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Kawasaki KX250F Motorcycle Service Manual – PDF DOWNLOAD
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Description
Kawasaki KX250F Motorcycle Service Manual – PDF DOWNLOAD
FILE DETAILS:
Kawasaki KX250F Motorcycle Service Manual – PDF DOWNLOAD
Language : English
Pages : 390
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Kawasaki KX250F 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 KX250F 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...................................... 23 Throttle Grip Free Play................................................. 31 Hot Start Lever Free Play............................................... 32 Idle Speed.............................................................. 33 Valve Clearance: between cam and valve lifter........................... 39 Adjustment shims........................................................ 40 Cylinder Head Warp...................................................... 41 Cylinder Inside Diameter................................................ 42 Piston/Cylinder Clearance............................................... 42 Friction Plate Thickness................................................ 45 Steel Plate Thickness................................................... 45 Friction and Steel Plates Warp.......................................... 45 Recommended Engine...................................................... 46 Connecting Rod Big End Side Clearance................................... 48 Standard Tire........................................................... 49 Rim Runout (with tire installed)........................................ 50 Chain 20-link Length.................................................... 51 Standard Chain.......................................................... 51 Chain Slack............................................................. 52 Rear Sprocket Warp...................................................... 54 Length [A].............................................................. 55 Recommended Disc Brake Fluid............................................ 57 Lining Thickness........................................................ 59 Length.................................................................. 66 Recommended Oil......................................................... 69 Fork Cylinder Unit Oil Level ........................................... 70 Length.................................................................. 74 Recommended Oil......................................................... 74 Recommended Oil......................................................... 83 Spark Plug Gap.......................................................... 89 Service Fuel Level (below the bottom edge of the carb. body)............105 Float Height............................................................105 Recommended Coolant.....................................................133 Radiator Cap Relief Pressure............................................142 Camshaft Bearing Clearance..............................................160 Camshaft Journal Diameter...............................................160 Camshaft Runout.........................................................160 Cam Height..............................................................160 Cylinder Compression....................................................161 Valve/Valve Guide Clearance Measurement (Wobble Method).................167 Valve Seating Surface Outside Diameter..................................168 Valve Seating Surface Width Standard....................................168 Piston Diameter.........................................................175 Piston Ring/Ring Groove Clearance.......................................175 Piston Ring Groove Width................................................176 Piston Ring Thickness (Top).............................................176 Piston Ring End Gap.....................................................176 Piston Pin Diameter.....................................................177 Piston Pin Hole Diameter................................................177 Small End Inside Diameter...............................................177 Release Shaft Lever Position............................................196 Adjusting Washers.......................................................196 Release Shaft Lever Position and Adjusting Washer Selection.............196 Clutch Spring Free Length...............................................197 Friction Plate/Clutch Housing Clearance.................................197 Oil Pump Pressure (oil temperature 90°C, @4 000 rpm)....................217 Connecting Rod Big End Radial Clearance.................................241 Connecting Rod Big End Side Clearance...................................241 Connecting Rod Bend.....................................................243 Connecting Rod Twist....................................................243 Shift Fork Ear Thickness................................................247 Gear Groove Width.......................................................247 Shift Fork Guide Pin Diameter...........................................247 Shift Drum Groove Width.................................................247 Axle Runout/100 mm (3.937 in.)..........................................259 Thickness...............................................................294 Runout..................................................................294 Rebound Damping Adjuster Setting........................................305 Compression Damping Adjuster Setting....................................306 Length..................................................................308 Recommended Oil.........................................................314 Fork Cylinder Unit Oil Level ...........................................314 Length..................................................................319 Recommended Oil.........................................................319 Fork Spring Free Length.................................................321 Rebound Damping Adjuster Setting........................................322 High Speed Compression Damping Adjuster Setting.........................323 Low Speed Compression Damping...........................................323 Spring Preload Adjustment...............................................324 Shock Absorber Spring Free Length.......................................324 Sleeve Outside Diameter.................................................334 Bolt Runout ............................................................334 Table 1 Magneto Output Voltage..........................................366 Table 2 Stator Coil Resistance..........................................366 Ignition Timing.........................................................367 Ignition Coil Winding Resistance........................................368 Throttle Sensor Input Voltage...........................................373 Throttle Sensor Output Voltage..........................................374 Throttle Sensor Input Voltage...........................................375 Throttle Sensor Output Voltage..........................................375 Throttle sensor Output Voltage..........................................375 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, 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 KX250T6F Left Side View............................................. 15 KX250T6F 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 Inside Circlip Pliers:.............................................. 30 Fuel System......................................................... 31 Fuel Hose and Connection Inspection............................. 31 Throttle Grip Free Play Inspection.............................. 31 Throttle Grip Free Play Adjustment.............................. 31 Hot Start Lever Free Play Inspection............................ 32 Idle Speed Inspection (Carburetor Inspection)................... 32 Idle Speed Adjustment (Carburetor Adjustment)................... 33 Special Tool -.............................................. 33 Air Cleaner Element Cleaning and Inspection..................... 34 Fuel System Clean............................................... 36 Special Tool -.............................................. 36 Cooling System.................................................. 37 Coolant Level Inspection.................................... 37 Coolant Deterioration Inspection............................ 38 Radiator Hoses and Connections Inspection................... 38 Torque -................................................ 38 Engine Top End.................................................. 39 Valve Clearance Inspection.................................. 39 Special Tool -.......................................... 39 Valve Clearance Adjustment.................................. 39 Torque -................................................ 41 Cylinder Head Warp Inspection............................... 41 Cylinder Wear Inspection.................................... 42 Piston/Cylinder Clearance................................... 42 Piston, Piston Ring and Piston Pin Replacement.............. 42 Exhaust System Inspection................................... 43 Silencer Packing Change..................................... 43 Torque -................................................ 44 Engine Right Side............................................... 44 Clutch Adjustment........................................... 44 Friction and Steel Plates Inspection........................ 45 Engine Lubrication System....................................... 46 Engine Oil Change........................................... 46 Torque -................................................ 46 Oil Filter Change........................................... 47 Torque -................................................ 47 Breather Hose Inspection.................................... 47 Crankshaft/Transmission......................................... 48 Crankshaft Inspection....................................... 48 Wheel/Tires..................................................... 48 Air Pressure Inspection/Adjustment.......................... 48 Tires Inspection............................................ 49 Spoke Tightness Inspection.................................. 49 Torque -................................................ 49 Rim Runout Inspection....................................... 50 Special Tools -......................................... 50 Wheel Bearing Inspection.................................... 50 Special Tools -......................................... 50 Final Drive..................................................... 51 Drive Chain Wear Inspection................................. 51 Drive Chain Slack Inspection................................ 52 Drive Chain Slack Adjustment................................ 52 Torque -................................................ 52 Drive Chain Lubrication..................................... 53 Sprocket Wear Inspection.................................... 54 Rear Sprocket Warp Inspection............................... 54 Special Tool -.......................................... 54 Brakes.......................................................... 54 Brake Lever and Pedal Adjustment............................ 54 Torque -................................................ 55 Brake Fluid Level Inspection................................ 56 Torque -................................................ 56 Brake Fluid Change.......................................... 57 Torque -................................................ 59 Brake Pad Wear Inspection................................... 59 Brake Master Cylinder Cup and Dust Seal Replacement......... 59 Special Tool -.......................................... 59 Special Tool -.......................................... 60 Torque -................................................ 60 Caliper Piston Seal and Dust Seal Replacement............... 60 Torque -................................................ 62 Brake Hose and Connection Check............................. 63 Brake Hose Replacement...................................... 63 Torque -................................................ 64 Suspension...................................................... 65 Front Fork Inspection....................................... 65 Front Fork Oil Change (each fork leg)....................... 65 Special Tool -.......................................... 65 Special Tool -.......................................... 67 Special Tool -.......................................... 67 Special Tool -.......................................... 70 Torque -................................................ 70 Special Tool -.......................................... 72 Special Tool -.......................................... 73 Torque -................................................ 73 Torque -................................................ 73 Special Tool -.......................................... 74 Torque -................................................ 74 Torque -................................................ 75 Rear Shock Absorber Oil Change.............................. 75 Torque -................................................ 80 Torque -................................................ 84 Swingarm and Uni-Trak Linkage Inspection.................... 84 Special Tools -......................................... 84 Swingarm and Uni-Track Linkage Pivot Lubricate.............. 85 Steering........................................................ 85 Steering Inspection......................................... 85 Special Tools -......................................... 85 Steering Adjustment ........................................ 85 Special Tools -......................................... 85 Special Tool -.......................................... 86 Torque -................................................ 86 Torque -................................................ 87 Stem Bearing Lubrication.................................... 87 Frame........................................................... 88 Frame Inspection............................................ 88 Electrical System............................................... 88 Spark Plug Cleaning and Inspection.......................... 88 Special Tool -.......................................... 88 Owner's Tool -.......................................... 88 Torque -................................................ 89 Special Tool -.......................................... 89 Owner's Tool -.......................................... 89 Chassis Parts Lubrication and Cable Inspection.................. 89 Lubrication................................................. 89 Points: Lubricate with Grease........................... 89 Cables: Lubricate with Rust Inhibitor................... 90 Pivots: Lubricate with motor oil........................ 90 Nut, Bolt, and Fastener Tightness Inspection.................... 90 Tightness Inspection........................................ 90 Nut, Bolt and Fastener to be checked.................... 91 Fuel System............................................................. 93 Fuel Level Gauge, M18 × 1.0:........................................ 99 If the throttle grip has excessive free play due to cable stretc....100 Free Play Inspection............................................100 Free Play Adjustment............................................100 Throttle Cable Replacement......................................100 Torque -....................................................101 Throttle Cable Lubrication......................................102 Throttle Cable Inspection.......................................102 Hot Start Cable Removal.........................................102 Hot Start Cable Installation....................................103 Torque -....................................................103 Hot Start Lever Free Play Inspection............................103 Hot Start Lever Free Play Adjustment............................103 Hot Start Cable Lubrication.....................................103 Hot Start Cable Inspection......................................103 Since the carburetor regulates and mixes the fuel and air going ....104 Idle Speed Inspection...........................................104 Idle Speed Adjustment...........................................104 Service Fuel Level Inspection...................................104 Special Tool -..............................................104 Service Fuel Level Adjustment...................................105 Carburetor Removal..............................................106 Carburetor Installation.........................................108 Torque -....................................................108 Torque -....................................................109 Fuel Inspection.................................................109 Carburetor Disassembly..........................................109 Carburetor Cleaning.............................................114 Carburetor Inspection...........................................114 Carburetor Assembly.............................................116 Air Cleaner Housing Removal.........................................122 Air Cleaner Housing Installation................................122 Torque -....................................................122 Element Removal.................................................122 Element Installation............................................123 Element Cleaning and Inspection.................................123 Fuel Tank Removal...................................................124 Fuel Tank Installation..........................................124 Fuel Tap Removal................................................125 Fuel Tap Installation...........................................125 Fuel Tank and Tap Cleaning......................................125 Fuel Tap Inspection.............................................125 Cooling System..........................................................127 Bearing Driver Set:.................................................131 Check the coolant level each day before riding the motorcycle, a....132 Coolant Level Inspection........................................132 Coolant Deterioration Inspection................................132 Coolant Draining................................................132 Coolant Filling.................................................133 Torque -....................................................133 Air Bleeding....................................................134 Cooling System Pressure Testing.................................134 Cooling System Flushing.........................................135 Water Pump Cover Removal............................................136 Water Pump Cover Installation ..................................136 Torque -....................................................136 Torque -....................................................137 Impeller Removal................................................137 Impeller Installation...........................................137 Torque -....................................................137 Water Pump Inspection...........................................137 Water Pump Gear Removal.........................................138 Water Pump Gear Installation....................................138 Oil Seal and Bearing Removal....................................138 Oil Seal and Bearing Installation...............................139 Special Tool -..............................................139 Radiator Removal....................................................140 Radiator Installation...........................................141 Torque -....................................................141 Radiator Inspection.............................................141 Radiator Cap Inspection.........................................142 Filler Neck Inspection..........................................142 Radiator Hoses, Breather Hose Inspection........................142 Radiator Hoses, Breather Hose Installation......................142 Torque -....................................................142 Engine Top End..........................................................143 Cam Height..........................................................150 Camshaft Runout.....................................................150 Valve Stem Diameter.............................................150 Valve Stem Bend.....................................................150 Compression Gauge, 20 kgf/cm :......................................151 Cylinder Head Cover Removal.........................................154 Cylinder Head Cover Installation................................154 Sealant -...................................................154 Torque -....................................................154 Camshaft Chain Tensioner Removal....................................155 Camshaft Chain Tensioner Installation...........................155 Torque -....................................................155 Torque -....................................................155 Camshaft Removal....................................................156 Special Tool -..................................................156 Camshaft Installation...........................................157 Torque -....................................................157 Torque -....................................................159 Torque -....................................................159 Special Tool -..............................................159 Camshaft Chain Removal..........................................159 Camshaft Chain Installation.....................................159 Torque -....................................................159 Camshaft and Camshaft Cap Wear..................................160 Torque -....................................................160 Camshaft Runout.................................................160 Cam Wear........................................................160 Cylinder Compression Measurement....................................161 Special Tool -..................................................161 Owner's Tool -..................................................161 Special Tools -.................................................161 Torque -........................................................161 Cylinder Head Removal...........................................162 Cylinder Head Installation......................................163 Torque -....................................................163 Torque -....................................................164 Torque -....................................................164 Cylinder Head Cleaning..........................................164 Cylinder Head Warp..............................................164 Valve Clearance Inspection..........................................165 Valve Removal...................................................165 Special Tools -.............................................165 Valve Installation..............................................165 Special Tools -.............................................165 Valve Guide Removal.............................................166 Special Tool -..............................................166 Valve Guide Installation........................................166 Special Tool -..............................................166 Special Tool -..............................................167 Valve/Valve Guide Clearance Measurement (Wobble Method).........167 Valve Seat Inspection...........................................168 Valve Seat Repair...............................................168 Special Tools -.............................................168 Seat Cutter Operation Care:.................................169 Valve Seat Repair...............................................172 Cylinder Removal....................................................173 Piston Removal..................................................173 Special Tool -..............................................173 Cylinder and Piston Installation................................173 Special Tools -.............................................175 Cylinder Wear...................................................175 Piston Wear.....................................................175 Piston/Cylinder Clearance.......................................175 Piston Ring/Ring Groove Clearance...............................175 Piston Ring Groove Width........................................176 Piston Ring Thickness...........................................176 Piston Ring End Gap Measurement.................................176 Piston, Piston Pin, Connecting Rod Wear Inspection..............177 Carburetor Holder Installation......................................178 Torque -........................................................178 WARNING.............................................................179 Muffler Removal.................................................179 Muffler Installation............................................179 Torque -....................................................179 Engine Right Side.......................................................181 Outside Circlip Pliers:.............................................187 Due to friction plate wear and clutch cable stretch over a long ....188 Clutch Lever Free Play Inspection...............................188 Clutch Lever Free Play Adjustment...............................188 Clutch Lever Installation.......................................188 Clutch Cable Removal............................................188 Clutch Cable Installation.......................................189 Clutch Cable Inspection and Lubrication.........................189 Clutch Cover Removal................................................190 Clutch Cover Installation.......................................190 Torque -....................................................190 Right Engine Cover Removal......................................190 Right Engine Cover Installation.................................191 Torque -....................................................191 Torque -....................................................192 Release Shaft Removal...........................................192 Release Shaft Installation......................................192 Oil Seal Installation...........................................192 Special Tool -..............................................193 Special Tool -..............................................193 Clutch Removal......................................................194 Special Tool -..................................................194 Clutch Installation.............................................194 Torque -....................................................195 Special Tool -..............................................195 Torque -....................................................196 Friction and Steel Plates Wear, Damage Inspection...............196 Friction and Steel Plate Warp Inspection........................196 Clutch Spring Free Length Inspection............................197 Clutch Housing Finger Damage....................................197 Friction Plate/Clutch Housing Clearance.........................197 Clutch Hub Spline Damage........................................197 Primary Gear Removal................................................198 Special Tool -..................................................198 Primary Gear Installation.......................................198 Torque -....................................................198 Special Tool -..............................................198 External Shift Mechanism Removal....................................199 External Shift Mechanism Installation...........................199 Torque -....................................................199 Torque -....................................................200 Torque -....................................................200 External Shift Mechanism Inspection.............................200 Kick Pedal Assy Removal.............................................202 Kick Pedal Assy Installation....................................202 Torque -....................................................202 Kick Pedal Assy Disassembly.....................................202 Kick Pedal Assy Assembly........................................202 Idle Gear Removal...............................................202 Idle Gear Installation..........................................203 Kickshaft Removal...............................................203 Kickshaft Installation..........................................203 Torque -....................................................203 Kickstarter Assembly Disassembly/Assembly.......................204 Special Tool -..............................................204 Engine Lubrication System...............................................205 Oil Pressure Gauge, 5 kgf/cm :......................................211 WARNING.............................................................212 Engine Oil Level Inspection.....................................212 Engine Oil Change...............................................212 Oil Filter Change...............................................213 Oil Screen Cleaning.............................................213 Oil Pump Removal....................................................214 Special Tool -..................................................214 Special Tool -..................................................214 Oil Pump Installation...........................................215 Torque -....................................................216 Special Tool -..............................................216 Oil Pump Inspection.............................................216 Oil Pressure Measurement............................................217 Special Tools -.................................................217 Engine Removal/Installation.............................................219 Jack:...............................................................222 Engine Removal......................................................223 Special Tools -.................................................223 Engine Installation.............................................225 Torque -....................................................225 Crankshaft/Transmission.................................................227 Bearing Puller:.....................................................231 Crankcase Disassembly...............................................232 Special Tool -..................................................233 Special Tool -..................................................233 Crankcase Assembly..............................................234 Special Tool -..............................................235 Special Tool -..............................................236 Torque -....................................................236 Torque -....................................................236 Torque -....................................................236 Special Tool -..............................................237 Sealant -...................................................237 Torque -....................................................238 Torque -....................................................238 Torque -....................................................238 Crankshaft Removal..................................................240 Special Tool -..................................................240 Crankshaft Installation.........................................240 Special Tool -..............................................240 Special Tool -..............................................240 Crankshaft Disassembly..........................................240 Crankshaft Assembly.............................................240 Crankshaft Inspection...........................................241 Connecting Rod Bend.............................................243 Connecting Rod Twist............................................243 Transmission Shaft Removal..........................................244 Transmission Shaft Installation.................................244 Transmission Shaft Disassembly..................................245 Special Tool -..............................................245 Transmission Shaft Assembly.....................................245 Special Tool -..............................................245 Shift Fork Bending..............................................247 Shift Fork/Gear Groove Wear.....................................247 Shift Fork Guide Pin/Shift Drum Groove Wear.....................247 Gear Damage.....................................................247 Bearing Replacement.................................................248 Special Tool -..................................................248 Bearing Inspection..............................................248 Oil Seal Inspection.............................................249 Wheels/Tires............................................................251 Inside Circlip Pliers:..............................................255 Front Wheel Removal.................................................256 Special Tools -.................................................256 Front Wheel Installation........................................256 Torque -....................................................256 Torque -....................................................257 Rear Wheel Removal..............................................257 Special Tools -.............................................257 Rear Wheel Installation.........................................258 Torque -....................................................259 Wheels Inspection...............................................259 Spoke Tightness Inspection......................................259 Rim Runout Inspection...........................................259 Axle Inspection.................................................259 Tire Removal........................................................260 Special Tool -..................................................260 Special Tools -.................................................261 Tire Installation...............................................261 Air Pressure Inspection/Adjustment..............................262 Hub Bearing Removal.................................................263 Special Tool -..................................................263 Hub Bearing Installation........................................263 Special Tool -..............................................263 Special Tool -..............................................263 Hub Bearing Inspection..........................................263 Final Drive.............................................................265 Outside Circlip Pliers:.............................................269 Drive Chain Slack Inspection........................................270 Drive Chain Slack Adjustment....................................270 Wheel Alignment Inspection......................................270 Wheel Alignment Adjustment......................................270 Drive Chain Wear Inspection.....................................270 Drive Chain Lubrication.........................................270 Drive Chain Removal.............................................270 Drive Chain Installation........................................270 Engine Sprocket Removal.............................................272 Special Tool -..................................................272 Engine Sprocket Installation ...................................272 Special Tool -..............................................272 Torque -....................................................272 Rear Sprocket Removal...........................................272 Rear Sprocket Installation......................................273 Torque -....................................................273 Sprocket Wear Inspection........................................273 Rear Sprocket Warp Inspection...................................273 Brakes..................................................................275 Inside Circlip Pliers:..............................................281 Brake Lever Play Adjustment.........................................282 Brake Pedal Position/Pedal Play Adjustment......................282 Brake Pedal Removal.............................................282 Brake Pedal Installation........................................282 Torque -....................................................282 WARNING.............................................................283 Fluid Level Inspection..........................................283 Fluid Change....................................................283 Bleeding the Brake Line.........................................284 Torque -....................................................285 Caliper Removal.....................................................286 Caliper Installation............................................286 Torque -....................................................286 Torque -....................................................286 Torque -....................................................286 Caliper Disassembly.............................................287 Fluid Seal Damage...............................................287 Dust Seal and Cover Damage......................................287 Piston Cylinder Damage..........................................287 Caliper Holder Shaft Wear.......................................287 Brake Pad Removal...............................................288 Brake Pad Installation..........................................288 Torque -....................................................289 Brake Pad Inspection............................................289 CAUTION.............................................................290 Front Master Cylinder Removal...................................290 Front Master Cylinder Installation..............................290 Torque -....................................................291 Torque -....................................................291 Rear Master Cylinder Removal....................................291 Rear Master Cylinder Installation...............................291 Torque -....................................................291 Front Master Cylinder Disassembly...............................292 Rear Master Cylinder Disassembly................................292 Master Cylinder Assembly........................................292 Master Cylinder Inspection (Visual Inspection)..................293 Brake Disc Inspection...............................................294 Special Tool -..................................................294 Brake Disc Removal..............................................294 Brake Disc Installation.........................................294 Torque -....................................................294 Brake Hose Removal/Installation.....................................295 Brake Hose Inspection...........................................295 Suspension..............................................................297 Oil Seal & Bearing Remover:.........................................303 Air Pressure........................................................305 Special Tools -.................................................305 Torque -........................................................305 Rebound Damping Adjustment......................................305 Special Tools -.............................................305 Compression Damping Adjustment..................................306 Special Tools -.............................................306 Oil Change/Oil Level Adjustment (each fork leg).................306 Front Fork Removal..............................................306 Front Fork Installation.........................................307 Torque -....................................................308 Torque -....................................................308 Front Fork Disassembly (each fork leg)..........................308 Special Tool -..............................................308 Special Tool -..............................................309 Special Tool -..............................................309 Front Fork Assembly.............................................313 Special Tool -..............................................313 Special Tool -..............................................315 Torque -....................................................315 Special Tool -..............................................317 Torque -....................................................318 Torque -....................................................318 Special Tool -..............................................319 Torque -....................................................319 Torque -....................................................320 Inner Tube Inspection...........................................320 Slide/Guide Bushing Inspection..................................321 Dust Seal/Oil Seal Inspection...................................321 Spring Tension..................................................321 Rear Shock Absorber.................................................322 Rebound Damping Adjustment......................................322 Compression Damping Adjustment..................................322 Spring Preload Adjustment.......................................323 Special Tools -.............................................323 Special Tools -.............................................324 Special Tool -..............................................324 Torque -....................................................324 Torque -....................................................324 Spring Tension..................................................324 Rear Shock Absorber Removal.....................................325 Special Tools -.............................................325 Rear Shock Absorber Installation................................325 Torque -....................................................325 Spring Replacement..............................................325 Special Tools -.............................................326 Rear Shock Absorber Disassembly (Oil Change)....................326 Rear Shock Absorber Assembly....................................326 Rear Shock Absorber Scrapping...................................326 Swingarm Removal....................................................327 Special Tools -.................................................327 Swingarm Installation...........................................327 Torque -....................................................327 Swingarm Bearing Removal........................................328 Special Tool -..............................................328 Swingarm Bearing Installation...................................328 Special Tool -..............................................328 Drive Chain Guide, Guide Roller, Chain Slipper Wear.............328 Swingarm Bearing, Sleeve Inspection.............................329 Tie-Rod Removal.....................................................330 Special Tools -.................................................330 Tie-Rod Installation............................................330 Torque -....................................................330 Rocker Arm Removal..............................................330 Special Tools -.............................................330 Rocker Arm Installation.........................................331 Torque -....................................................331 Tie-Rod and Rocker Arm Bearing Removal..........................332 Special Tools -.............................................332 Tie-Rod and Rocker Arm Bearing Installation.....................332 Needle Bearing Inspection.......................................333 Uni-Trak Linkage Inspection.........................................334 Tie-Rod and Rocker Arm Sleeve Wear..............................334 Tie-Rod and Rocker Arm Mounting Bolt Bend.......................334 Steering................................................................335 Bearing Puller Adapter:.............................................338 Steering Inspection.................................................339 Steering Adjustment.............................................339 Steering Stem, Stem Bearing Removal.............................339 Special Tool -..............................................340 Special Tool -..............................................340 Special Tools -.............................................340 Steering Stem, Stem Bearing Installation........................340 Special Tools -.............................................340 Special Tools -.............................................341 Special Tool -..............................................341 Torque -....................................................341 Torque -....................................................341 Stem Bearing Lubrication........................................342 Stem Bearing Wear, Damage.......................................342 Stem Warp.......................................................342 Handlebar Removal...................................................343 Handlebar Installation..........................................343 Torque -....................................................345 Torque -....................................................345 Frame...................................................................347 Frame Inspection....................................................350 Rear Frame Removal..............................................350 Rear Frame Installation.........................................350 Torque -....................................................351 Engine Guard Installation.......................................351 Seat Removal........................................................352 Seat Installation...............................................352 Side Cover Removal..................................................353 Side Cover Installation.........................................353 Front Fender Removal................................................354 Rear Fender Removal.............................................354 Rear Flap Removal...............................................354 Electrical System.......................................................355 Timing Light:.......................................................359 There are numbers of important precautions that are musts when s....361 Wiring Inspection...................................................362 Magneto Cover Removal...............................................363 Magneto Cover Installation......................................363 Sealant -...................................................363 Torque -....................................................363 Flywheel Magneto Removal........................................363 Special Tool -..............................................364 Special Tool -..............................................364 Flywheel Magneto Installation...................................364 Special Tool -..............................................364 Special Tool -..............................................364 Torque -....................................................364 Stator Removal..................................................365 Stator Installation.............................................365 Torque -....................................................365 Torque -....................................................365 Sealant -...................................................365 Flywheel Magneto Inspection.....................................365 Special Tool -..............................................366 Special Tool -..............................................366 Ignition Timing Inspection..........................................367 Special Tool -..................................................367 Special Tool -..................................................367 Torque -........................................................367 Safety Instructions.................................................368 Stick Coil Removal..............................................368 Stick Coil Installation.........................................368 Stick Coil Inspection...........................................368 Spark Plug Cleaning and Inspection..............................368 Spark Plug Gap Inspection.......................................369 C.D.I. Unit Removal.............................................369 C.D.I. Unit Inspection..........................................369 Special Tools -.............................................370 Trouble shooting chart..........................................371 Special Tool -..............................................372 Special Tool -..............................................372 Special Tool -..............................................373 Special Tool -..............................................373 Crankshaft Sensor Inspection................................374 Special Tool -..........................................374 Throttle Sensor Inspection..........................................375 Throttle Sensor Position Adjustment.............................376 Special Tool -..............................................376 Neutral Switch Inspection...........................................377 Special Tool -..................................................377 Neutral Switch Connections......................................377 Appendix................................................................379 This is not an exhaustive list, giving every possible cause for ....386 Engine Doesn't Start, Starting Difficulty:......................386 Engine won't turn over:.....................................386 No fuel flow:...............................................386 Engine flooded:.............................................386 Fuel/air mixture incorrect:.................................386 No spark; spark weak:.......................................386 Compression Low:............................................386 Poor Running at Low Speed:......................................386 Spark weak:.................................................386 Fuel/air mixture incorrect:.................................386 Compression low:............................................386 Other:......................................................386 Poor Running or No Power at High Speed:.........................387 Firing incorrect:...........................................387 Fuel/air mixture incorrect:.................................387 Compression low:............................................387 Knocking:...................................................387 Other:......................................................387 Engine Overheating:.............................................387 Firing incorrect:...........................................387 Fuel/air mixture incorrect:.................................387 Compression high:...........................................387 Engine load faulty:.........................................387 Lubrication inadequate:.....................................387 Coolant incorrect:..........................................387 Cooling system component incorrect:.........................387 Clutch Operation Faulty:........................................387 Clutch slipping:............................................387 Clutch not disengaging properly:............................387 Gear Shifting Faulty:...........................................388 Doesn't go into gear; shift pedal doesn't return:...........388 Jumps out of gear:..........................................388 Overshifts:.................................................388 Abnormal Engine Noise:..........................................388 Knocking:...................................................388 Piston slap:................................................388 Valve noise:................................................388 Other noise:................................................388 Abnormal Drive Train Noise:.....................................388 Clutch noise:...............................................388 Transmission noise:.........................................388 Drive chain noise:..........................................388 Abnormal Frame Noise:...........................................388 Front fork noise:...........................................388 Rear shock absorber noise:..................................388 Disc brake noise:...........................................388 Other noise:................................................388 Abnormal Exhaust Color:.........................................388 White smoke:................................................388 Black smoke:................................................389 Brown smoke:................................................389 Handling and/or Stability Unsatisfactory:.......................389 Handlebar hard to turn:.....................................389 Handlebar shakes or excessively vibrates:...................389 Handlebar pulls to one side:................................389 Suspension operation trouble: (Too hard)....................389 (Too soft)..................................................389 Brake Doesn't Hold:.............................................389
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- This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
- This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
- Require some other service manual or have any queries: please WRITE to us at [email protected]
S.V
