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KX250F

Quick Reference Guide

KX250F

Motorcycle

Service Manual

All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Quality Assurance Department/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 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.

LIST OF ABBREVIATIONS

Foreword

NOTE

○This note symbol indicates points of particular interest for more efficient and convenient operation.

•Indicatesdone. a procedural step or work to be ○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

1-2 GENERAL INFORMATION

Before Servicing

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

Especially note the following:

Edges of Parts

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

Solvent

Use a high 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.

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.

GENERAL INFORMATION 1-3

Before Servicing

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 or cotter pins must be replaced with new ones whenever disassembled.

Assembly Order

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

Tightening Sequence

Bolts, nuts, or screws must be tightened according to the specified sequence to prevent case warpage or deformation which can lead to malfunction. If the specified tightening sequence is not indicated, tighten the fasteners alternating diagonally.

1-4 GENERAL INFORMATION

Before Servicing

Tightening Torque

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

Often, the tightening sequence is followed twice-initial tightening and final tightening with torque wrench.

Force

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

Gasket, Oring

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

Liquid Gasket, Locking Agent

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

Press

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

GENERAL INFORMATION 1-5

Before Servicing

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.

Circlips, Cotter Pins

Replace circlips or cotter pins that were removed with new ones. Install the circlip with its sharp edge facing outward and its chamfered side facing inward to prevent the clip from being pushed out of its groove when loaded. Take care not to open the clip excessively when installing to prevent deformation.

Lubrication

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

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).

1-6 GENERAL INFORMATION

Before Servicing

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.

GENERAL INFORMATION 1-7

Model Identification

KX250–N1 Left Side View

KX250–N1 Right Side View

1-8 GENERAL INFORMATION

General Specifications

GENERAL INFORMATION 1-9

General Specifications

1-10 GENERAL INFORMATION

Unit Conversion Table

Units of Temperature:

2-2 PERIODIC MAINTENANCE

Periodic Maintenance Chart

The maintenance must be done in accordance with this chart to keep the motorcycle in good running condition.

PERIODIC MAINTENANCE 2-3

Periodic Maintenance Chart

2-4 PERIODIC MAINTENANCE

Torque and Locking Agent

PERIODIC MAINTENANCE 2-5

Torque and Locking Agent

2-6 PERIODIC MAINTENANCE

Torque and Locking Agent

PERIODIC MAINTENANCE 2-7

Torque and Locking Agent

Basic Torque for General Fasteners

2-8 PERIODIC MAINTENANCE

Specifications

PERIODIC MAINTENANCE 2-9

Specifications

Spark Plug Wrench, M16 : 57001–1262

PERIODIC MAINTENANCE 2-11

Periodic Maintenance Procedures

Fuel System

Fuel Hose and Connection Inspection

○The fuel hoses are designed to be used throughout the motorcycle’s life without any maintenance, however, if the motorcycle is not properly handled, the inside the fuel line

•can cause fuel to leak [A] or the hose to burst. Check the fuel hose.

Replace the fuel hose if any fraying, cracks [B] or bulges [C] are noticed.

•Check that the hose [A] are securely connected and

•clamps [B] are tightened correctly.

When installing, route the hose according to Cable, Wire,

•and Hose Routing section in the Appendix chapter. When installing the fuel hose, avoid sharp bending, kinking, flattening or twisting, and route the fuel hose with a minimum of bending so that the fuel flow will not be obstructed.

Replace the hose if it has been sharply bent or kinked.

Throttle• Grip Free Play Inspection

Check throttle grip free play [B] by lightly turning the throttle grip [A] back and forth.

If the free play is improper, adjust the throttle cable.

•Check that the throttle grip moves smoothly from full open to close, and the throttle closes quickly and completely in all steering positions by the return spring.

If the throttle grip does not return properly, check the throttle cable routing, grip free play, and cable damage. Then

•lubricate the throttle cable.

Run the engine at the idle speed, and turn the handlebar all the way to the right and left to ensure that the idle speed does not change.

If the idle speed increase, check the throttle cable free play and the cable routing.

Throttle• Grip Free Play Adjustment

Loosen the locknuts [A] [B] at the upper end of the throttle

•cable.

Screw both throttle cable adjuster [C] [D] to give the throt-

•tle grip plenty of play.

Turn out the decelerator adjuster [C] until there is no play

•when the throttle grip is completely closed.

•Tighten the locknut [A].

Turn the accelerator cable adjuster [D] until 2 3 mm

•(0.08 0.12 in.) of throttle grip play is obtained. Tighten the locknut [B].

Operation with an improperly adjusted, incorrectly routed, or damaged cable could result in an unsafe riding condition.

PERIODIC MAINTENANCE 2-13

Periodic Maintenance Procedures

•Check the idle speed, using the engine revolution tester [A] for high accuracy.

If the idle speed is out of specified range, adjust it.

Idle• Speed Adjustment

First, turn in the air screw [A] using the pilot screw adjuster [A], until it seats lightly, and back it out the specified number of turns. (see specifications in the Fuel System chapter)

•Start the engine and warm it up thoroughly.

•Turn the idle adjusting screw [B] until the idle speed is correct.

To increase idle speed [C]

• To decrease idle speed [D]

Open and close the throttle a few times to make sure that the idle speed is with in the specified range. Readjust if necessary.

Air Cleaner Element Cleaning and Inspection

NOTE

○In dusty areas, the element should be cleaned more frequently than recommended interval.

○After riding through rain or on muddy roads, the element should be cleaned immediately.

○Since repeated cleaning opens the pores of the element, replace it with a new one in accordance with the Periodic Maintenance Chart. Also, if there is a break in the element material or any other damage to the element, replace the element with a new one.

WARNING

Clean the element 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. Because of the danger of highly flammable liquids, do not use gasoline or a low flash-point solvent to clean the element.

2-14 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

•Remove:

Seat (see Frame chapter)

Wing Bolt [A]

• Air Cleaner Element [B]

Stuff a clean, lint-free towel into the carburetor so no dirt

•is allowed to enter the carburetor.

Wipe out the inside of the air cleaner housing with a clean damp towel.

CAUTION

Check inside of the inlet tract and carburetor for dirt. If dirt is present, clean the intake tract and carburetor thoroughly. You may also need to replace the element and seal the housing and inlet tract.

•Separate the element [A] from the frame [B].

•Clean the element [A] in a bath of a high-flash-point solvent using a soft bristle brush.

•Squeeze it dry in a clean towel [A]. Do not wring the ele-

•ment 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.

•Assemble the element.

Remove the towel from the carburetor.

NOTE

○Remove the radiator cap in two steps. First turn the cap counterclockwise to the first stop and wait there for a few seconds. Then push down and turn it further in the same direction and remove the cap.

PERIODIC MAINTENANCE 2-15

Periodic Maintenance Procedures

•Apply grease to all connections and screw holes in the air

•cleaner housing and intake tract.

Install the element onto its frame, and coat the element lip and lip seat with a thick layer of all-purpose grease to assure a compete seal.

•Install the air cleaner element so that its tab faces [A] upward and its projections [B] align with the holes [C] in

•the housing.

•Tighten the wing bolt [D] Install the seat.

Cooling System

WARNING

To avoid burns, do not remove the radiator cap or try to change the coolant when the engine is still hot. Wait until it cools down.

Coolant on tires will make them slippery and can cause an accident and injury. Immediately wash away any coolant that spills on the wheels.

Since coolant is harmful to the human body, do not use for drinking.

Coolant Level Inspection

NOTE

○Check the level when the engine is cold (room or ambi-

•Lean the motorcycle slightly to the right until the radiator cap is level to the ground so that the radiator cap is located uppermost in order to exhaust the air accumulated in the

•radiator.

Remove the radiator cap [A].ent temperature).

2-16 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

•Check the coolant level. The coolant level [A] should be at the bottom of the filler neck [B].

If the coolant level is low, add coolant through the filler opening to the bottom of the filler neck. Install the cap.

Recommended coolant:

Permanent type of antifreeze (soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators)

Water and coolant mixture ratio: 1:1 (water 50 %, Coolant 50 %)

Total amount:

1.2 L (1.27 US qt.)

Coolant• Deterioration Inspection

Visually inspect the coolant.

If whitish cotton-like wafts are observed, aluminum parts in the cooling system are corroded. 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 a cooling system leak. It may be caused by exhaust gas leaking into the cooling system.

Radiator Hoses and Connections Inspection

○The high pressure inside the radiator hose [A] can cause coolant to leak [B] or the hose to burst if the line is not properly maintained. Visually inspect the hoses for signs of deterioration. Squeeze the hoses. A hose should not be hard and brittle, nor should it be soft or swollen.

Replace the hose if any fraying, cracks [C] or bulges [D]

•are noticed.

Check that the hoses are securely connected and clamps are tightened correctly.

Torque — Radiator Hose Clamp Screws: 1.5 N·m (0.15 kgf·m, 13 in·lb)

PERIODIC MAINTENANCE 2-17

Periodic Maintenance Procedures

Engine Top End

Valve Clearance Inspection

NOTE

○Valve clearance must be checked and adjusted when the engine is cold (at room temperature).

•Remove:Cylinder Head Cover (see Engine Top End chapter) Timing Inspection Cap [A]

Flywheel Cap [B]

•Fist, bring the piston to the top-dead-center of its compression stroke to inspect the valve clearance (the position at the end of the compression stroke), when the cam lobe faces outside of the camshaft.

○Place a wrench over the flywheel nut and turn it counterclockwise to align the TDC mark [A] with the center of the grove [B] of the inspection hole.

•Using a thickness gauge [A], measure the clearance between each cam lob and valve lifter, for all four valves.

○For the purpose of adjusting the valve clearances, record the measured values.

If the valve clearance is not within the specified range, adjust it.

Valve• Clearance Adjustment

Remove the camshaft caps [A] (see Engine Top End

•chapter).

•Remove the camshafts [B] (see Engine Top End chapter).

•Remove the valve lifters [C] of the applicable valve. Remove the shim [D] from the top of the spring retainer.

2-18 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

NOTE

○Mark and record the locations of the valve lifters and shims so that they can be reinstalled in their original positions.

•Clean the shim to remove any dust or oil.

•Measure the thickness of the removed shim [A].

•Select a new shim thickness calculation as follows. A = (B – C) + D

[A] Replace Shim Thickness

[B] Measured Valve Clearance

[C] Specified Valve Clearance

[D] Present Shim Thickness

Example:

(0.31 mm – 0.10 0.15 mm) + 2.60 mm = 2.81 2.76 mm

○Exchange the shims for the 2.775 or 2.800 size shim.

CAUTION

Don’t use the shims for another models. This could cause wear of the valve stem end, and valve stem damage.

Cylinder Head Warp

Service Limit:

0.05 mm (0.0020 in.)

PERIODIC MAINTENANCE 2-19

Periodic Maintenance Procedures

CAUTION

Be sure to remeasure the clearance after selecting a shim. The clearance can be out of the specified range because of the shim tolerance.

○If there is no valve clearance, use a shim that is a few sizes smaller, and remeasure the valve clearance.

•When installing the shim, face the marked side [A] toward the valve lifter [B]. At this time, apply engine oil to the shim or the valve lifter to keep the shim in place during camshaft installation.

CAUTION

Do not put shim stock under the shim. This may cause the shim to pop out at high rpm, causing extensive engine damage.

Do not grind the shim. This may cause it to fracture, causing extensive engine damage.

•Apply engine oil to the valve lifter surface and install the

•lifter.

•Install the camshaft (see Engine Top End chapter).

•Recheck the valve clearance and readjust if necessary. Install the cylinder head cover (see Engine Top End chapter), timing inspection cap, and the flywheel cap.

Torque — Timing Inspection Cap: 4 N·m (0.4 kgf·m, 35 in·lb) Flywheel Cap: 5 N·m (0.5 kgf·m, 43 in·lb)

Cylinder• Head Warp Inspection

•Remove the cylinder head (see Engine Top End chapter). Lay a straightedge [A] across the lower surface of the head at several different points, and measure warp by inserting 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 surface is badly damaged.

•Remove the valves (see Engine Top End chapter).

•Space the carbon out of the combustion chamber and

•exhaust port with a scraper [A] or a suitable tool.

•Clean the cylinder head, using high-flash point solvent. Blow out any particles which may obstruct the oil passage

•in the cylinder head using compressed air. Install the valves (see Valve Installation).

PERIODIC MAINTENANCE 2-21

Periodic Maintenance Procedures

Exhaust• System

The exhaust system, in particular the silencer, is designed to reduce exhaust noise and conduct the exhaust gases away from the rider while minimizing power loss. If carbon has built up inside the silencer, exhaust efficiency is

•reduced, causing engine performance to drop.

If the silencer is badly damaged, dented, cracked or rusted, replace it. Replace the silencer packing if the exhaust noise becomes too loud or engine performance drops.

Silencer• Packing Change

•Remove the silencer (see Engine Top End chapter). Remove the inner pipe mounting bolts [A].

•Tap the bracket [A] of the silencer body with a plastic mallet [B] to separate from the inner pipe.

•Pull off the old silencer packing, and install the new silencer packing [A] into the silencer.

•Install the end [A] of the inner pipe [B] to the baffle [C].

•Apply a non-permanent locking agent to the pipe mount-

•ing bolts.

Install the silencer body.

2-22 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

•Apply silicone sealant to the circumference [A] of the si-

•lencer pipe.

Install the muffler (see Engine Top End chapter).

Engine Right Side

WARNING

To avoid a serious burn, never touch the hot engine or exhaust chamber during clutch adjustment.

Clutch• Lever Free Play Adjustment

•Slide the clutch lever dust cover out of place.

•Loosen the knurled locknut [A].

Turn the adjuster [B] so that the clutch lever will have 2 3 mm (0.08 0.12 in.) of play [C].

NOTE

○Be sure that the outer cable end at the clutch lever is fully seated in the adjuster at the clutch lever, or it could slip into the place later, creating enough cable play to prevent clutch disengagement.

•If it cannot be done. Turn the adjuster [A] so that 5 6

•mm (0.20 0.24 in.) [B] of threads are visible. Tighten the locknut.

PERIODIC MAINTENANCE 2-23

Periodic Maintenance Procedures

•Slide the adjuster cover [A] back.

•If it cannot be done, loosen the locknut [B] at the middle of the clutch cable, and turn the adjusting nut [C] so that

•clutch lever has 2 3 mm (0.08 0.12 in.) of play.

After the adjustment is made, tighten the locknut, and start the engine and check that the clutch does not slip and that it release properly.

Friction• and Steel Plates Inspection

•Remove the clutch plates (see Engine Right Side chapter) Visually inspect the friction and steel plates to see if they show any signs of seizure, or uneven wear.

If any plates show signs of damage, replace the friction

•plates and steel plates as a set.

Measure the thickness [A] of the friction and steel plates with vernier calipers.

If they have worn past the service limit, replace them with new ones.

•Place each friction plate or steel plate on a surface plate, and measure the gap between the surface plate [A] and each friction plate or steel plate [B] with a thickness gauge [C]. The gap is the amount of friction or steel plate warp. If any plate is warped over the service limit, replace it with a new one.

Engine Lubrication System

Engine• Oil Change

Warm up the engine thoroughly so that the oil will pick up

•any sediment and drain easily. Then stop the engine.

•Place an oil pan beneath the engine.

•Remove the oil filler cap [A].

Remove the drain plug [B] and drain the engine oil in the oil filter oil chamber.

2-24 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

•Remove the engine oil drain plugs on the bottom of the engine, and let the oil drain completely.

Drain Plug (for crank room oil sump) [A] Drain Plug (for transmission oil sump) [B]

NOTE

○Hold the motorcycle upright so that the oil may drain completely.

•Replace the gaskets at the drain plugs with a new one.

•After the oil has completely drained out, install the drain plugs with the gaskets, and tighten them.

1.35 L (1.43 US qt.) (when filter is remove)

1.5 L (1.6 US qt.) (when engine is completely dry)

NOTE

○The oil viscosity may need to be changed to accommodate atmospheric conditions in your riding area.

•Checkter). the oil level (see Engine Lubrication System chap-

Oil• Filter Change

Drain:

Engine oil (see Engine Oil change)

• Coolant (see Coolant change)

Unscrew the water pipe bolt [A] and pull out the water pipe

•end [B].

Unscrew the water pump cover bolts [C].

PERIODIC MAINTENANCE 2-25

Periodic Maintenance Procedures

•Using the pry point [A], remove the water pump cover [B].

•Remove the oil filter [A].

•Replace the oil filter with a new one.

•Apply grease to the grommet.

•Be sure to install the filter with the grommet [A] facing inside as shown.

CAUTION

Inside–out installation stop oil flow, causing engine seizure.

•Install the spring [A] and dowel pins [B].

•Replace the pump cover gasket [C] with a new one.

•Apply grease to the pump cover gasket.

Install the water pump cover and water pipe (see Cooling

•System chapter). Tighten:

○Apply a non-permanent locking agent to two cover bolts (see Cooling System chapter).

○Tighten two cover bolt with the washer (see Cooling System chapter).

Torque — Water Pump Cover Bolts : 9.8 N·m (1.0 kgf·m, 87 in·lb)

Water Pump Cover Bolts (with washer) : 7.0 N·m (0.7 kgf·m, 61 in·lb)

Coolant Drain Plug : 7.0 N·m (0.7 kgf·m, 61 in·lb)

• Water Pipe Bolt : 9.8 N·m (1.0 kgf·m, 87 in·lb)

Pour in the specified type and amount of oil (see Engine

Oil Change) and coolant (see Cooling System chapter).

2-26 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Oil• Screen Cleaning

Split the crankcase (see Crankshaft/Transmission chap-

•ter).

•Remove the oil screen [A].

Clean the oil screens with a high-flash point solvent and remove any particles stuck to them.

WARNING

Clean 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 solvent.

•Check the screens [A] carefully for any damage, holes, broke wires gasket pulling off.

•If the screen is damaged, replace it. Install:

Oil Screen (see Crankshaft/Transmission chapter) Crankcase (see Crankshaft/Transmission chapter)

Breather• Hose Inspection

Be certain that the breather hose are routed without being flattened or kinked and is connected correctly.

•If it is not, correct it.

Inspect the breather hose [A] for damage or sings of deterioration.

○This hose should not be hard and brittle, nor should be soft swollen.

Replace it if any cracks or swelling is noticed.

Crankshaft/Transmission

Crankshaft Inspection

Connecting• Rod Big End Radial Clearance

Set the crankshaft on V blocks, and place a dial gauge [A]

•against the connecting rod big end.

Push [B] the connecting rod first towards the gauge and then in the opposite direction. The difference between two gauge readings is the radial clearance.

If the radial clearance exceeds the service limit, crankshaft should be either replaced or disassembled and crankpin, needle bearing, and connecting rod big end examined for wear.

PERIODIC MAINTENANCE 2-27

Periodic Maintenance Procedures

Connecting• Rod Big End Side Clearance

Measure the connecting rod big end side clearance [A].

If the clearance exceeds the service limit, replace the crankshaft assembly.

Crankshaft• Runout

Set the crankshaft in a flywheel alignment jig or on V blocks, and place a dial gauge as shown and turn the crankshaft slowly. The maximum difference in gauge reading is the crankshaft runout.

If the runout at either point exceeds the service limit, replace the crankshaft assembly with a new one or align the crankshaft so that the runout falls within the service limit. 8 mm (0.354 in.) [A]

•First correct the horizontal misalignment by striking the projecting crank half [A] with a plastic, soft lead, or brass

•hammer as shown.

Recheck the runout with a dial gauge and repeat the process until the runout falls within the service limit.

2-28 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

•Next, correct the vertical misalignment by either driving a wedge [A] in between the crank halves or by squeezing them in a vice, depending on the nature of the misalignment.

CAUTION

Do not hammer the crank half at the point [B].

If flywheel misalignment cannot be corrected by the above method, replace the crankpin or the crankshaft itself.

Connecting Rod Big End Seizure

In case of serious seizure with damaged flywheels, the crankshaft must be replaced.

In case of less serious damage, disassemble the crankshaft and replace the crankpin, needle bearing, and connecting rod.

Wheel/Tires

Air• Pressure Inspection/Adjustment

Using tire air pressure gauge [A], measure the tire pressure when the tires are cold.

Adjust the tire air pressure to suit track conditions and rider preference, but do not stray too far from the recommended pressure.