3 Quick Reference Guide This quick reference guide will assist you in locating 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 exact pages to locate the specific topic required. General Information 1 j Periodic Maintenance 2 j Fuel System (DFI) 3 j Cooling System 4 j Engine Top End 5 j Clutch 6 j Engine Lubrication System 7 j Engine Removal/Installation 8 j Crankshaft/Transmission 9 j Wheels/Tires 10 j Final Drive 11 j Brakes 12 j Suspension 13 j Steering 14 j Frame 15 j Electrical System 16 j Appendix 17 j
5 KX250F Motorcycle Service Manual All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Quality Assurance Division/Motorcycle & Engine Company/Kawasaki Heavy Industries, Ltd., Japan. No liability can be accepted for any inaccuracies or omissions in this publication, although every possible care has been taken to make it as complete and accurate as possible. The right is reserved to make changes at any time without prior notice and without incurring an obligation to make such changes to products manufactured previously. See your Motorcycle dealer for the latest information on product improvements incorporated after this publication. All information contained in this publication is based on the latest product information available at the time of publication. Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts Kawasaki Heavy Industries, Ltd. Second Edition (0) : May 20, 2011
6 LIST OF ABBREVIATIONS A ampere(s) lb pound(s) ABDC after bottom dead center m meter(s) AC alternating current min minute(s) ATDC after top dead center N newton(s) BBDC before bottom dead center Pa pascal(s) BDC bottom dead center PS horsepower BTDC before top dead center psi pound(s) per square inch C degree(s) Celsius r revolution DC direct current r/min, rpm revolution(s) per minute F farad(s) TDC top dead center F degree(s) Fahrenheit TIR total indicator reading ft foot, feet V volt(s) g gram(s) (mass) W watt(s) h hour(s) Ω ohm(s) kg (mass) kgf (force) L liter(s) COUNTRY AND AREA CODES AU Australia EUR Europe BR Brazil US United States CA Canada
7 Foreword This manual is designed primarily for use by trained mechanics in a properly equipped shop. However, it contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily. Whenever the owner has insufficient experience or doubts his ability to do the work, all adjustments, maintenance, and repair should be carried out only by qualified mechanics. In order to perform the work efficiently and to avoid costly mistakes, read the text, thoroughly familiarize yourself with the procedures before starting work, and then do the work carefully in a clean area. Whenever special tools or equipment are specified, do not use makeshift tools or equipment. Precision measurements can only be made if the proper instruments are used, and the use of substitute tools may adversely affect safe operation. To get the longest life out of your vehicle: Follow the Periodic Maintenance Chart in the Service Manual. Be alert for problems and non-scheduled maintenance. Use proper tools and genuine Kawasaki Motorcycle parts. Special tools, gauges, and testers that are necessary when servicing Kawasaki motorcycles are introduced by the Service Manual. Genuine parts provided as spare parts are listed in the Parts Catalog. Follow the procedures in this manual carefully. Don t take shortcuts. Remember to keep complete records of maintenance and repair with dates and any new parts installed. How to Use This Manual In this manual, the product is divided into its major systems and these systems make up the manual s chapters. The Quick Reference Guide shows you all of the product s system and assists in locating their chapters. Each chapter in turn has its own comprehensive Table of Contents. For example, if you want stick coil information, use the Quick Reference Guide to locate the Electrical System chapter. Then, use the Table of Contents on the first page of the chapter to find the Stick Coil section. Whenever you see symbols, heed their instructions! Always follow safe operating and maintenance practices. DANGER DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury. WARNING WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury. NOTICE NOTICE is used to address practices not related to personal injury. This manual contains four more symbols which will help you distinguish different types of information. NOTE This note symbol indicates points of particular interest for more efficient and convenient operation. Indicates a procedural step or work to be done. Indicates a procedural sub-step or how to do the work of the procedural step it follows. It also precedes the text of a NOTE. Indicates a conditional step or what action to take based on the results of the test or inspection in the procedural step or sub-step it follows. In most chapters an exploded view illustration of the system components follows the Table of Contents. In these illustrations you will find the instructions indicating which parts require specified tightening torque, oil, grease or a locking agent during assembly.
9 GENERAL INFORMATION 1-1 General Information Table of Contents Before Servicing Model Identification General Specifications Technical Information - Dual Injector Unit Conversion Table
10 1-2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly operation on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustrations, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary. This section explains the items that require particular attention during the removal and reinstallation or disassembly and reassembly of general parts. Especially note the following: Edges of Parts Lift large or heavy parts wearing gloves to prevent injury from possible sharp edges on the parts. Solvent Use a high-flash point solvent when cleaning parts. High -flash point solvent should be used according to directions of the solvent manufacturer. Cleaning Vehicle before Disassembly Clean the vehicle thoroughly before disassembly. Dirt or other foreign materials entering into sealed areas during vehicle disassembly can cause excessive wear and decrease performance of the vehicle. Arrangement and Cleaning of Removed Parts Disassembled parts are easy to confuse. Arrange the parts according to the order the parts were disassembled and clean the parts in order prior to assembly.
11 Before Servicing GENERAL INFORMATION 1-3 Storage of Removed Parts After all the parts including subassembly parts have been cleaned, store the parts in a clean area. Put a clean cloth or plastic sheet over the parts to protect from any foreign materials that may collect before re-assembly. Inspection Reuse of worn or damaged parts may lead to serious accident. Visually inspect removed parts for corrosion, discoloration, or other damage. Refer to the appropriate sections of this manual for service limits on individual parts. Replace the parts if any damage has been found or if the part is beyond its service limit. Replacement Parts Replacement parts must be KAWASAKI genuine or recommended by KAWASAKI. Gaskets, O-rings, oil seals, grease seals, circlips, cotter pins or self-locking nuts must be replaced with new ones whenever disassembled. Assembly Order In most cases assembly order is the reverse of disassembly, however, if assembly order is provided in this Service Manual, follow the procedures given. Tightening Sequence Generally, when installing a part with several bolts, nuts, or screws, start them all in their holes and tighten them to a snug fit. Then tighten them according to the specified sequence to prevent case warpage or deformation which can lead to malfunction. Conversely when loosening the bolts, nuts, or screws, first loosen all of them by about a quarter turn and then remove them. If the specified tightening sequence is not indicated, tighten the fasteners alternating diagonally.
12 1-4 GENERAL INFORMATION Before Servicing Tightening Torque Incorrect torque applied to a bolt, nut, or screw may lead to serious damage. Tighten fasteners to the specified torque using a good quality torque wrench. Often, the tightening sequence is followed twice-initial tightening and final tightening with torque wrench. Force Use common sense during disassembly and assembly, excessive force can cause expensive or hard to repair damage. When necessary, remove screws that have a non -permanent locking agent applied using an impact driver. Use a plastic-faced mallet whenever tapping is necessary. Gasket, O-ring Hardening, shrinkage, or damage of both gaskets and O-rings after disassembly can reduce sealing performance. Remove old gaskets and clean the sealing surfaces thoroughly so that no gasket material or other material remains. Install new gaskets and replace used O-rings when re-assembling. Liquid Gasket, Non-permanent Locking Agent For applications that require Liquid Gasket or a Non-permanent Locking Agent, clean the surfaces so that no oil residue remains before applying liquid gasket or non-permanent locking agent. Do not apply them excessively. Excessive application can clog oil passages and cause serious damage. Press For items such as bearings or oil seals that must be pressed into place, apply small amount of oil to the contact area. Be sure to maintain proper alignment and use smooth movements when installing.
13 Before Servicing GENERAL INFORMATION 1-5 Ball Bearing and Needle Bearing Do not remove pressed ball or needle unless removal is absolutely necessary. Replace with new ones whenever removed. Press bearings with the manufacturer and size marks facing out. Press the bearing into place by putting pressure on the correct bearing race as shown. Pressing the incorrect race can cause pressure between the inner and outer race and result in bearing damage. Oil Seal, Grease Seal Do not remove pressed oil or grease seals unless removal is necessary. Replace with new ones whenever removed. Press new oil seals with manufacture and size marks facing out. Make sure the seal is aligned properly when installing. Apply specified grease to the lip of seal before installing the seal. Circlips, Cotter Pins Replace circlips or cotter pins that were removed with new ones. Take care not to open the clip excessively when installing to prevent deformation. Lubrication It is important to lubricate rotating or sliding parts during assembly to minimize wear during initial operation. Lubrication points are called out throughout this manual, apply the specific oil or grease as specified.
14 1-6 GENERAL INFORMATION Before Servicing Direction of Engine Rotation When rotating the crankshaft by hand, the free play amount of rotating direction will affect the adjustment. Rotate the crankshaft to positive direction (clockwise viewed from output side). Electrical Leads A two-color lead is identified first by the primary color and then the stripe color. Unless instructed otherwise, electrical leads must be connected to those of the same color. Instrument Use a meter that has enough accuracy for an accurate measurement. Read the manufacture s instructions thoroughly before using the meter. Incorrect values may lead to improper adjustments.
15 Model Identification GENERAL INFORMATION 1-7 KX250YB Left Side View KX250YB Right Side View Frame Number Engine Number
16 1-8 GENERAL INFORMATION General Specifications Dimensions Items Overall Length Overall Width Overall Height Wheelbase Road Clearance Seat Height Curb Mass: KX250YB KX250YC Front: KX250YB KX250YC Rear: KX250YB KX250YC mm (85.43 in.) 820 mm (32.3 in.) mm (50.00 in.) mm (58.07 in.) 330 mm (13.0 in.) 945 mm (37.2 in.) kg (233.1 lb) (US, CA) kg (232.8 lb) kg (234.2 lb) (US, CA) kg (234.0 lb) 51.6 kg (113.8 lb) 51.9 kg (114.4 lb) 54.1 kg (119.3 lb) (US, CA) 54.0 kg (119.1 lb) 54.3 kg (119.7 lb) (US, CA) 54.2 kg (119.5 lb) 7.2 L (1.9 US gal) KX250YB YC Fuel Tank Capacity Engine Type 4-stroke, single cylinder, DOHC 4 valve Cooling System Liquid-cooled Bore and Stroke mm ( in.) Displacement 249 cm³ (15.2 cu in.) Compression Ratio 13.5 : 1 Fuel System FI (Fuel Injection), KEIHIN 43 Starting System Primary kick Ignition System Digital DC-CDI Timing Advance Electronically advanced Ignition Timing BTDC 000 r/min (rpm) Spark Plug: Standard NGK CPR8EB-9 Option NGK CPR9EB-9 Valve Timing: Intake: Open BTDC 40 Close ABDC 72 Duration 292 Exhaust: Open BBDC 69 Close ATDC 49 Duration 298 Lubrication System Forced lubrication (semi-dry sump)
17 General Specifications GENERAL INFORMATION 1-9 Engine Oil: Grade Items Viscosity SAE 10W-40 Capacity Drive Train Primary Reduction System: Type KX250YB YC API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2 1.0 L (1.1 US qt) Gear Reduction Ratio (67/20) Clutch Type Transmission: Type Gear Ratios: Wet multi disc, Manual 1st (30/14) 2nd (28/16) 3rd (26/18) 4th (21/17) 5th (23/22) Final Drive System: Type 5-speed, constant mesh, return shift Chain drive Reduction Ratio (50/13) (EUR, BR) (49/13) Overall Drive Ratio gear (EUR, BR) gear Frame Type Tubular, semi-double cradle Steering Angle 42 to either side Caster (Rake Angle) 28.2 Trail mm (4.732 in.) Front Wheel: Tire Size 80/ M Tire Make/Type BRIDGESTONE M403, Tube type Rim Size Rear Wheel: Tire Size 100/ M Tire Make/Type BRIDGESTONE M404, Tube type Rim Size Front Suspension: Type Telescopic fork (upside down) Wheel Travel 315 mm (12.4 in.) Rear Suspension: Type Swingarm (New Uni-trak) Wheel Travel 310 mm (12.2 in.) Brake Type: Front and Rear Single disc
18 1-10 GENERAL INFORMATION General Specifications Items KX250YB YC Effective Disc Diameter: Front 225 mm (8.86 in.) Rear 215 mm (8.46 in.) Specifications are subject to change without notice, and may not apply to every country.
19 Technical Information - Dual Injector GENERAL INFORMATION 1-11 Overview Although the Kawasaki Ninja super-sports models are already equipped with dual injectors, the 2012 KX250YC is the first motocross model to adopt dual-injector technology. The dual injectors are installed in the throttle body and intake duct. The injector in the throttle body is the Downstream Injector. The injector in the intake duct is the Upstream Injector. By using two injectors, power feeling has improved in the middle to high speed range compared to conventional models (single injector type). 1. Downstream Injector 2. Throttle Body Assy 3. Upstream Injector 4. Intake Duct Downstream Injector [A] Upstream Injector [B] Fuel Injection Fuel injection is controlled by the ECU based on the throttle opening and engine speed. In the low speed range, the downstream injector alone will operate, and in the middle to high speed range, both the downstream and upstream injectors will operate. The shaded field in the image below shows the fuelinjection field of both injectors and the rest of the field shows the fuel injection field of the downstream injector.
20 1-12 GENERAL INFORMATION Technical Information - Dual Injector Image of the fuel injection field A. Throttle Opening B. Engine Speed C. Fuel Injection Field of Both Injector
21 GENERAL INFORMATION 1-13 Unit Conversion Table Prefixes for Units: Prefix Symbol Power mega M kilo k centi c 0.01 milli m micro µ Units of Mass: kg = lb g = oz Units of Volume: L = gal (US) L = gal (IMP) L = qt (US) L = qt (IMP) L = pint (US) L = pint (IMP) ml = oz (US) ml = oz (IMP) ml = cu in Units of Length: km = mile m = ft mm = in Units of Torque: N m = kgf m N m = ft lb N m = in lb kgf m = N m kgf m = ft lb kgf m = in lb Units of Pressure: kpa = kgf/cm² kpa = psi kpa = cm Hg kgf/cm² = kpa kgf/cm² = psi cm Hg = kpa Units of Speed: km/h = mph Units of Force: N = kgf N = lb kgf = N kgf = lb Units of Power: kw = PS kw = HP PS = kw PS = HP Units of Temperature:
23 PERIODIC MAINTENANCE 2-1 Periodic Maintenance Table of Contents Periodic Maintenance Chart Torque and Locking Agent Specifications Special Tools Periodic Maintenance Procedures Fuel System Fuel Hose and Connections Inspection Throttle Grip (Throttle Cable) Free Play Inspection Throttle Grip (Throttle Cable) Free Play Adjustment Throttle Body Cleaning Fuel Hose Replacement Idle Speed Inspection Idle Speed Adjustment Air Cleaner Element Cleaning and Inspection Fuel Tank Clean Cooling System Coolant Level Inspection Coolant Deterioration Inspection Water Hoses and Connections Inspection Engine Top End Valve Clearance Inspection Valve Clearance Adjustment Cylinder Head Warp Inspection Cylinder Wear Inspection Piston/Cylinder Clearance Inspection Piston, Piston Ring and Piston Pin Replacement Exhaust System Inspection Silencer Wool Replacement Clutch Clutch Operation Inspection Clutch Plates Inspection Engine Lubrication System Engine Oil Change Oil Filter Change Breather Hose Inspection Crankshaft/Transmission Crankshaft Inspection Wheel/Tires Air Pressure Inspection/Adjustment Tires Inspection Spoke Tightness Inspection Rim Runout Inspection Wheel Bearing Inspection Final Drive Drive Chain Wear Inspection Drive Chain Slack Inspection Drive Chain Slack Adjustment Drive Chain Lubrication Sprocket Wear Inspection Rear Sprocket Warp (Runout) Inspection
24 2-2 PERIODIC MAINTENANCE Brakes Brake Lever and Pedal Adjustment Brake Fluid Level Inspection Brake Fluid Change Brake Pad Wear Inspection Brake Master Cylinder Rubber Parts Replacement Caliper Rubber Parts Replacement Brake Hoses and Connections Inspection Brake Hose Replacement Suspension Front Fork Inspection Front Fork Oil Change Rear Shock Absorber Oil Change Swingarm and Uni-Trak Linkage Inspection Swingarm and Uni-Trak Linkage Pivot Lubrication Steering Steering Inspection Steering Adjustment Steering Stem Bearing Lubrication Frame Frame Inspection Electrical System Spark Plug Cleaning and Inspection Spark Plug Replacement General Lubrication and Cable Inspection Lubrication Nut, Bolt, and Fastener Tightness Inspection Tightness Inspection
25 Periodic Maintenance Chart PERIODIC MAINTENANCE 2-3 The maintenance must be done in accordance with this chart to keep the motorcycle in good running condition. FREQUENCY Each Every Every 6 Every 12 race 3 races races See races or or 2.5 or 7.5 or 15 Page 30 hours OPERATION hours hours hours Spark plug - clean and inspect 2-75 Spark plug - replace 2-75 Clutch - inspect 2-27 Clutch plates - inspect 2-28 Throttle cable - inspect and adjust 2-15 Air cleaner element - clean 2-18 Air cleaner element - replace If damaged 2-18 Throttle body assy - inspect and adjust 2-16 Engine Oil - change 2-29 E Piston and piston ring - replace 2-26 N G Cylinder head, cylinder - inspect 2-25 I Piston pin - replace 2-26 N Valve clearance - inspect 2-22 E Oil filter - replace 2-30 Exhaust system - inspect 2-26 Silencer wool - change 2-26 Kick pedal and shift pedal - clean Engine sprocket - inspect 2-36 Coolant level - inspect 2-20 Water hoses and connections - inspect 2-22 Crankshaft - inspect 2-31 Breather hose - inspect 2-30 Brake - adjust 2-37 Brake pad wear - inspect 2-41 Brake fluid level - inspect 2-38 Brake fluid - change Every 2 years 2-39 C Brake master cylinder cup and dust cover - replace Every 2 years 2-41 H Brake caliper fluid seal and dust seal - replace Every 2 years 2-42 A Brake hoses - replace Every 4 years 2-46 S Brake hoses, connections - inspect 2-46 S I Spoke tightness and rim runout - inspect 2-32 S Wheel bearing - inspect 2-33 Frame - inspect 2-74 Drive chain wear - inspect 2-33 Drive chain - inspect and adjust 2-34 Drive chain - lubricate 2-36
26 2-4 PERIODIC MAINTENANCE Periodic Maintenance Chart FREQUENCY Each Every Every 6 Every 12 race 3 races races See races or or 2.5 or 7.5 or 15 Page 30 hours OPERATION hours hours hours Wheels/tires - inspect 2-32 Rear sprocket - inspect 2-36 Front fork - clean and inspect 2-47 Front fork oil - change 2-47 Rear shock absorber oil - change 2-63 Cable - inspect 2-75 Fuel hose - replace Every 5 years 2-16 Fuel hose, connections - inspect 2-15 Fuel system - clean 2-20 Steering play - inspect 2-72 Steering stem bearing - lubricate 2-74 Swingarm and Uni-Trak linkage pivots - lubricate 2-72 Swingarm and Uni-Trak linkage pivots - inspect 2-71 Nuts, bolts, fasteners - inspect 2-76 General lubrication - perform 2-75 : Replace, add, adjust, clean or torque if necessary.
27 Torque and Locking Agent PERIODIC MAINTENANCE 2-5 Tighten all bolts and nuts to the proper torque using an accurate torque wrench. If insufficiently tightened, a bolt or nut may become damaged, strip an internal thread, or break and then fall out. The following table lists the tightening torque for the major bolts and nuts, and the parts requiring use of a non-permanent locking agent or silicone grease etc. When checking the tightening torque of the bolts and nuts, first loosen the bolt or nut by half a turn and then tighten to specified torque. Letters used in the "Remarks" column mean: AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque. G: Apply grease. L: Apply a non-permanent locking agent. Lh: Left-hand Threads MO: Apply molybdenum disulfide oil. (mixture of engine oil and molybdenum disulfide grease with a weight ratio 10 : 1) R: Replacement Parts S: Follow the specified tightening sequence. Si: Apply silicone grease (ex. PBC grease). Fastener Torque N m kgf m ft lb Remarks Fuel System Throttle Pulley Cover Bolts in lb Throttle Cable Mounting Bolts in lb Air Cleaner Duct Mounting Bolt in lb Air Cleaner Duct Mounting Nuts in lb Air Cleaner Housing Bolts in lb Air Cleaner Duct Clamp Screw in lb Intake Air Temperature Sensor Bolts in lb L Throttle Case Mounting Screws in lb Air Cleaner Element Wing Bolt in lb TORX Screw in lb Delivery Joint Bolt (KX250YC Model) in lb L Fuel Pump Bolts in lb L, S Water Temperature Sensor in lb Gear Position Switch Screws in lb L Cooling System Water Pump Cover Bolts (L = 30, 65 mm) in lb Water Pump Cover Bolts (L = 55 mm) in lb L Coolant Drain Bolt in lb Water Pump Impeller Bolt in lb Water Hose Clamp Screws in lb Water Pipe Bolt in lb Radiator Mounting Bolts in lb Radiator Screen Bolts in lb Radiator Shroud Bolts in lb Engine Top End Auto-Decompressor Bolt in lb Cylinder Head Cover Bolts in lb Camshaft Cap Bolts in lb S, MO
28 2-6 PERIODIC MAINTENANCE Torque and Locking Agent Fastener Torque N m kgf m ft lb Remarks Cylinder Head Bolts (M10) S, MO Cylinder Head Bolts (M6) in lb S Plug L Throttle Body Clamp Screw in lb Throttle Body Holder Clamp Screw in lb Cylinder Bolt in lb S Camshaft Chain Tensioner Cap Bolt Camshaft Chain Tensioner Mounting Bolts in lb Lower Camshaft Chain Guide Bolt in lb Rear Camshaft Chain Guide Bolt Exhaust Pipe Cover Bolts in lb Exhaust Pipe Holder Nuts S Muffler Mounting Bolts S Muffler Clamp Bolt in lb S Clutch Clutch Cover Bolts in lb Right Engine Cover Bolts in lb Clutch Spring Bolts in lb Clutch Hub Nut R Oil Filler Plug in lb Engine Lubrication System Breather Fitting L Oil Pump Mounting Bolts in lb L Oil Pump Idle Gear Shaft Screws in lb L Oil Filter Cap Bolts in lb Piston Oil Nozzle in lb Engine Oil Drain Bolt Engine Removal/Installation Upper Engine Mounting Bolts S Upper Engine Bracket Bolts S Middle Engine Mounting Nut R, S Middle Engine Bracket Nuts R, S Lower Engine Mounting Nut R, S Swingarm Pivot Shaft Nut R, S Crankshaft/Transmission Crankcase Bolts (L = 50 mm) in lb S Crankcase Bolts (L = 60 mm) in lb S Crankcase Bolts (L = 65 mm) in lb S Crankcase Bolts (L = 70 mm) in lb S Crankcase Bearing Retainer Screws L Piston Oil Nozzle in lb Reed Valve Screws in lb Primary Gear Nut Lh, R
29 Torque and Locking Agent PERIODIC MAINTENANCE 2-7 Fastener Torque N m kgf m ft lb Remarks Kick Pedal Bolt L Kick Ratchet Guide Bolt in lb L Ratchet Plate Bolt in lb L, S Ratchet Plate Screw L, S Shift Drum Cam Bolt L Gear Positioning Lever Nut in lb Shift Pedal Bolt in lb Wheels/Tires Spoke Nipples Not Less Than 2.2 Not Less Than 0.22 Not Less Than 19 in lb Front Axle Nut Front Axle Clamp Bolts AL Rear Axle Nut Final Drive Rear Sprocket Nuts R Engine Sprocket Cover Bolts (KX250YB Model) in lb Engine Sprocket Cover Bolts (KX250YC Model) in lb Brakes Front Brake Reservoir Cap Screws in lb Front Master Cylinder Clamp Bolts in lb S Brake Lever Pivot Bolt in lb Si Brake Lever Pivot Bolt Locknut in lb Brake Hose Banjo Bolts Brake Hose Clamp Mounting Bolt in lb Front Brake Disc Mounting Bolts in lb L Caliper Bleed Valve in lb Front Brake Pad Pin Front Caliper Mounting Bolts Rear Brake Reservoir Cap Screws in lb Rear Master Cylinder Mounting Bolts in lb Rear Master Cylinder Push Rod Locknut Brake Pedal Bolt L, G Rear Brake Disc Mounting Bolts L Rear Brake Pad Pin Plug in lb Rear Brake Pad Pin Rear Caliper Holder Shaft Si Suspension Left Front Fork Cylinder Unit Front Fork Clamp Bolts (Lower) AL Front Fork Clamp Bolts (Upper) AL, L Left Front Fork Adjuster Assembly Locknut Left Front Fork Base Valve Assembly
30 2-8 PERIODIC MAINTENANCE Torque and Locking Agent Fastener Torque N m kgf m ft lb Remarks Left Front Fork Adjuster Assembly L Pressure Relief Screws in lb Right Front Fork Top Plug Right Front Fork Piston Rod Nut Right Front Fork Bottom Plug L Swingarm Pivot Shaft Nut R Rocker Arm Pivot Nut G, R Tie-Rod Mounting Nuts G, R Rear Shock Absorber Mounting Nut (Upper) R Rear Shock Absorber Mounting Nut (Lower) R Rear Shock Absorber Spring Locknut Piston Rod Locknut R Gas Reservoir Damping Adjuster Assembly Steering Handlebar Clamp Bolts AL Steering Stem Head Nut Steering Stem Nut in lb Front Fork Clamp Bolts (Upper ) AL, L Front Fork Clamp Bolts (Lower) AL Handle Holder Nuts R Frame Rear Frame Mounting Bolts Footpeg Bracket Bolts (Upper) L Electrical System Gear Position Switch Screws in lb L Flywheel Nut Stator Coil Bolts in lb L Spark Plug in lb Magneto Cover Bolts in lb Crankshaft Sensor Bolts in lb L Flywheel Nut Cap in lb Timing Inspection Cap in lb
31 Torque and Locking Agent PERIODIC MAINTENANCE 2-9 Basic Torque for General Fasteners Threads diameter Torque (mm) N m kgf m ft lb in lb in lb
32 2-10 PERIODIC MAINTENANCE Specifications Fuel System Item Standard Service Limit Throttle Grip Free Play 2 3 mm ( in.) Idle Speed ±50 r/min (rpm) Air Cleaner Element Oil High quality foam air filter oil Cooling System Coolant: Type (recommended) Permanent type antifreeze Color Green Mixed Ratio Soft water 50%, coolant 50% Freezing Point 35 C ( 31 F) Total Amount 1.2 L (1.3 US qt.) Engine Top End Valve Clearance: Exhaust mm ( in.) Intake mm ( in.) Cylinder Head Warp 0.05 mm Cylinder Inside Diameter (see text) mm ( in.) mm ( in.) (3.035 in.) Piston/Cylinder Clearance mm Clutch ( in.) Clutch Lever Free Play 8 13 mm ( in.) Friction Plate Thickness mm ( in.) 2.5 mm (0.10 in.) Friction Plate Warp 0.15 mm ( in.) or less 0.3 mm (0.012 in.) Steel Plate Warp 0.15 mm ( in.) or less 0.3 mm (0.012 in.) Engine Lubrication System Engine Oil: Grade Castrol POWER1 R4 Racing 5W-40 or API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2 Viscosity SAE 10W-30, 10W-40, or 10W-50 Capacity 0.75 L (0.79 US qt.) (when filter is not removed) 0.80 L (0.85 US qt.) (when filter is remove) 1.00 L (1.06 US qt.) (when engine is completely dry) Crankshaft/Transmission Connecting Rod Big End Side mm 0.6 mm Clearance ( in.) (0.02 in.)
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DRP 2336 (11/19/04) This Motorcycle Operator s Handbook has been prepared to inform you of the basic knowledge and skills necessary for the safe operation of a motorcycle. Motorcycling is fun and exciting.