88-02 KA ATV Bayou 220 Manual-S

This service manuals covers the 1988-2002 Kawasaki Bayou 220 Series.
Some models may need supplemental manuals which have blue titles. Use the base
manual for everything not contained in the supplement if your model or year requires
a supplement.
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Kawasaki
KLF220
BAYOU
All Terrain Vehicle

Service Manual
Quick Reference Guide
General Information
1
2
End
5
ine Removal/Installation
ine Bottom EndlTransmission 7
8
9
10
11
12
13
14
15
nt - 1995 Late - 1997 Models
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
fo r the exact pages to locate the specific topic required.
16
lement - 1998 - 1999 Models 17

lement - 2000 - 2002 Models 18
KaVlasaki
KLF220
BAYOU
All Terrain Vehicle

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 pe rmission of Quality Assurance Division/Consumer Products & Machinery
Company/ Kawasaki Heavy Industries, Ltd. , Japan.
No liability can be accepted for any inaccuracies or omissions in this publication , although every possible
care has been taken to make it as complete and accurate as possible.
The right is reserved to make changes at any time without prior notice and without incurring an obligation
to make such changes to products manufactured previously. See your dealer for the latest information on
product improvements incorporated after this publication .
All information contained in this publication is based on the latest product information available at the time
of publication. Illustrations and photographs in this publication are intended for reference use on ly and may
not depict actual model component parts.
1987 Kawasaki Heavy Industries, Ltd.
12th Edition (1) :Apr. 20, 2007 (K)
LIST OF ABBREV IATIONS

A
ampere(s)
Ib
pound(s)
ABOC
after bottom dead center
meter(s)
AC
alternating current
min
minute(s)
ATOC
after top dead center
newton(s)
BBOC
before bottom dead center
Pa
pascal(s)
BOC
bottom dead center
PS
horsepower
BTDC
before top dead center
psi
pound (s) per square inch
degree(s) Celsius
revolution
DC
direct current
rpm
revolution(s) per minute
F
OF
farad(s)
TOC
top dead center
degree(s) Fahrenheit
TIR
total indicator reading
ft
foot, feet
volt(s)
9
h
gram(s)
watt(s)
hour(s)
ohm(s)
liter(s)
Read OWNER'S MANUAL before operating
....... ...
.~,.
*-\
~
~
..~.
.y;.!Y';-.....
"".~fllr._~...11
!o-.. ,,- ....y;:.-
. ... :;.";.
.._........
"~~w.~",.",w.~"
~
~ e.lf:.tf~~
- ,Y .~ .f.....
t. .;.,,~
~
!\. .
-,,!-jf~.
~.1I-~-VJl
.~.
, - .~iL.~1l..~ii:
~..
~
....
.y..::Y<io .. ';:
...
.- . .
;r:~
? .;."~"~"
~it. ~.u:.
.~........
.1I!r.
..
.,r,; ....
PLEASE DO NOT TAMPER WITH NOISE CONTROL SYSTEM

IUS Model only I
~:
*:
::r.:
~t
To minimize the noise emissions from this product, Kawasaki has equipped it with !\~:
;:":: effective intake and exhaust silencing systems. They are designed to give optimum per- ~:
:-i!\ formance while maintaining a low noise level. Please do not remove these systems, or alter ~!
~ them in anY which results in an increase in noise level.
!\o::;
~
~;Ko$~ti:.$~~~p.:~~~~:~'f.U.'f.U.'f.!-!~~:;w.~~~~'f..U.~~~~
.~., ............ ,............... , ".. :."~; ..,..... " ......... :>~:>:;:;:.'~;~; ............... ,.....:~ .... ~~; ......... ..
.....
This warning may apply to any of the following

components or any assembly containing one or
more of these components:Brake Shoes or Pads

Clutch Friction Material
Gaskets
Insulators
WARNING
CONTAINS
ASBESTOS
Breathing asbestos
dun is dlngerous
to health
Follow safety
instructions
SAFETY INSTRUCTIONS
e{)perate 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. If high speed tools are used,
they should always be so equipped.
elf possible, dampen before cutting or drilling.
-Dampen dust and place it in properly closed
receptacle and dispose of it safely.
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.
For the duration of the warranty period,
we recommend that all repairs and scheduled
maintenance be performed in accordance with
this service manual. Any owner maintenance or
repair procedure not performed in accordance
with this manual may void the warranty.
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 Vehicle parts. Special tools, gauges, and testers
that are necessary when servicing Kawasaki
vehicles 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 ignition 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 Ignition Coil section.
Whenever you see these WARNING and
CAUTION symbols, heed their instructions!
Always follow safe operating and maintenance
practices.
A WARNING
This warning symbol identifies special
instructions or procedures which, if not
correctly followed, could result in personal injury, or loss of life.
CAUTiON
This caution symbol identifies special
instructions or procedures which, if not
strictly observed, could result in damage to or destruction of equipment.
This manual contains four more symbols (in
addition to WARNING and CAUTION) which will
help you distinguish different types of information.
NOTE
note symbol indicates points of particular interest for more efficient and con venient operation.
o This
.Indicates 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. 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.
GENERAL INFORMATION 1-1
General Information
Table of Contents
Before SelVicing _. . .. . .. ....... ........ . ...... _. _......... _
1-2
Model Identification . ... . .. .. .. ........... _ . . . . . . . . . . . . . . . .
1-4
General Specifications . . .. . ............... . ...... . .... .... ..
1-5
Periodic Maintenance Chart . .... . ... ... .. : . . . . . . . . . . . . . . . . . .
1-7
Torque and Locking Agent . . .... . ... _... . .. ........ .. .. . . : . . .
1-8
Cable and Hamess Routing.. . . . . . ... . ... . . . . ... . . . . . . . . .. . . ..
1-10
1-2 GENERAL .INFORMATION
Before Servicing
Before starting to service a vehicle, careful reading of the applicable section is recommended to
eliminate unnecessary work. Photographs, diagrams, notes, cautions, warnings, and detailed descriptions have been included wherever necessary. Nevertheless, even a detailed 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 vehicle. Any dirt entering the engine or other
parts will work as an abrasive and shorten the life of the vehicle. For the same reason , before
installing a new part, clean off any dust or metal filings.
(2) Battery Ground
Remove the ground (-) lead 'from the battery before performing any disassembly operations
on the vehicle. This prevents: '
(a) the possibility of accidentally turning the engine over wh ile partially disassembled .
(b) sparks at electric~1 connections which will occur when they are disconnected.
(c) damage to electrical parts.
(3) Tighten ing 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 evenly in a cross pattern. Th is is to avoid
distortion of the part and/ or causing gas or oil leakage. Conversely when loosening the bolts,
nuts, or screws, first loosen all of them by about a quarter of turn and then remove them.
Where there is a tightening sequence indication in this Service Manual, the bolts, nuts, or
screws must be tightened in the order and method indicated.
(4) Torque
When torque values are given in this Service Manual, use them . Either' too little or too much
torque may lead to serious damage. Use a good quality, reliable torque wrench .
(5) Force
Common sense should dictate how much force is necessary in assembly and disassembly. If a
part seems especially difficult to remove or install, stop and examine what may be causing the
problem. Whenever tapping is necessary, tap lightly using a wooden or plastic-faced mallet. Use
an impact driver for screws (particularly for the removal of screws held by a locking agent) in
order to avoid damaging the screw heads.
, (6) Edges
Watch for sharp edges, especially during major engine disassembly and assembly. Protect your
hands w ith gloves or a piece of thick cloth when lifting the engine or turning it over.
(7) High-Flash Point Solvent
A high-flash point solvent is recommended to reduce fire danger. A commercial solvent commonly available in North America is Stoddard solvent (generic name) . Always follow manufacturer and container directions regarding the use of any solvent.
(8) Gasket, O-Ring
Do not reuse a gasket or O-ring once it has been in service. The mating 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
Follow manufacturer's directions for cleaning and preparing surfaces where these compounds
will be used. Apply sparingly. Excessive amounts may block engine oil passages and cause
serious damage. An example of a non-permanent locking agent commonly available in North
America is Loctite Lock'n Seal (Blue) .
(10) Press
'A part installed using a press or driver, such as a wheel bearing, 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 bearing, the bearing race which is affected by friction should be pushed
by a suitable driver. This prevents severe stress on the balls and races, and prevents races and
balls from being dented . Press a ball bearing until it stops at the stop in the hole or on the shaft.
(12) Oil Seal and Grease 'Seal

Replace any oil or grease seals that were removed with new ones, as removal generally damages
seals.
When pressing in a seal which has manufacturer's marks, press it in with the marks facing out.
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.
(13) Seal Guide
A seal guide 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 high temperature grease on the lips to
reduce rubber to metal friction.
(14) Circlip, Retaining Ring
Replace any circlips and .retaining rings that were removed with new ones, as removal weakens
and deforms them. When installing circlips and retaining rings, take care to compress or expand
them only enough to install them and no more.
(15) Lubrication
Engine wear is generally at its maximum while the e~gine is warming up and 'before all the
rubbing surfaces have an adequate lubricative film. During assembly, oil or grease (whichever is
more suitable) should be applied to any rubbing surface which has lost its lubricative film. Old
grease and dirty oil should be cleaned off. Deteriorated grease has lost its lubriCative quality and
may contain abrasive foreign particles.
Don't use just any oil or grease. Some oils and greases in particular should be used only in
certain applications and may be harmful if used in an application for which they are not intended.
This 'manual makes reference to molybdenum disulfide grease (MoS,) in the assembly of certain
engine and chassis parts_ Always check manufacturer recommendations before using such special
lubricants.
(16) Electrical Wires
All 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. On any of the two-color wires there is a greater
amount of one color and a lesser amount of a second color, so a two-color wire is identified by
first the primary color and thim 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 red the main color.
Wire (cross-section)
Name of Wire Color
Red
Wire strands
Yellow/red
Yellow
Red
(17) Replacement Parts
When there is a replacement instruction, replace these parts with new ones every time they are
removed. These replacement parts will be damaged or lose their original function once removed.
(18) Inspection
When parts have been disassembled, visually inspect these parts for the following conditions or
other damage. If there is any doubt as to the condition of them , replace them with new ones.
Abrasion
Crack
Hardening
Warp
Bent
Dent .
Scratch
Wear
Color change
Deterioration
Seizure
(19) Specifications
Specification tenms are defined as follows.
"Standards" show dimensions or performances which brand-new parts or systems have.
"Service limits" indicate the usable limits. If the measurement shows excessive wear or deteriorated performance, replace the damaged parts.
1-4 GENERAL INFORMATION
KLF220-A4/A5 (US, Canadian Model)
Model Identification
KLF22G-A 1 (US, Canadian Model)
KLF22G-A6 (US, Canadian Model)
KLF220-A 7 (US; Canadian Model)

KLF220-AS (US, Canadian Modell
GENERAL INFORMATION '-5
........................................................................................
General Specifications
........................................................................................
KLF22Q.Al
Items
Dimensions:
A2
A3
A3A
A4
A5
A6/A7/A8
Overall length
Overal l width
1745 mm
1 120 mm, (UIIC) 1 020 mm
Overall height
1 015 mm
Wheelbase
Seat height
Dry weight
1115mm
155mm
730 mm
183 kg, (UIIC) 181 kg
Curb weight: Front

Rear
88.5 kg,(UIIC) 88 kg
104.5 kg,(UIIC) 103 kg
Fuel tank capacity
10 L
IA)NGK
D8EA
NGK
D8EA
NGK D8EA,
(C)(E){UK)
DR8ES
Road clearance
I~II~IKI
Performance:
Minimum turning radius 2.7 m

Engine:
Bore and stroke

Displacement
Compression ratio
4stroke, SOHC, " cylinder

Air cooled
67.0 x 61.0 mm
215mL
9.3
Maximum horsepower
12.5 kW 117 PSI@7 500 r/min (rpmI.IUI-
Maximum torque
Type
Cooling system
Ignition system
17.7 Nm (1.8 k~m, 13.0 ft1 b)

@6000 r/min (rpmI,IUICarburetor, MIKUNI VM24SS
Recoil and Electrical starter
Magneto COl
Timing advance
Electronically advanced
Ignition timing
From 10' 8TDC@1 800 r/min (rpm)

to 35' BTDC@4600r/min (rpm)
NGK DR8ES (UIIA) NGK D8EA
Carburetion system
Starting system
Spark plug
Valve timing:
Open
Inlet
Close
Duration
Exhau st
Open
Close
Duration
35' 8TDC
57' ABDC
272'
54' BBDC
26' ATDC
260'
Forced lubrication (wet sump )
Lubrication system
Grade
SE, SF or SG class
En gine oil:
Viscosity SAE10W30, 10W40, 10W50,
20W40, or 20W50
Capacity 2.0 L
(U) : US model
(A) : Austral ian model
1040 mm
1040 mm
IC) : Canadian model

(UK) : UK model
1120mm
183 kg,(A) <- <-,(CIIEIIUK) <-, (A)(EIIUK)

185 kg
183.5 kg
<-,IAIIEIIUKI89
kg
88.5
kg,(A)
<<-,(U)(C) 88.5 kg IA)89 kg
<-,(C)(
EIIUK)
<-,
(AilE
IIU
K)
<-,(UIIC) 104.5 kg (A) 104 kg 104.5 kg, (A)<106 kg
105 kg
<-,(UIIC) 183 kg
(A) 184 kg
(E) : European model

(Continued on next page.)
'6 GENERAL INFORMATION
KLF220-A 1
A4
A2
A3
A3A
Gear
3.450 (69/20)
Wet multi disc and centrifugal
.~
<E-
<E<E-
<E<E<E-
<E<E<E-
Items
Drive Train:
A5
A61A71A8
Primary reduction system:
Type
Reduction ratio
Clutch type
Transmission: Type
5-speed plus reverse , constant mesh,
return shift
Gear ratios: 1st
2.923 (38113)
2nd
1.684 (32/19)
3rd
1.173 (27/23)
0.923 (24126)
4th
0.785 (22/28)
5th
Reverse 3.115 (27113 x 33122)
Final drive system :
Type
Reduction ratio
Overall drive ratio
Shaft
4.680 (1 B/ 15 x 39/ 10)
12.686 @Topgear
Final gear case oil:

Type
Capacity
AP I GL5 Hypoid gear oil SAE90

(above 5' C. 41 ' F) or SAE 80 (below
5' C.4 1' F)
0.2L
Frame:
Type
Caster (rake angle )
Camber
Toe-in
Tra il
Tread:
Front
Rear
Front tire : Type
Size
Rear tire:
Type
Size
Type
Wheel travel
Type
Rear:
Wheel travel
Suspension: Front:
Brake type: Front

Rear
Double tubular
4'
3'
30mm
17mm
764mm
776mm
Tubeless
AT 21 x8-9
Tubeless
AT22x 10-10
Independent swing arm
115mm
Torque tu be-link
125mm
Drum
<E<E-
<E-
<E<E<E-
<E-
<E<E-
<E<E<E<E-
12V 12Ah,
.., (A)1 2V
14Ah
<E<E-
~
~
<E-
<E-
Semi-sealed beam
12V25125W x 2
12V8W x2
Single phase AC
10 A@6000r/min (rpm!. 14 V
<E<E<E<E<E-
Electrical Equipm ent:
12V12Ah
Battery
Headlight:
Type
Bulb
Taillight
Magneto:
Type
Rated output
Drum
<E-
<E-
<E-
Specifications are subject to change without notice, and may not apply to every country_
ICIIEIIUKI
12V 14Ah
<E-
<E-
<E-
GENERAL INFORMATION 17
Periodic Maintenance Chart
The scheduled maintenance must be done in accordance with this chart to keep the vehicle in good
running condition. The first service is vitally important and must not be neglected.
First Service
Regular Service
= Clean, adjust, lubricate, tighten, or
replace parts as necessary.

Chassis
Brake wear - check *
Cable adjustments*
Battery - check
Steering play - check
General lubrication*
Nuts and bolts - tighten
Final gear case oil - change*
Engine
Air cleaner - service*
Clutch adjustment*
Valve clearance - check
Fuel system cleanliness - check *
Engine oil - change*
Oil filter - replace
Spark plug - clean and gap
Spark arrester - clean
*Service more frequently when operated in mud, dust, or otehr harsh riding conditions.
............................................................................
Torque and Locking Agent
............................................................................
The following tables list the tightening torque for the

major fasteners requiring use of a non-permanent locking
agent or liquid gasket.
Letter used in the "Remarks" column means:

L : Apply a nonpermanent locking agent to the threads.
o : Apply an oil to the threads and seated surface.
S : Tighten the . fasteners following the specified sequence.
St : Stake the fasteners to prevent loosening.
Fastener
Fuel System:
Carburetor Holder Bolts
Engine Top End:
Cylinder Head Bolts (8 mm Dia.)
(6 mm Dia.)
Camshaft Sprocket Bolt
Valve Clearance Adjusting Screw Locknuts
Camshaft Chain Guide Bolt
Engine Left Side:
Starter Clutch Allen Bolts
Recoil Starter Pulley Bolt
Ratchet Cover Nut
Engine Right Side:
Oil Pump Gear and Balancer
Drive Gear Nut: KLF22Q.A 1
KLF22Q.A2 ~
Balancer Gear Nut: KLF22Q.Al
KLF22Q.A2 ~
Clutch Spring Bolts
Primary Clutch Hub Nut
Secondary Clutch Hub Nut
Oil Pipe Banjo Bolts
Engine Removal/Installation:
Engine Mounting Bolts (8 mm Dia.)
(10 mm Dia.)
Engine Bracket Bolts
(*1): See Cylinder Head Installation
Use the basic torque table below for only the bolts
and nuts which do not require a specific torque value.
All of the values are for use with dry solvent-Gleaned
threads.
Basic Torque for General Fasteners
Torque
Thread
dia. (mm)
Nm
kgm
ft-Ib
5
6
8
10
12
14
16
18
20
3.4 - 4.9
5.9 -7.8
14 -19
25 - 34
44-61
73 -98
115 -155
165 - 225
225 - 325
0.35 -0.50
0.60 -0.80
1.4-1.9
2.6 - 3.5
4.5 -6.2
7.4 -10.0
11.5 -16.0
17.0 - 23
23 - 33
30 - 43 inlb
52 - 69 inlb
10.0 - 13.5
19.0 - 25
33 -45
54 -72
83 -115
125 -165
165 -240
N-m
Torque
k!l-m
ft-Ib
Remarks
9.8
1.0
87 in-Ib
34
9.8
34
12
8.8
3.5
1.0
3.5
1.2
0.9
25
87 in-Ib
25
104 in-Ib
78 in-Ib
(*1)
(*1)
0
34
59
12
3.5
6.0
1.2
25
83
125
78
120
12
78
78
15
8.5
13.0
8.0
12.0
1.2
8.0
8.0
1.5
87
104 in-Ib
26
34
26
2.7
3.5
2.7
19.5
25
19.5
43
104 in-Ib
61
94
58
58
58
11.0
0
0
0
0
Fastener
Engine Bottom End/Transmission:
Oil Drain Plug
Clutch Release Cam Pin
Return Spring Pin
Output Shaft Bearing Position Plate Screws
Neutral and Reverse Switch Screws
Crankcase Bolts
Relief Valve
Bearing Stopper Screw
Wheels/Tires:
Wheel Nuts
Final Drive:
Front Gear Case Bolts (8 mm Dia.)
KLF22Q.A 1
Drive Gear Nut:
KLF22Q.A2 Oil Seal Housing Nuts
Cam Damper Mounting Nut
Driven Gear Shaft Nut
KLF22Q.Al
Bearing Retainer:
KLF22Q.A2 Final Gear Case Drain Bolt
Speedometer Plug
Pinion Gear Nut
Ring Gear Nut
Final Gear Case Fi lIer Cap
Final Gear Case Cover Bolts
Axle Shaft Pipe Bolts
Propeller Shaft Housing Nuts
Brakes:
Rear Axle Nut
Front Axle Nut
Rear Brake Panel Bolts
Front Brake Panel Bolts
Suspension:
Front Suspension Arm Pivot Bolts
Rear Suspension' Arm Bolts
Shock Absorber Mounting Bolts
Steering:
Stem Clamp Allen Bolts
Stem Bottom End Nut
Tie-rod End Nuts
Tie-rod Adjusting Sleeve Locknuts
Knuckle Arm Pivot Nuts
Electrical System:
Spark Plug
(*2) : See Front Gear Case Installation
N-m
29
25
25
8.8
Torque
kg-m
3.0
2.5
2.5
0.9
ft-Ib
22
18.0
18.0
78 in-Ib
Remarks
L
L
L
L
8.8
15
3.9
0.9
1.5
0.4
78 in-Ib
11
35 in-Ib
34
3.5
25
25
78
120
25
78
147
108
120
20
20
69
147
15
25
20
25
2.5
8.0
12.0
2.5
8.0
15
11
12
2.0
2.0
7.0
15
1.5
2.5
2.0
2.5
18.0
58
87
18.0
(*2)
0
0
108
80
87
14.5
14.5
51
108
11.0
18.0
14.5
18.0
147
34
29
26
15
3.5
3.0
2.7
108
25
22
19.5
88
34
34
9.0
3.5
3.5
65
25
25
26
29
41
27
34
2.7
3.0
4.2
2.8
3.5
19.5
22
30
20
25
20
2.0
14.5
58
L
0
0
St
L
L
............................................................................
Cable Routing
.............................................................................
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Main Harness
Exciter Coil Leads
Pickup Coil Leads
Charging Coil Leads (Yellow)
Neutral and Reverse Switch Leads
Battery Ground Cable
Starter Motor Cable
Head Light Leads
Accessory Leads
Connect to the CDI unit lead connectors.
.......
o
Cl
m
m
:0
...
~
"TI
:0
3:
o
z
1.
2.
3.
4.
5.
6.
7.
Throttle Cable
Choke Cable
Switch Housing Lead
Front Brake Cable
Neutral and Reverse Indicator Lights
Coupler Cover
Taillight
Clamp
Through the clamp.
8.
9.
10.
11.
Front Brake Cable Equalizer

Reverse Cable
Battery
Battery Vent Hose
Clamp
Clamp on the
crankcase bolt.
Clamp on the
starter motor
mounting bolt.
1.
2.
3.
4.
5.
6.
7.
8.
Starter Motor
Engine
Fuel Tank
Carburetor Vent Hose
Breather Hose (for Engine)
Breather Hose (for Final Gear Case)
Breather Hose (for Rear Brake)
Rear Brake Cable
FUEL SYSTEM
Fuel System
Table of Contents
Exploded View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications ........ ... ....... . ............. _ . . . . . . . . . . . .
Special Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Throttle Case and Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Throttle Cable.Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Throttle Case Removal/Disassembly. . . . . . . . . . . . . . . . . . . . . . .
Throttle Case Assembly/I nstallation . . . . . . . . . . . . . . . . . . . . . . . .
Throttle Case Lubrication ................ . .. _. . . . . . . . . . . .
Choke Lever and Cable ................................... _. .
Choke Lever Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Choke Lever Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Carburetor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Carburetor Air Screw Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . .
Idie spe'ed Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Level Inspection/Adjustment . . . . . . . . . . . . . . . . . . . . . . . . .
Carburetor Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Carburetor Installation Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Carburetor Disassembly ........... ....... . _ . . . . . . . . . . . . . .
Carburet~r Assembly Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Carburetor Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Carbu retor Inspection. .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Cleaner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Cleaner Duct Installation Note ... ~ .. _. . . . . . . . . . . . . . . . . .
Air Cleaner Element Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Fuel Tank ........ _............. . . _. . . . . . . . . . . . . . . . . . . . . . .
Fuel Tank Removalll nstallation . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2
2-3
2-3
2-4
2-4
2-4
2-5
2-5
2-5
2-5
2-6
2-6
2-6
2-6
2-6
2-7
2-8
2-8
2-9
2-9
2-9
2-10
2-10
2-10
2-11
2-11
2-'
2-2 FUEL SYSTEM
....
........ ..............
Exploded
View ...... .................................. ......
.........................................' ...........
.............
~-
~~
~~@
~'lG
~
~
(jj)
CO>
~
~
;@
.
1. Jet Needle
2. Air Screw
3. Pilot Jet
4. Needle Jet
5. Main Jet
T1: 9.8 N-m (1.0 kg-m, 87 in-Ib}
G : Apply grease.
/"1
~,
'---
-A
FUEL SYSTEM 2-3
Specifications
Item
Th rottle Lever Free Play
Make/Type
Carburetor:
Main Jet
Main Air Jet
Jet Needle
Needle Jet
Pilot Jet
Pilot Air Jet
AirScrew
Starter Jet
Service Fuel Level
Float Height
Air Cleaner Element Oil:
Grade
Viscosity
Special Tool
Fuel Level Gauge: 57001-1017
Standard
2-3mm
Mikuni!VM24SS
#115
4> 1_8
5GN46-2
0-0
#30
4> 1.2
1% turns out
#45
5mm
21.8 mm
SE class
SAE30
2-4 FUEL SYSTEM
Th rottle Case and Cable
Throttle Case Removal/Disassembly

eRemove the throttle case screws and separate the case
halves.
Throttle Cable Adjustment

e<:heck throttle lever free play.
A. Throttle Case Screws

A. Throttle Lever Free Play : 2 - 3 mm
*If the free play is incorrect, loosen the locknut and
turn the adjuster until the proper amount of throttle
lever free play is obtained.
A. Adjuster
B. Locknut
NOTE
.Pull the cable tip from the throttle lever catch and then
remove the cable from the case.
A. Cable Tip
B. Locknut
the throttle cable cannot be adjusted by using the

adjuster at the throttle case, use the adjuster at the
carburetor. Do not forget to securely tighten the
adiuster locknut.
B. Locknut
Adjuster
D. Throttle Lever Bolt
eRe move the throttle lever bolt.
Off
A. Adjuster
c.
1.
2.
3.
4.
Throttle Lever Bolt

Throttle Lever
Spring
Bushings
FUEL SYSTEM 2-5
Throttle Case Assembly/Installation
eThrottle case assembly/installation is the reverse of

removal/disassembly. Note the following.
I WARNING.
OOperation with an improperly assembled throttle case
could result in unsafe riding condition .
eLubricate the throttle case and cable before assembly/

installation (see Throttle Case and Cable Lubrication).
eBe certain that the return spring is correctly installed
on the throttle lever.
A. Apply grease.
A. Return Spring Hook
eSwing the throttle control lever so that the carburetor

throttle valve is fully open. Turn the throttle limiter
screw until it is spaced about 1 mm away from the
throttle lever stop.
Choke Lever and Cable

u
NOTE
ORefer to the Owner's Manual for the function of the
throttle limiter and adjustment procedure of it.
h . . . . . . . . . . . . . u
Choke Lever Removal

-Unscrew the choke lever mounting screw.
eAdjust the throttle cable free play.
Throttle Case Lubrication

Whenever the throttle case is disassembled, and in
accordance with the Periodic Maintenance Chart, per-
form the following.

eApply a thin coating of multipurpose grease to the
throttle control lever pivot area and the throttle cable
end.
A. Mounting Screw
B. Choke Lever
C. Wave Washer
............ . ..... .
2-6 FUEL SYSTEM
eRemove the choke lever from the housing.
eRemove the clip and pull the cable from the housing.
A. Air Screw
eBack the air screw out the specified number of turns.
A.Clip
Choke Lever Lubrication

Whenever the choke cable is removed, lubricate the
choke lever as follows.
eApply a thin coating of multi-purpose grease to the
wave washer.
Air Screw Setting

Standard:
1Y.z turns out
Idle Speed Adjustment

eAdjust the air screw (see Carburetor Air Screw Adjustment).
.
eStart the engine and warm it up thoroughly.
eTurn ' the idle adjusting screw to obtain the slowest
smooth idle speed.
A. Apply grease.
A. Idle Adjusting Screw
Carburetor
Carburetor Air screw Adjustment

eTurn the carburetor air screw all the way in until it
seats lightly.
tCAUTlO~J
000 not overtighten the air screw or the carburetor
body will be damaged and require replacement.
Fuel Level Inspection/Adjustment
I WARNING.
oGasoline is extremely flammable and can be explosive
under cenain conditions. Tum the ignition switdt
OFF. 00 not smoke. Make sure the area is well
ventilated and free from any source of flame or sparks;
this includes any appliance with a pilot light.
FUEL SYSTEM 27
.Park the vehicle on a level surface.
e(;onnect the fuel level gauge (special tool) to the open
end of the carburetor overflow tube .
Turn the fuel tap to the ON position to feed fuel to the
carburetor and gauge, then loosen the carburetor drain
plug a few turns .
Read the fuel level in the gauge and compare it to the
specification. Screw in the carburetor drain plug.
NOTE
oKeeping the gauge vertical, align its "zero" line with

the bottom edge of the carburetor body. Then loosen
the drain plug to feed fuel to the gauge.
1. Float
2. Tang
.Measure the float height as shown.
Float height
1.
2.
3.
4.
5.
Fuel Level Gauge: 570011017

Overflow Tube
Carburetor Body Bottom Edge
Zero Line
Fuel Level
1. Float bowl mating surface

2. Float valve needle rod (loaded and pushed in)
3. Float
Float Height
Standard:
21.8mm
Service Fuel Level

5 mm below the bottom edge of the carburetor
body.
Carburetor Removal
I WARN.ING
*If the fuel level is incorrect, adjust it.
.To adjust the fuel level, bent the tang on the float arm
to change the float height.
Clnereasing the float height lowers the fuel level and
decreasing the float height raises the fuel level.
OGasoline is extremely flammable and can be explosive

under certain conditions. Tum the ignition switch
OFF. Do not smoke. Make sure the area is well
ventilated and fr~e from any source of flame or sparks;
2-8 FUEL SYSTEM
eTurn the fuel tap OFF.
eRemove the following parts.
Seat
Vent Hose
Fuel Hose
Clamps
Starter Plunger
eAfter installing the carburetor, adjust the following.

Throttle Cable
Idle Speed
Carburetor Disassembly
eRemove the carburetor.
eRe move the following parts from the carburetor body.
A.Clamps
B. Starter Plunger
ePull out the carburetor.

-Unscrew and remove the carburetor cap.
A. Pin
B. Float with Float Valve
A. Carburetor Cap
Carburetor Installation Notes
A. Main Jet Fence

B. Plate
C. Pilot Jet
eAlign the slit on the side of the throttle valve with the
guide pin in the carburetor body.
A. Guide Pin
B. Slit
A. Main Jet
B. Needle Jet Holder
C. Float Valve Seat
FUEL SYSTEM 2-9
Carburetor Cleaning
ODo not use compressed air on an assembled carburetor,

the floats may be crushed by the pressure.
ORemove as many rubber or plastic parts from the car
buretor as possible before cleaning the carburetor with
a cleaning solution. This will prevent damage or
deterioration of the parts.
olbe carburetor body has plastic parts 1Itat cannot be
removed_ DO NOT use a strong carburetor cleaning
solution which could attack 1Itese parts; instead, use
mild cleaning solution safe for plastic parts.
000 not use wire or any other hard instrument to clean
carburetor parts, especially jets, as 1Itey may be
damaged.
A. Needle Jet
eDisassemble the carburetor (see Carburetor Disassembly).

elmmerse all the metal parts in a carburetor cleaning
solution .
eRinse the parts in water.
eWhen the parts are clean, dry them with compressed
air.
eBlow the air and fuel passages with compressed air.
eAssemble the carburetor (see Carburetor Assembly).
Carburetor Assembly Notes

eTurn the carburetor body upside-down, and drop the
needle jet into place. The long end of the jet goes in
first.
Carburetorlnspecdon
eBefore removing the carburetor, check the fuel level
(see Fuel Level Inspection) .
*If the fuel level is incorrect, inspect the rest of the
carburetor before correcting it.

eDisassemble the carburetor (see Carburetor Disassembly) .
eClean the carburetor (see Carburetor Cleaning).
eCheck that the O-rings on the carburetor holder, starter
plunger, plunger cap, idle adjusting screw, air screw, air
bleed pipe, and float valve seat and the gaskets on the
carburetor cap and float bowl are in good condition.
A. Long End
!CAUTl~~1
a Do not force 1Ite needle jet holder (air bleed pipe) and
main jet or ovenighten them. The needle jet or the
carburetor body could be damaged requiring replacement.
A. O-rings
B. Gasket
2-10 FUEL SYSTEM
Air Cleaner
Air Cleaner Duct Installation Note

eThe arrow on the air cleaner duct must point toward
the front (carburetor side).
A. O-ring
B. Gasket
*If any of the O-rings or gaskets are not in good condition, replace them .
Push in the rod in the other end of the float valve
needle and then release it.
*If it does not spring out, replace the needle.
*Cleek the tip of the valve needle. It should be smooth,
without any grooves, scratches, or tears.
1. Arrow
2. Duct
Air Cleaner Element Cleaning
I WARNING.
-+---{2
OCean the element in a well-ventilated area, and. take

care that there is no spark or flame near the 'working
area. Because of the danger of highly flammable
liquids, do not use gasoline or low flash1XJint solvents
to clean the element.
Push and release
eRe move the following parts.

Seat
Air Cleaner Housing Cover
1. Rod
2. Valve Needle
3. Valve Needle Wear
echeck the tapered portion of the air screw for wear

or damage.
1 . Air Screw
2. Tapered Portion
A. Air Cleaner Housing Cover
B. Hooks
*If the air screw is worn or damaged on the tapered

portion , it will prevent the engine from idling smoothIy. Replace it.
eRe move the air cleaner element.
FUEL SYSTEM 2-11
I WARNING.
OGasoline is extremely flammable and can be explosive
under certain conditions. Turn the ignition switch
OFF. Do not smoke. Make sure the area is well
ventilated and free from any source of flame or sparks;
A. Air Cleaner Element
B. Screws
eRemove the side plate and peel the element off the
frame.
A. Bolts
CD
eDrain the fuel tank.

elnstallation is the reverse of removal. Note the
following.
OCheck the rubber dampers on the frame top-tubes .
.
1. Screw
2. Side Plate
3. Air Cleaner Element
eWash the element in a bath of high flash-point solvent

and then squeeze it dry,
fCAUTlON!
000 not wring or twist he element as it may tear.
eSaturate the element with SAE30 motor oil, and
squeeze out the excess.
eWrap the element in a clean, dry cloth and squeeze it as
dryas possible.
A. Dampers
"'If the dampers are damaged or deteriorated, replace

them.
OBe sure the fuel hose is clamped to the fuel tap to
prevent leaks.
Fuel Tank
Fuel Tank Removal/Installation

eRe move the front fender (see Frame chapter).
eTurn the fuel tap to the OFF position.
ePull the fuel hose off the tap.
ENGINE TOP END 3-1
Engine Top End

Table of Contents
Exploded View ...... . _ . _ . . . . . . . ..
3-2
Specifications. . . . . . . . . . . . . . . . . . ..
Special Tools . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head . . . . . . . . . . . . . . . . . . . . . ..
Cylinder Head Removal . . . . . . . . . . ..
Cylinder Head Installation. . . . . . . . ..
Cylinder Head Disassembly. . . . . . . ..
Cylinder Head Assembly. . . . . . . . ..
Valve Guide Removal. ..... ........
Valve Guide Installation .... . . . ... ..
Cylinder Compression Measurement . . . .
Cylinder Head Warp . . . . . . . . . . . . . . .
Camshaft Chain and Tensioner ..........
Camshaft Chain. . . . . . . . . . . . . . . . . . ..
Camshaft Chain Timing ...........
Camshaft Chain Removal . . . . . . . . . . .
Camshaft Chain Installation . . . . .. . .. .
Camshaft Chain Wear . . . . . . . . . . . . .
34
3-6
3-7
3-7
3-7
3-8
3-9
3-10
3-10
311
3-11
3-11
3-11
3-11
3-12
3-12
3-12
Camshaft Chain Guide Wear ....... .. 3-13

Camshaft Chain Tensioner. . . . . . . . . . . . . 3-13
Camshaft Chain Tensioner Removal
3-13
Camshaft Chain Tensioner
Installation ..... ..... .. ...... 3-13

Valves .. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Valve Clearance Adjustment ... . ..... 3-14
Measuring Valveto-Guide Clearance
(Wobble Method) ........ . . ....

Valve Spring Free Length .. .........
Valve Seat Inspection ... . , .. .... ...
Valve Seat Repair . . . . . . . . . . . . . . . .
Cylinder, Piston . . . .... .. . .. . .. .....
Removal . . . . . . . . . . . . . . . . . . . . .
Installation ... ....... .........
Cylinder Wear. . . . . . . . . . . . . . . . . .
Piston Wear . . . . . . . . . . . . . . . .. . ..
3-14
3-15
3-15
3-15
3-18
3-18
3-19
3-19
3-20
Piston Ring, Piston
Ring Groove Wear ..... _ . . . .. 3-20

Piston Ring End Gap. . . . . . . . . . . . . . 3-20
Exhaust System . . . . . . . . . . . . . . . . . . . ..
Spark Arrester . . . . . . . . . . . . . . . . . . . .
Spark Arrester Cleaning . . . . . . . . . .. . .
Exhaust Pipe and Muffler . . . . . . . . . . . . .
Exhaust Pipe and Muffler Removal .....
Exhaust Pipe and Muffler Installation . ..
3-20
3-20
3-21
3-21
3-21
3-21
3-2 ENGINE TOP E
__ ______
NO
Expl~d;;~v
:: : :
......................~~~ ................... ::: ...:::: ...:: ::.....::::...:::: ...::: ::.....
o(""""\B
o~~O
o
ENGINE TOp END 3-3
T1: 34 N-m (3.5 kg-m, 25 ft~b)

First Torquing: 13 N-m (1.3 kg-m, 113 in-Ib)
T2: 9 _8 N-m (1_0 kg-m, 87 in~b)
First Torquing: 5_9 N-m (0_6 kg-m, 52 in-I b)
T3 : 34 N-m (3.5 kg-m, 25 ft-Ib)
T4: 12 N-m (12 kg-m, 104 in~b)
T5: 8.8 N-m (0_9 kg-m, 78 in-Ib)
o : Apply engine oil.
SS : Apply silicone sealant.
M : Apply molybdenum disulfide grease.
34 ENGINE TOP END
.............................................................................
Specifications
Cylinder Head:
Item
Cylinder Head Warp
Standard
Service limit
0.05 mm
Standard
Service limit
0.15 - 0.20 mm
0.18 - 0.23 mm
45
0.8mm
1.0mm
Valve, Guides, Seats, Springs, Oil Seals:

Item
Valve Clearance:
IN.
EX.
Valve Seating Surface Angle
Valve Head Thickness: IN.
EX.
Valve Stem Bend
Valve Stem Diameter:
IN.
EX.
Valve Guide Inside Diameter
Valve/Valve Guide Clearance
(wobble method):
IN.
EX.
Valve Seating Surface Width:
IN.
EX.
Valve Seating Surface Diameter:
IN .
EX.
Valve Spring Free Length :
Inner
Outer
5,495 - 5.510 mm
5.480 - 5,495 mm
5.520 - 5.532 mm
0.4 mm
0.5mm
0.05 mm
5.48mm
5,47 mm
5.60 mm
0.02 - 0.08 mm
0.05 - 0.11 mm
0.23 mm
0.27 mm
0.5-1.0mm
0.5 -1.0mm
30.9 - 31.1 mm
26.9 - 27.1 mm
37.8 mm
40,4mm
36.2 mm
38.7 mm
Standard
Service Limit
127.00 - 127.36 mm
128.9 mm
Camshaft Chain, Guides and Tensioner:

Item
Camshaft Chain Length/20 Links
Valve Head
Valve Stem Bend
Valve head
45
ENGINE TOP END 35
Camshaft, Rocker Arms and Shafts:
Item
Standard
Rocker Arm Inside Diameter

Rocker Shaft Diameter
Cam Height
IN.
EX.
10.000 9.970 40.395 39.720 -
10.015 mm
9.995 mm
40.503 mm
39.828 mm
Service Limit
10.05 mm
9.95 mm
4O.30mm
39.62 mm
Cylinder, Piston, Rings:

Standard
Items
Cylinder Compression
(Usable Range)
with Recoil Starter
1 010 - 1 540 kPa

(10.3 - 15.7 kg/em', 146 - 223 psi)
1 030 - 1 570 kPa
(10.5 - 16.0 kg/em' .' 149 - 228 psi)
67.000 - 67.012 mm, and less
than 0.01 mm difference between
any two measurements
with Electric Starter

Cylinder Inside Diameter
Piston Diam~er
Piston/Cylinder Clearance
Piston Ring/Groove Clearance:
Top and Second
Piston Ring Groove Width:
Top
Second
Oil
Piston Ring Thickness:
Top
Second
Piston Ring End Gap:
Top
Second
Cam Height Measurement
Cam Height
-f---+------lHr-
66.960 - 66.975 mm
0.025 - 0.052 mm
Service Limit
67.10 mm, or more than

0.05 mm difference between any two measure
ments
66.81 mm
0.02 - 0.06 mm
0.16 mm
0.81 - 0.83 mm
1.21 -1 .23 mm
2.51 - 2.53 mm
0.91 mm
1.31 mm
2.61 mm
0.77 - 0.79 mm
1.1 7 -1.19 mm
0.70mm
1.10mm
0.15 - 0.35 mm
0.30 - 0.45 mm
0.7mm
0.8mm
3~
ENGINE TOP END

Valve Guide Arbor: 57001-1021
Special Tools
Compression Gauge: 57001-221
with Adapter Hose: 57001-1018
Valve Seat Cutter Holder 5.5: 57001-1125
Valve Spring Compressor Assembly: 57001-241

with Adapter: 57001-1019
Valve Seat Cutter Holder Bar: 57001-1128
(
,
Valve Seat Cutters:
Piston Pin Puller Assembly: 57001-910
Valve Guide Reamer: 57001-1020
(45 - 4>30:
(45 - 4>35:
(32 -4>35:
(SOo - 4>30:
(SOo - </>41:
57001-1187)
57001-1116)
57001-1121)
57001-1123)
57001-112.41
ENGINE TOP END 3-7
............................................................................
Cylinder Head
Cylinder Head Bolts
Cylinder Head Removal

_Remove the following.
Seat
Front Fender
Fuel Tank
Carburetor
Exh~ust Pipe
Breather Hose
Cylinder Head Bracket
A. Cylinder Head Bolts (8 mm)

B. Cylinder Head Bolts (6 mm)
-Remove the cylinder head.
B. Bolts
A. Cylinder Head Bracket

Oil Pipe
Camshaft Chain Tensioner
Camshaft Cover
A. Camshaft Cover
Cylinder Head Installation

elnstallation is the reverse of removal.
Note the
following.
-Blowout the oil passage with compressed air.
-Install a new cylinder head gasket.
-Be sure the dowel pins are in place.
B. Bolts
Camshaft Sprocket
A. Dowel Pins
-Slip the cylinder head into position.

-Set the camshaft chain timing (see Camshaft Chain
Timing).
-Install the camshaft chain tensioner.
NOTE
A. Camshaft Sprocket
B. Sprocket Bolt
Olnstall the longest banjo bolt in the cylinder head when

installing the oil pipe.
3-8 ENGINE TOP END
- Tighten the following bolts to the specified torque (see
Exploded View) .
Camshaft Sprocket Bolt
Cylinder Head Bolts
Banjo Bolts
Cylinder Head Bracket Bolts (see Engine Removal/
Installation chapter)
OApply oil to the threads and flanged portion of the
camshaft sprocket bolt.
eApply silicone sealant to the threads of the right front
cylinder head bolt, and oil to the threads of the others.
Oil all Gylinder head bolt flanges.
oTIghten the cylinder head bolts in a criss-cross pattern
as shown, in two steps.
A. Valve Caps
B. Rocker Shaft Retainer
C. Screws
1
Compression Release Mechanism
4
o : Apply oil.
A. Compression Release Mechanism

B. Retaining Bolt
Rocker Shaft
Rock"r Arm
Camshaft
NOTE
SS : Apply silicone sealant.
QScrew the camshaft. sprocket bolt into the shaft and

pull out the shaft with it.
Cylinder Head Bolt Torque

First Torquing
8 mm Bolt: 13 N-m (1.3 kg-m, 113 in-Ib)
6 mm Bolt: 5.9 N-m (0.60 kg-m, 52 in-Ib)
1Specified Torque
Cylinder Head Disassembly

eRemove the following.
Valve Caps
Rocker Shaft Retainer
A. Rocker Shaft
B. Camshaft Sprocket Bolt
C. Camshaft
ENGINE TOP END 3-9
.Press down the valv~ spring retainer with a valve spring
compressor assembly (special tool}, and the remove the
split keepers.
Cylinder Head Assembly

eAsst!mbly is the reverse of disassembly. Note the
following.
eReplace the oil seal on. the compression release
mechanism. if it is damaged.
A. Valve Spring Compressor Assembly: 57001-241
ORemove the valve spring retainer, springs, spring seat,

and valve.
A. Oil Seal
NOTE
OFor best results, do not reuse old valve stem oil seals,
especial/y if valves are replaced. .
eApply a thin coat of molybdenum disulfide grease to

the valve stem before valve installation.
elnstall the springs so that the closed coil end faces
downwards.
1. Valve
2. Spring Seat
3. Inner Spring
4. Outer Spring
5. Valve Spring Retainer
6_ Split Keepers
~
oPull off the valve stem oil seal.
~.,
~.:.
~
.r~
-~
A. Closed Coil End
A. Oil Seal
-Oil the rocker shafts.

elnstall each rocker shaft with the shaft notch to the
inside.
3-10 ENGINE TOP END

~
-See the camshaft chain timing (see Camshaft Chain

Timing).
-Check the valve clearance (see Valve Clearance Adjustment).
45
"'''-------1
Valve Guide Removal

eDisassemble the cylinder head.
NOTE
OHeat the area around the valve guide to 120 - 15d'C
(248 - 302F).
1. Notches
2. Retainer
eUsing the valve guide arbor (special tool)' tap out the
valve guide.
eThe 45 angle end of the rocker shaft retainer goes to

ward the exhaust side.
eBlow out the oil passage with compressed air.
1. Valve Guide Arbor: 57001-1021
Valve Guide Installation

A. Compressed Air
-Using the valve guide arbor (special tool), drive in the

valve guide until its flange touches the cylinder head.
NOTE
eLubricate the camshaft with engine oil, and then install

it.
eHook the compression release mechanism spring as
shown.
A. Spring
OHeat the area around the valve guide hole to 120150C (248 - 302F).
OApply oil to the valve guide outer surface before valve
guide installation.
OUsing the valve guide reamer (special tool), ream the
valve guide.
1. Valve Guide Reamer: "57001 -1020
ENGINE TOP END 3-11
Cylinder Compression Measurement
Cylinder Head Warp
-Warm up the engine thoroughly and then remove the

spark plugs.
-Attach the compression gauge and adapter (special
tools) firmly into the spark plug hole.
-Lay a straightedge across the lower surface of the head

at several different points, and measure warp by in
serting a thickness gauge between the straightedge and
the head.
*If warp exceeds the service limit, repair the mating
surface. Replace the cylinder head if the mating sur
face is badly damaged.
Cylinder Head Warp

Service Limit:
0.05 mm
A. Compression Gauge: 57001-221

B. Adapter: 57001 1018
-Hold the throttle wide open and crank the engine with
the recoil starter, or the electric starter.
-When the gauge stops rising, stop cranking and read the
gauge.
Cylinder Compression (Usable Rangel

with Recoil Starter
Camshaft Chain and Tensioner
1 010 - 1 540 kPa

(10.3 - 15.7 kg/cm'. 146 - 223 psil
Camshaft Chain:
with Electric Starter

1 030 - 1 570 kPa
(10.5 - 16.0 kg/cm'. 149 - 228 psil
-Remove the following.

Camshaft Cover
Timing Inspection Plug
Recoil Starter (to turn the crankshaft)
Camshaft Chain Timing
NOTE
OBattery must be fully charged.
*If cylinder compression is higher than the specified

range, check the following.
OCarbon build-up on the cylinder head combustion
chamber
OCarbon buildup on the piston head
*If cylinder compression is lower than the specified
range, check the following.
oValve not seating properly
OPiston/cylinder clearance excessive
eGas leakage around the cylinder head gasket
oValve clearance too small
A. Timing Inspection Plug
B. Recoil Starter
312 ENGINE TOP END
eTurn the crankshaft counterclockwise. until the "T"
mark on the magneto flywheel aligns with the pointer.
A. Chain Guard
B. Screws
eRe move the camshaft chain.

A. Pointer
B. T Mark
eThe punch mark on the camshaft sprocket should align

with the projection.
Camshaft Chain Installation

-umshaft chain installation is the reverse of removal.
Note the following.
[CAUTION]
OAiways pull the camshaft chain taut while turning the
crankshaft when the camshaft chain is loose. This
avoids kinking the chain on the lower (crankshaft)
sprocket. A kinked chain could damage both the chain
and the sprocket.
-Check the camshaft chain timing.

A. Projection
B. Punch Mark
Camshaft Chain Removal

Camshaft Cover
Camshaft Sprocket
Recoil Starter
Left Engine Cover
Magneto Flywheel (see Engine Left Side chapter)
Starter Clutch Gear
Chain Guard
Camshaft Chain Wear

eHold the chain taut with a force of about 5 kg in some
manner, and measure a 20~ink length. Since the chain
may wear unevenly J take measurements at several
places.
*If any measurement exceeds the service limit, replace
the chain.
Camshaft Chain 2().(ink Length

Standard:
Service Limit:
127.00 -127.36 mm
128.9mm
ENGINE TOP END 3-13
[CAUTlO~]
Chain Length Measurement
201 in k Length
000 not tum the engine while the camshaft chain

tensioner is removed . Engine damage could result.
Camshaft Chain Tensioner Installation

-Reassemble.the camshaft chain tensioner.
oRe move the lock bolt locking the push rod in place.
OC:ompress the spring and insert a wire in the hole.
Camshaft Chain Guide Wear

eVisually inspect the rubber on the guides.
*If the rubber is damaged, cut, or is missing pieces,
replace the guide.
Camshaft Chain Tensioner:

Camshaft Chain Tensioner Removal
NOTE
oTo temporarily remove the camshaft chain tensioner,

remove the lock bolt and screw in a longer bolt (6 mm
x 20 mml to hold the tensioner push rod in place, or
the tensioner must be disassembled and assembled
before installation.
oDrop the ball and retainer assembly onto the push rod.
OPusil the push rod up into the tensioner body held vertically.
oWhen the push rod is in as far as it will go, screw in the
lock bolt with its washer.
oPull out the wire, releasing the spring.
eTake out the tensioner mounting bolts and remove the

camshaft chain tensioner.
I
..- ..
1. Lock Bolt
2. Push Rod
3. Ball
A. Lock Bolt
B. Mounting Bolts
4. Spring
5. O-ring
elnstall the tensioner on the cylinder, loosen the lock

bolt and then tighten it.
-Be sure the G-ring is in place in the tensioner body.
314 ENGINE TOP END
............................................................................
Valves
Valve Clearance
Inlet
Exhaust
Standard
0.15 - 0.20 mm
0.18 - 0.23 mm
Valve Clearance Adjustment

NOTE
OCheck the valve clearance only when the engine is cold

(cool to the touch).
-Remove the following
Front Fender
Valve Caps
Timing Inspection Plug
Recoil Starter (to turn the crankshaft)
A. Adjusting Screw
B. Locknut
*If the valve clearance is not correct, continue with the

following procedure.
-Loosen the locknut and turn the adjusting screw until
the clearance is correct.
-Hold the adjusting screw from turning and tighten the
locknut to the specified torque (see Exploded View) .
A. Valve Adjusting Caps
-Turn the crankshaft counterclockwi5e, until the "T"

mark on the magneto flywheel align with the pointer.
Measuring ValvetoGuide Clearance

(Wobble Method)
If a small bore gauge is not available, inspect the valve
guide wear by measuring the valve to valve guide clear
ance with the wobble method , as indicated below.
_Insert a new valve into the guide and set a dial gauge
against the stem perpendicular to it as close as possible
to the cylinder head mating surface.
-Move the stem back and forth to measure valve/valve
guide clearance.
-Repeat the measurement in a direction at a right angle
to the first.
*If the reading exceeds the service limit, replace the
guide.
NOTE
oThe reading is not actual valve/valve guide clearance

because the measuring point is .a bove the guide.
A. Pointer
B. T Mark
ValveNalve Guide Clearance
(Wobble Method)
-Measure the clearance of each valve between the end of

the valve stem and the adjusting screw on the rocker
arm with a thickness gauge.
Inlet
Exhaust
Standard
Service Umit
0.02 - 0.08 mm
0.05 - 0.11 mm
023mm
0.27mm
ENGINE TOP END 3-15
NOTE
OThe valve stem and guide must be in good condition or

this check will not be valid.
*If the valve seating pattern is not correct, repair the
seat (see Valve Seat Repair) .
Valve guide
Valve Seating Pattern
Good
Too Wide
Too Narrow
Uneven
Valve Spring Free Length

eMeasure the valve spring free length with a vernier
caliper.
*If the free length is less than the service limit, replace
the spring.
Valve Spring Free Length
Inner
Standard:
Senice Limit:
37.8 mm
362mm
Outer
Standard
Service Umit:
4O.4mm
38.7 mm
eMeasure the outside diameter of the seatiAg pattern on

the valve seat.
*If the outside diameter of the valve .seating pattern is
too large or too small, repair the seat (see Valve Seat
Repair) .
Valve Seating Surface Outside Diameter

30.9 - 31 .1 mm
Intake:
26.9-27.1 mm
Exhaust:
Valve Seat Inspection

eRemove the valve (see Cylinder Head Disassembly).
-COat valve seat with machinist's dye.
ePush the valve into the guide.
eRotate the valve against the seat with a lapping tool.
ePuIl the valve out, and cheGk the seating pattern on the
valye head. It must be the correct width and even all
the way around.
Valve Seat Repair

Valve Seating Width
Standard:
os -1.omm
Valve Seating Area Dimensions
eelean the cylinder head thoroughly.

eUse the following proGedure and tools to repair the
valve seat.
Used Valve Seat Cutters
1. Valve
2. Valve Seat
3. Seating Area Outside
diameter
4. Seating Area Width
Intake Valve
45 = 4>35
32 = 4>35
60 = </>41
Exhaust Valve
45 = 4>30
32 = 4>35
60 = 4>30
57001-1116
57001-1121
57001-1124
570011187
57001-1121
57001-1123
316 ENGINE TOP END
Used Holder and Bar
Holder - </>5.5
Bar
570011125
570011128
Marks StamJl!!d on the Cutter:

The marks stamped on the back of the cutter repre
sent the following.
60 . . . . . . . . . . . . .Cutter angle
41.01/> .......... .Outer diameter of cutter
Cutter
Seat Cutter Operating Cares:
1. This valve seat cutter is developed to grind the valve
seat for repair. Therefore the cutter must not be used
for other purposes than seat repair.
2. Do not drop or strike the valve seat cutter J or the diamond particles may fall off.
3. Be sure to apply engine oil to the valve seat cutter
before grinding the seat surface. Also wash off
ground particles sticking to the cutter with washing
oil.
NOTE
OA wire brush must not be used to remove the ground

particles from the cutter. That will cause the dia
mond particles to fall off.
4. Setting the valve seat cutter holder in position, oper
ate the cutter in one hand. Do not apply too much
force to the diamond portion.
NOTE
oPrior to grinding, apply engine oil to the cutter and

during the operation, wash off any ground particles
sticking to the cutter with washing oil.
1. Outer Diameter of Cutter

2. Angle of Cutter
Operating Procedure:
eelean the seat area carefully.
ecoat the seat with machinist's dye.
eFit a 45 cutter to the holder and slide it into the valve
guide.
ePress down lightly on the handle and turn it right or
left. Grind the seating surface only until it is smooth.
{CAUTlO~ I
Valve Seat Cutter
0 00 not grind the seat too much. Overgrinding will

reduce valve clearance by sinking the valve into the
head. If the valve sinks too far into the head, it wilrbe
impossible to adjust the dearance, and the cylinder
head must be replacad.
,Valve Seat R_ir
Widened width of
engagement by machining
with 45 cutter
1. Cutter
2. Cutter Holder
3. Bar
5. After use, wash it with washing oil and apply thin
layer of engine oil before storing.
Ground volume
by 32 cutter
ENGINE TOP END 317
Valve Seat Repair
START
t
Machinist's
dye on seat
45 Grind
Tool:
Purpose:
45 Cutter
make seating area
smooth and round
Measure Seating Area 0.0.

Tool
Purpose:
Vernier Caliper
check seat O. O.
against spec.
Re{ults
t
Tool small
OK
45 Grind
Tool:
Purpose:
t
t
Too big
Machinist's
dye on seat
45Cutter
increase 0.0. of seat
area to spec.
t
32 Grind
Tool:
Purpose:
32Cutter
reduce 0.0. of seat area
to spec.
Measure Seat Width

Tool:
Purpose:
Vernier Caliper
check seat width
against spec.
Re+ts
I Too narrow I
Tool:
Purpose:
t
OK
t
t
Too wide
45 Grind
Machinist's
45 Cutter
increase width of seat
area beyond spec. to
dye on seat
increase 0.0.
60 Grind
Tool:
Purpose:
Lap Valve
Tools:
Purpose:
Valve lapper, grinding

compound
perfectly match valve
and seat area; check
valve head for damage
( FINISHED )
60 Cutter
reduce seat width
to spec.
3-18 ENGINE TOP END
eMeasure the outside diameter of the seating surface
with a vernier caliper.
*If the outside diameter of the seating surface is too
Valve lapping
small, repeat the 45 grind until the diameter is within

the specified range.
*If the outside diameter of the seating surface is too
large, make the 32 grind described below.

*If the outside diameter of the seating surface is within
\I.~----I
the specified range, measure the seat width as described

below.
eGrind the seat at a 32 angle until the seat 0.0. is
within the specified range.
OTo make the 32 grind, fit a 32 cutter to the holder,
and slide it into the valve guide.
oTurn the holder one turn at a time while pressing down
very lightly . Check the seat after each turn.
OThe 32 cutter removes material very quickly. Check

the seat outside diameter frequendy to prevent over~
grinding_
1. lapper
2. Valve Seat
3. Valve
OAfter making the 32 grind, return to the seat 0.0.

measurement step above.
eTo measure the seat width, use a vernier caliper to

measure the width of the 45 angle portion of the seat
at several places around the seat.
*If the seat width is too narrow, repeat the 45 grind
until the seat is slightly too wide, and the9 return to
the seat 0.0. measurement step above.
*If the seat width is too wide, make the 60 grind
described below.
*If the seat width is within the specified range, lap the
valve to the seat as described below .
eGrind the seat at 60 angle until the seat width is
oTo make the 60 grind, fit a 60 cutter to the holder,
and slide it into the valve guide.
oTurn the holder, while pressing down lightly.
OAfter making the 60 grind, return to the seat width
measurement step above.
elap the valve to the seat, once the seat width and 0.0.
are within the ranges specified above.
o Put a little coarse grinding compound on the face of
the valve in a number of places around the valve head.
oSpin the valve against the seat until the grinding compound produces a smooth, matched surface on both
the seat and the valve.
ORepeat the process with a fine grinding compound.
eThe seating area should be marked about in the middle
of the valve face.
*If the seat area is not in the right place on the valve,
check to be sure the valve is the correct part. If it is, it
may have been refaced too much; replace it.
eBe sure to remove all grinding compound before
assembly.
eWhen the engine is assembled, be sure to adjust the
valve clearances (see Valve Clearance Adjustment).
Cylinder. Piston
Removal
eRemove the cylinder head .
Pull out the camshaft chain front guide.
eLift the cylinder off.
.place a clean cloth under the piston and remove one
piston pin snap ring.
OUsing the piston pin pul/er assembly (special tool),
remove the piston pin.
1. Piston Pin Puller Assembly: 57001-910
ENGINE TOP END 3-19
Installation
elnstall the oil ring expander in the bottom piston ring
groove so the ends butt together.
000 not reuse the snap ring which was removed. Removal weakens and deforms the snap ring. It could
fall out and score the cylinder wall.
eBe sure the O-ring is in place at the bottom of the
cylinder.
eThe second ring must be installed with the "RN" inark

on the ring facing up.
Top and Second Rings
A. O-ring
Top
ring
Cylinder Wear
eMeasure the cylinder inside diameter taking a sidetoside and a frontto. back measurement at each of the 3
positions (total of 6 measurements) shown below.
2nd
ring
Cylinder Diameter Measurement
eThe arrow on the piston head must point toward the

front.
EB
40mm
A.Arrow
Cylinder Inside Diameter

67.000 -67 .012 mm
Standard
Service Umit:
67.10mm
20mm
3-20 ENGINE TOP END
Piston Wear
Piston Ring End Gap
eMeasure the piston outside diameter 5 mm up from the

bottom of the piston at a right angle to the direction of
the piston pin.
.Place the piston ring inside the cylinder, using the

piston to locate the ring squarely in place. Set it close
to the bottom of the cylinder, where cylinder wear is
low.
eMeasure the gap between the ends of the ring with a
thickness gauge.
Piston Outside Diameter
Standard :
Service Limit:
66.960 - 66.975 mm
66.81 mm
Piston Ring End Gap
Top
Second
Standard
0.2 -0.35 mm
0.3 - 0.45 mm
Service Limit
0.7mm
O.Bmm
CD
1. Piston Outside Diameter
Piston Ring, Piston Ring Groove Wear

e<:heck for uneven groove wear by inspecting the ring
seating.
*The "rings should fit perfectly parallel to the groove
surfaces. If not, the pilton must be replaced.
-With the piston rings in their grooves, make several
measurements with a thickness gauge to determine
piston ring/groove clearance.
Piston Ring/Groove Clearance
Standard
Top
0.02 - 0.06 mm
Second
0.02 - 0.06 mm
1. Gap
2. Piston Ring
Service Limit
0.16mm
0.16mm
Exhaust System
u
. . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . .
....... .
Spark Arrester:
This vehicle is equipped" with a spark arrester approved for off road use by the U.s. Forest Service.
It must be properly maintained to ensure its efficiency.
{CAUTIO~ I
1. Thickness Gauge
OThe spark arrester must be installed correctly and functioning properly to provide adequate fire protection.
ENGINE TOP END 3--21
Spark Arrester Cleaning
I WARNING.
oTa avoid burns, wear gloves while cleaning the spark
arrester. Since the engine must be run during this procedure, the muffler will become hot .
Remove the drain plug on the muffler.

eln an open area away from combustible materials, start
the engine with the transmission in neutral.
.Raise and lower engine speed while tapping on the

muffler with a rubber mallet until carbon particles are
purged from the muffler.
A. Clamp Bolt
B. Mounting Bolts
.Remove the exhaust pipe holder nuts.

oFar extra clearance, first remove the right side mud
flap.
1. Drain Plug
2. Spark Arrester
3. Mounting Bolt
WARNING'
000 not run the engine is a closed area. Exhaust gases
contain carbon monoxide, a colorless, odorless, poison
ous gas.
A. Holder Nuts
Breathing exhaust gas leads to carbon mon-
oxide poisoning, asphyxiation, and death .
Stop the engine .

Remove the spark arrester from the muffler.
.Scrape carbon deposits off the spark arrester and slide
it back into the muffler.
I WARNING'
ONewer run the engine with the spark arrester removed
near combustible materials. Hot carbon particles may
start a fire.
Exhaust Pipe and Muffler:

Exhaust Pipe and Muffler Removal
.Remove the muffler clamp bolt and mounting bolts.
Exhaust Pipe and Muffler Installation

.Installation is the reverse of removal. Note the following
.Replace tile exhaust gasket with new a one.
e<:heck for leaks at the exhaust gasket and at the muffler
clamp:
ENGINE LEFT SIDE 4-1
Engine Left Side

Table of Contents
Exploded View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2
Special Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3
Engine Left Side. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3
Engine Left Side Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3
Engine Left Side Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5
Recoil Starter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5
Recoil Starter Disassembly ..... . . . . .... ...... .. . _ . . . . . . . .
4-5
Recoil Starter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7
Recoil Starter Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7
Starter Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-8
Starter Clutch Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-8
Starter Clutch Installation Note. _ . .... .. . .... _ . . . . . . . . . . . .
4-8
Starter Clutch Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-8
4-2 ENGINE LEFT SIDE
....................
lew
...................................... ......... ............................
...................
~~~;~~d"'V"':"
T1: 12N-m (1.2k-
T2: 59 N-m (6 0 9 m, 104 in-Ib)

T3
. kg-m 43
: 34 N-m (3
,ftlb)
L : Apply a n~~ kg-m, 25 ft~b)
o : A pply engine-permanent
I
.
oil.
ocklOg agent.
_I
Special Tools
..............................................................................
Flywheel Holde" 57001-308
Engine Left Side
Engine Left Side Disassembly

Recoil Starter
Cam Damper Holder: 57001-1025
A. Recoil Starter
B. Bolts
Recoil Starter Pulley
NOTE
Flywheel Puller: 57001-1191
OHoid the pulley with the cam damper holder (special

tool)~ and unscrew the recoil staner pulley bolt.
Rotor Puller: 57001-1216
A. Cam Damper Holder: 57001-1025
NOTE
o The flywheel holder (PIN 57001-1313) can be used

instead of the flywheel holder (PIN 57001-308).
Engine Oil (drain)

Reverse Cable
Footpeg
Shift Pedal
Magneto Flywheel
NOTE
QUse the flywheel puller and the rotor puller (special
tools), when removing the magneto flywheel.
A.
R~verse
Cable
B. Mounting Nuts
Generator Cover
A. Flywheel Puller: 57001 -1191

B. Rotor Puller: 57001-1216
Woodruff Key
Spacer
Starter Idle Gear
Starter Clutch Gear
A. Generator Cover
B. Mounting Bolts
Pickup Coil
A. Starter Clutch Gear

B. Starter Idle Gear
A. Pickup Coil
B. Screws
C. Woodruff Key
D. Spacer
Front Gear Case (see Final Drive chapter)
Engine Left Side Assembly

eAssembly is the reverse of disassembly.
following.
eApply engine oil to the following.
Inner surface of the Starter Clutch Gear
Both ends of the Starter Idle Gear
Note the
e After installing the recoil starter pulley, fit the key into
the groove.
A. Groove
B. Key
1. Apply an engine oil.
eelean the tapered portion of both the flywheel and

cran kshaft.
Recoil Starter
Recoil Starter Disassembly

eRemove the-following.
Ratchet Cover
1. Cleaning Area
-check that the woodruff key is in place.
elnstall a new gasket, check that the knock pins are in
place.
A. Ratchet Cover
A. Knock Pins
Pawl and Pin

Pawl Guide
Rachet Cover Spring
Collar
B. Nut
A.Pawl
B. Recoil Guide
e. Pin
D. Rachet Cover Spring

E. Collar
A. Hold rope in notch.
-Remove the reel.

ePuIl the handle out 400 - 500 mm. Clamp the rope in
place with locking pliers.
WARNING'
OBe careful that the spring does not fly loose and injure
you. It is under great pressure.
aTum the reel one-quarter turn counterclockwise past
the rest position where no tension can be felt. Now,

slowly lift the reel straight up out of the housing.
NOTE
oThere should be no spring tension on the reel when

removing the reel. If tension is felt, push the reel back
into place and gently "wiggle" it until the reel may be
easily removed.
elf necessary 1 remove the spring.

oPlace the starter housing face down on a bench.
OStrike the bench sharply to safely remove the spring.
A. Handle Cap
eRemove the handle cap.

ePry the knot out of the handle and untie it. Pull the
handle off the rope.
eHold the recoil mechanism in one. hand while removing
the locking pliers with the other.
ePull the rope in through the rope hole in the housing
and hold it in the notch in the reel.
eSlowly allow spring tension to unwind the recoil
mechanism.
NOTE
000 not let the rope wedge between the reel and the
housing.
)~
.~
-----
C~
ENG INE LEFT SIDE 4-7
Recoil Starter Assembly

-Assembly is the reverse of disassembly. Note the
following.
elf the spring was removed , it must be installed as shown.
if it is not installed correctly, the starter will not
operate properly.
WARNING.
Olhe spring must be put under great pressure during
installation. Wear gloves to avoid injury.
A. Align hook and tab.
_Rotate the reel two turns clockwise to preload the

spring.
-The pawl and recoil guide must be installed as shown
for proper starter operation.
A. Hook spring end to this tab.
_Lightly grease the spring.

elf the rope was unwound from the reel, it must be
wound clockwise for correct starter operation.
A. Recoil Guide
B. Pawl
Recoil Starter Inspection

A. Turn reel to wind rope.
eExamine the pawl for chips or excessive wear.

eQ1eck the rope for excessive wear or fraying
e<:heck the condition of the recoil spring and ratchet
-Set the reel into place so that the hook on the spring
catches on the tab in the reel.
Olnspect the springs for breaks, rust, distortion, or
cover spring.
weakened condition.
............................................................................
Starter Clutch
............................................................................
Starter Clutch Removal
Starter Clutch Inspection

e Re move the starter motor (see Electrical System
chapter) .
eTurn the starter idle gear with your finger.
eRemove the magneto flywheel.

eGently pry the clutch rollers out. They will be followed by the spring caps and springs.
tf!
A. Turn freely.
A. Roller
B. Spring Cap
c. Spring
eHold the rotor with flywheel holder (special tool) and

take out the Allen bolts.
*If the idle gear turns clockwise freely, but not counterclockwise, the clutch is operating as it should.
*If the clutch does not operate as it should, or if it
makes noise, disassemble it, examine each part visually,
and replace any worn or damaged parts.
NOTE
oExamine the starter clutch gear as well. Replace it if it
is wom or damaged.
A. Flywheel Holder: 57001-308

A. Inspect surface.
Starter Clutch Installation Note

e Apply a non-permanent locking agent to the Allen bolts,
and tighten them to the specified torque (see Exploded
View) .
B. locked .
ENGINE RIGHT SIDE 5-1
Engine Right Side

Table of Contents
Exploded View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications . . .. . '.' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Right Side. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Right Side Disassembly .... . . ....... . . .. . _ . . . . . . . . .
Engine Right Side Assembly .. . ... ..... . .. . . . . ... . . .. " . . . .
Clutches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch Adjustment .. . . ... . . .. . ..... .. . .. " . . . . . . . . . . . . . .
Clutch Release Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch Release Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Primary Clutch Housing Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Primary Clutch Shoe Lining Wear . . . . . . . . . . . . . . . . . . . . . . . . . .
One-Way Clutch Inspection.. . . . . . .. . . . . . . . . . . . . . . . . . . . . ..
Friction Plate Wear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Friction and Steel Plate Warp. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch Spring Free Length Measurement. . . . . . . . . . . . . . . . . . . . .
Primary Reduction ... . . . . ... ... ... .". . . . . . . . . . . . . . . . . . . . . . . .
Gear Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Primary Gear/Crankshaft Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Secondary Gear/Collar Wear . . ....... . . . .... . . . .. _ . . . . . . . .
Lubrication System ..... . . . . .. . .... ... . _. ... .. .. . . . . . . .. . . . .
Engine Oil and Filer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Oil Level Inspection. . .. ... ... . . . .. . . . .. . . .. . .. ....
Engine Oil and Filter Change. . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Bypass Valve Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bypass Valve Installation .. . ..... .. . ~ . . . . . . . . . . . . . . . . . . . . .
Bypass Valve Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . .
OilPump ... . . . ... ..... . ... . . . . . .. ... . . . .. . . . ... .. .. . .
Oil Pump Disassembly ..... .. ... .. . ... . .... ... ... . ... ....
Oil Pump Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Screen Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Screen Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . .
5-2
5-3
5-3
5-4
5-4
5-5
5-6
5.0
5-7
5-7
5-7
5-7
5-7
5-8
5-8
5-8
5-9
5-9
5-9
5-9
5-10
5-10
5-10
5-10
5-11
5-11
5-11
5-11
5-11
5-11
5-12
5-12
5-12
5-2 ENGINE
E....................
~IGHT SIDE
xploded Vie ...................... .
..................... ~.... ...
'0'
.............................
...... ........................
ENGIN E RIGHT SIDE 5-3
Specifications
Standard
Service Limit
116.0 - 116.2 mm
116.5 mm
1.0 -1.3 mm
0.5mm
Friction Plate Thickness
2.9 -3.1 mm
2.6mm
Friction Plate Warp
Under 0.2 mm
0.3mm
Steel Plate Warp
Under 0.1 mm
0.3mm
37.2mm
35.7mm
0.02 - 0.11 mm
0.14mm
Primary Gear Inside Diameter
27.000 - 27.021 mm
27.03mm
Crankshaft Diameter
26.959 - 26.980 mm
26.94mm
Secondary Gear Inside Diameter
25.000 - 25.021 mm
25.03mm
Secondary Gear Collar Diameter
24.970 - 24.985 mm
24.95mm
SE or SF class
---
Item
Primary Clutch :
Primary Clutch Housing Inside Daimeter
Primary Clutch Shoe Groove Depth
Secondary Clutch :
Clutch Spring Free Length

Primary Reduction:
Gear Backlash
Lubrication System:
Engine Oil
Grade
Viscosity
SAE10W30,lOW40,
lOW50, 2OW40, 20W50
Capacity
Special Tools
Gear Holder: 570011015
Cam Damper Holder: 570011025
2.0 L
Socket Wrench: 570011214
-----
5-4 ENGINE RIGHT SIDE
............................................................................
Engine Right Side
............................................................................
Engine Right Side Disassembly
eDrain the engine oil.

Footpeg
Brake Pedal
Oil Filter
Right Engine Cover
A. Dent
B. Primary Clutch
C. Secondary Clutch
Oil Pump and Balancer Drive Gears

Balancer Gear
NOTE
oRemove the recoil starter and hold the pulley with the
cam damper holder (special tool), when unscrewing the
balancer gear nut and oil pump/balancer drive gear nut.
oUnscrew the oil pump/balancer drive gear nut with the
socket wrench (special tool).
A. Mounting Bolts
B. Right Engine Cover
Primary Clutch
Secondary Clutch
NOTE
OUsing the gear holder (special tool), hold the primary

gear and secondary gear to remove the primary and
secondary clutr:h hub nuts.
A_ Cam Damper Holder: 57001 -1025
A. Gear Holder: 57001-1015

B. Primary Clutch Hub Nut
C. Secondary Clutch Hub Nut
D. Ban Bearing
E. Pusher
OTurn the secondary clutch until the dent on the secondary clutch housing comes against the primary gear,
and pull o ut the primary clutch housing wi th the hub.
A_Socket Wrench : 57001 -1214

B_ Balancer Drive Gear
C. Balancer Gear
0 _Oil Pump Drive Gear
eBend the toothed washer tab, after tightening the nut.
eThere are spacers both sides of clutch housing.
Oil Pump
A.Oil Pump
B. Screws
1. Thinner Spacer
2. Collar
3. Clutch Housing
4. Thicker Spacer
External Shift Mechanism

(see Engine Bottom End/Transmission chapter)
eApply engine oil to the outer surface of collar and
clutch hub nut.
Engine Right Side Assembly

eAssembly is the reverse of disassembly. Note the
following.
eTighten the following fasteners to the specified torque
(see Exploded View).
Balancer Gear Nut
Oil Pump/Balancer Drive Gear Nut
Outch Spring Bolts
Primary Clutch Hub Nut
Secondary Clutch Hub Nut
elnstall the oil pump.
oFili the pump with engine oil before installation.
eBe sure the woodruff key on the crankshaft and
balancer shaft.
eAlign the punch marks on the balancer gear and the
balancer drive gear.
Olf new dry steel plates and friction plates are installed,
apply engine oil to the surfaces of each plate to avoid
dutch plate seizure.
eThere should be a gap between the clutch wheel and

housing.
A.Gap
A. Punch Marks
-Fit the projection on the cage into the groove on the

housing first, and then install the oneway clutch com
pletely.
A. Projection
B. Groove
A. Adjusting Screw Cover
B. Screws
eApply engine oil to the crankshaft and clutch hub

eLoosen the locknut-
nut.
eTurn the adjusting screw clockwise until it becomes
hard to turn.
eTurn the adjusting screw counterclockwise until it
becomes hard to turn.
eTighten the locknut without changing the adjusting
screw position.
A. Apply engine oil
NOTE
OWhen tightening the primary clutch hub nut, hold the

recoil starter pulley with the cam damper holder
(special tool: 57001-1025).
A. Adjusting Screw
B. Locknut
eAfter assembling the engine right side, adjust the

clutch.
Clutch Release Removal

Clutches
Clutch Adjustment
-Remove the adjusting screw cover.

Right Engine Cover
Adjusting Screw Cover
Locknut
ePuli the clutch release lever, and spring out of right
engine cover.
Primary Clutch Housing Inside Diameter
Standard:
Service Limit:
116.0 - 116.2 mm
116.5 mm
}~~I
Primary Clutch Shae Lining Wear
eVisually inspect the primary clutch shoe lining.
*If any of the linings are damaged, replace the shoes.
eMeasure the shoe groove depth.
aUse a depth gauge, and measure at several points as
shown .
*If any measurement is less than the service limit, replace all shoes as a set.
1. Right Engine Cover

2. Clutch Release Lever
3. Spring
4. Holder
5. Adjusting Screw
6. Oring
7. Locknut
4r-
Clutch Release Wear

eVisually inspect the O-ring at the clutch adjusting
screw.
*If O-ring is damaged, deteriorated, compressed, or
hardened, replace it.
Primary Clutch Housing Wear

eMeasure the inside diameter of the clutch housing
where the shoes wear against it.
oUse calipers and measure at several points as shown.
*If any measurement is greater than the service limit,
replace the clutch housing.
~~=::::::::::"
Primary Clutch Shoe Groove Depth
Standard:
1.0 - 1.3 mm
Service Umit:
0.5 mm
One-way Clutch Inspection

e Turn the primary clutch housing by hand. The primary
clutch housing should turn counterclockwise freely,
but should not turn clockwise.
A. Turn Freely.
B. Locked.
_Visually inspect the clutch parts;"one-way clutch. inner
race, and outer race at the primary clutch housing.
*If there is any worn or damaged part, replace it.
A. Inner Race
B. Oneway Clutch
C. Outer Race
Friction and Steel Plate Warp

*If any plate is warped over the service limit, replace the
plates as a set.
1. Friction or Steel Plate

2. Thickness Gauge
3. Surface Plate
Friction and Steel Plate Warp

Standard:
less than 0.2 mm
Service Limit:
0.3mm
Steel Plate Warp
Standard:
Service Limit:
less than 0.1 mm

O.3mm
Friction Plate Wear

*If any friction plate thickness is less than the service
limit, replace the friction plates as a set.
Clutch Spring Free Length Measurement

*If any of the springs is shorter than the service limit, it
must be replaced.
1. Friction Plate
Friction Plate Thickness

Standard:
2.9 - 3.1 mm
Service Limit:
2.6mm
1. Clutch Spring
ENGINE RIGHT SIDE 59
Clutch Spring Free Length
372 mm
Standard:
Service Limit :
35.7 mm
........................................................................ ...
~
PrimarY Reduction
Gear Backlash
eRemove the right engine cover (see Right Engine Cover
Removal) .
eSet a dial gauge against the teeth on one gear, and move
the gear back and forth while holding the other gear
steady. The difference between the highest and the
lowest gauge readings is the amount of backlash.
Pri/llary Gear Inside Diameter
Standard:
Service Limit:
Crankshaft Diameter
Standard:
Service Limit:
A. Move back and forth lightly.
27.000 - 27.021 mm
27.03 mm
26.959 - 26.980 mm
26.94 mm
B. Hold steady.
Secondary Gear/Collar Wear

Gear Backlash
Standard:
Service Limit:
0.02 - 0.11 mm
0.14mm
*If the inside diameter of the secondary gear is greater

than the service limit, replace it.
*If the outside diameter of the collar is less than the
service limit, replace it.
*If the amount of backlash exceeds the service limit,

replace both gears.
Primary Gear/Crankshaft Wear

*If the inside diameter of the primary gear is greater
than the service limit, replace it.
*If the outside diameter of the crankshaft is less than
the service limit, replace it (see Engine Bottom End!
Transmission chapter) .
Secondary Gear Inside Diameter
Standard:
25 .000 - 25.021 mm
25.03mm
Service Limit:
Secondary Gear Collar Diameter
Standard:
24.970 - 24.985 mm
24.95mm
Service Limit:
Lubrication System
A. Oil Drain Plug
Engine Oil and Filter:
-Remove the oil filter
Engine Oil Level Inspection

-Park the vehicle so that it is level, both side-to-side
and front-to-rear.
-The oil level should be between the upper and

lower level lines.
A. Gauge
A. Oil Filter Cover
B. Bolts
A. Oil Filter
B. Mounting Pin
B. Level Lines
NOTE
the oil has just been changed, start the engine and
run it for several minutes at idle speed. Stop the engine,
then wait several minutes until the oil settles.
Off
ICAUTlO~ J
ORacing the engine before the oil reaches ev~rv part can
cause engine seizure.
Engine Oil and Filter Change

-War01 up the engine, then stop it.
-Set a pan beneath the engine and remove the oil drain
plug.
-Install the new filter.

oThe large end of mounting pin goes in first.
-Install the oil drain plug with a new aluminum gasket,
and tighten it to the specified torque (see Exploded
View in the Engine Bottom End/Transmission chapter).
-Fill the engine with the specified oil and quantity .
Engine Oil
SE or SF class
SAE10W-30, lOW-40, lOW-50
20W-40, lOW-SO
2_0 L
Grade:
Viscosity:
Capacity:
-Visually inspect the bypass valve parts.

*If the spring is bent or distorted, replace it. If the
piston is worn, replace all of the bypass valve parts.
-Check the oil level (see Engine Oil Level Inspection)_
Oil Pump:
Oil Pump Disassembly

-Take out the oil pump cover screw and circlip.
Bypass Valve Removal

-Remove the oil filter (Oil draining is not necessary) _
-Drive the retaining pin qut of the filter mounting pin_
.....2
:
A. Screw
A- Filter Mounting Pin
B_ Retaining Pin
B. Circlip
-Lift the oil pump body from the gear.

-Drop the rotors out of the oil pump body.
-Drop out the spring and the bypass valve piston.
Bypass Valve Installation

-Drop the bypass valve piston closed end first into the
filter mounting pin.
.
-Put the spring into the mounting pin and compress it
beyond the small hole.
-Drive the retaining pin into the small hole to hold the
spring.
-Install the oil filter (see Engine Oil and Filter Change) .
Bypass Valve Cleaning and Inspection
A. Rotors
B. Oil Pump Body
C. Oil Pump Cover
eelean the bypass valve parts in a high flash point

solvent.
I WARNING'
OCIean the parts in a well-ventilated area, and take care
that there is no spark or flame anywhere near the
working area. Because of the danger of highly flammable liquids, do not use gasoline or low flash point
solvents.
Oil Pump Inspection

-Disassemble the oil pump.
-Visually inspect the oil pump body, rotors, and cover.
*If there is any damage or uneven wear, replace the oil
pump assembly.
Oil Screen:
Oil Screen Removal
eRemove the right engine cover.
A. Oil Screen
-Pull out the oil screen.
Oil Screen Cleaning and Inspection

-Clean the oil screen with high flash point solvent and
remove any particles stack to it.
I WARNING'
octean the screen in a well-ventilated area, and take
care that there is no spark or flame anywhere near the
working area. Because of the danger of highly flammable liquids, do not use gasoline or low flash point
solvents.
NOTE
awhile cleaning the screen, check for any metal particles

that might indicate intemal engine damage.
-Check the screen carefully for any damage: holes,

broken wires, gasket pulling off.
*If the screen is damaged, replace it.
ENGINE REMOVAL/INSTALLATION 6-1
Engine Removal/Installation
Table of Contents
Exploded View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2
Engine Removal/Installation . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . .
6-3
Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3
Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3
62 ENGINE REMOVAL/INSTALLATION
Exploded View
Tl : 26 N-m (2.7 kg-m, 19.5 fHb)

T2: 34 N-m (3.5 kg-m, 25 ftlb)
ENGINE REMOVAL/INSTALLATION 6-3
Engine Removal/Installation
eRemove the engine mounting bolts and bracket bolts.
Engine Removal
eDrain the engine oil (see Engine Right.5ide chapter).
Seat
Front Fender
Rear Fender
Fuel Tank
Carburetor
Muffler
Footpegs
Shift Pedal
Breather Hose
eDisconnect the following cable and leads from the
engine.
Reverse Lever and Cable
Starter Motor Lead
Magneto Leads
Pickup Coil Leads
Spark Plug Lead
Battery Ground Lead
Neutral and Reverse Switch Leads
A. Mounting Bolts
B. Bracket Bolts
eFree the engine from the propeller shaft.
Engine Installation
-I nstallation is the reverse of removal.
Note the
following.
eGrease the splines at the front end of the propeller
shaft.
A. Battery Ground Cable

eLoosen the propeller shaft dust cover clamp.
A. Apply grease.
A.Clamp
eSupport the vehicle so that the rear wheels are off the
ground.
eFit the driven gear shaft (engine) to the propeller shaft
while rotating one rear wheel slowly.
eApply grease to the universal joint outer surface.
6-4 ENGINE REMOVAL/INSTALLATION
1. Dust Cover
2. Universal Joint
3. Apply grease .
eTighten the engine mounting nuts and bracket nuts to

the specified torque (see Exploded View) .
eRoute the hoses, cables, and leads properly (see
General Information chapter).
eAdjust the reverse cable (see Engine Bottom End!
Transmission chapter).
ENGINE BOTTOM END/TRANSMISSION 7-1
Engine Bottom End/Transmission

Table of Contents
Exploded View .............. ' .' . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .
Sealant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
External Shift Mechanism. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
External Shift Mechanism Removal. . . . . . . . . . . . . . . . . . . . . . . . .
External Shift Mechanism Installation. . . . . .. . . . . . . . .. . . . . . . .
External Shift Mechanism Inspection. . . . . . . . . . . . . .. . . . . . . . .
Reverse Shift Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reverse Knob Free Play Adjustment. . . .. . . . .. . . .. . . . . . . . . . .
Reverse Shift Mechanism Removal. . . . . . . . . . . . . . . . . . . . . . . . .
Reverse Shift Mechanism Installation . . . . . . . . . . .. . . . . . . . . . . .
Crankcase Splitting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankcase Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankcase Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft and Connecting Rod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft Removal/Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft Installation. . . . . . . . . . . . . . . .. . . .. . .. . .. . . . . .. .
Crankshaft Disassembly. . . . . . . . . . . . . . . . .. . . . .. . . . . . . . .. . .
Crankshaft Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft Inspection/Maintenance. ... ............... . . . ....
Connecting Rod Bend/Twist. . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Connecting Rod Big End Radial Clearance . . . . . . . . . . . . . . . . . ..
Connecting Rod Big End Side Clearance. . . . . . . . . . . . . . . . . . . ..
Crankshaft Alignment. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . ..
Connecting Rod Big end Seizure. . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Transmission Removal/Disassembly. . .. . . . ... . . .. .. .. .... ....
Transmission RemovaL... . . .. . .. .. . . .. .. . .. .. . .... ... ...
Transmission Installation. . . . . . . . . . . . . . . .. . . .. . . . . . . . . . ...
Transmission Shaft Disassembly. . . .. . . .. . . . . .. . . . . . . . .. ...
Transmission Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Shift Drum Disassembly Note. . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Transmission Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Shift Fork Inspection .... . .. . . . .... .. . .. .. . .. .. .... .. ...
Shift Drum Inspection. ... . . . . . . ... . .... . .... .. ... .. .. ...
Transmission Gear Inspection.. . . . .. . ... .. .... ... .. .......
Ball and Needle Bearings . . .. . ... .. . . . .. ... . .. . . .. .. . . . . .... ..
Ball and Needle Bearings Replacement. . . . . . . . . . . . . . . . . . . . . .
Ball and Needle Bearings Wear. . . . . . . . . . . . . . . . . . . . . . . . . . . ..
7-2
7-4
7-4
7-4
7-5
7-5
7-5
7-6
7-6
76
7-7
7-7
7-8
7-8
7-8
1-9
7-9
7-9
79
7-9
7-10
7-10
7-10
7-10
711
7-11
7-12
7-12
7-12
7-12
7-12
7-13
7-13
714
7-14
714
714
7-15
7-15
7-15
7-15
7-2 ENGINE BOTTOM ENDITRANSMISSION
Exploded View
KLF22o-A2-
T1: 25 N-m (2.5 kg-m. 18 ft-fb}

T2: 29 N-m (3.0 kg-m. 22 ft-fb}
T3: 8.8 N-m (0.9 kg-m. 78 in-fbI
T4: 12 N-m (1.2 kg-m. 104 in-fbI
T5: 15 N'm (1 .5 kg-m. 11 ft-fb}
T6: 3.9 N-m (0.4 kg-m, 35 in-fbI
L : Apply a nonll..-manent locking agent.
o : Apply engine oil.
LG: Apply liquid gasket.
ENGINE BOTTOM ENDITRANSMISSION 7.3
7-4 ENGINE BOTTOM END/TRANSMISSION
............................................................................
Specifications
Item
Crankshaft, Connecting Rod:
Connecting Rod Bend
Connecting Rod Twist
Connecting Rod Big End Radial Clearance
Connecting Rod Big End Side Clearance
Crankshaft Runout
T ransm ission:
Shift Fork Ear Thickness
Gear Shift Fork Groove Width
Shift Fork Guide Pin Diameter
Shift Drum Groove Width
Special Tools
Standard
Service Lim it
Under 0.05/100 mm
Under 0.15 /100 mm
0.008 - 0.020 mm
0.4 - 0.5 mm
Under 0.04 mm TI R
0.2/100 mm
0.2/100 mm
0.07 mm
0.7mm
0.1 mm TIR
4.9- 5.0 mm
5.05 - 5.15 mm
5.9 -6.0mm
6.05 - 6.20 mm
4.8mm
5.3mm
5.8mm
6.3mm
Crankcase Splitting Tool: 570011098
............................................................................
Bearing Driver Set: 570011129

/'
,~
Crankshaft Jig: 57001 -1 174
Sealant
Kawasaki Bond (Liquid Gasket-Silver): 92104-002
Circlip Pliers: 57001-144
ENGINE BOTTOM ENDITRANSMISSION 75
Positioning Lever
External Shift Mechanism Removal

Shift Pedal
Clutches (see Engine Right Side chapter)
Clutch Release Cams and Ball Assembly
A. Return Spring Pin

C. Positioning Lever
B. Clutch Release Cam Pin
A. Outch Release Cams
B. Ball Assembly
External Shift Mechanism Installation

-Installation is the reverse of removal. Note the fol
lowing.
*If the return spring pin and/or cam pin were removed,
apply a nonpermanent locking agent to the threads
and tighten them to the specified torque (see Exploded
View) .
-Be sure the shift mechanism arm collar and clutch
Shift Pedal
Shift Mechanism Shaft
release inner cam are in place.
NOTE
OMove the shift mechanism arm out of its position on

the end of the shift drum, and pull out the shift mechanism shaft.
A. Collar
A. Shift Mechanism Shaft
B. Shift Mechanism Arm
B. Clutch Release Cam
-Install the ball assembly and clutch release outer cam.
7-6 ENGINE BOTTOM ENDfTRANSMISSION
"'If the cam area is damaged , or if the ball assembly is
worn visibly, replace the damaged part .
.............................................................................
Reverse Shift Mechanism
.............................................................................
A. Outch Release Cam
B. Ball Assembly
Reverse Knob Free Play Adjustment

-Check the reverse knob free play when the transmission
is in neutral.
External Shift Mechanism Inspection

eExamine the shift mechanism for any damage.
A. Splines
B. Springs
Reverse Knob Free Play
Standard:
2 - 3 mm
c. Lever
A. Reverse Knob
B. Free Play
OCheck the shift shaft, springs, shift mechanism arm.

"'If the shaft is bent, straighten or replace it. If the
spline is damaged, replace the shaft.
"'If the springs are damaged in any way, replace them.
"'If the sh ift mechanism arm is damaged in any way, reo
place the lever.
*If the free play incorrect, loosen the locknuts and move
the adjuster until the reverse knob has the proper
amounf of play.
A.Cam Area
A. Adjuster
B. Ball Assembly
B. Mounting Nuts
ENGINE BOTTOM ENDfTRANSMISSION 7-7
Reverse Shift Mechanism Removal

eDrain the engine oil.
eRemove the engine (see Engine Removal/Installation
chapter).
Reverse Shift Mechanism Installation

-, nstallation is the reverse of remova l.
Note the
following.
eSe sure the contact pin and dowel pin are in place.
Reverse Lever
A. Reverse Lever
B. Bolt
A. Dowel Pin
B. Contact Pin
Front Bevel Gear Case (see Final Drive chapter)

Neutral and Reverse Switch
Shift Drum Stop Lever
OPush the contact pin in the shift drum stopper and then
release it.
*If it does not spring out, replace the stopper.
eApply a non-permanent locking agent to the neutral
and reverse switch screws.

eRoute the neutral and reverse switch leads as shown.
A. Shift Drum Stop Lever

B. Neutral and Reverse Switch
C. Screws
A. Neutral and Reverse Switch Leads
A. Shift Drum Stopper
Crankcase Splitting
Crankcase Disassembly
chapter).
Starter Motor
oRefer to the Engine Top End chapter.

Cylinder Head
Cylinder
Piston
oRefer to the Final Drive chapter.
Front Bevel Gear Case
Front Drive Gear
ORefer to the Engine Right Side chapter.
Clutches
Oil Pump
Balancer Gear
ORefer to the Engine Left Side chapter.
A. Pry at these gaps
Generator Cover
Pickup Coil
Magneto Flywheel
Starter Clutch Gear
Camshaft Chain and Guide

Reverse Shift Mechanism
NOTE
Olf the crankcase is very tight, use the crankcase splitting
tool (special tool: 57001-1098).
Crankcase Assembly
NOTE
eRemove the crankcase bolts.
ePry gently at the gaps in the crankcase to split the case

halves apart.
08e certain that all parts are cleaned thoroughly before

assembly.
0810w through all oil passages with compressed air to
clear any blockage.
A. Compressed Air
............................................................................
Crankshaft and Connecting Rod
Crankshaft Removal/Disassembly
Crankshaft Removal
chapter).
eSplit the crankcase (see Crankcase Disassembly).
eRemove the transmission.
ePush the crankshaft out of the left crankcase half with

a press.
A. Compressed Air
D8e sure al/ transmission shafts, shift forks, and the shift
drum are in place in the left crankcase half.
I WARNING'
OCiean the engine parts in a well..yentilated are2, and
take cafe that there are no sparks or flame anywhere
near the working area; this includesilny appliance with
a pilot light. Do not use gasoline or a low flash-point
solvent to dean parts. A fire or explosion could result.
Crankshaft Installation
ePosition the right crankcase half so that the right-hand
main bearing housing .is seated on a suitable press fixture.
ePress the cr.ankshaft into the right-hand main bearing

housing.
Dlnsert crankshaft jig (special tool) between the crankshaft halvesJ opposite the crankpin, to prevent crank-
shaft distortion during installation.
eApply a small amount of engine oil to the transmission

gears, bearings, and shift drum.
-Be sure the mating surfaces of the crankcase halves are
clean and dry.
-Be sure the crankcase dowel pins are in position.
A.CrankshaftJig 570011174
-=--1
eThe remainder of Crankshaft Installation is the reverse

of removal.
Crankshaft Disassembly
A. Dowel Pins
eApply liquid gasket to the mating surface of the crank
case.
eFit the crankcase halves together and tighten the crank
case bolts securely.
eRotate the shift drum to the neutral position.
-Check to see that the crankshaft, drive shaft, and out
put shaft all turn freely.
*If any of the shafts do not turn freely, split the crankcase to locate the problem.
eThe remainder of Crankcase Assembly is the reverse of
disassembly.
NOTE
DSince assembly of the crankshaft demands exacting

tolerances, the disassembly and reassembly of the
crankshaft should only be performed by experienced
mechanics with die necessary tools and equipment.

DThe crankshaft left main bearing, chain sprocket, and
left crankshaft are available separately as spare parts,
however, it is recommended that the crankshaft assembly be replaced rather than attempting to replace the
components.
ePress the crankpin out of the crank halves to separate

the crank halves, connecting rod , crankpin needle
bearing, and crankpin.
710 ENGINE BOTTOM END/TRANSMISSION.
Crankshaft Assembly
-Check that the connecting rod radial clearance is within
specification (see Connecting Rod Big End Radial
Clearance) .
.Press the crank halves onto the crankpin until the connecting rod side clearance is within specification (see
Connecting Rod Big End Side Clearance).
.Press the camshaft chain sprocket onto the crankshaft
as shown. The chamfer side of it face to the ball
bearing.
OSelect an arbor of the same diameter as the piston pin

and at least 100 mm long, and insert the arbor through
the connecting rod small end.
OWith the connecting rod held vertically, use a height
gauge to measure the difference in the height of the
arbor above the surface plate over a 100 mm length to
determine the amount of connecting rod bend.
*If connecting rod bend exceeds the service limit, the
connecting rod must be replaced.
Connecting Rod Bend
Standard:
Under 0.05/100 mm
02/100 mm
Service L.i mit:
Crankshaft Assembly
eMeasure connecting rod twist.

OWith the crankshaft still in the alignment jig, hold the
connecting rod horizontally and measure the amount
that the arbor varies from being parallel with the crank
shaft over a 100 mm length of the arbor to determine
the amount of connecting rod twist.
100mm
1. Direction of Crankpin Center
2. Camshaft Chain Sp,rocket
3. Lefthand Main Bearing
eAdjust crankshaft runout until it is within specification
(see Crankshaft Runout).
*If connecting rod twist exceeds the service limit, the

connecting rod must be replaced.
Crankshaft Inspection/Maintenance:
Standard:
Service Limit:
Under 0.15/100 mm
02/1OOmm
Connecting Rod Bend/Twist

eMeasure connecting rod bend.
OSet the crankshaft in an alignment jig or in V blocks on

a surface plate.
Connecting Rod Bend

-Check big end radial clearance.
OSet the crankshaft in an alignment jig or on V blocks,
and place a dial gauge against the connecting rod big
end.
ENGINE BOTTOM ENOfTRANSMISSION 7-11
oPush the connecting rod first towards the gauge and
then
in
the opposite direction.
Crankshaft Runout
The difference
between the two gauge readin}:s is the radial clearance_

Standard:
Service Limit:
o.oos -
0.020 mm
0.07 mm
*If the radial clearance exceeds the service limit, the
crankshaft assembly must be replaced or disassembled
10_5 mm
and the crankpin, needle bearing, and connecting rod
big end examined for wear.
*If runcut at either location exceeds the service limit,

align the crankshaft so that runcut is within the service

eMeasure big end side clearance.
olnsert feeler gauges between the big end and either
crank half to determine clearance.
limits.
Crankshaft Runout
Standard:
; - Side Clearance
.----.-----+--.
Service Limit:
Under 0.04 mm TIR

0.1 mmTIR
eAlign the crankshaft .

oln the case of horizontal misalignment, strike the pro~
jecting crankshaft half with a plastic, soft lead, or brass

hammer as shown.
Horizontal Misalignment
*If big end side clearance exceeds the service limit, the
crankshaft assembly must be replaced or disassembled
and the connecting rod and thrust washers visually
inspected for wear.

Standard:
Service Limit:
0.4 - 0.5 mm
0.7mm
eRecheck the runout and repeat the process until the
Crankshaft Alignment
-check crankshaft alignment by measuring runout.
OWith the crankshaft in an alignment jig, turn the crankshaft slowly and measure runout at each of the
locations shown.
runout is within service limits.
oVertical misalignment is corrected either by driving a

wedge in between the crank halves, or by squeezing the
crank halves in a vise, depending on the nature of the
misalignment. .
7-12 ENGINE BOTTOM END!TRANSMISSION
.............................................................................
Vertical Misalignment
Transmission
n
I
a:
[]J
'-
cr
eSplit the crankcase (see Crankcase Disassembly).

ePull out the shift rods and take out the forks.
ePull all the transmission shafts out together.
-To remove the shift drum, remove the shift drum positioning lever and shift drum bearing stopper.
'-
Transmission Removal/Disassembly:
Transmission Removal
to
L.....L.....
L
A. Bearing Stopper
Oln case of both horizontal and vertical misalignment,

correct the horizontal misalignment first.
ORecheck big enil side clearance after aligning crankshaft
(see Connecting Rod Big End Side Clearance).
NOTE
crankshaft alignment cannot be corrected by the

above method, replace the crankpin or crank halves as
required.
Olf
Transmission Installation
eSet the transmission shafts together, and fit them into
the left crankcase half at'the same time.
OApply a small amount of engine oil to the transmission
gears, bearings, and shaft journals.
eFit each shift fork into the groove of the proper gear so
that the shift fork guide pin is in the proper groove on
the shift drum.
OApply a small amount of engine oil to the shift fork
fingers.
oThe fork rods are identical.
~/
,,
,
Connecting Rod Big End Seizure

eln case of serious seizure with damage to the crank
halves, the crankshaft must be replaced. If the seizure
was less severe, disassemble the crankshaft and replace
the crankpin, needle bearing, and connecting rod (see
Crankshaft Disassembly).
1. Output Shaft Shift Fork

2. Drive Shaft Shift Fork
Output Shaft
Reverse
,"",,3
Reverse Shaft
eAssemble the crankcase.
Transmission Shaft Disassembly

eUsing the circiip pliers (special tool)' remove the
circlips and disassemble the transmission shafts com
plately.
Transmission Shaft Assembly

following.
eReplace any circlips that were removed with new ones.
eAlways install circlips so that the opening is aligned
with a spline groove.
Cirdip and Installation
A. Circiip Pliers: 57001144
Transmission Gears
Drive Shaft
1st
Reverse
-The transmission gears can be identified by size;

Drive shaft gears - the smallest diameter gear is 1st
gear, and the largest is 5th.
Output shaft gears- the largest diameter gear is 1st
gear, and the smallest is 5th.
Shift Drum Disassembly Note
ORemove the shift drum and the disassemble the drum
as shown.
Shift Drum Parts
1. Shift Fork Ear Thickness

2. Shift Fork Guide Pin Diameter
1 . Shift Drum
2. Bearing
3. Pin
5. Pin
6. Pin Plate
7. Bolt
4. Operating Plate
Shift Fork Ear Thickness

Standard:
Service Limit:
4.9 - 5.0 mm
4.8mm
Shift Fork Guide Pin Diameter

Standard:
5.9- 6.0mm
Service Limit
5.8mm
*If the thickness of a shift fork ear is less than the
service limit, the shift fork must be replaced.
Transmission Maintenance:
Shift Fork Inspection
eVisually inspect the shift forks, and replace any fork
that is bent. A bent" fork could cause diffICulty in
*If the guide pin on any shift fork is less than the service
limit, the fork must be replaced.
shifting, or allow the transmission to jump out of gear
when under power.
Shift Drum Inspection

eMeasure the shift drum grooves.
A.90
eMeasure the following.
Shift Drum Groove Width
Standard:
Service limit:
6 .05 - 620 mm
6.3 mm
Ball and Needle Bearings

Ball and Needle Bearings Replacement
*If any shift drum groove is worn over the service limit,
the drum must be replaced.
-Using a press or puller, remove the ball bearing andlor

needle bearing.
NOTE
Transmission Gear Inspection
DIn the absence of the above mentioned tools, satisfactory results may be obtained by quickly heating the
case (in the area immediately su"ounding the bearingl
to approximately 93C (2od' F) max, and tapping the
bearing in or out.
_Measure the shift fork grooves.

-Using a press and the bearing driver set (special tool:
PIN 570011129), install the new bearing until it stops
at the bottom of its housing.
Ball and Needle Bearings Wear

Shift Fork Groove Width
Standard:
Service Limit:
5.05 - 5.15 mm
5.3 mm
*If a gear shift fork groove is worn over the service limit,
the gear must be replaced.
_Visually inspect the gear dogs and gear dog holes.
*Replace any gears that have damaged or excessively
worn dogs or dog holes.
1. Dog
2. Dog Hole
echeck the ball bearings.

oSince the ball bearings are made to extremely close
tolerances, the wear must be judged by feel rather than
measurement. Clean each bearing in a high f1ashpoint
solvent, dry it (do not spin the bearing while it is dry),
and oil it with engine oil.
oSpin the bearing by hand to cbeck its condition.
*If the bearing is noisy, does not spin smoothly, or has
any rough spots, replace it.
-Check the needle bearings.
oThe rollers in a needle bearing normally wear very
little, and wear is difficult to measure. Instead of
measuring, inspect the bearing for abrasion, color
change, or other damage.
*If there is any doubt as to the condition of a needle
beari ng, replace it.
Oil Pressure Relief Valve

Oil Pressure Relief Valve Inspection
Split the crankcase (see this chapter).
Remove the relief valve [Aj from the right crankcase.
Check to see if the steel ball [Bj inside the valve slides
smoothly when pushing it in with a wooden or other
soft rod, and see if it comes back to its seat by valve
spring [Cj pressure.
Il---\.A
CQ030101S1
NOTE
Olnspect the valve in its assembled state.
Disassembly and assembly may change the valve
performance.
*If any rough spots are found during above inspection,
wash the valve clean with a high flash-point solvent
and blowout any foreign particles that may be in the
valve with compressed air.
OClean the oil pressure relief valve in a wellventilated area, and take care that there are no
sparks or flame anywhere near the working area.
Because of the danger of highly flammable liquids,
do not use gasoline or low flash-point solvents.
*If cleaning does not solve the problem, replace the

relief valve as an assembly.
The relief valve is
precision made with no allowance for replacement of
individual parts .
Apply a non-permanent locking agent to the threads of
the relief valve, and tighten it.
Torque- Oil Pressure Relief Valve:
15 N-m (1.5 kg-m, 11.0 ft-Ib)
WHEELS!TIRES 8-1
Wheels/Tires
Table of Contents
Exploded View ..................... . ...... _... _ . . . . . . . . . . .
8-2
Specifications . ....... ....... . . ............ ..... . , . . . . . . . . .
8-3
Special Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . .
8-3
Wheel Alignment ....... ... . . . ... . _ . .. _........... _. . . . . . . . .
8-4
Steering Centering Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . .
8-4
Steering Centering Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-4
Toe-in Inspection. .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-5
Toe-in Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-6
Wheels (Rims) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-6
Wheel Removal . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . .
8-6
Wheel Installation ........................ . ........ _. . . .
8-6
Wheel Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-6
Wheel Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-7
T ires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-7
Tire Removal. .... . _ . . ............ .. .. ..... . ...... _ . . .
8-7
Tire Installation ... . . ... _ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-8
Tire Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-9
Wheel Bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
8-10
8-2 WHEELSITIRES
Exploded View
T1: 34 N-m (3.5 kg-m, 25 ft~b}
WHEELSITIRES 8-3
Specifications
Standard
Item
Wheel Alignment
Tires:
4'
Caster
Camber
Toe-in
Front
Rear
Tire Inflation Pressure (when cold) :
Front & Rear
3"
30mm
AT21 x 8.00 - 9
Dunlop, KT856 Tubeless
AT22 x 10.00 -10
Dunlop, KT857 Tubeless
21 kPa (0.21 kg/em', 3 psi)
Bearing Driver Set: 57001-1129
Special Tools
Tire Irons: 57001-1073
Jack Stand: 57001-1238
8-4 WHEELS/TIRES
Wheel Alignment
Toe-in is the amount that the front wheels are closer
together in front than at the rear at the axle height.

When there is toe-in, the distance A is greater than Bas
shown.
The purpose of toe-in is to prevent the front wheels

from getting out of parallel at any time, and to prevent
any slipping or scuffing action between the tires and the
ground. If toe-in is incorrect, the front wheels will be
dragged along the ground, scuffing and wearing the tread

knobs.
Caster and camber are built-in and require no adjustment.
Toe-in of Front Wheels
B
Front of Vehicle
t/
...-r:r-.-~
1J
rY,
"'<:::
'I
(
~~
~
A
A - B; Amount of Toein
(Distance A and B are measured at axle height)
Steering Centering Inspection
Steering Centering
eTest ride the vehicle.

*If the handlebar is straight when the vehicle is traveling
in a straight line, go on to the Toe-in Inspection procedure.
*Otherwise, go on to the Steering Centering Adjustment
procedure.
Steering Centering Adjustment

eSupport the vehicle so that the front wheels are off the
ground and the front axles about the same height as the
rear axle.
eHold a straightedge against the rear wheel rim on one

side at axle height.
1. Front Wheels
4. Straightedge
2. Vehicle Center Line
5. Rear Wheels
3. Parallel to each other.
WHEELSfTlRES 8-5
eWith the handlebar straight ahead, loosen the locknuts
and turn the tie-rod adjusting sleeve until the front
wheelan that side is parallel to the straightedge.
Toe-in Inspection
eSupport the vehicle on a stand so that the front wheels
are off the ground.
eApply a heavy coat of chalk near the center of the
front tires.
NOTE
oThe outside locknut on the tie-rod has left-hand
threads. Tum the wrench clockwise for loosening.
eUsing a needle nose scriber, make a thin mark near the

cenler of the chalk coating while turning the wheel.
A. Outside Locknut: left-hand threads
B. Adjusting Sleeve
e. Inside Locknut
OAdjust the tie-rod so that the visible thread length is

even on both ends of the tie-rod, or the threads could
be damaged_
Tie-rod Adjustment
eKeeping the front wheels off the ground, set the
handlebar straight ahead.
eAt the level of the axle height, measure the distance
between the scribed lines for both front and rear of the
front tires.
1. Visible Thread Length
eRepeat the straightedge procedure on the other side of

the vehicle. Now the front wheels are parallel to each
other and to the cenlet line of the vehicle.
eGo on to the Toe-in inspection procedure;
8-6 WHEELSITIRES
-Subtract the measurement of the front from the
measurement of the rear to get the toe-in.
*If the toe-in is not in the specified range, go on to the
Toe-in Adjustment procedure.
Wheel Removal
eLoosen the wheel nuts.
eSupport the vehicle on a stand so that the wheels are
off the ground.
eTake off the wheel nuts and remove the wheel.
Toe-in of Front Wheels
Standard:
Wheels (Rims)
30 mm
Toe-in Adjustment
eLoosen the locknuts and turn the adjusting sleeves the
same number of turns on both sides to achieve the
specified toe-in_
Wheel Installation
ePosition the wheel so that the valve stem is toward the
outside of the vehicle.
eMount the wheel on the studs.
eTighten the wheel nuts in a crisscross pattern to the
specified torque (see Exploded View).
A. Outside Locknut: Left-hand Threads

B. Adjusting Sleeve
C. Inside Locknut
NOTE
A. Valve Stem
OThe outside locknut on the tie-rod has left-hand

threads, Tum the locknut clockwise for loosening.
OThe toe-in will be near the specified value, if the tie-rod
length is 288 mm between the tie-rod ends.
Wheel Inspection
eExamine both sides of the rim for dents. If the rim is
dented, replace it.
OUneven thread length could cause tie-rod damage.

Rim Dent
Tie-rod Length Adjustment
/EqUal~
I
:rr
1t
IT]
288mm
eGheck the toe-in (see Toein Inspection).
eTighten the tie-rod locknuts to the specified torque
eTest ride the vehicle.
WHEELS/TIRES 87
-If the tire is removed, inspect the air sealing surfaces of
the rim for scratches or nicks. Smooth the sealing
surfaces with fine emery cloth if necessary.
............................................................................
Tires
.. ......................................................................... .
Tire Removal
-Remove the wheel.
-Unscrew the valve core to deflate the tire.
-Lubricate the tire beads and rim flanges on both sides

of the wheel with a soap and water solution, or water.
This helps the tire beads ,lip off the rim flanges.
yJl
1. Seali ng Surfaces
1. Apply lubricant.
Wheel Replacement
_Remove the wheel.
-Disassemble the tire from the rim.
-Install a new valve stem in the new rim.
o Remove the valve .cap, lubricate the valve stem with a
soap and water solution, and pull the vaive stem through
the rim from the inside out until it snaps into place.
[CAUTION
aDo not lubricate the tire beads and rim flanges with
engine oil or petroleum distillates because they will
deteriorate the tire.
-Break the tire beads away from both sides of the rim
with a bead breaker.
1. Pull the valve stem.
000 not reuse the valve stem.

000 not use engine oil or petroleum distillates to
lubricate the valve stem because they will deteriorate
the rubber.
-Mount the tire on the new rim.

-Install the wheel.
1. Bead Breaker
-Kneel on the side of the tire, forcing the tire bead into
the center well of the rim.
8-8 WHEELS/TIRES
Rim Center Wen
WARNING'
_~~~-~~L Valve Stem
0 00 not use the lubricant other than a water and soap

solution, or water to lubricate the tire beads and rim
because it may cause tire separation.
echeck the tire rotation mark on the front tires, and
install them on the rim accordingly.

OThe tires should be installed on the rims so that each
valve stem is toward the outside of the vehicle.
NOTE
Well
OThe direction of the tire rotation is shown by an arrow

on the tire sidewall.
eLubricate two tire irons (special tool) with a soap and

water solution, or water, and begin prying the first
bead off the rim near the valve stem.
000 not scratch the air sealing surfaces of the tire or

rim. Scratches or nicks on the sealing surfaces will
allow the tire to deflate.
eWork around the rim with' the tire irons a little at a
time, while continuing to hold the bead opposite the
irons in the center well of the rim.
A. Rotation Mark (Arrow)
B. Rotation Direction
eBy hand, slide as much of the first bead as possible over

the rim flange, starting at the side opposite the valve
stem.
OAs the bead "goes onto the rim, force the bead into the
center well of the rim to ease installation . .
Bead Installation
1. Tire Irons: 570011073
elift the second bead up into the center well and use
the same procedure as in removing the first bead.
Tire Installation
elnspect the rim (see Wheel Inspection).
e<:heck the tire for wear and damage (see Tire Inspection).
eLubricate the tire beads, rim flanges, and the tire irons
(special tools) with a soap and water solution, or water.
1. Tire Beads
2. Center Well
WHEELSfTlRES 8-9
eUse the tire irons (special tools) to install the rest of
the bead.
Bead
e<:heck to see that the rim lines on both sides of the tire
are parallel with the rim flanges.
ln~tallation
--
--...
A. Rim Line
1. Tire Irons: 57001-1073
elf the rim lines and the rim flanges are not parallel,
deflate the tire, lubricate the sealing surfaces again, and
eUse the same procedure to install the second bead.

eLubricate the tire beads again and center the tire on the
eAfter the beads are properly seated, check for air leaks.
Olnflate the tire to 35 kPa ( 0.35 kg/cm' , 5 psi). Apply
a soap and water solution around the tire bead and
check for bubbles.
eDeflate the tire to the specified pressure (see Specificati ons).
reinflate the tire.
rim.
eSupport the wheel rim on a suitable stand to prevent

the tire from slipping off.
Tire Air Pressure

Front:
Rear:
21 kPa (021 kg/em' 3.0 psi)

21 kPa (021 kg/em' . 3.0 psi)
e<:heck the tire pressu re using the air pressure gauge.

elnstall the wheel.
eWipe off the soap and water solution, or water on the
tire, and dry the tire before operation.
I WARNING.
1. Rim
2. Suitable Stand
a Do not operate the vehicle with the water and soaP. or

water still around the tire beeds. lbey will cause tire
separation, and a hazardous condition may resulL
elnflate the tire until the tire beads seat on the rim.
Maximum Tire Air Pressure

(to seat beads when cold)
Front and Rear: 250 kPa (2.5 kg/em' 36 psi)
I WARNING.
ODo not inflate the tire to more than the maximum tire
air pressure. Overinflation can explode the tire with
possibility of injury and loss of life.
Tire Inspection
eExami'ne the tire for damage and wear.
Olf the tire is cut or cracked, replace it.

o Lumps or high spots on the tread or sidewalls indicate
internal damage requiring tire replacement.
o Remove . any foreign objects from the tread. After

removal, check for leaks with a soap and water
solution.
OCheck the. shape of the tread knobs. If no vertical side

is left on the drive side of the knobs, replace the tire.
8-10 WHEELSfTlRES
Tire Inspection
Vertical Sides
Worn Away
// --~'"
=------..
!
// I \\
,~
.. ._+ -
'\
Wheel Bearings
.............................................................................
o Refer to Front Brake Drum section in the Brakes

chapter for the front wheel bearing information .
o Refer to Rear Axle and Bearing section in the Final
Drive chapter for the rear wheel bearing information.
FINAL DR IVE 9-1
Final Drive
Table of Contents
Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sealant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Final Gear Case Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Final Gear Case Oil Level Inspection. . . . . . . . . . . . . . . . . . . . . . .
Final Gear Case Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Bevel Gears and Cam Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Gear Case Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Gear Case Installation . . . . . . . . .. . .. . . . . . . . .. . . . . .. . .
Front Drive Gear Removal/Installation . . . . . . . . . . . . . . . . . . . . . .
Front Driven Gear and Cam Damper Removal . . . . . . . . . . . . . . . .
Front Driven Gear and Cam Damper Installation. . . . . . . . . . . . . .
Front Bevel Gear Adjustment . ..... . ... , . . . . . . . . . . . . . . . . . .
Bevel Gear Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Ball Bearing Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Seal Inspection ... .. . . . . . ..... . . ... . ................
Cam Damper Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Propeller Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Propeller Shaft Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Propeller Shaft Installation. .. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Propeller Shaft Lu brication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Propeller Shaft Joint and Pinion Gear Joint Inspection . . . . . . . . . .
. Propeller Shaft Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Axle Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Axle and Propeller Shaft Removal . . . . . . . . . . . . . . . . . . . ..
Rear Axle and Propeller Shaft Installation. . . . . . . .. . . . .. .. . . .
Axle Shaft Removal. . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .
Axle Shaft Installation . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . .
Final Bevel Gears . . .. . .. _ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pinion Gear Disassembly . . . . . . . . . . . . . . . .. . . . . . . . . . . .. . .. .
Pinion Gear Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Final Gear Case Disassembly. . . . . .. . . . . . . . . . . . . . . . . . . . . . . .
Final Gear Case Assembly. . . .. . . .. .. . . .. . . . . . . . . . . . . . ... .
Final Bevel Gear Adjustment. . . . . . . . . . . . . . . . . . . . . . . . .. . . ..
Bevel Gear Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Oil Seal Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Ball Bearing Inspection . . . . . . . ... . . . . . . . . . . . . . . . . . . . . . . . . .
9-2
9-4
9-4
9-5
9-6
9-6
9-6
9-6
9-6
9-7
9-7
9-8
9-9
9-9
9-12
9-12
9-12
9-12
9-12
9-12
9-13
9-13
9-13
9-13
9-14
9-14
9-14
9-15
9-15
9-16
9-16
9-17
9-17
9-18
918
921
921
9-21
9-2 FINAL DRIVE ......... . ....... _...................... ..
~~~;~d~~i~~::..........................................
...............................
KLF220-A2-
"'''' .. ,
FINAL DRIVE 9-3
T1: 25 N-m (2.5 kg-m, 18.0 ft-Ib)
T2 : KLF220-A1
78 N-m (8.0 kg-m, 58 ft-Ib)
: KLF22D-A2 20 N-m (12.0 kg-m, 87 ft-Ib)
T3: 15 N-m (1.5 kg-m, 11.0 ft-Ib)
T4: 147 N-m (15 kg-m, 108 ft-Ib)
T5: KLF22D-A 1
108 N-m (11 kg-m, 80 ft-Ib)
: KLF22D-A2120 N-m (12 kg-m, 87 ft-Ib)
T6: 20 N-m (2.0 kg-m, 14.5 ft-Ib)
T7: 69 N-m (7.0 kg-m, 51 ft~b)
St : Stake the fastener.
L : Apply a non-permanent locking agent.
SS : Apply silicone sealant_
G : Apply grease.
Apply engine oil.
o:
~~
O@r
- .
9-4 FINAL DRIVE
Specifications
Item
Final Gear Case Oil:
Type
Standard
API GL-5 Hypoid gear oil SAE 90
(above 5C, 41F) or SAE80 (below
5C, 41F)
Capacity
0.2 L
Bevel Gear Backlash: Front

Rear
SpeCial Tools
0.06 - 0.13 mm
(at d riven gear shaft nut)
0.13 - 0.25 mm
(at ring gear tooth)
Cirdip Pliers: 57001143
....... ... ,................................................................

~
Bevel Gear Holder: 57001-1193
FINAL DRIVE 9-5
Oil Seal and Bearing Remoyer: 57001-1058
Gear Holder: 57001-1015
Jack Stand: 57001 -1238
Hexagon Wrench: 57001-1194
.............................................................................
Sealant
.............................................................................
Kawasaki Bond (Silicone Sealant!: 56019-120
Bearing Retainer Wrench: 57001-1256
Socket Wrench: 57001-1214
9-6 FINAL DRIVE
I WARNING'
Final Gear Case Oil

Final Gear Case Oil Level Inspection
ePark the vehicle so that it is level"both side-to-side and
front-to rear.
eUnscrew the oil level inspection bolt the oil level is
correct if a small amount of oil comes out of the bolt
hole.
OWhen draining or filling the final gear case, be careful

that no oil gets on the tire or rim. Clean off any oil
that inadvertendy gets on them with a high flash-point
solvent.
eAfter the oil has completely drained out, install the

drain plug with a new aluminum gasket, and tighten it
to the specified torque (see Exploded View).

eUnscrew the oil level inspection plug.
ePour the oil into the case unt(1 the oil comes out of the
bolt hole.
Final Gear Case Oil
Type:
API GL- S Hypoid gear oil

0
SAE90 (above SoC, 41 Ft
SAE80 (below SOc, 41 0 Ft
Capacity:
02 L
NOTE
o"GL-5" indicates a qualitY and additive rating. "GL-6"
rated hypoid gear oils can also be used.
A. Filler Cap
B. Inspection Plug
*If no oil comes out, first check the final gear case for
oil leakage, remedy it if necessary., and add oil
through the filler opening. Use the same type and
brand of oil that is already in the final gear case.
elnstall the oil level inspection bolt.
eBe sure the O-ring is in place, and tighten the filler cap
to the specified torque (see Exploded View) .
eBe sure the O-ring is in place, and tighten the filler cap
Front Bevel Gears and Cam Damper
.............................................................................
Final Gear Case Oil Change
eWarm up the oil by running the vehicle so that the oil
will pick up any sediment and drain easily. Then stop
.
the vehicle.
ePark the vehicle so that it is level, both sideto-<ide
and front-to-rear.
eOrain the final gear case oil.
Front Gear Case Removal

eOrain the engine oil.
chapter).
Reverse Lever
Front Gear Case
A. Drain Plug
1. Front Gear Case
2. Mounting Bolts
FINAL DRIVE 9-7
Oil Seal Housing
A. Apply grease.
A. Oil Seal Housing
B. O-ring
B.Nuts
Oil Seal Housing Nuts
Front Gear Case Bolts
eApply grease to the splines at the front end of the
propeller shaft and fit the propeller shaft to the dri.ve
gear shaft.
Front Gear Case Installation

eFront gear case installation is the reverse of removal.
Note the following.
eThe front drive gear and driven gear are lapped as a set
in the factory to get the best tooth contact. They must
be replaced as a set.
eBe sure to check and adjust the bevel gear backlash and
tooth contact, when any of the parts which influence
these items are replaced (see Front Bevel Gear Ad
justment).
eApply silicone sealant to the threads of the front upper
gear case bolt (8 mm dia.).
A. Apply grease.
eTighten the engine mounting bolts to the specified
torque (see Exploded View in the Engine Removal/
Installation chapter).
eAdjust the reverse cable (see Engine Bottom
End/Transmission chapter).
eFili the engine with engine oil.
Front Drive Gear Removal/Installation

1. Apply silicone sealant.
2. Front Gear Case
eApply a high temperature grease to the oil seal and
install the oil seal housing to the front gear case. Be
sure the O-ring is in place in the groove on the housing.
eRemove the front gear case.

eRemove the right engine cover. Using the gear holder
(special tool: 57001.1015). hold the primary and sec
ondary gears to keep them from turning (see Engine
Right Side chapter).
oUnscrew the drive gear nut and take off the drive gear
and shim{s).
9-8 FINAL DRIVE
A. Drive Gear Nut
B. Front Drive Gear
elnstallation is the reverse of removal. Note the following.

Olnstall the shim(s) and drive gear onto the output shaft.
OOil the threads and seated surface on the drive gear nut,
and tighten it to the specified torque (see Exploded
View).
Front Driven Gear and Cam Damper Removal

eRemove the front gear case (see Front Gear Case Removal).
ePull the driven gear and cam damper assembly with
bearing housing out of the front gear Case. The shim(s)
comes off with the assemb Iy.
A. Bevel Gear Holder: 57001 1193

eHold the other end of shaft splines with the same tool.
eBend back the toothed washer tab, and unscrew the
driven gear shaft nut with the socket wrench (special
tool) .
A. Socket Wrench: 57001-1214

e Pull the shaft out of the bearing housing.
eT0 remove the ball bearing pressfitted into the front
gear case, use the oil seal and bearing remover (special
tool).
A. Bearing housing
B.Shim(s)
eUsing the bevel gear holder (special tool}, remove the

cam damper mounting nut.
A. Oil Seal and Bearing Remover: 57001-1058
FINAL DRIVE 99
eRemove the bearing retainer using the bearing retainer
tooth contact, when any of the parts which influence
wrench (special tool).
these items are replaced (see Front Bevel Gear Adjust

ment) .
Front Bevel Gear Adjustment

The backlash (distance one gear will move back and
forth without moving the other gear) and tooth contact
pattern of the bevel gears must be correct to prevent the
gears from making noise and being damag.ed.
When the any of the backlash-related parts are reo
placed; even if the purpose is not to replace the parts, be
sure to check and adjust the bevel gear backlash and
tooth contact by replacing shims.
A. Bearing Retainer Wrench: 570011256
B. Bearing Housing
Drive Gear Shims (* : Standard)
Front Driven Gedr and Cam Damper Installation

elnstallation is the reverse of removal. Note the fol
lowing.
eThe front drive gear and driven gear are lapped as a set
in the factory to get the best tooth contact. They must
be replaced as a set
eApply a non-permanent locking agent to the bearing
retainer and driven gear shaft nut.
ecH the threads and seated surface on the front cam

damper mounting nut.
eBend the toothed washer tab.
Bearing Retainer
Cam Damper Mounting Nut
1.
2.
3.
4.
5.
Cam Damp Mounting Nut

Washer
Driven Gear
Damper Cam Follower
Spring
6.
7.
8.
9.
Driven Gear Shaft

Shim
0Ring
Bearing Housing
Thickness
(mm)
Part Number
0.15
0.20
0.7
0.8
0.9
1.0'
1.1
1.2
1.3
920251573
920251574
920251534
920251535
920251536
920251537
920251575
920251538
920251533
Driven Gear Shims (* : Standard)

Thickness
(mm)
Part Number
0.1
0.15
0.5
0.8
1.0'
1.2
920251859
920251860
920251861
920251862
920251858
920251863
Backlash adjustment
eelean any dirt and oil off the bevel gear teeth.
elnstall the drive gear with the standard shim (see the
shim tables). and tighten the nut to the specified
torque (see Exploded View).
OOH the threads and seated surface on the nut.
elnstall the driven gear and cam damper assembly in the
front gear case with the standard shim (see the shim
tables), and tighten the mounting nuts to the specified
torque (see Exploded View) without the oil seal
housing.
9-10 FINAL DRIVE
1.
2.
3.
4.
5.
Bearing
Driven Gear Shaft
Transmission Output Shaft
Drive Gear Shim(s)
Drive Gear
-Install the front gear case on the crankcase, and tighten

the 8 mm case bolts to the specified torque (see Ex
ploded View) .
OCheck the backlash during the tightening of the case
mounting bolts. Stop tightening them immediately
if the backlash disappears and change the shim to a
6.
7.
8.
9.
-To measure the backlash, move the driven gear back

and forth while holding the drive gear steady. The
difference between the highest and lowest gauge
readings is the amount of backlash;
OTo hold the drive gear steady, hold the shift drum at
the full-turned position.
thinner one.
-Set up a dial gauge against the driven gear shaft nut to

check gear backlash .
A. Dial Gauge
B. Move.
Driven Gear
Driven Gear Shim(s)
Bearing Housing
A. Turn
FINAL DRIVE 911
*If the backlash is not within the limit, replace the
shim(s) at the drive and/or driven gear. To increase
backlash, decrease the thickness of the shim(s). To
decrease backlash, increase the thickness of the shim(s).
<>Change the thickness a little at a time.
eRe...check the backlash, and re-adjust as necessary.
Correct Tooth Contact Pattern

Drive Gear
Heel
Front Bevel Gear Backlash

Standard:
0.06 - 0.13 mm
(at drive gear shaft retainer)
Tooth contact adjustment

eApply checking compound to 4 or 5 teeth on the
driven gear.
NOTE
OApply checking compound to the teeth in a thin, even

coat with a fairly stiff paint brush. If painted too
thickly, the exact tooth pattem may not appear.
OThe checking compound must be smooth and firm,
with the consistency of tooth paste.
OSpecial compounds are available from automotive
supply stores for the purpose of checking differential
gear tooth pattems and contact. Use this for checking
the bevel gear.;.
Incorrect Tooth Contact Patterns

Example 1: Increase the thickness of the drive . gear
shim(s) by 0.05 mm, and/or decrease the thickness of
the driven gear shim(s) by 0.05 mm to correct the
pattern shown below. Repeat in 0.05 mm steps if
necessary.
Dri ve Gear
. Hell
eTurn the driven gear for 3 or 4 revolutions in the drive
and reverse (coast) directions, while creating a drag on
the drive gear.
eeheck the drive pattern and coast pattern of the bevel
gear teeth. The tooth contact patterns of both drive
and coast sides should be centrally located between the
top and bottom of the tooth, and a little closer to the
toe of the tooth.
*If the tooth contact pattern is incorrect, replace the
shim(s) at the drive gear and shim(s) at the driven gear,
following the examples shown. Then erase the tooth
contact patterns, and check them again. Also check
the backlash every time the shims are replaced. Repeat
the shim change procedure as necessary.
NOTE
Olf the backlash is out of the standard range after

changing shims, correct the backlash before checking
the tooth contact pattem.
Bottom
~/".'
Toe
Bottom
Top
9-12 FINAL DRIVE
Example 2: Decrease the thickness of the drive gear
shim(s) by 0.05 mm, andlor increase the thickness of the
drive gear shim(s) by 0.05 mm to correct the pattern
shown below. Repeat in 0.05 mm steps if necessary.
Cam Damper Inspection

_Visually inspect the damper cam (driven gear), cam
follower, spring, and shaft.
*Replace any part that appears damaged .
Drive Gear
Heel
~
Toe
Driven Gear
....---"':;
Bottom
Bottom
A. Cam (driven gear)

B. Cam Follower
C. Spring
D. Shaft
~
Top
Heel
Bevel Gear Inspection

_Visually check the bevel gears for scoring, chipping, or
other damage.
*Replace the bevel gears as a set if either gear is damaged.
Propeller Shaft
Propeller Shaft Removal

-Remove the rear axle and propeller shaft (see Rear
Axle and Propeller Shaft Removal) .
-Remove the propeller shaft housing mounting nuts and
take off the housing with the propeller shaft. The
spring comes off with the propeller shaft.
Ball Bearing Inspection

-Since the ball bearings are made to extremely close
tolerances, the wear must be judged by feel rather
than measuremenL Clean each bearing in a high f1ashpoint solvent, dry it (do not spin the bearing while it is
dry), and oil it with engine oil.
-Spin the bearing by hand to check its condition.
*If the b!aring is noisy, does not spin smoothly, or has
Oil Seal Inspection

- Inspect the oil seals.
*Replace it if the lips are misshapen, discolored (indicating that the rubber has deteriorated), hardened,
or been otherwise damaged .
A. .Propelier Shaft Housing

B. Mounting Nuts
C. Spring
FINAL DRIVE 913
_Remove the circlip with the circlip pliers (special tool:
57001143). and pull out the propeller shaft assembly
from the housing.
A. Apply grease.
A. Circlip
Propeller Shaft Joint and

Pinion Gear Joint Inspection
-Visually inspect the splines of both the propeller shaft
sliding joint and the pinion gear joint.
_If they are badly worn or chipped, replace the part
with a new one.
Propeller Shaft Installation

_Propeller shaft installation is the reverse of removal.
Note the following.
-Lubricate the propeller shaft before installation.
-Tighten the propeller shaft housing mounting nuts
Propeller Shaft Lubrication

-Wipe off the old grease, and apply fresh grease to
the parts shown.
A. Splines
Propeller Shaft Inspection

-Check that the universal joint works smoothly without
rattling or sticking.
_If it does not, the universal joint bearing is damaged.
Replace the propeller shaft with a new one.
-Visually inspect the universal joint grease cap.
*If there are any signs of deterioration damage, or
looseness, replace the propeller shaft.
_If grease leakage is noted, replace the propeller shaft.
1
A. Apply grease.
9-14 FINAL DRIVE
A. Universal Joint
B. Center Bearing
A.Clamp
B. Vent Hose
eUnscrew the following bolts.

Rear Shock Absorber Bolts(lower)
Suspension Arm Bolts
A. Grease Cap
B. Splines
el nspect the center bearing.

oSince the ball bearings are made to extremely close
tolerances, the wear must be judged by feel rather than
measurement.
OSpin the bearing by hand to check its condition.

any rough spots, replace the propeller shaft.
A. Bolts
eFree the rear axle with the propeller shaft from the
vehicle.
NOTE
Rear Axle Shafts

Rear Axle and Propeller Shaft Removal
olf the final gear case is full of oil, place the rear axle
right side up. If the rear axle is upside down or sideways, the oil will drain out of the case through the vent
hose.
elf the final gear case is to be disassembled, drain the
final gear case oil.

Rear Fender
Rear Wheels
Rear Hub
Rear Brake Panel
Dust Cover Clamp (loosen)
Vent Hose
Rear Axle and Propeller Shaft Installation

eRear axle and propeller shaft installation is the reverse
of removal. Note the following.
eGrease the splines at the front end of the propeller shaft.
FINAL DRIVE 9-15
aFit the propeller shaft to the driven gear shaft.
aApply grease to the universal joint outer surface.
b
A. Collar
1. Dust Cover
2. Unversal Joint
B. O-ring
3. Apply grease .
aTo remove the ball bearings and oil seals use the oil seal
and bearing remover (special tool).
aTighten the following bolts and nuts to the specified

torque (see Exploded View in th.e Suspension chapter).
Shock Absorber Bolts
Suspension Arm Pivot Bolts and Nuts
alf the final gear case oil was drained, fill the case with
oil.
OBefore removing the left axle shaft bearing, remove the

snap ring.
Axle Shaft Removal

eRemove the rear axle .
aRemove the left and right axle shaft pipes.

OCut away the sealant between the axle shaft pipe and
the final gear case.
A. Oil Seal and Bearing Remover: 57001-1058
Axle Shaft Installation

A. Axle Shaft Pipes
B. Mounting Bolts
C. Sealant
aRe move the collar and O-ring from the left axle shaft
pipe.
aAxle shaft installation is the reverse of removal. Note

the following.
aUsing a press and the bearing driver set (special tool:
57001-1129). install the oil seals and ball bearings until
they stop at the bottoms of their housings.
OPress in the oil seals with the manufacture's marks
facing out, as shown.
9-16 FINAL DR IVE
Right Side Axle
Left Side Axle
1. Oil Seal
2. Snap Ring
CD
Final Bevel Gears

Pinion Gear Disassembly
eRemove the rear axle and propeller shaft (see Rear
Axle and Propeller Shaft Removal).
ePull the pinion gear assembly off the final gear case.
The shim(s) comes off with the assembly . .
3. Bearing
eApply grease to the oil seals on the axle shaft pipes.
A. Pinion Gear Assembly .B. Shim(s)
ePry open the staking of the pinion gear nut with a small
chisel.
_Unscrew the pinion gear nut using the bevel gear holder
(special tool) to keep the pinion gear assembly as

shown ,. and remove the pinion gear nut, flat washer,
and pinion gear joint.
A. Apply grease.
eApply an even layer of silicone .sealant to the mating
surface of gear case and pipe.
eTighten the axle shaft pipe mounting bolts to the
specified torque (see Exploded View).
eThere is a collar at the left end of the axle shaft pipe.
InstaU the collar so that the chamfered side faces in to
compress the O-ring.
A. Bevel Gear Holder: 570011193

B. Pinion Gear
C. Pinion Gear Nut
e Pull out the pinion gear.

e Pry the oil seal off the housing.
eTo remove the bearing, unscrew the bearing retainer
A. Chamfered Side
B. Left Axle Shaft Pipe
using the hexagon wrench (special tool).
FINAL DRIVE 9-17
OWhen staking the nut, be careful not to apply shock to

the pinion and bearing. Such a shock could damage the
pinion and/or bearing.
tooth contactJ when any of the parts which influence

these items are replaced (see Final Bevel Gear
Adjustment).
A. Hexagon Wrench: 57001-1194

Final Gear Case Disassembly
Propelier Shaft
Axle Shafts
Pinion Gear Assembly
Final Gear Case Cover
Pinion Gear Assembly
ePinion gear assembly is the reverse of disassembly.
Note the following.
eThe pinion gear and ring gear are lapped as a set by the
factory to get the best tooth contact. They must be
replaced as a set.
elnstall the bearing and oil seal using the bearing driver
set (special tool: 57001-1129).
eApply a non-permanent locking agent to the bearing
retainer and tighten it to the specified torque (see Ex
ploded View) .
A. Final Gear Case Cover B. Bolts

OThe shim(s} comes off with the cover.
Ring Gear Assembly
1.
2.
3.
4.
Pinion Gear Nut

Pinion Gear Joint
O-Ring
Oil Seal
5.
6.
7.
8.
Pinion Gear Housing

Bearing
Bearing Retainer
Pinion Gear
eReplace the pinion gear nut with a new one.
eQil the threads and seated surface of the pinion gear

nut, and tighten it to the specified torque (see Ex
ploded View).
eStake the head of the pinion gear nut with a punch, to
secure the pinion gear nut in place.
A.Shim
B. Ring Gear Assembly
9-18 FINAL DRIVE
eBend back the toothed washer tab, and unscrew the
ring gear nut with a hook wrench.
[CAUTION]
aBe careful not to scratch the sealing surfaces of the
final gear case and case cover during the bearing
removal and installation. A scratched sealing surface
may allow oil to leak.
A. Ring Gear Nut

A. Sealing Surfaces
Final Gear Case Assembly

eAssembly is the reverse of disassembly.
following.
Note the
Final Bevel Gear Adjustment

The backlash (distance one gear will move back and
forth without moving the other gear) and ' toolh contact pattern of the bevel gears must be correct to
prevent the gears from making noise and being
damaged.
When anyone of the backlash-relate<t parts are
replaced or the pinion gear nut is loosened; even if the
purpose is not to replace the parts, check and adjust
the bevel gear backlash and tooth contact by replacing

shims.
The amount of backlash is influenced by the ring
gear 'position more than by the pinion gear position.
Tooth contact location is influenced by pinion gear
position-rnore than by ring gear position.
1. Ring Gear Nut

2. Toothed Washer
3. Speedmeter Gear
4. RingGear
5. Final Gear Shaft
eApply a nonpermanent locking agent to the following

fasteners, and tighten them to the specified torque (see
Exploded View).
Ring Gear Nut
Final Gear Case Cover Bolts
OAfter tightening the ring .gear nut, bend up the tab of
the toothed washer.
Backlash adjustmont
elnstall the pinion gear assembly with the standard
shim (see the shim tables), and tighten the propeller
shaft pipe mounting nuts to the specified torque (see
Exploded View) without the propeller shaft housing.
elnstall the ring geaf and differential gear housing in
the final gear case, and put the standard shim (see
the shim tables) onto the ring gear .
Put on the final gear case cover and tighten the cover
mounting bolts to the specified torque (see Exploded
View) .
OCheck the backlash while tightening of the cover
mounting bolts. Stop tightening them immediately if
the backlash disappears and change the ring gear shim
to a thinner one.
e Set up a dial gauge against a ring gear tooth to check

gear backlash .
FINAL DRIVE 9-19
1. Pinion Gear Nut

2. Pinion Gear Housing
3. Pinion Gear Shim(s)
4. Pinion Gear
5. Ring Gear Shim(s)

6. RingGear
Ring Gear shims for
7. Final Gear Case Cover

8. Final Gear Shaft
9. Final Gear Case
Pinion Gear Shims for
Backlash Adjustment
Tooth Contact Adjustment
Thickness
(mm)
Part Number
0.1
0.15
0.5
0.8
1.0
92025-1850
92025-1851
92015-1856
92025-1857
92025-1849
Thickness
(mm)
0.1
0.15
0.5
0.8
1.0
Part Number
92025-1865
92025-1866
92025-1867
92025-1868
92025-1864
(. : Standard)
A. Dial Gauge
B. Hold
C. Move
eTa measure the backlash, move the ring gear back

and forth while holding the pinion gear steady. The
difference between the highest and the lowest gauge
reading is the amount of backlash.
*If the backlash is not within the limit, replace the
ring gear shims. To increase backlash, decrease the
thickness of the shim(s). To decrease backlash, inincrease the thickness of the shim(s).
OChange the thickness a little at a time.
eRe-<;heck the backlash, and re-adjust as necessary.
9-20 FINAL DRIVE
eTurn the pinion gear for one revolution in the drive
Final Bevel Gear Backlash
0 .13 - 025 mm
(at ring gear tooth)
Standard:
Tooth contact adjustment

-Clean any dirt and oil off the bevel gear teeth.
eApply checking compound to 4 or 5 teeth on the
pinion gear.
NOTE
OApply checking compound to the teeth in a thin,
even coat with a fairly stiff paint brush. If painted
too thickly, the exact tooth pattem may not appear.
oThe checking compound. must be smooth and firm,
with the consistency of tooth paste.
OSpecial compounds are available from automotive
supply stores for the purpose of checking differential
gear tooth pattems and contact. Use one of these
for checking the bevel gears.
and reverse (coast) direction , while creating a drag on

the ring gear.
eRemove the ring and pinion gear assemblies to check
the drive pattern and coast pattern of the bevel gear
teeth . The tooth contact patterns of both (drive and
coast) sides should be centrally located between the
top and bottom of the tooth. The drive pattern can
be a little closer to the toe and the coast pattern can
be a somewhat longer and closer to the toe.
*If the tooth contact pattern is incorrect, replace the
pinion gear shim(s), following the examples shown.
Then erase the tooth contact patterns, and check
them again. Also check the backlash every time the
shim(s) are replaced . . Repeat the shim change pro
cedure as necessary.
NOTE
Olf the backlash is out of the standard range after
changing the pinion gear shim(s), change the ring gear
shim(s) to CO"ect the backlash before checking the
tooth contact pattem.
elnstall the shim(s) and pinion gear assembly, and

tighten the mounting nuts to the specified torque
elnstall the ring gear assembly in the final gear case,
and put the shim(s) onto the ring gear.
ePut on the final gear case cover and tighten the cover
mounting bolts to the specified torque (see Exploded
View).
Correct Tooth Contact Pattern
Heel
Ring Gear
Toe
Pinion Gear
Toe
Top
Toe
Bottom
Bottom
Heel
FINAL DRIVE 9-21
Incorrect Tooth Contact Patterns
Example 1: Decrease the thickness of the pinio n gear
shim(s) by 0.05 mm to correct the pattern shown

below. Repeat in 0.05 mm steps if necessary.
Heel
---Toe
..----.
Pinion Gear
.~
Heel
Toe
Bottom
Bottom
Example 2: Increase the thickness of the pinion gear
shim(s) by 0.05 mm to correct the pattern shown
below. Repeat in 0.05 mm steps if necessary.
Pinion Gear
~;r
'IV~
/
Top
-Bottom
Bottom
Heel
Bevel Gear Inspection
Ball Bearing Inspection
_Visually check the bevel gears for scoring, chipping,

or other damage.
*Replace the bevel gears as a set if either gear is
damaged.
-Inspect the final gear case ball bearings.

OSince the ball bearings are made to extremely close
tolerances, the wear must be judged by feel rather
than measurement. Clean each bearing in a high
flash-point solvent, dry it (do not spin the bearing
while.it is dry), and .oil it with engine oil.
oSpin the bearing by hand to check its condition.
Oil Seal Inspection

-Inspect the oil seal.
*Replace it if the lips are misshapen, discolored (indicating that the rubber has deteriorated), hardened,
or been otherwise damaged.
BRAKES 10-1
Brakes
Table of Contents
Exploded View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 102
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 10-3
Special Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 10-3
Brake Adju~ment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 10-4
Front Brake Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 10-4
Rear Brake Adjustment. . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . .. 10-5
Cam Lever Angle Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . .. 10-6
Brake Removal/Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 10-6
Front Brake Removal/Disassembly. . . . . . . . . . . . . . . . . . . . . . .. 10-6
Front Brake Assembly/Installation .. , . . . . . . . . . . . . . . . . . . . .. 10-7
Rear Brake Removal/Disassembly . . . . . . . . . . . . . . . . . . . . . . . .. 10-8
Rear Brake Assembly/I nstallation. . . . . . . . . . . . . . . . . . . . . . . .. 10-8
. Brake Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 10-9
Brake Drum Wear .................. _ . . . . . . . . . . . . . . . . .. 10-9
Brake Shoe Lin ing Wear . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . .. 10-9
Brake Cam and Cam Hole Wear . . . . . . . . . . . . . . . . . . . . . . . . . .. 10-9
Brake Shoe Spring Inspection . .... . . ....... . ... . .. .. .. . . . 10-10
Brake Lubrication ... .. ......... .. .... .... ........ ... .. 10-10
.e;;~i;;;;;;j;;i~:
.... ... :
10-2 BRAKES
....... ....................... .
.....................
ij)..
~ ~t
@
5 kg.... , 25 fHb)
Tl : 34 N.... (3.
m 19.5 fHb)
T2 26 N.... (2.7 kit" '108 ft.lb)
.
(15 klt"m,
T3: 147 N....
.... 22 ft.lb)
4
29
N
....
(3.0
kg,
locking agent.
T
L :. Apply a non -permanent .
G : Apply grease.
BRAKES 10-3
h
Specifications
............................................................................
Standard
Service Limit
Brake Lever Free Play
1-2mm
Brake Pedal Free Play
25 -35 mm
-----
Parking Brake Lever Free Play
2-3mm
---
Brake Shoe Lining Thickness
4.0mm
2.0mm
140.00 - 140.16 mm
140.75 mm
Rear
160.00 - 160.16 mm
160.65 mm
Front
14.957 - 14.984 mm
14.88 mm
Rear
16.957 - 16.984 mm
16.88 mm
Front
15.000 -
mm
15.15 mm
Rear
17.000 - 17.007 mm
80- 90
17.15 mm
Item
Brake Drum Inside Diameter: Front

Brake Cam Diameter:
Brake Cam Hole Diameter:
Brake Cam Lever Angle
Special Tools
~5.006
---
104 BRAKES
.............................................................................
Brake Adjustment
.............................................................................
Front Brake Adjustment
eTurn each adjuster at both lower ends of the cable so
that each brake cam lever will have 2 - 3 mm of free
play.
A. Equalizer
B. Case
echeck that the brake lining wear indicator points

within the USABLE RANGE when the brake is fully
applied.
*If does not, replace the brake shoes.
A. Adjuster
C. 2 -3 mm
B. Cam .Lever
eT urn the adjuster at the brake lever until the b

lever has the specified amount of free play.
A. Wear Indicator
B. USABLE RANGE
-check the cam lever angle when the brake is fully

applied.
A. Free Play
B. Locknut
C. Adjuster
Brake Lever Free Play
Standard:
1 - 2 mm
NOTE
OMake sure that the equalizer is lifted parallel to the

bottom of the case when brake lever is pulled in to
prevent the brakes from pulling to either side.
A. Cam Lever Angle
Cam Lever Angle

Standard:
80 _90
BRAKES 10-5
*If the cam lever angle is not within the specified
range, adjust it (see Cam Lever Angle Adjustment).
Parking Brake Lever Free Play
Standard:
2 - 3 mm
I WARNING.
0
OSince a cam lever angle greater than 90 reduces

braking effectiveness, carn lever angle adjustment
should not be neglected. Reduced braking effec
tiveness could lead to a crash.
Rear Brake Adjustment

.Measure from the top of the brake pedal in its rest
position to the upper surface of the footpeg. This
measurement should be 0 mm.
A. Lever .Free Play

B. Locknut
C. Adjuster
-Check that the brake lining wear indicator points

within the USABLE RANGE when the brake is fully
applied.
*If does not, replace the brake shoes.
A. Adjuster
B. Locknut
C.Omm
-Check and adjust the brake pedal free play.

Brake Pedal Free Play
Standard:
25 -35mm
aTa adjust the pedal free play, turn the adjuster at the
rear end of the brake cable.
A. Wear Indicator
B. USABLE RANGE
-check the cam lever angle when the brake is fully

applied.
A. Brake Pedal Adjuster

.Adjust the parking lever free play by turning the
adjuster at the lever.
A. Cam Lever Angle
10-6 BRAKES
Cam Lever Angle
Brake Removal/Disassembly
80 _90
Standard:
*If the cam lever angle is not within the range specified,
ajdust it. (see Cam Lever Angle Adjustment).
Front Brake Removal/Disassembly
I WARNING'
I WARNING'
0
OSince a cam lever angle greater than 90 reduces

braking effectiveness, cam lever . angle adjustment
should not be neglected. Reduced braking effectiveness could lead to a crash.
Cam Lever Angle Adjustment
OBrake linings contain asbestos fiber. Inhalation of

asbestos may cause serious scarring of the lungs and
may promote other internal injury and illness, indud
ing cancer. Observe the following precautions when
handling brake linings:
1. Never blow brake lining dust with compressed air.
2. If any components are to be cleaned, wash them
with detergent, then immediately discard the clean"ing
solution and wash your hands.
3.- Do not grind any brake lining material unless a
ventilation hood is available and properly used.
eRemove the cam lever.

oloosen the axle nut.
A. Cam Lever
A. Axle Nut
B. Bolt and Nut
eMount the cam lever at a new position so that the cam

lever has the proper angle when the brake is fully
applied.
Wheel (see Wheels/Tires chapter)

Axle Nut
Brake Cable lower End
Brake Drum
Cam Lever Angle (front and rearl

Standard:
80 _ goO
I WARNING'
OWhen remounting the cam, be sure that the position of
the indicator on the serrated shaft is not altered.
OA change in cam lever angle is caused by wear of internal brake parts. Whenever the cam lever angle is adjusted, also check for drag and proper operation, taking
particular note of the brake lining wear indicator
position.
Oln case of doubt as to braking effectiveness, disassemble and inspect all internal brake parts. Worn parts
could cause the brake to lock or fail.
B. Cotter Pin
A. Brake Drum
BRAKES 10-7
Brake Adjuster (at the brake cam lever)
Brake Panel
A. Brake Panel
ODrive out the bearings.
B. Bolts
eDisassemble the brake panel.

oRemove the brake shoes.
1. Bearings
2. Spacer
3. Metal Rod
oRemove the brake cam lever.
NOTE
OBefore removing the brake cam lever, mark the posi-
Front Brake Assembly/Installation
tion of the cam lever so that it can be installed later

in the same position.
I WARNING'
olmproper installation will cause ineffective braking,
which could lead to a crash .
eAssemble the brake panel, if it was disassembled.

oPush the brake cam into the panel.
olnstall the brake shoes.
Olnstall the O-ring and fit the indicator on the serrations
so that it points to the bottom end of the USABLE
RANGE.
oFit the brake cam lever so that the marks align.
A. Marks
oPull the brake cam out from the inside .
. eDisassemble the brake drum.
ORemove the collar and grease seal.
A. Indicator
A. Collar
B. Grease Seal
elnstall the brake panel.

OApply a non'permanent locking agent to the brake
panel mounting bolts, and tighten them to the specified
torque (see Exploded View).
eAssemble the brake drum, if it was disassembled .
10-8 BRAKES
Olnstall the bearings, using the bearing driver set (special
tool: 57001-1129).
OFit a new grease seal .
A. Breather Hose
eThe rear brake drum has no bearings, spacer, collar, or
1. Bearing
2. Collar
3. Drum
4 . Grease Seal
5 . Spacer
eGrease the grease seal lips, and install the brake drum.
eTighten the axle nut to the specified torque (see Exploded View).
elnstall a new cotter pin.
eAdjust the front brakes.
grease seal.
CD
1. Brake Drum Seal

2. Brake Drum
Rear Brake Assembly/Installation

Rear Brake Removal/Disassembly
I WARNING.
eRefer to Front Brake Assembly/Installation, noting the

following.
OGrease the O-ring, and install it.
OBrake linings contain asbestos fiber. I"halation of

asbestos may cause serious scaRing of 1IIe lungs and
may promote 01ller intemal injury and iIIn.... indusing
ca"cer. Observe 1IIe following precautiom when h8l1d
li"g brake li"i"gs:
1. Never blow brake lini"9 dust with compr...ed air.
2. If a"y compo,,""u are to be dea"ed. wash 1IIem
wi1ll deterge"t,1IIe" immediately discard 1IIe d08l1i"g
solutio" a"d wash your ha"ds.
3. Do "ot gri"d al1Y brake li"i"g material u"l... a vemi
latio" hood is av.il.ble ."d properly used.
eRefer to Front Brake Removal/Disassembly, noting
the following.
eBefore removing the brake panel, disconnect the
breather hose from the panel.
A. O-ring
B. Apply grease.
BRAKES 10-9
OApply low-temperature grease to the brake drum seal
lip. An example of low-temperature grease is NOK
TOPAS JL125.
Grease
*If any measurement is greater than the service limit,

replace the drum.
*If the drum is worn unevenly or scored, lightly turn the
drum on a brake drum lather or replace it. Do not turn
the drum beyond the service limit.
Brake Shoe Lining Wear

-Measure the lining thickness at several points; as shown.
Brake Shoe Uning Thickness
(Front and Rear)
Standard:
Service Limit:
4.omm
2.0mm
OThe rear brake drum has no bearings, spacer, collar, or

grease seal.
Brake Maintenance
Brake Drum Wear
eMeasure the inside diameter of the drum at several
points.
Front Brake Drum Inside Diameter

Standard:
Service Limit:
140.000 -140_160 mm
140.75 mm
Rear Brake Drum Inside Diameter

Standard:
160.000 -160.160 mm
Service Limit!
160.65mm
*If any measurement is less than the service limit, replace both shoes as a set.
*If the lining thickness is greater than the service limit,
do the following before installing the shoes.
eFile or sand down any high spots on the surface of the
lining.
-Use a wire brush to remove any foreign particles from
the lining.
eWash off any oil or grease with an oilless solvent.
ODo not use a solvent which will leave an oily residue or

the shoes will ha.e to be replaced.
Brake Cam and Cam Hole Wear

eMeasure the brake cam diameter.
Brake Cam Diameter

Front
Standard:
Service Limit
14.957 - 14.984 mm
14.88 mm
Rear
Standard:
Service Limit:
16.957 - 16.984 mm
16.88 mm
10-10 BRAKES
Cam Hole Inside Diameter
Front
Standard:
Service Limit
15.000 - 15.006 mm
15.15 mm
Rear
Standard:
Service Limit:
17.000.-17.007 mm
17.15 mm
eMeasure the inside diameter of the cam hole.
A. Apply grease
Brake Pedal Pivot

Front and Parking Brake Lever
*If the brake cam wear is less than the service limit,
replace the brake cam.
*If the cam hole wear is more than the service limit,
replace the brake panel.
Brake Shoe Spring Inspection

eVisually inspect the brake shoe springs for breaks or
distortion.
*If the springs are damaged in any way, replace them.
Brake Lubrication
Whenever the brake is disassembled, and in accordance with the Periodic Maintenance Chart, perform the
following.
eelean all old grease out of the brake parts with a cloth.
eApply high-temperature grease to the following:
Brake Shoe Anchor Pin
Spring Ends
Cam Surfaces
Brake Cam Groove
A. Apply grease
BRAKES 10-11
A. Apply grease.
-Lubricate the brake cable with a penetrating rust

inhibitor.
1. Pressure Cable Luber
SUSPENSION 11-1
Suspension
Table of Contents
Exploded View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-2
Shock Absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-3
Shock Absorber Removal/Installation. . . . . . . . . . . . . . . . . . . . . . .
11-3
Shock Absorber Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-3
Suspension Arm ........................ : . . . . . . . . . . . . . . .
11-3
Suspension Arm Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-3
Suspension Arm I mstallation. . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-4
Suspension Arm Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-4
112 SUSPENSION
Exploded View
T1: 88 N-m (9.0 kg-m, 65 ft4b)

T2: 34 N-m (35 kg-m, 25 ft4b)
G : Apply grease.
~--(T2
SUSPENSION 11-3
Shock Absorber
Shock Absorber Removal/Installation

-Support the vehicle on a stand so that the front and/or
rear wheels are off the ground.
-Remove the front and/or rear wheels.
eRemove the upper and lower shock absorber mounting
bolts and/or nuts.
1. Rubber Bushings
$uspension Arm
Suspension Arm Removal

-Remove the front suspension arm.
oRemove the following parts.
Front wheel {see Wheels/Tires chapter)
Front brake panel assembly (see Brakes chapter)
Front shock absorber
Steering knuckle (see Steering chapter)
oRemove the suspension ann by taking out the pivot
bolts.
A. Mounting Bolts
elnstallation is the reverse of removal.
Note the
following.
_Tighten the upper and lower shock absorber mounting
bolts to the specified torque (see Exploded View).
Shock Absorber Inspection

Since the shock absorbers are sealed units which
cannot be disassembled, only external checks are necessary.
*If one unit is damaged, replace both shock absorbers as
a set. If only one unit is replaced and the two are not
balanced, vehicle instability at high speed may result.
e<:heck the rubber bushings in the pivots.
*Replace any bushings that are worn, cracked hardened,
or otherwise damaged.
A. Suspension Arm Pivot Bolts
-Remove the rear suspension arms.

oRemove the rear wheels (see Wheels/Tires chapter).
ORe move the suspension arm pivot bolts and take the
suspension arms off the frame.
11-4 SUSPENSION
*If abnormal friction is felt, the rubber bushings may be
damaged. Remove the suspension arm to check for
rubber bushing damage.
e<:heck the rubber bushings in the pivots.
*Replace any bushings that are worn, cracked, hardened ,
or otherwise damaged .
A. Left Arm
B. Center Arms
C. Right Arm
D. Bolts
Suspension Arm Installation

eSuspension arm installation is the reverse of removal.
Note the following.

elnstall the front brake panel on the suspension arm.
Suspension arm pivot bolts
Shock absorber mounting bolts

Steering knuckle pivot nuts
Suspension Arm Inspection

eMove the suspension arm up and down to check for
abnormal friction.
A. Suspension Arm
STEERING 12-1
Steering
Table of Contents
Exploded View. . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . .
12-2
Steering .. _ ............................ _.......... _. . . . . . .
12-3
Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12-3
Handlebar Installation Note ..... .. __ ....... .. .. ... ... _ . . .
12-3
Steering Stem Removal ............ _ . . . . . . . . . . . . . . . . . . . . .
12-3
Steering Stem Installation . _ ........ _ . . . . . . . . . . . . . . . . . . . . .
12-4
Steering Knuckle Removal ...... _ .. _ ... _ ................ _
124
Tie-rod Removal ........ _ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12-5
Tie-rod Installation Notes .. _ ..................... _. . . . . . .
12-5
Tie-rod End Removal ............ _ . . . . . . . . . . . . . . . . . . . . . .
12-5
Maintenance and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12-5
Steering Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12-5
Steering Stem Warp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12-5
Steering Lubrication ................ _ . _ . . . . . . . . . . . . . . . . .
12-6
Steering Knuckle Pivot Lubrication ..... _ . . . . . . . . . . . . . . . . . . .
12-6
Steering Stem Clamp Inspection ......................... _ .
12-6
Steering Stem Bearing Inspection .............. _. . . . . . . . . . .
12-6
Tie-rod End Inspection ........... _ . . . . . . . . . . . . . . . .. . . . . .
12-6
12-2 STEERING
............................................................................
Exploded View
.................................... ........................................
Other than US and Canadian Model
KLF22D-A3A -
"7
T1:
T2:
T3:
T4:
T5:
26
29
41
27
34
N-rn
N-rn
N-rn
N-m
N-rn
(2.7 kg-rn.
(3.0 kg-rn.
(4.2 kg-rn.
(2.B kg-rn.
(3.5 kg-rn.
G : Apply grease.
19.5 ft~b)
22 ft~b)
30 ft~b)
20 ft~b)
25 ft~b)
STEERING 12-3
Steering
Removal and Installation:
Handlebar Installation Note

eTighten the holder rear bolts first and then the front
bolts. There will be a gap at the front part of the
clamp after tightening.
A. Bearing Housing Mounting Bolts

B.. Tie-rod End Nuts
[CAUTION
000 not loosen the locknuts at the ends of the tie-rod

adjusting sleeve, or the toe-in of the front wheels could
change.
Steering Clamp
A.Gap
Steering Stem Removal

Front Fender (see Frame chapter)
Fuel Tank
Handlebar
A. Steering Oamp
B. Bolts
ePull the steering stem out of the frame .

eTo remove the steering stem bearing, remove the cotter
pin and nut from the bottom end of the steering stem.
A. Front Brake Cable Equalizer
Bearing Housing Mounting Bolts

Tie-rod End Nuts
B. Bolts
A. Cotter Pin and Nut
12-4 STEERING
Steering Stem Installation
Steering Knuckle Removal
-Steering stem installation is the reverse of removal.

Note the following.
elnstall the steering stem bearing, grease seals, and collar
to the bottom end of the steering stem.
eLubricate the steering stem clamps, grease seals and
stem bearing (see Steering Lubrication) .
elnstall the grease seal facing the end forward to prevent
the entry of dirt.

Front Brake Panel (see Brakes chapter)
Brake Cable
Tierod End Nut
A. TIe-rod End Nut and Cotter Pin

eRemove the steering knuckle shaft and nut.
A. Ends
eAlign the marks on the steering stem clamps.
A. Shaft
B. Nut and Cotter Pin
eTake out the grease seals and sleeve.
A. Marks
eTighten the following fastene" to the specified torque

Stem lower end nut
Stem clamp bolts
Tie-rod end nuts
elnspect the following and adjust them, if necessary.
Toein (see Wheel/Tires chapter)
Front Brake Cable (see Brakes chapter).
,. Grease Seals
2. Sleeve
STEE RING 12-5
1
Tie-rod Removal
eRemove the tie-rod end nuts.
A_ Locknut
A_ Cotter Pins and Tie-rod End Nuts
B_ Tie-rod End
NOTE
[CAUTIO~:!
OThe locknut on the opposite end of the tie-rod from

the flattened area has left-hand threads_ Turn the
wrench clockwise for loosening_
000 not loosen the locknuts at the ends of the ti....od

adjusting sleeve, or the toe~n of the front wheels
could change_
OWhen removing the tie-rod, be careful not to bend it.
000 not remove the grease seal. It is packed with grease.
Tie-rod Installation Notes

eThe installation is the reverse of removal. Note the
following_
eThe right and left tie-rods are identical _
elnstall the tie-rod with the flattened area located
inboard_
Maintenance and Inspection:

Steering Inspection
eTurn the handlebar left and right, and check the
steering action.
*If the steering action is not smooth, or if the steering
binds or catches before the stop, lubricate the steering_
NOTE
OThe cables and wires will have some effect on the

steering action which must be taken into account.
-Check the steering action again _

*If the steering lubrication does not remedy the problem, inspect the steering stem warp, steering stem
A. Flattened Area
eTighten the tie-rod end nuts to the specified torque
(see Exploded View) _
elnspect the toe-in if necessary (see Wheels/Tires
chapter)_
clamps, and tie-rod ends.

*If you feel looseness, or if the steering rattles as it
turns, check the tightness of the steering bolts and nuts_
eTighten -loose bolts and nuts to the specified torque
(see Exploded View), and check the steering action
again .
*If the steering action does not change by tightening the
bolts and nuts, inspect the steering stem clampsl
steering stem bearingl tie-rod end and steering knuckle
pivots_
Steering Stem Warp

Tie-rod End Removal
e Remove the tie-rod.
eHolding the tie-rod flattened area, loosen the locknut

and unscrew the tie-rod end.
e Remove the steering stem_

-Check the steering stem for straightness_
oUse a straightedge along the stem_
*If the steering stem is bent, replace the steering stem_
12-6 STEERING
Steering Lubrication
eLubricate the steering stem clamps.
o Remove the steering stem.
OWipe all the old grease off the knuckle bushing sleeve,
and grease seals.
<>Grease the knuckle bushing, sleeve, and grease seal lips.
oWipe all the old grease off the steering stem and
clamps, and out of the grease seals.
OApply grease to the steering stem and pack the grease

seal grooves between the lips with grease.
Steering Stem Clamp Inspection

-Inspect the steering stem clamps.
*If there is roughness, excessive play, or seizure, replace
both clamps.
Steering Stem Bearing Inspection

elnspect the spherical bearing.
.
the steering stem bearing assembly.
elnspect each grease seal.
*If there is damage, wear or deterioration replace the
steering stem bearing assembly.
A. Steering Stem
B. Grease Seals
C. Steering Stem Clamps
eLubricate the steering stem bearing.

oDisassemble the steering stem bearing.
oWipe all the old grease off the steering stem and out of
bearing grease seal.
oPack the grease seal groove between the lips with
grease.
O~
A. Spherical Bearing
B. Grease Seals
Tie-Rod End Inspection

elnspect the spherical bearings.
the tie-rod end.
elnspect the grease seals.
*If there is damage, wear or deterioration replace the tierod end.
A. Apply grease.
Steering Knuckle Pivot Lubrication

eLubricate the knuckle pivot through the grease fitting
with a grease gun according to the Periodic Maintenance Chart.
0lt is normal for a small amount of grease to seep out
around the grease seals.
*If the knuckle pivot is disassembled, lubricate the
pivot as follows.
o
1. Grease Seal
2. Spherical Bearing
FRAME 13-1
Frame
Table of Contents
Exploded View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
132
Fender. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13-4
Front Fender Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13-4
Rear Fender Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
135
13-2 FRAME
...............
E~~i~d~d;:ii~::::::::::::::: . .............
...............................................
.
~
"
'.
"
KLF22()'A3 -
FRAME 13-3
than US ~~ Canadian model

rOther
______
I
I
------
i ~C9
I
I
I
I
I
L____
I
Other than USa;d-C;; - -. - - - - - J
KLF220-A3 _
nad.an Model
13-4 FRAME
ORemove the front fender.
Fender
Front Fender Removal

A. Screws
,.
A. Bolts
Front Cover
A. Screws
A. Front Cover
B. Screws
Ignition Switch
Reverse Knob
Fuel Tank Cover
A. Screw
A. Ignition Switch
B. Fuel Tank Cover
C. Screws
FRAME 13-5
Rear Fender Removal

eDisconnect the taillight connectors.
'A. Bolts
A. Connectors
eRemove the rear fender.
A. Bolts
A. Bolts
ELECTRICAL SYSTEM 14-1
Electrical System
Table of Contents
Precautions . . . . . . . . . . . . . . . . . . . . . . . . 142
Wiring Diagram
KLF220-Al, A2, A3 (All Models). ... _ . .. 14-3
KLF220-A4, A5, A6, A7, A8
(Canadian, UK models) .... . .... , .. 14-3
Exploded View . .. . . . ... ... .... . . _ .. 14-4
Specifications. . . . . . . . . . . . . . . . . . . . . . 14-6
Special Tools .. . . . _ _ . .. . ... _ . . 14-6
Battery . . . . . . . . . . . . .. . . _ . . . . . . . . . . 14-7
Precautions .. . . _ . . . .... . _ . . . . . . .. 14-7
Battery Removal/lnstallation _ .. _ . _ . _ . _ 14-7
Battery Removal. . . . . . . . . . . . . . . 14-7
Battery Installation .. . ... ... _ . . . . . 14-7
Electrolyte .. . . _. ' ... _ . _ . . . . . . . . .. 14-7
Electrolyte Level Inspection . . . . . . . . 14-7
Battery Charging .. ... .. __ ... . .. _ . .. 14-7
Battery Condition . . _ . _ .. _ . ... _ .. 14-7
Battery Initial Charging _ ... .. . . _ . . 14-8
Battery Ordinary Charging . . .. ... _ .. 14-9
Battery Test Charging _ . . _ . . _ . _ .. ... 14-10
Charging System '. . . . . . . . . . . . . . . .. _ .. 14-10
Magneto Flywheel Removal /
Installation ... _ .. . _ . ... ... . . . 14-10
Magneto Stator Removal /
Installation . ..... ___ .. ........ 14-10
Charging Coil Inspection __ .. .... _ ... 14-10
Regulator/ Rectifier Inspection . . . . . . . . 14-11
Ignition System ...... . . _ .. _ .. . .... _ . _ 14-13
Safety Instructions . . . . . . . . . . . . . . . .. 14-13
Ignition Coil Removal . ... . . ... . ... 14-13
Pickup Coil Removal / Installation . ... . . 14-13
COl Unit Removal .... _ ...... . . . . . 14-13
Ignition Coil Inspection ..... _ .. _ .. . 14-14
Exciter Coil Inspection . __ ... . . . . . . 14-15
Pickup Coil Inspection . . . . . . . . . . . . . 14-15
COl Unit Inspection .... _ . _ .. ..... . 14-15
Spark Plug Cleaning and Inspection .... . 14-16
Electric Starter System _ .. . _ . _ . .. _ . .. _ . . 14-16
Starter Motor . . . . . . . __ ... . . .. . .. . 14-16
Starter Motor Removal. _ ...... . _ . . _ 14-16
Starter Motor Installation . ..... _ . .. 14-17
Starter Motor Disassembly .... _ ... _ 14-17
Starter Motor Assembly . _ ...... . .. _ 14-17
Armature Inspection .. _ .. ... .. . .. _ 14-19
Brush Inspection _ __ .. _ ... _... . .. _ . 14-19
Commutator Cleaning and Inspection ... 14-19
Brush Leads Inspection. _ . . . . .. . .. .. 14-20
Brush Plate and Terminal Bolt
Inspection .. . . _ . . . . . . . . _ . . . . . 14-20
Starter Re lay, Starter Circuit Relay. . . . . . . .. 14-20

Starter Relay Inspection . . . . . . . . . . .. 14-21
Starter Circuit Relay Inspection . .. . ... 14-21
Lighting System . ... . .. . ... .... .. ' ... . 14-21
Headli!tot Beam
Headlight Beam Vertical Adjustment . .. . 14-21
Headli!tot Bulb Replacement _ . . . . . . .. 14-22
Taillight Bulb Replacement . . .. ..... . 14-22
Switches . . . . . . . . . . . . . . . . . . . . . . . . . . 14-22
Neutral and Reverse
Switch Removal/Installation ...... . 14-22
Switch Inspection . ... .. . . . . _ . . . .. 14-22
Fuse . _ . _ ... .. ........ . ... _ . . . . ... 14-23
Fuse Inspection .. .. .. . . _ . . . . .. . . 14-23
Electrical Wiring. . . . . . . . . . . . . . . . . . . .. 14-23
Wiring Inspection ...... ... ..... . . . 14-23
Wiring Diagram KLF220-A4, A5. A6, A7. A8
(US Model) . . ... .. . . . .. . .. . . . .... 14-24
Wiring Diagram KLF220-A3A, A4,A5,A6,A7,A8
(Australian Model) . . .. . . . .. . .... . . . . 14-25
Wiring Diagram KLF220-A4, A5, A6 , A8
(European Model) . . ....... . . . ... . .. 14-26
14-2 ELECTRICAL SYSTEM
Precautions
There are a number of important precautions that are
musts when servicing electrical systems. Learn and
observe all the rules below.
000 not reverse the battery lead connections. This
will burn out the diodes in the electrical parts.
OAlways check battery condition before condemning
other parts of an electrical system. A fully charged

battery is a must for conducting accurate electrical
system tests.
oThe electrical parts should never be struck sharpl y, as
with a hammer, or allowed to fall on a hard surface.
Such a shock to the parts can damage them.
aTc prevent damage to electrical parts, do not dis
connect the battery leads or any other electrical
connections when the ignition switch is on, or the
engine is running.
0 00 not use a meter illumination bulb rated for other

than voltage or wattage specified in the wiring diagram, as the meter or gauge panel could be warped
by excessive heat radiated from the bulb.
oTake care not to short the leads that are directly
connected to the battery positive (+) terminal to the
chassis ground.
oTroubles may involve one or in some cases all item s.
Never replace a defective part without determining

what CAUSED the failure. If the failure was caused
by some other item or items, they too must be
repaired or replaced, or the new replacement will
soon fail again.
oMake sure all connectors in the circuit are clean and
tight, and examine wires for signs of burning, fraying,
etc. Poor wires and bad connections will affect electrical system operation.
OMeasure coil and winding resistance when the part is
cold (at room temperature) .

o Electrical Connectors
Female Connectors
Male Connecton
OColor Codes:
BK
Black
Blue
BL
BR
Brown
CH
Chocolate
DG
G
GY
LB
LG
Dark green
Green
o
P
PU
R
W
Y
Gray
Light blue
Light gree n
Orange
Pink
Purple
Red
White
Yellow
....................................................................................
Wiring Diagram KLF220A 1, A2, A3 (All Models)
KLF220-A4, A5, A6, A7, AS
(Canadian, UK Models)
....................................................................................
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4f:---oi\ Silfl .. Button

Engln. SlOP Swllcl>
Sillter
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0,_
OV
Gray
litht IIluI
llghl GrMn
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Llghlln,Swllcn
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............
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8
T1: 20 Nm (2.0 kg-m, 14.5 ftl

1. COl Unit
2. Regulator/Rectifier
3. Ignition Coil
4. Pickup Coil
5. Neutral and Reverse Switch
6. Starter Circuit Relay
7. Starter Relay
8. Fuse
9. Horn Switch
<A>:Australian Model
(r-n~
L_i
_J
14.0 ELECTRICAL SYSTEM
Specifications
Standard
Item
Battery :
Electrolyte Level
Specific Gravity of Electrolyte
Charg ing System:
Regu lator/rectifier Output Voltage
Charging Coil Output
Charging Coil Resistance
Ign ition System:
Ignition Coil: Arcing Distance
Primary Winding Resistance
Secondary Winding Resistance
Type
Spark Plug:
Gap
Exciter Co iI Resistance
Pickup Coil Resistance
Pickup Coil Air Gap
Electric Starter System:
Starter Motor:
Brush Length
Commutator Diameter
U : US model
Special Tools
Between level lines

1.2S0 @20C (6S0 F)
---
Battery voltage - 15 V
31 V @40oo rpm
0.2 -O.sn
---
7 mm or more
0.09-0.13n
3.S - 5.S kn
NGK DSEA (U), tA)
NGK DRSES
0.6 -0.7 mm
100-190n
S5 -130n
0.7 0.25 mm
-----------------
11 mm
23mm
5mm
22mm
A : Australian model
Timing Light: 57001-1241
............................. , ................................................
Hand Tester: 57001-1394
Coil Tester: 57001-1242

Spark Plug Wrench: 57001-1024
Service Lim it
---
-----
---
eDisconnect the battery positive (+) cable.
Battery
-Unscrew the bolts and remove the battery from the

case.
Precautions:
Following a few simple rules will greatly extend the
life of the battery.
oWhen the level of the electrolyte in the battery is low,
add only distilled water to each cell, until the level is
at the upper level line marked on the outside of the
battery.
Ordinary tap water is not a substitute for
distilled water and will shorten the life of the battery.

oNever add sulphuric ac id solution to the battery. This
will make the electrolyte solution too strong and will
ruin the battery within a very short time.
oAvoid quick-charging the battery. A quick-charge will

damage the battery plates.
ONever let a good battery stand for more than 30 days
without giving it a supplemental charge, and never let
a discharged battery stand without charging it. If a
battery stands for any length of time, it slowly selfdischarges. Once it is discharged , the plates sulphate
(turn white), and the battery will no longer take a
charge.
OKeep the battery well-charged during cold weather so
that the electrolyte does not freeze and crack open the
battery. The more discharged the battery becomes, the
more easily it freezes.
OAlways keep the battery vent hose free of obstruction,
and make sure it does not get pinched, crimped, or
melted shut by contact with the hot muffler. If
battery gases cannot escape through this hose, they will
explode the battery.
oDON'T INSTALL THE BATTERY BACKWARDS.
The negative side is grounded.
Battery Installation
-Battery installation is the reverse of removal.
Note
the following.
-Connect the positive (+) cable first and then the
negative cable.
eRoute the battery vent hose observing the label for
the hose routing.
Electrolyte :
Electrolyte Level Inspection

eVisually check the electrolyte level in the battery.
Battery Removal/Installation:
Battery Remoal
A. Level Lines
eDisconnect the battery negative (-) cable.

*If the level line of electrolyte in any cell is below the
lower level line on the battery case, add distilled water
only to that cell.
Battery Charging:
Battery Condition
A. Negative Cable
B. Positive Cable
C. Bolts
eBefore charging, check battery condition by testing the

specific gravity of the electrolyte .in each cell.
oDrawa little fluid from the cell with a hydrometer.
oRead the level of the electrolyte on the floating scale.
This is the specific gravity of the electrolyte.
OFahrenheit: Add 0.004 points to reading for each 10F
above 68"F or subtract 0.004 points for each 10F
below6SoF.
Hydrometer
*If the specific gravity of any of the cells is more than

0.050 away from any other reading, the battery will
probably not accept a charge. If it generally best to
replace a battery in this condition.
)~
*If the specific gravity of all the cells is 1.280 or more

the battery is fully charged.
Battery Initial Charging

1. Read here.
-Look for sediment and white sulfation inside the

cells on the bottom of the plates.
Before being placed in service, a new battery should

be given an initial charging.
-Cut off the sealed end of the battery vent hose and
remove the filler caps.
-Fill each cell to the upper level line on the battery case
with fresh electrolyte at a temperature of 30C (86F)
or less. Let the battery stand for about 30 minutes
before charging.
NOTE
olf the electrolyte level drops, add electrolyte to the
upper level line before charging.
.
-Leaving the caps off the cells, connect the battery to a

charger, set the charging rate at 1/10 the battery
capacity, and charge it for 10 hours. For example, if
the battery is rated at 12 Ah, the charging rate would
be 1.2 A.
I WARNING'
A. Sulfation here
B. Sediment here
-See the Battery Troubleshooting Guide in Battery Test

Charging.
*If the specific gravity is below 1,280 the battery needs
to be ~harged.
NOTE
OThe specific fTBvity of the electrolyte varies with
changes in temperature, so the specific gravitY reading
must be corrected for the temperawre of the electrolyte.
OCelsius: Add 0.007 points to reading for each 10C
above 2(fC or subtract 0.007 points for each 10C
below 20C.
OKeep the battery away from sparks and open flames

during charging, since the battery gives off an explosive
gas mixture of hydrogen and oxygen. When using a
battery charger. connect the battery to the charger
before turning on the charger. This procedure prevents
sparks at the battery terminals which could ignite any
battery gases.
000 not use a high rate battery charger, as is typically

employed at . ..tomotive service stations, unless the
charger rate can be reduced to the I.vel 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
shorting. Higl;1erthan-normal charging rates also cause
the plates to shed active material. Deposits will accu
mulate, and can cause internal shorting.
Olf the temperature of the electrolyte rises above 45C
(11SF) during charging, reduce the charging rate to
lower the temperature, and increase charging time
proportionately.
-Connect a charger to the battery BEFORE plugging it

in or turning it on.
WARNING.
-Turn the charger off, then disconnect it form the

battery.
e<:heck battery voltage. Battery voltage should be 12
-13V.
e<:heck the specific gravity of each cell with a hydrom
eter (see Battery Condition).
*If the voltmeter or hydrometer readings are below
those specified, additional charging is necessary
before the battery can be installed.
OKeep the battery away from sparks and open flames

during charging, since the battery gives off an explosive
gas mixture of hydrogen and oxygen. When using a
battery charger, connect the battery to the charger
before turning on the charger. This procedure prevents
sparks at th-e battery terminals which could ignite any
battery gases.
-Set the charge rate and time according to the battery

condition previously determined (see Battery Con
dition), using the table.
[CAUTIO~J
Battery Ordinary Charging

-Remove the battery from the vehicle.
OAlways remove the battery from the vehicle for

charging. If the battery is charged while still installed,
battery electrolyte may spill and corrode the frame or
other parts of the vehide.
e<:lean off the battery using a baking sodaandwater
solution.
oMix one heaping tablespoon of baking soda in one cup
of water.
oBe careful not to get any of the cleaning solution in the
battery .
oThe terminals must be especially clean.
_If any of the cells are low, fill them to the LOWE R
level line with distilled water only. The electrolyte will
expand during charging, and the level will rise.
Battery Charging Rate/Time Table !12V 12Ah)
000 not use a high rate battery charger, as it typically

employed at automotive service stations, unless the
charger rate can be reduced to the level required.
Charging the battery at a rate h ;gher than specified may
ruin the battery. Charging at a high rate causes excess
heat which can warp the plates and cause internal
shorting. Higherthan-norrnal charging rates also cause
the plates to shed active material. Deposits will ac
cumulate, and can cause internal shorting.
olf the temperature of the electrolyte rises above 4 SoC
(llSF) during charging, reduce the charging rate to
lower the temperature, and increase charging time
proportionately.
_Turn the charger off or unplug it, then disconnect it
from the battery.
-Check battery condition (see Battery Condition).
*If the battery condition indicates that it is not fully
charged, additional charging time is necessary.
Battery Charging Rate/Time Table (12V l4Ah)
'''':1::::,:,:,:::,':'::.::,:::::::::::::::::
UM
1.00
.'
"
Battery Troubleshooting Guide
Suspect Battery
white (sulphated); + plates
Good Battery
(+) chocolate color
(-) gray
broken or corroded
Sediment
none, or small amount
sediment up to plates, causing short
Voltage
Electrolyte Level
above 12 V
above plates
above 1.200 in all cells; no two
cells more than 0.020 different
below 12 V
below top of plates
below 1.100, or difference of more
than 0.020 between two cells
Plates
Specific Gravity
Action
Replace
Replace
Test charge
Fill and test charge
Test charge
Battery Test Charging

elf the battery is suspected of being defective, sulfated,
or unable to take a charge, consult the table.
eTo test charge a battery, perform the ordinary charging
procedure and monitor the battery voltage and other
signs as mentioned below.
*If the battery voltage suddenly jumps to over 13 V just

after the start of charging, the plates are probably
sulfated. A good battery will rise to 12 V immediately
and then gradually go up to 12:S or 13 V in about 30
min to and hour after the start of charging.
*If one cell produces no gas bubbles or has a very low
specific gravity, it is probably shorted.
*If there does not appear to be enough sediment in a cell
to short the plates, but that cell has a very low specific
gravity after the battery is fully charged, the trouble
may be that there is not enough acid in that one cell.
In this case only, sulfuric acid solution may be added
to correct the specific gravity.
*If a fully charged battery not in use loses its charge
after 2 to 7 days; or if the specific gravity drops markedly, the battery is defective. The self-discharge rate of
a good battery is only about 1% per day.
A. Stator'Mounting Screws
elnstallation is the reverse of removal. Note the following.

eelean the contact surfaces on the magneto stator core
and the left engine cover.
Charging System
Magneto Flywheel Removal/lnst;1l1ation

eSee Engine Left Side chapter.
A. Clean.
Magneto Stator Removal/Installation
Charging Coil Inspection
eRemove the generator cover (see Engine Left Side

chapter).
eRemove the stator.
Charging Coil Output Voltage

eDisconnect the 6-pin connector from the regulatorl
rectifier.
*Any meter reading less than infinity (00) indicates a
short, necessitating stator replacement.
*If the stator coils have normal resistance, but the
voltage check showed the magneto to be defective; then
the flywheel magnets have probably weakened, and the
flywheel must be replaced.
A. Regulator/Rectifier
B. Connector
Regulator/Rectifier Inspection
-With a multi meter, check the charging coil output
according to the following table with the engine running
at 4,000 rpm.
Meter
Range
250VAC
Connections
Meter (+) to
Meter (-) to
Reading
@40oorpm
Yellow
Yellow
31 V
*If the output voltage is as specified, the magneto is

working properly. A much lower reading than that give
given in the table indicates that the magneto is defec
tive. Check charging coil resistance.
Charging Coil Resistance

-Disconnect the 6-pin connector from the regulator/
rectifier.
-Connect the multi meter as shown in the table.
Connections
Meter
Range
Meter (+) to
Meter (-) to
x112
Yellow
Yellow
RegulatorlRectifier output Voltage

-Warm up the engine.
eRemove the seat.
-Connect the multi meter to the battery terminals.
Meter
Range
25 DCV
Connections
Reading
Meter (+) to Meter (-) to
Battery
Battery (+) Battery (-)
terminal Voltage -15 V
terminal
-Stan the engine, and note the voltage readings at

various engine speeds with the headlight turned on and
then turned off.
oThe readings should show nearly battery voltage when
the engine speed is low, and as the engine speed rises,
the readings should also rise. But they must stay
*If the output voltage is much higher than specified in
the table the regulator/rectifier is defective.
*If the output voltage does not rise as the engine speed
increases, then the regulator/rectifier is defective or the
charging coil output is insufficient for the loads,
Reading
0.2 - 0.8 12
*If there is more resistance than shown in the Table, or

no meter reading (infinity), the stator has an open lead
and must be replaced. Much less than this resistance
means the stator is shorted, and must be replaced.
-Using the highest resistance range of the multimeter,
measure the resistance between each of the yellow
leads and chassis ground.
RegulatorlRectifier Internal Resistance

-Remove the regulator/rectifier.
_Zero the ohmmeter, and connect it to the regulator/
rectifier terminals.
-Check the resistance between the terminals following
the table.
*Any meter reading less than infinity (=) indicates a
short, necessitating replacement of the unit.
*If there is more resistance than the spe"cified value, the
unit has an open lead and must be replaced . Much less
than this resistance means the unit is shorted, and must
be replaced.
1412 ELECTRICAL SYSTEM
Regulator/Rectifier Terminal
B (Battery) Terminal
M (Monitor) Terminal
Regulator/ Rectifier
G (Ground) Terminal
If
==:vi
!..L
"
.L.
'v/
Test light
M2 (magneto)
M1 (magneto)
... '-,
,..l.,
~
n
12 V Battery
Regulator/Rectifier Resistance
Range
x lOOn
s::: Terminal
0
.."
""s:::
s:::
"0
"'"
Meter (+) Lead Connection
0.2 0.8 kU
0.3 lkU
=
=
=
=
...J
I"
"
::;;
"
M1 or 2
B
0.4 2kU
150 kU
Ml or 2
0.20.6 kU
0.2 0.6kU
0.5 3kU
*If the test light turns on, the regulator/rectifier is

defective. Replace it.
*If the test light does not turn on, continue the test.
eMomentarily apply 12 V to the voltage monitoring (M)
terminal by adding a 6 V battery.
_Check Ml and then M2 terminal respectively.
.~
Regulator/ Rectifier
I
Regulator/Rectifier Circuit Testing
eRemove the regulator/rectifier.
.Prepare the test tools shown.
Tools for Regulator/Rectifier Circuit Test
Test light
-----7
Bulb rated 12 V and 3 - 6 W
Batteries
-----7
6 V and 12 V batteries
Test wires -----7
5 auxiliary wires
J,:::::"\
=B
l1..
,...'-,
.~
.... '-,
12 V Battery
-Connect the test light and the 12 V battery to the
regulator/rectifier as shown.
-Check Ml and then M2 terminal.
!CAUTION
OThe test light limits the current flow through the

regulator/rectifier. Do not use an ammeter or multimeter in its place.
:vi
,/
M2
c:r=>
""......
~'
n

*If the test light does not turn on, continue the test.
eMomentarily apply 18 V to the voltage monitoring (M)
terminal by adding a 6 V battery .
-Check Ml and then M2 terminals.
ODo not apply more than 18 V to the regulator/rectifier
ODo not disconnect the battery leads or any other
and do not leave the 18 V applied for more than a few

seconds, or the unit will be damaged .
electrical connections when the ignition switch on, or

while the engine is running. This is to prevent COl
unit damage.
oDo not install "the battery backwards or the COl unit
could be damaged. The negative side is grounded.
Ignition Coil Removal
6 V Batter
_Disconnect the leads from the coil.

-Remove the ignition coil.
Regulator/Rectifie
~ c;G~H-_'"
Test Light
-I12 V Battery
A. Ignition Coil
*If the test light did not light when the 18 V was applied
momentarily to the voltage monitoring (M) terminal,
the regulator/rectifier is defective. Replace it.
*If the regulator/rectifier passes all of the tests described,
it may still be defective. If the charging system still
does not work properly after checking all of the com
ponents and the battery, test the regulator/rectifier
by replacing it with known good unit.
B. Bolt
Pickup Coil Removal/Installation

_See Engine Left Side chapter.
COl Unit Removal

eRemove the front cover .
............................................................................
Ignition System
Safety Instructions:
WARNING.
olbe ignition system produces extremely high voltage.
Do not touch the spark plugs, high tension coils, or
spark plug leads while the engine is running, or you
could receive a severe electrical shock.
A. Cover
B. Screws
14-14 ELECTRICAL SYST EM
eRemove the CDI Uflit
WARNING.
eTo avoid extremely high voltage shocks, do not touch
the coil or lead.
*If the distance reading is less than the specified value,

the ignition coil or spark plug cap is defective.
19nition Coil Arcing Distance
7. mm or more
eTo determine which part is defective, measure the
arcing distance again with the spark plug cap removed

fr9m the ignition coil lead.
*If the arcing distance is subnormal as before, the
trouble is with the ignition coil itself. If the arcing
A.CDI Unit
B. Bolts
distance is now normal, the trouble is with the spark
plug cap.
Measuring coil resistance
Ignition Coil Inspection

Measuring arcing distance
The most accurate test for determining the condition
of the ignition coil is made by measuring arcing distance

with a Kawasaki coil tester (special tool: 57001-1242).
shorts and shorts resulting from insulation breakdown
under high voltage.

eDisconnect the primary leads from the coil terminals.
eMeasure the primary winding resistance.
NOTE
OConnect an ohmmeter between the coil term inals.
OSince a tester other than the Kawasaki coil tester may

produce a different arcing distance, the Kawasaki coil
tester is recommended for reliable results.
.Remo~e
If the arcing tester is not available, the coil can be

checked for a broken or badly shorted winding with an
ohmmeter. However, an ohmmeter cannot detect layer
the ignition coil.
-COnnect the ignition coil (with the spark plug cap left
installed on the spark plug lead) to the tester, and
measure the arcing distance .
OSet the meter to the x 1 Q range, and read the meter.

eMeasure the secondary winding resistance.
OPull the spark plug cap off the lead.

OConnect an ohmmeter between the spark plug lead and
the black/yellow lead terminal.
oSet the meter to the x 1 kQ range, and read the meier.
*If the meter does not read as specified, replace the
coil.
...-----R------, r----Y/R---------.---------.
r---BKIR - - - ,
BL
BK
-<
til
_::0:
- ~
til
::0:
-<
o
1.
2.
3.
4.
Exciter Coil
Pickup Coil
Ignition Coil
CDI Un it
5. Ignition Switch
6. Engine Stop Switch
7. Spark Plug
-<
til
_::0:
~
~
Ignition Coil Winding Resistance
Primary windings:
Secondary windings:
0.09 - 0.13 n
3.8 - 5.8 kn
Ignition Coil Winding Resistance
eMeasure the exciter coil resistance as shown in the
table.
Meter
Range
x Ion
Connections
Red <E---? Black/Red
Reading
100 -190n
*If the meter does not read as specified, replace the

magneto stator.
Pickup Coil Inspection

eOisconnect the pickup coHlead connector (BL - BK).
1. Measure primary windin&.resistance.
2. Measure secondary winding resistance.
3. Ignition Coil
*If the meter reads as specified, the ignition coil windings
are probably good. However, if the ignition system still
does not perform as it should after all other components have been checked, test replace the coil with
one known to be good.
e<:heck the spark plug lead for visible damage.

*If the spark plug lead is damaged, replace the coil.
A. Pickup Coil Lead Connector
Exciter Coil Inspection
eMeasure the pickup coil resistance as shown in the
table.
eOisconnect the exciter coil lead connector (R - Bk/R) .

Meter
Range
x Ion
Connections
Blue E
" Black
Reading
85 -130 n
COl Unit Inspection

eRemove the COl unit (see COl Unit Removal) .
eSet the multi meter to the x 1 kn range and make the
measurements shown in the table.
A. Exciter Coil Lead Connector
*If the meter readings are not as specified, replace the

COl unit.
Internal Resistance of COl Unit
Unit: kit
Meter Positive (+) Lead Connection
...!..c:
4,)
.Q
.->
'"
:1!'
c:
c:
"
"
z8
~
~ "0
" ...J"'"
::<
Lead Color
BK/ R
BL
BK
G/W
BK/W
BK/Y
------
9 - 36
11-44
5 - 20
5 - 20
12 - 48
16 -64
6 - 28
12 - 48
6 - 28
BL
25 -100
25 -105
25 -100
20 - 80
BK
2- 8
2-8
---------=
2-8
G/W
-----=
20 - 80
=
=
=
=
BK/W
9 - 36
11 - 44
5 - 20
=
-----------
BK/Y
2-8
2-8
4 -16
BK/R
4-16
------ -----5 -20
2-8
'Measured with hand tester 57001-983.

A tester other than the hand tester of Kawasaki may show slightly different readings.
Spark Plug Cleaning and Inspection

eRemove the spark plug, and visually inspect it
eelean the spark plug, preferably in a sandblasting
device, and then clean off any abrasive particles. The
plug may also be cleaned using a high flash-point
solvent and a wire brush or other suitable tool.
*If the spark plug electrodes are corroded or damaged,
or if the insulator is cracked, replace the plug. Use the
standard spark plug or its equivalent.
eMeasure the spark plug gap with a wire-type thickness
gauge.
*If the gap is incorrect, carefully bent the side electrode with a suitable tool to obtain the correct gap.
Electric Starter System

Starter Motor:
Starter Motor Removal
e Re move the following.
Exhaust Pipe
Oil Pipes
Battery Ground Cable (Disconnect)
Starter Motor Cable
Spark Plug Gap

0.6-0.7 mm
A. Starter Motor
B. Starter Motor Cable
c. Mounting Bolts
e Remove the starter motor.
1.
2.
3.
4.
Insulator
Center Electrode
Plug Gap
Side Electrode
ODo not tap the end of the starter motor shaft or the
motor may be damaged.
Starter Motor Installation

_Starter motor installation is the reverse of removal.
Note the following.

-Clean the starter motor mounting lugs and the crank-
case where the lugs touch it, for good electrical

contact.
A. Front End Cover

B. Rear End Cover
C. Screws
eTake the armature out th~ pinion gear end.

eRemove the negative brush.
eRemove the positive brush and the terminal bolt.

A. Clean here.
elf the O-ring shows any damage or if it is hardened,
replace. it with a new one.
A. Positive Brush
B., Terminal Bolt
C. Nut
D. Negative Brush
Starter Motor Assembly

A. O-Ring
eAttach the starter motor cable at the angle shown.

following.
elnspect all the O-rings.
elnstall the terminal bolt and the parts removed as shown.
30
1. Starter Motor
\~,~
2. Starter Motor Cable
Starter Motor Disassembly

. eTake out the screws and remove both end covers.
SeD
1.
2.
.3.
4.
Nut
Washer
Large Insulator
Small Insulator
5. O-ring
6. Terminal Bolt
7. Insulator Bushing
8. Positive Brush
-Fit the yoke notch onto the end cover pin.
eFit the toothed washer tangs into the notches.
A. Pin
B. Notch
A. End Cover
B. O-ring
C. Slender O-ring
C. Toothed Washer
BK/Y
~~~~r----------BKN----------.
w-(:>(::r--1'----w -----,
BR
1. Ignition Switch
2. Engine Stop Switch
3. Starter Button
BR---,
4. Neutral Switch
5. Starter Relay
6. Fuse
7. Starter Circuit Relay

8. Starter Motor
9. Battery
-Align the mark on the pinion gear side end cover
with the mark on the yoke.
1. Commutator
A. Align the marks
2. Emery Cloth
eMeasure the diameter of the commutator.

*Replace the starter motor with a new one if the commutator diameter is less than the service limit.
Commutator Diameter
Standard:
Service Limit:
Brush Inspection
23mm
22mm
~easure the length of each brush.

-rf any is worn down to the service limit, replace all
brushes.
Starter Motor Brush Length

Standard:
Service Limit:
11 mm
5mm
1. Commutator Segment
2. Diameter
A. Brush
B. Length
Commutator Cleaning and Inspection

_Smooth the commutator surface if necessary with fine
emery cloth, and clean out the grooves.
3. Shaft
Armature Inspection
-Using the x 1 n ohmmeter range, measure the resist
ance between any two commutator segments.
*If there is a high resistance or no reading (00) between
any two segments, a winding is open and the stater
motor must be replaced.
eUsing the highest ohmmeter range, measure the resistance between the commutator and the shaft.
*If there is any reading at all, the armature has a short
and the starter motor must be replaced.
Brush Plate and Terminal Bolt Inspection
-Set the ohmmeter to the highest range.
eMeasure the resistance between the positive brush
holder and the end cover.

eMeasure the resistance between the terminal and the
end cover.
*If there is any reading at all, the insulator may be failed

and the washer (insulator) of the end cover must be
replaced.
1. Segment
2. Shaft
NOTE
OEven if the foregoing checks show the armature to be

gopd, it may be defective in some manner not readily
detectable with an ohmmeter. If all other starter
motor and starter motor circuit components check
good, but the starter motor still does not tum over or
only turns over weakly, replace the starter motor with
a new one.
A. Positive Brush Holder
B. End Cover
Brush Leads Inspect;on

_Set the ohmmeter to the x 1 n range
-Measure the resistance between the negative brush and
the plate.
_Measure the resistance between the positive brush and
the terminal.
Starter Relay, Starter Circuit Relay:

The starter relay and starter circuit relay are under
the seat.
*If there is not close to 0 n, the brush has an open and

othe brush must be replaced .
A. Starter Relay
B. Starter Circuit Relay
Starter Relay Inspection

eRemove the starter relay.
-Connect the ohmmeter and 12 V battery to the starter
relay as shown.
*If the relay does not work as specified, the relay is
defective. Replace the relay.
*If the relay does not work as specified, the relay is

defective.
Testing Relay
Meter Range: x 1 n range
Criteria: When battery is connected -+ 0 n
When battery is disconnected -+ 00
Testing Relay
Meter Range :
Criteria:
xl 12 range
When battery is connected -+ 0 12
When battery is disconnected -7 0Cl
Lighting System
u
CD
;o
Headlight Beam Vertical Adjustment
NOTE
OTurning the adjusting screw clockwise lowers the

headlight beam.
+
2. 12 V Battery
1. Tester
Starter Circuit Relay Inspection

eRemove the starter circuit relay.
econnect the ohmmeter and one 12-volt battery to the
relay as shown.
A. Adjusting Screw
Testing Relay

Hand "T ester
Relay
BR
CD
BK
<D and :
:
@ and
LG
12 V Battery
Relay Coil Terminals
Relay Switch Terminals L.._ _ _ _ _- - '
NOTE
OOn high beam, the brightest point should be slightly

below the level of the headlight. This is about 0.6 m
above the ground measured at 10 m from the center of
the front wheel, with no rider.
Headlight Bulb Replacement'

-Unscrew the adjusting screw.
-Unhook the tab from the stop and drop out the unit.
A. Pin Closest to Base.
eBe careful not to overtighten the lens mounting screws.
A. Tab
-Slide back the dust cover and remove the bulb socket
from the headlight unit. '
. u . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Switches
............................................................................
Neutral and Reverse Switch Removal/Installation

- Refer to the Engine Bottom End/Transmission chapter.
Switch Inspection
A. Bulb Socket
-Install the new bulb.
-Using the ohmmeter, check to see that only the con

nections shown in the table have continuity (about
zero ohms).
*If the sw itch has an open or a short, clean or replace it
with a new one.
Ignition Switch Connections

ON
OFF
Lighting Switch Connections
Tail Light Bulb Replacement

-Insert the new bulb by aligning the pins with the
grooves in the walls of the socket so that the pin closest
to the bulb base is to the upper right.
R/Y
HIGH
LOW
OFF
BR
R/ B'K
0()
()
ELECTRICAL SYSTEM
Engine Stop Switch Connections
Y/R
1~23
Fuse
BK/ Y
RUN
OFF
Fuse Element
Blown Element
r;:J'!iI
Starter Button Connections
BK/Y
BK
Pushed
Released
Terminals
{ CAUTlO~]
Neutral and Reverse Switch Connections

Gear Position
L/G
Ground
R/W
1st throught 5th

Neutral
OWhen replacing a fuse, be sure the new fuse matches

the specified fuse rating for that circuit. Installation of
a fuse with a higher rating may cause damage to wiring
and components.
Reverse
Fuse
Fuse Inspection
-Remove the fuse.
Electrical Wiring
Wiring Inspection
-Visually inspect the wiring for signs of burning, fraying,
etc.
*If any wiring is poor, apart and inspect it for corrosion,
dirt, and damage .
Pull each connector apart and inspect it for corrosion,
dirt, and damage.

*If the connector is corroded or dirty, clean it carefully.
If it is damaged, replace it.
e<:heck the wiring for continuity.
oUse the wiring diagram to find the ends of the lead
which is suspected of being a problem.
OConnect an ohmmeter between the ends of the leads.
*5et the meter to the xl n range, and read the meter.

*If the meter does not read 0 n, the lead is defective.
Replace the lead or the wiring loom if necessary.
A. Fuse
_Inspect the fuse element.
*If it is blown out, replace the fuse. Before replacing a
blown fuse, always check the amperage in the affected
circuit. If the amperage is equal to or greater than the
fuse rating, check the wiring and related components
for a short circuit.
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Wiring Diagram KLF220-A3A. A4. A5. A6. A7. AS
(Australian Modell
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...................................................................................
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Wiring Diagram KLF220-A4, A5, A6, AS
(European Model)
...................................................................................
PI~k ... p
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ffitffl
--uo-.~
'~/'~
a'~'f~
A~c-so'Y
1III m
T.,mlnltt
,f
lE=:P., Slarl BUllon

Eng'ne SloP
IQNITION SWITC H CONNECTIONS

Colo.
w
8.,V
ON
0,"
"
".
Swlt~h
Silfl..
MOIO.
Ll9hllno Switch
>OM
".
R.,,,,,
$ Ilft ..
(980511279A)
APPENDIX 15-1
Appendix
Table of Contents
Troubleshooting Guide .............. _ . . . . . . . .. . .. . . . . . . . . . . .
15-2
General Lubrication ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15-5
Lubrication . .. . . '.' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15-5
Bolt and Nut Tightening. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15-5
Tightness Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15-5
Unit Conversion Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15-6
15-2 APPENDIX
Troubleshooting Guide
NOTE
OThis is not an exhaustive list, giving every possible

cause for each problem listed. It is meant simply as a
rough guide to assist the troubleshooting for some of
the more common difficulties.
Compression low
Spark plug loose
Cylinder head not sumciently tightened down
No valve clearance
Cylinder, piston wqrn
Piston rings bad (worn, weak, broken, or sticking)
Piston ring/groove clearance excessive
Cylinder head gasket damaged
Cylinder head warped
Valve spring broken or weak
Valve not seating properly (valve bent, worn, or
carbon accumulation on the seating surface)
Compression release mechanism trouble
Engine Doesn't Start Starting Difficulty:

Starter motor not rotating
Neutral switch trouble
Starter motor trouble

Battery voltage low
Relays not contacting or operating

Starter button not contacting
Wiring open or shorted
Ignition switch trouble
Engine stop switch trouble
Fuse blown
Starter motor rotating but engine doesn't turn over

Starter motor clutch trouble
Engine worn't tum over
Valve seizure
Rocker arm seizure
Cylinder, piston seizure
Crankshaft seizure
Connecting rod small end seizure
Connecting rod big end seizure
Transmission gear or bearing seizure

Camshaft seizure
Balancer bearing seizure
Recoil starter springs broken
Recoil starter pawls not engaging
No fuel flow
Tank air vent obstructed
Fuel tap clogged
Fuel line clogged
Float vaive clogged
Engine flooded
F uellevel too high
Float valve worn or stuck open
Starting technique fau Ity
(When flooded, crank with the throttle fully open
to allow more air to reach the engine.)

No spark; spark weak
Spark plug dirty, broken, or maladiusted
Spark plug cap or high tension wiring trouble
Spark plug cap not in good contact
Spark plug incorrect
Pickup coil trouble
COl unit trouble
Exciter coil trouble
Ignition coil trouble
Magneto flywheel trouble
Ignition or engine stop switch shorted
Wiring shorted or open
Poor Running at Low Speed:

Spark weak:
Spark plug dirty, broken, or maladjusted
Spark plug cap or high tension wiring trouble
spark plug cap shorted or not in good contact
Spar~ plLlg incorrect
COl unit trouble
Pickup coil trouble

Magneto flywheel trouble
Fuel/air mixture incorrect:

Pilot screw and/or idle adjusting screw maladjusted
Pilot jet, or air passage clogged
Starter plunger stuck open
Air cleaner clogged, poorly seated, or missing

Fuel level too high or too low
Fuel tank air vent obstructed
Carburetor holder loose
Air cleaner duct loose

Compression low
Spark plug loose
Cylinder head not sufficiently tightened down
No valve clearance
Cylinder, piston worn
Cyl inder head gasket damaged
Valve not seating properly (valve bent, worn, or
Other
Throttle valve doesn't slide smoothly
Engine oil viscosity too high
Brake dragging
Final gear case oil level too high
Final gear case oil viscosity too high
Poor Running or No Power at High Speed:

Firing incorrect
Spark
Spark
Spark
Spark
plug dirty, broken, or maladjusted

plug cap or high tension wiring trouble
plug cap shorted or not in good contact
plug incorrect
APPENDIX 15-3
Pickup coil trouble
COl unit trouble
Fuel/air mixture incorrect
Main jet clogged or wrong size
Jet needle or needle jet worn
Air jet clogged
Fuel level too high or too low
Air cleaner clogged, poorly ~ated, or missing
Water or foreign matter in fuel
Fuel tank air vent obstructed
Fuel line clogged
Compression low
Spark plug loose
Cylinder head not sufficiently tightened down
No valve clearance

Cylinder head gasket damaged
Valve not seating properly (valve bent, or
Knocking
Carbon built up in combustion chamber
Fuel poor quality or incorrect
Miscellaneous
Throttle valve won't fully open
Throttle valve doesn't slide smoothly
Brake dragging
Clutch slipping
Overheating
Engine oil level too high
Final gear case oil level too high
Final gear caSe oil viscosity too high
Overheating
Firing incorrect
Spark plug dirty, broken, or maladjusted
Fuel/air mixture incorrect
Main jet clogged
Fuel level too low
Air cleaner poorly sealed, or missing

Air cleaner clogged
Compression high
Carbon built up in combustion chamber
Engine load faulty
Clutch slipping
Brake dragging
Lubrication inadequate
Engine oil level too low
Engine oil poor quality or incorrect
Clutch Operation Faulty

Clutch slipping
Friction and/or steel plates worn or warped
Clutch housing or shoe linings overworn or worn
unevenly
Clutch spring broken or weak
Clutch release maladjusted
Clutch release mechanism trouble
Clutch hub or housing unevenly worn
Clutch not disengaging properly
Friction and/or steel plates warped or too rough
Clutch spring tension uneven
Clutch shoe spring broken or weak
Engine oil deteriorated
Clutch housing frozen or crankshaft or drive shaft
Clutch release mechanism trou ble
Gear Shifting Faulty:

Doesn't go into gear; shift pedal doesn't return:
Clutch not disengaging
Shift fork(s) bent or seized
Gear(s) stuck on the shaft
Shift return spring weak or broken
Shift mechanism arm spring broken
Shift return spring pin loose
Shift drum positioning lever binding on pivot bolt
Shift mechanism arm broken
Shift drum damaged
Jumps out of gear:
Shift fork(s) worn
Gear groove(s) worn
Gear dogs, dog recesses, and/ or dog holes worn
Shift drum groove(s) worn
Shift drum positioning lever spring weak or broken
Shift fork guide pin(s) worn
Shift mechanism arm spring weak or broken
Drive shaft, output shaft, and/or gear splines worn
Overshifts:
Shift drum positioning lever spring weak or broken
Shift mechanism arm spring weak or broken
~bnormal
Engine Noise:
Knocking:
Carbon buil.t up in combustion chamber
Fuel poor quality o r incorrect
Incorrect spark plug heat range
Overheating
Piston slap:
Cylinder/ piston clearance excessive
Connecting rod bent
Piston pin, piston holes worn
15-4 APPENDIX
Valve noise:
Valve clearance incorrect
Camshaft bearing worn

Other noise :
Connecting rod small end clearance excessive
Connecting rod big end clearance excessive
Piston ring(s) worn, broken or stuck
Piston seizure, damage
Cylinder head gasket leaking
Exhaust pipe leaking at cylinder head connection
Crankshaft runout excessive
Engine mount(s) loose
Crankshaft bearing worn
Camshaft chain tensioner trouble
Camshaft chain , sprocket, guides worn
Loose magneto flywheel
Balancer bearing worn
Balancer gear worn or ch ipped
Abnormal Drive Train Noise:

Clutch noise:
Clutch housing and/or hub damaged
Transmission noise: .
Bearing worn
Transmission gears worn or chipped
Metal chips jammed in gear teeth
Engine oil insufficient or too thin
Drive train noise:

Bevel gear bearings worn
Propeller shaft bearing worn
Front bevel gear cam damper damage
Bevel gears worn or shipped
Bevel gears maladjusted
Insufficient lubricant
Brown smoke
Main jet too small
Fuel level too low
Air cleaner poorly sealed or missing
Handling and/or Stability Unsatisfactory

Handlebar hard to tum
Steering stem bearing damaged
Steering stem lubrication inadequate
Steering stem bent
Tire air pressure too lo w
Handlebar shakes or excessively vibrates
Tire(s) worn
Rim(s) warped
Rear axle runout excessive
Wheel bearing(s) worn
Handlebar mount(s) loose
Steering stem nut and/or stem clamp bolt(s) loose
Handlebar pulls to one side
Frame bent
Wheel maladjustment
Steering stem bent
Front or rear tire air pressure unbalanced uneven
Shock. absorption unsatisfactory
Too hard:
Tire air pressure too high
Too soft:
Shock absorber oil leaking
Shock absorber spring weak
Tire air pressure too low
Brakes Don't Hold:

Abnormal Frame Noise:
Shock absorber noise
Shock absorber damaged
Brake noise
Brake linings overworn or worn unevenly
Drum worn unevenly or scored
Brake spring(s) weak or broken
Foreign matter in hub
Brake not properly adjusted
Other noise
Brackets, nuts, bolts, etc. not properly mounted or
tightened
Exhaust Smokes Excessively

White smoke
Piston oil ring worn
Cylinder worn
Valve oil seal damaged
Valve guide worn
Black smoke
Air cleaner clogged
Main jet too large or fallen off
Fuel level too high
Brake not properly adjusted

Lin ings overworn or worn unevenly
Drum worn unevenly or scored
Cam, camshaft, shaft hole worn
Oil, grease on lining and drum
Dirt, water between lining and drum
Overheated
Battery Discharged
Battery faulty (e.g., plates su lphated, shorted
through sedimentation, electrolyte level too
low)
Battery leads making poor contact
Load excessive (e.g., bulb of excessive wattage)
Ignition switch trouble
Regulator/Rectifier trouble
Magneto trouble
Wiring faulty
Battery Overcharged
Regulator/Rectifier trouble
Battery trouble
APPENDIX 15-5
Bolts, Nuts, and Fasteners to be checked
General Lubrication
Lubrication
-Before lubricating each part, clean off"any rusty spots
with rust remover and wipe off any grease, oil, dirt, or
grime.
-Lubricate the points listed below with
indicated
tubricant.
NOTE
OWhenever the vehicle has been operated under wet or

rainy conditions, or especially after using a highpressure spray water perform the genera/lubrication.
l
Cables: Lubricate with Motor Oil

Brake Cab le
Throttle Cable
Choke Cable
Reverse Cable
Slide Points: Lubricate with Grease
Brake Cable Upper End
Throttle Cable Upper End
Choke Cable Upper End
Brake Lever
Brake Pedal Pivot Shaft
Throttle Lever Shaft
Choke Lever
.............................................................................
Bolt and Nut Tightening
.............................................................................
Tightness Inspection
-Check the tightness of the bolts and nuts listed here.
Atso, check to see that each cotter pin is in place and in
good conditipn.
*If there are loose fasteners, retorque them to the
specified torque foll owing the specified tightening
sequence. Refer to the appropriate chapter for torque
specifications. If torque specifications are not listed in
the appropriate chapter, see the Standard Torque Table
(see General Information chapter). For each fastener,
first loosen it by Y, turn, then tighten it.
*If cotter pins are damaged, replace them with new ones.
Wheels:
Front Hub Nuts and Cotter Pins
Rear Hub Nuts and Cotter Pins
Wheel Nuts
Brake:
Cam Lever Bolt
Brake Lever Bolt
Brake Lever Holder Bolt
Brake Pedal Pivot Cotter Pin
Brake Rod Cotter Pins
Steering/Suspension:
Handlebar Clamp Bolts
Stem Nut and Cotter Pin
Stem Clamp Allen Bolts
Stem Bearing Housing Bolts
Tie-rod End Nuts and Cotter Pins
Tierod Adjusting Sleeve Locknuts
Shock Absorber Mounting Bolts and Nuts
Suspension Arm Pivot Bolts
Steering Knuckle Pivot Nuts and Cotter Pins
Engine:
Engine Mounting Bolts

Engine Mounting Bracket Bolts
Ex haust Pipe Holder Nuts
Muffler Mounting Bolts
Muffler Clamp Bolt
Shift Pedal Bolt
Others:
Footpeg Mounting Bolts
Grab Rail Mounting Bolts
Throttle Case Clamp Screws
Carrier Mounting Bolts
15-6 APPENDIX
Units of Length:
Unit Conversion Table
km
m
mm
Prefixes for Units'

Prefix
mega
kilo
eenti
milli
micro
1,000,000
1,000
0.01
0.001
0.000001
x
x
x
x
x
Il
mile
ft
in
0.1020
0.7376
8.851
9.807
7.233
86.80
kg-m
ft-Ib
in-Ib
Units of Torque :
Units of Mass:
2.205
=
0.03527 =
x
x
0.6214 =
3.281
=
0.03937 =
Power
Symbol
M
k
e
m
kg
x
x
Nm
N-m
N-m
x
x
x
kg-m
kg-m
kg-m
x.
x
=
=
=
=
N-m
ft-Ib
in-Ib
=
=
Ib
oz
Units of Pressure:
Units of Volume :
L
L
L
L
L
L
mL
mL
mL
0.2642
0.2200
1.057
0.8799
2.113
1.816
0.03381
0.02816
0.06102
x
x
x
x
x
x
x
x
x
=
=
gal (US)
gal (imp)
qt (US)
qt (imp)
pint (US)
pint (imp)
oz (US)
oz (imp)
cu in
=
=
=
=
=
=
psi
em Hg
kPa
psi
kPa
0.6214
mph
1_360
1.341
0_7355
0.9863
PS
HP
kg/em 2
em Hg
kg/em2
x
x
x
x
x
x
kg/em2
0.01020
0.1450
0.7501
98.07
14.22
1_333
kPa
kPa
kPa
=
=
=
Units of Speed:
km/h
Units of Force:
Units of Power:
N
N
x
x
kg
kg
x
x
0.1020
0.2248
9.807
2.205
kg
Ib
kW
kW
x
x
N
lb.
PS
PS
x
x
=
=
kW
HP
Units of Temperature:
OF
40
-20
I
I
-40
4
:0
:I
I,
20:
-} 7.8
68
32
20
: 40
I I
0 :
4 .4
60
104
80
I I, I
100!
I'
40
20
26 . 7
120
!,
48.9
140
176
160
:180
I!
60
'1
80
71.1
212
200
,: 220
I, I
,
100
93.3
248
240 i 260
,
I, I
: 120
116
OF
284
280:
300
I'
,I
~ 140
138.
320
I
160
SUPPLEMENT -1995 LATE - 1997 MODELS 16-1
Supplement - 1995 Late - 1997 Models

This supplement chapter contains only the information unique to the models covered. Read both this
manual's front part (up to p. 15-6) and this chapter for complete information on proper service procedures.
Table of Contents
General Information .. .. ..............................................................................................16-2

Model Identification ............. .......... ..................... .......................................... 16-2
General Specifications .................................................................................... 16-3
Electrical System ....................................................................................................... 16-5
Exploded View ......................... ...... ................................................................16-5
Charging System ............................................................................................ 16-6
Ignition System .............................................................................................. 16-8
Electric Starter System ....................................................................................16-8
Wiring Diagram ..............................................................................................16-9
16-2 SUPPLEMENT - 1995 LATE - 1997 MODELS
General Information
KLF220-A9 (US, Canada Model)
SUPPLEMENT - 1995 LATE - 1997 MODELS 16-3
(C) : Canada model
(UK) : UK model
(A) : Australia model

(U) : US model
(E) : Europe model
KLF220-A8A/A9/ Al0
Item
Dimensions:
Overall length
Overall width
Overall height
Wheelbase
Ground clearance
Seat height
Dry weight
Curb weight:
Front
Rear
Fuel tank capacity

Performance:
Minimum turning radius
Engine:
Type
Cooling system
Bore and stroke
Displacement
Compression ratio
Maximum horsepower
Maximum torque
Open
Close
Duration
Exhaust:
2.7m
4-stroke, SOHC, l-cylinder
Air-cooled
67.0 x 61.0 mm
215 mL
9.3
12.5 kW (17 PS) @7 500 rl min (rpm) , (U) 17.7 N-m (1.8 kg-m, 13.0 ft-Ib) 6000 rl min (rpm) ,
(U) Carburetor, Mikuni VM24SS
Electric starter .& recoil starter
DC-COl
From 10 BTDC @1 800 rl min (rpm) to
35' BTDC @4 600 rlmin (rpm)
NGK D8EA, (C)(E)(UK) DR8ES
Carburetion system
Starting system
Ignition system
Timing advance
Ignition timing
Spark plug
Valve timing:
Inlet:
1745 mm
1 120 mm, (U) (C) 1 020 mm
1040 mm
1 115 mm
155mm
730mm
183 kg, (A)(E)(UK) 185 kg, (C) 183.5 kg
88.5 kg, (A)(E)(UK) 89 kg
104.5 kg, (A)(E)(UK) 106 kg, (C) 105 kg
10 L
Open
Close
Duration
Lubrication system
Grade
Engine oil:
Viscosity .
Capacity
35 BTDC
57 ABDC
272
54 BBDC
26 ATDC
260
Forced lubrication (wet sump)
SE, SF or SG class
SAE 10W-30, 10W-40, lOW-50, 20W-40, or 20W-50
2.0 L
Item
KLF220-A8A/A9/A10
Drive Train:
Primary reduction
System
Clutch type:
Transmission:
Type
Reduction ratio
Primary
Secondary
Type
Gear ratios: 1st
2nd
3rd
4th
5th
Reverse
Final drive
system:
Type
Reduction ratio
Overall drive ratio
Type
Capacity
Frame:
Type
Castor (rake angle)
Camber
Trail
Tread
Front tire:
Rear tire:
Suspension:
Type
Size
Type
Size
Front
Rear
Brake type:
Front
Rear
Electrical Equipment:
Battery
Headlight:
Type
Bulb
Taillight
Type
Alternator:
Rated output
Gear
3.450 (69/ 20)
Auto centrifugal, wet
Auto multi disc, wet
5-speed plus reverse, constant mesh, return shift
2.923 (38/ 13)
1.684 (32/ 19)
1.173 (27/ 23)
0.923 (24/26)
0.785 (22/28)
3.115 (27/ 11 x 33/ 22)
Shaft .
4.680 (18/15 x 39/ 10)
12.686 @Top gear
API GL-5 Hypoid gear oil SAE 90 (above 5C, 41F)
or SAE 80 (below 5C, 41F)
0.2 L
Double tubular
4
3
17mm
764mm
Front
Rear
776 mm
Tubeless
AT 21 x '8-9
Tubeless
AT22x10-10
Type
Independent swingarm
Wheel travel 115mm
Torque tube-link
Type
Wheel travel 125mm
Drum
Drum
12 V 12 Ah, (A)(C)(E)(UK) 12 V 14 Ah
Semi-sealed beam
12 V 25/25 W x 2
12V8Wx2
Three-phase AC
15 A @6 000 r/min (rpm), 14 V
.
A10: 13 A@8 000 r/ min (rpm), 14 V
Specifications are subject to change without notice, and may not apply to every country.
SUPPLEMENT - 1995 LATE - 1997 MODELS 16-5
Electrical System
Exploded View
1.
2.
3.
4.
COl Unit
Regulator/Rectifier
Starter Motor
Alternator
Charging. System
B
M G
Alternator Inspection
Disconnect the alternator connector.
Measure the alternator output voltage.
o Connect a voltmeter between the black leads. and start
the engine.
Alternator Output Voltage
Standard:
38 V AC and more @4.000 rlmin (rpm)
*If the output voltage shows the value in the table, the
alternator operates properly and the regulator/rectifier is
damaged. A much lower reading than that given in the
table indicates that the alternator is defective.

Measure the stator coil resistance.
o Connect an ohmmeter between the black leads.

Stator Coil Resistance
Standard: 0.4 - 1.1
* If the meter does not read as specified, replace the
alternator stator.
* If the coil has normal resistance, but the voltage inspect
showed the alternator to be defective; then the rotor
magnets have probably weakened, and the rotor must
be replace.
A1
A2 A3
Regulator Circuit Inspection

Prepare the test tools shown.
Tools for Regulator Circuit Test
Test Light
~
Bulb rated 12 V and 3 .- 6 W
Batteries
~
Three 12 V batteries
Test Wires
~
6 auxiliary wires
.Connect the test light and the 12 V battery to the

regulator/rectifier as shown.
Regulator/Rectnier Inspection
Rectifier Circuit Inspection
Remove the regulator/rectifier.
Connect an ohmmeter to the regulator/rectifier
terminals .
Check the resistance between the terminals following
the table.
*The resistance should be low in one direction and more
than ten times as much in the other direction. If any two
leads are low or high in both directions, the rectifier is
defective and must be replaced.
Check AI, A2, and A3 terminals respectively.
NOTE
o The actual meter reading varies with the meter used and
the individual rectifier, but. generally speaking the lower
reading should be from zero to the 1ii of the scale.
Rectifier Circuit Inspection
Connections
No.
Reading
Meter (+) to Meter (-) to
Al
2
3
4
A2
Al
5
6
A3
A2
0-
.100
% scale
or
Al
B

.If the test light does not turn on, continue the test.
.Momentarily apply 12 V to the voltage monitoring
terminal.
A3
10
11
Al
lOOn
A2
t--;z
00
The test light limits the current flow through the

regulator/rectifier.
Do not use an ammeter or
multimeter in its place.
A3
Meter
Range
CAUT10N
A2
00
A3
.Check AI, A2, and A3 terminals respectively.
*If the test light tums on, the regulator/rectifier is
*If the test light does not tum on, continue the test.
SUPPLEMENT - 1995 LATE - 1997 MODELS 16- 7
.Momentarily apply 24 V to the voltage monitoring
terminal by adding a 12 V battery.
Check A1 , A2, and A3 terminals respectively.
CAUTION
00 not apply more than 24 V to the regulator/ rectifier
and do not leave the 24 V applied for more than a few
seconds, or the unit will be damaged.
*If the test light did not light when the 24 V was applied
momentarily to the voltage monitoring terminal, the
regulator/ rectifier is defective. Replace it.

*If the regulator/ rectifier passes all of the tests described,
it may still be defective. If the charging system still does
not work properly after checking all of the components
and the battery, test the regulator/ rectifier by replacing
it with a known good unit
Ignition System
Pickup Coil Inspection
Pickup Coil Resistance
Standard:
100 -
150 0
COl Unit Inspection

Internal Resistance of COl Unit-
(KLF220-ASA-. Europe Models)
Unit:
Tester Positive (+) Lead Connection
Range
..
kO
0.45-1.8
00
0.8-3.2
16-64
00
0.45-1.8
00
0.4-1.6
15-60
00
2.6-10.5
2-8
2.5-10
29-116
00
0.8-3.2
0.4-1.6
00
16-64
00
00
00
00
00
00
3.5-15
3-13
00
3.5-14
30-120
x1 kO
Measure with the Kawasaki Hand Tester (PIN 57001-1394). A tester other than the Kawasaki Hand Tester may
show slightly different readings.
Tester Negative (-) Lead Connection
Internal Resistance of COl Unit-
(KLF220-A9 -
US Canada and Australia Models)
0.45-1.8
00
0.8--3.2
16-64
00
0.45-1.8
00
0.4":1.6
15-60
00
2.6-10.5
2-8
2.5-10
29-116
00
0.5-2.5
0.4-1.6
00
16-64
00
00
00
00
00
00
2-8
2.5-11
00
3-12.5
30-120
x1 kO
kO
Tester Positive (+) Lead Connection
Range
..
Unit:
Measure with the Kawasaki Hand Tester (PIN 57001-1394). A tester other than the Kawasaki Hand Tester may
show slightly different readings.
Tester Negative (-) Lead Connection
COl Unit Terminal
Electric Starter System
Brush Inspection
Starter Motor Brush Length
Standard:
10mm
Service Urnit:
6.Smm
Commutator Cleaning and Inspection

Commutator Diameter
Standard:
Service Limit:
28mm
27mm
:><:
r-
."
0
1.
Headlloht
2V~5/2SW
RH)
'~Y3I}'~Y-.
IY
IY18K
18K
Except UK model
i ~;~ -
iLloht \..Y-lJ-8K/y--cj<l.8K/Y
\.------- ------------------------- -'-<:).eK/Y
ACCeSSOry Term ina ls
(AuxIIIIHY LlQht)
sta r ter
Circu i t
Relay
6;
Reverse IM l cato r L10ht
12V3W
2. Neutral IndIcator lIoht
12V3W
lonltlon
Sw i tch
:I>
~w
~~
~ ~~~
iJ!J
.0
Accessory
Termlne. l s
:.?
:1.
::l
CQ
iir
CQ
iil
3
'C
's:"
0
rF"/Y:&l:'V':)
Q.
!!.
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rm
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Starter
Relay
1/8X3I}R/
U
. /Y
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U/T .
8X/y::J I CDI Unit
ckup
Co II
AI ternator
if
Co lor Code
I I BK
8K/Y-c::J<]- BK/y--,
Bl
BR
"Battery
l r CH
12Vl1Ah i ~ D G
G
GY
l B
l G
ImllOf Sl im comcTlOfS
<D
1. lloht/Dlmmer SWitch
2. Enolne Stop Sw it ch
3. starter Button
starter
Motor
-t
Neutrel find
Reverse 5'1'ltcl'I
Spark
Pluo
:::
6~
S-Slli
1~
I'i ======
-.l
Color
orr
I BR
ON
(9B051 - 1556A. \S57A)C
P
PU
R
W
Y
alack
Blue
Brown
Cllocolete
Dork Green
Green
Grey
Ll9ht Blue
ll9ht Gree~
Orenoe
Pi nk
purple
'ed
Wh I te
Yel l o'l'
-"
(I)
(I)
U1
S
m
I
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(I)
(I)
-.I
s:
o
C
m
r-
en
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(I)
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HeaOl19ht
12V25 /2 5W
~:~:~~on
R/l
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CID I/u
D-
ACCeSsory
Te r min als
<}- lIf T
s tarter
C ircuit
Relay
llV 3WX 2
Indlcelor lIOhl
inerso Neutra l
>:'0.
Fram.
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T/e rmln81
;;;::
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= ;:
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>:'0.
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12V 8W
Tall Ll9ht
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W
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OW
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11/1-
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12Vl1Afl
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color Code
BK
GY
LB
LG
Neutral l
Reverse
Sw I t eh
l hlhtl Entin. sterter
Lett Hand I eba r

LO
HI
R/BK
OR
5", I t c h Connec t I ons

Enolne stOg Switch
Color
OR
orr
RUM
".
Released
!LLJ-...!!
LIOh t
co or
Connect lone
co lor
.rr
BK/Y
IInlllOIl hUoh
n/w
OJr
tonllU l'IInt
OR
elue
Lloht Green
OranQ8
PInt
Wh I te
Horn Out ton .
storter Button
Color
Brown
Green
Gr ay
P
y
Lloht/olmrner switch
Black
Blue
Bl
BR
G
_1_
___.
0
C
L------1./1-D<l-1r./y
Dloot( Slop Button

Svl1ch SY ltch
.,'
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....
ID
ID
...,
Starter
Motor
~L
Color
en
............
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I/Y-
ID
ID
-I
I I
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8K
R/
III
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iii
I I I i I I,
12V25/25W
Head II Oht
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I'nln.
t LG [".n,,,,,.1
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[aro una[ J/W
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PUSh
Puah
(n051-1572A.1573A)
C/)
;0:
r-
Horn
Switch
Headlight
12V25/25W
Spee domete r
light 12V3. 4W
Starter
C ircuit
Relay
rii"n- -cB-
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<:)-11/'
!-II/H>Oj-
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.
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o ~ rm
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Terminals
9~
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r "
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Ground
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12V 8W
Tall light
l!I
ea
C
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II
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Rectltler
Headlight
12V25/25W
1/8IC311
~/Y
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1/1l
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111,-,<:.
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Color
LO
HI
lilY I R II/SK
Engine stop Switch

Color I 8R I Y/R
"/
Neutrall
Reverse
SW itch
color
Y/I
I n
co lor
Connections
Color
orr
Re I eeeed
orr
RUN
Pueh
Pueh
I n/Y
m
~
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Color COdeJ
BI(
BL
Black
BR
G
GY
LB
Blue
Brown
Green
Gray
LIOt\t Blu81
LG
lHlht Green'
or onge
Pink
Red
Wh I te
Yellow
R
W
Y
ignition hitch Cann.alion.
Horn Button
Starter Button
,rll
12V11Ah
starter
Left Handlebar SWitCh Connections
Motor
...
--:0BatterYI
Llth1l m~n, Sulton

~!r:~~ switch
llOht/Dlmmer Switch
rStar tar
Z
-I
Pickup
Coil
Alterntltor
=-~ C~__-'!" -1
,~:~-~
11II
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INeutral .. Reveree SWitCh Connectlona

,""A'U
color
I lC IorOUO(lI
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en
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(1I80si - Ui74A)
...
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o
SUPPLEMENT - 1998 - 1999 MODELS 17-1
Supplement - 1998 - 1999 Models

Table of Contents
Foreword ................ ...... ............ ..... .. ..... ........ .. ... .... ..... ...... ........ .... .... ... ........... .. ...... .. ,....... ......
How to Use this Manual..... .... ... ..... . ..... ...... .. ........ .... ........... ... ........ ..... .... ....... ... ........ ....... ....
General Information ..... ... ....... ..... ...... .... .............. .. ..... ............................ ... ..............................
General Specifications............... .... ... ....... ...... . .. .. .... ... ... ... .. ... .. ....... .... .. .. ... .. .... .. ...... ... ..........
Cable, Wire and Hose Routing .. .. ............ ...... .. .. .. ...... .. ... .... .. ..... ........ ...... ..... ..... .. .................. .
Fuel System................ ....... ...... .... ...... . ........ ..... ........ .......... ....... . .... .... ...... ....... .. .... ........ ......... .
Exploded View ................ ,........................ ... .... .. .. ................................... ...... .. .... .... .. ........... .
Specifications.. ............. ...... ............. ......... .... .. .... ... ... ... ...... ...... ........ .... ...... .. ... .. .. ....... . .. .. ..... .
Engine Top End ..... ........ . ..... ... ..... ...... .... ... ...... ... ... ..... ......... ....... ...... .... .... .. ... ........ ..... ... .. .. ..... .
Exploded View............... ... .. .............. ... .. .... . .. ....... ... ....... ... .. ... ..... ...... ..... ..... . ....... .. . ..............
Wiring Diagram.... ............. ..... ........ .. .............................. ... .. ...... .. ... . ..... ..... ... .. ...... .. ...... ......... ..
17-2
17-2
17-3
17-3
17-5
17-6
17-6
17-7
17-8
17-8
17-9
17-2 SUPPLEMENT - 1998 -1999 MODELS
Foreword
How to Use this Manual
This "Supplement 1998 - 1999 Models" designed to be used in conjunction with the front part of
this manual (up to 16-11)
The specifications and maintenance procedures described in this chapter are only those that are
unique to the KLF220-A 11 I A 12 models.
Complete and proper servicing of the KLF220-A11 /A12 models therefore requires mechanics to
read both this chapter and the front of this manual.
SUPPLEMENT - 1998 -1999 MODELS 17-3
General Information
KLF220-A11/A12
Items
Dimensions:
Overall length
1745 mm
Overall width
1 120 mm, (US) (CN) 1 020 mm
Overall height
1 040 mm
Wheelbase
1 115 mm
Ground clearance
155 mm
Seat height
730 mm
Dry weight
183 kg , (AS) (EU) (UK) 185 kg, (CN) 183.5 kg
Curb weight:
Front
88.5 g, (UK) 89 g
Rear
104.5 kg , (UK) 106 kg, (CN) 105kg
Fuel tank capacity
10 L
Performance:
2.7
Engine:
Type
4-stroke, SOHC, 1-cylinder
Cooling system
Air-cooled
Bore and stroke
67.0 x 61.0 mm
Displacement
215 mL
Compression ratio
9.3
Maximum horsepower
12.5 kW (17 PS) @7 500 r/m in (rpm) , (US)-
Maximum torque
17.6 Nm (1.8 kgfm, 13.0 ftlb) @6 000 r/min (rpm) ,

(US) -
Carburetion system
Carburetor, Mikuni VM24SS
Starting system
Electric starter & recoil starter
Ignition system
DC-CDI
Timing advance
Ignition timing
From 10 BTDC @1 800 r/min (rpm) to 35 BTDC

@4 600 r/min (rpm)
Spark plug
NGK D8EA (EU) (UK) NGK DR8ES
Valve timing:
Inlet
Exhaust
Open
35 BTDC
Close
5JO ABDC
Duration
272
Open
54 BBDC
Close
26 ATDC
Duration
260
Lubrication system
Engine Oil:
Grade
SE, SF or SG class
Viscosity
SAE10W-30, 10W-40, 1OW-50, 20W-40, or 20W-50
Capacity
2.0 L
Drive Train:
Primary reduction system: Type
Gear
Reduction ratio 3.450 (69/20)
General Information
KLF220-All1A12
Items
Clutch type:
Prima ry
Secondary

5-speed plus reverse , constant mesh, return shift
Transm ission: Type

Gear ratio 1st
2.923 (38/13)
2nd
1.684 (32/19)
3rd
1.173 (27/23)
4th
0.923 (24/26)
5th
0.785 (22 /28)
Reverse
3.115 (27/ 11 x 33122)
Type
Shaft
Final drive system:
Reduction ratio 4.680 (18/15 x 39/10)

12.686 @Top gear
Overall drive ratio

Type
API GL-5 Hypoid gear oil SAE90 (above 5C, 41 F)

or SAE 80 (below 5C, 41 F)
Capacity
0.2 L
Frame:
Type
Double tubular
Caster (rake angle)
Camber
Trail
17 mm
Tread
Front tire:
Rear tire:
Suspension:
764 mm
Rear
776mm
Type
Tubeless
Size
AT 21 x 8-9
Type
Tubeless
Size
AT 22 x 10-10
Front
Rear
Brake type:
Front
Type
Wheel travel
115 mm
Type
Torque tube-link
Wheel travel
125 mm
Front
Drum
Rear
Drum
12 V 11 Ah
Battery
Type
Semi-sealed beam
Bulb
12 V 25/25 W (R/H, UH)
Taillights:
Bulb
12 V 8 W (R/ H, UH)
Alternator:
Type
Three-phase AC
Rated output
13 Al14V @8 000 rl min (rpm)
Headlight:
(US): U.S.A. Model

(AS): Australia Model
(CN): Canada Model

(EU ): Europe Model
(UK): U.K. Model

(AS): Australia Model
Specification subject to change without notice, and may not apply to every country.
Cable, Wire and Hose Routing
California Model (KLF220-A11 -)
tun
1. Clamp
2. Tube
3. Clamp on the Frame
4. Cap
5. Joint
6. Clamp
7 . Clamp
8. Air Cleaner Assembly
.4 C
17-6 SUPPLEMENT - 1998 - 1999 MODELS
Fuel System
Exploded View
HC0203U13 C
1. California Model (KLF220-A 11 - )
Fuel System
Specifications
Item
Throttle Lever Free Play
Standard
2 - 3 mm
Carburetor:
MakefType
MikuniNM24-428 (CA) VM24-490
Main Jet
#115 (CA) #117.5
Main Air Jet
<1>1.8
Jet Needle
5GN46-2 (CA) 5GN58-1
Needle Jet
0-0 (CA) O-OM
Pilot Jet
#30
Pilot Air Jet
<1>1.2
Air Screw
1 112 turns out
Starter Jet
#45
Service Fuel Level
5 mm below the bottom edge of the carburetor

body
Float Height
21.8 mm

Grade
SE class
Viscosity
SAE30
(CA) California Model
Engine Top End
Exploded View
HE020U8U
1. California Model
A: To the Air Cleaner
0 : Apply engine oil.
55: Apply silicone sealant.
T1 : 34 Nm (3.5 kgfm, 25 ftlb)
First Torquing: 13 Nm (1.3 kgfm, 113 inlb)
T2 : 9.8 Nm (1.0 kgfm, 87 inlb)
First Torquing : 5.9 Nm (0.6 kgf.m, 52 inlb)
(Opt ion ) U. S . A . Mode I
Austral ia Model
r---'
Hor n
12V25 / 25W
12V25 / 251
( R I H)
,- - - - -
Speedometer
:liiht 12V3 . 4'11
L
____
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I I IK
RIY 1 1K
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II LuJ
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Austral ia Model
110
rn
Ilnitlon
Sw i tch
12V 31X2
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12V 1 SA
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C i r cui t
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Accessory
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12 V 8W
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tar t e r 1P"~III~-1
Relay
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Swi tch Connections

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St I r t
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Neu tra l & Reverse

Sw i tch Connections
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P Ul h
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Color Code
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Reverse
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liic_l!U~
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In,o un oll All
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OFF
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( 1IOSI-1UH )
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BK
BL
BR
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BK
GY
Ho r n BU;:lon
N e~tr.1
SWitch
Co l .. r
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Puoh
Code
B l ac k
Blue
B roln
Green
Connections
SI IY
SK / I
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S w i t c h C o n ne ct i ons
En,;" .
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Sw i tch
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III
VI
Tail Li,ht( L /H)

12 V 8W
Headl ight
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I<:} R ~
T~! I / Brake
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(R / H, l /H)
t<J-
rr=~-"~i~~~LG:~:t-:-1-'-to~l'J~====rw-t===~L=1'=~jl:--,m
Circuit
s"",,
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Accessory
Termina l s
I;;;::;;;::
, - ---,
Rear
hitch
~:~
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F r ont
Rflke
Li,llt
en
Mo d el
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& Reve~5e
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Ground
Gray
LB
Li I h t
LG
li,ht
OFf
B I u.
a,
Or an
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Pink
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Ntut .. ,
( 98051- 1184.1. )
R."er..
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Red
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Wh
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Ye I 10 11
Wiring Diagram
M-
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SUPPLEMENT- 2000 '""'-' 2002 Models
Table of Contents
Foreword ....... .... .... .... .... ..... .... .. ....................... ....... ................ .... ..................... . 18-2
General Information ................ .......................... . ................ ...................... ...... 18-3
Model Identificat ion .... ... .. ...... ................................. ..... ........... ............... 18-3
General Specifications .. .. .......... ........... ....... ... .. ............ .. ..... ........ ..... ...... 18-4
Periodic Mai ntenance Chart ..................... ............................................. 18-6
Fuel System .................................................................................... .. .... ............ 18-7
Specifications .. .... ...... .... ......... ..... ..... ... ...... ... ..................... ... ..... ............. 187
Brakes ....... .............................. ............. ... .. ................... .... .... .................... ..... 188
Exploded View .............. .................................................... ........ .............. 188
Frame ... ........ .... ... ...... ..... ....... .. ... .... ...... ........... .. .......................... .................... . 189
Exploded View ............. ......................................................................... 18-9
Electrical System ............. ........................ .................. .................... ... .............. 18-1 0
Exploded View .. .. ... .... ..... .... ...... ........ .. ..... ...... ............... ..... ..... ........... 18-10
W iring Diag ram ......... ......... ......... ... ................................... ........ ... .... 18- 11
Foreword
How to Use this Manual
This "SUPPLEMENT 2000 - 2002 Models" designed to be used in conjunction with the front part
of this manual (up to 17-11)
The specifications and maintenance procedures described in this chapter are only those that are
unique to the KLF220-A 13/A 14/A 15 models.
Complete and proper servicing of the KLF220-A 13/A 14/A 15 models therefore requires
mechanics to read both this chapter and the front of this manual.
General Information
KLF220-A 13 Left Side View
KLF220-A13 Right Side View
KLF220-A13/A14/A15
Item
Dimensions:
Overall length
Overall width
Overall height
Wheelbase
Ground clearance
Seat height
Dry weight
Curb weight:
Front
Rear
Fuel tank capacity
1745 mm
1120 mm, (US)(CN) 1020 mm
1040 mm
1115 mm
155 mm
730 mm
183 kg, (AS)(EU)(UK) 185 kg, (CN) 183.5 kg
88.5g, (UK) 89 g
104.5kg, (UK) 106 kg, (CN) 105 kg
10 L
Performance:
2.7 m
Engine:
Type
Cooling system
Bore and stroke
Displacement
Compression ratio
Maximum horsepower
Maximum torque
Carburetion system
Starting system
Ignition system
Timing advance
Ignition timing
Spark plug
Valve timing:
Inlet
Exhaust
Lubrication system
Engine Oil:
Grade
Viscosity
Capacity
Open
Closb
Duration
Open
Close
Duration
4-stroke, SOHC, 1-cylinder

Air-cooled
67.0 x 61.0 mm
215 mL
9.3
12.5 kW (17 PS) @7500 rlmin (rpm), (US) 17.6 N-m (1.8 kg-m, 13.0 f1-lb) @6000r/min(rpm), (US) Carburetor, Mikuni VM24SS
Electric starter & recoil starter
DC-CDI
From 10 BTDC @1BOO rlmin (rpm) to
35 BTDC @4600 rlmin (rpm)
NGKDRBES
35 BTDC
57 ABDC
272
54 BBDC
26 ATDC
260
SE, SF or SG class (A 13)
API SF or SG class, API SH or SJ of JASO MA class (A14)
SAE10W-30, 10W-40, 10W-50, 20W-40, or 20W-50 (A 13)
SAE5W-30, 10W-40, 10W-50, 20W-40, or 20W-50 (A14)
2.0 L
Item
Drive Train:
Primary reduction system:
Clutch type:
Transmission:
Type
Gear ratio
Final drive system:

Overall drive ratio:
Final gear case oil :
Frame:
Type
Caster (rake angle)
Camber
Trail
Tread
Type
Size
Rear tire:
Type
Size
Suspension: Front
KLF220-A131A141A15
Type
Reduction ratio
Primary
Secondary
1st
2nd
3rd
4th
5th
Reverse
Type
Reduction ratio
Type
Double tubular
4'
3'
Front
Rear
Front tire:
Rear
Brake type: Front
Rear
Battery
Headlight:
Type
Bulb
Tail/Brake lights:
Bulb
Alternator:
Type
Rated output
US: U.S.A. Model

AS: Australia Model
Gear
3.450 (69120)
5-speed plus reverse, constant mesh, return shift
2.923 (38113)
1.684 (32119)
1.173 (27123)
0.923 (24126)
0.785 (22128)
3.115 (27111 x 33(22)
Shaft
4.680 (18115 x 39(10)
12.686 @Topgear
API GL-5 Hypoid gear oil SAE90 (above 5'C, 41 F) or
SAE80 (below 5'C, 41 ' f)
0.2 L
Type
Wheel travel
Type
Wheel travel
17 mm
764mm
776mm
Tubeless
AT 21 x 8 - 9
Tubeless
AT 22 x 10 - 10
115 mm
Torque tube-link
125 mm
Drum
Drum
12 V 11 Ah (AS) (CN) (EU) (UK) 12 V 14 Ah
Semi-sealed beam
12 V 25/25 W (RIH, UH)
12 V 2718 W (RIH, UH)
Three-phase AC
13 Al14 V @8000 rl min (rpm)
CN: Canada Model

EU: Europe Model
UK: U.K. Model
Specifications are subject to change without notice, and may not apply to every country.
Periodic Maintenance Chart

The scheduled maintenance must be done in accordance with this chart to keep the vehicle in good
running condition . The first service is vitally important and must not be neglected.
First Service
Regular Service
.=Clean, adjust, lubricate, tighten, or

replace parts as necessary.
Chassis
Brake wear - check
Cable adjustments
Battery - check
Steering play - check
General lubrication
Nuts and bolts - tighten
Final gear case oil - change
Engine
Air cleaner - service
Throttle lever play - check
Clutch adjustment
Valve clearance - check
Fuel system cleanliness - check
Engine oil - change
Oil filter - replace
Spark plug - clean and gap
Spark arrester - clean
Service more frequently when operated in mud, dust or other harsh riding conditions.
Fuel System
Specifications
Item
Throttle Lever Free Play

Carburetor:
Makeffype
Main Jet
Main Air Jet
Jet Needle
Needle Jet
Pilot Jet
Pilot Air Jet
Air Screw
Starter Jet
Service Fuel Level
Float Height
Grade
Viscosity
(CA):California Model
Standard
2-3 mm
MikuniNM24SS
#1 17.5 (CA) #115
<~ 1.8
5GN64-1
0-6M
#30
<I> 1.3
2 5/8 turns out
#45
5 mm below the bottom edge
of the carburetor body
22.6 mm
SE class
SAE30
Brakes
Exploded View
f---{ 1
lrUOA01WI C
G:Apply grease
1. Right grip assembly
2. Brake switch
SUPPLE MENT - 2000 - 2002 MODELS 18-9
Frame
Exploded View
Other than U. S. A. Canada

and Europe Models
Other t han U. S. A and

Canada Models
Canada Model
:~ :
-, ~
UK and Eu rope Models

unu
on c
Electrical System
Exploded View
r9'~
'~
~o~~,
~~
" ?
HP02066BU
1.
2.
3.
4.
5.
6.
7.
Brake switch
Tail/Brake light
Horn button
Horn
(AS) KLF220-A3A - (EU, UK) KLF220-A13Reverse light
(EU, UK) KLF220-A13 -
'-
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KLF220-A13/A14/A1S Wiring Diagram (U.S.A. and Canada Models)
en
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88-02 KA ATV Bayou 220 Manual-S

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88-02 KA ATV Bayou 220 Manual-S

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This service manuals covers the 1988-2002 Kawasaki Bayou 220 Series.

I do apologize for any confusion the supplements may cause.

file:///C|/Users/Ken/Desktop/Midwest%20Manuals/index%20searchable.html[2/8/2010 3:01:03 PM]

All Terrain Vehicle

Quick Reference Guide

ine Bottom EndlTransmission 7

lement - 1998 - 1999 Models 17

All Terrain Vehicle

1987 Kawasaki Heavy Industries, Ltd.

12th Edition (1) :Apr. 20, 2007 (K)

LIST OF ABBREV IATIONS

after bottom dead center

after top dead center

before bottom dead center

bottom dead center

before top dead center

pound (s) per square inch

revolution(s) per minute

top dead center

total indicator reading

Read OWNER'S MANUAL before operating

!o-.. ,,- ....y;:.-

PLEASE DO NOT TAMPER WITH NOISE CONTROL SYSTEM

This warning may apply to any of the following

more of these components:Brake Shoes or Pads

e{)perate if possible out of doors or in a well

How to Use This Manual

Guide shows you all of the product's system

.Indicates a procedural step or work to be

Model Identification . ... . .. .. .. ........... _ . . . . . . . . . . . . . . . .

General Specifications . . .. . ............... . ...... . .... .... ..

Periodic Maintenance Chart . .... . ... ... .. : . . . . . . . . . . . . . . . . . .

Torque and Locking Agent . . .... . ... _... . .. ........ .. .. . . : . . .

Cable and Hamess Routing.. . . . . . ... . ... . . . . ... . . . . . . . . .. . . ..

(12) Oil Seal and Grease 'Seal

Name of Wire Color

KLF220-A4/A5 (US, Canadian Model)

KLF22G-A6 (US, Canadian Model)

KLF22G-A2 (US, Canadian Model)

KLF220-A 7 (US; Canadian Model)

KLF22G-A3 (US, Canadian Model)

Curb weight: Front

Fuel tank capacity

Minimum turning radius 2.7 m

Bore and stroke

4stroke, SOHC, " cylinder

12.5 kW 117 PSI@7 500 r/min (rpmI.IUI-

17.7 Nm (1.8 k~m, 13.0 ft1 b)

From 10' 8TDC@1 800 r/min (rpm)

IC) : Canadian model

183 kg,(A) <- <-,(CIIEIIUK) <-, (A)(EIIUK)

(E) : European model

Wet multi disc and centrifugal

Primary reduction system:

5-speed plus reverse , constant mesh,

Final gear case oil:

AP I GL5 Hypoid gear oil SAE90

Brake type: Front

Electrical Equipm ent:

= Clean, adjust, lubricate, tighten, or

replace parts as necessary.

The following tables list the tightening torque for the

Letter used in the "Remarks" column means: