Kawasaki Ninja ZX-10 Motorcycle Service Manual ZX1000B1 B2 B3 1988-1990

￨
,￨
￨
Ouick Reference Guide
Cooling System
Engine Top End j
Clutch
Engine Lubrication System ● Eng
Removal/lnstallation
Crankshaft/Transmission S
Wheels/Tires l
I Final Drive ￣ll 【il
→ ￣￣/ ▽E ・
This quick reference guide will assist you in
10cating a desired topic or procedure.
●Bend the pages back to match the black tab
of the desired chapter number with the black
tab on the edge at each table of contents
page ・
●Refer to the sectional table of contents for
the e χact pages to locate the specific topic required.

l S'
卜 - ・, NinjaZX ・10 ZX-10
てfty や …
々17
…711'
Motorcycle
Service Manual
AII rights reserved.No parts of this publication may be reproduced, stored in a retrieval system, o
「transmitted
in any form or by any means, electronic mechanical photocopyin9, recordin9 0r other-
wise,without the prior written permission of Quality Assurance Department/Consumer Products &
Components Group/Kawasaki Heavy lndustries, Ltd 。Japan
・
No liability can be accepted for any inaccuracies or.0missions in this publication, although every
possible care has been taken to make it as complete and accurate as possible.
The right is reserved to make changes at any time without prior notice and without incu rring an
obligation to make such changes to products manufactured previously.See your Motorcycle dealer
for the latest information on product improvements incorporated after this publication.
AIl information contained in this publication is based on the latest product information available at
the time of publication.￨￨lustrations and phot09raphs in this publication are intended for reference
use only and may not depict actual model component parts.
OKawasaki Heavy lndustries, Ltd,1987,1989,1991 Second Edilion (4):May 15, 1992(M)

LIST OF ABBREVIATIONS
A
ABDC ・minuteCs)newton(S)paScal(S)horSepowerpound(s)
AC
ATDC
BBDC
BDC
BTDC center
°C de9ree(S)CelsiuS 「rpmTDCTIRVW
DC direct current
F farad(s)
°F de9ree(s〉Fahrenheitfoot,feet9ram(s)hour(s)liter(s)
lbmminNPaPSpsl 卜ndicator readingvolt(S)watt(s)ohm(S)
ft
g
h Ω pound(S)meter(S)
L ampere(s)after bottom dead Centeraltemating Currentafter top dead centerbefore bottom dead centerbott
This w,aming may apply to any of the followin9
components or any assembly containin9 0ne or

more of these components:-
Brake Shoes or Pads

Clutch Friction Material
Gaskets
lnsulators
SAFETY INSTRUCT10NS
●Operate if possible out of doors or in a well

ventilated place.
●Preferably use hand tools or low speed tools
equipped,if necessary,with an appropriate dust

extraction facility.lf high speed tools are used,
they should always be so equipped.
●lf possible,dampen before cutting or drillin9.
●Dampen dust and place it in properly closed
receptacle and dispose of it safely.
Read OWNER ゛S MANUAL before operatin9

(Continued on ne χt page.)
●● ●曳J
嶽 ●
賑 ●岑1敷虜 ●t. 騨驚吻,.
ダ4 翫.ダ嘱鳶,.j
酔毎●.騨4 町參耳希希参考,44 ・J4 萄,參参集碑令慨丿曝・參44 祓籐喩.砂毎聚,騨屈竃,叔y 亀泰毎｀叡噺I
弗 1、,
参妬驚夕争奪.11●皿,a
咄個ぽぼ個個個ぽぼ濡: ぶぼぱ総総個個無咄咄ぼ詰ぼぽ:
・1
nl
TAMPERING WITH NOlSE CONTROL SYSTEM PROHIBITED
固
1 ゛ Federal law prohibits the following acts or the causing thereof:(1)The removal or
諮 rendering inoperative by any person other than for purposes of maintenance, repair,0
「
図 replacement,0f any device or element of design incorporated into any new vehicle form the purpose of noise control prior to its sale or deiivery to the ultimate purchaser ore while it is in use, 0r(
圀 been removed or rendered inoperative by any person,
1
なQ Among those acts presumed to constitute tampering are the acts listed be10w:
●Replacement of the original e χhaust system or muffler with a component not in compliance with Federal regulations.
●Removal of the muffler(s)or any intemal portion of the muffler(s).

●Removal of the air boxor air box cover.
●Modifications to the muffler(s)or air intake system by cuttin9,drillin9,0r other means
if such modifications result in increased noise levels.
扇指圧万
引恐鎌我辻ドレミ大辻渋渋火元言ミ光圧指ミ眉恐原原図原
Foreword
This manual is designed primarily for use by 幽●●幽幽輝寧●●●●●丿 ●●書●幽聊●●●●幽幽・ l ●・慟●●嘩・ ●● l ●・・騨●● l 禰 H o w ● ● 奮・騨 ●l 嘸 ●I
to Use this Manual

trained mechanics in a properly equipped shop
・However,it
contains enough detail and basic ● ● 種種種 ●丿丿・ ●● 種種種騨・種曾・ ● ● ● 鎔l
information to make it useful to the owner who
desires to perform his own basic maintenance ln preparing this manual,we divided the
and repair work.A basic knowledge of mechan- product into its major systems. These systems
became the manual's chapters.AIl information
ics,the proper use of tools,and workshop
for a particular system from adjustment through
procedures must be understood in order to carry
disassembly and inspection is located in a single
out maintenance and repair satisfactorily.
chapter 。
Whenever the owner has insufficient e χperienceor doubts his ability to do the
The Quick Reference Guide shows you all of
work,all adjust-
ments,maintenance,and repair should be the product ″s system and assists in locatingtheir chapters.Each chapter in t
carried out only by qualified mechanics.
ln order to perform the work efficiently and 。
to avoid costly mistakes,read the te χt,thoroughly The Periodic Maintenance Chart is located in
the General lnformation chapter. The chart
familiarize yourself with the
gives a time schedule for required maintenance
procedures before starting work, and then do
operations 。
the work carefully in a clean area.Whenever
lf you want spark plug information,for
special tools orequipment are specified, do not
example,90 to the Periodic Maintenance Chart
use makeshift t001s or equipment. Precision
first. The chart tells you how frequently to
measurements can only be made if the proper
clean and gap the plu9.Next,use the Ouick
instruments are used, and the use of substitute
Reference Guide to locate the Electrical System
tools may adversely 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 Plu9
especially,we recommend that all repairs and
section 。
scheduled maintenance be performed in accord-
Whenever you see these WARNING and
ance with this service manual. Any owner
CAUT10N symbols,heed their instructions!
maintenance or repair procedure not performed
Always follow safe operating and maintenance
in accordance with this manual may void the
practlces.
warranty.
To get the longest life out of your Motorcycle:
●FoIIow the Periodic Maintenance Chart in the

ヒyVARNING i
Service Manual.
●Be alert for problems and non-scheduled oThis waming symbol identifies special instruc-
maintenance. tions or procedures which,if not correctly
●Use proper tools and genuine Kawasaki Motor- f0110wed,could result in personal injury, 0 「
cycle parts, Special t001s, 9auges,and testers 10ss of life.
that are necessary when servicing Kawasaki
motorcycles are introduced by the Special TooI
Manual. Genuine parts provided as spare 匹亘￨

parts are listed in the Parts Catalo9
・
oThis caution symbol identifies special instruc-
●FoIIow the procedures in this manual carefuIly,
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 CAUT10N)which
will help you distinguish different types of

information.
NOTE
oThis note symbo! 加( がcates points of particuya 「
interest for more efficient and convenient
operation.
●lndicates a procedural step or work to be
done.
olndicates a procedural sub-step or how to do
the work of the procedural step it follows.
lt also precedes the te χt of a WARNING,
CAUT10N,0r NOTE,
★lndicates a conditional step or what action to

take based on the results of the test or
inspection in the procedural step or sub-step
it foSIows.
☆lndicates a conditional sub-step or what
action to take based upon the results of the
conditional step it follows.
ln most chapters an e χp10dedview illustra-tion of the system components follows theTable of Contents. ln these illustrations youwill find
the instructions indicating which parts
require specified tightening torque, 01l,9rease
or a locking agent during assembly.

GENERAL INFORMAT10N I-1
General lnformation
Table of Contents
Before Servici
1-2
4
︲5
General Specif
1 1
︲8 01 1
Periodic Maintenance
1
Torque and
Cable,Wire and Hose 1

14
1-2 GENERAL INFORMATION
Before Servicin9
● ● ● ● 幽 ● 巻 ● ● ●● 眼Is 幽・ a ● ●s 暉・巻・ ● ● 幽● l ● ● ● 暉 ● ●・幽・・幽 ● ● ● ● ● ● 蜀・ s ● ● ● ● ● ● ● ● ● ● 寧幽幽 ● ● ● ● 櫛巻 ● 寸瞼・ ● ●l ●
Before starting to service a motorcycle, careful readin9 0f the applicable section is recommended to
eliminate unnecessary work. Phot09raphs, dia9rams, notes, cautions ・ wamings ・ and detailed descrip ｀tions
have been included wherevernecessary,Nevertheless,even a detaHed account has limitations,
a certain amount of basic knowledge is also required for successful work,
Especially note the following:
(1)Dirt
Before removal and disassembly, clean the motorcycle. Any dirt entering the engine or other
parts w 川work as an abrasive and shorten the life of the motorcycle.For the same reason, before installing a new part,clean off any dust or metal filings,
(2)Battery Ground
Remove the 9round 卜)lead from the battery before performing any disassembly operations on the motorcycle. This prevents:
(a)the possibility of accidentally tuming the engine over while partiaHy disassembled.
(b)sparks at electrical connections which will occur when they are disconnected.
(c)damage to electrical parts.
(3)Tightening Sequence
Generally,when installing a part with several bolts, nuts,0r screws,they should aH be started
in their holes and tightened to a snug fit. Then tighten them evenly in a cross pattem. This is to
avoid distortion of the part and/or causin9 9as or oi 目eakage.Conversely when loosening the bolts,
「iuts,0r screws, first 100sen all of them by about a quarter of tum and then remove them.
Where there is a tightening sequence indication in this Service Manual,the bolts, nuts,0 「
screws must be tightened in the order and method indicated.
(4)Torque
The torque values given in this Service Manual should always be adhered to.Either too little
or t00 much torque may lead to serious damage. Use a 900d quality, reliable torque wrench.
(5)Force
Common sense should dictate how much force is necessary in assembly and disassembly.lf
a part seems especially difficult to remove or install, stop and e χamine what may be causing the problem.Whenever tapping is necessary,
an impact driver for screws (particularly for the removal of screws held by a locking agent)in
orderto avoid damaging the screw heads.
(6)Edges
Watch for sharp edges, especially during majorengine disassembly and assembly. Protect your
hands with 910ves or a piece of thick c10th when lifting the engine or tuming it over,
(7)High Flash-point SoIvent
A high flash'point solvent is recommended to reduce fire danger. A commercial solvent com-
monly available in North America is Stoddard solvent(9eneric name).Always follow manufac-
turer and container directions regarding the use of any solvent.

(8)Gasket,0-ring
Do not reuse a gasket or O-rin9 0nce it has been in service. The matin9
surfaces around the gasket should be free of foreign matter and perfectly smooth to
avoid oil or compression leaks.

(9)Liquid Gasket, Non-permanent Locking Agent
Fo110w manufacturer ″s directions for cleaning and preparing surfaces where these compounds w
Ⅲbe used
・Apply sparin91y. Excessive amounts may block engine oil passages and cause serious damage. An example of a non'permanent locking agent common
(10)Press
A part installed using a press or driver,such as a wheel bearin9, should first be coated with oil
on its outer or inner circumference so that it will go into place smoothly.

(11)Ball Bearing
When installing a ball bearin9,the bearing race which is affectedby friction should be pushed
by a suitable driver. This prevents severe stress on the balls and races, and prevents races and
balls from bein9dented.Press aball bearing until it stops at the stop in the hole or on the shaft.
(12)Oil Seal and Grease Seal
Replace any 011 0r 9rease seals that were removed with new ones, as remova1 9enerally damages
seals.
When pressing in a seal which has manufacturer ″s marks, press it in with the marks facin9 0ut.
Seals should be pressed into place using a suitable driver,which contacts evenly with the side of
seal,until the face of the seal is even with the end of the hole.
113)Seal Guide
A sea1 9uide is required for certain oil or grease seals during installation to avoid damage to the
seal lips. Before a shaft passes through a seal, apply a little oil, preferably high temperature
grease on the lips to reduce rubber to metal friction.
(14)Circlip,Retaining Ring
Replace any circlips and retainin9 rings that were removed with new ones, as removal weakens
and deforms them.When installing circlips and retaining rings,take care to compress or e χpand them only
enough to install them and no more.
(15)Lubrication
Engine wear is generally at its maximum while the engine is warming up and before all the
rubbing surfaces have an adequate lubricative film.During assembly, 011 0r 9rease (whichever is
more suitable)should be applied to any rubbing surface which has lost its lubricative film.01d
9rease and dirty oil should be cleaned off, Deteriorated grease has 10st its lubricative quality and
may contain abrasive foreign particles.
Don ″t use just any oil or 9rease. Some oils and 9reases in particular should be used only in certain applications and may be h
This manual makes reference to molybdenum disuifide 9 「ease(MoS2)in the assembly of certain engine and chassis parts
(16)Electrical Wires
AIl the electrical wires are either single-color or two-color and, with only a few exceptions,
must be connected to wires of the same color.0n any of the two-color wires there is a greater
amount of one color and a lesseramount of a second color, so a two,color wire is identified by
first the primary co10r and then the secondary color.For example, a yellow wire with thin red
stripes is referred to as a “yellow/red ″ wire; it would be a “red/yellow ″ wire if the colors were reversed to make
Wire(cross-section〉 Name of Wire Color
氷jr ￣￣ Red
Wire StrandS
Yellow
ぃ Red YeHow/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)lnspection
When parts have been disassembled,visually inspect these parts for the following conditions or
other damage. lf there is any doubt as to the condition of them, replace them with new ones.
Abrasion Crack Hardening Warp

Bent Dent Scratch Wear
CoIor change Deterioration Seizure

(19)Service Data
Numbers of service data in this te χt have following meanings:
“Standards": Show dimensions or performances which brand-new parts or systems have.

“Service limits": lndicate the usable limits. lf the measurement shows e χcessive wear or deteriorated performance,r
1-4 GENERAL INFORMAT10N
●畠●●・ ●Is 個l ●●・・I ●●●●s ●●● ●●・讐 l ●●●●● l ●・槽●●●● l・ ●・ ●・ ● M o d e l
ldentification
丿 ● ● 暉 ● ● 畠I
ZX1000 ・BI
ZX1000-B2
ZX1000-B3
0
GENERAL INFORMAT10N I ・5
●●I ●●I 働●●●●●●●●●●●●●●●● l ●●●●●・ l ● ●● l 佃●● ●●●●●寸・ ●●●●● ●● I ● I● ● I●●●●●●● I 審● 1 ●●●●●●● G e n e r a l
Speci f i c a t i o n s
● ● ●l 嚇匍 ● ●I ● ● ● 働・ ●l ● ●S
ltem ZX1000 ・BI/B2 ZX1000 ・B3

ぺ
Dimensions:
Overal日ength Overall width Overall
2 170 mm, O ⑧ ⑧(愈) 俵)2200mm715 mm /へ
./
へ
height 1 240 mm /
へ
Wheelbase 1 490 mm /へ
Road clearance 125 mm /へ
Seat height 790 mm
・/
Dry weight 222 kg, (巨)222.5kg /へ
Curb weight: Front 126 k9, (脳)126.5k9 /へ
Rear 128 kg 〆
へ
Fuel tank capacity 22.0L /へ
Performance:
Climbing ability 30° /
へ
Braking distance 12.5 m from 50 km/h /
へ
Minimum tuming radius 3.1m ← Climbing ability
Engine:
Type 4・stroke,DOHC,4 ・cylinder /ヘ
C0011ng system Liquid・ c001ed ノ
Bore and stroke 74.0 × 58.0mm /ヘ

Displacement 997 mL ノ
へ
Compression ratio 11.0, ⑥10.2 /へ
Ma χimum horsepower Max; 101 kW (137 PS)@10 000 「/min(rpm) 。( /ヘ
励) 谷)73.6kW(100 PS)@8 800 r/min ((pm) ノ (亘)65.5kW(89 PS) @9 000 r/min (
」
「pm
(ら)91.9kW(125 PS)@10 000 「/min(「pm 」 (IS04106),
/
へ
⑥53.0 k 剛72 PS)@6 000 「/min(rpm), /へ

(四)73.6 kW(100 PS)@8 800 r/min ( 「pm 」(DIN), @73.6 kW(100 PS)@9 000
「/min({pm}(DIN),
⑥75.1 kW(-)@8 800 r/min ((pm)(UTAC'S /へ
norm)
ド) 淵ごa5 ゛s)゜10 000
Maximum torque 103 N・m(10.5 kg-n, 76 ft

・lb)@9 000 「/min((pm),
⑧85 N-m {8,7 k9 ・m,63 ft-lb}@6 000 「/min((pm),( こ二(
愈)(8)89 N-m (9.1 k9-m,66 ft ・lb)@6 800 「/min (rpm), 愈)82 N-m (8.4 k9-m, 61
ごlb)@6 000 「/min((pm),@85 N-m
⑥QE)-
@89 N ・m{9,1 kg・m,66 ft-lb}@6 800 「/min(「pm 」【8.7 k9
・m,63 ft-lb】
(DIN) ぷ聚踏な1 ‰
j9000rymin{(pm)
Carburetorsystem Carburetors,Keihin CVKD36 ×4Electric
Starting system starter
二:
lgnition system Battery and coil (transistorized)
0
ltems ZX1000-BI/B2/B3
Timing advance Electronically advanced

19nition timing From 10 ° BTDC@1 000 r/min (rpm)to 35
° BTDC@7 500 「/min(rpm)
⑧From 10 ° BTDC@1 200 r/min (rpm) to 35
° BTDC @7 500 r/min (rpm)
Spark plug NGK CRgE or ND U27ESR-N

⑥ ④ ① 焙)NGK CgE or ND U27ES.NLeft to right, 1-2-3-4
Cylinder numbering method
Firin9 0rder 1-2-4-3

Valve timin9:
lnlet Open 38 ° BTDC, ⑥20 ° BTDC

Close 68 ° ABDC, ⑧50 ° ABDC
Duration 286 °,⑧250 °
E χhaust Open 60 ° BBDC, ⑧45 ° BBDC

Close 40 ° ATDC, ⑧25 ° ATDC
Duration 280 °,⑥250 °
Lubrication system Forced lubrication (wet sump with cooler)
Engine oil:
Grade
SE or SF class
Viscosity
SAE10W40,10W50,20W40,0r20W50
Capacity
4.0L
Drive Train:
Primary reduction system:
Type Gear
Reduction ratio 1.732(97/56)
Clutch type Wet multi disc
Transmission:
Type 6-speed,constant mesh, return shift
Gear ratios: l st 2.800 く42/15)
2nd 2.000(38/19)
3rd 1.590(35/22)
4th 1.333(32/24)
5th 1.153(30/26 〉
6th 1.035(29/28)
Finaldrive system:
Type
Chain drive
Reduction ratio 2.647(45/17)
Overall drive ratio 4.748
ltems
ZX1000 ・BI/B2/B3
Frame:
Type Tubular,double cradle

Caster(rake an91e) 26.5 °
Trail 101 mm
Front tire:
Type Tubeless
Size 120/70VR17-V280,1 20/70VB 1 7-V280 0r120/70 ZR17
Rear tire:
Type Tubeless
Size
160/60VR18-V280,160/60VB18-V280 0r160/60 ZR18
Front suspension:
Type Telescopic fork
Wheel travel 135 mm
Rear suspension:
Type Swing arm (uni-trak 〉120
Wheel travel mm
Brake type:
Front Dual disc
Rear Sin91e disc
Electrical Equipment:
Battery 12V14 Ah
Headlight:
Type
Semi-sealed beam
Bulb
12 V 60/55 W (quartz-halo9en)
Tail/brake light
12V5/21 W x 2,(謡) ⑨ ○12V8/27 W x2
Alternator:
Type Three-phase AC
Rated output 24A@6 000 r/min (rpm),14V
Voltage regulator:
Type Short-circuit
Specifications subject to change without notice, and may not apply to every country.
⑥:Australian Model
Canadian Model (lj §):UK Model
Californian Model ⑥:French Model
⑥:Swiss Model ○:Greek Model
曾:US
SA : Model
South African Model ⑧:Norwegian Model
( 谷亘):Austrian Model
留Sw : Swedish Model ①:ltalian Model
:West German Model ⑧:European Model

暉暉 ● 暉 ● 暉● ● ●S ● 恥嘸匍・ ● ●・ ● ●a ・憧輝l 韓● 腎● ● 軸 I ・雪 ● ● 糎寸糎
Periodic Maintenance Chart
The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in
900d running condition. The initial maintenance is vitally important and must not be ne91ected.
Whichever
フプIーk ゛ODOMETER READING
二心二
エ
Every
l言磁長座/
Sparl plu9 -clean
町
/ ツャャツツャ
● ● ● ● ● ●
● ● ● ● ● ●
Spark plu9 - check †
● ● ● ●
valve clearance - check ↑
● ● ● ● ● ●
Air suction valve(US),(S)-cheCk †
●
Air cleaner element - clean ● ●
Air Cleaner element 一 replace 5 cleanings ●
● ● ● ●
Throttle 9rip play - check↑
● ● ● ● ● ● ●
ldle speed - check †
● ● ● ● ● ● ●
Engine vaCuum SynChronization 一 CheCk 十
Fuel system - check ↑ ● ● ●
Coolant 一 change 2 years ●
Evaporative emiSsion control system (Cal)

● ● ● ● ● ● ●
-Check 十
● ● ● ●
Engine oil 一 change year
● ● ● ●
Oil filter - replace
● ● ● ●
Radiator hoses,conneCtionS - check † year
● ● ●
Fuel Filter一 replace
Fuel hose 一 replace 4 years
● ● ● ● ● ● ●
Clutch fluid level - check† month
Clutch fluid - change 2 years ●
ClutCh hose and pipe - replaCe 4 years

ClutCh master cylinder cup and duSt
seal - replace 2 years
Clutch slave cylinder pistonseal-replace 2 years
● ● ● ● ● ●
Drive chain wear 一 check †
Drive chain 一 lubricate 300 km
Drive chain slack - check 十 800 km
● ● ● ● ● ●
Brake pad wear - check ↑
month ● ● ● ● ● ● ●
Brake fluid level - check↑
Brake fluid 一 change 2 years ●
Brake hose 一 replace 4 years

GENERAL INFORMATION I-9
Whichever r
二/ ∧
゛ODOMETER READING
● k
Every
ly臨言ソノ
Brake maSter Cylinder Cup and duSt Seal
杉
/ 杉ャダャャャ
-replace 2 years
Caliper piston Seal and dust seal - replace
2 years
● ●
Brake light switch -check
十 ● ● ● ● ●
● ● ● ●
Steerin9 - check
↑ ● ● ●
Steering Stem bearing -lubriCate 2 years ●
Front fork oil

一 Change ●
●
Tire wear - check† ● ● ● ● ●
Swing arm pivot,uni-trak linkage

● ● ●
-lubriCate
month ● ● ● ● ● ● ●
Battery eleCtrolyte level - cheCk
†
● ● ● ● ● ●
Genera日ubrication - perform
● ● ● ●
Nut,bolt,and fastener tightness - check
↑
゛:For higher odom'eter readings, repeat at the frequency interval established here.
† :Replace,add,adjust,clean,or torque if necessary.
(Cal): Califomia vehicle only
(US):US only
(S):Swiss only
Torque and Lockin9 Agent
The following tables list the tightening torque for the major fasteners requiring use of a non-per-
manent locking agent or liquid gasket.
Letters used in the “Remarks" column mean:

L : Apply a non-permanent locking agent to the threads.
LG : Apply liquid ・9asekt to the threads.
:Apply an oil to the threads and seated surface.
:Tighten the fasteners following the specified sequence
t(
:Stake the fasteners to prevent loosenin9.

｀)OSSS
:Apply silicon sealant
Fastener TOrque Remarks

N-m k9-m ft-lb
Cool ing System :
Fan Switch
Water Temperature Sensor
Bleeder BOlt
Drain Plug
Engine Top End:
Cylinder Head Cover BOltS
Upper Chain Guide Mounting BOlts -
Rear Chain Guide Mounting Bolt 14.5
Chain Tensioner Mounting BOlts 87 1n-lb
CamShaft SproCket BOltS 11.0
Rocker Shaft End Cap 18.0
Main Oil Hose Banjo Bolts 18.0
Camshaft Cap BOlts 104 1n-lb S
Cylinder Head Bolts (10 mm Dia,) 29 S
Cylinder Head Bolts(11 mm Dia,) 38 S
Cylinder Head Bolt(6 mm Dia.) 87 1n-lb S
Cylinder Bolts 11.0
Clutch:
ClutCh HOSe Banjo B01tS 18
Clutch Slave Cylinder Mounting Bolts - - L
Ciutch Master Cylinder Clamp Bolts 1.1 95 1n-lb
Clutch Hose Joint 1.8 13.0
ClutCh Slave Cylinder Bleeder BOlt 0.80 69 1n-lb
Clutch Spring BOlts 1.0 87 1n-lb
ClutCh Hub Nut 13.5 98
Right Cover BOlts - - L( ゛1)L
Right Cover Damper BOltS 18157.87.89.8-209.81525251239519.81525-11187.89.8130-9.8
1.8
1.01.50.800.80
13.0 1.0
87 1n-lb -2.01.01.52.52.51.24.05.21.0
11.069 1n-lb69
SS L L 1n-lb87
L 1n-lb
FaStener TOrque Remarks

N-m k9-m ft-lb
Engine LubriCation System:
Oil PaSsage Plug
Drain Plug
CrankcaseOutsideoil Pipe Banjo BOltS 13.0
Oil Pump Gear HOlder SCreWS -
Oil Pump Mounting BOltS 104 1n-lb
Oil PUmp Relief valve - L
Main oil Pipe Banjo BOltS 18.0
Oil Pressure Switch 11.0 SS
Oil Pan BOlts - L( ゛2)(
oil COOler Pipe
Banjo Bolts (Oil cooler side) 18.0
Oil COOler Pipe
Banjo Bolts(Oil pan side) 25
Oil Filter BOlt 14.5
Engine Remova1/lnStallation:
Engine Mounting NutS 33
DOWn Tube Mounting BOltS 33
Crankshaft/Transmission:
Conneting Rod Big End Cap NUtS - ゛3) L L
Altemator Shaft Left End BOlt 18.0
Altemator Coupling BOlt 87 1n-lb
Altemator Coupling Nut 43
Altemator Shaft Chain TenSioner
Mounting BOlts 一 -
Altemator Shaft Chain Guide BOltS 一2.51.2 -
Altemator Shaft Chain Sprocket Bolts 18.0
one-way Clutch BOltS 104 1n-lb L
BalanCer Shaft GUide Pin Plate BOlt 一一 - L
Balancer Shaft Clamp Lever Mounting Bolt 一271527-- 一2.81.52.8 - L
CrankShaft Main Bearing Cap BOltS 20
CrankCaSe Bolts (6 mm Dia.) 11.0
CrankCaSe BoltS (8 mm Dia.) 20
Shift Drum Bearing HOlder AIlen BOlts 一 - L
Shift Drum Pin Plate Screw 一 - L
External Shift MeChanism Retum
Spring Pin 一一 - L
E χterna
【Shiaft Mecahnism Cover ScrewS Neutral181818-12-2515-,2534204444-259.859--2512
Switch
一15 1.81.81.8
一1.5 -1.2 13.0
-2.51.5
- 13.0
-2.53.52.04.54.5-2,51.06.0
L
11.0 L L
1・12 GENERAL INFORMAT10N

N-m k9-m ft-lb
Wheels/Tires:
Fomt AXle Nut
Front AXle Clamp BOltS
Tire Air valve Nuts
Rear AXle Nut
Final Drive:
Engine Sprocket Nut
Rear SproCket Nuts 54
Brakes:
Front Brake Reservoir Cap Screws 13 1n-lb
Brake Lever Pivot Nut 52 1n-lb
Front Master Cylinder Clamp Bolts 95 1n-lb
Brake Hose Banjo Bolts 18
Bleed valves 69 1n-lb
Caliper Mounting BOlts 25
Disc Mounting BOlts: Front 25
Rear 16.5
TOrque Link BOlt/Nut 18,0
Brake PedaS Mounting Bolt 78 1n-lb
SuspenSion:
Front Fork:
Top Plugs 16,5
FOrk Clamp BOlts 21
Drain Screws 13 1n-1b
Bottom AIlen Bolts 29
AXle Clamp BOlts 15.0
Rear ShoCk AbSorber:
Damper Adjuster Cable End 78 1n-lb
Airvalve Hose End 104 1n-lb
Shock Absorber Nuts 43
Rocker Arm Nut 6.0 43
Tie-Rod Nuts 6.0 43
Swing Arm PivotShaft Nut 9.0 65
Chain Adjuster Clamp Bolts 4.0 29
Steering:
Steering Stem Head Nut 4.0 29
Steering Stem Nut 0.50 43 1n-lb
Handlebar H01der Mounting B01tS 2.0 65 14.5
14.513 1n-lb
SLGL801.1
72 2.50.803.53.52.3
88201.510898741.55.911257,8343423258.823281,539218.8125959598
9.02.00.1511,010,07.50.150,60

N-m k9-m ft-lb
ElectriCal System:
Altemator Mounting BOltS
AIμmator Coupling Brades Bolt PiCkup Coil Mounting BOltS PiCkUp Coil COver B01tS Spark Plugs Timing
一
一14254.92.51.0 - - 1.418.087
2.50.50
- 1n-lb - ゛4)
10.0
Rotor BOlt 18.0
Altemator Cover Cap Nut 259.8 43 L LL(
( ゛1):See Clutch chapter

( ゛2):See Engine Lubrication chapter
( ゛3):See Cran kshaft/Transmission chapter
に4):See Electrical System chapter
Cable,Wire and Hose Routin9

個声 ● ・ ● ・・暉 ●
lgnition Coil Leads
Ground to ignition
coil mounting bolt.
Left Hom Leads
Fan Switch Leads
Side Stand
Switch Connector
Neutral Switch
Lead
Hamess
ノ
. へ
○
Cooling Hose
/
ちダ/ ゾ
/
゜ Hamess for lgnition
べ/ TO RH SWitCh Switch
housing
Water Temperature
Sensor
Main Hamess
4 Radiator Fan
9 tya7
ブ大
つ
Left Hom Right Hom
Fuel Tank Overflow
Hose
Fuel Level Gauge

Overflow Hose
Reserve Tan k Hose
BatteryVent Hose
Run starter motor

cable under the
To rear hamess
frame.
Rear Brake Reserve

Ground to the
Tank
crankcase bolt.
Swing Arm
Breather Hose
Rear Brake Switch
Air Cleaner Drain
Connector
Hose
Battery( 十)Lead
Ground to crankcase
bolt.
To starter
Starter Relay
Run brake cable
between throttle
cables and RH
RH Switch Housing switch housing

lgnition Switch
Leads Leads
ごClutch Hose
にChoke Cable
LH Switch Housing
Thorttle Cable
Leads
Run clutch hose

behind choke cable.
Clamp
Speedometer Cable
ArrowView “B"
Brake Hose
Speedometer Cable
Brake HoseJoint
Brake Hose Brake Hose

ldle Adjusting Screw
Clutch Slave Ajtemator Lead

Cylinder
Oil Pressure Switch
PiCkUp COj
Upper Fairing
Turn Signal Relay

Clamp
lnside of Rear Cowl
Clamp
二L 詰
Turn Signal Light (L)
Tail/Brake Light
US and Swiss model
Hose(Green)
To Separator
Vacuum
SwitchValve
万二To Canister
Throttle Cables
Hose(White)
Carburetor Air Cleaner
Cylinder Head
Thermostat Housing
Air Cleaner
Drain Hose
US Modej
Air Cleaner
FUEL SYSTEM 2-1
Fuel System
Table of Contents
ExplodedView ‥‥ ● 匍 ● ● ● ● 翻II 匍 ● ● ● ● ● ●I ● ● ● ● ●I 争 ● ● ● ● ● ・I S ● ● ● ● 曝I ● ●
2-2
Specificati
2-4
4゛ 55556
Speci
Throttle Grip and Ca
゛
Throttle Cable Adjustment
667789
Choke
Choke Cable Adj
｀0 1 1 1
一
Carbu
一
ldle Speed Adjustment
｀
High Altitude Performance Adjustment (US model)
・・・・・・・・・・・・
︲
Carburetor Synchroni
Service Fuel Level Adj
゛
Fuel System Cleanliness l
｀ 1 1 1 122222222 22 2 2
Carburetor Disassembly/
Carburetor lnspecti 2一 2 ︲2 2
Fuel Pump and

゛
lnstallat
lnspection 2-11
2-11
Element CI
2-11
Evaporative Emission Control system
(US Califomia Vehicle onl 2

12
Pa 咆Removal/l nstallation 2
12
12
2
Hose lnspection (Periodic lnspection) ・・・・・・・・・・・・・・・・・・・・・・・
Separator ln 2
12
2
Separator Operation Test ● ● ● ● ● ● ● ● ● ● ● ● ● い丿 ● ● ●a ● ● ● ● ● ● ● ● ● 曝・ ● ● 12
Canister l 2
13
2-2 FUEL SYSTEM
ExplodedView
尚尚m
卜
1.Jet Needle
2.Pilot Screw
3.Pilot Jet
4.Needle Jet Holder
5.MainJet
6.Valve Needle
US model
/
臨
勣門口∩日U
、 Mode
二_
FUEL SYSTEM 2 ・3
よ 1
幽斜聯も
卜
ゆ
シ
⑤
几リ= 。
ジジ
/j
7.FuelPump
8.Fuel Filter
① づ‰
/ 岬
十
{ 目目口wn 目u
ら
ら
八
‰
2・4 FUEL SYSTEM
Specifications
ltem ZX1000-BI ZX1000-B2 ZX1000-B3

Throttle Grip:
Throttle grip free play ← ←
Choke Cable:
Choke lever free play ← ←
Carburetor:
Make,type ← ←
Main jet ⑥130[1281, ←,
谷)135[1321100N14C,( ←, ⑧135
⑥(唇)盾)118,
㈲122
Maln alrlet ← ← '
Jet needle 唇)N54D38 ← ←
Pilotjet 【351130, ← ←
Pilot air jet ⑧14055, ← ←
Starterjet 屈)452 tums out, ← ←
Pilot sCrew ←,(四)
⑥(酋)1%, ⑨-, ⑥2345,0 mm below the猫 ←
mark13,0mm950
ServiCe fue
川evel F10at height ldle Speed ← ←
← ←
- 1 050
「/min(「pm) ← ←
⑧1 150 - 1 250「/min(rpm)Less than 2.7←kPa (2 cm H9) ←
SynChronization vaCuum 2-3mm2-3mmKeihin,CVKD36130, ← ←
⑥ ⑧⑥
⑧(妙目
⑥ :Australian model :European model :UK model

西) :Austrian model :Swiss model :West German model
谷) :Californian model :US model :High Altitude (US model)
匍岫 ● 奮 ● 働 ● ● ● ●
Pressure Cable Luber: K56019-021

Special T001s
Fuel Level Gauge: 57001 ・1017
Vacuum Gauge: 57001 ・1198
Drain Plug Wrench: 57001-1269
o Thevacuum gauge &tachometer(PyN 57001-72 ∂7 ノcan
be used instead of the vacuum gauge{PZN

57001-1198}.
FUEL SYSTEM 2-5
寸珊珊・珊● ●曇・ ● 丿嶋・珊 ● ● 動 ● 夥・ ● ● ● 衝動動 ●・ ● 喝 ●
Throttle Grip and Cables
Throttle Cable Adjustment
●Check throttle grip free play.
A.Accelerator Cable C. Adjusting Nuts

B.Decelerator Cable D.Locknuts
●Loosen the upper nuts,and tum both throttle cable ad-

justing nuts fully at the lower ends of the throttle cable
to give the throttle grip plenty of play.
●With the throttle grip completely closed,tum the
decelerator cable until the inner cable just becomes
tight.
●Turn the adjusting nut of the accelerator cable adjust-

1.Throttle Grip Free Play ing nut until the correct throttle grip free play is
obtained.
●Tighten the upper nut.
Throttle Grip Free Play
Standard: 2-3mm
★lf the free play is incorrect, loosen the locknut and

tum the adjuster of the accelerator cable until the
proper amount of throttle grip play is obtained.
● l 曝●●●暉●●畠● s ●罪●● l ●●●●●●●●●●●●●●● I C h o k e S ● ● ● ●S ●II 寸種 ● ● ●1 ●I ●
Cable
Choke Cable Adjustment
1.Adjuster 2.Locknut
●Tighten the locknut securely

・
★lf the play can not be adjusted by using the adjuster at
the throttle grip, use the adjusters at the carburetors.
●Remove the fuel tank. 1.Choke Lever
2.Play
2-6 FUEL SYSTEM
● 丿S 噛 ● ● ● ●● ● S ● ● 慟
●・ ●● ● ● & 寸 ● ●・ ● ● ● ● ● ●s ● ● ● 寸 ● ● 声 ● ● ● ● ● ● ●s ● ● ●Carburetors
●Check choke cable free play,

0Determine the amount of choke cable play at the
choke lever. Pull the choke lever untH the starter
plunger lever at the carburetor contacts with the starter
ldle Speed Adjustment
plunger; the amount of choke lever lower end trave 卜s
the amount of choke cable play ●Set the motorcycle on its center stand.
・
●Start the engine and warm it up thoroughly.
●Turn the handlebarfrom side to side while idling the
englne.
★lf idle speed varies, the throttle cables may be poorly
routed orthey may be damaged.
●Correct any problem before operating the motorcycle.
い/VARNING i
00peration with an improperly adjusted, incorrectly
routed,0r damaged cable could result in an unsafe
riding condition.
●Check idle speed.
ldle Speed
1.Starter Plunger Lever 3.Play
2. Starter Plunger Standard; 950-1 050 r/min ((pm)
⑧1 150 - 1 250 r/min ((pm)
Choke Cable (Lever)Play ●Tum the idle adjusting screw unti 卜dle speed is correct.
Standard: 2-3mm
●lf the play is incorrect, Ioosen the locknut and turn the
adjuster at the middle of the cable untjl the proper
amount of choke lever play js obtained.
oRemove the fuel tank.
A. ldle Adjusting Screw
High Altitude l:W ・yb/rma779.4 涛tjS ￡x77

凹t
μ ノSmO( か/ ノ
A. Adjuster B.Locknut
oTo improve the EMISS10N CONTROL PERFORM-
ANCE of vehicles operated above 4,000 feet, Kawasaki
recommends the following Environmental Protection
Agency(EPA) 叩proved modification,
●Tighten the jocknuts securely ●Change the main jet and pilot jet for high altitude use.
FUEL SYSTEM 2-7
High Altitude CarburetorSpecifications

NOTE
Main Jet: #128,( 巨D 孝132 oDo not tum the pilot screws carelessly during carbure-
Pilot Jet: #35

tors synchronizatjon. You may cause a poor runnjng at
10w engjne speed.
●Check idle speed.
Carburetor Synchronization Service Fue は.evel Adjustment
●Set the motorcycle on its center stand.
●Start the engine and warm it up thoroughly

・
●Check idle speed. I WARN・NG i
●Attach the vacuum gauge (special tool: P/N 57001-
oGasoline is extremely flammable and can be explosive
1198)to the fittings on the carburetors.
undercertain conditions.Turn the ignition switch
OFF. Do not smoke.Make sure the area is well
ventilated and free from any source of flame orsparks;
this includes any appliance with a p110t light.
●Remove the fuel tank and air cleaner bo χ.
●Connect a fuel tank to the carburetors with a suitable
hose.
●Prepare a fuel hose (6 mm in diameter and 300 mm in
length).
●Connect the fuel level gauge (special tool μo the carburetor float bowl with
hose.
●Check the fueHevel as shown.
oTurn out the carburetor drain plug a few turns.Wait
until the fue 川eve 目n the gauge settles.
NOTE
oKeeping the gauge vertical, a 心n its “zero' リine with the mark of the carburetor body
side. Then tum

1.Fittings
out the drain plug to feed fuel to the gauge.
2. Right Adjuster for Right Two Carburetors
3.Center Adjuster for Right and Left Pairs
4.Left Adjuster for Left Two Carburetors
●Start the engine and let it idle to measure the carbu-

retorintake vacuum.
レF
Carburetor SYnchronizationVacuum
Standard: Less than 2.7 kPa (2 cmH9)difference

④
between any two carburetors

卜
●Turn the adjusting screws to synchronize the carbu-

retors.
oFirst synchronize the jeft two and then the right two
carburetors by means of the left and right adjusting
screws. Then synchronize the left two carburetors and
the right two carburetors using the center adjusting
screw.
★lf the carburetor synchronization cannot be obtained
1.Fuel Level Gauge: 57001 -1 01 7
by using the adjusting screws, check for dirt or block-
2.Mark
agej and then check the pilot screw settings ・ 3. “Zero ¨Line
●Check the carburetor synchronization again.
4.Fuel Level
2-8 FUEL SYSTEM
Service Fuel Level Float Hight
See Specifications Standard: 13.0mm
NOTE
●To ajdust the fue 目evel,bend the tang on the float arm to change the float heightl
oDo not push the needle rod in during the f10at height
measurement.
Fuel System Cleanliness lnspection
l WARNING I
oGasoline is e χtremely flammable and can be explosive under certain conditions.Turn the ignition swit
sparks;
this includes any appliance with a pilot light.
2.Tang ●Connect a suitable hose tothe fitting at the bottom of

1.Float
each carburetor float bowl.
●Run the lower ends of the hoses into a suitable con-
tainer.
●Measure the fIoat height tilting the carburetor to touch ●Turn the fuel tap to the RES position.
the tang on the needle rod. ●Tum out eadh drain plug a few tums with the drain
01ncreasing the float height lowers the fuel level and plug wrench (special tool)and drain the float bowls.
decreasing the float height raises the fue 日evel.
Do not push
the needle rod.
A.Drain Plug
B.Drain Plug WrenchI S1001-1269
●Check to see if water or dirt comes out.

1.Bottom Edge of Carburetor Body ●Tighten the drain plugs and turn the fuel tap 'to OFF
2.Float Height position.
3.FIoat ★lf any water or dirt appeared during the above inspec-
tion,clean the fuel system.
FUEL SYSTEM 2,9
Carburetor DisassemblyyAssembly Plug installation (US model only)
ヒWARNING i
oGasoline is extremely flammable and can be e χplosive under certain conditions.Tum the ignition
switch
ventilated and free from any source offlame orsparks;
飯亘1
oDuring carburetor disassembly,be careful not to
damage the diaphragm. Never use a sharp edge to

remove the diaphragm.
1 . Apply bonding agent. 3.Pilot Screw

2.Plug
●For the US model, 「emove the pilot screw plug as fo110ws: 4.Carburetor Body
oPunch a hole in the plug and pry it at with an awl or ●Turn the carburetor body upside-down, and drop the
other suitable tool. needle jet into place so that the smal'ler diameter end of
the jet goes in first.
●Tum in the pilot 5crew and count the number of turns
unti 卜t seats fully but not tightly, and then remove the screw. This is to set the screw to its original position when assembling
・
●Turn in the pilot 5crew fully but not tightlyJ and then
back it out the same number of turn5 counte'd during
disassem bly.
●For the US model,install the pilot screw plug as

follows:
oln5tall a new plug in the pilot screw hole, and apply a
small amount of a bonding agent to the circumference

of the plug to fi χ the plug.
茫j2 』 1. Needle Jet 2.Small End
oDo not apPly too much bonding agent to the plu9 0 「

the pilot screw itself may be fixed.
匹亘1
oDo not force the needle jet holder(airbleed pipe)and
main jet of overtighten them. They could be damaged
requirin9 「eplacement.
1
Main Jet 2. Needle Jet Holder
2-10 FUEL SYSTEM
Carburetor lnspection
い/VARNING I
oGasoline is extremeSY flammable and can be explosive
under certain conditions.Turn the ignition switch
OFF. Do not smoke.Make sure the area is weU
ventilated and free from any source of flame or sparks;
●Slide the starter plunger lever right to left it to check
that the starter plungers move smoothly and return

with spring tension.
★lf the starter plungers do not work properly, replace
the carburetor5.
●Turn the throttle cable pulley to check that the
throttle butterfly valves move smoothly and retum by
sprlng tenslon ・
★lf the throttle valves do not more smoothly.Replace
the carburetors.
●Check that the O-rings on the float bowl and drain plug
and the diaphragm on the vacuum piston are in good
condition.
★lf any of the O-rings or diaphragms are not in good con-
dition, replace them.
●Check the plastic tip of the float valve needle. lt
should be smooth,without any grooves,scratches,o 「
tears.
③ ) ・
Push and release
1.Rod 3,Valve Needle Wear

2.Valve Needle
★lf the plastic tip is damaged, replace the needle.

●Check the tapered portion of the pilot screw for wear
or damage.
1.Pilot Screw 2.Tapered Portion
★lf the pilot screw is worn or damaged on the tape.red

portion,it will prevent the engine from idling 5moothly,
Replace it.
FUEL SYSTEM 2 ・11
●・ ● a 岫 ●・嘩韓 ● ●
Fuel Pump and Filter
●●●●●●●●●・ ●●●・ ●●・・● ●● s I ・ ●●● I ●・ ●・ ●・ I ・・ ●嘸●●●●●● 油・丿 ● 趣 ●・・蜀 ● 馨● ●● ● 岫
四而j
From Fuel Tank
oGas011ne is e χtremely flammable and can be explosive under certain conditions.Tum the ignition switch OFF. Do not smoke.Make sure the area is well ventilated and free from any source
sparks;
this incIudes any appliance with a pilot light.
0Be prepared for fuel spillage.
To Carburetor
Removal
1.FuelPump 3.Arrow
●Remove the following.
2.Fuel Filter
FuelTank
Air Cleaner Housing
Carburetor
●Disconnect the pump lead connector
○lnstall the fuel filterso that the arrow on it shows the

fuel flow from the fuel tank to the fuel pump.
oBe sure to route the hoses 50 they will not be kinked
or stretched.
lnspection
Refer to the Electrical System chapter.
A.FuelPump C.Connector
B.Fuel Filter
●機●●旬●●●・ ●機喝 l 機種●●●暉● I・・機●機● l 摯・ s 丿 ●● a ●機 s ● s I ●● l l ●●・ ● l・機●●機 I 騨● l ● ●機●● 機種l● ●機s ●●・IsAir Cleaner
●Remove the fule pump and filter. 翰S ● 暉 ● 曝 ● 曾 ●・ ● ● 鴫威 ● ● ● 幽 ●a ● ●
Eyement Cye ∂njng
[ 画而￣i
oClean the element in a well-ventilated area, and take
care that there is no spark or flame anywhere near the

lnstallation working area; this includes any appliance with a pilot
●lnstallation is the reverse ofremoval. Note the light. Because of the danger of highly flammable
following liquids,do not use gasoline or low flash ・point solvents to clean the element.A fi
・
●Connect the fuel hoses as shown. χplosion could result.
2-12 FUEL SYSTEM
Parts l:lemovalZlnstallation lVotes

●Remove the foHowing ・
FuelTank
Air Cleaner Housing Bolts
IWARNING i
Rubber Strap
●Take out the air cleaner element. oGasoSine is extremely flammable and can be explosive
undercertain conditions,Turn the ignition switch
ventilated and free from any source of flame orsparks;
巨亘]
01f gas011ne,soIvent,water orany other liquid enters the
canister,the canister's vapor absorbing capacity is
9reatlyreduced. lf the canister does become con-
taminated replace it with a new one.
●To prevent the gasoline from flowing into the canister

or from flowing out of the canister,hold the separator
A.AirCleanerElement B.Bolts perpendicular to the ground.

●Connect the hoses according to the diagram of the
system. Make sure they do not get pinched or
kinked.
口ARNING I
01f dirt or dust is allowed to pass through into the
carburetors,the throttle may become stuck, possibly
causing accident.
Hose lnspection (Periodic lnspection)

●Wash the element in a bath of high flash,point solvent
and then dry it with compressed air or by shaking it. ●Check that the hoses are securely connected.
●After cleaning,saturate a clean,lint-free towel with SE ●Replace any kin ked, deteriorated or damaged hoses.
class SAE 30 011 and apply the oil to the element by
tlpping thje foam side of the element with the towel.
S ∂ρ∂/7
∂rOr /rtSpeC が0/7
●Disconnect the hoses from the liquid/vapor separator,
and remove the separator from the motorcycle.

●V15ually inspect the separator for cracks and other
damage ・
★lf the 5eparatorhas any cracks or is badly damaged, re-
place it with a new one.
Evaporative Emission Control System

Separator Operation Test
(US CaliforniaVehicle only)
S ● 働 ● ● ● ● 畠 ●
I WARNING i
The Evaporative Emission Control System routes fuel
vapors from the fuel system into the running engine or oGasoline is extremely flammable and can be explosive
stores the vapors in a can15ter when the engine is stop- under certain conditions.Turn the ignition switch
ped.Although no adjustments are required, a thorough OFF. Do not smoke.Make sure the area is well
visual inspectjon must be made at the interva15 specified ventilated and free from any source of flame or spark;
by the Periodic Maintenance Chart. this includes any appliance with a pilot light.
FUEL SYSTEM 2-13
●Connect the hoses to the separator, and install the C ∂xlXSI∂/・/ηSp θC が0/7
5eparator on the motorcycle.
★lf the canister ha5 any crack or bad damage, replace it
●Disconnect the breather ho5e from the separator, and
wjth a new one.
inject about 20 mL of gasoline into the separator
through the hose fitting.
NOTE
●D15connect the fuel return hose from the fuel tank.
oThe canister is designed to work well through the
●Run the open end of the return hose in to the
container level with the tank top motorcycle's life wjthout any maintenance if jt is used
・
under normal conditions.
●Start the engine, and let it idje.
★lf the gasoline in the separator comes out of the hose,

the separatorworks well.lf it does not, 「eplace the separator wjth a new one.
レ一一
⑤
ぐ迅高夕
∧
ポ ○
万丑十
´9 2.Carburetor
3.Air Cleaner Hou51ng

4.Liquid/Vapor
Separator
5.CaniSter
6.Breather Ho5e
(Blue)
7.Fuel Retum Hose
(Red)
8.Purge Ho5e (Green)

9.Breather Hose
(Blue)
10.BreatherHose
(Yellow)
11.Vacuum Hose
(White)
C00LING SYSTEM 3-1
Cooling System
Table of Contents
3-2
3 3 4 4 4 5 5 6 6 6 6 7 7 8 8 9 9 9 93 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3
Specifi
Coolant FI
Coolant ‥.
Coolant Level ln
COO
COO
Remova
Water Pump l
Radiator and Rad
Remova
Radiator lnspecti
Radiator Cap l
Thermostat
lnstall
Thermostatic F an Switch , Water Temperature Sensor............... 3-10

3-2 COOLING SYSTEM
卜 ● ●・ ● ● ● ● ● 御・
ExplodedView
J グ￣ ④
甲言
TI : 18 N-m (1.8 kg-m, 13.0 ft,lb)
T2 : 15 N ・m (1.5 kg-m,11.0 ft-lb)T3: 7.8 N-m (0.8 kg-m,69 1n
・lb)SS: Apply silicone

sealant.
0 : Apply oil at installation 。
C00LING SYSTEM 3-3
S ●・ I I ・ ●l 聡I 卜 ●
Specifications
ltem Standard
COOlant:
Type
〉Soft water 50%,Coolant 50%-35

Mixed ratio
Freezing point °C(-31 °F)3j L
Total amount Permanent type of antifreeze (soft water and ethylene91ycol plus corros
Radiator:
Radiator cap relief preSSure 93 - 123 kPa (0.95 - 1.25 k9/cm
≒14-18 psi)
Thermostat:
valve opening temperature °C(176 - 183 ° F),(QK)69-73 °C(156 - 163 °F)More than 8 mm
valve full openin9 11ft 80-84 @95 °C(203 °F〉
( 皿§):UK model (ZX1 000-B l only)
種種・種●11 ●●4 ●l ●●●●種●種●●●鞠 l ● I I ● 種●●●●●● I C o o l a n t
FIow Ch a r t
● ● ● ●l ● ・ ●S ● 畠畠鐘巷 ● ● 暉暉暉卜l ● ●
When the engine is cold, the thermostat is closed, so that the coolant flow restricted through the
small h01e on the thermostat (air hole),causing the engine to warm up more quickly.
Frame
1.Water Pump
2.Water Hose
3.WaterPipe
4.Water jacket
5.Cylinder Head
6.WaterTemperature Sensor
7.Radiator Cap
8.Thermostat
9.Radjator Fan
10.Cooling Fan Switch
11.Radiator
3・4 COOLING SYSTEM
s 夥●s 働鴎・岫●馨齢●& 噛・丿 ●幽瘤・匍砥憾畠Coo l a n t

●Remove the following ・
｀Lower Fairing
Right Side Middle Fairing
Radiator Cap
Coolanf Leve 川nspection
NOTE
oCheck the jevel when the engine is cold (room or
ambient temperature ノ.
●Check the coolant level in the reservoir tank with the

motorcycle held perpendicularly.
★lf the coolant level is lower than the “L" mark,add coolant to the
“U " mark.
A.Radiator Cap
Drain Plug(bottom of water pipe)
A.ReservoirTank C. “L" MarkD.Tank Cap

B バ‘U"Mark
巨弧
oFor refillin9,add the specified mi χture of co01ant and soft water.Adding water alone dilutes the coolant and de9
「ades its anticorrosion properties.
0The diluted coolant can attack the aluminum engine A.Water Pipe B.Drain Bolt
parts. ln an emergency.soft watercan be added. But
the diluted coolant must be returned to the correct
mixtureratio within a few days ●Drain the co(51ant from the radiator.
・
●Pull off the reservoir tank hose and pour the coolant
olf coolant must be added often,0r the reservoir tank
into a container.
has run completely dry; there is probably leakage in the
cooling system. Check the system for leaks.
Coolant Drajnin9
I WARNING i
oTo avoid burns,do not remove the radiator cap ortry
to change the coolant when the engine is still hot. Wait
until it cooIs down.
0Coolant on tires will make them slippery and can cause
an accident and injury. lmmediately wipe up or wash
away any coolant that spills on the frame, engine,0 「
other painted parts

・
oSince coolant is harmful to the human bodyo do not
use for drinking.

A.Reservoir Tank Hose
C00LING SYSTEM 3-5
Cooyant Fi 川ng NOTE
●Tighten the drain plug to the specified torque (see Ex- oChoose a suitable mixture ratio by referring to the
plodedView).
coolant manufacturer's directions.
●Fill the radiator up to the thermostat housing filler

neck with coolant,and install the radiator cap
・
●Loosen the air bleeder bolt, until the coolant begins to

sIow out the airbleeder bolt hole (that is, when all the
remaining airhas been forced out).
●Tighten the air bleederbolt.
1.Coolant Level A.Air Bleeder Bolt B. Water Pump Cover

2.Thermostat Housing
●Start the engine,warm it up thoroughly until the

radiator fan turns on and then stop the engine.
NOTE ●Check the coolant level in the reservoir tank afterthe
engine c001s dowr1.
o'Pour jn the co01ant sjowly so that jt can expel the air
★lf the coolant level is lower than the ¨L" mark,add coolant to the
from the engine and radiator.
¨U"mark.
匹亘1
●Fillthereservoirtankuptothe “U"markwithcoolant and install the cap
oDo not add more coolant above the “U' ″ mark
巨巨]
oSoft ordistilled watermust be used with the antifreeze
(see below forantifreeze)in the cooling system.
○lf hard water is used in the system, it causes scales
accumulation in the waterpassages,and considerably
reduces the efficiency of the cooling system. PressureTestin9
●Remove the radiator cap,and install a co011ng system
pressure tester on the radiator filler neck.
Water and Coolant Mixture Ratio (Recommended)
NOTE
Soft Water 50%
Coolant 50% oWet the cap seaHng surfaces with water or coolant to
Freezing Point -35 °C(-31 °F) prevent pressure leaks.

3-6 COOLING SYSTEM
●BuHd up pressure in the system carefully until the

pressure reaches 123 kPa (1,25 kg/cm2,18 psi).
回亘]
oDuring pressure testin9,do not exceed the pressure for
which the system is designed.The ma χimum pressure is 123 kPa (1.25 k9/cm2,18 psi).
●Watch the gauge for at least 6 seconds.

★lf the pressure holds steady, the system is all right. A.Water Pump B.Mounting Bolts
lnstallation
●Note the position of the oil pump shaft projection and

turn the water pump shaft so that the projection fits
into the slot.
A.Pressure Tester
B.Adapter
★lf the pressure drops soon,check for leaks.
A.Water Pump Shaft B.011 Pump Shaft
働●糖・個●寸幽槽
・・ ●・ ●・幽幽馨●・l 幽血糖・暉●●幽・・騨騨●§ 幽●● 嘩蓼●●●働櫛● s 騨●●●● 幽幽●● ●苛聊● ●
・冒匍・露・丿 ●● 慟●・幽 a 幽 W a t e r
Pump
●・ ● ●
βθx刀01/∂/
●Drain the coolant.

●Remove the f0110wing Water Pump lnspection
・
CIutch Slave Cylinder (see Clutch chapter) ●Check the drainage outlet passage at the bottom of the
Engine Sprocket Cover water pump body for coolant leaks.
Water Pipes ★lf the machanical seal is damaged, the coolant leaks
●Unscrew the waterpump mounting bolts (2),and pull through the seal and drains through the passage. Re-
outthe waterpump ・ place the water pump unit.
COOLING SYSTEM 3-7
●Remove the folIowing

・
FuelTank
Falrlngs
Coolant(Drain)
Homs
Radiator Fan Connector
A.Drainage Outlet Passage

(at the bottom of the pump body)
●Visually check the impeller.

★lf the surface is corroded, 0r if the blades are damaged,
replace the water pump unit.
A.Radiator Fan Connector
Fan Switch Leads
A.lmpeller
A.Fan Switch Leads
Radiator Hoses
・S 讐・・幽働鎗 ●
Radiator and Radiator Fan
Removal
ヒy
岬mGi
oTheradiatorfan is connected directly to the battery
・
Theradiator fan may start even if the ignition switch is
off.NEVER TOUCH THE RADIATOR FAN UNTIL
THE RADIATOR FAN CONNECTOR IS DISCON-
NECTED. TOUCHING THE FAN BEFORE THE
CONNECTOR IS DISCONNECTED COULD CAUSE
INJURY FROM THE FAN BLADES. A.Radiator Hose

3-8 COOLING SYSTEM
Radiator lnspection
●Check the radiator core.

★lf there are obstructions to air flow, remove them.
★lf the corrugated fins are deformed, carefuHy straighten
them.
★lf the air passages of the radiator core are blocked more
than 20%by unremovable obstructions or irreparably
deformed fins, replace the radiator with a new one.
四ヱJ
oWhen cleaning the radiatorwith steam cleaner,be
careful ol the following to prevent radiator damage.

1)Keep the steam gun away more than 0.5mfrom the
A.RadiatorHose 「adiatorcore.
2 」Hold the steam gun perpendicularto the core surface.
3)Run the steam gun horizontally foUowing the core

Radiator Screen
fin direction.Running it vertically may damage the
Radiator Mounting Bolts
fin.
A.Radiator B. Radiator Mounting Bolts S ∂( が∂ ￡orC ∂ρ/rlsp ∂ctyox7
●Check the condition of the top and bottom valve seals
of the radiator cap.
★lf any one of them shows visible damage, replace the

Radiator Fan Mounting Bolts cap ・
1.BottomValve Seal 3.Valve Spring

A.Radiator Fan B.Fan Mounting Bolts 2.TopValve Seal
C00LING SYSTEM 3-9
●lnstaH the cap on a cooling system pressure tester.
NOTE
oWet the cap sealing surfaces with water or coolant to
prevent pressure leaks.
A.Reservoir Tank Hose D. Mounting Bolts

B.Sensor Connector E. Housing Screws
C.Radiator Hose
●Unscrew the housing screws remove the thermostat.
1.Pressure Tester 2. Radiator Cap
lnstallation
●Watchjni the pressure gauge, pump the pressure tester
●lnstail the thermostat noting the following
to buHd up the pressure. The cap must retain the ・
〇lnstall the thermostat in the housing so that the air
pressure at least 6 seconds.Also the cap must open at
hole is on top・
the pressure shown in the table.
RadiatorCap Relief Pressure
Standard: 93 - 123 kPa
(0.95 - 1.25 k9/cm2, 14 - 18 psi)
★lf the cap cannot h01d the specjfied pressure,0r if it
holds too much pressure,replace it with a new one.
A.Air Hole B.Thermostat
oBe sure to install the O-ring to the housing.

oFill the radiatorwith coolant.
● 槽 ● ● ●
Thermostat
Removal
●Remove the following lnspection
FuelTank ●Remove the thermostat,and inspect the thermostat
Falrlngs valve at room temperature.
Coolant(drain) ★lf the valve is open, replace the valve with a new one.
Reservoir Tank Hose ●To check valve openjng' temperatureX suspend the
Sensor Connector thermostat in a contajner of water andra15e the

Radiator Ho5e temperature of the water.
3-10 COOLING SYSTEM
A.Thermostatic Fan Switch
2.Thermometer
1
Thermostat
★lf the measurement is out of the service limit range,

replace the thermostat.
ThermostatValve Opening Temperature
80 - 84 °C (176 - 183 °F)
(jΞ)69 - 73 °C (156 - 163 °F)
A.Water Temperature Sensor
●Refer to the Electrical Sy5tem chapter for these

inspection.
Thermostatic Fan Switch
Water Temperature Sensor
●●機機種●I ● ●● ●●I ●種種●●●I ●● ●種種●●●・ s ●鯵種●機・ ●●看丿種讐機協働機●種種種●種●●●●看●機●●●卿看種働個・・・機働●種●●
呂亘]
oThe fan switch or the water temperature sensorshould
neverbe allowed to fall on a hard surface.Such a
shock to these parts can damage them.

ENGINE TOP END 4-1
EnginellOp End
Table of contents
2 4 6
4 4 4
Valve Face Contact lnspection ・
・・・・・・・.4-18Valve Seat Outside Diamete
Specificati
・・・・・・・・・.4-18Valve Seat Width lnspectio
Special Tool
‥ ‥ ‥ ‥ ‥4-18Valve Seat Repair(Valve La

Clean AirSystem(US model) ・・・・・・・・・
・・・.4-7 Air
‥ ‥ ‥4-19MeasuringValve-to
Suction Valve lnspection ・・・・・・・・・.4-7 Vacuum
・Guide Clearance
Switch Valve Test ・・・・・・・・・・.4 ・7 (Wobble Method)

・・・・・・・・・・・・・・.4-20
4 4 4
CX)CX)(X)
Cylinder Head
Cylinder, .4-21
Remova に
Cylinder Removal ・・・・・・・・・・・・・・・・.4-21
lnstall
Cylinder l
Camshaft Chain Tensioner. Piston
●●●●・ ●●●●●●I ●I ●4-8 .4-21
Removal ‥ ‥ .4-8
.4-21
4-8
Cylinder Wear ・・・・・・・・・・・・・・・・・・・.4-22
Camshaft,Camshaft Chain, RockerShaft
・・・・・.4,9 .4-22
Camshaft,RockerShaft Removal ・・・・・・.4-9
Piston Ring,Ring Groove Wear ・・・・・・・.4-23Piston Ring End Gap
Camshaft,Rocker Shaft lnstallation . ‥..4-10
・・・・・・・・・・・・・・.4-23
Chain Tim
Carburetor Holder ・
・・・・・ .4-23
Camshaft and Sprocket Assembly ・・・・・・.4-11Camshaft,Camshaft Cap Wear
Carburetor Holderlnstallation ・・・・・・・・.4-23
・・・・・・・・.4-11 .4-24
Cam
.4-24
Cylinder
Cylinder Compression Measurement ‥ ‥.4 ・12
Removal
● ● ● ● ●・ ●・・ ● ●lnstallation
.4-12
・・・・・・・・・・ .4-13
Valves ‥ ‥. ‥ ‥ ‥‥4-14
Valve Clearance Adjustment ・・・・・・・・
・.4-14
ValIve Removal .4-17
Valve lnstallation ‥. .4-17
Valve Guide Removal ・・・・・・・・・・ ‥.4-17
Valve Guide lnstallation .4-18
4-2 ENGINE TOP END
< ☆/
團万︿
ExplodedView
US and Swiss model
・・S 匍 ● ● 佩 ● ●
竹工も；
US and Swiss
model
/ トプ
Californian model
∧
よく J 鮮
浪とし
ENGINE TOP END 4-3
TI:9,8 N ・m {1,0 kg ・m,87 1n ・lb}
T2 : 12 N-m (1.2 k9-m, 104 1n-lb)
T3: 15 N ・m{1.5 k9-m, 11.0 ft-lb}
T4: 20 N-m (2.0 kg-m, 14.5 ft-lb)
T5:25 N-m (2.5 kg-m. 18.0 ft-lb)
T6: 39 N-m (4.0 kg-m,29 ft-lb)
T7:51 N-m {5.2 kg-m,38f 重-lb}
L : Apply a non-permanent locking agent

・M
: Apply molybdenum disulfide 9rease
・
SS : Apply silicone sealant.
0 : Apply engine oil.

︲4① 口
ヅ
八万
応
4-4 ENGINE TOP END
Specifications
ltem Standard Service Limit

Cy §inder Head, valves: valve Clearance: lnlet
一一一
Exhaust 一一一 005mm 0.25 mm
Cylinder head warp 一一一 0.5mm
valve head thiCkness lnlet
Exhaust 0,8mm 0.5mm

valve stem bend LeSSthan 0.01 mm TIR 0.05mmT
valve stem diameter: lnlet 4.975 - 4.990 mm 4.96 mm
Exhaust 4.955-4.970 mm 4.94mm
valve guide inside diameter: lnlet 5.000-5.012 mm 5.08 mm
E χhaust 5.000
valve/valve guide - 5.012(wobble
clearance mm method): 5.08 mm
lnlet 0.02 - 0.07 mm 0.18 mm

E χhaust 0.06 -
valve seating surfaCe: 0.11 mm diameter
Outside 0.21 mm
lnlet 29.3 -29.5mm 一一一

E χhaust Width 25.3 - 25.5mm 一一一
lnlet 0.5-1.0mm 一一一
ExhaUSt 0.5-1.0mm 一一一 33.6mm 38.6mm
valve Spring free length: lnner 35.5mm
Outer 40.5mm
valve Seat cutting an91e:
lnlet,ExhaUSt 32 °,45°,60° 54 一一一
Clean Air Sustem:
vaCuum SwitChvalve C 10sing preSSu re:
Open -y Close 0.13 -- 0.19

68 kPa
mm 0,18 - 0,24mm
一一一
(410 - 510 mmHg)
Valve Head Valve Stem Bend
、几1
ENGINE TOP END 4-5
Camshaft:
Cam height lnlet
EχhauSt Camshaft bearin9 011
celarance mm
Camshaft joumal diameter 24.900-24.922 mm mm
Camshaft bearing inside diameter 25.000 - 25.021 mm 25.08 mm
Camshaft runout not more than 0.02 mm TIR 0.1 mm TIR
Camshaft chain 20-link length 158.8-159.2mm 161.5mm
Rocker arm inside diameter 12.000 - 12.018 mm 12.05mm
Rocker shaft diameter 11.976-11.994 mm 11,44mm
Cylinder Compression: (usable range)
860 - 1 320 kPa
(8.8 - 13.5 k9/cm≒125- 192 psi)@370 r/min
(rpm 〉
Cylinder BIock, Piston:

Cylinder inside diameter 73.994 - 74.006 mm 74.11 mm
PiSton diameter 73.935 - 73.950 mm 73.79mm
Piston/cylinder clearance 0.044 - 0.071 mm 一一一
overSlze plSton and rlngS 十〇.5mm 0.03-0.07 mm 一一一 0.17 mm 0.16
Piston rin9/9roove clearance Top
Second 0.02 - 0.06mm mm
Piston rin9 9roove width Top 0.82 - 0.84Γ
Υlm 0.92mm
Second l.01-1.03 mm l.12 mm
Oil 2.51-2.53 mm 2.6mm
Piston ring thickness Top 0.77 - O。79 mm 0.97 0.7mm
Second - 0.99 mm 0.9mm
Piston ring end gap Top 0.2-0.35 mm 0.7mm
Second 0.2-0.35 mm 0.7mm
oil 36.667-36.807
0.2-0.7mmmm 36.667 - 36.807
36.57
l,0mmmm 0.078mm- 0.21
mm 36.57 0.121mm
Cam Height Measurement Camshaft Runout
Cam Height
。二回
4-6 ENGINE TOP END
Valve Seat Cutter 45 ≒ φ32 : 57001-1115ValveSeat Cutter45

・・・ ●・醤鎗 ● ● ● ● ● 鴎
Special T001s ° φ27.5:57001-1114Valve

- Seat Cutter32
● ●● ● ● ●S ● ● ● ●・・
° φ33:
- 57001-1199Valve Seat Cutter 32
°・φ30: 57001-1120Valve Seat Cutter 60
° φ30:
- 57001 ・1123
Piston Base: 57001,1263
①⑤ ⑤ り ①
Valve Guide Arbor: 57001-1203
Compression Gauge: 57001-221
Adapter: 57001 ・1317
子叉
Valve Guide Reamer: 57001-1204
Valve Spring Compressor Assembly: 57001-241

ハペ
Adapter: 57001-1202
Valve Seat CutterHolder: 57001-1208
毎＼＼
Bar:57001-1128
Piston Pin Puller Assembly: 57001-910

＼
CCO
Piston Ring CompressorAssembly(4):57001-1094

ENGINE TOP END 4-7
● 幽II ● ● ●S ● ●I ・丿 ●l ・
Vacuum Switch Valve Operation

Clean Air System (US model)
1.During Cruising (open throttle)
ノ1yrS ぴcI｀/
○η1/ ∂/レ
・e/ ダ
フSpθcr/0/7
Spring Diaphragm
●Visually inspect the reeds for cracks, folds,warps,heat
damage,0 「otherdamage
・
★lf there is any doubt as to the condition of the reed,
replace the air suction valve as an assembly.
Secondary airflows.
2. During[ngine Braking
A.Valve Holder B.Reeds
●Check the reed contact areas of the valve holder for

grooves,scratches,any signs of separation from the
holder,or heat damage.
★lf there is any doubt as to the condition of the reed
contact areas,replace the air suction valve as an

Secondary air cannot flow.
assembly.
●lf any carbon or other fDreign particles have accumu,

lated between the reed and the reed contact area, wash
the valve assembly with high flash-point solvent,
Vacuum Switch Valve C10sing Pressure
飯亘] Open うCIose: 54 - 68 kPa (410 - 510 mmH9)
oDo not scrape off the deposits with a scraper as this

could damage the rubber,requirin9 replacement of the
suction valve assembly.
1/11C￡/
ぴ周 SWyrC/7 1yQI/ レ
・e 71Sr
●Check the vacuum switch valve by blowing air into the

air hose fitting ・
oWhen the vacuum applied to the vacuum hose fitting of
the valve is Iow, the vacuum switch valve 15 0pened
and air fl・ows through the air hose fittings,
oWhen the vacuum rises gradually and reaches a certairl
level,the valve is cIosed and air does not flow.
★lf the vacuum switch valve does not operate a5
described,replace the valve.
4-8 ENGINE TOP END
●・ a ● 珈s 噛 ●s ● ● ● ● 機●●噂●籾・ ●●●●●●籾種騨・ ●丿・ ●籾●寸騨

・・ ● 機丿●個機働●籾臨● a・・籾●・・ ●・ ●・機籾●●馨個●● 機●●●寸●・ ●丁機軸●●●・・ ● 機嚇Camshaft
Chain Tensioner
Cylinder Head Cover
丁儒匍● 晦峰・・ ●・・ S 畠 ● 噛 ● ●
● ■ ■ ■ ■ 馨I ■ 讐種種
Removal Removaj
●Remove the following ・ ●Remove the tensionercap bolt,copper washer and
Falrlngs the spring ・

FuelTank ●Remove the mounting b01ts and take off the camshaft
Spark Plug Caps chain tensioner.
Carburetor
Baffle Plate
A.Mounting Bolts C.Copper Washer

A.Baffle Plate B.Spring D.Cap Bolt
●Remove the cylinder head cover bolts and take off the
cover.
匹亘￨
This is a non- 「etum type cam chain tensioner.Thepushrod does not retum to its origin
ynstalyation
「ules listed below:
●lnstallation is the reverse of removal. Note the
oWhenremoving the tensioner,do not take out the
following.
mounting bolts only halfway. Retightening the mount ・
●Apply silicone sealant to the cylinder head as shown.
ing bolts from this position could damage the tensioner
and the camshaft chain.0nce the bolts are loosened,
the tensioner must be removed and reset as described in

“Chain Tensionerlnstallation."
oDo not tum overthe crankshaft while the tensioneris
removed.This could upset the cam chain timin9,and
damage the valves.
1
Silicone Sealant Applied Areas
lnsta μation
●lnstallation is the reverse of removal.Note the fol

●Tighten the cylinder head coverbolts to the specified lowing.
torque(see E χploded View). 0Release the stopper and push into the rod.
ENGINE TOP END 4 ・9
A.Cooling Hose
A.Push Rod C.Push
B.Stopper D.Push into the rod.
●Remove the camshaft caps, and take off the camshaft
olnstall the tensioner body with the arrow on it pointing NOTE

upwards.
○/?θmQ 四が7∂//7/ ∂t rocker shaft,after removing the
cylinder head.
●Remove the rocker shaft end bolt and spring
A.Tensioner Body B. Arrow Mark
●Tighten the tensioner mounting bolts and cap bolt A.End Bolt B.Spring
to the specified torque (see E χploded View).
●Using a suitable bolt (8PI.25 χ more than 55 mm long),puH the rock
■ ●S
Camshaft,Camshaft Chain, Rocker Shaft
Camshaft,Rocker Shaft Remova!
●Remove the following

・
Cylinder Head Cover
Carburetors
Camshaft Chain Tensioner
●Drain the coolant about 500 mL, to remove the cooling
hose. A.Rocker Shaft B.BOlt

4-10 ENGINE TOP END
Camshaft Cap lnstallation
m 凹」
oThe crankshaft may be turned,while the camshafts are
removed.AIways pull the chain taut while tuming the
crankshaft.This avoids kinking the chain on the lower
(crankshaft)sprocket.A kinked chain could damage
both the chain and the sprocket. 11 甲
Camshaft Cap Number

Arrow Mark:
must be faced forwards
Camshaft,Rocker Shaft lnstallation
●lnstallation is the reverse of removal. Note the Front

ぐコ
following ・
●Apply engineoil to all cam parts and journals.
NOTE
oThe e χhaust camshaft has an E χ m ∂rk and the inlet camshaft has an 11V mark.Be careful not to mi
χ up these shafts.
Camshaft Cap Bolt Tightening Sequence
A.EX mar ゛k B.IN mark
●Tighten the rocker shaft end bolts to the spec げied torque(see E
χplodedView).
●lnstall the camshaft caps in the correct Iocations as
shown. Fronl
ぐ=]
呂呂
oThe camshaft caps are machined with the cylinder
head.So,if a cap is installed in a wron9 10cation,the
camshaft may seize because of improperoil clearance
in the bearings.
oFirst tighten down all camshaft cap bolts evenly to seat
the camshafts in place, then torque all bolts to the
specified torque (see ExplodedView).

ENGINE TOP END 4 ・11
Chain Timing Procedure

●Position the crankshaft at TDC for the #l and#4
pistons.
1.Bolt H01es for the lnlet Camshaft

2.Bolt H01es for the E χhaust Camshaft
A.Timing Mark ●lnstaH the sprockets so that the marked side faces
B.TDC markfor#l and#4 pistons outwards.
C.TDC markfor#2 and 毒3 pistons ●Apply a locking agent to the camshaft sprocket bolts
and tighten them to the specification (see E χploded View).
●Pull the tension side (exhaust side)of the chain taut to ●lf a new camshaft is to be used, apply a thin coat of a
install the chain. molybdenum disulfide grease to the cam surfaces.
oThe timing marks must be aligned with the cylinder
head upper surface and positioned respectively as
shown,after the camshaft chain slack is taken up by
the tensioner.
Cylinder Head Upper Surface
Camshaft,Camshaft Cap Wear
●Measure each clearance between the camshaft and the
camshaft cap using plastigage (press gauge).
NOTE
oTighten the camshaft cap bolts to the specifjed torque
fsee Exploded Viewj.
amS/7afra ・ゴ印/'Qd 吋ノ1SSeX7・ゐ/y
●Since the inlet and exhaust camshaft sprockets are the

same,they have a set of bolt holes forthe e χhaust camshaft and another for the intake.lnstall
the sprockets
1
asshown. Plastigage Width

4-12 ENGINE TOP END
NOTE
oDo not tum the camshaft when the plastigage is
between the joumal and camshaft cap,
な乳改訳eごお喩e迄ごぽ忿言
agaln.
★lf the clearance still remains out of the limit, 「eplace the cylinder head unit.
Camshaft Bearin9 011 Clearance
Standard: 0.078-0.121 mm
Service Limit: 0.21 mm A.Compression Gauge: 57001-221
B.Adapter: 57001-1255
C.Compression Gauge Gasket: 57001-1224
●Hold the throttle wide open and crank the engine with
the starter.
Camshaft Chajn Wear
●When the gauge stops rising, stop cranking and read the
●Hold the chain taut with a force of about 5 kg in some gauge.
manner,and measure a 20-link length. Since the chain
may wear unevenly,take measurements at several
places. Cylinder Compression
★lf any measurement exceeds the service limit, replace
Usable Range: 860-1 320 kPa@370 r/min (rpm)
the chain.
(8.8 - 13.5 k9/cm2, 125 - 192 psi)
Camshaft Chain 20-link Length

NOTE
Standard: 158.8 - 159.2mm

oUse the battery which is fully charged.
Service Limit: 161.5mm
★lf cylinder compression is higher than the specified

Chain Length Measurement range,check the following.
oCarbon build-up on the cylinder head combustion
chamber
20-link Length
oCarbon build-up on the piston head
★lf cylinder compression is lower than the specified
range,check the following.
0Valve not seating properly

oPiston/cylinder clearance e χcessive
oGa5 1eakage around the cylinder head gasket
oValve clearance too small
Removal

・
●・ ●・ ●S ・寸 ●・ ● ●S 翻 ● 暉轜 ●l ・
馨 ● 幽幽 ● ● ● ●SI ・・ ●● ● ● 暉 ● ●・ S ・ ●SI 暉 ● ●S 幽・・噂 ●・ ●・ ●I ● ●・ ● ● ● ● ●・・・ ●・ ● ● 幽 ●
Falrlng
Cylinder Head Coolant(Drain)
FuelTank
Radiator
Cy/ かd ∂/・COx77 ρyieSS/0 η ル1∂∂S ￡yremeflr Mufflers
●Perform the following Oil Hose (Cylinder head right side)
・
●Warm up the engine thoroughly and then remove the Carburetors
spark plugs
・ Cylinder Head Cover
●Attach the compression gauge,adapter and gasket Camshaft Chain Tensioner
(special tools)firmly into the spark plug hole. Camshafts
ENGINE TOP END 4-13
NOTE
NOTE
○Remove the cylinder head b01t(6 mm ノ and the cylinder bolts first.then remove the cylinder head
oThe camshaft caps are machined wjth the cylinder head
so げa new cy μnder head is installed. use the caps that are supplied with the new head.
b01ts.This prevents excessive stress on the small b01ts.
●Apply engine oil to the both sides of the cylinder head

bolt washers.
A.Cylinder Bolts B.Cylinder Head Bolt(6mm) 1.Cylinder Head Bolt

2.Washer
3・ Apply engine oil.
●Remove the cylinder head bolts and take bff the
cylinder head.
Location of Cylinder Head Bolts
lnstallation
●lnstallation is the reverse ofremoval. Note the
fojlowing ・
●lnstall the left most comshaft cap on the cylinder head.
●lnstall the two camshaft cap bolts through the leftmost
camshaft cap and cylinder head.

●lnstall the cylinder head on the cylinder.
3 ,
A.Leftmost camshaft cap B.BOltS
NOTE
oThe b01ts can not be put into the leftmost camshaft 1.10 mm Dia. B01t
cap after the cylinder head has been instaHed due to 2.11 mm Dia.Bolt
insufficient clearance between the camshaft cap bolts 3.10 mm
and the frame. 4.11 mm

4-14 ENGINE TOP END
●Torque the cylinder head bolts following the tightening Falrlng
sequence ・ Coolant(Drain)
oTighten them first t0 20 N-m (2.0 kg-m,14.5 ft-lb), FuelTank
and then tighten them to the specified torque (see Ex' Cooling Hose
plodedView). Ba 汗le Plate
Pickup Coil Cover
Cylinder Head Cover
●Using a thickness gauge, measure the valve clearance
between the rocker arm and the shim.
輿し
い ⑤い ⑤い ⑤ い
⑤
0When positionin9#4 piston TDC at the end of the
compression stroke:
inlet vaIve clearance of 孝2and#4 cylinders
e χhaust valve clearance of 毒3 and 毒4 cylinders
回に
くヨ
⑨ 爾
MeasuringValves
回くヨ
① ①
①①
EX
Front
タ
ンサ
⑨
01
≪ 二]
IN
#1 #2
⑨01
パ
oWhen positioning#l piston TDC at the end of the

compression stroke:
inlet valve clearance of#l and#3 cylinders

e χhaust valve clearance of 毒l and 毒2 cylinders
MeasuringValves 尋
○ ○
Ｅ
① ①
①
圈
●Tighten the cylinder bolts and cylinder head bolt

(6mm)to the specified torque (see ExplodedView).
#3 弁4
Valve Clearance
Standard: IN. 0.13 - 0.19 mm

Eχ. 0.18 - 0.24 mm
・ ● 鐘● 鐘・暮 ●・寸鐘鐘 ● ● ● ● ● ● ●I 眼lValves
★lf the valve clearance is not within the specified range

s ● 働a ・暉 ● ● ● 畠li ● ● ● ●a ●lllsll ●畠畠鋤自● l ●・ I 寧 ● ● 畠 ● 嘸I ●・ ●・ ● ● 嶮・ S ●I ● 畠 ● ●
●s ・ ● ● ● ●l ● ●・暉曇a ● ● ● ●l ● j
adjust the valve clearince.
●Adjust the valve clearance,as follows

。
Valve Clearance Adjustment
NOTE
NOTE
oTo select a new shim wllich brings valve cleanlnce
oValve clearance must be checked and adjusted when ￨/1/7
が?yj
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4-16 ENGINE TOP END
0681 688 ﹂ 8881 X881 9881 9881 6&8 ﹂ 8X8t &X81 9X81 9&81 tFX8t M以一｀ N 卜∞f 1X81 ○ に〃{ ︲saox6)p39wnN ﹂.uvd
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ENGINE TOP END 4-17
oSjide the rocker arm sideways and change the shim Va 八Xe lnstalyation
●Apply a thin coat of m01ybdenum disulfide grease to

the valve stem before valve installation.
●lnstall the springs so that the cIosed coil end faces
downwards.
A.Shim B.Rocker Arm
oRemeasure the valve clearance that was adjusted.Re- 1.Valve Stem 6.Retainer
adjust if necessary. 2.Spring Seats 7.Spring Seat
3.011 Seal 8.Closed Coil End
飯亘1 4.1nner Spring
5.0uter Spring
9.Split Keepers
oDo not put shim stock under the shim. This may cause
the shim to pop out at high rpm,causing extensive

engine damage ・
oDo not 9rind the shim.This may cause it to fracture,

causing extensive engine damage.
Va 八Xe Guide Removal
●Using the valve guide arbor(special tool),tap out the

晩7/ 四 β∂ 用0 旧/
valve guide.
●Using the valve spring compressor assembly (special
tool),remove the vaIve.
1.Valve Guide Arbor: 57001-1203
NOTE
1.Valve Sprjng Compressor Assembly: 57001 -241 oHeat the area around the valve gujde to 120-150 °C (248-302
2.Adapter: 57001-1202 °F ノ.
4-18 ENGINE TOP END
Vajve Seat Width lnspection

Valve Guide lnstallation
●Using the valve guide arbor (special tool),drive the ●Check the valve seating surface width.
valve guide until its flange touches to the cylinder head. oMeasure the seat width of the portion where there is no
build-up carbon (white portion)of the valve seat with a
vernler callper.
NOTE
oHeat the area around the valve guide hole to 120 一
150 ゜C(248-302 °F).
0Apply oil to the valve guide outer surface before valve
9uide installation.
0Using the valve guide reamer (speciaj tool ノ.ream the valve guide.
1.Valve
2.Valve Seat
3.Seating Surface Outside Diameter
4.Seating Surface Width
Valve Seating Surface Width (IN and EX)
1.Valve Guide Reamer: 57001 -1 204 Standard: 0.5-1.0mm
★1f the valve seating surface width is not within the

specified range,repair the valve seat.
1yj/wtF ∂ce Conl ∂cr //7sp θCr/0/1
●Check the valve face seating 5urface width.

0Measure the seat width of the portion wherethere is no
build-up carbon(white portion)of the valve face with a
vemler callper.
★lf the valve face seating surface width is not within the
specified range,replace the valve with a new one.
1.GOOd 2.Too wide
V ∂/1/ ∂S ∂∂rO ぴrsyde ￡)/∂mere/ ・
●lf the out51de diameter of the seating pattern on the
valve seat is too large or too small, repair the valve seat.
Valve Seating Surface Outside Diameter
Standard: lnlet: 29.3-29.5mm

3.Too narrow 4.Uneven
Exhaust: 25.3 - 25.5mm
ENGINE TOP END 4-19
V81 ゛e Se8t Repair (Valve Lappjn9, ノ NOTE
●Using the valve seat cutters (special tools),repair the oPrior t0 9rindin9, apply engine oil to the cutter and
valve seat.
during the operation, wash off any 9round partjcles
sticking to the cutter with washin9 011.
Valve Seat Cutters
lnletValves: 45 ° -φ32 57001-1115 5. After use, wash it withwashing oil and apply thin
32 ° -φ33 57001-1199 layer of engine oil before storing,
60 ° - φ30 57001-1123 ExhaustValves:45
° -φ27.5 57001-1114
32 ° - φ30 57001-1120
60 ° -φ30 57001-1123
Marks Stamped on the Cutter:
Holder and Bar The marks stamped on the back of the cutter re-
present the following.
Holder:
57001・120857001-1128 450 ・・・・・・・・・・・・.Cutter angle
Bar:
24.5 φ ‥ ‥ ‥ ‥ ‥ ‥Outerdiameterofcutter
★lf the manufacturer'5 1nstructions are not available, use
the f()llowing procedure.
Seat CutterOperating Care: ①

1 . This valve seaXt cutter is developed to grind the valve
for repair.Therefore the cutter must not be used for

other purposes than seat repair.
2. Do not drop ｀or shock the valve 5eat cutter, 0r the diamond particles may fall off.
3.Do not fail to apply engine oil to the valve seat cutter
before grinding the seat surface. Also wash off
ground particles sticking to the cutter with washing
oil. 1.0uterDiameter of Cutter
2.Angle of Cutter
NOTE 3.Cutter
oDo not use a wjre brush to remove the metal particles
from the cutter.lt will take off the diamond particles.
4.Setting the valve seat cutterholder jn position,

Operating Procedures:
0perate the c,utter in one hand.Do not apply t00
●Clean the seat area carefully
much force to the diamond portion. ・
●Coat the seat with machinist'5 dye
・
●Fit a 45 ° cutter to the holder and slide jt into the valve guide.
●Press down lightly on the handle and turn it right or

left.Grind the seating surface only until it is smooth.
巨弓]
oDo not 9 「ind the seat too much.0ver9 「inding w111
「educe valve clearance by sinking the valve into the head.lf the valve sinks too far
●Measure the outside diameter of the seating surface

with a vernier caliper
・
★lf the out51de diameter of the seating surface is too
2 。3.
Cutter Holder small,repeat the 450 grind untii the diameter is within
Bar the 5pecified range.
4-20 ENGINE TOP END
★lf the outside diameter of the seating surface is too ●Lap the valve to the seat, 0nce the seat width and 0.D.
large,make the 320 grind de5cribed below. are within the ranges specified above.
★lf the out51de diameter of the seating surface is within 0Put a little coarse grinding compound on the face of
the specified range,measure the seat width as described the valve in a number of places around the valve head.
oSpin the valve against the seat until the grinding com'
below.
●Grind the seat at a 32 poundrange.
° angle until the seat 0.D,is within the specified produces a smooth, matched surface on both
the seat and the valve.

oTo make the 32 ° grind,fit a 32 ° cutterto the holder, oRepeat the process with a fine grinding compound.
and slide it into the valve guide. ●The seating area should be marked about in the middle
0Turn the holderone turn at a time while pressing down of the valve face.
very lightly. Check the seat after each turn. ★lf the seat area is not in the right pljlce on the valve,
check to be sure the valve is the correct part. lfitis,it
may have been refaced t00 much; replace it ・
呂回 ●Be sure to remove all grinding compound before
assembly.
oThe 32 °cutterremoves material very quickly. Check the seat outside diameterfrequently to prevent
●When the engine over- 9be sure to adjust the
is assembledj
valve clearance (seeValve Clearance Adjustment).
「mdlng ・
Widened width of
engagement by machining Ground volume

with 45 ° cutter by 320 cutter
1.Lapper 3.Valve
2.Valve Seat
oAfter making the 320 grind, return to the seat 0,D.

measurement step above.
●To measure the 5eat width, use a vernier caliper to
measure the width of the 45 ルダ∂ お around
° angle portion of the seat at several places ￡jryrl!7the
1yj/￨ye-rO-G
seat. ￡jyd θC/ ∂∂r ∂yICe
{Wobble Method}
★lf tht seat width is too narrow, 「epeat the 45 ° grind until the lf a small bore gauge is not available, inspect the valve
seat is slightly too wide,and then return to guide wear by measuring the valve to valve guide
the seat 0.D.measurement step above. clearance with the wobble method,as indicated below.
★lf the seat width is too wide, make the 60 ●ln5ert a new valve into the guide and set a dial gauge
° grind described below.
against the stem perpendicular to it as cIose as possible
●Grind the seat at a 60 to the range

° angle until the seat width is within the 5pecified cylinder head matin 只surface.
●Move the stem back and forth to measure valve/valve

・
oTo make the 60 ° grind,fit 60 ° cutter to the holder holder,and slide it clearance.
guide into the valve guide.
●Repeat the measurement in a direction at a right angle
oTurn the holder, while pressing down lightly ・ to the first.
oAfter marking the 60 ★lf above.

° grind, 「eturn to the seat width measurement step the reading exceeds the service limit, replace the
guide.
ENGINE TOP END 4 ・21Cylinder lnsta
NOTE
・17 ys xtor
0771e / ・ad ∂caj ∂/￨/ ∂/1,∂ ル ∂/1/∂ 卯yd ∂c/ ∂aayIce ●Appjy engine oil to the cylinder bore.
ゐ∂c ∂￡jse が?∂/ 刀a∂s ￡j/7j/7gpa/ ηtjsa ゐ0
哨が?e gljyd ∂. ●Using the piston base and piston ring compressor
assemblies(special tools),instajl the cylinder block.
ValveyValve Guide Clearance

(Wobble Method)
Standard Service Limit
lnlet 0.02 - 0.07 mm 0.18 mm
Exhaust 0.06-0.11 mm 0.21 mm
A.Piston Base: 57001-1263
B.Piston Ring CompressorAssembly: 57001-1094
1.Valve Guide 3.Move the Valve.

2.New Valve
Piston Removal
●Remove the cylinder.
●Place a clean cloth under the pistons and remove the
piston pin snap rings from the outside of each piston.
●Using the piston pin puIler assembly (special tool),
remove the piston pins.
Cylinder,Piston
● 軸丿 ●・卜 ● ・ ●・ l ● 鐘 ●
●ll ● ● ● ● ● ● ● ● ● ●● ●・ ● ● ● ● 畠暉卿・ ● 畠ll 暉 ● ● ●as ●l 零 ● ● 岫鎗・ ● ● 働 ● ● ● ● ● ●s
Cy 面der Removal
●Remove the cylinder head.

●Remove the cylinder bolts.
1.Piston Pin Puller Assembly: 57001-910

2.Adapter
A.Cylinder Bolts
PIston lnsta!1 ∂tjon
●The top and second rings must be installed with the N

●Remove the cylinder.
or 2N marks on the ring5 facing up ・
4-22 ENGINE TOP END
C1// か ∂ θΓM/ θ∂「
●Measure the cylinder inside diameter taking a side-to,
side and a front-to back measurement at each of the 3
positions(total of 6 measurements)shown below.
1.Top Ring 2.Second Ring
●The piston ring openings must be po51tioned as shown

below.The openings of the oil ring steel rails must be
about 30 - 400 0f angle from the opening of the top
rlng.
Cylinder lnside Diameter:
Standard: 73.994,-74.006 mm
Service Limit: 74.11 mm
戸jsro ηl/1/ θ∂/・
●Measure the piston outside diameter 5 mm up from the
bottom of the piston at a right angle to the direction of
the p15ton pin.

﹁﹂DOQ
pUE
Piston Outside Diameter

如[] 一夕一japuEdX3
ぶ
1.Top Ring Standard: 73.935 - 73.950 mm

2.Second Ring Service Limit: 73.79 mm
3.011 Ring Steel Rails
4.011 Ring Expander
5.Arrow
●The arrow on the piston head must point toward the
front of the engine.
巨呂
oDo not reuse snap rings,as removal weakens and
1.PistonOutside Diameter
deforms them. They could fall out and score the
2.5 mm up from bottom
cylinder wall.
ENGINE TOP END 4-23
Piston Rin9.Piston Ring Groove Wear
●Check forunevengroove wea ‘r by inspecting thering seats.
★The rings should fit perfectly paraljel to the groove

surface5.1f not, the piston must be replaced.
●With the piston rings in their grooves, make several
measurements with a thickness gauge to deterilline
p15ton ring/g 「00ve clearance.
Piston Rin9/Groove Clearance
Top 0.03 0.07 mm 0.17 mm
Second 0.02 0.06mm 0,16 mm
2.Piston Ring
Carburetor Holder
● ● ● ● 價卿・
Carburetor H01der lnstallation

●lnstall the carburetor holder so that the pipe is up-
ward.Be careful of the clamp screw position.
1. Thickness Gauge
Piston Ring End Gap
●Place the piston ring inside the cylinder, using the

piston to locate the ring squarely in place. Set it cIose
to the bottom of the cylinder, where cylinder wear is
low.
●Measure the gap between the ends of the ring with a
A.Clamp Screws
thickness gauge.
Piston Ring End Gap [WARNING i

oOperation with an improperly installed carburetor
Top O 。20 0.35mm Second 0.200.7mm
0.35mm holderclamps could result in an unsafe riding condi-
0.7mm tion.
4・24 ENGINE TOP END
畠・ ● ● ●s 噂 ● 鴫 ● ● ●● ●● ● ● ●● ● ・ ●・ ● ●・・魯Muffler
●1 ● ● ● ● ● ● ●1111 畠 ●・・丿・ I ●・・・ ● ● ● ●Remova!

・
Coolant(draining)
Radiator
Homs(both left and right)
●Remove the nuts and take off the e χhaust pipe holders.
A.NUtS B.Holders
●Loosen the mufflerclamp b01t.
●Remove the muffler mounting bolts.

①レトノ
1.E χhaust Pipes2.Holders

4 .Mu 什ler
5.Mounting B01t
3.E χhaust Gasket 6. Clamp
CLUTCH 5-1
ClUtCh
Table of Contents
2 4 4 5 5 5 6 6 6 6 7 7 7 7 7 8 8 8 8 9 0 0 15 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5
ExplodedVi
Spec
Fluid Level lnsp
ClUtCh FlUid
Bleeding the Clutch Li
Master Cyli
ClUtCh SI
Rem
lnstallat
ClUtCh
Rem
5 5 5
F riction Plate
︲1.1
F riction and Steel Plate
Clutch Spring Free Length Measu

5 2 CLUTCH
・I ● ● ●・ ● 寸 ● ● 慟 ●l ● ● ●l ● 機 ● 鯵 ● 種・ ● 機● ● ●l ● ・ ● ●● l ● ● ● ●I 機l ● ●lll ● ● 哨 ● ●ll ● ● ・ ● ● ● ● ● ●l 機l ●l ● 機機種 ●機 ●
ExplodedView
卜岫種種種種S ・
ノンし○
言U
⑩i ⑤
◇
レ
/
CLUTCH 5-3
銕
‰
ぬ
≪ ふ)
≒ レ1 /
ノ回丿万
ぬ
TI : 9.8 N-m (1.0 k9 ・m.87 1n-lb)
T2: 11 N-m (1.1 kg-m,95 1n-lb)
1:3: 7.8 N-m (0.8 kg-m, 69 1n-lb)
T4: 18 N-m (1.8 kg-m, 13.0 ft-lb)
T5 : 25 N ・m (2.5 kg-m, 18.0 ft-lb)
∠ ノ T6: 130 N-m (13.5 k9-m.98 ft-lb)
示 L : Apply a non-permanent locking agent

・M
: Apply molybdenum disulfide 9rease.
①
うちグ
/ 脂ノ
ノ
5-4 CLUTCH
● 騰 ● ● 慟 ● ●● ● ● ● .●・・ ● ●SI ● 畠・丿 ●
Specifications
Recommended Clutch Fluid: Grade

Brand D.0.T.4Castrol Girlin9- UniversalCastrol GT (LMA)Castr
Clutch: Clutch Spring free length

Friction plate thickn
゛ess FriCtion and Steel plate
warp 33,2mm2.9-3.1mmLessthan 0.2mm
32,1mm2.75 mm0.3mm
Primary Reduction:
Primary gear/Clutch housing gear backlush0.03-0,10 mm 0.14 mm
Special TooI
凰働帰 ● ● ● 暉 ● ● ● ●● 讐幽・・・暉暉・寸・・ ● ●・ s 種種暉韓 ● 寸 ●・幽・露暉 ● ● ● ● 丁噛寸s ● ●・ ● ● 寥暉寸暉 ● 暉暉 ● ● ● 鐘露・慟噛凰・ ● 騨 ● 暉寥廓 ●Clutch
Holder: 57001 1243

-
ブノ
CLUTCH 5 ・5
● 噛IS ● ● ●・ ● ●
●●●●・ ●●●● 憾●●・ ●S・ ●● S・ ● I ●●● S S ●●●●橿 C l U t C h
Clutch Fluid Changin9
FlUid
●Remove the reservoir cap, andremove the rubbercap

● 輯韓 ●l ● ・ ● ● ● ● 寸 ● 輝 ●l ● 輝
on the bleed valve.

●Attach a clear plastic hose to the bleed valve on the
Fluid Leve 川nspection
clutch slave cylinder, and run the otherend of the hose
●Check the clutch fluld leve 目n the reservoir. into a container.
●Fill the reservoir with fresh fluid.
●Check the clutch fluid as follows.
A.Lower Level Line B.Upper Level Line
NOTE
○H01d the reservoir horizontal when checking clutch
flujd level.
★lf the fluid level is lower than the lowerlevel line,

fill the reservoir to the upper leve 目ine in the reservoir,
図而而￣i
oChange the fluid in the clutch line completely if the
fluid must be refilled but the type and brand of the
fluid that already is in the resenloirare unidentified. 1 。0pen the bleed valve.
After changing the fluid, use only the same type and 2.Squeeze the clutch lever and hold it.
brand 01 fluid thereafter.Mixing different types and 3.Close the bleed valve.
brands of 4.Release may

寸Iuid lowers the fluid boiling point and could cause the clutch to be ineffective.lt the also
clutch
causelever.
therubberclutch parts to deteriorate.
oRepeat this operation until fresh fluid comes out from
the plastic hose or the color of the fluid changes.

Recommended Clutch FIuid 0Check the fluid leve 目n the reservoir often, replenishing it as necessary
Grade: D.0.T.4 Heavy Duty Brake Fluid ・

Brand: Castrol GirUn9 ・Universal
NOTE
CastrQI GT (LMA)
olf the flujd in the reservoir runs completely out any
Castrol Disc Brake Fluid
time during fluid changin9.the bjeeding operation must
Check Shock Premium Heavy Duty
6e dof7 ∂01/ θΓ ∂g ∂j/1 かom 哨 ∂ ゐe が ηn/ ηgs 訥ごθ ∂// ・wj// /?
∂y ∂entered t 力e yjyle. I
NOTE
oSjnce the clutch fluid is the same as the brake fluid. 陽雨而￣

￣i
refer to Brake Fluid Section in Brakes for further
details. oDo not mix two brands of fluid.

5-6 CLUTCH
菌種 ● ●・ ● 桐 ● ● 嘸 ●
Bleeding the Clutch Line
●With the reserv()ir cap off, slowly pump the clutch lever Master Cylinder
several times until no air bubbles can be seen rising up
through the fluid from the hole5 at the bottom of the
lnstaljation
reservoir.This bleed5 the air from the master cylinder
end of the line ●When jnstalling the clutch master cylinder, be careful
。
of following.
NOTE
oThe master cylinderclamp with the arrow on it point-
oTap the clutch hose lightly 901ng from the lower end ing upwards.
to the upper end and bleed the air off at the reservoir. oTighten the upperclamp bolt first, and then the lower
clamp bolt to the specified torque (see Exploded
●Attach a clear plastic hose to the bleed valve on the View).
clutch slave cylinder,and run the other end of the hose

into a contajner.
●Bleed the clutch line as follows:
A.Tighten upper clamp bolt first.

B.UP mark
oReplace the aluminum washeron each side of the
clutch hose fitting with a new one.

0Tighten the banjo bolt to the 5pecified torque(see
Exploded View).
●Perf()「 m the following after installing the master cylinder.
1 Pump the clutch lever a few times until it becomes Bleed for clutch line
hard and then hold it squeezed. Check for cIutch operation
2 Quickly open and close the bleed valve 。 Check for fluid leakage
3
Release the clutch lever.
oCheck the fluid level in the reservoir often, replen15hing

it as necessary ・
NOTE
∂Xs ∂ss ∂ β7 ゐ/y

olf the fluid in the reservoi ・r runs completeyy out any time during bleeding,the bleedin9 0peration must be done over again from the begjnning sjnce air will have entered the
・
Clutch Lever
DustCover
line.
Circlip
Piston and Secondary Cup, Primary Cup

oRepeat this operation until no more air can be seen
Spring
coming out in to the plastic hose.
[WARNING i NOTE
oDo not mi χ two brands of fluid. oDo not remove the secondary cup from the pjston.
CLUTCH 5-7
1.Primary Cup 3.Piston

2.Secondary Cup 4.Circlip A.Slave Cylinder C, Banjo Bolt
B.Mounting Bolts
yIss∂/?7ゐ/1/ 回呂
●Clean the disassembled parts with clutch fluid and
○§mmediately wipe up any brake fluid that spills.lt may damage painted surfaces.
apply clutch fluid to the inner wall of the cylinder,
●Perform the following if the clutch slave cylinder is to

be removed but not disassembled.
製ヨ! 」
oTake care not to scratch the piston orthe inner wa11 0f
the cylinder.
胚亘1
01f the cIutch slave cylinder is removed and left alone,
the piston will be pushed out by the spring and the

clutch fluid will drain out 。
oRemove the clutch slave cylinderfrom the engine with

lnspection
the hose and push the piston into the cylinder as far as
●Check the following for wear, damage,cracks,0r dete- it will g0.
rioration: 0Squeeze the clutch lever 5jowly and hold it with a
Cylinder lnner Wall and Piston band.
Primary and Secondary Cups
-DustCover NOTE
Spring
oH01ding the clutch jever keeps the piston from coming
●Check that the relief and supply ports on the cylinder
OUt.
are not plugged.
lnstallation
●Note the following

・
oReplace the aluminum washers on each side of the
cIutch hose fjtting with new ones.
0Tighten the banjo bolt to the 5pecified torque(see
Exploded View).
Clutch Siave Cylinder
0Replace the spacer of the cIutch 51ave cylinder with
new one.
0Apply non-permanent locking agent to the two short
βemO 旧/ bolts of the slave cylinder mounting bolts.
●Remove the foHowing ・ 0Check the fluid level in the master cylinder reservoir,
Banjo ゛Bolt and bleed the air in the clutch line.
Mounting Bolts 0Check the clutch operation.
5-8 CLUTCH
Disassembly
●Using compressed air, remove the piston.

巨匠i]
0Cover the cylinder opening with a clean,heavy o Replace the fluid seai with a new one if it was removed
cloth. from the piston.
0Face the opening downwards.
oRemove the piston by lightly applying compressed
air to where the clutch line fits into the slave
cylinder.
嘩 ● 噂寸 ● ● 刄 ● 畷 ● ● ●
●●偏鳥偏 S s 鳥畠幽匍個・・帰・暉寸騨邨●●鳥・ S C l U t C h
Removal
Falrlngs
Clutch Cover
A.Apply compressed air. B.CIoth
飯亘]
01f the fluid seal is removed from the piston, replace the
seal with a new one. Removal would damage the seal.
阿呵
oTo avoid serious injury, never place Your fingersor
A.Clutch Cover B.BOltS
palm in front of the cylinder openin9. 1f you apply
high compressed air to the cylinder, the piston may

injure yourhand orfingers. Clutch Spring B01ts
Clutch Springs
Clutch Spring Plate (with thrust bearing and pusher)
yISS ∂r776/y
●Do the following ・

oApply clutch fluid to the outside of the piston and the
fluid seal.
olnstall the fluid seal as shown in the figure.
A.Clutch Spring Bolts B. Clutch Spring Plate
Friction Plates,Steel Plates

Clutch Hub
1
Cylinder 3.Fluid Seal oUsing the clutch Hub Holder (special tool),hold the
2
Piston 4.Spring clutch hub to remove the nut.
CLUTCH 5-9
y⊃X
1
Oil Groove 2.Direction of Rotation
A.Clutch Hub Holder: 57001 -1 243 olnstall the last friction plate fitting the tangs in the
B.Clutch Hub Nut groove on the housing as shown.
NOTE
01/Wle/1 rem01 冶7g 泊ec/ ￡jtc/1 /70 ￡jsかIZ.r ∂mQIye が?e ∂/ Γθ/71 ∂,
tor drive chain tensioner for easy handling fsee Crank-
s/7a 々/7'/ ・axtsmjssyoyl c/7apre り.
Sleeve
Clutch Housing
oUsing the tw0 6 mm bolts, pull out the sleeve.
A.Last Friction Plate
●lnstall the altemator drive chain tensioner, if it was

removed(see Crankshaft/Transmission chapter).
●Tighten the following fasteners to the specified torque
(see ExpjodedView).
Clutch Hub Nut
Clutch Spring Bolts
A.Sleeve B. Clutch Housing ●Apply molybdenum disulfide grease to the push rod
end.
lnstallation
●lnstallation is the reverse of removal.Note the fol-

Iowing. T])
●Discard the used clutch hub 5elf-locking nutJ and install
a new nut.
巨呂 1. Appjy molybdenum disulfide grease

2.Push Rod
〇lf new dryfriction plates and steel plates are installed,
3.Clutch Spring Plate
apply engine oil to the surfaces of each plate to avoid
clutch plate seizure.
●Apply silicone sealant to the crankcase halves mating

●lnstall the friction plates as shown in the figure.
surface on the front and rear sides of the cover mount.
5-10 CLUTCH
Friction Plate Wear
★lf any friction plate thickness is less than the service

limit,replace the friction plates as a set.
A.Silicone Sealant Applied Areas
●Squeeze the clutch lever slowly and hold it with a band

while push the spring plate push rod push into the
Friction Plate
clutch hub.
Friction Plate Thickness
Standard: 2.9-3.1mm
Seyvice Limit: 2.8mm
Friction and Steel Plate Warp

★lf any plate is warped over the service limit, replace the
plates as a set.
●Apply a non-permanent locking agent to the f0110wjng

bolts.
1.Friction or Steel Plate 3. Surface Plate

2.Thickness Gauge
Friction and Steet P §ate Warp
Standard: less than 0.2mm

CLUTCH 5-11
Clutch Spring Free Length l レタ

∂∂S ￡j/17
β7∂/7「
★lf any of the spring is shorter than the service limitJ it

must be replaced.
Clutch Spring
Clutch Spring Free Length
Standard: 33.2mm
ENGINE LUBRICAT10N SYSTEM 6-1
Engine Lubrication System

Table of Contents
ExplodedV 6-2
EngineOil FI
6-4
55666777788990000
一
Specifications ‥.
一
Engine Oil and Fi
｀一
Oil Leve 目Engine
一
Oil
一
Oil Filter C
一
Rem
゛
Oil Pump and Relief V
一
Oil Pump and Relief Valve Removal
｀
・・・・・・・・・・・・・・・・・・・・・・・・
一
Oil Pump and Relief Valve l
Oil Pump A 一 1 1 1 166666666666666

︲"'6 ︲6 ︲
Oil Pressure Measureme
ReliefVa 【ve Opening Pressure Measurement

・・・・・・・・・・・・・・・・・・ 6-10
Oil Pressure Measurem
6-11
6-2 ENGINE LUBRICATION SYSTEM
E χplodedView
● ● 倫 ● ●
● ● ● ● ●● S ●畠 ● ● ● ●Ill
軋回
ぜ
4
言駝
大
二賠
窓⑤
⑩(C)t
士
︽
①
汀回診句
○
レ
TI : 18 N-m (1.8 k9-m, 13.0 ft-lb)
T2: 12 N-m {1.2 k9-m, 1041n-lb}
T3: 25 N-m12.5 kg-m. 18.0ft ・lb)
T4: 15 N-mjl.5 k9-m, 11.0 ft-lb)
T5: 34 N-m {3.5 k9-m, 25 ft-lb}
T6: 20 N-m 12.0 k9 ・m, 14.5 ft-lb)

T7: 29 N-m {3.0 kg ・m,22 ft-lb}

・SS
: Apply silicone sealant.
參
⑤
二
レノ ∧
二_
●・ ●讐種種・・個 ●・嘘 ●・ ●丿
Engine Oil Flow Chart
● ● ● 華壇慟・ ● 昏睡凰華 ● 寸働・・ ●・曝露● ●● ●● ● l ・s ● ● ● 華 ● 刈曝 ● ● ● ●● 寸 ● ●● 種種華・曝● ●● ● ● ●● ●・・ ● ●・ ●● 種● 岫・ ● a ● ・ ● ●
2パヤーハ才づも] 。∠ 。
示斟言二
1.Transmission Chamber
2.Balancer Chamber
3.Screen
4.011Pump
1
5.011 Cooler
111j 6.ReliefValve
・i 7.011 Filter
8,Bypass Valve
9.0utput Shaft
10.011 Pressure Switch
il
11.Drive Shaft
12.Balancer
13.Crankshaft
14.Connecting Rod
15.Piston
○1 16.Piston Pin
____- 」
「一
①一
1 17.Alternator Shaft
--
18.StarterClutch
︲
19.Rocker Shaft
20.Rocker Arm
21.E χhaust Camshaft
22.1nlet Camshaft
● 凰・ ● 馨 ● ・・壽I
Specifications
ltem Standard
Engine Oil:
Grade
viSCOSity
Capacity SE Or SF classSAE 10W40, 10W50,20W40,0r20W502.7L(when filter is not
Oil Pressure Measurement:

Reliefvalve opening pressure ≒63 - 85 psi)196 - 294 kPa (2.0-3.
oil pressure @4,000 r/min (rpm),
oil temp. 90°C (194°F) 430 - 590 kPa (4.4-6.0 kg/cm psi)
Special Tools
SS ● ● ・ ● 欄・・
・働騨暉 ● ● ・鎗I
Oil Pressure
Gauge: 57001,164 Oil Pressure Gauge Adapter: 57001-1188
NOTE
○The oil pressure gauge adapter (PZN 57001-1278)can
be used instead of the oil pressure gauge adapter (PZN
57QQ7-77 ∂ ∂ ノ.
6-6 ENGINE LUBRICAT10N SYSTEM
Engine Oij Change

Engine Oil and Oil Filter ●Set the motorcycle up on its center stand after warm
ing up the engine.

●Remove the lower fairing
・
「而而￣i ●Remove the engine drain plugs to drain the oil.
oMotorcycle operation with insufficient,deteriorated.0 「
contaminated engine oil will cause accelerated wear and
mayresult in engine or transmission seizure, accident,
and lnjury.
Oil L.evel lnspectjon
●Check the engine oil level between the upper and lower
leve 卜n the gauge.
へ.UoDer Level B.Lower Level

A.Drain Plugs B.011 Filter Mounting Bolt
NOTE
○Situate the motorcycle so that it is perpendicular to the
ground. oThe oil in the filter can be drained by removing the

○lf the motorcycle has just been used, wait several filter mounting bolts and taking off the filter from the
minutes for all the oil to drain down. bolt.
0 げthe ojj has just been changed, start the engine and run it for several minutes ★Replace tJle drain plug gasket with a new one if it is
damaged.
ヽat idle speed. This fiHs the oil filter with oil. Stop the engine,then wait several minutes untij the oil settles.
●Tighten the drain plugs to the 5pecified torque(see

ExplodedView).
●Tighten the oil filter mounting bolt to the specified

torque(see E χplodedView).
●Pour in the specified type and amount of oil.
回回
oRacing the engine before the oilreaches everypart can
cause en91ne selzure ・ Engine Oil

○§f the engine 011 9ets extremely low or if the oil pump or oil passages cIo9 up or otherwise do not function properly,the oil pressure warning light will light.lf this light stays on when the engin
Grade: SE or SF class
Viscosity: SAE 10W40. 10W50,20W40,0 「20W504.0 L{engine is completel
Amount:
the engine immediatelY and find the 3.0L(filteris removed)

cause. 2.7L{filteris not removedl
ENGINE LUBRICATION SYSTEM 6-7
Oil Filter Change
●Drain the engine oil.

●Remove the oil filter mounting bolt and take off the
filter assembly.
NOTE
oThe oil fjlter bypass valve is assembled in the mountin9
bOlt.
A,011 Pipe C. Banjo Bolts

B.011 Hose
② つ
匹 ⑥
疹← ⑤
1.Mounting Bolt 5.Spring

2.0-ring 6.Washer
3.Filter Cover 7.Filter
4.011 Fence
●When installing the oil filter,be careful of the A.011 Pressure Switch Lead
following
・
●Apply oil to the mounting boltj turn the filter or the
mountjng b01t to work the filter into place. Be careful
that the filter grommets do not slip out of place. ●Remove the oil pan bolt5 and take off the oil pan.
0Tighten the filter mounting bolt to the specified torque
(see Exploded View).
☆Replace the O-rings with new ones if they are damaged.
0Pour in the specified type and amount of oil.
●・ ●・寸夥暉 ● 機巻軸・・・・・・ ● 機● s 寸機機巻・・暉郡 ● 噂寸la 曇 ●a ・ ●s ● ● 寸● 馨 ● ●● 巻 ● ● ●・・・ I I ● ● ●・巻瞳 ●卜巻機機・騨・騨機機・・ O i l
Pan
噫匍機● 盾個機 ● ● ●I 機 ●・盾 s ・祠巻事 ●・・ ● 機機騨 ●s 鴫犀暉機寸巻幽幽 ●・機・ ● ●・・・・ ● ・暉暉露暉寧暉 ● 機卜機● l ・寸 ● ●I ●s ●● 幽丿機丿機・
lnstallation
/?e/7?01/ ∂/ ●lnstallation is the reverse of removal.Note the fol-
●Remove the following lowing.

・
Falrlngs ●Apply a silicone sealant to the threads of the oil
Engine Ojl (Drain) pressure switch, and tighten it to the specified torque
Oil Filter (see E χploded View).
Radiator(see Cooling System chapter) ●Replace the gasket with a new one.
Oil Co01e 「 ●Replace the O- 「ings with new ones if they are damaged.oThe outlet side O
Muffler ・ring between the oil pan and the oil pump bracket must be in5talled so
Oil Pipe and Hose
Oil PI'essure Switch Lead
6・8 ENGINE LUBRICAT10N SYSTEM
Oil Pump and Relief Valve
Oil Pump and Relief Vahze Removal

Oil Pan
Oil Screen
Oil Pipe
Oil Pump Bracket Bolts
●Pull out the bracket and pump assembly
NOTE
oRemove the pickup coil cover,and tum the crankshaft
until the catches of the pump shaft ends are vertical.
A.0-Rings
A.Catches
●Apply a non-permanent locking agent to the threads of
the four oil pan bolts which are indicated by the
trjangularmarks.
●Remove the ojl pump ・

●Unscrew the relief valve
A.011Pump
A.Triangular Marks B.ReliefValve
ENGINE LUBRICATION SYSTEM 6-9
Oil Pump and Relief Valve lnstajlation ●C11eck that the oil pump shaft catches of both compo,
●Fill the pump with engine oil before installation. nents are vertical.
●Check that the collars and O-rings are in place, The
outlet side O-rings must be installed so that the flat
side faces the bracket.
喩 .- 、、 J
゛・゛心
A.Catches
A.CoHars B.0-Rings
●Apply non-permanent locking agent to the followingj

and torque them to the specified (see ExplodedView).
ReliefValve Oil Pump AssemblyA10te
Oil Pump Mounting Bolts
萌顛]
oDo not over-appSy a non-permanent locking agent to
the threads. This may block the oil passage.
●Check that the knock pin, nozzle,and O-ring are in

p-lace.The small hole of the nozzle must face the
bracket.
<
丿TI
叩￨リ
。S".iマ Thiner Rotors
]該 2.Thicker Rotors
齢権ノ￨lilF
,ノj;QF
A.Knock Pin C.0-ring ●Before installing the oil pump, be sure the shaft and
B.Nozzle rotors tum freely.
●lnstall the clamp on the oil pipes so that the clamp

Oil Cooler
opening faces downwards, asshown.
Removaj

EngineOil(Drain)
Falrlngs
Radjator
Oil Pipes
OH Cooler Mounting Bolt
A.Clamp B.011 Pipes
A.011 Pipes C.011 Cooler
B.Mounting Bolt
Oil Pressure Measurement
Oil Cooler Mounting Bolt

● 機 ● 機l 機種 ● ●l ●・ ● ●l ●l 騨 ● ●・ ● ● 機 ● ●・・ ● 機・畠・ ● ● 機 ● ● ● ● ● ● ● ● ● 騨 ●l ●寸機● a ● ● ● ● 機Is ●s ● 嘩 ● ●
ReliefValve Opening Pressure Measurement
NOTE
oMeasure the oij pressure before the engine is warmed
up if you want to test relief valve opening pressure,
●Remove the oil passage plug ・

●Attach the oil pressure gauge and adapter(special
tools)to the plug hole.
1 . Banjo Bolts
2.011 Pipes
lnstallation
●lnstallation.is the reverse of removal.Note the fo!-

lowing ・
●Replace the washer on each side of the hose fitting
with a new one if the banjo bolt was removed.
●Afterinstalling the oil cooler,tighten the banjo bolts A.011 Pressure Gauge: 57001 -1 64
to the specified torque (see Exploded View). B.Adapter:57001-1188
●Read the maximum oil pressure while running the

engine at various speeds.A normal relief valve keeps,
the maximum oil pressure between the specified
valves.
ReliefValve Opening Pressure

(4.4-6.0 kg/cm2,63 - 85 psi)
★lf the reading 15 much higherthan the standard or is

much lowerthan the standard,find the cause im-
mediately.
Oil Pressure Measurement
NOTE
oMeasure the oil pressure after the engine is warmed up,
●Attached the oil pressure gauge and adapter (special

tools)to the oij passage plug hole.
Oil Pressure
Standard: 196-294kPa
(2.0-3.0 k9/cm2,28 - 43 psi)
@4 000 「/min(rpm),90 °C(194 °F)
of oil temp.
★lf the oil pressure is much lower than the standard,

check the oil pump,relief valve, and/or crankshaft
bearing insert wearimmediately.
ENGINE REMOVAL/INSTALLAT10N 7-1
Engine Removal/lnstallation
Table of contents
7-2
Engine Removal/lnstal
7-3
7-3
lnstal
7-4
7-2 ENGINE REMOVAL/INSTALLAT10N
● ● ● ● ● 頓 ●S ● 哺齢 ●
ExplodedVew
零・l ●l ● ● ● ● ●● I ● 讐 ● ●● ●
●●●・寧●●●・ ●● 聊暉寧丁●●Is ・聊●●●●●●●● 1 ●
サレ句
ノハ TI: 44 N-m (4.5 k9-m,33 ft-lb)

ENGINE REMOVAL/INSTALLATION 7-3
● ●●・ 1 岫・
Engine Removal/lnstallation
● 哺憧 ●● ・ ● 丿 ● ● ● ● ll ・輝 ● 騨曾
Engine Removal

Falr ↓ngs
Engine Oil (Drain)
Coolant(Drain)
Seat
FuelTank
Radiator
Oil Cooler
Muffler
Air Cleaner Housing

Carburetors
A.011 Pressure Switch Lead
Fuel Pump and Filter
Clutch Slave Cylinder (see Clutch chapter)

Engine Sprocket
Vacuum Switch Valve and Hoses (US model only)

Baffle Plate
●Djsconnect wiring from the engine and free them from

the clamps,
Pickup Coil Lead
Battery Ground Lead
Starter Motor Lead
Oil Pressure Switch Wire
Side Stand Switch Leads

Alternator Leads
Neutral Switch Leads
A.Neutral Switch Lead

B.Side Stand Switch Lead Connector
●Remove the down tube.
A.Battery Ground Lead
A.Down Tube C. RearEngine Mounting Bolts

B.Bolts
●Support the engine with a stand before take out the

rear engine mounting b01ts.
A.Starter Motor Lead ●Remove the engine.
7-4 ENGINE REMOVAL/INSTALLATION
Engine lnstaHation
Iowing ・
●Tighten the following bolts to the specified torque (see
ExplodedView).
Engine Mounting Bolts
Down Tube Mounting B01ts
●Adjust the following ・
Throttle Cable
Choke Cable
Drive Chain
CRAN KSHAFT/TRANSMISS10N 8-1
Crankshaft/Transmission
Table of Contents
E χplO
8-2
Speci
8-4
Speci
8-5
Crankcase Splittin9
●●●●●●●●●●●●●●●●●●●●●●●●●●●●●●●●●●●●●●●●● 8-6
Crankcase
8-6
Crankcase Assem 8-6
Crankshaft/Connecti
8-8
Crankshaft R
8-8
8・
Crankshaft lnstallation N
8891333344445 5 5566666777799
一 IM '.'.'.'.'.1.1T IT rr
Connecting Rod R
Connecting Rod lnstal
Connecting Rod Big End Bearin9 1nsert/Crankpin Wear

・・・・・・・・・
8888888888 8 8888888888888
一
Crankshaft Main Bearin9 1n
Crankshaft Side Clea
一一
Bal
Balancer Rem
｀一
Balancer lnstallation N
Damper lnspectio
・
Needle Bearin9
｀一
r
Altemator Shaft/Starter Motor C
rrrrrrrrrrrrr(X)CX)CX)(X)
Altemator Chain and Tensioner
｀一
Altemator Chain and Tensioner lnstallation Note ・・・・・・・・・・・・・・Altemator
Shaft and
﹃
Starter Clutch
Altemator Shaft and Starter

一
ClUtCh
Altemator Shaft Chain W
″ ・
Starter Motor Clutch l

一
Transmissi
一
Extemal Shift Mechanism Rem

External Shift
｀
一
Extemal Shift Mechanism lnspectio

・
Transmission Shaft Re
｀
Transmission Shaft l
一
｀
・
Shift Drum and Fork Re

Shift Drum and Fork
″
/
8-2 CRANKSHAFT/TRANSMISS §ON
・l ● ● 畠 ● ● 砥畠S ・丿 ● ● 寸 ● ● ●
● 畠・ ●l 鴫噛僣 ●・丁 ● ●・ ● 畠 ●I ●l 嘸畠 ● ● ● ●
S ● ● ● ● ・ ● ●S ●・・ ●I ●・畠働 ● ● ● ● 畠I ● ●寸 ● ● ●卜 ●
EXplOdedVieW
・ ●・●● I ●● ● I● ●寸● ●● s ●●●・働●菌●●●

●●● I ●菌種●●菌 I ● s ●● s ●
●●種瞼・ ●●●・・個・匍●a ● 轜●菌●●●●菌●● I ●●●●●
丿
ダ
/ ダ !
のl ぼ
勺
愉
㈹
○ ノ
CRANKSHAFT/TRANSMISSION 8-3
ノ
1 : See Connecting Rod lnstallation
⑤ TI:25 N-m (2.5 k9-m,18.0 ft-lb)
T2: 9.8 N-m (1.0 k9-m,87 1n-lb)
T3: 59 N-m {6.0 k9-m,43 ft-lb}
T4: 12 N-m(1.2 k9-m, 104 1n-lb)
T5 : 27 N-m (2.8 k9 ・m,20 ft ・lb)
T6: 15 N-m (1.5 k9-m,11.0 ft-lb)
L : Apply a non,permanent locking agent

・M
: Apply molybdenum disulfide 9rease,
0 : Apply engine oil.
G : Apply 9rease.
ぐ
8-4 CRANKSHAFT/TRANSMISSION
噛 ●S
Specifications
慟 ● 奢匍 ● 嚇嘸 ● ● ● ● ● 闇値 ●・酋s ● 匍 ● 丿丿丿丿 ● 闇・ ● ●● ・暉讐 I ● ●・鴫 ●I 丿 ●・闇禰 ●I ●I ●I 卿 ● ●I ● 闇 ● 自 ● ● ● 檜 ● 輝II ● ● ● 値I 丿 ●●
ltem Standard ServiCe Limit
CrankShaft,ConneCting RodS:
Connecting rod bend 一一一
ConneCtin9 rod tWiSt 一一一0.13 - 0.33 mm0,036 - 0.066 mm34.984 -
ConneCtin9 rod big end Side CleamaCe
ConneCtin9 rod big end bearing
inSert/crankpin ClearanCe
Crankpin diameter: 35.000 mm
34,984-34.992 mm
Markin9 None
O 34.993 - 35,000 mm
Connectin9 rod big end bore diameter: 38.000 - 38,016 mm
38.000 - 38.008 mm
None Marking
O 38,009 - 38,016 mm
Connectin9 rod big end bearin9
1nsert thiCkneSS: Black 1,475 - 1 ,480 mm 一一--
Blue 1.480 - 1 .485 mm 一一---
White 1.485 - 1 .490 mm 0.2/100 mm0.2/100 mm0,50 mm0,10 mm34.97mm-
ConneCtin9 rod big end beamg inSert Selection:
Con-rod Big End

BOre Diameter
Marking Crankpin Diameter Markin9 Size 1nSert
Bearin9 Color Part Number
○ ○ Blue 92028-1407
None None
○ None White 92028-1547
None ○ Black 92028-1408
Crankshaft runout 一一一0.020 - 0.044 mm35.984 - 36.000 mm35.984 - 35.992

Crankshaft main bearing insert/
joumal clearance
Crankshaft main joumal diameter:

None Markin9 mm 一一一
1 35.993 - 36.000 mm
Crankcase main bearing bore diameter: 39.000-39.016 mm 一一一
39.000 - 39.008 mm
Markin9 0
None 39.009 - 39.016 mm 0.05 mm TIR0.08 mm35.96 mm
CRANKSHAFT/TRANSMISS10N 8-5
Crankshaft main bearing insert thiCknesS:

Brown 一一一
Black mm 一一一
Blue l.498 1.490

- 1 .502
- 1 mm
.494 mml,494
一一 -一 1 .498
Crankshaft main bearing insert SeleCtion:
Crankcase Main ゛
Bearing BOre
Diameter Marking Crankshaft MainJoumal Size lnSert
Bearing
DiameterCO10「 Part Number
Marking JoumalNos.
○ 1 Brown 92028-1102 2,4

92028-12741,3,5
None None Blue 92028・1100 2,4

92028・1272
1,3,5
○ None Black 92028-1101 2,4
None 1 92028-1273 1,3,5
゛The bearing inserts for Nos. 2 and 4 joumals have o11 9rooves.
CrankShaft Side ClearanCe

Altemator Shaft chain 20-link length 0.05 - 0.20 mm158.8 -0.40
159.2mm
mm161.5mm
Transmission:
Gear backlash
Gear shift fork 9roove width
Shift fork ear thickness
Shift fork guide pin diameter
Shift drum 9roove width 0,06 - 0.23 mm5.05 - 0.3mm5.3mm4.8mm7.8mm8.3mm
5.15 mm4,9-5.0mm7.9-8.0mm8.05-
Coupling Holder: 57001-1189

Special Tools
I ● ・・ ● ● ● ●丿 ● ●I ・・
Circlip Pliers: 57001-144
Liquid Gasket: 92104

・1003
Silicone Sealant: 56019
・120
⑤
8-6 CRANKSHAFT/TRANSMISS10N
●Pry the points indicated in the figure to split thecrank-

Crankcase Splittin9
case halves apart, and remove the lower crankcase half.
Crankcase Sp 附t 加9
●Remove the engine (see Engine Removal/lnstallation
chapter).
●Set the engine on a clean su げace and h01d the engine steady while parts are being removed
・
●Remove the folIowing parts from the engine.
E χternal Shift Mechanism Cover
Starter Motor
Alternator
Pickup Coil
Right Engine Cover
Alternator Chain Tensioner
OilPan
Oil Pump with Bracket
Remove the following parts only if the crankshaft is
to be removed.
Cylind びr Head A.Pry Point

Cylinder Block
Pistons
Alternator Shaft Chain and Sprockets
Remove the foHowing part only if the transmission
drive shaft assembly is to be removed.
Clutch
●Remove the upper crankcase bolts.
A.Pry Point
OltS B.8 mm Bolts
●Remove the lower crankcase b01ts.
Crankcase Assembly
NOTE
oThe upper crankcase half,the lower crankcase half. and
the crankshaft main bearing cap are machined at the
factory in the assembled state,so the crankcase halves
and the main bearing cap must be replaced together as
a set.
A 。6 mm Bolts
B.8 mm Bolts
●Assembly is the reverse of splitting. Note the
C.Remove is not necessary for crankcase split. following ・
CRANKSHAFT/TRANSMISS10N 8-7
●Before fitting the lowercase on the upper case, check

the following.
A.Do not apply a liquid gasket here.
●Hold the balancer so that the mark on the balancer
A.Knock Pins weight aligns with the center of the oil passage h01e.
oShift drum is in the neutral position (neutral posi-

tioning lever fits into the detent on the shift drum
bearing holder).
0#l and 4 pistons are at TDC.
A.Align mark with hole center
●Tighten the lower crankcase half bolts using the follow-

ing 3 steps.
0Lightly tighten all lowercrankcase halPbolts to a snug
fit.The three 8 mm bolts (sequence numbered l
through 3)have a flat washer.
0Torque the 8 mm bolts. The sequence r ↑umbers on the lower crankcase hal
A.Neutral Positioning Lever B. Neutral Detent
●With a high flash-point solvent, clean off the mating

surfaces of the crankcases halves and wipe dry.
●Apply a liquid gasket to the matjng surface of the
lowercrankcase half.
匹亘1
oDo not apply a liquid gasket around the crankshaft
main bearing inserts.
TorqueValue for8mm 白olts Connecting Rod Removal
●Remove the crankshaft.

First: 14 N ・m(1.4 kg-m, 10.0 ft-lb) Final: 27 N
・m{2.8 k9-m,20 ft-lb}
NOTE
oMark and record locations of the connecting rods and

〇Torque the 6 mm bolts to the specification(see
their big end caps so that they can be re-assembled in
E χplodedView).
their original pos 削ons.
●Aftertightening all crankcase bolts,check the follow-
ingitems:
oDrive shaft and output shafts tum freely ●Remove the connecting rods from the crankshaft.
・
oWhile spinning the output shaft, gears shift smoothly
from the l st t0 6th gear, and 6th t0 1st.
0When the output shaft stays still, the gear can not be
shift t0 2nd gear or other higher gear positions.
茫ヱj
oTo prevent damage to the crankpin surfaces,do not
allow the big end cap bolts to bump against them.
Connecting Rod lnstallation

Crankshaft/Connecting Rods
Cranl(shaft Removal
●Split the crankcase.
匹召]
●Remove the main bearing cap bolts with flat wa5hers, oTo minimize vibration,a pairof connectin9 「od(left tworods orright two)should have
and take off the cap ・ same weight
mark.
Crankshaft lnstaHation A10tes Weight Mark Location
巨弓]
01f the crankshaft orbearing inserts are replaced with
new ones,check clearance with plastigage before
assembling engine to be sure the correct bearing inserts

are installed.
●lnstall the crankshaft main bearing cap with the arrow

on it pointing forward.Tighten bolts to the specified
1.Big end cap

2.Connectingrod
3.Weightmark,alphabet
●lf the connecting rods or bearing inserts are replaced

with new ones check clearance with plastigage before
assembling engine to be sure the correct bearing inserts
are installed.
●Apply molybdenum disulfide grease to the upperjnner
surface of the connecting rod big end.
●Apply engine oil to the inner surface of upper or lower
A.Arrow point forward. bearing inserts.

NOTE
Connecting Rod and
Bearin9 1nsert
oSyj ・?c∂r/? ∂ 斤必tyoxl Xorce of tyJ θse ∂tyrtg sljx ヅ∂c θ ∂/7d thread portion of
new nuts is different from that of old
one, the nut tightening torque should be changed as
祁 ∂c μ/ ∂ ∂yxI が?e ∂ ゐ01ye t ∂ ゐye.
●Tighten the nuts 120 °more.
1.AppJy molybdenum disu げide grease ・2.Apply

engine oil.
匹顛]
oThe connecting rod bolts are designed to stretch when
tightened.Neverreuse them.Replace the connectin9
「od bolts with new ones.
●The connecting bolt,nut,and connecting rod are
treated with an anti-rust soIution, be sure to clean the
boltJ nut, and connectingrod thoroughly with high

巨亘]
flash-point solvent. oBe careful not to overtighten the nuts.
●Before assembling, measure the length of new con-
necting rod bolts and learn the valves to find out the ●Check the length of connecting rod bolts.
stretch of bolt. ★lf the stretch is more than service limit, the bolt has
stretched too much.Replace the bolt and nut with
「薇K 而￣i new ones. An overelongated bolt may break in use.
oClean the bolts, nuts,and connectin9 「ods in a well ・ Bolt Length B01t Length
ventilated area.and take care that there is no sparkor
=Stretch
After assembled Before assembling
flame anywhere nearthe working area,this includes
any appliance with a pilot light. Because of the danger

Service Limit
of highly flammable liquides,do not use gasoline or
New connectin9 rod O 。31 mm0.37mm
low flash-point solvents to clean them.
old connectin9 rod
匹亘1
01mmedia 重ely dry the bolts and nuts with compressed airaftercleanin9.
0Clean and dry the bolts and nuts completely.
●Apply a small amount of engine oil to the threads and

seating surface of the connecting rod bolts and nuts.
●Tighten the nuts to the specified torque, according to
whether connecting rod and nut are new or old. Bolt Length
Connecting
Rod Ass'y Nut TorqueN-m(kg-m,ft
川
「 Old 18(1.8,13.0)
New ln Ass'y O
Connecting Rod B 匈End Bearjng
New 20(2.0,14.5) /,7Se,・r忿r 回帰加Myar
01d ●Measure the beairng insert/crankpin clearance with a

(BOlt must be.new) 01d
New 24(2.4,17.4)
25(2.6,18.8) plastigage.
≪☆①
1.Crankpin 2.Plastigage
△Crankpin Diameter Marks, “ ○ ¨mark or no mark
NOTE
oTighten the big end cap nuts to the specified torque
(see Expjoded View),
○Do not move the connectin9 rod and crankshaft durin9
clearance measurement. ●Measure the connecting rod big end inside diameter,
and mark each connecting rod big end in accordance
with the inside diameter.
Connecting Rod Big End

NOTE
Bearin9 1nsert/Crankpin Clearance
Standard: 0.036 - 0.066 mm oTighten the cap nuts to the specified torque (see
Service Limit: 0.10 mm ExplodedView ノ.
0The mark already on the big end should almost coin-
cide with the measurement.
★lf clearance is within the standard, no bearing replace-

ment is required.
★lf clearance is between 0.066 mm and the service limit Connecting Rod Big End lnside Diameter Marks
(0.10 mm),replace the bearing inserts with inserts
None: 38.000 - 38.008 mm
painted blue. Check insert/crankpin clearance with the
O : 38.009 - 38.016 mm
plastigage.The clearance may e χceed the standard slightly,but it must not be less than the minimum in
order to avoid bearing seizure.

★lf clearance e χceeds the service limit, measure the diameter of the crankpins.
Crankpin Diameter
Standard:
34.984 - 35.000 mm
★lf any crankpin has worn past the service limit, replace
the crankshaft with a new one.
★lf the mea5ured crankpjn diameters are not less than
the service limit, but do not coincide with the original
diameter markings on the crankshaft, make new marks
1
on it. Big End Cap 3.Diameter Mark,
2
Connecting Rod “ ○"mark or no mark
Crankpin Diameter Marks

●Select the proper bearing insert jn accordance with the
None: 34.984 - 34.992 mm combination of the connecting rod and crankshaft
O : 34.993 - 35.000 mm coding ・

Big End Bearin9 1nsert Selection NOTE
Con-rod Big oTighten the crankcase b01ts to the specjfied torque (see
End Bore Dia- ExplodedView ノ.
meter Marking SizeMark

CrankpinDiameter
Bearing ColorPart Number
lnSert ○Do not tum the crankshaft during clearance r71easure-
m θη Γ.
None None Blue 92028-1407
○ ○
○ None White 92028-1547
None ○ Black 92028-1408 Crankshaft Main Bearin9 1nsert/Journal Clearance
Standard: 0.020 - 0.044 mm
＼ナ
★lf clearance is wjthin the standard, n0 6earing replace-
ment is required.
★lf clearance is between 0.044 mm and the service limit
(0.08 mm),replace the bearing inserts with inserts
painted white.Check insert/iournal clearance with the
plastigage.The clearance may exceed the standard
slightly, but it must not be less than the minimum in
order to avoid bearing seizure,

1.Bearing lnsert 2.ColorSize Mark
★lf clearance e χceeds the service limit,measure the diameter of the crankshaft main journa
●lnstaH the new inserts in the connQcting rod and check

jnsert/crankpin clearance with the plastigage.
Crankshaft Main Joumal Diameter
Standard: 35.984 - 36.000 mm

★lf any journal has wom past the service limit, replace
the crankshaft with a new one.
★lf the measured journal diameter5 are not less than the
service limit,but do not coincide with the original
Crankshaft Main Bearing lnsert たoumalWear diameter markjngs on the crankshaftJ make new marks
●Measure the bearing insert/crankshaft main journal on it.
clearance with a plastigage.
Crankshaft Main Journal DiameterMarks

一I
None 35.984 - 35.992 mm

一
l 35.993 - 36.000 mm
一
☆ 千千
口Crankshaft Main Joumal Diameter Marks, “1" mark or no mark
1.Crankshaft Main Journal 2.Plastigage
8-12 CRANKSHAFT/TRANSMISSION
●Measure the main bearing bore diameter,arid mark the
＼☆
upper crankcase half in accordance with the bore
diameter.
NOTE
oTighten the crankcase bolts to the specified torque (see
ExplodedView).
0The mark already on the upper crankcase half shoujd 1.Bearing lnsert 2.Sizc Color Mark
almost coincide with the measurement.
●lnstall the new inserts in the crankcase halves and

checkinsert/journal clearance with plastigage.
Crankcase Main Bearing Bore DiameterMarks
O : 39.000 - 39.008 mm
None: 39.009 - 39.016 mm
Crankshaft Runout
●Measure the crankshaftrunout.

★lf the measurement e χceeds the service limit, 「eplace the crankshaft.
#5 #4 #3 #2 #1
Crankshaft Runout
Service Limit: 0.05 mm TIR
Crankshaft Runout
C つ
●Select the proper bearing insert in accordance with the
combination of the crankcase and crankshaft coding.
Bearin9 1nsert Selection
Crankcase Main
Bearing Bore Size
Diameter Mark Color
Crankshaft MainJoumal
Bearing Part Number
DiameterMark
lnsert* joumal Nos.
○ 1 Brown 92028-1102 2,4

92028-1274 1,3,5
None None Blue 92028-1100 2,4

92028-1272 1,3,5
○ None Black 92028-1101 2,4
None 1 92028-1273 1,3,5
*The bearing inserts for Nos. 2 and 4 joumals have oil groove.
CRAN KSHAFT/TRANSMISSION 8-13
Crankshaft Side Clearance

8alancer lnstallation A/ ○r∂S
●lnsert a thickness gauge between the crankcase main ●When coupling the balancer weight and the gear,
bearing cap and the crank web at the N0. 2 journal to 0b5erve the following
・
determine clearance. oCheck that the damper rubbers are in place.
★lf the clearance e χceeds the service limit, replace the crankcase halves and main bearing cap as a set.
0Fit the balancer weight into the gear so that the weight
is opposite the mark on the gear.
NOTE
oThe upper crankcase half, lower crankcase half,and
main bearing cap are machined at the factory in the
assembled state.so they must be replaced as a set.
Crankshaft Side Clearance

A.Weight Portion B.Mark
●Fit the copper washers on both sides of the weight and

gear assembly.The projected side faces toward the
assembly.
A.Crankshaft B. Thickness Gauge
●sg ●ss ●菌●●I ●●●●菌●● l l ● l・ I ●菌●種菌種菌 l 種●菌●●・ ●● I 菌●種● I I 菌・菌 s I ・ ●●● a ●● I ● s 菌魯 l 種●● s i l 佃

種●・ ● B a l a n c e r
書丿丿棚 ● 臨機 ● ● ● 書欄・ l ● ● ●・丿 ● 櫛 ● 匍 ●・
A. Projected Side
召∂/∂ηC ∂/・/?ex77 ∂lxg/
●Split the cIrankcase.
●Unscrew the balancer shaft clamp bolts, and pull off

the cjamp jever.
●Unscrew the bolt holding the balancer shaft guide pin ●Turn the balancershaft untij the line mark on the end
plate,and take off the plate and guide pin. of the shaft points to the front.And then, install the
●Pull the bajancer shaft with the oil seal toward the right clamp lever.Tighten the b01t at the rear of the lever
out of the crankcase.At the same time, the balancer first then tighten the clamp bolt at the front of the
weight and gear assembly comes off. lever temporarily.
8-14 CRAN KSHAFT/TRANSMISS10N
BalancerShaft lnstallation
Alternator Shaft/Starter MotorClutch
Altemator Chain and Tensjoner F:lemoval
●Remove the right engine cover.

●Lock the altemator shaft chain tensioner.
oPush the tensioner guide and the rod stop lever so that
the stop lever keeps the rod from returning.
Free Positioned Lock Positioned
●Adjust the balancershaft position during the pre-
paration of the motorcycle.This adjustment must be
done when engine is cold.

ダ
0Start the engine and let it at idle.
0Loosen the clamp bolt and turn the balancershaft
countercIQckwise until the balancer gear makes a noise.
0Turn the shaft cIockw15e until the balancer gear stops
to make a noisej and tighten the clamp bolt securely.

首〉
回よ
Damper lnspection
●Remove the balancer and disassemble the weight and

gear assembly.
●Visually inspect the rubber dampers.

★lf they appear damaged or deteriorated,replace them.
●Remove the chain guide.
A.RubberDampers
A.Altemator Chain Tensioner
B.Bolts
Aleedle Bearing Wear C.Chain Guide
●Visually check the needle bearings.
oThe rollers in a needle bearing normally wear very
little,and wear is difficult to measure.lnstead of
measuring,inspect the bearing for abrasion,coIor ●Remove the altemator chain tensioner.
change,or other damage, ●Hold the altemator coupling with the coupling holder
★lf there is any doubt as to the condition of a needle (special tool),and remove the coupling nut and
bearing,replace it. sprocket bolt.
Altemator Shaft and Starter Clutch
lnstallation

f0110wing ・
●lf the starter motor idle gear is removed, install it so
that the small diameter gear side faces to the left.
A.Coupling Holder: 57001-1189
ePuIl the chain, sprocket,and coupling as a set.
A.ldle Gear
●Tighten the alternator coupling bolt to the spec 旧ed torque(see

ExplodedView).
Altemator Chain and Tensioner lnstallation

following ・
●Tighten the following bolt and nut to the specified

torque(sea E χploded View).
Altemator Shaft Chain Wear
Alternator Coupling Nut
AlternatOr Sprocket Bolt ●Hold the alternator shaft chain so that it may be pu 日ed tight.
●Lock the chain tensioner and install it with the
mounting bolts.The tensioner should be free from the ●Measure the length of 20 11nks (21 pins)with a vernier
locked position after instaljing it. caliper.

★lf the 20-link length of the alternator shaft chain is
greater than the service limit, replace it.
AlternatorShaft Chain 20-link length
Standard: 158.8 - 159.2mm

Servicg Limit: 1 61 。5mm
20-lin k Length
ノ1/把X77∂ ω Γ SX?∂ft ∂ηdSX ∂/・rer C/ ￡jrC/? /?∂X770 レg/

●Remove the alternator chain.
●Remove the coupling bolt at the left end of the shaft,
⑤
and then remove the coupling with the rubber dampers
・
●Holding the startermotor clutch, pull the alternator shaft off the crankcase.
Starter Motor Clutch lnspection Extemal Shift Mechanism lnstajlation
●Remove the starter motor. ●lnstallation is the rever5e of removal. Note the
●Turn the starter motor idle gear by hand. When viewed following ・
from the left side of the engine, the idle gear should ●The positioning leversare identical. The spring painted
tum counterclockwise freely,but should not turn white is forthe gear positioning lever ・
clockwise. ●The projected side of the collar must face toward the
lever.
A.Turn freely. B.Locked

1.Neutral Positioning Lever 3.Change Drum
2.Gear Positioning Lever 4.White Spring
E χtemal Shift Mechanism lnspection
●E χamine the shift shaft for any damage.

● 鎚睡慟 ● ● ● ● ●
TranSmlSSlOn
憧●●I 寸嘸●寸 ●● ●●●寸●●●寸●● ●●●●1● 種● 種種● l ●種種 I ● I ● I ● I 種種種 I I ●・種種●●憧●●●●馨●●● I ●● I ●●●● I I ・・ I ● E x t e m a l
Shift Mechanism Rem o v a j
●Drain the engine oil.
●Remove the engine (see Engine Removal/ln s t a l l a t i o n
chapter).

・
Engine Sprocket
Water Pump
E χternal Mechanism Cover
●Remove the shift 5haft, while moving the s h i f t m e c h a -
nism arm backward.
A.Splines C.Arm Spring

B.Return Spring D.Arm
★lf the shaft is bent, straighten or replace it.lf the
splines are damaged, 「eplace the shaft.
★lf the springs are damaged in any way, replace them.
★lf the shift mechanism arm is damaged in any wayJ
replace the arm.
●Check the return spring pin is not loose.
★lf it is Ioose, unscrewit,apply a non-permanent locking
agent to the threads,and tighten it to the specified
A.Neutral Positioning Lever torque(see E χplodedView).

D.ArmSpring
B.Gear Positionjng Lever ●Check the positioning levers and their springs for
E.Return Spring
C.Shift Mechanism Arm breaks or distortion.
F.Shjft Shaft
★lf the levers or springs are damaged in any way, replace
●Unscrew the nuts and remove the positioning levers. them.

oThe bearing set pirls and rings mu5t match properly

with the holes or grooves in the bearing outer races
・
When they are properly matched,there is no clearance
between the crankcase and the bearing outer races.
A.NeutraI Positioning Lever C. Springs

B.Gear Positioning Lever D. Return Spring Pin
●Visually inspect the shift drum pins, pin holder,and

pin plate.
★lf they are badly worn or if they show any damage,
A. No Clearance (both left and right sides)
replace them.
Transmission Disassembly
Transmission Shaft Removal
●Remove the transmiSsion shafts.
●Using the circlip pliers(special tool : 57001 -1 44)

NOTE
to remove the circlips, disassemble the transmission
olf the drive shaft assembly is to be disassembled, shafts.
remove the clutch. ●The 5th gear on the output shaft has three steel balls
assembled into it for the positive neutral finder
mechanism.Remove the 5th gear as the folloWing.
0Set the output shaft in a vertical position holding the
●Take out the drive and output shaft assemblies.
3rd gear ・
oSpin the 5th gear quickly and pul 目t off upward.
Transmission Shaft lnstallation

following
・
●Check to see that the set rings and set pins are in place
in the transmission bearing housings, and blow the oil
passages in the bearing housings clean with compressed
alr.
1.5th Gear 3. Spin quickly

2.3rd Gear
Transmission Assembly
●Assembly is the reverse of disassembly. Note the
following ・
A.Set Rings C.011 Passage Holes ●Replace any circlips that were removed with new ones.
B.Set Pins ●lnstall the circlips so that the opening is aligned with a
spline groove.
●￨
「Istall the drive and output shaft assemblies in the upper crankcase half,
●lnstall the t00thed washers so that the teeth are not
aligned with the circlip opening.

8-18 CRAN KSHAFT/TRANSM ISSION
1.Bearing Outer Race 6.Top(6th)Gear 11.5th Gear
2.Circlip 7,Bushing 12.1st Gear (Drive Shaft)
3.Needle Bearing 8.Toothed Washer
4.Thrust Washer 9.Circlip
5.2nd Gear 10.3 「d/4th Gear
1.Collar 7. Top(6th)Gear 13.1st Gear
2.Ball Bearjng 14.Thrust Washer

8.4th Gear
3.0utput Shaft 15.Needle Bearjng
9.Bushing
4.2nd Gear 10.3rd Gear 16.Bearing Outer Race
5.Toothed Washer 11.Steel Ball

6.Circlip 12.5th Gear
CRAN KSHAFT/TRANSMISS10N 8-19
巨呂
oDo not apply 9 「ease to the steel balls to hold them in place. This will cause
Shift Drum and Fork Removal

chapter).
Eχternal Sh げt Mechanism
OiI Pan
1
Cirdip 3.Groove Oil Pump and Bracket
2
Toothed Washer ●Unscrew the AIlen bolts holding the shift drum ball
bearing holder.
●lnstall the gear bushings on the shafts with their oi

holes aligned with the shaft oil holes.
qp; 」
A.Shift Drum B.Shift ROd
●Pull out the shift rod, and take off the shift forks.
●Pull out the shift drum.
oFit the steel balls into the 5th gear holes that are Shift Drum and Fork lnstajlation
smaller than the other holes as seen from the outside of ●lnstallation is the reverse of removal. Note the
the gear, and then install the gear on the shaft so that following
・
the steel balls align with the recesses in the shaft. ●Apply a non-permanent locking agent to the AIlen
bolts of the shift drum holding plate.
●The shift forks can be identified by their shape. lnstall
them as following.
A.5th Gear C.Racess
B.Steel Balls
WHEELS/TIRES 9-1
Wheels/Tires
Table of Contents
EXpl 9,2
Specifi 9-3
Special 9,4
Wheels 9-5
Front Wheel Remova
9-5
9 9 9 9 9 9 9 9 9 9 9 9 9 9 d
5 6 6 6 7 7 8 8 8 9 9 9 9 9 9 0
一
FrontW
一
RearWheel
一
RearWhee 目n
一
Wheel lnspection
﹃
Balance Weight lnstallation
一
Balance Weight R
一
Tires
一
Tire Air Pressure
一一
Hub Bearin9
一
Remova
・
‘
Lubri
Speedometer Gear
一｀
Disassembly
﹄7
Q)
Lubri
9-2 WHEELS/TIRES
ExplodedView
プ
. パル
レレル
訃二'シ 7 …
………: 言
ぐ
/心ヽ
、S
︲-
︲
・
ノク
⑨卜砧
ZX1000 ・BI
一一一一一一一一一一
』卜引L______-___
⑩
」ヒ__￨
゛匈j
一
TI:88 N-m (9.0 kg-m.65 ft-lb)

ノ
T2: 1.5 N-m (0.15 k9-m, 13 1n-lb)
T3 : 108 N-m (11.0 kg-m,80 ft-lb)
ノノつ白々Q
A 席白夕
ゆ卜 ⑩
⑩
匹朧ダ
二 ⑥ら ⑤
WHEELS/TIRES 9,3
嚇丿 ● ●I ● ● ・
Specifications
●1111S ● ・ ●
・l ・ ● ● ●・ ● ●・ ● ●・ ● ●

WheelS:
Tire tread depth. Front
Rear 3.9mm6.9mm lmm2mm(Under 130 km/h) (Under80 mp
(Over80 mph)
×
Standard
tire Front 120/70 VR17-V280 TUBELESS DUNLOP K455FG BRIDGEsTONE CYRox-03120
Rear 160/60 VR18-V280 TUBELESS DUNLOP K455A BRIDGESTONE CYROX-04160/
Load Air Pressure (when cold)
Under 210 km/h

(Under 130 mph) Over 210 km/h(Over 130 mph)
250 kPa (2.5 k9/cm2,36 psi)
US and
Canadian
Rear Upto180 k9 (397 1b ≒41 psi)
Tire air Model Front 〉 290 kPa (2.9 kg/cm
pressure 250 kPa
Other than
ノく2.5 k9/cm2,36 psi)
US and
Canadian Rear Upto975. k9 (215 1b)- 250 kPa (2.5k9/cm2,36 290
psi)kPa (2.9k9/cm2,41 psi)
Model Front 975.k9(215 1b卜
181 k9(399 1b) 290 kPa (2.9k9/cm2,41 psi)
Rim runout: A χial RadialA 一一一
一一一Under0.05 mm 0.5mm 0.8mm0.2mm(0.7mm:RL)
χle runout/100 mm:
一
一
94 WHEELS/TIRES
Bearing Driver Set: 57001-1129

Special Tools
寸 ● ● ● ● ● ● ● ● ●1 ● ● ● ● ● 僣 ● ● ●s ● 番 ●l 畠 ● ● ● ● ●● ●● ● ● ● ● ● ●・ ● ● 畠畠I 働 ● ●s ● ● ● ● ● 畠 ● ● ● 魯 ●・ ● ●s 畠 ● ●l ● ● ●畠 l 畠 ● ・Circlip
Pliers: 57001 -143
Bearing RemoverSet: 57001-1264
Rim Protector:57001 ・1063
おへ
Bead Breaker: 57001-1072 Bearing RemoverHead: 57001-1293
Tire aron: 57001 ・1073 NOTE
oThe tire irons (PyN 57001-1073)are included in the
bead breaker (PZN 57001-7Q72J.

WHEELS/TIRES 9-5
・ ● ● ● ● ●・ ● 聊寸 ● ● ●
Front Whee 川nstallation

WheelS(RimS)
●lnstaHation is the reverse of removal. Note the

●a ●●暉●●刄●●●●●●糎●・ I・・ I 寸 a ● a 馨●・
following ・
Front Wheel Removal

NOTE

oPut the speedometer gear drive onto the whee 川Iub notches,then install the hou
Lower Fairing
so that it fits in the
Speedometer Cable Lower End
drive notches.
Brake Caliper Mounting Bolts
oFit the speedometer gear housing stop to the fork le9
StOp,
A. Caliper Mounting Bojts B, Speedometer Cable

A.Notches C.Drive
B.Projections D.Housing
Right Side Axle Clamp Bolts (Loosen)

Axle(Loosen)
1.Housing Stop 2, Fork Leg Stop
oFit the collar on the right hand side of the hub.
A.Axle B.Axle Clam p B01ts
●Tighten the a χle nut to the specified torque (see E χ-

pIodedView).
●Tighten the axle clamp bolts to the specified torque

●Using the jack stand (special tool: 57001-1238),raise
(see E χplodedView).
the front wheel off the ground.
●Check the front brake.
●Pull out the axle to the right and drop the front wheel
out of the forks.
[少HI 叫
巨弓] oDo not attempt to drive the motorcycle until fully
depressing the brake lever then pump the brake lever
oDo not lay the wheel down on one of the discs.This until the pads are against the disc. The brakes will not
can damage or warp the disc.Place blocks underthe function on the first application of the lever if this is
wheel so that the discs do not toucll the ground. notdone.
9-6 WHEELS/TIRES
Rear Wheel Removal Rear WheeHnstallation

●Loosen the left and right adjuster clamp bolts. ●lnstallation is the reverse of removal. Note the
following ・
●Adjust the drive chain after installation (see Final Drive
chapter).
(see Exploded View).
Axle Nut
Adjuster Clamp Bolts (see Suspension chapter)
Caliper Mounting Bolts (see Brakes chapter)
Torque Link Nut(see Brakes chapter)
A. Adjuster' Clamp Bolt WheeHnspection
●Remove the tire from the wheel.

●Measure the rim runout by using the dial gauge.
●Remove the following 。

Retaining Ring
Torque Link Bolt and Nut

Axle Nut
A.Retaining Ring 1,Radial Runout 2.A χial Runout

B.Axle Nut
C.Torque Link Bolt and Nut
★lf rim runout e χceeds the service limit, check the wheel bearings.
●Pull out the a χle toward the left. ★lf the problem is not due to the bearings, the wheel
●PuH the drive chain toward the left, and remove the must be replaced.
rearwheel.
Axial Runout
呂亘] Service Limit: 0.5mm
oDo not lay the wheel on the 9 「ound with the disc facing down.This can damage or warp the disc. Place blocks
under the wheel so that the disc does not touch Radial Runout
the 9round. Service Limit: 0.8mm

WHEELS/TIRES 9-7
「而呵 (b)lnstallation completed.
oNeverattempt to repair a damaged wheel.lf there is
any damage besides wheel bearings,the wheel must be
replacad to insure safe operational condition.
8alance Weight lnstajlation
●Check if the weight portion has any play on the blade-

and-clip plate.
★lf it does, discard it. Weight

●Lubricate the bj 】ance weight blade, tire bead,and rim flange with a soap and water solution or rubber lubricant.This helps the balance weight sljp onto the
Clip
rim flange.
匹亘1
oDo not lubricate the tire bead with engine oil or
gasoline because they will deteriorate the tire.
●lnstall the balance weight on the rim.

oSlip the weight on the rim flange by pushing or lightly
hammering the weight in the direction shown in the
figure.
0Check that the blade and weight seat fuIly on the rim Balance Wejght Removal
flangej and that the clip is hooked overthe rim ridge (a)When the tire is not on the rim.
and reaches rjm flat portion. ●Push the blade portion toward the outside with a
regu 【ar tip screw driver,and slip the weight off the rim flange
レ吟Hlq ・
●Discard the used balance weight.
01f the balance weight has any play on the rim flange,
the blade and/or clip have been stretched.Replace
the loose balance weight.
Removing Balance Weight (without tire on rim)
0Do not reuse used balance weights.
Push
Balance Weight
[こて〉
Part Number Weight(gramS)

41075-1014
41075-1015
41075-1016 102030
lnstalling Balance Weight
(a)Press or lightly hammer the weight in
Tire Bead
(b)When the tire is on the rim.
●Pry the Balance weight off the rim flange using a

regular tip screw driver as shown in the figure.
olnsert a tip of the screw driver between the tire bead
and weight blade until the end of the tip reaches
the end of the wejght bjade.
oPush the driver grip toward the tire so that the
balance weight slip s off the rim flange,
●Discard the used balance weight.
9-8 WHEELS/TIRES
Removing Balance Weight (with tire on rim)
1.Depth Gauge
★lf any measurement is less than the service limit,

replace the tire.
Tire Tread Depth
Front
Standard 3.9mm
Service Limit lmm
Rear
●●●●●●● ●●●●寸●●・・ ●●I ●寸I ● ●●●個● I 欄●●●●参●●●●●●●
・ ●●●● ●●●
・ ●● ●●●●● l ●●●畠●● a● 畠●● I ●槽●●● T i r e S
Standard 6 。9mm
Service Limit 2mm(Up to 130 km/h)
3mm(Over130 km/h)
Tire Air Pressure lnspection

ZX1000-B2 and latest models
Rubber-type air valve and air valve hole modified
NOTE
wheels are used on the front and rear wheels,
oMeasurll the tire pressure when the tjre are cold (that is.
when the motorcycle has not been ridden more than a lnstallation
mile during the past 3 hours ノ,
●Remove the air valve and discard it 。
回弧
US and Canadian Model

oReplace the rubber-type air valve wheneverthe tire is
replaced.
Front 250 kPa(2.5 kg/cm2,36 psi)
oDo not reuse the air valve.
Rear Upto180 kg (397 1b)290 kPa(2.9 kg/cm2,41 psi)

AirValve
Other than US and Canadian Mode1
Front 250 kPa(2.5 kg/cm2,36 psi)
引b) 290 kPa(2.9 kg/cm2,41 psi)

97.5-181 kg
Rear Upto97.5 kg(21
(215 - 399 1b),
Over 210 km/h (130 mph)
Tire lnspection
●Visually inspect the tire for cracks and cuts, replacing

the tire in case of bad damage ・ 1.Plastic Cap 4.Valve Stem
●Measure the tread depth at the center of the tread with 2.Valve Core 5.Valve Seat
a depth gauge. 6.Valve Opened
3.Stem Seal
WHEELS/TIRES 9-9
●lnstall a new valve in the rim.
oRemove the valve cap, lubricate the stem with a soap
and water solution, and puH the stem through the rim
胚亘1
oDo not lay the wheel on the 9round with the disc
from the inside out unti 目t snaps into place.
facing down. This can damage or warp the disc. Place
blocks under the wheel so that the disc does not touch
the 9「ound.
lnstallation
二] 三
才 ●lnstall the bearings by using the bearing driver set
(special tools: 57001 ・1 129).
1.Apply soap and water solution, NOTE
2.Pull the stem out.

olnstall the bearings so that the marked or shielded sides
face out.
呂囲
oDo not use engine oil or petroleum distillates to lubri-
cate the stem because they will deteriorate the rubber,
Lubrjcation
NOTE
oSince the hub bearings are packed with 9rease and
shjeld.they are not required to be removed for
lubrication.
● ●・器機 ●・・ l ● ● ● ● ●・ ●I 糧I ●● ●● ● ● ● ● ● 機 ●・・機s ● ● 軸 ● ● ● 機 ● ● ●・ ● 齢 ●・ ● ● ● ●・ I ● ● ● 酪寸軸寸 ● ● ● ● 瞳 ● ●卜寸 I 慟 ●● ● H u b
Bearings
● ・ ● 機畠 ●・ ● 寥・ ●・ I I I ●・ I ・ ● s ● 軸・ ● 機機卜 s ・ ●a ●・機 ●・ ● 軸 ●● ●・ ●● ・ ●・・・ ● ● ●s ●・ ● 軸 ● ● ● 寸器 ●● ●● ●● ●寸機● ●・ ●
Removal
●Use the bearing remover (special tool)toremove the

hub bearings.
・ ●・細事蜀偉機器慟 ●
● ● ● 働 ● 事 ● ● 器機細● ● ・ ●棚機・・ ●・・ ● ● ●・細・ ● ● ● ● ●s ● 細・・ ● ● ● ● ● ●● 暉暉 ● ● ● 細細・ ●・ ● ● ●右 ● 騨卯 ● ● ●Speedometer
Gear Housin9
細 ● 細 ● ●・ l ● 機器 ● ● ● 器 ●ss ● ●・機種細幽幽 ● 雌事・細・ ●・ I ● ● ●・細 ●s ● ● 事器 ● ● 細細 l ●・ ● ● 細 ●・細 ● ● ● ● ● 細ll ● ● 細細・ ● ● 事細細
Disassembly and Assembly
NOTE
olt is recommended that the assembly be replaced rather
than attempting to repair the components.
●lnstall the speedometer gear housing so that it fits in
the speedometer gear drive notches (see Front Wheel
lnstallation).
A.Bearing Remover Set: 57001-1264
9-10 WHEELS/TIRES
Lubrication
●Clean and grease the speedometer gear housing ・
1.SpeedometerGear Housing
2.Grease.
FINAL DRIVE 10-1
Final Drive
Table of Contents
ExplodedVi
10-2
Specificati
10-3
Special
10-3
10-4
Drive Chain Slack Adjustm
10-4
Wheel Alignment Adju
10-4
Drive Chain W
10-5
10,5
Drive Chain R
10-5
Drive Chain
10-6
Sprocket,Co
10-6
Engine Sprocket Rem
10-6
Engine Sprocket l
10-7
Rear Sprocket R
10-7
Rear Sprocket lnstall 10-7
10-7
Coupling lnstallation Notes
・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・. 10-8
10-2 FINAL DRIVE
ExplodedView 曾
TI : 98 N-m (10.0 kg ・m,72 ft-lb)T2: 74 N-m (7.5 k9-m

ft-lb)
⑤
FINAL DRIVE 10-3

丿岫幽丁I 聊●●a ●●寸岫s ●●● & s ・ l ●● s・●●・ ● f・ ● i 嘸 s ●喝寸畠●鎗●嘩騨●●鐘・ ●寸 I 嘘畠・騨●● I・・夥●・
噂葬● a 岫暉寸・ ● s ●寥● S p e c i f i c a t i o n s

Drive Chain:
Make and type 一一一
一一一LeSS than 30 mm, 0r
Chain slack
more
than 45 mm
20-Link length 323 mm
Sprockets:
Rear sprocket warp Enuma EndlessEK532ZV-0 110 Link30 - 400.5mm
mm317.5 - 318.4mmunder0.4m
・ ● ● ● ● ● 鳥・ ●● 鳥● 歯 ●
● ● ● ● ● 珊珊 ● ●s 鳥 ● ● 慟 ● ● ● 鳥 ● ●・ I ● 鳥 ● ● ● ●s ● ● ●● ●● ●● 珊● ●鳥 ● 鳥● ・ ●● 慟 ●・寸 ●● ● ● 幽 ● ● ● ● ● ● S p e c i a l
Tools
Circlip Pliers: 57001 ・143
・ ● ● ● ● ● ● ●・ ● ● ● ● ●● ●
● ●s ● 珊 ● ● ● ● 鳥・ ● ● ●寸 ● ●● ● ●● ● ● 珊 ● ● 鳥 ●・ ●l 珊 ● ● ● ● 珊 ● ● ● ● ●ss 鳥珊 ●・ ● 鳥匍・・ ● ● 番鳥 ● ● ●Bearing
Driver Set: 57001

・1129
夢①.
丿
104 FINAL DRIVE
・腕 ● ● ● ●I ● ● ●ll 細細・ ● 細aa ・・ ●・・ s 畠l ● ● ● ● ● ● ● 寧l ・・・・s ● ● 細s ●・・寧 ●・細瞳s ●ss 暉s 暉嘸・ a 細 ● ●・ ● ● ●a ● ●l ●・ D r i V e
oThe left and right notches on the swing arm should

Chain
point to the same marks or positions on the left and
right adjusters.
s 細 ● 細 ●・ ● 暉・・翠 ●s 細仙 ● 曇 ● 慟s ●丿 s 細 ● 細細 ● ● ● 暑 s ・・ s s ・ ● 細腕・ ● 簒尋・・騨・ ●・ ● 細s ● ● ●・・夥 ●s ●・ ●s ● ●s ・・嘩s ・畠幽幽
Drive Chain Slack Adjustment
●Set the motorcycle up on its center stand, and check

面而而￣
￣i
the chain slack within the standard value.
oCheck to see if wheel alignment is properly adjusted.
oMisalignment of the wheel will result in abnormalwear,
and may result in an unsafe riding condition.

(see Expioded View).
Chain AdjusterClamp Bolts
Torque Link Nut
うこ
① 傷而j
1.Chain Slack
01f the clamp bolts are not securely tightened, an unsafe
riding condition may result.

Drive Chain Slack
Standard: 30 - 40 mm
●Loosen the following bolt and nut.

Torque Link Nut
Left and Right Chain Adjust Clamp Bolts
WheelA 向nment Adjustment
●Set the motorcycle up on its center stand.

●Check to see if wheel alignment is properly adjusted.
The left and right notches on the swing arm should
point to the same marks or positions on the left and
right adjusters.
A. Torque Link Nut B. Chain Adjuster Clamp Bolt
●Tum the chain adjusters forward or rearward with an

A11en wrench until the drive chain has the correct
amount of chain slack.
A.Swing Arm Notch B.Marks
●Remove the right retaining ring ・

●Lo05en the following bolt and nuts.
Axle Nut
Torque Link Nut
A.Allen Wrench B.Chain Adjuster Right Chain Ad.juster Clamp Bolt

FINAL DRIVE 10-5
Drive Chain 20-Link'Length
S 重andard: 317,5 - 318.4mm Service Limit: 323 mm
★lf anymeasurementexceeds the service limit, replace

the chain.Als0,replace the engjne and rear sprockets
when the drive chain is replaced.
湧/ARNING i
oForsafety,use only the standard chain. lt is an endless
type and should not be cut for installation.
じ.Chain Adjuster Clamp Bolt

B. Torque Link Nut D.Retaining Ring
●Turn the chain adjuster so that the left and right

notches on the swing arm point to the 5ame marks D
「 L ubrjcatjon
positions on the left and rjght adjuster
・
●Tighten the following bolt and nut5 to the specified
torque(see ExplodedVjew).
Axle Nut (5ee Wheels/Tires chapter) 匹亘]
Right Chain Adjuster Clamp Bolt
oThe O- 「ings between the side plates seal in the lubricant between the pin and the bushin9. To
Torque Link Nut
●lnsert the retajning ring to secure the a χle shaft.

「ings and resultant loss of lubricant,0bserve the followingrules.
jWA 剛NG i 0Use only kerosene ordiesel oil forcleaning an O-

「ing drive chain.
Any other cleaning s01ution such as
〇lf the axle nut or clamp bolts are not securely tight-
gasoline ortrichloroethylene will cause deterioration
ened or the retainingring is not installed, an unsafe
and swellin9 0f the O- 「ings
riding condition may result. ・
olmmediately blowthe chain dry with compressed air
aftercleaning
・
oComplete cleaning and drying the chain within 10
minutes.
Drive Chain Wear lnspection
●Stretch the chain taut hanging a 98 N (10 kg,20 1b)

●lf a specia 川ubricant is not available,a heavy oil such as SEA90 1s preferred to a lightjy oil
weight on the chain.
●Measurethe jength of 20 11nks on the straight part of

the chain from pin center of the l st pin to pin center
of the 21 st pin. Since the chajn may wear unevenly,
take measurement at several places.
M ‘ Oil Applied Areas
ルバ掛
1.Weight 3 Ruler
∂/7/1/∂ Cy7 ∂加/?
●Remove the fojlowing
∂/刀01/∂/
・
Clutch Slave Cylinder (see Cjutch chapter)
Sprocket Cover
2.Straight Part 4
Measure this length Engine Sprocket Nut
10-6 FINAL DRIVE
Swing Arm (see Suspension chapter)

NOTE
oWhen loosening the engine sprocket nut, jnsert the

●Pull the engine sprocket()ff the output shaft with the
stee けod into the rod h01e to hold the sprocket.
drive chain, and then 5eparate them.
Drive Chain lnstallation
lowing.
●Tighten the fo ¶Iowing fasteners to the specified torque (see Exploded View)
・
Engine Sprocket Nut
Swing Arm Pivot Nut (see Suspension chapter)
Shock Absorber Nut (see Suspension chapter)
Uni-trak Tie-rod Nut (see Suspension chapter)
●lnstall the rear wheel (see Wheels/Tires chapter) ・
●Adjust the drive chain after installation.

B.Rod Hose
A.Engine Sprocket
Rear Wheel (see Wheels/Tires)

Right Footpeg Bracket
・・ ● ● ● 啼鳥機種籾 ● ● 種種・ ● 幽 ●
・幽幽 ● ● 寸 ● 幽 ●S ・・幽・ ● ● ● ● ● ● ●I 寸幽幽暴 ● ● 幽S ●● 機幽 ● ● ●
幽幽 ● ● ● 幽S ● ●l 幽幽幽 ● 働l ・幽趣 ● 個 ●
SprOCket,COUplin9
●●・ ●・ ● ●●
・ ●● 種● 種● I ● 1 ●●● 種種種●●●●●●●● I I ●優寸種種● l ● I ●●● l● ● a 種● 種 s●● s s
寸種寸 l ● 種●●●●種種●●●●●●●幽
￡x7! 抑eSproCAret /?ex7701ya/
●Loosen the drive chain.

・
Clutch Slave Cylinder (see Clutch chapter)
Sprocket Cover
Engine Sprocket Nut
NOTE
A.BOStS oWhen loosening the engine sprocket nut, insert the
st ∂e/rod 訥to がle rod /? ○ye to /? ○/d がl ∂sX)/ ・oc1 吋.
Torque Link
A.Engine Sprocket Nut B.Rod Hole

A.Torque Link B.BOlt
FINAL DRIVE 10-7
●Remove the drive chain from the rear sprocket 。
NOTE
o/f yf ys dyytyc ￡jyr to /1qm01ye 功 ∂dr/1ye cyJ ∂//7 なom が?∂nga/ ・
吊gaet.remo ・/e 哨e gar a χye βa り1/71eeys/77,1?s c 力男,- terJ.
●Pull the engine sprocket off the output shaft.
A.Tooth Number Marking

Engine Sprocket lnstaljation

10wing.
●Tighten the following fasteners to the specified torque ●Tighten the rear sprocket nuts to the specified torque
(se ExplodedView). (see Exploded View).
[ngine Sprocket Nut ●lnstall the rear wheel (see Wheels/Tires chapter).
A χle Clamp Bolts (see Suspension chapter)
Torque Link Nut(see Brakes chapter)
●Bend the lockwasher after tightening the engine
sprocket nut.
印ylod 琵14/a 印
Elevate the rearwheel so that it will turn freelyJ and

set a dial gauge against the rear sprocket near the teeth
Rear Sprocket Removal a5 shown. Rotate the rear wheel. The difference
●Remove the rear wheel(see Wheels/Tires chapter) between the highest and lowest dial gauge readings is the
amount of runout (warp).
lf the runout e χceeds the service limitj replace therear sprocket.
斂呂
oDo not lay the wheel on the 9round with the disc
facing down.This can damage orwarp the disc. Place
blocks underthe wheel so the disc does not touch the
ground.
●Remove the rear sprocket nuts.

●Remove the rear sprocket.
1 Dial Gauge 3.Tum.

2 Rear Sprocket
Rear Sprocket lnstaHation

Rear Sprocket Warp
f0110wing ・
○lnstall the sprocket facing the tooth number marking Standard: Under0.4mm
outward. Service Limit: 0.5mm
10-8 FINAL DRIVE
Couplin9 1nstallation lVO 抱S
●Use an 0111ess s01vent to thoroughly clean any oil off
the damper,hub,and coupling

・
●lnstall the damper into the rear hub.
●Use a little adhesive to fasten the spacers into the
coupling during assembling.
●lnsert the coupling into the rear hub.
二
ダy 宍
丁
一
銀
./
1.Coupling 3.Damper
2.Spacer
NOTE
q,4yw ∂ys ljs θ ∂so ∂ρ ∂ ηdw ∂t θΓ so/ ぴtyQ ηto θ∂s ∂/77grt かg the coupling
into the hub. 1Vever use such luricant that
leaves oily residue.

BRAKES 11-1
Brakes
Table of Contents
EXpl
11-2
Specifications ‥. 11-4
Special T
11-4
Brake Pedal 11-5
Brake Light Sw 11-5
Brake Pedal Position Adjustm 11-5
11-6
Front Caliper Rem 11,6
Rear Caliper R 11-6
Caliper lnsta 11-6
Disa
11-6
Assembly Note 11-7
Brake P
11-7
11-7
lnstallation
Lining Wea
11-7
Master Cyli 11-7
Front Master Cyli
11-7
Rear Master Cylinder Removal 11-8
Rear Master Cylinder lnstallation N 11-8
lnspection and Adjustment after lnstallatio 11-8
Disa
11-8
11-8
lnspection(Visually) ‥ ‥ ‥‥ 11-9
11-9
W 11-9
11-9
Brake
Fluid Level lnspecti 11-10

Brake Fluid Chan9 11-10
Bleeding th 11
11-2 BRAKES
● ・ ●I ●l ・暉暉・I ・
ExplodedView
ズ
TI: 1.5N-m(0.15 kg-m, 13 1n-lb)
T2 : 8,8 N-m (0.9 k9 ・m,78 1n-lb)T3: 11 N-m (1.1 k9-m,95 1n-lb)T4:
︲11-
ヤドレ
25 N-m (2.5 k9-m, 18.0 ft-lb)
T5 : 7.8 N・m {0.80 kg-m,69 1n ・lb}T6: 34
︲
N-m (3.5 kg-m,25 ft-lb)
T7: 23 N-m (2.3 kg-m, 16.5 ft-lb)
T8: 5.9 N-m {0.60 k9-m,52 1n-lb}
G : Apply grease.
已
ゆ
サレよ
ー
甲
ル
.⑩
叩由
謳隨巡
/
ノ
汽リ
ノ
<
略 ‰ 賢 ↑
デ
こ
1
6
砂 0
ノ
△
BRAKES 11 ・3
-/
⑩
11 4 BRAKES
-
a 翻 ● ● ● ●l ● ● ・s ● 咄as ● ● 聊・ a l ● ● ●l ●l ● ● ● ● ● 咄咄 ● ●l ● ● ● ● 匍● 咄咄 ●● ●l ●1 ● 蜀1 ・ ●ISll ●I
SpeCifiCatiOnS
Brake Pedal:
Brake pedal position 45 mm below top of footpeg 一一一
Brake Pads:
Pad lining thickneSs 4.5mm lmm
Brake Discs:
Disc thickness: F ront
Rear
Disc runout 4.8-5.1mm5.8-6.1mmunder 0.15 mm 4.5mm5.0mm0.3mm
Brake Fluid:
Grade
Brand(recommended) D.0.T.4Castrol Girling-UniversalCastrol GT (LMA)Castrol Disc Brake FluidC
Specia §Tools
・ ● 峰 ● ● ● 喝 ●・ s I 畠 ●
● ● ● ● ●● ●● ●● ● 寸 ● ●・ ● ●l ● ● ● ● ● ●l ・ ●寸 ●畠 a 畠l ● ● ● ●・ ● ● ● ● ●畠 ●● ●・ I ● ●・ ●● 1 ●s ●・ ● ●畠 ● 鎗 C i r C l i p
PlierS: 57001 143

-
上水
BRAKES 11 ・5
● 眼 ● ● ● ● 嘘II ●S ・
Length ⑧
Brake Pedal
Standard: 119 士lmm
● ● 寧噂堰 ● ● ● ・
Brake Pedal Position Adjustment
●Check that the brake peda 卜s in the correct position.
Pedal Position
Rear Bral くe ￡-ight Switch Adjustment
Standard: About 45 mm below top of footpeg
●Check the operation of the rear brake light switch by
depressing the brake pedal.The brake light should go
on after about 10 mm of pedal travel.
A.Footpeg C.Pedal Position

B.Brake Pedal
A.Brake Pedal B.10 mm
NOTE
oUsually jt's not necessary to adjust the pedal posjtjon,

★lf it does not, adjust the brake light switch.
but always adjust it when the master cylinder js dis
・ ●Turn the adjusting nut to adjust the switch.
assembled.
olf the peda り)osition cannot be adjusted by tumjng the clevis,the brake pedal may be deformed or incorrectly installed.
●When the brake peda 卜s in its rest positionj measure the length
⑥indicated in the figure.
★lf the length ⑥ is not within the specified length,
adjust a nult.
A.Switch C.Light sooner.

B. Adjusting Nut D.Light later.
[弧翌]
oTo avoid damaging the electrical connections inside the
1.Master Cylinder 3.Clevis switch be sure that the switch body does not tum
2.Locknut during adjustmei,t.

11-6 BRAKES
Ca71per lnstallation
・1 ●I ●
Caliper ●Note the following ・

oTighten the caliper mounting bolts to the specified
Front Caliper Removal
oConnect the brake hose to the caliper putting a new
・ flat washer on each side of the brake hose fitting.
Banjo Bolt(at the caliper)
oTighten the banjo bolt to the specified torque(see Ex-
Caliper Mounting Bolts
plodedView).
oCheck the fluid level in the master cylinder (reservoir),
and bleed the brake line (see Bleeding the Brake).
cCheck the brake for we2!k braking power
・, brake drag,.
and fluid leakage.
I WARNING i
oDo not attempt to drive the motorcycle until a full

brake leverorpedal is obtainid by pumping the brake
leveror pedal until the pads are against the disc.The
brakes will notfunction on the first application of the
leveror pedal if this is not done.
A.Speedometer Cable C.Caliper Mounting Bolts

B. Banjo Bolt
★lf the caliper is to be disassembled after removalandif

compressed air is not available, remove the piston using
the following steps before disconnecting the brake hose
Disassembly jVO ￡θS
from the caliper.
●Using compressad ajrJ remove the piston.
0Remove the pads.
oCover the caliper opening with a clean, heavy cloth.
oPump the brake lever to remove the caliper piston.
0Remove the piston by lightly applying compressed air
NOTE to where the brake line fits into the caliper.
olmmediately wipe up any brake fluid that sp111s.
「而而Fi
oTo avoid serious injury,never place yourfingers or
palm inside the caliperopenin9. 1f yourapply com ‘
Rear Caliper Removal pressed airinto the caliper,the piston may crush your
hand or fingers.
●Remove the rear caliper in the same way as the front
caliper.
A.Banjo Bolt B.Caliper Mounting Bolts 1.Apply compressed air 2.ClOth

BRAKES 11-7
Assembly A10tes
1nstallationA/Q ΓθS
●Apply brake fluid to the outside of the piston and the
●Push the caliper pistons in by hand as far as they will
fluid seal,and push the piston into the cylinder by go.
hand.Take care that neither the cylinder nor the
piston skirt get scratched.
●Apply a thin coat of PBC (P01y Butyl Cuprysil)grease

to the caliper holder shafts and holder holes. (P6Cisa
l WARNING i
special high temperature, water-resistant grease)
・ oDo not attempt to drive the motorcycle until a full
●lnstall the anti-rattle spring in the calipers as shown.
brake leverorpedal is obtained by pumping the brake
leverorpedal until the pads are against the disc.The
brake will not function on the first application of the

leverorpedal if this is not done.
① Z.ining Wear
★lf the lining thickness of either pad is less than the
servic(2 11mit, 「eplace both pads in the caliper as a set.
Pad Lining Thickness

1. Anti ｀rattle Spring
Standard: 4.5mm
Service Limit: lmm
● ● ● ・ ● ・I ・
● ● ● 蜀晋露S ● 幽幽 ●● ●l 仙客
Brake Pads
● ● 塀 ● ●la ● ● ● ● ●
Removal
●Remove the caliper(see Front or Rear Caliper

Removal). 1.Lining Thickness
●Take off the piston side pad from the caliper holder. 2.Service Limit
●Push the caliper holder to the piston side,and then
remove the pad from the caliper holder shaft.
Master Cylinder
●a ・
Front Master Cylinder lnstallation
●The master cylinder clamp must be instaHed with the

arrow mark upward.
●Torque the upper clamp bolt first, and then the lower
clamp bolt to the specification (see E χpjoded View).
1.Pad 3.Pu5h the caliper holder. There will be a gap at tbe lower part of the clamp after
2.Caliper Holder tightening.
11-8 BRAKES
●Tighten the banjo bolts to the specified torque (see
ExplodedView).
●Tighten the rear master cylinder mounting bolts (2)
to the specified torque (see Exploded View).
lnspection and Adiustment after lnstallation
●Check and adjust the following items after installation
Brake Pedal Position
Rear Brake Light Switch Position
Brake Line Air Bleed
A.Tighten upper clamp bolts first. Brake Drag
B.Lower Clamp Bolt Braking Power
C.Arrow Mark Brake Fluid Leak
●Use a new flat washer on each side of the brake hose
fitting ・
●Tighten the banjo bolts to the specified torque (see
E χplodedView). Disassembly
●Remove the following parts.

DustCover
Rear Master Cylinder RemovaHVote Retainer
●Remove the cotter pin and then pull the joint pin out Piston with Secondary Cup
of the push rod clevis and brake pedal. Primary Cup

Spring
茫迎』
oDo not remove the secondary cup from the piston since
removal will damage them.
A.Clevis C.Joint Pin

B.Cotter Pin D.Push Rod
Rear ! レlaster Cylinder lnstallation Notes
●Use a new flat washer on each side of the brake hose
fitting. Be sure that the metal pipe is properly fitted

into the projection on the mastercylinder.
1.Primary Cup 3.Piston

2.Secondary Cup 4.Retainer
ノ1SSem ゐ/j/
●Note the following

oBefore assembly, clean all parts including the master
cylinderwith brake fluid or alcohol.
0App.ly brake fluid to the removed parts and to the
inner wall of the cylinder.
BRAKES 11-9
巨亘]
oExcept forthe disc pads and disc; use only disc brake
fluid,isopropyl alcohol,0 「ethyl alcohol,for cleaning brake parts. Do not use any other fluid forcleaning these parts. Gasoline,engine oil, 0
「any other petro ・

leum distillate will cause deterioration of the rubber
parts. 011 spilled on any part will be difficult to
wash off completely,and will eventually deteriorate
therubberuse in the disc brake.
oTake care not to scratch the piston or the inner wall of

the cylinder.
1.Brake Disc 2. Measuring Area

lnspection fVisually}
●Check that there are no scratches, wear,rust orpitting
on the following parts.
lnside of the Master Cylinder Front Disc Thickness

Outside of the Piston
Primary Cups
Standard: 4.8-5.1mm
Secondary Cups Service Limit 4.5mm
DustCovers
RetUrn Spring5
Rejief and Supply Port Plugged

Rear Disc Thickness
★lf they are damaged, replace them.
Warp
★lf runout exceeds the service limit, replace the disc.
1.Reservoir 7.Primary Cup

2.Diaphragm 8.Piston
3.Relief Port 9.Secondary Cup
4.Supply Port 10.Dust Cover
5.Cylinder 11.Brake Lever
6.Retum Spring
1.Brake Disc 2. Measuring Area

寸薗l●● ●● 脆●・●l ●丿 ●●紡・・ ●●錘寸 l ●●・・欄・禰錘紡丿・偏●・・ ●● B r a k e
Disc
寸 ●● 暉・・ ■ ● ● ● ● ● ● 寸 ● ● 愚・・ a ●・ ●喝 ● ● ●● 種種・・ I
Disc Runout
M/e ∂r
Standard: Under 0.2mm
★Replace the disc if it has worn past the service limit. Service Limit: 0.3mm
11-10 BRAKES
Recommended Disc Brake Fluid

● ●● ● ●・ ● ● ● 幽 ● 幽・・ ● 嘸 ●S
●●・ ●丿馨丁●●●機軸慟蜀軸機●軸聊軸●鴫●・ ●●騨機●●●機●
・ ●● 機
・ ●・・・・ B r a k e
Fluid
Type D.0.T.4
Brand Check Shock Premium Heavy Duty
Castrol Girlin9-Universal
Fluid Leve 川nspection
Castrol GT (LMA)
●Check the brake 刊uid leve 卜n the reservoir.
Castrol Disc Brake Fluid
Front Brake Fluid Reservoir

IF 二
Brake Fluid Change
NOTE
oThe procedure to change the front brake fluid is as
follows.Changing the rear brake fluid is the same as
for the front brake.
●Remove the reservoir cap,and remove the rubber cap

A.Lower Level Line B. Upper Level Line on the bleed valve.
●Attach a clear plastic hose tothe bleed valve on the
caliper,and run the other end of the hose into a
RearBrake Fluid Reservoir
container.
●Change the brake nuid as follows:
A.Upper Level Line B.Lower LeveI Line
NOTE
oHold the reservoir horizontal when checking brake
flujd level.
★lf the fluid level is Iower than the lower leve 目ineJ fill the reservoir to
the upper level line of the reservoir.
い∧/ARNING i
oChange the brake fluid in the brake line completely if
the brake fluid must berefilled but the type and brand
of the brake fluid that already is in the reservoir are
unidentified.After changing the fluid,use only the
same type and brand of fluid threrafter. Mi χing different types
and brands of brake fluid lowers the 1 。0pen the bleed valve.
brake fluid boiling point and could cause the brake to 2.Apply the brake and hold it.
be ineffective. lt may also cause the rubber brake parts 3.Close the bleed vaIve
to deteriorate. 4.Release the brake lever.
BRAKES 11-11
oCheck the fluid level in the reservoir often, replenishing

it as necessary.
NOTE
o げthe fluid in the reservoir runs completely out any time during fluid changing.the bleedin9 0peration must be done over again from the beginning since air w
川 have
entered the Hne.
oRepeat this operation unti けresh brake fluid comes out from the plastic hose or the colorof the fluid changes.
い∧/ARNING i
oDo not mix two brands of fluid.Change the brake

fluid in the brake line completely if the brake fluid
must be refilled but the type and brand of the brake
fluid that is already in the reservoir are unidentified.
81eeding the 8rake L 函e
NOTE
1 . Hold tlle brake appljed.
oThe procedure to bleed the front brake line is as

2. Quickly open and close the valve.
follows.81eeding the rear brake line is the same as for

3.Release the brake.
the front brake.
Bleed the air after the brake parts are removed or dis-
assembled.
oThe fluid level must be checked several times during

the bleeding operation and replenished as necessary
・oRepeat
●With thereservoir cap off, fill the reservoir with fresh thjs operation until no more air can be seen
brake fluid. coming out into the plastic hose.
●Slowly pump the brake leveror pedal several times

until no air bubbles can be seen rising up through the
fluid from the hole5 at the bottom of the reservoir.
NOTE
This bleeds the ajr from the master cylinder and the
brakeline. oFront Brake: Repe ∂t the above steps one more time for the other caliper.
0Rear Brake: Repeat the above steps one more tjme fol ・
the other bleed valve.

NOTE
0jf the brake lever ∂ction st 川feels soft or spongy. tap the bral(e hose with sujtable mean from bott
oTap the brake hose lightly 901ng from the caliper to the
reservojr side and let tlle ajr off from the reservoir ∂irw Ⅲrjse up to the top part of the hose,
when the brake lever has a sponge feeling. slowly pump the brake jever as the same manner as
above.
●Attach a clearplastic h(3se to the bleed valve on the 01f the fluid in the reservoir runs completely out any
caliper,and run the other end of the hose into a con- time during bleeding, the bleeding operation must be
tainer. done over again from the begjnnjng since air will have
●Bleed the brake line and the caliper as follows: entered the line.
11-12 BRAKES
口VARNING I
oWhen working with the disc brake, 0bserve the

precautions listed below.
1.Never reuse old brake fluid.
2.Do not use fluid from a container that has been
left unsealed or that has been open foralongtime.
3.Do not mix two types and brands of fluid for use
in the brake.This lowers the brake fluid boiling
point and could cause the brake to be ineffective.
lt may also cause the rubber brake parts to dete-
riorate.
4.Don't leave the reservoir cap off for any length of
time to avoid moisture contamination of the fluid.
5.Don't change the fluid in the rain or when a
strong wind is blowing

・
6.E χcept ″for the disc pads and discs, use only disc brake fluid, isopropyl alcoh01, 0r ethyl alcohol for cleaning brake parts. Do not use any other fluid for cleaning these parts. Gasoline,
oilj
or any other petroleum distillate will cause deteri-
oration of the rubber parts. 011 spilled on any part
will be difficult to wash off completely and will
eventually deteriorate the rubber used in the disc
brake.
7.When handling the disc pads ordisc,be careful
that no disc brake fluid or any oil gets on them.
Clean off any fluid oroil that inadvertently gets
on the pads or disc with a high flash-point solvent.
Do not use one which will leave an oily residue.
Replace the pads with new oneS if they cannot be
cleaned satisfactorily,
8.Brake fluid quickly ruins painted surfaces; any
spilled fluid should be completely wiped up imme-
diately.
9.1f any of the brake line fittings or the bleed valve
is opened at any timeJ the AIR MUST BE BLED
FROM THE BRAKE.

SUSPENSION 12-1
Suspension
Table of Contents
12-2
12-4
Special
12-4
Front Fork ● ● 12-5
Fork Oil Ch
12-5
12-5
12-6
12-6
12-6
lnner Tube lnspection ・・・・・・
12-7
Guide Bush l 12-7
Oil Seal and Dust Seal l 12-7
Spring T
12-7
RearSuspension(U
12-8
Rear Shock 12-8
Air Pressure Adj
12-8
Damping Force Adjustment ・・・・・・・ ● 丿丿・ ● 12-8
Rem
12-9
12-9
12-10
12-10
12-10
Tie- 12-11
Tie-rod R 12-11
Tie-rod lnstall
12-11
Rocker Arm R
12-11
12-11
Needle Bearin9 1 12-11
Tie-rod,Rocker Arm Sleeve lnsp
12-11
Tie-rod,Rocker Arm Needle Bearing Lubrication.............. 12-11
12-2 SUSPENS10N
ExplodedView
☆ 川旧
二
TI : 23 N-m (2.3 k9 ・m, 16.5 ft-lb)
T2: 28 N ・m (2.9 k9-m,21 ft-lb)
︲
士J手︲
な
T3:1.5 N-m (0.15 k9 ・m, 13 1n-lb)
T4: 39 N ・m (4.0 k9 ・m,29 ft ・lb)
T5:21 N-m (2.1 k9-m,15.0 ft-lb)
工 ②ぐ
LG : Apply liquid gasket
L : Apply a non ・permanent locking agent
。リ﹄決
⑩か ⑨ ◎図
⑨◎唐09㈲二皿でゲツ
白①
月
レ
司付
川哺一唱す
万よO
⑩
しI
﹁￣
ン
ふ
(E) ⑩)(C)- べX
レ
0
]
SUSPENSION 12-3
ノ
T6: 8.8 N-m (O 。90 k9-m,78 1n-lb)
T7 : 12 N-m (1.2 k9-m, 104 1n-lb)
卜
⑩ T8: 59 N-m (6.0 k9-m,43ft ・lb)
T9:88 N-m (9.0 k9-m,65 ft-lb)
M : Apply molybdenum disulfide grease.
・→サ √夕
謬
ノ
⑩ ニ⑩
ノ
レ
/
12-4 SUSPENSION
Specifications
Front Fork:
Forkoil: viscosity 一一一
Amount par unit ±4mL360 mL : When changing oil130 一一一
一一一
Fork oil level: 土2mm(FuHy compressed without Sprin9)488 mm

一一一478 mm
FOrk Spring free length SAE 10W20419
Rear Suspension:
Rear shock absorber air pressure ・e)O - 100 kPa (O
・- 1.0 k9/cm2, 14 pSi)2 0f 4 poSitionS

Rear shock absorber damper
adjuster position O(AtmoSpheric PreSSur
‥‥‥‥‥‥‥ Bearing Driver Set: 57001-1129

● ● ●I ● 騰I ・ ●
丿 ●l ● 丿 ● 匍I ●・
Special Tools
● ● 噛 ●・ ●s ● ● 種種讐慟 ● ●a
Front Fork Cylinder Holder Handle: 57001-183
Front Outer Tube Weight: 57001-1218

Front Fork Cylinder
Handle Adapter:
Front Oil Seal Driver: 57001-1219

SUSPENS10N 12-5
●・官 ● 雌 ● ●● 幽● 種種幽幽・ ● ●・ I ●Front ・・ ●・ l ●SI 聊 ●
Fork
●I 暉丿 ● 騨塀輝槽
Fork Oil Change

Handlebar Holder
Fork Top Plug

Fork Spring
Drain Screw
1.011 Level
Fork Oil Level
(Fully Compressed without sprin9)
130 ±2mm
★lf the oi 目s above or below the specified level,remove or add oil and recheck the
A.Drain Screw
目evel.
●Change the oH of the other fork leg in the same

manner.
●A110w the oil to drain into a suitable container. lfyou

pump the fork legs to force out the oil, be sure to catch
the oi 目n a container as it squirts out.
Removal
NOTE
・
0 ｀Apply a jiquid gasket to the threads of the drain screw and gasket. Falrlngs
Calipers
Front Wheel
F「ont Fender
●L00sen the upper and 10wer fork clamp bolts.
●With a twisting motion, work the fork leg down and
Front Fork Oil
out.
Viscosity SAE10W20
Amount per side
When changing oil: 360 mL

After disassembly and
completely dry: 419 ±4mL
NOTE
oPump the fork enough times to expel the air from the
upper and lower chambers.
●With the fork fully compressed insert a tape measure

orrod in the inner tube, and measure the distance from
the top of the inner tube to the oil. A.Upper Clamp Bolt B. Lower Clamp Bolts
-
12,6 SUSPENS10N
lnstajlation ●Remove the piston and cylinderunit and the short
spring from the top of the front fork tube.

●Remove the dust seal from the outer tube.
lowing.
●Remove the retainer and washer from the outer tube.
●lf the fork leg was disassembled, check the fork oil
●Mount the weight (special tool)on the top of the outer
leve1.
tube,by fitting the step of the weight (special tool)to
●lnstall the fork so that the top end of the inner tube
the top corner of the outertube.
projects 15 mm from the upper surface of the fork
●Holding the inner tube by hand in a vertical position,
clamps.
stroke the outer tube several times and pul 卜t down.
︽
1.1nnerTube
2.Fork Clamps
3.15 mm
●Tighten the upper and lower fork clamp bolts to the
二十
specified torque (see E χploded View).
●Tighten the caliper mounting bolts to the specified
torque(see E χplodedView in the Brake chapter).
●Check the front brake after installation.
[WARNING i
oDo not attempt to drive the motorcycle until a full

brake lever is obtained by pumping the brake lever
until the pads are against the disc.The brake will not
function on the first application of the lever if this is

not done.
1.1nnerTube
￡)yS∂ SS θダ77
ゐ /1/ 2.Fork Outer Tube Weight: 57001-1218
●Loosen the top plug, before removing the front fork. 3.0uterTube
●Remove the front fork. 4.Stroke
●Remove the top plug.
●Pour out the fork oil.
●Stop the cylinder from turning by using the front fork ●Take the cylinder base off the outer tube
cylinder holder handle and adapter(special tools).
Unscrew the Allen bolt and take the b01t, and gasket
out of the bottom of the outer tube.
yISSe β7ゐ/3/
●Assembly is the reverse of disassembly. Note the

following ・
●Check the following parts and replace them with new
1.Wrench 5.Handle: 57001-183 ones if necessary.
2.Bolt 6.0uter Tube Top Plug O-Ring
3.Cylinder 7.1nnerTube Guide Bush
4.Adapter:57001-1057 ●Replace the oil seal removed wjth a new one.

SUSPENS10N 12-7
oApply a non-permanent locking agent to the AIlen bolt Guide Bush lnspection
and tighten it to the specjfied torque (see Exploded ★Replace the guide bushes if they are damaged or worn.
View) ・
●lnstall the guide bush (with a used guide bush on it)
by tapping the u5ed guide bush with the fork oil seal
driver(special tool)until it stops. The slit of the bush

must be faced toward the left orright.
口▽
Guide Bush
Oj・'ISeal and Dust SeaOnspection
★lf dust seal is any damage or wear, replace it,

●Replace the oil seal with a new one wheneverit has
1.Driver: 57001-1219
been removed.
2.Used Guide Bush
3.Slit(toward the left or right)
4,New Guide Bush
5.Tap
●Use the fork oil seal driver (special tool)to install

the oil seal in the front fork.
lnner Tube lnspection
★lf the inner tube is damaged, replace it.

●Nicks or rust damage can sometimes be repaired by
using awet-stone to removesharp edges or raised area5 1,011 Seal 2.Dust Seal
which cause seal damage
・
★lf the damage is not repairable, replace the inner tube.
Since damage to the inner tube damages the oil seal,
replace the oil seal whenever the inner tube is repaired

or replaced.
Spring Tension
★lf the spring of either fork leg is shorter than the
呂皿] service limit, it must be replaced.lf the length of a

replacement spring and that of the remainjng spring
01f the innertube is badly bent orcreased,replace it. vary greatlyJ the remaining spring should also be
E χcessive bending,f0110wed by subsequent straight ・ replaced in orderto keep the fork leg5 balanced for
enin9,can weaken the innertube. motorcycle 5tability ・
12-8 SUSPENS10N
NOTE
oDo not use tire gauges for checking air pressure. They
may not indicate the correct ajr pressure because of air
leaks that occur when the gauge is applied to the valve.
Air Pressure kPa (k9/cm ≒psi)
Usable Range
One Rideror
Normal Riding Atmospheric 100(1.0,21)Pressure
NOTE
1.Fork Spring
2.Free Length oThe recommended ajr pressure js atmospherjc pressure
for average rider with no accessories.
ForkSpring Length
Standard: 488 mm [WARNING i

Service Limit: 478 mm
oBe sure to adjust the air pressure within the usable
range. Pressure too high or too low can produce a

hazardousriding condition.
00nly air ornitro9en gas can be used.Neverinject
oxygen orany kind of e χplosive gas.
oDo not incinerate the rear shock absorber.
Damp 岫Force Adjustment
●Tum the damper adjusting dial to the desired number

● 寧 ● 橿
RearSuspension(Uni-trak) until you feel a click.The numbers on the adjuster

show the setting position.
Rear ShOck AbSOrber:
ノ1//
・/)resS ￡j/
・eyk かjSrme/7t F ゛゛
●Note the following.
Put the motorcycle up on its center5tand to raise the
rear wheel off the ground.Use air pressure gauge 52005-
1003 which is specially made for air suspensions.
Check and adjust the air pressure when the rearshock
absorberis cold (room temperature).
A, Adjusting Dial
NOTE
oThe damping force can be left soft for average rjdjng

・
But it should be adjusted harder for high speed rjding,
or riding wjth a passenger. lf the damping feels too
soft or too stiff, adjust it in accordance wjth the
A.AirValve f0110wing tab19:

SUSPENS10N 12-9
Rebound Damping Adjustment ●Remove the shock absorber bolts and tie-rod bolt.
Adjuster
Position Damping FOrce
Setting Load Road Speed
1 Stronger SoftIHard
1 LightIHeavy
GoodIBad
Low1High
2
3
4
Removal

Seat
Side Cover
Rear Cowl
Battery
Rear Fender
●Remove the air valve mounting nut and free the air
hose.
●Remove the damping adjuster mounting bolts.
A.Shock Absorber Bolts

B.Tie-rod Bolt
A.Mounting Nut C.AirValve

B.Mounting Bolts D. Damping Adjuster
●Remove the shock absorber toward the ground.

●Disconnect the damping adjuster cable from the
adjuster.
lnstallation

lowing.
●Apply molybdenum disulfide grease to the inside of

the needle bearings.
●Tighten the shock absorber bolts and tie-rod bolt to
the specified torque (see E χpjoded Vjew).
●Set the damping adjuster as follows.
A. Damping AdjusterCable B.Nut 0Turn the damping adjusterdial N0.1 position.

12-10 SUSPENS10N
oSlide the dust cover off the top of the shock absorber. Shock Absorber Bolt (lower)
0Check that the gear mark l (red painted mark)is at the Tie-Rod Bolts
middle of the window.
olf the gear mark l is not at the middle of the window,
turn the plastic gear clockwise until the mark l is in the
middle of the window.
MarkI Match
A.BOltS
●Remove the swing arm pivot shaft while supporting the
swlng arm.
- ③
1.Gear Mark l (red painted mark)

2.Plastic Gear
3.Turning Direction
4.Shock Absorber Top
oConnect the cable to the damping adjuster.
Swing Arm:
Removal

RearWheel
A.Pivot Shaft
Brake Hose Guide
Chain Cover
Right Footpeg Bracket

●Remove the swing arm toward the rear
Torque Link
lnstallation
●lnstallation is the rever5e of removal.Note the fol-

10wing ・
●Apply molybdenum disulfide grease to the inside of
the needle bearings.
●Tighten the following nuts to the specified torque (see
ExplodedView).
Swing Arm Pivot Nut
Shock Absorber Nut
Tie-Rod Nut
Torque Link Nut
●Adjust the drive chain after installation (see Final Drive
A.Torque Link B.BOlt chapter),
SUSPENSION 12-11
Tie-ROd,ROCkerArm: Rocker Arm lnstallatjon

Tie-Rod Removal ●lnstallation is reverse of removal. Note the f0110wing.
●Remove the torque link from the caliper holder. ●Apply molybdenum disulfide grease to the inside of
●Remove the tie-rod lower bolt. the needle bearings.
●Tighten the following nut to the specified torque (see
ExplodedView).
Rocker Arm Nut

Shock Absorber Nut
Tie-Rod Nut
/Viedje 8earin9 1nspectjon
★lf there is any doubt as to the condition of either

needle bearing, replace the bearing and sleeve as a set.
A.Tie Rods B. Bolts
●Remove the tie-rod upper bolts and take the tie-rod off Tie-Rod,Rocker Arm Sleeve lnspection
●Remove the othertie- 「od.
★lf there is visible damage, replace the sleeve and needle
bearing as a set.
Tie-Rod lnstallation
●Appjy molybdenum disulfide grease to the inside of 77 θ- βOd./?OC んa ・ノ㎞77 Aleedle

the needle bearings. Bearing Lubrjcation
●Tighten the tie-rod upper and lower bolts to the
There is a grease nipple on the tie-rod and rocker arm
specified torque (see E χplodedView).
for lubrication.
●Force the molybdenum djsulfide grease into the
nipple until it comes out at both sides of the tie- 「odor rocker arm, and wipe
off any excess.
/?QCAra ・ノ1/7m /?
∂ /7701/
∂/
Falrlngs
Radiator
MufFler
●Remove the shock absorber boltJ tie- 「od bolt,and rockerarm shaft.
A.Rocker Arm B.BOltS

STEERING 13-1
Steerin9
Table of contents
ExplodedVi
13-2
Special
13-3
13-4
Adjustm
13-4
Steerin9 13-4
Rem
13-4
13-5
Steering Stem
13-6
Bearing Lubricati
13-6
Bearing Wear, Damage
13-6
Stem Cap Deterio 13-6
Steering Stem Warp 13-6
13-2 STEERING
ExplodedView
■ ● 槽 ● 働個・騰 ● 騰 ● ●・ ●・
TI: 39 N ・m (4.0 k9-m,29 ft-lb)T2 : 4.9 N
⑩皿・m (0.50 k9-m,43 1n-lb)T3: 20 N-m (2.0 k9-m, 1
「ease.
[ 戸3
/
/ ぶ
大尹
斗万
匹具
STEERING 13-3
● ●l ●・糎 ● 鴫l ●I ・ ●● 靴 ● S 曝 ●● 暴丿 ● 臨機・ ●S ● l ● ●丿 ● ●
Stem Nut Wrench: 57001-1100

Special Tools
●・ ●●●・l ●雌4 ●嘔●II ・ ●●●咄●●・ s ●●・ ● I ● I I ●● I・ ●●●眼韓 l 咄 I・珊幽●●●●●●羞●咄●●・珊珊 l 寸 l ●咄咄珊瑚● 珊●●●咄●・ S t e m
Bearing Driv e r : 5 7 0 0 1 - 1 3 7
Stem Bearing Remover: 57001-1107
Adapter: 57001-1074
Driver Press Shaft: 57001 ・1075
＼
Bearing Puller: 57001-158
Driver: 57001-1106,1076
Adapter:57001-317
Jack Stand: 57001-1238
Pole: 57001-1190
NOTE
o7T ｀he poles (PZN 57001-1190)are included in the bearing puller (PZN 57001-75sJ.
13-4 STEERING
●a ・・・個 ● ● ● ● ● ●
● ● ● 幽會 ●S ● ● ●・ ● 儒丿 ●
●Tighten the following bolt and nut to the specified

Steering torque(see E χplodedView).
Steering Stem Head Nut
Front Fork Clamp Bolt (see Suspension chapter)
ノ1(が・jSか71印「
●Check the steering again.
●Check the steering. ★lf the steering is still too tight or too loose,repeat the
oLift the front wheel off the ground using the jack stand adjustment.
(special to01: 57001 -1 238).
oWith the front wheel pointing straight aheadj alter-
nately tap each end of the handlebar.The front wheel
should swing fully left and right from the force of
gravity until the fork hits the stop ・
★lf the wheel binlds or catches before the stop, the ・ ● 咎咄咄 ● ● ●
Steering Stem
steering is too tight.

oFeel for steering looseness by pushing and pulling the 丿機 ● 機軸機 ●・機機・ ● ●・ ● 墟・・ ● 暉 ● 勤丿・ ●・・・ ●・糎・ ●・・ ●・ I 嘩・ s I ・
forks.
Removal
★lfyoufee 川ooseness,the steering is too loose.
●Remove the following parts
・
NOTE FuelTank
Falrlngs
oThe cables and wiring w Ⅲhave some effect on the motion of the fork which must be taken into account.
Handlebars
Front Wheel
Be sure the wires and cables are properly routed.
Front Fork Legs
0The bearings must be in good condition and properly
●Remove the brake hose joint from the stem base,and
lubricated in order for any test to be vaHd.
remove the front brake assembly as a set.
★Adjust the steering げnecessary ・

●Remove the following parts.
FueITank
Fork Lower Clamp Bolts (both sides)
Stem Head Cover
Stem Head Nut(L00sen)
●Adjust the steering with the stem nut wrench (special
tool),
A.Brake HoseJoint B,Bolts
●Remove 5tem head nut and take off the steering stem
head.
●Push up on the stem baseJ and remove the steering stem
locknut using the stem nut wrench (special tool),then
remove the steering stem base.
A.Stem Head Nut

B.Stem Nut Wrench: 57001-1100
★lf the steering is too tight, Ioosen the stem locknut a

fraction of a turn.
★lf the steering is too loose, tighten the locknut a frac-
tion of a turn.
NOTE
oTum the locknut l ノ8 tum at a time ma χimum. A.Stem Locknut B.Lockwasher

STEERING 13-5
●Remove the upper tapered roller bearing inner race.

●To remove the outer races pressed into the head pipe,
install the stem bearing remover (special to01)asshown
below.
NOTE
○lf either steerjng stem bearing is damaged バt is recommended that both the upper and lower
bearings 伽- cIuding
outer races ノshould be replaced with new ones.
へヽ
X 二
1.Driver Press Shaft: 57001-1075

2.Driver: 57001 -1 106
3.DI・iver: 57001 ,1 076
1.Stem Bearing Remover: 57001-1107 oApply grease to the lower tapered roller bearing, and
drive it onto the steering stem using the stem bearing
driver and adapter(special tools: 57001 ,1 37 and
●Remove the lower tapered roller bearing(with its
57001-1074).
grease seal)which is pressed onto the steering stem,
with the steering stem bearing puller and adapters

(special tools).
S4 腎 χ 謳
…
:…
…II
ユ,T7
A.Bearing Puller:57001-158 A.Stem Bearing Driver:57001-137

B.Adapter: 57001-317 B.Adapter: 57001-1074
C.Pole: 57001-1190
D.Tapered Roller Bearing

E.Stem Base
●The following four steps should be performed after
steering bearing installation. This procedure settles the

lnstallation bearings in place.
●lnstallation is the reverse of removal.Note the f01- 0Using the stem nut wrench, tighten the stem locknut to
Iowing. 39 N-m (4.0 kg-m, 29 ft-lb)of torque. (To tighten the
0Apply grease to the outerraces,and then drive them steering stem locknut to the specified torque, hook the
into the head pipe using the drivers and the driver press wrench on the stem locknut, and pull the wrench at the
shaft(special tools). hole by 22.2 kg force in the direction shown.)
13-6 STEERING
Bearing Wear, Damage

★Replace the bearing assembHes if they show damage
Stem Cap Deterioration,Damage
★Replace the grease sea 卜f necessary ・
1.Stem Nut Wrench: 57001-1100 3.22.2kg

2.180 mm Steering Stem Warp
★lf the steering stem shaft is bent, replace the steering
stem.
oCheck that there is no play and the steering stem turns

smoothlyJwithout the rattle.
☆lf notJ the steering stem bearing may be damaged.

0Again back out the stem locknut a fraction of a turn
unti 目t turns lightly.
0Tum the stem locknut lightly cIockwise until it just
becomes hard to tum.Do not overtighten, 0r the
steering will be too tight.
●Check and adjust the following items after installation.
Steering
Clutch
Throttle Cables
Choke Cable
Front Brake
Steering Stem Bearin9
8earing t.ubrication
●Perform the following.

oRemove the steering stem ・
oUsing a high flash,point so ¶vent,wa5h the upper and lower tapered roller bearings in the cages
・
oWipe the upper and lower outer races, which are
press-fitted into the frame head pipe, clean of grease
and dirt.
oVisually check the outer races and the rollers.
☆Replace the bearing assemblies if they show wear or
damage.
oPack the upper and lower tapered roller bearings in the
cages with grease, and apply light coat of grease to
the upper and lower outer races.
oln5tall the steering stem, and adjust the steering ・
FRAME 14-1
Frame
Table of contents
14-2
Fair
14-5
Fairing R 14-5
lnner Fairing Rem
14-6
Rear Cowl Rem
14-6
14-6
Rear Fender Rem
14-6
14-2 FRAME
ExplodedView
勁勁勁
ケ
/ が
FRAME 14-3
y
ソ
を
べ
ｙ丿
丿
む昌し
G : Apply 9rease
14 ・4 FRAME
汐﹂
ド
㈹ヰ
携T
ル
ド
ノ謳
ぷ
、⑤
グ
瘤゛
∩
FRAME 14-5
oRemove the front inner fairing.

Falrlngs
●喝 l 噛丿・・・・騨・ ● ● ● 幽丿
Fairin9 βemoval
●Remove the lower fairing.
A.Screws
oRemove the rear view mirrors.

A.Screws B.BOlt
●Remove the side fairings.
A.Mounting Nuts
A.Screws B.BOlt
oDisconnect the wiring connector

●Remove the upper faring as follows.
oRemove the windshield.
A.Screws A.Connector
14-6 FRAME
lnner Fairing Removal
●Take off the front inner fairingJ after remove the wind
shild.
A.Rear Cowl B.Mounting Screws
●Disconnect the wiring connectors for the brake, tail

and turn signa 川ight.
A.Screws B.Front lnner Fairing
●Take off the rear inner fairing, after removing the fuel
tank.
A.Screws B.Rear lnner Fairing
・匍畠 ● 丿岫騨麗麗 ● 韓・ ●寸・ ● ● ● ●● 瞳I ● 畠鎗・ ●・・輯暉重・ ● ●・ ●・ ●Fender
/?θ∂rCO ㎡/? ∂X77QI/∂/

丁暉●● 匍●● 老齢細丿● ●・個● 丁卿●●●●●・齢●細幽匍齢・・・丁●騨働●・卿●● l s ●●●●働畠寸卜 s ●●●齢●老・匍細欄鎗・● ●● 細雪丿・櫛・憧丿Rear

・
Seat Fender Remov ∂!
Side Cover ●Remove the following

・
●Take off the rear cowl with the tool box toward the Rear Cowl
rear. Rear Fender Rear Section

FRAME 14-7
A.Rear Fender Rear Section B. Bolts A.Junction Bo χ B. Rear Fender Mounting Bolt
Battery
●Take o 仔the rear fender front section toward the rear
IC lgniter
Starter Relay
Reservoir Tank Mounting Bolt
--
A 丿C lgniter B.BOltS
A.Starter Relay B. Reservoir Tank Mounting Bolt
Junction Bo χ
Rear Fender Mounting Bolt
ELECTRICAL SYSTEM 15-1
Electrical System
llble of Contents
Precautions ‥ ‥ ‥ ‥ ‥ ‥ ‥ ‥ ‥ ‥ ‥ ‥‥15-2Wiring Diagram{US and Canada}

Headlight
●●●●●●●●●●●●●●●●●●●●●●●●●●●15-28
‥ ‥ ‥ ‥ ‥‥15-3Wiring Dia9 Headlight Beam Horizontal
「am(Otherthan US and Canada). ‥15 ・4Parts Adjustment 15-28
Location
●●・ ●●・ ●・ ●・・ ●●・・ ●●●●●●・. 15 ・5 Headlight Beam Vertical
E χplodedView ・・・・・・・・・・Specifications 15-6 Adjustment ・・・・・・・・・・Headlight

‥ ‥ ‥ ‥15-28
・・・・・・・・・・・ ‥.15-9 Circuit ｀lnspectionHeadlight Reverse Lighting
Special Toolに ‥ 15・10

Battery
●●●●●●●●●●●●●●●●●●●●●●●●●●●●15-11 System lnspection ・・・ 15-28
・・・
Electrolyte Level lnspection ・・・・・・・・・.15-11 FuelPump
Electrolyte ● ● ●・ ●・・・・ ●●・ ●・ ● ● ● ●・・・ ●・・ ● ●15-30
Specific
Removal/lnstallation ・・・・・・・・・・・・
・・.15-30 1nspection
Gravity lnspection ・・・・・・・・・・・・・・.15,11 1nitial
・ ● ● ●・・・・・・・・ ● ●・・・・ ●・・
●15-30Cooling Fan System
Chargin9
・・・・・・・・・・・・・・・・・・.15-11 0rdinary ・・・・・・・・・・・・・・・・・・・.15-31 Fan System
Chargin9
・・・・・・・・・・・・・・・・.15-12 Circuit lnspection ・・・・・・・・.15-31 Fan lnspection
Altemator
● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● 15,12
Removal
・・・・・・・・・・・・・・・・・・.15,31 Fan Switch
● ● ● ● ● ● ● ● ● ● ● ● ● ● ‥ ‥15-12 lnspection ・・・・・・・・・・・・・.15-31Meters,Gauges
lnstallation..,........,.. 15-13 ・・・・・・・・・・・・・・・・・・・・・・.15-32 Tachometer Removal
Disassembly ・・・・・・・・・・ 15-13 ・・・・・・・・・・・・・・.15-32 Tachometer lnspection
Assembly
●●●●●●●●●●●●●●●●●●●●●●●15-14Stator Coil lnspection ・・・・・・・・・・・・・.15-32 Fuel Gauge
・・・・・・・・・・・・・.15-14 Operation lnspection ・・・・・・.15-33 Fuel Level
Rotor Coil lnspection ・・・・・
・・Slip 15-15 Sensor lnspection ・・・・・・・・・.15-33 Water Temperature
Ring Cleaning ‥ ‥ ‥ ‥‥
15・15 Gauge
Slip Ring Diameter ・・・・・・・・・・・・・・・.15-15 Operation lnspection ・・・・・・・・・・・・.15-34 Water Temperature

Carbon Brush Length.
‥ ‥Rectifier 15-15 Sensor
lnspection ・・・・・・ 15-15 lnspection
Regulator
‥15-35
Junction Bo χ
・・・・・・・・・・・・・・・ ‥15-36
AltematorTroubleshooting ・・・・・・・・・.15'16Test N0.1-Battery Discharged
Fuse Removal
・ ‥Fuse ‥15-36
・・・・・・・・.15-17Test N0.2 lnstallation
●●●●●●15-36
・Battery Overcharged ・・・・・・・.15,17 Fuse lnspection
・・・・・・・・・・・・・・・・・・.15-36Junction Box Fuse Circ
Test N0.3-Noise 。‥ ‥ 15-17
19nition Systern ●●●●●●........... 15-18 lnspection ‥ ‥ ‥ ‥ ‥ ‥ ‥ ‥ ‥ ‥15-36Starter Circuit and
Pickup Coil Removal ・・・・・・・・・ 15-18
Pickup Coil lnstallation
15-18 and Headlight Relay lnspection ・・・・
・.15-37Diode Circuit lnspecti
Pickup Coil lnspection ・・・・・・・・・
・・・・.15,18 1gnitjon
・・・・・・・・・・・・.15 ・37
Coil Removal/lnstallation
・・・・・.15 ・19
19nition Coil lnspection ・・・・・・・・・・
・・.15-19 Spark
Plug Gap
・・・・・・・・・・・・・・・・・・.15 ・20
1C lgniter lnspection ‥ ‥ ‥ ‥
‥ ‥ ‥ ‥15-20Electric Starter System
・・・・・・・・・・・・・・・・・.15 ・23
Starter Motor Removal ・・・・・・・・・・・

・・.15 ・23
StarterMotor lnstallation ・・・・・・
・・・・・.15-23 Starter Motor
Disassembly ・・・・・・・・・・.15-23 Starter Motor
Assembly ・・・・・・・・・・・・.15-24 Brush lnspection
・・・・・・・・・・・・・・・・・.15 ・25
Commutator Cleaning and
lnspection . ‥. 15-25
Armature lnspection ・・・・・・・・・・・・・・.15-25Negative Brush and
Lead Assembly lnspection ・・・・・・

・・・.15-25
Brush Plate lnspection 15-25
Starter Relay lnspection ・・・・・・・・・・・・.15-26
15-2 ELECTRICAL SYSTEM
●●●種・種
・ ●●I・ ●s ●●●●・l ●種種言●Pr e c a u t i o n s
Male Connectors
● ● ● ● ● 聊馨 ● 壇
There are a number of important precautions that are
musts when servicing electrical systems. Learn and
observe all the rules below.
0Do not reverse the battery lead connections.This
will burn out the diodes in the electrical parts.
0Always check battery condition before condemning
other parts of an electrical system. A fully charged
battery is a must for conducting accurate electrical
5ystem tests ・
oThe electrical parts should neverbe struck sharply, as
with a hammer, or allowed to fall on a hard surface.
Such a shock to thq parts can damage them

・ c(olorCodes
oTo prevent damage to electrical parts, do not dis- BK Black

connect the battery lead5 0r any otherelectrical BL Blue
connections when the ignition switch is on, 0r the
BR Brown
englne ls runnlng CH
・ Chocolate
oBecau5e of the large amount of current, never keep DG Dark green
the starter switch pushed when the starter motor G Green
will not tum over,0r the current may burn out the GY Gray
startermotor windings.
LB Lighl blue
oDo not use a meter illumination bulb rated for other
LG Light green
than voltage or wattage specified in the wiring di-
O Orange
agramj as the meter or gauge panel could be warped
P Pink
by excessive heat radiated from the bulb.
PU Purple
0Take care not to short the leads that are directly
R Red
connected to the battery positive ( 十)terminal to the chassis ground.
W White
Y Yellow
oTrouble5 may involve one or ・in some cases all items.
Never replace a defective part without determining
what CAUSED the failure.lf the failure was caused
by some other item or items, they too must be repaired
or replaced,0r the new replacement will soon fail
agaln.
oMake sure all connectors in the circuit are clean and
tight,and e χamine wire5 for 51gns of burning, fraying,
etc.Poor wire5 and bad connections will affect elec-
trical system operation.
0Measure coil and winding res15tance when the part is
cold(at room temperature).
oElectrical Connectors
Female Connectors
ZX1000 I Fronl Brakl ・しqhtSwllch
ELECTRICAL SYSTEM 15 ・3
-BI/B2/B3 Wiring Diagram
ンFngln ・jSIop S41 ↑ch

lUS and Canada)
F , j ,・¶ 3 SIJrlcr Bul いn
ルヤ和和
L I・ V ・・ I
働
Coollnri F,m Sw 巾h
●●●● ●●●● ●・ ●● ●●● ●●●● ●・ ●● ●●● ● I ●● ●曝● I ・ ● 1 ●●●● ●●●● ●●●● ●●● ●●●● ●●丿●丿 ● I I ●● ●●●● ●●● ●●●●● ●●● ●●● ● Sp.,6 PII,q ・,
S ・・・
. 1・ , O「
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1---J
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3 R,・.srBr.sklliLiqhlSWi?,h
r-'
下
LI
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︲
︱'-'ド
レレr
万ハ
口
トー
1qnitlon
Swilch
◇レー
レ
High Beam lndicalor Liqhl
12V3,4W
Righl Turn Signal lndlcalnr
Lih112V3,4W
Lefl Turn S19nal lndkalor

L19h112V3.4W
Oil Prelwre Warning Lighl

12V3.4W
Meler L 佃h1
12V3W
Neulral lndicalor Light
12V3.4W RearR1 りhl Tum S19nalLigh112V23W
Tachom 吋e
「
Ta11/Broke Lighl
Metg Light
12V8/27Wx2
12V3W
MelerLight
12V3,4W
COolant Temperalure Gauge
Meter Liht12V3W Rear Left Turn Signal

L19h1 12 V 23 W
Fuel Level Gauge
MelerL いt 12 V3W
Head119hl
12V60/55W
睦言
Turn Signal Relay
Front Right Turn Signal で}E

Lighl/Running Position {:t 白}
ヨ三BL 三{
gL BKyy
三FBK/Y GY
Ligh112V23W/8W GY
Front Left Turn Signal 〔E ① ② ③ ④ ⑤

Light/Runnlng Posltlon [j ズ:E三?BL BL 三jtK/Y・ GY
K/Y]三￨: 1.HornBu110n
Light12V23W/8W G 一
2.HazardSvりilch
3.TurnSignalSwIlch
4.Dimmer Swilch
5.SlarlerLockoul Swllch
LEFT HANDLEBAR SWITCH CONNECTIONS IGNITION SWITCH CONNECT10NS

S闇1rLock 卯tSwi卜ch HOrnButton DlmmerSwjtch Hazard SWilch RIGHT HANDLEBAR SWITCH CONNECTIONS
TurnSignalSwitch 19nition Batteり Tai 日
1qnition Ta112 Batte7 Ta113
CQ10
「 8K〃 Y/G LG C010「 BK/Y BKM CO10
「 RyBK 8LyY R〃 COIOr GY 0 G Color GY Starter8UU㎝ FrontBrakeLightSwltCh
CO10
「 BR W BL W/8K OyG EngineSU3pSwith
ReleaS
●d W ONgPu
刈 C- ・・ひ
や HI C 加・4-) 四 CSli
⊃ ON C 1・KIW) OFF,LOCK Q10「 Y/R Q10
「 BK/R BK/R COIOr 8K BK
OFF PUSji (← ヤ Rel
軸Sld
ON 心 r==.j= へ C ●4 ⊃ ー4)
・゛ '“ ' ‘ ・
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..1 1 ●・ . ● ●R ・, ● ・I
● ●III ¶・
Z χ1000・BI/B2/B3 Wiring Diagram (Other than US and Canada)

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MI,lerL りh112V3W
Najlral lndlcalor L19h ¶

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R1-'jr Rqh1 1u,r ・S,fjn,11L
叫'112V21W
IAMSQ3W
TaChOmeler
Ta 雨18rake L,Q11112V5,
MelerL 皿hl ・21W,21Sj8/27Wx2
12V3W
MelerLighl
12V3.4W
Co01antTempefalure
Gau 卯
● Rear Lefl Turn S・9nal

M 叫efLight 12V3WFuelLselG
Llght 12V21W
(AHS)23W
〃9 す
M 叫erLight
12V3W
Headlight
12V60/55W
緩⑤
C11yLight
12V4W
Turn Signal Relay

1111j
丿
匹
FrontRihlTurnSigna1 χ:l二:j
qKyV BK/
Light12V21W (
引
(A)ISS23W GY GY
︱-1 ｔII!11tl
肩
FrontLef卜TurnS19心IL
肘
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{AHS123W
Dimmer SwitCh
円
(G)
→
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SlartefL∝k ㎝tSwitchSideStaMSwilch
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口工 _。 l l
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匠二心 OilPres釦reSwi卜ch
￨ l Nltral Switch
L____________________ 一一一一一一」
LEFT HANDLEBAR SWITCH CONNECTIONS IGNITION SWITCH CONNECTIONS RIGHT HANDLEBAR SWITCH CONNECTIONS
LIQhl Battlry Ta111 Ta112 EngineS哨pSwl皿h HeadlightSwitCh StarlerBulton Front 8rake Lighl
￡h Swit
Staner Lock-I Switch HOmBUlt ㎝ Dim 四rSwitch TurnSillalSwitCh
ム
・ingButton
P 19nitiOn CCIOf Y/R Q10
「 RM RyBL BL 8L/Y COIぽ BKyR 8KyR CO10「 BK BK
CO10
「 BKyY YyG LG CO10「 BKyY BKyW Color R/8K 8L/Y R/Y Celor GY 0 G Color R/白K BR C010
「 BR W 6L
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・聊禰 ● ● ● 嘩畠 l 靴 ●
Parts LOcation
● ● 軸幽 ● ●s 自 ● 幽・ ● 嶋s ●・ l l ・ ●l ● 寸sI ●l 槽● ● ● l ●・幽 ●l ● 幽幽丿幽幽 ● 幽幽幽 ●l 幽 ●1 ●al 僧職s 幽・ ● 幽 ● ● 麗幽 ● 幽 ● 幽 ● ●a 幽幽・
A,Battery
B.Junction Bo χC.IC
lgniter
D.Fuel Filter
E.FueIPump
F.Starter Motor
G.lgnition Coil
H.Alternator
￨.Starter Relay
1.Main Fuse 30A
15・6 ELECTRICAL SYSTEM
ExplodedView
‰
ノ
牡
ケ︲
いドノ
⑤
嶮
6
＼ ljO
・
-
絆
//
謳
し
√L
￨尚甲で]
八O::)
⑩
ン尚 ④
半
(J:) ト
ダ ‰
≒。フン
ド
ノ 1.1gnition Coils
2.StarterRelay
3.1C 19niter
ニ
サ 4.Pickup Coil
ド
㎜ ■
<
言叉
'
Γ--
￢
上畷多
ぬ二回し___ 二___Frame No.
舗 JKAZXCBIOJA004564
ZXT00B-004564
5 。19nition Switch
TI:25 N-m (2.5 k9-m, 18.0 ft-lb)
T2:9.8 N ・m (1.0 kg ・m,87 1n-lb)
T3: 14 N-m(1.4 k9-m, 10.0 ft-lb)
T4:4.9 N-m (0.50 k9 ・m,43 1n ・lb)
SS : Apply silicone sealant.
≫
ブ
ほ＼
∧ 仏
☆☆ノ
よ①
⑤
15-8 E LECTR ICAL SYSTEM
氷 ⑥ トム作yy
冷千千ダパーJ
一︿゛
ゾレ
丿名 √① 一
〉ド ⑧
ノ _当
!
芒U
願
6.Turn Signal Relay
7.Horns
8.Side Stand Switch
9.Rear Brake Light Switch
〉 ⑤e
&
☆
Specifications
畠 ● 噛 ● 自慢卜 ● ● ● 嘸 ●1 ・・ ● ●
Battery:
Type 一一一
Specific 9ravity 12 V 14 Ah1.280@20

°C(68 °F〉一一一
Altemator:
Charging voltage 一一一
Rotor Coil resiStance Ω(ZX1000-BI),About6 nLess than l.0 一一一
Stator coil resistance Ω14.4mm10.5mm 一一一14.0mm4.5mm
Slip ring diameter
Carbon bruSh length 14.5 V Night@4 000 r/min (rpm)About 4
19nition SyStem:
Pickup coil air gap
Pickup coil reSiStanCe Ω6 mm or more2.6-3.2
lgnition coil:
3 needle arcing diStanCe
Primary winding resistance Ω13-17k
------------------
SeCondary winding reSiStance Ω0.7-0.8mm
Spark plu9 9ap 0.7mm400 - 490
Starter Motor:
Carbon bruSh length
Commutator 9roove depth
Commutator diameter 12 mm0.7mm28mm 8.5mm0.2mm27 mm
Switches and Sensors:

Rear brake light Switch
Fan switCh: OFF ぅON °C (205 - 212 °F)91 - 95
ON やOFF Water temperature SenSOr °C (196 - 203

reSiStanCe FUe°F)80
°C(176 °F):about 52 Ω100
°C(212 °F):about 27 nFull poSition 4 - 10
日evel SenSOr reSiStanCe ON after about 10 mmΩEmpty
pedal trave196
position -90100
----------------------
100 n
Spark Plu9
Standard
US,Australia,
ltaly,South AfriCa NGK CgEND U27ES-N
Other NGK CRgEND U27ESR-N

● ● ● ● ● ●・・ I ● ● ●I ●l ●
Special Tools
昏 ● ● 種 ● 種寸 ● 岫岫練種 ● ●s ● ● ● ●● ● ● ●l ●● ● 1 ●l ・ ● 種l ● ●・ s 種種 ● 軸 ●l 種 ●・ ●I ● ● 欄種種 ●・ ●・ ●IsI ● ● ●I ● ● 種種 ●・暴lls ●19nition
Coil Tester: 57001 -1 242
Hand Tester: 57001,983
Spark PlugWrench: 57001-1262

★lf the specific gravity is below l 。20(charge 60%)the battery needs t6

Battery
Electrolyte L.a/ ∂// ηSp θCr/0 η
●The electrolyte level should be between the upper and
the lower leve 目ines.

★lf the level of elcctrolyte in any cell is below the lower
/η/ ・tial Chargin9
level line, add only distillcd water to cell, until the level
is at the upperlevel Hne.
t WARNING i
匹蕪] oKeep the battery away from sparks and open flames
during chargin9, since the battery gives off an e χp10sive gas mi
χture of hydr09en and o χygen. When using a battery charger,connect the b

oOrdinary tap wateris not a substitute fordistilled
waterand will shorten the life of the battery.
procedure prevents
sparks at the battery termina1s which could ignite any
battery gases.
●Fill each cell to the upper leve 目ine on the battery case with fresh electrol
。280)at a temperature of 30
°C (86 °F)or less. Let the battery stand for about 30 mi
NOTE
olf the electrolyte level drops,add electrolyte to the
upper leveHine before chargjn9,
1.Upper Level Line 2.Lower Level Line
Electrolyte Specifi ・C GyW 哨// 叩; ・eC 如/1 ●Set the charging rate at l /1 0 the battery capacity, and
●Check battery condition by te5ting the specific gravity charge it for 10 hours.For e χample, if the battery is rated at 14 Ah, th
of the electrolyte in each cell with a hydrometer. 。4A.
oRead the level of the electrolyte on the floating scale.
HYdrometer
回亘]
01f the battery is not given a fuIl initial chargin9,itw 川
｀う
discharge in a few weeks.Afterthat it can not be
charged by supplement chargin9

・
ヰ
oDo not use a high rate battery charger,as is typically
employed at automotive service stationso unless the
chargerrate can be reduced to the level required.
Charging the battery at a rate higher than specified may
ruin the battery. Charging at a high rate causes excess

一心
heat which can warp the plates and cause interna §
shortin9. Higher-than ・normal chargin9 rates also cause the plates to shed active mate
・
01f the temperature of th6 electrolyte rises above 45 °C (115
°F)during chargin9,
「educe the chargin9 rate to lower the temperature,and incr
1.Read here.
一
一
Ordinary Chargin9
Alternator
陽而自
Removal
oKeep the battery away from sparks and open flames
during chargin9,since the battery gives off an explosive
gas mi χture of hydr09en and o χygen. When using a battery charger,connect the batterY to the charger before turnin9 0n the
NOTE
oAltemator removal is not necessary to remove the

charger. This procedure prevents
rectifier,regulator,and carbon brush assembly.They
sparks at the battery terminals which could ignite any
battery gases. can be removed often removing the altemator end
cover.
呂泗]
●Removethefollowing
・
Falrlngs
Altemator Lead Connector

oAIways remove the battery from the motorcycle for
Altemator Mounting Bolts
chargin9. 1f the battery is charged while still installed,
battery electrolyte may spill and corrode the frame or

otherparts of the motorcycle.
巨巨]
oDo not use a high rate battery charger,as is typically
employed at automotive service stations, 11nless the
chargerrate can be reduced to the level required.
Charging the battery at a rate higher than specified may
ruin the battery. Charging at a high rate causes excess
heat which can warp the plates and cause internal
shortin9, Higher-than-normal chargin9 rates also cause
the plates to shed active material.Deposits will accu ・
mulate,and can cause intemal shortin9.
01f the temperature of the electrolyte rises above 45 °C
(115 °F)during chargin9, 「educe the chargin9 rate to lower the temperature,and increase charging time proportionately.
A.Alternator B.Mounting Bolts
●Check the electrolyte level after charging ●Pull out the altemator.
・
Battery Charging Rate/Time Table (12V14Ah)
⊃ 二
1.28 -
1.24-
≧ヽ 1.20 一
驚匹
巴 1,16 -Qu
l.12 一
匹oぅ
石 1.08 ‘
忿 1.04- 1.00-
at l A Charge rate
at 2A Charge rate
￨
I I
「 1
l
1
i
1 1
I
1 1
I
1
I
1 1
I
1
I
1 1 1
I1
10
1 几 ①十
1 1
3
1
15
1 11 5
20 21
5 7 9 10.5
at 3A Charge rate ￨ l l 「￨ I I1 2
3 4 5 6 7
at 4A charge rate ￨￨￨￨￨1 2
3 4 5.3
Hours of Charging Time at Rates Shown

lnstallation
●Clean the alternator legs and crankcase where the alter-
nator is grounded.
●Apply a small amount of engine oil to the rubber
dampers and the O-ring

・
A.Brush Assembly C.Rectifier
B.Regulator D.Unsolder
●Remove the alternator coupling.
A 。0-ring C.Coupling Blades

B.Clean here.
●Apply non-permanent locking agent to the alternatD 「

mounting bolts,and tighten them to the specified
匹亘1
olf any resistance is felt when tightening the mounting
bolts,stop immediately, and check the alignment of
the coupling blades with the sIots in the rubberdamp-
ers.
A.Alternator Coupling B.Mounting Bolt
●Remove the stator housing ・
Disassembly

End Cover
Brush Assembly
Rectifier
Regulator
●Unsolder the wires on the rectifie
NOTE
014yyXe/1 ￡j
ηso/(y θΓ訥!7 泊e a/ ￡eyIxI
∂tor w// ・es to がle rectyfta ・
re/・x77yxla/. 必 yt9 託汝/3/. が/7yg/7 r 回りpeylltij/1 ヨs are
∂ρρ//∂d 117j ・ more 功 ∂刀ai￨/1yseco/7ds.' が7∂rect//7er1 (
がod ∂s /71∂yZ)ed ∂/71aged. A.Stator Housing B.Screws

●Press out the rotor shaft from the rotor housrng. ●Position the rotor bearing ring so that the projections
of it are aligned with the ring positioning groove.
1.Projections of Ring
2.Ring Groove
3.Rot9r Bearing
1.Rotor Shaft
●To remove the ball bearings, use a suitable puller. NOTE
oWhen s01dering the ajtemator wires to the rectifier
terminal.do it quickly, jf 削9h temperatures are appHed for more than a fe,w seconds,the
●Tighten the puHy nut to the specified torque(see E χ-
plodedView).
Stator Coi 川nspection

●Connect an ohmmeter ( χ1 Ω Γange)between the coil wires and read the mete
1.Rotor
2.Bearing Holder
3.Ball Bearing
yISS ∂j7?ゐ/1/
●Assembly is the reverse of disassembly.Note the fol-

10wing.
●When installing the rotor bearing, press the bearing and
bearing covers onto the rotor shaft.The bearing short
end from the bearing ring must face in.
★lf the meter does not read as specified,replace the

stator coil.
StatorCoil Resistance
Lessthan loOn
●Using the highest ohmmeter range,measure the resist-
ance between the statorcoil core and each of the coil
wlndlngs
・
★lf there j5 any reading at all, the stator coil winding has
1. Rotor Bearjng 2.Rotor a short and must be replaced.
Rotor CoiHnspection Carbon Brush L.ength
●Connect an ohmmeter(xI Ω Γange)between the slip rings and read●Measure

the meter.
the length of both carbon brushes that stick
out of the housing.
★lf either one is wom down to les5 than the service limit
replace it.
Carbon Brush Length(projected portion)

Standard: 10.5mm
Slip Ring
邸立
★lf the meter does not read as specifled, replace the
rotor.
RotorCoil Resistance
About4 Ω(ZX1000-BI)
About 6 Ω(ZX1000-B2 and latest models)
●Using the highest ohmmeter range, measure the resist-
ance between the rotor shaft and each of the slip rings
・
★lfthere is any reading at allJ the rotor coil has a short and must be replaced.
Rect 哺er lnspection
●Setanohmmeter to the l kn range.

●Check the resistance of the diode in both directions.
★lf any diode shows Iow or high resistance in both
Slip Ring Cleanjn9
directions,the diode is defective and the rectifier must
●Visually inspect the slip ring for dirt or pitting ・ be replaced.
★lf necessary, smooth the slip ring with N0. 300 - N0.
500 emery cloth.
NOTE
0777 ∂ ∂crij ∂/m ∂re/ ・read 加gy ∂ji ∂s w/ が?t 力 ∂/77 ∂ter ￡js∂d and
the indivjdual diode, but.generally speakjn9.the

Slip Ring Di ・
∂mea?/ ・
yower.reading should be from zero to half the scale.
★lf the measurement is less than the service limit, replace
the rotor.
Slip Ring Diameter

Standard: 14.4mm
呂亘] oThe test light should not go on at this time.

★lf the test light goes on, the regulatoris damaged and
must be replaced.
01f a megger ora meter with a large ・capacity battery is used,the rectifier will be damaged.
●Check the regulator internal resistance as shown.
Regulator lnspection
●Prepare testing tools ・

Test light: Bulb rated 12 V3.4W
Batteries: Tw0 12 Vbatteries
Test wires: Three au χiliary wires
製迎』
oThe test light works as an indicatorand a1so a current
limiter to protect the regulator from e χcessive current.
Do not use an ammeter instead of a test light.
●Connect the test light and the 12 Vbattery to the Regulator lnternal Resistance
regulator as shown,
Meter
Range ConnectionS
Meter(十)to Meter 卜)to Reading
X 100 Ω F E 170n
Xlk Ω E F 4kn
X 100 Ω IG E 800 n
Xlk Ω E IG 2kn
Xlk Ω F IG 2k Ω
/- X 100 Ω IG F 150 Ω
ぐ
Test Bulb 12 V3.4W
oThe test light should go on at this time. ★Meterreadings should be nearly values shown in the
table.lf the resistance is infinity (no reading)orO Ωj
the regulatoris damaged and must be replaced.
巨巨]
oDo not contact the regulator metal case with the wires
from the battery( 十)o 「(-)terminal during the test.
★lf the test light does not go on,the regulator is

AlternatOr TrOubleShOOting:
damaged and must be replaced.
For any charging system problems, always check the
●Connect the test light and tw0 12 Vbatteries to the
charging system wiring first (see Wiring lnspection),and
regulator as shown.
then check the system with the following tests shown in
the troubleshooting guide.
Troubleshooting Guide
Test
No. Trouble Symptoms ・
1 Battery djscharged Starter not tuming
2 Battery overcharged EleCtrolyte levellowering quiCkly
Test Bulb 12V3.4W 3 Noise Altemator noiSe

71ヲSr A10j-8attery Discharged ●Start the engine, and check the battery voltage with the
●Remove the nuts holding the alternator cover, and take englne runn 】ng
・
off the cover. ★lf the battery voltage is higherthan 13.5V,check the
●Check that the alternator leads and connectors are in following ・
good condition. oRegulator
★lf not, repair or replace the damaged parts ・ ★lf the battery voltage is lower than 13.5V,ch(jck the
●Replace the djscharged battery with a good battery following ・
・
●Check battery voltage with the engine running oCarbon brushes,Slip rings
・
★lfthe battery voltage is higher than 13.5V,the charging oRectifier
system 15 1n good condition. oStator coil
★lf the battery voltage 15 10wer than 13.5 V, check the oRotor coil
following.
●Ground the F terminal of the regulator to the chassis

with a au χiliary wire. Test jV0.2- ∂ ∂rt θりyQI/ ∂rC/7 ∂/17∂∂
●Check the regulator and/or rotor.

★Repair or replace the damaged parts.
Test jV0.3,Noise
●Check the bajl bearings, statorcoilJ and/or rectifier if
the alternator makes a noise.
★Repair or replace the damaged parts.
A.F Terminal
lgnition Switch
Altemator
[ 石] SI
回
Starter
Relay
Main Fuse
ま
W闘
30A
BB
+ -
Buttery
lgnition System
I WARN]NG I
oThe ignition system produces extremely high voltage ・

Do not touch the spark plugs, high tension coils,0 「
spark plug leads while the engine is runnin9, 0 「you could receive a
severe electrical shock.
巨呂
oDo not disconnect the battery leads or any other elec-
trical connections when the ignition switch is on, 0 「

A.Pickup CoiI
while the engine is runlnin9. This is to prevent lC
C.AirGap
B.Timing Rotor
igniter damage ・
ODo not install the battery backwards. The negative side
is 9roundedoThis is to prevent damage to the diodes

●Apply silicone sealant to the pickup coil grommet.
and lC igniter.
●Apply non-permanent locking agent to the two upper
left of pickup coil cover bolts.
Pickup Coij Removal

・
Fairings
Pickup Coil Lead Connector
Pickup Coil Cover
A.Bolts requiring locking agent
Pickup CoiHnspection
●Set the ohmmeter to the χ l k Ω Γange,and connect it to the pickup coil wires.
A.PiCkUpCOil B.Mounting Bolts

★lf there is more resistance than the specified value,the
coil has an open lead and must be replaced. Much less
than this resistance means the coil is shorted, and must
be replaced.
Pickup Coil Resistance

Pickup Coi 川nstaHation
400 - 490 Ω
●lnstall the pickup coil so that the air gap (clearance
between the timing rotor projection and the pickup
coil core)has correct clearance. ●Using the highe5t resistance range of the ohmmeter,
measure the resistance between the pickup coil leads
and chas15 ground.
★Any meter reading less than infinity ( ゜゜)indicates a short,necessitating replac
Pickup Coil AirGap
0.7mm assembly.
19nition Coij RemovalZlnstallation
●Remove the fuel tank.

①
●Disconnect the leads and remove the ignition coils.
1.1gnition Coil Tester: 57001-1242

A.lgnition Coils
2.1gnition Coil
●lnstall the ignition coil. Note the following

・
oConnect the primary winding leads to the ignition coil し些些j
terminals. oTo avoid extremely high voltage shocks, do not touch
Black Lead 4 to #1, 獅Coil the coil or lead.
Green Lead 4 to 礼#3 Coil
Red Leads 4 to both Cojls
★lf the distance reading is less than the specified value

the ignition coil or spark plug caps are defective.
19nition Coil Arcing Distance
6 mm or more
●To determine which part is defective,measure the
arcing distance again with the spark plug caps removed

from the ignition coil.
★lf the arcing distance is subnormal as before, the

trouble is with the ignition coil itself. げthe arcing distance is now no
is with the spark

plug caps ・
●lf the arcing tester is not available, the coil can be
checked fora broken or badly shorted winding with an

ohmmeter.
A. 井卜#4 COilB. C.Green Lead
毒2,#3 COil D.Black Lead

NOTE
c ゛An ohmmeter cannot detect layer shorts and shorts resulting from insulation breakdown under h
治11 voltage,
lgnition CoiHnspection
●Measure the primary winding resistance as follows.

NOTE
oConnect an ohmmeter between the coil terminals.
oThe most accurate test for determining the condition
0Set the meter to the χ 1 Ω Γange,and read the meter.
of the ignition coil is made by measurjng arcing dis ・
●Measure the secondary winding resistance as follows.0Connect an ohmmeter between th
tance wjth a ignition coij tester (specjal tool,yusing the
ご-needle method. Ω,and read the meter.

IC 19niter lnspection
●Set the ohmmeter to the x l k Ω Γange and make the measurements shown in the tabl
★lf the meter readings are not as specified, replace the lC

igniter.
呂泗]
oUse only Hand Tester 57001 ・983 for tbis test. A tester other than the Kawasaki Hand Tester m
叫 Show different readings
・
01f a me99er or a meter with a large ・capacity battery is used,the lC igniterwill be damaged.
1.Measure primary winding resistance Connector Terminal Number
2.Measure secondary winding resistance
3.1gnition Coil
●げthe meter does ・not read as specified, replace the coil.
19nition Coil Winding Resistance
Primary windings: 2.6-3.2n
Secondary windings: 13 - 17 kn
(k Ω)
Tester(十)Lead Connection
Termi-
nal No. 1 (X)
2 3 4 5 6
CX) C
Spark Plug Gap .E

＼ぬ o く) (g
φ.jM
●Measure the gap with a wire-type thickness gauge ・ 2 30- 70 30- 70 30-70 40- 100
18-30
★lf the gap is incorrect, carefully bend the side electrode
with a suitable tool to obtain the correct gap ・
J
一45 15-70
＼ 13-45 8.5-135- 9.5
Spark Plug Gap

｀て
コ3
3 13
OO CX ⊃
＼ OO ∞ ∞
4
＼
工l
0.7-0.8mm
5 35-150 40- 1508.5- 1335-150 18-35
＼
μ 1
6 2- 3.8 2.6-5 4- 6.5 2- 3.8 12-24

＼ (kn)
Tester(十)Lead Connection
TerminaI
Number 7 8 9 10
OO
』＼ ∞ ∞
8 ㎝) OO 35-70
1 9 ∞
＼ ∞ ∞
1.1nsulator
2.Center Electrode
710
＼
j
3.PlugGap (X3 28-60 ∞
4.Side Electrode
＼
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.[ ︰)UO!1!USI 'X
Oapu!1/b# ‘[#
。joJ]=()
u!d︲g '0Z; AF141]91JnS.6[1F]1!MS 91!MS UO!1!US
一 'E( jOIｙ
(一
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﹂ ‘9
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一)応c コー.ｙ
punS ap!S '8[ j04qauuo']U!d
︲6.t[ =o︰)ajQ ￡. 寸
AJOUI?8. 卜[ JopauuoE]cEIo[.0[ JopauuoD u!dt 'E
むつ○一().Q[ 屁コー一
'ljEdS.Q(qpU!l/&qE#t#lOJ)￨!OD UO!1!Uj
SoIpa
'u8uo')U!d
︲9. り
くOE asnj u!RW 'g[
﹂S 一品一い)一.[
jH
〉・
人
)18/9
A/) 一Ｓ
⑤
IC lgniter Troublesh00tin9:
Beginning
lnspect lC igniter
and pjckup coils.
' Do above へinspections
prove NO
Replace damaged
that lC igniter and
part,
pickup coils are
K good? ノ
Yes
Does engine still NO
operate poorly?
Replace lC
igniter.
Yes
Replace part
which is not replaced
NO Does engine still above step.
operate poorly?
Yes
Does engine still NO
Replace pickup operate p00 「ly?
coils.
Yes
NO Does engine still

operate poorly?
Yes
Trouble may be caused
by other ignition system
parts or engine itself.
End
・・寸・ ● 暉
Electric Starter System
Starter Motor Removal

chapter),
●Remove the foHowing.
Engine Oil (Drain)
E χtemal Shift Mechanism Cover

Starter Motor Cable
●Remove the starter motor mounting bolts and pull out

the starter motor.
A.Clean here.
匹亘]
●Apply a small amount of engine oii to the O-ring.
oDo not tap the starter motor shaft or body. Tappin9
0n the shaft or body could damage the motor.
A.0-ring
Starter Motor lnsta μation
●lnstallation is the reverse of removal. Note the follow-
lng ・ Disassembly
●Clean the starter motor legs and crankcase where the ●Remove the both end covers and puIl the armature out
starter motor is grounded.
ofthe yoke.
A.Clean here. A.End Covers B.BOltS

●Remove the brush plate.
A.Toothed Washer B.011 Seal
●Fit the tongue on the brush plate into the end cover
A.Brush Plate gr00ve.
●Remove the nut and remove the terminal b01t,and

then remove the brush with the plastic holder.
な濁﹂
B.Groove
A.Tongue
1.Nut
2.Washer ●Align the mark on the end cover with the terminal
φじ印い
ほ﹂
丿- ︱
り
3.Large Washer bolt.

ほ
t4
り
︱tX
4.SmaHWasher
5.Terminal Bolt
6.Plastic Holder
Assembly
●Assembly is the reverse of removal.Note the fol

lowing.
●Apply a thin coat of grease to the oil seal.
●Fit the toothed washer to the end cover. A.Mark B.Terminal Bolt
8rush lnspectjon Commutator Diameter

●Measure the length of each brush.
Standard: 28 mm
★lf any is wom down to the service limit, replace all
Service Limit: 27 mm
brushes.
Starter Motor Brush Length
Standard: 12 mm
Commutator Cleaning and lnspection
●Smooth the commutator surface if necessary with fine
emery cIoth,and clean out the grooves as HIustrated.
Armature lnspection
●Using the χ 1 Ωohmmeter range,measure the resistance between anytwo commut
・
★lf there is a high resistance or no reading ( “))between any two segments, a
and the starter

motor must be replaced.
1.Commutator 2.Emery Cloth
●Measure the diameter of the commutator.
★Replace the starter motor with a new one if the com

mutator diameter is iess than the service limit.
1.Segment 2.Shaft
●Using the highest ohmmeter range, measure the re-
sistance between the commutator and the shaft.
1.Commutator Segment 3. Shaft ★lf there is any reading at all, the armature has a short
2.Diameter and the starter motor must be replaced.

NOTE ★lf the meter does not read as specified,check the

terminal bolt insulations.
oEven if the fore901ng checks show the armature to be
☆lf the terminal bolt insulations are not defective,re-

900d パt may be defective jn some manner not readily detectable wjth an ohmmeter. lf a11 0ther starter motor and starter motor circuit components check good.but the starter motor st
place the brush plate.
川does not tum over or only tums over weakly, replace the starter motor with
∂r7 θy1/ 0/7e.
Starter Relay lnspection
●Remove the starter relay;

●Connect the ohmmeter and 12 Vbattery to the starter
relay as shown ・
★lf the relay does not work as specified バhe relay is defective.Replace the rela
/V'egative Brush and t.ead Assembly lnspection
・
●Using the χ l n ohmmeter range,measure the resistance as follows.
oBetween the brush and brush plate.
oBetween the brush hc)￨&r and brush plate. Testing Relay
MeterRange: xI Ω Γange
Criteria: When battery is connected 々O ΩWhen battery
is disconnected 々cg
BK/Y
8rush Plate lnspection
●Measure the resistance as follows.
Meter
Range Connections MeterReading
OO
A Xlk Ω Termjnal BoltらBrush Plate
B XI Ω Terminal BOltらPositive Brush On
(X) 1.Tester 2]2VBattery
C Xlkn Positive Brush
ぉNegative Brush
Ajanl?9. 心[
VOE asnj u!E1yN ' 寸[
AElal!jJalJnS.m[
j010wJMJns.n
q91!MS lltJlnaZ.t[
qr]4!MS lno¥)ol JaljnS.oD
Ξ)
o ぢQDco ︰)U!d ︲X '6
一一DJ (
﹂o ぢQc こo い)c 一a
︲o ﹁.8 AEIQj l!
コu ﹂一︰)jaljnS '1 X09 U
ー.9 J0190UU
〇一応c コ
〇︰)U!d ︲6.5; uonng jalJnS.
人/18
寸 tpl!MS
d()IS au!gu3. 哨
﹂〇ぢQ ⊂ に〇︰)U!d ︲9 'X qr)1!MS u(
ヨ
酒一ニぷ
曲
不
Head 向ht Bujb Replacement Λ10tes

Headlight
呂回
l ● ●S ● ● 寧 ● ● ● ● ● ● 聊l
jysd 匈力r ∂sx77 声yo/'迂叩胞/j4 涛as ￡m 印t

oWhen handling the quartz-ha109en bulbs, never touch
●Turn the adjuster on the headlight in or out until the
the glass portion with bare hands.AIways use a clean
beam points 5traight ahead. .
cIoth.011 contamination from hands or dirty rags can
reduce bulb life or cause the bulb to explode.
●Fit the dust coveronto the bulb firmly as shown in the

Headlight 8eam Verticaj Adjustment
figure.
●Tum the adjuster on the headlight in or out to adju5t
the headlight vertically.
GOOd Bad
DustCover 2.BUlb
●After installation, adjust the headlight aim,
1. Horizontal Adjuster 3,Phillips Screwdriver

2.Vertical Adjuster
NOTE
oOn high beam,the brightest pojnt should be slightly
be10w horizontal with the motorcycle on jts wheels and
the rider seated.Adjust the head 向ht to the proper angle accordjng t0 10ca
けegujations.
Headlight Circuit lnspection
The US and Canadian models contain a relay in the
headlight circuit.ln these models, the headlight does
not go on when thc ignition 5witch is first turned on, but
the headlight goeS on once the starter button is pushed
to start the engine, and stays on until the ignition switch
is tumed off.But the headlight goes out whenever the
starter button is pushed to restart the engjne after engine
stalling
・
仏①
VOE asnj u!1?W.a
﹂o ぢQcco い)U!d
︲6 '91
91!MS JqEE 一().g1
jopauuoD u!d'8. 寸﹁
﹂oぢQ ⊂co い)U!d
︲O[.m[
AjaUI?8.X[
l@!1Joll!]!pul ujEag tエ
l4S1
!
1@!lpEaH '()[
名o 一
︻︼.6 VO[asnj
l@!IIQ 工.8
/Q?F]1j l﹃
@﹄!
留I 工 ‘f
Mlaj l!n9﹂!Djc)ljnS.9 x09 uo!punf.5;
J04Dauuo')U!dt. 寸
AElall JaljnS.E
joE)auu()D U︲
!9d.X;
qr)1!MS uo!1!uS1 4
S 匍 ● ● ● 籾種 ●丿籾籾 ●・・噛聊 ● ● ・
Fuel Pump lnternal Resistance

FuelPump
Tester(十)Lead ConneCtion
R BK Y
The pump operates when the starter button is pushed CX
on or the englne ls runnlng
When fuel leve
・
叙
卜n the float chamber is Iow, the fuelpump operates to supply fue
卜 ⊃ ∞
目nto the float chamber.

BK ∞ ∞
When the fuel reaches a certain level, the fuel pressure
ド
上M
R
卜
＼
rises,and fuel pump stop ・
Y ∞ MOrethan 20k
Ω
RemovalZlnstallatjon
●Refer to the fuel system chapter
lnspection
lnternal Resistance
●Set the ohmmetertothexl k Ω Γange and make the measurements shown in the table.
★lf the meter readings are not as specified, replace the

fuel pump ・
1.1gnition Coil
FuelPump
-
一
Start Button
Engine Stop Switch
一234
5.1gnition Switch
6.Starter Relay
7.Main Fuse 30A
8.Battery
9.6-pin Connector
・・ ● ・個雪 ● ・ ● ・細細働 ● ● 糎 ●
CheGk forProper Operation
●Remove the fuel pump with fuel filter. Cooling Fan System
●Prepare a container f 川ed with kerosene.
●Prepare the rubber hoses, and connect them to the
/゜
∂/7S μ ￡
∂β7C かC ぴyr /jり Sp ∂ctyQj ワ
pump fittings.
●Disconnect the c0011ng fan switch leads from the
きConnect the suitable pressure gauge to the oulet,hose
cooling fan switch (BL/BK and BL/W wires)
as shown. ・
●Using an auxiliary wire, connect the cooling fan switch
leads.
★lf the fan turns, inspect the following.
Switches(Fan Switch)
★lf the fan does not turn, inspect the following,
Wires and Connectors

Junction Box Parts(Fan Relay and Fan Fuse)
Main Fuse
Fan
Fan lnspection
●Disconnect the 2-pin connector in the fan leads.

●Using two auxiliary wires, supply battery power to the
fan. .
★lf the fan does not turn at this time, the fan is defective
and must be replaced.
1.FuelPump
y｀ゞ9ロハTy
2.Pressure Gauge
3.0utlet Hose
4.1nlet Hose
5.Fuel Filter
6.Kerosene
ヴル﹂
K
7.4-pin Connector
8.Battery
④
↓j
1.Junction Bo χ2,Fan 5.Starter Relay
●Prepare the 4-pin connector with wires, and connect it Fuse 10A 6.Main Fuse 30A
into the pump wire connector. 3. Cooling Fan 7.Battery
●Connect the battery +wire to the Red and Yellow 4.Fan Switch 8.8 ・pin Connector
wires,then battery 一 wire to the Biack/Yellow wire at the pump connector
・ Fan Switch lnspectjon

★lf the pump does not operate, the pump is defective
・ ●Using an ohmmeter measure the intemal resistance of
●C105e the outlet hose while operating the fuel pump
・ the sensor across the terminal and the body at the
●When the pump is stopped, read the pressure gauge
・ temperatures shown in the table.
★lf the pressure gauge reading out of the specified pressure,the pu'mp is defective.
★lf the ohmmeter does not show the specified values,
replace the sensor.
Fan Switch Connections
oRising temperature: From OFF to ON

at96-100 °C(205 - 212 °F) oFalling
temperature: From ON to OFF

Fuel Pump Pressure
at 91 - 950C (196 - 203 °F) ON
: Less than 0.5 Ω
(0.11 - 0.16 kg/cm2, 1.6-2.3 psi) OFF : Morethan lM Ω
A.Meter Mounting Bolts
Speedometer Cable
Wiring Connectors
1.Fan Switch
●Suspend the switch in a container of coolant so that
the temperature-sensing prx 〕jection and threaded portion aresubmerged.
●Su5pend an accurate thermometer in the water.
NOTE
oThe switch and thermometer must not touch the
container sides or bottom.
A.Wiring Connectors
●Place the containerover'a sourceof heat and gradually
raise the temperature of the water while stirring the
water gently
・
匹亘1
oPlace the meteror gauge so that the face is up,lf a
meter or gauge is left upside down or sideways for any
length of time it will malfunction.
S ● ● ●・鎚丿馨・ ●
Meters,Gauges
7｀achometer Remova!
●Remove the following 711c/70 β?e 抱r //7Sp θc が○/7

・
Wideshild
●Check the tachometer ciruit wiring
・
lnner Fairing
★lf all wiring, main fuse, ignition coil check out goodJ
Meter Mounting Bolts
the unit is defective.
白①ふ立
1.1gnition Switch
2.4-pin Connector
3.Tachometer
4.9-pin Connector
5. 1gnition Coil ( 毒1,#4)6.Spark Plug
7.Starter Relay
8,Main Fuse 30A
9.Battery
○/
/①
Fuel Gauge Operation lnspection
●Prepare an auxiliary wire, and check the operation of /

the gauge.
Fuel Gauge Operation Check
19nition Switch Position: ON 。

ノ
Wire Location: Female 2-pin sensor connector
(disconnected)
Results: Gauge shouldread E when connector wires

上丿1
ブ ∧ 二
are opened.
Gauge should read F when connectorwires
wiresareshorted. ①
★lf the gauge readings are correct,the fue 川evel sensor is bad.lf these readings are not obtained, the
trouble is
with the gauge and/or wiring

・
●Check the fuel gauge circuit wiring (see Wiring ln-
ぐなに二回白
5pection).
★lf all wiring and components other than the fuel gauge
unit check out good the gauge is defecrtive.
●Measure the resistance of the fue 目evel sen50r with an ohmmeter.
★lf the ohmmeter does not show the specified values, 0 「

the readings do not change smoothly a5 the float moves
Fuel Level Sensor lnspection up and down, replace the sensor.
●Check that the float moves up and down smoothly

Fuel Level SensorResistance
without binding.lt should go down under its own
weight. Full Position:

4-10 Ω
★lf the float does not move smoothly, replace the sensor. Empty Position: 90 - 100 Ω
●lnspect the leads and 2-pin connector.

★lf they show any signs of damage, replace the sensor
1.Fuel Level Sensor 6.6-pin Connector
2.9-pin Connector 7.Starter Relay

3. Fuel Gauge 8.Main Fuse 30A
4.4-pin Connector 9.Battery

5.1gnition Switch
Water Temperature Gauge Oper ∂tjon lnspection
●Prepare an auxiliary wire,and check the operation of the gauge. 回巨]

oDo not 9round the wirin9 10nger than necessary. After
the needle swings to the H position, stop the test.
Otherwise the gauge could be damaged.
Gauge Operation Test
lgnition Switch Position: ON

★lf these readings are not correct, the trouble is with the
Wire Location: Female.SensorConnec 竃o
「
gauge and/or wiring
・
{disconnected} ●Check the water temperature gauge circuit wiring (see
Results: Gauge should read C when sensorwire is Wiring lnspection).
opened. ●lf all wiring and components other than the water tem-
Gauge should read H when connectorwire perature gauge unit check out goodJ the gauge is defec-
wireis9 「ounded to engine 。 tive.

① 心
居
1.1gnition Switch 6. StarterRelay

2.9-pin Connector 7.Main Fuse 30A
3.Water Temperature Gauge 8.Battery
4.4-pin Connector
5.Water Temperature Sensor
Water Temperature Sensor lnspection
●Suspend the sensor in a container of water so that the
temperature sensing projection and threaded portion
are submerged.
●Using an ohmmeter, measure the internal resistance of
the sensor across the terminal and the body at the tem-
peratures shown in the table.
1.Water Temperature Sensor 2. Thermometer

★lf the ohmmeter does not show the specified values, Fuse lnspection
replace the sensor.
●lnspect the fuse element.
★lf it is blown out, 「eplace the fuse.Before replacXng a blown fuse, always check the am
rating, check the wiring and related components

NOTE
for a short circuit. ・
0777 ∂sextso/' ∂/7d t/? θΓmost ∂tm ￡yst ηor to ￡yc/? が?∂cQ η-
tainer sides or bottom.
巨弓]
oWhen replacing a fuse,be sure the new fuse matches
the specified fuse rating for that circuito lnstallation of
a fuse with a higher rating may cause damage to wiring
and components.
Junction Bo χ
s 幽慟●・・ ● 鯵● 軸●●●llls ●l・晦●●s ●●●幽●・幽晦●●● l 欄機種●● 幽● 幽幽幽● ●幽・ s ・寸 ● l ●・ ●● 香・罪障 ●● ●● ●● ●● ●機●● ● l
The junction bo χ has fuses, relays and diodes.Therelays and diodes can not be removed.
Fuse Removal
●Unlock the hook to l げt up the lockingarm

・ 1.Housing 3.Terminals
●Pull the fuses straight out of the junction box with
2.Fuse' 4.B10wn Element
needle nose pliers.
Fuse lnst ∂11ation
★lf a fuse fails during operation, inspect the electrical Junction Bo χ Fuse Circuit lnspecti ・on
system to determine the cause, and then replace it with ●Remove thejunction bo χ from the motorcycle.
a new fuse of proper amperage. ●Pull off the connectors from the junction bo χ.
●Make 5ure all connector terminals are clean and tight,
and none of them have been bent.
★Clean the dirty terminals and, straighten slightly ・bent terminals.
●Check conductivity of the numbered terminals with
hand tester.
★lf the meter does not read as specified,replace the
junction bo χ.
Fuse Circuit lnspection
Meter ConneCtion Meter Reading ( Ω)

1-2 0
1-3A 0
6-7 0
6-17 0
1-7 ○○
3A-8 ∞
AJunction Box C.Lavel
8-17 (X3
B.Fuse Cover D.Main Fuse
SX ∂/・￡e/・.Circuit and Diode Circuit lnspection
Headlight Relay lnspection ●Remove the junction bo χ from the motorcycle.
●Remove the junction bo χ from the motorcycle. ●Pull off the connectors from the junction bo χ.
●Check conductivity of the following numbered ter ・ ●Check condLjctivity of the following pair of terminals.
minals by connecting an ohmmeter and one 12V
battery to the junction box as shown.
★lf the relay does not work as specified,rlplace the
lunctlon bo χ.
Terminals for Diode Circuit lnspection
Relay Circuit lnspection (with the battery disconnected) ゛13 ・8, ゛13-9,12-14,15-14,16-14
Meter Connection Meter Reading Ω

( )
゛US,Canadian Models only
Headlight ∞
Relay *7-8* フー13 ∞
Starter ∞
Relay 11 - 1312-13 ∞
★The resistance should be low in one directjon and more

than ten times as much in the other direction.lf any
diode shows low or high in both directions, the diode is
Relay Circuit lnspection (with the batterY connected) defective and the diode assembly must be replaced.
Meter
Connection BatteryConnection
MeterReading
+ - (
Ω)
Headlight *7-8 *9-13 0
NOTE
Starter 11 - 13 11 - 12 0
oThe actual meter reading varies wjth the meter used
and the indjvidual diode, but,generally speakin9,the

*US,Canadian Models only
lower readjng shoujd be from zero to one h ∂lf the scale.
Junction Box lnternal Circuit
ｙコ山く〇[ 一司に[
- 卜てづ廿︰
asnj V
゛“S ●
「
---- ︲I- ︲︱︲︱-IS ■I
〇[XQQ工
なI
ｖy一竺ぎ一﹃﹄
回工
かIII トO
・・- for US,Canadian models

9-Pin Connector 8-Pin Connector
APPENDIX 16,1
AppendiX
Table of Contents
Additional Considerations 16,2

Carbu 16-2
16-2
Spark PI 16-2
Troubleshooting G 16-4
16-8
16-8
Nut,Bolt,and Fastener 16-8
Tightness l 16-8
16-9
16・2 APPENDIX
When a plug of the correct heat ・range is being used,the electrodes will stay h
Additional Considerations for Racin9 the
carbon burned off,but co01 enough to keep from
damaging the engine and the plug itself.This tem-
This motorcycle has been manufactuI ・ed foruse ina reasonable perature
and prudent mannerand
is about as a
400 -8000C(750-1,4500F)and can
vehicle only. be judged by noting the condition and colorof the
However,some may wish to subject this motorcycle to ceramic insulator al-ound the center electrode.lf the
abnormal operation, such as would be e χperjenced underracing conditions.KAWASAKI STRONGLY
and of RECOM-MENDS THATcoIor,
ALL RIDERS RIDEisSAFELY ANDOBEY
ceramic is clean a light bl-own the plug
operating at the right temperature 。
A spark plug for higher opel ‘ating temperatures jsused fol
ALL LAWS AND REGULAT10NS CONCERN- ・racing, Such a plug is designed for bettercooling efficiency so that it will not
ING THEIR MOTORCYCLE AND ITS OPERAT10N 。
Racing should be done under supervised conditions, “colder"plug. lf a spark plug with toohjgh a heat range is used -that i
and recognized sanctioning bodies should be contacted ‘Icold" plug thatcools iteself too well - th
forfurther details.For those who desire to participate stay too c001 to
in competitive racing or related use,the following burn off the carbon, and the carbon will coIlect on the
technjcal information may prove useful. However, electrodes and the ceramic insulator 。
please note the following important points. The carbon on the electrodes conducts electricity,
●Youaree りtirely responsible fortheuseofyourmotor- cycle under abnormal and
conditions such
theascenter
rac,ing, and Kawasaki shall
by not be liable for any damages which might ari
can short electrode to ground either
coating the ceramic insulator or bridging across the gap ・Such
a short will prevent an effective spark.Carbon

build-up on the plug can also cause other troubles.lt
●Kawasaki's Limited Motorcycle Warranty and Limited
can heat up red-hot 4ndcausepreignition and knocking,
E りlission Contr01 Systems Warranty specifically e χ- which may eventually bum a hole in the top of the
clude motorcycles which are used in competitive or piston.
related uses. Please read the warranty carefully.
●Motorcycle racing is a very sophisticated sport, subject
to many variables. The following information is
theoretical only, and Kawasaki shall not be liable for Spark Plu9
any damages which might arise from alterations utili-
zing this information.
●When the motorcycle is operated on public roads, it
must be in its original state in order to ensure safety
and compliance with applicable regulations.
Carburetor:
Sometimes an alteratjon may be desirable for im-

proved performance under speciaj conditions when
proper mixture is not obtained after the carburetorhas
been properly adjusted, and all parts cleaned and found
to be functioning properly 。
lf the engine still e χhibits symptoms of overly leancarburetion afterall maintenance and adjustments arecorrectly perf()rmed, the main jet can be replaced with as
smaller numbered jet gives a

leaner mi χture and a larger numbered jet a richer mi χ-ture.
Spark PlUg:
The spark plug ignites the fuel/air mixture in the

combustion chamber.To do this effectively and at the
proper time, the correct spark plug must be used,and 1.Termina1 4.Gasket
the spark plug must be kept clean and adjusted. 2.1nsulator 5.Center electrode
Test have shown the plug listed in the “ElectrjcalSystem" chapter to be the best plug
3.Cement 6.Side electrode
for general use.

Since spark plug requjrements(;hange with the igni-
tion and carburetjon adjustments and with riding condi-
tions,whether ornot a spark plug of a correct heat range Spark Plu9 1nspection
is used should be determined by removing and inspect- ●Remove the spark plug and inspect the ceramic insu-
ing the plug lator.
・
APPENDIX 16-3
Spark Plug Condition
Carbon fouling Oil fouling Normaloperation Overheating
★Whether or not the rjght temperature plug is being used NOTE
can be ascertained by noting the condition of the

o 乃 ∂ 力e ∂t ra η 叩of 功esp ∂ 戌 ρ/ ￡jg たj ηc が0 ηs/ 欣e ∂
ceramic insuiator around the electrode.A light brown
thermostat for the engine. ぴs//1!7 がJ ∂wroxI!7 り/ ρ ∂of spark plug can
coIor indicates the correct plug is being used.lf the
make the engine run too hot fresultin9
ceramic is white,the plug is operating at too high a

わ ∂,l が,7e ぬj77a 叩yQrtoo co/ ∂ 佃/ 功poorp ∂ がor,77 ∂,Ic ∂.
temperature and it should be replaced with the ne χt m ・
・｀sfirin9.and stalling}.
colder type,
回呂
01f the spark plug is replaced with a type otherthan the
standard plu9,make certain the replacement plug has
the same thread pitch and reach{length of threaded
portion}and the same insulatortype{{egulartype or
projected type}as the sUndard plu9.
01f the plu9 reach is too short,carbon will build up on
the plug hole threads in the cylinderhead,causing over ・
heating and making it very difficult to insert the
correct spark plug later.
01f the reach is too long, carbon will build up on the ex-
posed spark plug threads causin9 0verheating,
preigniton,and possjbly burning a hole in the piston
top. ln addition,it may be impossible to remove the
plug withoul damaging the cylinderhead.
Plug Reach
T00 short Correctreach
Carbon
builds up here
Standard Spark Plug Threads
Diameter: 10 mm
Pitch: 1.25 mm
Reach: 12.7mm
16-4 APPENDIX
Compression Low:
Troubleshooting Guide Spark plug loose
Cylinder head not sufficiently tightened down

Novalve clearance
NOTE
Cylinder, piston wom
oThis is not an exhaustive ljst. 9Mng every possible Piston ring bad (worn,weak,broken,or sticking)
cause for each problem listed,lt js meant simply as a Piston ring/land clearance e χcessive
rough guide to assist the troubleshooting for some of Cylinder head gasket damaged
the more common difficultjes. Cylinder head warped
Valve spring broken or weak

Valve not seating properly (valve bent, wom, 0 「
Engine DOeSn ″t Start,Starting DiffiCUlty: carbon accumulation on the seating surface 」
Startermotornotrotating:
Starter lockout or neutral switch trouble
Starter motor trouble POOrRUnning at LOW Speed:
Battery v01tage low Spark weak:
Relays not contacting oroperating Battery voltage low
Starter button not contacting Spark plug dirty, broken, or maladjusted
Wiring open orshorted Spark plug cap or high tension wiring trouble
lgnition switch trouble Spark Plug cap shorted or not in good contact
Engine 5top switch trouble Spark plug incorrect

Fuse blown IC igniter trouble
Startermotorrotating but engine doesn ″t turn over: Pickup

Startermotor clutch trouble coil trouble
lgnition coil trouble
Engine won ″t turn over: Fuel/air mi χture incorrect:

Valve seizure Pilot screw maladjusted
Rockerarm seizure Pilotjet,or air passage clogged
Cylinder, piston seizure Air bleed pipe bleed holes clogged
Crankshaft seizure Pilot passage clogged
Connecting rod small end seizure Air cleaner clogged, poorly sealed, or missing
Connecting rod big end seizure Starter plunger stuck open
Transmlsslon gear or bearlng selzure Fuel level jn carburetor float bowl too high or too
Camshaft seizure Iow
Alternator shaft bearing seizure Fuel tank air vent obstructed
Balancer bearing seizure Carburetor holder loose
No fuel flow: Air cleaner duct loose
Fuel pump trouble Compression low:

Fuel tank air vent obstructed Spark plugloose
Fuel filter cIogged Cylinder head not sufficiently tightened down
Fuel tap c10gged No valve clearance
Fuel line clogged Cylinder,piston wom
Float valve clogged Piston ring bad (worn,weak, broken, 0r sticking)
Engine flooded: Pistonring/land clearance e χcessive
Fuel level in carburetorfloat bowl too high Cylinder head warped
Float valve wom or stuck open Cylinder head gasket damaged
Starting technique faulty Valve spring broken or weak
(When flooded, crank the engine with the throttie Valve not seating properly (valve bent, worn, 0 「
fully open to allow more air toreach the carbon accumulation on the seating surface 」
engine.) Other:
No spark; spark weak: IC igniter trouble
Battery voltage low Carburetors not synchronizing

Spark plug dirty, broken, or maladjusted Vacuum piston doesn't slide smoothly
Spark plug cap orhigh tension wiring trouble Engjne oil viscosity too high
Spark plug cap not in good contact Drive train trouble
Spark plug incorrect Brake dragging
IC igniter trouble Ajr suction valve trouble
Neutral,starter lockout,0r side stand switch Vacuum switch valve trouble

trouble
Pickup cojl trouble
lgnition coil trouble Poor Runnin9 0r No Power at High Speed:

jgnition or engjne stop switch shorted Firing incorrect:
Wiring shorted or open Spark plug dirty, broken, or maladjusted
Fuse blown Spark plug cap shorted or not in good contact
APPENDIX 16-5
Spark plug incorrect Engine load faulty:
lC igniter trouble Clutch slipping
Pickup coil trouble Engine oil level too high
lgnition coil trouble Engine oij viscosity too high
Fuel/air mixture incorrect: Drive train trouble
Starter plunger stuck open Brake dragging
Main iet clogged orwrong size Lubrication inadequate:
Jet needle or needle jet worn Engine oil level too low
Airjet clogged Engine oil poorquality orincorrect
Fuel level in carburetorfloat bowl too high or too Gauge incorrect:
low Water temperature gauge broken
Bleed holes of airbleed pipe orneedle jet clogged Water temperature sensor broken
Aircleaner cIogged, poorly sealedJ or missing Coolant incorrect:
Air cleaner duct poorly sealed Coolant level too low
Water of foreign matter in fuel Coolant deteriorated
Carburetor holder loose Cooling system component incorrect:
Fuel tank air vent obstructed RadiatorcIogged
Fuel tap cIogged Thermostat trouble
Fuel line cIogged Radiator cap trouble
Fuel pump trouble Thermostatic fan switch trouble
Compression low: Fan relay trouble
Spark plug joose Fan motor broken
Cylinder head not sufficiently tightened down Fan blade damaged
No valve clearance Waterpump notturning
Cylinder, piston worn Water pump impeller damaged
Piston ring bad (wom,weak,broken, 0r sticking)

Piston ring/land clearance e χcessive
OVerCOOling:
Cylinder head gasket damaged
Cylinder head warped Gaugeincorrect:
Valve spring broken orweak Watertemperature gauge broken
Valve not seating properly (valve bent,worn,o 「 Watertemperature sensor broken
carbon accumulation on the seating surface. 」 C0011ng system component incorrect:
Thermostatic fan switch trouble

Knocking:
Carbon built up in combustion chamber Thermostat trouble
Fuel poor quality orincorrect

Spark plug incorrect
Clutch OperatiOn Faulty:
lC igniter trouble
Clutch slipping:
Miscellaneous:
Friction plate wom or warped
Throttle valve won't fuIly open
Steel plate wom or warped
Vaccum piston doesn't sli(le smoothly
Clutch spring broken or weak
Brake dragging
Clutchrelease mechanism trouble
Clutch siipping
Clutch hub or housing unevenly wom
Overheating
Clutch not disengaging properly:
Engine oH level too high
Clutch plate warped or t00 rough
Engine oij visc()sity too high
Clutch spring tension uneven
Drive train trouble
Engine oil deteriorated
Air suction valve trouble
Engine oil viscosity too high
Vacuum switch valve trouble
Engine oi 川evel too high
Clutch housing frozen on drive 5haft

OVerheating:
Clutch release mechanism trouble
FIrmg mcorrect:
Clutch hub locknut loose
Spark plug dirty, broken, or maladjusted
Air in the clutch fluid line
Clutch fluid leak
IC ignitertrouble
Clutch fluid deteriorated
Fuel/air mi χture incorrect:
Primary or secondary cup damaged
Main jet clogged or wrong size
Master cylinder scratched inside
Fue 目evel in carburetor float bowl too low Carburetorholder loose
Air cleanerpoorly sealed, 0r missing Gear Shifting Faulty:

Air cleaner duct poorly sealed Doesn't 90 1nt0 9ear; shift pedal does't retum:
Air cleaner clogged Clutch not disengaging
Fuel pump trouble Shift fork bent or seized
Compression high: Gearstuck on the shaft
Carbon built up in combustion chamber
16-6 APPENDIX
Gear positioning lever binding Clutch housing/friction plate clearance e χcessive Clutch housing
Neutral positioning lever binding gearworn
Shift return spring weak or broken Transmission noise:
Shift return spring pin loose Bearingswom
Shift mechanism arm 5pring broken Transmission gearS wom or chipped
Shift mechanism arm broken Metal chips jammed in gearteeth
Shift pawl broken Engine oil insufficient
Jumps out of gear: Drive chain noise:
Shift fork worrl Drive chain adjusted improperly
Gear groove wom Chain worn
Gear dogs and/ordog holes worn Rear and/or engine sprocketworn
Shift drum groove wom Chain lubrication insufficient
Gearpositioning lever spring weak or broken Rear wheel misaligned
Shjft fork pin worn
Drive ‘shaftJ output shaft, and/or gearsplines wom Overshifts:
AbnOrmal Frame NOiSe:

Gearpositioning lever spring weak or broken
Front fork noise:
Shift mechanism arm spring broken
Oi 卜nsufficient or too thin
Spring weak or broken
Rearshock absorber noise:
AbnOrmal Engine NOiSe:
Shock absorber damaged
Knockin9:
Disc brake noise:
IC igniter trouble
Pad installed incorrectly
Carbon built up in combustion chamber
Pad surface glazed
Fuel poor quality or incorrect
Disc warped
Caliper trouble
Overheating
Othernoise:
Piston slap:
Bracket,nut,bolt,etc.not properly mounted or
Cylinder/piston clearance e χcessive
tightened
Cylinder, piston wom
Connecting rod bent
Piston pin,piston holes worn
Oil PreSSUre Warning Light GOeS On:
Valve noise:
Valve clearance incorrect Engine oil pump damaged
Valve spring broken or weak Engine oil screen clogged
Camshaft bearing worn Engine oil level too low
Othernoise: Engine oil viscosity too low
Connecting rod small end clearance e χcessive Camshaft bearings worn
Connecting rod big end clearance e χcessive Cran kshaft bearings wom
Piston ring wom, broken orstuck Oil pres5ure switch damaged
Piston seizure,damage Wiring damaged
Cylinder head gasket leaking Relief valve stuck open
E χhaust pipe leaking at cylinderhead connection Crankshaft runout e O-「ing at the oil pipe in the crankcase damaged
χcessive
Engine mounts loose
Cran kshaft bearing worn E χhaUSt SmOkeS E χCeSSiVely:
Primary gear worn or chipped White smoke:
Camshaft chain tensioner trouble Plston 011 「lng worn
Camshaft chain, sprocket, gujde wom Cylinderworn
Air suction valve damaged Valve oil seal damaged
Vacuum 5witch valve damaged Valve guide worn
Balancergear wom or chipped Engine oil level too high
Balancer shaft position maladjusted Black smoke:
Balancer bearing wom Air cleaner clogged
Balancer or alternator shaft coupling rubber Main jet too large or fallen off
damper damaged Starter plunger stuck open
Altematorshaft chain tensioner trouble Fuel level in carburetor float bowl too high
Altematorshaft chain, sprocket, guide worn Brown smoke:
Main jet too small
Fuel level in carburetor float bowl too low
Abnormal Drive Train NOise:
Air cleaner duct loose
Clutch noise: Air cleaner poorly sealed or missing
Weak or damaged rubber damper
APPENDIX 16-7
Handling and/OrStability UnSatiSfaCtOry: Battery Overcharged:
Handlebarhard to tum: Alternator trouble

Steering stem locknut too tight
Bearing damaged
Steering bearing lubrication inadequate
Steering stem bent
Tire air pressure too low
Handlebarshakes ore χcessively vibrates:
Tjre worn
Swlng arm plvot bearlng worn
Rjm warped, 0r not balanced
Wheel bearing worn
Handlebar clamp loose
Steering stem head nut loose
Handlebarpulls to one side:
Frame bent
Wheel misalignment
Swingarm bent or twisted
Steering maladjusted
Frontfork bent
Right/left fork legs unbalanced(oil level,air
pres5ure, anti-dive setting)
Shock absorption u nsatisfactory:
(Too hard)
Frorlt fork oil χcessive
e
Front fork oil viscosity too high
F「ont fork air pressure too high
Rear shock absorber air pressure too high
Tire air pressure too high
Front fork antj-dive mechanism trouble
Front fork bent
(Too soft)
Frorlt fork oil insufficient and/orleaking
Front fork oil viscosity too low
Front fork air pressure too low
Rear shock absorber air pressure too low
Front fork, rear shock absorber springweak
Rear shock absorber oil leaking
Front fork anti,dive mechanism trouble
Brake DOeSn ″t HOld:

Air in the brakeline
Pad or disc worn
Brake fluid leak
Disc warped
Contaminated pad
Brake fluid deteriorated
Primary or secondary cup damaged
Mastercylinderscratched inside
Battery DiSCharged:
Battery faulty(e ・g・,plates sulphated,shorted through sedimerltation,electrolyte level too low)
Batterly leads making poor contact

Load e χcessive (e ・g.,bulb of e χcessive wattage)
lgnition switch trouble
Alternator trouble
Wiring faulty
-
16-8 APPENDIX
● ● ●
GeneraI Lubrication Nut, Bolt, and IFastenerTightness

● 暉 ● ● ● ● ● ● ●
Lubrication Tightness lnspection

●Before lubricating each part, ( (heck and
ンlean off any rusty spots with rust remover the wipe
tightness
off any of the bolts
grease, and nuts listed here.
oil, dirt,o
「 Also, check to see that each cotter pin is jn place and in

grlme ・ good condition.
●Lubricate the points listed below with indicated
NOTE
lubricant.
oFor the engine fasteners,check the tightness of them

NOTE
when the engine js cold (at room temperature ノ.
oWhenever the vehicje has been operated under wet or
rainy conditions,01 ・especially after using a high- pressure spray water,perform the genera★lf there are loose fasteners,retorque them to the
川ubrication. specified torque following the specified tightening
sequence. Refer to the appropriate chapter for torque
Pivots: Lubricate with MotorOil. specifications.lf torque specifications are not in the
Center Stand appropriate chapter,see the Standard Torque Table.
Side Stand For each fastener, first loosen it by 3 ろturn,then tjghten it.
Clutch Lever
Brake Lever ★lf cotter pins are damaged, replace them with new
Brake Pedal ones.
Rear Brake Rod Joint
Nut,Bolt,and Fastenerto be checked

Points: Lubricate with Grease. Wheels:
Throttle lnner Cable Lower End Front A χle Nut
SpeedometerlnnerCable* Front Axle Clamp Bolts

*Grease the lowerpart of the inner cable sparingly. Rear Axle Nut
Chain Adjuster Clamp Bolts
Cables: Lubricate with Motor Oil. Brakes:

Choke Cable Front Master Cylinder Clamp Bolts
Throttle Cable Caliper Mounting Bolts
Rear Master Cylinder Mounting B01t
Torque Link Nut
Cable Lubrication Brake Lever Pivot Nut

Brake Pedal Bolt
Brake Rod Joint Cotter Pin

Suspension:
Front Fork Clamp Bolts
Front Fender Mounting Bolts

Rear Shock Absorber Mounting Bolts
Swing Arm Pivot Shaft Nuts
Uni-trak Link Nuts
Steering:
Stem Head Nut
Handlebar Mounting Bolts

Engine:
Engine Mounting Bolts
Cyljnder Head Bolts
Muffler Mounting Nuts
1.Cable Muffler Mounting Bolts
2.Pressure Cable Luber: K56019-021 MufflerConnecting Clamp Bolt
Clutch Master Cylinder Clamp Bolts
Clutch Lever Pivot Nut
Others:
Center Stand Bolts
Side Stand Bolt
Footpeg Mounting Bolts
Down Tube Mounting Bolts
Footpeg Bracket Mounting Bolts
APPENDIX 16-9
Unit Conversion Table

Units of Length
X X X
km 0 。6214 =3.281 mile
=0.03937 =
m ft
Prefi χes for Units:
mm ln
Prefix Symbol Power
mega
kilo ×1,000
Units of Torque:
centi ×0.01X 0.001
X X X
N-m 0,1020 =
milli kg-m
miCro MkCmμ X ×0.000001

I,000,000 N-m 0,7376 = ft-lb
N-m 8.851 = in-lb-
-
× X X
一一
k9-m 9,807 N-m
一一
k9-m 7.233 ft-lb
Units of Mass k9-m 86.80 in-lb
一
一
v cn
a)
X X
2 。205 =0.03527lb =
OZ
Units of Pressure:
X X X
kPa 0 。01020 =0,1450 =0.7501
Units of Volume:
k9/cm2=98.07
kPa
psl
LLLLLL
X X X X X X X X X
0 。2642 =0.2200 gal(US)

=1.057 kPa cm H9
X X X
9al(imp) k9/cm2 = kPa
= qt(US) k9/cm2 14.22 一
psI
0.8799 = qt(imp) cm H9 1.333 一
一
kPa
2.113 = pint(US)
1.816 = pint(imp)
mL 0.03381 = oz(US)
mL Units of Speed:
0.02816 = oz{imp}
mL 0.06102 = km/h x
cu ln 0.6214 = mph
Units of Force Units of Power:

NN
X X
0 。1020 =0.2248 k9=9.807 kW x 1 。360 =1.341 PS

kW x = HP
1b- -
PP
SS
CM7)kk
X X
X X
= N 0.7355 = kW
2.205 = lb 0.9863 = HP
Units of Temperature:
9( ゜C+40) 5 5( ゜F+40) 9
40= ゜F -40= ゜C
゜F ゜F
-4 32 68 248
104 176 212 284
:0
-40 -20
-
-
20
-
40 60 j 80 1001 120 140 160 j180 200 旨20 240 260
280: 300
0 ℃
1
I
j
︲4
0 20 40 60 80
100 1 120 μ40 160
17.8 4.4 26.7 48.9 71.1 93.3 116 138
゜C
-
一丿ニ
ノ
﹂
ノフ1 “ 昌I ≒
う呂ヶブト'｀ぐヽ)')
』行・ヘ … ーう
千ゾヤ …
べ/
こ.T.]
万1 。;j'
万i
4--"￣ 7
,兄丿、
どブ
でつ ≪ ・' 々
yT 、
☆ バ4
口ご
○ 卜 △
・/
、￣
MODEL APPLICA7101NII
Year Model Beginning Frame N0 。

- -
1988 JKAZXCBIOJA0000010 「
ZX1000-BI
ZXT00B-000001 0r 012452,
JKAZXCBIOKA0120010 「
ZX1000,B2 017001 0r ZXT00B-012001 0 「0170(j
｀1
㎜㎜㎜㎜■
JKAZXCBIOLA0280010 「
ZX1000 ・B3
ZXT00B-028001
.J ■I
This digit in the frame number ￠hanges from one..machine tcanother.
KjWVA5AKI
y, HEja/Y INousTRIE5,1 こrD.

coNsuMER PR00ucTs&coMPoNENTs GRouP
Part N0. 99924-1098-02

Kawasaki Ninja ZX-10 Motorcycle Service Manual ZX1000B1 B2 B3 1988-1990

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￨

Engine Top End j

Engine Lubrication System ● Eng

I Final Drive ￣ll 【il

This quick reference guide will assist you in

10cating a desired topic or procedure.

●Bend the pages back to match the black tab

of the desired chapter number with the black

tab on the edge at each table of contents

●Refer to the sectional table of contents for

the e χact pages to locate the specific topic required.

OKawasaki Heavy lndustries, Ltd,1987,1989,1991 Second Edilion (4):May 15, 1992(M)

This w,aming may apply to any of the followin9

components or any assembly containin9 0ne or

Brake Shoes or Pads

●Operate if possible out of doors or in a well

equipped,if necessary,with an appropriate dust

Read OWNER ゛S MANUAL before operatin9

圀 been removed or rendered inoperative by any person,

●Removal of the muffler(s)or any intemal portion of the muffler(s).

to Use this Manual

information to make it useful to the owner who

carried out only by qualified mechanics.

ln order to perform the work efficiently and 。

To get the longest life out of your Motorcycle:

●FoIIow the Periodic Maintenance Chart in the

motorcycles are introduced by the Special TooI

Manual. Genuine parts provided as spare 匹 亘￨

will help you distinguish different types of

oThis note symbo! 加( がcates points of particuya 「

interest for more efficient and convenient

the work of the procedural step it follows.

lt also precedes the te χt of a WARNING,

★lndicates a conditional step or what action to

inspection in the procedural step or sub-step

☆lndicates a conditional sub-step or what

action to take based upon the results of the

conditional step it follows.

the instructions indicating which parts

require specified tightening torque, 01l,9rease

or a locking agent during assembly.

Cable,Wire and Hose 1

have been included wherevernecessary,Nevertheless,even a detaHed account has limitations,

a certain amount of basic knowledge is also required for successful work,

Especially note the following:

(c)damage to electrical parts.

screws must be tightened in the order and method indicated.

orderto avoid damaging the screw heads.

(7)High Flash-point SoIvent

monly available in North America is Stoddard solvent(9eneric name).Always follow manufac-

turer and container directions regarding the use of any solvent.

avoid oil or compression leaks.

on its outer or inner circumference so that it will go into place smoothly.

(12)Oil Seal and Grease Seal

Wire(cross-section〉 Name of Wire Color

Abrasion Crack Hardening Warp

CoIor change Deterioration Seizure

Numbers of service data in this te χt have following meanings:

“Standards": Show dimensions or performances which brand-new parts or systems have.

Manual. Genuine parts provided as spare 匹亘￨

●畠●●・ ●Is 個l ●●・・I ●●●●s ●●● ●●・讐 l ●●●●● l ●・槽●●●● l・ ●・ ●・ ● M o d e l