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

Some models may need supplemental manuals which have blue titles. Use the base manual for everything not contained in the supplement if your model or year requires a supplement.

This manual is fully searchable, just hold down the control key and the F key to search on any word.

I do apologize for any confusion the supplements may cause.

This is the way Kawasaki originally set up these manuals.

I have attempted to organize and improve them as much as possible.

If you bought this manual from any other seller, they are reselling my work.

Please leave them negative feedback & email me at sales@midwestmanuals.com .

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www.midwestmanuals.com Kawasaki KLF220 BAYOU All Terrain Vehicle Service Manual

Kawasaki

KLF220

BAYOU

www.midwestmanuals.com Kawasaki KLF220 BAYOU All Terrain Vehicle Service Manual

All Terrain Vehicle Service Manual

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This quick reference guide will assist you in locating a desired topic or pro- cedure. -Bend the pages back to match the black tab of the desired chapter num- ber with the black tab on the edge at each table of contents page. -Refer to the sectional table of contents fo r the exact pages to locate the spe- cific topic required.

Quick Reference Guide

General Information 1 2 End 3 4 5 ine Removal/Installation 6 ine Bottom EndlTransmission 7
General Information
1
2
End
3
4
5
ine Removal/Installation
6
ine Bottom EndlTransmission
7
8
9
10
11
12
13
14
15
nt - 1995 Late - 1997 Models
16
lement - 1998 - 1999 Models 17
lement - 2000 - 2002 Models 18

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www.midwestmanuals.com KaVlasaki K L F 2 2 0 BAYOU All Terrain Vehicle Service Manual

KaVlasaki

KLF220

BAYOU

All Terrain Vehicle Service Manual

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LIST OF ABBREV IATIONS

 

A

ampere(s)

Ib

pound(s)

ABOC

after bottom dead center

m

meter(s)

AC

alternating current

min

minute(s)

ATOC

after top dead center

N

newton(s)

BBOC

before bottom dead center

Pa

pascal(s)

BOC

bottom dead center

PS

horsepower

BTDC

before top dead center

psi

pound (s) per square inch

°C

degree(s) Celsius

r

revolution

DC

direct current

rpm

revolution(s) per minute

F

farad(s)

TOC

top dead center

OF

degree(s) Fahrenheit

TIR

total indicator reading

ft

foot, feet

V

volt(s)

9

gram(s)

W

watt(s)

h

hour(s)

n

ohm(s)

L

liter(s)

 
W watt(s) h hour(s) n ohm(s) L liter(s)   Read OWNER'S MANUAL before operating

Read OWNER'S MANUAL before operating

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•••

PLEASE DO NOT TAMPER WITH NOISE CONTROL SYSTEM

IUS Model only I

To minimize the noise emissions from this product, Kawasaki has equipped it with

They are designed to give optimum per- Please do not remove these systems, or alter

an increase in noise level.

effective intake and exhaust silencing systems.

formance while maintaining a low noise level.

them in anY which results in

.•

.,r,;

*:

::r.:

~t

!\~:

~:

~!

!\o::;

~

•• " •• :."~;

"

~;Ko$~ti:.$~~~p.:~~~~:~'f.U.'f.U.'f.!-!~~:;w.~~~~'f U.~~~~

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:>~:>:;:;:.'~;~;

:~

This warning may apply to any of the following components or any assembly containing one or

more of these components:-

WARNING CONTAINS ASBESTOS Breathing asbestos dun is dlngerous to health Follow safety instructions Brake Shoes

WARNING

CONTAINS

ASBESTOS

Breathing asbestos

dun is dlngerous to health

Follow safety

instructions

Brake Shoes or Pads Clutch Friction Material Gaskets

Insulators

SAFETY INSTRUCTIONS

e{)perate

if

possible out

of doors or

in

a well

ventilated place.

.Preferably

use

hand

tools

or

low speed tools

equipped, if necessary. with an appropriate dust

extraction facility.

If high speed tools are used,

they should always be so equipped.

elf possible, dampen before cutting or drilling.

-Dampen

dust

and

place

it

in properly closed

receptacle and dispose of it safely.

~~;

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Foreword

This manual is designed primarily for use by trained mechanics in a properly equipped shop. However, it contains enough detail and basic in- formation to make it useful to the owner who de- sires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop proce- dures must be understood in order to carry out maintenance and repair satisfactorily. When- ever the owner has insufficient experience or doubts his ability to do the work, all adjust- ments, maintenance, and repair should be car- ried out only by qualified mechanics. In order to perform the work efficiently and to avoid costly mistakes, read the text, thor- oughly familiarize yourself with the procedures before starting work, and then do the work care- fully 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 ad- versely 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.

non-scheduled

problems and

• Be

alert for

maintenance.

• Use proper tools and genuine Kawasaki Vehi- cle parts. Special tools, gauges, and testers that are necessary when servicing Kawasaki vehicles are introduced by the Service Man- ual. Genuine parts provided as spare parts are listed in the Parts Catalog.

• Follow the procedures in this manual care- fully. Don't take shortcuts.

• Remember to keep complete records of main- tenance 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 Ta- ble of Contents, For example, if you want ignition coil informa- tion , use the Quick Reference Guide to locate the Electrical System chapter. Then , use the Table of Contents on the first page of the chap- ter to find the Ignition Coil section. Whenever you see these WARNING and CAUTION symbols, heed their instructions! Always follow safe operating and maintenance practices.

A WARNING

This warning symbol identifies special instructions or procedures which, if not correctly followed, could result in per- sonal injury, or loss of life.

special instructions or procedures which, if not correctly followed, could result in per- sonal injury, or

CAUTiON

This caution symbol identifies special instructions or procedures which, if not strictly observed, could result in dam- age to or destruction of equipment.

instructions or procedures which, if not strictly observed, could result in dam- age to or destruction

This manual contains four more symbols (in addition to WARNING and CAUTION) which will help you distinguish different types of informa- tion.

NOTE

o This note symbol indicates points of par- ticular interest for more efficient and con - venient operation.

.Indicates a procedural step or work to be done, Olndicates a procedural sub-step or how to do the work of the procedural step it follows. also precedes the text of a NOTE,

step or what action to

take based on the results of the test or inspec- tion in the procedural step or sub-step it fol- lows. 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 spec- ified tightening torque, oil, grease or a locking agent during assembly.

It

* Indicates a conditional

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GENERAL

INFORMATION

General Information

Table of Contents

1-1

INFORMATION General Information Table of Contents 1-1 Before SelVicing 1-2 Model Identification General
Before SelVicing 1-2 Model Identification General Specifications Periodic Maintenance Chart Torque and Locking Agent
Before SelVicing
1-2
Model Identification
General Specifications
Periodic Maintenance Chart
Torque and Locking Agent
Cable and Hamess Routing
1-4
1-5
:
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
• .
.
1-7
:
1-8
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
1-10

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1-2 GENERAL .INFORMATION

Before Servicing

Before starting to service a vehicle, careful reading of the applicable section is recommended to eliminate unnecessary work. Photographs, diagrams, notes, cautions, warnings, and detailed des- criptions have been included wherever necessary. Nevertheless, even a detailed account has limi- tations, a certain amount of basic knowledge is also required for successful work.

Especially note the following:

(1) Dirt

Any dirt entering the engine or other

parts will work as an abrasive and shorten the life of the vehicle. For the same reason , before installing a new part, clean off any dust or metal filings. (2) Battery Ground Remove the ground (-) lead 'from the battery before performing any disassembly operations

Before removal

and disassembly, clean the vehicle.

on the vehicle. This prevents: '

(a)

the possibility of accidentally turning the eng ine over wh ile partially disassembled .

(b)

sparks at electric~1 connections which will occur when they are disconnected.

(c)

damage to electrical parts.

(3)

Tighten ing Sequence

Generally, when installing a part with several bolts, nuts, or screws, start them all in their holes and tighten them to a snug fit . Then tighten them evenly in a cross pattern . Th is is to avoid distortion of the part and/ or causing gas or oil leakage. Conversely when loosening the bolts, nuts, or screws, first loosen all of them by about a quarter of turn and then remove them. Where there is a tightening sequence indication in this Service Manual, the bolts, nuts, or screws must be tightened in the order and method indicated. (4) Torque

When torque values are given in this Service Manual, use them . Eithe r' too little or too much torque may lead to serious damage. Use a good quality, reliable torque wrench . (5) Force Common sense should dictate how much force is necessary in assembly and disassembly. If a part seems especially difficult to remove or install, stop and examine what may be causing the problem. Whenever tapping is necessary, tap lightly using a wooden or plastic-faced mallet. Use an impact driver for screws (particularly for the removal of screws held by a locking agent) in order to avoid damaging the screw heads. , (6) Edges Watch for sharp edges, especially during major engine disassembly and assembly. Protect your hands w ith gloves or a piece of thick cloth when lifting the engine or turning it over. (7) High-Flash Point Solvent A high-flash point solvent is recommended to reduce fire danger. A commercial solvent com- monly available in North America is Stoddard solvent (generic name) . Always follow manufac- turer and container directions regarding the use of any solvent. (8) Gasket, O-Ring Do not reuse a gasket or O-ring once it has been in service. The mating surfaces around the gasket should be free of foreign matter and perfectly smooth to avoid oil or compression leaks. (9) Liquid Gasket, Non-Permanent Locking Agent Follow manufacturer's directions for cleaning and preparing surfaces where these compounds will be used. Apply sparingly. Excessive amounts may block engine oil passages and cause serious damage. An example of a non-permanent locking agent commonly available in North

America is Loctite

Lock'n Seal (Blue) .

(10) Press 'A part installed using a press or driver, such as a wheel bearing, should first be coated with oil on its outer or inner circumference so that it will go into place smoothly . (11) Ball Bearing When installing a ball bearing, the bearing race which is affected by friction should be pushed by a suitable driver. This prevents severe stress on the balls and races, and prevents races and balls from being dented . Press a ball bearing until it stops at the stop in the hole or on the shaft.

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GENERAL INFORMATION

1-3

(12) Oil Seal and Grease 'Seal Replace any oil or grease seals that were removed with new ones, as removal generally damages seals. When pressing in a seal which has manufacturer's marks, press it in with the marks facing out. Seals should be pressed into place using a suitable driver, which contacts evenly with the side of seal , until the face of the seal is even with the end of the hole. (13) Seal Guide A seal guide is required for certain oil or grease seals during installation to avoid damage to the seal lips. Before a shaft passes through a seal, apply a little high temperature grease on the lips to reduce rubber to metal friction. (14) Circlip, Retaining Ring Replace any circlips and .retaining rings that were removed with new ones, as removal weakens and deforms them. When installing circlips and retaining rings, take care to compress or expand them only enough to install them and no more. (15) Lubrication Engine wear is generally at its maximum while the e~gine is warming up and 'before all the rubbing surfaces have an adequate lubricative film. During assembly, oil or grease (whichever is more suitable) should be applied to any rubbing surface which has lost its lubricative film. Old grease and dirty oil should be cleaned off. Deteriorated grease has lost its lubriCative quality and may contain abrasive foreign particles. Don't use just any oil or grease. Some oils and greases in particular should be used only in certain applications and may be harmful if used in an application for which they are not intended . This ' manual makes reference to molybdenum disulfide grease (MoS,) in the assembly of certain engine and chassis parts_ Always check manufacturer recommendations before using such special lubricants. (16) Electrical Wires All the electrical wires are either single-color or two-color and, with only a few exceptions, must be connected to wires of the same color. On any of the two-color wires there is a greater amount of one color and a lesser amount of a second color, so a two-color wire is identified by first the primary color and thim the secondary color. For example, a yellow wire with thin red stripes is referred to as a ·yellow/red" wire; it would be a "red/ yellow" wire if the colors were reversed to make red the main color.

Wire (cross-section)

Name of Wire Color

Red  

Red

 

Wire strands

Yellow

Yellow/red

Red

(17) Replacement Parts When there is a replacement instruction, replace these parts with new ones every time they are removed. These replacement parts will be damaged or lose their original function once removed. (18) Inspection

When parts have been disassembled, visually inspect these parts for the following conditions or other damage. If there is any doubt as to the condition of them , replace them with new ones.

Abrasion

Crack

Hardening

Warp

Bent

Dent .

Scratch

Wear

Color change

Deterioration

Seizure

(19) Specifications Specification tenms are defined as follows. "Standards" show dimensions or performances which brand-new parts or systems have. "Service limits" indicate the usable limits. If the measurement shows excessive wear or dete- riorated performance, replace the damaged parts.

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1-4 GENERAL

INFORMATION

Model Identification

KLF22G-A1 (US, Canadian Model)

I O N Model Identification KLF22G-A1 (US, Canadian Model) KLF22G-A2 (US, Canadian Model) KLF22G-A3 (US, Canadian

KLF22G-A2 (US, Canadian Model)

(US, Canadian Model) KLF22G-A2 (US, Canadian Model) KLF22G-A3 (US, Canadian Model) KLF220-A4/A5 (US, Canadian

KLF22G-A3 (US, Canadian Model)

(US, Canadian Model) KLF22G-A3 (US, Canadian Model) KLF220-A4/A5 (US, Canadian Model) KLF22G-A6 (US, Canadian

KLF220-A4/A5 (US, Canadian Model)

(US, Canadian Model) KLF220-A4/A5 (US, Canadian Model) KLF22G-A6 (US, Canadian Model) KLF220-A7 (US; Canadian

KLF22G-A6 (US, Canadian Model)

(US, Canadian Model) KLF22G-A6 (US, Canadian Model) KLF220-A7 (US; Canadian Model) KLF220-AS (US, Canadian

KLF220-A7 (US; Canadian Model)

(US, Canadian Model) KLF22G-A6 (US, Canadian Model) KLF220-A7 (US; Canadian Model) KLF220-AS (US, Canadian Modell

KLF220-AS (US, Canadian Modell

(US, Canadian Model) KLF22G-A6 (US, Canadian Model) KLF220-A7 (US; Canadian Model) KLF220-AS (US, Canadian Modell

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GENERAL

INFORMATION

'-5

General Specifications

 

KLF22Q.Al

A2

 

A3

 

A3A

A4

 

A5

A6/A7/A8

174

5 mm

«-

 

«-

 

«-

«-

«-

«-

1 120 mm, (UIIC) 1 020 mm

«-

«-

«-

1120mm

«-

«-

1 015 mm

1040 mm

«-

«-

«-

«-

1040 mm

   

1115mm

«-

 

«-

 

«-

«-

«-

«-

155mm

«-

«-

«-

«-

«-

«-

730

mm

«-

«-

«-

«-

«-

«-

183

kg, (UIIC) 181 kg

«-

<-,(UIIC) 183 kg

(A)

184 kg

183 kg,(A) <-

<-,(CIIEIIUK)

<-, (A)(EIIUK)

   

183.5 kg

185

kg

88.5

kg,(UIIC) 88 kg

«-

<-,(U)(C) 88 .5 kg

IA)89 kg

88.5 kg,(A) <-

«-

<-,IAIIEIIUKI89 kg

104.5

kg,( UIIC) 103 kg

«-

<-,(UIIC) 104.5 kg

(A)

104 kg

104.5 kg, (A)<-

<-,(C)( EII UK) 105 kg

<-, (Ail EIIU K)

   

106

kg

10 L

«-

 

«-

 

«-

«-

«-

«-

2.7m

«-

 

«-

 

«-

«-

«-

«-

4·stroke, SOHC, " cylinder

«-

«-

 

«-

«-

«-

«-

Air cooled

«-

«-

«-

«-

«-

«-

67.0

x 61.0 mm

«-

«-

«-

«-

«-

«-

215mL

«-

«-

«-

«-

«-

«-

9.3

«-

«-

«-

«-

«-

«-

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

«-

«-

«-

«-

«-

«-

17.7

N·m

(1. 8 k~m, 13.0 ft·1 b)

«-

«-

«-

«-

«-

«-

@6000 r/min (rpmI,IUI- Carburetor, MIKUNI VM24SS

«-

«-

«-

«-

«-

«-

Recoil and Electrical starter

«-

«-

«-

«-

«-

«-

Magneto COl

«-

«-

«-

«-

«-

«-

Electronically advanced

«-

«-

«-

«-

«-

«-

From 10' 8TDC@1 800 r/min (rpm) to 35' BTDC@4600r/min (rpm) NGK DR8ES (UIIA) NGK D8 EA

«-

«-

«-

«-

«-

«-

«-

«-

IA)NGK

NGK

NGK D8EA,

«-

   

D8EA

(C)(E){UK)

D8EA

DR8ES

 

35' 8TDC

«-

 

«-

 

«-

«-

«-

«-

57' ABDC

«-

«-

«-

«-

«-

«-

272'

«-

«-

«-

«-

«-

«-

54' BBDC

«-

«-

«-

«-

«-

«-

26' ATDC

«-

«-

«-

«-

«-

«-

260'

«-

«-

«-

«-

«-

«-

Forced lubrication (wet sump)

«-

«-

«-

«-

«-

«-

SE, SF or SG class SAE10W30, 10W40, 10W50, 20W40, or 20W50 2.0 L

«-

«-

«-

«-

«-

«-

«-

«-

«-

«-

«-

«-

«-

«-

«-

«-

«-

«-

Items

Dimensions:

Overall length

Overall width

Overall height

Wheelbase

Road clearance

Seat height

Dry weight

Curb weight:

Front

Rear

Fuel tank capacity

Performance:

Minimum turning radius

Engine:

Type

Cooling system

Bore and stroke Displacement Compression ratio

Maximum horsepower

Maximum torque

Carburetion system

Starting system

Ignition system

Timing advance

Ignition timing

Spark plug

Valve timing:

Inlet

Exhau st

Open

Close

Duration

Open

Close

Du ration

Lubrication system

En gine oil:

Grade

Viscosity

Capacity

(U)

(A)

: USmodel Austral i an model

:

IC) : Canadian model (UK) : UK model

: European model

(Continued on next page.)

(E)

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'·6 GENERAL INFORMATION Items KLF220-A1 A2 A3 A3A I A4 A5 A61A71A8 Drive Train: Primary
'·6
GENERAL
INFORMATION
Items
KLF220-A1
A2
A3
A3A
I
A4
A5
A61A71A8
Drive Train:
Primary reduction system:
Type
Gear
~
~
~
~
~
~
Reduction ratio
3.450
(69/ 20)
~
~
~
~
~
~
Clutch type
We t multi disc and cent rifuga l
~
~
~
~
~
~
Transmission: Type
5-speed plus reverse, constant mesh,
~
~
~
~
~
~
return shift
Gear ratios: 1st
2.923
(38113)
~
~
~
~
~
~
2nd
1. 684
(32/19)
~
~
~
~
~
~
«-
3rd
1.173
(27/ 23)
~
~
~
~
~
4th
0.923
(24126)
~
~
~
~
~
~
5th
0.785
(22/28)
~
~
~
~
~
~
Reverse
3.115 (27113 x 33122)
~
~
~
~
~
~
Final dr ive system :
Type
Shaft
.~
~
~
~
~
~
Reduction ratio
Overall dr ive rat io
4.680
(1 B/ 15 x 39/ 10)
~
~
~
~
~
~
12.686 @Topgear
~
~
~
~
~
~
Final gear case oil:
Type
AP I GL· 5 Hypoid gear oil SAE90
(above 5' C. 41 ' F) or SAE 80 (below
5' C.4 1' F)
~
~
~
~
~
~
Capacity
0.2L
~
~
~
~
~
~
Frame:
Type
Double tubular
~
~
~
~
~
~
Caster (rake angle )
4'
~
~
~
~
~
~
Camber
3'
~
~
~
~
~
~
Toe-in
30mm
~
~
~
~
~
~
Tra il
17mm
~
~
~
~
~
~
Tread:
Front
764mm
~
~
~
<E-
~
~
Rear
776mm
~
~ <E-
~
~
~
Front t ire :
Type
Tubeless
<E-
<E-
<E-
~
~
~
Size
~
<E-
~
<E-
<E-
~
Rear tire:
Type
AT 21 x8-9
Tubeless
AT22x 10-10
<E-
<E-
~
~
~
~
Size
~
~
<E-
~ ~
~
Suspension:
Front:
Type
Independent swing arm
~
~
~
~ ~
<E-
Wheel travel
115mm
<E-
<E-
<E-
~
~
~
Rear :
Type
Torque tu be-link
<E-
~
<E-
~
~
~
Wheel travel
125mm
<E-
<E-
~
<E-
<E-
~
Brake type:
Front
Drum
<E-
~
~
<E-
<E-
~
Rear
Drum
<E-
~
~
~
~
~
Electrical Equipment:
12V 12Ah,
,
(A)1 2V
Ba ttery
12V12Ah
ICIIEIIUKI
<E-
~
~
~
14Ah
12V 14Ah
Type
Semi-sealed beam
<E-
<E-
Headlight:
~
~
~
~
Bulb
12V25125W x 2
12V8W x2
Single phase AC
<E-
~
<E-
~
~
~
<E-
<E-
Taillight
~
~
~
~
~
~
Magneto:
Type
<E-
<E-
<E-
~
Rated output
10
A@60 00r /min (rpm!.
14 V
~
~
~
<E-
~
<E-

Specifications are subject to change without notice, and may not apply to every country_

Periodic Maintenance Chart

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GENERAL

INFORMATION

1·7

The scheduled maintenance must be done in accordance with this chart to keep the vehicle in good running condition . The first service is vitally important and must not be neglected.

First Service Regular Service • = Clean, adjust, lubricate, tighten, or replace parts as necessary.
First Service
Regular Service
• = Clean, adjust, lubricate, tighten, or
replace parts as necessary.
Chassis
Brake wear - check*
Cable adjustments*
Battery - check
Steering play - check
General lubrication*
Nuts and bolts - tighten
Final gear case oil - change*
Engine
Air cleaner - service*
Clutch adjustment*
Valve clearance - check
Fuel system cleanliness -
Engine oil - change*
Oil filter - replace
Spark plug - clean and gap
Spark arrester - clean
check*

*Service more frequently when operated in mud, dust, or otehr harsh riding conditions.

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1-8 GENERAL

INFORMATION

Torque and Locking Agent

The following tables list the tightening torque for the major fasteners requiring use of a non-permanent locking agent or liquid gasket.

Letter used in the "Remarks" column means:

L

: Apply a non·permanent locking agent to the threads.

o

: Apply an oil to the threads and seated surface.

S

: Tighten

the .fasteners

following the

specified se-

quence.

St : Stake the fasteners to prevent loosening.

Use the basic torque table below for only the bolts and nuts which do not require a specific torque value. All of the values are for use with dry solvent-Gleaned threads.

Basic Torque for General Fasteners

Thread

 

Torque

 

dia. (mm)

 

N·m

 

kg·m

 

ft-Ib

5

3.4

-

4.9

0.35

-0 .50

30

-

43 in·lb

6

5.9

-7.8

0.60

-0.80

52

-

69 in·lb

8

14

-19

1.4-1.9

10.0 -

13.5

10

25

-

34

2.6

-

3.5

19.0 -

25

12

44-61

4.5

-6.2

 

33

-45

14

73

-98

7.4 -10.0

54

-72

16

115

-155

11.5

-16.0

83 -115

18

165

-

225

17.0 -

23

125

-165

20

225

-

325

23 -

33

165

-240

 

Fastener

 

Torque

Remarks

 

N-m

k!l-m

ft-Ib

Fuel System:

       

Carburetor Holder Bolts Engine Top End:

9.8

1.0

87

in-Ib

Cylinder Head Bolts (8 mm Dia.) (6 mm Dia.)

34

3.5

25

(*1)

9.8

1.0

87

in-Ib

(*1)

Camshaft Sprocket Bolt Valve Clearance Adjusting Screw Locknuts Camshaft Chain Guide Bolt Engine Left Side:

Starter Clutch Allen Bolts Recoil Starter Pulley Bolt Ratchet Cover Nut Engine Right Side:

Oil Pump Gear and Balancer Drive Gear Nut: KLF22Q.A 1 KLF22Q.A2 ~

34

3.5

25

0

12

1.2

104

in-Ib

8.8

0.9

78

in-Ib

34

3.5

25

L

59

6.0

43

12

1.2

104

in-Ib

83

8.5

61

125

13.0

94

Balancer Gear Nut:

KLF22Q.Al

78

8.0

58

0

KLF22Q.A2 ~

120

12.0

87

0

Clutch Spring Bolts Primary Clutch Hub Nut Secondary Clutch Hub Nut Oil Pipe Banjo Bolts Engine Removal/Installation:

Engine Mounting Bolts (8 mm Dia.) (10 mm Dia.)

12

1.2

104

in-Ib

78

8.0

58

0

78

8.0

58

0

15

1.5

11.0

26

2.7

19.5

34

3.5

25

Engine Bracket Bolts

26

2.7

19.5

(*1): See Cylinder Head Installation

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GENERAL

 

INFORMATION

1-9

   

Torque

 

Remarks

Fastener

N-m

kg-m

 

ft-Ib

Engine Bottom End/Transmission:

       

Oil Drain Plug Clutch Release Cam Pin Return Spring Pin Output Shaft Bearing Position Plate Screws Neutral and Reverse Switch Screws Crankcase Bolts Relief Valve Bearing Stopper Screw Wheels/Tires:

29

 

3.0

 

22

25

2.5

 

18.0

L

25

2.5

18.0

L

8.8

0.9

78

in-Ib

L

-

 

-

-

L

8.8

0.9

78

in-Ib

15

1.5

11

L

3.9

0.4

35

in-Ib

Wheel Nuts Final Drive:

34

3.5

25

S

Front Gear Case Bolts (8 mm Dia.) Drive Gear Nut: KLF22Q.A 1 KLF22Q.A2 - Oil Seal Housing Nuts Cam Damper Mounting Nut Driven Gear Shaft Nut Bearing Retainer: KLF22Q.Al KLF22Q.A2 - Final Gear Case Drain Bolt Speedometer Plug Pinion Gear Nut Ring Gear Nut Final Gear Case Fi lIer Cap Final Gear Case Cover Bolts Axle Shaft Pipe Bolts Propeller Shaft Housing Nuts Brakes:

25

2.5

 

18.0

(*2)

78

8.0

 

58

0

120

12.0

87

0

25

2.5

 

18.0

78

 

8.0

 

58

147

15

 

108

L

108

11

 

80

0

120

12

87

0

20

2.0

 

14.5

20

2.0

14.5

69

7.0

 

51

St

147

 

15

 

108

15

1.5

11.0

25

2.5

18.0

L

20

2.0

14.5

25

2.5

18.0

Rear Axle Nut Front Axle Nut Rear Brake Panel Bolts Front Brake Panel Bolts Suspension:

147

 

15

108

34

3.5

 

25

29

3.0

22

L

26

2.7

 

19.5

L

Front Suspension Arm Pivot Bolts Rear Suspension' Arm Bolts Shock Absorber Mounting Bolts Steering:

Stem Clamp Allen Bolts Stem Bottom End Nut Tie-rod End Nuts Tie-rod Adjusting Sleeve Locknuts Knuckle Arm Pivot Nuts Electrical System:

88

9.0

 

65

34

3.5

25

34

3.5

25

26

2.7

 

19.5

29

3.0

 

22

41

4.2

30

27

2.8

20

34

3.5

25

Spark Plug

20

2.0

 

14.5

(*2) : See Front Gear Case Installation

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·

Cable Routing

1. Main Harness

www.midwestmanuals.com · Cable Routing 1. Main Harness 2. Exciter Coil Leads 3. Pickup Coil Leads 4.

2. Exciter Coil Leads

3. Pickup Coil Leads

4. Charging Coil Leads (Yellow)

5. Neutral and Reverse Switch Leads

6. Battery Ground Cable

7. Starter Motor Cable

8. Head Light Leads

9. Accessory Leads

10. Connect to the CDI unit lead connectors.

.

o

Cl

m

Z

m

:0

~

Z

"TI

o

:0

3:

~

o

z

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www.midwestmanuals.com GENERAL INFORMATION 1-11 1. Throttle Cable 2. Choke Cable 3. Switch Housing Lead 4. Front

GENERAL

INFORMATION

1-11

1. Throttle Cable

2. Choke Cable

3. Switch Housing Lead

4. Front Brake Cable

5. Neutral and Reverse Indicator Lights

6. Coupler Cover

7. Taillight

3

Clamp

7

Indicator Lights 6. Coupler Cover 7. Taillight 3 Clamp 7 Through the clamp. 8. Front Brake

Through the clamp.

6. Coupler Cover 7. Taillight 3 Clamp 7 Through the clamp. 8. Front Brake Cable Equalizer

8.

Front Brake Cable Equalizer

9.

Reverse Cable

10.

Battery

11.

Battery Vent Hose

Clamp
Clamp

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1-12 GENERAL

INFORMATION

1
1

Clamp on the crankcase bolt.

Clamp on the

starter motor

mounting bolt.

1. Starter Motor

2. Engine

3. Fuel Tank

4. Carburetor Vent Hose

5. Breather Hose (for Engine)

6. Breather Hose (for Final Gear Case)

7. Breather Hose (for Rear Brake)

8. Rear Brake Cable

Hose (for Engine) 6. Breather Hose (for Final Gear Case) 7. Breather Hose (for Rear Brake)

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FUEL SYSTEM 2-'

Fuel System

Table of Contents

Exploded View.

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2-2

Specifications

2-3

. Throttle Case and Cable

Special Tools.

.

. Throttle Cable.Adjustment

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2-3

2-4

2-4

Throttle Case

2-4

Throttle Case Assembly/I nstallation

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2-5

Throttle Case Lubrication

 

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2-5

Choke Lever and Cable Choke Lever Removal.

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2-5

2-5

Choke

Carburetor.

. Lever Lubrication.

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Carburetor Air Screw

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2-6

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2-6

2-6

Idie spe'ed Adjustment

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2-6

Fuel Level

Inspection/Adjustment

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2-6

Carburetor Removal.

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2-7

. Carburetor Installation

2-8

Carburetor Disassembly

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2-8

Carburet~r Assembly

2-9

Carburetor Cleaning.

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2-9

Carbu retor

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2-9

Air Cleaner.

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. Air Cleaner Duct Installation Note

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2-10

2-10

Air Cleaner Element

2-10

Fuel Tank

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2-11

Fuel Tank Removalll nstallation

2-11

. . . . . . . . . . . . . . 2-11 Fuel

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2-2

FUEL

SYSTEM

Exploded View ···· ' ~ @ ~- ~~ ~~ @ ~'lG ~ ~ (jj) CO>
Exploded View ····
'
~
@
~- ~~
~~
@
~'lG
~
~
(jj)
CO>
~
1. Jet Needle
~
2. Air Screw
;@
3. Pilot Jet
. .
I
. /"1
4. Needle Jet
5. Main Jet
T1: 9.8 N-m (1.0 kg-m, 87 in-Ib}
G : Apply grease.
e ~,
~
.
'---
®-A

Specifications

www.midwestmanuals.com

FUEL

SYSTEM

2-3

Item Standard Th rottle Lever Free Play Carburetor: Make/Type Main Jet Main Air Jet Jet
Item
Standard
Th rottle Lever Free Play
Carburetor: Make/Type
Main Jet
Main Air Jet
Jet Needle
Needle Jet
Pilot Jet
Pilot Air Jet
AirScrew
Starter Jet
Service Fuel Level
Float Height
Air Cleaner Element Oil:
2-3mm
Mikuni!VM24SS
#115
4> 1_8
5GN46-2
0-0
#30
4> 1 .2
1% turns out
#45
5mm
21.8 mm
Grade
SE class
Viscosity
SAE30
Special Tool
Fuel Level Gauge: 57001-1017
1 .2 1% turns out #45 5mm 21.8 mm Grade SE class Viscosity SAE30 Special Tool

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2-4

FUEL SYSTEM

Th rottle Case and Cable

Throttle Cable Adjustment

e<:heck throttle lever free play.

Cable Adjustment e<:heck throttle lever free play. A. Throttle Lever Free Play : 2 - 3

A. Throttle Lever Free Play : 2 -

3 mm

*If the free play is incorrect, loosen the locknut and turn the adjuster until the proper amount of throttle lever free play is obtained.

the proper amount of throttle lever free play is obtained. A. Adjuster B. Locknut NOTE Off

A. Adjuster

B. Locknut

NOTE

Off the throttle cable cannot be adjusted by using the adjuster at the throttle case, use the adjuster at the carburetor. Do not forget to securely tighten the adiuster locknut.

Do not forget to securely tighten the adiuster locknut. A. Adjuster B. Locknut Throttle Case Removal/Disassembly

A. Adjuster

B. Locknut

Throttle Case Removal/Disassembly

eRemove the throttle case screws and separate the case

halves.

the throttle case screws and separate the case halves. A. Throttle Case Screws .Pull the cable

A. Throttle Case Screws

.Pull the cable tip from the throttle lever catch and then remove the cable from the case.

lever catch and then remove the cable from the case. A. Cable Tip B . L

A. Cable Tip

B. Locknut

c. Adjuster

D. Throttle Lever Bolt

eRemove the throttle lever bolt.

D. Throttle Lever Bolt eRemove the throttle lever bolt. 1. Throttle Lever Bolt 2. Throttle Lever

1. Throttle Lever Bolt

2. Throttle Lever

3. Spring

4.

Bushings

D. Throttle Lever Bolt eRemove the throttle lever bolt. 1. Throttle Lever Bolt 2. Throttle Lever

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Throttle Case Assembly/Installation

eThrottle

case

assembly/installation

is

the reverse of

removal/disassembly.

Note the following.

I WARNING.

OOperation with an improperly assembled throttle case could result in unsafe riding condition .

eLubricate the throttle case and cable before assembly/ installation (see Throttle Case and Cable Lubrication). eBe certain that the return spring is correctly installed on the throttle lever.

FUEL SYSTEM 2-5

I

J

installed on the throttle lever. FUEL SYSTEM 2-5 I J A. Return Spring Hook eSwing the
installed on the throttle lever. FUEL SYSTEM 2-5 I J A. Return Spring Hook eSwing the

A. Return Spring Hook

eSwing the throttle control lever so that the carburetor throttle valve is fully open. Turn the throttle limiter screw until it is spaced about 1 mm away from the throttle lever stop.

NOTE

ORefer to the Owner's Manual for the function of the throttle limiter and adjustment procedure of it.

eAdjust the throttle cable free play.

Throttle Case Lubrication

Whenever the throttle case is disassembled, and in

accordance with

the Periodic Maintenance Chart, per-

form the following. eApply a thin coating of multi·purpose grease to the throttle control lever pivot area and the throttle cable end.

control lever pivot area and the throttle cable end. A. Apply grease. Choke Lever and Cable

A. Apply grease.

Choke Lever and Cable

•••••••••••••••••••••••••••••••••• u

••••• h

u

Choke Lever Removal

-Unscrew the choke lever mounting screw.

h u Choke Lever Removal -Unscrew the choke lever mounting screw. A. Mounting Screw B. Choke
h u Choke Lever Removal -Unscrew the choke lever mounting screw. A. Mounting Screw B. Choke

A. Mounting Screw

B. Choke Lever

C. Wave Washer

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2-6

FUEL

SYSTEM

eRemove the choke lever from the housing. eRemove the clip and pull the cable from the housing.

eRemove the clip and pull the cable from the housing. A.Clip Choke Lever Lubrication Whenever the

A.Clip

Choke Lever Lubrication

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

wave washer.

a thin coating of multi-purpose grease to the wave washer. A. Apply grease. Carburetor Carburetor Air

A. Apply grease.

Carburetor

Carburetor Air screw Adjustment

eTurn the carburetor air screw all the way in until it seats lightly.

000

not

tCAUTlO~J

overtighten the air screw or the carburetor

body will be damaged and require replacement.

carburetor body will be damaged and require replacement. A. Air Screw eBack the air screw out

A. Air Screw

eBack the air screw out the specified number of turns.

Air Screw Setting Standard:

1Y.z turns out

Idle Speed Adjustment

eAdjust the air screw (see Carburetor Air Screw Ad- justment).

. eStart the engine and warm it up thoroughly. eTurn ' the idle adjusting screw to obtain the slowest smooth idle speed.

adjusting screw to obtain the slowest smooth idle speed. A. Idle Adjusting Screw Fuel Level Inspection/Adjustment

A. Idle Adjusting Screw

Fuel Level Inspection/Adjustment

I WARNING.

oGasoline is extremely flammable and can be explosive

under

OFF.

cenain

conditions.

00 not smoke.

Tum the ignition switdt

Make sure the area is well

ventilated and free from any source of flame or sparks;

this includes any appliance with a pilot light.

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.Park the vehicle on a level surface. e(;onnect the fuel level gauge (special tool) to the open end of the carburetor overflow tube . • Turn the fuel tap to the ON position to feed fuel to the carburetor and gauge, then loosen the carburetor drain

plug a few turns .

• Read the fuel level in the gauge and compare it to the specification. Screw in the carburetor drain plug.

NOTE

oKeeping the gauge vertical, align its "zero" line with the bottom edge of the carburetor body. Then loosen the drain plug to feed fuel to the gauge.

FUEL

SYSTEM

loosen the drain plug to feed fuel to the gauge. FUEL SYSTEM 1. Float 2. Tang

1. Float

2. Tang

2·7

feed fuel to the gauge. FUEL SYSTEM 1. Float 2. Tang 2·7 1. Fuel Level Gauge:

1. Fuel Level Gauge:

57001·1017

2. Overflow Tube

3. Carburetor Body Bottom Edge

4. Zero Line

5. Fuel Level

Service Fuel Level

5 mm below the bottom edge of the carburetor

body.

*If the fuel level is incorrect, adjust it. .To adjust the fuel level, bent the tang on the float arm to change the float height. Clnereasing the float height lowers the fuel level and decreasing the float height raises the fuel level.

.Measure the float height as shown.

3 1 Float height
3
1
Float height

1. Float bowl mating surface

2. Float valve needle rod (loaded and pushed in)

3. Float

Float Height

Standard:

21.8mm

Carburetor Removal

I WARN.ING •

OGasoline is extremely flammable and can be explosive

under certain

conditions.

Tum the ignition switch

OFF. Do not smoke. Make sure the area is well ventilated and fr~e from any source of flame or sparks; this includes any appliance with a pilot light.

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2-8

FUEL

SYSTEM

eTurn the fuel tap OFF. eRemove the following parts. Seat Vent Hose Fuel Hose Clamps Starter Plunger

parts. Seat Vent Hose Fuel Hose Clamps Starter Plunger A.Clamps B. Starter Plunger ePull out the

A.Clamps

B. Starter Plunger

ePull out the carburetor.

-Unscrew and remove the carburetor cap.

out the carburetor. -Unscrew and remove the carburetor cap. A. Carburetor Cap Carburetor Installation Notes eAlign

A. Carburetor Cap

Carburetor Installation Notes

eAlign the slit on the side of the throttle valve with the guide pin in the carburetor body.

throttle valve with the guide pin in the carburetor body. A. Guide Pin B. Slit eAfter

A. Guide Pin

B. Slit

eAfter installing the carburetor, adjust the following. Throttle Cable Idle Speed

Carburetor Disassembly

eRemove the carburetor.

eRemove the following parts from the carburetor body.

eRemove the following parts from the carburetor body. A. Pin B. Float with Float Valve A.

A. Pin

B. Float with Float Valve

from the carburetor body. A. Pin B. Float with Float Valve A. Main Jet Fence B.

A. Main Jet Fence

B. Plate

C. Pilot Jet

B. Float with Float Valve A. Main Jet Fence B. Plate C. Pilot Jet A. Main

A. Main Jet

B. Needle Jet Holder

C. Float Valve Seat

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A. Needle Jet

www.midwestmanuals.com A. Needle Jet Carburetor Assembly Notes eTurn the carburetor body upside-down, and drop the needle

Carburetor Assembly Notes

eTurn the carburetor body upside-down, and drop the needle jet into place. The long end of the jet goes in first.

jet into place. The long end of the jet goes in first. A. Long End !CAUTl~~1

A. Long End

place. The long end of the jet goes in first. A. Long End !CAUTl~~1 a Do

!CAUTl~~1

a Do not force 1Ite needle jet holder (air bleed pipe) and main jet or ovenighten them. The needle jet or the carburetor body could be damaged requiring replace- ment.

FUEL SYSTEM 2-9

Carburetor Cleaning

requiring replace- ment. FUEL SYSTEM 2-9 Carburetor Cleaning ODo not use compressed air on an assembled

ODo not use compressed air on an assembled carburetor, the floats may be crushed by the pressure. ORemove as many rubber or plastic parts from the car· buretor as possible before cleaning the carburetor with a cleaning solution. This will prevent damage or deterioration of the parts. olbe carburetor body has plastic parts 1Itat cannot be removed_ DO NOT use a strong carburetor cleaning solution which could attack 1Itese parts; instead, use • mild cleaning solution safe for plastic parts. 000 not use wire or any other hard instrument to clean carburetor parts, especially jets, as 1Itey may be damaged.

eDisassemble the carburetor (see Carburetor Dis- assembly). elmmerse all the metal parts in a carburetor cleaning

solution.

eRinse the parts in water. eWhen the parts are clean, dry them with compressed

air.

eBlow the air and fuel passages with compressed air. eAssemble the carburetor (see Carburetor Assembly).

Carburetorlnspecdon

eBefore removing the carburetor, check the fuel level (see Fuel Level Inspection) . *If the fuel level is incorrect, inspect the rest of the

carburetor before correcting it.

eDisassemble the carburetor (see Carburetor Disassem- bly) . eClean the carburetor (see Carburetor Cleaning). eCheck that the O-rings on the carburetor holder, starter

plunger, plunger cap, idle adjusting screw, air screw, air

bleed pipe, and float valve seat and the gaskets on the carburetor cap and float bowl are in good condition.

and float valve seat and the gaskets on the carburetor cap and float bowl are in

A . O-rings

B. Gasket

www.midwestmanuals.com

2-10 FUEL SYSTEM

www.midwestmanuals.com 2-10 FUEL SYSTEM A . O-ring B. Gasket *If any of the O-rings or gaskets

A . O-ring

B. Gasket

*If any of the O-rings or gaskets are not in good con-

dition, replace them.

• Push in the rod in the other end of the float valve

needle and then release it.

*If it does not spring out, replace the needle.

*Cleek the tip of the valve needle.

It should be smooth,

without any grooves, scratches, or tears.

Air Cleaner

Air Cleaner Duct Installation Note

eThe arrow on the air cleaner duct must point toward the front (carburetor side).

cleaner duct must point toward the front (carburetor side). 1. Arrow 2. Duct -+---{2 Push and

1. Arrow

2. Duct

-+---{2 Push and release
-+---{2
Push and release
side). 1. Arrow 2. Duct -+---{2 Push and release 1 . R o d 2. Valve

1. Rod

2. Valve Needle

3. Valve Needle Wear

echeck the tapered portion of the air screw for wear or damage.

the tapered portion of the air screw for wear or damage. 1 . Air Screw 2.

1 . Air Screw

2. Tapered Portion