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Ninja250R Kawasaki GPX250R

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Motorcycle Service Manual Supplement

Quick Reference Guide General Information

Engine Lubrication System Engine Removal/Installation Crankshaff/Transmisslon

Wheels/Tires

Final Drive Brakes

Electrical System Appendix Thi s q uic k re l..ol'lOt !JJide will ...i.l y ou in

locating I desired tap;c Of prOCOdUfl . lO8. nd 1110 Plgoo b ock 10 m. td1 th e block to b o f th . desi..-d ch epler " umbo r with \11. black tab on Ih o edge II l och labl . 01 """,tlntl p• . I R,f" 10 lho ~on.1 lObi. of """tent> th l l uet pages to 100 011 I.... specific topic requ i'td ,

'Of

•

Kawasaki

Ninja250R GPX250R

Motorcycle Service Manual Supplement All rights reserwd. fIIo J*'!' 01 this publQtion ITIlIy be .ep rod uced . nOted in 8 ntrieval system,or t ransm itted in "''1 form 0# by "''1 mMI'lI, elec1l'onic mec han ical photocopying, record il19 or othtrWiM, without Ihe pr ior _men penn i.ion of Ouality A -...I IlCll Oepertment/CoI'llUfTlW Products .. Components G,oup/K_ _ k i H. ..y l ndun, in, l td ., Japoln. No liab ility ca n be accepted fo. eny in8CCUrac ies o r om issions in ttl;s PIlbliut ion, alt hough - V poMib le c;ore has been ta ken 10 make it as c ampl118 and accurate at possible. The right is reserved to make CN nqes al any ti me wit hou t prior not ic. a nd wit tlout incurring aoeo Of p_ Clu"" F,ict _ fol . _ •• ~

I.......' ....

.__.-..-

SAFETY ' N$TIlUCTlO ~ -eJpoor... ,I _ ..nl" " OCI 0 ' _. ~ . tII ,

_,_

,.... out '" - .

.

Of ;" .

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or ''''''' - " " 10"

_ ,--'. il - . . y . ... itll .. " 1""_ " ' . duo' .....aet ;on II higl> ","" .oolo . .. _ . "' OY " ""ld 01....1" ba 00 oqul Pl*l . ' iI • •• •

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EMISSION CONT ROL I"iFOft'tI ATIO N

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""rts . IJ} T~tlfl in, SeCJJence Genenlly ,....nan inst "' ling " Pl'rt with ~ bgl ts , nU b, or IC!'IW$, they should IllI be Sl¥led in thei, hollIS and tiltl~d t o" snug ti L Then liltl len them _ I V in a cross panem . This is 10 avoid d istortion of tha part 1Ind/0lt caaing lP' or 0; 1 leakage _ Convet'1OllV wtIen loosen ing lhe bolts. n uts, 0 ' $1';_, first loosen "' I of them by about I quarter of !Um and t hen remove them. Whe re there is a tiltltlning il!quence indiCl t ion in this Service Man ual, th e I.x>lts, nu b , or lICrews must be tiltl_d in the orde, and methw ind icate d. 14} Torque The torque ValUIlS given in t his SeNiti Man ual shoul d alway s be Idhe.vd to . Eith er t oo liu le or too much lo rque may lead t o seriou l damage . Use a good q uality , relieble tor qu e wrench , (5) Force Co mmo n san$!! 1hould d icta le how much fOfCe is necessary in assembly and d isassemb ly, If a pert seems espec ially difficult to remove o r ins tall, ste p and e ~am i ne wha t may be ca using t he probl em. When"" er tap pinll it; necessary, ti P lillhl1 y u$ing a wooden o r pllllt ic flOCed mallet. U$!! an impact driver for screws (parl icularly fOf Ihe removal of screws held by a loc king age< f" l l uwi n ~_ ...., ppl~ a Ihin oeed . nd . di",r if nec",wv • ru rn t he fuel tap PRI po>il iu n.

! WARN ING I o Go. oline i. oxtr . "",lv flamml b l. I nd oon be explo. I• • und., certain cond ition. . Turn ttl. igniti on ... iteh OFF. 00 not . moke. M. k. til . . ttl. . ... i. \\Ion •• n~ l . tod I t>. ~de f iIoe at. bum... body .., thol iIoe " ""0" lino i> ..-..I .... 11;. m'len hi..., ' h... iIoe bonom odie o r 1M . ..bur n ... Ul blr~1Or flOOI bowl willi

.....

o Tu rn iIoe Iuei up 10 I.... PR I posi'ion 1 ' ted fu d 10 the u,buretor, ' ....n !urn 01 Ih' u,bureto' du jn plu~

• fo... , u,n•. oW, i, un ~llhc fue l l..el; n the i-'uiI< ..1110., o Ke. ping 'he ~u ~. 'i".M""nt,n, 801 .. R_ f ender "' '''''' tin. &011.

R... Fen..... front 5«, ion Mounlinl 801" Re. Ilu k. R...

Flo.. hei tht

""i,

( Remo"",!he """,,,til'll boll ."ll pull the ootof pl.u ,l CooI. n, Ru e "' ..;' T.n k

I . r1w [ bo wl m , ung su,f... 2, Flo", 0,.1.. n..d lc , od

), n"'l

. 'il i de the . pr inl! b.nd.

4, ~ 1 "'t H" il(hl

_Pul l the

I WARNIN G • ""tr_y

orr t he .i, cl••nc r dllame number of turn. , 000nlcd during di,."emb ly. oFor the US model, in' tall the pilol «re.... plug ., follow' In,tall • M w piug in the pilot ' c'e.... hole. and apply d ,ma ll amnu nt of a bonding agent to the circum· forence of the plug to h the p l u~.

FUEL SYSTEM 26

lCAUTlO Jil ' COD

prMoocI •• _

. . " . . . - ' f "'" . . . -

_

~ '

OR-.... -..",w-

Of ~M:

"'-._We ...... o _

......... don.

, _ _•

lor . . _

. - . - ...""'. . .. - ' f bo ....,

-

,

_

. . ... tho

a ,. " - tho_·

'I ' ,... tho _ _ ... 11II Tl>is ",ill _ I _ _ ...

do~""'_01 tho po , tI.

en..

'*"

_bwftor - . , 1180 p1.nic thol _ I bo , , _ . DO NOT MOO 0 . tt..... _burolO' ~"1 oolulion wlllcII Id ottodc 1hftt Pl!'U; In.rood, use I mild ~lgII 11 11'11 ol. ... lng , o!ullon ..10 for pIo.U•

_. ..n•.

1. Apply ~ boodiol"il"M. 2. Plug

0 00 n01 UIO .. i" or ony 0 011.. h" d In.trumanl ' o .... n _bo............. H por;ially iotl. .. ""'" _y bo

). Pi lot ""r,,,. 4. C.,burew , body

ICA UTlOJil I COo not 1lwI _

-0;... . - ."'"

., _ _ - . . . . _

_

. .....

P'ulI '"

' ...... - . _.

. R;"",

_,the ......

~nd

.

11>0: por .. 1n ",. tn .

e'4'lIm eM port,

01l'hen ... tiftl tf'Irid>or ,~,,," ... """"..,. the "",,,,,ti,,. W IOWl, ~r>d reono>'O the o:oolder in t h. t t he bol to m uf ,h. .. sed air or by shaking it.

I WARNING I 0 00 not u.. lIIIJOlin. or • low f1..h -pomt ool••nt to cl... n .... .Iem.nt . A Ii.. or explosion 0>u1d r..ult.

e Aller de. ni n ~ , ..Iurale lhe >pongc filler with -S E cia" SAE 30 oil, , que"e out the exce", then wrop it in a elean rag one

Fuel Tonk

Air Cleaner Elemen t tnspection

and Replacement e Reffi O>O the . ir ele. ner element (,ee Air Ci.'int r Elemenl Rcm o..I). 80(1.." the , ir d eaner element (,ee Air Cle. ner Element Cle.n ingl. eVi, ually inspect Ihe element 10f t"." or br.. k, . Check lhe elemem holder . nd wire """" n.

Fuel Tank Removal

I WARN IN G I 00 ..oli.... i••xtn m. ly fl. mmobl. OM e.n bo • • plo. i•• u ndo< cortoi" "".-.didon. . Tum tho ;gnition switch OFF. Do not .mlillO0 fuol into Ih. con"" .... .

1. Filte,

2. ().ring 3. G.aoI the UP in Al l I'·... " p",itiom , _Ur. Ihe un • • nd top with ,ompre. , *R"" tae< tho if th~ ar. damoge< fuel .,....... into 1M ,,"'.. 1M ..pon in • CMIi.w _ lilt pod . Allllo . . . . - _

OFF . 0 0 _ ...... _ -.tilI\IOd _ froo fro.,. ... y _

_ oJt fto_

_ _ _ .,..,.- _ _ • pilot

op«i roed

try tile Periodic; "' ';n.. ~ ChML

I"'"

.. _ O f ~;

hoo.e> to !he ......."". ...d in. lIII !he on lhe 1f\(l1OtC~ . o l)i""on.-:. tho b,ulher h""" f,om the d in;":' aboul 20 ml or ",101,... Into the \C1l¥n", 11"0011' tho " - flnin.. • 0;",,_ 1 doe fuel the fuef unk e Run the open ern! of Ihe re,u", _ in 10 the teydo 'S

I~

.on cIor , lid 10 _ .wfl'>out "

_ fIOr'tJIJ ~

/I _

_

_

Ih""'fIh

If>o

if it ;, ..-1

FUel SYSTEM 2-19

•

. Emi..,,,,, - Co nt rol Sy. .. m e••po,."'"

1 Fud Tan k

" Carb ureto r

, ,

•. ' ne' Hoo' in 3 U A ~q uid,IV. C e. por Sep.,at"r 4: 5. 6 7: B. 9.

,, • •" • •

C.ni" e, oo,c (Bluo) Bre. the' H H< g .. . Air BI. oding . Vi.uol Leak In,pee, mOlta t io F. n Sw itc ~, Wate r Temperat u," $on,o,. W.te, Temper. tu re Sensor Remova l Fan Switoh Rom"".i in".II.t;o n Not .. In. pect ion • T~ e r m Ol!at

E1a,.

M .~ ""I

3-3,

OOLI

3-2 C

NG SYSTEM

E~~i;;d~d·',.i ......... .........~

.

.

.

I ®/I /~ ~ I ",

1. F... Swito C4u«d b~ c ~h, u by " Of ".. ".. .;. m UJ\' to. ~ from rt..c:ooIing~.

000 nor

NOTE "., ...,;... io cokJ (room or

~J.

,;,.

~ by _ ..... Of ,;,. CICI. If ,;,. UP ;, ......OI.d. Ii, __ lI"' ;"fO';" e«>I4nr.._ ~.

_cooIn.,_-..y.

3.0 COOLING SYSTEM

• 1, R...",oi , Tank Tube 2. Radi.n o r H.,... - To En.,,"

B. CooIanl Ln.:1

3. CoIM>' lnel •.

~i a'o.-

Hoi:k

NOTE ~

itt

m. CDt;I/Mo,

~ ... ",.

if """ . . m. Ii.

I'mm,. ~ -.d fld-..,

on- ,.,..,.,. up_ "

__

itt '""" ....,.. Fim

tum If/II UP dat:f;..,.. ro m. finr _ . _ .... it ..dm. _oI m. _ .

eFili the ",.."",Ir Wl k up 10 the FU LL toOI.onl,.and in- WI the ,,",p,

I"

UTID'

.",., ""'"

"""t

-SUI"! the

ooo/inl.yo,em 10< leak... Ii.... ........ il up 11""ouply. ..d It>en ,top

"

in ,1>0 r"""""';' ,.. k .of. ... II>
«1< the cool.. . _

enlli'" """" _

.

.. f .... U>p 10 .... FuM ...... k d'>rou" the ......"'OIr unk o;>peninl .

wi th

I

C$oft 0< dilt/lt.d ..._ mun IN uMd ... It h tho .n~ff. ... 1M' bolo..- for .n'II..... ) In ,h. ""olln~ . y.tem. (lif IIor< FH... C~ .n ge in \~" [ngil\i, ible darnall", replace tho

o

""

ll. di. \O, Cop ( obIiQU ily)

1. St..m Gun

o Run the gun lion_

2. More Ihan SO mm

~or l l on t a l ly

following lhe co. e lin dire< -

1. Top S. al 2. Botto m Seal

3. Valve S p ,in ~

oWet the cap , ealing ,urf.ce. with wate, or ooolanl to p,""o nt p,e"ure le. ks. .I nllall the oap 00 a oooling ,ystem p,e"ure toster. • Wa tching Ihe pre"u,e goouge, pump the p,e" ure teste, to build up the p,. " u, . , Th. cap mu, t ,elain I ~ e pr"" u, e al lea" 6 ..,on ck_ AI.o the

_Oi ;c on""n til. water temp oralure ",n"" connect"'.

_Wateh the vol,c . A, ,oon ., the val'e Ham to open. 110 1. the temperat ure. * If it i, ou t of the ,e, vj~e limit range, ,op lace the ther_ mostat,

Tll.. mDltot Vol.. Oponi"ll T_mlNlrature

80,5 -S3SC ( 177 - 182" FI

A. Senwr B, Connector

C, Thermo, tat Hou'ing D, Housing Boll'

_Remove tho thermo'w h oo,i n ~ bolt', and poll thc ho u, ing o ut of the fram e. _Remo' e the therm"'tat eO'lcr and pull out the thermostat if ncec..ary.

Thermostll1ic Fan Swit ches

Water T am paratu ra $en$O r Water Temperature Sensor Rem oval

ThermostBt Inspecrion _ Remove the the'mo'tat, and inw oct the thermo'tal ,alve at room tempe rature. * If the v. lve i' open, replace the val,o with. new on. , _To check val, o upening tempe rato re, ,o,p. nd tho thermostat and an aceorate thermomete r in . con tainer of water. _Pl ac. the ~ ollt ai n e r O'Ier a ",urt e uf heat and g,.d oa ll ~ rai'e the tempcroturo of the water while 'tirring the w >t e r ge n tl ~ ,

OTho f. n owith Of th o woto, to-mpo .. tu , ""', , houk! no" r bo . Ilowed to f. 1l on • h.,d ,f.. co. S"",,,. >hod< to - . po, n con 110" - th orn.

_Remove the thermo' tat hou' ing (;ee . Thermo;tat H"",; ng Remo", l). • _ Rom",c the ",n",r I""" th e the rmo'tat hou ; i n~. _Remove the ", n; or from the th ermo;t.t h (>O." i n ~.

COOLI NG SYSTEM 3·13

Fan Switch Rem oval eu ,.in the cool, nl. eRemuve ,he fair ing, . Romo," th , , witc h .

rM' ,wileh w ,

l

- t-- -t--+ +,Cam

Ht ignt

ENGINE TOP END 4-5

Special Tools Refer to lh. B.1", Manu>1nu ling the follow ing.

Sealant

............................................................................ Kaw. ..ki Bond ISili _ S• • lant l : 56019-120

Compr. .. iOfl G....go: 5700 1·221 Ad.p..r: 57001-1225 Go. k01: 57001·1224

K.w... ki Bond l l iqu id G•• k• • _ Blockl : 92104-1003

s.. t Cutt.... : (46° _¢24 .5: 57001.1113) (32° h . - 0/122 : 5700 1-12061 (32°ln. _ 25: 57001 -11 18) 167,5' ~ ~2: 5 700 1·1207)

V. I• •

roe

__

4-6 ENGINE ~-_ .

H

H

__

_.

END

- _.....•_ -_ _ .._

_ _ • •• _ _

_

..

CyJindtlr Ht»d eo- RMnonJ _Doli n I!lc o:ooIonl 1_ CooIlnt Drain... in the Coolin, Syolem d>.tp1Of}. _ Re_ 1he followi", p.o< lO, Upper Fai. ..., (.... fr~me W plOf in th i. 'e..) Fuol T. nk (_ Fuel Sy, ..... h""'n.

I.

hoi" 10 Ihe Ij>e . nd U k< out the chOli n ten,;""er,

A. Ten, ioner

B. M(>un ting Bolb

~7

e Be , ure the Q-ring i, in pi,,,,, in the ton, i""e r body. el nH. 1I the ten,lo ne, to the cronke, ,,,. e Aftc, in, t. ll. tion of tho ten, ioner, uned, apply , th in 7001 221 2. Ad.pte " 57001 .12 25 3 . Gasket : 5 700 1·1224

4·12 ENGINE TOP END a U, ing the ' W ier nlOlOr,' ot. te the eng;no o..r with the th,ottle fully open until the oompresslon gaull" , top, ' i,ing; Ihe romp'e"ian it Ihe highe,! r..ding ah"'in· . ble. a Repea! lhe me. ,u remenl for the other cylinder.

_Remo, . the oylindcr head bolt" Cvlind..- Head In. talii tion

('1rv

Cvllnder ComPf'l"Oon (U..bl. Ra"llll) 980 _ 1500 kPa, 410 . /min (. pm f (to.O _ 15.3 kglom', 142 - 218 psif

0lf cylinder eompre"ion I; higher lhan hte m nd>rd value. ohock the fulluwing; 1. u rb"n l>u ild·up an the pi,ton on lhe pi,ton head and oylinder heJd. _ ole. n off . ny corban on the phto n he ,~ and oylinder head, 2. Cylinder head ga6 mm) 2. Cylinder Head Bolts 1¢8 mm) 3. Chain Guide Bolt (Upper)

aR emo.. the a ll h", . bJnjo bolt. a Before ' emo' ing tho oylinder he. d, hold the earburelO' to the J ir oledner duct with a ' lf in~,. a Pul1 off the cylinder heJd, and remove tho cylinder he.d ga., ket ,

A. Cylinder Head B. Carbu, etor

C.

5trin ~,

~ ou , i n g .

egern ove th ~ cylinder head cover. a Remo' e the cam. hafL a Remo, e the re. r cam' haft ohain guide boll luppe, ). and lJ ke the guide off the oylinder ho'd . a Pul1 the front c.m ,hall chain ~u ide off the cylinder head.

Cylinder Head Ins tallation Notes . When In' talling the cylinder head. be ca'eful of the following item" OReplace lhe cylinder head giI, ket with a new one. OT iW1 ten the cylinder heJd bnl\< (.ps ) J nd (¢ti) to lhe ,p ecif ied 'orque (,e e E ' p lod e~ View).

ENGINE TOP END 4-1 3 Cylind.r H.od Bal.. Tightening Order

~

a

©

•

@

,

I""•

©, ,~

,

Jl(

e

@

~, 0)

-~

"='!

1. V.I ,e SpringCompre.>r A>lemhly: 57001-241 2. Adapter: 5700 i-1202

oAfter cylinde, head in,t all.l ion. in.WII th, front camshaft "h. i" guide Jl Ihuwn. ~ ie _t

the are. around Ihe v_lye ~ u id e to ahout 120150·C {248 - 302'F ), and homme, lightly on -. Iveguide arbo r I, pecial tool) to ,emove the lllJ idc from the top of the head.

Cho,n GuOd.l n" .II.tion

VI I•• Guide Aomo,.1

1. ChJi n Guide 2, No SIJck

3 Fil he.,

1. V_I,e Guide Arhor: 57001-1203 the rear o>m.h.ft eh. in guide bult lupper) to the ' pecified torq"e be e Exploded View)_ "Tigille" the oil h",e banjo bolt 10 the , pecified tor que I>ee Exploded View). O Ti ~ h t e n

Cylinder Head Disassembly and A ssemb l y (Valve Mechanism Removal and Insrallarion) _U", yolve ' pring Comp r.,,,,r . " embly l,p eei_l t""l) to pre" down the v_l, e , pring retoiner. and remove the , plit keepe" ,

_Valve Guide 10'UII.tion, OAr r ly oil to the -. I,e guide outor . urfJce before in'tJ llation. oH.. t the ..ea oround the v_lve guide hole to , bout 120 - l$O'C (248 - 302' F). CO rive the v_I'e guide in from Ihe top of the hOod u, ing the ' ol,e guide "rb",. Tho f lJnge ' lup, the guide from going in too far. oRe_m Ihe val,. guide with" valve guide re"mer (, pec,,,1 1001 ) e, en if Ihe oil guide i, re-u", d.

4·14 ENGINE TOP END V.I•• Guid. Aoom...

A. Str>ighledge

1, V. lve Guide Reamer, 5700 1·1204

Cylindor Hood Worp

. Val, e In' tollalion. OChock to soc that lhe " I, e move, .moothly up and down in Ihe guide, oorcc r to IOC lh dl the valve SCali properly in the val¥c ,eat. If il doe. not, rep.i r the , . Ive ...l

0 .05 mm

Cylinder Head Cleaning . Before ioulfi do engine ..", mbly grea'" to the valve "om bofore valve in· , lallalion, OBo , ure to in,u ll the inner ,nd outer . pring ", at. onder the inne' . nd oute, , pring,. olnst. ll the .p ring, '0 lhat the d o"'d ooil ' nd i' facing toward lhe v. lve t ul.. OIl!, and lltr h.4d ~u id .

mot in8 "",foOte. ee'

V. l.. lappel, grinding compound pa-fe"tly matc h .al. e and , . ot are.: check " I•• ho. d fo r dam oge

FINISHE D

ENGINE TOP END 4-21 Cyli nder, Pi5ton

Cylinder Removal _ Romo, o th e following par!> before cylind er md p i'lon remo ,. l, Pol ili,," t he cran k,h. fl . t co mp" " ion ",ok. T OC for tho Nu mb. r 2 pi'to n, .nd lhe n lu rn 'hc clockwi,e Jbout90' , F J i f in~

Fucl Taok Coo l>nl D" ining RJdl>to r Muff ler (.,b urow r {Pu II t ho rea rward ) C>m..t1af! Chain Too'i oner I{' ar ( am,h. ft Ch.in Guid. Bolll Uppor) Cyl inder H..d Cover Cy linder H. >d _ Rom",. l ho w.te, pip. mu unl i o~ bo ll >nd ta ke o ff ' he pipo fro m Ine wale ' pump . _Romo ve lho romo" d , U, e pisto n p in pull.r m emb ly (, pe it only enough 10 in" .11 i' and no more.

COo not

, ..... ,n op , inljO. o. , omo•• 1 w.. b n••nd

defo, ,,,. I~o m , evlin"', w. U.

Tllt y eould fill oul I nd , eo'o tho

_Po,i lion each pi'lon ring so th•• lhe op.ning in lhe top .i ng . nd oil r in~ 'lce l .. ii, Me facing foward, • •nd the , . cond fing ond oil 'i ng exp. nder o pe ni n ~, r.ee . he re... The opening, of the oil ring , teel roil, mU'1 be aboul 30 - 40· of J ngle from lhe opening of . he ,op ring.

ENGINE TOP END 4-23

Piston Ring, Piston Ring Groove Wear

End G. p M. .....r. ""'n'

"Check f,.- un""en Kruuve wedr by in, peeti ng the ring ", ., ing. *Th. ring' , hould f il perfoclly p. rallcl 10 the groo. e " " fa.... If no' , lhe pi"on mu" be 'Oplocod. .with the pi,ton ring' ;n thoir groove< , make " " e,.1 mO..UfOment< with 0 thi,k ne.. gauge to determi"" pi,t on ringfgr""," cleo,.nco.

Pilton Ring G,o"," CI•• r. n•• Top , Soeond

Stond. rd

Sq uarely in place, SPJ " 41 01 , no

............................................................................. '10 I AIO

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

aorr no s-e

CLUTCH 5-6 kif tho clutch cannot be . dju, t,·d by thi, mOl hod, in, peet the clutch pam, _Tighten tho knurled locknut at the olulCh If oil lIttouIIo the oil M .. op "" IJfJ N ~ 10 - ; " , IN ~ .,,;dt .,..

n- .r ''''J' _ _ """'Of""'",".

..." In _

oR _

Ja.,

~ IN

....."..

t>iI

1'Iu ~

9. Oil r ill... !UI.... n.inc Bol.

.. I ..... oil filt.... 10 he d ..","", ......... it . ittl . _ Oil F i l~, Ind l4ounl in~ Bolt R~" Mod Inolll ll. ion No!e, ). the JI"~'" . 1 the d " in p1u, IOf domogo . o R ~ tho Iol,;lo,,,, . ,ttl ~ .- one if it i. d• ....,.... _ >\Ile r the oil h.. lbly . . . . . . . •. . ... _

T....... iooion .••. •• •.. • •.••• • • • .. • • •

Ex...-NI SlIott _

R..._.. __ .

••

Exl«no1 Sl>if! Ill_ om 1",,,llo1ion Nma _. • _.• .. . . .. . . Eo' ..... Shift Mocho niom I _ioon ... _ Sh&ft R•..-. . .. • ••.• _

•

Tr_

Cf Ex"'-'IJI' _.. Cr.nk,n,lt/Cor>ro8ctlng Rod., .. ,

n onom;o,ion Shaft ' m " llo, ion Od ... Sh,l t Oi

Crank' haf' Re"'ovol. . , Cran k, halt In" ollot i"" Ne'n Ccnntcti"ll Roo R_ I I

.

~ ion

.

Con ntcti"ll Roo In

O, i,. Sh.lt A

,

. _

End S".

Sh'f! Fc:rt

CI_alll»

.

f ork ' ....I... i"" .•.. . .

e-"II

Sh ift For ilx.- Gr_

Sh'f! f ort G_

Con.--ti"ll Roo 8 1g End ae.;"11 l nooortlO..,kpin W_

"'b1 y Not•• , •• , •• .

Shift 0 t m -Dly NoM • • • • • . • • SI'Oft 0. ~ y Ne"," . • • .. . •.. - 1od Inst ollootion Not

StI" .. "e,DO' Clu,m Di_ b l y Stor'", Me t", Clu'ch A...",bly Not• .. , Sta r,..

"e'OI' Clu,ch InolWCti "" . , .

.

• •

"'bly • • • . • . . .. .. Output Sholl Auembly NOln • •••. •• • !iN1l Drum _ fcrk R...-.I • • • • . . .•

•

Sl>il t O. c m _

0-,,,, .

.

"'bly . . . , •• •• •• .

Ou'pu. Shit! Di

O _ .... It/Connoct'''II Rod CtJnnooctl", Rod _

.

•

•

e.2

-

CRANKSH A FT(r RAN R.......... SMISS ION . ..,~ _ __ _._ - .. . . ....,.. , - . b ~ ·V · · ·: · · · · · _ · · · · _ · · · · · · ·

_

L .....y non c• . A-'" . A--' . wl.....v r"lu__ ' m......, o ' A id M • V_"9'M oi l -

•__ • ~kOl .-.0''''' - , to tho th , ......

Apply mol ybd . ; . Sh,ft D ,u m Iloll ·nu~ di", llidt 3 ' S1o"", Clut ch Bur"'9 Hol d.. o

g.-

.

. Shift Dru m 1>00' of. Noul r.J Switch ,(;o n;ng Bolt

6 . Dri.. h l .mol 6. s_8h ;It ModI... i,...

7.

0..,,,,,. $110ft

R..

",n

S

prin g

Pin

CRANKSHAFTfTRANSM ISSION 8-3

'\>-'""In}

G : Apply ~r• • ~k""". Lh : LAft-H. nd k m 104 in-Ibl T1 :12N-m(l .2 ~-m' 1 1 ,O ft~bl T2: 15 N-m 11 .5 k~-m' 14.5 ft -Ibl T3: 20 N-m 12.0 kg:.." 18 .0 ft .lbl T4 : 25N .m I2.6kg '20 ft~b) T5 : V N-m 12.8 k~:;:; . 25 ft.lb) T8 : 34 N-m 13.6 k~ '5 1 ft~b) T7 : 69 N -m (1.0 kt- m,

.... CRANKSHAfTn RANSMISSION Spec:ificlotiom

h.m

S.rvioll imit

S""'. .

er...lNft. Connecting Rods : - --

Cormecting rod bend Conneet ino rod twist Connleting rod big end side cle.anta Connect ing rod b ig eod bearing insert!cran" pin clearance Cra....pi.. d iameler:

--D.13 _ 0.38 mm

N o~

Marking

O.2l100 mm 0 .21100 mm D.50 mm

0 Co....ect in g rod big end bote d iamete r: Nona Marking 0 Connect ing rod big end bearing inie rt thickness: White/ Blue White /Black Whita/BrowtI

O,031 - 0.059mm 29 .984 - 30.000 rnm 29.984 - 29.994 min 29.995 - 30.000 mm 33.000 - 33.0 16 mm 33.000 - 33 .00B mm 33.009 _ 33.0 16 mm

O.10 mm 29.97 min

,

- --

---

1.490 - 1.494 mm 1.485 - 1.490 mm 1.4BO -1 .485 mm

---

---

Cormo!ct ing rod big end bearinll insert select ion : Con-«> m own mm, b. """0_ ~~ movnting the engino.

O/f rho

rho

UpptN

A. Neut,, 1Po>i lioning Bolt _Remove th e oi l pre" ure ,w itch le. d lermin.l, pre..ure ,wi'Ch and oil ho,". _Remo ve Ihe neUlr . 1,w itch. _Removo , he external ,h ift mechan hm . _Remove lhe ch. in guide lever bolt . nd l. ke the >toppHoke), and turn it cloekwi,. .bout9O' Altern.tor Rot or Oil Hose Banjo Bolt Cam,h.fl Ch,in Ten, ioner Cam,h.lb (..e Cam,haft, Rock... Arm Removal in Engine Top End chapter) Rocker Arm, Cylinder Head (,.. Cylinder Removal in Engine To p End ch.pter) Cylindor (Cylind or Removal in Engine To p End chopter) Pi"on, (' 00 Pi,ton Removal In Engine Top End ehopter)

A. Chain Guido B. Lever Boil

C. Guide Leve, D. Stop pe, Plale

_Removo the uprer c"n ke.,e h, lf bo lt< (4 0' 2 if 2 were removed just .fter engine remo.. l). _Turn th e eogine up, ide do wo. _Re"lU"" tile oi l lilter mounting bolt, oil filter , and large O·ring. _ Romovo th e oil "reen co,e r . nd ",eon if nece.." y. _ Romove the 6 mm . nd 8 mm lower cr, nk,,« half bolt. , pi, the two point> , ho wn to , plit the two c"nk· co,. h.I" , ,port, and lift off lhe iowor crank" .. half.

CRA NKSHAFT/TRANSMISSION 8-7 Set Pin• • nd Sot Ring. Inlt. li.tlo n

A. 6 mm Boll\

B, 8 mm Bolli

1 SCI Pim 2, Set Ring> 3. Upper O.nkca," Half

~

" Mo k• •u' . the c...nkco•• HI pin••, . pro po,ly . Iigned to . vold d."",11'1 to th e "...nkco••• upon Inot.li.tion , ODon't u•• u.u.1 .-t pin. b.o.u•• t~ • •• t pins of t~l. mod . 1 . r. d iff. r. nl f,om u.u .1 pin. T ~ .y ... ~o llow arod . 110 used 10 PO" o il, If you u.. u.u.1 pinl by mi.,. ke, Ihe . ....in• • Iw.y• •• i•••. OChe are rt pl.c . d with new on." check c! earonco with plOltlgago befnre ..",mbling engine to be ,u re the correcting t>earlng in.. m are in' talled. _Apply engine oil to Ihe be..ing In..m ,

Connecting Rod Removal e Remove Ihe cr,nk>h aft . e Make and record the location' of the connecli ng rod. and their big end caps '" that they con I>e ' . . ... mbled In their originol po,ition, . e Remove the con ne~t i ng rod big end cap nut>, and take nff the connecu ng rod and cap with the bearing In..m,

Crankshaf r/Connecting Rod Cleaning _Aftor removing Ih. connecl ing rod, from the UMlk,h aft, w.,h thorn Wilh , high fl .. h.point , olyent. _ Blow the crank,haft oil p.,~e with compr.,..d air to remove any foreigo pan icle, or re, idue thn may ha"" accumulated in the pa"age> ,

Connecting Rod Bend

A, Connecting Rod B, Big End C. p

C. Searing In..'I,

leAUT1O' 1 OTo pr • •• nt domogO to tho eronkpin . urt"".... do ollow m. big .1>II co p bolt . to hie t~ om .

""

_Me.,ure conneeting rod bend. oRemove the connecting rod bigend bearing in.. rt>, and reinstall the a rne diamete r'" the connecting rod big end, m d in"'rt the arbor Ihroogtl lh. con· neCii ng rod big M d. 0S. I«;t an .,bor of the >amo diameter ., the pi'ton pin ' and at le"'t 100 mm I "n ~ and in.. rl lhe ..oo r thro ugh the con necling rod ,m.1I end. oOn . 'url.ee pl. te, ..t tho big-end arbor on V block>. OWith the con necting rod held ,ertkally, u.. a height gauge 10 me", ure the difference in lhe height of the arbo' . bo"" lhe .urt;u;e plate OYO, a 100 mm length W deter mine the amount of connecting rod bend, *If cnnne replaced,

Connecting Rod Inr tallstion Now. _To minimi.e vibralion, a p.ir of connecling rod••hould ~lYe tho •• me weigtll mark. Tho woight mark i, indicoted by a copil.1 lell.r, and i, .umped on the co n n "cl in~ rod bigend, Woight Mo'k Locotion

Connoctlng Rod Bond So•• I"" Limit:

0 .2/ 100 mm

Connocting Rod Bond M... ufOmont

l00m m

""

1. BigEnd Cap 2. Connecting Rod 3. We ighl Mark , Alphabet

CRA NKSHA FT/T RA NSMISSION 8·11

Connecting Rod Twist e Me",ure conneoh connecting rod parJllel to th. criUlkshall .0 thdl lhe pi..ligage will be compre".d between crankpin and lhe beiring i ",ert. Olnlo ,""y 10 .......... re lhe runoul . TM di ffer> i, e limil, repl;oc. IlIo , .. nk,h ,h .

Cr_ tho" Aunout

$en.e< l imit:

OJ»

mill

TlA

cr...""'1t A.........

•

o ...tholt Moi.. 8M. ... InM, " J_ _ Cl_ _ S.ondo, d, 0 .0 14 _ 0 .0 :18 ",m So'.ie, Limit: 0.118 mm * 11 e, a nd 1.ke o ff t he , hift fo rks,

A. Op erat ing PI.,e Pin

c.

Pro icol ion

S, Ope rat ing PI. te

OSet t he , hifl dr " m in neu" a l po, il ion", ,hown

A.. Sh ill Fo rk (Dr;ve)

C. Sh ift Rod ,

B. Sh ift f or k, (Qu, p"t) _ Pull ou l th e , h ill d ru m ab()IJ 1 half, _ R. mo, e 1he O P' '' 1 i n ~ pl. .. ' ird ip and """ r" lng p l.,e. Sh ift D,u m

1. Sh ift Urum 2. Operating PI..e

], Operat ing PI.le Pin 4 Circi ip

N."".I POIi' ion

t

I, Nc'u tra l Po , it i u n in~ Bo lt 2 , G"kot 3. Spr ing 4, Pin 5 Neu tr. 1Switc h

8-22 CRANKSHAFT(TRANSMISSI QN OApply • linle engine oil to the , hilt rod ond >h ift fork finge". Insert the "' ift rod. running it through the ,hilt fork" fitt ing oach >hift frk ~u id e pin into the ,h ift d, om grove. The output , h.ft ,h ilt for k• • re identical. Shift Fork. 1... , .II.'ion

OApp ly • non-permanent I""ki ng .ge nt to the thr..d of the plate bolt" . nd lighten lhem.

Shi ft D rum Disassembly Note ORemove the , hift drum and the di.." emble tbe drum "' \hown. Shift Drum PII' h

1. 2. 3. 4. 5. 6.

1. Shift For k (Drive Shaft) 2. Shift For k< (Output Sh. ftl

7. 8.

9.

Qln".11 the . hilt drum holding pl",e .. , hown.

10.

Cird ip Operating Pldle Pin Shift Drum Pin Be"ing Holder Pin Pin Pldte Pin PI. t< Allen Boll

Shift D,um Holding Pl... Inou n. lion

Shift Drum A ssembl y Note$ nThe ,h ift drum pin, (61 ..e identical. OApply • non·perm,n ont looking agcnt tu tho pin pln < bolt, . nd ' Ighten if.

Gear 88l;klilSh _Split the crankcase lu ving ' he Ir.n, mi" ion in place. _Set a di. l gouge .ga in' lthe teeth un on. ge", . nd move th. gear back . n,

gc."

Ghalt lH , and output , haft RH, aT;'" m ile" in • n« dle b U re, In'toad of mt.,u ring. in, peet tho bearing fOf . bra. ion, color ch. nge, or ot her dam. go, *11 there i, .ny dOin ~

D Fo rk Leg Stop

_ Romovo the colter p in••n d 1""St lh. outer circumference of , h, rim, and rol. le the wheel to me"ure radial runou!. The difference hell"een the high"' l and lowe, t dial rcMJ ing>i, the amounl of run,,"," If rim ru nout ,"coed , lhc , cr, ice iimit, check the wheel hc..-ing, fiN . Repld,e them if they arc d.m,ged. " If th, problem i> no' due to lhe bearings me wheel m" ' l be rep laced. Do not an empl lu , opair . damaged wheel. A.iol Run.,., t So..i... limi" Rodio'Runou' S. , . i l im;" Rim Run.....

0.6 mm

0.8 rnm

1. Radi. 1 Runout 2. A, iol RunOll t

A. Axle NUL B Ch. in Adjumf

D. Adju'l ing Bolt E. Axle

C, I

F, ( ouerPin

"",n",

COo no' I. y ,h o wh..1 on tho !/found w;'h tho " i,.

facing down. Thil C3n d~m~g. or worp th. disc. Placo block, lind.. tho who. 1 '0 'h. dile d.... not ' ollch , h. ground.

Rear Wheel Installation ' In' lallali"" i, the ro""e of remo" ,1. 0Be wcful of thc following nen» . a Adiu>1 lhe drive ,h.in . h er im"li.rion (>ee Drive Chain Adju"m, n' in Final Dri,e chap,"rJ. aTighten lhe n le nut to the , pecified torque (' e< h · ploded View). aright. n lh. Wr4Ue link nut to the 0... b..n ot...u:hMl. R.pl.... tho 100 " bolan woi ~t . 000 not rou d bolon... woighU.

WHEELS!TIR ES 9·' Balonco' Woill' "

.'"

' ''1 Numb.. « 1015 ·I OH «107S-IOlS « 107S· lOl 6

'"

IbjWh.n Ih. t l'e i, on th. ' im,

oPr y "'" &.01..... _i~ t oIf the 'i m 0 ", .....n. 0 '....... up -... ~ in Ihe fi . etnoon • ~ p of 11>0 " . - ~ be' ...eon the beod ..d nt" bbdo ... IJ ee d .... tori... ... """ .. f ,,'"" be ot...iMd.

_ i

"""

Ho.r b a-i, . F.onr Hub Bearing RtHnt4I

!CA UTION I 1 , Depth

t'"

000 not Io¥ w_ ... """ _lid with tI>o di.. loci... down . Th i. - ' do_ or w..- p ,ho d «>Upll". 'IIu Iroon tho .._ . • Re",,,,", me di" mou"ti.. g Aile" boh. ... d lAe oll llle di" . • 1«",_ lhe &

~ltl. ~ 1pin , rnooth ly , o r h... ny ro ugh 'pot! , it mo" be re pl" ed , *If lh< b,w ing ls to be u,m

Speedomete r Gesr Housing A ssembi y Grease Sea/ Inspecti on and Lu brication If the w e,," , e. l, are " am in.d withou t rem o ying t he ' eai, t he m..IY" , lock fOf d i" o!oWiOll (indimc> badly wo rn o r m.ladiU'l ed _ e it he, t(}{J 100'" or 100 t ight - lhe chil n cou ld jump off the ,prooket or bre ak,

I WA RNIN G , cA eho in tt>at boook. or jump' off t h• •prock . " cou ld . n.g on tt>a . ngin••prock . t ar lo ok th . roor whH I• •• • • r.IV d.m.ging tIl . motofcycl• • nd oau. ing it to IPD ""t of control .

Drive Chain Slack Inspection _ Sel lhe mmorc y, le up ()(\ il< ee nte r ling be>ll> eyen ly, To keep the e hain . nd wheel a ligned, lhe not ch "" th e left e h. in a diusler , hool d . Iign wilh th e ,.me 5wing arm mar k t haI the right eh. in . diu, te, nolch align, wit h ,

! WARNING I

Chain Slaclc In' PO. tio n

f'M iu llgnm. nt of t ho w _ will ,• • ult in . bnor m. 1 woo, • • nd m.y ,••ult In .n unuf. ' id ing condition .

Cha in Slac k [)ol• • Choin SI.ck Stenderil , ,,,,h .. SAE 90 i, profetTed to a lighter oi l l>ecause it will stay 00 tho , haln longe r and pr o. ido bell er lubr;cdllon , Olf t he ch ain appe." ..peci . lly dirty . it shou ld be d.. ned befo re lubrioat ioo .

OTh. O ~lnwo betwoon th ••id. pl. ... .... In th o lubrl cont _ • • n th o p;n . nd tho bu.hing. To ..o id do m.g;ng ,h. O...ing• • nd , .. ~I..n' 10.. 01 I ~brl co n ' . o b..... ,h. 1Ilow lng rule• . cU.. o nly k. to.. n. or di. ..! o il 10' c1.. n i n ~ .n O il>\l dr;• • ch"; n. Any ot h.. " • • n lng oo l ~m.n su . 11II. 011... or tr lchloroe th vlen. will cou'" d et orloro t lon . nd swoliing 01 th e O...lng. , Clmm. d l... ly blow ,h. ch. ln d,y with oom pro... d . ir afw ol..n l"ll ' c Co mpl"e c1 ..nln g . nd drv ing th e oh.in wit hin 10 minu ... .

A. Engine Spro, ke t Co,", B. Shift Le"e r

C Foot peg Bradet

_ Re mo v. the LIt mufflor _ Remove t he rlgh l ,Ide foo ' peg br ae kel (... R i~hl FOOlpc~ B,.,kot Remov.1in Frame chapte r). e Re mo ve t he RH mu ffler. e Ke mo ve the rea, ca lipc, I",e Roar Cdlipe r Remova l in Bra ke>, h. pt er). e Re mo," lhc redr whee l I"" Rede Whee l Remov a l In Whee l,fTlrc, cho pter) _ Remo yo tilt , wing .. m pivol nu t . Do no t remo ve t he pivot , ha ft.

_AppiV o il to the side, o f the rolle" so t hat o il will penelrat. to the ro llers a nd bushings. Appl. t he oil to lhe O ·rlngs so l hat lhe O-rings will be co ated with 011. OWlpe o ff dn. CX,"" i l. Ori• • Ch. iR l ~ b r ico t i o n •

Oil Appl iod Ar ...

A. Pivo t Nut

S. Pivot Shaft

_ Rem",'e t he lo wer , hook absorher nut , Do not rc mo," The 1>011. _ Remo ".,. th o uni·t ra k l iNOd upper n ut. Do not remo ve ho lt .

,h.

f i NA L DRIV E 10·7

A. ROd[ Sh()ck AblOrbe , B, Tie·rod Up p.r Boh

C. Bolt

- Romu, " the Un;·tr ak t ie rrxl lower n ut. Do no t remo ;,e the bo lt. _ Rh-po;nt ,o lveot, dry ii, and paok il witlt good qualily bearing gre..e before im lillialion, Turn the bearing by hand a few tim.. lu make sor. the gr.a se i' dimiboted uniformly im ide the bearing., . nd wipe the old gr.... oot of lhe coupling before bearing in' lililation , e...ri"Sl Lubrlcot lon

3. ik.ring Driver 1. Grease.

10·10 FINAL DRI V E

Grease Seal lm pectlon IJn d Ll'bricatlon If the grea,o , eal, are e..mined wilhoo t " mo'i ng lhe ,.,.1, them, el' e" loo k for di>color. tion (indicu ing the rubber h" deter iouted L h..dening, dam, ge 10 lhe inlern, 1 ribbing, or other d.mage. If the ... 1or Inw nal ribbing h.. hardened, the de.,ance belween Ihe ... 1 "" d the . xl. ,Ieeve will not be u h n up. which will . llow dirt and moi,lu re 10 enter and re.ch the be.,ing. If in dou bt .. to i" condition . nd whenever tho , e. 1 i, ",moved for gr o .,i n~ Ihe be' ring, the ",.1 'h oold be replaced, The ,e. l, are ~eneral ly d , m .~ e d upon remov. 1

Damper Inspection Remove the rear wheel eo upl i n~ . and in,poeCl the rubber dampe r, Replace the d. mper if it 'ppe." d.m. ged or dete fioraled.

A_Rubber O.mpe r

BRAKES 11-1

Brakes Table of Contents 11-2

,,.

Exploded View . S ~i l ; cot i Q n •

,,.

.

SpeO ' Ho lder Sh.tt Wear .

11 -5

Broko P.d,. B r.~.

Pad Rom"".1

Broke Pad In' ta llati on Not o . Broko Pad l ining W••r In. pect; "" , Maoto' Cy linders. F' on t M••tor Cylinder Romo., I . F,ont M.",. , Cylinder

11-5 11 -5

1\·5

• •

In.tallation Not e< R. .. M.ot..,. Cylin d... Aemo., I. .

R.ar MO'!M Cvlindef

I

Fron t M. " . r 0,l lindor mblV No' .. .

.

I

.

F,ont Mast., Cylin d.r

I

A... m blv NO'e>

R"'" Ma"er Cyl inder Di.." embly Not es .. R..., Master Cyl inder A..emblv Not e. Malt er eylin""r In, pec t ion (Vi,ue l In. pection l . R..... '"' Remo . al Not e. R..er.," , In, t. llatio n Note' . ..

II

•

Insta ll.l ion Not .. Inspoet i"" ...,d Adj u th.t require . dju ll men l on the fro nt bra 'e . Howe,... if the brake lo, er hJ' a ,oil , o r " ,[>Ongy f..,ling", e hoek t ho brake flu id le,.1 in t ho m.,ter cy linder a nd bleed the .i r from lh. brake line I,co Bltembly. II th e br. ke ped, 1 hal • >on, Of " ' pongy f.. ling", leed lhe brake line ($te B l cedin ~ t he Brakel . e(hock t be b rake fo r WOJk braking powe r, b rake drag, and fluid leakage.

C81iper Disassembly Notes e th ing com pre, "'d J i" r.mo' . lbe pi, tu n. (;Cover tb. caliper o rc n;ng witb • dean. heavy cloth. c,Remo,e l be pi'lu n by lightly a pply ing w mpr c;>ed air 10 ", here tb e bra~e I;" . fit< into lhe c,l iper.

I WARNING I A Calipor Moonting Boll' B. Cable Lowor End C. Caliper tk >l der

D. Caliper E, B ra ~ e Hme

OTo ..oid ... iou, inju ry. Moer pIa"" yo ur fingO" or polm in,io lt at t he c,lip,,", and t igbton ;t loosely. e Rem""e lh. " Iipe' mun l;ng 00 1" an d lake off th. caliper. e Di\Conn,,, ' t he br"k . hos< f,,-,m l!'to cal iper.

Pilton Rom"".1

1. App ly co mp' e, ..d air ,

A.Cal iper B, C. liper Mounting Bol l> * If lho fro nl

roar caliper i, to be di.."omblcd Jf tor remo v.1 and if com pre'ston u>i n~ l he fo llowing >ler ' before d i, conneet ing tb e bra~ . ho, e fru m t he caliper, Of

2. Clo th

C81iper ASSflmb ly Notes eApply brake Il uid to lhe outside o f lhe pi'ton .nd t he flu id ..al. and p",h t he p i'ton into lbe cy linder by band. Tak. ca,. tb at neilher lhe ,y linde r nor tb e pl, ton , kin get ", ratohed.

1H l BRA KES e Apply • thin co.t of , ilicone gr.... to the cal ~pe' holder sh. ft, and holder hole< (silicon< gre... " • , peti.1high temrent gr••"'). _ In, toll the .nti-rattle , prin!:in the __lIper ., shown.

Dun Seal and Cover D1 4. Do" se.1

Repl" e the fluid ",.1, under any 01 lho followin!: conditi"" " (» fluid le.ab ge arou nd the pad; (b) brake> o..rheat; (c) there is . large difference in left . nd , ight pad we. r; (d) the ... 1 i, stuck to the pi, ton, If the fluid ,e.1 is '.pl"e d, replace the du,t ", al .. well. Ai' o, "' . place all ",.1, e.. ry other time lhe pad, are ch.nged.

1, r. d 2. Calipef Holder

3. Push the caliper hulder.

lHI BRAKES Rer M" . rer Cylind,.r R ,.maval e Remo"e the roll« pin and then pU ll Ihe pin ou t of the f'U,h rod d ovi. and brake pedJ I.

e f{emDVe lhe banjo bo lt to d"ronneCl the brake ho,", from the ma,l er cylinder••nd lemporar ily ,ec ure the end of the br.ke ho•• to ", me high place to h. p fluid 10" to a minimum. There i' a flat waded View), Be , ure that Ihe metal pipe i, prope, ly fitte d into the U...hapcd notch in th. m.,lc r cylinder. e Tighten the rear mWCr cylinder mou ntin~ bolt> (2) the , pecificd 'o rque (>ce hp lod,d View). OCh ock and .diu>! the following i" m, o Brak, pedal po, i' ion (..e Brake Pedal Po, i, ion In,p-eclin n), ORear br.k. li!l cover out nf it' plac" e RemoY< ' he retainer with a circlip plie" and pUll Out 'he pi, lon wilh >e fo' any d . m"~ e, *If th. ,p ring i' d~m~ ge d , repl"e it ,

Reservoir Removal ORemove the rear brake 'e",,,oi , mount ing bolt. oRemo, e the bolh and take the b..cket off the fra.... , oToke tho 't~rl o r ,e l. y off the b' acket , and pull the ' c' ervoi' (J ut of the f'a me.

F,o nt .nd Ru, Moo. ., Cylindo,

B, M(Junting eon _r ake (J ff the ,." ervoir u.p and diaph.. ~m , and empty the brake fluid into . , uitabl. container. _Sl ide the ho,", clam p" and pull the brake ho'o off the ,..crvoir. Immediateiy wip< up any brake nuid that , pill , .

Re.elvoir Installation Nares _In' \.111 the cl. mp, for e brake ho," end,. _Fill the , c, c" oi, wilh f,..h brake fluid, . nd bleed th' brake line I",e Bleeding the B, ~ k . ) .

Di,CI

•

•

Disc Wear Mea"" e the Ihid ne" of each dhc " the point wh. " it h" worn the mo, l , Roplae< tho di,c if it h.. worn pa' t the "'''ice limit. Ol,c Thickn. ..

1, Ro"'''oir

2.

Di~ p h'agm

3. Relief Port 4 , Supply port 5, Cylinde' 6 , Return Spring 7. P, imary Cup B. Pi' ton 9. Secondary Cup 10. Ou. t Co"" r

I I. Br~k e Ie"'" 12. Push Rod 13. Clamp 14. H"'"

I. B.. ke Disc 2. Mea50ring A, .,.

BR AKE S 11 ·11 F,o nt Ohc Thiel" ..... Stl ndt,d So,.ic. limit Aoa, Oi,. Thlckn. .. Stondord S"... ioo limit

NOTE

4 B - S.l mm

4.5 mm 5.3 -5.6 mm

5.0mm

CHoi d ,h. reservoir horizonr~1 wh80 ·.1lin... If tho f luid lovel is low. r than tho lowor lel'O l lin., fill lh. ro..rvoir to lho upper le..1 lin. of lhe re. orvoir .

I WARNING

Disc Clellfling Poor braki n~ c.n be c. "",d by oil on tho disc. Oil On tho disc muo_fto, . Mi~illll diff., .nt tVPO' MId brond. of brok. fluid low. .. t!Io broko fluid boiling point.nd could _ tl>o brlk o to bo in.ffocti•• . It mov . 100cou.. tho .lIbbor brok. PUll to 6o... io,ol*. F,ont a..k. Fluid A...' ....I'

Disc Warp Jock up the mot",cycle '0 thatlh. front whed 1cd.1 " tr. n,m illed direetly 10 lh< " Iiper fur hr. ' ing .cti"" , Air, howe.. r, i' . p, . coutlon. Ii. ted below.

d l.~

l>rok. , 0.... ' • • th o

1. N.,.r reU," o ld broke fluid , 2 , Do nol u," fluid from a co nu iner Ihat h... been I. ft un",. led or t hat h.. l>e< n o pen for a long time. 3 . Do nol mix two Iype brake fiuld or any o il geb on them . Clean otf any fluid Of o il th ai inadverten lly ge" on Ihe p. d, Or d i'" with a h igh fl.,h·point ", Ivont, Do no l u'" one wh ioh will le..e . n oiiy , e, idue, Replaoe the pad' wit h new on.. if thoy ,"nnol be cleane d sat i,fa ctorlly, 8 . Srake flu id QU ickly ruin, painted , urface>; any ,pilied fiu id ,hOO Ifully com p ,e""'. wittlou. moin .prin~ 1 Fo lt from lhe lo we r cnd of the o,Her lu be.

QThe o po,ot ion 01 oi. l.on1 fori.d lled IOr'!oe, hook the wreneh On the " em locknut, and pull the wrenell >. t the ~ole with 11 kg offorce in the direction , hown. To rq uo S, om Loeknu, to Soot IIeorlngo

,-t=::::-- -

1 Stem Be.ring Drive< ' 57001-137 2, Adapter: 57001-294 _ Apply gr.... 10 the upper and lower outo, ,"f ttl< evonly ou tw..d 10 d e.. th. , Io pp"'l.

Seat

~ d.

""""

I

tUUTlD N

1",r.J/~ tiOIl

. S1 ip the hool< of !tie ... t undo< th o br. ce 011 m. fuol lan k, . nd pu t \II< ,toppt" of tho ... 1 Into the ho""ln Ihe f,. _.

.--.n._.

0 0 0 not bond 0 ..... 1tHI . H:l1 "'01. 100 for. TIl•• couH:l

l Pu>h do.... l he . ubbe.- cbm pcr lo . ...., the fuol !.Int . e fo>ot>!f>"g Br.:b t R_ >4I Refe< '" lhe Boor Mo,....j ""tina Uw 10I"";"eCit iJ nol . - - , . '" rnnoow the rrodf\er ............

~"

I I Front Part of Rear Fender fnstallaulJfl _ In,,,,ll the """"nlinl bol".nd ",. >hor. in tho> OIllin.1 politi"" (oee h pl • Sealant. Battery . . Precaut io,," Electrol yte. EI. ctro lyt. level In, pect iDil Batte,y Charging. Battery ConditiDil Batt ery lnitlol Charging . . Batte ry Ordinary Charging Battery T..t Charging , Ch. '!ling Sy, tem . Altemator Co.e r Remo.aL .. AltemaID' Co.e, In,,. llotion Not• • Altem. to, RotOf Remo.a l . . Alte,n otor Roto ' In.t.l l.t lon Not.. St.tor Coil Rem",.1. .. St. tor Coil I",tollat lon Not.. . Altornato , In. pectlon . . . Rectiflo r I", pection . Regulator In. pecti on Regulator/Recti!ier Outpyt Voltag.ln.pectiDil . Ignit ion Svotem . , Safet. In,tm ct iDil' Pickup Coil R.moval Pickup Coil In. ta liatiDil Not.. . Spe, k Plug Rem"".1. .. .. Spe,k Plug In".II. tlon Note 1\I"Itlo n Coil R. m"".1 , . Ignition Coill nstoll.tio n Note• . .. Pickup Coil In. pe

Femole Conneeto n

Mole Connectoro

BR CH

BIJc k 8 1u, Bro wn (ho w loto

DG G

O M !; ~ r e ,· n

GY

G" ,.

L6 lG

Ligh[ blue Li&ht g, o'n

o

o.. ,, ~"

Gfocn

P Pin k Purple PU R Rod W Wilile Y Yellow o MeJ"" " co il " tid w i n d i n~ re' ''la nee whon th e pMl i, co ld 1.1 ro om tompe" l ure)

"U

16-2 ELECTRICAL SYSTEM

@~

/

. ~~

c}@

1.1C ..... 1. 3. ()I, l ' r - . two_ • 4.W_T......._ _ 5 . f .. lIiwndl I . • _ . Roloy 7. ROIIIII.-IRoct,Ii• • I . Plckwp Coil

IS : """"'" • _ _ 10 "'" ..._

T1 : 7 . Ill 12 : 12 Ill n : 13 ,. T4 : IS,. m T5: 69 N·",

(0 .80 19 ,,"I 11.2 k 104 in .... 113 , , -, 113 in 1 (U; kl.... . 11.0 h -lbl 17 .0 kl -"' , 51 h -lbl

.

ELECT RICAL SYSTEM 15-3

9 . Ignit ion $witch 10. Ru , Br• • LigM Switc h 11. Sid. SUnd Switch 12, Tum Sig",,1 R.lay 13. Junction Box 14. Fu•• L : Apply l1OI"I1>"' m. ... nt locIc ing _ nt. 16: 5.1/ N-m lO.60 kg-m, 52 in_b) T7 : 1.0 N·m lO.10 kg , 1/ in .lbl 30 in-Ibl T8: 3 .4 N.... (0 .35 kg

16-4 ELECT RICAL SYSTEM

L_ 2. St.,...

loU."." Swi!dl

1. I",ition Coih

-t. B.olllI"y

11. S,..-t... R.I.y 12. TumSil n. I Rol. y 11. ,"",,'ion&~

s. K: l&nil.. 6. r "" Swild!

9 . NcuInJ Swil'" 10. Sidr Sund Swi!dl

7. Oil .........'" Swild! I . Pickup Coi l

W .,.' .mpoOlul ion to th e ba lte ry. Th i, will mJko t ho olootro lyte ",Iu, iun to o d"'.. no l " hubbies '" h6 ' .. ry low .pet if" gr. vity. it i. probably "'orled. . if the r ~ doe> nOl ~ p pe., ' u be ~"OUgh ",dimenl in • ta",e i ' follow>: S,op the engine Connec, lhe multim. ,er ., , hown in table , No", the ,..dings (total 3 mea,urement)

Ch.rging $y'tom Wiring Di.g r.m

,

L Ignition Swi,oh Connect'" 1 3. Connoctor 2 AI,e m.tor Thyristor>

,,

," s

Diode, (R'o tifier) Conn ol Circuit (Ie) Regulat"'! Ren ifier 3 Conne1

0

8 ••• WI'

" T

~

WiR

-,

10 HI

0 0

,

a

v

v

0 === 0

400

200

200

10

10

10 kfl

200 I!

'"

SkU

- --- -- -- - - - I' " - - - - - -,

'"I'"

wo n ' 00 n 600

n

' 00 a

000 n

1. Retu l,tor!R ccl ifio, 2 , Te' t Light

3. 12 V Bane, y 4. BK

S. YJ 6, Y, 1. Y.

8. 6 Pin Con nector

Aegu l.to. / Ro

,n

if

+

jJ

1. Ignit io n Switch 2, 6-pin Co nnoctor

' i~,

'lJ'

8. Ignitin n Coil #1 C I" d 9. Spark Plug, Y In or

3 , [n~i ne Sto p Switch 4. G·p,n Con n«.Of

6. Jutleti on ecx

10. 11 Stan S'd or _ Lockuut' witc h . I e 51. nJ Switc h 12 Neutc.1Switch 13, St.ner Relay

7. Ignition Coli "'~vy ..... r , .,"de
• ."tlMl m.r.r ruding .,.ri.. with mOf'" used ."d .he indivi dual diode, but, gen",IlIly spHking. 10,"", ffJoding mould 1M from ,ero to th o lirwl 1> oft""

t""

"" ie,

FUM Circuit In. poet

Mell:r Connecti on

Meier Re.ding (0)

',-,"

o

6 -17 ' 3A - 8 '8 - 17 'U S Modei Only

Electric al Wi. ing

n

-o

Wiring inspectiDil _Vi,u. lly in, pect , he wiring fo r ,igo. of burning, f,"vi n~, clc . * If any wiring i. poor, .par l and in, pecl it fOf corro,ion, dirt, and damage,

15-40 ELECTR ICAL SYSTEM "'"11 uU

r

,dnD'

--I ~~

-

-

, oft ' '''' ...."

, ,,,,. " V >]IV

I

I

..

---J--L '-_

~ ~

" •• ""~

• ••• ..:...:;: • • , ..... ..-

..

• _....=-

~ .•~

• ••

._-

-- _"JOB -r-":". jI---":'" · · X i-:::-

~, -- I

H- I )

=l0 ,._ " '"-

•

~

~

"

-I , r- I)

~

... l ....

,Hen' .

':,"

I

- ---

•

._

.~

•

•5'\.

~

If

-

II

'-;" . -

-- -

---~ -:: -.' -"":0~ ,

_ 1 ....

~

::::.~

--

' ~18 ELECTRI CAL SYSTEM ... M

· _ · · . . _ · · · · · · · · · · . .· · · · · · · · · · · · ·· _ · · · . . _

· · · ·· · ·· · _· . . •

..

EX250·F2 Wiri"'ll Oiagr8m (U K llIld AU1tr8118 modell)

....................................._

.

--

,

=:;.-

•

'-'

. . ....,, 1.......-

;gM 12 V 3W

om $+tnol lndl-'"

J

, --'

-

" .UA

~"

,

,

~':.,.-,I,'"

•

r~-.-_ ,-._ ----,"!J]' -

_ 1 ~1U;

~

,

II •

S»!

T··- .. ..

- -,! 'rll-.ovvfl1a'< - --

~ > .>$ ,rr" f'? ,

• l:ol!!il11H: 1

fril ·ovv ~

1- - -

,

,

8 K/ Y _

.,

I .... ~

r;=

~

I,O~" ,:I ~ :1.

...

'-

~

, i

,., ......

,-

V

•

,- -

i;:..- '"'"- .::-

[.::.

-

.

• •

...''",-". ' ...

-

~

@ 'UK model

..... ..'0" . . .

, ~ '"

1'.,."f .,'.~•

,

.,.

Tu,n SOlIn" R, I.V

"'~ cr~

~ ~ "'~>!!.

,•

,'I

Y ~ ,

~ ::i~

Cooll"" f on l 1 V 2 .9 A

••

•

,• \ •

~

R. .. R ;gM T u,n S®," 21 W l ;g""2V23 ....

J tl l

- ' 'm

""N

..

?... ~~ ~

F!~/'" ""N

N' S K / ... SL

K/ "'m L{R

'~

•

• "" •

•

L..::;;,KfV-Q- R

G/B K =

T. ;o/S,," light '2V &!2' W

li ~ ~~

~

J

~'!.

•

,•

:;]

.... ,--.-,... , -1 \ ... '-...---~

.

"'~• "' •~

. ~

,.

~~

"c ~ up

'E. """'"

u

,

,0", •• '~

-.-

.;::-= , •• •'"~-Co;>

o

"on" "_

E"i"t', --=-,,:;ji>" '", .. ~'

~

.;~

,

'_

,"" I '" L::' :{T:'I ......

,~

.

iiH~

..." ,. ... -;:::;;;:; · ·_j~·';" "" 'I't"' .. "~ "" _ .~ " ••o;~ " : _ >-+-0 .

,..."t

;,

>; , "" . -. .

r=;;:

- ,. ...... _. '.. -...

-•.•

tt~ _· -.3':~ ~ " " + ,=!- .te m, Wo" anty , po< ifioal ly exc1 ud. motoroyo l., which . re u.. d in competit i.. or reloted ",e,. Pl. . .. re. d the warranty o"efully, _ Motoroycle racing i, a "ery , ophi' licn ed ' poo liable for . ny domille, which might ari.. from alt. rilion, utili,i n8 th i, inlor mollon. _When the motorcycle i, operated on public road" il mult be in it' or i~i nal , t. te in order to en,u ," ..fet y and compliance with applicable regulation' ,

When a plug 01 the correct heal range i, being u,od, the electwde' will >lay hot enough to ~eep all the carbon burned on, bUI e de, ieable for im· pro.ed perlor manoo under ,pe ciol ""ndition, when proper mixlUre I, not obu ined afte r the Cir burelo r ha' been properiy odiu' ted, ond oil part' demed and found to be functioning pwpe rly, If ' he engine Hill exhibit' , ymp lom, of o.erly le. n carburetion after il l mainwnance and .diu' tment' are ,urr~ ctl y performed, tho m;tin jet can be replace d with a , moiler or larger one , A , mailer numbered jet gi,", • I..nor mixtu", and • lorger numberod iet a rioher mix· ture ,

I---~~:fl

_ .. 1

-- '\-.--

\6 '-'

Spark Pl ug : Tho ,par~ plug ignite, the fuel/. i, mi'Wr< in the "" mbu,l ion oh.m ber, To do thi, effecti.. ly and il the proper tim! be ~ e p t olean and adju,te d, Te' t h"e , hown me plug li, t. d in the " EI« tr icol Sy, t.m" oh. pter to be the beot plug for gen. ral " .... Since ' pirk p l u ~ requiremeot, ch. nge with the ignilion , nd and with riding l '~

PI"ll Cond iti""

~,

/--~~

D rlx>n fou ling

Oil foo ling

* Whet he r or n ot Ihe right te mperal ure plug il be ing u.. d r"" moto r trou ble Bat tery vol",ge lo w Relay, no t ",nta ct ing O' operating S", . te r b utton not conta ct ing Wiring ope n or ,""orted Ignit ion ,w ilch tro uble Engine >lOp , wiICh t rouble M. in fu,e blown St•• tor motor ,outi ng but . ngino doo.n·, ' Urn .. . . " Starte r mol '" Clutc h t ro uble Engin. won'"u. n .. . . " Valve ,. izu re Rock. r arm seizure Cylind.r, p iston seizure C•• n k. haft .e izure Co nnecl ing rod small e nd ,e izure Con nect ing rod big end ' eizure T. on. mi" io n gear or b..ring . eiz ure Com,holt ..izu re

16-4 APPENDIX No fu.t flow:

Fuel le cloAAl'd Fuel t..,. air vent obstructed Fu.1 lap dogged r u.ll ine clogged Flo. t valvo dogged Engin. fl oodod: F u.l l e~1

in " rbu r. tor no>! bowllOO high wom or < oring< worn C" nk5h,1t bearinl!' worn Oil pre" u.e ' WilCh dam' ged Wiring damaged Reiief . alve , tuck open O.ring at the ," I pipe in the crankcase domaged

Block .mok. : Air cleaner clogll"d Main jel lO o large or fall en off Sw ter plunge. ' luck o pen Fuel le..1in carbureto r 11 0", bowl 100 bi8h Brown , mok. : Main jc, too , mall Fuel l..el in carbure to r fioat bowl too luw Air cleoner doct lo""e Air oleaner poo rly ..aled or mi> Mulfter Mounting Bolt< ',t ulfter Connecting Clamp Bolt, Clu,ch Lover Pivot Nut Others : C.n rer Stilnd Bolts Side Stilnd Bolt Fron t Foottl0S Mount ing Bolt< Fonttl« Bracket M (}U nti n~ Bait, Side Stilnd Bolt Side Stand Br.c kct Bola

_ _ _ _ _ _ _ _ _ _4

APPENDIX 16· 8 Units of length:

Unit ConVflrsion Table

'm m mm

P re ,xes f fOr UAI-ts: Prefix

Symbol M

m.,.

"

x

"m N·m Nm

9

0. 10 20 0.7 37 6 8. 851 9.807 7.233 86 .8 0

,

, x x

kg-m

'g

"

Unil$ 01 Torqu e:

X0.0 1 X0. 00 1 X o.ooooot

m

, ,

mile

X 1,000,000 x 1,000

c

UniU of Mass:

0.6214 3. 281 0,0393 7 ..

Power

•

k ilo centi milli micro

, , ,

' .m '.m

,

kg·m It-Ib in·lb

Nm tt-lb in·lb

2,205 0.0 3527 UniU of Pressure:

L L L L L L mL mL mL

x

, , , , , ,

, ,

0.26 42 0.2200 1.0 57 0.8799 2.113 1.8 16 0.03381 0.0 281 6 0.06102

• •

gal (US~ gal (imp) qt (US) qt (imp) pin t (US) pint (imp) oz (US) oz (imp) cu in

Units of force :

N N

'g 'g

, x

, ,

, , , , , ,

.e. .e. .e.

Units of Volume :

kg!cm ' kg/em' cm Hg

0,01020 0.1450 0.7501 98 .07 14 ,22 1.333

• • •

kg/em'

""em Hg .e. psi

.e.

Unih of Speed:

,

km/n

0.6 214

m,'

1.360 1.341 0.7355 0. 9863

es

Units of Power :

0.1020 0.2248

'g

•

'b N

9. 807 2.205

,

.W .W

x

,

es

,

es

'"

H' .W

"'

Uni ts of Temperatu re:

9("C +40) _40,,0F 5

'F

• •• ", ;0 ,., "140 , , I,I I I •, _ 11.' 'c

.

_2D:

..

., .

00 :

,.i !, i 2 ' .7

5 ('F+ 40) 9

40 " ' C

". ..I ... " . ". '" , .. .. .. . ,..,...

••

10 0 :

,

I

:,.0

II, ,

"

I!

7J.i

iI

, I, ,

1

.,

"., ,

20

,

I I

: 120

U.

'F

'" "., ". I ,

>0 0 :

... ... ,I

I

: 140

·C

MODEL A PPLICAT ION Vo.r

1988

o : Th h

Modol

B&gi"" ina Fromo No.

EX2 50· F2 JK AEXMF1DJA OOOOO l IUS, Co n. d. Mode l) EX250 ·F 2 EX2 50 F·OOOOO1 (Europ" . Go"" r.1 Mod. l)

d igit In th o fromo numbo. o""th or.

""'''\IM from

0 "" mochino to

KAWASAKI H E AV Y IN O U STRI E S , LTO. CONlIlIhER PROO\II::Tl; II. OOIoI'IlNHIn; [;ROOP

,

Part No . 99924- 1109-51

Printed in J.po n