2010 Kawasaki Kx250f Kx250xaf Service Manual Motorcycle

KX250F

Motorcycle Service Manual

Quick Reference Guide

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.

General Information

1 j

Periodic Maintenance

2 j

Fuel System

3 j

Cooling System

4 j

Engine Top End

5 j

Clutch

6 j

Engine Lubrication System

7 j

Engine Removal/Installation

8 j

Crankshaft/Transmission

9 j

Wheels/Tires

10 j

Final Drive

11 j

Brakes

12 j

Suspension

13 j

Steering

14 j

Frame

15 j

Electrical System

16 j

Appendix

17 j

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KX250F

Motorcycle Service Manual All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Quality Assurance Division/Consumer Products & Machinery Company/Kawasaki Heavy Industries, Ltd., Japan.

No liability can be accepted for any inaccuracies or omissions in this publication, although every possible care has been taken to make it as complete and accurate as possible.

The right is reserved to make changes at any time without prior notice and without incurring an obligation to make such changes to products manufactured previously. See your Motorcycle dealer for the latest information on product improvements incorporated after this publication.

All information contained in this publication is based on the latest product information available at the time of publication. Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts.

Š 2009 Kawasaki Heavy Industries, Ltd.

First Edition (1) : Jul. 28, 2009 (S)

LIST OF ABBREVIATIONS A

ampere(s)

ABDC AC ATDC BBDC BDC BTDC °C DC F °F ft g h kg

after bottom dead center alternating current

lb m min

after top dead center before bottom dead center bottom dead center before top dead center degree(s) Celsius direct current farad(s) degree(s) Fahrenheit foot, feet gram(s) (mass)

N Pa PS psi r r/min, rpm TDC TIR V W

meter(s) minute(s) newton(s) pascal(s) horsepower pound(s) per square inch revolution revolution(s) per minute top dead center total indicator reading volt(s) watt(s)

hour(s) (mass) (force) liter(s)

Ω

ohm(s)

kgf L

pound(s)

COUNTRY AND AREA CODES AU BR CA

Australia Brazil Canada

EUR US

Europe United States

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.

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 Motorcycle parts. Special tools, gauges, and testers that are necessary when servicing Kawasaki motorcycles 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 stick 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 Stick Coil section.

Whenever you see symbols, heed their instructions! Always follow safe operating and maintenance practices.

DANGER DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury.

WARNING WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION CAUTION indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

NOTICE NOTICE is used to address practices not related to personal injury.

This manual contains four more symbols which will help you distinguish different types of information.

NOTE This note symbol indicates points of par○ ticular interest for more efficient and convenient operation. a procedural step or work to be • Indicates done.

○Indicates 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.................................................................................................................

General Specifications............................................................................................................

Unit Conversion Table ............................................................................................................

1 1-2 1-7 1-8 1-10

1-2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly operation on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustrations, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary. This section explains the items that require particular attention during the removal and reinstallation or disassembly and reassembly of general parts.

Especially note the following:

Edges of Parts Lift large or heavy parts wearing gloves to prevent injury from possible sharp edges on the parts.

Solvent Use a high-flash point solvent when cleaning parts. High -flash point solvent should be used according to directions of the solvent manufacturer.

Cleaning Vehicle before Disassembly Clean the vehicle thoroughly before disassembly. Dirt or other foreign materials entering into sealed areas during vehicle disassembly can cause excessive wear and decrease performance of the vehicle.

Arrangement and Cleaning of Removed Parts Disassembled parts are easy to confuse. Arrange the parts according to the order the parts were disassembled and clean the parts in order prior to assembly.

GENERAL INFORMATION 1-3 Before Servicing Storage of Removed Parts After all the parts including subassembly parts have been cleaned, store the parts in a clean area. Put a clean cloth or plastic sheet over the parts to protect from any foreign materials that may collect before re-assembly.

Inspection Reuse of worn or damaged parts may lead to serious accident. Visually inspect removed parts for corrosion, discoloration, or other damage. Refer to the appropriate sections of this manual for service limits on individual parts. Replace the parts if any damage has been found or if the part is beyond its service limit.

Replacement Parts Replacement parts must be KAWASAKI genuine or recommended by KAWASAKI. Gaskets, O-rings, oil seals, grease seals, circlips, cotter pins or self-locking nuts must be replaced with new ones whenever disassembled.

Assembly Order In most cases assembly order is the reverse of disassembly, however, if assembly order is provided in this Service Manual, follow the procedures given.

Tightening 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 according to the specified sequence to prevent case warpage or deformation which can lead to malfunction. Conversely when loosening the bolts, nuts, or screws, first loosen all of them by about a quarter turn and then remove them. If the specified tightening sequence is not indicated, tighten the fasteners alternating diagonally.

1-4 GENERAL INFORMATION Before Servicing Tightening Torque Incorrect torque applied to a bolt, nut, or screw may lead to serious damage. Tighten fasteners to the specified torque using a good quality torque wrench. Often, the tightening sequence is followed twice-initial tightening and final tightening with torque wrench.

Force Use common sense during disassembly and assembly, excessive force can cause expensive or hard to repair damage. When necessary, remove screws that have a non -permanent locking agent applied using an impact driver.

Use a plastic-faced mallet whenever tapping is necessary.

Gasket, O-ring Hardening, shrinkage, or damage of both gaskets and O-rings after disassembly can reduce sealing performance. Remove old gaskets and clean the sealing surfaces thoroughly so that no gasket material or other material remains. Install new gaskets and replace used O-rings when re-assembling.

Liquid Gasket, Non-permanent Locking Agent For applications that require Liquid Gasket or a Non-permanent Locking Agent, clean the surfaces so that no oil residue remains before applying liquid gasket or non-permanent locking agent. Do not apply them excessively. Excessive application can clog oil passages and cause serious damage.

Press For items such as bearings or oil seals that must be pressed into place, apply small amount of oil to the contact area. Be sure to maintain proper alignment and use smooth movements when installing.

GENERAL INFORMATION 1-5 Before Servicing Ball Bearing and Needle Bearing Do not remove pressed ball or needle unless removal is absolutely necessary. Replace with new ones whenever removed. Press bearings with the manufacturer and size marks facing out. Press the bearing into place by putting pressure on the correct bearing race as shown.

Pressing the incorrect race can cause pressure between the inner and outer race and result in bearing damage.

Oil Seal, Grease Seal Do not remove pressed oil or grease seals unless removal is necessary. Replace with new ones whenever removed.

Press new oil seals with manufacture and size marks facing out. Make sure the seal is aligned properly when installing.

Apply specified grease to the lip of seal before installing the seal.

Circlips, Cotter Pins Replace circlips or cotter pins that were removed with new ones. Take care not to open the clip excessively when installing to prevent deformation.

Lubrication It is important to lubricate rotating or sliding parts during assembly to minimize wear during initial operation. Lubrication points are called out throughout this manual, apply the specific oil or grease as specified.

1-6 GENERAL INFORMATION Before Servicing Direction of Engine Rotation When rotating the crankshaft by hand, the free play amount of rotating direction will affect the adjustment. Rotate the crankshaft to positive direction (clockwise viewed from output side).

Electrical Leads A two-color lead is identified first by the primary color and then the stripe color. Unless instructed otherwise, electrical leads must be connected to those of the same color.

Instrument Use a meter that has enough accuracy for an accurate measurement. Read the manufacture’s instructions thoroughly before using the meter. Incorrect values may lead to improper adjustments.

GENERAL INFORMATION 1-7 Model Identification KX250XAF Left Side View

KX250XAF Right Side View

Frame Number

Engine Number

1-8 GENERAL INFORMATION General Specifications Items Dimensions Overall Length Overall Width Overall Height Wheelbase Road Clearance Seat Height Curb Mass: Front Rear Fuel Tank Capacity Engine Type Cooling System Bore and Stroke Displacement Compression Ratio Carburetion System Starting System Ignition System Timing Advance Ignition Timing Spark Plug: Standard Option Valve Timing: Inlet: Open Close Duration Exhaust: Open Close Duration Lubrication System Engine Oil: Grade Viscosity Capacity

KX250XAF 2 170 mm (85.43 in.)

820 mm (32.3 in.)

1 270 mm (50.00 in.)

1 470 mm (57.87 in.)

340 mm (13.4 in.)

955 mm (37.6 in.)

105.1 kg (231.7 lb) (US, CA) 105.0 kg (231.5 lb) 50.8 kg (112 lb) 54.3 kg (119.7 lb) (US, CA) 54.2 kg (119.5 lb) 8.0 L (2.1 US gal) 4-stroke, single cylinder, DOHC 4 valve Liquid-cooled 77.0 × 53.6 mm (3.03 × 2.11 in.)

249 cm³ (15.2 cu in.)

13.2 : 1 Carburetor, KEIHIN FCR-MX37 Primary kick Digital AC-CDI Electronically advanced BTDC 8° @2 000 r/min (rpm) NGK CR8E NGK CR9E

BTDC 41° ABDC 71° 292° BBDC 69° ATDC 49° 298° Forced lubrication (semi-dry sump) API SG, SH, SJ or SL with JASO MA, MA1 or MA2 SAE 10W-40 1.0 L (1.1 USqt)

GENERAL INFORMATION 1-9 General Specifications Items Drive Train Primary Reduction System: Type Reduction Ratio Clutch Type Transmission: Type Gear Ratios: 1st 2nd 3rd 4th 5th Final Drive System: Type Reduction Ratio Overall Drive Ratio Frame Type Steering Angle Caster (Rake Angle) Trail Front Wheel: Tire Size Tire Make/Type Rim Size Rear Wheel: Tire Size Tire Make/Type Rim Size Front Suspension: Type Wheel Travel Rear Suspension: Type Wheel Travel Brake Type: Front and Rear Effective Disc Diameter: Front Rear

KX250XAF

Gear 3.350 (67/20) Wet multi disc, Manual 5-speed, constant mesh, return shift 2.142 1.769 1.444 1.200 1.045

(30/14) (23/13) (26/18) (24/20) (23/22)

Chain drive 3.692 (48/13) 12.931 @Top gear Semi-double cradle 42° to either side 27.4° 118.6 mm (4.669 in.)

80/100-21 51M BRIDGESTONE M403, Tube type 21 × 1.60 100/90-19 57M BRIDGESTONE M404, Tube type 19 × 1.85 Telescopic fork (upside down) 315 mm (12.4 in.)

Swingarm (New Uni-trak) 310 mm (12.2 in.)

Single disc 225 mm (8.86 in.)

215 mm (8.46 in.)

Specifications are subject to change without notice, and may not apply to every country.

1-10 GENERAL INFORMATION Unit Conversion Table Prefixes for Units: Prefix mega kilo centi milli micro

Symbol M k c m µ

Units of Length:

× × × × ×

Power 1 000 000 1 000 0.01 0.001 0.000001

Units of Mass: kg g

× ×

2.205 0.03527

= =

lb oz

km m mm

× × ×

0.6214 3.281 0.03937

= = =

mile ft in

Units of Torque: N·m N·m N·m kgf·m kgf·m kgf·m

× × × × × ×

0.1020 0.7376 8.851 9.807 7.233 86.80

= = = = = =

kgf·m ft·lb in·lb N·m ft·lb in·lb

Units of Pressure: Units of Volume: L L L L L

× × × × ×

0.2642 0.2200 1.057 0.8799 2.113

= = = = =

L mL mL mL

× × × ×

1.816 0.03381 0.02816 0.06102

= = = =

gal (US) gal (imp) qt (US) qt (imp) pint (US) pint (imp) oz (US) oz (imp) cu in

Units of Force: N N kgf kgf

× × × ×

0.1020 0.2248 9.807 2.205

Units of Temperature:

kPa kPa kPa kgf/cm² kgf/cm² cm Hg

× × × × × ×

0.01020 0.1450 0.7501 98.07 14.22 1.333

= = = = = =

kgf/cm² psi cm Hg kPa psi kPa

=

mph

= = = =

PS HP kW HP

Units of Speed: km/h

×

0.6214

Units of Power: = = = =

kgf lb N lb

kW kW PS PS

× × × ×

1.360 1.341 0.7355 0.9863

PERIODIC MAINTENANCE 2-1

Periodic Maintenance Table of Contents Periodic Maintenance Chart ...................................................................................................

Torque and Locking Agent......................................................................................................

Specifications .........................................................................................................................

Special Tools ..........................................................................................................................

Periodic Maintenance Procedures..........................................................................................

Fuel System.........................................................................................................................

Fuel Hose and Connection Inspection ..............................................................................

Throttle Grip (Throttle Cable) Free Play Inspection ..........................................................

Throttle Grip (Throttle Cable) Free Play Adjustment.........................................................

Hot Starter Lever (Hot Starter Cable) Free Play Inspection..............................................

Idle Speed (Carburetor) Inspection ..................................................................................

Idle Speed (Carburetor) Adjustment ................................................................................

Air Cleaner Element Cleaning and Inspection ..................................................................

Fuel System Clean............................................................................................................

Cooling System....................................................................................................................

Coolant Level Inspection...................................................................................................

Coolant Deterioration Inspection.......................................................................................

Water Hoses and Connections Inspection ........................................................................

Engine Top End ...................................................................................................................

Valve Clearance Inspection ..............................................................................................

Valve Clearance Adjustment.............................................................................................

Cylinder Head Warp Inspection ........................................................................................

Cylinder Wear Inspection..................................................................................................

Piston/Cylinder Clearance Inspection ...............................................................................

Piston, Piston Ring and Piston Pin Replacement .............................................................

Exhaust System Inspection...............................................................................................

Muffler Baffle Replacement...............................................................................................

Clutch...................................................................................................................................

Clutch Operation Inspection..............................................................................................

Clutch Plates Inspection ...................................................................................................

Engine Lubrication System ..................................................................................................

Engine Oil Change............................................................................................................

Oil Filter Change ...............................................................................................................

Breather Hose Inspection .................................................................................................

Crankshaft/Transmission .....................................................................................................

Crankshaft Inspection .......................................................................................................

Wheel/Tires..........................................................................................................................

Air Pressure Inspection/Adjustment..................................................................................

Tires Inspection.................................................................................................................

Spoke Tightness Inspection ..............................................................................................

Rim Runout Inspection......................................................................................................

Wheel Bearing Inspection .................................................................................................

Final Drive............................................................................................................................

Drive Chain Wear Inspection ............................................................................................

Drive Chain Slack Inspection ............................................................................................

Drive Chain Slack Adjustment ..........................................................................................

Drive Chain Lubrication.....................................................................................................

Sprocket Wear Inspection.................................................................................................

Rear Sprocket Warp (Runout) Inspection .........................................................................

Brakes..................................................................................................................................

2-3 2-5 2-9 2-11 2-12 2-12 2-12 2-12 2-12 2-13 2-13 2-14 2-15 2-17 2-18 2-18 2-19 2-19 2-19 2-19 2-20 2-22 2-22 2-23 2-23 2-23 2-24 2-25 2-25 2-26 2-26 2-27 2-28 2-28 2-29 2-29 2-29 2-29 2-30 2-30 2-30 2-31 2-31 2-31 2-32 2-33 2-34 2-34 2-34 2-35

2

2-2 PERIODIC MAINTENANCE Brake Lever and Pedal Adjustment ..................................................................................

Brake Fluid Level Inspection.............................................................................................

Brake Fluid Change ..........................................................................................................

Brake Pad Wear Inspection ..............................................................................................

Brake Master Cylinder Rubber Parts Replacement ..........................................................

Caliper Rubber Parts Replacement ..................................................................................

Brake Hoses and Connections Inspection ........................................................................

Brake Hose Replacement .................................................................................................

Suspension ..........................................................................................................................

Front Fork Inspection ........................................................................................................

Front Fork Oil Change (each fork leg) ..............................................................................

Rear Shock Absorber Oil Change.....................................................................................

Swingarm and Uni-Trak Linkage Inspection .....................................................................

Swingarm and Uni-Trak Linkage Pivot Lubrication ...........................................................

Steering ...............................................................................................................................

Steering Inspection ...........................................................................................................

Steering Adjustment .........................................................................................................

Steering Stem Bearing Lubrication ...................................................................................

Frame ..................................................................................................................................

Frame Inspection ..............................................................................................................

Electrical System .................................................................................................................

Spark Plug Cleaning and Inspection.................................................................................

Spark Plug Replacement ..................................................................................................

General Lubrication and Cable Inspection...........................................................................

Lubrication ........................................................................................................................

Nut, Bolt, and Fastener Tightness Inspection ......................................................................

Tightness Inspection .........................................................................................................

2-35 2-36 2-37 2-39 2-39 2-41 2-44 2-44 2-46 2-46 2-46 2-56 2-65 2-65 2-66 2-66 2-66 2-68 2-68 2-68 2-69 2-69 2-69 2-70 2-70 2-71 2-71

PERIODIC MAINTENANCE 2-3 Periodic Maintenance Chart The maintenance must be done in accordance with this chart to keep the motorcycle in good running condition.

FREQUENCY OPERATION Spark plug - clean, inspect †

Each Every 3 Every 6 Every 12 See race or races or races or races or Page 2.5 hr 7.5 hr 15 hr 30 hr

•

Spark plug - replace Clutch - inspect Clutch plates - inspect † Throttle cable - inspect and adjust Air cleaner element - clean

• • • •

Air cleaner element - replace Carburetor - inspect and adjust

2-69

•

2-69 2-25 2-26 2-12 2-15

If damaged

•

2-13

• • •

Engine Oil - change E N G I N E

Piston and piston ring - replace Cylinder head, cylinder - inspect Piston pin - replace

•

Valve clearance - inspect † Hot starter cable - inspect

• •

Muffler baffle- change Kick pedal and shift pedal - clean Engine sprocket - inspect † Coolant level - inspect Water hoses and connections - inspect †

• • • •

•

Brake - adjust † Brake pad wear - inspect † Brake fluid level - inspect † Brake fluid - change Brake master cylinder cup and dust cover - replace C H Brake caliper fluid seal and dust seal - replace A Brake hoses - replace S Brake hoses, connections - inspect † S I Spoke tightness and rim runout - inspect † S Wheel bearing - inspect †

•

Frame - inspect Drive chain wear - inspect † Drive chain - inspect and adjust Drive chain - lubricate

2-22

•

2-23 2-19 2-28 2-24 – 2-34 2-18 2-19

•

• • • •

2-29 2-28 2-35 2-39 2-36

Every Every Every Every

• • • • • • •

2-23

2-23

Crankshaft - inspect Breather hose - inspect

2-27

2-13

Oil filter - replace Exhaust system - inspect†

2-15

2 2 2 4

years years years years

2-37 2-39 2-41 2-44 2-44 2-30 2-31 2-68 2-31 2-32 2-34

2-4 PERIODIC MAINTENANCE Periodic Maintenance Chart FREQUENCY OPERATION Wheels/tires - inspect Rear sprocket - inspect † Front fork - inspect and clean

Each Every 3 Every 6 Every 12 See race or races or races or races or Page 2.5 hr 7.5 hr 15 hr 30 hr

• • •

2-30 2-34 2-46

• •

Front fork oil - change Rear shock absorber oil - change Cable - inspect

•

Fuel hose - replace Fuel hose, connections - inspect † Fuel system - clean Steering play - inspect †

•

Swingarm and Uni-Trak linkage pivots - inspect † Nuts, bolts, fasteners - inspect † General lubrication - perform †: Replace, add, adjust, clean or torque if necessary.

• •

2-12 2-12

•

2-17 2-66

Steering stem bearing - lubricate Swingarm and Uni-Trak linkage pivots - lubricate

2-56 2-70

Every 4 years

•

2-46

• •

•

2-68 2-65 2-65 2-71 2-70

PERIODIC MAINTENANCE 2-5 Torque and Locking Agent Tighten all bolts and nuts to the proper torque using an accurate torque wrench. If insufficiently tightened, a bolt or nut may become damaged, strip an internal thread, or break and then fall out. The following table lists the tightening torque for the major bolts and nuts, and the parts requiring use of a non-permanent locking agent or silicone grease etc.

When checking the tightening torque of the bolts and nuts, first loosen the bolt or nut by half a turn and then tighten to specified torque.

Letters used in the "Remarks" column mean: AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque.

G: Apply grease.

L: Apply a non-permanent locking agent.

Lh: Left-hand Threads MO: Apply molybdenum disulfide oil. (mixture of engine oil and molybdenum disulfide grease with a weight ratio 10 : 1) R: Replacement Parts S: Follow the specified tightening sequence.

Si: Apply silicone grease (ex. PBC grease).

Fastener Fuel System Throttle Pulley Cover Bolt Throttle Cable Bolts Hot Starter Plunger Cap Bolt Air Cleaner Element Wing Bolt Air Cleaner Duct Nuts Air Cleaner Duct Bolt Air Cleaner Housing Bolts Cooling System Water Pump Cover Bolts (L = 30, 65 mm) Water Pump Cover Bolts (L = 55 mm) Coolant Drain Bolt Water Pump Impeller Bolt Water Hose Clamp Screws Water Pipe Bolt Radiator Mounting Bolts Radiator Screen Bolts Radiator Shroud Bolts Engine Top End Auto-Decompressor Bolt Cylinder Head Cover Bolts Camshaft Cap Bolts Cylinder Head Bolts (M10) Cylinder Head Bolts (M6) Plug Decompressor Plug Plate Bolt Carburetor Holder Clamp Screw

N·m

Torque kgf·m

ft·lb

3.4 3.5 1.0

0.35 0.36 0.10

30 in·lb 31 in·lb 9 in·lb

–

–

–

3.0 7.1 9.8

0.30 0.72 1.0

27 in·lb 63 in·lb 87 in·lb

9.8

1.0

87 in·lb

9.8

1.0

87 in·lb

7.0 7.0 3.0 9.8 9.8 9.8 9.8

0.71 0.71 0.31 1.0 1.0 1.0 1.0

62 62 27 87 87 87 87

12 9.8 9.8 49 12 20 9.8 2.0

1.2 1.0 1.0 5.0 1.2 2.0 1.0 0.20

106 in·lb 87 in·lb 87 in·lb 36 106 in·lb 15 87 in·lb 18 in·lb

Remarks

Hand Tighten

L

in·lb in·lb in·lb in·lb in·lb in·lb in·lb

S, MO S, MO S L

2-6 PERIODIC MAINTENANCE Torque and Locking Agent Fastener Carburetor Clamp Screw Cylinder Bolt Camshaft Chain Tensioner Cap Bolt Camshaft Chain Tensioner Mounting Bolts Lower Camshaft Chain Guide Bolt Rear Camshaft Chain Guide Bolt Exhaust Pipe Cover Screws Exhaust Pipe Holder Nuts Muffler Mounting Bolts Muffler Clamp Bolt Clutch Clutch Cover Bolts Right Engine Cover Bolts Clutch Spring Bolts Clutch Hub Nut Oil Filler Plug Primary Gear Nut Engine Lubrication System Breather Fitting Oil Pump Mounting Bolts Oil Pump Idle Gear Shaft Screws Oil Filter Cap Bolts Piston Oil Nozzle Engine Oil Drain Bolt Engine Removal/Installation Upper Engine Mounting Bolts (M10) Upper Engine Bracket Bolts (M8) Middle Engine Mounting Nut (M10) Middle Engine Bracket Nuts (M8) Lower Engine Mounting Nut (M10) Swingarm Pivot Shaft Nut Crankshaft/Transmission Crankcase Bolts 50 mm (2.0 in.)

Crankcase Bolts 60 mm (2.4 in.)

Crankcase Bolts 65 mm (2.6 in.)

Crankcase Bolts 70 mm (2.8 in.)

Crankcase Bearing Retainer Bolts Piston Oil Nozzle Reed Valve Screws Primary Gear Nut Kick Pedal Bolt Kick Ratchet Guide Bolt

2.0 12 20

Torque kgf·m 0.20 1.2 2.0

ft·lb 18 in·lb 106 in·lb 15

9.8

1.0

87 in·lb

9.8 15 12 15

1.0 1.5 1.2 1.5

87 in·lb 11 106 in·lb 11

21 11

2.1 1.1

15 97 in·lb

9.8 9.8 9.8 98 5.0 98

1.0 1.0 1.0 10 0.51 10

87 in·lb 87 in·lb 87 in·lb 72 44 in·lb 72

15 7.0 5.9 9.8 2.9

1.5 0.71 0.60 1.0 0.30

11 62 in·lb 52 in·lb 87 in·lb 26 in·lb

20

2.0

15

49 29 49 29 49 98

5.0 3.0 5.0 3.0 5.0 10

36 21 36 21 36 72

S S R, S R, S R, S R, S

9.8 9.8 9.8

1.0 1.0 1.0

87 in·lb 87 in·lb 87 in·lb

S

9.8 15 2.9 7.0 98 25 8.8

1.0 1.5 0.30 0.71 10 2.5 0.90

87 in·lb 11 26 in·lb 62 in·lb 72 18 78 in·lb

N·m

Remarks

S

S S S

R Lh, R L L L

S S S L

Lh, R L L

PERIODIC MAINTENANCE 2-7 Torque and Locking Agent Fastener Ratchet Plate Bolt (Front) Ratchet Plate Bolt (Rear) Shift Drum Cam Bolt Gear Positioning Lever Nut Shift Pedal Bolt Wheels/Tires Spoke Nipples Front Axle Nut Front Axle Clamp Bolts Rear Axle Nut Final Drive Rear Sprocket Nuts Engine Sprocket Cover Bolts Brakes Front Brake Reservoir Cap Screws Front Master Cylinder Clamp Bolts Brake Lever Pivot Bolt Brake Lever Pivot Bolt Locknut Brake Hose Banjo Bolts Brake Hose Clamp Mounting Bolt Front Brake Disc Mounting Bolts Caliper Bleed Valve Front Brake Pad Pin Front Caliper Mounting Bolts Rear Brake Reservoir Cap Screws Rear Master Cylinder Mounting Bolts Rear Master Cylinder Push Rod Locknut Brake Pedal Bolt Rear Brake Disc Mounting Bolts Rear Brake Pad Pin Plug Rear Brake Pad Pin Rear Caliper Holder Shaft Suspension Front Fork Cylinder Unit Front Fork Clamp Bolts (Lower) Front Fork Clamp Bolts (Upper) Front Fork Adjuster Assembly Locknut Front Fork Base Valve Assembly Front Fork Adjuster Assembly Pressure Relief Screws Swingarm Pivot Shaft Nut Rocker Arm Pivot Nut

N·m 9.8 15 24 8.8 9.8

Torque kgf·m 1.0 1.5 2.4 0.90 1.0

ft·lb 87 in·lb 11 18 78 in·lb 87 in·lb

Not Less Than 2.2 79 20 108

Not Less Than 0.22 8.1 2.0 11.0

Not Less Than 19 in·lb 58 15 80

34 4.9

3.5 0.50

25 43 in·lb

1.5 8.8 5.9 5.9 25 3.0 9.8 7.8 17 25 1.5 9.8 17 25 23 2.5 17 27

0.15 0.90 0.60 0.60 2.5 0.31 1.0 0.80 1.7 2.5 0.15 1.0 1.7 2.5 2.3 0.25 1.7 2.8

13 in·lb 78 in·lb 52 in·lb 52 in·lb 18 27 in·lb 87 in·lb 69 in·lb 13 18 13 in·lb 87 in·lb 13 18 17 22 in·lb 13 20

34 20 20 22 30 69 1.3 98 59

3.5 2.0 2.0 2.2 3.1 7.0 0.13 10 6.0

25 15 15 16 22 51 12 in·lb 72 44

Remarks L, S L, S L

AL

R

S Si

L

L, G L

Si

AL AL, L

L R R

2-8 PERIODIC MAINTENANCE Torque and Locking Agent Fastener Tie-Rod Mounting Nuts Rear Shock Absorber Mounting Nut (Upper) Rear Shock Absorber Mounting Nut (Lower) Rear Shock Absorber Spring Locknut Piston Rod Locknut Gas Reservoir Damping Adjuster Assembly Steering Handlebar Clamp Bolts Steering Stem Head Nut Steering Stem Nut Front Fork Clamp Bolts (Upper ) Front Fork Clamp Bolts (Lower) Frame Rear Frame Mounting Bolts Footpeg Bracket Bolts (Upper) Electrical System C.D.I. Unit Mounting Bolts Spark Plug Timing Inspection Cap Flywheel Cap Magneto Cover Bolts Flywheel Nut Stator Bolts Crankshaft Sensor Bolts Neutral Switch Neutral Switch Terminal Screw

N·m 59

Torque kgf·m 6.0

ft·lb 44

39

4.0

29

R

34

3.5

25

R

45 37

4.6 3.8

33 27

R

29

3.0

21

25 98 4.9 20 20

2.5 10 0.50 2.0 2.0

18 72 43 in·lb 15 15

AL, L AL

34 54

3.5 5.5

25 40

L

9.8 13 3.9 4.9 9.8 49 7.0 7.0 12 1.5

1.0 1.3 0.40 0.50 1.0 5.0 0.71 0.71 1.2 0.15

87 in·lb 115 in·lb 35 in·lb 43 in·lb 87 in·lb 36 62 in·lb 62 in·lb 106 in·lb 13 in·lb

Remarks R

AL

Basic Torque for General Fasteners Threads diameter (mm) 5 6 8 10 12 14 16 18 20

Torque N·m 3.4 ∼ 4.9 5.9 ∼ 7.8 14 ∼ 19 25 ∼ 34 44 ∼ 61 73 ∼ 98 115 ∼ 155 165 ∼ 225 225 ∼ 325

kgf·m 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 ∼ 23.0 23 ∼ 33

ft·lb 30 ∼ 43 in·lb 52 ∼ 69 in·lb 10.0 ∼ 13.5 19.0 ∼ 25 33 ∼ 45 54 ∼ 72 83 ∼ 115 125 ∼ 165 165 ∼ 240

L L

PERIODIC MAINTENANCE 2-9 Specifications Item Fuel System Throttle Grip Free Play Hot Starter Lever Free Play Idle Speed Air Cleaner Element Oil Cooling System Coolant: Type (recommended) Color Mixed Ratio Freezing Point Total Amount Engine Top End Valve Clearance: Exhaust Inlet Cylinder Head Warp

Standard

Service Limit

2 ∼ 3 mm (0.08 ∼ 0.12 in.)

0.5 ∼ 1.0 mm (0.02 ∼ 0.04 in.)

1 950 ±50 r/min (rpm) High quality foam air filter oil

– – – –

Permanent type antifreeze Green Soft water 50%, antifreeze 50% –35°C (–31°F) 1.2 L (1.3 US qt.)

– – –

0.17 ∼ 0.22 mm (0.0067 ∼ 0.0087 in.)

0.10 ∼ 0.15 mm (0.0039 ∼ 0.0059 in.)

–––

Cylinder Inside Diameter (see text) 77.000 ∼ 77.012 mm (3.0315 ∼ 3.0320 in.)

Piston/Cylinder Clearance 0.041 ∼ 0.068 mm

– – – –

– – – –

– – – –

– – – –

– – – –

– – – – – – 0.05 mm (0.0020 in.)

77.10 mm (3.035 in.)

– – –

(0.0016 ∼ 0.0027 in.)

Clutch Clutch Lever Free Play Friction Plate Thickness Friction Plate Warp Steel Plate Warp Engine Lubrication System Engine Oil: Grade

Viscosity Capacity

8 ∼ 13 mm (0.3 ∼ 0.5 in.)

2.72 ∼ 2.88 mm (0.107 ∼ 0.113 in.)

0.15 mm (0.0059 in.) or less 0.15 mm (0.0059 in.) or less

Castrol “POWER1 R4 Racing” 5W-40 or API SG, SH, SJ or SL with JASO MA, MA1 or MA2 SAE 10W-30, 10W-40, or 10W-50 0.75 L (0.79 US qt.) (when filter is not removed) 0.80 L (0.85 US qt.) (when filter is remove) 1.00 L (1.06 US qt.) (when engine is completely dry)

– – – 2.5 mm (0.10 in.)

0.3 mm (0.012 in.)

0.3 mm (0.012 in.)

– – – – – – – – –

Crankshaft/Transmission Connecting Rod Big End Side Clearance

0.25 ∼ 0.35 mm (0.0098 ∼ 0.0138 in.)

0.6 mm (0.02 in.)

2-10 PERIODIC MAINTENANCE Specifications Item Wheels/Tires Rim Runout (with tire installed): Axial Radial Tires Air Pressure (Front/Rear) Standard Tire: Front: Size Make Type Rear: Size Make Type Final Drive Drive Chain Slack Drive Chain 20-link Length Rear Sprocket Warp (Runout) Brakes Brake Lever Free Play Brake Fluid Type: Front Rear Brake Pad Lining Thickness: Front Rear Suspension Fork Oil: Viscosity Capacity (per unit): Cylinder Unit Cylinder Unit Oil Level Outer Tube Rear Shock Absorber Oil: Viscosity Capacity Electrical System Spark Plug Gap

Standard

TIR 1.0 mm (0.039 in.) or less TIR 1.0 mm (0.039 in.) or less 100 kPa (1.00 kgf/cm², 14 psi)

Service Limit

TIR 2.0 mm (0.079 in.)

TIR 2.0 mm (0.079 in.)

– – –

80/100-21 51M BRIDGESTONE M403, Tube

– – – – – – – – –

100/90-19 57M BRIDGESTONE M404, Tube

– – – – – – – – –

52 ∼ 58 mm (2.0 ∼ 2.3 in.)

317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.)

TIR 0.4 mm (0.016 in.) or less

– – – 323 mm (12.7 in.)

TIR 0.5 mm (0.020 in.)

Adjustable (to suit rider)

– – –

DOT3 or DOT4 DOT3 or DOT4

– – – – – –

4.0 mm (0.16 in.)

6.4 mm (0.25 in.)

1 mm (0.04 in.)

1 mm (0.04 in.)

SHOWA SS-19 or equivalanet SAE 5W

– – –

180 mL (6.09 US oz.)

42 ∼ 49 mm (1.7 ∼ 1.9 in.)

369 ±2.5 mL (12.5 ±0.085 US oz.)

– – – – – – 307 ∼ 408 mL (10.4 ∼ 13.8 US oz.)

SHOWA SS-25 or equivalent SAE 2.5W Approximately 395 mL (13.4 US oz.)

– – – – – –

0.7 ∼ 0.8 mm (0.026 ∼ 0.031 in.)

– – –

PERIODIC MAINTENANCE 2-11 Special Tools Inside Circlip Pliers: 57001-143

Carburetor Drain Plug Wrench, Hex 3: 57001-1269

Steering Stem Nut Wrench: 57001-1100

Filler Cap Driver: 57001-1454

Jack: 57001-1238

Pilot Screw Adjuster, D: 57001-1588

Attachment Jack: 57001-1252

Jack Attachment: 57001-1608

Spark Plug Wrench, Hex 16: 57001-1262

Top Plug Wrench, 50 mm: 57001-1645

2-12 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel System Fuel Hose and Connection Inspection

○If the motorcycle is not properly handled, the inside the

•

fuel line can cause fuel to leak [A].

Check the fuel hose.

Replace the fuel hose if any fraying, cracks [B], bulges [C] or ozone cracks [D] are noticed.

that the hose [A] are securely connected and • Check clamps [B] are tightened correctly. the hose according to Cable, Wire, and Hose Rout• Route ing section in the Appendix chapter.

○Avoid sharp bending, kinking, flattening or twisting, and route the fuel hose with a minimum of bending so that the fuel flow will not be obstructed.

Replace the hose if it has been sharply bent or kinked.

Throttle Grip (Throttle Cable) Free Play Inspection

throttle grip free play by lightly turning the throttle • Check grip [A] back and forth [B].

Throttle Grip Free Play Standard: 2 ∼ 3 mm (0.08 ∼ 0.12 in.)

•

•

If the free play is improper, adjust the throttle cable.

Check that the throttle grip moves smoothly from full open to close, and the throttle closes quickly and completely in all steering positions by the return spring.

If the throttle grip does not return properly, check the throttle cable routing, grip free play, and cable damage. Then lubricate the throttle cable.

Run the engine at the idle speed, and turn the handlebar all the way to the right and left to ensure that the idle speed does not change.

If the idle speed increase, check the throttle cable free play and the cable routing.

Throttle Grip (Throttle Cable) Free Play Adjustment

the locknuts [A] [B] at the upper end of the throttle • Loosen cable. both throttle cable adjuster [C] [D] to give the throt• Screw tle grip plenty of play. out the decelerator adjuster [C] until there is no play • Turn when the throttle grip is completely closed. the locknut [A].

• Tighten Turn the accelerator cable adjuster [D] until 2 ∼ 3 mm • (0.08 ∼ 0.12 in.) of throttle grip play is obtained.

• Tighten the locknut [B].

PERIODIC MAINTENANCE 2-13 Periodic Maintenance Procedures

•

If the throttle grip free play cannot be adjusted with the adjuster, replace the throttle cables.

Turn the handlebar from side to side while idling the engine. If idle speed varies, the throttle cable may be poorly routed or it may be damaged.

WARNING Operation with an improperly adjusted, incorrectly routed or damaged cables could result in an unsafe riding Condition. Follow the service manual to make sure to correct any of these conditions.

Hot Starter Lever (Hot Starter Cable) Free Play Inspection

the clutch lever dust cover back.

• Slide Check hot starter lever play [A] when pulling the start • lever [B]thelightly.

Hot Starter Lever Free Play Standard: 0.5 ∼ 1.0 mm (0.02 ∼ 0.04 in.)

If the free play is improper, adjust the hot starter cable. the locknut [A] and turn the adjuster [B] to obtain • Loosen the proper lever free play. the locknut securely.

• Tighten Check that the hot starter lever moves smoothly from full • open to close, and the lever closes quickly and completely in all steering positions by the return spring.

If the hot starter lever does not return properly, check the hot starter cable routing, free play and cable damage.

Then lubricate the hot starter cable.

Idle Speed (Carburetor) Inspection NOTICE This motorcycle is designed for competition use only. Therefore, the radiator does not incorporate a coolant reserve tank or radiator fan. Prolonged idling of the engine with no airflow through the radiator can cause coolant loss and engine overheating resulting in possible engine damage. Any riding conditions that increase engine temperature will further reduce idling time before coolant loss occurs. These conditions include high ambient temperature, sandy or muddy terrain, or other conditions causing high engine loads at low speeds.

Furthermore, warming the engine up excessively before operation, or leaving idling with the hot engine temperature after operation results in the engine overheating, too.

2-14 PERIODIC MAINTENANCE Periodic Maintenance Procedures the engine and warm it up thoroughly.

• Start With the engine idling, turn the handlebar to both sides.

• If handlebar movement changes the idle speed, the throttle cable may be improperly adjusted or incorrectly routed, or it may be damaged. Be sure to correct any of these conditions before riding (see Cable, Wire, and Hose Routing section in the Appendix chapter).

WARNING Operation with an improperly adjusted, incorrectly routed or damaged cables could result in an unsafe riding Condition. Follow the service manual to make sure to correct any of these conditions. the idle speed, using the engine revolution tester • Check [A] for high accuracy.

Idle Speed Standard:

1 950 ±50 r/min (rpm)

If the idle speed is out of specified range, adjust it.

Idle Speed (Carburetor) Adjustment

in the pilot screw using the pilot screw adjuster [A] • Turn until it seats lightly.

• Back it out the specified number of turns.

Special Tool - Pilot Screw Adjuster, D: 57001-1588 Pilot Screw Standard:

1 1/2 turns out (US, CA) 2 1/8 turns out

NOTE

○When removing the pilot screw adjuster from the carburetor, lift the carburetor lightly with suitable tool. the engine and warm it up thoroughly.

• Start Turn • correct.the idle adjusting screw [A] until the idle speed is

•

To increase idle speed [B] To decrease idle speed [C] Open and close the throttle a few times to make sure that the idle speed is within the specified range. Readjust if necessary.

PERIODIC MAINTENANCE 2-15 Periodic Maintenance Procedures Air Cleaner Element Cleaning and Inspection NOTE

○In dusty areas, the element should be cleaned more frequently than recommended interval. ○After riding through rain or on muddy roads, the element should be cleaned immediately. ○Since repeated cleaning opens the pores of the element, replace it with a new one in accordance with the Periodic Maintenance Chart. Also, if there is a break in the element material or any other damage to the element, replace the element with a new one.

WARNING Gasoline and low-flash point solvents can be flammable and/or explosive and cause severe burns. Clean the element in a well-ventilated area, and take care that there is no spark or flame anywhere near the working areas. Do not use gasoline or low-flash point solvents to clean the element.

• Remove: Seat (see Seat Removal in the Frame chapter) • •

Wing Bolt [A] Air Cleaner Element [B] Stuff a clean, lint-free towel into the air cleaner duct so no dirt is allowed to enter the carburetor.

Wipe out the inside of the air cleaner housing with a clean damp towel.

NOTICE Check inside of the inlet tract and carburetor for dirt. If dirt is present, clean the inlet tract and carburetor thoroughly. You may also need to replace the element and seal the housing and inlet tract.

• Separate the element [A] from the frame [B].

2-16 PERIODIC MAINTENANCE Periodic Maintenance Procedures the element [A] in a bath of a high-flash point sol• Clean vent using a soft bristle brush.

it dry in a clean towel [A]. Do not wring the ele• Squeeze ment or blow it dry; the element can be damaged. all parts of the element for visible damage.

• Check If any parts of the element are damaged, replace them.

cleaning, saturate the element with a high-quality • After foam-air-filter oil, squeeze out the excess, then wrap it in a clean towel and squeeze it as dry as possible. ○Be careful not to tear the sponge filter.

Assemble the element.

Remove the towel from the air cleaner duct.

• • grease to all connections and screw holes in the air • Apply cleaner housing and inlet tract. the element onto its frame, and coat the element • Install lip and lip seat with a thick layer of all-purpose grease to assure a complete seal.

the air cleaner element so that its tab [A] faces • Install upward and its projections [B] align with the holes [C] of

•

the air cleaner housing.

Tighten the wing bolt [D].

PERIODIC MAINTENANCE 2-17 Periodic Maintenance Procedures Fuel System Clean

WARNING Gasoline is extremely flammable and can be explosive under certain conditions. Always stop the engine and do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. the fuel tap to the OFF position.

• Turn Place • tube [A].a suitable container beneath the carburetor drain the drain plug [B] from the bottom of the float • Unscrew bowl and check for water or dirt in the fuel.

Special Tool - Carburetor Drain Plug Wrench, Hex 3 [C]: 57001-1269

•

If any water or dirt comes out, clean the carburetor, fuel tap and fuel tank.

Tighten the drain plug securely.

WARNING Gasoline and low-flash point solvents can be flammable and/or explosive and cause severe burns. Clean the tank in a well-ventilated area, and take care that there are no sparks or flame anywhere near the working area. Do not use gasoline or low-flash point solvents to clean the tank. the fuel tank and drain the fuel (see Fuel Tank • Remove Removal in the Fuel System chapter). some high-flash point solvent into the fuel tank and • Pour shake the tank to remove dirt and fuel deposits. the solvent out of the tank.

• Drain Remove the fuel tap (see Fuel Tap Removal in the Fuel • System chapter). the fuel tap filter screen in a high-flash point sol• Clean vent. high-flash point solvent through the tap in all lever • Pour positions. the tank and tap with compressed air.

•○Dry Take care not to damage the fuel tap screen with the com-

•

pressed air.

Install: Fuel Tap (see Fuel Tap Installation in the Fuel System chapter) Fuel Tank (see Fuel Tank Installation in the Fuel System chapter)

2-18 PERIODIC MAINTENANCE Periodic Maintenance Procedures Cooling System WARNING Coolant can be extremely hot and cause severe burns, is toxic and very slippery. Do not remove the radiator cap or attempt to change the coolant when the engine is hot; allow it cool completely.

Immediately wipe any spilled coolant from tires, frame, engine or other painted parts. Do not ingest coolant.

Coolant Level Inspection NOTE

○Check the level when the engine is cold (room or ambient temperature). the right radiator shroud (see Radiator Removal • Remove in the Cooling System chapter). the motorcycle slightly to the left until the radiator • Lean cap is level to the ground so that the radiator cap is located

•

uppermost in order to exhaust the air accumulated in the radiator.

Remove the radiator cap [A].

NOTE

○Remove the radiator cap in two steps.

First turn the cap counterclockwise to the first stop and wait there for a few seconds. Then push down and turn it further in the same direction and remove the cap.

the coolant level. The coolant level [A] should be • Check at the bottom of the filler neck [B].

If the coolant level is low, add coolant through the filler opening to the bottom of the filler neck. Install the cap.

Recommended Coolant Permanent type antifreeze (soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators) Water and Coolant Mixture Ratio Soft Water: 50% Antifreeze: 50% Freezing Point: –35°C (–31°F) Total Amount: 1.2 L (1.3 US qt.)

PERIODIC MAINTENANCE 2-19 Periodic Maintenance Procedures NOTICE For refilling, add the specified mixture of coolant and soft water. Adding water alone dilutes the coolant and degrades its anticorrosion properties.

The diluted coolant can attack the aluminum engine parts. In an emergency, soft water alone can be added. But the diluted coolant must be returned to the correct mixture ratio within a few days.

Coolant Deterioration Inspection

inspect the coolant.

• Visually If whitish cotton-like wafts are observed, aluminum parts in the cooling system are corroded. If the coolant is brown, iron or steel parts are rusting. In either case, flush the cooling system.

If the coolant gives off an abnormal smell, check for a cooling system leak. It may be caused by exhaust gas leaking into the cooling system.

Water Hoses and Connections Inspection

the radiator shroud (see Radiator Removal in the • Remove Cooling System chapter).

○The high pressure inside the water hoses [A] can cause

•

coolant to leak [B] or the hose to burst if the line is not properly maintained. Visually inspect the hoses for signs of deterioration. Squeeze the hoses. A hose should not be hard and brittle, nor should it be soft or swollen.

Replace the hose if any fraying, cracks [C] or bulges [D] are noticed.

Check that the hoses are securely connected and clamps are tightened correctly.

Torque - Water Hose Clamp Screws: 3.0 N·m (0.31 kgf·m, 27 in·lb)

Engine Top End Valve Clearance Inspection NOTE

○Valve clearance must be checked and adjusted when the engine is cold (at room temperature).

• Remove: Cylinder Head Cover (see Cylinder Head Cover Removal in the Engine Top End chapter) Timing Inspection Cap [A] Flywheel Nut Cap [B] Special Tool - Filler Cap Driver: 57001-1454

2-20 PERIODIC MAINTENANCE Periodic Maintenance Procedures the piston to the TDC (compression stroke) to in• Place spect the valve clearance.

○Place a wrench over the flywheel nut [A] and turn it counterclockwise to align the TDC mark [B] with the center of the groove [C] of the inspection hole. ○In the TDC, the cam lobes turn to the outside each other.

Timing Mark [D]

a thickness gauge [A], measure the clearance be• Using tween each cam lobe and valve lifter for all 4 valves.

○For the purpose of adjusting the valve clearances, record the measured values.

Valve Clearance Standard: Exhaust

0.17 ∼ 0.22 mm (0.0067 ∼ 0.0087 in.)

Inlet

0.10 ∼ 0.15 mm (0.0039 ∼ 0.0059 in.)

If the valve clearance is not within the specified range, adjust it.

Valve Clearance Adjustment

• Remove: Camshaft Cap [A] (see Camshaft Removal in the Engine • •

Top End chapter) Camshafts [B] (see Camshaft Removal in the Engine Top End chapter) Remove the valve lifters [C] of the applicable valve.

Remove the shim [D].

NOTE

○Mark and record the locations of the valve lifters and shims so that they can be reinstalled in their original positions.

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