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FURY 125 FURY 125R Motorcycle Assembly & Preparation Manual

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Despiece y Ensaamblaje de Fury 125 kawasaki Motors.

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  • FURY 125FURY 125R

    MotorcycleAssembly & Preparation

    Manual

  • Foreword

    In order to ship Kawasaki vehicles asefficiently as possible, they are partiallydisassembled before crating. Since some of themost commonly removed parts have a directbearing on a vehicle's reliability and safety,conscientious pre-sale assembly andpreparation becomes extremely important. Goodsetup procedures can prevent needles warrantyclaims and give customers a greater sense ofconfidence in Kawasaki and their KawasakiDealers.

    This Assembly and Preparation Manualexplain step by step procedures of the followingitem for all Kawasaki Fury125.

    1. Uncrating2. Assembly3. Preparation

    CAUTIONCAUTION indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

    NOTE

    This note symbol indicates points ofti l i t t f ffi i t d

    WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.

    WARNING!

    NOTICENOTICE is used to address practices not ralated to personal injury.

    !

    The selling dealers assumes soleresponsibility for any unauthorized modificationsprior to sale. Refer to your Service Binder forany Service Bulletins specifying FactoryDirected Modifications (Special Claims) whichmust be performed before the vehicle is readyfor sale.

    Whenever you see the following symbols needtheir instruction! Always follow safe operatingand maintenance practice.

    Kawasaki Motor Philippines Corporation acceptsno liability for any inaccuracies or omissions in thispublication, although every possible measure hasbeen taken to make it as complete and accurate aspossible. All procedures and specifications subjectto change without notice.

    particular interest for more efficient andconvenient operation.

  • Table of Contents

    Uncrating ..........................................................................................4Opening Crate....................................................................................4 Parts Check ......................................................................................5-6

    Assembly ............................................................................................7Handlebar .........................................................................................7 Front Fender .....................................................................................7 Front wheel Installation.......................................................................8 Brake Disc Cleaning ...........................................................................8 Rear View Mirrors ( Left and Right) ....................................................9

    Preparation ........................................................................................10 Battery Service .................................................................................10 Battery Activation .................................................................................11-12 Front Brake Fluid ................................................................................13Rear Brake Fluid. .................................................................................14 Drive Chain ........................................................................................15Rear Shock Absorber ..........................................................................17 Tire Air Pressures ...............................................................................17 Fuel .................................................................................................17 Engine Oil (4-Stroke) ..................................................................................18 Throtle Grip and Cable ...............................................................................19 Idle Speed Adjustment ...............................................................................19 Choke Lever and Cable ..............................................................................20Rear Brake Light Switch 20Rear Brake Light Switch ..............................................................................20 Headlight Aim .............................................................................................20 Fastener Check .............................................................................................21-22 Standard Torque Table ................................................................................23 Test Ride the Motorcycle .............................................................................23A & P Check List ...........................................................................................23

  • UNCRATING 4

    Uncrating NOTICEWhen you remove the crate bracket from the motorcycle, be careful not to drop any parts and bracket onto the fuel tank and other components, and not to scratch the fuel tank by the crate bracket. This could dama-ge the fuel tank or components.

    Remove first the two lower flange bolts (D= 8, L=25) at the steering stem and discard it.

    Remove the two upper bolts (D= 8, L=60 ) and washer (D=24.5) to take off the crate bracket and foam pad and discard them.

    DA

    Opening Crate

    Crates have sharp edges and may have nails or screws that can cause cuts and injury. Always wear protective gloves, boots and eye protection when uncrating to prevent injury.

    WARNING!

    Clear a space about 6m (20ft) square to give your self plenty of space to work.

    Place the crate upright on its base.Remove the parts box.

    A. Upper FlangeBolt (D= 8 , L=60 )B. Lower FlangeBolt (D= 8 , L=25 )C. Crate BracketD. Washer (D=24.5 )Remove the top and sides of the crate.

    B

    C

    The steel crate panel plates and fasteners have sharp edges. Always wear protective gloves, boots and eye protection when uncrating to prevent injury.

    WARNING!

  • UNCRATING 5

    Open the parts box, and check the parts against the illustrations. There may be minor differences between these illustrations and the actual vehicle parts. In the following charts under Remarks, D = diameter in millimeters, and L = length in millimeters.

    1

    Prats Check

    23

  • UNCRATING 6

    4224

    2 111

    3 154112

    4 15 1

    1

    No. Part Name Qty. Remarks

    1

    HANDLEBAR MOUNTING BOLTS D = 8 , L = 50SPACERPLUGS D = 30PLUGS D = 14.5FRONT WHEEL PIN-COTTERCOLLAR D = 24 , L = 24.5FRONT FENDERCOLLAR D = 16SCREW D = 6 , L = 14CLAMPCLAMP L = 78.8BOLT-FLANGED D = 6 , L = 16BATTERY ELCTROLYTE, 12 V 3 AhOWNERS MANUAL

    TOOL KIT

  • ASSEMBLY 7

    AssemblyHandlebar Installation

    Install the right handlebar with the mounting bolts (D = 8 , L = 50) (2) in place.

    I t ll fi t th d th th l ft

    A. Plastic Plugs (D=14) (4) , (D=30) (2)B. Socket Bolt (D = 8 , L = 50) (4)C. Left and Right HandlebarD. Spacers

    Install the front fender on the fork legs, and install the collar (D=16)(4) with screw(D=6, L=14) (4) at the left and right of the fork legs.

    A. Boltflange (D=6,L=16)B. Collar (D=16) and Screw (D=6,L=14)C. Front FenderD. Clamp

    Install the flange bolt (D=6,L=16)at the right side with collar (D=16) inside of front fender, and install the clamp cable guide holder at the right i t ll d t bl

    D

    B

    C

    A

    Handlebar

    A. Brake HoseB. Clamp

    A. Speedometer CableB. Clamp

    Install first the spacer and then the left handlebar in the same manner as the right handlebar.Tighten the left and right handlebar mounting bolts to the specified torque.

    Torque: 23 Nm (2.3 kgfm, 17 ftlb)Push the plastic plugs (D=14)(4) into the

    handlebar mounting bolts and Install the platic plug (D=30)(2) to left and right handlebar.

    Install the front brake hose clamp on the left side(L = 78.8) with flangebolt (D=6, L=16) inside of the front fender and then tighten it.

    Front Fender InstallationInstall the front fender with its facing forward.

    install speedometer cable.

    A. Front FenderB. ForwardC. Back

    A

    B C

    A

    B

    A

    B

    Front Fender

  • ASSEMBLY 8

    Lift the motorcycle off the crate base and support the motorcycle with a suitable stand or jack to install the front wheel.

    Check the wheel rotation mark on the front tire.

    A. Axle NutB. Front AxleC. Pin-Cotter

    Discard the crate base.

    C B

    A

    A. Front AxleB. Case-Assy-MeterC. Axle NutD. CollarE. Pin-Cotter

    Torque: 48 Nm (4.9 kgfm , 35 ftlb)

    E

    D

    ABC

    It may take several application of the brake lever before the brake pads contack the disc,

    WARNING

    Tigten the front axle nut (D= 17) to the spe-cified torque and install the pin-cotter.

    Loosen the left axle nut and remove the front axle.

    Front Wheel Installation

    !

    A. Front WheelB. ArrowC. Rotation

    NOTE

    Fit the axle collar on the left sides of the front wheel hud. The collar are identical.

    The direction of the wheel is shown by an arrow on the front tire. Install the wheel so that the ratation mark coincides with wheel ratational direction.

    A

    B C

    Position the front wheel assembly between the fork leg.

    Insert the front brake disk between the brake pads of the caliper.

    p ,which could result in increased stopping distance and cause an accident resulting in injury or death. Do not attempt to ride the motorcycle until a firm brake lever is obtained by pumping the lever unit the pads are against the disc.

    Clean the front brake disc using oilless solvent.

    An anticorrosive treatment applied to the brake discs will increase braking distance and can cause an accident resulting in se-rious injury or death. Remove the anticor-rosive treatment using an oilless solvent.

    WARNING

    Brake Disc Cleaning

    !

    Insert the front axle from the right side of the wheel and push it completely through.

  • ASSEMBLY 9

    Turn the stay to assure visibility to the rear with the operator sitting on the motorcycle.

    Adjust the rear view mirror by slightly moving only the mirror portion of the assembly.

    Conventional Type (Single Nut)Loosen the lucknut completely.Screw the rear view morror in completely, and

    then back it two turns out.Turn the mirror stay to assure visibility to the

    rear with the operator sitting on the motorcycle and tighten the locknut securely.

    Adjust the rear view mirror by slightly moving only the mirror portion of the assembly.

    NOTICEDo not force to tighten and / or loosen the upper hexagonal area (adapter) with a span-ner or wrench. Disassembly of this area is not possible. Non-permanent locking agent is already applied to the threads of this inner area. Forcible loose- ning may damage the adapter and/or the turning mecha-nism of the stay.

    B

    A

    B

    A

    Rear View Mirror (Left and Rigth)

    A. LocknutB. Rear View Mirror (Right)

    Installation and adjustment of the left side mirror is common with the right side. Follow the procedure specified for the right side.

    Turning Stay TypeScrew the mounting area of the right rear view

    mirror into the holder all the way, and tighten the lower hexagonal area securely.

    A. Lower Hexagonal Area for TighteningB. Upper Hexagonal Area (Adapter)C. Rear View Mirror (Right)

    A. StayB. Mirror

    Installation and adjustment of the left side mirror is common with the right side. Follow the procedure specified for the right side.

    B

    C

    B

    A

  • PREPARATION 10

    Preparation

    The battery used in this motorcycle is a sealed type and never needs to be refilled. Follow the procedure for activating a new battery to ensure the best possible battery performance.

    Activating the battery requires two steps, filling the battery with electrolyte , and charging. Read the electrolyte safety label and the following procedure carefully before activation.

    Make sure to use the electrolyte packed in the

    NOTICEIncorrect Battery Activation will reduce battery performance and service life. Be sure to strictly follow the Battery Service instructions in this Manual.

    Insert the ignition key into the switch ignition and turn counterclockwise to open the seat.

    Seat Unlock

    Battery RemovalTake the battery out of the battery case.

    A

    B

    A. SeatB. Seat Lock

    Battery Service

    y pcrate with the unit.Make sure that the model name of the elec-trolyte container matches the model name of the battery. These names must be the same.Battery Model Name for:AX125A/B: YTX4L-BS

    A. Model Name of the ElectrolyteB. Model Name of the Battery

    NOTICE

    Sealed battery electrolyte has a higher cancentration of sulfuric acid. Each con-tainer contains the proper amount of electrolyte for its specific battery. Insu- fficient or incorrect electrolytre will reduce battery performance and service life. Electrolyte over capacity can lead to battery cracking or leaking and result in corrosion damage to the vehicle.

    A. Rubber BandB. Negative (-) CableC. Terminal CapD. Positive (+) CableE. BatteryClean the terminals.

    NOTICEBe sure to disconnect the negative (-) cable first.

    Battery Specification

    E

    Make YuasaBattery Type YTX4L-BS

    Battery Capacity 12 V 3 Ah

  • PREPARATION 11

    Filling the Battery with Electrolyte

    NOTICEDo not remove the alluminum sealing sheet [A] from the filler ports [B] until just prior to use. Be sure to used the dedica-ted eloctrolyte container for correct elec-trolyte volume.

    Place the batterry on the a level surface.Check to see that the sealing sheet [A] has no

    peeling, tears, or holes in it.Remove the sealing sheet [A].

    NOTEThe battery is vacuum sealed. If the sea-

    ling sheet has leaked air into the battery,it may required longer initial charge.

    Place the electrolyte container upside down with the six sealed cells into the filler ports of the battery. Hold the container level, push down the break the seals of all six cells. You will see air bubbles rising into each cell as the port fill.

    NOTEDo not tilt the electrolyte container.

    Check the elctrolyte flow.If no air bubbles [A] are coming up from the filler

    ports, or if the container cells have not emptied completely, tap [B] the container a few times.

    Battery Activation

    Remove the electrolyte container from the vinyl bag.Detach the strip of caps [A] from the con- tainer

    and set asidem, these will be used later to seal the battery.

    NOTEDo not pierce or otherwise open the sea-led

    cells [B] of the electrolyte container. Donot attemp to separate individual cells.

    p y p [ ]

    Keep the container in a place for 20 minutes or more. Don't remove the container from the battery untill it's empty, the battery requires all the electrolyte from the container for proper operation.

    NOTICERemoval of the container before it is completely empty can shorten the sevice life of the battery. Do not remove the elec trolyte container until it is completely empty and 20 minutes have elapsed.

    Gently remove the container from the battery.Let the battery sit for 30 minutes prior to

    charging to allow the electrolyte to permeate into the plate optimum performance.

  • PREPARATION 12

    NOTECharging the battery immediately after filling

    can shorten service life. Let the battery sit for at least 30 minutes after filling.

    Place the strip of caps [A] loosely over the filler ports.

    Newly activated sealed batteries requred an initial charge.Standard Charge 0.4 A x 5 ~ 10 hours

    If using a recommended battery charger, follow th h ' i t ti f l ti t d

    Initial Charge

    NOTICEOnce the strip of caps [A] is installed on- to the battery, never remove the caps, nor add water or electrolyte to the battery.

    NOTETo ensure maximum battery life and

    customer satisfaction, is recommended the battery be load tasted at three times its amp-hour rating for 15 seconds.Re-check valtage and if less than 12.8Voltrepeat the charging cycle and load test. If still bellow 12.8 V the battery is effective.

    Battery InstalationTurn the ignition switch OFF.Visualy inspect the surface of the battery

    container. If any signs of cracking or electrolyte leakcage fron the battery, replace it.

    Apply a little grease on the terminals to pre-vent corrosion.

    Connect the positive (+) cable first andthe charger's instructions for newly activated sealed battery.Kawasaki- recommended chargers:

    Opimate IIIYuasa 1.5 Amp Automatic ChargerBattery Mate 150-9

    If the above chargers are not available, use equivalent one.

    NOTECharging rates will vary depending on how

    long the battery has been stored, tempera-ture, and the type of the charger used. Let battery sit 30 minutes after initial charge, then check voltage using voltmeter. If it is not at least 12.8 V, repeat charging cycle.

    After charging is complete, press down firmly with both hands to seat the strip of caps [A] into the battery (don't pound or hammer) When pro-perly installed, the strip of the caps will be level with the top of the battery.

    Connect the positive (+) cable first, and cover the terminal with the cap.

    Connect the negative (-) cable.Hook the rubber band.

    A. Rubber BandB. Negative Cable (-)C. CapD. Positive Cable (+)

  • PREPARATION 13

    Front Brake Fluid Level InspectionWith the front brake fluid reservoir held hori-

    zontaly, check that the fluid lavel is above the lower level line.

    Operate the brake lever several times.If it feel spongy, there might be air in the brake

    line. If necessary,bleed the air in the front brake line.Also check for fluid leakage around the fitings and bleed the air in the front brake line.

    Remove the reservoir cap and diaphragm, andthat there a plenty of fluid in the reservior.

    NOTEThe fluid level must be checked several

    times during the bleeding operation and replenished as necessary. If the fluid in the reservior runs completely out any time during bleeding, the bleeding operation must be repeated from the beginning since air will have entered the line.

    Attach a clear plastic hose to the bleed valve on the front brake caliper and run the other end of the hose into a container.

    With the reservoir cap off, slowly pump the brake lever several times until no air bubbles can be

    Front Brake Fluid

    Front Brake Line Air Bleeding

    A. Front Brake Fluid ReservoirB. Lower Level LineC. Upper Level LineIf the fluid level is lower than the lower level

    line, fill the brake fluid to the upper level line.Loosen the screws to remove the front brake

    fluid reservoir cap and diaphragh

    NOTICEBrake fluid quikly ruins painted surfaces. Wipe up any spilled fluid immediately.

    lever several times until no air bubbles can be seen rising up through the fluid from the holes at the bottom of the reservoir.This bleed the air from the brake master cylinder end of the line.

    A. Open Bleed ValveB. Apply the Brake and Hold ItC. Close the Bleed Valve D. Release the Brake

    Pump the brake lever a few times until it be-comes hard and then, holding the lever squee-zed, quickly open ( turn counterclockwise) and close the bleed valve. Then release the lever. Repeat this operation until no more air can be seen coming out into the plastic hose.

    fluid reservoir cap and diaphragh.Fill the reservoir to the upper level line with

    DOT3 or DOT4 brake fluid. Inside the front brake reservior is a stepped line showing the upper level line.

    Hold the reservior horizontal by turning the handlebar when checking brake fluid level.

    Brake fluid that is contaminated by mois-ture or dirt, mixed or contains air has a lower boiling point and can cause the brake to be ineffective or fail, and it may cause rubber parts to deterioate, resulting in an accident causing injury or death. Never re-use old brake fluid. Do not use fluid from a container that has been left unsealed or that has been open for a long time. Do not mix two types and brands of fluid for use in the brake. Don't leave the reservior cap off for any length of time to avoid moisture contamination of the fluid. Don't add or cha-nge the fluid in the rain or when a strong wind is blowing.

    WARNING!

    NOTE

  • PREPARATION 14

    Rear Brake Fluid Level InspectionWith the rear brake fluid reservior held hori-

    zontal, check that the fluid level is between the upper and lower lines. Operate the brake pedal several times.

    If it feels spongy, there might be air in the brake line.

    If necessary, bleed the air in the rear brake line.

    Also check for fluid leakage around the fitings.

    Torque: 78 Nm (0.80 kgfm, 69 inlb)

    When air bleeding is finished, check that the fluid level is between the upper and lower lever lines.

    Tighten the bleed valve to the specified torque. Install the diaphragm and reservior.

    Apply the brake fiocefully for a few seconds, and check that the fluid leakage around the fittings.

    A. Rear Brake Fluid ReservoirB. Reservoir CupC. Boltflange

    B

    A

    C

    Rear Brake Fluid

    If the fluid level in the reservior is lower than the lower level line, check for the fluid leaks in the brake line, and fill the reservoir.

    Loosen the cap stopper screw to remove the reservoir to the upper level line with DOT3 or DOT4 brake fluid.

    NOTICEBrake fluid quick ruins painted surfaces. Wipe up any spilled fluid immediately.

    First, tighten the rear brake fluid reser-voir cap clockwise by hand until slight resista- nce is felt indicating that the reservoir cap is seated on the reservoir body, then screw to tighten the reservoir cap while holding the brake fluid reservoir body.

    NOTE

    Rear Brake Line Air BleedingRemove the reservoir cap and diaphragm, and

    that there a plenty of fluid in the reservior.

    NOTEThe fluid level must be checked several

    times during the bleeding operation and replenished as necessary. If the fluid in the reservior runs completely out any time during bleeding, the bleeding operation must be repeated from the beginning since air will have entered the line.

    Attach a clear plastic hose to the bleed valve on the front brake caliper and run the other end of the hose into a container.

    With the reservoir cap off, slowly pump the brake lever several times until no air bubblescan be seen rising up through the fluid from the holes at the bottom of the reservoir.This bleed the air from the brake master cylinder end of the line.

    Pump the brake lever a few times until it be-comes hard and then, holding the lever squee-zed, quickly open ( turn counterclockwise) and close the bleed valve. Then release the lever. Repeat this operation until no more air can be seen coming out into the plastic hose.

    A. ReservoirB. Lower Level LineC. Upper Level Line

  • PREPARATION 15

    When air bleeding is finished, check that the fluid level is between the upper and lower level lines.Tighten the bleed valve to the specified torque.

    Torque: 7.8 Nm (0.80 kgfm, 69 inlb)Install the diaphragm and reservior cap.

    NOTEFirst tighten the rear brake fluid reser-vior

    A. 20~25mm ( 0.79 ~ 1.18 in )If the drive chain is too tight or too loose,

    adjust so that the chain slack will be within the standard value.

    A chain that breaks or jump off the sprocket could snag on the engine sprocket or lock the rear wheel, severely damaging the mo- torcycle and causing it to go out of control. Inspect the chain for damage and proper adjustment.

    WARNING

    A. Open Bleed ValveB. Close the Bleed Valve

    B

    A

    !

    First, tighten the rear brake fluid reser-vior cap clockwise by hand untill slight resistance is felt indicating that the cap is seated on the reservoir body, then tighten the cap an additional 1/6 turn while holding the brake fluid reservior body.

    Tighten the reservior cap topper screw.Apply the brake forcefully for a few seconds

    and check for fluid leakage around the fittings.

    Drive Chain Slack and wheel Alignment Inspection

    Set the motorcycle up on its side stand.Make sure that the drive chain has the specified

    amount of play, and that the left and right notches are on the same marks or points on tne left and right of the swingarm.

    Misalignment of the wheel will result in ab-normal wear, and may result in an unsafe riding condition. Be sure the wheel is pro-perly aligned.

    WARNING

    Rotate the rear wheel to find the position where the chain is tightest, and measure the maximum chain slack by pulling up and puni-shing down the chain midway between the engine sprocket and rear sprocket.

    Drive Chain Slack Adjustment Remove the cotter pin, and loosen the rear axle

    nut. Loosen the left and right chain adjus-ter lock nut.

    If the chain is too tight, turn in the left and right chain adjusters evenly.

    Turn both chain adjusters evenly until the drivechain has the correct amount of slack. To keep the chain and wheel alignment indicator notches should align with the same marks on each side of the swingarm.

    A. IndicatorB. AdjusterC. Notch

    Drive Chain

    !If the chain is too loose, turn out the left and

    right chain adjusters evenly.

  • PREPARATION 16

    A. Cotter PinB. Chain AdjusterC. Nut AdjusterD. Axle NutE. AX125A Model

    Loosen once and tighten again when the slot goes past the nearest hole. B

    C

    AD

    A. Cotter PinB. Turning Clockwise

    B A

    E

    E

    NOTEWheel aligment can also be checked using

    the straightendge or string method.

    Tighten both chain adjuster locknuts.Tighten the rear axle nut to the specified torque.

    Torque: 53 Nm (5.4 kgfm, 39 ftlb)Rotate the wheel, measure the chain slack

    again at the tightest position, and readjust if necessary.

    Install a new cotter pin.NOTE

    When inserting the cooter pin if the slots in the nut align with the cotter pin hole in the axle, tighten the nut clockwise up to the next Its should be within 30 degrees.

    A. Cotter PinB. Turning Clockwise

    Check the rear brake effectiveness.

    Bend the cotter pin over the nut .

    A. Cotter PinB. Axle NutC. Chain Adjuster D. Nut AdjusterE. AX125B Model

    C

    A loose axle nut can lead to an accident resulting in serious injury or death. Tighten the axle nut to the proper torque and be sure the cotter pin is installed correctly.

    WARNING!

  • PREPARATION 17

    Spring Preload Inspection

    STD Spring Preload: 2nd Position

    A. Spring Preload AdjusterB. Wrench

    Turn the preload adjaster to the 2nd position.

    Fill the fuel tank with one gallon or four liters of unleaded gasoline. Use a gasoline with a minimum antiknock index rating according to the recommendation of your country. Refer to the following table.

    Check the position of the spring preload on the rear shockk absorber.

    Rrear Shock Absorder Fuel

    Gasoline is extremely flamable and can be explosive under certain conditions, creating the potentials of serious burns. 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. Never fill the tank completely to the top. If the tank is filled completely to the top, heat may cause the fuel to expand and overflow through the vents in the tank cap. After refueling, make sure the tank cap is closed securely. If gasoline is spilled on the fuel tank, wipe it off immediately.

    WARNING!

    A. Tire Air Pressure Gauge

    Tire Air Pressure AX125A/BFront: 175 kPa (1.75 kgf/cm, 25 psi)Rear: 200 kPa (2.00 kgf/cm, 28 psi)

    To prevent flat-spotting during shipment, the tire are over-inflated before crating. Adjust the tire pressures to the specified values in the front and rear, and make sure to tighten the caps securely.

    The antiknock index is an average of the Re-search Octane Number (RON) and the Motor Octane Number (MON), as shown in the table.

    For US and Canadian Models

    For Other than US and Canadian Models

    Octane Rating Method MinimunRating

    Antiknock (RON + MON) Index ___________

    287

    Octane Rating Method MinimunRating

    Research Octane Number (RON) 91

    Check the fuel tank cap, and check for any leaks.

    Tire Air Pressure

  • PREPARATION 18

    Engine Oil Level InspectionNOTE

    This vehicle's engine is filled with 20W-40 oil from the factory. DO NOT DRAIN and refill the crannkcase before use. Check oil level and drain plug tightness.

    Engine Oil Drain Plug Torque: 29 Nm ( 3.0 kgfm, 21 ftlb)

    A. Oil Filller CapB. Oil Level GaugeC. High Level LineD. Low Level Line

    When replacing the cap, be sure the O-ring is in place, and tighten the cap.

    Recommended Engine OilType: API, SG, SH, SJ, SL or SM with

    JASO MA, MA1 or MA2

    Engine Oil (4-stroke)

    A. Engine Oil Drain Plug Park the vehicle on the level ground.Before starting the engine, check that the

    engine has oil.With the motorcycle held level, check that

    the engine has oil through the oil level sight gauge in the lower left side of the engine.

    NOTICEIf the engine is run without oil, it will be severely damaged.

    Start the engine and run it for several minutes at idle speed. Stop the engine, then wait several minutes until the oil settles.

    With the motorcycle held level, check the engine oil level through the oil level sight gauge. The oil level should come up between the upper and lower level lines next to the gauge.

    If the oil level is too high, remove the excess oil through the oil fillter opening, using a syringe or some other suitable device.

    If the oil level is too low, add oil to reach the correct level. Use the same type of oil that is already in the engine.

    ,

    Viscosity: SAE 10W-40

    Capacity: 0.95 L (1.0 US qt)[when filter is not removed]1.0 L (1.0 US qt)

    [when filter is removed] 1.1 L (1.2 US qt)

    [when the engine is completely dry]

    Although 10W-40 engine oil is the recommen-ded oil for most conditions, the oil viscosity may need to be changed to accomodate atmosphe-ric condition in your area.

  • PREPARATION 19

    Loosen the locknut at upper end of the throttle cable, and turn the adjusting nut until the proper amount of throttle grip play is obtained.

    Tighten the locknut.Throttle Grip and Cable

    Inspect the throttle grip free play. If the free play is incorrect, adjust the throttle cables.

    Throttle Grip Free Play:2 ~ 3 mm (0.08 ~ 0.12 in)

    Check that the throttle grip moves smoothly from full open to close, and the throttle closes quikly and completely in all steering positions by the return properly, check the throttle cable routing, grip free play, and for possible cable damage. Then lubricate the throttle cables.

    Operation with an improperly adjusted, incorrectly routed, or damaged cable could result in an unsafe riding condition.Be sure the cables are routed correctly, properly adjusted and are not damaged in any way.

    WARNING

    Start the engine, and warn it up thoroughly.Adjust the idle speed by turning the idle

    adjusting screw.Idle Speed: 1 300 r/min (rpm)

    Throttle Grip and Cable

    Idle Speed Adjustment

    !

    A. Throttle Grip B. Throttle Grip Play

    2~3 mm (0.08 ~ 0.12 in.)

    Run the engine at the idle speed, and turn the handlebar all the way to the right and left to ensure that the idle speed does not change. If the idle speed increases, check the throttle grip free play.

    Throttle Grip and Cable

    A. LocknutB. Adjusting NutC. Throttle Cable

    A. Idle Adjusting ScrewOpen and close the throttle a few times to

    make sure that the idle speed does not change. Readjust if necesary.

    With the engine idling, turn the handlebar to each side. If handlebar movement change the idle speed, the throttle throttle cable may be improperly adjusted or incorrectly routed, or it may be damage. Be sure to correct any of these conditions before riding.

    Operation with damage cable could result in an unsafe riding condition.

    WARNING!

  • PREPARATION 20

    Choke Lever Free Play Inspection

    Check that the choke lever returns properly and that the inner cable slides smoothly.

    Push that the choke lever back all the way to its released possition.

    A. Choke Cable Free PlayB. Choke Lever

    B

    NOTICE

    To avoid damaging the electrical connec-tions inside the switch, be sure that the switch body does not turn during adjust-ment.

    Horizontal AdjustmentThe headlight beam is adjustable horizontally. If

    not properly adjusted horizontally,the beam will point to one side rather than straight ahead.

    Choke Lever and Cable

    Headlight Aim

    Determine the amount of the choke cable play the choke lever.

    Choke Lever Free Play:2 ~ 3 mm (0.08 ~ 0.12 in.)

    Rear Brake Light Switch Adjustment

    Turn on the ignition switch. The brake light shoult illuminate when the brake pedal is de-pressed.

    A. Rear Brake Light SwitchB. Adjusting NutC. Lights Sooner.D. Lights Later.

    A. Bolt

    NOTEOn high beam, the brightest point should

    be slightly below horizontal with the motorcycle on its wheels and the rider seated. Adjust the headlight to the proper angle according to local regulation.

    A. Brightest Point

    Rear Brake Light Switch

    If it does not, turn the adjusting nut at the rear brake light switch as required.

  • PREPARATION 21

    The torque values listed are for assembly and preparation items only, see the appropriate Service Manual for a more comprehensive list. Check tightness of all fasteners that are in the table before retail delivery. Also check to see that each cotter pin or circlip is in place.

    4 611

    9

    11

    16

    2

    1

    3

    Fastener Check

    12

    5

    13

    8

    7

    14

    1015

  • PREPARATION 22

    Nm kgfm ftlb

    1 23 2.3 17 G2 44 4.5 32

    3 8.8 0.9 78 in.lb4 25 2.5 185 7.8 0.8 69 in.lb6 25 2.5 187 25 2.5 188 7.8 0.8 69 in.lb

    9 49 5 36

    10 25 2.5 1811 25 2.5 18

    12 29 3 21

    No. FastenerTorque

    Remarks

    SteeringHandlebar mounting boltsSteering stem head bolt

    BrakesFront master cylinder clamp boltsFront caliper mounting bolts Front brake bleed valveRear master cylinder mounting boltsRear caliper mounting bolts Rear brake bleed valve

    SuspensionRear Shock Absorber Mounting Nuts

    OthersFront footpeg bracket bolts (Left and Right)Rear footpeg bracket bolts (Left and Right)

    Engine oil drainEngine oil drain bolt

    C tt i Ci li13 - - - -14 - - - -15 - - - -16 - - - -

    Cotter pins or CirclipsFront axle nut cotter pinRear axle nut cotter pinRear master cylinder rod cotter pinRear footpeg pin circlip (Left and Right)

    Letters used in the '' Remarks '' column means:- G: Apply grease.

  • PREPARATION 23

    This table relating tigtening torque to thread diameter, list the basic torque for bolts and nuts. Used this table for only the bolts and nuts which do not require a specific torque value. All of the values are for use with dry solvent cleaned threads.

    General Fasteners

    Electrical System:Headlight - check high and low beam.Taillight - check operation.Brake Light - check operation.Turn Signal Lights - check operation.Horn - check operation.Instrument Lights and Inicator Lights - check operation.

    Engine Stop Switch Works:Starter Interlock Switch Works:No Unusual Noises:No Fuel, Oil Brake Fluid, Or Coolant Leaks:

    PREPARATION COMPLETE.

    New tires are slippery and may cause loss of control and injury. A brake-in period of 160 km (100miles) is necessary to establish normal tire

    WARNING

    Standard Torque Table

    !

    Complete the test ride checklist.Control Cables:Throttle control cables must work wiyhout binding in any steering possition.

    Steering:Action is free from lock to lock.

    Suspension:

    Engine:

    Check the operation.

    Electric stater works properly and engine starts promptly. Good throttle response and return.

    Transmission and Clutch:Smooth operation.

    Brakes:Adequate, smooth stopping power, No drag.

    traction.During brake-in, avoid sudden and maxi-mum braking and accelaration, and hard cornering.

    Complete the A & P Check List.

    A & P Check List

    Test Ride the Motorcycle

  • Kawasaki Motor Philippines Corporation

    Part No. 99939-1335-01