![Kawasaki KX450F (2006) [6/369] List of abbreviations](/img/pdf.png)
Kawasaki KX450F (2006) [6/369] List of abbreviations
![Kawasaki KX450F (2006) [6/369] List of abbreviations](/views2/1121205/page6/bg6.png)
LIST OF ABBREVIATIONS
A
ampere(s)
lb
pound(s)
ABDC after bottom dead center
m
meter(s)
AC
alternating current min
minute(s)
ATDC after top dead center
N
newton(s)
BBDC before bottom dead center
Pa
pascal(s)
BDC
bottom dead center
PS
horsepower
BTDC before top dead center
psi
pound(s) per square inch
°C degree(s) Celsius
r revolution
DC
direct current
r/min, rpm revolution(s) per minute
F
farad(s) TDC
top dead center
°F degree(s) Fahrenheit
TIR total indicator reading
ft foot, feet
V
volt(s)
g
gram(s) (mass)
W
watt(s)
h
hour(s) Ω ohm(s)
kg
(mass)
kgf (force)
L
liter(s)
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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