. oThe clutch torque is defined as the mean reading of the torque during about a quarter turn of the wrench .
LSD Clutch Torque
LSD Clutch Plates Inspection eVisually inspect the friction plates and steel plates to see if they show any signs of seizure, overheating, or uneven wear. *If any plates shown signs of damage, or if the friction plates have worn past the service limit, replace the friction plates and steel plates as a set.
Outside Friction Plate Thickness
Standard: 7.8 - 13.0 N-m (0.8 -1.3 kg-m, 69 - 113 in-Ib)
Standard: Service Limit:
2.3 - 2.4 mm 2.1 mm
Inside Friction Plate Thickness Standard: 2.7 - 2.8 mm 2.4mm Service Limit: ·f :'> A'
®
~
\
!
\
~",r (:
A. Front Axles
,
B. Differential Unit
*If the clutch -torque is out of the specified range, disassemble the differential unit (see Differential Unit and Ring Gear Disassembly) and replace the clutch spring shim(s). Either shim will do.
1. Outside Friction Plate
2. Inside Friction Plate
9-14 FINAL DRIVE Pinion Gear Unit Disassembly eRemove the pinion gear unit (see Front Final Gear Case Disassembly). ePry open the toothed washer tab on the pinion gear slotted nut. eUnscrew the pinion gear slotted nut using the pinion gear holder and the socket wrench (special tools).
1. Slot 2. Tab
3. Claw
eBend the tab over the nut.
Front Final Bevel Gear Adjustment A. Pinion Gear Holder: 57001-1281 B. Socket Wrench: 57001-1283
eRemove the slotted nut,.. flat washer, and toothed washer. ePull the pinion gear out of the bearing housing. eRemove the tapered roller bearing inner race as necessary using the bearing puller (special tool: 57001158).
In order to prevent one gear from moving away from the other gear under load, the tapered roller bearings must be properly preloaded. Also the backlash (distance one gear will move back and forth without moving the other gear) and tooth contact pattern oJ the bevel gears must be correct to prevent the gears from making noise and being damaged. Above three adjustments are of critical importance and must be carried out following the correct sequence and method. Front Final Bevel Gear Adjustment Procedure Preload the pinion gear bearings.
Pinion Gear Unit Assembly ePinion gear unit assembly is the reverse of disassembly. Note the following. eThe pinion gear and ring gear are lapped as a set in the factory to get the best tooth contact. They must be replaced as a set. eVisually inspect the tapered bearings for abrasion, color change, or other damage. *If there is any doubt as to the condition of a bearing, replace the bearing housing and the bearings as a set. eBe sure to check and adjust the pinion gear bearing preload and the bevel gear backlash and tooth contact, when any of the backlash-related parts are replaced (see Front Final Bevel Gear Adjustment). oWhen the pinion gear slotted nut is loosened, even if the purpose is not to replace the parts, check and adjust the bearing preload. eApply an oil to the threads and seating surface of the pinion gear slotted nut, and tighten it to the specified torque (see Exploded View). *If none of the toothed washer tabs align, tighten the nut further just enough to align one of the tabs with a slot in the nut.
Assemble the final gear case completly.
eWhen anyone of the backlash-related parts are replaced or the pinion gear nut is loosened; even if the purpose is not to replace the parts, check and adjust the bearing preload, the bevel gear backlash, and tooth contact by replacing shims. eThe amount of backlash is influenced by the ring gear position more than by the pinion gear position. eTooth contact location is influenced by pinion gear position more than by ring gear position.
FINAL DRIVE 9-15 Front Final Gear Case (Backlash-Related Parts)
Shims for Preload Adjustment
Front
Ring Gear Shims for Backlash Adjustment
Thickness (mm)
Part Number
1.70 1.72 1.74 1.76 (primary) 1.78 1.80
92025-1072 92025-1073 92025-1074 92025-1075 92025-1076 92025-1077
Pinion Gear Shims for Tooth Contact Adjustment
Thickness (mm)
Part Number
0.1 0.15 0.5 0.8 1.0 (primary)
92025-1850 92025-1851 92025-1856 92025-1857 92025-1849
Collars for Preload Adjustment
Thickness (mm)
Part Number
10.2 10.3 10.4 10.5 10.6 10.7 (primary) 10.8 10.9 11.0 11.1 1l.2
92027-1401 92027-1402 92027-1403 92027 -1404 92027-1405 92027-1 406 92027-1407 92027-1408 92027-1409 92027-1410 92027-1411
1. 2. .3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.
Thickness (mm)
Part Number
O.l 0.l5 0.5 0.8 1.0 (primary) 1.2
92025-1919 92025-1920 92025-1921 92025-1922 92025-1923 92025-1924
Ring Gear Cover Front Final Gear Case Ring Gear Ring Gear Shims for Backlash Adjustment Left Differential Cap Ball Bearing Collarfor Preload· Adjustment (affects preload only) Shims for Preload Adjustment (affects preload only) Pinion Gear Shims for Tooth Contact Adjustment Pinion Gear Tapered Roller Bearing Pinion Gear Bearing Housing Tapered Roller Bearing (affects preload only) Oil Seal Collar (affects preload only) Pinion Gear Slotted Nut (affects preload only)
9-16 FINAL DRIVE Bearing Preload Adjustment eCheck and adjust the bearing preload in the following cases. oWhen any of the parts listed below are replaced with new ones. Pinion Gear Collar Shim Tapered Roller Bearings Pinion Gear Bearing Housing Oil Seal Collar oWhen the pinion gear slotted .nut is loosened; even if the nut is not replaced. elnstall the pinion gear bearing housing (see Pinion Gear Unit Disassembly/Assembly) and tighten the pinion gear slotted nut to the specified torque (see Exploded View). eDo not install the oil seal and O-rings, and do not lock the washer until the correct bearing preload is obtained.
OTo start with, choose a shim or collar so that the bearings are just SNUG with NO play but also with NO preload. OAn over-preload on the bearings could damage the bearings.
A. Spring Scale B. Pinion Gear Holder: 57001-1281 C. 200 mm
Using Torque Wrench:
eApply specified gear oil to the bearings, and tur!1 the gears more than 5 turns to allow the bearings to seat. eMeasure the bearing preload. Bearing preload is defined as the force or torque which is needed to start the gear shaft turning.
.~ -~,,~n ~.
NOTE OPreload can be measured either with a spring scale or a beam-type torque wrench. When measured with a spring scale, the preload is designated by force (N, kg), and when measured with a torque wrench, it is des· ignated by torque (N-m, kg-m, in-Ib).
A. Torque Wrench B. Pinion Gear Holder: 57001-1281
*If the preload is out of the specified range, replace the collar and/or spacer. oTo increase preload, decrease the size of the spacer or collar. To decrease preload, increase the size Qf the spacer or' collar. oChange the thickness a little at a time. eRe-check the bearing preload, and re-adjust as necessary.
Pinion Gear Bearing Preload Using Spring Scale: eHook the spring scale on the handle at a point 200 mm apart from the center of the gear shaft. Hold the bearing housing in a vise so that the gear shaft is vertical. eApply force to the handle horizontally and at a right angle to it.
Using spring scale:
1.5 - 3.0 N (0.15 - 0.30 kg)
Using torque wrench:
0.3 - 0.6 N-m (0.03 - 0.06 kg-m, 2.6 - 52 in-Ib)
FINAL DRIVE 9-17 Backlash Adjustment eCheck and adjust the gear backlash when any of the parts shown in the Backlash-Related Parts are replaced with a new one. eCiean any dirt and oil off the bevel gear teeth. eAssemble the front final gear case (see Front Final Gear Case Assembly). Do not install the O-rings during adjustment. oCheck the backlash during the tightening of the ring gear cover bolts and stop tightening them immediately if the backlash disappears. Then, change the ring gear shim to a thinner one. eSet up a dial gauge against a ring gear tooth to check gear backlash as shown.
A. B. C. D.
Move Front Axle Pinion Gear Holder: 57001-1285 Dial Gauge Dial Gauge Holder: 57001-1049
NOTE OApply checking compound to the teeth in a thin, even coat with a fairly stiff paint brush. If painted too thickly, the exact tooth pattern may not appear. OThe checking compound must be smooth and firm, with the consistency of tooth paste. OSpecial compounds are available from. automotive supply stores for the purpose of checking differential gear tooth patterns am;! contact. Use one of these for checking the bevel gears.
eAssemble the front final gear case (see Front Final Gear Case Assembly). Do not install the O-rings during adjustment. eTurn the pinion gear for one revolution in the drive and reverse (coast) direction, while creating a drag on the ring gear. oUse the pinion gear holder (special tool: 57001-1281) and the left front axle. eRemove the ring gear and pinion gear unit to check the drive pattern and coast pattern of the bevel gear teeth. oThe tooth contact patterns of both (drive and coast) sides should be centrally located between the top and bottom of the tooth. The drive pattern can be a little closer to the toe and the coast pattern can be a somewhat longer and closer to the toe. *If the tooth contact pattern is incorrect, replace the pinion gear shim(s), following the examples shown. eThen erase the tooth contact patterns and check them again. Also check the backlash every time the shim{s) are replaced. Repeat the shim change procedure as necessary.
NOTE
eTo measure the backlash, move the left front axle (ring gear side) back and forth while holding the pinion gear steady. The difference between the highest and the lowest gauge reading is the amount of backlash. *If the backlash is not within the limit, replace the ring gear shims. To increase backlash, decrease the thickness of the shim{s). To decrease backlash, increase the thickness of the shim{s). oChange the thickness a little at a time. eRe-check the backlash, and re-adjust as necessary.
Final Bevel Gear Backlash Standard:
0.09 - 0.20 mm (at ring gear tooth)
Tooth contact adjustment -Clean any dirt and oil off the bevel gear teeth. eApply checking compound to 4 or 5 teeth on the pinion gear.
Off the backlash is out of the standard range after changing the pinion gear shim(s), change the ring gear shim(s) to correct the backlash before checking the tooth contact pattern.
9-18 FINAL DRIVE Correct Tooth Contact Pattern
Bottom
Heel
Toe
Top
-k. -------.. ------
Pinion Gear
-+---
.
Bottom
Incorrect Tooth Contact Patterns
Examplel: Decrease the thickness of the pinion gear shim(s) by 0.05 mm to correct the pattern shown below. Repeat in 0.05 mm steps if necessary.
Bottom
Toe Heel
Bottom
Ring Gear
Example 2: Increase the thickness of the pinion gear shim(s) by 0.05 mm to correct the pattern shown below. Repeat in 0.05 mm steps if necessary. _ - - - Heel Bottom
Toe
-,I Pinion Gear
~.
Heel
Bottom
.
----------
FINAL DRIVE 9-19 Bevel Gear Inspection eVisually check the bevel gear-s for scoring, chipping, or other damage. *Replace the bevel gears as a set if either gear is damaged.
Differential Gear Inspection eVisually check the differential gears for scoring, chipping, or other damage. eAlso, inspect the differential pinion gear shaft and gear housing where the differential gears rub. *If they are scored, discolored, or otherwise damaged, replace them as a set.
A. Differential Gear Housing B. Pinion Gear Shaft
C. Pinion Gears
e Drain the engine oil (see Engine Right Side chapter in the Base Manual) . eSupport the rear part of the frame on blocks or the jack (special tool: PN 57001-1238) so that the suspension arms are free from loads. eRemove the following parts. Rear Fender (see Frame chapter) Wiring Straps for Brake Cables and Vent Hoses Brake Pedal Adjuster and Parking Brake Lever Adjuster on Rear Brake Panel Rear Shock Upper Mounting Bolts and Nuts Suspension Arm Pivot Shaft Propeller Shaft Joint Boot Clamp Screw
1. Propeller Shaft Joint Boot Clamp Screw 2. Suspension Arm Pivot Shaft
D. Side Gears
Tapered Roller Bearing Inspection eVisually inspect the bearings for abrasion, color change, or other damage. *If there is any doubt as to the condition of a bearing, replace it.
e Move the propeller shaft to the rear along with the wheels just enoug~ to free the shaft from the engine. e Re move the propeller shaft housing nuts. eTake off the propeller shaft. The spring comes off with the propeller shaft.
............................................................................ Rear Propeller Shaft
............................................................................ Rear Propeller Shaft Removal NOTE
alt is not necessary to remove the rear shocks, rear wheels, and rear axle assembly. e Remove the rear final gear case skid plate. e Drain the rear final gear case oil (see Rear Final Gear Case Oil Change).
1. Propeller Shaft Housing Nuts
Rear Propeller Shaft Installation e lnstallation is the reverse of removal. Note the fol lowing. e Wipe the old grease off and grease the front end splines of the shaft and the pinion gear joint splines. e Be sure to install the spring on the pinion gear nut of the rear final gear case.
9-20 FINAL DRIVE *If the joint boot is torn , worn, or deteriorated, replace the joint boot ahd check the propeller shaft (see Rear Propeller Shaft Boot Replacement).
A. Apply grease.
B. Spring
elnstall the propeller shaft. A. Front
B. Joint Boot
Rear Propeller Shaft Joint Boot Replacement eRemove the rear propeller shaft . (see Rear Propeller Shaft Removal). eRemove the circlip with the circlip pliers (special tool: PN 57001-143) and pull out the shaft from the housing.
1. Joint Boot 2. Universal Joint
3. Apply grease.
eTighten the following bolts and nuts to the specified torque (see Exploded View). Propeller Shaft Housing Nuts Suspension Arm Pivot Bolts Rear Shock Mounting Bolts and Nuts eFili the engine oil (see Specifications in the Engine Right Side chapter in this text) and the rear final gear case oil (see Rear Final Gear Case Oil Change) . eRun the brake cables and the vent hoses according to the Wiring, Cable, and Hose Routing in the General Information chapter). eAdjust the brake pedal and the parking brake (see Brakes chapter).
Rear PropellerShaft Joint Boot Inspection eVisually inspect the rear propeller shaft joint boot in accordance with the Periodic Maintenance Chart (see General Information chapter) or if the shaft is noisy during, operation.
A. Circlip
-Check that the universal joint works smoothly without rattling or sticking. *If it does not, the bearing of the universal joint is damaged. Replace the propeller shaft with a new one. eVisually inspect the grease seal and cap for the universal joint. *If there is any signs of deterioration, damage, or loosen, replace the propeller shaft. *If the grease leakage is noted, replace the propeller shaft.
FINAL DRIVE 9-21 Rear Axle
............................................................................. Rear Axle Unit Removal
A. Universal Joint B. Grease Seal
C. Center Bearing D. Splines
A. Grease Cap
B. Splines
eRemove the rear final gear case skid plate. eDrain the rear final gear case oil (see Rear Final Gear Case Oil Change). eDrain the engine oil (see Engine Right Side chapter in the Base Manual). eRemove the following parts. Rear Fender (see Frame chapter) Rear Wheels Brake Drum (see Brakes chapter) Rear Brake Panel (see Brakes chapter) Rear Propeller Shaft Joint Boot Front End eRemove the foHowing parts. Center Arm Bolts Lower Mounting Bolts of Rear Shock Absorbers Suspension Arm Pivot Bolts
A. Joint Boot Clamp
B. Center Arm Bolts
C. Lower Mounting Bolts D. Pivot Bolts
eMove the rear axle unit to the rear just enough to free from the vehicle. eRemove the propeller shaft by taking off the housing nuts.
elnspect the center bearing. oSince the ball bearings are ' made to extremely close tolerances, the wear must be judged by feel rather than measurement. oSpin the bearing by hand to check its condition. *If the bearing is noisy, does not spin smoothly, or has any rough spots, replace the propeller shaft. eExamine the bearing seal for tears or leakage. *If the seal is torn or is leaking, replace the propeller shaft. eVisually inspect the splines on the propeller shaft. *If they are badly worn or chipped, replace the propeller shaft. Also, inspect the splines on the sub-transmission output shaft and the pinion gear joint.
A. Housing Nuts
B. Rear Axle Unit
9-22 FINAL DRIVE
Rear Axle Unit Installation Notes elnstallation is the reverse of removal. Note the following. eRefer to the Brakes chapter for Brake Panel Installation. eWipe the old grease off and grease the propeller shaft splines and the pinion gear joint splines (see Propeller Shaft Installation). eTighten the following bolts and nuts to the specified torque (see Exploded View). Propeller Shaft Housing Nuts Suspension Arm Pivot Bolts Rear Shock Mounting Bolts and Nuts Center Arm Nuts eFill the engine oil (see Specifications of Engine Right Side chapter in this text) and the rear final gear case oil (see Rear Final Gear Case Oil Change) .
A. Splines
*If the splines are twisted or damaged in any way, replace the rear axle.
Rear Axle Unit Disassembly eRemove the rear axle unit (see Rear Axle Unit Removal). eTake off the right and left axle pipes by removing the pipe nuts.
Rear Axle Unit Assembly eAssembly is the reverse of removal. Note the following. eUsing a press and the bearing driver set (special tool: PN 57001-1129), install the right side oil seal and ball bearings until they bottom out. And install the left side oil seal until it is flush with the pipe end.
Left Side Axle
Right Side Axle
I
~~=r'
I f
I I
A. Axle Pipes
CD eTake each axle out of the axle pipes. eTo remove the ball bearing, remove the oil seal and circlip for the left-hand axle. eRemove each bearing or oil seal, using the oil seal and bearing remover (special tool: 57001-1058). elnspect the condition of the splines at each end of the axle.
1. Oil Seal 2. Snap Ring
I· 3. Bearing
e Apply grease to the oil seals on the axle pipes.
FINAL DRIVE 9-23
(;:' A f'
.\::
\
A. Apply grease.
A. Filler Opening
eTighten the axle pipe nuts to the specified torque (see Exploded View). eFill the rear final gear case with the specified oil (see Rear Final Gear Case Oil Change).
*If it is insufficient, first check the rear final gear case for oil leakage, remedy it if necessary, and add oil through the filler opening. Use the same type and brand of oil that is already in the final gear case. e Be sure the O-ring is in place, and tighten the filler cap to the specified torque (see Exploded View).
Rear Axle Bearing Inspection eRemove the rear axle (see Rear Axle Unit Disassembly). NOTE
OSince the bearings are packed with grease and sealed, they can not be lubricated.
Rear Final Gear Case Oil Change eWarm up the oil by running the vehicle so that the oil will pick up any sediment and drain easily. Then stop the vehicle. e Park the vehicle so that it is level, both side-to-side and front-to-rear. ePlace an oil pan beneath the rear final gear case and remove the drain plug.
eRefer to Ball or Needle Bearing section in this chapter for sealed bearing inspection.
Rear Final Gear Case Rear Final Gear Case Oil Level Inspection ePark the vehicle so that it is level, both side-to-side and front-to rear. eRemove the filler cap.
A. Remove the drain plug.
I WARNING. oBe careful not to allow any dirt or foreign materials to enter the gear case.
oWhen draining or filling the final gear case, be careful that no oil gets on the tire or rim. Clean off any oil that inadvertently gets on them with a high-flash point solvent.
e Check the oil .level. The oil level should come to the bottom of the filler opening.
e After the oil has completely drained out, install the drain plug with a new aluminum gasket and tighten it to the specified torque (see Exploded View).
9-24 FINAL DRIVE eFili the final gear case up to the bottom of filler opening with the oil specified below. Rear Final Gear Case Oil Type:
API GL-S Hypoid gear oil SAE90 (above SoC, 41°F) SAE80 (below SoC, 41°F)
Capacity:
0.2 L
ePull the ring gear out of the case. ePry open the staking of the pinion gear nut with a small chisel. eUnscrew the pinion gear nut using the bevel gear holder (sp'ecial tool) to keep the pinion gear assembly as shown.
NOTE
0"GL-5" indicates a quality and additive rating. "GL-6" rated hypoid gear oils can also be used. eBe sure the O-ring is in place and tighten the filler cap to the specified torque (see Exploded View).
Rear Final Gear Case Removal eThe final gear case is removed during disassembling the rear axle unit. Refer to Rear Axle Unit Disassembly section.
Rear Final Gear Case Installation Notes
A. Bevel Gear Holder: 57001-1193 B. Pinion Gear Nut eRemove the pinion gear joint and the oil seal. eUnscrew the pinion gear bearing holder set plug. eUnscrew the pinion gear bearing holder using the hexagon wrench (special tool).
elnstallation is the reverse of removal. Note the following. eTighten the axle pipe nuts to the specified torque (see Exploded View). eFili the rear final gear case with' the specified oil (see Rear Final Gear Case Oil Change).
Rear Final Gear Case Disassembly eRemove the rear final gear case (see Rear Final Gear Case Removal). eUnscrew the ring gear cover bolts and pull off the cover. The shim{s) comes off with the cover. A. Pinion Gear Bearing Holder (Right-Hand Threads) B. Bearing Holder Set Plug C. Hexagon Wrench (41 mm,57001-1284) ePull out the pinion gear unit.
Rear Final Gear Case Assembly Notes
A. Ring Gear Cover
eAssembly is the reverse of disassembly. Note the following. -Check the following parts. Oil Seal (see Oil Seal section) Ball Bearings (see Ball or Needle Bearing section)
FINAl:. DRIVE 9-25 eVisually check the bevel gears for scoring, chipping, or other damage. *Replace the bevel gears as a set if either gear is damaged since they are lapped as a set in the factory to get the best tooth contact. eBack out the ring gear thrust plug fully.
eTighten the following parts to the specified torque (see Exploded View). Pinion Gear Bearing Holder (Oil the threads and seating surface) Pinion Gear Bearing Holder Set Plug Ring Gear Cover Bolt~ (tightening order 10 mm -+ 8mm) eReplace the pinion gear nut with a new one. eApply an oil to the threads and seating surface of the pinion gear nut, and .tighten them to the specified torque (see Exploded View). eStake the head of the pinion gear nut with a punch to secure the pinion gear nut.
OWhen staking the nut, be careful not to apply shock to the pinion and their bearing. Such a shock could damage the pinion and/or bearings.
A. Ring Gear Thrust Plug
B. Locknut
eBe sure to check and adjust the bevel gear backlash and tooth contact when any of the backlash-related parts are replaced (see Rear Final Bevel Gear Adjustment). elnstall the pinion gear bearing holder with the deeper recess side facing outboard and tighten it to the specified torque (see Exploded View). eReplace the pinion gear nut and the oil seal with the new ones. eVisually inspect the splines of the pinion gear joint. *If they are badly worn or chipped, replace the joint with a new one. Also, check the propeller shaft internal splines. elnstall the pinion gear joint.
A. Splines
B. Pinion Gear Joint
eAfter installing the pinion gear bearing holder set plug, install the oil seal using the fork oil seal driver (special tool: PN 57001-1104). Flush the seal face with the end of the hole. eTurn the ring gear thrust plug clockwise until it becomes hard to turn. eBack out the plug )h turn from that point. eTighten the locknut to the specified torque keeping the plug position (see Exploded View).
9-26 FINAL DRIVE Rear Final Bevel Gear Adjustment The backlash and tooth contact pattern of the bevel gears must be correct to prevent the gears from making noise and being damaged. eAfter replacing any of the backlash-related parts, be sure to check and adjust the backlash and tooth contact of the bevel gears. First, adjust backlash, and then tooth contact by replacing shims. 1. 2. 3. 4.
5. 6. 7. 8.
Pinion Gear Pinion Gear Shim(s) Ring Gear Thrust Plug Ring Gear Cover
Ring Gear Bearing Ring Gear Ring Gear Shim(s) Rear Final Gear Case
(J)
Pinion Gear Shims for Tooth Contact Adjustment Thickness (mm) 0.12 0.15 0.18 0.8 0.9 1.0 (primary) 1.1 1.2 1.3 1.4
Part Number 92025-1668 92025-1669 92025-1670 92025-1671 92025-1672 92025-1673 92025-1674 92025-1675 92025-1676 92025-1677
/
Ring Gear Shims for Backlash Adjustment Thickness (mm) 0.1 0.15 0.5 0.8 1.0 (primary)
Part Number 92025-1850 92025-1851 92025-1856 92025-1857 92025-1849
FINAL DRIVE 9-27 Backlash Adjustment eClean any dirt and oil off the bevel gear teeth. eBack out the ring gear thrust plug fully.
not install the pinion bearing holder set plug, the oil seal, and the O-ring during adjustment.
000
elnstall the pinion gear assembly with the primary (1.0 mm thickness) shim. elnstall the pinion gear bearing holder with the deeper recess side facing outward. eTighten the pinion gear bearing holder to the specified torque (see Exploded View). elnstall the ring gear assembly with the 'primary (1.0mm thickness) shim, and .tighten the ring gear case cover bolts to the specified torque (see Exploded View). oCheck the backlash during the tightening of the cover bolts, and stop tightening them immediately if the backlash disappears. Then, change the ring gear shim to a thinner one. eTemporarily, install the rear axle in the gear case and hold it with a vise so that the ring gear is lower than the pinion gear. eMount a dial gauge on the vise so that the tip of the gauge is against the splined portion of the pinion gear joint. eTo measure the backlash, move the pinion gear nut back and forth while holding the rear axle steady. The difference between the highest and the lowest gauge reading is the amount of backlash. oMeasure backlash at three locations equally spaced on the splines. Rear Final Bevel Gear Backlash: 0.07 - 0.17 mm
Tooth contact adjustment -Clean any dirt and oil off the bevel gear teeth . eApply checking compound to 4 or 5 teeth of the pinion gear.
NOTE OApply checking compound to the teeth in a thin, even coat with a fairly stiff paint brush. If painted too thickly, the exact tooth pattern may not appear. oThe checking compound must be smooth and firm, with the consistency of tooth paste. OSpecial compounds are available at automotive supply stores for the purpose of checking differential gear tooth patterns and contact.
elnstall the shim(s) and pinion gear assembly, and tighten the bearing holder to the specified torque (see Exploded View). elnstall the shim(s) and ring gear assembly, and tighten the cover bolts to the specified torque (see Exploded View). eTurn the pinion gear for one revolution in the drive and reverse (coast) direction, while creating a drag on the ring gear. eRemove the ring gear and pinion gear unit to check the drive pattern and coast pattern of the bevel gear teeth. oThe tooth contact patterns of both (drive and coast) sides should be centrally located between the top and bottom of the tooth. The drive pattern can be a little closer to the toe and the coast pattern can be a somewhat longer and closer to the toe. *If the tooth contact pattern is incorrect, replace the pinion gear shim(s), following the examples shown (see Correct Tooth Contact Pattern in Front Final Bevel Gear Adjustment section). eThen erase the tooth contact patterns, and check them again. Also check the backlash every time the shim(s) are replaced. Repeat the shim change procedure as necessary.
NOTE Olf the backlash is out of the standard range after changing the pinion gear shim(s), change the ring gear shim(s) to correct the backlash before checking the tooth contact pattern.
A. Hold the axle. C. Dial Gauge B. Move the pinion gear nut.
*If the backlash is not within the limit, replace the ring gear shims. To increase backlash, decrease the thickness of the shim(s). To decrease backlash, increase the thickness of the shim(s). ilChange the thickness a little at a time. eRe-check the backlash, and readjust as necessary.
Pinion Gear Disassembly eRemove the pinion gear (see Rear Final Gear Case Disassembly). eRemove the pinion gear bearing as necessary using the bearing puller (special tool: 57001-158).
9-28 FINAL DRIVE
Pinion Gear Assembly Note elnstall the pinion gear bearing on the pinion gear with the bearing driver (special tool : 57001-382) until the bearing is firmly seated against the pinion gear.
A. Front Final Gear Case B. Oil Seal & Bearing Remover: 57001-1058
NOTE
1. Bearing Driver: 57001-382 2. Pinion Gear Bearing
Bevel Gear Inspection eVisually check the bevel gears for scoring, chipping, or other damage. *Replace the bevel gears as a set if either gear is damaged .
Oln the absence of the above mentioned tools, satisfactory results may be obtained by heating the case to approximately 93°C (200°F) max., and tapping the bearing in or out.
000 not heat the case with a torch. This will warp the case. Soak the case in oil and heat the oil.
-Using a press and the bearing driver set (special tool: PN 57001-1129), install the new bearing until it stops at the bottom of its housing.
..........................................................•.................
CD
Oil Seal
Oil Seal Inspection elnspect the oil seals. *Replace any if the lips are misshapen, discolored (indicating that the rubber has deteriorated), hardened, or been otherwise damaged.
1. Bearing Drive Set: PN57001-1129
Ball or Needle Bearings
Ball or Needle Bearing Inspection Ball or Needle Bearing Replacement eUsing a press, puller, the bearing driver set (special tool: PN 57001-1129) or the oil seal & bearing remover (special tool), remove the ball bearing.
-Since the ball bearings are made to extremely close tolerances, the wear must be judged by feel rather than measurement. Clean each bearing in a high-flash point solvent, dry it (do not spin the bearing while it is dry), and oil it with the specified oil.
FINAL DRIVE 9-29
I WARNING I -Clean the parts in a well-ventilated area, and take care that there are no sparks or flame anywhere near the working area; this includes any appliance with a pilot light. Do not use gasoline or low-flash point solvent to clean parts. A fire or explosion could result.
-Turn the bearing back and forth while checking for roughness or binding, *If the bearing is noisy, does not spin smoothly, or has any rough spots, replace it.
CD
1. Turn the bearing.
-Since sealed bearings are packed with grease and sealed, they can not be lubricated. -Turn the sealed bearing back and forth while checking for roughness or binding. *If roughness or binding is found, replace the bearing. -Examine the bearing seal for tears or leakage. *If the seal is torn or is leaking, replace the bearing.
I
1. Turn the bearing.
2. Bearing Seal
-Check the needle bearing in the rear final gear case. oThe rollers in a needle bearing normally wear very little and wear is difficult to measure. Instead of meas'uring, inspect the bearing for abrasion, color change, or other damage. *If there is any doubt as to the condition of a needle bearing, replace the needle bearing and rear final gear case as a set.
BRAKES 10-1
Brakes Table of Contents Exploded View . . . . . . . . . . . . . . . . . . . . Specifications. . . . . . . . . . . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . Brake Adjustment . . . . . . . . . . . . . . . . . . Front Brake Lever Free Play Inspection . . . . . . . . . . Brake Pedal Position Adjustment .... Brake Pedal Free Play Adjustment ... Parking Lever Free Play Adjustment .. Cam Lever Angle Adjustment . . . . . . Brake Fluid . . . . . . . . . . . . . . . . . . . ... Brake Fluid Recommendation .... . . Brake Fluid Level Inspection . . . . . . . Brake Fluid Changing . . . . . . . . . ... Brake Line Air Bleeding . . . . . . . . . . Calipers .... . ... . . . . . . . . . . . . . . . . . Caliper Removal . . . . . . . . .. . . . . . Caliper Installation Notes . . . . . . . . . Caliper Disassembly Notes . . . . . . . . . Caliper Assembly Notes .. . ... .... Caliper Fluid Seal Damage . . . . . . . . . Caliper Dust Seal and Cover Damage . . Caliper Piston and Cylinder Damage .. Caliper Holder Shaft Wear . . . . . . . . . Brake Pads . . . . . . . . . . . . . . . . . . . . . . . Brake Pad Removal . . . . . . . . . . . . . Brake Pad Installation Notes . . . . . . . Brake Pad Wear Inspection . . . . . . . . Master Cylinder and Wheel Cylinders ... .. . Master Cylinder Removal . . . . . . . . . Master Cylinder Installation . . . . . . . . Master Cylinder Disassembly . . . . . . . Master Cylinder Assembly . . . . . . . . .
. . . .
10-2 104 104 10-5
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-5 10-5 10-5 10-5
. .. . . . .
lP-6 10-6 10-6 10-6 10-7 10-7 10-7 10-7 10-7 10-8 10-8 10-8 10-8 10-9
.
. . .
Master Cylinder Inspection .... . ... . Brake Lever Lubrication . . . . . . . . . . . Brake Discs . . . . . . . . . . . .. ... .. .... . Disc Installation Notes . . . . . . . . . .. . Disc Wear ... .. . . . . . . . . . . . . . . . . Disc Cleaning . . . . . . . . . . . . . . . . . . Disc Warp Inspection . . . . . . . . . . . . . Brake Hoses . . . . . . . . . . . . . . . . . . . . . . . Brake Hose Removal . . . . . . . . . . . . . Brake Hose Installation Notes . . . . . . . Brake Hose Inspection . . . . . . ..... . Brake Drum . . . . . . . . . . . . . . . . . . . . . . . Rear Brake Drum Removal . . . . . . . . . Rear Brake Drum Installation .. .. .. . Brake Drum Wear .... .. .... .... . Brake Drum Seal Wear . . . . . . . . . . . . Brake Drum Disassembly/ Assembly Note .. . . . . . . . ... .. . Brake Panel Assemblies. . . . . . . . . . . . . . . . Brake Panel Removal .. .. .. .... .. . Brake Panel Installation . . . . . . . . . . . Brake Shoe Lining Wear . . . . . . . . . . . Brake Shoe Spring Inspection . . . . . . . Brake Panel Disassembly . . . . . . . . . . . Brake Panel Assembly Notes ... .. .. . Brake Camshaft Lubrication .. . .... . Brake Pedal and Cables . . . . . . . . • . . . . . . . Brake Pedal and Cable Removal ..... . Brake Pedal and Cable Installation .... . Brake Cable Inspection . . . . . . . . . . . . Brake Pedal and Cable Lubrication ... .
*
Base Manual
. 10-9 10-9 10-9 10-9 10-9 10-10 10-10
* 10-10 10-10 10-10 10-10 10-10
.
10-11 10-11 10-11 10-11 10-12
.
..
10-12 10-12 10-13 10-13 10-13 10-13 10-14 10-14
[I[I
10-2 BRAKES
lew
E~~i~d~·V···:·············· ··············
................. .
..;;:.:.~ ....;............. ........ ..... ............................... .......... . G :A y adhesive. .. PP . pply grease L . . . Apply non-perman agent. ent locking
o : Apply 01. '1 Si : Apply 51'1'Icone grea T1 se. : 25 N-m (25 T2: 20 N-m (2'0 kg-m, 18 ft-Ib) T3: 8.8 N-m (() 9~g-m, 14.5 ft-Ib) T4: 5.9 N-m (0'60 kg-m, 78 in.Jb) T5: 7.8 N-m (0:80 kg-m, 52 in-Ib) T6: 145 N-m (150 kg-m, 69 in.Jb) T7: 29 N-m (30 kg-m, 110 ft-Ib) T8: 1.0 N-m (01 g-m, 22 ft-Ib) T9: 37 N-m (3 ~ kg-m, 9 in.Jb) T10: 18 N • g-m, (27 ft-Ib) -m (18 k T11: 23 N-m (2'3 k gem, 13.0 ft-Ib) T12: 34 N-m (3' gem, 16.5 ft-Ib) .5 kg-m, 25 ft-Ib)
k
8
BRAKES 10-3
@
/ ~--~ ~ @
U
Drain Bolt
~o>
!\
10-4 BRAKES Specifications Refer to the Base Manual noting the following.
Item Brake Fluid Grade Front Disc Brake: Brake lever free play Pad lining thickness Disc thickness Disc runout Rear Drum Brake: Parking brake lever play Rear brake pedal free play Cam lever angle Drum inside diameter Brake shoe thickness
Standard D.O.T.3 Non-adjustable 4.5 3.3 - 3.7 mm 0.2 mm or under 1-2mm 15 - 25 mm 80 - 90° 180.000 - 180.140 mm 5mm
Special Tools Refer to the Base Manual noting the following. Jack: 57001-1238
oThis tool may be used instead of the common tool.
Service Limit
Outside Circlip Pliers: 57001-144
--1 mm 3.0mm 0.3mm
------180.75 mm 2.5mm
BRAKES 10-5 Brake Pedal Free Play Adjustment
Brake Adjustment
eMeasure the distance the brake pedal moves before the brake starts to take hold. Pedal free play should be 15 - 25 mm.
Front Brake Lever Free Play Inspection Disc or disc pad wear is automatically compensated for and has no effect on brake lever action. So there are no parts that require adjustment on the front brake. However if the brake lever has a soft, or "spongy feeling," check the brake fluid level in the master cylinder and bleed the air from the brake line (see Bleeding the Brake in the Base Manual).
Brake Pedal Free Play Standard:
15 - 25 mm
NOTE oCheck the- brake fluid level in accordance with the Periodic Maintenance Chart.
Brake Pedal Position Adjustment eMeasure from the top of the brake pedal in its rest position to the upper surface of the right footpeg. This measurement should be 0 to 5 mm above the top of the footpeg . A. Brake Pedal
B. 15 - 25 mm
eTo adjust the pedal free play, turn the adjuster at the rear end of the brake cable.
A. Footpeg B. 0 - 5 mm
C. Brake Pedal
eTo adjust the pedal position, loosen the locknut, turn the adjusting bolt, and then tighten the locknut. Now adjust the brake pedal free play.
A. Brake Pedal Adjuster B. Parking Brake Lever Adjuster
OAlways maintain proper pedal free play. Brake shoes will expand with the heat of operation. If adjustment is too tight (too little free play), the brake could overheat and damage the drive train and engine.
Parking Lever Free Play Adjustment
A. Adjusting Bolt
B. Locknut
eLoosen the locknut and turn the adjuster at the parking lever in as far as it will go. eTighten the locknut. eTurn the adjuster at the rear end of the brake cable so that the brake lever has 1 - 2 mm of free play.
10-6 BRAKES
,--------
- If the caliper is to be disassembled after removal and if compressed air is not available, remove the piston using the following procedure. If both calipers are to be disassembled, be sure to do this procedure to both at the same time. o Remove the pads. oTemporarily reconnect the brake hose to the caliper. The banjo bolt need not be torqued. oPump the brake lever to remove the caliper piston. o Immediately wipe up any brake fluid that spills. o Disconnect the brake hose from the caliper.
1. 1 - 2 mm
Caliper Installation Notes NOTE OSince the above two free play adjustments (pedal and lever) affect each other, make them at the same time.
-After adjustments, check for brake drag (there should be none) and effectiveness.
-Connect the brake hose to the caliper putting a new flat washer on each side of the brake hose fitting. - Check the fluid level in the reservoir and bleed the brake line (see Bleeding the Brake Line in the Base Manual). -Check the brakes for good braking power, no brake drag, and no fluid leakage.
Caliper Disassembly Notes - Using compressed air, remove the piston. O~over the caliper opening with a clean, heavy cloth. oRemove the piston by lightly applying compressed air to where the brake line fits into the caliper.
Calipers Caliper Removal -Remove the front wheels (see Wheel Removal in the Wheels/Tires chapter). -Separate the brake hose from the caliper by taking off the banjo bolt. -Remove the caliper mounting bolts and take off the calipers.
A. Mounting Bolts B. Caliper
I WARNING. OTo avoid serious injury, never place your fingers or palm inside the caliper opening. If you apply compressed air into the caliper, the piston may crush your hand or fingers.
C. Front A. Apply compressed air.
B. Cloth
BRAKES 10-7 Caliper Assembly Notes
I WARNING I o Except for the disc pads ~nd discs; use only disc brake fluid, isopropyl alcohol, or ethyl alcohol, for cleaning brake parts. Do not use any other fluid for cleaning these parts. Gasoline, motor oil, or any other petroleum distillate will cause deterioration of the rubber parts. Oil spilled on any part will be difficult to wash off completely, and will eventually deteriorate the rubber used in the disc brake.
A. Anti-Rattle Spring
-Apply brake fluid to the outside of the piston and the fluid seal, then push the piston' into the cylinder by hand . Take care that neither the cylinder nor the piston skirt gets scratched .
Caliper Fluid Seal Damage The fluid seal around the piston maintains the proper pad/disc clearance. If the seal is not satisfactory, pad wear will increase, and constant pad drag on the disc will raise brake and brake fluid temperature .. - Replace the fluid seals under any of the following conditions: (a) fluid leakage around the pad; (b) brakes overheat; (c) there is a large difference in inner and outer pad wear; (d) the seal is stuck to the piston. If the fluid seal is replaced, replace the dust seal as well. Also, replace all seals every other time the pads are changed.
Caliper Dust Seal and Cover Damage - Check that the dust seals and covers are not cracked worn, swollen·, or otherwise damaged. - If they show any damage, replace them.
® 1. 2. 3. 4. 5. 6. 7. 8. 9.
®
Caliper Outer Pad Inner Pad Dust Seal Fluid Seal Piston Pad Mounting Allen Bolts Caliper Holder Shafts Friction Boot
- Apply a thin coat of silicone grease to the caliper holder shafts and holder holes. (Silicone grease is a special high temperature, water-resistant grease). - Install the anti-rattle spring in the calipers as shown.
Caliper Piston and Cylinder Damage - Visually inspect the piston and cylinder surfaces. *Replace the caliper if the cylinder and piston are badly scored or rusty .
Caliper Holder Shaft Wear The caliper body must slide smoothly on the caliper holder shafts. If the body does not slide smoothly, one pad will wear more than the other, pad wear will increase, and constant drag on the disc will raise brake and brake fluid temperature. - Check to see that the caHper holder shafts are not badly worn or stepped, and that the rubber friction boots are not damaged . * If the rubber friction boot is damaged, replace the rubber friction boot. * If the caliper shaft is damaged, replace the caliper assembly.
10-8 BRAKES
Brake Pad Installation Notes
Brake Pads
-Before installation, clean the pads with a high-flash point solvent.
I WARNING' OWhen handling the disc pads, be careful that no disc brake fluid or any oil gets on them. Clean off any fluid or oil that inadvertently gets on the pads with a highflash point solvent_ Do not use one which will leave an oil residue. Replace the pads with new ones if they cannot be cleaned satisfactorily.
WARNING' OWhen handling the disc pads or disc, be careful that no disc brake fluid or any oil gets on them. Clean off any fluid or oil that inadvertently gets on the pads or disc with a high-flash point solvent. Do not use one which will leave an oily residue. Replace the pads with new ones if they cannot be cleaned satisfactorily.
-Push the caliper piston in by hand as far as it will go, and then install the pads.
I WARNING'
Brake Pad Removal -Remove the front wheel (see Wheel Removal in Wheels/ Tires chapter). -Remove the pad mounting Allen bolts.
o Do not attempt to drive the vehicle until a full brake lever is obtained by pumping the brake lever until the pads are against each disc. The brake will not function on the first application if this is not done.
Brake Pad Wear .Inspection
A. Pad Mounting Allen Bolts
-Lift off the caliper by taking off the mounting bolts with the hose left installed. -Push the caliper holder toward the piston side and then remove the pads.
A. Pads
In accordance with the Periodic Maintenance Chart, inspect the brake pads for wear. -Remove the front wheels in order to check the front brake pads. -Check the lining thickness of the pads in each caliper. The pad thickness can be checked with the pad installed. *If the lining thickness of either pad is less than the service limit, replace both pads in the caliper as a set. Pad Lining Thickness Standard: Service Limit:
A. Service Limit
4.5mm 1 mm
B. Lining Thickness
BRAKES 10-9
Master Cylinder and Wheel Cylinders OSince the wheel cylinder is not on the model, the information of the wheel cylinder is omitted.
Brake Lever Lubrication Whenever the master cylinder is disassembled, or in accordance with the Periodic Maintenance Chart, perform the following. eLubricate the brake lever by applying a light coating of silicone grease to the brake lever pivot screw and the contact with the piston.
A. Marked Side eAfter installing the discs, check the disc runout. Completely clean off any grease that has gotten on either side of the disc with a high-flash point solvent. Do not use one which will leave an oily residue.
Disc Wear eMeasure the thickness of each brake disc at the point where it has worn the most. *Replace the disc if it has worn past the service limit.
Front Disc Thickness Standard: Service Limit:
3.3-3.7 mm 3.0mm
1. Apply grease .
............................................................................... Brake Discs
I WARNING' oWhen handling the discs, be careful that no disc brake fluid or any oil gets on them. Clean off any fluid or oil that inadvertently gets on the discs with a high-flash point solvent. Do not use one which will leave an oily residue.
Disc Installation Notes eTighten the disc mounting Allen bolts to the specified torque. The disc must be installed with the chamfered hole side facing toward the front hub. The marked side must face outward.
1. Brake Disc 2. Measuring Area
Disc Cleaning Poor braking can be caused by oil on a disc. Oil on a disc must be cleaned off with an oilless cleaning fluid such as trichloroethylene or acetone.
I WARNING I o These cleaning fluids are usually highly flammable and harmful if breathed for prolonged periods. Be sure to heed the fluid manufacturer's warnings.
10-10 BRAKES Brake Disc Warp Inspection eJack up the vehicle so that the front wheels are off the ground. eFor front disc inspection, remove the front wheels, and turn the handlebar fully to one side. eSet up a dial gauge against the disc as shown, and measure disc runout. *If runout exceeds the service limit, replace the disc.
A. Front Brake Hose
Brake Drum 1. Brake Disc
2. Turn the disc by hand.
Disc Runout Standard: Service Limit:
02 mm or under O.3mm
Since the front brake drums are not on the model, the information of the front brake drum is omitted.
Rear Brake Drum Removal Refer to the Base Manual noting the following. e Remove the right rear wheel for rear brake drum removal.
Brake Hoses
Rear Brake Drum Installation Refer to the Base Manual noting the following. e Do not overgrease the inside seal lip of the brake drum seal.
Brake Hose Installation Notes e Using a new copper washer for each side of the hose fitting, tighten the banjo bolt to the specified torque (see Exploded View in this manual). e Run the brake hose according to the Wiring, Cable, and Hose Routing section in the General Information chapter. eBleed the air from the brake line (see Brake Line Air Bleeding in the Base Manual).
Brake Hose Inspection The high pressure inside the brake line can cause fluid to leak or the hose to burst if the line is not properly maintained. e Bend and twist the rubber hose while examining it. * Replace it if any cracks or bulges are not~d.
A. Brake Drum Seal
BRAKES 10-11 Brake Drum Seal Lubrication Grease
Brake Panel Assemblies Since the front brake panels are not on the model, the information is omitted.
Brake Panel Removal Do not grease here.
-Remove the following parts. Right Rear Wheel Brake Drum Brake Cables Brake Panel Vent Hose -Remove the panel assembly from the axle pipe by taking off the mounting bolts.
Brake Drum Seal Wear Refer to the Base Manual noting the following. -Tighten the brake drum drain bolt to the specified torque (see Exploded View).
A. Brake Panel B. Drain Hole
A. Drain Bolt
Brake Drum Disassembly/Assembly Note -Do not press the drum bolt out. *If the drum bolt is damaged, replace the drum and bolts as a unit.
c.
Mounting Bolts D. Front
WARNING' Brake linings contain asbestos fiber. Inhalation of asbestos may cause serious scarring of the lungs and may promote other internal injury and illness, including cancer. Observe the following precautions when handling brake linings. ONever blow brake lining dust with compressed air. Olf any components are to be cleaned, wash with detergent, then immediately discard the cleaning solution and wash you hands. 0 00 not grind any brake lining material unless a ven.tilation hood is available and properly used.
Brak.e Panel Installation
1. ReafBrake Drum 2. Drum Bolt
- Tighten the brake panel mounting bolts to the specified torque after applying a non-permanent locking agent to the threads (see Ex ploded View). - Run the brake cables and vent hoses according to the Wiring, Cable, and Hose Routing in the General Information chapter. - Adjust the brake pedal and the parking brake (see Brake Adjustment in this chapter) .
10-12 BRAKES Brake Panel Disassembly
Brake Panel Assembly Notes
e Remove the following parts. Shoe Spring of the anchor pin side Circlips Anchor Pin Holder
e(lean the old grease from the camshaft and regrease it. e Apply grease to the camshaft and the anchor pins and very lightly on the cam surfaces. Do not overgrease. e Push the camshaft into the panel so that the triangular mark on the cam surface points toward the center of the panel.
WARNING ' Olmproper installation will cause ineffective braking.
A. Shoe Spring
C. Circlips
B. Anchor Pin Holder
e Using a clean cloth around the linings to prevent grease or oil from getting on them, remove the brake shoes by pulling up on the center of the linings. A. Triangular Mark
oThe brake shoe springs are identical. e Fit the springs onto the brake shoes. Wrap a clean cloth around the lin ings to prevent grease or oil from getting on them, and install the shoes on the brake panel. e lnstall the O-ring and fit the indicator on the serration so that it points to the lower line of the USABLE RANGE.
A Brake Shoes
B. Lift
e Before removing the brake cam lever, mark the position of the cam lever so that it can be installed later in the same position.
A. Indicator B. Lower Line
A. Brake Cam Lever
C. USABLE RANGE
e lnstall the cam lever in its original position on the camshaft, and tighten its bolt. .
BRAKES 10-13 Brake Camshaft Lubrication eDisassemble the drum brake. eUsing a high-flash point solvent, clean the old grease off the brake camshaft, camshaft hole, and other pivot points. *Replace the dram brake parts if they show wear or damage. eApply grease to the brake pivot points (brake shoe anchor pins and cam surface of the camshaft) and fill the camshaft groove with grease. Do not get any grease so that it does not get on the linings or drum after brake assembly.
ORemove the seal of the brake pedal cable and take off the cable from the frame. ORemove the cotter pin and the joint from the brake pedal.
o R,mo," the b"k, p,dal "bl,.
!
~
.~ ;---....
1. Cotter Pin 2. Joint
3. Seal
eTurn the adjuster at the rear end of the parking brake cable to give the cable plenty of play. eLoosen the knurled locknut at the parking brake lever and screw in the adjuster_ eLine up the slots in the brake lever, knurled locknut, and adjuster, and then free the cable from the lever.
1. Anchor Pins 2. Brake Camshaft
-: ..... -
Brake Pedal and Cables
. < .::- ~
......::::=:===:
......
Brake Pedal and Cable Removal This model does not have a brake cable equalizer and has a parking brake lever installed on the left side of the handle. eRemove the brake cables. oUnscrew the adjusters at the rear ends of the cables, and pull the cable out of the joints and cable mounts. Do not lose the joints and springs.
1. Adjuster 2. Knurled Locknut
3. Pull the cable. 4. Slots
oRemove the fenders. oRemove the parking brake cable.
Brake Pedal and Cable Installation
A. Adjusters B. Joints
C. Springs
eSince the brake pedal does not have a punch mark for alignment, just install the brake pedal on the brake pedal pivot shaft. eGrease the brake pedal pivot shaft and brake cable. eReplace the pivot shaft cotter pin with a new one. eRun the brake cables and vent hoses according to the Wiring, Cable, and Hose Routing in the General Information chapter. eAdjust the brake pedil and the parking brake (see Brake Adjustment in this chapter).
10-14 BRAKES Brake Cable Inspection . With the brake cable disconnected at both ends, the cable should move freely in the cable housing.
Brake Pedal and Cable Lubrication Refer to the Base Manual, noting the following . • Lubricate the parking brake cable or the brake pedal cable in accordance with the Periodic Maintenance Chart, or whenev er the cable is removed (see General Information chapter and General Lubrication in the Appendix chapter). o Use the pressure cable luber to lubricate the cable.
SUSPENSION 11·1
Suspension Table of Contents Exploded View ........................................... .
11-2
Specifications ............................... . ............ .
11-3
Special Tools ............................................. .
11-3
Suspension .............................................. .
11-4
Shock Absorber Spring Force Adjustment .................. .
11-4
Shock Absorber Removal ............................... .
11-4
Shock Absorber Installation ............................. .
*
Shock Absorber Assembly Note .......................... .
11-4
Front Suspension Arm Removal .......................... .
11-4
Front Suspension Arm I nstallation Note .................... .
11-4
Rear Suspension Arm (Rod) Removal ...................... . Rear Suspension Arm (Rod) Installation ....... . ............ .
11-4 11-5
Front Suspension Arm Disassembly ............. . ...... . .. .
11-5
Front or Rear Suspension Arm Assembly Notes .............. .
11-5
Shock Absorber and Suspension Arm Inspection ............. .
.*
*
Base Manual
[III
11-2 SUSPENSION E~~i~d~·V"i·~~·····
................................................
L : Apply non-permanent locking agent. R : Replacement Parts W : Apply water, or soap and water solution, T1 : 34 N-m T2: 88 N-m T3: 49 N-m T4: 52 N-m
(3.5 kg-m, 25 ft-Ib) (9.0 kg-m, 65 ft-Ib) (5.0 kg-m, 36 ft-Ib) (5.3 kg-m, 38 ft-Ib)
_© (1).)
I
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@
SUSPENSION 11-3 Specifications ..............................................................................
Outside Circlip Pliers: 57001-144
Refer to the Base Manual noting the following. Front Shock Absorber Spring Preload Standard setting position: No.2 Rear Shock Absorber Spring preload Standard setting position: No.2
Special Tools
Jack: 57001-1238
o Refer to the Base Manual noting the following additional tools. Wrench (Owner's tool): 92110·1040, or Steering Stem Nut Wrench (special tool): 57001-1100
Inside Circlip Pliers: 57001-143
Bearing Driver Set: 57001-1129
11-4 SUSPENSION Shock Absorber Assembly Note
Suspension
e Lubricate the rubber dampers with a soap and water solution when installing the rubber dampers.
Shock Absorber Spring Force Adjustment Refer to the Base Manual noting the following. oThe spring adjusting sleeve on the front and rear shock absorbers hCj.ve 3 positions so that the spring can be adjusted for different terrain and loading conditions. elf the spring action feels too soft or too stiff, adjust it in accordance with the following table. oTurn the adjusting sleeve on each shock absorber to the desired position with a wrench {Owner's tool or special tool}.
o Do not lubricate the rubber dampers with engine oil or petroleum distillates because they will deteriorate the rubbers. ePress the rubber dampers in using a suitable bearing driver in the bearing driver set {special tool: PN 57001-1129}.
Spring Action Position
Spring Force
1
2 (STD)
3
1
Stronger
Setting
Load
Terrain
, Speed
Soft
Light
Good
Low
1! r !
Hard
Heavy
Bad
High
Front Suspension Arm Removal eRemove the following parts. Steering. Knuckle {see Steering Knuckle Removal in the Steering chapter} Brake Hose eRemove the upper suspension arm by taking off the , pivot bolts. , eRemove the lower suspension arm
by
taking off the
pivot bolts. eRepeat the same procedure on the other side of the vehicle.
Front Suspension Arm Installation Note: elnstallation' is the reverse of removal. Note the following. eRefer to each chapter for the following parts installation. Steering Knuckle (see Steering Knuckle Installation in the Steering chapter) Brake Hose (see Wiring, Cable, or Hose Routing in the General Information chapter) elnstall the front suspension arms so that each "F" mark faces upward and forward. A. Adjusting Sleeve (Front Shock shown) B. Wrench (Owner's tool): 92110-1040, or Steering Stem Nut Wrench {special tool}: 57001-1100
Fmnt~
eCheck to see that each pair of adjusting sleeves (front two adjusting sleeves or rear two) are turned to the same relative position.
WARNING. o If a pair of adjusting sleeves (front two adjusting sleeves or rear two) are not adjusted equally, handling may be impaired and a hazardous condition may
result.
1. "F" mark
Shock Absorber Removal
Rear Suspension Arm (Rod) Removal
Refer to the Base Manual, noting the following. eRemove the fenders to access the absorber.
Refer to Suspension Arm Removal in the Suspension chapter in the Base Manual.
SUSPENSION 11-5 Rear Suspension Arm (Rod) Installation
Front or Rear Suspension Arm Assembly Notes
OSuspension arm installation is the reverse of removal. Note the following. elnstall the center arms noting the installation direction. elnstall the left rear suspension arm so that the "F" mark faces upward and forward. Center Arm Installation
eWhen installing the rubber dampers into the arm, lubricate the outer surface of the dampers with a soap and water solution.
o Do not lubricate the rubber dampers with engine oil or petroleum distillates because they will deteriorate the rubbers.
~ I
ePosition the dampers in the front suspension arm as shown using a suitable bearing driver in the bearing driver set (special tool: PN57001·1129). Front Suspension Arm Bushing Installation
1. Slotted hole faces the front. 2. Longer bracket faces the front. 3. Suspension Arm "F" mark
2
Front Suspension Arm Disassembly eRemove the front suspension arm (see Front Suspension Arm Removal). -Remove the rubber bushings using a press and a suitable bearing driver in the bearing driver set (special tool: PN 57001-1129). -Holding the suspension arm with a vise, remove the circlip and unscrew the knuckle joint.
1. Rubber Bushings 2. Circlip
3. Knuckle Joint
not remove the knuckle joint boot. with grease.
000
It is packed
1. Arm 2. Bushing
3. 0.15 - 0.85 mm
STEERING 12-1
Steering Table of Contents Exploded View ........................................... .
12-2
Specification ............................................. .
12-3
Steering ................................................. .
12-3
Steering Stopper Adjustment ............................ .
12-3
Handlebar Removal .................................... .
12-3
Handlebar Installation .................................. .
12-3
Handlebar Grip Removal. ............................... '. Steering Stem Removal ................................. .
* * *
Steering Stem Installation ............................... .
12-4
Tie-Rod End or Steering Knuckle Joint Boot Inspection ........ .
12-4
Tie-Rod Removal ..................................... .
12-4
Tie-Rod End Installation Notes .............. . ............ .
12-5
Steering Knuckle Removal .............................. .
12-5
Steering Knuckle I nstallation Notes ....................... .
12-5
Steering Inspection .................................... .
* *
Handlebar Grip Installation ..................... . ........ .
Steering Stem Warp .................................... . Steering Stem Bearing, Tie-Rod Bearing, and Steering Knuckle Upper and Lower Joint Inspection
*.
*
Steering Knuckle Bearing Removal ........................ .
12-6
Steering Knuckle Bearing I nstallation Notes ................. .
12-6
Steering Knuckle Bearing Inspection ....................... .
12-6
Base Manual
I
~
I
12-2 STEERING
............................................................ Exploded View ...................
:
....... ................. :.................................. . A . Apply adhesive.
. ..•..•.••..•..•
G : Apply grease. L .· Ap p Iy non·permanent lock·
R : Replacement Parts
109 agent.
W : solut. Apply water ' or soa p and water Ion.
T1 T2': 20 N·m · 29 N-m T3: 41 N-m ~:~ 25 N·m · 88 N·m
(2 .0 k g-m, 14.5 ft-Ib) (3.0 kg-m, 22 ft·lb) (4 .2 k g-m, 30 ft-Ib) (2.5 kg-m, 18.0 ft-lb) (9.0 kg-m, 65 ft-lb)
T6: 27 N-m (2.8 kg·m, 20 ft·lb) T7 : 8.8 N-m (0.9 kg-m. 78 in·lb) ~: ~ 34 N-m (3.5 kg-m, 25 ft·lb) · 52 N·m (5.3 kg·m, 38 ft-Ib) T10: 49 N·m (5.0 kg-m, 36 ft-Ib)
G
@)
\
STEERING 12-3
Specification Steering Angle Right: Left:
Handlebar Removal e Remove the following parts from the handlebar. Left-Hand Switch Housing Parking Brake Lever Throttle Case Front Brake Master Cylinder eRemove the handlebar holder bolts and lift off the handlebar.
Steering Stopper Clearance Less than 1.0 mm
Handlebar Installation Steering
Steering Stopper Adjustment
eHandlebar installation is the reverse of removal. Note the following. elnstall the handlebar so that the angle of the handlebar matches the angle of the steering stem as shown.
eTurn the handlebar all the way to the left and adjust the right steering stopper bolt protrusion by adding or removing the shim. eWith the tie-rod arm stopper against the suspension arm stopper, the clearance between the stopper bolt and the frame stopper must be less than 1.0 mm.
A. Parallel
eTighten the holder rear bolts first and then the front bolts. When the holder is ~orrectly installed, there will be even gap at the front and no gap at the rear after tightening.
A. Suspension Arm Stopper
B. Tie-Rod Arm Stopper C. Clearance D. Steering Stopper Bolt E. Shim(s)
eTurn the handlebar all the way to the right and adjust the left stopper bolt in the same way.
A. Front B. Even Gap
C. No Gap
12-4 STEERING
Steering Stem Installation _Refer to the Base Manual noting the following. oWhen replacing the stem clamps, replace both clamps as a unit. eWipe all the old grease out of the steering stem, grease seals, and clamps_ eApply grease to the steering stem and pack the grease seal grooves between the lips with grease. Grease the mating surface of the clamp, also. elnstall the grease seal facing the end rearward to prevent the entry of dirt.
Tie-Rod End, or Steering Knuckle Joint Boot Inspection e!nspect each boot in accordance with the Periodic Maintenance Chart (see General Information chapter). *If tear, wear, deterioration, or grease leaking is found, replace the tie-rod end, or steering knuckle joint.
A. Joint Boots B. Knuckle Joints
A. Ribs and Grooves B. Ends
C. Clamp Mating Surface
C. Tie-Rod Ends
Tie-Rod Removal eRemove the front fender (see Frame chapter). eRemove the cotter pin and the tie-rod end nuts on both ends. eRemove the tie-rod.
eAlign the relief marks on the steering stem clamps.
A. Tie-Rod Ends
A. Marks
OWhen removing the tie-rod, be careful not to bend it. not loosen the locknuts at the end of the tie-rod adjusting sleeve, or the toe-in of the front wheels will be changed. 000 not remove the tie-rod end grease seal. It is packed with grease. 000
eRoute the cables, the wires, and the brake hose according to the Wiring, Cable, and Hose Routing section in the General Information chapter.
STEERING 12-5
Tie-Rod End Installation Notes -Check that the seal lip of the boot is on the shank. -Oil the bolt body.
-Remove the cotter pins, then remove the steering knuckle upper and lower joint nuts. -Tap the steering knuckle and remove it.
Tie-Rod End Installation
1. Boot Lip 2. Shank
3. Apply oil
A. Tap the steering knuckle.
B. Front Axle
Steering Knuckle Installation Notes OThe installation is the reverse of removal. Note the following. -Clean the sealing surfaces, and the tapered holes. -Grease the sealing surface.
Steering Knuckle Removal -Remove the following parts. Front Wheel Hub (see Wheels/Tires chapter in this text) Tie-Rod Arm Nuts Tie-Rod Arm Bolts ShOCK Absorber Lower Mounting Bolt and Nut
A. Sealing Surfaces
A. Tie-Rod Arm Bolts and Nuts
B. Tapered Hole
-Clean the shanks of the knuckle joint. -Check that the joint boot does not have tear, wear, deterioration, or grease leakage. -Check that the seal lip of the boot is on the sealing surface of the shanks as ~own.
12-6 STEERING Knuckle Joint Installation
Good
Not good
A. Bearing Driver Set: 57001-1129 B. Steering Knuckle
Steering Knuckle Bearing Installation Notes Installation is the reverse of removal. Note the following. ~ eThe marked side of the bearing faces outward. eGrease the lips of the new grease seals.
1. Shanks 2. Boot Lips
3. Grease here.
Steering Knuckle Bearing Inspection NOTE
eTighten the knuckle joint nuts to the specified torque (see Exploded View). elnsert the new cotter pin into the knuckle joint. eApply a non-permanent locking agent to the threads of the tie-rod arm bolts. eTighten the tie-rpd arm bolts and nuts to the specified torque (see Exploded View). elnsert the new cotter pins in the bolts_
oSince the bearings are packed with grease and sealed they can not be lubricated. eRemove the steering knuckle (see Knucle Removal). eTurn the bearing back and forth while checking for roughness or binding. *If roughness or binding is found, replace the bearing. eExamine the bearing seal for tears or leakage. *If the seal is torn or is leaking, replace the bearing.
!
Steering Knuckle Bearing Removal eRemove the knuckle (see Knuckle Removal). eRemove the following parts. Grease Seals Circlip eDrive the bearing out using a suitable bearing driver in the bearing driver set (PN: 57001-1129).
1. Bearing Seal
2. Turn
FRAME 13-1
Frame Table of Contents Exploded View .....•...................................... Seat .................................................... . Seat Removal ........................................ . Seat Installation ...................................... . Front and Rear Fenders .................................... . Front Fender Removal ................................. . Front Fender Installation Notes ......... . ................ Rear Fender Removal .................................. Rear Fender Installation Notes ........................... Frame Exchange .......................................... Suggested Parts Removal Order ........................... Suggested Parts Installation Order ................. .. ......
. . . . . .
Decals ....... " ......................................... . Decal Removal ....................................... . Decal Application ..................................... .
13-2 13-4 13-4 13-4 13-4 13-4 13-5 13-5 13-5
* * * * *
*'
~
I
* : Base Manual
13-2 FRAME E~~i:;d~·V·i·~~···················· · ····················
...........,
© Front Carrier
Rear Carrier
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FRAME 13-3
® : Australia Model (B) : UK Model
© : Canada Model
13-4 FRAME
............................................................................... .............................................................................
Seat
Front and Rear Fenders
Seat Removal
Front Fender Removal
-Pull the seat lock lever up.
-Remove the following parts. Seat (see Seat Removal) Fuel Tank Rear Cover (see Fuel System chapter) Fuel Tank Cap Front Carrier
WARNING
I
oGasoline is extremely flammable and can be explosive under certain conditions, Turn the ignition switch OFF. Do not smok~. Make sure the area is well ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light.
-Move the fuel tank front cover forward, then lift the cover.
A. Pull.
- Lift the rear- of the seat, slide it toward the rear slightly, and lift it off the vehicle.
Seat Installation -Slip the seat hook under the brace on the frame, and put the stoppers into the holes in the frame. A. Front Carrier Bolts
A. Brace B. Seat Hook
B. Fuel Tank Front Cover
C. Stoppers
D. Holes
-While pushing the rear part of the seat down, push the seat lock lever down until the lock clicks.
1. Fuel Tank Front Cover
-Install the fuel tank cap at once. ORemove the following mounting screws and bolts.
FRAME 13-5
Front Fender Installation Notes Olnstallation is the reverse of removal. eFit the tabs on the fuel tank covers in place. elnstall the mounting screws, bolts, nuts, and flanged collars in the original positions.
Rear Fender Removal. eRemove the following parts. Seat (see Seat Remoal) Rear Carrier Ten Rear Fender Mounting Bolts and Screws including the Bolts in the Storage Case A. Bolts
A. Four Mounting Bolts
B. Carrier
A. Mounting Bolts
.
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....... _. . . ~ .· . . . . ".... .. \a.
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.
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A. Two Mounting Bolts in the Storage Case B. Mounting Bolts C: Four Screws and Nuts eTake off the rear fender.
1/
A. Screws
Rear Fender Installation Notes
eTake off the front fender.
eRear fender installation is the reverse of removal. Note the following. el nstall the mounting screws, bolts, and nuts in the original positions (see Exploded View).
ELECTRICAL SYSTEM 14-1
Electrical System Table of Contents Precautions .. . . . . . . . . . . . . . . . . . . . . Exploded View . . ... . . . . . . . . . . .. ... Wiri ng Diagram . . . . . . . . . . . . . ....... Specifications . . . . . . . . . . ... . . ... ... Special Tools . . . . . . . . . . . . . . . ...... Battery .. .... . .... . . . .. .. .... . .. Precautions . . . . . . . . . . . . . . . . . . . . Battery Removal/Installation . . ... . ... Battery Removal. . . . . . . . . . . . . . . Battery Installation ... . . . . . . . . . . Electrolyte . . . . . . . . . . . . . . . . . . . . . Electrolyte Level Inspection .. .... . Battery Charging . .. .. . . . . . . . . . . . . Battery Condition ..... . . . ...... Battery Initial Charging . . . . . . . . .. Battery Ordinarily Charging . ....... Battery Test Charging . . . . . . . . . . . . Charging System .. . . . . . . . . . . . . .' .... Part Removal . . . . . . . . . . .. . ... . .. Alternator Rotor Removal . . . . . . . . Alternator Rotor Installation . ...... Alternator Stator Removal . . ...... Alternator Stator Installation . . ..... Charging System Checkout . . . . . . . . . . Charging System Operational Inspection . . . . . . . . . Stator Coil Resistance Inspection .... Rectifier Circuit Inspection . . . . . . . . Regulator Circuit Inspection ..... . . Ignition System .... .. . . . . . . . . . .. ... Safety Instructions . . . . . . . . .. ..... Part Removal . . . .. . . . . . . . . . . .... Engine Stop Switch Removal ....... Engine Stop Switch Installation ..... Ignition Coil Removal ... . .. ..... Ignition Coil Installation ... . . . .. .. Spark Plug Removal or Installation ... Pickup Coil Removal . . .. . .... . .. Pickup Coil Installation . . . . . . . . . . Ignition System Checkout . . . . . . . . . . . Ignition Timing Test . . . . . . . . . . . . Ignition Coil Inspection . . . . . . . . .. Spark Plug Cleaning and Inspection ... Spark Plug Gap . . . . . . . . . . . . . . . . IC Igniter Inspection .. .... .. . ... Pickup Coil Inspection ...... . .... Alternator Rotor Inspection .......
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
* 14-2 14-4 14-5 14-5 14-6
* 14-6
* 14-6
* * 14-6 14-6
* 14-6
* 14-6 14-6 14-6 14-8 *
* 14-8
* 14-8
* * 14-8
* 14-8
* * 14-8 14-8 14-9
* * 14-9 14-9 *
Electric Starter System .. . . . .... . ... . . . Part Removal .. . .... . .. . ... .. ... . Starter Motor Removal .. . .. . ..... . Starter Motor Installation . . . . . .... . Starter Motor Disassembly .. . . .... . Starter Mot or Assembly . . . . . . . . . . . Starter Button Removal .. . . . ..... . Starter Button Installation .... . ... . Starter System Checkout . . . . ....... . Starter Motor Brush Length ..... . .. . Starter Motor Brush Spring Tension .. . Starter Motor Commutator Inspection .. Starter Motor Armature Inspection ... . Brush Assembly Inspection ... . .... . Starter Relay Inspection .. . . ...... . Starter Circuit Relay Inspection ..... . Starter Button Inspection ... . . .... . Lighting System ... .. . . . . . . . . . . . . . . . Headlight Beam .. .. . . . . . . . . . . . . . . . Headlight Beam Vertical Adjustment .. . Bulb Replacement . . . . . . . . . . . . . . . . . Headlight Bulb Replacement . . . . . . . . Taillight Bulb Replacement ... . .... . Neutral and Reverse Indicator Light Bulb Replacement . ... ... ....... . Part. Removal '. . . . . • . . . . . . . ....... Light Switch Removal . . . . . . . . . . . . Light Switch Installation . . . . . . . . . . . Neutral and Reverse Switch Removal .. Neutral and Reverse Switch Installation .. . .. . . ..... . Ignition Switch . . . . . . . . ... . . . ...... . Ignition Switch Removal or Install ati on. . . . . . . . . . . . . . . . . . Switches . . .. ... .. .. .. .. .. . . ..... . Neutral and Reverse Switch Inspection . ..... . ..... . Ignition Switch, Light Switch, Engine Stop Switch, and Starter Button . . . . . . . . . . . . . Electrical Wiring . . . . . . . . . . . . ....... . Wiring Inspection .. . . . . . . . . . . .. .
*
* 14-9
* *
*
Base Manual
14-10
* * * * * * * * * * * * * * * * 14-11 14-11 14-11 14-11 14-11
* * * * * * * 14-11 14-11 14-11 14-11
14-12
*
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14-2 ELECTRICAL SYSTEM Exploded View
r:/ ~00 g
CW
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1. Pickup Coil 2. Regulator/Rectifier 3 . Neutral and Reverse Switch 4. Starter Relay 5. Starter Circuit Relay 6. IC Igniter 7. Light Switch and Engine Stop Switch 8. Ignition Switch T1 : 59 N-m (6.0 kg-m, 43 ft-Ib) T2: 14 N-m (1.4 kg-m, 10.0 ft-Ib) T3: 4.4 N-m (0.45 kg-m, 39 ft-Ib)
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ELECTRICAL SYSTEM 14-5
Specifications
Timing Light: 57001-1241
oThis tool may be used instead of the common tool. Refer to the Base Manual noting the following.
Battery 12 V 14 Ah Capacity: Specific gravity: 1.27 ±0.01 @20°C (6SoF) Electrolyte volume: 0.9L Charging System Battery charging coil resistance: 0.1 - 0.7 Q Ignition System Spark plug gap: 0.6 - 0.7 mm Spark plug cap resistance: 3.75 - 6.25 kQ IC igniter resistance: in this text Ignition coil resistance (with the spark plug cap removed) Primary winding: 1.8 - 2.8 Q Secondary winding: 10 - 16 kQ Pickup coil air gap: 0.9 mm
Coil Tester: 57001-1242
oThis tool may be used instead of the Kawasaki Electrotester (PN 57001-980).
Special Tools Spark Plug Wrench (Owner's Tool): 92110-1109 Outside Circlip Pliers: 57001-144
Flywheel Puller: 57001-1191
Hand Tester: 57001-1394
Rotor Puller: 57001-1099 or 1216
14-6 ELECTRICAL SYSTEM
............................................................................. Battery
Charging System
Battery Removal/Installation: Battery Installation
Part Removal: Altern§1tor Rotor Removal
Refer to the Base Manual noting the following. -Install the battery so that the terminal side faces the front. -Route the battery vent hose and wiring according to the Wiring, Cable, or Hose Routing section in the General Information chapter.
-Remove the left engine cover (see Left Engine Cover Removal in the Engine Left Side chapter). -Thread the flywheel puller (special tool: 57001-1191 and rotor puller (special tool: 57001-1099) onto the alternator rotor. -Holding the flywheel puller, turn the rotor puller until the alternator rotor is forced off the end of the crankshaft.
.............................................................................
I WARNING I o Keep the battery vent hose outlet away from the frame and brake system components. Battery electrolyte will corrode and weaken them. Do not let the vent hose become folded, pinched, or melted by the exhaust system. An unvented battery will not keep a charge and it may crack from built-up gas pressure.
Battery Charging: Battery Condition ORefer to the Base Manual noting the following. *If the specific gravity is below 1.200, the battery needs t9 be charged. 1. Flywheel Puller: 57001-1191 2. Rotor Puller: 57001-1099 or 1216
Battery Ordinary Charging o Refer to the Base Manual noting the following. -Set the charging rate and time ~ccording to the battery condition previously determined (see Battery Condition), using the table.
Olf the rotor is difficult to remove and a hammer is used to tap the rotor puller, be careful not to strike the alternator rotor itself. Striking the rotor can cause the magnets to lose their magnetism.
Battery Charging Rate/TIme Table (12V 14Ah) 1.270 Fully Charged
.....:;>-
-'"
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to: .y
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1.27 1.24 1.20 1.16 1.12 1.08 1.04 1.00
at 1A charge rate
!..1~
- Sample - - - - - - - - -
I
:...................•................. :~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ :~ :~ :~ :~ :~ :~ :~ :~ :~ :~ :~ :~ :~: ~ :~ :~ :~ :~ :~ :~; i ~ 14".5: f: ~: ~: ~: ~: ::::::1·.080' ::::.: :::::::::::::::: r .Ii<>~~s.. . . . . . . . ... Totally Discharged .. .
::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::.:.. ::.:.:.: .. ::!:::::::::::::::::::::::::::::::::::::::::::: 15
10
5
at 2A charge rate
3
at 3A charge rate
2
at 4A charge rate
~-~~~~~~~
20 21
5 3
4
2 3 Hours of Charging Time at Rates Shown
5
4
9
10.5
6
7
5.3
ELECTRICAL SYSTEM 14-7 Charging and Lighting Circuit
BR
BR
ON
OFF
CD1
W
w
W
'O--~~~~~--~~--4---------------------, BK/V
a:
>
III
> M2
M3
B
6 Pin Connector
>
>
CJ
...I
~ CJ
~
~
III
b!
@
N
OFF:t @)
R/BK R/BK
> ..... a: BK/Y
BK/V
1. 2. 3. 4. 5.
Ignition Switch Reverse Indicator Light Neutral Indicator Light Neutral and Reverse Switch Alternator
6. Regulator/Rectifier 7. Diodes 8. Thyristers 9. Control Unit 10.30AFuse
A. Neutral and Reverse J ndicator Light Connectors B. Switch Connector
A. Regulator/Rectifier
11. 12. 13. 14. 15.
BK/V
Headlights Light Switch Speedometer Light ( ® Working Light (option) Taillights
®)
14-8 ELECTRICAL SYSTEM
Alternator Rotor Installation eAlternator rotor installation is the reverse of removal. Note the following. ec:lean the inside of the rotor and the end of the crankshaft thoroughly or the taper will not fit snugly. eFit the rotor onto the crankshaft so that the woodruff key fits in the groove in the hub of the rotor. elnstall the left engine cover (see Left Engine Cover Installation in the Engine Left Side chapter) . eClean the alternator bolt. eTighten the alternator rotor bolt to the specified torque (see Exploded View).
Ignition System Part Removal: Ignition Coil Removal eRemove the fuel tank (see Fuel System chapter in this manual). ePull the spark plug lead off the spark plug. eDisconnect G/W lead and Y/R lead from the coil. eTake off the nuts and remove the coil.
Charging System Checkout: Stator Coil Resistance Inspection • • • •
Remove the seat (see Frame chapter). Disconnect the alternator connectors. Measure the stator coil resistance. Connect the hand tester (special tool: PN 57001 -1394) between the yellow leads. o Set the hand tester to x 1 n range, and read the tester.
Stator Coil Resistance 0.1-0.7 Q
A. Ignition Coil
B. Front
Ignition Coil Installation Refer to the Base Manual noting the following.
Fuel Tank Bracket
<=Jt
\ \
.
\
\\
\0
)
c. G/W Lead
A. Front B. Y/R Lead 1 . Alternator Connectors
*If the tester does not read as specified, replace the alternator stator. * If the coil has normal resistance, but the voltage inspect showed the alternator to be defective; then the rotor magnets have probably weakened, and the rotor must be replaced.
Polarity of Ignition Coil
(-)
~
II I
~ ~
L ___
Connect
~_8~~~- green/white lead G)~connect
yellow/red lead
EL ECTRICAL SYSTEM 14-9 Spark Plug Removal or Installation
Ie Igniter Inspection
-Remove or install the spark plug using the spark plug wrench (e.g. owner's tool) from the vehicle right side. -Tighten the spark plug to the specified torque (see Exploded View).
o Refer to the Base Manual noting the following. - Set the hand tester (special tool) to the x 1 kQ range.
IC Igniter Resistance*
Tester Positive (+) Lead Connection
Range xl kU "0
G/W
"'c:
"'0 0>-
00
00
00
BK/W
1- 5
1 - 10
BL
50 150
(BK/W)
*
00
~ 1 - 10
1-<>
A. Spark Plug Wrench (Owner's Tool): 92110-1109
(BK/W)
5 - 15
~O>
~o
BL
Y/R
Zti
o>c: "c:
BK/W
~
0>
~
Yj R
G/W
'" .J 0>
I
Unit: kU
1- 5
00
~ 50150
1 - 10
0
00
00
I~ 00
1 - 10 0 50150
i~
Measure with the Kawasaki Hand Tester (PN 570011394). A tester other than the Kawasaki Hand Tester may show slightly different readings.
IC Igniter Terminal
Ignition System Checkout: Ignition Timing Test -Remove the ignition timing inspection plug. - Attach the timing light (special tool : PN 57001-1241) and a tachometer in the manner prescribed by the manufacturer. - Start the engine and aim the t iming light at the timing light mark on the alternator rotor. - Run the engine at the speeds specified and note the alignment of the timing marks.
A. Advanced Mark B. F Mark
C. Top Mark D. Timing Inspection Hole
Y/R
$
(BK/W)
BL
A. IC Igniter Connectors
G/W
14-10 ELECTRICAL SYSTEM Ignition System Circuit
BKjY
Y/R
fK/W BL
Q)
:::
- -::: oc
ON
ON
U
>-
0)'
OFF
a
@
(?FF
:::CJ>
~-I 0)0)
~
0)
CD
,l
<..:)
@ 1. 2. 3. 4.
Electric Starter System
7
Battery 30A Fuse Ignition Switch Engine Stop Switch
5. 6. 7. 8.
Pickup Coil Igniter Ignition Coil Spark Plug
Refer to the Base Manual, noting the following. Electric Starter Circuit
CD
~-----W ----~[>O---w--'"
~\ OFF TON
®
a::
a:I
~
a::
Ir
L---,CDr--_--,IIl.--_.... r;J....., y fR
G; ~
CD
a::
~ To igniter
a::
III
>OFF
T 1. Ignition Switch 2. Starter Circuit Relay 3. 30 A Fuse
RUN
o @
® 4. Starter Button 5. Engine Stop Switch 6. Neutral Switch
7. Starter Motor 8. Starter Relay 9. Battery
ELECTRICAL SYSTEM 14-11 Lighting System Headlight Beam:
Headlight Beam Vertical Adjustment NOTE
o Turning
the adjusting screw clockwise lowers the headlight beam.
A. Bulb Socket
-Install the new bulb.
A. Adjusting Screw
Ignition Switch NOTE
oOn high beam, the brightest point should be slightly below horizontal with the vehicle on its wheels and the rider seated. Adjust both headlights to the same angle.
Ignition Switch Removal or Installation o Refer to the Base Manual noting that the rubber damper and the bracket are not on the model.
Switches
Neutral and Reverse Switch Inspection o Refer to the Base Manual noting the following. -Remove the seat for switch connector access.
Bulb Replacement:
Headlight Bulb Replacement -Unscrew the adjusting screw. -Unhook the tab from the stop and drop out the unit. -Slide back the dust cover and remove the bulb socket from the headlight unit.
Neutral and Reverse Switch inspection
Gear Position 1 st through 5th Neutral Reverse
G
Ground
RjW
14-12 ELECTRICAL SYSTEM
Ignition Switch, Light Switch, Engine Stop Switch, and Starter Button Inspection -Refer to the Base Manual noting the following. -Remove the fuel tank rear cover (see Fuel Tank Removal in the Fuel System chapter in this manual). -Unfasten the upper strap of the vinyl cover and open the velcro.
Engine Stop Switch Connections
Y/R
BR
OFF RUN To Starter Button
Starter Button Connections
BK Pushed Released To En gine Sto p
A. Strap
B. Vinyl Cover
A. Ignition Switch Connectors: BR, W B. Light Switch, Engine Stop Switch, and Starter Button Connector
Ignition Switch Connections
W
BR
OFF
c
ON
Light Switch Connections
R OFF LO HI
BR
R/Y
R/BK
Y/R
APPENDIX 15-1
Appendix Table of Contents Considerations for Various Riding Conditions.................... .
15-2
Carburetor ............................................. .
15-2
Spark Plug ............................................. .
15-2
Spark Plug Inspection .................................. .
15-3
Troubleshooting Guide ..................................... .
15-4
General Lubrication ....................................... .
15-7
Lubrication .......................................... .
15-7
Bolt and Nut Tightening .................................... .
15-8
Tightness Inspection ................................... .
15-8
Unit Conversion Table ...................................... .
*
* : Base Manual
15-2 APPENDIX Considerations for Various Riding Conditions
Spark Plug
This vehicle has been designed and manufactured to operate under a wide range of riding conditions. However, it is not feasible to anticipate all of the conditions under which this vehicle might be used. Extremes of temperature, altitude, and riding usage may make changing some carburetor parts or the spark plug desirable to maintain the vehicle in peak operating condition.
Carburetor: Sometimes an alteration may be desirable for good performance under different riding conditions when proper mixture is not obtained after the carburetor has been properly adjusted, and all parts cleaned and found to be functioning properly. If the engine still exhibits symptoms of overly rich or lean carburetion after all maintenance and adjustments are correctly performed, the main jet can be replaced with a smaller or larger one. A smaller numbered jet gives a leaner mixture and a larger numbered jet a richer mixture.
Reach
Plug gap
1. Terminal 2. Insulator 3. Cement
4. Gasket 5. Center Electrode 6. Side Electrode
Spark Plug: The spark plug ignites the fuel and air mixture in the combustion chamber. To do this effectively and at the proper time, the correct spark plug must be used, and the spark plug must be kept clean and the gap adjusted. Tests have shown the plug listed in the General Information chapter to be the best plug for general use. Since spark plug requirements change with the ignition and carburetion adjustments and with riding conditions, whether or not a spark plug of the correct heat range is used should be determined by removing and inspecting the plug. When a plug of the correct heat range is being used, the electrodes will stay hot enough to keep all the carbon burned off, but cool enough to keep from damaging the engine and the plug itself. This temperature is about 400 - 800°C (750 - 1 ,450°F) and can be judged by noting the condition and color of the ceramic insulator around the center electrode. If the ceramic is clean and of a light brown color, the plug is operating at the right temperature.
A spark plug for higher operating temperatures sometimes may be needed for severe conditions, such as continuous high-speed riding, or towing heavy loads. Such a plug is designed for better cooling efficiency so that it will not overheat and thus is often called a "colder" plug. If a spark plug with too high a heat range is used - that is, a "cold" plug that cools itself too well, - the plug will stay too cool to burn off the carbon, and the carbon will collect on the electrodes and the ceramic insulator. The carbon on the electrodes conducts electricity, and can short the center electrode to ground by either coating the ceramic insulator or bridging across the gap. Such a short will prevent an effective spark. Carbon build-up on the plug can also cause other troubles. It can heat up red-hot and cause preignition and knocking, which may eventually burn a hole in the top of the piston.
APPENDIX 15-3 Spark Plug Condition
Carbon Fouling
Oil Fouling
Spark Plug InsPeG.tion
Overheating
Standard Spark Plug Threads
eRemove the spark plug and inspect the ceramic insulator. *Whether or not the right temperature plug is being used can be ascertained by noting the condition of the ceramic insulator around the electrode. A light brown color indicates the correct plug is being used. If the ceramic is black, it indicates that the plug is firing at too Iowa temperature, so the next hotter type should be used instead. If the ceramic is white, the plug is operating at too high a temperature and it should be replaced with the next colder type.
o If the spark plug is replaced with a type other than the standard plug, make certain the replacement plug has the same thread pitch and reach (length of threaded portion) and the same insulator type (regular type or projected type) as the standard plug. Olf the plug reach is too short, carbon will build up on the plug hole threads in the cylinder head, causing overheating and making it very difficult to insert the correct spark plug later. o If the reach is too long, carbon will build up on the exposed spark plug threads causing overheating, preignition, and possibly burning a hole in the piston top. In addition, it may be impossible to remove the plug without damaging the cylinder head. Plug Reach
Too Short
Normal Operation
Correct Reach
Diameter: Pitch: Reach:
12 mm 1.25 mm 19.0 mm
NOTE
o The heat range of the spark plug functions like a thermostat for the engine. Using the wrong type of spark plug can make the engine run too hot (resulting in engine damage) or too cold (with poor performance, misfiring and stalling).
15-4 APPENDIX
............................................................................. Troubleshooting Guide
............................................................................. NOTE
OThis is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties.
Engine Doesn't Start, Starting Difficulty Recoi,1 starter n,ot operating Recoil starter springs broken Recoil starter pawl not engaging Starter motor not rotating Neutral switch trouble Starter motor trouble Battery voltage low Relays not contacting or operating Starter button not contacting Wiring open or shorted Ignition switch trouble Engine stop switch trouble Fuse blown Starter motor rotating but engine doesn't turn over Starter motor clutch trouble Engine won't turn over Valve seizure Rocker arm seizure Cylinder, piston seizure Crankshaft seizure Connecting rod small end seizure Connecting rod big end seizure Transmission gear or bearing seizure Camshaft seizure Balancer bearing seizure No fuel flow Tank air vent obstructed Fuel tap clogged Fuel line clogged Float valve clogged Engine flooded Fuel level too high Float valve worn or stuck open Starting technique faulty (When flooded, crank with the throttle fully open to allow more air to reach the engine.) No spark; spark weak Spark plug dirty, broken, or maladjusted Spark plug cap or spark plug lead trouble Spark plug cap not in good contact Spark plug incorrect Pickup coil trouble IC igniter trouble Ignition coil trouble Battery voltage low Ignition or engine stop switch shorted Wiring shorted or open Compression low Spark plug loose Cylinder head not sufficiently tightened down
No valve clearance Cylinder, piston worn Piston rings bad (worn, weak, broken, or sticking) Piston ring/land clearance excessive Cylinder head gasket damaged Cylinder head warped Valve spring broken or weak Valve not seating properly (valve bent, worn, or carbon accumulation on the seating surface)
Poor Running at Low Speed Spark weak Spark plug dirty, broken, or maladjusted Spark plug cap or spark plug lead trouble Spark plug cap shorted or not in good contact Spark plug incorrect IC igniter trouble Pickup coil trouble Ignition coil trouble Battery voltage low Fuel/air mixture incorrect Pilot screw and/or idle adjusting screw maladjusted Pilot jet, or air passage clogged Starter plunger stuck open Air cleaner clogged, poorly seated, or missing Fuel level too high or too low Fuel tank air vent obstructed Carburetor holder loose Air cleaner duct loose Compression low Spark plug loose Cylinder head not sufficiently tightened down No valve clearance Cylinder, piston worn Piston rings bad (worn, weak, broken, or sticking) Piston ring/land clearance excessive Cylinder head gasket damaged Cylinder head warped Valve spring broken or weak Valve not seating properly (valve bent, worn, or carbon accumulation on the seating surface) Other Vacuum piston doesn't slide smoothly Engine oil viscosity too high Brake dragging Front or rear final gear case oil viscosity too high
Poor Running or No Power at High Speed Firing incorrect Spark plug dirty, broken, or maladjusted Spark plug cap or spark plug lead trouble Spark plug cap shorted or not in good contact Spark plug incorrect Pickup coil trouble IC igniter trouble Ignition coil trouble Fuel/air mixture incorrect Main jet clogged or wrong size Jet needle or needle jet worn
APPENDIX 15·5 Air jet clogged Bleed hole of air bleed pipe or needle jet clogged Fuel level too high or too low Air cleaner clogged, poorly seated, or missing Starter plunger stuck open Water or foreign matter in fuel Carburetor holder loose Air cleaner duct loose Fuel tank air vent obstructed Fuel line clogged Fuel tap clogged Compression low Spark plug loose Cylinder head not sufficiently tightened down No valve clearance Cylinder, piston worn Piston rings bad (worn, weak, broken, or sticking) Piston ring/land clearance excessive Cylinder head gasket damaged Cylinder head warped Valve spring broken or weak Valve not seating properly (valve bent, worn or carbon accumulation on the seating surface.) Knocking Carbon built up in combustion chamber Fuel poor quality or incorrect Spark plug incorrect IC igniter trouble Miscellaneous Throttle valve won't fully open Vacuum piston doesn't slide smoothly Brake draggingClutch slipping Overheating Engine oil level too high Engine oil viscosity too high Front or rear final gear case oil viscosity too high
Overheating Firing incorrect Spark plug dirty, broken, or maladjusted Spark plug incorrect Ie igniter trouble Fuel/air mixture incorrect Main jet clogged Fuel level too low Carburetor holder loose Air cleaner poorly sealed, or missing Air cleaner duct loose Air cleaner clogged Compression high Carbon built up in combustion chamber Engine load faulty Clutch slipping Engine oil level too high Engine oil viscosity too high Drive train trouble Brake dragging Lubrication inadequate Engine oil level too low Engine oil poor quality or incorrect
Front or rear final gear case overheating Insufficient oil Bevel gears maladjusted LSD clutches in front final gear case maladjustment
Clutch Operation Faulty Clutch slipping Friction and/or steel plates worn or warped Clutch housing or shoe linings overworn or worn unevenly Clutch spring broken or weak Clutch release maladjusted Clutch release mechanislTl trouble Clutch hub or housing unevenly worn Clutch not disengaging properly Friction and/or steel plates warped or too rough Clutch spring compression uneven Clutch shoe spring broken or weak Engine oil deteriorated Engine oil viscosity too high Engine oil level too high Clutch housing frozen on crankshaft or drive shaft Clutch release mechanism trouble
Gear Shifting Faulty Doesn't go into gear; shift pedal doesn't return Clutch not disengaging Shift fork(s) bent or seized Gear(s) stuck on the shaft Shift return spring weak or broken Shift mechanism arm spring broken Shift return spring pin loose Shift drum positioning lever binding on pivot bolt Shift mechanism arm broken Shift drum damaged Jumps out of gear Shift fork(s) worn Gear groove(s) worn Gear dogs, dog recesses, and/or dog holes worn Shift drum groove(s) worn Shift drum positioning -lever spring weak or broken Shift fork guide pin(s) worn Shift mechanism arm spring weak or broken Drive shaft, output shaft,and/or gear splines worn Overshifts Shift drum positioning lever spring weak or broken Shift mechanism arm spring weak or broken
Abnormal Engine Noise Knocking IC igniter trouble Carbon built up in combustion chamber Fuel poor quality or incorrect Incorrect spark plug heat range Overheating Piston slap Cylinder/piston clearance excessive Cylinder, piston worn Connecting rod bent Piston pin, piston holes worn
15-6 APPENDIX Valve noise Valve clearance incorrect Valve spring broken or weak Camshaft bearing worn Other noise Connecting rod small end clearance excessive Connecting rod big end clearance excessive Piston ring(s) worn, broken or stuck Piston seizure damage Cylinder head gasket leaking Exhaust pipe leaking at cylinder head connection Crankshaft runout excessive Engine mount(s) loose Crankshaft bearings worn Primary gear worn or chipped Camshaft chain tensioner trouble Camshaft chain, sprocket, guides worn Balancer bearing worn Balancer gear worn or chipped
Abnormal Drive Train Noise Clutch noise Clutch housing and/or hub damaged Transmission noise Bearings worn Transmission gears worn or chipped Metal chips jammed in gear teeth Engine oil insufficient or too thin Front or rear· final gear case noise: Insufficient lubricant Incorrect oil (Front final gear case) Bevel gear bearings worn Bevel gears' worn or chipped Bevel gears maladjusted Worn clutch friction plate (Front final gear case) Worn clutch spring (Front final gear case) Thrust plug maladjusted (Rear final gear case) Damaged side gears or pinions (Front final gear case) Front Axle or propeller shaft noise Constant velocity universal joint damage
Abnormal Frame Noise Shock absorber noise Shock absorber damaged Brake noise Brake linings overworn or worn unevenly Drum worn unevenly or scored Brake spring(s) weak or broken Foreign matter in hub Brake not properly adjusted Other noise Brackets, nuts, bolts, etc. not properly mounted or tightened
Exhaust Smokes Excessively White smoke Piston oil ring worn Cylinder worn Valve oil seal damaged Valve guide worn
Cylinder head gasket damaged Engine oil level too high Black smoke Air cleaner clogged Main jet too large or fallen off starter plunger stuck open Fuel level too high Brown smoke Main jet too small Fuel level too low Air cleaner duct loose Air cleaner poorly sealed or missing
Handling and/or Stability Unsatisfactory Handlebar hard to turn: Tire air pressure too low Steering bearing damaged Steering bearing lubricant inadequate Steering stem 'bent Damaged steering knuckle joint Damaged tie-rod end LSD clutch maladjusted (front final gear case) Noise when turning Damaged side gear or pinion (Front final gear case) Worn clutch friction plates (Front gear case) Worn clutch spring (Front final gear case) Handlebar shakes or excessively vibrates Tire(s) worn Wheel rim(s) warped Rear axle runout excessive Wheel bearing(s) worn Handlebar mount(s) loose Steering stem nut and/or stem clamp bolt(s) loose Handlebar pulls to one side Frame bent Wheel maladjustment Suspension arm bent or twisted Steering stem bent Tie-rod bent Front or rear tire air pressure unbalanced Front or rear shock absorber unbalanced Shock absorption unsatisfactory Too hard: Tire air pressure too high Shock absorber maladjusted Too soft: Shock absorber oil leaking Shock absorber spring weak Tire air pressure too low Shock absorber maladjusted
Brakes Don't Hold Front Brake Air in the barke line Brake fluid leak Brake fluid deteriorated Primary or secondary cup trouble Master cylinder scratched inside Brake not properly adjusted Pad overworn or worn unevenly
APPENDIX 15-7 Oil, grease on pads and disc Disc worn or warped Brake overheated Rear Brake Brake not properly adjusted Linings overworn or worn unevenly Drum worn unevenly or scored Oil, grease on lining and drum Dirt, water between lining and drum Overheated
General lubrication Lubrication eBefore lubricating each part, clean off any rusty spots with rust remover and wipe off any grease, oil, dirt, or grime. eLubricate the points listed below with indicated lubricant. NOTE
Battey Discharged Battery faulty (e.g., plates sulphated, shorted through sedimentation, electrolyte level too low) Battery leads making poor contact Load excessive (e.g., bulb of excessive wattage) Ignition switch trouble Regulator/Rectifier trouble Alternator trouble Wiring faulty
Battery Overcharged Regulator /Rectifier trouble Battery trouble
OWhenever the vehicle has been operated under wet or rainy conditions, or especially after using a high-pressure spray water, perform the general lubrication.
Cables: Lubricate with Motor Oil Brake Cables Throttle Cable Choke Cable Reverse Gear Cable
e Lubricate the cables by seeping the oil between the cable and housing. oThe cable may be lubricated by using a pressure cable luber with an aerosol cable lubricant.
Cable Lubrication
Slide Points: Lubricate with Grease Brake Cable Ends Throttle Cable Ends Reverse Cable Lower End Brake Lever Brake Pedal Pivot Shaft Throttle Lever Shaft Speedometer Cable
15-8 APPENDIX Bolt and Nut Tightening Tightness Inspection e<::heck the tightnes!i of the bolts and nuts listed here. Also, check to see that each cotter pin is in place and in good condition. *If there are · loose fasteners, retorque them to the specified torque following the specified tightening sequence. Refer to the appropriate chapter for torque specifications. If torque specifications are not listed in the appropriate chapter, see the basic torque table (see Torque and Locking Agent in the General Information chapter). For each fastener, first loosen it by }'2turn, then tighten it. *If cotter pins are damaged, replace them with new ones. 1. Front Propeller Shaft Joint Circlip
Bolts, Nuts, and Fasteners to be checked Wheels: Front Hub Nuts and Cotter Pins Rear Axle Nuts and Cotter Pins Wheel Nuts Brakes: Master Cylinder Clamp Allen Bolts Brake Lever Pivot Bolt Brake Lever Pivot Nut Caliper Mounting Bolts Brake Pedal Cotter Pin Steering/Suspension: Handlebar Clamp Bolts Stem Nut and Cotter Pin Stem Clamp Allen Bolts Stem Bearing Housing Bolts Tie-Rod End Nuts and Cotter Pins Tie-Rod Adjusting Sleeve Locknuts Shock Absorber Mounting Bolts and Nuts Suspension Arm Pivot Bolts Steering Knuckle Pivot Nuts and Cotter Pins Engine: Engine Mounting Bolts Engine Mounting Bracket Bolts Exhaust Pipe Holder Nuts Muffer Mounting Bolts Muffer. Clamp Bolt S~ift Pedal Bolt Final Drive (Front) Front Propeller Shaft Joint Circlip Others: Footpeg Mounting Bolts Grab Rail Mounting Bolts Throttle Case Clamp Screws Carrier Mountlng Bolts
SUPPLEMENT - 1990 -
1994 MODELS 16-1
Supplement -1990-1994 Models This supplement chapter contains only the information unique to the models covered. Read both this manual's front part (up to p. 15-8) and this chapter for complete information on proper service procedures.
Table of Contents
General Information. . . . • . . . . . . . • . • . . . . . . . . . . . . . . . . . . . • . . . . ..
16-2
Model Identification. . . . . . . . . . • . . . • . • . . . . . . . . . . . • . . . . . . . . .. 16-2 General Specifications. . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . . . . . . •.
16-4
Crankshaft/Transmission. . . . . . . . . . . . . . . . • . . . . . . . . . . . . . . • . . . . .. 16-8 Exploded View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . ..
16-8
Frame .... , ...... , .................••........... , . . . . .. . ..
16-8
Exploded View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
16-8
Wiring Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 16-9
16-2 SUPPLEMENT - 1990 -
General Information Model Identification
KL F300-C2/C2A
KLF300-C3
1994 MODELS
SUPPLEMENT - 1990 -
KLF300-C4
KLF300 - C5 / C6
1994 MODELS 16-3
16-4 SUPPLEMENT - 1990 -
1994 MODELS
General Specifications
®: Australia model © : Canada model
®:
UK model
(,.) : I dentical to left side.
@ : US model
Item
KLF300-C2/C2A
KLF300-C3
KLF300-C4
,. ,. ,. ,. ,. ,. ,.
,. ,. ,. ,. ,.
Dimensions: Overall length Overall width Overall height Wheelbase <;lr.ound clearance Seat height Dry weight Curb weight: Fr.ont Rear Fuel tank capacity
1 860 mm 1 100 mm 1 105 mm 1 200 mm 225 mm 805 mm 260 kg ® 261 kg 138.5 kg ® 139 kg 129.5 kg ® 130 kg 11 L, ® 8.2 L
Performance: Minimum turning radius
2.9m
,.
Engine: Type C.o.oling system B.ore and str.oke Displacement C.ompression rati.o Max imum h.orsep.ower
4-str.oke, SOHC, 1-cylinder Air c.o.oled 76.0 x 64.0 mm 290 mL 8.6 14.7 kW (20 PS) @6 500 r/min (rpm),
,. ,. ,. ,. ,. ,.
,. ,. ,.
@-
,.
261 kg 138.5 kg ® 139 kg 130.5 kg ® 130 kg
,. 23.6 N-m (2.4 kg-m, 17.3 ft-Ib) 5500 r/min (rpm), @ ,. Carburet.or, Keihin CVK32 Carbureti.on system ,. Electric starter & rec.oil starter Starting system ,. Battery and C.oil (transist.orized) Igniti.on system ,. Electr.onicallyadvanced Timing advance Fr.om 10° BTDC@2 000 r/min (rpm) Fr.om 10° BTDC @1 300 Igniti.on timing t.o 306 BTDC @3 200 r/min (rpm) r/min (rpm) t.o 30° BTDC @4 000 r/min (rpm) Spark plug NGK D8EA, ®®© NGK DR8ES-L NGK DR7EA, @ DR8EA, ®© DR8ES-L ,. 21° BTDC Open Valve timing: Inlet ,. 59° ABDC Cl.ose ,. Durati.on 260° ,. 56° BBDC Exhaust Open ,. 24° ATDC Cl.ose ,. Durati.on 260° ,. F.orced lubricati.on (wet sump) Lubricati.on system ,. Engine .oil: Grade SE .or SF class ,. SAE 10W-30, 10W-40, 10W-50, VisC.osity 20W-40, .or 20W-50 Capacity 2.2 L 2.4 L Maximum t.orque
,. ,.
,.
,. ,. ,.
,. ,. ,.
,. ,. ,.
,. ,. ,. ,.
,.
,.
,.
,.
,. ,. ,.
,.
Drive Train: Primary reducti.on Type System: Reducti.on rati.o Clutch type: Primary Sec.ondary
Gear 2.888 (78/27) . Aut.o centrifugal, wet Aut.o multi disc, wet
,.
,.
,. ,.
,. ,. ,.
,.
SUPPLEMENT - 1990 KLF300-C2/C2A, C3, C4
Item Transmission :
Final drive system:
Type Gear ratio:
1st 2nd 3rd 4th 5th Reverse
Type Reduction ratio
Overall drive ratio Front final gear case oil Rear final gear case oil:
High Low
Type Capacity Type Capacity
Frame: Type Caster (rake angle) Camber Trail Tread Front tire: Rear tire : Suspension :
Type Size Type Size Front Rear
Brake type :
1994 MODELS 16-5
Front Rear
Electrical Equipment: Battery Type Headlight: Bulb Taillight Type Alternator: Rated output
Front Rear
Type Wheel travel Type Wheel travel
10-speed plus reverse, constant mesh, return shift 3.090 (34 / 11) 1.928 (27 / 14) 1_368 (26/19) 1.000 (23/23) 0.769 (20/26) 3.072 (26/11 x 26/20) Shaft (four wheel drive) 5.416 (33 / 33 x 20116 x 39/9) 6.910 (37 / 29 x 20/ 16 x 39/ 9) High: 12.037 Low : 15.357 API GL-5 Hypoid gear oil for LSD SAE140 or SAE85W-140 0.25 L API GL-5 Hypoid gear oil SAE 90 (above 5°C, 41°F) or SAE 80 (below 5° C, 41° F) 0.2 L Double tubular 1.0° 0° @1 G 5mm 844mm 840mm Tubeless AT 24 x 8-11 Tubeless AT 24x 10-11 Double wishbone 110 mm Torque tube 120mm Disc (Hydraulic) x 2 Drum (Mechan ical, on Rightside) 12 V 14Ah Semi-sealed beam 12 V 25/25 W x 2 12V8Wx2 Three-phase AC 23_5 A @9 000 r/min (rpm), 14 V
Specifications are subject to change without notice, and may not apply to every country.
16-6 SUPPLEMENT - 1990 -
1994 MODELS
General Specifications
..............................................................................
®: Australia model ®: Europe model
@: @;
KLF300-CS/C6
Item Dimensions: Overall lengtr Overall width Overall height Wheelbase Ground clearance Seat height Dry weight Curb weight: Front Rear Fuel tank capacity Performance: Minimum turning radius Engine: Type Cool ing system Bore and stroke Displacement Compression ratio Maximum horsepower Maximum torque
1 860 mm 1120 mm, ®®® 1 210 mm 1 105 mm 1200mm 225mm 805mm 260 kg, ®®®263 kg, 261 kg 138.5 kg, ®®® 139 kg, 138.5 kg 129.5 kg, 132 kg, 130.5 kg 11 L
©
®®®
Exhaust
©
4-stroke, SOHC, l-cylinder Air cooled 76.0 x 64.0 mm 290mL 8.6 14.7 kW (20 PSI @6 500 r/min (rpm), @ 23.6 N-m (2.4 kg-m, 17.3 ft-Ib) 5500 r/min (rpm),
@-
Carburetor, Keihin CVK32 Electric starter & recoil starter Battery and coil (transistorized) Electronically advanced From 10° BTDC @1 300 r/min (rpm) to 30° BTDC @4 000 r/min (rpm) NGK D8EA, NGK DR8ES-L, DR7EA 21° BTDC 59° ABDC 260° 56° BBDC 24° ATDC 260° Forced lubrication (wet sump) SE or SF class SAE 10W-30, 10W-40, lOW-50, 20W-40, or 20W-50 2.4 L
®©
Inlet
©
2.9m
Carburetion system Starting system Ignition system Timing advance Ignition timing Spark plug Valve timing:
©: Canada model
UK model US model
Open Close Duration Open Close Duration
Lubrication system Engine oil: Grade Viscosity Capacity Drive Train: Primary reduction System: Type Reduction ratio Clutch type: Primary Secondary
Gear 2.888 (78/27) Auto centrifugal, wet Auto multi disc, wet
®®
SUPPLEMENT - 1990 Item Transmission: Type Gear ratio:
Final drive system:
KLF300-CS/C6 1st 2nd 3rd 4th 5th Reverse
Type Reduction ratio
High Low
Overall drive ratio Front final gear case oil
Type
Rear final gear case oil:
Capacity Type Capacity
Frame: Type Caster (rake angle) Camber Trail Tread Front tire: Rear tire: Suspension:
Type Size Type Size Front Rear
Brake type:
1994 MODELS 16-7
Front Rear
Type Wheel travel Type Wheel travel
Front Rear Electrical Equipment: Battery Headlight: Type Bulb Taillight Type Alternator: Rated output
10-speed plus reverse, constant mesh, return shift 3.090 (34111) 1.928 (27/14) 1.368 (26/19) 1.000 (23/23) 0.769 (20/26) 3.072 (26/11 x 26/20) Shaft (four wheel drive) 5.416 (33/33 x 20/16 x 39/9) 6_910 (37/29 x 20/16 x 39/9) High: 12_037 Low: 15.357 API GL-5 Hypoid gear oil for LSD SAE140 or SAE 85W-140 0.25 L, (C6) 0.40 L API GL-5 Hypoid gear oil SAE 90 (above 5°C, 41°F) or SAE 80 (below 5°C, 41° F) 0.2 L, 0.3 L, (C6) 0.3 L
®®®
Double tubular · 1.0° 0° @1 G 5mm 844mm 860mm Tubeless AT 24x 8-11 Tubeless AT 24 x 10-11 Double wishbone 110mm Torque tube 120mm Disc (Hydraulic) x 2 Drum (Mechanical, on Rightside) 12 V 19 Ah, (Q) 12 V 14 Ah Semi-sealed beam 12 V 25/25 W x 2 12V8Wx2 Three-phase AC 23.5 A @9 000 r/min (rpm), 14 V
Specifications are subject to change without notice, and may not apply to every country.
16-8 SUPPLEMENT - 1990 -
1994 MODELS
Crankshaft/Transmission Exploded View
........................................................................... . -
Refer to the front part of this manual, noting the following. On and after K LF300-C3
1. Reverse Knob and Cable Assembly
Frame Exploded View Refer to the front part of this manual, noting the following.
On and after KLF30o-C2
US, Canada Models On and After KLF300-C2
o
1. Foot Board Steps 2. Rear Fender Front Flaps
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(12048)
SUPPLEMENT - 1995 - 1998 MODELS 17-1
Supplement - 1995 - 1998 Models This supplement chapter contains only the information unique to the models covered. Read both this manual's front part (up to p.16-1 0) and this chapter for complete information on proper service procedures.
Table of Contents General Information .............................•............. 17-2 Model Identification· ...................................... 17-2 General Specifications .................................... 17-4 Wiring, Cable, and Hose Routing ........................... 17-6 Fuel System ............... · .... ··.·················.·····.··· 17-7 Exploded View· .......................................... 17-7 Specifications ............................................ 17-7 Engine Top End··············································· 17-8 Exploded View· .......................................... 17-8 Wheels{fires . .. .............................. ........... ..... 17-8 Specifications ............................................ 17-8 Final Drive ................................................... 17-9 Exploded View· .......................................... 17-9 Electrical System .. ........................ .. .... ... ..... .... 17-10 Exploded View· ........ . . ... .. .. .. ............ .. ........ 17-10 Ignition System . ................... ... . . .... .......... .. 17-10 Carburetor Heater· .............. . . ...... ................ 17-11 Wiring Diagram ....... ........ .. .... ... ....... ............... 17-12 Switch ...................................................... 17-16
17-2 SUPPLEMENT - 1995 - 1998 MODELS
General Information Model Identification KLF300-C7/C7A
KLF300-C8
SUPPLEMENT - 1995 - 1998 MODELS 17-3
KLF300- C9
17-4 SUPPLEMENT - 1995 - 1998 MODELS
General Specifications (A) : Australia model (E) : Europe model
(8) : UK model (U) : US model
(C) : Canada model
Items
KLF300-C7 -
Dimensions: Overall length Overall width Overall height Wheelbase Ground clearance Seat height Dry weight Curb weight: Front Rear Fuel tank capacity
1 860 mm 1 120 mm, (A)(B)(E) 1 210 mm 1 105mm 1 200 mm 225mm 805mm 260 kg, (A) (B) (E) 263 kg, (C)261 kg 138.5 kg , (A)(B)(E) 139 kg, (C) 138.5 kg 129.5 kg, (A)(B)(E) 132 kg, (C) 130.5 kg 11 L
Performance: Minimum turning radius
2.9 m
Engine: Type Cooling system Bore and stroke Displacement Compression ratio Maximum horsepower Maximum torque
4-stroke, SOHC, 1 -cylinder Air-cooled 76 .0 x 64.0 mm 290 mL 8.6 14.7 KW(20 PS) @6 500 r/ min(rpm), (U) 23.6 N-m(2.4 kg-m, 17.3 ft-Ib) @5 500 r/ min(rpm), (U) Carburetor, Keihin CVK34 Electric starter & recoil starter Battery and coil (transistorized) Electronically advanced From 10° BTDC @1 300 r/min(rpm) to 30° BTDC @4 000 r/min (rpm) NGK D8EA, (A)(C) NGK DR8ES-L, (B)(E) DR7EA
Carburetion system Starting system Ignition system Timing advance Ignition timing Spark plug Valve timing : Inlet:
Exhaust:
Open Close Duration Open Close Duration
21 ° (BTDC) 59° (ABDC) 260° 56°(BBDC) 24° (ATDC) 260° Forced lubrication(wet sump)
Grade Viscosity Capacity
SE,SF, or SG class SAE1 OW-30, 10W-40, 1 OW-50, 20W-40, or 20W-50 2.4 L
Lubrication system Engine oil :
SUPPLEMENT - 1995 - 1998 MODELS 17-5
Items
KLF300-C7-
Drive Train: Primary reduction system : Type Reduction ratio Clutch type: Primary Secondary Transmission: Type Gear ratios: 1st 2nd 3rd 4th 5th Reverse Final drive system: Type Reduction ratio: High Low Overall drive ratio Front final gear case oil: Type
Rear final gear case oil:
Capacity Type Capacity
Frame: Type Caster (rake angle) Camber Trail Tread:
Front tire: Rear tire: Suspension : Front: Rear: Brake type:
Front Rear Type Size Type Size Type Wheel travel Type Wheel travel
Front Rear
Electrical Equipment: Battery Type Headlight: Bulb Taillight Type Alternator: Rated output
Gear 2.888(78/27) Auto centrifugal, wet Auto multi disc, wet 1 O-speed plus reverse, constant mesh, return shift 3.090 (34/11 ) 1.928 (27/14) 1.368 (26/19) 1 .000 (23/23) 0.769 (20/26) 3.072 (26/11 x 26/20) Shaft (four wheel drive) 5.416 (33/33 x 20/16 x 39/9) 6.910 (37/29 x 20/16 x 39/9) High: 12.037 Low: 15.357 API GL-5 Hypoid gear oil for LSD SAE140 or SAE90W -140 0.40 L API GL-5 Hypoid gear oil SAE 90 (above 5°C, 41°F) or SAE80 (below 5°C, 41°F) 0.3 L Double tubuar 1.0° 00@1 G 5mm 844mm 860 mm Tubeless AT24 x 8-11 Tubeless AT24 x 10-11 Double wishbone 110 mm Torque tube 120 mm Disc (Hydraulic) x 2 Drum (Mechanical, on Rightside) 12V19Ah, (U) 12V14Ah Semi-sealed beam 12 V 25/25 W x 2 12 V 8W x 2 Three-phase AC 23.5 A @9 000 r/min (rpm), 14 V
Specifications are subject to change without notice, and may not apply to every country.
17-6 SUPPLEMENT - 1995 - 1998 MODELS
Wiring, Cable, and Hose Routing Breather Tube Assembly (KLF300-C10-, California Model)
6
I rI 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
Clamp (92037 -1181 ) Clamp (92170-1552) Clamp (92037 -1271 ) Tube (92059-1789, to Cylinder Head) Joint (59071 -1124) Tube (92191-1170, to Air Cleaner Assembly) Air Cleaner Assembly (11010-1622 ) Cylinder Head Cap Carburetor Install the clamp (92170-1552) so that the clearances between the tube and near parts are more than 5mm.
SUPPLEMENT - 1995 - 1998 MODELS 17-7
Fuel System Exploded View KLF300-C9 ....
,
.... KLF300-C7/C7A
ooo08~~
Specifications Item
Standard
Service Limit
Carburetor: Make, type Main jet Main air jet Needle jet Jet needle Pilot jet Pilot air jet Pilot screw Starter jet Service fuel level Float height Optional parts:
Keihin, CVK32 #125, #138 (KLF300- C9 ~, except CAl #50, #70 (KLF300-C9~, except CAl #6 N36W, N24G(KLF300-C9~) #38 #140 2118 turns out, 2 turns out (KLF300-C8~) #58, #65 (KLF300-C8~) 0.5 mm (below) ~ 1.5 mm (above) 17 ± 2mm Main jet Pilot jet Starter jet
Idle Speed Main Jet: Altitude:
(CA): California model
#120,122,128, 130 #132, 135,140, 142 (KLF300-C9~, except CAl #35,40 #60,62 #68, 70 (KLF300-C8~)
1300+ 50 r/min (rpm) 500
~
1500
1500
~
2500
2500
~
3500
3500
~
4500
#122 #135 #120 #132 #115 #128 #112 #125
-- - -- ------- - -- -- ---- -- -- --
(KLF300-C9-)
(92063-1073), (KLF300-C1 0- ,CAl (92063-1 014, KLF300 - C9~, except CAl (92063-1072), (92063-1076, KLF300-C9~, except CAl (92063 -1118), (92063 -1 074, KLF300-C9~, except CAl (92063 -1117), (92063 -1 069, KLF300-C9~, except CAl
- ---- -- -- ----
--- --
17-8 SUPPLEMENT - 1995 - 1998 MODELS
Engine Top End Exploded View
KLF300-C10-, California Model
WheelslTires Specifications
Wheel Alignment Caster: 1° (non-adjustable) Camber: 0° (non-adjustable) @lG Toe-in: 20 mm Standard Tires Front:
Rear:
AT 24 x 8-11 Dunlop KT962, KnobbylTrail Tubeless (U)Goodyear, Tracker MPlTraii Tubeless AT 24 x 10-11 Dunlop KT962, KnobbylTrail Tubeless (U)Goodyear, Tracke.r MPlTrail Tubeless
Tire Air Pressure (when cold) Front: 35 kPa (0.35 kg/cm 2 , 5 psi) 28 kPa (0.28 kg/cm 2 , 4 psi) Rear: Maximum Tire Air Pressure (to seat beads, when cold) Front: 250 kPa (2.5 kg/cm 2 , 36 psi) 250 kPa (2.5 kg/cm 2 , 36 psi) Rear: Maximum Vehicle Load: 195 kg (430 Ib) (U): UK model
SUPPLEMENT - 1995 - 1998 MODELS 17-9
Final Drive Exploded View
KLF300-C7-
17-10 SUPPLEMENT - 1995 - 1998 MODELS
Electrical System Exploded View KLF300-C7 -, UK Model
Ignition System (KLF300-C7A-, Europe Models) Ie Igniter Inspection
o Refer to the Base Manual noting the following . • Set the hand tester (special tool) to the x 1 kO range. IC Igniter Resistance·
Unit: kO
Tester Positive (+) Lead Connection
..
Range x1kO
BL
Y/R
R/W
G/W
(BK/W)
BK/W
BL
-
75 - 300
55 ,." 220
80,." 320
50,." 200
50,." 200
Y/R
75,." 300
-
3 ,." 12
5,." 22
2.5 ,." 11
2.5 ,." 11
R/W
50,." 200
2.5 ,." 11
-
1.8"" 7
0.4 ,." 1.6
0.4,." 1.6
G/W
00
00
00
-
00
00
(BK/W)
50,." 200
2.2,." 8.4
0.3,." 1.5
1.3,." 5.5
-
0
BK/W
50,." 200
2.2 ,." 8.4
0.3 ,." 1:5
1.3 - 5.5
0
-
•
Measure with the Kawasaki Hand Tester (PN 57001-1394). A tester other than the Kawasaki Hand Tester" may show slightly different read ings. •• Tester Negative ( - ) Lead Connection IC Igniter Terminal Y/R
R/W
BK/W
G/W
~
(BK/W)
BL
SUPPLEMENT - 1995 - 1998 MODELS 17-11 Carburetor Heater (KLF300-C7-, UK model) Control Unit Inspection • Remove the control unit. .Set the hand tester to the x 1 kG range and make the measurements shown in the table. If the tester readings are not as specified, replace the control unit.
B
*
Unit: kQ
Control Unit Resistance
Tester Positive (+) Lead Connection
.
1
2
3
4
5
1
-
7-28
00
6.5-28
17-80
2
00
-
00
00
00
-
3
6-26 9.5-40
4
4.4-19 1.4-6
00
-
6.5-28
5
13-60 10-45
00
6.5-28
-
A. Thermostatic Sensor
B. Thermostat
*If the tester does not read as specified, replace the sensor. Carburetor Thermostatic Sensor Resistance (Reference only)
Standard:
9.5-40 24-150
3.0 - 7.2 kn @12°C (53.6°F)
*: Tester Negative (-) Lead Connection
Carburetor Heater Inspection 3
• Disconnect the carburetor heater connector. • Using the hand tester, measure the resistance of the heater. • Connect the tester between the heater terminal and carburetor ground. If the tester does not read as specified, replace the heater.
*
Carburetor Heater Resistance
Standard:
Carburetor Thermostatic Sensor Inspection • Remove the carburetor thermostatic sensor. • Suspend the sensor in a container of water so that the temperature sensing projection and threaded portion are submerged . • Using the hand tester, measure the internal resistance of the sensor across the terminal and the body at the temperatures shown in the table.
NOTE
o The sensor and thermostat must not touch the container sides or bottom.
11- 20
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Front Brake light SWltch (Option)
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17-16 SUPPLEMENT -1995 -1998 MODELS
Switch
Switch Inspection • Using the hand tester, check to see that only connections shown in the table have continuity (about zero ohms) . o For the handlebar switches and ignition switch, refer to the tables in the wiring diagram. If the switch has an open or short, repair it or replace it with a new one. Special Tool- Hand Tester : 57001-1394
*
Front/Rear/Parking Brake Light Switch
BL
When front/parking brake lever is grasped or brake pedal is pushed down When front/parking brake lever or brake pedal is released
BR
- -
Horn Switch
- --
BKIY BKIW When Horn Switch is pushed When Horn Switch is released
SUPPLEMENT - 1999 MODEL 18-1
Supplement - 1999 Model Table of Contents Foreword ................ ... ... ... .......................... ......... ... ...... ... .. .......... ............................................ How to Use this Manual. ... .... ..... ...... .... .. .... ..... ... ......... .... ............ .. .. .. ........... .. ... .. . ...... ..... ..... General Information .. ..... .... ... .. . ..... .. ..... .... ... .. ........ .... .... ... .... ........ ...... ... .. ...... .. ...... .... ..... ..... .... General Specifications.. ... .... ......... ..... ... .... .... ... ... ........... .... ............................ ................ ..... . Final Drive.............................. .... .. ............... ...... .............. ... .... .... ......... ........ .... ...... ......... ........ Exploded View....................... ..... ...... .... ..... ... .......... ......... ..... ... .......... ...... .. ........... ...... ......... Brakes. ....... ..... ...... .... ... ... ..... .. ... .... ... ....... .... ... ......... .... ....... .. ............... ... ..... ..... .... .... .. ... ... ...... Exploded View (Canada Model) ............ ... ... ..... ... .... ..... .. ........ .... ..... ....... ...... .... ... ..... ...... ... .. Electrical System. ... ..... ... .... .... ... ... ............. ....... ..... .. .... .. .......... ...... .. ... ... ................ ... ..... .. ..... .. Exploded View.... ... ........ ............. .. ........ ..... .. ... ......... ... .... .. ... ...... ...... .... .. .. ...... ...... ......... ....... Charging System .... ....... ...... .. ..... ... ........... .... ....................................................................... Regulator/Rectifier Output Voltage Inspection ........... .......... ....... ... .. .. .... ...... ...... ....... .. ...... Alternator Inspection....... .................... .. ...... .. .. ..... .. ............... .... .... .... .... .. .................... .... .. Regulator/Rectifier Inspection............................ .. ................ ........ .... .... ............................. Wiring Diagram (U. S.A and Canada Models) .......... .. .... .. ...... ...... .......... .. .. ........................ .. Wiring Diagram (A ustralia Model)................ .... .. .... .. .. ... .................. .. .... ...... .. .... ........ .......... . Wiring Diagram (Europe and U.K. Models) .. .. ........ .. .... .. .. .. ...... .... .. .. ...................................
18-2 18-2 18-3 18-3 18-6 18-6 18-7 18-7 18-8 18-8 18-9 18-9 18-10 18-11 18-14 18-16 18-18
18-2 SUPPLEMENT - 1999 MODEL Foreword How to Use th is Manual This "Supplement 1999 Models" designed to be used in conjunction with the front part of this manual (up to 17-16) and/or Base Manual KLF300 Service Manual - Part No. 99924-1057-01 . The specifications and maintenance procedures described in this chapter are only those that are unique to the KLF300-C11 model. Complete and proper servicing of the KLF300-C11 model therefore requires mechanics to read both this chapter and the front of this manual.
SUPPLEMENT - 1999 MODEL 18-3 General Information General Specifications Item
KLF300-C11
Dimensions
Overall Length
1 860 mm
Overall Width
1 120 mm , (A) (B) (E) 1 210 mm
Overall Height
1 105 mm
Wheelbase
1 200 mm
Ground Clearance
225 mm
Seat Height
805 mm
Dry Weight
260 kg, (A) (B) (E) 263 kg, (C) 261 kg
Curb Weight: Front
138.5 kg, (A) (B) (E) 139 kg , (C) 138.5 kg
Rear
129.5 kg , (A) (B) (E) 132 kg , (C) 130.5 kg
Fuel Tank Capacity
11 L
Performance
Minimum Turning Radius
2.9 m
Engine
Type
4-stroke , SOHC , 1-cylinder
Cooling System
Air-cooled
Bore and Stroke
76.0 x 64.0 mm
Displacement
290 mL
Compression Ratio
8.6
Maximum Horsepower
14.7 kW (20 PS)
Maximum Torque
23.6 N·m (2.4 kgf·m, 17.3 ft·lb) @5 500 r/min (rpm), (U) -
Carburetion System
Carburetor, Keihin CVK34
Starting System
Electric starter & recoil starter
Ignition System
Battery and coil (transistorized)
Timing Advance
Electronically advanced
Ignition Timing
From 10° BTDC (rpm)
Spark Plug
NGK D8EA, (A) (C) NGK DR8ES-L, (B) (E) DR7EA
@
@1
6500 r/min (rpm) , (U)-
300 r/min (rpm) to 30° BTDC @4 000 r/min
Valve Timing: Inlet: Open
21 ° (BTDC)
Close
59° (ABDC)
Duration
260°
Exhaust: Open
56° (BBDC)
Close
24° (ATDC)
Duration
260°
Lubrication System
Forced lubrication (wet sump)
Engine Oil: Grade
SE, SF or SG class
Viscosity
SAE 10W-30 10W-40, 1OW-50, 20W-40, or 20W-50
Capacity
2.4 L
18-4 SUPPLEMENT - 1999 MODEL General Information Item
KLF300-C11
Drive Train Primary Reduction System: Type
Gear
Reduction Ratio
2.888 (78/27)
Clutch Type: Primary
Auto centrifugal, wet
Secondary
Auto multi disc, wet
Transmission: Type
10-speed plus reverse, constant mesh, return shift
Gear Ratio: 1st
3.090 (34/11)
2nd
1.928 (27/14)
3rd
1.368 (26/19)
4th
1.000 (23/23)
5th
0.769 (20/26)
Reverse
3.072 (26/11 x 26/20)
Final Drive System: Type
Shaft
Reduction ratio High
5.416 (33/33 x 20/16 x 39/9)
Low
6.910 (37/29 x 20/16 x 39/9)
Overall Drive Ratio:
High : 12.037, Low: 15.357
Front Final Gear Case Oil: Type
API GL-5 Hypoid gear oil for LSD SAE140 or SAE90W-140
Capacity
0.40 L
Rear Final Gear Case Oil : Type
API GL-5 Hypoid gear oil SAE90 (above 5°C, 41 °F) or SAE80 (below 5°C, 41 °F)
Capacity
0.3 L
Frame Type
Double tubular
Caster (Rake Angle)
1.0°
Chamber
0° @1 G
Trail
5 mm
Tread Front
844 mm
Rear
860 mm
Front Tire: Type
Tubeless
Size
AT 24 x 8-11
Rear Tire : Type
Tubeless
Size
AT 24 x 10-11
SUPPLEMENT - 1999 MODEL 18-5 General Information Item
KLF300-C11
Suspension : Front Type
Double wishbone
Wh eel Trave l
11 0 mm
Rear Type
Torque tube
Wheel Travel
120 mm
Brake Type: Front
Disc (Hydraulic) x 2
Rear
Drum (Mechanical, on Rightside)
Electrical Equipment Battery
12 V 19 Ah, (U) 12 V 14 Ah
Headlight: Type
Semi-sealed beam
Bulb
12 V 25/25 W (RH/LH)
Taillights: Bulb
12 V 8 W (RH/LH)
Tail/Brake Lights: Bulb
(C) 12 V 18/5 W (RH/LH)
Alternator: Type
Three-phased AC
Rated Output
23.5 A @9 000 r/min (rpm), 14 V
Specifications subject to change without notice, and may not apply to every country. A: Australia Model B: UK Model C: Canada Model E: Europe Model U: US Model
18-6 SUPPLEMENT - 1999 MODEL Final Drive Exploded View o
o Front Prope I I er Shaft G
Rear
Prope I I er
Shaft
HK02038BW4
1. G: R: T1:
Circlip Apply grease. Replacement Parts 34 N·m (3.5 kgf·m, 25 ft·lb)
A: KLF300-C11
C
SUPPLEMENT - 1999 MODEL 18-7 Brakes Exploded View (Canada Model)
HL02027BW4
1 . Brake Switch R: Replacement Parts Si: Apply silicone grease. T1: 1.0 N·m (0 .10 kgf·m, 9 in ·lb) T2: 5.9 N·m (0.60 kgf·m, 52 in·lb) T3: 1.2 N·m (0.12 kgf·m, 10 in·lb) T4: 8.8 N·m (0.90 kgf·m, 78 in·lb) T5: 25 N·m (2.5 kgf·m, 18 ft·lb) T6: 20 N·m (2 .0 kgf·m , 14.5 ft·lb)
C
18-8 SUPPLEMENT - 1999 MODEL Electrical System Exploded View
HP02058BW4
1. Regulator/Rectifier 2. Tail/Brake Light (Canada Model) 3. Bulb (12 V 18/5 W)
C
SUPPLEMENT - 1999 MODEL 18-9 Electrical System Charging System Regulator/Rectifier Output Voltage Inspection • Remove the seat (see Frame chapter). • Check the battery condition (see Battery section). • Warm up the engine to obtain actual alternator operating conditions. • Check that the ignition switch is turned off, and connect the hand tester to the battery terminal. Special Tool - Hand Tester: 57001-1394
• Start the engine, and note the voltage readings at various engine speeds with the headlight turned on and then turned off. The readings should show nearly battery voltage when the engine speed is low, and as the engine speed rises, the readings should also rise. But they must be kept under the specified voltage. Regulator/Rectifier Output Tester Range 25 V DC
Connections Tester (+) to
Tester (-) to
Battery (+)
Battery (-)
Reading 14-15V
• Turn off the ignition switch to stop the engine, and disconnect the hand tester. If the regulator/rectifier output voltage is kept between the values given in the table, the charging system is considered to be working normally. *If the output voltage is much higher than the values specified in the table, the regulator/rectifier is defective or the regulator/rectifier leads are loose or open. If the battery voltage does not rise as the engine speed increases, then the regulator/rectifier is defective or the alternator output is insufficient for the loads. Check the alternator and regulator/rectifier to determine which part is defective.
*
*
18-10 SUPPLEMENT - 1999 MODEL Electrical System Alternator Inspection There are three types of alternator failures: short, open (wire burned out), or loss in rotor magnetism. A short or open in one of the coil wires will result in either a low output, or no output at all. A loss in rotor magnetism, which may be caused by dropping or hitting the alternator, by leaving it near an electromagnetic field, or just by aging, will result in low output. • To check the alternator output voltage, do the following procedures. ODisconnect the alternator connector [A]. OConnect the hand tester as shown in the table. OStart the engine. ORun it at the rpm given in the table. ONote the voltage readings (total 3 measurements). Regulator/Rectifier Output Voltage Tester Range
250 V AC
Connections Tester (+)to
Tester (-) to
One black lead
Another black lead
Reading
39 - 59 V
* If the output voltage shows the value in the table, the alternator operates properly and the regulator/rectifier is damaged. A much lower reading than that given in the table indicates that the alternator is defective. • Check the stator coil resistance as follows. OStop the engine. ODisconnect the alternator connector. OConnect the hand tester as shown in the table. ONote the readings {total 3 measurement}. Stator Coil Resistance Tester Range x 1 0
Connections Tester (+) to
Tester (-) to
One black lead
Another black lead
Reading
0.33 - 0.49 0
*If there is more resistance than shown in the table, or no hand tester reading (infinity) for any two leads, the stator has an open lead and must be replaced. Much less than this resistance means the stator is shorted, and must be replaced. • Using the highest resistance range of the hand tester, measure the resistance between each of the black leads and chassis ground. *Any hand tester reading less than infinity (oo) indicates a short, necessitating stator replacement. *If the stator coils have normal resistance, but the voltage check showed the alternator to be defective; then the rotor magnetism has probably weakened, and the rotor must be replaced. Special Tool - Hand Tester: 57001-1394
SUPPLEMENT - 1999 MODEL 18-11 Electrical System Regulator/Rectifier Inspection Front Fender (see Frame chapter) Connectors [A] (disconnect) Bolts [B] and Regulator/Rectifier [C]
Rectifier Circuit Check • Check conductivity of the following pair of terminals. Rectifier Circuit Inspection
W/R-Y1, W/R-Y2, W/R-Y3 Tester connection r - - - - - - - - - - - - - - - - - l BK-Y1, BK-Y2 , BK-Y3
*The resistance should be low in one direction and more
than ten times as much in the other direction. If any two leads are low or high in both directions, the rectifier is defective and must be replaced.
HP09006BS 1
C
HP09018BSl
C
NOTE
o The
actual meter reading varies with the meter used and the individual rectifier, but generally speaking the lower reading should be from zero to one half the scale.
Regulator Circuit Check To test the regulator out of circuit, use three 12 V batteries and a test light (12 V 3 - 6 W bulb in a socket with leads).
CAUTION The test light works as an indicator and also a current limiter to protect the regulator/rectifier from excessive current. Do not use an ammeter instead of a test light. • Check to be sure the rectifier circuit is normal before continuing. Regulator Circuit Test-1st Step • Connect the test light and the 12 V battery to the regulator/rectifier as shown. • Check Y1, Y2, and Y3 terminal respectively. *If the test light turns on , the regulator/rectifier is defective. Replace it. *If the test light does not turn on , continue the test.
®: I I
I
18-12 SUPPLEMENT - 1999 MODEL Electrical System Regulator Circuit Test-2nd Step • Connect the test light and the 12 V battery in the same manner as specified in the "Regulator Circuit Test-1 st Step". • Apply 12 V to the BR terminal. • Check Y1 , Y2, and Y3 terminal respectively. *If the test light turns on, the regulator/rectifier is defective. Replace it. If the test light does not turn on, continue the test.
=>Ef----l@: I I
I
*
Regulator Circuit Test-3rd Step • Connect the test light and the 12 V battery in the same manner as specified in the "Regulator Circuit Test-1 st Step". • Momentarily apply 24 V to the BR terminal by adding a 12 V battery. • Check Y1, Y2, and Y3 terminals respectively.
HP09019BSl
C
HP09020BS l
C
=>Ef----l@: I I
I
CAUTION Do not apply more than 24 V to the regulator/rectifier and do not leave the 24 V applied for more than a few seconds, or the until will be damaged.
* If the test light did not light when the 24 V was applied momentarily to the BR terminal, the regulator/rectifier is defective. Replace it. *If the regulator/rectifier passes all of the tests described , it may still be defective. If the charging system still dose not work properly after checking all of the components and the battery, test the regulator/rectifier by replacing it with a known good unit.
SUPPLEMENT - 1999 MODEL 18-13 Electrical System Charging System Circu it
CD R @ = BW
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1. Ignition Switch 2 . Alternator 3. Regulator/Rectifier 4. Battery 5. Main Fuse 30 A 6. Load
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18-14 SUPPLEMENT - 1999 MODEL Electrical System Wiring Diagram (U.S.A and Canada Models)
G)Reverse
Indicator
Lig ht
12V3.4W
®N e u t r a I
Indica tor
Lig ht
12V3.4W
,--------, I
Wo r k L i g h t 12 V6 5I 60 W ( 0 P) 1
I
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I
R/ B K -{::~R
~- R I Y -{:::
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Y
/ BK
R I Y- - - + 4 B K I Y - - -+-+-+-1-+-+-+--+-------..- + - - - - -- - - - - + 4- - -
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I fleadl ight 12V25/25W (L fl)
>- >- >-
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Left
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Switch Switch
But ton
LEFT HANDLEBAR SWITCH CONNECTIONS L i ght / D i mme r Color
OFF
R/ y
R
Sw it ch Engine Stop Switch Starter Button R/ BK
BR
Color
BR
Y / R Color
OFF
LO HI
Push
RUN
Y/ R
BK
Re I eased
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W1L1762BW5
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SUPPLEMENT - 1999 MODEL 18-15 Electrical System
Canada
Model
( OP )
Canada
Model
I
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II
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( Canada
I Tail
Model )
L igh t ( LH )( R H )
-12 V 8 W
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( U . S . A.
~_R_ _ _ ~
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--------~~~------------------_r----+-r__r--~---------- w --------_.
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Spa rk
Starter Ci rc uit Relay
Plug
~~~
Starter Mot 0 r
Color Code BK BL BR G GY LB LG I GN I TI ON SW I TCH CONNECT IONS
Color
OFF ON
BR
W
NEUTR AL & REVER SE SW I TCH CONNE CT I ONS
Gear Po sit i on 1st through 5th
L G Ground R! W
Neutral Reverse
0
P PU R W
Y
Bla ck Blue Br own
Green Gray l i ght Blue l ight Gree n Orange Pink Purp l e Red White Ye I low
( 98051 - 17628,17638 )
W1R1762BW5
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18-16 SUPPLEMENT - 1999 MODEL Electrical System Wiring Diagram (Australia Model)
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-
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0 __ ~ 0-l
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Ignition Switch
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0 CD
0
LEFT HANDLEBAR SWITCH CONNECTIONS Light / Dimmer Switch Engine Stop Switch Starter Button Color
OFF
R/ Y
R
R/ BK
BR
Color
OFF
BR
Y/ R Color Y/ R Released
LO HI
Push
RUN
<;:--;>
BK
<;:-~
I
W1L1764BW5
C
SUPPLEMENT - 1999 MODEL 18-17 Electrical System
Accessory T ermina l
- B L --D - BK / Y -t::>C]-BK / Y - R-D
>-
"' --..
~ ~
1
'" '"
cp
~
'" '"
'"
-
BL-CJ BK / Y-{:>C]- B K / Y R -D
=-® =-®
T a i I L ig h t (RH) 12V 8w
T a i I L ight (LH) 12V 8w
~Q '"
1'" ~
~
I
w
~
Main 30A
Fuse
n n , -.~ im I
'"
1l
m~ >->->-::":::0::::0:::0::::::':::
coco .................. a::a
'" '" Reg ul ator/ Rect i f i ter
0:::
<.::I::":::::":::
al....Jenm
It )
Battery 1 2V19AH
I gnltlon Co il
Ig ni ter Spark
~ __
::!J
Starter C ir cu i t Relay P lug
~%~"'~
Starter Mot 0 r
Color Code
I GN I TI ON SW I TCH CONNECT IONS
Co l or
OFF ON
I BR
I I
I
I
W
NEU TRAL & REVERSE SWITCH CONNECT I ONS
Gear Position 1st through 5th Neutra l
Reverse
LG
Ground
R/ W
c- ..:J c- ~
BK BL BR G GY LB LG
Black Blue Green Gray Light Blue Light Green
a
Orange
P PU R W Y
Pink Purple Red White Ye I low
Brown
( 98051-17648 )
W1R1764BW5
C
18-18 SUPPLEMENT - 1999 MODEL Electrical System Wiring Diagram (Europe and U.K. Models) Indicator Light 12V3.4W Indicator Light 12V3.4W
1. Reverse 2. Neutral
Neutral and Reverse Ignition Switch
SfRo M Head light 12V25 / 25W ( RH)
Working Light 12V60 / 55W ( Opt ion)
@
R/ BK----t>D-R / BKR/ Y ----t>D- R/ Y BK / Y----CJ<:]-BK / Y - 1 - -
/;~""1-R/BK (C\y g: <:::S
-{>O-R / BK-+-+-+-----,
_
--i
7 -
f..J-BK / Y -LJ
~ RI Y - { > O - RI Y
-+-+-+---,
_+_+-<~-+-+-I-+_+_-----__t------_+_+_--
"----~
Speedmeter Light 12V3.4W
Head light 12V25 / 25W (L H)
I >- >- >-
~
...J ...... Ol "" Ol
@ Left
R/ BK----t>D-R / BK-fR/ Y ----t>D- R/ Y -
$$
Ol Ol Ol
...J "" Ol Ol
"" "" ""
~~"P
BK / Y----CJ<:]-BK / Y-----
Handlebar
~
Switch
1. Light / Dimmer Switch 2. Engine Stop Switch 3. Starter Button
Alternator
(0 Left
®
Coi I
0)
Handlebar
Switch
LEFT HANDLEBAR SWITCH CONNECTIONS L i ght / D i mmer Sw itch Engine Stop Swi t ch Starter Button Color R/ Y R R/ BK BR Color BR Y/ R Color Y/ R BK OFF
OFF
Re l eased
LO HI
Push
RUN
<;-~
<;-~
I I
W1L1765BW5
C
SUPPLEMENT - 1999 MODEL 18-19 Electrical System
UK
r-------
Mode I (European
Mode I
for
_________ l ___ . , Control
Unitl
8: c: ~
co
3:
VI
---[::>CJ--- VI BK
Carburetor Thermo Sensor
Accessory Terminal
~~~ .......
~G>-
BK / RurK / R~
BK / Y
Opt ion)
L
_
----,
BK / Y------+_+-~-------+~----_,
VI BK
l
Tail Light (R / H)
r
rl--.--_+-+ c:::;::c::::
1 2 V8W
3:et::
He't)~~!1 QQ~&i Re I ay
1
II
L _ _ _ ...,
BK / Y@
I .,,,,, I
1
L::::: __
..,
L
II
~
----------..,
ci::::
Tail
I
Light
(LlH)
______________~~--------------------~_+~L-~~~----+_~---------- VI
12V8W
F use
n >- >- >-
Starter Ci rcuit Rei a y
Ignition Co i I
~Jr--"____ _ fi,
Starter Mot 0 r
Plug
Color Code
~~ 1GN 1T1ON SW 1TCH CON NECTIONS Co 1or
OFF ON
I BR I I
I I
W
NEUTRAL & REVERSE SlIl TCH CONNECT IO NS
Gear
Position
LG
Ground
R/W
1 st t hrou g h 5th Neutral Reverse
C. ..:J C- ..:J
(9B051- 1765B.1766B )
BK BL BR G GY LB LG 0
P PU R W Y
Black Blue Brown Green
Gray Light Blu e Light Green Orange Pin k Purple Red White Ye I low 'If 1 R1765BW5
C
SUPPLEMENT - 2000 - 2002 MODELS 19-1
Supplement - 2000 - 2002 Models Table of Contents Foreword .......................... .. ............ .... .. ............. ............. ..... ... ..... ... .. .... ...... ..... . 19-2 General Information ..... .. ... .. .. .... ...... ... ... ...... ....... ................. ...... ... .. .. ..... ... ... ..... . 19-3 Model Identification .... ............ ......... ... .... ... ..... ... .... ... ................ ... .. .. .... ... 19-3 General Specifications ... .................. .. .... ... .. .. .... ..... ... ...... .... .... .... ........... 19-4 Torque and Locking Agent.. ... ........... ..... .. .......... ...... .. ...... .. ..... ..... ......... . 19-6 Periodic Maintenance Chart ....... .... ... .... .. .... .. ... ....... .. ... .... .. .. .. ..... .. .. ...... . 19-7 Engine Left Side .. .... .. .. .... .. ..... .......... ...... ... ....... .......... .... ..... ...... .... .. .. ... ... ... ... ... 19-8 Exploded View ....... .. ....... ........ ....... .. ...... .. ......... .. ... .... ... ....... ... .. .. ... ...... ... 19-8 Brakes .. ... .. ...... ...... .......... .. .... .. ... ... ... ...... ... ... ... .. .... ...... ............ ...... .... ... ......... ... 19-9 Exploded View ... .............................. ... ..... .... ... ............... ...... .... ...... .. .... ... 19-9 Steering ... .... ...... .... .. ... ..... .. ..... ...... .. ...... ..... ........ ..... ... ...... .......... ...... ..... .... .... .. 19-10 Exploded View .. ........... ...... ......... ........ ......... .... .... ... ...... .. ......... ... .... ..... . 19-10 Frame .... .... .......... .......... .... ...... ..... .......... .. .... .. ... .. .. ...... .. .......... ...... ....... .... ..... . 19-11 Exploded View .. ........... ....... ........ ... ........... .. ... ....... ......... ...... .. .. ... ......... . 19-11 Electrical System .. .. ... .. .... ...... .... ... ........ ... ........ ... .. ...... .. ... .. .. ... .. ..... ... .... .... ..... . 19-12 Exploded View .. ... ... ..... ....... .. ...... .... .... ... ... .. ... ....... ... .. ...... .... ........ .. ... ... . 19-12 Wiring Diag ram ........... .... .. ... .. .... ... ..... ... ..... ..... .. ........... .. ..... .. .. ... .... ..... . 19-14
19-2 SUPPLEMENT - 2000 - 2002 MODELS
Foreword
How to Use this Manual
This "SUPPLEMENT 2000 - 2002 Models" designed to be used in conjunction with the front part of this manual (up to 18-19) and/or Base Manual KLF300Service Manual - Part No. 99924-1057-01 . The specifications and maintenance procedures described in this chapter are only those that are unique to the KLF300-C12 - C14models. Complete and proper servicing of the
KLF300-C12~C14
this chapter and the front of this manual.
models therefore requires mechanics to read both
SUPPLEMENT - 2000 - 2002 MODELS 19-3
General Information Model Identification KLF300-C12 Left Side View
KLF300-C12 Right Side View
19-4 SUPPLEMENT - 2000 - 2002 MODELS
General Specifications Item Dimensions: Overall length Overall width Overall height Wheelbase Ground clearance Seat height Dry weight Curb weight: Front Rear Fuel tank capacity Performance: Minimum turning radius Engine: Type Cooling system Bore and stroke Displacement Compression ratio Maximum horsepower Maximum torque Carburetion system Starting system Ignition system Timing advance Ignition timing Spark plug Valve timing:
Inlet
Exhaust
KLF300-C12'"'-'C14
1860 mm 1120 mm, (EU, UK) 1210 mm 1105 mm 1200 mm 225mm 805mm 260 kg, (EU, UK) 263 kg 138.5 kg, (EU, UK) 139 kg 129.5 kg, (EU, UK) 132 kg 11 L 2.9m
Open Close Duration Open Close Duration
Lubrication system Engine Oil: Grade
Viscosity Capacity
Drive Train: Primary reduction system: Clutch type:
Type Reduction ratio Primary Secondary
4-stroke, SOHC, 1-cylinder Air cooled 76.0 x 64.0 mm 290 mL 8.6 14.7 kW (20 PS) @6500 r/min (rpm), (US) 23 .6 N·m (2.4 kgf·m, 17.3 ft·lb) @5500 r/min(rpm), (US) Carburetor, Keihin CVK32 Electric starter & recoil starter Battery and coil (transistorized) Electronically advanced From 10° BTDC @1300 r/min (rpm) to 30° BTDC @4000 r/min (rpm) NGK DR8EA, (EU, UK) DR7EA 21 ° BTDC 59° ABDC 260° 56° BBDC 24° ATDC 260° Forced lubrication (wet sump) SE, SF or SG class (C14~) API SF or SG API SH or SJ with JASO MA SAE10W-30, 10W-40, 1OW-50, 20W-40, or 20W-50 (C14~) SAE5W-30, 10W-40, 1OW-50, 20W-40, or 20W-50 2.2 L (EU, UK) 2.4 L
Gear 2.888 (78/27) Auto centrifugal, wet Auto multi disc, wet
SUPPLEMENT - 2000 - 2002 MODELS 19-5
Item Transmission:
Type Gear ratio:
KLF300-C12 - C14 10-speed plus reverse, constant mesh, return shift 1st 2nd 3rd 4th
3.090 (34/11 ) 1.928 (27/14) 1.368 (26/19) 1.000 (23/23)
5th Reverse
0.769 (20/26) 3.072 (26/11 x 26/20)
High
Shaft 5.416 (33/33 x 20/16 x 39/9) 6.910 (37/29 x 20/16 x 39/9)
Final drive system: Type Reduction ratio
Low
High: 12.037 Low: 15.357 API GL-5 Hypoid gear oil for LSD SAE140 or SAE85W-140
Overall drive ratio: Front final gear case oil:
Type
Rear final gear case oil :
Capacity Type
0.4 L 0 API GL-5 Hypoid gear oil SAE90 (above 50 C, 41 F) or 0 SAE80 (below 50 C, 41 F)
Capacity
0.3 L
Frame: Double tubular
Type Caster (rake angle)
0
1.0 0 0 @1G
Chamber Trail Tread
Front Rear
Front tire:
Type Size
Rear tire:
Type
Rim size:
Size Front Rear
5mm 844mm 860 mm Tubeless AT24x8-11 Tubeless AT 24 x 10-11 11 x 6.5 11 x 8.0
Suspension: Front
Type Wheel travel
Double wishbone 110 mm
Rear
Type Wheel travel
Torque tube 120 mm
Brake type:
Front Rear
Disc (Hydraulic) x 2 Drum (Mechanical, on Rightside)
Electrical Equipment: Battery Headlight:
12 V 14 Ah (EU, UK) 12 V 19 Ah Type
Bulb Tail/Brake lights: Bulb Alternator:
Type Rated output
Semi-sealed beam 12V25/25Wx2 12 V 18/5 W x 2 Three-phase AC 23.5 A/14 V @9000 r/min (rpm)
Specifications are subject to change without notice, and may not apply to every country. EU: Europe Model, UK: U.K. Model, US: U.S.A. Model
19-6 SUPPLEMENT - 2000 - 2002 MODELS
Torque and Locking Agent Parts Engine Left Side: Alternator rotor bolt Starter clutch Allen bolt Recoil starter flange nut
N·m
Torque kgf·m
ft·lb
59
6.0
43
34
3.5 0.85
25
8.3
L: Apply a non-permanent locking agent to the threads.
74 in·lb
Remarks
L
SUPPLEMENT - 2000 - 2002 MODELS 19-7
Periodic Maintenance Chart
The scheduled maintenance must be done in accordance with this chart to keep the vehicle in good running condition . The first service is vitally important and must not be neglected.
Regular Service
First Service
After10h~%~%~
. =Clean , adjust, lubricate, tighten, or replace parts as necessary.
~ o
of use
<;}
~0
o'b-
Engine:
•• •• •• ••
* Clutch adjustment * Air cleaner--service
Valve clearance--check Fuel system cleanliness--check Throttle lever play --check Engine oil--change
*
*
*
Oil filter--replace Spark plug--clean and gap Spark arrester--clean Chassis:
• •• •
Joint boots--check
* Rear brake lining wear--check * Front brake pad wear--check * Rear brake adjustment--check
Brake fluid level--check Brake fluid--change Cable adjustment
*
Battery--check Steering--check General lubrication
*
Bolts and nuts--tighten Front and rear final gear case oil--change Master cylinder piston assembly and dust seal--replace Caliper piston seal and dust seal--replace Brake hose--replace
*
•• • ••
~
;y.;:y
0
<;}
~0
o'b-
I
I
• •
0
<;}.g
o'b-
I I
• •••
I
0
•• • •
0
<;} vI:?
;y
See Page
2-7 5-3 3-6 (2-10) (2-4) 5-3 (5-11 )
•
14-5 3-11 9-7 ,20 12-4 10-5
II
(10-6) 10-8
• I I
(10-8) (10-8)
**
14-6
•
(12-6) 15-7 15-8
I I
•
9-10,23
2 years
(10-11 )
2 years
10-7
I
2 years
10-10
I
I
* :Service more frequently when operated in mud, dust, or other harsh ridin conditions. * * : Refer to 2, 7, and 10 chapters.
(xx-xx): Reference Page in the Base Manual
~
;y.;:y
I•
•• • • ••
~
;y.;:y
19-8 SUPPLEMENT - 2000 - 2002 MODELS Engine Left Side Exploded View
T2
©
Kl3Bll
1. Torque Limiter G : Apply high temperature grease. L : Apply non~permanent locking agent. o : Apply engine oil. Lh: Left-Hand Threads R : Replacement Parts Rh: Right-Hand Threads
T1: 59 N·m (6.0 kgf·m, 43 ft·lb) T2: 34 N·m (3.5 kgf·m, 25 ft·lb) T3: 8.3 N·m (0 .85 kgf·m, 74 in·lb) T4: 7.8 N·m (0.8 kgf·m, 69 ft·lb)
•• C
SUPPLEMENT - 2000 - 2002 MODELS 19-9 Brakes Exploded View
KUI04
Si: Apply silicone grease. 1. Brake Switch T1: 8.8 N·m (0.90 kgf·m, 78 in·lb) T2: 5.9 N·m (0.60 kgf·m, 52 in·lb) T3: 1.0 N·m (0 .10 kgf·m , 9 in·lb) T 4: 1.2 N·m (0.12 kgf·m, 10 in·lb)
II C
19-10 SUPPLEMENT - 2000 - 2002 MODELS Steering Exploded View
1 . KLF300-C14 Model A: Apply adhesive T1: 20 N·m (2.0 kgf-m, 14.5 ft·lb)
SUPPLEMENT - 2000 - 2002 MODELS 19-11
Frame Exploded View r---------- ---i
'--d;---
./
H0020008"2 C
1. Rear Carrier 2. Canada Model 3. Other than U.S.A. , Canada and Europe Models
19-12 SUPPLEMENT - 2000 - 2002 MODELS Electrical System Exploded View (KLF300-C12 -)
HP02059BW3
1. 2. 3.
Parking Switch Front Brake Light Switch Rear Brake Light Switch 4. Tail/Brake Light 5. Bulb (12 V 18/5 W)
C
SUPPLEMENT - 2000 - 2002 MODELS 19-13
Dummy page
19-14 SUPPLEMENT - 2000 - 2002 MODELS
KLF300-C12~C14
Wiring Diagram (U.S.A. and Canada Model)
r-- - - - - - - - - - - - - - - - - - -
I
I I
Carburelor Healer
Carburelor Thermo. Sensor
I
(]~-1
C I
II I
b
r
I
" I I
L__ -,
I
r:J- : :~
I:«~::- I
LIJ
L--~
~ ! i LT
- -
, rBK/Y - - - ---L-,,_ .--, , ~--- W - - ~ I I \ ,BK -I LJ ---- BK - - - , , __ J
~ __J
~
:>-
m ,', ! :>-;;;:>-
c ,""
~,,~G/W- -
Rei a y ,L He a I e r ~
r
~
I'
I
k~}--Y/R--r- ' I 'I
I I
~
""
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r
I' :'
l
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I
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:>-
L _-_- -==-__-_--1~
~?~~ i.J
i..j
I
L
L:: _ _ :::'J
:>-
it
I
:>- ,
,
R/BK~R/BK
oo=E
R/ Y --t:>CJ-- R/ Y BK/Y -CJ
Headlighl 12V25/25W
Light
®Neulral
Indicator
Light
S wit c h Indicator Light I g nit ion 12V 3.4WX2 S wit c h
12V 3,4W
LTJL,'
1 1 ' ..
I I
Indicator
iS pee d 0 met e rl I L i ght I
I' ' _'I :',;::''': L? J " __j UI ~o::
~~
""
i --(6P)--l
L_J 0::
:£ ; -,- -rl " : II ,,-? ,,-?
L -" -'-,
II :
(DReverse
N e u I r a I /R eve r s e
,
~
1
__ - l
L
L~j
\:r'-l
J,o::r-Io::T-~11 ,..
ar ure o r , Healer 12V23W,
I jl-
5,;. ~~ ~
, :
, LB K / R-fYl- B K/ R-
-+-~- r __ ~---BK/Y -1 LW---,-_:~~ __ r --- W -~
I
I
I
L,-----,J l,-,-, -, --,-J
- -II
l:~i: j
I
I
:Contro l Unit:
~ - -
l--~-~
~
(OPl(Canada Modelll ,--- - -,
I
-'
a::
>-
""<0
I
..,
- '
a::
~
a::
I
I
1
(R H) I
!
E
\
--i- -R/BK--{> O - R/BK ~--- R/ Y ---{ > CJ- R/ Y __ J-B K/y---{ ::J<}- BK/Y
-
Work Light 12V65/60W (0 P)
-', ~
>- >- >-
OOJ,
~ ~
R/B K--f>CJ-R / BK R/ Y --[:::>CJ-- R/ Y BK/Y--c:::J<]--BK/Y
Headl ight 12V25/25W
..,""
>"" 0:: ,0::<00::,"" 0:: ~[Q>-m
a::
-,,,,,
:>- >- :>-
..,<0
~~ ~
(L H)
>-
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>>->-::'::0::::
UI
:::::n
Pickup Coi I Alter
Lell
Handlebar
(DLight/Dimmer ®Engine 0Starler
Switch
Switch
Stop Sw itch But l on
Nator
LEFT HANDLEBAR E Light/Dimmer S w I I c h Color R/Y ( R R/BK BR OFF LO HI L--
SUPPLEMENT - 2000 - 2002 MODELS 19-15
ht
12V3.4W
ht
12V3 .4 W
I~ U; rake vitch
Parki n g Brake Light Swilch
~
~ cO '" ¥-~ >::
0:: a:l
-'
-'
m
0::"
"'m" t-
0::
m
I
'Tai I/Brake Lights 12 V 5/18 WX 2
>-
0::
~~
-'
0::
' BKI Y-[:::::::>C]- BKI Y r- R---CJ
cO
-' a:l
m
Acce s sory Terminal
Rear Brake Lighl Switch
m
BL---cJ<:J- B L BK/y{>D- BK/Y t-R---CJ
F
I W-
>-
~-'
>-
>-
LL.
co
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:;':0::
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n.
n
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(+)
(- )
Bat t e r y 12V19AH y.
I g nit ion Co i I
Jlatorl I i fit e r
(U. S. A Mode I
Slarter
S I art e r C i r cui I Rei a y Plug
6
Slarier
~~~~~ :A R SWITCH I
Color OFF RUN
Color Cod e BK Black BL Blue BR Brown CH Chocolate
I g nit e r Spark
En,in .
12V 14AH)
Relay
CONNECTIONS Swilch S I a r I e r B u I Ion BR Y/R Color Y/R BK - , Releas ', Pus h ~~
SIDP
<;JIll
-
I
Molor
DG Oark Oreln G Green
19NITJO Jl
SW ITCH
Color OFF ON
CQHJlECl10U
NEUTRAL & REVERSE SWITCH CONNECTIONS 8tar lit
Position t h r 0 UI h
LG
Ground
R/W
51 h
Ne u t r a I Reverse
(98051-1856A)
GY LB LG 0
Gray LI,hl
Blu.
Lill'lt
ar.ln
Orange
P Pink PU Pur pie R W Y
Red Wh i Ie Yellow LF300C01A3 C
19-16 SUPPLEMENT - 2000 - 2002 MODELS
KLF300-C12 Wiring Diagram (Australia Model)
- - - - -Carburetor - - - -----------, (OP) I r---;Carburetor Heater _ _ " I
Thermo. Sensor
I
I -;1- - - ---,
I I
r -- "'") (<,.
, -:,. ,
l:~Fj
: ,C •• tro'
,
I
I I
I
L
---:
I
T-- - - -f
I
I ~:- ~ ', H.ater12V23W Car bur e t lor __
_
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r--:J
rBK-t LJ---BK----, , __ ::I ,
I
i
I r.,il>L}- . ~ -r L__ ~[J ~~~"-- IR-Il-: : I ::~: I
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I.~:·I
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c-'"
IR. I ..
;,;,,,---G/WV
I
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Ullt,
L;;;-T,.,-;--,--'
BK/R, fl-BK/R- - - ~ , I ""+-L___ B KI Y-t I r-B KI V- - - ----'-- r LW-.:--;--"1----W--~ I L..---W - - ~ I L
I
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____ ~ - -
r--J ~ ~ -
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ILlI~1
Sw
12~. 4.
-J:: GQ I
J L::: _ _L::J
Indicator
LI ,h t
®N.utral
~ ~ 'll
"
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,1'ITII yf1 --dII
f, L;.
I
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I ~~ ________ LL_-_--==--_-_J" ~I L _____ ~
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RIB K--c>e::r-RI BK R/Y---E>C::]--R/Y BK/V--D
(:A;.:J
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I
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g
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,
Front
t
:;.:
I I
IC! IT~,;.: 1 ~rmCD ~. :~.J:o~~:
~~ 8 ~~9~ y~ ~ ~ ~~ >-
Headli,ht 12V25/25W (R H)
N I U t r a I I R• v e r Switch
I
h L I 'h t
~~ cp
62~y
~
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~
:
I
I
I I
( ~-- t--R/BK-{>D-R/B K }----R I Y---{:::>CJ--R I V \ __ J---BK/Y-{::]<::J---BKI Y Work Li,ht 12V65/60W (0 P)
11
CEE
I B K--c>e::r-RI B K R/V---t>CJ--R/Y BK/Y--D
H.-adll,ht 12V25/25W
a:
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>-
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a:
0'
~
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>-,.
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it~lJrj-h Horn
Left
Handllbar
G)Lilht/Dimmlr
Switch
Switch
®Enlinl Stop Switch 0starttr
Button
Horn 12V 1. 5 A
~
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>-
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Pic k u p Col I Altlrnator
Switch
LEFT HANDLEBAR SWITCH Eo.l . . SI L1,ht/Dlmmer Switch Color R/V R R/BK BR Co lor OFF OFF LO HI RUN
SUPPLEMENT - 2000 - 2002 MODELS 19-17
r
Licht
12V3.4W
r Licht 12V3.4W
L I (h t
Pukine Brate Liehl Switch
Rear Brake LiChl Switch
Acc.llory T.rminal. BL----LkJ--B L ,BK/Y--t>CJ- BK/Y r- R -Q:::::J-- R
6 6 co::
--'
ID
ID
r~ :0::
co::
ID
ID
"'ID" BL-D
~ BK/Y~BK/Y
r-R-c:J<:r--R
1 --'
Tai I/Brake Lights 12 V 5/18 WX 2
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n
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Battery 12V19AH
I,. III a. Co i I
Stater Circuit RI lay
~
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(+)
sperk
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Plue Starter Molor
~~~~'%.
SWITCH CONNECTIONS S.il.~ Stul.r Button BR - Y/R Color Y/R Color BK
e"I •• SI.,
OFF RUN
<:-
.,
Reill"
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I
, •• ,TIOI 'W'TCI CO.IECTlal.
IEUTRAL , REYERIE •• ITCH eOIIEeTIOI. 8, ... _
Color OFF
8.ar P •• i I I ••
ON
Neutral Re'lr.e
III t'r ••• '
LG
R/W
St.
(98051-1857A)
Color Cod. BK Black BL Blul BR Brown eH Choco lita DG Dllk art .. G Grlln GY Gray LB LiCht Blu LG Llchl a .... 0 Orln'l p Pink PU Purp I. R R.d W Whit. Y VI Ilow LnOOCOlA3 C
19-18 SUPPLEMENT - 2000
2002 MODELS
KLF300-C12'"'-'C14 W·lYIng . Diagram (Europe Model) (DReverss
Indicator
light
12V3. 4W
®N.utral
Indicator
Light
12V3.4W
Ignition
Carbur.tor H. at. r 12V23W
Headllcht 12V25/25W (RH)
It: >II> C:I
~R/BK-t>D--R/BK
~ R/Y -c>D-R/YB K/ Y --c:J
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.
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f;, Spark
0 If
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S wit c h
Stop Switch Button
~
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f-L";'FT HANDLEBAR Licht/Dimmer S .S WITCH CONNECT Enll •• s Color RI wItch Color OFF Y R R/BK BR OFF LO RUN; l HI
=
L
SUPPLEMENT - 2000 - 2002 MODELS 19-19
(0 P)
Europe Model
:-=--=---=----~
arburetor
I Accessory Terminals (Treiler LiChl)
Tai I/ Brake Lights 12 V 5/18 WX 2
Reverse Li 12Vl0W
I
~
I
hi
>-
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(-)
BattelY 12V19AH /
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---~
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-
II
Color Code BK Black BL Blu. BR Bro.n CH Cho.ollto
Slarter Moter
~Y/R----------~~-_-~
Co i I
18NITION SWITCH CONNECTIONS
NECTIONS lint 51o, S.II.h
o lor )FF
tUN
BR ~
VIR
.,
S I a r I e r Bulton
Co lor
YIR
BK
R,I"'I
Push
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I
Color I BR I W L BY OFF I I I ON I
IEUTRAL , REVERSE SWITCH COINECTIO •• S •• r POlltlo. lot
LG
Ground
R/W
DG
Dork 8rltn
G GY LB LG
Breen Bray
0 P
PU
Ur.,.11 Sill
Neutral R.verl.
R
(98051-1858B)
W Y
Lllhl BIUt LlIH 8111.
Orlnl' Pin k Purpl. Red Wh it. y. I 10. LFSOOCOSAS C
SUPPLEMENT - 2003 - 2006 MODELS 20-1
Supplement - 2003 -., 2006 Models Table of Contents Foreword................................................................................................................................ How to Use this Manual........... .... .......... .. ........ .. ..................... .... .............. ... ................. ....... General Information .. ......... .. ...... ............. .............................. ................... ... ...................... .. .... General Specifications ........ ........................... ........ .. ... .. .......... ............ ......... ........................ Fuel System............... ..................... .......... .......... .. .... ..... .... ........ .. ........ ......... ........ ........ .......... Specifications.......... ... ... ... .. ........... .. ................. .. ..... ... ..... ... ... ... ................... ...... ........ ... ... ..... Carburetor................ ............................. .......................... .... ..... ......... .................. ................. Carburetor Pilot Screw Adjustment...................... ........ ............................. ............ ............ Fuel Level Inspection ... .... ..... .... .............. ............................. .... ............ ..... .. ........ .............. Engine Right Side................ ...... ......................................................................................... .... Specifications............................................................................................. ................ ... ..... .. Engine Oil and Oil Filter................................................. ................... .. .... ............................. Engine Oil Change............... ... ...... .. .... .. .... ............. .. ................................... ...... ............ .. .. WheellTires ............ ..... .... .... .. ....... .. .............. .... .... .. ...... ..... ............... .... .......... .... ..... ... ........ .. .. Front Hub.... .. .. .. .... .. .. .... .... .. ............................................................................... .................. Front Hub Installation .. .. .... ... . .. ..... ...... .. ............. ............ ..... ..... ....... .. ... ................. .. ... ........ Rear Hub.. ................ .... ............... ... ....... ...... .... .. .... ......... ........ .......... ...... ......... .. ..... .. ..... ...... Rear Hub Installation .. ... ........ ..... .............. ...... ................... .. ........................ .. ..... .. .... ..... ... Brakes.... .... ....... .. ....... ....... .......................................... ...... ...... .... .. .... .. .... ............... ...... ......... . Exploded View ........... .. ............ ................. .. ......................................................................... Frame..... ..... .............. ...... .......... ....... .... .... .. ................. ..... ..... ...... ............ ......... ........ .. .. .. ....... . Exploded View...................................................................... .. .... .... ............. .. ...... .... .. .... ..... . Electrical System ... ....... ............. ................... ...... ...................... .. ... ... ........ ....... .... ..... ..... ........ . Exploded View........................................... .... ............................. ..... .............. ...... ................ Wiring Diagram (U.S .A. and Canada Models) ..................................................................... Wiring Diagram (Europe and U.K. Models) ........ .. ................. .. ......... .. .... .. .... .. ..... .. .. ...... ......
20-2 20-2 20-3 20-3 20-6 20-6 20-7 20-7 20-7 20-8 20-8 20-8 20-8 20-9 20-9 20-9 20-9 20-9 20-10 20-10 20-11 20-11 20-12 20-12 20-14 20-16
20-2 SUPPLEMENT - 2003 - 2006 MODELS Foreword How to Use th is Manual This "Supplement 2003 - 2006 Models" designed to be used in conjunction with the front part of this manual (up to 19-19) and/or Base Manual KLF300 Service Manual - Part No. 99924-1057-02. The specifications and maintenance procedures described in this chapter are only those that are unique to the KLF300-C15 - C6F models. Complete and proper servicing of the KLF300-C15 - C6F models therefore requires mechanics to read both th is chapter and the front of this manual.
SUPPLEMENT - 2003 - 2006 MODELS 20-3 General Information General Specifications Item
KLF300-C1S - C6F
Dimensions:
Overall Length
1 860 mm
Ove rall Width
1 120 mm (EU, UK) 1 210 mm
Overall Height
1 105 mm
Wh eelbase
1 200 mm
Ground Clearance
225 mm
Seat Height
805 mm
Dry Weight
260 kg, (CN) 261 kg, (EU, UK) 263 kg
Curb Weight:
Front
138.5 kg, (EU, UK) 139 kg
Rear
129.5 kg, (CN) 130.5 kg, (EU, UK) 132 kg
Fuel Tank Capacity
11 L
Performance
Minimum Turning Radius
2.9 m
Engine
Type
4-stroke, SOHC, 1-cyli nder
Cooling System
Air cooled
Bore and Stroke
76.0 x 64.0 mm
Displacement
290 cm 3
Compression Ratio
8.6
Maximum Horsepower
14.7 kW (20 PS) @ 6 500 r/min (rpm), (US) -
Maximum Torque
23.5 N·m (2.4 kgf·m, 17.3 ft·lb) @5 500 r/min (rpm), (US) -
Carburetion System
Carburetor, Keihin CVK32
Starting System
Electric starter & recoil starter
Ignition System
Battery and coil (transistorized)
Timing Advance
Electronically advanced
Ignition Timing
From 10° BTDC @1 300 r/min (rpm) to 30° BTDC @4 000 r/min (rpm)
Spark Plug Valve Timing:
NGK DR8EA, (EU, UK) DR7EA Inlet
Exhaust
Lubrication System Engine Oil:
Type
Open
21 ° BTDC
Close
59° ABDC
Duration
260°
Open
56° BBDC
Close
24° ATDC
Duration
260° Forced lubrication (wet sump) API SF or SG API SH or SJ with JASO MA
Viscosity
SAE 10W-40
Capacity
2.2 L (CN, EU, UK) 2.4 L
20-4 SUPPLEMENT - 2003 - 2006 MODELS General Information Item
KLF300-C1S - C6F
Drive Train Primary Reduction System: Clutch Type: Transm ission:
Type
Gear
Reduction Ratio
2.888 (78/27)
Primary
Auto centrifugal, wet
Secondary
Auto multi disc, wet
Type
10-speed plus reverse, constant mesh, return shift
Gear Ratio:
1st
3.090 (34/11)
2nd
1.928 (27/14)
3rd
1.368 (26/19)
4th
1.000 (23/23)
Sth
0.769 (20/26)
Reverse
3.072 (26/11 x 26/20)
Final Drive System: Type
Shaft
Reduction ratio
High
S.416 (33/33 x 20/16 x 39/9)
Low
6.910 (37/29 x 20/16 x 39/9)
Overall Drive Ratio:
High: 12.037, Low:1S.3S7
Front Final Gear Case Oil: Type
API GL-S Hypoid gear oil for LSD SAE140 or SAE90
Capacity Rear Final Gear Case Oil: Type
0.4 L API GL-S Hypoid gear oil SAE90 (above SoC, 41°F) or SAE80 (below SoC, 41 °F)
Capacity
0.3 L
Frame: Type
Double tubular
Caster (Rake Angle)
1.0°
Chamber
0° @1G
Trail
S mm
Tread Front Tire: Rear Tire: Rim Size: Suspension:
844 mm
Rear
860 mm
Type
Tubeless
Size
AT 24 x 8-11
Type
Tubeless
Size
AT24x10-11
Front
11 x 6.S
Rear
11 x 8.0
Front Rear
Brake Type:
Front
Type
Double wishbone
Wheel Travel
110 mm
Type
Torque tube
Wheel Travel
120 mm
Front
Disc (Hydraulic) x 2
Rear
Drum (Mechanical, on Rightside)
SUPPLEMENT - 2003 - 2006 MODELS 20-5 General Information KLF300-C1S - C6F
Item Electrical Equipment:
12 V 14 Ah (CN, EU, UK) 12 V 19 Ah
Battery Headlight:
Type
Semi-sealed beam
Bulb
12 V 25/25 W x 2
Tail/Brake Lights: Bulb
12 V 18/5 W x 2
Alternator:
Type
Three-phased AC
Rated Output
23.5 A/14 V @9 000 r/min (rpm)
Specifications subject to change without notice, and may not apply to every country. CN: Canada Model EU: Europe Model UK: U.K. Model US: U.S.A. Model
20-6 SUPPLEMENT - 2003 - 2006 MODELS Fuel System Specifications Standard
Item Carburetor Specifications Make, Type
Keihin, CVK32
Main Jet
#138 , (CAL) #125
Main Air Jet
#70, (CAL) #50
Needle Jet
#6
Jet Needle Mark
N24G
Pilot Jet (Slow Jet)
#38
Pilot Air Jet (Slow Air Jet)
#140
Pilot Screw (Turns Out)
2
Starter Jet
#65
Service Fuel Level (from carburetor body bottom edge)
-1.5 mm (below) - 0.5 mm (above)
Float Height
17 ± 1 mm
Engine Speed (for reference)
1 300 ± 50 r/min (rpm)
Optional Parts Main Jet
#132, #135, #140, #142 (CAL)#120,#122 , #128, #130
Pilot Jet (Slow Jet)
#35 , #40
Starter Jet
#68, #70
CAL: California Model
SUPPLEMENT - 2003 - 2006 MODELS 20-7 Fuel System Carburetor Carburetor Pilot Screw Adjustment • Loosen the carburetor holder clamp screws (Front and Rear). • Tilt the carburetor to the right of the vehicle for easy access to the pilot screw. • Turn the pilot screw in until it seats lightly, and back it out 2 turns. Carburetor Pilot Screw Setting Standard: 2 turns out
• Reposition the carburetor properly and tighten the clamp screws securely. OFit the carburetor ridge into the groove on the duct.
Fuel Level Inspection
A. WARNING Gasoline is extremely flammable and can be explosive under certain conditions. Turn the ignition switch OFF. Do not smoke. Make sure the area is well ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. • Park the vehicle on a level surface. • Connect the fuel level gauge [A] to the open end of the carburetor overflow tube . Special Tool - Fuel Level Gauge: 57001-1017
• Hold the gauge vertically against the side of the carburetor body so that the "zero" line [B] is several millimeters higher than the bottom edge [C] of the carburetor body. • Turn the fuel tap to the ON position to feed fuel to the carburetor and gauge , then turn out the carburetor drain plug [D] a few turns. • Wait until the fuel level in the gauge settle. • Keeping the gauge vertical , slowly lower the gauge until the "zero" line is even with the bottom edge of the carburetor body.
NOTE
o Do
not lower the "zero" line below the bottom edge of the carburetor body If the gauge is lowered and then raise it again, the fuel level measured shows somewhat higher than the actual fuel level. If the gauge is lowered too far, dump the fuel out of it into a suitable container and start the procedure over again.
• Read the fuel level in the gauge and compare it to the specification. • Tighten the drain plug and remove the fuel level gauge. If the fuel level is incorrect, adjust it.
*
Fuel Level -1.5 mm (below) - 0.5 mm (above) from the bottom edge of the carburetor body
HC060 12BS2
C
20-8 SUPPLEMENT - 2003 - 2006 MODELS Engine Right Side Specifications Item
Standard
Engine Oil: Type
API SF or SG API SH or SJ with JASO MA
Viscosity
SAE 10W-40
Capacity
2.2 L (U .S.A., Canada Models) 2.4 L (Europe, U.K. Models)
Engine Oil and Oil Filter Engine Oil Change
SAE 20W-50 SAE 20W-40
Recommended Engine Oil Type: API SF or SG API SH or SJ with JASO MA Viscosity:
SAE 10W-40
Capacity:
2.2 L (U.S.A., Canada Models) 2.4 L (Europe, U.K. Models)
o Depending on the atmospheric temperature of your riding area, the engine oil viscosity should be changed accordingly to the chart.
>
SAE 10W - 40 SAE 10W -3 0 <, SAE 5W-30
I I
-2 0
-10
0
10
20
30
40 ( C)
'4
1'4
3'2
5'0
6'8
8'S
104 ( DF )
!
!
!
I
I
,
NOTE
I
SAE 10W - 50
!
HU09002BS 1 C
SUPPLEMENT - 2003 - 2006 MODELS 20-9 Wheelrrires Front Hub Front Hub Installation eTighten:
A
Torque - Front Hub Nuts: 145 N·m (15.0 kgf.m, 110 ft·lb)
elnsert a new cotter pin [A].
NOTE
o When
inserting the cotter pin, if the slots in the nut do not align with the cotter pin hole in the axle, tighten the nut clockwise [BJ up to next alignment. Olt should be within 30 degree. OLoosen once and tighten again when the slot goes past the nearest hole.
HJ07007B S 1
C
HJ07008BS 1
C
e Bend the cotter pin [A] over the nut [B]. e Check the front brake.
A WARNING Do not attempt to drive the motorcycle until a full brake lever is obtained by pumping the brake lever until the pads are against the disc. The brake will not function on the first application of the lever if this is not done.
Rear Hub Rear Hub Installation e Refer to the above figures in the Front Hub Installation. e Tighten: Torque - Rear Axle Nuts: 145 N·m (15.0 kgf.m, 110 ft·lb)
elnsert a new cotter pin [A].
NOTE
o When
inserting the cotter pin, if the slots in the nut do not align with the cotter pin hole in the axle, tighten the nut clockwise [BJ up to next alignment. Olt should be within 30 degree. o Loosen once and tighten again when the slot goes past the nearest hole. e Bend the cotter pin [A] over the nut [B]. e Check the rear brake.
A
20-10 SUPPLEMENT - 2003 - 2006 MODELS Brakes Exploded View
T6
~
T7
T7
Hl 020 0 8BW4
1 . Brake Switch L: Apply non-permanent locking agent. R: Replacement Parts Si : Apply silicone grease .
T1 : 1.0 N·m (0.10 kgf·m, 9 in·lb) T2 : 1.2 N·m (0.12 kgf·m , 10 in·lb) T3 : 5.9 N·m (0.60 kgf·m, 52 in·lb) T4: 7.8 N·m (0 .80 kgf·m , 69 in·lb) T5: 8.8 N·m (0 .90 kgf·m, 78 in·lb) T6: 18 N·m (1.8 kgf·m, 13 ft·lb) T7: 20 N·m (2.0 kgf·m, 14.5 ft·lb) T8: 23 N·m (2.3 kgf·m, 16.5 ft·lb) T9: 25 N·m (2 .5 kgf·m , 18 ft·lb) T1 0: 37 N·m (3.8 kgf.m, 27 ft·lb)
C
SUPPLEMENT - 2003 - 2006 MODELS 20-11 Frame Exploded View
,
4
~
~
~
4
•
H0020 14BW4
1. Canada Model 2. U.K. Model 3. U.S.A. Model 4. Option (U.S.A. and Canada Models)
C
20-12 SUPPLEMENT - 2003 - 2006 MODELS Electrical System Exploded View
HP 0 2030B.,,4
1. Working Light (Optional Parts) 2. Light Switch and Engine Stop Switch 3. Lock Key (Optional Parts) 4. Reflector Reflex (Europe and U.K. Models) 5. Horn Button (Europe and U.K. Models) 6. Ignition Switch (Other than Europe and U.K. Models) 7. Ignition Switch (Europe and U.K. Models) 8. Rear Brake Light Switch 9. KLF300-C15 - Model
C
SUPPLEMENT - 2003 - 2006 MODELS 20-13 Electrical System Dummy Page
20-14 SUPPLEMENT - 2003 - 2006 MODELS Electrical System Wiring Diagram (U.S.A. and Canada Models)
1- - --- -( ~P~u ~ e~o-r-I I
I
Carburetor Th er mo. Sensor
"~
Hea te r *Refe r to the --I mode l Wi ri ng I D i agram
i ----;Q-- - i I (~I I
i~i \.J../
I I
II
- (Ca~ M;,de
U K:Control
I
Un i t :
T- - --T '";;T';'- J,-r ' ~ '"
I
'LLBK / R-rl1-BK / R---~ ! f"'L>-~ L(>.'. - BK / Y-i r BK/ Y- - I I
Carburetor
I
Hea ter
I
II
'L
12V23W
I I
\
I r-r"--"'~'"''::
:l ~[r~~:;:~ i-h~:"::'f~l~;; ~ ~ ~ ~~ - -
'"'
L ---
I I
"
Indicator
L ig ht
12V3 . 4W
CDNeutral
Indica tor
L ig ht
12V3 .4W
L
\! n
u
I
--
Neutra l / Rev erse Switch
I gn i tion Sw itch
\~
" ~~ L _-_--==--_-_~
I
G)Reverse
----'-r--
I I
c--W _ _ _ --.J I I L J iBK-L'T - BK- -- -: :---
LW--t::·r_-_}----W--4
I
III
r - - - ---,
Indicator
rcKLF300l
12V
L ig ht
3.4WX2
1 1 ~2~ °1tg:'-;: :1 GSFli] :I ~~ I I I I lQJ 144
I
~
h 0:::
3:
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c:::
3:
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~V ~
~
2 66~ ..........
(",!)a:::
-00 "~~I~'~'~/-/- - - ~ L ~;L~ ~: ~_t :Y~I L3~I~ J
I
I
BK / Y~BK / Y -----.
~
~
Headl ight
12V25 / 25W ( R H)
~
- ---t-R / B K-[>C]-R / BK f-- RI Y ----[::cr-R I Y ----+~ __ ...l- B K I Y-CJ<:::r- B K I Y-----+-If--t-t-t-i-+~----_r_+--------------------+_t__---
Work
L ig ht
12V65 / 60W ( 0 P)
I
@
'"
>- >- >-
a> '"
~ >- >- >-
R / BK--[>CJ----R / BK R / Y~R / Y----+~ BK / Y ~BK / Y---~
Head li ght 12V25 / 25W ( L H)
~ ~'"
0000
A l terna tor Le ft
Ha n dl e bar
G)L igh t / D im mer CD En gine (DStarter
Stop
Switch
Switc h Switc h
Button
CD
CD
(D
L EF T HAN DLEB AR L i ght / Di mm e r Co lor R/ Y R OFF LO HI
Sw itch R / B K BR
SW IT C H CONN E CTIO NS Encine
Co l or OFF RUN
Stop
BR
Switch
Y/ R
Starter Button Colo r Y / R BK R e l ease
C;:-.-,
Pu s h
c;:-~
I
W2 L0026AW5
C
SUPPLEMENT - 2003 - 2006 MODELS 20-15 Electrical System
Pa rking Brake Li ght Sw itch F ro n t
Brake
L ig ht Switch
Accessory T erminal
Rear Brake Li g h t Switch
r - - - - B L ---D<:}-B L ~ .-B K / Y-t:>D--B K / Y
- R-D
~
I---I-- B L -D<.J--B L I-
BK/ Y-!>D-B K/ Y
~R---D
W----------,
----------~~--------------------_+----~+__4--4_+_---------
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( U. S . A.
Model
12V 14AH )
Starter
Circuit
Regulator /
Rela y
Rectifiter
Spa r k P l u g
~"""~~,,~
Starter
Color Code BK Black BL Blue B R Brown CH Chocolate
Motor
DG
GY LB LG I GHI TIO N S lI fCH
CO III ECI I CNS
Co l o rJ BRJ W OFF J J ON J~
NEU TRAL
Gear
,,,
& REVERSE
Po s i t ion
S1IITCH
LG
Gr
CONN ECT IOMS 0
1,1
nd
PU
throv,h
Neutral''"
Reverse
0
R/ W
<=- ..::> c:.. 11K
(98 052-0026A.1136A )
W
Dar k
Green
Green G ray L i I: h t
Bl ue
li, h t
Green
Orange
Pink Pur p i e Red Wh it e Ye I low
'lf2R0026AW5
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20-16 SUPPLEMENT - 2003 - 2006 MODELS Electrical System Wiring Diagram (Europe and U.K. Models)
(DReverse
Indicator
Light 12V3.4W
0Neutral
Indicator
L ight 12V3.4W
Ignition Switch
/ -----i-R / BK--t>D-R / BK
~
f--- RI Y ---t>CJ-R I Y-4-++---, __ .J----!l KI Y---{::J
Work Light 12V65 / 60W . ( OP) BK / Y-c:::J<:J--BK / Y
~R~R--++--+-~--+-+-t--~
Speedometer Li ght 12V3.4W
CID
RI BK-t>O-R I BK- RI Y ---t>O-R I Y BK / Y~BK / Y--
Headl ight 12V25 / 25W ( L H)
Left
Handlebar Switch
>-
3:
>-
#m~ ~~ II
o
!!!!ITT! •. ,."""
Rectifier
Pickup Coi I
(D Li ght / Dimmer Switch 0Engi ne Stop Switch G)Starter Button
s,"< ".,
~
W~ LEFT HANDLEBAR SWITCH CONNECTIONS Light / Dimmer Switch Eng i ne Stop Sw it ch Starter Button Color BR Y / R Color Y / R BK Color R / Y R R/ BK BR OFF Rei e a s e OFF Push <;JIIIII~ LO RUN HI I
W2l0028AW5
C
SUPPLEMENT - 2003 - 2006 MODELS 20-17 Electrical System
r-:- I
I-
( OP )
Europe
Model
Carburetor
~ Thermo.
Sensor
~==a:::
a::
I
Accessory
( Trai ler
;'"'2:;;;::: L _
Terminals
Light )
BK / R [ [ E K / R BK / Y BK / Y ----~~rt--------~+__ -~ W--c:>D-- w Car bur e tor BK Heater
12""
r-----;: I I
W B Kl
( Tall / Brake Light
-----=;;
"8~" ~s~~
".""
~
B L -DO-B K / Y ~ R-D
I
"' ~ ~-~:-y- --=>7B'~~BK/y-®12V
8 / 27WX2
~
Relay
: i
:
l!:_-:~ S~ J
R~~-=Ba=-R{RW Reverse 12 V10 W
----------------~----------------,r~--t_----~_t--~--~-------w
I~ Light
"
u.
<=
.- ..:
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::e M
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Color Code BK B l ack BL Blue BR B row n Choc ol 3t e CH Dar k Gre e n DG G Gr e e n G ray GY l i g h t Blue LB LG l i g h t G r een Orange 0 P Pi nk Pur pie PU Red W White Y Yellow
W2ROO 28" "5
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