Kawasaki KLX110 Service Manual

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KLX110 KLX110L Motorcycle Service Manual ...

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This quick reference guide will assist you in locating a desired topic or pro- cedure. •Bend the pages back to match the black tab of the desired chapter num- ber with the black tab on the edge at each table of contents page. •Refer to the sectio...

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KLX110 KLX110L Motorcycle Service Manual All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without...

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LIST OF ABBREVIATIONS A ampere(s) lb pound(s) ABDC after bottom dead cente r m meter(s) AC alternating current min minute(s) ATDC after top dead center N newton(s) BBDC before bottom dead center Pa pascal(s) BDC bottom dead center PS horsepower BTDC ...

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Foreword This manual is designed primarily for use by trained mechanics in a properly equipped shop. However, it contains enough detail and basic in- formation to make it useful to the owner who de- sires to perform his own basic maintenance and repa...

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GENERAL INFORMATION 1-1 1 General Information Table of Contents Before Servicing ..................................................................................................................... 1-2 Model Identification..............................

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1-2 G ENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly opera- tion on a motorcycle, read the p recautions given below. To facilitate actual operations, notes, illustra- tio...

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GENERAL INFORMATION 1-3 Before Servicing Arrangement and Clea ning of Removed Pa rts Disassembled parts are easy to confuse. Arrange the parts according to the order the parts were disassembled and clean the parts in order prior to assembly. Storage ...

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1-4 G ENERAL INFORMATION Before Servicing Tightening Sequence Generally, when installing a part with several bolts, nuts, or screws, start them all in their holes and tighten them to a snug fit. Then tighten them according to the specified se- quence...

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GENERAL INFORMATION 1-5 Before Servicing Press For items such as bearings or oil seals that must be pressed into place, apply small amount of oil to the con- tact area. Be sure to maintain proper alignment and use smooth movements when installing. Ba...

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1-6 G ENERAL INFORMATION Before Servicing Lubrication It is important to lubricate rotating or sliding parts during assembly to minimize wear during initial operation. Lubri- cation points are called out throughout this manual, apply the specific oil...

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GENERAL INFORMATION 1-7 Model Identification KLX110CA Left Side View KLX110CA Right Side View Frame Number Engine Number ...

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1-8 G ENERAL INFORMATION Model Identification KLX110DA Left Side View KLX110DA Right Side View ...

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GENERAL INFORMATION 1-9 General Specifications Items KLX110CA ∼ CE, KLX110DA ∼ DE Dimensions Overall Length 1 560 mm (61.42 in.) Overall Width 650 mm (25.59 in.) Overall Height: KLX110C 955 mm (37.60 in.) KLX110D 990 mm (38.98 in.) Wheelbase 1 07...

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1-10 GENERAL INFORMATION General Specifications Items KLX110CA ∼ CE, KLX110DA ∼ DE Valve Timing: Inlet: Open 25° BTDC Close 55° ABDC Duration 260° Exhaust: Open 60° BBDC Close 20° ATDC Duration 260° Lubrication System Forced lubrication (we...

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GENERAL INFORMATION 1-11 General Specifications Items KLX110CA ∼ CE, KLX110DA ∼ DE Front Tire: Size 2.50-14 4P.R. Make/Type IRC, GS-45F, Tube Rear Tire: Size 3.00-12 4P.R. Make/Type IRC, GS-45F, Tube Rim Size: Front 14 × 1.40 Rear 12 × 1.60 Fro...

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1-12 GENERAL INFORMATION Unit Conversion Table Prefixes for Units: Prefix Symbol Power mega M × 1 000 000 kilo k × 1 000 centi c ×0.01 milli m × 0.001 micro µ × 0.000001 Units of Mass: kg × 2.205 = lb g × 0.03527 = oz Units of Volume: L × 0....

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PERIODIC MAINTENANCE 2-1 2 Periodic Maintenance Table of Contents Periodic Maintenance Chart .............. 2-2 Torque and Locking Agent................. 2-4 Specifications .................................... 2-8 Special Tools .........................

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2-2 P ERIODIC MAINTENANCE Periodic Maintenance Chart The maintenance m ust be done in accordance with this chart to keep the motorcycle in good running condition. Periodic Inspection FREQUENCY Initial Every hours(month (s)) 5 50 100 OPERATION (1) (6)...

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PERIODIC MAINTENANCE 2-3 Periodic Maintenance Chart Periodic Replacement Parts FREQUENCY Initial Every hours (month (s)) 5 50 100 OPERATION (1) (6) (12) See Page Engine oil - change • • • 2-19 Oil filter - replace • • 2-20 Fuel hose - repla...

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2-4 P ERIODIC MAINTENANCE Torque and Locking Agent Tighten all bolts and nuts to the proper torque using an accurate torque wrench. If insufficiently tightened, a bolt or nut may become damaged, strip an internal thread, or break and then fall out. T...

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PERIODIC MAINTENANCE 2-5 Torque and Locking Agent Torque Fastener N·m kgf·m ft·lb Remarks Clutch Primary Clutch Hub Nut (KLX110C) 72 7.3 53 Secondary Clutch Hub Nut (KLX110C) 72 7.3 53 Clutch Hub Nut (KLX110D) 72 7.3 53 Primary Gear Nut (KLX110D) ...

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2-6 P ERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener N·m kgf·m ft·lb Remarks Brake Pedal Bolt 8.8 0.90 78 in·lb Suspension Front Fork Clamp Bolts (Upper) 20 2.0 15 Front Fork Clamp Bolts (Lower) 30 3.1 22 Steering Stem Nut 4.9 0.50 ...

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PERIODIC MAINTENANCE 2-7 Torque and Locking Agent Basic Torque for General Fasteners Threads dia. Torque (mm) N·m kgf·m ft·lb 5 3.4 ∼ 4.9 0.35 ∼ 0.50 30 ∼ 43 in·lb 6 5.9 ∼ 7.8 0.60 ∼ 0.80 52 ∼ 69 in·lb 8 14 ∼ 19 1.4 ∼ 1.9 10.0 �...

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2-8 P ERIODIC MAINTENANCE Specifications Item Standard Service Limit Fuel System Throttle Grip Free Play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) ––– Idle Speed 1 600 ∼ 1 700 r/min (rpm) ––– Air Cleaner Element Oil High quality foam air filter oi...

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PERIODIC MAINTENANCE 2-9 Specifications Item Standard Service Limit Final Drive DriveChainSlack KLX110C Models 11 ∼ 16 mm (0.4 ∼ 0.6 in.) ––– KLX110D Models 8 ∼ 13 mm (0.3 ∼ 0.5 in.) ––– Drive Chain 20-Link Length 254.0 ∼ 254.6 ...

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2-10 PERIODIC MAINTENANCE Special Tools Steering Stem Nut Wrench: 57001-1100 Valve Adjusting Screw Holder: 57001-1217 Jack: 57001-1238 Spark Plug Wrench, Hex 16: 57001-1262 Fork Oil Level Gauge: 57001-1290 Filler Cap Driver: 57001-1454 ...

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PERIODIC MAINTENANCE 2-11 Periodic Maintenance Procedures Fuel System Fuel Hose and Connection Inspection ○ The fuel hoses are designed to be used throughout the motorcycle’s life without any maintenance, however, if the motorcycle is not properl...

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2-12 PERIODIC MAINTENANCE Periodic Maintenance Procedures If the throttle grip free play cannot be adjusted with the adjuster at the upper end of the throttle cable, use the lower cable adjuster at the carburetor. • Remove the shroud (see Shroud Re...

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PERIODIC MAINTENANCE 2-13 Periodic Maintenance Procedures Idle Speed Adjustment NOTICE The pilot screw [A] is set at the factory and should not be adjusted. But if necessary, set the pilot screw as follows: NOTE ○ For US and CA models, the pilot sc...

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2-14 PERIODIC MAINTENANCE Periodic Maintenance Procedures WARNING Gasoline and low flash-point solvents can be flammable and/or explosive and cause severe burns. Clean the element in a well-ventilated area, and take care that there is no spark or fla...

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PERIODIC MAINTENANCE 2-15 Periodic Maintenance Procedures • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System chapter) Fuel Hose [A] • Replace the fuel hose with a new one. • Fix the both ends of the fuel hose with the clamps [A] secu...

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2-16 PERIODIC MAINTENANCE Periodic Maintenance Procedures Engine Top End Valve Clearance Inspection NOTE ○ Valve clearance must be checked and adjusted when the engine is cold (at room temperature). • Remove: Valve Adjusting Covers [A] (see Camsh...

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PERIODIC MAINTENANCE 2-17 Periodic Maintenance Procedures Spark Arrester Cleaning This vehicle is equipped with a spark arrester. It must be properly maintained to ensure its efficiency. NOTICE The spark arrester must be installed correctly and funct...

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2-18 PERIODIC MAINTENANCE Periodic Maintenance Procedures Clutch Release Adjustment (KLX110C) • Loosen the adjusting screw locknut [A]. • Turn the adjusting screw [B] counterclockwise until it be- comes hard to turn. • Loosen the adjusting scre...

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PERIODIC MAINTENANCE 2-19 Periodic Maintenance Procedures Friction and Steel Plates Inspection • Remove the clutch plates (see Secondary Clutch Disassembly (KLX110C) or Clutch Hub Disassembly (KLX110D) in the Clutch chapter). • Visually inspect t...

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2-20 PERIODIC MAINTENANCE Periodic Maintenance Procedures WARNING The engine and exhaust system get extremely hot during normal operation and can cause serious burns. Never touch the engine or exhaust pipe during oil change. • Place an oil pan bene...

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PERIODIC MAINTENANCE 2-21 Periodic Maintenance Procedures • Replace the oil filter [A] with a new one. • Apply engine oil to the grommet [B]. • Be sure to install the filter with the grommet facing inside. NOTICE Inside out installation stops o...

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2-22 PERIODIC MAINTENANCE Periodic Maintenance Procedures Tires Inspection As the tire tread wears down, the tire becomes more sus- ceptible the puncture and failure. • Remove any imbedded stones or other foreign particles from the tread. • Visua...

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PERIODIC MAINTENANCE 2-23 Periodic Maintenance Procedures Rim Runout Inspection • Place the jack under the frame so that the front/rear wheel off the ground. Special Tool - Jack: 57001-1238 • Inspect the rim for small cracks, dents, bending, or w...

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2-24 PERIODIC MAINTENANCE Periodic Maintenance Procedures Final Drive Drive Chain Slack Inspection • Raise the rear wheel off the ground, rotate the rear wheel to find the place where the chain is tightest (because it wears unevenly). • Check the...

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PERIODIC MAINTENANCE 2-25 Periodic Maintenance Procedures • Tighten both chain adjuster locknuts s ecurely. • Tighten the axle nut. Torque - Rear Axle Nut: 64 N·m (6.5 kgf·m, 47 ft·lb) • Rotate the wheel, measure the chain slack again at the...

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2-26 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Stretch the chain taut by hanging a 10 kg (20 lb) weight [A] on the chain. • Measure the length of 20 links [B] on the straight part [C] of the chain from the pin center of the 1st pin t...

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PERIODIC MAINTENANCE 2-27 Periodic Maintenance Procedures Sprocket Wear Inspection • Visually inspect the front and rear sprocket teeth for wear and damage. If they are worn as illustrated or damaged, replace the sprocket. [A] Worn Tooth (Engine Sp...

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2-28 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Leve r Free Play Adjustment • Slide the brake lever dust c over [A] out of place. • Loosen the locknut [B] and turn the adjuster [C] so that the brake lever will have 4 ∼ 5 mm (0.1...

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PERIODIC MAINTENANCE 2-29 Periodic Maintenance Procedures Brake Pedal Free Play Adjustment • Turn the adjusting nut [A] at the brake cam lever so that the pedal has proper play. • Operate the pedal a few times to see that it returns to its rest p...

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2-30 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Shoe Lining Thickness [A] Standard: Front 2.10 ∼ 3.00 mm (0.08 ∼ 0.12 in.) Rear 3.85 ∼ 4.15 mm (0.152 ∼ 0.163 in.) (When the wear indicator is within the USABLE RANGE.) Service l...

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PERIODIC MAINTENANCE 2-31 Periodic Maintenance Procedures • Before removing the cam lever [A], mark the position [B] of the cam lever. • Remove the brake cam lever bolt [C] and nut [D], and then pull out the brake cam lever from the brake camshaf...

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2-32 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Panel Lubrication • Disassemble the brake panel (see Brake Panel Disas- sembly in the Brakes chapter). • Clean all old grease out of the brake parts with a cloth. • Apply high-temp...

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PERIODIC MAINTENANCE 2-33 Periodic Maintenance Procedures • Drain the fork oil [A] with the fork upside down. NOTE ○ Pump the fork tube several times to discharge the oil. • Pour in the specified type and amount of oil. Suspension Oil - SS-8 (1...

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2-34 PERIODIC MAINTENANCE Periodic Maintenance Procedures Swingarm Pivot Inspection • Raise the rear wheel off the ground with the jack. Special Tool - Jack: 57001-1238 • Move the swingarm [A] side to side to check for worn, damaged or loose susp...

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PERIODIC MAINTENANCE 2-35 Periodic Maintenance Procedures • Loosen the front fork upper clamp bolts [A], and remove the steering stem head nut [B] and steering stem head [C]. • Turn the steering stem nut [A] with the steering stem nut wrench [B] ...

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2-36 PERIODIC MAINTENANCE Periodic Maintenance Procedures Frame Frame Inspection • Clean the frame with steam cleaner. • Visually inspect the frame [A] for cracks, dents, bending, or warp. If there is any damage to the frame, replace it. WARNING ...

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PERIODIC MAINTENANCE 2-37 Periodic Maintenance Procedures • Measure the gap [A] with a wire-type thickness gauge. If the gap is incorrect, carefully bend the side electrode [B] with a suitable tool to obtain the correct gap. Spark Plug Gap Standard...

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2-38 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Check that the battery terminals are not corroded. If necessary, remove the battery (see Battery Removal in the Electrical System chapter) and clean the terminals and cable ends using a so...

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PERIODIC MAINTENANCE 2-39 Periodic Maintenance Procedures • With the cable disconnected at the both ends, the cable should move freely [A] within the cable housing. If cable movement is not free after lubricating, if the cable is frayed [B], or if ...

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2-40 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brakes: Rear Brake Adjust Nut Brake Lever Pivot Bolt Brake Pedal Bolt Torque Link Nuts Torque Link Nut Cotter Pins Suspension: Front Fork Clamp Bolts Rear Shock Absorber Mounting Bolts, Nuts S...

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FUEL SYSTEM 3-1 3 Fuel System Table of Contents Exploded View........................................................................................................................ 3-2 Specifications ....................................................

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3-2 FUEL SYST EM Exploded View ...

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FUEL SYSTEM 3-3 Exploded View Torque No. Fastener N·m kgf·m ft·lb Remarks 1 Carburetor Holder Bolts 5.2 0.53 46 in·lb 2 Throttle Cable Housing Cap Screws 0.6 0.06 5.3 in·lb 3. Throttle Cable 4. Choke Cable 5. Throttle Grip 6. Carburetor Cap 7. R...

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3-4 FUEL SYST EM Exploded View ...

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FUEL SYSTEM 3-5 Exploded View Torque No. Fastener N·m kgf·m ft·lb Remarks 1 Air Cleaner Cover Screws 1.5 0.15 13 in·lb 2 Air Cleaner Housing B olts 3.5 0.36 31 in·lb 3 Air Duct Clamp Screw 2.0 0.20 18 in·lb 4 Fuel Tap Mounting Bolts 4.4 0.45 39...

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3-6 FUEL SYST EM Specifications Item Standard Throttle Grip and Cable Throttle Grip Free Play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Carburetor Make/Type KEIHIN PB18 Idle Speed 1 600 ∼ 1 700 r/min (rpm) Main Jet #78 Main Air Jet #180 Jet Needle NCFA Thrott...

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FUEL SYSTEM 3-7 Special Tool Fuel Level Gauge: 57001-1017 ...

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3-8 FUEL SYST EM Throttle Grip and Cable If the throttle grip has excessive free play due to cable stretch or misadjustment, there w ill be a delay in throttle re- sponse. Also, the throttle valve may not open fully at full throttle. On the other han...

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FUEL SYSTEM 3-9 Throttle Grip and Cable • Lubricate the cable. • Apply grease to the tips of the cables. • Insert the throttle valve assembly. • Run the throttle cable in accordance with the Cable, Wire and Hose Routing s ection in the Append...

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3-10 FUEL SYSTEM Throttle Grip and Cable Choke Cable Installation • Installation is the reverse of removal. • Install the choke cable in accordance with the Cable, Wire and Hose Routing section in the Appendix chapter. • After the installation,...

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FUEL SYSTEM 3-11 Carburetor Since the carburetor regulates and mixes the fuel and air going to the engine, there are two general types of carbure- tor trouble: too rich a mixture (too much fuel), and too lean a m ixture (too little fuel). Such troubl...

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3-12 FUEL SYSTEM Carburetor • Check the fuel level in the gauge. Service Fuel Level (below the bottom edge of the carburetor body) Standard: 3.0 ± 1 mm (0.12 ± 0.04 in.) • Screw the carburetor drain plug. • Turn the fuel tap to the OFF positi...

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FUEL SYSTEM 3-13 Carburetor Float Bowl Mating Surface [A] Float Valve Needle Rod (contacted but unloaded) [B] Float [C] Float Height [D] NOTE ○ Measure the height with the carburetor upside down. ○ Do not push the needle rod in during the float h...

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3-14 FUEL SYSTEM Carburetor Carburetor Installation • Installation is the reverse of removal. • Fit the slit [A] and the projection [B], and insert the throttle valve assembly [C] into the carburetor body. • Replace the O-ring with a new one. �...

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FUEL SYSTEM 3-15 Carburetor • Remove the following parts from the carburetor body. Idle Adjusting Screw [A] O-ring [B] Spring [C] Pilot Screw [D] Washer [E] Spring [F] O-ring [G] O-ring [H] Pilot Jet [A] Needle Jet [B] Needle Jet Holder [C] Main Je...

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3-16 FUEL SYSTEM Carburetor • Immerse all the metal parts in carburetor cleaning solu- tion. • Rinse the parts in water. • After the parts are cleaned, dry them with compressed air. • Blow through the air and fuel passages with compressed air...

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FUEL SYSTEM 3-17 Carburetor • Remove the float valve needle. • Check the float valve needle [A]. If the needle is worn [B] as shown in the figure, replace the valve needle. • Push the rod [C] in the valve needle, and then release it [D]. If the...

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3-18 FUEL SYSTEM Carburetor Carburetor Assembly • Clean the disassembly parts before assembling. • Clean the fuel and air passages with high flash-point sol- vent and compressed air. • Install the needle jet [A] i nto the carburetor so that the...

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FUEL SYSTEM 3-19 Air Cleaner Air Clean er Housing Removal • Remove the shroud (see Shroud Removal in the Frame chapter). • Loosen the clamp screw [A] and pull out the air cleaner duct [B] from the carburetor. • Remove the air cleaner housing mo...

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3-20 FUEL SYSTEM Air Cleaner Air Cleaner Element Installation • Installation is the reverse of removal. • When installing the element, coat the lip of the element with a thick layer of all purpose grease [A] to assure a complete seal against the ...

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FUEL SYSTEM 3-21 Fuel Tank Fuel Tank Removal WARNING Gasoline is extremely flammable and can be ex- plosive under certain conditions. Always stop the engine and d o not smoke. Make sure the area is well-ventilated and free from any source of flame or...

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3-22 FUEL SYSTEM Fuel Tank Fuel Tap Removal • Remove the fuel tank (see Fuel Tank Removal). • Drain the fuel. • Remove the mounting bolts [A] and take off the fuel tap [B]. Fuel Tap Installation • Replace the O-ring [A] with a new one. • In...

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FUEL SYSTEM 3-23 Fuel Tank • Turn the fuel tap to the OFF position. • Place a s uitable container beneath the carburetor drain hose [A]. • Loosen the drain plug [B] from the bottom of the float bowl and check for water or dirt in the fuel. If a...

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ENGINE TOP END 4-1 4 Engine Top End Table of Contents Exploded View................................... 4-2 Specifications .................................... 4-6 Special Tools ..................................... 4-8 Camshaft Chain Tensioner .........

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4-2 ENGINE TOP END Exploded View ...

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ENGINE TOP END 4-3 Exploded View Torque No. Fastener N·m kgf·m ft·lb Remarks 1 Valve Adjusting Cap B olts 5.2 0.53 46 in·lb 2 Cylinder Head Bolts 12 1.2 106 in·lb S, L 3 Cylinder Head Nuts 22 2.2 16 S Rocker Shaft Holder Plate Bolts (KLX110CA/DA...

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4-4 ENGINE TOP END Exploded View ...

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ENGINE TOP END 4-5 Exploded View Torque No. Fastener N·m kgf·m ft·lb Remarks 1 Camshaft Chain Tensioner Cap Bolt 5.2 0.53 46 in·lb 2 Camshaft Chain Tensioner Mounting Bolts 5.2 0.53 46 in·lb L 3 Muffler Cover Screws 3.0 0.31 27 in·lb 4 Exhaust ...

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4-6 ENGINE TOP END Specifications Item Standard Service Limit Rocker Arm, Rocker Arm Shaft Rocker Arm Inside Diame ter 10.000 ∼ 10.015 mm (0.3937 ∼ 0.3943 in.) 10.05 mm (0.396 in.) Rocker Arm Shaft Diameter 9.980 ∼ 9.995 mm (0.3929 ∼ 0.3935 i...

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ENGINE TOP END 4-7 Specifications Item Standard Service Limit Cylinder, Piston Cylinder Inside Diameter 52.997 ∼ 53.009 mm (2.0865 ∼ 2.0870 in.) 53.10 mm (2.0905 in.) Piston Diameter 52.969 ∼ 52.981 mm (2.0854 ∼ 2.0859 in.) 52.82 mm (2.080 in...

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4-8 ENGINE TOP END Special Tools Compression Gauge, 20 kgf/cm²: 57001-221 Valve Spring Compressor Assembly: 57001-241 Piston Pin P uller Assembly: 57001-910 Valve Seat C utter, 45° - 27.5: 57001-1114 Valve Seat Cutter, 32° - 25: 57001-1118 Valve S...

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ENGINE TOP END 4-9 Special Tools Valve Seat Cutter, 67.5° - 22: 57001-1207 Comp ression Gauge Ad apter, M10 × 1.0: 57001-1317 Valve Seat Cutter Holder, 4.5: 57001-1330 Valve Guide Arbor, 4.5: 57001-1331 Valve Guide Reamer, 4.5: 57001-1333 Filler Ca...

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4-10 ENGINE TOP END Camshaft Chain Tensioner Camshaft Chain Tensioner Removal NOTICE This is a non-return type cam chain tensioner. The push rod does not return to its original position once it moves out to take up cam chain slack. Ob- serve all the ...

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ENGINE TOP END 4-11 Camshaft Chain Tensioner Camshaft Chain Tensioner I nstallation • Remove the tensioner cap bolt and O-ring. • While compressing the push rod [A], turn it clockwise [B] with a standard tip screwdriver until the rod protrusion c...

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4-12 ENGINE TOP END Camshaft Camshaft Removal • Remove the rocker arms (see Rocker Arm Removal). • Pull out the camshaft [A]. Camshaft Installation • Clean the camshaft with high flash-point solvent. • Apply clean engine oil to all cam parts....

[Page 97] Kawasaki KLX110 -

ENGINE TOP END 4-13 Camshaft KACR Installation • Install: Weight [A] • Insert the shaft [B] as shown. Retaining Plate Camshaft Sprocket Bolts Camshaft Sprocket Cover KACR Inspection The Kawasaki Automatic Compression Release (KACR) momentarily op...

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4-14 ENGINE TOP END Camshaft Camshaft Sprocket Removal • Remove: Camshaft Sprocket Cover Bolts [A] Camshaft Sprocket Cover [B] • Remove the timing inspection cap [A] and rotor nut cap [B]. Special Tool - Filler Cap Driver [C]: 57001-1454 • Turn...

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ENGINE TOP END 4-15 Camshaft • Use a suitable tool [A] or wire to keep the chain [B] from falling down into the cylinder block. NOTICE Always pull the camshaft chain taut while turning the crankshaft when the camshaft chain is loose. This avoids ki...

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4-16 ENGINE TOP END Camshaft • Apply grease to the new O-ring [A] and install the camshaft sprocket cover [B]. • Tighten: Torque - Camshaft Sprocket Cover Bolts [C]: 5.2 N·m (0.53 kgf·m, 46 in·lb) NOTICE Rotation of the crankshaft with imprope...