TABLE OF CONTENTS
GENERAL INFORMATION
Oil circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1
Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1
Checking the oil level . . . . . . . . . . . . . . . . . . . . . . .A1
Changing the engine oil . . . . . . . . . . . . . . . . . . . . .A2
Cleaning the oil screen . . . . . . . . . . . . . . . . . . . . . .A2
Changing the oil filter . . . . . . . . . . . . . . . . . . . . . . .A3
Checking the oil level in the hydraulic clutch . . . . .A4
Bleeding the clutch . . . . . . . . . . . . . . . . . . . . . . . . .A4
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A5
Preservation for winter operation . . . . . . . . . . . . . .A5
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A5
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A6
DISMOUNTING AND MOUNTING THE ENGINE
Dismounting the engine . . . . . . . . . . . . . . . . . . . . .B1
Mounting the engine . . . . . . . . . . . . . . . . . . . . . . .B5
Bleeding the cooling system . . . . . . . . . . . . . . . . . .B9
Adjusting the decompression cable . . . . . . . . . . . .B9
Adjusting the throttle cable . . . . . . . . . . . . . . . . . .B9
DISASSEMBLING THE ENGINE
Blocking the engine . . . . . . . . . . . . . . . . . . . . . . . .C1
Removing the rotor . . . . . . . . . . . . . . . . . . . . . . . . .C2
Removing the pressure relief valve . . . . . . . . . . . . .C2
Removing the clutch . . . . . . . . . . . . . . . . . . . . . . . .C3
Removing inner clutch hub . . . . . . . . . . . . . . . . . . .C4
Removing primary pinion and the idler shaft gear
. .C4
Removing the oil pump . . . . . . . . . . . . . . . . . . . . .C5
Removing the chain tensioner . . . . . . . . . . . . . . . .C6
Separating the timing chain . . . . . . . . . . . . . . . . . .C6
Removing the cylinder head . . . . . . . . . . . . . . . . . .C7
Separating the housing . . . . . . . . . . . . . . . . . . . . .C7
Removing the crankshaft . . . . . . . . . . . . . . . . . . . .C8
Removing the transmission . . . . . . . . . . . . . . . . . . .C8
Removing the idler shaft . . . . . . . . . . . . . . . . . . . . .C9
SERVICING THE INDIVIDUAL PARTS
Important . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D1
Left housing half . . . . . . . . . . . . . . . . . . . . . . . . . .D1
Right housing half . . . . . . . . . . . . . . . . . . . . . . . . . .D2
Pressure relief valve . . . . . . . . . . . . . . . . . . . . . . . .D3
Clutch cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D3
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D4
Press out the crank pin . . . . . . . . . . . . . . . . . . . . . .D5
Press in the crank pin . . . . . . . . . . . . . . . . . . . . . . .D6
Checking the crankshaft journal . . . . . . . . . . . . . . .D7
Outer dimension of the crankshaft webs . . . . . . . .D7
Balancing the axial clearance of the crankshaft . . .D8
Nikasil cylinder coating . . . . . . . . . . . . . . . . . . . . . .D9
Measuring the piston and cylinder liner,
determining the piston mounting clearance . . . . .D9
Checking the piston . . . . . . . . . . . . . . . . . . . . . . .D10
Checking the piston ring end gap . . . . . . . . . . . .D10
Checking the oil pump for wear . . . . . . . . . . . . . .D10
Cylinder head top section . . . . . . . . . . . . . . . . . .D11
Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . .D12
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D14
Timing chain tensioner . . . . . . . . . . . . . . . . . . . . .D15
Timing train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D15
Checking the clutch for wear . . . . . . . . . . . . . . . .D16
Checking the kickstarter for wear . . . . . . . . . . . . .D17
Shift mechanism . . . . . . . . . . . . . . . . . . . . . . . . . .D18
Assembling the main shaft (four-speed) . . . . . . . .D19
Assembling the main shaft (six-speed) . . . . . . . . .D20
Assembling the countershaft (four/six-speed) . . .D21
Starter drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D22
Checking the freewheel. . . . . . . . . . . . . . . . . . . . .D22
Checking the freewheel hub . . . . . . . . . . . . . . . . .D22
ASSEMBLING THE ENGINE
Mounting the idler shaft . . . . . . . . . . . . . . . . . . . . .E1
Mounting the crankshaft . . . . . . . . . . . . . . . . . . . .E2
Mounting the cylinder head . . . . . . . . . . . . . . . . . .E4
Mounting the timing chain . . . . . . . . . . . . . . . . . . .E5
Mounting the timing chain tensioner . . . . . . . . . . .E7
Adjusting the valve clearance . . . . . . . . . . . . . . . . .E7
Mounting the oil pump . . . . . . . . . . . . . . . . . . . . . .E8
Mounting the shift mechanism . . . . . . . . . . . . . . . .E8
Mounting the kickstarter shaft . . . . . . . . . . . . . . . . .E9
Mounting the clutch . . . . . . . . . . . . . . . . . . . . . . . .E9
Mounting the clutch cover . . . . . . . . . . . . . . . . . .E11
Mounting the pressure relief valve . . . . . . . . . . . .E13
Mounting rotor and pick up . . . . . . . . . . . . . . . . .E13
ELECTRIC SYSTEM
Checking for loss of current . . . . . . . . . . . . . . . . . .F1
Dismounting/mounting the battery . . . . . . . . . . . . .F1
Charging the battery . . . . . . . . . . . . . . . . . . . . . . . .F1
Filling the battery . . . . . . . . . . . . . . . . . . . . . . . . . .F2
Checking the starter . . . . . . . . . . . . . . . . . . . . . . . .F2
Checking the starter relay . . . . . . . . . . . . . . . . . . . .F3
Checking the main fuse . . . . . . . . . . . . . . . . . . . . . .F3
Checking the voltage regulator . . . . . . . . . . . . . . . .F4
Kokusan 4K3B dynamic generator values . . . . . . . .F4
Troubleshooting in the ignition system . . . . . . . . . .F5
CDI unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F6
Checking the ignition coil . . . . . . . . . . . . . . . . . . . .F6
Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . .F7
Checking the stator and pulse generator . . . . . . . .F7
Replacing the stator in FC models (Kokusan 4K-3A) . .
F7
Replacing the stator in FE and FS models (Kokusan 4K-3B
) . .F7
Static ignition values Kokusan 4K-3A/B . . . . . . . . .F8
Static generator values Kokusan 4K3B . . . . . . . . .F10
FUEL SYSTEM
KEIHIN FCR-MX 39/41 . . . . . . . . . . . . . . . . . . . . . .G1
Disassembling the carburetor . . . . . . . . . . . . . . . . .G2
Choke slide and hot start knob . . . . . . . . . . . . . . .G5
Accelerator pump . . . . . . . . . . . . . . . . . . . . . . . . . .G5
Jet needle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G5
Float needle valve . . . . . . . . . . . . . . . . . . . . . . . . .G5
Throttle slide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G6
Assembling the carburetor . . . . . . . . . . . . . . . . . . .G6
Adjusting the throttle sensor position . . . . . . . . .G10
Checking the throttle sensor . . . . . . . . . . . . . . . .G11
Dismounting and mounting the throttle sensor . .G11
Adjusting the idle . . . . . . . . . . . . . . . . . . . . . . . . .G12
Checking/adjusting the float height . . . . . . . . . . .G13
TROUBLESHOOTING
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . .H1
TECHNICAL SPECIFICATIONS
Engine 450, 501 . . . . . . . . . . . . . . . . . . . . . . . . . . . .I1
Carburetor 450, 501 . . . . . . . . . . . . . . . . . . . . . . . . .I1
Engine 550, 650 . . . . . . . . . . . . . . . . . . . . . . . . . . . .I2
Carburetor 550, 650 . . . . . . . . . . . . . . . . . . . . . . . . .I2
Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I3
Engine torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I4
Chassis torques . . . . . . . . . . . . . . . . . . . . . . . . . . . .I5
Mounting clearances, engine wear limits . . . . . . . ..I6
PERIODIC MAINTENANCE SCHEDULE
FC 450, 550/4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .J1
FE 450 - 650e/6, FS 450, 650e/6 . . . . . . . . . . . . . . .J2
Additional work - driver . . . . . . . . . . . . . . . . . . . . . .J3
Additional work - workshop . . . . . . . . . . . . . . . . . ..J4
WIRING DIAGRAMS
FC models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .K1
FE models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .K2
FE USA models . . . . . . . . . . . . . . . . . . . . . . . . . . . .K4
FS models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .K6
Cable colors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .K8
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