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    176 views150 pages

    Kawasaki KZ900 Service Manual Haynes

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    johnnyryota

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    © All Rights Reserved
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    Kawasaki 900 and 1000 Fours Owners Workshop Manual by George Collett Yih an adtional Chapter on the 2900 ang 21000 madels by Pete Shoemark Models covered. 21 9803c¢ Four eylinder DOHC 1972/73 21A © 903cc.— Four cylinder DOHC 1973/74 218 903cc_-—Fourcylinder DOH = 1974/75 7900 803ec Four eylinder DOHC 1975/76 21000 1015ce Four eylinder DOHC =——_1976/on above doter Importation into UR ISBN 085696 222 X © Haynes Publishing Group 1975 and 1977 es All rights served. No part ofthis book may be reproduced or transmitted in ‘ny form or by any means electronic ar mechanical, ineiuding photocopying, ‘eeording or by any information storage or retrieval system, without permission In writing rom tne copyright holder Printed in England Ae HAYNES PUBLISHING GROUP SPARKFORD YEOVIL SOMERSET ENGLAND (etributed inthe USA by HAYNES PUBLICATIONS INC 861 LAWRENCE DRIVE NEWBURY PARK CALIFORNIA 91320 USA — Acknowledgements ‘The autor wishes to thank Kawasaki Motors (UK Limited forthe tsehneal assistance givan so feoly wis his manual wae tasing prepared, and for permission to reproduce tel’ ctowngs “The model used forthe photographie sequences was supplied by Dick Motique of Lang Eaton Nottinghamshire, who also provided tho new parts and geekotsusac in the rebuild. Brian Hostal assisted with the dismanting and rebuilding of the Iachine end also devieed various ingeniour methods (or About this manual ‘overcoming the lck of servos tools, Les Bracior arrenged ond took all the photopranhs. The suthor would ais like to thank Jett Clow for his guidance and editorship, nally thanks to NGK Spare Plage (UK) Limited for tho provision of spark plug photographs, Avon Fuubber Company Limited for their avi on tye iting ani tothe Bristol -awaiaki Cente for pormiting vs to photograph the 21000 ‘del featured on the tran cover. ‘The author of this manual has the conviction thatthe only way in whieh a meaningiul and easy to follow text can be ‘ertcan ita fret co the work himgalt, under conditions simlar those found in the average home. As a real, the hand oon In the photographs are sometimes the hands of the author ogetier with another engineer who assstod. Tho machine photographed ues ¢ used mate! that had covered thee thousand fils, s0 thatthe eonations encountered would be sian €2 those found by the overage eer. Unies: specially mentioned, snd thetetore consterad xsontil, Knnosoki gence tools have not boon used. There it invarahly some. altemathe meant of sickening oF removing oma wit component nhan saree tools are not avails ana {he sk oF damape asco be avoided at al costs. Each of the avon Chapters ie civided into numbered Sections \Wrahin the Sactons are numbered paragraphs. In consequence, frost reference thoughout tis manust f both strsiht formar and logiesl When 2 reerence it made “See Section 1.8 t means {ce Section 1. parasraph 6 in the same Chapter. If another Chapter wore meant, the txt would read See Chapter 4, Section {I All the ahotographe ae captioned with 8 Section paragraph huriber 10. which they refer and are always relevant to the (Chapter text adjacent. Figure numbers (ususlly tine illustrations) appeer in ‘numerical order, within 3 sian Chapter. Figure 1.2 therefore efor to the fst figure Chapter t ‘Left hand and ight hand descriptions of parts ot the machine for the rmchine ial, vefer fo tha right ond oft side of the ‘meching, with the eda seated in the vial rising postion, ‘Wins every eare te taken to anaure thatthe information in this manual is correct, no lability can be accepted by the uthore or publisher for loss, damage or injury, caused By any terrain or omissions from tho information ven Contents Chapter Section Page Introductory popes Dimension and weights 4 Introduction tothe 21 eriee . ‘Orsering spare parts 6 Recommended lubricants 9 Floutine maintenance 5 Quik glance maintonanee 8 (Chaptor 1/Engina, clutch and gearbox Enginegeacbox moval 13 Examination and renovation -general 2% Dismanttng ~gonorat is FResssombly - general 2 Starting ae runing a rebuilt unit 5 ‘Chapter 2/Fuel system and ibrietion| ‘Ar leaner 7% Carburetors 0-78 Gil pum. 79 Petrol tak nd tap 3 esr chain Ibrication & (Chaptor Vignition system ‘Condensers - removal nd replacement 86 CContsct brokers -adiustment 5 Crankshaft aiterator- chosing output a4 Ignition eos -chacking 5 Ignition timing 35.87 Spark plugs checking and rsetting the gaps 87 (Chapter 4/ Frame and forks Frame - examination and renovation 88 Front forks 88-80 ‘Steering nead bearings 89 Surporsion ants = reer 3 Swinging arm Fre 97-133 {Chapter S/he, brakes and 705 Braker Front 110 ear 106 ‘Cush deve: examination and renovation 108 Final drip chain: examination sn luoreston 109 “Tyros: romana and veplacement 8 Wheels Front 102 - 108, Rear 106 (Chapter 6/Etecwicl system ‘Alternator erenkehatt 120 Battery - maintenance and chasing procedure 120 Fuss locaton 12 Hnclabar awitohoe 126 Silleon rectifier «location and replacement 120 Volta regulator = testing 12 Wiring irae 129-130, (Chopter 7/The 2000 end 21000 models ‘General derrintion 133 Final drive chain «msintenanee anc renewal 133 Hydroulc die rakes. modifications 135 Far brake calipr: maintenance, removal and replacement ary Fear brake mastreylinder: matitenanee, removal and renovation 135, Swinging arm fork: temoval and renovation 133 Wiring degra 140.141 rie conversion tables 1a Index 145-148 ‘Gonorl descriptions and specifications are given In each Chapter immediatly after the lst of Contents Fault diagnosis is lven atthe nd of each appropriate Chapter Fighthand view of the Kawasaki 900ce sariet 21 Model_ dimensions Overall longth (Overall width Overall eight hootbace Ground clearence Dry weight {6.8 in (2.208 mm) Us models 18.5 in (2.250 mm) European models 31.5 in (800 mm) US models 5323 in (820 mun} European mocois 45.3 in (1.160 mm) US models {46.3 n (1.175 mm) European models 158.7 in (1.490 mm) 6.3 in (160 me) 1506 tb £290 ks) Introduction to the Kawasaki Z1 series When the 900 cc 21 model wa frst introduced in 1972 it wat obvious that Kawarali had scored 3 huge sucess. Tho ‘romth of the compeny hod been ile short of phencmenal, Dermnepe cauting some people to wonder Now it was sehinvad “The ansner ley in the vest rources af the firm and the extent of their technological knowow, which extended Ineo allroad, Shipping, and sieraft transportation on a srand sale, All thea fctvities rolled into one form Kaneeaki Heavy Incurries, giant ‘manufacturing complex that produces an astonishing verety of Droduets and markets them all over the worl. ‘This just © bare outline ofthe industrial might of Kawasski It ie the Motoreycla Division of Kanaaki Heavy Industries that hos ettrocted most interest, the meteoric vise of this section being equal to that of the parent company Being as 3 wale. In Ordering spare parts just 2 fow years Kawasaki has become the fourth largest ‘matorcyele manufacturer in the world and that in Il! quite {an sccomplishment wen It is recalled shat some European {companies have been manufacturing machines for over 60 year. Kawosski has now become soriously involved with racing, to such an extent thatthe fel factory teams In rials, road racing {and motoeross, and were the only Jepanese monutocturer to participate inthe 48th 1.8.0.7, held in Barkshire, U.S.A. More Important is the readiness of Kawascki to incorporate the hard learn! lessons larnt st the race tock, into thelr 703d going mochines. In this way they have succesfully capitalised on theit Competition successes, putting the knowledge they have gained {2 the alsposal of all those who purcheae their high quality products ‘When ordering spare parte for 8 Kawasaki Iti sdviable to dal direct with an official Kawasakl gant who should be able to Eipply most of the ports from stoke Pars eannot be obtained direct from Kawasaki U.K. all orders must be routed via an ‘Spproved agont at Is comman with most other mak Always quote the frame and engine numbers in full. The frame number it stamped on the left hond side of the stering head and the engine number on top of the crankcase tothe rear ff the evlinder block, on the right hand side. Frame number location ft fe always best to quote the colour scheme for any of the cycle parts that have to be ordered. Use only genuine Kawasaki parts, Pattorn parts should be avoided a they ore usualy inferior in quality. Some of the more expendable parts such at bulbs, spark plugs, chains, 1yre, ls ed greats et, can bo obtained ftom accessory stores end motor factors, who have convenient ‘pening hours, charge lower prices and can often be found nearer home. Its also posible to abun perts on # Mail Order Basis from @ number of specallste who adverse regulary in the ‘motorcycle magazine. Engine number location Routine maintenance The importance of maintaining a motoreycle conscientiously and carefully cannot be overstresed. Aport from the obvious benefits of safety and economy, a well-maintained motorcycle will gunerally bo ridden with more care and carsideretion than fone that fe unkempt or out-of tune, Therefore it become all the mote Important that necessary tasks be cred out exactly wher presribod and with great care. Not only isa rider risking ogre ‘eal more than just money with a badly kept machine, he also ‘uns great rise in safety both to himself dod to the machine ‘Keeping a machine propery serviced nos! not be excessively ‘consuming, although sovices should be performed regularly land in a profesional manner, Th various maintnance tab Seseribed in detall, under ther respective mileage and calender hoacings. It should be remembered that the interval between the various maintenanco (Woks sors only as a guide. As the tmechine get older, i crvan hard or is uted under particularly Sdvors conditions it ls sdvsabl to reduce the interval between tach chock, a specie item is mentioned but not described in deta, it will be found in the oppropriowe Chapter. No special tools are Tequired for the routine maintenance tarks,epart from those found in machine's toolkit. A. good set of pan ring matic spanners are also Very usifl, especially for items such as the Sump. drain plug ete. Thoir purchaso will represent 2 good Daily hock tho oil lvol of tho engine-goar unit. This ean be done ‘through tha sight "window at the bottom of the right hand ferankesse cover. The correct level is between the two linet marked atthe side ofthe windows (Chock the tyre prossuros. Always chock whan the tyres are cool, using an acurate tyre pressure gauoe. Make sure tho lights, horn, flazing indicators and speedo: meter function correctly. The efficient working of thes isa Statutory requirement by iow. ‘Check thet the micros ae post locknts are ful tightone "Make sure the roar chan is comocty adjusted. Chock that the hancigbars ten 10. the ight and let tmoothly, slo that both brakes are working eoctvey. toned correcty, and thatthe Welty or every 200 rniles Tn addition 10 the items already mentioned in the dally heck, nepoct and adjust the final driv chain ‘Chock and if necessary adjust both brakes, also the level of ‘the braka fluid inthe master oyindar. Top up if nocesar. Chock the level of electrolyte in the battery. Examine the wheal spokes fr looseness and retension them wath 9 =poke Ke, it necetsary ake sure the clutch cable i adjsted correctly and has the recouary free play. Check the oil content of the chain ile i fisted Monthly or every 1,000 miles ‘Complete all the previous checks mantionad in the daly an weekly service then attend tothe fllowng items. ‘Change tho engine oll Mote thatthe ol filter element must bee channes every 2,000 miles or, i the engine hee boen rebuilt, ster the fst 1/000 mile. This should be secomplished whilst ‘the engine i drained of el. Wipe off any metal lings that mey be attached to the sump Gain plug, replace and tighten the pug RMT Filling master evindor FIM Topping up engine ot Routine maintonance Check all she nuts ond bolts on the machine, including the evlinr head bolts and the exhaust pipe clamps. (Check and it necessary lbricste the control cables. Six monthly or every 2,000 mits ‘Complete all the checks listed in the daily, weekly and 200 mila monty sevigs and than the fllowing Fiemove the aperk plugs claan and adjust the points gop. If the slactroder are badly eroded or the insulators cracked of body fouled, the plugs should be ranewod. ‘Check snd, if necessary, adjust the contact breaker points ‘There are two sett of points; when the point have bean raset varity the accuracy of the ignition ting, (Chock the valve clearances withthe engine cold anc adust if (Check alto the tension of the comshatt chain. Femove a cles the i iter etme Remove the filter bowl from the petrol ‘ep and clean both the bow and the filter. Check also that the fuel lines are free from soaimont. (Chock the clutch able for adjustment and readiust if ‘Remove and clean the final crive rear chain, then lubricate before replacement If not of the predubvicated typ. Chock aio ‘the condition of both gearbox and rear wheel sprockets. ‘Mae sure. all four carburettor are clean and adjusted correctly check thet they are synchronized with ch other. ‘Yeutly oF every 6,000 miles ‘Complete ail the checks under the dally, weekly, month, and six_ monthly ‘headings, then entry ‘out the’ following Flomove and claan the engine oil filter at the oil pump pick up, tts retained by thvee sevens Fenew the si cleaner element. Remove the rear wheel and check the condition of thoes emave the front wheel, and if the disc pads are down or close 10 the red danger lina, they should be ranowod. Mecsure the oll lave! in the Tront forks and top up if ‘Chock and adjust the steering head bearings, also check the setion of the steering lock. Lubricate it with afew drops of ol Check slzo the tyrae for war: use 0 treed gauge tO maasure the depth of tread. Check the tyres for erocks in tho sidewall ‘nd replace if found, in te interest of safety. brake RMS Checking the points gop FAME Use guidelines on rer fork won aajsting thee Quick glance routine maintenance, adjustments and capacities Contact breaker points Spark plug 9205 Spark plus Fol tank capacity Front fork ol capacity Engina/gnarbox ol expacity (Oi Tank (rear ein) capacity 0012- 0.016 in, (0:3 10.04 mm) 0.028 0.031 in, (0.7 100.8 mm) (Normal use) N.G.K. B@ ES.) Ivery high speed) NLG.K. 9 ES.) 14am "Ren, 25 Imp. gallons. (4.2 US gallons) (18 ves) 169 ce par log ares 7 Imp. pints (1 US gallon} 0.9 tite (21 model only! Ten 261 From) 31 PS Rear } Sole rider 26. Frond BES Fon wip der Recommended lubricants Erin/garbox uit caso GTX Chan ak cos! $790 Telescope oka cont TOF Hydrautie, rant brake mas contrat cables ‘Greate nipples Control Universal Giring Brake and Cluteh Fld Ccentrot Everyman oi Ccstrat LM Grease Lubrication points 1 CONTROL CABLES 2 HYDRAULIC BRAKE RESERVOIR 3 FRONT FORKS 4 SPEEDOMETER AND TACHOMETER CABLES “ARINGS 15 ENGINC/GEARBOX Ol. Chapter 1 Engine, clutch and gearbox Contents Gener! description. : ‘Valves, valve sens nd valve guides: examination and re Operations with engine/gorbov unt inthe frame 2 novation 2 Opsations with engine/gerbox temoved ew. Ss Camhafts, tappets, end camshalt sprockets: examination Method af engine gearbox removel 4 andranovation we 4 Removing the engine/gcertox unit = Clutch and rear chain of! pump: examination and re: Dismantling the engine nd gearbox: general” 6 ovation = = Ss 25 Dismantling the apeine and gearbox: removing the camshats, Gearbox components: eraminetion <8 evlinder head, and evlinder block 7. Flassembling the cylinder head 7 7 ‘Dismantling the engine/gearbox: removing te pistons anc Engine and geeroox reaxsembly: ganeral 28 piston sins = 8 Engin and gearbox reassembly: replacing the eranksnatt "29 Dismantling the engine an goat: removing the contact Engine and gearbox reassembly: rebuilding tho goarbox 30 bresker asembty 9 Engine and geerbox: rebuiling the clutch, alterntor, and Darnanting the engine and gearbox: removing he clutch "10 contact breaker =. we =a Diaroniting the engine and gearbox: removing the alternstor Engine and gearbox ressembly replacing the plstons and snd starter motor 11 eylinder block _ 22 Diamantina the engine ond gearbox: removing the final Engine and gearbox ressembly replacing the eylinder rive sproctet 12 headland comshsts, timing the engine 38 emai the engine sis gearbox: rimoving the oll tei” 13 Engine and gearbox rnseemby: dusting the valve lear [smentling the engine and gesroox: separating the erankeasee4 oo pm Fermoving the erenkahat sey ad get clusters 18 i goarbx ease epacing the carburetors 35 Dismantling the gearbox: eeranting the sear clustee 18 Engine and gearbox reneobly: replacing the angina ana Examinaron and renovation geet 17 geotox ite the frame ee 38 Corl, big end, msn bearing: examination and Soaring and running the rebuilt enginaunit “SZ, norman 18 Taking he rate machine onthe road DoT i se ekaminstion and replant S19 Faulecingnosis engine an : Zoe Gylinde bloc: examination snarenovation’” 20° Fault lagna: elateh Prone ond piston eng: exaerination and novation. 21 Faultdiogesi: gearbox Cylinderhead examination andrenowstion 2 “ewe Specifications Engine Typo = eylindee wansverse .0.H.C. imine 4 stoke air cooled Bore and stroke ci 66% 65 me Displacement 906 ex. Compression ratio ae 5101 aximum horsepower : B2hp. @8,500+.p, Maximum torewe rite 58.3 4 bo 7000p Mm. (78 kgm@7.000r.9.m) Cylinder block a | fluminium alloy, ste! liners (tinder hes ‘lrininm alloy, angles plug threads. Pistons ‘Twpe eer me Aluminium alloy Oversize avaiable“. SI O18 mm (0.020 inch) and 1.0 mn [0.040 inchl Piston rings Number per piston cm mae Tip compression and one il contrat End 398 (0.008 "0.016 in, (0.2 — 0:4 men) wear init 0.028 i, 2 Chapter 1/Engine clutch and gearbox Groowe clearance: ‘Top ring Second ring ing Cylinder block Bore woar limit Valves: Valve stem dlamater: inet \ave stom ciamatar: exhaust Wear mit ile: E Wor imi exhaust: ‘Valve springs: Valve timing: Inlet opens Inet closes Exhaust opens Exhaust closes ‘clutch Number of inert patos. Numnber of pain plates = “Thickness of te inserted patee Wear limit of inserted plates : Clutch springs frepangth Clutch sorings- vee limit a Torque wrench settings Ovlindor hood ruts. ai Exhaust manifold ruts ‘Cylinder heed bolt. ‘Cylinder head cover bolts (Crankshaft cap bolts ‘Crankesse nuts (6 9 mm| CCrankeace nate (@ © mm! Si : ‘Camshaft cap bolts af ‘Clutch centre hob mit : Generator rotor to erankahott Engine oi! purnp bolts E Engine sorocket mut. ee 11 General dserption “Tho ongine unit Fitted to the Kawasaki Z1 series i ofthe 4 cvlindar inne type, fitted transversely across the frame. The valves are operated by doublo overhead camsnatts driven off the crankshaft by a contre chain. The two camshafts ere located in ‘tho cylinder head casting, and the cemshattehsin dive spertae ‘through a castin tunnel between the four cylinders. Adjustment Of the chain is effected by @ chain tensioner, feed tothe reer OF the cylinder block. “The engine/gear unit i of sluminium alloy construction, with the erankesse divided horizontally ‘The 21 series have a wet Sump, pressure fed lubrication system, which incorporates goa driven 0 pum, an oil iter, 2 sfety by-pass vel, and an oil pressure switch ‘Ol vapours casted Inthe crankcae oe vented through an oi broather to the air cleaner hove where they ere recirculated into the crankcase, providing anol tight systom, “The oll pump © a tun shat dual rotor unit, which fe driven off tho eraniehateby & gear ‘An oil strainer is fittad to the intake side of the oil pump, (0.0018 — 0.003: in. (0.045 — 0.060 mm) 10.0008 — 0.0020 in 10.010 — 0.050.mm) Seme 1 rm (0.08937 inches) If eylinderrebore exceeds 1 mm cylinder ‘lock wil have to be repiaced with = new one. 6.965 — 6.830/mm. (0.2742 ~ 0.2748 in) 6.985 ~ 6.970 mm. (0.2738 — 0.2744 in) {6.6 mm (0.270 In} 16. mm (0.270 in} 36.0 mm (1.42 inchd 138.3 mm (1-55 inch) 35.0 mm (1.38 in) ‘38.01mm (1.50 inch) 0.002" 0.008 inch (0.05 — 1.0mm) 30° BDC. 70° ABDC 0° gape 30° ATDC 8 3.7mm ~ 3.9mm (0.148 — 0.154in) 3.4 mn (0.134 in) 33.8 mm (1.33 in) 2.3mm (127 in) lo fe kgm 26 35 400 ine tae 2 105 ins Ibs 12 102 ins Ibe 12 % 26 70 ns tbs oe 8 25 135 fe- ibs 15 87-108 2-15 8 25 WO ins tbe 8 87-108 12-15 whieh serves to. proteet_the pump mechanism from any impurities in the oil that might cause damage. "Theil fier unit whieh is housed in the sump i: en alloy canistor with © pope element. As the oil iter becomes cloased ‘with impurities, is ability to oporataeficenty i reduced, and len ie becomes so clogged that It begins to impede the ol flow, ‘the by-pass valve opens and fOutes the ol around the fiter. This fof course result in unfiltered el being circulated throughout the fengine, 2 condition that will be avowed Ifthe filter element is hanged a the preserbed Intervals “The brication Wow is a8 follows: Oil is dwn from the sump through the il trainer tothe pump, ‘thon i Bates ‘heough the ol iter (gr around it i the by:pser valve isin operation) to the pipe in which the all pressure switch Is ‘mounted. It is then routed through theee branch syste. Tho first system lubricates the erankahatt_moin basrings and crankpins. The ol s town by the erankahett's rotating motion | ‘onto the eylinder vals providing the eplah lvbrestion for the pistons. The oil ther drips “down into” the sump, %0 be recirculated “The second system lubricates the eyinder head assembly. Oit flows up through passages in the eylinger block, through the Chapter 1/Engine clutch and gearbox 13 ‘camshaft bushes, dawn over the cams, through the cam lifters or tappets) and back to the sump By way of holes in the bese of ‘the tappet, and the am ehain tunnel i th cylinder head. ‘The third system foods the transmission bearings an then drains back tothe sump for recirculation. "Tho engine # bull innit withthe gaeDox, Ths means that when the engine i completely dismantia, the clutch end {gearbox are diamsntld too. This tae Is made easy by arranging ‘he erankease to separate horizontally, 2 Operations withthe engine/unit inthe frame 11 is not necessary to remove the engine from the frame 19 carry out certain operations in fact it can be an advantage. Tasks {that can be carried out with th engine in stu areas follos 2) Removal and replacement of the clutch 1) Removal and replacement of the whee! generator. ©) Removal and replacemant of te goneratar rotor 14) Removal and replacement of the carburettor. 2), Removal and replscerent of the starter motor. {1 Removal and replacement OF the rear cha 0 pump 2 When severat tasks have to be undertaken simultaneously, it ‘wll probably Be edvantagsous to remove the complete engine Unit from the frame, an operation that should take ebout an hour ands alt. Ths glos the sdvantago of much batter access tnd more working sae. ‘3 Operations with the engne/gearbax unit removed from the frame ') Removal and replacemont of the oyindor head unit. 1) Removal and replacement of the cylinder block. 2). Removal and replacerant of te pistons. {) Remove! and replacement of de crankuhate assembly. ‘¢) Removal and replacement of the maia Bearings 1 Removal and replacement of the gear clusters and olotore. 1) Removal and replacement of the kickstart mochenitm, _gearbox bearings, and gear change mechanism. 44 Mathod of engina/geerbox removal ‘Az mentioned previously, the engine and gearbox are bult inaunit and itis necnsary to remove the complete engine unit to shin seca 0 either component "The engine uni secured to the frame with thee long bolts anc twelv shart mounting bats After tote have Deon rernoved fnd the necesery electreal connections disconnected, together withthe carburetor ful pipes, plug leads and exhaust system, the engine is ready for removal. Dismentling of the engine unit tan only be scsomplished aftr the engine Unit hss been removed from the fame and refting cannot take placa until the eine Unites boon reassombed. 15 Romoving the o ine/gearbox unit 1 Place the machine femly Its contre stand so that it stands fon a smooth, level surface. Th ies! patition for working isto place the machine on ® stout wooden stand about 18 inches high, rostng on its contre stand 2" Make sure you have clean, wellit place to work in aed.» 00d set of tools. You wil need a laat thre sta of erosead {Philins) screwdrivers, Small, medium and large, and plenty of clean lint fee "39. 3" Remove the oil sump plu, azo the ol iar drain plug, and ‘rain the al into a sultsle tray. Approximately one gallon of al ‘il rain off 4 Oisconnect and remove the batty. The battery is located Dbonoath tho dualeoat, in 2 credla compartment. 1 should be lifted straight up, being careful not 20 ll the content 5 ‘Drain and remove the pattol tank. The tank is held by a ‘rubber clip atthe rear thet engene in lip welded onto the rar ff the tank. Unhook the rubber Band snd pull the fuel tank of, Toward the roe 18 "Remove the fined clips (rom all four exhautt pipes. Thay 1 held by two nuts par clamp, securod to suds ited into the fylinder head. It is 2 good idea to soak these nuts in penetrating fl before undoing thom, to safeguard ajinst breskage of the ‘Studs in the eylinder head. lemeve the mounting bolts atthe Fear of the sloncart and push the slloncers forward, moving hem a a pair Wom ech side. Remove the right hend riders footrest by removing the two retaining bolts. 7 Detach the rear brake cable from is anchor point n Tear of the brake pecal, 0 the 5.6 Remove tha floned clipe Chapter 1/Engine, clutch and gearbox 5 8 Tako off tho spark plug lds, and tuck them out ofthe may. FFomove the tachometer cable from directly in front of the feylinder head! By undoing the knutled nut 9° Remove the negative battry Toad from its earth on the ‘engine, unplug the blue connector (note you heve to squeeze tht onector the sids aro spring loaded, this i 9 safeguard to hold hem tight wen assembled, 10 Disconnect the black wire and the green wee thet join the Ignition calls to the contact breaker points, Remove the water ‘wie eer the relay terminal infront ofthe electrical panel end hear to the rear right hand frame tube. Remove te air eleanor Zsombly by undoing the eossheaded sereve on the carburettor hoses 11 Loosan all eight clamps on the carburettors and pull the carburettor assim off to the rear. Looten the acustere on the two throttle cablee snd unhook the throttle cables frm the 2 Remove the rubber hose from the oil bresther assembly sicuated at the raer of the engine, and ramove the oll breather Seombly. Take Off tho lft hand riders footrest, and remove the ‘nar change pedal complet 5.94 Unplug the blue connector 5.108 Remove air leaner ascembly 5.13 Take off starter motor cover 8 Chapter 1/Engine, clutch and gearbox 5.17 Slowly 13 Take off the starter motor and gasket, Ramove the rear chan cil pum cover fit fitted), pull the hose off the pump and plug ‘he hoe with a zerow to provent oil leakage. Romove tho chain cover, pull the epit pin out from the clutch release lever and Unhoske the clutch eabl. Unhook the spring ftom the stepswitch land take off the suite, Romnove the geetbox sprocket cover and Femove the pearbox sprocket nut after preventing rotation bY applying the rear brake. Disenaone the sprocket from the rear chain and allow th Tatar to hang in position. Knead not be Femoved completely. {V4 Loosen the lockrut on the rear ake padl position adjusting bolt and turn the bolt downwards until i holds the beake padal ‘wel ut ofthe way 15 Uso 9 smol jock or sltrnatvely « block to put undor the crankcase {0 take the weight off the engine bolts. Femove the huts off the thees long engine bolts ard completa remove the short engine mounting bolts from the lower centre mounting on tach side of the machine. Thase are bolted to thaaded plates {hat fit up Into the bottom of the erankeate. 16 Remave the right hand rear engine mounting bolts, ramove the cantre and front right hand side engine mounting bracket, then remove te tres long engine mounting bolts ong at the ont and two atthe rear of the engin. 17 Level the engine and slowly lft it straight up sbout 1 Inch (51mm), then move it to the righ lightly s that te rear of the ‘engine sipe over the raat lover mounting bracket. alsa the front of the engine lite at this stage, 20 that 1 wll cleat tho frome, thon lower the left hand sa of the engina nd pul the fngine out of the frame eral, lifting. diagonally. upwards fowards the right hand toe t should be noted that two persons bre needed to handle an engine of this ize. engine unit upwards {Dismantling the engina/gearbox: gonsral 1 Before commencing work on the engine unit, the extemal surfaces sould be clesned thoroughly. A motorcycle engine hot vary litle protection from the hazards of rood grit and other foreign matter, due to it having to bo constructed to taka ‘aantage of af eoaing 2 There are a number of proprietary clesning solvents on the ‘market including Jzer end Gun, ti best to soak the parts in ‘one of thee solvents, using @ cheap paint brush. Allow the Solvent to penetrate the dirt, and afterwards wah down with water, making. sure not 10 iet water penetrate the electra! {ystem or get into the engine, as many parts aro now mar exposed. 3. Hove 2 goed st of tools ready, including a eet of open rng matric spanner (these havea ring one and and are open ended at the othor and, a tow matric socket spannere ofthe salar ies, 5.17A Engine unt is very heavy fend an impact serevervar with 9 election of bite for tho ‘rosshesd sorews. If one is not avilable, a crosshead screwdriver swath a T handle fitted ean somtimes be used as a substitute. Work on a clean surface and have 3 supply of clean lint fre ray ‘vai 4 Never use fore to remove eny stubbom part unles specifi ‘mention is mado of this requirement inthe text. There i invariably good reason why a parti difficult to remove, often| because the clsmantling procedure has been taken cut of 7. Dismantiing the engine and gearbox: removing the eamshas, the cylinder head, and eylinder block 1 Place the engine on the bench anc remove the cemshaft cover. To remove the camshafts, slacken the camshaft chain Tensioner and’ undo’ the Bolte holding. the camshaft cover, Remove the chain guide sprocket located at the top of the engine, unbolt the camsnefe caps, and mark the eplit bushes Under each cap to shovr thelr location. This Is important se any ‘bushes that Nave to be reused mutt go back in heir original locstions. 2 The camshaft can now be remaved by slipping them uncer ‘the camshaft chain, Unsorew the tachometer eable an take out the tachometer pinion, #9 that it does not cause cmage t0 the ‘camshaft worm during cama instalation ta later ste 3°'The cylinder bead © now ready for emoval. Start by removing the two bolts t each ond of the cylinder head, chan Undo the twolve cylinder head nus with suitable socket swroneh 4° Remove all the valve tspets and shims. Koop thom separate for installation in thei original locations. This is most important. Famove the cylinder head with soft headed malet to break it {rao fom its saat, necessary 55" The evlinder block can now be removed by tapping upward with @ soft headed mie. Ax the eylinder Block Is ralsed Ie best to ped the erankease mouths with clean rag to eliminete any foreign particles trom falling lato tho crankcase, especially if bottom ‘nd everhaul isnot contemplated. Cateh the pistons oe they emerge trom the cylinder bores, and lower the camshett chain through the contre tunnel on a placy of we 8 Diemanting the engine and gearbox: removing the pistons and piston rings 1 Rlomove the lelips trom the pistons by inverting © erevcriver (or apiece of walding rod chemfered ‘one endl, ‘hrough the groove atthe rer of tho piston. Disead them. Never Fig. 1.3. Camshats and valves Inlet comshote Exhaust camshot Inlet camahart sprocket Exnauet camsnatt sprocket Bott" bolt Toppet 8 oft Valve sorng collr- 16 off Valee spring retanor™=8 off Inner vate spring "8 oft Qutor val spring 8 off Oilsesi for vive Boft Valve soring seat 8. off Inlecvalve off Exhaust vate: off ‘Teppot sim: 8 off i : é i 3 Z 10.4 Pll off the hub Chapter 1/Engine, clutch and gearbox ose old cirlis during the rb 2 Using a rife of suitable diameter, tap each gudgeon pin out ‘of position by supperting ech piston and connecting rod in| turn, Marc each piston inti the skirt co that Iti ropacod in| the same postion. If the gudgeon pins area tight fit into the Connecting rods, #& advieabie to worm the pistans. One way i 10 ook a ag in very Hot water, wring the water Out snd wrap the fag round tho piston very quickly. The resultant expansion ‘should ease the grip af the piston bosses ‘Dismantling the engine and gearbox: removing the eontact breaker asimbly that hold the cover on the front right hond side of the engine. ‘Tole cover hae D.O.MLC. ramped on i. Then remove the theve screws holding the contact breaker assembly with condansors sttachad, lift otf the plate, separating the wires by pulling them ‘out of the connoctor 2° Remove the Dal that holds the auto-sdvance mechanism to ‘the shaft, and remove the scvence mechaniim with the cam. [Now undo the six serews holding the backplate, Note the are ‘wo dowels that loess into tha sige of the erankcasa. Aftar this plate ft ramoved, the evnkshat i exposed 40 Dismantling the engine and gearbox: removing the clutch 1 Aitor making aure tht all the oll has bean drained from the clutch housing, st previously mentioned at the beainning ofthis ‘Chepter, undo the eight crostad sorove that retain the clutch ‘cover, and remove both cover and aeskat. 2" Remove the fva pressure plate boft, the clutch springs, and the preture plate. Take out the clutch mushracm pushrod, nd tilt the engine over, 20 tat the stool ball wil fall out (otherwise know as the release berg) 12" Remove the eluteh plates (there are eight trition, and seven pisin plates). ‘The clutch plates can be removed by using 2 hooked pises of wire to lft them out, Than remove the clutch hhub centre nt by either using the secial tool that holds the hub iil, ors sutable substi 4 Remove the auter washer, the hub, and the inner washer. The Cluteh cuter ease cannot Be removed until the erankcases are Seperate. The Kekstart cover can now be remaved trom the rear of the Clutch cate, by undoing the four erowshead screve. The Kikstart, Spring con be pulled out with a par of long nosed pliers 111 Dismantling the engine and gearbox: removing the alternator And starter motor 1 Turn to the opposite side ofthe engine (afe hand, remove the six crosshead screws that hold on the outer cover. The rmakars name KAWASAKI’ ie stamped an the cover. Aftor this over is removed togetner with is gasket, the rotor will be ‘xpoced, It" rotor extractor is nat avallable, the rear whee! spindle can be serewed into the thread of the rotor, after the rotor securing bolt ané washer have bean removed. By tapping ‘Sutwards under the head of the spindlo afer it has been tightened, the rotor should come off, with the starter pinion attach. Note: On no cecount hammer the rotor 2 Take aut the two long batts that Ft vorticaly in the ond of tho starr motor bracket, unsore the sorter cable from the terminal, and raleose the cable {tom the clamp. The start ‘ator ean now be pulls! out from the crankcase 3» The starter pinion with gear can now alo be removed, TAC Take off rtor with oe 11.2 Removing the starter motor em 124 Rlemove gear change mechanism 112.48 Undo bolt and remove detent lever i L GD 0 = 4 ipeaeserey eon on ex) 15 Washer 16 Botton” GD 0 <0 Chapter 1/Engine, lutch and gearbox. 112 Diemantiing the engine and gearbox: removing the fina dive sprocket 1 Pull out the clutch pushrod, disconnect the neutral switch situated atthe bottom of the sprocket guard, unserew the three crosshead seraws and remove the sprocket guard. 2° Flattn the bent up ex of the Gb washer locking the Sprocket nut, undo the sprocket nut while stopping the sprocket ‘rom turing (one way of doing this to puta piece of chain ‘onto the sprocket and then 10 hold both ends of the chain in vice). Remove the sprackat. 2 Take off the transmission cover and socket, remove the ‘sprocket distance collar and take oft tha 0! ring that fs behing the collar. Note: ‘The "O' ring it to stop oil leakage from the crankeae, 44" Remove the gear change dotent ever mounting bot, unhook the lever spring, and remove the lever 13 Dieman 19 the engine and gearbox: removing the ol ite 1 The oll filter i located underneath the ump. The fer has 3 rain plu, that should normally be removed when changing the fengine oll; However, at me a0 taking the iter out complete It ‘an be left in and the whole fitar plata removed by undoing the ‘centre mounting bolt. The flter asembly with tho slement wll then comme dorn from tha crankcase, Takeoff tho rubber goskets fand remove the filter elmer. 14 Dismantling the engine and gearbox: exparating the evank- 1 Take aut the crankcase bolts from the top sie of the engine (two of them at the cuntre potition just Behind tho erankahatt have eable clips attsched), Remove the centre camchain guide roller. 2 Turn the engine upside down on the bench, end remove the oil strainer, oll pan, end gasket. Undo the two bolts that retain the oll pump. ‘The pum can now be removed. Remove the feventeen 6 mm and tho eight 8 mm Bolts from the crankcase Bottom half, Do not remove the four bolts that hold the ‘rankahat. 3 Thore are three jack bolt postions in the lower crankcsse. To Seperate the crankoues, sora three & mm bolts int there nolas {cro at the front and one atthe rear postion ofthe engin), and ‘the erankoases wil separate. Tako coro to screw in the bolts fovenly, half a turn ata time, {0 make ure the crankcase ‘saparatae evenly. 16 Dismantling th engine and gearbox: removing the crankshaft assembly and gear clusters 1 To remove the erankshat assembly undo the four bolts that hola the canto crankshaft bearing esp. This bearing cap is bored “in ing” witn the eronkeate, Thore le only one position for i with the arrow pointing towerds the front of the engin. 2 Toke out the erankahaftassomBly from the uppor crankcase half and slip aff the cam-hain 3 The gosrbox moinshatt complete with g tlutch hausing can now be removed. 42 Lift out the layshart with yoarclustar, alco the kickstart shaft and pinion 5 Lightly tap out the selector fork roc! snd remove the 840 Selector forks. Remove the detent arm, bond back the locking {2b of the lockwasher, and remove the gear change fork pin 6 Bend. bock the locktab on the selector drum bolt, then Lntorew ane remove the lector drum positioning bolt. The cap bolt need not be removed from the top of the positioning bolt. 7. Pall the selctor crum out of the erankcaso along with the third goa selector fork. 5 cluster, and the 114.2 Undo tne sorens £0 remove svainer NS 18.2 Lift up cxankshott essembly Grankcase complete Gi pressure switch body head serew 8 tt ‘owe ‘Oring 2off her body Pug BH 10 Bitter pug 18 “O'ning torbresther body 30 ‘O'nng= Bort 1 2 3 a & $ 7 a 3 10 Chapter 1/Engine, clutch and gearbox. 3 15.48 Remove Kickstart shaft assambiy 15.6 Unscrew seluctor fork bolt 18 Dismantling the gearbox: dismantling the gear clusters 1 To dlsmantie the mainehat, fret remave the outer Bush, then the retaining ving and shim and next the neo roller beering land the two spacers Afr this take ff the 2nd gear pinion and the Sth goar pinion with the Sth geor bush, tho splined washer and external civcip. Next remow the sing Se gra, the cirelp Snd splined washer, snd the ath goer with bush, On the opposite ‘nd ofthe shaft, next to the fixed pinion, 1s 2 roller basing. This tan be ramoved fst hoe to be reneved, using a bearing puller “Take of the split set ring halves, 2 Start to dismantle the layshaft goars by fire removing the bush, retaining ing and shin, and than the nese rll beeing ‘nd two specing washors. Next remove the lrge 1 gear and the ‘him located behind the gesr pinion. 3° Rotate the layshafe while removing the 4th ger, so thatthe three balls will move. Then pull the bearing from the shaft with = bearing puller, not forgetting to remove the beating set ngs haves first. Pemove the washer and the large Sr goor pinion, then remove the 2nd gear bush, the splined washer and. the $07 Pullout sector drum 4 Take off the sliding Sth gear pinion, the external crt, and ‘the second splined wathor. Romowe th large 3re goer with the ‘bus ond arly, remove the wather, 16.10 Take off ball Bering, on otner enc 16.3 Careful not to mispace the twee balls in fourth guar 16:38 Pul off ball bearing 36 Chapter 1/Engine, clutch and gearbox: 16.30 Then splined washer and circlip, 117 Examination and renovation: general 1 Before examining the parts of the dismantad engine unit for oor itis esentil that they should be cleaned thoroughly. Use fs 'petroliperatin mix to remove all races of old ell and Suda which may have sccurmuleted within the engine 2 Examine the erankease castings for cracks oF other sins of Gamage. Ifa exack is discovered it wil equi speciait rena. 23 Examine carefully each part determine the extent of wes, ‘checking with the telorance figures sted in the Specifications feotion of this Chepter. there is eny question of doubt play fate ano ene 4 ‘Use & clean lint feo rag fo loaning and drying the voious components, This will bviats the risk. of small particles ‘obitricting the internal cilweye, and causing the lubriestion system 10 fall 18 Crankshaft big ends and mein beorn renovation 1 allure of the big end bearing is invariably accompanied by @ knock within the erankces which progressively becomes worse. 16.4 Takeoff sing gat Some vibration wil iso be experianced 2° There should be no vertical ploy mhstsoever in the big end bearings, after che oil has been washed out. If even 2 smal amount of vertical play ie evidant, the Bearings are due for replacement. (A small amount of endfloa is both necesary and {eceptablel. Do nor continue to run the machine with worn big tend Beacngs, for there is «risk of breaking the connecting rade for erankehatt 3. The contruction of the crankshaft assembly procudes the possibility of repalr by the private owner or avon most agents. ty the majority of cases it will be necessry to obttin & replacement assy compete, froma KAWASAKI agent. “4 Failure of tha main basrings is usally evident i the form of ‘an ‘audible rumble from the crankesre, sosompanied by Vibration, whieh Is felt tough the footests and hendlebe 55 The crankshaft main bearings are of the cage roller ty woot is evident inthe form oF play or if roughness indicated then they are rotated, replocemant is necesary. Always check {or wear when the old oll has bean washed out of the assembly. Wilt i is possible to remove the outer bearings at each ond of the etankshaft, is probable that the cant bearings are also ‘wom. Hare agen, it ll be necessary to obtain 2 replacement rankshate assay. Chapter 1/Engine, clutch and gearbox a 18.1 The main bearings ere of the caged roller type 6 Failure of both the big end besrings end the min besringe may not necsssrly occur a the result of high mileage cover, tho machine is used infrequently or fora accession of short journeys, i is possibe that condensation within the engine may {ause premature bearing fllore. The condition of the flywheels is usually the best guide. Whon condensation troubles occur, the ‘yhoo wll tend to rust end become discoloured 19 Oi zeae: examination and replacement 1 Oil seal filo i iticult to dotineprocizly. Usually i takes the form of oil showing on the ouside of the machine, and there |s nothing worse than thoes unsightly. patches of l'on the sroure where the machine hes een standing. One of the most frucal places to lock for an oll leak is behind tho gearbox Final rive sprocket. The sal and 0’ ring that fits on the shat should be renewed If thoes any sign of lake 2 Another seal to watch isthe clutch pushrod seal that fits nto the crankcase in front of the gearbox sprocket. This sea can be replaced from the outside. fm) one! 0.040 inch (1.0 mm). If boring in excess of 1.0 mm Docomes necassary, the cylinder block must be Fenewod snes ‘on ines are not svsilabla from Keweeak 66 Woke sure the excernal cooling fs ofthe cylinder block are ee from oil and rood dirt, seth ean prevent the free flow of airover the engine and cause overheating problems, 21 Pistons ane piston rings: examination snd renovation 1 If arabore becomes ngsessary, th existing pistons and piston rings can be disregard because they will have to be replaced by their nee overs, 2" Fomove all tacos of earbon from the piston erowns, using @ blunt era scraper to avoid sevtching the surfoes, Finish off by polishing the crowns of each piston with matal polit 20 thet ‘earbon will not achore so rapidly inthe future. Never use emery fleth on te soft aluminium. '3 Piston wear Usually occurs at the skirt or lower and of the piston and taka the form of vertical sreske or soore marks on the thrust side of tha piston. Damage of this nature. will ecasitate renewal 44 The piston ring grooves may become enlarged in us, slowing the rings to have a greater side Float. If the clearance exceede 10.005 inch the pistons are due fr replacement. 15 To measure tho ond gap, inert soch piston ring Into its cylinder bore, using the crown of the bare piston to locate ft shout 1 inch from the top of the bors. Moke aur it equare in the bore and inset feler gauge in the end gep of the ring. 1 tho enc gap exceeds 0.028 ineh (0.7 mm) the ring mutt be renewed. The standard esp is 0.008 - 0.016 inch (0.2 0.4 mm) When refitting new piston rings, iti algo necesary to check the end gop. If there is insufficient clearance, the rings wl break lp in tha Dora wet the engine fe unning and cause extensive ‘damage. The ring gap may be increased by ling the end ofthe rings witha fine fe “The ring should be supported onthe end as much et possible to avoid breakage wen filing, and should be filed square wth the end. Remove only a amall amount of metal ata time and keoprechecking the clarance inthe bore. 2 Cylinder head examination and renovation 20 Cylinder block: examination an renovation 1. The usual indieation of bedly worn eylinder bores and pistons is excessive smoking ftom the exhausts. This uavaly fakes the form of @ blue haze tending to develop into white hate os the meer becomes more pronounce. 2 The other indieation ie plston slap, a form of a metalic ratle ‘which occurs when there site load gn the engine I the top of the bore is examined carofll, it wil ba found that tharo ie 3 ridge on the thrust side, the dopth of which will vary according te the rata of wear which has taken place. This marks the limit (0 tease of the top piston rng. 3 Maasure. the bore diamater just below the ridge using an internat micrometer, oF 3 dial gouge. Compare the reading You fotain wits the reading at the bottom oF the cylinder bore, which hes not been ‘subjected to any piston wour. If the ‘ifferance in readings exceeds 0,008 mm (0002 In.) the eylincee Dock will have to be bored and honed, and fitted with the required oversize pistons. it's moaning instrument ie not availabe, the amount of Cylinder ‘bore weer can Oe messured by inserting the piston (without rings) £0 that it is spproximatoly % inch trom tho top fof the bore. If it posible to insert 2 0.006 inch fesler gaune Between the piston and eylindar wall on the thrust side of the piston, remedial action most be token, ‘5 Kowasakl supply pistons in two oversize: 0.020 inch (0.8 1 Remove sll traces of carbon from the eylinder head using a blunt ended scraper (the round end of an old steel rue will do). Finih by polishing with metal polih to give 2 smooth shiny surfacs. This wll ad gos flow and wil also prevent carbon from fcharing 20 frm in the fate. 2 Check the condition of the spark plug hole threads. If the thveade are worn or crossed they ean bp reclaimed by 3 Helcoll Inert. Most motorcycle deslers operate this service wich is very simp, cheap, ond efectve 3” Gean the cylinder head fins with a wire brush, to prevent ‘overheating, through dit blocking the fins. 44" Lay the cylinder hood on a sheet of % inch plate glass to check for distortion. Aluminium alley cylinder heeds distort ‘ery easly, especially if the eylinder head bolts are tightened {down unevenly. tthe amount of distortion ie only light, ei Dermisaable to rub the head down until ite fat once agin by ‘wrapping a sheet of very fine emery cloth around the plat glass ‘axe and rubbing with a rotary moti. 5 If the cylinder head i distorted badly (one way of termining this ie If sho eylingar head gaskets have a tendency to keep blowing, the ewd vl have to be machined by 2 ‘compatent engineer exparieneed in this type of work. Ths wall, ff course, tase the compression ofthe engine, and if foo much i femoved can adversaly affect the performance of the engin. Hf there is sk of this happaning, the only remedy Ws 8 new Feplacement cylinder heed. Chapter 1/Engine, clutch and gearbox 23 Valves valve seats and valve guides: examination and 1 Remove the valve tppets and shims, Keeping them saparate for installation in their orginal locations. Compress the valve Springs with 2 valve spring compressor, and remove the split valve tollet, leo the oll seals from the valve guides, a¢ fe Best 9 fenew these latter components. 2" Remove the valves ond springs, making sur to kaop to the locations during assembly. Inspect the valves for_ wear, ‘overheating or burning. and replace them a= nocasary. Measure the head of the valve using verniar calipers. The standard measurement of tho head is: 0034 - 0.020 inch (0.85 - 1.15, ‘mm. Replace when the meesurement is below 0.020 inch (0.5 im). Carefully inspect the face of tha va for pitting, This an ‘Sometimes be taken out by using acoare grinding paste first and finshing off with 2 fing grinding paste, using 2 suetion grinder swith» rotary setion, Keep lifting the suction grinder to datrioute the atte on the valve face venly. Tho value surface angl s 45°. 3 Carefully inspect the valve set for pitting, if Ue alight it ‘may be possible to grind thi out by hand, using the Wetion ‘tinder and valve tochnique, asin the preceding paragraph. Ifthe pitting is too bad, the seat will require recuting with 2 seat 44" Measure the bore of wech valve guide in atleast four places Using 2 small Bore gauge. and. miromator. ‘The standard ‘measurement for the guide (internal diameters 0.2756 0.2762 ineh (7.000- 7-015 mm Ifthe messuremant sxcoeds 0.280 inch (7:10 mm the guide sould be reolsced witha new one. 5 If 3 small bore gouge and micrometer are not availble, inser 4 naw valve into the guide, and zat ail gouge aginst the valve fem. Gently move she vaive babk and forth in the guide ans ‘measure the travel of the valve in each diection. The guide wil Ihave to bo renawd if the cleaanee between the valve and guide ‘exeseds 0.004 inch (0.10 mal inlet ond exhaust 16. To install new valve guides, ist fit the crelip into the groove ound the auide then heat the area around the guide hole to 12509 - 3002F (120°. 150°C) and drive the guide in from the top of the cylinder head wsing a suitable drift, until the eicip eaehotits seat Use 2 7 mm reamer 10 ream 'the guides. This ‘must be done even if the ld guides sre used, Note: slays rotate the teamer to the right, and keep rotating Mt until it is withdrawn 7 tnmmect the valve springs for tit oF 2 collapsed condition. [Measure the free longth ofthe springs with 2 verior gouge and fenaw the springs @ 2 complete set if there is any variation in length betisen the springs. The moasuraments ara a¢ follows: Tnnerspring: 142i (3B0m) Standard Inner spring: 1-38 meh (350mm) ‘Wear it Outer spring: 1 B5inch (38.3) Standard Outer spring: FSDinch (280mm) Wear limit “Tho valve sprnge should slaaysbe replaced as » comple ta ensure maximum performance 24 Camshafts, appets and cama sprockets: examination are ‘TTmapect the came for vane of var eich as scored lobes, culfing, or Indentation. The cams should have 2 smooth suroce. ‘The complete camshaft murt be replaced ny Tae ate worn or indented, tough lubreation fllure ete. 2 "inspect the valve tappets for damage or fracture, aso the hime. Measure the shims with a micrometer eauge. Note: The ‘ype of value feppet used On all machines up to engine number 21.6.00979 har coused some frocturing of the shims. Those {appats mere of the concaw type, wires the new tye ta sre lvol It i Suitable to use now shims when replacing the Tapets, 2s the Old ones thal have been in use may alraady have arte to feature 2" Examine the camshaft chein eprockess for worn, broken or ‘hipped teeth. This fe important, 0 kagp the carm chain at the ALT Inspect cams for weae x 242 This shim has fractures 40 Chapter 1/Engine, clutch and gearbox 24.28 Measucing shim vith ierometer go 24.3 A broken tensioner, cauted through a slack chain ‘corract tension at all times. Indeed, the machine festured in thi ‘manual hed the eam chain tensioner weonaly adjusted, which in turn had broken the cam chain guide through the slckness of ‘tha eam chain in operation. 4" A'worn camshaft chain wl cause cstinetvp ‘atl thet wil not aliteppear, even when the tensioner i reaciusta. Some Indleation of the amount of war that hse akan place i given if ‘he chain f held at both ends and twisted sidaways. A badly worn chain sill bend into ‘8 pronounced are. If thre i any Soubt about a chan, it should be renowed without question. I's ‘hain breakage occurs, serious engine damage al result 55 Examine the rubber pod on the end of the chain tension push bar If itis wom or damaged, Te shoukd be replaced. The push boris a push ft into tha holder. 125 Clutch ae rer esin oil pump: examination and ranovatan 1 “The clutch assembly contains eight frition plates apd nen steel plates. The friction plates are stel with bonded cork, The Clutch housing incorporates rubber dampers and springs, these fra to reduce clutch vibration and anateh. The clutch role ‘uter operating worm gear is mae of nylon, and the Inner gear I made of stel. There bs 2 clutch najusting serv locetad in the 245 Remove tensioner body, to examine rubber pad Inner roleato gear which, when turned, dusts the clutch pushrod clearance. When the clutch needs adjustment, always fet this edstmant correct first, before finishing with the ‘Sperating cable. 2°" Check tho condition of the clutch deve, 10 ensure none of the teeth ore chipped, broken or badly worn: Give the pin an {nition plates 2 wash with 4 patellparattin mix in check that ‘they are not bucklad or distorted. Ramove all aces of fretion Gust, otherwise a gfacual bulla up ofthis msteria wall occur are Sect clutch action. 13 Visual inspection wil dow whether the tongues ofthe clutch Plater have become burrad and whether corramonding Indentations have formed in the slots with which they engage Burrs in the clutch housing should be removed with 2 ile, also the plates, provided the indentetons oe not too reat 44" Checie the thickness of the tietion plates The standord ‘thickness f 0.146 - 0.164 inch (3.73.9 mm. The wart (1134 ino 13.4 mm) '5 Inspect the clutch ples for norpoge by placing them on =| ‘heat of gla or rimilar flat surore, Place @ fooler gauge under: hath tho plato and the surface. The standarc tolorabla worpoa for the fiction plates i under 0.008 inch (0-15 evr) wlth 3 service limit of Q.012 inch (0.30 men Pain stel patos have 3 ‘Standard tolerable warpage of under 0.008 inch (0.20 me) with 25.10 The becder sew in chain ol pump (Z1 model only) {service limit of 0.016 inch (0.40 mm. 5 Inspect the clutch spring By standing thom together on afl surface. If they vary in height, the complete set should be renewed, "Roll the clutch pushrod on a shoot of glass to check for ‘ruenets. Algo make ture the clutch operating worm gear it greased for easy ection B Mako sure that the noodle role damaged. The whole clutch assembly there should be no undue wobato 9 The early 2.1. modal ae fitted with a rar chain oll pump, ‘riven by the layenatt and fed from a sparats oll tank located behind the loft hand eover under the dualseat. The ell pump is located in the outer chain cover ‘fitted over the rear chain final dive sprocket. To goin aoobs, unscrew the wo erossheod screw that hold the pump to the cover, and remove the pump ‘The "O' rings ond the check valve ore the only porte likely te "wear, and consoquantly are. the only wa replacemant pars. It any other parte of the pump are worn oF ‘dameged, the entire pump ately will have to ba replaced. 10 Cheek that the ehace vale will paso only in one direction snd that it isnot clogged. The valve cen be elesned with petal fr solvent in 9 syringe. Whenever the oll pump le ing it tros and not os on this bearing and 42 Chapter 1/Engine, clutch and gearbox enter the pump. The pump must then be bled of air by turning ‘the bleeder Bolt until oil flowe from the hole and then re Uightening i ‘11 Lubricate all the parts of the pump when reassembling, then rotato the rear wheel_until the pin in the lays (locatad through the eeerbox sprocket) ie brought into alignment with the groove in the oll pump shaft. Ths Is essntial for correct installation, othorwise the pump will not seot correctly. Blood ‘the pump ad make sure the love inthe oil tank is core. 26 Gearbox components: examinetion 1 Give all the gearbox components a close visual oxamination {or signs of wear oF damage, such as chipped oc broken tot, ‘wom doge or worn splinas and bent selector arma, Ifthe machine has shown @ tendency to jump aut of gear, look especially for ‘worn dogs onthe beck of the geo pnions or wearin the selector tracks of the gear Salector drum. In the former cas, woar wil ba ‘vidant in the form af rounded corner or oven a wedoe - shaped Drofile in an extreme case. The corners of the slactor drum ‘wacks will wear fit, ll such wear is event by the appesrance fof ebrightly polished surace. 2 “In the solsetor arms veer usuolly occurs arose the fork that lengages withthe siding gear pinions, causing a certain smount of Floppinass in the gear change movement. A bent selector will Immedistely be obvious, especialy #f overheating hae blued the sree, 3 All_gearbox componants that prove faulty will have to be replaced with new ones, 25 there is no sstsfactory method af feelaiming them. 27 Rascmbliog the cylinder bead 1 Commence reassembly by replcing the eight valves (four inlet end four exhaust). Do not omit to lubricate the valve stars with engine ol before inserting them Into the guides, and make fura that the valve calles are ssted correctly. A light tap on the fond of the vlve stm, sftrsssombly, isa good check. Make ture ‘ew ol seals are fitted tothe valve quid, 2 "Roplace the bearing halves for the camshafts, making sure that their notches locate into the cylinder hesd casting, end cevlinder head cover, then install the tappets and shims to thelr orract locations. Any shims or toppets that show signe of Fracture (inspect under magifying glass) must ba replaced with rw ones, Shims are supplied in different thicknesses to faiitate valve clearance adjustment on an inaiviual basis. 28 Engine and gearbox reassembly: general 1 All the engine and gosrbox components should be cleaned thoroughly before they are replaced, and be placed elas to the ‘working aes 2 The castings and covers that have all had goskete attached ‘should bp loaned, preferably with a clean raj soaked with ‘methylated spirit, This wil act ae a solvent for the geskot foment. Thiele 2 for etter method than reverting to soap, (with the risk of damage to the mating suraces, 3" Hove availble all the necesary tools and a con filled with ‘lean engine cl. Make sure all the new gaskets and any replace ‘ant parts required are valable anc to hand. There « nothing more ‘frustrating than having to. stop in the middle of Feassembly sequence because 8 vita gasket or part has been overlooked. Always use gnuine ‘Kawasaki’ parts. 42" hake sure tha working area ie well lit and clean, with plenty of space, as the Kawasaki engine is very big and foiry heavy, althouuh easy to work on. Role to the torque and clearance Settings whorovor they aro given. Many of the smaller bolts ae tosily sheared if overtightoned. Always use the correct size Seremdriver bit for the erosenaad serene and NEVER an ordinary flat blace scremdriver or wors stil 3 punch. Any screws heving hoads that sre Eadly damaged will prove almost imposible to remove on the next occasion, 20x reassembly: replacing the crankshaft 29 Engine and 1 Invert the upper crankcase and place it on the morkbanch. ‘Commence reestembly by lowering the crankshaft assembly fata position, zaking care to locate all the holes in the outer tracks of the msin bearings with the corresponding dows loosed in the Crankcats. Make sure tha cam drive chain looped over the {rankshaft at this stage. Feed the connecting rods through the ‘pertres in the crankcase and once the crankshaft isn postion, rotate it to. make sure all the main Besrings revolve fool, and ‘hat the sx'main ‘beringt are located correctly with the 4 donels. 2° Refit the crankshaft eantre bearing cap into postion. The bearing cap is bored in line with the erankeas, and must be Installad wath the arrow on the cap pointing towards the front of the engine. Secure the four bolts with 18 Toe (2.5 ka m) toraue in the nurnbared sequence shown, 27.2 Fit bushes into correct lation 29.1 The crankanatt and camenain. Note white marks fo timing 90.24 Note bush inside ith gear 27 “4 Chapter 1/Engine, clutch and gearbox ‘30 Engine and guarbax reassembly: rebuilding the gearbox 1 With the upper erankease stil Inverted on the banch and with ‘the crankshaft sesomy fvtalld, start to rebuild te gearbox Ey ‘teembling the meinahafe gear cluster 2 Flapiaco tho tn gear with bush 21T. Tha splined washes ‘wlth the external secporciclip follows ond then the Src ge (YT) seegar ctctip,splinad washer, the bush that fits inside the Sth gear and the Sth gear (237). Next oplace the small 2nd gear (eT), the two spacers, the neccla roller bearing togather th the shim and seagar circa, and the end bush. Place the bearig ‘on the opoceite and ofthe that, and make sur these ings thet locate the bearings are in position, 3 To rebuilt tho layshaFtclustor replace the shim behing the rg 1st gear (SBTI. Tiss the only gear withthe sx large holes bored in Tt Follow up wath the two spacers, the naccle roller Dearing, the shim, seesercrlip and the outer bush, Next repizge ‘the thre stool halls ineide the 4th goar (207) and eatit the oper tthe shett, The reason forthe ste! bale inside the gear pinion is to facts the election of neutral whem changing from 1 oe 4 Feplace the distance washer, the 3 gear (367) the spina washer, sbeger ciel and tha Sth goar (287). Then replace the Seopa crclin she distance splined washer and the 2nd geor bush {opether with the 2nd guar [6T). This is the large abar with the 1x large slongrted holes. Next coplace the distance washer and ‘the goerbox main bearing, Plao the string in position. The layshatt cluster can now be atsombled into the inverted ‘upper orankease making sure to locate the main besting with set ing into the groove and the dowel in tha erankease with the hole {in the bush atthe opposite enc of the shaft. 6 place the mainshatt cluster, agsin making eure that the ‘main bearing engages with the st rag In the crankcase, also that the erankease Gove engagor with the bush at tho opposite ond of the shat 7. The kickstart shafe assembly can now be replaced, making sure to position the ratchet onto the stop, whichis located an the crankeae 8 The clutch housing with needle roller bearing, and sheust ‘washer, positioned on the thaft behind the housing, ean now be ‘oploced. This must be corrlad out before the erankeaee halvee are joines, 18 Rope the goar selector drum withthe selator fork into the ower erankease half, and locate the drum vith the indent pln Bend over the tab washar on tho pin. The indent pin locetae In the and track of the cum and i spring load 10 Locate tho slactor forks with the siding 4th and Sth gear pinions then enter the slector fork shaft through the side ofthe frankoaso. Whon sssomblad. with the forks. in the correct position, fit tha external elellp over the end of the od to lorste the rod. 11 Before joining the erenkcas halves make sure the ‘O° ring located in the eantre of the erankcass. This seals the main oil ppasage for the whole of the engine. Thoroughly clean she frankcase meting surfees, and epply 8 liquid jointing cement 12 the surface of the loner half Seeura the eight & mm bolts in the lower oranseate half to 18 1 Ibe (2.6 kg ml: Tighten evenly following the order of the numbers stamped on the lower crankcase half. The desde of bolts number 6 and’@ should! be ‘coated with ler, to prevent oll seepove. 12 Now secure the twonty-tho 6 mm bolts to 2 torque of 70 Inch Ibs oF (0.8 ky m) ond coet the thread ofthe remaining bot with aqui seatane 13 Install the oll pump with the ‘O' ring inserted in the crankcase, the pure is located by two dowale. Check thatthe oil pump drive gear meshes corratly with the crankshaft gear wien installing the oil pump. Tighten the two mounting bolts to 8 orquo attng of 70 Inc oe (02 kg, 14 Replace the 0" ring on the tayshoft before installing the ‘ransmission cover, to provent oil leak. Uso 2 guide to protect ‘the oil seel when’ replacing the transmission inner cover, ard 30.2¢ Fit spacers ast 30.20 Set rings engage in grooves 30.134 The pump is located with to dowels 48. Chapter 1/Engine, clutch and gearbox 30.16 Make sure oil filter is clean install the distance collar over the layshatt whan the cover isin place, othernise the sal wll be damaged 4 Replace the oil sump cover wien the 91 mm 0" rng tin place tnd use a now gaskat, When the sump is bolted up, fit 3 how ol filter element to the filter unit, not omitting the spring land “Oring. When the sump bolts have been tightened up and ‘the desin plug secured, the engine unit ean be turned overt te correct position, withthe crankcase apertures facing upwards. ‘31 Engine and grarbox: rebuilding the clutch, alternator and contect brosor 1 place the breather assembly on top of the upper erankeate ‘withthe two eroschesdserows, and the polished alloy cover with the entire fixing and pipe forthe breather tube. The ol presre ‘switch can now be replaced. Make sure the two 'O" ringer in ‘otiton fst. Replace the rubber cap, 2 Rotate the Hickstart shaft all the way round to the right before hooking the retum spring into the hole in the shaft, this fives the spring the eorract tension. The kickstart cover ean now Be replaced with the four screws. S11 Two strove sure broathar base '3 place the detont lever with the bolt, and locate the return soring with tho pin. The detontlver engages behind the shroud, ‘onthe salector drum. 4° The foorchange lever shaft comatote with the selector paws nd spring con nov be inorted into the erankat, the sprocket

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