Kawasaki KDX200 (1989-1994) [64/174] Right engine cover installation notes

Содержание

• Kawasaki kdx200 1
• Read owner s manual before operating 2
• Foreword 3
• Othis note symbol indicates points of partic 4
• Ular interest for more efficient and con 4
• Venient operation 4
• Appendix 5
• Electrical system 5
• Engine bottom end transmission 5
• Engine removal lnstallation 5
• Engine right side 5
• Engine top end 5
• Quick reference guide 5
• Steering 5
• General information 6
• Table of contents 6
• 2 general information 7
• Before servicing 7
• Especially note the following 7
• 7 yellow 8
• General information 1 3 8
• Wire strands 8
• General information 1 7 12
• Good running condition 12
• Periodic maintenance chart 12
• The maintenance must be done in accordance with this chart to keep the motorcycle in 12
• Fuel system 18
• Table of contents 18
• 6 fuel system 23
• Ooperation with an improperly adjusted incorrectly 23
• Routed or damaged cable could result in an un safe riding condition 23
• Throttle cable adjustment 23
• Throttle grip and cable 23
• Throttle grip free play 23
• Throttle grip free play inspection 23
• Cable inspection 24
• Cable lubrication 24
• Fuel system 2 7 24
• Improperly adjusted cable could result in an unsafe riding condition 24
• Operation with an incorrectly routed or 24
• Throttle cable inspection 24
• Throttle cable installation notes 24
• Throttle cable lubrication 24
• 8 fuel system 25
• Carburetor 25
• Gasoline is extremely flammable and can be ex 25
• Idle speed adjustment 25
• Idle speed inspection 25
• Operation with an improperly adjusted incorrectly 25
• Plosive under certain conditions always stop the engine and do not smoke make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light 25
• Routed or damaged cable could result in an un safe riding condition 25
• Service fuel level inspection 25
• Below the bottom edge of the carb body 1 1 mm 26
• Float height 26
• Float height measurement 26
• Fuel system 2 9 26
• Ogasoline is extremely flammable and can be ex 26
• Plosive under certain conditions always stop the engine and do not smoke make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light 26
• Service fuel level 26
• Service fuel level adjustment 26
• Carburetor removal 27
• Cautjo 27
• Fuel system clean 27
• And make sure they do not get pinched by the chain or shock absorber 28
• Carburetor disassembly 28
• Carburetor installation notes 28
• Fuel spilled from the carburetor is hazardous 28
• Fuel system 2 11 28
• Oalways keep the tubes free of obstruction 28
• 12 fuel system 29
• And take care that there is no spark or flame anywhere near the working area this includes any appliance with a pilot light because of the danger of highly flammable liquids do not use gasoline or low flash point solvent to clean the carburetor 30
• Carburetor as possible before cleaning the car buretor with a cleaning solution this will prevent damage or deterioration of the parts 30
• Carburetor assembly notes 30
• Carburetor cleaning 30
• Carburetor inspection 30
• Carburetor the float may be deformed by the pressure 30
• Fuel system 2 13 30
• Ociean the carburetor in a well ventilated area 30
• Odo not use a strong carburetor cleaning solution 30
• Odo not use compressed air on an assembled 30
• Odo not use wire or any other hard instrument 30
• Ogasoline is extremely flammable and can be ex 30
• Oremove as many rubber or plastic parts from the 30
• Plosive under certain conditions always stop the engine and do not smoke make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light 30
• To clean carburetor parts especially jets as they may be damaged 30
• Which could attack the plastic parts instead use a mild high flash point cleaning solution safe for plastic parts 30
• 14 fuel system 31
• Air cleaner 31
• Air cleaner element removal 31
• Air cleaner housing installation notes 31
• Air cleaner housing removal 31
• Float valve needle wear 31
• Loosen the air cleaner duct clamp remove the following parts 31
• N m 2 kg m 19 ft lb 31
• Remove the air cleaner housing 31
• Seat air cleaner housing cap side covers coolant reserve tank rear fender rear flap rear frame pipe 31
• Tightening torque 31
• Air cleaner element cleaning and inspection 32
• Air cleaner element installation notes 32
• Because of the danger of highly flammable liquids 32
• Clean the element in a well ventilated area and 32
• Do not use gasoline or a low flash point solvent to clean the element 32
• Fuel system 2 15 32
• Take care that there are no sparks or flame any where near the working area this includes any appliance with a pilot light 32
• 16 fuel system 33
• Fuel tank 33
• Fuel tank installation notes 33
• Fuel tank removal 33
• Fuel tap inspection 33
• Fuel tap installation notes 33
• Fuel tap removal 33
• Ogasoline is extremely flammable and can be ex 33
• Plosive under certain conditions always stop the engine and do not smoke make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light 33
• Care that there is no sparks or flame anywhere near the working area because of the danger of highly flammable liquids do not use gasoline or low flash point solvent to clean the tank 34
• Fuel system 2 17 34
• Fuel tank and tap cleaning 34
• Fuel tank cap inspection 34
• Fuel tap 34
• Ociean the tank in a well ventilated area and take 34
• 18 fuel system 35
• Reed valve 35
• Reed valve inspection 35
• Reed valve installation 35
• Reed valve removal 35
• Reed warp 35
• Service limit 0 mm 35
• Cooling system 36
• Table of contents 36
• 4 cooling system 39
• Cause an accident and injury immediately wipe up or wash away any coolant that spills on the frame engine or other painted parts 39
• Coolant 39
• Coolant change 39
• Coolant deterioration 39
• Coolant draining 39
• Coolant inspection 39
• Coolant level 39
• Not use for drinking 39
• Ocoolant on tires will make them slippery and can 39
• Or try to inspect the coolant level or change the coolant when the engine is still hot wait until it cools down 39
• Osince coolant is harmful to the human body do 39
• T0 avoid burns do not remove the radiator cap 39
• 18 psi 41
• 6 cooling system 41
• Air bleeding 41
• Cooling system pressure testing 41
• Oduring pressure testing do not exceed the pres 41
• Radiator filler neck 41
• Sure for which the system is designed to work the maximum pressure is 125 kpa 1 5kg c 41
• Cautio 42
• Cooling system flushing 42
• Water pump cover removal 42
• 8 cooling system 43
• Impeller inspection 43
• Impeller installation 43
• Impeller removal 43
• N m 0 kg m 61 in lb 43
• Obe sure to pull out the shaft toward the inside of 43
• The cover to prevent the oil seal lips from peeling 43
• Tightening torque 43
• Water pump cover installation notes 43
• Water pump shaft installation notes 43
• Water pump shaft removal 43
• All of them with new ones at the same time 44
• Cooling system 3 9 44
• O f the oil seal or ball bearing is removed replace 44
• O jse a bearing driver larger in diameter than the 44
• Obe sure to apply a molybednum disulfide grease 44
• Oil seal and press the oil seal into the hole until the edge of the oil seal is flush with the step for the bail bearing 44
• Oil seal installation 44
• To the water pump shaft when installing if it is in stalled dry the seals may wear excessively 44
• 10 cooling system 45
• Be careful of the following to avoid damage to the fins 45
• D0 not tear the radiator tubes while straighten 45
• From the radiator 45
• Ing the fins 45
• Keep the air nozzle over 0 m 20 in away 45
• Oblow air perpendicularly to the radiator core onever blow air at an angle against the fins but 45
• Onever shake the air nozzle at a right angle against 45
• Owhen cleaning the radiator with compressed air 45
• Radiator 45
• Radiator cap inspection 45
• Radiator cleaning 45
• Radiator inspection 45
• Radiator installation 45
• Radiator removal 45
• Straight through them in the direction of natural air flow 45
• The fins be sure to move it at a level with the fins 45
• 125kpa 0 5 1 5 kg c 46
• 14 18 psi 46
• Cooling hoses breather hose 46
• Cooling hoses breather hose inspection 46
• Cooling system 3 11 46
• Filler neck inspection 46
• Installation notes 46
• Radiator cap relief pressure 46
• Engine top end 47
• Table of contents 47
• 119 185 psi 51
• 1280kpa 8 13 kg c 51
• Cylinder compression measurement 51
• Cylinder compression usable range 51
• Cylinder head 51
• Cylinder head installation notes 51
• Cylinder head removal 51
• Engine top end 4 5 51
• 6 engine top end 52
• Cylinder head warp 52
• Cylinder head warp inspection 52
• Exhaust valve kips 52
• Exhaust valve removal 52
• Left hand threads 52
• N m 2 kg m 18 ft lb 52
• N m 2 kg m 20 ft lb 52
• N m 3 kg m 22 ft lb 52
• Oexhaust valve operating shaft lever nut has 52
• Service limit 0 3 mm 52
• Tightening torque 52
• Engine top end 4 7 53
• Exhaust valve installation notes 53
• 8 engine top end 54
• Exhaust valve operating rod installation 54
• Cylinder installation notes 55
• Cylinder piston 55
• Cylinder removal 55
• Engine top end 4 9 55
• Left hand threads 55
• N m 0 5 kg m 74 in lb 55
• N m 2 kg m 18 ft lb 55
• Oexhaust valve operating shaft lever nut has 55
• Piston removal 55
• Tightening torque 55
• 10 engine top end 56
• And deforms them they could fall out and score the cylinder wall 56
• Carbon particles can be very abrasive to piston 56
• Do not reuse snap rings as removal weakens 56
• Piston installation notes 56
• Piston ring position 56
• Rings don t allow such particles to fall onto the cylinder walls 56
• Any two measurements 57
• Cylinder inside diameter 57
• Cylinder inside diameter measurement 57
• Cylinder wear inspection 57
• Difference between any two 57
• Engine top end 4 11 57
• Measurements 57
• Piston diameter 57
• Piston diameter measurement 57
• Service limit 65 9 mm 57
• Service limit 66 0mm or more than 0 5mm 57
• Standard 65 39 65 54 mm 57
• Standard 66 16 66 31mm and less than 0 1mm difference between 57
• 0 92 mm 58
• 12 engine top end 58
• Piston cylinder clearance 58
• Piston ring end gap 58
• Piston ring end gap inspection 58
• Piston ring groove clearance 58
• Piston ring groove width second ring 58
• Piston ring piston ring groove inspection 58
• Piston ring thickness second ring 58
• Ring end gap measurement 58
• Service limit 0 0 mm 58
• Service limit 1 0 mm 58
• Service limit 1 mm 58
• Standard 0 25 0 65 mm service limit 0 8 mm 58
• Standard 0 5 0 5 mm 58
• Standard 1 15 1 35 mm 58
• Standard 1 7 1 9 mm 58
• Connecting rod wear inspection 59
• Engine top end 4 13 59
• Expansion chamber removal 59
• Muffler expansion chamber spark arrester 59
• Piston pin diameter 59
• Piston pin hole diameter 59
• Piston piston pin 59
• Service limit 15 6 mm 59
• Service limit 16 7 mm 59
• Service limit 21 5 mm 59
• Small end inside diameter 59
• Standard 15 95 16 00 mm 59
• Standard 16 00 16 06 mm 59
• Standard 21 03 21 14 mm 59
• 14 engine top end 60
• Before cleaning the spark arrester the exhaust sys tem becomes very hot soon after the engine is stared 60
• Expansion chamber installation notes 60
• Functioning properly to provide adequate fire pro tection 60
• Spark arrester cleaning 60
• Spark arrseter 60
• T0 avoid bums be sure the exhaust system is cold 60
• The spark arrester must be installed correctly and 60
• Engine right side 61
• Table of contents 61
• 4 engine right side 64
• Fall out when installing the right engine cover 64
• Left hand threads 64
• O f the gear drive pin is not positioned level it may 64
• Oexhaust valve operating shaft lever nut has 64
• Right engine cover 64
• Right engine cover installation notes 64
• Right engine cover removal 64
• Do not remove the clutch release shaft unless it 65
• Engine right side 5 5 65
• Exhaust valve operating shaft lever nut has 65
• Is absolutely necessary if removed you must replace the oil seal with a new one 65
• Left hand threads 65
• N m 0 5 kg m 74 in lb 65
• N m 0 kg m 61 in lb 65
• Right engine cover disassembly 65
• Tightening torgue 65
• Tightening torque 65
• 6 engine right side 66
• Disassembly assembly notes 66
• Exhaust advancer assembly 66
• N m 0 kg m 35 in lb 66
• Right engine cover assembly notes 66
• Tightening torque 66
• Clutch 67
• Clutch adjustment 67
• Engine or exhaust chamber during clutch adjust ment 67
• Engine right side 5 7 67
• To avoid a serious burn never touch the hot 67
• Warning i 67
• 8 engine right side 68
• Clutch removal disassembly 68
• 1 4 mm 1 0 mm 69
• Apply transmission oil to the surfaces of each plate to avoide clutch plate seizure 69
• Clutch installation notes 69
• Clutch plate thickness 69
• Engine right side 5 9 69
• Friction and clutch plate wear damage inspection 69
• Friction plate thickness 69
• N m 0 5kg m 82 in lb 69
• N m 8 kg m 58 ft lb 69
• O f dry clutch plates and friction plates are installed 69
• Service limit 2 mm 69
• Standard 2 2 3 8 mm 69
• Standard service limit 69
• Tightening torque 69
• 10 engine right side 70
• Clutch hub spline inspection 70
• Clutch spring free length 70
• Clutch spring free length measurement 70
• Friction and clutch plate thickness measurement 70
• Friction and clutch plate warp 70
• Friction and clutch plate warp inspection 70
• Friction and clutch plate warp measurement 70
• Friction plate clutch housing clearance 70
• Service limit 0 mm 70
• Service limit 37 mm 70
• Standard 0 0 0 0 mm 70
• Standard 39 mm 70
• Standard not more than 0 5 mm 70
• Engine right side 5 11 71
• External shift mechanism 71
• External shift mechanism inspection 71
• External shift mechanism installation notes 71
• External shift mechanism removal 71
• N m 2 kg m 14 ft lb 71
• Tightening torque 71
• 12 engine right side 72
• Kick shaft assembly removal 72
• N m 8 kg m 58 ft lb 72
• Primary gear installation notes 72
• Primary gear kickstarter 72
• Primary gear removal 72
• Tightening torque 72
• Caution 73
• Disassembly assembly notes 73
• Engine right side 5 13 73
• Kick shaft assembly installation notes 73
• Kick starter idle gear installation notes 73
• Kickstarter assembly 73
• Kickstarter idle gear removal notes 73
• Owhen assembling the ratchet gear onto the kick 73
• Shaft align the punch mark on the ratchet gear with the punch mark on the kick shaft 73
• Engine removal lnstallation 74
• Table of contents 74
• Engine bracket mounting nuts 76
• Engine installation notes 76
• Engine mounting nuts 76
• Engine removal 76
• Engine removal installation 6 3 76
• Engine removal lnstallation 76
• Mounting bolt take precautions to insure the frame is well supported and that the motorcycle will not fall over when the pivot shaft is removed 76
• N m 3 kg m 22 ft lb 76
• N m 8 kg m 58 ft lb 76
• Othe swing arm pivot shaft also serves as the engine 76
• Pivot shaft nut 76
• Tightening torque 76
• Warning 76
• Engine bottom end transmission 77
• Table of contents 77
• Amount 0 5 l 81
• Engine bottom end transmission 7 5 81
• Grade se class 81
• N m 2 kg m 14 ft lb 81
• Oil change 81
• Oil level inspection 81
• Omotorcycle operation with insufficient deteri orated or contaminated transmission oil will cause accelerated wear and may result in trans mission seizure accident and injury 81
• Tightening torque 81
• Transmission oil 81
• Viscosity sae 10w30 or 10w40 81
• 6 engine bottom end transmission 82
• Crankcase assembly 82
• Crankcase splitting 82
• Engine bottom end transmission 7 7 83
• 8 engine bottom end transmission 84
• Crankshaft connecting rod 84
• Crankshaft disassembly note 84
• Crankshaft installation notes 84
• Crankshaft removal 84
• 0 43 mm 85
• Big end seizure 85
• Connecting rod big end radial clearance 85
• Connecting rod big end side clearance 85
• Crankshaft assembly notes 85
• Crankshaft runout 85
• Engine bottom end transmission 7 9 85
• Service limit 85
• Service limit 0 0 mm 85
• Service limit 0 5 mm 85
• Side clearance 85
• Standard 85
• Standard 0 0 0 0 mm 85
• Standard not more than 0 3mm 85
• 10 engine bottom end transmission 86
• Cautîon 86
• Crankshaft alignment 86
• Crankshaft runout 86
• Horizontal misalignment 86
• Odon t hammer the flywheel at point a 86
• Vertical misalignment 86
• Circlip and toothed washer installation 87
• Drive shaft gears 87
• Engine bottom end transmission 7 11 87
• Transmission 87
• Transmission shaft assembly notes 87
• Transmission shaft disassembly notes 87
• Transmission shaft installation notes 87
• Transmission shaft removal 87
• 12 engine bottom end transmission 88
• N m 2 kg m 17 ft lb 88
• Output shaft gears 88
• Shift drum and fork installation notes 88
• Shift fork identification 88
• Tightening torque 88
• 14 engine bottom end transmission 90
• Ball bearing needle bearing wear 90
• Gear damage 90
• Gear dog gear dog hole damage 90
• Table of contents 91
• Wheels tires 91
• Brake lever is obtained by pumping the brake lever until the pads are against the disc the brake will not function on the first application of the lever if this is not done 95
• D0 not lay the wheel on the ground with the disc 95
• Facing down this can damage or warp the disc place blocks under the wheel so the disc does not touch the ground 95
• Front wheel installation notes 95
• Front wheel removal 95
• N m 9 kg m 65 ft fo 95
• Odo not attempt to drive the motorcycle until a full 95
• Tightening torque 95
• Wheels 95
• Wheels tires 8 5 95
• 6 wheels tire 96
• Brake pedal is obtained by pumping the brake pedal until the pads are against the disc the brake will not function on the first application of the pedal if this is not done 96
• Do not attempt to drive the motorcycle until a full 96
• Do not lay the wheel on the ground with the disc 96
• Facing down this can damage or warp the disc place blocks under the wheel so the disc does not touch the ground 96
• N m 10 kg m 72 ft lb 96
• N m 2 kg m 18 ft lb 96
• Rear wheel installation notes 96
• Rear wheel removal 96
• Tightening torque 96
• Wheel alignment inspection 96
• Ately a missing spoke places an additional load on the other spokes which will eventually cause other spokes to break 97
• Axle inspection 97
• Axle runout 100 mm 97
• N m 0 5 kg m 13 in lb 97
• Not over 3n m 0 kg m 26 in lb 97
• O f any spoke breaks it should be replaced immedi 97
• Repair limit 97
• Rim inspection 97
• Rim runout with tire installed 97
• Service limit 97
• Spoke inspection 97
• Standard 97
• Tightening torque 97
• Under 0 0 mm 97
• Wheel alignment adjustment 97
• Wheel inspection 97
• Wheels tires 8 7 97
• 8 wheels tires 98
• Caution 98
• Do not lay the wheel on the ground with the disc 98
• Facing down this can damage or warp the disc place blocks under the wheel so the disc does not touch the ground 98
• Never lubricate with mineral oil engine oil or gasoline because they win cause deterioration of the tire 98
• Tire removal 98
• 10 wheels tire 100
• Bearing removal 100
• Do not lay the wheel on the ground with the disc 100
• Facing down this can damage or warp the disc place blocks under the wheel so the disc does not touch the ground 100
• Front hub bearing 100
• Hub bearing 100
• Hub bearing installation notes 100
• Hub bearing removal notes 100
• Rear hub bearing 100
• Grease seal inspection and lubrication 101
• Hub bearing inspection and lubrication 101
• Meter gear housing 101
• Meter gear housing assembly notes 101
• Meter gear housing disassembly 101
• Wheels tire 8 11 101
• 12 wheels tires 102
• Meter gear housing lubrication 102
• Meter gear housing pin removal meter gear housing lubrication 102
• Final drive 103
• Table of contents 103
• Bearing driver set 57001 1129 105
• 4 final drive 106
• Drive chain 106
• Drive chain slack 106
• Drive chain slack adjustment 106
• Drive chain slack inspection 106
• N m 10 kg m 72 ft lb 106
• O f the axle nut is not securely tightened an un 106
• Safe riding condition may result 106
• Standard 50 60 mm 106
• Tightening torque 106
• Wheel alignment inspection 106
• 6 final drive 108
• Cautio 108
• Do not lay the wheel on the ground with the disc 108
• Drive chain installation notes 108
• Drive chain lubrication 108
• Drive chain removal 108
• Engine sprocket installation notes 108
• Engine sprocket removal 108
• Facing down this can damage or warp the disc place blocks under the wheel so that the disc does not touch the ground 108
• N m 2 kg m 19 ft lb 108
• Rear sprocket installation notes 108
• Rear sprocket removal 108
• Sprocket 108
• Tightening torque 108
• 3 227 3 mm 109
• 55 9 mm 109
• Engine 109
• Final drive 9 7 109
• Rear sprocket warp 109
• Service limit 109
• Service limit 0 mm 109
• Sprocket diameter 109
• Sprocket warp inspection 109
• Sprocket wear inspection 109
• Standard 109
• Standard under 0 mm 109
• Brakes 110
• Table of contents 110
• Circlip pliers 57001 143 113
• Air must be bled from the brake 114
• Brake adjustment 114
• Brake lever pedal free play adjustment 114
• Brakes 10 5 114
• Disc brakes 114
• Front brake lever play adjustment 114
• Owhen working with the disc brake observe the 114
• Precautions listed below 114
• Rear brake pedal position adjustment 114
• 6 brakes 115
• Caliper 115
• Caliper disassembly 115
• Caliper installation notes 115
• Caliper removal 115
• N m 2 kg m 18 ft lb 115
• Palm inside the caliper opening if you apply com pressed air into the caliper the piston may crush your hand or fingers 115
• Rear brake pedal play adjustment 115
• Tightening torque 115
• To avoid serious injury never place your fingers or 115
• Brakes 10 7 116
• Caliper assembly notes 116
• Caliper holder shaft wear 116
• Fluid seal damage 116
• Piston and cylinder damage 116
• Seal and cover damage 116
• Caution 117
• Do not attempt to drive the motorcycle until a 117
• Faces any spilled fluid should be completely wiped up immediately 117
• Front master cylinder removal 117
• Full brake lever or pedal is obtained by pumping the brake lever or pedal until the pads are against the disc the brake will not function on the first application of the lever or pedal if this is not done 117
• Lining thickness measurement 117
• Obrake fluid quickly ruins painted or plated sur 117
• Pad inspection 117
• Pad installation 117
• Pad lining thickness mm 117
• Pad removal 117
• Brakes 10 9 118
• Tightening torque 118
• 10 brakes 119
• Front master cylinder 119
• Front master cylinder disassembly 119
• N m 2 kg m 18 ft lb 119
• Odo not remove the secondary cup from the piston 119
• Rear master cylinder 119
• Rear master cylinder disassembly 119
• Rear master cylinder installation notes 119
• Since removal will damage it 119
• Tightening torque 119
• Brakes 10 11 120
• Front and rear master cylinder 120
• Master cylinder assembly notes 120
• Master cylinder inspection 120
• Visual inspection 120
• Brake fluid change 122
• Brake fluid level inspection 122
• Brakes 10 13 122
• Changing brake fluid 122
• D0 not mix two brands of fluid change the brake 122
• Fluid in the brake line completely if the brake fluid must be refilled but the type and brand of the brake fluid that is already in the reservoir are unknown 122
• Front brake fluid reservoir 122
• Rear brake fluid reservoir 122
• 14 brakes 123
• Bleeding the brake line 123
• Filling up the brake line 123
• N m 0 kg m 69 in4b 123
• Tightening torque 123
• Any spilled fluid should be completely wiped up immediately 124
• Brake fluid quickly ruins painted or plated surfaces 124
• Brake hose 124
• Brake hose inspection 124
• Brake hose removal lnstallation notes 124
• Brakes 10 15 124
• N m 2 kg m 18 ft lb 124
• Tightening torque 124
• Suspension 125
• Table of contents 125
• Air pressure 129
• Compression damping adjustment 129
• Front fork 129
• Front fork adjustment 129
• Othe left and right foric legs must have the same 129
• Shock damping 129
• Suspension 11 5 129
• 170 mm 130
• 6 suspension 130
• Adjustable range 130
• Fork spring 130
• Kayaba gio or sae10w 130
• Oil level adjustment 130
• Othe top bolts are under extreme spring pressure 130
• Recommended oil 130
• Standard oil level 130
• Usa care when removing the top bolts wear eye and face protection 130
• Fork oil change 131
• Front fork oil capacity 131
• Kay aba g10 or sae 10w 131
• Recmmended oil 131
• Suspension 11 7 131
• 8 suspension 132
• Fork oil level measurment 132
• Front fork installation notes 132
• Front fork oil level standard 132
• Front fork removal 132
• N m 2 kg m 14 ft lb 132
• N m 2 kg m 18 ft lb 132
• N m 9 kg m 65 ft lb 132
• Tightening torque 132
• Allen bolt installation removal 133
• Front fork disassembly 133
• Suspension 11 9 133
• 10 suspension 134
• Front fork assembly notes 134
• Front fork separation 134
• Guide bush installation 135
• Inner tube inspection 135
• N m 7 kg m 52 ft lb 135
• Suspension 11 11 135
• Tightening torque 135
• 12 suspension 136
• Excessive bending followed by subsequent 136
• Fork spring free length 136
• Guide bush inspection 136
• O f the inner tube is badly bent or creased replace it 136
• Oil seal and outer tube seal inspection 136
• Service limit 486 mm 136
• Spring tension 136
• Standard 496 mm 136
• Straightening can weaken the inner tube 136
• Compression damping adjustment 137
• Gas reservoir 137
• Rear shock absorber 137
• Rear suspension uni trak 137
• Rebound damping adjustment 137
• Suspension 11 13 137
• 14 suspension 138
• Gas pressure adjustment adjustable range 138
• Ouse only nitrogen gas do not incinerate the gas reservoir 138
• Spring preload adjustment 138
• To adjust the gas pressure 138
• Cautioft 139
• N m 4 kg m 29 ft lb 139
• N m 8 kg m 60 ft lb 139
• Owhen pulling out the mounting bolts lift the rear 139
• Rear shock absorber bolt upper and lower 139
• Rear shock absorber installation notes 139
• Rear shock absorber removal 139
• Rear shock absorber spring replacement 139
• Suspension 11 15 139
• Tightening torque 139
• Uni trak tie rod nut 139
• Wheel slightly forcing or tapping on a bolt could damage the bolt sleeve and bearing 139
• 16 suspension 140
• Oalways release nitrogen gas pressure before ex 140
• Obe sure to point the reservior valve away from you 140
• Plosive separation of parts 140
• Rear shock absorber disassembly oil change 140
• When releasing nitrogen gas pressure an oil mist is often released with the nitrogen 140
• Rear shock absorber assembly notes 141
• Suspension 11 17 141
• O f the circlip is not a certain fit in the groove in 143
• Suspension 11 19 143
• The rear shock body the push rod assembly may come out of the shock absorber when injecting the nitrogen gas or riding the motorcycle 143
• 20 suspension 144
• Do not use air or other gases since they may cause premature wear rust fire hazard or sub standard performance 144
• Gas do not incinerate or disassemble the rear shock absorber 144
• Mechanic perform this procedure 144
• N m 8 kg m 58 ft lb 144
• N m 8 kg m 60 ft lb 144
• Obefore a rear shock absorber is scrapped replease 144
• Ohigh pressure gas is dangerous have a qualified 144
• Opressurize the gas reservoir with nitrogen gas only 144
• Osince the rear shock absorber contains nitrogen 144
• Pivot shaft nut 144
• Scrapping 144
• Swing arm 144
• Swing arm installation notes 144
• Swing arm removal 144
• The nitrogen gas completely do not point the valve to your face or body then 144
• Tie rod rear mounting nut 144
• Tie rod removal 144
• Tie rod rocker arm 144
• Tightening torque 144
• N m 8 kg m 60 ft lb 145
• Rocker arm installation notes 145
• Rocker arm nut 145
• Rocker arm removal 145
• Suspension 11 21 145
• Tie rod installation notes 145
• Tie rod nut 145
• Tightening torque 145
• 22 suspension 146
• Bolt runout 146
• Mounting bolt bend 146
• Rocker arm 146
• Service limit 146
• Service limit 21 5 mm 146
• Sleeve 146
• Sleeve outside diameter 146
• Standard 146
• Standard 21 87 22 00 mm 146
• Under 0 mm 146
• Uni trak maintenancce 146
• Steering 147
• Table of contents 147
• 4 steering 150
• N m 2 kg m 14 ft lb 150
• N m 4 kg m 33 ft lb 150
• Steering adjustment 150
• Steering inspection 150
• Tightening torque 150
• N m 2 kg m 18 ft lb 151
• Steering 12 5 151
• Steering removal lnstallation 151
• Steering stem removal 151
• Tightening torque 151
• 6 steering 152
• N m 0 kg m 35 in lb 152
• N m 4 kg m 33 ft lb 152
• Outer race installation 152
• Steering stem installation notes 152
• Steering stem race installation notes 152
• Steering stem race removal 152
• Tightening torque 152
• Bearing wear damage 153
• Steering 12 7 153
• Steering maintenance 153
• Steering stem bearing lubrication 153
• Steering stem warp 153
• Electrical system 154
• Table of contents 154
• 6 electrical system 159
• Female connectors 159
• Male connectors 159
• Precautions electrical wiring 159
• Wiring inspection 159
• Electrical system 13 7 160
• Flywheel magneto removal 160
• Ignition timing adjustment 160
• Ignition timing flywheel magneto 160
• Onever strike the grab bar or the flywheel itself 160
• Striking the bar can bend it if the flywheel is 160
• Struck the magnets may lose their magnetism 160
• 8 electrical system 161
• Flywheel magneto inspection 161
• Flywheel magneto installation 161
• N m 6 kg m 47 ft lb 161
• Tightening torque 161
• Do not touch the spark plugs high tension coils or spark plug leads while the engine is running or you could receive a severe electrical shock 162
• Electrical system 13 9 162
• Ignition coil arcing distance 162
• Ignition coil inspection 162
• Ignition coil installation 162
• Ignition coil removal 162
• Ignition coil test 162
• Ignition coil winding resistance 162
• Ignition system 162
• Mm or more 162
• Othe ignition system produces extremely high voltage 162
• Primary windings 1 q 15 162
• Safety instructions 162
• Secondary windings 5 kfi 15 162
• To avoid extremely high voltage shocks do not 162
• Touch the coil or lead 162
• 10 electrical system 163
• Capacity battery or the cdi unit will be damaged 163
• Cdi unit inspection 163
• Ignition coil winding resistance spark plug gap 163
• Odo not use a megger or a meter with a large 163
• Spark plug cleaning and inspection 163
• Spark plug gap 163
• Spark plug gap inspection 163
• This test a tester other than the kawasaki hand tester may show different readings 163
• Use only kawasaki hand tester 57001 983 for 163
• Cdi unit test using the kawasaki hand tester 164
• Electrical system 13 11 164
• Stator coil inspection 164
• Stator coil resistance 164
• 12 electrical system 165
• Headlight beam vertical adjustment 165
• Headlight bulb replacement notes 165
• Headlight unit removal lnstallation note 165
• Lighting system 165
• Taillight bulb replacement note 165
• Touch the glass portion with bare hands always use a clean cloth oil contamination from hands or dirty rags can reduce bulb life or cause the bulb to explode 165
• When handling the quartz halogen bulbs never 165
• Electrical system 13 13 166
• Removal lnstallation note 166
• Taillight lens 166
• Appendix 167
• Table of contents 167
• 2 appendix 168
• Compression low 168
• Engine doesn t start starting difficulty 168
• Engine flooded 168
• Engine won t turn over 168
• Firing incorrect 168
• Fuel air mixture incorrect 168
• Kips ports stuck open 168
• No fuel flow 168
• No spark spark weak 168
• Poor running at low speed 168
• Poor running or no power at high speed 168
• Spark weak 168
• Troubleshooting guide 168
• Appendix 14 3 169
• Clutch not disengaging property 169
• Clutch operation faulty 169
• Clutch slipping 169
• Compression high 169
• Compression low 169
• Coolant incorrect 169
• Cooling system component incorrect 169
• Doesn t go into gear shift pedal does t return 169
• Engine load faulty 169
• Engine rpm will not rise property 169
• Firing incorrect 169
• Fuel air mixture incorrect 169
• Gear shifting faulty 169
• Kips ports stuck closed 169
• Knocking 169
• Lubrication inadequate 169
• Overheating 169
• 4 appendix 170
• Abnormal drive train noise 170
• Abnormal engine noise 170
• Abnormal frame noise 170
• Brownish smoke 170
• Clutch noise 170
• Disc brake noise 170
• Drive chain noise 170
• Excessive white smoke 170
• Exhaust smoke 170
• Front fork noise 170
• Handlebar hard to turn 170
• Handlebar pulls to one side 170
• Handlebar shakes or excessivery vibrates 170
• Handling and or stability unsatisfactory 170
• Jumps out of gear 170
• Knocking 170
• Other noise 170
• Overshifts 170
• Piston slap 170
• Rear shock absorber noise 170
• Transmission noise 170
• Appendix 14 5 171
• Brakes don t hold 171
• Cable lubrication 171
• Cables lubricate with motor oil 171
• General lubrication 171
• Pivots lubricate with motor oil 171
• Points lubricate with grease 171
• Shock absorption unsatisfactory 171
• 6 appendix 172
• Prefixes for units 172
• Unit conversion table 172
• Unit of temperature 172
• Units of force 172
• Units of length 172
• Units of mass 172
• Units of power 172
• Units of pressure 172
• Units of speed 172
• Units of torque 172
• Units of volume 172
• List of abbreviations unit conversion table 173
• 3937 inch 174
• 4488 inch 174
• 4803 inch 174
• 5118 inch 174
• Decimal equivalents 174
• Inch mm inch inch mm inch 174

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5 4 ENGINE RIGHT SIDE Right Engine Cover Installation Notes Right Engine Cover Right Engine Cover Removal Drain the transmission oil see Transmission Oil Change in the Engine Bottom End Transmission chapter Drain the coolant see Coolant Change in the Cool ing System chapter Remove the following parts Kick Pedal Clutch Cable Lower End Brake Pedal Expansion Chamber Impeller Pull off the water pump hose lower end Remove the right cover side KIPS cover from the cylinder Remove the shaft lever nut and take off the shaft lever Installation is the reverse of removal Note the following There are two knock pins on the mating surfaces of the crankcase and right engine cover In case the exhaust advancer assembly has been removed install it and turn the gear so as to level the gear drive pin CAUTION o f the gear drive pin is not positioned level it may fall out when installing the right engine cover CAUTjoj oExhaust valve operating shaft lever nut has left hand threads A Gear Drive Pin level position Turn the clutch release lever toward the rear Install the right engine cover using the kick shaft oil seal guide special tool to protect the cover oil seal A Shaft Lever B Nut A Kick Shaft Oil Seal Guide 57001 263 Turn the clutch release lever toward the rear and free the release shaft from the clutch spring plate pusher Take off the oil filler cap and remove the right engine cover and bolts Fit the shaft lever boss in the groove of the valve operating rod collar and install the shaft lever on the lever shaft Tighten the shaft lever nut to the specified torque