![Kawasaki KX450F (2006) [31/369] Hot starter lever free play](/img/pdf.png)
Kawasaki KX450F (2006) [31/369] Hot starter lever free play
![Kawasaki KX450F (2006) [31/369] Hot starter lever free play](/views2/1121205/page31/bg1f.png)
PERIODIC MAINTENANCE 2-13
Periodic Maintenance Procedures
Hot Starter Lever Free Play Inspection
•
Slide the clutch lever dust cover [A] back.
•
Check the hot starter lever play [B] when pulling the start
lever [C] lightly.
Hot Starter Lever Free Play
Standard: 0.5 ∼ 1.0 mm (0.02 ∼ 0.04 in.)
If the free play is improper, adjust the hot starter cable.
•
Slide the adjuster cover [A] back.
•
Loosen the locknut [B] and turn the adjuster [C] to obtain
the p roper lever free play.
•
Tighten the locknut securely.
•
Check that the hot starter lever moves smoothly from full
open to close, and the lever closes quickly and completely
in all steering positions by the return spring.
If the hot starter lever does not return properly, check the
hot starter cable routing, free play and cable damage.
Then lubricate the hot starter cable.
Idle Sp eed Inspection
CAUTION
This motorcycle is designed for competition use
only. Therefore, the radiator does not incorporate
a coolant reserve tank or cooling fan. Prolonged
idling of the engine with no airflow through the
radiator can cause coolant loss and engine over-
heating resulting in possible engine damage. Any
riding conditions that increase engine temperature
will further reduce idling time before coolant loss
occurs. These conditions include high ambient
temperature, sandy or muddy terrain, or other con-
ditions causing high engine loads at low speeds.
Furthermore, warming the engine up excessively
before operation, or leaving idling with the hot
engine temperature after operation results in the
engine overheating, too.
•
Start the engine and warm it up thoroughly.
•
With the engine idling, turn the handlebar to both sides
[A].
If handlebar movement changes the idle speed, the throt-
tle cable may be improperly adjusted or incorrectly routed,
or it may be damaged. Be sure to correct any of these
conditions before riding (see Cable, Harness, Hose Rout-
ing section in the Appendix chapter).
WARNING
Operation with a n improperly adjusted, incorrectly
routed, or damaged cable could result in an unsafe
riding c
ondition.
Содержание
- Tables 1
- Quick reference guide 3
- Kx450f 5
- Motorcycle service manual 5
- List of abbreviations 6
- Foreword 7
- How to use this manual 7
- General information 9
- General information 1 1 9
- Table of contents 9
- 2 general information 10
- Arrangement and cleaning of removed parts 10
- Before servicing 10
- Before starting to perform an inspection service or carry out a 10
- Cleaning vehicle before disassembly 10
- Edges of parts 10
- Solvent 10
- Assembly order 11
- Before servicing 11
- General information 1 3 11
- Inspection 11
- Replacement parts 11
- Storage of removed parts 11
- Tightening sequence 11
- 4 general information 12
- Before servicing 12
- Gasket o ring 12
- Liquid gasket non permanent locking agent 12
- Tightening torque 12
- Ball bearing and needle bearing 13
- Before servicing 13
- Circlips cotter pins 13
- General information 1 5 13
- Lubrication 13
- Oil seal grease seal 13
- 6 general information 14
- Before servicing 14
- Direction of engine rotation 14
- Electrical wires 14
- Instrument 14
- General information 1 7 15
- Kx450d6f left side view 15
- Kx450d6f right side view 15
- Model identification 15
- 8 general information 16
- General specifications 16
- General information 1 9 17
- General specifications 17
- 10 general information 18
- Prefixes for units 18
- Unit conversion table 18
- Units of force 18
- Units of length 18
- Units of mass 18
- Units of power 18
- Units of pressure 18
- Units of speed 18
- Units of temperature 18
- Units of torque 18
- Units of volume 18
- Periodic maintenance 19
- Periodic maintenance 2 1 19
- Table of contents 19
- 2 periodic maintenance 20
- Periodic maintenance 2 3 21
- Periodic maintenance chart 21
- The maintenance must be done in accordance with this chart to ke 21
- 4 periodic maintenance 22
- Periodic maintenance chart 22
- Periodic maintenance 2 5 23
- Tighten all bolts and nuts to the proper torque using an accurat 23
- Torque and locking agent 23
- 6 periodic maintenance 24
- Torque and locking agent 24
- Periodic maintenance 2 7 25
- Torque and locking agent 25
- 8 periodic maintenance 26
- Basic torque for general fasteners 26
- Torque and locking agent 26
- Periodic maintenance 2 9 27
- Specifications 27
- 10 periodic maintenance 28
- Specifications 28
- Periodic maintenance 2 11 29
- Special tools 29
- Steering stem nut wrench 29
- 12 periodic maintenance 30
- Fuel hose and connection inspection 30
- Fuel system 30
- Periodic maintenance procedures 30
- Throttle grip free play 30
- Throttle grip free play adjustment 30
- Throttle grip free play inspection 30
- Warning 30
- Caution 31
- Hot starter lever free play 31
- Hot starter lever free play inspection 31
- Idle speed inspection 31
- Periodic maintenance 2 13 31
- Periodic maintenance procedures 31
- Warning 31
- 14 periodic maintenance 32
- Idle speed 32
- Idle speed adjustment 32
- Periodic maintenance procedures 32
- Warning 32
- Periodic maintenance 2 15 33
- Periodic maintenance procedures 33
- 16 periodic maintenance 34
- Fuel inspection 34
- Periodic maintenance procedures 34
- Warning 34
- Cooling system 35
- Fuel tank filter and tap cleaning 35
- Fuel tap and filter inspection 35
- Periodic maintenance 2 17 35
- Periodic maintenance procedures 35
- Warning 35
- 18 periodic maintenance 36
- Periodic maintenance procedures 36
- Engine top end 37
- Periodic maintenance 2 19 37
- Periodic maintenance procedures 37
- 20 periodic maintenance 38
- Example 38
- Periodic maintenance procedures 38
- Valve clearance between cam and valve lifter 38
- Adjustment shims 39
- Periodic maintenance 2 21 39
- Periodic maintenance procedures 39
- 22 periodic maintenance 40
- Cylinder head warp 40
- Cylinder inside diameter 40
- Periodic maintenance procedures 40
- Exhaust system inspection 41
- Muffler baffle change 41
- Periodic maintenance 2 23 41
- Periodic maintenance procedures 41
- Piston cylinder clearance 41
- Piston piston ring and piston pin replacement 41
- 24 periodic maintenance 42
- Engine right side 42
- Periodic maintenance procedures 42
- Warning 42
- Friction plate thickness 43
- Periodic maintenance 2 25 43
- Periodic maintenance procedures 43
- 26 periodic maintenance 44
- Engine lubrication system 44
- Friction and steel plates warp 44
- Periodic maintenance procedures 44
- Recommended engine 44
- Periodic maintenance 2 27 45
- Periodic maintenance procedures 45
- 28 periodic maintenance 46
- Air pressure inspection adjustment 46
- Connecting rod big end side clearance 46
- Crankshaft inspection 46
- Crankshaft transmission 46
- Periodic maintenance procedures 46
- Wheel tires 46
- Periodic maintenance 2 29 47
- Periodic maintenance procedures 47
- Standard tire 47
- Warning 47
- 30 periodic maintenance 48
- Periodic maintenance procedures 48
- Rim runout inspection 48
- Rim runout with tire installed 48
- Wheel bearing inspection 48
- Chain slack 49
- Final drive 49
- Periodic maintenance 2 31 49
- Periodic maintenance procedures 49
- Warning 49
- 32 periodic maintenance 50
- Chain 20 link length 50
- Periodic maintenance procedures 50
- Warning 50
- Periodic maintenance 2 33 51
- Periodic maintenance procedures 51
- Standard chain 51
- Warning 51
- 34 periodic maintenance 52
- Brakes 52
- Length a 52
- Periodic maintenance procedures 52
- Rear sprocket warp 52
- Warning 52
- Periodic maintenance 2 35 53
- Periodic maintenance procedures 53
- Warning 53
- 36 periodic maintenance 54
- Brake fluid change 54
- Periodic maintenance procedures 54
- Recommended disc brake fluid 54
- Warning 54
- Periodic maintenance 2 37 55
- Periodic maintenance procedures 55
- 38 periodic maintenance 56
- Brake master cylinder cup and dust seal replacement 56
- Brake pad wear inspection 56
- Lining thickness 56
- Periodic maintenance procedures 56
- Warning 56
- Periodic maintenance 2 39 57
- Periodic maintenance procedures 57
- 40 periodic maintenance 58
- Periodic maintenance procedures 58
- Warning 58
- Periodic maintenance 2 41 59
- Periodic maintenance procedures 59
- Warning 59
- 42 periodic maintenance 60
- Periodic maintenance procedures 60
- Periodic maintenance 2 43 61
- Periodic maintenance procedures 61
- 44 periodic maintenance 62
- Caution 62
- Front fork inspection 62
- Front fork oil change each fork leg 62
- Periodic maintenance procedures 62
- Suspension 62
- Periodic maintenance 2 45 63
- Periodic maintenance procedures 63
- 46 periodic maintenance 64
- Periodic maintenance procedures 64
- Warning 64
- Caution 65
- Periodic maintenance 2 47 65
- Periodic maintenance procedures 65
- 48 periodic maintenance 66
- Periodic maintenance procedures 66
- Periodic maintenance 2 49 67
- Periodic maintenance procedures 67
- 50 periodic maintenance 68
- Periodic maintenance procedures 68
- Periodic maintenance 2 51 69
- Periodic maintenance procedures 69
- Warning 69
- 52 periodic maintenance 70
- Periodic maintenance procedures 70
- Periodic maintenance 2 53 71
- Periodic maintenance procedures 71
- Rear shock absorber inspection 71
- Rear shock absorber oil change 71
- Warning 71
- 54 periodic maintenance 72
- Periodic maintenance procedures 72
- Periodic maintenance 2 55 73
- Periodic maintenance procedures 73
- 56 periodic maintenance 74
- Caution 74
- Periodic maintenance procedures 74
- Warning 74
- Caution 75
- Periodic maintenance 2 57 75
- Periodic maintenance procedures 75
- Warning 75
- 58 periodic maintenance 76
- Periodic maintenance procedures 76
- Steering 76
- Steering adjustment 76
- Steering inspection 76
- Swingarm and uni track linkage pivot lubricate 76
- Swingarm and uni trak linkage inspection 76
- Periodic maintenance 2 59 77
- Periodic maintenance procedures 77
- 60 periodic maintenance 78
- Frame inspection 78
- Periodic maintenance procedures 78
- Stem bearing lubrication 78
- Warning 78
- Cable inspection 79
- Electrical system 79
- Periodic maintenance 2 61 79
- Periodic maintenance procedures 79
- Spark plug gap 79
- 62 periodic maintenance 80
- Nut bolt and fastener tightness inspection 80
- Periodic maintenance procedures 80
- Periodic maintenance 2 63 81
- Periodic maintenance procedures 81
- Fuel system 83
- Fuel system 3 1 83
- Table of contents 83
- Exploded view 85
- Fuel system 3 3 85
- Exploded view 87
- Fuel system 3 5 87
- 6 fuel system 88
- Specifications 88
- Fuel system 3 7 89
- Special tool 89
- 8 fuel system 90
- Free play adjustment 90
- Free play inspection 90
- Throttle cable replacement 90
- Throttle grip and cable 90
- Fuel system 3 9 91
- Throttle grip and cable 91
- Warning 91
- 10 fuel system 92
- Hot starter cable installation 92
- Hot starter cable removal 92
- Hot starter lever free play inspection 92
- Throttle grip and cable 92
- Warning 92
- Fuel system 3 11 93
- Hot starter cable inspection 93
- Hot starter cable lubrication 93
- Hot starter lever free play adjustment 93
- Throttle grip and cable 93
- 12 fuel system 94
- Carburetor 94
- Warning 94
- Carburetor 95
- Float height 95
- Fuel system 3 13 95
- Service fuel level adjustment 95
- Service fuel level below the bottom edge of the carb body 95
- Warning 95
- 14 fuel system 96
- Carburetor 96
- Warning 96
- Carburetor 97
- Fuel system 3 15 97
- 16 fuel system 98
- Carburetor 98
- Warning 98
- Carburetor 99
- Fuel system 3 17 99
- 18 fuel system 100
- Carburetor 100
- Carburetor 101
- Fuel system 3 19 101
- 20 fuel system 102
- Carburetor 102
- Carburetor 103
- Carburetor cleaning 103
- Carburetor inspection 103
- Caution 103
- Fuel system 3 21 103
- Warning 103
- 22 fuel system 104
- Carburetor 104
- Carburetor 105
- Fuel system 3 23 105
- 24 fuel system 106
- Carburetor 106
- Carburetor 107
- Fuel system 3 25 107
- 26 fuel system 108
- Carburetor 108
- Carburetor 109
- Fuel system 3 27 109
- 28 fuel system 110
- Air cleaner 110
- Air cleaner housing installation 110
- Air cleaner housing removal 110
- Caution 110
- Element removal 110
- Air cleaner 111
- Element cleaning and inspection 111
- Element installation 111
- Fuel system 3 29 111
- 30 fuel system 112
- Fuel filter installation 112
- Fuel filter removal 112
- Fuel tank 112
- Fuel tank installation 112
- Fuel tank removal 112
- Warning 112
- Fuel system 3 31 113
- Fuel tank 113
- Fuel tank filter and tap cleaning 113
- Fuel tap and filter inspection 113
- Cooling system 115
- Cooling system 4 1 115
- Table of contents 115
- Cooling system 4 3 117
- Exploded view 117
- 4 cooling system 118
- Specifications 118
- Cooling system 4 5 119
- Special tool 119
- 6 cooling system 120
- Coolant 120
- Warning 120
- Coolant 121
- Cooling system 4 7 121
- Recommended coolant 121
- 8 cooling system 122
- Coolant 122
- Cooling system 4 9 123
- Water pump 123
- 10 cooling system 124
- Impeller installation 124
- Impeller removal 124
- Oil seal and bearing removal 124
- Water pump 124
- Water pump inspection 124
- Caution 125
- Cooling system 4 11 125
- Oil seal installation 125
- Water pump 125
- 12 cooling system 126
- Radiator 126
- Radiator removal 126
- Caution 127
- Cooling system 4 13 127
- Radiator 127
- Radiator cap inspection 127
- Radiator inspection 127
- Radiator installation 127
- 14 cooling system 128
- Filler neck inspection 128
- Radiator 128
- Radiator cap relief pressure 128
- Radiator hoses breather hose inspection 128
- Radiator hoses breather hose installation 128
- Engine top end 129
- Engine top end 5 1 129
- Table of contents 129
- Engine top end 5 3 131
- Exploded view 131
- Engine top end 5 5 133
- Exploded view 133
- 6 engine top end 134
- Specifications 134
- Engine top end 5 7 135
- Specifications 135
- 8 engine top end 136
- Cam height a 136
- Dial gauge a 136
- Specifications 136
- Valve stem diameter a 45 b 136
- Engine top end 5 9 137
- Special tools and sealant 137
- 10 engine top end 138
- Special tools and sealant 138
- Engine top end 5 11 139
- Special tools and sealant 139
- 12 engine top end 140
- Cylinder head cover 140
- Camshaft chain tensioner 141
- Camshaft chain tensioner installation 141
- Camshaft chain tensioner removal 141
- Caution 141
- Engine top end 5 13 141
- 14 engine top end 142
- Camshaft chain tensioner 142
- Camshaft 143
- Engine top end 5 15 143
- 16 engine top end 144
- Camshaft 144
- Camshaft 145
- Engine top end 5 17 145
- 18 engine top end 146
- Camshaft 146
- Cam height 147
- Camshaft 147
- Camshaft bearing clearance 147
- Camshaft journal diameter 147
- Camshaft runout 147
- Engine top end 5 19 147
- 20 engine top end 148
- Cylinder compression 148
- Cylinder compression measurement 148
- Cylinder head 148
- Cylinder head 149
- Engine top end 5 21 149
- 22 engine top end 150
- Cylinder head 150
- Cylinder head 151
- Cylinder head cleaning 151
- Cylinder head warp 151
- Engine top end 5 23 151
- 24 engine top end 152
- Valves 152
- Caution 153
- Engine top end 5 25 153
- Valve guide installation 153
- Valve guide removal 153
- Valves 153
- 26 engine top end 154
- Valve valve guide clearance measurement wobble method 154
- Valves 154
- Engine top end 5 27 155
- Valve seating surface outside diameter 155
- Valve seating surface width standard 155
- Valves 155
- 28 engine top end 156
- Valves 156
- Engine top end 5 29 157
- Valves 157
- 30 engine top end 158
- Valves 158
- 32 engine top end 160
- Cylinder and piston 160
- Cylinder and piston 161
- Engine top end 5 33 161
- 34 engine top end 162
- Cylinder and piston 162
- Cylinder wear 162
- Piston cylinder clearance 162
- Piston diameter 162
- Piston ring ring groove clearance 162
- Piston wear 162
- Cylinder and piston 163
- Engine top end 5 35 163
- Piston ring end gap 163
- Piston ring groove width 163
- Piston ring thickness 163
- 36 engine top end 164
- Connecting rod small end inside diameter 164
- Cylinder and piston 164
- Piston pin diameter 164
- Piston pin hole diameter 164
- Piston piston pin connecting rod wear inspection 164
- Carburetor holder 165
- Engine top end 5 37 165
- 38 engine top end 166
- Muffler 166
- Muffler baffle replacement 166
- Muffler installation 166
- Muffler removal 166
- Warning 166
- Engine right side 167
- Engine right side 6 1 167
- Table of contents 167
- Engine right side 6 3 169
- Exploded view 169
- Engine right side 6 5 171
- Exploded view 171
- 6 engine right side 172
- Specifications 172
- Engine right side 6 7 173
- Special tools 173
- 8 engine right side 174
- Clutch cable removal 174
- Clutch lever and cable 174
- Clutch lever free play adjustment 174
- Clutch lever free play inspection 174
- Clutch lever installation 174
- Warning 174
- Caution 175
- Clutch cable inspection and lubrication 175
- Clutch cable installation 175
- Clutch lever and cable 175
- Engine right side 6 9 175
- 10 engine right side 176
- Clutch cover and right engine cover 176
- Clutch cover and right engine cover 177
- Engine right side 6 11 177
- 12 engine right side 178
- Clutch 178
- Clutch installation 178
- Clutch removal 178
- Clutch 179
- Engine right side 6 13 179
- 14 engine right side 180
- Adjusting washers 180
- Clutch 180
- Release shaft lever position 180
- Release shaft lever position and adjusting washer selection 180
- Clutch 181
- Clutch plate length 181
- Clutch spring free length 181
- Engine right side 6 15 181
- 16 engine right side 182
- Clutch 182
- Clutch housing finger damage 182
- Clutch hub spline damage 182
- Friction plate clutch housing clearance 182
- Engine right side 6 17 183
- Primary gear 183
- 18 engine right side 184
- External shift mechanism 184
- Engine right side 6 19 185
- External shift mechanism 185
- 20 engine right side 186
- External shift mechanism 186
- Engine right side 6 21 187
- Idle gear removal 187
- Kick pedal assy assembly 187
- Kick pedal assy disassembly 187
- Kick pedal assy installation 187
- Kick pedal assy removal 187
- Kickstarter 187
- 22 engine right side 188
- Kickstarter 188
- Engine right side 6 23 189
- Kick shaft assembly disassembly assembly 189
- Kickstarter 189
- Engine lubrication system 191
- Engine lubrication system 7 1 191
- Table of contents 191
- Engine lubrication system 7 3 193
- Exploded view 193
- Engine lubrication system 7 5 195
- Lubrication system chart 195
- 6 engine lubrication system 196
- Specifications 196
- Engine lubrication system 7 7 197
- Special tools 197
- 8 engine lubrication system 198
- Engine oil and oil filter 198
- Warning 198
- Engine lubrication system 7 9 199
- Engine oil and oil filter 199
- Warning 199
- 10 engine lubrication system 200
- Engine oil and oil filter 200
- Oil screen feed installation 200
- Oil screen feed removal 200
- Oil screen scavenge cleaning 200
- Warning 200
- Engine lubrication system 7 11 201
- Engine oil and oil filter 201
- Warning 201
- 12 engine lubrication system 202
- Oil pressure relief valve 202
- Warning 202
- Engine lubrication system 7 13 203
- Oil pump 203
- 14 engine lubrication system 204
- Oil pump 204
- Engine lubrication system 7 15 205
- Oil pump 205
- Oil pump inspection 205
- 16 engine lubrication system 206
- Oil pressure 206
- Oil pump pressure oil temperature 90 c 4 000 rpm 206
- Warning 206
- Engine removal installation 207
- Engine removal installation 8 1 207
- Table of contents 207
- Engine removal installation 8 3 209
- Exploded view 209
- 4 engine removal installation 210
- Special tool 210
- Caution 211
- Engine removal 211
- Engine removal installation 211
- Engine removal installation 8 5 211
- Warning 211
- 6 engine removal installation 212
- Engine removal installation 212
- Engine removal installation 213
- Engine removal installation 8 7 213
- 8 engine removal installation 214
- Engine removal installation 214
- Warning 214
- Crankshaft transmission 215
- Crankshaft transmission 9 1 215
- Table of contents 215
- Crankshaft transmission 9 3 217
- Exploded view 217
- 4 crankshaft transmission 218
- Specifications 218
- Crankshaft transmission 9 5 219
- Special tools and sealant 219
- 6 crankshaft transmission 220
- Crankcase 220
- Crankcase 221
- Crankshaft transmission 9 7 221
- 8 crankshaft transmission 222
- Caution 222
- Crankcase 222
- Crankcase assembly 222
- Warning 222
- Crankcase 223
- Crankshaft transmission 9 9 223
- 10 crankshaft transmission 224
- Crankcase 224
- Crankcase 225
- Crankshaft transmission 9 11 225
- 12 crankshaft transmission 226
- Crankcase 226
- Crankcase 227
- Crankshaft transmission 9 13 227
- 14 crankshaft transmission 228
- Crankshaft 228
- Connecting rod big end radial clearance 229
- Connecting rod big end side clearance 229
- Crankshaft 229
- Crankshaft inspection 229
- Crankshaft transmission 9 15 229
- 16 crankshaft transmission 230
- Caution 230
- Connecting rod bend 230
- Crankshaft 230
- Connecting rod twist 231
- Crankshaft 231
- Crankshaft transmission 9 17 231
- 18 crankshaft transmission 232
- Transmission 232
- Crankshaft transmission 9 19 233
- Transmission 233
- 20 crankshaft transmission 234
- Shift fork bending 234
- Transmission 234
- Crankshaft transmission 9 21 235
- Gear damage 235
- Shift fork gear groove wear 235
- Shift fork guide pin shift drum groove wear 235
- Transmission 235
- 22 crankshaft transmission 236
- Balancer 236
- Balancer installation 236
- Balancer removal 236
- Bearings oil seals 237
- Crankshaft transmission 9 23 237
- 24 crankshaft transmission 238
- Bearings oil seals 238
- Table of contents 239
- Wheels tires 239
- Wheels tires 10 1 239
- Exploded view 241
- Wheels tires 10 3 241
- 4 wheels tires 242
- Specifications 242
- Special tools 243
- Wheels tires 10 5 243
- 6 wheels tires 244
- Caution 244
- Front wheel installation 244
- Front wheel removal 244
- Wheels rims 244
- Warning 245
- Wheels rims 245
- Wheels tires 10 7 245
- 8 wheels tires 246
- Wheels rims 246
- Warning 247
- Wheels rims 247
- Wheels tires 10 9 247
- 10 wheels tires 248
- Axle inspection 248
- Axle runout 100 mm 3 4 in 248
- Wheels rims 248
- Wheels tires 10 11 249
- 12 wheels tires 250
- Air pressure inspection adjustment 251
- Wheels tires 10 13 251
- 14 wheels tires 252
- Hub bearings 252
- Final drive 253
- Final drive 11 1 253
- Table of contents 253
- Exploded view 255
- Final drive 11 3 255
- 4 final drive 256
- Specifications 256
- Drive chain 257
- Drive chain installation 257
- Drive chain lubrication 257
- Drive chain removal 257
- Drive chain slack adjustment 257
- Drive chain slack inspection 257
- Drive chain wear inspection 257
- Final drive 11 5 257
- Warning 257
- Wheel alignment adjustment 257
- Wheel alignment inspection 257
- 6 final drive 258
- Drive chain 258
- Caution 259
- Engine sprocket installation 259
- Engine sprocket removal 259
- Final drive 11 7 259
- Rear sprocket removal 259
- Sprockets 259
- 8 final drive 260
- Rear sprocket installation 260
- Rear sprocket warp inspection 260
- Sprocket wear inspection 260
- Sprockets 260
- Brakes 261
- Brakes 12 1 261
- Table of contents 261
- Brakes 12 3 263
- Exploded view 263
- Brakes 12 5 265
- Exploded view 265
- 6 brakes 266
- Specifications 266
- Brakes 12 7 267
- Special tools 267
- 8 brakes 268
- Brake lever brake pedal 268
- Brake fluid 269
- Brakes 12 9 269
- Fluid change 269
- Fluid level inspection 269
- Warning 269
- 10 brakes 270
- Brake fluid 270
- Warning 270
- Brake fluid 271
- Brakes 12 11 271
- Warning 271
- 12 brakes 272
- Caliper 272
- Brakes 12 13 273
- Caliper 273
- Caliper disassembly 273
- Caliper holder shaft wear 273
- Dust seal and cover damage 273
- Fluid seal damage 273
- Piston cylinder damage 273
- Warning 273
- 14 brakes 274
- Caliper 274
- Warning 274
- Brakes 12 15 275
- Master cylinder 275
- 16 brakes 276
- Master cylinder 276
- Brakes 12 17 277
- Master cylinder 277
- Master cylinder inspection visual inspection 277
- 18 brakes 278
- Brake disk 278
- Runout 278
- Thickness 278
- Brake hose 279
- Brake hose inspection 279
- Brake hose removal installation 279
- Brakes 12 19 279
- Suspension 281
- Suspension 13 1 281
- Table of contents 281
- Exploded view 283
- Suspension 13 3 283
- Exploded view 285
- Suspension 13 5 285
- 6 suspension 286
- Specifications 286
- Special tools 287
- Suspension 13 7 287
- 8 suspension 288
- Front fork 288
- Rebound damping adjuster setting 288
- Compression damping adjuster setting 289
- Front fork 289
- Suspension 13 9 289
- 10 suspension 290
- Front fork 290
- Front fork 291
- Suspension 13 11 291
- 12 suspension 292
- Front fork 292
- Warning 292
- Caution 293
- Front fork 293
- Suspension 13 13 293
- 14 suspension 294
- Front fork 294
- Front fork 295
- Suspension 13 15 295
- 16 suspension 296
- Front fork 296
- Front fork 297
- Suspension 13 17 297
- 18 suspension 298
- Front fork 298
- Warning 298
- Front fork 299
- Suspension 13 19 299
- 20 suspension 300
- Adjuster assembly inspection 300
- Base valve assembly inspection 300
- Cylinder unit inspection 300
- Front fork 300
- Caution 301
- Dust seal oil seal inspection 301
- Fork spring free length 301
- Front fork 301
- Guide bush inspection 301
- Inner tube inspection 301
- Spring tension 301
- Suspension 13 21 301
- 22 suspension 302
- Rear shock absorber 302
- Rear suspension uni trak 302
- Rebound damping adjuster setting 302
- High speed compression damping 303
- Low speed compression damping 303
- Rear suspension uni trak 303
- Suspension 13 23 303
- 24 suspension 304
- Rear suspension uni trak 304
- Shock absorber spring free length 304
- Spring preload adjustment 304
- Spring tension 304
- Caution 305
- Rear shock absorber installation 305
- Rear shock absorber removal 305
- Rear suspension uni trak 305
- Spring replacement 305
- Suspension 13 25 305
- 26 suspension 306
- Rear shock absorber assembly 306
- Rear shock absorber disassembly oil change 306
- Rear shock absorber scrapping 306
- Rear suspension uni trak 306
- Warning 306
- Caution 307
- Suspension 13 27 307
- Swingarm 307
- Swingarm removal 307
- 28 suspension 308
- Swingarm 308
- Suspension 13 29 309
- Swingarm 309
- 30 suspension 310
- Caution 310
- Rocker arm removal 310
- Tie rod installation 310
- Tie rod removal 310
- Tie rod rocker arm 310
- Rocker arm installation 311
- Suspension 13 31 311
- Tie rod and rocker arm bearing removal 311
- Tie rod rocker arm 311
- 32 suspension 312
- Tie rod rocker arm 312
- Bolt runout 313
- Sleeve outside diameter 313
- Suspension 13 33 313
- Tie rod and rocker arm mounting bolt bend 313
- Tie rod and rocker arm sleeve wear 313
- Uni trak linkage inspection 313
- Uni trak maintenance 313
- Steering 315
- Steering 14 1 315
- Table of contents 315
- Exploded view 317
- Steering 14 3 317
- 4 steering 318
- Special tools 318
- Steering 319
- Steering 14 5 319
- Steering adjustment 319
- Steering inspection 319
- Steering stem stem bearing removal 319
- 6 steering 320
- Steering 320
- Steering 321
- Steering 14 7 321
- 8 steering 322
- Steering 322
- Warning 322
- Handlebar 323
- Handlebar installation 323
- Handlebar removal 323
- Steering 14 9 323
- 10 steering 324
- Handlebar 324
- Frame 15 1 325
- Table of contents 325
- Exploded view 327
- Frame 15 3 327
- 4 frame 328
- Engine guard installation 328
- Frame inspection 328
- Rear frame installation 328
- Rear frame removal 328
- Frame 15 5 329
- Seat installation 329
- Seat removal 329
- 6 frame 330
- Side cover 330
- Side cover installation 330
- Side cover removal 330
- Fender 331
- Frame 15 7 331
- Front fender removal 331
- Rear fender removal 331
- Rear flap removal 331
- Electrical system 333
- Electrical system 16 1 333
- Table of contents 333
- Electrical system 16 3 335
- Exploded view 335
- 4 electrical system 336
- Specifications 336
- Electrical system 16 5 337
- Special tools and sealant 337
- Electrical system 16 7 339
- Precautions 339
- Warning 339
- 8 electrical system 340
- Electrical wiring 340
- Electrical system 16 9 341
- Flywheel magneto 341
- Flywheel removal 341
- Magneto cover installation 341
- Magneto cover removal 341
- 10 electrical system 342
- Flywheel magneto 342
- Electrical system 16 11 343
- Flywheel magneto 343
- 12 electrical system 344
- Flywheel magneto 344
- Table 1 magneto output voltage 344
- Table 2 stator coil resistance 344
- Electrical system 16 13 345
- Ignition timing 345
- 14 electrical system 346
- Ignition coil removal 346
- Ignition system 346
- Safety instructions 346
- Warning 346
- Electrical system 16 15 347
- Ignition coil winding resistance 347
- Ignition system 347
- Needle arcing distance 347
- Warning 347
- 16 electrical system 348
- C d i unit inspection 348
- C d i unit removal 348
- Caution 348
- Ignition system 348
- Spark plug gap inspection 348
- Electrical system 16 17 349
- Ignition system 349
- Warning 349
- Electrical system 16 19 351
- Ignition system 351
- Warning 351
- 20 electrical system 352
- Ignition system 352
- Throttle sensor input voltage 352
- Electrical system 16 21 353
- Ignition system 353
- Throttle sensor output voltage 353
- 22 electrical system 354
- Throttle sensor 354
- Throttle sensor input voltage 354
- Throttle sensor output voltage 354
- Electrical system 16 23 355
- Throttle sensor 355
- Throttle sensor position adjustment 355
- 24 electrical system 356
- Gear position switch removal 356
- Switch inspection 356
- Switches 356
- Electrical system 16 25 357
- Gear position switch resistance 357
- Switches 357
- Appendix 359
- Appendix 17 1 359
- Table of contents 359
- 2 appendix 360
- Cable wire and hose routing 360
- Appendix 17 3 361
- Cable wire and hose routing 361
- 4 appendix 362
- Cable wire and hose routing 362
- Appendix 17 5 363
- Cable wire and hose routing 363
- 6 appendix 364
- Cable wire and hose routing 364
- Appendix 17 7 365
- Engine doesn t start starting difficulty 365
- Poor running at low speed 365
- Troubleshooting guide 365
- 8 appendix 366
- Clutch operation faulty 366
- Engine overheating 366
- Poor running or no power at high speed 366
- Troubleshooting guide 366
- Abnormal drive train noise 367
- Abnormal engine noise 367
- Abnormal frame noise 367
- Appendix 17 9 367
- Gear shifting faulty 367
- Troubleshooting guide 367
- 10 appendix 368
- Abnormal exhaust color 368
- Brake doesn t hold 368
- Handling and or stability unsatisfactory 368
- Troubleshooting guide 368
- Model application 369
- Part no 9924 1355 01 369
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