Quick Reference Guide

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io_n_____

I Fuel System
L - - ._ _ _ _ _
.:w
K:iI

I Engine Top End

L
. -_ _ _ _
.:II
Ell
Engine Left Side

Engine Right Side

Engine Removal/Installation

Engine Bottom End/Transmission

Wheels/Tires

Final Drive

Brakes

Suspension

Steering

This quick reference guide will assist you in Frame

locating a desired topic or procedure.
eSend the pages back to match the black tab
of the desired chapter number with the black Electrical System
tab on the edge at each table of contents
page.
eRefer to the sectional table of contents for
the exact pages to locate the specif ic topic
Appendix
or procedure requ ired.
Kawasaki KLF300

All Terrain Vehicle

Service Manual
~l:;~~%~~w;:~~:V:~;'~:~~:>"~~,~:&~~'!!~:}.~:>"~~'l:~{~C:~~:.'v.(;'fJ:-;~~~;t>.'~~V~~~
~~~n.~1ti~~~~~d;;l!!..'i\)~~~*~~{ui~~~~~~~r~~l!tJa.c~~d~~~~*,~
~ PLEASE DO NOT TAMPER WITH NOISE CONTROL SYSTEM ~
~ (US Model onlyl ~
~% To minimize the noise emissions from this product, Kawasaki has equipped it with ~
~ effective intake and exhaust silenc ing systems. They are designed to give optimum per- A ...
S~ formance while maintaining a low noise level. Please do not remove these systems, or alter ~
~ them in any which results in an increase in noise level. ~

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This w,arning may apply to any of the following

components or any assembly containing one or
more of these components: -

Brake Shoes or Pads

Clutch Friction Material
Gaskets
Insulators

WARNING SAFETY INSTRUCTIONS

CONTAINS
ASBESTOS
-Operate if possible out of doors or in a well
Breathing asbestos
dust is dangerous
ventilated place.
to health .Preferably use hand tools or low speed tools
equipped, if necessary, with an appropriate dust
Fol low safety
instructions extraction facility. If high speed tools are used,
they should always be so equipped .
If possible, dampen before cutting or drilling .
Dampen dust and place it in properly closed
receptacle and dispose of it safely.

LIST OF ABBREVIATIONS

A ampere(s) Ib 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 rpm revolution(s) per minute
F farad(s) TDC top dead center
OF degree(s) Fahrenheit TIR total indicator reading
ft foot, feet V volt(s)
g gram(s) W watt(s)
h hour(s) S1 ohm(s)
L liter(s)

Read OWNER'S MANUAL before operating

 Foreword
This manual is designed primarily for use by
trained mechanics in a properly equipped shop.
However, it contains enough detail and basic
information to make it useful to the owner who
desires to perform his own basic maintenance
and repair work. A basic knowledge of mechan-
ics, the proper use of tools, and workshop
procedures must be understood in order to carry
out maintenance and repair satisfactorily.
Whenever the owner has insufficient experience
or doubts his ability to do the work, all adjust-
ments, maintenance, and repair should be
carried out only by qualified mechanics.
In order to perform the work efficiently and
to avoid costly mistakes, read the text, thor-
oughly familiarize yourself with the procedures
before starting work , and then do the work
carefully in a clean area . Whenever special tools
or equipment are specified, do not use makeshift
tools or equipment. Precision measurements can
only be made if the proper instruments are used,
and the use of substitute tools may adversely
affect safe operation.
For the duration of your warranty period,
especially, we recommend that all repairs and
scheduled maintenance be performed in accord-
ance with this service manual. Any owner
maintenance or repair procedure not performed
in accordance with this manual may void the
warranty.
To get the longest life out of your vehicle:
- Follow the Periodic Maintenance Chart in the
Service Manual.
-Be alert for problems and non-scheduled
maintenance.
-Use proper tools and genuine Kawasaki vehicle
parts. Special tools, gauges, and testers
that are necessary when servicing Kawasaki
vehicles are introduced by the Special Tool
Manual. Genuine parts provided as spare parts
are listed in t he Parts Catalog.
-Follow the procedures in this manual carefully.
Don't take shortcuts.
_ Remember to keep complete records of main-
tenance and repair with dates and any new
parts installed.
How to Use this Manual
In preparing this manual, we divided the
product into its major systems. These systems
became the manual 's chapters. All information
for a particular system from adjustment
through disassembly and inspection is located in
a single chapter.
The Quick Reference Guide shows you all of
the product's systems and assists in locating
their chapters. Each chapter in turn has its own
comprehensive Table of Contents.
The Periodic Maintenance Chart is located in
the General Information chapter. The chart
gives a time schedule for required maintenance
operations.
If you want spark plug information, for
example, go to the Periodic Maintenance Chart
first. The chart tells you how frequently to
clean and gap the plug. Next, use the Quick
Reference Guide to locate the Electrical System
chapter. Then, use the Table of Contents on the
first page of the chapter to find the Spark Plug
section.
Whenever you see these WARNING and
CAUTION symbols, heed their instructions!
Always follow safe operating and maintenance
practices.
I WARNING.
oThis warning symbol identifies special instruc-
tions or procedures which, if not correctly
followed, could result in personal injury, or
loss of life.
oThis caution symbol identifies special instruc-
tions or procedures which, if not strictly
observed, could result in damage to or destruc-
tion of equipment.
This manual contains five more symbols (in
addition to WARNING and CAUTION) which
will help you distinguish different types of
information.
NOTE
o This note symbol indicates points of particular
interest for more efficient and convenient
operation.
elndicates a procedural step or work to be done.
o lndicates a procedural sub-step or how to do
the work of the procedural step it follows.
It also precedes the text of a WARNING,
CAUTION, or NOTE.
*Indicates a conditional step or what action to
take based on the results of the test or inspec-
tion in the procedural step or sub-step it
follows.
<r Indicates a conditional sub-step or what action
to take based upon the results of the condi-
tional step it follows.

In most chapters an exploded view illustration

of the system components follows the Table of
Contents. In these illustrations you will find
the instructions indicating which parts require
specified tightening torque, oil, grease or a
locking agent during assembly.
 GENERAL INFORMATION 1-1

10

General Information
Table of Contents

Before Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Model Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
General Specifications ............................... . . . . . . 16
Torque and Locking Agent. . . . . . . . . . . . . ... . . . .. . . .. . . . . . .. . .. 18
Periodic Maintenance Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
'-2 GENERAL INFORMATION

Before Servicing

Before starting to service a vehicle, careful reading of the applicable section is recommended to
eliminate unnecessary work. Photographs, diagrams, notes, cautions, warnings, and detailed des-
criptions have been included wherever necessary. Nevertheless, even a detailed account has limi-
tations, a certain amount of basic knowledge is also required for successful work.

Especially note the following:

(1) Dirt
Before removal and disassembly, clean the vehicle. Any dirt entering the engine or -other
parts will work as an abrasive and shorten the life of the vehicle. For the same reason, before
installing a new part, clean off any dust or metal filings.
(2) Battery Ground
Remove the ground (-) lead from the battery before performing any disassembly operations
on the vehicle. This prevents:
(a) the possibility of accidentally turning the engine over while partially disassembled.
(b) sparks at electrical connections which will occur when they are disconnected.
(c) damage to electrical parts.
(3) Tighten ing Sequence
Generally, when installing a part with several bolts, nuts, or screws, start them all in their holes
and tighten them to a snug fit. Then tighten them evenly in a cross pattern. This is to avoid
distortion of the part and/or causing gas or oil leakage. Conversely when .loosening the bolts,
nuts, or screws, first loosen all of them by about a quarter of turn and then remove them.
Where there is a tightening sequence indication in this Service Manual, the bolts, nuts, or
screws must be tightened in the order and method indicated.
(4) Torque
When torque values are given in this Service Manual, use them. Either too little or too much
torque may lead to serious damage . Use a good quality , reliable torque wrench.
(5) Force
Common sense should dictate how much force is necessary in assembly and disassembly. If a
part seems especially difficult to remove or install, stop and examine what may be causing the
problem. Whenever tapping is necessary, tap lightly using a wooden or plastic-faced mallet. Use
an impact driver for screws (particularly for the removal of screws held by a locking agent) in
order to avoid damaging the screw heads.
(6) Edges
Watch for sharp edges, especially during major engine disassembly and assembly. Protect your
hands with gloves or a piece of thick cloth when lifting the engine or turning it over.
(7) High-Flash Point Solvent
A high-flash point solvent is recommended to reduce fire danger. A commercial solvent com-
monly available in North America is Stoddard solvent (generic name). Always follow manufac-
turer and container directions regarding the use of any solvent.
(B) Gasket, O-Ring
Do not reuse a gasket or O-ring once it has been in service. The mating surfaces around the
gasket should be free of foreign matter and perfectly smooth to avoid oil or compression leaks.
(9) Liquid Gasket, Non-Permanent Locking Agent
Follow manufacturer's directions for cleaning and preparing surfaces where these compounds
will be used. Apply spar ingly. Excessive amounts may block engine oil passages and cause
serious damage. An example of a non-permanent locking agent commonly available in North
America is Loctite Lock ' n Seal (Blue) .
(10) Press
A part installed using a press or driver, such as a whee l bearing, should first be coated with oil
on its outer or inner circumference so that it w ill go into place smoothly .
(11) Ball Bearing
When installing a ball bearing, the bearing race which is affected by friction should be pushed
by a su itable driver. This prevents severe stress on the balls and races, and prevents races and
balls from being dented . Press a ball bearing until it stops at the stop in the hole or on the shaft.
 GENERAL INFORMATION 1-3

(12) Oil Seal and Grease Seal

Replace any oil or grease seals that were removed with new ones, as removal generally damages
seals.
When pressing in a seal which has manufacturer's marks, press it in with the marks facing out.
Seals should be pressed into place using a suitable driver, which contacts evenly with the side of
seal, until the face of the seal is even with the end of the hole.
(13) Seal Guide
A seal guide is required for certain oil or grease seals during installation to avoid damage to the
seal lips. Before a shaft passes through a seal, apply a little high temperature grease on the lips to
reduce rubber to metal friction.
(14) Circlip, Retaining Ring
Replace any circlips and retaining rings that were removed with new ones, as removal weakens
and deforms them. When installing circlips and retaining rings, take care to compress or expand
them only enough to install them and no more.
(15) Lubrication
Engine wear is generally at its maximum wh il e the engine is warming up and before all the
rubbing surfaces have an adequate lubricative film. During assembly, oil or grease (whichever is
more suitable) should be applied to any rubbing surface which has lost its lubricative film. Old
grease and dirty oil should be cleaned off. Deteriorated grease has lost its lubricative quality and
may contain abrasive foreign particles.
Don't use just any oil or grease. Some oils and greases in particular should be used only in
certain applications and may be harmful if used in an application for which they are not intended.
This manual makes reference to molybdenum disulfide grease (MoS,) in the assembly of certain
engine and chassis parts. Always check manufacturer recommendations before using such special
lubricants.
(16) Electrical Wires
All the electrical wires are either single-color or two-color and, with on ly a few exceptions,
must be connected to wires of the same color. On any of the two-color wires there is a greater
amount of one color and a lesser amount of a second color, so a twocolor wire is identified by
first the primary color and then the secondary color. For example, a yellow wire with thin red
stripes is referred to as a "yellow/ red" wire; it would be a "red/ yellow" wire if the colors were
reversed to make red the main color.

Wire (cross-section) Name of Wire Color

e: Red

~~ r
Wire strands
Yellow/ red
f--
.... Yellow

Red
'"
(17) Replacement Parts
When there is a replacement instruction , replace these parts with new ones every time they are
removed. These replacement parts will be damaged or lose their original function once removed.
(18) Inspection
When parts have been disassembled, visually inspect these parts for the following conditions or
other damage. If there is any doubt as to the condition of them, replace them with new ones.
Abrasion Crack Hardening Warp
Bent Dent Scratch Wear
Color change Deterioration Seizure
(19) Specifications
Specification terms are defined as follows.
"Standards" show dimensions or performances which brand-new parts or systems have.
"Service limits" indicate the usable limits. If the measurement shows excessive wear or dete-
riorated performance, replace the damaged parts.
14 GENERAL INFORMATION

Model Identification

KLF300-A 1 Left Side View:

KLF300-A 1 Right Side View:

 GENERAL INFORMATION 1-5

KLF300-A2 Left Side View

KLF300-A2 Right Side View

1-6 GENERAL INFORMATION

General Specifications

Items KL F300-A 1, A2
Dimensions:
Overall length 1,B50 mm
Overall width 1,100mm
Overall height 1,045 mm
Wheelbase 1,200 mm
Ground clearance 195 mm
Seat height 750mm
Dry weight 226 kg, @ 223 kg
Curb weight : Front 109.5 kg, @ 10B.5 kg
Rear 126.5 kg, @ 124.5 kg
Fuel tank capacity B.2 L
Performance :
Minimum turning radius 3.0 m (Locked axle mode)
2.6 m (Differential mode)
Engine:
Type 4-stroke, SOHC, 1cylinder
Cool i ng system Air cooled
Bore and stroke 76.0 x 64.0 mm
Displacement 290 mL
Compression ratio B.6
Maximum horsepower 15.4 kW (21 PS) @7,OOO r/min (rpm). @
Maximum torque 22.6 N-m (2.3 kg-m , 16.6 ft-Ib)
@6,OOO r/min (rpm). @
Carburetion system Carburetor, Keihin CVK32
Starting system Electric starter
I gn ition system Battery and coil (Transistorized)
Timing advance Electronically advanced
Ignition timing From 10 BTDC @1,300 r/min (rpm) to
400 BTDC @4,OOO r/min (rpm)
Spark plug NGK BBES, BRBES
Valve timing: Inlet Open 2r BTDC
Close 65 ABDC
Duration 272
Exhaust Open 62 BBDC
Close 30 ATDC
Duration 272
Lubrication system Forced lubrication (wet sump)
Engine oil: Grade SE or SF class
Viscosity SAE 10W-30 , 10W-40, 1OW-50, 20W-40, 20W-50
Capacity 1.7 L

(Continued on next page.)

: U.K. Models : Canadian Models @: U.S. Models

 GENERAL INFORMATION 1-7

Items KLF300-A 1, A2
Drive Train:
Primary reduction system: Type Gear
Reduction ratio 2_888 (78127)
Clutch type Primary Auto centrifugal, wet
Secondary Auto multi disc, wet
Transmission: Type 5-speed plus reverse, constant mesh, return shift
Gear ratios: 1st 3_090 (34/11)
2nd 1_928 (27/14)
3rd 1_368 (29/19)
4th 1_000 (23123)
5th 0_769 (20/26)
Reverse 3_072 (26/11 x 26/20)
Final drive system: Type Shaft
Reduction ratio 4_886 (20/16 x 43/11)
Overall drive ratio 10_858 @Top gear
Final gear case oil : Type API GL-5 Hypoid gear oil SAE 90 (above 5 C, 41 F)
or SAE 80 (below 5C, 41F)
Capacity 0_3 L
Frame:
Type Double tubular
Caster (rake angle) 4
Camber 0.8 @lG
Trail 17 mm
Tread 830mm
Front tire: Type Tubeless
Size 22 x 9_00-10
Rear tire: Type Tubeless
Size 24 x 11.00-10
Suspension : Front Type Double wishbone-link
Wheel travel 115 mm
Rear Type Torque tube-link
Wheel travel 120 mm
Brake type: Front Drum (Hydraulic)
Rear Drum (Mechanical)
Electrical Equipment:
Battery 12 V 19 Ah
Headlight: Type Semi-sealed beam
Bulb 12 V 60W
Taillight 12V8Wx2
Alternator: Type Three-phase AC
Rated output 23.5 A@9,000 r/ min (rpm), 14 V
Voltage regulator: Type Short-circuit

Specifications are subject to change without notice, and may not apply to every country.
1-8 GENERAL INFORMATION
............................................................................ Use the basic torque table below for only the bolts
Torque and Locking Agent and nuts which do not require a specific torque value.
All of the values are for use with dry solvent-cleaned
The following tables list the tightening torque for the threads.
major fasteners requiring use of a non-permanent locking Basic Torque for General Fasteners
agent or liquid gasket. Torque
Th read
dia. (mm) N-m kg-m ft-Ib
Letter used in the "Remarks" colu mn means: 5 3.4 - 4.9 0.35 - 050 30 - 43 in- Ib
L : App ly a non-permanent lockingagentto the threads. 6 5_9 - 7_8 0_60 -0_80 52 - 69 in-Ib
o : App ly an oil to the threads and seated surface. 8 14 -19 1.4 - 1.9 10_0 - 135
S : Tighten the faste ners fo ll owing the specified se- 10 25 - 34 2.6 - 35 19_0-25
quence.
12 44 -61 4.5 - 6_2 33 - 45
St : Stake the fasteners to prevent loosening,
14 73 -98 7.4-10_0 54 -72
16 115 '- 155 11.5 - 16_0 83 -115
18 165 - 225 17.0 - 23 125 -165
20 225 - 325 23 - 33 165 -240

Torque
Fastener Remarks
N-m kg-m ft-Ib
Engine Top End:
Cylinder Head Bolts: 6mm 12 1.2 104 in-Ib S
8mm 29 3.0 22 S
Cylinder Bolt 12 1_2 104 in-Ib
Valve Clearance Adjusting Screw
Locknuts 12 1.2 104 in-Ib
Camshaft Sprocket Bolt .41 4.2 30
Camshaft Chain Guide Pivot Bolt 9.8 1.0 87 in-Ib
Engine Left Side:
Starter Clutch Allen Bolts 49 5.0 36 L
Engine Right Side:
Oil Drain Plug 29 3.0 22
Primary Clutch Hub Nut 125 13.0 94 o
Secondary Clutch Hub Nut 78 8.0 58 o
Secondary Clutch Spring Bolts 12 1.2 104 in-Ib
Engine Removal/Installation:
Engine Mounting Bolts: 8 mm 25 2.5 18.0
10mm 34 3.5 25
Engine Mounting Bracket Bolts 25 2.5 18.0
Engine Bottom End/Transmission:
Oil Pipe Banjo Bolts 20 2.0 14.5
Shift Drum Stopper Bolt 12 1.2 104 in-Ib
Shift Drum Pin Plate Bolt 12 1.2 104 in-Ib
Shift Shaft Return Spring Pin 17 1.7 12.0 L
Clutch Release Cam Pin 17 1.7 12.0 L
Balancer Gear Nut 83 8.5 61 o
Balancer Drive Gear and Oil Pump
Drive Gear Nut 78 8.0 58 o
Wheels/Tires:
Wheel Nuts 34 3.5 25
Front Hub Nuts 34 3.5 25
 GENERAL INFORMATION 1-9

Torque
Fastener Remarks
N-m kg-m ft-Ib
Final Drive:
Front Gear Case Bolts (8 mm) 25 2.5 18.0
Output Shaft LH Bearing Housing ,B olts 12 1.2 104 in-Ib
LH Bearing Holder 98 10.0 72 St
Drive Gear Nut: 14 mm (when 16 mm) 88 (93) 9.0(9.5) 65 (69) 0
Driven Gear Nut 78 8.0 58 0
Driven Gear Shaft Oil Sea l Housing Nuts 25 2.5 18.0
Front Gear Case Plug (Odometer Gear
20 2.0 14.5
Holder: Option)
Propeller Shaft Housing Nuts 25 2.5 18.0
Axle Shaft Pipe Bolts 20 2.0 14.5
Pinion Gear Nut 78 8.0 58 0, St
Ring Gear and Differential
29 3.0 22 L
Gear Housing Bolts
Final Gear Case Cover Bolts 25 2.5 18.0
Final Gear Case Filler Cap 29 3.0 22
Final Gear Case Drain Plug 20 2.0 14.5
Differential Shift Fork Holder Screws 6.9 0.70 61 in-Ib
Brakes:
Master Cylinder Clamp Bolts 11 1.1 95 in-Ib S
Brake Lever Pivot Nut 5.9 0.60 52 in-Ib
Wheel Cylinder Bolts 7.8 0.80 69 in-Ib
Shoe Adjuster Bolts 7.8 0.80 69 in-Ib
Brake Panel Mounting Bolts:
Front 20 2.0 14.5
Rear 29 3.0 22
Rear A xle Nuts 145 15.0 110
B rake Hose Banjo Bolts 25 2.5 18.0
Brake Pipe Nipple 20 2.0 14.5
Brake Pedal Nut 29 3.0 22
Suspension:
Shock Absorber Mounting Bolts 34 3.5 25
Suspension Arm Pivot Bolts: 10mm 34 3.5 25
12 mm 88 9.0 65
Steering:
Handlebar Holder Bolts 20 2.0 14.5 S
Stem Clamp Allen Bolts 20 2.0 14.5
Stem Bottom End Nut 29 3.0 22
Stem Bearing Housing Bolts 20 2.0 14.5
Tie-rod End Nuts 41 4.2 30
Tie-rod Adjusting Sleeve Locknuts 29 3.0 22
Knuckle Arm Pivot Nuts 41 4.2 30
Electrical System :
Alternator Rotor Bolt 59 6.0 43
Spark Plug 27 2.8 20
Neutral and Reverse Indicator Switch
Mounting Screws
- - - L
1-10 GENERAL INFORMATION

Periodic Maintenance Chart

The scheduled maintenance must be done in accordance with this chart to keep the vehicle in good
running condition. The first service is vitally important and must not be neglected.

First Service Regular Service

= Clean, adjust, lubricate, tighten, or

replace parts as necessary.

Chassis :
Brake adjustment - check'
Brake wear - check '
Brake fluid level - check
Brake fluid - change
Master cylinder cup and dust seal
2 years
- replace
Wheel cylinder piston seal and
2 years
dust seal - replace
Brake hose - replace 2 years
Cable adjustment'
Steering play - check
Final gear case oil - change'
General lubrication "
Bolts and nuts - tighten
Battery - check
Engine:
Clutch adjustment'
Valve clearance - check
Fuel system cleanliness - check'
Air cleaner - service'
Engine oil - change'
Oil filter - change'
Spark plug - clean and gap
Spark arrester - clean
'Service more frequently when operated in mud, dust, or other harsh riding conditions.
 FUEL SYSTEM 2-1

Fuel System
Table of Contents

Exploded View . . . . . . . . . . . . . . . . . . . . . 2-2 Fuel System Cleanliness Inspection . . . . . 2-10

Specifications .... . ... . . . . . . . . . . . . . . . . 23 Carburetor Removal . . . . . . . . . . . . . . . 2-10
Special Tool . _ .. __ .. _ ...... _ . . . . . . . _ 2-3 Carburetor Installation 2-10
Throttle Case and Cable . . . . . . . . 2-4 Carburetor Disassembly 2-10
Throttle Lever Free Play Inspection . . . . .. 204 Carburetor Assembly . . . . . . . .... . ... . 211
Throttle Cable Adjustment . . __ .... ___ . 2-4 Carburetor Cleaning . . . . . . . . ... . . . . . 2-12
Throttle Case Removal/Disassembly. . . . .. 2-4 Carburetor Inspection . ... ... . . . . . . . . 2-12
Throttle Case Assembly/Installation. . . . .. 2-4 Air Cleaner . _ . . . . . . __ .. _ . _ ... _ ...... 2-13
Throttle Cable Removal .... __ . ______ . 2-5 Air Cleaner Element Removal . . . . . . ... 2-13
Throttle Cable Installation . _ ... _ .... _. 2-5 Air Cleaner Element Installation . ... ... 2-14
Throttle Case and Cable Lubrication ..... 25 Air Cleaner Removal . . . . . . . . . . . . . . . . 2-14
Throttle Case Inspection . 2-6 Air Cleaner Installation .. . . . . . . . . .... 2-14
Throttle Cable Inspection. 2-6 Air Cleaner Element Cleaning . .... . .... 2-14
Choke Lever and Cable . . . . . . . . . . . . . . . .. . 2-6 Air Cleaner Element Inspection
Choke Lever and Cable Removal . . . . . . . . 2-6 and Replacement . . . . . . . . . . . . . . . . 215
Choke Lever and Cable Installation 2-7 Fuel Tank. _ .... __ .. __ . . . . . . . . . . . ... 2-15
Choke Lever and Cable Lurbication 2-7 Fuel Tank Removal .. . _ . . . . . . . . . . . . . 2-15
Choke Cable Inspection. . . . . . . . . . . .. 2-8 Fuel Tank Installation . . . . . . . . . . . . . . 2-15
Carburetor . . . . . . . . . . . . . . . . . . . . . . . . .. 2-8 Fuel Tap Removal . ... _ . _ .. _ .. . .. 2-16
Carburetor Pilot Screw Adjustment. . . . .. 2-8 Fuel Tank Inspection .... _ . _ ... . .... 2-16
Idle Speed Adjustment _ . _ . . . . . . . . . .. 2-9 Fuel Tank and Tap Cleaning .... _ .. . _ . 2-16
Fuel Level Inspection ... . . . . . . . . . . .. 2 9 Fuel Tap Inspection .... _ . . . . . . _ .. . 2-16
Fuel Level Adjustment . . . . . .. .. . . . .. 2-9
2-2 FUEL SYSTEM

Exploded View

~J

A : Apply adhesive.
 FUEL SYSTEM 2-3

Specifications

Item Standard
Throttle Lever Free Play 2-3mm
Carburetor: Make!Type Keihin/ CVK32
Main Jet (Option) # 130(# 125,128,132,135)
Main Air Jet # 100
Jet Needle N27Q
Needle Jet #6
Pilot Jet (Option) # 38 (# 35,40)
Pilot Air Jet # 140
Pilot Screw 2'/, turns out
Starter Jet (Option) # 55 (# 58 , 60)
Service Fuel Level (from the bottom
0_5 mm below - 1.5 mm above
edge of carburetor body)
Float Height 17.0 2 mm
Air Cleaner Element Oil:
Grade SE class
Viscosity SAE30

............................................................. ...... .........

Special Tool

Alo ng with comm on ha nd tools, th e following more

specialized too l is required for complete fue l system
servicing.

Fuel Level Gauge: 570011017

24 FUEL SYSTEM

Throttle Case and Cable

Throttle Lever Free Play Inspection

-Check t hrottle lever free play.
*If free play is not within spec ifications, adjust the
throttle cable (see Throttle Cable Adjustment).

Throttle Lever Free Play

Standard: 2-3mm

A. Throttle Case Screws

o Pul1 the cable tip from the throttle lever catch.

a loosen the locknut and unscrew the adjuster.

A. Throttle Lever Free Play C. Locknut

B. Adjuster

A. Cable Tip D. Throttle Lever Bolt

B. Locknut E. Limiter Screw
Throttle Cable Adjustment C. Ad ju ster F. Grommet
-Slide the cable adjuster dust cover out of place .
eTurn the adjuster until throttle lever free play is correct.
Turning the adjuster "out" (lengthening the adjuster) eDisassemble the throttle case.
will reduce free play. ORemove the throttl e lever bolt, lockwasher, and flat
-Slide back the dust cover. washer, and lift the throttle lever and return spr ing
from the case. The control lever pivot bushing comes
off with the lever.
NOTE OLoosen the locknut and unscrew the throttle limiter
screw.
Olf the throttle cable cannot be adjusted by using the
adjuster at the throttle case, use the adjuster at the o Pull the throttle control lever out of the case.
carburetor. Do not forget to securely tighten the
adjuster mounting nuts.

Throttle Case Assembly/Installation

Throttle Case Removal/Disassembly
eRemove the throttle case.
oRemove the throttle case screws and pull the case open.
oSlide the cable adjuster dust cover out of place, and
take off the grommet.
-Throttle case assembly/installation is the reverse of
removal/disassembly. Note t he fo llowing.
_Lubricate the throttle case and cable before assemb ly/
installation (see Throttle Case and Cable Lubrication).
eBe certain that the return spring is correctly installed
on the throttle lever.

-.
A. Return Spring Hook
eTighten the throttle lever bolt to 6.9 N-m (0.7 kg-m,
61 inlb) of torque .
eSwing the throttle co ntrol lever so that the carburetor
throttle valve is fully open. Turn the throttle limiter
screw until it is spaced about 1 mm away from the
throttle lever stop.
I WARNING.
COperation with an improperly assembled throttle case
could result in an unsafe riding condition.
eAdjust the throttle cable (see Throttle Cable Adjust-
ment).
Throttle Cable Removal
eRemove the front fender (see Front Fender Removal in
the Frame chapter).
eRemove and disassemble the throttle case to free the
upper end of the cable from the case (see Throttle Case
Removal/ Disassembly) .
eSlip the cable lower end out of the pUlley.
A. Cable End
FUEL SYSTEM 2-5
-Loosen the mounting nuts at the cable lower end
adjuster and free the cable from the bracket.
eNote cable routing for proper installation, and pull the
cable from the vehicle.
Throttle Cable Installation
eThrottie cab le install ation is the reverse of removal.
Note the following.
eLubricate the throttle cable before installation (see
Throttle Case and Cable Lubrication).
eRoute the cab le as shown.
A. Throttle Cable
I WARNING.
<::Operation with an improperly adjusted, incorrectly
routed, or damaged cable could result in an unsafe
riding condition.
eAdjust the throttle cable (see Throttle Cable Adjust-
ment).
Throttle Case and Cable Lubrication
Whenever the throttle case is disassembled, or in
accordance with the Periodic Maintenance Chart, per-
form the following.
eApply a thin coating of multi-purpose grease to the
throttle control lever pivot area and the throttle cable
ends.
2~ FUEL SYSTEM

A. Apply grease.
*If the lever bends, disassemble the throttle case, and
clean and iubricate the throttle case (see Throttle Case
and Cable Lubrication).
-Examine the lever and case for cracks. Replace the
case assembly if it is cracked.

Throttle Cable Inspection

-With the throttle cable disconnected at the both ends,
the cable should move freely within the cable housing.

A. Apply grease.

_Lubricate the throttle cable by seeping the oil between

the cable and cable housing.

Cable Lubrication

*If cable movement is not fre e after lu brication (see

Throttle Case and Cable Lubrication), if the cable is
frayed, or if the cable housing is kinked, replace the
cable.

Choke Lever and Cable

Throttle Case Inspection Choke Lever and Cable Removal

-With the throttle cable disconnected from the throttle -Remove th e carburetor (see Carburetor Removal).
lever, the lever should move freely and return smoothly -Unscrew the starter plunger cap and pull out the starter
by spring. plunger.
 FUEL SYSTEM 2-7

ePull the choke lever off the housing, and free the choke
cable upper end from the lever. Th.ere i!l the wave
washer between the lever and the housing.
eNote the choke cable routing for proper installation,
and pull the cable from the vehicle.

Choke Lever and Cable Installation

-Choke cable installation is the reverse of removal. Note
the following.
eLubricate the choke cable before installation (see
Choke Cable Lubrication). Do not lubricate the choke
lever.
A. Starter Plunger Cap eFit the choke cable upper end to the catch on the
choke lever as shown.

eHold the starter plunger spring compressed, and free

the choke cable lower end from the plunger.

A. Choke Cable Upper End

eRoute the choke cable as shown.

A. Cable End B. Starter Plunger

_Unscrew the choke lever mounting screw and take off

the lockwasher and fl at wa sher.

A. Choke Cable

Choke Lever and Cable Lubrication

Whenever the choke cable removed, lubricate the
choke cable as follows and do not lubricate the choke
lever : wave washer betwee n the lever and the housing.
A. Choke Lever B. Lever Mounting Screw
2-8 FUEL SYSTEM
A. Do not grease. B. Wave Washer
-Lubricate the choke cable by seeping the oil between
the cable and cable housing.
Cable Lubrication
Choke Cable Inspection
-With the choke cable disconnected at the both ends,
the cable should move freely within the cable housing.
*If cable movement is not free after lubricating (see
Choke Cable Lubrication), if the cable is frayed, or
if the cable housing is kinked, replaced the cable.
Carburetor
Carburetor Pilot Screw Adjustment
eRemove the car~uretor (see Carburetor Removal ).
eTurn the carbu retor pilot screw all the wa y in until it
seats lightly.
[CAUTIO~]
000 not overtighten the pilot screw or the carburetor
body will be d~maged and require replacement.
A. Pilot Screw
eBack the pilot screw out the specified number of turns.
Carburetor Pilot Screw Setting
Standard:
Idle Speed Adjustment
-Adjust the pilot screw if necessary (see Carburetor Pilot
Screw Adjustment) .
-Start the engine and warm it up thoroughly.
eTurn the idle adjusting screw to obtain the slowest
smooth idle speed.
A. Idle Adjusting Screw
 FUEL SYSTEM 29

Fuel Level Inspection Fuel Level Adjustment

I WARN ING '
OGasoline is extreme ly flammable and can be explosive
under certain conditions. Turn the ignition switch
OFF. 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.
.Park the vehicle on a level surface.
-Connect the fuel level gauge (special tool) to the open
end of the carburetor overflow tube.
-Remove the carburetor (see Carburetor' Removal).
-Drain the carburetor into a suitab le container,
-Remove the float bowl by taking out the screws with
lockwashers.
-Slide out the pivot pin and remove the float.
-Bend t he tang on the float arm very slighty to change
the float height. Increasing the float height lowers the
fuel level and decreasing the float height raises the fuel
level.
Float Height
Standard: 17.0 mm

A. Fuel Level Gauge: 570011017 C. Drain Plug

B. Carburetor body bottom edge

A. Tang
-Hold the gauge vertically against the side of the car
buretor body so that the "zero" line is several milli
meters higher than the bottom edge of the carburetor
body. -Assemble the carburetor, install it on the vehicle, and
-Turn the fuel tap to the ON position to feed fuel to the recheck the fuel level.
carbu retor and gauge, then turn out the carburetor *If the fuel level cannot be adjusted by this method, the
drain plug a few turns . float or the float valve is damaged,
-Wait until the fuel level in the gauge settle.
eKeeping the gauge vertical, slowly lower the gauge until
the "zero" line is even with the bottom edge of the car- Float Height MeasurementKeihin Carburetor
buretor body.

NOTE
ODo not lower the nzerou line below the bottom edge of
the carburetor body, If the gauge is lowered and then
raise it again, the fuel level measured shows somewhat 2
higher than the actual fuel level. If the gauge is @
lowered too far, dump the fuel out of it into a suitable
container and start the procedure over again.

-Read the fue l level in the gauge and compare it to the

specification,
-Tighten the drain plug and remove the fuel level gauge .
*If the fuel level is incorrect, adjust it (see Fuel Level
Adjustment).
Float height
Fuel Level
1. Float bowl mating surface
0.5 1 mm above the bottom edge of the 2. Float valve needle rod (contacted but unloaded)
carburetor body 3. Float
2-10 FUEL SYSTEM

Fuel System Cleanliness Inspection Carburetor Installation

ec:arburetor Installation is the reverse of removal. Note
IWARNING I the following.
eRoute the carburetor vent hose as shown.
oGasoline is extremely flammable and can be explosive
under certain conditions. Turn the ignition switch
OFF. 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.

eRun the lower end of the carburetor overflow tube to a

suitable container.
eTurn out the carburetor drain plug a few t urns and
drain the fuel system.

A. Carburetor Vent Hose

-Check fuel leakage from the carburetor.

I WARNING.
oFuel spilled from the carburetor is hazardous.

A. Drain Plug
e<:heck to see if water or dirt comes out.
eTighten the drai n pi ug.
*If any water or dirt appears during the above in
spection, clean the fuel system (see Carburetor
Cleaning and Fuel Tank and Tap Cleaning).
eAdjust the pilot screw (see Carburetor Pi lot Screw
Adjustment).
elf the carburetor has been disassembled, or if there is
some other reason that the fuel level may be incorrect,
inspect the fuel level (see Carburetor Fuel Level In-
spection).
eAdjust the idle speed (see Idle Speed Adjustment).
eAdj ust the throttle cable (see Throttle Cable Adjust-
ment) .

Carburetor Removal
eRemove the fuel tank (see Fuel Tank Removal).

IWARNING I Carburetor Disassembly

OGasoline is extremely flammable and can be explosive
under certain conditions. Turn the ignition switch
OFF. 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.
-Remove the carburetor (see Carburetor Removal).
-Remove the carburetor top end as fo llows.
-Remove the upper chamber cover screws and take off
the cover and spring.
ePul1 out the vacuum piston with the diaphragm.

eSlip the throttle cable lower end out of the carburetor

pulley (see Throttle Cable Removal).
eLoosen the clamps on the carburetor holder and the air
cleaner duct. a During carburetor disassembly, be careful not to
ePul1 the air cleaner duct off the mouth of the carbu- damage the diaphragm. Never use a sharp edge to
retor. remove diaphragm .
ePull the carburetor out the carburetor holder.
eUnscrew the starter plunger cap and free the lower end
of the carburetor choke cable from the carburetor (see -Slide the jet needle out of the vacuum piston from the
Choke Cable Removal). bottom. It will come out with a spring seat.
 FUEL SYSTEM 2-11

Carburetor Assembly
ecarburetor assembly is the reverse of disassembly.
Note the following.
eTurn the carburetor body upside-down, and drop the
needle iet into place. The smaller diameter end of the
jet goes in first.

A. Vacuum Piston c. let Needle

B. Spring Seat

_Remove the carburetor bottom end as follows.

-Unscrew the pilot screw and remove it with its spring,
washer, and O-ring.
eRemove the float bowl screws and take off the float
bowl and D-ring.
-Slide out the float pivot pin, remove the float, and A. Small End
drop out the float needle v'llve with its hanger.

-Carefully screw in the air bleed pipe. It will seat

against the needle iet, pushing the end of the iet into
the carburetor bore.

000 not force the air bleed pipe or overtighten it. The
needle jet or the carburetor body could be damaged
requ iring replacement.

eDrop the float valve needle into the valve seat and hold
the float in place with the tab hooked into the needle
hanger.

A. Float Pivot Pin c. Air Bleed Pipe

B. Main let D. Pilot 1et

-Unscrew the main jet, pilot jet, and air bleed pipe.
ePush the needle iet out from the inside of the carburetor
with your finger.

A. Needle Hanger

eSlip the float pivot pin through the pivot posts and the
float. The float stop tab must be on the correct side as
A. Needle let shown.
2-12 FUEL SYSTEM
I WARNING.
Olf the flo'at is improperly installed, the specified fuel
level cannot be maintained. Fuel spilled from the
carburetor is hazardous.
-Set the floa t he ight as specified (see Fuel Level Adjust-
ment) .
-Slip th e needle through the hole in the ce nter of the
vacuum piston, and put the spring seat on the top of
the need le. Turn the seat so that it does not block the
hol e at the bottom of th e vacuum piston.
A. Spring Seat B. Ho le
-After installing the upper chamber cover, check that
the vacuum pisto n slides up and down smoothl y
without binding in the carburetor bore.
Carburetor Cleaning
I WARNING'
OClean the carburetor in a wellventilated area, 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 solvents
to clean the carburetor. A fire or explosion could
result.
000 not use compressed air on an assembled carburetor,
the floats may be crushed by the pressure, and the
vacuum piston diaphragms may be damaged.
ORemove as many rubber or plastic parts from the car
buretor as possible before cleaning the carburetor with
a cleaning solution. This will prevent damage or
deterioration of the parts.
OThe carburetor body has plastic parts that cannot be
removed. DO NOT use a strong carburetor cleaning
solution which could attack these parts; instead, use a
mild high flashpoint cleaning solution safe for plastic
parts.
-Di sassemble the carburetor (see Carburetor Disassem
bl y).
-Immerse all the metal parts in a carb ur etor cleaning
sol utio n.
-Rinse the parts in water .
-When the parts are clean, dry them with compressed air.
-Blow t he ai r and fuel passages wit h co mpressed air.
-Assemble th e carbureto r (see Carburetor Asse mbl y).
Carburetor Inspection
-Before removing the carburetor, check th e fuel level
(see Fuel Leve l Inspection).
*If the fu el level is incorrect, inspect the rest of the
carburetor before correcting it.
-Remove the carburetor (see Carbureto r Removal).
-Turn the thro ttle cable pulley to check th at the
throttle butterfly va lve moves smoothl y and returns
back with the spring tension .
*If th e throttl e valve does not move smooth ly, replace
t h e carburetor.
A. Throttle Butterfly Valve
-Disassemble th e carburetor (see Carbu retor Disassem
bly).
eelean the car buretor (see Carburetor Cl eani ng).
eeheck that t he O-rings o n the float bo wl, drai n plug,
pilot sc rew, and carburetor ho lder, and the di ap hragm
o n th e vacu um piston .
 FUEL SYSTEM 213

A. O-rings B. Diaphragm A. Tapered Portion

*If the pilot screw is worn or damaged on the tapered

portion, it will prevent the engine from idling smoothly.
Replace it.
-Check that the vacuum piston moves smoothly in the
carburetor body. The surface of the piston must not
be excessively worn.
*If the vacuum piston does not move smoothly, or if it
,/
is very loose in the carburetor body, replace both the
body and the vacuum piston.

A. O-ring

*If any of the O-rings or diaphragm are not in good con-

dition, rep lace th em.
e<:heck the plastic tip of the float valve needle. It
should be smooth, without any grooves, scratches, or
tears.
............................................................................
Air Cleaner
........................................................................... .
Air Cleaner Element Removal
eRemove the seat (see Seat Removal in the Frame
chapter).
eRemove the air cleaner cover by tak ing out the screws
and then lifting the cover. The baffle plate comes out
with the cover.

A. Tip B. Rod

*If the plastic tip is damaged, replace the needle .

Push in the rod in the other end of the float valve
needle and then release it.
*If it does not spring out, replace the needle .
-Check the tapered portion of the pilot screw for wear
or damage. A. Screws B. Baffte Plate
2-14 FUEL SYSTEM
-Uft the air cleaner element straight up and o ut. The
element holder will come free with it.
A. Gasket B. Element C. Holder
Air Cleaner Element Installation
-Element installation is the reverse of removal. Note the
following.
-Set the element holder in place, as shown, with its
lower edge in the slot in the bottom of the air cleaner.
A. Slot
-Smear a little grease on the foam gasket.
-Slide the air cleaner element into place with the foam
gasket toward the engine.
Air Cleaner Removal
eRemove the seat (see Seat Removal in the Frame
chapter).
eTake out the bolts holding the air cleaner to the frame.
eLoosen the clamp on the duct to the air cleaner mouth.
Pull the air cleaner out of the frame.
A. Bolts B. Clamp
Air Cleaner Installation
-Air cleaner installation is the reverse of removal. Note
the following.
elf the drain was removed, twist it into place on the
bottom of the air cleaner.
A. Drain
Air Cleaner Element Cleaning
eRe move the air cleaner element (see Air Cleaner
Element Removal).
WARNING.
OClean the element in a wellventilated area, 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 solvents
to clean the element. A fire or explosion could result .
 FUEL SYSTEM 2-15

ePeel the air cleaner element off the plastic frame inside
it. Fuel Tank
u
. . .
. . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..

Fuel Tank Removal

eRemove the front fender (see Front Frender Removal
in the Frame chapter).
-Tu rn the fuel tap to the OFF position.
-Pull the fuel hose off the tap.

IWARNING.
oGasoline is extremely flammable and can be explosive
under certain conditions. Turn the ignition switch
OFF. 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.
A. Element B. Frame C. Screen
-Remove the bolt with lockwasher and flat washer from
-Wash the element in a bath of high flash-point solvent the rear end of the tan k.
and then squeeze it dry.

!CAUTlO~]
0 00 not wring or twist the element as it may tear.

-Saturate the element with SAE30 motor o il, or a

commercially available air cleaner oil, and squeeze out
the excess.
eWrap the element in a clean, dry cloth and squeeze it as
dryas possible.
-Pull the element back over the plastic frame.
-Inspect the element before installing it (see Air Cleaner
Element Inspection and Replacement and Air Cleaner
Element Installation).

Air Cleaner Element Inspection A Bolt

and Replacement
eRemove the air cleaner element (see Air Cleaner
Element Removal).
eelean the air cleaner element (see Air Cleaner Element -Tilt the tank out the rear of the frame.
Cleaning) . -Drain the fuel tank.
-Visually check the element for tears or breaks in the OArrange a suitable container under the fuel tank.
foam. Check the foam gasket also, and the plastic a Turn the fuel tap to the RES position to drain the fuel
frame and screen . into the conta iner.
*If the . element or gasket have any tears or breaks,
replace the element.
*If the plastic frame and/or screen are damaged or
distorted, replace the damaged one.

Fuel Tank Installation

NOTE
ORepeated cleaning opens the pores of the foam in the
element. Replace the element after cleaning it five
times or if it is damaged.
eFuel tank installation is the reverse of removal. Note
the following .
-Read the WARNING in the Fuel Tank Removal section.
eeheck the rubber dampers on the frame top-tubes and
on the rear end of the fuel tank.
2-16 FUEL SYSTEM

Fuel Tank and Tap Cleaning

-Remove the fuel tank and drain it (see Fuel Tank
Removal).
-Pour some high flashpoint solvent into the fuel tank
and shake the tank to remove dirt and fuel deposits.

WARNING.
oelean the tank in a wellventilated area, 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 solvents
to clean the tank. A fire or explosion could result.
A. Dampers

*If the dampers are damaged or deteriorated, replace -Pour the solvent out the tank.
them. -Remove the fuel tap from the tank by taking out the
-Be sure the fuel hose is clamped to the fuel tap to bolts with nylon washers.
prevent leaks. -Clean the fuel tap flIter screens in a high flash-point
solvent.
-Pour high flash-point solvent through the tap in both
ON and RES positions.
Fuel Tap Removal -Dry the tank and tap with compressed air.
_Remove the fuel tank and drain it (see Fuel Tank -Install the tap in the tank ( see Fuel Tap Installation).
Removal). -Install the fuel tank (see Fuel Tank Installation).
-Remove the bolts with nylon flat washers and take out
the fuel tap and spacer.

Fuel Tap Inspection

-Check the fuel tap filter screens for any breaks or
deterioration.

A. Bo lts B. Spacer

Fuel Tap Installation

eFuel tap installation is reverse of removal. Note the
following.
eBe sure the O-rings are in good condition to prevent A. Screens
leaks.
-Be sure to clamp the fuel hose to the tap to prevent
leaks.
eSe sure the nylon washers are in good condition to *If the fuel tap screens have any breaks or are deterio-
prevent leaks. rated, it may allow dirt to reach the carburetor, causing
000 not use steel washers in place of the nylon washers, poor running. Replace the fuel tap.
because they will not seal the bolts properly and fuel *If the fuel tap leaks, or allows fuel to fiow when it is
will leak. OFF, replace the damaged gasket or a-rings.
 ENGINE TOP END 3-1

Engine Top End

Table of Contents

Exploded View . . . . . . . . . . . . . . . . . . 32 Camshaft . . . . . . . . . . . . . . . . . . . . . . . . 3-19

Specifications . . . . . . . . . . . . . . . . .. . . . . 34 Camshaft Removal. . . . . . . . . . . . . . . . 3.1 9 ' : '
Special Tools . . . . . . . . . . . . . . . . . . . . . . 36 Camshaft Insta llation .. . . . . . . . . .. . . 3-19':'
Cylinder Head .... 3-7 Cam Wear Inspection . . . . . . . . . . . . . . 319
Cylinder Head Removal 3-7 Camshaft Bearing Inspection . . . . . . . . . 319
Cylinder Head Installation .. .. . . . .. . 3-7 Camshaft Chain, Guides and Tensioner . . . . . . 3-20
Cy linder Head Cleaning . . . . . . . . . . . . 3-8 Camshaft Chain . . . . . . . . . . . . . . . . . .. . 320
Cylinder Head Warp ... . ..... . 38 Camshaft Chain Removal . . . . . . . . . . . 3-20
Va lves, ,G uides, Seats, Springs, Oil Seals .... . 38 Camshaft Chain Installation .... . . . . . . 3-20
Valves .... . . . . . . . . . . . . . . _ . 3-8 Camshaft Chain Wear . . . . . . . . . . . . . . 3-20
Valve Clearance Check . . . . . . . . . 38 Camshaft Chain Guides . ... .. . . 3-20
Va lve Clearance Adjustment . . . . . . . . . 3-9 Camshaft Chain Guide Removal . . 3-20
Va lve Removal . . .... . . . . . . .. . . . . 3-9 Camshaft Chain Guide Installation. 3-20
Valve In stallation .... . . . . . . . . .. . . 3-10 Camshaft Chain Gu ide Wear . . . . . . . . . 3-21
Va lve Visual In spection . . . . . . . .... . 3-10 Camshaft Chain T ensioner. 321
Va lve Head Thickness . . . . . . . . .... . 311 Camshaft Chain Tensioner Removal ... . 3-21
Valve Stem Bend . . . . . . . . . . . .... . 3-11 Camshaft Chain Tensioner Installation . . . 3 21
Valve Stem Diameter . ... . ... . .... . 3-11 Camshaft Chain Tensioner Wear ... ... . 3-22
Valve Guides .. . . . . . . . . . . . . . . . ... . 3-11 Cylinder, Piston and Rings . . . . . . . . . . . .. . 3-22
Valve Guide Inside Diameter . ... . 3-11 Cylinder Removal / Installation .. . . . . . . . . 3-22
Va lve Guide Removal. . . . . . . . . . .. . . 3-11 Cylinder Removal .. . . . . . . . . . . . . . . 322
Va lve Guide Installation . . . . . . . . . 3-12 Cylinder Install ation . . . . . . . ... .. . . 3-22
Valve Seats . . . . . . . . . . . . . . . ... . . . . 3-12 Piston and Ring Removal / Installation . ... . 3-23
Valve Seat Inspection . . . . . . . . . . . . . 3-12 Piston and Rin g Removal .. . . . . . . . . . 3-23
Valve Seat Repair . . . . . . . 3-13 Piston and Ring In stallation . . . . . . . . . 3-24
Valve Springs ... . . . . . . . . . . . . . . . 316 Cylinder, Piston and Ring Maintenance . .. . 3-25
Valve Spring Removal / Installation . ... . 316 Compression Measurement .... . . . . . . 325
Valve Spring Free Length . . . . . . . . . . . 31 6 Cylinder/ Piston Wear . . . . . . . . . . . .. . 326
Va lve Stem Oil Seals . . . . . . . . . . . . . . . . 3 16 Piston / Cylinder Clearance .... .. . . . . 3-27
Va lve Stem Oil Seal Removal . . . . . . . . 3-16 Cylinder Boring and Honing . . . . . . . . . 3-27
Valve Stem Oil Seal Installation . . . . . . . 316 Piston/Cylinder Seizure .. . . . . . . . . . 3-28
Camshaft Sprocket .... . . . . . . . . . . . . . . . 3-16 Piston Cleaning . . . . . . . . . . . . . . . . . 3-28
Camshaft Sprocket Removal . .. . .. .. . 3-16 Piston Ring and Ring Groove Wear . ... . 328
Camshaft Sprocket Installation .. . .. . . 3-17 Piston Ring End Gap . ... . . . . . . . . . . 328
Camshaft, Rocker Arms and Shafts . . . . . . . . 3-17 Exhaust System 3-29
Rocker Arms and Shafts . . . . . . . 3-17 Spark Arrester 3-29
Rocker Arm and Shaft Removal .. 3-17 Spark Arrester Cleaning . . 3-29
Rocker A rm and Shaft Installation . .. 3-18 Exhaust Pipe and Muffler . . 3-29
Rocker Arm Inspection 3-18 Exhaust Pipe and Muffler Removal . .. . . 3-29
Rocker Shaft Diameter ... .. . . . . .. . 3-18 Exhaust Pipe and Muffler Installation . . . 3-30
Exhaust System Inspection. 3-30
3-2 ENGINE TOP END

Exploded View

l : Apply a non-permanent locking agent.

M : Apply a molybdenum disulfide grease.
n : 29 Nm (3.0 kgm, 22 ftlb) for used parts.
34 Nm (3.5 kgm, 25 ftlb) for new parts.
T2: 12 N-m (1.2 kgm, 104 inlb)
T3: 41 Nm (4.2 kgm, 30 ftlb)
T4: 9.8 Nm (1.0 kgm, 87 inlb)
 ENGINE TOP ENO 3-3

T2

T4
34 ENGINE TOP END

Specifications

Cylinder !-lead:
Item Standard Service Li m it
Cylinder Head Warp 0.05 mm

Valve, Guides, Seats, Springs, Oil Seals:

Item Standard Service Limit
Valve Clearance: IN . 0.10 - 0.15 mm --
EX. 0. 15 - 0.20 mm --
Valve Seating Surface Angle 45 --
Valve Head Thickness: IN. 0.80 - 1.20 mm 0.5mm
EX. 0.80 - 1.20 mm 0.7 mm
Valve Stem Bend 0.02 mm TIR 0.05mm TIR
Valve Stem Diameter: IN . 6.965 - 6.980 mm 6.95 mm
EX. 6.950 - 6.970 mm 6.94 mm
Valve Guide Inside Diameter 7.000 - 7.015 mm 7.08mm
Va Ive Seati ng Width 0.5 -1.0 mm --
Valve Seating Surface Diameter:
IN. 35.7 - 36.3 mm --
EX. 29.7 -30.3 mm --
Valve Spring Free Length : Inner 32.4 mm 31.1 mm
Outer 37 .3 mm 35.8 mm

Camshaft, Rocker Arms and Shafts:

Item Standard Service Limit
Rocker Arm Inside Diameter 13.000 - 13.018 mm 13.05 mm
Rocker Shaft Diameter 12.976 - 12.994 mm 12.95 mm
Cam Height 40.876 - 40.984 mm 40.78 mm
 ENGINE TOP END 3-5

Camshaft Chain, Guides and Tensioner:

Item Standard Service Limit
Camshaft Chain Length/20-l ink 160.00 -160.56 mm 162.4 mm
Camshaft Chain Guide Groove
Depth: Front No groove 2.0mm
Rear No groove 1.5 mm

Cylinder, Piston, Rings:

Item Standard Service Limit
Cylinder Compression 795 - 1,240 kPa
(8.1 - 12.6 kg/cm 2 , 115 - 179 psi)
Cylinder Inside Diameter 76.000 - 76.012 mm, and less 76.10 mm, or more
than 0.01 mm difference between than 0.05 mm differ-
any two measurements ence between any two
measurements
Piston Diameter 75.950 - 75.965 mm 75.81 mm
Piston/Cylinder Clearance 0.035 - 0.062 mm
Piston Ring/Groove Clearance
Top 0.03 - 0.07 mm 0.17 mm
Second 0.02 - 0.06 mm 0.16 mm
Piston Ring Groove Width:
Top 1.22 -1.24 mm 1.32 mm
Second 1.21-1.23mm 1.31 mm
Oil 2.51 - 2.53 mm 2.61 mm
Piston Ring Thickness:
Top & Second 1.170 -1.190 mm 1.10mm
Piston Ring End Gap:
Top & Second 0.20 - 0.35 mm 0.7mm
3-6 ENGINE TOP END

Piston Pin Puller Assy: 57001-910

Special Tools (use Adapter "C": 57001-914)

Along with common hand tools, the following more

specialized tools are required for complete engine top
end servicing,
o
Valve Guide Reamer: 57001-162 U
o

#4 Seat Cutter: 57001 -1116

#5SeatCutter: 57001-1117
#9 Outside Cutter: 57001-1121
#10 Outside Cutter: 57001-1122
Valve Guide Arbor: 57001-163 #12 Inside Cutter: 57001 -1124

Cutter Holder: 57001-1126

Compression Gauge: 57001-221
with Adapter Hose: 57001-1159

Bar: 57001-1128

Valve Spring Compressor Assy: 57001-241

 ENGINE TOP END 37

Cylinder Head Installation

Cylinder Head
_Blowout the oil passage with compressed air.

Cylinder Head Removal

eRemove the following parts.
Fuel Tank
Carburetor
Exhaust Pipe and Muffler
Crankshaft Sprocket
ePull the spark plug cap off the spark plug.
eRemove the cylinder head bracket bolts and nuts, and
take off the brackets.

A. Compressed Air

-Install a new cylinder head gasket.

A. Cylinder Head Brackets

eRemove the cylinder base bolt.

eLoosen the cylinder head bolts completely and remo ve
all the bolts.
A. Cylinder Head Gasket C. Dowel Pins
B. Orings

eBe sure the dowel pins and O-rings are in place .

eSlip the cylinder head into position. Be sure the hook
of the front camshaft chain guide hangs on the cylinder
catch, and is between the cylinder and the cylinder
head.

A.8 mm Cylinder Head Bolts C. Cylinder Base Bolt

B. 6 mm Cylinder Head Bolts

-Remove the cylinder head.

OLift the head clear of t he dowel pins in the cyl inder.
oS lide the head out of the frame. A. Chain Guide Hook B. Catch
3-8 ENGINE TOP END
eTighten the cylinder head bolts in a criss-cross pattern
as shown, in two steps.

-Use a thickness gauge to measure the space between the

straightedge and the head.

Cylinder Head Bolt Torque

Cylinder Head Warp
First Torquing
Service Limit: 0.05 mm
8 mm Bolt: 15 N-m (U kg-m, 11.0 ft-Ib)
6 mm Bolt: 5_9 N-m (0.60 kg-m, 52 in-Ib)
Final Torquing
8 mm Bolt: 29 N-m (3_0 kg-m, 22 ft-Ib)
6 mm Bolt: 12 N-m (1_2 kg-m, 104 in-Ib)

eTighten the cyli nder base bolt to the specified torque

(see Exploded View).
elnstall the cylinder head brackets, and tighten the bolts
to the specified torque (see Exploded View in the
Engi,n e Removal/Installation chapter).
eThe remainder of Cylinder Head Installation is the
reverse of removal.

A. Straightedge B. Thickness Gauge

*If the cylinder head is warped more than the service

limit, replace it.
Cylinder Head Cleaning *If the cylinder head is warped less than the service limit,
repair the head by rubbing th e lower surface on emery
eRemove the cylinder head (see Cylinder Head
paper secured to a surface plate (first No. 200, then
Removal).
No. 400).
eRemove the valves (see Valve Removal).
eWash the head with a high flash-point solvent.
_Scrape the carbon out of the combustion chamber and
exhaust port with a suitable tool.
elnstall the valves (see Valve Installation).
elnstall the cylinder head (see Cylinder Head Installa-
tion).
Valves, Guides, Seats, Springs, Oil Seals

Valves:
Valve Clearance Check
Cylinder Head Warp
NOTE
eClean the cylinder head (see Cylinder Head Cleaning)_
-Lay a straightedge across the lower surface of the OCheck the valve clearance only when the engine is cold
cylinder head at the positions shown. Icool to the touch}.
 ENGINE TOP END 3-9
-Remove the fuel tank (see Fuel Tank Removal in the
Fuel System chapter).
-Take out the bolts and remove the valve adjusting caps
with O-rings.

A. Thickness Gauge C. Locknut

A. Valve Adjusting Caps
-Unscrew the left engine cover guard screws, and take
off the guard.
-Remove the timing inspection plug and cover center
plug.
_Turn the crankshaft counterclockwise with a wrench
on the alternator rotor bolt, and watch the intake
valve. When the intake valve opens and closes, keep
turning the crankshaft counterclockwise until the T
mark on the alternator rotor aligns with the slot, as
shown.
B. Adjusting Screw
Valve Clearance Adjustment
-Check the valve clearance (see Valve Clearance Check).
*If the valve clearance is not correct, continue with the
following procedure.
- Loosen the locknut and turn the adjusting screw until
the clearance is correct.
*If it is not possible to open the clearance far enough,
the valve may have been sunk too far into the head
during valve seat repair. It may be possible to grind the
end of the stem slightly to gain clearance.
Valve Stem Griding Minimum after
grinding 4.0 mm

Do not grind off

more than 0.2 mm
-Hold the adjusting screw from turning and tighten the
locknut to the specified torque (see Exploded View).
eRecheck the clearance.
*If the clearance is incorrect, repeat the adjustment
procedure.
*If the clearance is correct, perform the adjustment
procedure on the other valve.
Valve Removal
-Remove the cylinder head (see Cylinder Head
A.Slot C. Timing Inspection Plug Removal).
B. T Mark D. Cover Center Plug eRemove the follow ing parts from the cylinder head.
Camshaft
Rocker Arm and Shafts
_Measure the clearance of each valve between the end of -Use the valve spring compressor assy (special tool) to
the valve stem and the adjusting screw on the rocker press down the valve spring retainer.
arm with a thickness gauge. eRemove the spl it keepers.
*If the valve clearance is not correct, adjust it (see Valve eLoosen the valve spring compressor and take out the
Clearance Adjustment). fo llowing parts:
Valve Spring Retainer
Outer Spring
Valve Clearance (when cold)
Inner Spring
Intake: 0 .10 - 0.15 mm ePush out the valve .
Exhaust 0.15-0.20mm eRepeat the procedure for the other valve .
3-10 ENGINE TOP END
-Repeat the procedure for the other valve.
elnstall the removed parts to the cylinder head.
-Install the cylinder head (see Cylinder Head Installa
tion).
-Check and adjust the valve clearance as needed (see
Valve Clearance Check and Valve Clearance Adjust
ment).

Valve Visual Inspection

elnspect the valve head seating area for erosion, nicks,
and warpage.
A. Valve Spring Compressor Assy: 57001241
B. Split Keepers

Valve Installation
elf a new valve is to be used, check the valve-te-guide
clearance (see Valve Stem Diameter, Valve Guide Inside
Diameter).
*If there is too little clearance, ream the valve guide (see
Valve Guide Installation).
*If there is too much clearance, install a new valve guide
(see Valve Guide Removal and Valve Guide
Installation ).
-Check the valve seating (see Valve Seat Inspection).
eAfter proper valve seating has been confirmed, replace
the valve stem oil seal (see Valve Stem Oil Seal
Removal and Valve Stem Oil Seal Installation).
-Smear the valve stem end with a thin coat of
molybdenum disulfide engine assembly grease, and
push the valve into the guide.
.Put the inner and outer springs in place.
oPlace the springs so that the closed coil end of each
spring faces down.
A. Stem End B. Stem C. Seating Area
*If the valve head seating area is warped, replace the
valve.
*If the valve head seating area is eroded or nicked, it
may be possible to repair the valve on a valve refacing
machine. Follow the refacing machine manufacturer's
instructions.
elnspect the stem for obvious wear, discoloration, and
stem end damage.
*If the stem is obviously worn or discolored, replace the
valve.
*If the stem end is damaged, it may be possible to repair
it on a valve refacing machine (see Valve Stem
Grinding).
eGo on to Valve Head Thickness, Valve Stem Bend, and
Valve Stem Diameter.

Valve Head Shape

~~

A. Closed Coil End

_Set the spring retainer on the springs.

_Use the valve spring compressor to press down the valve
spring retainer.
elnstall the split keepers, and slowly remove the spring
Valve Head
Thickness

l \
compressor. Be sure the keepers stay in place, holding
the retainer down . 45
 ENGINE TOP END 3-11
Valve Head Thickness Valve Guides:
eMeasure the thickness of the valve head. Valve Guide Inside Diameter
*If the valve head thickness is less than the service limit, -Use a small hole gauge and a micrometer to measure
replace th e valve. the inside diameter of the valve guide at four places
down the length of the gu ide.
Valve Head Thickness *If any measurement is greater than the service limit,
Intake Standard: 0.80 - 1.20 mm replace the va lve guide (see Va lve Guide Removal and
Service Limit: 0.5 mm Valve Guide Installation).
Exhaust Standard: 0.80 - 1.20 mm
Service Limit: 0.7 mm Valve Guide Inside Diameter
Standard: 7.000 - 7.015 mm
Service Limit: 7.0Bmm

Valve Stem Bend

-Support the valve in V blocks at each end of the stem.

Valve Stem Bend

ePosition a dial gauge perpendicular to the stem.

-Turn the valve and read the variation on the dial gauge.
*If the stem bend is greater than the service limit,
replace the valve. Valve Guide Removal
eRemove the cylinder head (see Cylinder Head
Valve Stem Bend Removal).
Standard: 0.02 mm TlR eRemove the valve (see Valve Removal).
Service Limit: 0.05mm TIR -Remove the valve stem oil seal (see Valve Stem Oil Seal
Removal).
eHeat the area around the guide to 120 to 150C (250
to 300F) .
eFit the valve guide arbor (special tool) into the guide
from the combustion chamber side of the head.
eDrive the guide out of the head by hammering lightly
on the arbor.

Valve Stem Diameter

_Measure the diameter of the valve stem in two direc -
1
tions at right angles, at four different positions on the
stem.
*If any single "measurement is less than the service limit,
replace the valve .

Valve Stem Diameter

Intake Standard: 6.965 - 6.980 mm
Service Limit: 6.95 mm
Exhaust Standard: 6.950 - 6.970 mm
Service Limit: 6.94 mm A. Valve Guide Arbor: 57001163
3-12 ENGINE TOP END

Valve Guide Installation Valve Seats:

-Clean the valve guide hole in the cylinder head.
-Lightly oil the valve guide.
-Set the circlip onto the valve guide groove.
-Heat the cylinder head around the valve guide hole to
120 to 150C (250 to 300F).
-Use the valve guide arbor and a hammer to drive the
guide into the head from the outside until the circlip
on the guide seats aga inst the head.
-Allow the cylinder head to cool.
eReam the valve guide with the valve guide reamer
(special tool) even if the old gu ide is reused.
Valve Seat Inspection
-Remove the valve (see Valve Removal).
-Coat valve seat with machinist 's dy e.
ePush the valve into the guide.
eRotate the valve against the seat with a lapping tool.
.Pull the valve out, and check the seating pattern on the
valve head. It must be the correct width and even all
the way around.

Valve Seating Width

Standard: 0 .5 - 1.0 mm

NOTE
OThe valve stem and guide must be in good condition or
this check will not be valid.

*If the valve seating pattern is not correct, repair the

seat (see Valve Seat Repair) .
eMeasure the outside diameter of the seating pattern on
the valve seat.
A. Valve Guide Reamer: 57001-162 *If the outside diameter of the valve seating pattern is
too large or too small, repair the seat (see Valve Seat
Repair).

-Check valve seating (see Valve Seat Inspection).

-Install the valve stem oil seal (see Valve Stem Oil Seal Valve Seating Surface Outside Diameter
Installation).
-Install the valve (see Valve Installation ). Intake : 35.7 - 36.3 mm
-Install the cylinder head (see Cylinder Head Installation). Exhaust : 29.7 - 30.3 mm

Valve Seating Pattern

1. Valve
2. Valve Seat
Good Too Wide Too Narrow Uneven 3. Seating Area Outside
diameter
4. Seating Area Width
 ENGINE TOP END 3-13

Valve Seat Repair Valve Seat Cutter

.Clean the cylinder head thoroughly (see Cylinder Head
Cleaning) .
Use the following procedure and tools to repair the
valve seat.

Used Valve Seat Cutters

Intake Valve
45 -41.5 57001-1117
@ 32 -38_5 57001-1122
@ 60 -41.0 57001-1124
Exhaust Valve
45 -35 _0 57001-1116
32 -35_0 57001-1121
@ 60 -41.0 57001-1124
1. Cutter
2_ Cutter Holder
3_ Bar

Used Holder and Bar 5. After use, wash it with washing oil and apply thin
Holder - 7.0 57001 -1126 layer of eng ine oil before storing.
Bar 57001-1128

Marks Stamped on the Cutter:

Seat Cutter Operating Cares:
1. This valve seat cutter is developed to grind the valve
seat for repair. Therefore the cutter must not be used
for other purposes than seat repair.
2. Do not drop or shock the valve seat cutter, or the dia
mond particles may falloff.
3. Do not fail to app ly engine oil to the valve seat cutter
before grinding the seat surface. Also wash off
ground particles st icking to the cutter with washing
o il.
The marks stamped on the back of the cutter repre-
sent the follow ing.
CD ....... _.. __ . _Cutter number, selected from
CD to 0
45 _. __ ......... __ Cutter angle
24.5 . _ ... ___ .. _ ... Outer diameter of cutter
KSOO ... . .. .. _ . _ .. Manufactured lot number
Cutter
Outer Diameter of Cutter

NOTE
OA wire brush must not be used to remove the ground
particles from the cutter. That will cause the diamond Ang le of Cutter
particles to fall off.

4. Setting the valve seat cutter hol der in position, oper-

ate the cutter in one hand. Do not apply too much
force to the diamond portion.
NOTE
OPrior to grinding, apply engine oil to the cutter and
during the operation, wash off any ground particles
sticking to the cutter with washing oil.
Operating Procedures:
-Clean the seat area carefull y,
-Coat the seat with machinist's dye.
-Fit a 45 cutter to the holder and slide it into the valve
guide .
-Press down lightly on the handle and turn it right or
left. Grind the seating surface only until it is smooth.
3-14 ENGINE TOP END
Valve Seat Repair
( START )
t
I Machinist's
dye on seat

t
45 Grind
Tool: 45 Cutter
Purpose: make seating area
smooth and round

t
Measure Seating Area O.D.
Tool Vern ier Caliper
Purpose: check seat O.D.
again st spec.

t ,I
Reiults

t
I
,
Tool small I I OK I I Too big

t
I

Tool:
Purpose:
45 Grind
45Cutter
increase 0.0. of seat
area to spec.
,
Machinist's
dye on seat

32 Grind
Tool: 32Cutter
Purpose: reduce 0.0. of seat area
to spec.

Measure Seat Width

Tool: Vern ier Caliper
Purpose: check seat width
against spec.

Re+ts

t t t
I Too narrow I I OK I I Too wide I
t t
Tool:
Purpose:
45 Grind
45 Cutter
increase width of seat
area beyond spec. to
increase 0.0.
,
Machinist's
dye on seat

60 Grind
Tool : 60 Cutter
Purpose: reduce seat width
to spec.

Lap Valve
Tools: Valve lapper, grinding
compound
Purpose: perfectly match valve

l
,
and seat area; check
valve head for damage

FINISHED )
 ENGINE TOP END 3-15

[CAUTlO~] eTo measure the seat width, use a vernier caliper to

measure the width of the 45 angle portion of the seat
at several places around the seat (see Valve Seat In
000 not grind the seat too much . Overgrinding will ,pection ).
reduce valve clearance by sinking the valve into the
*If the seat width is too narrow, repeat the 45 grind
head. If the valve sinks too far into the head, it will be
un til the seat is slightly too wide, and then return to
impossible to adjust the clearance, and the cylinder
the seat O .D. measurement step above.
head must be replaced..
*If the seat width is too wide, make the 60 grind
described below.
*If the seat width is within the specified range, lap the
valve to the seat as described below.
Valve Seat Repair eGrind the seat at a 60 angle until the seat width is
within the specified range.
oTo make the 60 grind, f it a 60 cutter to the holder,
and slide it into the valve guide.
aTurn the holder, while pressing down lightly.
Widened width of
Volume ground DAfter making the 60 grind, return to the seat width
engagement by machining
by 32 cutter measurement step above.
with 45 cutter
eLap the valve to the seat, once the seat width and 0.0.
are within the specified range.
aPut a little coarse grind ing compound on the face of
the valve in a number of places arou nd the valve head.
a$pin the valve against the seat until the gr inding com-
pound produces a smooth, matched surface on both
the seat and the valve.
ORepeat the process with a fine grindi ng compound.

Vo lume ground
by 60 cutter Valve Lapping

eMeasure th e outside diameter of the seating surface

with a vernier caliper (see Valve Seat Inspection).
*If the outside diameter of the seating surface is too
small, repeat the 45 grind until the diameter is within
the specified range.
*If the outside diameter of t h e seating surface is too
large, make the 32 grind described below.
*If the outside diameter of the seat in g surface is within
the specified range, measure the seat width as described
below. 1. Lapper
eGrind the seat at a 32 angle until th e seat 0.0. is 2. Va lve Seat
within the specifi ed range. 3. Valve
aTo make the 32 grind, fit a 32 cutter to the holder,
and sl ide it into the va lve guide.
aTurn the holder one turn'at a t ime while pressing down
very lightly . Check the ,eat after each turn.
eThe seating area should be marked about in the middle
[CAUTIO~ I of the valve face .
* If the seat area is not in the right place on the valve,
aThe 32 cutter removes material very quickly. Check check to be sure the valve is the correct part. If it is, it
the seat outside diameter frequently to prevent may have been refaced too much; replace it.
overgrinding. eBe sure to remove all grinding compound before
assembly.
OAfter making the 32 grind, return to the seat 0 .0. eWhen the engine is assembled, be sure to adjust the
measurement step above. ~alve clearances (see Valve Clearance Adjustment).
3-16 ENGINE TOP END

Valve Springs:
Valve Spring Removal/Installation
eThe valve springs are removed and installed dur ing valve
removal and installation (see Valve Removal and Va lve
Installation) .
.Push the seal clip down over the seal until it seats in the
groove in the seal.
elnstall the valve (see Valve Installation).

Camshaft Sprocket
Valve Spring Free Length
eMeasure the valve spring free length with a vernier
caliper. Camshaft Sprocket Removal
*If the free length is less than the service limit, replace eRemove the fue l tank (see Fuel Tank Removal in the
the spring. Fuel System chapter).
-Unscrew the left engine cover guard screws, and take
off the guard.
Valve Spring Free Length -Remove the cover center plug.
Inner Standard: 32.4mm -Remove the bolts and take off the camshaft cover.
Service Limit: 31.1 rnm olt may be necessary to pry the cover off with a screw-
Outer Standard: 37.3 mm driver. There are prying gaps under the screw hole
Service Limit: 35.8 rnm bosses.

Valve Stem Oil Seals:

Valve Stem Oil Seal Removal
eRemove the valve (see Valve Removal).
eRemove the seal clip with a small screw driver or other
pointed tool.
ePull the valve stem oil seal off the end of the valve
gu ide. The inner and outer spring seats can be removed
from the head.

A. Camshaft Cover B. Cylinder Head Vent Hose

-Turn the crankshaft with a wrench on the alternator

t rotor bolt until the "LF300" mark on the camshaft
sprocket aligns with the pointer on the cylinder head.

A. Oil Seal C. Inner Spring Seat

B. Clip D. Outer Spring Seat

Valve Stem Oil Seal Installation

NOTE
aFar best res'-!'ts, do not reuse old valve stem oil seals,
espec;ally if valves are replaced.

eSe sure the end of the valve guide is clean.

eBe sure the inner and outer spring seats are in place.
eOil the inside of the seal and slip it over the end of the
guide. A. Pointer B. "LF300" Mark
 ENGINE TOP END 3-17

-Remove the camshaft chain tensioner (see Camshaft
.Chain Tensioner Removal).
-Remove the camshaft sprocket bolt.
o Hold the crankshaft from turning with a wrench on the
alternator rotor bolt.
-Slide the sprocket off the shoulder on the camshaft and
out from under the chain.
-Support the chain on a screwdriver or other tool stuck
in the hole in the head.
-Screw in the bolt and tighten it to the specified torque
(see Exploded View), while holding the crankshaft
from turning with a wrench on the alternator rotor
bolt.
-Install the camshaft chain tensioner (see Camshaft
Chain Tensioner Installation).
-Sefore going any further, check the cam timing.
oTurn the crankshaft counterclockwise with a wrench
on the alternator rotor bolt, until the "LF300" mark
on the sprocket realigns with the pointer on the head .

Camshaft Sprocket Installation

-Remove the timing inspection plug, and check to see
that the "T" mark on the alternator rotor aligns with olf any resistance is felt when turning the crankshaft,
the slot. stop immediately, or you may bend the valves.

oThe "T" mark on the alternator rotor should align with

the slot.
*If the camshaft timing is not correct, remove the
sprocket from the camshaft, and install it again as
detailed above.
-Smear a little engine oil on the camshaft cover D-ring,
and push the cover into place.
-Put in the camshaft cover bolts and tighten them
securely.
-Install the timing inspection plug, cover center plug,
and guard.
-Install the fuel tank (see Fuel Tank Installation in the
Fuel System chapter).

A. Slot C. Timing Inspection Plug

B, T Mark D. Cover Center Plug

Camshaft, Rocker Arms and Shafts

*If the "T" mark is not aligned, hold the camchain taut
............................................................................
and turn the crankshaft with a wrench on the alter- Rocker Arms and Shafts:
nator rotor bolt.
Rocker Arm and Shaft Removal
-Fit the sprocket under the chain and slip it over the
-Remove the camshaft sprocket (see Camshaft Sprocket
shoulder on the camshaft so that the "LF300" mark on
Removal).
the sprocket aligns with the pointer on the cylinder
-Take out the screw and remove the rocker shaft
head.
retainer.

A. Pointer B. "LF300" Mark A. Rocker Shaft Retainer

3-18 ENGINE TOP END
eTake out the bolts and remove the valve adjusting caps.
eLoosen all the cylinder head bolts to free the cylinder
head from the tension .
Pull out the rocker shafts and remove the rocker arms .
A. Rocker Arm B. Shaft
Rocker Arm and Shaft Installation
-Rocker arm and shaft ins tall ation is the reverse of
removal. Note the following.
eBefore installation of the rocker arms and shafts, turn
the camshaft so that the cam lobes point to the
"down".
A. Cam Lobes B. Down
eTighten all the cylinder head bolts as following the
specified sequence and torquing (see Cylinder Head
Installation).
-After installation, be sure to check and adjust the valve
clearance (see Valve Clearance Ad justme nt ).
Rocker Arm Inspection
-Inspect the area on the rocker where the cam rubs.
A. Rocker Wear Area B. Adjusting Screw
*If the rocker arm is scored, discolored or otherwise
damaged, replace it. Also inspect the camshaft lobes
(see Cam Wear Inspection).
- Insp ect the end of the valve clearance adjusting screw
where it con tacts the valve stem.
*If the end of the adjusting screw is mushroomed or
damaged in any way , or if the screw will not turn
smooth ly, rep lac e it. Also inspect the end of the valve
stem (see Valve Visual Inspection).
eMeasure the ins ide diameter of the rocker arm with a
dial bore gauge.
*If the rocker arm inside diameter is larger than the
service limit, replace it. Also check the rocker shaft
diameter (see Rocker Shaft Diameter).
Rocker Arm Inside Diameter
Standard: 13.000 - 13.018 mm
Service Limit: 13.05 mm
Rocker Shaft Diameter
eMeasure the diameter of the rocker shaft where the
rocker arm pivots on it with a mi crometer.
*If the rocker shaft diameter is smaller than the service
limit, replace it. Also check the rocker arm in side
dialjleter (see Rocker Arm Inspection).
Rocker Shaft Diameter
Standard: 12.976 -12.994 mm
Service Limit: 12.95 mm
 ENGINE TOP END 319

Camshaft:
Camshaft Removal
eRemove the camshaft sprocket (see Camshaft Sprocket
Removal).
eTake out the screws and remove the bearing retainer.

A. Cam Lobes

A. Bearing Retainer Cam Wear Inspection

ePull the camshaft straight out of the head.
oScrew the camshaft sprocket bolt into the end of the
camshaft and pull it with the camshaft.
eMeasure the height of each cam lobe with a micrometer.
*If the cam height is less than the service limit for either
lobe, replace the camshaft.
eGo on to Camshaft Bearing Inspection.

Cam Height
Standard: 40.876 - 40.984 mm
Service Limit : 40.78 mm

Camshaft Installation
_Camshaft installation is the reve rse of removal. Note
the following. Cam Height
eBlow the oil passage with compressed air.

Camshaft Bearing Inspection

-Check the ball bearing which is pressfitted on the
camshaft.
oSince the ball bearing is made to extremely close
tolerances, the wear must be judged by feel rather than
A. Compressed Air measurement. Clean the bearing in a high flashpoint
solvent, dry it (do not spin the bearing while it is dry),
and oil it with engine oil.
OSpin the bearing by hand to check its condition.
eCarefully push the camshaft into the cylinder head *If the bearing is noisy, does not spin smoothly, or has
with the cam lobes"dow n" . any rough spots, replace it.
3-20 ENGINE TOP END
............................................................................. Camshaft Chain 20-Link Length
Camshaft Chain, Guides and Tensioner
............................................................................. 20l in k Length

Camshaft Chain:
Camshaft Chain Removal
eRemove the camshaft sprocket (see Camshaft Sprocket

Removal).
eRemove the starter chain and sprockets (see Starter
Chain and Sprocket Removal in the Engine Left Side
chapter).
o 5 kg

-Take out the screw and remove the camshaft chain

guard below the left hand end of the crankshaft.
*If the 20 link length of the camshaft chain is greater
than the service limit, replace it.

Camshaft Chain 20-Link Length

Standard: 160.00 - 160.56 mm
Service Limit: 162 .4 mm

Camshaft Chain Guides :

Camshaft Chain Guide Removal
eRemove the cylinder head (see Cylinder Head
Removal).
A. Chain Guard eRemove the starter chain and sprockets (see Starter
Chain and Sprocket Removal in the Engine Left Side
-Remove the camshaft chain. chapter) .
ePull up the front chain guide.
eRemove the pivot bolt and take off the rear chain
guide.

Camshaft Chain Installation

ecamshaft chain installation is the reverse of removal.
Note the following.

OAlways pull the camshaft chain taut while turning the

crankshaft when the camshaft chain is loose. This
avoids kinking the chain on the lower (crankshaft)
sprocket. A kinked chain could damage both the chain
and the sprocket.

eSe sure the camshaft chain guard holes fit onto the pins
on the crankcase. A. Front Chain Guide B. Rear Chain Guide

Camshaft Chain Guide Installation

Camshaft Chain Wear -Camshaft chain guide install ation is the reverse of
eHold the camshaft chain so that it may be pulled tight. removal. Note the following .
eMeasure the length of 20 links (21 pins) with a vern ier eThe front camshaft chain guide is marked "UP" on the
caliper. top end.
 ENGINE TOP END 3-21

Camshaft Chain Guide Groove Depth

.00'

r,

eThe front guide bottom end fits into a notch in the

crankcase.

Camshaft Chain Tensioner:

Camshaft Chain Tensioner Removal
eLoosen the lockbolt in the top of the camshaft chain
tens ioner. Do not remove it yet.
o eTake out the tensioner mounting bolts and remove the
camshaft chain tensioner.

0 00 not turn the engine while the camshaft chain

tensioner is removed. Engine damage could result.

eTighten the rear guide pivot bolt to the specified

torque (see Exploded View ).

Camshaft Chain Guide Wear

eVisually inspect the rubber on the guides.
*If the rubber is damaged, cut, or is missing pieces,
replace the guide.
eMeasure the depth of the groove in the guides.
*If either camshaft chain guide is worn beyond the
service limit, replace it. A. Lockbolt B. Mounting Bolts

-Remove the lockbolt.

Camshaft Chain Guide Groove Depth
e<:arefully pull the push rod out of the tensioner bod y.
Front Standard: No groove Do not drop the ball and retainer assembly or the
Service Limit: 2.0 mm spring.
Rear Standard: No groove eSlide the ball and retainer assembly and the spring off
Service Limit: 1.5 mm the push rod .
3-22 ENGINE TOP END

Camshaft Chain Tensioner Installation Camshaft Chain Tensioner Wear

-Slip the spring over the push rod and compress it down eVisually inspect the push rod, the ball and retainer
past the hole. assembly, and the tensioner body.
elnsert a piece of wire in the hole to hold the spring in
place.

A. Push Rod D. Tensioner Body

B. Spring E. O-ring
C. Ball and Retainer Assembly

A. Spring .c. Push Rod

B. Wire eSlide the push rod in and out of the tensioner body
without the spring or ball and retainer assembly.
*If the parts show any damage, or if the push rod does
not slide smoothly in the tensioner body, replace the
camshaft chain tensioner.
eDrop the ball and retainer assembly onto the push rod .
ePush the push rod into the tensioner body.
_When the push rod is in as far as it will go, screw in the
lockbolt with its washer to lock the push rod .
Push out the wire to release the spring.

Cylinder, Piston and Rings

Chain Tensioner (push rod is locked)

Cylinder Removal/I nstallation:

3
Cylinder Removal
eRemove the cylinder head (see Cylinder Head
Removal).
eRemove the cylinder head gasket, O-rings, and dowel
pins.
ePry up the cylinder with a suitable tool to free the
cyli nd er from the crankcase.
eLift the cy lind er off.
elmmediately stuff a c lean cloth around the piston to
prevent parts or dirt from fa ll ing into the cran~case .
1. Lockbolt 4. Spring
2. Push Rod 5. O-ring
3. Ball and Retainer Assembly
Cylinder Installation

eSe sure the O-ring is in place in the tensioner body.
_After installing the tensioner, loosen the lockbolt and
then tighten it. With the bolt loosened, the spring
inside takes up any slack automatically.
NOTE
Olfa new cylinder is installed, be sure to check piston/
cylinder clearance before starting (see Piston/Cylinder
Clearance).
 ENGINE TOP END 3-23
eBlow out the oil passage with compressed air to be sure Piston Rings
it is not blocked.
-Clean any remains of the old cylinder base gasket from
the bottom of the cyl inder and the top of the crank-
case.
-Remove the cloth from around the piston.
-Be sure the dowel pins are in place in the crankcase.

~ Front

Arrow

~
"
~-~
~~

1. Top ring
2. Second ring
3. Steel rail, oil ring
4. Expander, oil ring

A. Dowel Pins B. Cylinder Base Gasket eFit the cylinder down over the piston and rings.
OHoid the rings into their groove with your fingers so
that the cylinder does not catch on them.

-Install a new cylinder base gasket.

-Turn the crankshaft until the piston is at BDC.
OHoid the camshaft chain taut.
oTurn the crankshaft until the piston is all the way
down.
-Turn the piston rings so that the gaps are in the
specified positions.

Piston Ring Gap Positions

Ring Gap Position
A.Piston Rings
Top Forward
Second Rear
O il Expander Forward
ePush the cylinder down solidly against the crankcase.
Top Oil Rail 30 Left of Forward -I nstall the cylinder head (see Cy linder Head Installation).
Bottom O il Rai l 30 Right of Forward

-Oil the piston rings and smear some oil inside the
cylinder bore.
-Hold the cylinder in position above the case and push
the camshaft chain up through the tunnel.
-The camshaft chain guides also fit inside the tunnel.
Piston and Ring Removal/Installation:
Piston and Ring Removal
-Remove the cylinder (see Cylinder Removal).
-Remove one of the piston pin snap rings.
3-24 ENGINE TOP END

Piston and Ring Installation

NOTE
Olf a new piston is used~ check piston to cylinder
clearance (see Piston/Cylinder Clearance)1 and use new
piston rings.

elnstall the oil ring expander in the bottom piston ring

groove so the ends butt together.

Oil Ring Expander Installation

A. Piston Pin Snap Ring

.Push out the piston pin, and remove the piston.

o lf necessary, use the piston pin puller assy. (special
tool).

-Install the oil ring steel rails, one above the expander
and one below it.
oSpread the rail with your thumbs, but only enough to
fit the rail over the piston.
oRelease the rail into the bottom piston ring groove.

A. Piston Pin Puller Assy: 57001910

B. Adapter "C": 57001914
eRemove the top and second piston rings.
oSpread the ring open with your thumbs.
oPush up on the opposite side with your fingers.
NOTE
oThe oil ring rails have no "topU or "bottom".
-Install the second and top rings in that order.
-Install the top and second rings so that each liN"
marked side faces up.

A. Spread. B. Push up.

eRemove the oil ring upper and lower steel rails.

OSpread the rail open with your thumbs.
OPush up on the opposite side with your fingers.
-Remove the oil ring-expander. A. "N" Mark
 ENGINE TOP END 3-25

Top and Second Rings Cylinder, Piston and Ring Maintenance:

Compression Measurement
eBefore measuring compression, do the following:
"N" mark OCheck cylinder head bolt torque (see Cylinder Head
Installation).
Top ring o Be sure the battery is full y charged (see Battery
Up Condition in the Electrical System chapter).
oWarm up the engine (if the engine will run ).
o During warm-up, check for leaks around the cylinder
head gasket .
Remove the spark plug.
"N" mark
.Set the compression gauge and adapter hose (special
2nd ring too ls) into the spark plug hol e.
.Hold the throttle wide open and crank the engine with
the starter.
.When the gauge stops rising, stop cranking and read th e
gauge .

'nstall the piston pin .

oOi l the piston pin lightly and slide it through the side
of the piston without a snap ring.
OHoid the piston in position over the connecting rod ,
with the arrow pointing forward, and slide th e piston
pin the rest of the way through the connecti ng rod and
pisto n. - ,r

A. Compression Gau ge: 57001-221

B. Adapter Hose: 570011159

Cylinder Compression
Standard: 795 - 1,240 kPa
(S.l -12.6 kg/em', 115 - 179 psi)
A. Arrow pointing forward.

*I f the compression is withi n the speci fied range, the

Olnstall a new pisto n pin snap ring. piston rings, cyl inder and va lves are probab ly in good
co nd itio n.
*I f the com pression is hi gher than the specified range,
see the Compression Too High tab le.

!CAUTIO~] *If the co mpression is belo w the specified range, sq uirt a

little oil into t he spark plug hole and repeat the
compressio n measurement.
0 00 not reuse the snap ring which was removed.
-(llf the co mp ression does not chan ge very much , the
Removal weakens and deforms th'e snap ring. It could
piston rings are probably OK. See the Wet
fall out and score the cylinder wall. Compression - No Change tab le.
-(llf the co mpression increases, the piston rings are not
seal ing properly . See the Wet Compression - Increase
.'nsta" the cylinder (see Cylinder Insta llatio n) . tab le.
3-26 ENGINE TOP END

Compression Too High

Possible Problems
Carbon build up on
piston head and cylinder
head
Cylinder head or base
gasket too thin
Solutions References
Piston Cleaning and Cylinder Head
Remove carbon
Cleaning
Valve Stem Oil Seal Inspection,
Check possible oil Valve Stem Diameter, Valve Guide
leaks to combustion Inside Diameter, and check piston
chamber oil ring for visible damage.
Cylinder Head Removal, Cylinder
Replace gaskets Head Installation, Cylinder
Removal, and Cylinder Installation

Wet Compression - No Change

Possible Problems Solutions References
Valve Clearance Check, and Valve
I mproper valve clearance Check clearance
Clearance Adjustment
Valve Seat Inspection, and Valve Seat
Worn valve seats Check seats
Repair
Valve Visual Inspection, and Valve
Burned valve Check valves
Head Thickness
Check head Cylinder Head Removal, and Cylinder
gasket Head Installation
Cylinder head leak
Check head
Cylinder Head Warp
flatness

Wet Compression - Increase

Possible Problems Solutions References
Cylinder/Piston Wear, Piston/
Too much piston-to-
Check clearance Cylinder Clearance, and
cylinder clearance
Cylinder Boring and Honing
Piston Ring and Ring Groove
Worn piston rings, and Check piston and
Wear, and Piston Ring End
ring grooves rings
Gap (top and second only).

Cylinder/Piston Wear *If any of the cylinder inside diam~ter measurements is

eMeasure the cylinder inside diameter.
oUse a dial bore gauge to measure frontto-back and
side-ta-side at the points shown below.
Cylinder Inside Diameter
Standard: 76.000 - 76 .012 mm, and less than
0.01 mm difference between any two
meas.urements
Service Limit: 76.10 mm, or more than 0.05 mm
difference between any two measure-
ments
greater t han the service limit, the cylinder must be
bored oversize and then honed (see Cylinder Boring
and Honing) . However, if the amount of boring
necessary would make the cylinder inside diameter
greater than the bore limit, the cylinder must be
replaced.
NOTE
Olf the cylinder has been bored oversize, use the
Oversize Cylinder Inside Diameter table.
 ENGINE TOP END 327
Oversize Cylinder Inside Diameter
Standard Service Limit Bore Limit
Standard plus 0.1 mm, or more than
Measure at bottom of cylinder for
0.05 mm difference between any two 77.0 mm
baseline standard diameter measurements

Oversize Piston Diameter

Standard Service Limit
75.950 - 75.965 mm plus 0.5 or 1.0
Standard size minus 0.15 mm
mm as stamped in piston head

Cylinder Diameter Measurement *If the piston diameter is less than the service limit,
replace it.

NOTE
Olf the cylinder has been bored oversize, use the
Oversize Piston Diameter table.
10mm

E9 40mm
20mm

Piston/Cylinder Clearance
-Measure the piston diameter (see Cylinder/Piston Wear).
eMeasure the cylinder inside diameter with a dial bore
gauge at the bottom of the cylinder.
-Subtract the piston diameter from the cylinder inside
diameter to get the piston/cylinder clearance.
*If the piston/cylinder clearance is less than the
specified range, use a smaller piston or increase the
cylinder inside diameter by honing (see Cylinder Boring
eMeasure the piston diameter at the point shown with a and Honing).
micrometer. *If the piston/cylinder clearance is greater than the
specified range, use a larger piston or bore to the next
larger oversize (see Cy lind er Boring and Honing).
Piston Diameter
Standard: 75.950 - 75.965 mm Piston/Cylinder Clearance
Service Limit: 75.81 mm
Standard: 0.035 - 0.062 mm

Piston Diameter Measurement

Cylinder Boring and Honing

-When boring and honing a cylinder, fo llow the boring
and honing too l manufacturer's instructions. Note the
following .
-Before boring a cylinder, measure the diameter of the
piston to be used. Bore and hone the cylinder to
obta in the standard piston/ cylinder clearance specified.
_Cylinder inside diameter must not vary by more than
0.01 mm at any point.
-Do not measure the cyli nd er inside d iameter imme-
diately after boring or honing, because the boring and
honing operations heat the cylinder. Heat affects
cylinder size.
328 ENGINE TOP END

Piston/Cylinder Seizure
e ln case of seizure, remove the cylinder (see Cylinder
Removal).
_Visua ll y inspect the cylinder and piston damage.
*If there is only light damage, smooth the piston with
#400 emery cloth. Remove small aluminum deposits
from the cylinder with #400 emery cloth or light
honing.
*If the damage is severe, the cylinder must be bored
oversize and an oversized piston installed.

Piston Cleaning
eRemove the piston and piston rings (see Piston and
Ring Removal).
[CAUTlO~J
ONever clean the piston head with the engine assembled.
Carbon particles will fall between the piston and
cylinder and damage the crankshaft bearings.
I
A. Thickness Gauge
*If the piston ring groove clearance is greater than the
service limit, measure the ring thickness and groove
width as follows to decide whether to replace the rings,
the piston or both.
eMeasure the piston ring groove width.
OUse a vernier caliper at several points around the
piston .

Piston Ring Groove Width

esc rape the carbon off the piston head. Top Standard: 1.22 -1.24 mm
cUse the scraping tool carefully . Do not gouge the Service Limit: 1.32 mm
piston head. Second Standard: 1.21 -1 .23 mm
-Clean the piston ring groove with a broken piston ring Service Limit: 1.31 mm
or other suitable tool. Oil Standard: 2.51 - 2.53 mm
Service Limit: 2.61 mm

*If the width of any of the three grooves is wider than

the service limit at any point, replace the piston.
OBe careful not to widen the ring grooves or the piston eMeasure the piston ring thickness.
must be replaced. oUse a micrometer to measure at several points around
the ring.

Piston Ring Thickness (Top & Second)

Standard: 1.170 -1.190 mm
Service Limit: 1.10 mm
Piston Ring and Ring Groove Wear
*If any of the measurements is less than the service limit
-Visually inspect the piston rings and ring grooves.
on either of the rings, replace the entire set of rin gs.
*If the piston rings are worn unevenl y or damaged,
replace t hem.
NOTE
*If the ring grooves are worn unevenly or damaged,
replace both the pi ston and piston rings. OWhen using new rings in a used piston, check for
eMeasure the clearance between the top and second uneven groove wear. The rings should fit perfectly
rings and their grooves. parallel to the groove sides. If not, replace the piston.
o lnstall the rings in their grooves.
OUse a thickness gauge to measure the clearance at
several points around the piston.

pjston Ring End Gap (top and second only)

eRemove the piston rings (see Piston and Ring Removal).
Piston Ring/Groove Clearance ePush each ring (one at a time) into the bottom end of
Top Standard: 0.03 - 0.07 mm the cylinder.
Service Limit: 0.17 mm OUse the piston to push it in to be sure it is square.
Second Standard: 0.02 - 0.06 mm eMeasu re the gap between the ends of the ring with a
Service Limit: 0.16 mm th ickness gauge. .
 ENGINE TOP END 3-29

A. Piston Ring B. Thickness Gauge A. Drain Plug c. Mounting Bolt

B. Spark Arrester
*If the end gap of either ring is greater than the service
limit, replace the entire set of rings.
WARNING.

Piston Ring End Gap (Top & Second) 000 not run the engine in a closed area. Exhaust gases
Standard: 0.20 - 0.35 mm contain carbon monoxide; a colorless, odorless,
Service Limit: 0.7mm poisonous gas. Breathing exhaust gas leads to carbon
monoxide poisoning, asphyxiation, and death .
oNever run the engine with the spark arrester removed.
Hot carbon particles may start a fire.

NOTE
i
ORun the engine with the spark arrester installed during
Exhaust System cleaning. This keeps the exhaust pressure higher and
makes carbon panicles purge easier.

Spark Arrester: eStop the engine .

This vehicle is equipped with a spark arrester ap- elnstall the drain plug.
proved for offroad use by the U.s. Forest Service. It eRemove the spark arrester mounting bolt from the
must be properly maintained to ensure its efficiency. In muffler.
accordance with the Periodic Maintenance Chart, clean
ePull the spark arrester out of the muffler.
the spark arrester.
eScrape carbon deposits off the spark arrester and slide
it back into the muffler.
elnstall the mounting bolt and tighten it securely.
Spark Arrester Cleaning

I WARNING.
aTa avoid burns, wear gloves while cleaning the spark Exhaust Pipe and Muffler:
arrester. Since the engine must be run during this
Exhaust Pipe and Muffler Removal
procedure, the muffler will become hot.
e Loosen the muffler clamp bolt until the clamp turns
freely on the muffler.
-Take out the muffler mounting bolts. Do not lose the
coll ars.
OThe spark arrester must be installed correctly and OFor extra clearance, first remove the rear fender
functioning properly to provide adequate fire pro- assembly (see Rear Fender Removal in the Frame
tection. chapter).
eRemove the muffler from the rear of the frame.
eRemove the drain plug on the rear muffler. eTake off the exhaust pipe holder nuts at the cylinder
eln an open area away from combustible materials, start head.
the engine with the transmission in neutral. -Work the exhaust pipe out of the frame and remove it.
eRaise and lo wer engine speed while tapping on the -Remove the exhaust pipe ho ld er and split coll ar.
muffler with a rubber mallet until carbon particles are -Remove the exhaust pipe gasket from the cylinder
purged from the muffler. head.
3-30 ENGINE TOP END
OPosition the exhaust pipe in the exhaust port.
oSlide the holder into place on the studs.
oThread on the nuts, but do not tighten them yet.
eFit the gasket into the muffler so that the chamfered
side of the gasket faces to the front.

A. Mounting Bolts

A. Chamfer

eSl ip the muffler in to place from tlie rear of the frame,

so that it fits over the exhaust pipe.
aBe sure that the collars are in place in the rubber
dampers in the muffler.
OHoid the muffler up and put in the mounting bolts, but
do not tighten them yet.
eTighten the exhaust pipe holder nuts evenly and
securely.
A. Holder Nuts B. Clamp _Tighten the muffler mounting bolts securely_
eTighten the muffler clamp bolt securely.
elf the rear fender was removed, install it (see Rear
Fender Installation in the Frame chapter).

Exhaust Pipe and Muffler Installation

-Smear a little grease on a new exhaust pipe gasket and
stick it in to the exhaust port in the cylinder head.
_Slip the exhaust pipe holder over the exhaust pipe.
eAttach the exhaust pipe loosely to the cylinder head.
OTape the sp lit collar in place as shown.
Exhaust System Inspection
eBefore removing the exhaust system, check for signs of
leakage at the exhaust pipe gasket in the cylinder head
and at the muffler clamp .
*If there are signs of leakage around the exhaust pipe
gasket, it should be replaced. If the muffler-to-exhaust
pipe joint leaks, tighten the clamp.
eRemove the exhaust system (see Exhaust Pipe and
Muffler Removal).
el nspect the gasket for damage and signs of leakage.
*If the gasket is damaged or has been leaking, replace it.
-Check t he exhaust pipe and muffler for dents, cracks,
rust and holes.
*If the ex haust pipe or muffler is damaged or holes, it
should be replaced for best performance and least noise.

A. Split Keeper B. Holder

 ENGINE LEFT SIDE 4-1

Engine Left Side

Table of Contents

Exploded View ...... .. . ... . _ ................... . ....... .. . 4-2

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... ... 4-3
Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... ... 4-3
Left Engine Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... ... 4-4
Left Engine Cover Removal. . . . . . . . . . . . . . . . . . . . . . . . .... ... 4-4
Left Engine Cover Installation. . . . . . . . . . . . . . . . . . . . . . . . .. ... 4-4
Alternator Rotor and Stator (see Electrical System chapter)
Pickup Coil (see Electrical System chapter)
Starter Clutch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....... 4-4
Starter Clutch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . ....... 4-4
Starter Clutch Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . ... .. 4-5
Starter Clutch Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . ... .. 4-5
Starter Chain and Sprockets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... .. 4-5
Starter Chain and Sprocket Removal. . . . . . . . . . . . . . . . . . . ... .. 4-5
Starter Chain and Sprocket Installation ........... _ . . . . . ... .. 4-5
Starter Chain Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
42 ENGINE LEFT SIDE

Exploded View
.......................................... ................................. .

Engine No. 017644 and up

L : Apply a non-permanent locking agent.

Tl : 49 N'm (5.0 kgm. 36 ftlb)
 ENGINE LEFT SIDE 4-3

Specifications

Item Standard Service Limit

Starter Chain 20-Link Length 155.8-156.1 mm 158.0 mm

Special Tool

Along with common hand tools, the following more

special ized tool is req uired for complete engine left
side servicing.

Flywheel Holder: 57001-308

NOTE
OThe flywheel holder (57001-1313) can be used instead
of the flywheel holder (57001-308).
4-4 ENGINE LEFT SIDE

Left Engine Cover

Left Engine Cover Removal

.Place an o il pan be neath the engine left side .
eDi scon nect the al ternator co nnector and pickup coi l
co nn ector.
eRemove the left engine cover.
o Remove the differential shift lever case.
oUnsc rew the cover mounting bolts.

A. Grommet for Alternator Lead

B. Grommet for Pickup Coil Lead

-Tighten the front gea r case 8 mm mounting bolt to t he

specified to rque (see Exp loded View in the Final Dri ve
chapter).
eAdd engine o il (see En gine Oil and Oil Filter Change in
the Engine Right Side chapter).

A. Left Engine Cover Mounting Bolts

B. Differe ntia l Shift Lever Case

Left Engine Cover Installation
-Left engi ne cover installation is the reverse of removal.
Note the following.
eBe su re all of the o ld gasket has been removed fro m the
left engin e cover and the left hand crankcase seali ng
surfaces.
-Check the dowel pi ns are in place, and fit a new gasket
o n the cra nkc ase.
Starter Clutch
Starter Clutch Removal
-Remove the alternator rotor (see Alternator Rotor
Removal in the El ectrical System chapter).
eH o ld the roto r with t he flyw hee l holder (special tool)
and take out the All en bolts.

A. Dowe l Pins A. Flywheel Holder: 57001-308

eFit th e lead gromme ts into the notch es on the left

e ngin e cove r. eTake out the one-way clutch.
 ENGINE LEFT SIDE 45
NOTE
OExamine the staner chain sprocket as well. Replace it
if it is worn or damaged.

A. One-way Clutch

Starter Clutch Installation

-Starter clutch installation is the reverse of removal. A. Inspect surface.
Note the following.
eApply a non-permanent locking agent to the threads of
the Allen bolts which hold the starter clutch to the
flywheel.
-Tighten the Allen bolts to the specified torque (see
Exploded View) . Starter Chain and Sprockets

Starter Chain and Sprocket Removal

eRemove the alternator rotor (see Alternator Rotor
Starter Clutch Inspection Removal in the Electrical System chapter).
eRemove the left engine cover (see Left Engine Cover -Take out the screw and remove the sprocket guide.
Removal ).
eTurn the alternator rotor.

A. Sprocket Guide

A. Turn freely. B. Turn with starter chain sprocket.

.Pull both sprockets off simultaneously with the chain.

*If the alternator rotor turns counterclockwise freely

from the starter chain sprocket, but not clockwise, the
clutch is operating as it should.
*If the clutch does not operate as its should, or if it
makes noise, disassemble it (see Starter Clutch
Removal), examine each part visually, and replace any
worn or damaged parts.
Starter Chain and Sprocket Installation
-Starter chain and sprocket installation is the reverse of
removal. Note the following.
-The protruding side of the small sprocket must face in.
4-6 ENGINE LEFT SIDE

A. Toward engine.

eThe protruding side of the large sprocket must face

out.

Starter Chain Wear

eHold the starter chain taut with a force of about 5 kg
in some manner, and measure a 20link length. Since
the chain may wear unevenly, take measurements at
several places.
*If any measurement exceeds the service limit, replace
the chain.

Starter Chain 20Link Length

Standard: 155.8 - 156.1 mm
Service limit: 158.0 mm

Starter Chain Measurement

1st 2nd
20!ink Length 21st
 ENGINE RIGHT SIDE 5-1

Engine Right Side

Table of Contents

Exploded View . ... .. .. . . . . . . . . . ... . 52 Primary Gear Installation. . . . . . . . . . 5-9

Specifications . .. . . . . . . . . . . . . ... .. . . 53 Seco ndar y Gear Removal . . . . . . . . . . 5-9
Special Tool s . . . . . . . . . . . . . . . . _ . ... . 53 Secondary Gear Install atio n. . . . . . . . . 59
Right Engine Cover . . . . . . . . . . . . . . ... . 54 Primary and Secondary Gear Damage . . 5-9
Right Engine Cover Removal . .... .. . 54 Gear Backlash. . . . . . . . . . . . . . . . .. 510
Right Engine Cover Installation . .... . 54 Primary Gear /Crankshaft Wear. . . . . 5-10
Clutches .. . . . . . . . . . . . . . . . . . . . . . . . 5-4 Secondary Gearl Collar Wear. . . . . . .. 510
Clutch Adjustment . . ... .... . . .. . . . 54 Lubrication System . . . . . . . . . .. .. . ... . 511
Clutch Adjustment .... . ....... 54 Engine Oil and Filter . . . . . . . . . . . . . . . 511
Clutch Removal . . . . . . . . . . . . . .. . . . 55 Engine Oil Level Inspection . . . . . .. . . 511
Clutch Removal . . . . . . . . . . . .. . . 55 Engine Oil and Filter Change . ... . .. . 511
CI utch In stallation . .... . . . . . . . . . . 56 Oil Pump . . . . . . . . . . . ..... . .. .. . . 512
Clutch Inspection . .. . . . . . . . . . . ... . 57 Oil Pump Removal. . . . . . . .. . . . . . . 512
Primar y Clutch Housi ng Wear ...... . 57 Oil Pump Installation . .. ... . . . . . . . 512
Primary Clutch Shoe Lining Wear . . .. . 57 Oil Pump Disassembly . . . . . . . . . . . . 513
One-way Clutch Inspection . . . . . . . . . 57 Oil Pump Assembly . . . . . . . . . . . . . . 513
Friction Plate Wear and Damage . . . . . . 58 Oil Pump Inspection . . . . . . . . . . . . . 513
Friction Plate and Steel Plate Warp . . . . 58 Oil Screen . . . . . . . . . . . . . . ... . ... . 513
Secondary Clutch Housing Oil Screen Removal . . . . . . . . . . . . . . 513
Finger Damage . . . . . . . . . . . . . . . 58 Oil Screen Installation . . . . . . . . . . . , 513
Secondary Clutch Hub Spline Damage . . 58 Oil Screen Cleaning and In spection . .. . 514
Secondary Clutch Spring Wear . .. . .. . 58 Oil Filter Bypass Valve . . . . . . . . ... , .. 514
Clutch Release . . . . . . . . ... . . . . . . . . 59 Bypass Valve Removal . . . . . . . . .. . . 514
Clutch Release Removal . .. .. . . ... . 59 Bypass Valve Installation . .. .. , 514
Clutch Release Installation . .. . . . . . . 59 Bypass Va lve Cleaning and Inspection . . 514
Clutch Release Wear . .. 59
Primary Reduction . . . . . . . . . . . . . . . . . . 5-9
Primary Gear Remova l. . . . . . . . . . . . 5-9
5-2 ENGINE RIGHT SIDE

Exploded View

M : Apply a molybdenum disulfide grease.

Q : Apply an oil to the threads and seated surface.
T1: 125 N-m (13.0 kgm. 94 ft-Ibl
T2: 12 N-m (1.2 kg-m. 104 in-Ibl
T3: 78 N-m (8.0 kg-m. 58 ft-Ibl
T4: 29 N-m (3.0 kg-m. 22 ft-Ibl
 ENGINE RIGHT SIDE 5-3

Specifications

Clutches :

Item Standard Service Limit

Primary Clutch:
Primary Clutch Housing I nside Diameter 125_0 - 125_2 mm 125_5 mm
Primary Clutch Shoe Groove Depth 1_0 mm 0.5mm
Secondary Clutch:
Friction Plate Thickness 2.92 - 3.08 mm 2.8mm
Friction Plate Warp Under 0.15 mm 0.3mm
Steel Plate Warp Under 0.2 mm 0.3 mm
Clutch Spring Free Length 30.38 mm 28.8 mm

Primary Reduction:

Item Standard Service Limit

Gear Backlash 0.02 - 0.11 mm 0.14 mm
Primary Gear I nside Diameter 27.000 - 27.021 mm 27.03 mm
Crankshaft Diameter 26.959 - 26.980 mm 26.94 mm
Secondary Gear Inside Diameter 25.000 - 25.021 mm 25.03 mm
Secondary Gear Collar Diameter 24.970 - 24.985 mm 24.95 mm

Lubrication System:
Item Standard Service Limit

Engine Oil: Grade SE or SF class --

Viscosity SAE 10W-30, 10W-40, lOW-50,
20W-40,20W-50 --
Capacity: 1.7L --

Gear Holder: 57001-1015

Special Tools

Along with common hand tools, the following

more specialized tools are required for complete engine
right side serv icin g.
Flywheel Holder: 57001-308

NOTE
oThe flywheel holder 157001-1313) can be used instead
of the flywheel holder 157001-308).
5-4 ENGINE RIGHT SIDE

Right Engine Cover

Right Engine Cover Removal

eDrain the engine oil (see Engine Oil and Oil Filter
Change).
eRemove the right footpeg .
-Take out the bolts and remove the right engine cover.
oThe clutch release assembly comes out with the right
engine cover.

Right Engine Cover Installation

eBe sure all of the old gasket has been removed from the
right engine cover and the right hand crankcase sealing A. Compressed Air
surfaces.
ec:heck that the following items are in place:
Dowel pins -Install the right engine cover and tighten the screws
Clutch release cams and ball assembly securely.
eAdjust the clutch (see Clutch Adjustment).
elnstall the right footpeg.
eFili the engine with oil (see Engine Oil and Oil Filter
Change).

Clutches

Clutch Adjustment:
Clutch Adiustment
aRemove the clutch release adjusting screw cover.
A. Dowel Pins
B. Clutch Release Cams and Ball Assembly
oThe projected portion of the ball assembly must be
faced in.

A. Clutch Release Adjusting Screw Cover

aloosen the clutch release adjusting screw locknut.

A. Projected Portion
OAp ply a molybdenum disulfide grease to the pivot of
the outer cam.
eFit a new right engine cover gasket.
eUsing compressed air, blowout any particles which
may obstruct the oil passage on the right engine cover.
aTurn the adjusting screw clockwise until it becomes
hard to turn.
aTurn the adjusting screw counterclockwise until it
becomes hard to turn.
eTighten the locknut without changing the adjusting
screw position.
 ENGINE RIGHT SIDE 5-5

A. Adjusting Screw B. Locknut A. Recess

eTake out the primary clutch hub assembly, in'ner race,

and one-way clutch :
elnstall the clutch release adjusting screw cover. Dinner race can easily be removed by turning clockwise.

Clutch Removal:
Clutch Removal
eRemove the right engine cover (see Right Engine Cover
Removal ).
-Using the gear holder (special tool), hold the primary
gear and secondary gear to keep them from turning,
and remove the primary clutch hub nut.

A. Turn clockwise. C. One-way Clutch

B. Inner Race

.Remove the secondary clutch hub and clutch plate

assembly as a set.
.Remove the secondary clutch housing and sleeve.
There is the spacer behind the sleeve .
To remove the secondary clutch plates, unscrew the
clutch spring bolts and take off the spring plate and
springs.

A. Gear Holder: 57001-1015 D. Ball Bearing

B. Primary Clutch E. Pusher
C. Secondary Clutch

elf the seconday clutch will be removed, remove the

pusher and ball bearing from the secondary clutch
spring plate, and loosen the secon dary clutch hub nut
at this time .
-;-'.'''-, Llle secondary clutch until the recess on the
secondary clutch housing comes against the primary
gear, and pull out the primary clutch housing with the
hub. A. Spring Plate B. Secondary Clutch Hub
5-6 ENGINE RIGHT SIDE

Clutch Installation
Primary and secondary clutch instaltation is the reverse
of removal. No te the following.
-Assemble the secondary clutch plates.
o lnstall the friction plates and steel plates to the clutch
hub, starting with a friction plate and alternating them.
.cross tighte n the secondary cl utch sp ring bolts evenly
to th e specified torque (see Explo ded View) .
e Be sure that the clutch whee l spli nes fit onto th e cl utch
hub splines. When t he cl utch wheel is installed
correctly, there is no gap be tween the clutch whee l an d
the nex t friction plate, and clutch plates have no play.

( CAUTlO~J
Olf new dry steel plates and friction plates are installed,
apply engine oil to the surfaces of each plate to avoid
clutch plate seizure.

o lnstall the clutch wheel so that the mark on the clutch

wheel is aligned with the mark on the clutch hub.

A. Clutch Wheel C. No gap

B. Friction Plate

-Fit the one-wa y clutch in to the primary clutch housing.

A. Align th e marks.
B. Clutch Wheel
OFit the projec tion on the cage into the groove o n the
hou sing first, and then install the oneway clutch
completely.
C. Clutch Hu b

Olnsta ll the c lutch spring plate with the springs an d

spring bolts temporarily, and fit the cl utc h hub an d
plate assemb ly in to t he cl utch housi ng aligning the
friction plate tangs with the cl utch housing fi ngers and
clutch hub spli nes wit h the dri ve shaft spli nes.

A. Projection B. Groove

eTighten the primary an d secondary clutch hub nuts to

A. Align the friction plate tangs with the clutch hou sing t he specified torque (see Exploded View).
fingers. OApp ly a small amou nt of oil to the threads an d the
B. Align the clutch hub splines with the drive shaft seating surfaces of the primary and secondary clutch
spli nes. hub nu ts.
 ENGINE RIGHT SIDE 5-7

Clutch Inspection:
Primary Clutch Housing Wear
eMeasure the inside diameter of the clutch housing
where the shoes wear against it.
o Use calipers and measure at several points as shown.
*If an y measurement is greater than the service limit,
replace the primary clutch housing.

v One-way Clutch Inspection

f
eRemove the right engine cover (see Right Engine Cover
Removal).
-Turn the primary clutch housing by hand. When
viewed from the right side of the engi ne, the primary
clutch housing shou ld turn counterclockwise freely,
but should not turn clockwise.

Primary Clutch Housing Inside Diameter

Standard: 125.0 -125.2 mm
Service Limit: 125.5 mm

Primary Clutch Shoe Lining Wear

-Visuall y inspect the primary clutch shoe lining for
uneven wear, discoloration, or missing frict ion
material, cracks, or other damage.
*If any of the linings are damaged, replace the shoes as a
set.

A. Turn freely. B. Locked.

*If the one-way clutch does not operate as it should or if

it makes noise, go to the next step.
-Remove the primary clutch (see Clutch Removal).
Visually inspect the clutch parts: one-way clutch, inner
race, and outer race at the primary clutch housing.
*If there is any worn or damaged part, replace it.

A. Primary Clutch Shoe Linings

eMeasure the shoe groove depth.

o Use a depth gauge, and measure at several po in ts as
shown.
*If any measurement is less than the service limit,
replace all shoes as a set.

Primary Clutch Shoe Groove Depth

Standard: 1.0mm A. 1nner Race c. Ou ter Race
Service Limit: 0.5mm B. Oneway Clutch
5-8 ENGINE RIGHT SIDE

Friction Plate Wear and Damage Secondary Clutch Housing Finger Damage
-Visually inspect the friction plates for uneven wear, eVisually inspect the fingers of the clutch housing where
discoloration, or missing friction material, cracks, or the housing of the friction plates hit them.
other damage. *If they are badly worn or if there are grooves cut where
*If any of the friction plates are damaged, replace the tangs hit, replace the housing. Also, replace the
~-. . friction plates if their tangs are damaged.
eMeasure the thickness of the friction paltes at several
points.

Friction Plate Thickness

Standard: 2.92 - 3.08 mm
Service Limit: 2.8mm

Friction Plate Thickness

A. Clutch Housing Finger

Secondary Clutch Hub Spline Damage

*It any of the measurements is less than the service
-Visually inspect where the teeth on the steel plates
limit, replace the friction plate.
wear against the splines of the clutch hub.
*If there are notches worn into the splines, replace the
clutch hub. Also, replace the steel plates if the ir teeth
are damaged.
Friction Plate and Steel Plate Warp
-Lay each plate on a surface plate.
-Hold one side down and use a th ickness gauge to
measure the gap between the other side of the plate
and the surface plate .
*If any of the clutch plates is warped beyond the service
limit, replace it.

Friction Plate and Steel Plate Warp

Standard: Under 0.15 mm (Friction Plate)
Under 0.2 mm (Steel Plate)
Service Limit: 0.3mm

A. Clutch Hub Spline

Secondary Clutch Spring Wear

eMeasure the spring free length.
*If measurement is less than the service limit, replace
it.

Clutch Spring Free Length

A. Friction Plate C. Thickness Gauge Standard: 30.38 mm
B. Steel Plate Service Limit: 28.8 mm
 ENGINE RIGHT SIDE 5-9

Clutch Release: *If the Coring is damage, deteriorated, compressed, or

Clutch Release Removal hardened, replace it. If the cam area is damaged, or if
eRemove the right engine cover (see Right Engine Cover the ball assembly is worn visibl y, replace the damaged
Removal). part. Also inspect the clutch release lever spring for
eRemove the clutch release adjusting screw cover from damage. Replace it if necessary.
the outsid e of the right engine cover.
-Unscrew the locknut and adjusting screw.
eTake off the flat washer and Oring.
ePull the clutch release lever and spring out of the right
engi ne cover.
eRemove the Ering, and pull the clevis pin from the
clutch release lever clevis.

........................................................................... ..
Primary Reduction
.............................................................................
Primary Gear Removal
eTh e primary gear is removed during primary clutch
removal (see Clutch Removal).

Primary Gear Installation

A. Clutch Release Lever D. Ering eThe primary gear is installed during primary clutch
B. Clevis E. Spring installation (see Clutch Installation).
C. Pin
Secondary Gear Removal
eThe secondary gear is removed during clutch removal
ePul1 the release cams and ball assemb ly from the shift (see Clutch Removal) .
shaft.
Secondary Gear Installation
eThe secondary gear is installed during clutch
Clutch Release Installation installation (see Clutch Installation).
eclutch release installation is the reverse of removal.

Primary and Secondary Gear Damage

Clutch Release Wear eVisually inspect the teeth on the primary and
eVisually inspect the O-ring at the clu tch adjusting secondary gears.
screw, the cam area, and the ball assembly. *If heavy damage is found, replace the damaged gear.
*If light damage is found, repair it with an oil-stone.

A. Cam Area
5-10 ENGINE RIGHT SIDE

Gear Backlash
eRemove the right engine cover (see Right Engine Cover
Removal).
-Set a dial gauge against the teeth on one gear, and move
the gear back and forth whi le holding the other gear
steady. The difference between the highest and the
lowest gauge readings is the amount of backlash.
*If the amount of backlash exceeds the service limit,
replace both gears.

Gear Backlash
Standard : 0.02 -0.11 mm
Service Limit: 0.14 mm

*If the inside diameter of the primary gear is greater

than the service limit, replace it.
*If the outside diameter of the crankshaft is less than
the service limit, replace it.

Primary Gear Inside Diameter

Standard: 27.000 - 27.021 mm
Service Limit: 27.03 rnm
Crankshaft Diameter
Standard: 26.959 - 26.980 mm
Service Limit: 26.94 mm

A. Move back and forth lightly. B. Hold steady.

Secondarv Gear/Collar Wear

eMeasure the in side diameter of the secondary gear.
eMeasure the outside diameter of the collar mounting on
the drive shaft.

Primary Gear/Crankshaft Wear

eMeasure the inside diameter of the primary gear.
eMeasure the outside diameter of the crankshaft.

1r

*If the inside diameter of the secondary gear is greater

than the service limit, replace it.
*If the outside d iameter of the coll ar is less than the
service limit, replace it.
 ENGINE RIGHT SIDE 5-11

Secondary Gear Inside Diameter Engine Oil and Filter Change

Standard: 25.000 - 25.021 mm -Warm up t he engine, then shu t if off.
Service Limit: 25.03 mm -Set a pan beneath t he engi ne and remove the oil drain
plug.
Secondary Gear Collar Diameter
Standard: 24.970 - 24.985 mm
Service Limit: 24.95 mm

Lubrication System

Engine Oil and Filter:

Engine Oil Level Inspection
-Park the vehicle so that it is level, both side-to-side and A. Oi l Drain Plug
front-to-rear.
-If the o il has just been changed, start the engine and
-Remove the oil filter.
run it for several minutes to fill the oi l fi lter.
oTake out the oi l filter cover bolts.

OAllow the engine to idle for several minutes so that oil

may reach all parts of the engine. Racing a "dry"
engine may cause severe damage.

-Stop the engine and wait several minutes for all the oil
to drain back to the sump.
echeck the level of the oil in the window gauge in the
lower part of the ri ght engine cover.
.The o il leve l should be between the lines next to the
gauge.

A. Oil Filter Cover Bolts

o Remove the oi l filter cover.

o Pull out the o il filter; the filter mountin g pin wil l
probab ly come out with it.

A. Gauge B. Leve l Lines

*If the level is too hi gh, suc k the excess oil out the filler
hole with a sy ringe or other suitable device.
*If the level is too low, add oil throu gh the filler hole.
Use the same type and make of oil that is already in
the engi ne. A. Oil Filter B. Filter Mounting Pin
5-12 ENGINE RIGHT SIDE

o Pull the filter off the pin.

elnstall the new filter.
a Be sure both filter grommets are in place. Oil them
lightly and push the filter onto the pin.

A. Oil Pump Guard B. Oil Pump Gear

ePull the oil pump gear from the oi l pump.

eTake out the screws and remove the oil pump.

A. Grommets

OPut the filter with pin into the filter cavity. The larger
end of the pin goes in first.
OCheck that the filter cover Oring is in place.
Olnstall the o il filter cover and tighten the bolts secu rely .
elnstall the oil drain plug with a new aluminum gasket,
and tighten it to the specified torque (see Exploded
View).
eFili the engine with the specified oil and quantity.

A. Screws
Engine Oil
Grade: SE or SF class
Viscosity: SAE 10W-30, 10W-40, 10W-50,
20W-40, or 20W-50 Oil Pump Installation
Capacity: 1.7 L elnstallation is the reverse of removal. Note the
following.
eSe sure the dowel pins under the oi l pump are in place.

eBe sure the Oring is In place, and install the filler cap.

Oil Pump:
Oil Pump Removal
eRemove the primary clutch (see Clutch Removal) .
-Take out the screws and remove the oil pump guard. A. Dowel Pins
 ENGINE RIGHT SIDE 5-13

eFill the pump with engine oil before installation. ePull the pin out of the pump shaft, and pull off the
shaft.

Oil Pump Assembly

eOi l pump assembly is the reverse of disassembly. Note
the following.
eSe sure the dowel pi n is in place in the pump body.
eBefore installing the oil pump, be sure the gear and
rotors turn freely.

Oil Pump Inspection

A. Oi l eVisual ly inspect the oil pump body, rotors, and cover.
* If there is any damage or uneven wear, rep lace the oil
pump assembly.

Oil Pump Disassembly

eRemove the o il pump (see Oil Pump Removal).
eTake out the oil pump cover screw.

Oil Screen:
Oil Screen Removal
eRemove the right engine cover (see Right Engine Cover
Removal).
ePul1 the screen out of the crankcase.

A. Screw

eTake off the oi l pump cover.

eD rop the rotors out of the oil pump body.

A. Oil Screen

Oil Screen Installation

eOil screen installation is the reverse of removal. Note
the followi ng.
A. Rotors C. Oil Pump Cover e(lean the screen thoroughly whenever it is removed for
B. Oil Pump Body D. Dowel Pin any reason.
5-14 ENGINE RIGHT SIDE

Oil Screen Cleaning and Inspection -Drop out the spring and the bypass valve piston.
eelean the oil screen with high flash-point solve nt and
remove any particles stuck to it.

I WARNING.
OClean the screen in a wellventilated area, and take care
Bypass Valve Installation
that there is no spark or flame anywhere near the
-Drop the bypass valve piston closed end first into the
working area. Because of the danger of highly
filter mounting pin.
flammable liquids, do not use gasoline or low
ePut the spring into the mounting pin and compress it
flash-point solvents.
beyond the small hole.
eDrive the retaining pin into the small hole to hold the
spri ng.
elnstall the oil filter (see Engine Oil and Filter Change).

Bypass Valve Cleaning and Inspection

eelean the bypass va lve parts in a high flash-point
solvent.

NOTE
aWhile cleaning the screen, check for any metal particles
that might indicate internal engine damage.
-Check the scree n carefully for any damage: holes,
broken wires, gasket pulling off.
*If the screen is damaged, replace it.
WARNING.
oelean the parts in a well-ventilated area, and take care
that there is no spark or flame anywhere near the
working area. Because of the danger of highly
flammable liquids. do not use gasoline or low flash-
point solvents.
eVisually inspect the bypass valve parts.
*If the sp ring is bent or distorted, rep lace it. If the
piston is worn, replace all of the bypass valve parts.

Oil Filter Bypass Valve:

Bypass Valve Removal
eRemove the oil filter (see Engine Oil and Filter Change .
Oil draining is not necessary).
eDrive the retaining pin out of the filter mounting pin.

A. Filter Mounting Pin B. Retaining Pin

 ENGINE REMOVAL/INSTALLATION 6'

Engine Removal/Installation
Table of Contents

Exploded View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Engine Removal / I nstallation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Engine Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
6-2 ENGINE REMOVAl/INSTALLATION

Exploded View

T1 : 25 N-m (2.5 kg-m, 18.0 ftlb)

T2: 34 N-m (3.5 kg-m, 25 ft-Ib)
 ENGINE REMOVAl/INSTALLATION 6-3

Engine Removal/lnstallation

Engine Removal
eDrain the engine oil (see Engine Oil and Fi lter Change
in the Engine Right Side chapter).
eRemove the following parts.
Front Fender and Rear Fender
Fuel Tank
Carburetor
Exhaust Pipe and Muffler
Differential Shift Lever Case
Shift Pedal
eDisconnect the followi ng cable and leads from the
engine. A. Mounting Bolts B. Bracket Bolts
Reverse Cable
Starter Motor Lead
Alternator Leads
Pickup Coil Leads eFree the cy linder head vent hose and carburetor vent
Spark Plug Lead hose from the frame.
Battery Ground Lead eLoosen the propeller shaft dust cover front clamp.
eRemove the engine mounting bolts and bracket bolts.
Olt may be necessary to support the engine while sliding
out the engine mounting bolts.
eLift the engine up to free the engine from the mounts,
pull the engine to the right si de of the frame, and free
the engine from the propeller shaft.

Engine Installation
eEngine installation is the reverse of removal. Note the
following.
eApply grease to the sp lines at the front end of the
propeller shaft and fit the propeller shaft front end to
the front driven gear shaft rear end.
A. Differential Shift Lever Case OFar extra clearance, first slide back the rear ax le and
B. Battery Ground Lead propeller shaft (see Front Gear Case Removal in the
Final Drive chapter).

A. Mounting Bolts C. Dust Cover Clamp

B. Bracket Bolts A. Apply grease.
64 ENGINE REMOVAl/INSTALLATION

eTighten the engine mounting bolts and bracket bolts to

the specified torque (see Exploded View) .
eRoute the vent hoses as shown.

A. Cylinder Head Vent Hose

A. Carburetor Vent Hose

eFil1 t he engine with engine oil (see Engine Oi l and

Filter Change in the Engine Right Side chapter).
eAdju st the reverse cable (see Reverse Cable Adjustment
in the Engine Bottom End/Transmission chapter).
 ENGINE BOTTOM END/TRANSMISSION 7-1

Engine Bottom End/Transmission

Table of Contents

Exploded View ... . ..... . . . . . . . .. 7-2 Reverse Knob and Cable . . . . . . . . . . . . . 711
Specifications . . . . . . . . . . . . . . . . . . . . 7-4 Reverse Knob Free Play inspection .... 711
Special Tools . . . . . . . .. . . . . . . . . . . . . . 7-4 Reverse Cable Adjustment . . . . . . . . . . 711
Crankcase Splitting .. . . . . . . . . . . .. . . . . . 7-5 Reverse Knob and Cable Removal . . . . . 711
Crankcase Disassembly . . . . . ... .. 7-5 Reverse Knob and Cable Installation .. . 711
Crankcase Assembly . . . . . . . . . . . . 7-5 Reverse Cable Lubrication . . . . . . . . . . 7-12
Crankshaft and Connecting Rod ... . .. . .. . 7 -6 Reverse Cable Inspection . . . . . . . . . . . 7-12
Crankshaft Removal . . . . . . . . . .. .. 7 -6 Transmission Shafts, Shift Drum, Forks ... 7-12
Crankshaft Installation .... . . . . . . . 76 Transmission Removal . . . . . . . . . . . . . 7-12
Crankshaft Disassembly. . . . . . . . . . ..
Crankshaft Assemb ly _ . . . . . . . . . . ..
Connecting Rod Bend /Twist . . . . . . ..
76
7-6
7-7
Transmission Installation. . . . . . . . .
Transmission Shaft Disassembly . . ....
Transmission Shaft Assembly . . . . . ...
Shift Fork Bending . . . . . . _ . .
7-12
7-13
7-14
7-14
II
Connecting Rod Big End
Radial Clearance. . . . . . . . . . . . .. 7-8 Shift Fork/Gear Groove Wear . . . . . . . . 7-14
Connecting ,Rod Big End Shift Fork Guide Pin /Shift Drum
Side Clearance. . . . . . . . . . . . . . .. 7-8 Groove Wear .. .... . . . . . . . . . . . 7 -14
Crankshaft Alignment. . . . . . . . . . . .. 7-8 Gear Dog/Gear Dog Hole and
Co nnecting Rod Big End Seizure . . . . .. 7-9 Recess Damage. . . . . . . . . . . 7-15
Transmission . . . . . . . . . . . . . . . . . . . . . .. 7-9 Balancer .. 7-15
Transmission External Shift Mechanism ... 7-9 Balancer Drive Removal . . . . . . . . . . . 7-15
External Shift Mechanism Removal 7-9 Balancer Drive Installation .. _ . . . . 7-16
External Shift Mechanism Balancer Removal . . . . . . . . _ . . . .... 7-16
Installation . . . . . . . . . . __ . . . . . 7-10 Balancer Installation . . . . . . . . . . . . . . 7-16
External Shift Mechanism Ball and Needle Bearings . . . . . . . .. ... . _ . 7-16
Inspection. . . . . . . . . . . . . . 7-10 Ball and Needle Bearing
Shift Drum Stop Lever Removal . . . . . . 7-10 Replacement .. . . . . . . . . . . . .... 7-16
S hift Drum Stop Lever Installation . . . . 7-10 Ball and Needle Bearing Wear . . . . . . . . 7-16
Shift Drum Stop Lever Inspection . . . . . 7-10
7-2 ENGINE BOTTOM END/TRANSMISSION
.............................................................................
Exploded View
.............................................................................

L : Apply a non-permanent lock ing agent.

LG: Apply a liquid gasket.
o : Apply an oil to the threads and seated surface.
T1 : 78 N-m (8.0 kgm. 58 ft-Ib)
T2: 83 Nm (8.5 kg-m. 61 ftlb)
T3: 20 N-m (2.0 kg-m. 14.5 ftlb)
T4: 17 Nm (1.7 kgm. 12.0 ftlb)
T5: 12 N-m (1 .2 kgm.104 inlb)
ENGINE BOTTOM END/TRANSMISSION 7-3

~
i'l/

r~" T5

~
T5
-L -
"
jY~
/
c:J
-
74 ENGINE BOTTOM END/TRANSMISSION

Specifications

Crankshaft, Connecting Rod:

Item Standard Service Limit

Connecting Rod Bend Under 0.05/100 mm 0.2/100 mm

Connecting Rod Twist Under 0.05/100 mm 0.2/100 mm
Connecting Rod Big End Radial Clearance O.OOS - 0.020 mm 0.07 mm
Connecting Rod Big End Side Clearance 0.25 - 0.35 mm 0.6mm
Crankshaft Runout: Left Half Under 0.03 mm T1R O.OSmm TIR
Right ;Half Under 0.04 mm T1R 0.10mmTIR

Transmission:
Item Standard Service Limit
Shift Fork Ear Thickness 4.4 -4.5 mm 4.3mm
Gear Shift Fork Groove Width 4.55 - 4.65 mm 4.Smm
Shift Fork Guide Pin Diameter 5.9 - 6.0 mm 5.Smm
Shift Drum Groove Width 6.05 - 6.20 mm 6.3mm

Bearing Driver Set: 570011129

Special Tools

Along with common hand tools , th e following more

specialized tools are required for complete engine
bottom end / transmission servicing.

Circlip Pliers: 57001144

Crankshaft Jig: 570011174

Oil Seal Guide: 57001264

Flywheel Holder: 57001308

e

Socket Wrench : 570011214

NOTE
oThe flywheel holder 1570011313} can be used instead
of the flywheel holder 157001-30B}.
 ENGINE BOTTOM END/TRANSMISSION 7-5

Crankcase Splitting

Crankcase Disassembly
eRemove the engi ne (see Engine Removal in the Engine
Removal/Installation chapter).
eRemove the following parts.
Piston
Starter Motor
Oil Filter
Front Bevel Gear Case
Front Bevel Drive Gear
Output Shaft LH Bearing Housing
Shift Drum Stop Lever
Neutral and Reverse Switch A. Pry at these gaps.
Clutches
Oil Pump o Lift off the left crankcase half.
External Shift Mechanism
Alternator Rotor
Camshaft Chain and Guides
eRemove the gaskets and dowel pins on the outside of
the eran kcase. Crankcase Assembly
-Remove the banjo bolts and take off the oil pipe.
NOTE
aBe certain that all pans are cleaned thoroughly before
assembly.
OBlow through all oil passages with compressed air to
clear any blockage.

A. Banjo Bolts

eRemove the crankcase bolts.

A. Compressed Air

_Separate the crankcase halves.

o Pry at the gaps at the front and rear of the crankcase to
split the case halves apart. A. Compressed Air
7-6 ENGINE BOTTOM END/TRANSMISSION
08e sure all transmission shafts, shift forks, and the shift
drum are in place in the right crankcase half.
I WARNING'
OClean the engine parts in a wellventilated area, and
take care that there are no sparks or flame anywhere
near the working area; this includes any appliance with
a pilot light. Do not use gasoline or a low flashpoint
solvent to clean parts. A fire or explosion could result.
eApply a small amount of engine oil to the transmission
gears, bearings, and shift drum.
eBe sure the mating surfaces of the crankcase halves are
clean and dry.
eBe sure the crankcase dowel pins are in position.
A. Dowel Pi ns
eApply a liquid gasket to the mating surface of the right
crankcase half.
-Fit the left crankcase half on the right crankcase half,
an d tigh ten the cran kcase bol ts securel y.
eRotate the shift drum to the neutral position.
e<:heck to see that the crankshaft, drive shaft, and
output shaft all turn freely.
*If any of the shafts do not turn freely, split the crank-
case to locate the problem.
eThe remainder of Crankcase Assembly is the reverse of
disassembly.
Crankshaft and Connecting Rod
Crankshaft Removal
eRemove the balancer drive gear (see Balancer Drive
Removal).
eSplit the crankcase (see Crankcase Disassembly) .
eRemove the transmission (see Transmission Removal).
eRemove the crankshaft from the right crankcase half
with a press.
Crankshaft Installation
ePosition the right crankcase half so that the RH main
bearing housing is seated on a suitable press fixture .
ePress the crankshaft into the RH main bearing.
Olnsert the crankshaft jig (special tool) between the
crankshaft halves, opposite the crankpin, to prevent
crankshaft distortion during installation.
A. Crankshaft Jig: 57001-1174
eThe remainder of Crankshaft Installation is the reverse
of Crankshaft Removal.
Crankshaft Disassembly
NOTE
OSince assembly of the crankshaft demands exacting
tolerances, the disassembly and reassembly of the
crankshaft should only be performed by experienced
mechanics with the necessary tools and equipment.
oThe crankshaft left main bearing, chain sprocket, and
left crankshaft are available separately as spare pan,
however, it is recommended that the crankshaft
assembly be replaced rather than attempting to replace
the components.
ePress the crankpin out of the crank halves to separate
the crank halves, connecting rod, crankpin needle
bearing, and crankpin.
Crankshaft Assembly
e<:heck that the connecting rod radial clearance is within
specifications (see Connecting Rod Big End Radial
Clearance) .
ePress the crank halves onto the crankpin until con-
necting rod side clearance is within specifications (see
Connecting Rod Big End Side Clearance).
 ENG INE BOTTOM END/TRANSMISSION 7-7
Crankpin Oil Passage Alignment Connecting Rod Bend

Vi ew A

A
ePress the camshaft chain sprocket into the crankshaft
as shown. The chamfered side of it faces to the ball
bearing.
OSelect an arbor of the same diameter as the piston pin
and at least 100 mm long, and insert the arbor through
Camshaft Chain Sprocket Installation the connecting rod small end.
OWith the connecting rod held vertically, use a height
gauge to measure the difference in the height of the
arbor above the surface plate over a 100 mm length to
determine the amount of connecting rod bend.
1 *If connecting rod bend exceeds the service limit, the
connecting rod must be replaced.

Connecting Rod Bend

Standard: Under 0.05/100 mm
Service Limit: 0 .2/100 mm

eMeasure connecting rod twist.

OWith the crankshaft still in the alignment jig, hold the
connecting rod horizontall y and measure the amount
that the arbor varies from being parallel with the crank-
shaft over a 100 mm length of the arbor to determine
the amount of connecting rod twist.

1. Direction of Crankpin Center Connecting Rod Twist

eAdjust crankshaft runout until runout is within specifi- 100mm

cations (see Crankshaft Runout).

*If connecting rod twist exceeds the service limit, the

connecting rod must be replaced.

Connecting Rod Bend/Twist

eMeasure connecting rod bend. Connecting Rod Twist
OSet the crankshaft in an alignment jig or in V blocks on Standard: Under 0.05/100 mm
a surface plate. Service Limit: 0.2/100 mm
7-8 ENGINE BOTTOM END/TRANSMISSION

Connecting Rod Big End Radial Clearance *If big end side clearance exceeds the service limit, the
-Check big end radial clearance. crankshaft assembly must be replaced or disassembled
oSet the crankshaft on V blocks, and place a dial gauge and the connecting rod and thrust washers visually
against the connecting rod big end. inspected for wear.

Connecting Rod Big End Radial Clearance Connecting Rod Big End Side Clearance
Standard: 0.25 - 0 .35 mm
Service Limit: 0.6mm

Crankshaft Alignment
-Check crankshaft alignment by measuring runout.
OWith the crankshaft on V blocks, turn the crankshaft
slowly and measure runout at each of the locations
shown.
o Push the connecting rod first towards the gauge and
then in the opposite direction. The difference between
the two gauge read ings is the radial clearance.
*If the rad ial clearance exceeds the service limit, the
crankshaft assembly must be replaced or disassemb led Crankshaft Runout
and the crankpin, need le bearing, and connecting rod
big end examined for wear.
, ~,
Connecting Rod Big End Radial Clearance 9mm

Standard: 0.008 - 0.020 mm

Service Limit: 0 .07mm

Connecting Rod Big End Side Clearance

eMeasure big end side clearance.
o lnsert feeler gauges between the big end and either
crank half to determine clearance.

Connecting Rod Big End Side Clearance *If runout at either location exceeds the service lim it,
align the crankshaft so that runout is with in the service
limits.
T Side Clearance
Crankshaft Runout
Left Half Standard: Under 0.03 mm TI R
Service Limit: 0.08 mmTIR
Right Half Standard: Under 0.04 mm TI R
Serivce Limit: 0 .10 mm TIR

eAlign the crankshaft.

01n the case of horizontal misalignment, strike the pro-
jecting crankshaft half with a plastic, soft lead, or brass
hammer as shown.

Flywheel Horizontal Misalignment
eRecheck the runout and repeat the process until the
runout is within service limits.
OVertical misalignment is corrected either by driving a
wedge in between the crank halves, or by squeezing the
cr4nk halves in a vise, depending on the nature of the
misalignment.
Flywheel Vertical Misalignment
O' n case of both horizontal and vertical misalignment,
correct the horizontal misalignment first.
oRecheck big end side clearance after aligning crankshaft
(see Connecting Rod Big End Side Clearance).
NOTE
Off crankshaft alignment cannot be corrected by the
above method, replace the crankpin or crank halves as
required.
ENGINE BOTTOM END/TRANSMISSION 79
Connecting Rod Big End Seizure
-In case of serious seizure with damage to the crank
halves, the crankshaft must be replaced. If the seizure
was less severe, disassemble the crankshaft and replace
the crankpin, needl e bearing, and connecting rod (see
Crankshaft Disassembly) .
............................................................................
Transmission
Transmission External Shift Mechanism:
External Shift Mechanism Removal
eRemove the clutches (see Clutch Removal in the
Engine Right Side chapter).
eTake off the clutch release cam and ball assembly.
eRemove the bolt and take off the shift pedal.
-Move the shift mechanism arm out of its position on
the end of the shift drum, and pull out the shift
mechanism shaft.
A. Pull out the mechanism shaft.
B. Return Spring
C. Clutch Release Cam
-Remove the shift drum positioning lever bolt and take
off the lever with its spring.
A. Shift Drum Positioning Lever
B. Spring
C. Return Spring Pin
D. Clutch Release Cam Pin
7-10 ENGINE BOTTOM END/TRANSMISSION
External Shift Mechanism Installation
eExternal shift mechanism installation is the reverse of
removal. Note the following.
e<:heck the shift drum positioning lever swings smoothly
after tightening the pivot bolt.
eSe sure the shift mechanism arm collar and clutch
release cam are in place.
A.Coliar S. Clutch Release Cam
eUse the oil seal guide (special tool) to protect the seal
during shift mechanism installation.
A. Oil Seal Guide: 57001-264
ePosition the shift shaft return spring ends on either side
of the return spirng pin.
External Shift Mechanism Inspection
eExamine the shift mechanism for any dama2e.
A. Splines S. Springs C. Lever
CCheck the shift shaft for bending or damage to the
spline.
"'If the shaft is bent, straighten or replace it. If the
spline is damaged, replace the shaft.
CCheck the springs for breaks or distortion.
*If the springs are damaged in any way, replace them.
OCheck the shift mechanism arm for distortion.
* If the shift mechanism arm is damaged in any way,
replace the lever.
OCheck the return spring pin and/or cam pin is not loose.
-trlf it is loose, unscrew it, apply a non-permanent locking
agent to the threads, and tighten it to the specified
torque (see Exploded View).
Shift Drum Stop Lever Removal
eRemove the front gear case (see Front Gear Case
Removal in the Final Drive chapter).
ePull the shift drum stop lever off the crankcase with its
spring.
A. Shift Drum Stop Lever B. Spring
Shift Drum Stop Lever Installation
-Shift drum stop lever installation is the reverse of
removal.
Shift Drum Stop Lever Inspection
e<:heck the shift drum stop lever for distortion.
*If the shift drum stop lever is damaged in any way,
replace the lever.
e<:heck the spring for break or distortion.
*If the spring is damaged in any way, replace the spring.
 ENGINE BOTTOM END/TRANSMISSION 7-11

Reverse Knob and Cable: Reverse Knob and Cable Removal

Reverse Knob Free Play Inspection -Remove the screws and take off the reverse knob
-Check the reverse knob free play when the transmission assembly with the cable.
is in neutral.
e lf free play is not within specifications, adjust the
reverse cable (see Reverse Cable Adjustment).

Reverse Knob Free Play

Standard: 2 - 3mm

A. Screws B. Cable Holder .

ePull the cable holder out the assembly, and free the
reverse cable upper end from the assemb ly.
aLoosen the mounting nuts and take off the cable
adjuster from its bracket.

eFree the cable from the vehicle.

A. Reverse Knob B. Free Play

Reverse Knob and Cable Installation

e lnstallation is the reverse of removal. Note the
fo ll owing.
-When the reverse lever was removed, mount the lever
on the shift drum stop lever shaft so that the slot of the
Reverse Cable Adjustment lever aligns with the mark on the front gear case.
aLoosen the mounting nuts at the adjuster of the reverse
cable, and slide the adjuster until t he reverse knob has
the proper amount of play.
-Tighten the mounting nuts after adj ustment.

A. Mounting Nuts B. Align mark with slot .

*If the reverse lever is difficult to install in the above

position, reinstall the lever aligning the slot with just
forward tooth of the shaft serration.
_Route the reverse cable as shown.
eAdjust the reverse cable (see Reverse Cable Adjust-
A. Adjuster B. Mounting Nuts ment).
7-12 ENGINE BOTTOM END/TRANSMISSION

*If cable movemen t is not free after lubricating (see

Reverse Cable Lubrication), if the cable is frayed, or
if the housing is kinked, replace the cable.

Transmission Shafts, Shift Drum, Forks:

Transmission Removal
-Split the crankcase (see Crankcase Disassembly).
-Pull out the shift rods and take out the forks .
Pull out the transmission shafts at the same time.
eT 0 remove the shift drum, remove the shift drum
positioning lever and shift drum bearing stopper.
A. Reverse Cable

Reverse Cable Lubrication

Whenever the reverse cable is removed, lubricate the
reverse cable as follows.
eLubricate the reverse cable by seep in g the oil between
the cable and cable housing.
eApply a small amount of multi-purpose grease to the
cable lower end.

Cable Lubrication

A. Shift Drum Positioning Lever B. Bearing Stopper

Transmission Installation
-Set the transmission shafts, and fit them into the right
crankcase half at the same time.
OAppJy a small amount of engine oil to the transmission
gears, bearings, and shaft journals.

Reverse Cable Inspection

-With the reverse cable disconnected at the both ends,
the cable should move freely within the cable housing.

-Fit each shift fork into the groove of the proper gear so
that the shift fork guide pin is in the proper groove on
the shift drum.
oApply a small amount of engine oil to the shift fork
fingers.
oThe forks for the output shaft are identical.

-Install the shift rods.
OApply a small amount of engine oil to the shift rods.
olnsert the shorter shift rod through the drive shaft
fork, and the longer rod through the output shaft
forks.
ENGINE BOTTOM END/TRANSMISSION 7-13
Transmission Shaft Disassembly
eRemove the transmission shafts (see Transmission
Removal) .
-Using the circlip pliers (special tool), remove the circlip
and disassemble the transmission shafts completely.

A. Short B. Long
A. Circlip Pliers: 57001-144

Transmission Gears

Drive Shaft
4th

Reverse

Output Shaft
2nd
\

Reverse Shaft

A. Short B. Long

-Assemble the crankcase (see Crankcase Assembly).

714 ENGINE BOTTOM END/TRANSMISSION

Transmission Shaft Assembly Shift Fork/Gear Groove Wear

eAssembly is the reverse of disassembly. Note the eMeasure the thickness of the ears on each shift fork,
following. and measure the width of the shift fork grooves on
eReplace any circlips that were removed with new ones. transmission gears.
eAlways install circlips so that the opening is aligned
with a spline groove.
Shift Fork Ear Thickness
Standard: 4 .4 - 4.5 mm
Circlip Installation Service Limit: 4.3mm

Gear Shift Fork Groove Width

Standard: 4.55 - 4.65 mm
Service Limit:
l 4 .8mm

*If the thickness of a shift fork ear is less than the

service limit, the shift fork must be replaced.
*If a gear shift fork groove is worn over the service limit,
the gear must be replaced.

e The transmission gears can be identified by size;

Drive shaft gears - the smallest diameter gear is 1 st
gear, and the largest is 5th .
Output shaft gears -the largest diameter gear is 1st
gear, and the smail est is 5th.

Shift Fork Bending

eVisually inspect the shift forks, and replace any fork
that is bent. A bent fork could cause difficulty in
shifting, or allow the transmission to jump out of gear
when under power.

Shift Fork Guide Pin/Shift Drum Groove Wear

eMeasure the diameter of each shift fork guide pin, and
measure the width of each shift drum groove.

Shift Fork Guide Pin Diameter

Standard: 5 .9 - 6 .0 mm
Service Limit: 5 .8mm

Shift Drum Groove Width

Standard: 6.05 - 6.20 mm
Service Limit: 6.3mm
 ENGINE BOTTOM ENO!TRANSMISSION 7-15

Balancer

Balancer Drive Removal

-Remove the clutches (see Clutch Removal in the
Engine Right Side chapter).
eRemove the left engine cover (see Left Engine Cover
Removal in the Engine Left Side chapter).
-Fit the flywheel holder (special tool: P/N 57001-308)
to the alternator rotor.
eRemove the balancer gear nut and gear while holding
the crankshaft from turning.

A. Shift Fork Guide Pin

A. Balancer Gear C. Oil Pump Drive Gear

A. Shift Drum Grooves B. Balancer Drive Gear

*If the guide pin on any shift fork is less than the service
limit, the fork must be replaced.
*If any shift drum groove is worn over the service limit, -Flatten the side of the toothed washer where it is bent
the drum must be replaced. up against the nut mounting the balancer drive gear and
oil pump drive gear.
eRemove the nut with the socket wrench (special tool),
and take off the oil pump drive gear and balancer drive
Gear Dog/Gear Dog Hole and Recess Damage gear.
-Visually inspect the gear dogs, gear dog holes and/or
recesses. Replace any gears that have damaged or
excessively worn dogs, dog holes, or recesses.

A. Recess B. Dog C. Dog Hole A. Socket Wrench: 570011214

7-16 ENGINE BOTTOM END/TRANSMISSION
Balancer Drive Installation
eBalancer drive installation is the reverse of removal.
Note the following.
eMesh the balancer gear with the balancer drive gear so
that the punch mark on the balancer gear aligns with
the punch mark on the drive gear.
A. Align punch marks.
-Position the toothed washer on the crankshaft.
of it the claw of the washer into the groove of the oil
pump drive gear.
A. Fit claw into groove. B. Chamfer
-Apply oil to the threads and seating su rface of the
balancer drive and oil pump drive gear mounting nut.
-Install the nut so that the chamfered side of the nut
faces in .
-Tighten the nut to the specified torque (see Exploded
View).
*If none of the toothed washer tabs align, tighten the
nut further just enough to align one of the tabs with a
slot in the nut.
Tab
o
eBend the tab over the nut.
Balancer Removal
eRmove the balancer drive gear (see Balancer Drive
Removal).
-Split the crankcase (see Crankcase Splitting).
_Lift the balancer out of the right hand crankcase half.
Balancer Installation
_Balancer installation is the reverse of removal.
Ball and Needle Bearings
Ball and Needle Bearing Replacement
eUsing a press or puller, remove the ball bearing and/or
needle bearing.
NOTE
Din the absence of the above mentioned tools, saris
factory results may be obtained by heating the case to
approximately 93C (200F) max., and tapping the
bearing in or out.
000 not heat the case with a torch. This will warp the
case. Soak the case in oil and heat the oil.
-Using a press and the bearing driver set (special tool:
PIN 570011129), install the new bearing until it stops
at the bottom of its housing,
Ball and Needle Bearing Wear
_Check the ball bearings.
oSince the ball bearings are made to extremely close
to lerances, the wear must be judged by feel rather
than measurement. Clean each bearing in a high f1ash-
point solvent, dry it (do not spin the bearing while it is
dry), and oil it with engine oil.
oSpin the bearing by hand to check its condition .
*If the bearing is noisy, does not spin smoothly, or
has any rough spots, replace it.
-Check the needle bearings.
oThe rollers in a needle bearing normally wear very
little, and wear is difficult to measure. Instead of
measuring, inspect the bearing for abrasion, color
change, or other damage.
*If there is any doubt as to the condition of a needle
bearing, rep lace it.
 WHEELsrrlRES 8-'

Wheels/Tires
Table of Contents

Exploded View .. . .. .. ..... . ...... . ... .. ......... .. ....... 82

Specifications ... . .. . ......... . . . ......... . .. . .......... . . . 82
Special Tools ... .. ........... . ............. . ..... ... . ... .. . 83
Wheel Alignment ...... .. .................... . .... . . ...... . 83
Steering Centering Inspection ............................ . 83
Steering Centering Adjustment ...... .... .. . .... ..... . .... . 83
Toe-in Inspection ......... ....... .... .. . . ....... .. . . .. . 8-4
Toein Adjustment .................................... . 85
Wheels (Rims) . ....... . .... . ............. . ................ . 85
Wheel Removal ........... . ...... . ... . ........ .... ... . . 85
Wheel Installation ........................ . ....... .. ... . 85
Wheel Inspection . ...... . .......... . . .. .. ...... ... . ..
Wheel Replacement .................... . ............ . ..
86
86
DI
Tires ............... . ... . ...... . ............ ... ...... . .. 86
Tire Removal. . . ........... . .. .. ......... . .. . .. . . ..... . 86
Tire Installation ......................... . . ....... .. ... . 87
Tire Inspection ........... ... ... . .. ..... .. ... ... . .. .. 88
Front Hub Bearings .................. . ....... ... .......... . 8-8
Front Hub Bearing Removal .... . .. . ........ .. .... ... .. 8-8
Front Hub Bearing Installation ... ... ... . . . .. .. .... .. .. ... . 8-9
Front Hub Bearing Inspection ........................ .. .. . 89
8-2 WHEELS/TIRES

Exploded View

T1

T1

G : Apply grease.
T1 : 34 N-m (3.5 kgm. 25 ftlb)
Specifications

Wheel Alignment
Caster 4 0 (non-adjustable)
0
Camber: 0.8 (non-adjustable)
Toe-in 27 mm
Tire Payload: 182 kg (400 Ib)
Standard Tires
Front 22 x 9.0010
Dunlop KT761. Knobby/Trail Tubeless
Rear 24 x 11.0010
Dunlop KT765. Knobby/Trail Tubeless
Tire Air Pressure (when cold)
Front 21 kPa (0.21 kg/em 2 3 psi)
Rear 21 kPa (0.21 kg/em 2 3 psi)
Maximum Tire Air Pressure (to seat beads, when cold)
Front 137 kPa (1.4 kg/em 2 20 psi)
Rear 137 kPa (1.4 kg/em 2 20 psi)
 WHEELS/TIRES 8-3
.............................................................................
Special Tools Wheel Alignment

Jack: 57001-1238 Toe-in is the amount that the front wheels are closer
together in front than at the rear at the axle height.
When there is toe-in, the distance A is greater than B as
shown. The purpose of toe-in is to prevent the front
wheels from getting out of parallel at any time, and to
prevent any slipping or scuffing action between the tires
and the ground. If toe-in is incorrect, the front wheels
will be dragged along the ground, scuffing and wearing
the tread knobs.
Caster and camber are built-in and require no adjust-
ment.

Toe-in of Front Wheels

B
Front of Vehicle
rl
Tire Irons: 57001-1073
!/
i=-
'" D (/~

F=

- ' .- -

V
'" -= i.=
, ))
h ~ A
'" A

A - B = Amount of Toe-in
Air Pressure Gauge: 52005-1082 (Distance A and B are measured at hub height)

Steering Centering Inspection

Bearing Driver Set: 57001-1129
-Test ride the vehicle.
*If the handlebar is straight when the vehicle is traveling
in a straight line, go on to the Toe-in Inspection
procedure.
*Otherwise, go on to the Steering Centering Adjustment
procedure.

Steering Centering Adjustment

-Support the vehicle so that the front wheels are off the
ground and the front axles about the same height as the
rear axle.
eHold a straightedge against the rear wheel rim on one
side at axle height.
8-4 WHEELS/TIRES

eRe peat the straightedge procedure on the other side of

the vehicle. Now the front wheels are parallel to each
other and to the center line of the vehicle.
eCo on to the Toein Inspection procedure.

Toe-in Inspection
eSupport the veh icle on a stand or the jack (special tool:
57001-1238) so that the front wheels are off the
ground.
eApply a heavy coat of chalk near the center of the
front tires.
A. Straightedge B. Jack: 570011238 _Using a needle nose scriber, make a thin mark near the
eWith the handlebar straight ahead, loosen the locknuts center of the chalk coating while turning the whe~l.
and turn the tierod adjusti ng sleeve the same number
of turns on both sides until the front wheel on that side
is parallel to the straightedge.
NOTE
oThe outside locknut on the tierod has lefthand
threads. Turn the wrench clockwise for loosening.

eKeeping the front wheels off the ground, set the

handlebar straight ahead.
eAt the level of the axle height, measure the distance
between the scribed lines for both front and rear of the
front tires.

A. Outside Locknut: lefthand threads

B. Adjusting Sleeve
C. Inside Locknut
Steering Centering

I
r

-Subtract the measurement of the front from the

measurement of the rear to get the -toe-in.
*If the toe-in is not in the specified range, go on to the
Toe-in Adjustme nt procedure.

e<.:heck the toe-in (see Toein Inspection).

Toe~n of Front Wheels
eTighten the tie-rod locknuts to the specified torque
(see Exploded View in the Steering chapter). Standard: 27 mm
eTest ride the vehicle. .
 WHEELS/TIRES 8-5

Toe-in Adjustment
Wheels (Rims)
eLoosen the locknuts and turn the adjusting sleeves the
same number of turns on both sides to ach ieve the
spec ified toe- in .
Wheel Removal
eSupport the vehicle on a stand or the jack (special tool:
57001-1238) 50 that th e wheels are off the gro und.
ePull off the wheel cap.
eTake off the wheel nuts holding the wheel to the hub.

Wheel Installation
eMount the wheelan the studs.
ePosition the whee l so that the valve stem is toward the
outside of the vehicle.
-Check the tire rotation mark on the front and rear
tires, and install them on the rim accordingly_

A. Adjusting Sleeve B. Locknuts C. Front

NOTE
OThe outside locknut on the tie-rod has left-hand
threads. Turn the locknut clockwise for loosening.
OThe toe-in will be near the specified value, if the tie-rod
length is 380 mm between the tie-rod ends.

Tie-rod Length Adjustment

A. Rotation Mark

o Far the front whee ls, align the "shoe check hole" and
"shoe adjust hole" on the rim with the holes on the
drum respectively.
oTighten the whee l nu ts in a criss-cross pattern to the
specified torque (see Exploded View).

1. Front
2 . Left-hand Thread
3. Tie-rod Length

e<:heck the toe-in (see Toe-in Inspection).

eTighten the tie-rod locknuts to the specified torque
(see Exploded View).
eTest ride the vehicle. A. Valve Stem
8-6 WHEELS/TIRES

Wheel Inspection
eExamine both sides of the rim for dents. If the rim is
dented, replace it. 000 not use engine oil or petroleum distillates to
Rim Dent lubricate the stem because they will deteriorate the
<0\\ \ \ II , , I I 1/7r; rubber.

00 Dent 'in eMount the tire on the new rim (see Tire Installation).
elnstall the wheel (see Wheel Installation).
~
~ \ '/)
.;:,
c: ';J
C :J
:::J
=:J
:=J
.::::J
j}
v </. ' ___ _ - ,- Tires
<IIcill"",\\\\\V
elf the tire is removed, inspect the air sealing surfaces of Tire Removal
the rim for scratches or nicks. Smooth the sealing
eRemove the wheel (see Wheel Removal ).
surfaces with fine emery cloth if necessary. _Unscrew the valve core to deflate the tire.
o Use a proper valve core tool.

A. Sealing Surfaces

Wheel Replacement
eRemove the wheel (see Wheel Removal). A. Valve Core Tool
eDisassemb le the tire from the rim (see Tire Removal).
elnstall a new valve stem in the new rim.
ORemove the valve cap, lubricate the stem with a soap
eLubricate the tire beads and rim flanges on both sides
of the wheel with a soap and water solution, or water.
and water solution, or water and pull the stem through
the rim from the inside out until it snaps into place.
This helps the tire beads slip off the rim flanges.

A. Pull. A. Apply lubricant.

 WHEELS/TIRES 8-7
eWork around the rim with the tire irons a little at a
time, while continuing to hold the bead opposite the
irons in the center well of the rim.
000 not lubricate the tire beads and rim flanges with
engine oil or petroleum distillates because they will
deteriorate the tire.

eBreak the tire beads away from both sides of the rim
with a tire tool.

I;

A. Tire Irons: 570011073

eLift the second bead up into the center well and use
the same procedure as in removing the first bead.

Tire Installation
elnspect the rim (see Wheel Inspection).
e<:heck the tire for wear and damage (see Tire Inspec
tion).
eLubricate the tire beads, rim flanges, and the tire irons
(special tools) with a soap and water so lution, or water.
eKneel on the side of the tire, forcing the tire bead into
the center well of the rim.
I WARNING.
000 not use the lubricant other than a water and soap
Rim Center Well solution, or water to lubricate the tire beads and rim
because it may cause tire spearation.

_,--r~~~~..,..,,~valve Stem et:heck the tire rotation mark on the front and rear
tires, and install them on the rim accordingly.
OThe tires should be installed on the rims so that each
valve stem is toward the outside of the vehicle.
NOTE
OThe direction of the tire rotation is shown by an arrow
on the tire side wall.
eBy hand, slide as much of the first bead as possible over
the rim flange, starting at the side opposite the valve
stem.
oAs the bead goes onto the rim, force the bead into the
Well center well of the rim to ease installation.
eUse the tire irons to install the rest of the bead.
eUse the same procedure to install the second bead.
eLubricate the tire beads again, center the tire on the
rim, and inflate the tire until the tire beads seat on the
eLubricate two tire irons with a soap and water, or rim.
water and pry the bead.
I WARNING I
000 not inflate the tire to more than 137 kP. (1 .40
kg/cm 2 20 psi). Overinflation can cause the tire to
explode, causing personal injury.
000 not scratch the air sealing surfaces of the tire or
rim. Scratches or nicks on the sealing surfaces will e<:heck to see that the rim lines on both sides of the tire
allow the tire to deflate. are parallel with the rim flanges.
8-8 WHEELS/TIRES

Front Hub Bearings

Front Hub Bearing Removal

.Pull off the wheel cap.
eRemove the cotter pin and loosen the hub nut.

A. Rim Line

.If the rim lines and the rim flanges are not parallel,
deflate the tire, lubricate the sealing surfaces again, and
reinflate the tire .
After the beads are properly seated, check for air leaks.
olnflate the tire to 35 kPa (0.35 kg/em', 5 psi). Apply a
soap and water solution around the tire bead and check
for bubbles. A. Hub Nut
eDeflate the tire to spedfied pressure (see Specifica-
tions). .Pull off the wheel with the hub assembl y, and pullout
Install the wheel (see Wheel Installation). the collar .
-Wipe off the soap and water solution on the tire, and
dry out the tire before operation. WARNING.

I WARNING. OBrake linings contain asbestos fi~er. Inhalation of

0 00 not operate the vehicle when the water and soap
still exist around the tire beads. They will cause the
tire separation, and a hazardous condition may result.
Tire Inspection
.Examine the tire for damage and wear.
a lf the tire is cut or cracked, replace it.
o Lumps or high spots on the tread or sidewalls indicate
internal damage requiring tire replacement.
ORemove any foreign objects from the tread. After
removal, check for leaks with a soap and water solution.
OCheck the shape of the tread knobs. If no vertical side
is left on the drive side of the knobs, replace the tire.
asbestos may cause serious scarring of the lungs and
may promote other internal injury and illness,
including cancer. Observe the following precautions
when handling brake linings :
1. Never blow brake lining dust with compressed air.
2. If any components are to be cleaned, wash them
with detergent, then immediately discard the
cleaning solution and wash your hands.
3. Do not grind any brake lining material unless a
ventilation hood is available and properly used.
eRemove the grease seals, bearings and spacer pipe.

Tire Wear
Vertical Sides
Worn Away

/-----rJ/
/ /' ~'" .

/ I \
I ~ \
I // ~ .
~ -1- \ A. Collar B. Grease Seal

OPosition the hub assembly on wooden blocks to allow
bearing removal.
WHEELS!TIRES 8-9
Olnsert the spacer pipe into the hub assembly.
o Drive out the remaining bearing and grease seal by
tapping on the spacer pipe with a suitable driver.
eDeburr the spacer pipe as needed.

Front Hub Bearing Installation

e ln stallation is the reverse of removal. Note the
following.
eDrive either bearing into the hub assembly with the
bearing driver set (special tool: PIN 57001 -1129).

A. Wooden Block

OPry the spacer pipe toward one side.

eApply grease to the lips of the grease seals.

eTighten the hub nut to the specified torque (see
Exploded View).

A. Spacer Pipe

ODrive the bearing out by tapping on the exposed

portion of the spacer pipe end with a hammer and
metal rod. The grease seal is tapped out with the
bearing.
Front Hub Bearing Inspection
eRemove the hub assembly (see Front Hub Bearing
Removal).
eTurn each bearing back and forth while checking for
roughness or binding.
*If roughness or bind in g is found, replace the bearing.
eExamine the bearing seal for tears or leakage.
*If the seal is tarn or is leaking, replace the bearing.

A. Metal Rod

Final Drive
Table of Contents
Exploded View .. . ...... ...... .... 9-2
Specifications . . . . . . . . .. . . . . .. ... . . 9-4
Special Tools .... .. . . . . . . . . . . . . . . . . ' 9-5
Final Gear Case Oil . . . . . . . . . . . . . . . . .. . 9-6
Final Gear Case Oil Level Inspection ... 96
Final Gear Case Oil Change. . . . . . . . 9-6
Front Bevel Gears and Cam Damper . . . . . . . ' 96
Front Gear Case Removal. . . . . . . . . .. 96
Front Gear Case Installation. . . . . . . .. 98
Front Drive Gear Removal/
Installation . . . . . . . . . . . . . . . . . . 9-9
Front Driven Gear and Cam
Damper Removal ... .. ... . ... . . 9-9
Front Driven Gear and Cam
Damper Installation .. . . . . . . . . . . 9-9
Front Bevel Gear Adjustment 9-10
Bevel Gear Inspection . . . . . . . . . . . .. 9 14
8all Bearing Inspection . . . . . . . . . . . . 9-14
Tapered Roller Bearing Inspection . . . . . 914
Oil Seal Inspection . . . . . . . . . . . . . . . 914
Cam Damper Inspection . ... , . . . . . . . 914
Propeller Shaft _ .. _ .. _ ..... _ . . . . . . . . . 9-14
Propeller Shaft Removal . _ ... .. .... 9-14
Propeller Shaft Installation . . . . . . . . . . 915
Propeller Shaft Lubrication . . . . . . . . . 915
Prope ller Shaft Joint and Pin ion
Joint Inspection . . . . . . . . . , . . . . . 9-15
Propeller Shaft Inspection . . . . . . _ ... 915
Rear Axle Shafts . . . . . . . . . . . . . . . . . . . . 9-16
Rear Ax le and Propell er Shaft
Removal . . . . . . . _ . . . . . . . . . . . . 9-16
Rear Axle and Propeller Shaft
Installa tion. . . _ .. _ _ . _ 9-16
Axle Shaft Remova l . .... _ ....... 9-17
FINAL DRIVE 9-1
Axle Shaft Installation . ... . ... .. . 9-17
Axle Shaft Inspection . ... . . . . . . __ . 9-18
Ball Bearing Inspection . . . . . . . . . . . . 9-18
Oi l Seal Inspection ...... . . . . . . . . . . 918
Final Bevel Gears and Differential Gears . . . . . 9 18
Pinion Gear Disassembly . . . . .... ... 9 18
Pinion Gear Assembly . . . . . . . . . . . . . 9-19
Ring Gear and Differential Gear
Disassembly . . . . . . . . . . . . . . _ ... 919
Ring Gear and Differential Gear
Assemb ly . . . . . . . . . . . . . . . . . . . 9-20
Final Bevel Gear Adjustment .... . ... 920
Bevel Gear Inspection . . . . .. . . . . . .. 925
Differential Gear Inspection . . . . . . . .. 9-25
Tapered Roller Bearing Inspection . .. . . 9-25
Ball Bearing Inspection . . . . . . . . . . . . 925
Oil Seal Inspection . . . . . . . . . . . . . . . 9-25
Differential Shift Mechanism . . . . . . . . . . . . 925
Shift Lever Case and Cable Removal .... 9-25
Shift Lever Case and
Cable Installation . . . . . . . . . . . . . . 9-26
Shifter and Shift Fork Removal .... . _. 9-26
Shifter and Shift Fork Installation . _ ... 9-26
Differential Cable Adjustment . . . . . . . . 927
Differential Cable Lubrication . . . . . . . . 928
Differential Cable Inspection . . . . . . . . 9-28
Shifter and Shift Fork Inspection . . ... 9-28
 F
9-2 INAL DRIVE
.......... ......... ................... .... . ...... ..............

E~~;~~~~ View .................................................... .

........................ Option

Engine No. 013932 and up.. 16mm

14mm @
16mm @
a

8mm

- @
 FINAL DRIVE 9-3

o
~

G : Apply grease.
L : Apply a non-permanent locking agent.
o : Apply an oil to the threads and seated surface.
St : Stake the fastener.
T1 : 25 N-m (2.5 kg-m, 18.0 ftlb)
T2: 88 N-m (9.0 kgm, 65 ft-Ib)
T3: 98 N-m (10.0 kg-m, 72 ftlb)
T4: 12 N-m (1.2 kg-m, 104 in-Ib)
T5: 20 N-m (2.0 kgm, 14.5 ft-Ib)
T6: 78 N-m (8.0 kgm, 58 ft-Ib)
T7: 29 N-m (3.0 kgm, 22 ft-Ib)
T8: 6.9 N-m (0.70 kg-m, 61 inlb)
T9: 93 N-m (9.5 kg-m, 69 ft-Ib)
94 FINAL DRIVE

Specifications

Item Standard

Final Gear Case Oil:

Type API GL-5 Hypoid gear oil SAE 90
(above 5C, 41 F) or SAE80 (below
5C,41F)
Capacity 0.3 L
Bevel Gear Bearing Preload 0.3 - 0.6 N-m
(0.03 - 0.06 kg-m, 2.6 - 5.2 in-Ib)
Bevel Gear Backlash : Front 0.06 - 0.10 mm
(at bearing preload nut)
Rear 0.08 - 0.25 mm
(at ring gear tooth)
 FINAL DRIVE 9-5
............................................................... v ....
Oil Seal & Bearing Remover: 570011058
Special Tools

A[ong with common hand too ls, the following more

specialized tools are required for complete final drive
servicing.

Circlip Pliers: 57001 143

Bearing Driver Set: 570011129

Circlip Pliers: 57001144

Bevel Gear Holder: 570011193

Bearing puller: 57001158

Hexagon Wrench: 570011194

Driven Gear Holder: 570011215

Oil Seal Guide: 57001264
(Two guides are required)

Gear Holder: 570011015 o

9-6 FINAL DRIVE

Final Gear Case Oil

Final Gear Case Oil Level Inspection

.Park the vehicle so that it is level, both side-ta-side and
front-to rear.
eRemove the filler cap.

rCAUTlO~]
a Be careful not to allow any dirt or foreign materials to
enter the gear case.
A. Drain Plug
echeck the oil level. The oil level sho uld come to th e
bottom of the filler opening.
WARNING I
OWhen draining or filling the final gear case, be careful
that no oil gets on the tire or rim. Clean off any oil
that inadvertently gets on them with a high flash-point
solvent.

eAfter the oil has completely drained out, install the

drain plug with a new aluminum gasket, and tighten it
to the specified torque (see Exploded View).
eFi l1 the final gear case up to the bottom of filler
opening with the oil specified below.

Final Ga.r Case Oil

Type: API GL-5 Hypoid gear oil
A. Filler Opening SAE90 (above SoC, 41F)
SAE80 (balowSoC, 41F)
Capacity: 0.3 L
*If it is insufficient, first check the final gear case for
oil leakage, remedy it if necessary, and add oil through NOTE
the filler opening. Use the same type and brand of oil Q
N
GL-5" indicates a quality and additive rating. HGL_6 H

that is already in the final gear case. rated hypoid gear oils can also be used.
eBe sure the O-ring is in place, and tighten the filler
cap to the specified torque (see Exploded View).
eBe sure the Oring is in place, and tighten the filler cap
to the specified torque (see Exploded View).

Front Bevel Gears and Cam Damper

Final Gear Case Oil Change

-Warm up the oil by running the vehicle so that the oil Front Gear Case Removal
w ill pick up any sediment and drain easily. Then stop eLoosen the clamp screw at the front of the propeller
the vehicle. shaft dust cover .
Park the vehicle so that it is level, both side-ta-side eSupport the rear of the frame so that the rear wheels
and front-to-rear . are off the ground.
Place an oil pan beneath the final gear case, and remove -Remove t he pivot bolts at the front of the left and
the drain plug. right suspension arms.

eRemove the upper mounting bolts and nuts at the left
and right rear shock absorbers.
ePu ll the rear axle and propeller shaft toward the rear to
free the propeller shaft front end from the front drive
gear shaft rear end.
A. Pivot Bolt C. Dust Cover Clamp
B. Upper Mounting Bolt
ePlace an oil pan beneath the engine left side.
eRemove the shift pedal clamp bolt and take off the
pedal from the shaft.
eRemove the reverse lever clamp bolt and take off the
lever from the shaft.
eRemove the oil sea l housing mounting nuts and take
off the housing.
A. Oil Seal Housing B. Mounting Nuts
eRemove the front gear case mounting bolts and take
off the case. The differential shift lever case, differen-
tial cable bracket, and reverse cable bracket come off
with the mounting bolts.
FINAL DRIVE 9-7
A. Front Gear Case C. Differential Shift
B. Cable Brackets Lever Case
eRemove the drive gear and output shaft LH bearing
housing to complete the removal of the front gear case
gasket.
OSh ift the transmission gears in any gear position.
ORemove the right engine cover (see Right Engine Cover
Removal in the Engine Right Side chapter).
OUsing the gear holder (special tool: PIN 57001 -101 5)'
hold the primary and secondary gears to keep them
from turn ing (see Clutch Removal in the Engine Right
Side chapter).
OUnscrew the drive gear nut and take off the drive gear
and shim(s).
A. Drive Gear Nut B. LH Bearing Housing
ORemove the bolts holding the output shaft LH bearing
housing and pu ll out the bearing housing.
o Remove the gasket and dowel pins from the crankcase.
eTo remove the output shaft LH bearing from its
housing, remove the bearing holder using the hexagon
wrench (special tool) and drive out the bearing with the
bearing driver set (special too l: PIN 5700 1-11 29) if
necessary.
9-8 FINAL DRIVE

eApply grease to the oil seals on the front gear case, and
use the oil seal guides (special tools) to protect the oil
seals during case installation.

A. Hexagon Wrench: 57001-1194

B. Bearing Holder

A. Oil Seal Guides: 57001-264

Front Gear Case Installation
eFront gear case installation is the reverse of removal.
Note the following.
-The front drive gear and driven gear are~ lapped as a set
in the factory to get the best tooth contact. They must eTighten the front gear case 8 mm bolts to the specified
be replaced as a set. torque (see Exploded View).
eBe sure to check and adjust the bearing preload and the eApply a high temperature grease to the oil seal and
beve( gear backlash and tooth contact, when any of the install the oil seal housing to the front gear case. Be
parts which influence these items are replaced (see sure the Qring is in place in the groove on the housing.
Front Bevel Gear Adjustment).
-Install the LH bearing, bearing housing, and drive gear.
Olf the LH bearing was removed, drive the bearing into
the bearing housing.
Olnstall the bearing holder so that the flat side of it faces
out, and tighten it to the specified torque (see
Exploded View).
OStake the bearing holder after torquing with a punch .

OWhen staking the holder, be careful not to apply shock

to the bearing. Such a shock could damage the bearing.

A. Apply grease . B. O-ring

Ol nstall the LH bearing and housing to the crankcase,
and tighten the housing bolts to the specified torque
(see Exploded View). The front gear case gasket
should be installed after finishing the front bevel gear
adjustment. eTighten the oil seal housing nuts to the specified torque
Ol nstall the shim(s) and drive gear onto the output shaft. (see Exploded View).
OA pply an oil to the threads and seated surface on the eApply grease to the splines at the front end of the
drive gear nut, and tighten it to the specified torque propeller shaft and fit the propeller shaft to the drive
(see Exploded View). gear shaft.
 FINAL DRIVE 9-9
-Bend back the toothed washer tabs and remove the
beari ng preload nut.
.Pull the tapered roller bearings and housing out of the
shaft.
Dlf necessary, use the bearing puller (special tool: PIN
57001158).
-Using the driven gear holder (special tool), remove the
driven gear nut and take off the driven gear, damper
cam follower, and spring. The spring seat is press-fitted
onto the shaft.

A. Apply grease.

-Tighten the following fastener to the spe<;ified torque

(see Exploded View in the Suspension chapter) .
Rear Shock Absorber Mounting Bolts and Nuts
Rear Suspension Arm Pivot Bolts
-Adjust the reverse cable (see Reverse Cable Adjustment
in the Engine Bottom/Transmission chapter).
_Add engine oil as if necessary (see Engine Oil Level
Inspection in the Engine Right Side chapter).

A. Driven Gear D. Spring Seat

B. Damper Cam Follower E. Driven Gear Holder:
C. Spring 57001-1215
Front Drive Gear Removal/Installation
_The front drive gear is removed and installed during
front gear case removal and installation (see Front Gear eTa remove the ball bearing pressfitted onto the front
Case Removal and Installation ). gear case, use the oil seal and bearing remover (special
tool).

Front Driven Gear and Cam Damper Removal

eRemove the front gear case (see Front Gear Case
Removal) .
Pull the driven gear and cam damper assembly out of
the front gear case. The shim(s) comes off with the
assembly.

A. Oi l Seal and Bearing Remover: 57001 1058

Front Driven Gear and Cam Damper Installation

eFront driven gear and cam damper installation is the
reverse or removal. Note the following,
eThe front drive gear and dr iven gear are lapped as a set
A. Bearing Preload Nut C. Shim(s) in the factory to get the best tooth contact. They
B. Bearing Housing must be replaced as a set.
910 FINAL DRIVE
eBe sure to check and adjust the bearing preload and the Drive Gear Shims (* : Standard)
bevel gear backlash and tooth contact, when any of the
Thickness
parts which influence these items are replaced (see Part Number
(mm)
Front Bevel Gear Adjustment).
eReplace the driven gear nut with a new one. 0.15 920251573
eApply an oil to the threads and seated surface on the 0.20 920251574
front driven gear nut, and t ighten it to the specified 0.7 920251534
torque (see Exploded View). 0.8 920251535
0.9 920251536
1.0' 920251537
1 .1 920251575
1.2 920251538
1.3 920251533

Front Bevel Gear Adjustment Driven Gear Shims (* : Standard)

In order to prevent one gear from moving away from
Thickness
the other gear under load, the tapered roller bearings Part Number
(mm)
must be properly preloaded. Aslo the backlash (d istance
one gear will move back and forth without moving the 0.1 920251697
other gear) and tooth contact pattern of the bevel gears 0.15 920251698
must be correct to prevent the gears from making no ise 0.5 920251699
and being damaged. 0.8 920251700
Above three adjustments are of critical importance 1.0' 920251701
and must be carried out in the correct sequence and 1.2 920251702
method.

Front Bevel Gear Adjustment Procedure

I Preload the driven gear bearings.

I Preload adjustment
eAssemble the bearing housing, and tighten the bearing
, I preload nut to adjust the bearing preload.

I Adjust gear backlash.

,,
I [CAUTlO~]
OTo start with, tighten the bearing prelpad nut so that
I
the bearings are just SNUG with NO play but also with

I Adjust tooth contact pattern.

I NO preload.
OAn over-preload on the bearings could damage the

, I
bearings.

eApply engine oil to the bearings, and turn the gear

I Assemble the front gear case completly.
I shaft more than 5 turns to allow the bearings to seat.
eMeasure the bearing preload. Bearing preload is
difined as the force or torque which is needed to start
the gear shaft turning.

When the any of the backlashrelated parts are
rep laced, or the bearing preload nut is loosened; even if
the purpose is not to replace the parts, be sure to check
and adjust the bearing preload and the bevel gear
backlash and tooth contact by replacing shims.
NOTE
OPreload can be measured either with a spring scale or
with a beam-type torque wrench. When measured with
a spring scale, the preload is designated by force (N,
kg), and when measured with a torque wrench, it is
designated by torque (N'm, kgm, infbi.
 FINAL DRIVE 9-11

BacklashRelated Parts

1 . Front Gear Case 10. Drive n Gear Bearing

2. Ball Bearing Housing
3. Driven Gear Shaft 11. Tapered Roller Bearing
4. Dri ve n Gear Parts which influence the bearing
5. Ball Bearing preload only
6. Bearing Housing 12. Tapered Roll er Bearing
7. Drive Gear Shim(s) *13. Bearing Preload Nut *Whenever the nut is loosened, even if
8. Drive Gear the purpose is not to rep lace the parts.
9. Dri ve n Gear Shim(s)

Using Spring Scale: Using Torqu e Wrench:

Hook t he spring scale on the handle at a point 180
mm apart from the center of the gear shaft.
Hold the bearing housing in a vise so that the gear
shaft axis is vertical. App ly force to the handle
horizontally and at a right angle to it.

A. Torque Wrench

*If th e preload is out of the specified range, loosen o r

tighten the bearing preload nut. To decrease preload,
A. Spring Scale C. Driven Gear Holder: 570011215 loosen the bearing preload nut. To increase preload ,
B. Hole D. 180 mm tighten the nut.
9-12 FINAL DRIVE
*Change the tightening torque of the nut a little at a OTo hold the drive gear steady, hold the shift drum at
time. the full-turned position.
eRe..check the bearing preload , and re-adjust as necessary.

Preload for Driven Gear Bearings

Using spring scale: 1.7 - 3.3 N (0.17 - 0.33 kg)
Using torque wrench: 0.3 - 0 .6 N-m
(0.03 - 0 .06 kg-m,
2.6 - 5.2 in~bl

Backlash adjustment
eelean any dirt and oil off the bevel gear teeth. A. Turn B. Neutral Detent
elnstall the drive gear with the standard shim (see the
shim tables), and tighten the nut to the specified
torque (see Exploded View).
OApply an oil to the threads and seated surface on the *If the backlash is not within the limit, replace the
nut. shim(s) at the driven gear. To increase backlash,
-Install the driven gear and cam damper assembly to the decrease the thickness of the shim(s). To decrease
front gear case with the standard shim (see the shim backlash, increase the thickness of the shim(s) .
tablesL and tighten the mounting nuts to the specified *Change the thickness a little at a time.
torque (see Exploded View) without the oil seal eRe-check the backlash, and re-adjust as necessary .
housing.
-Install the front gear case to the crankcase, and tighten
the 8 mm case bolts to the specified torque (see
Front Bevel Gear Backlash
Exploded View).
OCheck the backlash during the tightening of the case Standard: 0.06 -0.10 mm
mounting bolts, and stop tightening them immediately (at bearing preload nut)
if the backlash disappears . Then, change the shim to a
thinner one.
-Set up a dial gauge against a bearing preload nut of the
driven gear shaft to check gear backlash.

Tooth contact adjustment

-Clean any dirt and oil off the bevel gear teeth.
eApply checking compound to 4 or 5 teeth on the
driven gear.

NOTE
OApply checking compound to the teeth in a thin, even
coat with a fairly stiff paint brush. If painted too
thickly, the exact tooth pattern may not appear.
OThe checking compound must be smooth and firm,
with the consistency of tooth paste.
OSpecial compounds are available from automotive
supply stores for the purpose of checking differential
gear tooth patterns and contact. Use this for checking
A. Dial Gauge B. Move.
the bevel gears.

eTo measure the backlash, move the driven gear back

and forth while holding the drive gear steady . The _Turn the driven gear for 3 or 4 revolutions in the drive
difference between the highest and lowest gauge and reverse (coast) directions, while creating a drag on
readings is the amount of backlash. the drive gear.
 FINAL DRIVE 9-13

e<:::heck the drive pattern and coast pattern of the bevel Correct Tooth Contact Pattern
gear teeth. The tooth contact patterns of both drive
and coast sid es should be centrally located between th e Drive Gear
top and bottom of the tooth, and a little closer to the
toe of the tooth.
* If the tooth contact pattern is incorrect, replace the
shim(s) at the drive gear and shim(s) at the driven gear,
Bottom
following the examples shown. Then erase the tooth
contact patterns, and check them agai n. Also check . I
~~
the backlash every time the shims are replaced. Repeat
the shim change procedure as necessary.

NOTE
Olf the backlash is out of the standard range after
changing shims correct the backlash before checking
i
'"''#/
Bottom

the tooth contact pattern.

, Toe
~'" Bottom

Driven Gear ______ ~_ ~,

Bottom \ ~
Heel

Incorrect Tooth Contact Patterns

Example 1: Increase the thickness of the drive gear Example 2: Decrease the thickness of the drive gear
shim (s) by 0.05 mm, and/or decrease the thickness of the shim(s) by 0.05 mm, and /or increase the thickness of the
driven gear shim (s) by 0.05 mm to correct the pattern driven gear shim(s) by 0.05 mm to correct the pattern
shown below. Repeat in 0.05 mm steps if necessary. shown below. Repeat in 0.05 mm steps if necessary.

Drive Gear
Drive Gear

Bottom

~/". '
Toe Top ,---

Bottom

Toe
TOe
Bottom

9 e
Bottom
Driven Gear ~
Driven Gear
.......--"':;
~
Top
Bottom T
\ op Bottom

Heel Heel
9-14 FINAL DRIVE

Bevel Gear Inspection

_V isuall y check the bevel gears for scoring, chipping, or Propeller Shaft
other damage.
*Replace the bevel gears as a set if either gear is damaged.
Propeller Shaft Removal
eRemove the rear axle and propeller shaft (see Rear
Axle and Propeller Shaft Removal).
eRe mo ve the propeller shaft housing mounting nuts and
Ball Bearing Inspection ta ke off the housing with the propeller shaft. The
spring comes off with the propeller shaft.
-Since the ball bearings are made to extremely close
tolerances, the wear must be judged by feel rather
than measurement. Clean each bearing in a high f1ash-
point solvent, dry it (do not spin the bearing while it is
dry), and oil it with engine oil.
eSpin the bearing by hand to check its condition.
*If the bearing is noisy, does not spin smoothly. or
has any rough spots, replace it.

Tapered Roller Bearing Inspection

-V isuall y inspect the bearing for abrasion, color change,
or other damage.
*If there is any doubt as to the condition of a bearing,
replace it.

A. Propeller Shaft Housing C. Spring

B. Mounting Nuts

Oil Seal Inspection

-Inspect the oil seals.
*Replace it if the lips are misshapen, disco lored (in
dicating that the rubber has deteriorated), hardened,
or been otherwise damaged.
eRemove the circlip with the circlip pliers (special tool:
PIN 57001-143), and pull out the propeller shaft
assembly from the housing.

Cam Damper Inspection

eVisuall y inspect the damper cam (driven gear), cam
follower, spring, and shaft.
*Replace the part if it appears damaged.

rM
,
A. Circlip

eRemove the circlip with the circlip pliers (special tool:

PIN 57001-144), and pull out the propelier shaft from
A. Cam (driven gear) C. Spring the propeller shaft joint. The washer comes off with
B. Cam Follower D. Shaft the joint.
 FINAL DRIVE 9-15

A. Circlip B. Propeller Shaft Joint A. Apply grease.

Propeller Shaft Joint and

Propeller Shaft Installation
.Propeller shaft installation is the reverse of removal.
Note the following.
eLubricate the propeller shaft before installation (see
Propeller Shaft Lubrication).
-Tighten the propeller shaft housing mounting nuts
to the specified torque (see Exploded View).
Pinion Gear Joint Inspection
_Visually inspect the internal splines of the propeller
shaft sliding joint.
*If they are badly worn or chipped, replace the joint
with a new one .
Visually inspect the splines of the pinion gear joint.
*If they are badly worn or chipped, replace the joint
with a new one.

Propeller Shaft Lubrication

eLubricate the propeller shaft joint.
OWipe the old grease off the propeller shaft joint and
pinion gear joint, and apply grease to the splines on
them.

A. Splines

Propeller Shaft Inspection

A. Apply grease.
eLubricate the propeller shaft.
oWipe the old grease off the splines on the propeller
shaft, and apply grease to them.
e(;heck that the universal joint works smoothly without
rattling or sticking.
*If it does not, the bearing of the universal joint is
damaged. Replace the propeller shaft with a new one.
.Visually inspect the grease seal and cap for the universal
joint.
*If there is any signs of deterioration, damage, or loosen,
replace the propeJler shaft.
*If the grease leakage is noted, replace the propeller
shaft.
9-16 FINAL DRIVE

-Loosen the clamp screw at the fro nt of the propeller

shaft dust cover.
-Support the vehicle with the frame so that the rear axle
are free from loads.
eRemove the lower mounting bolts of the left an d right
rear shock absorbers.
-Remove the suspension arm pivot bolts and nuts
mounting to the rear axle, and free the rear axle with
the propeller shaft from the vehicle.

A. Universal Joint C. Center Bearing

B. Grease Seal D. Splines

A. Dust Cover Clamp C. Pivot Bolts

B. Lower Mounting Bolt

NOTE
Olf the final gear case is full of oil, place the rear axle so
that the correct side of it is up. If the rear axle is
A. Grease Cap B. Splines
upside down or sideways, the oil will be drained out of
the case through the vent hose.

_Inspect the center bearing.

oSince the ball bearings are made to extremely close
tol erances, the wear must be judged by feel rather than
measurement.
oSpin the bearing by hand to check its condition.
*If the bearing is noisy , does not spin smoothly, or has
any rough spots, replace the propeller shaft.
eVisuall y inspect the splines on the propeller shaft.
*If they are badly worn or chipped, replace the propeller
shaft. Also, inspect the splines on the front driven gear
shaft.
Rear Axle and Propeller Shaft Installation
eRear axle and propeller shaft in stallation is the reverse
of removal. Note the following.
eApply grease to the splines at the front end of the
propeller shaft and fit the propeller shaft to the drive
gear shaft.

Rear Axle Shafts

Rear Axle and Propeller Shaft Removal

elf the final gear case is to be disassembled, drain the
final gear case oi l (see Final Gear Case Oil Change).
eRemove the following parts.
Rear Wheels
Rear Drums
Rear Brake Panels A. Apply grease.
 FINAL DRIVE 9-17

eTighten the following bolts and nuts to the specified

torque (see Exploded View in the Suspension chapter).
Shock Absorber Lower Mounting Bolts
Suspension Arm Pivot Bolts and Nuts
eRoute the fin al gear case vent hose as shown.

A. Oil Seal and Bearing Remover: 57001-1058

Axle Shaft Installation

elf the final gear case oil was drained, fill the case with
oil (see Final Gear Case Oil Change).
eAxle shaft installation is the reverse of removal. Note
the following.
eUsing a press and the bearing driver set (special tool:
PIN 57001-1129), install the oil seals and ball bearings
until they stop at the bottoms of their housings.
eSe sure the differential shifter and collar are in place
when installing the left axle shaft.

Axle Shaft Removal

eRemove the rear axle and propeller shaft (see Rear
Axle and Propeller Shaft Removal).
eRemove the axle shaft pipe mounting bolts, and take
off the left and right axle shaft pipes with shafts. The
aluminum gasket comes off with each shaft pipe.

A. Differential Shifter B. Collar

eApp ly grease to the oil seals on the axle shaft pipes.

A. Axle Shaft Pipes

.Pull the collar off the left axle shaft.

eTa remove the ball bearings press-fitted onto the axle
shaft pipes, use the oil seal and bearing remover (special
tool). Also remove the oil seal behind each bearing
using the same special tool. A. Apply grease.
9-18 FINAL DRIVE
eTighten the axle shaft pipe mounting bolts to the
specified torque (see Exploded View) .
Axle Shaft Inspection
-Inspect the condition of the splines at each end of the
axle.
A. Splines
*If the splines are twisted or damaged in any way,
replace the rear axle.
Ball Bearing Inspection
elnspect the axle shaft pipe ball bearings.
oTurn each bearing back and forth while checking for
roughness or binding.
A. Bearing Seal
*If roughness or binding is found, replace the bearing.
eExamine the bearing seal of the ax le shaft pipe bearing
for tears or leakage.
*If the seal is torn or is leaking, replace the bearing.
Oil Seal Inspection
-Inspect the oil seals.
*Replace any if the lips are misshapen, discolored (in~
dicating that the rubber has deterioratedL hardened,
or been otherwise damaged.
.............................................................................
Final Bevel Gears and Differential Gears
Pinion Gear Disassembly
eRemove the rear axle and propeller shaft (see Rear
Axle and Propeller Shaft Removal).
ePull the pinion gear assembly off the final gear case.
The sh im (s} comes off with the assembly.
OPry at the gaps at the left and right of the pinion gear
bearing housing flange.
A. Pinion Gear Assembly B. Shim(s}
.Pry open the staking of the pinion gear nut with a small
ch isel.
_Unscrew the pinion gear nut using the bevel gear holder
(special tool) to keep the pinion gear assembly as
shown, and remove the pinion gear nut, flat washer,
shim(s), and pinion gear joint. The Oring is between
the pinion gear joint and the bearing.
A. Bevel Gear Holder: 57001-1193
B. Pinion Gear
 FINAL DRIVE 919
ePut! the pinIon gear out of the bearing housing. ePull the ring gear and differential gear hous.ing out of
ePry the oil seal off the bearing housing, and remove the case.
the tapered roller bearing inner race .

Pinion Gear Assembly

ePinion gear assembly is the reverse of disassembly.
Note the following.
eThe pi nion gear and ring gear are lapped as a set in the
,.
.~ ,tit
factory to get the best tooth contact. They must be
replaced as a set.
eSe sure to check and adjust the pinion gear bearing ..

preload and the bevel gear backlash and tooth contact, , ~ "~f
when an y of the parts which influence these items are
replaced (see Final Bevel Gear Adjustment).
o When the pinion gear nut is loosened, even if the ~ ~"
--~'.
propose is not to replace the parts, check and adjust
the bearing preload.
eReplace the pinion gear nut with a new one.
eApply an oil to the threads and seated surface on the A. Ring Gear
pinion gear nut, and tighten them to the specified B. Differential Gear Housing
torque (see Exploded View).
eStake the head of the pinion gear nut with a punch, to
secure the pinion gear nut in place after finishing the
bearing preload adjustment.

eRemove the bolts and separate the rin g gear and

OWhen staking the nut. be careful not to apply shock to
the pinion and their bearing. Such a shock could
damage the pinion and/or bearings.
differential gear housing cover from the housing. The
differential left side gear comes off with the housing
cover.

Ring Gear and Differential Gear Disassembly

eRemove the rear axle and propeller shaft (see Rear
Axle and Propeller Shaft Removal) .
eRemove the pinion gear assembly (see Pinion Gear Dis-
assembly).
eRemove the axle shafts (see Axle Shaft Remova l).
eUnscrew the final gear case cover bolts, and pull off the
gear case cover. The shim(s) comes off with the cover.

A. Housing Cover C. Right Side Gear

B. Left Side Gear D. Pinion Gears

eDrive the retaining pin out of the differential gear

hou sing, and pull the pinion gear shaft off the housing.
The pinion gears and right side gear can be removed
from the housing. The copper th rust washer is behind
A. Final Gear Case Coyer each gear.
9-20 FINAL DRIVE
A. Thrust Washer
eTo remove the ball bearings press-fitted onto the final
gear case and case cover, use a press and bearing driver
set (special tool: PIN 57001 11 29).
OBe careful not to scratch the sealing surfaces of the
final gear case and case cover during the bearing
removal and installation. A scratched sealing surface
may allow oil to leak.
A. Sealing Surfaces
Ring Gear and Differential Gear Assemblv
eRing gear and differential gear assembly is the reverse
of disassembly. Note the following.
eThe ring gear and pinion gear are lapped together at the
factory to get the best tooth contact. They must be
replaced as a set.
eBe sure to check and adjust the pinion gear bearing pre~
load and the bevel gear backlash and tooth contact,
when any of the parts which influence these items are
replaced (see Final Bevel Gear Ad justment) .
eApply a non -permanent locking agent to the threads of
the ring gear and differ-ential gear housing assembly
bolts, and tighten them to the specified torque (see
Exploded View) .
-Using a press and the bearing driver set (special tool:
PIN 57001-1129), install the ball bearings until they
stop at the bottom of their housings.
eTighten the fin al gear case cover bolts to the specified
torque (see Exploded View).
Final Bevel Gear Adjustment
In order to prevent one gear from moving away from
the other gear under load, the tapered roller bearings
must be properly preloaded. Also the backlash (distance
one gear will move back and forth without moving the
other gear) and tooth contact pattern oJ the bevel gears
must be correct to prevent the gears from making noise
and being damaged.
Above three adjustments are of critical importance
and must be carried out fo ll owing the correct sequence
and method.
Final Bevel Gear Adjustment Procedure
I Preload the pinion gear bearings.
I
,
I Adjust gear backlash.
II'
I
~
I Adjust tooth contact pattern.
I
, /
I Assemble the final gear case completly.
I
When anyone of the backlash-related parts are
replaced or the pinion gear nut is loosened; even jf the
purpose is not to rep1ac.e the parts, check and adjust the
bearing preload and the bevel gear backlash and tooth
contact by replacing shims.
The amount of backlash is influenced by the ring
gear position more than by the pinion gear position.
Tooth contact location is influenced by pinion gear
position more than by ring gear position.
 FINAL DRIVE 921
Backlash-Related Parts

Parts which influence the bearing

1. Pinion Gear Bearing Housing
preload only
2. Pinion Gear Shim(s)
3. Final Gear Case 11. Tapered Roller Bearing
4. Tapered Roller Bearing 12. Pinion Gear Joint
5. Final Gear Case Cover 13. Preload Adjustment Shim(s)
6. Ring Gear *14. Pinion Gear Nut
7. Ball Bearing
8. Differential Gear Housing
9. Ring Gear Shim(s)
10. Pinion Gear *Whenever the nut is loosened, even if the
purpose is not to replace the parts .

Shims for Preload Adjustment Ring Gear Shims for Pinion Gear Shims for
Thickness Backlash Adjustment Tooth Contact Adjustment
Part Number Thickness
(mm) Thickness
Part Number Part Number
0 .1 92025-1287 (mm) (mm)
0.15 92025-1656 0.1 92025-1709 0.1 92025-1703
0.2 92025-1288 0.15 92025-1710 0.15 92025-1704
0.3 92025-1289 0.5 92025 -1711 0.5 92025-1705
0.5 92025-1290 0.8 92025-1712 0.8 92025-1706
0.6 92025-1291 1.0* 92025-1713 1.0* 92025 -1707
0.7 92025-1292 1.2 92025-1714 1.2 92025-1708
0.8 92025-1293 (* : Standard) (* : Standard)
0.9 92025-1294
1.0 92025-1295
1.2 92025-1657
1.3 92025-1282
9-22 FINAL DRIVE
Preload adjustment
eAssemble the pinion gear bearing housing, and t ighten
the pinion gear nut to the specified torque (see
Exploded View). Do not install the oi l seal unt il the
correct bearing preload is obtained.
Using Spring Scale:
Hook the spring scale on the hand le at a point 200
mm apart from the center of the gear shaft. Hold the
bearing housing in a vise so that the gear shaft axis is
vert ical. Apply force to the handle horizontally and at
a right angle to it.

OTa start with, choose a shim or shims so that the

bearings are just SNUG with NO play but also with NO
preload.
GAn over-preload on the bearings could damage the
bearings.

eApply final gear case oil to the bearings, and turn the
gear shaft more than 5 turns to allow the bearings to
seat.
eMeasure the bearing preload. Bearing preload is
defined as the force or torque which is needed to start
the gear shaft turning.

NOTE
OPreload can be measured either with a spring scale or a A. Spring Scale C. Bevel Gear Holder: 57001-1193
beam-type torque wrench. When measured with a B. Hole D.200mm
spring scale, the preload is designated by force (N, kg),
and when measured with a torque wrench, it is des-
ignated by torque (Nm, kg-m, in-fbi.

Preloading Bearings

(A) Before Tightening (B) After Tightening

"'_---~~~~~ffiI-- No clearance
Initial
Clearance

Under Under
no preload preload

1. Washer
2. Shim(s)

Using Torque Wrench:
A. Torque Wrench
*If the preload is out of the spec ified range, replace th e
shims under the flat washer. To increase preload,
decrease th e thickness of the shim(s). To decrease
preload , increase the thickness of the shim(s).
CChange th e thickness a littl e at a tim e.
eRe-check the bearing preload, and re-adju st as nec-
essary.
Preload for Pinion Gear Bearings
Using spring scale: 1.5 -3.0 N
(0.15 - 0.30 kg)
Using torque wrench: 0 .3 -0.6 Nm
(0.03 - 0.06 kgm,
2.6 - 5.2 inlb)
Backlash adjustment
eelean any dirt and o il off the bevel gear teeth.
e lnstall the pinion gear assembly with the stand ard shim
(see th e sh im t ables), and tighten the propeller shaft
pipe mounting nuts to the specified torque (see
Exploded View) without t he propeller shaft housing.
e lnstall t he ring gear and differential gear housing to the
final gear case, and put the stan dard shim (see the sh im
tables) onto the ring gear.
ePut on the final gear case cover and t ighte n the cover
mounting bolts to the specified torque (see Exploded
View) .
OCheck t he backlash durin g the t ightening of the cover
mounting bo lts, and stop tighte nin g them imm ediate ly
if the backlas h disappears. Then, change the ring gear
sh im to a thinner one.
eSet up a dial gauge against a ring gear tooth to check
gear backlash.
FINAL DRIVE 9-23
A. Dial Gauge B. Hold c. Move
eTa measure the backlash, move the ring gear back and
forth whil e hold ing the pinion gear steady. The dif
ference between the highest and the lowest gauge read -
ing is the amou nt of back lash.
*If the backlash is not w.ithin the limit, rep lace th e ring
gear shims. To increase backlash, decrease the thickn ess
of the sh im (s) . To decrease backlash, increase the
thickness of the shim(s) .
CChan ge the thickness a litt le at a time.
eRe-check the backlash, and re-adjust as necessary.
Final Bevel Gear Backlash
Standard: 0.08 - 0.25 mm
(at ring gear tooth)
Tooth contact adjustment
eelean any dirt and oil off th e bevel gear teeth.
eApply checking compound to 4 or 5 teeth on the
pinion gear.
NOTE
OApply checking compound to the teeth in a thin, even
coat with a fairly stiff paint brush. If painted too
thickly, the exact tooth pattern may not appear.
OThe checking compound must be smooth and firm~
with the consistency of tooth paste.
OSpecial compounds are available from automotive
supply stores for the purpose of checking differential
gear tooth patterns and contact. Use one of these for
checking the bevel gears.
elnstall the shi m(s) and pinIOn gear assem bl y, and
tighten the mounting nuts to th e speci fied torqu e (see
Exp loded View).
elnstall the ring gear and differential gear housing to t he
final gear case, and put the shim (s) onto the ring gear.
ePut o n the fi nal gear case cover and tigh ten the cover
mounting bolts to the specified torque (see Exploded
View).
924 FINAL DRIVE
Correct Tooth Contact Pattern

Ring Gear
Bottom

Top Heel
Pinion Gear Toe

Bottom

I ncorrect Tooth Contact Patterns

Example 1: Decrease the thickness of the pinion gear
shim (s) by 0.05 mm to correct the pattern shown below.
Repeat in 0.05 mm steps if necessary.

Ring Gear
Bottom

-+-------- :~
Heel
------- I Toe
Pinion Gear
Toe

Bottom

Bottom
Example 2: Increase the thickness of the pinIOn gear
shim(s) by 0.05 mm to correct the pattern shown below.
Repeat in 0.05 mm steps if necessary.

Bottom

Heel

Pinion Gear

~'~
/
Heel
~-Bottom
Top
Bottom
 FINAL DRIVE 9-25
eTurn the pinion gear for one revolution in the drive and Oil Seal Inspection
reverse (coast) direction, while creating a drag on the elnspect the o il seal.
ring gear . *Replace it if the lips are misshapen, discolored (in-
eRemove the ring and pinion gear assemblies to check dicating that the ru bber has deteriorated)' hardened,
the drive pattern and coast pattern of the beve l gear or been otherwise damaged.
teeth. The tooth contact patterns of both (d rive and
coast) sides should be centrally located between the
top and bottom of the tooth. The drive pattern can be
a little closer to the toe and the coast pattern can be a
somewhat longer and closer to the toe.
*If the too th contact pattern is incorrect, replace the
pinion gear shim(s). following the examples shown .
Then erase th e tooth contact patterns, and check them
aga in. Also chec k the backlash every time the shim(s) Differential Shift Mechanism
are replaced . Rep eat the shim change procedure as
necessary.
Shift Lever Case and Cable Removal
eRemove two front gear case bolts holding the
NOTE
differential shift lever case.
O ff the backlash is out of the standard range after
changing t he pinion gear shim(s), change the ring gear
shim(s) to correct the backlash before checking the
tooth contact pattern.

Bevel Gear Inspection

eVisuall y check the bevel gears for scoring, chipping, or
other damage.
*Rep lace the bevel gears as a set if either gear is
damaged.

Differential Gear Inspection

eVisually check the different ial gears for scoring,
chipping, or other damage.
*Replace the differential gears as a set if either gear is
damaged. Also, inspect the thrust washers, differential
pinio n gear shaft, and gear housing where the
diffe renti al gears rub. If they are sco red, discolored,
or otherwise damaged, replace them.
A. Differential Shift Lever Case C. Cable Bracket
B. Remove these bolts .
ePry open the cable bracket and free the cable from it.
eLoosen the mounting nuts and take off the cable
adjuster fro m its bracket.
ePull th e cable tip out of th e catch o n the lever and free
t he case and cable from th e vehicle .

Tepered Roller Bearing Inspection

eVi suall y inspect t he bearings for abras ion, color change,
or other damage.
*If there is any doubt as to the condition of a bearing,
replace it.

Ball Bearing Inspection

elnspect the final gear case ball bearings.
05ince the ball bearings are made to extremely close
to lerances, the wear must be jud ged by feel rather than
meas urement. Clean each bearing in a high flashpo in t
solvent, dry it (do not spin the bearing while it is dry).
and o il it with engi ne oil.
OSpi n the bearing by hand to check its condition .
*If t he bearing is no isy, does not spin smoothly, or has A. Mounting Nuts C. Cable Tip
any ro ugh spo ts, replace it. B. Adjuster
9-26 FINAL DRIVE
-Separate the cable from the case.
ORemove the screws and take off the plate.
oPull the cable housing out of the case and free the cable
tip from the catch on the shift lever. Do not lose the
rubber seals.

A. Differential Shift Fork Lever

B. Left Suspension Arm
C. Shock Absorber Lower Mounting Bolt
D. Left Axle Shaft and Pipe

A. Cable Tip C. Do not loosen this pivot bolt.

B. Rubber Seals ePull the differential shifter off the shift fork ears.

000 not loosen the shift lever pivot bolt. Loosening the
pivot bolt upsets the position of the special designed
collar under the lever. and could cause malfunctioning
of the lever action.

Shift Lever Case and Cable Installation

_Shift lever case and cable installation is the reverse of
removal. Note the following.
eLubricate the differential cable (see Differential Cable
Lubrication) .
eTighten the front gear case 8 mm bolt to the specified
torque (see Exploded View). A. Differential Shifter C. Shift Fork Holder
eAdjust the differential cable (see Differential Cable B. Shift Fork
Adjustment).

eUnscrew the shift fork holder screws and pull off the
holder with the gasket. Now, the shift fork can be
Shifter and Shift Fork Removal removed.
eDrain the final gear case oil (see Final Gear Case Oil
Change).
-Support the vehicle with the frame so that the rear
axle are free from loads.
eRemove the following parts.
Differential Shift Fork Lever
Rear Left Wheel
Rear Left Drum and Panel Shifter and Shift Fork Installation
Left Suspension Arm _Shifter and shift fork installation is the reverse of
Left Shock Absorber Lower Mounting Bolt removal. Note the following.
Left Axle Shaft eApply grease to the shift fork shaft .
 FINAL DRIVE 927

A. Apply grease. A. Cable Housi ng D. Differential Shift Lever

B. Holder (in "LOCK" position)
C. Cable Bracket
-Tighten the shift fork holder screws to the specified
torque (see Exp loded View). -Rotating the rear whee ls, shift the rear ax le into the
-Adjust the differential cable (see Differential Cable lockedaxle mode by turning the shift fork shaft clock-
Adjustment). wise.

Differential Cable Adjustment

Whenever the differential cable is removed and the
differential shift lever play is excessive, adjust the
differential cable.
-Push the different ial shift lever down all the way to the
"LOCK" position.
-Unhook the shift fork lever return spring.
-Remove the sh ift fork lever nut and take off the lever.

A. Shift Fork Shaft B. Turn clockwise.

-Fit the cable tip in to t he catch on the shift fo rk lever

and mount the lever o nto the shaft pu lli ng the cable
taut.

A. Shift Fork Lever C. Cable Adjuster

B. Return Spring D. Mounting Nuts

_ Loosen the cable adjuster mounting nuts.

-Sl ide the cable housing forward until the front end of it
seats fully in to the holder on the case, tighten the cable
adjuster mounting nuts without changing the position
of the cable hous ing and clamp the open end of the
cable bracket to secure the cable housing in place. A. Shift Fork Lever B. Pull the cable taut.
9-28 FINAL DRIVE
eHook the shift fork lever return spring.

Differential Cable Lubrication

Whenever the differential cable is removed, lubricate
the differential cable as follows .
-Lubricate the differential cable by seeping the oil
between the cable and cable housing.

Cable Lubrication

Shifter and Shift Fork Inspection

_Visually inspect the dogs on the shifter and different ial
gear housing, and the shifter groove, and shift fork.
*If they are damaged or worn excessivel y, replace them.

-Apply a thin coating of mUlti-purpose grease to the

differential sh ift lever pivot area and the differential
cable ends.

A. Dogs B. Shift Fork C. Groove

-Check that the shifter slides smoothly on the axle

shaft.
*If it does not slide smoothly, repair the splines on th e
sh ifter and axle shaft or replace them if necessary.

A. Apply grease.

Differential Cable Insepction

-With the differential cable disconnected at the both
ends, the cable should move freel y within the cable
housing.
*If cable movement is not free after lubricating (see
Differential Cable Lubrication), if the cable is frayed ,
or if the housing is kinked, replace the cable. A. Shifter
 BRAKES 10-1

Brakes
Table of Contents

Exploded View . . . . . . . . . . . . . . .. . .. 10-2 Brake Hoses ..... _ . . . . .. . . . . .. .... 1012

Specifications .. _ . . . . . . . . ... .. . . . . . 10-4 Brake Hose Removal. . .. . . . . . . . . 1012
Special T oo l . . . . . . . . . . . . . . .. ... . . . . 10-4 Brake Hose Installation. . . . . . . . . . .. 10-12
Brake Adjustment .. . . . . . . . . . . . . . . . . . . 10-5 Brake Hose Inspection. . . . . . . . . . . .. 10-13
Front Brake Lever Brake Drums . _ . _ .. .. .. _ ... _ . . . . .. 10-13
Free Play Inspection 10-5 Front Brake Drum
Brake Shoe Adjustment 10-5 Removal/Installation . ... . .. . . .. . 1013
Rear Brake Pedal Rear Brake Drum Removal . .. . . . . . . . 1013
Free Play Inspection . . . . . . ... . . . 10-6 Rear Brake Drum Installation . . . . . . . . 10-13
Rear Brake Pedal Free Play Front or Rear Drum Disassembly/
Adjustment . . . . . . . . . . . . . . . .. . 10-6 Assembly Note ... ..... ..... . 10-13
Cam Lever Angle Adjustment . .. . . .. . 10-7 Brake Drum Wear ....... ....... 1014
Brake Fluid ................... . . .. . . 10-7 Rear Brake Drum Seal Wear . . . . . . . . . 1014
Brake Fluid Recommendation . ... . . . 10-7 Brake Panel Assemblies .. . . . . . . . . . . . . . . 1014
Brake Fluid Level Inspection ... . ... . 10-8 Front Brake Panel
Brake Fluid Changing . . . . . . . . . . . . 10-8 Removal/Disassembly 1014
Brake Line Air Bleeding . . . . . . . . ... . 10-9 Front Brake Panel
Master Cylinder and Wheel Cylinders .... . . . 10-10 Assembly/Installation 1015
Master Cylinder Remova l . . . . . . . . . . . 10-10 Rear Brake Panel
Master Cylinder Installation .... .. . . . 10-10 Removal/Disassembly 1015
Master Cylinder Disassembly . .... . . . . 10-11 Rear Brake Panel
Master Cylinder Assembly . . ... . ... . 1011 Assembly/Installation . . . . . . .. . . . 1015 I
Wheel Cyli nder Removal ........ . . . 10-11 Brake Shoe Lining Wear . . . . . . . . . . . . 10.16~
Wheel Cylinder Installation . .. ... . . . . 10-11 Brake Shoe Spring Inspection . . . . . . . . 10-16~
Wheel Cy li nder Disassembly ... . .. .. . 10-11 Brake Camshaft and
Wheel Cylinder Assembly .......... 10-11 Camshaft Hole Wear ... . .. . . . . . . 10-16
Master Cyli nder Inspection . ... .. ... . 1011 Brake Panel Lubrication . . . . . . . . . . . . 1016
Whee l Cylinder Inspection . . . . . .. . . . 10-12 Brake Pedal and Cables . . . . . . . . . . . . . . . . 10-17
Brake Lever Lubr ication .......... . 10-12 Brake Pedal and Cable Removal . .. . .. . 10-17
Brake Pedal and Cable Installation .. . . . 10-18
Brake Cable Inspection . . . . . . . . . . . . 101B
Brake Pedal and Cable Lubrication . _ . _. 10-1B
10-2 BRAKES
........
E
........ _.. View .. __
__ ~ploded u u __ u u u u . u . u u . u
.................
.... ........ . ............ ........... ..........................

lJ:'
~ ~ d)~~:
T1

@
I I

$ T4

I @J~
t @~ ~@ ~
@~~~@~ ~

A'A. pply adhesive

G 'A pply grease .
S,.
I : Apply silic .
Tl : 25 N.m (2 one grease.
5
T2: 20 N-m (2. kgm, lS ft-Ibl
0
T3: 11 N-m (1. kgm, 14.5 ft-Ibl
:---'"""1
___' .. Frame No T4: 5.9 N-m (~~~g-m, 95 in-Ibl
T5: 7.S N.m (O.SO kg-m, 52 in-Ibl
JKALFSA1DG
JKALFSA lDG:04250 and up or T6: 145 N-m (150kg-m, 69 inlbl
LF300A-004250 09409 and up or T7: 29 N.m (30 ' kg-m, 110 ft-Ibl
and up . kg-m, 22 ft-Ibl
 BRAKES 10-3

G
10-4 BRAKES

Specifications

Brakes:

Item Standard Service Limit

Front Brake Lever Free Play 25 -30 mm - -

Rear Brake Pedal Free Play 20 - 30mm --
Rear Brake Cam Lever Angle 80 - 90 --
Brake Fluid: Grade D.O.T.3 --
Brand Recommended as below. --
Brake Drum Inside Diameter 160.000 - 160.160 mm 160.65 mm
Brake Shoe Lining Thickness 4.0mm 2.0mm
Rear Brake Camshaft Diameter 16.957 - 16.984 mm 16.83 mm
Rear Brake Camshaft Hole Diameter 17.000 - 17.027 mm 17.15 mm

Recommended Brake Fluid

Type Brand
Atlas Extra Heavy Duty
Shell Super Heavy Duty
Texaco Super Heavy Duty
D.O.T.3 Wagner Lockheed Heavy Duty
Castro I GirlingUniversal
Castro I GT (LMA)
Castro I Disc Brake Fluid

Special Tool
Jack: 57001 1238
Along with common hand tools, the following more
speciali zed tools are required for complete brake
servicing.

Circlip Pliers: 57001 143

 BRAKES 10-5

Brake Adjustment

Front Brake Lever Free Play Inspection

ePull the front brake lever fully until the front brake is
dragged firmly. This is the free play.

~=r@
~ '\ A. Shoe Check Hole B. Lining Thickness
~_J ,
":.. _ _ - _ - _ _ _ 0#

Brake Shoe Lining Thickness

Standard: 4.0mm
Service Limit: 2.0mm

*If any lining thickness is less than the service limit,

A. Brake Lever Free Play
replace both shoes as a set.
eApply a brake several times.
elnsert a thin screwdriver through the hole marked
"SHOE ADJUST", and turn the brake shoe adjusting
*If the front brake lever free play is incorrect, adjust the wheel in the direction shown below to expand the shoe.
brake shoe to drum clearance for both front wheels
(see Brake Shoe Adjustment).
*If the free play cannot be corrected by adjusting the
brake shoes, there might be air in the brake lines and
the air bleeding must be necessary (see Brake Line Air
Bleeding).

Front Brake lever Free Play

Standard: 25 -30mm

-Operate the lever a few times to see that it returns to

its rest position i'mmediately upon release.
eRotate the front wheels to check for brake drag.
-Check braking effectiveness.
*If there is any doubt as to the conditions of the brake, A. Shoe Adjust Hole B. Turn adjusting wheel.
check the brake parts for wear or damage.

-Continue turn ing the adjusting wheel until a firm drag

Brake Shoe Adjustment
eSupport the vehicle on a stand so that the front wheels
are off the ground.
ePull the rubber cap out of the wheel.
eThrough the inspection hole marked "SHOE CHECK",
inspect the brake shoe lining thickness at several points.
is felt when attempting to rotate the wheel.
eTurn back the adjusting wheel until the wheel just
turns free and then turn back three clicks rrore to
provide running clearance.
000 not adjust the brake shoes too close to the drum.
The brake will drag, heat up and lock. The lining will
be charred and rendered useless.
10-6 BRAKES

eApply a brake several times and rotate the wheel to
check for brake drag.
-Repeat the previous step one more time for the other
shoe.
Rear Brake Pedal Free Play Inspection
-Depress the rear brake pedal lightly by hand. This is
the free play.
*If the rear brake pedal free play is incorrect and each
lining wear indicator points within the USABLE
RANGE, adjust the rear brake pedal free play (see
Rear Brake Pedal Free Play Adjustment).
e()perate the pedal a few times to see that it returns to
its rest position immediately upon release.
eRotate the rear wheels to check for brake drag.
-Check braking effectiveness.
*If there is any doubt as to the cond iti ons of the brake,
check the brake parts for wear or damage.

Rear Brake Pedal Free Play Adjustment

Rear Brake Pedal Free Play -Support the vehicle on a stand or the jack (special too l:
57001-1238) so that t he rear wheels are off the ground.
Standard: 20 -30mm -Loosen the locknut and turn the brake pedal position
adjusting bolt until the brake cable equal izer stops by
the frame bracket.

A. Brake Pedal Free Play

A. Adjusting Bolt C. Equalizer
B. Locknut D. Bracket

e<:heck each brake lining wear indicator points with in

the USABLE RANGE when the brake is fully applied. -Shift the rear ax le to the unlockedaxle mode.
*If does not, the brake shoes must be immediately re -Turn the adjuster at the rear end of the cable until a
placed and the other brake parts examined. light drag is felt when attempting to rotate the wheel.

A. USABLE RANGE B. Wear Indicator A. Adjuster

 BRAKES 10-7
eRepeat the above step one more time for the ot her Cam Lever Angle Adjustment
cable. eRemove the bolt and nut, and take off t he cam lever.
eMount the cam lever at a new position so that t he cam
lever has a proper angle when the brake is full y app lied.
NOTE
Olf the rear brake cables cannot be adjusted by using the
adjusters at the rear ends of the cables, use the adjusters
at the equalizer. Do not forget to securely tighten the Cam Lever Angle
adjuster mounting nuts. Standard:

eAdjust the brake pedal position to suit you by turning

the brake pedal adjust ing bolt.
eTighten the locknut.
eTurn both adjusters at the rear ends of th e brake cables
until the brake pedal has the correct amount of play.
The adj usters must be turned in the same direction and
the same number of t urns . Th is will keep the eq ualizer
in th e stra ight ahead positio n.
-Check the cam lever comes to the proper angl e with the
brake cable when t he brake is full y applied.
Cam Lever Angle
Standard:
eAdju st the rear brake pedal free play (see Rear Brake
Pedal Free Play Adjustment).
WARNING'
OWhen remounting the cam, be sure that the position of
the ind icator on the serrated shaft is not altered.
OA change in cam lewr angle is caused by wear of inter-
nal brake parts. Whenever the cam lever angle is
adjusted, also check for drag and proper operation,
taking particular note of the brake lining wear indicator
position .
Din case of doubt as to braking effectiveness, disas-
semble and inspect all internal brake parts. Worn parts
could cause the brake to lock or fail.

*If does not, adjust t he cam lever angle (see Cam Lever
Angle Adj ustment).

WARNING'
0
OSince a cam lever angle greater than 90 reduces
braking effectiveness. cam lever angle adjustment
should not be neglected.

Brake Fluid

Brake Fluid Recommendation

Recommended fluids are given in the table below. If
none of the recommended fluid s are available, use extra
heavy-du ty brake fluid only from a contai ner mar ked
D.O.T.3.

-o Recommended Brake Fluid

Type D.O.T.3
Brand Atlas Extra Heavy Duty
Shell Super Heavy Duty
A. Cam Lever Angle (80 - 90) Texaco Super Heavy Duty
Wagner Lockheed Heavy Duty
Castrol Girting-Universal
Castrol GT (LMA)
Castrol Disc Brake Fluid
10-8 BRAKES
WARNING I
oNever reuse old brake fluid.
000 not use fluid from a container that has been left un-
sealed or that has been open for a long time.
000 not mix two types and brands of fluid for use
in the brake. This lowers the brake fluid boiling
point and could cause the brake to be ineffective.
It may also cause the rubber brake parts to deteriorate.
ODon't leave the reservoir cap off for any length of time
to avoid moisture contamination of the fluid.
ODon't add or change the fluid in the rain or when a
strong wind is blowing.
Olf any of the brake line fittings or the bleed valve is
opened at any time, the AIR MUST BE BLED FROM
THE BRAKE.
!CAUTlO~]
OBrake fluid quickly ruins painted surfaces; any spilled
fluid should be completely wiped up immediately.
Brake Fluid Level Inspection
.Position the reservoir horizontal, and check that the
fluid level in the reservoir is higher than the lower revel.
A. Lower Level
*If the fluid level is lower than the lower leve l, check for
the flu id leakage of the brake line, and add the fluid as
follows.
ORemove the reservoir cap, and fill the reservoir to the
upper level line in the reservoir with the same type and
brand of the fluid that already is in the reservoir. And
then install the reservoir cap.
I WARNING I
OChange the fluid in the brake line completely if the
fluid must be refilled but the type and brand of the
fluid that already is in the reservoir are unidentified .
A. Upper Level Line
eApply a brake forcefully for a few seconds, and check
for fluid leakage around the fittings.
I WARNING I
Olf the brake lever has a soft or "sponge feeling" when
it is applied, there might be air in the brake line or the
brake may be defective. Since it is dangerous to
operate the vehicle under such conditions, bleed
the air from the brake line immediately.
Brake Fluid Changing
eRemove the front wheels (see Wheel Removal in the
Wheels/Tires chapter).
eRemove the reservoir cap, and remove the rubber cap
on the bleed valve.
eAttach a clear plastic hose to the bleed valve on the
wheel cylinder, and run the other end of the hose into
a con tai ner .
-Open the bleed valve (counterclockwise to open). and
pump the brake lever until all the fluid is drained from
the line.
e<:lose the bleed valve.
eRepeat the above 4 steps one more time for the other
side.
eFi li the reservoi r with fresh brake fluid.
eOpen the bleed valve, apply the brake by the brake
lever, close the valve with the brake held applied, and
then quickly release the lever. Repeat this operation
until the brake line is filled and fluid starts coming out
of the plastic hose.
NOTE
oReplenish the fluid in the reservoir as often as neces-
sary to keep it from running completely out.
eRepeat the above 2 steps one more time for the other
side.
eBleed the air from the lines (continue with Brake Line
Air Bleeding).
 BRAKES 10-9

eTighten the bleed valves to the specified torque (see NOTE

Exploded View).
OThe fluid level must be checked several times during
elnstall the front whee ls (see Wheel Installation in the
the bleeding operation and replenished as necessary. If
Wheels/Tires chapter).
the fluid in the reservoir runs completely out any time
during bleeding, the bleeding operation must be done
Filling up Brake Line
over again from the beginning since air will have
entered the line.

-Connect a clear plastic hose to the bleed valve at the

wheel cylinder, running the other end of the hose
into a container .
With th~ reservo ir cap off, slowly pump the brake lever
several times until no air bubbles can be see rising up
through the fluid from the holes at the bottom of the
reservoir. Th is bleeds the air from the master cylinder
end of the line.
ePump the brake lever a few times until it becomes hard
and then, holding the lever squeezed, quick ly open
(turn counterclockwise) and close the bleed valve.
Then release the lever. Repeat this operation untiL no
more air can be seen com ing out into the plastic hose.
-Repeat the previous step one more time for the other
sid e.
eWhen air bleeding is finished, check that the fluid is
filled to the upper level line marked in the reservoir.

,..
.

1. Open the bleed valve .

2. Apply the brake lever and hold it. A. Upper Level Line
3. Close the bleed va lve.
4. Then release the brake lever suddenly.

e ln stall the reservoi r cap.

Brake Line Air Bleeding
eRemove the front wheels (see Wheel Removal in the
Wheels/Tires chapter).
eRemove the reservoir cap, and check that there is
plenty of fluid in the reservoir.
eTighten the bleed valves to the specified torque (see
Exploded View).
eApply the brake lever forcefully for a few seconds, and
check for fluid leakage around the fittings.
e ln stall the front wheels (see Wheel Installation in the
Wheels/Tires chapter).
10-10 BRAKES

Bleeding Brake Line

A. Banjo Bolt C. Clamp Bolts

B. Master Cylinder

-. eRemove the clamp bol ts and take off the master

cylinder.

@.,
,
Master Cylinder Installation
eMaster cylinder installation is the reverse of removal.
Note the following.
eThe master cylinder clamp must be installed with the
UP mark faced upwards.
eTorque the upper clamp bolt first, and then the lower
clamp bolt (see Exploded View). There will be a gap at
the lower part of the clamp after tightening.

1. Hold the brake lever applied.

2. Quickly open and close the bleed valve.
3. Release the brake lever.

.............................................................................
Master Cylinder and Wheel Cylinders

A. Tighten upper clamp bolt first.

Master Cylinder Removal
ePull back the dust cover, and remove the banjo bolt to
disconnect the upper brake hose from the master
cylinder. There is an aluminum washer on each side of
the hose fitting .
elmmediately wipe up any brake fluid that spills.
OBrake fluid quickly ruins painted surfaces; any spilled
fluid should be completely wiped up immediately.
B. UP mark
-Use a new flat washer on each side of the brake hose
fitting, and tighten the banjo bolt to the specified
torque (see Exploded View).
eBleed the brake line after master cylinder installation
(see Brake Line Air Bleeding).
-Check that the brake line has proper fluid pressure and
no fluid leakage.

Master Cylinder Disassembly
eRemove the master cylinder (see Master Cylinder
Removal).
-Remove the reservoir cap and diaphragm, and empty
out the brake fluid.
eRemove the locknut and pivot screw, and remove the
brake lever.
-Slide the dust cover out of its place.
-Remove the retainer with the circlip priers (special
tool: PIN 57001143) and pull the piston with
secondary cup, and take off the primary cup and
spring.
NOTE
ODo not remove the secondary cup from the piston since
removal will damage them.
Master Cylinder
1. Spring 4. Piston
2. Primary Cup 5. Dust Cover
3. Secondary Cup
Master Cylinder Assembly
eMaster cylinder assembly is the reverse of disassembly.
Note the following.
eBefore assembly, clean all parts including the master
cylinder with brake flu id or alcohol, and apply brake
fluid to the removed parts and the inner wall of the
cylinder.
OUse only brake fluid. isopropyl alcohol, or ethyl
alcohol, for cleaning brake parts. Do not use any other
fluid for cleaning these parts. Gasoline, motor oil,
or any other petroleum distillate will cause
deterioration of the rubber parts. Oil spilled on any
part will be difficult to wash off completely, and will
eventually deteriorate the rubber used in the brake.
-Lubricate the brake lever (see Brake Lever Lubrication).
Wheel Cylinder Removal
eThe wheel cylinders are removed during front brake
panel disassembly (see Front Brake Panel Removal /
Disassembly).
BRAKES 10-11
Wheel Cylinder Installation
-The wheel cylinders are installed during front brake
panel assembly (see Front Brake Panel Assembly/
Installation).
Wheel Cylinder Disassembly
.Remove the wheel cyl inder (see Wheel Cylinder
Removal).
-Pull the dust covers out of the cylinder.
.Pull the pistons and cups out of the cylinder.
.'"
A. Dust Covers C. Cups
B. Pistons
Wheel Cylinder Assembly
-Wheel cylinder assembly is the reverse of disassembly.
Note the fol lowing.
-Before assembly, clean all parts including the wheel
cylinder with brake fluid or alcohol, and apply brake
fluid to the removed parts and the inner wall of the
cylinder.
DUse only brake fluid, isopropyl alcohol, or ethyl
alcohol, for cleaning brake parts. Do not use any
other fluid for cleaning these parts. Gasoline, motor
oil, or any other petroleum distillate will cause
deterioration of the rubber parts. Oil spilled on any
part will be difficult to wash off completely, and will
eventually deteriorate the rubber used in the brake .
Master Cylinder Inspection (Visual Inspection)
-Check that there are no scratches, rust or pitting on
the inside of the master cylinder and on the outside
of the piston.
* If the master cylinder or piston shows any damage,
replace them .
-Inspect the pr imary cup and secondary cup.
10-12 BRAKES
*If a cup is worn, damaged, softened (rotted), or
swollen, replace the piston assembly. Brake Hoses
*If fluid leakage is noted at the brake lever, the piston ............................................ . ....................... ! ........

assembly shou ld be replaced to renew the cup.

-Check the dust cover for damage.
*If it is damaged , replace it.
-Check that. the relief and supply ports are not plugged .
*If the small relief port becomes plugged , blow the
ports clean with compressed air.
-Check the piston return spring for any damage.
*If the spring is damaged, replace the piston assembly.
Brake Hose Removal
-Remove the banjo bolts at both ends of the brake hose,
and pull the hose off the vehicle. There is a copper
washer on eac h side of the hose fitting.
eTo remove the metal pipe, unscrew the metal pipe
nipple and pull out the reta iner.

NOTE
OThe cups and spring are pan of the piston assembly.
Replace the piston assembly if anyone of the cups or
the spring requires replacement.

Wheel Cylinder Inspection (Visual Inspection)

e<:heck that there are no scratches, rust or pitting on the
inside of the wheel cylinder and on the outside of the
pistons.
*If the wheel cylinder or piston shows any damage,
replace the cylinder.
-Inspect the cups. A. Metal Pipe Nipple B. Retainer
*If a cup is worn, damaged, softened (rotted), or
swoll en, replace the cylinder.
*If flu id leakage is noted at the dust covers, the cylinder -Immediately wipe up any brake fluid that spills.
should be replaced to renew th e cup.
-Check the dust covers for damage.
*If these are damaged, replace them. {CAUTION I
OBrake fluid quickly ruins painted surfaces; any spilled
fluid should be completely wiped up immediately.

Brake Lever Lubrication

Whenever the master cylinder is disassembled, and in
accordance with the Periodic Maintenance Chart,
perform the following .
_Lubricate the brake lever by applying a light coating of Brake Hose Installation
si licone grease to the brake lever pivot screw and the elf the hose protector was removed, in sta ll it to the
contact with the piston. fram e bracket by applying an ad hesive to it.

A. App ly grease. A. Hose Protector

 BRAKES 1013

eUsing a new copper washer for each side of the hose

fitti ngs, tighten the banjo bolts to the specified torque
(see Exploded View).
eTighten the metal pipe nipple to the specified torque
(see Exp lo ded View) .
eBleed the air from the brake line (see Brake Line Air
Bleeding).
Brake Hose Inspection
eThe high pressure inside the brake line can cause fluid
to leak or the hose to burst if th e line is not properly
maintained. Bend and twist the rubber hose whil e
examining it.
*Replace it if any cracks or bulges are noticed.
eThe metal pipe which feeds the brake fluid to the
2-way joint is made of plated steel, and will rust if the
plating is damaged .
*Replace the hose if it is rusted, cracked (especial ly
check the fittings), or if the plating is badly scratched.
I WARNING'
OBrake linings contain asbestos fiber. Inhalation of
asbestos may cause serious scarring of the lungs and
may promote other internal injury and illness,
including cancer. Observe the following precautions
when handling brake linings:
1. Never blow brake lining dust with compressed air.
2. If any components are to be cleaned, wash them
with detergent, then immediately discard the
cleaning solution and wash your hands.
3. Do not grind any brake lining material unless a
ventilation hood is available and properly used.
Rear Brake Drum Installation
eRear brake drum installation is the reverse of removal.
Note the following.
eApply a low-temperature grease to the brake drum seal
lip. An example of a low-temperature grease is NOK
TOPAS J L152.

Brake Drum Seal Lubrication

Grease
Brake Drums

Front Brake Drum Removal/Installation

eThe front brake drums are removed and installed
during front hub bearing removal and installation (see
Front Hub Bearing Removal and Front Hub Bearing
Installation in the Wheels/Tires chapter).

Rear Brake Drum Removal

eRemove the rear wheels (see Wheel Removal in the
Wheels/Tires chapter) .
eRemove the cotter pins and loosen the axle nuts. Hold eTighten the axle nut to the specified torque (see
the axle from turning by applying the rear brake while Exploded View).
loosening the axle nuts.

Front or Rear Drum Disassembly/

Assembly Note
eDo not press the drum bolts out.
*If the drum bolt is damaged, replace the drum and
bolts as a unit.

A. Axle Nut

1. Front Drum 3. Rear Drum

ePu ll each brake drum off the end of the axle. 2 . Drum Bolts
10-14 BRAKES
Brake Drum Wear
eMeasure the inside diameter of the drum.
DUse calipers and measure at several points.
*If any measurement is greater than the service limit,
replace the drum.
*If the drum is worn unevenly or scored, lightly turn the
drum on a brake drum lathe or replace it. Do not turn
the drum beyond the service limit.
Brake Drum Inside Diameter
Standard : 160.000 -160.160 mm
Service limit : 160.65 mm
Rear Brake Drum Seal Wear
Whenever the braking efficiency of the rear brake has
decreased, perform the following.
eRemove the drain plug at the bottom of the rear brake
panel and check to see if any water comes out.
A. Drain Plug
*If any water drains, the rear brake drum seal is
damaged and must be immediately replaced. Also,
inspect the other brake parts.
.............................................................................
Brake Panel Assemblies
Front Brake Panel Removal/Disassembly
eRemove the front brake drum (see Front Brake Drum
Removal).
WARNING I
OBrake linings contain asbestos fiber . Inhalation of
asbestos may cause serious scarring of the lungs and
may promote other internal injury and illness,
including cancer. Observe the following precautions
when handling brake linings:
1. Never blow brake lining dust with compressed air.
2. If any components are to be cleaned, wash them
with detergent, then immediately discard the
cleaning solution and wash your hands.
3. Do not grind any brake lining material unless a
ventilation hood is available and properly used.
eRemove the brake shoe springs.
A. Brake Shoe Springs
eRemove the retainers and take off the brake shoes.
oPush the shoe hold-down spring and twi st the pin to
remove them.
NOTE
OHold the brake shoes with a clean cloth to protect the
linings from grease or dirt.
A. Shoe Hold-down Spring

eRemove the banjo bolt to disconnect the lower end of
the brake hose from the wheel cylinder. There is an
aluminum washer on each side of the hose fitting.
Olmmediately wipe up any brake fiuid that spills.
[CAUTlO~]
OBrake fluid quickly ruins painted surfaces; any spilled
fluid should be completely wiped up immediately.
A. Brake Hose Banjo Bolt
eRemove the brake panel mounting bolts, and take off
the brake panel assembly.
A. Brake Panel Mounting Bolts C. Shoe Ad ju ster
B. Wheel Cylinder
Remove the bolts and take off the brake shoe adjuster.
eRemove the bolts and take off the wheel cylinder .
Front Brake Panel Assembly/Installation
Front brake panel assembly/ instal lation is the reverse
of removal/disassembly. Note the following.
BRAKES 10-15
eTighten the following bolts to the specified torque (see
Exploded View).
Wheel Cylinder Mounting Bolts
Shoe Adjuster Mounting Bolts
Brake Panel Mounting Bolts
Brake Hose Banjo Bolt
.Lubricate the brake panel parts (see Brake Panel
Lubrication).
eBleed the brake line (see Brake Line Air bleeding) after
brake panel installation.
eAdjust the brake shoe to drum clearance (see Brake
Shoe Ad justme nt).
Rear Brake Panel Removal/Disassembly
.Remove the rear brake drum (see Rear Brake Drum
Removal).
WARNING I
OBrake linings contain asbestos fiber. Inhalation of
asbestos may cause serious scarring of the lungs and
may promote other internal injury and illness,
including cancer. Observe the following precautions
when handling brake linings:
1. Never blow brake lining dust with compressed air.
2. If any components are to be cleaned, wash them
with detergent, then immediately discard the cleaning
solution and wash your hands.
3. Do not grind any brake lining material unless a
ventilation hood is available and properly used .
Unscrew the adjuster at the rear end of the rear brake
cable, and pull the cable out of the join t. Do not lose
the joint and spring.
eRemove the brake panel mounting bo lts and plate, and
take off the brake panel assembly and Oring .
Hold the brake shoes, one in each hand with a clean
cloth to protect the linings from grease and dirt.
.Pu ll up on the shoes to remove them from the panel.
eRe move the spr in gs to separate the two shoes .
Mark the cam and lever so that they can "be aligned the
same way during assemb ly.
eRemove the brake cam lever and wear indicator.
.Pu II the brake cam o ut from the inside. Do not lose
the dust seal.
Rear Brake Panel Assembly/Installation
eRear brake panel assembly/ installation is the reverse of
removal. Note the fo ll owing .
eLubricate the rear brake panel parts (see Brake Panel
Lubrication) .
Install the wear indicator so that it points to the
bottom end of the usable range projection.
eTighten the brake panel mounting bolts to the specified
torque (see Exploded View).
oApp ly grease to the Oring and fit it onto the end of
the axle pipe .
OThe projected portion of the plate must be faced in.
10-16 BRAKES

ODo not use a solvent which will leave an oily residue or

the shoes will have to be replaced .

Brake Shoe Spring Inspection

-Visually inspect the brake shoe springs for breaks or
distortion.
*If the springs are damaged in any way, replace them.

A. Projected Portion

eAdjust the rear brake pedal free play (see Rear Brake
Pedal Free Play Adjustment).
Brake Camshaft and Camshaft Hole Wear
eMeasure the camshaft diameter.
*If any measurement is less than the service limit,
replace the camshaft.

Brake Shoe Lining Wear

eMeasure the lining thickness.
oUse a caliper or scale, and measure at several points as
shown. Brake Camshaft Diameter
Standard : 16.957 -16.984 mm
Service Limit : 16.83 mm

eMeasure the inside diameter of the camshaft hole in the

brake panel.
OUse a small hole gauge in several directions insi?e the
hole, and then measure the small hole gauge with a
micrometer.
*If any measurement is larger than the service limit,
replace the brake panel.

Brake Camshaft Hole Inside Diameter

Standard: 17.000 -1 7.027 mm
Service Limit: 17.15 mm
Brake Shoe Lining Thickness
Standard: 4.0mm
Service Limit: 2.0mm

Brake Panel Lubrication

*If any measurement is less than the service limit, Whenever the brake panel assembly is disassembled,
replace both shoes as a set. perform the following.
*If the lining thickness is greater than the service limit, eelean all old grease out of the brake panel parts with a
do the following before install ing the shoes. cloth.
eFile or sand down any high spots on the surface of the eFor the front brake panel, apply a high-temperature
lining. grease to the following.
-Use a wire brush to remove any foreign particles from Brake Panel and Brake Shoe Contact Points
the lining. Wheel Cylinder Piston Ends
-Wash off any oil or grease with an oilless solvent. Brake Shoe Adjuster Ends
 BRAKES 10-17

A. App ly grease . A. Ad justers B. Equalizer

-For the rear brake panel, apply a high-temperature -Remove the brake pedal and lever.
grease to the following. o Unhook the return spring.
Brake Shoe Anchor o Remove the cotter pin and nu t, and pull off the brake
Spring Ends pedal and lever. Do not lose the O-rings.
Camshaft Groove
Cam Surfaces

Brake Pedal and Cables

Brake Pedal and Cable Removal

-Remove the brake cables.
o Unscrew the adjusters at the rear ends of the cables,
and pull the cable out of the joints and cable mounts.
Do not lose the joints and springs .

A. Return Spri ng B. Cotter Pin

eRemove the parking bra ke levers.

OUnhook return spring.
ORemove the clamp bolt and pull off the upper and
lower levers. Do not lose the Orings and caps.

A. Adjuster C. Spring
B. Joint

Oloosen the mounting nuts, pull the front adjusters of

the cables off the mounts, and free the front ends of
the cables from the equalizer . A. Upper Lever B. Lo wer Lever
10-18 BRAKES

Brake Pedal and Cable Installation

-Brake pedal and cable installation is the reverse of
removal. Note the following.
-Lubricate the brake pedal, cables, and/or parking brake
lever (see Brake Pedal and Cable Lubrication).
-Install the brake pedal so that the punch mark on the
pedal is aligned with the mark on the shaft of the lever.
elnstall the upper and lower parking brake levers
aligning the punch marks on both levers.

Brake Pedal and Cable Lubrication

eelean all old grease out of the brake parts with a cloth.
-Apply a multi-purpose grease to the following:
Brake Pedal Pivot Shaft
Parking Brake Lower Lever Shaft

A. Align marks.

-Route the rear brake vent hoses as shown .

A. Apply grease B. O-rings

-Clean any excess grease from the parts before assemb ly.
-Lubricate the brake cable by seep ing the oil between
the cable and cab le housing.

Cable Lubrication

A. Rear Brake Vent Hose B. Brake Cables

-Adjust the rear brake pedal free play (see Rear Brake
Pedal Free Play Adjustment) .

Brake Cable Inspection

-With the brake cable disconnected at the both ends, the
cable should move freely within the cable housing.
*If cable movement is not free after lubricating (see
Brake Pedal and Cable Lubrication), if the cable is
frayed, or if the cable housing is kinked, replace the -Oil the follow ing lightly:
cable. Brake adjusters
 SUSPENSION 11-1

Suspension
Table of Contents

Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 2
Suspension .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3
Shock Absorber Spring Force Adjustment.. . .. .. .. . . . .. ... . . 113
Shock Absorber Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3
Shock Absorber Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Suspension Arm Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Suspension Arm Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4
Suspension Arm Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 4
Shock Absorber and Suspension Arm Inspection . . . . . . . . . . . . . 11-4

m
"-2 SUSPENSION

Exploded View

T1
~~
G : Apply grease.
ff ~~ ~~ @:l
Tl : 34 N-m (3.5 kg-m, 25 ft-Ib)
T2: 88 N-m (9.0 kgm, 65 ft-Ib)
 SUSPENSION 11-3

e<:heck to see that a pair of adjusting sleeves (front two

Suspension adjusting sleeves or rear two) are turned to the same
relative position.

Shock Absorber Spring Force Adjustment

The spr in g adjusting sleeve on each shock absorber
has 5 positions so that the spring can be adjusted for
WARNING.
different terrain and loading conditions.
Olf a pair of adjusting sleeves (front two adjusting sleeves
If the spring action feels too soft or too stiff, adjust it
or rear MO) are not adjusted equally, handling may be
in accordance with the following table.
impaired and a hazardous condition may result.

Spring Action
Spring
Position Setting Load Terrain Speed Shock Absorber Removal
Force
esupport the veh icle on a stand so that the front and/or
1 Stronger Soft Light Good Low
rear wheels are off the ground.
2 (sTD)

11111
-Remove the upper and lower shock absorber mounting
3 bolts and/or nuts.
4 eHolding the wheels, pull out the mounting bolts and
then shock absorbers.
5 Hard Heavy Bad High
o Remove the rear wheels (see Wheel Removal in the
Wheels/Tires chapter) to remove the lower mounting
bolts of the rear shock absorbers easy.

A. Adjusting Sleeve

A. Shock Absorber Mounting Bolts

eTurn the adjusting sleeve on each Sh.DCk absorber to the

des ired position with a hook spanner.

Shock Absorber Installation

-Shock absorber instal lation is the reverse of removal.
Note the following.
-Tighten the upper and lower shock absorber mounting
bolts to the specified torque (see Exploded View) .

Suspension Arm Removal

A. Adjusting Sleeve
eRemove the front and/or rear wheels (see Wheel
Removal in the Wheels/ Tires chapter).
-To remove the front suspension arms, first remove the
following parts.
Brake Drums and Panel Assembl ies
Steering Knuckles
Shock Absorber Lower Mounting Bolts
B. Hook Spanner Brake Hose Clamps from Upper Arms
114 SUSPENSION
eTa remove the rear suspens ion arms, first remove the
final gear case guard.
eRemove the suspension arm pivot bolts and take the
suspension arms off the frame.
Suspension Arm Installation
eSuspension arm installation is the reverse of removal.
Note the following.
eLub ricate the suspension arm pivots of the front upper
and center arms (see Suspension Arm Lubrication ).
_Tighten the suspension arm pivot bolts and shock
absprber lower mounting bolts to the specified torque
(see Exploded View).

Suspension Arm Lubrication

eLubricate the suspension arm pivots of the front upper
and center suspension arms.
oRemove the front suspension arms.
oWipe all the o ld grease out of the sleeves, bushings, and
grease seals.
oA pply fresh grease to the sleeves and grease seal lips.

A. Upper Arm C. Center Arms

B. Lower Arm

Shock Absorber and Suspension Arm Inspection

eV isuall y inspect the rubber bushings in the upper and
lower mountings of the shock absorbers, and the ends
of the rear and front lower suspension arms.
*If they are worn, cracked, hardened, or otherwise
damage, replace them with new ones.

A. Left Arm B. Center Arms

A. Right Arm B. Center Arms

 STEERING 12-1

Steering
Table of Contents

Ex ploded View. ' .' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2

Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-3
Handlebar Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-3
Handlebar Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-3
Handlebar G rip Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-3
Handlebar G rip Installation .. . . .. ... _ .. . . .. _ . . . . . . . . . . . . . . 12-4
Steeri ng Stem Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-4
Steering Stem Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-4
Steering Knuckle and Ti erod Removal . . . . . . . . . . . . . . . . . . . . . . 12-5
Steering Knuckle and Tierod Installation . . . . . . . . . . . . . . . . . . . . 12-5
Steering Knuck le Stopper Adjustment . . . . . . . . . . . . . . . . . . . . . . 12-6
Steering Inspection. .. .. .. . . . . . . . .. . .. .. . .. . .. . . .. . . . .. . 12-6
Steering Stem Warp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Steering Stem Bearing, Tierod Bearing, and
Steering Knuckle Upper and Lower Joint Inspection . . . . . . . . . 12-6
Steeri ng Lu brication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-7
12-2 STEERING

E~-~;~~~~'~i'~:"""""""""""""""""" '" ..............

A : Apply adhesive.
G : Apply grease.
Lh: Left-Hand Threads
T1 : 20
T2' N-m (2
29 N ( '0 k gm, 14.5 ft-Ib)
. -m
T3:41 N- (' 30kgm, 22 ft-Ib)
m 42 kg-m, 30 ft-Ib)
 STEERING 12-3

Steering

Handlebar Removal
-Remove the fuel tank (see Fuel Tan k Removal in the
Fuel System chapte r).
-Remove the fol lowing parts from the handlebar.
LH Switch Housing
Throttle Case
Front Brake Master Cylinder
-Remove the stem head cover screws and ignition
switch ring nut, .and take off the cover.

A. Parallel B. Gap C. No Gap

eTighten the holder rear bolts first and then the front
bolts. When the holder is correctly instal!ed, there will
be even gap at the front and no gap at t he rear after
tighten ing.

Handlebar Grip Removal

-Remove the screw and take off the plug.

A. Screws B. Ring Nut

-Remove the handlebar holder bolts and lift off the

handl ebar.

A. Plug

_Slide a thin drift between the grip and the hand lebar.

A. Handlebar Holders

Handlebar Installation
eHandlebar installation is the reverse of removal. Note
the following.
-I nstall the handlebar so that the angle of the handlebar
matches the angle of the steering stem as shown. A. Drift
12-4 STEERING
eApply a small amount of Kawasaki Electric Contact
Cleaner or equivalent into the opening next to the drift.
ePull the drift out and quickly slide the grip off the
handlebar. Twist the grip as you pull.

Handlebar Grip Installation

eApply an adhesive which is recommended by the
manufacturer for bonding rubb er to metal, to the
inside of the grip.
eSlide the grip into position on the handlebar.

A. Clamp Allen Bolts

Steering Stem Removal

eRemove the following parts.
Front Fender
Fuel Tank
Handlebar
eRemove the following parts from the stem head.
Reverse Knob with Cable
Headlight with Brackets
Ignition Switch
Neutral and Reverse Indicator Light Sockets

A. Tie-rod End Nuts B. Mounting Bolts

ePull the steering stem out of the frame.

eTa remove the steering stem bearing, remove the cotter
pin and remove the nut from the bottom end of the
steering stem.

A. Headlight C. Reverse Knob ~I

B. Ignition Switch D. Neutra l and Reverse Lights I
I

eRemove the cotter pin and remove the tie-rod end nut
from each tie-rod at the steer ing stem.

000 not loose the locknuts at both end of the tie-rod A. Steering Stem Bearing
adjusting sleeve, or the toe-in of the front wheels will
be changed.

eRemove the mounting bolts of the steering stem

bearing housing. Steering Stem Installation
eRemove the steering stem clamp Allen bolts, and take -Steering stem installation is the reverse of removal.
off the clamps and grease seals. Note the following.
 STEERING 12-5

eLubricate the steering stem clamp and stem bearing

(see Steering Lubrication).
elnstall the steering stem clamps so that the ribs on both
grease seals fit into the grooves on the steering stem aDo not loosen the locknut at both ends of the tie-rod
clamps. adjusting sleeve. or the toe-in of the front wheels will
be changed.
elnstall the grease seal facing the end forward to prevent
the entry of dirt.
eRemove the cotter pins and remove the steering
eAlign the marks on the steering stem clamps (The
knuckle upper and lower joints nuts.
mark made during removal).
eTap the steering knuckle to remove the knuckle joints.

[~AUTlO~J
000 not loosen the locknut of the steering knuckle
stopper bolt, or the bolt will turn and the steering
knuckle stopper adjustment may be necessary.

Steering Knuckle and Tie-rod Installation

eSteering knuckle and tie-rod installation is the reverse
of removal. Note the following.
eelean the studs of the steering knuckle upper and lower
joints and the tapered holes of the knuckle, or the
tapers will not fit snugly.

A. Ribs B. Grooves

eTighten the stem bottom end nut, stem bearing housing

mounting bolts, stem clamp Allen bolts, and tie rod
end nuts to the specified torque (see Exploded View).
elnspect the toe-in if necessary (see Toe-in Inspection
in the Wheels/Tires chapter).

Steering Knuckle and Tie-rod Removal

eRemove the following parts from the steering knuckle.
Wheel with Hub Assembly
Brake Panel Assembly with Brake Hose
eRemove the cotter pin and remove the tie-rod end nut
at the steering knuckle.

A. Clean.
elnstall the suitable nut on the tierod end and tap the
nut to remove the tie-rod. eThe left and right tie-rods must be installed as shown.
The tie-rod painted yellow is for the left tie-rod.

A. Steering Knuckle C. Joint Nuts

B. Tie-rod End Nut A. Left Tie-rod B. Yellow Paint Mark
12-6 STEERING
A. Right Tie-rod
eTighten the steering knuckle upper and lower joint
nuts and tie-rod end nuts to the specified torque (see
Exploded View)_
elnspect the toe-in if necessary (see Toe-in Inspection in
the Wheels/Tires chapter).
eAdjust the steering knuckle stopper if necessary (see
Steering Knuckle Stopper Adjustment).
Steering Knuckle Stopper Adjustment
eTurn the handlebar left or right until the edge of the
stem stop bracket touches with the frame bracket.
oTurn the handlebar left if the right steering knuckle
stopper will be adjusted and turn the handlebar right if
the left stopper will be adjusted.
A. Stem Stop Bracket
-Loosen the locknut and turn the steering knuckle
stopper bolt so that the head of it touch with the
bracket on the lower suspension arm.
eTighten the locknut securely.
A. Steering Knuckle Stopper Bolt B. Locknut
Steering Inspection
eTurn the handlebar left to right, and check the steering
action.
*If the steering action is not smooth, or if the steering
binds or catches before the stop, lubric~te the steering.
NOTE
OThe cables and wires will have some effect on the
steering action which must be taken into account.
e<:heck the steering action again.
*If the steering lubrication does not remedy the pro-
blem, inspect the steering stem warp and/or steering
stem clamps, stem bearing and tie-rod bearings.
*If you feel looseness, or if the steering is turned with
the rattle, check the tighteness of the bolts and nuts of
the steering parts.
eTighten loose bolts and nuts to the specified torque
(see Exploded View). and check the steering action
again.
*If the steering action does not change by re-tightening
the bolts and nuts, inspect the steering stem clamps,
stem bearing, tie-rod bearings, and steering knuckle
upper and lower joints.
oWhen replacing the stem ciamps, replace both ciamps as
a set.
Steering Stem Warp
eRemove the steering stem.
-Check the steering stem for straightness.
OUse a straightedge along the stem.
*If the steering stem is bent, replace the steering stem.
Steering Stem Bearing, Tie-rod Bearing,
and Steering Knuckle Upper
and Lower Joint Inspection
elnspect each spherical bearing for roughness, excessive
play, or seizure.
*If roughness, excessive play, or seizure is found, replace
the steering stem bearing, tie-rod, or suspension arm.
 STEERING 12-7

Steering Lubrication
eLubricate the steering stem clamp.
o Remove the steering stem.
oWipe all the old grease out of the steering stem, grease
seals, and clamps.
o ,A_pply grease to the steering stem and pack the grease
seal grooves between the lips with grease.

A. Steering Stem C. Clamps

B. Grease Seals

-Lubricate the steering stem bearing.

o Disassemble the steering stem bearing.
OWipe all the old grease out of the steering stem and
bearing grease seal.
oPack the grease seal groove between the lips with
grease.

A. Grease Seals
 FRAME 13-1

Frame
Table of Contents

Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Seat Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-4
Seat Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . 13-4
Front and Rear Fenders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Front Fender Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Front Fender Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Rear Fender Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-5
Rear Fender Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Frame Exchange. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-6
Suggested Parts Removal Order . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-6
Suggested Parts Installation Order. . . . . . . . . . . . . . . . . . . . . . . . . . 13-6
Decals ... . . . ...... ..... . ... . .. ..... . . . ... . .. . .. , . . . . . . . . . 136
Decal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Decal Application. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-6

m
 13-2 FRAME __......................... .

E~~;~d~~i~~ ............:::::::::::::............................
....................................

.t>

. @ '~
,~~ / ' ~
...

Frame No.
JKALF8A1DG 8512289 and up '" r~~~~f

~r~~
'-
"""
/'

'-
 FRAME 13-3

II
13-4 FRAME

Seat Front and Rear Fenders

Seat Removal Front Fender Removal

ePull the seat lock lever up. eRemove the front carrier and guard.
o Remove the front carrier and front guard mounting
bolts, and take off the carrier and guard. The bolts
holding the carr ier with the front fender have the
flanged collars.

A. Pull.

eLift the rear of the seat, slide it toward the rear A. Mounting Bolts
sl ightly, and lift it off the vehicle.

eRemove the seat (see Seat Removal).

eRemove the fuel tank covers.
ORemove the mounting screws, flanged collars, and nuts,
Seat Installation and pull off the tail cover.
eSe sure the rubber dampers are in place on the bottom
of the seat.
eSl ip the hook on the bottom of the front end of the
seat under the brace on the frame.

A. Tail Cover B. Upper Cover

A.Hook B. Brace
Push the rear of the seat down so that the seat locks on
the bottom of the rear of the seat lock on the catches.
OUnscrew the fuel tank cap, remove the mounting bolts
and flanged collars, and take off the upper cover.
eRemove the front fender side covers .
ORemove the mounting screws and nuts, and take off
the sid e covers.
 FRAME 13-5

A. Side Cover A. Mounting Bolts

eRemove the front fender.

oRemove the front fender mounting bolts and flanged
collars, four screws and nuts of the mud flaps, and take
off the front fender.
eRemove the seat (see Seat Removal).
eRemove the rear fender.
oPull off the storage cover.
ORemove the rear fender mounting bolts and flanged
collars and take off the rear fender.

A. Mounting Bolts
B. Remove these screws (both left and right sides).

A. Mounting Bolts

eTa remove the mud flaps, take out the screws and nuts.

e To remove the mud flaps, take out the screws and nuts.

Front Fender Installation

aFront fender installation is the reverse of removal.

Rear Fender Removal Rear Fender Installation

eRemove the rear carrier. eRear fender installtion is the reverse of removal. Note
ORemove the rear carrier mounting bolts and take off the following.
the rear carrier. Th e bolts from the lower side of the eBe sure the rubber plug is in place in the bottom of the
fender have the flanged collars and dampers. storage case.
13-6 FRAME

Decal Application
Frame Exchange
eelean the surface where the decal is to be applied with
acetone or paint thinner.

Suggested Parts Removal Order

eTo exchange the frame, remove the parts in this order. I WARNING.
Seat
Front and Rear Fenders OThese fluids are usually highly flammable and harmful
Fuel Tank if breathed for prolonged periods. Be sure to heed the
Muffler and Exhaust Pipe fluid manufacturer's warnings.
Battery and Case
Air Cleaner ePeel away the end of the decal backing and stick the
Front Suspension and Steering exposed part of the decal onto the vehicle.
Rear Suspension and Rear Axle eWhen you are sure the decal is in the right place, peel
Engine with Carburetor the rest of the backing off, holding the decal stretched
Electrical Components above the surface where it is to be applied.
Frame Fittings eWorking from the end which was stuck down first,
press the rest of the decal against the surface, little by
little, w ith a squeegee or sim ilar artist's tool.
Suggested Parts Installation Order
eT 0 install the parts on the new frame, reverse the order
of removal.

Decals

Decal Removal
eHeat the decal gently with a heat gun, heat lamp, or
hair drier.

eBe very careful not to wrinkle the decal or get air

bubbles under it.
elf air bubbles do get under the decal, use the following
procedure.
OPrick the bubble with a fine needle or slit it with a
modeling knife.

A. Peel slowly.

ePeel up the end of the decal and slowl y pull it off,

heating the decal as you go.
eelean off the adhesive left on the vehicle surface with
acetone or paint thinner.
A. Slit bubble.
I WARNING.
oUse the squeegee to push the air out of the hole in the
oThese fluids are usually highly flammable and harmful bubble, and stick the decal tightly to the surface.
if breathed for prolonged periods. Be sure to heed the -When the entire decal has been applied, go over it
fluid manufacturer's warnings. several times with the squeegee to burnish it.

Electrical System
Table of Contents
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . 142
KLF300A1, A2 Wiring Diagram ... . .. . .... 143
Exploded View . . . . . . . ... . . . . . . . . . . . . 144
Specifications .. . . . . . . . . . . . . . . . . . . . ... 14~6
Special Tools .... ... . . . . . . . . . , .... 14-6
Battery ..... ... . . . . . . . . . . . . . . , ..... 147
Precautions . . . . . . . . . . . . . . . . . . . . .. 14-7
Battery Removal /Insta llation . . . . . . . . . . 14-7
Battery Removal . . . . . . . . . . . .. ... 14-7
Battery Installation . . . . . . . . . . . . . . . 14-8
Electrolyte . . . . . . . . . . . . . . . . . . . . . . 148
Electrolyte Level Inspection .. _ . .. ... 14-8
Battery Charging . . . . . . . . . . . ...... 14-8
Battery Condition .. ... . .... . . . . . . 148
Battery Initial Charging . . . . . . . . . . . 14-9
Battery Ordinary Charging ..... . ... 14-9
Battery Test Charging . . . . . . . . .... 14-10
Chargi ng System . . . . . . . . . . . . . . . . . . . . 14-11
Part Removal , . . . . . . . . . . . . . . . . . . . . 1411
Alternator Rotor Removal . . . . . . . . .. 14-11
Alternator Rotor Installation . .. .. ... . 14-11
Alternator Stator Removal . . . . . . . . .. 1411
Alternator Stator Installation ... . .... 14-11
Charging System Checkout . . . . . . . . . . . . 14-11
Charging System
Operational Inspection .... . . ... . 14-11
Stator Coil Resistance . . . . . . . . . ... . 1412
Rectifier Circuit Inspection . . . . . . . . . 1412
Regulator Circuit Inspection . .... . . . . 1412
Ignition System . . . . . . . . . . . . . . . . . . . . . 14-14
Safety Instruction s . . . . . . . . . . . . . . . . . 1414
Part Removal . . . . . . . . . . . . . . . . . . . . . 14-14
Engine Stop Switch Removal . . . . . . . . 14-14
Engine Stop Switch Installation . . . . . . . 1414
Ign ition Coil Removal . . . . . . .. .... . 1414
Ignition Coil Installation . . . . . . . ... . 1415
Spark Plug Removal . . . . . . . . .' .... 14-15
Spark Plug Installation .... ... . .... 14-15
Pickup Coil Removal . . . . . . . . . . . . . . 14-15
Pickup Coil Installation . . . . . . . . . . . 14-15
Ignition System Checkout . . . . . . . . . . . . 14-15
Ignition Timing Test . . . . . . . . . . . . . . 1415
Engine Stop Switch Inspection . . . . . . . 1416
Ignition Coil Inspection . . . . . . . . . . . . 14-16
Spark Plug Cleaning and Inspection .... 14-17
Spark Plug Gap . . . . . . . . . . . . . . . . . 14-17
IC Ignitor Inspection . . . . . . . . . . . . . . 14-17
Pickup Coil Inspection . . . . . . . . . . . . . 1418
Alternator Rotor Inspection . . . . . . . . . 1418
Electric Starter System . . . . . . . . . . . . . . . . 1419
ELECTRICAL SYSTEM 141
Part Removal . . . . . . . . .. ..... 14-19
Starter Motor Removal ... . . . . . . . . . 14-19
Starter Motor Installation . .... . ... . . 1419
Starter Motor Disassembly . . . . . . . . .. 1419
Starter Motor Assembly . . . . . . . . . . . . 14-20
Starter Button Removal ... .. . . . . . . . 1422
Starter Button Installation .... . .... . 14-22
Starter System Checkout . . . . . . . . . . . . . 14-22
Starter Motor Brush Length . . . . . . . . . 14-22
Starter Motor Brush Spring Tension . . . . 14-22
Starter Motor
Commutator Inspection . . . . . . . . . . 1422
Starter Motor Armature Inspection .... 14-23
Brush Assembly Inspection . . . . . . . . . . 14-23
Starter Relay Inspection . . . . . . . . . . . 14-24
Starter Circuit Relay Inspection . . . . . . 14-24
Starter Button Inspection . . . . . . . . . . . 14-25
Lighting System . . . . . . . . . . . . . . . . . . . . . 14-25
Headlight Beam
Headlight Beam Vertical Adjustment .... 14-25
Bulb Replacement. . . . . . . . . . . . . . . . . . 14-25
Headlight Bulb Replacement .... . .... 14-25
Taillight Bulb Replacement . .. . . .... 14-26
Neutral and Reverse Indicator
Light Bulb Replacement . . . . . . . . . . . 14-26
Part Removal . . . . . . . . . . . . . . . .. .... 14-26
Light Switch Removal . . . . . . . . . . . . 14-26
Light Switch Installation . . . . . . ..... 14-27
Neutral and Reverse
Switch Removal . . . . . . . . . . . . . . . 14-27
Neutral and Reverse
Switch Installation . . . . . . . . . . . . . 14-27
Lighting System Checkout . . . . . . . . . . . . 14-27
Light Switch Inspection . . . . . . . . . . . 14-27
Neutral and Reverse
Switch Inspection. '" . . . . . . . . 1427
Ignition Switch . . . . . . . . . . . . . . . .. .. . 14-28
Ignition Switch Removal . . . . . . . . . . 14-28
Ignition Switch Installation . . . . . .... 1428
Ignition Switch Inspection .. .. . . . . . . 1428
Electrical Wiring . . . . . . .. . . . . . . . . . . . . . 14-28
Wiring Inspection . . . . . ... .. . . ... . 14-28
14-2 ELECTRICAL SYSTEM

OColor Codes:
Precautions
BK Black
BL Blue
There are a number of important precautions that are BR Brown
musts when servicing electrical systems. Learn and CH Chocolate
observe all the ru les below. DG Dark green
000 not reverse the battery lead connections. This G Green
will burn out the diodes in the electrical parts. GY Gray
OAlways check battery condition before condemning LB Light blue
other parts of an electrical system. A fully charged LG Light green
battery is a mu st for conducting accurate electrical o Orange
system tests. P Pink
oThe electrical parts should never be struck sharply. as PU Purple
with a hammer, or allowed to fall on a hard surface. R Red
Such a shock to the parts can damage them . W White
a Ta prevent damage to electrical parts, do not dis- Y Yellow
connect the battery leads or any other electrical OMeasure coil and winding resistance when the part is
connections when the ignition switch is on l or th e cold (at room temperature).
engine is funning.
o Becau se of the large amount of current, never keep
the starter switc h pushed when the starter motor
will not turn over, or the current may burn out the
starter moto r windings.
0 00 not use a indicator bulb rated for other than voltage
or wattage specified in the wiring diagram , as the
indicator panel could be warped by excessive heat
radiated from the bulb.
OTake care not to short the leads that are directly
connected to the battery positive (+) terminal to the
chassis grou nd.
o Troubles may in volve one or in some cases all items.
Never replace a defective part without determining
what CAUSED t he failure. If the failure was brough
on by some other item or items, they too must be
repaired or replaced, or the new replacement will
soon fail agai n.
o Make sure all connectors in the circuit are clean and
tight, and exam ine wires for signs of burning, fra ying,
etc. Poor wires and bad connections will affect elec-
trical system operation .
o El ectrical Connectors

Female Connectors

Male Connectors
 ELECTRICAL SYSTEM 14-3

A2w;;i~~D;~~;;;;;;::::::::::::::::::::
KLF300A1,
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to ' - ----
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V. HB
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II 5.
14-4 ELECTRICAL
....... SYSTEM
...................'.~~
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.......... ........... .......... .......... ..........

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 ELECTRICAL SYSTEM 14-5

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14-6 ELECTRICAL SYSTEM

Specifications

Item Standard Service Limit

Battery:
Electrolyte Level Between level lines --
Electrolyte Volume 1.15 L --
Specific Gravity of Electrolyte 1.2S0 @20C (6S0 F) --
Charging System:
Regulator/rectifier Output Voltage Battery voltage - 15 V --
Charging Coil Resistance 0.2 -O.S n --
Ignition System:
Ignition Coil: Arcing Distance 7 mm or more --
Primary Winding Resistance 1.S - 2.S n --
Secondary Winding Resistance 10 - 16 kn --
Spark Plug: Type NGK BSES --
. NGK BRSES --
Gap 0.7 -O.S mm --
Pickup Coil Resistance 390 - 590 n --
Electric Starter System:
Starter Motor: Brush Length 12.0 -12.5 mm 6mm
Brush Spring Tension 6S0 - 920 g --

Circlip Pliers: 57001144

Special Tools

Along with common hand tools, the following more

specialized tools are required for comp lete electrical
system servicing.

Spark Plug Wrench : 57001-110 Flywheel Holder: 57001-308

 ELECTRICAL SYSTEM 14-7

Timing light: 57001-1241 Rotor Puller: 57001-1099

NOTE
oThe flywheel holder (57001-13131 can be used instead
of the flywheel holder (57001-30B).
oThe rotor puller (57001-1216) can be used instead of
the rotor puller (57001-1099).

Battery

Precautions:
Coil Tester: 57001-1242 Following a few simple rules will greatly extend the
life of the battery.
oWhen the level of the electrolyte in the battery is low,
add only distilled water to each cell, until the level is
at the upper level line marked on the outside of the
battery. Ordinary tap water is not a substitute for
distilled water and will shorten the life of the battery.
ONever add sulphuric acid solution to the battery. This
will make the electrolyte solution too strong and will
ruin the battery within a very short time.
OAvoid quick-charging the battery. A quick-charge will
damage the battery plates.
ONever let a good battery stand for more than 30 days
without giving it a supplemental charge, and never let
a discharged battery stand without charging it. If a
battery stands for any length of time, it slowly self-
discharges. Once it is discharged, the plates sUlphate
(turn white), and the battery will no longer take a
charge.
OKeep the battery well-charged during cold weather so
that the electrolyte does not freeze and crack open the
battery. The more discharged the battery becomes, the
more easily it freezes.
OAlways keep the battery vent hose free of obstruction,
Hand Tester: 57001-983 and make sure it does not get pinched, crimped, or
melted shut by contact with the hot muffler. If
battery gases cannot escape through this hose, they will
explode the battery.
ODON'T INSTALL THE BATTERY BACKWARDS.
The negative side is grounded.

Battery Removal/I nstallation:

Battery Removal
eRemove the seat (see Seat Removal in the Frame
chapter).
-Disconnect the battery negative (-) cable.
14-8 ELECTRICAL SYSTEM
Battery Charging:
Battery Condition
-Before charging, check battery condition by testing the
specific gravity of the electrol yte in each cel l.
DDrawa little fluid from the cel l with a hydrometer.
DRead the level of the electrolyte on the fioating scale.
This is the specific gravity of the electrolyte.

Hydrometer

A. Negative Cable C. Rubber Band

B. Positive Cable

eDisconnect the battery positive (+) cable.

eUnhook the rubber band and remove the battery from Read
the battery case. Do not lose the damper under t he here
battery.

Battery Installation
eBattery installation is the reverse of removal. Note the
following.
-Connect the positive (+) cable first and then the
negative cable.
eRoute the battery vent hose observing the label for the
hose routing.

Electrolyte: -Look for sediment and white sulfation inside the cells
Electrolyte Level Inspection on the bottom of the plates.
eVisually check the electrolyte level in the battery.

- ... .., - ~ ~

~
.
'" rJ
y

A. Sulfation here B. Sediment here
A. Level Lines

eSee the Battery Troubleshooting Guide in Battery Test

*If the level of electrolyte in any cell is below the Charging.
lower level line on the battery case, add distilled water *If the specific gravity is below 1.200, the battery needs
only to that cell. to be charged.

NOTE
OThe specific gravity of the electrolyte varies with
changes in temperature, $0 the specific gravity reading
must be corrected for the temperature of the electro
Iyte.
oCelsius: Add 0.007 points to reading for each 10C
above 20C or subtract 0.007 points for each 10C
below 20C.
OFahrenheit: Add 0.004 points to reading for each 10F
above 68F or subtract 0.004 points for each 10F
below 68F.
*If the specific gravity of any of the cells is more than
0.050 away from any other read ing, the battery will
probably not accept a charge. It is gene rally best to
replace a battery in this condition.
*If the specific gravity of all the cells is 1.280 or more
the battery is fully charged.
Battery Initial Charging
Before being placed in service, a new battery should
be given an initial charging.
e<:ut off the sealed end of the battery vent hose and
remove the filler caps.
eFili each cell to the upper level line on the battery case
with fresh electrolyte at a temperature of 30C (86F)
or less. Let the battery stand for about 30 minutes
before charging.
NOTE
Olf the electrolyte level drops, add electrolyte to the
upper level line before charging.
eLeaving the caps off the celis, connect the battery to a
charger, set the charging rate at 1/10 the battery
capacity, and charge it for 10 hours. For example J if
the battery is rated at 18 Ah, the charging rate would
be 1.8 A.
WARNING'
OKeep the battery away from sparks and open flames
during charging, since the battery gives off an explosive
gas mixture of hydrogen and oxygen. When using a
battery charger, connect the battery to the charger
before turning on the charger. This procedure prevents
sparks at the battery terminals which could ignite any
battery gases.
[CAUTIO~]
000 not use a high rate battery charger, as it typically
employed at automotive service stations, unless the
charging rate can be reduced to the level required.
Charging the battery at a rate higher than specified may
ruin the battery. Charging at a high rate causes excess
heat which can warp the plates and cause internal
shorting. Higher-than -normal charging rates also cause
the plates to shed active material. Deposits will accu-
mulate, and can cause internal shorting.
ELECTRICAL SYSTEM 14-9
Olf the temperature of the electrolyte rises above 45C
(11SoF) during charging, reduce the charging rate to
lower the temperature, and increase charging time
proportionately.
-Turn the charger off, then disconnect it from the
battery.
e<:heck battery vo ltage. Battery voltage should be 12-
13 V.
e<:heck the specific gravity of each cell with a hydrom-
eter (see Battery Cond ition).
*If the voltmeter or hydrometer readings are below
those specified, additional charging is necessary before
the battery can be installed.
Battery Ordinary Charging
eRemove the battery from the vehicle.
OAlways remove the battery from the vehicle for
charging. If the battery is charged while still installed,
battery electrolyte may spill and corrode the frame or
other parts of the vehicle.
e<:lean off the battery using a baking sodaandwater
solution.
OMix one heaping tablespoon of baking soda in one cup
of water.
o Be careful not to get any of the cleaning solution in the
battery.
oThe terminals mu st be especiall y clean.
elf any of the cells are low, fill them to the LOWER
level line with distilled water only. The electrolyte will
ex pand during charging, and the level will rise.
e<:onnect a charger to the battery BEFORE plugging it
in or turning it on.
WARNING.
OKeep the battery away from sparks and open flames
during charging, since the battery gives off an explosive
gas mixture of hydrogen and oxygen. When using a
battery charger, connect the battery to the charger
before turning on the charger. This procedure prevents
sparks at the battery terminals which could ignite any
battery gases.
-Set the charge rate and time acco rding to the battery
condition previously determined (see Battery Con-
dition), using the table .
14-10 ELECTRICAL SYSTEM
Battery Charging Rate/Time Table (12V 19Ah)

1.28 ~FUIlY Charged

1.24
.::-
." '"
1.20
<:5 1.16 1.140

""'u" 1.12 Sample l:?~

"c. 1.08
'" 1.04 ::: ::::::: ::::: :::: ::: ::::::::: :::::::: :::: :::: :::::: :;: :iH~ :~ '~ri: .:: .::.::.::.::.:::::
' . ' . J
:::: :: :::1.080 ~ :: : :.: :::: ::: ::: : :::
. . . . . . Totally dIScharged ..
1.00 ::::::::::::::::::::::::::::::::::::::::::::::::::::::~j. :~.U\;j:::::::::::::::::::::::::::::::::::::::::::::::::::
at 1 A charge rate
at 2A charge rate 5 10 14.3
at 3A charge rate 3 5 7 9 9.5
at 4A charge rate 2 3 4 6 7.1
at 5A charge rate 2 3 4 5 5.7
Hours of Charging Time at Rates Shown

Battery Test Charging

000 not use a high rate battery charger, as is typically
employed at automotive service stations, unless the
charging rate can be reduced to the level required.
Charging the battery at a rate higher than specified may
ru in the battery. Charging at a high rate causes excess
heat which can warp the plates and cause internal
shorting. Higher-than -normal charging rates also cause
the plates to shed active material. Deposits will ac-
cumulate, and can cause internal shorting.
olf the temperature of the electrolyte rises above 4SOC
(11S0F) during charging, reduce the charging rate to
lower the temperature, and increase charging time
proportionately.
eTurn t he charger off or unplug it, then disconnect it
from the battery.
e<:heck battery condition (See Battery Condition).
*If the battery condition indicates that it is not fully
charged, additional charging t ime is necessary.
elf the battery is suspected of being defective, sulfated,
or unable to take a charge, consult the table.
eTo test charge a battery, perform the ordinary charging
procedure and mon itor the battery voltage and other
signs as mentioned below.
*If the battery voltage sudde nly jumps to over 13 V just
after the start of charging, the plates are probably
su lfated. A good battery will rise to 12 V immediately
and then gradually go up to 12.5 or 13 V in about 30
min. to an hour after the start of charging.
*If one cell produces no gas bubbles or has a very low
specific gravity, it is probably shorted.
*If there does not appear to be enough sediment in a cell
to short the plates, but that cell has a very low specific
gravity after the battery is fully charged, the trouble
may be that there is not enough ac id in that one cell.
In this case only, su lfuric acid solution may be added
to correct the specific gravity .
*If a fully charged battery not in use loses its charge
after 2 to 7 days; or if the specific gravity drops mark
edly, the battery is defective. Th e selfdisc harge rate of
a good battery is only about 1% per day.

Battery Troubleshooting Guide

Good Battery Suspect Battery Action
(+) chocolate color white (sulphated); + plates
Plates Replace
H gray broken or corroded
Sediment none, or small amount sediment up to plates, causing short Replace
Voltage above 12 V below 12 V Test charge
Electrolyte Level above plates below top of plates Fill and test charge
above 1.200 in all cells; no two below 1.100, or difference of more
Specific Gravity Test charge
cells more than 0.020 different than 0.020 between two cells

.............................................................................
Charging System
.............................................................................
Part Removal:
Alternator Rotor Removal
eRemove the left engine cover (see Left Engine Cover
Removal in the Engine Left Side chapter).
eHold the alternator rotor from turning with the
flywheel holder (special tool)' and remove the rotor
bolt.
-Thread in the rotor puller (special tool) and turn the
rotor puller until the rotor is forced off the end of the
cran kshaft.
ELECTRICAL SYSTEM 14-11
-Clean the inside of the rotor and the end of the crank-
shaft thoroughly or the taper will not fit snugly.
-Fit the rotor onto the crankshaft so that the woodruff
key fits in the groove in the hub of the rotor.
eTighten the alternator rotor bolt to the specified
to rque (see Exploded View).
Alternator Stator Removal
eRemove the left engine cover (see Left Engine Cover
Removal in the Engine Left Side chapter).
-Remove the pickup coil (see Pickup Coil Removal).
eUnscrew the mounting screw and take off the wiring
holder.
eUnscrew the mountin g screws and pull the stator out
the left engine cover.

A. Flywheel Holder: 57001-308

B. Rotor Puller: 57001-1099

!CAUTlO~]
Olf the rotor is difficult to remove and a hammer is A. Alternator Stator Mounting Screws
used to tap the rotor puller. be careful not to strike the B. Pickup Coil
rotor itself. Striking the rotor can cause the magnets to C. Wiring Holder
lose their magnetism.

Alternator Rotor Installation Alternator Stator Installation

eAlternator stator installation is the reverse of removal.
eAlternator rotor installation is the reverse of removal.
Note the following.

Charging System Checkout:

Charging System Operational Inspection
-Check battery condition (see Battery Condition).

NOTE
OAlways check battery condition before condemning
other pans of the charging system. The battery must
be fully charged in order to conduct accurate charging
A. Key B. Groove C. Clean. system tests.
14-12 ELECTRICAL SYSTEM
_Warm up the engine to bring the components up to Rectifier Circuit Inspection
their normal operating temperatures. _Remove the regulator/rectifier.
eMeasure regulator/rectifier output voltage at various
engine speeds with the headlight turned on and then
turned off.
OConnect a voltmeter across the battery terminals.
*The readings should show nearly battery yoltage when
the engine speed is low, and as the engine speed rises,
the readings should also rise. But they must stay
within the specified range.
*If the output voltage is much higher than the spec-
ification, the regulator/rectifier is defective, or the
regulator/rectifier leads are loose or open.
*If the output voltage does not rise as the engine speed
increase, then the regulator/rectifier is defective or the
alternator output is insufficient for the loads.

RegulatorlRectifier Output Voltage

Battery Voltage - 15 V

A. Regulator/Rectifier

-Zero the ohmmeter, and connect it to the regulator/

Stator Coil Resistance
-Disconnect the alternator connector.
_Measure the stator coil resistance.
<:Connect the multimeter between the yellow leads.
OSet the meter to x 1 n range, and read the meter.
rectifier terminals.
_Check the resistance between the terminals following
the table.
*The resistance should be low in one direction and
more than ten times as much in the other direction.
If any two leads are low or high in both directions,
the rectifier is defective and must be replaced.

NOTE
Stator Coil Resistance oThe actual meter reading varies with the meter used
0.2 -0.8 Q and the individual rectifier, but, generally speaking the
lower reading should be from zero to the one - second
of the scale.

Regulator/Rectifier Terminal

B (Battery) Terminal M (Monitor) Terminal

G (Ground) Terminal

*If the meter does not read as specified, replace the

alternator stator.
*If the coil has normal resistance, but the yoltage Al A2 A3
inspect showed the alternator to be defective; then (Alternator) (Alternator) (Alternator)
the rotor magnets have probably weakened, and the
rotor must be replaced.
 ELECTRICAL SYSTEM 14-13
Rectifier Circuit Inspection *If the test light turns on, the regulator/ rectifier is
defective. Replace it.
Connections Meter
No . Reading *If the test light does not turn on, continue the test.
Meter (+) to Meter (-) to Range eMomentarily app ly 12 V to the voltage monitoring
1 A1 terminal.
e<:heck A 1, A2, and A3 terminals respectively.
2 A2 B =
3 A3
4 A1 Regulator Circuit Test-2nd Step
5 A2 G o- x 10 n
6 A3 Y2 scale or Regu Iator / Recti fi er
x lOa n
r-2- B
A1
A2
I :
A3
A1
r2Q.
G A2 =
r2.1.- Test Light
12 A3

+
Regulator Circuit Inspection
eRemove the regulator/ rectifier. 12 V Battery
ePrepare the test tools shown.

Tools for Regulator Circuit Test *If the test light turns on, the regulator/rectifier is
Test light -+ Bulb rated 12 V and 3 - 6 W defective. Replace it.
Batteries Two 12 V batteries *If the test light does not turn on, continue the test.
Test wires S auxiliary wires eMomentarily apply 24 V to the voltage monitoring
terminal by add ing a 12 V battery.
e<:heck A 1, A2, and A3 term inals respectively.
e<:onnect the test light and the 12 V battery to the
regulator/ rectifier as shown.
e<:heck A 1, A2, and A3 terminals respectively .

Regulator Circuit Test-1st Step 000 not apply more than 24 V to the regulator/rectifier
and do not leave the 24 V applied for more than a few
seconds, or the unit will be damaged.

Regulator/ Rectifier
Regulator Circuit Test-3rd Step
12 V Battery
,...--, ,...--,

Test Light Regu la tor/ Rec tifi er

8
+ =Al

12 V Battery Test Light

ICAUTlO~ I +
oThe test light limits the current flow through the
regulator/rectifier. Do not use an ammeter or
multimeter in its place. 12 V Battery
14-14 ELECTRICAL SYSTEM
*If the test light did not light when the 24 V was applied eRemove the switch lever screw and take out the lever.
momentarily to the voltage monitoring terminal, the
regulator/rectifier is defective. Replace it.
*1 f the regulator/rectifier passes all of the tests described,
it may still be defective. If the charging system still
does not work properly after checking all of the
components and the battery, test the regulator/ rectifier
by replacing it with a known good unit.

Ignition System

Safety Instructions: A. Switch B. Remove these screws.

I WARNING.
eRe move the wIring clamp screw and starter button
OThe ignition system produces extremely high voltage. holder screw, and pull the switch free of the case.
Do not touch the spark plug, high tension coil. or spark
plug lead while the engine is running, or you could
receive a severe electrical shock.
Engine Stop Switch Installation
-Clean any corrosion or dirt off the contacts.

000 not disconnect battery leads or any other electrical

connections when the ignition switch is on, or while
the engine is running. Doing so could cause Ie ignitor
damage.
0 00 not install the battery backwards or the Ie ignitor
could be damaged. The negative side is grounded.

Part Removal:
Engine Stop Switch Removal
The engine stop switch is inside the LH switch
housing. The switch and its component parts are not
ava ilable separately. However, the switch may be
removed for cleaning. Be very careful not to lose any
parts or the entire LH switch housing will have to be A. Clean.
replaced.
eTake out the screws that clamp the LH switch housing
to the handlebar. ePush the switch part, down into the case.
elnstall the wiring clamp and starter button holder.
ePut the switch lever in place and fasten it with a screw
and washer.
eAssemble the LH switch housing on the handlebar and
tighten the screws securely.

Ignition Coil Removal

eRemove the front fender (see front Fender Removal in
the Frame chapter).
eRemove the fuel tank (see Fuel Tank Removal in the
Fuel System chapter).
ePull the spark plug lead off the spark plug.
eDisconnect the green/white lead and yellow/red lead
from the coil.
A. Screws eTake off the nuts and remove the coil.
 ELECTRICAL SYSTEM 14-15

Pickup Coil Removal

eRemove the left engine cover (see Left Engine Cover
Removal in the Engine Left Side chapter).
-Unscrew the mounting screw and take off the wiring
holder.
-Unscrew the mounting screws and take off the pickup
coil.

A. Ignition Coil

Ignition Coil Installation

elgnition coil installation is the reverse of removal. Note
the following.
eThe + and - markings next to the primary coil termi- A. Pickup Coil
nals on the ignition coil body indicate the polarity of
the terminals. The polarity of the spark plug lead is
as shown when the primary leads are connected as Pickup Coil Installation
indicated in the figure. But both the primary wires ePickup coil installation is the reverse of removal.
can be connected with either terminal on the ignition
coil without changing the engine performance.

Ignition System Checkout:

Polarity of Ignition Coil For any ignition system problems, always check the
ignition timing first (if the engine will run).

Ignition Timing Test

eRemove the ignition timing inspection plug.
H
~~o --=J~
-Attach a timing light (special tool: PIN 57001-1241)
iI I L____
8 ~- green / white lead
Connect
and a tachometer in the manner prescribed by the
manufacturer.
(i) . Connect
yellow/red lead eStart the engine and aim the timing light at the timing
mark on the alternator rotor.
eRun the engine at the speeds specified and note the
alignment of the timing marks.

Spark Plug Removal

_Carefully pull the spark plug cap from the spark plug
and unscrew the spark plug.
o lf necessary, use the spark plug wrench (special tool:
PI N 57001-110).

Spark Plug Installation

_I nstallation is the reverse of removal. Note the
following.
-Tighten the spark plug to the specified torque (see A. Timing Inspection Hole C. F Mark
Exploded View). B. Slot D. Advanced Marks
14-16 ELECTRICAL SYSTEM

Ignition Timing
Engine speed -Connect the ignition coil (with the spark plug cap left
Slot aligned with:
rlmin (rpm) installed at the end of the spark plug lead) to the tester
2,100 and below F mark on flywheel in the manner prescribed by the manufacturer and
measure the arcing distance.
4,200 and above Advanced marks on flywheel
Ignition Coil Arcing Distance

*If the ignition timing is incorrect, replace the Ie 7 mm or more

ignitor.

I WARNING'
OTo avoid extremely high voltage shocks, do not touch
the ignition coil body or leads.

Engine Stop Switch Inspection

eDisconnect the connectors from the LH switch housing.
eUsing an ohmmeter, check to see that only the can
nections shown in the table have conti nuity (about
zero ohms).
*If the switch has an open or short, disassemble it and
clean it (see Engine Stop Switch Removal). Test it
again. If it still does not wo rk, replace the LH switch *If the distance reading is less than the specified value,
housing, the ignition coil or spark plug cap is defective.
eTo determine which part is defective, measure the
arcing distance again with the spark plug cap removed
from the ignition coil.
Engine Stop Switch Connections *If the arcing distance is subnormal as before, the

IYI
Y/ R BR trouble is with the ignition coil itself. If the arcing dis-
tance is now normal, the trouble is with the spark plug
cap.

Measuring coi l res istance:

If the arcing tester is not availab le, the coil can be
checked for a broken or badly shorted wind ing with an
ohmmeter. However, an ohmmeter cannot detect layer
shorts and shorts resulting from insulation breakdown
under high vo ltage.
eMeasure the primary winding resistance.
OC:onnect the mu ltimeter between the co il terminal and
the coil core.
OSet the meter to the x 1 n range, and read the meter.
Ignition Coil Inspection eMeasure the. secondary wind ing resistance.
Measuring arcing distance: o Pull the spark plug cap off the lead.
-Measure the arcing distance with a Kawasaki coil tester CConnect the multi meter between the spark plug lead
(special tool: PN 57001-1242) to check the condition and the coil core.
of the ignition coil. aSet the meter to the x 1 kn range, and read the meter.

NOTE
OSince a tester other than the Kawasaki coil tester may Ignition Coil Winding Resistance
produce a different arcing distance, the Kawasaki coil Primary Windings: 1.8 - 2.8 n
tester is recommended for reliable results. Secondary Windings: 10 - 16 kn
 ELECTRICAL SYSTEM 14-17

Ignition Coil Winding Resistance Spark Plug Gap

CD @
o (:)

Q) 0

1. Measure primary winding resistance.

2. Measure secondary winding resistance.
3. Ignition coil

*If the meter does not read as specified, replace the coil.
*If the meter reads as specified, the ignition coil
~~~~~~ 0.7 - 0.8 mm
windings are probably good. However, if the ignition
system still does not perform as it should after all other
1. Terminal 4 . Gasket
components have been checked, test replace the coil
2. Insulator 5. Center Electrode
with one known to be good.
3. Cement 6. Side Electrode
-Check the spark plug lead for visible damage.
*If the spark plug lead is damaged, replace t he co il.

Spark Plug Cleaning and Inspection
-Clean the spark plug, preferably in a sandblasting
device, and then clean off any abrasive particles. The
plug may also be cleaned using a high flash-point
solvent and a wire brush or other suitable tool. If the
spark plug electrodes are corroded or damaged, or if
the insulator is cracked, replace the plug. Use the
standard spark plug or its eq uival ent.
IC Ignitor Inspection
-Set the multimeter to the x 1 kn range and make the
measurements shown in the table.
*If the meter readings do not correspond to the table,
replace the IC ignitor.
NOTE
OSince a tester other than the hand tester of Kawasaki
may show different readings, the hand tester of
Kawasaki is recommended for reliable results.

Spark Plug Gap

-Measure the gap with a wire-type thickness gauge. If
the gap is incorrect, carefull y bend the outer electrode
with a suitable tool to obtain the correct gap.

Spark Plug Gap

0.7 -O.Bmm A. IC Ignitor
14-18 ELECTRICAL SYSTEM

Internal Resistance of Ie Ignitor'"

Tester (+) Lead

Battery Ig. Coil Ground PC (+) PC (-)
"0 Battery C A E A Value

"'"
...J Ig. Coil ----------
=kn =kn =kn =kn
A 1.8 - 2.6 kn
1 Ground A --------
D E on
B 200 - 1 ,000 kn

s
~

------- C 3-4.2kn

"
f-
~ PC (+)
PC (-) A
B B
D on
B
------
E
B

-------
D
E
2.3 - 3.2 kQ
80 - 150 kQ

* Measured with hand tester 57001-983.

A tester other than the hand tester of Kawasaki may show slightly different readings.

Ie Ignitor Terminals
Pickup Coil Resistance
390 -590 Q

*If the meter does not read as specified, replace the

pickup coil.
Battery ---H-l II+I--Ig. Coil

I-U---Ground

PC (+) ---!H--l I-U--PC (-)

Alternator Rotor Inspection

_Check the timing projection for damage such as
chipping or grooving.

Pickup Coil Inspection

eMeasure the pickup coil resistance.
OConnect the multi meter between the black lead and the
blue lead.
OSet the meter to the x 10 n range, and read the meter.

A. Tim ing Projection

*If the timing projection on the rotor is visib ly damaged,

replace the alternator rotor.
 ELECTRICAL SYSTEM 14-19
elf the O-ring shows any damage or if it is hardened,
Electric Starter System replace it with a new one .
Push the starter motor into the case, guiding the
sprocket onto the shaft at the same time.
Part Removal:
Starter Motor Removal
eRe move the left engine cover (see Left Engine Cover
Removal in the Engine Left Side chapter).
-Remove the starter motor cable.
oSlide back the rubber cover.
oTake off the nut and washers, and pull off the cable.
eRemove the starter motor retaining bolts.

A. Starter Motor Sprocket B. Engine Side

NOTE
o The protruding side of the sprocket must face in.

A. Bolts B. Starter Motor Cable

eGentl y pry the starter motor out of the engine case,

Starter Motor Disassembly
eRemove the starter motor (see Starter Motor Removal).
[CAUTION! eTake out the long screws with lock washers.
000 not tap the end of the starter motor shaft or the
motor may be damaged.

Starter Motor Installation

-Starter motor installation is the reverse of removal.
Note the following.
_Clean the starter motor mounting lugs and the crank
case where the lugs touch it, for good electrical
contact.

A. Right End Cover B. Left End Cover

elf only the brushes are to be removed, pull off only the
right end cover.
-Grasp the brush springs with needle nose pliers, and
pull them off the brush plate.
eRaise the brush plate to allow the brushes to clear the
A. Crankcase Surface B.Oring end of the commutator.
14-20 ELECTRICAL SYSTEM

.Push on the armature to remove the left end bearing

plate. Be careful not to drop the thrust washers.
eln order to lubricate the gear set bearing, remove the
circlip with the circlip pliers (special tool) .

A. Brush Plate B. Springs

-Slip the brushes out of the brush holders on the brush

plate.
-Free the brush plate by working the brush leads out
of the slots in the plate.
eTa remove the positive brushes, first take off the A. Circlip Pliers.: 57001-144
teminal nut with its steel and fiber washer ..

Starter Motor Assemblv

-Starter motor assembly is the reverse of removal. Note
the following.
elf the gear set was removed, grease the shaft, gears, and
bearing plate.

A. Terminal Bolt

-Push the terminal bolt out toward the inside.

-Pull the brush leads to remove the brush assembly.
-To remove th e gear set, pull the left end cover off. Be
careful not to drop the gears.

A. Grease .

Put the thrust washers onto the armature shaft.

-Put the bearing plate into the yoke so that the bearing
protrudes toward the armature and the notch aligns
A. Left End Cover B. Bearing Plate with the key in the yoke . .
 ELECTRICAL SYSTEM 14-21
elnstall the brush springs.
OPut the spring down over the post on the brush plate so
that it is wou ld clockwise.
OTwist the "curl" end of the spring clockwise and slip it
into the slot in the brush holder.
OPush the spri ng down onto the post until it seats
against the step.

A. Notch C. Thrust Washers

B. Key D.Oring

eBe sure the large O-ring is in place, and push the left
end cover into the starter yoke so that the notch on the
'nternal gear aligns with the key in the yoke.
ePush the negative brushes into the holders immediate ly
clockwise from where the brush leads are mounted to A. Step
the brush plate.
-Drop the thrust washers over the end of the armature
shaft.
el nstall the right end cover so that the long vertical tab
on. the brush plate aligns with the key slot in the cover.

A. Brush Lead Mounting B. Slots

eHold the brush plate over the end of the starter and
push the positive brush leads through the slots in the A. Tab C. Thrust Washers
brush plate. B. Key Slot
ePush the brush plate into place with the tab in the
OAs a furt her check, these marks shou ld al ign on the
notch as shown.
outs ide of the starter.

B. Notc h A. Align marks.

14-22 ELECTRICAL SYSTEM
eTighten the long screws to the specified torque (see
Exploded View).

Starter Button Removal

The starter button is inside the LH switch housing.
The starter button and its component parts are not
available separately. However, the starter button may be
removed for cleaning. Be very carefu l not to lose any
parts or the entire switch housing will have to be
replaced.
eRemove the engine stop switch (see Engine Stop
Switch Removal).
ePull the starter button free of the LH switch housing. A. Bru sh Length

*ff the brushes are shorter than the service limit, replace
them.

Starter Motor Brush Spring Tension

elf a brush spring tension measuring device is available,
the tension shou ld be as specified.

A. Starter Button Contacts

_Spray the starter button contacts with contact cleaner.

A. Brush Spring
Starter Button Installation
_Starter button install ation is the reverse of removal.
Starter Motor Brush Spring Tension
680 - 920 9

*If the tension is less than the lower limi t specified,

replace the spri ng.
*If the brush springs are able to sna p the brushes firmly
into place, they ma y be considered serviceable. If they
cannot, replace them .
Starter System Checkout:
Starter Motor Brush Length
eMeasure the overall length of each brush.

Starter Motor Commutator Inspection

-I nspect the surface of the commutator.
Starter Motor Brush Length *If it is grooved dirty, polish it with a piece of very fine
Standard: 12.0 - 12.5 mm sandpaper.
Service Limit: 6mm *If the grooves are dirty, clean them carefully .
 ELECTRICAL SYSTEM 14-23

*If the resistance is less than infinite, ~he armature is

shorted. Replace the starter motor.

Brush Assembly Inspection

-Measure the resistance between the two positive
brushes.
oUse a multimeter set to the x 1 n range.

Starter Motor Armature Inspection

eMeasure t he resistance between each segment and all
the others.
o Use a muJtimeter set to the x 1 n range.

A. Positive Brushes B. Yoke

*If the resistance is greater than 0 n, replace the positive

A. Segments
* If the resistance is too high or even infin ite, the
armature winding has an open circuit. Replace the
starter motor.
eMeasure the resistance between the commutator and
the armature shaft.
DUse a multi meter set to the xl kn range.
brush assembly.
eMeasure the resistance between the pos it ive brushes
and the starter yoke.
o Use a multimeter set to the xl kn range.
*If the resistance is less than infinite. the positive brush
assembly is shorted to ground. Replace the . positive
brush assembly.
-Measure the resistance between the negative brushes.
DUse a multimeter set to the x 1 n range.

A. Negative Brushes B. Pos itive Brush Ho lders

14-24 ELECTRICAL SYSTEM

*If the res istance is greater than 0 Q, rep lace the Starter Circuit Relay Inspection
negative brush assembly. -Remove the starter circuit re lay that is mounted on the
eMeasure the res istance between the pos itive brush rear of the battery case.
holders and the plate.
o Use a mu lt im eter set to the x 1 kn range .
*If the res istance is less than inf inite, replace the
negative brush assem bly.

Starter Relay Inspection

eRemove the rear fender (see Rear Fender Removal in
th e Frame chapter) .
e Disconn ect the black lead to th e starter mo to r.

A. Starter Circui t Relay

-Connect an ohmmeter and one 12 V battery to the

re lay as show n.
*If the relay does not work as specified, the relay is
defective.
A. Lead t o St arter Moto r C. Small Plu g
B. Larger Termi na ls
Testing Relay
eMeasure the continuity of the relay when activated.
oCo nnect a multi me ter across the larger term inals of Meter range : x 1 n range
t he re lay. Criteria: When battery is connected .... 0 n
OSet the meter to the x 1 n range . When battery is disconnected .... 00 n
CCheck that the transmi ssion is in neutral.
oTurn on the ignition switch.
OPush the starter button and read the meter.
Testing Relay
* If the relay does not click or if the meter reads more
than 0 n) the relay is defective. Replace it .
*If the relay clicks once but the meter does not read 0
fl, the re lay is defective. Rep lace it.
* If t he relay does not click at all, proceed with the
fo llowing. Ohmmeter
_Disconnect the small plug in the relay.
-Co nnect a mu ltimeter across the pins in the re lay pl ug.
-Set the meter to the x 1 n range) and read the meter . Q
* If th e 'meter does not read close to 0 n, the relay is
defective. Re place it. Relay
* If the met er reads close to 0 fl, t he re lay may be good.
Check the vo ltage to the relay fro m the starter bu tt on .
Q) CD
-Connect a mu ltimeter across the brown and black leads @)<%I
in the co nnector from the main harness.
-Set t he meter to the 25 V DC range.
tID CD
- Turn on the ignit ion switch, push the starter button ,
and read the meter.
*If the meter reads battery voltage, the circ ui t is good.
If the re lay would not click in t he previous tests, it is +
defective. Replace it.
*If the meter reads much less than battery voltage or no 1 2 V Battery
voltage at all, the circuit is bad. Check the following.
Starter Button
Starter Circuit Re lay CD and <%I Relay Coi l Termi nals
Wiring Q) and @) Relay Switch Terminals
 ELECTRICAL SYSTEM 14-25

Starter Button Inspection eSlide back the dust cover and remove the bulb holder
eDisconnect the connectors from the LH switch housing. and bulb from the headlight unit.
eTurn the engine stop switch to the RUN position. oTurn the holder counterclockwise and pull it out.
-Using an ohmmeter, c heck to see that the connections
shown in the table continuity (about zero ohms).
*If the starter button has an open or short, disassemble
it and clean it (see Starter Button Removal). Test it
again. If it stil l does not wo rk, replace the LH switch
housing.
Starter Button Connections

I~I
BK VIR

1-
.............................................................................
Lighting System
.............................................................................
Headlight Beam:
Headlight Beam Vertical Adjustment
eLoosen the headlight mounting knobs and move the
headlight up or down to adjust the headlight vertically.
eSe sure the socket is clean .
elnsert the new bulb by aligning the tangs with the
catches in the headlight unit.
.Push the holder in, turn it clockwise, and release it. It
should lock in position.
eSlide back the dust cover completely as shown in the
label behind the unit. The c'TOP" mark on the cover
must point up.

A. Headlight Mounting Knobs

eTighten the mounting knobs.
A. "TOP" Mark
Bulb Replacement: elnstall the removed parts in the reverse order of
Headlight Bulb Replacement removal noting the following.
eRemove the headlight mounting knobs, and take the eBe sure the flanged collars are in place in the rubber
headlight unit off the housing. dampers in the headlight housing.
eoisconnect the bulb socket from the headlight unit. elnstal l the headlight unit so that the "TOP" mark on
the lens points up.

A. Knobs B. Headlight Unit A. "TOP" Mark

14-26 ELECTRICAL SYSTEM

Taillight Bulb Replacement Neutral and Reverse Indicator

eRemove the taillight mounting bolts. Light Bulb Replacement
-Remove the steering stem head cover screws and
ignition switch ring nut, and take off the cover .
Push each bulb down, turn it counterclockwise, and
pull it out.

A. Mounting Bolts

-Turn the socket counterclockwise and pull it out .

Push the bulb in, turn it counterclockwise, and pull it
out.

eBe sure the socket is clean.

eAligning the new bulb's pins with t he grooves in the
walls of the socket, push the bulb in, turn it clockwise,
and release it.

A. Socket

eBe sure the socket is clean .

elnsert the new bulb by al igning the pins with the
grooves in the walls of the socket.
.Push the bulb in, turn it clockwise, and release it. It
should lock in position.
elnsert the socket by aligning the tangs with the catches
in the housing so that the triangular mark points up,
A. Pins B. Grooves
and turn it clockwise to lock in position.

eFit the rubber boot in the place.

eReplace the stem head cover and screw on the ignition
switch ring nut and cover holding screws.

Part Removal:
Light Switch Removal
The light switch is inside the LH switch hous in g. The
switch and its component parts are not available
separately. However, the switch may be removed for
cleaning. Be very careful not to lose any parts or the
A. Triangular Mark entire LH switch housing will have to be replaced.

eTake out the screws which clamp the LH switch
housing to the handlebar.
A. Screws
eDisconnect the connector from the LH switch housing,
and free the LH switch housing from the frame.
eTake out the screws inside the housing, and remove the
clamps.
A. Screws B. Switch Contacts
eTake out the switch mount ing screw, and remove the
switch.
eSpray the swi tch contacts with contact cleaner while
snapping the switch on and off.
o Reassemble the switch in the reverse order of
disassembl y.
Light Switch Installation
eLight switch installation is the reverse of removal. Be
su re to put a ll the wire clamps in.
ELECTRICAL SYSTEM 14-27
Neutral and Reverse Switch Removal
eRemove the front gear case (see Front Gear Case
Removal in the Final Drive chapter).
eDisconnect the neutral and reverse switch connector.
eRemove the screws an d take off the switch.
A. Neutral and Reverse Switch
Neutral and Reverse Switch Installation
eNeutral and reverse switch installation is the reverse of
removal. Note the following.
-Clean any corrosion or dirt off the contacts.
eApply a non-permanent locking agent to the threads of
the switch mounting screws.
Lighting System Checkout:
Light Switch Inspection
eDisconnect the connector from the LH switch housing.
eUsing an ohmmeter, check to see that only the
connections shown in the table have contin uity (about
zero ohms).
*If the switch has an open or shQrt, disassemble it and
clean it (see Li ght Switch Removal). Test it again. If
it still does not work , rep lace the LH switch housing.
Light Switch Connections
I~I
BR R
Neutral and Reverse Switch Inspection
eDisconnect the connector from the neutral and reverse
switch.
eUsing a ohmmeter, check to see that the connections
shown in the table have continuity (about zero ohms).
*If the switch wi ll not close, it may be removed for
cleaning (see Neutral and Reserve Switch Removal), or
the entire switch may be replaced.
14-28 ELECTRICAL SYSTEM

Neutral and Reverse Switch Inspection eDisconnect the wire leads.

Gear Position G Ground R
1 st through 5th
Neutral
Reverse I Ignition Switch Installation
elgnition switch installation is the reverse of removal.
Note the followi ng.
eRemove the neutral and reverse switch (see Neutral and eAlign the notches in the bracket and rubber damper
Reverse Switch Removal) . with the protrusion on the side of the ignition switch.
Push in the pin in the shift drum stopper and then
release it.
*If it does not spring out, it can be disassembleo'for
repair. Disassemble the shift drum stopper and check
the contact pin and spring. Replace the damaged part. Ignition Switch Inspection
eDisconnect the ignition switch leads .
Using an ohmmeter, check to see that only the
connections shown in the table have continuity (about
zero ohms).
*If the switch has an open or short, rep lace it with new
one.

Ignition Switch Connections

White Brown
OFF
ON
OFF

A. Pin B. Spring

I gnition Switch
Ignition Switch Removal
-Remove the steering stem head cover screws and
ignition switch ring nut, and take off the cover.
.Pull the rubber damper off the ignition switch, and
drop the switch out the bottom of the bracket.
.............................................................................
Electrical Wiring
.............................................................................
Wiring Inspection
eVisually inspect the wiring for signs of burning, fraying, .
etc.
*If any wiring is poor, replace the damaged wiring.
-Pu ll eac h connector apart and inspect it for corrosion,
dirt, and damage.
*If the connec tor is corroded or dirty, clean it carefully.
If it is damaged, replace it.
-Check the wiring for continuity.
oU,e the wiring diagram to find t he ends of the lead
which is suspected of being a problem.
OC:o nnect an ohmmeter between the ends of the lead s.
OSet t he meter to the x 1 n range, and read the meter.
*If the meter does not read 0 n, the lead is defective.
Replace the lead or the wiring loom if necessary.

A. Rubber Damper B. Bracket

 APPENDIX 15-1

Appendix
Table of Contents

Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . 15-2

General Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-5
Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-5
Bolt and Nut Tightening. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-5
Tightness Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-5
Unit Conversion Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-6
15-2 APPENDIX
No valve clearance
Troubleshooting Guide Cylinder, piston worn
Piston rings bad (worn, weak, broken, or sticking)
Piston ring/land clearance excessive
NOTE Cylinder head gasket damaged
OThis is not an exhaustive list, giving every possible Cylinder head warped
cause for each problem listed. It is meant simply as a Valve spring broken or weak
rough guide to assist the troubleshooting for some of Valve not seati ng properly (valve bent, worn, or
the more common difficulties. carbon accumulation on the seating surface)

Poor Running at low Speed

Spark weak
Spark plug dirty, broken, or maladjusted
Engine Doesn't Start, Starting Difficulty Spark plug cap or spark plug lead trouble
Spark plug cap shorted or not in good contact
Starter motor not rotating
Spark plug incorrect
Neutral switch trouble
IC ignitor trouble
Starter motor trouble
Pickup co il trouble
Battery voltage low
Ignition coil trouble
Relays not contacting or operating
Battery voltage low
Starter button not contacting
Wiring open or shorted Fuel/air mixture incorrect
Ignition switch trouble Pilot screw and/or idle ad justing screw maladjusted
Engine stop switch trouble Pilot jet, or air passage clogged
Fuse blown Starter plunger stuck open
Starter motor rotating but engine doesn't turn over Air cleaner clogged, poorly seated, or missing
Starter motor clutch trouble Fuel level too high or too low
Engine won't turn over Fuel tank air vent obstructed
Valve seizure Carburetor holder loose
Rocker arm seizure Air cleaner duct loose
Cylinder, piston seizure Compression low
Spark plug loose
Crankshaft seizure
Cylinder head not sufficiently tightened down
Connecting rod small end seizure
No valve clearance
Connecting rod big end seizure
Cylinder, piston worn
Transmission gear or bearing seizure
Piston rings bad (worn, weak, broken, or sticking)
Camshaft seizure
Piston ring/land clearance excessive
Balancer bearing seizure
Cylinder head gasket damaged
No fuel flow
Cylinder head warped
Tank air vent obstructed
Valv e spring broken or weak
Fuel tap clogged
Valve not seating properly (valve bent, worn, or
Fuel line clogged
carbon accumulation on the seating surface)
Float valve clogged
Other
Engine flooded Vacuum piston doesn't slid e smoothly
Fuel level too high Engine oil viscosity too high
Float valve worn or stuck open Brake dragging
Starting technique faulty Final gear case oil viscosity too high
(When flooded, crank with the throttle fully open
to allow more air to reach the engi ne.)
No spark; spark weak
Spark plug dirty, broken, or maladjusted
Spark plug cap or high tension wiring trouble Poor Running or No Power at High Speed
Spark plug cap not in good contact Firing incorrect
Spark plug incorrect Spark plug dirty, broken, or maladjusted
Pickup coi l trouble Spark plug cap or spark plug lead trouble
IC ignito r trouble Spark plug cap shorted or not in good contact
Ignition coil troub le Spark plug incorrect
Battery voltage low Pickup coil trouble
Ignition or engine stop switch shorted IC ignitor trouble
Wiring shorted or open Ignition coil t rouble
Compression low Fuel/air mixture incorrect
Spark plug loose Main jet clogged or wrong size
Cylinder head not sufficiently tighte ned down Jet needle or needle jet worn
 APPENDIX 15-3

Air jet clogged Clutch Operation Faulty

Bleed hole of air bleed pipe or needle jet clogged Clutch slipping
Fuel level too high or too low Friction and/or steel plates worn or warped
Air cleaner clogged, poorly seated, or missing Clutch housi ng or shoe linings overworn or worn
Starter plunger stuck open unevenly
Water or foreign matter in fue l Clutch spring broken or weak
Carburetor holder loose Clutch release maladjusted
Air cleaner duct loose Clutc h release mechanisrp trouble
Fuel tank air vent obstructed Clutch hub or housing unevenly worn
Fuel line clogged Clutch not disengaging properly
Fuel tap clogged Friction and/or steel plates warped or too rough
Compression low Clutch spring compression uneven
Spark plug loose Clutch shoe spring broken or weak
Cylinder head not sufficiently tightened down Engine oil deteriorated
No valve clearance Engine oil viscosity too high
Cylinder, piston worn Engine oil level too high
Piston fing s bad (worn, weak, broken, or sticking) Clutch housing frozen on crankshaft or drive shaft
Piston ring/ land clearance excessive Clutch release mechanism trouble
Cylinder head gasket damaged
Cylinder head warped Gear Shifting Faulty
Valve spring broken or weak Doesn't go into gear; shift pedal doesn't return
Valve not seating properly (valve bent, worn or CI~tch not disengaging
carbon accumulation on t he seating surface.) Shift fork(s) bent or seized
Knocking Gear(s) stuck on the shaft
Carbon built up in combustion chamber Sh ift return spring weak or broken
Fuel poor quality or incorrect Shift mechanism arm spring broken
Spark plug incorrect Shift return spring pin loose
IC ignitor trouble Shift drum positioning lever bind in g on pivot bolt
Miscellaneous Shift mechanism arm broken
Throttle valve won't fully open Shift drum damaged
Vacuum piston doesn't slide smoothly Jumps out of gear
Brake dragging Shift fork(s) worn
Clutch slippi ng Gear groove(s) worn
Overheating Gear dogs, dog recesses, and /or dog holes worn
Engine oil level too high Shift drum groove(s) worn
Engine oil viscosity too high Shift drum positioning lever spring weak or broken
Final gear case oil viscosity too high Shift fork guid e pin(s) worn
Shift mechanism arm spring weak or broken
Drive shaft, output shaft, and / or gear splines worn
Overshifts
Overheating Sh ift drum positioning lever spring weak or broken
Firing incorrect Shift mechanism arm spring weak or broken
Spark plug dirty, broken, or maladjusted
Spark plug incorrect
IC ignitor trouble Abnormal Engine Noise
Fuel/air mixture incorrect Knocking
Main jet clogged IC ignitor troub le
Fuel level too low Carbo n built up in combustion chamber
Carburetor holder loose Fuel poor quality or incorrect
Air cleaner poorly sealed, or missing Incorrect spark plug heat range
Air cleaner duct loose Overheating
Air cleaner clogged Piston slap
Compression high Cylinder/piston clearance excessive
Carbon built up in combustion chamber Cylinder, piston worn
Engine load faulty Connecting rod bent
Clutch slipping Piston pin, piston holes worn
Engine oil level too high Valve noise
Engine oil viscosity too high Valve clearance incorrect
Drive train trouble Valve spring broken or weak
Brake dragging Camshaft bearing worn
Lubrication inadequate Other noise
Engine oil leve l too low Connecting rod small end clearance excessive
Engine oil poor quality or incorrect Connecting rod big end clearance excessive
154 APPENDIX

Piston ring(s) worn, broken or stuck Handling and/or Stability Unsatisfactory

Piston seizure damage Handlebar hard to turn
Cylinder head gasket leaking Steering stem bearing damaged
Exhaust pipe leaking at cylinder head connection Steering stem lubrication inadequate
Crankshaft runout excessive Steering stem bent
Engine mount(s) loose Tire air pressure too low
Crankshaft bearings worn Handlebar shakes or excessively vibrates
Primary gear worn or chipped Tire(s) worn
Camshaft chain tensioner trouble Rim(s) warped
Camshaft chain, sprocket, 19uides worn Rear axle ru nout excessive
Balancer bearing worn Wheel bearing(s) worn
Balancer gear worn or chipped Handlebar mount(s) loose
Steering ste m nut and/or stem clamp bolt(s) loose
Handlebar pulls to one side
Abnormal Drive Train Noise
Frame bent
Clutch noise Wheel maladjustment
Clutch housing and/or hub damaged Steering stem bent
Transmission noise
Front or rear tire ai r pressure unbalanced
Bearings worn Front or rear shock absorber unbalanced
Transmission gears worn or chipped Shock absorption unsatisfactory
Metal chips jammed in gear teeth Too hard:
Engine oil insufficient or too thin
Tire air pressure too high
Drive train noise
Shock absorber maladjusted
Bevel gear bearings worn
Too soft:
Propeller shaft bearing worn
Shock absorber oi l leak ing
Front bevel gear cam damper damage
Shock absorber spring weak
Bevel gears worn or chipped
Tire air pressure too low
Bevel gears maladjusted
Shock absorber maladjusted
Insufficient lubricant

Brake Doesn't Hold

Abnormal Frame Noise Air in the brake lin e
Shock absorber noise Brake fluid leak
Shock absorber damaged Brake fluid deteriorated
Brake noise Primary or secondary cup trouble
Brake linings overworn or worn unevenly Master or wheel cylinder scratched inside
Drum worn unevenly or scored Brake not properly adjusted
Brake spring(s) weak or broken Linings overworn or worn unevenly
Foreign matter in hub Drum worn unevenly or scored
Brake not properly adjusted Oil, grease on linin g and drum
Other noise Dirt, water between lining and drum
Brackets, nuts, bolts, etc. not properly mounted or Overheated
tightened
Battery Discharged
Exhaust Smokes Excessively Battery faulty (e.g., plates sulphated, shorted
White smoke th rough sedimentation, electrolyte leve l too
Piston oil ring worn low)
Cylinder worn Battery leads making poor contact
Valve oil seal damaged Load excessive (e.g., bulb of excessive wattage)
Valve guide wo rn Ignition switch trouble
Cylinder head gasket damaged Regulator/Rectifier trouble
Engine oil level too high Alternator trouble
Black smoke Wi rin g faulty
Air cleaner clogged
Main jet too large or fallen off Battery Overcharged
Starter plunger stuck open Regulator/ Rectifier trouble
Fuel level too high Battery trouble
Brown smoke
Main jet too small
Fuel level too low
Air cleaner duct loose
Air cleaner poorly sealed or missing
 APPENDIX 15-5

Brakes:
General Lubrication Ma,ter Cy lin der Clamp Allen Bolts
Brake Lever Pivot Screw Nut
Brake Pedal Nut and Cotter Pin
Lubrication Brake Cable Equalizer Cotter Pins
eBefore lubricating each part, clean off any rusty spots Steeing/Suspension:
with rust remover and wipe off any grease, oil, dirt, or Handlebar Clamp Bolt,
grime. Stem Nut and Cotter Pin
eLubricate the points listed below with indicated Stem Clamp Allen Bolt,
lubricant. Stem Bearing Hou,ing Bolt,
Tierod End Nut' and Cotter Pins
NOTE Tierod Adjusting Sleeve Locknut,
OWhenever the vehicle has been operated under wet or Shock Ab,orber Mounting Bolt, and Nut,
rainy conditions, or especially after using a high- Suspension Arm Pivot Bolts and Nuts
pressure spray water, perform the general lubrication. Steering Knuckle Pivot Nuts and Cotter Pins
Engine:
Engine Mounting Bolts
Engine Mounting Bracket Bolt,
Cables: Lubricate with Motor Oil Exhau,t Pipe Holder Nuts
Muffler Mounting Bolt,
Brake Cable,
Muffler Clamp Bolt
Throttle Cable
Shift Pedal Bolt
Choke Cable
Others:
Reverse Cab Ie
Footpeg Mounting Bolt,
Differential Shift Cable
Grab Rail Mounting Bolt,
Throttle Ca,e Clamp Screw,
Carrier Mounting Bolts
Slide Points: Lubricate with Grease
Brake Cable End,
Throttle Cable End,
Reverse Cable Lower End
Differential Shift Cable End,
Brake Lever
Brake Pedal Pivot Shaft
Throttle Lever Shaft

Bolt and Nut Tightening

Tightness Inspection
-Check the tightness of the bolt' and nut, li,ted here.
Also, check to see that each cotter pin is in place and in
good condition.
*If there are loose fasteners, retorque them to the
,pecified torque following the 'pecified tightening
sequence. Refer to the appropriate chapter for torque
specifications. If torque specifications are not Iisted in
the appropriate chapter, see the basic torque table (see
Torque and Locking Agent in the General Information
chapter). For each fastener, first loosen it by ySturn,
then t ighten it.
*If cotter pins are damaged, replace them with new ones.

801ts, Nuts, and Fasteners to be checked

Wheels:
Front Hub Nuts and Cotter Pin,
Rear Axle Nuts and Cotter Pins
Wheel Nut,
15-6 APPENDIX
..... ........... ..... ......................... .......................... .....
Units of Length:
Unit Conversion Table
km x 0 _6214 mile
m x 3.281 ft
Prefixes for Units:
mm x 0.03937 in
Prefix Symbol Power
mega M x 1,000,000
kilo k x 1,000
Units of Torque:
eenti e x 0_01
milli m x 0_001 N-m x 0.1020 kg-m
micro J1 x 0_000001 N-m x 0.7376 = ft-Ib
N-m x 8.851 in- Ib
kg-m x 9.807 N-m
kg-m x 7.233 ft-Ib
Units of Mass: kg-m x 86.80 in-Ib
kg x 2_205 Ib
g x 0_03527 oz

Units of Pressure:
kPa x 0.01020 kg/em'
Units of Volume: kPa x 0.1450 psi
L x 0.2642 gal (US) kPa x 0.7501 em Hg
L x 0.2200 = gal (imp) kg/em ' x 98.07 kPa
L x 1.057 qt (US) kg/em ' x 14.22 = psi
L x 0.8799 qt (imp) em Hg x 1.333 = kPa
L x 2.113 pint (US)
L x 1.816 pint (imp)
mL x 0.03381 oz (US)
mL x 0.02816 oz (imp) Units of Speed :
mL x 0.06102 cu in km/h x 0.6214 = mph

Units of Foree: Un its of Power :

N x 0.1020 kg kW x 1.360 PS
N x 0.2248 Ib kW x 1.341 HP
kg x 9.807 N PS x 0.7355 kW
kg x 2.205 Ib PS x 0.9863 HP

Units of Temperature:

9 rC+40) -40= OF 40= C

5

OF 4
OF
32 6B 104 176 212 246 2B 4
40 -20 :0 20 : 40 60
, 60 120 140 160 : 180 200 240 i, 260 280: 300
:I ,I
100:
,: 220 320

I
I I
I I I
I I, I
I'
I !I I Ii 'I
I I I, I I
I I, I I I, i; I
I I
40 -2 0 : 0 : 20 40 60 BO : 100 : 120 : 140 160
-17 . 8 4.4 26.7 48.9 71.1 93.3 116 136
c c
 KLF 300
Kawasaki BAYOU 300

All Terrain Vehicle

Service Manual
Supplement
 Quick Reference Guide

General Information
Fuel System
Engine Top End
Engine Left Side 41
Engine Right Side 51
~E=n~g=i=n=e=R=e=m==o=v=al=/l=n=s=ta=I=la=t=io=n=======611
~E=n=g=i=n=e=B=o=tt=o=m=E=n=d=lT=r=a=n=s=m=i=s=s=io=n==7I
~W=h=e=e=ls=lT==ir=es==================81
~F=in=a=I=D=r=iv=e===================9.
Brakes 10.
Suspension . 11.
Steering 12.
Frame 13.
Electrical System 14
I Appendix 15
Supplement - 1989 - 1997 Models 16

This quick reference guide will assist

Supplement - 1998 - 1999 Models 17
you in locating a desired topic or pro-
cedure.
Supplement - 2000 - 2002 Models 18
-Send the pages back to match the
black tab of the desired chapter num- Supplement - 2003 - 2006 Models 19
ber with the black tab on the edge at
each table of contents page.
-Refer to the sectional table of contents
for the exact pages to locate the spe-
cific topic required.
 LIST OF ABBREVIATIONS

A ampere(s) Ib 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 rpm revolution(s) per minute
F farad(s) TDC top dead center
of degree(s) Fahrenheit TIR total indicator reading
ft foot, feet V volt(s)
g gram(s) W watt(s)
h hour(s) n ohm(s)
L liter(s)

US Model only
~~~~~~~~~~~~~~~~~~~~~~~~~$~~
~ ~
m PLEASE DO NOT TAMPER WITH NOISE CONTROL SYSTEM ~

~
W. To minimize the noise emissions from this product, Kawasaki has equipped it with
~
~
~ effective intake and exhaust silencing systems. They are designed to give optimum per- .....
~ formance while maintaining a low noise level. Please do not remove these systems, or alter ~
~ them in any which results in an increase in noise level. . ~

~~~~~~~~~~~~~~~~~~~~~~~~~~~~

This warning may apply to any of the following

components or any assembly containing one or
more of these components:-

Brake Shoes or Pads

Clutch Friction Material
Gaskets
Insulators

WARNING SAFETY INSTRUCTIONS

CONTAINS
ASBESTOS
-Operate if possible out of doors or in a well
Breath ing asbestos
dust is dangerou s
ventilated place.
to health .Preferably use hand tools or low speed tools
equipped, if necessary. with an appropriate dust
Follow safety
instructions extraction facility . If high speed tools are used ,
they should always be so equipped.
elf possible, dampen before cutting or drilling.
eDam pen dust and place it in properly closed
receptacle and dispose of it safely.

Read OWNER'S MANUAL before operating

 Foreword
This service manual supplement contains
only the information unique to the models cov-
ered. It must be used with the base service
manual listed below. Read both this sup-
plement and the base manual for complete
information on proper service procedures for
the models covered by this manual.
Base Manual Part Number
KLF300 Service Manual 99924-1057 -02
This manual is designed primarily for use by
trained mechanics in a properly equipped shop.
However, it contains enough detail and basic in-
formation to make it useful to the owner who de-
sires to perform his own basic maintenance and
repair work. A basic knowledge of mechanics,
the proper use of tools, and workshop proce-
dures must be understood in order to carry out
maintenance and repair satisfactorily. When-
ever the owner has insufficient experience or
doubts his ability to do the work, all adjust-
ments, maintenance, and repair should be car-
ried out only by qualified mechanics.
In order to perform the work efficiently and
to avoid costly mistakes, read the text, thor-
oughly familiarize yourself with the procedures
before starting work, and then do the work care-
fully in a clean area. Whenever special tools or
equipment are specified, do not use makeshift
tools or equipment. Precision measurements
can only be made if the proper instruments are
used , and the use of substitute tools may ad-
versely affect safe operation.
For the duration of the warranty period,
we recommend that all repairs and scheduled
maintenance be performed in accordance with
this service manual. Any owner maintenance or
repair procedure not performed in accordance
with this manual may void the warranty.
To get the longest life out of your vehicle:
Follow the Periodic Maintenance Chart in the
Service Manual.
Be alert for problems and non-scheduled
maintenance.
Use proper tools and genuine Kawasaki Vehi-
cle parts. Special tools, gauges, and testers
that are necessary when servicing Kawasaki
vehicles are introduced by the Service Man-
ual. Genuine parts provided as spare parts
are listed in the Parts Catalog.
Follow the procedures in this manual care-
fully. Don't take shortcuts.
Remember to keep complete records of main-
tenance and repair with dates and any new
parts installed.
How to Use This Manual
In this manual , the product is divided into
its major systems and these systems make up
the manual's chapters. The Quick Reference
Guide shows you all of the product's system
and assists in locating their chapters. Each
chapter in turn has its own comprehensive Ta-
ble of Contents.
For example, if you want ignition coil informa-
tion, use the Quick Reference Guide to locate
the Electrical System chapter. Then, use the
Table of Contents on the first page of the chap-
ter to find the Ignition Coil section.
Whenever you see these WARNING and
CAUTION symbols, heed their instructions!
Always follow safe operating and maintenance
practices.
A WARNING
This warning symbol identifies special
instructions or procedures which, if not
correctly followed, could result in per-
sonal injury, or loss of life.
CAUTION
This caution symbol identifies special
instructions or procedures which, if not
strictly observed, could result in dam-
age to or destruction of equipment.
This manual contains four more symbols (in
addition to WARNING and CAUTION) which will
help you distinguish different types of informa-
tion.
NOTE
o This note symbol indicates points of par-
ticular interest for more efficient and con-
venient operation.
Indicates a procedural step or work to be
done.
Olnd icates a procedural sub-step or how to do
the work of the procedural step it follows. It
also precedes the text of a NOTE.
* Indicates a conditional step or what action to
take based on the results of the test or inspec-
tion in the procedural step or sub-step it fol-
lows.
In most chapters an exploded view illustration
of the system components follows the Table of
Contents. In these illustrations you will find the
instructions indicating which parts require spec-
ified tightening torque, oil, grease or a locking
agent during assembly.
 GENERAL INFORMATION 1-1

General Information
Table of Contents

Before Servicihg ....... . . .. . . . .... . . ....... .. . ... .. ... . .... .

Model Identification . .. .. . . .. . . .. .. ....... .. . . ... ...... .. . . . 1-2
General Specifications .. ... . . .... .... . . . . .... . . ... .. . . ...... . 1-4
Periodic Maintenance Chart ...... .. . .. . . .... . . .. .. . .. . . ..... . . 1-6
Torque and Locking Agent .. . . . . . ... .. .... . . ... .. .... . . ..... . 1-7
Wiring, Cable, or Hose Routing . ... .. . . .. .... ..... ..... . . . . ... . 1-10

* : Base Manual
'-2 GENERAL INFORMATION
,0

Model Identification
.............................................................................

KLF300-Bl (US model)

 GENERAL INFORMATION 1-3

KLF300-Bl (Australia model!

14 GENERAL INFORMATION

General Specifications

: Australia model : UK model

@: Canada model @: US model
Item KLF300-Bl
Dimensions:
Overall length 1910 mm
Overall width 1115mm, 1160mm
Overall height 1035 mm
Wheelbase 1210 mm
G rou nd clearance 195 mm
Seat height 750 mm
Dry weight 223 kg, 226 kg
Curb weight: Front lOB kg, 109.5 kg
Rear 125 kg, 126.5 kg
Fuel tank capacity 9 L, B.2 L
Performance:
Minimum turning radius 2.9 m (Locked axle mode)
2.6 m (Differential mode)
Engine:
Type 4-stroke, SOHC, l-cylinder
Cooling system Air cooled
Bore and stroke 76.0 x 64.0 mm
Displacement 290 mL
Compression ratio B.6
Maximum horsepower 15.4 kW (21 PSI @7000 r/ min (rpm), @ -
Maximum torque 22.6 N-m (2.3 kg-m, 16.6 ft-Ib) @6000 r/ min (rpm),
@-
Carburetion system Carburetor, Keihin CV K32
Starting system Electric starter & recoil starter
Ignition system Battery and coil (transistorized)
Timing advance Electronically advanced
Ignition timing From 10 BTDC @1300 r/min (rpm) to
40 BTDC @4000 r/min (rpm)
Spark plug NGK BBES, @ NGK BRBES
Valve timing: Inlet Open 27 BTDC
Close 65 ABDC
Duration 272
Exhaust Open 62 BBDC
Close 30 ATDC
Duration 272
Lubrication system Forced lubrication (wet sump)
Engine oil : Grade SE, SF or SG class
Viscosity SAE 10W-30, 10W40, lOW-50, 20W-40, or 20W-50
Capacity 1.7 L

(Continued on next page.)

 GENERAL INFORMATION 1-5

Item KLF300-Bl
Drive Train:
Primary reduction system: Type Gear
Reduction ratio 2.888 (78/27)
Clutch type: Primary Auto centrifugal, wet
Secondary Auto multi disc, wet
Transmission: Type 5-speed plus reverse, constant mesh, return shift
Gear ratio: 1st 3.090 (34/11)
2nd 1.928 (27/14)
3rd 1.368 (26/19)
4th 1.000 (23/23)
5th 0.769 (20/26)
Reverse 3.072 (26/11 x 26/20)
Final drive system : Type Shaft
Reduction ratio 4.886 (20/16 x 43/11), 5.584 (20/14 x 43/11)
Overall drive ratio 10.858, 12.409 @Topgear
Final gear case oil : Type API G L-5 Hypoid gear oil SAE 90 (above 5C, 41 F) or
SAE 80 (below 5C, 41 F)
Capacity 0.3 L
Frame:
Type Double tubular
Caster (rake angle) 3.0
Chamber 1.0@1G
Trail 13 mm
Tread Front 834mm
Rear 844mm
Front tire: Type Tubeless
Size 22 x 9.00-10
Rear tire : Type Tubeless
Size 24 x 11.00-10
Suspension: Front Type Double wishbone-link
Wheel travel 125 mm
Rear Type Torque tube-link
Wheel travel 120mm
Brake type: Front Disc (Hydraulic)
Rear Drum (Mechanical)
Electrical Equipment:
Battery 12 V 14 Ah
Headlight: Type Semi-sealed beam
Bulb 12 V 65/60 W, Option
Taillight 12V8Wx2, -
Alternator: Type Three-phase AC
Rated output 23.5 A @9000 r/min (rpm), 14 V
Voltage regu lator: Type Short-circuit

Specifications are subject to change without notice, and may not apply to every country.
1-6 GENERAL INFORMATION

Periodic Maintenance Chart

The scheduled maintenan~e must be done in accordance with this chart to keep the vehicle in good
running condition. The first service is vitally important and must not be neglected.

First Service Regular Service

AM':% .~.~~ :~
= Clean, adjust, lubricate, tighten, or
replace parts as necessary . '" ~ C\;) 4' 05 ~ ~
of use i:-""" i:-""" i:-""" i:-
! ~'"
l?
! ~'" 0'" ~'"
l? l?
!()-J' See
Page
Engine:
Air cleaner--service* 2-7
Clutch adjustment* 5-3
Valve clearance--check 3-6
Fuel system cleanliness--check * (2-10)
Engine oil--change* (5-11 )
Oil filter--replace* (5-11)
Spark plug-clean and gap (14-17)
Spark arrester--clean 3-11
Chassis:
Rear brake adjustment--check* (10-6)
Rear brake lining wear--check* (10-6)
Front brake pad wear--check * 10-7
Brake fluid level--check (10-8)
Brake fluid--change (10-8)
Cable adjustment* **
Battery--check 14-6
Steering play--check ( 12-6)
General lubrication* 15-4
Bolts and nuts--tighten 15-4
Final gear case oil--change* (9-6)
Master cylinder piston assembly and
2 years (10-11)
dust seal--replace
Caliper piston seal and dust seal--replace 2 years 10-6
Brake hose--replace 2 years 10-9

* : Service more frequently when operated in mud , dust, or other harsh rid ing conditions.
** : Refer to 2, 7,9, and 10 chapters.
(xx-xx) : Reference Page in the Base Manual
 GENERAL INFORMATION 1-7

Torque and Locking Agent

The following tables list the tightening torque for the major fasteners requiring use of non-perma-
nent locking agent or liquid gasket.

Letters used in the "Remarks" column mean:

L : Apply non-permanent locking agent to the threads.
0: Apply oil to the threads and seated surface.
S : Tighten the fasteners following the specified sequence.
St: Stake the fasteners to prevent loosening.
: UK model

Torque
Parts Remarks
N-m kg-m ft-Ib
Fuel System:
Throttle lever bolt 6.9 0.7 61 in-Ib
Fuel tap plate mounting screws 0.8 0.08 7 in-Ib
Engine Top End:
Spark plug 27 2.8 20
Cylinder head bolts:8 (used bolts) 29 3 .0 22 S
8 (new bolts) 34 3 .5 25 S
Cylinder head bolts: 6 12 1.2 104 in-Ib S
Cylinder bolts 12 1.2 104 in-Ib S
Valve adjusting screw locknuts 12 1.2 104 in-Ib
Camshaft sprocket bolt 41 4.2 30
Camshaft chain guide pivot bolt 9.8 1.0 87 in-Ib
Engine Left Side:
Alternator rotor bolt 59 6.0 43
Starter clutch Allen bolts 49 5.0 36 L
Recoil starter flange nut 8 .3 0 .85 74 in-Ib
Engine Right Side:
Oil drain plug 29 3.0 22
Primary clutch hub nut 125 13.0 94 0
Secondary clutch hub nut 78 8.0 58 0
Secondary clutch spring bolts: (used bolts) 12 1.2 104 in-Ib
(new bolts) 15 1.5 11.0
Oil pipe banjo bolts 20 2.0 14.5
Engine Removal/I nstallation:
Engine mounting bolts: 8mm 25 2.5 18.0 S
10 mm 34 3.5 25
Engine mounting bracket bolts 25 2 .5 18.0
H! GENERAL INFORMATION

Torque
Parts Remarks
N-m kg-m ft-Ib
Engine Bottom End/Transmission:
Oil drain plug 29 3.0 22
Oil pipe banjo bolts 20 2.0 14.5
Neutral switch mounting screw - - - L
Shift drum stopper bolt 12 1.2 104 in-Ib
Shift drum pin plate bolt 12 1.2 104 in-Ib
Shift shaft return sprin9 pin 17 1.7 12.0 L
Clutch release cam pin 17 1.7 12.0 L
Oil pressure relief valve 15 1.5 11.0 L
Balancer gear nut 120 12.0 87 a
Balancer drive gear and oill pump drive gear nut 145 15.0 110 a
Wheels/Tires:
Wheel nuts 34 3.5 25
Front hub nuts 34 3.5 25
Rear axle nuts 145 15.0 110
Toe-in locknuts 27 2.8 20
Final Drive:
Front gear case bolts: 8mm 25 2.5 18.0
Output shaft LH bearing housing bolts 12 1.2 104 in-Ib
LH bearing holder 98 10.0 72 St
Drive gear nut: 16mm 93 9.5 69 a
Driven gear nut 7B B.O 58 a
Driven gear shaft oil seal housing nuts 25 2.5 18.0
Front gear case plug (Speedometer gear holder:
' Option for other than . ) 20 2.0 14.5
Propeller shaft housing nuts 25 2.5 18.0
Axle shaft pipe bolts 25 2.5 18.0
Pin ion gear nut 7B B.O 58 0, St
Ring gear and differential gear housing bolts 29 3.0 22 L
Final gear case cover bolts 25 2.5 18.0
Final gear case filler cap 29 3.0 22
Final gear case drain plug 20 2.0 14.5
Differential shift fork holder screws 6.9 0.70 61 inlb
Brakes:
Bleed valves 7.B O.B 69 in-Ib
Brake hose banjo bolts 25 2.5 18
Caliper mounting bolts 25 2.5 18
Disc mounting bolts 37 3.8 27
Brake lever pivot bolt 5.9 0.6 52 inlb
8rake lever pivot bolt locknut 5.9 0.6 52 in-Ib
Front master cylinder clamp bolts B.8 0.9 78 in-Ib
Front brake fluid reservoir cap screws 1.0 0.1 9 in-Ib
 GENERAL INFORMATION 1-9

Torque
Parts Remarks
N-m kg-m ft-Ib
Rear drum drain bolts 29 3.0 22
Brake panel mounting bolts 29 3.0 22 L
Rear brake pedal mounting bolt 29 3.0 22
Rear axle nuts 145 15.0 110
Suspensions:
Shock absorber mounting bolts 34 3 .5 25
Suspension arm pivot bolts : 12 mm 88 9.0 65
Rear suspension arm (rod): 10 mm 34 3.5 25 L
Steering:
Handlebar clamp bolts 20 2.0 14.5
Stem clamp Allen bolts 25 2 .5 18.0
Stem bottom end nut 29 3.0 22
Stem bearing housing bolts 20 2.0 14.5
Tie-rod end nuts 41 4.2 30
Tie-rod adjusting sleeve locknuts 27 2.8 20
Knuckle joint nuts 41 4.2 30
Electrical System:
Spark plug 27 2.8 20
Alternator rotor bolt 59 6.0 43
Neut ral and reverse indicator
switch mounting screws - - - L
Starter circu it relay term inal nuts 4.4 0.45 39 in-Ib
Taillight assembly mounting screws 7.8 0.8 69 in-Ib

The table below, relating tightening torque to thread diameter, lists the basic torque for the bolts
and nuts. Use th is table for only the bolts and nuts which do not require a specific torque val ue. All
of the varues are for use with dry solvent-cleaned threads.
General Fasteners:

Torque
Threads dia . (mm)
N-m kg-m ft lb
5 3.4 - 4.9 0.35 - 0.50 30 - 43 in-Ib
6 5.9 - 7.8 0.60 - 0.80 52 - 69 in-Ib
8 14 - 19 1.4 - 1.9 10.0 - 13.5
10 25 - 34 2.6 - 3.5 19.0 - 25
12 44 - 61 4.5 - 6.2 33 -45
14 73 - 98 7.4-10.0 54-72
16 115 - 155 11 .5 - 16.0 83 - 115
18 165 - 225 17.0 - 23.0 125 - 165
20 225 - 325 23 -33 165 - 240
1-10 GENERAL INFORMATION

Wiring, Cable, or Hose Routing

View Q (other than UK model) ViewQ

5

L~.
/

Cooling Fan Installation (UK model)

ViewP Clamp
To Fan Switch (BL, BR)

10

Strap

~
Front
Strap
ViewR

18
Fuel Tank Bracket

Refer to View W.

@ Straps
@

o Tube B

Tube C
 GENERAL INFORMATION 1-11

ViewS

Front
Front

Clamps @
Fuel Tank Bracket

Tube A

Air Cleaner Housing Brackets

1. Viny l Cover
2. Main Harness 18. Neutral and Reverse Switch Connectors
3. Accessary Connectors (for Auxiliary Light, 19. Alternator Connector
R, BK/Y) 20. Pickup Coil Connector
4. Cooling Fan Connectors (BR, BK/ Y) from 21. IC Igniter Connectors
Main Harness 22 . Battery Ground Cable
5. To Neutral and Reverse Indicator Lights 23. Fuse 30A
(LG, BR, R/W) 24. Battery Positive Cable
6. To Headlight (R/Y, R/BK, BK/Y) 25. Starter Relay
7 . To Ignition Switch (BR, W) 26 . Igniter
8. To Left-Ha nd Switch 27. Starter Circuit RelaY
9 . Cooling Fan 28. Battery Vent Hose
10. Fan Motor Vent Hose 29. Main Harness Positioning Mark - white tape
11. Cooling Fan Leads (BL, BK/Y) (Aline with bolt hole position)
12. Cooling Fan lOA Fuse (BR) 30. Ignition Coil Leads
1 3 . Electric Starter Cable 31. Electric Starter Terminal
14. Neutral and Reverse Switch Leads 32. Engine Breather Hose
15. Alternator and Pickup Coil Leads 33 . Reverse Cable
16. Engine Ground Lead 34. Regulator/Rectifier Connector
17. Engine Ground Terminal and Clamp 35. Taillight Connectors
1-12 GENERAL INFORMATION

ViewU

Strap

ViewT

View V

~ !
Front I

36. Fuel Tank Vent Hose

37. Brake Hose
38. Choke Cable
39. Throttle Cable
40. Final Gear Case Breather Hose
41. Joint for Carburetor Vent Hose
42. Right Rear Brake Panel Vent Hose
43. Brake Cables
44. Carburetor Vent Hose
45. Differential Shift Lever Case
46. Differential Cable
47. Left Rear Brake Panel Vent Hose
 GENERAL INFORMATION 113

ViewW

the throttle
cable to the right
side of the steerin g
stem.
Strap

Tube C

47
47

Clamp Clamp

o

Fuel System
Table of Contents
Exploded View .. . . . . . . . . . . . . . . . ... 22
Specifications . . . . . . . . . . . . . . . . . . . .. 24
Special Tools . . . . . . . . . . . . . . . . . . . 24
Throttle Case and Cable . . . . . ... . . .... . 25
Throttle Lever Free Play Inspection .. .
Throttle Cable Adjustment . . ...... .
Throttle Case Removal/Disassembly . . .
Throttle Case Assembly/Installation . . .
Throttle Cable Removal . . . . . . . . . . .
Throttle Cable Installation .. ...... .
Throttle Case and Cable Lubrication .. . 2-5
Throttle Case Inspection . .. . . . .... .
Throttle Cable Inspection . . . . . . . .. .
I
Choke Lever and Cable . . . . . . . . . . . . . 2-5
Choke Lever and Cable Removal . ... . 25
Choke Lever and Cable Installation . . . . 26
Choke Lever and Cable Lubrication .. . 2-6
Choke Cable Inspection . . . . . . . . . . . 2-6
Carburetor .. . . . . . . . . . . . . . . . . . .. .. . 2-6
Carburetor Pilot Screw Adjustment . .. . 2-6
Idle Speed Adjustment . . . . . . . . . . . . 27
Fuel Levell nspection ... . . . . . . . . . .
Fuel Level Adjustment . ... . . . . . . . .
FUEL SYSTEM 2-1
Fuel System Cleanliness Inspection . . . .
Carburetor Removal. . . . . . . . . . . . . .
Carburetor Installation . . . .. .. . ...
Carburetor Disassembly . .. . .. .. .. .
Carburetor Assembly . .. . . . . . .... .
Carburetor Cleaning . . . . . . . . . . . . . .
Carburetor Inspection . . . . . . . . . . . .
Air Cleaner .. .... .. . . . . . . . . . . . . . . . . 27
Air Cleaner Element Cleaning . . . . . . . 27
Air Cleaner Housing Dust and/or
Water Inspection .. . . . . . . . . . . . . 28
Fuel Tank ..... . . . . . . . . . . . . . . . . . . . 2-9
Fuel Tank Removal . . . . . . . . . . . .. 2-9
Fuel Tank Installation Notes . .. . . .. . 2-10
Fuel Tap Removal . . . . . . . . . . . . ..
Fuel Tank Inspection . .. .... ... .. .
Fuel Tank and Tap Cleaning .......
Fuel Tap Inspection .. . . . . . . . . . . . .
Fuel Level Gauge Removal . . . . . . . . . 2-10
Fuel Level Gauge Installation Notes .. . 2-10
Fuel Level Gauge Check .. .. . . . . . . . 2-11
Fuel Tank Damper Installation .. . . . . . 211
Base Manual
2-2 FUEL SYSTEM

~~~;~~~~ V;~~ " " " " " " " " " "" "

o @)
~ _ _LI _ _

2
~

.
~~ G '
~ . .

~ ~I ~=======
~)' ~~l
. -

>.
I'

1.Choke Lever
2.Throttle Cable
3.Choke Cable
4.Throttle Case
5.Starter Jet
6.Pilot Jet
7.Main Jet
A : Apply adhesive
G : Apply grease. .
o : Apply oil.

L_D
Oe: Apply cleaner element oil
R : Replacement Parts .

T1: 6.9 Nm (0.70 kg-m, 61 in-Ibl

T2: 0.8 Nm (0.08 kg-m, 7 in-Ibl
- - ---
 FUEL SYSTEM 23

~ I
I

~
I
I

I
~ I
I
~
I
I
I
I
I

'<:: :
I

~@Ah: I
I
,
I
~

--~
24 FUEL SYSTEM

Specifications

Refer to the Base Manual noting the following.

Item Standard
Carburetor Specifications
Make, type: Keihin, CVK32
Main jet: #128
Main air jet: # 100
Needle jet: #6
Jet needle mark : N27Q
Pilot jet (slow jet) : # 38
Pilot air jet (slow air jet): # 140
Pilot screw (turns out): 2'/,
Starter jet : # 55
Service fuel level (from carburetor body
bottom edge) : 0.5 mm below - 1.5 mm above
Float height: 17 2 mm
Engine Speed (for reference) 1300 100 r/ min (rpm)
Optional Parts
Main jet: # 122,125,130,132
Pilot jet (slow jet): # 35, # 40
Starter jet: # 58, # 60

Special Tools

ORefer to the Base Ma nu al noting the following addi

tio nal too ls.

Pilot Screw Adjuster "A": 570011239

 FUEL SYSTEM 2-5

Throttle Case and Cable

Throttle Case and Cable Lubrication

o Refer to the Base Manual noting the following .
Lubricate the throttle case and cable in accordance
with the Periodic Maintenance Chart, or whenever the
case and cable are removed (see General Information
chapter and General Lubrication in the Appendix
chapter).
OUse the pressure cable luber to lubricate the throttle
cable.

A. Cable End B. Starter Plunger

-Unscrew the choke lever mounting screw and take off

the plane washer and the wave washer.

Choke Lever and Cable

Choke Lever and Cable Removal A. Lever Mounting Screw B. Choke Lever
Unscrew the starter plunger cap and pull out the starter
plunger.
Remove the choke lever and free the choke cable upper
end from the lever.
.Pull off the retaining ring and free the choke cable
housing from the switch housing.

A. Starter Plunger Cap

A. Retaining Ring

-Hold the starter plunger sp ring compressed, and free

the choke cable lower end from the plunger. .Pull the cable out of the vehicle.
2-6 FUEL SYSTEM
.. ...........................................................................
Choke Lever and Cable Installation
Carburetor
-Choke cable installation is the reverse of removal.
Note the following.
_ Lubricate the choke cable (see General Lubrication in
the Appendix chapter) and grease the wave washer Carburetor Pilot Screw Adjustment
before installation . Loosen the carburetor holder clamp screws.
elnstall the wave washer, plane washer, and screw in
that order.

A. Clamp Screws (Front and Rear)

1. Screw 3. Wave Washer -Tilt the carburetor to the right of the vehicle for easy
2. Plane Washer access to the pilot screw.

_Route the choke cable according to the Wiring, Cable,

or Hose Routing section in the General Information
chapter.

Choke Lever and Cable Lubrication

Lubricate the wave washer and the flat washer of the
choke lever, and the choke cable in accordance with
the Periodic Maintenance Chart, or whenever the lever A. Pilot Screw
and cable are removed (see General Information
chapter and General Lubrication in the Appendix
chapter).
OUse the pressure cable luber to lubricate the choke eTurn the pilot screw in until it seats lightly, and back it
cable. out 21/8 turns.

Carburetor Pilot Screw Setting

Standard:

Choke Cable Inspection e Reposition the carburetor properly and tighten the
-With the choke cable disconnected at both ends, the clamp screws securely.
cable should move freely in the cable hou sing. OF it the carburetor ridge into the groove on the duct.

Idle Speed Adjustment
eAdjust the pilot screw if necessary (see Carburetor
Pilot Screw Adjustment).
-Start the engine and warm it up thoroughly.
eTurn the idle adjusting screw to obtain the slowest
smooth idle speed.
A. Idle Adjusting Screw
*If the engine idle is still not stable, adjust the pilot
screw to obtain the slowest smooth idle speed using the
pilot screw adjuster "A" (special tool) .
A. Pilot Screw Adjuster "A": 57001-1239
WARNING I
OOperation with an improperly adjusted. incorrect
routed, or damaged cable could result in an unsafe
riding condition .
a Te avoid a serious burn, never touch a hot engine or an
exhaust pipe during carburetor adjustment.
_Open and close the throttle a few ti mes to make sure
that the idle speed does not change. Readjust if
necessary.
FUEL SYSTEM 2-7
NOTE
OWith engine idling, turn the handlebar to each side. If
handlebar movement changes idle_speed, the throttle
cable may be incorrectly routed, or it may be damaged.
Air Cleaner
A clogged air cleaner restricts the engine's air intake,
increasing fuel consumption, r~ducing engine power, and
causing spark p lug fouling.
I WARNING I
OA clogged air cleaner may allow dirt and dust to enter
the carburetor and stick the throttle open. This could
cause an accident.
[~AUTIO~.l
o A clogged air cleaner may allow dirt and dust to enter
the engine causing excessive wear and possibly engine
damage.
The air cleaner element must be cleaned periodically
(see the Periodic Maintenance Chart in the General
Informatio n chapter). In dusty areas, the element
should be cleaned more frequently than the recom-
mended interval. After riding through rain or on muddy
terrain, the element should be cleaned immediately,
Air Cleaner Element Cleaning
Remove the seat .
Pull up the snaps and remove the air cleaner cover.
A. Air Cleaner Cover B. Snaps
2-8 FUEL SYSTEM
e Loosen t he clamp screw, remove the ele ment fix ing
sc rew, then pull the air cleaner element up out of the
air cleaner housing.
A. Screws B. Elemen t
Push a clean, lint-free towel into t he air cleaner ho using
to kee p dirt or other foreign material from entering.
I WARNING.
o If dirt or dust is allowed to pass through into the
carburetor, the throttle may become stuck open,
possibly causing an accident.
o If dirt gets through into the engine, excessive engine
wear and possibly engine damage will occur.
eRemove the element stoppe r from the rear end of the
element bo dy by removi ng the screw.
A. Screw B. Stopper
.Pu ll t he element off th e body, then off t he inner metal
net.
A. Element B. Metal Net
elnspect the element for damage. If it is torn o r punc-
tured, replace it.
elf the element is not obv iou sly damaged, clean it in a
bath of high -flash point solve nt, and squeeze it dry.
I WARN.ING
Oelean the element in a well-ventilated area, and take
ample care that there are no sparks or flame anywhere
near the working area; this includes any appliance
with a pilot light. Do not use gasoline or a low-flash
point solvent to clean the element. A fire or ex-
plosion could result.
eAfter cleaning, saturate the element with SE or SF
class SAE 30 oil, squeeze o ut the excess, t hen wrap it
in a clean rag and sq ueeze it as dryas possib le. Be
careful, not to tear the ele me nt.
NOTE
o Special oils for foam air cleaner elements can be used.
OReplace the element after cleaning it five times or if it
is damaged.
Air Cleaner Housing Dust
and/or Water Inspection
e Push open the two drain hoses on t he bottom of the a ir
cleaner housing to expel dust and /o r water accumul-
ated inside .
A. Drai n Hoses
 FUEL SYSTEM 2-9
elnstall the fuel tank ca p at once.
Fuel Tank _Remove the fuel ta nk front cover by pullin g it up and
turning it to e ith er side between th e fron t carrier and
the steering stem .
Fuel Tank Removal
-Remo ve the sea t (see Frame chapter in this manual).
eR emove the fuel tank rear cove r.

A . Front Cover

A. Rear Cover B. Screws

eTake off t he fue l tank cap. -Remove the breather and vent hoses fro m the cla mp on
t he rear of the fuel tank .
[ WARNING I e Remove the following bolts.

OGasoline is extremely flammable and can be explosive

under certain conditions. Turn the ignition switch
OFF. 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 .

Remove th e fuel tank top cover .

A. Fuel Tank Mounting Bolts (3)

B. Front Fend er Mounting Bo lts (2)

eTurn the fuel tap to t he OFF position .

ePul1 the fuel hose off the tap.
A . Screws C. Top Cover -Bend the front fender tabs o utward and remove the
B. Tank Cap f uel tank .
2-10 FUEL SYSTEM

Fuel Tank Installation Notes eRemove the fuel tank upper cover by taking off the
eFuel tank installation is the reverse of removal. Note two mounting screws.
the following. -Install the fuel tank cap immediately.
_Pry off the gauge cap and discard the cap.

WARNING I -Check the grooves in the fue l tank boss. If the grooves
are damaged by removing the cap or can not hold the
cap nails, the fuel tank must be replaced.
OGasoline is extremely flammable and can be explosive
under certain conditions. Turn the ignition switch
OFF. 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.

-Check the rubber dampers on the frame top-tube.

A. Gauge Cap B. Grooves

-Pu ll out the fuel level gauge.

A. Dampers

*If the dampers are damaged or deteriorated, replace

them .
Be sure the fuel hose is clamped to the fuel tap to
prevent leakage.

I WARNING I
o Fuel spilled from the fuel tap is hazardous.

-Install the breather and vent hoses on the fuel tank and
secure them with the clamp (see Wiring, Cable, or Hose
Routing section in the General Informat ion chapter).
A. Fuel Level Gauge

Fuel Level Gauge Installation Notes

Fuel Level Gauge Removal Olnstallation is the reverse of removal. Note the fol -
-Remove the fuel tank cap. lowing.

I WARNING I
OGasoline is extremely flammable and can be explosive
under certain conditions . Turn the ignition switch
OFF. 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.
WARNING I
OGasoline is extremely flammable and can be explosive
under certain conditions. Turn the ignition switch
OFF. 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.

elnstall the fuel level gauge so that the Y:z scale faces the
front.
e Push the new gauge cap over the gauge so that the
notch align s with the V2 scale.
FUEL SYSTEM 2-11
Fuel Tank Damper Installation
eApply an adhesive which is recommended by the
manufacturer for bonding rubber to metal to the inside
of the rubber dampers and install them as shown.
eFace each split of the dampers inward of the vehicle.

Damper Installation

A. Front C. Notch
B. Y, Scale

eCheck that the gauge cap nail s fit securely in the

grooves in the fuel tank boss. 1. Rubber Dampers
2. 10 - 15 mm
3 . Splits

Fuel Level Gauge Check

-Remove the fuel level gauge from the fuel tank (see
Fuel Level Gauge Removal) .
-Check that the float moves up and down smoothly
without binding. It sho uld go down und er its own
weight.
*If the float does not move smoothly or has visual
damage, replace the gauge.

A. Fuel Level Gauge c. Up and Down Smoothly.

B. Float
 ENGINE TOP END 3-1

Engine Top End

Table of Contents
Exploded View .. . .. . .. . ... .. ..... 3-2 Camshaft Installation . . . . . . . . . . . . .
Specifications ... . .. .. ... . . .. . . .... . 34 Cam Wear Inspection . . .. . ... .. . . .
Special Tools . . . . . . . . . . . . . . . . . . . . . 34 Camshaft Bearing Inspection . . . . . . . .
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . 34 Camshaft Chain, Guides, and Tensioner .... . 3-9
Cylinder Head Removal . ... . . . . . . . . . 34 Camshaft Chain . . .. ... . . . . . . . . . . . .
Cylinder Head Installation Notes . . .... . 3-5 Camshaft Chain Removal .. ... ....
Compres~.ion Releasing Lever Removal 3-5 Camshaft Chain Installation . . . . . . . . .
Compression Releasing Camshaft Chain Wear .. ... . ....... ,
Lever Installation . . . . . . . . . . . . . . 3-5 Camshaft Chain Guides . . . . . . . . . . . . . .
Cylinder Head Assembly Note ... . .. .. . 3-6 Camshaft Chain Guide Removal . . ... .
Cylinder Head Cleaning . . . . . . . . . . .. . Camshaft Chain Guide Installation . .. .
Cylinder Head Warp . . . . . . . . . . . .... . Camshaft Chain Guide Wear . . . . . . . .
Valves, Guide, Seats, Springs, Oil Seals .... . 3-6 Camshaft Chain Tensioner .. .. . . . . . . . . 3-9
Valves ..... . . . . . . . . . . . . . . . . . . . . 36 Camshaft Chain Tensioner Removal .. . 3-9
Valve Clearance Check . . . . . . . . ... . 3-6 Camshaft Chain
Valve Clearance Adjustment . . . . . . . . Tensioner Installation . .. .. . . . . . . 3-9
Valve Removal . . . . . . . . . . . . . . . . . Camshaft Chain Tensioner Wear . . . .. .
Valve Installation . . . . . . . .. . . . . . Cylinder, Piston and Rings . . . . . . . . . . . . . 3-10
Valve Visual Inspection . . . . . . . . . . . Cylinder Removal/Installation . . . . . . . . .
Valve Head Thickness .. . . . . . . . . . . . Cylinder Removal . . . . . . . . . . . . . . .
Valve Stem Bend ...... . , . ...... . Cylinder Installation Note . . . . . . . . . . 3-10
Valve Stem Diameter . . . . . . . . . . . . . Cylinder Assembly Note ...... . ... . 3-10
Valve Stem Grinding . ... . ... . ... . 3-7 Piston and ring Removal/Installation . ... . 3-10
Valve Guides .. . . . . . . . . . . . . . . . . . . 3-7 Piston and Ring Removal . . . . . . . . . .
Valve Guide Inside Diameter . . . . . . . Piston and Ring Installation .. .. . ... . 310
Valve Guide Removal . . . . . . . . .. .. . Cylinder, Piston and Ring Maintenance . . . 3-10
Valve Guide Installation ... .. . . . . . . 37 Compression Measurement . . . . . . . . . 3-10
Valve Seats .. . . . . . . . . . . . . . . . . . . . . Cylinder/Piston Wear . . . . . . . . . . . . .
Valve Seat Inspection . . . . . . . . . . . . Piston/Cylinder Clearance . . . . . . . . . .
Valve Seat Repair . . . . . . . . . . . . . . . Cylinder Boring and Honing ... . ... .
, Valve Springs . .. . . .. . . . . . . . . . . . . . Piston/Cylinder Seizure . . . . . . . . .. .
Valve Spring Removal/Installation ... . Piston Cleaning ... . . . . . . . . . . . . . .
Valve Spring Free Length . . . . . . . . . . Piston Ring and Ring Groove Wear . .. .
Valve Stem Oil Seals . .... .. . .... . , . Piston Ring End Gap . . . . . . . . . . . . .
Valve Stem Oil Seal Removal . . . . . . , . Exhaust System .. . . . . . . . . . . . . . . . . . . 3-11
Valve Stem Oil Seal Installation ... . . . Spark Arrester ... . . . . . . . . . . . . . .. . 3-11
Camshaft Sprocket . . . . . . . . . . . . . . . .. . 3-7 Spark Arrester Cleaning . . . . . . . . . . . 311
Camshaft Sprocket Removal . . . . . . . . 3-7 Exhaust Pipe and Muffler ... . . . . . . . . . 312
Camshaft Sprocket Installation ..... . 38 Exhaust Pipe and
Camshaft, Rocker Arms and Shafts .... . .. . 3-8 Muffler Removal Note . . . . . . . . . . 3-12
Rocker Arms and Shafts . . ...... . ... . 3-8 Exhaust Pipe and Muffler Installation .. 312
Rocker Arm and Shaft Removal ..... . 3-8 Exhaust System Inspection ... . . . . . .
Rocker Arm and Shaft Installation ... . Carburetor Holder . . . . . . . . . . . . . . . . . . . 312
Rocker Arm Inspection . . . . . . . . . . Carburetor Holder Installation . .. . . . . 3-12
Rocker Shaft Diameter. .... .. .. ..
Camshaft . . . . . . . . . . . . . . . . . . . . .. . Base Manual
Camshaft Removal. .. .. . .. . , .. , ..
3-2 ENGINE TOP END
.............................................................................
Exploded View
.............................................................................

1. Manual Compression Release

l : Apply non-permanent locking agent.
M : Apply molybdenum disulfide grease.
Q : Apply engine oil.
R : Replacement Parts
T1 : 29 N-m (3.0 kg-m, 22 fHb) for used parts
34 N-m (3.5 kg-m, 25 ft~b) for new parts
T2: 12 N-m (1.2 kg-m, 104 in~b)
T3: 41 N-m (42 kg-m, 30 ft~b)
T4: 9 .8 N-m (1 .0 kg-m, 87 in~b)
3-4 ENGINE TOP END
.............................................................................
Specifications CyHnder Head

Refer to the Base Manual noting the following. Cylinder Head Removal
Remove the follow in g parts.
Cylinder Compression Front Fender (see Frame chapter)
(Usable range, with compression release operated) Fuel Tank (see Fuel System chapter in this text)
Carb uretor (see Fuel System chapter in the Base
Using Recoil Starter
Manual)
825 - 1280 kPa Exhaust Pipe and Muffler (see Base Manual)
(8.4 - 13.0 kg/em' .119 - 185 psi) Camshaft Sprocket (see this chapter)
Using Electric Starter Spark Plug Cap
795 - 1240 kPa Cylinder Head Breather Hose and Hose Clamp
(8.1 -12.6 kg/em' .115 - 179 psi) eRemove the cylinder head bracket mounting bolts,the
cylinder head mounting bolt, and nut, then take off the
brackets,

Special Tools

Refer to the Base Manual noting the fo llowing

additional tool.

Bearing Driver Set: 57001-1129

A. Cylinder Head Bracket Mounting Bolts

B. Cylinder Head Breather Hose and Hose Clamp
C. Cylinder Head' Mounting Bolt and Nut

-Remove the cylinder base bolt.

_ Loosen th e cylinder head bolts completely starting
with the 6 mm bolts and remove all the bolts.

A. 6 mm Cylinder Base Bolt

B. 6 mm Cylinder Head Bolts
C. 8 mm Cylinder Head Bolts

-Lift the cylinder head clear of the dowel pins in the

cylinder and slide the cylinder head out of the f rame.
 ENGINE TOP END 3-5
Cylinder Head Installation Notes .Pull out the lever along with the washer and return
eRefer to the Base Manual noting the following. spring.
elnstall a new cylinder heaa gasket.
elnspect the new head gasket, and if the seal coating
breaks away, replace the gasket.

1. Cylinder Head Gasket

*If the cylinder head or the cylinder head bolts are new
ones, tighten the 8 mm bolts to 34 N-m (3.5 kg-m, 25
fHb) of torque.
eFirst tighten the three cylinder head bracket mounting A. Oil Seal C. Washer
bolts, then tighten the cylinder head mounting bolt and B. Return Spring
nut to the specified torque (see Cylinder Head Removal),

Compression Releasing Lever Removal Compression Releasing Lever Installation

eReplace the oil seal in the cylinder head. Use a suitable
bearing driver from the bearing driver set (special tool:
[CAUTlO~:l PN 57001-1129) when installing the oil seal.
elnstall the return spring on the compression releasing
o Do not remove the compression releasing lever unless it lever as shown.
is absolutely necessary. If removed, the oil seal re-
placement may be required.

eRemove the front fender (see Frame chapter in this

manual) .
Remove the bolt holding the compression releasing
lever.

A. Return Spring

eOil the lever shaft and install the washer and lever
A. Bolt C. Front assembly.
B. Compression Releasing Lever eTighten the bolt securely.
3-6 ENGINE TOP END

Cylinder Head Assembly Note Remove the timing in spection plug.

elnsert the rubber dampers in the fin grooves starting
with the first groove from the top.
Rubber Damper Installation
2 20mm
eTurn the crankshaft counterclockwise with a wrench
on the alternator rotor bolt, and watch the intake
valve. When the intake valve opens and closes, keep
turning the crankshaft counterclockwise until the T
mark on the alternator rotor aligns with the slot, as
shown.

2
,-.
5 mm ".
2
1

1. Cylinder Head 2. Ru b ber Dam pers A. Timing Inspection Plug C. T Mark

B. Slot

Valves, Guides, Seats, Springs, Oil Seals

eMeasure the clearance of each valve between the end of
the valve stem and the adjusting screw on the rocker
Valves:
arm with a thickness gauge.
Valve Clearance Check
*If the valve clearance is not correct, adjust it (see Valve
Clearance Adjustment).
NOTE
OCheck the valve clearance only when the engine is cold
(cool to the touch).
Valve Clearance (when cold)
Remove the front fender (see Frame chapter in this
manual). Intake: 0.10 - 0.15 mm
eRemove the fuel tank (see Fuel Tank Removal in the Exhaust: 0.15 - 0.20 mm
Fuel System chapter) .
eTake out the bolts and remove the valve adjusting caps
with O-fings.

A. Thickness Gauge C. Locknut

A. Valve Adjusting Caps B. Front B. Adjusting Screw
 ENGINE TOP END 3-7
elnstall the valve adjusting caps so that the UP mark is
on top.

A. Valve Guide Reamer: 57001-162

A. UP Mark eCheck valve seating (see Valve Seat Inspection).

eDiscard the valve stem oil seal and install the new oil
seal (see Va lve Stem Oil Seal Installation).
elnstall the va lve (see Valve Installation).
elnstall the cylinder head (see Cylinder Head Installa-
Valve Stem Griding tion).
eThe end of the valve stem may be ground slightly to
remove damage or to gain valve clearance after valve
job.
eFoliow the valve refacing machine manufacturer's
instructions.
............................................................................ ,;

Camshaft Sprocket

Valve Stem Griding

Camshaft Sprocket Removal
Remove the front fender (see Front Fender Removal in
Minimum after the Frame chapter).
grinding 4.0 mm eRemove the fuel tank (see Fuel Tank Removal in the
Fuel System chapter).
eRemove the ignition timing inspection plug and the
recoil starter (see Recoil Starter Remova l in the Engine
Left Side chapter) .
eRemove the bolts and take off the camshaft cover.
Olt may be necessary to pry the cover off with a screw-
Do not grind off driver. There are prying gaps under the screw hole
more than 0.2 mm bosses.

Valve Guides:
Valve Guide Installation
eClean the valve guide hol e in the cylinder head.
e Lightly oil the valve guide.
eHeat the cylinder head around the va lve guide hole to
120 to 150C (250 to 300 F) .
Use the valve guide arbor and a hammer to drive the
guide into the head from the outside until the guide
flange seats against the head.
eAliow the cylinder head to cool.
Ream the valve guide with the valve gu id e reamer
(special too l) even if the old guide is reused. A. Camshaft Cover B. Gap
3-8 ENGINE TOP END

eTurn the crankshaft with a wrench on the alternator -Fit the sprocket under the chain and slip it over the
rotor bolt until the "LF300" mark on the camshaft shoulder on the crankshaft so that the "LF300" mark
sprocket aligns with the pointer on the cylinder head . on the sprocket aligns with the pointer on the cylinder
head.

A . Pointer B. "LF300" Mark

A. Pointer B. "LF300" Mark
-Screw the bolt in and tighten it to the specified torque
(see Exploded View), wh ile holding the crankshaft
Remove the camshaft chain tensioner (see Camshaft from turning with a wrench on the alternator rotor
Chain Tensioner Removal) .
bolt.
- Remove the camshaft sprocket bolt while holding the -Install the camshaft chain tensioner (see Camshaft
crankshaft from turning with a wrench on the alter-
Chain Tensioner Installation).
nator rotor bolt.
_Before go ing any further, check the cam timing.
-Slide the sprocket off the shoulder on the camshaft o Turn the crankshaft counterclockwise with a wrench
and out from the chain. on the alternator rotor bolt, until the "LF300" mark
-Support the chain on a screwdriver or other tool stuck on the sprocket aligns with the pointer on the head.
in the hole in the head.

Camshaft Sprocket Installation
-Remove the timing inspection plug, and check to see
that the "T" mark on the alternator rotor aligns with
the slot.
[i:AuT,o~1
o If any resistance is felt when turning the crankshaft,
stop immediately, or you may bend the valves.
OThe liT" mark on the alternator rotor should align with
the slot.
*If the camshaft timing is not correct, remove the
sprocket from the camshaft, and install it again as
detailed above.
_Smear a little engine oil on the camshaft cover Qring
and push the cover into place so that the UP mark
faces up.
-Put in the camshaft cover bolts and tighten them
securely.
-Install the timing inspection plug, and the recoi l
starter.
-Install the fuel tank (see Fuel Tank Installation in the
Fuel System chapter).

A. nmi~g In~pectiQ!1
Plug C. Slot
Camshaft, Rocker Arms and Shafts
B. Alternator Rotor Bolt D. T Mark
Rocker Arms and Shafts:
*If the liT" mark is not aligned, hold the camshaft chain Rocker Arm and Shaft Removal
taut and turn the crankshaft with a wrench on the _ Remove the camshaft sprocket (see Camshaft Sprocket
alternator rotor bolt. Removal).
 ENGINE TOP END 3-9
eTake out the screw and remove the rocker shaft
retainer.
eRemove the compression releasing lever (see Compres-
o Do not turn the engine while the camshaft chain
sion Releasing Lever Removal).
tensioner is removed. Engine damage could result.

A. Rocker Shaft Retainer A. Lockbo lt B. Mounting Bolts

eTake out th e bolts and remove the valve adj usting caps.
-Loosen all the cylinder head bolts to free the cylinder
head from the stress (see Cylinder Head Removal).
ePull out the rocker shafts and remove the rocker arms.
- Remove the lockbolt.
-Carefully pull the push rod out of the tensioner body.
Do not drop the ball and retainer assembly or the
spring.
-Slide the ball and retainer assembly and the spring off
the push rod.

Camshaft Chain Tensioner Installation

eSlip the spring over the push rod and compress it down
past the hole.
elnsert a piece of wire in the hole to hold the spring in
place.

A. Rocker Arm B. Shaft

Camshaft Chain, Guides, and Tensioner

Camshaft Chain Tensioner: A. Spring C. Push Rod

Camshaft Chain Tensioner Removal
_ Loosen the lockbolt in the top of the camshaft chain
tensioner. Do not remove it yet.
eTake out the tensioner mounting bolts and remove the
camshaft chain tensioner.
B. Wire
-Drop the ball and retainer assembly onto the push rod.
-Push the push rod into the tensioner body.
3-10 ENGINE TOP END
-When the push rod is in as far as it wi ll go, screw in the
lock bolt with its washer to lock the push rod .
Pull out the wire to release the spring.
Chain Tensioner (push rod is locked)
Piston and Ring Removal/Installation:
Piston and Ring Installation
Refer to the Base Manual noting the following.
elnsta ll the second and top rings in that order.
elnstall the top and seco nd rings so that each "N"
marked side faces up .

1 1

Top and Second Rings

-_.""" mark

Top ring
Up

1. Lockbolt 4. Spring
2. Push Rod 5. O-Ring UN" mark
3. Ball and Retainer Assembly
2nd ring
eSe sure the O~ring is in place in the tensioner body.
eAfter installing the tensioner, loosen the lock bolt and
then tighten it. With the bolt loosened, the spring
inside takes up any slack automatically.

Cylinder, Piston and Ring Maintenance:

Cylinder, Piston and Rings
Cylinder Installation Note
ORefer to the Base Manual noting the following.
-Install a new cylinder base gasket.
o lnspect the new base gasket and if the seal coating
breaks away, replace the gasket.
Cylinder Assembly Note
elnsert the rubber dampers in the fin grooves starting
with the first groove from the top.
Compression Measurement
eBefore measuring compression, do the following:
o Be su re the battery is fully charged (see Battery Con-
dition in the Electrical System chapter in this Manual).
OWarm up the engine (if the engine will run).
ODuring warm-up, check for leaks around the cylinder
head gasket.
e Remove the spark plug.
-Set the compression gauge and adapter hose (special
tools) into the spark plug hole .
Pull up the recoil starter until the compression is felt.
Then, push up the compression releasing lever each
time to start the engine.

Rubber Damper Installation

20mm

CD

1. Rubber Dampers
2. Cylinder A. Compression Releasing Lever

e Hold the throttle wide open and crank the engine with
the recoil starter, or the electric starter.
eWhen the gauge stops rising, stop cranking and read the
gauge.
A. Compression Gauge: 57001-212
B. Adapter Hose: 57001-1159
Cylinder Compression (Usable Range)
with Recoil Starter
825 - 1280 kPa
(8.4 -13.0 kglem', 119 -185 psi)
, or with Electric Starter
795 - 1240 kP
. (8.1 - 12.6 kg/em', 115 - 179 psi)
*If the compression is within the specified range, the
piston rings, cylinder and valves are probably in good
condition.
*If the compression is higher than the specified range,
see the Compression Too High table in the Base
Manual.
*If the compression is below the specifi ed range, check
the cylinder head bolt torq ue (see Cylinder Head
Installation in this manual).
*If the compression is still below the specified range,
squ irt a little o il into the spark plug hole and repeat the
compression measurement.
* If the compression does not change very much, the
piston rings are probably OK. See the Wet Compres-
sion - No Change tab le in the Base Manual.
*If the compression increases, the piston rings are not
sealing properly. See the Wet Compression - Increase
table in the Base Manual.
ENGINE TOP END 3-11
Exhaust System
Spark Arrester:
This vehicle is equipped with a spark arrester ap-
proved for off-road use by the U.S. Forest Service. It
must be properly maintained to ensure its efficiency.
In accordance with the Periodic Maintenance Chart,
clean the spark arrester.
Spark Arrester Cleaning
I WARNING I
OTo avoid burns, wear gloves while cleaning the spark
arrester. Since the engine must be run during this
procedure, the muffler will become hot.
OThe spark arrester must be installed correctly and
functioning properly to provide adequate fire pro-
tection.
e Remove the drain plug on the rear muffler.
eln an open area away from combustible materials, start
the engine with the transmission in neutral.
eRaise and lower engine speed while tapping on the
muffler with a rubber mallet until carbon particles are
purged from the muffler.
A. Drain Plug C. Mounting Bolt
B. Spark Arrester
WARNING I
0 00 not run the engine in a closed area. Exhaust gases
contain carbon monoxide; a colorless, odorless, poi-
sonous gas. Breathing exhaust gas leads to carbon
monoxide poisoning, asphyxiation, and death.
ONever run the engine with the spark arrester removed.
Hot carbon particles may start a fire.
3-12 ENGINE TOP END
NOTE Muffler Clamp Installation
ORun the engine with the spark arrester installed during
cleaning. This keeps the exhaust pressure higher and
makes carbon particles purge easier.

eStop the engine.

elnstall the drain plug.
eRemove the spark arrester mounting bolt from the
muffler.
ePull the spark arrester out of the muffler.
-Scrape carbon deposits off the spark arrester and slide
it back into the muffler.
elnstall the mounting bolt and tighten it securely.

Exhaust Pipe and Muffler:

1 . Gasket Stopper of Clamp 3 . Gasket
Exhaust Pipe and Muffler Removal Note 2. Exhaust Pipe
ORefer to the Base Manual noting the following .
Remove the rear fender (see Frame chapter in this
manual) to access the muffler clamp. eTighten the exhaust pipe holder nuts evenly and
securely.
eTighten the muffler mounting bolts securely.
eTighten the muffler clamp bolt securel y.
Exhaust Pipe and Muffler Installation
ORefer to the Base Manual noting the following.
eFit a new gasket into the muffler so that the chamfered
side of the gasket faces to the front.

Carburetor Holder

Carburetor Holder Installation

el nstall the carburetor holder so that the projection
faces upward.

Carburetor Holder Installation

A. Chamfer

eTemporarily install the muffler clamp on the muffler 1. Projection

so that the gasket sto pper faces the rear.
eSlip the muffler into place from the rear of the frame,
so that it fits ove r the exhaust pipe. eTighten the bolts to a snug fit, then tighten them
a Be sure that the collars are in place in the rubber evenly.
dampers in the muffler.
o Hold the muffler up and put in the mounting bolts, but
do not tighten them yet.
elnsert the muffler clamp over the exhaust pipe so that
the gasket stopper of the clamp contacts the end of the
exhaust pipe.
 ENGINE LEFT SIDE 4-1

Engine Left Side

Table of Contents
@]I
Exploded View . ....... . ............... . .. ...... ... . .... . . . 4-2
Specifications ....... . .. ....... . ................... . . . ... . . *
Special Tool . . .................... . . . . ................... . 4-3
Recoil Starter . . . ... . . .. ..... . . .. .. . . .. . . .. . . . .. .. . ....... . .4-3
Recoil Starter Removal .. .. .... . . .. . .. ... ... . .... ...... . . 4-3
Recoil Starter Disassembly ...... . ... . ... ..... ...... . .... . 4-3
Recoil Starter Assembly Notes . ... . .. .. . . .... . ........... . 4-4
Recoil Starter Cleaning .. . ........ . . .. . .. ... ..... .... ... . 4-6
Recoil Starter Inspection .. ... .. ...... _...... . .. . . ....... . 4-6
Left Engine Cover . ......... . ....... .. ... . . ...... . .. .. . .... . 4-6
Left Engine Cover Removal. . ... ... . .. . . .. ......... . .. . . . . 4-6
Left Engine Cover Installation Notes . . . . ...... . . ........... . 4-7
Alternator Rotor and Stator (see Electrical System chapter in this Manual)
Pickup Coil (see Electrical System chapter in the Base Manual)
Starter Clutch . . .... . .................. . ... . . . ...... . ..... . *
Starter Clutch Removal ... .. ..... ... ...... .. .. . .. .. . .. .. . *
Starter Clutch Installation ............................... . *
Starter Clutch Inspection .. ....... . .. . .. .. ...... .. . .. . .. . *
Starter Chain and Sprockets . . ... . .... . ... ....... . .. . ...... .. . 4-7
Starter Chain and Sprocket Removal. ...... . . ......... . . . . . . *
Starter Chain and Sprocket Installation . .. ... . .. .. ... . ...... . *
Starter Chain Wear ....... . ... . .. .... .. . ......... .. .. . . . *
Torque Limiter Inspection .. ............ . ... . .... . ... .. . . 4-7

* Base Manual
4-2 ENGINE LEFT SIDE

...................~~~............
E~;;~d~~-,i------"-"""""""" ................................. .
........................... ..........

T2

1.
G Torque
. L'Imlter
.
L . Apply h'Ig h temp
: Apply non-perm erature grease .
; Ap PI Y engine oil.anent Ioc k mg
' agent .
O .
T1
. 59 N-m (60 k
T2; 34 N-m (3 '5 g-m, 43 ft-Ib)
T3 .' 83 . kg-m ' 25ft Ib)
. N-m (0.85 kg-m, 74 in-Ib}
 ENGINE LEFT SIDE 43

Special Tool

Refer to the Base Manual noting the following

additional tool.

Hook Wrench: 570011101

A. Reel C. Locking Pliers

B. Handle Cap

eHold the reel in one hand wh il e removing the locking

pliers with the other.
ePull the rope in through the rope hole in the housing
and hold it in the notch in the reel.

NOTE
ODD not let the rope wedge between the reel and the
housing.
Recoil Starter

Recoil Starter Removal

eRemove the recoi l starter by taking out the mounting
bolts.

A. Hold rope in notch .

eSlowly allow recoil spring tension to unwind the reel.

eRemove the fr iction plate by taking off the flange nul.

A. Bolts

Recoil Starter Disassembly

eRemove the recoil starter (see Recoil Starter Removal).
ePull the handle out 100 - 200 mm. Clamp the rope in
place with locking pliers.
e Remove the handle cap.
ePry the knot out of the handle and untie it. Pull the
handle off the rope. A. Friction Plate B. Flange Nut
44 ENGINE LEFT SIDE

I WARNING.
o Be careful that the spring does not fly loose and does
not injure you. It is under great pressure.
oTum the reel one-quarter tum counterclockwise past
the rest position where no tension can be felt. Now.
slowly lift the friction plate straight up out of the
housing.

e Remove the friction plate and friction plate spring.

e Remove the pawl and pawl spring.

\
1. Pawl
2. Pawl Spring
3. Friction Spring
4. Friction Plate A. Strike bench.
5. Flange Nut

e Remove the reel noting the following.

I WARNING.
o Be careful that the spring does not fly loose and does RecoilStarter Assembly Notes
not injure you. It is still under great pressure. eAssembly is the reverse of disassembly. Note the
o Tum the reel one.quarter tum counterdockwise past following.
the rest position where no tension can be felt. Now, elf the recoil spring was removed, install it as shown. If
slowly lift the friction plate straight up out of .the will
it is not installed correctly, the starter not operate
housing.
properly . .

NOTE
o There should be no spring tension on the reel when
removing the reel. Lift the reel slightly. If tension is
felt, push the reel back into pla<;e and gently "wiggle"
it until the reel may be easily removed.
I WARNING.
o The recoil spring must be put under great pressure
during installation. Wear gloves to avoid injury.

eHook the outer end of the recoil spring onto the

elf necessary, remove the recoil spring as follows. housing tab.
OPlace the starter housing facing down on a bench. e Reel the recoil spring clockwise into the housing from
oStrike the bench sharply to safely remove the. spring. outside to inside.
 ENGINE LEFT SIDE 4-5

A. Hook reco il spring end onto the tab. A. Turn reel to wind rope.

-Set the reel into place so that the hook on the spring
catches on the tab in the reel.
NOTE
OPush the recoil spring against the housing securely to
prevent the spring from slipping off during installation.

-Lightly grease the spring.

A. Al ign hook and tab.

-Grease the pawl spring and pawl and install them as

shown .
eGrease the friction plate and install the friction plate
and spring being careful of the spring hook position.

A. Grease recoil spring.

elf the rope was unwound from the reel , it must be

wound clockwise for correct starter operation.
-Wind the rope four turns around the smaller diameter
of the reel and half turn around the larger diameter.

NOTE
A. Pawl D. Friction Plate Spring Hooks
o Turn the reel counterclockwise to wind the rope B. Pawl Spring E. Grease here.
clockwise. This prevents the rope from twisting. C. Friction Plate
4-6 ENGINE LEFT SIDE
eTighten the flange nut to the specified torque (see
Exploded View). Left Engine Cover
eTurn the reel four turns clockwise to preload the
spring.
o The rope should protrude about 350 mm when the reel Left Engine Cover Removal
notch aligns with the hole as shown. eRemove the recoil starter (see Recoil Starter Removal) .
eHolding the recoil starter pulley steady with the hook
wrench (special tool), loosen the alternator rotor bolt.

A. Hole C. About 350 mm

B. Notch

A. Alternator Rotor Bolt

Recoil Starter Cleaning
eDisassemble the recoil starter (see Recoil Starter
Disassembly) .
elmmerse only the metal parts in a bath of high-flash
point s~lvent.
WARNING.
OClean the starter in a well-ventilated area, and take care
that there are no sparks or flame anywhere near the
working area; this includes any appliance with a pilot
light. Do not use gasoline or a low-flash point solvent
to clean the starter. A fire or explosion could result.
B. Hook Wrench: 57001-1101
eRemove the alternator rotor bolt, the pulley and the
key. The pulley may be pulled out easily.
ePlace an oil pan beneath the engine left side .
e Remove the seat and disconnect the alternator con-
nector and pickup coil connector.
eRemove the left engine cover.
o Remove the differential shift lever case.
o Unscrew the left engine (Over mounting bolts (8).

o Do not clean any non-metallic parts in the solvent as

they may be damaged_

OUse compressed air to dry the cleaned components.

Recoil Starter Inspection

e Ciean the recoil starter (see Recoil Starter Cleaning).
eExamine the starter pawl for chips or excessive wear.
_Check the starter rope for excessive wear or fraying.
-Check the condition of the recoil spring, and friction
plate spring. A. Left Engine Cover Mounting Bolts
o lnspect the springs for breaks, rust, distortion, or B. Differential Shift Lever Case
weakened condition . C. Lever Case Mounting Bolts
 ENGINE LEFT SIDE 4-7
Left Engine Cover Installation Notes
ORefer to the Base Manual noting the following.
eGrease the left engin e cover oil seal.
-Check that the pu lley Oring is in good condition.
-Clean the pulley boss and apply oil to the Oring and
the boss .
Push the pulley into the left engine cover oi l seal.
- Fit the key in the groove between the pulley and shaft.
-Insert the alternator rotor bolt.

1. Torque Limiter

A. Grooves B. Key

-Using the hook wrench (special tool), tighten the

alternator rotor bolt to the specified torque (see Ex
ploded View).

A. Hook Wrench: 570011101

.............................................................................
Starter Chain and Sprocket

Torque Limiter Inspection

eRemove the torque limiter and visually inspect it.
*If the limiter has wear, discoloration, or other damage,
replace it as a unit.

Engine Right Side
Table of Contents
Exploded View ......... . . . . . . . . . .
Specifications .. . . . . . . . . . . . . . . . . . . . .
Special Tools ......... . . . . . ... . .. . .
Right Engine Cover . . . .... . . .. . . . . .. .
Right Engine Cover Removal . . . . . . . .
Right Engine Cover Installation .. .. . .
Clutches ...... . ... . . . . . . . . . . . . .. .
Clutch Adjustment . .... . . . . . ....
Clutch Adjustment . .. . ..... . . . . .
Clutch Removal . . . . . . ... . . . . . . . . .
Clutch Removal . . .... .. .... . .
Clutch Installation . . .. . .... .. ...
Clutch Inspection . . .. . . . . . . . . . .. . .
Primary Clutch Housing Wear . . . . . . .
Primary Clutch Shoe Lining Wear . ... .
One-Way Clutch Inspection ..... . .. .
Friction Plate Wear and Damage .. .. . .
Friction Plate and Steel Plate Warp . .. .
Secondary Clutch Housing
Finger Damage . .. . . . . . . . . . . . .
Secondary Clutch Hub Spline Damage ..
Secondary Clutch Spring Wear . . .. .. .
Clutch Release . . . . . . . . . . . . . . . . . .
Clutch Release Removal . . . ... ... . .
Clutch Release Installation .. .. . ... .
Clutch Release Wear. .. ... . . . . . . . .
Balancer . . . . . . . . . . . . . . . . . . . . . . . .
Primary Reduction . . . . . . . . .. . . . . .. . .
Primary Gear Removal .. . . . . . . . . . .
ENGINE RIGHT SIDE 5-1
52 Primary Gear Installation
53 Secondary Gear Removal
Secondary Gear Installation . . . . . .. . .
Primary and Secondary Gear Damage ..
Gear Backlash . . .. .... . .. . .. . .. .
Primary Gear/Crankshaft Wear . . . . . . .
5-3 Secondary Gear/Collar Wear ....... .
53 Lubrication System . . . . . . . . . . .. . . . .. . 53
5-3 Engine Oil and Filter . . . .... ... . . .
5-3 Engine Oil Level Inspection . . .. .. .. .
Engine Oil and Filter Change ... . ..
5-3 Oil Pump ... . .. . ... . . ... . . . . . . 5-3
Oil Flow Inspection . ... . . . . . . . . 5-3
Oil Pump Removal. . . .... . ... . . .
Oil Pump Installatio n . .. ... ... ..
Oil Pump Disassembly .... . . . ..
Oil Pump Assembly . . .... .. .. .
Oil Pump Inspection .... . . .. . ...
Oil Screen . ; . . . . . . . . . . . . . . . . . .. .
Oil Screen Removal . . . ... . ... .. . .
Oil Screen Installation . . . . . . . . . . . .
Oil Screen Cleaning and Inspection . .. .
Oil Filter Bypass Valve . .. . ......... .
Bypass Valve Removal . . . . . . . . . . . .
Bypass Valve Installation .. ... . ... .
Bypass Valve Cleaning and Inspection ..
5-3
Base Manual
5-2 ENGINE RIGH~___~~~.~ ...............................
....................... ....... ~ 1@
;;i;;;;;;; vi;:;; ..................................................
~ ~

. ~~ . ~

~/
M

.
1 :~o
~
~ M
.
~ @6' fiT I:) Ii)
~

o~~~ :;

. ~I~ /l(~
~ ~l. ~ IV
M ." . ~
v~
o . /~o
~
,
0 / "

I bdenum
M . Apply moy . disulfide grease.
. I engine OIl. ft Ib)
o : App y (130 kg-m. 94 - sed bolts
25 N-m. 'n Ib) for u
T1: 1
T2:12N-m (1 . 2 kkgm,
m 104 I -
11 .0ft .lb ) f or new bolts
15 Nm (1.5 g- '58 ft-Ib)
T3: 7B N -m (B.O ~g-~, 22 ft-Ib)
'"
T4: 29 N-m (3.0 g-m' 14.5 ft-Ib)
T5 : 20 N-m (2.0 kg ,
 ENGINE RIGHT SIDE 5-3

Specifications
Refer to the Base Manual noting the following.
o The engine oi l of SAE 10W-30 can also be used.
Clutch Removal:
Clutch Installation
o Refer to the Base Manual noting the following.
*If the c lu tch spring plate or the clutch spring bolts are
new ones, tighten the spring bolts evenly to 15 N-m
(1.5 kg-m, 11.0 fHb) of torque.

Balancer
Clutches

Refer to Engine Bottom End/Transmission in the

Clutch Adjustment: Base Manual for the information.
Clutch Adjustment o Balancer punch mark alignment is needed at balancer
Remove the clutch release adjusting screw cover. gear installation .

Lubrication System

Oil Pump:
Oil Flow Inspection
eRun the engine at idle speed.

I WARNING I
a During oil flow inspection, do not open the throUle
valve. Hot oil will squirt out of the banjo bolt, and
may cause a serious burn.
A. Clutch Release Adjusting Screw Cover
B. Screws e Loosen the main oil pipe banjo bolt on the left crank-
case as shown J and check that the oil seeps out around
the banjo bolt .
Loosen the locknut.
eTurn the clutch release adjusting screw clockwise until
it becomes hard to turn, then turn the screw back
counterclockwise until it become hard to turn.

A. Main Oil Pipe Banjo Bolt

eTighten the banjo bolt to the specified torque (see

Exploded View).
A. Locknut B. Adjusting Screw eStop the engine.
eWipe up any oil that spills oh the engine or the frame .
*If the oil does not flow out, inspect the oil filter and
eTighten the locknu t without changing the adjusting the oil pump.
screw position. *If the oil filter and the oil pump are not at fault,
elnstall the adjusting screw cover. inspect the rest of the lubrication system .
 ENGINE REMOVAL/INSTALLATION 6-1

Engine Removal/Installation
Table of Contents

Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Engine Removal/I nstallation .... . ... .. ... .. . .... .. ... . ..... . . . 6-2
Engine Removal . . ... . .. . ... . .. ..... . .. ...... . ...... .. . *
Engine Installation Note . .. .. . ... ... . _ . . . . . . . . . . . . . . . . . . . 6-2

* : Base Manual
6-2 ENGINE REMOVAL/INSTALLATION

Exploded View

T1 : 25 N-m (2.5 kgm, 18.0 ftlb)

T2: 34 Nm (3.5 kgm, 25 ftlb)

. @
, (
/

Engine Removal/Installation

Engine Installation Note

Refer to the Base Manual, noting the following.
eF irst tighten the upper three bracket bolts, then
tighten the lower bracket bolt and nut to the specified
torque (see Exploded View).

A. Three Bracket Bolts

B. Lower Bracket Bolt and Nut

Engine Bottom End/Transmission
Table of Contents
Exploded View .. . ... . ........ 72
Specifications . .... . .. . . . . . . . . .. .. . .
Special Tools . .. . . . . . . . . ... . . . . . . . .
Sealant . . . . . . . . . . . . . . . .. ... . . . . . .
Crankcase Splitting . . . . . . . . . . . . . . . . .
Crankcase Disassembly . ... . . .. . . . .
Crankcase Assembly . . . . . . . . . . . . . .
Crankshaft and Connecting Rod . . . . . . . . . .
Crankshaft Removal. . . . . . . . . . . . . .
Crankshaft Installation . . . . . . . . ... .
Crankshaft Disassembly . . . . . . . . . . .
Crankshaft Assembly . . . . . . . . . . . .
Connecting Rod Bend/Twist . ..... . .
Connecting Rod Big End
Radial Clearance . . . . . . . ... ... .
Connecting Rod Big End
Side Clearance . . . . . .
Crankshaft A lignment . . . . . . . . . . . .
Connecting Rod Big End Seizure . . .. .
Transmission . . . . . . . . . . . . . . . . . . . . . .
Transmiss ion External Shift Mechanism . . .
External Shift Mechanism Removal. .. .
External Shift Mechanism Installation . .
External Shift Mechanism Inspection ..
Sh ift Drum Stop Lever Removal. .... .
Shift Drum Stop Lever Installation ... .
Shift Drum Stop Lever Inspection . .. .
Reverse Knob and Cable . . . . . . . . . . . .
Reverse Knob Free Plav Inspection . ...
ENGINE BOTTOM END/TRANSMISSION 71
Reverse Cable Adjustment . . . . . . . . . .
74 Reverse Knob and Cable Removal. ... .
74 Reverse Knob and Cable Installation . . . 74
74 Reverse Cable Lubrication . . . . . . . . . . 75
Reverse Cable Inspection . . . . . . . . . . [II
Transmission Shafts, Shift Drum, Forks . . . 75
Transmission Removal . . . . . . . . . . . .
74 Transmission Installation . . . . . . . . . .
Transmission Shaft Disassembly . . . . . .
Transmission Shaft Assembly . . . . . . . . 75
Sh ift Fork Bending ........... . .
Shift Fork/Gear Groove Wear
Sh ift Fork Guide Pin/
Shift Drum Groove Wear . . . . . . . . .
Gear Dog/Gear Dog Hole and
Recess Damage . . . . . . . . . . . . . . .
Oil Pressure Relief Valve . . . . . . . . . . . . . . 7-6
74 Oil Pressure Relief Valve Inspection . . 76
Balancer .. . . . . . . . . . . . . . . . . . . . . . . .
74 Balancer Drive Removal . . . . . . . . . . .
Balancer Drive Installation . . . . . . . . .
Ba lancer Removal . . . . . . . . . . . . . . .
Balancer Installation ... . . . . . . . .. .
Ball and Needle Bearings . . . .. . . ... ..
Ball and Needle Bearing
Replacement . . . . . . . . . . . . . . . .
Ball and Needle Bearing Wear ..... .
74
Base Manual
7-2 ENGINE BOTTOM END/TRANSMISSION
.............................................................................
. Exploded View
.............................................................................

e" ~.L .?ID

~U
~
~'/'11">'Y/ ;'I a
1'\, 1 KLF300-B2-
,g ~~ ~// ~~--

1.60lts 6,65
2.601t6,85
3.601ts6,35

G :App I y grease
L :App ly non-permanent
locking agent
LG:Apply 1 iquid gasket
o :Apply engine oi I
R :Replacement Parts

T1:145Nm(15. Okgm. 110ftlb)

T2:120Nm(12 . Okgm, 87ftlb)
T 3 : 20 N . m (2. 0 kg m, 1 4. 5 ft 1 b)
T4:17Nm(1. 7kgm, 12. Oft lb )
T5:12N m(1 . 2kgm, 104in l b)
T6:29Nm(3. Okgm, 22ftlb)
T7:15Nm(1. 5kg'm, 11. Oftlb)
7-4 ENGINE BOTTOM END/TRANSMISSION

Specifications Crankshaft and Connecting Rod

Refer to the Base Manual noting the following. Crankshaft Alignment

Refer to the Base Manual noting the following.
Crankshaft, Connecting Rod: .Put the crankshaft on V blocks when measuring
Connecting rod big end radial clearance: runout.
0.08 - 0.020 mm (service limit: 0.07 mm)
Cold fitting tolerance between
crankpin and crank webs:
0.08 - 0.108 mm
Crankshaft Runout

Special Tools

ORefer to the Base Manual noting the additional tool. 43mm 9mm

*If runout at either location exceeds the service limit,

align the crankshaft so that the runout is within the
service limits.

Crankshaft Runout
Left Half Standard: Under 0.03 mm T1R
Service Limit: 0.08 mm T1R
Sealant Right Half Standard: Under 0.04 mm T1R
Service Limit: 0.10 mm TIR

Kawasaki Bond (Liquid Gasket - Silver): 92104'()02

eApply this liqu id gasket to the cran kcase mating

surface .

Transmission

Reverse Knob and Cable:

Reverse Knob and Cable Installation
Olnstallation is the reverse of removal. Note the fol
lowing.
elf the reverse lever was removed, mount the lever on
the sh ift drum stop lever shaft so that the slot in the
lever aligns with the mark on the front gear case.
 ENGINE BOTTOM END/TRANSMISSION 7-5

Transmission Shafts, Shift Drums, Forks:

Transmission Shaft Assembly
-Assembly is the reverse of disassembly. Note the
following.
-Replace any circlips that were removed with new ones.
-Always install circiips so that the opening is aligned
with a spline groove.

Circlip Installation

A. Mounting Nut B. Align mark with slot.

*If the reverse lever is difficult to install in the position

described above, install it rotated one tooth counter-
clockwise.

eThe transmission gears can be identified by size;

Drive shaft gears - the smallest diameter gear is 1 st
gear, and the largest is 5th.
Output shaft gears - the largest diameter gear is 1 st
gear, and the smallest is 5th.

1. Mark 2. Reverse Lever

eRoute the reverse cable according to the Wiring, Cable,

or Hose Routing section in the General Information
chapter.
-Adjust the reverse cable (see Reverse Cable Adjust
ment).

Reverse Cable Lubrication

Lubricate the reverse cable in accordance with the
Periodic Maintenance Chart, or whenever the cable is
removed (see General Information chapter and General
Lubrication in the Appendix chapter).
7-6 ENGINE BOTTOM END/TRANSMISSION

Oil Pressure Relief Valve

Oil Pressure Relief Valve Inspection

Split the crankcase (see Base Manual).
Remove the relief va lve [AI from the right crankcase.
Check to see if the steel ball [BI inside the valve slides
sm oothly when pushing it in w ith a wooden or other
soft rod, and see if it comes back to its seat by va lve
spring [CI pressure.

I~_, A

NOTE
Olnspecl Ihe valve in its assembled slale, Disas-
sembly and assembly may change Ihe valve
performance.

*If any rough spots are found during above inspection,

wash the valve clean with a high flash-p oint solvent
and blowout any foreign particles that may be in the
valve with compressed air.

WARNING'

OCle.n the oil pressure relief valve in a well-

ventilated area, and take care that there are 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 solvents.

*If cleaning does not solve the problem, rep lace the
relief valve as an assembly. The relief va lve is
precision made w ith no allowance for replacement of
individual parts.
App ly a non-permanent locking agent to the threads of
the relief valve, and tighten it.

Torque- Oil Pressure Relief Valve:

15 N-m (1.5 kg-m, 11.0 It-Ibl
 WHEELS/TIRES 81

Wheels/Tires
Table of Contents

Exploded View ........................... . ...... .. ....... . 82

Specifications ...... .. . . ........ . .. .. .... . .. .............. . 83
Special Tools ........................................... . . . 83
Wheel Alignment .... . .......... . .. . ..... .... ... ... ..... ... . 84
Steering Centering Inspection ................... . .... . ... . 84
84
~
Steering Centering Adjustment ...... . .. .. .... ....... . . . .. .
Toein Inspection ................................. . ... . 8-5
Toein Adjustment . .. . .. . . .. .. ... . . .. . .... ...... .. . .. . . 8-5
Wheels (Rims) ......... . ..... . .. . .. . ........ . . . ........ . .. . 8-6
Wheel Removal .......... . .. .. . .......... . .. .......... . 8-6
Wheel Installation . .. .. . . ... .. ..... .... ........ .. ..... . . 8-6
Wheel Inspection . .... . .......... .. .. .................. . 8-7
Wheel Replacement .. . .. ... .. . . ..... . ..... . .... .. . ..... . 8-7
Tires ........... . . .. . . . ...... .. , .. .. ..... . . . . . '" ....... . 8-8
Tire Removal. .... . .......................... .. .... . .. . 8-8
Tire Installation .......... . : ........................... . 8-8
Tire Inspection ........ . .. .......... ... .... . . . . . .. .. . . 8-10
Front Hub .... .... .. .. ........... ... .... ... . . ... .. . .. .... . 8-11
Front Hub Removal ... . . . ..... . ......... . ... .. . .. ..... . 8-11
Front Hub Installation Notes ..................... . ...... . 8-11
Front Hub Disassembly/Assembly Note ............. . .... . . . 8-11
Front Hub Bearing Removal Note ............ .. .......... . . 8-11
Front Hub Bearing Installation Notes .... . ................. . 8-12
Front Hub Bearing Inspection ............................ . 8-12
Rear Hub ......... ... . . .. . .. . ... .. ... . .. . .... . . . . . .. ... ... . 8-12
Rear Hub Installation ........ ...... ......... . .. ........ . 8-12

*: Base Manual
8-2 WHEELS!TIRES

Exploded View
........................................................ .................... ':,

G : Apply grease.
R : Replacement Parts
W : Apply water, or soap and water solution.
T1 : 34 Nm (3.5 kgm, 25 ftlb)
T2: 27 Nm (2.8 kgm, 20 ftlb)
T3 : 41 Nm (4.2 kgm, 30 ft-lb)
T4: 145 Nm (15.0 kgm, 110 ftlb)

Front Wheel

~~@
.,
....',
- "" @

Rear Wheel

@
 WHEElS/TIRES 83

Specifications

Wheel Alignment
Caster: 3 (non.,adjustable)
Camber: 1 (non.,adjustable) @ 1G
Toe-in: 27mm

Standard Tires
Front: 22 x 9.0010
Dunlop KT761. Knobby/Trail Tubeless
Rear: 24x 11.0010
Dunlop KT765. Knobby/Trail Tubeless

Tire Air Pressure (when cold)

Front: 21 kPa (021 kg/em' .3 psi)
Rear: 21 kPa (021 kg/em' 3 psi)

Maximum Tire Air Pressure (to seat beads, when cold)

Front: 140 kPa (1.4 kg/em' 20 psi)
Rear: 140 kPa (1.4 kg/em' 20 psi)

Maximum Vehicle Load: 182 kg (400 Ib)

Special Tools

Refer to the Base Manual noting the following

additional tools.

Jack: 57001-1238 Air Pressure Gauge: 52005-1082

OThis tool may be used instead of the common tool. o Be sure to use this gauge for low pressure tire instead
of the conventional air pressure gauge (52005-1003).

Q------.l!~
84 WHEELS/TIRES
eHold a straightedge against the rear wheel rim on one
Wheel Alignment side at axle height.

Toe-in is the amount that the front wheels are closer

together in front than at the rear at the axle height.
When there is toe-in, the distance A is gre;~.ter than Bas
shown. The purpose of toe-in is to prevent the front
wheels from getting out of parallel at any time, and to
prevent any slipping or scuffing action between the tires
and the ground. If toe-in is incorrect, the front wheels
will be dragged along the ground, scuffing and wearing
the tread knobs.
Caster and camber are built-in and require no adjust-
ment.

Toe~n of Front Wheels

A. Straightedge B. Jack: 57001-1238

B
Front of Vehicle

'7
'\ D '7
'"
"-
eWith the handlebar straight ahead, loosen the locknuts
...... and turn the tie-rod adjusting sleeve the same number

f- ~
_.. f-
of turns on both sides until the front wheel on that
side is parallel to the straightedge.

(~
i"='
/,
l
-~
~ A
A
NOTE
OThe yel/ow locknut on the tie-rod has left-hand
threads. Turn the wrench clockwise for loosening.
A - B = Amount of Toe-in
(Distance A and B are measured at axle height)

Steering Centering Inspection

eTest ride the vehicle.
*If the handlebar is straight when the vehicle is traveling
in a straight line, go on to the Toe-in inspection pro-
cedure.
*Otherwise, go on to the Steering Centering Adjustment
procedure.

Steering Centering Adjustment A. Front

eSupport the vehicle so that the front wheels are off the B. Yellow Locknut: left-hand threads
ground and the front axles about the same height as C. Adjusting Sleeve
the rear axle. D. Inside Locknut
 WHEELS!TIRES 8-5

Steering Centering eKeeping the front wheels off the ground, set the
handlebar straight ahead .
At the level of the axle height, measure the distance
between the scribed lines for both front and rear of the
4 front tires.

1. Front Wheels 4. Straightedge eSubtract the measurement of the front from the
2. Vehicle Center Line 5. Rear Wheels measurement of the rear to get the toe-in.
3. Parallel to each other. *If the toe-in is not in the specified range, go on to the
Toe-in Adjustment procedure.

Toe-in of Front Wheels

eRepeat the straightedge procedure on the other side of Standard: 27 mm
the vehicle. Now the front wheels are parallel to each
other and to the center line of the vehicle.
-Go on to the Toe-in Inspection procedure.
Toe-in Adjustment
e Loosen the locknuts and turn the adjusting sleeves the
same number of turns on both sides to achieve the
specified toe-in.
Toe-in Inspection
eSupport the vehicle on a stand or the jack (special tool:
57001-1238) so that the front wheels are off the
ground.
eApply a heavy coat of chalk near the center of the
front tires.
-Using a needle nose scriber, make a thin mark near the
center of the chalk coating while turning the wheel.

A. Front C. Adjusting Sleeve

B. Locknuts

NOTE
o The yellow locknut on the tie-rod has left-hand
threads. Turn the locknut clockwise for loosening.
o The toe-in will be near the specified value, if the tie-rod
length is 367 mm between the tie-rod ends.
8-6 WHEELS/TIRES
Tie-Rod Length Adjustment Wheel Installation
.Position the whee l so that the air valve is toward the
outside of the vehicle.
_Check the tire rotation mark on the front and rear
tires, and install the wheels accord in gly.

NOTE
OThe direction of the tire rotation is shown by an arrow
on the tire sidewall.

1. Front 2. Tie-Rod Length

-Check the toe-in (see Toe-in Inspection).

-Tighten the toe-in locknuts to the specified torque (see
Exploded View) .
-Test ride the vehicle.

A. Rotation Mark (Arrow)

B. Rotation Direction
.............................................................................
Wheels (Rim)
.................................................. ...........................
Wheel Remo.val
eLoosen the wheel nuts. -Mount the wheelan the studs.
-Support the vehicle on the jack (special tool) or a stand eTighten the wheel nuts in a criss-cross pattern to the
so that the wheels are off the ground. specified torque (see Exploded View).

A. Stand or Jack: 57001-1238

-Take off the wheel nuts and remove the wheel. A. Valve Stem
 WAEELSITIRES 8-7
Wheel Inspection Air Valve
Examine both sides of the rim for dents. If the rim is
dented, replace it.

Rim Dent

3) -- - - 1

.....

1. Plastic Cap 4. Valve Stem

2. Valve Core 5. Valve Seat
-if the tire is removed, inspect the air sealing surfaces of 3. Stem Seal 6. Valve Opened
the rim for scratches or nicks. Smooth the sealing
surfaces with fine emery cloth if necessary.
elnstall a new air valve in the rim.
Rim Inspection a Remove the valve cap, lubricate the stem with a soap
and water solution, and pull the .stem through the rim
from the inside out until it snaps into place.

1. Sealing Surfaces

1. Pull the stem.

Wheel Replacement
e Remove the wheel (see Wheel Removal).
eDisassemble the tire from the rim (see Tire Removal).
ORemove the air va lve and discard it. 0 00 not use engine oil or petroleum distillates to
lubricate the stem because they will deteriorate the
rubber.

OReplace the air valve whenever the tire is replaced. eMount the tire on the rim (see Tire Installation).
o Do not reuse the air valve. elnstall the wheel (see Wheel Installation).
8-8 WHEELS!TIRES
eKneel on the side of the tire, forcing the tire bead into
Tires the center well of the rim.

Tire Removal Rim Removal

e Remove the wheel (see Wheel Removal).
-Unscrew the valve core to deflate the tire.
o Use a proper valve core tool. Valve Stem

OOO OD
Well

-Lubricate two tire irons (special tool) with a soap and

water solution, or water, then pry the bead.

A. Valve Core Tool

[CAUTlO~]
o Do not scratch the air sealing surfaces of the tire or
eLubricate the tire beads and rim flanges on both sides rim. Scratches or nicks on the sealing surfaces will
of the wheel with a soap and water solution, or water. allow the tire to deflate.
This helps the tire beads slip off the rim flanges.
eWork around the rim with the tire irons a little at a

!CAUTION! time, whi le continuing to hold the bead opposite the

irons in the center well of the rim.
a Do not lubricate the tire beads and rim flanges with
engine oil or petroleum distillates because they will
deteriorate the tire.

eBreak the tire beads away from both sides of the rim
with a bead breaker.

Breaking Tire Bead

1. Tire Irons: 570011073

e Lift the second bead up into the center well and use
the same procedure as in removing the first bead.

Tire Installation
elnspect the rim (see Wheel Inspection).
1. Bead Breaker eReplace the air valve with a new one (see Wheel Re
2. Apply lubricant. placement).
 WHEELS/TIRES 8-9
-By hand, slide as much of the first bead as possible
[CAUTION! over the rim flange .
o Replace the air valve whenever the tire is replaced . As the bead goes onto the rim, force the bead into the
0 00 not reuse the air valve. renter well of the rim to ease installation.

-Check the tire for wear and damage (see Tire Inspec-
Bead Installation
tion) .
Lubricate the tire beads, rim flanges, and the tire irons
(special tools) with a soap and water solution, or water.

I WARNING.
o Do not use the lubricant other than a water and soap
solution, or water to lubricate the tire beads and rim
because it may cause tire separation.

1. Tire Beads 2. Center Well

-Use the tire irons {special tools} to install the rest of

the bead.

1. Apply lubricant.
Bead Installation

-Check the tire rotation mark on the front and rear

tires, and install them on the rim accordingly.
oThe tires should be installed on the rim so that each
air valve is toward the outside of the vehicle.

NOTE
o The direction of the tire rotation is shown by an arrow
on the tire sidewall.

1. Tire Irons: 57001-1073

-Use the same procedure to install the second bead.

eLubricate the tire beads again and center the tire on
the rim.
-Support the wheel rim on a suitable stand to prevent
A. Rotation Mark {Arrow} B. Rotation Direction the tire from slipping off.
8-10 WHEELS/TIRES
Tire Air Pressure
Front and Rear:
21 kPa (021 kg/em 2 3.0 psi)

-Check the tire pressure using the air pressure gauge for
low air pressure (special tool).

I---@
1. Rim 2. Suitable Stand

elnflate the tire until the tire beads seat on t he rim.

Maximum Tire Air Pressure A. Air Pressure Gauge: 52005-1082

(to seat beads when cold)
Front and Rear: 140 kPa (1.4 kg/em 2 20 psi) elnstall the wheel (see Wheel Installation).
-Wipe off the soap and water so lution, or water on the
tire, and dry the tire before operation .
WARfIIlfIIG
0 00 not inflate the tire to more than the maximum tire I WARNING.
air pressure. Overinflation can explode the tire with
0 00 not operate the vehicle with the water and soap. or
possibility of injury and loss of life.
water still around the tire beads. They will cause tire
separation, and a hazardous condition may result.
eCheck to see that the rim lines on both sides of the tire
are parallel with the rim flanges.

Tire Inspection
eExamine the tire for damage and wear.
Olf the tire is cut or cracked, replace it.
o Lumps or high spots on the tread or sidewalls indicate
internal damage requiring tire replacement.
o Remove the any fore ign objects from the tread . After
removal, check for leaks with a soap and water solu-
tion.
oCheck the shape of the tread knobs. If no vertical side
is left on the drive side of the knobs, replace the tire.

Tire Inspection

Vertical Sides
Worn Away
1. Rim Line 2. Rim Flange /_-~t
elf the rim lines and the rim flanges are not parallel,
deflate the tire, lubricate the sealing surfaces again, and /
/' ~ "" \
reinflate the tire.
eAfter the beads are properly seated, check fo r air leaks. / 1:-----.. \
Olnflate the tire to 35 kPa (0.35 kg/em 2 , 5 psi). Apply
I ;; I ~ .
~_.. J. . I. . _+_
a soap and water solution around the tire bead and
check for bubbles.
eDefiate the tire to the specified pressure.
\
 WHEELS!TIRES 8-11
eGrease the lips of the hub end seal.
Front Hub

Front Hub Removal

Hub End Seal Lubrication
Remove the cotter pin and loosen the hub nut.

Grease

eTighten the hub nut to the specified torque (see

A. Hub Nut B. Cotter Pin Exploded View).
elnsert a new cotter pin (see Front Hub Removal).

ePull off the wheel (see Wheel Removal).

eRemove the cal iper by taking off the mounting bolts,
and let the caliper hang free.
eRemove the hub nut and pull off the front hub.
Front Hub Disassembly/Assembly Note
eDo not press the hub bolts out.
*If the hub bolt is damaged, replace the hub and bolts as
a unit (see Front Hub Installation).
Front Hub Installation Notes
e Be sure to install the Dring on the knuckle shaft after
greasing the O-ring.

Front Hub Installation

Front Hub Bearing Removal Note
eRemove the front hub.
eRemove the grease seals, bearings and spacer pipe as
follows.
OPull out the collars on both sides.
o Remove the grease seals using a suitable hook.

1. Front Hub 4. Knuckle Shaft

2 . Hub End Seal 5. Hub Bolts
3. D-Ring A. Collar B. Grease Seal
8-12 WHEELS!TIRES
o Pry the spacer pipe toward one side. Front Hub Bearing Inspection
o Drive the bearing out by tapping on the exposed
portion of the spacer pipe end with a hammer and NOTE
metal rod.
OSince the bearings are packed with grease and sea/ed,
they can not be lubricated.

e Remove the hub assembly (see Front Hub Removal).

eTurn each bearing back and forth while checking for
roughness or binding.
*If roughness or binding is found, replace the bearing.
eExamine the bearing seal for tears or leakage.
*If the seal is torn or is leaking, replace the bearing.

Rear Hub

Rear Hub Installation

eGrease the axle splines.
eTighten the rear axle nut to the specified torque (see Ex-
ploded View).
elnsert a new cotter pin.

1. Metal Rod

Olnsert the spacer pipe into the hub assembly.

ODrive out the remaining bearing by tapping on the
spacer pipe with a suitable driver.
eDeburr the spacer pipe as needed.

Front Hub Bearing Installation Notes

elnstallation is the reverse of removal. Note the fol-
lowing.
eDrive either bearing into the hub assembly with the
bearing driver set (special tool) until it bottoms out.
The marked side of the bearing faces outboard .

A. Ax le Splines B. Cotter Pin

A. Bearing Driver Set: 570011129

eGrease the lips of the grease seals.


Final Drive
Table of Contents
Exploded View ........ . . .. .... ...
Specifications . . . . . . . . . ... .. . . .. . . . .
Special Tools . ...... .. . . . ..... 94
Sealant . . . . . . . . . . . . . . .. . . . . . . . .. .
Final Gear Case Oil . . . . . . . . . . . ... ... .
Final Gear Case Oil Level Inspection . . .
Final Gear Case Oil Change . .. .. ... .
Front Bevel Gears and Cam Damper . .. . .. .
Front Gear Case Removal . . . . . . . . . .
Front Gear Case Installation
Fro nt Drive Gear Removal!
Installation . . . . . . . . . . . . . . . . . .
Front Driven Gea r and Cam
Damper Removal. . .. . ... .. . . . .
Front Drive Gear and Cam
Damper Installation . ... . . . . . . . .
Front Bevel Gear Adjustment . . . . . . .
Beve l Gear Inspection . .. . . . . . . . . . .
Ball Bearing Inspection . ... . . . . . . . .
T ape red Roller Bearing Inspection . .. .
Oil Seal Inspection . . . . . . . . . . . . . . .
Cam Damper Inspection . . .. . . . . . . .
Propeller Shaft . ... .... . . . . . . .... . .
Propeller Shaft Removal ... .. .... .
Propeller Shaft Installation ... . .... .
Propeller Shaft Lubrication . . . . . . . . .
Propeller Shaft Joint and
Pinion Joint Inspection . . . . . . . . .
Propeller Shaft Inspection .. .. . . ...
Rear Axle Shafts .. .. .. . . . . . . . . . . _ .. .
Rea r A xle and
Propelle r Shaft Removal ..... _ . .
FINAL DRIVE 9-1
92 Rear Axle and
Propeller Shaft Installation . .. . . . .
Axle Shaft Removal . .......... . .
94 Axle Shaft Installation ... . . ...... . 94
Axle Shaft Inspection . . . . . . . . .. . . .
Ball Bearing Inspection . . . . . . . .. .. .
Oil Seal Inspection . . . . . . . . . . . . . . .
Final Bevel Gears and Differential Gears ... .
Pinion Gear Disassembly . . . . . . . . . .
Pinion Gear Assembly . . . . . . . . . . . .
Ri n9 Gear and
Differential Gear Disassembly . ....
Ring Gear and
Differential Gear Assem~ly ... . .. .
Final Bevel Gear Adjustment . .. . . . . .
Bevel Gear Inspection . . . . . . . . . . . . .
Differential Gear Inspection . ..... . .
Tapered Roller Bearing Inspection . .. .
Ball Bearing Inspecti on . . . . . . . . . . . .
Oil Seal Inspection . ... . . . . . ..... .
Differential Shift Mechanism .. .. . ... .. . . 94
Shift Lever Case and Cable Removal .. .
Shift Lever Case and
Cable Installation . . . . . . .. . . .. .
Shifter and Shift Fork Removal .. ... .
Shifter and Shift Fork Installation . .. .
Differential Cable Adjustment ... ... .
Differential Cable Lubrication . ... .. . 94
Differential Cable Inspection . . .... . .
94 Shifter and Shift Fork Inspection .. .. .
Base Manual
9-2 FINA L DR IVE

Exploded View

G : Apply grease.
L : Apply non-permanent locking agent.
o : Apply hypoid gear oil to the threads and seated surface. I
R : Replacement Parts

~
SS : Apply silicone sealant.
St : Stake the fastener .

T1 : 25 N-m (2.5 kg-m , 18.0 ftlb)

T2 : 93 N-m (9.5 kg-m, 69 ftlb)
T3: 98 N-m (10.0 kgm, 72 ftlb)
T4 : 12 N-m (1.2 kgm, 104 in-Ib) =v,./
~ ~
T5: 20 N-m (2.0 kgm, 14.5ft-lb)
T6: 78 N-m (8.0 kg-m, 58 ft-Ib)
T7: 29 N-m (3.0 kgm, 22 ft-Ib) UK model,
T8: 6.9 N-m (0.70 kg-m, 61 in-Ib) Optional Parts for other than UK model -~ ~
~ ~~
.~ @

~--
1

1. Front Gear Case

2. Drive Gear
3. Driven Gear
4. Propelier Shaft
5. Axle Shaft Pipe (Right)
6. Axle Shaft (Right)
7. Axle Shaft Pipe (Left)
8. Axle Shaft (Left)
9. Final Gear Case
 FINAL DRIVE 93

G
9-4 FINAL DRIVE

Special Tools

o Refer to the Base Manual noting the following

additional tool.

1. App ly silicone sealant.

Sealant 2. Axle Shaft Pipes
.............................................................................. 3. Final Gear Case
4. Final Gear Case Cover
Kawasaki Bond (Silicone Sealant): 56019-120

Differential Shift Mechanism

Differential Cable Lubrication

o Lubricate the differential cable in accordance with the
Periodic Maintenance Chart, or whenever the cable is
removed (see General Information chapter and General
Lubrication in the Appendix chapter).
OUse the pressure cable luber to lubricate the cable.

Rear Axle Shafts

Axle Shaft Installation

o Refer to the Base Manual noting the following.
eApply silicone sealant (PN 56019-120) to the mating
surface between the axle shaft pipes, the final gear case,
and cover as shown.

Brakes
Table of Contents
Exploded View. . . . . . . . . . . . . . . . . . . .. 102
Specifications. . . . . . . . . . . . . . . . . . . . .. 10-4
Special Tools. . . . . . . . . . . . . . . . . . .. 10-4
Brake Adjustment. . . . . . . . . . . . . . . .. 105
Front Brake Lever
Free Play Inspection 10-5
Rear Brake Pedal
Free Play Inspection
Rear Brake Pedal
Free Play Adjustment . . . . . . . . . . .
Cam Lever Angle Adjustment . . . . . . .
Parking Brake Cable Lubrication . . . . . 105
Parking Brake Cable Inspection . . . . . .
Brake Fluid . . .. .. ..... .. . ... ... . . .
105
Brake Fluid Recommendation .. . . . . .
Brake Fluid Level Inspection . . . . . . . .
Brake Fluid Changing .. .. . . . . . . . . .
Brake Line Air Bleeding _ . _ . . . . . . . .
Calipers . .. ... .. ... . .. ... ... . . . . . . 105
Caliper Removal . .... .. . . . . . . . . . 105
Caliper Installation Notes . . . . . . . . . . 105
Caliper Disassembly Notes . . . . . . . . . . 105
Caliper Assembly Notes . . . . . . . . . . . 106
Caliper Fluid Seal Damage . . . . . . . . . . 106
Caliper Dust Seal and Cover Da'm age . . . 106
Caliper Piston and Cylinder Damage . . . 106
Caliper Holder Shaft Wear . . . . . . . . . . 106
Brake Pads .. ..... . .. ... ...... . .. . . 107
Brake Pad Removal .. . ..... . _ . . . . 107
Brake Pad Instal lation Notes . . . . . . . . 107
Brake Pad Wear Inspection . . . . . . . . . 107
Master Cylinder and Wheel Cylinders . . . . . . . 107
Master Cylinder Removal . . . . . . . . . .
Master Cylinder Installation . . . . . .. .
Master Cylinder Disassembly . . . . . .. .
Master Cylinder Assembly . . . . . . . . . .
BRAKES 10-1
Master Cylinder Inspection . . . . . . . . .
Brake Lever Lubrication . . . ... . . . . . 107
Discs . . . . . . . . . . . . . . ... . ... . ... .. . 108
Disc Installation Notes . . . . . . . . . . . . 10-8
Disc Wear . . . . . . . . . . . . . . . . . . . . . 108
Disc Cleaning . .. . . . . . . . . . . . . . . . 108
Disc Warp In spection . . . . . . . . . . . . . 109
Brake Hoses . ... . . . . . . . . . . .. ' .' . . . . . 109
Brake Hose Removal . . . . . . . . . . . . . 109
Brake Hose Installation Notes . . . . . . . 109
Brake Hose Inspection . . . . . . . . . . . . 109
Bake Drums . . . . . . . . . . . . . . . . . . . . . . . 109
Rear Brake Drum Removal . . . . . . . . .
Rear Brake Drum Installation . . . . .. . 109
[!QI
Brake Drum Wear . . . . . . . . . . . . .. .
Rear Brake Drum Seal Wear . . . . . . . . . 1010
Rear Brake Drum Disassembly!
Assembly Note . . . . . . . .. . . ... . 1010
Brake Panel Assemblies . . . . . .. " . . . . . . . . 1010
Rear Brake Panel Removal !
Disassembly . .. . . . . . . . . .. .. . .
Rear Brake Panel Assembly/
Installation . . . . . . . . . . . . . . . . . .
Brake Shoe Lining Wear . ... .. .. . . .
Brake Shoe Spring Inspection . . . . . . .
Brake Camshaft and
Camshaft Hole Wear .. .....
Brake Panel Lubrication . .. . . . . . . . .
Brake Pedal and Cables . . . . . . . . . . .....
Brake Pedal and Cable Removal ..... .
Brake Pedal and Cable Installation . . . .
Brake Cable Inspection . .. . . . . . . . . .
Brake Pedal and Cable Lubrication . .. .
Base Manual
10-2 BRAKES

Exploded View

A : Apply adhesive.
G : Apply grease.
l : Apply non-permanent locking
agent.
o : Apply oil.
Si : Apply silicone grease .

T1: 25 N-m (2.5 kg-m. 18 ftlb)

T2 : 20 Nm (2.0 kgm, 14.5 ftlb)
T3: 8.8 N-m (0.90 kg-m, 78 in-I b)
T4: 5.9 Nm (0.60 kgm, 52 inlb)
T5: 7.8 Nm (0.80 kg-m, 69 inlb)
T6: 145 N-m (15.0 kgm , 110 ft-Ib)
T7: 29 N-m (3.0 kgm, 22 ft-Ib)
T8 : 1.0 Nm (0.10 kg-m, 9 in-Ib)
T9: 37 Nm (3.8 kgm, (27 ftlb)
 BRAKES 10-3

, G

~.

@G
10-4 BRAKES

Specifications

Refer to the Base Mariual noting the following.

Item Standard Service Limit

Brake Fluid Grade DOT3 or 4 - --
Front Disc Brake:
Brake lever free play Non-adjustable - --
Pad lining thickness 4.5 mm 1 mm
Disc thickness 3.3 -3.7 mm 3.0 mm
Disc runout 0.2 mm or under 0.3 mm
Rear Drum Brake:
Cam lever angle 80 - 90 - --
Drum inside diameter 160.000 - 160.160 mm 160.65 mm

Special Tools

Refer to the Base Manual noting the following.

Jack: 57001-1238

OThis tool may be used instead of the common tool.


Brake Adjustment
Front Brake Lever Free Play Inspection
Disc or disc pad wear is automatically compensated
for and has no effect on brake lever action . So there are
no parts that require adjustment on the front brake.
However if the brake lever has a soft, or "spongy
feeling," check the brake fluid level in the master
cylinder and bleed the air from the brake line (see
Bleeding the Brake in the Base Manual).
NOTE
OCheck the brake fluid level in accordance with the
Periodic Maintenance Chart.
Parking Brake Cable Lubrication
Lubricate the parking brake cable in accordance with
the Periodic Maintenance Chart, or whenever the cab le
is removed (see Genera l Information chapter and
General Lubrication in the Appendix chapter),
OUse the pressure cable luber (special tool: PN 56019-
021) to lubricate the cable .
Parking Brake Cable Inspection
eWith the brake cab le disconnected at both ends, the
cable should move freely in the cable housing (see
General Lubrication in the Appendix chapter).
Calipers
Caliper Removal
eRemove the front wheels (see Wheel Removal in the
Wheels/Tires chapter).
eSeparate the brake hose from the caliper by taking off
the banjo bolt.
-Remove the caliper mounting bolts and take off the
calipers.
A. Mounting Bolts C. Front
B. Caliper
BRAKES 10-5
elf the caliper is to be disassembled after removal and if
compressed air is not available, remove the piston using
the following procedure. If both calipers are to be
disassembled, be sure to do this procedure to both at
the same time.
o Remove the pads.
o Temporarily reconnect .the brake hose to the caliper.
The banjo bolt need not be torqued.
o Pump the brake lever to remove the caliper piston.
o lmmediately wipe up any brake fluid that spills.
o Disconnect the brake hose from the caliper.
Caliper Installation Notes
-Connect the brake hose to the caliper putting a new
flat washer on each side of the brake hose fitting .
eCh~ck the fluid level in the reservoir and bleed the
brake line (see Bleeding the Brake Line in the Base
Manual).
eCheck the brakes for good braking power, no brake
drag, and no fluid leakage.
Caliper Disassembly Notes
-Using compressed air, remove the piston.
o eaver the caliper opening with a clean, heavy cloth.
ORemove the .piston by lightly applying compressed air
to where the brake line fits into the caliper.
WARNING I
OTo avoid serious injury, never place your fingers or
palm inside the caliper opening. If you apply com-
pressed air into the caliper, the piston may crush
your hand or fingers.
1. Apply compressed air. 2. Cloth
10-6 BRAKES

Caliper Assembly Notes Anti-Rattle Spring Installation

I WARNING I
OExcept for the disc pads and discs; use only disc brake
fluid, isopropyl alcohol. or ethyl alcohol. for cleaning
brake parts. Do not use any other fluid for cleaning
these parts. Gasoline, motor oil, or any other
petroleum distillate will cause deterioration of the
rubber parts. Oil spilled on any part will be difficult to
wash off completely, and will eventually deteriorate
the rubber used in the disc brake.

-Apply brake fluid to the outside of the piston and

piston rod , and the fluid seal, then push the piston into
the cylinder by hand. Take care t hat neither the
cylinder nor the piston sk irt gets scratched.
elnstall the dust sea l around the front caliper piston.
Check that the dust seal is properly fitted into the
grooves in the piston and cal iper.
1. Anti-Rattle Spring
Caliper Fluid Seal Damage
The fluid seal around the piston maintains the proper
pad/disc clearance. If the seal is not satisfactory, pad
wear will increase, and constant pad drag on the disc will
raise brake and brake fluid temperature.
_ Replace the fluid seals under any of the following
conditions: (a) fluid leakage around the pad; (b) brakes
overheat; (c) there is a large difference in inner and
outer pad wear; (d) the seal is stuck to the piston. If
the fluid seal is replaced, replace the dust seal as we ll.
Also, replace all sea ls every other time the pads are
changed.

Caliper Dust Seal and Cover Damage

-Check that the dust seals and covers are not cracked
worn, swo llen , or otherwise damaged.
_If they show any damage, replace them.

Caliper Piston and Cylinder Damage

-Visually in spect the piston and cylinder surfaces.
*Replace the caliper if the cylinder and piston are badly
scored or rusty.
1. Caliper
2. Brake Pad
3. Brake Pad
4. Caliper Holder Shafts Caliper Holder Shaft Wear
5. Dust Cover The caliper body must sl ide smoothl y on the caliper
6. Piston holder shafts. If the body does not sl ide smooth ly, one
7. Anti-Rattle Spring pad will wear more than the other, pad wear will in-
8. Dust Seal crease, and constant drag on the disc will raise brake and
9. Fluid Seal brake fluid temperature.
10. Friction Boot -Check to see that the caliper holder shafts are not
badly worn or stepped, and that the rubber friction
boots are not damaged.
eApply a th in coat of silicone grease to the caliper *If the rubber friction boot is damaged, replace the
holder shafts and holder holes. (Silicone grease is a rubber friction boot.
special high temperature, water-resistant grease). *If the caliper shaft is damaged, replace the caliper
-Install the anti-rattle spring in the calipers as shown. assembly.
 BRAKES 10-7

Brake Pads WARNING I

o Do not attempt to drive the vehicle until a full brake

I WARNING I lever is obtained by pumping the brake lever until the

OWhen handling the disc pads, be careful that no disc
brake fluid or any oil gets on them. Clean off any fluid
or oil that inadvertently gets on the pads with a high-
flash point solvent. Do not use one which will leave an
oil residue. Replace the pads with new ones if they
cannot be cleaned satisfactorily .
Brake Pad Removal
-Remove the front wheel (see Wheel Removal in
Wheels/Tires chapter).
- Lift off the cal iper by taking off the mounting bolts .
Push the cal iper holder toward the piston side and then
remove the pads.
pads are against each disc. The brake will not function
on the first application if this is not done .
Brake Pad Wear Inspection
In accordance with the Periodic Maintenance Chart,
inspect the brake pads for wear .
Remove the front whee ls in order to check the front
brake pads.
-Check the lining th ickness of the pads in each caliper.
The pad thickness can be checked with the pad in-
stalled.
*If the lining thickness of either pad is less than the
service limit, replace both pads in the caliper as a set.
Pad Lining Thickness
Standard: 4.5mm
Service limit: 1 mm

Front Brake Pad

1. Pad 2. Caliper Holder

1. Service Limit 2. Lining Thickness

Brake Pad Installation Notes

-Before installation, clean the pads with a high-flash
point solvent.
Master Cylinder and Wheel Cylinders
I WARNING I
OWhen handling the disc pads or disc, be careful that no o Since the whee l cylinder is not on the model, the
disc brake fluid or any oil gets on them. Clean off any information of the wheel cylinder is omitted.
fluid or oil that inadvertently gets on the pads or disc
with a high-flash point solvent. Do not use one which
will leave an oily residue. Replace the pads with new
ones if they cannot be cleaned satisfactorily. Brake Lever Lubrication
Whenever the master cylinder is disassembled, or in
.Push the cal iper piston in by hand as far as it will go, accordance with the Periodic Maintenance Chart, per
and then install the pads. form the following.
10-8 BRAKES

e Lubricate t he brake lever by appl ying a light coati ng of -After installi ng the discs. check the disc runout.
silicone grease to th e brake lever pivot screw and th e Co mpl etely clea n off any grease th at has gotte n on
contact with the piston. either side of th e d isc with a hi gh-flash point so lve nt.
Do no t use one which will leave a n oil y resid ue.

Disc Wear
eMeasure the th ickness of each di sc a t the point where it
has worn the most .
*Replace th e disc if it has worn pas t t he service lim it.

A. Apply grease.

Discs

I WARNING I
OWhen handling the discs, be careful that no disc brake
fluid or any oil gets on them. Clean off any fluid or o il
that inadvertently gets on the discs with a high-flash
point solvent. Do not use one which will leave an oily 1. Brake Disc
residue. 2. Measuring Area

Disc Installation Notes Front Disc Thickness

eTighten the disc mountin g Allen bol ts to the specified Standard: 3.3-3.7 mm
torque. The disc must be installed with th e chamfered Service Limit: 3.0mm
hole side facing toward the front hub . The marked
side must face o utward .

Disc Cleaning
Poor brak ing can be ca used by o il on a di sc. O il o n a
di sc must be cleaned off wit h a'1 oilless cleanin g fluid
such as trich loroethylene o r aceto ne .

WARNING I
OThese cleaning fluids are usually highly flammable and
harmful if breathed for prolonged periods. Be sure to
A. Marked Side heed the fluid manufacturer's warnings.
 BRAKES 10-9

Disc Warp Inspection Brake Hose Inspection

e Jack up the vehicle so that the wheels are off the
ground.
eFor front disc inspection, remove the front wheels, and
turn the handlebar fully to one side.
eSet up a dial gauge against the disc as shown, and
measure disc runout.
*If runout exceeds the service limit, replace the disc.
The high pressure inside the brake line can cause fluid
to leak or the hose to burst if the line is not properly
maintained.
eBend and twist the rubber hose while examining it.
*Replace it if any cracks or bulges are noted.

A. Front Brake Hose

A. Brake Disc B. Turn the disc by hand.

Disc Runout
Standard: 0.2 mm or under
Brake Drums
Service Limit: O.3mm

Since the front brake drums are not on the model,

the information of the front brake drum is omitted.

Rear Brake Drum Installation

Refer to the Base Manual noting the following.
-Do not overgrease the inside seal lip of the brake drum
Brake Hoses seal.

Brake Hose Removal

Refer to the Base Manual noting that there is no
metal pipe nipple and retainer on the model.

Brake Hose Installation Notes

Using a new copper washer for each side of the hose
fitting, tighten the banjo bolt to the specified torque
(see Exploded View in this manual).
eRun the brake hose according to the Wiring, Cable, and
Hose Routing section in the General Information
chapter.
eBleed the air from the brake line (see Brake Line Air
Bleeding in the Base Manual). A. Brake Drum Seal
1010 BRAKES

Brake Drum Seal Lubrication

Grease

'-----<:- -----1 Do not grease here.

1. Rear Brake Oru m

2. Drum Bolt

Rear Brake Drum Seal Wear

Refer to the Base Manual noting the following.
eTighten the brake drum drain bolt to the specified
torque (see Exploded View). Brake Panel Assemblies

. Since the front brake panels are not on the model,

the information is omitted.

A. Drain Bolt

Rear Brake Drum Disassembly/Assembly Note

eOo not press the drum bolt out.
*If the drum bolt is damaged, replace the drum and
bolts as a unit .
 SUSPENSION 11 1

Suspension
Table of Contents

Exploded View ... ...... .. .. .. . .. . .. . . .... .. . ........ . .... . 11-2

Specifications .. ....... . ... .. . . . ....... . . . .... . ...... ... .. . 11-3
Special Tools . .. . . ... ... . .. .. . .... .... .... .. . .. ....... .... . 11-3
Suspension . .. . . ... ... ....... .. . . . ... ...... . ........ ..... . 11-4
Shock Absorber Spring Force Adjustment .... . .... .. ..... .. . 11-4
Shock Absorber Removal .. . . . . . ..... ......... ..... . ... . . *
Shock Absorber Installation .... . .... .. .. ... .... . ... . ... . . *
Shock Absorber Assembly Note . . ... . ..... ... . . .. .. ..... . . 11-4
Front Suspension Arm Removal ... . .. ....... .......... .. . . 11-4
Rear Suspension Arm (Rod) Removal. ..... . . ......... . .... . 11-4
. Rear Suspension Arm (Rod) Installation ...... .. .. .. ...... . . . 11-5
Front Suspension Arm Disassembly ... .. ... . .... .. .. .. .. . . . 11-5 [!II
Front or Rear Suspension Arm Assembly Notes ....... . ...... . 11-5
Shock Absorber and Suspension Arm Inspection *

* Base Manual
112 SUSPENSION

Exploded View

~(@-------(W

l: Apply non-permanent locking

agent.
R : Replacement Parts
W : Apply water, or soap and water
solution .
,
T1: 34 Nm (3.5 kgm. 25 ftlb)
T2: 88 Nm (9.0 kgm. 65 ftlbl

t
@------""@
I
 SUSPENSION 11-3

Specifications

Refer to the Base Manual noting the fo llowin g.

Front Shock Absorber Spring Preload

Standard setting position: No.2

R""r Shock Absorber Spring Preload

Standard setting position: No.2

Jack: 57001-1238
Special Tools

ORefer to the Base Manual no tin g th e following addi-

ti onal tool s.

Wrench (Owner's tool): 92110-1040, or

Steering Stem Nut Wrench (special tool): 57001-1100

Inside Circlip Pliers : 57001-143 Bearing Driver Set: 570011129

11-4 SUSPENSION
Shock Absorber Assembly Note
Suspension Lubricate the rubber dampers with a soap and water
solution when installing the rubber dampers.

Shock Absorber Spring Force Adjustment

Refer to the Base Manual noting the following.
o The spring adjusting sleeve on the front and rear shock [CAUTIO~]
absorbers have 5 positions so that the spring can be
adjusted for different terrain and loading conditions. o Do not lubricate the rubber dampers with engine oil or
elf the spring action feels too soft or too stiff, ad just it petroleum distillates because they will deteriorate the
in accordance with the following table. rubbers.
o Turn the adjusting sleeve on each shock absorber to the
desired position with a wrench (Owner's tool or special
ePress the rubber dampers in using a suitable bearing
tool: 92110-1040 or 57001-1100)
driver in the bearing driver set (special tool: PN
57001-1129).

Spring Action
Spring
Position Setting Load Terrain Speed
Force
1 Soft Light Good Low
2 (sTD)
3
4
j 1 1 J 1
Front Suspension Arm Removal
e Remove the follow in g parts.
Tie-Rod (see Tie-Rod Removal)
Knuckle (see Knuckle Removal)
5 Stronger Hard Heavy Bad High
'1!:---;O/
~~
~
/
" ~ ~
/

...v9Y
~~

~ =" ~~
~'-...~@~

/~
A. Adjusting Sleeve (Rear Shock shown)
1. Knuckle 2. Tie-Rod

eRemove the upper suspension arm.

eRemove the lower suspension arm by taking off the
eCheck to see that each pair of adjusting sleeves (front pivot bolts.
two adj usting sleeves or rear two) are turned to the eRepeat the same procedure on the other side of the
same relative position. vehicle.

WARNING'
o If a pair of adjusting sleeves (front two adjusting
sleeves or rear two) are not adjusted equally, handling Rear Suspension Arm (Rod) Removal
may be impaired and a hazardous condition may Refer to Suspension Arm Removal in the Suspension
result. . chapter in the Base Manual.

Rear Suspension Arm (Rod) Installation
o Suspension arm Installation is the reverse of removal.
Note the following.
elnstall the center arms noting the installation direction.
SUSPENSION 11-5
Front or Rear Suspension Arm Assembly Notes
-When installing the rubber dampers into th e arm,
lubricate th e outer surface of the dampers with a soap
and water solution.

Center Arm Installation

o Do not lubricate the rubber dampers with engine oil or

petroleum distillates because they will deteriorate the
rubbers.

~I ePosition the dampers in the arm as shown using a

suitable bearing driver in the bearing driver set (special
tool: PN 57001-1129) .

I

Front Suspension Arm Bushing Installation

1. Slotted hole faces the front.

2. Longer bracket faces the front.

Front Suspension Arm Disassembly

Remove the front suspension arm (see Front Suspen-
sion Arm Removal).
eRemove the rubber bushings using a press and a suit-
able bearing driver in the bearing driver set (special
tool: PN 57001-1129).
eHolding the suspension arm with a vise, remove the 1. Arm 3.0.15 - 0.85 mm
circlip and unscrew the knuckle joint. 2. Bushing

t:--@
,

1. Rubber Bushings 3. Knuckle Joint

2. Circlip

0 00 not remove the knuckle joint grease seal. It is

packed with grease .
 STEERING 12-1

Steering
Table of Contents

Exploded View . ... ........ ... . ... . . ...... . .. ... . . .... ... . 12-2
Specification ................................. .... .... .... . 12-3
Steering ................... .. ............... . . . ... . . .. ... 12-3
Handlebar Removal .... ......... .. ......... .. ..... ... .. . *
Handlebar Installation .. .... .. ... .... .. . . . . ........ ... .. . 123
Handlebar Grip Removal .............. . ... . ............. . *
Handlebar Grip Installation ............ .. ............. . .. . *
Steering Stem Removal ..... . .... ... . . .......... . .. . '. . . . . *
Steering Stem Installation .. .. ....... . .... . . .......... . . . . 12-3
TieRod Removal ... . .................... .. .. ... .. .. .. . 12-3
Tie-Rod End Installation Notes ... ...... ..... .. . . .. ....... . 12-4
Steering Knuckle Removal ... ...... . .... . . . . ..... . . . ... . . 12-4
Steering Knuckle I nstallation Notes . ... . .. .. . .. ...... . .... . 125
Steering Knuckle Stopper Adjustment .. .... ... .... ....... * [gI
Steering Inspection .. ......................... ... .... .. . *
Steering Stem Warp .. . . . ........ ...... ..... ... . ........ . *
Steering Stem Bearing, Tie-Rod Bearing, and
Steering Knuckle Upper and Lower Joint Inspection ........ *
Steering Lubrication ...... . ... . ... .. ... .... . .......... . . 12-5

* . Base Manual
12-2 STEERING

E~~i~d;;d-v'i'~""""
..................... '''''' '' ''''''' ' ........................ _... .
~.........

A:A pp Iy adhesive
R:
G 'AppIy grease . .
. Replacement P
W ' A I arts
~a)
. pp y. water ' or soap and water
sol utlon.
~__.JIc;)l
T1 : 20 N-m (2 0 k g m
T2: 29 N-m (3'0 k , 14.5 ft-Ib)
T3: 41 N.m (4 ' g-m, 22 ftlb)
T4: 25 N-m (22 kgm, 30 ft-Ib)
kg-m, 18.0 ft~b)
5
T5: 88 N-m (9'0
. kgm , 65ftIb)
 .STEERING 12-3

Steering Stem Installation

Specification Refer to the Base Manual noting the following.
o When replacing the stem clamps, replace both clamps
as a unit.
Steering Angle el nstall the grease sea l facing the end rearward to
0
Right: 48 prevent the entry of dirt.
0
Left: 48

Steering

Handlebar Installation
eHandlebar installation is the reverse of removal. Note
the following.
elnstall the handlebar so that the angle of the handlebar
matches the angle of the steering stem as shown.

A. Ribs and Grooves B. Ends

eAlign the relief marks on the steering stem clamps.

A. Parallel

eTighten the holder rear bolts first and then the front
bolts. When the holder is correctly installed, there will
be even gap at the front and no gap at the rear after
tightening,

A. Marks

Rou te the cables, the wires, and the brake hose ac-
cording to the Wiring, Cable, or Hose Routing section
in the General Information chapter.

Tie-Rod Removal
e Remove the following parts.
A. Front C. No Gap Front Fender (see Frame chapter in this text)
B. Even Gap Front Wheel (see Wheels/Tires chapter in this text)
12-4 STEERING
_ Remove the following parts to free the tie-rod from the
stress.
Front Shock Absorber (see Base Manual)
Front Suspension Arm Pivot Bolts (upper)
Tie-Rod End Installation Notes
-Check that the seal lip is on the shank.
-Oil the bolt body.

Tie-Rod End Installation

o
A. Upper Suspension Arm Pivot Bolts
B. Shock Absorber
1. Seal Lip 3. Apply oil
2. Shank

_ Remove the cotter pin and the tie-rod end nut at the
steering knuckle .
Remove the cotter pin and the tie-rod end nut at the
steering stem. Steering Knuckle Removal
-Install a suitable spare nut on the tie-rod end and tap -Remove the following parts.
the nut to remove the tie-rod. Front Wheel Hub (see Wheels/Tires chapter in this
text)
Tie-Rod (see Tie-Rod Removal)
Stone Guard
Remove the cotter pins, then remove the steering
knuckle upper and lower joint nuts.

o Do not loosen the locknut of the steering knuckle

stopper bolt. or the bolt will turn and the steering
knuckle stopper adjustment may be necessary.

A. Tap the spare nut.

OWhen removing the tie-rod, be careful not to bend it.

o Do not loosen the locknuts at the end of the tie-rod
adjusting sleeve. or the toe~n of the front wheels will
be changed.
aDo not remove the grease seal. It is packed with
grease. A. Steering Knuckle Stopper Bolt
 STEERING 12-5
-Tap the steering knuckle and remove it. Knuckle Joint Installation

Good Not good

o o
A. Tap the steering knuckle.

Steering Knuckle Installation Notes

o The installation is the reverse of removal. Note the
following.
-Clean the sealing surfaces, and the tapered holes.

1. Shanks 2. Seal Lips

-Tighten the knuckle joint nuts to the specified torque

(see Exploded View).

Steering Lubrication
Refer to the Base Manual noting the following.
-Grease the steering stem clamp mating surface, too .

A. Sealing Surfaces B. Tapered Holes

_Clean the shanks of the knuckle joint.

_Check that the grease seal does not have tear, wear,
deterioration, or grease leakage.
_Check that the seal lip is on the sealing surface of the
shanks as shown .
 FRAME 131

Frame
Table of Contents

Exploded View ........................................... . 13-2

Seat ..... .. . . . . .... .. ... . ... .. ..... .. ... .. .. ..... . .... .. 13-4
Seat Removal .. .......... . ..... .. .... . ... .. . . .. . ... .. . 13-4
Seat Installation ... ..... .. . . . .. . ..... .. ........... .... . 13-4
Front and Rear Fenders .. . . .. ....... ..... . .. .... .... ...... . . 13-4
Front Fender Removal ... . . . ............ .. ......... . .. . . 13-4
Front Fender Installation Notes .. .. .. . . . .... ... ........ 13-5
Front Carrier Removal ..... . ......... . . ... ..... . ..... . . . 13-5
Rear Fender Removal .................................. 13-5
Rear Fender Installation Notes ........................... . 13-6
Rear Carrier Removal .................................. . 13-6
Frame Exchange ........ .......... .. . ... ... ... ...... . ..... . *
Suggested Parts Removal Order. .......................... . *
Suggested Parts Installation Order. ... ... . . ....... .. .. . .... . *
Decals .................................................. . *
Decal Removal ... . ....... .. . . .... .. .. ........ . ...... . . *
Decal Application . ...... ...... . .. ........... . . .. ...... . *

* : Base Manual
13-2 FRAME

Exploded View
.............................................................................
Front Carrier

1. Bolts, Washers, 8 x 16
2. Flanged Bolts, 8 x 20
3. Flanged Bolts, 6 x 16
4. Bolts, Washers, 8 x 16
5. Bolts, Washers, 6 x 18
6. Bolts, Washers, 8 x 14
7. Bolts, Washers, 8 x 18

,
,,,
,: ~
, -
Canada Model
: @ - - - - Australia Model
Rear Carrier ~--- KLF300-B 1,B2,B6 -
KLF300-B6-
,, ,
r-. Europe Model
KLF300-B4-
UK Model
KLF300-B3-
,,

(/
='1/",,,/ '.
,,
I
~~ ')
.:"'%::-
,"'''''''-,.-r

KLF300-B3-

KLF300B3-
r--------
, ---- --,

,
~--- -- ----- --- -~
 FRAME 13-3

~ 8. Screws 6 x 14
9. Black Screws 6 x 18
~~. Bolts, Washers 6 x 18
. Bolts, Washers 6 x 20

~. ~
@-'ff~ &1.
(ij - ' '"

- <$><>d~
- y~
8 .~ @ rK!-~~??~B}-
134 FRAME
............................................................................. ..............................................................................
Seat Front and Rear Fenders
0.0 0 '

Seat Removal Front Fender Removal

-Pull the seat lock lever up . - Remove the follow ing parts.
Seat (see Seat Removal)
Fuel Tank Tail Cover (with Two Screws)
Fuel Tank Cap

WARNING'
o Gasoline is extremely flammable and can be explosive
under certain conditions. Turn the ignition switch
OFF. 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.

Fuel Tank Upper Cover (with Two Screws)

Front Carrier (see Front Car rier Removal)
Fuel Tank Side Cover (just pull it out)

A. Pull.

-Lift the rear of the seat, slide it toward th e rear slight-

ly, and lift it off the veh icle.

Seat Installation
-Slip the seat hook under the brace o n the frame, and
put the stoppers in to the holes in the frame.
A. Fuel Tank Side Cover
B. Fuel Tank Upper Cover with Two Screws
C. Fuel Tank Tail Cover with Two Screws

-Install the fuel tank cap at once.

ORe move the mounting screws and take off the side
covers.

A. Brace C. Stoppers
B. Seat Hook D. Holes

-While pushing the rear part of the seat down, push the
seat lock lever down until the lock clicks. A. Side Cover B. Screws
 FRAME 13-5
e Remove the front fender mounting bolts and flanged Front Carrier Removal
collars, fo ur screws and nuts of the mud flaps. eJ ust remove the following six bolts.

A. Mounting Bolts

A. Mounting Bolts
B. Remove these screws (both right and left sides).
Rear Fender Removal
eRe move the follow ing parts.
Seat (see Seat Removal)
eRemove the four mounting bolts of the fender front Eight Rear Fender Mounting Bolts including the Bolts
part. in the Storage.Case

A. Six Mounting Bolts B. Storage Case

A. Mounting Bolts

eTake off the front fender along with the carrier.

Front Fender Installation Notes

o Installation is the reverse of removal.
eFit the tabs on the front fe nder cover and the fuel tank
side cover in place. A. Two Mounting Bolts in the Storage Case
elnstall the mounting screws, bolts, nu ts, and flanged
collars in the original positions (see Exploded View). eTake off the rear fender along with the carrier.
13-6 fRAME

Rear Fender Installation Notes

Rear fender installation is the reverse of removal. Note
the following.
_ Be sure the rubber plug is in place in the bottom of the
storage case .
-Fit the front fender tabs into the slits in the rear
fender.
elnstall the mounting screws, bolts, nuts, and flanged
collars in the original positions (see Exploded View).

Rear Carrier Removal

- Just remove the following eight bolts.

A. Carrier Mounting Bolts (8)


Electrical System
Table of Contents
Precautions . . . . . . . . . . . . . . . . . . . . . . .
Exploded View .......... ..... ..... 14-2
KLF300-B1 Wiring Diagram ... .. ...... . 14-4
Specifications . . ..... .. . . . . . . ... ... . 145
Special Tools .... .. . . . .. . .. . ..... 145
Battery ..... . . . .... . .... . .. ..... 146
Precautions . . ...... . ... ... . .... .
Battery Removal/Installation . . .... ... . 146
Battery Removal ... .. ..........
Battery Installation . .... . . . . . . . . . . 14-6
Electrolyte ... .. .... . .. .. ... ....
Electrolyte Level inspection . .. .... .
Battery Charging .... . . . . . . . . . .... 146
Battery Condition ...... . .... . .. . 146
Battery Initial Charging .. ........
Battery Ordinarily Charging..... . .. 146
Battery Test Charging . . . . . . . . . ... .
Charging System ...... . .. .. ...... .. . 14-6
Part Removal . . . . . . . . . . . . . . . . . . . . 14-6
Alternator Rotor Removal . . . . . .. . . 14-6
Alternator Rotor Installation ....... 14-6
Alternator Stator Removal . . . . . . . . .
Alternator Stator Installation . . . . . . . .
Charging System Checkout . . . . . . . ... . 148
Charging System
Operational Inspection . . . . . . . . . .
Stator Coil Resistance Inspection . ... . 148
Rectifier Circuit Inspection . .. . . . . . .
Regulator Circuit Inspection . . . . . . . .
Ignition System ..... . . ... ... .... .. . 14-8
Safety Instructions ..... ... ... .. ..
Part Removal . . . . . . . . . . . . . . . . . . .
.
.
148
Engine Stop Switch Removal ... .... . Ignition Switch Removal or
Engine Stop Switch Installation ..... . Installation . . . . . . .. . . . . . . . . . . 1411
Ignition Coil Removal .. . . . . . . . . . . 148
Ignition Coil Installation . . . . . . . . . . . 148
Spark Plug Removal or Installation ... . 149
Pickup Coil Removal ..... .... ... .
Pickup Coil Installation . . . . . . . . . .
Ignition System Checkout . ..... .... 149
Ignition Timing Test . . . . . . . . . . .. . 149
Ignition Coil Inspection . . . . . . . . . . . 145
Spark Plug Cleaning and Inspection ... .
Spark Plug Gap . . . . . . . . . . . .. . . . .
IC Igniter Inspection . . . . . . . . ... . 149
Pickup Coil Inspection . . .... . ....
Alternator Rotor Inspection . . . . . . . .
ELECTRICAL SYSTEM 14-1
Electric Starter System . .. ... ". . . . . . . . . . 1410
Part Removal . . . . . . . . . . . . . . . . . . . .
Starter Motor Removal . . . . . . . . . .
Starter Motor Installation ... . ... .. .
Starter Motor Disassembly ........ .
Starter Motor Assembly .. .. . .. . .
Starter Button Removal . .. ... . . .. .
Starter Button Installation ... .. .. . .
Starter System Checkout . . . . ... ... . .
Starter Motor Brush Length ........ .
Starter Motor Brush Spring Tension . . .
Starter Motor Commutator Inspection . .
Starter Motor Armature Inspection . . . .
Brush Assembly Inspection ...... .. .
Starter Relay Inspection . . ... . . . . . .
Starter Circuit Relay Inspection . . . . . .
Starter Button Inspection . .. . . .. .. .
Lighting System ....... .. .. ........ . 1411
Headlight Beam . . ....... .. ... . ... . 1411
Headlight Beam Vertical Adjustment .. . 1411
Bulb Replacement. ..... . ...... ... .
Headlight Bulb Replacement ....... .
Taillight Bulb Replacement ..... ... .
Neutral and Reverse Indicator Light
Bulb Replacement ... ....... .... .
Part Removal . ... . ....... ....... .
Light Switch Removal .... .. . .. . . .
Light Switch Installation .... .. . . .. .
Neutral and Reverse Switch Removal ..
Neutral and Reverse
Switch Installation ..... . . ..... .
Ignition Switch . . . . . . . . . . . . . . . . . . . . .
1411
[HI
Switches . . . . . . . . . . . . . . . . . . . . . . . . 1411
Neutral and Reverse
Switch Inspection . ... . . . . . . .. . 14-11
Ignition Switch, Light Switch,
Engine Stop Switch, Starter Button,
and Fan Switch Inspection ..... 14-11
Cooling Fan System
(UK Model) .. . ....... ..... . . . .. . 14-12
Cooling Fan Installation .......... 1412
Fan Motor Inspection . . . . . . . . . . . . . 1412
Electrical Wiring . .. . . . . . . . . . . . . .... .
Wiring Inspection ... .. . . . . . . . . .
* Base Manual
14-2 ELECTRICAL SYSTEM
.............................................................................
Exploded View
.............................................................................

~~ "
~g
@
()

.~
~
/~

(Do not apply oil)

e-
g

"-

T1 : 59 N-m (6_0 kg-m, 43 ft-Ib)

T2 : 27 N-m (2_8 kg-m, 20 ft-Ib)
T3: 4.4 N-m (0_45 kg-m. 39 ft-Ib)
T4 : 7_8 N-m (0_80 kg-m, 69 in-Ib)
 ELECTRICAL SYSTEM 14-3

g;l I~I
_ LJ~
IjJI~ ~

i
I
~~ !
,
ld I

l - ______ -.J

1. Pickup Coil
2. Regulator/Rectifier
3. Neutral and Reverse Switch
4. Starter Relay
5. Starter Circuit Relay
6. IC Igniter
7. Ligh~ Switch and Engine Stop Switch
8. Igmtlon Switch
9. Cooling Fan Switch
 .............................................................................
Wiring Diagram US, Canada model fKLF300-81 _) .,....
.j,.
............................................................................. UK, Australia model fKLF300-81 - 83)

~
m
r-

=l~
PICkUp

~
Altlmeto.
Ig"lIIon COli
SwitCh
i~

~
~..:~

A R,guletorl
:II

~
Rectlfl'r

~ 9 r-

.H
, "
"
~:i~li
II
".
". ~
m
Neutral I ndicator
Ught12VlW " ----=- " -+-1-+-1- "J Sp.rk Plug
3:

Reve". IndiCator
LI9hl12V3W

r- - -
,.~,.~ ':'B~
an " '8R~8R
Accessory Terminals
"., A""'''" L,,'n
H

"'lJ
L
i
i _j'
..
.
___ _ _ _ __ _"-_
Q?

--J
"

I
~..:!i
US model
KLF300-B4-
---BL - - - - 0

o
<J
R -------,
8K/Y _ _
~ ,- - - --l

I HUdllytll

~"1
l
;;<--0<.-- ..'"
"' ,,' .,,"
L 11--'
- L:= " ::=J II ~Il---
' '

:, ,~~f :~
,12V65/60W RtT_ ------c.p-
_ _....
II" /I
8" V:,II.,=
II D<I~",

1", ~::...-J'
_ 1_ _ _ _ ..
I - - -9"-
'
- R Taillight

-~~:~""' ,!~
J .. , .,,_ . "v.w., '

"""" 0,"" L
II '
:
:1'1' 1 '" - "" --.. ,".......;;;
I..... '
,,_
-
.. ~ ..
I

,
~-
Fin

,'.''''
-
~8l-

_______

UK model only
:
---1
AceelSo.y
r Te rmln llS
~ ~
::ii;
BK
BL
BR
G
GY
LB
Color Code
Black
Blue
Brown
Green
Gray
Light Blue
r----
. ~ " -"1 _.. .
["f":. :C
LG Light Green
Ru~l 511r\e, Blltton
~ 0 Orange
l~FF
H'
1.1 0'"
Eniline Slop Switch

Light Switch
~ LO;:.' P
R
W
Pink
Red
White
ILO
Y Yellow
(980511043D,10a8A,1225B)
 ELECTRICAL SYSTEM 14-5

Specifications Special Tools

Refer to the Base Manual noting the following. Refer to the Base Manual noting the following.

TIming Light: 570011241

Battery
OThis tool may be used instead of the common tool.
Capacity: 12 V 14 Ah
Specific gravity: 1.28 @20C (68F)
Electrolyte volume: 0.9L
Charging System
Battery charging coil resistance: 0.1 - 0.7 n
Ignition System
Spark plug cap resistance: 3.75 - 6.25 kn
Ie igniter resistance: in this text
Ignition coil resistance
(with the spark plug cap removed)
Primary winding: 1.8 - 2.8 n
Secondary winding: 10 - 16 kn

Coil Tester: 57001-1242

Ignition Coil Winding Resistance
OThis tool may be used instead of the Kawasaki Elec-
trotester (PN 57001-980). "

CD
o

Spark Plug Wrench (Owner's Tool): 92110-1109

1. Measure primary winding resistance.

2. Measure secondary winding resistance.
3. Ignition Coil

Flywheol Puller: 57001-1191

14-6 ELECTRICAL SYSTEM

Battery Charging System

Battery Removal/Installation: Part Removal:

Battery Installation
Refer to the Base Manual noting the following.
-Install the battery so that the terminal side faces the
front.
Route the battery vent hose and wiring according to
the Wiring, Cable, or Hose Routing section in the
General Information chapter.
I WARNING'
o Keep the battery vent hose outlet away from the frame
and brake system components. Battery electrolyte will
corrode and weaken them. Do not let the vent hose
become folded, pinched, or melted by the exhaust
system. An unvented battery will not keep a charge
and it may crack from built-up gas pressure.
Alternator Rotor Removal
eRemove the left engine cover (see Left Engine Cover
Removal in the Engine Left Side chapter).
eThread the flywheel puller (special tool: 570011191)
and rotor puller (special tool: 57001-1099) onto the
alternator rotor.
eHolding the flywhee l puller, turn the roto r pu ller until
the alternator rotor is forced off the end of the crank-
shaft.
Olf the rotor is difficult to remove and a hammer is used
to tap the rotor puller. be careful not to strike the
rotor itself. Striking the ro.t or can cause the magnets to
lose their magnetism.

Alternator Rotor Installation

Battery Charging:
Battery Condition
o Refer to the Base Manual noting the fo ll owing.
*If the specific grav ity is below 1.200, the battery needs
to be charged.
Battery Ordinary Charging
o Refer to the Base Manual noting the following.
-Set the charging rate and time according to the battery
condition previously determined (see Battery Condi-
t ion), using the table.
eAlternator rotor installation is the reverse of rem oval.
Note the following.
eelean the inside of the rotor and the end of the crank-
shaft thoroughly or the taper will not fit sn ugly.
-Fit the rotor onto the crankshaft so that the woodruff
key fits in the groove in the hub of the rotor.
-Install the left engine cover (see Left Engine Cover
Installation in the Engine Left Side chapter) .
-Clean the alternator rotor bolt, tighten the alternator ro-
tor bolt to the specified torque (see Exploded View).

Battery Charging RatelTime Table (12V 14Ah)

1.28 ~ Fully Charged

1.24

at 1 A charge rate 5 10
0
15
I , 20 21
I
at 2A charge rate 3 5 7 9 10.5
0
at 3A charge rate 1 2 3 4 5 6 7
at 4A charge rate 2 3 4 5.3
Hours of Charging Time at Rates Shown
 ELECTRICAL SYSTEM 14-7

Charging and Lighting Circuit

BR ON OFF Q) w w
BR w
BR BK/Y

a:
<II

B G

r1
6 Pin Connector -!l @

I
~

-
r'\ ,"
>
<II
~
;;:

- +
"
<II
@

7'T
d BK/Y

R/BK A
~
R/B~ mL...:B::.:K1::.Y~)C:r-=B::.:K:.;/Y~
IL-_-r...r::-
i R/BK
BR BR ~
~_---I~ R OFF o""-.J,~ HI
r-~~l 0 ILO @
I L- R/Y
R R
V'-' BK/Y

1. Ignition Switch 6. Regulator/Rectifier 11. Battery

2. Reverse Indicator Light 7. Diodes 12. Light Switch
3. Neutral Indicator Light 8. Thyristers 13. Headlight
4. Neutral and Reverse Switch 9. Control Unit 14. Taillight
5. Alternator 10. 30A Fuse

A. Headlight Connectors, A. Regulator/Rectifier

Ignition Switch Connectors, and
Light Switch Connector
14-8 ELECTRICAL SYSTEM

Charging System Checkout: e Pull the spark plug lead off the spark plug.
Stator Coil Resistance Inspection eDisconnect G/W lead and Y/R lead from the coil.
eRemove the seat (see Frame chapter) . eTake off the nuts and remove the coil.
eDisconnect the a lternator connector.
eMeasure the stator coil resistance.
OConnect the hand tester (special too l: PN 57001-1394)
between the yellow leads.
OSet the hand tester to x 1 n range, and read the tester.

Stator Coil Resistance

0.1 -0.7 n

Front A. Ignition Coil B. Front

=J

Ignition Coil Installation

Refer to the Base Manual noting the following.

1. Alternator Connector

*If the tester does not read as specified, replace the

alternator stator.
*If the coil has normal resistance, but the voltage A. Front C. G/W Lead
inspect showed the alternator to be defective; then the B. Y/R Lead
rotor magnets have probably weakened, and the rotor
must be replaced.
Polarity of Ignition Coil

(-)
Ignition System !I 1 9~
o l _____ -=-J~
8 ~-
G) .
green/white lead
Connect
Connect
yellow/red lead
Part Removal:
Ignition Coil Removal
. e Remove the fuel tank (see Fuel System chapter in this
manual).
 ELECTRICAL SYSTEM 14-9

Spark Plug Removal or Installation Ie Igniter Inspection

- Remove or install the spark plug using the spark plug o Refer to the Base Manual noting the following.
wrench (e.g. owner's tool) from the vehicle right side. -Set the hand tester (special tool) to the x 1 kU range.
-Tighten the spark plug to the specified torque (see
Exploded View).
Ie Igniter Resistance* Unit: kU
Range Tester Positive (+) Lead Connection
xl kU G/W Y/R BK/W BL (BK/W)

".J
0
G/W
~ = = = =

~
3- 2- 60- 2-
Y/R
I0
30 15 500 15
>

~
0.8 - 1.2- 30-
"0
~o
0-
BK/W
8.0 12.0 300
0
Zt;

~
,0
00
50- 70- 30 - 30 -
BL
i
t-u
500 550 300 300

~
0.8 - 1.2 - 30 -
(BK/W) 0
8.0 12.0 300

A. Spark Plug Wrench (Owner's Tool): 92110-1109 Measure with the Kawasaki Hand Tester (PN 57001 -
1394). A tester other than the Kawasaki Hand Tester
may show slightly different readings.

Ie Igniter Terminal

Ignition System Checkout:

Ignition Timing Test Y/R G/W
eRemove the ignition timing inspection plug. ~~

~
-Attach the timing light (special tool: PN 57001-1241)
and a tachometer in the manner prescribed by the
manufacturer.
_Start the engine and aim the timing light at the timing
light mark on the alternator rotor.
Run the engine at the speeds specified and note the (BK/W) BL
alignment of the timing marks.
BK/W

A. Advanced Mark C. Top Mark

B. F Mark D. Timing Inspection Hole A. IC Igniter Connectors
14-10 ELECTRICAL SYSTEM

Ignition System Circuit

~---------------BK/Y --------------~
.----Y/R--11;::===t--,
BK
BL

ON

(5)FF
ON
rLf
~ ~FF~-'
U@ '" '"
-
;;: L?

~Q) r

--
o<~
>-L?
r

1
~
(j)- ~
~
r-'

1. Battery 5. Pickup Coil

2. 30A Fuse 6. Igniter
3. Ignition Switch 7. Ign ition Coil
4. Engine Stop Switch 8. Spark Plug
Electric Starter System

Refe r to the Base Manual, noting the fo llowing.

Electric Starter Circuit
CD
~-----W---~~~--W-~

*\
TON
a:
OFF

<II

~
a:
<II

4
~
<II a:
<II
p"'---" '" ;~;"'
~
:
<II
I
a: a: -'"
>-
~

'" >
OFF

T RUN
o

1. Ignition Switch 4. Starter Button 7. Starter Motor

2. Starter Circuit Relay 5. Engine Stop Switch 8. Starter Relay
3. 30 A Fuse 6. Neutral Switch 9. Battery
 ELECTRICAL SYSTEM 1411

Ignition Switch, Light Switch,

Lighting System
Engine Stop Switch, Starter Button,
and Fan Switch Inspection
Headlight Beam: -Refer to the Base Manual noting the following.
-Remove the fuel tank front cover (see Fuel Tank
Headlight Beam Vertical Adjustment
Removal in the Fuel System chapter in this manual).
eLoosen the headlight mounting knobs and move the
-Unfasten the upper strap of the vinyl cover and open
headlight up or down to adjust the headlight vertically.
the velcro.

A. Headlight Mounting Knobs

A. Strap B. Vinyl Cover

-Tighten the mounting knobs .

.............................................................................
Ignition Switch
.............................................................................
Ignition Switch Removal or Installation
GRefer to the Base Manual noting that the rubber
damper and the bracket are not on the model.

Switches
A. Ignition Switch Terminals: BR, W
B. Light Switch, Engine Stop Switch, and Starter Button
Neutral and Reverse Switch Inspection Connector
GRefer to the Base Manual noting the following.
-Remove the seat.

Neutral and Reverse Switch Inspection

Gear Position G Ground R Ignition Switch Connections
1 st through 5th W BR
Neutral OFF
Reverse (
ON C I J
14-12 ELECTRICAL SYSTEM
Light Switch Connections Wire Connections
R BR R/Y R/BK BL +-> Battery (+)
BK/Y +-> Battery (-)
OFF
LO oThe fan should rotate counterclockwise when it is
HI viewed from the rear.

Engine Stop Switch Connections

Y/R BR
OFF
RUN

To Starter Button

Starter Button Connections

BK Y/R
Pushed
Released
1. Rotation Direction
To Engine Stop

*If the fan does not rotate at this time, the fan is
defective and must be replaced.
Fan Switch Inspection (U K Model)
BR BL [ WARNING.
OFF
o Be careful not to touch the fan blades to avoid injury .
ON c
*If the fan rotates, inspect the fan switch or the wiring
(see Electrical Wiring section in the Base Manual and
Switches section in this manual).

Cooling Fan System

BK/Y
BR

Cooling Fan System (UK Modell

~
'"
@~
Cooling Fan Installation
-Install the cooling fan and connect the leads according (?)
a:
'" -'"
>
~

~BRj
to the Wiring, Cable, or Hose Routing section in the @
General Information chapter.

+
L BL~
BL
Fan Motor Inspection CD
-Unfasten the upper strap of the vinyl cover and open
the velcro (see Switches section) .
Disconnect the fan lead connectors. 1. Battery 4. Fan Switch
-Using two auxiliary wires, supply 12 V battery power 2. 30 A Fuse 5 . Cooling Fan
to the fan. 3. lOA Fan Fuse
 APPENDIX 15-1

Appendix
Table of Contents

Considerations for Various Riding Conditions.................... . 15-2

Carburetor ................ .. ... . .. ... .... . ...... . .. . .. . . 15-2
Spark Plug ..... .. . ... ......... . ..... .. .. ..... ......... . . 15-2
Spark Plug Inspection ...... . ... . . ... ........... ... . .. . . . 15-3
Troubleshooting Guide . .. .. . .... . ... . ... .. . .. .............. . 15-3
General Lubrication ....... .. . . ........... .. .... . . ... ...... . 15-4
Lubrication .. ..... ........ ............. .... ....... .. . . 15-4
Bolt and Nut Tightening ................. .... . .. ............ . 15-4
Tightness Inspection . ..... . . . . . ... . ........ . . . . . .. . .... . 15-4
Unit Conversion Table .. . .................... . ....... ... ... . . *

* : Base Manual
15-2 APPENDIX
Spark Plug
Considerations for Various Riding Conditions

This vehicle has been designed and manufactured to

operate under a wide range of riding conditions.
However, it is not feasible to anticipate all of the condi-
tions under which this vehicle might be used. Extremes
of temperature, altitude, and riding usage may make
changing some carburetor parts or the spark plug de-
sirable to maintain the vehicle in peak operating condi-
tion.

Carburetor:
Sometimes an alteration may be desirable for good
performance under different riding conditions when
proper mixture is not obtained after the carburetor has Reach
been properly adjusted, and all parts cleaned and found
to be functioning properly.
If the engine still exhibits symptoms of overly rich or
Plug gap
lean carburetion after all maintenance and adjustments
are correctly performed, the main jet can be replaced
with a smaller or larger one. A smaller numbered jet
gives a leaner mixture and a larger numbered jet a richer
mixture.

1. Terminal 4. Gasket
2. Insulator 5. Center Electrode
3. Cement 6. Side Electrode

Spark Plug:
The spark plug ignites the fuel and air mixture in the
combustion chamber. To do this effectively and at the
proper time, the correct spark plug must be used, and
the spark plug must be kept clean and the gap adjusted.
Tests have shown the plug listed in the General
Information chapter to be the best plug for general use.
Since spark plug requirements change with the igni-
tion and carburetion adjustments and with riding condi-
tions, whether or not a spark plug of the correct heat
range is used should be determined by removing and
inspecting the plug.
When a plug of the correct heat range is being used,
the electrodes will stay hot enough to keep all the
carbon burned off, but cool enough to keep from
damaging the engine and the plug itself. This temper-
ature is about 400 - 800C (750 - 1 ,450 F) and can be
judged by noting the condition and color of the ceramic
insulator around the center electrode. If the ceramic is
clean and of a light brown color, the plug is operating at
the right temperature.
A spark plug for higher operating temperatures
sometimes may be needed for severe conditions, such as
continuous high-speed riding, or towing heavy loads.
Such a plug is designed for better cooling efficiency so
that it will not overheat and thus is often called a
"colder" plug. If a spark plug with too h;gh a heat range
is used - that is, a "cold " plug that cools itse lf too well,
- the plug will stay too cool to burn off the carbon, and
the carbon will collect on the electrodes and the ceramic
insulator.
The carbon on the electrodes conducts electricity,
and can short the center electrode to ground by either
coating the ceramic in sulator or bridging across the gap.
Such a short will prevent an effective spark. Carbon
build-up on the plug can also cause other troubles. It
can heat up red-hot and cause preignition and knocking,
which may eventually burn a hole in the top of the
piston.
 APPENDIX 15-3
Spark Plug Condition

Carbon fouling Oil fouling Normal operation Overheating

Spark Plug Inspection Standard Spark Plug Threads

Remove the spark plug and inspect the ceramic insula- Diameter: 12 mm
tor. Pitch: 1.25 mm
*Whelher or not the right temperature plug is being used
can be ascertained by noting the condition of the Reach: 19.0 mm
ceramic insulator around the electrode. A light brown
color indicates the correct plug is being used. If the NOTE
ceramic is black, it indicates that the plug is firing at
too Iowa temperature, so the next hotter type should o The heat range of the spark plug functions like a
be used instead. If the ceramic is white, the plug is thermostat for the engine. Using the wrong type of
operating at too high a temperature and it should be spark plug can make the engine run too hot (resulting
replaced with the next colder type. in engine damage) or too cold (with poor performance,
misfiring and stalling).

[i;AUTIO~]
a lf the spark plug is replaced with a type other than the
standard plug, make certain the replacement plug has
the same thread pitA:h and reach (length of threaded Troubleshooting Guide
portion) and the same insulator type (regular type or
projected type' as the standard plug.
a lf the plug reach is too short, carbon will build up on Refer to the Base Manual, noting the following.
the plug hole threads in the cylinder head, causing
overheating and making it very difficult to insert the Engine Doesn't Start, Starting Difficulty
correct spark plug later. Recoil starter not operating
o If the reach is too long, carbon will build up on the Recoil starter springs broken
exposed spark plug threads causing overheating, Recoil starter pawl not engaging
preignition, and possibly burning a hole in the piston
top. In addition, it may be impossible to remove the Overheating
plug without damaging the cylinder head. Cooling fan won't turn over (U K model)
Cooling fan fuse broken
Plug Reach Cooling fan switch trouble
Cooling fan motor broken
Too Short Correct Reach Cooling fan damaged
Cooling fan broken

Brakes Don't Hold

Front Brake
Air in the brake line
Brake fluid leak
Brake fluid deteriorated
Primary or secondary cup trouble
Master cyl inder scratched inside
Brake not properly adjusted
Pad overworn or worn unevenly
Oil, grease on pads and disc
Carbon
builds up here Disc worn or warped
Brake overheated
154 APPENDIX
Rear Brake
Brake not properly adiusted Bolt and Nut Tightening
Linings Qverworn or worn unevenly
Drum worn unevenly or scored
Oil, grease on lining and drum Tightness Inspection
Dirt, water between lining and drum Refer to the Base Manual noting the following.
Overheated
Bolts, Nuts, and Fasteners to be checked

Brakes:
Brake Lever Pivot Bolt
Brake Lever Pivot Nut
Caliper Mounting Bolts

General Lubrication

Lubrication
Refer to the Base Manual noting the following.

Cables: Lubricate with Motor Oil

Brake Cables
Throttle Cable
Choke Cable
Reverse Gear Cable
Differential Shift Cable

Lubricate the cables by seeping the oil between the

cable and housing.
o The cable may be lubricated by using a pressure cable
luber with an aerosol cable lubricant.

Cable Lubrication 1. Brake Lever Pivot Bolt

2. Brake Lever Pivot Nut
3. Caliper Mounting Bolts

Cable: Lubricate with Grease

Speedometer Cable (option)
 SUPPLEMENT - 1989 - 1997 MODELS 16-1

Supplement - 1989 - 1997 Models

This supplement chapter contains only the information unique to the models covered. Read both this
manual's front part (up to p. 15-4) and this chapter for complete information on proper service procedures.

Table of Contents

General Information ....... . . ........................ ............................................................16-2

Model Identification .. . ......................... .. .......... .. ........................................... 16-2
General Specifications .......................... ..... .............. .......................................... 16-4
Fuel System.... ................................... .. ...... ................................... ............ 16-16
Exploded View ........... .............................. ... .....................................................16-16
Specifications ......... .... ................ .. ........... ................................... ..................... 16-16
Engine Top End ........ .. ....... ............. .. ..... .. ......... .. .........................................16-17
Specifications.. .. ................................................... ................. 16-17
Piston, Piston Rings.. .. ....................................................................... 16- 17
Engine Right Side ................. .......................... ........ ... ........... .............................. 16-17
Exploded View ..................................................................................................16-17
Frame............................... .................... .... ........... ................... .. ........... 16-18
Exploded View .............. .. ................................................................................16-18
Electrical System. . .................. ........................... .. .......... ............................ 16-18
Exploded View...... ....................... .. .... ....... .. ............................ ............... 16-18
Battery .. .. .................... ............. .......... .. .......... ............. ....... .. ................. 16-19
Ignition System.... ........................ ................ ................. .. ........ 16-20
Switches ............. ........................ ........ ........... .. . .. .... 16-20
Icing Circuit (KLF300-B8 -, UK model) ................ . ....................... 16-21
Wiring Diagram.. .. .......... .. .. .. .. .......... .. ............. ...... ..................... ...... ..... 16-22
16-2 SUPPLEMENT - 1989 - 1997 MODELS

General Information
Model Identification

KLF300-B2:

KLF300-B3/B3A:

KLF300-B4:
 SUPPLEMENT - 1989 - 1997 MODELS 16-3
KLF300-B5:

KLF300-B6:

KLF300-B7:
16-4 SUPPLEMENT - 1989 - 1997 MODELS

General Specifications (KLF300-B2)

(A): Australia model (B): UK model

(C): Canada model (U): US model

Item KLF300-B2
Dimensions:
Overall length 1910 mm
Overall width 1115 mm, (A) 1160 mm
Overall height 1065 mm
Wheelbase 1210 mm
Ground clearance 195mm
Seat height 750mm
Dry weight 223 kg, (A)( B) 226 kg
Curb weight: Front 10B kg, (A)(B) 109.5 kg
Rear 125 kg, (A)(B) 126.5 kg
Fuel tank capacity 9 L, (B) B.2 L
Performance:
Minimum turning radius 2.9 m (Locked axle mode)
2.6 m (Differential mode)
Engine:
Type 4-stroke, SOHC, 1-cylinder
Coo ling system Air cooled
Bore and stroke 76.0 x 64.0 mm
Displacement 290mL
Compression ratio B.6
Maximum horsepower 14.3 kW (19.5 PSI @ 6500 rl min (rpm) , (U) -
Maximum torque 22.6 N-m (2.3 kg -m, 16.6 ft-Ib) @ 5500 rl min (rpm),
(U) -
Carburetion system Carburetor, Keihin CVK32
Starting system Electric starter & recoil starter
Ignition system Battery and coil (transistorized)
Timing advance Electronically advanced
Ignition timing From 10" BTDC @ 2000 rl min (rpm) to
30" BTDC @ 3200 rl min (rpm)
Spark plug NGK DBEA, (A)(8)(C) NGK DRBES-L
Valve timing: Inlet Open 21 " BTDC
Close 59" ABDC
Duration 260"
Exhaust Open 56" BBDC
Close 24" ATDC
Duration 260"
Lubrication system Forced lubrication (wet sump)
Engine oil: Grade SE, SF or SG class
Viscosity SAE 10W-30, 10W-40, 1 OW-50, 20W-40, or 20W-50
Capacity 1.7 L
 SUPPLEMENT - 1989 - 1997 MODELS 16-5
Item KLF300-B2
Drive Train:
Primary reduction system: Type Gear
Reduction ratio 2.888 (78/27)
Clutch type: Primary Auto centrifugal, wet
Secondary Auto multi disc, wet
Transmission: Type 5-speed plus reverse, constant mesh, return shift
Gear ratio: 1st 3.090 (34/11 )
2nd 1.928(27/14)
3rd 1.368 (26/19)
4th 1.000 (23/23)
5th 0.769 (20/26)
Reverse 3.072 (26/11 x 26/20)
Final drive system: Type Shaft
Reduction ratio 4.886 (20/16 x 43/11). (A)(B) 5.584 (20/14 x 43/11)
Overall drive ratio 10.858, (A)(B) 12.409@Topgear
Final gear case oil: Type API GL-5 Hypoid gear oil SAE 90 (above 5"C, 41"F) or
SAE 80 (below 5"C, 41 "F)
Capacity 0.3 L
Frame:
Type Double tubular
Caster (rake angle) 3.0"
Camber 1.0"@ 1 G
Trail 13mm
Tread: Front 834mm
Rear 844mm
Front tire: Type Tubeless
Size 22 x 9.00-10
Rear tire: Type Tubeless
Size 24 x 11 .00-1 0
Suspension: Front Type Double wishbone-link
Wheel travel 125 mm
Rear Type Torque tube-link
Wheel travel 120mm
Brake type: Front Disc (Hydraulic)
Rear Drum (Mechanical)
Electrical Equipment:
Battery 12V14Ah
Headlight: Type Semi-sealed beam
Bulb 12 V 65/60 W, (B) -
Taillight 12V8W x 2, (B)-
Alternator: Type Three-phase AC
Rated output 23.5 A@ 9000 r/min (rpm), 14 V

Specifications are subject to change without notice, and may not apply to every country.
16-6 SUPPLEMENT - 1989 - 1997 MODELS

General Specifications (KLF300-B3/B3A)

(A): Australia model (B): UK model

(C) : Canada model (U): US model

Item KLF300-B3/ B3A [(A) only]

Dimensions:
Overall length 1910 mm
Overall width 111 5 mm, (A) 11 60 mm
Overall height 1065 mm
Wheelbase 1210 mm
Ground clearance 195 mm
Seat height 750mm
Dry weight 226 kg, B3A(A) 228 kg
Curb weight: Front 109.5 kg, B3A(A) 111 kg
Rear 126.5 kg, B3A(A) 127 kg
Fuel tank capacity 9 L, (B) 8.2 L
Performance:
Minimum turning radius 2.9 m (Locked axle mode)
2.6 m (Differential mode)
Engine:
Type 4-stroke, SOHC, 1-cylinder, piston reed valve
Cooling system Air cooled
Bore and stroke 76.0 x 64.0 mm
Displacement 290 mL
Compression ratio 8.6
Maximum horsepower 14.3 kW (19.5 PS) @ 6500 rl min (rpm) , (U) -
Maximum torque 22.6 N-m (2.3 kg-m, 16.6 ft -Ib) @ 5500 rl min (rpm).
(U) -
Carburetion system Carburetor, Keihin CVK32
Starting system Electric starter & recoil starter
Ignition system Battery and coil (transistorized)
Timing advance Electronically advanced
Ignition timing From 10" BTDC @ 2000 rl min (rpm) to
30" BTDC @ 3200 rl min (rpm)
Spark plug NGK D8EA, (A)(B)(C) NGK DR8ES - L
Valve timing: Inlet Open 21" BTDC
Close 59" ABDC
Duration 260"
Exhaust Open 56" BBDC
Close 24" ATDC
Duration 260"
Lubrication system Forced lubrication (wet sump)
Engine oil: Grade SE, SF or SG class
Viscosity SAE 1OW-30, 1OW-40, 1OW-50, 20W-40, or 20W-50
Capacity 1.7 L
 SUPPLEMENT - 1989 ~ 1997 MODElS 16-7
Item KLF300-B3/B3A [(A) only]
Drive Train:
Primary reduction system: Type Gear
Reduction ratio 2.888 (78/27)
Clutch type: Primary Auto centrifugal. wet
Secondary Auto multi disc, wet
Transmission: Type 5-speed plus reverse, constant mesh, return shift
Gear ratios: 1 st 3.090 (34/11)
2nd 1.928(27/14)
3rd 1.368 (26/19)
4th 1.000 (23/23)
5th 0.769 (20/26)
Reverse 3.072 (26/11 x 26/20)
Final drive system: Type Shaft
Reduction ratio 4.886 (20/16 x 43/11), (A)(B) 5.584 (20/14 x 43/11)
Overall drive ratio 10.858, (A)(B) 12.409 @ Top gear
Final gear case oil: Type API GL-5 Hypoid gear oil SAE 90 (above 5"C, 41"F) or
SAE 80 (below 5"C, 41"F)
Capacity 0.3 L
Frame:
Type Double tubular
Caster (rake angle) 3.0"
Camber 1.0"@ 1 G
Trail 13 mm
Tread: Front 834mm
Rear 844mm
Front tire: Type Tubeless
Size 22 x 9.00-10
Rear tire: Type Tubeless
Size 24 x 11 .00-1 0
Suspension: Front Type Double wishbone-link
Wheel travel 125 mm
Rear Type Torque tube-link
Wheel travel 120 mm
Brake type: Front Disc (Hydraulic)
Rear Drum (Mechanical)
Electrical Equipment:
Battery 12V14Ah
Headlight: Type Sem i-sea led beam
Bulb 12 V 65/60 W, (B) -
Taillight 12V8W x 2,(B)-
A lternator: Type Three- phase AC
Rated output 23.5 A@ 9000 r/min (rpm), 14 V

Specifications are subject to change without notice, and may not apply to every country.
16-8 SUPPLEMENT - 1989 - 1997 MODELS

General Specifications (KLF300-B4)

(A): Australia model (B): UK model (C): Canada model

(E): Europe model (U): US model

Item KLF300-B4
Dimensions:
Overall length 1910 mm
Overall width 1115 mm, (A)(E) 1160 mm
Overall height 1065 mm
Wheelbase 1210 mm
Ground clearance 195mm
Seat height 750mm
Dry weight 226 kg, (A) 228 kg
Curb weight: Front 109.5 kg, (A) 111 kg
Rear 126.5 kg, (A) 127 kg
Fuel tank capacity 9 L, (B) 8.2 L
Performance:
Minimum turning radius 2.9 m (Locked axle mode)
2.6 m (Differential mode)
Engine:
Type 4-stroke, SOHC, 1 -cylinder
Cooling system Air cooled
Bore and stroke 76.0 x 64.0 mm
Displacement 290mL
Compression ratio 8.6
Maximum horsepower 14.3 kW (19.5 PS) @6500r/ min (rpm), (U) -
Maximum torque 22.6 N-m (2.3 kg-m, 16.6 ft-Ib) @ 5500 rl min (rpm) ,
(U)-
Carburetion system Carburetor, Keihin CVK32
Starting system Electric starter & recoil starter
Ignition system Battery and coil (transistorized)
Timing advance Electronically advanced
Ignition timing From 10 BTDC @ 1300 rl min (rpm)to
30 BTDC @ 4000 rl min (rpm) .
Spark plug NGK D8EA, (A)(C) NGK DR8ES-L, (B)(E) NGK DR7EA
Valve timing: Inlet Open 21 BTDC
Close 59 ABDC
Duration 260
Exhaust Open 56 BBDC
Close 24 ATDC
Duration 260
Lubrication system Forced lubrication (wet sump)
Engine oil: Grade SE, SF or SG class
Viscosity SAE 10W-30, 10W-40, lOW-50, 20W-40, or 20W-50
Capacity 1.7 L
 SUPPLEMENT - 1989 - 1997 MODELS 16-9
Item KLF300-B4
Drive Train:
Primary reduction system: Type Gear
Reduction ratio 2.888 (78/27)
Clutch type: Primary Auto centrifugal, wet
Secondary Auto multi disc. wet
Transmission: Type 5-speed plus reverse. constant mesh. return shift
Gear ratios: 1 st 3.090 (34/11)
2nd 1.928(27/14)
3rd 1.368 (26/19)
4th 1.000 (23/23)
5th 0.769 (20/26)
Reverse 3.072 (26/11 x 26/20)
Final drive system: Type Shaft
Reduction ratio 4.886 (20/16 x 43/11).
(A)(B)(E) 5.584 (20/14 x 43(11)
Overall drive ratio 10.858. (A)(B)(E) 12.409 @ Top gear
Final gear case oil: Type API GL-5 Hypoid gear oil SAE 90 (above 5'C. 41'F) or
SAE 80 (below 5'C, 41'F)
Capacity 0.35 L
Frame:
Type Double tubular
Caster (rake angle) 3.0'
Camber 1.0' @ 1 G
Trail 13 mm
Tread: Front 834mm
Rear 844mm
Front tire: Type Tubeless
Size 22 x 9.00-10
Rear tire: Type Tubeless
Size 24 x 11 .00-10
Suspension: Front Type Double wishbone-link
Wheel travel 125 mm
Rear Type Torque tube-link
Wheel travel 120mm
Brake type: Front Disc (Hydraulic)
Rear Drum (Mechanical)
Electrical Equipment :
Battery 12V14Ah
Headlight: Type Semi-sealed beam
Bulb 12 V 65/60 W
Taillight 12V8Wx2
Alternator: Type Three-phase AC
Rated output 23.5 A@9000 r/min (rpm). 14 V

Specifications are subject to change without notice. and may not apply to every country.
16-10 SUPPLEMENT - 1989 - 1997 MODELS

General Specifications (KLF300-B5)

(A) : Australia model (B): UK model (C) : Canada model

(E): Europe model (U): US model

Item KLF300-B5
Dimensions:
Overall length 1910 mm
Overall width 1115 mm, (A)(E) 1160 mm
Overall height 1065 mm
Wheelbase 1210 mm
Ground clearance 195 mm
Seat height 750 mm
Dry weight 226 kg, (A) 228 kg, (B)(C)(E) 227 kg
Curb weight Front 109.5 kg, (A) 111 kg
Rear 126.5 kg, (A) 127 kg, (B)(C)(E) 127.5 kg
Fuel tank capacity 9 L, (B) 8.2 L
Performance:
Minimum turning radius 2.9 m (Locked axle mode)
2.6 m (Differential mode)
Engine:
Type 4-stroke, SOHC, 1-cylinder
Cooling system Air cooled
Bore and stroke 76.0 x 64.0 mm
Displacement 290 mL
Compression ratio 8.6
Maximum horsepower 14.3 kW (19.5 PS) @ 6500 r/ min (rpm). (U) -
Maximum torque 22.6 N-m (2.3 kg-m, 16.6 ft -Ib) @ 5500 r/ min (rpm),
(U) -
Carburetion system Carburetor, Keihin CVK32
Starting system Electric starter & recoil starter
Ignition system Battery and coil (transistorized)
Timing advance Electronically advanced
Ignition timing From 10" BTDC @ 1300 r/ min (rpm)to
30" BTDC @ 4000 r/ min (rpm)
Spark plug NGK D8EA, (A)(C) NGK DR8ES-L, (B)(E) NGK DR7EA
Valve timing : Inlet Open 21 " BTDC
Close 59" ABDC
Duration 260"
Exhaust Open 56" BBDC
Close 24" ATDC
Duration 260"
Lubrication system Forced lubrication (wet sump)
Engine oil: Grade SE, SF or SG class
Viscosity SAE 10W-30, 10W-40, 10W-50, 20W-40, or 20W-50
Capacity 1.7 L
 SUPPLEMENT - 1989 - 1997 MODELS 16-11
Item KlF300-8S
Drive Train :
Primary reduction system: Type Gear
Reduction ratio 2.888 (78/ 27)
Clutch type: Primary Auto centrifugal, wet
Secondary Auto multi disc, wet
Transmission: Type 5-speed plus reverse, constant mesh, return shift
Gear ratios: 1st 3.090 (34/11 )
2nd 1.928(27/14)
3rd 1.368 (26/19)
4th 1.000 (23/23)
5th 0.769 (20/26)
Reverse 3.072 (26/ 11 x 26/20)
Final drive system: Type Shaft
Reduction ratio 4.886 (20/ 16 x 43/11),
(A)(B)(C)(E) 5.584 (20/14 x 43/ 11)
Overa ll drive ratio 10.858, (A)(B)(C)(E) 12.409@Topgear
Final gear case oil : Type API Gl-5 Hypoid gear oil SAE 90 (above 5"C, 41 "F) or
SAE 80 (below 5"C, 41 "F)
Capacity 0.35 L
Frame:
Type Double tubular
Caster (rake angle) 3.0"
Camber 1.0" @ 1 G
Trail 13 mm
Tread: Front 834mm
Rear 844mm
Front tire: Type Tubeless
Size 22 x 9.00-10
Rear tire: Type Tubeless
Size 24 x 11 .00-10
Suspension: Front Type Double wishbone-link
Wheel travel 125 mm
Rear Type Torque tube-link
Wheel travel 120 mm
Brake type: Front Disc (Hydraulic)
Rear Drum (Mechanical)
Electrical Equipment:
Battery 12V14Ah, (B)(C)(E) 12V19Ah
Headlight: Type Semi-sealed beam
Bulb 12 V 65/ 60 W
Taill ight 12V8W x2
A lternator: Type Three-phase AC
Rated output 23.5 A @ 9000 r/ min (rpm), 14 V

Specifications are subject to change w ithout notice, and may not apply to every country.
16-12 SUPPLEMENT - 1989 - 1997 MODELS

General Specifications (KLF300-B6/B7)

(A): Australia model (B): UK model (C): Canada model

(E): Europe model (U): US model

Item KLF300-B6/B7
Dimensions:
Overall length 1910 mm
Overa II width 1115 mm, (A)(E) 1160 mm
Overall height 1065 mm
Wheelbase 1210 mm
Ground clearance 195 mm
Seat height 750mm
Dry weight 226 kg, (A)(B)(E) 229 kg, (C) 227 kg
Curb weight: Front 109.5 kg, (A)(B)(E) 110 kg
Rear 126.5 kg, (A)(B)(E) 129 kg, (C) 127.5 kg
Fuel tank capacity 9L
Performance:
Minimum turning radius 2.9 m (Locked axle mode)
2.6 m (Differential mode)
Engine:
lype 4-stroke, SOHC, 1-cylinder, piston reed valve
Cooling system Air cooled
Bore and stroke 76.0 x 64.0 mm
Displacement 290 mL
Compression ratio 8.6
Maximum horsepower 14.3 kW (19.5 PS) @6500r/min (rpm). (U) -
Maximum torque 22.6 N-m (2.3 kg-m, 16.6 ft-Ib) @ 5500 r/min (rpm),
(U)- .
Carburetion system Carburetor, Keihin CVK32
Starting system Electric starter & recoil starter
Ignition system Battery and coil (transistorized)
liming advance Electronically advanced
Ignition timing From 10" BlOC @ 1300 r/min (rpm)to
30" BlOC @ 4000 r/min (rpm)
Spark plug NGK D8EA, (A)(C) NGK DR8ES-L, (B)(E) NGK DR7EA
Valve timing: Inlet Open 21" BlOC
Close 59" ABDC
Duration 260"
Exhaust Open 56" BBDC
Close 24" AlDC
Duration 260"
Lubrication system Forced lubrication (wet sump)
Engine oil: Grade SE, SF or SG class
Viscosity SAE 1 OW-30, 10W-40, 1OW-50, 20W-40, or 20W-50
Capacity 1.7 L
 SUPPLEMENT - 1989 - 1997 MODELS 16-13
Item KLF300-B6/B7
Drive Train:
Primary reduction system: Type Gear
Reduction ratio 2.888 (78/27)
Clutch type: Primary Auto centrifugal. wet
Secondary Auto multi disc, wet
Transmission: Type 5-speed plus reverse, constant mesh, return shift
Gear ratios: 1 st 3.090 (34/11)
2nd 1.928(27/14)
3rd 1.368 (26/19)
4th 1.000 (23/23)
5th 0.769 (20/26)
Reverse 3.072 (26/11 x 26/20)
Final drive system: Type Shaft
Reduction ratio 4.886 (20/ 16 x 43/11),
(A)(B)(C)(E) 5.584 (20/14 x 43/11)
Overall drive ratio 10.858, (A)(B)(C)(E) 12.409 @ Top gear
Final gear case oil: Type API GL-5 Hypoid gear oil SAE 90 (above 5C, 41 F) or
SAE 80 (below 5C, 41F)
Capacity 0.35 L
Frame:
Type Double tubular
Caster (rake angle) 3.0
Camber 1.0@ 1 G
Trail 13 mm
Tread: Front 834 mm
Rear 844mm
Front tire: Type Tubeless
Size 22 x 9.00-10
Rear tire: Type Tubeless
Size 24 x 11 .00-1 0
Suspension: Front Type Double wishbone-link
Wheel travel 125 mm
Rear Type Torque tube-link
Wheel travel 120mm
Brake type: Front Disc (Hydraulic)
Rear Drum (Mechanical)
Electrical Equipment:
Battery 12 V 14 Ah, (A)(B)(C)(E) 12 V 19 Ah
Headlight: Type Semi-sealed beam
Bulb 12 V 65/60 W
Taillight 12V8W x2
Alternator: Type Three-phase AC
Rated output 23.5 A @ 9000 r/ min (rpm) , 14 V

Specifications are subject to change without notice, and may not apply to every country.
16-14 SUPPLEMENT - 1989 - 1997 MODELS

General Specifications (KlF300-B8/B8A/B9/B10)

(A) : Australia model (B): UK model (C) : Canada model

(E) : Europe model (U): US model

Item KlF300-B8/B8A/B9/B10
Dimensions:
Overall length 1910 mm
Overall width 1115 mm, (A)(B)(E) 1160 mm
Overall height 1065 mm
Wheelbase 1210 mm
Ground clearance 195 mm
Seat height 750mm
Dry weight 226 kg, (A)(B) (E) 229 kg, (C) 227 kg
Curb weight: Front 109.5 kg, (A)(B)(E) 110 kg
Rear 126.5 kg, (A)(B)(E) 129 kg, (C) 127.5 kg
Fuel tank capacity 9L
Performance:
Minimum turning radius 2.9 m (Locked axle mode)
2.6 m (Differential mode)
Engine:
Type 4-stroke, SOHC, 1-cylinder, piston reed valve
Cooling system Air cooled
Bore and stroke 76.0 x 64.0 mm
Displacement 290 mL
Compression ratio 8.6
Maximum horsepower 14.3 kW (19.5 PS) @ 6500 r/ min (rpm). (U) -
Maximum torque 22.6 N-m (2.3 kg-m, 16.6 ft-Ib) @ 5500 r/ min (rpm).
(U) -
Carburetion system Carburetor, Keihin CVK32
Starting system Electric starter & recoil starter
Ignition system Battery and coil (transistorized)
Timing advance Electronically advanced
Ignition timing From 10 BTDC @ 1300 r/ min (rpm)to
30 BTDC @ 4000 r/ min (rpm)
Spark plug NGK D8EA (A)(C) NGK DRBES-L, (B)(E) NGK DR7EA
Valve timing: Inlet Open 21 BTDC
Close 59 ABDC
Duration 260
Exhaust Open 56 BBDC
Close 24 AlOC
Duration 260
Lubrication system Forced lubrication (wet sump)
Engine oil : Grade SE, SF or SG class
Viscosity SAE 1OW-30, 1OW-40, 1 OW-50, 20W-40, or 20W-50
Capacity 1.7 L
 SUPPLEMENT -1989 - 1997 MODELS 16-15
Item KLF300-B8/B8A/B9/B10
Drive Train:
Primary reduction system: Type Gear
Reduction ratio 2.888 (78/27)
Clutch type: Primary Auto centrifugal, wet
Secondary Auto multi disc, wet
Transmission: Type 5-speed plus reverse, constant mesh, return shift
Gear ratios: 1st 3.090 (34/11)
2nd 1.928(27 / 14)
3rd 1.368 (26/19)
4th 1.000 (23/23)
5th 0.769 (20/26)
Reverse 3.072 (26/11 x 26/20)
Final drive system: Type Shaft
Reduction ratio 4.886 (20/16 x 43/11),
(A)(B)(C)(E) 5.584 (20/14 x 43/11)
Overall drive ratio 10.858, (A)(B)(C)(E) 12.409 @Top gear
Final gear case oil: Type API GL-5 Hypoid gear oil SAE 90 (above 5"C, 41"F) or
SAE 80 (below 5"C, 41F)
Capacity 0.35 L
Frame:
Type Double tubular
Caster (rake angle) 3.0
Camber 1.0@ 1 G
Trail 13mm
Tread: Front 834mm
Rear 844mm
Front tire: Type Tubeless
Size 22 x 9.00-10
Rear tire: Type Tubeless
Size 24 x 11.00-10
Suspension: Front Type Double wishbone-link
Wheel travel 125mm
Rear Type Torque tube-link
Wheel travel 120mm
Brake type: Front Disc (Hydraulic)
Rear Drum (Mechanical)
Electrical Equipment:
Battery 12V14Ah, (A)(B)(C)(E) 12V19Ah
Headlight: Type Semi-sealed beam
Bulb 12 V 25/25 W x 2
Taillight 12V8W x2
Alternator: Type Three- phase AC
Rated output 23.5 A@ 9000 rlmin (rpm), 14 V

Specifications are subject to change without notice, and may not apply to every country.
16-16 SUPPLEMENT - 1989 - 1997 MODELS

Fuel System
Exploded View

Specifications

Item Standard Service limit

Carburetor:
Make, type Keihin, CVK32 ---
Main jet #130, #125 (KLF300- B9 -) ---
Main air jet #100 ---
Needle jet #6 ---
Jet needle N36X, N74T (KLF300-B9 -) ---
Pilot jet #38 ---
Pilot air jet #140 ---
Pilot screw 2~ turns out, 2% (KLF300-B9 -) ---
Starter jet #58, #65 (KLF300-B9 -) ---
Service fuel level 0.5 mm (below) - 1.5 mm (above) ---
Float height 17 2 mm ---
Optional parts:
Main jet #125,128,132,135 ---
#120,122,128,130 (KLF300-B9-)
Pilot jet #35,40 ---
Starter jet #60,62 ---
#68, 70 (KLF300- B9 -)
 SUPPLEMENT - 1989 - 1997 MODELS 16-17

Engine Top End

Specifications

Item Standard Service Limit

Camshaft:
Cam height 40.642 - 40.782 mm 40.54mm
Cylinder. Piston:
Cylinder inside diameter 76 .000 - 76 .012 mm 76.10mm
Piston diameter 75.96Q - 75.975 mm 75.81 mm
Piston / cylinder clearance 0.025 - 0.052 mm -- -
Piston ring / groove clearance:
Top 0.03 - 0.07 mm 0.17 mm
Second 0.02 - 0.06 mm 0 .16 mm
Piston ring thickness 0.97 - 0.99 mm 0.90 mm
Piston ring groove width:
Top 1 .02 - 1.04 mm 1.12mm
Second 1 .01 - 1 .03 mm 1.11 mm

Piston. Piston Rings Engine Right Side

Top and Second Rings Exploded View

L: Apply non-permanent locking agent.

n: 15 N-m (1.5 kg-m.ll.0ft-fb)

Top
ring

T1

"N" mark
2nd
ring
16-18 SUPPLEMENT - 1989 - 1997 MODELS

Frame Electrical System

Exploded View Exploded View

KLF300-88-
i KLF300-88-
r - - --- -- ------------- ,

dJ

L ______ _ _____ _ ____ _ __ ~

/ " KLF300-88~ UK Model

/
/ r---- ------ ---- --- - --,
/
/

/
/
/
,
/ @,
/
/
/
)
r
, i>
, /
/
/

:~
/
/
/
/
/
Australia Mo del
-
/

KLF300-81, 82, 86-

Europe Model
KLF300-84-
UK Model
KLF300-83-85

L ____ ____ ______ ______ ~

KL3BOS-1W4 C
 SUPPLEMENT - 1989 - 1997 MODELS 16-19

KLF300-BBA-
Europe Model'

,, '''
,,
, ''
,,
,,
,,

i~ ___ ___ 1
,,,
,

KLF300-B3A-
Australia Mod'el

I
L - - _-I

Battery

Battery Ch ar91n9
. Rate /TIme
. Table (12 V 1 9 Ah)

1.265 Fully Charged

1.24
.~ 1.20
>
'" 1.16

"-
.='
u
~
Q.
If)
1.1

at 3A charge rate

Hours of Ch arglng
. Time at Rates Shown
16-20 SUPPLEMENT - 1989 1997 MODELS
KLF300-BSA -, Europe Model:
Ignition System Ie Igniter Resistance Unit" x kO

Range Tester Positive ( + ) Lead Connection

Ie Igniter- Resistance Unit: x kO
x 1 kQ BL Y/R R/W G/W (BK/W) BK/W
Range Tester Positive (+) Lead Connection
.. 75 55 80 50 50
x 1 kO G/W Y/R BK/W BL (BK/W) BL -
-300 -220 -320 -200 -200
.. G/W - 00 00 00 00
Y/R
75 -
3 5 2.5 2.5
- 1 - 10 1 - 10 -300 -12 -22 -11 -11
Y/R 5 - 15 00

- 50 2.5 1.8 0 .4 0.4

BK/W 1 - 5 1 - 10 00 0 R/W -
-200 -11 -7 -1.6 -1.6
50 - 50 - - 50 -
BL 00 G/W 00 00 00 - 00 00
150 150 150
50 2.2 0.3 1.3
(BK/W) 1 - 5 1 - 10 0 00 - (BK/W) - 0
-200 -8.4 -1.5 -5.5
50 2.2 0.3 1.3
BK/W 0 -
Measure with the Kawasaki Hand Tester (PN -200 -8.4 -1.5 -5.5
57001 -1394). A tester other than the Kawasaki Hand
Tester may show slightly different readings.
Tester Negative (- ) Lead Connection Measure with the Kawasaki Hand Tester (PN
57001 -1394). A tester other than the Kawasaki Hand
Tester may show slightly different readings.
Ie Igniter Terminal Tester Negative (-) Lead Connection

Ie Igniter Terminal
YiR G/W
~~

~
YIR R/W

~
(BK/W) BL

BK/W
(BK/W) BL

BK/W G/W
Switches

Horn Button Connections

BK/W BK/Y

Push
 SUPPLEMENT - 1989 - 1997 MODELS 16-21

Icing Circuit (KLF300-B8-, UK model)

Control Unit Inspection - J i r

JI
Remove the control unit.
.Set the hand tester to the x 1 kO range and make the
measurements shown in the table.
* If the tester readings are not as specified, replace the @
control unit.
Control U nit Resistance Unit: kO
Tester Positive (+) Lead Connection
A Thermostatic Sensor B. Thermostat
1 2 3 4 5
. 1 - 7- 28 00 6.5-28 17-80
*If the tester does not read as specified, replace the
sensor.
2 00 - 00 00 00 Carburetor Thermostatic Sensor Resistance (Reference only)
Standard: 3.0 - 7.2 kO @12' C (53.6' F)
-
24-
3 6-26 9 .5-40 9.5-40
150
4 4.4-19 1.4-6 00 - 6.5-28
5 13-60 10-45 00 6.5-28 - Carburetor Heater Inspection
Disconnect the carburetor heater connector.
Using the hand tester, measure the resistance of the
': Tester Negative (-) Lead Connection heater.
.Connect the tester between the heater terminal and
carburetor ground.
* If the tester does not read as specified, replace the
heater.
3 Carburetor Heater Resistance
Standard: 11 ..... 20 0

Carburetor Thermostatic Sensor Inspection

Remove the carburetor thermostatic sensor .
Suspend the sensor in a co ntainer of water so that the
temperature sensing projection and threaded portion are
submerged .
Using the hand tester, measure the internal resistance
of the sensor across the terminal and the body at the
temperatures shown in the table.

NOTE
o The sensor and thermostat must not touch the container
sides or bottom.
 ...
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~
~
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en
,
?. N
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Neutral Ind lc. to,
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to
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. "'1J , "
0
to
, 111111 "' IIII 'D
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to
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to
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spndomele.
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Color Code
LBK/v ~ BK Black I
" BL
.," Blue

~
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BR Brown
Horn Bunon ~"" -
~BKrw
; : .. :.!:; G Green
GY Gray
"- r-
LB Light Blue
,,, LG Light Green
II RlJ~1
n~ . 0
P
Orange
Pink
o
"'
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R Red
Horn
L!l LO
O. W
Y
White
Yellow
12VBW
(9805 112058 )
 ::<
t.lll ni ti on Sli l t cn
2. Ne u t r a l l Re v er se Swit ch
r
."
:E
:;-
3. Rever se Ind i cat or lig h t w
:i'
Opt i on
~ . Neu t ral Indic a t or l loht
?
0M
CQ

=!J
j" .. ,.... ""
' Fan Switch ~ BR I CD 00
Acce SSOr y
'"co C
iii'
\Y-- 8l l1I~Sl I
Termlnels CQ

.." I~
12" m2
c(J)
~81-<>c}--- ~l
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,
8l SA

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12VBWX2
C.

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(")

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I I 1I U l I T
c.
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.. 1
u

~B /Y-O<}U71mu/,:cKfu71111 ::.. :-
Headlll;lht
(Right)
12V25 /2 5W
...... - ............ .....-........... . ....]-"1
:

I _ _ ..... _ _.... _...... _ .......... ... . ...................... _ ..... __ .

R R

~ I I ,~,:
..c.
0

iii

D-' ~ III
Accessor y Term I no 1'5 <J-BK/Y , Qr.J :

n l1
( for Auxiliary light )

III III nl ............

VI
C

~ ~ ~ ~m ~s
~
'"C
'"C
Headlight
fi5['m:g:g:'I'l ==- r
~'~/Y-CJ<}-,V/Y
(left)
12V25/25W m
: .........
Hill
,.. S
~~-:::-;

~
~~~ ~-- :'~:'~t:~, ~~
~~ m

,~
IGnition Starter Z
Relay -oj
. =. . . . . Rect I r IIH col t Starter
C I r cu I t
Re I ay (CN) Canada Model

.~I'[l
Ion I te r
.....
~ork Plug CD
AI ternotor Pickup Starter Mot o r CO
Co I I :>.'\.'\.'\.'\.'\.'\.,--.::"". CD
t_, _. , J'!~ Color Code I
BK Black .....
CD0 BL Blue
Brown
CD
CD
l ert Handlebar Sw i tch DR
-.j
l.Llght / Olmmer Switch G Green
2. Engine stoo Sw i tch GY Gray
3. starter Button LB Llgnt Blu8 ' S
LEfT HANDLEBAR SWITCH CONNECTIONS ICNITICN SWITCH CCHMrCTlOMS Neutrol ~ lIev&ru SW it Ch connections LG Lloht Green o
SwitCh EQlne Stop SwitCh I Starter Button C~I
or, BR ... I.w GOIIr Position I LG rounal R/W
0
p
Dranoe
Pink
C
m
OM
lOt throuoh 5th
~ Re. r
VI
~ ROvIH!O
W White
Va I low
(98051 - 1500A.1501A)C
Y
.....
,
'"
N
W
 .....
',..."
."

::I. '",
Neutral
t.l!everse InGlcetor tlont
!zU. 4' Contro l unit 8, ::l
\C
N
.j>

Flln Sltltch = U
'"
Ignition Renrse
SwitCh :wtlCh
Z. Neutral Inilicetor tloht
123.4W
g Accessory
Terli ine is
III
po 0
iir
(f)
c:
8L~ GSl~;~
C

::~ID :~:===~~_-l'i
~--l-Sl--__ 6~I
\C "'C

s:'" iil "'C

r-
%=1L-!>D-8L ~
w---{>C}-

coollno Flln II OJ 14-1

'"':. u ~ ....
"",,,,,,
In,,", so,,,, " "I \~. o
"-
!!.
3 m
S
~: ~~ ~~ H~
m

~ ~~
Taillight,
2

~~ ~I ~LJ~ ~: fF
12VB 'IIx2
carburetor ~

R~R~
Heater
""',, -
"/'-=r-H/O
l~~J ~~
UV2]W
Helldllght 'I"m'/U=!f'/U.<>CH/":::;-] :1'1 .....
!IW,'5W IIY
U/Y III
nil ..1fT~ -i>D 1fT
~ ~ __ ..1
S
.. ::

I I
Raley
. . ... ... -.::-
II II II w
(Q
CO
(Q

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I
I I I III .....

LI ,ht 12V3." ~U/'-c:J<J-U/' II I III W. (Q

(Q
-oJ
S
m =~ ~~~~:~ ~~ ~[l
I I .~ 0
0
m
CID m $i ~ ~~!;S ._J
Helld ll ght R/81C--t:::>C]- I/U r-
!IW,'5W I/Y -t>D- 1/'
U IY--D<J- n/'
s'"'s.:~ =: ... ::. ~o:~!; # starter
c I reu I t
I!t I IV
BatterY
12V19Ah
(f)

~
S"'S=S:: ~~ ",,,,,,8!;S

"f~
lj, -~.I
Alternator Pickup Coil Starte r Motor
"" ~'~,,""=='J
'/1-
"', .1IT SDftrk colo r Code
BK Black
"'.~"\I""' "."~,,
<D <D (j) &~
"'UU
3. Stllrte r Button :Q"J, Bl Blue
BR Brown
G Green
GY Gray
LB L10ht Blue
LErr HANDLEBAR SW ITCH CONNECTI ONS
llQht/Dlmme r SwItCh
.. ..
EnQ l ne 5100 Swi t Ch
,,
Stllrter Button
COlor
orr
..
I;.ITION S.IICM CONNECTIOn
W
Neut ral' lleversa Swltcn Connections
Gatlr POSitIon LC GrOund R/W
LG lI0ht Grear
0
P
OranQe
Pink
color
orr
R , R ~/BK co I or
oro 'I' cO lor
li e I eesell " ON ~
1& t throuOh 5t h
Nautrtll
R
W
Red
Wh I t e
1O pUSh lIeverse
Y Yellow
HI OU" (9B 051-150lA )
 Na Utra l "r- ~
." "T1
5:
l Qn l t lon I!enr se
'"
? ::l

"~ ~ ij
Fan Sit Itch
= ::-------=(cf"'vJ-)
I' 1.fUverse Indicator llQht
12V3.4W
Acca sso rv
TQrmlM l s III
Q)
(,Q

C
%-- ,,--t>CI- "fUse SA L 2. Neutrel I nd l cetor l lQht
12V3 . ,
~~
iii'
(,Q

I~
Cool i ng Fan ~
--;:

~~ ~~LJH~ ._.11: "~

I~
Taillights ~
12YBWX2 !O!.
.;. U!!. !!. U"" iii'
Headlight ~/8K --t::>C}-1/U

- J J_ Q)
'2VI'/2"
(RH'
R/Y --t::>CJ-l/r
BK/Y--c:J<]-u/r =- "
Q.

I I I II II m
"0
<J-II~ I
~~~ ~
~
Accessory Terminals
(Auxiliary Light) I -;:::J I 'C
CD
speedometer :=.
_ LI --c8-'l ....:c I

~ ~~~
Light 12V3.4W r CD
~

l ie ;
.....
n
0

_ ~
~
III ~? lill
~iis.
CD
'C

'-H sn= n n 777 ."1

0
~

~ i"~ulorn ~,:,.'
"-J - 00

'iT'iTil' j 'm,~. ~ -~=-

"",=.__
~;s;; ~ ,,, ' ,,, ,, ',
I , .-' C

;;.h~- ~ ~S ~

R/8K~'/1
n' ' C
Headlight o_;;SS I C
HW/ 2SW Rll
nIl
III
11/1 _ I
....... "
" '"
_
ss I I 17 ="- Betury ~
"'tI
"'tI
I -- - ,,)
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Q.
r-
!!.
m
.'_ 11 [-JI 0-
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co II ---
I III s:m
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...... ,
2
IlI,Il1ct, ...... .......... .....
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.... "'CO
L:::J ,to"" -i
...
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Sterter ~otor

____ L-'. __ J
En""
2_1.lIontlDl :mer 'vlt Ch "','," Color Code
BK Black
ID
00
CD
CD (j) (j) 3. surter ~~~t~~ltCh BL Blue
tAustrall1l model only
BR
G
GY
Brown
Green
Grav
...1
CD
LB CD

.. -
LIght elue
LEfT HANDLEBAR SW ITCH CONNECT IONS IUllIOM ' .. ITCM COMN[CT I ONS NeutreL L lIevtrU 5111ten connection! LG L i ght Greer -..I

cOlor
Lloht/Olmme r
T

5~ltch

RISK .. C() I or ..
Englna St o p SIIItCh
T
5tllrter Button
CO(()f T
"
CoL or
OTT
Glter POSItion
1St thrOUgh 5th
LC Ground ./- 0
p
Qranoe
Pink s:0
orr OF T lilt I eesad ON c-= Naut ral
R .ed
Wh I te
CO Push ReVltrSIt
W C
RUN
Y Ya II ow m
HI (91051-150lJ..150H)
r-
OO
...,
'"
N
U'1
16-26 SUPPLEMENT - 1989 - 1997 MODELS

Wiring Diagram

KLFlOO-8SA -, Europe Model

-gu;;:;~ ...~ ~
~

oH-IH=f=t+WI-+t-t++I
-.
o

>0
-<

'-DO--' - --

-- - - ------ ------------------------- ---------------------.

;;~ ~'-<>CJ-'
-;;::::: U-CJ<]-1I8
=: l~-CJ<J-.l'
.8-t>C}-MI
D-c:::J<}-1/1f

ss- S.s~

W~ ~ ~ ~~~,
r
: ... ,
~~ --.
: ...
,,<

@ @
..
0

.
o
~

o g~
~ ~
~
>
N
-~
{i~
o

o
o
u
~~~ <
~
~~
 SUPPLEMENT -1998 -1999 MODELS 17-1

Supplement - 1998 ~ 1999 Models

Table of Contents
Foreword .. ... ..... ........ ..... ..... ..... ..... .... . ...... .... ... ..... .... ..... .. ...... ... .. ...... ........ .... ... .. .......... ..... ..... 17-2
How to Use this Manual..... ... ... ... ... ... ... .... .......... ....... ..... ..... .. .. ... .... .... ... ... .... .. ......... .. .. ...... 17-2
General Information.............................. ...... .. ......... ...... .... .. ........... .. ... ................. .. ........ ... ... .... 17-3
General Specifications. .. ... .. ... .... ...... ........ ....... ... ........ ........ .... ..... ......... ... ..... ......... .. ..... .... 17-3
Final Drive .... ..... .......... ........ ...... ...... ..... .... ... ...... .... .... .... .... ..... .. ... .... .. ....... .... ... .. ....... ....... ... 17-6
Exploded View (KLF300-B12 - ) ...................................................... ... ..... ........ .... ........... ... 17-6
Brakes ..... ..... ........ .... .. ..... ...................................................... ... .. ... ..... ... .. ... .......... ........ .... .... 17-7
Exploded View (KLF300-B 12, Canada Model) .. ... ........ ... .... .. ..... ..... .... ... ....... .... .. ....... ....... .. 17-7
Electrical System...... . ... ............ ... ........ ....... ...... ....... ..... ... ......... ..... ...... ........ ...... ..... .. ...... ... ..... 17-8
Exploded View (KLF300-B12) ................................................ .... .. .... .. ...... ........... ................ 17-8
Charg ing System (KLF300-B12 - ).... .......... .. ....... ............. .. ......... ... ... ..... ... ........... ....... .. .... .. 17-9
Regulator/Rectifier Output Voltage Inspection ................................. ....... ............... ... .. ... ... 17-9
Alternator Inspection .... ...... ...... ... ...... ...... ............ ... ... ............. ... . ..... ...... .. .... .... ... ....... .. ...... 17-10
Regulator/Rectifier Inspection .................................................................. ... ........ .............. 17-11
Wiring Diagram (KLF300B-11, U.S.A/Canada/Austraria Models)........ ...... ........ ..... ...... ....... 17-14
Wiring Diagram (KLF300B-12, U.S.A/Canada/Austraria Models) ....... ................................ 17-16
Wiring Diagram (KLF300B-11 , U.KlEurope Models) ..... ........ .. ............ ........ .......... .............. 17-18
Wiring Diagram (KLF300B-12, U.KlEurope Models) .......... .... .... .. .. ...... ...... ...... ....... .. .... ... ... 17-20
17-2 SUPPLEMENT -1998 - 1999 MODELS
Foreword

How to Use this Manual

This "Supplement 1998 - 1999 Models" designed to be used in conjunction with the front part of this
manual (up to 16-26) and/or Base manual KLF300 Service Manual - Part No. 99924-1057-01.
The specifications and maintenance procedures descried in this chapter are only those that are
unique to the KLF300B11 - B12 models.
Complete and proper servicing of the KLF300B11 - B12 models therefore requires mechanics to
read both this chapter and the front of this manual.
 SUPPLEMENT -1998 -1999 MODELS 17-3
General Information
General Specifications
Item KLF300B11/B12
Dimensions
Overall Length 1 910 mm
Overall Width 1 115 mm, (A) (B) (E) 1 160 mm
Overall Height 1065mm
Wheelbase 1210 mm
Ground Clearance 195 mm
Seat Height 750 mm
Dry Weight 226 kg , (A) (B) (E) 229 kg, (C) 227 kg
Curb Weight:
Front 109.5 kg, (A) (B) (E) 110 kg
Rear 126.5 kg, (A) (B) (E) 129 kg , (C) 127.5 kg
Fuel Tank Capacity 9L
Performance
2.6 m (Differential mode)
Minimum Turning Radius
2.9 m (Locked axle mode)
Engine
Type 4-stroke, SOHC, 1-cylinder
Cooling System Air-cooled
Bore and Stroke 76.0 x 64.0 mm
Displacement 290 mL
Compression Ratio B.6
Maximum Horsepower 14.3 kW (19.5 PS) @ 6500 rl min (rpm), (U) -
Maximum Torque 22 .6 Nm (2.3 kgfm , 16.6 ftlb) @5 500 rl min (rpm). (U)-
Carburetion System Carburetor, Keihin CVK32
Starting System Electric starter & recoil starter
Ignition System Battery and coil (transistorized)
Timing Advance El ectronically advanced
From 10 BTDC @1 300 rl min (rpm) to 30 BTDC @4 000 rlmin
Ignition Timing
(rpm)
Spark Plug NGK DBEA, (A) (C) NGK DRBES-L, (B) (E) DR7EA
Valve Timing:
Inlet:
Open 21 (BTDC)
Close 59 (ABDC)
Duration 260
Exhaust:
Open 56 (BBDC)
Close 24 (ATDC)
Duration 260
Lubrication System Forced lubrication (wet sump)
17-4 SUPPLEMENT -1998 -1999 MODELS
General Information

Item KLF300B11/B12
Engine Oil:
Grade SE, SF or SG class
Viscosity SAE 10W-30 10W-40, 1OW-50, 20W-40, or 20W-50
Capacity 1.7 L
Drive Train
Primary Reduction System:
Type Gear
Reduction Ratio 2 .888 (78/27)
Clutch Type:
Primary Auto centrifugal, wet
Secondary Auto multi disc, wet
Transmission:
Type 5-speed plus reverse , constant mesh, return shift
Gear Ratio:
1st 3.090 (34111)
2nd 1.928 (27/ 14)
3rd 1.368 (26/19)
4th 1.000 (23/23)
5th 0.769 (20/26)
Reverse 3.072 (26/ 11 x 26/20)
Final Drive System:
Type Shaft
Reduction ratio 4.886 (26/16 x 43/11)
(A) (8) (C) (E) 5.584 (20/14 x 43/11)
Overall Drive Ratio: 10.858 (A) (8) (C) (E) 12.409 @Top gear
Final Gear Case Oil:
Type API GL-5 Hypoid gear oil SAE90 (above 5C, 41 F) or SAE80
(below 5C, 41 F)
Capacity 0.35 L
Frame
Type Double tubular
Caster (Rake Angle) 3.0
Chamber 1.00 @1G
Trail 13 mm
Tread
Front 834 mm
Rear 844 mm
Front Tire :
Type Tubeless
Size 22 x 9.00-10
Rear Tire:
Type Tubeless
Size 24 x 11 .00-10
 SUPPLEMENT -1998 -1999 MODELS 17-5
General Information

Item KLF300B11/B12
Suspension:
Front
Type Double wishbone-link
Wheel Travel 125 mm
Rear
Type Torque tube-link
Wheel Travel 120 mm
Brake Type:
Front Disc (Hydraulic)
Rear Drum (Mechanical)
Electrical Equipment
Battery 12 V 14 Ah (A) (B) (C) (E) 12 V 19 Ah
Headlight:
Type Semi-sealed beam
Bulb 12 V 25/25 W (RH/LH)
Taillights:
Bulb 12 V 8 W (RH/LH)
Tail/Brake Lights:
Bulb (C) 12 V 18/5 W (RH/LH), KLF300-B12
Alternator:
Type Three-phased AC
Rated Output 23.5 A @9 000 r/min (rpm), 14 V
Specification subject to change without notice, and may not apply to every country.
AS: Australian Model
EU: European Model
UK: U.K. Model
US: U.S.A. Model
17-6 SUPPLEMENT -1998 -1999 MODELS
Final Drive
Exploded View (KLF300-B12 -)

HK020 39 Bn c

1. Rropeller Shaft
G: Apply grease.
T1 : 25 Nm (2.5 kgm , 18.0 ftlb)
 SUPPLEMENT -1998 -1999 MODELS 17-7
Brakes
Exploded View (KLF300-B12, Canada Model)

S j }----\
1":\;------{T2

@~--I::f

HL020288W3 C

1. Brake Switch
Si: Apply silicone grease.
T1 : 1.0 Nm (0.10 kgf.m, 9 in.lb)
T2 : 5.9 Nm (0.60 kgfm, 52 inlb)
T3: 1.2 Nm (0.12 kgfm, 10 inlb)
T4: 8.8 Nm (0.90 kgfm, 78 inlb)
17-8 SUPPLEMENT -1998 -1999 MODELS
Electrical System
Exploded View (KLF300-B12)

1. Regu lator/Rectifier
2. Tail/Brake Light (Canada Model)
3. Bulb (12 V 18/5 W)
4. 7.8 Nm (0.8 kgfm, 69 inlb)
 SUPPLEMENT -1998 -1999 MODELS 17-9
Electrical System
Charging System (KLF300-B12-)
Regulator/Rectifier Output Voltage Inspection
Remove the seat (see Frame chapter) .
Check the battery condition (see Battery section) .
Warm up the engine to obtain actual alternator operating
conditions.
Check that the ignition switch is turned off, and connect
the hand tester to the battery terminal.
Special Tool- Hand Tester: 57001-1394
Start the engine, and note the voltage readings at vari-
ous engine speeds with the headlight turned on and then
turned off. The readings shou ld show nearly battery volt-
age when the engine speed is low, and as the engine
speed rises , the readings should also rise . But they must
be kept under the specified voltage.
Regulator/Rectifier Output
Connections
Tester Range Reading
Tester (+) to Tester (-) to
25 V DC Battery (+) Battery (-) 14 - 15 V
Turn off the ignition switch to stop the engine, and discon-
nect the hand tester.
* If the regulator/rectifier output voltage is kept between the
values given in the table, the charging system is consid-
ered to be working normally.
*11 the output voltage is much higher than the values spec-
ified in the table, the regulator/rectifier is defective or the
regulator/rectifier leads are loose or open.
* II the battery voltage does not rise as the engine speed
increases, then the regulator/ rectifier is defective or the
alternator output is insufficient for the loads. Check the
alternator and regulator/rectifier to determine which part
is defective.
17-10 SUPPLEMENT -1998 -1999 MODELS
Electrical System
Alternator Inspection
There are three types of alternator failures: short, open
(wire burned out), or loss in rotor magnetism . A short or
open in one of the coil wires will result in either a low output,
or no output at all. A loss in rotor magnetism , which may be
caused by dropping or hitting the alternator, by leaving it
near an electromagnetic field, or just by aging, will result in
low output.
To check the alternator output vo ltage, do the following
procedures.
ODisconnect the alternator connector [A] .
OConnect the hand tester as shown in the table.
OStart the engine.
O Run it at the rpm given in the table .
ONote the voltage readings (total 3 measurements).
Regulator/Rectifier Output Voltage
Connections
Tester Range Reading
Tester (+) to Tester (-) to
Another black
250 V AC One black lead 39 - 59 V
lead
* If the output voltage shows the value in the table, the alter-
nator operates properly and the regulator/rectifier is dam-
aged. A much lower reading than that given in the table
indicates that the alternator is defective.

Check the stator coil resistance as follows .

OStop the engine.
ODisconnect the alternator connector.
OConnect the hand tester as shown in the table.
ONote the readings (total 3 measurement).
Stator Coil Resistance
Connections
Tester Range Reading
Tester (+) to Tester (-) to
Another black
x 1 n One black lead
lead
0.33 - 0.49 n
*If there is more resistance than shown in the table , or no
hand tester reading (infinity) for any two leads, the stator
has an open lead and must be replaced. Much less than
this resistance means the stator is shorted, and must be
replaced .
Using the highest resistance range of the hand tester,
measure the resistance between each of the black leads
and chassis ground.
*Any hand tester readi ng less than infinity (oo) indicates a
short, neceSSitating stator replacement.
* If the stator coils have normal resistance , but the voltage
check showed the alternator to be defective; then the rotor
magnetism has probably weakened, and the rotor must
be replaced .
Special Tool - Hand Tester: 57001-1394
 SUPPLEMENT -1998 -1999 MODELS 17-11
Electrical System

Regulator/Rectifier Inspection
Front Fender (see Frame chapter)
Connectors [A] (disconnect)
Bolts [B] and Regulator/Rectifier [C]

Rectifier Circuit Check

Check conductivity of the following pair of terminals .
Rectifier Circuit Inspection
W/R-Yl, W /R-Y2 , W /R-Y3
Tester connection f - - - - - - - ' - - - --'-- - -- ---l
BK-Yl , BK-Y2, BK-Y3
*The resistance should be low in one direction and more
than ten times as much in the other direction. If any two
leads are low or high in both directions, the rectifier is HP09006BS 1 C

defective and must be replaced.

NOTE
o The actual meter reading varies with the meter used
and the individual rectifier, but generally speaking the
lower reading should be from zero to one half the scale.
Regulator Circuit Check
To test the regulator out of circuit, use three 12 V batteries
and a test light (12 V 3 - 6 W bulb in a socket with leads).
CAUTION
The test light works as an indicator and also a cur-
rent limiter to protect the regulatorlrectifier from ex-
cessive current. Do not use an ammeter instead of
a test light.
Check to be sure the rectifier circuit is normal before con-
tinuing.

Regulator Circuit Test-1st Step

Connect the test light and the 12 V battery to the regula-

:
tor/rectifier as shown.
Check Y1 , Y2, and Y3 terminal respectively.
*If the test light turns on, the regulator/rectifier is defective. I I I
Replace it.
*11 the test light does not turn on , continue the test.

HP09018BSI C
17-12 SUPPLEMENT -1998 -1999 MODELS
Electrical System
Regulator Circuit Test-2nd Step
Connect the test light and the 12 V battery in the same
manner as specified in the "Regulator Circuit Test-1 st
Step".
Apply 12 V to the SR terminal.
=-<j'---,@:
I I I
Check Y1, Y2, and Y3 terminal respectively.
* If the test light turns on, the regulator/rectifier is defective.
Replace it.
*11 the test light does not turn on, continue the test.
' - - - - - ' HP09019BS I C

Regulator Circuit Test-3rd Step

Connect the test light and the 12 V battery in the same
manner as specified in the "Regulator Circuit Test-1st
Step".
Momentarily apply 24 V to the SR terminal by adding a 12
V battery.
=+-.@:I I I

Check Y1 , Y2 , and Y3 terminals respectively.

CAUTION
L......_--' HPOU208S1 C
Do not apply more than 24 V to the regulator/recti-
fier and do not leave the 24 V applied for more than
a few seconds, or the until will be damaged.

* If the test light did not light when the 24 V was applied
momentarily to the SR terminal , the regulator/rectifier is
delective. Replace it.
* If the regulator/rectifier passes ali of the tests described,
it may still be defective. If the charging system stili dose
not work properly after checking all of the components
and the battery, test the regulator/rectifier by replacing it
with a known good unit.
 SUPPLEMENT -1998 -1999 MODELS 17-13
Electrical System
Charging System Circuit

CD
~~R~B:~~~ __________________
II I I II >- >-
II >-
"-
""
a>
'1
'"

~ "'
>- >- >- >>->-3::~~~:;:

P wllj~~
~ TT

'" '"'" '" '"

'" '" '" '"
>->->- ....................
3:: ~
o::::::..:::~
OJ OJ c:c

I I I I I I I I
0
CD
CD

IIP090UB1I3 C

1. Ignition Switch
2. Alternator
3. Regulator/Rectifier
4. Battery
5. Main Fuse 30 A
6. Load
17-14 SUPPLEMENT -1998 -1999 MODELS
Electrical System
Wiring Diagram (KLF300B-11, U.S.AlCanadaiAustraria Models)

Au str al ia Model only

( u. s. A. I Canada Model Option ) Ignition
r---- - - - - , Switch

~
I Coo l ing Fan
Switch
Neutral / Rev erse
Switch
FuseSA

~~
Coo l ing Fa n

~ ~

~~
~
, ~ I
L __ __ _
- - - - - - - - - - --, : to I
Headlight

,.. -."'<>0<,.. ---' W

12 V25 / 2S "

~
( RH)

Opt ion
@ / BK-c>cJ-R
K/ -!>D-. K I
' I' -CJ<l- R/ y
Y-
1
B K / y-t>=:J-B K / Y -
R/ y -CJ<J- R/Y
,
~ ~
~

~
lj2/
~.t----' I ;;-.-~;l ~
~

I :-BK /Y-{>' :
I
I~~!k
J---, I'----C~
Light ; - - -
L!..!.Y 62 /-.! 0 .!....J <J-BK I , U
,

~
~ ,

m*
~ ~ ~
~~

oo=E ,~~~,~ ~I~PN

,-
~
I BK---t>CJR / B K
KI 'I----{:>Q< KI
R/ Y ----CJ<} RI Y -
~
H eadl ight ~ ~

12V25 /2 51'1

,~: o~ ~
( L H)

L.ft H,"dI.b" S.'to"

ffim
~~!j:;; ~ ~~b :S~ :;~: : P"k,p C,II
G)Light / Dilllller Switch L ri~
..1 I Alternator
G) En gine Stop Switch
(';\
0Starte r Button
f7\
~ H orn Button
OFF : H II :
~ __ L-ol
T-
:p: :1r: L.J
,
. I
f4\
~

L _ _ _ _ _ .J

CD Austral ia Model only

LEFT HAN DLEBAR S" IT CH CONNECT IONS

LI ht / Dir.... er
Color , I, , Swi teh
RI SK B'
Enl;n. Stop S.itch
Color BR ' I,
Starter
Colo r
Bu tton
, I' BK
OFF
LO
HI
OFF Release
Pu s h ~
..,
'UN I

1111UUIS C
 SUPPLEMENT -1998 - 1999 MODELS 17-15
Electrical System

CDR eve r s e I nd j cat 0 r L i g ht 1 2 V 3. 4 W

N e u t r a I I n die a tor L i g ht 1 2 V 3. 4 W

Option(U.S.A.Modelon l y)

r - - -- - , r -----..,

Ta i I/Brake Light
12V 8/27WX2

I
<J-B l-+::tjt~'
-<}-BK/Y
I <J-- R-~-'<::''''
L ___ _ _ _ _ _ _ _ _ _ _ _ _ .J

Tail light
12V aWX2
, - - - I B l--CJ
r- BKI Y-c:J<:J-B KI' 'Y~j:t
, - R --c:J<O-- R -

~
,>
- ~

~;
~
-

~
,>
~
~

~
(, ) (- )

Battery

i~~i
12V19AH
0

Ignition
lb __ ::!J 12V14AH(U. s. A. II "del)
0
Starter Relay
COl I Starter
Regulator ! Circuit
Recti f ie r Rei a y

Starter Motor
Color Code
BK Black
Spark Plug Bl Blue
BR Brown
CH Chocolate
DG lh rk Green
G Green
GY Gco
lB Licht Blu e
' 1" . . . . ,IC N co .. Eel, n UIR H , REH U E SI I ICH COUECTIHS lG Licht Green

Color I BR W G e. r PO lition lG Ground R/'

0
P
Oran
OFF ," t ~ f. UI h
"" PU
Pink
Purp l e
ON Neutral
R R.d
Reverse
(9805 1 -1668A)
Y White
Ye I low
(98 05 1 - 1669A )
(9805 1 - 1 670A)
.lRl868AIS C
17-16 SUPPLEMENT -1998 - 1999 MODELS
Electrical System
Wiring Diagram (KLF300B-12, U.S.AlCanadalAustraria Models)

I gnition
Switch

Cool ing
S.i teh
Fan

F use5A
fl Neutral / Rever s e
Switch

~~
Cool ing Fan

::: ~

~~
I
~

Head light
12V25 / 25W
( R H) o ~

00] M ~
1 SK--l>CJ-' I S K - R / BK~R / BK----

Opt ion
K I ---{>O- B K / Y---'
RI Y --c:J<}- ' / Y
SK I Y{>C}-SK I Y-
R! Y -D<J- R/ Y l ~~
, ~

f/\!3/
- ---,---, I ;---:{:;l ~
~

I }- BK / V-[::> :
I
I!~~k
~~ /~O~
__ ..r---, I Y----c:]
Light : - __ ::J
~BK I Y
,J
" - - - - - - ---:::: Tl.-
I
I
@:I R---i.>1---J R

ISpeedomete r
L igh"t .
L _~
BK / Y~K I
D
Y
11 2 V 3. 4 YI I

tA:str~lia -1II~;j -;;"1 yJ

( OPtion ) U. s. A. / Canada Mode ls
~

m#
~ ,
~ ~~
~ ~

CEE
/ BK~R / B K
K I 'I----{>C]o KI Y -
R / Y~R / Y -
Headl ight
1 2V25/25W
( l H)
>-

~ ~
:0::<11::..:
...... a:: ...... m ...... o::a
~

:11 ~
~
~
~
~
~
~
~
~
~

Austral ia Mode l only

LEFT HANDLEBAR S"I TCH CONNEC T IONS

Light / O inllner Switch En lin e Slop S . itcll Sta r ter Butt on
Color ,/Y R IR / BK BR Color BR Y/ , Color Y/ , SK
OFF OFF
.,
R e lease
lO Push
HI 'UN <;.

II L175781S C
 SUPPLEMENT -1998 -1999 MODELS 17-17
Electrical System

G)Reverse Indicator Light lZV3.4W

(DN e u t r a I I n die a tor Li g ht I 2 V 3 . 4 If
Canada Model onl y
r ,
Canada lIodei (Option) Canada
only Model only
j----, r - - -.,
Accessary Term i nal
Front I Rea r I
Brake light Bra k e l i gh t.
Switch r
------r-r:~ Ta i J / Brake Light
Switch
lZV 8/27WX2

____________ J
L

~ ~~
~
~

I I
,- - -- , Ta i l l i g h t
12V 81 X2
~
';;;
O~
-ltD
~ ~
~
BL-D
r- B K I Y--CJ<J-B K / Y

I 1 - R---c::kJ-- R

..,
~

) 0
._<

r
Q. '0
SM

n, ~
,
~

~n ~
~

11l ~ ~
~~ ~~ ~
~

~
(+) (- )

Battery

i~~i o
12V19AH

I g ni tion
l!: __ ::!J 12V14AH(U. s. A. Model)
Starter Re lay
Co i I Starter
Circuit
Relay

Starter Motor
Co lor Code
BK Bl ack
Spark Plug BL Blu e
BR Brown
CH Chocolate
OG Di r k Oraon
G Green
GY Gray
LB Li c ht 8 1u.
LG Licht Oroon
IU" ' OI " 'I e. o... HI IO U HU1Ul
HVEHE SII' eM cowuel IO~S
0 Orange
Color BR " G , P" s i t i .. n LG Ground RI. P Pink
OFF ," th . . ",h
'" PU Purple
ON Neutral
.- . " R Rod
Reverse
(9805 1-17578 )
Y White
Ye I low
(98051-1758B)
(98051-11598)
IIRI757BW5 C
17-18 SUPPLEMENT -1998 - 1999 MODELS
Electrical System
Wiring Diagram (KLF300B-11, U.KlEurope Models)

(DReverse Indicator Light 12V3.4W

(DNeutral In dicator l ight 12V3,4111

I gnition Neutral /Reverse

Coo Ii" g F," S. i 'h =:: ===Er::v~'""~.~~0-)+~=~

F use SA
Switch Sw i tch

<J--B K I y-++h

/BK-l>CJ-R/BK---
K ( 'f--C:::D-B K / Y
RI Y -c::J<J- RI Y
Headl ight
IlV2S /25 W
(L H)

Pickup Coi I
Alter n <ltor

Left Handlebar Switch

(DLight/Dimmer Swi teh
(DEngine Stop Switch

CD CD (DStarter Button

LE FT HAND LEBAR SWITCH CONNEC T IONS

light / Dimmer Switch En,ine Stop Sw i tch Starter Button
Co I or R/Y R R/BK BR Color BR Y/R Color VIR BK
OFF OFF Release
La
HI RU N
-- Push ~-=>

1111671A15 C
 SUPPLEMENT - 1998 -1999 MODELS 17-19
Electrical System

UK Model
,-------- - - - - - - - - -- - - -..,
I
ICarburetor
1
Thermo Sensor I Cnntrol Un i t I I
Accessary Terminal

-iii
I

l~ ~ 1~~~
1
1 ..... lI: ......................

I: BK/{[E/R~H~~
L -
1
1
~
1
1
1
"--BK/Y
LI-i>D--I

Carburetor
Heater 12V23W
-BK
BK /Y

BKl
I

l~l
!::Io::
;;;1
1
r T8 i r Li g ht s
""'<>:: .......
0:: 1 I2V BWX2
1 ,- ,, ' - - - ~

"""""'I~!iIi ~~:
~ ~
-'""""""' ~
1 -BK I Y-D<J-BK I Y
Heater ,R --cJ<J--R
1 Relay
1
I I ,
~

~
1 I I
1
- l!:: __ ::!J ;:;:::1
~ ~ 1 ~

L - - - - - - - - - - - - - - - - .., I

1
'-,
1
~ ~<
,
0
If

r
OM
1 .-
1
1
~

1 1

'--n
I
~
1
,
~

1 ~

~lJ
~
-

-,n ' mr II
1

,
~
~
I
1 ~,
~

~~ ~

#if'
~
~ ~ I I ~

l!:: __ ::!J

~t:
('I (-)

* ~
~
Battery
~-;;;;::. , J St.t., 12V\9AH
Circu i t ~
II TI ,
;;;j
~
> 0:.
~::;:"""' ' ' ' ' I
T~1'i'
1

~~
Relay 0
w.m
T r .............. Starter Rei ay
~~
1
Regulator i Igniter 1

~
Rectifier
1
1
J
Color Code
~~/;-- Starter Mo t 0 r BK B I a c k
Y/ R

~
Bl B I u e
I gnition
....
COl I
_- - -- - - -- BR B row n
CH Chocolate
DG O. r k Gr .o~

~~"~""~,,
G Gr e e n
GY G"
lB l i ,ht 81"e
Spa r k Plug lG l i .h t Gr n
ION I T I ON Sl lle H eO N"E crrOiS HUIUl l un.a Si lleR CO HIIO H$ 0 Orange
Color BR I W GY Il , P o. i t ion lG IGr oun d . /1 P Pink
OFF I" lh.6U,h St h
I PU Purpl e
ON Neu tra I
Rel/erse 'od
I White
Y Ye I low
( 98051 -167 1A )
(98051-1672A)

IIRI871AIS C
17-20 SUPPLEMENT -1998 -1999 MODELS
Electrical System
Wiring Diagram (KLF300B-12, U.KlEurope Models)

(DReverse Indica t or Li gh t 12V3 . 'II

0Neutral In d ic a t o r Light 12V3.4II1'

Ign i tion Neut ral / Reverse

=:: ===~\.:C:'~:""~()-~=~l Sw itch Switch

Cool; "g F," S.;, h

Fuse 5A
Q
: ':~'~: I':" &=n-c=-n
(' H }/BK-{>c}-' / BK~ ' / BK-f>C}-' / BK -
s1
~~
~M
Option
K I 't-{:::>CJ-B K I
' I V -c:J<}- ' I V"
K I -!>CJ-lI K I 'I--
' I v CJ<}- ' I V 1 >
, ~

I,~/~"~R / ~~~ ~~
I
I
I','."
.. .1- RI V
HK / --
lIg ht.-
---C2j
V----[>
-- , <}-BK / V 11-fr=~~~bJ=b;;;;~~~~~~~~~g
L.!1 V~ 5!... 6 ~ -c>8----- R

SP"d,m.t'~/ V-c=}<J-BK/VL1-+~+-~~-+4-~~--+---------"
li g h t
-
12V3 . 4 1

I " -{>C}-, I BK-r-r-
K / 't--[:::::O--B K / Y
' I V -c:J<}- R/ V
Headl ight
12V2S / 25W
( l H)

Pickup C oi I
Alternator
Left Handlebar Switch
(D l i g h t / 0 i m mer Sw i t c h
Eng i ne Stop Switch
0S tar t e r But to n

LEFT HANDLEBAR SWITCH CONNECT IO NS

L i ght / Dimlller Switch Enl;n. Stop S.;tch Starter But ton
Colo r R/ y R RI SK 8R Color BR VI R Colo r Y/ R I BK
OFF OFF Rll l el511 .L
LO Pus h
HI 1 RUN

11 Ll7B0815 C
 SUPPLEMENT -1998 -1999 MODELS 17-21
Electrical System

UK Model
r------- --------,
I
,Carburetor Thermo Sensor
Cnntro I Un i ~ Accessary Terminal

~
J ~I~11
[
"IW," IR--;:j f;;~
-BK/Y BK/y ~
Lw-l>C}-w

Carbu r etor
.-BK BKl liT
w
L

L ____
_ _ CCI ___ ,
+-I-__,, Tail lights
Hea ter 12V23W a:::~a::: r _ _ _ _ .~~ 12V g"x2

'- "::::::"\U~II ~s~~::

Rei a y :&~~R~:(~Y~ttj
I
I
I
I
I I L J

I _ I I ~a::1
IL __
l!:: __ ::!J ;;~ I >
- - - - - - - - - - - - --.., I ~
~

w,
I

Starter Relay

Regulator ! I gn i ter I
Rectifier
I
L-_ _ _-----' I
J
Color Code

rr===f-l~~~=:~~=~=-=_=_=_t=_=_J ~ Starter Motor BK Black

lj
BL Blue
Ignition Coi I BR Brown
CH Chocolat e
OG D or k Gr e e n

~"~t,,~~,,
G Gr e e n
GY G ray
lB L ie nt Blue
Spark Plug
IG NITI ON SI IH H CONNECT IO NS NE U TRAl ' REVERSE HITCH CONNECTIONS
lG L i, "t are. n
0 Orange
Color 8R w GY Geu Pos ition LG GrounG R/ W P P ink
OFF PU Purpl e
ON Neutral R R,d
Reverse W White
Y Ye I I 0"
(98051-17608)
(98051-176IB)

11R1760SIS C
 SUPPLEMENT - 2000 - 2002 MODELS 18-1

Supplement - 2000 - 2002 Models

Table of Contents
Foreword.............. ........... ......... ...... ........ ...... ........ ....... .... .... ........ ..... ... ... .... .. .... ....... .. ..... ....... 18-2
How to Use this Manual......... ...... ..... ... ...... ........ ....... ..... ..... ... .... .... ... ... ...... .... ...... ... .. ..... ... ... 18-2
General Information....................................... .......... .. ............. ....... .......... ..... .............. ............ 18-3
Model Identification ............. ..... ..... ...... ... .. ... ...... ......... ... ...... ....... ......... ....... ........... ... ............ 18-3
General Specification.................................................................. ................... ..... ... .. ............ 18-4
Torque and Locking Agents ... .................... ........ ... .... .. ....... ......... ..... .... ............ ...... ... ....... .... 18-6
Periodic Maintenance Chart.................. ... ... ...... ... .... .. .... ..... ...... . ...... ..... ... .. ..... ...... .... ...... .... 18-7
Wiring, Cable, and Hose Routing ................. ............. ..... .. ............ ......... ................ ..... ......... 18-8
Fuel System... ...... ..... ........ ..... ....... ......... ......... ..... .... .......... .... ....... ... ..... .... .... ....... ......... ... ....... 18-9
Exploded View................................. .............. ......... ..... .... ..... ........ .......... ............................. 18-9
Specification... .... .... .... ............... .. .... ....... ... ... ..... .... ...... ......... ........ .......... ..... .. .... ...... .... ...... .. 18-9
Engine Top End . ... ..... .... ........................ .............. ... .... ....... ..... ........ ....... ... ..... ...... .... ... .... ....... 18-10
Exploded View...... .................. . ........ ...... ........ ......... .. .. ..... ..... ........ .. ........ ........... ........ ... ....... 18-10
Brakes .................................................................................................................................... 18-11
Exploded View (KLF300-B13 - ) ...................................................... .................................... 18-11
Frame.......... ............. ................................................................. ........................................ ... .. 18-12
Exploded View (KLF300-B13 -, UK/Australia Models) ..... .. .............. ..... .... ... .... ................... 18-12
Electrical System. .... .............. ..... ... ........... ............ ....... ........ ...... ...... ............... ....... . ..... ... .... .... 18-13
Exploded View (KLF300-B 13 - ) ............... ..... ......................... .... ... .......... ............ ......... ... .... 18-13
KLF300-B13 - B15 Wiring Diagram (U.S.A Model).................................... ........... ........ ...... 18-14
KLF300-B13 - B15 Wiring Diagram (Canada Model)....................... .. .... .. ... .. .. ............... .. ... 18-16
KLF300-B 13 - B 15 Wiring Diagram (Australia Model) . .... ....... ....... ... ............ ... .......... ... ... ... 18-18
KLF300-B13 - B15 Wiring Diagram (U.K Model) ........ .... ................... ....... ..... ....... .............. 18-20
KLF300-B13 - B15 Wiring Diagram (Europe Model)........................................................... 18-22
18-2 SUPPLEMENT - 2000 - 2002 MODELS
Foreword

How to Use this Manual

This "Supplement 1998 - 1999 Models" designed to be used in conjunction with the front part of this
manual (up to 17-20) and/or Base manual KLF300 Service Manual - Part No. 99924-1057-01.
The specifications and maintenance procedures descried in this chapter are only those that are
unique to the KLF300B13 - B15 models.
Complete and proper servicing of the KLF300B 13 - B 15 models therefore req uires mechanics to
read both this chapter and the front of this manual.
 SUPPLEMENT - 2000 - 2002 MODELS 18-3
General Information

Model Identification
KLF300-B13 Left Side View

KLF30D-B13 Right Side View

18-4 SUPPLEMENT - 2000 - 2002 MODELS
General Information
General Specification
Item KLF300-B13-B15
Dimensions:
Overall length 1910 mm
Overall width 1115 mm, (EU, UK, AS) 1160 mm, (B15 ~ ) 1160 mm
Overall height 1065 mm
Wheelbase 1210 mm
Ground clearance 195mm
Seat height 750mm
Dry weight 226 kg, (EU, UK, AS) 229 kg
Curb weight: Front 109.5 kg, (EU, UK, AS) 110 kg
Rear 126.5 kg, (EU, UK, AS) 129 kg
Fuel tank capacity 9L
Performance:
Minimum turning radius 2.9 m (Locked axle mode)
2.6 m (Differential mode)
Engine:
Type 4-stroke, SOHC, l -cylinder
Cooling system Air cooled
Bore and stroke 76.0 x 64.0 mm
Displacement 290 mL
Compression ratio 8.6
Maximum horsepower 14.3 kW (19.5 PS) @6500 r/min (rpm), (US)-
Maximum torque 22.5 N m (2 .3 kg m, 16.6 ft lb) @ 5500 r/min (rpm), (US) -
Carburetion system Carburetor, Keihin CVK32
Starting system Electric starter & recoil starter
Ignition system Battery and coil (transistorized)
Timing advance Electronicallyadvenced
Ignition timing From 10 BTDC @1300 r/min (rpm) to
30 BTDC @ 4000 r/mim (rpm)
Spark plug NGK DR8EA, (EU , UK) DR7EA
Valve timing: Inlet Open 21 BTDC
Close 59 ABDC
Duration 260
Exhaust Open 56 BBDC
Close 24 ATDC
Duration 260
Lubrication system Forced lubrication (wet sump)
Engine Oil : Grade SE, SF or SG class
(B15 ~ ) API SF or SG
API SH or SJ with JASO MA
Viscosity SAE10W-30, 10W-40, lOW-50, 20W-40, or 20W-50
(B15~ ) SAE5W-30, 10W-40, 1OW-50, 20W-40 or 20W-50
Capacity 1.7L
 SUPPLEMENT - 2000 - 2002 MODELS 18-5
General Information

Item KLF300-B13-B15
Drive Train:
Primary reduction system: Type Gear
Reduction ratio 2.888 (78/27)
Clutch type: Primary Auto centrifugal, wet
Secondary Auto multi disc, wet
Transmission: Type 5-speed plus reverse, constant mesh, return shift
Gear ratio 1st 3.090 (34/11)
2nd 1.928 (27/14)
3rd 1.368 (26119)
4th 1.000 (23/23)
5th 0.769 (20/26)
Reverse 3.072 (26/11 x 26/20)
Final drive system: Type Shaft
Reduction ratio 4.886 (20/16 x 43/1),
(EU , UK, AS) 5.584 (20/14 x 43/11)
Overall drive ratio: 10.858 @Top gear, (EU, UK, AS) 12.409 @ Top gear
Final gear case oil: Type API GL-5 Hypoid gear oil SAE90 (above 50 C, 41 F) or
0
SAE80 (below 50 C, 41 F)
0.35 L
Frame:
Type Double tubular
0
Caster (rake angle) 3.0
0
Chamber 1.0 @ 1G
Trail 13mm
Tread Front 834 mm
Rear 844 mm
Front tire: Type Tubeless
Size AT 22 x 9.00-10
Rear tire: Type Tubeless
Size AT 24 x 11.00-10
Rim Size: Type 10 x 7.0
Size 10 x 8.5
Suspension: Front Type Double wishbone-link
Wheel travel 125 mm
Rear Type
Wheel travel
Brake type: Front
Rear
Electrical Equipment:
Battery 12 V 14 Ah (EU, UK, AS) 12 V 19 Ah
Headlight: Type Semi-sealed beam
Bulb 12 V 25/25 W L & R
Reverse light (EU , UK) 12 V 10 W
Tail/Brake lights 12V8/27Wx2
Alternator: Type Three-phase AC
Rated output 23.5 Al14 V @9000 r/min (rpm )
Voltage regulator: Type Short-circuit

Specifications are subject to change without notice, and may not apply to every country.
EU: Europe Model, UK: U.K. Model, AS: Australia Model, US: U.S.A. Model
18-6 SUPPLEMENT - 2000 - 2002 MODELS
General Information
Torque and Locking Agents

Torque
Parts
N-m Kg-m ft-Ib Remarks

Engine Left Side:

Alternator rotor bolt 59 6.0 43
Starter clutch Allen bolts 34 3.5 25 L
Recoil starter flange nut 8.3 0.85 74 in-Ib

L : Apply non-permanent locking agent to the threads.

 SUPPLEMENT - 2000 - 2002 MODELS 18-7
General Information
Periodic Maintenance Chart
The scheduled maintenance must be done in accordance with this chart to keep the vehicle in good
running condition. The first service is vitally important and must not be neglected.

First Service Regular Service

A~'''"~~:~:~~
.=Clean, adjust, lubricate, tighten, or
replace parts as necessary. of use "., a- "., a- "., a- ".,
7o0'11-~'o 0
l0'11-~'o
000
l0'11-~'o la-,,OJ See
Page
Engine:
*
Air cleaner--service
Clutch adjustment *
27
5-3
Valve clearance--check
Fuel system cleanliness--check * 3-6
(2-10)
Throttle lever play --check
Engine oil--change *
(2-4)
(5-11 )
Oil filter--replace *
Spark plug-clean and gap

(5-11)
(14-17)
Spark arrester--clean 3-11
Chassis:
Rear brake adjustment--check *
Rear brake lining wear--check *
(10-6)
(10-6)
Front brake pad wear--check *
Brake fluid level--check
10-7
(10-8)
Brake fluid--change
Cable adjustment * (10-8)

**
Battery--check 14-6
Steering play--check
General lubrication * (126)
15-4
Bolts and nuts--tighten
Final gear case oil--change *
15-4
(9-6)
Master cylinder piston assembly and
2 years (1011)
dust seal--replace
Caliper piston seal and dust seal--replace 2 years 10-6
Brake hose--replace 2 years 109

* :Service more frequently when operated in mud, dust, or other harsh riding conditions .
* *: Refer to 2, 7, 9, and 10 chapters.
(xx-xx): Reference Page in the Base Manual
18-8 SUPPLEMENT - 2000 - 2002 MODELS
General Information
Wiring, Cable, and Hose Routing
Breather Tube Assembly (California Model)

LF300B0 1W4 C

1. Clamp 10. Carburetor

2. Clamp 11 . Install the clamp so that the clearances between
3. Clamp the tube and near parts are more than 5 mm .
4. Tube (10 Cylinder Head)
5. Joint
6. Tube (to Air Cleaner Assembly)
7. Air Cleaner Assembly
8. Cylinder Head
9. Cap
 SUPPLEMENT - 2000 - 2002 MODELS 18-9
Fuel System
Exploded View

California Model
Kl3801 W2 C

Specifications
Item Standard Service Limit
Carburetor:
Make, type Keihin, CVK32 - --
Main jet #125 - --
Main air jet #100 - --
Needle jet #6 - --
Jet needle N74T - --
Pilot jet #38 - --
Pilot air jet #140 - --
Pilot screw 2 1/8 turns out - --
Starter jet #65 - --
Service fuel level (from carbu retor 0.5 mm (below) - 1.5 mm (above)
- --
body bottom edge) (CA) 1.5 mm (above) - 0.5 (below)
Float height 17 2 mm - --
Idle speed 1 300 100 r/min (rpm ,) - --
(CA) 1 300 50 r/min (rpm)
Optional parts:
Main jet #120, 122, 128, 130 - --
Pilot jet #35, 40 - --
Starter jet #68, 70 - --
CA: Californian Model
18-10 SUPPLEMENT - 2000 - 2002 MODELS
Engine Top End
Exploded View

,--- - ---
I

-- ~
Cal ifornia Model
XUII02 .s C

1. Manual Compression Release

L : Apply non-permanent locking agent.
M : Apply molybdenum disulfide grease.
o : Apply engine oil.
R : Replacement Parts
T1 : 29 N-m (3.0 kg-m, 22 ft-Ib) for used parts
34 N-m (3.5 kg-m, 25 ft-Ib) for new parts
T2: 12 N-m (1.2 kg-m, 104 in-Ib)
 SUPPLEMENT - 2000 - 2002 MODELS 18-11
Brakes

Exploded View (KLF300-B13 -)

S i \-----1
Vr-----{T2

HL020UBIJ C

1. Brake Switch
2. Boot
Si: Apply silicone grease.
T1: 1.0 Nm (0.10 kgfm , 9 inlb)
T2: 5.9 Nm (0.60 kgfm , 52 inlb)
T3: 1.2 Nm (0.12 kgfm, 10 inlb)
T4: 8.8 Nm (0.90 kgfm, 78 in.lb)
18-12 SUPPLEMENT - 2000 - 2002 MODELS
Frame
Exploded View (KLF300-B13 -, UK/Australia Models)

eo

H002043B12 C

1. Shovel Holder
 SUPPLEMENT - 2000 - 2002 MODELS 18-13
Electrical System
Exploded View (KLF300-B13-)

A }-----1

HPOl062BU C

1. Bulb (27/8 W)
2. Bulb (10 W)
T1: 7.8 Nm (0.8 kgfm , 69 inlb)
A: Europe/Australia/UK Models (UK Model Apply for KLF300-B13-)
B: UK/Europe Models
 18-14 SUPPLEMENT - 2000 - 2002 MODELS
Electrical System
KLF300-813 - 815 Wiring Diagram (U.S.A Model)
(DRe,erle Indicator
Nlutrl ' Indic;ator
Neutral/R".r
Iinilion Switch
Fr
S. i 'C h Li ,

Hlldl i ,hi
12V25/25W ~

(RH) CIllR/BK--t>D-R /BK- R/BK~R/BK---- ~

R/Y -{>C]-- R/Y R/Y --{>O-R/Y - "- '"

m I I
BK/Y ---c:J<} BK/Y.- I- BK/Y-D<f BK/Y 1 '"
m

~
~,
~ ~~

"''''

~
R/B K---{:>C}-R/BK l- I-

Hlldli,hl
12V25/25W
(L H)
CIll
R/Y--c:>D-- R/Y I-
BK/Y ---CJ<}BK/Y

~ '" '"
,a::Dla::,~
a::: ~1D,.m
'"m
~~~
#
~
m m
'"
I

[
L-------'Pic:kup Coil
AI t.rnalor

LEFT HANDLEBAR
LIft Hlndl,bar Switch l(rht/Dlmmor 50 It. h
Color R/Y R R/BK BR
CDLI,ht/ Olmm.r Switch OFF
QUE"'ln. Stop Switch LO
HI
I~
I
@Start.r Button '------!
 SUPPLEMENT - 2000 - 2002 MODELS 18-15
Electrical System

Idle.tor Licht 12V3.4W

Idlcltol Licht 12V3.4W
Rlar Br ake
Lilht Switch
Accesl.', Terminal
Front Br,lt ,

2)~
Lieht Switch

OJ
~ H
~1
., .,
~Tail /Brak,
I~
., .,'"
~

~~
L ic hte
2V 8/27WX2
., ., BL---D<J- BL /
.,
~

'" r- BK / Y ~ BK /Y L~
.rR---c:::J<J-R
\ a
.,
';' '"
~
'--
I
W-

c
--
~
~

/ c

C$ -c
_0
"'~

~ ~ ~ ~ ~
n n. .,,,,
"''-
i!il!!ilIII!I

II}
Bat lery
12V14AH

'enlllDn
c ,I I Stlrt,r R,la,
Starter
C Ire u I t
Rl lul,tor/ Ril,y
Rlctlfi,r
Co lor Cod,
I,nit" M BK Blaok
p Co i I BL Blo,
BR Bro wn
St 'rt, r Motor ,
CH Chocolate
DB hr. a"l.

Splrk PIUI G 6rt.n

BY GrlY
LB Lilli! III ..
LG Lis ., Gr . . .
HDLEBAR SW ITCH CONNECTIONS I . . ITID' lTc r CD.neTI.n IEur_AL I REYERIE ITCN CO,.EeTIOI. o Orin"
It, h It., Stul,r Button Color BR W a , P .. ltI,n La R/W

-
En, ' n Swllc' 9r nll P Pink
BK BR Color BR Y/R Color Y/R BK OFF Ur . . . . 5 ..
'"N,utra' PU Purpl.
OFF R,I, II. I ON R R,d
Pu." Rlv,r W Wh It,
. .-;> RUN I I Y l,ll ..
(98051-1860A)

lnOClllllAJ C
 18-16 SUPPLEMENT - 2000 - 2002 MODELS
Electrical System
KLF300-813 - 815 Wiring Diagram (Canada Model)
(DR"'rlt I"dle .tor Lie
Op tion 0N,utral Indicator Lie
1- - - - - - - - - - - - - - 1
, H.utrII/Rt,r
S.II, h
Caal II ~'n i t ion S. it c h

t
Front
Fin S., teb
--l l i I ht !

I
CD

.- .- ,. ~

r
~
..... .,
IE CJ:':
..... ..... ClIIE
.,
.,
Y
Y
R/Y-{>O--R/Y-
BK/Y-cJ<J-BK/Yl '" '"
.,
1 '"I '"I
L

~
,......
~~~
., '" ~>:

(jD;
~
/BK--C>CJ--RI BK

He.dli,hl
R/y---t>CJ--RI Y
B KI Y---c::::J<:J---B KIY
,a:::
~ '"
IE ~ID>-m
'"
ID a:: ........ ::.::
.,'" #1 *
~
12V25/25W
(L H)
~~~ ~ '" ~ >- :

Jrrh'iJ
OFF'
'~ __HI'L-l "
AI t.rnttor
Pickup Call

CD
Le ft Hlndllb,r Switch
(DLilht/Dimm.r Swlleh
illEn,ln. Stop S.lleh
CDS rttr Button
 SUPPLEMENT - 2000 - 2002 MODELS 18-17
Electrical System

t.r Licht 12V3,4W

t.r Licht 12V3,4W

Re i ' Br,k.
Lilhl SWi t ch

~
Front Br.k.
Licht Swlt .. h

~ . ~~
ACCls"" Terminll

~ .,
m m m
IC

~~
T, II / Bra k. llcht .
12V 8 / 27W X 2

~
,., .,
BL ~ BL
r- BK/Y ~ BK/Y II
1\
---
"!
e
i
~
m - R ----D<l- R
i m '-

W-

fC:"\ ~
~
. ...
~
Q

-.
~~

:E
~'
~

11l >
"'
> ~
~
..n "' a:: C!' :.::
n
~
'" >

1+1
~
~

I-)
Bttt.r,.
12V19AH

I, nit Ion
Col I Stut., R.I.,
Slarter
R'lul.tor/ Circuit
R. J.)'
R,Cllfl.f
I ,n it, J
I I Color Cod
Start.r Motor BK BIIOk
BL Blu.
BR Brown
SPlrk Plu, CH Chacal_1I
DG Darll; Grltn
G Gr n
BY Gr"
LB lIH' 11111
LG LI,1Il Gr .. .
'"ITIOI .WIT el COllECT IOU 'E~l'AL l RE'EIIE 'WITCH CO"EeTla o Orlnl'
Color BR I W a r PD. 1 t I all LG 18, .. ,,4 R/W P Pin k
OFF 111 """' su I PU Purple
ON N.utral R R. d
R.v., -' \I Whit.
Y y,llow
(98051-1861A)
LfUOIUU
 18-18 SUPPLEMENT - 2000 - 2002 MODELS
Electrical System
KLF300-813 - 815 Wiring Diagram (Australia Model)

(DRIV.r ladle.tor Lie

0Ntutr,1 Indlc.tor Ltc

N. u t r a I /R. , r I
S.I tch Frol
l enition Bnl

'n ' ij
Cool inl Fan

~
Sw I t co h

Cool I", Fin

W=
BL---!:>D-
__ BL - - - - - - ,

,~ '"I
H,.dllrht
12V25/25W
(RH)
~~
,
~~ ~~ H~ ~
III:': ~........
'"
.......
'"
-"CD ca

@, /BK--f>D-R / B K - -RIB K-{>c:J-RI B K -

I I
L
~

R/Y-t>CJ-- R/Y R/Y--f>D-R/Y- ~ '"

Option
BK/Y--CJ<J--B K/Y BK/Y-CJ<J-BK/Yl '" '"
It
\
j )--.---R/B-::{::l
:-" - R/Y----C:> I
t ,.... ....... I
J----B/Y---~ ,
Iwork Lllhl r- -~-:::J
Li~V_65/6~~~ <J-BKI Y

@'r)-- R--t>B- R
Speedometer
Li I h-I
L BK/Y --C!<:J-BKI Y
12V3.4W

'" ~'"'
~~~ J' >- >-:

,-11. ~ ~
R/BK---c>D R/BK I-
R/Y-!>CJ- R/Y

*
BK/Y---CJ<} BK/Y
Htadlllhi ~

..
>< '"
........ 1E 1D1E , : . :
12V25/25W ~ID>-m ~~~ J>< >- >-:
(L H) "'

III
~Loi
I
b Horn
~12V l.5AAllorn.lor
Pickup Coil
G
OFF: HI' :~' rr-h
~
CD
__ ~l
CD
:11:
CD L -UJHorn Bullon

Left Hlndl.b.r Switch LEFT HANOLEBH

CD L II hi 10 I mmer So I I c h Licht/Dimmer Swllch
Color R/Y R R/BK BR
Enllnl Stop Switch OFF
0SlIrt.r Button LO
HI
~
 SUPPLEMENT - 2000 - 2002 MODELS 18-19
Electrical System

or L II hi 12V3 . 4W
or Lie hi 12V3.4W
Rear
Brake Lilht
S. it c h
Fro n t
Brat, Lilht
Sw i t c h

6
ti
.,~ .,'"
.,~ .,'"

~~
Accesli.ry Terminal

~l
., .,'"
~

~
.,'" ~~ .------B L--c:J<J--B L-"-H+""
r s:
.---- Tai I/Brlt. Licht

i
- BK/Y-D<J-BK/Y 12V 8/21WX2
'"
i .,
~ r R --CJ<J-- R----'.-'.;;:-
\ ="l
'-

------rr.-------~----------------_+~_r----rt----------W -

(t) H
8.tt,rl
12V19AH

I,nI I Ion
Coli St.rt.r
SlIrt.r RallY

R"ul.tor/ Circuit
R,ctlfl.r R,II,
lin It. r
Color Code
BK Blick
St.rt.f Motor BL BI u 0
BR Sf awn
CH Chocolat,
Spark Plul DG Duk Grn.
G are,n
GY Gr BY
LB LI,u Blue
LO LI.hl areen
.EBAR SWI TCH CONNECTIONS
h hll'" St., S_lha. Stlrt,r Button
"lIT I 01 '11 Tel CDIIUT tall

Ca I 0 J BR I W
IEUTIAL l REvellE 'W ITe" CO"EeTIOI,
e r P"III,. LO 18, .... 11 R/W
o
P
OrIn,.
PI nk
BR Co lor BR Y/R Colar Y/R BK OFF lit Ur 111 5111 I PU Purplo
OFF R.I .... ON N.utr.1
R Rod
.,
II)

RUN
_L p" h RIVlr I
(98D51-1862A)
W Wh It 0
Y V,llow
LfJDD80UI C
 18-20 SUPPLEMENT - 2000 - 2002 MODELS
Electrical System
KLF300-B13 - B15 Wiring Diagram (U.K Model)
CD R,VlrI. Indicator Lilt,
0 N,u t f l l 'ndlcator li, ~

I,nition Switcb
C.rb
Neutr.I/R,Ylrs.

==::===~C"~~==~l
S. i t c h
Cool inl Fan Swich

Fuse SA KO 1/2W

Coolin.

Heldll,ht
Fan
toe = - _ B_L ------:>~ ! ~~
~ ~ ~~
12V25/25W
(R H)

(ID; /BK-t>CJ-R/BK -
R/Y---t>CJ-R/Y
R/BK{>C}-R/BK-
R/Y -!>D-R/Y-
>
~ ~
9
BK/Y-CJ<]-BK/Y r- - BK/YCJ<::]-BK/Yl '"
Opt Ion I
It
I \
j )-i--R/;K-=C;:l
}--- R/Y- ---:> I
j - B K/Y -.."----' I
Iwork Li-; h l r - - -~-~ -<}-BK/Y-l-++---1
[1_2~65/~~!J --r>B--R

sP"dom'I'~~Y~BK/yL4-+~---+-+~1-~-+~---~-~~-~
. LII h I
12V3.4W

(ID; / BK-t>CJ-R/BK-
R/Y---t>CJ-R/Y -
BK/Y-CJ<]-BK/Y-
H.ldlllni
12V25/25W
(L H)

1
PI ckup Col

H0 r n
12V1.5A

lift Handl.bar Switch

Spa
(D li,ht/Dimmtr S.llch LEFT HANDLEBAR SWll
Enllnl Stop Switch Lllhl/Dlmmor S.I ten EI,I
Color RIY R R/BK BR Colo
0S1.rt.r Bultoll OFF I OFF
Horn Button
LO
HI I RUN
 ~E_~le~c~tr~ic~a~I~S~Y~SlEt~e~m~==========S=UU~PPLEMENT
=
" u, .. "" ====~~-=2=OO=O~-~2~~~~~~~1
002 MODELS 18-21

or L 4W
;(hI12V3 , 4W

Carburetor Thermo SenBor

'" ,.
BK/mE
K/R~~,.~~~
'" '" ~
~W BK~/~Y====--~-+~--
W BK/Y B

Ca,bu' ttor BK
BKl 1
W Tai!/Br.kl

~~
He.t,r l 2V23 LI I h t I
12V 8/27WX2
.[Pl >- ><

~ '" fl
.. ,., ""'1lJilil
HI.ter
R,I.,

-,
"
::!J
I
I

~
I
I

LI h I
OW
I W-
-

--,

l
-

(II 1
SI.lor V~ Blttefy-I

IF~~~~~JI
C ire u i t :!IBR"'"
12V19AH
R,I., I-""" ~

Starter R. I 8 Y
I ,n it, r
R.(ulator/
Recti!'lor
J
M
kup Coil
---L rn I ---Ll_ Color Cod. l
r;=---r~~ B/W _ _ _
YI R ---________---.J==~
Starter lIIotor
I' = II BK Black
BL Blul

U
~ enltion Cui BR Brown
~:
. G
Chocollt
Duk Brltn

~~~~""
Gr n
6Y Gr.y
LB lI,hl 81
Spark Plu, La lI.1tt a ..
~ o
COIUECTI~
rlill
~R SWITCH CO 1&111110/11 ,WITCII CONNECT I ONI ~ REVERIE Oranr.
EIIIII. St NNECTIOHS a'if POIIIII ITCH
i Colo It,BR ,.Ihll St Color BR W' BY 'Itn" ... 5UII LB II 11111.1 R/W P Pin k
~
Off' Y/R C:;'lor YIR
0' Bullon
B OFF I PU Purpl,
R.I'... K ON
Noultll -T R R,d
I Pu.h Rlv,r.. I W Wh I I.
-'
RUN Y Y,llow
198051-186 3A)
Lf300a04,U C
 18-22 SUPPLEMENT - 2000 - 2002 MODELS
Electrical System
KLF300-813 - 815 Wiring Diagram (Europe Model)
Ignition Switch

Neutrai/R e yersl
5.1 Ie h

Fuse 5A.

Cool inl Fin BL-I:>CJ-- Bl - - - ----'

H,adlirht
12V25/25W
(R H)
"' ~ ~
""

OOJ L~~
R/B K--J::>L:J-R/ BK R/BK~R/BK ---- >

Op I Ion
R/Y-----{>LJ-R/ Y
B K / y-CJ<J-- B K /Y
R/ Y-----{>LJ- R/ Y -
K/ Y-cJ<:}- BK/ Yl . '"
"-
><
~

~~.'-. R/i"K ~:-;:l .-

I{ t-- R/Y ----C:>
I
I . ..r.. BK/Y -;::~ <}- BK/ Y
I~ork Lilhtr- - -
U_2J65/~~!J R---t>B--R

SP.o d.n"~/Y-c::J<J-BK/
L I I hi
Y
12V3.IW
-
.
~

.
>
~
"-
>< > ~"- >
.. ><
r-
OOJ R/B K--J::>L:J-R/ BK-
R/Y --t>CJ- R/ Y-

~ 0 ~ ~
.... i
BK/Y-cJ<:}- BK/ Y-

H.ldJilht > >< ~ > H0 r "

1. 5A ~ ><
12V25/25W >->->- >
(L H)

AI t.rnator
Pickup Coil
L
L.ft Hlndl.b" Switch
LEFT HANDLEBAR SWI -
(Dlilht/Dimm.r S.ltch Lllht/Dlmmer S.I t c h el ,lI..
Color R/Y R RI'BK BR Colo
<!lEnll Slop SWlteh OFF OFF
(!)sta rt.r Button LO
HI RUN
 SUPPLEMENT - 2000 - 2002 MODELS 18-23
Electrical System

(DR".r Indi cator Lilill 12V3.4W

0H,utral Indic ator Lilh! t2V3.4W
$I Ace ry Terminal

~B"k' LICh~.ar
Brake Lllht
'"'2 Front
\V S.I tch H S.i leb

M
CD
~:
T a i 1/8 r I k.
L I ,h t

. 12V B/27WX2

~ ~~.
m ~
B L ----c:J<l- B L
~
m '" ( -~
-BK/Y~BK/Y

~~.. '"
r-R---c:::J<J---R
'--
~
'- ~..,
'" ~
..,
'"
i i ~
i
I
'"
I -
R1w--c:J<J-- RIW
B R ---c:::J<J--- B R I~
R ",r Ll,ht
W- 12VlOW

--
~
~

~'"
0
C~

,-
-
.
~

- - ~
- n n. ~
III
~

1-)
Battery

..
~
.., .. 12Vl9AH

I ( nit ion Start., Rill'

Co i I Stat.r
C ire u i t
R'cuiltor/ RelaY
Rlcl i f i"
Iiniter

) Co I I Color Cod.
St.rter Mo tor BK Black
BL B I",
BR Brown
Spark Plug CH Chocol,t,
. DG Dart 8'fI"
G G r I. n
GY Gra,
LB lI,lIt Blut
La lint a".n
AR SWITCH CONNECTIONS IGNITION .W ITC" COllECTIONS IEUTRAl REYEalE .W ITCH CO.'ECTIO.' o Orin
ED,I", StD, S.lld Start.r Bunon Color BR I W I OY Stat POll I hll LB BrDUII4 R/W P Pin k
Co lor BR I Y/R Color Y/R BK OFF I I III I . " . . . 51. PU Purpl,
OFF I R,I, , ON Neutral R RId
I PUlh <;- I11III[) Re,., I W Wh I t I
RUN ~ Y Y'llow
(9BOSI-IB6H)
LfaGGIIOIU C
 SUPPLEMENT - 2003 - 2006 MODELS 19-1

Supplement - 2003 - 2006 Models

Table of Contents
Foreword ......... ... ........ ............. ............ .... ... ....... ..... ..... ........ .......... ............. .......... ....... ........... 19-2
How to Use this Manual........................... ................. ... ..... ......... ....... ....... .. .. .... ... .... ............. 19-2
General Information.............. .... ... .. ............................... .......................................................... 19-3
General Specifications........... ............ ........ .. .. .......... ....... .... .............. ........ .......... ........... ...... 19-3
Fuel System......................... .. .... ........... ........................ .......................... ....... ......... .. .............. 19-6
Specifications........... .. .. ... ...... ........ .... .................... .. ...... ...... ....................... .......... .... ............ 19-6
Engine Right Side.................... ............. ........ ............... .......... ............... ........ .. ........ .. ... ........... 19-7
Specifications............ ............... .. ....... ..... ............................. .. ............. ...... ............ ...... .......... 19-7
Engine Oil and Oil Filter................... .............. ... .. ........ .... ...... .............. ........ ............... ........ .. 19-7
WheelslTires................................ .. ........ ....... ....... .......... .......... .............. ......... ... ..................... 19-8
Front Hub.... .......................... .. ....... .... ..... ........................ ....... ..... ................. ......... ..... .... ...... 19-8
Front Hub Installation ............. .. ... .. ........ ................................... ......... ............................... . 19-8
Rear Hub ............................................................................................................................. 19-8
Rear Hub Installation ........................ ....... ................ ............ .. .... ....... .... ...... ........ .. .. .......... 19-8
Brakes................................... ... ......... ..... ..... .. ....... ...................... ............ .......... ........ .... .......... 19-9
Exploded View...................................... ....... ...... .. ... .. ................ .. .......... ............................... 19-9
Frame... ..................... .......... .................... ........ ................ ....... ..... ...... ...... ....... .......... ........ ...... 19-10
Exploded View .... ......... .. .. ......................................................... :..... .. ... .. .. .... .... ..... ............... 19-10
Electrical System............... ................. .. .... .. .. ........ .......... ............. ........... ............ ....... ........... .. 19-11
Exploded View............................................... .. .............. ............ .. .... .. .... .......... ........ .. .. ........ 19-11
Wiring Diagram (U.S.A. Model) .............. ...... ... ...................................... ........... ....... ............ 19-12
Wiring Diagram (Australian Model)......... .. ......... ...... ....... ......... .............. .......... .... .... ...... ...... 19-14
Wiring Diagram (European Model) .......... ........... .. ............ .......... .. .......... ........... .. ................ 19-16
Wiring Diagram (U.K. Model).............................................. .................... ..... ............ ............ 19-18
19-2 SUPPLEMENT - 2003 - 2006 MODELS
Foreword
How to Use this Manual
This "Supplement 2003 - 2006 Models" designed to be used in conjunction with the front part of this
manual (up to 18-23) and/or Base manual KLF300 Service Manual - Part No. 99924-1057-02.
The specifications and maintenance procedures descried in this chapter are only those that are
unique to the KLF300-B16 - B6F models.
Complete and proper servicing of the KLF300-B16 - B6F models therefore requires mechanics to
read both this chapter and the front of this manual.
 SUPPLEMENT - 2003 - 2006 MODELS 19-3
General Information
General Specifications
Item KLF300-B16 - B6F
Dimensions
Overall Length 1 910 mm
Overall Width 1 160 mm
Overall Height 1 065 mm
Wheelbase 1 210 mm
Ground Clearance 195 mm
Seat Height 750 mm
Dry Weight 226 kg , (AS, EU, UK) 229 kg
Curb Weight:
Front 109.5 kg, (AS, EU , UK) 110 kg
Rear 126.5 kg , (AS, EU , UK) 129 kg
Fuel Tank Capacity 9 L
Pertormance
Minimum Turning Radius 2.9 m (Locked axle mode)
2.6 m (Differential mode)
Engine
Type 4-stroke, SOHC, 1-cylinder
Cooling System Air cooled
Bore and Stroke 76.0 x 64.0 mrn
Displacement 290 cm 3
Compression Ratio 8.6
Maximum Horsepower 14.3 kW (19.5 ps) @6 500 r/min (rpm) , (US)-
Maximum Torque 22.5 Nm (2.3 kgfm, 16.6 ftlb) @5 500 r/min (rpm), (US)-
Carburetion System Carburetor, Keihin CVK 32
Starting System Electric starter & recoil starter
Ignition System Battery and coil (transistorized)
Timing Advance Electronically advanced
Ignition Timing From 10 BTDC @1 300 r/min (rpm) to 30 BTDC @4 000 r/min
(rpm)
Spark Plugs NGK DR8EA, (EU , UK) DR7EA
Valve Timing:
Inlet:
Open 21 BTDC
Close 59 ABDC
Duration 260
Exhaust:
Open 56 BBDC
Close 24 ATDC
Duration 260
Lubrication System Forced lubrication (wet sump)
19-4 SUPPLEMENT - 2003 - 2006 MODELS
General Information

Item KLF300-816 - 86F

Engine Oil:
Type API SE, SF or SG
API SH or SJ with JASO MA
Viscosity SAE10W40
Capacity 1.7 L
Drive Train
Primary Reduction System:
Type Gear
Reduction Ratio 2 .888 (78/27)
Clutch Type :
Primary Auto centrifugal, wet
Secondary Auto multi disc, wet
Transmission:
Type 5-speed plus reverse, constant mesh , return shift
Gear Ratios:
1st 3.090 (34111)
2nd 1.928 (27/14)
3rd 1.368 (26/19)
4th 1.000 (23/23)
5th 0.769 (20/26)
Reverse 3.072 (26/ 11 x 26120)
Final Drive System:
Type Shaft
Reduction Ratio 4.886 (20/16 x 43/1), (AS, EU , UK) 5.584 (20/14 x 43/11)
Overall Drive Ratio 10.858 @Top gear, (AS, EU , UK) 12.409 @Top gear
Final Gear Case Oil:
Type API GL-5 Hypoid gear oil SAE90 (above 5C, 41 F) or SAE80
(below 5C, 41 F)
Capacity 0.35 L
Frame
Type Double tubular
Caster (Rake Angle) 3.0
Chamber 1.00 @1G
Trail 13 mm
Tread:
Front 834 mm
Rear 844 mm
Front Tire :
Type Tubeless
Size AT 22 x 9-10
Rear Tire:
Type Tubeless
Size AT 24 x 11 -10
 SUPPLEMENT - 2003 - 2006 MODELS 19-5
General Information

Item KLF300-B16 - B6F

Rim Size:
Front 10 x 7.0
Rear 10 x 8.5
Suspension:
Front:
Type Double wishbone-link
Wheel Travel 125 mm
Rear:
Type Torque tube-link
Wheel Travel 120 mm
Brake type:
Front Disc (hydrau lic) L & R
Rear Drum (mechanical} L & R
Electrical Equipment
Battery 12 V 14 Ah, (AS, EU, UK) 12 V 19 Ah
Headlight:
Type Semi-sealed beam
Bulb 12 V 25/25 W L & R
Reverse Light (EU, UK) 12 V 10 W
Tail/Brake Lights 12 V 8/27 W x 2
Alternator:
Type Three-phase AC
Rated Output 23.5 Al14 V @9 000 r/min (rpm)
Voltage Regulator:
Type Short-Circuit
Specification subject to change without notice, and may not apply to every country.
AS: Australian Model
EU: European Model
UK: U.K. Model
US: U.S.A. Model
19-6 SUPPLEMENT - 2003 - 2006 MODELS
Fuel System

Specifications
Item Standard Service Limit
Carburetor
Make, Type Keihin ,CVK32 - --
Main Jet #125 - --
Main Air Jet #100 - --
Needle Jet #6 - --
Jet Needle N74T - --
Pilot Jet #38 - --
Pilot Air Jet # 140 - --
Pilot Screw 2 118 turns out - --
Starter Jet #65 - --
Service Fuel Level (from Carburetor 0.5 mm (above) - 1.5 mm (below)
Body bottom Edg e)
- --
Float Height 17 2 mm - --
Idle Speed 1 300 100 rl min (rpm),
(CA) 1 300 50 rl min (rpm)
- --
Optional Parts:
Main Jet #120,#122 , #128, #130 - --
Pilot Jet #35 , #40 - --
Starter Jet #68, #70 - --
CA: California Model
 SUPPLEMENT - 2003 - 2006 MODELS 19-7
Engine Right Side
Specifications
Item Standard Service Limit
Engine Oil
Type API SE, SF or SG - --
API SH or SJ with JASO MA
Viscosity SAE 10W-40 - --
Capacity 1.7 L - --

Engine Oil and Oil Filter

Recommended Engine Oil SAE 20W 50
Type: API SE, SF or SG SAE 20W 40 ~
API SH or SJ with JASO MA SAE lOW 50
Viscosity: SAE 10 W-40 SAE lOW 40
Capacity: 1.7 L SAE lOW 30
( SAE 5W 30
NOTE I I
, -", , , , cc)
ODepending on the atmospheric temperature of your rid-
ing area, the engine oil viscosity should be changed ac-
-.
20 020

, ", ", "", " "'", ,

40
I &4(F)

HU09002BSI ,
cording to the chart.
19-8 SUPPLEMENT - 2003 - 2006 MODELS
WheelsfTires
Front Hub
Front Hub Installation
A
eTighten:
Torque Front Hub Nuts: 34 Nm (3.5 kgfm, 25 ft-lb)
e Insert a new cotter pin [A].
NOTE
o When inserting the cotter pin, if the slots in the nut do
not align with the cotter pin hole in the axle, tighten the
nut clockwise fBJ up to next alignment.
HJ070078S1 C
O ft should be within 30 degree.
OLoosen once and tighten again when the slot goes past
the nearest hole.
e Bend the cotter pin [A] over the nut [B].

~
A
I
~
r----

Il J07008B$ 1 C

Rear Hub
Rear Hub Installation
e Refer to the above figures in the Front Hub Installation.
eTighten:
Torque Rear Axle Nuts: 145 Nm (15.0 kgfm, 110 ftlb)
elnsert a new cotter pin [A].
NOTE
o When inserting the cotter pin, if the slots in the nut do
not align with the cotter pin hole in the axle, tighten the
nut clockwise fBJ up to next alignment.
O lt should be within 30 degree.
OLoosen once and tighten again when the slot goes past
the nearest hole.

e Bend the cotter pin [A] over the nut [B].

 SUPPLEMENT - 2003 - 2006 MODELS 19-9
Brakes

Exploded View

T3

~
o
~ /-~

~>
I- i~'j
~ .~ l
~ i~ ~~
~~ ~ "
0'

HL02007BU C

L: Apply non-permanent locking agent.

R: Replacement Parts
Si: Apply silicone grease.
T1: 1.0 Nm (0.10 kgfm, 9 inlb)
T2: 1.2 N-m (0.12 kgfm , 10 inlb)
T3: 5.9 Nm (0.60 kgfm , 52 inlb)
T4: 7.8 Nm (0.80 kgfm, 69 inlb)
T5: 8.8 N.m (0.90 kgfm , 78 inlb)
T6: 25 Nm (2.5 kgfm, 18 ftlb)
T7: 37 Nm (3.8 kgfm , 27 ftlb)
19-10 SUPPLEMENT - 2003 - 2006 MODELS
Frame
Exploded View

~002013 B .~ C

1. Australian and U.K. Models

2. European and U.K. Models
 SUPPLEMENT 2003 - 2006 MODELS 19-11
Electrical System

Exploded View

KP02031BU t

1. Ignition Switch
3. Cooling Fan SWitc~glne Stop Switch
2. Light Switch and E .

4. Australian Model
5. Other than USA M
6 . U.K. Model . . . odels
7. Optional Parts
8. KLF300-B1 7 -
T1: 7.8 Nm (0 .80 kgf.m, 69 in.lb)
19-12 SUPPLEMENT - 2003 - 2006 MODELS
Electrical System
Wiring Diagram (U.S.A. Model)

KLF300-B17rv

Neutra I/Reverse
Switch

- -
Headl ight
12V25/25W
( R H) oo=F I"
,I
R/
----c>CJ- RI B K - R/BK-l>C}R / B K -
V----r:>e:J-< , I V-
V -c:J<J- R/V
-<!, I -[:::>CJo , I V-
R/V -c:J<J- R/VJ
~Q
,
~
~
~
~
0
~
,
~

I
Opt ion
I
~(J-~-t--- RI ,-;-=r:;l
1- B K / ---[:> I
I
I

L
__ I-R/V -L~
I'Iork Light
~2!65 / 6~W_ ~
,-- <:J--BK I V J
::--D-
I - -~ - - -= R---[::1----J
Option
-
R
\~---,
I : I
I LBK I V{::::j<J-BK I V
5peedometer L ight I
C 12V3.41'1
------
.---J
~
-.>-. . . <>:: ,:c::""""
1%1 . . . . 1%1 ~ ~ ~
~ ,
,- ~ ~ ~ ~ ~

~
R / BK ----[>[:=J-R I B

Headl ight
12V2S / 25W
( L H)
B K I 'f----[>O-B K I V-
R I Y ----cJ<:} R / V -

~
,
~

~
~

#
~ ~

Left Hand lebar Switch

G)Light / Oimmer Switch
GDEngine Stop Switch
' - - - - - - - - ' Pickup Coi I
G)Starter Button
Alternator

WZL0021 Al5 C
 SUPPLEMENT - 2003 - 2006 MODELS 19-13
Electrical System

(DRevers e
Ne u tral
Indicator Li ght 1 2 V 3 .
In dicator Li ght 1 2 V3 .
... Rear Bra k e
Accessarv Term inal

e
L i &: h t Switch
Front Bra k e ,-
Li ght Swi tch ,-

t:
I
CD CD

M
~ ~
m m

- ~
~ ~
m m ~

~~
~ ~ ~ , 8j
~
~ m ~
m

~- ~~
~ ~
m m
Ta i IIBrake

~~
li ,hts
12V S / 27'11'X2
, ~ ~
~ ~ r - - Bl -c:::J<J-
Bl
8j
m m r- BK / Y-c:::J<}- BK I Y

i
~ ~
8j
-R - D < J - R
~ ~ ~
m
1
'-'
((! ..,
~

c
.- <
:) 00
~~

- ,
~

11 n- n.D
~

~:/
m

~
,
~
,
~

*~
::>->->-:;: .... :::; , ,~ a:: CI:><: :><:
<rI...Jmm
~

~
~ ~
m

m~ ~
mr
I<I (-J

~
Battery

lillnn
12Vl4A H
....... ...J ....... 0:::-:

111,,~~j
I I
",I,;;
II nit i .. "
Co i I
l!:: __ ::!J
Starter Starter Relay

-
Ci r cuit
Regula tor!
Rec tifier
I Rei ay
~
M
Color Code

~~~,~,~
BK B lack
Starter Mo tor Bl Blue
BR B r o. n
CH Chocolate
Spark PIUI DO Dirk Gt een
G Green
GY Gn
LB l; '~t S lu _
LG l; '~t G",n
,u" ,n U I H. CGU H IlOO I UUIIH , REVERSE $l ITe M CO NNE CT i o n
0 Oran~e
Color
OFF
BR
I
GI
I It
Po s itio n
t h".,h 5H
LG Ground R/ 'II P
PU
Pink
Purple
ON Neutral R R.,
Reve r se

Y
'll'h i te
Ye I low
( 98052 - 1 13 1 A)
(98 052 -0021A)

ItR002 1A1S c
19-14 SUPPLEMENT - 2003 - 2006 MODELS
Electrical System
Wiring Diagram (Australian Model)

KLF300-B17rv

Cool ing Fan Neutr .. I / Reverse

Sw i tch Switch

Fuse5A

Headlight
12V2S / 25W
( RH )
/
CID
B K--[>{J-R / B K RIB K-C>D-R / B K
K I --!>CJ-B K I, BK/V-c>D-SK / Y
Option
R/Y -D<J-R / Y 'I, -CJ<J- 'I,
- """'--e---' I ;---~;l
f/\!3/
I f--BK / Y--[> :
I __ ..1----, I ,----L]
I!~~k l i ght ; - __ ::J
L!..!.Y 62 / ~ O.!....J <J-B K/ v-+-H--,

@~) ____ ,~,--+++--H~-H-H--~--~

Speedometer
L i ghot
L BK / V---D<:J--BK / Y
12.V3.4Yf

C!rE
I BK---[>CJ-R / B K
K / 'f----[::::O-B K / Y
R( Y ----D<J R/ V
Head light ~ ~ =

mm
12V25 / 25W
( L H)

i
L.ft
'i'Li,n
~
""dI.b"
t/ Dimmer
S.;'oh
Switch
~S!=jS:::~::;b
L T-
9" 0
~~1~~nl . 5A
:~ Alternator
Pickup Co i I

0Engine Stop Switch OFF: HI' ::;;: ,~_L1

(DStarter Button
L. __ L-ol :
66 :
II Button
CD CD CD LU.J """

LEFT HAN DLEBAR SW I TCH CONN ECTIONS

' I' , I, Starter 'I,

Light / Dimmer Switch Ent i n" Stop S. i tch Button

-
Co l or RISK BR Color BR Y Co l or 8K
OFF OFF Release
LO Pus h <;-
HI 'UN

12L0022AIS C
 SUPPLEMENT - 2003 - 2006 MODELS 19-15
Electrical System

G)Reve r se Indicator Light 12V3 .4W

0Neutral Indi cator light 12V3 .4W

Rear
Brake Light
Switch

ft"~:
Front Accessary Terminal
Brake light

CD @

M
'8~~ ~~ B r;v
J ~
m

" T a i I / B r ake
12V 8 / 2 HI'X2
Li,ht

J)
~ ~~ J ~ BL---c::J<J-B L
~ ..... "'" m
I I y-cJ<J-a K I

1 T
-B KI Y

I
J ~
m r' ----CJ<J-- , ~

~1
1'=< :/
.0
2~

III ~ ~ ~n
~~ ~~
n, ~

~
~

~
(+) (-)

Battery

i~~i
12V19AH

Ignition
lJ:: __ ::!J
Starter Rei a y
Co j I Starter
Circuit
Re lay

Co lor Code
BK Black
Spark Plug BL Blu e
BR Brown
CH Chocolate
OG Dirk Green
G Green
GY G"
LB Lil ht Blue
LG LiJ;t.t a'ccn

-
,U",OI II ITC. COOOl'I,OOl NEUTRAL
REVERSE SlilCH CO U ECllon
,I,
Color
OFF
ON
BR 6e. , 1'0 .
t~''''ft
'"Neutra I
j

...
t i on LG Ground
0
P
,
PU
Oran
P ink
Purple

R,d
Reverse
(98052-11321.)
Y White
Ve I low
(98052-0022A)
12R0022A15 C
19-16 SUPPLEMENT - 2003 - 2006 MODELS
Electrical System

Wiring Diagram (European Model)

KLF300-B17 rv
Ignition
S. it c h

Fuse SA

Cool ing Fan

L __~ ~ ~

~~
BL

Headl ight
.!-l
, ~

12V25 / 25W ~ m

(ID' ~~
( RH) ~ ~

~
I BK --l>D-' I " - . - . I ' ,--{>C]--. I " -
B K I Y --[>c::J-- 8 K 1'-
,
f- BK I '--{>C]--BK I , -

Option
I , --c:J<J-' I I , -c:::J<)-. I 'l '
~
~
m
17~~
--'::"1-., I ~-=i:>l
m

I
I
:--BK/V-{>"
J--'IY -r~
1".0_' k L j I h t r - - -
I
<J-BK I , U l
L.!..! V.! 5!.... 6 ~ R ---->B----- R

S, d 0
Li ght
.,.~ ,-c::J<J-" I I ,
~

12V3.4W

~ ~ ~ m
m ~ ~

~<><:;"'::a)
,
~

~
~
,

~ P2. ~ ~
~ ~ ~ ~
m m ~

(ID'1'
m
R/ BK--l>D-R I BK
BK I , --[>c::J--BK I ,-
.1,, -

jrrh'JJ' ~jr '~5A

-D<J-

~~~ ~;;:::;
Headlight
12V2S / 25W
( L H)

OFF'I HI' I I "tJ-

LII.J
Left Handlebar Switch ~ __ L-ol Horn P' k C 'I
Button Alternator "" "
G)Light / Dimmer Switch CD CD 0)
G)Engine Stop Switch
0Starter Button

ULOG23AWS C
 SUPPLEMENT - 2003 - 2006 MODELS 19-17
Electrical System

0Reverse Indicat o r l ight 12V3 , 4".

0Neutral Indicator Light 12V3 , 4W

Rear Brake Light

Switch Accessary Termi na I

~
Fro n t Brake Li ght
Switch
I
00

M fl r El
m m

~
m
~
m

~~ ~
Tai I / Brake
lights

~ ~~ ~~
~ ~~
~;;; 12V 8 / 27'f1X2
~ ~ m
m m

i
,
~ ~

1
~

'I
~
~

----------~--+_t_----_+~----------t_+_----_+~----~_+-------R/~
~
R /.~
j
m

::::::::::::::::::::::~~::i::::::::::::~~========~~====~~====~J-~~~~==-~B~R~~BR
"
~ Reverse
12 V 1 OW
Light

~ , ~

~ ~
m

~
,
) ~
m

(.) (-)

Battery
12V19AH
77
I gn It Ion Rei ay
Starter
Co i I Stater
Circuit
Relay
Regulator /
Rectifier
I g nit e r -.J M
Color Cod e
Starter Motor
"
BL
BR
BI a c k
Blue
Brown
Spark Plug eH Chocolate
00 o. r ~ Gr e e n
0 Gr e e n
GY G ray
LB L i ,h t Blye
LG L iE h t Gr e e n
I G~ITlII N HI TCH COHHECIIOHS HEUIU L I HOEHH SIlltH COUECIIONS Orange
0
Color
OFF
BR
GY Geo.
I ..
Position
tn ,eUlh h I!
lG Grou~GI R / 'Ir
I
P Pink
PU Purple
ON Neutral R Rod
Reverse

y
White
Ye I low
(98052-1133A)
( 98052 -0 023A )

nR0023AII5 G
19-18 SUPPLEMENT - 2003 - 2006 MODELS
Electrical System
Wiring Diagram (U.K. Model)

(DReverse Indicator Light 12V3 .4".

0Heutral Ind icator L ight 12V3 .4'11'

KLF300-B17 ;-v

Fuse 5A

Cooling Fan

Head light
12V2S / 25W
( RH)

/BK-{>CJ-' /BK-
Option
I.~/
':::'_-1- , I
B-;;-=C;l K I I'--{>C]--e KI
R / Y -c:::rc:J- R / Y

I :----s K/ Y----[::> I
I __ r ' I Y --{:2j
j'll'.o_rk Lightr- - - <:}-BK / Y--+++'
L.!.1V~5!...6~ -c>8- R

SP"do,.t'~/Y-c=}<J-BK/y"=~=ti=~t:Ei=ti=t===~====t:===t=t====~==========~r----=====
light
12V3 . 4W
1-

J~ ~
~ ~

/BK-{>CJ-R/BK
K / 'f--C::D-B K I Y
, I Y -c:::rc:J- , I Y -
~ . '2
Headl ight
12V2S / 25W
( l H)

>-;1:: O Swi tch

Alternator
Pickup Coil

J_112yH~~;A
'b6~
OFF"~~OH_~o~':P-"
~
Left Handl ebar Switch
(D l ight / O immer Switch
:L
lli
'tj---l CD CD CD
Engi ne

(DSt arter
Stop

Button
Switch

Horn Button
LEFT HANDLEBAR SW ITCH CONNECTIONS

..- ..-
Co lor ,/Y ,
L i ght / O i mller Switch
RI SK BR
Enline
Color
Stop
BR
Sw i tch
Y/ ,
Starter
Co lor
But ton
Y/ , 8K
OFF OFF R II I II a S II
LO Push
HI 'UH I
 SUPPLEMENT - 2003 - 2006 MODELS 19-19
Electrical System

Carburetor Thermo Sensor Cnntrol Uni t Accessary Terminal

@ -/

~
~l~~~
~I ' ~'" .
BK/~[(gr'~H~~
-

Carburetor
"--BK/Y
w---c>D--w
-BK
BK/Y ~
BKl
~

,~
~
ro ~ Tai IIBrake
Heater 12V23W l~l lights

f"'- ""
12V 8/2711lx2

"'""""'Il!~1 ~~
,--- ~ ~
BL'" Bl
~
"
~ ~
81
Heater -, -----D<J--' 81
Relay

I I

-
I

~ :!J
I
~~
, - - - ' I W-cJ<:]-, I .
r--B '---D<I---B , (~
"
~ ~
,~
Reverse l i ght
~
ro 1 2 V lOW

.~ ..,
~<

I O~
0

lf~

11 . . -i 00'--r-II
I
~
,
~

~
ro

~,
~

m~ #~"
I I ro ; ~
ro

~ __ :!J 1 (- )

~
)<:j~ ~~~~ ~~
T Battery
Stater
12V19AH
Circuit
~

Hlff/n
Relay

I)C>-~ ~~
'" !z
I IT! " ~~
Starter Rei a y

Regu lator /
I gniter

~
Reet ifi er

Color Code
=~Y // W, Starter Motor BK u e BI ack

g Ignition COl I
Bl
CH
BI
BR Br own
Choco I at e
DGG Green
Da rk Gr eo n

:0.~~~'" GY
lB
G ray
L ic ht B l ue
Spa r k PI ug
I GH I T I ON SI I TCH CONHE CT IONS H U IRA t ' UYEMSE SI I ICH COU EC IIONS
lG0 L i lht
Orange
Green

Color
OFF
BR
GY Ge. r
lot
Posit i on
th ' O ~ l h 5t h
lG Ground ' I. P
,
PU
Pin k
Purple
ON Neutral 'od
Reverse

y
Whit e
Ye I low
(98052-1134A)
(98052-0024A)

W2R002HI5 c
 KLF300
BAYOU
Kawasaki 4X4

All Terrain Vehicle

Service Manual
Supplement
 Quick Reference Guide

e_n_e_ra_I_I_n_fo_r_m_a_t_i_o_n_____________1_11
~G__
~F_u_e_I_S~ys_t_e_m_________________2_11
~E_n~g~in_e__
To~p~E_n_d______________ 3_11
Le_f_t_S_id_e______________4_11
~E_n~g~in_e__
R~ig~h_t_S_id_e_____________5_11
~E_n~g~in_e__
II
~E_n---,g=-i_n_e_R_e_m_o_v_a_I/_1n_s_t_a_lI_a_ti_o_n______
6
Engine Bottom EndlTransmission 7 II
WheelslTires
L - - -_ _ _ _ _ _ _ _ 8 II
~F_i_n_a_I_D_r_iv_e_____________________9~1I
Brakes 10 11
Suspension 11 11
Steering 12 11
Frame 13 11
Electrical System II 14
Appendix 15 II
Supplement - 1990 - 1994 Models 16 II
Supplement - 1995 - 1998 Models 17 II
This quick reference guide will assist
you in locating a desired topic or pro-
cedure.
Supplement - 1999 Model 18
-Bend the pages back to match the
black tab of the desired chapter num- Supplement - 2000 - 2002 Models 19 .
ber with the black tab on the edge at
each table of contents page. Supplement - 2003 - 2006 Models 20
-Refer to the sectional table of contents
for the exact pages to locate the spe-
cific topic required.
 LIST OF ABBREVIATIONS
A ampere(s) Ib pounds(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) Celcius r revolution
DC direct current rpm revolution(s) per minute
F farad(s) TDC top dead center
of degree(s) Fahrenheit TIR total indicator reading
ft foot, feet V volt(s)
9 gram(s) W waU(s)
h hour(s) n ohm(s)
L liter(s)

Read OWNER'S MANUAL before operating.

 i EMISSION CONTROL INFORMATION I
To protect the environment in which we all live, Kawasaki has incorporated crankcase emission
(1) and exhaust emission (2) control systems in compliance with applicable regulations of the
California Air Resources Board.
1. Crankcase Emission Control System
A sealed-type crankcase emission control system is used to eliminate blow-by gases. The blow
-by gases are led to the breather chamber through the crankcase. Then, it is led to the air cleaner.
Oil is separated from the gases while passing through the inside of the breather chamber from
the crankcase, and then returned back to the bottom of crankcase.
2. Exhaust Emission Control System
The exhaust emission control system applied to this engine family is engine modifications that
consist of a modified carburetor and an ignition system having optimum ignition timing character-
istics.
The carburetor has been calibrated to provide lean air/fuel mixture characteristics and optimum
fuel economy with a suitable air cleaner and exhaust system.
A maintenance free ignition system provides the most favorable ignition timing and helps main-
tain a thorough combustion process within the engine which contributes to a reduction of exhaust
pollutants entering the atomosphere.
The Clean Air Act, which is the Federal law covering motor vehicle pollution, contains what is
commonly referred to as the Act's "tampering provisions."
"Sec. 203(a) The following acts and the causing thereof are prohibited ...
(3)(A) for any person to remove or render inoperative any device or element of design installed
on or in a motor vehicle or motor vehicle engine in compliance with regulations under this
title prior to its sale and delivery to the ultimate purchaser, or for any manufacturer or dealer
knowingly to remove or render inoperative any such device or element of design after such
sale and delivery to the ultimate purchaser.
(3)(B) for any person engaged in the business of repairing , servicing , selling, leasing, or trading
motor vehicles or motor vehicle engines, or who operates a fleet of motor vehicles know-
ingly to remove or render inoperative any device or element of design installed on or in a
motor vehicle or motor vehicle engine in compliance with regulations under this title follow-
ing its sale and delivery to the ultimate purchaser... "

NOTE
o The phrase "remove or render inoperative any device or element of design" has been generally
interpreted as follows:
1. Tampering does not include the temporary removal or rendering inoperative of de-
vices or elements of design in order to perform maintenance.
2. Tampering could include:
a.Maladjustment of vehicle components such that the emission standards are ex-
ceeded.
b.Use of replacement parts or accessories which adversely affect the performance
or durability of the motorcycle.
c.Addition of components or accessories that result in the vehicle exceeding the stan-
dards.
d.Permanently removing, disconnecting, or rendering inoperative any component or
element of design of the emission control systems.
WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL LAW,
THE VIOLATION OF WHICH IS PUNISHABLE BY CIVIL PENALTIES NOT EXCEEDING
$10,000 PER VIOLATION.
 PLEASE DO NOT TAMPER WITH NOISE CONTROL SYSTEM
(US MODEL only)

To minimize the noise emissions from this product, Kawasaki has equipped it with effective
intake and exhaust silencing systems. They are designed to give optimum performance while
maintaining a low noise level. Please do not remove these systems, or alter them in any which
results in an increase in noise level.
 Foreword
This service manual supplement contains
only the information unique to the models cov-
ered. It must be used with the base service
manual listed below. Read both this sup-
plement and the base manual for complete
information on proper service procedures for
the models covered by this manual.
Base Manual Part Number
KLF300 Service Manual 99924-1057 -02
This manual is designed primarily for use by
trained mechanics in a properly equipped shop.
However, it contains enough detail and basic in-
formation to make it useful to the owner who de-
sires to perform his own basic maintenance and
repair work. A basic knowledge of mechanics,
the proper use of tools, and workshop proce-
dures must be understood in order to carry out
maintenance and repair satisfactorily. When-
ever the owner has insufficient experience or
doubts his ability to do the work, all adjust-
ments, maintenance, and repair should be car-
ried out only by qualified mechanics.
In order to perform the work efficiently and
to avoid costly mistakes, read the text, thor-
oughly familiarize yourself with the procedures
before starting work , and then do the work care-
fully in a clean area. Whenever special tools or
equipment are specified , do not use makeshift
tools or equipment. Precision measurements
can only be made if the proper instruments are
used , and the use of substitute tools may ad-
versely affect safe operation .
For the duration of the warranty period,
we recommend that all repairs and scheduled
maintenance be performed in accordance with
this service manual. Any owner maintenance or
repair procedure not performed in accordance
with this manual may void the warranty.
To get the longest life out of your vehicle:
Follow the Periodic Maintenance Chart in the
Service Manual.
Be alert for problems and non-scheduled
mai ntenance.
Use proper tools and genuine Kawasaki Vehi-
cle parts . Special tools, gauges, and testers
that are necessary when servicing Kawasaki
vehicles are introduced by the Service Man-
ual. Genuine parts provided as spare parts
are listed in the Parts Catalog.
Follow the procedures in this manual care-
fully. Don't take sho rtcuts.
Remember to keep complete records of main-
tenance and repair with dates and any new
parts installed.
How to Use This Manual
In this manual , the product is divided into
its major systems and these systems make up
the manual's chapters. The Quick Reference
Guide shows you all of the product's system
and assists in locating their chapters. Each
chapter in turn has its own comprehensive Ta-
ble of Contents.
For example, if you want ignition coil informa-
tion , use the Quick Reference Guide to locate
the Electrical System chapter. Then , use the
Table of Contents on the first page of the chap-
ter to find the Ignition Coil section .
Whenever you see these WARNING and
CAUTION symbols , heed their instructions!
Always follow safe operating and maintenance
practices.
A WARNING
This warning symbol identifies special
instructions or procedures which, if not
correctly followed , could result in per-
sonal injury, or loss of life.
CAUTION
This caution symbol identifies special
instructions or procedures which, if not
strictly observed, could result in dam-
age to or destruction of equipment.
This manual contains four more symbols (in
addition to WARNING and CAUTION) which will
help you distinguish different types of informa-
tion.
NOTE
o This note symbol indicates points of par-
ticular interest for more efficient and con-
venient operation.
Indicates a procedural step or work to be
done.
Olndicates a procedural sub-step or how to do
the work of the procedural step it follows . It
also precedes the text of a NOTE.
* Indicates a conditional step or what action to
take based on the results of the test or inspec-
tion in the procedural step or sub-step it fol-
lows.
In most chapters an exploded view illustration
of the system components follows the Table of
Contents. In these illustrations you will find the
instructions indicating which parts require spec-
ified tightening torque, oil , grease or a locking
agent during assembly.
 GENERAL INFORMATION 1-1

General Information
Table of Contents

Before Servicing ....................... . .................. . *

Model Identification ....................................... . 1-2
General Specifications ............................... . ...... . 1-4
Torque and Locking Agent .................................. . 1-6
Wiring, Cable, and Hose Routing .............. .. ....... . ...... . 1-10
Periodic Maintenance Chart.................................. . 1-14

* : Base Manual
1-2 GENERAL INFORMATION

Model Identification

KLF300-C1 (US model)

 GENERAL INFORMATION 1-3

KLF300-C1 (UK model)

1-4 GENERAL INFORMATION

General Specifications

: Australia model : UK moclel

: Canada model @: US model

Item KLF300-C1
Dimensions:
Overall length 1 860 mm
Overall width 1100 mm
Overall height 1 105 mm
Wheelbase 1200 mm
Ground clearance 225mm
Seat height 805mm
Dry weight 257 kg, 260 kg
Curb weight: Front 137 kg, 138.5 kg
Rear 128 kg, 129.5 kg
Fuel tank capacity 11 L, B 8.2 L
Performance:
Minimum turning radius 2.9 m
Engine:
Type 4-stroke, SOHC, l-cylinder
Cooling system Air cooled
Bore and .stroke 76.0 x 64.0 mm
Displacement 290mL
Compression ratio 8.6
Maximum horsepower 14.7 kW (20 PS) @6 SOO rim in (rpm). @ -
Maximum torque 23.6 N-m (2.4 kg-m, 17.3ft-lb) 5500r/min (rpm).
@-
Carburetion system Carburetor, Keihin CVK32
Starting system Electric starter & recoil starter
Ignition system Battery and coil (transistorized)
Timing advance Electronically advanced
Ignition timing From 10 BTDC @2 000 rim in (rpm) to
30 BTDC @3 200 r/min (rpm)
Spark plug NGK D8EA, NGK DR8ES-t_
Valve timing: Inlet Open 21 BTDC
Close 59 ABDC
Duration 260
Exhaust Open 56 BBDC
Close 24 ATDC
Duration 260
Lubrication system Forced lubrication (wet sump)
Engine oil: Grade SE or SF class
Viscosity SAE 10W-30, 10W-40, lOW-50, 20W-40, or 20W-50
Capacity 2.2 L
Drive Train:
Primary reduction
system: Type Gear
Reduction ratio 2.888 (78/27)
Clutch type: Primary Auto centrifugal, vyet
Secondary Auto multi disc, wet
 GENERAL INFORMATION 1-5

Item KLF300-C1
Transmission: Type 10-speed plus reverse, constant mesh, return shift
Gear ratio: 1st 3.090 (34/11)
2nd 1.928 (27/14)
3rd 1.368 (26/19)
4th 1.000 (23/23)
5th 0.769 (20/26)
Reverse 3.072 (26/11 x 26/20)
Final drive
system: Type Shaft (four wheel drive)
Reduction ratio High 5.416 (33/33 x 20/16 x 39/9)
Low 6.910 (37/29 x 20/16 x 39/9)
Overall drive ratio High: 12.037 Low: 15.357
Front final gear case oil Type API GL-5 Hypoid gear oil for LSD SAE140 or SAE85W-14Q
Capacity 0.25 L
Rear final gear case oil: Type API GL-5 Hypoid gear oil SAE 90 (above 5C, 41F)
or SAE 80 (below 5C, 41F)
Capacity 0.2 L
Frame:
Type Double tubular
Caster (rake angle) 1.0
Camber 0 @1 G
Trail 5mm
Tread Front 844mm
Rear 840mm
Front tire: Type Tubeless
Size AT 24 x 8-11
Rear tire: Type Tubeless
Size AT 24 x 10-11
Suspension: Front Type Double wishbone
Whee I travel 110mm
Rear Type Torque tube
Wheel travel 120mm
Brake type: Front Disc (Hydraulic) x 2
Rear Drum (Mechanical, on Rightside)
Electrical Equipment:
Battery 12 V 14 Ah
Headlight: Type Sem i-sealed beam
Bulb 12 V 25/25 W x 2
Taillight 12V8Wx2
Alternator: Type Th ree-phase AC
Rated output 23.5 A @9 000 r/min (rpm), 14 V

Specifications are subject to change without notice, and may not apply to every country
1-6 GENERAL INFORMATION
............................................................................ The table below, relating tightening torque to thread
T or.que and Locking Agent diameter, lists the basic torque for the bolts and nuts.
............................................................................ Use this table for only the bolts and nuts which do not
The following tables list the t ightening torque for the require a specific torque value. All of the values are for
major fasteners requiring use of a non-permanent locking use with dry solvent-cleaned threads.
agent or liquid gasket. Basic Torque for General Fasteners
Letter used in the "Remarks" column means : Torque
L : Apply a non-permanent locking agent to the Thread
dia. (mm) N-m kg-m ft-Ib
threads.
LG: Apply liquid gasket to the threads. 5 3.4 - 4.9 0.35 - 0.50 30 - 43 in-Ib
Lh: Left-hand threads. 6 5.9 -7.8 0.60 -0.80 52 - 69 in-Ib
M : Apply a molybdenum disulfide grease. 8 14 - 19 1.4 - 1.9 10.0 -13.5
o : Apply an oil to the threads and seated surface. 10 25 -34 2.6 - 3.5 19.0 - 25
S : Tighten the fasteners following the specified se- 12 44 - 61 4.5 - 6.2 33 - 45
quence. 14 73 - 98 7.4-10.0 54 -72
St : Stake the fasteners to prevent loosening. 16 115 - 155 11.5 -16.0 83 -115
Se : Nut or bolt seating surface 18 165 - 225 17.0 - 23 125 -165
Th: Threads 20 225 - 325 23 - 33 165 - 240

Torque
Parts Remarks
N-m kg-m ft-Ib
Fuel System:
Throttle lever bolt 6.9 0.7 61 in-Ib
Fuel tap plate mounting screws 0.8 0.08 7 in-Ib
Engine Top End:
Spark plug 14 1.4 10.0
Cylinder head bolts: </>8 (used bolts) 29 3.0 22 S
</>8 (new bolts) 34 3.5 25 S
Cylinder head bolts: </>6 12 1.2 104 in-Ib S
Cylinder bolts 12 1.2 104 in-Ib S
Valve adjusting screw locknuts 12 1.2 104 in-Ib
Camshaft sprocket bolts 41 4.2 30
Camshaft chain guide pivot bolt 9.8 1.0 87 in-Ib
Engine Left Side:
Alternator rotor bolt 59 6.0 43
Starter clutch Allen bolts 49 5.0 36 L
Recoil starter flange nut 8.3 0.85 74 in-I b
Engine Right Side:
Oil drain plug 29 3.0 22
Primary clutch hub nU,t 125 13.0 94 o (Se, Th)
Secondary clutch hub nut 78 8.0 58 a
Secondary clutch spring bolts: (used bolts) 12 1.2 104 in-Ib
(new bolts) 15 1.5 11.0
Oil pipe banjo bolts 20 2.0 14.5
Oil pressure relief valve 15 1.5 11.0 L
Engine Removal/I nstallation:
Engine mounting bolts: 8mm 25 2.5 18.0 S
10mm 37 3.8 27
Engine mounting bracket bolts 25 2.5 18.0
 GENERAL INFORMATION 1-7

Torque
Parts Remarks
N -m kg -m ft-Ib

Engine Bottom End/Transmission

Oil drain Plug 29 3.0 22
Oil Pipe Banjo Bolts 20 2.0 14.5
Sub-transmission:
Sub-transmission case bolts: 8 mm 25 2.5 18.0 L (3 bolts)
LH bearing housing bolts (engine output) 12 1.2 104 in-Ib
LH bearing housing bolts (engine output) 120 12.0 87 o (Se, Th)
Engine output shaft nut 120 12.0 87 o (Se, Th)
Oil pipe cap screws (drive shaft) 7.8 0.8 69 in -Ib
Bearing holder (drive shaft) 120 12.0 87 o (Se,Th)
Drive shaft slotted nut 180 18.5 135 o (Se, Th)
Bearing housing nuts (drive shaft) 25 2.5 18.0
Needle bearing nut (drive shaft) 120 12.0 87 o (Se, Th)
Front oil seal housing bolts (output shaft) 11 1.1 95 in-Ib
Rear oil seal housing bolts (output shaft) 8.8 0.9 78 in-Ib
Output shaft slotted nut 180 18.5 135 o (Se, Th)
Shift rod bolt 7.8 0 .8 69 in-Ib
Tie-rod lever bolt 7.8 0.8 69 in-Ib
Neutral switch mounting screw - - - L
Shift drum stopper bolt 12 1.2 104 in-Ib
Shift drum pin plate bolt 12 1.2 104 in-Ib
Shift shaft return spring pin 17 1.7 12.0 L
Oil pressure relief valve 15 1.5 11 .0 L
Balancer gear nut 120 12.0 87 0
Balancer drive gear and oil pump drive gear nut 145 15.0 110 0
Wheels/Tires:
Wheel Nuts 34 3.5 25
Front hub nuts 145 15.0 110
Rear axle nuts 145 15.0 110
Final Drive:
Front Final Drive:
Front axle cap bolts 8.8 0.9 78 in-Ib
Front final gear case mounting
bolts and nuts: 10mm 37 3.8 27
8mm 25 2.5 18.0 L (2 bolts)
Oil filler cap 29 3.0 22
Oil drain plug 20 2.0 14.5
Pinion gear bearing housing nuts 25 2.5 18.0
1-8 GENERAL INFORMATION

Torque
Parts Remarks
N-m kg-m ft-Ib
Pinion gear slotted nut 120 12.0 87 o (Se, Th)
Ring gear cover bolts: 10mm 47 4.8 35 S
8mm 25 2.5 18.0 S
Ring gear bolts 49 5.0 36
Differential case torx bolts 32 3.3 24 L
Rear Final Drive:
Oil filler cap 29 3.0 22
Oil drain plug 20 2.0 14.5
Propeller shaft housing nuts 34 3.5 25
Ax Ie pipe nuts 34 3.5 25
Speedometer gear holder screw 7.8 0.8 69 in-Ib
Ring gear thrust plug nut 54 5.5 40
Pinion gear bearing holder set plug 7.8 0.8 69 in-Ib
Pinion gear bearing holder 120 12.0 87 o (Se, Th)
Pinion gear nut 69 7.0 51 St,O (Se,Th)
Rear gear cover bolts: 10mm 47 4.8 35
8mm 25 2.5 18.0
Brakes:
Bleedvalves 7.8 0.8 69 in-Ib
Brake hose banjo bolts 25 2.5 18
Parking lever lock mounting screw - - - L
Caliper mounting bolts 25 2.5 18
Caliper pad mounting Allen bolts 18 1.8 13.0
Caliper shafts 18 1.8 13.0
Caliper shafts 23 2.3 16.5 L
Disc mounting bolts 37 3.8 27
Brake pipe nipples 20 2.0 14.5
Brake lever pivot bolt 5.9 0.6 52 in-Ib
Brake lever pivot bolt locknut 5.9 0.6 52 in-Ib
Front master cylinder clamp bolts 8.8 0.9 78 in-Ib
Front brake fluid reservoir cap screws 1.0 0.1 9 in-Ib
Rear drum drain bolts 29 3.0 22
Brake panel mounting bolts 34 3.5 25 L
Rear axle nuts 145 15.0 110
Suspensions:
Shock absorber mOl:Jnting nuts 34 3.5 25
Suspension arm pivot bolts: 12 mm 88 9.0 65
Rear suspension arm (rod): 10mm 34 3.5 25
Steering knuckle joint 49 5.0 36 L
 GENERAL INFORMATION 1-9

Torque
Parts Remarks
N-m kg-m ft-Ib
Steering:
Steering stopper nut 8.8 0.9 78 in-Ib
Handlebar clamp bolts 20 2.0 14.5
Stem clamp Allen bolts 25 2.5 18.0
Stem bottom end nut 29 3.0 22
Stem bearing housing bolts 20 2.0 14.5
Tie-rod end nuts 41 4.2 30
Tie-rod adjusting sleeve locknuts 27 2.8 20
Tie-rod arm bolts 49 5.0 36 L
Tie-rod arm locknuts 34 3.5 25
Steering knuckle arm nuts 52 5.3 38

Electrical System:
Spark plug 14 1.4 10.0
Alternator rotor bolt 59 6.0 43
Neutral and reverse indicator switch
mounting screws - - - L
Starter circuit relay terminal nuts 4.4 0.45 39 in-Ib
Taillight assembly mounting screws 7.8 0.8 69 in-Ib
1-10 GENERAL INFORMATION

Wiring, Cable, and Hose Routing

I----

Strap

_Straps
V-:::::;;;;~~--

ViewR

Fuel Tank Bracket

1. Left-Hand Switch Leads

2. Neutral and Reverse Indicator Light Leads
=jt Straps

(LG, HR, R/W)

3. Ignition Switch Leads (BR, W)
4. Choke Cable
5. Vinyl Cover
o
6 . Left Headlight Leads
o Tube B

7. Right Headlight Leads Tube C

8. Main Harness @
9. Neutral and Reverse Switch Leads
10. Alternator and Pickup Coil Leads
11. Engine Ground Lead
12. Engine Ground Terminal and Clamp
13. Electric Starter Cable
 GENERAL INFORMATION 1-1 1

ViewS

~@
@
~~~-@

Front Front

~ . ~ -----@
Air Cleaner Housing Brackets W
- -,
I

B : UK Model

14. IC Igniter Connectors

15. Accessory Connectors
16. Battery Ground Cable
17. Fuse 30A
18. Battery Positive Cable
19. Starter Relay
20. Igniter
21. Starter Circuit Relay
22. Battery Vent Hose
23. Ignition Coil Leads
24. Electric Starter Terminal
25. Engine Breather Hose
26. Main Harness Position Mark - white tape
27. Regulator/Rectifier Connector
28. Taillights
1-12 GENERAL INFORMATION

Clamps

_ _-;.:,..;+_ _ _ _ _ _ Front

Straps - - - - - f L } ) ) - .

25. Put in the engine breather hose here.

29. Throttle Cable

30. Fuel Tank Vent Hose
31. Reverse Cable
32. Parking Brake Cable
33. Upper Brake Hose
34. Front Final Gear Case Vent Hose
35. Rear Axle Vent Hose
36. Brake Panel Vent Hose
37. Carburetor Vent Hose
38. Brake Cable
39. Ignition Switch
40. Lower Brake Hose (brake caliper)
 GENERAL INFORMATION 1-13

C1amp---~tfB "-- - - @

Straps

Tube A
Tube B -----.r'-----<L
Front

TubeC Clamp

Tube B

Straps

T
A

~@
Front

Scetion AA

Clamp
Front Suspension Arm
1-14 GENERAL INFORMATION

Periodic Maintenance Chart

The scheduled maintenance must be done in accordance with this chart to keep the vehicle in good
running condition. The first service is vitally important and must not be neglected.

First Service Regular Service

AherlA~~~~
= Clean, adjust, lu bricate, tighten, or
replace parts as necessary. of use ~ '!-..~ ~f13 '!-..~ ~03 '!-..~ ~~
~ <:) ~ <:) ~ <:) ~ ~ See
0' 0'~ 0'~ ~ 0'~
~ ~ ~.::i;. ~ Page

Engine:
Air cleaner--service* 2-7
Clutch adjustment* 5-3
Valve clearance--check 3-6
Fuel system c1eanliness--check* (2-1 0)
Engine oil--change* 5-3
Oil filter--replace* (5-11 )
Spark plug--c1ean and gap 14-5
Spark arrester--c1ean 3-11
Chassis:
9-7,20
Joint boots--check* 12-4
Rear brake adjustment--check* 10-5
Rear brake lining wear--check* (10-6)
Front brake pad wear--check* 10-8
Brake fluid level--check (10-8)
Brake fluid--change (10-8)
Cable adjustment* **
Battery--check 14-6
Steering--check ( 12-6)
General lubrication* 15-7
Bolts and nuts--tighten 15-8
Front and rear final gear case oil --change* 9-10,23
Master cylinder piston assembly and
2 years (10-11)
dust seal--replace
Caliper piston seal and dust seal--replace 2 years 10-7
Brake hose--replace 2 years 10-10

* : Service more frequently when operated in mud, dust, or other harsh riding conditions. IS.
**: Refer to 2, 7, and 10 chapters.
(xx-xx): Reference Page in the Base Manual
 FUEL SYSTEM 2-1

Fuel System
Table of Contents

Exploded View . . . . . . . . . . . . . . . . . . . . . 2-2 Fuel System Cleanliness Inspection ... . *

Specifications . . . . . . . . . . . . . . . . . . . . . . 2-4 Carburetor Removal. . .. . . . . . . . . . . *
Special Tools . . . . . . . . . . . . . . . . . . . . . . 2-4 Carburetor Installation .. . ..... ... . *
Throttle Case and Cable ...... . . . . . . . . . 2-5 Carburetor Disassembly . . . . . . . . . . . *
Throttle Lever Free Play Inspection .. . * Carburetor Assembly . . . . . . . . . . . . . *
Throttle Cable Adjustment . . . . . . . . . * Carburetor Cleaning . . . . . . . . . . . . . . *
Throttle Case Removal/Disassembly .. . * Carburetor Inspection . . . . . . . . ... . *
Throttle Case Assembly/Installation .. . * Air Cleaner ..... . . . . . . . . . . . . . . . . . . . 2-7
Throttle Cable Removal .... ... ... . * Air Cleaner Element Cleaning ...... . 2-7
Throttle Cable Installation .... .. .. . * Air Cleaner Housing Dust and/or
Throttle Case and Cable Lubrication .. . 2-5 Water Inspection . . . . . . . . . . . . . . 2-8
Throttle Case Inspection . . . . . . .. .. . * Fuel Tank . . . . ..... .. . . . . . . . ... .. . 2-9
Throttle Cable Inspection .... . .... . * Fuel Tank Removal .. . . . . . . . . . .. . 29
Choke Lever and Cable . . . . . . . . . . . . . . . . 2-5 Fuel Tank Installation Notes . . . . . . . . 2-9
Choke Lever and Cable Removal . ... . 2-5 Fuel Tap Removal . . . . . . . . . . . . . . . *
Choke Lever and Cable Installation . .. . 2-6 Fuel Tank and Tap Cleaning . ...... . *
Choke Cable Lubrication . . . . . . . .. . 2-6 Fuel Tap Inspection . . . . . . . . . . . . . . *
Choke Cable Inspection .... . ..... . 2-6 Fuel Level Gauge Removal . . . . . . . . . 2-9
Carburetor. . . . . . . . . . . . . . . . . . . . ... . 2-6 Fuel Level Gauge Installation Notes .. . 210
Carburetor Pilot Screw Adjustment ... . 2-6 Fuel Level Gauge Check . . . . . . . . . . . 210
Idle Speed Adjustment . . . . . . . . . . . . 2-7 Fuel Tank Damper Installation ...... . 2-10
Fuel Level Inspection .. . . . . . . . . . . . * * Base Manual
Fuel Level Adjustment . . . . . . . . . . . .
2~2 FUE1. SYSTEM

~~~
E~~~~~~V:
................... ....................:::::::::::::::::::::::::::::::::

1. Choke Lever
2.. Throttle Cable
3. Choke Cable
4. Throttle Case
5. Starter Jet
6. Pilot Jet
7. Main Jet
G:
A'A pply adhesive.
o . Apply grease
: Apply oil. .
Oe:
R : Apply
Replacecleaner element oil
ment Parts .
o
T2: 0.8 N-m (0.08 kg-m, 6~ in-Ib)
. N-m (0.70
T1'. 69
kg-m, 7 m-Ib) _I
 FUEL SYSTEM 2-3

European Model
2-4 FUEL SYSTEM

Specifications

Refer to the Base Manual noting the following.

Item Standard
Carburetor Specifications
Make, type: Keihin, CVK32
Main jet: #125
Main air jet: #50
Needle jet: #6
Jet needle mark: N36W
Pilot jet (slow jet): #38
Pilot air jet (slow air jet): #140
Pilot screw (turns out): 21/8
Starter jet: #58
Service fuel level (from carburetor body
bottom edge) : 0.5 mm below - 1.5 mm above
Float height: 17 1 mm
Engine Speed (for reference) 1 300 100 r/min (rpm)
Optional Parts
Main jet: #120, 122, 128, 130
Pilot jet (slow jet): #35,#40
Starter jet: #60,62

Special Tools

o Refer to the Base Manual noting the following addi-

tional tools.

Pilot Screw Adjuster "A": 57001-1239

 FUEL SYSTEM 2-5

Throttle Case and Cable

Throttle Case and Cable Lubrication

o Refer to the Base Manual noting the following .
Lubricate the throttle case and cable in accordance
with the Periodic Maintenance Chart, or whenever the
case and cable are removed (see General Information
chapter and General Lubrication in the Appendix
chapter).
o Use the pressure cable luber to lubricate the throttle
cable.

A. Cable End B. Starter Plunger

.Unscrew the choke lever mounting screw and take olf

the plane washer and the wave washer.

Choke Lever and Cable

Choke Lever and Cable Removal A. Lever Mounting Screw B. Choke Le.ver
Unscrew the starter plunger cap and pull out the starter
plunger.
Remove the choke lever and free the choke cable upper
end from the lever .
Pull off the retaining ring and free the choke cable
housing from the switch housing.

A. Starter Plunger Cap

A. Retaining Ring

Hold the starter plunger spring compressed, and free

the choke cable lower end from the plunger. Pull the cable out of the vehicle.
2-6 FUEL SYSTEM
Choke Lever and Cable Installation
-Choke cable installation is the reverse of removal. Carburetor
Note the following.
-Lubricate the choke cable (see General Lubrication in
the Appendix chapter) before installation. Carburetor Pilot Screw Adjustment
-Install the wave washer, plane washer, and screw in - Loosen the carburetor holder clamp screws.
that order.

A. Clamp Screws (Front and Rear)

1. Screw 3. Wave Washer -Tilt the carburetor to the right of the vehicle for easy
2. Plane Washer access to the pilot screw.

-Route the choke cable according to the Wiring, Cable,

and Hose Routing s~ction in the General Information
chapter.

Choke Cable Lubication

-Lubricate the choke cable in accordance with the A. Pilot Screw
Periodic Maintenance Chart, or whenever the lever and
cable are removed (see General I nformation chapter
and General Lubrication in the Appendix chapter).
o Use the pressure cable luber to lubricate the choke -Turn the pilot screw in until it seats lightly, and back it
cable. out 21/8 turns.

Carburetor Pilot Screw Setting

Standard:

Choke Cable Inspection - Reposition the carburetor properly and tighten the
-With the choke cable disconnected at both ends, the clamp screws securely .
cable should move freely in the cable housing. o Fit the carburetor ridge into the groove on the duct.

Idle Speed Adjustment
e Adjust the pilot screw if necessary (see Carburetor
Pilot Screw Adjustment).
eStart the engine and warm it up thoroughly.
eTurn the idle adjusting screw to obtain the slowest
smooth idle speed.
A. Idle Adjusting Screw
*If the engine idle is still not stable, adjust the pilot
screw to obtain the slowest smooth idle speed using the
pilot screw adjuster "A" (special tool) .
A. Pilot Screw Adj uster "A"; 57001-1239
I WARNING'
oOperation with an improperly adjusted, incorrect
routed, or damaged cable could result in an unsafe
riding condition.
OTo avoid a serious burn, never touch a hot engine or an
exhaust pipe during carburetor adjustment.
eOpen and close the throttle a few times to make sure
that the idle speed does not change. Readjust if
necessary.
FUEL SYSTEM 2-7
NOTE
OWith engine idling, turn the handlebar to each side. If
handlebar movement changes idle speed, the throttle
cable may be incorrectly routed, or it may be damaged.
Air Cleaner
A clogged air cleaner restricts the engine's air intake,
increasing fuel consumption, reducing engine power, and
causing spark plug fouling.
I WARNING'
OA clogged air cleaner may allow dirt and dust to enter
the carburetor and stick the throttle open. This could
cause an accident.
OA clogged air cleaner may allow dirt and dust to enter
the engine causing excessive wear and possibly engine
damage.
The air cleaner element must be cleaned periodically
(see the Periodic Maintenance Chart in the General
Information chapter). In dusty areas, the element
should be cleaned more frequently than the recom-
mended interval. After riding through rain or on muddy
terrain, the element should be cleaned immediately.
Air Cleaner Element Cleaning
e Remove the seat.
ePull up the snaps and remove the air cleaner cover.
A. Air Cleaner Cover B. Snaps
2-8 FUEL SYSTEM
e Loosen the clamp screw, remove the element fixing
screw, then pull the air cleaner element up out of the
air cleaner housing.
A. Element B. Screws
ePush a clean, lint-free towel into the air cleaner housing
to keep dirt or other foreign material from entering.
I WARNING.
Olf dirt or dust is allowed to pass through into the
carburetor, the throttle may become stuck open,
possibly causing an accident.
Olf dirt gets through into the engine, excessive engine
wear and possibly engine damage will occur.
eRemove the element stopper from the rear end of the
element body by removing the screw.
A. Screw B. Stopper
ePull the element off the body, then off the inner metal
net.
A. Element B. Metal Net
elnspect the element for damage. If it is torn or punc-
tured, replace it.
elf the element is not obviously damaged, clean it in a
bath of high-flash point solvent, and squeeze it dry.
I WARNING.
OClean the element in a well-ventilated area, and take
ample care that there are no sparks or flame anywhere
near the working area; this includes any appliance
with a pilot light. Do not use gasoline or a low-flash
point solvent to clean the element. A fire or ex-
plosion could result.
eAfter cleaning, saturate the element with SE or SF
class SAE 30 oil, squeeze out the excess, then wrap it
in a clean rag and squeeze it as dryas possible. Be
careful not to tear the element.
NOTE
OSpecialoils for foam air cleaner elements can be used.
oReplace the element after cleaning it five times or if it
is damaged.
Air Cleaner Housing Dust
and/or Water Inspection
ePush open the drain hose on the bottom of the air
cleaner housing to expel dust and/or water accumul-
ated inside.
A. Drain Hose

Fuel Tank
Fuel Tank Removal
eRemove the seat (see Frame chapter in this manual).
eTake off the fuel tank cap.
I WARNING'
oGa~oline is extremely flammable and can be explosive
under certain conditions. Tum the ignition switch
OFF. 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.
eMove the fuel tank top cover to the rear, then lift
the cover.
A. Top Cover
el nstall the fuel tank cap at once.
eRemove the breather and vent hoses from the clamp on
the rear of the fuel tank.
eRemove the four tank mounting bolts.
eTurn the fuel tap to the OFF position.
ePul1 the fuel hose off the tap.
eBend the front fender tabs outward and remove the
fuel tank.
A. Fuel Tank
FUEL SYSTEM 2-9
Fuel Tank Installation Notes
e Fuel tan k installation is the reverse of removal. Note
the following.
WARNING'
oGasoline is extremely flammable and can be explosive
under certain conditions. Tum the ignition switch
OFF. 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.
e Check the rubber dampers on the frame top-tube.
*If the dampers are damaged or deteriorated, replace
them.
e Be sure the fuel hose is clamped to the fuel tap to
prevent leakage.
WARNING'
o Fuel spilled from the fuel tap is hazardous.
Fuel Level Gauge Removal
e Remove the fuel tank cap.
I WARNING'
oGasoline is extremely flammable and can be explosive
under certain conditions. Turn the ignition switch
OFF. 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.
eRemove the fuel tank upper cover by taking off the
two mounting screws.
elnstall the fuel tank cap immediately.
ePry off the gauge cap and discard the cap.
-Check the grooves in the fuel tank boss. If the grooves
are damaged by removing the cap or can not hold the
cap nails, the fuel tank must be replaced.
A. Gauge Cap C. Fuel Level Gauge
B. Grooves
2-10 FUEL SYSTEM

-Pull out the fuel level gauge.

Fuel Level Gauge Installation Notes

01 nstallation is the reverse of removal. Note the fol-
lowing.
\
WARNING.
OGasoline is extremely flammable and can be explosive
under certain conditions. Turn the ignition switch A. Fuel Level Gauge c. Up and Down Smoothly.
OFF. Do not smoke. Make sure the area is well B. Float
ventilated and free from any source of flame or sparks;
this includes any appliance with a pilot light.

-I nstall the fuel level gauge so that the Y2 scale faces the
front.
-Push the new gauge cap over the gauge so that the
notch aligns with the 12 scale.
Fuel Tank Damper Installation
-Apply an adhesive which is recommended by the
manufacturer for bonding rubber to metal to the inside
of the rubber dampers and install them as shown.
-Face each split of the dampers inward of the vehicle.

A. Front C. Notch
B. 12 Scale

-Check that the gauge cap nails fit securely in the

grooves in the fuel tank boss. 1. Rubber Dampers
2.10 -15 mm
3. Splits

Fuel Level Gauge Check

_ Remove the fuel level gauge from the fuel tank (see
Fuel Level Gauge Removal) .
-Check that the float moves up and down smoothly
without binding. It should go down under its own
weight.
*If the float does not move smoothly or has visual
damage, replace the gauge.
 ENGINE TOP END 3-1

Engine Top End

Table of Contents
Exploded View . . . . . . . . . .. . . . . . . . . . . 3-2 Camshaft Installation . . . . . . . . . . . . . *
Specifications .... . ..... ... . . . . . . . . . 3-4 Cam Wear Inspection . . . . . . . . . . . . . *
Special Tools . . . . . . . . . . . . . . . . . . . . . . 3-4 Camshaft Bearing Inspection .... . .. . *
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . 3-4 Camshaft Chain, Guides, and Tensioner . .. . . 3-9
Cylinder Head Removal . . . . . . . . . . . . . 3-4 Camshaft Chain . .. . . . . . . . . . . . . . . . . *
Cylinder Head Installation Notes . . . . . . . 3-5 Camshaft Chain Removal . . . . . . . . . . *
Compression Releasing Lever Removal
Compression Releasina
3-5 Camshaft Chain Installation . . . . . . . . .
Camshaft Chain Wear .... .. . . . . . . .
*
*
[]I
Lever Installation .. . . . . . . . . . . . . . 3-5 Camshaft Chain Guides . . . . . . . . . . . . . . *
Cylinder Head Assembly Note .. . ..... . 3-6 Camshaft Chain Guide Removal ..... . *
Cylinder Head Cleaning . . . . . . . . . . . . . * Camshaft Chain Guide Installation ... . *
Cylinder Head Warp . . . . . . . . . . . . . . . . * Camshaft Chain Guide Wear . . . . . . . . *
Valves, Guide, Seats, Springs, Oil Seals .... . 3-6 Camshaft Chain Tensioner. . . . . . ..... . 3-9
Valves . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Camshaft Chain Tensioner Removal .. . 3-9
Valve Clearance Check . . . . . . . .... . 3-6 Camshaft Chain
Valve Clearance Adjustment .. . . . . . . * Tensioner Installation . . . . . . . . . . . 3-9
Valve Removal .... .. . . . . . . . . . . . . * Camshaft Chain Tensioner Wear ..... . *
Valve Installation . . . . . . . . ... ... . * Cylinder, Piston and Rings . . . . . . . . . . . . . 3-10
Valve. Visual Inspection . . . . . . . . . . . * Cylinder Removal/Installation . . . . . . . . . *
Valve Head Thickness . . . . . . . . .... . * Cylinder Removal ............... . *
Valve Stem Bend . . . . . . . . . . . . . . . . * Cylinder Installation Note . . . . . . . . . . 3-10
Valve Stem Diameter .... . . .. .... . * Cylinder Assembly Note . . . . . . . . . . . 3-10
Valve Stem Grinding . . . . . . . . . ... . 3-7 Piston and ring Removal/Installation .. .. . 3-10
Valve Guides . . . . . . . . . . . . . . . . . . . . 3-7 Piston and Ring Removal ..... . .. .. . *
Valve Guide Inside Diameter . . . . . . . . * Piston and Ring Installation .... . ... . 3-10
Valve Guide Removal . . . . . . . . . . . . . * Cylinder, Piston and Ring Maintenance .. , 3-10
Valve Guide Installation . . . . . . . . . . . 3-7 Compression Measurement . . . . . . . . . 3-10
Valve Seats . . . . . . . . . . . . . . . . . . . . . . * Cylinder/Piston Wear . . . . . . . . . . . . . *
Valve Seat Inspection . . . . . . . . . . . . . * Piston/Cylinder Clearance ..... . ... . *
Valve Seat Repair . . . . . . . . . . . . . . . * Cylinder Boring and Honing .. ..... . *
Valve Springs . . . . . . . . . . . . . . . . . . . . * Piston/Cylinder Seizure . . . . . . . . . . . *
Valve Spring Removal/Installation ... . * Piston Cleaning . . . . . . , . . . . . . . . . . *
Valve Spring Free Length . . . . . . . . . . * Piston Ring and Ring Groove Wear ... . *
Valve Stem Oil Seals . . . . . . . . . . . . . . . * Piston Ring End Gap . . . . . . . . . . . . . *
Valve Stem Oil Seal Removal . . . . . . . . * -Exhaust System .. . . . . . . . . . . . . . . . . . . 3-11
Valve Stem Oil Seal Installation . . ... . * Spark Arrester . . . . . . . . . . . . . . . . . . . 3-11
Camshaft Sprocket . . . . . . . . . . . . . . . . . . 3-7 Spark Arrester Cleaning . . . . . . . . . . . 3-11
Camshaft Sprocket Removal . . . . . . . . 3-7 Exhaust Pipe .... . . . . . . . .. . . . . . . . . 3-12
Camshaft Sprocket Installation ..... . 3-8 Exhaust Pipe Removal Note . . . . . . . . 3-12
Camshaft, Rocker Arms and Shafts . .. ... . . 3-8 Exhaust Pipe Installation . . . . . . . . . . 3-12
Rocker Arms and Shafts . . . . . . . . . . . . . 3-8 Exhaust System Inspection . . . . . . . . . *
Rocker Arm and Shaft Removal . . . . . . 3-8 Carburetor Holder . . . . . . . . . . . . .... .. . 3-12
Rocker Arm and Shaft Installation ... . * Carburetor Holder Installation ... .. . . 3-12
Rocker Arm Inspection . . . . . . . . . . *
Rocker Shaft Diameter .... . . . . . . . . *
Camshaft . . . . . . . . . . . . . . . . . . . . .. . * * Base Manual
Camshaft Removal. . . . . . . . . . . . . . . *
3-2 ENGINE TOP END

Exploded View

.@

1. Manual Compression Release

L : Apply non-permanent locking agent.
M : Apply molybdenum disulfide grease.
D : Apply engine oil.
R : Replacement Parts
T1: 29 N-m (3.0 kg-m, 22 ft-lb) for used parts
34 N-m (3.5 kg-m, 25 ft-lb) for new parts
T2: 12 N-m (12 kg-m, 104 in-lb)
T3: 41 N-m (42 kg-m, 30 ft-lb)
T4: 9.8 N-m (1.0 kg-m, 87 in-lb)
ENGINE TOP END 3-3
3-4 ENGINE TOP END

Specifications Cylinder Head

Refer to the Base Manual noting the following. Cylinder Head Remova/
Remove the following parts.
Camshaft Cam Height: Front Fender (see Frame chapter)
Inlet, Exhaust: 40.642 - 40.782 mm Fuel Tank (see Fuel System chapter in this text)
(Service Limit: 40.54 mm) Carburetor (see Fuel System chapter in the Base
Cylinder Compression (Usable range, with Manual)
compression release operated) Exhaust Pipe (see Exhaust Pipe Removal)
Camshaft Sprocket (see this chapter)
Using Recoil Starter
Spark Plug Cap
825 - 1 280 kPa Cylinder Head Breather Hose and Hose Clamp
(8.4 - 13.0 kg/cm 2 , 119 - 185 psi) Remove the cylinder head bracket bolts, the cylinder
Using Electric Starter head mounting bolt, and nut, then take off the brack-
795 - 1 240 kPa ets.
(8.1 -12.6 kg/cm 2 , 115 - 179 psi)
Cylinder, Piston:
Cylinder inside diameter:
76.000 -76.012 mm
(Service Limit: 76.010 mm)
Piston diameter: 75.960 - 75.975 mm
(75.81 mm)
Piston/cylinder clearance: 0.025 - 0.052 mm
Oversize piston and rings: +0.5 and +1.0 mm
Piston ring/groove clearance
Top: 0.03 - 0.07 mm (0.17 mm)
Secondary: 0.02- 0.06 mm (0.16 mm)
Piston ring thickness:
Top, second: 0.97 - 0.99 mm (0.90 mm)
Piston ring groove width:
Top: 1.02 -1.04 mm (1.12 mm) A. Cylinder Head Bracket Mounting Bolts
Second: 1.01-1.03 mm (1.11 mm) B. Cylinder Head Breather Hose and Hose Clamp
C. Cylinder Head Mounting Bolt and Nut

Remove the cylinder base bolt.

Loosen the cylinder head bolts completely starting
with the 6 mm bolts and r.emove all the bolts.
Special Tools

Refer to the Base Manual noting the following

additional tool.

Bearing Driver Set: 57001-1129

A.8 mm Cylinder Head Bolts

B. 6 mm Cylinder Head Bolts
C. 6 mm Cylinder Base Bolt

Lift the cylinder head clear of the dowel pins in the

cylinder and slide the cylinder head out of the frame.
 ENGINE TOP END 3-5
Cylinder Head Installation Notes - Pull out the lever along with the washer and return
- Refer to the Base Manual noting the following. spring.
-Install a new cylinder head gasket.
-Inspect the new head gasket, and if the seal coating
breaks away, replace the gasket.

1. Cylinder Head Gasket

*If the cylinder head or the cylinder head bolts are new
ones, tighten the 8 mm bolts to 34 N-m (3.5 kg-m, 25
ft-lb) of torque.
-First tighten the upper three br.acket mounting bolts, A. Oil Seal C. Washer
then tighten the lower bracket bolt and nut ):0 the B. Return Spring
specified torque (see Cylinder Head Removal and
Exploded View).

Compression Releasing Lever Removal Compression Releasing Lever Installation

- Replace the oil seal in the cylinder head. Use a suitable
bearing driver from the bearing driver set (special tool:
PN 57001-1129) when installing the oil seal.
-Install the return spring on the compression releasing
o Do not remove the compression releasing lever unless it lever as shown.
is absolutely necessary. If removed, the oil seal re-
placement may be required.

-Remove the front fender (see Frame chapter in this

manual).
- Remove the bolt holding the compression releasing
lever.

A. Return Spring

-Oil the lever shaft and install the washer and lever
A. Bolt C. Front assembly.
B. Compression Releasing Lever -Tighten the bolt securely.
3-6 ENGINE TOP END

Cylinder Head Assembly Note e Remove the timing inspection plug.

elnsert the rubber dampers in the fin grooves starting
with the first groove from the top.
Rubber Damper Installation
e Turn the crankshaft counterclockwise with a wrench
on the alternator rotor bolt, and watch the intake
valve. When the intake valve opens and closes, keep
turning the crankshaft counterclockwise until the T
mark on the alternator rotor aligns with the slot, as
shown.

1. Cylinder Head
o
2. Rubber Dampers A. Timing Inspection Plug C.- T Mark
B. Slot

Valves, Guides, Seats, Springs, Oil Seals e Measure the clearance of each valve between the end of
the valve stem and the adjusting screw on the rocker
arm with a thickness gauge.
Valves: *If the valve clearance is not correct, adjust it (see Valve
Valve Clearance Check Clearance Adjustment).

NOTE
oCheck the valve clearance only when the engine is cold
(cool to the touch). Valve Clearance (when cold)
Intake: 0.10 - 0.15 mm
eRemove the fuel tank (see Fuel Tank Removal in the Exhaust: 0.15 - 0.20 mm
Fuel System chapter).
eTake out the bolts and remove the valve adjusting caps
with O-rings.

A. Thickness Gauge C. Locknut

A. Valve Adjusting Caps B. Front B. Adjusting Screw
 ENGINE TOP END 3-7
-Install the valve adjusting caps so that the UP mark is
on top.

A. Valve Guide Reamer: 57001-162

A. UP Mark -Check valve seat (see Valve Seat Inspection).

-Discard the valve stem oil seal and install the new oil
seal (see Valve Stem Oil Seal Installation).
-Install the valve (see Valve Installation).
-Install the cylinder head (see Cylinder Head Installa-
Valve Stem Griding tion).
-The end of the valve stem may be ground slightly to
remove damage or to gain valve clearance after valve
job.
-Follow the valve refacing machine manufacturer's
instructions.
............................................................................
Camshaft Sprocket

Valve Stem Griding

Camshaft Sprocket Removal
-Remove the front fender (see Front Fender Removal in
Minimum after the Frame chapter).
grinding 4.0 mm -Remove the fuel tank (see Fuel Tank Removal in the
Fuel System chapter).
- Remove the ignition timing inspection plug and the
recoil starter (see Recoil Starter Removal in the Engine
Left Side chapter).
-Remove the bolts and take off the camshaft cover.
olt may be necessary to pry the cover off with a screw-
Do not grind off driver. There are prying gaps under the screw hole
more than 0.2 mm bosses.

Valve Guides:
Valve Guide Installation
-Clean the valve guide hole in the cylinder head.
- Lightly oil the valve guide.
-Heat the cylinder head around the valve guide hole to
120 to 150C (250 to 300F) .
- Use the valve guide arbor and a hammer to drive the
guide into the head from the outside until the guide
flange seats against the head.
-Allow the cylinder head to cool.
- Ream the valve guide with the valve guide reamer
(special tool) even if the old guide is reused. A. Camshaft Cover B. Gaps
3-8 ENGINE TOP END

-Turn the crankshaft with a wrench on the alternator - Fit the sprocket under the chain and slip it over the
rotor bolt until the "LF300" mark on the camshaft shoulder on the crankshaft so that the "LF300" mark
sprocket aligns with the pointer on the cylinder head. on the sprocket aligns with the pointer on the cylinder
head.

A. Pointer B. "LF300" Mark

A. Pointer B. "LF300" Mark
-Screw the bolt in and tighten it to the specified torque
(see Exploded View), while holding the crankshaft
- Remove the camshaft chain tensioner (see Camshaft from turning with a wrench on the alternator rotor
Chain Tensioner Removal).
bolt.
- Remove the camshaft sprocket bolt while holding the
- Install the camshaft chain tensioner (see Camshaft
crankshaft from turning with a wrench on the alter-
Chain Tensioner Installation).
nator rotor bolt.
- Before going any further, check the cam timing.
-Slide the sprocket off the shoulder on the camshaft oTurn the crankshaft counterclockwise with a wrench
and out from the chain . on the alternator rotor bolt, until the "LF300" mark
-Support the chain on a screwdriver or other tool stuck on the sprocket aligns with the pointer on the head.
in the hole in the head.

o If any resistance is felt wilen turning tile crankshaft,

Camshaft Sprocket Installation
stop immediately, or you may bend the valves.
- Remove the timing inspection plug, and check to see
that the "T" mark on the alternator rotor aligns with
o The "T" mark on the alternator rotor should align with
the slot.
the slot.
*If the camshaft timing is not correct, remove the
sprocket from the camshaft, and install it again as
detailed above.
- Smear a little engine oil on the camshaft cover O-ring
and push the cover into place so that the UP mark
faces up.
-Put in the camshaft cover bolts and tighten them
securely.
- Install the timing inspection plug, and the . recoil
starter.
- Install the fuel tank (see Fuel Tank Installation in the
Fuel System chapter).

A. Timirig Inspection Plug C. T Mark Camshaft, Rocker Arms and Shafts

B. Slot
Rocker Arms and Shafts:
*If the "T" mark is not aligned, hold the camshaft chain Rocker Arm and Shaft Removal
taut and 'turn the crankshaft with a wrench on the - Remove the camshaft sprocket (see Camshaft Sprocket
alternator rotor bolt. Removal).
 ENGINE TOP END 3-9
eTake out the screw and remove the rocker shaft
retainer.
e Remove the compression releasing lever (see Compres-
o Do not turn the engine while the camshaft chain
sion Releasing Lever Removal).
tensioner is removed. Engine damage could result.

A. Rocker Shaft Retainer A. Lockbolt B. Mounting Bolts

eTake out the bolts and remove the valve adjusting caps.
e Loosen all the cylinder head bolts to free the cylinder
head from the stress (see Cylinder Head Removal).
ePull out the rocker shafts and remove the rocker arms.
eRemove the lock bolt.
eCarefully pull the push rod out of the tensioner body.
Do not drop the ball and retainer assembly or the
spring.
eSlide the ball and retainer assembly and the spring off
the push rod.

Camshaft Chain Tensioner Installation

eSlip the spring over the push rod and compress it down
past the hole.
elnsert a piece of wire in the hole to hold the spring in
place.

A. Rocker Arm B. Shaft

Camshaft Chain, Guides, and Tensioner

Camshaft Chain Tensioner: A. Spring C. Push Rod

Camshaft Chain Tensioner Removal
e Loosen the lockbolt in the top of the camshaft chain
tensioner. Do not remove it yet.
eTake out the tensioner mounting bolts and remove the
camshaft chain tensioner.
B. Wire
eDrop the ball and retainer assembly onto the push rod.
ePush the push rod into the tensioner body.
3-10 ENGINE TOP END
eWhen the push rod is in as far as it will go, screw in the Piston and Ring Removal/Installation:
lock bolt with its washer to lock the push rod. Piston and Ring Installation
ePull out the wire to release the spring. Refer to the Base Manual noting the following.
elnstall the second and top rings in that order.
Chain T~nsioner (push rod is locked) elnstall the top and second rings so that each "N"
marked side faces up.

L Top and Second Rings

"N" mark

Top
ring

1. Lockbolt 4. Spring
2. Push Rod 5. O-Ring
3. Ball and Retainer Assembly

eBe sure the O-ring is in place in the tensioner body.

eAfter installing the tensioner, loosen the lockbolt and
2nd
then tighten it. With the bolt loosened, the spring
ring
inside takes up any slack automatically.

Cylinder, Piston and Ring Maintenance:

Cylinder, Piston and Rings
Cylinder Installation Note
o Refer to the Base Manual noting the following.
elnstall a new cylinder base gasket.
o Inspect the new base gasket and if the seal coating
breaks away, replace the gasket.
Cylinder Assembly Note
elnsert the rubber dampers in the fin grooves starting
with the first groove from the top.
Compression Measurement
eBefore measuring compression, do the following:
oBe sure the battery is fully charged (see Battery Con-
dition in the Electrical System chapter in this Manual).
oWarm up the engine (if the engine will run).
oDuring warm-up, check for leaks around the cylinder
head gasket.
e Remove the spark plug.
eSet the compression gauge and adapter hose (special
tools) into the spark plug hole.
ePull up the recoil starter until the compression is felt.
Then, push up the compression releasing lever each
time to start the engine.

Rubber Damper Installation

20mm

1. Rubber Dampers
2. Cylinder A. Compression Releasing Lever

eHold the throttle wid~ open and crank the engine with
the recoil starter, or the electric starter.
eWhen the gauge stops rising, stop cranking and read the
gauge.
A. Compression Gauge: 57001-212
B. Adapter Hose: 57001-1159
Cylinder Compression (Usable Range)
with Recoil Starter
825 - 1280 kPa
(8.4 -13.0kg/cm 2 , 119 -185 psi)
, or with Electric Starter
795 - 1240 kPa
(8.1 - 12.6 kg/cm 2 ,115 - 179 psi)
*If the compression is within the specified range, the
piston rings, cylinder and valves are probably in good
condition.
*If the compression is higher than the specified range,
see the Compression Too High table in the Base
Manual.
*If the compression is below the specified range, check
the cylinder head bolt torque (see Cylinder Head
Installation in this manual).
*If the compression is still below the specified range,
squirt a little oil into the spark plug hole and repeat the
compression measurement.
*If the compression does not change very much, the
piston rings are probably OK. See the Wet Compres-
sion - No Change table in the Base Manual.
*If the compression increases, the piston rings are not
sealing properly. See the Wet Compression - Increase
table in the Base Manual.
ENGINE TOP END 3-11
Exhaust System
Spark Arrester:
This vehicle is equipped with a spark arrester ap-
proved for off-road use by the U.S. Forest Service. It
must be properly maintained to ensure its efficiency.
In accordance with the Periodic Maintenance Chart,
clean the spark arrester.
Spark Arrester Cleaning
I WARNING I
OTo avoid burns, wear gloves while cleaning the spark
arrester. Since the engine must be run during this
procedure, the muffler will become hot.
o The spark arrester must be installed correctly and
functioning properly to provide adequate fire pro-
tection.
eRemove the drain plug on the rear muffler.
eln an open area away from combustible materials, start
the engine with the transmission in neutral.
eRaise and lower engine speed while tapping on the
muffler with a rubber mallet until carbon particles are
purged from the muffler.
A. Drain Plug C. Mounting Bolt
B. Spark Arrester
WARNING.
000 not run the engine in a closed area. Exhaust gases
contain carbon monoxide; a colorless, odorless, poi-
sonous gas. Breathing exhaust gas leads to carbon
monoxide poisoning, asphyxiation, and death.
oNever run the engine with the spark arrester removed.
Hot carbon particles may start a fire.
3-12 ENGINE TOP END

NOTE e Temporarily install the muffler clamp on the muffler

so that the gasket stopper faces the rear.
oRun the engine with the spark arrester installed during
e lnsert the muffler clamp over the exhaust pipe so that
cleaning. This keeps the exhaust pressure higher and
the gasket stopper of the clamp contacts the end of the
makes carbon particles purge easier.
exhaust pipe.
eStop the engine.
elnstall the drain plug.
e Remove the spark arrester mounting bolt from the Muffler Clamp Installation
muffler.
ePull the spark arrester out of the muffler.
eScrape carbon deposits off the spark arrester and slide
it back into the muffler.
elnstall the mounting bolt and tighten it securely.

Exhaust Pipe:
Exhaust Pipe Removal Note
eRefer to the Base Manual noting the following.
eFirst, take off the exhaust pipe holder nuts at the
cylinder head.
eRemove the mud guard to loosen the muffler clamp
bolt until the clamp turns freely on the muffler.
o
1. Gasket Stopper of Clamp 3. Gasket
2. Exhaust Pipe 4. Front

eTighten the exhaust pipe holder nuts evenly and

securely.
e Tighten the muffler clamp bolt securely.

A. Muffler Clamp Bolt

eWork the exhaust pipe out of the frame and remove it. Carburetor Holder

Exhaust Pipe Installation Carburetor Holder Installation

elnstallation is the reverse of removal. Note the fol-
lowing.
eFit a new gasket into the muffler so that the chamfered
side of the gasket faces to the front.
e lnstall the carburetor holder so that the projection
faces upward .
Carburetor Holder Installation

1. Projection

e Tighten the bolts to a snug fit, then tighten them

A. Chamfer evenly.
 ENGINE LEFT SIDE 4-1

Engine Left Side

Table of Contents
[II
Exploded View ........................................... . 4-2
Specifications ............................................ . *
Special Tool ............................................. . 4-3
Reco iI Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Recoil Starter Removal ................................. . 4-3
Recoil Starter Disassembly .............................. . 4-3
Recoil Starter Assembly Notes ........................... . 4-4
Recoil Starter Cleaning ................................. . 4-6
Recoil Starter Inspection ................................ . 4-6
Left Engine Cover ......................................... . 4-6
Left Engine Cover Removal. ............................. . 4-6
Left Engine Cover Installation Notes....................... . 4-7
Alternator Rotor and Stator (see Electrical System chapter in this Manual)
Pickup Coil (see Electrical System chapter in the Base Manual)
Starter Clutch ............................................ . *
Starter Clutch Removal ................................. . *
Starter Clutch Installation ............................... . *
Starter Clutch Inspection ............................... . *
Starter Chain and Sprockets ................................. . 4-7
Starter Chain and Sprocket Removal. ...................... . *
Starter Chain and Sprocket Installation ..................... . *
Starter Chain Wear .................................... . *
Torque Limiter Inspection .............................. . 4-7
Sub-Transmission Lever. .................................. . 4-7
Sub-Transmission Lever Removal ......................... . 4-7
Front Propeller Shaft .................................... . 4-7
Sub-Transmission Case .......... ... .. , ................... . 4-7

* : Base Manual
4-2 ENGINE LEFT SIDE

Exploded View

~
@ ~/ ,

@@

1. Torque Limiter
G : Apply high temperature grease.
,
L : Apply non-permanent locking agent.
o : Apply engine oil. 1/
Lh: Left-Hand Threads ~/.
R : Replacement Parts
Rh: Right-Hand Threads
T1 : 59 N-m (6.0 kg-m, 43 ft-Ib)
T2 : 49 N-m (5.0 kg-m, 36 ft-Ib)
T3: 8.3 N-m (0.85 kg-m, 74 in-Ib)
T4: 7.8 N-m (0.8 kg-m, 69 in-Ib
 ENGINE LEFT SIDE 4-3

Special Tool

Refer to the Base Manual noting the following

additional tool.

Hook Wrench: 57001-1101

A. Reel C. Locking Pliers

B. Handle Cap

eHold the reel in one hand while removing the locking

pliers with the other.
e Pull the rope in through the rope hole in the housing
and hold it in the notch in the reel.

NOTE
oDo not let the rope wedge between the reel and the
housing.
fJecoil Starter

Recoil Starter Removal

eRemove the front propeller shaft cover (see Front
Propeller Shaft Removal in the Final Drive chapter)
and the recoil starter by taking out the mounting bolts.

A. Hold rope in notch.

eSlowly allow recoil spring tension to unwind the reel.

eRemove the friction plate by taking off the flange nut.

A. Starter Bolts B. Propeller Shaft Cover

Recoil Starter Disassembly

e Remove the recoil starter (see Recoil Starter Removal).
ePull the handle out 100 - 200 mm . Clamp the rope in
place with locking pliers.
eRemove the handle cap .
Pry the knot out of the handle and untie it. Pull the
handle off the rope. A. Friction Plate B. Flange Nut
4-4 ENGINE LEFT SIDE

I WARNING'
o Be careful that the spring does not fly loose and does
not injure you. It is under great pressure.
OTurn the reel one-quarter turn counterclockwise past
the rest position where no tension can be felt. Now,
slowly lift the friction plate straight up out of the
housing.

e Remove the friction plate and friction plate spring.

e Remove the pawl and pawl spring.

\
1. Pawl
2. Pawl Spring
3. Friction Spring
4. Friction Plate A. Strike bench.
5. Flange Nut

e Remove the reel noting the following.

I WARNING'
o Be careful that the spring does not fly loose and does
not injure you. It is still under great pressure.
o Turn the reel one-quarter tum counterclockwise past
the rest position where no tension can be felt. Now,
slowly lift the friction plate straight up out of the
housing.
Recoil Starter Assembly Notes
eAssembly. is the reverse of disassembly. Note the
following.
elf the recoil spring was removed, install it as shown. If
it is not installed correctly, the starter will not operate
properly.

NOTE
WARNING'
o There should be no spring tension on the reel when
removing the reel. Lift the reel slightly. If tension is o The recoil spring must be put under great pressure
felt, push the reel back into place and gently "wiggle" during installation. Wear gloves to avoid injury.
it until the reel may be easily removed.

e Hook the outer end of the recoil spring onto the

elf necessary, remove the recoil spring as follows. housing tab.
o Place the starter housing facing down on a bench. e Reel the recoil spring clockwise into the housing from
OStrike the bench sharply to safely remove the spring. outside to inside.
 ENGINE LEFT SIDE 4-5

CD

1. Hook recoil spring end onto the tab. A. Turn reel to wind rope.

eGrease the reel and set the reel into place so that the
hook on the spring catches on the tab in the reel.
NOTE
OPush the recoil spring against the housing securely to
prevent the spring from slipping off during installation.

e Lightly grease the spring.

A. Align hook and tab. B. Grease here.

eGrease the pawl spring and pawl and install them as

shown.
eGrease the friction plate and install the friction plate
and spring being careful of the spring hook position.

A. Grease recoil spring.

elf the rope was unwound from the reel, it must be

wound clockwise for correct starter operation.
eWind the rope four turns around the smaller diameter
of the reel and half turn around the larger diameter.

NOTE
A. Pawl D. Friction Plate Spring Hooks
o Turn the reel counterclockwise to wind the rope B. Pawl Spring E. Grease here.
clockwise. This prevents the rope from twisting. C. Friction Plate
4-6 ENGINE LEFT SIDE
-Tighten the flange nut to the specified torque (see
Exploded View). Left Engine Cover
-Turn the reel four turns clockwise to preload the
spring.
Left Engine Cover Removal
- Remove the recoil starter (see Recoil Starter Removal).
-Holding the recoil starter pulley steady with the hook
wrench (special tool), loosen the alternator rotor bolt.

A. Turn clockwise

A. Alternator Rotor Bolt

Recoil Starter Cleaning
- Disassemble the recoil starter (see Recoil Starter
Disassembly).
-Immerse only the metal parts in a bath of high-flash
point solvent.
WARNING'
OClean the starter in a well-ventilated area, and take care
that there are no sparks or flame anywhere near the
working area; this includes any appliance with a pilot
light. Do not use gasoline or a low-flash point solvent
to clean the starter. A fire or explosion could result_
B. Hook Wrench: 57001-1101
- Remove the alternator rotor bolt, the pulley and the
key. The pulley may be pulled out easily.
- Place an oil pan beneath the engine left side.
- Remove the following parts.
Seat
Sub-Transmission Shift Lever Assembly
Left Engine Cover Mqunting Bolts (8)
- Take off the left engine cover.
- If necessary, remove the rear fender (see Frame
chapter) and pull out the alternator connectors to com-
plete the left engine cover removal.

ODo not clean any non-metallic parts in the solvent as

they may be damaged.

oUse compressed air to dry the cleaned components.

Recoil Starter Inspection

-Clean the recoil starter (see Recoil Starter Cleaning).
- Examine the starter pawl for chips or excessive wear.
- Check the starter rope for excessive wear or fraying.
- Check the condition of the recoil spring, and friction
plate spring.
o Inspect the springs for breaks, rust, distortion, or A. Left Engine Cover Mounting Bolts
weakened condition. B. Sub-Transmission Shift Lever Assembly
 ENGINE LEFT SIDE 4-7

Left Engine Cover Installation Notes

o Refer to the Base Manual noting the following.
-Grease the left engine cover oil seal.
-Check that the pulley O-ring is in good condition.
- Clean the pulley boss and apply oil to the O-ring and
the boss.
-Push the pulley into the left engine cover oil seal.
-Fit the key in the groove between the pulley and shaft.
-Insert the alternator rotor bolt.

1. Torque Limiter

Sub-Transmission Lever
.............................................................................
Sub- Transmission Lever Removal
A. Grooves B. Key -Take off the sub-transmission lever by removing the
following bolts and nut.

-Using the hook wrench (special tool), tighten the

alternator rotor bolt to the specified torque (see Ex-
ploded View).

A. Bolts B. Nut

A. Hook Wrench: 57001-11 01

Front Propeller Shaft

Refer to the Final Drive chapter.

Starter Chain and Sprocket

Sub-Transmission Case
Torque Limiter Inspection
-Remove the torque limiter and visually inspect it.
*If the limiter has wear, discoloration, or other damage, Refer to the Engine Bottom End/Transmission
replace it as a unit. chapter.
 ENGINE RIGHT SIDE 5-1

Engine Right Side

Table of Contents

Exploded View . . . . . . . . . . . . . . . . . . . . . 5-2 Primary Gear Installation *

Specifications . . . . . . . . . . . . . . . . . . . . . . 53 Secondary Gear Removal *
Special Tools .... . . . . . . . . ... . . . . . . . * Secondary Gear Installation . . . . . . . . . *
Right Engine Cover . . . . . . . . . . . . . . . . . . * Primary and Secondary Gear Damage .. *
Right Engine Cover Removal . . . . . . . . * Gear Backlash . . . . . . . . . . . . . . . . . . *
Right Engine Cover Installation .... . . * Primary Gear/Crankshaft Wear . . . . . . . *
Clutches . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Secondary Gear/Collar Wear . . . . . . . . *
Clutch Adjustment . . . . . . . . . . . . . .. . 5-3 Lubrication System . . . . . . . . . . . . . . . . . . 5-4
Clutch Adjustment . . . . . . . . . . . . . . 5-3 Engine Oil and Filter .... . . . . . . . . .. . *
Clutch Removal . . . . . . . . . . . . . . . . . . 53 Engine Oil Level Inspection . . . . . . . . . *
Clutch Removal . . . . . . . . . . . . . . . . * Engine Oil and Filter Change . . . . . . . . *
Ch"tch Installation . . . . . . . . . . . . . . . 5-3 Oil Pump . . . . . . . . . . . . . . . . . . . . . . . 5-4
Clutch Inspection . . . . . . . . . . . . . . . . . * Oil Flow Inspection . . . . . . . . . . . . . . 5-4
Primary Clutch Housing Wear . . . . . . . * Oil Pump Removal. . . . . . . . . . . . . . . *
Primary Clutch Shoe Lining Wear .... . * Oil Pump Installation . . . . . . . . . . . . . *
One-Way Clutch Inspection . . . . . . . . . * Oil Pump Disassembly . . . . . . . . . . . . *
Friction Plate Wear and Damage . . . . . . * Oil Pump Assembly . . . . . . . . . . . . . . *
Friction Plate and Steel Plate Warp ... . * Oil Pump Inspection ..... . . ..... . *
Secondary Clutch Housing Oil Screen .. . ..... ... .. . . . . . . . . . *
Finger Damage . . . . . . . . . . . . . . . * Oil Screen Removal .... . .. . ..... . *
Secondary Clutch Hub Spline Damage .. * Oil Screen Installation . . . . . . . . . . . . *
Secondary Clutch Spring Wear ... ... . * Oil Screen Cleaning and Inspection ... . *
Clutch Release . . . . . . . . . . . . . . . . . . . 5-3 Oil Filter Bypass Valve . . . . . . . . . . . . . . *
Clutch Release Removal . . . . . . . . . . . 5-3 Bypass Valve Removal . . . . . . . . . . . . *
Clutch Release Installation . . . . . . . . . 5-3 Bypass Valve Installation . . . . . . . . . . *
Clutch Release Wear . . . . . . . . . . . . . . * Bypass Valve Cleaning and Inspection .. *
Balancer . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Primary Reduction . . . . . . . . . . . . . . . . . . * * Base Manual

Primary Gear Removal . . . . . . . . . . . . *

5-2 ENGINE RIGHT SIDE

Exploded View

Remove this oil pipe

when the optional oil
cooler is used. ~
,------- -I
~~, T5 I
----;;>t~ @ I
I I
l : Apply non-permanent locking agent. I
M : Apply molybdenum disulfide grease.
D : Apply engine oil.
T1 : 125 N-m (13.0 kg-m, 94 ft-lb)
T2: 12 N-m (1.2 kg-m, 104 in-Ib) for used bolts
15 N-m (1.5 kg-m, 11.0 ft-Ib) for new bolts
T3: 78 N-m (8.0 kg-m, 58 ft-Ib)
T4: 29 N-m (3.0 kg-m, 22 ft-Ib)
T5: 20 N-m (2.0 kg-m, 14.5 ft-Ib)
T6: 15 N-m (1.5 kg-m, 11.0ft-lb)
 ENGINE RIGHT SIDE 5-3
............................................................................ Clutch Removal:
Specifications Clutch Installation
............................................................................ e Refer to the Base Manual noting the following.
Refer to the Base Manual noting the following. *If the clutch spring plate or the clutch spring bolts are
new ones, tighten the spring bolts evenly to 15 N-m
Engine oil: (1.5 kg-m, 11.0 ft~b) of torque.
Grade: SE or SF class Clutch Release:
Viscosity: SAE10W-30 can also be used Clutch Release Removal
Capacity: 2.2 L eRemove the clutch release adjusting screw cover from
Relief valve opening pressure: the outside of the right engine cover.
430- 590 kPa (4.4 - 6.0 kg/cm 2 , 63 - 85 psi) eUnscrew the upper adjusting screw and locknut.
eRemove the right engine cover (see Right Engine Cover
............................................................................ Removal in the Base Manual).
Clutches eRemove the following parts from the right engine
............................................................................ cover .
E-Ring and Spring
Clutch Adjustment: Clutch Pusher
Clutch Adjustment .Pull the release cams and ball assembly off the release
eRemove the clutch release adjusting screw cover. shaft.
Clutch Release Installation
eBe careful of the installation direction of the clutch
pusher, the release cams, and the release bearing.
eScrew the upper adjusting screw fu lIy in the release
cam B.

A. Clutch Release Adjusting Screw Cover

B. Screws

eLoosen the locknut for the upper adjusting screw. 1. E-Ring 4. Re lease Cam A
eTurn the clutch release adjusting screw clockwise until 2. Clutch Pusher 5. Release Bearing
it becomes hard to turn, then turn the screw back 3. Upper Adjusting Screw 6. Release Cam B
counterclockwise until it becomes hard to turn .
eLoosen the lower adjusting screw locknut and set the
lower adjusting screw so that the eccentric pin is as
close the upper adjusting screw as possible.
eTighten the locknut.

A. Locknut B. Upper Adjusting Screw

eTighten the locknut without changing the adjusting 1. Upper Adjusting Screw
screw position. 2. Eccentric Pin
elnstall the adjusting screw cover. 3. Lower Adjusting Screw
5-4 ENGINE RIGHT SIDE
..... .......................................................................
'.. .
Clutch Release Lever Installation
-Grease the splines (A) of the clutch release lever (B),
Balancer
-Install the clutch release lever on the shift shaft (C) so
that the lever points toward the center (D) of the Refer to Engine Bottom End/Transmission in the
secondary clutch,
Base Manual for the information.
oBalancer punch mark alignment is needed at balancer
gear installation.

Lubrication System

Oil Pump:
Oil Flow Inspection
- Run the engine at idle speed.

I WARNING'
ODuring oil flow inspection, do not open the throttle
valve. Hot oil will squirt out of the banjo bolt, and
may cause a serious burn.

- Loosen the main oil pipe banjo bolt on the left crank-
-Install the right engine cover.
case as shown, and check that the oil seeps out around
- Loosen the locknut for the upper clutch release ad-
the banjo bolt.
justing screw.
-Turn the adjusting screw counterclockwise until it
becomes hard to turn, and then turn it further 12 to
1 turn to the same direction.

A. Main Oil Pipe Banjo Bolt

A. Locknuts C. Lower Adjusting Screw

B. Upper Adjusting Screw -Tighten the banjo bolt to the specified torque (see Ex-
ploded View).
-Stop the engine.
- Loosen the locknut for the lower clutch release ad- -Wipe up any oil that spills on the engine or the frame.
justing screw. *If the oil does not flow out, inspect the oil filter, the
-Turn the lower adjusting screw clockwise and then relief valve, and the oil pump.
counterclockwise (about 12 turn) until it becomes hard *If the oil filter, the relief valve, and the oil pump are
to turn on either direction, and then stop 'it in the not at fault, inspect the rest of the lubrication system.
middle position.
-Tighten the locknut.
-Turn the upper clutch release adjusting screw clockwise
two or three turns, and then turn it counterclockwise
until it becomes hard to turn.
-Tighten the locknut.
-Install the adjusting screw cover.
 ENGINE REMOVAL/INSTALLATION 6-1

Engine Removal/Installation
Table of Contents

Exploded View ........................................... . 6-2

Engine Removal/Installation ................................. . 6-3
Engine Removal ......... . ............................ .
Engine I nstallation Note ................................ .
6-3
6-3
~
Another Way of Engine Removal/Installation Notes ........... . 6-3

* : Base Manual
6-2 ENGINE REMOVAL/INSTALLATION

Exploded View (fi) T1 : 25 N-m (2.5 kg-m, 18.0 ft-Ib)

............................................................................. ~~ T2: 37 N-m (3.8 kg-m, 27 ft-Ib)

~4ft CID
 ENGINE REMOVAL/INSTALLATION 6-3

Engine Installation
Engine Removal/Installation eEngine installation is the reverse of removal. Note the
following.
eTighten the engine mounting bolts and bracket bolts to
Engine Removal the specified torque (see Exploded View).
eDrain the engine oil (see Engine Right Side chapter in eFirst tighten the upper three bracket bolts, then tighten
the Base Manual). the lower bracket bolt and nut to the specified torque
eRemove the following parts. (see Exploded View).
Front Fender and Rear Fender (see Frame chapter)
Fuel Tank (see Fuel System chapter)
Carburetor (see Fuel System chapter in the Base
Manual)
Exhaust Pipe (see Engine Top End chapter)
Sub-Transmission Assembly (see Engine Bottom End/
Transmission chapter)

-i
'\..
A. Three Bracket Bolts
B. Lower Bracket Bolt and Nut

eGrease the splines at the front end of the propeller

shaft.
elnstall the front end of the propeller shaft on the sub-
A. Sub-Transmission Assembly
transmission output shaft while gently turning the rear
wheels in order to fit the splines.
eDisconnect the following cables, hoses, and leads from
eRun the following cables, hoses, and leads according to
the engine. the Wiring, Cable, and Hose Routing section in the
Carburetor Vent Hose General Information chapter.
Cylinder Head Vent Hose. Throttle Cable
Oil Hoses Choke Cable
Parking Brake Cable Reverse Cable
Reverse Cable Parking Brake Cable
Starter Motor Lead Carburetor Vent Hose
Neutral Leads Cylinder Head Vent Hose
Pickup Coil Leads Leads
Spark Plug Lead eAdjust the following parts (see each appropriate
Battery Ground Lead chapter).
eRemove the engine mounting bolts and bracket bolts. Throttle Cable
eRemove the engine from the vehicle left side. Reverse Cable (see Engine Bottom End/Transmission
chapter)
Parking Brake Cable
eFili the engine with engine oil (see Engine Right Sjde
chapter).
eAdjust the carburetor idle screw.

Another Way of Engine

Removal/Installation Notes

NOTE
oThe engine can be removed with the sub-transmission
1 . Mounting Bolts 3. Sub-Transmission Case and the rear propeller shaft left installed. But it may
2. Bracket Bolts 4. Dust Cover Clamp Screw be a two-man operation.
6-4 ENGINE REMOVAL/INSTALLATION
e Refer to Engine Removal/Installation procedure above
noting the following.
e Remove the following parts.
Left Footpeg
Front Propeller Shaft (see Final Drive chapter)
Rear Propeller Shaft Joint Boot Front End
Engine Mounting Bolts and Bracket Bolts
e Move the engine forward with the sub-transmission left
installed to free it from the rear propeller shaft.
eRemove the engine from the vehicle left side.

1. Splines
2. Rear Propeller Shaft Joint Boot

e When installing the engine, note the following.

OA person should insert the rear end of the sub-
transmission output shaft in the rear propeller shaft
while holding the engine. Another person should turn
the rear wheels by hand to fit the splines.
 ENGINE BOTTOM ENDITRANSMISSION 7-1

Engine Bottom End ITransmission

Table of Contents

Exploded View .... . ..... . . . . . . ... ... . 72 Balancer . . . . . . .. . . . . . . . . . . . . . . . . . . . 7-8

Specifi.c ations . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 Balancer Drive Removal . . . . . . . . . . . . . *
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . 7-5 Balancer Drive Installation Note . . . . . . . . 7-8
Sealant . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Balancer Removal . . . . . . . . . . . . . . . . . *
Crankcase Splitting . . . . . . . . . . .... . . . . . . 7-7 Balancer Installation . . . . . . . . . . . . . . . *
Crankcase Disassembly .. . . . . . . . . . . . . 7-7 Sub-Transmission Lever . . . . . . . . . . . . . . . . . 7-9
Crankcase Assembly . . . . . . . . . . . . . . . . * Sub-Transmission Case ... ... .... . . . . . . . . 7-9
Crankshaft and Connecting Rod .... . . . . . . . . 77 Sub-Transmission
Crankshaft Removal. . . . . . . . . . . . . . . . * Shift Fork Removal . . . . . . . . . . . . . . 7-9
Crankshaft Installation . . . . . . . . : .... * Sub-Transmission
Crankshaft Disassembly . . . . . .... ... . * Shift Fork Installation . . . . . . . . . . . . 7-9 [II
Crankshaft Assembly . . . . . . . . . . . . . . . * Sub-Transmission Case Removal . . . . . . . . 7-9
Connecting Rod Bend/Twist . . . . . . . . . . * Sub-Transmission Case Installation . . . . . . 7-10
Connecting Rod Big End Sub-Transmission Case Disassembly .... . 7-11
Radial Clearance . . . . . . . . . . . . . . . . * SubTransmission Case Assembly . . . . . . . 7-12
Connecting Rod Big End Sub-Transmission Drive Shaft
Side Clearance . . . . . . . . . . . . . . . . . * Disassembly . . . . . . . . . . ... .. ... . 7-12
Crankshaft Alignment . . . . . . . . . . . . . . 7-7 Sub-Transmission Drive Shaft
Connecting Rod Big End Seizure . . . . . . . * Assembly . . . . . . . . . . . ... . . . . . . . 7-13
Transmission ... . . . . . . . . . . . . . . . . . : .. . 7-7 Sub-Transmission Drive Shaft Bearing
Transmission External Shift Mechanism . ... . * Housing Disassembly . . . . . . . . . . . . . 7-13
External Shift Mechanism Removal. .... . * Sub-Transmission Drive Shaft Bearing
External Shift Mechanism Installation .. . . * Housing Assembly . . . . . . . . . . . . . . . 7-13
External Shift Mechanism Inspection ... . * Sub-Transmission Bevel Gear
Shift Drum Stop Lever Removal. . . . . . . . * Adjustment . . . . . . . .. ... .. .... . 7-13
Shift Drum Stop Lever Installation . . . . . . * Bevel Gear Inspection . . . . . . . . . .. ... . 7-16
Shift Drum Stop Lever Inspection . . . . . . Cam Damper Inspection . . . . . . . . . . .. . 7-16
Reverse Knob and Cable . . . . . . . . . . . . . . . 7-7 Ball and Needle Bearings . . . . . . . ..... . . . . . . *
Reverse Knob Free Play Inspecti on . . . . . . * Ball and Needle Bearing
Reverse Cable Adjustment . . . . . . . . . . . . 7-7 Replacement . . . . . . . . . . . . . . . . .. *
Reverse Knob and Cable Removal. . . . . . . 7-7 Ball and Needle Bearing Wear . . . . . . . . . . *
Reverse Knob and Cable Installation .... . 7-8 . 7-16
Oil Seal . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reverse Cable Lubrication . . . . . . . . . . . . 7-8 Oil Seal Inspection . . . . . . . . . . . . . . . .
. 7-16
Reverse Cable Inspection . . . . . . . . . . . . * Oil Pressure Relief Valve . . . . . . . . . . . . . .. . 7-17
Transmission Shafts, Shift Drum, Forks .... . 7-8 Oil Pressure Relief Valve Inspection .... . 7-17
Transmission Removal . . . . . . . . . . . . . . *
Transmission Installation . . . . . . . . . . . . 7-8 * Base Manual
Transmission Shaft Disassembly . . . . . . . . *
Transmission Shaft Assembly .... . . . . . . 7-8
Shift Fork Bending . . . . . . . . . . . . . . . . *
Shift Fork/Gear Groove Wear . . . . . . . . . *
Shift Fork Guide Pin/Shift Drum
Groove Wear . . . . . . . . . . . . . . . . . . . *
Gear Dog/Gear Dog Hole and
Recess Damage. _ . .. .... . .. .. . . . *
7-2 ENGINE BOTTOM ENDITRANSMISSION

~.~
/
.~~ ' i ~'r-------=;.\ ~.Y0
L---.~ .,

Remove this oil pipe

when the optional oil
G : Apply grease. ,/~o~l:.r ~ ~e~. __ -,
L : Apply non-permanent locking agent. I T3 I
LG : Apply liquid gasket. I
o : Apply engine oil. I
R : Replacement Parts

T1 : 145 N-m (15.0 kg-m. 110 ft-Ib)

T2 : 120 N-m (12.0 kg-m. 87 ft-Ib)
T3 : 20 N-m (2.0 kg-m. 14.5 ft-Ib)
T4 : 17 N-m (1.7 kg-m.12.0 ft-Ib)
T5 : 12 N-m (1.2 kg-m. 104 in-Ib) I
T6 : 29 N-m (3.0 kg-m.22 ft-Ib) I
@I
>1 ~ 1
L ________I
 ENGINE BOTTOM . ENO/TR ANSMISSION
. 7-3
R

~~-~~)g; !~~~~~
/~~ .
~~~
~

T7: 25 N-m (2 m
18: 120 N-m (;5 kt , 18.0 ft-Ib)
2
T9: 7.8 N-m (0 8k kg-m, 87 ft-Ib)
T10: 180 N ( g-m, 69 inlb)
T1 1.. 11 N-m
-m(11
18.5
k k 9-m,135ft-lb)
T12: 8.8 N-m (09 g-m,95 in-Ib)
T13: 15 N-m (1 5 kg-m, 78 in-Ib)
. kg-m,11.0ft-lb)
7-4 ENGINE BOTTOM END/TRANSMISSION
r - - - - - - - - - - - - - - - - - - - -- -
I " - I Oil Cooler
I ~@ ~ . Option @
@ I
I

L _ _ _ _ _ _ _ -,

pIp
I
:
~

:~
 ENGINE BOTTOM END/TRANSMISSION 7-5
Circlip Pliers: 57001144
Specifications

Refer to the Base Manual notin g the following.

Crankshaft. Connecting Rod:

Connecting rod big end radial clearance:
0.008 - 0.020 mm (service limit: 0.07 mm)
Cold fitting tolerance between
crankpin and crank webs:
0.089 - 0.112 mm

Sub Transmission
Bevel gear backlash (at drive shaft slotted nut groove)
Socket Wrench: 570011214
0.04 - 0.09 ml1;l
Shift fork ear thickness
4.4 - 4.5 mm (service limit: 4.3 mm)
Shifter groove
4.55 - 4.65 mm (service limit: 4.8 mm)
Shift fork guide pin diameter
4.9 - 5.0 mm (service limit: 4.8 mm)
Shift fork lever groove
5.1 - 5.2 mm (service limit: 5.3 mm)

Reverse Knob:
Reverse knob free play
3-4mm Bearing Driver Set: 57001 1129

Special Tools

Along with common hand tools, the following more

specialized tools are required for comp lete engine
bottom end/transmission servicing.

Crankshaft Jig: 570011174

Oil Seal Guide: 57001264

7-6 ENGINE BOTTOM END/TRANSMISSION

Jack: 570011238 Oil Seal and Bearing Remover: 570011058

Hexagon Wrench: 570011194

Pinion Gear Holder: 570011281

Socket Wrench: 570011282

...........................................................................
Sealant

Kawasaki Bond (Liquid Gasket Silver): 92104'{)02

- Apply this liquid gasket to the crankcase mating

Gear Holder: 570011015 surface.
 ENGINE BOTTOM END/TRANSMISSION 7-7

Crankcase Splitting Transmission

Crankcase Disassembly Reverse Knob and Cable

Refer to the Base Manual noting the following.
-Remove the sub-transmission gear case instead of the
front bevel drive gear to disassemble the crankcase.
Reverse Cable Adjustment
-Remove the front propeller shaft cover (see Engine
Left Side chapter).
-Loosen the mounting nuts at the adjuster of the reverse
cable, and slide the adjuster until the reverse knob has
the proper amount of play.
- Tighten the mounting nuts after adjustment.

Crankshaft and Connecting Rod

A. Adjuster B. Mounting Nuts

Crankshaft Alignment
Refer to the Base Manual noting the following.
-Put the crankshaft on V blocks when measuring
runout.

Reverse Knob and Cable Removal

-Remove the screws and take off the reverse knob
Crankshaft Runout
assembly with the cable installed (see Base Manual).
-Pull the cable holder out the assembly and free the
reverse cable upper end from the assembly.
-Remove the following parts to free the cable lower end.
Front Propeller Shaft (see Final Drive chapter)
9mm Cable Holder
Reverse Lever Bolt

*If runout at either location exceeds the service limit,

align the crankshaft so that the runout is within the
service limits.

Crankshaft Runout
A. Cable Holder B. Reverse Lever Bolt
Left Half Standard: Under 0.03 mm TlR
Service Limit: 0.08 mm TIR -Remove the front fender (see Frame chapter) and the
Right Half Standard: Under 0.04 mm TlR fuel tank (see Fuel System chapter) to free the cable
Service Limit: 0.10 mm TIR from the vehicle.
7-8 ENGINE BOTTOM END/TRANSMISSION

Reverse Knob and Cable Installation Transmission Shaft Assembly

Refer to the Base Manual noting the following. The
reverse lever of this model has a D-shaped hole and no
alignment mark. Install the lever on the reverse shaft
shown.
eRoute the reverse cable according to the Wiring, Cable,
and Hose Routing section in the General Information
chapter.
eAdjust the reverse cable (see Reverse Cable Adjust-
ment).
eAssembly is the reverse of disassembly. Note the
following.
eReplace any circiips that were removed with new ones.
eAlways install circiips so that the opening is aligned
with a spline groove.
Circlip Installation

Reverse Cable Lubrication

elubricate the reverse cable in accordance with the
Periodic Maintenance Chart, or whenever the cable is
removed (see General Information chapter and General
lubrication in the Appendix chapter).

eThe transmission gears can be identified by size;

Drive shaft gears - the smallest diameter gear is 1st
Transmission Shafts, Shift Drums, Forks gear, and the largest is 5th.
Output shaft gears - the largest diameter gear is 1st
Transmission Installation
gear, and the smallest is 5th.
Refer to the Base Manual noting the following.
aThe shift forks are not identical.
elnstall the shift forks as shown.

NOTE Balancer
aBe careful not to confuse the shift forks.
Balancer Drive Installation Notes
Refer to the Base Manual, noting the following.
Shift Fork Installation
eApply oil to the seating surface and threads of the
balancer drive gear and oil pump drive gear slotted nut.
eTighten the slotted nut to the specified torque (see Ex-
ploded View).
*If none af the toothed washer tabs align, tighten the
nut further just enough to align one of the tabs with a
slot in the nut.
,---CD
2

1. Drive Shaft Shift Fork (I.D. No. 73)

2. Output Shaft Shift Fork (I.D. No. 74)
3. Output Shaft Shift Fork (I.D. No. 72) 1. Slot 3. Claw
4. Shift Rod 2. Tab
 ENGINE BOTTOM END/TRANSMISSION 7-9

Sub- Tr.ansmission Shift Fork Installation

Sub-Transmission Lever elnstall the shift fork with the identification number
facing forward as shown above.
eGrease the O-rings.
Refer to the Engine Left Side chapter sub- eApply engine oil to the shift fork and shift rod.
transmission lever information. eBe sure to install the shift fork guide pin in the shift
fork lever and install the shift fork ears in the shifter
groove in the sub-transmission case.
eTighten the following bolts to the specified torque (see
Exploded View).
Shift Rod Bolt
Tie-Rod Lever Bolt
Sub-Transmission Case

Sub-Transmission Shift Fork Removal

eRemove the following parts.
Rear Fender {see Frame chapter}
Tie-Rod Lever
Sub-Transmission Shift Fork Holder
Sub- Transmission Case Removal
eDrain the engine oil {see Engine Right Side chapter in
the Base Manual}.
eRemove the following parts.
Rear Fender {see Frame chapter}
Left Footpeg and Guard
Shift Pedal
Sub-Transmission Shift Fork Holder (see Sub-
Transmission Shift Fork Removal).
Oil Pipe and Oil Pipe Cap

A. Holder Bolts {4}

B. Tie-Rod Lever Bolt

eRemove the shift rod bolt and the rubber cap.

ePry out the shift rod to remove the shift fork and the
sh ift fork lever.

A. Shift Pedal C. Left Guard

B. Sub-Transmission Case D. Left Footpeg

eSupport the rear part of the frame on blocks or the

jack {special tool: PN 57001-1238} so that the suspen-
sion arms are free from loads.
eRemove the following parts.
Wiring Straps for Brake Cables and Vent Hoses
Brake Pedal Adjuster and Parking Brake Lever Ad-
juster on Rear Brake Panel
Rear Shock Upper Mounting Bolts and Nuts
Suspension Arm Pivot Shaft
Rear Propeller Shaft Joint Boot Clamp Screw
1. Rubber Cap 4. Shift Fork Lever eMove the propeller shaft and rear axle to the rear just
2. Shift Rod 5. Shift Fork enough to free the propeller shaft from the sub-
3. Identification No. 75 transmission shaft.
7-10 ENGINE BOTTOM END/TRANSMISSION
O(Jsing the gear holder (special tool: PN57001-1015),
hold the primary and secondary gears to keep them
from turning (see Engine Right Side chapter in the
Base Manual).
OUnscrew the drive bevel gear nut and take off the
drive bevel gear and shim(s}.

A. Propeller Shaft Front End

*If necessary, check the bevel gear backlash (see Sub-

Transmission Bevel Gear Adjustment).
eRemove the oil seal housing for the sub-transmission
output shaft.
eBend open the toothed washer tabs on each of the sub-
transmission shaft slotted nuts.
eRemove the drive shaft and output shaft slotted nuts
using the socket wrench (special tool).
eApply front brake to hold shafts steady.
1. Drive Bevel Gear Nut
2. Left-Hand Bearing Housing
ORemove the bolts holding the output shaft left-hand
bearing housing and pull out the bearing housing.
oRemove the gasket and dowel pins from the crankcase.
eTo remove the output shaft left-hand bearing from its
housing, remove the bearing holder using the hexagon
wrench (special tool) and drive out the bearing with the
bearing driver set (special tool: PN 57001-1129) if
necessary.

A. Slotted Locknuts
B. Socket Wrench: 57001-1282
CD

eRemove the following parts.

Front Propeller Shaft (see Final Drive chapter)
Left Engine Cover (see Engine Left Side chapter) 1. Hexagon Wrench: 57001-1194
Reverse Cable Lower End (see Reverse Cable Re- 2. Bearing Holder
moval)
Sub-Transmission Case Mounting Bolts (First 8 mm,
then 6 mm bolts)
eTake off the sub-transmission case.
eRemove the drive" bevel gear and output shaft left-hand
bearing housing from the crankcase to remove the sub-
transmission case gasket as follows. Sub- Transmission Case Installation
ORemove the right engine cover (see Engine Right Side eSub-transmission case installation is the reverse of
chapter in the Base Manual). removal. Note the following.
 ENGINE BOTTOM END/TRANSMISSION 7-11

NOTE eApply a high temperature grease to the oil seal and

install the oil seal housing in the sub-transmission case.
OCheck and adjust the bevel gear backlash and tooth
Be sure the O-ring is in place in the groove on the
contact when any of the backlash-related pans are
housing.
replaced.

eDo not install the sub-transmission case gasket yet if

the bevel gear adjustment is .to be done. Otherwise,
install a new gasket.
""Install the left-hand bearing and housing on the crank-
case and tighten the housing bolts to the specified
torque (see Exploded View).
eApply oil to the seating surface and threads of the
bearing holder and install the holder with the flat side
facing out.
elnstall the shim(s) and drive bevel gear on the engine
output shaft.
-Check and adjust the bevel gear backlash and tooth
contact when any of the backlash-related parts are
replaced (see Sub-Transmission Bevel Gear Adjust-
ment).
eAssemble the sub-transmission case (see Sub-Transmis-
sion Case Assembly).
eApply a non-permanent locking agent to the following
8 mm bolts.
eTighten the 8 mm bolts to the specified torque (see Ex-
ploded View) and then tighten the 6 mm bolts.

1. Apply grease.

eTighten the following parts to the specified" torque (see

Exploded View).
1. Apply non-permanent locking agent to the threads. Oil Seal Housing Nuts
Oil Pipe Cap Screws
eApply oil to the seating surface and threads of the drive Oil Pipe Banjo Bolts
and output shaft slotted nuts. elnstall the following parts.
eTighten the slotted nuts to the specified torque (see Front Propeller Shaft (see Final Drive chapter)
Exploded View). Rear Propeller Shaft (see Final Drive chapter)
*If none of the toothed washer tabs align, tighten the Reverse Cable (see Reverse Cable Installation)
nut further just enough to align one of the tabs with a eAdjust the reverse cable (see Reverse Cable Adjust-
slot in the nut. ment).
eAdd engine oil as necessary (see Specifications in the
text and Engine Right Side chapter in the Base
Manual).

Sub- Transmission Case Disassembly

eRemove the sub-transmission case (see SUb-Transmis-
sion Case Removal). The slotted nuts on the sub-
transmission drive shaft and output shaft should be
removed during case removal.
eRemove the following parts in the order shown.
Bearing Holder for Sub-Transmission Drive Shaft
Front Oil Seal Housing for Sub-Transmission Output
Shaft
Sub-Transmission Output Shaft
1. Slot 3. Claw Output Gears and Cam Damper
2. Tab Sub-Transmission Drive Shaft Assembly
7-12 ENGINE BOTTOM END/TRANSMISSION
A. Bearing Holder for Sub-Transmission Drive Shaft
B. Front Oil Seal Housing
A. Cam Damper
eTo remove the ball bearings press-fitted In the sub-
transmission gear case, use the bearing driver set
(special tool).
A. Bearing Driver Set: 57001-1129
eDisassemble the sub-transmission drive shaft as neces-
sary (see Sub-Transmission Drive Shaft Disassembly).
eDisassemble the sub-transmission drive shaft bearing
housing as necessary (see Sub-Transmission Drive Shaft
Bearing Housing Disassembly).
Sub-Transmission Case Assembly
eAssembly is the reverse of disassembly. Note the fol-
lowing.
eUse a high-flash point solvent to clean the case and all
the gears and shafts.
eApply engine oil to the gears and the shafts where they
turn in the case.
eAssemble the sub-transmission drive shaft (see Sub-
Transmission Drive Shaft).
eAssemble the sub-transmission drive shaft bearing
housing (see Su boT ransmission Drive Shaft Bearing
Housing Assembly).
elnstall the ball bearings using a bearing driver from
thc bearing driver set (special tool: PN 57001-1129)
which contacts bearing outer race.
elnstall the bearing holder for the sub-transmission drive
shaft so that the grooves al ign with the bolt holes in
the casc.
A. Bearing Holder B. Grooves
eGrease the front oil seal.
eTighten the following parts to the specified torque (see
Exploded View).
Bearing Housing Nuts (drive shaft)
Front Oil Seal Housing Bolts (output shaft)
-Temporarily, install the toothed washers, washers, and
slotted nuts.
elnstall the sub-transmission case on the engine.
eTighten the slotted nuts to the specified torque (see
Exploded View). Do not bend over a washer tab yet.
Sub-Transmission Drive Shaft Disassembly
eRemove the sub-transmission drive shaft unit (see Sub-
Transmission Case Disassembly).
eHold the largest diameter gear and driven bevel gear of
the unit with a vise and unscrew the needle bearing nut.
eUse aluminum plates to prevent damage to the gears.

CD
1. Aluminum Plate 3. Driven Bevel Gear
2. Largest Diameter Gear 4. Needle Bearing Nut
eRemove the gears and the shifter.
Sub-Transmission Drive Shaft Assembly
eReplace the circlip that was removed with a new one.
eAlways install the circlip so that the opening is aligned
with a spline groove.
Circlip Installation
eApply engine oil to the seating surface and threads of
the needle bearing nut and tighten the nut to the
specified torque (see Exploded View).
Sub-Transmission Drive Shaft
Bearing Housing Disassembly
e Remove the bearing housing (see Sub-Transmission
Case Disassembly) .
e Hold the bearing housing with a vise and unscrew the
bearing holder using the hexagon wrench (special
tool).
e Use aluminum plates to prevent damage to the housing.
ENGINE BOTTOM END/TRANSMISSION 7-13
A. Bearing Holder
B. Hexagon Wrench: 57001-1194
eDrive out the bearing with the bearing driver set
(special tool: PN 57001-1129).
Sub-Transmission Drive Shaft
Bearing Housing Assembly
elnstall the bearing holder (drive) with the flat side
facing out.
eApply engine oil to the seating surface and threads of
the bearing holder.
eTighten the bearing holder to the specified torque (see
Exploded View).
Sub-Transmission Bevel Gear Adjustme'lt
In order to prevent one gear from moving away from
the other gear under load, the backlash and tooth
contact pattern of the bevel gears must be correct to
prevent the gears from making noise and being damaged.
When replacing anyone of the backlash-related parts,
be sure to check and adjust the backlash and tooth
contact. First adjust the backlash, and then tooth
contact by replacing shims.
These two adjustments are of critical importance and
must be carried out in the correct sequence, using the
procedures shown.
Sub-Transmission Bevel Gear Adjustment Procedure
Assemble the sub-transmission gear
case completly. -
7-14 ENGINE BOTTOM END/TRANSMISSION

Sub-Transmission Backlash-Related Parts

r /
Drive Bevel Gear Shims Driven Bevel Gear Shims
Thickness Thickness
Part Number Part Number
(mm) (mm)
0.15 92025-1573 0.1 92025-1897
0.20 92025-1574 0.15 92025-1898
0.7 92025-1534 0.5 92025-1899
0.8 92025-1535
0.8 92025-1900
0.9 92025-1536
1.0 (primary) 92025-1537 1.0 (primary) 92025-1901
1.1 92025-1575 1.2 92025-1902
1.2 92025-1538
1.3 92025-1533

1. Sub-Transmission Case 7. Drive Bevel Gear Shim(s)

2. Drive Bevel Gear 8. Spacer
3_ Sub-Transmission Drive Shaft 9. Driven Bevel Gear Shim(s)
4. Driven-Bevel Gear 10. Driven Gear Bearing Housing
5. Ball Bearing 11. Ball Bearing
6. Left-Hand Bearing Housing

Bevel Gear Backlash Adjustment
eTemporarily, install the sub-transmission case on the
crankcase.
eThe following parts are not required to install.
Propeller Shafts
Sub-Transmission Case Gasket
Sub-Transmission Output Shaft
Shift Fork Holder
Oil Pipe Cap
Bearing Holder a-Ring
eDo not lock the drive shaft slotted nut yet.
eClean any dirt and oil off the bevel gear teeth.
elnstall the drive bevel gear with the primary shim (see
the shim tables).
eApply oil to the seating surface and threads of the
engine output shaft slotted nut and tighten it to the
specified torque (see Exploded View).
eAssemble the driven bevel gear with the primary shim
(see the shim tables).
elnstall the sUb-transmission case on the crankcase, and
tighten the 8 mm case bolts to the specified torque (see
Exploded View).
eCheck the backlash during the tightening of the case
mounting bolts and stop tightening them immediately
if the backlash disappears. Then, change the shim to a
thinner one.
eSet up a dial gauge against the drive shaft slotted nut
groove to check gear backlash.
A. Move B. Dial Gauge
eTo measure the backlash, turn the shifter clockwise and
counterclockwise while holding the drive bevel gear
steady. The difference between the highest and lowest
gauge readings is the amount of backlash.
oTo hold the drive bevel gear steady, another man may
turn the shift drum a little from the neutral position
and hold it at the position shown using a wrench_
ENGINE BOTTOM ENDITRANSMISSION 7-15
1. Turn 3. Clutch
2. Neutral Detent
*If the backlash is not within the limit, repface the
shim(s) at the drive bevel and/or driven bevel gear.
~hange the thickness a little at a time.
e Re-check the backlash, and re-adjust as necessary.
Sub-Transmission Bevel Gear Backlash
Standard: 0.04 - 0.09 mm
(at drive shaft slotted nut groove)
Tooth contact adjustment
e Clean any dirt and oil off the bevel gear teeth .
e Apply checking compound to 4 or 5 teeth on the
driven bevel gear.
NOTE
oApply checking compound to the teeth in a thin, even
coat with a fairly stiff paint brush. If painted too
thickly, the exact tooth pattern may not appear.
oThe checking compound must be smooth and firm
with the consistency of tooth paste.
oSpecial compounds are available from automotive
supply stores for the purpose of checking differential
gear tooth patterns and contact. Use this for checking
the bevel gears.
e Turn the driven bevel gear for 3 or 4 turns in the drive
and reverse (coast) directions, while creating a drag on
the drive bevel gear.
- Check the drive pattern and coast pattern of the bevel
gear teeth. The tooth contact patterns of both drive
and coast sides should be centrally located between the
top and bottom of the tooth, and a little closer to the
toe of the tooth.
* If the tooth contact pattern is incorrect, replace the
shim(s) at the drive bevel gear and shim(s) at the driven
bevel gear, following the examples shown. Then erase
the tooth contact patterns, and check them again. Also
check the backlash every time the shims are replaced.
Repeat the shim change procedure as necessary.
716 ENGINE BOTTOM END/TRANSMISSION

NOTE Example2: Decrease the thickness of the drive bevel

gear shim(s) by 0.05 mm, and/or decrease the thickness
o/f the backlash is out of the standard range after of the driven bevel gear shim(s) by 0.05 mm to correct
changing shims, correct the backlash before checking the pattern shown below. Repeat in 0.05 mm steps if
the tooth contact pattern. necessary .

Correct Tooth Contact Pattern

Heel , t~~ot~m
~!wm TO~
TO~
Toe

Toe Toe

Bottom-fTOP
Toe

1-
1. Drive Gear
~~ 2. Driven Gear
Heel
Bottom Top Bevel Gear Inspection
1. Drive Gear eVisually check the bevel gears for scoring, chipping, or
2. Driven Gear other damage.
Heel *Replace the bevel gears as a set if either gear is damaged.

Cam Damoer Insoection

eVisually inspect the damper cam (sub-transmission
Incorrect Tooth Contact Patterns
0l:ltput shaft), cam follower, spring, and shaft.
Example 1: Increase the thickness of the drive bevel *Replace the part if it appears damaged.
gear shim(s) by 0.05 mm, and/or increase the thickness
of the driven bevel gear shim(s) by 0.05 mm to correct
the pattern shown below. Kepeat in 0.05 mm steps if
necessary.

Heel

2\~~ttom /

TOP~ Toe ,
A. Spring
B. Cam
C. Cam Follower
D. Shaft

Toe Oil Seal

Bottom~ ~oP Oil Seal Inspection

elnspect the oil seals.
*Replace it if the lips are misshapen, discolored (in-
1. Drive Gear Heel dicating that the rubber has deteriorated), hardened
2. Driven Gear or otherwise damaged.
 ENGINE BOTTOM END/ TRANSMISSION 7-17

Oil Pressure Relief Valve

Oil Pressure Relief Valve Inspection

Split the crankcase (see Base Manual).
Remove the relief valve [A] from the right crankcase.
Check to see if the steel ball [B] inside the valve slides
smoothly when pushing it in with a wooden or other
soft rod, and see if it comes back to its seat by valve
spring [C] pressure.

NOTE
Olnspect the valve in its assembled state, Disas-
sembly and assembly may change the valve
performance.

*If any rough spots are found during above inspection ,

wash the valve clean with a high flash-point solvent
and blow out any foreign particles that may be in the
valve with compressed air.

I WARNING .
OClean the oil pressu re relief valve in a well-
ventilated area, and take care that there are 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 solvents.

*If cleaning does not solve the problem , replace the

relief valve as an assembly. The relief valve is
precision made with no allowance for replacement of
individual parts .
Apply a non-permanent locking agent to the threads of
the relief valve, and tighten it

Torque- Oil Pressure Relief Valve :

15 N-m (1.5 kg-m, 11.0 ft-Ib)
 WHEELSITIRES 8-1

Wheels/Tires
Table of Contents

Exploded View ........................................... . 8-2

Specifications ............................................ . 8-3
Special Tools ............................................. . 8-3
Wheel Alignment .......................................... . 8-4
Steering Centering Inspection ................. ..... ...... . 8-4
Steering Centering Adjustment ........................... . 8-4
Toe-in Inspection ..................................... . 8-5 []]I
Toe-in Adjustment .................................... . 8-5
Wheels (Rims) ............................................ . 8-6
Wheel Removal ....................................... . 8-6
Wheel Installation ..................................... . 8-6
Wheel Inspection ...................................... . 8-7
Wheel Replacement .................................... . 8-7
Tires ............................................ '" .... . 8-8
Tire Removal. ........................................ . 8-8
Tire Installation ....................................... . 8-8
Tire Inspection ....................................... . 8-10
Front Hub ......... ...................................... . 8-11
Front Hub Removal ................................... . 8-11
Front Hub Installation Notes .......... , ................. . 8-11
Front Hub Disassembly/Assembly Note .................... . 8-11
Front Wheel Bearing Removal/Installation .................. . 8-11
Rear Hub ................................................ . 8-11
Rear Hub Installation .................................. . 8-11
Rear Hub Disassembly/Assembly Note ..................... . 8-12

* Base Manual
8-2 WHEELS/TIRES

Exploded View
.............................................................................
G : Apply grease.
R : Replacement Parts
W : Apply water, or soap and water solution.
T1 : 34 Nm (3.5 kgm, 25 ft-Ib)
T2: 27 N-m (2.8 kgm, 20 ft-lb)
T3: 41 N-m (4.2 kg-m, 30 ft-lb)
T4 : 145 N-m (15.0 kg-m, 110 ft-Ib)

Front Wheel

Rear Wheel
 WHEELS/TIRES 8-3

Specifications

Wheel Alignment
Caster: 1 (non-adjustable)
Camber: 0 (non-adjustable) @ 1G
Toe-in: 20 mm

Standard Tires
Front: AT 24 x 8-11
Dunlop KT962, Knobby/Trail Tubeless
Rear: AT 24 x 10-11
Dunlop KT962, Knobby/Trail Tubeless

Tire Air Pressure (when cold)

Front: 35 kPa (0.35 kg/cm 2 , 5 psi)
Rear: 28 kPa (028 kg/cm 2 , 4 psi)

Maximum Tire Air Pressure (to 'seat beads, when cold)

Front: 250 kPa (2.5 kg/cm 2 , 36 psi)
Rear: 250 kPa (2.5 kg/cm2, 36 psi)

Maximum Vehicle Load: 195 kg (430Ib)

Special Tools

Refer to the Base Manual noting the following

additional tools.

Jack: 570011238 Air Pressure Gauge: 52005-1082

aThis tool may be used instead of the common tool. aBe sure to use this gauge for low pressure tire instead
of the conventional air pressure gauge (52005-1003).

~~\
\ \
\ \ Bearing Driver Set: 57001-1129
8-4 WHEELS/TIRES
e Hold a straightedge against the rear wheel rim on one
Wheel Alignment side at axle height.

Toe-in is the amount that the front wheels are closer

together in front than at the rear at the axle height.
When there is toe-in, the distance A is greater than Bas
shown. The purpose of toe-in is to prevent the front
wheels from getting out of parallel at any time, and to
prevent any slipping or scuffing action between the tires
and the ground. If toe-in is incorrect, the front wheels
will be dragged along the ground, scuffing and wearing
the tread knobs.
Caster and camber are built-in and require no adjust-
ment.

Toe-in of Front Wheels

Front Side
A. Straightedge B. Jack: 57001-1238
~-----------B------------~

c D

eWit;h the handlebar straight ahead, loosen the locknuts

and turn the tie-rod adjusting sleeve the same number
of turns on both sides until the front wheel on that
side is parallel to the straightedge.

A
NOTE
OThe white locknut on the tie-rod has left-hand threads.
Turn the wrench clockwise for loosening.
A - B = Amount of Toe-in
(Distance A and B are measured at axle height)
(Distance C and D should be equal)

Steering Centering Iilspection

eTest ride the vehicle.
*If the handlebar is straight when the vehicle is traveling
in a straight line, go on to the Toe-in inspection pro-
cedure.
*Otherwise, go on to the Steering Centering Adjustment
procedure.

Steering Centering Adjustment

eSupport the vehicle so that the front wheels are off the A. Front
ground and the front axles about the same height as - B. White Locknut: left-hand threads
the rear axle. C. Adjusting Sleeve

Steering Centering
CD
1. Front Wheels 4. Straightedge
2. Vehicle Center Line 5. Rear Wheels
3. Parallel to each other.
- Repeat the straightedge procedure on the other side of
the vehicle. Now the front wheels are parallel to each
other and to the center line of the vehicle.
-Go on to the Toe-in Inspection procedure.
Toe-in Inspection
-Support the vehicle on a stand or the jack (special tool:
57001-1238) so that the front wheels are off the
ground.
-Apply a heavy coat of chalk near the center of the
front tires.
-Using a needle nose scriber, make a thin mark near the
center of the chalk coating while turning the wheel.
-Keeping the front wheels off the ground, set the
handlebar straight ahead.
-Set the wheels so that the marks on the tires are at the
front side and at the level of the axle height.
-At the level of the axle height, measure the distance
between the scribed lines.
WHEELSITIRES 8-5
1. Measure the distance between lines.
-Turn the wheels until the marks on the front tires.are
at the rear side and at the same level as the axle.
-Measure the distance between the scribed lines at the
rear side.
-Subtract the measurement of the front from the
measurement of the rear to get the toe-in. At the same
time the distances C and D should be equal (see
Illustration Toe-in .of Front Wheels).
*If the toe-in is not in the specified range, go on to the
Toe-in Adjustment procedure.
Toe-in of Front Wheels
Standard: 20 mm
Toe-in Adjustment
-Loosen the locknuts and turn the adjusting sleeves the
same number of turns on both sides to achieve the spe-
cified toe-in.
A. Front C. Adjusting Sleeve
B. Locknuts
NOTE
oThe white locknut on the tie-rod has left-hand threads.
Turn the locknut clockwise for loosening.
o The toe-in will be near the specified value, if the tie-rod
length is 305 mm between the tie-rod ends.
8-6 WHEELS!TIRES
TIe-Rod Length Adjustment Wheel Installation
ePosition the wheel so that the air valve is toward the
outside of the vehicle.
-Check the tire rotation mark on the front and rear
tires, and install the wheels accordingly.

NOTE
o The direction of the tire rotation is shown by an arrow
on the tire sidewall.

1. Front 2. Tie-Rod Length

eCheck the toe-in (see Toe-in Inspection).

eTighten the tie-rod locknuts to the specified torque
(see Exploded View).
eTest ride the veJiicle.

1. Rotation Mark (Arrow)

.............................................................................. 2. Rotation Direction
Wheels (Rim)

Wheel Removal
e Loosen the wheel nuts. eMount the wheel on the studs.
eSupport the vehicle on the jack (special tool) or a stand eTighten the wheel nuts in a criss-cross pattern to the
so that the wheels are off the ground. specified torque (see Exploded View).

'" \ \

A. Stand or Jack: 57001-1238

eTake off the wheel nuts and remove the wheel.

 WHEELSITIRES 8-7

Wheel Inspection Air Valve

eExamine both sides of the rim for dents. If the rim is
dented, replace it.

Rim Dent
CD

_ r.-t-t-
0 ---1

1. Plastic Cap 4. Valve Stem

2. Valve Core 5. Valve Seat
elf the tire is removed, inspect the air sealing surfaces of 3. Stem Seal 6. Valve Opened
the rim for scratches or nicks. Smooth the sealing
surfaces with fine emery cloth if necessary.
elnstall a new air valve in the rim .
Rim Inspection oRemove the valve cap, lubricate the stem with a soap
and water solution, and pull the stem through the rim
from the inside out until it snaps into place.

1. Sealing Surfaces

1. Pull the stem.

Wheel Replacement
eRemove the wheel (see Wheel Removal).
eRemove the tire from the rim (see Tire Removal).
oRemove the air valve and discard it. 000 not use engine oil or petroleum distillates to
lubricate the stem because they will deteriorate the
rubber.

o Replace the air valve whenever the tire is replaced. eMount the tire on the rim (see Tire Installation).
000 not reuse the air valve. elnstall the wheel (see Wheel Installation).
8-8 WHEELS/TIRES
-Kneel on the side of the tire, forcing the tire bead into
Tires the center well of the rim.

Tire Removal Rim Removal

-Remove the wheel (see Wheel Removal).
-Unscrew the valve core to deflate the tire.
o Use a proper valve core tool.

Well

- Lubricate two tire irons (special tool) with a soap and

water solution, or water, then pry the bead.

1. Valve Core Tool

o Do not scratch the air sealing surfaces of the tire or

-Lubricate the tire beads and rim flanges on both sides rim. Scratches or nicks on the sealing surfaces will
of the wheel with a soap and water solution, or water. allow the tire to deflate.
This helps the tire beads slip off the rim flanges.
-Work around the rim with the tire irons a little at a
time, while continuing to hold the bead opposite the
irons in the center well of the rim.
o Do not lubricate the tire beads and rim flanges with
engine oil or petroleum distillates because they will
deteriorate the tire.

-Break the tire beads away from both sides of the rim
with a bead breaker.

Breaking Tire Bead

1. Tire Irons: 57001-1073

- Lift the second bead up into the center well and use
the same procedure as in removing the first bead.

Tire Installation
-Inspect the rim (see Wheel Inspection).
1. Bead Breaker -Replace the air valve with a new one (see Wheel Re-
2. Apply lubricant. placement).
 WHEE LSITIRES 8-9

- By hand, slide as much of the first bead as possible

over the rim flange.
- As the bead goes onto the rim, force the bead into the
o Replace the air valve whenever the tire is replaced.
000 not reuse the air valve.
center well of the rim to ease installation.

-Check the tire for wear and damage (see Tire Inspec-
Bead InStallation
tion) .
- Lubricate the tire beads, rim flanges, and the tire irons
(special tools) with a soap and water solution, or water .

I WARNING I
o Do not use the lubricant other than a water and soap
solution, or water to lubricate the tire beads and rim
because it may cause tire separation.

1. Tire Beads 2. Center Well

- Use the tire irons (special tools) to install the rest of

the bead.

1. Apply lubricant.
Bead Installation

-Check the tire rotation mark on the front and rear

tires, and install them on the rim accordingly.
oThe tires should be installed on the rim so that each
air valve is toward the outside of the vehicle.

NOTE
o The direction of the tire rotation is shown by an arrow
on the t;re sidewall.

ROTATION
1. Tire Irons: 57001 -1073

- Use the same procedure to install the second bead.

- Lubricate the tire beads again and center the tire on
the rim.
- Support the wheel rim on a suitable stand to prevent
1. Rotation Mark (Arrow) 2. Rotation Direction the tire from slipping off.
8-10 WHEELS!TIRES

Tire Air Pressure

Front: 35 kPa (0.35 kg/cm 2 , 5 psi)
Rear: 28 kPa (0.28 kg/cm 2 , 4 psi)

-Check the tire pressure using the air pressure gauge for
low air pressure (special tool).

~-I
1. Rim 2. Suitable Stand \ &
\
\
'

-Inflate the tire until the tire beads seat on the rim.

Maximum Tire Air Pressure (to seat beads when cold)
Front and Rear: 250 kPa (2.5 kg/cm 2 , 36 psi)
WARN.ING
000 not inflate the tire to more than the maximum tire
air pressure. Overinflation can explode the tire with
possibility of injury and loss of life.
-Check to see that the rim lines on both sides of the tire
are parallel with the rim flanges .
1. Air Pressure Gauge: 52005-1082
-Install the wheel (see Wheel Installation).
-Wipe off the soap and water solution, or water on the
tire, and dry the tire before operation.
I WARNING.
000 not operate the vehicle with the water and soap, or
water still around the tire beads. They will cause tire
separation, and a hazardous condition may result.

Tire Inspection
-Examine the tire for damage and wear.
Olf the tire is cut or cracked, replace it.
OLumps or high spots on the tread or sidewalls indicate
internal damage requiring tire replacement.
oRemove the any foreign objects from the tread. After
removal, check for leaks with a soap and water solu-
tion.
oCheck the shape of the tread knobs. If no vertical side
is left on the drive side of the knobs, replace the tire.

Tire Inspection
Vertical Sides
Worn Away
1. Rim Line 2. Rim Flange
/---~J---l
-If the rim lines and the rim flanges are not parallel, / ~~
deflate the tire, lubricate the sealing surfaces again, and
reinflate the tire.
/ \
-After the beads are properly seated, check for air leaks.
Olnflate the tire to 45 kPa (0.45 kg/cm 2 , 6.4 psi). Apply
/ \
a soap and water solution around the tire bead and /
,
// I '\
~
check for bubbles.
-Deflate the tire to the specified pressure. -+-
 WHEELS/TIRES 8-11

eTighten the hub nut to the specified torque (see

Front Hub Exploded ViewL
elnsert a new cotter pin and bend it over the nut.
Front Hub Removal
e Remove the cotter pin and loosen the hub nut.
CD
/
CD

1. Cotter Pi n
1. Hub Nut 2. Cotter Pin

ePuli off the wheel (see Wheel Removal).

eRemove the caliper by taking off the mounting bolts,
and let the caliper hang free.
eRemove the hub nut and pull off the front hub.
Front Hub Disassembly/Assembly Note
eDo not press the hub bolts out.
*If any hub bolt is damaged, replace the hub and bolts
as a unit.

1. Hub Bolts
A. Hub Nut

Front Hub Installation Notes

eGrease the axle splines.

Front Wheel Bearing Removal/Installation

This model has a wheel bearing in the steering
knuckle. Refer to Knuckle Bearing Removal/Installation
in the Steering chapter.

............................................................................
Rear Hub

Rear Hub Installation

eqrease the axle splines.
eTighten the rear axle nut to the specified torque (see
Exploded View).
1. Grease the splines. elnsert a new cotter pin .
8-12 WHEELSITIRES

1. Axle Splines 2. Cotter Pin

Rear Hub Disassembly/Assembly Note

eDo not press the hub bolts out.
*If any hub bolt is damaged, replace the hub and bolts
as a unit.

1. Hub Bolts
 FINAL DRIVE 9-1

Final Drive
Table of Contents

Exploded View . . : . . . . . . . . . . . . . . . . . . .. 9-2 Rear Propeller Shaft . . . . . . . . . . . . . . . . . . . . 9-19

Full Time 4 Wheel-Drive Mechanism. . . . . . . .. 9-4 Rear Propeller Shpft Removal . . . . . . . . . 9-19
Specifications. . . . . . . . . . . . . . . . . . . . . . .. 9-5 Rear Propeller Shaft Installation . . . . . . . . 9-19
Special Tools. . . . . . . . . . . . . . . . . . . . . . .. 9-5 Rear Propeller Shaft Joint
Front Propeller Shaft. . . . . . . . . . . . . . . . . .. 9-7 Boot Inspection .. . . . . . . ..... .. . 9-20
Front Propeller Shaft Removal. . . . . . . .. 9-7 Rear Propeller Shaft Joint Boot
Front Propeller Shaft Replacement . . . . . . . . . . . . . . . . . . 9-20
Installation Notes. . . . . . .. . . . . . .. 9-7 Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . 9-21
Front Axle . . . . . . . . . . . . . . . . . . . . . . . . .. 9-7 Rear Axle Unit Removal . . . . . . . . . . . . . 9-21
Front Axle Joint Boot Inspection. . . . . .. 9-7 Rear Axle Unit Ihstallation Notes .... .. . 9-22
Front Axle Removal . . . . . . . . . . . . . ..
Front Axle Installation Notes . . . . . . . ..
9-7
9-8
Rear Axle Unit Disassembly . . . . . . . . . .
Rear Axle Unit Assembly . . . . . . . . . . . .
9-22
9-22
~
Front Axle Joint Boot Replacement. . . .. 9-8 Rear Axle Bearing Inspection .... .. .. .. . 9-23
Front Final Gear Case . . . . . . . . . . . . . . . . .. 9-9 Rear Final Gear Case . . . . . . . . . . . . . . . . . . . 9-23
Fornt Final Gear Case Oil Level Rear Final Gear Case Oil
Inspection. . . . . . . . . . . . . . . . . . .. 9-9 Level Inspection . . . . . . . . . . . . . . . . 9-23
Front Final Gear Case Oil Change . . . . . . . 9-10 Rear Final Gear Case Oil Change ..... . . . 9-23
Front Final Gear Case Removal . . . . . . . . 9-10 Rear Final Gear Case Removal . . . . . . . . . 9-24
Front Fillal Gear Case RearFinal Gear Case Installation Notes .. . 9-24
Installation Notes ..... . . . . . . . .. . 9-11 Rear Final Gear Case Disassembly . . . . . . . 9-24
Front Final Gear Case Disassembly . . . . . . 9-11 Rear Final Gear Case Assembly Notes ... . 9-24
Front Final Gear Case Assembly. . . . . . . . 9-11 Rear Final Bevel Gear Adjustment . .. .. . 9-26
Differential Unit and Ring Gear Pinion Gear Disassemblx . . .. . .. .... . 9-27
Disassembly. . . . . . . . . . . . . . . . . . . 9-12 Pinion Gear Assembly Note . . . . . . . . . . . 9-28
Differential Unit and Ring Gear Bevel Gear Inspection . . . . . . . . . . . . . . . 9-28
Assembly. . . . . . . . . . . . . . . . . . . . . 9-12 Oil Seal . . . . . . . . . . . . ... . . . . . . . ... .. . 9-28
LSD Clutch Torque Inspection .. . .... .. 9-13 Oil Seal Inspection . . . . . . . . . . . . . . . . . 9-28
LSD Clutch Plates Inspection . . . . . . . . .. 9-13 Ball Bearing or Needle Bearing . . . . . . . . . . . . . 9-28
Pinion Gear Unit Disassembly .... ... .. 9-14 Ball or Needle Bearing Replacement .... . 9-28
Pinion Gear Unit Assembly .. . . . . . . . . . 9-14 Ball or Needle Bearing Inspection ...... . 9-28
Fornt Final Bevel Gear Adjustment . . . . . . 9-14
Bevel Gear Inspection . . . . . . . . . . . . . . . 9-19
Differential Gear Inspection . . . . . . . . . . 9-19
Tapered Roller Bearing Inspection ... ... 9-19
9-2 FINAL DRIVE

Circlip
Front Propeller Shaft .
 FINAL DRIVE 9-3

Circlip
~
Rear Propeller Shaft

I
t I ["'- ~v
lj-------,
~ I~
~::G

, B: UK ModeJ

i
Q) /'
T1 : 8.8 N-m (0.9 kg-m, 78 in-Ib)
T2 : 37 N-m (3.8 kg.m, 27 ft-Ib)
T3 : 25 N-m (2.5 kg-m, 18.0 ft-Ib)
T4 : 29 N-m (3.0 kg-m, 22 ft-Ib)
hront Carrier T5 : 20 N-m (2.0 kg-m, 14.5 ft-Ib)
T6 : 120 N-m (12.0 kg-m, 87 ft-Ib)
T7 : 47 N-m (4.8 kg-m, 35 ft-Ib)
T8 : 49 N-m (5.0 kg-m, 36 ft-Ib)
T9 : 32 N-m (3.3 kg-m, 24 ft-Ib)
T10: 34 N-m (3.5 kg-m, 25 ft-lb)
T11: 7.8 N-m (0.8 kg-m, 69 in-Ib)
T12: 54 N-m (5.5 kg-m, 40 ft-Ib)
T13: 69 N-m (7.0 kg-m, 51 ft-Ib)

G : Apply grease.
L : Apply non-permanent locking agent.
o : Apply hypoid gear oil.
R : Replacement Parts
SG : Specified Grease
St : Stake the fastener.
9-4 FINAL DRIVE
............................................................................
Full Time 4 Wheel- Drive Mechanism
............................................................................

iJ Front

Front Final

10

Sub-Transmission

1. Engine Output Shaft

2. Bevel Gears (Sub-Transmission)
3. Sub-Transmission Shifter
4. Drive Shaft (Sub-Transmission)
5. Output Shaft (Sub-Transmission)
6. Rear Propeller Shaft
7. Bevel Gears (Rear Final) ~
8. Rear Axles
9. Front Propeller Shaft '----
10. Bevel Gears (Front Final)
11. LSD Clutches
12. Differential Gears Rear Final
13. Front Axles
 FINAL DRIVE 9-6

Outside Circlip Pliers: 57001-144

Specifications

Front final gear case:

Gear case oil
Grade: API GL-5 hypoid gear oil for LSD
(Limited Slip Differential gears)
Viscosity: SAE140 or SAE85 W-140
Oil level: filler opening level
Amount: 025 L
LSD clutch torque: 7.8 -13.0 N~ (0.8 -1.3 kg-m, Pinion Gear Holder: 57001-1281
69 -113 in-lb)
Outside friction
plate thickness: 2.3 -2.4 mm
(Service limit: 2.1 mm)
Inside friction plate
thickness: 2.7 -2.8 mm
(Service limit: 2.4 mm)
Pinion gear bearing
preload: 0.3 - 0.6 N~ (0.03 - 0.06 Socket Wrench: 57001-1283
kg~, 2.6 - 52in-lb)
Bevel gear backlash: 0.09 - 020 mm
(at ring gear tooth)
Rear final gear case:
Gear case oil
Grade: API GL-5 hypoid gear oil
Viscosity: when above 5C (41F) SAE90
when below 5C (41F) SAE80
Oil level: filler opening bottom
Amount: 0.2 L
Rear final bevel
Gear backlash: 0.07 - 0.17 mm
(at pinion gear.spline)
Ring gear thrust plug: % turn out
Ring gear thrust plug Bearing Puller: 57001-158
gap (for reference): 0.3 - 0.5 mm

..............................................................................
Special Tools

Along with common hand tools, the following more

specialized tools are required for complete final drive
servicing.

Socket Wrench: 57001-1268

Dial Gauge Holder: 57001-1049

o
9-6 FINAL DRIVE

Pinion Gear Holder: 57001-1285 Bearing Driver Set: 57001-1129

Jack: 57001-1238

Bevel Gear Holder: 57001-1193

Hexagon Wrench: 57001-1284

Inside Circlip Pliers: 57001-143

Front Fork Oil Seal Driver: 57001-1104

Oil Sea.1 & Bearing Remover: 57001 -1058

Bearing Driver: 57001-382

 FINAL DRIVE 9-7
............................................................................
Front Propeller Shaft Front Axle

Front Propeller Shaft Removal Front Axle Joint Boot Inspection

eRemove the front propeller shaft cover using the socket eVisuaily inspect the front axle joint boots in accord-
wrench (special tool: 57001-1268). ance with the Periodic Maintenance Chart (see General
Information chapter) or if the axles are noisy during
operation.

A. Front Propeller Shaft Cover

B. Mounting Bolts

eRemove the circlip with the outside circlip pliers
(special tool: PN 57001-144).
ePuil back the propeller shaft sliding joint. The spring
comes off with the joint.
A. Front Axle Joint Boots
*If the joint boot is torn, worn, deteriorated, or leaks
grease, replace the joint boots as a set and check the
universal joints (see Front Axle Joint Boot Replace-
ment).

Front Axle Removal

eRemove the following parts.
Steering Knuckle (Steering Knuckle Removal in the
Steering chapter)
Front Axle Cap Bolts

A. Propeller Shaft Sliding Joint B. Circlip

eRemove the propeller shaft from the vehicle.

ePuil out the universal joints.

Front Propeller Shaft Installation Notes

e lnstallation is the reverse of removal. Note the fol-
lowing.
eWipe the old grease off the splines of the propeller
shaft, the propeller shaft joint, and the universal joints.
elnspect the splines of the prop~lIer shaft, the sliding
joint, and the universal joints.
*If the splines are twisted or damaged in any way,
replace the shaft, the sliding joint, or the universal
joints.
eApply grease to them. A. Front Axle Cap Bolts
eReplace the circlip with a new one.
eAlign the yoke angle of the front propeller shaft and
the output shaft. ePuil the front axle out of the front final gear case.
9-8 FINAL DRIVE

Front Axle Installation Notes - Remove the following parts in the order shown.
-Installation is the reverse of removal. Note the fol- 1. Larger Retaining Ring
lowing. (to split the outboard and inboard shafts)
-Wipe the old grease off the splines of the axle and the 2. Smaller Retaining Ring
cap oil seal, and grease them. 3. Ball Bearing
-Visually inspect the splines of the axle. 4. Inboard Joint Boot
*If they are badly worn or chipped, replace the axle
with a new one.
-Be sure to install the space'r in the recess of the front Inboard Joint DiSassembly
final gear case.
@ CD @

-Unlock the boot bands for the outboard joint boot and
remove the boot.
oThe outboard joint can not be disassembled .
. oReplace the inboard and outboard joint boots.
-Check the universal joints.
*If any joint does not work smoothly without rattling or
sticking, the joint bearing is damaged. Replace the axle
with a new one.
1. Spacer - Visually inspect the splines on the shaft.
*If they are badly worn or chipped, replace the axle.
-Tighten the cap bolts to the specified torque (see Ex- oAssembly is the reverse of disassembly. Note the fol-
ploded View). lowing.
- Clean off the joint parts.

Front Axle Joint Boot Replacement

-Remove the front axle (see Front Axle Removal).
-Unlock the boot bands for the inboard joint boot and
move the boot toward the outboard joint.
ONever clean the boots with mineral oil or gasoline
because they will deteriorate the boot .

P\lck the outboard joint with about 40g of the special

grease .
Pack the inboard joint with about 2Sg of the special
grease at fi rst.

OBe sure to use the special grease in the boot set.

- Install the larger retaining ring so that the opening is

A. Boot Bands B. Move the boot aligned with one of the projections.
 FINAL DRIVE 9-9

1. Retaining Ring 3. Outer Race 1. Pull 2. Tangs

2. Opening

-Pack the inboard joint with the rest of the grease

(about 20g).
-Fit the joint boot lips onto the grooves on the axle.
oPosition the joint boot as shown.
Front Final Gear Case
.............................................................................
Front Final Gear Case Oil Level Inspection
21 mm 82mm 78 mm 48 mm ePark the vehicle so that it is level, both sideto-side and

~
front-to rear.
eRemove the filler cap.

OBe careful not to allow any dirt or foreign materials to

enter the gear case.

ec:heck the oil level. The oil level should come to the
Outboard Joint Boot bottom of the filler opening.
Inboard Joint Boot

eSlightly open the larger diameter end of the joint boot

to equalize the air pressure inside the boot.

A. Filler Opening

*If it is insufficient, first check the front final gear case

ec:lamp the boot band and bend the tangs securely to
hold down the end of the band.
for oil leakage, remedy it if necessary, and add oil
through the filler opening. Use the same type and
brand of oil that is already in the final gear case.
-Be sure the O-ring is in place, and tighten the filler cap
to the specified torque (see Exploded View).
9-10 FINAL DRIVE

Front Final Gear Case Oil Change
eWarm up the oil by running the vehicle so that the oil
will pick up any sediment and drain easily. Then stop
the vehicle.
ePark the vehicle so that it is level, both side-to-side and
front-to-rear.
eRemove the gear case skid plate.
ePlace an oil pan beneath the front final gear case and
remove the drain plug.
Front Final Gear Case Removal
eDrain the gear case oil (see Front Final Gear Case Oil
Change).
eRe move the following parts.
Front Propeller Shaft (see Front Propeller Shaft
Removal)
Right Front Axle (see Front Axle Removal)
Front Final Gear Case Bolts and Nuts

A. Drain Plug B. Front A. Gear Case Bolts B. Right Front Axle

WARNING I eLoosen the right and left suspension arm pivot bolts on
front and upper.
OWhen draining or filling the final gear case, be careful
elt may be necessary to support the case while sliding
that no oil gets on the tire or rim. Clean off any oil
out the case bolts.
that inadvertently gets on them with a high-flash point
solvent.

eAfter the oil has completely drained out, install 'the

drain plug with a new aluminum gasket, and tighten it
to the specified torque (see Exploded View).
eFill the gear case up to the bottom of filler opening
with the oil specified below.

Front Final Gear Case Oil

Grade: API GL.o hypoid gear oil for LSD
(Limited Slip Differential gears)
Viscosity: SAE140 or SAE85 W-140
Amount: 0.25 L

A. Gear Case Bolts C. Front

NOTE B. Suspension Arm Pivot Bolts

O"GL-5" indicates a quality and additive rating.

eBe sure the O-ring is in place, and tighten the filler cap eRe move the vent hose from the gear case.
to the specified torque (see Exploded View). eRemove the left front axle cap bolts and pull out the
elnstall the gear case skid plate. front final gear case from the vehicle right side.
 FINAL DRIVE 911

Front Final Gear Case Installation Notes e Take out the ring gear and differential unit.
e lnstallation is the reverse of removal. Note the fol-
lowing.
After installing the gear case vent hose, install the gear
case bolts and nuts.
eTighten the following bolts and nuts to the specified
torque (see Exploded View) .
Front Axle Cap Bolts
Suspension Arm Pivot Bolts
Front Final Gear Case Bolts and Nuts
eApply a non-permanent locking agent to the threads of
the two case bolts on the front side.
eFili the front final gear case with the specified oil (see
Front Final Gear Case Oil Change).

Front Final Gear Case Disassembly

eRemove the front final gear case (see Front Final Gear A. Differential Unit B. Ring Gear
Case Removal).
e Remove the bearing housing nuts .
e Take out the pinion gear unit.

Front Final Gear Case Assembly

e lnspect the following parts.
Ball Bearings (see Ball or Needle Bearing section)
Oil Seal (see Oil Seal section)
e Visually check the pinion gear and ring gear for scoring,
chipping, or other damage.
* Replace the bevel gears as a set if either gear is damaged
since they are lapped as a set in the factory to get the
best tooth contact.
e lnstall the following parts in the order shown.
Defferential Unit and Ring Gear (see Differential Unit
and Ring Gear Assembly)
Ring Gear Shim
A. Pinion Gear Unit B. Bearing Housing Nuts Ring Gear Cover
Pinion Gear Unit (see Pinion Gear Unit Assembly)

e Remove the ring gear cover bolts, starting with the

smaller bolts.

A. Ring Gear Shim

Olnstall the pinion gear unit with the ring gear side of
A. Smaller Bolts C. Larger Bolts the case facing down.
B. Pry Points oAlign the air vent passage shown with the hose nipple.
9-12 FINAL DRIVE
oThe clutch plates, springs, spring shims, and side gears
come out.

Differential Unit and Ring Gear Assembly

e Assembly is the reverse of removal. Note the fol-
lowing.

NOTE
aBe sure to install the right and left side parts of the unit
in the original position.
e lnspect the clutch plates (see Clutch Plate Inspection)
A. Air Vent Passage B. Hose Nipple and the other differential unit parts. Replace any
damaged parts.
e Measure and record the thickness of the original clutch
oTighten the following fasteners to the specified torque spring shim(s).
(see Exploded View). e Apply the specified gear oil to the differential unit
Ring Gear Cover Bolts (first tighten 10 mm, then 8 parts.
mm) e Note direction and position of the friction plate and
Pinion Gear Bearing Housing Nuts the clutch spring.
OAdjust the following items (see Front Final Bevel Gear
Adjustment)
Front Final Gear Back-Lash
Front Final Gear Tooth-Contact

Differential Unit and Ring Gear Disassembly

e Re move. the differential unit and ring gear (see Front
Final Gear Case Disassembly).

NOTE
000 not interchange the right and left side parts in the
differential unit.

e Remove the following parts to disassemble the

differential unit.
Ring Gear
Differential Caps

1. Clutch Spring Shim(s) 4. Steel Plate

2. Clutch Spring 5. Inside Friction Plate
3. Outside Friction Plate

eTemporarily assemble the differential unit and inspect

A. Ring Gear Bolts
B. Mark here for assembly later.
the clutch torque (see LSD Clutch Torque Inspection).
e lnstall the front axles to center the steel plates.
eTighten t he following bolts to the specified torque (see
Exploded View).
Differential Case Torx Bolts (Apply non-permanent
C. Differential Cap locking agent)
Ring Gear Bolts
 FINAL DRIVE 9-13

oAlso, check the clutch plates and replace them as

necessary (see Clutch Plates Inspection).
oTo increase clutch torque, increase the thickness of the
shim(s).
OChange the thickness a little at a time.
e Re-check the clutch torque and re-adjust as necessary.

Clutch Spring Shim(s)

Thickness Part Number
(mm)
1.0 92025-1908
1.2 92025-1909
1:4 92025-1910
A. Front Axle C. Mark 1.6 92025-1911
B. T orx Bolts D. Dowel Pin 92025-1912
1.8

LSD Clutch Torque Inspection

eRemove the differential unit and ring gear (see Front
Final Gear Case Disassembly).
eRemove the ring gear from the differential unit.
elnsert both front axles in the unit.
eHold one of the front axles with a vise.
elnstall the hUb nut on the other axle.
eMeasure the clutch torque using a torque wrench. Turn
the wrench evenly.
oThe clutch torque is defined as the mean reading of the
torque during about a quarter turn of the wrench .
LSD Clutch Plates Inspection
eVisually inspect the friction plates and steel plates to
see if they show any signs of seizure, overheating, or
uneven wear.
*If any plates shown signs of damage, or if the friction
plates have worn past the service limit, replace the
friction plates and steel plates as a set.

LSD Clutch Torque

Outside Friction Plate Thickness
Standard: 7.8 - 13.0 N-m (0.8 -1.3 kg-m,
69 - 113 in-Ib) Standard: 2.3 - 2.4 mm
Service Limit: 2.1 mm

Inside Friction Plate Thickness

Standard: 2.7 - 2.8 mm
Service Limit: 2.4mm
f :'>
A'
~
!
\ \
~",r (:
,

A. Front Axles B. Differential Unit

*If the clutch -torque is out of the specified range, dis-

assemble the differential unit (see Differential Unit and
Ring Gear Disassembly) and replace the clutch spring
shim(s). Either shim will do. 1. Outside Friction Plate 2. Inside Friction Plate
9-14 FINAL DRIVE

Pinion Gear Unit Disassembly

eRemove the pinion gear unit (see Front Final Gear Case
Disassembly).
ePry open the toothed washer tab on the pinion gear
slotted nut.
eUnscrew the pinion gear slotted nut using the pinion
gear holder and the socket wrench (special tools).

1. Slot 3. Claw
2. Tab

eBend the tab over the nut.

Front Final Bevel Gear Adjustment

A. Pinion Gear Holder: 57001-1281
B. Socket Wrench: 57001-1283
eRemove the slotted nut,.. flat washer, and toothed
washer.
ePull the pinion gear out of the bearing housing.
eRemove the tapered roller bearing inner race as
necessary using the bearing puller (special tool: 57001-
158).
In order to prevent one gear from moving away from
the other gear under load, the tapered roller bearings
must be properly preloaded. Also the backlash (distance
one gear will move back and forth without moving the
other gear) and tooth contact pattern oJ the bevel gears
must be correct to prevent the gears from making noise
and being damaged.
Above three adjustments are of critical importance
and must be carried out following the correct sequence
and method.
Front Final Bevel Gear Adjustment Procedure

Preload the pinion gear bearings.

Pinion Gear Unit Assembly

ePinion gear unit assembly is the reverse of disassembly.
Note the following.
eThe pinion gear and ring gear are lapped as a set in the
factory to get the best tooth contact. They must be
replaced as a set.
eVisually inspect the tapered bearings for abrasion,
color change, or other damage.
*If there is any doubt as to the condition of a bearing,
replace the bearing housing and the bearings as a set.
eBe sure to check and adjust the pinion gear bearing pre- Assemble the final gear case completly.
load and the bevel gear backlash and tooth contact,
when any of the backlash-related parts are replaced (see
Front Final Bevel Gear Adjustment).
oWhen the pinion gear slotted nut is loosened, even if eWhen anyone of the backlash-related parts are replaced
the purpose is not to replace the parts, check and or the pinion gear nut is loosened; even if the purpose
adjust the bearing preload. is not to replace the parts, check and adjust the bearing
eApply an oil to the threads and seating surface of the preload, the bevel gear backlash, and tooth contact by
pinion gear slotted nut, and tighten it to the specified replacing shims.
torque (see Exploded View). eThe amount of backlash is influenced by the ring gear
*If none of the toothed washer tabs align, tighten the position more than by the pinion gear position.
nut further just enough to align one of the tabs with a eTooth contact location is influenced by pinion gear
slot in the nut. position more than by ring gear position.
 FINAL DRIVE 9-15

Front Final Gear Case (Backlash-Related Parts) Shims for Preload Adjustment
Thickness
(mm) Part Number

1.70 92025-1072
Front 1.72 92025-1073
1.74 92025-1074
1.76 (primary) 92025-1075
1.78 92025-1076
1.80 92025-1077

Ring Gear Shims for Pinion Gear Shims for

Backlash Adjustment Tooth Contact Adjustment
Thickness Thickness
(mm) Part Number
(mm) Part Number
0.1 92025-1850
O.l 92025-1919
0.15 92025-1851
0.l5 92025-1920
0.5 92025-1856
0.5 92025-1921
0.8 92025-1857
0.8 92025-1922
1.0 (primary) 92025-1849
1.0 (primary) 92025-1923
1.2 92025-1924
Collars for Preload Adjustment
1. Ring Gear Cover
Thickness 2. Front Final Gear Case
Part Number
(mm) .3. Ring Gear
10.2 92027-1401 4. Ring Gear Shims for Backlash Adjustment
10.3 92027-1402 5. Left Differential Cap
10.4 92027-1403 6. Ball Bearing
10.5 92027 -1404 7. Collarfor Preload Adjustment (affects preload only)
10.6 92027-1405 8. Shims for Preload Adjustment (affects preload only)
10.7 (primary) 92027-1 406 9. Pinion Gear Shims for Tooth Contact Adjustment
10.8 92027-1407 10. Pinion Gear
10.9 92027-1408 11. Tapered Roller Bearing
11.0 92027-1409 12. Pinion Gear Bearing Housing
11.1 92027-1410 13. Tapered Roller Bearing (affects preload only)
1l.2 92027-1411 14. Oil Seal Collar (affects preload only)
15. Pinion Gear Slotted Nut (affects preload only)
9-16 FINAL DRIVE

Bearing Preload Adjustment

eCheck and adjust the bearing preload in the following
cases.
oWhen any of the parts listed below are replaced with
new ones.
Pinion Gear
Collar
Shim
Tapered Roller Bearings
Pinion Gear Bearing Housing
Oil Seal Collar
oWhen the pinion gear slotted .nut is loosened; even if
the nut is not replaced.
elnstall the pinion gear bearing housing (see Pinion Gear
Unit Disassembly/Assembly) and tighten the pinion
gear slotted nut to the specified torque (see Exploded A. Spring Scale
View). B. Pinion Gear Holder: 57001-1281
eDo not install the oil seal and O-rings, and do not lock C. 200 mm
the washer until the correct bearing preload is ob-
tained.

OTo start with, choose a shim or collar so that the Using Torque Wrench:
bearings are just SNUG with NO play but also with NO
preload.
OAn over-preload on the bearings could damage the
bearings.

eApply specified gear oil to the bearings, and tur!1 the

gears more than 5 turns to allow the bearings to seat.
eMeasure the bearing preload. Bearing preload is .~ -~,,~n
defined as the force or torque which is needed to start ~.
the gear shaft turning.

NOTE
OPreload can be measured either with a spring scale or a
beam-type torque wrench. When measured with a
A. Torque Wrench
spring scale, the preload is designated by force (N, kg),
B. Pinion Gear Holder: 57001-1281
and when measured with a torque wrench, it is des
ignated by torque (N-m, kg-m, in-Ib).
*If the preload is out of the specified range, replace the
collar and/or spacer.
oTo increase preload, decrease the size of the spacer or
collar. To decrease preload, increase the size Qf the
spacer or' collar.
oChange the thickness a little at a time.
eRe-check the bearing preload, and re-adjust as nec-
essary.

Pinion Gear Bearing Preload

Using Spring Scale:
eHook the spring scale on the handle at a point 200 mm Using spring scale: 1.5 - 3.0 N
apart from the center of the gear shaft. Hold the (0.15 - 0.30 kg)
bearing housing in a vise so that the gear shaft is
vertical. Using torque wrench: 0.3 - 0.6 N-m
eApply force to the handle horizontally and at a right (0.03 - 0.06 kg-m,
angle to it. 2.6 - 52 in-Ib)
 FINAL DRIVE 9-17

Backlash Adjustment NOTE

eCheck and adjust the gear backlash when any of the OApply checking compound to the teeth in a thin, even
parts shown in the Backlash-Related Parts are replaced coat with a fairly stiff paint brush. If painted too
with a new one. thickly, the exact tooth pattern may not appear.
eCiean any dirt and oil off the bevel gear teeth. OThe checking compound must be smooth and firm,
eAssemble the front final gear case (see Front Final Gear with the consistency of tooth paste.
Case Assembly). Do not install the O-rings during ad- OSpecial compounds are available from. automotive
justment. supply stores for the purpose of checking differential
oCheck the backlash during the tightening of the ring gear tooth patterns am;! contact. Use one of these for
gear cover bolts and stop tightening them immediately checking the bevel gears.
if the backlash disappears. Then, change the ring gear
shim to a thinner one.
eSet up a dial gauge against a ring gear tooth to check
gear backlash as shown.
eAssemble the front final gear case (see Front Final Gear
Case Assembly). Do not install the O-rings during ad-
justment.
eTurn the pinion gear for one revolution in the drive and
reverse (coast) direction, while creating a drag on the
ring gear.
oUse the pinion gear holder (special tool: 57001-1281)
and the left front axle.
eRemove the ring gear and pinion gear unit to check the
drive pattern and coast pattern of the bevel gear teeth.
oThe tooth contact patterns of both (drive and coast)
sides should be centrally located between the top and
bottom of the tooth. The drive pattern can be a little
closer to the toe and the coast pattern can be a some-
what longer and closer to the toe.
*If the tooth contact pattern is incorrect, replace the
pinion gear shim(s), following the examples shown.
eThen erase the tooth contact patterns and check them
A. Move Front Axle again. Also check the backlash every time the shim{s)
B. Pinion Gear Holder: 57001-1285 are replaced. Repeat the shim change procedure as
C. Dial Gauge necessary.
D. Dial Gauge Holder: 57001-1049

NOTE
eTo measure the backlash, move the left front axle (ring
Off the backlash is out of the standard range after
gear side) back and forth while holding the pinion gear
changing the pinion gear shim(s), change the ring gear
steady. The difference between the highest and the
shim(s) to correct the backlash before checking the
lowest gauge reading is the amount of backlash.
tooth contact pattern.
*If the backlash is not within the limit, replace the ring
gear shims. To increase backlash, decrease the thick-
ness of the shim{s). To decrease backlash, increase the
thickness of the shim{s).
oChange the thickness a little at a time.
eRe-check the backlash, and re-adjust as necessary.

Final Bevel Gear Backlash

Standard: 0.09 - 0.20 mm
(at ring gear tooth)

Tooth contact adjustment

-Clean any dirt and oil off the bevel gear teeth.
eApply checking compound to 4 or 5 teeth on the
pinion gear.
9-18 FINAL DRIVE
Correct Tooth Contact Pattern

Bottom

Toe Pinion Gear

Top

-k. -------..
Heel

Bottom ------
.
-+---

Incorrect Tooth Contact Patterns

Examplel: Decrease the thickness of the pinion gear shim(s) by 0.05 mm to correct the pattern shown below. Repeat
in 0.05 mm steps if necessary.

Bottom

Toe
Heel

Bottom
Ring Gear

Example 2: Increase the thickness of the pinion gear shim(s) by 0.05 mm to correct the pattern shown below. Repeat
in 0.05 mm steps if necessary.

_ - - - Heel

-,I
Bottom

Toe
Pinion Gear

Heel
~.
Bottom . ----------
 FINAL DRIVE 9-19

Bevel Gear Inspection e Drain the engine oil (see Engine Right Side chapter in
eVisually check the bevel gear-s for scoring, chipping, or the Base Manual) .
other damage. eSupport the rear part of the frame on blocks or the
*Replace the bevel gears as a set if either gear is damaged. jack (special tool: PN 57001-1238) so that the sus-
pension arms are free from loads.
eRemove the following parts.
Rear Fender (see Frame chapter)
Differential Gear Inspection Wiring Straps for Brake Cables and Vent Hoses
eVisually check the differential gears for scoring, Brake Pedal Adjuster and Parking Brake Lever
chipping, or other damage. Adjuster on Rear Brake Panel
eAlso, inspect the differential pinion gear shaft and gear Rear Shock Upper Mounting Bolts and Nuts
housing where the differential gears rub. Suspension Arm Pivot Shaft
*If they are scored, discolored, or otherwise damaged, Propeller Shaft Joint Boot Clamp Screw
replace them as a set.

1. Propeller Shaft Joint Boot Clamp Screw

2. Suspension Arm Pivot Shaft
A. Differential Gear Housing C. Pinion Gears
B. Pinion Gear Shaft D. Side Gears
e Move the propeller shaft to the rear along with the
wheels just enoug~ to free the shaft from the engine.
Tapered Roller Bearing Inspection e Re move the propeller shaft housing nuts.
eTake off the propeller shaft. The spring comes off with
eVisually inspect the bearings for abrasion, color change,
the propeller shaft.
or other damage.
*If there is any doubt as to the condition of a bearing,
replace it.

............................................................................
Rear Propeller Shaft
............................................................................
Rear Propeller Shaft Removal
1. Propeller Shaft Housing Nuts
NOTE
alt is not necessary to remove the rear shocks, rear Rear Propeller Shaft Installation
wheels, and rear axle assembly. e lnstallation is the reverse of removal. Note the fol -
lowing.
e Wipe the old grease off and grease the front end splines
e Remove the rear final gear case skid plate. of the shaft and the pinion gear joint splines.
e Drain the rear final gear case oil (see Rear Final Gear e Be sure to install the spring on the pinion gear nut of
Case Oil Change). the rear final gear case.
9-20 FINAL DRIVE

*If the joint boot is torn , worn, or deteriorated, replace

the joint boot ahd check the propeller shaft (see Rear
Propeller Shaft Boot Replacement).

A. Apply grease. B. Spring

elnstall the propeller shaft.

A. Front B. Joint Boot

Rear Propeller Shaft Joint Boot Replacement

eRemove the rear propeller shaft . (see Rear Propeller
Shaft Removal).
eRemove the circlip with the circlip pliers (special tool:
PN 57001-143) and pull out the shaft from the
housing.

1. Joint Boot 3. Apply grease.

2. Universal Joint

eTighten the following bolts and nuts to the specified

torque (see Exploded View).
Propeller Shaft Housing Nuts
Suspension Arm Pivot Bolts
Rear Shock Mounting Bolts and Nuts
eFili the engine oil (see Specifications in the Engine
Right Side chapter in this text) and the rear final
gear case oil (see Rear Final Gear Case Oil Change) .
eRun the brake cables and the vent hoses according to
the Wiring, Cable, and Hose Routing in the General
Information chapter).
eAdjust the brake pedal and the parking brake (see A. Circlip
Brakes chapter).
-Check that the universal joint works smoothly without
rattling or sticking.
*If it does not, the bearing of the universal joint is
damaged. Replace the propeller shaft with a new one.
eVisually inspect the grease seal and cap for the universal
Rear PropellerShaft Joint Boot Inspection joint.
eVisually inspect the rear propeller shaft joint boot in *If there is any signs of deterioration, damage, or loosen,
accordance with the Periodic Maintenance Chart (see replace the propeller shaft.
General Information chapter) or if the shaft is noisy *If the grease leakage is noted, replace the propeller
during, operation. shaft.
 FINAL DRIVE 9-21

Rear Axle
.............................................................................
Rear Axle Unit Removal
eRemove the rear final gear case skid plate.
eDrain the rear final gear case oil (see Rear Final Gear
Case Oil Change).
eDrain the engine oil (see Engine Right Side chapter in
the Base Manual).
eRemove the following parts.
Rear Fender (see Frame chapter)
Rear Wheels
Brake Drum (see Brakes chapter)
Rear Brake Panel (see Brakes chapter)
Rear Propeller Shaft Joint Boot Front End
A. Universal Joint C. Center Bearing
eRemove the foHowing parts.
B. Grease Seal D. Splines
Center Arm Bolts
Lower Mounting Bolts of Rear Shock Absorbers
Suspension Arm Pivot Bolts

A. Joint Boot Clamp C. Lower Mounting Bolts

A. Grease Cap B. Splines B. Center Arm Bolts D. Pivot Bolts

eMove the rear axle unit to the rear just enough to free
from the vehicle.
eRemove the propeller shaft by taking off the housing
nuts.

elnspect the center bearing.

oSince the ball bearings are ' made to extremely close
tolerances, the wear must be judged by feel rather than
measurement.
oSpin the bearing by hand to check its condition.
*If the bearing is noisy, does not spin smoothly, or has
any rough spots, replace the propeller shaft.
eExamine the bearing seal for tears or leakage.
*If the seal is torn or is leaking, replace the propeller
shaft.
eVisually inspect the splines on the propeller shaft.
*If they are badly worn or chipped, replace the propeller
shaft. Also, inspect the splines on the sub-transmission
output shaft and the pinion gear joint. A. Housing Nuts B. Rear Axle Unit
9-22 FINAL DRIVE

Rear Axle Unit Installation Notes

elnstallation is the reverse of removal. Note the
following.
eRefer to the Brakes chapter for Brake Panel Installation.
eWipe the old grease off and grease the propeller shaft
splines and the pinion gear joint splines (see Propeller
Shaft Installation).
eTighten the following bolts and nuts to the specified
torque (see Exploded View).
Propeller Shaft Housing Nuts
Suspension Arm Pivot Bolts
Rear Shock Mounting Bolts and Nuts
Center Arm Nuts
eFill the engine oil (see Specifications of Engine Right
Side chapter in this text) and the rear final gear case oil
(see Rear Final Gear Case Oil Change) . A. Splines

*If the splines are twisted or damaged in any way,

replace the rear axle.

Rear Axle Unit Disassembly

eRemove the rear axle unit (see Rear Axle Unit
Removal). Rear Axle Unit Assembly
eTake off the right and left axle pipes by removing the eAssembly is the reverse of removal. Note the fol-
pipe nuts. lowing.
eUsing a press and the bearing driver set (special tool:
PN 57001-1129), install the right side oil seal and ball
bearings until they bottom out. And install the left
side oil seal until it is flush with the pipe end.

Left Side Axle Right Side Axle

I
~~=r'
If

A. Axle Pipes
II

I
CD
eTake each axle out of the axle pipes.
eTo remove the ball bearing, remove the oil seal and 1. Oil Seal 3. Bearing
circlip for the left-hand axle. 2. Snap Ring
eRemove each bearing or oil seal, using the oil seal and
bearing remover (special tool: 57001-1058).
elnspect the condition of the splines at each end of the
axle. e Apply grease to the oil seals on the axle pipes.
 FINAL DRIVE 9-23

(;:'
A f'
.\::

A. Apply grease. A. Filler Opening

*If it is insufficient, first check the rear final gear case

eTighten the axle pipe nuts to the specified torque (see
Exploded View).
eFill the rear final gear case with the specified oil (see
Rear Final Gear Case Oil Change).
for oil leakage, remedy it if necessary, and add oil
through the filler opening. Use the same type and
brand of oil that is already in the final gear case.
e Be sure the O-ring is in place, and tighten the filler cap
to the specified torque (see Exploded View).

Rear Axle Bearing Inspection Rear Final Gear Case Oil Change
eRemove the rear axle (see Rear Axle Unit Disassembly). eWarm up the oil by running the vehicle so that the oil
will pick up any sediment and drain easily. Then stop
the vehicle.
NOTE
e Park the vehicle so that it is level, both side-to-side
OSince the bearings are packed with grease and sealed, and front-to-rear.
they can not be lubricated. ePlace an oil pan beneath the rear final gear case and
remove the drain plug.
eRefer to Ball or Needle Bearing section in this chapter
for sealed bearing inspection.

Rear Final Gear Case

Rear Final Gear Case Oil Level Inspection

ePark the vehicle so that it is level, both side-to-side and
front-to rear. A. Remove the drain plug.
eRemove the filler cap.
I WARNING.
oWhen draining or filling the final gear case, be careful
that no oil gets on the tire or rim. Clean off any oil
oBe careful not to allow any dirt or foreign materials to that inadvertently gets on them with a high-flash point
enter the gear case. solvent.

e After the oil has completely drained out, install the

e Check the oil .level. The oil level should come to the drain plug with a new aluminum gasket and tighten it
bottom of the filler opening. to the specified torque (see Exploded View).
9-24 FINAL DRIVE

eFili the final gear case up to the bottom of filler ePull the ring gear out of the case.
opening with the oil specified below. ePry open the staking of the pinion gear nut with a small
chisel.
eUnscrew the pinion gear nut using the bevel gear holder
Rear Final Gear Case Oil
(sp'ecial tool) to keep the pinion gear assembly as
Type: API GL-S Hypoid gear oil shown.
SAE90 (above SoC, 41F)
SAE80 (below SoC, 41F)
Capacity: 0.2 L

NOTE
0"GL-5" indicates a quality and additive rating. "GL-6"
rated hypoid gear oils can also be used.

eBe sure the O-ring is in place and tighten the filler cap
to the specified torque (see Exploded View).

Rear Final Gear Case Removal

eThe final gear case is removed during disassembling the A. Bevel Gear Holder: 57001-1193
rear axle unit. Refer to Rear Axle Unit Disassembly B. Pinion Gear Nut
section.
eRemove the pinion gear joint and the oil seal.
eUnscrew the pinion gear bearing holder set plug.
eUnscrew the pinion gear bearing holder using the
Rear Final Gear Case Installation Notes hexagon wrench (special tool).
elnstallation is the reverse of removal. Note the fol-
lowing.
eTighten the axle pipe nuts to the specified torque (see
Exploded View).
eFili the rear final gear case with' the specified oil (see
Rear Final Gear Case Oil Change).

Rear Final Gear Case Disassembly

eRemove the rear final gear case (see Rear Final Gear
Case Removal).
eUnscrew the ring gear cover bolts and pull off the
cover. The shim{s) comes off with the cover.
A. Pinion Gear Bearing Holder (Right-Hand Threads)
B. Bearing Holder Set Plug
C. Hexagon Wrench (41 mm,57001-1284)

ePull out the pinion gear unit.

Rear Final Gear Case Assembly Notes

eAssembly is the reverse of disassembly. Note the fol-
lowing.
-Check the following parts.
Oil Seal (see Oil Seal section)
A. Ring Gear Cover Ball Bearings (see Ball or Needle Bearing section)

eVisually check the bevel gears for scoring, chipping, or
other damage.
*Replace the bevel gears as a set if either gear is damaged
since they are lapped as a set in the factory to get the
best tooth contact.
eBack out the ring gear thrust plug fully.
A. Ring Gear Thrust Plug B. Locknut
eBe sure to check and adjust the bevel gear backlash and
tooth contact when any of the backlash-related parts
are replaced (see Rear Final Bevel Gear Adjustment).
elnstall the pinion gear bearing holder with the deeper
recess side facing outboard and tighten it to the spe-
cified torque (see Exploded View).
eReplace the pinion gear nut and the oil seal with the
new ones.
eVisually inspect the splines of the pinion gear joint.
*If they are badly worn or chipped, replace the joint
with a new one. Also, check the propeller shaft
internal splines.
elnstall the pinion gear joint.
A. Splines B. Pinion Gear Joint
FINAl:. DRIVE 9-25
eTighten the following parts to the specified torque (see
Exploded View).
Pinion Gear Bearing Holder (Oil the threads and
seating surface)
Pinion Gear Bearing Holder Set Plug
Ring Gear Cover Bolt~ (tightening order 10 mm -+
8mm)
eReplace the pinion gear nut with a new one.
eApply an oil to the threads and seating surface of the
pinion gear nut, and .tighten them to the specified
torque (see Exploded View).
eStake the head of the pinion gear nut with a punch to
secure the pinion gear nut.
OWhen staking the nut, be careful not to apply shock to
the pinion and their bearing. Such a shock could
damage the pinion and/or bearings.
eAfter installing the pinion gear bearing holder set plug,
install the oil seal using the fork oil seal driver (special
tool: PN 57001-1104). Flush the seal face with the
end of the hole.
eTurn the ring gear thrust plug clockwise until it be-
comes hard to turn.
eBack out the plug )h turn from that point.
eTighten the locknut to the specified torque keeping the
plug position (see Exploded View).
9-26 FINAL DRIVE

Rear Final Bevel Gear Adjustment

The backlash and tooth contact pattern of the bevel gears must be correct to prevent the gears from making noise
and being damaged.
eAfter replacing any of the backlash-related parts, be sure to check and adjust the backlash and tooth contact of the
bevel gears. First, adjust backlash, and then tooth contact by replacing shims.

1. Pinion Gear 5. Ring Gear Bearing

2. Pinion Gear Shim(s) 6. Ring Gear
3. Ring Gear Thrust Plug 7. Ring Gear Shim(s)
4. Ring Gear Cover 8. Rear Final Gear Case

(J)

Pinion Gear Shims for

Tooth Contact Adjustment
/
Ring Gear Shims for
Backlash Adjustment
Thickness Thickness
Part Number Part Number
(mm) (mm)
0.12 92025-1668 0.1 92025-1850
0.15 92025-1669 0.15 92025-1851
0.18 92025-1670 0.5 92025-1856
0.8 92025-1671 0.8 92025-1857
0.9 92025-1672 1.0 (primary) 92025-1849
1.0 (primary) 92025-1673
1.1 92025-1674
1.2 92025-1675
1.3 92025-1676
1.4 92025-1677

Backlash Adjustment
eClean any dirt and oil off the bevel gear teeth.
eBack out the ring gear thrust plug fully.
000 not install the pinion bearing holder set plug, the oil
seal, and the O-ring during adjustment.
elnstall the pinion gear assembly with the primary (1.0
mm thickness) shim.
elnstall the pinion gear bearing holder with the deeper
recess side facing outward.
eTighten the pinion gear bearing holder to the specified
torque (see Exploded View).
elnstall the ring gear assembly with the 'primary (1.0mm
thickness) shim, and .tighten the ring gear case cover
bolts to the specified torque (see Exploded View).
oCheck the backlash during the tightening of the cover
bolts, and stop tightening them immediately if the
backlash disappears. Then, change the ring gear shim
to a thinner one.
eTemporarily, install the rear axle in the gear case and
hold it with a vise so that the ring gear is lower than the
pinion gear.
eMount a dial gauge on the vise so that the tip of the
gauge is against the splined portion of the pinion gear
joint.
eTo measure the backlash, move the pinion gear nut
back and forth while holding the rear axle steady. The
difference between the highest and the lowest gauge
reading is the amount of backlash.
oMeasure backlash at three locations equally spaced on
the splines.
Rear Final Bevel Gear Backlash: 0.07 - 0.17 mm
A. Hold the axle. C. Dial Gauge
B. Move the pinion gear nut.
*If the backlash is not within the limit, replace the ring
gear shims. To increase backlash, decrease the thick-
ness of the shim(s). To decrease backlash, increase the
thickness of the shim(s).
ilChange the thickness a little at a time.
eRe-check the backlash, and readjust as necessary.
FINAL DRIVE 9-27
Tooth contact adjustment
-Clean any dirt and oil off the bevel gear teeth .
eApply checking compound to 4 or 5 teeth of the
pinion gear.
NOTE
OApply checking compound to the teeth in a thin, even
coat with a fairly stiff paint brush. If painted too
thickly, the exact tooth pattern may not appear.
oThe checking compound must be smooth and firm,
with the consistency of tooth paste.
OSpecial compounds are available at automotive supply
stores for the purpose of checking differential gear
tooth patterns and contact.
elnstall the shim(s) and pinion gear assembly, and
tighten the bearing holder to the specified torque (see
Exploded View).
elnstall the shim(s) and ring gear assembly, and tighten
the cover bolts to the specified torque (see Exploded
View).
eTurn the pinion gear for one revolution in the drive and
reverse (coast) direction, while creating a drag on the
ring gear.
eRemove the ring gear and pinion gear unit to check the
drive pattern and coast pattern of the bevel gear teeth.
oThe tooth contact patterns of both (drive and coast)
sides should be centrally located between the top and
bottom of the tooth. The drive pattern can be a little
closer to the toe and the coast pattern can be a some-
what longer and closer to the toe.
*If the tooth contact pattern is incorrect, replace the
pinion gear shim(s), following the examples shown (see
Correct Tooth Contact Pattern in Front Final Bevel
Gear Adjustment section).
eThen erase the tooth contact patterns, and check them
again. Also check the backlash every time the shim(s)
are replaced. Repeat the shim change procedure as
necessary.
NOTE
Olf the backlash is out of the standard range after
changing the pinion gear shim(s), change the ring gear
shim(s) to correct the backlash before checking the
tooth contact pattern.
Pinion Gear Disassembly
eRemove the pinion gear (see Rear Final Gear Case Dis-
assembly).
eRemove the pinion gear bearing as necessary using the
bearing puller (special tool: 57001-158).
9-28 FINAL DRIVE

Pinion Gear Assembly Note

elnstall the pinion gear bearing on the pinion gear with
the bearing driver (special tool : 57001-382) until the
bearing is firmly seated against the pinion gear.

A. Front Final Gear Case

B. Oil Seal & Bearing Remover: 57001-1058

NOTE
Oln the absence of the above mentioned tools, satis-
1. Bearing Driver: 57001-382 factory results may be obtained by heating the case to
2. Pinion Gear Bearing approximately 93C (200F) max., and tapping the
bearing in or out.

Bevel Gear Inspection 000 not heat the case with a torch. This will warp the
eVisually check the bevel gears for scoring, chipping, or case. Soak the case in oil and heat the oil.
other damage.
*Replace the bevel gears as a set if either gear is damaged .
-Using a press and the bearing driver set (special tool:
PN 57001-1129), install the new bearing until it stops
at the bottom of its housing.

........................................................................... CD
Oil Seal

Oil Seal Inspection

elnspect the oil seals.
*Replace any if the lips are misshapen, discolored (in-
dicating that the rubber has deteriorated), hardened,
or been otherwise damaged.

1. Bearing Drive Set: PN57001-1129

Ball or Needle Bearings

Ball or Needle Bearing Inspection
-Since the ball bearings are made to extremely close
Ball or Needle Bearing Replacement tolerances, the wear must be judged by feel rather than
eUsing a press, puller, the bearing driver set (special measurement. Clean each bearing in a high-flash point
tool: PN 57001-1129) or the oil seal & bearing re- solvent, dry it (do not spin the bearing while it is dry),
mover (special tool), remove the ball bearing. and oil it with the specified oil.
 FINAL DRIVE 9-29

I WARNING I
-Clean the parts in a well-ventilated area, and take care
that there are no sparks or flame anywhere near the
working area; this includes any appliance with a pilot
light. Do not use gasoline or low-flash point solvent to
clean parts. A fire or explosion could result.
-Check the needle bearing in the rear final gear case.
oThe rollers in a needle bearing normally wear very
little and wear is difficult to measure. Instead of
meas'uring, inspect the bearing for abrasion, color
change, or other damage.
*If there is any doubt as to the condition of a needle
bearing, replace the needle bearing and rear final gear
case as a set.

-Turn the bearing back and forth while checking for

roughness or binding,
*If the bearing is noisy, does not spin smoothly, or has
any rough spots, replace it.

CD

1. Turn the bearing.

-Since sealed bearings are packed with grease and sealed,

they can not be lubricated.
-Turn the sealed bearing back and forth while checking
for roughness or binding.
*If roughness or binding is found, replace the bearing.
-Examine the bearing seal for tears or leakage.
*If the seal is torn or is leaking, replace the bearing.

1. Turn the bearing. 2. Bearing Seal

 BRAKES 10-1

Brakes
Table of Contents

Exploded View . . . . . . . . . . . . . . . . . . . . . 10-2 Master Cylinder Inspection .... . ... .

.
Specifications. . . . . . . . . . . . . . . . . . . . . . 104 Brake Lever Lubrication . . . . . . . . . . . 10-9
Special Tools . . . . . . . . . . . . . . . . . . . . . . 104 Brake Discs . . . . . . . . . . . .. ... .. .... . 10-9
Brake Adjustment . . . . . . . . . . . . . . . . . . . 10-5 Disc Installation Notes . . . . . . . . . .. . 10-9
Front Brake Lever Disc Wear ... .. . . . . . . . . . . . . . . . . 10-9
Free Play Inspection . . . . . . . . . . . 10-5 Disc Cleaning . . . . . . . . . . . . . . . . . . 10-9
Brake Pedal Position Adjustment .... . 10-5 Disc Warp Inspection . . . . . . . . . . . . . 10-10
Brake Pedal Free Play Adjustment ... . 10-5 Brake Hoses . . . . . . . . . . . . . . . . . . . . . . . 10-10
*
Parking Lever Free Play Adjustment ..
Cam Lever Angle Adjustment . . . . . .
.
.
.
10-5 Brake Hose Removal . . . . . . . . . . . . .
Brake Hose Installation Notes . . . . . . . 10-10
Brake Fluid . . . . . . . . . . . . . . . . . . . ... .
.. 10-10
Brake Fluid Recommendation .... . . .
. Brake Hose Inspection . . . . . . ..... .
10-10
. Brake Drum . . . . . . . . . . . . . . . . . . . . . . .
Brake Fluid Level Inspection . . . . . . .
Brake Fluid Changing . . . . . . . . . ...
.
.
. Rear Brake Drum Removal . . . . . . . . . 10-10
10-10
[I[I
Brake Line Air Bleeding . . . . . . . . . . .
. Rear Brake Drum Installation .. .. .. .
Brake Drum Wear .... .. .... .... .
.
Calipers .... . ... . . . . . . . . . . . . . . . . . . lP-6 Brake Drum Seal Wear . . . . . . . . . . . . 10-11
Caliper Removal . . . . . . . . .. . . . . . . 10-6 Brake Drum Disassembly/
Caliper Installation Notes . . . . . . . . . . 10-6 Assembly Note .. . . . . . . . ... .. . 10-11
Caliper Disassembly Notes . . . . . . . . . . 10-6 Brake Panel Assemblies. . . . . . . . . . . . . . . . 10-11
Caliper Assembly Notes .. . ... .... . 10-7 Brake Panel Removal .. .. .. .... .. . 10-11
10-7
Caliper Fluid Seal Damage . . . . . . . . .
Caliper Dust Seal and Cover Damage . .
.
. 10-7
Brake Panel Installation . . . . . . . . . . .
Brake Shoe Lining Wear . . . . . . . . . . .
.
10-12

Caliper Piston and Cylinder Damage .. . 10-7 Brake Shoe Spring Inspection . . . . . . .
..
Caliper Holder Shaft Wear . . . . . . . . . . 10-7 Brake Panel Disassembly . . . . . . . . . . . 10-12
Brake Pads . . . . . . . . . . . . . . . . . . . . . . . . 10-8 Brake Panel Assembly Notes ... .. .. . 10-12
Brake Pad Removal . . . . . . . . . . . . . . 10-8 Brake Camshaft Lubrication .. . .... . 10-13
Brake Pad Installation Notes . . . . . . . . 10-8 Brake Pedal and Cables . . . . . . . . . . . . . . . 10-13
Brake Pad Wear Inspection . . . . . . . . . 10-8 Brake Pedal and Cable Removal ..... . 10-13
Master Cylinder and Wheel Cylinders ... .. . . 10-9 Brake Pedal and Cable Installation .... . 10-13
Master Cylinder Removal . . . . . . . . . .
. Brake Cable Inspection . . . . . . . . . . . . 10-14
Master Cylinder Installation . . . . . . . . .
. Brake Pedal and Cable Lubrication ... . 10-14
Master Cylinder Disassembly . . . . . . . .
.
Master Cylinder Assembly . . . . . . . . . .
.

* Base Manual
10-2 BRAKES
lew
E~~i~d~V:
................. .
..;;:.:.~
G :A
....;.............
y adhesive.
........ ..... ...............................
..........
..
.
PP
. pply grease
L . .
. Apply non-perman
agent. ent locking

o : Apply 01. '1

Si : Apply 51'1'Icone grea
T1 se.
: 25 N-m (25
T2: 20 N-m (2'0 kg-m, 18 ft-Ib)
T3: 8.8 N-m (() 9~g-m, 14.5 ft-Ib)
T4: 5.9 N-m (0'60 kg-m, 78 in.Jb)
T5: 7.8 N-m (0:80 kg-m, 52 in-Ib)
T6: 145 N-m (150 kg-m, 69 in.Jb)
T7: 29 N-m (30 k
kg-m, 110 ft-Ib)
T8: 1.0 N-m (01 g-m, 22 ft-Ib)
T9: 37 N-m (3 ~ kg-m, 9 in.Jb)
8
T10: 18 N g-m, (27 ft-Ib)
-m (18 k
T11: 23 N-m (2'3 k gem, 13.0 ft-Ib)
T12: 34 N-m (3' gem, 16.5 ft-Ib)
.5 kg-m, 25 ft-Ib)
 BRAKES 10-3

/
~--~
~ Drain Bolt

@
U ~o>
!\
10-4 BRAKES

Specifications

Refer to the Base Manual noting the following.

Item Standard Service Limit

Brake Fluid Grade D.O.T.3
Front Disc Brake:
Brake lever free play Non-adjustable ---
Pad lining thickness 4.5 1 mm
Disc thickness 3.3 - 3.7 mm 3.0mm
Disc runout 0.2 mm or under 0.3mm
Rear Drum Brake:
Parking brake lever play 1-2mm ---
Rear brake pedal free play 15 - 25 mm ---
Cam lever angle 80 - 90 ---
Drum inside diameter 180.000 - 180.140 mm 180.75 mm
Brake shoe thickness 5mm 2.5mm

Special Tools

Refer to the Base Manual noting the following.

Jack: 57001-1238 Outside Circlip Pliers: 57001-144

oThis tool may be used instead of the common tool.

 BRAKES 10-5

Brake Pedal Free Play Adjustment

Brake Adjustment eMeasure the distance the brake pedal moves before the
brake starts to take hold. Pedal free play should be 15
- 25 mm.
Front Brake Lever Free Play Inspection
Disc or disc pad wear is automatically compensated
for and has no effect on brake lever action. So there are Brake Pedal Free Play
no parts that require adjustment on the front brake. Standard: 15 - 25 mm
However if the brake lever has a soft, or "spongy
feeling," check the brake fluid level in the master
cylinder and bleed the air from the brake line (see
Bleeding the Brake in the Base Manual).

NOTE
oCheck the- brake fluid level in accordance with the
Periodic Maintenance Chart.

Brake Pedal Position Adjustment

eMeasure from the top of the brake pedal in its rest posi-
tion to the upper surface of the right footpeg. This
measurement should be 0 to 5 mm above the top of the
footpeg .
A. Brake Pedal B. 15 - 25 mm

eTo adjust the pedal free play, turn the adjuster at the
rear end of the brake cable.

A. Footpeg C. Brake Pedal

B. 0 - 5 mm

eTo adjust the pedal position, loosen the locknut, turn

the adjusting bolt, and then tighten the locknut. Now
adjust the brake pedal free play.
A. Brake Pedal Adjuster
B. Parking Brake Lever Adjuster

OAlways maintain proper pedal free play. Brake shoes

will expand with the heat of operation. If adjustment
is too tight (too little free play), the brake could over-
heat and damage the drive train and engine.

Parking Lever Free Play Adjustment

eLoosen the locknut and turn the adjuster at the parking
lever in as far as it will go.
eTighten the locknut.
eTurn the adjuster at the rear end of the brake cable so
A. Adjusting Bolt B. Locknut that the brake lever has 1 - 2 mm of free play.
10-6 BRAKES
- If the caliper is to be disassembled after removal and if
compressed air is not available, remove the piston using
the following procedure. If both calipers are to be
disassembled, be sure to do this procedure to both at
,-------- the same time.
o Remove the pads.
oTemporarily reconnect the brake hose to the caliper.
The banjo bolt need not be torqued.
oPump the brake lever to remove the caliper piston.
o Immediately wipe up any brake fluid that spills.
o Disconnect the brake hose from the caliper.

1. 1 - 2 mm

Caliper Installation Notes

NOTE
OSince the above two free play adjustments (pedal and
lever) affect each other, make them at the same time.
-After adjustments, check for brake drag (there should
be none) and effectiveness.
-Connect the brake hose to the caliper putting a new
flat washer on each side of the brake hose fitting.
- Check the fluid level in the reservoir and bleed the
brake line (see Bleeding the Brake Line in the Base
Manual).
-Check the brakes for good braking power, no brake
drag, and no fluid leakage.

Caliper Disassembly Notes

- Using compressed air, remove the piston.
O~over the caliper opening with a clean, heavy cloth.
Calipers oRemove the piston by lightly applying compressed air
to where the brake line fits into the caliper.

Caliper Removal
-Remove the front wheels (see Wheel Removal in the
Wheels/Tires chapter). I WARNING.
-Separate the brake hose from the caliper by taking off
the banjo bolt. OTo avoid serious injury, never place your fingers or
-Remove the caliper mounting bolts and take off the palm inside the caliper opening. If you apply com-
calipers. pressed air into the caliper, the piston may crush
your hand or fingers.

A. Mounting Bolts C. Front

B. Caliper A. Apply compressed air. B. Cloth
 BRAKES 10-7

Caliper Assembly Notes

I WARNING I
o Except for the disc pads ~nd discs; use only disc brake
fluid, isopropyl alcohol, or ethyl alcohol, for cleaning
brake parts. Do not use any other fluid for cleaning
these parts. Gasoline, motor oil, or any other
petroleum distillate will cause deterioration of the
rubber parts. Oil spilled on any part will be difficult to
wash off completely, and will eventually deteriorate
the rubber used in the disc brake.

A. Anti-Rattle Spring
-Apply brake fluid to the outside of the piston and the
fluid seal, then push the piston' into the cylinder by
hand . Take care that neither the cylinder nor the
piston skirt gets scratched .

Caliper Fluid Seal Damage

The fluid seal around the piston maintains the proper
pad/disc clearance. If the seal is not satisfactory, pad
wear will increase, and constant pad drag on the disc will
raise brake and brake fluid temperature ..
- Replace the fluid seals under any of the following
conditions: (a) fluid leakage around the pad; (b) brakes
overheat; (c) there is a large difference in inner and
outer pad wear; (d) the seal is stuck to the piston. If
the fluid seal is replaced, replace the dust seal as well.
Also, replace all seals every other time the pads are
changed.

Caliper Dust Seal and Cover Damage

- Check that the dust seals and covers are not cracked
worn, swollen, or otherwise damaged.
- If they show any damage, replace them.

Caliper Piston and Cylinder Damage

- Visually inspect the piston and cylinder surfaces.
*Replace the caliper if the cylinder and piston are badly
scored or rusty .
1. Caliper
2. Outer Pad
3. Inner Pad
4. Dust Seal Caliper Holder Shaft Wear
5. Fluid Seal The caliper body must slide smoothly on the caliper
6. Piston holder shafts. If the body does not slide smoothly, one
7. Pad Mounting Allen Bolts pad will wear more than the other, pad wear will in-
8. Caliper Holder Shafts crease, and constant drag on the disc will raise brake and
9. Friction Boot brake fluid temperature.
- Check to see that the caHper holder shafts are not
badly worn or stepped, and that the rubber friction
boots are not damaged .
- Apply a thin coat of silicone grease to the caliper * If the rubber friction boot is damaged, replace the
holder shafts and holder holes. (Silicone grease is a rubber friction boot.
special high temperature, water-resistant grease). * If the caliper shaft is damaged, replace the caliper
- Install the anti-rattle spring in the calipers as shown. assembly.
10-8 BRAKES
Brake Pads
I WARNING'
OWhen handling the disc pads, be careful that no disc
brake fluid or any oil gets on them. Clean off any fluid
or oil that inadvertently gets on the pads with a high-
flash point solvent_ Do not use one which will leave an
oil residue. Replace the pads with new ones if they
cannot be cleaned satisfactorily.
Brake Pad Removal
-Remove the front wheel (see Wheel Removal in Wheels/
Tires chapter).
-Remove the pad mounting Allen bolts.
A. Pad Mounting Allen Bolts
-Lift off the caliper by taking off the mounting bolts
with the hose left installed.
-Push the caliper holder toward the piston side and then
remove the pads.
A. Pads
Brake Pad Installation Notes
-Before installation, clean the pads with a high-flash
point solvent.
WARNING'
OWhen handling the disc pads or disc, be careful that no
disc brake fluid or any oil gets on them. Clean off any
fluid or oil that inadvertently gets on the pads or disc
with a high-flash point solvent. Do not use one which
will leave an oily residue. Replace the pads with new
ones if they cannot be cleaned satisfactorily.
-Push the caliper piston in by hand as far as it will go,
and then install the pads.
I WARNING'
o Do not attempt to drive the vehicle until a full brake
lever is obtained by pumping the brake lever until the
pads are against each disc. The brake will not function
on the first application if this is not done.
Brake Pad Wear .Inspection
In accordance with the Periodic Maintenance Chart,
inspect the brake pads for wear.
-Remove the front wheels in order to check the front
brake pads.
-Check the lining thickness of the pads in each caliper.
The pad thickness can be checked with the pad in-
stalled.
*If the lining thickness of either pad is less than the
service limit, replace both pads in the caliper as a set.
Pad Lining Thickness
Standard: 4.5mm
Service Limit: 1 mm
A. Service Limit B. Lining Thickness
 BRAKES 10-9

Master Cylinder and Wheel Cylinders

OSince the wheel cylinder is not on the model, the

information of the wheel cylinder is omitted.

Brake Lever Lubrication

Whenever the master cylinder is disassembled, or in
accordance with the Periodic Maintenance Chart, per-
form the following.
eLubricate the brake lever by applying a light coating of
silicone grease to the brake lever pivot screw and the
contact with the piston. A. Marked Side

eAfter installing the discs, check the disc runout.

Completely clean off any grease that has gotten on
either side of the disc with a high-flash point solvent.
Do not use one which will leave an oily residue.

Disc Wear
eMeasure the thickness of each brake disc at the point
where it has worn the most.
*Replace the disc if it has worn past the service limit.

Front Disc Thickness

Standard: 3.3-3.7 mm
Service Limit: 3.0mm

1. Apply grease .

...............................................................................
Brake Discs

I WARNING' 1. Brake Disc

2. Measuring Area
oWhen handling the discs, be careful that no disc brake
fluid or any oil gets on them. Clean off any fluid or oil
that inadvertently gets on the discs with a high-flash
point solvent. Do not use one which will leave an oily Disc Cleaning
residue. Poor braking can be caused by oil on a disc. Oil on a
disc must be cleaned off with an oilless cleaning fluid
such as trichloroethylene or acetone.

Disc Installation Notes

eTighten the disc mounting Allen bolts to the specified
torque. The disc must be installed with the chamfered
hole side facing toward the front hub. The marked
side must face outward.
I WARNING I
o These cleaning fluids are usually highly flammable and
harmful if breathed for prolonged periods. Be sure to
heed the fluid manufacturer's warnings.
10-10 BRAKES

Brake Disc Warp Inspection

eJack up the vehicle so that the front wheels are off the
ground.
eFor front disc inspection, remove the front wheels, and
turn the handlebar fully to one side.
eSet up a dial gauge against the disc as shown, and
measure disc runout.
*If runout exceeds the service limit, replace the disc.

A. Front Brake Hose

Brake Drum

1. Brake Disc 2. Turn the disc by hand. Since the front brake drums are not on the model,
the information of the front brake drum is omitted.

Disc Runout
Standard: 02 mm or under
Service Limit: O.3mm Rear Brake Drum Removal
Refer to the Base Manual noting the following.
e Remove the right rear wheel for rear brake drum
removal.

Rear Brake Drum Installation

Brake Hoses Refer to the Base Manual noting the following.
e Do not overgrease the inside seal lip of the brake drum
seal.
Brake Hose Installation Notes
e Using a new copper washer for each side of the hose
fitting, tighten the banjo bolt to the specified torque
(see Exploded View in this manual).
e Run the brake hose according to the Wiring, Cable, and
Hose Routing section in the General Information
chapter.
eBleed the air from the brake line (see Brake Line Air
Bleeding in the Base Manual).

Brake Hose Inspection

The high pressure inside the brake line can cause fluid
to leak or the hose to burst if the line is not properly
maintained.
e Bend and twist the rubber hose while examining it.
* Replace it if any cracks or bulges are not~d. A. Brake Drum Seal
 BRAKES 10-11
Brake Drum Seal Lubrication
Brake Panel Assemblies
Grease

Since the front brake panels are not on the model,

the information is omitted.

Brake Panel Removal

Do not grease here. -Remove the following parts.
Right Rear Wheel
Brake Drum
Brake Cables
Brake Panel Vent Hose
-Remove the panel assembly from the axle pipe by
taking off the mounting bolts.
Brake Drum Seal Wear
Refer to the Base Manual noting the following.
-Tighten the brake drum drain bolt to the specified
torque (see Exploded View).

A. Brake Panel c. Mounting Bolts

B. Drain Hole D. Front

A. Drain Bolt
WARNING'

Brake linings contain asbestos fiber. Inhalation of

Brake Drum Disassembly/Assembly Note
-Do not press the drum bolt out.
*If the drum bolt is damaged, replace the drum and
bolts as a unit.
asbestos may cause serious scarring of the lungs and may
promote other internal injury and illness, including
cancer. Observe the following precautions when han-
dling brake linings.
ONever blow brake lining dust with compressed air.
Olf any components are to be cleaned, wash with deter-
gent, then immediately discard the cleaning solution
and wash you hands.
0 00 not grind any brake lining material unless a ven-
.tilation hood is available and properly used.

Brak.e Panel Installation

- Tighten the brake panel mounting bolts to the specified
torque after applying a non-permanent locking agent to
the threads (see Ex ploded View).
- Run the brake cables and vent hoses according to the
Wiring, Cable, and Hose Routing in the General
Information chapter.
1. ReafBrake Drum - Adjust the brake pedal and the parking brake (see
2. Drum Bolt Brake Adjustment in this chapter) .
10-12 BRAKES

Brake Panel Disassembly Brake Panel Assembly Notes

e Remove the following parts. e(lean the old grease from the camshaft and regrease it.
Shoe Spring of the anchor pin side e Apply grease to the camshaft and the anchor pins and
Circlips very lightly on the cam surfaces. Do not overgrease.
Anchor Pin Holder e Push the camshaft into the panel so that the triangular
mark on the cam surface points toward the center of
the panel.

WARNING '
Olmproper installation will cause ineffective braking.

A. Shoe Spring C. Circlips

B. Anchor Pin Holder

e Using a clean cloth around the linings to prevent grease

or oil from getting on them, remove the brake shoes by
pulling up on the center of the linings.

A. Triangular Mark

oThe brake shoe springs are identical.

e Fit the springs onto the brake shoes. Wrap a clean
cloth around the lin ings to prevent grease or oil from
getting on them, and install the shoes on the brake
panel.
e lnstall the O-ring and fit the indicator on the serration
so that it points to the lower line of the USABLE
RANGE.

A Brake Shoes B. Lift

e Before removing the brake cam lever, mark the position

of the cam lever so that it can be installed later in the
same position.

A. Indicator C. USABLE RANGE

B. Lower Line

e lnstall the cam lever in its original position on the cam-

A. Brake Cam Lever shaft, and tighten its bolt. .
 BRAKES 10-13

Brake Camshaft Lubrication ORemove the seal of the brake pedal cable and take off

!
eDisassemble the drum brake. the cable from the frame.
eUsing a high-flash point solvent, clean the old grease ORemove the cotter pin and the joint from the brake
off the brake camshaft, camshaft hole, and other pivot pedal.
points. o R,mo," the b"k, p,dal "bl,.
*Replace the dram brake parts if they show wear or
damage.
eApply grease to the brake pivot points (brake shoe
anchor pins and cam surface of the camshaft) and fill
the camshaft groove with grease. Do not get any grease
so that it does not get on the linings or drum after
brake assembly.
~
.~
;---....

1. Cotter Pin 3. Seal

2. Joint
eTurn the adjuster at the rear end of the parking brake
cable to give the cable plenty of play.
eLoosen the knurled locknut at the parking brake lever
1. Anchor Pins
and screw in the adjuster_
2. Brake Camshaft
eLine up the slots in the brake lever, knurled locknut,
and adjuster, and then free the cable from the lever.

Brake Pedal and Cables -: ..... -

. < .::- ~
......::::=:===:
......

Brake Pedal and Cable Removal

This model does not have a brake cable equalizer and
has a parking brake lever installed on the left side of the
handle.
eRemove the brake cables.
oUnscrew the adjusters at the rear ends of the cables, 1. Adjuster 3. Pull the cable.
and pull the cable out of the joints and cable mounts. 2. Knurled Locknut 4. Slots
Do not lose the joints and springs.
oRemove the fenders.
oRemove the parking brake cable.

Brake Pedal and Cable Installation

eSince the brake pedal does not have a punch mark for
alignment, just install the brake pedal on the brake
pedal pivot shaft.
eGrease the brake pedal pivot shaft and brake cable.
eReplace the pivot shaft cotter pin with a new one.
eRun the brake cables and vent hoses according to the
Wiring, Cable, and Hose Routing in the General
Information chapter.
A. Adjusters C. Springs eAdjust the brake pedil and the parking brake (see
B. Joints Brake Adjustment in this chapter).
10-14 BRAKES

Brake Cable Inspection

. With the brake cable disconnected at both ends, the
cable should move freely in the cable housing.

Brake Pedal and Cable Lubrication

Refer to the Base Manual, noting the following .
Lubricate the parking brake cable or the brake pedal
cable in accordance with the Periodic Maintenance
Chart, or whenev er the cable is removed (see General
Information chapter and General Lubrication in the
Appendix chapter).
o Use the pressure cable luber to lubricate the cable.
 SUSPENSION 111

Suspension
Table of Contents

Exploded View ........................................... . 11-2

Specifications ............................... . ............ . 11-3
Special Tools ............................................. . 11-3
Suspension .............................................. . 11-4
Shock Absorber Spring Force Adjustment .................. . 11-4
Shock Absorber Removal ............................... . 11-4
Shock Absorber Installation ............................. . *

Shock Absorber Assembly Note .......................... . 11-4

Front Suspension Arm Removal .......................... . 11-4
Front Suspension Arm I nstallation Note .................... . 11-4
Rear Suspension Arm (Rod) Removal ...................... . 11-4
Rear Suspension Arm (Rod) Installation ....... . ............ . 11-5 [III
Front Suspension Arm Disassembly ............. . ...... . .. . 11-5
Front or Rear Suspension Arm Assembly Notes .............. . 11-5
.*
Shock Absorber and Suspension Arm Inspection ............. .

* Base Manual
11-2 SUSPENSION
E~~i~d~V"i~~ ................................................

L : Apply non-permanent locking

agent.
R : Replacement Parts
W : Apply water, or soap and water
solution,

T1 : 34 N-m (3.5 kg-m, 25 ft-Ib)

T2: 88 N-m (9.0 kg-m, 65 ft-Ib)
T3: 49 N-m (5.0 kg-m, 36 ft-Ib)
T4: 52 N-m (5.3 kg-m, 38 ft-Ib)

_
(1).)
I

I
@
 SUSPENSION 11-3
Outside Circlip Pliers: 57001-144
Specifications
..............................................................................
Refer to the Base Manual noting the following.
Front Shock Absorber Spring Preload
Standard setting position: No.2

Rear Shock Absorber Spring preload

Standard setting position: No.2

Jack: 57001-1238
Special Tools

o Refer to the Base Manual noting the following addi-

tional tools.

Wrench (Owner's tool): 921101040, or

Steering Stem Nut Wrench (special tool): 57001-1100

Inside Circlip Pliers: 57001-143 Bearing Driver Set: 57001-1129

11-4 SUSPENSION

Shock Absorber Assembly Note

Suspension e Lubricate the rubber dampers with a soap and water
solution when installing the rubber dampers.

Shock Absorber Spring Force Adjustment

Refer to the Base Manual noting the following.
oThe spring adjusting sleeve on the front and rear shock
o Do not lubricate the rubber dampers with engine oil or
absorbers hCj.ve 3 positions so that the spring can be
petroleum distillates because they will deteriorate the
adjusted for different terrain and loading conditions.
rubbers.
elf the spring action feels too soft or too stiff, adjust it
in accordance with the following table.
oTurn the adjusting sleeve on each shock absorber to the ePress the rubber dampers in using a suitable bearing
desired position with a wrench {Owner's tool or special driver in the bearing driver set {special tool: PN
tool}. 57001-1129}.

Spring Action
, Front Suspension Arm Removal
Position Spring Setting Load Terrain Speed
Force eRemove the following parts.
Steering. Knuckle {see Steering Knuckle Removal in
1 Soft Light Good Low the Steering chapter}
2 (STD)

3
1
Stronger
1! r !
Hard Heavy Bad High
,
Brake Hose
eRemove the upper suspension arm by taking off the
pivot bolts.
, eRemove the lower suspension arm by taking off the
pivot bolts.
eRepeat the same procedure on the other side of the
vehicle.

Front Suspension Arm Installation Note:

elnstallation' is the reverse of removal. Note the
following.
eRefer to each chapter for the following parts instal-
lation.
Steering Knuckle (see Steering Knuckle Installation in
the Steering chapter)
Brake Hose (see Wiring, Cable, or Hose Routing in the
General Information chapter)
elnstall the front suspension arms so that each "F" mark
faces upward and forward.
A. Adjusting Sleeve (Front Shock shown)
B. Wrench (Owner's tool): 92110-1040, or Steering
Stem Nut Wrench {special tool}: 57001-1100 Fmnt~

eCheck to see that each pair of adjusting sleeves (front

two adjusting sleeves or rear two) are turned to the
same relative position.

WARNING.
o If a pair of adjusting sleeves (front two adjusting
sleeves or rear two) are not adjusted equally, handling
may be impaired and a hazardous condition may
result. 1. "F" mark

Shock Absorber Removal Rear Suspension Arm (Rod) Removal

Refer to the Base Manual, noting the following. Refer to Suspension Arm Removal in the Suspension
eRemove the fenders to access the absorber. chapter in the Base Manual.
 SUSPENSION 11-5
Rear Suspension Arm (Rod) Installation Front or Rear Suspension Arm Assembly Notes
OSuspension arm installation is the reverse of removal. eWhen installing the rubber dampers into the arm,
Note the following. lubricate the outer surface of the dampers with a soap
elnstall the center arms noting the installation direction. and water solution.
elnstall the left rear suspension arm so that the "F"
mark faces upward and forward.
Center Arm Installation
o Do not lubricate the rubber dampers with engine oil or
~
I
petroleum distillates because they will deteriorate the
rubbers.

ePosition the dampers in the front suspension arm as

shown using a suitable bearing driver in the bearing
driver set (special tool: PN570011129).

Front Suspension Arm Bushing Installation

1. Slotted hole faces the front.

2. Longer bracket faces the front. 2
3. Suspension Arm "F" mark

Front Suspension Arm Disassembly

eRemove the front suspension arm (see Front Suspen-
sion Arm Removal).
-Remove the rubber bushings using a press and a suit-
able bearing driver in the bearing driver set (special
tool: PN 57001-1129).
-Holding the suspension arm with a vise, remove the 1. Arm 3. 0.15 - 0.85 mm
circlip and unscrew the knuckle joint. 2. Bushing

1. Rubber Bushings 3. Knuckle Joint

2. Circlip

000 not remove the knuckle joint boot. It is packed

with grease.
 STEERING 12-1

Steering
Table of Contents

Exploded View ........................................... . 12-2

Specification ............................................. . 12-3
Steering ................................................. . 12-3
Steering Stopper Adjustment ............................ . 12-3
Handlebar Removal .................................... . 12-3
Handlebar Installation .................................. . 12-3
Handlebar Grip Removal. ............................... '. *
Handlebar Grip Installation ..................... . ........ . *
Steering Stem Removal ................................. . *
Steering Stem Installation ............................... . 12-4
Tie-Rod End or Steering Knuckle Joint Boot Inspection ........ . 12-4
Tie-Rod Removal ..................................... . 12-4
Tie-Rod End Installation Notes .............. . ............ . 12-5 I

Steering Knuckle Removal .............................. . 12-5 ~

Steering Knuckle I nstallation Notes ....................... . 12-5 I
Steering Inspection .................................... . *
Steering Stem Warp .................................... . *
Steering Stem Bearing, Tie-Rod Bearing, and
Steering Knuckle Upper and Lower Joint Inspection *
Steering Knuckle Bearing Removal ........................ . 12-6
Steering Knuckle Bearing I nstallation Notes ................. . 12-6
Steering Knuckle Bearing Inspection ....................... . 12-6

*. Base Manual
12-2 STEERING
............................................................
Exploded View ...................
:
....... ................. :.................................. .
A . Apply adhesive. . .........
G : Apply grease.
L . Ap p Iy nonpermanent lock
R : Replacement Parts 109 agent.
Apply water ' or soa p and water
W : solut.
Ion.

T1
T2': 20 Nm (2 .0 k g-m, 14.5 ft-Ib)
29 N-m (3.0 kg-m, 22 ftlb)
T3: 41 N-m (4 .2 k g-m, 30 ft-Ib)
~:~ 25 Nm (2.5 kg-m, 18.0 ft-lb)
88 Nm (9.0 kg-m, 65 ft-lb)
T6: 27 N-m (2.8 kgm, 20 ftlb) G
T7 : 8.8 N-m (0.9 kg-m. 78 inlb)
~: ~ 34 N-m (3.5 kg-m, 25 ftlb) @)
52 Nm (5.3 kgm, 38 ft-Ib)
T10: 49 Nm (5.0 kg-m, 36 ft-Ib)
\
 STEERING 12-3
Handlebar Removal
Specification e Remove the following parts from the handlebar.
Left-Hand Switch Housing
Parking Brake Lever
Steering Angle Throttle Case
Right: Front Brake Master Cylinder
eRemove the handlebar holder bolts and lift off the
Left:
handlebar.

Steering Stopper Clearance

Less than 1.0 mm

Handlebar Installation
Steering eHandlebar installation is the reverse of removal. Note
the following.
elnstall the handlebar so that the angle of the handlebar
Steering Stopper Adjustment matches the angle of the steering stem as shown.
eTurn the handlebar all the way to the left and adjust
the right steering stopper bolt protrusion by adding or
removing the shim.
eWith the tie-rod arm stopper against the suspension arm
stopper, the clearance between the stopper bolt and the
frame stopper must be less than 1.0 mm.

A. Parallel

eTighten the holder rear bolts first and then the front
bolts. When the holder is ~orrectly installed, there will
be even gap at the front and no gap at the rear after
tightening.

A. Suspension Arm Stopper

B. Tie-Rod Arm Stopper
C. Clearance
D. Steering Stopper Bolt
E. Shim(s)

eTurn the handlebar all the way to the right and adjust A. Front C. No Gap
the left stopper bolt in the same way. B. Even Gap
12-4 STEERING

Steering Stem Installation Tie-Rod End, or Steering

_Refer to the Base Manual noting the following. Knuckle Joint Boot Inspection
oWhen replacing the stem clamps, replace both clamps e!nspect each boot in accordance with the Periodic
as a unit. Maintenance Chart (see General Information chapter).
eWipe all the old grease out of the steering stem, grease *If tear, wear, deterioration, or grease leaking is found,
seals, and clamps_ replace the tie-rod end, or steering knuckle joint.
eApply grease to the steering stem and pack the grease
seal grooves between the lips with grease. Grease the
mating surface of the clamp, also.
elnstall the grease seal facing the end rearward to
prevent the entry of dirt.

A. Joint Boots C. Tie-Rod Ends

B. Knuckle Joints

A. Ribs and Grooves C. Clamp Mating Surface Tie-Rod Removal

B. Ends eRemove the front fender (see Frame chapter).
eRemove the cotter pin and the tie-rod end nuts on both
ends.
eRemove the tie-rod.
eAlign the relief marks on the steering stem clamps.

A. Tie-Rod Ends

A. Marks

OWhen removing the tie-rod, be careful not to bend it.

eRoute the cables, the wires, and the brake hose ac-
cording to the Wiring, Cable, and Hose Routing section
in the General Information chapter.
000 not loosen the locknuts at the end of the tie-rod ad-
justing sleeve, or the toe-in of the front wheels will be
changed.
000 not remove the tie-rod end grease seal. It is packed
with grease.
 STEERING 12-5

Tie-Rod End Installation Notes -Remove the cotter pins, then remove the steering
-Check that the seal lip of the boot is on the shank. knuckle upper and lower joint nuts.
-Oil the bolt body. -Tap the steering knuckle and remove it.

Tie-Rod End Installation

1. Boot Lip 3. Apply oil A. Tap the steering knuckle. B. Front Axle
2. Shank

Steering Knuckle Installation Notes

OThe installation is the reverse of removal. Note the fol-
lowing.
-Clean the sealing surfaces, and the tapered holes.
-Grease the sealing surface.

Steering Knuckle Removal

-Remove the following parts.
Front Wheel Hub (see Wheels/Tires chapter in this
text)
Tie-Rod Arm Nuts
Tie-Rod Arm Bolts
ShOCK Absorber Lower Mounting Bolt and Nut

A. Sealing Surfaces B. Tapered Hole

-Clean the shanks of the knuckle joint.

-Check that the joint boot does not have tear, wear,
deterioration, or grease leakage.
-Check that the seal lip of the boot is on the sealing
A. Tie-Rod Arm Bolts and Nuts surface of the shanks as ~own.
12-6 STEERING

Knuckle Joint Installation

Good Not good

A. Bearing Driver Set: 57001-1129

B. Steering Knuckle

Steering Knuckle Bearing Installation Notes

Installation is the reverse of removal. Note the fol-
lowing.
~ eThe marked side of the bearing faces outward.
eGrease the lips of the new grease seals.

Steering Knuckle Bearing Inspection

1. Shanks 3. Grease here.
2. Boot Lips
NOTE
eTighten the knuckle joint nuts to the specified torque oSince the bearings are packed with grease and sealed
(see Exploded View). they can not be lubricated.
elnsert the new cotter pin into the knuckle joint.
eApply a non-permanent locking agent to the threads of eRemove the steering knuckle (see Knucle Removal).
the tie-rod arm bolts. eTurn the bearing back and forth while checking for
eTighten the tie-rpd arm bolts and nuts to the specified roughness or binding.
torque (see Exploded View). *If roughness or binding is found, replace the bearing.
elnsert the new cotter pins in the bolts_ eExamine the bearing seal for tears or leakage.
*If the seal is torn or is leaking, replace the bearing.

Steering Knuckle Bearing Removal

eRemove the knuckle (see Knuckle Removal).
eRemove the following parts.
Grease Seals
Circlip
eDrive the bearing out using a suitable bearing driver in
the bearing driver set (PN: 57001-1129). 1. Bearing Seal 2. Turn
 FRAME 13-1

Frame
Table of Contents

Exploded View ........................................... 13-2

Seat .................................................... . 13-4
Seat Removal ........................................ . 13-4
Seat Installation ...................................... . 13-4
Front and Rear Fenders .................................... . 13-4
Front Fender Removal ................................. . 13-4
Front Fender Installation Notes ......... . ................ . 13-5
Rear Fender Removal .................................. . 13-5
Rear Fender Installation Notes ........................... . 13-5
Frame Exchange .......................................... . *
Suggested Parts Removal Order ........................... . *
Suggested Parts Installation Order ................. .. ...... . *
Decals ....... " ......................................... . *
Decal Removal ....................................... . *
*'
~
Decal Application ..................................... .

* : Base Manual
13-2 FRAME

E~~i:;d~Vi~~ ...........,

Front Carrier

Rear Carrier

r--------
I ~ """', I
-,
I "-
I
, > ,
I "-
I
'~
5 ::--------
1 , I
I I
I
I I
I I
I
L __ _ _ _ _ _ -.l ,Option other than I _ _ _ _ _ ...1
.1---
 FRAME 13-3

: Australia Model
(B) : UK Model
: Canada Model
13-4 FRAME
...............................................................................
Seat Front and Rear Fenders
.............................................................................
Seat Removal Front Fender Removal
-Pull the seat lock lever up. -Remove the following parts.
Seat (see Seat Removal)
Fuel Tank Rear Cover (see Fuel System chapter)
Fuel Tank Cap
Front Carrier

WARNING I
oGasoline is extremely flammable and can be explosive
under certain conditions, Turn the ignition switch
OFF. Do not smok~. Make sure the area is well venti-
lated and free from any source of flame or sparks; this
includes any appliance with a pilot light.

-Move the fuel tank front cover forward, then lift the
cover.

A. Pull.

- Lift the rear- of the seat, slide it toward the rear slight-
ly, and lift it off the vehicle.

Seat Installation
-Slip the seat hook under the brace on the frame, and
put the stoppers into the holes in the frame.
A. Front Carrier Bolts B. Fuel Tank Front Cover

A. Brace C. Stoppers
B. Seat Hook D. Holes 1. Fuel Tank Front Cover

-While pushing the rear part of the seat down, push the -Install the fuel tank cap at once.
seat lock lever down until the lock clicks. ORemove the following mounting screws and bolts.
 FRAME 13-5

Front Fender Installation Notes

Olnstallation is the reverse of removal.
eFit the tabs on the fuel tank covers in place.
elnstall the mounting screws, bolts, nuts, and flanged
collars in the original positions.

Rear Fender Removal.

eRemove the following parts.
Seat (see Seat Remoal)
Rear Carrier
Ten Rear Fender Mounting Bolts and Screws includ-
ing the Bolts in the Storage Case
A. Bolts

A. Four Mounting Bolts B. Carrier

A. Mounting Bolts

"_j
. _fe")

.
,

....... _. . . ~
. . . . . ".... .. \a.
' .
~...

A. Two Mounting Bolts in the Storage Case

B. Mounting Bolts
, C: Four Screws and Nuts
I
tbi __/
eTake off the rear fender.
/
/

1/
A. Screws Rear Fender Installation Notes
eRear fender installation is the reverse of removal. Note
the following.
el nstall the mounting screws, bolts, and nuts in the
eTake off the front fender. original positions (see Exploded View).
 ELECTRICAL SYSTEM 14-1

Electrical System
Table of Contents

Precautions .. . . . . . . . . . . . . . . . . . . . . . * Electric Starter System .. . . . .... . ... . . . 14-10

Exploded View . . ... . . . . . . . . . . .. ... . 14-2 Part Removal .. . .... . .. . ... .. ... . *
Wiri ng Diagram . . . . . . . . . . . . . ....... . 14-4 Starter Motor Removal .. . .. . ..... . *
Specifications . . . . . . . . . . ... . . ... ... . 14-5 Starter Motor Installation . . . . . .... . *
Special Tools . . . . . . . . . . . . . . . ...... . 14-5 Starter Motor Disassembly .. . . .... . *
Battery .. .... . .... . . . .. .. .... . .. . 14-6 Starter Mot or Assembly . . . . . . . . . . . *
Precautions . . . . . . . . . . . . . . . . . . . . . * Starter Button Removal .. . . . ..... . *
Battery Removal/Installation . . ... . ... . 14-6 Starter Button Installation .... . ... . *
Battery Removal. . . . . . . . . . . . . . . . * Starter System Checkout . . . . ....... . *
Battery Installation ... . . . . . . . . . . . 14-6 Starter Motor Brush Length ..... . .. . *
Electrolyte . . . . . . . . . . . . . . . . . . . . . . * Starter Motor Brush Spring Tension .. . *
Electrolyte Level Inspection .. .... . . * Starter Motor Commutator Inspection .. *
Battery Charging . .. .. . . . . . . . . . . . . . 14-6 Starter Motor Armature Inspection ... . *
Battery Condition ..... . . . ...... . 14-6 Brush Assembly Inspection ... . .... . *
Battery Initial Charging . . . . . . . . .. . * Starter Relay Inspection .. . . ...... . *
Battery Ordinarily Charging . ....... . 14-6 Starter Circuit Relay Inspection ..... . *
Battery Test Charging . . . . . . . . . . . . . * Starter Button Inspection ... . . .... . *
Charging System .. . . . . . . . . . . . . .' .... . 14-6 Lighting System ... .. . . . . . . . . . . . . . . . 14-11
Part Removal . . . . . . . . . . .. . ... . .. . 14-6 Headlight Beam .. .. . . . . . . . . . . . . . . . 14-11
Alternator Rotor Removal . . . . . . . . . 14-6 Headlight Beam Vertical Adjustment .. . 14-11
Alternator Rotor Installation . ...... . 14-8 Bulb Replacement . . . . . . . . . . . . . . . . . 14-11
Alternator Stator Removal . . ...... . * Headlight Bulb Replacement . . . . . . . . 14-11
Alternator Stator Installation . . ..... . * Taillight Bulb Replacement ... . .... . *
Charging System Checkout . . . . . . . . . . . 14-8 Neutral and Reverse Indicator Light
Charging System Bulb Replacement . ... ... ....... . *
Operational Inspection . . . . . . . . . . * Part. Removal '. . . . . . . . . . . . ....... *
Stator Coil Resistance Inspection .... . 14-8 Light Switch Removal . . . . . . . . . . . . *
Rectifier Circuit Inspection . . . . . . . . . * Light Switch Installation . . . . . . . . . . . *
Regulator Circuit Inspection ..... . . . * Neutral and Reverse Switch Removal .. *
Ignition System .... .. . . . . . . . . . .. ... . 14-8 Neutral and Reverse
Safety Instructions . . . . . . . . .. .....
Part Removal . . . .. . . . . . . . . . . ....
.
.
*
14-8
Switch Installation .. . .. . . ..... .
Ignition Switch . . . . . . . . ... . . . ...... .
*
14-11
~
Engine Stop Switch Removal ....... . * Ignition Switch Removal or
Engine Stop Switch Installation ..... . * Install ati on. . . . . . . . . . . . . . . . . . 14-11
Ignition Coil Removal ... . .. ..... . 14-8 Switches . . .. ... .. .. .. .. .. . . ..... . 14-11
Ignition Coil Installation ... . . . .. .. . 14-8 Neutral and Reverse
Spark Plug Removal or Installation ... . 14-9 Switch Inspection . ..... . ..... . 14-11
Pickup Coil Removal . . .. . .... . .. . * Ignition Switch, Light Switch,
Pickup Coil Installation . . . . . . . . . . . * Engine Stop Switch, and
Ignition System Checkout . . . . . . . . . . . . 14-9 Starter Button . . . . . . . . . . . . . 14-12
Ignition Timing Test . . . . . . . . . . . . . 14-9 Electrical Wiring . . . . . . . . . . . . ....... .
Ignition Coil Inspection . . . . . . . . .. . * Wiring Inspection .. . . . . . . . . . . .. . *
Spark Plug Cleaning and Inspection ... . *
Spark Plug Gap . . . . . . . . . . . . . . . . . *
IC Igniter Inspection .. .... .. . ... . 14-9
Pickup Coil Inspection ...... . .... . *
Alternator Rotor Inspection ....... . * * Base Manual
14-2 ELECTRICAL SYSTEM

Exploded View

r:/
~00
CW ~
g

.~
~
~

CO
0
~

1. Pickup Coil
2. Regulator/Rectifier
3 . Neutral and Reverse Switch
4. Starter Relay
5. Starter Circuit Relay
6. IC Igniter
7. Light Switch and Engine Stop Switch
8. Ignition Switch
T1 : 59 N-m (6.0 kg-m, 43 ft-Ib)
T2: 14 N-m (1.4 kg-m, 10.0 ft-Ib)
T3: 4.4 N-m (0.45 kg-m, 39 ft-Ib)
r-- - I -~- [ ~ECTlRICAL@S:STEM 1~
~) n
~
, Working Light " r/

'v=
Q

l),~
(Optional Parts) , ';j I

, CD. .
. , ~
.~ YO~
l(W.
I

. r----

~ .~, IAI~,
,@I-r0 . "\..! ~y
~ . ~ ,a
~ ! /!.1P ~
~~~w .~~ , 0// f '
'---- - - - - _---.JI
@'" ~~

Headlights
)a~ G'~
 -'
c:c:o oIiIo
C (/),,1 : ""r- :.: J.
:: w :
~ ~~~ : 0 : m
~&.&.e: 0 r-
Altern.tor Pickup I ID ID I : I : m
Coli ::I - - : : I
Ignition I;';';'; I (")
Switch ~ .... ~ : Q :
:.:: IID~ .... ::1
,..:;;:; o 0 00 -f
c..-_c.. 1 :E l
!!. l l!!. : :;" .
: n
.. 0 0 .. "
OI\)c:11 0 : 5" :
: Ul : r-
""""~
R.v.rs~~tCh ~i" ~
~
.A ~ 7o 7 0
: c:
iii' : en
0/" I\) (Q Ie
Ua::lClI::
...JG)CDQ) YI
... . -<
III :
~~"! ~
3 1 m
~~
c:J .... 3:
Noutral Indiclitor LO - - G < l - LO LO .
Light 12 v 3.4 W
~ I: J SPlrk Plug

m
'"
r
1 :i::l~"'>-)-
il ~
~...J~~
COC)-lC

Revors" Indicator AcceSSOI

Light 12 V 3.4 w Termlna
~" ~.',"-~-""
~,~,."
r UK modol 12" 3.4 W I
r- - -
- -,1 "111
I @R-::=ll::;
- l..... BK/Y~~ ~ CD
l,J rr"
.....:::= : ==- L....-BKfW-
L..--8L - ~ B K/V --c:>CJo---1 BK/Y
- - - --,.- - _ I CD I 8'/ , '-- " "-
-~-C_ YlR /l ~K~r--+--~
I Working LIght MI
112V65/60W R R X::=~-==--' R Taillights
~ "II III "i
18 R IY-----, 12 V 8 W)( 2
'~I-.."~;~~~G I , I I I;

I _ _
L - - - ~ , Option ~

Fus.
~,
30A ~
Color Code
~~ .. ..
BK Black
~

BL Blue
BR Brown
G Green
~ GY Gray
LB Light Blue
.1-==-8'
L..-.+-----ona. Startar Button
I .___ ..
LG
0
P
Light Green
Orange
Pink
Engine Stop Switch
~
8'1LQ:;:0r
+ R Red
Light Switch
Battery
OFF 12 V 14 Ah W White
I~ Y Yellow
r (1080C, 1100B)
 ELECTRICAL SYSTEM 14-5

Timing Light: 57001-1241

Specifications
oThis tool may be used instead of the common tool.
Refer to the Base Manual noting the following.

Battery
Capacity: 12 V 14 Ah
Specific gravity: 1.27 0.01 @20C (6SoF)
Electrolyte volume: 0.9L
Charging System
Battery charging coil resistance: 0.1 - 0.7 Q
Ignition System
Spark plug gap: 0.6 - 0.7 mm
Spark plug cap resistance: 3.75 - 6.25 kQ
IC igniter resistance: in this text
Ignition coil resistance Coil Tester: 57001-1242
(with the spark plug cap removed)
oThis tool may be used instead of the Kawasaki Elec-
Primary winding: 1.8 - 2.8 Q
trotester (PN 57001-980).
Secondary winding: 10 - 16 kQ
Pickup coil air gap: 0.9 mm

Special Tools
Spark Plug Wrench (Owner's Tool): 92110-1109

Outside Circlip Pliers: 57001-144

Flywheel Puller: 57001-1191

Hand Tester: 57001-1394

Rotor Puller: 57001-1099 or 1216

14-6 ELECTRICAL SYSTEM
.............................................................................
Battery Charging System
.............................................................................
Battery Removal/Installation: Part Removal:
Battery Installation Altern1tor Rotor Removal
Refer to the Base Manual noting the following. -Remove the left engine cover (see Left Engine Cover
-Install the battery so that the terminal side faces the Removal in the Engine Left Side chapter).
front. -Thread the flywheel puller (special tool: 57001-1191
-Route the battery vent hose and wiring according to and rotor puller (special tool: 57001-1099) onto
the Wiring, Cable, or Hose Routing section in the the alternator rotor.
General Information chapter. -Holding the flywheel puller, turn the rotor puller until
the alternator rotor is forced off the end of the crank-
I WARNING I shaft.

o Keep the battery vent hose outlet away from the frame
and brake system components. Battery electrolyte will
corrode and weaken them. Do not let the vent hose
become folded, pinched, or melted by the exhaust
system. An unvented battery will not keep a charge
and it may crack from built-up gas pressure.

Battery Charging:
Battery Condition
ORefer to the Base Manual noting the following.
*If the specific gravity is below 1.200, the battery needs
t9 be charged.
1. Flywheel Puller: 57001-1191
2. Rotor Puller: 57001-1099 or 1216

Battery Ordinary Charging

o Refer to the Base Manual noting the following.
-Set the charging rate and time ~ccording to the battery
condition previously determined (see Battery Condi-
tion), using the table.
Olf the rotor is difficult to remove and a hammer is
used to tap the rotor puller, be careful not to strike
the alternator rotor itself. Striking the rotor can
cause the magnets to lose their magnetism.

Battery Charging Rate/TIme Table (12V 14Ah)

1.270 Fully Charged
1.27
1.24
.....:;>- 1.20

-'"
(,.!)
<.)
to:
1.16
1.12
!..1~ - Sample - - - - - - - - - ~-~~~~~~~
I
.y
:~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ :~ :~ :~ :~ :~ :~ :~ :~ :~ :~ :~ :~ :~: ~ :~ :~ :~ :~ :~ :~; i ~ 14".5: f: ~: ~: ~: ~: ::::::1.080' ::::.: ::::::::::::::::
1.08
~
V') 1.04 :.................................... r .Ii<>~~s.. . . . . . . . ... Totally Discharged .. .
1.00
::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::.:.. ::.:.:.: .. ::!::::::::::::::::::::::::::::::::::::::::::::
at 1A charge rate 5 10 15 20 21
at 2A charge rate 3 5 9 10.5
at 3A charge rate 2 3 4 5 6 7
at 4A charge rate 2 3 4 5.3
Hours of Charging Time at Rates Shown
 ELECTRICAL SYSTEM 14-7

Charging and Lighting Circuit

BR BR ON
OFF CD1 W W w
'O--~~~~~--~~--4---------------------,
BK/V

a:
III
> >
M2 M3 B
6 Pin Connector

> >
CJ
...I

~
CJ ~ ~
III

b! N @

OFF:t
@)
R/BK
R/BK

>
.....
a:
BK/Y

BK/V
BK/V
1. Ignition Switch 6. Regulator/Rectifier 11. Headlights
2. Reverse Indicator Light 7. Diodes 12. Light Switch
3. Neutral Indicator Light 8. Thyristers 13. Speedometer Light ( )
4. Neutral and Reverse Switch 9. Control Unit 14. Working Light (option)
5. Alternator 10.30AFuse 15. Taillights

A. Neutral and Reverse J ndicator Light Connectors A. Regulator/Rectifier

B. Switch Connector
 14-8 ELECTRICAL SYSTEM
Alternator Rotor Installation
eAlternator rotor installation is the reverse of removal. Ignition System
Note the following.
ec:lean the inside of the rotor and the end of the crank-
shaft thoroughly or the taper will not fit snugly. Part Removal:
eFit the rotor onto the crankshaft so that the woodruff Ignition Coil Removal
key fits in the groove in the hub of the rotor. eRemove the fuel tank (see Fuel System chapter in this
elnstall the left engine cover (see Left Engine Cover manual).
Installation in the Engine Left Side chapter) . ePull the spark plug lead off the spark plug.
eClean the alternator bolt. eDisconnect G/W lead and Y/R lead from the coil.
eTighten the alternator rotor bolt to the specified eTake off the nuts and remove the coil.
torque (see Exploded View).

Charging System Checkout:

Stator Coil Resistance Inspection
Remove the seat (see Frame chapter).
Disconnect the alternator connectors.
Measure the stator coil resistance.
Connect the hand tester (special tool: PN 57001 -1394)
between the yellow leads.
o Set the hand tester to x 1 n range, and read the tester. A. Ignition Coil B. Front

Stator Coil Resistance

0.1-0.7 Q Ignition Coil Installation
Refer to the Base Manual noting the following.

Fuel Tank Bracket

<=Jt \
.
\
\\
\ )
\0

A. Front c. G/W Lead

B. Y/R Lead

1 . Alternator Connectors Polarity of Ignition Coil

(-)

~
*If the tester does not read as specified, replace the Connect
alternator stator.
* If the coil has normal resistance, but the voltage
II I~ ~ L ___ ~_8~~~- green/white lead
inspect showed the alternator to be defective; then the G)~connect
yellow/red lead
rotor magnets have probably weakened, and the rotor
must be replaced.
 EL ECTRICAL SYSTEM 14-9

Spark Plug Removal or Installation Ie Igniter Inspection

-Remove or install the spark plug using the spark plug o Refer to the Base Manual noting the following.
wrench (e.g. owner's tool) from the vehicle right side. - Set the hand tester (special tool) to the x 1 kQ range.
-Tighten the spark plug to the specified torque (see
Exploded View).
IC Igniter Resistance* Unit: kU
Range Tester Positive (+) Lead Connection
xl kU G/W Yj R BK/W BL (BK/W)

"0
'"
0>
.J
G/W
~ 00 00 00 00

I
0>
Y/R 5 - 15
~ 1 - 10 00 1 - 10

~
~ 1- 5 1 - 10
"'c:
"'0
BK/W 00 0
0>-
Zti

I~
~O>
o>c: 50 - 50- 50-
"c: BL 00
~o 150 150 150
1-<>
(BK/W) 1- 5 1 - 10 0 00
i~

A. Spark Plug Wrench (Owner's Tool): 92110-1109 * Measure with the Kawasaki Hand Tester (PN 57001-
1394). A tester other than the Kawasaki Hand Tester
may show slightly different readings.

IC Igniter Terminal

Ignition System Checkout:

Ignition Timing Test Y/R G/W
-Remove the ignition timing inspection plug.

$
- Attach the timing light (special tool : PN 57001-1241)
and a tachometer in the manner prescribed by the
manufacturer.
- Start the engine and aim the t iming light at the timing
light mark on the alternator rotor.
- Run the engine at the speeds specified and note the (BK/W) BL
alignment of the timing marks.

A. Advanced Mark C. Top Mark

B. F Mark D. Timing Inspection Hole A. IC Igniter Connectors
14-10 ELECTRICAL SYSTEM

Ignition System Circuit

BKjY
Y/R

Q) fK/W BL

ON
ON
- -:::
oc
>- <..:)
:::

a (?FF
:::CJ>
U
0)'
OFF
@ ~-I
0)0)

~
0) 7
CD @
,l
1. Battery 5. Pickup Coil
2. 30A Fuse 6. Igniter
3. Ignition Switch 7. Ignition Coil
4. Engine Stop Switch 8. Spark Plug
Electric Starter System

Refer to the Base Manual, noting the following.

Electric Starter Circuit
CD ~-----W ----~[>O---w--'"

~\ OFF
TON

a::
a:I

~ a::
~ To igniter

~
CD
Ir
r;J....., y fR
L---,CDr--_--,IIl.--_....

G;
a::
III
a::
>-
OFF

T RUN

@
o

1. Ignition Switch 4. Starter Button 7. Starter Motor

2. Starter Circuit Relay 5. Engine Stop Switch 8. Starter Relay
3. 30 A Fuse 6. Neutral Switch 9. Battery
 ELECTRICAL SYSTEM 14-11

Lighting System

Headlight Beam:
Headlight Beam Vertical Adjustment

NOTE
o Turning the adjusting screw clockwise lowers the
headlight beam.

A. Bulb Socket

-Install the new bulb.

A. Adjusting Screw
Ignition Switch

NOTE
Ignition Switch Removal or Installation
oOn high beam, the brightest point should be slightly
o Refer to the Base Manual noting that the rubber
below horizontal with the vehicle on its wheels and the damper and the bracket are not on the model.
rider seated. Adjust both headlights to the same angle.

Switches

Neutral and Reverse Switch Inspection

o Refer to the Base Manual noting the following.
-Remove the seat for switch connector access.

Neutral and Reverse Switch inspection

Bulb Replacement:
Headlight Bulb Replacement Gear Position G Ground RjW
-Unscrew the adjusting screw. 1 st through 5th
-Unhook the tab from the stop and drop out the unit. Neutral
-Slide back the dust cover and remove the bulb socket
from the headlight unit. Reverse
14-12 ELECTRICAL SYSTEM

Ignition Switch, Light Switch, Engine Stop Engine Stop Switch Connections
Switch, and Starter Button Inspection Y/R BR
-Refer to the Base Manual noting the following.
OFF
-Remove the fuel tank rear cover (see Fuel Tank
Removal in the Fuel System chapter in this manual). RUN
-Unfasten the upper strap of the vinyl cover and open
the velcro. To Starter Button

Starter Button Connections

BK Y/R
Pushed
Released

To En gine Sto p

A. Strap B. Vinyl Cover

A. Ignition Switch Connectors: BR, W

B. Light Switch, Engine Stop Switch, and Starter Button
Connector

Ignition Switch Connections

W BR
OFF
ON c

Light Switch Connections

R BR R/Y R/BK
OFF
LO
HI
 APPENDIX 15-1

Appendix
Table of Contents

Considerations for Various Riding Conditions.................... . 15-2

Carburetor ............................................. . 15-2
Spark Plug ............................................. . 15-2
Spark Plug Inspection .................................. . 15-3
Troubleshooting Guide ..................................... . 15-4
General Lubrication ....................................... . 15-7
Lubrication .......................................... . 15-7
Bolt and Nut Tightening .................................... . 15-8
Tightness Inspection ................................... . 15-8
Unit Conversion Table ...................................... . *

* : Base Manual
15-2 APPENDIX

Spark Plug
Considerations for Various Riding Conditions

This vehicle has been designed and manufactured to

operate under a wide range of riding conditions.
However, it is not feasible to anticipate all of the condi-
tions under which this vehicle might be used. Extremes
of temperature, altitude, and riding usage may make
changing some carburetor parts or the spark plug de-
sirable to maintain the vehicle in peak operating condi-
tion.

Carburetor:
Sometimes an alteration may be desirable for good
performance under different riding conditions when
proper mixture is not obtained after the carburetor has Reach
been properly adjusted, and all parts cleaned and found
to be functioning properly.
If the engine still exhibits symptoms of overly rich or
Plug gap
lean carburetion after all maintenance and adjustments
are correctly performed, the main jet can be replaced
with a smaller or larger one. A smaller numbered jet
gives a leaner mixture and a larger numbered jet a richer
mixture.

1. Terminal 4. Gasket
2. Insulator 5. Center Electrode
3. Cement 6. Side Electrode

Spark Plug:
The spark plug ignites the fuel and air mixture in the
combustion chamber. To do this effectively and at the
proper time, the correct spark plug must be used, and
the spark plug must be kept clean and the gap adjusted.
Tests have shown the plug listed in the General
Information chapter to be the best plug for general use.
Since spark plug requirements change with the igni-
tion and carburetion adjustments and with riding condi-
tions, whether or not a spark plug of the correct heat
range is used should be determined by removing and
inspecting the plug.
When a plug of the correct heat range is being used,
the electrodes will stay hot enough to keep all the
carbon burned off, but cool enough to keep from
damaging the engine and the plug itself. This temper-
ature is about 400 - 800C (750 - 1 ,450F) and can be
judged by noting the condition and color of the ceramic
insulator around the center electrode. If the ceramic is
clean and of a light brown color, the plug is operating at
the right temperature.
A spark plug for higher operating temperatures
sometimes may be needed for severe conditions, such as
continuous high-speed riding, or towing heavy loads.
Such a plug is designed for better cooling efficiency so
that it will not overheat and thus is often called a
"colder" plug. If a spark plug with too high a heat range
is used - that is, a "cold" plug that cools itself too well,
- the plug will stay too cool to burn off the carbon, and
the carbon will collect on the electrodes and the ceramic
insulator.
The carbon on the electrodes conducts electricity,
and can short the center electrode to ground by either
coating the ceramic insulator or bridging across the gap.
Such a short will prevent an effective spark. Carbon
build-up on the plug can also cause other troubles. It
can heat up red-hot and cause preignition and knocking,
which may eventually burn a hole in the top of the
piston.
 APPENDIX 15-3
Spark Plug Condition

Carbon Fouling Oil Fouling Normal Operation Overheating

Spark Plug InsPeG.tion Standard Spark Plug Threads

eRemove the spark plug and inspect the ceramic insula- Diameter: 12 mm
tor. Pitch: 1.25 mm
*Whether or not the right temperature plug is being used Reach: 19.0 mm
can be ascertained by noting the condition of the
ceramic insulator around the electrode. A light brown
color indicates the correct plug is being used. If the NOTE
ceramic is black, it indicates that the plug is firing at
too Iowa temperature, so the next hotter type should o The heat range of the spark plug functions like a
be used instead. If the ceramic is white, the plug is thermostat for the engine. Using the wrong type of
operating at too high a temperature and it should be spark plug can make the engine run too hot (resulting
replaced with the next colder type. in engine damage) or too cold (with poor performance,
misfiring and stalling).

o If the spark plug is replaced with a type other than the

standard plug, make certain the replacement plug has
the same thread pitch and reach (length of threaded
portion) and the same insulator type (regular type or
projected type) as the standard plug.
Olf the plug reach is too short, carbon will build up on
the plug hole threads in the cylinder head, causing
overheating and making it very difficult to insert the
correct spark plug later.
o If the reach is too long, carbon will build up on the
exposed spark plug threads causing overheating,
preignition, and possibly burning a hole in the piston
top. In addition, it may be impossible to remove the
plug without damaging the cylinder head.

Plug Reach

Too Short Correct Reach

15-4 APPENDIX
............................................................................. No valve clearance
Troubleshooting Guide Cylinder, piston worn
............................................................................. Piston rings bad (worn, weak, broken, or sticking)
Piston ring/land clearance excessive
NOTE Cylinder head gasket damaged
OThis is not an exhaustive list, giving every possible Cylinder head warped
cause for each problem listed. It is meant simply as a Valve spring broken or weak
rough guide to assist the troubleshooting for some of Valve not seating properly (valve bent, worn, or
the more common difficulties. carbon accumulation on the seating surface)

Engine Doesn't Start, Starting Difficulty Poor Running at Low Speed

Recoi,1 starter n,ot operating Spark weak
Recoil starter springs broken Spark plug dirty, broken, or maladjusted
Recoil starter pawl not engaging Spark plug cap or spark plug lead trouble
Starter motor not rotating Spark plug cap shorted or not in good contact
Neutral switch trouble Spark plug incorrect
Starter motor trouble IC igniter trouble
Battery voltage low Pickup coil trouble
Relays not contacting or operating Ignition coil trouble
Starter button not contacting Battery voltage low
Wiring open or shorted Fuel/air mixture incorrect
Ignition switch trouble Pilot screw and/or idle adjusting screw maladjusted
Engine stop switch trouble Pilot jet, or air passage clogged
Fuse blown Starter plunger stuck open
Starter motor rotating but engine doesn't turn over Air cleaner clogged, poorly seated, or missing
Starter motor clutch trouble Fuel level too high or too low
Engine won't turn over Fuel tank air vent obstructed
Valve seizure Carburetor holder loose
Rocker arm seizure Air cleaner duct loose
Cylinder, piston seizure Compression low
Spark plug loose
Crankshaft seizure
Cylinder head not sufficiently tightened down
Connecting rod small end seizure
No valve clearance
Connecting rod big end seizure
Cylinder, piston worn
Transmission gear or bearing seizure
Piston rings bad (worn, weak, broken, or sticking)
Camshaft seizure
Piston ring/land clearance excessive
Balancer bearing seizure
Cylinder head gasket damaged
No fuel flow
Cylinder head warped
Tank air vent obstructed
Valve spring broken or weak
Fuel tap clogged
Valve not seating properly (valve bent, worn, or
Fuel line clogged
carbon accumulation on the seating surface)
Float valve clogged
Other
Engine flooded Vacuum piston doesn't slide smoothly
Fuel level too high Engine oil viscosity too high
Float valve worn or stuck open Brake dragging
Starting technique faulty Front or rear final gear case oil viscosity too high
(When flooded, crank with the throttle fully open
to allow more air to reach the engine.)
No spark; spark weak
Spark plug dirty, broken, or maladjusted
Spark plug cap or spark plug lead trouble Poor Running or No Power at High Speed
Spark plug cap not in good contact Firing incorrect
Spark plug incorrect Spark plug dirty, broken, or maladjusted
Pickup coil trouble Spark plug cap or spark plug lead trouble
IC igniter trouble Spark plug cap shorted or not in good contact
Ignition coil trouble Spark plug incorrect
Battery voltage low Pickup coil trouble
Ignition or engine stop switch shorted IC igniter trouble
Wiring shorted or open Ignition coil trouble
Compression low Fuel/air mixture incorrect
Spark plug loose Main jet clogged or wrong size
Cylinder head not sufficiently tightened down Jet needle or needle jet worn
 APPENDIX 155

Air jet clogged Front or rear final gear case overheating

Bleed hole of air bleed pipe or needle jet clogged Insufficient oil
Fuel level too high or too low Bevel gears maladjusted
Air cleaner clogged, poorly seated, or missing LSD clutches in front final gear case maladjustment
Starter plunger stuck open
Water or foreign matter in fuel
Carburetor holder loose Clutch Operation Faulty
Air cleaner duct loose Clutch slipping
Fuel tank air vent obstructed
Friction and/or steel plates worn or warped
Fuel line clogged Clutch housing or shoe linings overworn or worn
Fuel tap clogged unevenly
Compression low Clutch spring broken or weak
Spark plug loose Clutch release maladjusted
Cylinder head not sufficiently tightened down Clutch release mechanislTl trouble
No valve clearance Clutch hub or housing unevenly worn
Cylinder, piston worn Clutch not disengaging properly
Piston rings bad (worn, weak, broken, or sticking) Friction and/or steel plates warped or too rough
Piston ring/land clearance excessive Clutch spring compression uneven
Cylinder head gasket damaged Clutch shoe spring broken or weak
Cylinder head warped Engine oil deteriorated
Valve spring broken or weak Engine oil viscosity too high
Valve not seating properly (valve bent, worn or Engine oil level too high
carbon accumulation on the seating surface.) Clutch housing frozen on crankshaft or drive shaft
Knocking Clutch release mechanism trouble
Carbon built up in combustion chamber
Fuel poor quality or incorrect Gear Shifting Faulty
Spark plug incorrect Doesn't go into gear; shift pedal doesn't return
IC igniter trouble Clutch not disengaging
Miscellaneous Shift fork(s) bent or seized
Throttle valve won't fully open Gear(s) stuck on the shaft
Vacuum piston doesn't slide smoothly Shift return spring weak or broken
Brake dragging- Shift mechanism arm spring broken
Clutch slipping Shift return spring pin loose
Overheating Shift drum positioning lever binding on pivot bolt
Engine oil level too high Shift mechanism arm broken
Engine oil viscosity too high Shift drum damaged
Front or rear final gear case oil viscosity too high Jumps out of gear
Shift fork(s) worn
Gear groove(s) worn
Overheating Gear dogs, dog recesses, and/or dog holes worn
Firing incorrect Shift drum groove(s) worn
Spark plug dirty, broken, or maladjusted Shift drum positioning -lever spring weak or broken
Spark plug incorrect Shift fork guide pin(s) worn
Ie igniter trouble Shift mechanism arm spring weak or broken
Drive shaft, output shaft,and/or gear splines worn
Fuel/air mixture incorrect
Overshifts
Main jet clogged
Shift drum positioning lever spring weak or broken
Fuel level too low
Shift mechanism arm spring weak or broken
Carburetor holder loose
Air cleaner poorly sealed, or missing
Air cleaner duct loose
Air cleaner clogged Abnormal Engine Noise
Compression high Knocking
Carbon built up in combustion chamber IC igniter trouble
Engine load faulty Carbon built up in combustion chamber
Clutch slipping Fuel poor quality or incorrect
Engine oil level too high Incorrect spark plug heat range
Engine oil viscosity too high Overheating
Drive train trouble Piston slap
Brake dragging Cylinder/piston clearance excessive
Lubrication inadequate Cylinder, piston worn
Engine oil level too low Connecting rod bent
Engine oil poor quality or incorrect Piston pin, piston holes worn
15-6 APPENDIX

Valve noise Cylinder head gasket damaged

Valve clearance incorrect Engine oil level too high
Valve spring broken or weak Black smoke
Camshaft bearing worn Air cleaner clogged
Other noise Main jet too large or fallen off
Connecting rod small end clearance excessive starter plunger stuck open
Connecting rod big end clearance excessive Fuel level too high
Piston ring(s) worn, broken or stuck Brown smoke
Piston seizure damage Main jet too small
Cylinder head gasket leaking Fuel level too low
Exhaust pipe leaking at cylinder head connection Air cleaner duct loose
Crankshaft runout excessive Air cleaner poorly sealed or missing
Engine mount(s) loose
Crankshaft bearings worn
Primary gear worn or chipped Handling and/or Stability Unsatisfactory
Camshaft chain tensioner trouble
Handlebar hard to turn:
Camshaft chain, sprocket, guides worn
Tire air pressure too low
Balancer bearing worn
Steering bearing damaged
Balancer gear worn or chipped
Steering bearing lubricant inadequate
Steering stem 'bent
Damaged steering knuckle joint
Abnormal Drive Train Noise
Damaged tie-rod end
Clutch noise
LSD clutch maladjusted (front final gear case)
Clutch housing and/or hub damaged
Noise when turning
Transmission noise
Damaged side gear or pinion (Front final gear case)
Bearings worn
Worn clutch friction plates (Front gear case)
Transmission gears worn or chipped
Worn clutch spring (Front final gear case)
Metal chips jammed in gear teeth
Handlebar shakes or excessively vibrates
Engine oil insufficient or too thin Tire(s) worn
Front or rear final gear case noise: Wheel rim(s) warped
Insufficient lubricant Rear axle runout excessive
Incorrect oil (Front final gear case) Wheel bearing(s) worn
Bevel gear bearings worn
Handlebar mount(s) loose
Bevel gears' worn or chipped
Steering stem nut and/or stem clamp bolt(s) loose
Bevel gears maladjusted Handlebar pulls to one side
Worn clutch friction plate (Front final gear case) Frame bent
Worn clutch spring (Front final gear case) Wheel maladjustment
Thrust plug maladjusted (Rear final gear case) Suspension arm bent or twisted
Damaged side gears or pinions (Front final gear case) Steering stem bent
Front Axle or propeller shaft noise Tie-rod bent
Constant velocity universal joint damage Front or rear tire air pressure unbalanced
Front or rear shock absorber unbalanced
Shock absorption unsatisfactory
Abnormal Frame Noise Too hard:
Shock absorber noise Tire air pressure too high
Shock absorber damaged Shock absorber maladjusted
Brake noise Too soft:
Brake linings overworn or worn unevenly Shock absorber oil leaking
Drum worn unevenly or scored Shock absorber spring weak
Brake spring(s) weak or broken Tire air pressure too low
Foreign matter in hub Shock absorber maladjusted
Brake not properly adjusted
Other noise
Brackets, nuts, bolts, etc. not properly mounted or
tightened
Brakes Don't Hold
Front Brake
Air in the barke line
Exhaust Smokes Excessively Brake fluid leak
White smoke Brake fluid deteriorated
Piston oil ring worn Primary or secondary cup trouble
Cylinder worn Master cylinder scratched inside
Valve oil seal damaged Brake not properly adjusted
Valve guide worn Pad overworn or worn unevenly
 APPENDIX 15-7
Oil, grease on pads and disc
Disc worn or warped General lubrication
Brake overheated
Rear Brake
Brake not properly adjusted Lubrication
Linings overworn or worn unevenly eBefore lubricating each part, clean off any rusty spots
Drum worn unevenly or scored with rust remover and wipe off any grease, oil, dirt, or
Oil, grease on lining and drum grime.
Dirt, water between lining and drum eLubricate the points listed below with indicated lubri-
Overheated cant.

NOTE
OWhenever the vehicle has been operated under wet or
Battey Discharged rainy conditions, or especially after using a high-pres-
Battery faulty (e.g., plates sulphated, shorted sure spray water, perform the general lubrication.
through sedimentation, electrolyte level too
low)
Battery leads making poor contact
Load excessive (e.g., bulb of excessive wattage) Cables: Lubricate with Motor Oil
Ignition switch trouble Brake Cables
Regulator/Rectifier trouble Throttle Cable
Alternator trouble Choke Cable
Wiring faulty Reverse Gear Cable

Battery Overcharged e Lubricate the cables by seeping the oil between the
Regulator /Rectifier trouble cable and housing.
Battery trouble oThe cable may be lubricated by using a pressure cable
luber with an aerosol cable lubricant.

Cable Lubrication

Slide Points: Lubricate with Grease

Brake Cable Ends
Throttle Cable Ends
Reverse Cable Lower End
Brake Lever
Brake Pedal Pivot Shaft
Throttle Lever Shaft
Speedometer Cable
15-8 APPENDIX

Bolt and Nut Tightening

Tightness Inspection
e<::heck the tightnes!i of the bolts and nuts listed here.
Also, check to see that each cotter pin is in place and in
good condition.
*If there are loose fasteners, retorque them to the
specified torque following the specified tightening
sequence. Refer to the appropriate chapter for torque
specifications. If torque specifications are not listed in
the appropriate chapter, see the basic torque table (see
Torque and Locking Agent in the General Information
chapter). For each fastener, first loosen it by }'2turn,
then tighten it.
*If cotter pins are damaged, replace them with new ones.

1. Front Propeller Shaft Joint Circlip

Bolts, Nuts, and Fasteners to be checked

Wheels:
Front Hub Nuts and Cotter Pins
Rear Axle Nuts and Cotter Pins
Wheel Nuts
Brakes:
Master Cylinder Clamp Allen Bolts
Brake Lever Pivot Bolt
Brake Lever Pivot Nut
Caliper Mounting Bolts
Brake Pedal Cotter Pin
Steering/Suspension:
Handlebar Clamp Bolts
Stem Nut and Cotter Pin
Stem Clamp Allen Bolts
Stem Bearing Housing Bolts
Tie-Rod End Nuts and Cotter Pins
Tie-Rod Adjusting Sleeve Locknuts
Shock Absorber Mounting Bolts and Nuts
Suspension Arm Pivot Bolts
Steering Knuckle Pivot Nuts and Cotter Pins
Engine:
Engine Mounting Bolts
Engine Mounting Bracket Bolts
Exhaust Pipe Holder Nuts
Muffer Mounting Bolts
Muffer. Clamp Bolt
S~ift Pedal Bolt
Final Drive (Front)
Front Propeller Shaft Joint Circlip
Others:
Footpeg Mounting Bolts
Grab Rail Mounting Bolts
Throttle Case Clamp Screws
Carrier Mountlng Bolts
 SUPPLEMENT - 1990 - 1994 MODELS 16-1

Supplement -1990-1994 Models

This supplement chapter contains only the information unique to the models covered. Read both
this manual's front part (up to p. 15-8) and this chapter for complete information on proper service
procedures.

Table of Contents

General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 16-2

Model Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 16-2
General Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-4
Crankshaft/Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 16-8
Exploded View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 16-8
Frame .... , ...... , ............................ , . . . . .. . .. 16-8
Exploded View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 16-8
Wiring Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 16-9
16-2 SUPPLEMENT - 1990 - 1994 MODELS

General Information

Model Identification

KL F300-C2/C2A

KLF300-C3
 SUPPLEMENT - 1990 - 1994 MODELS 16-3

KLF300-C4

KLF300 - C5 / C6
16-4 SUPPLEMENT - 1990 - 1994 MODELS

General Specifications

: Australia model : UK model (,.) : I dentical to left side.

: Canada model @ : US model

Item KLF300-C2/C2A KLF300-C3 KLF300-C4

Dimensions:
Overall length 1 860 mm ,. ,.
Overall width 1 100 mm ,. ,.
Overall height 1 105 mm ,. ,.
Wheelbase 1 200 mm ,. ,.
<;lr.ound clearance 225 mm ,. ,.
Seat height 805 mm ,. ,.
Dry weight 260 kg 261 kg ,. 261 kg
Curb weight: Fr.ont 138.5 kg 139 kg ,. 138.5 kg 139 kg
Rear 129.5 kg 130 kg ,. 130.5 kg 130 kg
Fuel tank capacity 11 L, 8.2 L ,.
Performance:
Minimum turning radius 2.9m ,. ,.
Engine:
Type 4-str.oke, SOHC, 1-cylinder
,. ,.
C.o.oling system Air c.o.oled
,. ,.
B.ore and str.oke 76.0 x 64.0 mm
,. ,.
Displacement 290 mL
,. ,.
C.ompression rati.o 8.6
,. ,.
Max imum h.orsep.ower 14.7 kW (20 PS) @6 500 r/min (rpm), ,. ,.
@-
Maximum t.orque 23.6 N-m (2.4 kg-m, 17.3 ft-Ib) ,. ,.
5500 r/min (rpm), @ -
Carbureti.on system Carburet.or, Keihin CVK32 ,. ,.
Starting system Electric starter & rec.oil starter ,. ,.
Igniti.on system Battery and C.oil (transist.orized) ,. ,.
Timing advance Electr.onicallyadvanced ,. ,.
Igniti.on timing Fr.om 10 BTDC@2 000 r/min (rpm) Fr.om 10 BTDC @1 300 ,.
t.o 306 BTDC @3 200 r/min (rpm) r/min (rpm) t.o 30 BTDC
@4 000 r/min (rpm)
Spark plug NGK D8EA, NGK DR8ES-L NGK DR7EA, @ DR8EA, ,.
DR8ES-L
Valve timing: Inlet Open 21 BTDC ,. ,.
Cl.ose 59 ABDC ,. ,.
Durati.on 260 ,. ,.
Exhaust Open 56 BBDC ,. ,.
Cl.ose 24 ATDC ,. ,.
Durati.on 260 ,. ,.
Lubricati.on system F.orced lubricati.on (wet sump) ,. ,.
Engine .oil: Grade SE .or SF class ,. ,.
VisC.osity SAE 10W-30, 10W-40, 10W-50, ,. ,.
20W-40, .or 20W-50
Capacity 2.2 L ,. 2.4 L
Drive Train:
Primary reducti.on
System: Type Gear ,. ,.
Reducti.on rati.o 2.888 (78/27) . ,. ,.
Clutch type: Primary Aut.o centrifugal, wet ,. ,.
Sec.ondary Aut.o multi disc, wet ,. ,.
 SUPPLEMENT - 1990 - 1994 MODELS 16-5

Item KLF300-C2/C2A, C3, C4

Transmission : Type 10-speed plus reverse, constant mesh, return shift
Gear ratio: 1st 3.090 (34 / 11)
2nd 1.928 (27 / 14)
3rd 1_368 (26/19)
4th 1.000 (23/23)
5th 0.769 (20/26)
Reverse 3.072 (26/11 x 26/20)
Final drive
system: Type Shaft (four wheel drive)
Reduction ratio High 5.416 (33 / 33 x 20116 x 39/9)
Low 6.910 (37 / 29 x 20/ 16 x 39/ 9)
Overall drive ratio High: 12.037 Low : 15.357
Front final gear case oil Type API GL-5 Hypoid gear oil for LSD SAE140 or SAE85W-140
Capacity 0.25 L
Rear final gear case oil: Type API GL-5 Hypoid gear oil SAE 90 (above 5C, 41F)
or SAE 80 (below 5 C, 41 F)
Capacity 0.2 L
Frame:
Type Double tubular
Caster (rake angle) 1.0
Camber 0 @1 G
Trail 5mm
Tread Front 844mm
Rear 840mm
Front tire: Type Tubeless
Size AT 24 x 8-11
Rear tire : Type Tubeless
Size AT 24x 10-11
Suspension : Front Type Double wishbone
Wheel travel 110 mm
Rear Type Torque tube
Wheel travel 120mm
Brake type : Front Disc (Hydraulic) x 2
Rear Drum (Mechan ical, on Rightside)
Electrical Equipment:
Battery 12 V 14Ah
Headlight: Type Semi-sealed beam
Bulb 12 V 25/25 W x 2
Taillight 12V8Wx2
Alternator: Type Three-phase AC
Rated output 23_5 A @9 000 r/min (rpm), 14 V

Specifications are subject to change without notice, and may not apply to every country.
16-6 SUPPLEMENT - 1990 - 1994 MODELS

General Specifications
..............................................................................

: Australia model @: UK model : Canada model

: Europe model @; US model

Item KLF300-CS/C6
Dimensions:
Overall lengtr 1 860 mm
Overall width 1120 mm, 1 210 mm
Overall height 1 105 mm
Wheelbase 1200mm
Ground clearance 225mm
Seat height 805mm
Dry weight 260 kg, 263 kg,
261 kg
Curb weight: Front 138.5 kg, 139 kg,
138.5 kg
Rear 129.5 kg, 132 kg,
130.5 kg
Fuel tank capacity 11 L
Performance:
Minimum turning radius 2.9m
Engine:
Type 4-stroke, SOHC, l-cylinder
Cool ing system Air cooled
Bore and stroke 76.0 x 64.0 mm
Displacement 290mL
Compression ratio 8.6
Maximum horsepower 14.7 kW (20 PSI @6 500 r/min (rpm), @ -
Maximum torque 23.6 N-m (2.4 kg-m, 17.3 ft-Ib) 5500 r/min (rpm),
@-
Carburetion system Carburetor, Keihin CVK32
Starting system Electric starter & recoil starter
Ignition system Battery and coil (transistorized)
Timing advance Electronically advanced
Ignition timing From 10 BTDC @1 300 r/min (rpm) to
30 BTDC @4 000 r/min (rpm)
Spark plug NGK D8EA, NGK DR8ES-L, DR7EA
Valve timing: Inlet Open 21 BTDC
Close 59 ABDC
Duration 260
Exhaust Open 56 BBDC
Close 24 ATDC
Duration 260
Lubrication system Forced lubrication (wet sump)
Engine oil: Grade SE or SF class
Viscosity SAE 10W-30, 10W-40, lOW-50, 20W-40, or 20W-50
Capacity 2.4 L
Drive Train:
Primary reduction
System: Type Gear
Reduction ratio 2.888 (78/27)
Clutch type: Primary Auto centrifugal, wet
Secondary Auto multi disc, wet
 SUPPLEMENT - 1990 - 1994 MODELS 16-7

Item KLF300-CS/C6
Transmission: Type 10-speed plus reverse, constant mesh, return shift
Gear ratio: 1st 3.090 (34111)
2nd 1.928 (27/14)
3rd 1.368 (26/19)
4th 1.000 (23/23)
5th 0.769 (20/26)
Reverse 3.072 (26/11 x 26/20)
Final drive
system: Type Shaft (four wheel drive)
Reduction ratio High 5.416 (33/33 x 20/16 x 39/9)
Low 6_910 (37/29 x 20/16 x 39/9)
Overall drive ratio High: 12_037 Low: 15.357
Front final gear case oil Type API GL-5 Hypoid gear oil for LSD SAE140
or SAE 85W-140
Capacity 0.25 L, (C6) 0.40 L
Rear final gear case oil: Type API GL-5 Hypoid gear oil SAE 90 (above 5C, 41F)
or SAE 80 (below 5C, 41 F)
Capacity 0.2 L, 0.3 L, (C6) 0.3 L
Frame:
Type Double tubular
Caster (rake angle) 1.0
Camber 0 @1 G
Trail 5mm
Tread Front 844mm
Rear 860mm
Front tire: Type Tubeless
Size AT 24x 8-11
Rear tire: Type Tubeless
Size AT 24 x 10-11
Suspension: Front Type Double wishbone
Wheel travel 110mm
Rear Type Torque tube
Wheel travel 120mm
Brake type: Front Disc (Hydraulic) x 2
Rear Drum (Mechanical, on Rightside)
Electrical Equipment:
Battery 12 V 19 Ah, (Q) 12 V 14 Ah
Headlight: Type Semi-sealed beam
Bulb 12 V 25/25 W x 2
Taillight 12V8Wx2
Alternator: Type Three-phase AC
Rated output 23.5 A @9 000 r/min (rpm), 14 V

Specifications are subject to change without notice, and may not apply to every country.
16-8 SUPPLEMENT - 1990 - 1994 MODELS

Crankshaft/Transmission

Exploded View
........................................................................... .
-

Refer to the front part of this manual, noting the

following.

On and after K LF300-C3

1. Reverse Knob and Cable Assembly

Frame

Exploded View

Refer to the front part of this manual, noting the

following.

On and after KLF30o-C2

US, Canada Models

On and After KLF300-C2

1. Foot Board Steps

2. Rear Fender Front Flaps
 "r
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ICI

Neutral Indlcltor LO ~ LO : , LO ---.J ....

~~
III
3
Light 12 V 3.4'"
S~rk Plug
c
en
'" s:

J'
CD
I I II
~ ~ I I ~
~..J~~
" . , II

'."~,
'qJ ::t'..J~ , 0
CD .. ~ Q.
.,
a:
Rev.rloe Ind lCltor
Ll9hl12 V 3.4 W
(f'F-. II ./. -DCl- ./.
,~.. '~II
h Accessory
Termlnlls -!!!..
..

r~ r~
..... BK/Y~B en
L.. L- ~ ==::;- L-el
L--BK/W-=-
C
YlA YlA R UJ!,i "tI
_K/

K/

K"
- Taillights r-0
eK
e. ~ 12 V 8 W x 2 m
s:
m
BL
Z
til BA
-i
.
HtldlI9hts
~~ Fu
30A . ..
~,
~
Color Code 8

I
12 V 25/25 W @ E B K / V. --C::>O::)OO-BKty BK Black
R/Y~
-J--I-J
BL Blue

~
RISK --<::<:J---R/BK
BR Brown

12V25/"W~ J I I G
GY
Green
Gray
~
B K/Y -c::>c::J- BK/Y . .
LB Light Blue s:
_e'l _. _ _ _ _ _
R/Y
o

r
R/BK --PO Light Green
LG
Sta,ter Button e,.. I I 0 Orange om
P Pink r
EnQlnl Stop Switch
+ ~ LO;:~ R Red en
Ught Switch
Blttery
12V14Ah W White -"
~I 0)
Y Yellow I

(1218A) 10
 -4
en
:: r- : ". I
-A
o
Alternator PICkup
I)!';') :.-. ." :
:W:
:C 0:
en
C

~"""~
Ignition Coli :(11 Q: "0
Switch .:"~ .... ]1
::=:0= "0

m
~:;~
r

R.v.rs~~ICh W
N:
: II)

: m

~ " A =~
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m
2

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~

l!I~Jo::lIC
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II
0/.
Y'P!'
.- .
C.

.- -,-..
:
: m :E:
:i':'

J
!
, <>

Neutral Indicator ~ LO --I

'" ~

Lo
.,.,
~~
: IQ:
: 0: 8
Light 12 V 3.4 W
- - - G < ) - LO
: i":
SPlrk P1ug CQ: .."
II) :

'"
CD

'"celli)-)-)-
' , , ,
: 3:. ~
os:

l,J
I I e:'~
om
RGvorse Indicator -DO-R/W
Light 12 V 3.4 W (,('f=-. e

Speedometer L ren
r-- - '2\t3.4W

, } R-~

BK/V~ I
::;
,,
w B K/V --<>0----. B K/V .----r -li\
I Working Light _ .K' IY~II~Y
,~ x::='~~--' R
.
I 12 V 65/60 W Taillights
_ 12V8Wx 2

I __

Al.
~ ~ 1_
L - - -~" Option 0;

Headl ights

12V25/25W@E
~
~"~~ e,, .,
~,
.,~

BK
Color Code
Black

I
BK/V----a<>--BK/V
R/V ---O<:J-----!-J '" BL Blue
~

~
RISK --D<::r--R/BK
BR Brown
'"I>~~IICIi~~
. '"
Ho:n- ) ) G Green
Switch Horn
,
12V25/25W
(d-ce::: --O<I_BK/V J
(X
GY
LB
Gray
Light Blue
~R/8K~-------_-J.

r "~
Light Green
Starter Button " LG
0 Orange
Engine Stop Switch Stl'ter Motor P Pink
R Red
Light Switch
OFF W White
Y Yellow
(12048)
 SUPPLEMENT - 1995 - 1998 MODELS 17-1

Supplement - 1995 - 1998 Models

This supplement chapter contains only the information unique to the models covered. Read both this manual's front part
(up to p.16-1 0) and this chapter for complete information on proper service procedures.

Table of Contents

General Information .......................................... 17-2

Model Identification ...................................... 17-2
General Specifications .................................... 17-4
Wiring, Cable, and Hose Routing ........................... 17-6
Fuel System ............... .... ... 17-7
Exploded View .......................................... 17-7
Specifications ............................................ 17-7
Engine Top End 17-8
Exploded View .......................................... 17-8
Wheels{fires . .. .............................. ........... ..... 17-8
Specifications ............................................ 17-8
Final Drive ................................................... 17-9
Exploded View .......................................... 17-9
Electrical System .. ........................ .. .... ... ..... .... 17-10
Exploded View ........ . . ... .. .. .. ............ .. ........ 17-10
Ignition System . ................... ... . . .... .......... .. 17-10
Carburetor Heater .............. . . ...... ................ 17-11
Wiring Diagram ....... ........ .. .... ... ....... ............... 17-12
Switch ...................................................... 17-16
17-2 SUPPLEMENT - 1995 - 1998 MODELS

General Information
Model Identification

KLF300-C7/C7A

KLF300-C8
 SUPPLEMENT - 1995 - 1998 MODELS 17-3

KLF300- C9
17-4 SUPPLEMENT - 1995 - 1998 MODELS

General Specifications

(A) : Australia model (8) : UK model (C) : Canada model

(E) : Europe model (U) : US model

Items KLF300-C7 -
Dimensions:
Overall length 1 860 mm
Overall width 1 120 mm, (A)(B)(E) 1 210 mm
Overall height 1 105mm
Wheelbase 1 200 mm
Ground clearance 225mm
Seat height 805mm
Dry weight 260 kg, (A) (B) (E) 263 kg, (C)261 kg
Curb weight: Front 138.5 kg , (A)(B)(E) 139 kg, (C) 138.5 kg
Rear 129.5 kg, (A)(B)(E) 132 kg, (C) 130.5 kg
Fuel tank capacity 11 L
Performance:
Minimum turning radius 2.9 m
Engine:
Type 4-stroke, SOHC, 1 -cylinder
Cooling system Air-cooled
Bore and stroke 76 .0 x 64.0 mm
Displacement 290 mL
Compression ratio 8.6
Maximum horsepower 14.7 KW(20 PS) @6 500 r/ min(rpm), (U) -
Maximum torque 23.6 N-m(2.4 kg-m, 17.3 ft-Ib) @5 500 r/ min(rpm),
(U) -
Carburetion system Carburetor, Keihin CVK34
Starting system Electric starter & recoil starter
Ignition system Battery and coil (transistorized)
Timing advance Electronically advanced
Ignition timing From 10 BTDC @1 300 r/min(rpm) to
30 BTDC @4 000 r/min (rpm)
Spark plug NGK D8EA, (A)(C) NGK DR8ES-L, (B)(E) DR7EA
Valve timing :
Inlet: Open 21 (BTDC)
Close 59 (ABDC)
Duration 260
Exhaust: Open 56(BBDC)
Close 24 (ATDC)
Duration 260
Lubrication system Forced lubrication(wet sump)
Engine oil :
Grade SE,SF, or SG class
Viscosity SAE1 OW-30, 10W-40, 1 OW-50, 20W-40, or 20W-50
Capacity 2.4 L
 SUPPLEMENT - 1995 - 1998 MODELS 17-5

Items KLF300-C7-
Drive Train:
Primary reduction system :
Type Gear
Reduction ratio 2.888(78/27)
Clutch type: Primary Auto centrifugal, wet
Secondary Auto multi disc, wet
Transmission: Type 1 O-speed plus reverse, constant mesh, return shift
Gear ratios: 1st 3.090 (34/11 )
2nd 1.928 (27/14)
3rd 1.368 (26/19)
4th 1 .000 (23/23)
5th 0.769 (20/26)
Reverse 3.072 (26/11 x 26/20)
Final drive system:
Type Shaft (four wheel drive)
Reduction ratio: High 5.416 (33/33 x 20/16 x 39/9)
Low 6.910 (37/29 x 20/16 x 39/9)
Overall drive ratio High: 12.037 Low: 15.357
Front final gear case oil: Type API GL-5 Hypoid gear oil for LSD SAE140
or SAE90W -140
Capacity 0.40 L
Rear final gear case oil: Type API GL-5 Hypoid gear oil SAE 90 (above 5C, 41F)
or SAE80 (below 5C, 41F)
Capacity 0.3 L
Frame:
Type Double tubuar
Caster (rake angle) 1.0
Camber 00@1 G
Trail 5mm
Tread: Front 844mm
Rear 860 mm
Front tire: Type Tubeless
Size AT24 x 8-11
Rear tire: Type Tubeless
Size AT24 x 10-11
Suspension : Front: Type Double wishbone
Wheel travel 110 mm
Rear: Type Torque tube
Wheel travel 120 mm
Brake type: Front Disc (Hydraulic) x 2
Rear Drum (Mechanical, on Rightside)
Electrical Equipment:
Battery 12V19Ah, (U) 12V14Ah
Headlight: Type Semi-sealed beam
Bulb 12 V 25/25 W x 2
Taillight 12 V 8W x 2
Alternator: Type Three-phase AC
Rated output 23.5 A @9 000 r/min (rpm), 14 V

Specifications are subject to change without notice, and may not apply to every country.
17-6 SUPPLEMENT - 1995 - 1998 MODELS

Wiring, Cable, and Hose Routing

Breather Tube Assembly (KLF300-C10-, California Model)

I rI
1. Clamp (92037 -1181 )
2. Clamp (92170-1552)
3. Clamp (92037 -1271 )
4. Tube (92059-1789, to Cylinder Head)
5. Joint (59071 -1124)
6. Tube (92191-1170, to Air Cleaner Assembly)
7. Air Cleaner Assembly (11010-1622 )
8. Cylinder Head
9. Cap
10. Carburetor
11. Install the clamp (92170-1552) so that the clearances between the tube and near parts are more than 5mm.
 SUPPLEMENT - 1995 - 1998 MODELS 17-7

Fuel System
Exploded View

KLF300-C9 ....

, .... KLF300-C7/C7A

ooo08~~

Specifications

Item Standard Service Limit

Carburetor:
Make, type Keihin, CVK32 -- -
Main jet #125, #138 (KLF300- C9 ~, except CAl - --
Main air jet #50, #70 (KLF300-C9~, except CAl - --
Needle jet #6
Jet needle N36W, N24G(KLF300-C9~) ---
Pilot jet #38 ---
Pilot air jet #140 -- -
Pilot screw 2118 turns out, 2 turns out (KLF300-C8~) - --
Starter jet #58, #65 (KLF300-C8~) - --
Service fuel level 0.5 mm (below) ~ 1.5 mm (above) - --
Float height 17 2mm ---
Optional parts:
Main jet #120,122,128, 130 - --
#132, 135,140, 142 (KLF300-C9~, except CAl
Pilot jet #35,40 - --
Starter jet #60,62 - --
#68, 70 (KLF300-C8~)
Idle Speed 1300+ 50 r/min (rpm) (KLF300-C9-)
Main Jet:
Altitude: 500 ~ 1500 #122 (92063-1073), (KLF300-C1 0- ,CAl - --
#135 (92063-1 014, KLF300 - C9~, except CAl ---
1500 ~ 2500 #120 (92063-1072), - --
#132 (92063-1076, KLF300-C9~, except CAl - --
2500 ~ 3500 #115 (92063 -1118), - --
#128 (92063 -1 074, KLF300-C9~, except CAl ---
3500 ~ 4500 #112 (92063 -1117), ---
#125 (92063 -1 069, KLF300-C9~, except CAl - --
(CA): California model
17-8 SUPPLEMENT - 1995 - 1998 MODELS

Engine Top End

Exploded View

KLF300-C10-, California Model

WheelslTires
Specifications

Wheel Alignment
Caster: 1 (non-adjustable)
Camber: 0 (non-adjustable) @lG
Toe-in: 20 mm

Standard Tires
Front: AT 24 x 8-11
Dunlop KT962, KnobbylTrail
Tubeless
(U)Goodyear, Tracker MPlTraii
Tubeless
Rear: AT 24 x 10-11
Dunlop KT962, KnobbylTrail
Tubeless
(U)Goodyear, Tracke.r MPlTrail
Tubeless

Tire Air Pressure (when cold)

Front: 35 kPa (0.35 kg/cm 2 , 5 psi)
Rear: 28 kPa (0.28 kg/cm 2 , 4 psi)

Maximum Tire Air Pressure

(to seat beads, when cold)
Front: 250 kPa (2.5 kg/cm 2 , 36 psi)
Rear: 250 kPa (2.5 kg/cm 2 , 36 psi)

Maximum Vehicle Load: 195 kg (430 Ib)

(U): UK model
 SUPPLEMENT - 1995 - 1998 MODELS 17-9

Final Drive
Exploded View

KLF300-C7-
17-10 SUPPLEMENT - 1995 - 1998 MODELS

Electrical System
Exploded View

KLF300-C7 -, UK Model

Ignition System
(KLF300-C7A-, Europe Models)

Ie Igniter Inspection
o Refer to the Base Manual noting the following .
Set the hand tester (special tool) to the x 1 kO range.

IC Igniter Resistance Unit: kO

Tester Positive (+) Lead Connection
Range
x1kO BL Y/R R/W G/W (BK/W) BK/W
.. BL - 75 - 300 55 ,." 220 80,." 320 50,." 200 50,." 200
Y/R 75,." 300 - 3 ,." 12 5,." 22 2.5 ,." 11 2.5 ,." 11
R/W 50,." 200 2.5 ,." 11 - 1.8"" 7 0.4 ,." 1.6 0.4,." 1.6
G/W 00 00 00 - 00 00

(BK/W) 50,." 200 2.2,." 8.4 0.3,." 1.5 1.3,." 5.5 - 0

BK/W 50,." 200 2.2 ,." 8.4 0.3 ,." 1:5 1.3 - 5.5 0 -
Measure with the Kawasaki Hand Tester (PN 57001-1394). A tester other than the Kawasaki Hand Tester"
may show slightly different read ings.
Tester Negative ( - ) Lead Connection

IC Igniter Terminal

Y/R R/W

~
(BK/W) BL

BK/W G/W
 SUPPLEMENT - 1995 - 1998 MODELS 17-11

Carburetor Heater
(KLF300-C7-, UK model)

Control Unit Inspection

Remove the control unit.
.Set the hand tester to the x 1 kG range and make the
measurements shown in the table. B
* If the tester readings are not as specified, replace the
control unit.

Control Unit Resistance Unit: kQ A. Thermostatic Sensor B. Thermostat

Tester Positive (+) Lead Connection
1 2 3 4 5
*If the tester does not read as specified, replace the
. 1 - 7-28 00 6.5-28 17-80
sensor.

Carburetor Thermostatic Sensor Resistance (Reference

2 00 - 00 00 00 only)

- Standard: 3.0 - 7.2 kn @12C (53.6F)

3 6-26 9.5-40 9.5-40 24-150
4 4.4-19 1.4-6 00 - 6.5-28
5 13-60 10-45 00 6.5-28 -
*: Tester Negative (-) Lead Connection

Carburetor Heater Inspection

Disconnect the carburetor heater connector.
Using the hand tester, measure the resistance of the
3
heater.
Connect the tester between the heater terminal and
carburetor ground.
* If the tester does not read as specified, replace the
heater.

Carburetor Heater Resistance

Standard: 11- 20 n

Carburetor Thermostatic Sensor Inspection

Remove the carburetor thermostatic sensor.
Suspend the sensor in a container of water so that the
temperature sensing projection and threaded portion are
submerged .
Using the hand tester, measure the internal resistance
of the sensor across the terminal and the body at the
temperatures shown in the table.

NOTE
o The sensor and thermostat must not touch the container
sides or bottom.
 -'
,..
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I

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~~
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N

en
1
N
eutrGI
Gnd
Sonl tion Reverse
1. Reverse I
12V3.4W
2. N9utrG 1 I
ndlcGtor Lloht

12V3 . 4W ndlcetor Lloht

s:n
&.~
c
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ft ~~ 1m
"C
- _.
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ar
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Ta 1IIIght CC
12vaWx2 Al -'
3 CD
CD
Headlight I~ (11
12V25/25W
( RH)
-'
CD
CD
CO
work Ing
Light s:
12V60/SSW
(Opt Ion)
0
0
m
r-

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=!U/1-CJ<J-U/I
Speedometer
LlQht
12VJ.4W
I -i>CJ-1

fM .~.
...

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Head light mmlTTIT? ,...,...>om cx

HW/ II ReQUla~:r
25W

<) IReet I Ie

Pickup IQnltlon
co II
Alternator Coil
rr===C]S=:},;==~ starter Motor

~ : ~m~e Sw I teh
ijf:;,. PISoark
UQ
3. Starter S~~~t~~1 teh
~~
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r-

a cs
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~
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c. ~
Neutral
and
t.Reverse Indicator Light
12V3.4W
2.Neutral Indicator Light
t2V3.4W r--------------"
UK model
~~-
I I
I
;
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~
CO

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1a:1
. Reverse
Ignit Ion Switch I~ C
iii'

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II III
CD 1..-----, I I
, , CO
Cl0- model iil
M
I ~ -Accessor-' I
3
BK "' I Terminal~ II
>- ;::.
I r ~, II

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Head light,co",
12V25/25W
(RH)
@ R/BK-l>D-N1l<
R/Y --{>{:=I-WI-
SK/Y --c:J<l--a</'(
c __ _
------------
Heater
Relay

w~~:
_ _ _ _ , ",;0 I
ii'" III ~I~I
":': G
"
I

,
I
I I I

, c -- -- -
c
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R

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s:m

@:i;:~51 mm ~ ".0.# :I~~[l

Z
Speedometer -4
Light R ---l>CJ-R
12V3 .4W
~ @;:a;o I "'~ Cblor Cbde ....l

1i SK Slack
CD
CD

,a:~a:a:", c ,~ ~ ~O!~~ii
>->->- -,,,, I I

".~.
<D
SL Blue C1I
fiIlIIQ--~-om!IiI
Headlight SR Brown
12V25/25W "
I' Iii
r '" -,
" II Relay
Start
(LH)
" gnlter: I ~
' "CO";; CH
OG
Chocolate
Dark Green
....l
CD
G Green CD
GY Gray 00

~eg~ltlOnr ~ II II' s:
P,ck up I LB Light Blue
LG Light Green
OFF H:. Alt ernator Call - - - - - Starter Motor
o
,~"'
0 Orange

~spark
P Pink C
LUg",/O :: ' PU Purple
,Cog''" ""'" c -- : '
R Red
m
3.Starter Ssto p Switch - - - - - - I r-
utton Plug W White C/)
<D ~ @ ~
(9B051-1559A, 1563 A) C Y Yellow
....l

,
-.J
....l
W
 ~

_r-
C"T1 " "
~
I

i. Reverse Indicator
light 12V3. 4W
2. Neutral Indicator
!n8
Q) I
,J::o.

CJ)
Neutral
light 12V3 . 4W
:::l n C
and Front 0..0
Ignition Reverse Brake Parking Rear ""C
Brake Brake ""C
Switch Switch light
SWltch light light
Accessory Q r-
SWltch SWltch
;0.. ~::;' m

~il ij
(Option) (Option) (Opt ion) Terminals
S
H
~& ~rt:, (!~~\
BL -0<:1,,- BL =!)- Taillight 12VBW(RH)

9~,.
BK/Y-t>C!-BK/Y Brake light 12V27W
iii' :;' m
.. U
d:
U
A-c:J<}- A (Option)
:::l<O Z
~ ~
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~~ ~~ H~
m OJ CD ...J
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BK/Y{>O-BKIY
Taillight 12VBW(LH)
Brake Light 12V27W
0..<0
~@
~
(0

Headl ight CIDA/BK---l>D-A/BK ~Q

,. fB:t ~ ~ ~ ~ffi ID
-' 0:
ID
-'
ID ID
-' 0: A ~ A (Option)
~3
(0
(11
12V25/25W A/Y ---l>D- A/Y
~
L-J
(RH) BK/Y-cJ<j-BK/ Y 0:

I'~
(0
I I 1 (0
00
Work ing
Light
12V65/60W (t-l
- ."'--~rA/ BK----t: ' A/BK
f-AIY --{:,8= A/Y I I I l I .
Maln Fuse s
(Option) :;;:t.. J-BK/Y- -i,,)<J--BK/y
1 30A o
I I I II II I
~. ~~n! IIII"'~
I C
m
r-
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~ ~
0.LU "',.
~~ ~ ID~
Headl ight CIDA/BK---l>D-A/BK IIII lli"'''''''
12V25/25W A/Y ---l>D- A/Y
(LH) BK/Y-cJ<j-BK/Y
ID]ID
~lr~~~~ ID
~-'
~ ~CI:J:
~ ~ ;;;
(US) 12V 14Ah

~~A
Ignition"

~:::n
~
COlI'
,. l!: __ ::!J,
~a:ma:~~ ; Starter
Cir '
Rel~~lt Color Code

~.
Igniter
BK Black
(Option) Pickup BL Blue
Alternator Coi 1 'f Starter Motor BR Brown
nTTrl ~
G Green
~a:ffia:fE.~
a:. (?al)-m
I! II ! :L . . ..., ~__ L-'liJ Spark Plug GY I Gra
LB Light Blue
LG ight Green
I I
, L+l L,
I
,
I I
CD@ o Oran e
[t-t(~'Cll P Pink
~ ~.~tv:T! i. Light/Oimmer Switch
2. Engine Stop Switch R I Red
L_J_'lf--l 3 . Starter Button W I White
(US): U.S. Model
Y I Yellow
CD@
i. Oimmer Switch (98051-1673A, 1674A) C
2 . Engine Stop Switch
3. Starter Button
 ~
-'
"T1
C
~,
8
..
Neutral
and
Reverse
~~
0
Q)
IgnItIon SWitch 1 Reverse
2: Neutral Indicator Light 12V3.4W ::J I

IlQJ
SwitCh Indicator Light 12V3.4W Accessory
[:l)
Speedometer
Light 12V3.41~ II M
CD
Terminals

Bl-D
BK/Y-!>CJ-BK/Y
A-CJ<}- A
= }
s:~
o
c..,
_.
(1) _.
_:::s
-co

~~ ~~ ~ M
Tallllgh
12V811x2

~ ~ :1 ~ ~ ~~
Bl-CJ
BK/Y-t>CJ-SKIY
R -D<l- R
=
Headl ight A/BK-l>D-R/BK
12V25/25W A/Y -l>D- A/Y L-1
(RH) BK/Y-CJ<]- BK/Y

Working Main Fuse

(~
---' --f----R/BK-{>CJ-R/BK 30A
Light
12V65/60W
(Option)
, Y.. J-BK/Y-CJ<l-BK/Y
-- f- R/Y --t>CJ- R/Y
en
c

>->->- ...J~ ~J
n
.?::a3: :.0:
..... ,
"tJ
"tI
r-
m

~~ ~
~"

s:m
:::.:::(()
l!l>

~~
Head1 ight @A/BK-l>D-R/BK
12V25/25W R/Y -!>CJ- R/Y
(LH) BK/Y-CJ<]-BK/Y
2:
~~ (:~~
~
0:0: w ~ w > ffiffi -I

cr &w~w
~ r=J ~~
Q
i::",ffio:o:",
I!!oiI!! I
Starter
Circuit
Relay
~
(D
(D
U'I

()f~ i'~
ill J ,H,
L,
lL: ~ ~~ ~~\ft..~\~
>-" Horn
12Vl.5A PIcku Starter Motor
l'--L-,li "',m'W Co>1 0
Spark Plug
~
(D
(D
00

,. CD @ LVJ s:
Horn
Swl tch o
3: ~gine ~~grSS.'ltch
2' LIghtiO
C
arter Butto~ltch m
r-
en
~

-..J
I
~

U'I
17-16 SUPPLEMENT -1995 -1998 MODELS
Switch

Switch Inspection
Using the hand tester, check to see that only connections shown in
the table have continuity (about zero ohms) .
o For the handlebar switches and ignition switch, refer to the tables in
the wiring diagram.
* If the switch has an open or short, repair it or replace it with a new
one.
Special Tool- Hand Tester : 57001-1394

Front/Rear/Parking Brake Light Switch

BL BR
When front/parking brake lever is
grasped or brake pedal is pushed down
When front/parking brake lever or
- -
brake pedal is released

Horn Switch

- --
BKIY BKIW
When Horn Switch is pushed

When Horn Switch is released

 SUPPLEMENT - 1999 MODEL 18-1

Supplement - 1999 Model

Table of Contents
Foreword ................ ... ... ... .......................... ......... ... ...... ... .. .......... ............................................ 18-2
How to Use this Manual. ... .... ..... ...... .... .. .... ..... ... ......... .... ............ .. .. .. ........... .. ... .. . ...... ..... ..... 18-2
General Information .. ..... .... ... .. . ..... .. ..... .... ... .. ........ .... .... ... .... ........ ...... ... .. ...... .. ...... .... ..... ..... .... 18-3
General Specifications.. ... .... ......... ..... ... .... .... ... ... ........... .... ............................ ................ ..... . 18-3
Final Drive.............................. .... .. ............... ...... .............. ... .... .... ......... ........ .... ...... ......... ........ 18-6
Exploded View....................... ..... ...... .... ..... ... .......... ......... ..... ... .......... ...... .. ........... ...... ......... 18-6
Brakes. ....... ..... ...... .... ... ... ..... .. ... .... ... ....... .... ... ......... .... ....... .. ............... ... ..... ..... .... .... .. ... ... ...... 18-7
Exploded View (Canada Model) ............ ... ... ..... ... .... ..... .. ........ .... ..... ....... ...... .... ... ..... ...... ... .. 18-7
Electrical System. ... ..... ... .... .... ... ... ............. ....... ..... .. .... .. .......... ...... .. ... ... ................ ... ..... .. ..... .. 18-8
Exploded View.... ... ........ ............. .. ........ ..... .. ... ......... ... .... .. ... ...... ...... .... .. .. ...... ...... ......... ....... 18-8
Charging System .... ....... ...... .. ..... ... ........... .... ....................................................................... 18-9
Regulator/Rectifier Output Voltage Inspection ........... .......... ....... ... .. .. .... ...... ...... ....... .. ...... 18-9
Alternator Inspection....... .................... .. ...... .. .. ..... .. ............... .... .... .... .... .. .................... .... .. 18-10
Regulator/Rectifier Inspection............................ .. ................ ........ .... .... ............................. 18-11
Wiring Diagram (U. S.A and Canada Models) .......... .. .... .. ...... ...... .......... .. .. ........................ .. 18-14
Wiring Diagram (A ustralia Model)................ .... .. .... .. .. ... .................. .. .... ...... .. .... ........ .......... . 18-16
Wiring Diagram (Europe and U.K. Models) .. .. ........ .. .... .. .. .. ...... .... .. .. ................................... 18-18
18-2 SUPPLEMENT - 1999 MODEL
Foreword

How to Use th is Manual

This "Supplement 1999 Models" designed to be used in conjunction with the front part of this manual
(up to 17-16) and/or Base Manual KLF300 Service Manual - Part No. 99924-1057-01 .
The specifications and maintenance procedures described in this chapter are only those that are
unique to the KLF300-C11 model.
Complete and proper servicing of the KLF300-C11 model therefore requires mechanics to read both
this chapter and the front of this manual.
 SUPPLEMENT - 1999 MODEL 18-3
General Information

General Specifications
Item KLF300-C11
Dimensions
Overall Length 1 860 mm
Overall Width 1 120 mm , (A) (B) (E) 1 210 mm
Overall Height 1 105 mm
Wheelbase 1 200 mm
Ground Clearance 225 mm
Seat Height 805 mm
Dry Weight 260 kg, (A) (B) (E) 263 kg, (C) 261 kg
Curb Weight:
Front 138.5 kg, (A) (B) (E) 139 kg , (C) 138.5 kg
Rear 129.5 kg , (A) (B) (E) 132 kg , (C) 130.5 kg
Fuel Tank Capacity 11 L
Performance
Minimum Turning Radius 2.9 m
Engine
Type 4-stroke , SOHC , 1-cylinder
Cooling System Air-cooled
Bore and Stroke 76.0 x 64.0 mm
Displacement 290 mL
Compression Ratio 8.6
Maximum Horsepower 14.7 kW (20 PS) @ 6500 r/min (rpm) , (U)-
Maximum Torque 23.6 Nm (2.4 kgfm, 17.3 ftlb) @5 500 r/min (rpm), (U) -
Carburetion System Carburetor, Keihin CVK34
Starting System Electric starter & recoil starter
Ignition System Battery and coil (transistorized)
Timing Advance Electronically advanced
From 10 BTDC @1 300 r/min (rpm) to 30 BTDC @4 000 r/min
Ignition Timing
(rpm)
Spark Plug NGK D8EA, (A) (C) NGK DR8ES-L, (B) (E) DR7EA
Valve Timing:
Inlet:
Open 21 (BTDC)
Close 59 (ABDC)
Duration 260
Exhaust:
Open 56 (BBDC)
Close 24 (ATDC)
Duration 260
Lubrication System Forced lubrication (wet sump)
Engine Oil:
Grade SE, SF or SG class
Viscosity SAE 10W-30 10W-40, 1OW-50, 20W-40, or 20W-50
Capacity 2.4 L
18-4 SUPPLEMENT - 1999 MODEL
General Information

Item KLF300-C11
Drive Train
Primary Reduction System:
Type Gear
Reduction Ratio 2.888 (78/27)
Clutch Type:
Primary Auto centrifugal, wet
Secondary Auto multi disc, wet
Transmission:
Type 10-speed plus reverse, constant mesh, return shift
Gear Ratio:
1st 3.090 (34/11)
2nd 1.928 (27/14)
3rd 1.368 (26/19)
4th 1.000 (23/23)
5th 0.769 (20/26)
Reverse 3.072 (26/11 x 26/20)
Final Drive System:
Type Shaft
Reduction ratio
High 5.416 (33/33 x 20/16 x 39/9)
Low 6.910 (37/29 x 20/16 x 39/9)
Overall Drive Ratio: High : 12.037, Low: 15.357
Front Final Gear Case Oil:
Type API GL-5 Hypoid gear oil for LSD SAE140 or SAE90W-140
Capacity 0.40 L
Rear Final Gear Case Oil :
Type API GL-5 Hypoid gear oil SAE90 (above 5C, 41 F) or SAE80
(below 5C, 41 F)
Capacity 0.3 L
Frame
Type Double tubular
Caster (Rake Angle) 1.0
Chamber 0 @1 G
Trail 5 mm
Tread
Front 844 mm
Rear 860 mm
Front Tire:
Type Tubeless
Size AT 24 x 8-11
Rear Tire :
Type Tubeless
Size AT 24 x 10-11
 SUPPLEMENT - 1999 MODEL 18-5
General Information

Item KLF300-C11
Suspension :
Front
Type Double wishbone
Wh eel Trave l 11 0 mm
Rear
Type Torque tube
Wheel Travel 120 mm
Brake Type:
Front Disc (Hydraulic) x 2
Rear Drum (Mechanical, on Rightside)
Electrical Equipment
Battery 12 V 19 Ah, (U) 12 V 14 Ah
Headlight:
Type Semi-sealed beam
Bulb 12 V 25/25 W (RH/LH)
Taillights:
Bulb 12 V 8 W (RH/LH)
Tail/Brake Lights:
Bulb (C) 12 V 18/5 W (RH/LH)
Alternator:
Type Three-phased AC
Rated Output 23.5 A @9 000 r/min (rpm), 14 V

Specifications subject to change without notice, and may not apply to every country.
A: Australia Model
B: UK Model
C: Canada Model
E: Europe Model
U: US Model
18-6 SUPPLEMENT - 1999 MODEL
Final Drive
Exploded View

o
Front Prope I I er Shaft

Rear Prope I I er Shaft

HK02038BW4 C

1. Circlip
G: Apply grease.
R: Replacement Parts
T1: 34 Nm (3.5 kgfm, 25 ftlb)
A: KLF300-C11
 SUPPLEMENT - 1999 MODEL 18-7
Brakes

Exploded View (Canada Model)

HL02027BW4 C

1 . Brake Switch
R: Replacement Parts
Si: Apply silicone grease.
T1: 1.0 Nm (0 .10 kgfm, 9 in lb)
T2: 5.9 Nm (0.60 kgfm, 52 inlb)
T3: 1.2 Nm (0.12 kgfm, 10 inlb)
T4: 8.8 Nm (0.90 kgfm, 78 inlb)
T5: 25 Nm (2.5 kgfm, 18 ftlb)
T6: 20 Nm (2 .0 kgfm , 14.5 ftlb)
18-8 SUPPLEMENT - 1999 MODEL
Electrical System

Exploded View

HP02058BW4 C

1. Regulator/Rectifier
2. Tail/Brake Light (Canada Model)
3. Bulb (12 V 18/5 W)
 SUPPLEMENT - 1999 MODEL 18-9
Electrical System

Charging System
Regulator/Rectifier Output Voltage Inspection
Remove the seat (see Frame chapter).
Check the battery condition (see Battery section).
Warm up the engine to obtain actual alternator operating
conditions.
Check that the ignition switch is turned off, and connect
the hand tester to the battery terminal.
Special Tool - Hand Tester: 57001-1394
Start the engine, and note the voltage readings at vari-
ous engine speeds with the headlight turned on and then
turned off. The readings should show nearly battery volt-
age when the engine speed is low, and as the engine
speed rises, the readings should also rise. But they must
be kept under the specified voltage.
Regulator/Rectifier Output
Connections
Tester Range Reading
Tester (+) to Tester (-) to
25 V DC Battery (+) Battery (-) 14-15V
Turn off the ignition switch to stop the engine, and discon-
nect the hand tester.
* If the regulator/rectifier output voltage is kept between the
values given in the table, the charging system is consid-
ered to be working normally.
*If the output voltage is much higher than the values spec-
ified in the table, the regulator/rectifier is defective or the
regulator/rectifier leads are loose or open.
* If the battery voltage does not rise as the engine speed
increases, then the regulator/rectifier is defective or the
alternator output is insufficient for the loads. Check the
alternator and regulator/rectifier to determine which part
is defective.
18-10 SUPPLEMENT - 1999 MODEL
Electrical System

Alternator Inspection
There are three types of alternator failures: short, open
(wire burned out), or loss in rotor magnetism. A short or
open in one of the coil wires will result in either a low output,
or no output at all. A loss in rotor magnetism, which may be
caused by dropping or hitting the alternator, by leaving it
near an electromagnetic field, or just by aging, will result in
low output.
To check the alternator output voltage, do the following
procedures.
ODisconnect the alternator connector [A].
OConnect the hand tester as shown in the table.
OStart the engine.
ORun it at the rpm given in the table.
ONote the voltage readings (total 3 measurements).
Regulator/Rectifier Output Voltage
Connections
Tester Range Reading
Tester (+)to Tester (-) to
Another black
250 V AC One black lead 39 - 59 V
lead
* If the output voltage shows the value in the table, the alter-
nator operates properly and the regulator/rectifier is dam-
aged. A much lower reading than that given in the table
indicates that the alternator is defective.

Check the stator coil resistance as follows.

OStop the engine.
ODisconnect the alternator connector.
OConnect the hand tester as shown in the table.
ONote the readings {total 3 measurement}.
Stator Coil Resistance
Connections
Tester Range Reading
Tester (+) to Tester (-) to
Another black
x 1 0 One black lead 0.33 - 0.49 0
lead
*If there is more resistance than shown in the table, or no
hand tester reading (infinity) for any two leads, the stator
has an open lead and must be replaced. Much less than
this resistance means the stator is shorted, and must be
replaced.
Using the highest resistance range of the hand tester,
measure the resistance between each of the black leads
and chassis ground.
*Any hand tester reading less than infinity (oo) indicates a
short, necessitating stator replacement.
*If the stator coils have normal resistance, but the voltage
check showed the alternator to be defective; then the rotor
magnetism has probably weakened, and the rotor must
be replaced.
Special Tool - Hand Tester: 57001-1394
 SUPPLEMENT - 1999 MODEL 18-11
Electrical System

Regulator/Rectifier Inspection
Front Fender (see Frame chapter)
Connectors [A] (disconnect)
Bolts [B] and Regulator/Rectifier [C]

Rectifier Circuit Check

Check conductivity of the following pair of terminals.
Rectifier Circuit Inspection
W/R-Y1, W/R-Y2, W/R-Y3
Tester connection r - - - - - - - - - - - - - - - - - l
BK-Y1, BK-Y2 , BK-Y3
*The resistance should be low in one direction and more
than ten times as much in the other direction. If any two
leads are low or high in both directions, the rectifier is HP09006BS 1 C

defective and must be replaced.

NOTE
o The actual meter reading varies with the meter used
and the individual rectifier, but generally speaking the
lower reading should be from zero to one half the scale.

Regulator Circuit Check

To test the regulator out of circuit, use three 12 V batteries
and a test light (12 V 3 - 6 W bulb in a socket with leads).
CAUTION
The test light works as an indicator and also a cur-
rent limiter to protect the regulator/rectifier from ex-
cessive current. Do not use an ammeter instead of
a test light.

Check to be sure the rectifier circuit is normal before con-

tinuing.

Regulator Circuit Test-1st Step

Connect the test light and the 12 V battery to the regula-

:
tor/rectifier as shown.
Check Y1, Y2, and Y3 terminal respectively.
*If the test light turns on , the regulator/rectifier is defective.
I I I
Replace it.
*If the test light does not turn on , continue the test.

HP09018BSl C
18-12 SUPPLEMENT - 1999 MODEL
Electrical System

Regulator Circuit Test-2nd Step

Connect the test light and the 12 V battery in the same
manner as specified in the "Regulator Circuit Test-1 st
Step".
Apply 12 V to the BR terminal.
=>Ef----l@:
I I I
Check Y1 , Y2, and Y3 terminal respectively.
*If the test light turns on, the regulator/rectifier is defective.
Replace it.
* If the test light does not turn on, continue the test.
HP09019BSl C

Regulator Circuit Test-3rd Step

Connect the test light and the 12 V battery in the same
manner as specified in the "Regulator Circuit Test-1 st
Step".
Momentarily apply 24 V to the BR terminal by adding a 12
=>Ef----l@:
I I I
V battery.
Check Y1, Y2, and Y3 terminals respectively.
CAUTION
HP09020BS l C
Do not apply more than 24 V to the regulator/recti-
fier and do not leave the 24 V applied for more than
a few seconds, or the until will be damaged.

* If the test light did not light when the 24 V was applied
momentarily to the BR terminal, the regulator/rectifier is
defective. Replace it.
*If the regulator/rectifier passes all of the tests described ,
it may still be defective. If the charging system still dose
not work properly after checking all of the components
and the battery, test the regulator/rectifier by replacing it
with a known good unit.
 SUPPLEMENT - 1999 MODEL 18-13
Electrical System

Charging System Circu it

CD
R
@ = BW =iJJ== BW
R

w~
i i I I i
I
>-
r
>-
>-
"--
:.c::
co
== CD

9 ~
>- >- >- >->->-;;: ;;: ~~~

~ ><:: ><:: ><:: em ==

o o

CD

HP09024BW3 C

1. Ignition Switch
2 . Alternator
3. Regulator/Rectifier
4. Battery
5. Main Fuse 30 A
6. Load
18-14 SUPPLEMENT - 1999 MODEL
Electrical System
Wiring Diagram (U.S.A and Canada Models)

G)Reverse Indicator Lig ht 12V3.4W

N e u t r a I Indica tor Lig ht 12V3.4W

,--------,
I

I Wo r k L i g h t
12 V6 5I 60 W
(Ej----t-- R/ B K -{::~R
~- R I Y -{:::
I

/ BK
R I Y- - - + 4 -
1
( 0 P) __ 5- B K I Y -L B K I Y - - -+-+-+-1-+-+-+--+-------..- + - - - - -- - - - - + 4- - -

I
fleadl ight >- >- >-

R / BK~R / BK

~ ~
12V25/25W
R/ Y ~R / Y---+-+
(L fl)
B K I Y ---c::::J<:]- B K I Y - - - - - '

mm
~

:w::; ::.:::.::: ...,J::::':::

a::lICCo:li alCC

>- "" '"

~~
lJr~h'iJ
OFF ...
!\
I---~
HI
! 0
1' ,
Left
Alternator
fl and I ebar
G) Li g h t / Dimmer
Pickup
Coi I
Sw itch
Switch
Engine Stop Switch
CD 0 0) G)S tar t e r But ton

LEFT HANDLEBAR SWITCH CONNECTIONS

L i ght / D i mme r Sw it ch Engine Stop Switch Starter Button
Color R/ y R R/ BK BR Color BR Y / R Color Y/ R BK
OFF OFF Re I eased
LO Push S-~
HI RUN S--=?

W1L1762BW5 C
 SUPPLEMENT - 1999 MODEL 18-15
Electrical System

Canada Model ( OP ) Canada Model

I
I--~-I---~--I
Accessory
I I I
Te rm inal
I Fron t Parkin g
II

Re a r II
I ~~:~: ~~:~: B rake

~f1f--J S~h ~ehi

, - - - - BL ---CJ<J-BL~ T a i 1/ Bra k eLi g h t ( R H)
,BK / Y -{:>O-B K / Y 12 V 5 / 18 W
r-R --D<J----R (Ca nad a Mode I )

---c::J<:J-- B L~

~~-v~---~~
BL T a i I / Bra k eLi g h t (L H )
~ BK / Y-t>D-BK / Y 12 V 5 / 1 8 W
~R--D<J----R ( Canada Model )

I c ; :K/ Y -@l
1 i I<J- R I Tail L igh t ( LH )( R H )
....J c::: ..J ....J 0:::

m f m I D-B K I Y ~ I
~_R_ _ _ ~
-12 V 8 W
( U . S . A. Mod e I )

--------~~~------------------_r----+-r__r--~---------- w --------_.

Main Fu se
30A

n n, -
I
'"

c::: C!:J ~::.::: ::.::: ..........

co ....J co CD

Regulator /
I gnltlon
Coi I
1m
ll:: - - ::!J
Starter
Ci rc uit
R ect i f iter Relay
I gn iter
v Spa rk Plug

~~~
Starter
Mot 0 r

Color Code
BK Bla ck
BL Blue
BR Br own
G Green
GY Gray
LB l i ght Blue
LG l ight Gree n
I GN I TI ON SW I TCH CONNECT IONS NEUTR AL & REVER SE SW I TCH CONNE CT I ONS 0 Orange
Color BR W Gear Po sit i on L G Ground R! W P Pink
PU Purp l e
OFF 1st through 5th
R Red
ON Neutral W White
Reverse Y Ye I low
( 98051 - 17628,17638 )

W1R1762BW5 C
18-16 SUPPLEMENT - 1999 MODEL
Electrical System
Wiring Diagram (Australia Model)

1- - -- ~O~)~b~r~::- - - -- --I
I Heater Control Unit I
IC arb u ret 0 r * Ref e r tot h e i - -i
T her m >_~ e .':1 0 __ ~ 0-l UK. . T - - --T CDReverse Indicator Light 1 2 V 3. 4W
,--()------,
I
mode I W, r, ng
D
'-r- '-- '-I-,-'
N e u t r a I Indicator Light 1 2 V 3. 4W
I :.>
I
I
I
I la gram
I :t:: 3:: a::
c:::
~~~ "

I:I I i~i
'-V
L LB K / Rrn-BK / R----~ ! j'"'LI
~ ~
,A,

C ar~: -:=::(~:~-;BWK ~i : ;-"::BWK=--~

--BKiY,

I
, r-BK / Y - - - - - - - - ' - ,

__ ~
~_J I
" I
- I
1
\ '"
\
Ignition
Neutral /
Reverse Indicator
Switch Light
iTr--11
tr:I
Switch
I 1 Heater, i )J..,,!, 12V 3.4WX2

~~
1 12V23W' "'''''~''''
r-;:::r-- -- --~ Rei a y !:::;;;::: u 12V 3 . 4W
00
:~" i -->C--J- H eat e r ,-l- L ~ Speedometer
I ..1

1 ,:5: , ~}-G/W - - r ---, IT fill ~~

L i ght

[ttf
~
I L!J~}- YI R- ....:-: ---, I I' ! _ ' I r'lr'l
L t i l I , I '! 'I''''
~
L 111--C:1J ~~
~

1 1 '" ~ '"~ "-'" "- ",,,,

... ... '"

~~
- .... ......J "" ~m

~~ ~ ~~
"-"- 1 "-

L _--_-- -==---_- _---"....J

I ~'f 0>- I '" '"

~~
~~
L ____ __ uu _ _ _ _ _ _ _ _ .-J ~ ~
m
'" "- "- '" '"m

R / BK~R / BK

I
Headl ight '" '"
12V25 /2 5W RI Y---1>D- RI Y - - - - - - , "-
(R H ) B KI Y --CJ<J- B KI Y - - - - - - , '"m
1
,--------1
, ,
I W0 r kL i g ht
12V65 / 60W
(I2----t- R/ BK -{::~R / BK
f-R / Y --t:: R/ Y - - - + - 1
1
( 0 P) _.or BKI Y --C
B K I Y - - -+-l-++--H-+-..........- - - - - , - - - - t - - - - - - - - - t - i- - -

L ________ ........J -

Headl ight
ij
12V25/25W
( L H) (ID R/ BK-t>CJ-R / BK
RI Y
BK / Y
-t>D---
RI Y - - - - t - +
-D<J-
BK / Y - - - - - '
o
Left Handlebar Switch
(DLight / Dimmer Switch
Engine Stop Switch
@S tar t e r But ton
@Horn Button

o 0 CD 0

LEFT HANDLEBAR SWITCH CONNECTIONS

Light / Dimmer Switch Engine Stop Switch Starter Button
Color R/ Y R R/ BK BR Color BR Y/ R Color Y/ R BK
OFF OFF Released
LO Push <;:-~

HI RUN <;:--;> I

W1L1764BW5 C
 SUPPLEMENT - 1999 MODEL 18-17
Electrical System

Accessory
T ermina l

- B L --D
- BK / Y -t::>C]-BK / Y
- R-D<J-R
=- T a i I L ig h t (RH)
12V 8w

>-
"' --..
'"
'" -
BL-CJ
BK / Y-{:>C]- B K / Y
R -D<J-R
=- T a i I L ight (LH)
12V 8w

~ cp ~ ~Q
'"
1'"
~
~
~
'"
'" '"

1 I
w

~
Main Fuse
30A

n n , -.~
I
'"

1l
m~
0::: <.::I::":::::":::
al....Jenm

im
It )
Battery
1 2V19AH
>->->-::":::0::::0:::0::::::':::
coco .................. a::a

'" '" ~ __ ::!J

I gnltlon
Co il Starter
Reg ul ator/ C ir cu i t
Rect i f i ter Ig ni ter Relay
Spark P lug

~%~"'~
Starter
Mot 0 r

Color Code
BK Black
BL Blue
BR Brown
G Green
GY Gray
LB Light Blue
LG Light Green
a Orange
I GN I TI ON SW I TCH CONNECT IONS NEU TRAL & REVERSE SWITCH CONNECT I ONS P Pink
Co l or I BR I W Gear Position LG Ground R/ W PU Purple
OFF I I 1st through 5th R Red
ON I Neutra l c- ..:J W White
Reverse c- ~ Y Ye I low
( 98051-17648 )

W1R1764BW5 C
18-18 SUPPLEMENT - 1999 MODEL
Electrical System
Wiring Diagram (Europe and U.K. Models)

1. Reverse Indicator Light 12V3.4W

2. Neutral Indicator Light 12V3.4W
Neutral
and
Reverse
Ignition
Switch

SfRo M
Head light
12V25 / 25W
( RH)
@ R/ BK----t>D-R / BK-
R/ Y ----t>D- R/ Y -
BK / Y----CJ<:]-BK / Y - 1 - -

Working
Light
12V60 / 55W
/;~""1-R/BK
(C\y
<:::S
g:
_
7 -
--i
-{>O-R / BK-+-+-+-----,
~ RI Y - { > O - RI Y
f..J-BK / Y -LJ<J-BK / Y
-+-+-+---,
_+_+-<~-+-+-I-+_+_-----__t------_+_+_--
"----~
( Opt ion)

Speedmeter
Light I ~
...J ......
12V3.4W >- >- >-
Ol ""
Ol

Head light
~ $$
12V25 / 25W @ R/ BK----t>D-R / BK-f-
R/ Y ----t>D- R/ Y - "" "" ""
Ol Ol Ol
...J
Ol Ol
""

~~"P
BK / Y----CJ<:]-BK / Y-----
(L H)

Left Handlebar Switch

1. Light / Dimmer Switch
2. Engine Stop Switch
3. Starter Button Alternator Coi I

(0 0)
Left Handlebar Switch

LEFT HANDLEBAR SWITCH CONNECTIONS

L i ght / D i mmer Sw itch Engine Stop Swi t ch Starter Button
Color R/ Y R R/ BK BR Color BR Y/ R Color Y/ R BK
OFF OFF Re l eased <;-~
LO Push I
HI RUN <;-~ I

W1L1765BW5 C
 SUPPLEMENT - 1999 MODEL 18-19
Electrical System

UK Mode I (European Mode I for Opt ion)

r-------
_________ l ___ . ,
Control Unitl

8: c:
~ 3:
~~~
.......
Accessory
Terminal

co ~G>-

BK / RurK / R~
BK / Y BK / Y------+_+-~-------+~----_,
L _
----,

VI ---[::>CJ--- VI VI r Tail Light

Carburetor BK BK l rl--.--_+-+
(R / H)
1 2 V8W
Thermo Sensor c:::;::c:::: 3:et::

He't)~~!1 QQ~&i
Re I ay 1
II II
1 I
.,,,,, I
L

L _ _ _ ...,
..,

BK / Y@
L::::: __ ~ ci::::
----------.., I Tail Light
(LlH) 12V8W
______________~~--------------------~_+~L-~~~----+_~---------- VI

F use

>- >- >-

n
Starter
Ci rcuit
Rei a y

Ignition
Co i I

~Jr--"____ _ Starter
Mot 0 r
fi, Plug
Color Code
~~ BK Black
BL Blue
BR Brown
G Green
1GN 1T1ON SW 1TCH CON NECTIONS NEUTRAL & REVERSE SlIl TCH CONNECT IO NS
GY Gray
Co 1or I BR I W Gear Position LG Ground R/W LB Light Blu e
OFF I I 1 st t hrou g h 5th LG Light Green
ON I Neutral C. ..:J 0 Orange
Reverse C- ..:J P Pin k
(9B051- 1765B.1766B ) PU Purple
R Red
W White
Y Ye I low
'If 1 R1765BW5 C
 SUPPLEMENT - 2000 - 2002 MODELS 19-1

Supplement - 2000 - 2002 Models

Table of Contents

Foreword .......................... .. ............ .... .. ............. ............. ..... ... ..... ... .. .... ...... ..... . 19-2
General Information ..... .. ... .. .. .... ...... ... ... ...... ....... ................. ...... ... .. .. ..... ... ... ..... . 19-3
Model Identification .... ............ ......... ... .... ... ..... ... .... ... ................ ... .. .. .... ... 19-3
General Specifications ... .................. .. .... ... .. .. .... ..... ... ...... .... .... .... ........... 19-4
Torque and Locking Agent.. ... ........... ..... .. .......... ...... .. ...... .. ..... ..... ......... . 19-6
Periodic Maintenance Chart ....... .... ... .... .. .... .. ... ....... .. ... .... .. .. .. ..... .. .. ...... . 19-7
Engine Left Side .. .... .. .. .... .. ..... .......... ...... ... ....... .......... .... ..... ...... .... .. .. ... ... ... ... ... 19-8
Exploded View ....... .. ....... ........ ....... .. ...... .. ......... .. ... .... ... ....... ... .. .. ... ...... ... 19-8
Brakes .. ... .. ...... ...... .......... .. .... .. ... ... ... ...... ... ... ... .. .... ...... ............ ...... .... ... ......... ... 19-9
Exploded View ... .............................. ... ..... .... ... ............... ...... .... ...... .. .... ... 19-9
Steering ... .... ...... .... .. ... ..... .. ..... ...... .. ...... ..... ........ ..... ... ...... .......... ...... ..... .... .... .. 19-10
Exploded View .. ........... ...... ......... ........ ......... .... .... ... ...... .. ......... ... .... ..... . 19-10
Frame .... .... .......... .......... .... ...... ..... .......... .. .... .. ... .. .. ...... .. .......... ...... ....... .... ..... . 19-11
Exploded View .. ........... ....... ........ ... ........... .. ... ....... ......... ...... .. .. ... ......... . 19-11
Electrical System .. .. ... .. .... ...... .... ... ........ ... ........ ... .. ...... .. ... .. .. ... .. ..... ... .... .... ..... . 19-12
Exploded View .. ... ... ..... ....... .. ...... .... .... ... ... .. ... ....... ... .. ...... .... ........ .. ... ... . 19-12
Wiring Diag ram ........... .... .. ... .. .... ... ..... ... ..... ..... .. ........... .. ..... .. .. ... .... ..... . 19-14
19-2 SUPPLEMENT - 2000 - 2002 MODELS
Foreword

How to Use this Manual

This "SUPPLEMENT 2000 - 2002 Models" designed to be used in conjunction with the front part
of this manual (up to 18-19) and/or Base Manual KLF300Service Manual - Part No. 99924-1057-01 .
The specifications and maintenance procedures described in this chapter are only those that are
unique to the KLF300-C12 - C14models.

Complete and proper servicing of the KLF300-C12~C14 models therefore requires mechanics to read both
this chapter and the front of this manual.
 SUPPLEMENT - 2000 - 2002 MODELS 19-3
General Information
Model Identification

KLF300-C12 Left Side View

KLF300-C12 Right Side View

19-4 SUPPLEMENT - 2000 - 2002 MODELS

General Specifications

Item KLF300-C12'"'-'C14
Dimensions:
Overall length 1860 mm
Overall width 1120 mm, (EU, UK) 1210 mm
Overall height 1105 mm
Wheelbase 1200 mm
Ground clearance 225mm
Seat height 805mm
Dry weight 260 kg, (EU, UK) 263 kg
Curb weight: Front 138.5 kg, (EU, UK) 139 kg
Rear 129.5 kg, (EU, UK) 132 kg
Fuel tank capacity 11 L
Performance:
Minimum turning radius 2.9m
Engine:
Type 4-stroke, SOHC, 1-cylinder
Cooling system Air cooled
Bore and stroke 76.0 x 64.0 mm
Displacement 290 mL
Compression ratio 8.6
Maximum horsepower 14.7 kW (20 PS) @6500 r/min (rpm), (US) -
Maximum torque 23 .6 Nm (2.4 kgfm, 17.3 ftlb) @5500 r/min(rpm), (US) -
Carburetion system Carburetor, Keihin CVK32
Starting system Electric starter & recoil starter
Ignition system Battery and coil (transistorized)
Timing advance Electronically advanced
Ignition timing From 10 BTDC @1300 r/min (rpm) to
30 BTDC @4000 r/min (rpm)
Spark plug NGK DR8EA, (EU, UK) DR7EA
Valve timing: Inlet Open 21 BTDC
Close 59 ABDC
Duration 260
Exhaust Open 56 BBDC
Close 24 ATDC
Duration 260
Lubrication system Forced lubrication (wet sump)
Engine Oil: Grade SE, SF or SG class
(C14~) API SF or SG
API SH or SJ with JASO MA
Viscosity SAE10W-30, 10W-40, 1OW-50, 20W-40, or 20W-50
(C14~) SAE5W-30, 10W-40, 1OW-50, 20W-40, or 20W-50
Capacity 2.2 L (EU, UK) 2.4 L
Drive Train:
Primary reduction
system: Type Gear
Reduction ratio 2.888 (78/27)
Clutch type: Primary Auto centrifugal, wet
Secondary Auto multi disc, wet
 SUPPLEMENT - 2000 - 2002 MODELS 19-5

Item KLF300-C12 - C14

Transmission: Type 10-speed plus reverse, constant mesh, return shift
Gear ratio: 1st 3.090 (34/11 )
2nd 1.928 (27/14)
3rd 1.368 (26/19)
4th 1.000 (23/23)
5th 0.769 (20/26)
Reverse 3.072 (26/11 x 26/20)
Final drive system:
Type Shaft
Reduction ratio High 5.416 (33/33 x 20/16 x 39/9)
Low 6.910 (37/29 x 20/16 x 39/9)
Overall drive ratio: High: 12.037 Low: 15.357
Front final gear case oil: Type API GL-5 Hypoid gear oil for LSD SAE140 or
SAE85W-140
Capacity 0.4 L
0
Rear final gear case oil : Type API GL-5 Hypoid gear oil SAE90 (above 50 C, 41 F) or
0
SAE80 (below 50 C, 41 F)
Capacity 0.3 L
Frame:
Type Double tubular
0
Caster (rake angle) 1.0
0
Chamber 0 @1G
Trail 5mm
Tread Front 844mm
Rear 860 mm
Front tire: Type Tubeless
Size AT24x8-11
Rear tire: Type Tubeless
Size AT 24 x 10-11
Rim size: Front 11 x 6.5
Rear 11 x 8.0
Suspension: Front Type Double wishbone
Wheel travel 110 mm
Rear Type Torque tube
Wheel travel 120 mm
Brake type: Front Disc (Hydraulic) x 2
Rear Drum (Mechanical, on Rightside)
Electrical Equipment:
Battery 12 V 14 Ah (EU, UK) 12 V 19 Ah
Headlight: Type Semi-sealed beam
Bulb 12V25/25Wx2
Tail/Brake lights: Bulb 12 V 18/5 W x 2
Alternator: Type Three-phase AC
Rated output 23.5 A/14 V @9000 r/min (rpm)

Specifications are subject to change without notice, and may not apply to every country.
EU: Europe Model, UK: U.K. Model, US: U.S.A. Model
19-6 SUPPLEMENT - 2000 - 2002 MODELS

Torque and Locking Agent

Torque
Parts Remarks
Nm kgfm ftlb
Engine Left Side:
Alternator rotor bolt 59 6.0 43
Starter clutch Allen bolt 34 3.5 25 L
Recoil starter flange nut 8.3 0.85 74 inlb

L: Apply a non-permanent locking agent to the threads.

 SUPPLEMENT - 2000 - 2002 MODELS 19-7

Periodic Maintenance Chart

The scheduled maintenance must be done in accordance with this chart to keep the vehicle in good
running condition . The first service is vitally important and must not be neglected.

First Service Regular Service

. =Clean , adjust, lubricate, tighten, or

replace parts as necessary. After10h~%~%~
of use
<;}
o
~
~0
o'b-
;y.;:y
<;}
0
~

o'b-
~0
;y.;:y
<;}.g
~
0
o'b-
;y.;:y ~
0
<;} vI:?
;y
0
See
Page
Engine:
*
Air cleaner--service
Clutch adjustment *
Valve clearance--check


I 2-7
5-3
3-6
Fuel system cleanliness--check
Throttle lever play --check
*
(2-10)
(2-4)

Engine oil--change * 5-3
*
Oil filter--replace
Spark plug--clean and gap
I
(5-11 )
14-5
Spark arrester--clean I 3-11
Chassis: I
I

Joint boots--check
I 9-7 ,20
12-4
Rear brake adjustment--check *
Rear brake lining wear--check *
II
10-5
(10-6)
Front brake pad wear--check *
Brake fluid level--check
10-8
(10-8)
Brake fluid--change

(10-8)
Cable adjustment
Battery--check
* I **
14-6
I
Steering--check
General lubrication * (12-6)
15-7
Bolts and nuts--tighten
Front and rear final gear case oil--change * I

15-8
9-10,23
Master cylinder piston assembly and I 2 years (10-11 )
dust seal--replace
Caliper piston seal and dust seal--replace
I 2 years 10-7
I
Brake hose--replace I 2 years 10-10

* :Service more frequently when operated in mud, dust, or other harsh ridin conditions.
* * : Refer to 2, 7, and 10 chapters.
(xx-xx): Reference Page in the Base Manual
19-8 SUPPLEMENT - 2000 - 2002 MODELS
Engine Left Side
Exploded View

T2

Kl3Bll C

1. Torque Limiter
G : Apply high temperature grease. T1: 59 Nm (6.0 kgfm, 43 ftlb)
L : Apply non~permanent locking agent. T2: 34 Nm (3.5 kgfm, 25 ftlb)
o : Apply engine oil. T3: 8.3 Nm (0 .85 kgfm, 74 inlb)
Lh: Left-Hand Threads T4: 7.8 Nm (0.8 kgfm, 69 ftlb)
R : Replacement Parts
Rh: Right-Hand Threads
 SUPPLEMENT - 2000 - 2002 MODELS 19-9

Brakes
Exploded View

KUI04 II C

Si: Apply silicone grease.

1. Brake Switch
T1: 8.8 Nm (0.90 kgfm, 78 inlb)
T2: 5.9 Nm (0.60 kgfm, 52 inlb)
T3: 1.0 Nm (0 .10 kgfm , 9 inlb)
T 4: 1.2 Nm (0.12 kgfm, 10 inlb)
19-10 SUPPLEMENT - 2000 - 2002 MODELS
Steering

Exploded View

1 . KLF300-C14 Model
A: Apply adhesive
T1: 20 Nm (2.0 kgf-m, 14.5 ftlb)
 SUPPLEMENT - 2000 - 2002 MODELS 19-11
Frame

Exploded View

r---------- ---i

'--d;--- ./

H0020008"2 C

1. Rear Carrier
2. Canada Model
3. Other than U.S.A. , Canada and Europe Models
19-12 SUPPLEMENT - 2000 - 2002 MODELS
Electrical System
Exploded View (KLF300-C12 -)

HP02059BW3 C

1. Parking Switch
2. Front Brake Light Switch
3. Rear Brake Light Switch
4. Tail/Brake Light
5. Bulb (12 V 18/5 W)
 SUPPLEMENT - 2000 - 2002 MODELS 19-13

Dummy page
 19-14 SUPPLEMENT - 2000 - 2002 MODELS

KLF300-C12~C14 Wiring Diagram (U.S.A. and Canada Model)

r-- - - - - - - - - - - - - - - - - - - ~

I Carburelor (OPl(Canada Modelll

I Carburelor Healer ,--- - -,
Thermo. Sensor :Contro l Unit:
I ~ - - L,-----,J
l--~-~ - -II l,-,-, -, --,-J (DReverse Indicator Light
I (]~-1 , : 5,;. ~~ ~ Neulral Indicator Light
I l:~i: j , LB K / R-fYl- B K/ R- - - ~ ! i <!>LT L~j
I I -+-- ~- r __ ~---BK/Y -1 , rBK/Y - - - ---L-,,_ .--, :>-
I
LW---,-_:~~ __ r --- W -~ , ~--- W - - - ~ I I \ , N e u I r a I /R eve r s e
,BK -I LJ ---- BK - - - , , __ J "" S wit c h
C b I I L__ -, " I I \~
I ar ure o r ,
Healer 12V23W, ~
J,o::r-Io::T-~11
,..
\:r'-l I g nit ion
Indicator Light
I m ,', S wit c h 12V 3.4WX2
r r:J- : :~ ~ __ - l
1
! :>-;;;:>- ~
: ;
0::
L_J
i --(6P)--l
II I jl-
I:~::- I
~ __J Rei a y ,L
He a I e r ~
L -" -'-,
r -,- -rl " 12V 3,4W
c ,""
~,,~G/W- - r ~ II : : II ,,-? ,,-? iS pee d 0 met e rl
I LIJ k~}--Y/R--r- ' I I I' ' _'I :',;::''': I L i ght I
L--~
it
I' I
'I

~~ I I
I
L? J
I' :'

" __j UI ~o::

1 1 ' ..
LTJL,'
'
l
"" I
L L:: _ _ :::'J " I I I
L _-_- -==-__-_--1~
:>-<!> <!>:>- :>- ,
~?~~
L i.J i..j

-' - ' <D

..,
,
oo=E
R/BK~R/BK >-
a:: a::

R/ Y --t:>CJ-- R/ Y ~
BK/Y -CJ<J--BK/Y ""<0
a::

I 1
I
Headlighl I
12V25/25W
(R H)
I

! E --i- -R/BK--{> O - R/BK

~--- R/ Y ---{ > CJ- R/ Y
\ __ J-B K/y---{ ::J<}- BK/Y -
Work Light
12V65/60W
(0 P)

>- >- >- -',~

..,""
>-

OOJ, ~ ~ m~
R/B K--f>CJ-R / BK
R/ Y --[:::>CJ-- R/ Y
BK/Y--c:::J<]--BK/Y
Headl ight >- "" 0::
,0::<00::,"" :>- >- :>-
-,,,,,
12V25/25W 0:: ~[Q>-m a:: ..,<0 >>->-::'::0::::
UI<o
<D

~~ ~
(L H)

:::::n
Pickup Coi I
Alter Nator

LEFT HANDLEBAR
Lell Handlebar Switch Light/Dimmer S w I I c h E
Color R/Y R R/BK BR (
(DLight/Dimmer Switch OFF
Engine Stop Sw itch LO
HI
0Starler But l on L--
 SUPPLEMENT - 2000 - 2002 MODELS 19-15

ht 12V3.4W
ht 12V3 .4 W

I~
U;
rake Acce s sory
vitch Parki n g Brake Rear Brake Terminal
Light Swilch Lighl Switch
~

~
' BKI Y-[:::::::>C]- BKI Y

>::

'"
cO 0::
a:l
-'
a:l
cO
-' 0:: >-
r- R---CJ<l-R

'Tai I/Brake Lights

~~
0::"

-~
"'m" 12 V 5/18 WX 2
BL---cJ<:J- B L

0::
m
-'
m
-'
m
0::
m
t- BK/y{>D- BK/Y
t-R---CJ<l-R F
I I
W-
..
.,
'"

~
LL.

co
-<
... C)

:::E""

n n.
:;.:

>- >- ~-' >- :;':0:: O::::c:J~!M:::

"""
~
:;.:

(+) (- )
Bat t e r y
12V19AH
y.
I g nit ion (U. S. A Mode I 12V 14AH)
Co i I S I art e r Slarter Relay
C i r cui I
Jlatorl Rei a y
I i fit e r Color Cod e
I g nit e r BK Black
Spark Plug BL Blue
6 BR Brown
Slarier Molor
~~~~~
CH Chocolate
DG Oark Oreln
G Green
GY Gray
LB LI,hl Blu.
LG Lill'lt ar.ln
:A R SWITCH CONNECTIONS 19NITJO Jl SW ITCH CQHJlECl10U NEUTRAL & REVERSE SWITCH CONNECTIONS 0 Orange
En,in . SIDP Swilch S I a r I e r B u I Ion Color 8tar Position LG Ground R/W P Pink

-
I Color BR
- ,
Y/R Color Y/R BK OFF lit t h r 0 UI h 51 h PU Pur pie
OFF Releas ', ON Ne u t r a I R Red
Pus h ~~ Reverse W Wh i Ie
RUN <;JIll I Y Yellow
(98051-1856A)
LF300C01A3 C
 19-16 SUPPLEMENT - 2000 - 2002 MODELS

KLF300-C12 Wiring Diagram (Australia Model)

- - - - -Carburetor
r---;Carburetor - - - -----------,
(OP) I
Heater _ _ "
I Thermo. Sensor " : -
,C tro'
---:
Ullt,
I
I ____ ~ - -I T-- - - -f I

r -- "'")
-;1- - - ---,
(<,. , I
_ L;;;-T,.,-;--,--'
",,,~a:
""~,,,,""
I , -:,. ,
l:~Fj
I
I L
I
r--:J
BK/R, fl-BK/R- - - ~ , I
.., I .., '" >-
I I
G)Rlvlrae Indicator LI ,h t
I I ""+-- L___ B KI Y-t I r-B KI V- - - ----'-- r
LW-.:--;--"1----W--~ I L..---W - - - ~ I
I- +---.,
f,
L;.
~
N.utral

~:- ~
', H.ater12V23W
Car bur e t lor
L __ rBK-t LJ---BK----,
, __ ::I ,
r--J
~ ~ -
U \
I I \

\
~
'll N I U t r a I I R v e r I I
I i i ,j.i II ;;" I,nltlon Switch
I ""a:" IE: I I " Front

I r.,il>L}- . ~ -r ~~ ~ ~
,1'ITII yf1 --dII IC! IT~,;.: 1 ~rmCD ~. :~.J:o~~:
I
I ::~: I
I.~:I
c-'"
;,;,,,---G/W-
L__ ~[J ~~~"-- IR-Il-: :
I

" "
H at. r
IR. I ..
:IL: /:
J
-J:: GQ
L::: _ _L::J
I
'!' >:-
r!7r!7

" "
LJ
-:1 s, I I d I "
ILlI~1

I
12~. 4.
J1.
Sw (:A;.:J
g <!J: h L I 'h t

I
L ~~ ________
_____ ~ LL_-_--==--_-_J" ~I ~~ 8 ~~9~ y~
~ ~ ~~
t 62~y ~~
~cp
" :;.: ~"
a::
,,~:
IE:

I
~ :
C!ll.
RIB K--c>e::r-RI BK
R/Y---E>C::]--R/Y >-

"..,""I
I
a: I I I
Headli,ht
BK/V--D<J-BK/V
, I
12V25/25W
(R H)
II

( ~-- t--R/BK-{>D-R/B K
}----R I Y---{:::>CJ--R I V
\ __ J---BK/Y-{::]<::J---BKI Y

Work Li,ht
12V65/60W
(0 P)
I
~ I >-

11
>-
-'"
..,"'"
>~..,
>- >- >-
..,
CEE ~
I B K--c>e::r-RI B K

#
a:
R/V---t>CJ--R/Y

~D~
BK/Y--D<J-BKI Y >-

H.-adll,ht >- "" a: "m""

~ 0' ;:=
@J
12V25/25W
T
~
(L H)

>-,.
""
Horn
12V R.,ulator
::; ::; 1. 5 A

it~lJrj-h Altlrnator
Pic k u p Col I

Horn Switch

Left Handllbar Switch LEFT HANDLEBAR SWITCH

L1,ht/Dlmmer Switch Eo.l . . SI
G)Lilht/Dimmlr Switch Color R/V R R/BK BR Co lor
Enlinl Stop Switch OFF OFF
LO
0starttr Button HI RUN
 SUPPLEMENT - 2000 - 2002 MODELS 19-17

r Licht 12V3.4W
r Licht 12V3.4W

Pukine Rear Acc.llory T.rminal.

L I (h t Brate Liehl Brake LiChl
Switch Switch
BL----LkJ--B L

6 6
,BK/Y--t>CJ- BK/Y
r- R -Q:::::J-- R

co:: --' --' co:: >-

co:: , Tai I/Brake Lights
ID ID ID ID
"'ID" 12 V 5/18 WX 2

r~ ~.~ BL-D<J--BL
~ BK/Y~BK/Y
r-R-c:J<:r--R

1
:0:: --' co::

i
:II

ID

WI
...-.
~l$ .....
c:
-<
_0
::IE <'>

>- ,., n
>- a:: ,., ,., co:: n~ 9
(+)
i

(-)
Battery
I,. III a. 12V19AH
Co i I

Stater Stller R,I.y

Circuit
RI lay
Color Cod.
BK Black

~
sperk Plue
Starter Molor BL Blul
~~~~'%. BR Brown
eH Choco lita
DG Dllk art ..
G Grlln
GY Gray
LB LiCht Blu
SWITCH CONNECTIONS , ,TIOI 'W'TCI CO.IECTlal. IEUTRAL , REYERIE ITCH eOIIEeTIOI. LG Llchl a ....
S.il.~ Stul.r Button 8, ... _ 0 Orln'l
e"I SI., Color 8.ar P i I I LG R/W p
Color BR - Y/R Color Y/R Pink
BK OFF III t'r ' St.
OFF Neutral PU Purp I.
ON
.,
Reill"
Pu.h R R.d
Re'lr.e
W Whit.
RUN <:- I (98051-1857A) Y VI Ilow
LnOOCOlA3 C
 19-18 SUPPLEMENT - 2000 2002 MODELS

KLF300-C12'"'-'C14 WlYIng
. Diagram (Europe Model)
(DReverss Indicator light 12V3. 4W
N.utral Indicator Light 12V3.4W

Ignition

Carbur.tor
H. at. r
12V23W

Headllcht
12V25/25W It: >-
II> C:I
(RH)

~R/BK-t>D--R/BK
~ R/Y -c>D-R/Y-
B K/ Y --c:J<J-- B K/ Y --i---l-

1j?--1-
1~fl----~---r~t-tl------r----t------~==========f=F=========~~~~~=
R/Y ___ ~~--_~
~__R/BK----<- - '--...JR /BK ---r--r-t----~
-..r--L

_-----++-L-~
\ I

__ ..1---- K/ Y___{~:]<:J-BR:)y---1-++---
12' 65/".
Work
. ~"/YCJ<i-BK/Y'
Licht
~I ------H---=l -

R--C>CJ-R II I
-i-t-t--+-r-+-UJ.J

~ ~m;:Om 0~ aFrl
'E~~E~ ~
S PI I d 0 mit I r L I h I a::
12V3.4W c t . >- II> I I

R/B K-t>D--R/BK--I--'
>- >- >-

~~ '1T-'
>-~
R/ Y -[:::::C}--R / Y
BK/Y~BK/Y~ ";;;:;12V
Htadlicht
12V25/25W
(LH) >- it-h
It: ;;;

~ ,1D'oa
a:: It:
Reculator/
Reetlfier

OF~
rl.l ~ ~.~, ~."" ' '" . . "
HI' :V;
Pickup Coi I

lenition
,- __ ~ol~ f;, Spark PluC
CD 0
L.ft Handl.bar Switch ~
~~z
CD l i c h t /D i mm If S wit c h f-L";'FT HANDLEBAR
Licht/Dimmer S .S WITCH CONNECT
Enll s
EnCin. Stop Switch Color RI wItch
OFF Y R R/BK BR Color
0Sterter Button OFF -
LO
l HI = L
RUN;
 SUPPLEMENT - 2000 - 2002 MODELS 19-19

(0 P) Europe Model
arburetor :-=--=---=----~
I
Accessory Terminals
(Treiler LiChl)

Tai I/ Brake Lights

12 V 5/18 WX 2

I Reverse Li I hi
12Vl0W

~ >-

~V_
' ~~~
(tl (-)
BattelY
12V19AH
/

Sierter Relay

---~ I Slarter Moter

Color Code
BK Black
~a/W - II BL Blu.
~Y/R----------~~-_-~ BR Bro.n
Co i I CH Cho.ollto
DG Dork 8rltn
G Breen
GY Bray
LB Lllhl BIUt
LG LlIH 8111.
NECTIONS 18NITION SWITCH CONNECTIONS IEUTRAL , REVERSE SWITCH COINECTIO 0 Orlnl'
lint 51o, S.II.h S I a r I e r Bulton Color I BR I W L BY S r POlltlo. LG Ground R/W P Pin k
o lor BR VIR Co lor YIR BK OFF I I I lot Ur.,.11 Sill PU Purpl.
)FF R,I"'I ON I Neutral R Red

tUN ~
., Push c;-. ~
I
R.verl.
(98051-1858B)
W
Y
Wh it.
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 SUPPLEMENT - 2003 - 2006 MODELS 20-1

Supplement - 2003 -., 2006 Models

Table of Contents
Foreword................................................................................................................................ 20-2
How to Use this Manual........... .... .......... .. ........ .. ..................... .... .............. ... ................. ....... 20-2
General Information .. ......... .. ...... ............. .............................. ................... ... ...................... .. .... 20-3
General Specifications ........ ........................... ........ .. ... .. .......... ............ ......... ........................ 20-3
Fuel System............... ..................... .......... .......... .. .... ..... .... ........ .. ........ ......... ........ ........ .......... 20-6
Specifications.......... ... ... ... .. ........... .. ................. .. ..... ... ..... ... ... ... ................... ...... ........ ... ... ..... 20-6
Carburetor................ ............................. .......................... .... ..... ......... .................. ................. 20-7
Carburetor Pilot Screw Adjustment...................... ........ ............................. ............ ............ 20-7
Fuel Level Inspection ... .... ..... .... .............. ............................. .... ............ ..... .. ........ .............. 20-7
Engine Right Side................ ...... ......................................................................................... .... 20-8
Specifications............................................................................................. ................ ... ..... .. 20-8
Engine Oil and Oil Filter................................................. ................... .. .... ............................. 20-8
Engine Oil Change............... ... ...... .. .... .. .... ............. .. ................................... ...... ............ .. .. 20-8
WheellTires ............ ..... .... .... .. ....... .. .............. .... .... .. ...... ..... ............... .... .......... .... ..... ... ........ .. .. 20-9
Front Hub.... .. .. .. .... .. .. .... .... .. ............................................................................... .................. 20-9
Front Hub Installation .. .. .... ... . .. ..... ...... .. ............. ............ ..... ..... ....... .. ... ................. .. ... ........ 20-9
Rear Hub.. ................ .... ............... ... ....... ...... .... .. .... ......... ........ .......... ...... ......... .. ..... .. ..... ...... 20-9
Rear Hub Installation .. ... ........ ..... .............. ...... ................... .. ........................ .. ..... .. .... ..... ... 20-9
Brakes.... .... ....... .. ....... ....... .......................................... ...... ...... .... .. .... .. .... ............... ...... ......... . 20-10
Exploded View ........... .. ............ ................. .. ......................................................................... 20-10
Frame..... ..... .............. ...... .......... ....... .... .... .. ................. ..... ..... ...... ............ ......... ........ .. .. .. ....... . 20-11
Exploded View...................................................................... .. .... .... ............. .. ...... .... .. .... ..... . 20-11
Electrical System ... ....... ............. ................... ...... ...................... .. ... ... ........ ....... .... ..... ..... ........ . 20-12
Exploded View........................................... .... ............................. ..... .............. ...... ................ 20-12
Wiring Diagram (U.S .A. and Canada Models) ..................................................................... 20-14
Wiring Diagram (Europe and U.K. Models) ........ .. ................. .. ......... .. .... .. .... .. ..... .. .. ...... ...... 20-16
20-2 SUPPLEMENT - 2003 - 2006 MODELS
Foreword

How to Use th is Manual

This "Supplement 2003 - 2006 Models" designed to be used in conjunction with the front part of this
manual (up to 19-19) and/or Base Manual KLF300 Service Manual - Part No. 99924-1057-02.
The specifications and maintenance procedures described in this chapter are only those that are
unique to the KLF300-C15 - C6F models.
Complete and proper servicing of the KLF300-C15 - C6F models therefore requires mechanics to
read both th is chapter and the front of this manual.
 SUPPLEMENT - 2003 - 2006 MODELS 20-3
General Information

General Specifications
Item KLF300-C1S - C6F
Dimensions:
Overall Length 1 860 mm
Ove rall Width 1 120 mm (EU, UK) 1 210 mm
Overall Height 1 105 mm
Wh eelbase 1 200 mm
Ground Clearance 225 mm
Seat Height 805 mm
Dry Weight 260 kg, (CN) 261 kg, (EU, UK) 263 kg
Curb Weight: Front 138.5 kg, (EU, UK) 139 kg
Rear 129.5 kg, (CN) 130.5 kg, (EU, UK) 132 kg
Fuel Tank Capacity 11 L
Performance
Minimum Turning Radius 2.9 m
Engine
Type 4-stroke, SOHC, 1-cyli nder
Cooling System Air cooled
Bore and Stroke 76.0 x 64.0 mm
Displacement 290 cm 3
Compression Ratio 8.6
Maximum Horsepower 14.7 kW (20 PS) @ 6 500 r/min (rpm), (US) -
23.5 Nm (2.4 kgfm, 17.3 ftlb) @5 500 r/min (rpm),
Maximum Torque
(US) -
Carburetion System Carburetor, Keihin CVK32
Starting System Electric starter & recoil starter
Ignition System Battery and coil (transistorized)
Timing Advance Electronically advanced
Ignition Timing From 10 BTDC @1 300 r/min (rpm) to
30 BTDC @4 000 r/min (rpm)
Spark Plug NGK DR8EA, (EU, UK) DR7EA
Valve Timing: Inlet Open 21 BTDC
Close 59 ABDC
Duration 260
Exhaust Open 56 BBDC
Close 24 ATDC
Duration 260
Lubrication System Forced lubrication (wet sump)
Engine Oil: Type API SF or SG
API SH or SJ with JASO MA
Viscosity SAE 10W-40
Capacity 2.2 L (CN, EU, UK) 2.4 L
20-4 SUPPLEMENT - 2003 - 2006 MODELS
General Information

Item KLF300-C1S - C6F

Drive Train
Primary Reduction
System: Type Gear
Reduction Ratio 2.888 (78/27)
Clutch Type: Primary Auto centrifugal, wet
Secondary Auto multi disc, wet
Transm ission: Type 10-speed plus reverse, constant mesh, return shift
Gear
1st 3.090 (34/11)
Ratio:
2nd 1.928 (27/14)
3rd 1.368 (26/19)
4th 1.000 (23/23)
Sth 0.769 (20/26)
Reverse 3.072 (26/11 x 26/20)
Final Drive System:
Type Shaft
Reduction ratio High S.416 (33/33 x 20/16 x 39/9)
Low 6.910 (37/29 x 20/16 x 39/9)
Overall Drive Ratio: High: 12.037, Low:1S.3S7
Front Final Gear Case Oil: Type API GL-S Hypoid gear oil for LSD SAE140 or SAE90
Capacity 0.4 L
Rear Final Gear Case Oil: Type API GL-S Hypoid gear oil SAE90 (above SoC, 41F) or
SAE80 (below SoC, 41 F)
Capacity 0.3 L
Frame:
Type Double tubular
Caster (Rake Angle) 1.0
Chamber 0 @1G
Trail S mm
Tread Front 844 mm
Rear 860 mm
Front Tire: Type Tubeless
Size AT 24 x 8-11
Rear Tire: Type Tubeless
Size AT24x10-11
Rim Size: Front 11 x 6.S
Rear 11 x 8.0
Suspension: Front Type Double wishbone
Wheel Travel 110 mm
Rear Type Torque tube
Wheel Travel 120 mm
Brake Type: Front Disc (Hydraulic) x 2
Rear Drum (Mechanical, on Rightside)
 SUPPLEMENT - 2003 - 2006 MODELS 20-5
General Information

Item KLF300-C1S - C6F

Electrical Equipment:
Battery 12 V 14 Ah (CN, EU, UK) 12 V 19 Ah
Headlight: Type Semi-sealed beam
Bulb 12 V 25/25 W x 2
Tail/Brake Lights: Bulb 12 V 18/5 W x 2
Alternator: Type Three-phased AC
Rated Output 23.5 A/14 V @9 000 r/min (rpm)

Specifications subject to change without notice, and may not apply to every country.
CN: Canada Model
EU: Europe Model
UK: U.K. Model
US: U.S.A. Model
20-6 SUPPLEMENT - 2003 - 2006 MODELS
Fuel System

Specifications
Item Standard
Carburetor Specifications
Make, Type Keihin, CVK32
Main Jet #138 , (CAL) #125
Main Air Jet #70, (CAL) #50
Needle Jet #6
Jet Needle Mark N24G
Pilot Jet (Slow Jet) #38
Pilot Air Jet (Slow Air Jet) #140
Pilot Screw (Turns Out) 2
Starter Jet #65
Service Fuel Level (from carburetor body
-1.5 mm (below) - 0.5 mm (above)
bottom edge)
Float Height 17 1 mm
Engine Speed (for reference) 1 300 50 r/min (rpm)
Optional Parts
Main Jet #132, #135, #140, #142
(CAL)#120,#122 , #128, #130
Pilot Jet (Slow Jet) #35 , #40
Starter Jet #68, #70
CAL: California Model
 SUPPLEMENT - 2003 - 2006 MODELS 20-7
Fuel System

Carburetor
Carburetor Pilot Screw Adjustment
Loosen the carburetor holder clamp screws (Front and
Rear).
Tilt the carburetor to the right of the vehicle for easy ac-
cess to the pilot screw.
Turn the pilot screw in until it seats lightly, and back it out
2 turns.
Carburetor Pilot Screw Setting
Standard: 2 turns out
Reposition the carburetor properly and tighten the clamp
screws securely.
OFit the carburetor ridge into the groove on the duct.

Fuel Level Inspection

A. WARNING
Gasoline is extremely flammable and can be ex-
plosive under certain conditions. Turn the ignition
switch OFF. 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.

Park the vehicle on a level surface.

Connect the fuel level gauge [A] to the open end of the
carburetor overflow tube .
Special Tool - Fuel Level Gauge: 57001-1017
Hold the gauge vertically against the side of the carbure-
tor body so that the "zero" line [B] is several millimeters
higher than the bottom edge [C] of the carburetor body.
Turn the fuel tap to the ON position to feed fuel to the
carburetor and gauge , then turn out the carburetor drain
plug [D] a few turns.
Wait until the fuel level in the gauge settle.
Keeping the gauge vertical , slowly lower the gauge until
the "zero" line is even with the bottom edge of the carbu-
retor body.
NOTE
o Do not lower the "zero" line below the bottom edge of
the carburetor body If the gauge is lowered and then
raise it again, the fuel level measured shows somewhat
higher than the actual fuel level. If the gauge is lowered HC060 12BS2 C

too far, dump the fuel out of it into a suitable container

and start the procedure over again.
Read the fuel level in the gauge and compare it to the
specification.
Tighten the drain plug and remove the fuel level gauge.
* If the fuel level is incorrect, adjust it.
Fuel Level
-1.5 mm (below) - 0.5 mm (above) from the bottom
edge of the carburetor body
20-8 SUPPLEMENT - 2003 - 2006 MODELS
Engine Right Side
Specifications
Item Standard
Engine Oil:
Type API SF or SG
API SH or SJ with JASO MA
Viscosity SAE 10W-40
Capacity 2.2 L (U .S.A., Canada Models)
2.4 L (Europe, U.K. Models)

Engine Oil and Oil Filter

Engine Oil Change SAE 20W-50

Recommended Engine Oil SAE 20W-40

I
Type: API SF or SG SAE 10W - 50 >
API SH or SJ with JASO MA SAE 10W - 40

Viscosity: SAE 10W-40 SAE 10W -3 0

Capacity: 2.2 L (U.S.A., Canada Models) <, SAE 5W-30

I I
2.4 L (Europe, U.K. Models) -2 0 -10 0 10 20 30 40 ( C)
'4 1'4 3'2 5'0 6'8 8'S 104 ( DF )
, ! ! ! I I !

HU09002BS 1 C
NOTE
o Depending on the atmospheric temperature of your rid-
ing area, the engine oil viscosity should be changed ac-
cordingly to the chart.
 SUPPLEMENT - 2003 - 2006 MODELS 20-9
Wheelrrires

Front Hub
Front Hub Installation
eTighten:
A
Torque - Front Hub Nuts: 145 Nm (15.0 kgf.m, 110 ftlb)
elnsert a new cotter pin [A].
NOTE
o When inserting the cotter pin, if the slots in the nut do
not align with the cotter pin hole in the axle, tighten the
nut clockwise [BJ up to next alignment.
Olt should be within 30 degree.
HJ07007B S 1 C
OLoosen once and tighten again when the slot goes past
the nearest hole.

e Bend the cotter pin [A] over the nut [B].

e Check the front brake.
A WARNING
Do not attempt to drive the motorcycle until a full
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 A
this is not done.
HJ07008BS 1 C

Rear Hub
Rear Hub Installation
e Refer to the above figures in the Front Hub Installation.
e Tighten:
Torque - Rear Axle Nuts: 145 Nm (15.0 kgf.m, 110 ftlb)
elnsert a new cotter pin [A].
NOTE
o When inserting the cotter pin, if the slots in the nut do
not align with the cotter pin hole in the axle, tighten the
nut clockwise [BJ up to next alignment.
Olt should be within 30 degree.
o Loosen once and tighten again when the slot goes past
the nearest hole.

e Bend the cotter pin [A] over the nut [B].

e Check the rear brake.
20-10 SUPPLEMENT - 2003 - 2006 MODELS
Brakes

Exploded View

T6

~ T7

T7

Hl 020 0 8BW4 C

1 . Brake Switch T1 : 1.0 Nm (0.10 kgfm, 9 inlb)

L: Apply non-permanent locking agent. T2 : 1.2 Nm (0.12 kgfm , 10 inlb)
R: Replacement Parts T3 : 5.9 Nm (0.60 kgfm, 52 inlb)
Si : Apply silicone grease . T4: 7.8 Nm (0 .80 kgfm , 69 inlb)
T5: 8.8 Nm (0 .90 kgfm, 78 inlb)
T6: 18 Nm (1.8 kgfm, 13 ftlb)
T7: 20 Nm (2.0 kgfm, 14.5 ftlb)
T8: 23 Nm (2.3 kgfm, 16.5 ftlb)
T9: 25 Nm (2 .5 kgfm , 18 ftlb)
T1 0: 37 Nm (3.8 kgf.m, 27 ftlb)
 SUPPLEMENT - 2003 - 2006 MODELS 20-11
Frame

Exploded View

, ~ ~
4

~

4

H0020 14BW4 C

1. Canada Model
2. U.K. Model
3. U.S.A. Model
4. Option (U.S.A. and Canada Models)
20-12 SUPPLEMENT - 2003 - 2006 MODELS
Electrical System

Exploded View

HP 0 2030B.,,4 C

1. Working Light (Optional Parts)

2. Light Switch and Engine Stop Switch
3. Lock Key (Optional Parts)
4. Reflector Reflex (Europe and U.K. Models)
5. Horn Button (Europe and U.K. Models)
6. Ignition Switch (Other than Europe and U.K. Models)
7. Ignition Switch (Europe and U.K. Models)
8. Rear Brake Light Switch
9. KLF300-C15 - Model
 SUPPLEMENT - 2003 - 2006 MODELS 20-13
Electrical System

Dummy Page
20-14 SUPPLEMENT - 2003 - 2006 MODELS
Electrical System

Wiring Diagram (U.S.A. and Canada Models)

1- - --- -( ~P~u ~ e~o-r-- - (Ca~ M;,de III

I Carburetor Hea te r r - - - ---, I
Th er mo. Sensor *Refe r to the U K:Control Un i t :
I "~ --I mode l Wi ri ng T- - --T
i ----;Q-- - i I D i agram '";;T';'- J,-r G)Reverse Indicator L ig ht 12V3 . 4W
I (~I I I ' ~ '" CDNeutral Indica tor L ig ht 12V3 .4W
I i~i
\.J../
'LLBK / R-rl1-BK
- BK / Y-i
/ R---~ ! f"'L>-~ L(>.'.
r BK/ Y- - -
I ----'-r--
I LW--t::r_-_}----W--4 c--W _ _ _ --.J I
I I I Neutra l / Rev erse
I 'L I L J \ I gn i tion Switch
iBK-L'T - BK- -- -: :--- I I \~ Sw itch
Carburetor I r-r"--- \!
II Hea ter 12V23W
I
I "'~'"'':: II n rcKLF300l
Indicator
12V 3.4WX2
L ig ht

:l ~[r~~:;:~ i-h~:"::'f~l~;;
- - ~ ~ ~ ~~ '"' I I
u 1 1 ~2~ 1tg:'-;: :1 GSFli] :I ~~
I I I I lQJ 144
I " I " L -- I I ~

2 66~
c:::

~~ L _-_--==--_-_~ h
0::: 3: 3: CJ .......... (",!)a:::

~ ~V ~

-00 "~~I~'~'~/-/- - - ~ L ~;L~ ~: ~_t :Y~I L3~I~

I J I I

L ---
BK / Y~BK / Y -----. ~ ~
Headl ight
12V25 / 25W
( R H)

~
- ---t-R / B K-[>C]-R / BK
f-- RI Y ----[::cr-R I Y ----+~
__ ...l- B K I Y-CJ<:::r- B K I Y-----+-If--t-t-t-i-+~----_r_+--------------------+_t__---
Work L ig ht
12V65 / 60W
( 0 P)

I '"
>- >- >- a> '"

@
~ ~
R / BK--[>CJ----R / BK
R / Y~R / Y----+~
BK / Y ~BK / Y---~

Head li ght
12V25 / 25W >- >- >- ~'"
0000

( L H)

A l terna tor
Le ft Ha n dl e bar Switch

G)L igh t / D im mer Switc h

CD En gine Stop Switc h

(DStarter Button CD CD (D

L EF T HAN DLEB AR SW IT C H CONN E CTIO NS

L i ght / Di mm e r Sw itch Encine Stop Switch Starter Button
Co lor R/ Y R R / B K BR Co l or BR Y/ R Colo r Y / R BK
OFF OFF R e l ease
LO Pu s h c;:-~
HI RUN C;:-.-, I

W2 L0026AW5 C
 SUPPLEMENT - 2003 - 2006 MODELS 20-15
Electrical System

Pa rking Brake
Li ght Sw itch
Accessory
F ro n t Brake
Rear Brake T erminal
L ig ht Switch
Li g h t Switch
r - - - - B L ---D<:}-B L ~
.-B K / Y-t:>D--B K / Y
- R-D<l---R

Ta i I / Bra ke Li ghts
12V 8 / 27WX2

I---I-- B L -D<.J--B L ~
I- BK/ Y-!>D-B K/ Y
~R---D<J--R

----------~~--------------------_+----~+__4--4_+_--------- W----------,

J?:<~
h .. 0
'+' :E ""

I >-

'"' "

1l a:::

m~
0::':::: x::
co ---l co co

>->->-::'::::0:::0:::0:::::'::::
co m '

Regulator /
Rectifiter
. . . . . co
'"''"' I gnition
Co i I
WLb __ ::!J
Starter
Circuit
Rela y
( U. S . A. Model
/

12V 14AH )

Spa r k P l u g
Color Code

~"""~~,,~
Starter Motor BK Black
BL Blue
B R Brown
CH Chocolate
DG Dar k Green
Green
GY G ray
LB L i I: h t Bl ue
LG li, h t Green
I GHI TIO N S lI fCH CO III ECI I CNS NEU TRAL & REVERSE S1IITCH CONN ECT IOMS Orange
0
Co l o rJ BRJ W Gear Po s i t ion LG Gr 0 1,1 nd R/ W Pink
OFF J J
,,, throv,h PU Pur p i e
ON J~ Neutral''" <=- ..::> Red
Reverse c:.. 11K W Wh it e
Ye I low
(98 052-0026A.1136A )

'lf2R0026AW5 C
20-16 SUPPLEMENT - 2003 - 2006 MODELS
Electrical System

Wiring Diagram (Europe and U.K. Models)

(DReverse Indicator Light 12V3.4W

0Neutral Indicator L ight 12V3.4W

Ignition Switch

/ -----i-R / BK--t>D-R / BK

~ f--- RI Y ---t>CJ-R I Y-4-++---,

__ .J----!l KI Y---{::J<J-B KI Y~-t--+-----t---If--t---t-+--+-~--t----------+-t-----~--+-+-~-
Work Light
12V65 / 60W
. ( OP) BK / Y-c:::J<:J--BK / Y

~R~R--++--+-~--+-+-t--~ 3: >- >-

#m~
Speedometer Li ght
12V3.4W

CID
RI BK-t>O-R I BK- -
RI Y ---t>O-R I Y -
BK / Y~BK / Y--
~~ !!!!ITT!
Headl ight
12V25 / 25W
( L H)

Left Handlebar Switch

o II
Pickup Coi I
. ,."""
Rectifier

(D Li ght / Dimmer Switch

~
0Engi ne Stop Switch
G)Starter Button
s,"< ".,
W~
LEFT HANDLEBAR SWITCH CONNECTIONS
Light / Dimmer Switch Eng i ne Stop Sw it ch Starter Button
Color R / Y R R/ BK BR Color BR Y / R Color Y / R BK
OFF OFF Rei e a s e

LO Push <;JIIIII~
HI RUN I

W2l0028AW5 C
 SUPPLEMENT - 2003 - 2006 MODELS 20-17
Electrical System

( OP ) Europe Model
r-:- -
I Carburetor
~ Thermo. Sensor

I- a:: ~==a::: Accessory Terminals

I ( Trai ler Light )
BK / R [ [ E K / R
BK / Y
;'"'2:;;;::: L _
BK / Y ----~~rt--------~+__
-~
W--c:>D-- w W r-----;: B L -D<J--B L ~
Car bur e tor BK B Kl I I I B K / Y --t>O-B K / Y (
Heater ~ R-D<J--R Tall / Brake
-----=;; Light

12"" ".""
Relay
"8~" ~s~~ "' ~ ~-~:-y- --=>7B'~~BK/y-12V
~
8 / 27WX2

: :
i l!:_-:~ S~ J R~~-=Ba=-R{RW I~
Reverse Light
----------------~----------------,r~--t_----~_t--~--~-------w 12 V10 W

"
u.
<=
.- ..:
'"'"
::e M

>-

liill~~d
3:
"-

~
CD

I I
S'"";' i
Circuit >-
R e lay ~ ~
CD ""
~
>-
"-
I I ""
I l!: - - ~ ,.--'-c::r'--, 1+) 1- )
Battery
12V19AH

Starter Relay

~
- --~ Starter Moter
Color Code
BK B l ack
G/W
Y / R--------- - - -+----
~ BL Blue
BR B row n
--------------
Ignition Coi I CH Choc ol 3t e
DG Dar k Gre e n
G Gr e e n
GY G ray
LB l i g h t Blue
LG l i g h t G r een
IG ,'4 I T I OH S WITC H COHHECTIONS N EUTRAl & REVERSE SJI'I TCH CO NNECT t ON S
Orange
0
Color I BR I W I GY G e:l r Posit i on LG Ground R/ W P Pi nk
OFF L I L I" throu , h 5t h PU Pur pie
ON I Neutra I <::.. ~ Red
Reverse c:.. ~ W White
(98052-0028A, 1138A) Y Yellow

W2ROO 28" "5 C