1994 kawasaki klf220 a7 bayou service repair manual
- 2. 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. Quick Reference Guide General Information 1 2 End 3 4 5 ine Removal/Installation 6 ine Bottom EndlTransmission 7 8 9 10 11 12 13 14 15 nt - 1995 Late - 1997 Models 16 lement - 1998 - 1999 Models 17 lement - 2000 - 2002 Models 18
- 3. KaVlasaki KLF220 BAYOU All Terrain Vehicle Service Manual All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Quality Assurance Division/Consumer Products & Machinery Company/Kawasaki Heavy Industries, Ltd., Japan. No liability can be accepted for any inaccuracies or omissions in this publication, although every possible care has been taken to make it as complete and accurate as possible. The right is reserved to make changes at any time without prior notice and without incurring an obligation to make such changes to products manufactured previously. See your dealer for the latest information on product improvements incorporated after this publication. All information contained in this publication is based on the latest product information available at the time of publication. Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts. © 1987 Kawasaki Heavy Industries, Ltd. 12th Edition (1) :Apr. 20, 2007 (K)
- 4. LIST OF ABBREVIATIONS A ampere(s) Ib pound(s) ABOC after bottom dead center m meter(s) AC alternating current min minute(s) ATOC after top dead center N newton(s) BBOC before bottom dead center Pa pascal(s) BOC bottom dead center PS horsepower BTDC before top dead center psi pound (s) per square inch °C degree(s) Celsius r revolution DC direct current rpm revolution(s) per minute F farad(s) TOC top dead center OF degree(s) Fahrenheit TIR total indicator reading ft foot, feet V volt(s) 9 gram(s) W watt(s) h hour(s) n ohm(s) L liter(s) Read OWNER'S MANUAL before operating
- 5. ~ "~~w.~",.",w.~"....~...~...- ,·Y .~. ....t. .;¥.,,~••.••~...!. :;¥.";¥..._........;r:~...? .;¥."~"~".~,. -,,!-jf~. ~.1I-~-VJl e.lf:.tf~~f. .~. ,- .~iL.~1l..~ii:. •• •~it. ~.u:. • .~........ • ••• ~.. • ..~. .y;.!Y';-..... "".~fllr._~...11 .y..::Y<io ..';: ... .1I!r...!o-.. ,,- .y;:.- .- .. .•.... .,r,;.... *- PLEASE DO NOT TAMPER WITH NOISE CONTROL SYSTEM *:~ IUS Model onlyI ::r.:•• ~ ~t ~: To minimize the noise emissions from this product, Kawasaki has equipped it with !~: ;:":: effective intake and exhaust silencing systems. They are designed to give optimum per- ~: :-i! formance while maintaining a low noise level. Please do not remove these systems, or alter ~! ~ them in anY which results in an increase in noise level. !o::;..... ~ ~;Ko$~ti:.$~~~p.:~~~~:~'f.U.'f.U.'f.!-!~~:;w.~~~~'f..U.~~~~.~., ............,..............., ••"..••:."~;..,..... ".........:>~:>:;:;:.'~;~;...............,.....:~....~~;........... WARNING CONTAINS ASBESTOS Breathing asbestos dun is dlngerous to health Follow safety instructions This warning may apply to any of the following components or any assembly containing one or more of these components:- Brake Shoes or Pads Clutch Friction Material Gaskets Insulators SAFETY INSTRUCTIONS e{)perate if possible out of doors or in a well ventilated place. .Preferably use hand tools or low speed tools equipped, if necessary. with an appropriate dust extraction facility. If high speed tools are used, they should always be so equipped. elf possible, dampen before cutting or drilling. -Dampen dust and place it in properly closed receptacle and dispose of it safely.
- 6. Foreword This manual is designed primarily for use by trained mechanics in a properly equipped shop. However, it contains enough detail and basic in- formation to make it useful to the owner who de- sires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop proce- dures must be understood in order to carry out maintenance and repair satisfactorily. When- ever the owner has insufficient experience or doubts his ability to do the work, all adjust- ments, maintenance, and repair should be car- ried out only by qualified mechanics. In order to perform the work efficiently and to avoid costly mistakes, read the text, thor- oughly familiarize yourself with the procedures before starting work, and then do the work care- fully in a clean area. Whenever special tools or equipment are specified, do not use makeshift tools or equipment. Precision measurements can only be made if the proper instruments are used, and the use of substitute tools may ad- versely affect safe operation. For the duration of the warranty period, we recommend that all repairs and scheduled maintenance be performed in accordance with this service manual. Any owner maintenance or repair procedure not performed in accordance with this manual may void the warranty. To get the longest life out of your vehicle: • Follow the Periodic Maintenance Chart in the Service Manual. • Be alert for problems and non-scheduled maintenance. • Use proper tools and genuine Kawasaki Vehi- cle parts. Special tools, gauges, and testers that are necessary when servicing Kawasaki vehicles are introduced by the Service Man- ual. Genuine parts provided as spare parts are listed in the Parts Catalog. • Follow the procedures in this manual care- fully. Don't take shortcuts. • Remember to keep complete records of main- tenance and repair with dates and any new parts installed. How to Use This Manual In this manual, the product is divided into its major systems and these systems make up the manual's chapters. The Quick Reference Guide shows you all of the product's system and assists in locating their chapters. Each chapter in turn has its own comprehensive Ta- ble of Contents, For example, if you want ignition coil informa- tion, use the Quick Reference Guide to locate the Electrical System chapter. Then, use the Table of Contents on the first page of the chap- ter to find the Ignition Coil section. Whenever you see these WARNING and CAUTION symbols, heed their instructions! Always follow safe operating and maintenance practices. A WARNING This warning symbol identifies special instructions or procedures which, if not correctly followed, could result in per- sonal injury, or loss of life. CAUTiON This caution symbol identifies special instructions or procedures which, if not strictly observed, could result in dam- age to or destruction of equipment. This manual contains four more symbols (in addition to WARNING and CAUTION) which will help you distinguish different types of informa- tion. NOTE o This note symbol indicates points of par- ticular interest for more efficient and con- venient operation. .Indicates a procedural step or work to be done, Olndicates a procedural sub-step or how to do the work of the procedural step it follows. It also precedes the text of a NOTE, *Indicates a conditional step or what action to take based on the results of the test or inspec- tion in the procedural step or sub-step it fol- lows. In most chapters an exploded view illustration of the system components follows the Table of Contents. In these illustrations you will find the instructions indicating which parts require spec- ified tightening torque, oil, grease or a locking agent during assembly.
- 7. GENERAL INFORMATION 1-1 General Information Table of Contents Before SelVicing _. . .. . .. ....... ........ . ...... _. _......... _ 1-2 Model Identification . ... . .. •.. .. ........... _. . . . . . . . . . . . . . . . 1-4 General Specifications . . .. . ............... . ...... . .... .... .. 1-5 Periodic Maintenance Chart . .... . ... ... .. : . . . . . . . . . . . . . . . . • . . 1-7 Torque and Locking Agent . . .... . ... _... . .. ........ .. .. . . : . . . 1-8 Cable and Hamess Routing.. . . . . . ... . ... . . . . ... . . . . . . . . .. . . .. 1-10
- 8. 1-2 GENERAL .INFORMATION Before Servicing Before starting to service a vehicle, careful reading of the applicable section is recommended to eliminate unnecessary work. Photographs, diagrams, notes, cautions, warnings, and detailed des- criptions have been included wherever necessary. Nevertheless, even a detailed account has limi- tations, a certain amount of basic knowledge is also required for successful work. Especially note the following: (1) Dirt Before removal and disassembly, clean the vehicle. Any dirt entering the engine or other parts will work as an abrasive and shorten the life of the vehicle. For the same reason, before installing a new part, clean off any dust or metal filings. (2) Battery Ground Remove the ground (-) lead 'from the battery before performing any disassembly operations on the vehicle. This prevents: ' (a) the possibility of accidentally turning the engine over while partially disassembled. (b) sparks at electric~1 connections which will occur when they are disconnected. (c) damage to electrical parts. (3) Tightening Sequence Generally, when installing a part with several bolts, nuts, or screws, start them all in their holes and tighten them to a snug fit. Then tighten them evenly in a cross pattern. This is to avoid distortion of the part and/or causing gas or oil leakage. Conversely when loosening the bolts, nuts, or screws, first loosen all of them by about a quarter of turn and then remove them. Where there is a tightening sequence indication in this Service Manual, the bolts, nuts, or screws must be tightened in the order and method indicated. (4) Torque When torque values are given in this Service Manual, use them. Either'too little or too much torque may lead to serious damage. Use a good quality, reliable torque wrench. (5) Force Common sense should dictate how much force is necessary in assembly and disassembly. If a part seems especially difficult to remove or install, stop and examine what may be causing the problem. Whenever tapping is necessary, tap lightly using a wooden or plastic-faced mallet. Use an impact driver for screws (particularly for the removal of screws held by a locking agent) in order to avoid damaging the screw heads. , (6) Edges Watch for sharp edges, especially during major engine disassembly and assembly. Protect your hands with gloves or a piece of thick cloth when lifting the engine or turning it over. (7) High-Flash Point Solvent A high-flash point solvent is recommended to reduce fire danger. A commercial solvent com- monly available in North America is Stoddard solvent (generic name) . Always follow manufac- turer and container directions regarding the use of any solvent. (8) Gasket, O-Ring Do not reuse a gasket or O-ring once it has been in service. The mating surfaces around the gasket should be free of foreign matter and perfectly smooth to avoid oil or compression leaks. (9) Liquid Gasket, Non-Permanent Locking Agent Follow manufacturer's directions for cleaning and preparing surfaces where these compounds will be used. Apply sparingly. Excessive amounts may block engine oil passages and cause serious damage. An example of a non-permanent locking agent commonly available in North America is Loctite Lock'n Seal (Blue) . (10) Press 'A part installed using a press or driver, such as a wheel bearing, should first be coated with oil on its outer or inner circumference so that it will go into place smoothly. (11) Ball Bearing When installing a ball bearing, the bearing race which is affected by friction should be pushed by a suitable driver. This prevents severe stress on the balls and races, and prevents races and balls from being dented. Press a ball bearing until it stops at the stop in the hole or on the shaft.
- 9. GENERAL INFORMATION 1-3 (12) Oil Seal and Grease'Seal Replace any oil or grease seals that were removed with new ones, as removal generally damages seals. When pressing in a seal which has manufacturer's marks, press it in with the marks facing out. Seals should be pressed into place using a suitable driver, which contacts evenly with the side of seal, until the face of the seal is even with the end of the hole. (13) Seal Guide A seal guide is required for certain oil or grease seals during installation to avoid damage to the seal lips. Before a shaft passes through a seal, apply a little high temperature grease on the lips to reduce rubber to metal friction. (14) Circlip, Retaining Ring Replace any circlips and .retaining rings that were removed with new ones, as removal weakens and deforms them. When installing circlips and retaining rings, take care to compress or expand them only enough to install them and no more. (15) Lubrication Engine wear is generally at its maximum while the e~gine is warming up and 'before all the rubbing surfaces have an adequate lubricative film. During assembly, oil or grease (whichever is more suitable) should be applied to any rubbing surface which has lost its lubricative film. Old grease and dirty oil should be cleaned off. Deteriorated grease has lost its lubriCative quality and may contain abrasive foreign particles. Don't use just any oil or grease. Some oils and greases in particular should be used only in certain applications and may be harmful if used in an application for which they are not intended. This'manual makes reference to molybdenum disulfide grease (MoS,) in the assembly of certain engine and chassis parts_ Always check manufacturer recommendations before using such special lubricants. (16) Electrical Wires All the electrical wires are either single-color or two-color and, with only a few exceptions, must be connected to wires of the same color. On any of the two-color wires there is a greater amount of one color and a lesser amount of a second color, so a two-color wire is identified by first the primary color and thim the secondary color. For example, a yellow wire with thin red stripes is referred to as a ·yellow/red" wire; it would be a "red/yellow" wire if the colors were reversed to make red the main color. Wire (cross-section) Name of Wire Color Red Wire strands Yellow/red Yellow Red (17) Replacement Parts When there is a replacement instruction, replace these parts with new ones every time they are removed. These replacement parts will be damaged or lose their original function once removed. (18) Inspection When parts have been disassembled, visually inspect these parts for the following conditions or other damage. If there is any doubt as to the condition of them, replace them with new ones. Abrasion Crack Hardening Warp Bent Dent . Scratch Wear Color change Deterioration Seizure (19) Specifications Specification tenms are defined as follows. "Standards" show dimensions or performances which brand-new parts or systems have. "Service limits" indicate the usable limits. If the measurement shows excessive wear or dete- riorated performance, replace the damaged parts.
- 10. 1-4 GENERAL INFORMATION KLF220-A4/A5 (US, Canadian Model) Model Identification KLF22G-A1 (US, Canadian Model) KLF22G-A6 (US, Canadian Model) KLF22G-A2 (US, Canadian Model) KLF220-A7 (US; Canadian Model) KLF22G-A3 (US, Canadian Model) KLF220-AS (US, Canadian Modell
- 11. GENERAL INFORMATION '-5 ........................................................................................ General Specifications ........................................................................................ Items KLF22Q.Al A2 A3 A3A A4 A5 A6/A7/A8 Dimensions: Overall length 1745mm «- «- «- «- «- «- Overall width 1120 mm, (UIIC) 1020 mm «- «- «- 1120mm «- «- Overall height 1015 mm I~II~IKI 1040 mm 1040 mm «- «- «- «- Wheelbase 1115mm «- «- «- «- «- «- Road clearance 155mm «- «- «- «- «- «- Seat height 730 mm «- «- «- «- «- «- Dry weight 183 kg, (UIIC) 181 kg «- <-,(UIIC) 183 kg (A) 184 kg 183 kg,(A) <- <-,(CIIEIIUK) <-, (A)(EIIUK) 183.5 kg 185 kg Curb weight: Front 88.5 kg,(UIIC) 88kg «- <-,(U)(C) 88.5 kg IA)89 kg 88.5 kg,(A) <- «- <-,IAIIEIIUKI89 kg Rear Fuel tank capacity Performance: Minimum turning radius Engine: Type Cooling system Bore and stroke Displacement Compression ratio Maximum horsepower Maximum torque Carburetion system Starting system Ignition system Timing advance Ignition timing Spark plug Valve timing: Inlet Open Close Duration Exhaust Open Close Duration Lubrication system Engine oil: Grade Viscosity Capacity (U) : USmodel (A) : Australian model 104.5 kg,(UIIC) 103 kg «- 10 L «- 2.7m «- 4·stroke, SOHC, " cylinder «- Air cooled «- 67.0 x 61.0 mm «- 215mL «- 9.3 «- 12.5 kW 117 PSI@7 500 r/min (rpmI.IUI- «- 17.7 N·m (1.8 k~m, 13.0 ft·1 b) «-@6000 r/min (rpmI,IUI- Carburetor, MIKUNI VM24SS «- Recoil and Electrical starter «- Magneto COl «- Electronically advanced «- From 10' 8TDC@1 800 r/min (rpm) «-to 35' BTDC@4600r/min (rpm) NGK DR8ES (UIIA) NGK D8EA «- 35' 8TDC «- 57' ABDC «- 272' «- 54' BBDC «- 26' ATDC «- 260' «- Forced lubrication (wet sump) «- SE, SF or SG class «- SAE10W30, 10W40, 10W50, 20W40, or 20W50 «- 2.0 L «- IC) : Canadian model (UK) : UK model <-,(UIIC) 104.5kg «- «- «- «- «- «- «- «- «- «- «- «- «- «- «- «- «- «- «- «- «- «- «- «- «- (A) 104 kg 104.5 kg, (A)<- «- «- «- «- «- «- «- «- «- «- «- «- «- «- «- «- «- «- «- «- «- «- «- «- «- «- «- «- IA)NGK NGK D8EA D8EA «- «- «- «- «- «- «- «- «- «- «- «- «- «- «- «- «- «- «- «- (E) : European model (Continued on next page.) <-,(C)(EIIUK) <-, (AilEIIU K) 105 kg 106 kg «- «- «- «- «- «- «- «- «- «- «- «- «- «- «- «- «- «- «- «- «- «- «- «- «- «- «- «- NGK D8EA, «-(C)(E){UK) DR8ES «- «- «- «- «- «- «- «- «- «- «- «- «- «- «- «- «- «- «- «-
- 12. '·6 GENERAL INFORMATION Items KLF220-A1 A2 A3 A3A I A4 A5 A61A71A8 Drive Train: Primary reduction system: Type Gear ~ ~ ~ ~ ~ ~ Reduction ratio 3.450 (69/20) ~ ~ ~ ~ ~ ~ Clutch type Wet multi disc and centrifugal ~ ~ ~ ~ ~ ~ Transmission: Type 5-speed plus reverse, constant mesh, ~ ~ ~ ~ ~ ~ return shift Gear ratios: 1st 2.923 (38113) ~ ~ ~ ~ ~ ~ 2nd 1.684 (32/19) ~ ~ ~ ~ ~ ~ 3rd 1.173 (27/23) «- ~ ~ ~ ~ ~ 4th 0.923 (24126) ~ ~ ~ ~ ~ ~ 5th 0.785 (22/28) ~ ~ ~ ~ ~ ~ Reverse 3.115 (27113 x 33122) ~ ~ ~ ~ ~ ~ Final drive system: Type Shaft ~ ~ ~ ~ ~ .~ Reduction ratio 4.680 (1 B/15 x 39/10) ~ ~ ~ ~ ~ ~ Overall driveratio 12.686 @Topgear ~ ~ ~ ~ ~ ~ Final gear case oil: Type API GL·5 Hypoid gear oil SAE90 (above 5' C. 41' F) or SAE 80 (below ~ ~ ~ ~ ~ ~ 5' C.41' F) Capacity 0.2L ~ ~ ~ ~ ~ ~ Frame: Type Double tubular ~ ~ ~ ~ ~ ~ Caster (rake angle ) 4' ~ ~ ~ ~ ~ ~ Camber 3' ~ ~ ~ ~ ~ ~ Toe-in 30mm ~ ~ ~ ~ ~ ~ Trail 17mm ~ ~ ~ ~ ~ ~ Tread: Front 764mm ~ ~ ~ <E- ~ ~ Rear 776mm ~ ~ ~ ~ <E- ~ Front tire : Type Tubeless ~ <E- ~ <E- <E- ~ Size AT 21 x8-9 ~ <E- ~ <E- <E- ~ Rear tire: Type Tubeless ~ ~ <E- <E- ~ ~ Size AT22x 10-10 ~ ~ <E- ~ ~ ~ Suspension: Front: Type Independent swing arm ~ ~ ~ ~ ~ <E- Wheel travel 115mm ~ <E- <E- <E- ~ ~ Rear: Type Torque tu be-link ~ <E- ~ <E- ~ ~ Wheel travel 125mm <E- <E- ~ <E- <E- ~ Brake type: Front Drum <E- ~ ~ <E- <E- ~ Rear Drum ~ <E- ~ ~ ~ ~ Electrical Equipment: 12V 12Ah, Battery 12V12Ah ~ ~ <E- ~ ICIIEIIUKI .., (A)12V 12V 14Ah 14Ah Headlight: Type Semi-sealed beam ~ ~ ~ <E- <E- ~ Bulb 12V25125W x 2 ~ ~ ~ <E- ~ <E- Taillight 12V8W x2 ~ ~ ~ <E- <E- ~ Magneto: Type Single phase AC <E- ~ <E- <E- ~ ~ Rated output 10 A@6000r/min (rpm!. 14 V ~ <E- ~ <E- ~ ~ Specifications are subject to change without notice, and may not apply to every country_
- 13. GENERAL INFORMATION 1·7 Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the vehicle in good running condition. The first service is vitally important and must not be neglected. • = Clean, adjust, lubricate, tighten, or replace parts as necessary. Chassis Brake wear - check* Cable adjustments* Battery - check Steering play - check General lubrication* Nuts and bolts - tighten Final gear case oil - change* Engine Air cleaner - service* Clutch adjustment* Valve clearance - check Fuel system cleanliness - check* Engine oil - change* Oil filter - replace Spark plug - clean and gap Spark arrester - clean First Service Regular Service • • • • • • • • • • • • • • • • • • • • • • • • • • • • *Service more frequently when operated in mud, dust, or otehr harsh riding conditions.
- 14. 1-8 GENERAL INFORMATION ............................................................................ Torque and Locking Agent ............................................................................ The following tables list the tightening torque for the major fasteners requiring use of a non-permanent locking agent or liquid gasket. Letter used in the "Remarks" column means: L : Apply a non·permanent lockingagent to the threads. o :Apply an oil to the threads and seated surface. S : Tighten the .fasteners following the specified se- quence. St : Stake the fasteners to prevent loosening. Fastener Fuel System: Carburetor Holder Bolts Engine Top End: Cylinder Head Bolts (8 mm Dia.) (6 mm Dia.) Camshaft Sprocket Bolt Valve Clearance Adjusting Screw Locknuts Camshaft Chain Guide Bolt Engine Left Side: Starter Clutch Allen Bolts Recoil Starter Pulley Bolt Ratchet Cover Nut Engine Right Side: Oil Pump Gear and Balancer Drive Gear Nut: KLF22Q.A1 KLF22Q.A2 ~ Balancer Gear Nut: KLF22Q.Al KLF22Q.A2 ~ Clutch Spring Bolts Primary Clutch Hub Nut Secondary Clutch Hub Nut Oil Pipe Banjo Bolts Engine Removal/Installation: Engine Mounting Bolts (8 mm Dia.) (10 mm Dia.) Engine Bracket Bolts (*1): See Cylinder Head Installation Use the basic torque table below for only the bolts and nuts which do not require a specific torque value. All of the values are for use with dry solvent-Gleaned threads. Basic Torque for General Fasteners Thread Torque dia. (mm) N·m kg·m ft-Ib 5 3.4 - 4.9 0.35 -0.50 30 - 43 in·lb 6 5.9 -7.8 0.60 -0.80 52 - 69 in·lb 8 14 -19 1.4-1.9 10.0 - 13.5 10 25 - 34 2.6 - 3.5 19.0 - 25 12 44-61 4.5 -6.2 33 -45 14 73 -98 7.4 -10.0 54 -72 16 115 -155 11.5 -16.0 83 -115 18 165 - 225 17.0 - 23 125 -165 20 225 - 325 23 - 33 165 -240 Torque Remarks N-m k!l-m ft-Ib 9.8 1.0 87 in-Ib 34 3.5 25 (*1) 9.8 1.0 87 in-Ib (*1) 34 3.5 25 0 12 1.2 104 in-Ib 8.8 0.9 78 in-Ib 34 3.5 25 L 59 6.0 43 12 1.2 104 in-Ib 83 8.5 61 125 13.0 94 78 8.0 58 0 120 12.0 87 0 12 1.2 104 in-Ib 78 8.0 58 0 78 8.0 58 0 15 1.5 11.0 26 2.7 19.5 34 3.5 25 26 2.7 19.5
- 15. GENERAL INFORMATION 1-9 Fastener Torque Remarks N-m kg-m ft-Ib Engine Bottom End/Transmission: Oil Drain Plug 29 3.0 22 Clutch Release Cam Pin 25 2.5 18.0 L Return Spring Pin 25 2.5 18.0 L Output Shaft Bearing Position Plate Screws 8.8 0.9 78 in-Ib L Neutral and Reverse Switch Screws - - - L Crankcase Bolts 8.8 0.9 78 in-Ib Relief Valve 15 1.5 11 L Bearing Stopper Screw 3.9 0.4 35 in-Ib Wheels/Tires: Wheel Nuts 34 3.5 25 S Final Drive: Front Gear Case Bolts (8 mm Dia.) 25 2.5 18.0 (*2) Drive Gear Nut: KLF22Q.A1 78 8.0 58 0 KLF22Q.A2 - 120 12.0 87 0 Oil Seal Housing Nuts 25 2.5 18.0 Cam Damper Mounting Nut 78 8.0 58 Driven Gear Shaft Nut 147 15 108 L Bearing Retainer: KLF22Q.Al 108 11 80 0 KLF22Q.A2 - 120 12 87 0 Final Gear Case Drain Bolt 20 2.0 14.5 Speedometer Plug 20 2.0 14.5 Pinion Gear Nut 69 7.0 51 St Ring Gear Nut 147 15 108 Final Gear Case Fi lIer Cap 15 1.5 11.0 Final Gear Case Cover Bolts 25 2.5 18.0 L Axle Shaft Pipe Bolts 20 2.0 14.5 Propeller Shaft Housing Nuts 25 2.5 18.0 Brakes: Rear Axle Nut 147 15 108 Front Axle Nut 34 3.5 25 Rear Brake Panel Bolts 29 3.0 22 L Front Brake Panel Bolts 26 2.7 19.5 L Suspension: Front Suspension Arm Pivot Bolts 88 9.0 65 Rear Suspension'Arm Bolts 34 3.5 25 Shock Absorber Mounting Bolts 34 3.5 25 Steering: Stem Clamp Allen Bolts 26 2.7 19.5 Stem Bottom End Nut 29 3.0 22 Tie-rod End Nuts 41 4.2 30 Tie-rod Adjusting Sleeve Locknuts 27 2.8 20 Knuckle Arm Pivot Nuts 34 3.5 25 Electrical System: Spark Plug 20 2.0 14.5 (*2): See Front Gear Case Installation
- 16. ·............................................................................ Cable Routing ............................................................................. 1. Main Harness 2. Exciter Coil Leads 3. Pickup Coil Leads 4. Charging Coil Leads (Yellow) 5. Neutral and Reverse Switch Leads 6. Battery Ground Cable 7. Starter Motor Cable 8. Head Light Leads 9. Accessory Leads 10. Connect to the CDI unit lead connectors. .......o Cl m Z m :0 ~ ... Z "TI o :0 3: ~o z
- 17. GENERAL INFORMATION 1-11 1. Throttle Cable 2. Choke Cable 3. Switch Housing Lead 4. Front Brake Cable 5. Neutral and Reverse Indicator Lights 6. Coupler Cover 7. Taillight 3 7 Clamp Through the clamp. 8. Front Brake Cable Equalizer 9. Reverse Cable 10. Battery Clamp 11. Battery Vent Hose
- 18. 1-12 GENERAL INFORMATION Clamp on the crankcase bolt. 1. Starter Motor 2. Engine 3. Fuel Tank 4. Carburetor Vent Hose 5. Breather Hose (for Engine) Clamp on the starter motor mounting bolt. 6. Breather Hose (for Final Gear Case) 7. Breather Hose (for Rear Brake) 8. Rear Brake Cable 1
- 19. FUEL SYSTEM 2-' Fuel System Table of Contents Exploded View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Specifications ........ ... ....... . ............. _. . . . . . . . . . . . 2-3 Special Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Throttle Case and Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Throttle Cable.Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Throttle Case Removal/Disassembly. . . . . . • . . . . . . . . . . . . . . . . . 2-4 Throttle Case Assembly/I nstallation . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Throttle Case Lubrication ................ . .. _. . . . . . . . . . . . 2-5 Choke Lever and Cable ................................... _. . 2-5 Choke Lever Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Choke Lever Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Carburetor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Carburetor Air Screw Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Idie spe'ed Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Fuel Level Inspection/Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Carburetor Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Carburetor Installation Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Carburetor Disassembly........... ....... . _. . . . . . . . . . . . . . 2-8 Carburet~r Assembly Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Carburetor Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Carburetor Inspection. .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Air Cleaner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Air Cleaner Duct Installation Note ... ~ .. _. . . . . . . . . . . . . . . . . . 2-10 Air Cleaner Element Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2-10 Fuel Tank ........ _............. . . _. . . . . . . . . . . . . . . . . . . . . . . 2-11 Fuel Tank Removalll nstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
- 20. 2-2 FUEL SYSTEM ..........................Exploded View ····.............................................. .........................................' ...........~ ............. @ ~- ~~~~ @ ~'lG ~(jj) ~ CO> ~ ~ ;@ . . I . /"1 e ~, ~ . ' - - - •®-A 1. Jet Needle 2. Air Screw 3. Pilot Jet 4. Needle Jet 5. Main Jet T1: 9.8 N-m (1.0 kg-m, 87 in-Ib} G : Apply grease.
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