Instruction/ maintenance manual of the product ER-5 (2001) Kawasaki
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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 for the exact pages to locate the spe- cific topic required.
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ER-5 Motorcycle Service Manual All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical phot.
LIST OF ABBREVIA TIONS A ampere(s) lb pound(s) ABDC after bottom dead center m meter(s) AC alternating current min minute(s) AT D C after top dead center N newton(s) BBDC before bottom dead center Pa .
EMISSION CONTROL INFORMA TION T o protect the environment in which we all live, K awasaki has incorporated crankcase emis- sion (1) and exhaust emission (2) control system s in compliance with applicable regulations of the United States Environmental Protection Agency and California Air Resources Board.
T AMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for purposes of maint.
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.
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GENERAL INFORMA TION 1- 1 1 General Information T able of C ontents Before Servicing ................................................................................................................ ..... 1-2 Model Identification.......................
1-2 GENERAL INFORMA TION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly opera- tion on a motorcycle, read the precautions given below .
GENERAL INFORMA TION 1-3 Before Servicing (10) Liquid Gasket, Locking Agent Clean and prepare surfaces where liquid gasket or non-permanent locking agent will be used. Apply them sparingly . Excessive amount may b lock engine oil passages and cause serious dam- age.
1-4 GENERAL INFORMA TION Before Servicing T wo-Colo r Electrical (19) 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.
GENERAL INFORMA TION 1-5 Model Identification ER500-C1, D1 Left Side View ER500-C1, D1 Righ t Side View.
1-6 GENERAL INFORMA TION General Specifications Items EN500-C1 ∼ C2 EN500-C3 ∼ EN500-D1 Dimensions Overall Length 2 070 mm (81.5 in.) ← ← Overall Width 730 mm (28.74 in.) ← ← Overall Height 1 070 mm (42.13 in.) ← ← Wheelbase 1 430 mm (56.
GENERAL INFORMA TION 1-7 General Specifications Items EN500-C1 ∼ C2 EN500-C3 ∼ EN500-D1 Lubrication System Forced lubrication ← ← Engine Oil: Grade API SE, SF , SG or API SH or SJ with JASO MA ← ← Visco sity SAE10W-40 ← ← Capacity 3.4 L (3.
1-8 GENERAL INFORMA TION General Specifications Items EN500-C1 ∼ C2 EN500-C3 ∼ EN500-D1 Electrical Equipment Battery 12 V 10 Ah ← ← Headlight: Ty p e Semi-seal ed beam ← ← Bulb 12 V 60/55 .
GENERAL INFORMA TION 1-9 Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the motorcycle i n good running condition.
1-10 GENERAL INFORMA TION Periodic M aintenance Chart FREQUENCY Whichever comes first * ODOMET ER READING × 1 000 km (× 1 000 mile) 1 6 12 18 24 30 36 INSPECTION Every (0.
GENERAL INFORMA TION 1-1 1 T orque and Locking Agent T ighten all bolts and nuts to the proper torq ue using an accurate torque wrench. An insufficiently tightened bolt or nut may become damaged or fall off, possibly resulting in damage to the motorcycle and injury to the rider .
1-12 GENERAL INFORMA TION T orque and Locking Agent T orque Fastener N·m kgf·m ft·lb Remarks W ater Pipe Bolts 9.8 1.0 87 in·lb L Cylinder Head Jacket Plug 9.8 1. 0 87 in·lb L Air Suction V alve Cover Bolts 11 1.1 95 in·lb Coolant Drain Plug 11 1.
GENERAL INFORMA TION 1-13 T orque and Locking Agent T orque Fastener N·m kgf·m ft·lb Remarks Engine Oil Drain Plug 29 3.0 22 Oil Pan Mounting Bolts 11 1.1 95 i n·lb Oil Pump Mounting Bolts 11 1.1 95 in· lb Breather Body Bolt 5.9 0.6 52 in ·lb Engine Removal/Installation Downtube Bolts 44 4.
1-14 GENERAL INFORMA TION T orque and Locking Agent T orque Fastener N·m kgf·m ft·lb Remarks Front Brake Light Switch Mounting Screw 1.2 0.12 10 in·lb Caliper Mounting Bolts 34 3.5 25 Caliper Bleed V alves 7.8 0.8 69 in·lb Brake Disc Mounting B olts 27 2.
GENERAL INFORMA TION 1-15 T orque and Locking Agent T orque Fastener N·m kgf·m ft·lb Remarks Starter Clutch Allen Bolts 34 3.5 25 L Sidestand Switch Mounting Screw 3.9 0.4 35 in·lb L Sidestand Mounting Bolt 44 4.5 33 Starter Motor T erminal Locknut 6.
1-16 GENERAL INFORMA TION Special T ools a nd Sealants Piston Ring Pliers: 57001-1 15 Oil Pressure Gauge, 5 kgf/cm²: 57001-125 Bearing Puller: 57001-135 Bearing Puller Adapter: 57001-136 Steering Ste.
GENERAL INFORMA TION 1-17 Special T ools and S ealan ts V alve Spring Compressor Assembly: 57001-241 Bearing Puller Ad apter: 57001-317 Bearing Driver , 32: 57001-382 Piston Pin Puller Assembly: 57001-910 Fuel Level Gauge: 57001-1017 V alve Guide Arbor , 5.
1-18 GENERAL INFORMA TION Special T ools a nd Sealants Bead Breaker Assembly: 57001-1072 Steering Stem Bearin g Driver Adapter , 34.5: 57001-1074 Head Pipe Outer Race Press Shaft: 57001-1075 Head Pipe Outer Race Driver , 51.5: 57001-1076 V alve G uide Reamer , 5.
GENERAL INFORMA TION 1-19 Special T ools and S ealan ts Va l v e S e a t C u t t e r, 3 2 ° - 25: 57001-1 1 18 Va l v e S e a t C u t t e r, 3 2 ° - 30: 57001-1 120 Va l v e S e a t C u t t e r, 6 0 ° - 30: 57001-1 123 V alve Seat Cutter Holder , 5.
1-20 GENERAL INFORMA TION Special T ools a nd Sealants Rotor Puller , M16/M18/M20/M22 × 1.5: 57001-1216 Fork O uter T ube Weight: 57001-1218 Front Fork Oil Seal Driver: 57001-1219 Jack: 57001-1238 Ti.
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1-22 GENERAL INFORMA TION Special T ools a nd Sealants Kawasaki Bond (Silicone Sealan t): 56019-120 Kawasaki Bond (Liquid Gasket - Black) TB1 105: 92104-100 3.
GENERAL INFORMA TION 1-23 Cable, Wire, and Hose Routing 1. V acuum Hose 2. Air Hose 3. Fuel Hose 4. Throttle and Choke C ables 5. Fuel Filters 6. Fuel T ap 7. T o the air suction valve. 8. T o the vacuum switch valve. 9. Clamp 10. T o the fuel tap. 1 1.
1-24 GENERAL INFORMA TION Cable, Wire, and Hose Routing 1. Throttle Cables 2. Choke Cable 3. Right Handlebar Switch Leads 4. Horn 5. Clutch Cable 6. Left Handlebar Switch Leads 7. Brake H ose 8. Speedometer Cable 9. Run the cables outside. 10. Run the clutch cable inside the cross pipe.
GENERAL INFORMA TION 1-25 Cable, Wire, and Hose Routing 1. Handlebar Switch Harness 2. Main Harness 3. Radiator Fan Switch 4. Alternator Connector 5. Pickup C oil Connector 6. Neutral Switch Lead 7. Sidestand Switch Lead 8. Battery Negative Lead 9. Battery Positive Lead 10.
1-26 GENERAL INFORMA TION Cable, Wire, and Hose Routing 1. Radiator 2. Thermostat Housing 3. Coolant Filter 4. Carburetor 5. Reserve T ank 6. Coolant V alve 7. Reserve T ank Overflow Hose 8. Air Cleaner Drain H ose 9. Cross P ipe 10. Damper 1 1. Radiator Cover 12.
GENERAL INFORMA TION 1-27 Cable, Wire, and Hose Routing 1. Reserve T ank 2. Reserve T ank Overflow Hose 3. Clamps.
1-28 GENERAL INFORMA TION Cable, Wire, and Hose Routing 1. Starter Motor 2. Positive Lead 3. Negative Lead 4. Plate 5. Pickup Coil 6. Pickup Coil Mounting Bolts 7. T ighten the starter motor negative lead terminal with the rear starter mounting bolt. 8.
GENERAL INFORMA TION 1-29 Cable, Wire, and Hose Routing 1. #1 Ignition Coil Connectors 2. Radiator Fan Switch Connector 3. Left Handlebar Switch Connectors 4. W ater T emperature Switch Ground T ermi- nal 5. W a ter T emperature Switch 6. Battery Negative Lead 7.
1-30 GENERAL INFORMA TION Cable, Wire, and Hose Routing 1. Fuel T ank 2. Fuel T ank Upper Drain Hose 3. Catch T ank 4. Reserve T ank Hose 5. Main Harness 6. Fuel T ank Lower Drain Hose 7. Plug 8. Reserve T ank Overflow Hose 9. Air Cleaner Drain H ose 10.
FUEL SYSTEM 2-1 2 Fuel System T able of C ontents Exploded View ................................................................................................................... ..... 2-2 Specifications ..............................................
2-2 FUEL SYSTEM Exploded V iew 1. Throttle Cable (accelerator) 2. Throttle Cable (decelerator) 3. Choke Cable 4. Pilot Screw 5. Pilot (Slow) Jet 6. Needle Jet 7.
FUEL SYSTEM 2-3 Exploded V iew 1. V acuum Switch V alve 2. Air Cleaner Housing 3. Air Cleaner Element T1: 0.8 N·m (0.08 kgf·m, 7 in·lb) T2: 1.0 N·m (0.
2-4 FUEL SYSTEM Specifications Item Standard Throttle Grip Free Play 2 ∼ 3m m( 0 . 0 8 ∼ 0.12 in.) Choke Cable Free Play 2 ∼ 3m m( 0 . 0 8 ∼ 0.12 in.) Carburetors Mark, T y pe KEIHIN CVK34 Idle Speed 1 200 ±50 r/min (rpm) Pilot S crew (Turns Out) (1 1/4 ±1/4 for refe rence) Synchronization V acuum 2.
FUEL SYSTEM 2-5 Throttle Grip and Cables Throttle Cable Inspection Throttle Grip Free Play Inspection • Check throttle grip play [A] by lightly turning the throttle grip back and forth. If the free play is improper , adjust the throttle cable. Throttle Grip Free Play Standard: 2 ∼ 3 mm (0.
2-6 FUEL SYSTEM Throttle Grip and Cables • Check that the throttle pulley [A] stops against the idle adjusting screw [B], with the throttle grip released and stops against the carburetor stopper with the throttle grip opened. • T urn the handlebar from side to side while idling the en- gine.
FUEL SYSTEM 2-7 Choke C able Free Play Inspection • Push the choke lever [A] all the way to the front. • Check choke cable free play [B]. ○ Determine the amount of choke cable play at the choke lever .
2-8 FUEL SYSTEM Carburetors Idle Speed Inspection Idle Speed Inspection • Start the engine and warm it up thoroughly . • With the engine idling, turn the handlebar to both sides. If handlebar movement changes the idle speed, the throt- tle cable may be improperly adjusted or incorrectly routed, or it may be damaged.
FUEL SYSTEM 2-9 Carburetors Carburetor Removal WA R N I N G Gasoline is extremely flammable and can be ex- plosive under certain conditions. T urn the ignition switch OFF . Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light.
2-10 FUEL SYSTEM Carburetors • Install the holder clamps [A] as shown being careful of the screw position and the screw head [B] direction. W ARNING Install the clamp screws horizontally as shown. Otherwise the screws could come in contact with the vacuum adjusting screws, resulting in an un- safe riding condition.
FUEL SYSTEM 2-1 1 Carburetors • Connect fuel level gauge [A] to the rubber hose. Special T ool - Fuel Level Gauge: 57001-1017 • Hold the gauge vertically against the side of the carburetor body so that the "middle" line [B] is several millimeters higher than the bottom edge [D] of the carburetor body .
2-12 FUEL SYSTEM Carburetors • Bend the tang [A] on the float arm very slightly to change the float height. Increasing the float height lowers the fuel level and decreasing the float height raises the fuel level. Float Height 17.0 ±2.0 m m (0.67 ±0 .
FUEL SYSTEM 2-13 Carburetors • T urn in the pilot screw and count the number of turns until it seats fully but not tightly , and then remove the screw .
2-14 FUEL SYSTEM Carburetors • Slip the jet needle through the hole in the center of the vacuum piston, and put the spring seat [A] on the top of the needle. T urn the seat so that it does not block the hole [B] at the bottom of the vacuum piston. Carburetor Separation/Assembly • Read the W ARNINGS in the Carburetor Removal.
FUEL SYSTEM 2-15 Carburetors CAUTION Do not use compres sed air on an assembled car- buretor , or the floats may be crushed by the pres- sure, and the vacuum piston diaphragms may be damaged. Remove as many rubber or plastic parts from the carburetor as possible before cleaning the carburetor with a cleaning solution.
2-16 FUEL SYSTEM Carburetors • Disassemble the carburetors. • Clean the carburetors. • Check that the O-rings on the float bowl and drain plug and the diaphragm on the vacuum piston are in good con- dition. If any of the O-rings or diaphragms a re not in good con- dition, replace them.
FUEL SYSTEM 2-17 Air Clean er Element Removal • Remove: Left Side Cover (see Frame chapter) Screws [A] Nut [B] Inlet Pipe [C] • Remove the element [A]. • Push a clean, lint-free towel into the carburetor intake to keep dirt or other foreign material from entering.
2-18 FUEL SYSTEM Air Cleaner Air Cleaner Draining A drain hose [A] is provided beneath the air cleaner hos- ing, and catches the water or oil from the bottom of the hose.
FUEL SYSTEM 2-19 Fuel T ank Fuel T ank Removal WA R N I N G Gasoline is extremely flammable and can be ex- plosive under certain conditions. T urn the ignition switch OFF . Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light.
2-20 FUEL SYSTEM Fuel T ank • Remove the fuel tank [A]. • Drain the fuel tank. ○ Place a suitable container under the fuel tank. ○ T urn the fuel tap to the PRI position to drain the fuel into the container . Fuel T ank Installation • Read the WARNING in the Fuel T ank Removal section.
FUEL SYSTEM 2-21 Fuel T ank Fuel T ank and T ap C leaning • Remove the fuel tank and drain it. • Pour some high flash-point solvent into the fuel tank and shake the tank to remove dirt and fuel deposits.
2-22 FUEL SYSTEM Fuel Hose Fuel Hose and Connection Inspection ○ Check the fuel hose periodically in accordance with the Periodic Maintenance C hart, and if the motorcycle is not properly handled, the inside the fuel line can cause fuel to leak [A] or the hose to burst.
COOLING SYSTEM 3-1 3 Cooling System T able of C ontents Exploded View ................................................................................................................... ..... 3-2 Specifications ........................................
3-2 COOLING SYSTEM Exploded V iew 1. Radiator Fan Switch 2. W a ter T emperature Switch 3. Thermostat 4. Coolant Drain Plug T1: 2.5 N·m (0.25 kgf·m, 22 in·lb) T2: 7.8 N·m (0.8 kgf·m, 69 in·lb) T3: 1 1 N·m (1.1 kgf·m, 95 in·lb) T4: 9.8 N·m (1.
COOLING SYSTEM 3-3 Specifications Item Standard Coolant Provided when Shipping T ype (recommended) Permanent type antifreeze (soft water and ethylene glycol plus corrosion and rust inhibi tor chemicals for aluminum engines and radiators) Color Green Mixed Ratio Soft water 50%, coolant 50% Freezing Point –35°C (–31°F) T otal A mount 1 .
3-4 COOLING SYSTEM Coolant F low Chart Permanent type antifreeze is used as a coolant to protect the cooling system from rust and corrosion. When the engine starts, the w ater pump turns and the coolant circulates. The thermostat is a wax pellet type which opens or closes with coolant temperature changes.
COOLING SYSTEM 3-5 Coolant Coolant De terioration Inspection • Visually inspect the coolant i n the reservoir tank. ○ If whitish cotton-like wafts are observed, aluminum parts in the cooling system are corroded. If the coolant is brown, iron or steel parts are rusting.
3-6 COOLING SYSTEM Coolant Coolant Filling • Install the drain plug [A]. Always replace the gasket with a new one, if it is damaged. • T ighten the drain plug.
COOLING SYSTEM 3-7 Coolant • Remove the reserve tank cap. • Fill the reserve tank up to the F level [A] with coolant and install the cap. CAUTION Do not add more coolant above the F level. • Install the fuel tank. • Install the seat. Visual Le ak Insp ection Any time the system slowly loses water , inspect for leaks.
3-8 COOLING SYSTEM Coolant Flushing Over a period of time, the cooling system accumulates rust, scale, and lime in the water jacket and radiator . When this accumulation is suspected or observed, flush the cool- ing system.
COOLING SYSTEM 3-9 W ater Pump Water P ump Removal • Drain the coolant. • Loosen the clamp and remove the radiator hose [A] from the water pump cover [B]. • Remove the four cover bolts [C]. • With the water pipe [D] attached, remove the water pump cover .
3-10 COOLING SYSTEM Wa t er P um p • Be sure to install the water pipe O-rings [A], and apply high temperature grease to them. • Install the water pump cover with the water pipe, being careful of the two knock p ins [B]. T orque - W ater Pump Cover Bolts: 1 1 N·m (1.
COOLING SYSTEM 3-1 1 W ater Pump Impeller Assembly • Clean the s liding surface of the mechanical seal w ith a high flash-point solvent, and apply a little coolant to the sliding surface to give the mechanical seal initial lubrica- tion.
3-12 COOLING SYSTEM Radiator , Radiator Fan W ARNING The radiator fan is connected directly to the bat- tery . The radiator fan may start even if the ignition switch is off. NEVER TOUCH THE RADIA TOR F AN UNTIL THE RADIA T OR F AN CONNECTOR IS DIS- CONNECTED.
COOLING SYSTEM 3- 13 Radiator , Radiator Fan CAUTION When cleaning the radiator with steam cleaner , be careful of the following to prevent radiator damage. 1) Keep the steam gun [A] away more than 0.5 m (20 in.) [B] from the radiator core. 2) Hold the steam gun perpendicular to the core sur- face.
3-14 COOLING SYSTEM Radiator , Radiator Fan Radiator Hose a nd Connection Inspection ○ The high pressure inside the radiator hose can cause coolant to leak [A] or the hose to burst if the line is not properly maintained. Visually inspect the hoses for signs of deterioration.
COOLING SYSTEM 3- 15 Thermostat Thermostat Removal • Remove: Coolant (Draining) Seat (see Frame chapter) Fuel T ank (see Fuel System chapter) • Unscrew the thermostat housing bolts [A]. • Separate the housing from the housing cover [B]. • Pull out the thermostat [A].
3-16 COOLING SYSTEM Radiator Fan Switch, W a ter T emperature Switch CAUTION The fan switch or the water temperature switch should never be allowed to fall on a hard surface. Such a shock to these parts can damage them. Radiator Fan Switch Removal • Pull out the cover [A].
ENGINE T OP END 4-1 4 Engine T op E nd T able of C ontents Exploded View ................................... 4-2 Specifications .................................... 4-4 Clean Air System ............................... 4-6 V acuum Switch V alve Removal .
4-2 ENGINE T OP END Exploded V iew 1. Closed coil end faces downward. 2. Arrow points to the front (ER500-C1 ∼ C4). Install the piston so that the circle mark on the top of the piston come to front side of the engine (ER500-C5). 3. “N” marked side faces up.
ENGINE T OP END 4-3 Exploded V iew T1: 13 N·m (1.3 kgf·m, 9.5 ft·lb) T2: 9.8 N·m (1.0 kgf·m, 87 in·lb) T3: 1 1 N·m (1.1 kgf·m, 95 in·lb) T4: 12 N·m (1.2 kgf·m, 8.5 ft·lb) T5: 15 N·m (1.5 kgf·m, 1 1.0 ft·lb) T6: 20 N·m (2.0 kgf·m, 14.5 ft·lb) T7: 25 N·m (2.
4-4 ENGINE T OP END Specifications Item Standard Service Limit Clean Air System V acuum Switch V alve Closing Pressure Open → Close 57 ∼ 65 kPa (430 ∼ 490 mmHg) ––– Camshafts Cam Height: Exhaust 35.475 ∼ 35.591 mm (1.3967 ∼ 1.4012 in.) 35.
ENGINE T OP END 4-5 Specifications Item Standard Service Limit Outside diameter: Exhaust 24.0 ∼ 24.2 mm (0.945 ∼ 0.953 in.) ––– Inlet 28.3 ∼ 28.5 mm (1.1 14 ∼ 1.122 in.) ––– V a l v es p r i n gf r e el e n g t h : Inner 36.3 mm (1.
4-6 ENGINE T OP END Clean Air System V acuum Switch V alve Removal • Remove: Fuel T ank (see Fuel System chapter) • Remove the clamps [A] and take off the vacuum switch valve [B]. V a cuum Switch V alve Installation • Install the vacuum switch valve so that the air hole [A] faces downwards.
ENGINE T OP END 4-7 Clean A ir System Clean Air System Hose Inspection • Be certain that all the hoses are routed without being flat- tened or kinked, and are connected correctly to the air cleaner housing, silencer , vacuum switch valve, carbure- tors, and air suction valve covers.
4-8 ENGINE T OP END Cylinder Head Cover Cylinder Head Cover Removal • Drain the coolant (see Cooling System chapter). • Remove: Fuel T ank (see Fuel System chapter) Choke Cable Lower End [A] Throttle Cable Lower Ends [B] Spark Plug Caps [C] V acuum Switch V alve [D] Thermostat Housing [E] • Unscrew the cylinder head cover bolts [A].
ENGINE T OP END 4-9 Camshaft Chain T ensioner Camshaft Chain T ensioner Removal CAUTION This is a non-return type cam chain tensioner . The push rod does not return to its original position once it moves out to take up cam chain slack.
4-10 ENGINE T OP END Camshaft, Camshaft Chain Camshaft Removal • Remove the cylinder head cover . • Position the crankshaft at #2 piston TDC. ○ Using a wrench on the crankshaft rotation bolt tur.
ENGINE T OP END 4-1 1 Camshaft, Camshaft Chain • Engage the camshaft chain w ith the camshaft sprockets. ○ Pull the tension side [A] (inlet side) of the chain taut to install the chain. ○ The timing marks [B] on the inlet sprocket [C] must be aligned with the cylinder head upper surface [D].
4-12 ENGINE T OP END Camshaft, Camshaft Chain Camshaft, Camshaft Cap Wear The journal wear is measured using plastigage (press gauge), which is inserted into the clearance to be mea- sured. The plastigage indicates the clearance by the amount it is compressed and widened when the parts are assembled.
ENGINE T OP END 4-13 Rocker Shaft, Rocker Arm Rocker Shaft, Rocker Arm Removal • Remove the camshafts (see Camshaft Removal). • Unscrew the rocker shafts [A] and remove the rocker arms [B] and springs [C]. ○ Mark and record the rocker arm locations so that the rocker arm can be reinstalled in their original positions.
4-14 ENGINE T OP END Oil Pipe Cylinder Head Oil Pipe Removal • Remove the oil pipe mounting bolts [A] and pull the oil pipes [B] and O-rings out of the cylinder head. Cylinder Head Oil Pipe Installation • Flush out the oil pipes with a high flash-point solvent.
ENGINE T OP END 4-15 Cylinder Head Compression Measurement • Remove the seat (see Frame chapter). • Thoroughly warm up the engine so that the engine oil be- tween the piston and cylinder wall will help seal compres- sion as it does during normal running.
4-16 ENGINE T OP END Cylinder Head Cylinder Head Removal • Remove: Cylinder Head Cover (see Cylinder Head Cover Re- moval) Exhaust Pipes and Mufflers (see Crankshaft/T ransmis- sion chapter) Cam Cha.
ENGINE T OP END 4-17 Cylinder Head • Install a new cylinder head gasket with "UP" [A] marked side positioning to the right. NOTE ○ The camshaft caps are machined with the cylinder head so if a new cylinder head is installed, use the caps that are supplied with the new head.
4-18 ENGINE T OP END Cylinder Head • Using compressed air , blow out any particles which may obstruct the oil passage [A] in the cylinder head. • Install the valves (see V alve Installation).
ENGINE T OP END 4-19 Va l v e s V alve Clearance Inspection V alve Clearance Inspection NOTE ○ V alve clearance must be checked and adjusted w hen the engine is cold (room temperature). • Remove the cylinder head cover (see Cylinder Head Cover Removal).
4-20 ENGINE T OP END Va l v e s • Measure the clearance of each valve by inserting a thick- ness gauge [A] between the adjusting screw [B] and the valve stem. V alve Clearance (when cold) Inlet 0.13 ∼ 0.18 mm (0.0051 ∼ 0.0071 in.) Exhaust 0.18 ∼ 0.
ENGINE T OP END 4-21 Va l v e s Va l v e G ui d e R e mo va l • Remove: V alve (see V alve Removal) Oil Seal Spring Seats • Heat the area around the valve guide to about 120 ∼ 150°C (248 ∼ 302°F), and hammer lightly on the valve guide arbor [A] to remove the guide from the top of the head.
4-22 ENGINE T OP END Va l v e s If the width is too wide, too narrow o r uneven, repair the seat (see V alve Seat Repair). [F] Good [G] T oo Wide [H] T oo Narrow [J] Uneven V a l v eS e a t i n gS u r f a c eW i d t h Inlet 0.5 ∼ 1.0 mm (0.020 ∼ 0.
ENGINE T OP END 4-23 Va l v e s Seat Cutter Operating Cares 1. This valve seat cutter is developed to grind the valve for repair . Therefore the cutter must not be used for other purposes than seat repair . 2. Do not drop or shock the valve seat cutter , or the dia- mond particles may fall off.
4-24 ENGINE T OP END Va l v e s • Measure the outside diameter (O.D.) of the seating sur- face with a vernier caliper . If the outside diameter of the seating surface is too small, repeat the 45° grind [A] until the diameter is within t he specified range.
ENGINE T OP END 4-25 Va l v e s • Lap the valve to the s eat, once the seat width and O.D. are within the ranges specified above. ○ Put a little coarse grinding compound on the face of the valve in a number of places around the valve head.
4-26 ENGINE T OP END Va l v e s.
ENGINE T OP END 4-27 Cylinder , Piston Cylinder Removal • Remove the cylinder head (see Cylinder Head Removal). • Remove the main oil pipe mounting bolt. • Remove the bolts [A] and pull out the water pipe with wa- ter pump cover [B] (see Cooling System chapter).
4-28 ENGINE T OP END Cylinder , Piston Piston Installation • Install the oil ring expander [A] in the piston oil ring groove so that the expander ends [B] butt together , never overlap. • Install the upper and lower steel rails. There i s no UP or Down to the rails.
ENGINE T OP END 4-29 Cylinder , Piston Piston Ring, Piston Ring Groove Wear • Check for uneven groove wear by inspecting the ring seat- ing. The rings should fit perfectly parallel to the groove sur- faces.
4-30 ENGINE T OP END Cylinder , Piston Piston Diameter • Measure the outside diameter [A] of each piston 5 mm [B] up from the bottom of the piston at a right angle to the direction of the piston pin. If the measurement is under the service limit, replace the piston.
ENGINE T OP END 4-31 Carburetor Holder Carburetor Holder Installation • Install the carb uretor holders. The projection [A] faces upwards. • Install the holder clamps [A] as shown being careful of the screw position and the screw head [B] direction.
4-32 ENGINE T OP END Muffler Muffler Removal • Unscrew the muffler mounting bolt and nut [A]. • Remove the exhaust pipe holder nuts [A]. • T ake off the muffler [A]. Muffler Installation • Replace the exhaust pipe holder gaskets with new ones.
CLUTCH 5-1 5 Clutch T able of C ontents Exploded View ................................................................................................................... ..... 5-2 Specifications ........................................................
5-2 CLUTCH Exploded V iew 1. Starter Lockout Switch CL: Apply cable lubricant. G: Apply high temperature grease. M: Apply molybdenum disulfide grease. O: Apply engine oil.
CLUTCH 5-3 Exploded V iew T1: 1.5 N·m (0.15 kgf·m, 13 in·lb) T2: 9.3 N·m (0.95 kgf·m, 82 in·lb) T3: 1 1 N·m (1.1 kgf·m, 95 in·lb) T4: 132 N·m (13.
5-4 CLUTCH Specifications Item Standard Service Limit Clutch Lever Position Non-adjustable ––– Clutch Lever Free Play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) ––– Clutch Friction Plate Thickness 2.9 ∼ 3.1 mm (0.1 14 ∼ 0.122 in.) 2.75 mm (0.1082 in.
CLUTCH 5-5 Clutch Lever and Cabl e Due to f riction plate wear and clutch cable stretch over a long period of use, the clutch must be adjusted in accor- dance with the Periodic Maintenance Chart. WA R N I N G T o avoid a serious burn, never touch the engine or exhaust pipe during clutch adjustment.
5-6 CLUTCH Clutch Lever and Cable Cable Lubrication Whenever the clutch cable is removed, lubricate the clutch cable as follows. • Apply a thin coating of grease to the cable upper and lower ends. • Lubricate the cable with a penetrating rust inhibitor .
CLUTCH 5-7 Right Engine Cover Clutch Cover Removal • Drain the engine oil (see Engine Lubrication S ystem chapter). • Remove: Clutch Cable Right Footpeg Assembly Clutch Cover Bolts [A] • T urn the release lever [B] toward the front as shown, and remove the clutch cover .
5-8 CLUTCH Right Engine Cover • Free the clutch inner cable tip from the clutch release lever [A]. • T urn the release lever toward the rear [ B] as shown in the figure. • Pull the lever and shaft assembly out of the clutch cover . Clutch Release Installation CAUTION Always install a new oil seal when the clutch release shaft is removed.
CLUTCH 5-9 Clutch Clutch Removal • Drain the engine oil (see Engine Lubrication S ystem chapter). • Remove the clutch c over (see Clutch Cover Removal). • Remove the clutch spring bolts [A], washers [B] and springs. • Remove the clutch spring plate [C] with the thrust ball bearing [D] and pusher [E].
5-10 CLUTCH Clutch ○ The grooves [A] on the friction plate surfaces are cut tan- gentially and radially , install the friction plates so that the grooves run toward the center in the d irection of the clutch housing rotation (counterclockwise viewed from the en- gine right side).
CLUTCH 5-1 1 Clutch Clutch Spring Free Length Measurement • Measure the free length of the clutch spring [A]. If any spring is shorter than the service limit, it must be replaced. Clutch Spring Free Length Standard: 34.2 mm (1.346 in.) Service Limit: 33.
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ENGINE LUBRICA TION SYSTEM 6 -1 6 Engine Lubrication System T able of C ontents Exploded View ................................................................................................................... ..... 6-2 Engine Oil Flow Chart..........
6-2 ENGINE LUBRICA TION SYSTEM Exploded V iew 1. Oil Filter 2. Main Oil Passage Plug 3. Oil Pump Drive Gear 4. Oil Pump 5. Oil Screen 6. Oil Pressure Relief V alve 7.
ENGINE LUBRICA TION SYSTEM 6 -3 Exploded V iew T1: 1.5 N·m (0.15 kgf·m, 13 in·lb) T2: 7.8 N·m (0.80 kgf·m, 69 in·lb) T3: 1 1 N·m (1.1 k gf·m, 95 in·lb) T4: 12 N·m (1.2 kgf·m, 8.5 ft·lb) T5: 15 N·m (1.5 kgf·m, 1 1.0 ft·lb) T6: 17 N·m (1.
6-4 ENGINE LUBRICA TION SYSTEM Engine Oil Flow Chart.
ENGINE LUBRICA TION SYSTEM 6-5 Specifications Item Standard Engine Oil Grade API SE, SF , S G or API SH or SJ JASO MA Vis c os it y SAE 10W-40 Capacity 2.
6-6 ENGINE LUBRICA TION SYSTEM Engine Oil and Oil Filter W ARNING Motorcycle operation with insufficient, deteri- orated, or contaminated engine oil will cause accelerated wear and may result in engine or trans- mission seizure, accident, and injury .
ENGINE LUBRICA TION SYSTEM 6-7 Engine Oil and Oil Filter • Fill the engine with a good quality motor oil specified in the table. • Check the oil level. Engine Oil Grade: API SE, SF , SG or API SH or SJ with JASO MA Vis co s it y: SAE 10W 40 Capacity: 2.
6-8 ENGINE LUBRICA TION SYSTEM Oil Pan and Relief V alve Oil Pan Removal • Drain the engine oil (see Engine Oil Change). • Disconnect the oil pressure switch lead.
ENGINE LUBRICA TION SYSTEM 6-9 Oil Pan and Relief V alve Relief V alve Inspection • Remove the relief valve. • Check to see if the steel ball inside the valve slides smoothly when pushing it in with a wooden or other soft rod, and see if it comes back to its seat by valve spring pressure.
6-10 ENGINE LUBRICA TION SYSTEM Oil Pump Oil Pump Removal • Drain the coolant (see Cooling System chapter). • Drain the engine oil (see Engine Oil Change).
ENGINE LUBRICA TION SYSTEM 6-1 1 Oil Pump • Be sure to install the oil pump and outer oil pipe O-rings [A], and apply engine oil to them. • Install the oil pump outer oil pipe [B] and oil screen. ○ Apply a non-permanent locking agent to the oil pipe bolt and tighten it.
6-12 ENGINE LUBRICA TION SYSTEM Oil Pressure Measurement Oil Pressure Measurement NOTE ○ Measure the oil pressure after the engine is warmed up. • Remove: Right Footpeg Assembly Oil Passage Plug W ARNING If the oil passage p lug is removed while the engine is warm, hot engine oil will drain through the oil pas- sage; take care against burns.
ENGINE REMOV AL/INST ALLA TION 7-1 7 Engine Removal/Installation T able of C ontents Exploded View ................................................................................................................... ..... 7-2 Engine Removal/Installation .
7-2 ENGINE REMOV AL/INST ALLA TION Exploded V iew T1: 44 N·m (4.5 kgf·m, 33 ft·lb) T2: 25 N·m (2.5 kgf·m, 18 ft·lb).
ENGINE REM OV AL/INST ALLA TION 7-3 Engine Removal/Installation Engine Removal • Set the motorcycle up on its center stand. • Squeeze the brake lever slowly and hold it with a band [A]. WA R N I N G Be sure to hold the front brake when removing the engine, or the motorcycle may fall over .
7-4 ENGINE REMOV AL/INST ALLA TION Engine Removal/Installation • Remove: Battery Negative Lead [A] Starter Motor Lead [B] • Remove: Oil Pressure Switch Lead [A] Neutral Switch Lead [B] Sidestand Switch Lead Connector [C] • Support the engine with a stand or jack [A].
ENGINE REM OV AL/INST ALLA TION 7-5 Engine Removal/Installation • Insert the rear mounting bolts from the left side of the engine. • T ighten the rear engine upper mounting bolt and nut first to eliminate the gap betwe en the engine and frame bracket, and then the rear engine lower mounting bolt and nut.
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CRANKSHAFT/TRANSMISSION 8-1 8 Crankshaft/T ransmission T able of C ontents Exploded View ................................................................................................................... ..... 8-2 Specifications .....................
8-2 CRANKSHAFT/TRANSMISSION Exploded V iew 1. 8 mm Bolt (55 mm l.) 2. 6 mm Bolts (60 mm l.) 3. 6 mm Bolts (80 mm l.) 4. 6 mm Bolts (40 mm l.) 5. 8 mm Bolts (80 mm l.) 6. 8 mm Bolts (40 mm l.) 7. Neutral Switch T1: 8.8 N·m (0.9 kgf·m, 78 in·lb) T2: 1 1 N·m (1.
CRANKSHAFT/TRANSMISSION 8-3 Exploded V iew G: Apply high tempera ture grease. L: Apply a non -permanent locking agent. LG: Apply liquid gasket-black. M: Apply a thin coat of molybdenum disulfide grease. O: Apply engine oil. S: Follow the specific tightening sequence.
8-4 CRANKSHAFT/TRANSMISSION Specifications Item Standard Service Limit Crankshaft, Connecting Rods Connecting Rod Bend ––– 0.2/100 mm (0.0079/4 in.) Connecting Rod T wist ––– 0.2/100 mm 0.0079/4 in.) Connecting Rod Big End Side Clearance 0.
CRANKSHAFT/TRANSMISSION 8-5 Specifications Item Standard Service Limit Crankshaft Main Bearing Insert Thickness: Brown 1.490 ∼ 1.494 mm (0.0587 ∼ 0.0588 in.) ––– Black 1.494 ∼ 1.498 mm (0.0588 ∼ 0.0590 in.) ––– Blue 1.498 ∼ 1.502 mm (0.
8-6 CRANKSHAFT/TRANSMISSION Specifications Item Standard Service Limit Shift Fork Ear Thickness 4.9 ∼ 5.0 mm (0.193 ∼ 0.197 in.) 4.8 mm (0.189 in.) Shift Fork Guide Pin Diameter 7.900 ∼ 8.000 mm (0.31 10 ∼ 3150 in.) 7.8 mm (0.307 in.) Shift Fork Dowel Pin Diameter 7.
CRANKSHAFT/TRANSMISSION 8-7 Crankcase Splitting Crankcase Splitting • Remove the engine (see Engine Removal/Installation chapter). • Set the engine on a clean surface and hold the engine steady while parts are being removed.
8-8 CRANKSHAFT/TRANSMISSION Crankcase Splitting Crankcase Assembly CAUTION The upper crankcase half and th e lower crankcase half are machined at the factory in the assembled state, so the crankcase halves must be replaced to- gether as a set. • Using compressed air , blow out the oil passages [A] in the crankcase halves.
CRANKSHAFT/TRANSMISSION 8-9 Crankcase Splitting • T ighten the lower crankcase-half bolts using the following 3 steps: ○ T ighten all lower crankcase-half bolts to a snug fit.
8-10 CRANKSHAFT/TRANSMISSION Clutch Housing/Primary Ch ain Clutch Housing/Primary Chain Removal • Remove the engine. • Remove: Cylinder Head, Cylinder and Pistons (see Engine T op End chapter) Starter Clutch Sprocket (see Electrical System chapter) Clutch (except the Clutch Housing) • Split the crankcase.
CRANKSHAFT/TRANSMISSION 8-1 1 Crankshaft/Connecting Rods Crankshaft Removal • Split the crankcase (see Crankcase Splitting). • Remove the clutch housing and the primary chain.
8-12 CRANKSHAFT/TRANSMISSION Crankshaft/Connecting Rods Big End Cap [A] Connecting Rod [B] Weight Mark, Alphabet [C] Diameter Mark [D] • Apply engine oil to the inner surface of the upper and lower bearing inserts [A]. • Apply a small amount of engine oil to the threads [B] and seating surface [C] of the connecting rod big end cap nuts.
CRANKSHAFT/TRANSMISSION 8-13 Crankshaft/Connecting Rods • Measure the connecting rod twist. ○ With the big-end arbor [A] still on V blocks [C], hold the connecting rod horizontal and measure the dif ference in the height of the arbor [B] above the surface plate over a 100 mm (4 in.
8-14 CRANKSHAFT/TRANSMISSION Crankshaft/Connecting Rods If the clearance is within the standard, no bearing insert replacement is required. If the clearance is between 0.066 mm and the service limit (0.10 mm, 0.0039 in.), replace the bearing inserts [A] w ith inserts painted blue [B] Check insert/crankpin clearance with a plastigage.
CRANKSHAFT/TRANSMISSION 8-15 Crankshaft/Connecting Rods • Select the proper bearing i nsert in accordance with the combination of the connecting rod and crankshaft coding. • Install the new insert in the connecting rod and check in- sert/journal clearance with a plastigage.
8-16 CRANKSHAFT/TRANSMISSION Crankshaft/Connecting Rods If the clearance is within the standard, no bearing insert replacement is required. If the clearance is between 0.044 mm and the service limit (0.08 mm), replace the bearing inserts [A] with i n- serts painted blue [B] Check insert/journal clearance with a plastigage.
CRANKSHAFT/TRANSMISSION 8-17 Crankshaft/Connecting Rods Crankshaft Main Bearing Insert Selection Bearing Insert* Crankcase Main Bearing Bore Diameter Mark Crankshaft Main Journal Diameter Mark Size Co.
8-18 CRANKSHAFT/TRANSMISSION Balancer Balancer Removal • Split the crankcase (see Crankcase Splitting). • Pull the balancer shaft with the balancer gear out of the crankcase. Balancer Installation • Apply oil to the inside of the balancer shaft bearing insert.
CRANKSHAFT/TRANSMISSION 8-19 Balancer If either journal has worn past the service limit, replace the balancer shaft with a new one. If the measured journal diameters are not less than the service l imit, but do not coincide with the original diameter markings on the balancer shaft, write new marks on it.
8-20 CRANKSHAFT/TRANSMISSION T ransmission External Shift Mechanism Removal • Remove: Engine Sprocket (see Final Drive chapter) Chain G uard [A] Neutral Switch Lead Connector [B] • Place an oil pan beneath the external shift mechanism cover [A]. • Remove the external shift m echanism cover bolts [B].
CRANKSHAFT/TRANSMISSION 8-21 T ransmission • Apply high temperature grease to the seal lips. • Insert the shift shaft into the cover [A], and then fit the shift mechanism arm [B] to the shift drum [C]. • T ighten the cover bolts. T orque - Ext ernal Shift Mechanism Cover Bolts: 1 1 N·m (1.
8-22 CRANKSHAFT/TRANSMISSION T ransmission T ransmission Shaft Installation • With a high flash-point solvent, clean off the outer cir- cumferences of the transmission ball bearings and needle bearings, and their bearing housings, and wipe dry .
CRANKSHAFT/TRANSMISSION 8-23 T ransmission Drive Shaft Assembly • Apply engine oil liberally to the drive shaft, gears, bear- ings and bushing. • Install the drive shaft ball bearing using the bearing driver [A]. Special T ool - Bearing Driver , 32: 57001-382 • Replace any circlips that were removed with new ones.
8-24 CRANKSHAFT/TRANSMISSION T ransmission Output Shaft Assembly • Assembly is the reverse of disassembly . Note the follow- ing. • Apply engine oil liberally to the output shaft, gears, bear- ings, bushing and O-ring. • Install the output shaft ball bearing, O-ring and collar us- ing the bearing driver .
CRANKSHAFT/TRANSMISSION 8-25 T ransmission • The output s haft gears c an be identified by size: the largest diameter gear is 1st gear , and the smallest is 6th. Be sure that all parts are put back in the correct sequence and facing the proper direction, and that all circlips and washers are properly in place.
8-26 CRANKSHAFT/TRANSMISSION T ransmission Shift Drum and Fork Installation • Insert the shift drum [A] into the crankcase part way , install the 3rd/4th shift fork [B] with the longer side [C] facing the neutral switch, i.e., the longer side goes onto the drum first.
CRANKSHAFT/TRANSMISSION 8-27 T ransmission Shift Drum Disassembly • Remove the screw [A] and the pin plate [B]. • Pull out the shift drum cam [C]. • T ake of f the ball bearing [D]. • Pull off the dowel pin [E]. Shift Drum Assembly • Set the dowel pin into larger hole of the two which is the farthest hole [A] from the center .
8-28 CRANKSHAFT/TRANSMISSION T ransmission Ball and Needle Bearing Wear • Check the following ball bearings: shift drum LH, drive shaft RH, and output shaft LH. ○ Since the ball bearings are made to extremely c lose toler- ances, the wear must be judged by feel rather than mea- surement.
WHEELS/TIRES 9-1 9 Wheels/T ires T able of C ontents Exploded View ................................................................................................................... ..... 9-2 Specifications ...........................................
9-2 WHEELS/TIRES Exploded V iew T1: 20 N·m (2.0 kgf·m, 14.5 ft·lb) T2: 88 N·m (9.0 kgf·m, 65 ft·lb) T3: 98 N·m (10.0 kgf·m, 72 ft·lb) G: Apply grease. R: Replacement P arts S: Follow the specific tightening sequence. WL: Apply soap and water solution or rubber lubricant.
WHEELS/TIRES 9-3 Specifications Standard Item EN500-C1 ∼ C2, D1 EN500-C3 ∼ Service Limit Wheels (Rims) Rim Runout: Radial ––– ––– 0.5 mm (0.02 in.) Axial –– – ––– 0.8 mm (0.03 in.) Axle Runout/100 mm (3.94 in.) 0.1 mm (0.004 in.
9-4 WHEELS/TIRES Wheels (Rims) Front Wheel Removal • Remove the speedometer cable lower end [A]. • Loosen the front axle nut [B]. • Raise the front wheel off the ground.
WHEELS/TIRES 9-5 Wheels (Rims) Rear Wheel Removal • Remove: Cotter P in [A] Rear Axle Nut [B] (loosen) • Raise the rear wheel off the ground using the center stand. • Remove: Cotter P in [A] T orque Link Nut and Bolt [B] Adjuster [C] and Brake Rod [D] Rear Axle Nut • Pull out the rear axle to the right and drop the rear wheel.
9-6 WHEELS/TIRES Wheels (Rims) • Insert a new cotter pin [A]. NOTE ○ When inserting the cotter pin, if the slots in the nut do not align with the cotter pin hole in the axel, tighten the nut clockwise [B] up to next alignment. ○ It should be within 30 degree.
WHEELS/TIRES 9-7 Wheels (Rims) Axle Inspection • Visually inspect the front and rear axle for damages. If the axle is damaged or bent, replace it. • Measure the axle runout with a dial gauge. If axle runout exceeds the service limit, replace the axle.
9-8 WHEELS/TIRES Wheels (Rims) • Repeat the entire procedure as many times as necessary to achieve correct wheel balance. • Permanently install the balance weight. Balance Weight Part Number Wei gh t: g ( US o z ) 41075-1059 10 ( 0.35) 41075-1060 20 ( 0.
WHEELS/TIRES 9-9 Wheels (Rims) • Check that the weight [A] and clip [B] are fully seated on the rim [C] and that the clip is hooked over the rib [D]. WA R N I N G If the balance weight has any play on the rim, the clip of the weight has been stretched.
9-10 WHEELS/TIRES Tir e s Air Pressure Inspection/Adjustment • Measure the tire air pressure with an air pressure gauge [A] when the tires are cold (that is, when the motorcycle has not been rid den more than a mile during the past 3 hours). Adjust the tire air pressure according to the specifications if necessary .
WHEELS/TIRES 9-1 1 Tir e s Tire Remova l CAUTION Do not lay the front wheel on the ground with the disc facing down. This can damage or warp the disc. Place blocks under the wheel so that the disc does not touch the ground.
9-12 WHEELS/TIRES Tir e s Tire Installation • Inspect the rim and the tire, and replace them if neces- sary . • Clean the sealing surfaces of the rim and tire, and smooth t h es e a l i n gs u r f a c e so ft h er i mw i t haf i n ee m e r yc l o t hi f necessary .
WHEELS/TIRES 9-13 Tir e s • Position the tire on the rim so that the valve [A] is at the tire balance mark [B] (the chalk mark made during removal, or the yellow paint mark on a new tire). • Install the tire bead on the rim using a suitable commer- cially available tire changer .
9-14 WHEELS/TIRES Hub Bearing Hub Bearing Removal • Remove the wheel, and take out the following. CAUTION Do not lay the wheel on the ground with the disc facing down. This can damage or warp the disc. Place blocks under the w heel so that the disc does not touch the ground.
WHEELS/TIRES 9-15 Hub Bearing • Replace the circlips with new ones. Special T ool - Inside Circ lip Pliers: 57001-143 • Replace the grease seal with new ones. • Press in the grease seals so that the seal surface flush with the end of the hole. ○ Apply high temperature grease to the grease seal lips.
9-16 WHEELS/TIRES Speedometer G ear Disassembly and Assembly NOTE ○ It is recommended that the assembly be replaced rather than attempting to repair the components. • Install the speedometer gear so that it fits in the speedometer gear drive notches (see Front Wheel Installation).
FINAL DRIVE 10-1 10 Final Drive T able of C ontents Exploded View ................................................................................................................... ..... 10-2 Specifications ...........................................
10-2 FINAL DRIVE Exploded V iew 1. Drive Chain Joint (ER500-C4 ∼ ) T1: 1 1 N·m (1.1 kgf·m, 95 in·lb) T2: 127 N·m (13.0 kgf·m, 94 ft·lb) T3: 59 N·m (6.0 kgf·m, 43 ft·lb) T4: 98 N·m (10.0 kgf·m, 72 ft·lb) CO: Apply chain oil. G: Apply grease.
FINAL DRIVE 10-3 Specifications Item Standard Service Limit Drive Chain Chain Slack 35 ∼ 40 mm (1.4 ∼ 1.6 in.) ––– 20-link Length 317.5 ∼ 318.
10-4 FINAL DRIVE Drive Chain Drive Chain Sla ck Inspection Drive Chain Slack Inspection NOTE ○ Check the slack with the motorcycle setting on its c enter stand. ○ Clean the chain if i t is dirty , and lubricate it if it appears dry . • Check the wheel alignment (see Wheel Alignment Inspec- tion).
FINAL DRIVE 10-5 Drive Chain • Bend the cotter pin [A] over the nut [B]. • T urn the wheel, measure the chain slack again at the tight- est position, and readjust if necessary . • T ighten the torque link nut. T orque - T orque Link Nut: 34 N·m (3.
10-6 FINAL DRIVE Drive Chain Drive Chain W ear Inspection • Remove: Chain Cover • Rotate the rear wheel to inspect the drive chain for dam- aged rollers, loose pins and links. If there is any irregularity , replace the drive c hain. Lubricate the drive chain if it appears dry .
FINAL DRIVE 10-7 Drive Chain CAUTION The O-rings between the side plates seal in the lu- bricant between the pin and the bushing. T o avoid damaging the O-rings and resultant loss of lubri- cant, observe the following rules: Use only kerosene or diesel oil for cleaning an O -ring drive chain.
10-8 FINAL DRIVE Drive Chain • Grind [A] pin head to make it flat. • Set cutting and rivetting pin [B] as shown. • Screw pin holder until it touches the l ink pin. • Be sure that the cutting pin hits center of the link pin. • Screw the handlebar [A] into the body .
FINAL DRIVE 10-9 Drive Chain • Fit the plate holder (A) to the link plate. • T urn the pin holder by hand until the plate holder (B) touches the other link plate. • T urn the pin holder by a wrench clockwise until two pins of link come into groove of the plate holder (A).
10-10 FINAL DRI VE Drive Chain • After staking, check the staked area of the link pin for cracks. • Measure the outside diameter [A] of the link pin and link plates width [B]. Link Pin Outside Diameter Standard: 5.6 ∼ 6.0 m m (0. 22 ∼ 0.24 in.
FINAL DRIVE 10-1 1 Sprocket, Coupling Engine Sprocket Re mova l • Remove the bolts [A]. • Pull the engine sprocket cover [B]. • Flatten out the bended washer [A]. • Remove the engine sprocket nut [B] and washer . NOTE ○ When loosening the engine sprocket nut, hold the rear brake on.
10-12 FINAL DRI VE Sprocket, Coupling Rear Sprocket Removal • Remove the rear wheel (see Wheel/T ires chapter). • Remove the rear sprocket nuts [A]. • Remove the rear sprock et [ B ]. Rear Sprocket Installation • Install the sprocket facing the tooth number marking [A] outward.
FINAL DRIVE 10-13 Sprocket, Coupling Coupling Bearing Removal • Remove: Coupling Grease Seal [A] • Remove the bearing by tapping from the brake drum side. Special T ool - Bearing Driver Set: 57001-1 129 [A] Coupling Bearing Installation • Replace the bearing with a new one.
10-14 FINAL DRI VE Sprocket, Coupling Coupling Bearing Inspection a nd Lubrication NOTE ○ It is not necessary to remove the coupling bearing for inspection and lubrication. If the bearing is removed, it will need to be replaced with a new one. • Spin the bearing by hand to check its condition.
BRAKES 1 1-1 11 Brakes T able of C ontents Exploded View ................................... 1 1-2 Specifications .................................... 1 1-4 Brake Lever ....................................... 1 1-5 Lever Position Adjustment ..........
1 1-2 BRAKES Exploded V iew T1: 7.8 N·m (0.80 kgf·m, 69 in·lb) T2: 25 N·m (2.5 kgf·m, 18.0 ft·lb) T3: 1 1 N·m (1.1 kgf·m, 95 in·lb) T4: 1.0 N·m (0.10 kgf·m, 9 in·lb) T5: 5.9 N·m (0.60 kgf·m, 52 in·lb) T6: 1.5 N·m (0.15 kgf·m, 13 in·lb) T7: 1.
BRAKES 1 1-3 Exploded V iew.
1 1-4 BRAKES Specifications Item Standard Service Limit Front Brake Brake Lever Position 4-way adjustable (to suit rider) ––– 5-way adjustable (to suit rider): ER500-C4 ∼ Brake Lever Free Play Non-adjustable ––– Pad Lining Thickness 4.5 mm (0.
BRAKES 1 1-5 Brake Lever Lever Position Adjustment The adjuster has 4 positions so that the brake lever posi- tion can be adjusted to suit the operator ’s hand. • Push the lever forward and turn the adjuster [A] to align the number with the Arrow mark [B] on the lever holder .
1 1-6 BRAKES Caliper Caliper Removal • Drain the brake fluid. • Loosen the banjo bolt [A] at the brake hose lower end, and tighten it loosely . • Unscrew the caliper mounting bolts [B], and detach the caliper [C] from the disc. • Unscrew the banjo bolt and remove the brake hose [D] from the caliper .
BRAKES 1 1-7 Caliper • Insert a wooden board [A] 5 mm thick inside the calipe r opening. • Pump the brake lever until the pistons [B] push the wooden board. • Remove the wooden board and pull out the piston by hand. • Remove the other parts of the caliper .
1 1-8 BRAKES Caliper • Apply brake fluid to the outside of the piston, and push the piston into the cylinder by hand. T ake care that neither the cylinder nor the piston skirt get scratched. • Replace the shaft rubber friction boot [A] and dust cover [B] with new ones if they are damaged.
BRAKES 1 1-9 Brake Pads Brake Pad Removal • Remove the caliper with the hose installed. • Remove the clip and take off the pad pin. • Remove: Piston Side Pad [A] • Remove the other pad [A]. Brake Pad Installation • Push the caliper piston in by hand as far as it will go.
1 1-10 BRAKES Master Cylinder Master Cylinder Re mova l • Disconnect the front brake switch wires [A]. • Remove the banjo bolt [B] to disconnect the upper brake hose end from the master cylinder [C]. There is a flat washer [D] on each side of the hose fitting.
BRAKES 1 1-1 1 Master Cylinder Master Cylinder Assembly • Before assemb ly , clean all parts including the master cylinder with brake fluid or alcohol. CAUTION Except for the disc pads and disc, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol, for cleaning brake parts.
1 1-12 BRAKES Brake Disc Brake Disc Removal • Remove the wheel (see Wheels/T i res chapter). • Unscrew the mounting Allen bolts [A], and take off the disc [B]. Brake Disc Installation • Install the brake disc on the wheel so that the marked side [A] faces out.
BRAKES 1 1-13 Brake Fluid Level Inspect ion • Check that the brake fluid level in the front brake reservoir [A] is above the lower level line [B]. NOTE ○ Hold the reservoir horizontal by turning the handlebar when checking brake f luid level.
1 1-14 BRAKES Brake F luid Bleeding the Brake Line The brake fluid has a very low compression coef ficient so that almost all the movement of the brake lever is transmit- ted directly to the caliper for braking action. Air , however , is easily c ompressed.
BRAKES 1 1-15 Brake Fluid • Install the reservoir cap. • Remove the rubber cap from the bleed valve on the caliper . • Attach a clear plastic hose to the bleed valve on the caliper , and run the other end of the hose into a con- tainer .
1 1-16 BRAKES Brake F luid W ARNING When working with the disc brake, observe the pre- cautions listed below. 1. Never reuse old brake fluid. 2. Do not use fluid from a container that has been left unsealed or that has been open for a long time. 3. Do not mix two types and brands of fluid for use in the brake.
BRAKES 1 1-17 Brake Hose Brake Hoses and Connections Inspection • Inspect the brake hose and fittings for deterioration, cracks and signs of leakage. ○ The high pressure inside the brake line can cause fluid to leak [A] or the hose to burst if the line is not properly main- tained.
1 1-18 BRAKES Brake P edal and Cable Brake Play Inspection Brake Pedal Position Inspection • With the brake pedal [A] in the correct position, inspect the brake pedal position [B] as shown. Footpeg [C] Pedal P osition Standard: About 20 mm (0.79 in.
BRAKES 1 1-19 Brake P edal and Cable Brake P edal Rem oval • Remove: Adjuster [A] Clevis P in [ B] Return Spring [C] • Remove the brake rod rear end. • Loosen the locknut and turn in the adjusting bolt to keep the pedal free from it. • Unscrew the right footpeg bracket bolts [A].
1 1-20 BRAKES Brake P an el and Drum Brake Lining Wear Inspection • Check that the brake lining wear indicator [A] points within the USABLE RANGE [B] when the rear brake is fully ap- plied. If does not, the shoes must be immediately replaced and the other brake parts examined.
BRAKES 1 1-21 Brake P an el and Drum Brake P anel Rem oval • Remove the rear wheel (see Wheels/T ires chapter). • Separate the brake panel [A] from the wheel. Brake Panel Installation • Installation is the reverse of removal. Note the following.
1 1-22 BRAKES Brake P an el and Drum • Link the brake shoes together with the springs, and push them onto the panel in the reverse of removal. • Put the dust seal over the end of the cam shaft. • Install the return spring. • Install the indicator [A] on the serration so that it points to the extreme right of the U SABLE RANGE box [B].
BRAKES 1 1-23 Brake P an el and Drum Brake Camshaft and Camshaft Hole Wear • Remove the brake camshaft (see B rake Panel Disassem- bly). • Measur e the sh aft dia meter [A] . ○ Use a micrometer at the point shown. If any measurement is less than the service limit, replace the camshaft.
1 1-24 BRAKES Brake P an el and Drum • Lubricate the brake pedal by applying a m ulti-purpose grease to the brake shaft pivot groove [A]. • Clean any excess grease from the parts before assembly . • Lubricate the brake cable (see Brake Cable Lubrication).
SUSPENSION 12-1 12 Suspension T able of C ontents Exploded View ................................................................................................................... ..... 12-2 Specifications .............................................
12-2 SUSPENSION Exploded V iew FO: Apply fork oil. L: Apply a non-permanent locking agent. R: Replacement P arts S: Follow he specific tightening sequence.
SUSPENSION 12-3 Exploded V iew 1. Needle Bearings: Face the manufacturer ’s marks out. T3: 34 N·m (3.5 k gf·m, 25 ft·lb) T4: 88 N·m (9.0 k gf·m, 65 ft·lb) G: Apply gre ase.
12-4 SUSPENSION Specifications Item Standard Service Limit Front Fork (per one unit) Fork Inner T ube Diameter 37 mm (1.46 in.) Fork Spring Setting Non-adjustable Air Pressure Atmospheric pressure (No.
SUSPENSION 12-5 Front Fork Fork Oil Change The oil should be changed in accordance with the Periodic Maintenance Chart. • Remove the front fork (see Fork Removal). • Hold the outer tube vertically in a vise. • Remove the cap. • Push the top plug [A] down to remove the plug retaining ring [B], and then remove the plug.
12-6 SUSPENSION Front Fork • Install the fork spring with the smaller diameter end [A] facing down. • Install: Fork Spring Seat Spacer • Install the front fork (see Front Fork Installation).
SUSPENSION 12-7 Front Fork • Hold the front fork horizontally in a vise [A]. • Stop the cylinder unit [B] from turning by using the special tools. • Unscrew the Allen bolt [C], and take the gasket out of the bottom of the outer tube.
12-8 SUSPENSION Front Fork • Put the cylinder unit [A] with the spring into the inner tube [B] protruding from the inner tube, and install the cylinder base [C] onto the bottom end of the cylinder unit. ○ Install the cylinder base with the tapered end [D] up.
SUSPENSION 12-9 Front Fork Inner T ube, Outer T ube Inspection • Visually inspect the inner tube [A] for scoring or scratches on the outer surface of it and repair any damage. • Nick or rust damage can sometimes be repaired by using a wet- stone to remove sharp edges or raised areas which cause seal damage.
12-10 SUSPENSION Rear Shock Absorber Spring Preload Adjustmen t The spring preload adjuster on each rear shock absorber has 5 positions so that the spring tension can be adjusted for different road and loading conditions. • Using the hook wrench [A], turn the adjuster to adjust the spring tension.
SUSPENSION 12-1 1 Rear Shock Absorber Bushing Wear • Visually inspect the rubber bushings [A]. If they show any signs of damage, replace them. Rear Shock A bsorber Oil Leak Inspection • Visually inspect the shock absorber for oil leakage. If the oil leakage is found on it, replace the shock absorber with a new one.
12-12 SUSPENSION Swingarm CAUTION Do not tap the swingarm pivot shaft when removing or installing. Push or pull the pivot shaft while turn- ing the shaft. T apping on the shaft could damage the needle bearings in the swingarm. Swingarm Removal • Remove: Rear Wheel (see Wheels/T ires chapter) Rear Shock Absorber Lower Mounting Bolts and Nut [A].
SUSPENSION 12-13 Swingarm Swingarm Installation • Installation is the reverse of removal. • T ighten the pivot shaft nut. T orque - Swingarm Pivot Nut: 88 N ·m (9.0 kgf·m, 65 ft·lb) • T ighten the torque link nut. T orque - T orque Link Nut: 34 N·m (3.
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STEERING 13-1 13 Steering T able of C ontents Exploded View ................................................................................................................... ..... 13-2 Specifications .................................................
13-2 STEERING Exploded V iew T1: 44 N·m (4.5 kgf·m, 33 ft·lb) T2: Hand-tight T3: 25 N·m (2.5 kgf·m, 18 ft·lb) T4: 3.4 N·m (0.35 kgf·m, 30 in·lb) T5: 20 N·m (2.0 kgf·m, 14.5 ft·lb) T6: 29 N·m (3.0 kgf·m, 22 ft·lb) AD: Apply adhesive. G: Apply grease.
STEERING 13-3 Specifications Special T ools - Jack: 57001-1238 Steering Stem Wrench: 5 7001-1 100 Head Pipe Outer Race Press Shaft: 57001- 1075 Bearing Puller: 57001-158 Head Pipe Outer Race Driver , 46.5: 57001-1 106 Head Pipe Outer Race Driver , 51.
13-4 STEERING Handlebar Handlebar Removal • Remove: Clutch Cable Upper End Right and Left Handlebar Switch Housing Throttle Grip Brake Master Cylinder • Unscrew the handle bar mounting bolts [A] and remove the handlebar [B] and clamp [C].
STEERING 13-5 Handlebar Rear View Mirrors (Left and Rig ht) Installation • Screw the mounting area of the right rear view mirror into the holder all the way , and tighten the lower hexagonal area for tightening securely .
13-6 STEERING Steering Steering Inspection Steering Inspection • Check the steering. ○ Lift the front wheel off the ground using the jack. Special T ool - Jack: 57001- 1238 ○ With the front wheel pointing s traight ahead, alternately tap each end of the handlebar .
STEERING 13-7 Steering • T ighten the steering stem head bolt [A] and fork lower clamp bolts [B]. T orque - Steering Stem Head B olt: 44 N·m (4.5 kgf·m, 33 ft·lb) Fork Lower Clamp Bolts: 29 N·m (3.0 kgf·m, 22 ft·lb) • Check the steering again.
13-8 STEERING Steering Stem Steering Stem Removal • Remove the handlebar . Loosen the s tem head bolt [A] Remove the Front Fork [B] (see Suspension chapter) • Remove: Headlight T urn Signal Light Bracket Bolts [A] Headlight Housing Bolts [B] Meter Unit • Remove the stem head bolt [A] and lift up the steering stem head [B].
STEERING 13-9 Steering Stem • Install the stem cap [A], and hand tighten the stem nut [B]. T orque - S t eering S tem N ut: 4.9 N·m (0.50 kgf·m , 43 in·lb, for refere n ce ) NOTE ○ Install the steering stem nut so that the recess side [C] faces down.
13-10 STEERING Steering Stem Bearing Stem Bearing Removal • Remove the s teering stem (see this chapter). • T o remove the outer races [A] pressed in the head pipe [B], insert a bar [C] into the head pipe, and hammer evenly around the circumference of the opposite race to drive it out.
STEERING 13-1 1 Steering Stem Bearing • Settle the inner races in place as follows. ○ Using the steering stem nut wrench, tighten the stem nut 20 N·m (2.0 kgf·m, 14.5 ft·lb) of torque. T o tighten the steering stem nut to the specified torque, hook the wrench on the stem nut, and pull the wrench at the hole by 11 0 N (1 1.
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FRAME 14-1 14 Frame T able of C ontents Exploded View ................................................................................................................... ..... 14-2 Specifications .......................................................
14-2 FRAME Exploded V iew T1: 34 N·m (3.5 kgf·m, 25 ft·lb) T2: 44 N·m (4.5 kgf·m, 33 ft·lb) T3: 25 N·m (2.5 kgf·m, 18 ft·lb) O: Apply oil. G: Apply grease.
FRAME 14-3 Exploded V iew.
14-4 FRAME Specifications Special T ool - Jack: 57001-1238.
FRAME 14-5 Seat Seat Removal • Insert the ignition switch key [A] into the seat lock. • T urn the ignition switch key clockwise. • Swing open the seat and remove it. Seat Installation • Slip the hook [A] of the seat under the brace [B] on the fuel tank.
14-6 FRAME Side Covers Side Cover Removal • Remove the seat (see this chapter). • Remove the screw [A]. • Pull the rear part and front part of the side cover [A] evenly outward to clear the stoppers [B]. • Remove the side cover . • Remove the other side cover in the same manner .
FRAME 14-7 Seat Cover Seat Cover Removal • Remove the seat (see this chapter). • Remove both side covers (see this chapter). • Unscrew the mounting bolts [A] and remove the tail grip [B]. • Remove the screws [A ]. • With the tail of the seat covers joined, bend open the seat cover [A] and pull them out backward.
14-8 FRAME Fenders Front Fender Removal • Remove the front wheel (see Wheels/Ti res chapter). • Remove the bolts [A] and take off the front fender [B] rear- ward.
FRAME 14-9 Frame Frame Inspection • Visually inspect the frame [A] for cracks, dents, bending, or warp. If there is any damage to the frame, replace it. WA R N I N G A repaired frame may fail in use, possibly causing an accident. If the frame is bent, dented, cracked, or warped, replace it.
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ELECTRICAL SYSTEM 15-1 15 Electrical System T able of C ontents Parts Location.................................... 15-3 Exploded View ................................... 15-4 Specifications ................................... 15-8 ER500-C1 ∼ C2, D1 Wiring Diagram (other than Australia) .
15-2 ELECTRICAL SYSTEM Radiator Fan Switch Inspection ... 15-62 W ater T emperature Switch Inspection .................................. 15-63 Fuel Gauge Operation Inspection 15-63 Fuel Level Sensor Inspection....... 15-64 Fuses ..................... .
ELECTRICAL SYSTEM 15-3 Parts Location 1. Starter Lockout Switch 2. Horn 3. Radiator Fan Switch 4. #1 Ignition Coil 5. Spark Plugs 6. W ater T emperature Switch 7. Starter Motor 8. MF Battery 9. IC Igniter 10. Fuse Box 1 1. Alternator 12. Pickup Coil 13.
15-4 ELECTRICAL SYSTEM Exploded V iew 1. Starter Lockout Switch 2. Front Brake Light Switch 3. Horns 4. City Light (other than Australia) T1: 1.2 N·m (0.12 kgf·m, 10 in·lb) T2: 3.4 N·m (0.35 kgf·m, 30 in·lb) L: Apply a non-permanent locking agent.
ELECTRICAL SYSTEM 15-5 Exploded V iew 1. Regulator/Rectifier 2. Fuse Box 3. T urn Signal Relay 4. Rectifiers 5. IC Igniter 6. Starter Circuit Relay 7. Diode T1: 5.
15-6 ELECTRICAL SYSTEM Exploded V iew.
ELECTRICAL SYSTEM 15-7 Exploded V iew 1. Ignition Switch 2. W ater T emperature Switch 3. Radiator Fan 4. Radiator Fan Switch 5. Ignition Coils 6. Spark Plugs 7. Rear Brake Light Switch 8. Alternator Starter 9. Pickup Coil 10. Starter Motor 11 . 3 0 A M a i n F u s e 12.
15-8 ELECTRICAL SYSTEM Specifications Item Standard Service Limit Battery Ty p e Sealed Battery Capacity 12 V 10 Ah V oltage 12.6 V or more Charging System Alternator T ype Three-phase AC DC Battery Charging V oltage 14 ∼ 15 V @4 000 r/min (rpm) Alternator Output V oltage 46 ∼ 64 V @4 000 r/min (rpm) Stator Coil Resistance 0.
ELECTRICAL SYSTEM 15-9 Specifications Item Standard Service Limit W ater T emperature S witch Connections: Rising T emperature From OFF to ON @1 10 ∼ 120°C (230 ∼ 248°F) Falling T emperature From ON to OFF @108°C (226°F) ∼ temperature less than ON ON: Less than 0.
15-10 ELECTRICAL SYSTEM ER500-C1 ∼ C2, D1 Wiring Diagram (other than Australia).
ELECTRICAL SYSTEM 15-1 1 ER500-C1 ∼ C2, D1 Wiring Diagram (other than A ustralia).
15-12 ELECTRICAL SYSTEM ER500-C1 ∼ , D1 Wiring Diagram (Australia).
ELECTRICAL SYSTEM 15-13 ER500-C1 ∼ , D1 Wiring Diagram (Australia).
15-14 ELECTRICAL SYSTEM ER500-C3 ∼ Wiring Diagram (oth er than Australia).
ELECTRICAL SYSTEM 15-15 ER500-C3 ∼ Wiring Diagram (othe r than Australia).
15-16 ELECTRICAL SYSTEM Precautions There are a number of important precautions that are musts when servicing electrical systems. Learn and ob- serve all the rules below . ○ Do not reverse the battery lead connections. This will burn out the diodes in the electrical parts.
ELECTRICAL SYSTEM 15-17 Precautions Male Connectors [B].
15-18 ELECTRICAL SYSTEM Electrical Wiring Wiring Inspection • Visually inspect the wiring for signs of burning, fraying, etc. If any wiring is in poor condition, replace the damaged wiring. • Pull each connector [A] apart and inspect it for corrosion, dirt, and damage.
ELECTRICAL SYSTEM 15-19 Battery Battery Removal/Installation • Remove: Seat (see Frame Chapter) ○ Remove the battery cover [A] by taking off three screws. • Remove the negative (–) lead [A] from the battery first. • Remove the positive (+) lead [B] from the battery and pull out the battery .
15-20 ELECTRICAL SYSTEM Battery • T ake the electrolyte container out of the vinyl bag. • Detach the seal caps [A] from the container . NOTE ○ Do not discard the seal cap because it is used as the battery plugs later . ○ Do not peel back or pierce the seals [B] on the container .
ELECTRICAL SYSTEM 15-21 Battery Initial Charge While a sealed battery can be used after only filling with electrolyte, a battery may not be able to sufficiently move a s tarter motor to start an engine in the cases shown in the table below , where an initial charge is required before use.
15-22 ELECTRICAL SYSTEM Battery Interchange The sealed battery can fully display its performance only when combined with a proper vehicle elec- tric system. Therefore, replace the sealed battery only on a motorcycle which was originally equipped with the sealed battery .
ELECTRICAL SYSTEM 15-23 Battery NOTE ○ If the current does not flow when charging, raise the voltage initially (25 V as maximum), and let down the voltage to charge when the current starts to flow as a yardstick. If ammeter shows no change in current after 5 minutes, you need a new battery .
15-24 ELECTRICAL SYSTEM Charging System Alternator Rotor/Starter C lutch Removal • Remove the engine sprocket cover (see Final Drive chap- ter). • Loosen the left footpeg mounting bolt and let the footpeg hang down. • Remove the shift pedal. • Remove the circlip and washer from the shift shaft.
ELECTRICAL SYSTEM 15-25 Charging System • Holding the rotor [A] steady , remove the Allen bolts [B] to separate the rotor and starter clutch [C]. Starter Clutch Sprocket Removal • Remove: Alternat.
15-26 ELECTRICAL SYSTEM Charging System • T ighten the rotor bolt while holding the rotor steady with the flywheel holder , and turn the rotor bolt counterclock- wise to install i t.
ELECTRICAL SYSTEM 15-27 Charging System Alternator Inspection There are three types of alternator failures: short, open (wire burned out), or loss in rotor magnetism. A short or open in one of the coil wires will result in either a low output or no output at all.
15-28 ELECTRICAL SYSTEM Charging System Regulator/Rectifier Removal • Remove the right side cover and disconnect the regula- tor/rectifier connector [A]. • Unscrew two mounting bolts [B] and remove the regula- tor/rectifier [C] from the battery case.
ELECTRICAL SYSTEM 15-29 Charging System Regulator/Rectifier Inspection Rectifier circuit check • Remove the right side cover (see Frame chapter). • Disconnect the regulator/rectifier lead connector [A].
15-30 ELECTRICAL SYSTEM Charging System Regulator Circuit Check • Prepare the following: T est Light Bulb: one 12 V 3.4 W bulb Batteries: three 12 V batteries Wires: five wires of appropriate lengths CAUTION The test light works as an indicator and also a cur- rent limiter to protect the regulator/rectifier from ex- cessive current.
ELECTRICAL SYSTEM 15-31 Charging System Charging System Circuit 1. Ignition Switch 2. Alternator 3. Regulator/Rectifier 4. Battery 5. Main Fuse 30 A 6.
15-32 ELECTRICAL SYSTEM Ignition System Ignition System Circuit 1. Diode 2. Fuse Box 3. Ignition Switch 4. Engine Stop Switch 5. Starter Button 6. Spark Plugs 7. Ignition Coils 8. T achometer 9. Ignition Fuse 10 A 10. Neutral Switch 1 1. Starter Lockout Switch 12.
ELECTRICAL SYSTEM 15-33 Ignition System WA R N I N G The ignition system produces extremely high volt- age. Do not touch the spark plugs, ignition coils, or spark plug leads while the engine is running, or you could receive a severe electrical shock.
15-34 ELECTRICAL SYSTEM Ignition System Ignition Coil Removal/Installation • Remove the fuel tank (see Fuel System chapter). • Disconnect the leads and remove the ignition coils. • Install the ignition coils. Note the following. ○ Connect the primary winding leads to the ignition coiled terminals as shown.
ELECTRICAL SYSTEM 15-35 Ignition System NOTE ○ The hand tester cannot detect layer shorts and shorts resulting from insulation breakdown under high voltage. • Disconnect the primary leads from the coil terminals. • Measure the primary winding resistance [A] as follows: ○ Connect the hand tester between the coil terminals.
15-36 ELECTRICAL SYSTEM Ignition System Spark P lug Removal/Installation • Remove the fuel tank (see Fuel System chapter). • Carefully pull the spark plug cap from the spark plug and unscrew the spark plug. • Using the 18 mm plug wrench [A]. • T ighten the spark plug.
ELECTRICAL SYSTEM 15-37 Ignition System • T o examine the condition of the igniter , connect the igniter checker to the igniter as shown. Special T ools - Igniter Checker Set: 57001-1378 [A] Wiring Harness Adap ter , #14: 57001-1381 [C] IC Igniter [B] Battery [D] ○ Set the select knob to position “A”.
15-38 ELECTRICAL SYSTEM Ignition System Starter Button O peration C heck • Remove the seats (see Frame chapter). • Set the Hand T ester [A] to the × 25 V DC range, connect it to the IC igniter [B] l ead as follows.
ELECTRICAL SYSTEM 15-39 Ignition System • T urn the ignition switch ON. • Shift the gears to neutral, and run the engine stop switch. • T urn the starter motor for several seconds and read the maximum value on the tester .
15-40 ELECTRICAL SYSTEM Ignition System T roubleshooting.
ELECTRICAL SYSTEM 15-41 Ignition System Pickup Coil Peak V oltage Inspection • Measure the peak voltage of the pickup coil as follows: ○ Remove the left side cover . ○ Remove the pickup coil c onnector [A]. NOTE ○ T o obtain a correct measurement, the wires as well as the wire connections must be correct.
15-42 ELECTRICAL SYSTEM Ignition System NOTE ○ The actual meter reading varies with the meter used and the individual diode, but, generally speaking, the lower reading should be from zero to one half the scale.
ELECTRICAL SYSTEM 15-43 Electric Starter System Electric Starter Circuit 1. Ignition Switch 2. Engine Stop Switch 3. Starter B utton 4. Starter Circuit Relay 5. Starter Circuit Relay 6. Fuse Box 7. Ignition Fuse 10 A 8. Starter Lockout Switch 9. Neutral Switch 10.
15-44 ELECTRICAL SYSTEM Electric St arter Syst em Starter Motor Removal • Remove the alternator cover . • Remove the starter chain guide screws [A] and remove the starter chain guide [B] with the guide stay [C]. • Disconnect the starter motor lead [A].
ELECTRICAL SYSTEM 15-45 Electric Starter System Starter Motor Disassembly • Unscrew the starter motor through bolts [A] and pull off the gear cover [B] and the end cover [C]. • Pull the armature [D] out of the yoke housing [E], and remove the end bracket [F].
15-46 ELECTRICAL SYSTEM Electric St arter Syst em • Make sure that the marks [A] on the covers and yoke housing align with each other . • T ighten the through bolts. T orque - St arter Motor Through Bolts: 6.9 N·m (0.7 kgf·m, 65 in·lb) Starter Chain Wear • Pull the starter chain tig ht.
ELECTRICAL SYSTEM 15-47 Electric Starter System • Connect the hand tester [A] and 12 V battery [B] to the starter circuit relay [C] as shown. If the relay does not work as specified, the relay is defec- tive.
15-48 ELECTRICAL SYSTEM Electric St arter Syst em • Measure the diameter [A] of the commutator [B]. Replace the starter motor with a new one if the commu- tator diameter is less than the service limit. Commutator Diameter Standard: 28 m m (1.10 in.) Service Limit: 27 m m (1.
ELECTRICAL SYSTEM 15-49 Lighting System Headlight Circuit (Australia, ER500-C1 ∼ ,D 1 ) 1. Ignition Switch 2. High Beam Indicator Light 3. Headlight 4. Engine Stop Switch 5. Starter Button 6. Diode 7. Diode 8. Starter Circuit Relay 9. Diode 10. Headlight Circuit Relay 1 1.
15-50 ELECTRICAL SYSTEM Lighting System Headlight Circuit (Oth er than Australia, ER500-C1 ∼ C2) 1. Ignition Swit ch 2. Headlight Swit ch 3. Fuse Box 4. T aillight Fuse 10 A 5. Headlight Fuse 10 A 6. High Beam Indicator Light 7. Headlight 8. City Light 9.
ELECTRICAL SYSTEM 15-51 Lighting System Headlight Circuit (Other than Australia, ER500-C3 ∼ ) 1. Ignition Switch 2. Headlight Switch 3. Fuse Box 4. T aillight Fuse 10 A 5. Headlight Fuse 10 A 6. High Beam Indicator Light 7. Headlight 8. City Light 9.
15-52 ELECTRICAL SYSTEM Lighting System • Connect the hand tester [A] and 12 V battery [B] to the starter circuit relay [C] as shown. If the relay does not work as specified, the relay is defec- tive.
ELECTRICAL SYSTEM 15-53 Lighting System • Fit the dust cover [A] with the T op mark upward onto the bulb firmly as shown in the figure. Good [B] Bad [C] • After installation, adjust the headlight aim. Headlight Unit/Housing Removal • Remove the screws [A] on both sides.
15-54 ELECTRICAL SYSTEM Lighting System • Insert the new bulb by aligning the pins with the grooves in the walls of the socket so that the pin closest to the bulb base [A] is to the upper right. T ail/Brake Light Lens Removal/Installation • Be careful not to overtighten the lens mounting screws.
ELECTRICAL SYSTEM 15-55 Lighting System T urn Signal Light Circuit 1. T urn Signal Indicator Light 2. Front R ight T urn Signal Light 3. Front Left T urn Signal Light 4. T urn Signal Relay 5. T u rn Signal Fuse 10 A 6. Fuse Box 7. Rear Right T urn Signal Light 8.
15-56 ELECTRICAL SYSTEM Radiator Fan Sys tem Fan System Circuit Inspection • Disconnect leads from the radiator fan switch [A]. • Using an auxiliary wire [B], connect the radiator fan switch leads. If the fan turns, inspect the fan switch. If the fan does not turn, inspect the following.
ELECTRICAL SYSTEM 15-57 Meter Unit Meter Unit Removal • Remove the headlight unit and housing. • Remove the speedometer cable upper end [ A] and the mounting nuts [B]. • Disconnect the meter connectors and take of f the meter unit [C]. CAUTION Place the meter unit so that the face is up.
15-58 ELECTRICAL SYSTEM Meter Unit T achometer Inspection • Check the tachometer circuit wiring (see Wiring Inspec- tion). If all wiring and co mponents other than the tachometer unit check out good, the unit is suspect. Check the unit as shown. ○ Remove the headlight body .
ELECTRICAL SYSTEM 15-59 Meter Unit T achomete r Circuit 1. T achometer 2. Fuse Box 3. Ignition Fuse 10 A 4. Ignition Switch 5. Main Fuse 30 A 6. Battery 7.
15-60 ELECTRICAL SYSTEM Meter Unit W ater T emperature W arning System 1. Ignition Swit ch 2. Fuse Box 3. Ignition Fuse 10 A 4. Starter Relay 5. Main Fuse 30 A 6. W a ter T emperature W arning Light 7. Oil Pressure W arning Light 8. Rectifier 9. W a ter T emperature Switch 10.
ELECTRICAL SYSTEM 15-61 Switches and Sensors Brake Light Switch Ispection Rear Brake Light Timing Inspection • T urn on the ignition switch. • Check the operation of the rear brake light switch by de- pressing the brake pedal. The brake light should go on as specified.
15-62 ELECTRICAL SYSTEM Switches and Sensors Oil Pressure S witch Connections* *: Engine lubrication system is in good condition Side Stand Switch Connections* Radiator Fan Switch Inspection • Remove the fan switch (see Cooling System chapter).
ELECTRICAL SYSTEM 15-63 Switches and Sensors Water T emperature Switch Inspection • Remove the w ater temperature switch (see Cooling Sys- tem c hapter). • Suspend the switch [A] in a container of coolant so that the temperature sensing projection and threaded portion are submerged.
15-64 ELECTRICAL SYSTEM Switches and Sensors Fuel Gauge Circuit 1. Ignition Swit ch 2. Fuel Gauge 3. Fuse Box 4. Ignition Fuse 10 A 5. Fuel Level Sensor 6. Battery 7. 30 A Main Fuse 8. Starter Relay Fuel Level Senso r Inspection • Remove the fuel tank (see Fuel System chapter).
ELECTRICAL SYSTEM 15-65 Switches and Sensors • Using a hand tester , measure the resistance across the terminals in the fuel level sensor lead connector [A]. If the tester reading are not as specified, or do not change smoothly according as the float moves up and down, re- place the sensor .
15-66 ELECTRICAL SYSTEM Fuses 30 Ampere Fuse Removal • Remove the left side cover (see Frame chapter). • Disconnect the 30 ampere fuse connector [A]. • Pull out the main fuse [B] from the starter relay with a pair of needle nose pliers. Fuse Box Fuse Removal • Remove the seat (see Frame chapter).
APPENDIX 16-1 16 Appendix T able of C ontents T roubleshooting Guide ................................................................................................... ........ 16-2 General Lubrication ................................................
16-2 APPENDIX T roubleshooting Guide NOTE ○ This is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties.
APPENDIX 16-3 T roubleshooting Guide Cylinder head not sufficiently tightened down No valve clearance Cylinder , piston worn Piston ring bad (worn, weak, broken, or sticking) Piston ring/groove cleara.
16-4 APPENDIX T roubleshooting Guide Brake dragging Lubrication inadequate: Engine oil level too low Engine oil poor quality or incorrect Coolant incorrect: Coolant level too low Coolant deteriorated .
APPENDIX 16-5 T roubleshooting Guide Abnormal Drive T rain Noise: Clutch noise: Clutch rubber damper weak or damaged Clutch housing/friction plate clearance ex- cessive Clutch housing gear worn T rans.
16-6 APPENDIX T roubleshooting Guide Brake Doesn ’t Hold: Disc brake: Air in the brake line Pad or disc worn Brake fluid leakage Disc warped Contaminated pad Brake fluid deteriorated Primary or seco.
APPENDIX 16-7 General Lubrication Lubrication (Periodic Mainte nance) • Before lubricating each part, clean off any rusty spots with rust remover and wipe off any grease, oil, dirt, or grime. • Lubricate the points listed below with indicated lubricant.
16-8 APPENDIX Nut, Bolt, and Fastener Tightness Tightness Inspection • Check the tightness of the bolts and nuts listed here. Also, check to see that each cotter pin is in place and in good condition. NOTE ○ For the engine fasteners, check the tightness of them when the engine is cold (at room temperature).
APPENDIX 16-9 Unit C onversion T able Prefixes for Units: Prefix Symbol Power mega M ×1 0 0 0 0 0 0 kilo k × 1 000 centi c ×0 . 0 1 milli m × 0.001 micro µ × 0.000001 Units o f Mass: k g ×2 . 2 0 5 =l b g × 0.03527 = oz Units of V olume: L × 0.
An important point after buying a device Kawasaki ER-5 (2001) (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Kawasaki ER-5 (2001) yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Kawasaki ER-5 (2001) - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Kawasaki ER-5 (2001) you will learn all the available features of the product, as well as information on its operation. The information that you get Kawasaki ER-5 (2001) will certainly help you make a decision on the purchase.
If you already are a holder of Kawasaki ER-5 (2001), but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Kawasaki ER-5 (2001).
However, one of the most important roles played by the user manual is to help in solving problems with Kawasaki ER-5 (2001). Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Kawasaki ER-5 (2001) along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
