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2012 KAWASAKI EX250JC Service Repair Manual .pdf



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MODEL APPLICATION
Year
2008
2009
2010
2011
2012

Model
EX250J8
EX250J9
EX250JA
EX250JB
EX250JC

Beginning Frame No.
JKAEXMJ1□8DA00001
JKAEXMJ1□9DA17355
JKAEXMJ1□ADA49773
JKAEXMJ1□BDA71588
JKAEXMJ1□CDA96621

□:This digit in the frame number changes from one machine to another.

Part No.99924-1391-05

Printed in Japan

Ninja 250R

Motorcycle
Service Manual

Quick Reference Guide

This quick reference guide will assist
you in locating a desired topic or procedure.
•Bend the pages back to match the
black tab of the desired chapter number with the black tab on the edge at
each table of contents page.
•Refer to the sectional table of contents
for the exact pages to locate the specific topic required.

General Information

1 j

Periodic Maintenance

2 j

Fuel System

3 j

Cooling System

4 j

Engine Top End

5 j

Clutch

6 j

Engine Lubrication System

7 j

Engine Removal/Installation

8 j

Crankshaft/Transmission

9 j

Wheels/Tires

10 j

Final Drive

11 j

Brakes

12 j

Suspension

13 j

Steering

14 j

Frame

15 j

Electrical System

16 j

Appendix

17 j

Ninja 250R

Motorcycle
Service Manual
All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or
transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise,
without the prior written permission of Quality Assurance Division/Motorcycle & Engine Company/Kawasaki
Heavy Industries, Ltd., Japan.
No liability can be accepted for any inaccuracies or omissions in this publication, although every possible
care has been taken to make it as complete and accurate as possible.
The right is reserved to make changes at any time without prior notice and without incurring an obligation
to make such changes to products manufactured previously. See your Motorcycle dealer for the latest
information on product improvements incorporated after this publication.
All information contained in this publication is based on the latest product information available at the time
of publication. Illustrations and photographs in this publication are intended for reference use only and may
not depict actual model component parts.

© 2007 Kawasaki Heavy Industries, Ltd.

5th Edition (1): May 18, 2011

LIST OF ABBREVIATIONS
A
ABDC
AC
ATDC
BBDC
BDC
BTDC
°C
DC
F
°F
ft
g
h
L

ampere(s)
after bottom dead center
alternating current
after top dead center
before bottom dead center
bottom dead center
before top dead center
degree(s) Celsius
direct current
farad(s)
degree(s) Fahrenheit
foot, feet
gram(s)
hour(s)
liter(s)

lb
m
min
N
Pa
PS
psi
r
rpm
TDC
TIR
V
W


pound(s)
meter(s)
minute(s)
newton(s)
pascal(s)
horsepower
pound(s) per square inch
revolution
revolution(s) per minute
top dead center
total indicator reading
volt(s)
watt(s)
ohm(s)

COUNTRY AND AREA CODES
AU
CA
CAL
CO

Australia
Canada
California
Colombia

ID
MY
PH
US

Indonesia
Malaysia
Philippines
United States

EMISSION CONTROL INFORMATION
To protect the environment in which we all live, Kawasaki has incorporated crankcase emission (1) and exhaust emission (2) control systems in compliance with applicable regulations of
the United States Environmental Protection Agency and California Air Resources Board. Additionally, Kawasaki has incorporated an evaporative emission control system (3) in compliance
with applicable regulations of the California Air Resources Board on vehicles sold in California
only.
1. Crankcase Emission Control System
This system eliminates the release of crankcase vapors into the atmosphere. Instead, the vapors
are routed through an oil separator to the inlet side of the engine. While the engine is operating,
the vapors are drawn into combustion chamber, where they are burned along with the fuel and air
supplied by the fuel injection system.
2. Exhaust Emission Control System
This system reduces the amount of pollutants discharged into the atmosphere by the exhaust
of this motorcycle. The fuel, ignition, and exhaust systems of this motorcycle have been carefully
designed and constructed to ensure an efficient engine with low exhaust pollutant levels.
The exhaust system of this model motorcycle manufactured primarily for sale in California includes a catalytic converter system.
3. Evaporative Emission Control System
Vapors caused by fuel evaporation in the fuel system are not vented into the atmosphere. Instead, fuel vapors are routed into the running engine to be burned, or stored in a canister when
the engine is stopped. Liquid fuel is caught by a vapor separator and returned to the fuel tank.
The Clean Air Act, which is the Federal law covering motor vehicle pollution, contains what is
commonly referred to as the Act’s “tampering provisions”.
“Sec. 203(a) The following acts and the causing thereof are prohibited...
(3)(A) for any person to remove or render inoperative any device or element of design installed
on or in a motor vehicle or motor vehicle engine in compliance with regulations under this
title prior to its sale and delivery to the ultimate purchaser, or for any manufacturer or dealer
knowingly to remove or render inoperative any such device or element of design after such
sale and delivery to the ultimate purchaser.
(3)(B) for any person engaged in the business of repairing, servicing, selling, leasing, or trading
motor vehicles or motor vehicle engines, or who operates a fleet of motor vehicles knowingly to remove or render inoperative any device or element of design installed on or in a
motor vehicle or motor vehicle engine in compliance with regulations under this title following its sale and delivery to the ultimate purchaser...”

NOTE

○The phrase “remove or render inoperative any device or element of design” has been generally
interpreted as follows.
1. Tampering does not include the temporary removal or rendering inoperative of devices or elements of design in order to perform maintenance.
2. Tampering could include.
a.Maladjustment of vehicle components such that the emission standards are exceeded.
b.Use of replacement parts or accessories which adversely affect the performance
or durability of the motorcycle.
c.Addition of components or accessories that result in the vehicle exceeding the standards.
d.Permanently removing, disconnecting, or rendering inoperative any component or
element of design of the emission control systems.

WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL LAW,
THE VIOLATION OF WHICH IS PUNISHABLE BY CIVIL PENALTIES NOT EXCEEDING $10
000 PER VIOLATION.

TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED
Federal law prohibits the following acts or the causing thereof. (1) The removal or rendering
inoperative by any person other than for purposes of maintenance, repair, or replacement, of any
device or element of design incorporated into any new vehicle for the purpose of noise control
prior to its sale or delivery to the ultimate purchaser or while it is in use, or (2) the use of the
vehicle after such device or element of design has been removed or rendered inoperative by
any person.
Among those acts presumed to constitute tampering are the acts listed below.
Replacement of the original exhaust system or muffler with a component not in compliance
with Federal regulations.
Removal of the muffler(s) or any internal portion of the muffler(s).
Removal of the air box or air box cover.
Modifications to the muffler(s) or air inlet system by cutting, drilling, or other means if such
modifications result in increased noise levels.






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 Motorcycle parts. Special tools, gauges, and
testers that are necessary when servicing
Kawasaki motorcycles are introduced by the
Service Manual. Genuine parts provided as
spare parts are listed in the Parts Catalog.
Follow the procedures in this manual carefully. Don’t take shortcuts.
Remember to keep complete records of maintenance and repair with dates and any new
parts installed.








How to Use This Manual
In this manual, the product is divided into its
major systems and these systems make up the
manual’s chapters.

The Quick Reference Guide shows you all
of the product’s system and assists in locating
their chapters. Each chapter in turn has its own
comprehensive Table of Contents.
For example, if you want 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 symbols, heed their instructions! Always follow safe operating and
maintenance practices.

DANGER
DANGER indicates a hazardous situation which, if not avoided, will result in
death or serious injury.

WARNING
WARNING indicates a hazardous situation which, if not avoided, could result
in death or serious injury.

NOTICE
NOTICE is used to address practices not
related to personal injury.
This manual contains four more symbols
which will help you distinguish different types
of information.

NOTE

○This note symbol indicates points of particular interest for more efficient and convenient operation.
a procedural step or work to be
• Indicates
done.

○Indicates a procedural sub-step or how to do
the work of the procedural step it follows. It
also precedes the text of a NOTE.
Indicates a conditional step or what action to
take based on the results of the test or inspection in the procedural step or sub-step it follows.
In most chapters an exploded view illustration
of the system components follows the Table of
Contents. In these illustrations you will find the
instructions indicating which parts require specified tightening torque, oil, grease or a locking
agent during assembly.

GENERAL INFORMATION 1-1

General Information
Table of Contents
Before Servicing .....................................................................................................................
Model Identification.................................................................................................................
General Specifications............................................................................................................
Unit Conversion Table ............................................................................................................

1
1-2
1-7
1-8
1-11

1-2 GENERAL INFORMATION
Before Servicing
Before starting to perform an inspection service or carry out a disassembly and reassembly operation on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustrations, photographs, cautions, and detailed descriptions have been included in each chapter wherever
necessary. This section explains the items that require particular attention during the removal and
reinstallation or disassembly and reassembly of general parts.
Especially note the following.

Battery Ground
Before completing any service on the motorcycle, disconnect the battery cables from the battery to prevent the engine from accidentally turning over. Disconnect the ground
cable (–) first and then the positive (+). When completed
with the service, first connect the positive (+) cable to the
positive (+) terminal of the battery then the negative (–) cable to the negative terminal.

Edges of Parts
Lift large or heavy parts wearing gloves to prevent injury
from possible sharp edges on the parts.

Solvent
Use a high-flush point solvent when cleaning parts. High
-flush point solvent should be used according to directions
of the solvent manufacturer.

Cleaning vehicle before disassembly
Clean the vehicle thoroughly before disassembly. Dirt or
other foreign materials entering into sealed areas during vehicle disassembly can cause excessive wear and decrease
performance of the vehicle.

GENERAL INFORMATION 1-3
Before Servicing
Arrangement and Cleaning of Removed Parts
Disassembled parts are easy to confuse. Arrange the
parts according to the order the parts were disassembled
and clean the parts in order prior to assembly.

Storage of Removed Parts
After all the parts including subassembly parts have been
cleaned, store the parts in a clean area. Put a clean cloth
or plastic sheet over the parts to protect from any foreign
materials that may collect before re-assembly.

Inspection
Reuse of worn or damaged parts may lead to serious accident. Visually inspect removed parts for corrosion, discoloration, or other damage. Refer to the appropriate sections
of this manual for service limits on individual parts. Replace
the parts if any damage has been found or if the part is beyond its service limit.

Replacement Parts
Replacement Parts must be KAWASAKI genuine or
recommended by KAWASAKI. Gaskets, O-rings, oil seals,
grease seals, circlips, cotter pins or self-looking nuts must
be replaced with new ones whenever disassembled.

Assembly Order
In most cases assembly order is the reverse of disassembly, however, if assembly order is provided in this Service
Manual, follow the procedures given.

1-4 GENERAL INFORMATION
Before Servicing
Tightening Sequence
Generally, when installing a part with several bolts, nuts,
or screws, start them all in their holes and tighten them to
a snug fit. Then tighten them according to the specified sequence to prevent case warpage or deformation which can
lead to malfunction. Conversely when loosening the bolts,
nuts, or screws, first loosen all of them by about a quarter turn and then remove them. If the specified tightening
sequence is not indicated, tighten the fasteners alternating
diagonally.

Tightening Torque
Incorrect torque applied to a bolt, nut, or screw may
lead to serious damage. Tighten fasteners to the specified
torque using a good quality torque wrench.

Force
Use common sense during disassembly and assembly,
excessive force can cause expensive or hard to repair damage. When necessary, remove screws that have a non
-permanent locking agent applied using an impact driver.
Use a plastic-faced mallet whenever tapping is necessary.

Gasket, O-ring
Hardening, shrinkage, or damage of both gaskets and
O-rings after disassembly can reduce sealing performance.
Remove the old gaskets and clean the sealing surfaces
thoroughly so that no gasket material or other material remains. Install the new gaskets and replace the used O-rings
when re-assembling

Liquid Gasket, Non-permanent Locking Agent
For applications that require Liquid Gasket or a
Non-permanent Locking Agent, clean the surfaces so
that no oil residue remains before applying liquid gasket or
non-permanent locking agent. Do not apply them excessively. Excessive application can clog oil passages and
cause serious damage.

GENERAL INFORMATION 1-5
Before Servicing
Press
For items such as bearings or oil seals that must be
pressed into place, apply small amount of oil to the contact area. Be sure to maintain proper alignment and use
smooth movements when installing.

Ball Bearing and Needle Bearing
Do not remove pressed ball or needle unless removal is
absolutely necessary. Replace with new ones whenever
removed. Press bearings with the manufacturer and size
marks facing out. Press the bearing into place by putting
pressure on the correct bearing race as shown.
Pressing the incorrect race can cause pressure between
the inner and outer race and result in bearing damage.

Oil Seal, Grease Seal
Do not remove pressed oil or grease seals unless removal
is necessary. Replace with new ones whenever removed.
Press new oil seals with manufacture and size marks facing
out. Make sure the seal is aligned properly when installing.

Apply specified grease to the lip of seal before installing
the seal.

Circlips, Cotter Pins
Replace the circlips or cotter pins that were removed with
new ones. Take care not to open the clip excessively when
installing to prevent deformation.

1-6 GENERAL INFORMATION
Before Servicing
Lubrication
It is important to lubricate rotating or sliding parts during
assembly to minimize wear during initial operation. Lubrication points are called out throughout this manual, apply
the specific oil or grease as specified.

Direction of Engine Rotation
When rotating the crankshaft by hand, the free play
amount of rotating direction will affect the adjustment. Rotate the crankshaft to positive direction (clockwise viewed
from output side).

Electrical Wires
A two-color wire is identified first by the primary color and
then the stripe color. Unless instructed otherwise, electrical
wires must be connected to those of the same color.

Instrument
Use a meter that has enough accuracy for an accurate
measurement. Read the manufacture’s instructions thoroughly before using the meter. Incorrect values may lead
to improper adjustments.

GENERAL INFORMATION 1-7
Model Identification
EX250J8 Left Side View (United States and Canada)

EX250J8 Right Side View (United States and Canada)

Frame Number

Engine Number

1-8 GENERAL INFORMATION
General Specifications
EX250J8 ∼ JC

Items
Dimensions
Overall Length
Overall Width
Overall Height
Wheelbase
Road Clearance
Seat Height
Dry Mass
EX250J8
Curb Mass:
EX250J9 ∼ JC
Front
Rear
Fuel Tank Capacity
Performance
Minimum Turning Radius
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
Cylinder Numbering Method
Firing Order
Valve Timing:
Inlet:
Open
Close
Duration
Exhaust:
Open
Close
Duration

2 085 mm (82.1 in.), (AU) 2 080 mm (81.9 in.)
715 mm (28.1 in.)
1 110 mm (43.7 in.), (AU) 1 115 mm (43.9 in.)
1 400 mm (55.1 in.), (AU) 1 390 mm (54.7 in.)
130 mm (5.1 in.), (AU, ID) 140 mm (5.5 in.)
775 mm (30.5 in.)
152 kg (335 lb), (CAL) 153 kg (337 lb), (IN) 154 kg (340 lb)
170 kg (375 lb), (AU) 169 kg (373 lb)
82 kg (181 lb), (ID) 83 kg (183 lb)
88 kg (194 lb), (AU, ID) 87 kg (192 lb)
18 L (4.8 US gal.)
2.7 m (8.9 ft)
4-stroke, DOHC, 2-cylinder
Liquid-cooled
62.0 × 41.2 mm (2.5 × 1.6 in.)
249 cm³ (15.2 cu in.)
11.6
24 kW (32.6 PS) @11 000 r/min (rpm)
(ID) 23.4 kW (31.8 PS) @11 000 r/min (rpm)
22.0 N·m (2.24 kgf·m, 16.2 ft·lb) @9 500 r/min (rpm)
Carburetor, Keihin CVK 30× 2
Electric starter
Battery and coil (transistorized)
Electronically advanced
From 10° BTDC @1 300 r/min (rpm) to
35° BTDC @4 000 r/min (rpm)
NGK CR8E or ND U24ESR-N
Left to right, 1-2
1-2

36° BTDC
56° ABDC
272°
61° BBDC
31° ATDC
272°

GENERAL INFORMATION 1-9
General Specifications
Items
Lubrication System
Engine Oil:
Type
Viscosity
Capacity
Drive Train
Primary Reduction System:
Type
Reduction Ratio
Clutch Type
Transmission:
Type
Gear Ratios:
1st
2nd
3rd
4th
5th
6th
Final Drive System:
Type
Reduction Ratio
Overall Drive Ratio
Frame
Type
Caster (Rake Angle)
Trail
Front Wheel:
Tire Type
Tire Size:
EX250J8
EX250J9 ∼ JC
Rim Size
Rear Wheel:
Tire Type
Tire Size:
EX250J8
EX250J9 ∼ JC
Rim Size
Front Suspension:
Type
Wheel Travel

EX250J8 ∼ JC
Forced lubrication (wet sump)
API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2
SAE10W-40
1.7 L (1.80 US qt)

Gear
3.087 (71/23)
Wet multi disc
6-speed, constant mesh, return shift
2.600
1.789
1.409
1.160
1.000
0.893

(39/15)
(34/19)
(31/22)
(29/25)
(27/27)
(25/28)

Chain drive
3.214 (45/14), (AU) 3.071 (43/14)
8.859 @Top gear, (AU) 8.466 @Top gear
Tubular, diamond
26°
82 mm (3.2 in.)
Tubeless
110/70-17M/C 54H
110/70-17M/C 54S
17 M/C × MT2.75
Tubeless
130/70-17M/C 62H
130/70-17M/C 62S
17 M/C × MT3.50
Telescopic fork
120 mm (4.7 in.)

1-10 GENERAL INFORMATION
General Specifications
Items
Rear Suspension:
Type
Wheel Travel
Brake Type:
Front
Rear
Electrical Equipment
Battery
EX250J8
EX250J9 ∼ JC
Headlight:
Type
Bulb:
High
Low
Tail/brake Light
Alternator:
Type
Rated Output
EX250J8 ∼ JA
EX250JB ∼ JC

EX250J8 ∼ JC
Swingarm (uni-trak)
130 mm (5.1 in.)
Single disc
Single disc

12 V 6 Ah
12 V 8 Ah
Semi-sealed beam
12 V 55 W + 55 W (quartz-halogen)
12 V 55 W (quartz-halogen)
12 V 5/21 W
Three-phase AC
19 A @5 000 r/min (rpm), 14 V
20 A @5 000 r/min (rpm), 14 V

Specifications are subject to change without notice, and may not apply to every country.
AU: Australia Model
ID: Indonesia Model

GENERAL INFORMATION 1-11
Unit Conversion Table
Prefixes for Units:
Prefix
mega
kilo
centi
milli
micro

Symbol
M
k
c
m
µ

Units of Length:
×
×
×
×
×

Power
1 000 000
1 000
0.01
0.001
0.000001

Units of Mass:
kg
g

×
×

2.205
0.03527

=
=

lb
oz

=
=
=
=
=
=
=
=
=

gal (US)
gal (IMP)
qt (US)
qt (IMP)
pint (US)
pint (IMP)
oz (US)
oz (IMP)
cu in

km
m
mm

×
×
×

0.6214
3.281
0.03937

=
=
=

mile
ft
in

=
=
=
=
=
=

kgf·m
ft·lb
in·lb
N·m
ft·lb
in·lb

=
=
=
=
=
=

kgf/cm²
psi
cm Hg
kPa
psi
kPa

=

mph

=
=
=
=

PS
HP
kW
HP

Units of Torque:
N·m
N·m
N·m
kgf·m
kgf·m
kgf·m

×
×
×
×
×
×

0.1020
0.7376
8.851
9.807
7.233
86.80

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

Units of Pressure:
kPa
kPa
kPa
kgf/cm²
kgf/cm²
cm Hg

×
×
×
×
×
×

0.01020
0.1450
0.7501
98.07
14.22
1.333

Units of Speed:
km/h

×

0.6214

Units of Force:
N
N
kg
kg

×
×
×
×

0.1020
0.2248
9.807
2.205

Units of Temperature:

=
=
=
=

kg
lb
N
lb

Units of Power:
kW
kW
PS
PS

×
×
×
×

1.360
1.341
0.7355
0.9863

PERIODIC MAINTENANCE 2-1

Periodic Maintenance
Table of Contents
Periodic Maintenance Chart ...................................................................................................
Torque and Locking Agent......................................................................................................
Specifications .........................................................................................................................
Special Tools ..........................................................................................................................
Periodic Maintenance Procedures..........................................................................................
Fuel System.........................................................................................................................
Air Cleaner Element Cleaning...........................................................................................
Air Cleaner Element Installation........................................................................................
Throttle Control System Inspection...................................................................................
Choke Operation Inspection .............................................................................................
Engine Vacuum Synchronization Inspection.....................................................................
Idle Speed Inspection .......................................................................................................
Idle Speed Adjustment......................................................................................................
Fuel Hose Inspection (fuel leak, damage, installation condition) ......................................
Evaporative Emission Control System (CAL Model) ...........................................................
Evaporative Emission Control System Inspection ............................................................
Cooling System....................................................................................................................
Coolant Level Inspection...................................................................................................
Radiator Hose Damage and Installation Condition Inspection..........................................
Coolant Filter Cleaning (Australia Model) .........................................................................
Air Suction System ..............................................................................................................
Air Suction System Damage Inspection............................................................................
Engine Top End ...................................................................................................................
Valve Clearance Inspection ..............................................................................................
Valve Clearance Adjustment.............................................................................................
Clutch...................................................................................................................................
Clutch Operation Inspection..............................................................................................
Wheels/Tires ........................................................................................................................
Air Pressure Inspection.....................................................................................................
Wheel/Tire Damage Inspection.........................................................................................
Tire Tread Wear, Abnormal Wear Inspection ....................................................................
Wheel Bearing Damage Inspection ..................................................................................
Drive Train ...........................................................................................................................
Drive Chain Lubrication Condition Inspection ...................................................................
Drive Chain Slack Inspection ............................................................................................
Drive Chain Slack Adjustment ..........................................................................................
Wheel Alignment Inspection .............................................................................................
Drive Chain Wear Inspection ............................................................................................
Chain Guide Inspection.....................................................................................................
Brake System ......................................................................................................................
Brake Fluid Leak (Brake Hose and Pipe) Inspection ........................................................
Brake Hose and Pipe Damage and Installation Condition Inspection...............................
Brake Operation Inspection ..............................................................................................
Brake Fluid Level Inspection.............................................................................................
Brake Pad Wear Inspection ..............................................................................................
Brake Light Switch Operation Inspection ..........................................................................
Suspensions ........................................................................................................................
Front Forks/Rear Shock Absorber Operation Inspection ..................................................
Front Fork Oil Leak Inspection..........................................................................................
Rear Shock Absorber Oil Leak Inspection ........................................................................

2-3
2-7
2-12
2-14
2-15
2-15
2-15
2-16
2-16
2-18
2-18
2-19
2-19
2-20
2-20
2-20
2-21
2-21
2-22
2-22
2-22
2-22
2-23
2-23
2-24
2-26
2-26
2-27
2-27
2-27
2-27
2-28
2-29
2-29
2-29
2-30
2-31
2-31
2-32
2-32
2-32
2-32
2-33
2-33
2-34
2-34
2-35
2-35
2-35
2-35

2

2-2 PERIODIC MAINTENANCE
Rocker Arm Operation Inspection.....................................................................................
Tie-Rod Operation Inspection ...........................................................................................
Swingarm Pivot Lubrication ..............................................................................................
Steering System ..................................................................................................................
Steering Play Inspection ...................................................................................................
Steering Play Adjustment..................................................................................................
Steering Stem Bearing Lubrication ...................................................................................
Electrical System .................................................................................................................
Lights and Switches Operation Inspection........................................................................
Headlight Aiming Inspection .............................................................................................
Sidestand Switch Operation Inspection ............................................................................
Engine Stop Switch Operation Inspection.........................................................................
Others ..................................................................................................................................
Chassis Parts Lubrication .................................................................................................
Bolts, Nuts and Fasteners Tightness Inspection...............................................................
Replacement Parts ..............................................................................................................
Air Cleaner Element Replacement....................................................................................
Fuel Hose Replacement ...................................................................................................
Coolant Change ................................................................................................................
Radiator Hose and O-ring Replacement...........................................................................
Engine Oil Change............................................................................................................
Oil Filter Replacement ......................................................................................................
Brake Hose and Pipe Replacement..................................................................................
Brake Fluid Change ..........................................................................................................
Master Cylinder Rubber Parts Replacement ....................................................................
Caliper Rubber Parts Replacement ..................................................................................
Spark Plug Replacement ..................................................................................................

2-35
2-36
2-36
2-36
2-36
2-37
2-37
2-38
2-38
2-40
2-41
2-42
2-43
2-43
2-44
2-45
2-45
2-45
2-45
2-47
2-48
2-48
2-49
2-49
2-51
2-52
2-53

PERIODIC MAINTENANCE 2-3
Periodic Maintenance Chart
The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in
good running condition.The initial maintenance is vitally important and must not be neglected.

Periodic Inspection
FREQUENCY Whichever
comes
first
1
INSPECTION
Fuel System

Every

6

(0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5)

Air cleaner element - clean
Throttle control system (play,
smooth return, no drag) - inspect

year

Choke operation - inspect

year




Engine vacuum synchronization
- inspect
Idle speed - inspect
Fuel leak (fuel hose and pipe) inspect
Fuel hose and pipe damage inspect
Fuel hose and pipe installation
condition - inspect
Evaporative emission control
system function (CAL) - inspect
Cooling System

year
year
year

Coolant level - inspect
Coolant leak (water hose and
pipe) - inspect

year

Water hose damage - inspect

year

Water hose installation condition
- inspect
Coolant filter - clean
Air Suction System
Air suction system damage inspect
Engine Top End

year











Clutch
Clutch operation (play,
disengagement, engagement) inspect
Wheels and Tires


































2-15






2-21

year

Tire tread wear, abnormal wear
- inspect
year

2-16
2-18
2-18
2-19
2-20
2-20
2-20
2-20

2-22
2-22
2-22
2-22



Wheel/tire damage - inspect

Wheel bearing damage - inspect













year

Valve clearance - inspect

Tire air pressure - inspect

12

* ODOMETER READING
× 1 000 km
(× 1 000 mile) See
Page
18
24
30
36







2-22







2-23







2-26
















2-27
2-27
2-27
2-28

2-4 PERIODIC MAINTENANCE
Periodic Maintenance Chart
FREQUENCY Whichever
comes
first
1
INSPECTION
Drive Train
Drive chain lubrication condition
- inspect #
Drive chain slack - inspect #

Every

6

(0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5)

Every 600 km (375 mile)

2-29

Every 1 000 km (600 mile)

2-29




Drive chain wear - inspect #
Drive chain guide wear - inspect
Brakes
Brake fluid leak (brake hose and
pipe) - inspect
Brake hose and pipe damage inspect
Brake hose and pipe installation
condition - inspect
Brake operation (effectiveness,
play, no drag) - inspect
Brake fluid level - inspect

year
year
year
year
6 months







Brake pad wear - inspect #
Brake light switch operation inspect
Suspension
Front forks/rear shock absorber
operation (damping and smooth
stroke) - inspect
Front forks/rear shock absorber
oil leak - inspect

12

* ODOMETER READING
× 1 000 km
(× 1 000 mile) See
Page
18
24
30
36



year

Rocker arm operation - inspect
Tie-rods operation - inspect














































2-31









2-32

2-32

2-32
2-32
2-33
2-33
2-34
2-34







2-35














2-35
















Swingarm pivot - lubricate

2-35
2-36
2-36

Steering
Steering play - inspect
Steering stem bearings lubricate
Electrical System
Lights and switches operation inspect
Headlight aiming - inspect
Sidestand switch operation inspect
Engine stop switch operation inspect

year





2 years

year
year
year
year






2-36
2-37

2-38
2-40
2-41
2-42

PERIODIC MAINTENANCE 2-5
Periodic Maintenance Chart
FREQUENCY Whichever
comes
first
1
INSPECTION
Others
Chassis parts - lubricate
Bolts and nuts tightness - inspect

Every

6

12

* ODOMETER READING
× 1 000 km
(× 1 000 mile) See
Page
18
24
30
36

(0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5)

year












2-42
2-43

#: Service more frequently when operating in severe conditions; dusty, wet, muddy, high speed or
frequent starting/stopping.
*: For higher odometer readings, repeat at the frequency interval established here.

2-6 PERIODIC MAINTENANCE
Periodic Maintenance Chart
Periodic Replacement Parts
FREQUENCY Whichever
comes
first

* ODOMETER READING
× 1 000 km
(× 1 000 mile)
1

CHANGE/REPLACE ITEM
Air cleaner element # - replace
Fuel hose - replace

Every
2 years
5 years

Coolant - change

3 years

Radiator hose and O-ring - replace

3 years

Engine oil # - change

year

Oil filter - replace

year

Brake hose and pipe - replace

4 years

Brake fluid - change

2 years

Rubber parts of master cylinder and caliper replace

4 years

Spark plug - replace

12

24

36

48

See
Page

(0.6) (7.5) (15) (22.5) (30)
2-44
2-44






















2-44
2-46








2-47
2-47
2-48
2-48
2-50
2-52

#: Service more frequently when operating in severe conditions; dusty, wet, muddy, high speed or
frequent starting/stopping.
*: For higher odometer readings, repeat at the frequency interval established here.

PERIODIC MAINTENANCE 2-7
Torque and Locking Agent
Use a torque wrench to tighten bolts and nuts to their specified torque values. If too little torque is
applied, the bolts and nuts could loosen and fall out. If too much torque is applied, the threads could
be sheared off.
To tighten a bolt or a nut, or to check their torque, loosen the bolt or nut one-half turn before tightening it to the specified torque.
Letters used in the “Remarks” column mean:
EO: Apply engine oil.
G: Apply grease.
L: Apply a non-permanent locking agent to the threads.
M: Apply molybdenum disulfide grease.
MO: Apply molybdenum disulfide oil solution.
R: Replacement Parts
S: Tighten the fasteners following the specified sequence.
Si: Apply silicone grease.
SS: Apply silicone sealant.
Fastener
Fuel System
Fuel Tap Mounting Bolts
Fuel Gauge Mounting Bolts
Air Cleaner Housing Cap Bolts/Screws
Air Cleaner Housing Screws
Air Cleaner Housing Mounting Bolts
Air Cleaner Housing Clamp Screws
Separate Bracket Bolt
Cooling System
Water Temperature Switch
Thermostat Cover Bolts
Thermostat Housing Mounting Bolts
Radiator Fan Switch
Radiator Bolts
Radiator Cap Bracket Bolt
Water Pipe Bolts
Water Hose Clamp Screws
Drain Bolt
Water Pump Cover Bolts
Water Pump Bolts
Reserve Tank Cap
Reserve Tank Bolts
Reserve Tank Bracket Bolt
Engine Top End
Cylinder Head Cover Bolts
Camshaft Sprocket Bolts
Chain Tensioner Cap Bolt
Air Suction Cover Bolts
Vacuum Switch Valve Bracket Bolts
Rear Camshaft Chain Guide Bolt-Lower

N·m

Torque
kgf·m

ft·lb

2.5
6.9
2.5
1.15
9.8
2.0
9.8

0.25
0.7
0.25
0.12
1.0
0.2
1.0

22
61
22
10
87
18
87

7.5
9.8
9.8
23.5
9.8
9.8
9.8
3.0
9.8
9.8
9.8

9.8
9.8

0.76
1.0
1.0
2.4
1.0
1.0
1.0
0.31
1.0
1.0
1.0

1.0
1.0

66 in·lb
87 in·lb
87 in·lb
17
87 in·lb
87 in·lb
87 in·lb
27 in·lb
87 in·lb
87 in·lb
87 in·lb

87 in·lb
87 in·lb

9.8
15
5.0
9.8
9.8
17

1.0
1.5
0.5
1.0
1.0
1.7

87 in·lb
11
44 in·lb
87 in·lb
87 in·lb
13

Remarks

in·lb
in·lb
in·lb
in·lb
in·lb
in·lb
in·lb
SS

Hand-Tighten

L

2-8 PERIODIC MAINTENANCE
Torque and Locking Agent
Fastener
Chain Tensioner Mounting Bolts
Camshaft Cap Bolts
Cylinder Head Bolt (M6)
Cylinder Head Bolts (M8)
Water Passage Plugs
Carburetor Holder Clamp Screws
Water Drain Bolt
Muffler Body Rear Cover Bolts
Muffler Body Mounting Bolt
Muffler Body Clamp Bolt
Muffler Cover Bolts
Muffler Cover Clamp Screw
Exhaust Pipe Mounting Bolt
Exhaust Pipe Holder Nuts
Clutch
Clutch Lever Holder Clamp Bolts
Clutch Spring Bolts
Clutch Hub Nut
Oil Filler Plug
Clutch Cover Bolts
Engine Lubrication System
Oil Hose Banjo Bolts
Oil Pressure Relief Valve
Crankcase Oil Passage Plug
Oil Passage Plugs for Oil Pump
Oil Pipe Banjo Bolts
Oil Drain Bolt
Oil Pressure Switch
Oil Pressure Switch Terminal Bolt
Oil Filter Mounting Bolts
Oil Breather Mounting Bolts
Oil Pump Mounting Bolts
Oil Screen Cover Bolts
Plug
Breather Bolt
Engine Removal/Installation
Engine Mounting Bracket Bolts and Nuts
Engine Mounting Nuts
Crankshaft/Transmission
Oil Breather Mounting Bolts
Crankcase Bolts 6
Crankcase Bolts 8 (L = 90)
Crankcase Bolts 8 (L = 73)

N·m
9.8
12
12
31.4
20
2.0
5.9
9.8
30
17
9.8
6.9
9.8
12

Torque
kgf·m
1.0
1.2
1.2
3.2
2.0
0.2
0.6
1.0
3.1
1.7
1.0
0.70
1.0
1.2

ft·lb
87 in·lb
106 in·lb
106 in·lb
23
15
18 in·lb
52 in·lb
87 in·lb
22
13
87 in·lb
61 in·lb
87 in·lb
104 in·lb

8.8
8.8
132

9.8

0.9
0.9
13.5

1.0

78 in·lb
78 in·lb
97.4

87 in·lb

19.6
15
15
20
12
19.6
15
1.5
19.6
9.8
9.8
9.8
19.6
9.8

2.0
1.5
1.5
2.0
1.2
2.0
1.5
0.15
2.0
1.0
1.0
1.0
2.0
1.0

14.5
11
11
15
104 in·lb
14.5
11
13 in·lb
14.5
87 in·lb
87 in·lb
87 in·lb
14.5
87 in·lb

64
64

6.5
6.5

47
47

9.8
12
24
19

1.0
1.2
2.4
1.9

87 in·lb
104 in·lb
18
14

Remarks

S
MO, S
MO, S
L

L

Hand-Tighten

L
L

SS

L
L

L
MO, S
MO, S

PERIODIC MAINTENANCE 2-9
Torque and Locking Agent
Fastener
Starter Motor Clutch Bolts
Connecting Rod Big End Cap Nuts
Shift Drum Bearing Holder Bolt
Shift Drum Pin Plate Bolt
Neutral Switch
External Shift Mechanism Return Spring Pin
Shift Drum Positioning Bolt
Shift Lever Link Bolt
Front Tie-Rod Locknut (Left-Hand Threads)
Rear Tie-Rod Locknut (Right-Hand Threads)
EX250J8 ∼ JB (with a non-permanent locking
agent)
Shift Pedal Mounting Bolt
EX250JB ∼ JC (with a non-permanent locking
agent)
Shift Pedal Mounting Bolt
Wheels/Tires
Front Axle Nut
Rear Axle Nut
Final Drive
Engine Sprocket Cover Bolts
Engine Sprocket Nut
Rear Sprocket Nuts
Rear Sprocket Studs
Brakes
Brake Lever Pivot Bolt Locknut
Bleed Valve
Front Master Cylinder Clamp Bolts
Brake Disc Mounting Bolts
Brake Hose Banjo Bolts
Front Caliper Mounting Bolts
Front Brake Light Switch Screw
Brake Lever Pivot Bolt
Front Reservoir Cap Screws
Reservoir Mounting Bolt
Bleed Valve
Brake Pedal Pivot Bolt
Push Rod Locknut
Brake Disc Mounting Bolts
Brake Hose Banjo Bolts
Rear Master Cylinder Mounting Bolts
Rear Caliper Mounting Bolts

N·m
34.3
27.5
12
9.0
15
19.6
24.5
12
7.0
7.0

Torque
kgf·m
3.5
2.8
1.2
0.9
1.5
2.0
2.5
1.2
0.7
0.7

ft·lb
25
20
104 in·lb
80 in·lb
11
14.5
18
104 in·lb
62 in·lb
62 in·lb

20

2.0

15

25

2.5

18

88
98

9.0
10.0

65
72

9.8
127
59


1.0
13
6.0


87 in·lb
94
44


5.9
5.5
8.8
27
25
25
1.0
1.0
1.5
6.9
5.5
8.8
18
27
25
25
25

0.6
0.55
0.9
2.8
2.5
2.5
0.1
0.1
0.15
0.7
0.55
0.9
1.8
2.8
2.5
2.5
2.5

52 in·lb
49 in·lb
78 in·lb
20
18
18
9 in·lb
9 in·lb
13 in·lb
61 in·lb
49 in·lb
78 in·lb
13
20
18
18
18

Remarks
L
MO
L
L
L

L

MO
R
L

S
L

L
L

2-10 PERIODIC MAINTENANCE
Torque and Locking Agent
Fastener
Suspension
Front Fork Clamp Bolts (Upper)
Front Fork Clamp Bolts (Lower)
Front Fork Bottom Allen Bolts
Rocker Arm Pivot Nut
Tie-Rod Nuts
Rear Shock Absorber Mounting Nuts
Swingarm Pivot Nut
Steering
Steering Stem Nut
Handlebar Holder Mounting Bolts
Steering Stem Head Bolt
Front Fork Clamp Bolts (Upper)
Front Fork Clamp Bolts (Lower)
Frame
Sidestand Nut
Front Footpeg Bracket Mounting Bolts
Rear Footpeg Bracket Mounting Bolts
Sidestand Switch Bolt
Windshield Mounting Screws
Electrical System
Tail/Brake Light Mounting Bolts
Plugs on Alternator Cover
Alternator Cover Bolts
Alternator Rotor Bolt
Alternator Stator Bolts
Regulator/Rectifier Bolts
Starter Motor Clutch Bolts
Crankshaft Sensor Screws
Ignition Coil Bolts
Spark Plugs
Starter Motor Terminal Locknut
Starter Motor Assembly Bolts
Starter Motor Mounting Bolts
Starter Relay Terminal Nut
Oil Pressure Switch
Neutral Switch

N·m

Torque
kgf·m

ft·lb

21
30
20
59
59
59
98

2.1
3.1
2.0
6.0
6.0
6.0
10.0

15
22
15
44
44
44
72

4.9
25
44
20
30

0.5
2.5
4.5
2.0
3.1

43 in·lb
18
32
15
22

39
25
25
8.8
0.42

4.0
2.5
2.5
0.90
0.043

29
18
18
78 in·lb
3.7 in·lb

5.9

9.8
88.2
12
9.8
34.3
3.0

13
9.8
3.5
9.8
5.0
15
15

0.6

1.0
9.0
1.2
1.0
3.5
0.30

1.3
1.0
0.36
1.0
0.5
1.5
1.5

52 in·lb

87 in·lb
65
104 in·lb
87 in·lb
25
27 in·lb

115 in·lb
87 in·lb
31 in·lb
87 in·lb
44 in·lb
11
11

Remarks

L
R
R
R

R

L

Hand-Tighten

L
see text

SS

PERIODIC MAINTENANCE 2-11
Torque and Locking Agent
The table below, relating tightening torque to thread diameter, lists the basic torque for the bolts and
nuts. Use this table for only the bolts and nuts which do not require a specific torque value. All of the
values are for use with dry solvent-cleaned threads.

Basic Torque for General Fasteners
Threads
dia. (mm)
5
6
8
10
12
14
16
18
20

N·m
3.4 ∼ 4.9
5.9 ∼ 7.8
14 ∼19
25 ∼ 34
44 ∼ 61
73 ∼ 98
115 ∼ 155
165 ∼ 225
225 ∼ 325

Torque
kgf·m
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 ∼ 23.0
23 ∼ 33

ft·lb
30 ∼ 43 in·lb
52 ∼ 69 in·lb
10.0 ∼ 13.5
19.0 ∼ 25
33 ∼ 45
54 ∼ 72
83 ∼ 115
125 ∼ 165
165 ∼ 240

2-12 PERIODIC MAINTENANCE
Specifications
Item
Fuel System
Throttle Grip Free Play
Idle Speed
Carburetor Synchronization Vacuum
Air Cleaner Element
Cooling System
Coolant:
Type (Recommended)
Color
Mixed Ratio
Freezing Point
Capacity
Engine Top End
Valve Clearance:
Inlet
Exhaust
Clutch
Clutch Lever Free Play
Engine Lubrication System
Engine Oil:
Grade
Viscosity
Capacity
Level
Wheels/Tires
Tread Depth:
Front:
BRIDGESTONE
DUNLOP
IRC
Rear:
BRIDGESTONE
DUNLOP
IRC
Air pressure: (when Cold)
Front
Rear
Final Drive
Drive Chain Slack

Standard

Service Limit

2 ∼ 3 mm (0.08 ∼ 0.12 in.)
1 300 ±50 r/min (rpm)
Less than 2.7 kpa (2 cmHg) difference
between two carburetors
Polyurethane foam

– – –
– – –

Permanent type antifreeze
Green
Soft water 50%, coolant 50%
–35°C (–31°F)
1.5 L (1.59 US qt)







0.15 ∼ 0.24 mm (0.0059 ∼ 0.0094 in.)
0.22 ∼ 0.29 mm (0.0087 ∼ 0.0114 in.)

– – –
– – –

2 ∼ 3 mm (0.08 ∼ 0.12 in.)

– – –

API SG, SH, SJ, SL or SM with JASO MA,
MA1 or MA2
SAE 10W-40
1.3 L (1.4 US qt) (when filter is not removed)
1.6 L (1.7 US qt) (when filter is removed)
Between upper and lower level lines (Wait 2 ∼
3 minutes after idling or running)

– – –
– – –













– – –
– – –
– – –
– – –

4.6 mm (0.181 in.)
4.5 mm (0.177 in.)
4.2 mm (0.165 in.)

1 mm (0.04 in.)

7.0 mm (0.276 in.)
7.4 mm (0.291 in.)
6.5 mm (0.256 in.)

2 mm (0.08 in.) up to
130 km/h (80 mph)
3 mm (0.12 in.) over
130 km/h (80 mph)

Up to 170 kg (375 lb) load: 200 kPa (2.0
kgf/cm², 28 psi)
Up to 170 kg (375 lb) load: 225 kPa (2.25
kgf/cm², 32 psi)

– – –

20 ∼ 30 mm (0.8 ∼ 1.2 in.)

– – –

– – –

PERIODIC MAINTENANCE 2-13
Specifications
Item
Brakes
Brake Fluid:
Grade
Brake Pad Lining
Thickness:
Brake Light Timing:
Front
Rear
Electrical System
Type

Standard

DOT4
4.5 mm (0.18 in.)

Service Limit

– – –
1 mm (0.04 in.)
– – –

Pulled ON
ON after 10 mm (0.39 in.) of pedal travel
CR8E, U24ESR-N

– – –

2-14 PERIODIC MAINTENANCE
Special Tools
Steering Stem Nut Wrench:
57001-1100

Vacuum Gauge KEK-55-5:
57001-1369

Filler Cap Driver:
57001-1454

PERIODIC MAINTENANCE 2-15
Periodic Maintenance Procedures
Fuel System
Air Cleaner Element Cleaning

• Remove:
Right Side Cover (see Side Cover Removal in the Frame
chapter)
Air Cleaner Cap Bolts [A]
Air Cleaner Cap [B]

• Pull out the air cleaner element [A].

• Separate the plastic holders [A].

WARNING
If dirt or dust is allowed to pass through into the
carburetor, the throttle may become stuck, possibly
causing accident. Replace the air cleaner element
according to the maintenance chart.

NOTICE
If dirt gets through into the engine, excessive engine wear and possibly engine damage will occur.

2-16 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
WARNING
Gasoline and low-flash point solvents can be
flammable and/or explosive and cause severe
burns. Clean the element in a well ventilated area,
and take care that there is no spark or flame anywhere near the working areas. Do not use gasoline
or low-flash point solvents to clean the element.
the element [A] in a bath of high-flash point solvent.
• Clean
Squeeze it dry in a clean towel. Do not wring the element
or blow it dry; the element can be damaged.
Check all the parts of the element for visible damage.
If any of the parts of the element are damaged, replace
them.
After cleaning, saturate the element with a high-quality
foam-air-filter oil, squeeze out the excess, then wrap it in
a clean towel and squeeze it as dry as possible.
○Be careful not to tear the sponge filter.




Air Cleaner Element Installation

the removed parts in reverse of removal.
• Install
Torque
the air cleaner cap bolts.

Torque - Air Cleaner Cap Bolts: 2.5 N·m (0.25 kgf·m, 22
in·lb)

Throttle Control System Inspection

that the throttle grip moves smoothly from full open
• Check
to close [A], and the throttle closes quickly and completely
by the return spring in all steering positions.
If the throttle grip doesn’t return properly, check the throttle cable routing, grip free play, and cable damage. Then
lubricate the throttle cable.

the throttle grip free play [A].
• Check
If the free play is incorrect, adjust the throttle cable.
Throttle Grip Free Play
Standard: 2 ∼ 3 mm (0.08 ∼ 0.12 in.)

PERIODIC MAINTENANCE 2-17
Periodic Maintenance Procedures
the locknut [A], and screw accelerator cable ad• Loosen
juster [B] in completely so as to give the throttle grip plenty










of play.
Turn the accelerator cable adjuster until 2 ∼ 3 mm (0.08 ∼
0.12 in.) of throttle grip play is obtained.
Tighten the locknut.

If the throttle cables can not be adjusted by using the cable adjuster at the upper end of the throttle cable, use the
cable adjusters at the lower ends of the throttle cables.
Remove:
Side Cover (see Side Cover Removal in the Frame chapter)
Right Lower Fairing (see Lower Fairing Removal in the
Frame chapter)
To make service easy, unscrew the reserver tank bolts
and remove the reserver tank with hoses
Turn out both upper nuts [A] and turn in both lower nuts [B]
as far as they will go so as to give the throttle grip plenty
of play.
With the throttle grip completely closed, turn out the lower
nut and turn in the upper nut of the decelerator cable [C]
until the inner cable just becomes tight.
Turn out the lower nut and turn in the upper nut of the
accelerator cable [D] until the correct free play is obtained.

that the throttle linkage lever [A] stops against the
• Check
idle adjusting screw [B] with the throttle grip closed.

2-18 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Choke Operation Inspection

• Remove:
Front Seat (see Front Seat Removal in the Frame chapter)
Fuel Tank (see Fuel Tank Removal)
Side Covers (see Side Cover Removal in the Frame
chapter)
Lower Fairings (see Lower Fairing Removal in the Frame
chapter)
Fuel Tank (see Fuel Tank Removal)
Push the choke lever [A] back all the way to its released
position.
Check choke cable free play [B].
○Determine the amount of choke cable play at the choke
lever.
If the free play is incorrect, adjust the choke cable.




Choke Cable Free Play
Standard: 2 ∼ 3 mm (0.08 ∼ 0.12 in.)

the choke lever back all the way to its released po• Push
sition.
the choke lever until the starter plunger lever [A] at the
• Pull
carburetor touches the starter plunger [B]; the amount of
choke lever travel is the amount of choke cable play.

the locknut [A], and turn the adjuster [B] until the
• Loosen
cable has the proper amount of free play.
• Tighten the locknut securely.

Engine Vacuum Synchronization Inspection

the motorcycle using the center stand so that it is
• Situate
perpendicular to the ground.
the fuel tank, and connect the sub-fuel tank to
• Remove
supply the fuel.
the right lower fairing.
• Remove
Warm
up
engine.
• Check thethe
idle
and adjust if necessary.
• Pull the vacuumspeed
hoses
off, and attach vacuum gauge [A]
• to the vacuum hose fittings
on the carburetors.
Special Tool - Vacuum Gauge KEK-55-5: 57001-1369

PERIODIC MAINTENANCE 2-19
Periodic Maintenance Procedures
the engine and let it idle to measure the carburetor
• Start
intake vacuum.
If the intake vacuum difference between the two cylinders
exceeds the limit, adjust the synchronization.
Engine Vacuum Synchronization
Less than 2.7 kPa (2 cmHg) difference between both
cylinders

the adjusting screw [A] to synchronize the carbure• Turn
tor.



If the carburetor synchronization cannot be obtained by
using the adjusting screw, check for dirt or blockage, and
then check the pilot screw settings.
Check the Carburetor Synchronization again.

NOTE

○Do not turn the pilot screws carelessly during carburetor
synchronization. You may cause poor running at low
engine speed.
Idle Speed Inspection

the engine and warm it up thoroughly.
• Start
With
the
• [A]. engine idling, turn the handlebar to both sides
If handlebar movement changes the idle speed, the
throttle cables may be improperly adjusted or incorrectly
routed or damaged. Be sure to correct any of these
conditions before riding (see Throttle Control System
Inspection or Cable, Wire, and Hose Routing section in
the Appendix chapter).

WARNING
Operation with improperly adjusted, incorrectly
routed or damaged cables could result in an unsafe
riding Condition. Follow the service manual to be
make sure to correct any of these conditions.
idle speed.
• Check
If the idle speed is out of the specified range, adjust it.
Idle Speed
Standard:

1 300 ±50 r/min (rpm)

Idle Speed Adjustment

the engine and warm it up thoroughly.
• Start
Turn
the
screw [A] until the idle speed is correct.
•○Open andadjusting
close the throttle a few times to make sure that
the idle speed is within the specified range. Readjust if
necessary.

2-20 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Fuel Hose Inspection (fuel leak, damage,
installation condition)

○The fuel hose is designed to be used throughout the motorcycle’s life without any maintenance. However, if the
motorcycle is not properly handled, the high pressure inside the fuel line can cause fuel to leak [A] or the hose to
burst. Remove the fuel tank (see Fuel Tank Removal in
the Fuel System chapter) and check the fuel hose.
Replace the fuel hose if any fraying, cracks [B], bulges [C]
or ozone cracks [D] are noticed.
that the hose [A] are securely connected and
• Check
clamps [B] are tightened correctly.
that the hoses are routed according to Cable, Wire,
• Check
and Hose Routing section in the Appendix chapter.
Replace the hose if it has been sharply bent or kinked.

Evaporative Emission Control System (CAL Model)
Evaporative Emission Control System Inspection
the canister as follows.
•○Inspect
Remove:

Left Lower Fairing (see Lower Fairing Removal in the
Frame chapter)
○Remove the canister [A], and disconnect the hoses from
the canister.
○Visually inspect the canister for cracks or other damage.
If the canister has any cracks or bad damage, replace it
with a new one.

NOTE

○The canister is designed to work well through the motorcycle’s life without any maintenance if it is used under
normal conditions.

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