After removal, check for leaks with a soap and water solution. Measure the tread depth at the center of the tread with a depth gauge [A]. Since the tire may wear unevenly, take measurements at several places.
If any measurements are less than the service limit, replace the tire. Visually inspect the steering knuckle joint boots [B]. If the joint boot is torn, worn, deteriorated, or leaks grease, replace the knuckle joint see Suspension Arms section in the Suspension chapter. If the joint boot is torn, worn, or deteriorated, replace the joint boot and check the propeller shaft see Rear Propeller Shaft section in Final Drive chapter. If the clearance is not the specified length, adjust the cable.
Then stop the. Park the vehicle so that it is level, both side to side and front to back. Remove the front right hand side cover see Frame chapter. Place an oil pan beneath the front final gear case and remove the drain plug [A]. When draining or filling the final gear case, do not spill oil the tire or rim.
Clean any oil that may spill with a high flash-point solvent. Place an oil pan beneath the rear final gear case and remove the drain plug [A]. If the fluid level is lower than the lower level line, check for fluid leakage of the brake line, and add the fluid as follows:.
And then install the reservoir cap. Do not mix two brands of brake fluid. Change the brake fluid in the brake line completely if the brake fluid must be refilled but the type and brand of the brake fluid that is already in the reservoir are unidentified. Fill the reservoir with new brake fluid. Check the fluid level in the reservoir often, replenishing it as necessary.
Do not operate the vehicle and service the brake system immediately. If the seals are not satisfactory, pad wear will increase, and constant pad drag on the disc will raise brake and brake fluid temperature. Replace the fluid seals. Pad Lining Thickness Standard: 4 mm 0. Service Limit:. Bend and twist the rubber hose while examining it.
Replace the hose if any cracks [B] or bulges [C] are noticed. Tighten any loose fittings. If the play is incorrect, adjust it. If the free play is incorrect, adjust it. Rear Brake Lever Loosen the knurled locknut [A] and turn the adjuster [B] at the rear brake lever in as far as it will go.
Tighten the locknut. Rear Brake Pedal Turn the brake pedal adjuster [B] at the rear end of the brake cable until the brake pedal has the correct amount of play. If the steering action is not smooth, or if the steering binds or catches before the stop, lubricate the steering stem bearing. If you feel looseness, or if the steering rattles as it turns, check the tightness of the steering bolts and nuts. Tighten loose bolts and nuts to the specified torque see Steering chapter , and check the steering action again.
If the steering action does not change by tightening the bolts and nuts, inspect the steering stem clamps, steering stem bearings, tie-rod bearings, and steering knuckle joints. If it does not as specified, adjust the brake light timing.
Brake Light Timing Standard: On after about 10 mm 0. NOTICE To avoid damaging the electrical connections inside the switch, be sure that the switch body does not turn during adjustment. If cable movement is not free after lubricating, if the cable is frayed [B], or if the cable housing is kinked [C], replace the cable.
Points: Lubricate with Grease. Also, check to see that each cotter pin is in place and in good condition. If there are loose fasteners, retorque them to the specified torque following the specified tightening sequence. Refer to the appropriate chapter for torque specifications. If torque specifications are not listed in the appropriate chapter, see the Basic Torque Table see Torque and Locking Agent. If cotter pins are damaged, replace them with new ones. Throttle Lever and Cable Throttle Cable Installation Throttle Case Inspection Throttle Cable Lubrication and Inspection Choke Lever and Cable Choke Cable Lubrication and Inspection Service Fuel Level Inspection Service Fuel Level Adjustment Carburetor Synchronization Inspection Carburetor Synchronization Adjustment Carburetor Removal Carburetor Installation Carburetor Disassembly Carburetor Assembly Carburetor Separation Carburetor Joining Carburetor Cleaning Carburetor Inspection Air Cleaner Air Cleaner Element Removal Air Cleaner Housing Removal Air Cleaner Housing Installation Fuel Tank Check Valve Installation Fuel Tank Cleaning Fuel Pump Removal Pump Filter Cleaning Fuel Pump Installation Fuel Pump Inspection Choke Lever 8.
Choke Cable 9. Throttle Cable Throttle Lever Jet Needle Pilot Jet Main Jet Needle Jet Pilot Screw O: Apply engine oil. Fuel Pump 7. Fuel Tank Breather 8. Check Valve 9. Insert the fuel breather tube end into the frame hole. Joints Gr: Apply grease. R: Replacement Parts. Air Cleaner Housing Bolt M6 33 mm 1. Joint 9. Fuel Tank Breather Check Valve without arrow mark Joints Fuel Level Sensor Fuel Pump Fuel Pump Mounting Bracket Check Valve with arrow mark L: Apply a non-permanent locking agent.
Torque - Throttle Case Assembly Screws: 3. Turn the throttle limiter screw [A] until it is spaced about 1 mm 0. Tighten the locknut [D]. Be sure the throttle case is assembled correctly.
Follow the service manual to make sure to correct any of these conditions. If the lever is heavy, disassemble the throttle case, clean and lubricate the throttle case. Examine the lever and case for cracks. Replace the case assembly if it is cracked. Refer to the General Lubrication in the Periodic Maintenance chapter for the cable lubrication and inspection.
Torque - Throttle Limiter Screw: 3. Make sure the area is well ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. Special Tool - Fuel Level Gauge: If it is lowered and then raised, the gauge will show a fluid level that is higher than the actual level, which will require a remeasurement.
At this time, the float valve [E] rod must not be depressed. Assemble the carburetor and recheck the fuel level. If the fuel level cannot be adjusted by this method, the float or the float valve is damaged. Carburetor Synchronization Inspection idle speed. If the vacuum is out of the specified range, adjust it. Carburetor Synchronization Vacuum Standard: Less than 2. You may cause poor running at low engine speed. Never use a sharp edge to remove the diaphragm.
NOTICE Do not apply force to the jet or overtighten it, or this could damage the jet or the carburetor body, requiring replacement. Before assembling the carburetor, replace the O-rings with new ones. Turn the seat so that it does not block the hole [B] at the bottom of the vacuum piston.
After installing the upper chamber cover, check that the vacuum piston slides up and down smoothly without binding in the carburetor bore. If they are not, loosen the carburetor joining bolts and align the carburetors on a flat surface. Retighten the carburetor joining bolts.
If there is a difference between two carburetors, turn the balance adjusting screw [B] to obtain the same clearance. Install the carburetors see Carburetor Installation. Adjust the synchronization see Synchronization Adjustment. Clean the carburetor in a well-ventilated area, and take care that there are no sparks or flame anywhere near the working area; this includes any appliance with a pilot light.
Do not use gasoline or a low flash-point solvent to clean the carburetor. NOTICE Do not use compressed air on an assembled carburetor, the float may be crushed by the pressure, and the vacuum piston diaphragm may be damaged. Remove as many rubber or plastic parts from the carburetor as possible before cleaning the carburetor with a cleaning solution. This will prevent damage or deterioration of the parts. The carburetor body has plastic parts that cannot be removed.
Do not use a strong carburetor cleaning solution which could attack these parts; instead, use a mild high flash-point cleaning solution safe for plastic parts. Do not use wire or any other hard instrument to clean carburetor parts, especially jets, as they may be damaged. Assemble the carburetor see Carburetor Assembly. If the throttle valve does not move smoothly, replace the carburetor. If the plastic tip is damaged [C], replace the float valve [B]. Push the rod [D] in the other end of the float valve needle and then release it [E].
If it does not spring out, replace the float valve. If the pilot screw is worn or damaged on the tapered portion, it will prevent the engine from idling smoothly. Replace it. The surface of the piston must not be excessively worn. If the vacuum piston does not move smoothly, or if it is very loose in the carburetor body, replace both the body and the vacuum piston.
Metal Mesh [B] with Element After removing the element, stuff pieces of lint-free, clean cloth into the air cleaner ducts to keep dirt out of the carburetor and engine.
Replace the air cleaner element according to the maintenance chart. If the dampers are damaged or deteriorated, replace them. Tighten the fuel tank bolts. Be sure the fuel hose is clamped to the fuel pump fitting. Install the check valve as following. Check Valve with allow mark Install the check valve so that the arrow [A] faces fuel tank. Check Valve without allow mark Install the check valve [A] so that the orange color side [B] faces fuel tank.
Black Color [C]. Clean the tank in a well-ventilated area, and take care that there are no sparks or flame anywhere near the working area; this includes any appliance with a pilot light. Do not use gasoline or a low flash-point solvent to clean the tank. If the filter screen has any break or is deteriorated, it may allow dirt to reach the carburetor, causing poor running. Replace the fuel tap.
Replace the O-ring or fuel tap. If replace the O-ring, disassemble the fuel tap as follow. Apply grease to the lever, and assemble the fuel tap.
Such a shock to the pump can damage it. Disconnect the battery — terminal. To avoid fuel spills, draw it from the tank when the engine is cold. Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately. Clean the pump filter in a well-ventilated area, and take care that there are no sparks or flame anywhere near the working area; this includes any appliance with a pilot light.
Do not use gasoline or a low flash-point solvent to clean the pump filter. If the fuel pump does not operate as described, replace it with a new one. Coolant Flow Chart Coolant Deterioration Inspection Coolant Level Inspection Coolant Draining Coolant Filling Pressure Testing Water Pump Water Pump Cover Removal Water Pump Cover Installation Water Pump Impeller Removal Water Pump Impeller Installation Water Pump Impeller Inspection Water Pump Leakage Inspection Mechanical Seal Replacement Radiator Removal Radiator Installation Radiator Fan Removal Radiator Fan Installation Radiator Inspection Radiator Cap Inspection Thermostat Removal Thermostat Installation Thermostat Inspection Radiator Fan Switch Radiator Fan Switch Removal Radiator Fan Switch Installation Radiator Fan Switch Inspection Coolant Temperature Switch Water Temperature Switch Removal Water Temperature Switch Installation Water Temperature Switch Inspection Coolant Valve Inspection Thermostat Coolant Valve Coolant Filter When the engine starts, the water pump coupled with the oil pump turns and the coolant circulates.
The thermostat is a wax pellet type which opens or closes with coolant temperature changes. The thermostat continuously changes its valve opening to keep the coolant temperature at the proper level. When coolant temperature is below When coolant temperature is more than The radiator fan draws air through the radiator core when there is not sufficient air flow such as at low speeds.
This increases up the cooling action of the radiator. In this way, this system controls the engine temperature within narrow limits where the engine operates most efficiently even if the engine load varies. The system is pressurized by the radiator cap to suppress boiling and the resultant air bubbles which can cause engine overheating. As the engine warms up, the coolant in the radiator and the water jacket expands.
The excess coolant flows through the radiator cap and hose to the reserve tank to be stored there temporarily. Conversely, as the engine cools down, the coolant in the radiator and the water jacket contract, and the stored coolant flows back to the radiator from the reserve tank. The radiator cap has two valves. One is a pressure valve which holds the pressure in the system when the engine is running.
When the engine cools down, another small valve vacuum valve in the cap opens. As the coolant cools, the coolant contracts to form a vacuum in the system. The vacuum valve opens and allows the coolant from the reserve tank to enter the radiator. Radiator 2. Radiator Cap 3. Radiator Fan Switch 4. Radiator Fan 5. Water Temperature Sensor 6.
Thermostat 7. Cylinder 8. Cylinder Head 9. Water Pump Reserve Tank If the coolant is brown, iron or steel parts are rusting. In either case, flush the cooling system. If the coolant gives off an abnormal smell, check for cooling system leak.
It may be caused by exhaust gas leaking into the cooling system. Adding water alone dilutes the coolant and degrades its anticorrosion properties. The diluted coolant can attach the aluminum engine parts. In an emergency, soft water can be added. But the diluted coolant must be returned to the correct mixture ration within a few days. If coolant must be added often, or the reserve tank has run completely dry; there is probably leakage in the cooling system.
Check the system for leaks. The maximum pressure is kPa 1. If the pressure drops soon, check for leaks. Torque - Water Pump Impeller: 7. If there is a coolant leak, the mechanical seal in the pump could be damaged. Replace the mechanical seal with a new one see Mechanical Seal Replacement. Special Tool - Bearing Driver Set: NOTICE If either the mechanical seal, oil seal, or the ball bearing is removed, make sure to replace all of them simultaneously with a new one.
Be careful not to block the inspection hole with the oil seal. If the inspection hole is blocked, the coolant may pass through the oil seal and flow into the crankcase. Apply coolant to the surfaces of the rubber seal and sealing seat [A], and press the rubber seal [B] and sealing seat into the impeller by hand until the seat bottoms out. Tighten the water pump impeller by turning the bolt clockwise.
The radiator fan is connected directly to the battery and may start even if the ignition switch is off. Do not touch the radiator fan until it has been disconnected from the battery. This could damage the radiator fins, resulting in loss of cooling efficiency. Torque - Radiator Fan Mounting Nut: 2.
If the corrugated fins [A] are deformed, carefully straighten them. If any one of them shows visible damage, replace the cap. The relief valve opens, indicated by the gauge hand flicks downward. If the cap cannot hold the specified pressure, or if it holds too much pressure, replace it with a new one. If the valve is open, replace the valve with a new one.
If the measurement is out of the specified range, replace the thermostat. Thermostat Valve Opening Temperature Such a shock to the part can damage it. Remove the radiator fan switch [A]. Camshaft Chain Tensioner Camshaft Chain Tensioner Removal Camshaft Chain Tensioner Installation Rocker Case Rocker Case Removal Rocker Case Installation Rocker Arm Removal Rocker Arm Installation Rocker Arm Inspection Rocker Shaft Diameter Measurement Camshaft Removal Camshaft Installation Camshaft Assembly Cam Wear Camshaft Bearing Wear KACR Inspection KACR Removal KACR Installation Camshaft Chain Removal Camshaft Chain Installation Camshaft Chain Guide Wear Cylinder Head Cylinder Compression Measurement Cylinder Head Removal Cylinder Head Installation Cylinder Head Cleaning Cylinder Head Warp Valve Removal Valve Installation Valve Guide Removal Valve Guide Installation Valve-to-Guide Clearance Measurement Valve Seat Inspection Valve Seat Repair Valve Lapping Cylinder and Piston Cylinder Removal Piston Removal Cylinder, Piston Installation Cylinder Wear Piston Wear Cylinder Boring and Honing Piston Ring Groove Width Piston Ring Thickness Piston Ring End Gap Exhaust System Muffler and Exhaust Pipe Removal Muffler and Exhaust Pipe Installation Exhaust System Inspection Fastener Rocker Case Bolts 55 mm 2.
Rocker Case Bolts mm 5. Vacuum Hose to the Fuel Tap Vacuum Hose to the Fuel Pump MO: Apply molybdenum disulfide oil. Clamp G: Apply grease for oil seal and O-ring. TIR 0. The push rod does not return to its original position once it moves out to take up cam chain slack. Observe all the rules listed below: When removing the tensioner, do not take out the mounting bolts only partway. Retightening the mounting bolts from this position could damage the tensioner and the camshaft chain.
Do not turn over the crankshaft while the tensioner is removed. This could upset the cam chain timing, and damage the valves. The rocker arms could bend the valves.
Sealant - Liquid Gasket, TB Torque - Rocker Case Bolts: 8. If the rocker arm is scored, discolored or otherwise damaged, replace it. Also inspect the camshaft lobes. Inspect the end of the valve clearance adjusting screws [B] where it contacts the valve stem.
If the end of the adjusting screw is mushroomed or damaged in any way, or if the screw will not turn smoothly, replace it. Also inspect the end of the valve stem. Measure the inside diameter [C] of the rocker arm with a dial bore gauge.
If the rocker arm inside diameter is larger than the service limit, replace it. Also check the rocker shaft diameter see Rocker Shaft Diameter Measurement. Rocker Arm Inside Diameter Standard: Service Limit: If the rocker shaft diameter is smaller than the service limit, replace it.
Also check the rocker arm inside diameter see Rocker Arm Inspection. Rocker Shaft Diameter Standard: Cam Height Standard: Exhaust. The plastigage indicates the clearance by the amount it is compressed and widened when the parts are assembled. Cut strips of plastigage to journal width. Place a strip on each journal parallel to the camshaft with the camshaft installed in the correct position so that the plastigage will be compressed between the journal and rocker case.
Install the rocker case, tightening the bolts in the correct sequence to the specified torque see Rocker Case Installation. Measure the widest portion of the plastigage. Camshaft Bearing Clearance 18 Standard: 0. Service Limit: 0. Camshaft Bearing Clearance 22 Standard: 0. If any clearance exceeds the service limit, measure the diameter of the camshaft journal.
Camshaft Journal Diameter 18 Standard: Camshaft Journal Diameter 22 Standard: If the camshaft journal diameter is less than the service limit, replace the camshaft with a new one and measure the clearance again. If the clearance still remains out of the limit, replace the cylinder head and the rocker case. This allows some of the compression pressure to escape, making it easy to turn over the engine during starting. Due to the simplicity of the mechanism, no periodic maintenance is needed.
There are only two symptoms of problems with the KACR mechanism [A]: compression is not released during starting, and compression is released during running. Remove the camshaft see Camshaft Removal. Visually inspect the spring. If damaged, deformed, or missing, replace the spring. Remove the spring and move the weights back and forth. If the weights do not move smoothly, replace the KACR unit.
Also inspect the exhaust rocker arm for any damage, and replace the rocker arm if necessary. If the weights do not move easily from the retracted position, replace the KACR unit. Install the KACR unit. Hook the arms [B] on the pins. Apply a non-permanent locking agent to the camshaft sprocket bolts [C] and tighten them. Align the key groove [A] on the crankshaft with the embossed line [B] on the crankcase.
When the gauge stops rising, stop cranking and read the gauge. The following table should be consulted if the obtainable compression reading is not within the usable range. Problem Cylinder compression is higher than usable range. Incorrect cylinder head gasket thickness.
Replace the gasket with a standard part. Damaged or missing compression release Replace the spring. Replace damaged gasket and Gas leakage around cylinder head check cylinder head warp. Bad condition of valve seating Repair if necessary. Incorrect valve clearance. Adjust the valve clearance.
Compression release weights do not move Replace the compression release smoothly unit. Tighten the cylinder head bolts following the tightening sequence as shown.
Cylinder Head Warp Service Limit: 0. If the cylinder head is warped more than the service limit, replace it. If the cylinder head is warped less than the service limit, repair the head by lapping the lower surface with emery paper secured to a surface plate first No. Using the valve spring compressor assembly, remove the valve. If there is too little clearance, ream the valve guide see Valve Guide Installation.
Check the valve seat see Valve Seat Inspection. Apply a thin coat of molybdenum disulfide grease to the valve stem. Install each spring so that the closed coil end faces downwards. Valve Stem Oil Seal Hammer lightly on the valve guide arbor [A] to remove the guide from the top of the head. Special Tool - Valve Guide Arbor,. Special Tool - Valve Guide Reamer,.
Valve-to-Guide Clearance Measurement If a small bore gauge is not available, inspect the valve guide wear by measuring the valve to valve guide clearance with the wobble method as indicated below. Insert a new valve [A] into the guide [B] and set a dial gauge against the stem perpendicular to it as close as possible to the cylinder head mating surface. Repeat the measurement in a direction at a right angle to the first. If the reading exceeds the service limit, replace the guide.
It must be the correct width and even all the way around. Measure the outside diameter [D] of the seating 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. If the valve seating pattern is not correct, repair the seat see Valve Seat Repair. Measure the seat width [E] of the portion where there is no build-up carbon white portion of the valve seat with vernier calipers.
If the width is too wide, too narrow or uneven, repair the seat see Valve Seat Repair. Seat Cutter Operation Care 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. Do not drop or shock the valve seat cutter, or the diamond particles may fall off. Do not fail to apply engine oil to the valve seat cutter before grinding the seat surface.
Also wash off ground particles sticking to the cutter with washing oil. It will take off the diamond particles. Setting the valve seat cutter holder in position, operate the cutter in one hand. Do not apply too much force to the diamond portion. After use, wash it with washing oil and apply thin layer of engine oil before storing. Cutter angle [B] Outer diameter of cutter [C].
Operating Procedures Clean the seat area carefully. Press down lightly on the handle and turn it right or left. Grind the seating surface only until it is smooth. Overgrinding will reduce valve clearance by sinking the valve into the head. If the valve sinks too far into the head, it will be impossible to adjust the clearance, and the cylinder head must be replaced.
Original Seating Surface [B]. If the outside diameter of the seating surface is within the specified range, measure the seat width as described below. Turn the holder one turn at a time while pressing down very lightly. Check the seat after each turn. Check the seat outside diameter frequently to prevent overgrinding.
If the seat width is within the specified range, lap the valve to the seat as described below. Correct Width [B].
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. Be sure to remove all grinding compound before assembly.
When the engine is assembled, be sure to adjust the valve clearance see Valve Clearance Adjustment in Periodic Maintenance chapter. They could fall out and score the cylinder wall. The openings of the oil ring steel rails must be.
If any of the cylinder inside diameter measurements exceeds the service limit, replace the cylinder. If the measurement is under service limit, replace the piston. Piston Diameter Standard: If only a piston is replaced, the clearance may exceed the standard slightly. But it must not to be less than the minimum of the clearance in order to avoid piston seizure.
The oversize piston requires oversize rings. Oversize Piston and Rings: 0. However, if the amount of boring necessary would make the inside diameter greater than 0. If the exact figure for the rebored diameter is unknown, it can be roughly determined by measuring the diameter at the base of the cylinder. The rings should fit perfectly parallel to groove surfaces.
If not, replace the piston and all the piston rings. If the piston ring groove clearance is greater than the service limit, measure the ring thickness and groove width as follows to decide whether to replace the rings, the piston or both.
If the width of any of the two grooves is wider than the service limit at any point, replace the piston. Piston Ring Thickness Standard: Top. If any of the measurements is less than the service limit on either of the rings, replace all the rings. The rings should fit perfectly parallel to the groove sides. If not, replace the piston. Set it close to the. Measure the gap [B] between the ends of the ring with a thickness gauge.
Forest Service. It must be properly maintained to ensure its efficiency. In accordance with the Periodic Maintenance Chart, clean the spark arrester. But do not tighten the following nuts and bolts. If there are signs of leakage around the exhaust pipe gasket, it should be replaced.
If the muffler-to-exhaust pipe joint leaks, tighten the clamp. Remove the exhaust pipe and muffler see Muffler and Exhaust Pipe Removal. Inspect the gasket for damage and signs of leakage. If the gasket is damaged or has been leaking, replace it. Check the exhaust pipe and muffler for dents, cracks, rust and holes. If the exhaust pipe or muffler is damaged or has holes, it should be replaced for best performance and least noise. Torque Converter Torque Converter Cover Removal Torque Converter Cover Installation Torque Converter Cover Disassembly Torque Converter Cover Assembly Drive Belt Drive Belt Removal Drive Belt Installation Converter Drive Belt Inspection Drive Pulley Drive Pulley Removal Drive Pulley Disassembly Drive Pulley Inspection Drive Pulley Assembly Drive Pulley Installation Driven Pulley Driven Pulley Removal Driven Pulley Disassembly Driven Pulley Inspection Driven Pulley Assembly Driven Pulley Installation High Altitude Setting Information G: Apply grease for oil seal and O-ring.
M: Apply molybdenum disulfide grease. The pulleys of the belt drive torque converter are precision balanced components designed to operate within certain rpm limits. Modifications to the engine or pulleys that increase rpm may cause failure. If it is done, the learning control of Kawasaki Engine Brake Control system works and the engine brake actuator works an error operation. Converter Cover [D] Front [E].
This is the normal running mode. Engine rpm is limited when the switch is in the OFF position. Measurement Length [E] Standard: 1. If the measurement is less than 1. If the measurement is more than 2. If the length is not within the specified length after the actuator lever assembly is replaced, replace the torque converter cover, and install the actuator lever assembly When installing a new belt, install it so the printed information [A] can be read from beside the vehicle.
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