1337 02 An130b6f - c6f

KAZE ZX130
Motorcycle
Service Manual
Quick Reference Guide
General Information 1 j
Periodic Maintenance 2 j
Fuel System 3 j
Engine Top End 4 j
Clutch 5 j
Engine Lubrication System 6 j
Engine Removal/Installation 7 j
Crankshaft/Transmission 8 j
Wheels/Tires 9 j
Final Drive 10 j
Brakes 11 j
Suspension 12 j
Steering 13 j
Frame 14 j
Electrical System 15 j
Troubleshooting 16 j
This quick reference guide will assist

you in locating a desired topic or pro-
cedure.
•Bend the pages back to match the
black tab of the desired chapter num-
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.
KAZE ZX130
Motorcycle
Service Manual
All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or
transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise,
without the prior written permission of Quality Division/Consumer Products & Machinery Company/Kawasaki
Heavy Industries, Ltd., Japan.
No liability can be accepted for any inaccuracies or omissions in this publication, although every possible
care has been taken to make it as complete and accurate as possible.
The right is reserved to make changes at any time without prior notice and without incurring an obligation
to make such changes to products manufactured previously. See your dealer for the latest information on
product improvements incorporated after this publication.
All information contained in this publication is based on the latest product information available at the time
of publication. Illustrations and photographs in this publication are intended for reference use only and may
not depict actual model component parts.
© 2005 Kawasaki Heavy Industries. Ltd. Second Edition (1): Mar. 10, 2006 (K)
LIST OF ABBREVIATIONS
A ampere(s) lb pound(s)
ABDC after bottom dead center m meter(s)
AC alternating current min minute(s)
ATDC after top dead center N newton(s)
BBDC before bottom dead center Pa pascal(s)
BDC bottom dead center PS horsepower
BTDC before top dead center psi pound(s) per square inch
°C degree(s) Celsius r revolution
DC direct current r/min, rpm revolution(s) per minute
F farad(s) TDC top dead center
°F degree(s) Fahrenheit TIR total indicator reading
ft foot, feet V volt(s)
g gram(s) (mass) W watt(s)
h hour(s) Ω ohm(s)
kg (mass)
kgf (force)
L liter(s)
Read OWNER’S MANUAL before operating.

Foreword
This manual is designed primarily for use by The Quick Reference Guide shows you all
trained mechanics in a properly equipped shop. of the product’s system and assists in locating
However, it contains enough detail and basic in- their chapters. Each chapter in turn has its own
formation to make it useful to the owner who de- comprehensive Table of Contents.
sires to perform his own basic maintenance and For example, if you want ignition coil informa-
repair work. A basic knowledge of mechanics, tion, use the Quick Reference Guide to locate
the proper use of tools, and workshop proce- the Electrical System chapter. Then, use the
dures must be understood in order to carry out Table of Contents on the first page of the chap-
maintenance and repair satisfactorily. When- ter to find the ignition coil section.
ever the owner has insufficient experience or Whenever you see these WARNING and
doubts his ability to do the work, all adjust- CAUTION symbols, heed their instructions!
ments, maintenance, and repair should be car- Always follow safe operating and maintenance
ried out only by qualified mechanics. practices.
In order to perform the work efficiently and
WARNING
to avoid costly mistakes, read the text, thor-
oughly familiarize yourself with the procedures This warning symbol identifies special
before starting work, and then do the work care- instructions or procedures which, if not
fully in a clean area. Whenever special tools or correctly followed, could result in per-
equipment are specified, do not use makeshift sonal injury, or loss of life.
tools or equipment. Precision measurements
can only be made if the proper instruments are CAUTION
used, and the use of substitute tools may ad-
This caution symbol identifies special
versely affect safe operation.
instructions or procedures which, if not
For the duration of the warranty period,
strictly observed, could result in dam-
we recommend that all repairs and scheduled
age to or destruction of equipment.
maintenance be performed in accordance with
this service manual. Any owner maintenance or This manual contains four more symbols (in
repair procedure not performed in accordance addition to WARNING and CAUTION) which will
with this manual may void the warranty. help you distinguish different types of informa-
To get the longest life out of your vehicle: tion.
• Follow the Periodic Maintenance Chart in the
Service Manual. NOTE
• Be alert for problems and non-scheduled ○This note symbol indicates points of par-
maintenance. ticular interest for more efficient and con-
• Use proper tools and genuine Kawasaki Mo- venient operation.
torcycle parts. Special tools, gauges, and
testers that are necessary when servicing • Indicates
done.
a procedural step or work to be
Kawasaki motorcycles are introduced by the
Service Manual. Genuine parts provided as
○Indicates a procedural sub-step or how to do
the work of the procedural step it follows. It
spare parts are listed in the Parts Catalog. also precedes the text of a NOTE.
• Follow the procedures in this manual care-
fully. Don’t take shortcuts.
Indicates a conditional step or what action to
take based on the results of the test or inspec-
• Remember to keep complete records of main-
tenance and repair with dates and any new
tion in the procedural step or sub-step it fol-
lows.
parts installed. In most chapters an exploded view illustration
of the system components follows the Table of
How to Use This Manual Contents. In these illustrations you will find the
In this manual, the product is divided into its instructions indicating which parts require spec-
major systems and these systems make up the ified tightening torque, oil, grease or a locking
manual’s chapters. agent during assembly.
GENERAL INFORMATION 1-1
General Information 1
Table of Contents
Before Servicing ..................................................................................................................... 1-2
Model Identification................................................................................................................. 1-7
General Specifications............................................................................................................ 1-10
Unit Conversion Table ............................................................................................................ 1-13
1-2 GENERAL INFORMATION
Before Servicing
Before starting to perform an inspection service or carry out a disassembly and reassembly opera-
tion on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustra-
tions, photographs, cautions, and detailed descriptions have been included in each chapter wherever
necessary. This section explains the items that require particular attention during the removal and
reinstallation or disassembly and reassembly of general parts.
Especially note the following.
Battery Ground
Before completing any service on the motorcycle, discon-
nect the battery cables from the battery to prevent the en-
gine from accidentally turning over. Disconnect the battery
cable (–) first and then the battery cable (+). When com-
pleted with the service, first connect the battery cable (+) to
the positive (+) terminal of the battery then the battery cable
(–) to the negative (–) terminal.
Edges of Parts
Lift large or heavy parts wearing gloves to prevent injury
from possible sharp edges on the parts.
Solvent
Use a high-flush point solvent when cleaning parts. High
-flush point solvent should be used according to directions
of the solvent manufacturer.
Cleaning vehicle before disassembly

Clean the vehicle thoroughly before disassembly. Dirt or
other foreign materials entering into sealed areas during ve-
hicle disassembly can cause excessive wear and decrease
performance of the vehicle.
Before Servicing
Arrangement and Cleaning of Removed Parts
Disassembled parts are easy to confuse. Arrange the
parts according to the order the parts were disassembled
and clean the parts in order prior to assembly.
Storage of Removed Parts

After all the parts including subassembly parts have been
cleaned, store the parts in a clean area. Put a clean cloth
or plastic sheet over the parts to protect from any foreign
materials that may collect before re-assembly.
Inspection
Reuse of worn or damaged parts may lead to serious ac-
cident. Visually inspect removed parts for corrosion, discol-
oration, or other damage. Refer to the appropriate sections
of this manual for service limits on individual parts. Replace
the parts if any damage has been found or if the part is be-
yond its service limit.
Replacement Parts
Replacement Parts must be KAWASAKI genuine or
recommended by KAWASAKI. Gaskets, O-rings, oil seals,
grease seals, circlips or cotter pins must be replaced with
new ones whenever disassembled.
Assembly Order
In most cases assembly order is the reverse of disassem-
bly, however, if assembly order is provided in this Service
Manual, follow the procedures given.
Before Servicing
Tightening 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 according to the specified se-
quence to prevent case warpage or deformation which can
lead to malfunction. Conversely when loosening the bolts,
nuts, or screws, first loosen all of them by about a quar-
ter turn and then remove them. If the specified tightening
sequence is not indicated, tighten the fasteners alternating
diagonally.
Tightening Torque
Incorrect torque applied to a bolt, nut, or screw may
lead to serious damage. Tighten fasteners to the specified
torque using a good quality torque wrench.
Force
Use common sense during disassembly and assembly,
excessive force can cause expensive or hard to repair dam-
age. When necessary, remove screws that have a non
-permanent locking agent applied using an impact driver.
Use a plastic-faced mallet whenever tapping is necessary.
Gasket, O-ring
Hardening, shrinkage, or damage of both gaskets and
O-rings after disassembly can reduce sealing performance.
Remove the old gaskets and clean the sealing surfaces
thoroughly so that no gasket material or other material re-
mains. Install the new gaskets and replace the used O-rings
when re-assembling.
Liquid Gasket, Non-permanent Locking Agent

For applications that require Liquid Gasket or a
Non-permanent Locking Agent, clean the surfaces so
that no oil residue remains before applying liquid gasket or
non-permanent locking agent. Do not apply them exces-
sively. Excessive application can clog oil passages and
cause serious damage.
Before Servicing
Press
For items such as bearings or oil seals that must be
pressed into place, apply small amount of oil to the con-
tact area. Be sure to maintain proper alignment and use
smooth movements when installing.
Ball Bearing and Needle Bearing

Do not remove pressed ball or needle unless removal is
absolutely necessary. Replace with new ones whenever
removed. Press bearings with the manufacturer and size
marks facing out. Press the bearing into place by putting
pressure on the correct bearing race as shown.
Pressing the incorrect race can cause pressure between
the inner and outer race and result in bearing damage.
Oil Seal, Grease Seal

Do not remove pressed oil or grease seals unless removal
is necessary. Replace with new ones whenever removed.
Press new oil seals with manufacture and size marks facing
out. Make sure the seal is aligned properly when installing.
Apply specified grease to the lip of seal before installing

the seal.
Circlips, Cotter Pins

Replace the circlips or cotter pins that were removed with
new ones. Take care not to open the clip excessively when
installing to prevent deformation.
Before Servicing
Lubrication
It is important to lubricate rotating or sliding parts during
assembly to minimize wear during initial operation. Lubri-
cation points are called out throughout this manual, apply
the specific oil or grease as specified.
Direction of Engine Rotation

When rotating the crankshaft by hand, the free play
amount of rotating direction will affect the adjustment. Ro-
tate the crankshaft to positive direction (clockwise viewed
from output side).
Electrical Wires
A two-color wire is identified first by the primary color and
then the stripe color. Unless instructed otherwise, electrical
wires must be connected to those of the same color.
Instrument
Use a meter that has enough accuracy for an accurate
measurement. Read the manufacture’s instructions thor-
oughly before using the meter. Incorrect values may lead
to improper adjustments.
Model Identification
AN130-A1 Left Side View
AN130-A1 Right Side View

AN130-B1 Left Side View
AN130-B1 Right Side View

AN130-C1 Left Side View
AN130-C1 Right Side View

General Specifications
Items AN130-A1 AN130-B1, B6F AN130-C1, C6F

Dimensions
Overall Length 1 905 mm (75.0 in.)
Overall Width 725 mm (28.5 in.)
Overall Height 1 055 mm (41.5 in.)
Wheel Base 1 250 mm (49.2 in.)
Road Clearance 140 mm (5.5 in.)
Seat Height 750 mm (29.5 in.)
Dry Weight 101 kg (223 lb) 102.5 kg (226 lb) 103.5 kg (228 lb)
Curb Weight:
Front 47 kg (104 lb) 48.5 kg (107 lb) 49 kg (108 lb)
Rear 59 kg (130 lb) 59 kg (130 lb) 59.5 kg (131 lb)
Fuel Tank Capacity 3.8 L (1.0 US gal)
Performance
Minimum Turning Radius 1.9 m (6.2 ft)
Engine
Type 4-stroke, SOHC, single cylinder
Cooling System Air-cooled
Bore and Stroke 53.0 × 59.1 mm (2.09 × 2.33 in.)
Displacement 130 cm³ (7.93 cu in.)
Compression Ratio 10 : 1
Maximum Horsepower 7.1 kW (9.6 PS) @7 500 7.1 kW (9.6 PS) 7.2 kW (9.8 PS) @7
r/min (rpm) @7 500 r/min (rpm) 500 r/min (rpm)
– (TH)
Maximum Torque 10.7 N·m (1.09 kgf·m, 7.9 ft·lb) @5 500 r/min (rpm)
Carburetion System Carburetor, KEIHIN NCV24
Starting System Kick Kick and Electric
Ignition System DC-CDI
Timing Advance Electronically advance
Ignition Timing From 12.5° BTDC @1 500 r/min (rpm) to 33.5° BTDC @4 600 r/min
(rpm)
Spark Plug NGK C6HSA (Option: DENSO U20FS-U)
Valve Timing:
Inlet:
Open 31° (BTDC)
Close 55° (ABDC)
Duration 266°
Exhaust:
Open 64° (BBDC)
Close 34° (ATDC)
Duration 278°
Lubrication System Forced lubrication (wet sump)

Engine Oil:
Grade API SE, SF or SG
API SH or SJ with JASO MA
Viscosity SAE10W-40
Capacity 1.1 L (1.2 US qt)
Drive Train
Primary Reduction System:
Type Gear, centrifugal
Reduction Ratio 3.000 (69/23)
Clutch Type Centrifugal & W. M. Disc
Transmission:
Type 4-speed, Rotary (Down)
Gear Ratios:
1st 2.500 (35/14)
2nd 1.591 (35/22)
3rd 1.154 (30/26)
4th 0.966 (28/29)
Final Drive System:
Type Chain drive
Reduction Ratio 3.000 (42/14)
Overall drive Ratio 8.694 @Top gear
Frame
Type Backbone
Caster (Rake Angle) 26°
Trail 72 mm (2.83 in.)
Front Tire:
Type NF35, Tube NR72, Tube NF35, Tube (TH)
Size 70/90-17 M/C 38P
Rear Tire:
Type NR75, Tube NR72, Tube NR75, Tube (TH)
Size 80/90-17 M/C 44P
Rim Size:
Front 17 × 1.40
Rear 17 × 1.60
Front Suspension:
Type Telescopic fork
Wheel Travel 90 mm (3.54 in.)
Rear Suspension:
Type Swingarm
Wheel Travel 90 mm (3.54 in.)
Brake Type:
Front Single disc
Rear Drum

Electrical Equipment
Battery 12 V 2.5 Ah 12 V 3.5 Ah
12 V 3.0 Ah (PH)
Headlight:
Type Semi-sealed beam
Bulb 12 V (18/18 W) × 2
Brake/Trail Light 12 V 18/5 W
Alternator:
Type Single-phase AC
Rated Output –
Specifications are subject to change without notice, and may not apply to every country.
TH: Thailand Model
PH: Philippine Model
Unit Conversion Table
Prefixes for Units: Units of Length:
km × 0.6214 = mile
Prefix Symbol Power
m × 3.281 = ft
mega M × 1 000 000
mm × 0.03937 = in.
kilo k × 1 000
centi c × 0.01
milli m × 0.001 Units of Torque:
micro µ × 0.000001 N·m × 0.1020 = kg·m
N·m × 0.7376 = ft·lb
N·m × 8.851 = in·lb
Units of Mass: kg·m × 9.807 = N·m
kg × 2.205 = lb kg·m × 7.233 = ft·lb
g × 0.03527 = oz kg·m × 86.80 = in·lb
Units of Volume: Units of Pressure:

L × 0.2642 = gal (US) kPa × 0.01020 = kg/cm²
L × 0.2200 = gal (imp) kPa × 0.1450 = psi
L × 1.057 = qt (US) kPa × 0.7501 = cm Hg
L × 0.8799 = qt (imp) kg/cm² × 98.07 = kPa
L × 2.113 = pint (US) kg/cm² × 14.22 = psi
L × 1.816 = pint (imp) cm Hg × 1.333 = kPa
mL × 0.03381 = oz (US)
mL × 0.02816 = oz (imp) Units of Speed:
mL × 0.06102 = cu in. km/h × 0.6214 = mph
Units of Force: Units of Power:

N × 0.1020 = kg kW × 1.360 = PS
N × 0.2248 = lb kW × 1.341 = HP
kg × 9.807 = N PS × 0.7355 = kW
kg × 2.205 = lb PS × 0.9863 = HP
Units of Temperature:
PERIODIC MAINTENANCE 2-1
Periodic Maintenance
Table of Contents
2
Periodic Maintenance Chart ................................................................................................... 2-3

Torque and Locking Agent...................................................................................................... 2-5
Specifications ......................................................................................................................... 2-8
Special Tools .......................................................................................................................... 2-10
Periodic Maintenance Procedures.......................................................................................... 2-11
Fuel System......................................................................................................................... 2-11
Throttle Cable Inspection .................................................................................................. 2-11
Choke Operation Inspection ............................................................................................. 2-11
Idle Speed Inspection ....................................................................................................... 2-12
Air Cleaner Element Cleaning........................................................................................... 2-13
Fuel Hose Installation Condition Inspection...................................................................... 2-13
Engine Top........................................................................................................................... 2-14
Valve Clearance Inspection .............................................................................................. 2-14
Clutch................................................................................................................................... 2-15
Operation Inspection......................................................................................................... 2-15
Wheels/Tires ........................................................................................................................ 2-15
Spoke Tightness Inspection (AN130-A1/B1, B6F Models) ............................................... 2-15
Rim Runout Inspection (AN130-A1/B1, B6F Models) ....................................................... 2-16
Tire Air Pressure Inspection.............................................................................................. 2-16
Wheel/Tire Damage Inspection......................................................................................... 2-17
Tire Tread Wear, Abnormal Wear Inspection .................................................................... 2-17
Wheel Bearing Damage Inspection .................................................................................. 2-17
Drive .................................................................................................................................... 2-18
Drive Chain Slack Inspection ............................................................................................ 2-18
Drive Chain Slack Adjustment .......................................................................................... 2-19
Drive Chain Wear Inspection ............................................................................................ 2-20
Chain Guide Wear Inspection ........................................................................................... 2-20
Drive Chain Lubrication..................................................................................................... 2-21
Brakes.................................................................................................................................. 2-21
Brake Pad Wear Inspection .............................................................................................. 2-21
Brake Fluid Leak (Brake Hose and Pipe) Inspection ........................................................ 2-21
Brake Fluid Level Inspection............................................................................................. 2-22
Brake Hose Damage and Installation Condition Inspection.............................................. 2-22
Brake Operation Inspection .............................................................................................. 2-22
Brake Shoe Lining Wear Inspection.................................................................................. 2-23
Brake Light Switch Operation Inspection .......................................................................... 2-24
Suspension .......................................................................................................................... 2-24
Front Forks/Rear Shock Absorber Operation Inspection .................................................. 2-24
Front Fork Oil Leak Inspection.......................................................................................... 2-25
Rear Shock Absorber Oil Leak Inspection ....................................................................... 2-25
Steering ............................................................................................................................... 2-25
Steering Play Inspection ................................................................................................... 2-25
Steering Stem Bearing Lubrication ................................................................................... 2-27
Electrical System ................................................................................................................. 2-27
Spark Plug Condition - Inspection..................................................................................... 2-27
Spark Plug Removal/Installation ....................................................................................... 2-27
2-2 PERIODIC MAINTENANCE
Headlight Aiming Inspection ............................................................................................. 2-27

Light and Switches Operation Inspection.......................................................................... 2-28
Others .................................................................................................................................. 2-30
Chassis Parts Lubrication ................................................................................................. 2-30
Bolt, Nut, and Fastener Tightness Inspection ................................................................... 2-32
Replacement Parts .............................................................................................................. 2-33
Fuel Hose Replacement ................................................................................................... 2-33
Air Cleaner Element Replacement.................................................................................... 2-33
Engine Oil Change............................................................................................................ 2-34
Oil Filter Replacement ...................................................................................................... 2-35
Brake/Master Cylinder/Caliper Rubber Parts Replacement.............................................. 2-35
Brake Fluid Change .......................................................................................................... 2-35
Brake Hose Replacement ................................................................................................. 2-36
Periodic Maintenance Chart
The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in
good running condition.The initial maintenance is vitally important and must not be neglected.
Periodic Inspection
FREQUENCY Whichever * ODOMETER READING
comes × 1 000 km
first (× 1 000 mile) See
Page
1 6 12 18 24 30 36
ITEM Every (0.6) (4) (7.5) (12) (15) (20) (24)
Fuel System
Throttle cable - inspect year • • • • 2-11
Choke operation - inspect year • • • • 2-11
Idle speed - inspect • • • • 2-12
Air cleaner element - clean • • • 2-13
Fuel hoses installation condition - inspect year • • • • 2-13
Fuel leak (fuel hose) - inspect year • • • • 2-13
Fuel hoses damage - inspect year • • • • 2-13
Engine Top End
Valve clearance - inspect • • • 2-14
Clutch
Clutch operation (play, disengagement,
engagement) - inspect • • • • 2-15
Wheels and Tires

Spoke tightness and rim runnout - inspect
AN130-A1/B1, B6F • • • • • • • 2-15
Tire air pressure - inspect year • • • 2-16

Wheel/tire damage - inspect • • • 2-17
Tire tread wear, abnormal wear - inspect • • • 2-17
Wheel bearing damage - inspect year • • • 2-17
Drive
Drive chain slack - inspect # Every 1 000 km (600 mile) 2-18
Drive chain wear - inspect # • • • • • • 2-20
Drive chain guide wear - inspect • • • 2-20
Drive chain lubrication condition - inspect # Every 600 km (400 mile) 2-21
Brakes
Brake pad wear - inspect # • • • • • • 2-21
Brake fluid leak (brake hose and pipe) -
inspect
year • • • • • • • 2-21
Brake fluid level - inspect 6 month • • • • • • • 2-22

Brake hose damage - inspect year • • • • • • • 2-22
Brake hose installation condition - inspect year • • • • • • • 2-22
Brake operation (effectiveness, play, no
drag) - inspect
year • • • • • • • 2-22
Brake lining wear - inspect • • • • • • 2-23

Brake light switch operation - inspect • • • • • • • 2-24
Periodic Maintenance Chart

comes × 1 000 km
Page
1 6 12 18 24 30 36
ITEM Every (0.6) (4) (7.5) (12) (15) (20) (24)
Suspension
Front forks/rear shock absorber operation
(smooth stroke) - inspect • • • 2-24
Front forks/rear shock absorber oil leak -

inspect
year • • • 2-25
Steering
Steering play - inspect year • • • • 2-25
Steering stem bearings - lubricate 2 years • 2-27
Electrical System
Spark plug condition - inspect • • • 2-27
Headlight aiming - inspect year • • • 2-27
Lights and switches operation - inspect year • • • 2-28
Others
Chassis parts - lubricate year • • • 2-30
Bolts and nuts tightness - inspect • • • • 2-32
#: Service more frequently when operating in severe conditions; dusty, wet, muddy, high speed or
frequent starting/stopping.
*: For higher odometer readings, repeat at the frequency interval established here.
Periodic Replacement Parts

comes × 1 000 km
Page
1 12 24 36 48
ITEM Every (0.6) (7.5) (15) (24) (30)
Fuel hose - replace 4 years • 2-33
Air cleaner element - replace # 2 years 2-33
Engine oil - change # year • • • • • 2-34
Oil filter - replace year • • • • • 2-35
Master cylinder/caliper rubber parts - replace 4 years • 2-35
Brake fluid - change 2 years • • 2-35
Brake hoses - replace 4 years • 2-36
#: Service more frequently when operating in severe conditions; dusty, wet, muddy, high speed or
frequent starting/stopping.
*: For higher odometer readings, repeat at the frequency interval established here.
Torque and Locking Agent
The following tables lists the tightening torque for the major fasteners requiring use of a
non-permanent locking agent or liquid gasket.
Letters used in the “Remarks” column mean:

AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque.
L : Apply non-permanent locking agent to the threads.
S : Tighten the fasteners following the specified sequence.
R : Replacement parts
Torque
Fastener Remarks
N·m kgf·m ft·lb
Engine Top End
Rocker Arm Shaft Stopper Screws 4.9 0.5 43 in·lb L
Valve Adjusting Screw Locknuts 8.8 0.9 78 in·lb
Camshaft Sprocket Bolt 12 1.2 104 in·lb L
Cylinder Head Nuts 22 2.2 16.0 S
Cylinder Head Bolts 12 1.2 104 in·lb L, S
Tensioner Mounting Bolts 8.8 0.9 78 in·lb L
Tensioner Cap Bolt 4.9 0.5 43 in·lb
Camshaft Sprocket Cover Bolts 8.8 0.9 78 in·lb
Camshaft Chain Guide Holder Bolts 8.8 0.9 78 in·lb
Valve Adjusting Cap Bolts 8.8 0.9 78 in·lb
Inlet Pipe Bolts 8.8 0.9 78 in·lb
Muffler Cover Screws 4.9 0.5 43 in·lb
Muffler Mounting Bolt 21 2.1 15
Exhaust Pipe Holder Nuts 21 2.1 15
Clutch
Clutch Cover Bolts 8.8 0.9 78 in·lb
Clutch Cover Damper Bolts 2.9 0.3 26 in·lb
Clutch Cover Oil Seal Screws 2.9 0.3 26 in·lb
Primary Clutch Hub Nut 77 7.9 57 R
Secondary Clutch Hub Bolt 49 5.0 36 R, L
Secondary Clutch Spring Bolts 8.8 0.9 78 in·lb
Clutch Adjusting Locknut 19 1.9 13.5
Engine Lubrication System
Oil Hose Banjo Bolts 25 2.5 18
Oil Pump Mounting Screws 4.9 0.5 43 in·lb
Oil Filter Cap Bolts 8.8 0.9 78 in·lb
Engine Oil Drain Plug 29 3.0 22
Engine Removal/Installation
Engine Mounting Nuts 44 4.5 23
Engine Bracket Nuts 25 2.5 18
Crankshaft/Transmission
Crankcase Bolts 8.8 0.9 78 in·lb S
Bearing Stopper Screw 5 mm 2.9 0.3 26 in·lb
Bearing Stopper Screw 6 mm 4.9 0.5 43 in·lb
Shift Return Spring Pin 34.3 3.5 25 L
Torque
Fastener Remarks
N·m kgf·m ft·lb
Shift Drum Allen Bolt 9.8 1.0 87 in·lb L
Shift Drum Position Bolt 19 1.9 14
Shift Drum Positioning Lever Screw 5.9 0.6 52 in·lb
Kick Lever Bolt 12 1.2 104 in·lb
Shift Pedal Clamp Bolt 12 1.2 104 in·lb
Cam Chain Guide Stopper Bolts 8.8 0.9 78 in·lb
Wheels/Tires
Spoke Nipples 1.5 ∼ 2.1 0.15 ∼ 0.21 13 ∼ 18 in·lb
Front Axle Nut 49 5.0 36
Rear Axle Nut 54 5.5 40
Final Drive
Rear Sprocket Nuts 34 3.5 25
Drive Chain Cover 4.9 0.5 43 in·lb
Brakes
Caliper Bleed Valve 7.8 0.80 69 in·lb
Brake Hose Banjo Bolts 25 2.5 18
Brake Lever Pivot Bolt 4.9 0.5 43 in·lb
Brake Lever Pivot Locknut 4.9 0.5 43 in·lb
Front Brake Reservoir Cap Screws 1.5 0.15 13 in·lb
Front Brake Light Switch Screw 1.0 0.1 9 in·lb
Front Master Cylinder Clamp Bolts 8.8 0.9 78 in·lb S
Caliper Mounting Bolts 25 2.5 18.0
Pad Pins 17 1.7 12.5
Brake Disc Mounting Bolts 23 2.3 17
Cam Lever Clamp Bolt 6.9 0.7 61 in·lb
Suspension
Front Fork Clamp Bolts 34 3.5 25 AL
Front Fork Bottom Allen Bolts 20 2.0 14.5 L
Swing Arm Pivot Shaft Nut 88 9.0 65
Rear Shock Absorber Mounting Bolts and Nut 34 3.5 25
Steering
Steering Stem Lock Nut 44 4.5 33
Handlepole Bracket Bolt 49 5.0 36
Steering Stem Nut 4.9 0.5 43 in·lb
Frame
Foot Peg Bracket Mounting Bolts 25 2.5 18
Foot Peg Bracket Mounting Bolts (Rear) 25 2.5 18
Side Stand Bracket Bolts 25 2.5 18
Drive Chain Cover 4.9 0.5 43 in·lb
Electrical System
Tail/Brake Light Screws 4.0 0.4 35 in·lb
Gear Position Switch Screws 2.9 0.3 26 in·lb
Turn Signal Light Screws (Front) 0.8 0.08 7 in·lb
Torque
Fastener Remarks
N·m kgf·m ft·lb
Spark Plug 13 1.3 113 in·lb
Electrical Starter Mounting Screw 4.9 0.5 43 in·lb
Starter Motor Terminal Screw 2.0 0.2 17 in·lb
Brush Holder Plate Screws 1.0 0.1 9 in·lb
Terminal Cover Plate Screws 2.0 0.2 17 in·lb
End Cover Screws 4.4 0.45 39 in·lb
Starter Motor Clutch Allen Bolts 12 1.2 104 in·lb R, L
Magneto Flywheel Bolt 49 5.0 36 R, L
Stator Coil Mounting Screws 4.9 0.5 43 in·lb
Crankshaft Sensor Mounting Screws 2.9 0.3 26 in·lb
Magneto Cover Bolts 8.8 0.9 78 in·lb
Timing Inspection Cap 2.4 0.25 21 in·lb
Magneto Center Plug 2.4 0.25 21 in·lb
Ignition Coil Bolts 2.9 0.3 26 in·lb
Regulator/Rectifier Mounting Nut 4.9 0.5 43 in·lb
The table below, relating tightening torque to thread diameter, lists the basic torque for the bolts and
nuts. Use this table for only the bolts and nuts which do not require a specific torque value. All of the
values are for use with dry solvent-cleaned threads.
Basic Torque for General Fasteners
Torque
Threads dia. (mm)
N·m kgf·m ft·lb
5 3.4 ∼ 4.9 0.35 ∼ 0.50 30 ∼ 43 in·lb
6 5.9 ∼ 7.8 0.60 ∼ 0.80 52 ∼ 69 in·lb
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 ∼ 23 125 ∼ 165
20 225 ∼ 325 23 ∼ 33 165 ∼ 240
Specifications
Item Standard Service Limit

Fuel System
Throttle Grip Free Play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) – – –
Idle Speed 1 250 ∼ 1 350 r/min (rpm)
Air Cleaner Element Oil:
Grade SE, SF or SG class
Viscosity SAE 30
Engine Top End
Valve Clearance:
Exhaust 0.04 ∼ 0.08 (0.0016 ∼ 0.0031 in.) – – –
Inlet 0.04 ∼ 0.08 (0.0016 ∼ 0.0031 in.) – – –
Clutch
Clutch Release 1/4 turn out
Engine Oil:
Type API SE, SF or SG
Viscosity SAE 10W-40
Capacity 0.90 L (0.95 US qt, when filter is not removed)
0.96 L (1.01 US qt, when filter is removed)
1.10 L (1.16 US qt, when engine is completely
dry)
Level Between upper and lower level lines
(Wait several minutes after idling or running)
Tires
Tread Depth:
Indonesia, Philippine:
Front 3.9 mm (0.15 in.) 1 mm (0.04 in.)
Rear 4.9 mm (0.19 in.) 2 mm (0.08 in.)
Thailand:
Front 4.0 mm (0.16 in.) 1 mm (0.04 in.)
Rear 5.1 mm (0.20 in.) 2 mm (0.08 in.)
Air pressure: (when cold)
Front 200 kPa (2.00 kg/cm², 29 psi) – – –
Rear 225 kPa (2.25 kg/cm², 32 psi) – – –
Final Drive
Drive Chain Slack 20 ∼ 35 mm (0.79 ∼ 1.38 in.) – – –
20 Link Length ––– 259 mm (10.2 in.)
Brakes
Brake Lever Free Play Non-adjustable – – –
Brake Pedal Free Play 20 ∼ 30 mm (0.79 ∼ 1.18 in.) – – –
Shoe Lining Thickness 3.85 ∼ 4.15 mm (0.152 ∼ 0.163 in.) 2 mm (0.079 in.)
Brake Fluid:
Grade DOT3 or DOT4 – – –
Specifications

Brake Pad Lining thickness:
Front 5 mm (0.2 in.) 1 mm (0.04 in.)
Brake Light Timing:
Front Pulled ON – – –
Rear ON after about 15 mm (0.59 in.) of pedal travel – – –
Electrical System
Spark Plug Gap 0.6 ∼ 0.7 mm (0.024 ∼ 0.028 in.) – – –
Special Tools
Valve Adjusting Screw Holder: Socket Wrench:
57001-1217 57001-1643
Periodic Maintenance Procedures
Fuel System
Throttle Cable Inspection
Throttle Grip Free Play Inspection
•Check the throttle grip free play [A].
If the free play is incorrect, adjust the throttle cable (see
below).
Throttle Grip Free Play
Standard: 2 ∼ 3 mm (0.08 ∼ 0.12 in.)
• Check that the throttle grip moves smoothly from close to

full open, and the throttle closes quickly and completely
in all steering positions by the return spring.
If the throttle grip doesn’t return properly, check the throt-
tle cable routing, grip free play, and cable damage. Then
lubricate the throttle cable.
• Run the engine at the idle speed, and turn the handlebar
all the way to the right and left to ensure that the idle speed
doesn’t change.
If the idle speed increases, check the throttle grip free play
and the cable routing.
Throttle Grip Free Play Adjustment
If necessary, adjust the throttle cable as follows:
○Loosen the locknut [A].
○Turn the adjuster [B] until the proper amount of throttle
grip free play is obtained.
○Tighten the locknut securely.

•Remove both ends of the throttle cables.
•With the throttle cable disconnected at both ends, the ca-
ble should move freely [A] within the cable housing.
○If cable movement is not free after lubricating, if the cable
is frayed [B], or if the cable housing is kinked [C], replace
the cable.
Choke Operation Inspection

• Check that the choke lever returns properly and that the
inner cable slides smoothly.
If the inner cable does not slides smoothly, inspect the
choke cable routing, free play, cable damage and choke
plunger damage.
○Check the choke cable free play [A].
○Push the choke lever [B] back all the way to its released
position.
○Determine the amount of choke cable play at the left
switch housing. Pull out and push in the cable housing
[C], the amount of cable travel is the amount of cable
play.
Choke Cable Free Play
Standard: 2 ∼ 3 mm (0.08 ∼ 0.12 in.)
If the free play is in correct, replace the cable.
Idle Speed Inspection
• Start the engine and warm it up thoroughly.
• Turn
gine.
the handlebar from side to side while idling the en-
If handlebar movement changes the idle speed, the throt-

tle cable may be improperly adjusted or incorrectly routed,
or it may be damaged. Be sure to correct any of these
conditions before riding (see Cable, Harness, Hose Rout-
ing in the Appendix chapter).
WARNING
Operation with an improperly adjusted, incorrectly
routed, or damaged cable could result in an unsafe
riding condition.
• Check idle speed.

Idle Speed
Standard: 1 250 ∼ 1 350 r/min (rpm)
If the idle speed is out of the specified range, adjust it.

○Start the engine and warm it up thoroughly.
○Turn the idle adjusting screw [A] to obtain desired idle
speed. If no idle is preferred, turn out the screw until the
engine stops.
○Open and close the throttle a few times to make sure that
the idle speed is as desired. Readjust if necessary.
Air Cleaner Element Cleaning
NOTE
○In dusty areas, the element should be cleaned more
frequently than the recommended interval.
○After riding through rain or on muddy roads, the element
should be cleaned immediately.
○Since repeated cleaning opens the pores of the ele-
ment, replace it with a new one in accordance with the
Periodic Maintenance Chart. Also, if there is a break in
the element material or any other damage to the ele-
ment, replace the element with a new one.
WARNING
Clean the element in a well-ventilated area, and
make sure that there is no spark or flame near the
working area. Because of the danger or highly
flammable liquids, do not use gasoline or low flash
point solvents to clean the element.
• Remove the air cleaner element.

• and then dry
Clean the element in a bath of a high-flash point solvent,
it with compressed air or by shaking it.
• SG class SAE30saturate
After cleaning, the element [A] with SE, SF, or
oil, squeeze out [B] the excess oil.
• Wrap the element with a clean lint-free cotton towel [C]
and compress it [D] several times by hand.
Oil volume soaked in the oil cleaner element: 5 ±2 g (0.176
±0.071 oz.)
• Visually check the element for tears or breaks.
If the element has any tears or breaks, replace the ele-
ment.
Fuel Hose Installation Condition Inspection
○If the motorcycle is not properly handled, the inside the
fuel line can cause fuel to leak [A] or the hose to burst.
Remove the left leg shield inner cover (see Frame chap-
ter) and check the fuel hose.
Replace the fuel hose if any fraying, cracks [B], bulges
[C], ozonic cracks [D] are noticed.
• Check that the hoses [A] are securely connected and

clamps [B] are tightened correctly.
Engine Top
Valve Clearance Inspection
CAUTION
If valve clearance is left unadjusted, the wear will
eventually cause the valves to remain partly open,
which lowers performance, burns the valves and
the valve seats, and may cause serious engine dam-
age.
NOTE
○Valve clearance must be checked when the engine is
cold (at room temperature).
• Remove:
Left Leg Shield (see Right and Left Leg Shields Removal
in the Frame chapter)
Spark Plug (see Spark Plug Replacement)
Camshaft Sprocket Cover [A]
Valve Adjusting Caps [B]
• Turn the camshaft sprocket counterclockwise [A] and

align the line [B] on the camshaft sprocket with the pro-
jection [C] on the mating surface of the cylinder head.
• Measure the clearance of each valve by inserting a thick-

ness gauge [A] between the adjusting screw and the valve
stem.
Valve Clearance (when engine cold)
Standard:
Inlet 0.04 ∼ 0.08 mm (0.0016 ∼ 0.0031 in.)
Exhaust 0.04 ∼ 0.08 mm (0.0016 ∼ 0.0031 in.)
If a valve clearance is incorrect, adjust it.
○Use a valve adjusting screw holder [A] to holding the valve
adjusting screw [B], loosen the adjusting screw locknut
[C] and insert the 0.05 thickness gauge [D] between valve
and adjusting screw and turn the adjusting screw until the
adjusting screw stops.
○Remove the thickness gauge.
Special Tools - Valve Adjusting Screw Holder: 57001-1217
○Tighten:
Torque - Valve Adjusting Screw Locknut: 8.8 N·m (0.90
kgf·m, 78 in·lb)
Clutch
Operation Inspection
• Loosen the adjusting screw locknut [A].
• comes hard
Turn the adjusting screw [B] counterclockwise until it be-
to turn, and then back it out a quarter turn.
• Tighten
position.
the locknut without changing the adjusting screw
• Start the engine and inspect the conditions of engine shift-

ing the pedal a few times.
Torque - Adjusting Screw Locknut: 19 N·m (1.9 kgf·m, 13.5
ft·lb)
Wheels/Tires
Spoke Tightness Inspection (AN130-A1/B1, B6F
Models)
• Check that all the spokes are tightened evenly.
Standard spoke tightening torque is shown below. Over-
or under-tightening may cause breakage.
Torque - Spokes: 1.5 ∼ 2.1 N·m (0.15 ∼ 0.21 kgf·m, 13 ∼ 18
in·lb)
• Check the rim runout.
WARNING
If any spoke breaks, it should be replaced immedi-
ately. A missing spoke places an additional load on
the other spokes, which will eventually cause other
spokes to break.
Rim Runout Inspection (AN130-A1/B1, B6F Models)
• Raise the front/rear wheel off the ground.
• Remove the wheel, and support it with the tire by the axle.
• ing.
Inspect the rim for small cracks, dents, bending, or warp-
If there is any damage to the rim, it must be replaced.

• Set a dial gauge against the side of the rim, and rotate
the rim to measure axial runout [A]. The difference be-
tween the highest and lowest dial readings is the amount
of runout.
• Set a dial gauge to the outer circumference of the rim,
and rotate the rim to measure radial runout [B]. The dif-
ference between the highest and lowest dial readings is
the amount of runout.
• If rim runout exceeds the service limit, check the hub bear-
ing first. Replace them if they are damaged. If the prob-
lem is not to the bearings, correct the rim warp (runout).
A certain amount of rim warp can be corrected by recen-
tering the rim. Loosen some spokes and tighten others
within the standard torque to change the position of dif-
ferent parts of the rim. If the rim is badly bent, however, it
should be replaced.
Rim Runout (with tire installed)
Standard:
Axial 0.8 mm (0.03 in.) or less
Radial 1.0 mm (0.04 in.) or less
Service Limit:
Axial 2.0 mm (0.08 in.)
Radial 2.0 mm (0.08 in.)
Tire Air Pressure Inspection

• Remove the air valve cap.
• Measure the tire air pressure with an air pressure gauge
[A] when the tires are cold (that is, when the motorcycle
has not been ridden more than a mile during the past 3
hours).
• Install the air valve cap.
Adjust the tire air pressure according to the specifications
if necessary.
Air Pressure (when Cold)
Front: 200 kPa (2.00 kgf/cm², 29 psi)
Rear: 225 kPa (2.25 kgf/cm², 32 psi)
Wheel/Tire Damage Inspection
• Remove any imbedded stones [A] or other foreign parti-
cles [B] from tread.
• Visually inspect the tire for cracks and cuts, and replace
the tire if necessary. Swelling or high spots indicate inter-
nal damage, requiring tire replacement.
• Visually inspect the wheel for cracks, cuts and dents dam-
age.
If any damage is found, replace the wheel if necessary.
Tire Tread Wear, Abnormal Wear Inspection

As the tire tread wears down, the tire becomes more sus-
ceptible to puncture and failure. An accepted estimate is
that 90% of all tire failures occur during the last 10% of tread
life (90% worn). So it is false economy and unsafe to use
the tires until they are bald.
• Measure the tread depth at the center of the tread with a
depth gauge [A]. Since the tire may wear unevenly, take
measurement at several places.
If any measurement is less than the service limit, replace
the tire (see Tire Removal/Installation in the Wheels/Tires
chapter).
Tread Depth
Indonesia Thailand
Philippine
Standard:
Front 3.9 mm (0.15 in.) 4.0 mm (0.16 in.)
Rear 4.6 mm (0.18 in.) 5.1 mm (0.20 in.)
Service Limit:
Front 1 mm (0.04 in.)
Rear 2 mm (0.08 in.)
WARNING
To ensure safe handling and stability, use only the
recommended standard tires for replacement, in-
flated to the standard pressure.
Wheel Bearing Damage Inspection

• Raise the front wheel off the ground.
• Inspect thehandlebar
Turn the all the way to the right or left.
• ing and pulling [A] the ofwheel.
roughness the front wheel bearing by push-
• Spin [B] the front wheel lightly, and check for smoothly
turn, roughness, binding or noise.
If roughness, binding or noise is found, remove the front
wheel and inspect the wheel bearing (see Bearing Inspec-
tion in the Wheels/Tires chapter).
• Raise the rear wheel off the ground.

• ing and the
Inspect roughness of the rear wheel bearing by push-
pulling [A] the wheel.
• turn, roughness,
Spin [B] the rear wheel lightly, and check for smoothly
binding or noise.
If roughness, binding or noise is found, remove the rear
wheel and inspect the wheel bearing (see Bearing Inspec-
tion in the Wheels/Tires chapter) and coupling (see Cou-
pling Bearing Inspection in the Final Drive chapter).
Drive
Drive Chain Slack Inspection
• Check to see that the notches [A] on the alignment indi-
cators on both sides are in the same relative position at
the rear end [B] of the hole in each swingarm.
If they are not, adjust the chain slack and align them.
WARNING
Misalignment of the wheel will result in abnormal
wear and may result in an unsafe riding condition.
NOTE
○Clean the chain if it is dirty, and lubricate it if it appears
dry.
•○Set the motorcycle up on its center stand.

Rotate the rear wheel to find the position where the chain
is tightest.
○Measure the vertical movement (chain slack) [A] midway
between the sprockets.
If the chain slack exceeds the standard, adjust it.
Chain Slack
Standard: 20 ∼ 35 mm (0.8 ∼ 1.4 in.)
Drive Chain Slack Adjustment
• Remove the cotter pin [A] from the rear axle nut.
• Loosen:
Rear Axle Nut [B]
Adjusting Nut [C]
Both Chain Adjuster Locknuts [D]
• Turn both chain adjusters [E] evenly until the drive chain
has the correct amount of slack.
• Check to see that notches on the alignment indicators are
in the same relative position on both sides.
WARNING
wear and may result in an unsafe riding condition.
Torque - Rear Axle Nut: 54 N·m (5.5 kgf·m, 40 ft·lb)
WARNING
If the axle nut is not securely tightened, an unsafe
riding condition may result.
• Turn the wheel, measure the chain slack again at the tight-
est position, and readjust if necessary.
• Adjust the brake pedal free play.
• Insert a new cotter pin [A].
NOTE
○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 [B] up to next alignment.
○It should be within 30 degree.
○Loosen once and tighten again when the slot goes past
the nearest hole.
• Bend the cotter pin [A] over the nut [B].

• Check the rear brake effectiveness.
WARNING
If the axle nut is not securely tightened and the cot-
ter pin and snap pin are not installed, an unsafe rid-
ing condition may result.
• Tighten the chain adjuster locknuts.

Drive Chain Wear Inspection
• Remove the chain cover.
• Rotate the rear wheel to inspect the drive chain for dam-
aged rollers, and loose pins and links.
If there is any irregularity, replace the drive chain.
Lubricate the drive chain if it appears dry.
• Stretch the chain taut by hanging a 98 N (10 kg, 20 lb)
weight [A] on the chain.
• Measure the length of 20 links [B] on the straight part [C] of
the chain from the pin center of the 1st pin to the pin center
of the 21st pin. Since the chain may wear unevenly, take
measurements at several places.
If any measurements exceed the service limit, replace the
chain. Also, replace the front and rear sprockets when the
drive chain is replaced.
Chain 20-link Length
Service Limit: 259 mm (10.2 in.)
WARNING
If the drive chain wear exceeds the service limit, re-
place the chain or an unsafe riding condition may
result. A chain that brakes or jumps off the sprock-
ets could snag on the engine sprocket or lock the
rear wheel, severely damaging the motorcycle and
causing it to go out of control. For safety, use only
the standard chain.
Standard Chain
Make: KMC
Type: 420DX
Link: 108 Links
Chain Guide Wear Inspection

• Visually inspect the chain guide [A].
Replace the chain guide if it shows any signs of abnormal
wear or damage.
Drive Chain Lubrication
• The chain should be lubricated with a lubricant which will
both prevent the exterior from rusting and also absorb
shock and reduce friction in the interior of the chain.
If the chain is especially dirty, it should be washed in
diesel oil or kerosene, and afterward soaked in a heavy
oil. Shake the chain while it is in the oil so that oil will pen-
etrate to the inside of each roller.
• An effective, good quality lubricant specially formulated
for chains is best for regular chain lubrication.
If a special lubricant is not available, a heavy oil such as
SAE 90 is preferred to a lighter oil because it will stay on
the chain longer and provide better lubrication.
• Apply oil to the sides of the rollers so that oil will penetrate
to the rollers and bushings.
• Wipe off any excess oil.
Oil Applied Areas [A]
Brakes
Brake Pad Wear Inspection
• Remove
chapter).
the pads (see Brake Pad Removal in the Brakes
• Check the lining thickness [A] of the pads in caliper.

If the lining thickness of either pad is less than the service
limit [B], replace both pads in the caliper as a set.
Brake pad [C]
Brake Pad Thickness
Standard: 6.0 mm (0.236 in.)
Service Limit: 1 mm (0.04 in.)
• Install the pads and pad pins (see Brake Pad Installation
in the Brakes chapter).
• Tighten:
Torque - Pad Pins: 17 N·m (1.7 kgf·m, 12.5 ft·lb)
Brake Fluid Leak (Brake Hose and Pipe) Inspection

• Apply the brake lever or pedal and inspect the brake fluid
leak from the brake hoses [A] and fittings [B].
If the brake fluid leaked from any position, inspect or re-
place the problem part.
Brake Fluid Level Inspection
• Check that the brake fluid level [A] in the front brake reser-
voir is above the lower gauge end.
NOTE
○Hold the reservoir horizontal by turning the handlebar
when checking brake fluid level.
If the fluid level is lower than the lower level line, remove
the reservoir cap [A] and fill the brake fluid to the upper
level line [B] in the reservoir.
WARNING
Do not mix two brands of fluid. Change the brake
fluid in the brake line completely if the brake fluid
must be refilled but the type and brand of the brake
fluid that is already in the reservoir are unidentified.
After changing the fluid, use only the same type and
brand of fluid thereafter.
Recommended Disc Brake Fluid

Grade: DOT3 or DOT4
Brake Hose Damage and Installation Condition

Inspection
• Inspect the brake hose and
cracks and signs of leakage.
fittings for deterioration,
○The high pressure inside the brake line can cause fluid to
leak [A] or the hose to burst if the line is not properly main-
tained. Bend and twist the rubber hose while examining
it.
Replace the hose if any cracks [B] or bulges [C] are no-
ticed.
Tighten any loose fittings.
Torque - Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18
ft·lb)
• Inspect the brake hose routing.
If any brake hose routing is incorrect, route the brake hose
according to Cable, Wire, and Hose Routing section in the
Appendix chapter.
Brake Operation Inspection
• Check the brake pedal free play [A] when the pedal is
pushed down lightly by hand.
Brake Pedal Free Play
Standard: 20 ∼ 30 mm (0.79 in. ∼ 1.18 in.)
• Inspect the operation of the front and rear brake by run-

ning the vehicle on the dry road.
If the brake operation is insufficiency, inspect the brake
system.
WARNING
When inspecting by running the vehicle, note a
surrounding traffic situation enough in the place of
safety.
If the pedal has improper play, adjust it.

○Turn the adjusting nut [A] at the brake cam lever so that
the lever has proper play.
• Operate the pedal a few times to see that it returns to its
rest position immediately upon release.
• Rotate the rear wheel to check for brake drag.
• Check braking effectiveness.
If there is any doubt as to the conditions of the brake,
check the brake parts for wear or damage.
Brake Shoe Lining Wear Inspection

• Check whether the brake lining wear indicator [A] points
within the USABLE RANGE [B] when the brakes are firmly
applied, or remove the brake shoes and inspect the lining
thickness at few locations.
If the lining thickness is out of the range, or beyond the
service limit, replace the brake shoes as a set and inspect
other brake parts.
If the lining thickness is greater than the service limit, do
the following before installing the shoes.
○File or sand down any high spots on the surface of the
lining.
○Use a wire brush to remove any foreign particles from the
lining. Use a wire brush to remove any foreign particles
from the lining.
Brake Shoe Lining Thickness [A]

Standard: 3.85 ∼ 4.15 mm (0.152 ∼ 0.163 in.)
(When the wear indicator is within the
USABLE RANGE.)
Service limit: 2 mm (0.079 in.)
(When the wear indicator is out of the
USABLE RANGE.)
• Wash off any oil or grease with an oilless cleaning fluid

such as trichloroethylene or acetone.
WARNING
These cleaning fluids are usually highly flammable
and harmful if breathed for prolonged periods. Be
sure to heed the fluid manufacturer’s warnings.
• Install the brake panel (see Brake Panel Installation in the

Brake chapter).
Brake Light Switch Operation Inspection
Front Brake Light Switch Inspection
• Turn on the ignition switch.
• The brake light should go on [A] when the front brake lever
is applied.
If it does not, replace the switch.
Rear Brake Light Switch Inspection/Adjustment

•Turn on the ignition switch.
•Check the operation of the rear brake light switch by de-
pressing the brake pedal [A]. The brake light should go
on after about 15 mm (0.59 in.) of the pedal travel [B].
If it does not, adjust the brake light switch.

• Remove the right side cover.
• Turn the adjusting nut [B] to adjust the switch [A].
[C] Lights sooner
[D] Lights later
CAUTION
To avoid damaging the electrical connections in-
side the switch, be sure that the switch body does
not turn during adjustment.
Suspension
Front Forks/Rear Shock Absorber Operation
Inspection
• Pump the forks down and up [A] 4 or 5 times, and inspect
the smooth stroke.
If the forks do not smoothly or noise is found, inspect the
fork oil level or fork clamps (see Front Fork Oil Change in
the Suspension chapter).
• Pump the seat down and up [A] 4 or 5 times, and inspect

the smooth stroke.
If the shock absorber does not smoothly stroke or noise is
found, inspect the oil leak or shock absorber clamps (see
Rear Shock Absorber Oil Leak Inspection in this chapter).
Front Fork Oil Leak Inspection

• Visually inspect the front forks [A] for oil leakage, scoring
or scratches on the outer surface of the inner tubes.
Replace or repair any defective parts, if necessary.
Rear Shock Absorber Oil Leak Inspection

• Visually inspect the shock absorbers [A] for oil leakage.
If they are oil leaked, one unit feels weaker than the other,
replace both shock absorber as a set.
Steering
Steering Play Inspection
Steering Inspection
If the steering is too tight, it will be difficult to turn the han-
dlebar quickly, the motorcycle may pull to one side, and the
steering stem bearings may become damaged. If the steer-
ing is to loose, the handlebar will vibrate and the motorcycle
will be unstable and difficult to steer in a straight line.

• tap each front
With the wheel pointing straight ahead, alternately
end of the handlebar. The front wheel should
swing fully left and right from the force of gravity until the
fork hits the stop.
If the wheel binds or catches before the stop, the steering
is too tight.
• Feel for steering looseness by pushing and pulling the
forks.
If you feel looseness, the steering is too loose.
NOTE
○The cables and wring will have some effect on the mo-
tion of the fork which must be takes into account.
○Be sure the wires and cables are properly routed.
○The bearings must be in good condition and properly
lubricated in order for any test to be valid.
Steering Adjustment
• Remove:
Front Step Through Cover (see Front Step Cover Re-
moval in the Frame chapter)
Right Leg Shield Inner and Outer (see Right Leg Shield
Inner/Outer Removal in the Frame chapter)
Speedometer Cable of the Wheel Side
Handle Pole Bracket Bolt
• Upwardly the handlebar with all fitting parts.
• Remove the steering stem locknut.
○Using the box wrench and hook wrench.
Tool - Hook Wrench: 92110-1183
• Loosen the steering stem locknut [A].
Special Tool - Steering Stem Nut Wrench: 57001-1643 [B]
• Adjust the steering.
If the steering is too tight, loosen the stem nut a fraction
of a turn.
If the steering is too loose, tighten the stem nut a fraction
of a turn.
NOTE
○Turn the stem nut 1/8 turn at a time maximum.
○If the stem nut turns off too far, the bearing balls in the
steering stem may fall out of place. This will necessitate
steering stem removal and installation.
• Turn the stem nut [A] lightly clockwise until it just becomes
hard to turn. Do not overtighten, or the steering will be too
tight.
Torque - Steering Stem Nut: 4.9 N·m (0.50 kgf·m, 43 in·lb)
Special Tool - Steering Stem Nut Wrench: 57001-1643 [B]
•○Tighten:
Using the box wrench [A] and hook wrench [B].
Torque - Steering Stem Locknut: 44 N·m (4.5 kgf·m, 33 ft·lb)
Tool - Hook Wrench: 92110-1183 [B]
• Check the steering again.
If the steering is still too tight or too loose, repeat the ad-
justment. If the proper condition cannot be obtained in
spite of correct adjustment, inspect the steering parts.
• Installation is the revers order of removal.
Steering Stem Bearing Lubrication
• Remove the steering stem (see Steering chapter).
• Wipe the old grease off the races and balls, washing them
in a high-flash point solvent if necessary.
Replace the bearing part if they show wear or damage.
• Apply grease liberally to the upper and lower races, and
stick the bearing balls [A] in place with grease.
• Install the steering stem (see Steering chapter).
• Adjust the steering.
Electrical System
Spark Plug Condition - Inspection
Spark Plug Cleaning/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 tool.
If the spark plug center electrode [A] and/or side electrode
[B] are corrected or damaged, or if the insulator [C] is
cracked, replace the plug.
•Use the standard spark plug or its equivalent.
•Measure the gap [D] with a wire-type thickness gauge.
If the gap is incorrect, carefully bend the side electrode
with a tool to obtain the correct gap.
Spark Plug Gap: 0.6 ∼ 0.7 mm (0.024 ∼ 0.028 in.)
Spark Plug Removal/Installation

• Remove the plug cap.
• Remove or install the spark plug using the spark plug
wrench [A].
Special Tool - Spark Plug Wrench, Hex 16: 57001-1262
Torque - Spark Plug: 13 N·m (1.3 kgf·m, 9.5 ft·lb)
• Fit the plug cap securely.
• stallation
Pull up the shark plug cap lightly to make sure of the in-
of the spark plug cap.
Headlight Aiming Inspection
The headlight beam is adjustable vertically. If adjusted
too low, nor high beam will illuminate the road far enough
ahead. If adjusted too high, the high beam will fail to illu-
minate the road close ahead, and the low beam will dazzle
oncoming drivers.
• Inspect the headlight beam for aiming.
• Open the lid cover.
• Peel the boot [A].
• Loosen the screw [B] to adjust the headlight vertically.
• Move the headlight body up or down.
• After adjusting the headlight beam, make sure to put the
boot back in its place.
NOTE
○On high beam, the brightest point should be slightly be-
low horizontal with the motorcycle on its wheels and the
rider seated. Adjust the headlight to the proper angle
according to local regulations.
Headlight Beam [A]
Light and Switches Operation Inspection

First Step
• Turn on the ignition switch and start the engine.
• The following lights should go on according to below ta-
bles.
Thailand Models
Headlights [A] goes on
Taillight [B] goes on
Neutral Indicator Light [C] goes on
Indonesia, Philippine Models

Neutral Indicator Light goes on
• Push the headlight switch [A] to P position [B].

City Light [D] goes on
Taillight goes on
• Push the headlight switch to ON position [C].

Headlights goes on
If the light does not go on, inspect or replace the following
item.
Headlight Switch (Indonesia, Philippine Models, see
Switch Inspection in the Electrical System chapter)
Battery (see Charging Condition in the Electrical System
chapter)
Applicable Bulb (see Wiring Diagram in the Electrical
System chapter)
Meter Unit for Neutral Indicator Light (see Indicator Bulb
Replacement and Wiring Diagram in the Electrical Sys-
tem chapter)
Fuse 10 A (see Fuse Inspection in the Electrical System
chapter)
Ignition Switch (see Switch Inspection in the Electrical
System chapter)
Gear Position Switch (see Gear Position Switch Inspec-
tion in the Electrical System chapter)
Magneto (see Magneto Inspection in the Electrical Sys-
tem chapter)
Harness (see Wiring Inspection in the Electrical System
chapter)
• Turn off the ignition switch
• The all light should go off.
If the light does not go off, replace the ignition switch.
Second Step
•Set the dimmer switch [A] to low position.
•Star the engine.
•The low beam headlights should go on.
If the low beam headlight does not go on, inspect or re-
place the following items.
Headlight Bulb (see Headlight Bulb Replacement in the
Electrical System chapter)
Dimmer Switch (see Switch Inspection in the Electrical
System chapter)
Harness (see Wiring Inspection in the Electrical System
chapter)
• Set the dimmer switch to high beam position.

• [A] should
The high beam headlights and high beam indicator light
go on.
If the high beam headlight and/or high beam indicator light
does not go on, inspect or replace the following item.
Headlight High Beam Bulb (see Headlight Bulb/Indicator
Bulb Replacement in the Electrical System chapter)
Dimmer Switch (see Switch Inspection in the Electrical
System chapter)
• Turn off the ignition switch.
• The headlights and high beam indicator light should go
off.
Third Step
•Turn on the ignition switch.
•Turn on the turn signal switch [A] (left or right position).
•The left or right turn signal lights [B] (from and rear) ac-
cording to the switch position should flash.
•The turn signal indicator light [C] in the meter unit should
flash.
If the each light does not flash, inspect or replace the
following item.
Turn Signal Light Bulb (see Turn Signal Bulb Replace-
ment in the Electrical System chapter)
Meter Unit for Turn Signal Indicator Light (see Indicator
Bulb Replacement in the Electrical System chapter)
Turn Signal Switch (see Switch Inspection in the Electri-
cal System chapter)
Turn Signal Relay (see Turn Signal Relay Inspection in
the Electrical System chapter)
Harness (see Harness Inspection in the Electrical Sys-
tem chapter)
•Push the turn signal switch.
•The turn signal lights and indicator light should go off.
If the light does not go off, inspect or replace the hollowing
item.
Turn Signal Switch
Turn Signal Relay
Others
Chassis Parts Lubrication
• Before lubricating each part, clean off any rusty spots with
rust remover and wipe off any grease, oil, dirt, or grime.
• Lubricate the points listed below with indicated lubricant.
NOTE
○Whenever the vehicle has been operated under
wet or rainy conditions or especially after using a
high-pressure water spray, perform the general lubri-
cation.
Chain: Lubricate with Heavy Oil.
Pivots: Lubricate with Motor Oil.
Brake Rod Joint
Rear Footpegs
Points: Lubricate with Grease [A].
Choke Cable Lower End
Throttle Cable Upper End
Speedometer Gear Housing and Inner Cable Lower End
Side Stand
Center Stand
Brake Lever Pivot (Apply silicon grease)
Brake Pedal
Kick Pedal
Cables: Lubricate with Cable Lubricant.

Choke Cable
Throttle Cable
Front Brake Cable
•Lubricate the cables by seeping the oil between the cable
and housing.
○The cable may be lubricated by using a commercially
available pressure cable lubricator with an aerosol cable
lubricant.
• With the cable disconnected at the both ends, the cable

should move freely [A] within the cable housing.
If cable movement is not free after lubricating, if the cable
is frayed [B], or if the cable housing is kinked [C], replace
the cable.
Bolt, Nut, and Fastener Tightness Inspection
• Check the tightness of bolts and nuts listed here. Also,
check to see that each cotter pin is in place and in good
condition.
NOTE
○For the engine fasteners, check the tightness of them
when the engine is cold (at room temperature).
If there are loose fasteners, retorque them to the spec-
ified torque following the specified tightening sequence.
Refer to the appropriate chapter for torque specifications.
If torque specifications are not in the appropriate chapter,
see the Standard Torque Table. For each fastener, first
loosen it by 1/2 turn, then tighten it.
If cotter pins are damaged, replace them with new ones.
Bolt, Nut and Fastener to be checked
Wheels:
Spoke Nipples
Front Axle Nut Cotter Pin
Front Axle Nut
Rear Axle Nut Cotter Pin
Rear Axle Nut
Final Drive:
Chain Adjuster Locknuts
Rear Sprocket Nuts
Brakes:
Rear Brake Adjust Nut
Brake Lever Pivot Nut
Brake Pedal Bolt
Brake Rod Joint Cotter Pin
Suspension:
Front Fork Clamp Bolts
Swingarm Pivot Shaft Nut
Rear Shock Absorber Mounting Bolts
Steering:
Stem Nut
Handlepole Bracket Bolt
Engine:
Engine Mounting Bolts, Nuts
Cylinder Head Bolts and Nuts
Shift Pedal Bolts
Exhaust Pipe Holder Nuts
Muffler Bolt and Nut
Others:
Side Stand Bolt
Footpeg Mounting Bolts
Center stand Cotter Pin
Replacement Parts
Fuel Hose Replacement
• Remove:
Right and left Leg shield Inner Cover (see Frame chap-
ter)
Fuel (drain)
Air Cleaner Housing [A] (see Fuel System chapter)
Vacuum Hose [B]
Clamps [C]
Fuel Hoses [D]
• Fit the fuel hoses [A] onto the fitting fully and install the
hose clamp [B] beyond the raised rib [C]. Do not tach the
claw portion of clamp to other part.
• When installing, route the hoses according to Cable,

Wire, and Hose Routing section in the Appendix chapter.
• When installing the fuel hoses, avoid sharp bending, kink-
ing, flattening or twisting, and route the fuel hoses with a
minimum of bending so that the fuel flow will not be ob-
structed.
Replace the hose if it has been sharply bent or kinked.
Air Cleaner Element Replacement
• Remove:
Front Fender Rear (see Front Fender Rear Removal in
the Frame chapter)
Air Cleaner Housing Screws [A]
• Remove:
Element Mounting Screw [A]
Element [B]
• After removing the air cleaner, cover the carburetor with

pieces of lint-free, clean cloth to keep dirt out of the engine
and carburetor.
WARNING
If dirt or dust is allowed to pass through into the car-
buretor, the throttle valve may become stuck, pos-
sibly causing an accident.
CAUTION
If dirt gets through into the engine, excessive en-
gine wear and possibly engine damage will occur.
• Install the holder [A].

• Install the wire
Install the element [B].
• Install the otherscreen [C] and tighten it.
• removed parts.
Engine Oil Change

• Support the motorcycle perpendicular to the ground.
• any sediment
Warm up the engine thoroughly so that the oil will pick up
and drain easily. Then stop the engine.
• Remove the engine
Place an oil pan beneath the engine.
•○The oil in the oil filter oilcandrain plug [A] to drain the oil.
be drained by removing the filter.
• After the oil has completely drained, install the drain plug
with its gasket.
Replace the drain plug gasket with a new one if it is dam-
aged.
• Tighten:
Torque - Engine Oil Drain Plug: 29 N·m (3.0 kgf·m, 22 ft·lb)
• Pour in the specified type and amount of oil.
Recommended Engine Oil:
Grade: API SE, SF or SG
Viscosity: SAE10W-40
Capacity: 0.90 L (0.95 US qt, when filter is not
removed)
0.96 L (1.01 US qt, when filter is removed)
1.10 L (1.16 US qt, When engine is
completely dry)
NOTE
○Depending on the atmospheric temperature of your rid-
ing area, the engine oil viscosity should be changed ac-
cording to the chart:
Oil Filter Replacement

• Drain the engine oil.
• Remove the oil filter cap bolts [A] and oil filter cap [B].
• Replace the filter element [A] with a new one.

• Set the spring [B] into the oil filter cap.
NOTE
○Install the filter element so that the bypass valve side
outward.
• Apply grease [C] to the O-ring [D].

• Fit the O-ring onto the oil filter cap [E].
• [F] Crankcase
Install the oil filter cap.
Side
Torque - Oil Filter Cap Bolts: 8.8 N·m (0.9 kgf·m, 78 in·lb)
Brake/Master Cylinder/Caliper Rubber Parts

Replacement
• Refer to the Master Cylinder Inspection in the Brakes
chapter.
• Refer to the Caliper Fluid Seal Damage in the Brakes
chapter.
• Refer to the Caliper Dust Cover/Rubber Boot Damage in
the Brakes chapter.
Brake Fluid Change
• Level the brake fluid reservoir.
• Remove the
Remove reservoir cap.
• caliper. rubber cap from the bleed valve [A] on the
the
• Attach a clear plastic hose [B] to the bleed valve, and run
the other end of the hose into a container.
• Fill the reservoir with fresh specified brake fluid.
• Change the brake fluid as follows:
NOTE
○The fluid level must be checked often during the chang-
ing operation and replenished with fresh brake fluid. If
the fluid in the reservoir runs out any time during the
changing operation, the brakes will need to be bled
since air will have entered the brake line.
○Repeat this operation until fresh brake fluid comes out
from the plastic hose or the color of the fluid changes.
Open the bleed valve [A].
Pump the brake lever and hold it [B].
Close the bleed valve [C].
Release the brake lever [D].
• Remove the clear plastic hose.

• Tighten the bleed valve, and install the rubber cap.
Torque - Caliper Bleed Valve: 7.8 N·m (0.8 kgf·m, 69 in·lb)
Front Reservoir Cap Screws: 1.5 N·m (0.15 kgf·m,
13 in·lb)
• After changing the fluid, check the brake for good braking
power, no brake drag, and no fluid leakage.
If necessary, bleed the air from the lines (see Bleeding
the Brake Line in the Brakes chapter).
Brake Hose Replacement
CAUTION
Brake fluid quickly ruins painted plastic surfaces;
any spilled fluid should be completely washed away
immediately.
• Remove:
Handle Cover Front and Rear (see Frame chapter)
Headlight Cover (see Handle Covers Removal in the
Frame chapter)
Right Leg Shield Inner (see Right Leg Shield Inner Re-
moval in the Frame chapter)
Banjo Bolt [A]
Clamp Bolts [B]
• When removing the brake hose, take care not to spill the
brake fluid on the painted or plastic parts.
• When removing the brake hose [C], temporarily secure
the end of the brake hose to some high place to keep
fluid loss to a minimum.
• Immediately wash away any brake fluid that spills.
• There are washers on each side of the brake hose fitting.
Replace them with new ones when installing.
• Tighten:
Torque - Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18
ft·lb)
• When installing the hoses [B], avoid sharp bending, kink-

ing, flatting or twisting, and route the hoses according to
Cable, Wire, and Hose Routing section in the Appendix
chapter.
• Fill the brake line after installing the brake hose (see
Brake Fluid Change).
FUEL SYSTEM 3-1
Fuel System
Table of Contents
3
Exploded View........................................................................................................................ 3-2
Specifications ......................................................................................................................... 3-6
Special Tool ............................................................................................................................ 3-7
Throttle Grip and Cables ........................................................................................................ 3-8
Throttle Cable Inspection .................................................................................................. 3-8
Throttle Cable Removal .................................................................................................... 3-8
Throttle Cable Installation ................................................................................................. 3-8
Choke Cable Free Play/Adjustment.................................................................................. 3-8
Choke Cable Removal ...................................................................................................... 3-9
Choke Cable Installation ................................................................................................... 3-9
Cable Inspection ............................................................................................................... 3-9
Cable Lubrication .............................................................................................................. 3-9
Carburetor .............................................................................................................................. 3-10
Idle Speed Inspection ....................................................................................................... 3-10
Idle Speed Adjustment...................................................................................................... 3-10
Pilot Screw Adjustment ..................................................................................................... 3-10
Service Fuel Level Inspection ........................................................................................... 3-10
Service Fuel Level Adjustment ......................................................................................... 3-11
Fuel System Inspection..................................................................................................... 3-12
Carburetor Removal.......................................................................................................... 3-12
Carburetor Installation....................................................................................................... 3-13
Carburetor Disassembly ................................................................................................... 3-14
Carburetor Assembly ........................................................................................................ 3-15
Carburetor Cleaning.......................................................................................................... 3-16
Carburetor Inspection ....................................................................................................... 3-17
Air Cleaner.............................................................................................................................. 3-19
Air Cleaner Element Removal........................................................................................... 3-19
Air Cleaner Element Installation........................................................................................ 3-19
Air Cleaner Element Cleaning and Inspection .................................................................. 3-19
Air Cleaner Element Replacement.................................................................................... 3-19
Air Cleaner Housing Removal........................................................................................... 3-19
Air Cleaner Housing Installation........................................................................................ 3-19
Air Cleaner Drain Cap Inspection ..................................................................................... 3-20
Fuel Tank ................................................................................................................................ 3-21
Fuel Tank Removal ........................................................................................................... 3-21
Fuel Tank Installation ........................................................................................................ 3-21
Fuel Tank Cleaning ........................................................................................................... 3-21
Fuel Tank Cap Inspection ................................................................................................. 3-22
Fuel Hose and Installation Condition Inspection............................................................... 3-22
Fuel Hose Replacement ................................................................................................... 3-22
3-2 FUEL SYSTEM
Exploded View
FUEL SYSTEM 3-3
Exploded View
O: Apply oil.
3-4 FUEL SYSTEM
Exploded View
FUEL SYSTEM 3-5
Exploded View
C: Apply cable lubricant.
G: Apply grease.
3-6 FUEL SYSTEM
Specifications

Throttle Grip and Cables
Throttle Grip Free Play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) – – –
Carburetor
Make/Type KEIHIN NCV24 – – –
Main Jet #85 – – –
Main Air Jet #100
Jet Needle NGLB – – –
Jet Needle Clip Position non-adjustable
Throttle Valve Cutaway 10° 30’ – – –
Pilot Jet (Slow Jet) #35 – – –
Pilot Air Jet (Slow Air Jet) #130
Pilot Screw 2 1/4 turns out – – –
Starter Jet #48
Idle Speed 1 250 ∼ 1 350 r/min (rpm) – – –
Service Fuel Level 9.1 mm (0.36 in.) ∼ 7.1 mm (0.28 in.) – – –
(below from the mating surface of the float bowl)
Float Height 15.8 mm (0.62 in.) ∼ 19.8 mm (0.78 in.) – – –
Air Cleaner
Air Cleaner Element Oil:
Grade SE, SF or SG class – – –
Viscosity SAE30 – – –
FUEL SYSTEM 3-7
Special Tool
Fuel Level Gauge:
57001-1017
3-8 FUEL SYSTEM
Throttle Grip Free Play Inspection
•Refer to the Throttle Cable Inspection in the Periodic
Maintenance chapter.
Throttle Grip Free Play Adjustment
•Refer to the Throttle Grip Free Play Adjustment in the
Periodic Maintenance chapter.
Throttle Cable Removal
• Remove:
Handle Cover Front (see Frame chapter)
Handle Cover Rear (see Frame chapter)
Right Leg Shield Outer (see Frame chapter)
Right Leg Shield Inner (see Frame chapter)
• Remove the right handlebar switch housing, and then re-
move the upper end of throttle cable from the throttle grip.
• Unscrew the adjust nut [A] and remove the end [B] of the
throttle cable.
Throttle Cable Installation
• Install the throttle cable in accordance with Cable, Wire,
and Hose Routing section in Appendix chapter.
• Install the lower end of the throttle cable in the cable
bracket on the carburetor after installing the upper end
[A] of the throttle cable in the grip.
○When the right handlebar switch housing is assembled,
as the front half of the housing [B] has small projection
[C], fit the projection of it into the small hole [D] in the
handlebar.
○Install the handlebar switch housing.
•After installation, adjust cable properly.
WARNING
Operation with incorrectly routed or improperly ad-
justed cables could result in an unsafe riding con-
dition.
• Start the engine.

• Turn thethehandlebar
Adjust idle speed.
• gine. from side to side while idling the en-
If idle speed varies, the cable may be poorly routed or it

may be damaged.
• Correct any problem operating the motorcycle.
WARNING
Operation with an improperly adjusted, incorrectly
routed or damaged cable could result in an unsafe
riding condition.
Choke Cable Free Play/Adjustment

• Refer to the Choke Operation Inspection in the Periodic
FUEL SYSTEM 3-9
Choke Cable Removal
• Remove:
Handle Cover Front (see Frame chapter)
Handle Cover Rear (see Frame chapter)
Right Leg Shield Outer (see Frame chapter)
Right Leg Shield Inner (see Frame chapter)
Carburetor (see Carburetor Removal)
• Remove the cable lower end [A] with the plunger.
• Pull out the cable upper end [A] and remove the tip [B] to
the choke lever.
○The choke lever [C] is fully in.
Choke Cable Installation

• Apply grease to the tips.
• Install the cables in accordance with the Cable, Wire and
Hose Routing section in the Appendix chapter.
• After installation, adjust each cable properly.
WARNING
Operation with incorrectly routed or improperly ad-
justed cables could result in an unsafe riding con-
dition.
Cable Inspection
• Refer to the General Lubrication in the Periodic Mainte-
nance chapter.
Cable Lubrication
• Refer to the General Lubrication in the Periodic Mainte-
nance chapter.
3-10 FUEL SYSTEM
Carburetor
Idle Speed Inspection
• Refer to the Idle Speed Inspection in the Periodic Main-
tenance chapter.
Idle Speed Adjustment
• Refer to the Idle Speed Adjustment in the Periodic Main-
tenance chapter.
Pilot Screw Adjustment
○The pilot screw [A] is set at the factory and should not
be removed. But if necessary, remove the pilot screw as
follows:
• Turn in the pilot screw and count the number of turns until
it seats fully but not tightly.
• Remove the pilot screw.
• To install, turn in the pilot screw until it seats fully but not
tightly, and then back it out the same number of turns
counted during disassembly. This is to set the screw to
its original position.
NOTE
○The standard number of turns the pilot screw must be
backed out varies by carburetor. The values given in the
specifications should be used only when the number of
the original back out turns is unavailable.
Service Fuel Level Inspection
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.
• Remove the carburetor, and hold it upright on a stand (see

Carburetor Removal).
• Prepare an auxiliary fuel tank and connect the fuel hose
to the carburetor.
• Prepare a fuel hose (6 mm (0.20 in.) outer diameter and
about 300 mm (11.8 in.) long).
• Connect the fuel level gauge [A] to the carburetor float
bowl with the fuel hose.
Special Tool - Fuel Level Gauge: 57001-1017
• Hold the gauge vertically against the side of the carburetor
body so that the top line [B] is several millimeters higher
than the mating surface [C] of the float bowl.
• Turn the fuel tap to feed fuel to the carburetor and gauge,
then turn the carburetor drain plug [D] out a few turns.
• Wait until the fuel level [E] in the gauge settles.
FUEL SYSTEM 3-11
Carburetor
NOTE
○Do not lower the top line below the mating surface of
the float bowl. If the gauge is lowered and then raised
again, the fuel level measured shows somewhat 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 fuel level in the gauge and compare to the spec-
ification.
Service Fuel Level
Standard: 9.1 mm (0.36 in.) ∼ 7.1 mm (0.28 in.)
below from the mating surface of the float
bowl.
• Tighten the drain plug and remove the fuel level gauge.
If the fuel level is incorrect, adjust it (see Service Fuel
Level Adjustment).
• Install the carburetor.
Service Fuel Level Adjustment
WARNING
light.
• Remove the carburetor, and drain the fuel into a suitable

container.
• Remove the float bowl [A] by taking out the screws [B].
• Unscrew the pivot pin screw [A] and remove the float [B].
• Bend the tang [A] on the float arm very slightly to change
the float height.
3-12 FUEL SYSTEM
Carburetor
• Drive in the pivot pin [B] to install the float [C].

• Measure the
Remove float chamber gasket.
• surface [A]thewithfloattheheight [D] from the float bowl mating
carburetor upside down.
○Increasing the float height lowers the fuel level and de-
creasing the float height raises the fuel level.
Float Height
Standard: 15.8 mm (0.62 in.) ∼19.8 mm (0.78 in.)
• Assemble the carburetor, and recheck the fuel level.

If the fuel level cannot be adjusted by this method, the
float or the float valve is damaged.
Fuel System Inspection
WARNING
light.
Make sure the engine is cold before working. Wipe
any fuel off the engine before starting it.
• Using a screw driver, turn out the drain plug [A] a few turns
and drain the carburetor to a suitable container and check
to see if water or dirt come out.
If any water or dirt appears during the above inspection,
clean the fuel system (see Carburetor Cleaning and Fuel
Tank Cleaning in the Fuel System chapter).
• Tighten the drain plug securely.
• Visually inspect the fuel filter [A].

Replace the fuel filter if it appears dark and dirty. At the
same time, check other areas of the fuel system to see if
they are dirty.
Carburetor Removal
WARNING
light.
FUEL SYSTEM 3-13
Carburetor
• Remove:
Right Leg Shield outer and inner (see Frame chapter)
Clamps [A] (loosen)
Throttle Cable Lower End [B] (see Throttle Cable Re-
moval in this chapter)
Intake Pipe Bolts [C]
• Remove:
Fuel Hose [A] (carburetor side)
Choke Cable Lower End [B]
Throttle Sensor Connector [C]
Hose [D]
Drain Hose (under side)
• Pull the carburetor out of the air cleaner duct end, and
then pull it out of the carburetor holder from the vehicle’s
right side.
• Stuff pieces of lint-free, clean cloth into the carburetor
holder and the air cleaner duct to keep dirt out of the en-
gine and air cleaner.
WARNING
If dirt or dust is allowed to pass through into the
carburetor, the throttle may become stuck, possibly
causing an accident.
CAUTION
If dirt gets through into the engine, excessive en-
gine wear and possibly engine damage will occur.
Carburetor Installation
• Installation is the reverse of removal.
•○Check fuel leakage
After installing the carburetor, perform the following.
from the carburetor.
WARNING
Fuel spilled from the carburetor is hazardous.
○Adjust the following.
Idle Speed
3-14 FUEL SYSTEM
Carburetor
Carburetor Disassembly
• Remove the carburetor (see Carburetor Removal).
WARNING
light.
• Remove:
Upper Chamber Cover Screw [A]
• Remove:
Upper Chamber Cover [A]
Spring [B]
Vacuum Piston and Diaphragm [C]
CAUTION
During carburetor disassembly, be careful not to
damage the diaphragm. Never use a sharp edge to
remove the diaphragm.
• Using the needle nose pliers, the holder [A] is pulled out
and remove the jet needle [B] from the vacuum piston [C].
• Replace the O-ring [D] with a new one.
• The pilot screw is set at the factory and should not be

removed. But if necessary, remove the pilot screw as
follows.
○Replace the O-ring with a new one.
○Turn in the pilot screw and count the number of turns until
it seats fully but not tightly, and then remove the screw.
Use this number of turns to set the screw to its original
position during assembly.
NOTE
○A carburetor has different “turns out” of the pilot screw
for each individual unit. When setting the pilot screw,
use the “turns out” determined during disassembly. Use
the specification in this manual only if the original num-
ber is unknown.
FUEL SYSTEM 3-15
Carburetor
• Remove:
Float Bowl Screws [A]
Float Bowl [B]
• Remove:
Screw [A]
Float [B] with Float Valve Needle
Pilot Jet [C]
Main Jet [D]
Needle Jet Holder [E]
Carburetor Assembly
• Clean the disassembly parts before assembling.
• Clean the fuel and air passages with a high flash point
solvent and compressed air.
• Install the needle jet [A] into the carburetor so that the
smaller diameter end [B] of the jet goes in first.
• Carefully screw in the needle jet holder. It will seat against

the needle jet, pushing the end of the jet into the carbu-
retor bore.
CAUTION
Do not force the needle jet holder [A] and main jet
[B] or overtighten them. The needle jet or the car-
buretor body could be damaged requiring replace-
ment.
• Turn in the pilot screw fully but not tightly, and then back it
out the same number of turns counted during disassem-
bly.
CAUTION
Do not force the needle jet and main jet or over-
tighten them. They could be damaged requiring re-
placement.
3-16 FUEL SYSTEM
Carburetor
• Put the float valve needle into the valve seat.

• throughinstalling
Before the float, insert the tang on the float plate
the clip [A] on the valve needle.
• Set the floatscrew
Tighten the [B]
• Adjustment). height as specified (see Service Fuel Level
• Slip the jet needle [A] through the hole in the center of the
vacuum piston [B].
• Replace the O-ring [C] with a new one.
• Using the needle
O-ring and spring [D] are set in the holder.
• of the needle. nose pliers, put the holder [E] on the top
• Align the diaphragm tang [A] with the notch in the upper
chamber, and fit the diaphragm sealing lip into its groove.
• After installing the upper chamber cover, check that the
vacuum piston slides up and down smoothly without bind-
ing in the carburetor bore.
•○After installing the carburetor, do the following.

Check the fuel leakage.
○Adjust the following items if necessary.
Idle Speed
Carburetor Cleaning
WARNING
Clean the carburetor in a well-ventilated 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 high
flammable liquids, do not use gasoline or low flash
-point solvents to clean the carburetor.
FUEL SYSTEM 3-17
Carburetor
CAUTION
Do not use compressed air on an assembled carbu-
retor, or the float may be deformed by the pressure.
Remove as many rubber or plastic parts from the
carburetor as possible before cleaning the carbu-
retor with a cleaning solution.
This will prevent damage to or deterioration of the
parts.
Do not use a strong carburetor cleaning solution
which could attack the plastic parts; instead, use
a mild high-flash point cleaning solution safe for
plastic parts.
Do not use wire or any other hard instrument to
clean carburetor parts, especially jets, as they may
be damaged.
• Disassemble the carburetor.

• tion.
Immerse all the metal parts in a carburetor cleaning solu-
• Rinse the parts in water.

• Blow through
When the parts are clean, dry them with compressed air.
• air. the air and fuel passages with compressed
• Assemble the carburetor.

Carburetor Inspection
WARNING
light.
• Remove the carburetor.

• (see Fuel Level Inspection).
Before disassembling the carburetor, check the fuel level
• Turn the carburetor cable pulley to check that the throttle

valve [A] moves smoothly and returns by spring force.
If the throttle valve does not move smoothly, replace the
carburetor.
3-18 FUEL SYSTEM
Carburetor
• Disassemble
bly).
the carburetor (see Carburetor Disassem-
• Clean the carburetor (see Carburetor Cleaning).

• aphragmthat[B]the
Check O-ring [A] of the carburetor and the di-
on the vacuum piston are in good condition.
If the O-ring or the diaphragm is not in good condition,
replace them.
• Check the plastic tip [A] of the float valve needle [B]. It
should be smooth, without any grooves, scratches, or
tears.
If the plastic tip is damaged [C], replace the needle.
• Push the rod [D] in the other end of the float valve needle,
and then release it [E].
If the rod does not spring out, replace the float valve nee-
dle.
• Check the tapered portion [A] of the pilot screw [B] for
wear or damage.
If the pilot screw is worn or damaged on the tapered por-
tion, it will prevent the engine from idling smoothly. Re-
place it.
• Check that the vacuum piston [A] 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 the piston
and/or the carburetor.
• Disassemble the carburetor, and clean the fuel, air pas-

sages with a high-flash point solvent and compressed air.
• Stuff the lint-free, clean cloths into the air cleaner housing
to keep dirt or other foreign material from entering.
WARNING
If dirt or dust is allowed to pass through into the car-
buretor, the throttle valve may become stuck, pos-
sibly causing an accident.
FUEL SYSTEM 3-19
Air Cleaner
Air Cleaner Element Removal
• Refer to the Air Cleaner Element Replacement in the Pe-
riodic Maintenance chapter.
Air Cleaner Element Installation
Air Cleaner Element Cleaning and Inspection
• Refer to the Air Cleaner Element Cleaning in the Periodic
Air Cleaner Element Replacement
Air Cleaner Housing Removal
• Remove:
Right and Left Leg Shield Inner Cover (see Frame chap-
ter)
Air Cleaner housing Mounting Bolt [A]
Carburetor Clamp Screw [B]
• Remove:
Air Cleaner housing Mounting Bolts [A]
• Remove:
Hose [A]
Air Cleaner Housing Installation

3-20 FUEL SYSTEM
Air Cleaner
Air Cleaner Drain Cap Inspection
• Inspect the air cleaner drain cap [A].
If necessary, drain the oil in the cap.
• Reinstall the cap to original position.
FUEL SYSTEM 3-21
Fuel Tank
Fuel Tank Removal
WARNING
light.
• Remove:
Right and Left Leg Shield Inner Cover (see Frame chap-
ter)
Fuel (drain)
Fuel Level Sensor Lead Connector [A]
• The steering is turned left side fully.
• Remove:
Headlight Bracket (up side) [A]
Headlight Bracket (down side) [B] (Loosen)
• Remove:
Bolts [A]
Screw [B]
Fuel Tank Cap
• The bracket is knocked down forward.
• Remove the fuel tank [C] with fuel hose.
Fuel Tank Installation

• Fuel tank installation is the reverse of removal.
Fuel Tank Cleaning
• Remove the fuel tank and drain it.
• shake the tank
Pour some high-flash point solvent into the fuel tank and
to remove dirt and fuel deposits.
WARNING
Clean the tank in a well-ventilated area, and take
care that there is no spark or flame anywhere near
the working area. Because of the danger or highly
flammable liquids, do not use gasoline or low-flash
point solvents to clean the tank.
3-22 FUEL SYSTEM
Fuel Tank
• Pour the solvent out of the tank.

• Install the fuel tank.
Fuel Tank Cap Inspection
• Remove the fuel tank cap.
• age.
Visually inspect the gasket on the tank cap for any dam-
Replace the gasket if it is damaged.

• Check to see if the breather [A] is not clogged up.
If they are clogged, then blow the breather free with com-
pressed air.
Fuel Hose and Installation Condition Inspection

• Refer to the Fuel Hose and Installation Condition Inspec-
tion in the Periodic Maintenance chapter.
Fuel Hose Replacement
• Refer to the Fuel Hose Replacement in the Periodic Main-
tenance chapter.
ENGINE TOP END 4-1
Engine Top End

Table of Contents
Exploded View................................... 4-2 Valve Removal ............................. 4-24
Specifications .................................... 4-6 Valve Installation .......................... 4-24 4
Special Tools ..................................... 4-8 Valve Guide Removal .................. 4-24
Camshaft Chain Tensioner ................ 4-10 Valve Guide Installation ............... 4-25
Camshaft Chain Tensioner Valve Clearance Adjustment........ 4-25
Removal .................................... 4-10 Valve Seat Inspection .................. 4-25
Camshaft Chain Tensioner Valve Seat Repair ........................ 4-26
Installation ................................. 4-10 Valve Head Thickness Inspection 4-29
Camshaft ........................................... 4-12 Valve Stem Bend Inspection ........ 4-29
Camshaft Removal ...................... 4-12 Valve Stem Diameter Inspection.. 4-30
Camshaft Installation ................... 4-12 Valve Guide Inside Diameter
Camshaft Inspection .................... 4-12 Inspection.................................. 4-30
KACR Inspection.......................... 4-12 Valve to Guide Clearance
KACR Removal............................ 4-13 Measurement ............................ 4-30
KACR Installation......................... 4-13 Cylinder, Piston.................................. 4-32
Camshaft Bearing Inspection....... 4-14 Cylinder Removal......................... 4-32
Camshaft Sprocket Removal ....... 4-14 Cylinder Installation...................... 4-32
Camshaft Sprocket Installation .... 4-15 Piston Removal............................ 4-33
Camshaft Chain Removal ............ 4-16 Piston Installation......................... 4-33
Camshaft Chain Installation ......... 4-16 Cylinder Inside Diameter
Camshaft Chain Guide Wear ....... 4-17 Measurement ............................ 4-34
Rocker Arm, Rocker Arm Shaft ......... 4-18 Piston Diameter Measurement .... 4-35
Rocker Arm Removal................... 4-18 Piston/Cylinder Clearance ........... 4-35
Rocker Arm Installation................ 4-18 Piston Ring End Gap ................... 4-35
Rocker Arm & Arm Shaft Wear .... 4-19 Piston Ring, Piston Ring Groove
Cylinder Head.................................... 4-20 Inspection.................................. 4-36
Compression Measurement......... 4-20 Piston, Piston Pin, Connecting
Cylinder Head Removal ............... 4-21 Rod Wear Inspection................. 4-37
Cylinder Head Installation ............ 4-22 Piston, Piston Pin, Connecting
Cylinder Head Cleaning ............... 4-22 Rod Inspection .......................... 4-37
Cylinder Head Warp Inspection ... 4-23 Muffler................................................ 4-38
Valve Clearance Inspection ......... 4-23 Muffler Removal........................... 4-38
Valves ................................................ 4-24 Muffler Installation........................ 4-38
4-2 ENGINE TOP END
Exploded View
ENGINE TOP END 4-3
Exploded View
Torque
No. Fastener Remarks
N·m kgf·m ft·lb
1 Cylinder Head Bolts 12 1.2 104 in·lb L, S
2 Cylinder Head Nuts 22 2.2 16 S
3 Valve Adjusting Cap Bolts 8.8 0.90 78 in·lb
4 Camshaft Sprocket Cover Bolts 8.8 0.90 78 in·lb
5 Rocker Arm Shaft Stopper Screws 4.9 0.50 43 in·lb L
6 Valve Adjusting Screw Locknuts 8.8 0.90 78 in·lb
7 Camshaft Sprocket Bolts 12 1.2 104 in·lb L
8 Camshaft Chain Guide Holder Bolts 8.8 0.90 78 in·lb
9 Inlet Pipe Bolts 8.8 0.90 78 in·lb
EO: Apply engine oil.
G: Apply grease.
L: Apply a non-permanent locking agent.
M: Apply molybdenum disulfide grease.
R: Replacement Parts
S: Follow the specific tightening sequence.
4-4 ENGINE TOP END
Exploded View
ENGINE TOP END 4-5
Exploded View
Torque
N·m kgf·m ft·lb
1 Tensioner Mounting Bolts 8.8 0.9 78 in·lb
2 Tensioner Cap Bolt 4.9 0.5 43 in·lb L
3 Muffler Mounting Bolt 21 2.1 15
4 Exhaust Pipe Holder Nuts 21 2.1 15
5 Muffler Cover Screws 4.9 0.5 43 in·lb
4-6 ENGINE TOP END
Specifications

Rocker Arm, Rocker Arm Shaft
Rocker Arm Inside Diameter 10.000 ∼ 10.015 mm (0.3937 ∼ 0.3943 in.) 10.05 mm (0.396 in.)
Rocker Arm Shaft Diameter 9.980 ∼ 9.995 mm (0.3929 ∼ 0.3935 in.) 9.95 mm (0.392 in.)
Camshaft
Cam Height 31.325 ∼ 31.439 mm (1.2333 ∼ 1.2378 in.) 31.23 mm (1.230 in.)
Cylinder Head
Cylinder Compression (Usable
Range):
Kick:
AN130A 567 ∼ 908 kPa (5.78 ∼ 9.26 kgf/cm², 82 ∼ – – –
132 psi) @5 times
AN130B1, B6F/C1, C6F 420 ∼ 698 kPa (4.28 ∼ 7.12 kgf/cm², 61 ∼ – – –
101 psi) @5 times
Electric Starter: 350 ∼ 598 kPa (3.57 ∼ 6.1 kgf/cm², 51 ∼ – – –
87 psi) @425 r/min (rpm)
Cylinder Head Warp ––– 0.03 mm ( 0.001 in.)
Valve
Valve Clearance:
Exhaust 0.04 ∼ 0.08 mm (0.0016 ∼ 0.0031 in.) – – –
Inlet 0.04 ∼ 0.08 mm (0.0016 ∼ 0.0031 in.) – – –
Valve Head Thickness:
Exhaust 0.8 mm (0.031 in.) 0.5 mm (0.020 in.)
Inlet 0.5 mm (0.020 in.) 0.25 mm (0.010 in.)
Valve Stem Bend TIR 0.01 mm (0.0004 in.) or less TIR 0.05 mm (0.002
in.)
Valve Stem Diameter:
Exhaust 4.462 ∼ 4.472 mm (0.1757 ∼ 0.1761 in.) 4.44 mm (0.1748 in.)
Inlet 4.475 ∼ 4.490 mm (0.1762 ∼ 0.1768 in.) 4.46 mm (0.1756 in.)
Valve Guide Inside Diameter:
Inlet 4.500 ∼ 4.512 mm (0.1772 ∼ 0.1776 in.) 4.58 mm (0.1803 in.)
Valve Guide Clearance
(Wobble Method):
Inlet 0.02 ∼ 0.08 mm (0.0008 ∼ 0.0031 in.) 0.23 mm (0.0091 in.)
Valve Seat Cutting Angle 45°, 32°, 60°, 67.5° – – –
Valve Seat Surface:
Outside Diameter:
Exhaust 19.9 ∼ 20.1 mm (0.783 ∼ 0.791 in.) – – –
Inlet 22.9 ∼ 23.1 mm (0.902 ∼ 0.909 in.) – – –
Width:
Exhaust 0.80 ∼ 1.15 mm (0.031 ∼ 0.045 in.) – – –
Inlet 0.80 ∼ 1.15 mm (0.031 ∼ 0.045 in.) – – –
Valve Spring Free Length 36.6 mm (1.441 in.) 35.8 mm (1.409 in.)
ENGINE TOP END 4-7
Specifications

Cylinder, Piston
Cylinder Inside Diameter 52.997 ∼ 53.009 mm (2.0865 ∼ 2.0870 in.) 53.10 mm (2.0905 in.)
Piston Diameter 52.972 ∼ 52.983 mm (2.0855 ∼ 2.0859 in.) 52.82 mm (2.0795 in.)
Piston/Cylinder Clearance 0.014 ∼ 0.034 mm (0.00055 ∼ 0.00134 in.) – – –
Over Size Piston and Rings +0.25 (0.0098 in.) +0.50 (0.0197 in.)
+0.75 (0.0295 in.) +1.0 (0.0394 in.)
Piston Ring/Groove Clearance:
Top 0.020 ∼ 0.060 mm (0.0008 ∼ 0.0024 in.) 0.16 mm (0.0063 in.)
Second 0.010 ∼ 0.050 mm (0.0004 ∼ 0.0020 in.) 0.15 mm (0.0059 in.)
Piston Ring Groove Width:
Top 0.81 ∼ 0.83 mm (0.0319 ∼ 0.0327 in.) 0.91 mm (0.0358 in.)
Second 0.80 ∼ 0.82 mm (0.0315 ∼ 0.0323 in.) 0.90 mm (0.0354 in.)
Piston Ring Thickness:
Top 0.77 ∼ 0.79 mm (0.0303 ∼ 0.0311 in.) 0.70 mm (0.0276 in.)
Second 0.77 ∼ 0.79 mm (0.0303 ∼ 0.0311 in.) 0.70 mm (0.0276 in.)
Piston Ring End Gap:
Top 0.10 ∼ 0.20 mm (0.0039 ∼ 0.0079 in.) 0.50 mm (0.020 in.)
Second 0.30 ∼ 0.45 mm (0.0118 ∼ 0.0177 in.) 0.75 mm (0.0295 in.)
Oil 0.10 ∼ 0.60 mm (0.0039 ∼ 0.0236 in.) 0.90 mm (0.0354 in.)
Piton Pin Diameter 12.995 ∼ 13.000 mm (0.5116 ∼ 0.5118 in.) 12.96 mm (0.510 in.)
Piston Pin Hole Diameter 13.001 ∼ 13.007 mm (0.5118 ∼ 0.5121 in.) 13.08 mm (0.515 in.)
Connecting Rod Small End 13.003 ∼ 13.014 mm (0.5119 ∼ 0.5124 in.) 13.05 mm (0.514 in.)
Inside Diameter
4-8 ENGINE TOP END
Special Tools
Compression Gauge, 20 kgf/cm²: Valve Seat Cutter, 60° - 30:
57001-221 57001-1123
Valve Spring Compressor Assembly: Valve Seat Cutter Holder Bar:

57001-241 57001-1128
Piston Pin Puller Assembly: Valve Spring Compressor Adapter, 20:

57001-910 57001-1154
Valve Seat Cutter, 45° - 27.5: Valve Seat Cutter, 45° - 22:
57001-1114 57001-1205
Valve Seat Cutter, 32° - 25: Valve Seat Cutter, 32° - 22:
57001-1118 57001-1206
ENGINE TOP END 4-9
Special Tools
Valve Seat Cutter, 67.5° - 22: Valve Seat Cutter Holder, 4.5:
57001-1207 57001-1330
Valve Adjusting Screw Holder: Valve Guide Arbor, 4.5:

57001-1217 57001-1331
Compression Gauge Adapter, M10 × 1.0: Valve Guide Reamer, 4.5:

57001-1317 57001-1333
4-10 ENGINE TOP END
Camshaft Chain Tensioner
Camshaft Chain Tensioner Removal
CAUTION
This is a non-return type cam chain tensioner. The
push rod does not return to its original position
once it moves out to take up cam chain slack. Ob-
serve all the rules listed below:
When removing the tensioner, do not take out the
mounting bolts only halfway. Retightening the
mounting bolts from this position could damage
the tensioner and the camshaft chain. Once the
bolts are loosened, the tensioner must be removed
and reset as described in “Chain Tensioner Instal-
lation”. Do not turn over the crankshaft while the
tensioner is removed. This could upset the cam
chain timing, and damage the valves.
• Remove:
Left Leg Shield Inner Cover (see Frame chapter)
• disassembly
Loosen the cap bolt [A] before tensioner removal for later
convenience.
• chain tensioner [C]. bolts [B] and remove the camshaft
Unscrew the mounting
CAUTION
Do not turn over the crankshaft while the tensioner
is removed. This could upset the cam chain timing,
and damaging the valves.
Camshaft Chain Tensioner Installation

• Remove the tensioner cap bolt and O-ring.
• with a suitable screwdriver
While compressing the push rod [A], turn it clockwise [C]
[B] until the rod protrusion
comes to about 10 mm (0.394 in.) from the tensioner
body.
CAUTION
Do not turn the rod counterclockwise at installation.
This could detach the rod and the tensioner cannot
be reinstalled.
• While holding the rod in position with a suitable push rod

holder plate [A] install the tensioner on the cylinder block.
[B] 8.5 mm (0.335 in.)
[C] 3.5 mm (0.138 in.)
[D] 7 mm (0.276 in.)
[E] 16 mm (0.630 in.)
NOTE
○To make the procedure easy, use a holder plate to keep
the rod from pushing out, A replacement chain ten-
sioner (spare parts) has a holder plate. The holder plate
can be made less than 1 mm (0.0394 in.) thick steel
plate as shown.
ENGINE TOP END 4-11
• Tighten the mounting bolt [A].

Torque - Tensioner Mounting Bolts: 8.8 N·m (0.9 kgf·m, 78
in·lb)
• Take out the holder plate.
• Install the O-ring and tighten the cap bolt.
Torque - Tensioner Cap Bolt: 4.9 N·m (0.5 kgf·m, 43 in·lb)
• Install the left leg shield.
4-12 ENGINE TOP END
Camshaft
Camshaft Removal
• Remove:
Camshaft Chain Tensioner (see this chapter)
Camshaft Sprocket (see this chapter)
Rocker Arms (see this chapter)
• Pull out the camshaft [A].
Camshaft Installation
• Clean the camshaft with a high-flash point solvent.
• Apply clean engine oil to all cam parts.
• Install the
Install camshaft in the cylinder head.
• Install the other
the rocker arm.
•○Check and adjustremoved parts.
the valve clearance.
Camshaft Inspection
• Visually inspect the cam for wear or damage.
If there is any damage or wear, replace the camshaft.
• Measure the height [A] of each cam.
Cam Height
Standard:
Exhaust 31.325 ∼ 31.439 mm (1.2333 ∼ 1.2378 in.)
Inlet 31.325 ∼ 31.439 mm (1.2333 ∼ 1.2378 in.)
Service Limit:
Exhaust 31.23 mm (1.230 in.)
Inlet 31.23 mm (1.230 in.)
If any cam is worn down past service limit, replace the
camshaft.
KACR Inspection
The Kawasaki Automatic Compression Release (KACR)
momentarily opens the inlet valves on the compression
stroke at very low speeds. This allows some of the com-
pression pressure to escape, making it easy to turn over
the engine during starting.
Due to the simplicity of the mechanism, no periodic main-
tenance is needed. There are only two symptoms of prob-
lems with the KACR mechanism [A]: compression is not re-
leased during starting, and compression is released during
running.
ENGINE TOP END 4-13
Camshaft
(1) If compression is not released during starting, the weight
is not returning to their rest position.
• Remove the camshaft (see Camshaft Removal).
• Remove the KACR unit.
• Visually inspect the spring.
If damaged, deformed, or missing, replace the spring.
• Remove the spring and move the weight back and forth.
If the weight do not move smoothly, replace the KACR
unit. Also inspect the inlet rocker arm for any damage,
and replace the rocker arm if necessary.
[A] Rest Position (compression is released)
[B] Weight
[C] Spring
(2) If compression is released while the engine is running,
the weights are not swinging out.
• Remove the spring and move the weights back and forth.
If the weight do not move easily from the retracted posi-
tion, replace the KACR unit. Also inspect the inlet rocker
arm for any damage, and replace the rocker arm if nec-
essary.
[A] Running Position (compression is not released)
[B] Weight
[C] Spring
KACR Removal
• Remove:
Camshaft Sprocket Cover
Camshaft Sprocket Bolts [A]
Bracket [B]
Pin [C]
Weight [D]
Spring [E]
KACR Installation
• Install:
Weight [A]
Spring [B]
Pin [C]
Bracket
Camshaft Sprocket Bolts
4-14 ENGINE TOP END
Camshaft
Camshaft Bearing Inspection
• Visually inspect each camshaft bearing [A].
If there is any damage replace the camshaft.
• Turn the bearing back and forth while checking for rough-
ness or binding.
If roughness or binding is found, replace the camshaft.
If it is noisy, does not spin smoothly, or has any rough
spots, replace the camshaft.
Camshaft Sprocket Removal

• Remove:
Magneto Cover Caps (see Electrical System chapter)
• Remove the camshaft sprocket cover bolts [A] and take

off the cover [B].
• Turn the crankshaft counterclockwise until the line mark

[A] on the KACR unit aligns with the sprocket cover mating
surface projection [B].
• Remove the camshaft chain tensioner.
• With a wrench on the magneto flywheel bolt to keep the
crankshaft from turning remove the camshaft sprocket
bolts [C].
• Remove the camshaft sprocket.
• Using a suitable tool [A] or wire to keep the chain [B] from
falling down into the cylinder block.
CAUTION
Always pull the camshaft chain taut while turning
the crankshaft when the camshaft chain is loose.
This avoids kinking the chain on the lower (crank-
shaft) sprocket. A kinked chain could damage both
the chain and the sprocket.
ENGINE TOP END 4-15
Camshaft
Camshaft Sprocket Installation
• Turn the crankshaft counterclockwise [A] and align the “T”
mark [B] with the middle of the notch [C].
• Remember to pull the camshaft chain taut before rotating
the crankshaft.
• Pull the lower side of the chain taut and fit it onto the
sprocket so that the “T” line [A] on the sprocket aligns with
the sprocket cover mating surface projection [B].
•Fit the sprocket up into place.
○Turn the camshaft [C] so that the cam lobes point back-
ward while holding the sprocket steady to align the bolt
holes [D].
• Install the pin [A].
• Apply a non-permanent locking agent to the camshaft

sprocket bolts [A] with plate [B].
4-16 ENGINE TOP END
Camshaft
• Keep the crankshaft from turning by holding a wrench [A]

on the magneto flywheel bolt.
• Tighten:
Torque - Camshaft Sprocket Bolts: 12 N·m (1.2 kgf·m, 104
in·lb)
• Install the camshaft chain tensioner.
•○Turn thethecrankshaft
Check camshaft chain timing.
two turns in the counterclockwise, the
crankshaft is at TDC, and re-check the camshaft chain
timing.
If the timing mark is aligned, the camshaft chain timing is
correct.
CAUTION
Rotation of the crankshaft with improper camshaft
timing could cause the valve to contact each other
or the piston, and bend.
If any resistance is felt when turning the crankshaft,
stop immediately, and check the camshaft chain
timing.
Camshaft Chain Removal

• Left Leg Shield (see Frame chapter)
Remove

Camshaft Sprocket
Cylinder Head
Magneto Cover (see Electrical System chapter)
Magneto Flywheel (see Electrical System chapter)
Woodruff Key (see Electrical System chapter)
Torque Limiter
Starter Motor Clutch Gear (AN130-B1/C1 Models)
• Remove
[B].
the camshaft chain holder [A] and chain guides
• Take off the camshaft chain [C].
Camshaft Chain Installation

• Install the camshaft chain to the crankshaft and it is pulled
up to the camshaft sprocket pass through camshaft chain
hole in the cylinder.
• Keep the chain.
• Install the upper chain guide and camshaft chain guide
holder.
Torque - Camshaft Chain Guide Holder Bolts: 8.8 N·m (0.9
kgf·m, 78 in·lb)
• Insert the lower chain guide [A] securely as shown.
• Install the other removed parts.
ENGINE TOP END 4-17
Camshaft
Camshaft Chain Guide Wear
• Visually inspect the guides.
If the guide is damaged, replace the guide.
4-18 ENGINE TOP END
Rocker Arm Removal
• Remove:
Left Leg Shield (see Frame chapter)
Camshaft Sprocket Bolts [A] and Plate [B]
Camshaft Sprocket [C] (see Camshaft Sprocket Re-
moval)
• Remove:
Valve Adjusting Cover Bolts [A]
Valve Adjusting Covers [B]
Rocker Arm Shaft Stopper Screw [C]
Rocker Arm Shaft Stopper [D]
• While holding the rocker arm [A] with hand, pull out the
rocker arm shaft [B] and take off the rocker arms.
○Mark and record the rocker arm locations so that the
rocker arm can be reinstalled in their original positions.
Rocker Arm Installation

• Clean the rocker arms and rocker arm shafts with a high
-flash point solvent.
• Apply a clean engine oil to the rocker arm shaft outside
and rocker arm cam parts.
• Turn the camshaft so that the cam lobes point downward.
• rocker the
Install each rocker arm shaft, running it through each
arm.
• Install the rocker arm shaft stopper [A] so that the each
rocker arm shaft protrusion [B] face to face.
• Apply a non-permanent locking agent to the rocker arm
shaft stopper screws.
• Tighten:
Torque - Rocker Arm Shaft Stopper Screws: 4.9 N·m (0.5
kgf·m, 43 in·lb)
•○Install the camshaft sprocket.
Check and adjust the valve clearance.
CAUTION
When install the valve adjusting covers, be careful
not to drop of protrude the O-rings from the cover
grooves. If the O-ring is installed improperly, oil will
leak.
ENGINE TOP END 4-19
Rocker Arm & Arm Shaft Wear
• Visually
rubs.
inspect the area on the rocker arm where the cam
If there is any damage or uneven wear, replace the arm.

• Spin the bearing [A] by hand to check its condition.
If the bearing is noisy, does not spin smoothly, or has any
rough spots, replace the arm.
• Measure the inside diameter [B] of each rocker arm with
a cylinder gauge.
Rocker Arm Inside Diameter
Standard: 10.000 ∼ 10.015 mm (0.3937 ∼ 0.3943 in.)
Service Limit: 10.05 mm (0.396 in.)
If it exceeds the service limit, replace the arm.
• Measure the diameter [C] of each rocker arm shaft where
the rocker arm fits.
Rocker Arm Shaft Diameter
Standard: 9.980 ∼ 9.995 mm (0.3929 ∼ 0.3935 in.)
If the diameter is less than the service limit, replace the
rocker arm shaft.
4-20 ENGINE TOP END
Cylinder Head
Compression Measurement
• Warm up the engine thoroughly.
• Stop the engine.
• and adapter
Remove the spark plug and attach compression gauge
firmly into the spark plug hole.
Special Tools - Compression Gauge, 20 kgf/cm²: 57001-221
[A]
Compression Gauge Adapter, M10 × 1.0:
57001-1317 [B]
• With the throttle fully open, turn the engine over sharply
with the kick starter several times until the compression
gauge stops rising; the compression is the highest read-
ing obtainable.
Cylinder Compression
Usable Range:
AN130A 567 ∼ 908 kPa (5.78 ∼ 9.26
kgf/cm², 82 ∼ 132 psi) @5
times
AN130B1, B6F/C1, C6F 420 ∼ 698 kPa (4.28 ∼ 7.12
kgf/cm², 61 ∼ 101 psi) @5
times
• Using the starter motor, turn the engine over with the
throttle fully open until the compression gauge stops ris-
ing; the compression is the highest reading obtainable
(AN130-B/C Models).
Cylinder Compression
Usable Range: 350 ∼ 598 kPa (3.57 ∼ 6.1 kgf/cm², 51 ∼
87 psi) @425 r/min (rpm)
ENGINE TOP END 4-21
Cylinder Head
The following table should be consulted if the obtainable compression reading is not within the us-
able range.
Problem Diagnosis Remedy (Action)
Cylinder compression Carbon accumulation on piston and in Remove the carbon deposits
is higher than usable combustion chamber possibly due to and replace damaged parts if
range damaged valve stem oil seal and/or necessary.
damaged position oil rings (This may be
indicated by white exhaust smoke).
Incorrect cylinder head gasket, cylinder Replace to gasket with a
base gasket thickness. standard part.
Damaged KACR spring. Replace the spring.
KACR weight do not move smoothly. Replace the KACR unit.
Cylinder compression Gas leakage around cylinder head. Replace damaged gasket and
is lower than usable check cylinder head warp.
range Bad condition of valve seating. Repair if necessary.
Incorrect valve clearance. Adjust the valve clearance.
Incorrect piston/cylinder clearance. Replace the piston and/or
cylinder
Piston seizure. Inspect the cylinder (and liner)
and replace/repair the cylinder
and/or piston as necessary.
Bad condition of piston ring and/or piston Replace the piston and/or the
ring grooves. piston rings.
KACR weight do not move smoothly. Replace the KACR unit.
• Remove the compression gauge and adapter, and install
the spark plug.
Torque - Spark Plug: 13 N·m (1.3 kgf·m, 113 in·lb)
Cylinder Head Removal

• Remove:
Right and Left Leg Shield Inner Covers (see Frame
chapter)
Front Footpeg Assembly [A]
• Remove the exhaust pipe holder nuts [B], and muffler
mounting bolt [C] and then the muffler with the exhaust
pipe holder.
• Remove the plug cap [A].

• Unscrew the inlet pipe bolts [B].
4-22 ENGINE TOP END
Cylinder Head
• Remove:
Camshaft Sprocket
• Remove the cylinder head bolts [A] first, then remove the
nuts [B], and take off the cylinder head.
Cylinder Head Installation

• Check to see that the two dowel pins [A] are in place on
the cylinder.
• Install a new cylinder head gasket [B].
• Set the O-ring [C] in the oil pipe.
• Fit the cylinder head onto the cylinder block using a

screwdriver or wire to keep the chain from falling down
into the cylinder block.
• Apply a non-permanent locking agent to the cylinder head
bolts.
• Tighten the cylinder head nuts and bolts following the
tightening sequence as shown.
First Torque -
Cylinder Head Bolts: 5.9 N·m (0.6 kgf·m, 52 in·lb)
Cylinder Head Nuts: 13 N·m (1.3 kgf·m, 113 in·lb)
Final Torque -
Cylinder Head Bolts: 12 N·m (1.2 kgf·m, 104 in·lb)
Cylinder Head Nuts: 22 N·m (2.2 kgf·m, 16 ft·lb)
• Install the camshaft sprocket.
Cylinder Head Cleaning
• Scrape out any carbon, and wash the head with a high
-flash point solvent.
ENGINE TOP END 4-23
Cylinder Head
Cylinder Head Warp Inspection
• Lay a straightedge across the lower surface of the cylinder
head at several positions.
• Use a thickness gauge [A] to measure the space between
the straightedge [B] and the cylinder head.
Cylinder Head Warp
Standard: –––
If the cylinder head is warped more than the service limit,
replace it.
If the cylinder head is warped less than the service limit,
repair the head by rubbing the lower surface on emery
paper secured to a surface plate (first No. 200, then No.
400).
Valve Clearance Inspection
• Refer to the Valve Clearance Inspection in the Periodic
4-24 ENGINE TOP END
Valves
Valve Removal
• Remove:
Cylinder Head
Rocker Arm & Rocker Arm Shaft
Camshaft
• Using the valve spring compressor assembly to press
down the valve spring retainer, remove the split keeper.
Special Tools - Valve Spring Compressor Assembly: 57001
-241 [A]
Valve Spring Compressor Adapter, 20:
57001-1154 [B]
• Remove the tool and then remove the spring retainer,

spring, and spring seat.
• Push out the valve.
• Pull off the valve stem oil seal.
Valve Installation
• Replace the valve stem oil seal [B].
• If a new valve
Push a new valve stem oil seal into place.
is to be used, check the valve to guide
clearance.
If there is too much clearance, install a new valve guide.
•Check the spring seat [C].
•Apply a thin coat of molybdenum disulfide grease to the
valve stem [A].
•Install spring [E] so that the closed coil end [D] faces
downwards, white paint faces upward.
•Install the spring retainer [F] press it down with the valve
spring compressor assembly, and put on the split keepers
[G].
•After making sure that the split keepers and valve stem
are all properly fitted, remove the tool.
•Install:
Camshaft
Rocker Arm & Arm Shaft
Cylinder Head
○Check the valve clearance, and adjust if necessary.
Valve Guide Removal
• Remove:
Cylinder Head
Valve
Valve Stem Oil Seal
• Hammer lightly on the valve guide arbor [A] to remove the
guide from the top of the head.
Special Tool - Valve Guide Arbor, 4.5: 57001-1331
ENGINE TOP END 4-25
Valves
Valve Guide Installation
○Valve guide are identical.
• Lightly oil the valve guide outer surface.
• until the circlip
Drive the valve guide in from the top of the cylinder head
stops the guide from going in too far.
• Ream the valve guide
Allow the cylinder head to cool.
• even if the old guide is reused.
with the valve guide reamer [A]
Special Tool - Valve Guide Reamer, 4.5: 57001-1333
Valve Clearance Adjustment

• Refer to the Valve Clearance Check in the Periodic Main-
tenance chapter.
Valve Seat Inspection
• Remove the valve.
• and valve seat
Check the valve seat surface [A] between the valve [B]
[C].
○Coat valve seat with machinists dye.
○Push the valve into the guide.
○Rotate 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.
• Measure the outside diameter [D] of the seating pattern
on the valve seat.
If the outside diameter is too large or too small, repair the
seat (see Seat Repair).
Valve Seat Surface Outside Diameter
Standard:
Inlet 22.9 ∼ 23.1 mm (0.902 ∼ 0.909 in.)
Exhaust 19.9 ∼ 20.1 mm (0.783 ∼ 0.791 in.)
NOTE
○The 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.
• Measure the seat width [E] of the portion where there is
no build-up carbon (white portion) of the valve seat with a
vernier caliper.
Good [F]
If the width is too wide [G], too narrow [H] or uneven [J],
repair the seat (see Seat Repair).
Valve Seat Width
Standard:
Inlet 0.80 ∼ 1.15 mm (0.031 ∼ 0.045 in.)
Exhaust 0.80 ∼ 1.15 mm (0.031 ∼ 0.045 in.)
4-26 ENGINE TOP END
Valves
Valve Seat Repair
• Repair the valve seat with the valve seat cutters.
Special Tools - Valve Seat Cutter Holder, 4.5: 57001-1330
Valve Seat Cutter Holder Bar: 57001-1128
Inlet
Special Tools - Valve Seat Cutter, 45° - 27.5: 57001-1114
Valve Seat Cutter, 32° - 25: 57001-1118
Exhaust
Special Tools - Valve Seat Cutter, 32° - 22: 57001-1206
Valve Seat Cutter, 67.5° - 22: 57001-1207
If the manufacturer’s instructions are not available, use
the following procedure.
Seat Cutter Operating Care

1. This valve seat cutter is developed to grind the valve for
repair. Therefore the cutter must not be used for other
purpose than seat repair.
2. Do not drop or shock the valve seat cutter, or the dia-
mond particles may fall off.
3. Do not fail to apply engine oil to the valve seat cutter
before grinding the seat surface. Also wash off ground
particles sticking to the cutter with washing oil.
NOTE
○Do not use a wire brush to remove the metal particles
from the cutter. It will take off the diamond particles.
4. Setting the valve seat cutter holder in position, operate
the cutter in one hand. Do not apply too much force to
the diamond position.
NOTE
○Prior to grinding, apply engine oil to the cutter and dur-
ing the operation, wash off any ground particles sticking
to the cutter with washing oil.
5. After use, wash the cutter with washing oil and apply a
thin layer of engine oil before storing.
Marks Stamped on the cutter
The marks stamped on the back of the cutter [A] represent
the following.
60° ........................... Cutter angle [B]
30 .......................... Outer diameter of cutter [C]
ENGINE TOP END 4-27
Valves
Operating Procedures
•Clean the seat area carefully.
•Coat the seat with machinist’s dye.
•Fit a 45° cutter [A] to the holder [B] and slide it into the
valve guide.
•Press down lightly on the handle [C] and turn it right or
left. Grind the seating surface only until it is smooth.
CAUTION
Do not grind the seat too much. Overgrinding will
reduce valve clearance by sinking the valve into the
head. If the valve sinks too far into the head, it will
be impossible to adjust the clearance, and the cylin-
der head must be replaced.
○Valve seat area form is as follows:

Widened Width [A] of engagement by machining with
45° cutter
Ground Volume [B] by 32° cutter
32° [C]
Correct Width [D]
Ground Volume [E] by 60° cutter
60° [F]
• Measure the outside diameter of the seating surface with

a vernier caliper.
If the outside diameter of the seating surface is too small,
repeat the 45° grind [A] until the diameter is within the
specified range.
Original Seating Surface [B]
NOTE
○Remove all pittings of flaws from 45° ground surface.
○After grinding with 45° cutter, apply thin coat of machin-
ist’s dye to seating surface. This makes seating surface
distinct and 32° and 60° grinding operation easier.
○When the valve guide is replaced, be sure to grind with
45° cutter for centering and good contact.
4-28 ENGINE TOP END
Valves
If the outside diameter of the seating surface is too large,
make the 32° grind described below.
If the outside diameter [A] of the seating surface is within
the specified range, measure the seat width as described
below.
•Grind the seat at a 32° angle [B] until the seat outside
diameter is within the specified range.
○To make the 32° grind, fit a 32° cutter into the holder, and
slide it into the valve guide.
○Turn the holder one turn at a time while pressing down
very lightly. Check the seat after each turn.
CAUTION
The 32° cutter removes material very quickly.
Check the seat outside diameter frequently to pre-
vent overgrinding.
○After making the 32° grind, return to the seat outside di-
ameter measurement step above.
• To measure the seat width, use a vernier caliper to mea-
sure the width of the 45° angle portion of the seat at sev-
eral places around the seat.
If the seat width is too narrow, repeat the 45° grind until
the seat is slightly too wide, and then return to the seat
outside diameter measurement step above.
If the seat width is too wide, make the 60° [A] grind de-
scribed below.
If the seat width is within the specified range, lap the valve
to the seat as described below.
•Grind the seat at a 60° angle until the seat width is within
the specified range.
○To make the 60° grind, fit 60° cutter into the holder, and
slide it into the valve guide.
○Turn the holder, while pressing down lightly.
○After making the 60° grind, return to the seat width mea-
surement step above.
Correct Width [B]
ENGINE TOP END 4-29
Valves
• Lap the valve to the seat using a lapper, once the seat
width and outside diameter are within the ranges specified
above.
○Put a little coarse grinding compound on the face of the
valve in a number of places around the valve head.
○Spin the valve against the seat until the grinding com-
pound produces a smooth, matched surface on both the
seat and the valve.
○Repeat the process with fine grinding compound.
[A] Lapper
[B] Valve Seat
[C] Valve
•The seating area should be marked about in the middle
of the valve face.
If the seat area is incorrect place on the valve, be sure
to check the valve is the correct part. If it is, it may have
been refaced too much replace the valve.
•Be sure to remove all grinding compound before assem-
bly.
•When the engine is assembled, be sure to adjust the valve
clearance (see Valve Clearance Adjustment).
Valve Head Thickness Inspection
• Measure the thickness of valve head.
Valve Head Thickness [A]
Standard:
Exhaust valve 0.8 mm (0.031 in.)
Inlet valve: 0.5 mm (0.020 in.)
Service Limit:
Inlet valve: 0.25 mm (0.010 in.)
If it is under the service limit, replace the valve.
Valve Stem Bend Inspection
• Support the valve at both ends of the straight stem por-
tion, and set a dial gauge against the center of the stem.
• Turn the valve and read the variation in the dial gauge [A].
Valve Stem Bend
Standard: TIR 0.01 mm (0.0004 in.) or less
Service Limit: TIR 0.05 mm (0.002 in.)
If it is bent over the service limit, replace the valve.
4-30 ENGINE TOP END
Valves
Valve Stem Diameter Inspection
• Measure the diameter of the valve stem.
Valve Stem Diameter [A]
Standard:
Inlet valve 4.475 ∼ 4.490 mm (0.1762 ∼ 0.1768 in.)
Exhaust valve 4.462 ∼ 4.472 mm (0.1757 ∼ 0.1761 in.)
Service Limit:
Inlet valve 4.46 mm (0.1756 in.)
Replace the valve if the stem is worn to less than the
service limit.
Valve Guide Inside Diameter Inspection
If a small bore gauge and micrometer are available, mea-
sure the valve guide as follows.
• Measure the inside diameter [A] of the valve guide. Since
the guide wears unevenly, measure the diameter at four
place up and down the guide.
Valve Guide Inside Diameter
Standard:
Exhaust 4.500 ∼ 4.512 mm (0.1772 ∼ 0.1776 in.)
Inlet 4.500 ∼ 4.512 mm (0.1772 ∼ 0.1776 in.)
Service Limit:
Exhaust 4.58 mm (0.1803 in.)
Inlet 4.58 mm (0.1803 in.)
If any measurement exceeds the service limit, replace the
valve guide.
Valve to Guide Clearance Measurement
If a small bore gauge is not available, inspect the valve
guide wear by measuring the valve to valve guide clearance
with the wobble method as indicated below.
• Insert a new valve [A] into the valve guide [B] and set a
dial gauge against the stem perpendicular to it as close
as possible to the cylinder head mating surface.
• Move the stem back and forth [C] to measure valve/valve
guide clearance.
Valve/Valve Guide Clearance (Wobble Method)
Standard:
Exhaust 0.06 ∼ 0.11 mm (0.0024 ∼ 0.043 in.)
Inlet 0.02 ∼ 0.08 mm (0.0008 ∼ 0.031 in.)
Service Limit:
Exhaust 0.25 mm (0.0098 in.)
Inlet 0.23 mm (0.0091 in.)
• Repeat
the first.
the measurement in a direction at a right angle to
If the reading exceeds the service limit, replace the guide.

NOTE
○The reading is not actual valve/valve guide clearance
because the measuring point is above the guide.
ENGINE TOP END 4-31
Valves
4-32 ENGINE TOP END
Cylinder, Piston
Cylinder Removal
• Removed the cylinder head.
• Take out the cylinder block with oil pipe, O-rings, lower
camshaft chain guide, and remove the gasket. There are
knock pins on the cylinder base.
• Wrap a clean cloth [A] around the base of the piston so
that no parts or dirt will fall into the crankcase.
Cylinder Installation
NOTE
○If the cylinder block is replaced with a new one, piston to
cylinder clearance must be checked against the speci-
fied value.
• Install a new cylinder base gasket [A] and be sure that

two knock pins [B] are properly fitted in the crankcase.
• Install the oil pipe [C] with O-ring [D].
• Pull the camshaft chain taut top avoid kicking it and use
a wrench on the crankshaft to set the piston at BDC.
• Position the piston ring opening as follows.
Top Ring-Exhaust Side [A]
Second Ring-Inlet Side [B]
Upper Steel Rail-About 30° ∼ 90° of angle to the right [C]
Expander-Rear [D]
Lower Steel Rail-About 30° ∼ 90° of angle to the left [C]
Piston [E]
• Apply engine oil to the piston rings and the cylinder inside
surface.
• Pull the camshaft chain up through the cylinder and insert
a screwdriver to keep the chain from falling back into the
engine.
• Place the upper camshaft chain guide inside the cylinder
blocks.
• Fit the bottom of the cylinder over the piston rings, press-
ing in on opposite sides of the rings as necessary. Take
care that the rings do not slip out of their proper positions.
• Insert the lower camshaft chain guide [A] all the way
down.
• Install the cylinder head.
ENGINE TOP END 4-33
Cylinder, Piston
Piston Removal
• Remove the cylinder.
• Wrap a clean cloth around the base of the piston.
• Using the plier [A] and remove the snap ring [B].
• Remove the piston by pushing its pin pull out the side
that the snap ring was removed. Use the piston pin puller
assembly [A] if the pin is tight.
Special Tool - Piston Pin Puller Assembly: 57001-910
• Remove the piston rings [A]. Carefully spread the ring

opening with your thumbs and then push up on the op-
posite side of the ring to remove it.
Piston Installation
NOTE
○The oil ring rails have no “top” or “bottom”.
• Install the oil ring expander [A] in the bottom piston ring
groove so that the ends [B] but together, never overlap.
• Install the oil ring steel rails, one above the expander and
one below it.
○Spread the rail with your thumbs, but only enough to fit
the rail over the piston.
○Release the rail into the bottom piston ring groove.
• Do not mix up the top ring and second ring.
• Install the
Install top ring [A] so that the “O” mark [B] faces up.
• up. the second ring [C] so that the “N” mark [D] faces
4-34 ENGINE TOP END
Cylinder, Piston
NOTE
○If a new piston is used, check piston to cylinder clear-
ance (see Piston/Cylinder Clearance), and use new pis-
ton rings.
• Install the piston so that the EX mark [A] on the piston

toward exhaust side.
• Fit a new piston snap ring into the side of the piston so
that the ring opening [A] does not coincide with the slit [B]
of the piston pin hole.
○When installing a piston pin snap ring, compress it only
enough to install it no more.
CAUTION
Do not reuse snap rings, as removal weakens and
deforms them. They could fall out and score the
cylinder wall.
Cylinder Inside Diameter Measurement

• Since there is a difference in cylinder wear in different di-
rections, take a side to side and a front to back measure-
ment at each of the 3 locations (total of 6 measurements)
shown in the figure.
If any of the cylinder inside diameter measurements ex-
ceeds the service limit, the cylinder will have to bored to
oversize and then honed.
Cylinder Inside Diameter
Standard: 52.997 ∼ 53.009 mm (2.0865 ∼ 2.0870
in.) and less than 0.01 mm (0.0004
in.) difference between any two
measurements
Service Limit: 53.10 mm (2.0905 in.) or 0.05 mm
(0.002 in.) difference between any two
measurements
10 mm (0.394 in.) [A]
60 mm (2.362 in.) [B]
20 mm (0.787 in.) [C]
ENGINE TOP END 4-35
Cylinder, Piston
Piston Diameter Measurement
• up
Measure the outside diameter [A] of the piston 5 mm [B]
from the bottom of the piston at a right angle to the
direction of the piston pin.
Piston Diameter
Standard: 52.972 ∼ 52.983 mm (2.0855 ∼ 2.0859 in.)
NOTE
○Abnormal wear such as a marked diagonal pattern
across the piston skirt may mean a bent connecting
rod or crankshaft.
Piston/Cylinder Clearance
The most accurate way to find the piston clearance is
by making separate piston and cylinder diameter measure-
ments and then computing the difference between the two
values. Measure the piston diameter as just described, and
measure the cylinder diameter at the very bottom of the
cylinder.
Piston/Cylinder Clearance
Standard: 0.014 ∼ 0.034 mm (0.00055 ∼ 0.0134 in.)
NOTE
○Whenever the piston cylinder has been replaced with a
new one, the motorcycle must be broken in the same
as with a new machine.
Piston Ring End Gap

• Place the piston ring [A] inside the cylinder, using the pis-
ton to locate the ring squarely in place. Set it close to the
bottom of the cylinder, where cylinder wear is low.
• Measure the gap [B] between the ends of the ring with a
thickness gauge.
Piston Ring End Gap
Standard:
Top 0.15 ∼ 0.30 mm (0.0059 ∼ 0.0118 in.)
Second 0.30 ∼ 0.45 mm (0.0118 ∼ 0.0177 in.)
Oil 0.10 ∼ 0.60 mm (0.0039 ∼ 0.0236 in.)
Service Limit:
Top 0.60 mm (0.0236 in.)
Second 0.75 mm (0.0295 in.)
Oil 0.90 mm (0.0354 in.)
4-36 ENGINE TOP END
Cylinder, Piston
Piston Ring, Piston Ring Groove Inspection
• Visually
grooves.
inspects the piston rings and the piston ring
If the rings are worn unevenly or damaged, they must be

replaced.
If the piston ring grooves are worn unevenly or damaged,
the piston must be replaced and fitted with new rings.
• Check for uneven groove wear by inspecting the ring seat-
ing.
The rings should fit perfectly parallel to the groove sur-
faces. If not, the piston must be replaced.
• With the piston rings in their grooves, make several mea-
surements with a thickness gauge [A] to determine piston
ring groove clearance.
Piston Ring/Groove Clearance

Standard:
Top 0.020 ∼ 0.060 mm (0.0008 ∼ 0.0024 in.)
Second 0.010 ∼ 0.050 mm (0.0004 ∼ 0.0020 in.)
Service Limit:
Top 0.16 mm (0.0063 in.)
Second 0.15 mm (0.0059 in.)
Piston Ring Thickness

Standard:
Top 0.77 ∼ 0.79 mm (0.0303 ∼ 0.0311 in.)
Second 0.77 ∼ 0.79 mm (0.0303 ∼ 0.0311 in.)
Service Limit:
Top 0.70 mm (0.0276 in.)
Second 0.70 mm (0.0276 in.)
Piston Ring Groove Width

Standard:
Top 0.81 ∼ 0.83 mm (0.0319 ∼ 0.0327 in.)
Second 0.80 ∼ 0.82 mm (0.0315 ∼ 0.0323 in.)
Service Limit:
Top 0.91 mm (0.0358 in.)
Second 0.90 mm (0.0354 in.)
If the clearance exceeds the service limit, remove the pis-

ton rings, and measure the thickness of the piston rings
and the width of the ring grooves. If the ring has worn
down to less than the service limit, replace the ring, if the
groove width exceeds the service limit replace the piston.
ENGINE TOP END 4-37
Cylinder, Piston
Piston, Piston Pin, Connecting Rod Wear Inspection
• Visually inspect the snap rings [A] are fitted in place.
If the ring shows weakness or deformation, replace the
ring. Also if the pin hole groove shows excessive wear,
replace the piston.
• Visually inspect the piston pin hole and connecting rod
small end hole.
If the piston pin hole shows uneven wear, replace the pis-
ton.
If the rod small end hole shows uneven wear, replace the
rod, or crankshaft assembly.
• Visually inspect the outer surface of the piston pin [B].
If the pin shows color change or stepped wear, replace
the pin.
Piston, Piston Pin, Connecting Rod Inspection
• Measure the inside diameter of both piston pin holes in
the piston.
Piston Pin Hole Inside Diameter [A]
Standard: 13.001 ∼ 13.007 mm (0.5118 ∼ 05121 in.)
If either piston pin hole diameter exceeds the service limit,
replace the piston.
• Measure the diameter of the piston pin.
Piston Pin Diameter [B]
Standard: 12.995 ∼ 13.000 mm (0.5116 ∼ 0.5118 in.)
If the piston pin diameter is less than the service limit at
any point, replace the piston pin.
Measure the inside diameter [A] of the connecting rod
small end.
Connecting Rod Small End Inside Diameter
Standard: 13.003 ∼ 13.014 mm (0.5119 ∼ 0.5124 in.)
Service limit: 13.05 mm (0.514 in.)
If the diameter exceeds the service limit, replace the con-
necting rod.
4-38 ENGINE TOP END
Muffler
Muffler Removal
• Unscrew the front footpeg bolts and remove the footpeg
assembly [A].
• Unscrew the muffler mounting bolt [B].
• Unscrew the exhaust pipe holder nuts [A].
• Pull out the muffler mounting bolt and remove the muffler
assembly.
Muffler Installation
• Check the gasket and replace it if damaged.
Torque - Muffler Mounting Bolt: 21 N·m (2.1 kgf·m, 15 ft·lb)
Exhaust Pipe Holder Nuts: 21 N·m (2.1 kgf·m, 15
ft·lb)
• After tightening the mounting bolts and nuts securely,
thoroughly warm up the engine, wait until the engine
cools down and tighten all mounting bolts and nuts.
CLUTCH 5-1
Clutch
Table of Contents
Exploded View........................................................................................................................ 5-2
Specifications ......................................................................................................................... 5-4
Special Tools .......................................................................................................................... 5-5
Clutch Cover........................................................................................................................... 5-6
Clutch Cover and Oil Screen Removal ............................................................................. 5-6 5
Clutch Cover and Oil Screen Installation .......................................................................... 5-6
Clutches.................................................................................................................................. 5-8
Clutch Removal................................................................................................................. 5-8
Clutch Installation.............................................................................................................. 5-8
Secondary Clutch Disassembly ........................................................................................ 5-10
Secondary Clutch Assembly ............................................................................................. 5-10
Primary Clutch Housing Wear........................................................................................... 5-11
Primary Clutch Shoe Lining Wear..................................................................................... 5-11
One-Way Clutch Inspection .............................................................................................. 5-11
Clutch Plate Wear and Damage ....................................................................................... 5-12
Clutch Plate Warp ............................................................................................................. 5-12
Secondary Clutch Housing Finger Damage...................................................................... 5-12
Secondary Clutch Hub Spline Damage ............................................................................ 5-12
Secondary Clutch Spring Free Length Measurement....................................................... 5-13
Clutch Release Adjustment............................................................................................... 5-13
5-2 CLUTCH
Exploded View
CLUTCH 5-3
Exploded View
Torque
N·m kgf·m ft·lb
1 Clutch Cover Bolts 8.8 0.9 78 in·lb
2 Clutch Cover Damper Bolts 2.9 0.3 26 in·lb
3 Clutch Cover Oil Seal Screws 2.9 0.3 26 in·lb
4 Primary Clutch Hub Nut 77 7.9 57
5 Secondary Clutch Hub Bolt 49 5.0 36 L, R
6 Secondary Clutch Spring Bolts 8.8 0.9 78 in·lb
7 Clutch Adjusting Locknut 19 1.9 13.5
G: Apply grease.
R: Replacement Part
5-4 CLUTCH
Specifications

Primary Clutch
Primary Clutch Housing Inside 112.0 ∼ 112.4 mm (4.4094 ∼ 4.4252 in.) 112.7 mm (4.44 in.)
Diameter
Primary Clutch Shoe Groove Depth 1 mm (0.04 in.) 0.5 mm (0.02 in.)
Secondary Clutch
Friction Plate Thickness 2.9 ∼ 3.0 mm (0.1142 ∼ 0.1181 in.) 2.6 mm (0.102 in.)
Friction Plate Warp 0.1 mm (0.0039 in.) or less 0.3 mm (0.0118 in.)
Steel Plate Warp 0.15 mm (0.0059 in.) or less 0.3 mm (0.0118 in.)
Clutch Spring Free Length 40.0 mm (1.575 in.) 38.1 mm (1.50 in.)
Clutch Release 1/4 turn out – – –
CLUTCH 5-5
Special Tools
Clutch Holder 1: Gear Holder, m2.0:
57001-1507 57001-1557
5-6 CLUTCH
Clutch Cover
Clutch Cover and Oil Screen Removal
• Drain the engine oil (see Engine Lubrication System).
• Remove:
Front Footpeg [A]
Kick Pedal [B]
Muffler Assembly [C]
• Remove:
Clutch Cover Bolts [A]
• Pull out the clutch cover [B].
• Unscrew the clutch adjuster locknut [A].

• with the cover.plate [B] and the release shaft [C] come out
The release
• Pull out the oil screen [A].
Clutch Cover and Oil Screen Installation

• Clean
screen.
any metal particles and other dirt out of the oil
• Using compressed air, blow out any particles which may

obstruct the oil passage [A] in the clutch cover.
CLUTCH 5-7
Clutch Cover
• Apply grease to the O-ring and install it.

• but no the
Turn in release plate [A] into the release shaft [B] fully
tightly and then back it out the three turns, and
insert it into the hole [C] of clutch cover securely.
• Tighten the locknut into the release shaft from the oppo-
site side.
Torque - Clutch Adjusting Locknut: 19 N·m (1.9 kgf·m, 13.5
in·lb)
• Check that the ball bearing is in place.

• Check that theto the
Apply grease kick shaft oil seal lips.
• crankcase. two dowel pins are in place on the
• Install the clutch cover. Be sure that the release cam [A],
and release ball assembly [B] are not falling down.
• Tighten the clutch cover bolts.

Torque - Clutch Cover Bolts: 8.8 N·m (0.9 kgf·m, 78 in·lb)
• Adjust the clutch (see Clutch Release Adjustment in Pe-
riodic Maintenance chapter).
5-8 CLUTCH
Clutches
Clutch Removal
• Remove the clutch cover (see this chapter).
• Pull out the clutch release lever [A].
• Release Ball Assembly [B]
Remove:
Release Cam [C]

Ball Bearing [D]
• Remove the primary clutch hub nut [A], while holding the
primary clutch steady with the primary clutch holder [B].
Special Tool - Primary Clutch Holder: 57001-1507
• Pull out the primary clutch hub [C].
• Remove the secondary clutch hub bolt, while holding the

secondary clutch steady with the gear holder [A].
Special Tool - Gear Holder, m2.0: 57001-1557
• Remove
together.
the primary clutch [A] and secondary clutch [B]
○Do not remove the one-way clutch from the primary

clutch.
• Remove the spacer from the drive shaft.
Clutch Installation
• Apply engine oil to the clutch sleeves and drive shaft,
crankshaft.
• Install the spacer [A] to the drive shaft.
•○Hard to install
Insert the secondary clutch.
the secondary clutch, turn the drive shaft
while pushing the clutch.
• Tighten the secondary clutch bolt, while holding the sec-
ondary clutch steady with the gear holder.
Torque - Secondary Clutch Hub Bolt: 49 N·m (5.0 kgf·m, 36
ft·lb)
Special Tool - Gear Holder, m2.0: 57001-1557
CLUTCH 5-9
Clutches
If the primary clutch housing disassembled, assemble it
as follows.
○Install the gear [B] to the primary clutch housing [A].
○Install the spring [C] to the holder [D].
○Fit the tooth form of the gears, and press the holder to the
clutch housing.
○Before installing the clutch housing, mark [E] on the tip of
optional tooth (1 place).
○The gear shall be rotated clockwise [F] more than 1 tooth
and less than 2 teeth (Confirm that marking is rotated).
•Install the clutch housing.
If the one-way clutch and race dropped from the primary

clutch housing install it as follows.
○Put the one-way clutch [A] in the clutch housing halfway
with the rotation mark [B] facing out.
○Fit the race [C] with the machining unevenness side [D]
facing to the outside into the one-way clutch and push
them together in the clutch housing.
• Install the clutch hub.

• clutch steady
Tighten the primary clutch nut while holding the primary
with the primary clutch holder.
Special Tool - Primary Clutch Holder: 15001-1507
Torque - Primary Clutch Hub Nut: 77 N·m (7.9 kgf·m, 57
ft·lb)
• Install the ball bearing [A].
• Apply
bly.
grease to the release cam and release ball assem-
• Install the release cam [A] and release ball assembly [B].
• shaft line
Install the release lever [C] to the shift shaft, with shift
[D] aligning to release lever line [E].
• Adjust the clutch
Install the cover.
• riodic Maintenance
clutch (see Clutch Release Adjustment in Pe-
chapter).
5-10 CLUTCH
Clutches
Secondary Clutch Disassembly
• Remove the secondary clutch.
• Unscrew the clutch spring bolts [A] and take off the spring
plate [B] and springs [C].
• Remove the clutch hub [A] and clutch wheel [B].

• Remove the secondary clutch plates [C].
Secondary Clutch Assembly

• Install the friction plates [A] and steel plates [B] on the
secondary clutch hub [C], starting with a friction plate and
alternating them.
CAUTION
If new dry steel plates and friction plates are in-
stalled, apply engine oil to the surfaces of each
plate to avoid clutch plate seizure.
• Install the clutch wheel on the clutch hub.

• Install the clutch spring plate [A] with the springs and
spring bolts temporarily and fit the clutch hub and plate
assembly into the clutch housing [B].
• Tighten:
Torque - Secondary Clutch Spring Bolts: 8.8 N·m (0.9
kgf·m, 78 in·lb)
CLUTCH 5-11
Clutches
Primary Clutch Housing Wear
• Measure the inside diameter [A] of the clutch housing slid-
ing surface.
○Use a vernier caliper and measure at several points as
shown.
If any measurement is greater than the service limit, re-
place the primary clutch housing.
Primary Clutch Housing Inside Diameter
Standard: 112.0 ∼ 112.4 mm (4.4094 ∼ 4.4252 in.)
Primary Clutch Shoe Lining Wear

• Remove the primary clutch hub (see Clutch Removal).
• even wear, discoloration,
Visually inspect the primary clutch shoe linings [A] for un-
missing friction material, cracks
or other damage.
If any of the linings are damaged, replace the primary
clutch hub.
•○Measure the groove depth [A].

Use a depth gauge, and measure at several points as
shown.
If any measurement is less than the service limit, replace
the primary clutch hub.
Primary Clutch Shoe Groove Depth
One-Way Clutch Inspection

• Remove the clutch cover.
• Turn the primary clutch housing by hand. When view from
the right side of the engine, the primary clutch housing
should turn counterclockwise freely [A] but should not turn
clockwise.
If the one-way clutch does not operate as it should or if it

makes noise, go to the next steps.
○Remove the primary clutch.
○Check that the one-way clutch is installed so that the ro-
tation mark faces out.
○Visually inspect the one-way clutch [A] and the race [B] in
the primary clutch housing.
If there is any worn or damaged part, replace it.
5-12 CLUTCH
Clutches
Clutch Plate Wear and Damage
• Visually inspect the friction and steel plates for uneven
wear, discoloration, missing friction material, cracks, or
other damage.
If any plates show signs of damaged, replace the friction
and steel plates as a set.
• Measure the thickness of the friction plates [A] at several
points.
Friction Plate Thickness [B]
Standard: 2.9 ∼ 3.0 mm (0.1142 ∼ 0.1181 in.)
If any of the measurement is less than the service limit,
replace the plates as a set.
Clutch Plate Warp
• Place each friction plate or steel plate [A] on a surface
plate [B] and measure the gap between the surface plate
and each plate with a thickness gauge [C]. The gap is the
amount of friction and steel plate warp.
If any of the clutch plate is warped beyond the service
limit, replace the plate with a new one.
Friction Plate and steel Plate Warp
Standard: 0.15 mm (0.0059 in.) or less (Steel Plate)
0.1 mm (0.0039 in.) or less (Friction
Plate)
Secondary Clutch Housing Finger Damage

• Visually inspect the clutch housing finger [A] where the
friction plate tangs [B] hit them.
If they are badly worn or if there are groove cuts where the
tangs hit, replace the housing. Also, replace the friction
plates if their tangs are damaged.
Secondary Clutch Hub Spline Damage

• Visually inspect where the teeth on the steel plates wear
against the clutch hub splines.
If there are notches worn into the clutch hub splines [A],
replace the clutch hub. Also, replace the steel plates if
their teeth are damaged.
CLUTCH 5-13
Clutches
Secondary Clutch Spring Free Length Measurement
• Measure the spring free length [A].
If measurement is less than the service limit, replace it.
Clutch Spring Free Length
Clutch Release Adjustment

• Refer to the Clutch Operation Inspection in the Periodic
ENGINE LUBRICATION SYSTEM 6-1

Table of Contents
Exploded View........................................................................................................................ 6-2
Engine Oil Flow Chart............................................................................................................. 6-4
Specifications ......................................................................................................................... 6-5
Engine Oil and Oil Filter.......................................................................................................... 6-6
Oil Level Inspection........................................................................................................... 6-6
Engine Oil Change............................................................................................................ 6-6
Engine Oil and Oil Filter.......................................................................................................... 6-7 6
Oil Filter Replacement ...................................................................................................... 6-7
Oil Screen Cleaning .......................................................................................................... 6-7
Engine Oil Pump..................................................................................................................... 6-8
Engine Oil Pump Removal................................................................................................ 6-8
Engine Oil Pump Installation............................................................................................. 6-8
Engine Oil Pump Inspection.............................................................................................. 6-8
Oil Pressure Measurement..................................................................................................... 6-9
Oil Pressure Measurement ............................................................................................... 6-9
6-2 ENGINE LUBRICATION SYSTEM
Exploded View
Exploded View
Torque
N·m kgf·m ft·lb
1 Oil Pump Mounting Screws 4.9 0.5 43 in·lb
2 Oil Filter Cap Bolts 8.8 0.9 78 in·lb
3 Engine Oil Drain Plug 29 3.0 22
G: Apply grease.
R: Replacement parts
Engine Oil Flow Chart
1. Crankshaft
2. Oil Screen
3. Oil Filter
4. Camshaft
5. Oil Pump
6. Oil Passage (Cylinder)
Specifications

Engine Oil
Grade API SE, SF or SG
API SH or SJ with JASO MA – – –
Viscosity SAE 10W-40 – – –
Capacity:
(When filter is not removed) 0.90 L (0.95 US qt.) – – –
(When filter is removed) 0.96 L (1.01 US qt.) – – –
(When engine is completely dry) 1.10 L (1.16 US qt.) – – –
Level Between upper and lower level lines – – –
Oil Pressure Measurement
Oil Pressure @4 000 rpm (r/min) Oil 39 ∼ 78 kPa (0.4 ∼ 0.8 kgf/cm², 6 ∼ 11 psi) – – –
Temperature 50°C (140°F)
Engine Oil and Oil Filter
In order for the engine transmission and clutch to function
properly, always maintain the engine oil at the proper level
and change the oil and replace the oil filter in accordance
with the Periodic Maintenance chapter.
WARNING
Motorcycle operation with insufficient, deteri-
orated, or contaminated engine oil will cause
accelerated, wear and may result in engine or
transmission seizure, accident, and injury.
Oil Level Inspection

• Ifit for
the oil has just been changed, start the engine and run
several minutes at idle speed. This fills the oil filter
with oil. Stop the engine, then wait several minutes until
the oil settles.
CAUTION
Racing the engine before the oil reaches every part
can cause engine seizure.
• Iffortheallmotorcycle has just been used, wait several minutes

the oil to drain down.
• unscrew motorcycle
With the held level by using the center stand,
the oil filler cap, wipe the dipstick on the cap dry,
and reinsert it without screwing.
CAUTION
Be careful not to allow any dirt or foreign materials
to enter the engine.
• Pull out the oil filler cap [A] and check the oil level by the
dipstick [B] on the cap. The oil level should be between
the “H” (High) [C] and “L” (Low) [D] lines on the dipstick.
• Ifthetheoiloilfillerlevel is too high, remove the excess oil through

opening using a syringe or some other suitable
device.
• If the oil level is too low, add the oil to reach the correct
level. Use the same type and brand of oil that is already
in the engine.
Engine Oil Change

• Refer to the Engine Oil Change in the Periodic Mainte-
nance chapter.
Engine Oil and Oil Filter
Oil Filter Replacement
• Refer to the Oil Filter Replacement in the Periodic Main-
tenance chapter.
Oil Screen Cleaning
• Remove the clutch cover (see Clutch chapter).
•○Clean the screen
Pull out the oil screen [A].
with high-flash point solvent, and then
dry it.
○Clean the screen thoroughly whenever the engine oil is
changed.
NOTE
○While cleaning the screen, check for any metal particles
that engine indicate internal damage.
WARNING
Clean the oil screen in a well-ventilated area, and
take care that there are no sparks or flame any-
where near the working area, this includes any ap-
pliance with a pilot light.
Do not use gasoline or a low-flash point solvent to
clean the oil screen. A fire or explosion could re-
sult.
Replace the screen with a new one if it is damaged.
• Install:
Oil Screen
Clutch Cover
Engine Oil Pump
Engine Oil Pump Removal
• Remove the clutch cover (see Clutch chapter).
• Remove the clutch assemblies (see Clutch chapter).
• screws [A] can be removed
Turn the crankshaft so that the engine oil pump mounting
through the pump gear holes,
and remove the screws and oil pump [B].
Engine Oil Pump Installation

• Replace the O-rings with new ones.
• Check
place.
to see that the knock pin [A] and O-rings [B] are in
•○Install the oil pump and screws.

When installing the oil pump, be sure the oil pump gear [A]
and pump drive gear [B] on the crankshaft mesh properly.
Torque - Oil Pump Mounting Screws: 4.9 N·m (0.5 kgf·m, 43
in·lb)
Engine Oil Pump Inspection

• Visually inspect the oil pump body [A], outer rotor [B], in-
ner rotor [C] and cover [D].
If there is any damage or uneven wear, replace the oil
pump assembly.
• Remove the oil filter cap (see Oil Filter Replacement in the
Periodic Maintenance chapter), and attach the oil pres-
sure cap [A], adapter [B] and gauge [C].
Special Tools - Oil Pressure Gauge, 5 kgf/cm²: 57001-125
Oil Pressure Gauge Adapter, M10 × 1.25:
57001-1182
Oil Pressure Cap: 57001-1651
• Start the engine and warm up the engine.

• pressureengine
Run the
gauge.
at the specified speed, and read the oil
If the oil pressure is much lower than the standard, check

the oil pump and crankshaft bearing insert wear.
If the reading is much higher than the standard, check
the oil pump screen and oil filter first, oil passages for
clogging.
Oil Pressure
Standard: 39 ∼ 78 kPa (0.4 ∼ 0.8 kgf/cm², 6 ∼ 11 psi)
@4 000 r/min (rpm), oil temperature 50°C
(122°F)
• Stop the engine.

• cap. the oil pressure gauge, adapter and oil pressure
Remove
WARNING
Take care against burns form hot engine oil that
will drain through the oil passage when the gauge
adapter is removed.
• Install the oil filter cap (see Oil Filter Replacement in the
Periodic Maintenance chapter).
ENGINE REMOVAL/INSTALLATION 7-1
Table of Contents
Exploded View........................................................................................................................ 7-2
Engine Removal/Installation ................................................................................................... 7-4
Engine Removal................................................................................................................ 7-4
Engine Installation............................................................................................................. 7-5
7
7-2 ENGINE REMOVAL/INSTALLATION
Exploded View
Exploded View
Torque
N·m kgf·m ft·lb
1 Engine Mounting Nuts 44 4.5 33
2 Engine Bracket Nuts 25 2.5 18
7-4 ENGINE REMOVAL/INSTALLATION
Engine Removal
• Drain the engine oil (see Engine Oil Change in the Peri-
odic Maintenance chapter).
• Remove:
Headlight Cowling
Front Step Through Cover
Left Leg Shield Outer
Right Leg Shield Outer
Rear Step Through Cover
Left Leg Shield Inner
Right Leg Shield Inner
Tail Cover
Left Side Cover
Right Side Cover
• Remove:
Footpeg Bracket Mounting Bolts [A]
Muffler Mounting Bolt [B]
Footpeg Bracket
• Take off the front footpeg assembly.
• Remove:
Muffler [A]
Rear Right Footpeg Bracket [B]
Brake Pedal [C]
Kick Pedal [D]
Intake Pipe Bolts [E]
Spark Plug Cap [F]
Battery Cable (–) (Earth Terminal) [G]
Starter Motor Cable Connector [H]
Magneto Lead Connector [I]
Gear Position Switch Lead Connector [J]
Ignition Coil [K]
• Remove:
Engine Mounting Nuts [A]
Engine Bracket Nuts [B]
• Remove:
Shift Pedal [A]
Engine Sprocket Cover [B]
Engine Sprocket (see Final Drive chapter)
Drive Chain (see Final Drive chapter)
Breather Tube Lower End [C]
• Support the engine with a suitable stand.

• mount thetheengine.
Remove three engine mounting bolts [A] and dis-
Engine Installation
• Support the engine with a suitable stand and set it at the
correct position.
• Insert the lower engine mounting bolt [A] from left side of
the engine.
• Install the middle [B] and upper [C] engine mounting bolts.
• Tighten:
Torque - Engine Mounting Nuts: 44 N·m (4.5 kgf·m, 33 ft·lb)
Engine Bracket Nuts: 25 N·m (2.5 kgf·m, 18 ft·lb)
• Install the removed parts.
• Adjust the drive chain (see Final Drive chapter).
CRANKSHAFT/TRANSMISSION 8-1
Crankshaft/Transmission
Table of Contents
Exploded View........................................................................................................................ 8-2
Specifications ......................................................................................................................... 8-6
Special Tools & Sealant.......................................................................................................... 8-7
Crankcase Splitting................................................................................................................. 8-8
Crankcase Splitting ........................................................................................................... 8-8
Crankcase Assembly ........................................................................................................ 8-9
Crankshaft, Connecting Rod .................................................................................................. 8-12
Crankshaft Disassembly and Assembly............................................................................ 8-12
Disassembly...................................................................................................................... 8-12
Assembly .......................................................................................................................... 8-12
Connecting Rod Big End Seizure .....................................................................................
Connecting Rod Big End Radial Clearance ......................................................................
8-13
8-13
8
Connecting Rod Big End Side Clearance ......................................................................... 8-13
Crankshaft Runout ............................................................................................................ 8-13
Crankshaft Alignment........................................................................................................ 8-14
Crankshaft Main Bearing Wear......................................................................................... 8-14
Transmission .......................................................................................................................... 8-15
Shift Pedal Removal ......................................................................................................... 8-15
Shift Pedal Installation ...................................................................................................... 8-15
External Shift Mechanism Removal .................................................................................. 8-15
External Shift Mechanism Inspection................................................................................ 8-15
Shift Drum Removal.......................................................................................................... 8-16
Shift Drum Installation....................................................................................................... 8-16
Transmission Removal ..................................................................................................... 8-16
Transmission Installation .................................................................................................. 8-16
Transmission Shaft Disassembly ...................................................................................... 8-17
Transmission Shaft Assembly........................................................................................... 8-17
Shift Fork Bending ............................................................................................................ 8-18
Shift Fork Ear/Gear Shift Fork Groove Wear .................................................................... 8-19
Shift Fork Guide Pin/Shift Drum Groove Wear ................................................................. 8-19
Gear Dog/Gear Dog Hole Damage................................................................................... 8-19
Ball Bearing, Needle Bearing, and Oil Seal............................................................................ 8-20
Ball Bearing and Outer Race Replacement ...................................................................... 8-20
Ball and Needle Bearing Wear.......................................................................................... 8-20
Oil Seal Inspection ............................................................................................................ 8-21
Kickstarter............................................................................................................................... 8-22
Kickstarter Removal.......................................................................................................... 8-22
Kickstarter Installation....................................................................................................... 8-22
Kickstarter Assembly ........................................................................................................ 8-22
Kickstarter Inspection........................................................................................................ 8-22
8-2 CRANKSHAFT/TRANSMISSION
Exploded View
Exploded View
Torque
N·m kgf·m ft·lb
1 Magneto Flywheel Bolt 49 5.0 36 R, L
2 Primary Clutch Hub Nut 77 7.9 57
3 Shift Return Spring Pin 34.3 3.5 25 L
4 Bearing Stopper Screw 5 mm (0.20 in.) 2.9 0.3 26 in·lb
5 Bearing Stopper Screw 6 mm (0.24 in.) 4.9 0.5 43 in·lb
6 Engine Oil Drain Plug 29 3.0 22
7 Crankcase Bolts 8.8 0.9 78 in·lb S
8 Crankcase Studs – – – L
9 Shift Drum Position Bolt 19 1.9 14
G: Apply grease.
LG: Apply liquid gasket.
Exploded View
Exploded View
Torque
N·m kgf·m ft·lb
1 Gear Position Switch Screws 2.9 0.30 26 in·lb
2 Shift Drum Allen Bolt 9.8 1.0 87 in·lb L
3 Shift Pedal Clamp Bolt 12 1.2 108 in·lb
4 Shift Return Spring Pin 34.3 3.5 25 L
5 Kick Lever Bolt 12 1.2 104 in·lb
6 Shift Drum Positioning Lever Screw 5.9 0.6 52 in·lb
G: Apply grease.
Specifications

Crankshaft, Connecting Rods
Connecting Rod:
Big End Radial Clearance 0.001 ∼ 0.020 mm (0.00004 ∼ 0.00078 in.) 0.07 mm (0.0028 in.)
Big End Side Clearance 0.1 ∼ 0.2 mm (0.004 ∼ 0.008 in.) 0.4 mm (0.016 in.)
Crankshaft Runout TIR 0.03 mm (0.0012 in.) or less TIR 0.08 mm
(0.0031 in.)
Transmission
Shift Fork Ear Thickness 4.4 ∼ 4.5 mm (0.173 ∼ 0.177 in.) 4.3 mm (0.169 in.)
Gear Shift Fork Groove Width 4.55 ∼ 4.65 mm (0.179 ∼ 0.183 in.) 4.8 mm (0.189 in.)
Shift Fork Guide Pin Diameter 4.9 ∼ 5.0 mm (0.193 ∼ 0.197 in.) 4.8 mm (0.189 in.)
Shift Drum Groove Width 5.05 ∼ 5.20 mm (0.199 ∼ 0.205 in.) 5.3 mm (0.209 in.)
Kick Shaft
Kick Shaft Diameter 19.959 ∼ 19.980 mm (0.7858 ∼ 0.7866 in.) 19.94 mm (0.7850 in.)
Kick Gear Inside Diameter 20.000 ∼ 20.021 mm (0.7874 ∼ 0.7882 in.) 20.06 mm (0.7898 in.)
Special Tools & Sealant
Outside Circlip Pliers: Bearing Driver Set:
57001-144 57001-1129
Bearing Puller: Crankshaft Jig:

57001-158 57001-1174
Crankcase Splitting Tool Assembly: Kawasaki Bond (Liquid Gasket - Silver):

57001-1098 92104-002
Crankcase Splitting
Crankcase Splitting
• Remove the engine (see Engine Removal in the Engine
Removal/Installation chapter).
• Set the engine on a clean surface and hold the engine
steady while parts are being removed.
• Remove:
Cylinder Head (see Cylinder Head Removal in the En-
gine Top End chapter)
Cylinder (see Cylinder Removal in the Engine Top End
chapter)
Piston (see Piston Removal in the Engine Top End chap-
ter)
Clutch Cover (see Clutch Cover and Oil Screen Removal
in the Clutch chapter)
Primary Clutch, Secondary Clutch (see Clutch Removal
in the Clutch chapter)
Kick Shaft (see Kick Starter Removal)
Oil Filter & Oil Pump (see Oil Filter Replacement in the
Periodic Maintenance chapter & Engine Oil Pump Re-
moval in the Engine Lubrication System chapter)
External Shift Mechanism (see External Shaft Mecha-
nism Removal)
Magneto Cover (see Magneto Cover Removal in the
Electrical System chapter)
Magneto Flywheel (see Magneto Flywheel Removal in
the Electrical System chapter)
Starter Motor & Gear (AN130-B1, B6F/C1, C6F Model,
see Starter Motor & Starter Motor Idle Gears Removal
in the Electrical System chapter)
Gear Position Switch
Crankcase Bolts [A]
• Screw the crankcase splitting tool [A] into the left side of
the crankcase [B]. Be certain to screw the adapters in all
the way.
Special Tool - Crankcase Splitting Tool Assembly: 57001
-1098
• Tighten the center bolt of the crankcase splitting tool to
split the crankcase.
○Remove the left crankcase half.
• Remove the crankshaft from the right crankcase half us-

ing a press [A].
CAUTION
Do not remove the ball, needle bearings and the oil
seals unless it is necessary. Removal may damage
them.
• Press the remaining bearing out of the crankcase half if

the bearing remains on the crankcase half.
Crankcase Splitting
Crankcase Assembly
CAUTION
Right and left crankcase halves are machined at the
factory in the assembled state, so the crankcase
halves must be replaced as a set.
• Chip off the old gasket from the mating surfaces of the
crankcase halves.
• Using compressed air, blow out the oil passages [A] in the
crankcase halves and the crankshaft.
• With a high-flash point solvent, clean off the mating sur-
faces of the crankcase halves and wipe dry.
WARNING
Clean the engine parts in a well-ventilated area, and
take care that there are no sparks or flame any-
where near the working area; this includes any ap-
pliance with a pilot light. Do not use gasoline or a
low-flash point solvent to clean parts. A fire or ex-
plosion could result.
• Using a press and the bearing driver set, install new bear-
ings until they bottoms out.
○Press the output shaft bearing [A] in the left crankcase
half so that the shielded side [B] faces to the oil seal.
Special Tool - Bearing Driver Set: 57001-1129
• Apply high-temperature grease to the lips of the oil seals.
• the sealin surface
Press the oil seals [C] of the left crankcase half so that
is flush [D] with the end of the hole.
• Install the height of this rubber bushing [A] by the press

and the bearing driver set until the end of an outer collar
of this bushing [B] shall be 32.3 mm (1.27 in.) ∼ 32.8 mm
(1.29 in.) [C] from the fitting surface [D] of left crankcase
[E].
• Install the height of this rubber bushing [A] by the press

and the bearing driver set until the end of an outer collar
of this bushing [B] shall be 44.7 mm (1.76 in.) ∼ 45.2 mm
(1.78 in.) [C] from the fitting surface [D] of left crankcase
[E].
Crankcase Splitting
• Insert the crankshaft jig [A] between the crankshaft fly-

wheels opposite the connecting rod big end to protect fly-
wheel alignment. This tool is easily adjustable to fit in any
gap between the flywheel.
Special Tool - Crankshaft Jig: 57001-1174
• Tighten the shift drum screws [A] and drive shaft bearing
retainer screw [B] to the right crankcase.
Torque - Bearing Stopper Screws 5 mm: 2.9 N·m (0.3 kgf·m,
29 in·lb)
Bearing Stopper Screw 6 mm: 4.9 N·m (0.5 kgf·m,
43 in·lb)
• Fit the crankshaft into the right crankcase half using a

press [A].
• Install:
Shift Drum [A]
Transmission Shaft Assemblies [B]
Shift Forks [C]
• Check that the shift drum is in neutral position.
• Check that two dowel pins [D] and O-rings [E] in place of
the right crankcase half.
• Set the crankcase installing jig [F].
Special Tool - Crankshaft Jig: 57001-1174
• Make sure that the mating surfaces of the crankcase

halves are completely free of oil or contamination.
• Apply liquid gasket to the mating surface of the left
crankcase half as shown.
Sealant - Kawasaki Bond (Liquid Gasket-Silver): 92104
-002
NOTE
○Do not apply liquid gasket to this aria [A].
Crankcase Splitting
• Fit the crankcase halves together hitting with a plastic

hammer on the left crankcase side.
○Check to see that the crankshaft, and out put shaft all turn
freely.
If the crankshaft will not turn, it is probably not centered.
Tap the mount portion of the crankcase with a plastic ham-
mer [A] to reposition it. If it does not free up, split the
crankcase again and find the cause.
Spinning the output shaft, shift the transmission through
all the gears to make certain there is not binding and that
all the gears shift properly.
• Clean the cylinder and oil filter cap of the mating surface
and wipe off the liquid gasket forced out.
• Tighten the crankcase screws in that order shown.

Torque - Crankcase Bolts: 8.8 N·m (0.9 kgf·m, 78 in·lb)
NOTE
○Apply a non-permanent locking agent to this screw [10]
only.
• Remove the crankcase installing jig.

Crankshaft, Connecting Rod
Crankshaft Disassembly and Assembly
CAUTION
Since assembly of the crankshaft demands exact-
ing tolerance, the disassembly and reassembly
of the crankshaft should only be performed by
experienced mechanics with the necessary tools
and equipment. The crankpin, connecting rod, and
right crankshaft are available separately as spare
parts, however it is recommended that the crank-
shaft assembly be replaced rather than attempting
to replace the components.
Disassembly
• Iffollow
it should be necessary to disassemble the crankshaft,
the following procedures.
• using thethe
Remove camshaft chain drive sprockets and bearing,
bearing puller if the drive sprocket and bearing
remains on the crankshaft.
• Use a press to remove the crankpin.
• Removal of the crankpin separates the flywheels, con-
necting rod, big end needle bearing, and crankpin.
Special Tool - Bearing Puller: 57001-158
Assembly
• Press the bearing until it bottoms out.
• flywheel ascamshaft
Press the
shown.
chain drive sprocket [A] on to the left
Crankpin [B]
28.4 ±0.3 mm (1.118 ±0.012 in.) [C]
• Crankpin [A] is set to the oil line [C] of crankshaft [B].
• Apply engine oil to the big end bearing.

• crankpinthedirection
Press crank halves onto the crankpin, noting the
until connecting rod side clearance is
within specification as shown.
Side Clearance [A]: 0.1 ∼ 0.2 mm (0.0039 ∼ 0.0079 in.)
Crankpin Depth [B]: 0.8 ∼ 1.2 mm (0.0315 ∼ 0.0472 in.)
• Check the following items after the crankshaft assembly.
Connecting Rod Radial Clearance
Connecting Rod Side Clearance
Crankshaft Runout
Connecting Rod Big End Seizure
In the case of serious seizure with damaged flywheels,
the crankshaft must be replaced.
In the case of less serious damage, disassemble the
crankshaft and replace the crankpin, needle bearing,
side washers, and connecting rod.
Connecting Rod Big End Radial Clearance
• Set the crankshaft in flywheel alignment jig or on V blocks,
and place a dial gauge [A] against the big end of the con-
necting rod.
• Push [B] the connecting rod first towards the gauge and
then in the opposite direction. The difference between the
two gauge readings is the radial clearance.
If the radial clearance exceeds the service limit, the crank-
shaft should be either replaced or disassembled and the
crankpin, needle bearing, and connecting rod big end ex-
amined for wear.
Connecting Rod Big End Radial Clearance
Standard: 0.001 ∼ 0.020 mm (0.00004 ∼ 0.00078 in.)
Connecting Rod Big End Side Clearance

• Measure the side clearance [A] of the connecting rod with
a thickness gauge.
If the clearance exceeds the service limit, replace the
crankshaft.
Connecting Rod Big End Side Clearance
Standard: 0.1 ∼ 0.2 mm (0.004 ∼ 0.008 in.)
Crankshaft Runout
• Set the crankshaft in a flywheel alignment jig or on V
blocks, and place a dial gauge [A] against the points indi-
cated.
Measurement Point [B]: 8 mm (0.315 in.)
• Turn the crankshaft slowly. The maximum difference in
gauge readings is the crankshaft runout.
Crankshaft Runout
Standard: TIR 0.03 mm (0.0012 in.) or less
Service Limit: TIR 0.08 mm (0.0031 in.)
Crankshaft Alignment
If the runout at either point exceeds the service limit, align
the flywheels so that the runout falls within the service
limit.
•In the case of horizontal misalignment, which is the most
common, strike the projecting rim of the flywheel with a
plastic, soft lead, or brass hammer as indicated in the
figure.
•Recheck the runout with a dial gauge, repeating the
process until the runout falls within the service limit.
○Vertical misalignment is corrected either by driving a
wedge in between the flywheels, or by squeezing the
flywheel rims in a vise, depending on the nature of the
misalignment.
• Incorrect
the case of both horizontal and vertical misalignment,
the horizontal misalignment first.
• (see Connecting
Recheck big end side clearance after aligning crankshaft
Rod Big End Side Clearance).
NOTE
○If crankshaft alignment cannot be corrected by the
above method, replace the crankpin or crank halves as
required. Recheck the runout and repeat the process
until the runout is within service limit.
CAUTION
Don’t hammer the flywheel at the point [A].
Crankshaft Main Bearing Wear

• Wash the bearings in high-flash point solvent, blow them
dry (DO NOT SPIN THEM), and lubricate them with en-
gine oil.
• Turn each bearing [A] over by hand and see that it makes
no noise, turns smoothly and has no rough spots.
If any of the bearings are defective, replace them.
Transmission
Shift Pedal Removal
• Remove the foot peg [A].
• Remove the clamp bolt [C].
• Remove the shift pedal [B] from the shift shaft.
Shift Pedal Installation

• Install the shift pedal so that the engine sprocket cover
line [A] and shift pedal [B] may become the horizontal.
External Shift Mechanism Removal

• Drain the engine oil (see Engine Lubrication System
chapter).
• Remove:
Clutch (see Clutch Removal in the Clutch chapter)
Shift Pedal
• Remove the shift shaft [A] while pushing [B] the shift
mechanism arm [C] toward the shift shaft.
External Shift Mechanism Inspection

• Examine the shift shaft [A] for any damage.
If the shaft is bent, straighten or replace it.
If the splines [B] are damaged, replace the shaft.
If the springs [C] [D] are damaged in any way, replace
them.
If the shift pawl [E] is damaged in any way, replace the
shift shaft assembly.
• Check the return spring pin [A] is not loose.

If it is loose, unscrew it to apply a non-permanent locking
agent to the threads, and tighten it.
Torque - Shift Return Spring Pin: 34.3 N·m (3.5 kgf·m, 25
ft·lb)
• Check the gear positioning lever [B], and their springs [C]
for breaks or distortion.
If the lever or springs are damaged in any way, replace
them.
• Visually inspect the shift drum cam [D].
If the cam is badly worn or if it shows any damage, replace
it.
Transmission
Shift Drum Removal
• Remove:
Shift Drum Allen Bolt [A]
Cam Holder [B]
Shift Drum Cam [C]
Shift Drum Holder
Dowel Pins
• Split the crankcase.
• Remove the shift drum.
Shift Drum Installation

• Assembly the crankcase.
• Install the holder [A] aligning its holes [B] with the dowel
pins [C].
• Install the shift drum cam [A] aligning its holes [B] with the
dowel pins [C].
• Install the holder and tighten the Allen bolt.
Torque - Shift Drum Allen Bolt: 9.8 N·m (1.0 kgf·m, 87 in·lb)
Transmission Removal
• Split the crankcase.
• Shift Rod [A]
Remove:
Shift Drum [B]

Shift Forks [C]
Transmission Shafts [D]
Transmission Installation
• Apply a clean engine oil to the transmission gears, bear-
ings, and shaft journal, and fit the output [A] and drive
shaft [B] assemblies as a set into the right crankcase half.
• Set the shift drum in neutral position.
Transmission
• Apply a clean engine oil to the shift fork fingers, and fit
each shift fork into its gear-groove so that the shift fork
guide pin is in the proper shift drum-groove.
NOTE
○Fingers of the 1st/3rd shift fork are longer than the fin-
gers of the 2nd/4th shift fork.
• Apply a clean engine oil to the shift rod [A], and insert
each rod running it through each shift fork [B].
• Set the tip of stopper [A] between the shift drum [B] and
shift rod [C] as shown.
• Set the shift drum in neutral position, that is, drive and
output shaft turn freely.
• Assemble the crankcase.
NOTE
○Shall be checked that it is impossible to shift change
from top position to neutral position when output shaft
is driven.
Transmission Shaft Disassembly

• Remove the transmission shafts.
• Using the circlip pliers to remove the circlip, disassemble
the transmission shaft.
Special Tool - Outside Circlip Pliers: 57001-144
Transmission Shaft Assembly

•○Assemble the transmission gears as shown.
Replace the old circlip with a new one if it is removed.
○The drive shaft gears can be identified by size; the small-
est diameter gear is 1st gear, and the largest it 4th. Be
sure that all parts are put back in the correct sequence,
facing the proper direction, and that the circlip and the
washer are properly in place.
2nd Gear [A]
3rd Gear [B]
4th Gear [C]
1st Gear [D]
Circlip [E]
Shim [F]
Transmission
○The output shaft gears can be identified by size; the
largest diameter gear is 1st gear, and the smallest is
4th. Be sure that all parts are put back in the correct
sequence and facing the proper direction, and that the
circlip is properly in place.
2nd Gear [A]
3rd Gear [B]
4th Gear [C]
1st Gear [D]
Circlip [E]
Spacer [F]
Stopper [G]
Spring [H]
○Always install circlips so that the opening is aligned with

a spline groove. To install a circlip without damage, first
fit the circlip onto the shaft expanding it just enough to
install it, and then use a suitable gear to push the circlip
into place.
[A] Opening of Circlip
[B] Groove of Shaft Spline
Shift Fork Bending

• Visually 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.
[A] 90°
Transmission
Shift Fork Ear/Gear Shift Fork Groove Wear
• Measure the thickness [A] of the shift fork ears.
If the thickness of a shift fork ear is less than the service
limit, the shift fork must be replaced.
Shift Fork Ear Thickness
Standard: 4.4 ∼ 4.5 mm (0.173 ∼ 0.177 in.)
• Measure the width [A] of the gear shift fork grooves in the
transmission gears.
If a gear shift fork groove is worn over the service limit,
the gear must be replaced.
Gear Shift Fork Groove Width
Standard: 4.55 ∼ 4.65 mm (0.179 ∼ 0.183 in.)
Shift Fork Guide Pin/Shift Drum Groove Wear

• Measure the diameter [A] of each shift fork guide pin, and
measure the width of each shift drum groove.
If the guide pin on any shift fork is less than the service
limit, the fork must be replaced.
Shift Fork Guide Pin Diameter
Standard: 4.9 ∼ 5.0 mm (0.193 ∼ 0.197 in.)
If any shift drum groove [A] is worn over the service limit,
the drum must be replaced.
Shift Drum Groove Width
Standard: 5.05 ∼ 5.20 mm (0.199 ∼ 0.205 in.)
Gear Dog/Gear Dog Hole Damage

• Visually inspect the gear dogs [A] and gear dog holes [B].
Replace any damaged gears or gears with excessively
worn dogs or dog holes.
Ball Bearing, Needle Bearing, and Oil Seal
Ball Bearing and Outer Race Replacement
CAUTION
Do not remove the ball bearing or needle bearing
outer race unless it is necessary. Removal may
damage them.
• Using a press or puller, remove the ball bearing and/or

needle bearing outer race.
NOTE
○In the absence of the above mentioned tools, satisfac-
tory results may be obtained by heating the case to ap-
proximately 93°C (200°F) max., and tapping the bearing
in or out.
CAUTION
Do not heat the case with a blowtorch. This will
warp the case. Soak the case in oil and heat the
oil.
• Using a press and the bearing driver set [A], install the
new bearing or outer race until it stops at the bottom of its
housing.
Ball and Needle Bearing Wear

CAUTION
Do not remove the ball bearings for inspection. Re-
moval may damage them.
•○Check the ball bearings.

Since the ball bearings are made to extremely close toler-
ances, the wear must be judged by feel rather than mea-
surement. Clean each bearing in a high-flash point sol-
vent, dry it (do not spin the bearing while it is dry), and oil
it with engine oil.
○Spin [A] 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.

The 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 bear-
ing, replace it.
Ball Bearing, Needle Bearing, and Oil Seal
Oil Seal Inspection
• Inspect the oil seal.
Replace it if the lips are misshapen, discolored (indicating
that the rubber has deteriorated), hardened or otherwise
damaged.
Kickstarter
Kickstarter Removal
• Remove:
Clutch Cover (see Clutch chapter)
Clutch
• Remove the return spring [A] with needle nose pliers [B].
• Remove the kick shaft assembly [C], twisting it counter-
clockwise.
• There is a thrust washer between the kick shaft end and
the crankcase.
Kickstarter Installation
• Install the setplate [A] facing the marking [B] outward.
• Set the spring [C] and the insert the spring end [D].
• Install the plastic spring guide [E].
Kickstarter Assembly
• Apply a thin coat of molybdenum disulfide grease [A] to
the ratchet teeth and the kick gear inside.
Ratchet [B]
Kick Gear [C]
Kick Shaft [D]
Spring Guide [E]
Return Spring [F]
Setplate [G]
Circlips [H]
Washers [I]
• Replace the circlips that were removed with new ones.
Kickstarter Inspection
• Visually inspect the parts and portion listed below.
Kick Shaft Return Spring [A]
Setplate [B]
Ratchet Portion [C] of the Kick Gear [D] and Ratchet
Gear [E]
If there is any kind of damage, replace the damaged part.
Kickstarter
• Measure
fits.
the kick shaft diameter [A] where the kick gear
If it is under the service limit, replace the shaft.

• Measure the inside diameter [B] of the kick gear.
If it exceeds the service limit, replace the gear.
Kick Shaft, Kick Gear Diameter
Standard:
Kick Shaft 19.959 ∼ 19.980 mm
(0.7858 ∼ 0.7866 in.)
Kick Shaft Gear 20.000 ∼ 20.021 mm
(0.7874 ∼ 0.7882 in.)
Service Limit:
Kick Shaft 19.94 mm (0.7850 in.)
Kick Shaft Gear 20.06 mm (0.7898 in.)
WHEELS/TIRES 9-1
Wheels/Tires
Table of Contents
Exploded View........................................................................................................................ 9-2
Specifications ......................................................................................................................... 9-6
Special Tools .......................................................................................................................... 9-7
Wheels (Rims) ........................................................................................................................ 9-8
Front Wheel Removal ....................................................................................................... 9-8
Front Wheel Installation .................................................................................................... 9-8
Rear Wheel Removal........................................................................................................ 9-10
Rear Wheel Installation..................................................................................................... 9-10
Spoke Tightness Inspection (AN130-A1/B1, B6F Models) ............................................... 9-11
Rim Runout Inspection (AN130-A/B Models).................................................................... 9-11
Wheel Inspection .............................................................................................................. 9-12
Axle Inspection.................................................................................................................. 9-12
Rim and Spoke Removal (AN130-A1/B1, B6F Models).................................................... 9-13
Rim and Spoke Installation (AN130-A1/B1, B6F Models)................................................. 9-13
9
Spoke Replacement (AN130-A1/B1, B6F Models) ........................................................... 9-13
Tires........................................................................................................................................ 9-14
Tire Air Pressure Inspection.............................................................................................. 9-14
Wheel/Tire Damage Inspection......................................................................................... 9-14
Tire Tread Wear, Abnormal Wear Inspection .................................................................... 9-14
Wheel Bearing Damage Inspection .................................................................................. 9-14
Tire and Tube Removal..................................................................................................... 9-14
Tire and Tube Installation.................................................................................................. 9-15
Hub Bearing............................................................................................................................ 9-16
Hub Bearing Removal....................................................................................................... 9-16
Hub Bearing Installation.................................................................................................... 9-16
Bearing Inspection ............................................................................................................ 9-16
Bearing Lubrication ........................................................................................................... 9-17
Speedometer Gear Housing................................................................................................... 9-18
Speedometer Gear Housing Disassembly........................................................................ 9-18
Speedometer Gear Housing Assembly............................................................................. 9-18
Lubrication ........................................................................................................................ 9-19
9-2 WHEELS/TIRES
Exploded View
AN130-A1/B1, B6F
WHEELS/TIRES 9-3
Exploded View
Torque
N·m kgf·m ft·lb
1 Spoke Nipples 1.5 ∼ 2.1 0.15 ∼ 0.21 13 ∼ 18 in·lb
2 Front Axle Nut 49 5.0 36
3 Rear Axle Nut 54 5.5 40
G: Apply grease.
WL: Apply soap and water solution.
9-4 WHEELS/TIRES
Exploded View
AN130-C1/C6F
WHEELS/TIRES 9-5
Exploded View
Torque
N·m kgf·m ft·lb
1 Front Axle Nut 49 5.0 36
2 Rear Axle Nut 54 5.5 40
G: Apply grease.
WL: Apply soap and water solution.
9-6 WHEELS/TIRES
Specifications

Wheels
Rim Runout (with tire installed):
AN130-A1/B1, B6F:
Axial 0.8 mm (0.03 in.) or less 2.0 mm (0.08 in.)
Radial 1.0 mm (0.04 in.) or less 2.0 mm (0.08 in.)
AN130-C1, C6F:
Axial 0.5 mm (0.02 in.) or less 1.0 mm (0.04 in.)
Radial 0.8 mm (0.03 in.) or less 1.0 mm (0.04 in.)
Axle Runout/100 mm 0.1 mm (0.004 in.) 0.2 mm (0.008 in.)
Rim Size:
Front 17 × 1.40 – – –
Rear 17 × 1.60 – – –
Tires
Standard Tire:
Front 70/90-17 M/C 38P IRC NR72
Rear 80/90-17 M/C 44P IRC NR72
Thailand:
Front 70/90-17 M/C 38P IRC NF35
Rear 80/90-17 M/C 44P IRC NR75
Tire Air Pressure:
Front 200 kPa (2.00 kgf/cm², 29 psi) – – –
Rear 225 kPa (2.25 kgf/cm², 32 psi) – – –
Tread Depth:
Front 3.9 mm (0.15 in.) 1 mm (0.04 in.)
Rear 4.6 mm (0.18 in.) 2 mm (0.08 in.)
Thailand:
Front 4.0 mm (0.16 in.) 1 mm (0.04 in.)
Rear 5.1 mm (0.20 in.) 2 mm (0.08 in.)
WHEELS/TIRES 9-7
Special Tools
Bearing Driver Set: Bearing Remover Head, 10 × 12:
57001-1129 57001-1266
Bearing Remover Shaft, 9:

57001-1265
9-8 WHEELS/TIRES
Wheels (Rims)
Front Wheel Removal
• Remove:
Cotter Pin [A]
Front Axle Nut [B]
Caliper Mounting Bolts [C]
Caliper [D]
• Using a jack, raise the front wheel off the grand.
• Remove:
Speedometer Cable End [A]
• Pull
[C].
out the axle [B] and remove the speedometer gear
• Remove the wheel.

• Insert a wooden
The collar [A] comes apart.
• caliper (to preventboard between the pads in the front
the caliper pistons from coming out).
CAUTION
Do not lay the wheel down on one of the discs. This
can damage or warp the disc. Place blocks un-
der the wheel so that the disc does not touch the
ground.
Front Wheel Installation

• Apply grease to the seal lip [A] of the speedometer gear.
• notchesspeedometer
Fit the
[C].
gear projections [B] in the wheel hub
• Fit the collar [A] on the right side of the hub.

WHEELS/TIRES 9-9
Wheels (Rims)
• Fit the speedometer gear groove [A] to the fork stop [B]
and install the front wheel.
• Install the axle from the left side.
• Tighten the front axle nut [A] temporary.

• Tighten thecaliper
Install the [B].
• caliper mounting bolts [C] and front axle nut.
Torque - Caliper Mounting Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb)
Front Axle Nut: 49 N·m (5.0 kgf·m, 36 ft·lb)

NOTE
the nearest hole.
• Bend the cotter pin [A] over the nut.
• Insert the speedometer inner cable into the speedometer

gear housing while turning the wheel so that the end [A]
of the inner cable will seat into the square hole [B] of the
speedometer gear pinion.
• Tighten the cable nut with pliers.
• Check the front brake effectiveness (see Brakes chapter).
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
this is not done.
9-10 WHEELS/TIRES
Wheels (Rims)
Rear Wheel Removal
• Set the motorcycle up on its center stand.
• Remove:
Adjusting Nut [A]
Cotter Pin [B]
Rear Axle Nut [C]
CAUTION
Do not depress the brake pedal deeply with the
brake rod inserted into the brake cam lever joint,
this may elongate the spring beyond its allowable
spring extension.
• Remove:
Rear Axle Shaft [A]
Drive Chain [B]
• Remove the rear wheel from the motorcycle.
Rear Wheel Installation

• Apply high-temperature grease to the grease seal.
• Install the collar on the left [A] and right of the rear hub.
WHEELS/TIRES 9-11
Wheels (Rims)
• Fit the tongue [A] on the swingarm into the groove [B] on
the rear brake panel.
• Install the rear wheel.

• Adjust the drive
Install the chain.
• chapter). drive chain slack (see Periodic Maintenance
• Turn the brake panel clockwise until the brake cam lever
joint goes beyond the brake rod end then insert the brake
rod end into the joint hole.
CAUTION
Do not insert the brake rod into the cam lever joint
by depressing the brake pedal deeply, this will ex-
tend the brake spring beyond its allowable spring
extension.
• Tighten:
Torque - Rear Axle Nut: 54 N·m (5.5 kgf·m, 40 ft·lb)
NOTE
the nearest hole.
• Bend the cotter pin [A] over the nut [B].

• Adjust:
Drive Chain Slack (see Periodic Maintenance chapter)
Brake Pedal Free Play (see Periodic Maintenance chap-
ter)
Spoke Tightness Inspection (AN130-A1/B1, B6F

Models)
• Refer to the Spoke Tightness Inspection in the Periodic
Rim Runout Inspection (AN130-A/B Models)
• Refer to the Rim Runout Check in the Periodic Mainte-
nance chapter.
9-12 WHEELS/TIRES
Wheels (Rims)
Wheel Inspection
• Raise the front/rear wheel off the ground.
Special Tool - Jack: 57001-1238
• Spin the wheel lightly, and check for roughness or binding.
If roughness or binding is found, replace the hub bearings.
• Inspect
warp.
the wheel for small cracks, dents, bending, or
If there is any damage to the wheel, replace the wheel.

• Remove the wheel, and support it with the tire by the axle.
• Measure
gauge.
the rim runout, radial [A] and axial [B], with a dial
If rim runout exceeds the service limit, check the hub bear-
ings.
If the problem is not due to the bearings, replace the
wheel.
AN130-C1, C6F
Rim Runout (with Tire Installed)
Standard:
Axial TIR 0.5 mm (0.02 in.) or less
Radial TIR 0.8 mm (0.03 in.) or less
Service Limit:
Axial TIR 1.0 mm (0.04 in.) or less
Radial TIR 1.0 mm (0.04 in.) or less
WARNING
Never attempt to repair a damaged wheel. If there
is any damage besides wheel bearings, the wheel
must be replaced to insure safe operational condi-
tion.
AN130-A1/B1, B6F
•Refer to the Rim Runout Inspection in the Periodic Main-
tenance chapter.
Axle Inspection
• Visually inspect the front and rear axle for damages.
If the axle is damaged or bent, replace it.
• Place the axle in V blocks that are 100 mm (3.94 in.) [A]
apart, and set a dial gauge on the axle at a point halfway
between the blocks.
• Turn the axle to measure the runout. The difference be-
tween the highest and lowest dial readings is the amount
of runout.
If runout exceeds the service limit, replace the axle.
Axle Runout/100 mm
WHEELS/TIRES 9-13
Wheels (Rims)
Rim and Spoke Removal (AN130-A1/B1, B6F Models)
• Remove the tire and tube.
• Remove the rubber band.
• don’t get mixed
Tape or wire all the spoke intersections so that the spokes
up, and unscrew the nipples from all the
spokes with a screwdriver; separate the rim from the
spokes and hub.
[A] Tape
Rim and Spoke Installation (AN130-A1/B1, B6F

Models)
• Install the drum at smaller diameter side if the rim has a
mark attached.
• Install the drum with a arrow mark rotating direction if it
has an arrow mark.
• Tighten the spokes evenly so that the radial (out from the
axle) and axial (side to side) runouts are less than the
service limit. Make sure that the spokes are tightened
evenly within the standard torque range.
Tightening Torque
Spokes: 1.5 ∼ 2.1 N·m (0.15 ∼ 0.21 kgf·m, 13 ∼ 18 in·lb)
Spoke Replacement (AN130-A1/B1, B6F Models)

• Insert the newtirespoke
Reduce the air pressure by a small amount.
• the nipple. through the hub, and bend it to meet
• Tighten the nipples with a spoke wrench.

Tightening Torque
Spokes: 1.5 ∼ 2.1 N·m (0.15 ∼ 0.21 kgf·m, 13 ∼ 18 in·lb)
• Inflate the tire to the specified pressure.

• Install the wheel.
9-14 WHEELS/TIRES
Tires
Tire Air Pressure Inspection
• Refer to the Tire Air Pressure Inspection in the Periodic
Wheel/Tire Damage Inspection
• Refer to the Wheel/Tire Damage Inspection in the Peri-
odic Maintenance chapter.
Tire Tread Wear, Abnormal Wear Inspection
• Refer to the Tire Tread Abnormal Wear Inspection in the
Periodic Maintenance chapter.
Wheel Bearing Damage Inspection
• Refer to the Wheel Bearing Damage Inspection in the Pe-
Tire and Tube Removal
• Remove
moval).
the wheel from the motorcycle (see Wheel Re-
• To maintain wheel balance, mark [A] the valve stem posi-

tion on the tire with chalk so that the tire can be reinstalled
in the same position.
• Take out the valve core [B] to let out the air.
• Remove the valve stem nut [C].
• Lubricate the tire beads and rim flanges on both sides with
a soap and water solution. This helps the tire beads slip
off the rim flanges.
CAUTION
Never lubricate with mineral oil (engine oil) or gaso-
line because they will cause deterioration of the tire.
• Break the beads away from both sides of the rim.

• soap and water
Lubricate the tire irons [A] and rim protectors [B] with a
solution, or rubber lubricant.
• pry the tire off theofrim
Step on the side the tire opposite the valve stem, and
with tire iron of the bead breaker
protecting the rim with rim protectors.
NOTE
○For easier removal, always position the tire iron oppo-
site the valve stem in the rim well, and pry the tire bead
a little at a time.
CAUTION
Take care not inset the tire irons so deeply that the
tube gets damaged.
• Remove the tube when one side of the tire is pried off.
• rim from the tire.
Pry the other side of the tire off the rim, and remove the
WHEELS/TIRES 9-15
Tires
Tire and Tube Installation
• Put just enough air in the tube to keep it from getting
caught between the tire and rim. Too much air makes
fitting difficult, and too little will make the tube more liable
to be pinched by the irons.
• Dust the tube and inside the tire with talcum powder, and
insert the tube into the tire now, even if the tire was com-
pletely removed from the rim. Insert the valve stem into
the rim, and screw the nut on loosely.
• Lubricate the tire beads and rim flanges with a soap and
water solution.
• By hand, slide as much as possible of the lower side of the
tire bead over the rim flange, starting at the side opposite
the valve.
• Use tire irons to install the remaining part of the tire instal-
lation, position the part of the bead which is already over
the rim flange in the rim well.
• Install the other side of the tire bead onto the rim in the
same manner.
• Check that the tube is not pinched between the tire and
rim.
• Lubricate the tire beads and rim flanges with a soap and
water solution to help seat the tire beads in the sealing
surfaces of the rim while inflating the tire.
• Position the tire on the rim so that the valve [A] is at the tire
balance mark [B] (the chalk mark made during removal or
the yellow paint mark on an new tire).
• Center the rim in the tire beads, and inflate the tire with
compressed air until the tire beads seat in the rim flange.
• Check the tire rotation mark on the front and rear tires and
install them on the rim accordingly.
Tire Rotation Mark [A]
Rotation Direction [B]
• Check to see that the rim lines on both sides of the tire
sidewalls are parallel with the rim flanges.
If the rim lines and tire sidewall lines [A] are not parallel,
remove the valve core. Lubricate the rim flanges and tire
beads. Install the valve core and inflate the tire again.
• Inflate the tire to the specified pressure.
• Install the air valve cap.
• Install the wheel.
9-16 WHEELS/TIRES
Hub Bearing
Hub Bearing Removal
• To remove the grease seals, pry out the grease seal using
a screwdriver.
• Using the bearing remover shaft and bearing remover
head, remove the hub bearings [A].
Special Tools - Bearing Remover Shaft, φ9: 57001-1265 [B]
Bearing Remover Head, φ10 × φ12: 57001
-1266 [C]
Hub Bearing Installation

• Before installing the hub bearings, blow any dirt or foreign
particles out the hub with compressed air to prevent con-
tamination of the bearings.
•Inspect the bearings and replace them if necessary.
•Install the bearings [A] using the bearing driver set [B] so
that the marked or shield sides face out.
○Press in the bearings until they bottom out.
NOTE
○For correct tire alignment, the right bearing must be in-
stalled first rather than left bearing in both front and rear
hubs.
• Inspect the grease seal [A] and replace if necessary.

• Apply high-temperature grease to the grease seal lips.
• flush with
Press in the grease seal so that the seal surface [B] is
the end of the hole.
Special Tool - Bearing Driver Set: 57001-1129 [C]
Bearing Inspection
Since the hub bearings are made to extremely close tol-
erances, the clearance cannot normally be measured.
CAUTION
Do not remove any bearings for inspection. If any
bearings are removed, they will need to be replaced
with new ones.
• Turn each bearing in the hub back and forth [A] while
checking for plays, roughness, or binding. If bearing play,
roughness, or binding is found, replace the bearing.
• Examine the bearing seal [B] for damage or leakage.
If the seal is damaged or is leaking, replace the bearing.
WHEELS/TIRES 9-17
Hub Bearing
Bearing Lubrication
• Wash the bearings with a high flash-point solvent, dry
them (do not spin them while they are dry), and oil them.
• Spin each bearings by hand to check its condition.
If it is noisy, does not spin smoothly, or has any rough
spots, it must be replaced.
• If the same bearing is to be used again, re-wash it with a
high flash-point solvent, and dry it.
• Pack each bearings with good quality bearing grease [A]
before installation. Turn each bearing around by hand
a few times to make sure the grease is distributed uni-
formly inside the bearing, and wipe the old grease out of
the bearing housings on the wheel hub before bearing in-
stallation.
9-18 WHEELS/TIRES
Speedometer Gear Housing
Speedometer Gear Housing Disassembly
NOTE
○It is recommended that the speedometer gear housing
be replaced rather than attempting to repair the compo-
nents.
• Pull the speedometer gear housing [A] and collar off the
front wheel.
• Pull
[C].
out the grease seal [B] using a hook and snap ring
• Pull the washer [D] and the speedometer gear [E].

If the speedometer cable bushing or speedometer pinion
needs to be removed, replace them as follows:
○Using a 2 mm (0.08 in.) rod [A], tap out the pin.
○Pull out the speedometer cable bushing [A] and pinion [B].
Speedometer Gear Housing Assembly

• Apply a grease to the pinion and the speedometer cable
bussing, and install them to the speedometer gear hous-
ing.
NOTE
○When the bushing shall be replaced with new one, it is
necessary to bore the hole of 2 mm (0.08 in.) for the
spring pin to it.
• After inserting a new pin, stake the housing hole to secure

the pin in place.
• Apply a grease to the speedometer gear.
• Install:
Washer
Speedometer Gear
Snap Ring
• Replace the grease seal with a new one.
• Apply a grease to the oil seal lips.
• Press in the oil seal until it bottoms out.
• Install the speedometer gear housing so that it fits in the
speedometer gear drive notches.
WHEELS/TIRES 9-19
Speedometer Gear Housing
Lubrication
• Clean and grease [A] the speedometer gear housing [B].
FINAL DRIVE 10-1
Final Drive
Table of Contents
Exploded View........................................................................................................................ 10-2
Specifications ......................................................................................................................... 10-4
Special Tools .......................................................................................................................... 10-5
Drive Chain............................................................................................................................. 10-6
Drive Chain Slack Inspection ............................................................................................ 10-6
Drive Chain Slack Adjustment .......................................................................................... 10-6
Wheel Alignment Inspection/Adjustment .......................................................................... 10-6
Drive Chain Wear Inspection ............................................................................................ 10-6
Chain Guide Wear Inspection ........................................................................................... 10-6
Drive Chain Lubrication..................................................................................................... 10-6
Drive Chain Removal ........................................................................................................ 10-6
Drive Chain Installation ..................................................................................................... 10-7
Sprockets, Coupling ............................................................................................................... 10-8
Engine Sprocket Removal ................................................................................................ 10-8
Engine Sprocket Installation ............................................................................................. 10-8
Rear Sprocket Removal.................................................................................................... 10-8 10
Rear Sprocket Installation................................................................................................. 10-9
Coupling Bearing Removal ............................................................................................... 10-9
Coupling Bearing Installation ............................................................................................ 10-9
Coupling Bearing Inspection and Lubrication ................................................................... 10-9
Coupling Damper Inspection............................................................................................. 10-10
Sprocket Wear Inspection................................................................................................. 10-10
Sprocket Diameter Inspection........................................................................................... 10-10
Rear Sprocket Warp Inspection ........................................................................................ 10-10
10-2 FINAL DRIVE
Exploded View
FINAL DRIVE 10-3
Exploded View
Torque
N·m kgf·m ft·lb
1 Rear Axle Nuts 54 5.5 40
2 Rear Sprocket Nuts 34 3.5 25
3 Drive Chain Cover 4.9 0.5 43 in·lb
4 Engine Sprocket Cover Screws 4.9 0.5 43 in·lb
G: Apply grease.
HO: Apply heavy oil.
10-4 FINAL DRIVE
Specifications

Drive Chain
Make KMC – – –
Type 420DX – – –
Link 108 links
Drive Chain Slack 20 ∼ 35 mm (0.79 ∼ 1.38 in.) – – –
20 Link Length 254.0 ∼ 254.6 mm (10.0 ∼ 10.02 in.) 259 mm (10.2 in.)
Sprocket
Engine Sprocket Diameter 49.10 ∼ 49.30 mm (1.933 ∼ 1.941 in.) 48.4 mm (1.91 in.)
Rear Sprocket Diameter 161.49 ∼ 161.99 mm (6.358 ∼ 6.378 in.) 161.2 mm (6.35 in.)
Rear Sprocket Warp 0.4 mm (0.016 in.) or less 0.5 mm (0.02 in.)
FINAL DRIVE 10-5
Special Tools
Outside Circlip Pliers: Bearing Driver Set:
57001-144 57001-1129
10-6 FINAL DRIVE
Drive Chain
Drive Chain Slack Inspection
• Refer to the Drive Chain Slack Check in the Periodic
Drive Chain Slack Adjustment
• Refer to the Drive Chain Slack Adjustment in the Periodic
Wheel Alignment Inspection/Adjustment
• Check to see that the notches [A] on the alignment indi-
cators on both sides are in the same relative position at
the rear end [B] of the hole in each swingarm.
If they do not, adjust the chain slack and align the wheel
alignment (see Drive Chain Slack Adjustment in the Peri-
odic Maintenance chpater).
NOTE
○Wheel alignment can be also checked using the
straightedge or string method.
WARNING
wear, and may result in an unsafe riding condition.
Drive Chain Wear Inspection

• Refer to the Drive Chain Wear Check in the Periodic Main-
tenance chapter.
Chain Guide Wear Inspection
• Refer to the Chain Guide Wear Inspection in the Periodic
Drive Chain Lubrication
• Refer to the Drive Chain Lubrication in the Periodic Main-
tenance chapter.
Drive Chain Removal
• Remove:
Screws [A]
Drive Chain Cover [B]
Engine Sprocket Cover
FINAL DRIVE 10-7
Drive Chain
• Remove the clip [A] from the drive chain master link using
pliers, and remove the master link.
• Free the drive chain from the sprockets, being careful that
the chain does not get dirty from contact with the ground.
Drive Chain Installation

• Fit the drive chain back onto the sprockets with the ends
at the rear sprocket.
• Install the master link from the frame side.
• [B] in the clip
Instal the [A] so that the closed end of the “U” pointed
direction of chain rotation [C].
WARNING
Incorrect installation of the master link clip can al-
low it to catch on an adjacent part. If the clip dis-
lodges, the chain could come a part, and this could
result in rear wheel lockup and loss of control.
• Fit the projection [A] of the swingarm into the hole [B] of
the chain cover.
• Tighten the screws.
• justment indrive
Adjust the chain slack (see Drive Chain Slack Ad-
the Periodic Maintenance chapter).
• Check the rear brake (see Brake Pedal Free Adjustment
in the Brakes chapter).
10-8 FINAL DRIVE
Sprockets, Coupling
Engine Sprocket Removal
• Remove:
Foot Peg [A]
Shift Pedal [B]
Screws [C]
Engine Sprocket Cover [D]
• Remove the circlip [A] and take off the sprocket [B] with
drive chain [C].
• Pull the collar and O-ring off the output shaft.
Special Tool - Outside Circlip Pliers: 57001-144
Engine Sprocket Installation

• Apply high-temperature grease to the O-ring.
•○Install the O-ring and collar [A] to the output shaft.
The chamfered side [B] of the collar must be faced in.
• Install the engine sprocket so that the spot faced side [A]
face out, and drive chain together.
• Fit the circlip [B] with the round side facing [C] in as shown.
• Install: the drive chain slack if necessary.
Adjust
• Engine Sprocket Cover
Drive Chain Cover
Rear Sprocket Removal

• Remove the rear wheel (see Wheels/Tires chapter).
• bent over thetheside
Straighten side of the double lockwasher [A] that it
of the rear sprocket nut [B].
• to separate the rear sprocketnutsandandcoupling.
Remove the rear sprocket double lockwashers
FINAL DRIVE 10-9
Sprockets, Coupling
Rear Sprocket Installation
• Install the rear sprocket facing the tooth number making
[A] outward.
• Tighten:
Tightening Torque - Rear Sprocket Nuts: 34 N·m (3.5
kgf·m, 25 ft·lb)
• Bend the one side of the double lockwasher over the rear
sprocket nuts.
• Install the rear wheel.
Coupling Bearing Removal
• Pull out the coupling collar from the left.
• Remove the oil seal.
• tool, removebearing
Using the driver set [A] or some other suitable
the bearing [B] by tapping from the drum
side.
Special Tools - Bearing Driver Set: 57001-1129
Coupling Bearing Installation

• Inspect the bearing, and replace it if necessary.
• Press in the bearing [A] so that the marked side faces out
until it is bottomed.
• Replace the oil seal with a new one.
• the end of theoilhole.
Press in the seal so that the seal surface is flush with
○Apply high-temperature grease to the oil seal lips.

Special Tool - Bearing Driver Set: 57001-1129 [B]
Coupling Bearing Inspection and Lubrication

Since the coupling bearing is made to extremely close
tolerances, the clearance cannot normally be measured.
• Wash the bearing with a high flash-point solvent, dry it
(do not spin it while it is dry), and oil it. Spin it by hand to
check its condition.
If it is noisy, doesn’t spin smoothly, or has any rough
sports, it must be replaced.
• Ifflash-point
the bearing is to be used again, rewash it with a high
solvent, dry it, and pack it with good quality
bearing grease. Turn the bearing around by hand a few
times to make sure the grease [A] is distributed uniformly
inside the bearing, and wipe the old grease out of the
coupling before bearing installation.
10-10 FINAL DRIVE
Sprockets, Coupling
Coupling Damper Inspection
• Remove the rear wheel coupling, and inspect the rubber
dampers [A].
Replace the dampers if they appear damaged or deterio-
rated.
Sprocket Wear Inspection

• Visually inspect the engine and rear sprocket teeth for
wear and damage.
If they are worn as illustrated or damaged, replace the
sprocket with new ones and inspect the drive chain wear.
Worn Tooth (Engine Sprocket) [A]
Worn Tooth (Rear Sprocket) [B]
Direction of Rotation [C]
NOTE
○If a sprocket requires replacement, the chain is proba-
bly worn also. When replacing a sprocket, inspect the
chain.
Sprocket Diameter Inspection
• Measure
the tooth.
the diameter [A] of the sprocket at the base of
If the sprocket is worn down to less than the service limit,

replace the sprocket.
Sprocket Diameter
Standard:
Engine Sprocket 49.10 ∼ 49.30 mm (1.933 ∼ 1.941 in.)
Rear Sprocket 161.49 ∼ 161.99 mm (6.358 ∼ 6.378
in.)
Service Limit:
Engine Sprocket 48.4 mm (1.91 in.)
Rear Sprocket 161.2 mm (6.35 in.)
Rear Sprocket Warp Inspection

• Raise the rear wheel so that it will turn freely, and set a
dial gauge [A] against the rear sprocket [B] near the teeth
as shown in the figure.
• Rotate [C] the rear wheel, and read the dial gauge. The
difference between the highest and lowest dial gauge
readings is the amount of runout (warp).
If the runout exceeds the service limit, replace the rear
sprocket.
Rear Sprocket Warp
Standard: 0.4 mm (0.016 in.) or less
BRAKES 11-1
Brakes
Table of Contents
Exploded View................................... 11-2 Brake Disc Warp .......................... 11-15
Specifications .................................... 11-6 Brake Fluid ........................................ 11-16
Special Tool ....................................... 11-7 Brake Fluid Level Inspection........ 11-16
Caliper .............................................. 11-8 Brake Fluid Change ..................... 11-16
Caliper Removal .......................... 11-8 Bleeding the Brake Line............... 11-16
Caliper Installation ....................... 11-8 Brake Hose ....................................... 11-18
Caliper Disassembly .................... 11-8 Brake Hose Replacement ............ 11-18
Caliper Assembly ......................... 11-9 Brake Hose and Connection
Caliper Fluid Seal Damage .......... 11-10 Inspections ................................ 11-18
Caliper Dust Cover/Rubber Boot Brake Pedal and Rod ........................ 11-19
Damage..................................... 11-10 Brake Pedal Free Play
Caliper Piston and Cylinder Inspection/Adjustment............... 11-19
Damage..................................... 11-10 Brake Pedal and Rod Removal.... 11-19
Caliper Holder Shaft Wear ........... 11-11 Brake Pedal and Rod Installation. 11-20
Brake Pads ........................................ 11-12 Brake Panel and Drum ...................... 11-21
Brake Pad Removal ..................... 11-12 Cam Lever Angle Inspection ....... 11-21
Brake Pad Installation .................. 11-12 Cam Lever Angle Adjustment ...... 11-21
Brake Pad Wear Inspection ......... 11-12 Brake Panel Removal .................. 11-22 11
Master Cylinder ................................. 11-13 Brake Panel Installation ............... 11-22
Master Cylinder Removal............. 11-13 Brake Panel Disassembly ............ 11-22
Master Cylinder Installation.......... 11-13 Brake Panel Assembly................. 11-23
Master Cylinder Disassembly ...... 11-13 Brake Drum Wear Inspection....... 11-23
Master Cylinder Assembly ........... 11-14 Brake Shoe Lining Wear
Master Cylinder Inspection (Visual Inspection.................................. 11-23
Inspection)................................. 11-14 Camshaft Wear Inspection........... 11-24
Brake Disc ........................................ 11-15 Brake Shoe Springs Inspection.... 11-24
Brake Disc Removal .................... 11-15 Brake Panel Lubrication............... 11-24
Brake Disc Installation ................. 11-15 Brake Light Switch Operation
Brake Disc Wear .......................... 11-15 Inspection.................................. 11-24
11-2 BRAKES
Exploded View
BRAKES 11-3
Exploded View
Torque
N·m kgf·m ft·lb
1 Brake Lever Pivot Bolt 4.9 0.50 43 in·lb
2 Brake Lever Pivot Locknut 4.9 0.50 43 in·lb
3 Front Reservoir Cap Screws 1.5 0.15 13 in·lb
4 Front Brake Light Switch Screw 1.0 0.10 9 in·lb
5 Brake Hose Banjo Bolt 25 2.5 18
6 Brake Disc Mounting Bolts 23 2.4 17
7 Caliper Mounting Bolts 25 2.5 18
8 Caliper Bleed Valves 7.8 0.80 69 in·lb
9 Pad Pins 17 1.7 13
10 Front Master Cylinder Clamp Bolts 8.8 0.9 78 in·lb
B: Apply brake fluid.
Si: Apply silicone grease.
11-4 BRAKES
Exploded View
BRAKES 11-5
Exploded View
Torque
N·m kgf·m ft·lb
1 Cam Lever Clamp Bolt 6.9 0.7 61 in·lb
G: Apply grease.
11-6 BRAKES
Specifications

Brake Lever and Pedal
Brake Lever Free Play Non-adjustable – – –
Brake Pedal Free Play 20 ∼ 30 mm (0.79 ∼ 1.18 in.) – – –
Brake Drum, Brake Shoes
Shoe Lining Thickness 3.85 ∼ 4.15 mm (0.152 ∼ 0.163 in.) 2.0 mm (0.079 in.)
Shoe Spring Free Length 30.8 ∼ 31.2 mm (1.213 ∼ 1.228 in.) 32.5 mm (1.280 in.)
Drum Inside Diameter 110.000 ∼ 110.087 mm (4.330 ∼ 4.334 in.) 110.75 mm (4.360 in.)
Camshaft Diameter 14.957 ∼ 14.984 mm (0.589 ∼ 0.590 in.) 14.88 mm (0.586 in.)
Camshaft Hole Inside Diameter 15.000 ∼ 15.027 mm (0.590 ∼ 0.592 in.) 15.15 mm (0.596 in.)
Cam Lever Angle 80° ∼ 90° – – –
Brake Fluid
Grade DOT3 or DOT4
Brake Pad, Brake Disc
Pad Thickness: 5.0 mm (0.197 in.) 1 mm (0.04 in.)
Disc Thickness 3.7 ∼ 4.2 mm (0.146 ∼ 0.165 in.) 3.5 mm (0.138 in.)
Disc Runout 0.15 mm (0.006 in.) or less 0.3 mm (0.012 in.)
BRAKES 11-7
Special Tool
Inside Circlip Pliers:
57001-143
11-8 BRAKES
Caliper
Caliper Removal
• Loosen the banjo bolt [A] at the brake hose lower end,
and tighten it loosely.
• Unscrew the caliper mounting bolts [B], and detach the
caliper [C] from the disc.
• Unscrew the banjo bolt and remove the brake hose [D]
from the caliper (see Brake Hose Removal/Installation).
CAUTION
Immediately wash away any brake fluid that spills.
NOTE
○If the caliper is to be disassembled after removal and if
compressed air is not available, disassemble the caliper
before the brake hose is removed (see Caliper Disas-
sembly).
Caliper Installation
•○Install the caliper and brake hose lower end.
Replace the washers that are on each side of hose fitting
with new ones.
• Tighten:
Torque - Caliper Mounting Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb)
Brake Hose Banjo Bolt: 25 N·m (2.5 kgf·m, 18 ft·lb)
• Check the fluid level in the brake reservoir.
• Check thebrake
Bleed the line (see Bleeding the Brake Line).
• and no fluid leakage.
brake for good braking power, no brake drag,
WARNING
brake lever is obtained by pumping the brake lever
until the pads are against the disc. The brake will
not function on the first application of the lever if
this is not done.
Caliper Disassembly
• Loosen the pad pins [A].
• Caliper (see Caliper Removal)
Remove:
Pad Pins
Pads [B]
• Push the piston in.
BRAKES 11-9
Caliper
• Remove:
Pad Spring [A]
Caliper Holder [B]
• Using compressed air, remove the piston.
WARNING
To 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.
○Insert a wooden board [A] 5 mm (0.20 in.) thick inside the

caliper opening.
○Apply compressed air [B] to the banjo bolt hole to allow
the pistons [C] to protrude and stop at the wooden board.
○Remove the wooden board and pull out the piston by
hand.
If compressed air is not available, with the brake hose
still attached, apply the brake lever to remove the pistons.
The remaining process is as described above.
• Remove:
Dust Seals [A]
Fluid Seals (piston seals) [B]
Rubber Boot [C]
Bleed Valve
CAUTION
Immediately wash away brake fluid that spills.
Caliper Assembly
• Clean all parts other than the outer and inner pads.
CAUTION
For cleaning the parts, use only disc brake fluid,
isopropyl alcohol, or ethyl alcohol
• Install the bleed valve [A] and the rubber cap [B].
• Tighten:
• Replace the fluid seals [A] with new ones, apply brake
fluid to them , and install them in the caliper body. Either
side of the fluid seal may face outboard.
• Check the dust seals [B] and replace them with new ones
if they are damaged.
11-10 BRAKES
Caliper
• Apply brake fluid to the inside of the cylinders and to the

outside of the pistons and push the pistons [A] into the
cylinders.
• Check the rubber boot [B] and dust cover [C] and replace
them with new ones if they are damaged.
• Apply a thin coat of silicon grease to the holder shafts [D]
and the holder holes.
• Install:
Pad Spring [A]
Caliper Holder [B]
Pads and Pad Pins
• Tighten:
• Install the caliper (see Caliper Installation).
Caliper Fluid Seal Damage

The fluid seal (piston seal) [B] is placed around the pis-
ton to maintain clearance between the pad and the disc. If
the seal is in a poor condition, it could lead the pad to wear
excessively or the brake to drag, which may cause the tem-
perature of the disc or the brake fluid to increase.
• Replace the fluid seal if it exhibits any of the conditions
listed below.
○Brake fluid leakage around the pad.
○Brakes overheat.
○Considerable difference in inner and outer pad wear.
○Seal and piston are stuck together.
If the fluid seal is replaced, replace the dust seal [A] as
well. Also, replace all seals every other time the pads are
changed.
Caliper Dust Cover/Rubber Boot Damage
• Check that the dust cover [F] and rubber boot [C] are not
cracked, worn, swollen, or otherwise damaged.
If they show any damage, replace it.
Caliper Piston and Cylinder Damage
• Visually
damage.
inspect the piston [D] and cylinder surfaces for
Replace the caliper if the cylinder and piston are badly

scored or rusty.
Caliper Holder Shafts [E]
BRAKES 11-11
Caliper
Caliper Holder Shaft Wear
The caliper body must slide smoothly on the caliper holder
shafts. If the body does not slide smoothly, only one pad
will wear more than the other, pad wear will increase, and
constant drag on the disc will raise the brake and brake fluid
temperature.
• Visually inspect the caliper holder shafts for excessive
wear or warp, rubber boot and dust cover for damage.
If the rubber boot and dust cover is damaged, replace the
rubber boot.
If the caliper holder shaft is damaged, replace the caliper
holder.
11-12 BRAKES
Brake Pads
Brake Pad Removal
• Loosen the caliper pins [A].
• Remove the caliper with the hose attached.
• Pad Pin
Remove:
Pads [B]
Brake Pad Installation

• Before
solvent.
installation, clan the pads with a high-flash point
• Push
go.
[A] the caliper pistons in by hand as far as they will
• Install the pads and pad pins.

• Tighten:
• Instal the caliper (see Caliper Installation).
WARNING
brake lever or pedal is obtained by pumping the
brake lever or pedal until the pads are against the
disc. The brakes will not function on the first appli-
cation of the lever or pedal if this is not done.
Brake Pad Wear Inspection

• Refer to the Brake Pad Wear Inspection in the Periodic
BRAKES 11-13
Master Cylinder
Master Cylinder Removal
• Remove:
Head Light Cover (see Frame chapter)
Meter Cover (see Frame chapter)
•Disconnect the front brake light switch connectors [A].
•Remove the banjo bolt [B] to disconnect the brake hose
from the master cylinder (see Brake Hose Removal/In-
stallation).
○When removing the brake hose, temporarily secure the
end of the brake hose to same high place to keep fluid
loss to a minimum.
•Unscrew the clamp bolts [C], and take off the master cylin-
der [D] as an assembly with the reservoir, brake lever, and
brake switch installed.
CAUTION
Immediately wash away any brake fluid that spills.
Master Cylinder Installation

• Set the front master cylinder to match its mating surface
[A] to the punched mark [B] of the handlebar.
• Tighten the upper clamp bolt first, and then the lower
clamp bolt. There will be a gap at the lower part of the
clamp after tightening.
• Replace the washers that are on each side of the hose
fitting with new ones.
• Tighten:
Torque - Brake Hose Banjo Bolt: 25 N·m (2.5 kgf·m, 18 ft·lb)
• Bleed the brake line (see Bleeding the Brake Line).
• Check the brake for good braking power, no brake drag,
and no fluid leakage.
Master Cylinder Disassembly
• Remove
moval).
the master cylinder (see Master Cylinder Re-
• Remove the reservoir cap and diaphragm, and pour the

brake fluid into a container.
• Unscrew the pivot nut and pivot bolt, and remove the
brake lever.
• Pull the dust cover out of place, and remove the circlip.
Special Tool - Inside Circlip Pliers : 57001-143
• Pull out the piston [A], secondary cup [B], primary cup [C],
and return spring [D].
CAUTION
Do not remove the secondary cup from the piston
since removal will damage it.
11-14 BRAKES
Master Cylinder
Master Cylinder Assembly
• Before assembly, clean all parts including the master
cylinder with brake fluid or alcohol.
CAUTION
Except for the disc pads and disc, 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, engine oil, or any
other petroleum distillate will cause deterioration of
the rubber parts. Oil spilled on any part will be diffi-
cult to wash off completely, and will eventually de-
teriorate the rubber used in the disc brake.
• Apply brake fluid to the removed parts and to the inner

wall of the cylinder.
• Take care not to scratch the piston or the inner wall of the
cylinder.
• Apply silicone grease (ex. PBC grease):
Brake Lever Pivot Bolt
Brake Lever Pivot Contact
Dust Cover
• Tighten:
Torque - Front Resevoir Cap Screws: 1.5 N·m (0.15 kgf·m,
13 in·lb)
Brake Lever Pivot Bolt: 4.9 N·m (0.50 kgf·m, 43
in·lb)
Brake Lever Pivot Locknut: 4.9 N·m (0.50 kgf·m,
43 in·lb)
Master Cylinder Inspection (Visual Inspection)

• Disassemble the master cylinder.
• Check that there are no scratches, rust or pitting on the
inner wall [A] of the master cylinder and on the outside of
the piston [B].
If a master cylinder or piston shows any damage, replace
them.
• Inspect the primary cup [C] and secondary cup [D].
If a cup is worn, damaged softened (rotted), or swollen,
the piston assembly should be replaced to renew the
cups.
If fluid leakage is noted at the brake lever, the piston as-
sembly should be replaced to renew the cups.
• Check the dust cover [E] for damage.
If the dust cover is damaged, replace it.
• Check the piston return spring [F] for any damage.
If the spring is damaged, replace it.
• Check that relief port [G] and supply port [H] are not
plugged.
If the relief port becomes plugged, the brake pads will
drag on the disc. Blow the ports clean with compressed
air.
BRAKES 11-15
Brake Disc
Brake Disc Removal
• Remove the wheel (see Wheels/Tires chapter).
• Unscrew the mounting bolts [A], and take off the disc [B].
Brake Disc Installation

• Install the brake disc on the wheel so that the marked side
[A] faces out.
• Tighten:
Torque - Brake Disc Mounting Bolts: 23 N·m (2.3 kgf·m, 17
ft·lb)
Brake Disc Wear

• Visually inspect the disk.
Replace the disc if it shows any damage or crack.
• Measure the thickness of the disc [A] at the point where it
has worn the most.
If the disc has worn past the service limit, replace it.
[B] Measuring Area
Brake Disc Thickness
Standard: 3.7 ∼ 4.2 mm (0.146 ∼ 0.165 in.)
Brake Disc Warp

• Using a jack, raise the
Wheels/Tires chapter).
wheel off the ground (see
○For front disc inspection, turn the handlebar fully to one

side.
• Set up a dial gauge against the disc [A] as shown and
measure disc runout, while turning [B] the wheel by hand.
If runout exceeds the service limit, replace the disc.
Disc Runout
Standard: 0.15 mm (0.006 in.) or less
11-16 BRAKES
Brake Fluid
Brake Fluid Level Inspection
• Refer to the Brake Fluid Level Inspection in the Periodic
Brake Fluid Change
• Refer to the Brake Fluid Change in the Periodic Mainte-
nance chapter.
Bleeding the Brake Line
The brake fluid has a very low compression coefficient so
that almost all the movement of the brake lever is transmit-
ted directly to the caliper for braking action. Air, however, is
easily compressed. When air enters the brake lines, brake
lever movement will be partially used in compressing the
air. This will make the lever feel spongy, and it will be a loss
in braking power.
WARNING
Be sure to bleed the air from the brake line when-
ever brake lever action feels soft or spongy after
the brake fluid is changed, or whenever a brake line
fitting has been loosened for any reason.
• Remove the reservoir cap, and fill the reservoir with fresh
brake fluid to the upper level line in the reservoir.
• With the reservoir cap off, slowly pump the brake lever
several times until no air bubbles can be seen rising up
through the fluid from the holes at the bottom of the reser-
voir.
○Bleed the air completely from the master cylinder by this
operation.
•Install the reservoir cap.
•Remove the rubber cap from the bleed valve on the
caliper.
•Attach a clear plastic hose to the bleed valve, and run the
other end of the hose into a container.
•Bleed the brake line and the caliper.
○Repeat this operation until no more air can be seen com-
ing out into the plastic hose.
1. Pump the brake lever until it becomes hard, and apply
the brake and hold it [A].
2. Quickly open and close [B] the bleed valve while hold-
ing the brake applied.
3. Release the brake [C].
BRAKES 11-17
Brake Fluid
NOTE
○The fluid level must be checked often during the bleed-
ing operation and replenished with fresh brake fluid as
necessary. If the fluid in the reservoir runs completely
out any time during bleeding, the bleeding operation
must be done over again from the beginning since air
will have entered the line.
○Tap the brake hose lightly from the caliper to the reser-
voir for more complete bleeding.
• Remove the clear plastic hose.

• Tighten:
Front Reservoir Cap Screws: 1.5 N·m (0.15 kgf·m,
13 in·lb)
• Check the fluid level.
• power, no brakeis drag,
After bleeding done, check the brake for good braking
and no fluid leakage.
WARNING
When working with the disc brake, observe the pre-
cautions listed below.
1. Never reuse old brake fluid.
2. Do not use fluid from a container that has been left
unsealed or that has been open for a long time.
3. Do 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.
4. Don’t leave the reservoir cap off for any length of
time to avoid moisture contamination of the fluid.
5. Don’t change the fluid in the rain or when a strong
wind is blowing.
6. Except for the disc pads and disc, 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, engine oil, or any
other petroleum distillate will cause deterioration of
the rubber parts. Oil spilled on any part will be diffi-
cult to wash off completely and will eventually dete-
riorate the rubber used in the disc brake.
7. When 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 satisfacto-
rily.
8. Brake fluid quickly ruins painted surfaces; any
spilled fluid should be completely washed away
immediately.
9. If any of the brake line fittings or the bleed valve is
opened at any time, the AIR MUST BE BLED FROM
THE BRAKE LINE.
11-18 BRAKES
Brake Hose
Brake Hose Replacement
• Refer to the Brake Hose Replacement in the Periodic
Brake Hose and Connection Inspections
• Refer to the Brake Hose Damage and Installation Con-
nection Inspection in the Periodic Maintenance chapter.
BRAKES 11-19
Brake Pedal and Rod
Brake Pedal Free Play Inspection/Adjustment
• Refer to the Brake Pedal Free Play Check in the Periodic
Brake Pedal and Rod Removal
• Remove:
Rear Brake Adjusting Nut [A]
Brake Rod [B]
Brake Cam Lever Joint [C]
Spring [D]
• Remove:
Rear Right Footpeg Bracket Bolts [A]
Muffler Mounting Bolt [B] and Nut
Rear Right Footpeg Bracket [C]
• Remove:
Rear Brake Light Switch Spring [A]
Rear Brake Light Switch Bolt [B]
Rear Right Footpeg Bracket [C]
• Remove:
Brake Pedal Return Spring [A]
Cotter Pin [B]
11-20 BRAKES
Brake Pedal and Rod
Brake Pedal and Rod Installation
• Apply a multi purpose grease to the sleeve outside.
• Install:
Spring [A]
Brake Pedal [B]
Cotter Pin [C]
• Using a suitable tool [D] to set the spring.
• Bend the cotter pin.
• Before installation the brake pedal, set in the return spring
each end to the brake pedal.
○Brake Light Switch Spring [A] to be set for forward [B] as

shown.
• Tighten:
Torque - Rear Right Footpeg Bracket Bolt: 25 N·m (2.5
kgf·m, 18 ft·lb)
• Install the brake cam lever joint in the cam lever with
punch mark [A] facing front side as shown.
BRAKES 11-21
Brake Panel and Drum
Cam Lever Angle Inspection
• Check that the brake cam lever comes to an 80° ∼ 90° an-
gle [A] with the brake rod when the brake is fully applied.
If it does not, adjust the brake cam lever angle.
Cam Lever Angle
Standard: 80° ∼ 90°
○After adjusting the cam lever angle, make sure to adjust
the pedal free play.
WARNING
Since a cam lever angle greater than 90° reduces
braking effectiveness, cam lever angle adjustment
should not be neglected.
Cam Lever Angle Adjustment

CAUTION
Do not depress the brake pedal deeply in order to
separate the brake rod from the brake cam lever
joint, this may extend the brake spring beyond its
allowable spring extension.
• Remove:
Rear Wheel (see Wheels/Tires chapter)
Brake Panel
Cam Lever Bolt [A]
• Before removing the cam lever [B], mark [C] the position
of the cam lever on the camshaft.
• Remove the cam lever, and move it by one crest of the
threads to reinstall.
• Remove the cam lever, and move it by on crest of the
threads to reinstall.
• Tighten:
Torque - Cam Lever Clamp Bolt: 6.9 N·m (0.7 kgf·m, 61
in·lb)
WARNING
When remounting the cam lever, be sure that the
position of the wear indicator on the serrated shaft
is not altered.
A change in cam lever angle is caused by wear of
internal brake parts. Whenever the cam lever angle
is adjusted, also check for drag and proper opera-
tion, taking particular note of the brake lining wear
indicator position.
In case of doubt as to braking effectiveness, disas-
semble and inspect all internal brake parts. Worn
parts shall result in the brake to lock or fail.
• Install the rear wheel (see Wheels/Tires chapter).

11-22 BRAKES
Brake Panel Removal
• Remove the rear wheel (see Rear Wheel Removal in the
Wheels/Tires chapter).
• Separate the brake panel [A] from the wheel.
Brake Panel Installation

• Place the brake panel in the drum and install the rear
wheel (see Wheels/Tires chapter)
Brake Panel Disassembly
CAUTION
Do not depress the brake pedal deeply in order to
separate the brake rod from the brake cam lever
joint, this may extend the brake spring beyond its
allowable spring extension.
• Remove
wheel.
the wheel and separate the brake panel from the
• Using a clean cloth around the linings to prevent grease

or oil from getting on them, remove and install the brake
shoes [A] by pulling up on the center of the linings.
• Remove the Bolt [A] and nut [B].

• Pull the brakebrake
Remove the cam lever [C].
• cam shaft out from the brake panel inside.
BRAKES 11-23
Brake Panel Assembly
• Wipe of any oil grease from the various areas of the brake
panel.
• Apply a thin coat of grease:
Anchor Pin [A]
Shoe Spring, both ends [B]
Camshaft cam face [C]
Camshaft shaft portion [D]
○Do not allow grease to come in contact with the lining of
the brake shoes.
○Wipe off any excess grease.
• Install the shoe springs [A] as shown in the photograph.
• come in contact
Install the brake shoes, making sure that grease does not
with the lining [B].
• Instal the O-ring and fit the indicator [A] on the serration
so that it points to the extreme right of the USABLE RANG
[B].
• Install the cam lever is its original position by aligning it
with the mark.
• Tighten:
Torque - Cam Lever Clump Bolt: 6.9 N·m (0.7 kgf·m, 61
in·lb)
Brake Drum Wear Inspection

If the drum is worn unevenly or if it is scored, turn the drum
down on a brake drum lathe or replace the hub with a new
one (Do not turn it down to the service limit, and do not
turn it down if any diameter measurement exceeds the
service limit).
• Measure the inside diameter [A] of the brake drum. Since
uneven drum wear will decrease braking effectiveness,
take measurement at a minimum of two places.
If any diameter measurement exceeds the service limit,
replace the hub with a new one.
Brake Drum Inside Diameter
Standard: 110.000 ∼ 110.087 mm (4.330 ∼ 4.334 in.)
Brake Shoe Lining Wear Inspection

• Refer to the Brake Shoe Lining Wear Inspection in the
Periodic Maintenance Chart.
11-24 BRAKES
Camshaft Wear Inspection
• Measure the shaft diameter [A].
If it is worn down to less than the service limit, replace the
shaft.
• Measure the inside diameter [B] of the camshaft hole.
If it is worn past the service limit, replace the brake panel.
Brake, Camshaft, Hole Diameter
Standard:
Camshaft 14.957 ∼ 14.984 mm (0.589 ∼ 0590 in.)
Hole 15.000 ∼ 15.027 mm (0.590 ∼ 0.592 in.)
Service Limit:
Camshaft 14.88 mm (0.586 in.)
Hole 15.15 mm (0.478 in.)
Brake Shoe Springs Inspection

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

• Measure the free length of the brake shoe springs.
If either is stretched beyond the service limit, replace both
springs.
Brake Shoe Springs Inspection
Standard: 30.8 ∼ 31.2 mm (1.213 ∼ 1.228 in.)
Brake Panel Lubrication

• Disassemble the front brake panel.
• Apply high-temperature
Clean all old grease out of the brake parts with a cloth.
• Brake Shoe Anchor Pingrease[A]
to the following.
Spring Ends [B]

Cam Surfaces [C]
Cam Shaft Groove [D]
Brake Light Switch Operation Inspection

• Refer to the Brake Light Switch Operation Inspection in
the Periodic Maintenance chapter.
SUSPENSION 12-1
Suspension
Table of Contents
Exploded View........................................................................................................................ 12-2
Specifications ......................................................................................................................... 12-4
Special Tools .......................................................................................................................... 12-5
Front Fork ............................................................................................................................... 12-6
Front Fork Removal (each fork leg) .................................................................................. 12-6
Front Fork Installation (each fork leg) ............................................................................... 12-6
Fork Oil Change................................................................................................................ 12-6
Disassembly (each fork leg).............................................................................................. 12-7
Assembly (each fork leg) .................................................................................................. 12-9
Inner Tube Inspection ....................................................................................................... 12-9
Oil Seal Inspection ............................................................................................................ 12-10
Spring Tension Inspection................................................................................................. 12-10
Front Fork Oil Leak Inspection.......................................................................................... 12-10
Rear Shock Absorbers ........................................................................................................... 12-11
Removal (each shock absorber) ....................................................................................... 12-11
Installation (each shock absorber) .................................................................................... 12-11
Shock Absorber Inspection ............................................................................................... 12-11
Swingarm................................................................................................................................ 12-12
Swingarm Removal........................................................................................................... 12-12
Swingarm Installation........................................................................................................ 12-12 12
Rubber Bushing Inspection............................................................................................... 12-12
Rear Shock Absorber Oil Leak Inspection ........................................................................ 12-12
12-2 SUSPENSION
Exploded View
SUSPENSION 12-3
Exploded View
Torque
N·m kgf·m ft·lb
1 Front Fork Clamp Bolts 34 3.5 25 AL
2 Front Fork Bottom Allen Bolts 20 2.0 14.5 L
3 Rear Shock Absorber Mounting Bolts and Nut 34 3.5 25
4 Swingarm Pivot Nut 88 9.0 6.5
AL: Tighten the two clamp bolts alternately to times to ensure even tightening torque.
L: Apply non-permanent locking agent.
O: Apply Oil
12-4 SUSPENSION
Specifications

Front Fork
Oil Viscosity SHOWA SS-8 or equivalent – – –
Oil Capacity (par unit):
After disassembly and completely dry:
Indonesia, Philippine 64.5 ±2.5 mL (2.18 ±0.08 US oz.) – – –
Thailand 69.5 ±2.5 mL (2.35 ±0.08 US oz.) – – –
Oil Level (fully compressed, without
main spring):
Indonesia, Philippine 105 ±2 mm (4.13 ±0.08 in.) – – –
Thailand 86 ±2 mm (3.39 ±0.08 in.) – – –
Main Spring Free Length:
Indonesia, Philippine 314.3 mm (12.37 in.) 308 mm (12.13 in.)
Thailand 329.3 mm (12.96 in.) 323 mm (12.72 in.)
SUSPENSION 12-5
Special Tools
Fork Cylinder Holder Handle: Bearing Driver Set:
57001-183 57001-1129
Fork Cylinder Holder Adapter: Fork Oil Level Gauge:

57001-1011 57001-1290
12-6 SUSPENSION
Front Fork
Front Fork Removal (each fork leg)
• Remove:
Front Wheel (see Wheels/Tires chapter)
Front Fender Rear (see Frame chapter)
Front Fender Front (see Frame chapter)
• Loosen the upper fork clamp bolts [A].

• With a twisting
Loosen the lower fork clamp bolts [B].
• motion, work the fork leg down and out.
Front Fork Installation (each fork leg)

• Check the O-ring at the top plug and replace it with a new
one if it is damaged.
• Check the fork oil level.
• Tighten: fork.
Install the
•
Torque - Fork Clamp Bolts: 34 N·m (3.5 kgf·m, 2.5 ft·lb)
NOTE
○Tighten the two clamp bolts alternately two times to en-
sure even tightening torque.
Fork Oil Change

• Remove:
Front Fork Leg (see Front Fork Removal)
Top Plug
Long Spring
• Drain the oil into a suitable container, pumping as neces-
sary to empty out all the oil [A].
• Do the same to the other fork leg.
• Pour in the specified type and amount of fork oil.
Front Fork Oil
SHOWA SS-8 or equivalent
Amount per side:
After disassembly and completely dry:
Indonesia, Philippine: 64.5 ±2.5 mL (2.18 ±0.08 US
oz.)
Thailand: 69.5 ±2.5 mL (2.35 ±0.08 US oz.)
NOTE
○Measure the oil level absolutely.
SUSPENSION 12-7
Front Fork
•○Measure the oil level as follows.

Hold the outer tube vertically in a vise.
○Pump the inner tube several times to expel air bubbles.
○Fork fully by pushing up the outer tube.
○Wait until the oil level settles.
○With the fork leg fully compressed, insert a tape measure
or rod into the inner tube, and measure the distance from
the top of the inner tube to the oil level [A].
Oil Level (Fully compressed without spring)
Standard:
Indonesia, Philippine (105 ±2 mm (4.13 ±0.08 in.)
Thailand (86 ±2 mm (3.39 ±0.08 in.)
If the oil is above or below the specified level, remove or
add oil and recheck the oil level.
• Fork oil level may also be measured using the fork oil level
[A] gauge as follows.
Special Tool - Fork Oil Level Gauge: 57001-1290
○Set the oil gauge stopper [B] so that its lower side shows
the oil level distance specified [C].
○With the fork leg fully compressed, and without fork
spring, insert the gauge tube into the inner tube [D] and
position the stopper across the inner tube top end [E].
NOTE
○The gauge tube is graduated in 1 cm (0.39 in) divisions.
○The syringe body is graduated in 10 mL (0.34 US oz.)
division, excluding the gauge tube which is about 5 mL
(0.17 US oz.) capacity.
○Pull the handle slowly to draw out the excess oil until no
more oil comes up the tube.
If no oil is drawn out, there is not enough oil in the inner
tube. Pour in some more oil, then draw out the excess.
If the oil is above or below the specified level, remove or
add oil and recheck the oil level.
• Change the oil in the other fork leg in the same manner.
• Install the parts removed.
Disassembly (each fork leg)
• Remove the fork dust covers and clean out any dirt or
sand that has accumulated on the inner tube surfaces.
Be careful not to damage either the oil seals [A] or the
inner tube [B] surfaces.
12-8 SUSPENSION
Front Fork
• Push the top plug [A] and remove the snap ring [B].
• O-ring [C]
Remove:
Long Spring [D]

Dust Cover [E]
• Drain the fork oil.
• Hold the outer tube horizontally in a vice.

• holder handle
Stop the cylinder [A] from turning by using the fork cylinder
[B] and adapter [C].
Special Tools - Fork Cylinder Holder handle: 57001-183
Fork Cylinder Holder Adapter: 57001-1011
• Unscrew the Allen bolt [D], then take the bolt and gasket
out the bottom of the outer tube.
• Separate the inner tube [A] from the outer tube [B] by
pulling them out.
• Remove the fork cylinder unit [A] and short spring [B] from
the inner tube.
• Remove the retaining ring [A] from the outer tube.

• Remove the oil seal [B], using a thin-bladed screwdriver
if necessary.
SUSPENSION 12-9
Front Fork
Assembly (each fork leg)
• Replace the following parts removed with new ones.
Retaining Ring
Oil Seal
Bottom Allen Bolt Gasket
• Install the oil seal, using the bearing driver set [A].
• Install the retaining ring with a new one.
• Insert the cylinder unit [A] with the short spring [B] into the
inner tube.
○If the cylinder piston ring [C] is removed, install it so that
its cutting side is downward.
• Apply grease to the oil seal lip.
• Insert the inner tube to the outer tube.
• Apply a non-permanent locking agent to the allen bolt.
• Tighten the Allen bolt, using the fork cylinder holder han-
dle and adapter to stop the cylinder from turning.
Torque - Front Fork Bottom Allen Bolts: 20 N·m (2.0 kgf·m,
14.5 ft·lb)
Special Tools - Fork Cylinder Holder handle: 57001-183
Fork Cylinder Holder Adapter: 57001-1011
• Insert the fork spring [A] so that the closed coil side [B]
faces upwards.
• Fill the fork oil.
Inner Tube Inspection

• Visually
age.
inspect the inner tube [A], and repair any dam-
• Nicks or rust damage can sometimes be repaired by using

a wet-stone to remove sharp edges or raised areas which
cause seal damage.
If the damage is not repairable, replace the inner tube.
Since damage to the inner tube damages the oil seal,
replace the oil seal whenever the inner tube is repaired
or replaced.
• Temporarily assemble the inner and outer tubes, and
pump them back and forth manually to check for smooth
operation.
CAUTION
If the inner tube is badly bent or creased, replace
it. Excessive bending, followed by subsequent
straightening, can weaken the inner tube.
12-10 SUSPENSION
Front Fork
Oil Seal Inspection
• Inspect
damage.
the oil seal [A] for any signs of deterioration or
Replace it if necessary. Replace the oil seal with a new

one whenever it has been removed.
Spring Tension Inspection

• Since a spring [A] becomes shorter as it weakens, check
its free length [B] to determine its condition.
If the spring of either fork leg is shorter than the service
limit, it must be replaced. If the length of a replacement
spring and that of the remaining spring vary greatly, the
remaining spring should also be replaced in order to keep
the fork legs balanced for motorcycle stability.
Fork Spring Free Length
Standard:
Indonesia, Philippine 314.3 mm (12.37 in.)
Thailand 329.3 mm (12.96 in.)
Service Limit:
Indonesia, Philippine 308 mm (12.13 in.)
Thailand 323 mm (12.72 in.)
Front Fork Oil Leak Inspection

• Refer to the Front Fork Oil Leak Inspection in the Periodic
SUSPENSION 12-11
Rear Shock Absorbers
Removal (each shock absorber)
• Remove:
Right and Left Side Covers (see Right and Left Side
Cover Removal in the Frame chapter)
Seat Covers (left and right) (see Frame chapter)
Muffler (see Engine Top End chapter)
• Remove the shock absorber mounting bolts [A], and pull
off the shock absorber.
Installation (each shock absorber)

• Install the shock absorber.
• Tighten:
Torque - Rear Shock Absorber Mounting Bolts or nut: 34
N·m (3.5 kgf·m, 25 ft·lb)
Shock Absorber Inspection
Since the rear shock absorbers are sealed units which
cannot be disassembled, only external checks of operation
are necessary.
• With the shock absorbers removed, compress each one
and see that the compression stroke is smooth and that
there is damping in addition to spring resistance to com-
pression. When the unit is released, the spring should not
suddenly snap it to full length. It should extend smoothly
with notable damping. When the shock absorber is oper-
ated, there should be no oil leakage.
If either shock absorber does not perform all of these op-
erations satisfactorily, or if one unit feels weaker than the
other, replace both shock absorbers as a set. If only one
unit is replaced and the two are not balanced, motorcycle
instability at high speeds may result.
• Check the rubber bushings [A].

Replace any that are worn, cracked, hardened, or other-
wise damaged.
12-12 SUSPENSION
Swingarm
Swingarm Removal
• Remove:
Rear Wheel (see Rear Wheel Removal in the
Wheels/Tires chapter)
Side Covers (see Frame chapter)
Seat Covers (left and right ) (see Frame chapter)
Drive Chain Cover
Rear Footpeg Bracket (left and right)
Muffler (see Engine Top End chapter)
Rear Shock Absorber Lower Ends (left and right)
• Remove the pivot shaft nut [A] and pull out the pivot shaft
[B] toward left side.
• Pull back the swingarm and take off the swingarm.
• Remove the chain guide rubber [A].

• bushing withthea rubber
To remove bushing [B] at the pivot, tap out the
suitable tool.
Swingarm Installation
• Apply engine oil to the rubber bushing outside.
• the collar
Press in the left rubber bushing [A] first, and then install
[B] and right rubber bushing [C]
○Press in the left rubber bushing so that the rubber portion
surface is flush [F] with the [E] surface of the swingarm
pipe [D].
• Tighten the pivot shaft nut after installed the rear shock
absorber.
Torque - Rear Shock absorber mounting Bolts: 34 N·m (3.5
kgf·m, 25 ft·lb)
Swingarm Pivot Nut: 88 N·m (9.0 kgf·m, 65 ft·lb)
Rubber Bushing Inspection

• Visually inspect the rubber bushings.
If they are deteriorated or damaged, replace them.
Rear Shock Absorber Oil Leak Inspection
• Refer to the Rear Shock Absorber Oil Leak Inspection in
STEERING 13-1
Steering
Table of Contents
Exploded View........................................................................................................................ 13-2
Special Tools .......................................................................................................................... 13-4
Steering .................................................................................................................................. 13-5
Steering Play Inspection ................................................................................................... 13-5
Steering Adjustment.......................................................................................................... 13-5
Steering Stem......................................................................................................................... 13-6
Steering Stem, Stem Bearing Removal ............................................................................ 13-6
Steering Stem, Stem Bearing Installation ......................................................................... 13-7
Steering Stem Bearing ........................................................................................................... 13-9
Steering Stem Bearing Lubrication ................................................................................... 13-9
Steering Stem Bearing Inspection .................................................................................... 13-9
Steering Stem Warp.......................................................................................................... 13-9
Handlebar ............................................................................................................................... 13-10
Handlebar Removal .......................................................................................................... 13-10
Handlebar Installation ....................................................................................................... 13-10
13
13-2 STEERING
Exploded View
STEERING 13-3
Exploded View
Torque
N·m kgf·m ft·lb
1 Steering Stem Nut 4.9 0.50 43 in·lb
2 Steering Stem Locknuts 44 4.5 33
3 Handle Pole Bracket Bolts 49 5.0 36
AD: Apply adhesive.
G: Apply grease.
13-4 STEERING
Special Tools
Bearing Puller Adapter: Steering Stem Bearing Driver, 42.5:
57001-136 57001-1344
Bearing Puller: Stem Bearing Driver Adapter, 42:

57001-158 57001-1510
Bearing Driver Set: Steering Stem Nut Wrench:

57001-1129 57001-1643
STEERING 13-5
Steering
Steering Play Inspection
• Refer to the Steering Inspection in the Periodic Mainte-
nance chapter.
Steering Adjustment
• Refer to the Steering Adjustment in the Periodic Mainte-
nance chapter.
13-6 STEERING
Steering Stem
Steering Stem, Stem Bearing Removal
• Remove:
Handle Covers (see Frame chapter)
Headlight Cowling (see Frame chapter)
Front Wheel (see Wheels/Tires chapter)
Front Fender (see Frame chapter)
Front Fork (see Suspension chapter)
• Remove the handlepole bracket bolt [A] and take off the
handlebar unit [B].
• Pushing up the stem base, remove the steering stem lock-

nut [A], stem nut [B], and stem cap [C], then remove the
steering stem [D] and stem base.
Special Tool - Steering Stem Nut Wrench: 57001-1643
• Remove the upper inner race and steel balls.

• insert a barthe
To remove outer races [A] pressed into the head pipe,
[C] into the head pipe [B], and hammer evenly
around the circumference of the opposite race to drive it
out.
• Remove the lower inner race [A] on the steering stem with
a bearing puller [B].
Special Tools - Bearing Puller: 57001-158
Bearing Puller Adapter: 57001-136 [C]
STEERING 13-7
Steering Stem
Steering Stem, Stem Bearing Installation
• Apply oil to the outer races and then drive them into the
head pipe using the bearing driver set [A]. Be sure to
press them in until the races bottom out.
• Apply oil to the lower inner race, and then drive it onto
the steering stem using the stem bearing driver [A] and
adapter [B]. Be sure to press it on until it stops at the stem
base.
Special Tools - Steering stem Bearing Driver: 57001-1344
Stem Bearing Driver Adapter: 57001-1510
• Using a high-flash point solvent, clean the stem bearing

races and balls. Apply grease to the upper and lower
outer races in the head pipe so that the steel balls [A] will
stick in place during stem insertion.
• Install the upper steel balls (19) and lower steel balls (20).
• Install the upper inner race.
• Check the upper and lower steel ball in place.

• Insert the steering stem into the head pipe.
• Install the
Install steering stem cap [A].
• surface upward,
the steering stem nut [B] so that the chamfer side
and install the steering stem locknut [C]
by hand.
•○Settle the inner races in place as follows:

Using the steering stem nut wrench, tighten the stem nut
to 20 N·m (2.0 kgf·m, 14 ft·lb) of torque.
Special Tool - Steering Stem Nut Wrench: 57001-1643
○Check that there is no play and the steering stem turn
smoothly without rattle. If not, the bearing on the inner
race may be damaged.
○Again back out the stem nut a fraction of a turn until it
turns lightly.
13-8 STEERING
Steering Stem
• Turn the stem nut lightly clockwise until it just becomes

hard to turn. Do not overtighten, or the steering will be
too tight.
Torque - Steering Stem Nut: 4.9 N·m (0.50 kgf·m, 43 in·lb,
for reference)
• Tighten:
Torque - Steering Stem Locknut: 44 N·m (4.5 kgf·m, 33 ft·lb)
Tool - Hook Wrench: 92110-1183
• Install the handlebar unit on the steering stem.
• Tighten:
Torque - Handlepole Bracket Bolt: 49 N·m (5.0 kgf·m, 36
ft·lb)
• Check and adjust the following.
Steering
Front Brake
Headlight Beam
STEERING 13-9
Steering Stem Bearing
Steering Stem Bearing Lubrication
• Refer to the Steering Stem Bearing Lubrication in the Pe-
Steering Stem Bearing Inspection
• Using a high-flash point solvent, wipe the bearings clean
of grease and dirt.
• Check the races and balls.
If the balls or races are worn, or if either race is dented,
replace both races and all the balls for that bearing as a
set.
Steering Stem Warp
• Whenever the steering stem is removed, or if the steering
cannot be adjusted for smooth action, check the steering
stem for straightness.
If the steering stem shaft is bent, replace the steering
stem.
13-10 STEERING
Handlebar
Handlebar Removal
• Remove:
Handle Cover Front (see Handle Cover Front Removal
Handle Cover Rear (see Handle Cover Rear Removal in
the Frame chapter)
Choke Lever [A]
Right Handlebar Switch Housing [B]
Throttle Grip [C]
Throttle Cable [D]
Master Cylinder [E]
• Remove the handlepole bracket bolt [F] and take off the
handlebar unit.
Handlebar Installation
• Installation is the reverse order of removal.
• Tighten:
Torque - Handlepole Bracket Bolt: 49 N·m (5.0 kgf·m, 36
ft·lb)
• Insert master cylinder.
• grip.
Apply adhesive cement to the inside of the left handlebar
• Insert the left handlebar grip.

•○Fit the the
Install left and right switch housings.
projection [A] into a small hole [B] in the handlebar
unit.
• Check and adjust the following.
FRAME 14-1
Frame
Table of Contents
Exploded View........................................................................................................................ 14-2
Seat ........................................................................................................................................ 14-6
Seat Removal ................................................................................................................... 14-6
Seat Bracket Removal ...................................................................................................... 14-6
Handle Covers........................................................................................................................ 14-7
Handle Cover Front Removal ........................................................................................... 14-7
Handle Cover Rear Removal ............................................................................................ 14-7
Handle Cover Front Installation ........................................................................................ 14-8
Headlight Cowling................................................................................................................... 14-9
Headlight Cowling Removal.............................................................................................. 14-9
Headlight Cowling Installation........................................................................................... 14-9
Step Through/Leg shields....................................................................................................... 14-10
Front Step Through Cover Removal ................................................................................. 14-10
Front Step Through Cover Installation .............................................................................. 14-10
Right and Left Leg Shields Outer Removal....................................................................... 14-10
Right and Left Leg Shields Outer Installation.................................................................... 14-10
Right and Left Leg Shields Inner Removal ....................................................................... 14-11
Rear Step Through Cover Removal.................................................................................. 14-11
Tail Cover Removal........................................................................................................... 14-11
Side Cover/Storage Case....................................................................................................... 14-12
Right and Left Side Covers Removal................................................................................ 14-12
Right and Left Storage Caps Removal ............................................................................. 14-12
Rear Storage Case Removal ............................................................................................ 14-12
Front Storage Case Removal ........................................................................................... 14-12
Front Fender/Rear Fender...................................................................................................... 14-13
14
Front Fender Rear Removal ............................................................................................. 14-13
Front Fender Rear Installation .......................................................................................... 14-13
Front Fender Front Removal............................................................................................. 14-13
Front Fender Front Installation.......................................................................................... 14-13
Rear Fender Removal....................................................................................................... 14-14
14-2 FRAME
Exploded View
FRAME 14-3
Exploded View
Torque
N·m kgf·m ft·lb
1 Foot Peg Bracket Mounting Bolts 25 2.5 18
2 Foot Peg Bracket Mounting Bolts (Rear) 25 2.5 18
3 Side Stand Bracket Bolts 25 2.5 18
AD: Apply adhesive.
G: Apply grease.
14-4 FRAME
Exploded View
FRAME 14-5
Exploded View
Torque
N·m kgf·m ft·lb
1 Drive Chain Cover 4.9 0.5 43 in·lb
14-6 FRAME
Seat
Seat Removal
• Insert the ignition switch key into the seat lock [A] and turn
the key clockwise [B].
• Swing open the seat [C].
• Remove:
Rubber Band [A]
Tool Kit Bag [B]
Seat Mounting Bolts [C]
Seat [D]
Seat Bracket Removal

• Remove:
Seat (see this chapter)
Seat Bracket Nut [A]
Seat Bracket [B]
FRAME 14-7
Handle Covers
Handle Cover Front Removal
• Remove:
Master Cylinder Boot
Screws [A]
Rear View Mirrors [B]
• Separate the handle cover front [A] from the handle cover
rear [B] as follows.
• Remove:
Turn signal light connectors [C]
Handle Cover Rear Removal

• Remove the handle cover front.
• Remove the screws [A]
• Pull out the handle cover rear [B].
• Remove the speedometer cable upper end [A].

• Remove:
Connectors [B]
• Remove the screws [A] and take off the meter unit [B].
14-8 FRAME
Handle Covers
Handle Cover Front Installation
• Before installation of the meter and headlight cover, check
the cable, wiring is correctly.
• Fit the projections [A] of the handle cover front into the
holes [B] of the handle cover rear.
FRAME 14-9
Headlight Cowling
Headlight Cowling Removal
• Open the rid cover.
• Remove:
Bolts [A]
Headlight Cover [B]
Headlight Cowling Installation

• Before installation of the headlight cover bracket, check
the cable, wiring is correctly.
• Fit the projections [A] of the headlight cover into the holes
[B] of the leg shields.
• Fit the tab [C] of the headlight cover into the rib [D] of the
leg shields.
14-10 FRAME
Step Through/Leg shields
Front Step Through Cover Removal
• Remove:
Screws [A]
Front Step Through Cover [B]
Front Step Through Cover Installation

• Fit the projections [A] of the front step through cover into
the holes.
Right and Left Leg Shields Outer Removal

• Remove the screws [A], and take off the right and left leg
shields outer [B].
Right and Left Leg Shields Outer Installation

• Fit the tabs [A] of the headlight cover into the rib slots [B]
of the leg shields outer.
• Tighten the screws.
FRAME 14-11
Step Through/Leg shields
Right and Left Leg Shields Inner Removal
• Remove:
Headlight Cowling (see this chapter)
Right and Left Leg Shields Outer
Screw [A]
Leg Shields Inner [B]
Rear Step Through Cover Removal

• Remove:
Seat
Right and Left Shields Inner
Screws [A]
Rear Step Through Cover [B]
Tail Cover Removal

• Open the seat.
• Remove:
Screws [A]
Tail Cover [B]
14-12 FRAME
Side Cover/Storage Case
Right and Left Side Covers Removal
• Remove:
Rear Step Through Covers
Tail Cover
Screws [A]
Right and Left Side Covers [B]
Right and Left Storage Caps Removal

• Remove:
Right and Left Side Covers
Screws [A]
Right and Left Storage Caps [B]
Rear Storage Case Removal

• Remove:
Right and Left Storage Caps
Bolts [A]
Rear Storage Case [B]
Front Storage Case Removal

• Remove:
Rear Storage Case
Battery (see Battery Removal in the Electrical System
chapter)
Screws [A]
Bolts [B]
Front Storage Case [C]
FRAME 14-13
Front Fender/Rear Fender
Front Fender Rear Removal
• Remove:
Speed Meter Cable Lower End [A]
Clamp [B]
Bolts [A]
Front Fender Rear Installation

• Fit the tab [A] into the rib slot [B].
Front Fender Front Removal

• Remove:
Front Fender Rear
Brake Hose Clamp Bolt [A]
Ignition Switch Mounting Bolt [B]
Front Wheel (see Front Wheel Removal in the
Wheels/Tires chapter)
• Remove:
Bolts [A]
Front Fender Front [B]
Front Fender Front Installation

14-14 FRAME
Front Fender/Rear Fender
Rear Fender Removal
• Remove:
Right and Left Side Cover (see Right and Left Covers
Removal)
Connector [A]
Tail Light Unit [B]
• Remove:
Screws [A]
Rear Fender [B]
ELECTRICAL SYSTEM 15-1
Electrical System
Table of Contents
Part Location .......................................................................................................................... 15-3
Exploded View........................................................................................................................ 15-4
Specifications ......................................................................................................................... 15-10
Special Tools and Sealant ...................................................................................................... 15-11
Wiring Diagram (AN130-A Model) .......................................................................................... 15-12
Wiring Diagram (AN130-B1 Thailand Model) ......................................................................... 15-14
Wiring Diagram (AN130-B1, B6F Indonesia, Philippine and AN130-C1, C6F Models).......... 15-16
Precautions............................................................................................................................. 15-18
Electrical Wiring...................................................................................................................... 15-19
Wiring Inspection .............................................................................................................. 15-19
Battery .................................................................................................................................... 15-20
Battery Removal ............................................................................................................... 15-20
Battery Installation ............................................................................................................ 15-20
Battery Activation .............................................................................................................. 15-21
Precautions ....................................................................................................................... 15-23
Interchange ....................................................................................................................... 15-24
Charging Condition Inspection.......................................................................................... 15-24
Refreshing Charge............................................................................................................ 15-25
Charging System .................................................................................................................... 15-27
Magneto Cover Removal .................................................................................................. 15-27
Magneto Cover Installation ............................................................................................... 15-27
Magneto Cover Disassembly ............................................................................................ 15-27
Magneto Cover Assembly................................................................................................. 15-28
Magneto Flywheel Removal.............................................................................................. 15-28
Magneto Flywheel Installation........................................................................................... 15-29
Charging Voltage Inspection ............................................................................................. 15-29 15
Magneto Inspection........................................................................................................... 15-30
Regulator/Rectifier Inspection........................................................................................... 15-30
Ignition System ....................................................................................................................... 15-32
Crankshaft Sensor Resistance Inspection ........................................................................ 15-33
Crankshaft Sensor Peak Voltage Inspection..................................................................... 15-33
Ignition Coil Removal ........................................................................................................ 15-34
Ignition Coil Installation ..................................................................................................... 15-34
Ignition Coil Resistance Inspection ................................................................................... 15-35
Spark Plug Removal/Installation ....................................................................................... 15-35
Spark Plug Cleaning/Inspection........................................................................................ 15-35
IC Igniter Inspection .......................................................................................................... 15-35
Electric Starter System (Other than AN130-A Models) .......................................................... 15-39
Starter Motor Removal...................................................................................................... 15-39
Starter Motor Installation................................................................................................... 15-39
Starter Motor Disassembly................................................................................................ 15-39
Starter Motor Assembly .................................................................................................... 15-41
Starter Motor Brush Length............................................................................................... 15-42
Commutator Cleaning/Inspection...................................................................................... 15-42
Armature Inspection.......................................................................................................... 15-43
Starter Relay Inspection.................................................................................................... 15-43
15-2 ELECTRICAL SYSTEM
Starter Motor Clutch Removal........................................................................................... 15-44

Starter Motor Clutch Installation........................................................................................ 15-44
Starter Motor Clutch Disassembly .................................................................................... 15-44
Starter Motor Clutch Assembly ......................................................................................... 15-45
Starter Motor Clutch Inspection ........................................................................................ 15-45
Starter Motor Idle Gears Inspection .................................................................................. 15-45
Lighting System ...................................................................................................................... 15-46
Headlight Aiming Inspection ............................................................................................. 15-46
Headlight Bulb Replacement ............................................................................................ 15-46
City Light Bulb Replacement (Other than Thailand Models)............................................. 15-46
Front Turn Signal Bulb Replacement................................................................................ 15-47
Brake Light Bulb Replacement ......................................................................................... 15-47
Rear Turn Signal Bulb Replacement ................................................................................ 15-47
Turn Signal Relay Inspection ............................................................................................ 15-48
Meter ...................................................................................................................................... 15-49
Meter Removal.................................................................................................................. 15-49
Meter Disassembly ........................................................................................................... 15-49
Indicator Bulb Replacement.............................................................................................. 15-49
Meter Assembly ................................................................................................................ 15-49
Fuel Gauge Operation Inspection ..................................................................................... 15-50
Tachometer Inspection...................................................................................................... 15-50
Switches and Sensor.............................................................................................................. 15-51
Light and Switches Operation Inspection.......................................................................... 15-51
Switch Inspection .............................................................................................................. 15-51
Gear Position Switch Removal ......................................................................................... 15-52
Gear Position Switch Installation ...................................................................................... 15-52
Gear Position Switch Inspection ....................................................................................... 15-53
Fuel Level Sensor Inspection............................................................................................ 15-53
Throttle Sensor Removal .................................................................................................. 15-54
Throttle Sensor Installation ............................................................................................... 15-54
Throttle Sensor Inspection ................................................................................................ 15-55
Fuse........................................................................................................................................ 15-56
Fuse Removal................................................................................................................... 15-56
Fuse Inspection................................................................................................................. 15-56
Part Location
1. Magneto
2. Crankshaft Sensor
3. Fuse 10 A
4. Battery 12 V
5. Regulator/Rectifier
6. Turn Signal Relay
7. Igniter
8. Ignition Switch
9. Ignition Coil
10. Rear Brake Light Switch
11. Starter Relay (AN130-B1, B6F/C1, C6F)
12. Starter Motor (AN130-B1, B6F/C1, C6F)
Exploded View
Exploded View
Torque
N·m kgf·m ft·lb
1 Spark Plug 13 1.3 113 in·lb
2 Stator Coil Mounting Screws 4.9 0.5 43 in·lb
3 Crankshaft Sensor Mounting Screws 2.9 0.3 26 in·lb
4 Ignition Coil Bolts 2.9 0.3 26 in·lb
5 Gear Position Switch Screws 2.9 0.3 26 in·lb
6 Regulator/Rectifier Mounting Nut 4.9 0.5 43 in·lb
7 Starter Mounting Screws 4.9 0.5 43 in·lb
8 Terminal Cover Plate Screws 2.0 0.2 17 in·lb
9 Brush Holder Plate Screw 1.0 0.1 9 in·lb
10 Starter Motor Terminal Screw 2.0 0.2 17 in·lb
11 End Cover Screws 4.4 0.45 39 in·lb
12 Magneto Cover Bolts 8.8 0.9 78 in·lb
13 Starter Motor Clutch Allen Bolts 12 1.2 104 in·lb L
14 Magneto Flywheel Bolt 49 5.0 36 R, L
G: Apply grease.
SS: Apply silicone sealant (Kawasaki Bond: 92104-0004).
Exploded View
Exploded View
Torque
N·m kgf·m ft·lb
1 Turn Signal Light Screws (Front) 0.8 0.08 7 in·lb
A: AN130-B Indonesia, Philippine and AN130-C1, C6F Models
B: AN130-B1, B6F/C1, C6F Models
Exploded View
Exploded View
Torque
N·m kgf·m ft·lb
1 Brake/Tail Light Screws 4.0 0.4 35 in·lb
Specifications

Battery
Type Sealed Battery – – –
Capacity 12 V 3.5 Ah, 12.5 V 2.5 Ah (AN130-A) – – –
12 V 3 Ah (Philippine Model)
Voltage 12.8 V (12.6 V Thailand) or more – – –
Charging System
Regulator/Rectifier Output Voltage Battery voltage ∼ 14.9 V – – –
Stator Coil Resistance:
Yellow Lead - Ground 0.1 ∼ 0.8 Ω – – –
White Lead - Ground 0.2 ∼ 1.0 Ω – – –
Ignition System – – –
Crankshaft Sensor Resistance 50 ∼ 200 Ω @20°C (68°F) – – –
Crankshaft Sensor Peak Voltage 2.0 V or more, 5.8 V or more (AN130-A)
Air Gap 0.7 mm (0.028 in.)
Ignition Coil:
Primary Winding Resistance 0.64 ∼ 0.78 Ω – – –
Secondary Winding Resistance 11.4 ∼ 14.0 kΩ – – –
Spark Plug:
Standard Plug NGK C6HSA – – –
Option ND U20FS-U – – –
Gap 0.6 ∼ 0.7 mm (0.024 ∼ 0.028 in.) – – –
Electric Starter System
Starter Motor
Brush Length 7 mm (0.276 in.) 3.5 mm (0.138 in.)
Commutator Diameter 22 mm (0.866 in.) 21.5 mm (0.846 in.)
Switches, Sensors
Rear Brake Light Timing On after about 15 mm (0.59 in.) pedal – – –
travel
Fuel Level Sensor Resistance:
Full Position 4 ∼ 10 Ω – – –
Empty Position 90 ∼ 100 Ω – – –
Throttle Sensor Resistance 4 ∼ 6 kΩ – – –
Special Tools and Sealant
Rotor Puller, M16/M18/M20/M22 × 1.5: Peak Voltage Adapter:
57001-1216 57001-1415
Spark Plug Wrench, Hex 16: Flywheel Puller, M28 × 1.0:

57001-1262 57001-1471
Flywheel Holder: Throttle Sensor Setting Adapter:

57001-1313 57001-1538
Hand Tester: Kawasaki Bond (Silicone Sealant):

57001-1394 92104-0004
Wiring Diagram (AN130-A Model)
Wiring Diagram (AN130-A Model)
Wiring Diagram (AN130-B1 Thailand Model)
Wiring Diagram (AN130-B1 Thailand Model)
Wiring Diagram (AN130-B1, B6F Indonesia, Philippine and AN130-C1, C6F Mod-
els)
Wiring Diagram (AN130-B1, B6F Indonesia, Philippine and AN130-C1, C6F Mod-
els)
Precautions
There are a number of important precautions that are
musts when servicing electrical systems. Learn and ob-
serve all the rules below.
○Always check battery condition before condemning other
parts of an electrical system. A fully charged battery is a
must for conducting accurate electrical system tests.
○The electrical parts should never be struck sharply, as
with a hammer, or allowed to fall on a hard surface. Such
a shock to the parts can damage them.
○To prevent damage to electrical parts, do not disconnect
the battery leads or any other electrical connections when
the ignition switch is on, or while the engine is running.
○Take care not to short the leads that are directly con-
nected to the battery positive (+) terminal to the chassis
ground.
○Troubles may involve one or in some cases all items.
Never replace a defective part without determining what
CAUSED the failure. If the failure was caused by some
other item or items, they must be repaired or replaced, or
the new replacement will soon fail again.
○Make sure all connectors in the circuit are clean and tight,
and examine leads for signs of burning, fraying, etc. Poor
wires and bad connections will affect electrical system op-
eration.
○Measure coil and winding resistance when the part is cold
(at room temperature).
○Color Codes:
BK: Black G: Green P: Pink
BL: Blue GY: Gray PU: Purple
BR: Brown LB: Light Blue R: Red
CH: Chocolate LG: Light Green W: White
DG: Dark Green O: Orange Y: Yellow
○Electrical Connectors
Female Connectors [A]
Male Connectors [B]

Electrical Wiring
Wiring Inspection
• Visually
etc.
inspect the wiring for signs of burning, fraying,
If any wiring is poor, replace the damaged wiring.

•Pull each connector [A] apart and inspect it for corrosion,
dirt, and damage.
If the connector is corroded or dirty, clean it carefully. If it
is damaged, replace it.
•Check the wiring for continuity.
○Use the wiring diagram to find the ends of the lead which
is suspected of being a problem.
○Connect the hand tester between the ends of the leads.
Special Tool - Hand Tester: 57001-1394
○Set the tester to the × 1 Ω range, and read the tester.
If the tester does not read 0 Ω, the lead is defective. Re-
place the lead or the wiring harness [B] if necessary.
Battery
Battery Removal
• Open the seat (see Seat Removal in the Frame chapter).
• Remove
[B].
the battery holder cover screws [A] and cover
• Disconnect the battery cable (–) cable and then battery

cable (+) to the positive (+) terminal of the battery.
CAUTION
Be sure to disconnect the battery cable (–) first.
• Remove the battery.

Battery Installation
• Visually inspect the surface of the battery container.
If any signs of cracking or electrolyte leakage from the
sides of the battery.
• Put the battery into the battery case.
• Connect the battery cable [A] (red cap) to the (+) terminal
first, and then the battery cable [B] to the (–) terminal.
• Apply a light coat of grease on the terminals to prevent
corrosion.
• Cover the terminal with the cap.
• Install the battery holder cover.

NOTE
○Make sure that the battery cables run along each
groove of the battery case as shown.
Comparison of Sealed Battery and Conventional Battery

Indonesia, Thailand Philippine – – –
Sealed Battery Sealed Battery
Battery Type (Conventional)
(Wet type) (Dry type)
Electrolyte filled not filled not filled
Top Sealing sealed use seal plug before activation none
Initial Charge done necessary necessary
Activation unnecessary necessary necessary
Electrolyte Maintenance unnecessary unnecessary necessary
Battery Model Code

Thailand Indonesia Philippine
AN130-A FTZ3
AN130-B1, B6F FTZ5S YTZ5S YTX4L-BS
AN130-C1, C6F YTZ5S YTX4L-BS
Battery
Battery Activation
Electrolyte Filling (Philippine Model)
• Make sure that the model name [A] of the electrolyte con-
tainer matches the model name [B] of the battery. These
names must be the same.
Battery Model Name for AN130: YTX4L-BS
CAUTION
Be sure to use the electrolyte container with the
same model name as the battery since the elec-
trolyte volume and specific gravity vary with the
battery type. This is to prevent overfilling of the
electrolyte, shorting the battery life, and deteriora-
tion of the battery performance.
CAUTION
Do not remove the aluminum sealing sheet [A] from
the filler ports [B] until just prior to use. Be sure to
use the dedicated electrolyte container for correct
electrolyte volume.
• Place the battery on a level surface.

• or holestoinseeit. that the sealing sheet has no peeling, tears,
Check
• Remove the sealing sheet.

NOTE
○The battery is vacuum sealed. If the sealing sheet has
leaked air into the battery, it may require a longer initial
charge.
• Remove the electrolyte container from the vinyl bag.

• aside, thesestrip
Detach the of caps [A] from the container and set
will be used later to seal the battery.
NOTE
○Do not pierce or otherwise open the sealed cells [B] of
the electrolyte container. Do not attempt to separate
individual cells.
• Place the electrolyte container upside down with the six

sealed cells into the filler ports of the battery. Hold the
container level, push down to break the seals of all six
cells. You will see air bubbles rising into each cell as the
ports fill.
NOTE
○Do not tilt the electrolyte container
Battery
• Check the electrolyte flow.

If no air bubbles [A] are coming up from the filler ports, or
if the container cells have not emptied completely, tap [B]
the container a few times.
• Keep the container in place for 20 minutes or more. Don’t
remove the container from the battery until it’s empty, the
battery requires all the electrolyte from the container for
proper operation.
CAUTION
Removal of the container before it is completely
empty can shorten the service life of the battery. Do
not remove the electrolyte container until it is com-
pletely empty and 20 minutes have elapsed.
• Gently remove the container from the battery.

• the
Let the battery sit for 30 minutes prior to charging to allow
electrolyte to permeate into the plates for optimum
performance.
NOTE
○Charging the battery immediately after filling can
shorten service life. Let the battery sit for at least 30
minutes after filling.
Initial Charge (Philippine Model)

• Place the strip [A] of caps loosely over the filler ports.
• Newly activated sealed batteries require an initial charge.
Standard Charge: 0.4 A × 5 ∼ 10 hours
If using a recommended battery charger, follow the
charger’s instructions for newly activated sealed battery.
Kawasaki-recommended chargers
Optimate III
Yuasa 1.5 Amp Automatic Charger
Battery Mate 150-9
If the above chargers are not available, use equivalent
one.
NOTE
○Charging rates will vary depending on how long the
battery has been stored, temperature, and the type of
charger used. Let battery sit 30 minutes after initial
charge, then check voltage using a voltmeter. If it is
not at least 12.8 V, repeat charging cycle.
Battery
• After charging is completed, press down firmly with both

hands to seat the strip of caps [A] into the battery (don’t
pound or hammer). When properly installed, the strip of
the caps will be level with the top of the battery.
CAUTION
Once the strip of the caps [A] is installed onto the
battery, never remove the caps, nor add water or
electrolyte to the battery.
NOTE
○To ensure maximum battery life and customer satisfac-
tion, it is recommended the battery be load tested at
three times its amp-hour rating for 15 seconds.
Re-check voltage and if less than 12.8 V repeat the
charging cycle and load test. If still below 12.8 V the
battery is defective.
Precautions
1) No need of topping-up
No topping-up is necessary in this battery until it ends its life under normal use. Forcibly prying off the
seal cap to add water is very dangerous. Never do that.
2) Refreshing charge.
If an engine will not start, a horn sounds weak, or lamps are dim, it indicates the battery has been
discharged. Give refresh charge for 5 to 10 hours with charge current shown in the specification
(see Specifications in this chapter).
When a fast charge is inevitably required, do it following precisely the maximum charge current
and time conditions indicated on the battery.
CAUTION
This battery is designed to sustain no unusual deterioration if refresh-charged according
to the method specified above. However, the battery’s performance may be reduced no-
ticeably if charged under conditions other than given above. Never remove the seal cap
during refresh charge.
If by chance an excessive amount of gas is generated due to overcharging, the relief valve
releases the gas to keep the battery normal.
3) When you do not use the motorcycle for months.
Give a refresh charge before you store the motorcycle and store it with the negative cable re-
moved. Give a refresh charge once a month during storage.
4) Battery life.
If the battery will not start the engine even after several refresh charges, the battery has ex-
ceeded its useful life. Replace it (Provided, however, the vehicle’s starting system has no prob-
lem).
Battery
WARNING
Keep 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.
No fire should be drawn near the battery, or no terminals should have the tightening loos-
ened.
The electrolyte contains sulfuric acid. Be careful not to have it touch your skin or eyes. If
touched, wash it off with liberal amount of water. Get medial attention if severe.
Interchange
A sealed battery can fully display its performance only when combined with a proper vehicle electric
system. Therefore, replace a sealed battery only on a motorcycle which was originally equipped with
a sealed battery.
Be careful, if a sealed battery is installed on a motorcycle which had an ordinary battery as original
equipment, the sealed battery’s life will be shortened.
Battery Date Inspection (Indonesia, Thailand Models)
• Remove the battery (see Battery Removal).
• Check the manufactured date stamp [A].
Day [B]
Month [C]
Year [D]
Country Code [E]
MFG Code [F]
Indonesia Model [G]
Thailand Model [H]
NOTE
○Do refresh charge with the battery that passes one
month or more.
Charging Condition Inspection

○Battery charging condition can be checked by measuring
battery terminal voltage with a digital voltmeter [A].
• Open the seat (see Seat Removal in the Frame chapter).
• Remove the battery holder cover (see Battery Removal in
this chapter).
• Disconnect the battery terminals.
CAUTION
Be sure to disconnect the battery cable (–) first.
• Measure the battery terminal voltage.

NOTE
○Measure with a digital voltmeter which can be read one
decimal place voltage.
Battery
If the reading is 12.8 V (12.6 V Thailand model) or more,
no refresh charge is required, however, if the read is be-
low the specified, refresh charge is required.
Battery Terminal Voltage
Standard: 12.8 V (12.6 V Thailand model) or more
Terminal Voltage (V) [A]
Battery Charge Rate (%) [B]
Refresh charge is required [C]
Good [D]
Refreshing Charge
• Remove the battery [A] (see Battery Removal).
• Do refresh charge by following method according to the
battery terminal voltage.
WARNING
This battery is sealed type. Never remove sealing
cap [B] even at charging. Never add water. Charge
with current and time as stated below.
Terminal Voltage: 11.5 ∼ less than 12.8 V (12.6 V Thailand

model)
Standard Charge 0.4 A × 5 ∼ 10 h (see following chart)
0.3 A × 5 ∼ 10 h (AN130A)
Quick Charge 3 A × 0.5 h
CAUTION
If possible, do not quick charge. If quick charge is
done unavoidably, do standard charge later on.
Terminal Voltage: less than 11.5 V

Charging Method: 0.4 A × 20 h
NOTE
○Increase the charging voltage to a maximum voltage of
25 V if the battery will not accept current initially. Charge
for no more than 5 minutes at the increased voltage then
check if the battery is drawing current. If the battery
will accept current decrease the voltage and charge by
the standard charging method described on the battery
case. If the battery will not accept current after 5 min-
utes, replace the battery.
Battery [A]
Battery Charger [B]
Standard Value [C]
Current starts to flow [D].
Battery
•○Determine the battery condition after refresh charge.

Determine the condition of the battery left for 30 minutes
after completion of the charge by measuring the terminal
voltage according to the table below.
Criteria Judgement
12.8 V (12.6 V Thailand
Good
model) or higher
12.0 ∼ lower than 12.8 V
Charge insufficient → Recharge
(12.6 V Thailand model)
lower than 12.0 V Unserviceable → Replace
Charging System
Magneto Cover Removal
• Remove:
Left and Right Side Cover (see Right and Left Side Cover
Removal in the Frame chapter)
Change Pedal
Foot Peg Assembly
Engine Sprocket Cover (see Engine Sprocket Removal
in the Final Drive chapter)
• Pull off the magneto connectors [A].
• Unscrew the magneto cover bolts [A] and remove the

magneto cover [B].
Magneto Cover Installation

• Check that two dowel pins are in place in the left
crankcase half.
• Replace the gasket.
• wiring grommet.sealant [A] around the circumference of the
Apply silicone
Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004

• Install the magneto cover.
• Tighten the magneto cover bolts [A].
Torque - Magneto Cover Bolts: 8.8 N·m (0.9 kgf·m, 78 in·lb)
• Fill the engine with engine oil (see Engine Oil Change in
the Periodic Maintenance chapter).
Magneto Cover Disassembly

• Remove the magneto cover.
• Crankshaft Sensor Screws [A]
Remove:
Clamp [B]
Stator Coil Screws [C]
• Pull the wiring grommet [D].
• Remove the crankshaft sensor, and stator coil as a set.
Charging System
Magneto Cover Assembly
• Install:
Stator Coil [A]
Crankshaft Sensor [B]
Clamp [C]
• Apply silicon sealant to the circumference of the wiring
grommet [D], and fit the grommet into the notch of the
cover securely.
Sealant - Kawasaki Bond (Silicon Sealant): 92104-0004
• Run the magneto lead [E] as shown.
• Tighten:
Torque - Stator Coil Mounting Screws: 4.9 N·m (0.5 kgf·m,
43 in·lb)
Crankshaft Sensor Mounting Screws: 2.9 N·m (0.3
kgf·m, 26 in·lb)
• Install the magneto cover.
Magneto Flywheel Removal
• Hold the flywheel steady with the flywheel holder [A] and
remove the flywheel bolt [B].
Special Tool - Flywheel Holder: 57001-1313
• Thread the flywheel puller [A] and rotor puller [B] onto the
flywheel [C].
• Holding the flywheel puller, turn the rotor puller until the
flywheel is forced off the end of the crankshaft.
• Using the flywheel and rotor pullers, remove the magneto
flywheel.
Special Tools - Rotor Puller, M16/M18/M20/M22 × 1.5: 57001
-1216
Flywheel Puller, M28 × 1.0: 57001-1471
CAUTION
If the rotor is difficult to remove, turn the puller shaft
using a wrench while tapping the head of the puller
shaft with a hammer. Do not attempt to strike the
grab bar or the alternator rotor itself. Striking the
bar or the rotor can cause the bar to bend or the
magnets to lose their magnetism.
Charging System
Magneto Flywheel Installation
• Using a high-flashpoint solvent, clean off the any oil or
dirt that may be on the crankshaft tapered portion [A] and
flywheel tapered portion [B].
• Fit the woodruff key [C] securely in the slot of the crank-
shaft before installing the flywheel on the crankshaft.
• Tighten the flywheel bolt while holding the flywheel
steadily with the flywheel holder.
Torque - Magneto Flywheel Bolt: 49 N·m (5.0 kgf·m, 36 ft·lb)
Special Tools - Flywheel Holder: 57001-1313
• Check that the starter motor clutch rollers are in place.

• rotate [B] thethestarter
While fitting magneto flywheel [A] onto the crankshaft,
clutch gear [C] clockwise.
NOTE
○Remove the idle gears and turn the starter clutch gear
clockwise.
Charging Voltage Inspection

• Check the battery condition (see Battery section).
• Warm up the engine to obtain actual magneto operating
conditions.
• Remove the right side cover.
• the hand tester
Check that the ignition switch is turned off, and connect
as shown in the table.
Charging Voltage
Tester Connections
Reading
Range Tester (+) to Tester (−) to
Battery (+) Battery (−) Battery voltage to
25 V DC
Terminal Terminal 14.5 ±0.5 V
• Start the engine, and note the voltage readings at various

engine speeds. The readings should show nearly battery
voltage when the engine speeds is low, and, as the engine
speed rises, the readings should also rise. But they must
be kept under the specified voltage.
• Stop the engine and disconnect the hand tester.
If the charging voltage is kept between the values given in
the table, the charging system is considered to be working
normally.
If the charging voltage is much higher than the values
specified in the table, the regulator/rectifier is defective
or the regulator/rectifier leads are loose or open.
If the charging voltage does not rise as the engine speed
increases, the regulator/rectifier is defective or the mag-
neto output is insufficient for the loads. Check the mag-
neto and regulator/rectifier to determine which part is de-
fective.
Charging System
Magneto Inspection
•○Check the stator coil resistance as follows:
Stop the engine.
○Connect the commercially available tester as shown in the
table.
○Note the readings.
Stator Coil Resistance Unit: Ω
Tester Connections
Reading
Range Tester Lead Another Lead
×1Ω Ground Yellow Lead [A] 0.1 ∼ 0.8
×1Ω Ground White Lead [B] 0.2 ∼ 1.0
If there is more resistance than shown in the table, or no
more reading (infinity), the stator has an open lead and
must be replaced. Much less than this resistance means
the stator is shorted, and must be replaced.
If the stator coils have normal resistance, but the voltage
check shows the magneto to be defective; then the fly-
wheel magnet has probably weakened, and the flywheel
must be replaced.
Regulator/Rectifier Inspection
• Remove:
Rear Step Through Cover (see Rear Step Through
Cover Removal in the Frame chapter)
Connector [A]
Regulator/Rectifier [B]
• With the Kawasaki hand tester, measure the internal re-

sistance in both directions between the terminals.
If the reading is not the specified value, replace the reg-
ulator/rectifier.
Internal Resistance (20°) Unit: kΩ
Tester (+) Lead
Terminal C L B E
(–)* C – ∞ 5 ∼ 50 ∞
L ∞ – ∞ 10 ∼ 100
B ∞ ∞ – ∞
E ∞ 10 ∼ 100 ∞ –
(–)*: Tester (−) Lead Connection
CAUTION
Use only Hand Tester 57001-1394 for this test. An
ohmmeter other than the Hand Tester may show
different readings. If a megger or a meter with a
large-capacity battery is used, the regulator will be
damaged.
Charging System
Charging Circuits
1. Ignition Switch
3. Load
4. Fuse 10 A
5. Magneto
6. Battery
Ignition System
Ignition System
WARNING
The ignition system produces extremely high volt-
age. Do not touch the spark plug, ignition coil, or
spark plug lead while the engine is running, or you
could receive a severe electrical shock.
CAUTION
Do not disconnect the battery leads or any other
electrical connections when the ignition switch on
or while the engine is running. This is to prevent
igniter damage.
Do not install the battery backwards. The negative
side is grounded. This is to prevent damage to the
diodes and Igniter.
Crankshaft Sensor Resistance Inspection

• Remove
Left Side Cover (see Right and Left Side Cover Removal
Crankshaft Sensor Lead Connector [A]
• Set the hand tester [B] to the × 100 Ω range, connect it to
the blue/yellow lead connector and chassis ground.
If there is more resistance than the specified value, the
coil has an open lead and must be replaced. Much less
than this resistance means the sensor is shorted, and
must be replaced.
Crankshaft Sensor Resistance: 50 ∼ 200 Ω
Crankshaft Sensor Peak Voltage Inspection
• Remove
Crankshaft Sensor Lead Connector
• Remove the spark plug cap but do not remove the spark
plug.
• Set the hand tester [A] to the × 10 V DC range, and con-
nect it to the peak voltage adapter [B] as shown in the
diagram.
• Connect the red lead to blue/yellow lead in the crankshaft
sensor connector [C] and black lead to chassis ground.
Special Tool - Peak Voltage Adapter: 57001-1415
Type: KEK-54-9-B
Brand: KOWA SEIKI
NOTE
○Be sure the battery is full charged.
Ignition System
[AN130-A Model]
• Kicking the kick pedal with the transmission gear in neu-
tral to measure the crankshaft sensor peak voltage.
• Repeat the measurement 5 or more times.
Crankshaft Sensor Peak Voltage
Standard: 5.8 V or more

[AN130-B1, B6F/C1, C6F Model]
• Turn the ignition switch on.
• Pushing the starter button, turn the engine 4 ∼5 seconds
with the transmission in neutral to measure the crankshaft
sensor peak voltage.
• Repeat the measurements 5 or more times.
Crankshaft Sensor Peak Voltage
Standard: 2.8 V or more
If the reading is less than the specified value, replace the

crankshaft sensor.
If the peak voltage adapter is not available, the sensor
can be checked for the broken or badly shorted winding
with the hand tester (see Crankshaft Sensor Resistance
Inspection).
Ignition Coil Removal
• Remove:
Spark Plug Cap
• Disconnect the ignition coil lead [A].
• Unscrew the bolts [B] and remove the ignition coil [C].
Ignition Coil Installation

• Tighten:
Install the ground lead terminal with the ignition coil.
•
Torque - Ignition Coil Bolts: 2.9 N·m (0.3 kgf·m, 26 in·lb)
• Fit the plug cap securely.
• Pull up the spark plug cap lightly to make sure of the in-
stallation of the spark plug cap.
Ignition System
Ignition Coil Resistance Inspection
• Remove the ignition coil.
•○Measure the primary winding resistance.
Connect the hand tester between the coil terminals.
○Set the tester to the × 1 Ω range, and read the meter.
•○Measure the secondary winding resistance.
Turn out the spark plug cap off the lead.
○Connect the hand tester between the spark plug lead and
the primary terminal.
○Set the tester to the × 1 kΩ range, and read the meter.
If the meter does not read as specified, replace the coil.
Measure primary winding resistance [A]
Measure secondary winding resistance [B]
Ignition Coil [C]
Ignition Coil Winding Resistance
Primary Windings: 0.64 ∼ 0.78 Ω
Secondary Windings: 11.4 ∼ 14.0 kΩ
If the hand tester reads as specified, the ignition coil wind-

ings are probably good. However, if the ignition system
still does not perform as it should after all other com-
ponents have been checked, replace the coil with one
known to be good.
• Check the spark plug lead for visible damage.
If the spark plug lead is damaged, replace the coil.
• Turn in the spark plug cap securely.
Spark Plug Removal/Installation
• Refer to the Spark Plug Removal/Installation in the Peri-
Spark Plug Cleaning/Inspection
• Refer to the Spark Plug Cleaning/Inspection in the Peri-
IC Igniter Inspection
CAUTION
When inspecting the IC igniter observe the follow-
ing to avoid damage to the IC Igniter.
Do not disconnect the IC igniter with the ignition
switch on. This may damage the IC igniter.
Do not disconnect the battery leads while the en-
gine is running. This may damage the IC igniter.
Igniter Input Voltage Check
• Remove:
Right Seat Cover
Ignition System
• Disconnect the igniter connector [A] of the main harness.
• Set the tester to the DC25 V range, and connect it be-

tween the BR lead terminal and BK/Y lead terminal.
Connection:
Tester Positive → Brown Lead
Tester Negative → Black/Yellow Lead

• Read the voltage of the tester.
Igniter Input Voltage
Standard: Battery Voltage
If it is none or low voltage, check the battery voltage, ig-
nition switch and ignition fuse in the fuse case.
Ignition Coil Primary Peak Voltage Inspection
NOTE
○Be sure the battery is fully charged.
• Remove:
Left Seat Cover (see Right and Left Side Cover Removal
• Remove the spark plug cap but do not remove the spark
plug.
Ignition System
• Install a new spark plug [A] into the spark plug cap and
ground it onto the engine.
• Install
[C].
the peak voltage adapter [B] into the hand tester
Special Tool - Peak Voltage Adapter: 57001-1415

Type: KEK-54-9-B
Brand: KOWA SEIKI
Hand Tester Range: × DC 250 V
• Connect the adapter between the ignition coil primary
lead terminal [D] and ground.
[E] Ignition Coil
[F] IC Igniter
[G] Battery
Primary Lead Connection:
Ignition Coil Adapter (R, +) Adapter (BK, −)
←→
Red Ground
WARNING
To avoid extremely high voltage shocks, do not
touch the spark plug or tester connections.
[AN130-A Model]
• Kicking the primary kick with the transmission in neutral
to measure the primary peak voltage.
Ignition Coil Peak Voltage
Standard: 120 V or more
[AN130-B1, B6F/C1, C6F Model]

• Pushing the starter button, turn the engine 4 ∼ 5 seconds
with the transmission in neutral to measure the primary
peak voltage.
Ignition Coil Primary Peak Voltage
Standard: 120 V or more
If the reading is less than the specified value, check the
following.
Ignition Coil (see Ignition Coil Resistance Inspection)
Crankshaft Sensor (see Crankshaft Sensor Inspection)
Throttle Sensor (see Throttle Sensor Inspection)
IC Igniter (see Igniter Input Voltage Check)
If the above inspection is no problem, replace the igniter.
Ignition System
Ignition System and Electric Starter Circuit
A. Other than AN130-A Model

1. Ignition Switch
2. Starter Button
3. Starter Relay
4. Starter Motor
5. Battery
7. Fuse 10 A
8. Magneto
9. Crankshaft Sensor
10. Igniter
11. Ignition Coil
12. Spark Plug
13. Throttle Sensor
14. Tachometer
Electric Starter System (Other than AN130-A Models)
Starter Motor Removal
• Remove:
Right Leg Shield (see Right and Left Leg Shields Outer
Removal in the Frame chapter)
• Remove the starter motor mounting screws [A].
• Disconnect the connector [B].
• Gently pry the starter motor [C] out of the crankcase.
Starter Motor Installation

• Install the starter motor terminal screw [A] and the rubber
cap [B] securely.
• Tighten:
Torque - Starter Motor Terminal Screw: 2.0 N·m (0.2 kgf·m,
17 in·lb)
• Apply a small amount of grease to the new O-ring [C].
• Tighten:the starter motor.
Insert
•
Torque - Starter Motor Mounting Screws: 4.9 N·m (0.5
kgf·m, 43 in·lb)
• Install the right leg shield.
Starter Motor Disassembly
• Remove the starter motor.
• Remove the end cover screws [A] with lockwashers.
• Hold the pinion gear portion [B] and pull out the york [C].
• Remove the armature [A] and packing [B] from the end
cover [C].
NOTE
○Wrap [D] the pinion gear portion by the vinyl tape before
removal of the armature.
NOTE
○Hold the carbon brush leads [A], using the suitable tool
[B] as shown.
• Pull out the carbon brush spring [A].

• and flat washers.
Remove the brush holder screws [B] with lockwashers
• Remove the (−) carbon brush [C].
• Remove the terminal cover plate screws [A] and terminal

cover plate [B].
•○Push the terminal [C] into the end cover.
Remove the terminal with (+) carbon brush.
• Remove
[B].
the brush holder plate [A] and insulator plates
• Using a suitable tool (or oil seal remover), remove the oil
seal [C] from the end cover.
• Using a suitable tool [A] (or bearing puller), remove the

bearing [B] from the armature shaft.
Starter Motor Assembly
• Smooth the commutator surface if necessary with fine
emery paper (more than #600).
• Blow or wipe the parts of the starter motor to clean the
dust or any carbon particles.
• Replace the oil seal with a new one.
• Apply engine oil to the oil seal outer circumference.
•○Install the
Press in the oil seal [A] as shown.
oil seal so that the marked side faces fork side.
• Replace the bearing with a new one.

• Press in the bearing [A] with a suitable tool [B] as shown.
NOTE
○Install the bearing with the marked side toward the pin-
ion gear.
○Spin the bearing by hand to check its condition. If it is
noisy or does not spin smoothly, replace it.
• Install the insulator plates and brush holder plate.

• side. terminal trough the grommet from inside to out-
Install the
• Tighten the brush holder plate screws (one the screw

should be tightened with the - carbon brush lead).
Torque - Brush Holder Plate Screws: 1.0 N·m (0.1 kgf·m, 9
in·lb)
• Apply adhesive cement [A] to the terminal [B] as shown.
• Install
outside.
the terminal cover plate so that the flat side faces
• Tighten:
Torque - Terminal Cover Plate Screws: 2.0 N·m (0.2 kgf·m,
17 in·lb)
• Insert
[A].
the (−) carbon brush spring into the brush holder
• Insert the (−) carbon brush [B] into the brush holder until
it is bottomed.
• Hold the (−) carbon brush in the brush holder so that a

suitable tool [A] could hold the (−) carbon brush lead [B]
as shown.
• Install the (+) carbon brush spring.

• Hold thethe(+)(+)carbon
Install carbon brush.
• Apply high-temperature brush lead with a suitable tool.
• Before inserting the armature
grease to the oil seal lip.
• portion by the vinyl tape. [A], wrap [B] the pinion gear
• Remove the suitable tool.
• Check that movement of the carbon brush and they touch

the commutator properly.
• Raise the lead.
• mature.
Apply high-temperature grease to the shaft end of the ar-
• Install the packing and yoke to the end cover.

• Tighten:
Torque - End Cover Screws: 4.4 N·m (0.45 kgf·m, 39 in·lb)
• Install the starter motor.
Starter Motor Brush Length
• Measure the overall length [A] of each brush.
Starter Motor Brush Length
Standard: 7 mm (0.276 in.)
If any is worn down to the service limit, replace the carbon
brush.
Commutator Cleaning/Inspection
○A dirty or damaged commutator will result in poor brush
contact and cause the brushes to wear down quickly. In
addition, particles from brush wear accumulating between
commutator segments may cause partial shorts.
• Smooth the commutator surface [A] if necessary with fine
emery paper [B] and clean out the grooves.
• Measure the diameter [A] of the commutator [B].

Commutator Diameter
Standard: 22 mm (0.866 in.)
Replace the starter motor with a new one if the commu-
tator diameter is less than the service limit.
Armature Inspection
• Using the × 1 Ω range of the hand tester, measure the
resistance [A] between any two commutator segments.
If there is a high resistance or no reading (∞) between any
two segments, a winding is open and the starter motor
must be replaced.
○Using the highest range of the hand tester, measure the
resistance [B] between the segments and the shaft.
If there is any reading at all, the armature has a short and
the starter motor must be replaced.
NOTE
○Even if the foregoing checks show the armature to be
good, it may be defective in some manner not readily
detectable with the hand tester. If all other starter motor
and starter motor circuit components check good, but
the starter motor still does not turns over or only turns
over weakly, replace the starter motor with a new one.
Starter Relay Inspection
• Remove:
Right Seat Cover
• Remove thethestarter
Disconnect connector [A].
• relay [B].
• Connect the hand tester [A] and 12 V battery [B] to the

starter relay [C] as shown.
If the relay does not work as specified, the relay is defec-
tive. Replace the starter relay.
Testing Relay
Hand Tester Range: ×1Ω range
Criteria: When battery is connected → 0 Ω
When battery is disconnected → ∞ Ω
Starter Motor Clutch Removal
• Drain the engine oil (see Engine Lubrication System
chapter).
• Remove:
Headlight Cowling (see Frame chapter)
Front Step Through Cover (see Frame chapter)
Leg Shield Outer (Both side) (See Frame chapter)
Rear Step Through Cover (see Frame chapter)
Leg Shield Inner (Both side) (see Frame chapter)
Tail Cover (see Frame chapter)
Engine Sprocket Cover (see Final Drive chapter)
Magneto Cover
• Pull the starter motor idle gear [A] and shaft out of the
crankcase.
• Remove the starter motor idle gear [B].
• Remove the
Remove the magneto flywheel [C].
• woodruff key, and starter motor clutch gear.
Starter Motor Clutch Installation

• Apply molybdenum disulfide grease to the idle gear shaft
and install them.
• Apply a molybdenum disulfide grease to the inside of the
starter motor clutch gear.
• Using a high-flash point solvent, wash the tapered por-
tions of the flywheel and crankshaft.
• Check that the starter motor clutch rollers [A] are in place.
•○Install the woodruff
Install the key.
magneto flywheel (with starter motor clutch),
rotating the starter motor clutch gear clockwise.
Starter Motor Clutch Disassembly
• Remove the magneto flywheel.
• bolts [A] to separate
Holding the magneto flywheel steady, remove the Allen
the rotor, one way clutch [B], and
holder [C].
Starter Motor Clutch Assembly
• Install
out.
the one way clutch [A] so that the flange [B] faces
• Apply a non-permanent locking agent to the starter motor

clutch Allen bolts.
• Tighten the starter motor clutch Allen bolts.
Torque - Starter Motor Clutch Allen bolts: 12 N·m (1.2
kgf·m, 104 in·lb)
Starter Motor Clutch Inspection

• crankcase.the starter motor idle gears [A] from the
Remove
• The starter motor clutch gear [A] should turn clockwise

freely [B] but should not turn counterclockwise [C].
If the starter motor clutch does not operate as it should or
if it makes noise, go to the next step.
• Disassemble the starter motor clutch, and visually inspect
the clutch parts.
If there is any worn or damaged part, replace it.
• Inspect the starter motor clutch gear [A].

If the sliding surfaces [B] are worn or damaged, replace
the starter motor clutch gear.
Starter Motor Idle Gears Inspection

• Remove:
Magneto Cover
Starter Motor Idle Gears [A]
• Visually inspect the idle gears.
If the gear has wear, discoloration, or other damage, re-
place it.
Lighting System
Headlight Aiming Inspection
• Refer to the Headlight Aiming Inspection in the Periodic
Headlight Bulb Replacement
• Remove the headlight cowling (see Headlight Cowling
Removal in the Frame chapter).
• Remove the headlight.
• Turn the lead plate
Peel the rubber boot [A].
• Pull out the bulb and[B]replace
counterclockwise, and remove it.
• it with a new one.

• holder [B] and ofturntheit lead
Install the tabs plate [A] in to the rib slots of the
clockwise.
○Adjust the headlight beam vertical.
City Light Bulb Replacement (Other than Thailand

Models)
• Remove the headlight cowling (see Headlight Cowling
• Remove the headlight
• Pull out the socket and bulb [A].
• Pull the bulb [A] straight out of the socket.

CAUTION
Do not turn the bulb. Pull the bulb out to prevent
damage to the bulb.
• Replace the bulb.

Lighting System
Front Turn Signal Bulb Replacement
• Remove the handle cover front (see Handle Cover Front
• Turn the holder [A] counterclockwise and remove it.

CAUTION
damage to the bulb.
Brake Light Bulb Replacement

• Swing open the seat.
• Remove the tail cover (see Tail Cover Removal in the
Frame chapter).
• Turn the bulb [A] counterclockwise and remove it.
Rear Turn Signal Bulb Replacement

• Swing open the seat.
• Frame chapter).
Remove the tail cover (see Tail Cover Removal in the

Lighting System

CAUTION
damage to the bulb.
Turn Signal Relay Inspection

• Remove the side covers (see Right and Left Side Cover
• Remove the turn signal relay [A].
• Connect one 12-volt battery [C] and turn signal lights [B]
as indicated in the figure, and count how many times the
lights flash for one minute.
If the lights do not flash as specified, replace the turn sig-
nal relay [A].
Testing Turn Signal Relay
(Example: Two lights are connected)
Load
Flash Times (c/m*)
Number of light Wattage (W)
1 10 Lights stay on
2 20 60 ∼ 120
*: Cycle(s) per minute
Meter
Meter Removal
• Remove the handle cove rear (see Handle Cover Rear
• Remove the screws [A] and take off the meter unit [B].
CAUTION
Place the meter so that the face is up. If a meter is
left upside down or sideways for any length of time,
it will malfunction.
Meter Disassembly
• Remove the meter unit.
• Unscrew the fuel gauge screws [A], tachometer screws
[B] and speedometer screws [C].
• Pull out the indicator lights [D] and meter light [E].
• Unscrew the meter screws [F].
Indicator Bulb Replacement

CAUTION
damage to the bulb. All the indicator bulbs are of a
wedge-base type. Do not use bulb rated for greater
wattage than the specified value.
• Remove the sockets with the bulb attached.

• [B].
To remove each bulb [A], pull the bulb out of the socket
Meter Assembly
• Install each lead on the original position shown.
BR Lead [A] BR, BL/R Lead [I]
BK/Y Lead [B] BR, LB Lead [J]
W/Y Lead [C] BR, LG Lead [K]
R/BK, BK/Y Lead [D] BK/Y Lead [L]
R/W, BR/Y Lead [E] BR Lead [M]
G, GY Lead [F] BK Lead [N]
BR, G/R Lead [G] R/W, BK/Y Lead [O]
BR, Y/G Lead [H]

Meter
Fuel Gauge Operation Inspection
• Remove the headlight cover.
• Disconnect the fuel level sensor lead connector [A].
• the gauge. auxiliary wire [B], and check the operation of
Prepare an
Fuel Gauge Operation Check

Ignition Switch Position: ON
Wire Location: Female 2-pin sensor connector
(disconnected)
Result: Gauge should read E when connector wires
are opened.
Gauge should read F when connector wires
are shorted.
If the gauge readings are correct, the fuel level sensor
is bad. Refer to the switches and sensor section. If
these readings are not obtained, the problem could be
the gauge and or wiring.
• Check the fuel gauge circuit wiring.
If all wiring and components other than the fuel gauge unit
are good, then the unit is defective.
Tachometer Inspection
• Remove the meter unit (see Meter Removal).
• the meter auxiliary
Using the leads, connect the 12 V battery [A] to
unit connector [B] as follows.
○Connect the battery positive (+) terminal to the terminal
[1].
○Connect the battery negative (–) terminal to the terminal
[6].
• Using an auxiliary lead, open and connect the terminal [4]
to the battery positive (+) terminal repeatedly.
• Then the tachometer needle [A] should flick.

If the needle does not flick, replace the meter assembly.
Switches and Sensor
Light and Switches Operation Inspection
• Refer to the Light and Switches Operation Inspection in
Switch Inspection
• Using the hand tester, check to see that only the con-
nections shown in the table have continuity (about zero
ohms).
If the switch has an open or short, repair it or replace it
with a new one.
Ignition Switch
Horn Button
Turn Signal Switch
Dimmer Switch
Starter Button (other than AN130-A Model)
Gear Position Switch

Switches and Sensor
Front Brake Light Switch
Rear Brake Light Switch
Headlight Switch (Other than Thailand Models)
Gear Position Switch Removal

• Remove:
Change Pedal
Magneto Cover
Screws [A]
Gear Position Switch [B]
• Disconnect the gear position switch lead connector [C].
• Remove:
O-ring [A]
Gear Position Switch Finger [B]
Spring [C]
Gear Position Switch Installation

• Insert the spring into the hole in the shift drum.
• towardtheholeswitch
Insert
side.
finger [A] so that the small diameter [B]
• Apply grease to the O-ring.

• Clean the contact points on the position switch.
• Tighten:
Torque - Gear Position Switch Screws: 2.9 N·m (0.3 kgf·m,
26 in·lb)
Switches and Sensor
Gear Position Switch Inspection
• Remove the gear position switch head and examine the
contact points for presence of oxidation, oil or dirt, etc.
• Clean the contact points, and ensure that the switch finger
is working correctly.
• Establish that the switch finger [A] is grounded properly
by connecting a voltmeter [B] across the battery positive
terminal [C] and the switch finger contact points. No or
low voltage reading indicates that the switch finger earth
is faulty or poor.
NOTE
○Perform correct voltmeter range setting in accordance
with the battery voltage of the model which will be
checked (12 V DC).
• With full connected wiring and the ignition switch in the

“ON” position connect a proper ground lead to each switch
head contact point [A] one by one, so that the correspond-
ing gear position indicator lamps [B] in the display panel
located in the meter unit is lighting up.
Fuel Level Sensor Inspection

• Remove the headlight cover.
• Drain the gasoline.
• Disconnectthethebolts
Unscrew [A].
• Remove the fuel level sensor.
connector [B].
•
• 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, replace the sensor.
[A] Float in full position
[B] Float in empty position
• Measure
tester.
the resistance of the fuel level sensor with hand
If the tester does not show the specified values, or the

readings do not change smoothly as the float moves up
and down, replace the sensor.
Fuel Level Sensor Resistance
Full Position: 4 ∼ 10 Ω
Empty Position: 90 ∼ 100 Ω
• Inspect the leads an 2-pin connector.

If they show any signs of damage, replace the sensor.
Switches and Sensor
Throttle Sensor Removal
CAUTION
Do not remove the throttle sensor [A] because the
sensor’s mounting position must be adjusted once
it is removed.
• Remove:
Carburetor (see Carburetor Removal in the Fuel System
chapter)
Screw [A]
Throttle Sensor [B]
Throttle Sensor Installation

• Replace the O-ring [A] and apply grease it.
• Install:
O-ring
Throttle Sensor [B] (temporally)
Screw [C]
Carburetor
• Check the idle speed (see Idle Speed Inspection in the
Periodic Maintenance chapter).
• Stop the engine and remove the carburetor.
CAUTION
Do not turn the idle adjusting screw [A] when re-
moving the carburetor.
• Connect the throttle sensor setting adapter [B] between

the connectors.
Special Tool - Throttle Sensor Setting Adapter: 57001
-1538
• Set the hand tester to DC 10 V range, connect the tester
leads to the adapter.
Hand Tester (–) → White Lead [C]
Hand Tester (+) → Red Lead [D]
• Loosen the throttle sensor mounting screw [E].
• Turn on the ignition switch.
• Adjust the position of the sensor until the output voltage
is within the specified voltage.
Throttle Sensor Output
Standard: 0.7 ±0.1 V
• Tighten the sensor mounting screw.

• the sensorthelead
Remove throttle sensor setting adapter, and connect
connectors.
Switches and Sensor
Throttle Sensor Inspection
• Remove:
Carburetor (see Fuel System chapter)
• leadstheto hand
Set tester to ×1 kΩ range, connect the tester
the throttle sensor connector as shown.
Throttle Sensor Connector [A]
Hand Tester [B]
Input Voltage Terminal [C]
Ground Terminal [D]
• Measure the resistance of the throttle sensor.
Throttle Sensor Resistance
[C] - [D]: 4 ∼ 6 kΩ
If the tester does not read as specified, replace the throttle
sensor.
Fuse
Fuse Removal
• Open the seat (see Frame chapter).
• Remove the battery holder cover.
• Open the fuse case [A] and take out the fuse [B].
Fuse Inspection
• Inspect the fuse element.
If it is blown out, replace the fuse. Before replacing a
blown fuse, always check the amperage in the affected
circuit. If the amperage is equal to or greater than the
fuse rating, check the wiring and related components for
a short circuit.
[A] Housing
[B] Fuse Element
[C] Terminals
[D] Blown Element
CAUTION
When replacing a fuse, be sure the new fuse
matches the specified fuse rating for that circuit.
Installation of a fuse with a higher rating may cause
damage to wiring and components.
TROUBLESHOOTING 16-1
Troubleshooting
Table of Contents
Cable, Harness and Hose Routing ......................................................................................... 16-2
Troubleshooting Guide ........................................................................................................... 16-10
16
16-2 TROUBLESHOOTING
Cable, Harness and Hose Routing
Speedometer/Brake Cable Routing
1. Choke Cable
2. Throttle Cable
3. Brake Hose
4. Clamp
Brake Hose Routing
1. Throttle Cable
2. Brake Hose
3. Starter Cable
4. Thread the cable through the hole of the bracket.
Handle Area Routing
1. Headlight Switch 9. Horn Button

2. Starter Button Switch 10. Turn Signal Switch
3. Clamp 11. Dimmer Switch
4. Throttle Cable 12. Meter
5. Front R.H. Turn Signal Light & Front 13. Front Brake Light Switch
Brake Light Switch 14. Natural
6. Speedometer Cable 15. Green
7. Front L.H. Turn Signal Light 16. Front R.H. Turn Signal Light
8. Choke Cable 17. Front L.H. Turn Signal Light
Fuel Hose Routing
1. Fit white taping area on the edge of 13. Inlet Pipe

bracket. 14. Insert
2. Seal Cover 15. Tube (Tap-Inlet Pipe)
3. Fuel Lid Cable 16. Clamp (Hold the clamp firmly as shown in
4. Drain Tube (Cover-Seal) this figure.)
5. Tank (Fuel) 17. Front
6. Tube (Air-Vent) 18. Rear
7. Tube (Filter-Tank) 19. To Handle Left
8. Tube (Tap-Filter) 20. Clamp
9. Tap 21. Fuel Lid Cable
10. Carburetor 22. To Handle Right
11. Tube (Tap-Carburetor) 23. Choke Cable
12. Drain Tube (Carburetor) 24. Throttle Cable
Upper Side Routing
1. Fuse 13. Clamp

2. Battery Terminal (+) 14. Throttle Sensor
3. Igniter 15. Starter Motor Cable
4. Regulator/Rectifier 16. Ignition Coil
5. Gear Position Switch 17. Starter Relay
6. Magneto 18. Turn Signal Relay
7. Ground Earth (Frame) 19. Battery Lead (–)
8. To Handle Cover 20. Rear Brake Light Switch
9. Fuel Gauge 21. Tail/Brake, Turn Signal Light
10. Headlight 22. To Head Light
11. Horn 23. Band
12. Ignition Switch
Upper Side Routing
1. Fuse (Main) 14. Ignition Switch

2. Fuse (Spare) 15. Fuel Lid Cable
3. Battery Cable (+) 16. Throttle Cable
4. Regulator/Rectifier 17. Starter Cable
5. Gear Position Switch 18. Frame Ground Earth
6. Magneto 19. Ignition Coil
7. Starter Motor Cable 20. Igniter
8. Speedometer Cable 21. Stater Relay
9. To Handlebar Cover Rear 22. Signal Relay
10. To Fuel Gauge 23. Battery Cable (–)
11. Drain Tube 24. Rear Brake Switch
12. Head Light 25. Battery
13. Horn 26. Tail/Brake Light
Right Side Routing
1. Turn Signal Relay 13. Dimmer Switch 24. Band

2. Battery Lead (–) 14. Front L.H. Turn Signal 25. Harness
3. Fuse Light 26. Frame
4. Battery Cable (+) 15. Meter 27. Location Band
5. Starter Relay 16. Headlight Switch 28. Throttle Sensor
6. Regulator/Rectifier 17. Starter Button 29. Starter Motor Cable
7. Igniter 18. Signal Lamp Front R.H. 30. Ignition Coil
8. Gear Position Switch 19. Front Brake Light Switch 31. Rear Brake Light Switch
9. Magneto 20. Fuel Gauge 32. Tail/Brake, Turn Signal
10. Ground Earth (Frame) 21. Headlight Light
11. Horn Switch 22. Horn
12. Turn Signal Switch 23. Ignition Switch
Right Side Routing
1. Tail/Brake, Rear Turn Signal Light 13. Ignition Switch

2. Storage Box 14. Starter Cable
3. Turn Signal Relay 15. Throttle Cable
4. Starter Relay 16. Throttle Sensor
5. Igniter 17. Carburetor
6. Bracket 18. Starter Motor
7. Regulator/Rectifier 19. Ignition Coil
8. Ground Earth (Frame) 20. Earth (Engine)
9. To Handle Cover Rear 21. Rear Brake Light Switch
10. Horn 22. White Mark
11. Headlight 23. Rear Brake Light Switch Spring
12. To Fuel Gauge
Troubleshooting Guide
NOTE Igniter broken
○This is not an exhaustive list, giving every Flywheel magneto damaged
possible cause for each problem listed. It Ignition or engine stop switch shorted
is meant simply as a rough guide to assist Wiring shorted or open
the troubleshooting for some of the more Fuel/air mixture incorrect:
common difficulties. Idle adjusting screw maladjusted
Pilot jet, or air passage clogged
Air cleaner clogged, poorly sealed or miss-
ing
Engine Doesn’t Start, Starting Difficulty:
Air cleaner duct loose
Starter motor not rotating:
Compression Low:
Starter motor defective
KACR defective
Battery voltage low
Cylinder, piston worn
Relay not contacting or operating
Piston ring bad (worn, weak, broken, or
Starter button not contacting
sticking)
Wiring open or shorted
Piston ring/land clearance excessive
Ignition switch defective
Cylinder head gasket
Engine stop switch defective
Cylinder head not sufficiently tightened
Engine stop switch off
down
Fuse blown
Cylinder head warped
Starter motor rotating but engine doesn’t
Spark plug loose
turn over (Other than AN130-A):
No valve clearance
Starter motor clutch defective
Valve spring broken or weak
Engine won’t turn over:
Valve not seating properly (valve bent, worn
Valve seizure
or carbon accumulation on the seating
Cylinder, piston seizure
surface)
Crankshaft seizure
Poor Running at Low Speed:
Connecting rod small end seizure
Spark weak:
Connecting rod big end seizure
Spark plug dirty, damaged, or maladjusted
Camshaft seizure
Spark plug cap or high tension wiring dam-
Transmission gear or crankcase bearing
aged
seizure
Spark plug cap shorted or not in good con-
Kickstarter return spring broken
tact
Kick ratchet gear not engaging
Spark plug incorrect
No fuel flow:
Crankshaft sensor trouble
No fuel in tank
Ignition coil damaged
Sticking of the valve in the fuel tap
Igniter broken
Fuel tap vacuum hose clogged
Flywheel magneto damaged
Fuel tap air vent obstructed
Fuel/air mixture incorrect:
Fuel tap clogged
Idle adjusting screw maladjusted
Fuel line clogged
Pilot jet, or air passage clogged
Float valve clogged
Air cleaner clogged, poorly sealed, or miss-
Engine flooded:
ing
Fuel level too high
Air cleaner duct loose
Float valve worn or stuck open
Choke valve closed
Starting technique faulty (When flooded,
Float level too high or too low
crank the engine with the throttle fully
Fuel tank air vent obstructed
opened to allow more air to reach the
Carburetor holder loose
engine.)
Compression low:
No spark, spark weak:
KACR defective
Ignition switch not on
Cylinder, Piston worn
Spark plug dirty, damaged or maladjusted
Piston rings bad (worn, weak, broken or
Spark plug cap or high tension wiring dam-
sticking)
aged
Piston ring/groove clearance excessive
Spark plug cap shorted or not in good con-
Cylinder head gasket
tact
Cylinder head not sufficiently tightened
Ignition coil damaged
down
Cylinder head warped Fuel poor quality or incorrect
No valve clearance Spark plug incorrect
Spark plug loose Miscellaneous:
Valve spring broken or weak Float level too high too or too low
Valve not seating properly (Valve bent, Main jet clogged
worn, or carbon accumulation on the Throttle valve does not fully open
seating surface). Air cleaner clogged
Crankshaft oil seal deteriorated or dam- Water or foreign matter in fuel
aged Brake dragging
Other: Clutch slipping
Throttle valve doesn’t slide smoothly Overheating
Engine oil viscosity too high Engine oil level too high
Brake dragging Engine oil viscosity too high
Poor Running or No Power at High Speed: Crankshaft bearing worn or damaged
Firing incorrect: Overheating:
Spark plug dirty, damaged, or maladjusted Firing incorrect:
Spark plug cap or high tension wiring dam- Spark plug dirty, broken, or maladjusted
aged Spark plug incorrect
Spark plug cap shorted or not in good con- Igniter trouble
tract Fuel/air mixture incorrect:
Spark plug incorrect Main jet clogged or wrong size
Ignition coil trouble Fuel level too low
Crankshaft sensor trouble Carburetor holder loose
Igniter trouble Air cleaner clogged
Fuel/air mixture incorrect: Air cleaner poorly sealed, or missing
Main jet clogged or wrong size Air cleaner duct loose
Jet needle or needle jet worn Compression high:
Jet needle clip in worn position Carbon built up in combustion chamber
Fuel level too high or too low Engine load faulty:
Air jet or air passage clogged Clutch slipping
Air cleaner clogged, poorly sealed or miss- Engine oil level too high
ing Engine oil viscosity too high
Air cleaner duct poorly sealed Brakes dragging
Carburetor holder loose Lubrication inadequate:
Fuel to carburetor insufficient Engine oil level too low
Water or foreign matter in fuel Engine oil poor quality or incorrect
Fuel tank air vent obstructed Clutch Operation Faulty:
Fuel line clogged Clutch slipping:
Fuel tap clogged No clutch release play
Air cleaner duct loose Friction plate worn or warped
Compression low: Steel plate worn or warped
KACR defective Clutch spring or weak
Cylinder, piston worn Clutch release maladjusted
Piston rings bad (worn, weak, broken, or Clutch release mechanism trouble
sticking) Clutch hub or housing unevenly worn
Piston ring/land clearance excessive Clutch not disengaging properly:
Cylinder head gasket Clutch release play excessive
Cylinder head not sufficiently tightened Clutch plate warped or too rough
down Clutch spring tension uneven
Cylinder head warped Engine oil deteriorated
No Valve clearance Engine oil level too high
Spark plug loose Engine oil viscosity too high
Valve not seating properly (Valve bent, worn Clutch housing frozen on drive shaft
or carbon accumulation on the seating Clutch release mechanism trouble
surface)
Knocking:
Carbon built up in combustion chamber
Gear Shifting Faulty: Abnormal Drive Train Noise:
Doesn’t go into gear shift pedal doesn’t Clutch noise:
return: Clutch housing or hub damaged
Clutch not disengaging Clutch housing/friction plate clearance ex-
Shift fork bent or seized cessive
Gear stuck on the shaft Clutch housing gear/primary gear backlash
Shift return spring weak or broken excessive
Shift pawl spring broken Transmission noise:
Shift return spring pin loose Crankcase bearing worn
Gear set level binding on pivot bolt Metal chip jammed in gear teeth
External shift mechanical arm worn Transmission gears worn or chipped
Shift drum damaged Engine oil insufficient or too thin
Jumps out of gear: Kick ratchet gear not properly disengaging
Shift fork worn from kick gear
Gear groove worn Kick idle gear worn or chipped
Gear dogs, holes, and/or recesses worn Drive chain noise:
Shift drum groove worn Drive chain adjusted improperly
Shift drum set lever spring weak or broken Chain worn
Shift fork guide pin worn Rear and/or engine sprocket(s) worn
Shift pawl spring weak or broken Chain lubrication insufficient
Drive shaft, output shaft, and/or gear Rear Wheel misaligned
splines worn Abnormal Frame Noise:
Overshifts: Front fork noise:
Shift drum set lever spring weak or broken Oil insufficient or too thin
Shift pawl spring weak or broken Spring weak or broken
Abnormal Engine Noise: Rear shock absorber noise:
Knocking: Shock absorber damaged
Carbon built up in combustion chamber Brake noise:
Fuel poor quality or incorrect Brake linings over worn or worn unevenly
Overheating Drum worn unevenly or scored
Spark plug incorrect Brake spring(s) weak or broken
Piston slap: Foreign matter in hub
Cylinder/piston clearance excessive Brake not properly adjusted
Cylinder, piston worn Other noise:
Connecting rod bent Bracket, nut, bolt, etc. not properly
Piston pin, piston holes worn mounted or tightened
Valve noise: Exhaust Smokes Excessively:
Valve clearance incorrect White smoke:
Valve spring broken or weak Piston oil ring worn
Camshaft journals worn Cylinder worn
Other noise: Valve oil seal damaged
Connecting rod small end clearance exces- Valve guide worn
sive Engine oil level too high
Connecting rod big end clearance exces- Black smoke:
sive Air cleaner clogged
Piston ring worn, broken, or stuck Main jet too large or fallen off
Piston seizure or damaged Choke valve closed
Cylinder head gasket leaking Float level too high
Exhaust pipe leaking at cylinder head con- Brown smoke:
nection Main jet too small
Crankshaft runout excessive Fuel level too low
Engine mounts loose Air cleaner duct loose
Crankshaft bearing worn Air cleaner poorly sealed or missing
Camshaft chain tensioner trouble Handling and/or Stability Unsatisfactory:
Camshaft chain, sprocket, guide worn Handlebar hard to turn:
Loose magneto flywheel Steering stem locknut too tight
Steering stem bearing damaged
Race(s) dented or worn Tire air pressure too low
Steering stem lubrication inadequate Brake Doesn’t Hold:
Steering stem bent Disc brake:
Tire air pressure too low Air in the brake line
Handlebar shakes or excessively vibrates: Pad or disc worn
Tire worn Brake fluid leakage
Swingarm bushing damaged Disc warped
Rim warped Contaminated pad
Spokes loose Brake fluid deteriorated
Front, rear axle runout excessive Primary or secondary cup damaged in mas-
Wheel bearing worn ter cylinder
Handlebar clamp bolt loose Drum Brake:
Steering stem head bolt and/or handlebar Brake not properly adjusted
bracket bolt loose Linings overworn or worn unevenly
Handlebar pulls to one side: Drum worn unevenly or scored
Frame bent Cam, camshaft, shaft hole worn
Wheel misalignment Oil, grease on lining and drum
Swingarm bent or twisted Dirt, water between lining and drum
Swingarm pivot shaft runout excessive Overheated
Steering stem bent Battery Discharged:
Front fork leg bent Battery faulty (e.g., plates sulphated,
Right/left front fork oil level uneven shorted through sedimentation, elec-
Rear shock absorber and/or swingarm bent trolyte level too low)
Shock absorption unsatisfactory: Battery lead making poor contact
(Too hard) Regulator/rectifier trouble
Front fork oil excessive Ignition switch damaged
Front fork oil viscosity too high Load excessive (e.g., bulb of excessive
Front fork bent wattage)
Tire air pressure too high Flywheel magneto damaged
(Too soft) Stator coil open or short
Front fork oil viscosity too low Wiring faulty
Front fork, rear shock absorber spring(s) Battery overcharged:
weak Regulator/rectifier trouble
Front fork oil leaking Battery trouble
Rear shock absorber oil leaking
MODEL APPLICATION
Year Model Beginning Frame No.
2005 AN130-A1/B1/C1
2006 AN130B6F/C6F
□:This digit in the frame number changes from one machine to another.
Part No.99924-1337-02 Printed in Japan

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KAZE ZX130

This quick reference guide will assist

Read OWNER’S MANUAL before operating.

Cleaning vehicle before disassembly

Storage of Removed Parts

Liquid Gasket, Non-permanent Locking Agent

Ball Bearing and Needle Bearing

Oil Seal, Grease Seal

Apply specified grease to the lip of seal before installing

Circlips, Cotter Pins

Direction of Engine Rotation

AN130-A1 Right Side View

AN130-B1 Right Side View

AN130-C1 Right Side View

Items AN130-A1 AN130-B1, B6F AN130-C1, C6F

Items AN130-A1 AN130-B1, B6F AN130-C1, C6F

Items AN130-A1 AN130-B1, B6F AN130-C1, C6F

Units of Volume: Units of Pressure:

Units of Force: Units of Power:

Periodic Maintenance Chart ................................................................................................... 2-3

Headlight Aiming Inspection ............................................................................................. 2-27

Wheels and Tires

Tire air pressure - inspect year • • • 2-16

Brake fluid level - inspect 6 month • • • • • • • 2-22

Brake lining wear - inspect • • • • • • 2-23

FREQUENCY Whichever * ODOMETER READING

Front forks/rear shock absorber oil leak -

Periodic Replacement Parts

Letters used in the “Remarks” column mean:

Item Standard Service Limit

Item Standard Service Limit

• Check that the throttle grip moves smoothly from close to

Throttle Cable Inspection

Choke Operation Inspection

If handlebar movement changes the idle speed, the throt-

• Check idle speed.

If the idle speed is out of the specified range, adjust it.

• Remove the air cleaner element.

• Check that the hoses [A] are securely connected and

• Turn the camshaft sprocket counterclockwise [A] and

• Measure the clearance of each valve by inserting a thick-

• Start the engine and inspect the conditions of engine shift-

If there is any damage to the rim, it must be replaced.

Tire Air Pressure Inspection

Tire Tread Wear, Abnormal Wear Inspection

Wheel Bearing Damage Inspection

• Raise the rear wheel off the ground.

•○Set the motorcycle up on its center stand.

Torque - Rear Axle Nut: 54 N·m (5.5 kgf·m, 40 ft·lb)

• Bend the cotter pin [A] over the nut [B].

• Tighten the chain adjuster locknuts.

Chain Guide Wear Inspection

• Check the lining thickness [A] of the pads in caliper.

Brake Fluid Leak (Brake Hose and Pipe) Inspection

Recommended Disc Brake Fluid

Brake Hose Damage and Installation Condition

• Inspect the operation of the front and rear brake by run-

If the pedal has improper play, adjust it.