Kawasaki KX450F Motorcycle Service Manual – PDF DOWNLOAD
FILE DETAILS:
Kawasaki KX450F Motorcycle Service Manual – PDF DOWNLOAD
Language : English
Pages : 369
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Kawasaki KX450F Motorcycle Service Manual – PDF DOWNLOAD
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 Special Tool Catalog or 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 ofmaintenance 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 these WARNING and CAUTION symbols, heed their instructions! Always follow safe operating and maintenance practices.
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Kawasaki KX450F Motorcycle Service Manual – PDF DOWNLOAD
tables...................................................................... 1 LIST OF ABBREVIATIONS................................................... 6 Units of Mass:.......................................................... 18 Units of Volume:........................................................ 18 Units of Force:......................................................... 18 Units of Length:........................................................ 18 Units of Torque:........................................................ 18 Units of Pressure:...................................................... 18 Units of Speed:......................................................... 18 Units of Power:......................................................... 18 Basic Torque for General Fasteners...................................... 26 Throttle Grip Free Play................................................. 30 Hot Starter Lever Free Play............................................. 31 Idle Speed:............................................................. 32 Valve clearance: between cam and valve lifter........................... 38 Example................................................................. 38 Adjustment shims........................................................ 39 Cylinder Head Warp...................................................... 40 Cylinder Inside Diameter................................................ 40 Piston/Cylinder Clearance............................................... 41 Friction Plate Thickness................................................ 43 Friction and Steel Plates Warp.......................................... 44 Recommended Engine...................................................... 44 Connecting Rod Big End Side Clearance................................... 46 Standard Tire........................................................... 47 Rim Runout (with tire installed)........................................ 48 Chain Slack............................................................. 49 Chain 20-link Length.................................................... 50 Standard Chain.......................................................... 51 Rear Sprocket Warp...................................................... 52 Length [A].............................................................. 52 Recommended Disc Brake Fluid............................................ 54 Lining Thickness........................................................ 56 Spark Plug Gap.......................................................... 79 Service Fuel Level (below the bottom edge of the carb. body)............ 95 Float Height............................................................ 95 Recommended Coolant.....................................................121 Radiator Cap Relief Pressure............................................128 Camshaft Bearing Clearance..............................................147 Camshaft Journal Diameter...............................................147 Camshaft Runout.........................................................147 Cam Height..............................................................147 Cylinder Compression....................................................148 Valve/Valve Guide Clearance Measurement (Wobble Method).................154 Valve Seating Surface Outside Diameter..................................155 Valve Seating Surface Width Standard....................................155 Piston Diameter.........................................................162 Piston Ring/Ring Groove Clearance.......................................162 Piston Ring Groove Width................................................163 Piston Ring Thickness...................................................163 Piston Ring End Gap.....................................................163 Piston Pin Diameter.....................................................164 Piston Pin Hole Diameter................................................164 Connecting Rod Small End Inside Diameter................................164 Release Shaft Lever Position............................................180 Adjusting Washers.......................................................180 Release Shaft Lever Position and Adjusting Washer Selection.............180 Clutch Plate Length.....................................................181 Clutch Spring Free Length...............................................181 Friction Plate/Clutch Housing Clearance.................................182 Oil Pump Pressure (oil temperature 90°C, @4 000 rpm)....................206 Connecting Rod Big End Radial Clearance.................................229 Connecting Rod Big End Side Clearance...................................229 Connecting Rod Bend.....................................................230 Connecting Rod Twist....................................................231 Axle Runout/100 mm (3.94 in.)...........................................248 Thickness...............................................................278 Runout..................................................................278 Rebound Damping Adjuster Setting........................................288 Compression Damping Adjuster Setting....................................289 Fork Spring Free Length.................................................301 Rebound Damping Adjuster Setting........................................302 High Speed Compression Damping..........................................303 Low Speed Compression Damping...........................................303 Spring Preload Adjustment...............................................304 Shock Absorber Spring Free Length.......................................304 Sleeve Outside Diameter.................................................313 Bolt Runout ............................................................313 Table 1 Magneto Output Voltage..........................................344 Table 2 Stator Coil Resistance..........................................344 Ignition Timing.........................................................345 3 Needle Arcing Distance................................................347 Ignition Coil Winding Resistance........................................347 Throttle Sensor Input Voltage...........................................352 Throttle Sensor Output Voltage..........................................353 Throttle Sensor Input Voltage...........................................354 Throttle Sensor Output Voltage..........................................354 Throttle sensor Output Voltage..........................................354 Gear Position Switch Resistance.........................................357 toc......................................................................... 1 Foreword................................................................ 7 General Information..................................................... 9 Before starting to perform an inspection service or carry out a .... 10 Edges of Parts.................................................. 10 Solvent......................................................... 10 Cleaning vehicle before disassembly............................. 10 Arrangement and Cleaning of Removed Parts....................... 10 Storage of Removed Parts........................................ 11 Inspection...................................................... 11 Replacement Parts............................................... 11 Assembly Order.................................................. 11 Tightening Sequence............................................. 11 Tightening Torque............................................... 12 Force........................................................... 12 Gasket, O-ring.................................................. 12 Liquid Gasket, Non-permanent Locking Agent...................... 12 Press........................................................... 12 Ball Bearing and Needle Bearing................................. 13 Oil Seal, Grease Seal........................................... 13 Circlips, Cotter Pins........................................... 13 Lubrication..................................................... 13 Direction of Engine Rotation.................................... 14 Electrical Wires................................................ 14 Instrument...................................................... 14 KX450D6F Left Side View............................................. 15 KX450D6F Right Side View............................................ 15 Prefixes for Units:................................................. 18 Units of Temperature:............................................... 18 Periodic Maintenance.................................................... 19 The maintenance must be done in accordance with this chart to ke.... 21 Tighten all bolts and nuts to the proper torque using an accurat.... 23 Steering Stem Nut Wrench:........................................... 29 Fuel System......................................................... 30 Fuel Hose and Connection Inspection............................. 30 Throttle Grip Free Play Inspection.............................. 30 Throttle Grip Free Play Adjustment.............................. 30 Hot Starter Lever Free Play Inspection.......................... 31 Idle Speed Inspection........................................... 31 Idle Speed Adjustment........................................... 32 Special Tools -............................................. 32 Air Cleaner Element Cleaning and Inspection..................... 32 Fuel Inspection................................................. 34 Fuel Tank, Filter and Tap Cleaning.............................. 35 Fuel Tap and Filter Inspection.................................. 35 Cooling System.................................................. 35 Coolant Level Inspection.................................... 36 Coolant Deterioration Inspection............................ 36 Radiator Hoses and Connections Inspection................... 37 Torque -................................................ 37 Engine Top End.................................................. 37 Valve Clearance Inspection.................................. 37 Special Tool -.......................................... 37 Valve Clearance Adjustment.................................. 38 Cylinder Head Warp Inspection............................... 40 Cylinder Wear Inspection.................................... 40 Piston/Cylinder Clearance................................... 41 Piston, Piston Ring and Piston Pin Replacement.............. 41 Exhaust System Inspection................................... 41 Muffler Baffle Change....................................... 41 Engine Right Side............................................... 42 Clutch Lever Free Play Check................................ 43 Clutch Lever Free Play Adjustment........................... 43 Friction and Steel Plates Inspection........................ 43 Engine Lubrication System....................................... 44 Engine Oil Change........................................... 44 Torque -................................................ 44 Oil Filter Change........................................... 45 Torque -................................................ 45 Breather Hose Inspection.................................... 45 Crankshaft/Transmission......................................... 46 Crankshaft Inspection....................................... 46 Wheel/Tires..................................................... 46 Air Pressure Inspection/Adjustment.......................... 46 Tires Inspection............................................ 47 Spoke Tightness Inspection.................................. 47 Torque -................................................ 47 Rim Runout Inspection....................................... 48 Special Tool -.......................................... 48 Wheel Bearing Inspection.................................... 48 Special Tool -.......................................... 48 Final Drive..................................................... 49 Drive Chain Slack Inspection................................ 49 Drive Chain Slack Adjustment................................ 49 Torque -................................................ 49 Drive Chain Wear Inspection................................. 50 Drive Chain Lubrication..................................... 51 Sprocket Wear Inspection.................................... 51 Rear Sprocket Warp Inspection............................... 52 Special Tool -.......................................... 52 Brakes.......................................................... 52 Brake Lever and Pedal Position Adjustment................... 52 Torque -................................................ 53 Brake Fluid Level Inspection................................ 53 Torque -................................................ 53 Brake Fluid Change.......................................... 54 Torque -................................................ 56 Brake Pad Wear Inspection................................... 56 Brake Master Cylinder Cup and Dust Seal Replacement......... 56 Special Tool -.......................................... 56 Special Tool -.......................................... 57 Torque -................................................ 57 Caliper Piston Seal and Dust Seal Replacement............... 58 Torque -................................................ 59 Brake Hose and Connection Check............................. 61 Brake Hose Replacement...................................... 61 Torque -................................................ 62 Suspension...................................................... 62 Front Fork Inspection....................................... 62 Front Fork Oil Change (each fork leg)....................... 62 Special Tool -.......................................... 63 Special Tool -.......................................... 63 Special Tool -.......................................... 64 Special Tool -.......................................... 64 Special Tool -.......................................... 65 Special Tool -.......................................... 65 Special Tool -.......................................... 67 Torque -................................................ 67 Special Tool -.......................................... 69 Special Tool -.......................................... 69 Torque -................................................ 70 Torque -................................................ 70 Special Tool -.......................................... 70 Special Tool -.......................................... 70 Special Tool -.......................................... 70 Rear Shock Absorber Inspection.............................. 71 Rear Shock Absorber Oil Change.............................. 71 Torque -................................................ 75 Swingarm and Uni-Trak Linkage Inspection.................... 76 Special Tool -.......................................... 76 Swingarm and Uni-Track Linkage Pivot Lubricate.............. 76 Steering........................................................ 76 Steering Inspection......................................... 76 Special Tool -.......................................... 76 Steering Adjustment ........................................ 76 Special Tool -.......................................... 76 Special Tool -.......................................... 77 Torque -................................................ 77 Torque -................................................ 78 Stem Bearing Lubrication.................................... 78 Frame........................................................... 78 Frame Inspection............................................ 78 Electrical System............................................... 79 Spark Plug Cleaning and Inspection.......................... 79 Special Tool -.......................................... 79 Owner's Tool -.......................................... 79 Torque -................................................ 79 Cable Inspection................................................ 79 Lubrication................................................. 79 Points: Lubricate with Grease........................... 80 Cables: Lubricate with Rust Inhibitor................... 80 Nut, Bolt, and Fastener Tightness Inspection.................... 80 Tightness Inspection........................................ 80 Nut, Bolt and Fastener to be checked.................... 81 Fuel System............................................................. 83 Fuel Level Gauge, M18 × 1.0:........................................ 89 If the throttle grip has excessive free play due to cable stretc.... 90 Free Play Inspection............................................ 90 Free Play Adjustment............................................ 90 Throttle Cable Replacement...................................... 90 Torque -.................................................... 91 Throttle Cable Lubrication...................................... 91 Throttle Cable Inspection....................................... 91 Hot Starter Cable Removal....................................... 92 Hot Starter Cable Installation.................................. 92 Hot Starter Lever Free Play Inspection.......................... 92 Hot Starter Lever Free Play Adjustment.......................... 93 Hot Starter Cable Lubrication................................... 93 Hot Starter Cable Inspection.................................... 93 Since the carburetor regulates and mixes the fuel and air going .... 94 Idle Speed Inspection........................................... 94 Idle Speed Adjustment........................................... 94 Service Fuel Level Inspection................................... 94 Special Tools -............................................. 94 Service Fuel Level Adjustment................................... 95 Carburetor Removal.............................................. 96 Carburetor Installation......................................... 98 Torque -.................................................... 98 Torque -.................................................... 98 Fuel Inspection................................................. 99 Carburetor Disassembly.......................................... 99 Carburetor Cleaning.............................................103 Carburetor Inspection...........................................103 Carburetor Assembly.............................................105 Air Cleaner Housing Removal.........................................110 Air Cleaner Housing Installation................................110 Torque -....................................................110 Element Removal.................................................110 Element Installation............................................111 Element Cleaning and Inspection.................................111 Fuel Tank Removal...................................................112 Fuel Tank Installation..........................................112 Fuel Filter Removal.............................................112 Fuel Filter Installation........................................112 Fuel Tank, Filter and Tap Cleaning..............................113 Fuel Tap and Filter Inspection..................................113 Cooling System..........................................................115 Bearing Driver Set:.................................................119 Check the coolant level each day before riding the motorcycle, a....120 Coolant Level Inspection........................................120 Coolant Deterioration Inspection................................120 Coolant Draining................................................120 Coolant Filling.................................................121 Torque -....................................................121 Air Bleeding....................................................121 Cooling System Pressure Testing.................................122 Cooling System Flushing.........................................122 Water Pump Cover Removal............................................123 Water Pump Cover Installation ..................................123 Torque -....................................................123 Torque -....................................................123 Impeller Removal................................................124 Impeller Installation...........................................124 Torque -....................................................124 Water Pump Inspection...........................................124 Oil Seal and Bearing Removal....................................124 Oil Seal Installation...........................................125 Special Tool -..............................................125 Special Tool -..............................................125 Radiator Removal....................................................126 Radiator Installation...........................................127 Torque -....................................................127 Radiator Inspection.............................................127 Radiator Cap Inspection.........................................127 Filler Neck Inspection..........................................128 Radiator Hoses, Breather Hose Inspection........................128 Radiator Hoses, Breather Hose Installation......................128 Torque -....................................................128 Engine Top End..........................................................129 Cam Height..........................................................136 Camshaft Runout.....................................................136 Valve Stem Diameter.............................................136 Valve Stem Bend.....................................................136 Compression Gauge, 20 kgf/cm :......................................137 Cylinder Head Cover Removal.........................................140 Cylinder Head Cover Installation................................140 Sealant -...................................................140 Torque -....................................................140 Camshaft Chain Tensioner Removal....................................141 Camshaft Chain Tensioner Installation...........................141 Torque -....................................................142 Torque -....................................................142 Camshaft Removal....................................................143 Special Tool -..................................................143 Camshaft Installation...........................................144 Torque -....................................................144 Torque -....................................................146 Special Tool -..............................................146 Camshaft Chain Removal..........................................146 Camshaft Chain Installation.....................................146 Torque -....................................................146 Camshaft and Camshaft Cap Wear..................................147 Camshaft Runout.................................................147 Cam Wear........................................................147 Cylinder Compression Measurement....................................148 Special Tool -..................................................148 Owner's Tool -..................................................148 Special Tools -.................................................148 Torque -........................................................148 Cylinder Head Removal...........................................149 Cylinder Head Installation......................................150 Torque -....................................................151 Torque -....................................................151 Cylinder Head Cleaning..........................................151 Cylinder Head Warp..............................................151 Valve Clearance Inspection..........................................152 Valve Removal...................................................152 Special Tools -.............................................152 Valve Installation..............................................152 Special Tools -.............................................152 Valve Guide Removal.............................................153 Special Tool -..............................................153 Valve Guide Installation........................................153 Special Tools -.............................................153 Special Tool -..............................................154 Valve/Valve Guide Clearance Measurement (Wobble Method).........154 Valve Seat Inspection...........................................155 Valve Seat Repair...............................................155 Special Tools -.............................................155 Seat Cutter Operation Care..................................156 Valve Seat Repair...............................................159 Cylinder Removal....................................................160 Piston Removal..................................................160 Special Tool -..............................................160 Cylinder and Piston Installation................................160 Special Tools -.............................................162 Cylinder Wear...................................................162 Piston Wear.....................................................162 Piston/Cylinder Clearance.......................................162 Piston Ring/Ring Groove Clearance...............................162 Piston Ring Groove Width........................................163 Piston Ring Thickness...........................................163 Piston Ring End Gap Measurement.................................163 Piston, Piston Pin, Connecting Rod Wear Inspection..............164 Carburetor Holder Installation......................................165 Torque -........................................................165 WARNING.............................................................166 Muffler Removal.................................................166 Muffler Installation............................................166 Torque -....................................................166 Muffler Baffle Replacement......................................166 Engine Right Side.......................................................167 Outside Circlip Pliers:.............................................173 Due to friction plate wear and clutch cable stretch over a long ....174 Clutch Lever Free Play Inspection...............................174 Clutch Lever Free Play Adjustment...............................174 Clutch Lever Installation.......................................174 Clutch Cable Removal............................................174 Clutch Cable Installation.......................................175 Clutch Cable Inspection and Lubrication.........................175 Clutch Cover Removal................................................176 Clutch Cover Installation.......................................176 Torque -....................................................176 Right Engine Cover Removal......................................176 Right Engine Cover Installation.................................176 Torque -....................................................177 Release Shaft Removal...........................................177 Release Shaft Installation......................................177 Clutch Removal......................................................178 Special Tool -..................................................178 Clutch Installation.............................................178 Special Tool -..............................................179 Torque -....................................................179 Torque -....................................................180 Clutch Plate Assembly Free Play Inspection/Adjustment...........181 Torque -....................................................181 Friction and Steel Plates Wear, Damage Inspection...............181 Friction and Steel Plate Warp Inspection........................181 Clutch Spring Free Length Inspection............................181 Clutch Housing Finger Damage....................................182 Friction Plate/Clutch Housing Clearance.........................182 Clutch Hub Spline Damage........................................182 Primary Gear Removal................................................183 Special Tool -..................................................183 Primary Gear Installation.......................................183 Torque -....................................................183 Special Tool -..............................................183 External Shift Mechanism Removal....................................184 External Shift Mechanism Installation...........................184 Torque -....................................................184 Torque -....................................................185 Torque -....................................................185 External Shift Mechanism Inspection.............................185 Kick Pedal Assy Removal.............................................187 Kick Pedal Assy Installation....................................187 Torque -....................................................187 Kick Pedal Assy Disassembly.....................................187 Kick Pedal Assy Assembly........................................187 Idle Gear Removal...............................................187 Idle Gear Installation..........................................188 Kickshaft Removal...............................................188 Kickshaft Installation..........................................188 Torque -....................................................188 Kick Shaft Assembly Disassembly/Assembly........................189 Special Tool -..............................................189 Engine Lubrication System...............................................191 Oil Pressure Gauge, 5 kgf/cm :......................................197 WARNING.............................................................198 Engine Oil Level Inspection.....................................198 Engine Oil Change...............................................198 Oil Filter Change...............................................199 Oil Screen (Scavenge) Removal...................................199 Oil Screen (Scavenge) Installation..............................199 Oil Screen (Feed) Removal.......................................200 Oil Screen (Feed) Installation..................................200 Torque -....................................................200 Oil Screen (Scavenge) Cleaning..................................200 Oil Screen (Feed) Cleaning......................................201 Oil Pressure Relief Valve Removal...................................202 Oil Pressure Relief Valve Installation..........................202 Torque -....................................................202 Oil Pressure Relief Valve Inspection............................202 Oil Pump (Scav enge) Removal........................................203 Oil Pump (Scavenge) Installation................................203 Torque -....................................................203 Oil Pump (Feed) Removal.........................................204 Oil Pump (Feed) Installation....................................204 Torque -....................................................204 Oil Pump Inspection.............................................205 Oil Pressure Measurement............................................206 Special Tool -..................................................206 Special Tools -.................................................206 Torque -........................................................206 Engine Removal/Installation.............................................207 Jack:...............................................................210 Engine Removal......................................................211 Special Tool -..................................................211 Engine Installation.............................................213 Torque -....................................................213 Crankshaft/Transmission.................................................215 Outside Circlip Pliers:.............................................219 Crankcase Disassembly...............................................220 Special Tool -..................................................221 Special Tool -..................................................221 Special Tool -..................................................221 Crankcase Assembly..............................................222 Special Tool -..............................................222 Special Tool -..............................................223 Special Tool -..............................................223 Special Tool -..............................................223 Special Tool -..............................................223 Special Tool -..............................................223 Special Tool -..............................................224 Special Tool -..............................................224 Torque -....................................................224 Torque -....................................................225 Special Tool -..............................................225 Sealant -...................................................225 Torque -....................................................226 Torque -....................................................226 Torque -....................................................227 Crankshaft Removal..................................................228 Crankshaft Installation.........................................228 Special Tool -..............................................228 Crankshaft Disassembly..........................................228 Crankshaft Assembly.............................................228 Crankshaft Inspection...........................................229 Connecting Rod Bend.............................................230 Connecting Rod Twist............................................231 Transmission Shaft Removal..........................................232 Transmission Shaft Installation.................................232 Transmission Shaft Disassembly..................................232 Special Tool -..............................................232 Transmission Shaft Assembly.....................................233 Special Tool -..............................................233 Shift Fork Bending..............................................234 Shift Fork/Gear Groove Wear.....................................235 Shift Fork Guide Pin/Shift Drum Groove Wear.....................235 Gear Damage.....................................................235 Balancer Removal....................................................236 Balancer Installation...........................................236 Torque -....................................................236 Bearing Replacement.................................................237 Special Tool -..................................................237 Bearing Inspection..............................................237 Oil Seal Inspection.............................................238 Wheels/Tires............................................................239 Inside Circlip Pliers:..............................................243 Front Wheel Removal.................................................244 Special Tool -..................................................244 Front Wheel Installation........................................244 Torque -....................................................245 Torque -....................................................245 Rear Wheel Removal..............................................245 Special Tool -..............................................245 Rear Wheel Installation.........................................246 Torque -....................................................247 Wheels Inspection...............................................247 Special Tool -..............................................247 Spoke Tightness Inspection......................................247 Rim Runout Inspection...........................................247 Axle Inspection.................................................248 Tire Removal........................................................249 Special Tool -..................................................249 Special Tools -.................................................250 Tire Installation...............................................250 Air Pressure Inspection/Adjustment..............................251 Hub Bearing Removal.................................................252 Special Tool -..................................................252 Hub Bearing Installation........................................252 Special Tool -..............................................252 Special Tool -..............................................252 Hub Bearing Inspection..........................................252 Final Drive.............................................................253 Drive Chain Slack Inspection........................................257 Drive Chain Slack Adjustment....................................257 Wheel Alignment Inspection......................................257 Wheel Alignment Adjustment......................................257 Drive Chain Wear Inspection.....................................257 Drive Chain Lubrication.........................................257 Drive Chain Removal.............................................257 Drive Chain Installation........................................257 Engine Sprocket Removal.............................................259 Engine Sprocket Installation ...................................259 Torque -....................................................259 Torque -....................................................259 Rear Sprocket Removal...........................................259 Rear Sprocket Installation......................................260 Torque -....................................................260 Sprocket Wear Inspection........................................260 Rear Sprocket Warp Inspection...................................260 Brakes..................................................................261 Inside Circlip Pliers:..............................................267 Brake Lever Adjustment..............................................268 Brake Pedal Position Adjustment.................................268 Brake Pedal Removal.............................................268 Brake Pedal Installation........................................268 Torque -....................................................268 WARNING.............................................................269 Fluid Level Inspection..........................................269 Fluid Change....................................................269 Bleeding the Brake Line.........................................270 Torque -....................................................270 Caliper Removal.....................................................272 Caliper Installation............................................272 Torque -....................................................272 Torque -....................................................272 Torque -....................................................272 Caliper Disassembly.............................................273 Fluid Seal Damage...............................................273 Dust Seal and Cover Damage......................................273 Piston Cylinder Damage..........................................273 Caliper Holder Shaft Wear.......................................273 Brake Pad Removal...............................................274 Brake Pad Installation..........................................274 Torque -....................................................274 Brake Pad Inspection............................................274 CAUTION.............................................................275 Front Master Cylinder Removal...................................275 Front Master Cylinder Installation..............................275 Torque -....................................................275 Torque -....................................................275 Rear Master Cylinder Removal....................................276 Rear Master Cylinder Installation...............................276 Torque -....................................................276 Front Master Cylinder Disassembly...............................276 Rear Master Cylinder Disassembly................................276 Master Cylinder Assembly........................................276 Master Cylinder Inspection (Visual Inspection)..................277 Brake Disc Inspection...............................................278 Special Tool -..................................................278 Brake Hose Removal/Installation.....................................279 Brake Hose Inspection...........................................279 Suspension..............................................................281 Oil Seal & Bearing Remover:.........................................287 Air Pressure........................................................288 Special Tool -..................................................288 Rebound Damping Adjustment......................................288 Special Tool -..............................................288 Compression Damping Adjustment..................................289 Special Tool -..............................................289 Oil Change (each fork leg)......................................289 Front Fork Removal..............................................289 Front Fork Installation.........................................290 Torque -....................................................290 Torque -....................................................290 Front Fork Disassembly (each fork leg)..........................291 Special Tool -..............................................291 Special Tool -..............................................291 Special Tool -..............................................292 Special Tool -..............................................292 Special Tool -..............................................293 Special Tool -..............................................294 Front Fork Assembly.............................................295 Special Tool -..............................................295 Special Tool -..............................................295 Special Tool -..............................................297 Torque -....................................................297 Special Tool -..............................................298 Special Tool -..............................................298 Torque -....................................................299 Torque -....................................................299 Special Tool -..............................................299 Special Tool -..............................................300 Special Tool -..............................................300 Adjuster Assembly Inspection....................................300 Base Valve Assembly Inspection..................................300 Cylinder Unit Inspection........................................300 Inner Tube Inspection...........................................301 Guide Bush Inspection...........................................301 Dust Seal/Oil Seal Inspection...................................301 Spring Tension..................................................301 Rear Shock Absorber:................................................302 Rebound Damping Adjustment......................................302 Compression Damping Adjustment..................................302 Spring Preload Adjustment.......................................303 Special Tool -..............................................303 Special Tool -..............................................304 Special Tool -..............................................304 Torque -....................................................304 Spring Tension..................................................304 Rear Shock Absorber Removal.....................................305 Special Tool -..............................................305 Rear Shock Absorber Installation................................305 Torque -....................................................305 Spring Replacement..............................................305 Special Tool -..............................................306 Rear Shock Absorber Disassembly (Oil Change)....................306 Rear Shock Absorber Assembly....................................306 Rear Shock Absorber Scrapping...................................306 Swingarm Removal....................................................307 Special Tool -..................................................307 Swingarm Installation...........................................308 Torque -....................................................308 Swingarm Bearing Removal........................................308 Special Tool -..............................................308 Swingarm Bearing Installation...................................308 Special Tool -..............................................308 Swingarm Bearing, Sleeve Inspection.............................309 Drive Chain Guide, Guide Roller, Chain Slipper Wear.............309 Tie-Rod Removal.....................................................310 Special Tool -..................................................310 Tie-Rod Installation............................................310 Torque -....................................................310 Rocker Arm Removal..............................................310 Special Tool -..............................................310 Rocker Arm Installation.........................................311 Torque -....................................................311 Tie-Rod and Rocker Arm Bearing Removal..........................311 Special Tools -.............................................311 Tie-Rod and Rocker Arm Bearing Installation.....................312 Needle Bearing Inspection.......................................312 Uni-Trak Linkage Inspection.........................................313 Tie-Rod and Rocker Arm Sleeve Wear..............................313 Tie-Rod and Rocker Arm Mounting Bolt Bend.......................313 Steering................................................................315 Bearing Puller:.....................................................318 Steering Inspection.................................................319 Steering Adjustment.............................................319 Steering Stem, Stem Bearing Removal.............................319 Special Tool -..............................................320 Special Tool -..............................................320 Special Tools -.............................................320 Steering Stem, Stem Bearing Installation........................321 Special Tools -.............................................321 Special Tools -.............................................321 Special Tool -..............................................321 Torque -....................................................321 Torque -....................................................322 Stem Bearing Lubrication........................................322 Stem Bearing Wear, Damage.......................................322 Stem Warp.......................................................322 Handlebar Removal...................................................323 Handlebar Installation..........................................323 Torque -....................................................324 Frame...................................................................325 Frame Inspection....................................................328 Rear Frame Removal..............................................328 Rear Frame Installation.........................................328 Torque -....................................................328 Engine Guard Installation.......................................328 Seat Removal........................................................329 Seat Installation...............................................329 Side Cover Removal..................................................330 Side Cover Installation.........................................330 Front Fender Removal................................................331 Rear Fender Removal.............................................331 Rear Flap Removal...............................................331 Electrical System.......................................................333 Timing Light:.......................................................337 There are numbers of important precautions that are musts when s....339 Wiring Inspection...................................................340 Magneto Cover Removal...............................................341 Magneto Cover Installation......................................341 Sealant -...................................................341 Torque -....................................................341 Flywheel Removal................................................341 Special Tool -..............................................342 Special Tool -..............................................342 Flywheel Installation...........................................342 Special Tool -..............................................342 Torque -....................................................342 Stator Removal..................................................343 Stator Installation.............................................343 Torque -....................................................343 Torque -....................................................343 Sealant -...................................................343 Flywheel Inspection.............................................343 Special Tools -.............................................344 Ignition Timing Inspection..........................................345 Special Tool -..................................................345 Special Tool -..................................................345 Safety Instructions.................................................346 Ignition Coil Removal...........................................346 Ignition Coil Inspection........................................347 Spark Plug Cleaning and Inspection..............................347 Spark Plug Gap Inspection.......................................348 C.D.I. Unit Removal.............................................348 C.D.I. Unit Inspection..........................................348 Special Tools -.............................................349 Special Tools -.............................................351 Special Tools -.............................................352 Special Tools -.............................................352 Crankshaft Sensor Inspection....................................353 Special Tool -..............................................353 Throttle Sensor Inspection..........................................354 Throttle Sensor Position Adjustment.............................355 Special Tool -..............................................355 Switch Inspection...................................................356 Special Tool -..................................................356 Engine Stop Switch Connection...................................356 Gear Position Switch Removal....................................356 Gear Position Switch Installation...............................357 Torque -....................................................357 Gear Position Switch Inspection.................................357 Special Tool -..............................................357 Appendix................................................................359 This is not an exhaustive list, giving every possible cause for ....365 Engine Doesn't Start, Starting Difficulty:......................365 Engine won't turn over:.....................................365 No fuel flow:...............................................365 Engine flooded:.............................................365 Fuel/air mixture incorrect:.................................365 No spark; spark weak:.......................................365 Compression Low:............................................365 Poor Running at Low Speed:......................................365 Spark weak:.................................................365 Fuel/air mixture incorrect:.................................365 Compression low:............................................365 Other:......................................................366 Poor Running or No Power at High Speed:.........................366 Firing incorrect:...........................................366 Fuel/air mixture incorrect:.................................366 Compression low:............................................366 Knocking:...................................................366 Other:......................................................366 Engine Overheating:.............................................366 Firing incorrect:...........................................366 Fuel/air mixture incorrect:.................................366 Compression high:...........................................366 Engine load faulty:.........................................366 Lubrication inadequate:.....................................366 Coolant incorrect:..........................................366 Cooling system component incorrect:.........................366 Clutch Operation Faulty:........................................366 Clutch slipping:............................................366 Clutch not disengaging properly:............................367 Gear Shifting Faulty:...........................................367 Doesn't go into gear; shift pedal doesn't return:...........367 Jumps out of gear:..........................................367 Overshifts:.................................................367 Abnormal Engine Noise:..........................................367 Knocking:...................................................367 Piston slap:................................................367 Valve noise:................................................367 Other noise:................................................367 Abnormal Drive Train Noise:.....................................367 Clutch noise:...............................................367 Transmission noise:.........................................367 Drive chain noise:..........................................367 Abnormal Frame Noise:...........................................367 Front fork noise:...........................................367 Rear shock absorber noise:..................................367 Disc brake noise:...........................................367 Other noise:................................................368 Abnormal Exhaust Color:.........................................368 White smoke:................................................368 Black smoke:................................................368 Brown smoke:................................................368 Handling and/or Stability Unsatisfactory:.......................368 Handlebar hard to turn:.....................................368 Handlebar shakes or excessively vibrates:...................368 Handlebar pulls to one side:................................368 Suspension operation trouble: (Too hard)....................368 (Too soft)..................................................368 Brake Doesn't Hold:.............................................368
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S.V
