Kawasaki KLR 250 Motorcycle Service Manual SupplementQuick Reference Guide | General Information El [Engine Top End sO [ Engine Removal/installation [idl “Bectical Stem Appendix EaKawasaki KLR 250 Motorcycle Service Manual Supplement 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 other- wise, without the prior written permission of Quality Assurance Department/Consumer Products Group/Kawasaki Heavy Industries, Ltd., Japan. No liability can be accepted for any inaccuracies or omissions in this publica 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. n, although every © Kawosaki Heavy Industies. Ltd. 1984, 1987, 1989, 1991, 1993, 1995, 1986 Eighth Editon (1) : Nov. 28, 1996 (K)LIST OF ABBREVIATIONS A ampere(s) Ib pound(s) ABDC after bottom dead center m meter(s) ac alternating current min minute(s) TDC 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 pst pound(s) per square inch °c degree(s) Celsius r revolution pc direct current ‘pm revolution(s) per minute F farad(s) Toc top dead center oF degree(s) Fahrenheit TR total indicator reading ft foot, feet v volts) 9 gram{s) w watt(s) h hour(s) a ohm(s) L liter(s) This warning may apply to any of the fellowing components or any assembly containing one or ‘more of these components:— Brake Shoes or Pa Clutch Friction Mater Gaskets Insulators WARNING SAFETY INSTRUCTIONS ‘CONTAINS Peet ‘Operate if possible out of doors or in a well reine vertiteted pie ‘shea ‘Prefereby ev hand tools oF low speed tools equipped, i necessary, with an appropriate dust — ‘extraction feciity. It high speed tools ae used, they should always bo so equipped. ‘if possible, dampen before cutting or dri Dampen dist and place it in propery closed receptacle and dispose off safely. Read OWNER’S MANUAL before operating.RAB AARSRAN RES SN SRSAS SERENE EMISSIONT CONTROL INFORMATION scene 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 reg ulations of the United States Environmental Protection Agency and California Air Re- sources Board. Additionally, Kawasaki has incorporated an evaporative emission control system (3) in compliance with applicable regulations of the California Air Resources Board on vehicles sold in California only. 1. Crankcase Emission Control System This system eliminates the release of crankcase vapors into the atmosphere. Instead, the vapors are routed through an oil separator to the intake side of the engine, While the engine is operating, the vapors are drawn into combustion chamber, where they are burned along with the fuel and air supplied by the carburetion system. 2. Exhaust Emission Control System This system reduces the amount of pollutants discharged into the atmosphere by the exhaust of this motorcycle, The fuel and ignition systems of this motorcycle have been carefully designed and constructed to ensure an efficient engine with low exhaust pollutant levels. 3, Evaporative Emission Control System Vapors caused by fuel evaporation in the fuel system are not vented into the atmos- phere. Instead, fuel vapors are routed into the running engine to be burned, or stored in a canister when the engine is stopped. Liquid fuel is caught by a vapor separator and returned to the fuel tank. RS 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... (B)(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 ttle prior to its sale and delivery to the ultimate purchaser, ‘or for any manufacturer or desler 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 opérates 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 thé ultimate purchaser...” SS (Continued on next page.)NOTE ©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 or rendering inoperative of devices or elements of design in order to perform maintenance. 2. Tampering could include: , Maladjustment of vehicle components such that the emission standards are exceeded. 6. Use of replacement parts or accessories which adversely affect the performance or durability of the motorcycle. ©. Addition of components or accessories thet result in the vehicle exceeding the standards. , 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. IEE SR a ESERIES TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noize control prior to its sale or delivery to the ultimate purchaser or while itis in use, or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person. Among those acts presumed to constitute tampering are the acts listed below: ‘*Replacement of the original exhaust system or muffler with a component not in com- pliance with Federal regulations, ‘Removal of the muffier(s) or any internal portion of the muffler{s). ‘Removal of the air box or air box cover. ‘°Modifications to the muffler(s) or air intake system by cutting, drilling, or other means if such modifications result in increased noise levels. a £ eroenenancenanerenenanenenanteerenentaenneerenForeword This KLR260 Service Manual Supplement is designed to be used in conjunction with the KLR600 Motorcycle Service Manual (P/N 99924-1050-01). The maintenance and repair procedures described in this supplement are only those thet are unique to the KLR250 motor- cycle, Most service operations for these models: remain identical to those described in the base Service Manual. Complete and proper servicing of the KLR260 motorcycle therefore requires both this supplement and the base Service Manual, The base Service Manual and this Supplement are designed primarily for use by motorcycle mechanics in a properiy equipped shop. However, they contain enough detail and, basic information to make them useful to. the operator who desires to perform his own basic maintenance and repair work. A basic know- ledge of mechanics, the proper use of tools, and work shop procedures must be understood in order to carry out maintenance and repair satisfactorily. Whenever the operator has insufficient experience or doubts his ability to do the work, the adjustments, maintenance, and repair should be carried out only by qualified mechanics. In order to perform the work efficiently and to avoid costly mistakes, the mechanic should read the text, thoroughly familiarize himself with the procedures before starting work, and then do the work carefully in a clean area. Whenever special tools and equipment are specified, makeshift tools or equipment should not be used. Precision measurements can only be made if the proper instruments are used, and ‘the use of substitute tools may adversely affect safe operation of the motorcycle. 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 asingle 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 scheduile 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. oThis warning symbol identifies special instruc- tions or procedures which, if not correctly followed, could result in personal injury, or loss of life. This caution symbol identifies special instruc- tions or procedures which, if not strictly served, 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 oThis note symbol indicates points of particular interest for more efficient and convenient ‘operation. ‘Indicates a procedural step or work to be done. olndicstes 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 inspec- tion in the procedural step or subrstep it follows, “Indicates a conditional sub-step or what action ‘to take based upon the results of the condi- tional 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. Pariodic Maintenance Chart. 12 14 15 181-2 GENERAL INFORMATION Before Servicing Before starting to service a motorcycle, careful reading of the applicable section is recommended to (inate unnecessary work, Photographs, diagrams, notes, cautions, warnings, and detailed des criptions have been included wherever necessary. Nevertheless, even a detailed account has limita- tions, a certain amount of basic knowledge is also required for successful work. Especially note the following: (1) Dirt Before removal and disassembly, clean the motorcycle. Any dirt entering the engine or other parts will work as an abrasive and shorten the life of the motorcycle. 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 motorcycle, 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) Tightening Sequence Generally, when installing a part with several bolts, nuts, or screws, they should all be started in their holes and tightened 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 sorews must be tightened in the order and method indicated. (4) Torque ‘The torque values given in this Service Manual should always be adhered to. 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 4 part seems especially difficult to remove or install, stop and examine what may be causing the problem, Whenever tapping is necessary, tep lightly using a wooden or piastic 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 com- ‘monly available in North America is Stoddard solvent (generic name). Alweys follow manufac- turer and container directions regarding the use of any solvent, (8) 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. uid Gasket, Non-permanent Locking Agent Follow manufacturer's directions for clesning and preparing surfaces where these compounds will be used. Apply sparingly. Excessive amounts may block engine oil passages and cause serious damage. An example of a nonpermanent 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 wheel bearing, should first be coated with oil on its outer or inner circumference so that it will 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 suitable 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. (9)GENERAL INFORMATION 1-3 (12) Oil Seal and Gresse Seal 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, (13) 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 oil, preferably high temperature grease on the lips to reduce rubber to metal friction. (14) Cirelip, Retaining Ring Repiace 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. generally at its meximum while the engine is warming up and before all the rubbing surfaces have an adequate lubricative film. During essembly, oil or grease (whichever is more suitable) should be applied to any rubbing surface which has lost its lubricetive 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 ate not intended. This manual makes reference to molybdenum disulfide grease (MoS, ) in the assembly of certal engine and chassis parts. Always check manufacturer recommendations before using such special lubricants, (16) Electrical Wires All the electrical wires are either single color or two color end, with only 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 4 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) Name of Wire Color Red Wire strands Yellow/red Yeliow 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 (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. inal function once removed. Abrasion Crack Hardening Warp Bent Dent Seratch Wear Color change Deterioration Seizure ' (19) Service Data Numbers of service data in this text have following meanings: ‘"Standards”: Show dimensions or performances which brand-new parts or systems have, “Service limits”: Indicate the usable limits, If the measurement shows excessive wear or dete- riorated performance, replace the damaged parts.1-4 GENERAL INFORMATION Model Identification KL250-D2 Left Side View: U.S. Model KL250-D2 Right Side View: European ModelGeneral Specifications GENERAL INFORMATION 1-5 toms 1250-02, D3 K1250.04,05| Ki2s0-08 KL250.07~ alone Overall tength | 2,200 mn, © @ © 2.140 mm <_ <_ <_ Ovrall width | 856 mm <_ <_ < Overall height — | 1.210mm <_ << <_ Wheelbase 118mm <_ <_ <_ Road clearance | 270 mm <_ <_ <_ Seat height 855 mm <_ <_ <_ Dry weight 1160 N (118 Ko), © @D O 1,180 rasta wiser) aa oa ae Curb weight: Front | 600 N (61 ka), G) 600 N (61.6 ka) <_ <_ <_ Rear |720N 73ks1,© DO TOON 2k] <— <_ <_ Fuel tank capacity | 11.0 L <— <= <_ Performance: Climbina aby | 32° <_ _ <_ Braking distance | 12.5m from 60 km/h <_ <_ <_ Mim ei | -_fi< < Engine: Type ‘A-stroke, DOHC, 4vave, 1-eylinder <_ <_ <_ Coolingsystem | Liguid-cooled <_ <_ <_ Bore and stroke | 740 x 58.0 mm <_ < <_ Displacement | 249. mL <_ <_ <— Compression ratio | 11.0 <_ < <_ Maximum horse- | 20.6 KW (28 PS) @9000 r/min (pm, <- <— _|te9kweesps) power }@2000 r/min rpm, © 12.5kW (17 PS) @7.000¢/min (om |OE@ — [OG — |@Or125 ew (17 Ps) }@7800 r/min (rpm) @ 12,5 kw (17 F5) @2,000 r/min DIN (cpm), DIN lo@ — Maximum torque | 23 Nem (2.3 kgm, 16.5 felb) ©8000 <_ <— 18.5 N-m (1.95 kg-m, losin (tom), 4ft-b) @7600 ¢/min o@ — }® 201m (20 rpm), ua)17.6 N-m a-m, 14.5 fib) [1.75 kg-m, 12.6 f-1b) (28.000 /min 3500 ¢/min (pm) © 19 Nem (1.9 kg-m, 13.5 feb) 4,000] cae join sfexin (rpm) @ 19m (1.9 kgm, 135 feb) 4,000 s/vin (rom) {O1N) Carburetion system | Carburetor, Keihin CVK34 <_ <_ <_ Starting system | Primary kick <_ <_ <_ Ignition system | CD <_ <_ <_ Timing advance | Electtcally edvancad <_ <_ <_ Fram’10" BTDC@1,200 r/min rem) to | ee Pia 36° BTDC 63,000 r/min fm) NGK DPROEA or ND X27EPR-U9 @OG@ NGK OPIEAS or <_ <_ ewe No x27EP-Ua {Continued on next page)16 GENERAL INFORMATION K1250.02, 03 Ku260-p4,05] KL26006 | _KL260-D7~ Inlet Open |41? BTDC <— | +@31etDc | + g@@@ar' swe Clow [51° ABoc < | +.@83° aBDC | ~, @EGG) 59° ane Duration |272° <— |«@2” + 9O@W0 200" Exhaust 70? pape <— |+@57se0c | ~ @e@wsr' anc [30° aTDC . Cutter Holder 5.5 mm:ENGINE TOP END 4-7 ‘Remove the following parts before camshaft removal. ‘Cylinder head cover ‘Camshaft chain tensioner Camshaft Chain Tensioner Camshaft caps Chain Tensioner Installation Refer to p. 36 of the Base Manual noting the following exception. ‘eWhen the chain tensioner Is installed; pay attention 10 the following items. Camshaft Installation Notes ‘oRemove the cap bolt and O-ring. ‘ePosition the crankshaftat TDC. While compressing the push rod, turn it clockwise with oT urn the crankshaft until the *T® mark is aligned with a suitable serewdeiver until it stops. the slit inthe inspection window. ay ee ‘A. Compress the rod ©. Arrow A. Timing Mark site B, Screwdriver B. Inspection Window. ‘When setting the camshaft chain timing, pay attention to the following items ‘Pull the exhaust side of the chain taut before fiting to Camshafts, Camshaft Chain the chain to the exhaust camshaft sprocket. The exhaust side timing mark must be aligned with the eylindor head upper surface Te inlet side timing mark must be positioned upward about 3° from the eylinder head upper surface. Camshaft Removal Notes ‘Position the crankshaft at TDC of compression stroke. Camshaft Chain Timing (Lefthand View) Front Exhaust Camshaft Inlet Camshaft48 ENGINE TOP END ‘install the camshaft caps in the correct locations as shown in the figuee. Camshaft Cap Installation Front Rear 1. Camshaft Cap (Exhaust, lft) 2. Camshaft Cap (Exhaust, ight) 3. Camshaft Cap (Inlet, eft) 4 Camshaft Cap (Ialet right) 5, Mark: Must be faced forward Camshafts Inspection inspect the camshafts. Af they are badly worn, replace them. ‘Replacement exhaust ‘camshafts from stock have the KAGR. and rocker arm. When the new exhaust camshaft is installed, exchange the KAGR. and rocker arm at the same time. Camshaft Chain Removal feRemove the following parts before camshaft chain removal. Camshafts ‘oMagneto flywheel Balancer chain Camshaft chain guide Camshafe Bearing Oil Clearance Inspection Refer to p. 3-10 of the Base Manual noting the following exception. (Camshaft Bearing Ol! Clearanco ‘Standard + 0,045 — 0.073 mm Service Limit: 0.18 mm Rocker Arms, Rocker Shafts Rocker Arms, and Rocker Shaft Removal ‘Remove the following parts before removing the recker arm and rocker shaft. ‘Cylinder head cover Camshafts ‘Rocker shaft plug (exhaust side) ‘A, Rocker Shaft B, Rocker Shaft Plug Rocker Arms and Rocker Shaft Installation Notes ‘eBlow the rocker arm oil passage clean with compressed air and apply oil to the rocker arm bore before instal- lation. ‘A. Rocker Arm B. Oil Passage‘install the retainer spring on each cocker arm so that the spring is on the other side of the rocker arm from the camshaft sprockets, aft, and insert the shaft running it through the oylinder head, the rocker arms and springs. ‘Tighten the-rocker shaft and rocker shaft plug to the specified torque (see Exploded Views). Rocker Arms and Rocker Shaft Inspection Note ‘inspect the rocker arms and rocker shafts. +f they are badly worn, replace them. The exhaust side rocker arm has an A to D mark. When changing the rocker arm with new one, select the rocker arm with same mark as former. NOTE off the marks are not matched, it will affact the timing when the cam pushes down the rocker arm and therefore KACR will not operate properly. ENGINE TOP END 49 KACR (KAWASAKI Automatic Compression Release) KACR Inspection Refer to p. 3-10 of the Base Manual noting the excep- ton. Af the weight do not move smoothly, replace the KACR unit, camshaft and rocker arm asa set. Cylinder Head Compression Measurement Refer to p. 3-17 of the Base Manual noting the following exception. cylinder Compression Usable Range: 410 —785 kPa (42-80 kg/em?*, 60 — 114 pei) Cylinder Head Removal Refer to p, 3:17 of the Base Manual noting the following exception. ‘eRemove the following parts before cylinder head removal. ‘Radiator hose ‘Cylinder head bracket Cylinder head cover ‘Camshaft chain tensioner Camshafts Gi! pipe (under the left side of the camshafts) ‘OE xhaust pipe Carburetor ‘Oil pipe (behind of the cylinder) Cylinder Head Installation Note ‘eWhen installing the carburetor holder, the projection faces to the right. A. Carburetor Holder B, Projection Faces Rightwards Torque the eylinder head bolts and nuts following the tightening sequence.410 ENGINE TOP END Cylinder Head Bolts, Nuts Tightening Sequenes NOTE OTarque them first to about 16 Nem (1.6 kom, 11.0 felb) of torque and then torque them to the soccitied torque. Cylinder Head Disassembly Note Refer to p, 3-18 of the Base Manual noting the following exception. ‘Remove the cylinder head parts by using these special tools. (057001-241; Valve spring compresser assembly 05701-1019: Adapter (057001-1021: Valve guide arbor 1©57001-1079: Valve guide reamer Valve Clearance Inspection ‘Valve clearance must be checked when the engine is cold (room temperature). ‘Remove the following parts before valve clearance inspection. - oF uel tank - Cylinder head bracket Radiator fan Cylinder head cover ‘Magneto cover upper and center plug ‘eUsing a wrench on the crankshaft rotation bolt, turn the crankshaft counterclockwise while watching the ‘movernent of the inlet valves (valves to the rear). ‘eWhen the valves have just finished opening and closing (moving downwards and returning upwards), turn the Crankshaft in the same direction for about another 14 turn until the "T" mark on the magneto flywheel is aligned with the slit in the inspection window in the magneto cover. ‘A. Timing Mark c. stir B. Inspection Window (Measure the clearance of each valve by inserting a thickness gauge between the adjusting screw and the valve stem, Valve Clesrance (when cold) Inlet, Exhaust: 0.20 - 0.24 mm Valve Clearance Adjustment HIF the valve clearance is incorrect, loosen the locknut and turn the adjusting screw until the correct clearance is obtained. feTighten the locknut,Valve Seat Inspection Refer to p. 316 of the Base Manual noting the exception. Valve Seating Surfaca Width Inlet, Exhaust: 0.5 ~1.0mm ‘Valve Seating Surface Outside Diameter Inlet 283-285 mm Exhaust + 243-245 mm Valve Seat Repair Refer to p. 3-16 of the Base Manual noting the exception ‘Follow the manufacturers instructions for the use of the valve seat cutter set. Valve Sent Cutter Sot Part Number: 57001-1110 Valve Cutters in Sot Inlet Valve 46° —¢320 57001-1115 32°-430.0 87001-1120 60" = 930.0 57001-1123, Exhaust Valve 46° 6275 S7001-41114 32° 628.0 570011119 60°— 930.0 57001-1123 Use this Holder and Bar Holder— 95.5 87001-1125 Bar 57001-1128 Cylinder, Piston Cylinder Removal ‘eRemove the following parts before cylinder removal. Cylinder head cover Carburetor Camshafts ‘Cylinder head Radiator hose (Cylinder side) ENGINE TOP END 4-11 Piston Removal Notes Wrap a clean cloth around the base of the piston to secure it in position for removal and so that no parts fall Into the crankcase. To remove the piston pin, use a piston pin puller (special tool), if the pin is tihgt. ‘A. Piston Pin Puller: $7001-910 8. Adapter Piston, Cylinder Installation Note ©Do not reuse snap rings, as removal weakens and deforms thom. They could fall out and score the cylinder wi ‘Do not mix up the top and second ring. ‘Cross Section of Piston Rings N mark Top ing 2nd ring,4-12 ENGINE TOP END ‘*Position each piston ring so that the opening in the top ring and oil ring stel rails are facing forwards, and the second ring and oil ring expander openings face the rear. The openings of the oil ring steel rails must be about 30 ~ 40° of angle from the opening of the top ring. Piston Ring Openings + Viewed from Front 1. Top ring 2 Second ring 3, Steel rail oil ring 4, Expander, ot ring ‘The arrow on the top of the piston must point toward the front. ‘install the cylinder and tighten the moutning bolts to the specified torque. cylinder 1. Cylinder Mounting Bolts ‘after cylinder installation, install the chain guide as shown. 1. Chain Guide Piston Ring End Gep Refer to p. 3-21 of the Base Manual noting the exception. Piston Ring End Gap Standard Sorive Limit Top, Second 02-035mm 0.7 mm ou 02-07mm 1.0mm Cylinder Inside Diameter Refer to p. 321 of the Base Manual noting the following exception, Cylinder inside Diametor Standard: 74,000 — 74,012 mm and lass than 0.01 mm difference between any two meas- urements. Sorvice Limit: 74.10 mm, or more than 0.05 mm difference between any two mess- urements. Piston Diameter Refer to p, 321 of the Base Manual noting the following exception, Piston Diameter Standard Servico Limit 73.950 — 73.985 mm 7381 mmMuffler Cleaning (U.S. model) To avoid burns, wear gloves while cleaning the muffier Sinco the ongine must be run during this procedure, the ‘muffler will become hot. ‘Remove the drain plugs from the muffler, E: ‘A. Drain Plugs ‘91n an open area away from combustible materials, start the engine with the transmission in neutral. ‘Raise and lower engine speed while tapping on the ‘muffler with a rubber mallot until carbon particles are purged from the muffle. (Do aot run the engine in a closed area, Exhaust casos contain carbon monoxide, a colorless, odorless, poison- fous gas. Breathing exhaust gas leads to carbon mon- oxide poisoning, asphyxiation, and death ‘*Stop the engine, ‘olnstall the drain plugs in the muffer. ‘Spark Arrester Cleaning (U.S. model) This motorcycle 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, [caution The spark arrester must bo installed correctly and fune- tioning property to provide adequate fire protection. ENGINE TOP END 4.13 WARNING ©To avoid burns, wear gloves while cleaning the spark tor. ‘eRemove the spark arrester mounting screw from the muffler ‘ePull the spark arrester out of the muffler. A. Screw B, Spark Arrester ‘eScrape carbon deposits off the spark arrester and slide it back into the muffler ‘install the mounting screw and tighten them securely, Never run the engine with the spork arrester removed. Hot carbon particles may start a fire.ENGINE RIGHT SIDE/LEFT SIDE 5-1 Engine Right Side/Left Side Table of Contents Exploded View 582 ‘Specification 53 ‘Special Tools 53 Right Engine Cover sees 54 Aight Engine Cover Removal... 54 Right Engine Cover Installation Notes ..... 5-4 cute Clute Lever Play Inspection . . . Bose Manual p. 4-8 Clutch Lever Play Adjustment . see Bt Cluteh Release Lover Removal. eee BB Clutch Retesse Lever instalation Notes..... 55 Qlutch Removal . 55 Clutch Installation Notes 55 Clutch Plate Wear, Damage Inspection ....... 88 Base Menwal p. 4-10 Friction and Steel Plato Warp Inspection ....... 56 Base Marwal p. 4-10 Clutch Housing Finger Inspection... Base Manual p. 4-10 Clutch Hub Spline Inspection Base Manual p. 4-11 External Shift Mechanism External Shift Mechanism Removal 87 External Shift Mechanism Installation Note : sesae oe External Shift Mechanism Inspection... 57 Primary Gear Primary Gear Removal.........--.2... 87 Primary Gear Installation Note ....-..... 58 Kick Starter... . Hee - 68 Kick Starter Removal... sss 58 Kick Starter Installation NOt@.. ove. e seve 58 Kick Starter Disassembly and Assembly Note... 6... 58 Kick Starter idle Gear Removal and Installation Notes. seveeeee 5B Water Pump... 34 “Base Manual p.5-9 Water Pump Removal. 3-4 — Base Manual p. 5-9 Water Pump Inspection. . Base Manual p. 5-9} Woter Pump Installation. ...... 3-4 Base Manual p.5-10 OW Filter... 64 Base Manual p. 413 1 Fter Removal and Installation Note... 64 aso Manual p.4-13, OW Pump... tease 65 011 Bump Removal. pre 11 Pump Installation Note... 65 Beso Manual p. 4-14 Oil Pump Disassambly 66... esse eee e OS i Pump Assembly Nowe . 65 Balancer Mechanism. 88 Fron Right Side Baencer Removel - 38 Front Right Side Boloncer Installation - a8 Rear Balancer Removal. : 88 ‘Rear Balancer Installstion Note 3a Front Left Side Balencer, Balancer Chain Removal. 39 Front Left Side Belsncer, Balancer Chain Installation Unchuding Chain Timing Procedure) . 89 Balancer Sprocket Removal Note 80 Balancer Sprocket Installation Note . eat Flywheel Magneto... 1611 Flywheel Magento Removal ....- 1641 Flyuheo! Magneto Installation. 15:12 Magneto Cover installation Note. ‘Magneto Stator Installation Note 16.12 Left Engine Cover Removal. +. 1512 Left Engine Cover installation Note ....... 1543 184262 ENGINE RIGHT SIDE/LEFT SIDE XZ : ay 1: Aeply nom permanant lsking eget t0 » the teas \2 Fee nennep array T1: 59 N-m (6.0 kg-m, 43 ft-lb) 12: 8.8 Nim (1.0 ep, 87 Ul) 13: 12 Wem (1.2 kp, 104 int) ‘T4: 39 N-m (4.0 kg-m, 29 ft-lb)Engine Right Side Specifications ENGINE RIGHT SIDE/LEFT SIDE 5-3 tem! ‘Standard Service Limit Cluteh lever play 2-3mm === Clutch spring free length 33.6 mm. 32.3 mm Friction plate thickness 27-29 mm 2.8mm Friction and steel plate warp Less than 0.15 mm 0.3 mm Primary Reduction: Primary gear/clutch housing Aertre pias gear backlash ‘Along with common hand tools, the following more specialized tools are required for complete clutch servicing. Goar Holder: 67001-1015 Oil Seal Guide: 6701-264 @ il Seal Guide: 57001.263, 9g5-4 ENGINE RIGHT SIDE/LEFT SIDE Right Engine Cover Right Engine Cover Removal ‘*Drain the engine oil ‘#Remove the following part before removing the right engine cover. Kick pedal ‘Lower end of the clutch cable Clutch releaso shaft Brake pedal and cable Radiator hose (cover side) Oil filter ‘Water pump impeller Right Engine Cover Installation Notes ‘*When installing the right engine cover, use a kick shaft oil seal guide (special tool} to avoid seal damage. A. Kick Shaft Oil Seal B. Oil Seal Guide: $7001-263, ‘eCheck that the O-ring is in good condition. Fit the oil filtor Oxing in place, being careful not to twist or damage it, Clutch Clutch Lever Play Adjustment Loosen the knurled locknut at the clutch lever, tun the adjuster to obtain the proper amount of lever play, and tighten the locknut. ‘If the upper cable adjuster has reached its limits, use the adjuster at the lower ‘end of the clutch cable. Loosen the knurled locknut at the clutch lover, and serew in the adjuster. A, Dust Boot ©. Cluteh Cable B. Adjusting Nuts ‘lide the lower cable adjuster to give the cable plenty of play, and readjust the lever play. ‘Turn the clutch release lever until it becomes hard to turn, At this time, check that the cluteh release lever to clutch cable angle is 80 — 90° B. Oil Filter Hole A. Oring A. 80-90"(eTighten the adjusting nut, Note (Be sure that the outer cable end at the clutch lever Is, {fully seated in the adjuster at the clutch lever, or it ‘could slip into place later, creating enough cable play to prevent clutch disengagement. ‘After the adjustment is made, start the engine and check that the clutch does not slip and that it releases Properly, Clutch Reiease Lever Removal ‘Remove the following pats before removing the clutch release lever. {Clutch cable upper end {from clutch lever) ‘Clutch cable lower end (from release lever) Positioning bolt ‘Turn the release lever counterclockwise zbout 90°, and then pull out the release lever and shaft assembly, A. Release Lever B, Turn about 90° Positioning Bolt Clutch Release Lever Installation Notes ‘eReiease lever and shaft assombly installation is the reverse of removal. Check the clearance between the release lever and the it engine cover, and install the positioning bolt. ENGINE RIGHT SIDE/LEFT SIDE 55 Clutch Removal Remove the right engine cover before removing the clutch. ‘Remove the clutch spring bolts, washers, and springs; then take off the clutch spring plate. ‘Remove the circlip with circlip pliers (special tool), and pull off the clutch hub, plates, and housing. A. Cirelip B. Circlip Pliers: $7001-144 ©. Clutch Hub Clutch installation Notes ‘install the friction plates and steel plates, starting with a friction plate and alternating them.