3*4 Cooling system 2 Radiator cap = check if problems such as overheating and loss of coolant acour, check the entire system as Gescribed in Chapter 1. The radiator cap opening pressure should be checked by a ealer sevice department or service station equipped with the epecial tester required to It the cep Is defective, replace it ‘with anew one, 2 Coolant reservoir— removal and installation +4 Remove the right faiing panel (H modes} or tight side cover (all others) (see Chapter 8). 2 Disconnect the hose(s) from the reservoir ‘and drain the coolant into a suitable container (see illustrations). I's a good idea to mark the positions of the hoses so they aren attached to the wrong fitting when the reservoir is installed, 3 Remove the reservoir retaining band (4 fasteners (all ethers) and detach the reservoir from the trame (see illustration). 4 Installation is the feverse of the removal procedure,Cooling system 3¢5, 4.2 Cooling system we exploded view 1 Coolant temperature 12 Reservoit tank retainer 24 Mounting pote 13 Coolant nose 25 Fan switets 2 Pressure cap 14 Ovrings 26.Cop 3. Thermostat cover 15 Coolant tube 27 Coolant hose 4 Pressure cap retainer 16 Gooleet tube 28 Water pump cover 5 17 Coolant hose 29:O-ring 6 tat 18 Fan 90 Water purip housing ? Thermostat housing 19 Racfator 1 O-ring 8 Coolant hose 20 Stone shield 32 Blood valve 9. Overtiow tube 21 Air bart 33 Carburetor warmer andi 16 Reservoir tank hose 22 Mounting damper ‘coolant3*6 Cooling system 326 Cooling system U.K, Land M models) ~ exploded view: 8. Radiator pressure cap 4 Radiator 5 Air bathe 8 Arrbaifle ? Fan 8 Mounting damper 10 Mounting bolt 11 Rachator bracketCooling system 3e7 ee 8 Remove the mounting fasteners arrova) from the:top and bottom of the reservoir tank 4 Cooling fan and & thermostatic fan switch - ‘check and replacement Check 1 It the engine is overheating and the cosling fan isn't corning on, frst remove the seat and heck the main fuse and fen fus6 (see Chapter 8) a fuse is blown, chack the fan eiccut foe a short ta ground/earth (eee the Wiring, Slagrams at the end of this book). the fisses. le 900d. remove the lower and upper faring {s00 Chapter 8), Weve necessary for access, ‘emove the fuel tank (see Chapter 4) 2 Follow the wiring harness from the fan motor to the connector and unplug i (see slustration), Using two jumper wists, apply battery voltage to the terminals in the fan motor side of the electrical connector. ifthe fan doesn’t work, replace the rotor. 2-H the fan does come on, the problem les in the thermostatic fan switch oF the wiring that connects the components. Remove the Jumper wires and plug in the electrical connector to the fan. Unplug the two wires from the thermostatic fan switch aad connect thee together with a short jumper wire (smo itustration 1.713, 1.10 or 1.16 for switch focation). If the fan comes on, the eireuit to tha motor is okay. and the thermostatic fan ‘nitch i datective (sea Step 10}, 4 the fan sti doesn't work, refer to the Wiig diagrams at the end of the book and heck the tan circuit for broken wires or poor connections 4.70 Remove two botts at the bottom of the fan bracket... 4.2 Disconnect the fan connector (Lmodel shown) Replacement Fan and motor Waring: Tho engine must be 5 Disconnect the cable trom the negative torminal of the battery, 6 Remove the radiator (see Saction 7) 7 Remove the three bolts (H models} or four ‘batts (all ethers) securing the fan bracket to the ragiator (see illustrations), neting which bolt the grouncifearth wire ls attached to. Separate the fan and bracket fram the radiator. 8 The fan, motor and bracket aren't avaitabie Separately. Roplace them as an assembiy it the fan doesn’t run, 8 Installation is the roverse of the removal procedure. Be sure to reinatal the ground/earth \wiro under tha bracket-to-radiator bol. Thermostatic fan switeh Warning: The engine must be AN completely cool before beginning this procedure. 410 Propore tre now surich by vappiag the thread with Teflon tape or by somting tne ‘reads with FIV sealant Disconnect the ‘ews ftom th deve, 1 Unecrow tn eich fom th racitor see lstration {.fa, 110 er tte tor twitch Yosalioa) and quichy install the new srt, tightening. to the torque sted in tie Chapters Speciation, 42 Connect te wes toe switch, 413 Check and, it necessary” od Sootant to the system fs Day Cerda cheeks}, andi twe bolts at the top 5 Goolant and sending unit — check and replacement Check 1 if the engine has been overheating but the Coolant temperature gauge hasn't been Indicating @ hotter than normal condition, begin with a eheck of the coolant lavel (see ‘Daily (pre-ride} checks’. W i's tow, add the recommended type of coslant and te aurd to locate the source of the teak 2 Remove the seat and the fuel tank (seo Chapter 4). Locate the coolant temperature Sending unit, whieh is serewed into the thermostat housing. Unplug the electrical connector from tha sending unit, turn the ignition key to the lun position (don't crank the engine ever) and nate the temperature ‘gauge = it should read Cola. ‘3 With the ignition key stil in the On position, onnoet ona end of a jumper wire to the sending unit wire and ground/earth the otter end ( stration). The needle on the temperature gauge should swing ever past the Hot mark, ‘Caution: Don't groundiearth the wire any Jonges than necessary or tha gauge may be damaged. 4 11 the gauge passes both of these tests, but Goein’t operate correctty under normal riding Conditions, the temperature sending init is elective and must be replaced. 5 if the gauge didn't respond to the tests Properly, either the vire to the gauge is bad or the gauge itset is corective, Replacement Sending unit Warning: The engine must bo A completely c90! before Beginning this procedure. 8 Prepare the ew sending wt by wrapping the threacs with Tonlon tap or by atog tne theeads with PTV sean 7 Daonnect the wie tom the sending unt Unser the sending uit rom tho thr ost housing. and quickly insta” ihe ner ony lightening It to. the torque lated in tis Chapters Specteaions 5.3 Disconnect the temperature sonding unit wire (arrow) and cannect It te ground fearth)3*8 Cooling system 6.4 Remove th 8 Reconnect the electrical connector to the sending unit. Chock and, if necessary, add cealant to the system (see ‘Daily (ore-riia) checks) Coolant temperature gauge 9 eter to Chaplar 9 for the coolant Temperatura gauge replacement procedure removal, check and instaltatton Warning: The engine must be completely coo! before: boginning this procedure. Removal 1 I1the thermostat is functioning propery, the coolant temperature gauge shauld rise to the normal operating temperature quickly and Must be completely submerged ‘They mut not touch th container sides of bottom. ‘67 Suopond the thermastat in water with a thermometer 1 Thermostat 2 Thermometer thermostat housing bolts (arrows)... then stay there, only rising above the normal asition occasionally when the engine gets Unusually hot. If the engine does not reach ermal aperating temporature: quickly, or Hf i overheats, the themnostat should be removed and checked, oF replaced with a new one. 2 Reler to Chapter 4 and drain the cooling system. Remove the upper fairing (H models) (or tower fairing (J, K, Land M models} (see Chapter 8) 9 It you're working on an H model, remove the pressure cap retainer and the two bolts securing the thermostat cover (s ilustration 8.2a or 3,2b). It's not necessary to disconnect the hoses from the cover, 44 Il youre workeng on a.J, K,L and model, remove the three bolts securing the thermostat cover (see illustration) and remove the cover, II's nel necessary to disconnect the hose(s) from the cover, but note the fecation of the ground/earth wire terminal that fits over ono of the housing bolts 5 On all models, withdraw the thermostat from the housing and remave the C-ring (eae Mlustration), Check Remove any coolant deposits, then visually ‘check the thermostat for corrasien, cracks land other damage. iit was open when it was removed, itis detective. Chack the O-ring for cracks and other damage, T Te check the thermostat operation, submerge it in a container of water along with a thermometer (see illustration} Warning: Antifreeze is poisonous. Don't use a cooking pan. The thermostat should be suspended 20 It doesn't touch the container. 8 Gradually heat the water in the container with @ hotplate or stave and check the temperatura whan the thermostat first starts to open 9 Continue heating the water and check the temperature when the thermostat is fully open. 8.5 ...and liftoff the cover to expese the thermostat; nate the ‘O-ring (arrow) 10 Lift the fully open thermostat out of the ‘water and measure the distance the vaive has ‘opened, 11 Compare the opening temperature, the fuby open temperature and the valve travel the values listed in this Chapter's Specifications 12 Hf these specifications are not met, or the thermostat does not open while the water is heated, replace it with a new one, Installation 19 Install the thermostat inta the housing with tho spring peeinting into the housing 14 install a neve O-ring in. thie groove in the thermostat cover. 15 Place the cover on the housing and instal the bolts, tahtening them securely. If you're werking on a, K, Lang M modal, be sure 19 place the groundiearth wire terminal over the proper bolt (see illustration). 16. The remainder of installation is the revérse of the removal procedure. Fil the cooling system with the recommended coolant (tee ‘Daily (pre-ride) chocks'. I you'r warking on ‘an H model, install the pressure cap retaines ‘6:15 Reinstall the ground (earth) wire ‘connector when installing the thermostat ‘cover (d, K, L and M models)Cooling system 309 78a Remove the radiator hoses 1.8 Slide the elip down the overflow hose and disconnect It from the fitting 7 Radiator — removal and installation Warning: The engine must be completely cool before beginning this procedture. Removal 1 Support the bike securely upnght, Remove components as necessary for access to the HY aNd disconnect the cable from the rapatve torminal (see Chapter} radhiator {arrow} 78a Remove the radiator maunting bolts (arrow) =L modal shown 2 Remove the upper and fower fairings: (H models) or the upper fairing (J, K, Land M models) (208 Chapter 8} 3 Remove the fuel tank (see Chapter 4) and rain the coolant (see Chapter 1), 4 Unplug the electrical connectors fae the tan ‘motor and the thermostatic fan switeh (see Mustration 9.22, 3.2b or 3.20) 5 Loosen the hose clamps an both radiator hoses (see illustrations), On H2 models, loasen the clamp on the coolant bypass hose. if you're working on a J, K, L and Mi model oonan the clamp on the oll cooter hose (eee llustration). Detach the hoses. Es) 1.100, Remove the stone shieid screws at the bottom of the ‘and the ail cooler hose on J. K, Land M modes: 7.8b The lower boits on some madels may ot cone allthe way out, but they ean ber ‘unscrewed far enough for radkator removal 6 Hf you're working on a J, K, Land M model disconnect the overflow hese teom the radiator filer neck (soe lustration). 7 It you're working on an H model, remove the oll cooler (s88 Chaptr 2) 8 Remove the radistor mounting bolts (see illustrations), 8 Lift the radiator out. Be sure to check the ‘ubber mounting dampers and replace them if thoy're wer, 10 Hf the radiator is to be repaired, pressure checked or reptaced, detach the cooling tan (688 Section 4) and the stone shield (o \Mustrations). 7.106 ...and ttt the stone shield to di A Upper hook B Bushing © Washer810 Cooling system 7.14 Ifthe radiator bracket needs replacing, unbett it trom the: brackets on the crankeaso 11 Caretuly examine the radiator tor evidence of leaks and damage. it is recommended that any necessary repairs be performed by a reputable radiator repair shop. 42 if the radiator Is clogged, or if lage amounts of rust ar scale have formed, the repair stiop will also do a thorough cleaning job: 18 Make sure the spaces between the going tubes and fing are clear, if necessary, use compressed air or running water 10 remove anything that may be clogging them. war cis 14 It you're working on a J, K, L and Mt model, check the radiator mounting bracket for bending of cracks and replace it as necessary (see illustration) Installation 15 Installation is the reverse of the removal procedure, with the following adleions a) Bo sure fo replace the hoses If they are ‘dotoriorated, 1) Be sue the meta! collars ae in place in the rulsber mounting dampers (see iMustration 7,196), WF the radiatar fing are bent ‘or flattoned, straighten them ry caretly with @ small 8.160 Loasen the hese clamps. . 6) Refi the cooling system with the recommended coolant (200 ‘Daly (are ride) checks) & Water pump — ss ‘check, removal, inspection & and installation zg Waring: The engine must be completely coo! befere beginning this procedure. (Note: The water pump on these madils can't (be overhauied = it mus! be replaced as @ unt ‘Check 1 Viwally check around the area af the watee [pump for cootant leaks, Try to datemmine tthe leak is simply the result of @ loose hose clamp ‘ordeteriorated hose. 2 Support the bike securely upright. 3 Remove the lower fainng (see Chapter €) 4 Drain the engine coolant following the procedure in Chapter 1 '§ Check around the weep hole for signs of coolant leakage (see illustration), If eeolant has been ieaking from the hole, the mechanical seal is damaged. It can't be teplaced separately, so the entire pump must be replaced, 8.18 . .. and remove the hose from the water pump coolant tube B.S Check the weep hole for signs of | (L modal shown) Removal lower fairing panel (see ‘Chapter 8). 7 Brain the coolant {see Chapter 1). 8 Remove the clutch release cylinder (see Chapter 23 9 Ramove the engi Chapter 6) 10 Loosen the coolant hose clamps at the water pump: 11 Remove the sift pedal (see Chapter 2, 42 Remove the water pump mounting bal (08 illustration 3.23 or 3.25). Pull the pure straight out to remove it, pulling It out ofthe ‘coolant heses as it's removed, J, K, Land M models 13 Remove the lower fairing panels (see Chapter 8 14 Drain the cooling system (sae Chapter 1) 15 Disconnect and remove the water pune) Upper hose (see illustrations). 16 Detach the brace, unbolt the coolant tute from the water pump cover and It It out (s00 thustrations) 17 Loosen the clamp and disconnect tha le hose from the water pump (eee llustration) 18 Remove the pump mounting bolts and it the pump off (see illustrations). rocket cover (88 8.16a Remove tho screw that secures th brace to the air battle ..‘Cooling system 3014 tunbott the brace from the water pump cover . 166 ‘ang lift the coolant tube out of the water pump ah 8.188, Remove the pump mounting bolts (arrows); note the terminal on the lower bolt Inspection 419 Unbolt the cover from the pump and tft 20 Check the pump ©. ness oF deterioration (see illustration), It's a good he O-ring whenaver the pump © 820 The caver O-ring should be replaced it there's any doubt ‘about ite condition 21 Try to wiggle the water pump impor back and-forth and in-and-out {see illustration), It ‘you can feel movement, the water pusrg mast be replaced. 22 Check the impaltar blades for corrosion. If ‘they are heavily correded, roplace the water PUMP ond flush the system tharowahily {it 8.17 Loosen the clamp and detach t lower hose from the water pump would also be a good idea to check the internal condition of the radiator, 23 If you're working on a, K, L and M merle, check the O-ring on the coolant tube for brittleness or deterioration (see ilustration) It's a.g00d idea to replace ft whenever the tubs ks rermaved, on 8.21 Ifthe impolier is ioose or corroded, replace the water pump.3012. Cooling system 6.23 The coolant tube O-ring should be replaced whenever the tube is removed from the pump cover pump O-ring with a thin ‘smear of multi-purpose grease. 25 Install the pump body before installing the cover, Tum the impelior sa the slot in the [pump shaft aligns with the dive tooth on the ll pup shaft incioe the engine (see tustrations) 28 Lubricate the cover O-ring with a thin smear of multi-purpose grease, then install tho O-ring and the caver. Tighten the cover and mounting bolts evenly and securely, but don't overtighten and strip out the bott holes. 27 The remainder of installation is the ravarse ofthe removal steps, 28 Fill the cooling system with the recommended coolant (see ‘Daily (ore-ride) checks). 29 Aun the engi feats. and check for coolant Warning: The engine must bo complotely coat before beginning this proceduro. 9 Coolant pipe(s) and passage. = removal and installation 9.5 Remove the Allen bolts to detach the coolant tube from the engine 6.25a Align the stot in the pump shaft (arrow)... 1 Support the bike securely upright 2 Ramova the fairing panais as necessary for ‘access (see Chapter 1} ‘9 Drain the engine coctant (eee Chapter 1). 4 Where necessary, remove the radiator (sae Section 7), carburetors or exhaust system {eee Chapter 4) ‘Coolant tubes 5 Remove the coolant tube-to-cylinder head bolts (see illustration 22a, 3.2b or the accompanying illustration) and separate the ‘tube fram the cylinder head. @ Remove the O-rings from the ends of the ‘tube and install new ones. If one of the ends ‘doesn’t have an O-ring, be sure to retrieve it ‘rom the engine. 7 Check the tube mounting holes in the ‘engine for corrosion, and remove ail traces of ‘corrosion if any exists 8 Install new O-rings on the tube ends. Lifbricating them with alittle clean engine ol ‘9 Instal the ends of the coolant tube into the Inoles in the engine. Install tho mounting bots, ‘ightening them securely. 10 Fill the cooling system with the recommended coolant (see Chapter 1) and ‘check for leaks. 11. The remainder of installation is the eeverse ‘of the removal precedure Coolant passa: (4, K Land M models) 12 Loosen the hose clamps and disconnect tho coolant hoses from the passage (48 ilustration), 13 Remove the mounting bolts and take the passage off the engine. 14 Clean all traces of old gasket and sear from the passage, 15 Install the passage, using a new gasket and tighten its botts securely 18 Fill the cooling system with recommended: coolant (see Chapter 1) ang ‘check for lank. 17. The remainder of instalation isthe reveew of the removal procedure, 10 Oil cooler — removal and installation x x H models Note: Wait until the engine is coot bate beginning this procedure, 1 Support the bike securely upeight and cia the engine oil ee Chapter 1). 2 Remove the lower fairing (s80 Chapter 9.12 Detach the coolant hoses and remove the mounting bol larvowrs). ‘ain Pan Under the front of the 8 In “carkease and remove the oil cooler hose-to- ‘garkcase union bolls (see Wlustratians), Fatiewe the sealing washers, 4 Remove the oil cooler mounting bolts and 16 the il cooler out. tation is the reverse of removal. Be suro to use new sealing washers If the old anes were leaking or damaged, and fill the crankcase with tha recommended type and amount of oll (see Chapter 1 and Daily (ore- ride) checks). If you're working en an Ht Cooling system 3°13 ‘model, tighten the union bohs te the torque. listed in this Chapter’s Specitications. J, K, L and M models © ‘Suppoet the bike securely upright: rain the ‘engine ofl and coolant (see Chapter 1).3°14 Cooling system 10.3b Oil cooler details (H2 models) 1 Stone shield 2 Oil cooler 10.8 Remove the oil cooler bolt 3 O-ring 10.9 Loosen the clamps (arrows) and disconnect the coolant hoses 7 Remove the right lower fairing panel (see Chapter 8). 8 If the exhaust system is in place on the engine, remove the oil cooler bolt with a 2 mm socket (see illustration). Pull the ol cooler forward away from the engine, disconnect the coolant hoses and take the ol cooler out, 9 If the exhaust system has been removed from the engine, disconnect the coolant hoses (See illustration), then remove the oil cooler ‘mounting bolt and lift off the oil cooler. 10 Installation is the reverse of the removal_ steps, with the following additions 9) Make sure the east nib on the crankcase fits between the locating tabs.on the of! cooler and make sure the hoses are Connected properly (see illustration), b) Ifthe exhaust system has been removed tighten the oil cooler bolt to the torque listed in this Chapter's Specifications wit 8 torque wrench. ¢) If the exhaust system is in place on the engine, tighten the all cooler bait to the specified torque with a wrench and spring scale. Place the wrench on the bolt and place the spring scale on the wrench at @ point 300 mm from the center of the bolt and at right angles ta the wrench. Pull on the spring scale with a force of 17 kg te tighten the bott to the specified torque 10.10 Connect the coolant hoses as shown; the tabs on the oil cooler (arrow ‘must fit around the cast rib on the crankcase| | Chapter 4 ae Fuel and exhaust systems Contents fea a cement —eervicing as vasusaes: Ake fitter housing ~ removal and instalation . ... pceenmei renee kepacicn ond nano, “Ai suction valves — check... anes Caratetr overaul~ generlinfoimation 5 -Cerburetor synetwonization - chick and adjustment . see Chaptec 1 Carburetors ~ disassembly, cleaning and inspaction . . ‘Dieburdtors = fuel level adjustment -....... ss perce feassembly and float height acustment _ ~removal and installation... conte Femoval, itallation and scjustmant . [Peportne enision conta eater (Calfomia mod sn ane Chie Degrees of difficulty raperames ein conflate (Calon exile oh — ‘emoval, inspection and installation Exhaust system = check Exhaust system ~ remaval and installation % Fuel pump ~ removal, testing and installation |. Fuel system - check and fiter replacement Fool tank cleaning and repair . Fuel tank = removal ang instalation General information ..... ‘ele tuelair mixture adjusiment = general miormation 5 Ice speed — check and adjuster! ‘see Chapter 1 Throttle cables and grip - removal, installation and adjustment... 10 Throttle speration/grip freepiny — cheek-and adjustment see Chaptor 1 | Easy, sitaie for x Fairy easy, suitable ovce wen tte for beginner with ‘eperenoe s some experience Unieaded or iow lead gasoline (petro subject te local regulations: minimum octane 91 RON (87 pump ectans) ‘18:Iters (4.7 US gal, 4.0 imp gal) 17 liters (2.5 US gat, 3.7 Imp gal) Keihin €vK-036 four Keihin Gvk-038 (foun eanin GVK-D89 (four) 190 128 300 NS2U 13.2 2mm (0.512 + 0.079 neh) 4 to 6 mm (0.187 to 0.236 Inches) below mark402 Fuel and exhaust systems Jet sizes and settings (H2 model) Main jot Allgxcopt US high attuda models 6.5. US high altitude models Main ai fat Jet needie Pict jot ‘loop US hgh ate models US high altitude models... - Pot ai jat ‘Aiexcept California medals. California made. Pilot screw setting DUTIES 1422 mm 0.512-0.079 inet) PT ENIIEIIEI, 4 to mem (0.187 10.0296 inenes) velow mark Jet sizes and sattings (J model) Main jet ‘Al except US high altitude models ‘Gylindars Tana 4. 122 Gyiinders 2 and 3 US high altitude models ‘Gylinders 1 and 4 Syinders 2 and 3 Main ir fet seer ee ee Jetnesdis vandé Gyinders2and 3 <2... 22.5 Pilot jot ‘Allexcept US high atttude modes... 38 US high afitude models... eee eeseeeee + 85 PAOL OI ses oe sees ee eceeeeee see nseeeee 130 Pit screw setting Preset 2iktuns out se 4.2 2 mm.S12 + 0.079 inch) 449 6 mm (0-187 19:0.236 inches) below mark Jet sizes and sotinge (K mode) Main jot ‘All @xeept US high altitude models 138 US high altitude modets « 135 Main air jet 2+ 100 Jetnesdle US except Catfomis models Cylinders 7 and 4 Gysnsers 2 and 3 Caltomia mode's Oylinders 1 and 4 Paige jet ‘Al except US high altitude models . 42 US high atitude models 0 Plot air it 120 Pilot scrow: US models. Preset UK models 4X tums out ‘Choke (starter jet 2 55 Float height Diicceece Sa 2nm 0.354 + 0,079 inch) Fuel level . Gx 1 mim (0.118 + 0.099 inches) above marksizes and settings (L model) et "Al except US high altitude models Oytnders Yard 4 Gyleders 2 ana 3 ‘ALoxcept US high altitude models US high altitude models et Alereept US high altitude madels Ginders tand.4 .,., Gylinders 2 and 3 USNgh altitude modets Gylnders 1 and 4 foe! systern consists of the fue! tank, tip, titer, electric tust pump, carburetors ‘connecting lines, hoses and control carburetors used on H, J and L mocsels four constam vacuum Keihing with 0 thettle valves. For cold starting, hment circu is actuated by a cable 8 Choke lever mounted on the left arburetors used on K and M modote tor fiat-side Mikuni with accelerator an fue eich. 170 190 165 185, Nae Nia 38 35 120 + Proset 2 tums out 52 190 200 185, 195 70 100 42 a 140 Proset 2 tums out 55 ‘exhaust system is a four-into-one Many ofthe ful system sence procedures are considered routine maintenance eens ‘nd for tha reson ar included in Chapter 1 2 Fuel tank— removal and installation Warning: Gasoline (petrol) is AY, strani ‘rma oe oes extra precautions when you work on any part of the Suet syste, Don't Smoke or allow open flames or bare light ‘bulbs near the work area, and don’t werk in # garage where a natural gas-type appliance (sueh as a water heater or Fuel and exhaust systems 4*3 13 = 2mm (0.512 x 0.079 inch) 4 to 6 mm (0.157 to 0.236 inches} below mark NIRA clip in fourth groove trom top) NHC (eps infith groove from top) 9 £2 man (0.354 = 0.078inen) 32 1 mimi0.118 + 0.039 inches) above mark «0.17 1000.16 Bars (1.6 to 2.3 psi) ‘clothes dryer) 's present. If you spill any fuel on your skin, rinse it off immediately with soap and water. When you perform any kind of work on the fuel system, wear Safely glasses and have an extinguisher Suitable for @ class B type fire (henwmable Fiquidis) on hand, 1 The fuel tank is held in place by bolts and ‘rubber insulators, which fit through a flange: Projecting from the tank. On H models, the ‘mounting flangos are belted to the tank: on J, K. Land M models they're an integral part of the tank. Removal H models (2 Remove the rear ducts, front seat and side ‘covers (860 Chapter 8).44 Fuel and exhaust systems 3 Remove the fuel tank mounting bolts (se imustration).. 4 Disconnect the fuel line between the fuel tap and carburetors. Detach the fuel tap from the frye, but teave the hoses that connect it tothe fuel tank attached, 5 It you're working on a California model, iaconnect the evaporative emission hoses {rom ther fittings on the tank (see Section 15). S Lit the fuel tank off the motoreyele, together withthe fuel tap, J, K, Land M models 7 I yau'e working 6 a J of L madel, remeve 8:40 covers (see Chapter 8) 8 it you're working on a K or M model remove the seat (ove Chapter 8). 8 Disconnect the rear ends of the sir ducts. {800 Chapter 8), 40. Remoue the mounting boits at the front ‘ond rear of the fuel tank (S66 istration: On Land M models, unbot he tank mounting bracket from the frame (see illustration). 11 Disconnect the fuel tap line that runs to the carburétors (see illustration), Ramove the uel tap mounting screws and spacers, but eave the fuel lines from the tap to the fuel tank connected {see illustration). 42 Lift the fuel tank off the motoreycle, #1 necessary, disconnect the Wel noses (or ‘evaporative emission system hoses on Calomia models) trom the tank (see illustration), Installation 18 Botore installing the tank, check the condition of the rubber mounting dampers — if they're hardened, eracked, or show any other sign of deterioration, replage them. 14 When installing the tank, reverse the removal procedure, Make sure the tank seats properly and dees not pinch any control s 1 All repairs to the fuel tank should be carried out by a professional who has experience in this eritical and potentially dangerous work, Even after cleaning and flushing of the fuel system, explosive fumes can remain and tite during ropa of the tak, 3 Fuel tank - cleaning and repair 2 I the tual tank is removed trom the vehicle, It should not Be placed in an area where ‘sparks or open flames could ignite the fumes ‘coming out of the:tank. Be especialy careful Inside garages where a natural gas-type applianee is located, because the pilot ight ‘could causa an explosion. a 4 Due to the increased emphasis on controling motorcycle exhaust emissions, certain governmental regulations have been formulated which directly affect the Carburotion ofthis machine n ardor ta comply ‘with the regulttios, the carburntors on some ‘models have a metal sealing plug pressed io the hole over the pilot screw (which contrs {he ie fuaValr mixture) on each carburetor 90 they can't be tamporod with. These shovls ‘only be remaved in the event of a complete ‘carburetor overhaul, and even then the serens ehould be retumed to their original sattings The plict serews on other models at accessible, but the use of an exhaust gas analyzer isthe only accurate vay to adjust the Ile foeVair mixture and be sure the machine ‘doesn't exceed the emissions regulations. 2 it tne engine runs rough at ice or ‘continually stalls, and i a carburetor overhad dos not cure the problem, take the motorcycle to a Kawasaki dealer service dopariment or other repair shop equipped ‘with an exhaust gas analyzer. They wall be sable to propery adjust the idle fuel/air mixture to achieve a Smooth idle and restore low ‘speed pastormance,Fuel and exhaust systems 4e54e6 Fuel and exhaust systems ‘and the mounting serew spacers 12 Diseonnect the tank hoses (L model shown)Fuel and exhaust systems 407 67a Squeeze the clip and slide it down the vent hose |. Carburetor overhaul — | general information | | J Foor engine pertormance, hesitation, hard isting, stalling, flooding and backfiring are 3 sors that major carburetor maintenance: ay be required, 2Keop in mind wet many eo-callod tatumior problems are really not carburetor fioblems at all, but mechanical problems. Wein the engine of ignition system Btunctons. Try to establish for certain that Pecarburetors are in need of maintenance Before beginning a major overnaul, 1 Crack the fuel tap, the in-line fue! ite (and J, K, Land M models also check the fuel JX Mters), the fue lines, the fuel tank cap Jer foxcept California models), the intake frail hose clamps, the vacuurn hoses, the B Wter element, the Gylinder compression, Pe soark plugs, and the carburetor Syeeteoniation before assuming that a Eaburetor overhaul is required. 4Uost carburetor prablems are caused by i particles, varnish and other deposits her build up in and block tho fuat and air fssages. Also, in time, gaskets and O-rings Brink or deteriorate and cause fuel and air Bese wich ad to poor partoemance, Hiner tho carburetor is overhauled, It is (pesraly disassembled compiotely and the firs are cleaned thoroughly with a carburetor Giicing solvent and dried with filtered Ishbecated compressed air. The fuel and air Dpesages are also Biewn through with ferpressed air 10 forco out any cet that may Jars been loosened but not removed by the Hehes!, Once the cleaning process is Hrrpiete, the carburetor is raassombied ineg Pow gaskets, O-rings and, ganerally, a Dp let coodio vaive and seat. Before disassembling the carburetors ffue sure you have a carburotor robvald kit fpbch wil include al necessary O-rings and ‘other parts). some carburetor cleaner, a supply of rags, some means of blowing out the carburetor passages and a clean place to work Hi ay oe coos mixing up parts. El 6 Carburetors = R removal and instaltation s Uris arate Gore A Se es Eran 2 errs area ee or allow open fiames or bare Night bulbs coh ieleatpare seteveceeate ae eestor maces San ee caee oes Snare a oem ar Te toe eee ee Se german seis pe bteeon perp erat een och G8 Disconnect the fuel line from the carburetor assembly “A «ind disconnect the hose from the carburetor fitting (arrow) Removal H, J and L models 4. Romave the fuel tank (soe Section 2) 2 Remove the air filter housing (see See. tion 12%, @ Disconnect the chake cable from the ‘carburetor assembly (sae Section 11), 4 Loosen the throttle cables ail the way and digconnéct them from the thrattie grip (see ‘Section 10} 5 If you're working on an H model, remove the idle speed screw extension. 1G Onallexcept L models, mark and dleconnect thevant hoses trem tha eartretors. 7 If you'ra working en an L model, squeeze the hose clamp and slide it down the vent hose, then disconnect the vent hese from the vent tube assembly (see illustrations), @ Disconnect the fual line from the carburetor sembly (see illustration. 9 Pull tho carburetor agsambly to the rea, clear of the intake maniold tubes (see lustration). Raise the assembly up tar ‘enough to disconnect the throttle cables from the ‘throttle pulley, thea remove the carburetors from the machine. 10 After the carburetors have been removed, stutf clean rags into the intake manifold tuber to pravant the entry of dirt or other objects, 6.9 Pull the carburetor assembly clear of the intake manifold tubes (L model shown)408 Fuel and exhaust systems K and M models 11, Remove the fuel tank (see Section 2), 12 Remove the air filter housing (see Sec tion 12), 13 Disconnect the choke cable from the carburetor assembly (see Section 11). 14 Loosen the throttle cables all the way and discennect them from the throttle grip (see Section 10}, 15 Mark and disconnect the fue! enricher solenoid hoses from the carburetors (see itustration) 16 Disconnect the fuel tine from the carburetor assembly. 417. Pull the carburetor assembly to the rear, lear of the intake manifold tubes. Raise the assembly up far enough to disconnect the throttle cables from the thrattle pulley, then romove the carburetors from the machina, 48 Altec the carburotors have been removed, stutf clean rags into the intake manifold tubes. {0 prevent the entry of dirt or other objects, Installation 419 Make sure the clamps on the intake manifolds are positioned correctly (see ittustrations}, 20 Position the assembly over the intake ‘manifold tubes, Lightly lubricate the ends ef the throttle cables with multi-purpose grease 6.15 Disconnect the fuel enricher solenoid hoses (arrows) ‘and attach themn to the throttle pulley. Make Sure the accelerator and decelerator cables ‘aro in thair proper positions. 21 Tit the front of the assembly down and Insect the fronts of the carburetors into the intake manifold tubes. Push the assembly forward and tighten the clamps, ‘22 Install the ai fler housing (eee Section 12). 23 Make sure the ducts from the alr fitter housing are seated properly, than slide the spring bands into pasition. 24 Conneet the chek cable to tha assembly and adjust i (¢80 Section 11). le QFip freeplay (swe 26. The remaincier of installation is the reversa Of the removal steps, Gasciine foetro ts LY atrometyitaramae, 20" take ‘itra procautions wien you work on any part ofthe fuel system. Bom smoke or alow open Hames or bare light bulbs hear the work araa, and don't work in a Garage where 9 natura gos-yp0 appar [buch os a water heater or clothes Oyen Is Intake joint screw positions = H models Present. i you spil any fuel on your shi rinse it off immediately with soap sod Water, Winer you perform any kind of wa ‘on the fuel system, wear safaty glasses and have a fire extinguisher suitable for class 8 fires (flammabie liquids) an hand. A, Jand L models Disassembly 11 Remove the carburetors from tha machine {83 described in Section 8. Set the assembly ‘on a clean working surtace. Note: Uniess te (O-rings om the fual and vent fittings botween the carburetors are leaking, con't detach te carburetors from their mounting bracket, ‘Also, work an one carburetor at 3 time # avoid getting parts mixed up. 2 If the carburetors. must be separated trom feach other, ramove the choke levee spring and ‘choke fever by removing the thes screws ar six plastic washers (two washers per sete, ‘one on each side of the lever) (eee iilustrations), then remove the screm: ‘securing the mounting plate to tse carburan {see lustrations). Mark the position af gach ‘carburetor and: gently separate them, natig how the throttle linkage is connected (ea itlustration) and being careful not to bose ay Springs oF fuel and vent fitings that are presi Dbattveen the carburetors (see Mustratioe) ae | mm | ‘6.180 Intake joint screw positions = Jand L models 6.19c Intake joint serew positions — K and M modelsFuel and exhaust systems. 4*9 7.20 . .. there are two plastic washers for each screw, ane en each side of the choke shaft... 724 ... separate the choke shaft trom the 7.28 Ifthe air cleaner intake boots must 7.2 The synchronizing screws and springs carburetors. ‘be separated trom the carburetars, (arrows) should look like this (H, J and L models) 1 Choke spring 2 Choke shaft 3 Throttle cable bracket 4 Carmuretore 5 Mounting plate ioe 3 xy 7-29 Carhuretar assembly details * i oy4°10 Fuel and exhaust systems. 7.8b . .. the screw that secures the choke cable bracket has dowel pin... +eand separate the diaphragm fram its groove and the Jocating tab (arrow) from its notch 7.96 Liftthe throttle piston outFuel and exhaust systems 411 4 Rereve the four screws securing the vacuum ber cover to the earburetor body. LN the ‘off and remove the piston spring (see ons). Peal the diaphragm away from its fn the carburetor Body, being Careful not ‘aw ft (see istration). Litt out the (H, Jang L modets) - exploded view Choke plunger cap 9. Trwoitle piston Spcing 10 Float chamber ceain Choke plunger screw Sorew 11 Float chamber gasket Vacuum chamber cover 12 Retaining serow Vacuum piston spring 13 Floats Spcing seat 14 Float pivot pin ot peel 15 Carburetor body 22 Pat screw Glaphragm/piston assembly (see ilustration) ‘4. Remove the piston spring seat and separate: the needs from the piston (see litustrations), 5 Remove the four screws retaining the float chamber to the carburetor body. then detach the chamber (see Illustrations). 76a Loosen the screw shown 6 Push the float pivot pin out and detach the float (and fuel inlet valve needle) from the carburetor body (see illustrations). Detach the vaive needle tr float. Remove the Fetaining screw and remove the necdie vaive ‘seat (se¢ illustration). "Tb... then push aut the float pivot pin 7.6 .. . and lft out the float, together with the needle valve tds ona .6d_ Remove the retaining screw and tit. ‘out the needle valve seat412 Fuel and exhaust systems 7.106 On installation, apply bending agent around the plug 710 The pilat screw on US models is beneath a plug (arrow) 1 Bondting agent 3. Pilot sero 2 Php 4 Carburetor bodyFuel and exhaust systems 4#13 7.118 Unscrew the choke plunger cap with a socket T Unscrew the main jet from the needic jot holder (see illustration), E Unscrew the needle jet holder/air bleed ioe (s0e ilestration), #Using & small, flat-bladed screwdriv femove the pilot jot (see illustrations), 10 The pilot (ele mixture} screw is located in the bottom of the carburetor body (see Mlus- trations). On US mosis, this serew is hidden behind a plug which wil have te be removed ‘hescree is to be taken out. To do this, punch a hole inthe plug with an aul or a soribe, then pry tout. Gn all models, turn the pilot screw in, ‘ounting the number of turns until it bottoms Ighty. Record that number for use when fealing the screw. New remave the pilot screw slong with its spring, washer and O-ring 11 The choke plunger ean be removed by vrscrnwing the nut that retains it te the cuburetor body (see Illustrations) if the thoke shaft has been removed (see Step 2), TA jeaning ‘Caution: Use only a carburetor cleaning solution that is safe for use with plastic parts (be sure to read the lobe! on the contained. 12 Submorge the metal eamponents in the carburetor cleaner for approximately thirty minutes (or longer, if the directions fecommend if 49 After the carburetor has soaked long ‘engugh for the cleaner to lacsen and dissove ‘most of the varnish and othar deposits, use a brush to remove the stubbom deposits, Rinse it again, thea dry it with compressed ait. Blow Outil of the fue and air passages inthe moin and upper body Caution: Never clean the jets or passages With @ piece of wire.or a dril bit, as they wil be enlarged, causing the fuel and air ‘metering rates to be upset. nd take out the spring and plunger Inspection 414. Check the operation of the choke plunger. Itt doesn't move smoothly, replace It, akong with the retum siping. 15 Check the tapered portion of the pilot screw for wear of damage (see illustration). Replace the pilot screw ifnacessary, 16 Check the carburetor body, feat chariber and vacuum chamber cover for cracks, distorted soaling surtaces and other damage. IW any detects are found, replace the tevity ‘component, although replacement ot tne ‘entire carburetor wll probably be necessary (eheck with your parts supplier for the availabilty of separato components). 47 Chock the jet noodie tor straightness by roiling it on a flat surface (such as a piece of (988), Replace if t's bent or ifthe pes wom, 18 Check the neadie jet and replace the carburetor i it's worn er damaged (see iilustration). 715 Check the tapered portion (A) of the pilot screw for waar oF damage 7.18 Check the piston insert and the needle jet for wear or damagede14. Fuel and exhaust systems i, 2 1 il Pos and cease 7.49 Check the tip of the fuel inlet valve needle for grooves or scratches, 1 Rod 3 Groove in tp 2 Valve neeato 7.26¢ Carburators (K and M models) - exploded view 1 Choke plunger cap 10 Jet meocto 2 1 Torte valve 3. Choke pkmger 12 Throttle valve 4 Cover screw 19 Drain serow cap 5. fixing chamber 14 Drain screw ‘cover 15 Fat chamber cover 8 Cover gastat 16 Pot screw plug 7 ‘Thratlo valve arm ws 8. Needte serow 17 Fat chamber cover 9 Jetneedie clip 9 1 Froat chamber O-ring 19 Needle valve and seat 20 Main jot 21 Plot at 22 Choke (starter jet 123 Pilot scrow 24 Allen bot 25 Accelerator link assembly 26 Accelerator pump rod 27 Accelerator shaftFuel and exhaust systems 4°15 727 Accelerator pump cover screws (A) and float chamber cover ‘Screws (By, pilot screw located in the recess in the cover (C) 19 Check the tip-of the fue! inlet valve neodt, I1itnas grooves oF scratches in it, must be replaced, Push in on the rod in the other end fhe needle, then release it~ if It doesn't toring hack, replace the valve needie (see Muswation), 20 Check the O-rings on the float chamber and the drain plug (in the float chamber). Feplace them i they're damaged. {A Operate the throttle shalt to make sure ‘Se throttle butterfly valve opens and closes anjothyy, it doesn't, replace the carburetor. 2 Check the floats for damage, This wil igually be apparent by the presence of fuel Irside one of the tloats. It the floats are anaged, they must be replaced. 23 Check the diaphragm for spits, holes and General deterioration, Holding it up to a ight Vihap to revaal probloms of this nature, 1M incor: the vacuum piston in the carburetor body and see that it maves up-and-down socthly. Check the surface of the piston for esr its worn excessively or dowsn't move ‘moth in the bore, replace the carburetor. Kand M models Disassembly’ 1% Feter to the carburetor synchronization procedure in Chapter 1 and remove the farburttor to cower, i Unscree the jet needle plug andi tit out ‘be et neacte (see illustrations) 7 On the bottom of the carburetor, remove ‘be accelerator pump Alon bolts and take off the accelerator pump components (see stration). 23 On the bottom of the carburetor, remove fh fcat chamber cover Alen bolts and take off 4 fost chamber cover (see hlustration 7.27) i Remove the float pivot pin, float and esd valve, Rlomove the retaining screw and ‘prove the reece valve seat $2 Unscrew the pilot fet, starter et, main jet i¢ main nozzle from the underside of the frtureter, Unscrew the ait jet from fs bore Just below the intake opening: (see tus tration 7.26c). 31 Perform Stop 10 above to remave the pilot Serer 32 It W's necessary to separate the carb- 7.328 The assembled carburetors should look like this ‘uretors, note carefully how the fuel fitting, vent fittings and throtte springs are installed, then remove the Allen bolts that hold the assembly together {see illustrations}. Carefully separate the carburetors from wach other. ‘7.32b Carburetor assembly details (K model shown, M model similar) Joins tings ‘4 Fuel enricher solenoid 5 Fust mtings4°16 Fuel and exhaust systems 30’ To remove tha choke shat, disconnect its totum spring and remove its mounting screws and washers {see illustrations). 34 To remove the choke plungers, refer to Step 11 above Cleaning and inspection 35 Peclorm Steps 12 through 22 above to elsan and inspact the carburetars. 36 ‘Check the accelerator pump dlaphragms ‘or cracks or Brittieness and replace them if their condition isin doubt. 8 Carburetors - reassembly and float height adjustment Caution: When installing the jets, bo Saroful not fo overstighten them = they're made of soft material and can strip or shear easily. Note: When reassembling the carburetors, be Sure 10 use the new O-rings, gaskets and other parts supplied in the robuiid kit H, J and L models 1 If the choke plunger was. removed, install it In its bore, followed by its spring and nut Tighten the nut securely and install the cap, x = 7:33a Disconnect the choke shaft spring (arrow) .. 8.9 Measure float height with a vernier ‘caliper or similar toot 2 Install the pilot secow (if removed) along ‘with its spring, washer and O-ring, taming iti until swats lightly, Now, tum the sorew out the number of tums that was previously ‘ecorded, If yau're working on a US model, instal a new metal plug in the hole over the ‘screw. Apply a ittie bonding agent around the circumference of the plug after it has been ‘seated. Install the pilot jet, tightening it securely. 4 Install the noodie jat hoider/air bleed pip Lightening It securely, 5 Install the main jet into the needie jet hholder/air bleed pipe, tightening it securely. 'G Drop the jat needle down into tts hole in the ‘vacuum piston and install the spring seat over the neodie. Make sure the spring saat doesn't ‘cover the hole at the bottom of the vacuum piston ~ reposition itt necessary. T ingtalt the diaphragmivacuum piston accembly into the-earburetor ody. Lower the: ‘Spring into the piston, Seat the bead of the diaphragm into the groove in the top of the ‘carburetor body, making sure the diaptiragm fen't distorted or kinked (x00 llustration 7.9. Ifthe diapheagm sees too large in diameter and doesn't want to soat in the groove, place the vacuum chamber cover ever the carburetor diaphragm, insert your finger into the throat of the carburetor and push up on tho vacuum piston. Push down gontly on the vacuum chamber cover ~ it should drop into place, indicating the laphragm hoe seated in its groove, 8 Install the vacuum chamber cover, tightening the screws securely. If you're warking on the no. 2 carburetor, don't forget to instal the cowel and choke cable-bracket (600 illustration 7.36). 9 lvert the carburetor. Attach the fue! nat valve needte to the float, Set the fat into position in the carburetor, making sue the ave noecie seats corractiy. Install the oat jvot pin. To check the Hoat hoight, mold th Corburetor so the float hangs down. then tt back until the valve noodles just seated the Tod in the ond of the valve shouldn't be comprasced). Measure the dstance frm the float chamber gasket surface tothe top 3 float (t00 hustration) and compare you measurement to the float height fisted in is Chapter's Specifications. it isn't at speciied, earetlly bend the tang tha contacts the valve needle un or down unl te float eight is correct, 10 instal tho O-ring into the groove in the float chamber. Place the float charnbor on thx carburetor and instal the screws. tightening them secure 411i the carburetors wore soparatod, inst rien! O-rings on the fuel and vert ftings Lubricate the O-rings on tho fitinge witha light fie of oll and install them into ther respective holes, making sure they sea completly (26e ilustration 7.29) 42 Position the coi springs between the carbureiors, gantly push the carburetor together, tien make sure tha toto linkage are correctly engaged. Check the fuel anf vent ftings to make sure they engage property aso, 419: Install the lower mounting plate and instal ‘the screws, but don’t tighten them compistely Yt. Set the carburetors on a. sheet o! slash. then align them with a straightedge placed tiong the edges of the bores, When te eaterines of the carburetors areal in herizental and vertical alignment. tighten the mounting plate serews sacurely. 414 Install the choke lever, making sus h engages correctly with all he choke pungen {sec ilustration). Positon a plastic wachoron {ach side ofthe choke lnver. except cn r0.2 carbutetor (eee Hhustration) and Install heFuel and exhaust systems 4°17 “hades .14b Bo sure ts reinstall the plastic woshers.on bath sides of the shaft 16 If they were removed, instal! the throttie stop screw, throttio cable bracket and the air cleaner housing intake fittings (see illustrations) K and M models 17 Assembly is the reverse of the disassembly procedure. Refer to Step 8 above to set float height, Reler to Step 2 above to install the pilot sere. 18 Install the carburetors (see Section 6) check the fuel level see Section 9) and synchronize the carburetors (see Chapter 1), ‘ Warning: Gasoline (petrol) is extremely flammable, so take ‘extra precautions when you work Ata Make sure the choke shaft engages all four plungers (arrows) soe, tightening them securely. install ir rium spring (soe ilustration 72a), then sake sure the choke mechanism operates oath. 18 install tho throttle linkage springs (see Musiration 7.20. Visually synchronize the trate buttery valves, turning the adjusting dérmes on the throttle linkage, if necessary to alae me clearance between the buttery wahe and throttle bore of each carburetor Geck to ensuto the throttle operates seat. 9 Carburetors - fuel level adjus A 82a Loosen the flozt chamber drain screw {12 On H, J and L models, the ‘9.2 ...0n Kand M models, is attached level magsuring tool is attached like this .. like this 1} Fuel iovol gaugo 2 Mark 1 Fuel level gacge 2 Mark (part no. 57001- 3 Top sine artna.$7001- 3. Tap ine 017) 4 Fuel fovey 1017, 4 Fuetievel 8.168 Throttle cable brackot details {L model shown) 8.18b If the-air cleaner joints were remaved, install thom like this ‘on any part of the fuel system. Dan't ‘smoke or allow open flames or bare light ‘bulbs near the work ares, and don"t work in @ garage where @ natural gas-type appliance (such as a water heater or clothes dryer) is present. if you spilt any fuel on your skin, rinso it off immediately With 30ap and water. When you perform any Kind of work on the fuel systems, wear Safety glosses and have-a fire extinguisher suitable for Class B fires (flammable Niquids) on hand. 1 Remove the fuel tank see Section 2) and the ais fitor housing (see Section 12), Connect ‘an auxiliary fuel tank to tho carburetors with & suitable length of hose, then support the Motorcycle in an upsight position. 2 Attach Kawasaki service tool no, 57001- 4017 to the drain fiting on the bottom of one Of the carburetor float chambers (al four will be checked) (see ilestrations). This is a clear Plastic tube graduated in milimeters. An allerative is to usa a length of clear plastic tubing and an accurate ruler. Hold the graduated tube (or the free end ef the clear plastic tube} against the carburetor body. as ‘shew in the accompanying dhustration. I the Kawasaki tool it being used, raise the zéca ‘mark to a point soveral maimaters above th bottom edge of the carburetor main body. ta piece of clear plastic tubing Is being used, ‘make @ mark on the tubing at a point several milfimeters above the bottom edge of the ‘carburetor main body. 3 Unscrew the drain screw at the bottam of ‘the float chamber a couple of turns, then fet4918 Fuel and exhaust systems 40.38 lamove the seraws from the front half of the throttle housing/switch 40.8 Detach the accelerator cable (A) from its guide anid the ‘decsierator cable (B} from the housing fuel flow info the tube, Wait for the fue! level to stabilize, then elowy lower the tbe until the 2z0r0 mark ig level with the fuel level mark on the carburetor body. Note: Gon't lower the zero mack below the bottom edge of the ‘carburetor then bring it Back yp ~ the reading won't.be accurate, 4 Measure the distance between the mark land top of the fuet level in the tuber gauge. This distance is th fuel level — write f dawn ‘on a piece of paper, sere In the drain screw, shut off the fuel flew, thon move on to the next carburetor and check ithe same way. 10.66 Lift the cable housings out of the ‘guides and slide the eables through the ‘slots Compare your tue! level readings to the value listed in this Chapter’s Specifications, i the fuel level in any carburetor is not correct, remove the float chamber and bend the tang up et down (eae Section 8), as necessary, then recheck the tuel level. Note: Bening the tang up increases the float height and lowers the fuel level ~ bending it down decreasies the ‘oat height and raises the tua! vet 6 After tha fuel lovel for each carburetor has ‘been adjusted, install the carburetor assembly {200 Section 6), 10 Throttle cables and grip — removal, installation and adjustment x Throttle cables Removal 1 Remove the tual tank (900 Section 2). 2 Loosen the accelerator cable lockwhaet and screw the cable adiuster in 3 Remove the cable/switch housing screws (a0@ illustration) and removo the tront and ‘ear halves of the housing (eee ilustratian). 4 Rotate the ends of the cables to align wit the slots in the throttle grip pulley, then detach the cables from the pulley (see illustration). 10.6a Loosen the lockwheels (A) and turn the adjusters (8) te create slack in the cables 5 Detach the accelerator cable, its guide the decelerator cable fram the cable/satal housing (#29 Illustration). 6 Loosen the midiine adjuster # necessay Create slack in the cables, then detach ® {rom the throttle pulley (see illustrations 7 Remove the cables, noting how they al routed Installation 8 Route the cables into place, Make su don't intertera with any other corsponents ‘aren't kinked or bent sharply 40)6c .... then rotate the cables to alga thom withthe pully slots and cisonsaa thom from the pulleyFuel and exhaust systems 4#19 10.12 Siide the decalorator cable into its ‘slot in the hausing Lubricate tne ond of the accelerator cable ‘eth muit-purpose grease and connect it 19 tre trotte pulley af the carburetor. Pass the [ar cable through the siot in the bracket. then seat the eabie housing in the bracket. 0 Repeat the previous step to connect the deetierator cable 1 Route the decelerator cable around the ticisice of the handlebar and connect it to fersarhoe in the-twottte grip pulley 12 Seat he decelerator eable in tho throttle favsng groove (s0e illustration), 13 Push the accelerator cable guide into flees, making sure the notched portion is eractly engaged with the housing (see Hi from the front side of the handlebar, fame tha accelerator cable to the forward fen te throttle rp pulley. Connect the Becsnrator cable tothe rearware hol (sae isrston) Beta the front haf ofthe cablo/switen Reng. making sure tho. locmiing pin fags wih the note in the handlebar I Pesos, rate tno housing back and forth, Bath cating pin drops inte tha hele and Bstovsing halves mate together. instal the fs and ugtten them securely Agustmont I Feiow he procedure cutined in Chapter Prete cperatanlors reply check and jssron, toast te cables. If Tam tno nandievars beck end forth to fair sree cabies dont couse ho stooing bene a tl tan, iz Pull tho cablo free of the bracket and side the cable through the slot in the bracke 10.13 Position the accelerator cable guicie inthe housing 19 With the engine idling, turn the handlebars through thei fll travel (tl left lock to full ight lock) and note whether idle speed increases. I it does, the cables are routed incorrectly. Correct this dangerous condition batore riding the bike Throttie grip Removal 20 Follow Steps 2 through 4 to detach the Upper ends of the throttle cables from the throttle grip pulley, 21 Siide the throttle grip off the handlebar. Installation 22 Gian the handlebar and apply a light coat of mult purpose grease, 23 Push the throttle grip on. 24 Attach the cables tellowing Steps 11 through 15, then adjust the cables following the procedure outlined in Chapter 1, Throttle operationigtin freeplay ~ chock and aghustment. 41 Choke cable — SS removal, installation = and adjustment Removal 1 Remove the seat and fuel tank (see Sec- tion 2) 2 Pull the choke cabla-casing away from its mounting bracket at the carhurator assembly, then pass the inner cabte through the opening ™ 10.14 Engage the decslerator cable (A) and ‘accelerator cable (B) with the throttle pulkey in the brocket (s9@ illustration}, Detach the ‘cable end from the ehoke lever by the no. 4 carburetor 3 Remove thetwo screws securing the choke sable/switch housing halves 10 the left handlebar (see illustration). Pull the front halt fof the housing off and separate the choke cable from the lever (s6e illustration), 4 Remove the eable, noting how it's routed Installation '§ Route the cable inta position. Connect the upper end of the cable te the choke lever. Make sure the cable guide seats properly in the housing. Pace the housing up against the handlebar, making sure the pin in the housing, fits into the hole in the handlebar, instafl the revs, tightening them securely. 6 Connect the lower end of the cable to the ‘choke lever. Pull buck on the cable casing and connect it to the bracket on the no. 3 carburetor. Adjustment 7 Check the freepiay at the choke plunger lever on the carburetor assembly. It should move about two to three milimaters (1/8 inch). 8 It tha freeptay isn't as specifiod, follow the ‘cable to its midline adjuster (it resembles the throttie cable adjuster). Loosen the cable adjusting lecknut and tum the adwuating mut in or Oxf, a necessary, unt the freeplay at the leveris correct. Tighten the focknut @ Install the fuel tank and all of the other components that were previously removed. 11.2b ... separate the housing halves and disengage the cable from the lover4°20 Fuel and exhaust systems 12.2 Air filter housing details (H modeis) 1 Fitar etoment 2 Catch tank 9 Ale filter housing 4 Pug 1217 Air filter housing details (Wand K modets) 1 Plug (UK models) 3 Carburetor intake 4 AVF titer howsing —@ Gatch tank 2 Intake stings manifold joints 5. Filter elernomt 42 Air filter housing — femoval and installation H models 1 Remove the fue! tank (see Section 2) intet ‘3 Remove the plugs that cover the alr tite, ‘housing bolts, then undo the Bolts. 4 Disconnect the eatch tank drain hose the crankcase breather hose, then lift the ar fiter housing off the 5 instalation is tha reverse of removal, and K models ‘6 Flemova the fuel tank (see Section 2, 7 Disconnect the eatch tank drain hose lttustration) 8 Remove the mounting screws (one at ead fear corner of the housing) and lt the oi iter housing att the matorcycte. 9 Installation is the reverse of removal. Land M models 10 Remove the side covers (see Chapter 11. Remove the fuel tank (see Section 2) 42 Remove the mounting bolt at the font the air fiter housing (see illustrations). 19 Disconnect the hosea from the aft intake ‘fittings on the earbure installation 13 Exhaust system — removal and installation 1 Remove ine lower fairing panels ts (Chapter 8). 2 Drain the coolant (cow Chapter 1). 412.42a Remove the mounting boit and) washer (arrow)