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Kawasaki KLF300 Bayou Service Manual
Kawasaki KLF300 Bayou Service Manual
Please understand that this is an older manual, some pictures may be darker than most of my
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I Fuel System
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Engine Removal/Installation
Wheels/Tires
Final Drive
Brakes
Suspension
Steering
KaVlasaki KLF300
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~ PLEASE DO NOT TAMPER WITH NOISE CONTROL SYSTEM ~
~ (US Model onlyl ~
~% To minimize the noise emissions from this product, Kawasaki has equipped it with ~
~ effective intake and exhaust silenc ing systems. They are designed to give optimum per- A ...
S~ formance while maintaining a low noise level. Please do not remove these systems, or alter ~
~ them in any which results in an increase in noise level. ~
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LIST OF ABBREVIATIONS
A ampere(s) Ib pound(s)
ABDC after bottom dead center m meter(s)
AC alternating current min minute(s)
ATDC after top dead center N newton(s)
BBDC before bottom dead center Pa pascal (s)
BDC bottom dead center PS horsepower
BTDC before top dead center psi pound(s) per square inch
°C degree(s) Celsius r revolution
DC direct current rpm revolution(s) per minute
F farad(s) TDC top dead center
OF degree(s) Fahrenheit TIR total indicator reading
ft foot, feet V volt(s)
g gram(s) W watt(s)
h hour(s) S1 ohm(s)
L liter(s)
Foreword
This manual is designed primarily for use by
How to Use this Manual
trained mechanics in a properly equipped shop.
However, it contains enough detail and basic
information to make it useful to the owner who In preparing this manual, we divided the
desires to perform his own basic maintenance product into its major systems. These systems
and repair work. A basic knowledge of mechan- became the manual's chapters. All information
ics, the proper use of tools, and workshop for a particular system from adjustment
procedures must be understood in order to carry through disassembly and inspection is located in
out maintenance and repair satisfactorily. a single chapter.
Whenever the owner has insufficient experience The Quick Reference Guide shows you all of
or doubts his ability to do the work, all adjust- the product's systems and assists in locating
ments, maintenance, and repair should be their chapters. Each chapter in turn has its own
carried out only by qualified mechanics. comprehensive Table of Contents.
In order to perform the work efficiently and The Periodic Maintenance Chart is located in
to avoid costly mistakes, read the text, thor- the General Information chapter. The chart
oughly familiarize yourself with the procedures gives a time schedule for required maintenance
before starting work, and then do the work operations.
carefully in a clean area. Whenever special tools If you want spark plug information, for
or equipment are specified, do not use makeshift example, go to the Periodic Maintenance Chart
tools or equipment. Precision measurements can first. The chart tells you how frequently to
only be made if the proper instruments are used , clean and gap the plug. Next, use the Quick
and the use of substitute tools may adversely Reference Guide to locate the Electrical System
affect safe operation. chapter. Then, use the Table of Contents on the
For the duration of your warranty period, first page of the chapter to find the Spark Plug
especially, we recommend that all repairs and section.
scheduled maintenance be performed in accord- Whenever you see these WARN ING and
ance with this service manual. Any owner CAUTION symbols, heed their instructions!
maintenance or repair procedure not performed Always follow safe operating and maintenance
in accordance with this manual may void the practices.
warranty.
To get the longest life out of your vehicle:
-Follow the Periodic Maintenance Chart in the
I WARNING.
Service Manual. oThis warning symbol identifies special instruc-
-Be alert for problems and non-scheduled tions or procedures which, if not correctly
maintenance. followed, could result in personal injury, or
-Use proper tools and genuine Kawasaki vehicle loss of life.
parts. Special tools, gauges, and testers
that are necessary when servicing Kawasaki
vehicles are introduced by the Special Tool
Manual. Genuine parts provided as spare parts
are listed in the Parts Catalog. o This caution symbol identifies special instruc-
-Follow the procedures in this manual carefully. tions or procedures which, if not strictly
Don't take shortcuts. observed, could result in damage to or destruc-
_ Remember to keep complete records of main- tion of equipment.
tenance and repair with dates and any new
parts installed. This manual contains five more symbols (in
addition to WARNING and CAUTION) which
will help you distinguish different types of
information.
NOTE
o This note symbol indicates points of particular
interest for more efficient and convenient
operation.
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General Information
Table of Contents
Before Servicing
Before starting to service a vehicle, careful reading of the applicable section is recommended to
eliminate unnecessary work. Photographs, diagrams, notes, cautions, warnings, and detailed des-
criptions have been included wherever necessary. Nevertheless, even a detailed account has limi-
tations, a certain amount of basic knowledge is also required for successful work.
e: Red
~~ r
Wire strands
Yellow/ red
f--
.... Yellow
Red
'"
(17) Replacement Parts
When there is a replacement instruction , replace these parts with new ones every time they are
removed. These replacement parts will be damaged or lose their original function once removed.
(18) Inspection
When parts have been disassembled, visually inspect these parts for the following conditions or
other damage. If there is any doubt as to the condition of them, replace them with new ones.
Abrasion Crack Hardening Warp
Bent Dent Scratch Wear
Color change Deterioration Seizure
(19) Specifications
Specification terms are defined as follows.
"Standards" show dimensions or performances which brand-new parts or systems have.
"Service limits" indicate the usable limits. If the measurement shows excessive wear or dete-
riorated performance, replace the damaged parts.
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Model Identification
General Specifications
Items KL F300-A 1, A2
Dimensions:
Overall length 1,B50 mm
Overall width 1,100mm
Overall height 1,045 mm
Wheelbase 1,200 mm
Ground clearance 195 mm
Seat height 750mm
Dry weight 226 kg, @ © 223 kg
Curb weight : Front 109.5 kg, @ © 10B.5 kg
Rear 126.5 kg, @ ©124.5 kg
Fuel tank capacity B.2 L
Performance :
Minimum turning radius 3.0 m (Locked axle mode)
2.6 m (Differential mode)
Engine:
Type 4-stroke, SOHC, 1·cylinder
Cool i ng system Air cooled
Bore and stroke 76.0 x 64.0 mm
Displacement 290 mL
Compression ratio B.6
Maximum horsepower 15.4 kW (21 PS) @7,OOO r/min (rpm). @ ©
Maximum torque 22.6 N-m (2.3 kg-m , 16.6 ft-Ib)
@6,OOO r/min (rpm). @ ©
Carburetion system Carburetor, Keihin CVK32
Starting system Electric starter
I gn ition system Battery and coil (Transistorized)
Timing advance Electronically advanced
Ignition timing From 10° BTDC @1,300 r/min (rpm) to
400 BTDC @4,OOO r/min (rpm)
Spark plug NGK BBES, ©® BRBES
Valve timing: Inlet Open 2r BTDC
Close 65° ABDC
Duration 272°
Exhaust Open 62° BBDC
Close 30° ATDC
Duration 272°
Lubrication system Forced lubrication (wet sump)
Engine oil: Grade SE or SF class
Viscosity SAE 10W-30 , 10W-40, 1OW-50, 20W-40, 20W-50
Capacity 1.7 L
Items KLF300-A 1, A2
Drive Train:
Primary reduction system: Type Gear
Reduction ratio 2_888 (78127)
Clutch type Primary Auto centrifugal, wet
Secondary Auto multi disc, wet
Transmission: Type 5-speed plus reverse, constant mesh, return shift
Gear ratios: 1st 3_090 (34/11)
2nd 1_928 (27/14)
3rd 1_368 (29/19)
4th 1_000 (23123)
5th 0_769 (20/26)
Reverse 3_072 (26/11 x 26/20)
Final drive system: Type Shaft
Reduction ratio 4_886 (20/16 x 43/11)
Overall drive ratio 10_858 @Top gear
Final gear case oil : Type API GL-5 Hypoid gear oil SAE 90 (above 5° C, 41 ° F)
or SAE 80 (below 5°C, 41°F)
Capacity 0_3 L
Frame:
Type Double tubular
Caster (rake angle) 4°
Camber 0.8° @lG
Trail 17 mm
Tread 830mm
Front tire: Type Tubeless
Size 22 x 9_00-10
Rear tire: Type Tubeless
Size 24 x 11.00-10
Suspension : Front Type Double wishbone-link
Wheel travel 115 mm
Rear Type Torque tube-link
Wheel travel 120 mm
Brake type: Front Drum (Hydraulic)
Rear Drum (Mechanical)
Electrical Equipment:
Battery 12 V 19 Ah
Headlight: Type Semi-sealed beam
Bulb 12 V 60W
Taillight 12V8Wx2
Alternator: Type Three-phase AC
Rated output 23.5 A@9,000 r/ min (rpm), 14 V
Voltage regulator: Type Short-circuit
Specifications are subject to change without notice, and may not apply to every country.
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1-8 GENERAL INFORMATION
............................................................................ Use the basic torque table below for only the bolts
Torque and Locking Agent and nuts which do not require a specific torque value.
All of the values are for use with dry solvent-cleaned
The following tables list the tightening torque for the threads.
major fasteners requiring use of a non-permanent locking Basic Torque for General Fasteners
agent or liquid gasket. Torque
Th read
dia. (mm) N-m kg-m ft-Ib
Letter used in the "Remarks" colu mn means: 5 3.4 - 4.9 0.35 - 050 30 - 43 in- Ib
L : App ly a non-permanent lockingagentto the threads. 6 5_9 - 7_8 0_60 -0_80 52 - 69 in-Ib
o : App ly an oil to the threads and seated surface. 8 14 -19 1.4 - 1.9 10_0 - 135
S : Tighten the faste ners fo ll owing the specified se- 10 25 - 34 2.6 - 35 19_0-25
quence.
12 44 -61 4.5 - 6_2 33 - 45
St : Stake the fasteners to prevent loosening,
14 73 -98 7.4-10_0 54 -72
16 115 '- 155 11.5 - 16_0 83 -115
18 165 - 225 17.0 - 23 125 -165
20 225 - 325 23 - 33 165 -240
Torque
Fastener Remarks
N-m kg-m ft-Ib
Engine Top End:
Cylinder Head Bolts: 6mm 12 1.2 104 in-Ib S
8mm 29 3.0 22 S
Cylinder Bolt 12 1_2 104 in-Ib
Valve Clearance Adjusting Screw
Locknuts 12 1.2 104 in-Ib
Camshaft Sprocket Bolt .41 4.2 30
Camshaft Chain Guide Pivot Bolt 9.8 1.0 87 in-Ib
Engine Left Side:
Starter Clutch Allen Bolts 49 5.0 36 L
Engine Right Side:
Oil Drain Plug 29 3.0 22
Primary Clutch Hub Nut 125 13.0 94 o
Secondary Clutch Hub Nut 78 8.0 58 o
Secondary Clutch Spring Bolts 12 1.2 104 in-Ib
Engine Removal/Installation:
Engine Mounting Bolts: 8 mm 25 2.5 18.0
10mm 34 3.5 25
Engine Mounting Bracket Bolts 25 2.5 18.0
Engine Bottom End/Transmission:
Oil Pipe Banjo Bolts 20 2.0 14.5
Shift Drum Stopper Bolt 12 1.2 104 in-Ib
Shift Drum Pin Plate Bolt 12 1.2 104 in-Ib
Shift Shaft Return Spring Pin 17 1.7 12.0 L
Clutch Release Cam Pin 17 1.7 12.0 L
Balancer Gear Nut 83 8.5 61 o
Balancer Drive Gear and Oil Pump
Drive Gear Nut 78 8.0 58 o
Wheels/Tires:
Wheel Nuts 34 3.5 25
Front Hub Nuts 34 3.5 25
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GENERAL INFORMATION 1-9
Torque
Fastener Remarks
N-m kg-m ft-Ib
Final Drive:
Front Gear Case Bolts (8 mm) 25 2.5 18.0
Output Shaft LH Bearing Housing ,B olts 12 1.2 104 in-Ib
LH Bearing Holder 98 10.0 72 St
Drive Gear Nut: 14 mm (when 16 mm) 88 (93) 9.0(9.5) 65 (69) 0
Driven Gear Nut 78 8.0 58 0
Driven Gear Shaft Oil Sea l Housing Nuts 25 2.5 18.0
Front Gear Case Plug (Odometer Gear
20 2.0 14.5
Holder: Option)
Propeller Shaft Housing Nuts 25 2.5 18.0
Axle Shaft Pipe Bolts 20 2.0 14.5
Pinion Gear Nut 78 8.0 58 0, St
Ring Gear and Differential
29 3.0 22 L
Gear Housing Bolts
Final Gear Case Cover Bolts 25 2.5 18.0
Final Gear Case Filler Cap 29 3.0 22
Final Gear Case Drain Plug 20 2.0 14.5
Differential Shift Fork Holder Screws 6.9 0.70 61 in-Ib
Brakes:
Master Cylinder Clamp Bolts 11 1.1 95 in-Ib S
Brake Lever Pivot Nut 5.9 0.60 52 in-Ib
Wheel Cylinder Bolts 7.8 0.80 69 in-Ib
Shoe Adjuster Bolts 7.8 0.80 69 in-Ib
Brake Panel Mounting Bolts:
Front 20 2.0 14.5
Rear 29 3.0 22
Rear A xle Nuts 145 15.0 110
B rake Hose Banjo Bolts 25 2.5 18.0
Brake Pipe Nipple 20 2.0 14.5
Brake Pedal Nut 29 3.0 22
Suspension:
Shock Absorber Mounting Bolts 34 3.5 25
Suspension Arm Pivot Bolts: 10mm 34 3.5 25
12 mm 88 9.0 65
Steering:
Handlebar Holder Bolts 20 2.0 14.5 S
Stem Clamp Allen Bolts 20 2.0 14.5
Stem Bottom End Nut 29 3.0 22
Stem Bearing Housing Bolts 20 2.0 14.5
Tie-rod End Nuts 41 4.2 30
Tie-rod Adjusting Sleeve Locknuts 29 3.0 22
Knuckle Arm Pivot Nuts 41 4.2 30
Electrical System :
Alternator Rotor Bolt 59 6.0 43
Spark Plug 27 2.8 20
Neutral and Reverse Indicator Switch
Mounting Screws
- - - L
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The scheduled maintenance must be done in accordance with this chart to keep the vehicle in good
running condition. The first service is vitally important and must not be neglected.
Chassis :
Brake adjustment - check' • •
Brake wear - check ' • •
Brake fluid level - check •
Brake fluid - change •
Master cylinder cup and dust seal
2 years
- replace
Wheel cylinder piston seal and
2 years
dust seal - replace
Brake hose - replace 2 years
Cable adjustment' • •
Steering play - check • •
Final gear case oil - change' • •
General lubrication " •
Bolts and nuts - tighten • •
Battery - check • •
Engine:
Clutch adjustment' • •
Valve clearance - check • •
Fuel system cleanliness - check' • •
Air cleaner - service' • •
Engine oil - change' • •
Oil filter - change' • •
Spark plug - clean and gap • •
Spark arrester - clean •
'Service more frequently when operated in mud, dust, or other harsh riding conditions.
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FUEL SYSTEM 2-1
Fuel System
Table of Contents
Exploded View
~J
A : Apply adhesive.
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FUEL SYSTEM 2-3
Specifications
Item Standard
Throttle Lever Free Play 2-3mm
Carburetor: Make!Type Keihin/ CVK32
Main Jet (Option) # 130(# 125,128,132,135)
Main Air Jet # 100
Jet Needle N27Q
Needle Jet #6
Pilot Jet (Option) # 38 (# 35,40)
Pilot Air Jet # 140
Pilot Screw 2'/, turns out
Starter Jet (Option) # 55 (# 58 , 60)
Service Fuel Level (from the bottom
0_5 mm below - 1.5 mm above
edge of carburetor body)
Float Height 17.0 ±2 mm
Air Cleaner Element Oil:
Grade SE class
Viscosity SAE30
-.
Throttle Cable Installation
eThrottie cab le install ation is the reverse of removal.
Note the following.
eLubricate the throttle cable before installation (see
Throttle Case and Cable Lubrication).
A. Return Spring Hook eRoute the cab le as shown.
I WARNING.
COperation with an improperly assembled throttle case
could result in an unsafe riding condition.
A. Throttle Cable
2~ FUEL SYSTEM
A. Apply grease.
*If the lever bends, disassemble the throttle case, and
clean and iubricate the throttle case (see Throttle Case
and Cable Lubrication).
-Examine the lever and case for cracks. Replace the
case assembly if it is cracked.
A. Apply grease.
Cable Lubrication
ePull the choke lever off the housing, and free the choke
cable upper end from the lever. Th.ere i!l the wave
washer between the lever and the housing.
eNote the choke cable routing for proper installation,
and pull the cable from the vehicle.
A. Choke Cable
Carburetor
[CAUTIO~]
000 not overtighten the pilot screw or the carburetor
body will be d~maged and require replacement.
Cable Lubrication
A. Pilot Screw
A. Tang
-Hold the gauge vertically against the side of the car·
buretor body so that the "zero" line is several milli·
meters higher than the bottom edge of the carburetor
body. -Assemble the carburetor, install it on the vehicle, and
-Turn the fuel tap to the ON position to feed fuel to the recheck the fuel level.
carbu retor and gauge, then turn out the carburetor *If the fuel level cannot be adjusted by this method, the
drain plug a few turns . float or the float valve is damaged,
-Wait until the fuel level in the gauge settle.
eKeeping the gauge vertical, slowly lower the gauge until
the "zero" line is even with the bottom edge of the car- Float Height Measurement·Keihin Carburetor
buretor body.
NOTE
ODo not lower the nzerou line below the bottom edge of
the carburetor body, If the gauge is lowered and then
raise it again, the fuel level measured shows somewhat 2
higher than the actual fuel level. If the gauge is @
lowered too far, dump the fuel out of it into a suitable
container and start the procedure over again.
I WARNING.
oFuel spilled from the carburetor is hazardous.
A. Drain Plug
eAdjust the pilot screw (see Carburetor Pilot Screw
Adjustment).
e<:heck to see if water or dirt comes out.
elf the carburetor has been disassembled, or if there is
eTighten the drain plug.
some other reason that the fuel level may be incorrect,
*If any water or dirt appears during the above in· inspect the fuel level (see Carburetor Fuel Level In-
spection, clean the fuel system (see Carburetor
spection).
Cleaning and Fuel Tank and Tap Cleaning).
eAdjust the idle speed (see Idle Speed Adjustment).
eAdjust the throttle cable (see Throttle Cable Adjust-
ment).
Carburetor Removal
eRemove the fuel tank (see Fuel Tank Removal).
Carburetor Assembly
ecarburetor assembly is the reverse of disassembly.
Note the following.
eTurn the carburetor body upside-down, and drop the
needle iet into place. The smaller diameter end of the
jet goes in first.
000 not force the air bleed pipe or overtighten it. The
needle jet or the carburetor body could be damaged
requ iring replacement.
eDrop the float valve needle into the valve seat and hold
the float in place with the tab hooked into the needle
hanger.
-Unscrew the main jet, pilot jet, and air bleed pipe.
ePush the needle iet out from the inside of the carburetor
with your finger.
A. Needle Hanger
eSlip the float pivot pin through the pivot posts and the
float. The float stop tab must be on the correct side as
A. Needle let shown.
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Carburetor Inspection
-Before removing the carburetor, check th e fuel level
(see Fuel Leve l Inspection).
*If the fu el level is incorrect, inspect the rest of the
A. Spring Seat B. Ho le carburetor before correcting it.
-Remove the carburetor (see Carbureto r Removal).
-Turn the thro ttle cable pulley to check th at the
throttle butterfly va lve moves smoothl y and returns
-After installing the upper chamber cover, check that back with the spring tension .
the vacuum pisto n slides up and down smoothl y *If th e throttl e valve does not move smooth ly, replace
without binding in the carburetor bore. t h e carburetor.
Carburetor Cleaning
I WARNING'
OClean 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 highly flammable
liquids , do not use gasoline or low flash-point solvents
to clean the carburetor. A fire or explosion could
result. A. Throttle Butterfly Valve
A. O-ring
A. Tip B. Rod
A. Bolts B. Clamp
A. Drain
A. Slot
WARNING.
Air Cleaner Removal OClean the element in a well·ventilated area, and take
eRemove the seat (see Seat Removal in the Frame care that there is no spark or flame anywhere near the
chapter). working area; this includes any appliance with a pilot
eTake out the bolts holding the air cleaner to the frame. light. Because of the danger of highly flammable
eLoosen the clamp on the duct to the air cleaner mouth. liquids. do not use gasoline or low flash-point solvents
• Pull the air cleaner out of the frame. to clean the element. A fire or explosion could result .
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FUEL SYSTEM 2-15
ePeel the air cleaner element off the plastic frame inside
it. Fuel Tank
. . .
• . . . . . . . . . . . . . . . . . . . . . 06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IWARNING.
oGasoline is extremely flammable and can be explosive
under certain conditions. Turn the ignition switch
OFF. Do not smoke. Make sure the area is well
ventilated and free from any source of flame or sparks;
this includes any appliance with a pilot light.
A. Element B. Frame C. Screen
-Remove the bolt with lockwasher and flat washer from
eWash the element in a bath of high flash-point solvent the rear end of the tan k.
and then squeeze it dry.
WARNING.
oelean the tank 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 highly flammable
liquids, do not use gasoline or low flash -point solvents
to clean the tank. A fire or explosion could result.
A. Dampers
*If the dampers are damaged or deteriorated, replace -Pour the solvent out the tank.
them. -Remove the fuel tap from the tank by taking out the
-Be sure the fuel hose is clamped to the fuel tap to bolts with nylon washers.
prevent leaks. -Clean the fuel tap flIter screens in a high flash-point
solvent.
-Pour high flash-point solvent through the tap in both
ON and RES positions.
Fuel Tap Removal -Dry the tank and tap with compressed air.
_Remove the fuel tank and drain it (see Fuel Tank -Install the tap in the tank ( see Fuel Tap Installation).
Removal). -Install the fuel tank (see Fuel Tank Installation).
-Remove the bolts with nylon flat washers and take out
the fuel tap and spacer.
A. Bo lts B. Spacer
Exploded View
T2
T4
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34 ENGINE TOP END
Specifications
Cylinder !-lead:
Item Standard Service Li m it
Cylinder Head Warp 0.05 mm
Bar: 57001-1128
A. Compressed Air
Valves:
Valve Clearance Check
Cylinder Head Warp
NOTE
eClean the cylinder head (see Cylinder Head Cleaning)_
-Lay a straightedge across the lower surface of the OCheck the valve clearance only when the engine is cold
cylinder head at the positions shown. Icool to the touch}.
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ENGINE TOP END 3-9
-Remove the fuel tank (see Fuel Tank Removal in the
Fuel System chapter).
-Take out the bolts and remove the valve adjusting caps
with O-rings.
Valve Installation
elf a new valve is to be used, check the valve-te-guide
clearance (see Valve Stem Diameter, Valve Guide Inside
Diameter).
*If there is too little clearance, ream the valve guide (see
Valve Guide Installation).
*If there is too much clearance, install a new valve guide
(see Valve Guide Removal and Valve Guide
Installation ).
-Check the valve seating (see Valve Seat Inspection). A. Stem End B. Stem C. Seating Area
eAfter proper valve seating has been confirmed, replace
the valve stem oil seal (see Valve Stem Oil Seal *If the valve head seating area is warped, replace the
Removal and Valve Stem Oil Seal Installation). valve.
-Smear the valve stem end with a thin coat of *If the valve head seating area is eroded or nicked, it
molybdenum disulfide engine assembly grease, and may be possible to repair the valve on a valve refacing
push the valve into the guide. machine. Follow the refacing machine manufacturer's
.Put the inner and outer springs in place. instructions.
oPlace the springs so that the closed coil end of each elnspect the stem for obvious wear, discoloration, and
spring faces down. stem end damage.
*If the stem is obviously worn or discolored, replace the
valve.
*If the stem end is damaged, it may be possible to repair
it on a valve refacing machine (see Valve Stem
Grinding).
eGo on to Valve Head Thickness, Valve Stem Bend, and
Valve Stem Diameter.
~~
l \
compressor. Be sure the keepers stay in place, holding
the retainer down . 45°
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ENGINE TOP END 3-11
Valve Head Thickness Valve Guides:
eMeasure the thickness of the valve head. Valve Guide Inside Diameter
*If the valve head thickness is less than the service limit, -Use a small hole gauge and a micrometer to measure
replace th e valve. the inside diameter of the valve guide at four places
down the length of the gu ide.
Valve Head Thickness *If any measurement is greater than the service limit,
Intake Standard: 0.80 - 1.20 mm replace the va lve guide (see Va lve Guide Removal and
Service Limit: 0.5 mm Valve Guide Installation).
Exhaust Standard: 0.80 - 1.20 mm
Service Limit: 0.7 mm Valve Guide Inside Diameter
Standard: 7.000 - · 7.015 mm
Service Limit: 7.0Bmm
NOTE
OThe valve stem and guide must be in good condition or
this check will not be valid.
1. Valve
2. Valve Seat
Good Too Wide Too Narrow Uneven 3. Seating Area Outside
diameter
4. Seating Area Width
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ENGINE TOP END 3-13
Used Holder and Bar 5. After use, wash it with washing oil and apply thin
Holder - ¢ 7.0 57001 -1126 layer of eng ine oil before storing.
Bar 57001-1128
NOTE
OA wire brush must not be used to remove the ground
particles from the cutter. That will cause the diamond Ang le of Cutter
particles to fall off.
t
45° Grind
Tool: 45° Cutter
Purpose: make seating area
smooth and round
t
Measure Seating Area O.D.
Tool Vern ier Caliper
Purpose: check seat O.D.
again st spec.
t ,I
Reiults
t
I
,
Tool small I I OK I I Too big
t
I
Tool:
Purpose:
45° Grind
45°Cutter
increase 0.0. of seat
area to spec.
,
Machinist's
dye on seat
32° Grind
Tool: 32°Cutter
Purpose: reduce 0.0. of seat area
to spec.
Re+ts
t t t
I Too narrow I I OK I I Too wide I
t t
Tool:
Purpose:
45° Grind
45° Cutter
increase width of seat
area beyond spec. to
increase 0.0.
,
Machinist's
dye on seat
60° Grind
Tool : 60° Cutter
Purpose: reduce seat width
to spec.
Lap Valve
Tools: Valve lapper, grinding
compound
Purpose: perfectly match valve
l
,
and seat area; check
valve head for damage
FINISHED )
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ENGINE TOP END 3-15
Vo lume ground
by 60° cutter Valve Lapping
Valve Springs: .Push the seal clip down over the seal until it seats in the
Valve Spring Removal/Installation groove in the seal.
eThe valve springs are removed and installed dur ing valve elnstall the valve (see Valve Installation).
removal and installation (see Valve Removal and Va lve
Installation) .
Camshaft Sprocket
Valve Spring Free Length
eMeasure the valve spring free length with a vernier
caliper. Camshaft Sprocket Removal
*If the free length is less than the service limit, replace eRemove the fue l tank (see Fuel Tank Removal in the
the spring. Fuel System chapter).
-Unscrew the left engine cover guard screws, and take
off the guard.
Valve Spring Free Length -Remove the cover center plug.
Inner Standard: 32.4mm -Remove the bolts and take off the camshaft cover.
Service Limit: 31.1 rnm olt may be necessary to pry the cover off with a screw-
Outer Standard: 37.3 mm driver. There are prying gaps under the screw hole
Service Limit: 35.8 rnm bosses.
-Remove the camshaft chain tensioner (see Camshaft -Screw in the bolt and tighten it to the specified torque
.Chain Tensioner Removal). (see Exploded View), while holding the crankshaft
-Remove the camshaft sprocket bolt. from turning with a wrench on the alternator rotor
o Hold the crankshaft from turning with a wrench on the bolt.
alternator rotor bolt. -Install the camshaft chain tensioner (see Camshaft
-Slide the sprocket off the shoulder on the camshaft and Chain Tensioner Installation).
out from under the chain. -Sefore going any further, check the cam timing.
-Support the chain on a screwdriver or other tool stuck oTurn the crankshaft counterclockwise with a wrench
in the hole in the head. on the alternator rotor bolt, until the "LF300" mark
on the sprocket realigns with the pointer on the head .
eTake out the bolts and remove the valve adjusting caps. Rocker Arm Inspection
eLoosen all the cylinder head bolts to free the cylinder -Inspect the area on the rocker where the cam rubs.
head from the tension .
• Pull out the rocker shafts and remove the rocker arms.
Camshaft:
Camshaft Removal
eRemove the camshaft sprocket (see Camshaft Sprocket
Removal).
eTake out the screws and remove the bearing retainer.
A. Cam Lobes
Cam Height
Standard: 40.876 - 40.984 mm
Service Limit : 40.78 mm
Camshaft Installation
_Camshaft installation is the reve rse of removal. Note
the following. Cam Height
eBlow the oil passage with compressed air.
Camshaft Chain:
Camshaft Chain Removal
eRemove the camshaft sprocket (see Camshaft Sprocket
¢
Removal).
eRemove the starter chain and sprockets (see Starter
Chain and Sprocket Removal in the Engine Left Side
chapter).
o 5 kg
eSe sure the camshaft chain guard holes fit onto the pins
on the crankcase. A. Front Chain Guide B. Rear Chain Guide
.00'
r,
NOTE
eSe sure the O-ring is in place in the tensioner body.
_After installing the tensioner, loosen the lockbolt and Olfa new cylinder is installed, be sure to check piston/
then tighten it. With the bolt loosened, the spring cylinder clearance before starting (see Piston/Cylinder
inside takes up any slack automatically. Clearance).
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ENGINE TOP END 3-23
eBlow out the oil passage with compressed air to be sure Piston Rings
it is not blocked.
-Clean any remains of the old cylinder base gasket from
the bottom of the cyl inder and the top of the crank-
case.
-Remove the cloth from around the piston.
-Be sure the dowel pins are in place in the crankcase.
~ Front
Arrow
~
"
~-~
~~
1. Top ring
2. Second ring
3. Steel rail, oil ring
4. Expander, oil ring
A. Dowel Pins B. Cylinder Base Gasket eFit the cylinder down over the piston and rings.
OHoid the rings into their groove with your fingers so
that the cylinder does not catch on them.
-Oil the piston rings and smear some oil inside the
cylinder bore. Piston and Ring Removal/Installation:
-Hold the cylinder in position above the case and push Piston and Ring Removal
the camshaft chain up through the tunnel. -Remove the cylinder (see Cylinder Removal).
-The camshaft chain guides also fit inside the tunnel. -Remove one of the piston pin snap rings.
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-Install the oil ring steel rails, one above the expander
and one below it.
oSpread the rail with your thumbs, but only enough to
fit the rail over the piston.
oRelease the rail into the bottom piston ring groove.
Cylinder Compression
Standard: 795 - 1,240 kPa
(S.l -12.6 kg/em', 115 - 179 psi)
A. Arrow pointing forward.
Cylinder Diameter Measurement *If the piston diameter is less than the service limit,
replace it.
NOTE
Olf the cylinder has been bored oversize, use the
Oversize Piston Diameter table.
10mm
E9 40mm
20mm
Piston/Cylinder Clearance
-Measure the piston diameter (see Cylinder/Piston Wear).
eMeasure the cylinder inside diameter with a dial bore
gauge at the bottom of the cylinder.
-Subtract the piston diameter from the cylinder inside
diameter to get the piston/cylinder clearance.
*If the piston/cylinder clearance is less than the
specified range, use a smaller piston or increase the
cylinder inside diameter by honing (see Cylinder Boring
eMeasure the piston diameter at the point shown with a and Honing).
micrometer. *If the piston/cylinder clearance is greater than the
specified range, use a larger piston or bore to the next
larger oversize (see Cy lind er Boring and Honing).
Piston Diameter
Standard: 75.950 - 75.965 mm Piston/Cylinder Clearance
Service Limit: 75.81 mm
Standard: 0.035 - 0.062 mm
Piston/Cylinder Seizure
e ln case of seizure, remove the cylinder (see Cylinder
Removal).
_Visua ll y inspect the cylinder and piston damage.
*If there is only light damage, smooth the piston with
#400 emery cloth. Remove small aluminum deposits
from the cylinder with #400 emery cloth or light
honing.
*If the damage is severe, the cylinder must be bored
oversize and an oversized piston installed.
A. Thickness Gauge
Piston Cleaning
eRemove the piston and piston rings (see Piston and *If the piston ring groove clearance is greater than the
Ring Removal). service limit, measure the ring thickness and groove
width as follows to decide whether to replace the rings,
[CAUTlO~J the piston or both.
eMeasure the piston ring groove width.
OUse a vernier caliper at several points around the
ONever clean the piston head with the engine assembled.
piston .
Carbon particles will fall between the piston and
cylinder and damage the crankshaft bearings.
I
Piston Ring End Gap (Top & Second) 000 not run the engine in a closed area. Exhaust gases
Standard: 0.20 - 0.35 mm contain carbon monoxide; a colorless, odorless,
Service Limit: 0.7mm poisonous gas. Breathing exhaust gas leads to carbon
monoxide poisoning, asphyxiation, and death .
oNever run the engine with the spark arrester removed.
Hot carbon particles may start a fire.
NOTE
· •• i ••••••••••• • ••••••••••••••••••••••• • •••••••••• • •••• • •• • •••••• •• •••••••••••
ORun the engine with the spark arrester installed during
Exhaust System cleaning. This keeps the exhaust pressure higher and
makes carbon panicles purge easier.
I WARNING.
aTa avoid burns, wear gloves while cleaning the spark Exhaust Pipe and Muffler:
arrester. Since the engine must be run during this
Exhaust Pipe and Muffler Removal
procedure, the muffler will become hot.
e Loosen the muffler clamp bolt until the clamp turns
freely on the muffler.
-Take out the muffler mounting bolts. Do not lose the
coll ars.
OThe spark arrester must be installed correctly and OFor extra clearance, first remove the rear fender
functioning properly to provide adequate fire pro- assembly (see Rear Fender Removal in the Frame
tection. chapter).
eRemove the muffler from the rear of the frame.
eRemove the drain plug on the rear muffler. eTake off the exhaust pipe holder nuts at the cylinder
eln an open area away from combustible materials, start head.
the engine with the transmission in neutral. -Work the exhaust pipe out of the frame and remove it.
eRaise and lo wer engine speed while tapping on the -Remove the exhaust pipe ho ld er and split coll ar.
muffler with a rubber mallet until carbon particles are -Remove the exhaust pipe gasket from the cylinder
purged from the muffler. head.
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A. Mounting Bolts
A. Chamfer
-Slip the muffler into place from the rear of the frame,
so that it fits over the exhaust pipe.
oBe sure that the collars are in place in the rubber
dampers in the muffler.
OHoid the muffler up and put in the mounting bolts, but
do not tighten them yet.
eTighten the exhaust pipe ho lder nuts evenly and
securely.
A. Holder Nuts B. Clamp _Tighten the muffler mounting bolts securely.
eTighten the muffler clamp bolt securely.
elf the rear fender was removed, install it (see Rear
Fender Installation in the Frame chapter).
Exploded View
..................... ... .... . .... . ........... . ... . ...... 0
.................. .
Specifications
Special Tool
NOTE
OThe flywheel holder (57001-1313) can be used instead
of the flywheel holder (57001-308).
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Starter Clutch
Left Engine Cover Installation
-Left engi ne cover installation is the reverse of removal. Starter Clutch Removal
Note the following. -Remove the alternator rotor (see Alternator Rotor
eBe su re all of the o ld gasket has been removed fro m the Removal in the El ectrical System chapter).
left engin e cover and the left hand crankcase seali ng eH o ld the roto r with t he flyw hee l holder (special tool)
surfaces. and take out the All en bolts.
-Check the dowel pi ns are in place, and fit a new gasket
o n the cra nkc ase.
•
A. One-way Clutch
A. Sprocket Guide
A. Toward engine.
1st 2nd
20·!ink Length 21st
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ENGINE RIGHT SIDE 5-1
Exploded View
T3@
Specifications
Clutches :
Primary Clutch:
Primary Clutch Housing I nside Diameter 125_0 - 125_2 mm 125_5 mm
Primary Clutch Shoe Groove Depth 1_0 mm 0.5mm
Secondary Clutch:
Friction Plate Thickness 2.92 - 3.08 mm 2.8mm
Friction Plate Warp Under 0.15 mm 0.3mm
Steel Plate Warp Under 0.2 mm 0.3 mm
Clutch Spring Free Length 30.38 mm 28.8 mm
Primary Reduction:
Lubrication System:
Item Standard Service Limit
NOTE
oThe flywheel holder 157001-1313) can be used instead
of the flywheel holder 157001-308).
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Clutches
Clutch Adjustment:
Clutch Adiustment
aRemove the clutch release adjusting screw cover.
A . Dowe[ Pins
B. Clutch Re[ease Cams and Sail Assemb[y
oThe projected portion of the ball assembly must be
faced in.
Clutch Removal:
Clutch Removal
eRemove the right engine cover (see Right Engine Cover
Removal ).
-Using the gear holder (special tool), hold the primary
gear and secondary gear to keep them from turning,
and remove the primary clutch hub nut.
Clutch Installation .cross tighten the seco ndary clutch spring bolts evenly
• Primary and secondary clutch installation is the reverse to the specified torque (see Exploded View) .
of remo va l. Note the fol low ing. o Be sure that the clutch wheel splines f it onto the clutch
-Assemble the secondary clutch plates. hub splines. When the clutch wheel is installed
o lnsta ll the friction plates and steel plates to th e clutch correctly, there is no gap be tween the clutch whee l and
hub, starting with a friction plate and alternating them. t he next friction plate, a nd clutch plates have no play_
( CAUTlO~J
Olf new dry steel plates and friction plates are installed,
apply engine oil to the surfaces of each plate to avoid
clutch plate seizure.
A. Projectio n B. Groove
Clutch Inspection:
Primary Clutch Housing Wear
eMeasure the inside diameter of the clutch housing
where the shoes wear against it.
o Use calipers and measure at several points as shown.
*If an y measurement is greater than the service limit,
replace the primary clutch housing.
f
eRemove the right engine cover (see Right Engine Cover
Removal).
-Turn the primary clutch housing by hand. When
viewed from the right side of the engi ne, the primary
clutch housing shou ld turn counterclockwise freely,
but should not turn clockwise.
Friction Plate Wear and Damage Secondary Clutch Housing Finger Damage
-Visually inspect the friction plates for uneven wear, eVisually inspect the fingers of the clutch housing where
discoloration, or missing friction material, cracks, or the housing of the friction plates hit them.
other damage. *If they are badly worn or if there are grooves cut where
*If any of the friction plates are damaged, replace the tangs hit, replace the housing. Also, replace the
~-. . friction plates if their tangs are damaged.
eMeasure the thickness of the friction paltes at several
points.
........................................................................... ..
Primary Reduction
.............................................................................
Primary Gear Removal
eTh e primary gear is removed during primary clutch
removal (see Clutch Removal).
A. Cam Area
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Gear Backlash
eRemove the right engine cover (see Right Engine Cover
Removal).
-Set a dial gauge against the teeth on one gear, and move
the gear back and forth whi le holding the other gear
steady. The difference between the highest and the
lowest gauge readings is the amount of backlash.
*If the amount of backlash exceeds the service limit,
replace both gears.
Gear Backlash
Standard : 0.02 -0.11 mm
Service Limit: 0.14 mm
1r
Lubrication System
-Stop the engine and wait several minutes for all the oil
to drain back to the sump.
echeck the level of the oil in the window gauge in the
lower part of the ri ght engine cover.
.The o il leve l should be between the lines next to the
gauge.
*If the level is too hi gh, suc k the excess oil out the filler
hole with a sy ringe or other suitable device.
*If the level is too low, add oil throu gh the filler hole.
Use the same type and make of oil that is already in
the engi ne. A. Oil Filter B. Filter Mounting Pin
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A. Grommets
OPut the filter with pin into the filter cavity. The larger
end of the pin goes in first.
CCheck that the filter cover O·ring is in place.
olnstall the o il filter cover and tighten the bolts secu rely.
elnstall the oil drain plug with a new aluminum gasket,
and tighten it to the specified torque (see Exploded
View).
eFili the engine with the specified oil and quantity.
A. Screws
Engine Oil
Grade: SE or SF class
Viscosity: SAE 10W-30. 10W-40. 10W-50.
20W-40. or 20W-50 Oil Pump Installation
Capacity: 1.7 L elnstallation is the reverse of removal. Note the
following.
eSe sure the dowel pins under the oi l pump are in place.
eBe sure the O·ring is.in place, and install the filler cap.
Oil Pump:
Oil Pump Removal
eRemove the primary clutch (see Clutch Removal).
-Take out the screws and remove the oil pump guard. A. Dowel Pins
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ENGINE RIGHT SIDE 5-13
eFill the pump with engine oil before installation. ePull the pin out of the pump shaft, and pull off the
shaft.
Oil Screen:
Oil Screen Removal
eRemove the right engine cover (see Right Engine Cover
Removal).
ePul1 the screen out of the crankcase.
A. Screw
A. Oil Screen
Oil Screen Cleaning and Inspection -Drop out the spring and the bypass valve piston.
eelean the oil screen with high flash-point solve nt and
remove any particles stuck to it.
I WARNING.
OClean the screen in a well·ventilated area, and take care
Bypass Valve Installation
that there is no spark or flame anywhere near the
-Drop the bypass valve piston closed end first into the
working area. Because of the danger of highly
filter mounting pin.
flammable liquids, do not use gasoline or low
ePut the spring into the mounting pin and compress it
flash-point solvents.
beyond the small hole.
eDrive the retaining pin into the small hole to hold the
spri ng.
elnstall the oil filter (see Engine Oil and Filter Change).
WARNING.
oelean the parts in a well-ventilated area, and take care
NOTE that there is no spark or flame anywhere near the
aWhile cleaning the screen, check for any metal particles working area. Because of the danger of highly
that might indicate internal engine damage. flammable liquids. do not use gasoline or low flash-
point solvents.
-Check the scree n carefully for any damage: holes,
broken wires, gasket pulling off. eVisually inspect the bypass valve parts.
*If the screen is damaged, replace it. *If the sp ring is bent or distorted, rep lace it. If the
piston is worn, replace all of the bypass valve parts.
Engine Removal/Installation
Table of Contents
Engine Removal/lnstallation
Engine Removal
eDrain the engine oil (see Engine Oil and Fi lter Change
in the Engine Right Side chapter).
eRemove the following parts.
Front Fender and Rear Fender
Fuel Tank
Carburetor
Exhaust Pipe and Muffler
Differential Shift Lever Case
Shift Pedal
eDisconnect the followi ng cable and leads from the
engine. A. Mounting Bolts B. Bracket Bolts
Reverse Cable
Starter Motor Lead
Alternator Leads
Pickup Coil Leads eFree the cy linder head vent hose and carburetor vent
Spark Plug Lead hose from the frame.
Battery Ground Lead eLoosen the propeller shaft dust cover front clamp.
eRemove the engine mounting bolts and bracket bolts.
Olt may be necessary to support the engine while sliding
out the engine mounting bolts.
eLift the engine up to free the engine from the mounts,
pull the engine to the right si de of the frame, and free
the engine from the propeller shaft.
Engine Installation
eEngine installation is the reverse of removal. Note the
following.
eApply grease to the sp lines at the front end of the
propeller shaft and fit the propeller shaft front end to
the front driven gear shaft rear end.
A. Differential Shift Lever Case OFar extra clearance, first slide back the rear ax le and
B. Battery Ground Lead propeller shaft (see Front Gear Case Removal in the
Final Drive chapter).
eFili the engine with engine oil (see Engine Oil and
Filter Change in the Engine Right Side chapter).
eAdjust the reverse cable (see Reverse Cable Adjustment
in the Engine Bottom End/Transmission chapter).
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ENGINE BOTTOM END/TRANSMISSION 7-1
Exploded View ... . • ..... • . . . . . . . • .. 7-2 Reverse Knob and Cable . . . . . . . . . . . . . 7·11
Specifications . . . . . . • . . . . • . . . . . . . . . . 7-4 Reverse Knob Free Play inspection .... 7·11
Special Tools . . . . . . . .. . . . . . . . . . . . • . . 7-4 Reverse Cable Adjustment . . . . . . . . . . 7·11
Crankcase Splitting .. . . . . . . . . . . .. . . . . . 7-5 Reverse Knob and Cable Removal . . . . . 7·11
Crankcase Disassembly . . . . . •... •.. 7-5 Reverse Knob and Cable Installation .. . 7·11
Crankcase Assembly . . . . . . . • . . • . . . 7-5 Reverse Cable Lubrication . . . . . . . . . . 7-12
Crankshaft and Connecting Rod ... . .. . .. . 7 -6 Reverse Cable Inspection . . . . . . . . . . . 7-12
Crankshaft Removal . . . . . . . • . . .. .. 7 -6 Transmission Shafts, Shift Drum, Forks ... 7-12
Crankshaft Installation .... . • . . . . . . 7·6 Transmission Removal . . . . . . . . . . . . . 7-12
Crankshaft Disassembly. . . . . . . . . . ..
Crankshaft Assemb ly _ . . . . . . . . . • . ..
Connecting Rod Bend /Twist . . . . . • . ..
7·6
7-6
7-7
Transmission Installation. . . . . . . . .
Transmission Shaft Disassembly . . ....
Transmission Shaft Assembly . . . . . ...
Shift Fork Bending . . . . . . _ . .
7-12
7-13
7-14
7-14
II
Connecting Rod Big End
Radial Clearance. . . . . . . . . . • . . .. 7-8 Shift Fork/Gear Groove Wear . . . . . . . . 7-14
Connecting ,Rod Big End Shift Fork Guide Pin /Shift Drum
Side Clearance. . . . . . . . . . . . . . .. 7-8 Groove Wear .. .... . . . . . . . . . . . 7 -14
Crankshaft Alignment. . . . . . . . . . . .. 7-8 Gear Dog/Gear Dog Hole and
Co nnecting Rod Big End Seizure . . . . .. 7-9 Recess Damage. . . . . . . . . . . 7-15
Transmission . . . . . . . . . . . . . . . . . . . . . .. 7-9 Balancer .. 7-15
Transmission External Shift Mechanism ... 7-9 Balancer Drive Removal . . . . . • . . . . . . 7-15
External Shift Mechanism Removal 7-9 Balancer Drive Installation .. _ . . . . 7-16
External Shift Mechanism Balancer Removal . . . . . . . . _ . . . .... 7-16
Installation . . . . . . . . . . __ . • . . . . 7-10 Balancer Installation . . . . . . . . . . . . . . 7-16
External Shift Mechanism Ball and Needle Bearings . . . . . . . .. ... . _ . 7-16
Inspection. . . . . . . . . . . . . . 7-10 Ball and Needle Bearing
Shift Drum Stop Lever Removal . . . . . . 7-10 Replacement .. . . . . . . . . . . . .... 7-16
S hift Drum Stop Lever Installation . . . . 7-10 Ball and Needle Bearing Wear . . . . . . . . 7-16
Shift Drum Stop Lever Inspection . . . . . 7-10
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7-2 ENGINE BOTTOM ENOITRANSMISSION
Exploded View
~
i'l/
r~" T5
~
T5
-L -
"
jY~
/
c:J
-
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Specifications
Transmission:
Item Standard Service Limit
Shift Fork Ear Thickness 4.4 -4.5 mm 4.3mm
Gear Shift Fork Groove Width 4.55 - 4.65 mm 4.Smm
Shift Fork Guide Pin Diameter 5.9 - 6.0 mm 5.Smm
Shift Drum Groove Width 6.05 - 6.20 mm 6.3mm
NOTE
oThe flywheel holder 157001·1313} can be used instead
of the flywheel holder 157001-30B}.
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ENGINE BOTTOM END/TRANSMISSION 7-5
Crankcase Splitting
Crankcase Disassembly
eRemove the engi ne (see Engine Removal in the Engine
Removal/Installation chapter).
eRemove the following parts.
Piston
Starter Motor
Oil Filter
Front Bevel Gear Case
Front Bevel Drive Gear
Output Shaft LH Bearing Housing
Shift Drum Stop Lever
Neutral and Reverse Switch A. Pry at these gaps.
Clutches
Oil Pump o Lift off the left crankcase half.
External Shift Mechanism
Alternator Rotor
Camshaft Chain and Guides
eRemove the gaskets and dowel pins on the outside of
the eran kcase. Crankcase Assembly
-Remove the banjo bolts and take off the oil pipe.
NOTE
aBe certain that all pans are cleaned thoroughly before
assembly.
OBlow through all oil passages with compressed air to
clear any blockage.
A. Banjo Bolts
A. Compressed Air
08e sure all transmission shafts, shift forks, and the shift Crankshaft Installation
drum are in place in the right crankcase half. ePosition the right crankcase half so that the RH main
bearing housing is seated on a suitable press fixture .
ePress the crankshaft into the RH main bearing.
I WARNING' Olnsert the crankshaft jig (special tool) between the
crankshaft halves, opposite the crankpin, to prevent
OClean the engine parts in a well·ventilated area, and crankshaft distortion during installation.
take care that there are no sparks or flame anywhere
near the working area; this includes any appliance with
a pilot light. Do not use gasoline or a low flash·point
solvent to clean parts. A fire or explosion could result.
NOTE
eApply a liquid gasket to the mating surface of the right
OSince assembly of the crankshaft demands exacting
crankcase half.
-Fit the left crankcase half on the right crankcase half, tolerances, the disassembly and reassembly of the
an d tigh ten the cran kcase bol ts securel y. crankshaft should only be performed by experienced
mechanics with the necessary tools and equipment.
eRotate the shift drum to the neutral position.
e<:heck to see that the crankshaft, drive shaft, and oThe crankshaft left main bearing, chain sprocket, and
output shaft all turn freely. left crankshaft are available separately as spare pan,
*If any of the shafts do not turn freely, split the crank- however, it is recommended that the crankshaft
case to locate the problem. assembly be replaced rather than attempting to replace
eThe remainder of Crankcase Assembly is the reverse of the components.
disassembly.
ePress the crankpin out of the crank halves to separate
the crank halves, connecting rod, crankpin needle
bearing, and crankpin.
Vi ew A
A
ePress the camshaft chain sprocket into the crankshaft
as shown. The chamfered side of it faces to the ball
bearing.
OSelect an arbor of the same diameter as the piston pin
and at least 100 mm long, and insert the arbor through
Camshaft Chain Sprocket Installation the connecting rod small end.
OWith the connecting rod held vertically, use a height
gauge to measure the difference in the height of the
arbor above the surface plate over a 100 mm length to
determine the amount of connecting rod bend.
1 *If connecting rod bend exceeds the service limit, the
connecting rod must be replaced.
Connecting Rod Big End Radial Clearance *If big end side clearance exceeds the service limit, the
-Check big end radial clearance. crankshaft assembly must be replaced or disassembled
oSet the crankshaft on V blocks, and place a dial gauge and the connecting rod and thrust washers visually
against the connecting rod big end. inspected for wear.
Connecting Rod Big End Radial Clearance Connecting Rod Big End Side Clearance
Standard: 0.25 - 0 .35 mm
Service Limit: 0.6mm
Crankshaft Alignment
-Check crankshaft alignment by measuring runout.
OWith the crankshaft on V blocks, turn the crankshaft
slowly and measure runout at each of the locations
shown.
o Push the connecting rod first towards the gauge and
then in the opposite direction. The difference between
the two gauge read ings is the radial clearance.
*If the rad ial clearance exceeds the service limit, the
crankshaft assembly must be replaced or disassemb led Crankshaft Runout
and the crankpin, need le bearing, and connecting rod
big end examined for wear.
, ~,
Connecting Rod Big End Radial Clearance 9mm
Connecting Rod Big End Side Clearance *If runout at either location exceeds the service lim it,
align the crankshaft so that runout is with in the service
limits.
T Side Clearance
Crankshaft Runout
Left Half Standard: Under 0.03 mm TI R
Service Limit: 0.08 mmTIR
Right Half Standard: Under 0.04 mm TI R
Serivce Limit: 0 .10 mm TIR
............................................................................
Transmission
External Shift Mechanism Installation CCheck the shift shaft for bending or damage to the
eExternal shift mechanism installation is the reverse of spline.
removal. Note the following. "'If the shaft is bent, straighten or replace it. If the
spline is damaged, replace the shaft.
e<:heck the shift drum positioning lever swings smoothly
CCheck the springs for breaks or distortion.
after tightening the pivot bolt.
*If the springs are damaged in any way, replace them.
eSe sure the shift mechanism arm collar and clutch
release cam are in place. OCheck the shift mechanism arm for distortion.
* If the shift mechanism arm is damaged in any way,
replace the lever.
OCheck the return spring pin and/or cam pin is not loose.
-trlf it is loose, unscrew it, apply a non-permanent locking
agent to the threads, and tighten it to the specified
torque (see Exploded View).
ePull the cable holder out the assembly, and free the
reverse cable upper end from the assemb ly.
aLoosen the mounting nuts and take off the cable
adjuster from its bracket.
Cable Lubrication
Transmission Installation
-Set the transmission shafts, and fit them into the right
crankcase half at the same time.
OApply a small amount of engine oil to the transmission
gears, bearings, and shaft journals.
-Fit each shift fork into the groove of the proper gear so
that the shift fork guide pin is in the proper groove on
the shift drum.
oApply a small amount of engine oil to the shift fork
fingers.
oThe forks for the output shaft are identical.
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ENGINE BOTTOM END/TRANSMISSION 7-13
-Install the shift rods. Transmission Shaft Disassembly
OApply a small amount of engine oil to the shift rods. eRemove the transmission shafts (see Transmission
olnsert the shorter shift rod through the drive shaft Removal) .
fork, and the longer rod through the output shaft -Using the circlip pliers (special tool), remove the circlip
forks. and disassemble the transmission shafts completely.
A. Short B. Long
A. Circlip Pliers: 57001-144
Transmission Gears
Drive Shaft
4th
Reverse
Output Shaft
2nd
\
Reverse Shaft
A. Short B. Long
Balancer
*If the guide pin on any shift fork is less than the service
limit, the fork must be replaced.
*If any shift drum groove is worn over the service limit, -Flatten the side of the toothed washer where it is bent
the drum must be replaced. up against the nut mounting the balancer drive gear and
oil pump drive gear.
eRemove the nut with the socket wrench (special tool),
and take off the oil pump drive gear and balancer drive
Gear Dog/Gear Dog Hole and Recess Damage gear.
-Visually inspect the gear dogs, gear dog holes and/or
recesses. Replace any gears that have damaged or
excessively worn dogs, dog holes, or recesses.
Balancer Installation
_Balancer installation is the reverse of removal.
0 00 not heat the case with a torch . This will warp the
case. Soak the case in oil and heat the oil.
eUsing a press and the bear ing driver set (special tool:
PIN 57001·1129), install the new bearing until it stops
at the bottom of its housing,
o
little, and wear is difficult to measure. Instead of
measuring, inspect the bearing for abrasion, color
change, or other damage.
*If there is any doubt as to the condition of a needle
bearing, rep lace it.
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WHEELsrrlRES 8-'
Wheels/Tires
Table of Contents
8-2 WHEELS/TIRES
Exploded View
T1
T1
G : Apply grease.
T1 : 34 N-m (3.5 kg·m. 25 ft·lb)
Specifications
Wheel Alignment
Caster 4 0 (non-adjustable)
0
Camber: 0.8 (non-adjustable)
Toe-in 27 mm
Tire Payload: 182 kg (400 Ib)
Standard Tires
Front 22 x 9.00·10
Dunlop KT761. Knobby/Trail Tubeless
Rear 24 x 11.00·10
Dunlop KT765. Knobby/Trail Tubeless
Tire Air Pressure (when cold)
Front 21 kPa (0.21 kg/em 2 • 3 psi)
Rear 21 kPa (0.21 kg/em 2 • 3 psi)
Maximum Tire Air Pressure (to seat beads, when cold)
Front 137 kPa (1.4 kg/em 2 • 20 psi)
Rear 137 kPa (1.4 kg/em 2 • 20 psi)
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WHEELS/TIRES 8-3
.............................................................................
Special Tools Wheel Alignment
Jack: 57001-1238 Toe-in is the amount that the front wheels are closer
together in front than at the rear at the axle height.
When there is toe-in, the distance A is greater than B as
shown. The purpose of toe-in is to prevent the front
wheels from getting out of parallel at any time, and to
prevent any slipping or scuffing action between the tires
and the ground. If toe-in is incorrect, the front wheels
will be dragged along the ground, scuffing and wearing
the tread knobs.
Caster and camber are built-in and require no adjust-
ment.
B
Front of Vehicle
rl
Tire Irons: 57001-1073
!/
i=-
'" D (/~
F=
- ' .- -
V
'" -= i.=
, ))
h ~ A
'" A
A - B = Amount of Toe-in
Air Pressure Gauge: 52005-1082 (Distance A and B are measured at hub height)
8-4 WHEELS/TIRES
Toe-in Inspection
eSupport the veh icle on a stand or the jack (special tool:
57001-1238) so that the front wheels are off the
ground.
eApply a heavy coat of chalk near the center of the
front tires.
A. Straightedge B. Jack: 57001·1238 _Using a needle nose scriber, make a thin mark near the
eWith the handlebar straight ahead, loosen the locknuts center of the chalk coating while turning the whe~l.
and turn the tie·rod adjusti ng sleeve the same number
of turns on both sides until the front wheel on that side
is parallel to the straightedge.
NOTE
oThe outside locknut on the tie·rod has left·hand
threads. Turn the wrench clockwise for loosening.
I
r
Toe-in Adjustment
Wheels (Rims)
eLoosen the locknuts and turn the adjusting sleeves the
same number of turns on both sides to ach ieve the
spec ified toe- in .
Wheel Removal
eSupport the vehicle on a stand or the jack (special tool:
57001-1238) 50 that th e wheels are off the gro und.
ePull off the wheel cap.
eTake off the wheel nuts holding the wheel to the hub.
Wheel Installation
eMount the wheelan the studs.
ePosition the whee l so that the valve stem is toward the
outside of the vehicle.
-Check the tire rotation mark on the front and rear
tires, and install them on the rim accordingly_
NOTE
OThe outside locknut on the tie-rod has left-hand
threads. Turn the locknut clockwise for loosening.
OThe toe-in will be near the specified value, if the tie-rod
length is 380 mm between the tie-rod ends.
o Far the front whee ls, align the "shoe check hole" and
"shoe adjust hole" on the rim with the holes on the
drum respectively.
oTighten the whee l nu ts in a criss-cross pattern to the
specified torque (see Exploded View).
1. Front
2 . Left-hand Thread
3. Tie-rod Length
Wheel Inspection
eExamine both sides of the rim for dents. If the rim is
dented, replace it. 000 not use engine oil or petroleum distillates to
Rim Dent lubricate the stem because they will deteriorate the
<0\\ \ \ II , , I I 1/7r; rubber.
00 Dent 'in eMount the tire on the new rim (see Tire Installation).
elnstall the wheel (see Wheel Installation).
~
~ \ '/)
.;:,
c: ';J
C :J
:::J
=:J
:=J
.::::J
j}
v </. ' ___ _ - ,-» Tires
<IIcill"",\\\\\V
elf the tire is removed, inspect the air sealing surfaces of Tire Removal
the rim for scratches or nicks. Smooth the sealing
eRemove the wheel (see Wheel Removal ).
surfaces with fine emery cloth if necessary. _Unscrew the valve core to deflate the tire.
o Use a proper valve core tool.
A. Sealing Surfaces
Wheel Replacement
eRemove the wheel (see Wheel Removal). A. Valve Core Tool
eDisassemb le the tire from the rim (see Tire Removal).
elnstall a new valve stem in the new rim.
ORemove the valve cap, lubricate the stem with a soap
eLubricate the tire beads and rim flanges on both sides
of the wheel with a soap and water solution, or water.
and water solution, or water and pull the stem through
the rim from the inside out until it snaps into place.
This helps the tire beads slip off the rim flanges.
eBreak the tire beads away from both sides of the rim
with a tire tool.
I;
eLift the second bead up into the center well and use
the same procedure as in removing the first bead.
Tire Installation
elnspect the rim (see Wheel Inspection).
e<:heck the tire for wear and damage (see Tire Inspec·
tion).
eLubricate the tire beads, rim flanges, and the tire irons
(special tools) with a soap and water so lution, or water.
eKneel on the side of the tire, forcing the tire bead into
the center well of the rim.
I WARNING.
000 not use the lubricant other than a water and soap
Rim Center Well solution, or water to lubricate the tire beads and rim
because it may cause tire spearation.
_,--r~~~~..,..,,~valve Stem et:heck the tire rotation mark on the front and rear
tires, and install them on the rim accordingly.
OThe tires should be installed on the rims so that each
valve stem is toward the outside of the vehicle.
NOTE
OThe direction of the tire rotation is shown by an arrow
on the tire side wall.
eBy hand, slide as much of the first bead as possible over
the rim flange, starting at the side opposite the valve
stem.
oAs the bead goes onto the rim, force the bead into the
Well center well of the rim to ease installation.
eUse the tire irons to install the rest of the bead.
eUse the same procedure to install the second bead.
eLubricate the tire beads again, center the tire on the
rim, and inflate the tire until the tire beads seat on the
eLubricate two tire irons with a soap and water, or rim.
water and pry the bead.
I WARNING I
000 not inflate the tire to more than 137 kP. (1 .40
kg/cm 2 • 20 psi). Overinflation can cause the tire to
explode, causing personal injury.
000 not scratch the air sealing surfaces of the tire or
rim. Scratches or nicks on the sealing surfaces will e<:heck to see that the rim lines on both sides of the tire
allow the tire to deflate. are parallel with the rim flanges.
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8-8 WHEELS/TIRES
A. Rim Line
.If the rim lines and the rim flanges are not parallel,
deflate the tire, lubricate the sealing surfaces again, and
reinflate the tire .
• After the beads are properly seated, check for air leaks.
olnflate the tire to 35 kPa (0.35 kg/em', 5 psi). Apply a
soap and water solution around the tire bead and check
for bubbles. A. Hub Nut
eDeflate the tire to spedfied pressure (see Specifica-
tions). .Pull off the wheel with the hub assembl y, and pullout
• Install the wheel (see Wheel Installation). the collar .
-Wipe off the soap and water solution on the tire, and
dry out the tire before operation. WARNING.
Tire Wear
Vertical Sides
Worn Away
/-----rJ/
/ /' ~'" .
/ I \
I ~ \
I // ~ .
~ -1- \ A. Collar B. Grease Seal
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WHEELS!TIRES 8-9
OPosition the hub assembly on wooden blocks to allow Olnsert the spacer pipe into the hub assembly.
bearing removal. o Drive out the remaining bearing and grease seal by
tapping on the spacer pipe with a suitable driver.
eDeburr the spacer pipe as needed.
A. Wooden Block
A. Spacer Pipe
A. Metal Rod
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FINAL DRIVE 9-1
Final Drive
Table of Contents
Exploded View .. . ...•... ......• .... 9-2 Axle Shaft Installation . ... . ... .. . 9-17
Specifications . . . . . . . . .. . . . . .. ... . . 9-4 Axle Shaft Inspection . ... . . . . . . __ . 9-18
Special Tools .... .. . . . . . . . . . . . . . . . . ' 9-5 Ball Bearing Inspection . . . . . . . . . . . . 9-18
Final Gear Case Oil . . . . . . . . . . . . . . . . .. . 9-6 Oi l Seal Inspection ...... . . . . . . . . . . 9·18
Final Gear Case Oil Level Inspection ... 9·6 Final Bevel Gears and Differential Gears . . . . . 9 ·18
Final Gear Case Oil Change. . . . . . . . 9-6 Pinion Gear Disassembly . . . . .... ... 9 · 18
Front Bevel Gears and Cam Damper . . . . . . . ' 9·6 Pinion Gear Assembly . . . . . . . . . . . . . 9-19
Front Gear Case Removal. . . . . . . . . .. 9·6 Ring Gear and Differential Gear
Front Gear Case Installation. . . . . . . .. 9·8 Disassembly . . . . . . . . . . . . . . _ ... 9·19
Front Drive Gear Removal/ Ring Gear and Differential Gear
Installation . . . . . . . . . . . . . . . . . . 9-9 Assemb ly . . . . . . . . . . . . . . . . . . . 9-20
Front Driven Gear and Cam Final Bevel Gear Adjustment .... . ... 9·20
Damper Removal ... .. ... . ... . . 9-9 Bevel Gear Inspection . . . . .. . . . . . .. 9·25
Front Driven Gear and Cam Differential Gear Inspection . . . . . . . .. 9-25
Damper Installation .. . . . . . . . . . . 9-9 Tapered Roller Bearing Inspection . .. . . 9-25
Front Bevel Gear Adjustment 9-10 Ball Bearing Inspection . . . . . . . . . . . . 9·25
Bevel Gear Inspection . . . . . . . . . . . .. 9 ·14 Oil Seal Inspection . . . . . . . . . . . . . . . 9-25
8all Bearing Inspection . . . . . . . . . . . . 9-14 Differential Shift Mechanism . . . . . . . . . . . . 9·25
Tapered Roller Bearing Inspection . . . . . 9·14 Shift Lever Case and Cable Removal .... 9-25
Oil Seal Inspection . . . . . . . . . . . . . . . 9·14 Shift Lever Case and
Cam Damper Inspection . ... , . . . . . . . 9·14 Cable Installation . . . . . . . . . . . . . . 9-26
Propeller Shaft _ .. _ .. _ ..... _ . . . . . . . . . 9-14 Shifter and Shift Fork Removal .... . _. 9-26
Propeller Shaft Removal . _ ... .. .... 9-14 Shifter and Shift Fork Installation . _ ... 9-26
Propeller Shaft Installation . . . . . . . . . . 9·15 Differential Cable Adjustment . . . . . . . . 9·27
Propeller Shaft Lubrication . . . . . . . . . 9·15 Differential Cable Lubrication . . . . . . . . 9·28
Prope ller Shaft Joint and Pin ion Differential Cable Inspection . . . . . . . . 9-28
Joint Inspection . . . . . . . . . , . . . . . 9-15 Shifter and Shift Fork Inspection . . ... 9-28
Propeller Shaft Inspection . . . . . . _ ... 9·15
Rear Axle Shafts . . . . . . . . . . . . . . . . . . . . 9-16
Rear Ax le and Propell er Shaft
Removal . . . . . . . _ . . . . . . . . . . . . 9-16
Rear Axle and Propeller Shaft
Installa tion. . . _ .. _ _ . _ 9-16
Axle Shaft Remova l . .... _ ..•..... 9-17
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F
9-2 INAL DRIVE
.......... ......... ................... .... . ...... ..............
14mm @
16mm @
a
8mm
- @
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FINAL DRIVE 9-3
o
~
G : Apply grease.
L : Apply a non-permanent locking agent.
o : Apply an oil to the threads and seated surface.
St : Stake the fastener.
T1 : 25 N-m (2.5 kg-m, 18.0 ft·lb)
T2: 88 N-m (9.0 kg·m, 65 ft-Ib)
T3: 98 N-m (10.0 kg-m, 72 ft·lb)
T4: 12 N-m (1.2 kg-m, 104 in-Ib)
T5: 20 N-m (2.0 kg·m, 14.5 ft-Ib)
T6: 78 N-m (8.0 kg·m, 58 ft-Ib)
T7: 29 N-m (3.0 kg·m, 22 ft-Ib)
T8: 6.9 N-m (0.70 kg-m, 61 in·lb)
T9: 93 N-m (9.5 kg-m, 69 ft-Ib)
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94 FINAL DRIVE
Specifications
Item Standard
rCAUTlO~]
a Be careful not to allow any dirt or foreign materials to
enter the gear case.
A. Drain Plug
echeck the oil level. The oil level sho uld come to th e
bottom of the filler opening.
WARNING I
OWhen draining or filling the final gear case, be careful
that no oil gets on the tire or rim. Clean off any oil
that inadvertently gets on them with a high flash-point
solvent.
that is already in the final gear case. rated hypoid gear oils can also be used.
eBe sure the O-ring is in place, and tighten the filler
cap to the specified torque (see Exploded View).
eBe sure the O·ring is in place, and tighten the filler cap
to the specified torque (see Exploded View).
A. Oil Seal Housing B. Mounting Nuts ORemove the bolts holding the output shaft LH bearing
housing and pu ll out the bearing housing.
o Remove the gasket and dowel pins from the crankcase.
eTo remove the output shaft LH bearing from its
eRemove the front gear case mounting bolts and take housing, remove the bearing holder using the hexagon
off the case. The differential shift lever case, differen-
wrench (special tool) and drive out the bearing with the
tial cable bracket, and reverse cable bracket come off
bearing driver set (special too l: PIN 5700 1-11 29) if
with the mounting bolts.
necessary.
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eApply grease to the oil seals on the front gear case, and
use the oil seal guides (special tools) to protect the oil
seals during case installation.
A. Apply grease.
, I
bearings.
NOTE
When the any of the backlash·related parts are OPreload can be measured either with a spring scale or
rep laced, or the bearing preload nut is loosened; even if with a beam-type torque wrench. When measured with
the purpose is not to replace the parts, be sure to check a spring scale, the preload is designated by force (N,
and adjust the bearing preload and the bevel gear kg), and when measured with a torque wrench, it is
backlash and tooth contact by replacing shims. designated by torque (N'm, kg·m, in·fbi.
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FINAL DRIVE 9-11
Backlash·Related Parts
A. Torque Wrench
Backlash adjustment
eelean any dirt and oil off the bevel gear teeth. A. Turn B. Neutral Detent
elnstall the drive gear with the standard shim (see the
shim tables), and tighten the nut to the specified
torque (see Exploded View).
OAp pl y an oil to the threads and seated surface on the *If the backl'ash is not with in the limit, replace the
nut. shim(s) at the driven gear. To increase backlash,
-Install the driven gear and cam damper assembly to the decrease the thickness of the shim(s). To decrease
front gear case with the standard shim (see "the shim backlash, increase the thickness of the sh im(s) .
tablesL and tighten the mounting nuts to the specified *Change the thickness a little at a time.
torque (see Exploded View) without the oil seal eRe-check the backlash, and re-adjust as necessary.
housing.
-Install the front gear case to the crankcase, and tighten
the 8 mm case bolts to the specified torque (see
Front Bevel Gear Backlash
Exploded View).
OCheck the backlash during the tightening of the case Standard: 0.06 - 0.10 mm
mounting bolts, and stop tightening them immediately (at bearing preload nut)
if the backlash disappears. Then, change the sh im to a
thinner one.
-Set up a dial gauge against a bearing preload nut of the
driven gear shaft to check gear backlash.
NOTE
OApply checking compound to the teeth in a thin, even
coat with a fairly stiff paint brush. If painted too
thickly, the exact tooth pattern may not appear.
o The checking compound must be smooth and firm,
with the consistency of tooth paste.
OSpecial compounds are available from automotive
supply stores for the purpose of checking differential
gear tooth patterns and contact. Use this for checking
A. Dial Gauge B. Move.
the bevel gears.
e<:::heck the drive pattern and coast pattern of the bevel Correct Tooth Contact Pattern
gear teeth. The tooth contact patterns of both drive
and coast sid es should be centrally located between th e Drive Gear
top and bottom of the tooth, and a little closer to the
toe of the tooth.
* If the tooth contact pattern is incorrect, replace the
shim(s) at the drive gear and shim(s) at the driven gear,
Bottom
following the examples shown. Then erase the tooth
contact patterns, and check them agai n. Also check . I
~~
the backlash every time the shims are replaced. Repeat
the shim change procedure as necessary.
NOTE
Olf the backlash is out of the standard range after
changing shims correct the backlash before checking
i
'"''#/
Bottom
Example 1: Increase the thickness of the drive gear Example 2: Decrease the thickness of the drive gear
shim (s) by 0.05 mm, and/or decrease the thickness of the shim(s) by 0.05 mm, and /or increase the thickness of the
driven gear shim (s) by 0.05 mm to correct the pattern driven gear shim(s) by 0.05 mm to correct the pattern
shown below. Repeat in 0.05 mm steps if necessary. shown below. Repeat in 0.05 mm steps if necessary.
Drive Gear
Drive Gear
Bottom
~/". '
Toe Top ,---
Bottom
Toe
TOe
Bottom
9 e
Bottom
Driven Gear ~
Driven Gear
.......--"':;
~
Top
Bottom T
\ op Bottom
Heel Heel
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rM
,
A. Circlip
A. Splines
NOTE
Olf the final gear case is full of oil, place the rear axle so
that the correct side of it is up. If the rear axle is
A. Grease Cap B. Splines
upside down or sideways, the oil will be drained out of
the case through the vent hose.
eTighten the axle shaft pipe mounting bolts to the Oil Seal Inspection
specified torque (see Exploded View) . -Inspect the oil seals.
*Replace any if the lips are misshapen, discolored (in~
dicating that the rubber has deterioratedL hardened,
or been otherwise damaged.
A. Splines
A. Bearing Seal
preload and the bevel gear backlash and tooth contact, , ~ "~f
when an y of the parts which influence these items are
replaced (see Final Bevel Gear Adjustment).
o When the pinion gear nut is loosened, even if the ~ ~"
--~'.
propose is not to replace the parts, check and adjust
the bearing preload.
eReplace the pinion gear nut with a new one.
eApply an oil to the threads and seated surface on the A. Ring Gear
pinion gear nut, ·and tighten them to the specified B. Differential Gear Housing
torque (see Exploded View).
eStake the head of the pinion gear nut with a punch, to
secure the pinion gear nut in place after finishing the
bearing preload adjustment.
A. Thrust Washer
eTo remove the ball bearings press-fitted onto the final Final Bevel Gear Adjustment
gear case and case cover, use a press and bearing driver In order to prevent one gear from moving away from
set (special tool: PIN 57001 ·11 29). the other gear under load, the tapered roller bearings
must be properly preloaded. Also the backlash (distance
one gear will move back and forth without moving the
other gear) and tooth contact pattern oJ the bevel gears
must be correct to prevent the gears from making noise
and being damaged.
OBe careful not to scratch the sealing surfaces of the Above three adjustments are of critical importance
final gear case and case cover during the bearing and must be carried out fo ll owing the correct sequence
removal and installation. A scratched sealing surface and method.
may allow oil to leak.
II'
I
~
A. Sealing Surfaces
I Assemble the final gear case completly.
I
When anyone of the backlash-related parts are
replaced or the pinion gear nut is loosened; even jf the
purpose is not to rep1ac.e the parts, check and adjust the
Ring Gear and Differential Gear Assemblv bearing preload and the bevel gear backlash and tooth
eRing gear and differential gear assembly is the reverse contact by replacing shims.
of disassembly. Note the following. The amount of backlash is influenced by the ring
eThe ring gear and pinion gear are lapped together at the gear position more than by the pinion gear position.
factory to get the best tooth contact. They must be Tooth contact location is influenced by pinion gear
replaced as a set. position more than by ring gear position.
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FINAL DRIVE 9·21
Backlash-Related Parts
Shims for Preload Adjustment Ring Gear Shims for Pinion Gear Shims for
Thickness Backlash Adjustment Tooth Contact Adjustment
Part Number Thickness
(mm) Thickness
Part Number Part Number
0 .1 92025-1287 (mm) (mm)
0.15 92025-1656 0.1 92025-1709 0.1 92025-1703
0.2 92025-1288 0.15 92025-1710 0.15 92025-1704
0.3 92025-1289 0.5 92025 -1711 0.5 92025-1705
0.5 92025-1290 0.8 92025-1712 0.8 92025-1706
0.6 92025-1291 1.0* 92025-1713 1.0* 92025 -1707
0.7 92025-1292 1.2 92025-1714 1.2 92025-1708
0.8 92025-1293 (* : Standard) (* : Standard)
0.9 92025-1294
1.0 92025-1295
1.2 92025-1657
1.3 92025-1282
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eApply final gear case oil to the bearings, and turn the
gear shaft more than 5 turns to allow the bearings to
seat.
eMeasure the bearing preload. Bearing preload is
defined as the force or torque which is needed to start
the gear shaft turning.
NOTE
OPreload can be measured either with a spring scale or a A. Spring Scale C. Bevel Gear Holder: 57001-1193
beam-type torque wrench. When measured with a B. Hole D.200mm
spring scale, the preload is designated by force (N, kg),
and when measured with a torque wrench, it is des-
ignated by torque (N·m, kg-m, in-fbi.
Preloading Bearings
"'_---~~~~~ffiI-- No clearance
Initial
Clearance
Under Under
no preload preload
1. Washer
2. Shim(s)
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FINAL DRIVE 9-23
A. Torque Wrench
eTa measure the backlash, move the ring gear back and
forth whil e hold ing the pinion gear steady. The dif·
ference between the highest and the lowest gauge read -
*If the preload is out of the spec ified range, replace th e ing is the amou nt of back lash.
shims under the flat washer. To increase preload, *If the backlash is not w.ithin the limit, rep lace th e ring
decrease th e thickness of the shim(s). To decrease gear shims. To increase backlash, decrease the thickn ess
preload , increase the thickness of the shim(s). of the sh im (s) . To decrease backlash, increase the
CChange th e thickness a littl e at a tim e. thickness of the shim(s) .
eRe-check the bearing preload, and re-adju st as nec- CChan ge the thickness a litt le at a time.
essary. eRe-check the backlash, and re-adjust as necessary.
NOTE
OApply checking compound to the teeth in a thin, even
Backlash adjustment
coat with a fairly stiff paint brush. If painted too
eelean any dirt and o il off the bevel gear teeth.
thickly, the exact tooth pattern may not appear.
e lnstall the pinion gear assembly with the stand ard shim
OThe checking compound must be smooth and firm~
(see th e sh im t ables), and tighten the propeller shaft
with the consistency of tooth paste.
pipe mounting nuts to the specified torque (see
OSpecial compounds are available from automotive
Exploded View) without t he propeller shaft housing.
supply stores for the purpose of checking differential
e lnstall t he ring gear and differential gear housing to the
gear tooth patterns and contact. Use one of these for
final gear case, and put the stan dard shim (see the sh im
checking the bevel gears.
tables) onto the ring gear.
ePut on the final gear case cover and t ighte n the cover
mounting bolts to the specified torque (see Exploded elnstall the shi m(s) and pinIOn gear assem bl y, and
View) . tighten the mounting nuts to th e speci fied torqu e (see
OCheck t he backlash durin g the t ightening of the cover Exp loded View).
mounting bo lts, and stop tighte nin g them imm ediate ly elnstall the ring gear and differential gear housing to t he
if the backlas h disappears. Then, change the ring gear final gear case, and put the shim (s) onto the ring gear.
sh im to a thinner one. ePut o n the fi nal gear case cover and tigh ten the cover
eSet up a dial gauge against a ring gear tooth to check mounting bolts to the specified torque (see Exploded
gear backlash. View).
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Ring Gear
Bottom
Top Heel
Pinion Gear Toe
Bottom
Ring Gear
Bottom
-+-------- :~
Heel
------- I Toe
Pinion Gear
Toe
Bottom
Bottom
Example 2: Increase the thickness of the pinIOn gear
shim(s) by 0.05 mm to correct the pattern shown below.
Repeat in 0.05 mm steps if necessary.
Bottom
Heel
Pinion Gear
~'~
/
Heel
~-Bottom
Top
Bottom
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000 not loosen the shift lever pivot bolt. Loosening the
pivot bolt upsets the position of the special designed
collar under the lever. and could cause malfunctioning
of the lever action.
eUnscrew the shift fork holder screws and pull off the
holder with the gasket. Now, the shift fork can be
Shifter and Shift Fork Removal removed.
eDrain the final gear case oil (see Final Gear Case Oil
Change).
-Support the vehicle with the frame so that the rear
axle are free from loads.
eRemove the following parts.
Differential Shift Fork Lever
Rear Left Wheel
Rear Left Drum and Panel Shifter and Shift Fork Installation
Left Suspension Arm _Shifter and shift fork installation is the reverse of
Left Shock Absorber Lower Mounting Bolt removal. Note the following.
Left Axle Shaft eApply grease to the shift fork shaft .
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FINAL DRIVE 9·27
Cable Lubrication
A. Apply grease.
Brakes
Table of Contents
10-2 BRAKES
........
E····················
.. ~ploded View································
............... .................
......... ............ ........... ..........................
11.:-
2;J ~,.,
$ T4
I @J~
t @~ ~@ ~
@~~~~~ ~
A'A
G : pply adhesive_
S- . Apply grease
I : Apply sili .
T1 : 25 N -m (;one grease.
5
T2: 20 N-m (2. kg-m, 18 ft-Ib)
0
T3: 11 N-m (1. kg-m, 14_5 ft-Ib)
:----;
___' .. Frame No T4: 5 .9 N-m (~~~g-m. 95 in-Ib)
T5: 7 _8 N-m (0_80 kg-m, 52 in~b)
JKALF8A1DG
JKALF8A 1 DG:04250 and up or T6: 145 N-m (150kg-m, 69 in-Ib)
LF300A~04250 09409 and up or
and up
T7: 29 N-m (30 - kg-m, 110 ft-Ib)
. kg-m, 22 ft-Ib)
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BRAKES 10-3
G
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10-4 BRAKES
Specifications
Brakes:
Special Tool
Jack: 57001 ·1238
Along with common hand tools, the following more
speciali zed tools are required for complete brake
servicing.
BRAKES 10-5
Brake Adjustment
~=r@
~ '\ A. Shoe Check Hole B. Lining Thickness
~_J ,
":.. _ _ - _ - _ _ _ 0#
10-6 BRAKES
eApply a brake several times and rotate the wheel to *If the rear brake pedal free play is incorrect and each
check for brake drag. lining wear indicator points within the USABLE
-Repeat the previous step one more time for the other RANGE, adjust the rear brake pedal free play (see
shoe. Rear Brake Pedal Free Play Adj ustme nt).
e()perate the pedal a few times to see that it returns to
its rest position immediately upon release.
eRotate the rear wheels to check for brake drag.
-Check brak ing effectiveness.
*If there is any doubt as to the conditions of the brake,
check the brake parts for wear or damage.
Rear Brake Pedal Free Play Inspection
-Depress the rear brake pedal lightly by hand. This is
the free play.
BRAKES 10-7
eRepeat the above step one more time for the ot her Cam Lever Angle Adjustment
cable. eRemove the bolt and nut, and take off t he cam lever.
eMount the cam lever at a new position so that t he cam
lever has a proper angle when the brake is full y app lied.
NOTE
Olf the rear brake cables cannot be adjusted by using the
adjusters at the rear ends of the cables, use the adjusters
at the equalizer. Do not forget to securely tighten the Cam Lever Angle
adjuster mounting nuts. Standard:
*If does not, adjust t he cam lever angle (see Cam Lever
Angle Adj ustment).
WARNING'
0
OSince a cam lever angle greater than 90 reduces
braking effectiveness. cam lever angle adjustment
should not be neglected.
Brake Fluid
10-8 BRAKES
WARNING I
oNever reuse old brake fluid.
000 not use fluid from a container that has been left un-
sealed or that has been open for a long time.
000 not mix two types and brands of fluid for use
in the brake. This lowers the brake fluid boiling
point and could cause the brake to be ineffective.
It may also cause the rubber brake parts to deteriorate.
ODon't leave the reservoir cap off for any length of time
to avoid moisture contamination of the fluid.
ODon't add or change the fluid in the rain or when a
strong wind is blowing.
Olf any of the brake line fittings or the bleed valve is
opened at any time, the AIR MUST BE BLED FROM
A. Upper Level Line
THE BRAKE.
I WARNING I
sary to keep it from running completely out.
eRepeat the above 2 steps one more time for the other
OChange the fluid in the brake line completely if the side.
fluid must be refilled but the type and brand of the eBleed the air from the lines (continue with Brake Line
fluid that already is in the reservoir are unidentified . Air Bleeding).
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BRAKES 10-9
,..
.
10-10 BRAKES
@.,
,
Master Cylinder Installation
eMaster cylinder installation is the reverse of removal.
Note the following.
eThe master cylinder clamp must be installed with the
UP mark faced upwards.
eTorque the upper clamp bolt first, and then the lower
clamp bolt (see Exploded View). There will be a gap at
the lower part of the clamp after tightening.
.............................................................................
Master Cylinder and Wheel Cylinders
NOTE
ODo not remove the secondary cup from the piston since
removal will damage them.
Master Cylinder
.'"
A. Dust Covers C. Cups
B. Pistons
1. Spring 4. Piston
2. Primary Cup 5. Dust Cover
3. Secondary Cup
Wheel Cylinder Assembly
-Wheel cylinder assembly is the reverse of disassembly.
Master Cylinder Assembly Note the fol lowing.
eMaster cylinder assembly is the reverse of disassembly. -Before assembly, clean all parts including the wheel
Note the following. cylinder with brake fluid or alcohol, and apply brake
eBefore assembly, clean all parts including the master fluid to the removed parts and the inner wall of the
cylinder with brake flu id or alcohol, and apply brake cylinder.
fluid to the removed parts and the inner wall of the
cylinder.
10·12 BRAKES
*If a cup is worn, damaged, softened (rotted), or
swollen, replace the piston assemb ly . Brake Hoses
*If fluid leakage is noted at the brake lever, the piston ••• •••••••••••••••••••••••••• •• • ••••• • •• ••••• •• • • •• ••• ••••• • • •• ••••• ! •• •••• ••
NOTE
OThe cups and spring are pan of the piston assembly.
Replace the piston assembly if anyone of the cups or
the spring requires replacement.
A. Axle Nut
10-14 BRAKES
WARNING I
OBrake linings contain asbestos fiber . Inhalation of
asbestos may cause serious scarring of the lungs and
may promote other internal injury and illness,
including cancer. Observe the following precautions
when handling brake linings:
1. Never blow brake lining dust with compressed air.
2. If any components are to be cleaned, wash them
with detergent, then immediately discard the
cleaning solution and wash your hands.
3. Do not grind any brake lining material unless a
ventilation hood is available and properly used.
*If any measurement is greater than the service limit,
replace the drum. eRemove the brake shoe springs.
*If the drum is worn unevenly or scored, lightly turn the
drum on a brake drum lathe or replace it. Do not turn
the drum beyond the service limit.
NOTE
OHold the brake shoes with a clean cloth to protect the
linings from grease or dirt.
A. Drain Plug
eRemove the banjo bolt to disconnect the lower end of eTighten the following bolts to the specified torque (see
the brake hose from the wheel cylinder. There is an Exploded View).
aluminum washer on each side of the hose fitting. Wheel Cylinder Mounting Bolts
Olmmediately wipe up any brake fiuid that spills. Shoe Adjuster Mounting Bolts
Brake Panel Mounting Bolts
Brake Hose Banjo Bolt
[CAUTlO~] .Lubricate the brake panel parts (see Brake Panel
Lubrication).
OBrake fluid quickly ruins painted surfaces; any spilled
eBleed the brake line (see Brake Line Air bleeding) after
fluid should be completely wiped up immediately.
brake panel installation.
eAdjust the brake shoe to drum clearance (see Brake
Shoe Ad justme nt).
WARNING I
OBrake linings contain asbestos fiber. Inhalation of
asbestos may cause serious scarring of the lungs and
may promote other internal injury and illness,
including cancer. Observe the following precautions
A. Brake Hose Banjo Bolt when handling brake linings:
1. Never blow brake lining dust with compressed air.
2. If any components are to be cleaned, wash them
eRemove the brake panel mounting bolts, and take off with detergent, then immediately discard the cleaning
the brake panel assembly. solution and wash your hands.
3. Do not grind any brake lining material unless a
ventilation hood is available and properly used .
10-16 BRAKES
A. Projected Portion
eAdjust the rear brake pedal free play (see Rear Brake
Pedal Free Play Adjustment).
Brake Camshaft and Camshaft Hole Wear
eMeasure the camshaft diameter.
*If any measurement is less than the service limit,
replace the camshaft.
-For the rear brake panel, apply a high-temperature -Remove the brake pedal and lever.
grease to the following. o Unhook the return spring.
Brake Shoe Anchor o Remove the cotter pin and nu t, and pull off the brake
Spring Ends pedal and lever. Do not lose the O-rings.
Camshaft Groove
Cam Surfaces
A. Adjuster C. Spring
B. Joint
A. Align marks.
Cable Lubrication
Suspension
Table of Contents
Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . 11 ·2
Suspension .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3
Shock Absorber Spring Force Adjustment.. . .. .. .. . . . .. ... . . 11·3
Shock Absorber Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3
Shock Absorber Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11·3
Suspension Arm Removal. . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . 11·3
Suspension Arm Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4
Suspension Arm Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 ·4
Shock Absorber and Suspension Arm Inspection . . . . . • . . . . . . . . 11-4
m
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2 S
,,- USPENSION........ .................. ..................... .
··········d···~·~i·~-;;·····
Explo e
....................... .... ................ .
...............................
' Q,
@ > T1
T1
~@:i
G : Apply grease. ~~
Tl : 34 N-m (3.5 kg-m, 65 ft-Ib)
25 ft-Ib)
Spring Action
Spring
Position Setting Load Terrain Speed Shock Absorber Removal
Force
esupport the veh icle on a stand so that the front and/or
1 Stronger Soft Light Good Low
rear wheels are off the ground.
2 (sTD)
11111
-Remove the upper and lower shock absorber mounting
3 bolts and/or nuts.
4 eHolding the wheels, pull out the mounting bolts and
then shock absorbers.
5 Hard Heavy Bad High
o Remove the rear wheels (see Wheel Removal in the
Wheels/Tires chapter) to remove the lower mounting
bolts of the rear shock absorbers easy.
A. Adjusting Sleeve
114 SUSPENSION
eTa remove the rear suspension arms, first remove the Suspension Arm Installation
final gear case guard. _Suspension arm installation is the reverse of removal.
eRemove the suspension arm pivot bolts and take the Note the following.
suspension arms off the frame. eLubricate the suspension arm pivots of the front upper
and center arms (see Suspension Arm Lubrication).
_Tighten the suspension arm pivot bolts and shock
absprber lower mounting bolts to the specified torque
(see Exploded View).
Steering
Table of Contents
12-2 STEERING
A : Apply adhesive.
G : Apply grease.
Lh: Left-Hand Threads
T1 : 20
T2' 29 N-m
N (2('0 k g·m, 14.5 ft-Ib)
. -m 3.0 kg-m 22
T3:41 N- m (42 kg-m,,ft-Ib)
30 ft-Ib)
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STEERING 12-3
Steering
Handlebar Removal
-Remove the fuel tank (see Fuel Tan k Removal in the
Fuel System chapte r).
-Remove the fol lowing parts from the handlebar.
LH Switch Housing
Throttle Case
Front Brake Master Cylinder
-Remove the stem head cover screws and ignition
switch ring nut, .and take off the cover.
eTighten the holder rear bolts first and then the front
bolts. When the holder is correctly instal!ed, there will
be even gap at the front and no gap at t he rear after
tighten ing.
A. Plug
_Slide a thin drift between the grip and the hand lebar.
A. Handlebar Holders
Handlebar Installation
eHandlebar installation is the reverse of removal. Note
the following.
-I nstall the handlebar so that the angle of the handlebar
matches the angle of the steering stem as shown. A. Drift
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12-4 STEERING
eApply a small amount of Kawasaki Electric Contact
Cleaner or equivalent into the opening next to the drift.
ePull the drift out and quickly slide the grip off the
handlebar. Twist the grip as you pull.
eRemove the cotter pin and remove the tie-rod end nut
from each tie-rod at the steer ing stem.
000 not loose the locknuts at both end of the tie-rod A. Steering Stem Bearing
adjusting sleeve, or the toe-in of the front wheels will
be changed.
STEERING 12-5
[~AUTlO~J
000 not loosen the locknut of the steering knuckle
stopper bolt, or the bolt will turn and the steering
knuckle stopper adjustment may be necessary.
A. Ribs B. Grooves
A. Clean.
elnstall the suitable nut on the tie·rod end and tap the
nut to remove the tie-rod. eThe left and right tie-rods must be installed as shown.
The tie-rod painted yellow is for the left tie-rod.
12-6 STEERING
NOTE
OThe cables and wires will have some effect on the
steering action which must be taken into account.
Steering Lubrication
eLubricate the steering stem clamp.
o Remove the steering stem.
oWipe all the old grease out of the steering stem, grease
seals, and clamps.
o ,A_pply grease to the steering stem and pack the grease
seal grooves between the lips with grease.
A. Grease Seals
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FRAME 13-1
Frame
Table of Contents
m
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E~~;~d~·~·i·~~ ............:::::::::::::............................
....................................
.t>
. @ '~
,~~ / ' ~
...
Frame No.
JKALF8A1DG 8512289 and up '" r~~~~f
~r~~
'-
"""
/'
'-
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FRAME 13-3
II
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13-4 FRAME
A. Pull.
eLift the rear o f the seat, slide it toward the rear A. Mounting Bolts
sl ightly, and lift it off the vehicle.
A.Hook B. Brace
OUnscrew the fuel tank cap, remove the mounting bolts
and flanged collars, and take off the upper cover.
eRemove the front fe nder side covers .
• Push the rear of the seat down so that the seat locks on o Remove the mounting screws and nuts, and take off
the bottom of the rear of the seat lock on the catches. the side covers.
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FRAME 13-5
A. Mounting Bolts
B. Remove these screws (both left and right sides).
A. Mounting Bolts
eTa remove the mud flaps, take out the screws and nuts.
e To remove the mud flaps, take out the screws and nuts.
13-6 FRAME
Decal Application
Frame Exchange
eelean the surface where the decal is to be applied with
acetone or paint thinner.
Decals
Decal Removal
.Heat the decal gently with a heat gun, heat lamp, or
hair drier.
A. Peel slowly .
Electrical System
Table of Contents
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . 14·2 Part Removal . . . . . . . . .. .••.... 14-19
KLF300·A1, A2 Wiring Diagram ... . .. . .... 14·3 Starter Motor Removal ... . . . . . . . . . 14-19
Exploded View . . . . . . . ... . . . . . . • . . . . . . 14·4 Starter Motor Installation . .... . ... . . 14·19
Specifications .. . . . . . . . . . . . . . . . . . . . ... 14~6 Starter Motor Disassembly . . . . . . . . .. 14·19
Special Tools .... •... . . . . . . . . . , • •.... 14-6 Starter Motor Assembly . . . . . . . . . . . . 14-20
Battery ..... ... . . . . . . . . . . . . . . , ..... 14·7 Starter Button Removal ... .. . . . . . . . 14·22
Precautions . . . . . . . . . . . . . . . . . . . . .. 14-7 Starter Button Installation .... . .... . 14-22
Battery Removal /Insta llation . . . . . . . . . . 14-7 Starter System Checkout . . . . . . . . . . . . . 14-22
Battery Removal . . . . . . . . . . . .. ... 14-7 Starter Motor Brush Length . . . . . . . . . 14-22
Battery Installation . . . . . . . . . . . . . . . 14-8 Starter Motor Brush Spring Tension . . . . 14-22
Electrolyte . . . . . . . . . . . . . . . . . . . . . . 14·8 Starter Motor
Electrolyte Level Inspection .. _ . .. ... 14-8 Commutator Inspection . . . . . . . . . . 14·22
Battery Charging . . . . . . . . . . . .•..... 14-8 Starter Motor Armature Inspection .... 14-23
Battery Condition .. ... . .... . . . . . . 14·8 Brush Assembly Inspection . . . . . . . . . . 14-23
Battery Initial Charging . . . . . . • . . . . . 14-9 Starter Relay Inspection . . . . . . . . . . . 14-24
Battery Ordinary Charging ....•. . ... 14-9 Starter Circuit Relay Inspection . . . . . . 14-24
Battery Test Charging . . . . . . . . • .... 14-10 Starter Button Inspection . . . . . . . . . . . 14-25
Chargi ng System . . . . . . . . . . . . . . . • . . . . . 14-11 Lighting System . . . . . . . . . . . . . . . . . . . . . 14-25
Part Removal , . . . . . . . . . . . . . . . . . . . . 14·11 Headlight Beam
Alternator Rotor Removal . . . . . . . . .. 14-11 Headlight Beam Vertical Adjustment .... 14-25
Alternator Rotor Installation . .. .. ... . 14-11 Bulb Replacement. . . . . . . . . . . . . . . . . . 14-25
Alternator Stator Removal . . . . . . . . .. 14·11 Headlight Bulb Replacement .... . .... 14-25
Alternator Stator Installation ... . .... 14-11 Taillight Bulb Replacement . .. . . .... 14-26
Charging System Checkout . . . . . . . . . . . . 14-11 Neutral and Reverse Indicator
Charging System Light Bulb Replacement . . . . . . . . . . . 14-26
Operational Inspection .... . . ... . 14-11 Part Removal . . . . . . . . . . . . . . . .. .... 14-26
Stator Coil Resistance . . . . . . . . . ... . 14·12 Light Switch Removal . . . . . . . . • . . . . 14-26
Rectifier Circuit Inspection . . . . . . . . . 14·12 Light Switch Installation . . . . . . ..... 14-27
Regulator Circuit Inspection . .... . . . . 14·12 Neutral and Reverse
Ignition System . . . . . . . . . . . . . . . . . . . . . 14-14 Switch Removal . . . . . . . . . . . . . . . 14-27
Safety Instruction s . . . . . . . . . . . . . . . . . 14·14 Neutral and Reverse
Part Removal . . . . . . . . . . . . . . . . . . . . . 14-14 Switch Installation . . . . . . . . . . . . . 14-27
Engine Stop Switch Removal . . . . . . . . 14-14 Lighting System Checkout . . . . . . . . . . . . 14-27
Engine Stop Switch Installation . . . . . . . 14·14 Light Switch Inspection . . . . . . • . . . . . 14-27
Ign ition Coil Removal . . . . . . .. .... . 14·14 Neutral and Reverse
Ignition Coil Installation . . . . . . . ... . 14·15 Switch Inspection. '" . . . . . . . . 14·27
Spark Plug Removal . . . . . • . . . .' .... 14-15 Ignition Switch . . . . . . . . . . . . . . . .•. .. . 14-28
Spark Plug Installation .... • ... . .... 14-15 Ignition Switch Removal . . . . . • . . . . . 14-28
Pickup Coil Removal . . . . . . . . . . . . . . 14-15 Ignition Switch Installation . . . . . .... 14·28
Pickup Coil Installation . . . • . . . . . . . . 14-15 Ignition Switch Inspection .. .. . . . . . . 14·28
Ignition System Checkout . . . . . . . . . . . . 14-15 Electrical Wiring . . . . . . .. . . . . . . . . . . . . . 14-28
Ignition Timing Test . . . . . . . . . . . . . . 14·15 Wiring Inspection . . . . . ... .. . . ... . 14-28
Engine Stop Switch Inspection . . . . . . . 14·16
Ignition Coil Inspection . . . . . . . . . . . . 14-16
Spark Plug Cleaning and Inspection .... 14-17
Spark Plug Gap . . . . . . . . . . . . . . . . . 14-17
IC Ignitor Inspection . . . . . . . . . . . . . . 14-17
Pickup Coil Inspection . . . . . . . . . . . . . 14·18
Alternator Rotor Inspection . . . . . . . . . 14·18
Electric Starter System . . . . . . . . . . . . . . . . 14·19
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OColor Codes:
Precautions
BK Black
BL Blue
There are a numb er of im portant precautions that are BR Brown
mu sts when servicing electrical systems. Learn and CH Chocolate
o bserve all the ru les below. DG Dar k green
0 00 not reverse th e battery lead connections. This G Green
will burn out the diodes in the electrical parts. GY Gray
OAlways check battery cond ition before condemning LB Light blue
other parts of an electrical system. A fully charged LG Light green
battery is a mu st for conducting accurate elec trical 0 Orange
system tests. P Pink
oThe electrical parts should neve r be struck sharply, as PU Purple
with a hamm er, or allowed to fall on a hard surface. R Red
Such a shock to the parts can damage them. W White
oTo prevent damage to electrical parts, do not dis- Y Yellow
connect the battery leads or any other electrical OMeasure coil an d wind in g resistance when the part is
connections when th e ignition switch is on, or the cold (at room temperature).
engine is running.
o Becau se of the large amount of current, never keep
the starter sw itch pushed when the starter motor
will not turn over, or the curre nt may burn out the
starter motor wi ndin gs.
0 00 not use a indicator bulb rated for other than voltage
or watt age spec ified in the wiring diagram , as the
indicator panel could be warped by excessive heat
radiated from the bulb.
oTake care not to short the leads that are directly
connected to the battery positive (+) terminal to the
chassis grou nd.
oTroubl es may involve o ne or in some cases all items.
Never replace a defective part without determining
what CAUSED t he failure. If the fa ilure was brough
on by some other item or items, they too must be
repaired or replaced, or the new replacement will
soon fail agai n.
o Make sure all connectors in the circuit are clean and
tight, and exam ine wi res fo r signs of burning, frayi ng,
etc. Poor wi res and bad connections will affect elec-
trical system operation.
o Electrical Connectors
Female Connectors
Male Connectors
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ELECTRICAL SYSTEM 14-3
·····················A2··w;;i~~·D;~~;;;;;;····::::::::::::::::::::
KLF300·A1,
....................................................... .
I
j
II
,.11
- -<>C>--
to ' - ----
II rt= :, - --- 1 ,.'
!
,•
! '
, !
!!
.
~ "'.~ :----"l ~ ~"'
-~fE~~~", "
I
~
,J! " . .. : .'
l
V. HB
~ 1- " -
','
II 5.
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14-4 ELECTRICAL
....... SYSTEM
...................'.~~
Expl~~~'\i:'''''''''''''''''''''''' ............................... .
.......... ........... .......... .......... ..........
~~
/ /iDOl
, i}
~~
t':
c:o ~
U~ ~
\) \J
. 59pplya
L :'A
T1 N.m non ·permanent lockin
T2' 2 (6.0 kg·m 43 ft 9 agent.
. 7 N.m (2 ' -Ib)
.8 kg-m , 20 ft -Ib)
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ELECTRICAL SYSTEM 14-5
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Specifications
NOTE
oThe flywheel holder (57001-13131 can be used instead
of the flywheel holder (57001-30B).
oThe rotor puller (57001-1216) can be used instead of
the rotor puller (57001-1099).
Battery
Precautions:
Coil Tester: 57001-1242 Following a few simple rules will greatly extend the
life of the battery.
oWhen the level of the electrolyte in the battery is low,
add only distilled water to each cell, until the level is
at the upper level line marked on the outside of the
battery. Ordinary tap water is not a substitute for
distilled water and will shorten the life of the battery.
ONever add sulphuric acid solution to the battery. This
will make the electrolyte solution too strong and will
ruin the battery within a very short time.
OAvoid quick-charging the battery. A quick-charge will
damage the battery plates.
ONever let a good battery stand for more than 30 days
without giving it a supplemental charge, and never let
a discharged battery stand without charging it. If a
battery stands for any length of time, it slowly self-
discharges. Once it is discharged, the plates sUlphate
(turn white), and the battery will no longer take a
charge.
OKeep the battery well-charged during cold weather so
that the electrolyte does not freeze and crack open the
battery. The more discharged the battery becomes, the
more easily it freezes.
OAlways keep the battery vent hose free of obstruction,
Hand Tester: 57001-983 and make sure it does not get pinched, crimped, or
melted shut by contact with the hot muffler. If
battery gases cannot escape through this hose, they will
explode the battery.
ODON'T INSTALL THE BATTERY BACKWARDS.
The negative side is grounded.
Hydrometer
Battery Installation
eBattery installation is the reverse of removal. Note the
following.
-Connect the positive (+) cable first and then the
negative cable.
eRoute the battery vent hose observing the label for the
hose routing.
Electrolyte: -Look for sediment and white sulfation inside the cells
Electrolyte Level Inspection on the bottom of the plates.
eVisually check the electrolyte level in the battery.
- ... .., - ~ ~
~
.
'" rJ
y
• ®
A. Sulfation here B. Sediment here
A. Level Lines
!CAUTlO~]
Olf the rotor is difficult to remove and a hammer is A. Alternator Stator Mounting Screws
used to tap the rotor puller. be careful not to strike the B. Pickup Coil
rotor itself. Striking the rotor can cause the magnets to C. Wiring Holder
lose their magnetism.
NOTE
OAlways check battery condition before condemning
other pans of the charging system. The battery must
be fully charged in order to conduct accurate charging
A. Key B. Groove C. Clean. system tests.
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A. Regulator/Rectifier
NOTE
Stator Coil Resistance oThe actual meter reading varies with the meter used
0.2 -0.8 Q and the individual rectifier, but, generally speaking the
lower reading should be from zero to the one - second
of the scale.
Regulator/Rectifier Terminal
+
Regulator Circuit Inspection
eRemove the regulator/ rectifier. 12 V Battery
ePrepare the test tools shown.
Tools for Regulator Circuit Test *If the test light turns on, the regulator/rectifier is
Test light -+ Bulb rated 12 V and 3 - 6 W defective. Replace it.
Batteries Two 12 V batteries *If the test light does not turn on, continue the test.
Test wires S auxiliary wires eMomentarily apply 24 V to the voltage monitoring
terminal by add ing a 12 V battery.
e<:heck A 1, A2, and A3 term inals respectively.
e<:onnect the test light and the 12 V battery to the
regulator/ rectifier as shown.
e<:heck A 1, A2, and A3 terminals respectively .
Regulator Circuit Test-1st Step 000 not apply more than 24 V to the regulator/rectifier
and do not leave the 24 V applied for more than a few
seconds, or the unit will be damaged.
Regulator/ Rectifier
Regulator Circuit Test-3rd Step
12 V Battery
,...--, ,...--,
8
+ =Al
ICAUTlO~ I +
oThe test light limits the current flow through the
regulator/rectifier. Do not use an ammeter or
multimeter in its place. 12 V Battery
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Ignition System
I WARNING.
eRe move the wIring clamp screw and starter button
OThe ignition system produces extremely high voltage. holder screw, and pull the switch free of the case.
Do not touch the spark plug, high tension coil. or spark
plug lead while the engine is running, or you could
receive a severe electrical shock.
Engine Stop Switch Installation
-Clean any corrosion or dirt off the contacts.
Part Removal:
Engine Stop Switch Removal
The engine stop switch is inside the LH switch
housing. The switch and its component parts are not
ava ilable separately. However, the switch may be
removed for cleaning. Be very careful not to lose any
parts or the entire LH switch housing will have to be A. Clean.
replaced.
eTake out the screws that clamp the LH switch housing
to the handlebar. ePush the switch part, down into the case.
elnstall the wiring clamp and starter button holder.
ePut the switch lever in place and fasten it with a screw
and washer.
eAssemble the LH switch housing on the handlebar and
tighten the screws securely.
A. Ignition Coil
Ignition Timing
Engine speed -Connect the ignition coil (with the spark plug cap left
Slot aligned with:
rlmin (rpm) installed at the end of the spark plug lead) to the tester
2,100 and below F mark on flywheel in the manner prescribed by the manufacturer and
measure the arcing distance.
4,200 and above Advanced marks on flywheel
Ignition Coil Arcing Distance
I WARNING'
OTo avoid extremely high voltage shocks, do not touch
the ignition coil body or leads.
IYI
Y/ R BR trouble is with the ignition coil itself. If the arcing dis-
tance is now normal, the trouble is with the spark plug
cap.
NOTE
OSince a tester other than the Kawasaki coil tester may Ignition Coil Winding Resistance
produce a different arcing distance, the Kawasaki coil Primary Windings: 1.8 - 2.8 n
tester is recommended for reliable results. Secondary Windings: 10 - 16 kn
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CD @
o (:)
Q) 0
*If the meter does not read as specified, replace the coil.
*If the meter reads as specified, the ignition coil
~~~~~~ 0.7 - 0.8 mm
windings are probably good. However, if the ignition
system still does not perform as it should after all other
1. Terminal 4 . Gasket
components have been checked, test replace the coil
2. Insulator 5. Center Electrode
with one known to be good.
3. Cement 6. Side Electrode
-Check the spark plug lead for visible damage.
*If the spark plug lead is damaged, replace t he co il.
IC Ignitor Inspection
-Set the multimeter to the x 1 kn range and make the
measurements shown in the table.
Spark Plug Cleaning and Inspection *If the meter readings do not correspond to the table,
-Clean the spark plug, preferably in a sandblasting replace the IC ignitor.
device, and then clean off any abrasive particles. The
plug may also be cleaned using a high flash-point NOTE
solvent and a wire brush or other suitable tool. If the
spark plug electrodes are corroded or damaged, or if OSince a tester other than the hand tester of Kawasaki
the insulator is cracked, replace the plug. Use the may show different readings, the hand tester of
standard spark plug or its eq uival ent. Kawasaki is recommended for reliable results.
"'"
...J Ig. Coil ----------
=kn =kn =kn =kn
A 1.8 - 2.6 kn
1 Ground A --------
D E on
B 200 - 1 ,000 kn
s
~
------- C 3-4.2kn
"
f-
~ PC (+)
PC (-) A
B B
D on
B
------
E
B
-------
D
E
2.3 - 3.2 kQ
80 - 150 kQ
Ie Ignitor Terminals
Pickup Coil Resistance
390 -590 Q
I-U---Ground
NOTE
o The protruding side of the sprocket must face in.
elf only the brushes are to be removed, pull off only the
right end cover.
-Grasp the brush springs with needle nose pliers, and
pull them off the brush plate.
eRaise the brush plate to allow the brushes to clear the
A. Crankcase Surface B.O·ring end of the commutator.
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A. Terminal Bolt
A. Grease .
eBe sure the large O-ring is in place, and push the left
end cover into the starter yoke so that the notch on the
'nternal gear aligns with the key in the yoke.
ePush the negative brushes into the holders immediate ly
clockwise from where the brush leads are mounted to A. Step
the brush plate.
-Drop the thrust washers over the end of the armature
shaft.
el nstall the right end cover so that the long vertical tab
on. the brush plate aligns with the key slot in the cover.
eHold the brush plate over the end of the starter and
push the positive brush leads through the slots in the A. Tab C. Thrust Washers
brush plate. B. Key Slot
ePush the brush plate into place with the tab in the
OAs a furt her check, these marks shou ld al ign on the
notch as shown.
outs ide of the starter.
*ff the brushes are shorter than the service limit, replace
them.
A. Brush Spring
Starter Button Installation
_Starter button install ation is the reverse of removal.
Starter Motor Brush Spring Tension
680 - 920 9
*If the res istance is greater than 0 Q, rep lace the Starter Circuit Relay Inspection
negative brush assembly. -Remove the starter circuit re lay that is mounted on the
eMeasure the res istance between the pos itive brush rear of the battery case.
holders and the plate.
o Use a mu lt im eter set to the x 1 kn range .
*If the res istance is less than inf inite, replace the
negative brush assem bly.
Starter Button Inspection eSlide back the dust cover and remove the bulb holder
eDisconnect the connectors from the LH switch housing. and bulb from the headlight unit.
eTurn the engine stop switch to the RUN position. oTurn the holder counterclockwise and pull it out.
-Using an ohmmeter, c heck to see that the connections
shown in the table continuity (about zero ohms).
*If the starter button has an open or short, disassemble
it and clean it (see Starter Button Removal). Test it
again. If it stil l does not wo rk, replace the LH switch
housing.
Starter Button Connections
I~I
BK VIR
1-
.............................................................................
Lighting System
............................................................................. eSe sure the socket is clean .
Headlight Beam: elnsert the new bulb by aligning the tangs with the
catches in the headlight unit.
Headlight Beam Vertical Adjustment
.Push the holder in, turn it clockwise, and release it. It
eLoosen the headlight mounting knobs and move the
should lock in position.
headlight up or down to adjust the headlight vertically. eSlide back the dust cover completely as shown in the
label behind the unit. The c'TOP" mark on the cover
must point up.
A. Mounting Bolts
A. Socket
Part Removal:
Light Switch Removal
The light switch is inside the LH switch housing. The
switch and its component parts are not available
separate ly. However, the switch may be removed for
cleaning. Be very careful not to lose any parts or the
A. Triangular Mark entire LH switch housing will have to be replaced.
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ELECTRICAL SYSTEM 14-27
eTake out the screws which clamp the LH switch Neutral and Reverse Switch Removal
housing to the handlebar. eRemove the front gear case (see Front Gear Case
Removal in the Final Drive chapter).
eDisconnect the neutral and reverse switch connector.
eRemove the screws an d take off the switch.
A. Screws
A. Neutral and Reverse Switch
I~I
BR R
eTake out the switch mount ing screw, and remove the
switch.
eSpray the swi tch contacts with contact cleaner while
snapping the switch on and off.
o Reassemble the switch in the reverse order of
disassembl y.
Neutral and Reverse Switch Inspection
eDisconnect the connector from the neutral and reverse
switch.
eUsing a ohmmeter, check to see that the connections
shown in the table have continuity (about zero ohms).
Light Switch Installation *If the switch wi ll not close, it may be removed for
eLight switch installation is the reverse of removal. Be cleaning (see Neutral and Reserve Switch Removal), or
su re to put a ll the wire clamps in. the entire switch may be replaced.
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A. Pin B. Spring
.............................................................................
Electrical Wiring
I gnition Switch .............................................................................
Wiring Inspection
Ignition Switch Removal eVisually inspect the wiring for signs of burning, fraying, .
-Remove the steering stem head cover screws and etc.
ignition switch ring nut, and take off the cover. *If any wiring is poor, replace the damaged wiring.
.Pull the rubber damper off the ignition switch, and -Pu ll eac h connector apart and inspect it for corrosion,
drop the switch out the bottom of the bracket. dirt, and damage.
*If the connec tor is corroded or dirty, clean it carefully.
If it is damaged, replace it.
-Check the wiring for continuity.
oU,e the wiring diagram to find t he ends of the lead
which is suspected of being a problem.
OC:o nnect an ohmmeter between the ends of the lead s.
OSet t he meter to the x 1 n range, and read the meter.
*If the meter does not read 0 n, the lead is defective.
Replace the lead or the wiring loom if necessary.
Appendix
Table of Contents
15-2 APPENDIX
No valve clearance
Troubleshooting Guide Cylinder, piston worn
Piston rings bad (worn, weak, broken, or sticking)
Piston ring/land clearance excessive
NOTE Cylinder head gasket damaged
OThis is not an exhaustive list, giving every possible Cylinder head warped
cause for each problem listed. It is meant simply as a Valve spring broken or weak
rough guide to assist the troubleshooting for some of Valve not seating properly (valve bent, worn, or
the more common difficulties. carbon accumulation on the seati ng surface)
15-4 APPENDIX
Brakes:
General Lubrication Ma,ter Cy lin der Clamp Allen Bolts
Brake Lever Pivot Screw Nut
Brake Pedal Nut and Cotter Pin
Lubrication Brake Cable Equalizer Cotter Pins
eBefore lubricating each part, clean off any rusty spots Steeing/Suspension:
with rust remover and wipe off any grease, oil, dirt, or Handlebar Clamp Bolt,
grime. Stem Nut and Cotter Pin
eLubricate the points listed below with indicated Stem Clamp Allen Bolt,
lubricant. Stem Bearing Hou,ing Bolt,
Tie·rod End Nut' and Cotter Pins
NOTE Tie·rod Adjusting Sleeve Locknut,
OWhenever the vehicle has been operated under wet or Shock Ab,orber Mounting Bolt, and Nut,
rainy conditions, or especially after using a high- Suspension Arm Pivot Bolts and Nuts
pressure spray water, perform the general lubrication. Steering Knuckle Pivot Nuts and Cotter Pins
Engine:
Engine Mounting Bolts
Engine Mounting Bracket Bolt,
Cables: Lubricate with Motor Oil Exhau,t Pipe Holder Nuts
Muffler Mounting Bolt,
Brake Cable,
Muffler Clamp Bolt
Throttle Cable
Shift Pedal Bolt
Choke Cable
Others:
Reverse Cab Ie
Footpeg Mounting Bolt,
Differential Shift Cable
Grab Rail Mounting Bolt,
Throttle Ca,e Clamp Screw,
Carrier Mounting Bolts
Slide Points: Lubricate with Grease
Brake Cable End,
Throttle Cable End,
Reverse Cable Lower End
Differential Shift Cable End,
Brake Lever
Brake Pedal Pivot Shaft
Throttle Lever Shaft
Tightness Inspection
-Check the tightness of the bolt' and nut, li,ted here.
Also, check to see that each cotter pin is in place and in
good condition.
*If there are loose fasteners, retorque them to the
,pecified torque following the 'pecified tightening
sequence. Refer to the appropriate chapter for torque
specifications. If torque specifications are not Iisted in
the appropriate chapter, see the basic torque table (see
Torque and Locking Agent in the General Information
chapter). For each fastener, first loosen it by ySturn,
then t ighten it.
*If cotter pins are damaged, replace them with new ones.
15-6 APPENDIX
..... ........... ..... ......................... .......................... .....
Units of Length:
Unit Conversion Table
km x 0 _6214 mile
m x 3.281 ft
Prefixes for Units:
mm x 0.03937 in
Prefix Symbol Power
mega M x 1,000,000
kilo k x 1,000
Units of Torque:
eenti e x 0_01
milli m x 0_001 N-m x 0.1020 kg-m
micro J1 x 0_000001 N-m x 0.7376 = ft-Ib
N-m x 8.851 in- Ib
kg-m x 9.807 N-m
kg-m x 7.233 ft-Ib
Units of Mass: kg-m x 86.80 in-Ib
kg x 2_205 Ib
g x 0_03527 oz
Units of Pressure:
kPa x 0.01020 kg/em'
Units of Volume: kPa x 0.1450 psi
L x 0.2642 gal (US) kPa x 0.7501 em Hg
L x 0.2200 = gal (imp) kg/em ' x 98.07 kPa
L x 1.057 qt (US) kg/em ' x 14.22 = psi
L x 0.8799 qt (imp) em Hg x 1.333 = kPa
L x 2.113 pint (US)
L x 1.816 pint (imp)
mL x 0.03381 oz (US)
mL x 0.02816 oz (imp) Units of Speed :
mL x 0.06102 cu in km/h x 0.6214 = mph
Units of Temperature:
OF ·4
OF
32 6B 104 176 212 246 2B 4
·40 -20 :0 20 : 40 60
, 60 120 140 160 : 180 200 240 i, 260 280: 300
:I ,I
100:
,: 220 320
I
I I
I I I
I I, I
I'
I !I I Ii 'I
I I I, I I
I I, I I I, i; I
I I
·40 -2 0 : 0 : 20 40 60 BO : 100 : 120 : 140 160
-17 . 8 4.4 26.7 48.9 71.1 93.3 116 136
°c °c
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General Information
Fuel System
Engine Top End
Engine Left Side 41
Engine Right Side 51
~E=n~g=i=n=e=R=e=m==o=v=al=/l=n=s=ta=I=la=t=io=n=======611
~E=n=g=i=n=e=B=o=tt=o=m=E=n=d=lT=r=a=n=s=m=i=s=s=io=n==7I
~W=h=e=e=ls=lT==ir=es==================81
~F=in=a=I=D=r=iv=e===================9.
Brakes 10.
Suspension . 11.
Steering 12.
Frame 13.
Electrical System 14 •
I Appendix 15 •
Supplement - 1989 - 1997 Models 16 •
KLF 300
KaYlasaki BAYOU 300
LIST OF ABBREVIATIONS
A ampere(s) Ib pound(s)
ABDC after bottom dead center m meter(s)
AC alternating current min minute(s)
ATDC after top dead center N newton(s)
BBDC before bottom dead center Pa pascal (s)
BDC bottom dead center PS horsepower
BTDC before top dead center psi pound(s) per square inch
°C degree(s) Celsius r revolution
DC direct current rpm revolution(s) per minute
F farad(s) TDC top dead center
of degree(s) Fahrenheit TIR total indicator reading
ft foot, feet V volt(s)
g gram(s) W watt(s)
h hour(s) n ohm(s)
L liter(s)
US Model only
~~~~~~~~~~~~~~~~~~~~~~~~~$~~
~ ~
m PLEASE DO NOT TAMPER WITH NOISE CONTROL SYSTEM ~
~
W. To minimize the noise emissions from this product, Kawasaki has equipped it with
~
~
~ effective intake and exhaust silencing systems. They are designed to give optimum per- .....
~ formance while maintaining a low noise level. Please do not remove these systems, or alter ~
~ them in any which results in an increase in noise level. . ~
~~~~~~~~~~~~~~~~~~~~~~~~~~~~
Foreword
This service manual supplement contains • Remember to keep complete records of main-
only the information unique to the models cov- tenance and repair with dates and any new
ered. It must be used with the base service parts installed.
manual listed below. Read both this sup-
plement and the base manual for complete How to Use This Manual
information on proper service procedures for
the models covered by this manual. In this manual , the product is divided into
its major systems and these systems make up
Base Manual Part Number the manual's chapters. The Quick Reference
KLF300 Service Manual 99924-1057 -02 Guide shows you all of the product's system
This manual is designed primarily for use by and assists in locating their chapters. Each
trained mechanics in a properly equipped shop. chapter in turn has its own comprehensive Ta-
However, it contains enough detail and basic in- ble of Contents.
formation to make it useful to the owner who de- For example, if you want ignition coil informa-
sires to perform his own basic maintenance and tion, use the Quick Reference Guide to locate
repair work. A basic knowledge of mechanics, the Electrical System chapter. Then, use the
the proper use of tools, and workshop proce- Table of Contents on the first page of the chap-
dures must be understood in order to carry out ter to find the Ignition Coil section.
maintenance and repair satisfactorily. When- Whenever you see these WARNING and
ever the owner has insufficient experience or CAUTION symbols, heed their instructions!
doubts his ability to do the work, all adjust- Always follow safe operating and maintenance
ments, maintenance, and repair should be car- practices.
ried out only by qualified mechanics. A WARNING
In order to perform the work efficiently and
This warning symbol identifies special
to avoid costly mistakes, read the text, thor-
instructions or procedures which, if not
oughly familiarize yourself with the procedures
correctly followed, could result in per-
before starting work, and then do the work care-
sonal injury, or loss of life.
fully in a clean area. Whenever special tools or
equipment are specified, do not use makeshift
tools or equipment. Precision measurements CAUTION
can only be made if the proper instruments are This caution symbol identifies special
used , and the use of substitute tools may ad- instructions or procedures which, if not
versely affect safe operation. strictly observed, could result in dam-
For the duration of the warranty period, age to or destruction of equipment.
we recommend that all repairs and scheduled
maintenance be performed in accordance with This manual contains four more symbols (in
this service manual. Any owner maintenance or addition to WARNING and CAUTION) which will
repair procedure not performed in accordance help you distinguish different types of informa-
with this manual may void the warranty. tion.
To get the longest life out of your vehicle:
NOTE
• Follow the Periodic Maintenance Chart in the
Service Manual.
o This note symbol indicates points of par-
ticular interest for more efficient and con-
• Be alert for problems and non-scheduled
venient operation.
maintenance.
• Use proper tools and genuine Kawasaki Vehi- • Indicates a procedural step or work to be
cle parts. Special tools, gauges, and testers done.
that are necessary when servicing Kawasaki Olnd icates a procedural sub-step or how to do
vehicles are introduced by the Service Man- the work of the procedural step it follows. It
ual. Genuine parts provided as spare parts also precedes the text of a NOTE.
are listed in the Parts Catalog.
• Follow the procedures in this manual care-
fully. Don't take shortcuts.
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* Indicates a conditional step or what action to of the system components follows the Table of
take based on the results of the test or inspec- Contents. In these illustrations you will find the
tion in the procedural step or sub-step it fol- instructions indicating which parts require spec-
lows. ified tightening torque, oil, grease or a locking
In most chapters an exploded view illustration agent during assembly.
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GENERAL INFORMATION 1-1
General Information
Table of Contents
* : Base Manual
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Model Identification
.............................................................................
14 GENERAL INFORMATION
General Specifications
Item KLF300-Bl
Drive Train:
Primary reduction system: Type Gear
Reduction ratio 2.888 (78/27)
Clutch type: Primary Auto centrifugal, wet
Secondary Auto multi disc, wet
Transmission: Type 5-speed plus reverse, constant mesh, return shift
Gear ratio: 1st 3.090 (34/11)
2nd 1.928 (27/14)
3rd 1.368 (26/19)
4th 1.000 (23/23)
5th 0.769 (20/26)
Reverse 3.072 (26/11 x 26/20)
Final drive system : Type Shaft
Reduction ratio 4.886 (20/16 x 43/11), ®® 5.584 (20/14 x 43/11)
Overall drive ratio 10.858, ®® 12.409 @Topgear
Final gear case oil : Type API G L-5 Hypoid gear oil SAE 90 (above 5·C, 41· F) or
SAE 80 (below 5·C, 41· F)
Capacity 0.3 L
Frame:
Type Double tubular
Caster (rake angle) 3.0·
Chamber 1.0·@1G
Trail 13 mm
Tread Front 834mm
Rear 844mm
Front tire: Type Tubeless
Size 22 x 9.00-10
Rear tire : Type Tubeless
Size 24 x 11.00-10
Suspension: Front Type Double wishbone-link
Wheel travel 125 mm
Rear Type Torque tube-link
Wheel travel 120mm
Brake type: Front Disc (Hydraulic)
Rear Drum (Mechanical)
Electrical Equipment:
Battery 12 V 14 Ah
Headlight: Type Semi-sealed beam
Bulb 12 V 65/60 W, ® Option
Taillight 12V8Wx2, ® -
Alternator: Type Three-phase AC
Rated output 23.5 A @9000 r/min (rpm), 14 V
Voltage regu lator: Type Short-circuit
Specifications are subject to change without notice, and may not apply to every country.
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The scheduled ·maintenan~e must be done in accordance with this chart to keep the vehicle in good
running condition. The first service is vitally important and must not be neglected.
AM':% .~.~~ :~
• = Clean, adjust, lubricate, tighten, or
replace parts as necessary . '" ~ C\;) 4' 05 ~ ~
of use i:-""" i:-""" i:-""" i:-
«! ~'"
l?
«! ~'" 0'" ~'"
l? l?
«!()-J' See
Page
Engine:
Air cleaner--service* • • 2-7
Clutch adjustment* • • 5-3
Valve clearance--check • • 3-6
Fuel system cleanliness--check * • • (2-10)
Engine oil--change* • • (5-11 )
Oil filter--replace* • • (5-11)
Spark plug-clean and gap • • (14-17)
Spark arrester--clean • 3-11
Chassis:
Rear brake adjustment--check* • • (10-6)
Rear brake lining wear--check* • • (10-6)
Front brake pad wear--check * • • 10-7
Brake fluid level--check • (10-8)
Brake fluid--change • (10-8)
Cable adjustment* • • **
Battery--check • • 14-6
Steering play--check • • ( 12-6)
General lubrication* • 15-4
Bolts and nuts--tighten • • 15-4
Final gear case oil--change* • • (9-6)
Master cylinder piston assembly and
2 years (10-11)
dust seal--replace
Caliper piston seal and dust seal--replace 2 years 10-6
Brake hose--replace 2 years 10-9
* : Service more frequently when operated in mud , dust, or other harsh rid ing conditions.
** : Refer to 2, 7,9, and 10 chapters.
(xx-xx) : Reference Page in the Base Manual
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The following tables list the tightening torque for the major fasteners requiring use of non-perma-
nent locking agent or liquid gasket.
Torque
Parts Remarks
N-m kg-m ft-Ib
Fuel System:
Throttle lever bolt 6.9 0.7 61 in-Ib
Fuel tap plate mounting screws 0.8 0.08 7 in-Ib
Engine Top End:
Spark plug 27 2.8 20
Cylinder head bolts:¢8 (used bolts) 29 3 .0 22 S
¢8 (new bolts) 34 3 .5 25 S
Cylinder head bolts: ¢6 12 1.2 104 in-Ib S
Cylinder bolts 12 1.2 104 in-Ib S
Valve adjusting screw locknuts 12 1.2 104 in-Ib
Camshaft sprocket bolt 41 4.2 30
Camshaft chain guide pivot bolt 9.8 1.0 87 in-Ib
Engine Left Side:
Alternator rotor bolt 59 6.0 43
Starter clutch Allen bolts 49 5.0 36 L
Recoil starter flange nut 8 .3 0 .85 74 in-Ib
Engine Right Side:
Oil drain plug 29 3.0 22
Primary clutch hub nut 125 13.0 94 0
Secondary clutch hub nut 78 8.0 58 0
Secondary clutch spring bolts: (used bolts) 12 1.2 104 in-Ib
(new bolts) 15 1.5 11.0
Oil pipe banjo bolts 20 2.0 14.5
Engine Removal/I nstallation:
Engine mounting bolts: 8mm 25 2.5 18.0 S
10 mm 34 3.5 25
Engine mounting bracket bolts 25 2 .5 18.0
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H! GENERAL INFORMATION
Torque
Parts Remarks
N-m kg-m ft-Ib
Engine Bottom End/Transmission:
Oil drain plug 29 3.0 22
Oil pipe banjo bolts 20 2.0 14.5
Neutral switch mounting screw - - - L
Shift drum stopper bolt 12 1.2 104 in-Ib
Shift drum pin plate bolt 12 1.2 104 in-Ib
Shift shaft return sprin9 pin 17 1.7 12.0 L
Clutch release cam pin 17 1.7 12.0 L
Oil pressure relief valve 15 1.5 11.0 L
Balancer gear nut 120 12.0 87 a
Balancer drive gear and oill pump drive gear nut 145 15.0 110 a
Wheels/Tires:
Wheel nuts 34 3.5 25
Front hub nuts 34 3.5 25
Rear axle nuts 145 15.0 110
Toe-in locknuts 27 2.8 20
Final Drive:
Front gear case bolts: 8mm 25 2.5 18.0
Output shaft LH bearing housing bolts 12 1.2 104 in-Ib
LH bearing holder 98 10.0 72 St
Drive gear nut: 16mm 93 9.5 69 a
Driven gear nut 7B B.O 58 a
Driven gear shaft oil seal housing nuts 25 2.5 18.0
Front gear case plug (Speedometer gear holder:
® ' Option for other than .® ) 20 2.0 14.5
Propeller shaft housing nuts 25 2.5 18.0
Axle shaft pipe bolts 25 2.5 18.0
Pin ion gear nut 7B B.O 58 0, St
Ring gear and differential gear housing bolts 29 3.0 22 L
Final gear case cover bolts 25 2.5 18.0
Final gear case filler cap 29 3.0 22
Final gear case drain plug 20 2.0 14.5
Differential shift fork holder screws 6.9 0.70 61 in·lb
Brakes:
Bleed valves 7.B O.B 69 in-Ib
Brake hose banjo bolts 25 2.5 18
Caliper mounting bolts 25 2.5 18
Disc mounting bolts 37 3.8 27
Brake lever pivot bolt 5.9 0.6 52 in·lb
8rake lever pivot bolt locknut 5.9 0.6 52 in-Ib
Front master cylinder clamp bolts B.8 0.9 78 in-Ib
Front brake fluid reservoir cap screws 1.0 0.1 9 in-Ib
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Torque
Parts Remarks
N-m kg-m ft-Ib
Rear drum drain bolts 29 3.0 22
Brake panel mounting bolts 29 3.0 22 L
Rear brake pedal mounting bolt 29 3.0 22
Rear axle nuts 145 15.0 110
Suspensions:
Shock absorber mounting bolts 34 3 .5 25
Suspension arm pivot bolts : 12 mm 88 9.0 65
Rear suspension arm (rod): 10 mm 34 3.5 25 L
Steering:
Handlebar clamp bolts 20 2.0 14.5
Stem clamp Allen bolts 25 2 .5 18.0
Stem bottom end nut 29 3.0 22
Stem bearing housing bolts 20 2.0 14.5
Tie-rod end nuts 41 4.2 30
Tie-rod adjusting sleeve locknuts 27 2.8 20
Knuckle joint nuts 41 4.2 30
Electrical System:
Spark plug 27 2.8 20
Alternator rotor bolt 59 6.0 43
Neut ral and reverse indicator
switch mounting screws - - - L
Starter circu it relay term inal nuts 4.4 0.45 39 in-Ib
Taillight assembly mounting screws 7.8 0.8 69 in-Ib
The table below, relating tightening torque to thread diameter, lists the basic torque for the bolts
and nuts. Use th is table for only the bolts and nuts which do not require a specific torque val ue. All
of the varues are for use with dry solvent-cleaned threads.
General Fasteners:
Torque
Threads dia . (mm)
N-m kg-m ft· lb
5 3.4 - 4.9 0.35 - 0.50 30 - 43 in-Ib
6 5.9 - 7.8 0.60 - 0.80 52 - 69 in-Ib
8 14 - 19 1.4 - 1.9 10.0 - 13.5
10 25 - 34 2.6 - 3.5 19.0 - 25
12 44 - 61 4.5 - 6.2 33 -45
14 73 - 98 7.4-10.0 54-72
16 115 - 155 11 .5 - 16.0 83 - 115
18 165 - 225 17.0 - 23.0 125 - 165
20 225 - 325 23 -33 165 - 240
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L~.
/
ViewP Clamp
To Fan Switch (BL, BR)
10
Strap
~
Front
Strap
ViewR
18
Fuel Tank Bracket
Refer to View W.
@ Straps
@
o Tube B
Tube C
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GENERAL INFORMATION 1-11
ViewS
Front
Front
Clamps @
Fuel Tank Bracket
Tube A
R~
Air Cleaner Housing Brackets
1. Vinyl Cover
2. Main Harness 18. Neutral and Reverse Switch Connectors
3. Accessary Connectors (for Auxil iary Light, 19. Alteroator Connector
R, BK/Y) 20. Pickup Coil Connector
4. Cooling Fan Connectors (BR, BK/ Y) from 21. IC Igniter Connectors
Main Harness 22 . Battery Ground Cable
5. To Neutral and Reverse Indicator Lights 23. Fuse 30A
(LG, BR, R/W) 24. Battery Positive Cable
6. To Headlight (R/Y, R/BK, BK/Y) 25. Starter Relay
7 . To Ignition Switch (BR, W) 26 . Igniter
8. To Left-Ha nd Switch 27. Starter Circuit Relay
9. Cooling Fan 28. Battery Vent Hose
10. Fan Motor Vent Hose 29. Main Harness Positioning Mark - white tape
11. Cooling Fan Leads (BL, BK/Y) (Aline with bolt hole position)
12. Cooling Fan lOA Fuse (BR) 30. Ignition Coi l Leads
13. Electric Starter Cable 31. Electric Starter Terminal
14. Neutral and Reverse Switch Leads 32. Engine Breather Hose
15. Alteroator and Pickup Coil Leads 33 . Reverse Cable
16. Engine Ground Lead 34. Regulator/Rectifier Connector
17. Engine Ground Ter minal and Clamp 35. Taillight Connectors
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ViewU
Strap
ViewT
View V
~ !
Front I
ViewW
the throttle
cable to the right
side of the steerin g
stem.
Strap
Tube C
47
47
Clamp Clamp
o
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Fuel System
Table of Contents
,
Throttle Cable Inspection . ..... . .. . • Fuel Tank Removal . . . . . . . . . . • . . . 2-9
Choke Lever and Cable ... ... . . . . . . . . . . 2-5 Fuel Tank Installation Notes . . . . . . . . 2-10
Choke Lever and Cable Removal .... . 2·5 Fuel Tap Removal . . . . . . . . . . . . .. . •
Choke Lever and Cable Installation . .. . 2·6 Fuel Tank Inspection . .. . . . . .. ... . *
Choke Lever and Cable Lubrication .. . 2-6 Fuel Tank and Tap Cleaning ....•... •
Choke Cable Inspection . . . . . . . . . . . 2-6 Fuel Tap Inspection ... . . . . . . . • . . . •
Carburetor . . . . . . . .. . . . . . . . . . . .... . 2-6 Fuel Level Gauge Removal . . . . . . . . . 2-10
Carburetor Pilot Screw Adjustment . .. . 2-6 Fuel Level Gauge Installation Notes .. . 2-10
Idle Speed Adjustment . . . . . . . . . . . . 2·7 Fuel Level Gauge Check . . . . . . . . . . . 2-11
Fuel Levell nspection .. . . . . . . . . .. . • Fuel Tank Damper Installation . . . . . . . 2·11
Fuel Level Adjustment . . . . . . . . . . . . • • Base Manual
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2.Throttle Cable
3.Choke Cable
4.Throttle Case
5.Starter Jet
6.Pilot Jet
7.Main Jet
A : Apply adhesive
G : Apply grease. .
o : Apply oil.
L_D
Oe: Apply cleaner element oil
R : Replacement Parts .
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24 FUEL SYSTEM
Specifications
Item Standard
Carburetor Specifications
Make, type: Keihin, CVK32
Main jet: #128
Main air jet: # 100
Needle jet: #6
Jet needle mark : N27Q
Pilot jet (slow jet) : # 38
Pilot air jet (slow air jet): # 140
Pilot screw (turns out): 2'/,
Starter jet : # 55
Service fuel level (from carburetor body
bottom edge) : 0.5 mm below - 1.5 mm above
Float height: 17 ±2 mm
Engine Speed (for reference) 1300 ±100 r/ min (rpm)
Optional Parts
Main jet: # 122,125,130,132
Pilot jet (slow jet): # 35, # 40
Starter jet: # 58, # 60
Special Tools
Choke Lever and Cable Removal A. Lever Mounting Screw B. Choke Lever
• Unscrew the starter plunger cap and pull out the starter
plunger.
• Remove the choke lever and free the choke cable upper
end from the lever.
.Pull off the retaining ring and free the choke cable
housing from the switch housing.
A. Retaining Ring
1. Screw 3. Wave Washer -Ti lt the carburetor to the right of the vehicle for easy
2. Plane Washer access to the pilot screw.
Choke Cable Inspection e Reposition the carburetor properly and tighten the
-With the choke cable disconnected at both ends, the clamp screws secure ly.
cable should move freely in the cable housing. OFit the carburetor ridge into the groove on the duct.
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Air Cleaner
I WARNING I
OA clogged air cleaner may allow dirt and dust to enter
the carburetor and stick the throttle open. This could
cause an accident.
A. Idle Adjusting Screw
[~AUTIO~.l
*If the engine idle is still not stable, adjust the pilot
screw to obtain the slowest smooth idle speed using the o A clogged air cleaner may allow dirt and dust to enter
pilot screw adjuster "A" (special tool) . the engine causing excessive wear and possibly engine
damage.
WARNING I
OOperation with an improperly adjusted. incorrect
routed, or damaged cable could result in an unsafe
riding condition .
a Te avoid a serious burn, never touch a hot engine or an
exhaust pipe during carburetor adjustment.
A. Screw B. Stopper
.Pull the element off th e body, then off the inner metal
net. A . Drai n Hoses
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FUEL SYSTEM 2-9
elnstall the fuel tank cap at once.
Fuel Tank _Remove the fuel tank front cover by pulling it up and
turning it to either side between th e front carrier and
the steering stem.
Fuel Tank Removal
-Remove the seat (see Frame chapter in this manual) .
• Remove the fuel tank rear cover.
A . Front Cover
eTake off the fuel tank cap. -Remove the breather and vent hoses from the damp on
the rear of the fuel tank.
[ WARNING I e Remove the fo llowing bolts.
Fuel Tank Installation Notes eRemove the fuel tank upper cover by taking off the
eFuel tank installation is the reverse of removal. Note two mounting screws.
the following. -Install the fuel tank cap immediately.
_Pry off the gauge cap and discard the cap.
WARNING I -Check the grooves in the fue l tank boss. If the grooves
are damaged by removing the cap or can not hold the
cap nails, the fuel tank must be replaced.
OGasoline is extremely flammable and can be explosive
under certain conditions. Turn the ignition switch
OFF. Do not smoke. Make sure the area is well
ventilated and free from any source of flame or sparks;
this includes any appliance with a pilot light.
A. Dampers
I WARNING I
o Fuel spilled from the fuel tap is hazardous.
-Install the breather and vent hoses on the fuel tank and
secure them with the clamp (see Wiring, Cable, or Hose
Routing section in the General Informat ion chapter).
A. Fuel Level Gauge
I WARNING I WARNING I
OGasoline is extremely flammable and can be explosive OGasoline is extremely flammable and can be explosive
under certain conditions . Turn the ignition switch under certain conditions. Turn the ignition switch
OFF. Do not smoke. Make sure the area is well OFF. Do not smoke. Make sure the area is well
ventilated and free from any source of flame or sparks; ventilated and free from any source of flame or sparks;
this includes any appliance with a pilot light. this includes any appliance with a pilot light.
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Damper Installation
A. Front C. Notch
B. Y, Scale
Refer to the Base Manual noting the following. Cylinder Head Removal
• Remove the following parts.
Cylinder Compression Fron t Fender (see Frame chapter)
(Usable range, with compression release operated) Fuel Tank (see Fuel System chapter in this text)
Carb uretor (see Fuel System chapter in the Base
Using Recoil Starter
Manual)
825 - 1280 kPa Exhaust Pipe and Muffler (see Base Manual)
(8.4 -13 .0 kg/em 2 ,119 -185 psi) Ca mshaft Sprocket (see this chapter)
Using Electric Starter Spark Plug Cap
795 - 1240 kPa Cylinder Head Breather Hose and Hose Clamp
(8.1 -12.6 kg/em 2 , 115 -179 psi) eRemove the cylinder head bracket mounting bolts,the
cylinder head mounting bolt, and nut, then take off the
brackets.
Special Tools
*If the cylinder head or the cylinder head bolts are new
ones, tighten the 8 mm bolts to 34 N-m (3.5 kg-m, 25
fHb) of torque.
eFirst tighten the three cylinder head bracket mounting A. Oil Seal C. Washer
bolts, then tighten the cylinder head mounting bolt and B. Return Spring
nut to the specified torque (see Cylinder Head Removal),
A. Return Spring
eOil the lever shaft and install the washer and lever
A. Bolt C. Front assembly.
B. Compression Releasing Lever eTighten the bolt securely.
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2
,-.
5 mm ".
2
1
Camshaft Sprocket
Valve Guides:
Valve Guide Installation
eClean the valve guide hol e in the cylinder head.
e Lightly oil the valve guide.
eHeat the cylinder head around the va lve guide hole to
120° to 150°C (250° to 300° F) .
• Use the valve guide arbor and a hammer to drive the
guide into the head from the outside until the guide
flange seats against the head.
eAliow the cylinder head to cool.
• Ream the valve guide with the valve gu id e reamer
(special too l) even if the old guide is reused. A. Camshaft Cover B. Gap
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eTake out th e bolts and remove the valve adj usting caps. - Remove the lockbolt.
-Loosen all the cylinder head bolts to free the cylinder -Carefully pull the push rod out of the tensioner body.
head from the stress (see Cylinder Head Removal). Do not drop the ball and retainer assembly or the
ePull out the rocker shafts and remove the rocker arms. spring.
-Slide the ball and retainer assembly and the spring off
the push rod.
1 1
-_.""" mark
Top ring
Up
1. Lockbolt 4. Spring
2. Push Rod 5. O-Ring UN" mark
3. Ball and Retainer Assembly
2nd ring
eSe sure the O~ring is in place in the tensioner body.
eAfter installing the tensioner, loosen the lock bolt and
then tighten it. With the bolt loosened, the spring
inside takes up any slack automatically.
20mm
CD
1. Rubber Dampers
2. Cylinder A. Compression Releasing Lever
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e Hold the throttle wide open and crank the engine with
the recoil starter, or the electric starter. Exhaust System
eWhen the gauge stops rising, stop cranking and read the
gauge.
Spark Arrester:
This vehicle is equipped with a spark arrester ap-
proved for off-road use by the U.S. Forest Service. It
must be properly maintained to ensure its efficiency.
In accordance with the Periodic Maintenance Chart,
clean the spark arrester.
I WARNING I
OTo avoid burns, wear gloves while cleaning the spark
arrester. Since the engine must be run during this
procedure, the muffler will become hot.
A. Compression Gauge: 57001-212 OThe spark arrester must be installed correctly and
B. Adapter Hose: 57001-1159 functioning properly to provide adequate fire pro-
tection.
Carburetor Holder
A. Chamfer
* Base Manual
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R
"o~~·~
T2 ©
@@
1. Torque
G . Li miter
.
. Apply high tem
l : Apply non.pe perature grease.
O:A I rmanentl '
T1 . pp y engine oil. ockong agent .
. 59 N-m (60
T2: 34 N-m (3'5 kg-m, 43 ft-Ib)
T3.83 . kg-m ' 25ft -Ib)
. . N-m (0.85 kg-m,74 in-Ib)
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Special Tool
NOTE
ODD not let the rope wedge between the reel and the
housing.
Recoil Starter
A. Bolts
I WARNING.
o Be careful that the spring does not fly loose and does
not injure you. It is under great pressure.
oTum the reel one-quarter tum counterclockwise past
the rest position where no tension can be felt. Now.
slowly lift the friction plate straight up out of the
housing.
\
1. Pawl
2. Pawl Spring
3. Friction Spring
4. Friction Plate A. Strike bench.
5. Flange Nut
I WARNING.
o Be careful that the spring does not fly loose and does RecoilStarter Assembly Notes
not injure you. It is still under great pressure. eAssembly is the reverse of disassembly. Note the
o Tum the reel one.quarter tum counterdockwise past following.
the rest position where no tension can be felt. Now, elf the recoil spring was removed, install it as shown. If
slowly lift the friction plate straight up out of .the will
it is not installed correctly, the starter not operate
housing.
properly . .
NOTE I WARNING.
o There should be no spring tension on the reel when
removing the reel. Lift the reel slightly. If tension is o The recoil spring must be put under great pressure
felt, push the reel back into pla<;e and gently "wiggle" during installation. Wear gloves to avoid injury.
it until the reel may be easily removed.
A. Hook reco il spring end onto the tab. A. Turn reel to wind rope.
-Set the reel into place so that the hook on the spring
catches on the tab in the reel.
NOTE
OPush the recoil spring against the housing securely to
prevent the spring from slipping off during installation.
NOTE
A. Pawl D. Friction Plate Spring Hooks
o Turn the reel counterclockwise to wind the rope B. Pawl Spring E. Grease here.
clockwise. This prevents the rope from twisting. C. Friction Plate
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1. Torque Limiter
A. Grooves B. Key
.............................................................................
Starter Chain and Sprocket
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25 N-m. 'n Ib) for u
T1: 1
T2:12N-m (1 . 2 kkg·m,
m 104 I -
11 .0ft .lb ) f or new bolts
15 N·m (1.5 g- '58 ft-Ib)
T3: 7B N -m (B.O ~g-~, 22 ft-Ib)
'"
T4: 29 N-m (3.0 g-m' 14.5 ft-Ib)
T5 : 20 N-m (2.0 kg· ,
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ENGINE RIGHT SIDE 5-3
Clutch Removal:
Specifications Clutch Installation
o Refer to the Base Manual noting the following.
*If the c lu tch spring plate or the clutch spring bolts are
Refer to the Base Manual noting the following.
new ones, tighten the spring bolts evenly to 15 N-m
o The engine oi l of SAE 10W-30 can also be used.
(1.5 kg-m, 11.0 fHb) of torque.
Balancer
Clutches
Lubrication System
Oil Pump:
Oil Flow Inspection
eRun the engine at idle speed.
I WARNING I
a During oil flow inspection, do not open the throUle
valve. Hot oil will squirt out of the banjo bolt, and
may cause a serious burn.
A. Clutch Release Adjusting Screw Cover
B. Screws e Loosen the main oil pipe banjo bolt on the left crank-
case as shown J and check that the oil seeps out around
the banjo bolt .
• Loosen the locknut.
eTurn the clutch release adjusting screw clockwise until
it becomes hard to turn, then turn the screw back
counterclockwise until it become hard to turn.
Engine Removal/Installation
Table of Contents
* : Base Manual
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~
T2: 34 N-m (3.5 kg-m. 25 ft-Ib)
. @
,
Engine Removal/Installation
1.60lts 6,65
2.601t6,85
3.601ts6,35
G :App I y grease
L :App ly non-permanent
locking agent
LG:Apply 1 iquid gasket
o :Apply engine oi I
R :Replacement Parts
Special Tools
ORefer to the Base Manual noting the additional tool. 43mm 9mm
Crankshaft Runout
Left Half Standard: Under 0.03 mm T1R
Service Limit: 0.08 mm T1R
Sealant Right Half Standard: Under 0.04 mm T1R
Service Limit: 0.10 mm TIR
Transmission
Circlip Installation
I~_, A
NOTE
Olnspecl Ihe valve in its assembled slale, Disas-
sembly and assembly may change Ihe valve
performance.
WARNING'
*If cleaning does not solve the problem, rep lace the
relief valve as an assembly. The relief va lve is
precision made w ith no allowance for replacement of
individual parts.
• App ly a non-permanent locking agent to the threads of
the relief valve, and tighten it.
WHEELS/TIRES 8·1
Wheels/Tires
Table of Contents
*: Base Manual
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8·2 WHEELS!TIRES
Exploded View
..............................................................................
G : Apply grease.
R : Replacement Parts
W : Apply water, or soap and water solution .
T1 : 34 N·m (3.5 kg·m. 25 ft·lb)
T2 : 27 N·m (2.8 kg·m. 20 ft·lb)
T3 : 41 N·m (4.2 kg·m. 30 ft-lb)
T4: 145 N·m (15.0 kg·m. 110 ft·lb)
Front Wheel
"., --~!@
".'
.
, "
•
Rear Wheel
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WHEElS/TIRES 8·3
Specifications
Wheel Alignment
Caster: 3° (non.,adjustable)
Camber: 1° (non.,adjustable) @ 1G
Toe-in: 27mm
Standard Tires
Front: 22 x 9.00·10
Dunlop KT761. Knobby/Trail Tubeless
Rear: 24x 11.00·10
Dunlop KT765. Knobby/Trail Tubeless
Special Tools
OThis tool may be used instead of the common tool. o Be sure to use this gauge for low pressure tire instead
of the conventional air pressure gauge (52005-1003).
Q------.l!~
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84 WHEELS/TIRES
eHold a straightedge against the rear wheel rim on one
Wheel Alignment side at axle height.
'7
'\ D '7
'"
"-
eWith the handlebar straight ahead, loosen the locknuts
...... and turn the tie-rod adjusting sleeve the same number
f- ~
_.. f-
of turns on both sides until the front wheel on that
side is parallel to the straightedge.
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NOTE
OThe yel/ow locknut on the tie-rod has left-hand
threads. Turn the wrench clockwise for loosening.
A - B = Amount of Toe-in
(Distance A and B are measured at axle height)
WHEELS!TIRES 8-5
Steering Centering eKeeping the front wheels off the ground, set the
handlebar straight ahead .
• At the level of the axle height, measure the distance
between the scribed lines for both front and rear of the
4 front tires.
1. Front Wheels 4. Straightedge eSubtract the measurement of the front from the
2. Vehicle Center Line 5. Rear Wheels measurement of the rear to get the toe-in.
3. Parallel to each other. *If the toe-in is not in the specified range, go on to the
Toe-in Adjustment procedure.
NOTE
o The yellow locknut on the tie-rod has left-hand
threads. Turn the locknut clockwise for loosening.
o The toe-in will be near the specified value, if the tie-rod
length is 367 mm between the tie-rod ends.
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8-6 WHEELS/TIRES
Tie-Rod Length Adjustment Wheel Installation
.Position the wheel so that the air val ve is toward the
outside of the vehicle.
_Check the tire rotation mark on the front and rear
tires, and install the wheels accordingly.
NOTE
o The direction of the tire rotation is shown by an arrow
on the tire sidewall.
-Take off the wheel nuts and remove the wheel. A. Valve Stem
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WAEELSITIRES 8-7
Wheel Inspection Air Valve
• Examine both sides of the rim for dents. If the rim is
dented, replace it.
Rim Dent
3) -- - - 1
.....
1. Sealing Surfaces
Wheel Replacement
e Remove the wheel (see Wheel Removal).
eDisassemble the tire from the rim (see Tire Removal).
ORemove the air va lve and discard it. 0 00 not use engine oil or petroleum distillates to
lubricate the stem because they will deteriorate the
rubber.
OReplace the air valve whenever the tire is replaced. eMount the tire on the rim (see Tire Installation).
o Do not reuse the air valve. elnstall the wheel (see Wheel Installation).
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8-8 WHEELS!TIRES
eKneel on the side of the tire, forcing the tire bead into
Tires the center well of the rim.
OOO OD
Well
eBreak the tire beads away from both sides of the rim
with a bead breaker.
e Lift the second bead up into the center well and use
the same procedure as in removing the first bead.
Tire Installation
elnspect the rim (see Wheel Inspection).
1. Bead Breaker eReplace the air valve with a new one (see Wheel Re·
2. Apply lubricant. placement).
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WHEELS/TIRES 8-9
-By hand, slide as much of the first bead as possible
[CAUTION! over the rim flange .
o Replace the air valve whenever the tire is replaced . • As the bead goes onto the rim, force the bead into the
0 00 not reuse the air valve. renter well of the rim to ease installation.
-Check the tire for wear and damage (see Tire Inspec-
Bead Installation
tion) .
• Lubricate the tire beads, rim flanges, and the tire irons
(special tools) with a soap and water solution, or water.
I WARNING.
o Do not use the lubricant other than a water and soap
solution, or water to lubricate the tire beads and rim
because it may cause tire separation.
1. Apply lubricant.
Bead Installation
NOTE
o The direction of the tire rotation is shown by an arrow
on the tire sidewall.
8-10 WHEELS/TIRES
Tire Air Pressure
Front and Rear:
21 kPa (021 kg/em 2 • 3.0 psi)
-Check the tire pressure using the air pressure gauge for
low air pressure (special tool).
I---@
1. Rim 2. Suitable Stand
Tire Inspection
eExamine the tire for damage and wear.
Olf the tire is cut or cracked, replace it.
o Lumps or high spots on the tread or sidewalls indicate
internal damage requiring tire replacement.
o Remove the any fore ign objects from the tread . After
removal, check for leaks with a soap and water solu-
tion.
oCheck the shape of the tread knobs. If no vertical side
is left on the drive side of the knobs, replace the tire.
Tire Inspection
Vertical Sides
Worn Away
1. Rim Line 2. Rim Flange /_-~t
elf the rim lines and the rim flanges are not parallel,
deflate the tire, lubricate the sealing surfaces again, and /
/' ~ "" \
reinflate the tire.
eAfter the beads are properly seated, check fo r air leaks. / 1:-----.. \
Olnflate the tire to 35 kPa (0.35 kg/em 2 , 5 psi). Apply
I ;; I ~ .
~_.. J. . I. . _+_
a soap and water solution around the tire bead and
check for bubbles.
eDefiate the tire to the specified pressure.
\
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WHEELS!TIRES 8-11
eGrease the lips of the hub end seal.
Front Hub
Grease
8-12 WHEELS!TIRES
o Pry the spacer pipe toward one side. Front Hub Bearing Inspection
o Drive the bearing out by tapping on the exposed
portion of the spacer pipe end with a hammer and NOTE
metal rod.
OSince the bearings are packed with grease and sea/ed,
they can not be lubricated.
Rear Hub
1. Metal Rod
Final Drive
Table of Contents
Exploded View
G : Apply grease.
L : Apply non-permanent locking agent.
o : Apply hypoid gear oil to the threads and seated surface. I
R : Replacement Parts ®
~
SS : Apply silicone sealant.
St : Stake the fastener .
~--
1 ®
G
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Special Tools
CD
BRAKES 10-1
Brakes
Table of Contents
10-2 BRAKES
Exploded View
A : Apply adhesive.
G : Apply grease.
L : Apply non-permanent locking
agent.
o : Apply oil.
Si : Apply silicone grease .
BRAKES 10-3
, G
~.
@G
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10-4 BRAKES
Specifications
Special Tools
Jack: 57001-1238
BRAKES 10-5
elf the caliper is to be disassembled after removal and if
Brake Adjustment compressed air is not available, remove the piston using
the following procedure. If both calipers are to be
disassembled, be sure to do this procedure to both at
Front Brake Lever Free Play Inspection the same time.
Disc or disc pad wear is automatically compensated o Remove the pads.
for and has no effect on brake lever action . So there are o Temporarily reconnect .the brake hose to the caliper.
no parts that require adjustment on the front brake. The banjo bolt need not be torqued.
However if the brake lever has a soft, or "spongy o Pump the brake lever to remove the caliper piston.
feeling," check the brake fluid level in the master o lmmediately wipe up any brake fluid that spills.
cylinder and bleed the air from the brake line (see o Disconnect the brake hose from the caliper.
Bleeding the Brake in the Base Manual).
NOTE
OCheck the brake fluid level in accordance with the
Periodic Maintenance Chart.
Caliper Installation Notes
-Connect the brake hose to the caliper putting a new
Parking Brake Cable Lubrication flat washer on each side of the brake hose fitting .
• Lubricate the parking brake cable in accordance with eCh~ck the fluid level in the reservoir and bleed the
the Periodic Maintenance Chart, or whenever the cab le brake line (see Bleeding the Brake Line in the Base
is removed (see Genera l Information chapter and Manual).
General Lubrication in the Appendix chapter), eCheck the brakes for good braking power, no brake
OUse the pressure cable luber (special tool: PN 56019- drag, and no fluid leakage.
021) to lubricate the cable .
Caliper Removal
eRemove the front wheels (see Wheel Removal in the
WARNING I
Wheels/Tires chapter). OTo avoid serious injury, never place your fingers or
eSeparate the brake hose from the caliper by taking off palm inside the caliper opening. If you apply com-
the banjo bolt. pressed air into the caliper, the piston may crush
-Remove the caliper mounting bolts and take off the your hand or fingers.
calipers.
10-6 BRAKES
Caliper Assembly Notes Anti-Rattle Spring Installation
I WARNING I
OExcept for the disc pads and discs; use only disc brake
fluid, isopropyl alcohol. or ethyl alcohol. for cleaning
brake parts. Do not use any other fluid for cleaning
these parts. Gasoline, motor oil, or any other
petroleum distillate will cause deterioration of the
rubber parts. Oil spilled on any part will be difficult to
CD
wash off completely, and will eventually deteriorate
the rubber used in the disc brake.
BRAKES 10-7
10-8 BRAKES
e Lubricate t he brake lever by appl ying a light coati ng of -After installi ng the discs. check the disc runout.
silicone grease to th e brake lever pivot screw and th e Co mpl etely clea n off any grease th at has gotte n on
contact with the piston. either side of th e d isc with a hi gh-flash point so lve nt.
Do no t use one which will leave a n oil y resid ue.
Disc Wear
eMeasure the th ickness of each di sc a t the point where it
has worn the most .
*Replace th e disc if it has worn pas t t he service lim it.
A. Apply grease.
Discs
I WARNING I
OWhen handling the discs, be careful that no disc brake
fluid or any oil gets on them. Clean off any fluid or o il
that inadvertently gets on the discs with a high-flash
point solvent. Do not use one which will leave an oily 1. Brake Disc
residue. 2. Measuring Area
Disc Cleaning
Poor brak ing can be ca used by o il on a di sc. O il o n a
di sc must be cleaned off wit h a'1 oilless cleanin g fluid
such as trich loroethylene o r aceto ne .
WARNING I
OThese cleaning fluids are usually highly flammable and
harmful if breathed for prolonged periods. Be sure to
A. Marked Side heed the fluid manufacturer's warnings.
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BRAKES 10-9
Disc Runout
Standard: 0.2 mm or under
Brake Drums
Service Limit: O.3mm
10·10 BRAKES
Grease
A. Drain Bolt
SUSPENSION 11 ·1
Suspension
Table of Contents
* Base Manual
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11-2 SUSPENSION
Exploded View
----@
•
T1: 34 N-m (3_5 kg-m, 25 ft-Ib)
T2: 88 N-m (9_0 kg-m, 65 ft-Ib)
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SUSPENSION 11-3
Specifications
Jack: 57001-1238
Special Tools
11-4 SUSPENSION
Shock Absorber Assembly Note
Suspension • Lubricate the rubber dampers with a soap and water
solution when installing the rubber dampers.
Spring Action
Spring
Position Setting Load Terrain Speed
Force
1 Soft Light Good Low
2 (sTD)
3
4
j 1 1 J 1
Front Suspension Arm Removal
e Remove the follow in g parts.
Tie-Rod (see Tie-Rod Removal)
Knuckle (see Knuckle Removal)
5 Stronger Hard Heavy Bad High
'1!:---;O/
~~
~
/
" ~ ~
/
...v®«9Y
~~
~ =" ~~ ®
~'-...~@~®
/~
A. Adjusting Sleeve (Rear Shock shown)
1. Knuckle 2. Tie-Rod
WARNING'
o If a pair of adjusting sleeves (front two adjusting
sleeves or rear two) are not adjusted equally, handling Rear Suspension Arm (Rod) Removal
may be impaired and a hazardous condition may Refer to Suspension Arm Removal in the Suspension
result. . chapter in the Base Manual.
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SUSPENSION 11-5
Rear Suspension Arm (Rod) Installation Front or Rear Suspension Arm Assembly Notes
o Suspension arm Installation is the reverse of removal. -When installing the rubber dampers into th e arm,
Note the following. lubricate th e outer surface of the dampers with a soap
elnstall the center arms noting the installation direction. and water solution.
t:--@
,
STEERING 12-1
Steering
Table of Contents
Exploded View . ... ........ •... . ... . . ...... . .. ... . . .... ... . 12-2
Specification ................................. .... .... .... . 12-3
Steering ................... •.. ............... . . . ... . . .. ... 12-3
Handlebar Removal .... ......... .. ......... .. ..... ... .. . *
Handlebar Installation .. .... .. ... .... .. . . . . ........ ... .. . 12·3
Handlebar Grip Removal .............. . ... . ............. . *
Handlebar Grip Installation ............ .. ............. . .. . *
Steering Stem Removal ..... . .... ... . . .......... . .. . '. . . . . *
Steering Stem Installation .. .. ....... . .... . . .......... . . . . 12-3
Tie·Rod Removal ... . .................... .. .. ... .. .. .. . 12-3
Tie-Rod End Installation Notes ... ...... ..... .. . . .. ....... . 12-4
Steering Knuckle Removal ... ...... . .... . . . . ..... . . . ... . . 12-4
Steering Knuckle I nstallation Notes . ... . .. .. . .. ...... . .... . 12·5
Steering Knuckle Stopper Adjustment .. ...•. ... ..•.. ....... * [gI
Steering Inspection .. ......................... ... .... .. . *
Steering Stem Warp .. . . . ........ ...... ..... ... . ........ . *
Steering Stem Bearing, Tie-Rod Bearing, and
Steering Knuckle Upper and Lower Joint Inspection .......•. *
Steering Lubrication ...... . ... . ... .. ... .... . .......... . . 12-5
* . Base Manual
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12-2 STEERING
...................................
Exploded View ................•............
......................................................................
........... -.
.......
(3'0 ~g-m,
T1 : 20 N-m
(2 0
T2: 29 N-m 14,5 ft-Ib)
T3: 41 N-m
(4' g-m, 22 ft-Ib)
T4' 25 N
(.2 kg·m, 30 ft-Ib)
, ·m 25k
T5: 88 N-m (9' g-m, 18.0 ft-Ib)
,0 kg-m, 65 ft-Ib)
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.STEERING 12-3
Steering
Handlebar Installation
eHandlebar installation is the reverse of removal. Note
the following.
elnstall the handlebar so that the angle of the handlebar
matches the angle of the steering stem as shown.
A. Parallel
eTighten the holder rear bolts first and then the front
bolts. When the holder is correctly installed, there will
be even gap at the front and no gap at the rear after
tightening,
A. Marks
• Rou te the cables, the wires, and the brake hose ac-
cording to the Wiring, Cable, or Hose Routing section
in the General Information chapter.
Tie-Rod Removal
e Remove the following parts.
A. Front C. No Gap Front Fender (see Frame chapter in this text)
B. Even Gap Front Wheel (see Wheels/Tires chapter in this text)
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12-4 STEERING
_ Remove the following parts to free the tie-rod from the Tie-Rod End Installation Notes
stress. -Check that the seal lip is on the shank.
Front Shock Absorber (see Base Manual) -Oil the bolt body.
Front Suspension Arm Pivot Bolts (upper)
o
A. Upper Suspension Arm Pivot Bolts
B. Shock Absorber
1. Seal Lip 3. Apply oil
2. Shank
_ Remove the cotter pin and the tie-rod end nut at the
steering knuckle .
• Remove the cotter pin and the tie-rod end nut at the
steering stem. Steering Knuckle Removal
-Install a suitable spare nut on the tie-rod end and tap -Remove the following parts.
the nut to remove the tie-rod. Front Wheel Hub (see Wheels/Tires chapter in this
text)
Tie-Rod (see Tie-Rod Removal)
Stone Guard
• Remove the cotter pins, then remove the steering
knuckle upper and lower joint nuts.
STEERING 12-5
-Tap the steering knuckle and remove it. Knuckle Joint Installation
o o
A. Tap the steering knuckle.
Steering Lubrication
Refer to the Base Manual noting the following.
-Grease the steering stem clamp mating surface, too .
FRAME 13·1
Frame
Table of Contents
* : Base Manual
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13-2 FRAME
Exploded View
.............................................................................
Front Carrier
1. Bolts, Washers, 8 x 16
2. Flanged Bolts, 8 x 20
3. Flanged Bolts, 6 x 16
4. Bolts, Washers, 8 x 16
5. Bolts, Washers, 6 x 18
6. Bolts, Washers, 8 x 14
7. Bolts, Washers, 8 x 18
,,,
~
,I: ~
__
Canada Model
: @ - - - - Australia Model
Rear Carrier ~--- KLF300-B 1,B2,B6-
KLF300-B6-
,, ,
r-, Europe Model
KLF300-B4-
UK Model
KLF300-B3-
KLF300·B3-
r -------- - --- --,
,,,
,
,
: i--il
I ~
- - - --i
I ~....<rf""
L..J ~. _"
I : - -
..,.,
•
I
I
~
1 '- __ ~' _ ' ; _ J
I
I
I
~ ___ __ _____ ___ _1
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FRAME 13-3
® ~ 8. Screws 6 x 14
9. Black Screws 6 x 18
~~. Bolts, Washers 6 x 18
. Bolts, Washers 6 x 20
~. ~
@-'ff~ &1.
(ij - ' '" •
- <$><>d~
- y~®
8 .~ @ rK!-~~??~B}-
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134 FRAME
............................................................................. ..............................................................................
Seat Front and Rear Fenders
••••••••••••••••••••••••••••••••••••••••••••••••••••••• 0.0 ••• ••••••••• •• ••• 0 '
WARNING'
o Gasoline is extremely flammable and can be explosive
under certain conditions. Turn the ignition switch
OFF. Do not smoke. Make sure the area is well
ventilated and free from any source of flame or sparks;
this includes any appliance with a pilot light.
A. Pull.
Seat Installation
-Slip the seat hook under the brace o n the frame, and
put the stoppers in to the holes in the frame.
A. Fuel Tank Side Cover
B. Fuel Tank Upper Cover with Two Screws
C. Fuel Tank Tail Cover with Two Screws
A. Brace C. Stoppers
B. Seat Hook D. Holes
-While pushing the rear part of the seat down, push the
seat lock lever down until the lock clicks. A. Side Cover B. Screws
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FRAME 13-5
e Remove the front fender mounting bolts and flanged Front Carrier Removal
collars, fo ur screws and nuts of the mud flaps. eJ ust remove the following six bolts.
A. Mounting Bolts
A. Mounting Bolts
B. Remove these screws (both right and left sides).
Rear Fender Removal
eRe move the follow ing parts.
Seat (see Seat Removal)
eRemove the four mounting bolts of the fender front Eight Rear Fender Mounting Bolts including the Bolts
part. in the Storage.Case
A. Mounting Bolts
13-6 FRAME
Electrical System
Table of Contents
~~ "
~g
® @
()
.~
~
/~
"-
®
g;l I~I
_ LJ~
IjJI~ ~
i
I
~~ !
,
ld I
l - ______ -.J
1. Pickup Coil
2. Regulator/Rectifier
3. Neutral and Reverse Switch
4. Starter Relay
5. Starter Circuit Relay
6. IC Igniter
7. Ligh~ Switch and Engine Stop Switch
8. Igmtlon Switch
9. Cooling Fan Switch
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.............................................................................
Wiring Diagram US, Canada model fKLF300-81 _) .,....
.j,.
............................................................................. UK, Australia model fKLF300-81 - 83)
~
m
r-
=l~
PICkUp
~
Altlmeto.
Ig"lIIon COli
SwitCh
i~
~
~..:~
A R,guletorl
:II
~
Rectlfl'r
~ 9 r-
•
.H
, "
"
~:i~li
II
".
". ~
m
Neutral I ndicator
Ught12VlW " ----=- " -+-1-+-1- "J Sp.rk Plug
3:
Reve". IndiCator
LI9hl12V3W
r- - -
,.~,.~ ':'B~
an " '8R~8R
Accessory Terminals
"., A""'''" L,,'n
H
"'lJ
L
i
i _j'
..
.
___ _ _ _ __ _"-_
Q?
--J
"
I
~..:!i
US model
KLF300-B4-
---BL - - - - 0
o
<J
R -------,
8K/Y _ _
~ ,- - - --l
I HUdllytll
~"1
l
;;<--0<.-- ..'"
"' ,,' .,,"
L 11--'
- L:= " ::=J II ~Il---
' '
:, ,~~·f :~
,12V65/60W RtT_ ------c.p-
_ _....
II" /I
8" V:,II.,=
II D<I~",
1", ~::...-J'
_ 1_ _ _ _ ..
I • - - -9"-
'
- R Taillight
-~~:~""' ,!~
J .. , .,,_ . • "v.w., '
"""" 0,"" L
II '
:
:1'1' 1 '" - "" --.. ,".......;;;
I..... '
,,_
-
.. ~ ..
I
,
~-
Fin
,'.''''
-
~8l-
_______
UK model only
:
---1
AceelSo.y
r Te rmln llS
~ ~
::ii;
BK
BL
BR
G
GY
LB
Color Code
Black
Blue
Brown
Green
Gray
Light Blue
r----
. ~ " -"1 _.. .
["f":. :C
LG Light Green
Ru~l 511r\e, Blltton
~ 0 Orange
l~FF
H'
1.1 0'"
Eniline Slop Switch
Light Switch
~ LO;:.' P
R
W
Pink
Red
White
ILO
Y Yellow
(98051·1043D,10a8A,1225B)
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Refer to the Base Manual noting the following. Refer to the Base Manual noting the following.
CD
o
1.24
at 1 A charge rate 5 10
0
15
I , 20 21
I
at 2A charge rate 3 5 7 9 10.5
0
at 3A charge rate 1 2 3 4 5 6 7
at 4A charge rate 2 3 4 5.3
Hours of Charging Time at Rates Shown
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BR ON OFF Q) w w
BR w
BR BK/Y
a:
<II
B G
® r1
6 Pin Connector -!l @
I
~
-
r'\ ,"
>
<II
~
;;:
- +
"
<II
@
7'T
d BK/Y
R/BK A
~
R/B~ mL...:B::.:K1::.Y~)C:r-=B::.:K:.;/Y~
IL-_-r...r::-
i R/BK
BR BR ~
~_---I~ R OFF o""-.J,~ HI
r-~~l 0 ILO @
I L- R/Y
R R
V'-' BK/Y
Charging System Checkout: e Pull the spark plug lead off the spark plug.
Stator Coil Resistance Inspection eDisconnect G/W lead and Y/R lead from the coil.
eRemove the seat (see Frame chapter) . eTake off the nuts and remove the coil.
eDisconnect the a lternator connector.
eMeasure the stator coil resistance.
OConnect the hand tester (special too l: PN 57001-1394)
between the yellow leads.
OSet the hand tester to x 1 n range, and read the tester.
1. Alternator Connector
(-)
Ignition System !I 1 9~
o l _____ -=-J~
8 ~-
G) .
green/white lead
Connect
Connect
yellow/red lead
Part Removal:
Ignition Coil Removal
. e Remove the fuel tank (see Fuel System chapter in this
manual).
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".J•
0
G/W
~ = = = =
~
3- 2- 60- 2-
Y/R
I0
30 15 500 15
>
~
0.8 - 1.2- 30-
"·0
~o
0-
BK/W
8.0 12.0 300
0
Zt;
~
,0
00
50- 70- 30 - 30 -
BL
i§
t-u
500 550 300 300
~
0.8 - 1.2 - 30 -
(BK/W) 0
8.0 12.0 300
A. Spark Plug Wrench (Owner's Tool): 92110-1109 • Measure with the Kawasaki Hand Tester (PN 57001 -
1394). A tester other than the Kawasaki Hand Tester
may show slightly different readings.
Ie Igniter Terminal
~
-Attach the timing light (special tool: PN 57001-1241)
and a tachometer in the manner prescribed by the
manufacturer.
_Start the engine and aim the timing light at the timing
light mark on the alternator rotor.
• Run the engine at the speeds specified and note the (BK/W) BL
alignment of the timing marks.
BK/W
~---------------BK/Y --------------~
.----Y/R--11;::===t--,
BK
BL
ON
(5)FF
ON
rLf
~ ~FF~-'
U@ '" '"
-
;;: L?
~Q) r
--
o<~
>-L?
r ®
1
~
(j)- ~
~
® r-'
*\
TON
a:
OFF
<II
~
a:
<II
4
~
<II a:
<II
p"'---" '" ;~;"'
~
:
<II
I
a: a: -'"
>-
~
'" >
OFF
®
T RUN
o
.............................................................................
Ignition Switch
.............................................................................
Ignition Switch Removal or Installation
GRefer to the Base Manual noting that the rubber
damper and the bracket are not on the model.
Switches
A. Ignition Switch Terminals: BR, W
B. Light Switch, Engine Stop Switch, and Starter Button
Neutral and Reverse Switch Inspection Connector
GRefer to the Base Manual noting the following.
-Remove the seat.
To Starter Button
*If the fan does not rotate at this time, the fan is
defective and must be replaced.
Fan Switch Inspection (U K Model)
BR BL [ WARNING.
OFF
o Be careful not to touch the fan blades to avoid injury .
ON c
*If the fan rotates, inspect the fan switch or the wiring
(see Electrical Wiring section in the Base Manual and
Switches section in this manual).
~BRj
to the Wiring, Cable, or Hose Routing section in the @
General Information chapter.
+
®L BL~
BL
Fan Motor Inspection CD
-Unfasten the upper strap of the vinyl cover and open
the velcro (see Switches section) .
• Disconnect the fan lead connectors. 1. Battery 4. Fan Switch
-Using two auxiliary wires, supply 12 V battery power 2. 30 A Fuse 5 . Cooling Fan
to the fan. 3. lOA Fan Fuse
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APPENDIX 15-1
Appendix
Table of Contents
* : Base Manual
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15-2 APPENDIX
Spark Plug
Considerations for Various Riding Conditions
Carburetor:
Sometimes an alteration may be desirable for good
performance under different riding conditions when
proper mixture is not obtained after the carburetor has Reach
been properly adjusted, and all parts cleaned and found
to be functioning properly.
If the engine still exhibits symptoms of overly rich or
Plug gap
lean carburetion after all maintenance and adjustments
are correctly performed, the main jet can be replaced
with a smaller or larger one. A smaller numbered jet
gives a leaner mixture and a larger numbered jet a richer
mixture.
1. Terminal 4. Gasket
2. Insulator 5. Center Electrode
3. Cement 6. Side Electrode
Spark Plug:
The spark plug ignites the fuel and air mixture in the
combustion chamber. To do this effectively and at the
proper time, the correct spark plug must be used, and A spark plug for higher operating temperatures
the spark plug must be kept clean and the gap adjusted. sometimes may be needed for severe conditions, such as
Tests have shown the plug listed in the General continuous high-speed riding, or towing heavy loads.
Information chapter to be the best plug for general use. Such a plug is designed for better cooling efficiency so
Since spark plug requirements change with the igni- that it will not overheat and thus is often called a
tion and carburetion adjustments and with riding condi- "colder" plug. If a spark plug with too h;gh a heat range
tions, whether or not a spark plug of the correct heat is used - that is, a "cold " plug that cools itse lf too well,
range is used should be determined by removing and - the plug will stay too cool to burn off the carbon, and
inspecting the plug. the carbon will collect on the electrodes and the ceramic
When a plug of the correct heat range is being used, insulator.
the electrodes will stay hot enough to keep all the The carbon on the electrodes conducts electricity,
carbon burned off, but cool enough to keep from and can short the center electrode to ground by either
damaging the engine and the plug itself. This temper- coating the ceramic in sulator or bridging across the gap.
ature is about 400 - 800°C (750 - 1 ,450° F) and can be Such a short will prevent an effective spark. Carbon
judged by noting the condition and color of the ceramic build-up on the plug can also cause other troubles. It
insulator around the center electrode. If the ceramic is can heat up red-hot and cause preignition and knocking,
clean and of a light brown color, the plug is operating at which · may eventually burn a hole in the top of the
the right temperature. piston.
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APPENDIX 15-3
Spark Plug Condition
[i;AUTIO~]
a lf the spark plug is replaced with a type other than the
standard plug, make certain the replacement plug has
the same thread pitA:h and reach (length of threaded Troubleshooting Guide
portion) and the same insulator type (regular type or
projected type' as the standard plug.
a lf the plug reach is too short, carbon will build up on Refer to the Base Manual, noting the following.
the plug hole threads in the cylinder head, causing
overheating and making it very difficult to insert the Engine Doesn't Start, Starting Difficulty
correct spark plug later. Recoil starter not operating
o If the reach is too long, carbon will build up on the Recoil starter springs broken
exposed spark plug threads causing overheating, Recoil starter pawl not engaging
preignition, and possibly burning a hole in the piston
top. In addition, it may be impossible to remove the Overheating
plug without damaging the cylinder head. Cooling fan won't turn over (U K model)
Cooling fan fuse broken
Plug Reach Cooling fan switch trouble
Cooling fan motor broken
Too Short Correct Reach Cooling fan damaged
Cooling fan broken
154 APPENDIX
Rear Brake
Brake not properly adiusted Bolt and Nut Tightening
Linings Qverworn or worn unevenly
Drum worn unevenly or scored
Oil, grease on lining and drum Tightness Inspection
Dirt, water between lining and drum Refer to the Base Manual noting the following.
Overheated
Bolts, Nuts, and Fasteners to be checked
Brakes:
Brake Lever Pivot Bolt
Brake Lever Pivot Nut
Caliper Mounting Bolts
General Lubrication
Lubrication
Refer to the Base Manual noting the following.
This supplement chapter contains only the information unique to the models covered. Read both this
manual's front part (up to p. 15-4) and this chapter for complete information on proper service procedures.
Table of Contents
General Information
Model Identification
KLF300-B2:
KLF300-B3/B3A:
KLF300-B4:
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KLF300-B6:
KLF300-B7:
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Item KLF300-B2
Dimensions:
Overall length 1910 mm
Overall width 1115 mm, (A) 1160 mm
Overall height 1065 mm
Wheelbase 1210 mm
Ground clearance 195mm
Seat height 750mm
Dry weight 223 kg, (A)( B) 226 kg
Curb weight: Front 10B kg, (A)(B) 109.5 kg
Rear 125 kg, (A)(B) 126.5 kg
Fuel tank capacity 9 L, (B) B.2 L
Performance:
Minimum turning radius 2.9 m (Locked axle mode)
2.6 m (Differential mode)
Engine:
Type 4-stroke, SOHC, 1-cylinder
Coo ling system Air cooled
Bore and stroke 76.0 x 64.0 mm
Displacement 290mL
Compression ratio B.6
Maximum horsepower 14.3 kW (19.5 PSI @ 6500 rl min (rpm) , (U) -
Maximum torque 22.6 N-m (2.3 kg -m, 16.6 ft-Ib) @ 5500 rl min (rpm),
(U) -
Carburetion system Carburetor, Keihin CVK32
Starting system Electric starter & recoil starter
Ignition system Battery and coil (transistorized)
Timing advance Electronically advanced
Ignition timing From 10" BTDC @ 2000 rl min (rpm) to
30" BTDC @ 3200 rl min (rpm)
Spark plug NGK DBEA, (A)(8)(C) NGK DRBES-L
Valve timing: Inlet Open 21 " BTDC
Close 59" ABDC
Duration 260"
Exhaust Open 56" BBDC
Close 24" ATDC
Duration 260"
Lubrication system Forced lubrication (wet sump)
Engine oil: Grade SE, SF or SG class
Viscosity SAE 10W-30, 10W-40, 1 OW-50, 20W-40, or 20W-50
Capacity 1.7 L
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Specifications are subject to change without notice, and may not apply to every country.
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Specifications are subject to change without notice, and may not apply to every country.
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Item KLF300-B4
Dimensions:
Overall length 1910 mm
Overall width 1115 mm, (A)(E) 1160 mm
Overall height 1065 mm
Wheelbase 1210 mm
Ground clearance 195mm
Seat height 750mm
Dry weight 226 kg, (A) 228 kg
Curb weight: Front 109.5 kg, (A) 111 kg
Rear 126.5 kg, (A) 127 kg
Fuel tank capacity 9 L, (B) 8.2 L
Performance:
Minimum turning radius 2.9 m (Locked axle mode)
2.6 m (Differential mode)
Engine:
Type 4-stroke, SOHC, 1 -cylinder
Cooling system Air cooled
Bore and stroke 76.0 x 64.0 mm
Displacement 290mL
Compression ratio 8.6
Maximum horsepower 14.3 kW (19.5 PS) @6500r/ min (rpm), (U) -
Maximum torque 22.6 N-m (2.3 kg-m, 16.6 ft-Ib) @ 5500 rl min (rpm) ,
(U)-
Carburetion system Carburetor, Keihin CVK32
Starting system Electric starter & recoil starter
Ignition system Battery and coil (transistorized)
Timing advance Electronically advanced
Ignition timing From 10· BTDC @ 1300 rl min (rpm)to
30· BTDC @ 4000 rl min (rpm) .
Spark plug NGK D8EA, (A)(C) NGK DR8ES-L, (B)(E) NGK DR7EA
Valve timing: Inlet Open 21 · BTDC
Close 59· ABDC
Duration 260·
Exhaust Open 56· BBDC
Close 24· ATDC
Duration 260·
Lubrication system Forced lubrication (wet sump)
Engine oil: Grade SE, SF or SG class
Viscosity SAE 10W-30, 10W-40, lOW-50, 20W-40, or 20W-50
Capacity 1.7 L
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Specifications are subject to change without notice. and may not apply to every country.
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Item KLF300-B5
Dimensions:
Overall length 1910 mm
Overall width 1115 mm, (A)(E) 1160 mm
Overall height 1065 mm
Wheelbase 1210 mm
Ground clearance 195 mm
Seat height 750 mm
Dry weight 226 kg, (A) 228 kg, (B)(C)(E) 227 kg
Curb weight Front 109.5 kg, (A) 111 kg
Rear 126.5 kg, (A) 127 kg, (B)(C)(E) 127.5 kg
Fuel tank capacity 9 L, (B) 8.2 L
Performance:
Minimum turning radius 2.9 m (Locked axle mode)
2.6 m (Differential mode)
Engine:
Type 4-stroke, SOHC, 1-cylinder
Cooling system Air cooled
Bore and stroke 76.0 x 64.0 mm
Displacement 290 mL
Compression ratio 8.6
Maximum horsepower 14.3 kW (19.5 PS) @ 6500 r/ min (rpm). (U) -
Maximum torque 22.6 N-m (2.3 kg-m, 16.6 ft -Ib) @ 5500 r/ min (rpm),
(U) -
Carburetion system Carburetor, Keihin CVK32
Starting system Electric starter & recoil starter
Ignition system Battery and coil (transistorized)
Timing advance Electronically advanced
Ignition timing From 10" BTDC @ 1300 r/ min (rpm)to
30" BTDC @ 4000 r/ min (rpm)
Spark plug NGK D8EA, (A)(C) NGK DR8ES-L, (B)(E) NGK DR7EA
Valve timing : Inlet Open 21 " BTDC
Close 59" ABDC
Duration 260"
Exhaust Open 56" BBDC
Close 24" ATDC
Duration 260"
Lubrication system Forced lubrication (wet sump)
Engine oil: Grade SE, SF or SG class
Viscosity SAE 10W-30, 10W-40, 10W-50, 20W-40, or 20W-50
Capacity 1.7 L
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Specifications are subject to change w ithout notice, and may not apply to every country.
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Item KLF300-B6/B7
Dimensions:
Overall length 1910 mm
Overa II width 1115 mm, (A)(E) 1160 mm
Overall height 1065 mm
Wheelbase 1210 mm
Ground clearance 195 mm
Seat height 750mm
Dry weight 226 kg, (A)(B)(E) 229 kg, (C) 227 kg
Curb weight: Front 109.5 kg, (A)(B)(E) 110 kg
Rear 126.5 kg, (A)(B)(E) 129 kg, (C) 127.5 kg
Fuel tank capacity 9L
Performance:
Minimum turning radius 2.9 m (Locked axle mode)
2.6 m (Differential mode)
Engine:
lype 4-stroke, SOHC, 1-cylinder, piston reed valve
Cooling system Air cooled
Bore and stroke 76.0 x 64.0 mm
Displacement 290 mL
Compression ratio 8.6
Maximum horsepower 14.3 kW (19.5 PS) @6500r/min (rpm). (U) -
Maximum torque 22.6 N-m (2.3 kg-m, 16.6 ft-Ib) @ 5500 r/min (rpm),
(U)- .
Carburetion system Carburetor, Keihin CVK32
Starting system Electric starter & recoil starter
Ignition system Battery and coil (transistorized)
liming advance Electronically advanced
Ignition timing From 10" BlOC @ 1300 r/min (rpm)to
30" BlOC @ 4000 r/min (rpm)
Spark plug NGK D8EA, (A)(C) NGK DR8ES-L, (B)(E) NGK DR7EA
Valve timing: Inlet Open 21" BlOC
Close 59" ABDC
Duration 260"
Exhaust Open 56" BBDC
Close 24" AlDC
Duration 260"
Lubrication system Forced lubrication (wet sump)
Engine oil: Grade SE, SF or SG class
Viscosity SAE 1 OW-30, 10W-40, 1OW-50, 20W-40, or 20W-50
Capacity 1.7 L
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Specifications are subject to change without notice, and may not apply to every country.
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Item KlF300-B8/B8A/B9/B10
Dimensions:
Overall length 1910 mm
Overall width 1115 mm, (A)(B)(E) 1160 mm
Overall height 1065 mm
Wheelbase 1210 mm
Ground clearance 195 mm
Seat height 750mm
Dry weight 226 kg, (A)(B) (E) 229 kg, (C) 227 kg
Curb weight: Front 109.5 kg, (A)(B)(E) 110 kg
Rear 126.5 kg, (A)(B)(E) 129 kg, (C) 127.5 kg
Fuel tank capacity 9L
Performance:
Minimum turning radius 2.9 m (Locked axle mode)
2.6 m (Differential mode)
Engine:
Type 4-stroke, SOHC, 1-cylinder, piston reed valve
Cooling system Air cooled
Bore and stroke 76.0 x 64.0 mm
Displacement 290 mL
Compression ratio 8.6
Maximum horsepower 14.3 kW (19.5 PS) @ 6500 r/ min (rpm). (U) -
Maximum torque 22.6 N-m (2.3 kg-m, 16.6 ft-Ib) @ 5500 r/ min (rpm).
(U) -
Carburetion system Carburetor, Keihin CVK32
Starting system Electric starter & recoil starter
Ignition system Battery and coil (transistorized)
Timing advance Electronically advanced
Ignition timing From 10· BTDC @ 1300 r/ min (rpm)to
30· BTDC @ 4000 r/ min (rpm)
Spark plug NGK D8EA (A)(C) NGK DRBES-L, (B)(E) NGK DR7EA
Valve timing: Inlet Open 21 · BTDC
Close 59· ABDC
Duration 260·
Exhaust Open 56· BBDC
Close 24· AlOC
Duration 260·
Lubrication system Forced lubrication (wet sump)
Engine oil : Grade SE, SF or SG class
Viscosity SAE 1OW-30, 1OW-40, 1 OW-50, 20W-40, or 20W-50
Capacity 1.7 L
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Specifications are subject to change without notice, and may not apply to every country.
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Fuel System
Exploded View
Specifications
Top
ring
T1
"N" mark
2nd
ring
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KLF300-88-
i KLF300-88-
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KLF300-BBA-
Europe Model'
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Australia Mod'el
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Hours of Ch arglng
. Time at Rates Shown
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Ie Igniter Terminal
YiR G/W
~~
~
YIR R/W
~
(BK/W) BL
BK/W
(BK/W) BL
BK/W G/W
Switches
BK/W BK/Y
Push
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JI
• Remove the control unit.
.Set the hand tester to the x 1 kO range and make the
measurements shown in the table.
* If the tester readings are not as specified, replace the @
control unit.
Control U nit Resistance Unit: kO
Tester Positive (+) Lead Connection
A Thermostatic Sensor B. Thermostat
1 2 3 4 5
. 1 - 7- 28 00 6.5-28 17-80
*If the tester does not read as specified, replace the
sensor.
2 00 - 00 00 00 Carburetor Thermostatic Sensor Resistance (Reference only)
Standard: 3.0 - 7.2 kO @12' C (53.6' F)
-
24-
3 6-26 9 .5-40 9.5-40
150
4 4.4-19 1.4-6 00 - 6.5-28
5 13-60 10-45 00 6.5-28 - Carburetor Heater Inspection
• Disconnect the carburetor heater connector.
• Using the hand tester, measure the resistance of the
': Tester Negative (-) Lead Connection heater.
.Connect the tester between the heater terminal and
carburetor ground.
* If the tester does not read as specified, replace the
heater.
3 Carburetor Heater Resistance
Standard: 11 ..... 20 0
NOTE
o The sensor and thermostat must not touch the container
sides or bottom.
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LEfT HANDLEBAR SWITCH CONNECTIONS ICNITICN SWITCH CCHMrCTlOMS Neutrol ~ lIev&ru SW it Ch connections LG Lloht Green o
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Wiring Diagram
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SUPPLEMENT -1998 -1999 MODELS 17-1
Item KLF300B11/B12
Engine Oil:
Grade SE, SF or SG class
Viscosity SAE 10W-30 10W-40, 1OW-50, 20W-40, or 20W-50
Capacity 1.7 L
Drive Train
Primary Reduction System:
Type Gear
Reduction Ratio 2 .888 (78/27)
Clutch Type:
Primary Auto centrifugal, wet
Secondary Auto multi disc, wet
Transmission:
Type 5-speed plus reverse , constant mesh, return shift
Gear Ratio:
1st 3.090 (34111)
2nd 1.928 (27/ 14)
3rd 1.368 (26/19)
4th 1.000 (23/23)
5th 0.769 (20/26)
Reverse 3.072 (26/ 11 x 26/20)
Final Drive System:
Type Shaft
Reduction ratio 4.886 (26/16 x 43/11)
(A) (8) (C) (E) 5.584 (20/14 x 43/11)
Overall Drive Ratio: 10.858 (A) (8) (C) (E) 12.409 @Top gear
Final Gear Case Oil:
Type API GL-5 Hypoid gear oil SAE90 (above 5°C, 41 °F) or SAE80
(below 5°C, 41 °F)
Capacity 0.35 L
Frame
Type Double tubular
Caster (Rake Angle) 3.0°
Chamber 1.00 @1G
Trail 13 mm
Tread
Front 834 mm
Rear 844 mm
Front Tire :
Type Tubeless
Size 22 x 9.00-10
Rear Tire:
Type Tubeless
Size 24 x 11 .00-10
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SUPPLEMENT -1998 -1999 MODELS 17-5
General Information
Item KLF300B11/B12
Suspension:
Front
Type Double wishbone-link
Wheel Travel 125 mm
Rear
Type Torque tube-link
Wheel Travel 120 mm
Brake Type:
Front Disc (Hydraulic)
Rear Drum (Mechanical)
Electrical Equipment
Battery 12 V 14 Ah (A) (B) (C) (E) 12 V 19 Ah
Headlight:
Type Semi-sealed beam
Bulb 12 V 25/25 W (RH/LH)
Taillights:
Bulb 12 V 8 W (RH/LH)
Tail/Brake Lights:
Bulb (C) 12 V 18/5 W (RH/LH), KLF300-B12
Alternator:
Type Three-phased AC
Rated Output 23.5 A @9 000 r/min (rpm), 14 V
Specification subject to change without notice, and may not apply to every country.
AS: Australian Model
EU: European Model
UK: U.K. Model
US: U.S.A. Model
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17-6 SUPPLEMENT -1998 -1999 MODELS
Final Drive
Exploded View (KLF300-B12 -)
HK020 39 Bn c
1. Rropeller Shaft
G: Apply grease.
T1 : 25 N·m (2.5 kg·m , 18.0 ft·lb)
www.midwestmanuals.com
SUPPLEMENT -1998 -1999 MODELS 17-7
Brakes
Exploded View (KLF300-B12, Canada Model)
S j }----\
1":\;------{T2
@~--I::f
HL020288W3 C
1. Brake Switch
Si: Apply silicone grease.
T1 : 1.0 N·m (0.10 kgf.m, 9 in.lb)
T2 : 5.9 N·m (0.60 kgf·m, 52 in·lb)
T3: 1.2 N·m (0.12 kgf·m, 10 in·lb)
T4: 8.8 N·m (0.90 kgf·m, 78 in·lb)
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17-8 SUPPLEMENT -1998 -1999 MODELS
Electrical System
Exploded View (KLF300-B12)
1. Regu lator/Rectifier
2. Tail/Brake Light (Canada Model)
3. Bulb (12 V 18/5 W)
4. 7.8 N·m (0.8 kgf·m, 69 in·lb)
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SUPPLEMENT -1998 -1999 MODELS 17-9
Electrical System
Charging System (KLF300-B12-)
Regulator/Rectifier Output Voltage Inspection
• Remove the seat (see Frame chapter) .
• Check the battery condition (see Battery section) .
• Warm up the engine to obtain actual alternator operating
conditions.
• Check that the ignition switch is turned off, and connect
the hand tester to the battery terminal.
Special Tool- Hand Tester: 57001-1394
• Start the engine, and note the voltage readings at vari-
ous engine speeds with the headlight turned on and then
turned off. The readings shou ld show nearly battery volt-
age when the engine speed is low, and as the engine
speed rises , the readings should also rise . But they must
be kept under the specified voltage.
Regulator/Rectifier Output
Connections
Tester Range Reading
Tester (+) to Tester (-) to
25 V DC Battery (+) Battery (-) 14 - 15 V
• Turn off the ignition switch to stop the engine, and discon-
nect the hand tester.
* If the regulator/rectifier output voltage is kept between the
values given in the table, the charging system is consid-
ered to be working normally.
*11 the output voltage is much higher than the values spec-
ified in the table, the regulator/rectifier is defective or the
regulator/rectifier leads are loose or open.
* II the battery voltage does not rise as the engine speed
increases, then the regulator/ rectifier is defective or the
alternator output is insufficient for the loads. Check the
alternator and regulator/rectifier to determine which part
is defective.
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17-10 SUPPLEMENT -1998 -1999 MODELS
Electrical System
Alternator Inspection
There are three types of alternator failures: short, open
(wire burned out), or loss in rotor magnetism . A short or
open in one of the coil wires will result in either a low output,
or no output at all. A loss in rotor magnetism , which may be
caused by dropping or hitting the alternator, by leaving it
near an electromagnetic field, or just by aging, will result in
low output.
• To check the alternator output vo ltage, do the following
procedures.
ODisconnect the alternator connector [A] .
OConnect the hand tester as shown in the table.
OStart the engine.
O Run it at the rpm given in the table .
ONote the voltage readings (total 3 measurements).
Regulator/Rectifier Output Voltage
Connections
Tester Range Reading
Tester (+) to Tester (-) to
Another black
250 V AC One black lead 39 - 59 V
lead
* If the output voltage shows the value in the table, the alter-
nator operates properly and the regulator/rectifier is dam-
aged. A much lower reading than that given in the table
indicates that the alternator is defective.
Regulator/Rectifier Inspection
Front Fender (see Frame chapter)
Connectors [A] (disconnect)
Bolts [B] and Regulator/Rectifier [C]
®:
tor/rectifier as shown.
• Check Y1 , Y2, and Y3 terminal respectively.
*If the test light turns on, the regulator/rectifier is defective. I I I
Replace it.
*11 the test light does not turn on , continue the test.
HP09018BSI C
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17-12 SUPPLEMENT -1998 -1999 MODELS
Electrical System
Regulator Circuit Test-2nd Step
• Connect the test light and the 12 V battery in the same
manner as specified in the "Regulator Circuit Test-1 st
Step".
• Apply 12 V to the SR terminal.
=-<j'---,@:
I I I
• Check Y1, Y2, and Y3 terminal respectively.
* If the test light turns on, the regulator/rectifier is defective.
Replace it.
*11 the test light does not turn on, continue the test.
' - - - - - ' HP09019BS I C
* If the test light did not light when the 24 V was applied
momentarily to the SR terminal , the regulator/rectifier is
delective. Replace it.
* If the regulator/rectifier passes ali of the tests described,
it may still be defective. If the charging system stili dose
not work properly after checking all of the components
and the battery, test the regulator/rectifier by replacing it
with a known good unit.
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SUPPLEMENT -1998 -1999 MODELS 17-13
Electrical System
Charging System Circuit
CD
~~R~B:~~~ __________________
II I I II >- >-
II >-
"-
""
a>
'1
'"®
~ "'
>- >- >- >>->-3::~~~:;:
P wllj~~
~ TT
I I I I I I I I
0
CD
CD
IIP090UB1I3 C
1. Ignition Switch
2. Alternator
3. Regulator/Rectifier
4. Battery
5. Main Fuse 30 A
6. Load
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17-14 SUPPLEMENT -1998 -1999 MODELS
Electrical System
Wiring Diagram (KLF300B-11, U.S.AlCanadaiAustraria Models)
~
I Coo l ing Fan
Switch
Neutral / Rev erse
Switch
FuseSA
~~
Coo l ing Fa n
~ ~
~~
~
, ~ I
L __ __ _
- - - - - - - - - - --, : to I
Headlight
~
( RH)
Opt ion
@ / BK-c>cJ-R
K/ ¥-!>D-. K I
' I' -CJ<l- R/ y
Y-
1
B K / y-t>£=:J-B K / Y -
R/ y -CJ<J- R/Y
,
~ ~
~
~
lj2/
~.t----' I ;;-.-~;l ~
~
I :-BK /Y-{>' :
I
I~~!k
•• J---, I'----C~
Light ; - - -
L!..!.Y 62 /-.! 0 .!....J <J-BK I , U
,
~
~ ,
m*
~ ~ ~
~~
12V25 /2 51'1
,~: o~ ~
( L H)
L _ _ _ _ _ .J
1111UUIS C
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SUPPLEMENT -1998 - 1999 MODELS 17-15
Electrical System
®N e u t r a I I n die a tor L i g ht 1 2 V 3. 4 W
Option(U.S.A.Modelon l y)
r - - -- - , r -----..,
Ta i I/Brake Light
12V 8/27WX2
I
<J-B l-+::tjt~·'
-<}-BK/Y
I <J-- R-~-'<::''''
L ___ _ _ _ _ _ _ _ _ _ _ _ _ .J
Tail light
12V aWX2
, - - - I B l--CJ
r- BKI Y-c:J<:J-B KI' 'Y~j:t§
, - R --c:J<O-- R -
~
,>
- ~
~;
~
-
~
,>
~
~
~
(, ) (- )
Battery
i~~i
12V19AH
0
Ignition
lb __ ::!J 12V14AH(U. s. A. II "del)
0
Starter Relay
COl I Starter
Regulator ! Circuit
Recti f ie r Rei a y
Starter Motor
Color Code
BK Black
Spark Plug Bl Blue
BR Brown
CH Chocolate
DG lh rk Green
G Green
GY Gco
lB Licht Blu e
' • • 1" . . . . ,IC N co .. Eel, ••• n UIR H , REH U E SI I ICH COUECTIHS lG Licht Green
I gnition
Switch
Cool ing
S.i teh
Fan
F use5A
fl Neutral / Rever s e
Switch
~~
Cool ing Fan
::: ~
~~
I
~
Head light
12V25 / 25W
( R H) o ~
00] M ~
1 SK--l>CJ-' I S K - R / BK~R / BK----
Opt ion
K I ¥---{>O- B K / Y---'
RI Y --c:J<}- ' / Y
SK I Y{>C}-SK I Y-
R! Y -D<J- R/ Y l ~~
, ~
f/\!3/
- ---,---, I ;---:{:;l ~
~
I }- BK / V-[::> :
I
I!~~k
~~ /~O~
__ ..r---, I Y----c:]
Light : - __ ::J
~BK I Y
,J
" - - - - - - ---:::: Tl.-
I
I
@:I R---i.>1---J R
ISpeedomete r
L igh"t .
L _~
BK / Y~K I
D
Y
11 2 V 3. 4 YI I
m#
~ ,
~ ~~
~ ~
CEE
/ BK~R / B K
K I 'I----{>C]o KI Y -
R / Y~R / Y -
Headl ight
1 2V25/25W
( l H)
>-
~ ~
:0::<11::..:
...... a:: ...... m ...... o::a
~
:11 ~
~
~
~
~
~
~
~
~
~
II L175781S C
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SUPPLEMENT -1998 -1999 MODELS 17-17
Electrical System
____________ J
L
~ ~~
~
~
I I
,- - -- , Ta i l l i g h t
12V 81 X2
~
';;;
O~
-ltD
~ ~
~
BL-D
r- B K I Y--CJ<J-B K / Y
I 1 - R---c::kJ-- R
• ..,
~
) 0
._<
r
Q. '0
SM
n, ~
,
~
~n ~
~
11l ~ ~
~~ ~~ ~
~
~
(+) (- )
Battery
i~~i o
12V19AH
I g ni tion
l!: __ ::!J 12V14AH(U. s. A. Model)
Starter Re lay
Co i I Starter
Circuit
Relay
Starter Motor
Co lor Code
BK Bl ack
Spark Plug BL Blu e
BR Brown
CH Chocolate
OG Di r k Oraon
G Green
GY Gray
LB Li c ht 8 1u.
LG Licht Oroon
IU" ' OI " 'I e. o... HI IO U HU1Ul
• HVEHE SII' eM cowuel IO~S
0 Orange
Color BR " G• • , P" s i t i .. n LG Ground RI. P Pink
OFF ," th . . ",h
'" PU Purple
ON Neutral
.- . " R Rod
Reverse
(9805 1-17578 )
•Y White
Ye I low
(98051-1758B)
(98051-11598)
IIRI757BW5 C
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17-18 SUPPLEMENT -1998 - 1999 MODELS
Electrical System
Wiring Diagram (KLF300B-11, U.KlEurope Models)
<J--B K I y-++h
®
/BK-l>CJ-R/BK---
K ( 'f--C:::D-B K / Y
RI Y -c::J<J- RI Y
Headl ight
IlV2S /25 W
(L H)
Pickup Coi I
Alter n <ltor
CD ® CD (DStarter Button
1111671A15 C
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SUPPLEMENT - 1998 -1999 MODELS 17-19
Electrical System
UK Model
,-------- - - - - - - - - -- - - -..,
I
ICarburetor
1
Thermo Sensor I Cnntrol Un i t I I
Accessary Terminal
-iii
I
l~ ~ 1~~~
1
1 ..... lI: ......................
I: BK/{[E/R~H~~
L -
1
1
~
1
1
1
"--BK/Y
LI-i>D--I
Carburetor
Heater 12V23W
-BK
BK /Y
BKl
I
l~l
!::Io::
;;;1
1
r® T8 i r Li g ht s
""'<>:: .......
0:: 1 I2V BWX2
1 ,- ,, ' - - - ~
"""""'I~!iIi ~~:
~ ~
-'""""""' ~
1 -BK I Y-D<J-BK I Y
Heater ,R --cJ<J--R
1 Relay
1
I I ,
~
~
1 I I
1
- l!:: __ ::!J ;:;:::1
~ ~ 1 ~
L - - - - - - - - - - - - - - - - .., I
1
'-,
1
~ ~<
·,•
0
If
r
OM
1 .-
1
1
~
•
1 1
'--n
I
~
1
,
~
1 ~
~lJ
~
-
-,·n ' mr II
1
,
~
~
I
1 ~,
~
~~ ~
#if'
~
~ ~ I I ~
l!:: __ ::!J
~t:
('I (-)
* ~
~
Battery
~»-;;;;::. , J St.t., 12V\9AH
Circu i t ~
II TI ,
;;;j
~
> 0:.
~::;:"""' ' ' ' ' I
T~1'i'
1
~~
Relay 0
w.m
T r .............. Starter Rei ay
~~
1
Regulator i Igniter 1
~
Rectifier
1
1
J
Color Code
~~/;-- Starter Mo t 0 r BK B I a c k
Y/ R
~
Bl B I u e
I gnition
....
COl I
_- - -- - - -- BR B row n
CH Chocolate
DG O. r k Gr .o~
~~"~""~,,
G Gr e e n
GY G"
lB l i ,ht 81"e
Spa r k Plug lG l i .h t Gr •• n
ION I T I ON Sl lle H eO N"E crrOiS HUIUl l un.a Si lleR CO •• HIIO H$ 0 Orange
Color BR I W GY Il •• , P o. i t ion lG IGr oun d . /1 P Pink
OFF I" lh.6U,h St h
I PU Purpl e
ON Neu tra I
Rel/erse • 'od
I White
Y Ye I low
( 98051 -167 1A )
(98051-1672A)
IIRI871AIS C
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17-20 SUPPLEMENT -1998 -1999 MODELS
Electrical System
Wiring Diagram (KLF300B-12, U.KlEurope Models)
Fuse 5A
Q
: ':~'~: I':" &=n-c=-n
(' H }®/BK-{>c}-' / BK~ ' / BK-f>C}-' / BK -
s1
~~
~M
Option
K I 't-{:::>CJ-B K I
' I V -c:J<}- ' I V"
K I ¥-!>CJ-lI K I 'I--
' I v CJ<}- ' I V 1 >
, ~
I,~/~"~R / ~~~ ~~
I
I
I','."
.. .1- RI V
HK / --
lIg ht.-
---C2j
V----[>·
-- , <}-BK / V 11-fr=~~~bJ=b;;;;~~~~~~~~~g
L.!1 V~ 5!... 6 ~ -c>8----- R
SP"d,m.t'~/ V-c=}<J-BK/VL1-+~+-~~-+4-~~--+---------"
li g h t
-
12V3 . 4 1
®
I " -{>C}-, I BK-r-r-
K / 't--[:::::O--B K / Y
' I V -c:J<}- R/ V
Headl ight
12V2S / 25W
( l H)
Pickup C oi I
Alternator
Left Handlebar Switch
(D l i g h t / 0 i m mer Sw i t c h
®Eng i ne Stop Switch
0S tar t e r But to n
11 Ll7B0815 C
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SUPPLEMENT -1998 -1999 MODELS 17-21
Electrical System
UK Model
r------- --------,
I
,Carburetor Thermo Sensor
Cnntro I Un i ~ Accessary Terminal
~
J ~I~11
[
"IW," IR--;:j f;;~
-BK/Y BK/y ~
Lw-l>C}-w
Carbu r etor
.-BK BKl liT
w
L
L ____
_ _ CCI ___ ,
+-I-__,, Tail lights
Hea ter 12V23W a:::~a::: r _ _ _ _ .~~ 12V g"x2
I _ I I ~a::1
IL __
l!:: __ ::!J ;;~ I >
- - - - - - - - - - - - --.., I ~
~
w,
I
Starter Relay
Regulator ! I gn i ter I
Rectifier
I
L-_ _ _-----' I
J
Color Code
lj
BL Blue
Ignition Coi I BR Brown
CH Chocolat e
OG D or k Gr e e n
~"~t,,~~,,
G Gr e e n
GY G ray
lB L ie nt Blue
Spark Plug
IG NITI ON SI IH H CONNECT IO NS NE U TRAl ' REVERSE HITCH CONNECTIONS
lG L i, "t are. n
0 Orange
Color 8R w GY Geu Pos ition LG GrounG R/ W P P ink
OFF PU Purpl e
ON Neutral R R,d
Reverse W White
Y Ye I I 0"
(98051-17608)
(98051-176IB)
11R1760SIS C
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SUPPLEMENT - 2000 - 2002 MODELS 18-1
Model Identification
KLF300-B13 Left Side View
Item KLF300-B13-B15
Drive Train:
Primary reduction system: Type Gear
Reduction ratio 2.888 (78/27)
Clutch type: Primary Auto centrifugal, wet
Secondary Auto multi disc, wet
Transmission: Type 5-speed plus reverse, constant mesh, return shift
Gear ratio 1st 3.090 (34/11)
2nd 1.928 (27/14)
3rd 1.368 (26119)
4th 1.000 (23/23)
5th 0.769 (20/26)
Reverse 3.072 (26/11 x 26/20)
Final drive system: Type Shaft
Reduction ratio 4.886 (20/16 x 43/1),
(EU , UK, AS) 5.584 (20/14 x 43/11)
Overall drive ratio: 10.858 @Top gear, (EU, UK, AS) 12.409 @ Top gear
Final gear case oil: Type API GL-5 Hypoid gear oil SAE90 (above 50 C, 41 ° F) or
0
SAE80 (below 50 C, 41 F)
0.35 L
Frame:
Type Double tubular
0
Caster (rake angle) 3.0
0
Chamber 1.0 @ 1G
Trail 13mm
Tread Front 834 mm
Rear 844 mm
Front tire: Type Tubeless
Size AT 22 x 9.00-10
Rear tire: Type Tubeless
Size AT 24 x 11.00-10
Rim Size: Type 10 x 7.0
Size 10 x 8.5
Suspension: Front Type Double wishbone-link
Wheel travel 125 mm
Rear Type
Wheel travel
Brake type: Front
Rear
Electrical Equipment:
Battery 12 V 14 Ah (EU, UK, AS) 12 V 19 Ah
Headlight: Type Semi-sealed beam
Bulb 12 V 25/25 W L & R
Reverse light (EU , UK) 12 V 10 W
Tail/Brake lights 12V8/27Wx2
Alternator: Type Three-phase AC
Rated output 23.5 Al14 V @9000 r/min (rpm )
Voltage regulator: Type Short-circuit
Specifications are subject to change without notice, and may not apply to every country.
EU: Europe Model, UK: U.K. Model, AS: Australia Model, US: U.S.A. Model
www.midwestmanuals.com
18-6 SUPPLEMENT - 2000 - 2002 MODELS
General Information
Torque and Locking Agents
Torque
Parts
N-m Kg-m ft-Ib Remarks
A~'''"~~:~:~~
.=Clean, adjust, lubricate, tighten, or
replace parts as necessary. of use "., a- "., a- "., a- ".,
«7o0'11-~'o 0
«l0'11-~'o
000
«l0'11-~'o «la-,,OJ See
Page
Engine:
*
Air cleaner--service
Clutch adjustment *
•• •• 2·7
5-3
Valve clearance--check
Fuel system cleanliness--check * •• •• 3-6
(2-10)
Throttle lever play --check
Engine oil--change * •• • ••
(2-4)
(5-11 )
Oil filter--replace *
Spark plug-·clean and gap
•• • •
(5-11)
(14-17)
Spark arrester--clean 3-11
Chassis:
Rear brake adjustment--check *
Rear brake lining wear--check *
•• •• (10-6)
(10-6)
Front brake pad wear--check *
Brake fluid level--check
• •• 10-7
(10-8)
Brake fluid--change
Cable adjustment * •• • • • (10-8)
**
Battery--check 14-6
Steering play--check
General lubrication * • • • (12·6)
15-4
Bolts and nuts--tighten
Final gear case oil--change * •• • •
15-4
(9-6)
Master cylinder piston assembly and
2 years (10·11)
dust seal--replace
Caliper piston seal and dust seal--replace 2 years 10-6
Brake hose--replace 2 years 10·9
* :Service more frequently when operated in mud, dust, or other harsh riding conditions .
* *: Refer to 2, 7, 9, and 10 chapters.
(xx-xx): Reference Page in the Base Manual
www.midwestmanuals.com
18-8 SUPPLEMENT - 2000 - 2002 MODELS
General Information
Wiring, Cable, and Hose Routing
Breather Tube Assembly (California Model)
LF300B0 1W4 C
California Model
Kl3801 W2 C
Specifications
Item Standard Service Limit
Carburetor:
Make, type Keihin, CVK32 - --
Main jet #125 - --
Main air jet #100 - --
Needle jet #6 - --
Jet needle N74T - --
Pilot jet #38 - --
Pilot air jet #140 - --
Pilot screw 2 1/8 turns out - --
Starter jet #65 - --
Service fuel level (from carbu retor 0.5 mm (below) - 1.5 mm (above)
- --
body bottom edge) (CA) 1.5 mm (above) - 0.5 (below)
Float height 17 ±2 mm - --
Idle speed 1 300 ±100 r/min (rpm ,) - --
(CA) 1 300 ±50 r/min (rpm)
Optional parts:
Main jet #120, 122, 128, 130 - --
Pilot jet #35, 40 - --
Starter jet #68, 70 - --
CA: Californian Model
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18-10 SUPPLEMENT - 2000 - 2002 MODELS
Engine Top End
Exploded View
,--- - ---
I
-- ~
Cal ifornia Model
XUII02 .s C
S i \-----1
Vr-----{T2
HL020UBIJ C
1. Brake Switch
2. Boot
Si: Apply silicone grease.
T1: 1.0 N·m (0.10 kgf·m , 9 in·lb)
T2: 5.9 N·m (0.60 kgf·m , 52 in·lb)
T3: 1.2 N·m (0.12 kgf·m, 10 in·lb)
T4: 8.8 N·m (0.90 kgf·m, 78 in.lb)
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18-12 SUPPLEMENT - 2000 - 2002 MODELS
Frame
Exploded View (KLF300-B13 -, UK/Australia Models)
eo
H002043B12 C
1. Shovel Holder
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SUPPLEMENT - 2000 - 2002 MODELS 18-13
Electrical System
Exploded View (KLF300-B13-)
A }-----1
HPOl062BU C
1. Bulb (27/8 W)
2. Bulb (10 W)
T1: 7.8 N·m (0.8 kgf·m , 69 in·lb)
A: Europe/Australia/UK Models (UK Model Apply for KLF300-B13-)
B: UK/Europe Models
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18-14 SUPPLEMENT - 2000 - 2002 MODELS
Electrical System
KLF300-813 - 815 Wiring Diagram (U.S.A Model)
(DRe,erle Indicator
®Nlutrl ' Indic;ator
Neutral/R".r ••
Iinilion Switch
Fr
S. i 'C h Li ,
Hlldl i ,hi
12V25/25W ~
~
~,
~ ~~
"''''
~
R/B K---{:>C}-R/BK l- I-
Hlldli,hl
12V25/25W
(L H)
CIll
R/Y--c:>D-- R/Y I-
BK/Y ---CJ<}BK/Y
~ '" '"
,a::Dla::,~
a::: ~1D,.m
'"m
~~~
#
~
m m
'"
I
[
L-------'Pic:kup Coil
AI t.rnalor
LEFT HANDLEBAR
LIft Hlndl,bar Switch l(rht/Dlmmor 50 It. h
Color R/Y R R/BK BR
CDLI,ht/ Olmm.r Switch OFF
QUE"'ln. Stop Switch LO
HI
I~
I
@Start.r Button '------!
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SUPPLEMENT - 2000 - 2002 MODELS 18-15
Electrical System
2)~
Lieht Switch
OJ
~ H
~1
., .,
~Tail /Brak,
I~
., .,'"
~
~~
L ic hte
2V 8/27WX2
., ., BL---D<J- BL /
.,
« ~
'" r- BK / Y ~ BK /Y L~
.rR---c:::J<J-R
\ a
.,
';' '"
~
'--
I
W-
c
--
~
~
/ c
C$ -c
_0
"'~
~ ~ ~ ~ ~
n n. .,,,,
"''-
i!il!!ilIII!I
II}
Bat lery
12V14AH
'enlllDn
c ,I I Stlrt,r R,la,
Starter
C Ire u I t
Rl lul,tor/ Ril,y
Rlctlfi,r
Co lor Cod,
I,nit" M BK Blaok
p Co i I BL Blo,
BR Bro wn
St 'rt, r Motor ,
CH Chocolate
DB hr. a"l.
-
En, ' n Swllc' 9r •• nll P Pink
BK BR Color BR Y/R Color Y/R BK OFF Ur . . . . 5 ..
'"N,utra' PU Purpl.
OFF R,I, II. I ON R R,d
Pu." Rlv,r •• W Wh It,
. .-;> RUN I I Y l,ll ..
(98051-1860A)
lnOClllllAJ C
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18-16 SUPPLEMENT - 2000 - 2002 MODELS
Electrical System
KLF300-813 - 815 Wiring Diagram (Canada Model)
(DR"'rlt I"dle .tor Lie
Op tion 0N,utral Indicator Lie
1- - - - - - - - - - - - - - 1
, H.utrII/Rt¥,r ••
S.II, h
Caal II ~'n i t ion S. it c h
t
Front
Fin S., teb
--l l i I ht !
I
CD ®
.- .- ,. ~
r
~
..... .,
IE CJ:':
..... ..... ClIIE
.,
.,
Y
Y
R/Y-{>O--R/Y-
BK/Y-cJ<J-BK/Yl '" '"
.,
1 '"I '"I
L
~
,......
~~~
., '" ~>:
(jD;
~
/BK--C>CJ--RI BK
He.dli,hl
R/y---t>CJ--RI Y
B KI Y---c::::J<:J---B KIY
,a:::
~ '"
IE ~ID>-m
'"
ID a:: ........ ::.::
.,'" #1 *
~
12V25/25W
(L H)
~~~ ~ '" ~ >- :
Jrrh'iJ
OFF'
'~ __HI'L-·l "
AI t.rnttor
Pickup Call
CD ® ®
Le ft Hlndllb,r Switch
(DLilht/Dimm.r Swlleh
illEn,ln. Stop S.lleh
CDS •• rttr Button
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SUPPLEMENT - 2000 - 2002 MODELS 18-17
Electrical System
Re i ' Br,k.
Lilhl SWi t ch
~
Front Br.k.
Licht Swlt .. h
~ . ~~
ACCls"" Terminll
~ .,
m m m
IC
~~
T, II / Bra k. llcht .
12V 8 / 27W X 2
~
,., .,
BL ~ BL
r- BK/Y ~ BK/Y II
1\
---
"!
e
i
~
m - R ----D<l- R
i m '-
W-
fC:"\ ~
~
.• ...
~
Q
-.
~~
:E
~'
~
11l >
"'
> ~
~
..n "' a:: C!' :.::
n
~
'" >
1+1
~
~
I-)
Bttt.r,.
12V19AH
I, nit Ion
Col I Stut., R.I.,
Slarter
R'lul.tor/ Circuit
R. J.)'
R,Cllfl.f
I ,n it, ·J
• I I Color Cod •
Start.r Motor BK BIIOk
BL Blu.
BR Brown
SPlrk Plu, CH Chacal_1I
DG Darll; Grltn
G Gr •• n
BY Gr"
LB lIH' 11111
LG LI,1Il Gr .. .
'"ITIOI .WIT el COllECT IOU 'E~l'AL l RE'EIIE 'WITCH CO"EeTla •• o Orlnl'
Color BR I W a•• r PD. 1 t I all LG 18, .. ,,4 R/W P Pin k
OFF 111 """' su I PU Purple
ON N.utral R R. d
R.v., •• -' \I Whit.
Y y,llow
(98051-1861A)
LfUOIUU
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18-18 SUPPLEMENT - 2000 - 2002 MODELS
Electrical System
KLF300-813 - 815 Wiring Diagram (Australia Model)
N. u t r a I /R. , • r I •
S.I tch Frol
l enition Bnl
'n ' ij
Cool inl Fan
~
Sw I t co h
W=
BL---!:>D-
__ BL - - - - - - ,
,~ '"I
H,.dllrht
12V25/25W
(RH)
~~
,
~~ ~~ H~ ~
III:': ~........
'"
.......
'"
-"CD ca
@'r)-- R--t>B- R
Speedometer
Li I h-I
L BK/Y --C!<:J-BKI Y
12V3.4W
'" ~'"'
~~~ J' >- >-:
® ,-11. ~ ~
R/BK---c>D R/BK I-
R/Y-!>CJ- R/Y
*
BK/Y---CJ<} BK/Y
Htadlllhi ~
..
>< '"
........ 1E 1D1E , : . :
12V25/25W « ~ID>-m ~~~ J>< >- >-:
(L H) "'
III
~Loi
I
b Horn
§~12V l.5AAllorn.lor
Pickup Coil
G
OFF: HI' :~' rr-h
~
CD
__ ~·l
CD
:11:
CD L -UJHorn Bullon
or L II hi 12V3 . 4W
or Lie hi 12V3.4W
Rear
Brake Lilht
S. it c h
Fro n t
Brat, Lilht
Sw i t c h
6
ti
.,~ .,'"
.,~ .,'"
~~
Accesli.ry Terminal
~l
., .,'"
~
~
.,'" ~~ .------B L--c:J<J--B L-"-H+""
r s:
.---- Tai I/Brlt. Licht
i
- BK/Y-D<J-BK/Y 12V 8/21WX2
'"
i .,
~ r R --CJ<J-- R----'.-'.;;:-
\ ="l
'-
------rr.-------~----------------_+~_r----rt----------W -
(t) H
8.tt,rl
12V19AH
I,nI I Ion
Coli St.rt.r
SlIrt.r RallY
R"ul.tor/ Circuit
R,ctlfl.r R,II,
lin It. r
Color Code
BK Blick
St.rt.f Motor BL BI u 0
BR Sf awn
CH Chocolat,
Spark Plul DG Duk Grn.
G are,n
GY Gr BY
LB LI,u Blue
LO LI.hl areen
.EBAR SWI TCH CONNECTIONS
h hll'" St., S_lha. Stlrt,r Button
"lIT I 01 '11 Tel CDIIUT tall
Ca I 0 J BR I W
IEUTIAL l REvellE 'W ITe" CO"EeTIOI,
e •• r P"III,. LO 18, .... 11 R/W
o
P
OrIn,.
PI nk
BR Co lor BR Y/R Colar Y/R BK OFF lit Ur ••• 111 5111 I PU Purplo
OFF R.I .... ON N.utr.1
R Rod
.,
II)
RUN
_L p" h RIVlr •• I
(98D51-1862A)
W Wh It 0
Y V,llow
LfJDD80UI C
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18-20 SUPPLEMENT - 2000 - 2002 MODELS
Electrical System
KLF300-B13 - B15 Wiring Diagram (U.K Model)
CD R,VlrI. Indicator Lilt,
0 N,u t f l l 'ndlcator li, ~
I,nition Switcb
C.rb
Neutr.I/R,Ylrs.
©==::===~C"~~==~l
S. i t c h
Cool inl Fan Swich
Fuse SA KO 1/2W
Coolin.
Heldll,ht
Fan
toe = - _ B_L ------:>~ ! ~~
~ ~ ~~
12V25/25W
(R H)
(ID; /BK-t>CJ-R/BK -
R/Y---t>CJ-R/Y
R/BK{>C}-R/BK-
R/Y -!>D-R/Y-
>
~ ~
9
BK/Y-CJ<]-BK/Y r- - BK/YCJ<::]-BK/Yl '"
Opt Ion I
It
I \
j )-i--R/;K-=C;:l
}--- R/Y- ---£:> I
j - B K/Y -.."----' I
Iwork Li-; h l r - - -~-~ -<}-BK/Y-l-++---1
[1_2~65/~~!J --r>B--R
sP"dom'I'~~Y~BK/yL4-+~---+-+~1-~-+~---~-~~-~
. LII h I
12V3.4W
(ID; / BK-t>CJ-R/BK-
R/Y---t>CJ-R/Y -
BK/Y-CJ<]-BK/Y-
H.ldlllni
12V25/25W
(L H)
1
PI ckup Col
H0 r n
12V1.5A
~E_~le~c~tr~ic~a~I~S~Y~SlEt~e~m~==========S=UU~PPLEMENT
=
" u, .. "" ====~~-=2=OO=O~-~2~~~~~~~1
002 MODELS 18-21
or L • 4W
;(hI12V3 , 4W
Ca,bu' ttor BK
BKl 1
W Tai!/Br.kl
~~
He.t,r l 2V23 LI I h t I
12V 8/27WX2
.[Pl >- ><
~ '" fl
.. ,., ""'1lJilil
HI.ter
R,I.,
-,
"
::!J
I
I
~
I
I
LI • h I
OW
I W-
-
--,
l
-
(II 1
SI.lor V~ Blttefy-I
IF~~~~~JI
C ire u i t :!IBR"'"
12V19AH
R,I., I-""" ~
Starter R. I 8 Y
I ,n it, r
R.(ulator/
Recti!'lor
J
M
kup Coil
---L rn I ---Ll_ Color Cod. l
r;=---r~~ B/W _ _ _
YI R ---________---.J==~
Starter lIIotor
I' = II BK Black
BL Blul
U
~ enltion Cui BR Brown
~:
. G
Chocollt
Duk Brltn
•
~~~~""
Gr •• n
6Y Gr.y
LB lI,hl 81
Spark Plu, La lI.1tt a ..
~ o
COIUECTI~
rlill
~R SWITCH CO 1&111110/11 ,WITCII CONNECT I ONI ~ • REVERIE •• Oranr.
EIIIII. St NNECTIOHS a'if POIIIII ITCH
i Colo It,BR ,.Ihll St Color BR W' BY 'Itn" ... 5UII LB II 11111.1 R/W P Pin k
~
Off' Y/R C:;'lor YIR
0' Bullon
B OFF I PU Purpl,
R.I'... K ON
Noultll -T R R,d
I Pu.h Rlv,r.. I W Wh I I.
-'
RUN Y Y,llow
198051-186 3A)
Lf300a04,U C
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18-22 SUPPLEMENT - 2000 - 2002 MODELS
Electrical System
KLF300-813 - 815 Wiring Diagram (Europe Model)
Ignition Switch
Neutrai/R e yersl
5.1 Ie h
Fuse 5A.
H,adlirht
12V25/25W
(R H)
"' ~ ~
""
OOJ L~~
R/B K--J::>L:J-R/ BK R/BK~R/BK ---- >
Op I Ion
R/Y-----{>LJ-R/ Y
B K / y-CJ<J-- B K /Y
R/ Y-----{>LJ- R/ Y -
K/ Y-cJ<:}- BK/ Yl . '"
"-
><
~
SP.o d.n"~/Y-c::J<J-BK/
L I I hi
Y
12V3.IW
-
.
~
.
>
~
"-
>< »> ~"- >
.. ><
r-
OOJ R/B K--J::>L:J-R/ BK-
R/Y --t>CJ- R/ Y-
~ 0 ~ ~
.... i
BK/Y-cJ<:}- BK/ Y-
AI t.rnator
Pickup Coil
L
L.ft Hlndl.b" Switch
LEFT HANDLEBAR SWI -
(Dlilht/Dimm.r S.ltch Lllht/Dlmmer S.I t c h el ,lI..
Color R/Y R RI'BK BR Colo
<!lEnll •• Slop SWlteh OFF OFF
(!)sta rt.r Button LO
HI RUN
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SUPPLEMENT - 2000 - 2002 MODELS 18-23
Electrical System
~B"k' LICh~.ar
Brake Lllht
'"'2 Front
\V S.I tch H S.i leb
M
CD
~:
T a i 1/8 r I k.
L I ,h t •
. 12V B/27WX2
~ ~~.
m ~
B L ----c:J<l- B L
~
m '" ( -~
-BK/Y~BK/Y
~~.. '"
r-R---c:::J<J---R
'--
~
'- ~..,
'" ~
..,
'"
i i ~
i
I
'"
I -
R1w--c:J<J-- RIW
B R ---c:::J<J--- B R I~
R ",r •• Ll,ht
W- 12VlOW
--
~
~
~'"
0
C~
,-
-
.
~
• - - ~
- n n. ~
III
~
1-)
Battery
..
~
.., .. 12Vl9AH
) Co I I Color Cod.
St.rter Mo tor BK Black
BL B I",
BR Brown
Spark Plug CH Chocol,t,
. DG Dart 8'fI"
G G r I. n
GY Gra,
LB lI,lIt Blut
La lint a".n
AR SWITCH CONNECTIONS IGNITION .W ITC" COllECTIONS IEUTRAl • REYEalE .W ITCH CO.'ECTIO.' o Orin ••
ED,I", StD, S.lld Start.r Bunon Color BR I W I OY Stat POll I hll LB BrDUII4 R/W P Pin k
Co lor BR I Y/R Color Y/R BK OFF I I III I . " . . . 51. PU Purpl,
OFF I R,I, •• , ON Neutral R RId
I PUlh <;- I11III[) Re,., •• I W Wh I t I
RUN ~ Y Y'llow
(9BOSI-IB6H)
LfaGGIIOIU C
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SUPPLEMENT - 2003 - 2006 MODELS 19-1
Specifications
Item Standard Service Limit
Carburetor
Make, Type Keihin ,CVK32 - --
Main Jet #125 - --
Main Air Jet #100 - --
Needle Jet #6 - --
Jet Needle N74T - --
Pilot Jet #38 - --
Pilot Air Jet # 140 - --
Pilot Screw 2 118 turns out - --
Starter Jet #65 - --
Service Fuel Level (from Carburetor 0.5 mm (above) - 1.5 mm (below)
Body bottom Edg e)
- --
Float Height 17 ±2 mm - --
Idle Speed 1 300 ±100 rl min (rpm),
(CA) 1 300 ±50 rl min (rpm)
- --
Optional Parts:
Main Jet #120,#122 , #128, #130 - --
Pilot Jet #35 , #40 - --
Starter Jet #68, #70 - --
CA: California Model
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SUPPLEMENT - 2003 - 2006 MODELS 19-7
Engine Right Side
Specifications
Item Standard Service Limit
Engine Oil
Type API SE, SF or SG - --
API SH or SJ with JASO MA
Viscosity SAE 10W-40 - --
Capacity 1.7 L - --
HU09002BSI ,
cording to the chart.
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19-8 SUPPLEMENT - 2003 - 2006 MODELS
WheelsfTires
Front Hub
Front Hub Installation
A
eTighten:
Torque· Front Hub Nuts: 34 N·m (3.5 kgf·m, 25 ft-lb)
e Insert a new cotter pin [A].
NOTE
o When inserting the cotter pin, if the slots in the nut do
not align with the cotter pin hole in the axle, tighten the
nut clockwise fBJ up to next alignment.
HJ070078S1 C
O ft should be within 30 degree.
OLoosen once and tighten again when the slot goes past
the nearest hole.
e Bend the cotter pin [A] over the nut [B].
~
A
I
~
r----
Il J07008B$ 1 C
Rear Hub
Rear Hub Installation
e Refer to the above figures in the Front Hub Installation.
eTighten:
Torque · Rear Axle Nuts: 145 N·m (15.0 kgf·m, 110 ft·lb)
elnsert a new cotter pin [A].
NOTE
o When inserting the cotter pin, if the slots in the nut do
not align with the cotter pin hole in the axle, tighten the
nut clockwise fBJ up to next alignment.
O lt should be within 30 degree.
OLoosen once and tighten again when the slot goes past
the nearest hole.
Exploded View
T3
~
o
~ /®-~
~>
I-® i~'j
~ .~ l
~ i~ ~~
~~ ~ "
0'
HL02007BU C
~002013 B .~ C
Exploded View
KP02031BU t
1. Ignition Switch
3. Cooling Fan SWitc~glne Stop Switch
2. Light Switch and E .
4. Australian Model
5. Other than USA M
6 . U.K. Model . . . odels
7. Optional Parts
8. KLF300-B1 7 -
T1: 7.8 N·m (0 .80 kgf.m, 69 in.lb)
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19-12 SUPPLEMENT - 2003 - 2006 MODELS
Electrical System
Wiring Diagram (U.S.A. Model)
KLF300-B17rv
Neutra I/Reverse
Switch
- -
Headl ight
12V25/25W
( R H) oo=F I"
,I
R/
----c>CJ- RI B K - R/BK-l>C}R / B K -
V----r:>e:J-< , I V-
V -c:J<J- R/V
-<!, I ¥-[:::>CJo , I V-
R/V -c:J<J- R/VJ
~Q
,
~
~
~
~
0
~
,
~
I
Opt ion
I
~(J-~-t--- RI ,-;-=r:;l
1- B K / ¥---[:> I
I
I
L
__ I-R/V -L~
I'Iork Light
~2!65 / 6~W_ ~
,-- <:J--BK I V J
::--D-
I - -~ - - -= R---[::1----J
Option
-
R
\~---,
I : I
I LBK I V{::::j<J-BK I V
5peedometer L ight I
C 12V3.41'1
------
.---J
~
-.>-. . . <>:: ,:c::""""
1%1 . . . . 1%1 ~ ~ ~
~ ,
,- ~ ~ ~ ~ ~
® ~
R / BK ----[>[:=J-R I B
Headl ight
12V2S / 25W
( L H)
B K I 'f----[>O-B K I V-
R I Y ----cJ<:} R / V -
~
,
~
~
~
#
~ ~
WZL0021 Al5 C
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SUPPLEMENT - 2003 - 2006 MODELS 19-13
Electrical System
(DRevers e
® Ne u tral
Indicator Li ght 1 2 V 3 .
In dicator Li ght 1 2 V3 .
... Rear Bra k e
Accessarv Term inal
e
L i &: h t Switch
Front Bra k e ,-
Li ght Swi tch ,-
t:
I
CD CD
M
~ ~
m m
- ~
~ ~
m m ~
~~
~ ~ ~ , 8j
~
~ m ~
m
~- ~~
~ ~
m m
Ta i IIBrake
~~
li ,hts
12V S / 27'11'X2
, ~ ~
~ ~ r - - Bl -c:::J<J-
Bl
8j
m m r- BK / Y-c:::J<}- BK I Y
i
~ ~
8j
-R - D < J - R
~ ~ ~
m
1
'-'
((! ..,
~
c
.- <
:) 00
~~
- ,
~
11 n- n.D
~
~:/
m
,
~
,
~
*~
~
~
~ ~
m
m~ ~
mr
I<I (-J
~
Battery
lillnn
12Vl4A H
....... ...J ....... 0:::-:
111,,·~~j
I I
",I,;;
II nit i .. "
Co i I
l!:: __ ::!J
Starter Starter Relay
-
Ci r cuit
Regula tor!
Rec tifier
I Rei ay
~
M
Color Code
~~~,~,~
BK B lack
Starter Mo tor Bl Blue
BR B r o. n
CH Chocolate
Spark PIUI DO Dirk Gt een
G Green
GY Gn
LB l; '~t S lu _
LG l; '~t G",n
,u" ,n U I H. CGU H IlOO I UUIIH , REVERSE $l ITe M CO NNE CT i o n
0 Oran~e
Color
OFF
BR
I
• GI • •
I It
Po s itio n
t h".,h 5H
LG Ground R/ 'II P
PU
Pink
Purple
ON Neutral R R.,
Reve r se
•
Y
'll'h i te
Ye I low
( 98052 - 1 13 1 A)
(98 052 -0021A)
ItR002 1A1S c
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19-14 SUPPLEMENT - 2003 - 2006 MODELS
Electrical System
Wiring Diagram (Australian Model)
KLF300-B17rv
Fuse5A
Headlight
12V2S / 25W
( RH )
/
CID
B K--[>{J-R / B K RIB K-C>D-R / B K
K I ¥--!>CJ-B K I, BK/V-c>D-SK / Y
Option
R/Y -D<J-R / Y 'I, -CJ<J- 'I,
- """'--e---' I ;---~;l
f/\!3/
I f--BK / Y--[> :
I __ ..1----, I ,----L]
I!~~k l i ght ; - __ ::J
L!..!.Y 62 / ~ O.!....J <J-B K/ v-+-H--,
C!rE
I BK---[>CJ-R / B K
K / 'f----[::::O-B K / Y
R( Y ----D<J R/ V
Head light ~ ~ =
mm
12V25 / 25W
( L H)
i
L.ft
'i'Li,n
~
""dI.b"
t/ Dimmer
S.;'oh
Switch
~S!=jS:::~::;b
L T-
9" 0
~~1~~nl . 5A
:~ Alternator
Pickup Co i I
-
Co l or RISK BR Color BR Y Co l or 8K
OFF OFF Release
LO Pus h <;-
HI 'UN
12L0022AIS C
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SUPPLEMENT - 2003 - 2006 MODELS 19-15
Electrical System
Rear
Brake Light
Switch
ft"~:
Front Accessary Terminal
Brake light
CD @
M
'8~~ ~~ B r;v
J ~
m
" T a i I / B r ake
12V 8 / 2 HI'X2
Li,ht
J)
~ ~~ J ~ BL---c::J<J-B L
~ ..... "'" m
I I y-cJ<J-a K I
1 T
-B KI Y
I
J ~
m r' ----CJ<J-- , ~
•
~1
1'=< :/
.0
2~
III ~ ~ ~n
~~ ~~
n, ~
~
~
~
(+) (-)
Battery
i~~i
12V19AH
Ignition
lJ:: __ ::!J
Starter Rei a y
Co j I Starter
Circuit
Re lay
Co lor Code
BK Black
Spark Plug BL Blu e
BR Brown
CH Chocolate
OG Dirk Green
G Green
GY G"
LB Lil ht Blue
LG LiJ;t.t a'ccn
-
,U",OI II ITC. COOOl'I,OOl NEUTRAL
• REVERSE SlilCH CO U ECllon
,I,
Color
OFF
ON
BR • 6e. , 1'0 .
t~''''ft
'"Neutra I
j
...
t i on LG Ground
0
P
,
PU
Oran
P ink
Purple
•
R,d
Reverse
(98052-11321.)
•Y White
Ve I low
(98052-0022A)
12R0022A15 C
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19-16 SUPPLEMENT - 2003 - 2006 MODELS
Electrical System
KLF300-B17 rv
Ignition
S. it c h
Fuse SA
~~
BL
Headl ight
.!-l
, ~
12V25 / 25W ~ m
(ID' ~~
( RH) ~ ~
~
I BK --l>D-' I " - . - . I ' ,--{>C]--. I " -
B K I Y --[>c::J-- 8 K 1'-
,
f- BK I '--{>C]--BK I , -
Option
• I , --c:J<J-' I I , -c:::J<)-. I 'l '
~
~
m
17~~
--'::"1-., I ~-=i:>l
m
I
I
:--BK/V-{>"
•• J--'IY -r~
1".0_' k L j I h t r - - -
I
<J-BK I , U l
L.!..! V.! 5!.... 6 ~ R ----£>B----- R
S, •• d 0
Li ght
.,.~ ,-c::J<J-" I I ,
~
12V3.4W
~ ~ ~ m
m ~ ~
~<><:;"'::a)
,
~
~
~
,
~ P2. ~ ~
~ ~ ~ ~
m m ~
(ID'1'
m
R/ BK--l>D-R I BK
BK I , --[>c::J--BK I ,-
.1,, -
~~~ ~;;:::;
Headlight
12V2S / 25W
( L H)
ULOG23AWS C
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SUPPLEMENT - 2003 - 2006 MODELS 19-17
Electrical System
~
Fro n t Brake Li ght
Switch
I
00
M fl r El
m m
~
m
~
m
~~ ~
Tai I / Brake
lights
~ ~~ ~~
~ ~~
~;;; 12V 8 / 27'f1X2
~ ~ m
m m
i
,
~ ~
1
~
'I
~
~
----------~--+_t_----_+~----------t_+_----_+~----~_+-------R/~
~
R /.~
j
m
::::::::::::::::::::::~~::i::::::::::::~~========~~====~~====~J-~~~~==-~B~R~~BR
"
~ Reverse
12 V 1 OW
Light
~ , ~
~ ~
m
~
,
) ~
m
(.) (-)
Battery
12V19AH
77
I gn It Ion Rei ay
Starter
Co i I Stater
Circuit
Relay
Regulator /
Rectifier
I g nit e r -.J M
Color Cod e
Starter Motor
"
BL
BR
BI a c k
Blue
Brown
Spark Plug eH Chocolate
00 o. r ~ Gr e e n
0 Gr e e n
GY G ray
LB L i ,h t Blye
LG L iE h t Gr e e n
I G~ITlII N HI TCH COHHECIIOHS HEUIU L I HOEHH SIlltH COUECIIONS Orange
0
Color
OFF
BR
• GY Geo.
I ..
Position
tn ,eUlh h I!
lG Grou~GI R / 'Ir
I
P Pink
PU Purple
ON Neutral R Rod
Reverse
•
y
White
Ye I low
(98052-1133A)
( 98052 -0 023A )
nR0023AII5 G
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19-18 SUPPLEMENT - 2003 - 2006 MODELS
Electrical System
Wiring Diagram (U.K. Model)
KLF300-B17 ;-v
Fuse 5A
Cooling Fan
Head light
12V2S / 25W
( RH)
/BK-{>CJ-' /BK-
Option
I.~/
':::'_-1- , I
®B-;;-=C;l K I I'--{>C]--e KI
R / Y -c:::rc:J- R / Y
I :----s K/ Y----[::> I
I __ r ' I Y --{:2j
j'll'.o_rk Lightr- - - <:}-BK / Y--+++'
L.!.1V~5!...6~ -c>8- R
SP"do,.t'~/Y-c=}<J-BK/y·"=~=ti=~t:Ei=ti=t===~====t:===t=t====~==========~r----=====
light
12V3 . 4W
1-
J~ ~
~ ~
®
/BK-{>CJ-R/BK
K / 'f--C::D-B K I Y
, I Y -c:::rc:J- , I Y -
~ ». '2
Headl ight
12V2S / 25W
( l H)
J_112yH~~;A
'b6~
OFF"~~OH_~o~':P-"
~
Left Handl ebar Switch
(D l ight / O immer Switch
:L
lli
'tj---l CD CD CD
®Engi ne
(DSt arter
Stop
Button
Switch
Horn Button
LEFT HANDLEBAR SW ITCH CONNECTIONS
..- ..-
Co lor ,/Y ,
L i ght / O i mller Switch
RI SK BR
Enline
Color
Stop
BR
Sw i tch
Y/ ,
Starter
Co lor
But ton
Y/ , 8K
OFF OFF R II I II a S II
LO Push
HI 'UH I
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SUPPLEMENT - 2003 - 2006 MODELS 19-19
Electrical System
@ -/
~
~l~~~
~I ' ~'" .
BK/~[(gr'~H~~
-
Carburetor
"--BK/Y
w---c>D--w
-BK
BK•/Y ~
BKl
~
,~
~
ro ~ Tai IIBrake
Heater 12V23W l~l lights
f"'- ""
12V 8/2711lx2
"'""""'Il!~1 ~~
,--- ~ ~
BL'" Bl
~
"
~ ~
81
Heater -, -----D<J--' 81
Relay
I I
-
I
~ :!J
I
~~
, - - - ' I W-cJ<:]-, I .
r--B '---D<I---B , (~
"
~ ~
,~
Reverse l i ght
~
ro 1 2 V lOW
.~ ..,
~<
I O~
0
lf~
11 . . -i 00'--r-II
I
~
,
~
~
ro
~,
~
m~ #~"
I I ro ; ~
ro
~ __ :!J 1» (- )
~
)<:j~ ~~~~ ~~
T Battery
Stater
12V19AH
Circuit
~
Hlff/n
Relay
I)C>-~ ~~
'" !z
I IT! " ~~
Starter Rei a y
Regu lator /
I gniter
~
Reet ifi er
Color Code
§§=~Y // W, Starter Motor BK u e BI ack
g Ignition COl I
Bl
CH
BI
BR Br own
Choco I at e
DGG Green
Da rk Gr eo n
:0.~~~'" GY
lB
G ray
L ic ht B l ue
Spa r k PI ug
I GH I T I ON SI I TCH CONHE CT IONS H€ U IRA t ' UYEMSE SI I ICH COU EC IIONS
lG0 L i lht
Orange
Green
Color
OFF
BR
• GY Ge. r
lot
Posit i on
th ' O ~ l h 5t h
lG Ground ' I. P
,
PU
Pin k
Purple
ON Neutral 'od
Reverse
•
y
Whit e
Ye I low
(98052-1134A)
(98052-0024A)
W2R002HI5 c
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KLF300
BAYOU
Kawasaki 4X4
e_n_e_ra_I_I_n_fo_r_m_a_t_i_o_n_____________1_11
~G__
~F_u_e_I_S~ys_t_e_m_________________2_11
~E_n~g~in_e__
To~p~E_n_d______________ 3_11
Le_f_t_S_id_e______________4_11
~E_n~g~in_e__
R~ig~h_t_S_id_e_____________5_11
~E_n~g~in_e__
II
~E_n---,g=-i_n_e_R_e_m_o_v_a_I/_1n_s_t_a_lI_a_ti_o_n______
6
Engine Bottom EndlTransmission 7 II
WheelslTires
L - - -_ _ _ _ _ _ _ _ 8 II
~F_i_n_a_I_D_r_iv_e_____________________9~1I
Brakes 10 11
Suspension 11 11
Steering 12 11
Frame 13 11
Electrical System II 14
Appendix 15 II
Supplement - 1990 - 1994 Models 16 II
Supplement - 1995 - 1998 Models 17 II
This quick reference guide will assist
you in locating a desired topic or pro-
cedure.
Supplement - 1999 Model 18 •
-Bend the pages back to match the
black tab of the desired chapter num- Supplement - 2000 - 2002 Models 19 .
ber with the black tab on the edge at
each table of contents page. Supplement - 2003 - 2006 Models 20 •
-Refer to the sectional table of contents
for the exact pages to locate the spe-
cific topic required.
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KLF 300
BAYOU 300
Kawasaki 4x4
© 1988 Kawasaki Heavy Industries, Ltd. 15th Edition (1) :Mar. 16, 2007 (K)
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LIST OF ABBREVIATIONS
A ampere(s) Ib pounds(s)
ABDC after bottom dead center m meter(s)
AC alternating current min minute(s)
ATDC after top dead center N newton(s)
BBDC before bottom dead center Pa pascal(s)
BDC bottom dead center PS horsepower
BTDC before top dead center psi pound(s) per square inch
°C degree(s) Celcius r revolution
DC direct current rpm revolution(s) per minute
F farad(s) TDC top dead center
of degree(s) Fahrenheit TIR total indicator reading
ft foot, feet V volt(s)
9 gram(s) W waU(s)
h hour(s) n ohm(s)
L liter(s)
NOTE
o The phrase "remove or render inoperative any device or element of design" has been generally
interpreted as follows:
1. Tampering does not include the temporary removal or rendering inoperative of de-
vices or elements of design in order to perform maintenance.
2. Tampering could include:
a.Maladjustment of vehicle components such that the emission standards are ex-
ceeded.
b.Use of replacement parts or accessories which adversely affect the performance
or durability of the motorcycle.
c.Addition of components or accessories that result in the vehicle exceeding the stan-
dards.
d.Permanently removing, disconnecting, or rendering inoperative any component or
element of design of the emission control systems.
WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL LAW,
THE VIOLATION OF WHICH IS PUNISHABLE BY CIVIL PENALTIES NOT EXCEEDING
$10,000 PER VIOLATION.
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To minimize the noise emissions from this product, Kawasaki has equipped it with effective
intake and exhaust silencing systems. They are designed to give optimum performance while
maintaining a low noise level. Please do not remove these systems, or alter them in any which
results in an increase in noise level.
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Foreword
This service manual supplement contains • Remember to keep complete records of main-
only the information unique to the models cov- tenance and repair with dates and any new
ered. It must be used with the base service parts installed.
manual listed below. Read both this sup-
plement and the base manual for complete How to Use This Manual
information on proper service procedures for
the models covered by this manual. In this manual , the product is divided into
its major systems and these systems make up
Base Manual Part Number the manual's chapters. The Quick Reference
KLF300 Service Manual 99924-1057 -02 Guide shows you all of the product's system
This manual is designed primarily for use by and assists in locating their chapters. Each
trained mechanics in a properly equipped shop. chapter in turn has its own comprehensive Ta-
However, it contains enough detail and basic in- ble of Contents.
formation to make it useful to the owner who de- For example, if you want ignition coil informa-
sires to perform his own basic maintenance and tion , use the Quick Reference Guide to locate
repair work. A basic knowledge of mechanics, the Electrical System chapter. Then , use the
the proper use of tools, and workshop proce- Table of Contents on the first page of the chap-
dures must be understood in order to carry out ter to find the Ignition Coil section .
maintenance and repair satisfactorily. When- Whenever you see these WARNING and
ever the owner has insufficient experience or CAUTION symbols , heed their instructions!
doubts his ability to do the work, all adjust- Always follow safe operating and maintenance
ments, maintenance, and repair should be car- practices.
ried out only by qualified mechanics. A WARNING
In order to perform the work efficiently and
This warning symbol identifies special
to avoid costly mistakes, read the text, thor-
instructions or procedures which, if not
oughly familiarize yourself with the procedures
correctly followed , could result in per-
before starting work , and then do the work care-
sonal injury, or loss of life.
fully in a clean area. Whenever special tools or
equipment are specified , do not use makeshift
tools or equipment. Precision measurements CAUTION
can only be made if the proper instruments are This caution symbol identifies special
used , and the use of substitute tools may ad- instructions or procedures which, if not
versely affect safe operation . strictly observed, could result in dam-
For the duration of the warranty period, age to or destruction of equipment.
we recommend that all repairs and scheduled
maintenance be performed in accordance with This manual contains four more symbols (in
this service manual. Any owner maintenance or addition to WARNING and CAUTION) which will
repair procedure not performed in accordance help you distinguish different types of informa-
with this manual may void the warranty. tion.
To get the longest life out of your vehicle:
NOTE
• Follow the Periodic Maintenance Chart in the
Service Manual.
o This note symbol indicates points of par-
ticular interest for more efficient and con-
• Be alert for problems and non-scheduled
venient operation.
mai ntenance.
• Use proper tools and genuine Kawasaki Vehi- • Indicates a procedural step or work to be
cle parts . Special tools, gauges, and testers done.
that are necessary when servicing Kawasaki Olndicates a procedural sub-step or how to do
vehicles are introduced by the Service Man- the work of the procedural step it follows . It
ual. Genuine parts provided as spare parts also precedes the text of a NOTE.
are listed in the Parts Catalog.
• Follow the procedures in this manual care-
fully. Don't take sho rtcuts.
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* Indicates a conditional step or what action to of the system components follows the Table of
take based on the results of the test or inspec- Contents. In these illustrations you will find the
tion in the procedural step or sub-step it fol- instructions indicating which parts require spec-
lows. ified tightening torque , oil , grease or a locking
In most chapters an exploded view illustration agent during assembly.
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General Information
Table of Contents
* : Base Manual
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Model Identification
General Specifications
Item KLF300-C1
Dimensions:
Overall length 1 860 mm
Overall width 1100 mm
Overall height 1 105 mm
Wheelbase 1200 mm
Ground clearance 225mm
Seat height 805mm
Dry weight 257 kg, ® ® 260 kg
Curb weight: Front 137 kg, ® ® 138.5 kg
Rear 128 kg, ® ® 129.5 kg
Fuel tank capacity 11 L, B 8.2 L
Performance:
Minimum turning radius 2.9 m
Engine:
Type 4-stroke, SOHC, l-cylinder
Cooling system Air cooled
Bore and .stroke 76.0 x 64.0 mm
Displacement 290mL
Compression ratio 8.6
Maximum horsepower 14.7 kW (20 PS) @6 SOO rim in (rpm). @ -
Maximum torque 23.6 N-m (2.4 kg-m, 17.3ft-lb) 5500r/min (rpm).
@-
Carburetion system Carburetor, Keihin CVK32
Starting system Electric starter & recoil starter
Ignition system Battery and coil (transistorized)
Timing advance Electronically advanced
Ignition timing From 10° BTDC @2 000 rim in (rpm) to
30° BTDC @3 200 r/min (rpm)
Spark plug NGK D8EA, ® ® © NGK DR8ES-t_
Valve timing: Inlet Open 21° BTDC
Close 59° ABDC
Duration 260°
Exhaust Open 56° BBDC
Close 24° ATDC
Duration 260°
Lubrication system Forced lubrication (wet sump)
Engine oil: Grade SE or SF class
Viscosity SAE 10W-30, 10W-40, lOW-50, 20W-40, or 20W-50
Capacity 2.2 L
Drive Train:
Primary reduction
system: Type Gear
Reduction ratio 2.888 (78/27)
Clutch type: Primary Auto centrifugal, vyet
Secondary Auto multi disc, wet
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Item KLF300-C1
Transmission: Type 10-speed plus reverse, constant mesh, return shift
Gear ratio: 1st 3.090 (34/11)
2nd 1.928 (27/14)
3rd 1.368 (26/19)
4th 1.000 (23/23)
5th 0.769 (20/26)
Reverse 3.072 (26/11 x 26/20)
Final drive
system: Type Shaft (four wheel drive)
Reduction ratio High 5.416 (33/33 x 20/16 x 39/9)
Low 6.910 (37/29 x 20/16 x 39/9)
Overall drive ratio High: 12.037 Low: 15.357
Front final gear case oil Type API GL-5 Hypoid gear oil for LSD SAE140 or SAE85W-14Q
Capacity 0.25 L
Rear final gear case oil: Type API GL-5 Hypoid gear oil SAE 90 (above 5°C, 41°F)
or SAE 80 (below 5°C, 41°F)
Capacity 0.2 L
Frame:
Type Double tubular
Caster (rake angle) 1.0°
Camber 0° @1 G
Trail 5mm
Tread Front 844mm
Rear 840mm
Front tire: Type Tubeless
Size AT 24 x 8-11
Rear tire: Type Tubeless
Size AT 24 x 10-11
Suspension: Front Type Double wishbone
Whee I travel 110mm
Rear Type Torque tube
Wheel travel 120mm
Brake type: Front Disc (Hydraulic) x 2
Rear Drum (Mechanical, on Rightside)
Electrical Equipment:
Battery 12 V 14 Ah
Headlight: Type Sem i-sealed beam
Bulb 12 V 25/25 W x 2
Taillight 12V8Wx2
Alternator: Type Th ree-phase AC
Rated output 23.5 A @9 000 r/min (rpm), 14 V
Specifications are subject to change without notice, and may not apply to every country
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Torque
Parts Remarks
N-m kg-m ft-Ib
Fuel System:
Throttle lever bolt 6.9 0.7 61 in-Ib
Fuel tap plate mounting screws 0.8 0.08 7 in-Ib
Engine Top End:
Spark plug 14 1.4 10.0
Cylinder head bolts: </>8 (used bolts) 29 3.0 22 S
</>8 (new bolts) 34 3.5 25 S
Cylinder head bolts: </>6 12 1.2 104 in-Ib S
Cylinder bolts 12 1.2 104 in-Ib S
Valve adjusting screw locknuts 12 1.2 104 in-Ib
Camshaft sprocket bolts 41 4.2 30
Camshaft chain guide pivot bolt 9.8 1.0 87 in-Ib
Engine Left Side:
Alternator rotor bolt 59 6.0 43
Starter clutch Allen bolts 49 5.0 36 L
Recoil starter flange nut 8.3 0.85 74 in-I b
Engine Right Side:
Oil drain plug 29 3.0 22
Primary clutch hub nU,t 125 13.0 94 o (Se, Th)
Secondary clutch hub nut 78 8.0 58 a
Secondary clutch spring bolts: (used bolts) 12 1.2 104 in-Ib
(new bolts) 15 1.5 11.0
Oil pipe banjo bolts 20 2.0 14.5
Oil pressure relief valve 15 1.5 11.0 L
Engine Removal/I nstallation:
Engine mounting bolts: 8mm 25 2.5 18.0 S
10mm 37 3.8 27
Engine mounting bracket bolts 25 2.5 18.0
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Torque
Parts Remarks
N -m kg -m ft-Ib
Torque
Parts Remarks
N-m kg-m ft-Ib
Pinion gear slotted nut 120 12.0 87 o (Se, Th)
Ring gear cover bolts: 10mm 47 4.8 35 S
8mm 25 2.5 18.0 S
Ring gear bolts 49 5.0 36
Differential case torx bolts 32 3.3 24 L
Rear Final Drive:
Oil filler cap 29 3.0 22
Oil drain plug 20 2.0 14.5
Propeller shaft housing nuts 34 3.5 25
Ax Ie pipe nuts 34 3.5 25
Speedometer gear holder screw 7.8 0.8 69 in-Ib
Ring gear thrust plug nut 54 5.5 40
Pinion gear bearing holder set plug 7.8 0.8 69 in-Ib
Pinion gear bearing holder 120 12.0 87 o (Se, Th)
Pinion gear nut 69 7.0 51 St,O (Se,Th)
Rear gear cover bolts: 10mm 47 4.8 35
8mm 25 2.5 18.0
Brakes:
Bleedvalves 7.8 0.8 69 in-Ib
Brake hose banjo bolts 25 2.5 18
Parking lever lock mounting screw - - - L
Caliper mounting bolts 25 2.5 18
Caliper pad mounting Allen bolts 18 1.8 13.0
Caliper shafts 18 1.8 13.0
Caliper shafts 23 2.3 16.5 L
Disc mounting bolts 37 3.8 27
Brake pipe nipples 20 2.0 14.5
Brake lever pivot bolt 5.9 0.6 52 in-Ib
Brake lever pivot bolt locknut 5.9 0.6 52 in-Ib
Front master cylinder clamp bolts 8.8 0.9 78 in-Ib
Front brake fluid reservoir cap screws 1.0 0.1 9 in-Ib
Rear drum drain bolts 29 3.0 22
Brake panel mounting bolts 34 3.5 25 L
Rear axle nuts 145 15.0 110
Suspensions:
Shock absorber mOl:Jnting nuts 34 3.5 25
Suspension arm pivot bolts: 12 mm 88 9.0 65
Rear suspension arm (rod): 10mm 34 3.5 25
Steering knuckle joint 49 5.0 36 L
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Torque
Parts Remarks
N-m kg-m ft-Ib
Steering:
Steering stopper nut 8.8 0.9 78 in-Ib
Handlebar clamp bolts 20 2.0 14.5
Stem clamp Allen bolts 25 2.5 18.0
Stem bottom end nut 29 3.0 22
Stem bearing housing bolts 20 2.0 14.5
Tie-rod end nuts 41 4.2 30
Tie-rod adjusting sleeve locknuts 27 2.8 20
Tie-rod arm bolts 49 5.0 36 L
Tie-rod arm locknuts 34 3.5 25
Steering knuckle arm nuts 52 5.3 38
Electrical System:
Spark plug 14 1.4 10.0
Alternator rotor bolt 59 6.0 43
Neutral and reverse indicator switch
mounting screws - - - L
Starter circuit relay terminal nuts 4.4 0.45 39 in-Ib
Taillight assembly mounting screws 7.8 0.8 69 in-Ib
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I----®
Strap
_Straps
V-:::::;;;;~~--
ViewR
ViewS
~@
@
~~~-@
Front Front
~ . ~ -----@
Air Cleaner Housing Brackets W
- -,
I
B : UK Model
Clamps
- - - t - . . + - - - - - - Front
Stral's----~ lItt--+--_@
C1amp---~tfB "-- - - @
Straps
Tube A
Tube B -----.r'-----<L
Front
TubeC Clamp
Tube B
Straps
T
A
~@
Front
Scetion AA
Clamp
Front Suspension Arm
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The scheduled maintenance must be done in accordance with this chart to keep the vehicle in good
running condition. The first service is vitally important and must not be neglected.
AherlA~~~~
• = Clean, adjust, lu bricate, tighten, or
replace parts as necessary. of use ~ '!-..~ ~f13 '!-..~ ~03 '!-..~ ~~
~ <:) ~ <:) ~ <:) ~ ~ See
0' 0'~ 0'~ ~ 0'~
~ ~ ~.::i;. ~ Page
Engine:
Air cleaner--service* • • 2-7
Clutch adjustment* • • 5-3
Valve clearance--check • • 3-6
Fuel system c1eanliness--check* • • (2-1 0)
Engine oil--change* • • 5-3
Oil filter--replace* • • (5-11 )
Spark plug--c1ean and gap • • 14-5
Spark arrester--c1ean • 3-11
Chassis:
9-7,20
Joint boots--check* • • 12-4
Rear brake adjustment--check* • • 10-5
Rear brake lining wear--check* • • (10-6)
Front brake pad wear--check* • • 10-8
Brake fluid level--check • (10-8)
Brake fluid--change • (10-8)
Cable adjustment* • • **
Battery--check • • 14-6
Steering--check • • ( 12-6)
General lubrication* • 15-7
Bolts and nuts--tighten • • 15-8
Front and rear final gear case oil --change* • • 9-10,23
Master cylinder piston assembly and
2 years (10-11)
dust seal--replace
Caliper piston seal and dust seal--replace 2 years 10-7
Brake hose--replace 2 years 10-10
* : Service more frequently when operated in mud, dust, or other harsh riding conditions. IS.
**: Refer to 2, 7, and 10 chapters.
(xx-xx): Reference Page in the Base Manual
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Fuel System
Table of Contents
1. Choke L ever
2.. Throttle Cable
3. Choke Cable
4. Throttle Case
5. Starter Jet
6. Pilot Jet
7. Main Jet
AG : Apply adhesive
.' A ppIy grease .
o : Apply·1 01. .
O e ·
. A pply
R : Replace
clean
er element oil.
ment Parts
o
T2: 0.8 N-m (0.08 kg-m, 6~ in-Ib)
T1: 6.9 N-m (0.70
kg-m, 7 m-Ib)
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FUEL SYSTEM 2-3
European Model
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Specifications
Item Standard
Carburetor Specifications
Make, type: Keihin, CVK32
Main jet: #125
Main air jet: #50
Needle jet: #6
Jet needle mark: N36W
Pilot jet (slow jet): #38
Pilot air jet (slow air jet): #140
Pilot screw (turns out): 21/8
Starter jet: #58
Service fuel level (from carburetor body
bottom edge) : 0.5 mm below - 1.5 mm above
Float height: 17 ±1 mm
Engine Speed (for reference) 1 300 ±100 r/min (rpm)
Optional Parts
Main jet: #120, 122, 128, 130
Pilot jet (slow jet): #35,#40
Starter jet: #60,62
Special Tools
Choke Lever and Cable Removal A. Lever Mounting Screw B. Choke Le.ver
• Unscrew the starter plunger cap and pull out the starter
plunger.
• Remove the choke lever and free the choke cable upper
end from the lever .
• Pull off the retaining ring and free the choke cable
housing from the switch housing.
A. Retaining Ring
1. Screw 3. Wave Washer -Tilt the carburetor to the right of the vehicle for easy
2. Plane Washer access to the pilot screw.
Choke Cable Inspection - Reposition the carburetor properly and tighten the
-With the choke cable disconnected at both ends, the clamp screws securely .
cable should move freely in the cable housing. OFit the carburetor ridge into the groove on the duct.
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Air Cleaner
I WARNING'
OA clogged air cleaner may allow dirt and dust to enter
the carburetor and stick the throttle open. This could
cause an accident.
A. Idle Adjusting Screw
*If the engine idle is still not stable, adjust the pilot
screw to obtain the slowest smooth idle speed using the OA clogged air cleaner may allow dirt and dust to enter
pilot screw adjuster "A" (special tool) . the engine causing excessive wear and possibly engine
damage.
I WARNING'
oOperation with an improperly adjusted, incorrect
routed, or damaged cable could result in an unsafe
riding condition.
OTo avoid a serious burn, never touch a hot engine or an
exhaust pipe during carburetor adjustment.
A. Screw B. Stopper
ePull the element off the body, then off the inner metal
net. A. Drain Hose
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WARNING'
o Fuel spilled from the fuel tap is hazardous.
I WARNING'
oGasoline is extremely flammable and can be explosive
A. Top Cover 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;
el nstall the fuel tank cap at once. this includes any appliance with a pilot light.
eRemove the breather and vent hoses from the clamp on
the rear of the fuel tank. eRemove the fuel tank upper cover by taking off the
eRemove the four tank mounting bolts. two mounting screws.
eTurn the fuel tap to the OFF position. elnstall the fuel tank cap immediately.
ePul1 the fuel hose off the tap. ePry off the gauge cap and discard the cap.
eBend the front fender tabs outward and remove the -Check the grooves in the fuel tank boss. If the grooves
fuel tank. are damaged by removing the cap or can not hold the
cap nails, the fuel tank must be replaced.
-I nstall the fuel level gauge so that the Y2 scale faces the
front.
-Push the new gauge cap over the gauge so that the
notch aligns with the 12 scale. Fuel Tank Damper Installation
-Apply an adhesive which is recommended by the
manufacturer for bonding rubber to metal to the inside
of the rubber dampers and install them as shown.
-Face each split of the dampers inward of the vehicle.
A. Front C. Notch
B. 12 Scale
Exploded View
.@
Refer to the Base Manual noting the following. Cylinder Head Remova/
e Remove the following parts.
Camshaft Cam Height: Front Fender (see Frame chapter)
Inlet, Exhaust: 40.642 - 40.782 mm Fuel Tank (see Fuel System chapter in this text)
(Service Limit: 40.54 mm) Carburetor (see Fuel System chapter in the Base
Cylinder Compression (Usable range, with Manual)
compression release operated) Exhaust Pipe (see Exhaust Pipe Removal)
Camshaft Sprocket (see this chapter)
Using Recoil Starter
Spark Plug Cap
825 - 1 280 kPa Cylinder Head Breather Hose and Hose Clamp
(8.4 - 13.0 kg/cm 2 , 119 - 185 psi) eRemove the cylinder head bracket bolts, the cylinder
Using Electric Starter head mounting bolt, and nut, then take off the brack-
795 - 1 240 kPa ets.
(8.1 -12.6 kg/cm 2 , 115 -179 psi)
Cylinder, Piston:
Cylinder inside diameter:
76.000 - 76.012 mm
(Service Limit: 76.010 mm)
Piston diameter: 75.960 - 75.975 mm
(75.81 mm)
Piston/cylinder clearance: 0.025 - 0.052 mm
Oversize piston and rings: +0.5 and +1.0 mm
Piston ring/groove clearance
Top: 0.03 - 0.07 mm (0.17 mm)
Secondary: 0.02- 0.06 mm (0.16 mm)
Piston ring thickness:
Top, second: 0.97 - 0.99 mm (0.90 mm)
Piston ring groove width:
Top: 1.02 -1.04 mm (1.12 mm) A. Cylinder Head Bracket Mounting Bolts
Second: 1.01-1.03 mm (1.11 mm) B. Cylinder Head Breather Hose and Hose Clamp
C. Cylinder Head Mounting Bolt and Nut
*If the cylinder head or the cylinder head bolts are new
ones, tighten the 8 mm bolts to 34 N-m (3.5 kg-m, 25
ft-lb) of torque.
-First tighten the upper three br.acket mounting bolts, A. Oil Seal C. Washer
then tighten the lower bracket bolt and nut ):0 the B. Return Spring
specified torque (see Cylinder Head Removal and
Exploded View).
A. Return Spring
-Oil the lever shaft and install the washer and lever
A. Bolt C. Front assembly.
B. Compression Releasing Lever -Tighten the bolt securely.
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1. Cylinder Head
o
2. Rubber Dampers A. Timing Inspection Plug C.- T Mark
B. Slot
Valves, Guides, Seats, Springs, Oil Seals e Measure the clearance of each valve between the end of
the valve stem and the adjusting screw on the rocker
arm with a thickness gauge.
Valves: *If the valve clearance is not correct, adjust it (see Valve
Valve Clearance Check Clearance Adjustment).
NOTE
oCheck the valve clearance only when the engine is cold
(cool to the touch). Valve Clearance (when cold)
Intake: 0.10 - 0.15 mm
eRemove the fuel tank (see Fuel Tank Removal in the Exhaust: 0.15 - 0.20 mm
Fuel System chapter).
eTake out the bolts and remove the valve adjusting caps
with O-rings.
Valve Guides:
Valve Guide Installation
-Clean the valve guide hole in the cylinder head.
- Lightly oil the valve guide.
-Heat the cylinder head around the valve guide hole to
120° to 150°C (250° to 300°F) .
- Use the valve guide arbor and a hammer to drive the
guide into the head from the outside until the guide
flange seats against the head.
-Allow the cylinder head to cool.
- Ream the valve guide with the valve guide reamer
(special tool) even if the old guide is reused. A. Camshaft Cover B. Gaps
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eTake out the bolts and remove the valve adjusting caps. eRemove the lock bolt.
e Loosen all the cylinder head bolts to free the cylinder eCarefully pull the push rod out of the tensioner body.
head from the stress (see Cylinder Head Removal). Do not drop the ball and retainer assembly or the
ePull out the rocker shafts and remove the rocker arms. spring.
eSlide the ball and retainer assembly and the spring off
the push rod.
Top
ring
1. Lockbolt 4. Spring
2. Push Rod 5. O-Ring
3. Ball and Retainer Assembly
20mm
1. Rubber Dampers
2. Cylinder A. Compression Releasing Lever
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I WARNING I
OTo avoid burns, wear gloves while cleaning the spark
arrester. Since the engine must be run during this
procedure, the muffler will become hot.
A. Compression Gauge: 57001-212 o The spark arrester must be installed correctly ·and
B. Adapter Hose: 57001-1159 functioning properly to provide adequate fire pro-
tection.
Exhaust Pipe:
Exhaust Pipe Removal Note
eRefer to the Base Manual noting the following.
eFirst, take off the exhaust pipe holder nuts at the
cylinder head.
eRemove the mud guard to loosen the muffler clamp
bolt until the clamp turns freely on the muffler.
o
1. Gasket Stopper of Clamp 3. Gasket
2. Exhaust Pipe 4. Front
eWork the exhaust pipe out of the frame and remove it. Carburetor Holder
1. Projection
* : Base Manual
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Exploded View
~
@ ~/ ,
@@
1. Torque Limiter
G : Apply high temperature grease.
L : Apply non-permanent locking agent.
o : Apply engine oiL
Lh: Left-Hand Threads
R : Replacement Parts
Rh: Right-Hand Threads
T1 : 59 N-m (6_0 kg-m, 43 ft-Ib)
T2 : 49 N-m (5.0 kg-m, 36 ft-Ib)
T3: 8_3 N-m (0_85 kg-m, 74 in-Ib)
T4: 7.8 N-m (0.8 kg-m, 69 in-Ib
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Special Tool
NOTE
oDo not let the rope wedge between the reel and the
housing.
fJecoil Starter
I WARNING'
o Be careful that the spring does not fly loose and does
not injure you. It is under great pressure.
OTurn the reel one-quarter turn counterclockwise past
the rest position where no tension can be felt. Now,
slowly lift the friction plate straight up out of the
housing.
\
1. Pawl
2. Pawl Spring
3. Friction Spring
4. Friction Plate A. Strike bench.
5. Flange Nut
I WARNING'
o Be careful that the spring does not fly loose and does Recoil Starter Assembly Notes
not injure you. It is still under great pressure. eAssembly. is the reverse of disassembly. Note the
o Turn the reel one-quarter tum counterclockwise past following.
the rest position where no tension can be felt. Now, elf the recoil spring was removed, install it as shown. If
slowly lift the friction plate straight up out of the it is not installed correctly, the starter will not operate
housing. properly.
NOTE
WARNING'
o There should be no spring tension on the reel when
removing the reel. Lift the reel slightly. If tension is o The recoil spring must be put under great pressure
felt, push the reel back into place and gently "wiggle" during installation. Wear gloves to avoid injury.
it until the reel may be easily removed.
CD
1. Hook recoil spring end onto the tab. A. Turn reel to wind rope.
eGrease the reel and set the reel into place so that the
hook on the spr·ing catches on the tab in the reel.
NOTE
OPush the recoil spring against the housing securely to
prevent the spring from slipping off during installation.
NOTE
A. Pawl D. Friction Plate Spring Hooks
o Turn the reel counterclockwise to wind the rope B. Pawl Spring E. Grease here.
clockwise. This prevents the rope from twisting. C. Friction Plate
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A. Turn clockwise
1. Torque Limiter
Sub-Transmission Lever
.............................................................................
Sub- Transmission Lever Removal
A. Grooves B. Key -Take off the sub-transmission lever by removing the
following bolts and nut.
A. Bolts B. Nut
Sub-Transmission Case
Torque Limiter Inspection
-Remove the torque limiter and visually inspect it.
*If the limiter has wear, discoloration, or other damage, Refer to the Engine Bottom End/Transmission
replace it as a unit. chapter.
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Exploded View
eLoosen the locknut for the upper adjusting screw. 1. E-Ring 4. Re lease Cam A
eTurn the clutch release adjusting screw clockwise until 2. Clutch Pusher 5. Release Bearing
it becomes hard to turn, then turn the screw back 3. Upper Adjusting Screw 6. Release Cam B
counterclockwise until it becomes hard to turn .
eLoosen the lower adjusting screw locknut and set the
lower adjusting screw so that the eccentric pin is as
close the upper adjusting screw as possible.
eTighten the locknut.
eTighten the locknut without changing the adjusting 1. Upper Adjusting Screw
screw position. 2. Eccentric Pin
elnstall the adjusting screw cover. 3. Lower Adjusting Screw
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Lubrication System
Oil Pump:
Oil Flow Inspection
- Run the engine at idle speed.
I WARNING.
ODuring oil flow inspection, do not open the throttle
valve. Hot oil will squirt out of the banjo bolt, and
may cause a serious burn.
- Loosen the main oil pipe banjo bolt on the left crank-
-Install the right engine cover.
case as shown, and check that the oil seeps out around
- Loosen the locknut for the upper clutch release ad-
the banjo bolt.
justing screw.
-Turn the adjusting screw counterclockwise until it
becomes hard to turn, and then turn it furthe r 12 to
1 turn to the same direction.
Engine Removal/Installation
Table of Contents
* : Base Manual
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~4[f C!D
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Engine Installation
Engine Removal/Installation eEngine installation is the reverse of removal. Note the
following.
eTighten the engine mounting bolts and bracket bolts to
Engine Removal the specified torque (see Exploded View).
eDrain the engine oil (see Engine Right Side chapter in eFirst tighten the upper three bracket bolts, then tighten
the Base Manual). the lower bracket bolt and nut to the specified torque
eRemove the following parts. (see Exploded View).
Front Fender and Rear Fender (see Frame chapter)
Fuel Tank (see Fuel System chapter)
Carburetor (see Fuel System chapter in the Base
Manual)
Exhaust Pipe (see Engine Top End chapter)
Sub-Transmission Assembly (see Engine Bottom End/
Transmission chapter)
-i
'\..
A. Three Bracket Bolts
B. Lower Bracket Bolt and Nut
NOTE
oThe engine can be removed with the sub-transmission
1 . Mounting Bolts 3. Sub-Transmission Case and the rear propeller shaft left installed. But it may
2. Bracket Bolts 4. Dust Cover Clamp Screw be a two-man operation.
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1. Splines
2. Rear Propeller Shaft Joint Boot
~.~
/
.~~ ' i ~'r-------=;.\ ~.Y0
L---.~ .,
®
R
O~ .
L _ _ _ _ _ _ _ -,
pIp
I
:
<!l
:~
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Sub· Transmission
Bevel gear backlash (at drive shaft slotted nut groove)
Socket Wrench: 57001·1214
0.04 - 0.09 ml1;l
Shift fork ear thickness
4.4 - 4.5 mm (service limit: 4.3 mm)
Shifter groove
4.55 - 4.65 mm (service limit: 4.8 mm)
Shift fork guide pin diameter
4.9 - 5.0 mm (service limit: 4.8 mm)
Shift fork lever groove
5.1 - 5.2 mm (service limit: 5.3 mm)
Reverse Knob:
Reverse knob free play
3-4mm Bearing Driver Set: 57001 · 1129
Special Tools
............................................................................
Sealant
Crankshaft Runout
A. Cable Holder B. Reverse Lever Bolt
Left Half Standard: Under 0.03 mm TlR
Service Limit: 0.08 mm TIR -Remove the front fender (see Frame chapter) and the
Right Half Standard: Under 0.04 mm TlR fuel tank (see Fuel System chapter) to free the cable
Service Limit: 0.10 mm TIR from the vehicle.
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NOTE Balancer
aBe careful not to confuse the shift forks.
Balancer Drive Installation Notes
Refer to the Base Manual, noting the following.
Shift Fork Installation
eApply oil to the seating surface and threads of the
balancer drive gear and oil pump drive gear slotted nut.
eTighten the slotted nut to the specified torque (see Ex-
ploded View).
*If none af the toothed washer tabs align, tighten the
nut further just enough to align one of the tabs with a
slot in the nut.
,----@)
A. Slotted Locknuts
B. Socket Wrench: 57001-1282
CD
1. Apply grease.
A. Cam Damper
eTo remove the ball bearings press-fitted in the sub- A. Bearing Holder B. Grooves
transmission gear case, use the bearing driver set
(special tool).
eGrease the front oil seal.
eTighten the following parts to the specified torque (see
Exploded View).
Bearing Housing Nuts (drive shaft)
Front Oil Seal Housing Bolts (output shaft)
-Temporarily, install the toothed washers, washers, and
slotted nuts.
elnstall the sub-transmission case on the engine.
eTighten the slotted nuts to the specified torque (see
Exploded View). Do not bend over a washer tab yet.
CD
eRemove the gears and the shifter. eDrive out the bearing with the bearing driver set
(special tool: PN 57001-1129).
r /®
Drive Bevel Gear Shims Driven Bevel Gear Shims
Thickness Thickness
Part Number Part Number
(mm) (mm)
0.15 92025-1573 0.1 92025-1897
0.20 92025-1574 0.15 92025-1898
0.7 92025-1534 0.5 92025-1899
0.8 92025-1535
0.8 92025-1900
0.9 92025-1536
1.0 (primary) 92025-1537 1.0 (primary) 92025-1901
1.1 92025-1575 1.2 92025-1902
1.2 92025-1538
1.3 92025-1533
NOTE
oApply checking compound to the teeth in a thin, even
coat with a fairly stiff paint brush. If painted too
thickly, the exact tooth pattern may not appear.
oThe checking compound must be smooth and firm
with the consistency of tooth paste.
oSpecial compounds are available from automotive
supply stores for the purpose of checking differential
gear tooth patterns and contact. Use this for checking
the bevel gears.
A. Move B. Dial Gauge e Turn the driven bevel gear for 3 or 4 turns in the drive
and reverse (coast) directions, while creating a drag on
the drive bevel gear.
- Check the drive pattern and coast pattern of the bevel
gear teeth. The tooth contact patterns of both drive
and coast sides should be centrally located between the
top and bottom of the tooth, and a little closer to the
eTo measure the backlash, turn the shifter clockwise and toe of the tooth.
counterclockwise while holding the drive bevel gear * If the tooth contact pattern is incorrect, replace the
steady. The difference between the highest and lowest shim(s) at the drive bevel gear and shim(s) at the driven
gauge readings is the amount of backlash. bevel gear, following the examples shown. Then erase
oTo hold the drive bevel gear steady, another man may the tooth contact patterns, and check them again. Also
turn the shift drum a little from the neutral position check the backlash every time the shims are replaced.
and hold it at the position shown using a wrench_ Repeat the shim change procedure as necessary.
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Heel , t~~ot~m
~!wm TO~
TO~
Toe
Toe Toe
Bottom-fTOP
Toe
1-
1. Drive Gear
~~ 2. Driven Gear
Heel
Bottom Top Bevel Gear Inspection
1. Drive Gear eVisually check the bevel gears for scoring, chipping, or
2. Driven Gear other damage.
Heel *Replace the bevel gears as a set if either gear is damaged.
Heel
2\~~ttom /
TOP~ Toe ,
A. Spring
B. Cam
C. Cam Follower
D. Shaft
NOTE
Olnspect the valve in its assembled state, Disas-
sembly and assembly may change the valve
performance.
I WARNING .
OClean the oil pressu re relief valve in a well-
ventilated area, and take care that there are no
sparks or flame anywhere near the working area.
Because of the danger of highly flammable liquids,
do not use gasoline or low flash-point solvents.
WHEELSITIRES 8-1
Wheels/Tires
Table of Contents
* Base Manual
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8-2 WHEELS/TIRES
Exploded View
.............................................................................
G : Apply grease.
R : Replacement Parts
W : Apply water, or soap and water solution.
T1 : 34 N'm (3.5 kg·m, 25 ft-Ib)
T2: 27 N-m (2.8 kg-m, 20 ft-lb)
T3: 41 N-m (4.2 kg-m, 30 ft-lb)
T4: 145 N-m (15.0 kg-m, 110 ft-Ib)
Front Wheel
Rear Wheel
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WHEELS/TIRES 8-3
Specifications
Wheel Alignment
Caster: 1° (non-adjustable)
Camber: 0° (non-adjustable) @ 1G
Toe-in: 20 mm
Standard Tires
Front: AT 24 x 8-11
Dunlop KT962, Knobby/Trail Tubeless
Rear: AT 24 x 10-11
Dunlop KT962, Knobby/Trail Tubeless
Special Tools
aThis tool may be used instead of the common tool. aBe sure to use this gauge for low pressure tire instead
of the conventional air pressure gauge (52005-1003).
~~\
\ \
\ \ Bearing Driver Set: 57001-1129
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8-4 WHEELS/TIRES
e Hold a straightedge against the rear wheel rim on one
Wheel Alignment side at axle height.
Front Side
A. Straightedge B. Jack: 57001-1238
~-----------B------------~
c D
A
NOTE
OThe white locknut on the tie-rod has left-hand threads.
Turn the wrench clockwise for loosening.
A - B = Amount of Toe-in
(Distance A and B are measured at axle height)
(Distance C and D should be equal)
WHEELSITIRES 8-5
Steering Centering
Toe-in Inspection
-Support the vehicle on a stand or the jack (special tool:
57001-1238) so that the front wheels are off the
ground. Toe-in Adjustment
-Apply a heavy coat of chalk near the center of the -Loosen the locknuts and turn the adjusting sleeves the
front tires. same number of turns on both sides to achieve the spe-
-Using a needle nose scriber, make a thin mark near the cified toe-in.
center of the chalk coating while turning the wheel.
8-6 WHEELS!TIRES
TIe-Rod Length Adjustment Wheel Installation
ePosition the wheel so that the air valve is toward the
outside of the vehicle.
-Check the tire rotation mark on the front and rear
tires, and install the wheels accordingly.
NOTE
o The direction of the tire rotation is shown by an arrow
on the tire sidewall.
Wheel Removal
e Loosen the wheel nuts. eMount the wheel on the studs.
eSupport the vehicle on the jack (special tool) or a stand eTighten the wheel nuts in a criss-cross pattern to the
so that the wheels are off the ground. specified torque (see Exploded View).
'" \ \
WHEELSITIRES 8-7
Rim Dent
CD
®_ r.-t-t-
0 ---1
1. Sealing Surfaces
Wheel Replacement
eRemove the wheel (see Wheel Removal).
eRemove the tire from the rim (see Tire Removal).
oRemove the air valve and discard it. 000 not use engine oil or petroleum distillates to
lubricate the stem because they will deteriorate the
rubber.
o Replace the air valve whenever the tire is replaced. eMount the tire on the rim (see Tire Installation).
000 not reuse the air valve. elnstall the wheel (see Wheel Installation).
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8-8 WHEELS/TIRES
-Kneel on the side of the tire, forcing the tire bead into
Tires the center well of the rim.
Well
-Break the tire beads away from both sides of the rim
with a bead breaker.
- Lift the second bead up into the center well and use
the same procedure as in removing the first bead.
Tire Installation
-Inspect the rim (see Wheel Inspection).
1. Bead Breaker -Replace the air valve with a new one (see Wheel Re-
2. Apply lubricant. placement).
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-Check the tire for wear and damage (see Tire Inspec-
Bead InStallation
tion) .
- Lubricate the tire beads, rim flanges, and the tire irons
(special tools) with a soap and water solution, or water .
I WARNING I
o Do not use the lubricant other than a water and soap
solution, or water to lubricate the tire beads and rim
because it may cause tire separation.
1. Apply lubricant.
Bead Installation
NOTE
o The direction of the tire rotation is shown by an arrow
on the t;re sidewall.
ROTATION
1. Tire Irons: 57001 -1073
8-10 WHEELS!TIRES
-Check the tire pressure using the air pressure gauge for
low air pressure (special tool).
~-I®
1. Rim 2. Suitable Stand \ &
\
\
'
-Inflate the tire until the tire beads seat on the rim.
Maximum Tire Air Pressure (to seat beads when cold) 1. Air Pressure Gauge: 52005-1082
Front and Rear: 250 kPa (2.5 kg/cm 2 , 36 psi)
-Install the wheel (see Wheel Installation).
-Wipe off the soap and water solution, or water on the
tire, and dry the tire before operation.
WARN.ING •
000 not inflate the tire to more than the maximum tire I WARNING.
air pressure. Overinflation can explode the tire with
000 not operate the vehicle with the water and soap, or
possibility of injury and loss of life.
water still around the tire beads. They will cause tire
-Check to see that the rim lines on both sides of the tire separation, and a hazardous condition may result.
are parallel with the rim flanges .
Tire Inspection
-Examine the tire for damage and wear.
Olf the tire is cut or cracked, replace it.
OLumps or high spots on the tread or sidewalls indicate
internal damage requiring tire replacement.
oRemove the any foreign objects from the tread. After
removal, check for leaks with a soap and water solu-
tion.
oCheck the shape of the tread knobs. If no vertical side
is left on the drive side of the knobs, replace the tire.
Tire Inspection
Vertical Sides
Worn Away
1. Rim Line 2. Rim Flange
/---~J---l
-If the rim lines and the rim flanges are not parallel, / ~~
deflate the tire, lubricate the sealing surfaces again, and
reinflate the tire.
/ \
-After the beads are properly seated, check for air leaks.
Olnflate the tire to 45 kPa (0.45 kg/cm 2 , 6.4 psi). Apply
/ \
a soap and water solution around the tire bead and /
,
// I '\
~
check for bubbles.
-Deflate the tire to the specified pressure. -+-
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WHEELS/TIRES 8-11
1. Cotter Pi n
1. Hub Nut 2. Cotter Pin
1. Hub Bolts
A. Hub Nut
............................................................................
Rear Hub
8-12 WHEELS!TIRES
1. Hub Bolts
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Final Drive
Table of Contents
Circlip ®
Front Propeller Shaft
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Circlip ®
~
Rear Propeller Shaft
I
t I ["'- ~v
® lj-------,
~ I~
~::G
, B: UK ModeJ
~
®
i
Q) /'
T1 : 8.8 N-m (0.9 kg-m, 78 in-Ib)
T2 : 37 N-m (3.8 kg.m, 27 ft-Ib)
T3 : 25 N-m (2.5 kg-m, 18.0 ft-Ib)
T4 : 29 N-m (3.0 kg-m, 22 ft-Ib)
hront Carrier T5 : 20 N-m (2.0 kg-m, 14.5 ft-Ib)
T6 : 120 N-m (12.0 kg-m, 87 ft-Ib)
T7 : 47 N-m (4.8 kg-m, 35 ft-Ib)
T8 : 49 N-m (5.0 kg-m, 36 ft-Ib)
T9 : 32 N-m (3.3 kg-m, 24 ft-Ib)
T10: 34 N-m (3.5 kg-m, 25 ft-lb)
T11: 7.8 N-m (0.8 kg-m, 69 in-Ib)
T12: 54 N-m (5.5 kg-m, 40 ft-Ib)
T13: 69 N-m (7.0 kg-m, 51 ft-Ib)
G : Apply grease.
L : Apply non-permanent locking agent.
o : Apply hypoid gear oil.
R : Replacement Parts
SG : Specified Grease
St : Stake the fastener.
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iJ Front
Front Final
Sub-Transmission
..............................................................................
Special Tools
o
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Jack: 57001-1238
eRemove the circlip with the outside circlip pliers A. Front Axle Joint Boots
(special tool: PN 57001-144).
ePuil back the propeller shaft sliding joint. The spring
comes off with the joint. *If the joint boot is torn, worn, deteriorated, or leaks
grease, replace the joint boots as a set and check the
universal joints (see Front Axle Joint Boot Replace-
ment).
Front Axle Installation Notes - Remove the following parts in the order shown.
-Installation is the reverse of removal. Note the fol- 1. Larger Retaining Ring
lowing. (to split the outboard and inboard shafts)
-Wipe the old grease off the splines of the axle and the 2. Smaller Retaining Ring
cap oil seal, and grease them. 3. Ball Bearing
-Visually inspect the splines of the axle. 4. Inboard Joint Boot
*If they are badly worn or chipped, replace the axle
with a new one.
-Be sure to install the space'!" in the recess of the front Inboard Joint Disassembly
final gear case.
@ CD ® @
-Unlock the boot bands for the outboard joint boot and
remove the boot.
oThe outboard joint can not be disassembled .
. o Replace the inboard and outboard joint boots.
-Check the universal joints.
*If any joint does not work smoothly without rattling or
sticking, the joint bearing is damaged. Replace the axle
with a new one.
1. Spacer - Visually inspect the splines on the shaft.
*If they are badly worn or chipped, replace the axle.
-Tighten the cap bolts to the specified torque (see Ex- oAssembly is the reverse of disassembly. Note the fol-
ploded View). lowing.
- Clean off the joint parts.
~
front-to rear.
eRemove the filler cap.
ec:heck the oil level. The oil level should come to the
Outboard Joint Boot bottom of the filler opening.
Inboard Joint Boot
A. Filler Opening
Front Final Gear Case Oil Change Front Final Gear Case Removal
eWarm up the oil by running the vehicle so that the oil eDrain the gear case oil (see Front Final Gear Case Oil
will pick up any sediment and drain easily. Then stop Change).
the vehicle. eRe move the following parts.
ePark the vehicle so that it is level, both side-to-side and Front Propeller Shaft (see Front Propeller Shaft
front-to-rear. Removal)
eRemove the gear case skid plate. Right Front Axle (see Front Axle Removal)
ePlace an oil pan beneath the front final gear case and Front Final Gear Case Bolts and Nuts
remove the drain plug.
WARNING I eLoosen the right and left suspension arm pivot bolts on
front and upper.
OWhen draining or filling the final gear case, be careful
elt may be necessary to support the case while sliding
that no oil gets on the tire or rim. Clean off any oil
out the case bolts.
that inadvertently gets on them with a high-flash point
solvent.
eBe sure the O-ring is in place, and tighten the filler cap eRe move the vent hose from the gear case.
to the specified torque (see Exploded View). eRemove the left front axle cap bolts and pull out the
elnstall the gear case skid plate. front final gear case from the vehicle right side.
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Front Final Gear Case Installation Notes e Take out the ring gear and differential unit.
e lnstallation is the reverse of removal. Note the fol-
lowing.
• After installing the gear case vent hose, install the gear
case bolts and nuts.
eTighten the following bolts and nuts to the specified
torque (see Exploded View) .
Front Axle Cap Bolts
Suspension Arm Pivot Bolts
Front Final Gear Case Bolts and Nuts
eApply a non-permanent locking agent to the threads of
the two case bolts on the front side.
eFili the front final gear case with the specified oil (see
Front Final Gear Case Oil Change).
Olnstall the pinion gear unit with the ring gear side of
A. Smaller Bolts C. Larger Bolts the case facing down.
B. Pry Points oAlign the air vent passage shown with the hose nipple.
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NOTE
aBe sure to install the right and left side parts of the unit
in the original position.
e lnspect the clutch plates (see Clutch Plate Inspection)
A. Air Vent Passage B. Hose Nipple and the other differential unit parts. Replace any
damaged parts.
e Measure and record the thickness of the original clutch
oTighten the following fasteners to the specified torque spring shim(s).
(see Exploded View). e Apply the specified gear oil to the differential unit
Rin.g Gear Cover Bolts (first tighten 10 mm, then 8 parts.
mm) e Note direction and position of the friction plate and
Pinion Gear Bearing Housing Nuts the clutch spring.
OAdjust the following items (see Front Final Bevel Gear
Adjustment)
Front Final Gear Back-Lash
Front Final Gear Tooth-Contact
NOTE
000 not interchange the right and left side parts in the
differential unit.
1. Slot 3. Claw
2. Tab
Front Final Gear Case (Backlash-Related Parts) Shims for Preload Adjustment
Thickness
(mm) Part Number
1.70 92025-1072
Front 1.72 92025-1073
1.74 92025-1074
1.76 (primary) 92025-1075
1.78 92025-1076
1.80 92025-1077
OTo start with, choose a shim or collar so that the Using Torque Wrench:
bearings are just SNUG with NO play but also with NO
preload.
OAn over-preload on the bearings could damage the
bearings.
NOTE
OPreload can be measured either with a spring scale or a
beam-type torque wrench. When measured with a
A. Torque Wrench
spring scale, the preload is designated by force (N, kg),
B. Pinion Gear Holder: 57001-1281
and when measured with a torque wrench, it is des·
ignated by torque (N-m, kg-m, in·lb).
*If the preload is out of the specified range, replace the
collar and/or spacer.
oTo increase preload, decrease the size of the spacer or
collar. To decrease preload, increase the size Qf the
spacer or' collar.
oChange the thickness a little at a time.
eRe-check the bearing preload, and re-adjust as nec-
essary .
NOTE
eTo measure the backlash, move the left front axle (ring
Off the backlash is out of the standard range after
gear side) back and forth while holding the pinion gear
changing the pinion gear shim(s), change the ring gear
steady. The difference between the highest and the
shim(s) to correct the backlash before checking the
lowest gauge reading is the amount of backlash.
tooth contact pattern.
*If the backlash is not within the limit, replace the ring
gear shims. To increase backlash, decrease the thick-
ness of the shim{s). To decrease backlash, increase the
thickness of the shim{s).
oChange the thickness a little at a time.
eRe-check the backlash, and re-adjust as necessary.
Bottom
-k. -------..
Heel
Bottom ------
.
-+---
Bottom
Toe
Heel
Bottom
Ring Gear
Example 2: Increase the thickness of the pinion gear shim(s) by 0.05 mm to correct the pattern shown below. Repeat
in 0.05 mm steps if necessary.
_ - - - Heel
-,I
Bottom
Toe
Pinion Gear
Heel
~.
Bottom . ----------
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Bevel Gear Inspection e Drain the engine oil (see Engine Right Side chapter in
eVisually check the bevel gear-s for scoring, chipping, or the Base Manual) .
other damage. eSupport the rear part of the frame on blocks or the
*Replace the bevel gears as a set if either gear is damaged. jack (special tool: PN 57001-1238) so that the sus-
pension arms are free from loads.
eRemove the following parts.
Rear Fender (see Frame chapter)
Differential Gear Inspection Wiring Straps for Brake Cables and Vent Hoses
eVisually check the differential gears for scoring, Brake Pedal Adjuster and Parking Brake Lever
chipping, or other damage. Adjuster on Rear Brake Panel
eAlso, inspect the differential pinion gear shaft and gear Rear Shock Upper Mounting Bolts and Nuts
housing where the differential gears rub. Suspension Arm Pivot Shaft
*If they are scored, discolored, or otherwise damaged, Propeller Shaft Joint Boot Clamp Screw
replace them as a set.
............................................................................
Rear Propeller Shaft
............................................................................
Rear Propeller Shaft Removal
1. Propeller Shaft Housing Nuts
NOTE
alt is not necessary to remove the rear shocks, rear Rear Propeller Shaft Installation
wheels, and rear axle assembly. e lnstallation is the reverse of removal. Note the fol -
lowing.
e Wipe the old grease off and grease the front end splines
e Remove the rear final gear case skid plate. of the shaft and the pinion gear joint splines.
e Drain the rear final gear case oil (see Rear Final Gear e Be sure to install the spring on the pinion gear nut of
Case Oil Change). the rear final gear case.
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Rear Axle
.............................................................................
Rear Axle Unit Removal
eRemove the rear final gear case skid plate.
eDrain the rear final gear case oil (see Rear Final Gear
Case Oil Change).
eDrain the engine oil (see Engine Right Side chapter in
the Base Manual).
eRemove the following parts.
Rear Fender (see Frame chapter)
Rear Wheels
Brake Drum (see Brakes chapter)
Rear Brake Panel (see Brakes chapter)
Rear Propeller Shaft Joint Boot Front End
A. Universal Joint C. Center Bearing
eRemove the foHowing parts.
B. Grease Seal D. Splines
Center Arm Bolts
Lower Mounting Bolts of Rear Shock Absorbers
Suspension Arm Pivot Bolts
eMove the rear axle unit to the rear just enough to free
from the vehicle.
eRemove the propeller shaft by taking off the housing
nuts.
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Rear Axle Bearing Inspection Rear Final Gear Case Oil Change
eRemove the rear axle (see Rear Axle Unit Disassembly). eWarm up the oil by running the vehicle so that the oil
will pick up any sediment and drain easily. Then stop
the vehicle.
NOTE
e Park the vehicle so that it is level, both side-to-side
OSince the bearings are packed with grease and sealed, and front-to-rear.
they can not be lubricated. ePlace an oil pan beneath the rear final gear case and
remove the drain plug.
eRefer to Ball or Needle Bearing section in this chapter
for sealed bearing inspection.
eFili the final gear case up to the bottom of filler ePuli the ring gear out of the case.
opening with the oil specified below. ePry open the staking of the pinion gear nut with a small
chisel.
eUnscrew the pinion gear nut using the bevel gear holder
Rear Final Gear Case Oil
(sp"ecial tool) to keep the pinion gear assembly as
Type: API GL-5 Hypoid gear oil shown.
SAE90 (above SoC, 41°F)
SAE80 (below SoC, 41°F)
Capacity: 02 L
NOTE
o"GL-5" indicates a quality and additive rating. "GL-6"
rated hypoid gear oils can also be used.
eBe sure the O-ring is in place and tighten the filler cap
to the specified torque (see Exploded View).
eVisually check the bevel gears for scoring, chipping, or eTighten the following parts to the specified torque (see
other damage. Exploded View).
*Replace the bevel gears as a set if either gear is damaged Pinion Gear Bearing Holder (Oil the threads and
since they are lapped as a set in the factory to get the seating surface)
best tooth contact. Pinion Gear Bearing Holder Set Plug
eBack out the ring gear thrust plug fully. Ring Gear Cover Bolt~ (tightening order 10 mm -+
8mm)
eReplace the pinion gear nut with a new one.
eApply an oil to the threads and seating surface of the
pinion gear nut, and .tighten them to the specified
torque (see Exploded View).
eStake the head of the pinion gear nut with a punch to
secure the pinion gear nut.
(J)
000 not install the pinion bearing holder set plug, the oil NOTE
seal, and the O-ring during adjustment. OApply checking compound to the teeth in a thin, even
coat with a fairly stiff paint brush. If painted too
elnstall the pinion gear assembly with the primary (1.0 thickly, the exact tooth pattern may not appear.
mm thickness) shim. oThe checking compound must be smooth and firm,
elnstall the pinion gear bearing holder with the deeper with the consistency of tooth paste.
recess side facing outward. OSpecial compounds are available at automotive supply
eTighten the pinion gear bearing holder to the specified stores for the purpose of checking differential gear
torque (see Exploded View). tooth patterns and contact.
elnstall the ring gear assembly with the 'primary (1.0mm
thickness) shim, and .tighten the ring gear case cover
bolts to the specified torque (see Exploded View). elnstall the shim(s) and pinion gear assembly, and
oCheck the backlash during the tightening of the cover tighten the bearing holder to the specified torque (see
bolts, and stop tightening them immediately if the Exploded View).
backlash disappears. Then, change the ring gear shim elnstall the shim(s) and ring gear assembly, and tighten
to a thinner one. the cover bolts to the specified torque (see Exploded
eTemporarily, install the rear axle in the gear case and View).
hold it with a vise so that the ring gear is lower than the eTurn the pinion gear for one revolution in the drive and
pinion gear. reverse (coast) direction, while creating a drag on the
eMount a dial gauge on the vise so that the tip of the ring gear.
gauge is against the splined portion of the pinion gear eRemove the ring gear and pinion gear unit to check the
joint. drive pattern and coast pattern of the bevel gear teeth.
eTo measure the backlash, move the pinion gear nut oThe tooth contact patterns of both (drive and coast)
back and forth while holding the rear axle steady. The sides should be centrally located between the top and
difference between the highest and the lowest gauge bottom of the tooth. The drive pattern can be a little
reading is the amount of backlash. closer to the toe and the coast pattern can be a some-
oMeasure backlash at three locations equally spaced on what longer and closer to the toe.
the splines. *If the tooth contact pattern is incorrect, replace the
Rear Final Bevel Gear Backlash: 0.07 - 0.17 mm pinion gear shim(s), following the examples shown (see
Correct Tooth Contact Pattern in Front Final Bevel
Gear Adjustment section).
eThen erase the tooth contact patterns, and check them
again. Also check the backlash every time the shim(s)
are replaced. Repeat the shim change procedure as
necessary.
NOTE
Olf the backlash is out of the standard range after
changing the pinion gear shim(s), change the ring gear
shim(s) to correct the backlash before checking the
tooth contact pattern.
*If the backlash is not within the limit, replace the ring
gear shims. To increase backlash, decrease the thick- Pinion Gear Disassembly
ness of the shim(s). To decrease backlash, increase the eRemove the pinion gear (see Rear Final Gear Case Dis-
thickness of the shim(s). assembly).
ilChange the thickness a little at a time. eRemove the pinion gear bearing as necessary using the
eRe-check the backlash, and readjust as necessary. bearing puller (special tool: 57001-158).
www.midwestmanuals.com
NOTE
Oln the absence of the above mentioned tools, satis-
1. Bearing Driver: 57001-382 factory results may be obtained by heating the case to
2. Pinion Gear Bearing approximately 93°C (200°F) max., and tapping the
bearing in or out.
Bevel Gear Inspection oDo not heat the case with a torch. This will warp the
-Visually check the bevel gears for scoring, chipping, or case. Soak the case in oil and heat the oil.
other damage.
*Replace the bevel gears as a set if either gear is damaged .
- Using a press and the bearing driver set (special tool:
PN 57001-1129), install the new bearing until it stops
at the bottom of its housing.
CD
Oil Seal
I WARNING I -Check the needle bearing in the rear final gear case.
oThe rollers in a needle bearing normally wear very
little and wear is difficult to measure. Instead of
-Clean the parts in a well-ventilated area, and take care
meas'uring, inspect the bearing for abrasion, color
that there are no sparks or flame anywhere near the
change, or other damage.
working area; this includes any appliance with a pilot
*If there is any doubt as to the condition of a needle
light. Do not use gasoline or low-flash point solvent to
bearing, replace the needle bearing and rear final gear
clean parts. A fire or explosion could result.
case as a set.
CD
BRAKES 10-1
Brakes
Table of Contents
Caliper Piston and Cylinder Damage .. . 10-7 Brake Shoe Spring Inspection . . . . . . .
..
Caliper Holder Shaft Wear . . . . . . . . . . 10-7 Brake Panel Disassembly . . . . . . . . . . . 10-12
Brake Pads . . . . . . . . . . . . . . . . . . . . . . . . 10-8 Brake Panel Assembly Notes ... .. .. . 10-12
Brake Pad Removal . . . . . . . . . . . . . . 10-8 Brake Camshaft Lubrication .. . .... . 10-13
Brake Pad Installation Notes . . . . . . . . 10-8 Brake Pedal and Cables . . . . . . . . • . . . . . . . 10-13
Brake Pad Wear Inspection . . . . . . . . . 10-8 Brake Pedal and Cable Removal ..... . 10-13
Master Cylinder and Wheel Cylinders ... .. . . 10-9 Brake Pedal and Cable Installation .... . 10-13
Master Cylinder Removal . . . . . . . . . .
. Brake Cable Inspection . . . . . . . . . . . . 10-14
Master Cylinder Installation . . . . . . . . .
. Brake Pedal and Cable Lubrication ... . 10-14
Master Cylinder Disassembly . . . . . . . .
.
Master Cylinder Assembly . . . . . . . . . .
.
* Base Manual
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10-2 BRAKES
lew
E~~i~d~·V···:·············· ··············
................. .
..;;:.:.~
G :A
....;.............
y adhesive.
........ ..... ...............................
..........
..
.
PP
. pply grease
L . .
. Apply non-perman
agent. ent locking
BRAKES 10-3
/
~--~
~ Drain Bolt
rr~
~
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10-4 BRAKES
Specifications
Special Tools
BRAKES 10-5
NOTE
oCheck the- brake fluid level in accordance with the
Periodic Maintenance Chart.
eTo adjust the pedal free play, turn the adjuster at the
rear end of the brake cable.
10-6 BRAKES
- If the caliper is to be disassembled after removal and if
compressed air is not available, remove the piston using
the following procedure. If both calipers are to be
disassembled, be sure to do this procedure to both at
,-------- the same time.
° Remove the pads.
oTemporarily reconnect the brake hose to the caliper.
The banjo bolt need not be torqued.
oPump the brake lever to remove the caliper piston.
° Immediately wipe up any brake fluid that spills.
° Disconnect the brake hose from the caliper.
1. 1 - 2 mm
Caliper Removal
-Remove the front wheels (see Wheel Removal in the
Wheels/Tires chapter). I WARNING.
-Separate the brake hose from the caliper by taking off
the banjo bolt. OTo avoid serious injury, never place your fingers or
-Remove the caliper mounting bolts and take off the palm inside the caliper opening. If you apply com-
calipers. pressed air into the caliper, the piston may crush
your hand or fingers.
BRAKES 10-7
I WARNING I
o Except for the disc pads ~nd discs; use only disc brake
fluid, isopropyl alcohol, or ethyl alcohol, for cleaning
brake parts. Do not use any other fluid for cleaning
these parts. Gasoline, motor oil, or any other
petroleum distillate will cause deterioration of the
rubber parts. Oil spilled on any part will be difficult to
wash off completely, and will eventually deteriorate
the rubber used in the disc brake.
A. Anti-Rattle Spring
-Apply brake fluid to the outside of the piston and the
fluid seal, then push the piston' into the cylinder by
hand . Take care that neither the cylinder nor the
piston skirt gets scratched .
10-8 BRAKES
I WARNING' WARNING'
OWhen handling the disc pads, be careful that no disc
OWhen handling the disc pads or disc, be careful that no
brake fluid or any oil gets on them. Clean off any fluid
disc brake fluid or any oil gets on them. Clean off any
or oil that inadvertently gets on the pads with a high-
fluid or oil that inadvertently gets on the pads or disc
flash point solvent_ Do not use one which will leave an
with a high-flash point solvent. Do not use one which
oil residue. Replace the pads with new ones if they
will leave an oily residue. Replace the pads with new
cannot be cleaned satisfactorily.
ones if they cannot be cleaned satisfactorily.
BRAKES 10-9
Disc Wear
eMeasure the thickness of each brake disc at the point
where it has worn the most.
*Replace the disc if it has worn past the service limit.
1. Apply grease .
...............................................................................
Brake Discs
10-10 BRAKES
Brake Drum
1. Brake Disc 2. Turn the disc by hand. Since the front brake drums are not on the model,
the information of the front brake drum is omitted.
Disc Runout
Standard: 02 mm or under
Service Limit: O.3mm Rear Brake Drum Removal
Refer to the Base Manual noting the following.
e Remove the right rear wheel for rear brake drum
removal.
BRAKES 10-11
Brake Drum Seal Lubrication
Brake Panel Assemblies
Grease
A. Drain Bolt
WARNING'
10-12 BRAKES
WARNING '
Olmproper installation will cause ineffective braking.
A. Triangular Mark
BRAKES 10-13
Brake Camshaft Lubrication ORemove the seal of the brake pedal cable and take off
!
eDisassemble the drum brake. the cable from the frame.
eUsing a high-flash point solvent, clean the old grease ORemove the cotter pin and the joint from the brake
off the brake camshaft, camshaft hole, and other pivot pedal.
points. o R,mo," the b"k, p,dal "bl,.
*Replace the dram brake parts if they show wear or
damage.
eApply grease to the brake pivot points (brake shoe
anchor pins and cam surface of the camshaft) and fill
the camshaft groove with grease. Do not get any grease
so that it does not get on the linings or drum after
brake assembly.
~
.~
;---....
10-14 BRAKES
SUSPENSION 11·1
Suspension
Table of Contents
* Base Manual
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11-2 SUSPENSION
Exploded View
SUSPENSION 11-3
Outside Circlip Pliers: 57001-144
Specifications
..............................................................................
Refer to the Base Manual noting the following.
Front Shock Absorber Spring Preload
Standard setting position: No.2
Jack: 57001-1238
Special Tools
11-4 SUSPENSION
Spring Action
, Front Suspension Arm Removal
Position Spring Setting Load Terrain Speed
Force eRemove the following parts.
Steering. Knuckle {see Steering Knuckle Removal in
1 Soft Light Good Low the Steering chapter}
2 (STD)
3
1
Stronger
1! r !
Hard Heavy Bad High
,
Brake Hose
eRemove the upper suspension arm by taking off the
pivot bolts.
, eRemove the lower suspension arm by taking off the
pivot bolts.
eRepeat the same procedure on the other side of the
vehicle.
WARNING.
o If a pair of adjusting sleeves (front two adjusting
sleeves or rear two) are not adjusted equally, handling
may be impaired and a hazardous condition may
result. 1. "F" mark
SUSPENSION 11-5
Rear Suspension Arm (Rod) Installation Front or Rear Suspension Arm Assembly Notes
OSuspension arm installation is the reverse of removal. eWhen installing the rubber dampers into the arm,
Note the following. lubricate the outer surface of the dampers with a soap
elnstall the center arms noting the installation direction. and water solution.
elnstall the left rear suspension arm so that the "F"
mark faces upward and forward.
Center Arm Installation
o Do not lubricate the rubber dampers with engine oil or
~
I
petroleum distillates because they will deteriorate the
rubbers.
STEERING 12-1
Steering
Table of Contents
*. Base Manual
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12-2 STEERING
...................................................
Exploded View ..........................
................
A : APpl~·~~~·~~;~~~············--························ .... -.- .•
G : Apply grease. .
L : Apply non-permanent lock·
R : Replacement Parts 109 agent.
. pp Iy water, or soap and
W·A
solution. water
STEERING 12-3
Handlebar Removal
Specification e Remove the following parts from the handlebar.
Left-Hand Switch Housing
Parking Brake Lever
Steering Angle Throttle Case
Right: Front Brake Master Cylinder
eRemove the handlebar holder bolts and lift off the
Left:
handlebar.
Handlebar Installation
Steering eHandlebar installation is the reverse of removal. Note
the following.
elnstall the handlebar so that the angle of the handlebar
Steering Stopper Adjustment matches the angle of the steering stem as shown.
eTurn the handlebar all the way to the left and adjust
the right steering stopper bolt protrusion by adding or
removing the shim.
eWith the tie-rod arm stopper against the suspension arm
stopper, the clearance between the stopper bolt and the
frame stopper must be less than 1.0 mm.
A. Parallel
eTighten the holder rear bolts first and then the front
bolts. When the holder is ~orrectly installed, there will
be even gap at the front and no gap at the rear after
tightening.
eTurn the handlebar all the way to the right and adjust A. Front C. No Gap
the left stopper bolt in the same way. B. Even Gap
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A. Tie-Rod Ends
A. Marks
STEERING 12-5
Tie-Rod End Installation Notes -Remove the cotter pins, then remove the steering
-Check that the seal lip of the boot is on the shank. knuckle upper and lower joint nuts.
-Oil the bolt body. -Tap the steering knuckle and remove it.
1. Boot Lip 3. Apply oil A. Tap the steering knuckle. B. Front Axle
2. Shank
12-6 STEERING
FRAME 13-1
Frame
Table of Contents
* : Base Manual
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13-2 FRAME
Rear Carrier
r--------
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www.midwestmanuals.com
FRAME 13-3
® : Australia Model
(B) : UK Model
© : Canada Model
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13-4 FRAME
...............................................................................
Seat Front and Rear Fenders
.............................................................................
Seat Removal Front Fender Removal
-Pull the seat lock lever up. -Remove the following parts.
Seat (see Seat Removal)
Fuel Tank Rear Cover (see Fuel System chapter)
Fuel Tank Cap
Front Carrier
WARNING I
oGasoline is extremely flammable and can be explosive
under certain conditions, Turn the ignition switch
OFF. Do not smok~. Make sure the area is well venti-
lated and free from any source of flame or sparks; this
includes any appliance with a pilot light.
-Move the fuel tank front cover forward, then lift the
cover.
A. Pull.
- Lift the rear- of the seat, slide it toward the rear slight-
ly, and lift it off the vehicle.
Seat Installation
-Slip the seat hook under the brace on the frame, and
put the stoppers into the holes in the frame.
A. Front Carrier Bolts B. Fuel Tank Front Cover
A. Brace C. Stoppers
B. Seat Hook D. Holes 1. Fuel Tank Front Cover
-While pushing the rear part of the seat down, push the -Install the fuel tank cap at once.
seat lock lever down until the lock clicks. ORemove the following mounting screws and bolts.
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FRAME 13-5
A. Mounting Bolts
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.
,
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.· . . . . ".... .. \a.
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A. Screws Rear Fender Installation Notes
eRear fender installation is the reverse of removal. Note
the following.
el nstall the mounting screws, bolts, and nuts in the
eTake off the front fender. original positions (see Exploded View).
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Electrical System
Table of Contents
Exploded View
r:/
~00
CW ~
g
.~
~
~
CO
0
~
1. Pickup Coil
2. Regulator/Rectifier
3 . Neutral and Reverse Switch
4. Starter Relay
5. Starter Circuit Relay
6. IC Igniter
7. Light Switch and Engine Stop Switch
8. Ignition Switch
T1 : 59 N-m (6.0 kg-m, 43 ft-Ib)
T2: 14 N-m (1.4 kg-m, 10.0 ft-Ib)
T3: 4.4 N-m (0.45 kg-m, 39 ft-Ib)
www.midwestmanuals.com
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(Optional Parts) , ';j I
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Headlights
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Altern.tor Pickup
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Switch
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~~
il
Noutral Indiclitor LO - - G < l - LO LO .
Light 12 v 3.4 W
SPlrk Plug
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-,1 "111
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-
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Revors" Indicator AcceSSOI
w
~,~,."
Light 12 V 3.4 Termlna
rr"
r- - - r UK modol 12" 3.4 W I
I @R-::=ll::;
- l..... BK/Y~~ ~
-~-C_ ~ "II III "i .....:::= : ==-
CD
L....-BKfW-
~ B K/V --c:>CJo---1 BK/Y
, "
'~I-.."~;~~~G I
- - - --,.- - _ I CD I 8'/ '-- "- L..--8L -
YlR /l ~K~r--+--~
I;
I Working LIght MI
112V65/60W R X::=~-==--' R Taillights
18 , R IY-----, I I
R
12 V 8 W)( 2
I _ _
L - - - ~ , Option ~
~~ Fus.
30A .. ..
~,
~
Color Code
I
BK Black
~
BL Blue
~
BR Brown
G Green
GY Gray
LB Light Blue
r
.1-==-8' LG Light Green
L..-.+-----ona. Startar Button
Battery
Capacity: 12 V 14 Ah
Specific gravity: 1.27 ±0.01 @20°C (6SoF)
Electrolyte volume: 0.9L
Charging System
Battery charging coil resistance: 0.1 - 0.7 Q
Ignition System
Spark plug gap: 0.6 - 0.7 mm
Spark plug cap resistance: 3.75 - 6.25 kQ
IC igniter resistance: in this text
Ignition coil resistance Coil Tester: 57001-1242
(with the spark plug cap removed)
oThis tool may be used instead of the Kawasaki Elec-
Primary winding: 1.8 - 2.8 Q
trotester (PN 57001-980).
Secondary winding: 10 - 16 kQ
Pickup coil air gap: 0.9 mm
Special Tools
Spark Plug Wrench (Owner's Tool): 92110-1109
o Keep the battery vent hose outlet away from the frame
and brake system components. Battery electrolyte will
corrode and weaken them. Do not let the vent hose
become folded, pinched, or melted by the exhaust
system. An unvented battery will not keep a charge
and it may crack from built-up gas pressure.
Battery Charging:
Battery Condition
ORefer to the Base Manual noting the following.
*If the specific gravity is below 1.200, the battery needs
t9 be charged.
1. Flywheel Puller: 57001-1191
2. Rotor Puller: 57001-1099 or 1216
-'"
(,.!)
<.)
to:
1.16
1.12
!..1~ - Sample - - - - - - - - - ~-~~~~~~~
I
.y
:~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ :~ :~ :~ :~ :~ :~ :~ :~ :~ :~ :~ :~ :~: ~ :~ :~ :~ :~ :~ :~; i ~ 14".5: f: ~: ~: ~: ~: ::::::1·.080' ::::.: ::::::::::::::::
1.08
~
V') 1.04 :...................•................. r .Ii<>~~s.. . . . . . . . ... Totally Discharged .. .
1.00
::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::.:.. ::.:.:.: .. ::!::::::::::::::::::::::::::::::::::::::::::::
at 1A charge rate 5 10 15 20 21
at 2A charge rate 3 5 9 10.5
at 3A charge rate 2 3 4 5 6 7
at 4A charge rate 2 3 4 5.3
Hours of Charging Time at Rates Shown
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BR BR ON
OFF CD1 W W w
'O--~~~~~--~~--4---------------------,
BK/V
a:
III
> >
M2 M3 B
6 Pin Connector
> >
CJ
...I
~
CJ ~ ~
III
b! N @
OFF:t
@)
R/BK
R/BK
>
.....
a:
BK/Y
BK/V
BK/V
1. Ignition Switch 6. Regulator/Rectifier 11. Headlights
2. Reverse Indicator Light 7. Diodes 12. Light Switch
3. Neutral Indicator Light 8. Thyristers 13. Speedometer Light ( ® ®)
4. Neutral and Reverse Switch 9. Control Unit 14. Working Light (option)
5. Alternator 10.30AFuse 15. Taillights
<=Jt \
.
\
\\
\ )
\0
(-)
~
*If the tester does not read as specified, replace the Connect
alternator stator.
* If the coil has normal resistance, but the voltage
II I~ ~ L ___ ~_8~~~- green/white lead
inspect showed the alternator to be defective; then the G)~connect
yellow/red lead
rotor magnets have probably weakened, and the rotor
must be replaced.
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"0
'"
0>
.J
G/W
~ 00 00 00 00
I
0>
Y/R 5 - 15
~ 1 - 10 00 1 - 10
~
~ 1- 5 1 - 10
"'c:
"'0
BK/W 00 0
0>-
Zti
I~
~O>
o>c: 50 - 50- 50-
"c: BL 00
~o 150 150 150
1-<>
(BK/W) 1- 5 1 - 10 0 00
i~
A. Spark Plug Wrench (Owner's Tool): 92110-1109 * Measure with the Kawasaki Hand Tester (PN 57001-
1394). A tester other than the Kawasaki Hand Tester
may show slightly different readings.
IC Igniter Terminal
$
- Attach the timing light (special tool : PN 57001-1241)
and a tachometer in the manner prescribed by the
manufacturer.
- Start the engine and aim the t iming light at the timing
light mark on the alternator rotor.
- Run the engine at the speeds specified and note the (BK/W) BL
alignment of the timing marks.
BKjY
Y/R
Q) fK/W BL
ON
ON
- -:::
oc
>- <..:)
:::
a (?FF
:::CJ>
U
0)'
OFF
@ ~-I
0)0)
~
0) 7
CD @
,l
1. Battery 5. Pickup Coil
2. 30A Fuse 6. Igniter
3. Ignition Switch 7. Ignition Coil
4. Engine Stop Switch 8. Spark Plug
Electric Starter System
~\ OFF
TON
®
a::
a:I
~ a::
~ To igniter
~
CD
Ir
r;J....., y fR
L---,CDr--_--,IIl.--_....
G;
a::
III
a::
>-
OFF
T RUN
@ ®
o
Lighting System
Headlight Beam:
Headlight Beam Vertical Adjustment
NOTE
o Turning the adjusting screw clockwise lowers the
headlight beam.
A. Bulb Socket
A. Adjusting Screw
Ignition Switch
NOTE
Ignition Switch Removal or Installation
oOn high beam, the brightest point should be slightly
o Refer to the Base Manual noting that the rubber
below horizontal with the vehicle on its wheels and the damper and the bracket are not on the model.
rider seated. Adjust both headlights to the same angle.
Switches
Ignition Switch, Light Switch, Engine Stop Engine Stop Switch Connections
Switch, and Starter Button Inspection Y/R BR
-Refer to the Base Manual noting the following.
OFF
-Remove the fuel tank rear cover (see Fuel Tank
Removal in the Fuel System chapter in this manual). RUN
-Unfasten the upper strap of the vinyl cover and open
the velcro. To Starter Button
To En gine Sto p
APPENDIX 15-1
Appendix
Table of Contents
* : Base Manual
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15-2 APPENDIX
Spark Plug
Considerations for Various Riding Conditions
Carburetor:
Sometimes an alteration may be desirable for good
performance under different riding conditions when
proper mixture is not obtained after the carburetor has Reach
been properly adjusted, and all parts cleaned and found
to be functioning properly.
If the engine still exhibits symptoms of overly rich or
Plug gap
lean carburetion after all maintenance and adjustments
are correctly performed, the main jet can be replaced
with a smaller or larger one. A smaller numbered jet
gives a leaner mixture and a larger numbered jet a richer
mixture.
1. Terminal 4. Gasket
2. Insulator 5. Center Electrode
3. Cement 6. Side Electrode
Spark Plug:
The spark plug ignites the fuel and air mixture in the
combustion chamber. To do this effectively and at the
proper time, the correct spark plug must be used, and A spark plug for higher operating temperatures
the spark plug must be kept clean and the gap adjusted. sometimes may be needed for severe conditions, such as
Tests have shown the plug listed in the General continuous high-speed riding, or towing heavy loads.
Information chapter to be the best plug for general use. Such a plug is designed for better cooling efficiency so
Since spark plug requirements change with the igni- that it will not overheat and thus is often called a
tion and carburetion adjustments and with riding condi- "colder" plug. If a spark plug with too high a heat range
tions, whether or not a spark plug of the correct heat is used - that is, a "cold" plug that cools itself too well,
range is used should be determined by removing and - the plug will stay too cool to burn off the carbon, and
inspecting the plug. the carbon will collect on the electrodes and the ceramic
When a plug of the correct heat range is being used, insulator.
the electrodes will stay hot enough to keep all the The carbon on the electrodes conducts electricity,
carbon burned off, but cool enough to keep from and can short the center electrode to ground by either
damaging the engine and the plug itself. This temper- coating the ceramic insulator or bridging across the gap.
ature is about 400 - 800°C (750 - 1 ,450°F) and can be Such a short will prevent an effective spark. Carbon
judged by noting the condition and color of the ceramic build-up on the plug can also cause other troubles. It
insulator around the center electrode. If the ceramic is can heat up red-hot and cause preignition and knocking,
clean and of a light brown color, the plug is operating at which may eventually burn a hole in the top of the
the right temperature. piston.
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APPENDIX 15-3
Spark Plug Condition
Plug Reach
15-4 APPENDIX
............................................................................. No valve clearance
Troubleshooting Guide Cylinder, piston worn
Piston rings bad (worn, weak, broken, or sticking)
Piston ring/land clearance excessive
NOTE Cylinder head gasket damaged
OThis is not an exhaustive list, giving every possible Cylinder head warped
cause for each problem listed. It is meant simply as a Valve spring broken or weak
rough guide to assist the troubleshooting for some of Valve not seating properly (valve bent, worn, or
the more common difficulties. carbon accumulation on the seating surface)
APPENDIX 15·5
15-6 APPENDIX
APPENDIX 15-7
Oil, grease on pads and disc
Disc worn or warped General lubrication
Brake overheated
Rear Brake
Brake not properly adjusted Lubrication
Linings overworn or worn unevenly eBefore lubricating each part, clean off any rusty spots
Drum worn unevenly or scored with rust remover and wipe off any grease, oil, dirt, or
Oil, grease on lining and drum grime.
Dirt, water between lining and drum eLubricate the points listed below with indicated lubri-
Overheated cant.
NOTE
OWhenever the vehicle has been operated under wet or
Battey Discharged rainy conditions, or especially after using a high-pres-
Battery faulty (e.g., plates sulphated, shorted sure spray water, perform the general lubrication.
through sedimentation, electrolyte level too
low)
Battery leads making poor contact
Load excessive (e.g., bulb of excessive wattage) Cables: Lubricate with Motor Oil
Ignition switch trouble Brake Cables
Regulator/Rectifier trouble Throttle Cable
Alternator trouble Choke Cable
Wiring faulty Reverse Gear Cable
Battery Overcharged e Lubricate the cables by seeping the oil between the
Regulator /Rectifier trouble cable and housing.
Battery trouble oThe cable may be lubricated by using a pressure cable
luber with an aerosol cable lubricant.
Cable Lubrication
15-8 APPENDIX
Tightness Inspection
e<::heck the tightnes!i of the bolts and nuts listed here.
Also, check to see that each cotter pin is in place and in
good condition.
*If there are · loose fasteners, retorque them to the
specified torque following the specified tightening
sequence. Refer to the appropriate chapter for torque
specifications. If torque specifications are not listed in
the appropriate chapter, see the basic torque table (see
Torque and Locking Agent in the General Information
chapter). For each fastener, first loosen it by }'2turn,
then tighten it.
*If cotter pins are damaged, replace them with new ones.
Table of Contents
General Information
Model Identification
KL F300-C2/C2A
KLF300-C3
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KLF300-C4
KLF300 - C5 / C6
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General Specifications
Specifications are subject to change without notice, and may not apply to every country.
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General Specifications
..............................................................................
Item KLF300-CS/C6
Dimensions:
Overall lengtr 1 860 mm
Overall width 1120 mm, ®®® 1 210 mm
Overall height 1 105 mm
Wheelbase 1200mm
Ground clearance 225mm
Seat height 805mm
Dry weight 260 kg, ®®®263 kg, ©
261 kg
Curb weight: Front 138.5 kg, ®®® 139 kg, ©
138.5 kg
Rear 129.5 kg, ®®® 132 kg, ©
130.5 kg
Fuel tank capacity 11 L
Performance:
Minimum turning radius 2.9m
Engine:
Type 4-stroke, SOHC, l-cylinder
Cool ing system Air cooled
Bore and stroke 76.0 x 64.0 mm
Displacement 290mL
Compression ratio 8.6
Maximum horsepower 14.7 kW (20 PSI @6 500 r/min (rpm), @ -
Maximum torque 23.6 N-m (2.4 kg-m, 17.3 ft-Ib) 5500 r/min (rpm),
@-
Carburetion system Carburetor, Keihin CVK32
Starting system Electric starter & recoil starter
Ignition system Battery and coil (transistorized)
Timing advance Electronically advanced
Ignition timing From 10° BTDC @1 300 r/min (rpm) to
30° BTDC @4 000 r/min (rpm)
Spark plug NGK D8EA, ®© NGK DR8ES-L, ®® DR7EA
Valve timing: Inlet Open 21° BTDC
Close 59° ABDC
Duration 260°
Exhaust Open 56° BBDC
Close 24° ATDC
Duration 260°
Lubrication system Forced lubrication (wet sump)
Engine oil: Grade SE or SF class
Viscosity SAE 10W-30, 10W-40, lOW-50, 20W-40, or 20W-50
Capacity 2.4 L
Drive Train:
Primary reduction
System: Type Gear
Reduction ratio 2.888 (78/27)
Clutch type: Primary Auto centrifugal, wet
Secondary Auto multi disc, wet
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Item KLF300-CS/C6
Transmission: Type 10-speed plus reverse, constant mesh, return shift
Gear ratio: 1st 3.090 (34111)
2nd 1.928 (27/14)
3rd 1.368 (26/19)
4th 1.000 (23/23)
5th 0.769 (20/26)
Reverse 3.072 (26/11 x 26/20)
Final drive
system: Type Shaft (four wheel drive)
Reduction ratio High 5.416 (33/33 x 20/16 x 39/9)
Low 6_910 (37/29 x 20/16 x 39/9)
Overall drive ratio High: 12_037 Low: 15.357
Front final gear case oil Type API GL-5 Hypoid gear oil for LSD SAE140
or SAE 85W-140
Capacity 0.25 L, (C6) 0.40 L
Rear final gear case oil: Type API GL-5 Hypoid gear oil SAE 90 (above 5°C, 41°F)
or SAE 80 (below 5°C, 41° F)
Capacity 0.2 L, ®®® 0.3 L, (C6) 0.3 L
Frame:
Type Double tubular ·
Caster (rake angle) 1.0°
Camber 0° @1 G
Trail 5mm
Tread Front 844mm
Rear 860mm
Front tire: Type Tubeless
Size AT 24x 8-11
Rear tire: Type Tubeless
Size AT 24 x 10-11
Suspension: Front Type Double wishbone
Wheel travel 110mm
Rear Type Torque tube
Wheel travel 120mm
Brake type: Front Disc (Hydraulic) x 2
Rear Drum (Mechanical, on Rightside)
Electrical Equipment:
Battery 12 V 19 Ah, (Q) 12 V 14 Ah
Headlight: Type Semi-sealed beam
Bulb 12 V 25/25 W x 2
Taillight 12V8Wx2
Alternator: Type Three-phase AC
Rated output 23.5 A @9 000 r/min (rpm), 14 V
Specifications are subject to change without notice, and may not apply to every country.
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Crankshaft/Transmission
Exploded View
........................................................................... .
-
Frame
Exploded View
"r
"
(..)
0
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0
I
AJterNtor PfCkup C')
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Ignition Coil (..)
Switch It a~
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~ ~ I I ~
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Rev.rloe Ind lCltor
Ll9hl12 V 3.4 W
(f'F-. II ./. -DCl- ./.
•• ,~.. '··~II
h Accessory
Termlnlls -!!!..
..
«
r~ r~
..... BK/Y~B en
L.. • L- ~ ==::;- L-el
L--BK/W-=-
C
YlA YlA R UJ!,i "tI
_K/
•
K/
•
K"
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e. ~ 12 V 8 W x 2 m
s:
m
BL
Z
til BA
-i
.
HtldlI9hts
~~ Fu ••
30A . ..
~,
~
Color Code 8
I
12 V 25/25 W @ E B K / V. --C::>O::)OO-BKty BK Black
R/Y~
-J--I-J •
BL Blue
~
RISK --<::<:J---R/BK
BR Brown
12V25/"W~ J I I G
GY
Green
Gray
~
B K/Y -c::>c::J- BK/Y . .
LB Light Blue s:
_e'l _. _ _ _ _ _
R/Y
o
r
R/BK --PO Light Green
LG
Sta,ter Button e,.. I I 0 Orange om
P Pink r
EnQlnl Stop Switch
+ ~ LO;:~ R Red en
Ught Switch
Blttery
12V14Ah W White -"
~I 0)
Y Yellow I
(1218A) 10
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-4
en
:: r- : ". I
-A
o
Alternator PICkup
I)!';') :.-. ." :
:»W:
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en
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Light 12 V 3.4 W
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CD
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RGvorse Indicator -DO-R/W
Light 12 V 3.4 W (,('f=-. e
Speedometer L · ren
r-- - '2\t3.4W
·
, ©} R-~
BK/V~ I
::;
,,
w B K/V --<>0----. B K/V .----r -li\
I Working Light _ .K' IY~II~Y
,~ x::='~~--' R
•.
I 12 V 65/60 W Taillights
_ 12V8Wx 2
I __
Al.
~ ~ 1_
L - - -~" Option 0;
Headl ights
12V25/25W@E
~
~"~~ e,,· .,
~,
.,~
BK
Color Code
Black
I
BK/V----a<>--BK/V
R/V ---O<:J-----!-J '" BL Blue
~
~
RISK --D<::r--R/BK
BR Brown
'"I>~~IICIi~~
. '"
Ho:n- ) ) G Green
Switch Horn
,
12V25/25W
(d-ce::: --O<I_BK/V J
(X
GY
LB
Gray
Light Blue
~R/8K~-------_-J.
r "~
Light Green
Starter Button " LG
0 Orange
Engine Stop Switch Stl'ter Motor P Pink
R Red
Light Switch
OFF W White
Y Yellow
(12048)
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Table of Contents
General Information
Model Identification
KLF300-C7/C7A
KLF300-C8
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KLF300- C9
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General Specifications
Items KLF300-C7 -
Dimensions:
Overall length 1 860 mm
Overall width 1 120 mm, (A)(B)(E) 1 210 mm
Overall height 1 105mm
Wheelbase 1 200 mm
Ground clearance 225mm
Seat height 805mm
Dry weight 260 kg, (A) (B) (E) 263 kg, (C)261 kg
Curb weight: Front 138.5 kg , (A)(B)(E) 139 kg, (C) 138.5 kg
Rear 129.5 kg, (A)(B)(E) 132 kg, (C) 130.5 kg
Fuel tank capacity 11 L
Performance:
Minimum turning radius 2.9 m
Engine:
Type 4-stroke, SOHC, 1 -cylinder
Cooling system Air-cooled
Bore and stroke 76 .0 x 64.0 mm
Displacement 290 mL
Compression ratio 8.6
Maximum horsepower 14.7 KW(20 PS) @6 500 r/ min(rpm), (U) -
Maximum torque 23.6 N-m(2.4 kg-m, 17.3 ft-Ib) @5 500 r/ min(rpm),
(U) -
Carburetion system Carburetor, Keihin CVK34
Starting system Electric starter & recoil starter
Ignition system Battery and coil (transistorized)
Timing advance Electronically advanced
Ignition timing From 10° BTDC @1 300 r/min(rpm) to
30° BTDC @4 000 r/min (rpm)
Spark plug NGK D8EA, (A)(C) NGK DR8ES-L, (B)(E) DR7EA
Valve timing :
Inlet: Open 21 ° (BTDC)
Close 59° (ABDC)
Duration 260°
Exhaust: Open 56°(BBDC)
Close 24° (ATDC)
Duration 260°
Lubrication system Forced lubrication(wet sump)
Engine oil :
Grade SE,SF, or SG class
Viscosity SAE1 OW-30, 10W-40, 1 OW-50, 20W-40, or 20W-50
Capacity 2.4 L
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Items KLF300-C7-
Drive Train:
Primary reduction system :
Type Gear
Reduction ratio 2.888(78/27)
Clutch type: Primary Auto centrifugal, wet
Secondary Auto multi disc, wet
Transmission: Type 1 O-speed plus reverse, constant mesh, return shift
Gear ratios: 1st 3.090 (34/11 )
2nd 1.928 (27/14)
3rd 1.368 (26/19)
4th 1 .000 (23/23)
5th 0.769 (20/26)
Reverse 3.072 (26/11 x 26/20)
Final drive system:
Type Shaft (four wheel drive)
Reduction ratio: High 5.416 (33/33 x 20/16 x 39/9)
Low 6.910 (37/29 x 20/16 x 39/9)
Overall drive ratio High: 12.037 Low: 15.357
Front final gear case oil: Type API GL-5 Hypoid gear oil for LSD SAE140
or SAE90W -140
Capacity 0.40 L
Rear final gear case oil: Type API GL-5 Hypoid gear oil SAE 90 (above 5°C, 41°F)
or SAE80 (below 5°C, 41°F)
Capacity 0.3 L
Frame:
Type Double tubuar
Caster (rake angle) 1.0°
Camber 00@1 G
Trail 5mm
Tread: Front 844mm
Rear 860 mm
Front tire: Type Tubeless
Size AT24 x 8-11
Rear tire: Type Tubeless
Size AT24 x 10-11
Suspension : Front: Type Double wishbone
Wheel travel 110 mm
Rear: Type Torque tube
Wheel travel 120 mm
Brake type: Front Disc (Hydraulic) x 2
Rear Drum (Mechanical, on Rightside)
Electrical Equipment:
Battery 12V19Ah, (U) 12V14Ah
Headlight: Type Semi-sealed beam
Bulb 12 V 25/25 W x 2
Taillight 12 V 8W x 2
Alternator: Type Three-phase AC
Rated output 23.5 A @9 000 r/min (rpm), 14 V
Specifications are subject to change without notice, and may not apply to every country.
www.midwestmanuals.com
I rI
1. Clamp (92037 -1181 )
2. Clamp (92170-1552)
3. Clamp (92037 -1271 )
4. Tube (92059-1789, to Cylinder Head)
5. Joint (59071 -1124)
6. Tube (92191-1170, to Air Cleaner Assembly)
7. Air Cleaner Assembly (11010-1622 )
8. Cylinder Head
9. Cap
10. Carburetor
11. Install the clamp (92170-1552) so that the clearances between the tube and near parts are more than 5mm.
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Fuel System
Exploded View
KLF300-C9 ....
, .... KLF300-C7/C7A
ooo08~~
Specifications
WheelslTires
Specifications
Wheel Alignment
Caster: 1° (non-adjustable)
Camber: 0° (non-adjustable) @lG
Toe-in: 20 mm
Standard Tires
Front: AT 24 x 8-11
Dunlop KT962, KnobbylTrail
Tubeless
(U)Goodyear, Tracker MPlTraii
Tubeless
Rear: AT 24 x 10-11
Dunlop KT962, KnobbylTrail
Tubeless
(U)Goodyear, Tracke.r MPlTrail
Tubeless
(U): UK model
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Final Drive
Exploded View
KLF300-C7-
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Electrical System
Exploded View
KLF300-C7 -, UK Model
Ignition System
(KLF300-C7A-, Europe Models)
Ie Igniter Inspection
o Refer to the Base Manual noting the following .
• Set the hand tester (special tool) to the x 1 kO range.
IC Igniter Terminal
Y/R R/W
~
(BK/W) BL
BK/W G/W
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Carburetor Heater
(KLF300-C7-, UK model)
NOTE
o The sensor and thermostat must not touch the container
sides or bottom.
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3. Starter Button ~~
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light 12V3. 4W
2. Neutral Indicator
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light 12V3 . 4W
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and Front 0..0
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Brake Brake ""C
Switch Switch light
SWltch light light
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Brake Light 12V27W
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BK Black
(Option) Pickup BL Blue
Alternator Coi 1 'f Starter Motor BR Brown
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G Green
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LB Light Blue
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2. Engine Stop Switch R I Red
L_J_'lf--l 3 . Starter Button W I White
(US): U.S. Model
Y I Yellow
CD®@
i. Oimmer Switch (98051-1673A, 1674A) C
2 . Engine Stop Switch
3. Starter Button
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and
Reverse
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2: Neutral Indicator Light 12V3.4W ::J I
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SwitCh Indicator Light 12V3.4W Accessory
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Speedometer
Light 12V3.41~ II M
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Terminals
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Switch Inspection
• Using the hand tester, check to see that only connections shown in
the table have continuity (about zero ohms) .
o For the handlebar switches and ignition switch, refer to the tables in
the wiring diagram.
* If the switch has an open or short, repair it or replace it with a new
one.
Special Tool- Hand Tester : 57001-1394
Horn Switch
- --
BKIY BKIW
When Horn Switch is pushed
General Specifications
Item KLF300-C11
Dimensions
Overall Length 1 860 mm
Overall Width 1 120 mm , (A) (B) (E) 1 210 mm
Overall Height 1 105 mm
Wheelbase 1 200 mm
Ground Clearance 225 mm
Seat Height 805 mm
Dry Weight 260 kg, (A) (B) (E) 263 kg, (C) 261 kg
Curb Weight:
Front 138.5 kg, (A) (B) (E) 139 kg , (C) 138.5 kg
Rear 129.5 kg , (A) (B) (E) 132 kg , (C) 130.5 kg
Fuel Tank Capacity 11 L
Performance
Minimum Turning Radius 2.9 m
Engine
Type 4-stroke , SOHC , 1-cylinder
Cooling System Air-cooled
Bore and Stroke 76.0 x 64.0 mm
Displacement 290 mL
Compression Ratio 8.6
Maximum Horsepower 14.7 kW (20 PS) @ 6500 r/min (rpm) , (U)-
Maximum Torque 23.6 N·m (2.4 kgf·m, 17.3 ft·lb) @5 500 r/min (rpm), (U) -
Carburetion System Carburetor, Keihin CVK34
Starting System Electric starter & recoil starter
Ignition System Battery and coil (transistorized)
Timing Advance Electronically advanced
From 10° BTDC @1 300 r/min (rpm) to 30° BTDC @4 000 r/min
Ignition Timing
(rpm)
Spark Plug NGK D8EA, (A) (C) NGK DR8ES-L, (B) (E) DR7EA
Valve Timing:
Inlet:
Open 21 ° (BTDC)
Close 59° (ABDC)
Duration 260°
Exhaust:
Open 56° (BBDC)
Close 24° (ATDC)
Duration 260°
Lubrication System Forced lubrication (wet sump)
Engine Oil:
Grade SE, SF or SG class
Viscosity SAE 10W-30 10W-40, 1OW-50, 20W-40, or 20W-50
Capacity 2.4 L
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18-4 SUPPLEMENT - 1999 MODEL
General Information
Item KLF300-C11
Drive Train
Primary Reduction System:
Type Gear
Reduction Ratio 2.888 (78/27)
Clutch Type:
Primary Auto centrifugal, wet
Secondary Auto multi disc, wet
Transmission:
Type 10-speed plus reverse, constant mesh, return shift
Gear Ratio:
1st 3.090 (34/11)
2nd 1.928 (27/14)
3rd 1.368 (26/19)
4th 1.000 (23/23)
5th 0.769 (20/26)
Reverse 3.072 (26/11 x 26/20)
Final Drive System:
Type Shaft
Reduction ratio
High 5.416 (33/33 x 20/16 x 39/9)
Low 6.910 (37/29 x 20/16 x 39/9)
Overall Drive Ratio: High : 12.037, Low: 15.357
Front Final Gear Case Oil:
Type API GL-5 Hypoid gear oil for LSD SAE140 or SAE90W-140
Capacity 0.40 L
Rear Final Gear Case Oil :
Type API GL-5 Hypoid gear oil SAE90 (above 5°C, 41 °F) or SAE80
(below 5°C, 41 °F)
Capacity 0.3 L
Frame
Type Double tubular
Caster (Rake Angle) 1.0°
Chamber 0° @1 G
Trail 5 mm
Tread
Front 844 mm
Rear 860 mm
Front Tire:
Type Tubeless
Size AT 24 x 8-11
Rear Tire :
Type Tubeless
Size AT 24 x 10-11
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SUPPLEMENT - 1999 MODEL 18-5
General Information
Item KLF300-C11
Suspension :
Front
Type Double wishbone
Wh eel Trave l 11 0 mm
Rear
Type Torque tube
Wheel Travel 120 mm
Brake Type:
Front Disc (Hydraulic) x 2
Rear Drum (Mechanical, on Rightside)
Electrical Equipment
Battery 12 V 19 Ah, (U) 12 V 14 Ah
Headlight:
Type Semi-sealed beam
Bulb 12 V 25/25 W (RH/LH)
Taillights:
Bulb 12 V 8 W (RH/LH)
Tail/Brake Lights:
Bulb (C) 12 V 18/5 W (RH/LH)
Alternator:
Type Three-phased AC
Rated Output 23.5 A @9 000 r/min (rpm), 14 V
Specifications subject to change without notice, and may not apply to every country.
A: Australia Model
B: UK Model
C: Canada Model
E: Europe Model
U: US Model
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o
Front Prope I I er Shaft
HK02038BW4 C
1. Circlip
G: Apply grease.
R: Replacement Parts
T1: 34 N·m (3.5 kgf·m, 25 ft·lb)
A: KLF300-C11
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SUPPLEMENT - 1999 MODEL 18-7
Brakes
HL02027BW4 C
1 . Brake Switch
R: Replacement Parts
Si: Apply silicone grease.
T1: 1.0 N·m (0 .10 kgf·m, 9 in ·lb)
T2: 5.9 N·m (0.60 kgf·m, 52 in·lb)
T3: 1.2 N·m (0.12 kgf·m, 10 in·lb)
T4: 8.8 N·m (0.90 kgf·m, 78 in·lb)
T5: 25 N·m (2.5 kgf·m, 18 ft·lb)
T6: 20 N·m (2 .0 kgf·m , 14.5 ft·lb)
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18-8 SUPPLEMENT - 1999 MODEL
Electrical System
Exploded View
HP02058BW4 C
1. Regulator/Rectifier
2. Tail/Brake Light (Canada Model)
3. Bulb (12 V 18/5 W)
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SUPPLEMENT - 1999 MODEL 18-9
Electrical System
Charging System
Regulator/Rectifier Output Voltage Inspection
• Remove the seat (see Frame chapter).
• Check the battery condition (see Battery section).
• Warm up the engine to obtain actual alternator operating
conditions.
• Check that the ignition switch is turned off, and connect
the hand tester to the battery terminal.
Special Tool - Hand Tester: 57001-1394
• Start the engine, and note the voltage readings at vari-
ous engine speeds with the headlight turned on and then
turned off. The readings should show nearly battery volt-
age when the engine speed is low, and as the engine
speed rises, the readings should also rise. But they must
be kept under the specified voltage.
Regulator/Rectifier Output
Connections
Tester Range Reading
Tester (+) to Tester (-) to
25 V DC Battery (+) Battery (-) 14-15V
• Turn off the ignition switch to stop the engine, and discon-
nect the hand tester.
* If the regulator/rectifier output voltage is kept between the
values given in the table, the charging system is consid-
ered to be working normally.
*If the output voltage is much higher than the values spec-
ified in the table, the regulator/rectifier is defective or the
regulator/rectifier leads are loose or open.
* If the battery voltage does not rise as the engine speed
increases, then the regulator/rectifier is defective or the
alternator output is insufficient for the loads. Check the
alternator and regulator/rectifier to determine which part
is defective.
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18-10 SUPPLEMENT - 1999 MODEL
Electrical System
Alternator Inspection
There are three types of alternator failures: short, open
(wire burned out), or loss in rotor magnetism. A short or
open in one of the coil wires will result in either a low output,
or no output at all. A loss in rotor magnetism, which may be
caused by dropping or hitting the alternator, by leaving it
near an electromagnetic field, or just by aging, will result in
low output.
• To check the alternator output voltage, do the following
procedures.
ODisconnect the alternator connector [A].
OConnect the hand tester as shown in the table.
OStart the engine.
ORun it at the rpm given in the table.
ONote the voltage readings (total 3 measurements).
Regulator/Rectifier Output Voltage
Connections
Tester Range Reading
Tester (+)to Tester (-) to
Another black
250 V AC One black lead 39 - 59 V
lead
* If the output voltage shows the value in the table, the alter-
nator operates properly and the regulator/rectifier is dam-
aged. A much lower reading than that given in the table
indicates that the alternator is defective.
Regulator/Rectifier Inspection
Front Fender (see Frame chapter)
Connectors [A] (disconnect)
Bolts [B] and Regulator/Rectifier [C]
®:
tor/rectifier as shown.
• Check Y1, Y2, and Y3 terminal respectively.
*If the test light turns on , the regulator/rectifier is defective.
I I I
Replace it.
*If the test light does not turn on , continue the test.
HP09018BSl C
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18-12 SUPPLEMENT - 1999 MODEL
Electrical System
* If the test light did not light when the 24 V was applied
momentarily to the BR terminal, the regulator/rectifier is
defective. Replace it.
*If the regulator/rectifier passes all of the tests described ,
it may still be defective. If the charging system still dose
not work properly after checking all of the components
and the battery, test the regulator/rectifier by replacing it
with a known good unit.
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SUPPLEMENT - 1999 MODEL 18-13
Electrical System
CD
R
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HP09024BW3 C
1. Ignition Switch
2 . Alternator
3. Regulator/Rectifier
4. Battery
5. Main Fuse 30 A
6. Load
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,--------,
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I Wo r k L i g h t
12 V6 5I 60 W
(Ej----t-- R/ B K -{::~R
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Pickup
Coi I
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Switch
®Engine Stop Switch
CD 0 0) G)S tar t e r But ton
W1L1762BW5 C
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SUPPLEMENT - 1999 MODEL 18-15
Electrical System
Re a r II
I ~~:~: ~~:~: B rake
---c::J<:J-- B L~
~~-v~---~~
BL T a i I / Bra k eLi g h t (L H )
~ BK / Y-t>D-BK / Y 12 V 5 / 1 8 W
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1 i I<J- R I Tail L igh t ( LH )( R H )
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( U . S . A. Mod e I )
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30A
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Ci rc uit
R ect i f iter Relay
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v Spa rk Plug
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Starter
Mot 0 r
Color Code
BK Bla ck
BL Blue
BR Br own
G Green
GY Gray
LB l i ght Blue
LG l ight Gree n
I GN I TI ON SW I TCH CONNECT IONS NEUTR AL & REVER SE SW I TCH CONNE CT I ONS 0 Orange
Color BR W Gear Po sit i on L G Ground R! W P Pink
PU Purp l e
OFF 1st through 5th
R Red
ON Neutral W White
Reverse Y Ye I low
( 98051 - 17628,17638 )
W1R1762BW5 C
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1- - -- ~O~)~b~r~::- - - -- --I
I Heater Control Unit I
IC arb u ret 0 r * Ref e r tot h e i - -i
T her m >_~ e .':1 0 __ ~ 0-l UK. . T - - --T CDReverse Indicator Light 1 2 V 3. 4W
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Neutral /
Reverse Indicator
Switch Light
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1 12V23W' "'''''~''''
r-;:::r-- -- --~ Rei a y !:::;;;::: u 12V 3 . 4W
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12V25 /2 5W RI Y---1>D- RI Y - - - - - - , "-
(R H ) B KI Y --CJ<J- B KI Y - - - - - - , '"m
1
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f-R / Y --t:: R/ Y - - - + - 1
1
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B K I Y - - -+-l-++--H-+-..........- - - - - , - - - - t - - - - - - - - - t - i- - -
L ________ ........J -
Headl ight
ij
12V25/25W
( L H) (ID R/ BK-t>CJ-R / BK
RI Y
BK / Y
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BK / Y - - - - - '
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Left Handlebar Switch
(DLight / Dimmer Switch
®Engine Stop Switch
@S tar t e r But ton
@Horn Button
o 0 CD 0
W1L1764BW5 C
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SUPPLEMENT - 1999 MODEL 18-17
Electrical System
Accessory
T ermina l
- B L --D
- BK / Y -t::>C]-BK / Y
- R-D<J-R
=-® T a i I L ig h t (RH)
12V 8w
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BK / Y-{:>C]- B K / Y
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12V 8w
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Main Fuse
30A
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Battery
1 2V19AH
>->->-::":::0::::0:::0::::::':::
coco .................. a::a
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Starter
Mot 0 r
Color Code
BK Black
BL Blue
BR Brown
G Green
GY Gray
LB Light Blue
LG Light Green
a Orange
I GN I TI ON SW I TCH CONNECT IONS NEU TRAL & REVERSE SWITCH CONNECT I ONS P Pink
Co l or I BR I W Gear Position LG Ground R/ W PU Purple
OFF I I 1st through 5th R Red
ON I Neutra l c- ..:J W White
Reverse c- ~ Y Ye I low
( 98051-17648 )
W1R1764BW5 C
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SfRo M
Head light
12V25 / 25W
( RH)
@ R/ BK----t>D-R / BK-
R/ Y ----t>D- R/ Y -
BK / Y----CJ<:]-BK / Y - 1 - -
Working
Light
12V60 / 55W
/;~""1-R/BK
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Speedmeter
Light I ~
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12V3.4W >- >- >-
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Head light
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12V25 / 25W @ R/ BK----t>D-R / BK-f-
R/ Y ----t>D- R/ Y - "" "" ""
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...J
Ol Ol
""
~~"P
BK / Y----CJ<:]-BK / Y-----
(L H)
(0 ® 0)
Left Handlebar Switch
W1L1765BW5 C
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SUPPLEMENT - 1999 MODEL 18-19
Electrical System
8: c:
~ 3:
~~~
.......
Accessory
Terminal
co ~G>-
BK / RurK / R~
BK / Y BK / Y------+_+-~-------+~----_,
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Re I ay 1
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L::::: __ ~ ci::::
----------.., I Tail Light
(LlH) 12V8W
______________~~--------------------~_+~L-~~~----+_~---------- VI
F use
Ignition
Co i I
~Jr--"____ _ Starter
Mot 0 r
fi, Plug
Color Code
~~ BK Black
BL Blue
BR Brown
G Green
1GN 1T1ON SW 1TCH CON NECTIONS NEUTRAL & REVERSE SlIl TCH CONNECT IO NS
GY Gray
Co 1or I BR I W Gear Position LG Ground R/W LB Light Blu e
OFF I I 1 st t hrou g h 5th LG Light Green
ON I Neutral C. ..:J 0 Orange
Reverse C- ..:J P Pin k
(9B051- 1765B.1766B ) PU Purple
R Red
W White
Y Ye I low
'If 1 R1765BW5 C
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SUPPLEMENT - 2000 - 2002 MODELS 19-1
Foreword .......................... .. ............ .... .. ............. ............. ..... ... ..... ... .. .... ...... ..... . 19-2
General Information ..... .. ... .. .. .... ...... ... ... ...... ....... ................. ...... ... .. .. ..... ... ... ..... . 19-3
Model Identification .... ............ ......... ... .... ... ..... ... .... ... ................ ... .. .. .... ... 19-3
General Specifications ... .................. .. .... ... .. .. .... ..... ... ...... .... .... .... ........... 19-4
Torque and Locking Agent.. ... ........... ..... .. .......... ...... .. ...... .. ..... ..... ......... . 19-6
Periodic Maintenance Chart ....... .... ... .... .. .... .. ... ....... .. ... .... .. .. .. ..... .. .. ...... . 19-7
Engine Left Side .. .... .. .. .... .. ..... .......... ...... ... ....... .......... .... ..... ...... .... .. .. ... ... ... ... ... 19-8
Exploded View ....... .. ....... ........ ....... .. ...... .. ......... .. ... .... ... ....... ... .. .. ... ...... ... 19-8
Brakes .. ... .. ...... ...... .......... .. .... .. ... ... ... ...... ... ... ... .. .... ...... ............ ...... .... ... ......... ... 19-9
Exploded View ... .............................. ... ..... .... ... ............... ...... .... ...... .. .... ... 19-9
Steering ... .... ...... .... .. ... ..... .. ..... ...... .. ...... ..... ........ ..... ... ...... .......... ...... ..... .... .... .. 19-10
Exploded View .. ........... ...... ......... ........ ......... .... .... ... ...... .. ......... ... .... ..... . 19-10
Frame .... .... .......... .......... .... ...... ..... .......... .. .... .. ... .. .. ...... .. .......... ...... ....... .... ..... . 19-11
Exploded View .. ........... ....... ........ ... ........... .. ... ....... ......... ...... .. .. ... ......... . 19-11
Electrical System .. .. ... .. .... ...... .... ... ........ ... ........ ... .. ...... .. ... .. .. ... .. ..... ... .... .... ..... . 19-12
Exploded View .. ... ... ..... ....... .. ...... .... .... ... ... .. ... ....... ... .. ...... .... ........ .. ... ... . 19-12
Wiring Diag ram ........... .... .. ... .. .... ... ..... ... ..... ..... .. ........... .. ..... .. .. ... .... ..... . 19-14
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This "SUPPLEMENT 2000 - 2002 Models" designed to be used in conjunction with the front part
of this manual (up to 18-19) and/or Base Manual KLF300Service Manual - Part No. 99924-1057-01 .
The specifications and maintenance procedures described in this chapter are only those that are
unique to the KLF300-C12 - C14models.
Complete and proper servicing of the KLF300-C12~C14 models therefore requires mechanics to read both
this chapter and the front of this manual.
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SUPPLEMENT - 2000 - 2002 MODELS 19-3
General Information
Model Identification
General Specifications
Item KLF300-C12'"'-'C14
Dimensions:
Overall length 1860 mm
Overall width 1120 mm, (EU, UK) 1210 mm
Overall height 1105 mm
Wheelbase 1200 mm
Ground clearance 225mm
Seat height 805mm
Dry weight 260 kg, (EU, UK) 263 kg
Curb weight: Front 138.5 kg, (EU, UK) 139 kg
Rear 129.5 kg, (EU, UK) 132 kg
Fuel tank capacity 11 L
Performance:
Minimum turning radius 2.9m
Engine:
Type 4-stroke, SOHC, 1-cylinder
Cooling system Air cooled
Bore and stroke 76.0 x 64.0 mm
Displacement 290 mL
Compression ratio 8.6
Maximum horsepower 14.7 kW (20 PS) @6500 r/min (rpm), (US) -
Maximum torque 23 .6 N·m (2.4 kgf·m, 17.3 ft·lb) @5500 r/min(rpm), (US) -
Carburetion system Carburetor, Keihin CVK32
Starting system Electric starter & recoil starter
Ignition system Battery and coil (transistorized)
Timing advance Electronically advanced
Ignition timing From 10° BTDC @1300 r/min (rpm) to
30° BTDC @4000 r/min (rpm)
Spark plug NGK DR8EA, (EU, UK) DR7EA
Valve timing: Inlet Open 21 ° BTDC
Close 59° ABDC
Duration 260°
Exhaust Open 56° BBDC
Close 24° ATDC
Duration 260°
Lubrication system Forced lubrication (wet sump)
Engine Oil: Grade SE, SF or SG class
(C14~) API SF or SG
API SH or SJ with JASO MA
Viscosity SAE10W-30, 10W-40, 1OW-50, 20W-40, or 20W-50
(C14~) SAE5W-30, 10W-40, 1OW-50, 20W-40, or 20W-50
Capacity 2.2 L (EU, UK) 2.4 L
Drive Train:
Primary reduction
system: Type Gear
Reduction ratio 2.888 (78/27)
Clutch type: Primary Auto centrifugal, wet
Secondary Auto multi disc, wet
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SUPPLEMENT - 2000 - 2002 MODELS 19-5
Specifications are subject to change without notice, and may not apply to every country.
EU: Europe Model, UK: U.K. Model, US: U.S.A. Model
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The scheduled maintenance must be done in accordance with this chart to keep the vehicle in good
running condition . The first service is vitally important and must not be neglected.
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~
0
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See
Page
Engine:
*
Air cleaner--service
Clutch adjustment *
Valve clearance--check
••
••
•• I• 2-7
5-3
3-6
Fuel system cleanliness--check
Throttle lever play --check
*
•• • • (2-10)
(2-4)
•••
Engine oil--change * 5-3
*
Oil filter--replace
Spark plug--clean and gap
•• I
(5-11 )
14-5
Spark arrester--clean I • 3-11
Chassis: I
I
Joint boots--check
• • I 9-7 ,20
12-4
Rear brake adjustment--check *
Rear brake lining wear--check *
•• •• II
10-5
(10-6)
Front brake pad wear--check *
Brake fluid level--check
• •• 10-8
(10-8)
Brake fluid--change
• • (10-8)
Cable adjustment
Battery--check
* •• • I **
14-6
I
Steering--check
General lubrication * • • • (12-6)
15-7
Bolts and nuts--tighten
Front and rear final gear case oil--change * •• • I
•
15-8
9-10,23
Master cylinder piston assembly and I 2 years (10-11 )
dust seal--replace
Caliper piston seal and dust seal--replace
I 2 years 10-7
I
Brake hose--replace I 2 years 10-10
* :Service more frequently when operated in mud, dust, or other harsh ridin conditions.
* * : Refer to 2, 7, and 10 chapters.
(xx-xx): Reference Page in the Base Manual
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T2 ©
Kl3Bll •• C
1. Torque Limiter
G : Apply high temperature grease. T1: 59 N·m (6.0 kgf·m, 43 ft·lb)
L : Apply non~permanent locking agent. T2: 34 N·m (3.5 kgf·m, 25 ft·lb)
o : Apply engine oil. T3: 8.3 N·m (0 .85 kgf·m, 74 in·lb)
Lh: Left-Hand Threads T4: 7.8 N·m (0.8 kgf·m, 69 ft·lb)
R : Replacement Parts
Rh: Right-Hand Threads
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SUPPLEMENT - 2000 - 2002 MODELS 19-9
Brakes
Exploded View
KUI04 II C
Exploded View
1 . KLF300-C14 Model
A: Apply adhesive
T1: 20 N·m (2.0 kgf-m, 14.5 ft·lb)
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SUPPLEMENT - 2000 - 2002 MODELS 19-11
Frame
Exploded View
r---------- ---i
'--d;--- ./
H0020008"2 C
1. Rear Carrier
2. Canada Model
3. Other than U.S.A. , Canada and Europe Models
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HP02059BW3 C
1. Parking Switch
2. Front Brake Light Switch
3. Rear Brake Light Switch
4. Tail/Brake Light
5. Bulb (12 V 18/5 W)
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SUPPLEMENT - 2000 - 2002 MODELS 19-13
Dummy page
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19-14 SUPPLEMENT - 2000 - 2002 MODELS
~~ I I
I
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R/ Y --t:>CJ-- R/ Y ~
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Pickup Coi I
Alter Nator
LEFT HANDLEBAR
Lell Handlebar Switch Light/Dimmer S w I I c h E
Color R/Y R R/BK BR (
(DLight/Dimmer Switch OFF
®Engine Stop Sw itch LO
HI
0Starler But l on L--
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SUPPLEMENT - 2000 - 2002 MODELS 19-15
ht 12V3.4W
ht 12V3 .4 W
I~
U;
rake Acce s sory
vitch Parki n g Brake Rear Brake Terminal
Light Swilch Lighl Switch
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Co i I S I art e r Slarter Relay
C i r cui I
Jlatorl Rei a y
I i fit e r Color Cod e
I g nit e r BK Black
Spark Plug BL Blue
6 BR Brown
Slarier Molor
~~~~~
CH Chocolate
DG Oark Oreln
G Green
GY Gray
LB LI,hl Blu.
LG Lill'lt ar.ln
:A R SWITCH CONNECTIONS 19NITJO Jl SW ITCH CQHJlECl10U NEUTRAL & REVERSE SWITCH CONNECTIONS 0 Orange
En,in . SIDP Swilch S I a r I e r B u I Ion Color 8tar Position LG Ground R/W P Pink
-
I Color BR
- ,
Y/R Color Y/R BK OFF lit t h r 0 UI h 51 h PU Pur pie
OFF Releas ', ON Ne u t r a I R Red
Pus h ~~ Reverse W Wh i Ie
RUN <;JIll I Y Yellow
(98051-1856A)
LF300C01A3 C
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r Licht 12V3.4W
6 6
,BK/Y--t>CJ- BK/Y
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~~~~'%. BR Brown
eH Choco lita
DG Dllk art ..
G Grlln
GY Gray
LB LiCht Blu
SWITCH CONNECTIONS , •• ,TIOI 'W'TCI CO.IECTlal. IEUTRAL , REYERIE •• ITCH eOIIEeTIOI. LG Llchl a ....
S.il.~ Stul.r Button 8, ... _ 0 Orln'l
e"I •• SI., Color 8.ar P •• i I I •• LG R/W p
Color BR - Y/R Color Y/R Pink
BK OFF III t'r ••• ' St.
OFF Neutral PU Purp I.
ON
.,
Reill"
Pu.h R R.d
Re'lr.e
W Whit.
RUN <:- I (98051-1857A) Y VI Ilow
LnOOCOlA3 C
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KLF300-C12'"'-'C14 W·lYIng
. Diagram (Europe Model)
(DReverss Indicator light 12V3. 4W
®N.utral Indicator Light 12V3.4W
Ignition
Carbur.tor
H. at. r
12V23W
Headllcht
12V25/25W It: >-
II> C:I
(RH)
~R/BK-t>D--R/BK
~ R/Y -c>D-R/Y-
B K/ Y --c:J<J-- B K/ Y --i---l-
1j?--1-
1~fl----~---r~t-tl------r----t------~==========f=F=========~~~~~=
R/Y ___ ~~--_~
~__R/BK----<- - '--...JR /BK ---r--r-t----~
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_-----++-L-~
\ I
__ ..1----£ K/ Y___{~:]<:J-BR:)y---1-++---
12' 65/".
Work
. ~"/YCJ<i-BK/Y'
Licht
~I ------H---=l -
R--C>CJ-R II I
-i-t-t--+-r-+-UJ.J
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R/B K-t>D--R/BK--I--'
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R/ Y -[:::::C}--R / Y
BK/Y~BK/Y~ ";;;:;12V
Htadlicht
12V25/25W
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It: ;;;
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Pickup Coi I
lenition
,- __ ~ol~ f;, Spark PluC
CD ® 0
L.ft Handl.bar Switch ~
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CD l i c h t /D i mm If S wit c h f-L";'FT HANDLEBAR
Licht/Dimmer S .S WITCH CONNECT
Enll •• s
®EnCin. Stop Switch Color RI wItch
OFF Y R R/BK BR Color
0Sterter Button OFF -
LO
l HI = L
RUN;
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SUPPLEMENT - 2000 - 2002 MODELS 19-19
(0 P) Europe Model
arburetor :-=--=---=----~
I
Accessory Terminals
(Treiler LiChl)
I Reverse Li I hi
12Vl0W
~ >-
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' ~~~
(tl (-)
BattelY
12V19AH
/
Sierter Relay
tUN ~
., Push c;-. ~
I
R.verl.
(98051-1858B)
W
Y
Wh it.
y. I 10.
LFSOOCOSAS C
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SUPPLEMENT - 2003 - 2006 MODELS 20-1
General Specifications
Item KLF300-C1S - C6F
Dimensions:
Overall Length 1 860 mm
Ove rall Width 1 120 mm (EU, UK) 1 210 mm
Overall Height 1 105 mm
Wh eelbase 1 200 mm
Ground Clearance 225 mm
Seat Height 805 mm
Dry Weight 260 kg, (CN) 261 kg, (EU, UK) 263 kg
Curb Weight: Front 138.5 kg, (EU, UK) 139 kg
Rear 129.5 kg, (CN) 130.5 kg, (EU, UK) 132 kg
Fuel Tank Capacity 11 L
Performance
Minimum Turning Radius 2.9 m
Engine
Type 4-stroke, SOHC, 1-cyli nder
Cooling System Air cooled
Bore and Stroke 76.0 x 64.0 mm
Displacement 290 cm 3
Compression Ratio 8.6
Maximum Horsepower 14.7 kW (20 PS) @ 6 500 r/min (rpm), (US) -
23.5 N·m (2.4 kgf·m, 17.3 ft·lb) @5 500 r/min (rpm),
Maximum Torque
(US) -
Carburetion System Carburetor, Keihin CVK32
Starting System Electric starter & recoil starter
Ignition System Battery and coil (transistorized)
Timing Advance Electronically advanced
Ignition Timing From 10° BTDC @1 300 r/min (rpm) to
30° BTDC @4 000 r/min (rpm)
Spark Plug NGK DR8EA, (EU, UK) DR7EA
Valve Timing: Inlet Open 21 ° BTDC
Close 59° ABDC
Duration 260°
Exhaust Open 56° BBDC
Close 24° ATDC
Duration 260°
Lubrication System Forced lubrication (wet sump)
Engine Oil: Type API SF or SG
API SH or SJ with JASO MA
Viscosity SAE 10W-40
Capacity 2.2 L (CN, EU, UK) 2.4 L
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20-4 SUPPLEMENT - 2003 - 2006 MODELS
General Information
Specifications subject to change without notice, and may not apply to every country.
CN: Canada Model
EU: Europe Model
UK: U.K. Model
US: U.S.A. Model
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20-6 SUPPLEMENT - 2003 - 2006 MODELS
Fuel System
Specifications
Item Standard
Carburetor Specifications
Make, Type Keihin, CVK32
Main Jet #138 , (CAL) #125
Main Air Jet #70, (CAL) #50
Needle Jet #6
Jet Needle Mark N24G
Pilot Jet (Slow Jet) #38
Pilot Air Jet (Slow Air Jet) #140
Pilot Screw (Turns Out) 2
Starter Jet #65
Service Fuel Level (from carburetor body
-1.5 mm (below) - 0.5 mm (above)
bottom edge)
Float Height 17 ± 1 mm
Engine Speed (for reference) 1 300 ± 50 r/min (rpm)
Optional Parts
Main Jet #132, #135, #140, #142
(CAL)#120,#122 , #128, #130
Pilot Jet (Slow Jet) #35 , #40
Starter Jet #68, #70
CAL: California Model
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SUPPLEMENT - 2003 - 2006 MODELS 20-7
Fuel System
Carburetor
Carburetor Pilot Screw Adjustment
• Loosen the carburetor holder clamp screws (Front and
Rear).
• Tilt the carburetor to the right of the vehicle for easy ac-
cess to the pilot screw.
• Turn the pilot screw in until it seats lightly, and back it out
2 turns.
Carburetor Pilot Screw Setting
Standard: 2 turns out
• Reposition the carburetor properly and tighten the clamp
screws securely.
OFit the carburetor ridge into the groove on the duct.
HU09002BS 1 C
NOTE
o Depending on the atmospheric temperature of your rid-
ing area, the engine oil viscosity should be changed ac-
cordingly to the chart.
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SUPPLEMENT - 2003 - 2006 MODELS 20-9
Wheelrrires
Front Hub
Front Hub Installation
eTighten:
A
Torque - Front Hub Nuts: 145 N·m (15.0 kgf.m, 110 ft·lb)
elnsert a new cotter pin [A].
NOTE
o When inserting the cotter pin, if the slots in the nut do
not align with the cotter pin hole in the axle, tighten the
nut clockwise [BJ up to next alignment.
Olt should be within 30 degree.
HJ07007B S 1 C
OLoosen once and tighten again when the slot goes past
the nearest hole.
Rear Hub
Rear Hub Installation
e Refer to the above figures in the Front Hub Installation.
e Tighten:
Torque - Rear Axle Nuts: 145 N·m (15.0 kgf.m, 110 ft·lb)
elnsert a new cotter pin [A].
NOTE
o When inserting the cotter pin, if the slots in the nut do
not align with the cotter pin hole in the axle, tighten the
nut clockwise [BJ up to next alignment.
Olt should be within 30 degree.
o Loosen once and tighten again when the slot goes past
the nearest hole.
Exploded View
T6
~ T7
T7
Hl 020 0 8BW4 C
Exploded View
, ~ ~
4
~
•
4
H0020 14BW4 C
1. Canada Model
2. U.K. Model
3. U.S.A. Model
4. Option (U.S.A. and Canada Models)
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20-12 SUPPLEMENT - 2003 - 2006 MODELS
Electrical System
Exploded View
HP 0 2030B.,,4 C
Dummy Page
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20-14 SUPPLEMENT - 2003 - 2006 MODELS
Electrical System
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Headl ight
12V25 / 25W
( R H)
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Work L ig ht
12V65 / 60W
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R / BK--[>CJ----R / BK
R / Y~R / Y----+~
BK / Y ~BK / Y---~
Head li ght
12V25 / 25W >- >- >- ~'"
0000
( L H)
A l terna tor
Le ft Ha n dl e bar Switch
(DStarter Button CD CD (D
W2 L0026AW5 C
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SUPPLEMENT - 2003 - 2006 MODELS 20-15
Electrical System
Pa rking Brake
Li ght Sw itch
Accessory
F ro n t Brake
Rear Brake T erminal
L ig ht Switch
Li g h t Switch
r - - - - B L ---D<:}-B L ~
.-B K / Y-t:>D--B K / Y
- R-D<l---R
Ta i I / Bra ke Li ghts
12V 8 / 27WX2
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I- BK/ Y-!>D-B K/ Y
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Regulator /
Rectifiter
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'"''"' I gnition
Co i I
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Starter
Circuit
Rela y
( U. S . A. Model
/
12V 14AH )
Spa r k P l u g
Color Code
~"""~~,,~
Starter Motor BK Black
BL Blue
B R Brown
CH Chocolate
DG Dar k Green
Green
GY G ray
LB L i I: h t Bl ue
LG li, h t Green
I GHI TIO N S lI fCH CO III ECI I CNS NEU TRAL & REVERSE S1IITCH CONN ECT IOMS Orange
0
Co l o rJ BRJ W Gear Po s i t ion LG Gr 0 1,1 nd R/ W Pink
OFF J J
,,, throv,h PU Pur p i e
ON J~ Neutral''" <=- ..::> Red
Reverse c:.. 11K W Wh it e
Ye I low
(98 052-0026A.1136A )
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20-16 SUPPLEMENT - 2003 - 2006 MODELS
Electrical System
Ignition Switch
~
/ -----i-R / BK--t>D-R / BK
f--- RI Y ---t>CJ-R I Y-4-++---,
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Work Light
12V65 / 60W
. ( OP) BK / Y-c:::J<:J--BK / Y
#m~
Speedometer Li ght
12V3.4W
CID
RI BK-t>O-R I BK- -
RI Y ---t>O-R I Y -
BK / Y~BK / Y--
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Headl ight
12V25 / 25W
( L H)
~
0Engi ne Stop Switch
G)Starter Button
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LEFT HANDLEBAR SWITCH CONNECTIONS
Light / Dimmer Switch Eng i ne Stop Sw it ch Starter Button
Color R / Y R R/ BK BR Color BR Y / R Color Y / R BK
OFF OFF Rei e a s e
LO Push <;JIIIII~
HI RUN I
W2l0028AW5 C
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SUPPLEMENT - 2003 - 2006 MODELS 20-17
Electrical System
( OP ) Europe Model
r-:- -
I Carburetor
~ Thermo. Sensor
12"" ".""
Relay
"8~" ~s~~ "' ~ ~-~:-y- --=>7B'~~BK/y-®12V
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8 / 27WX2
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Reverse Light
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Battery
12V19AH
Starter Relay
~
- --~ Starter Moter
Color Code
BK B l ack
G/W
Y / R--------- - - -+----
~ BL Blue
BR B row n
--------------
Ignition Coi I CH Choc ol 3t e
DG Dar k Gre e n
G Gr e e n
GY G ray
LB l i g h t Blue
LG l i g h t G r een
IG ,'4 I T I OH S WITC H COHHECTIONS N EUTRAl & REVERSE SJI'I TCH CO NNECT t ON S
Orange
0
Color I BR I W I GY G e:l r Posit i on LG Ground R/ W P Pi nk
OFF L I L I" throu , h 5t h PU Pur pie
ON I Neutra I <::.. ~ Red
Reverse c:.. ~ W White
(98052-0028A, 1138A) Y Yellow
MODEL APPLICATION
Year Model Beginning Frame No.
JKALF8C1 oKB50001 ,or
1989 KLF300-C1
LF300C-60000 1
JKALF8C1 oLB507501 ,or
1990 KLF300-C2
LF300C600951
1990 KLF300-C2A JKALF8C10LB511551
JKALF8C1 OMB515401, or
1991 KLF300-C3
LF300C-602101
JKALF8C1 ONB521201, or
1992 KLF300-C4
LF300C-603201
JKALF8C1 OPB527201 ,or
1993 KLF300-C5
LF300C-603651
1994 KLF300-C6 JKALF8C10RB532701
JKALF8C1 08B540601 ,or
1995 KLF300-C7IC7 A
LF300C-604701
JKALF8C1 oTB548951 ,or
1996 JKLF300-C8
LF300C-605801
JKALF8C1 OVB557001, or
1997 KLF300-C9
LF300C-606501
JKALF8C1 oWB563201 ,or
1998 KLF300-C10
LF300C-607501
1999 KLF300-C11 JKALF8C10XB57901
JKALF8C10YB571101, or
2000 KLF300-C12 JKLF8C1 OYB576901, or
JKALF300CCB609501
JKALF8C1 0lB5821 01 , or
2001 KLF300-C13
JKALF300CCB61 0501
JKALF8C102B590201, or
2002 KLF300-C14
JKALF300CCB611301
JKALF8C1 03B593501 ,or
2003 KLF300-C15
JKALF300CCB612001
JKALF8C104B596101, or
2004 KLF300-C16
JKALF300CCB612601
JKALF8C105B596701, or
2005 KLF300-C17
JKALF300CCB613300
2006 KLF300C6F JKALF300CCB613901
o:This digit in the frame number changes from one machine to another.
..cKawasaki 111111111111111111111111111111111111111111111111111111111111111111111111111
*99924·1117·65*
KAWASAKI HEAVY INDUSTRIES,LTD.
Consumer Products & Machinery Company