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Ninja ZX-10R
Motorcycle
Service Manual

Summary of Contents

  • Page 1

    Ninja ZX-10R Motorcycle Service Manual...

  • Page 2

    Quick Reference Guide General Information Periodic Maintenance Fuel System (DFI) Cooling System Engine Top End Clutch Engine Lubrication System Engine Removal/Installation Crankshaft/Transmission Wheels/Tires 10 j Final Drive 11 j Brakes 12 j Suspension 13 j Steering 14 j Frame 15 j Electrical System 16 j Appendix...

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    All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Quality Division/Consumer Products & Machinery Company/Kawasaki Heavy Industries, Ltd., Japan.

  • Page 5

    LIST OF ABBREVIATIONS ampere(s) pound(s) ABDC after bottom dead center meter(s) alternating current minute(s) ATDC after top dead center newton(s) BBDC before bottom dead center pascal(s) bottom dead center horsepower BTDC before top dead center pound(s) per square inch °C degree(s) Celsius revolution direct current...

  • Page 6

    EMISSION CONTROL INFORMATION To protect the environment in which we all live, Kawasaki has incorporated crankcase emis- sion (1) and exhaust emission (2) control systems in compliance with applicable regulations of the United States Environmental Protection Agency and California Air Resources Board. Addi-...

  • Page 7

    TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Federal law prohibits the following acts or the causing thereof. (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.

  • Page 8

    Be alert for problems and non-scheduled ticular interest for more efficient and con- maintenance. • venient operation. Use proper tools and genuine Kawasaki Mo- • torcycle parts. Special tools, gauges, and Indicates a procedural step or work to be testers that are necessary when servicing done.

  • Page 10: Table Of Contents

    GENERAL INFORMATION 1-1 General Information Table of Contents Before Servicing ........................Model Identification......................... General Specifications......................Unit Conversion Table ......................1-12...

  • Page 11: Before Servicing

    1-2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly opera- tion on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustra- tions, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary.

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    Replacement Parts Replacement Parts must be KAWASAKI genuine or recommended by KAWASAKI. Gaskets, O-rings, oil seals, grease seals, circlips or cotter pins must be replaced with new ones whenever disassembled.

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    1-4 GENERAL 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 to prevent case warpage or deformation which can lead to malfunction.

  • Page 14

    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. Ball Bearing and Needle Bearing Do not remove pressed ball or needle unless removal is absolutely necessary.

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    1-6 GENERAL 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 or grease as specified. Direction of Engine Rotation When rotating the crankshaft by hand, the free play amount of rotating direction will affect the adjustment.

  • Page 16: Model Identification

    GENERAL INFORMATION 1-7 Model Identification ZX1000D6F (Europe) Left Side View ZX1000D6F (Europe) Right Side View...

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    1-8 GENERAL INFORMATION Model Identification ZX1000D6F (United States and Canada) Left Side View ZX1000D6F (United States and Canada) Right Side View Frame Number Engine Number...

  • Page 18: General Specifications

    GENERAL INFORMATION 1-9 General Specifications Items ZX1000D6F (Ninja ZX-10R) Dimensions Overall Length 2 065 mm (81.3 in.) Overall Width (CA), (CAL), (US) 730 mm (28.7 in.) 705 mm (27.8 in.) Overall Height 1 130 mm (44.5 in.) Wheelbase 1 390 mm (54.7 in.) Road Clearance 120 mm (4.7 in.)

  • Page 19

    1-10 GENERAL INFORMATION General Specifications Items ZX1000D6F (Ninja ZX-10R) Duration 292° Lubrication System Forced lubrication (wet sump with cooler) Engine Oil: Type API SE, SF or SG API SH, SJ or SL with JASO MA Viscosity SAE10W-40 Capacity 4.0 L (4.2 US qt)

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    GENERAL INFORMATION 1-11 General Specifications Items ZX1000D6F (Ninja ZX-10R) Brake Type: Front Dual discs Rear Single disc Electrical Equipment Battery 12 V 10 Ah Headlight: Type Semi-sealed beam Bulb: High 12 V 55 W + 65 W (quartz-halogen) 12 V 55 W (quartz-halogen) Tail/Brake Light 12 V 0.5/4.1 W (LED)

  • Page 21: Unit Conversion Table

    1-12 GENERAL INFORMATION Unit Conversion Table Prefixes for Units Units of Length × 0.6214 mile Prefix Symbol Power × 3.281 mega × 1 000 000 × 0.03937 kilo × 1 000 centi × 0.01 Units of Torque milli × 0.001 N·m ×...

  • Page 22

    PERIODIC MAINTENANCE 2-1 Periodic Maintenance Table of Contents Periodic Maintenance Chart ....................Torque and Locking Agent...................... Specifications ......................... 2-13 Special Tools .......................... 2-15 Maintenance Procedure ......................2-16 Fuel System (DFI)........................ 2-16 Throttle Control System Inspection................... 2-16 Engine Vacuum Synchronization Inspection..............2-16 Idle Speed Inspection .......................

  • Page 23

    2-2 PERIODIC MAINTENANCE Steering Play Adjustment....................2-37 Steering Stem Bearing Lubrication ................... 2-38 Steering Damper Oil Leak Inspection ................2-38 Electrical System ......................... 2-39 Lights and Switches Operation Inspection................ 2-39 Headlight Aiming Inspection ..................... 2-41 Sidestand Switch Operation Inspection ................2-42 Engine Stop Switch Operation Inspection.................

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    PERIODIC MAINTENANCE 2-3 Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition.The initial maintenance is vitally important and must not be neglected. Periodic Inspection FREQUENCY Whichever * ODOMETER READING comes ×...

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    2-4 PERIODIC MAINTENANCE Periodic Maintenance Chart FREQUENCY Whichever * ODOMETER READING comes × 1 000 km first (× 1 000 mile) Page (0.6) (7.5) (12) (15) (20) (24) INSPECTION Every Brake System Brake fluid leak (brake hose and • • • • • • • year 2-33 pipe)-inspect...

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    PERIODIC MAINTENANCE 2-5 Periodic Maintenance Chart Periodic Replacement Parts FREQUENCY Whichever * ODOMETER READING come × 1 000 km first (× 1 000 mile) Page (0.6) (7.5) (15) (24) (30) CHANGE/REPLACE ITEM Every Air cleaner element # Every 18 000 km (12 000 mile) 2-47 •...

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    2-6 PERIODIC MAINTENANCE Torque and Locking Agent The following tables list the tightening torque for the major fasteners requiring use of a non-permanent locking agent or silicone sealant etc. Letters used in the “Remarks” column mean: AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque. G: Apply grease.

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    PERIODIC MAINTENANCE 2-7 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Radiator Lower Bolt 0.71 62 in·lb Radiator Upper Bolt 0.71 62 in·lb Water Hose Clamp Screws 0.20 18 in·lb Water Hose Fitting Bolts 89 in·lb Water Passage Plugs 19.6 Water Pump Cover Bolts 89 in·lb...

  • Page 29

    2-8 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Clutch Clutch Cover Mounting Bolts 89 in·lb Clutch Hub Nut 13.3 Clutch Lever Clamp Bolts 0.80 69 in·lb Clutch Spring Bolts 87 in·lb Oil Filler Plug – –...

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    PERIODIC MAINTENANCE 2-9 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Crankcase Bolts (M6, L = 40 mm) 106 in·lb Drive Shaft Cover Bolts Gear Position Lever Bolt 106 in·lb Oil Passage Plugs Piston Oil Jet 0.31 27 in·lb Plate Screw 0.51 Plug...

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    2-10 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Front Fork Bottom Allen Bolts Front Fork Clamp Bolts (Lower) Front Fork Clamp Bolts (Upper) Front Fork Top Plugs Piston Rod Nuts Rear Shock Absorber Bracket Nut Rear Shock Absorber Nut (Lower) Rear Shock Absorber Nut (Upper) Swingarm Pivot Adjusting Shaft...

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    PERIODIC MAINTENANCE 2-11 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Gear Position Switch Screws 0.31 27 in·lb Headlight Mounting Screws 0.12 11 in·lb Idle Gear Cover Bolts 89 in·lb Left Handlebar Switch Housing Screws (M5, L = 25) 0.36 31 in·lb License Plate Light Cover Screws...

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    2-12 PERIODIC MAINTENANCE Torque and Locking Agent The table below, relating tightening torque to thread diameter, lists the basic torque for the bolts and nuts. Use this table for only the bolts and nuts which do not require a specific torque value. All of the values are for use with dry solvent-cleaned threads.

  • Page 34

    PERIODIC MAINTENANCE 2-13 Specifications Item Standard Service Limit Fuel System (DFI) – – – Throttle Grip Free Play 3 mm (0.08 0.12 in.) Idle Speed 1 100 ±50 r/min (rpm) – – – Throttle Body Vacuum 31.5 ±1.3 kPa (236 ±10 mmHg) at idle speed –...

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    2-14 PERIODIC MAINTENANCE Specifications Item Standard Service Limit Final Drive Drive Chain Slack 35 mm (1.2 1.4 in.) – – – Drive Chain Wear (20-link 317.5 318.2 mm (12.50 12.53 in.) 323 mm (12.7 in.) Length) Standard Chain: Make RK EXCEL –...

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    PERIODIC MAINTENANCE 2-15 Special Tools Inside Circlip Pliers: Vacuum Gauge: 57001-143 57001-1369 Steering Stem Nut Wrench: Extension Tube: 57001-1100 57001-1578 Jack: Pilot Screw Adjuster, D: 57001-1238 57001-1588 Oil Filter Wrench: Jack Attachment: 57001-1249 57001-1608...

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    2-16 PERIODIC MAINTENANCE Maintenance Procedure Fuel System (DFI) Throttle Control System Inspection • Check the throttle grip free play [A]. If the free play is incorrect, adjust the throttle cables. Throttle Grip Free Play Standard: 3 mm (0.08 0.12 in.) •...

  • Page 38

    PERIODIC MAINTENANCE 2-17 Maintenance Procedure • Connect a vacuum gauge (special tool) and hoses [A] to the fittings on the throttle body. Special Tool - Vacuum Gauge: 57001-1369 • Connect a highly accurate tachometer to one of the stick coil primary leads. •...

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    2-18 PERIODIC MAINTENANCE Maintenance Procedure If a value of measured vacuum pressure is out of the specified range after synchronization, adjust the bypass screws [A]. Special Tool - Pilot Screw Adjuster, D: 57001-1588 • Adjust lower vacuum between #1 and #2 to higher vac- uum of #1 and #2.

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    PERIODIC MAINTENANCE 2-19 Maintenance Procedure • Back out the same number of turns counted when first turned in. This is to set the screw to its original position. NOTE ○ A throttle body has different “turns out” of the bypass screw for each individual unit.

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    2-20 PERIODIC MAINTENANCE Maintenance Procedure Idle Speed Adjustment • Start the engine and warm it up thoroughly. • Turn the adjusting screw [A] until the idle speed is correct. ○ Open and close the throttle a few times to make sure that the idle speed is within the specified range.

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    PERIODIC MAINTENANCE 2-21 Maintenance Procedure Evaporative Emission Control System (California Model) Evaporative Emission Control System Inspection • Inspect the canister as follows. ○ Remove the right upper inner fairing (see Upper Inner Fairing Removal in the Frame chapter). ○ Remove the canister [A], and disconnect the hoses from the canister.

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    2-22 PERIODIC MAINTENANCE Maintenance Procedure Cooling System Coolant Level Inspection NOTE ○ Check the level when the engine is cold (room or ambi- ent temperature). • Check the coolant level in the reserve tank [A] with the motorcycle held perpendicular (Do not use the sidestand). If the coolant level is lower than the “L”...

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    PERIODIC MAINTENANCE 2-23 Maintenance Procedure • Remove the cylinder head cover (see Cylinder Head Cover Removal in the Engine Top End chapter). • Remove the timing inspection cap [A] and starter clutch bolt cap [B] on the starter clutch cover [C]. •...

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    2-24 PERIODIC MAINTENANCE Maintenance Procedure ○ When positioning #1 piston TDC at the end of the compression stroke: Inlet Valve Clearance of #1 and #3 Cylinders Exhaust Valve Clearance of #1 and #2 Cylinders Measuring Valve [A] ○ When positioning #4 piston TDC at the end of the compression stroke: Inlet Valve Clearance of #2 and #4 Cylinders Exhaust Valve Clearance of #3 and #4 Cylinders...

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    PERIODIC MAINTENANCE 2-25 Maintenance Procedure Adjustment Shims Thickness Part Number Mark 1.300 92180-0108 1.325 92180-0109 1.350 92180-0110 1.375 92180-0111 1.400 92180-0112 1.425 92180-0113 1.450 92180-0114 1.475 92180-0115 1.500 92180-0116 1.525 92180-0117 1.550 92180-0118 1.575 92180-0119 1.600 92180-0120 1.625 92180-0121 1.650 92180-0122 1.675 92180-0123...

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    2-26 PERIODIC MAINTENANCE Maintenance Procedure CAUTION Be sure to remeasure the clearance after selecting a shim. The clearance can be out of the specified range because of the shim tolerance. ○ If there is no valve clearance, use a shim that is a few sizes smaller, and remeasure the valve clearance.

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    PERIODIC MAINTENANCE 2-27 Maintenance Procedure • Start the engine and run it at idle speed. • Plug [A] the air switching valve hose [B] end with your finger and feel vacuum pulsing in the hose. If there is no vacuum pulsation, check the hose line for leak.

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    2-28 PERIODIC MAINTENANCE Maintenance Procedure • Push the release lever [A] toward the front of the motor- cycle until it becomes hard to turn. ○ At this time, the release lever should have the proper an- gle shown. 60° [B] If the angle is wrong, check the clutch and release parts for wear.

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    PERIODIC MAINTENANCE 2-29 Maintenance Procedure Tread Depth Standard: Front 6.0 mm (0.24 in.) Rear 6.5 mm (0.26 in.) Service Limit: Front 1 mm (0.04 in.) (AT, CH, DE) 1.6 mm (0.06 in.) Rear 2 mm (0.08 in.) (Up to 130 km/h) 3 mm (0.12 in.) (Over 130 km/h) WARNING To ensure safe handling and stability, use only the...

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    2-30 PERIODIC MAINTENANCE Maintenance Procedure Drive Train Drive Chain Lubrication Condition Inspection • If a special lubricant is not available, a heavy oil such as SAE 90 is preferred to a lighter oil because it will stay on the chain longer and provide better lubrication. •...

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    PERIODIC MAINTENANCE 2-31 Maintenance Procedure Drive Chain Slack Adjustment • Remove the cotter pin [A], and loosen the rear axle nut [B]. • Loosen the both chain adjuster locknuts [C]. If the chain is too loose, turn out the left and right chain adjuster [D] evenly.

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    2-32 PERIODIC MAINTENANCE Maintenance Procedure Wheel Alignment Inspection • Check that the notch [A] on the left alignment indicator [B] aligns with the same swingarm mark or position [C] that the right alignment indicator notch aligns with. If they do not, adjust the chain slack and align the wheel alignment (see Drive Chain Slack Adjustment).

  • Page 54

    PERIODIC MAINTENANCE 2-33 Maintenance Procedure Chain Guide Wear Inspection • Remove: Swingarm (see Swingarm Removal in the Suspension chapter) • Visually inspect the chain guide [A]. Replace the chain guide if it shows any signs of abnormal wear or damage. Brake System Brake Fluid Leak (Brake Hose and Pipe) Inspection •...

  • Page 55

    2-34 PERIODIC MAINTENANCE Maintenance Procedure Brake Fluid Level Inspection • Check that the brake fluid level in the front brake reservoir [A] is above the lower level line [B]. NOTE ○ Hold the reservoir horizontal by turning the handlebar when checking brake fluid level. If the fluid level is lower than the lower level line, fill the reservoir to the upper level line [C].

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    PERIODIC MAINTENANCE 2-35 Maintenance Procedure If it does not, adjust the brake light switch. • While holding the switch body, turn the adjusting nut to adjust the switch. Switch Body [A] Adjusting Nut [B] Light sooner as the body rises [C] Light later as the body lowers [D] CAUTION To avoid damaging the electrical connections in-...

  • Page 57

    2-36 PERIODIC MAINTENANCE Maintenance Procedure Front Fork Oil Leak Inspection • Visually inspect the front forks [A] for oil leakage. Replace or repair any defective parts, if necessary. Rear Shock Absorber Oil Leak Inspection • Visually inspect the shock absorber [A] for oil leakage. If the oil leakage is found on it, replace the shock absorber with a new one.

  • Page 58

    PERIODIC MAINTENANCE 2-37 Maintenance Procedure Steering System Steering Play Inspection • Remove the lower fairings (see Lower Fairing Removal in the Frame chapter). • Lift the front wheel off the ground using the jack. Special Tools - Jack: 57001-1238 Jack Attachment: 57001-1608 •...

  • Page 59

    2-38 PERIODIC MAINTENANCE Maintenance Procedure • Install the claw washer [A] so that its bent side [B] faces upward, and engage the bent claws with the grooves of stem locknut [C]. • Hand tighten the stem locknut until it touches the claw washer.

  • Page 60

    PERIODIC MAINTENANCE 2-39 Maintenance Procedure Electrical System Lights and Switches Operation Inspection First Step • Turn on the ignition switch. • The following lights should go on according to below table. goes on City Light [A] Taillight [B] goes on goes on License Plate Light [C] Meter Panel Illumination Light (LED) [D]...

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    2-40 PERIODIC MAINTENANCE Maintenance Procedure Third Step • Turn on the turn signal switch [A] (left or right position). • The left or right turn signal lights [B] (front and rear) ac- cording to the switch position should flash. • The turn signal indicator light (LED) [C] in the meter unit should flash.

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    PERIODIC MAINTENANCE 2-41 Maintenance Procedure • Set the dimmer switch to high beam position. • The low beam [A] and high beam [B] headlights should go on. • The high beam indicator light (LED) [C] should go on. If the high beam headlight and/or high beam indicator light (LED) does not go on, inspect or replace the following item.

  • Page 63

    2-42 PERIODIC MAINTENANCE Maintenance Procedure NOTE ○ ON high beam, the brightest points should be slightly below horizontal with the motorcycle on its wheels and the rider seated. Adjust the headlight to the proper an- gle according to local regulations. ○...

  • Page 64

    PERIODIC MAINTENANCE 2-43 Maintenance Procedure If the sidestand switch operation does not work, inspect or replace the following item. Battery (see Charging Condition Inspection in the Elec- trical System chapter) Main Fuse 30 A (see Fuse Inspection in the Electrical System chapter) Ignition Fuse 10 A (see Fuse Inspection in the Electrical System chapter)

  • Page 65

    2-44 PERIODIC MAINTENANCE Maintenance Procedure Others Chassis Parts Lubrication • Before lubricating each part, clean off any rusty spots with rust remover and wipe off any grease, oil, dirt, or grime. • Lubricate the points listed below with indicated lubricant. NOTE ○...

  • Page 66

    PERIODIC MAINTENANCE 2-45 Maintenance Procedure • With the cable disconnected at both ends, the inner 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 the cable housing is kinked [C], replace the cable.

  • Page 67

    2-46 PERIODIC MAINTENANCE Maintenance Procedure Bolt, Nut and Fastener to be checked Engine: Clutch Lever Pivot Nut Engine Mounting Bolts Exhaust Pipe Clamp Bolts Exhaust Pipe Manifold Holder Nuts Muffler Body Mounting Bolts Wheels: Front Axle Clamp Bolts Front Axle Nut Rear Axle Nut Rear Axle Nut Cotter Pin Brakes:...

  • Page 68

    PERIODIC MAINTENANCE 2-47 Maintenance Procedure Replacement Parts Air Cleaner Element Replacement NOTE ○ In dusty areas, the element should be replaced more frequently than the recommended interval. ○ After riding through rain or on muddy roads, the element should be replaced immediately. WARNING If dirt or dust is allowed to pass through into the throttle assembly, the throttle may become stuck,...

  • Page 69

    Install a new element [A] so that the element ends [B] insert along the rib [C] in the housing. CAUTION Use only the recommended air cleaner element (Kawasaki part number 11013-0004). Using another air cleaner element will wear the engine prema- turely or lower the engine performance. •...

  • Page 70

    PERIODIC MAINTENANCE 2-49 Maintenance Procedure • Push and pull [A] the fuel hose joint [B] back and forth more than two times and make sure it is locked and doesn’t come off. WARNING Make sure the fuel hose joint is installed correctly on the delivery pipe or the fuel could leak.

  • Page 71

    2-50 PERIODIC MAINTENANCE Maintenance Procedure • Remove: Bolts [A] Coolant Reserve Tank [B] • Remove the cap [C] and pour the coolant into a container. • Install the coolant reserve tank. Torque - Coolant Reserve Tank Mounting Bolts: 7.0 N·m (0.71 kgf·m, 62 in·lb) •...

  • Page 72

    PERIODIC MAINTENANCE 2-51 Maintenance Procedure • Bleed the air from the cooling system as follows. ○ Start the engine with the radiator cap removed and run it until no more air bubbles [A] can be seen in the coolant. ○ Tap the radiator hoses to force any air bubbles caught inside.

  • Page 73

    2-52 PERIODIC MAINTENANCE Maintenance Procedure Radiator Hose and O-ring Replacement • Drain the coolant (see Coolant Change). • Remove: Lower Fairings (see Lower Fairing Removal in the Frame chapter) Middle Fairings (see Middle Fairing Removal in the Frame chapter) Throttle Body Assembly (see Throttle Body Assembly Removal in the Fuel System (DFI) chapter) Thermostat Housing [A] (see Thermostat Housing Re- moval in the Cooling System chapter)

  • Page 74

    PERIODIC MAINTENANCE 2-53 Maintenance Procedure Engine Oil Change • Situate the motorcycle so that it is vertical after warming up the engine. • Remove the engine oil drain bolt [A] to drain the oil. ○ The oil in the oil filter can be drained by removing the filter (see Oil Filter Replacement).

  • Page 75

    2-54 PERIODIC MAINTENANCE Maintenance Procedure • Replace the filter with a new one. • Apply engine oil to the gasket [A] before installation. • Tighten the filter with the oil filter wrench. Torque - Oil Filter: 31 N·m (3.2 kgf·m, 23 ft·lb) NOTE ○...

  • Page 76

    PERIODIC MAINTENANCE 2-55 Maintenance Procedure • Level the brake fluid reservoir. • Remove the reservoir cap. • Remove the rubber cap from the bleed valve [A] on the caliper. • Attach a clear plastic hose [B] to the bleed valve, and run the other end of the hose into a container.

  • Page 77

    2-56 PERIODIC MAINTENANCE Maintenance Procedure Master Cylinder Rubber Parts Replacement Front Master Cylinder Disassembly • Remove the front master cylinder (see Front Master Cylin- der Removal in the Brakes chapter). • Remove the seal cover [A], circlip [B], connector [C] and O-ring [D].

  • Page 78

    PERIODIC MAINTENANCE 2-57 Maintenance Procedure • Apply brake fluid to the new parts and to the inner wall of the cylinder. • Take care not to scratch the piston or the inner wall of the cylinder. • Tighten the brake lever pivot bolt and the nut. Silicone Grease - Brake Lever Pivot Bolt Torque - Brake Lever Pivot Bolt: 1.0 N·m (0.10 kgf·m, 9 in·lb)

  • Page 79

    2-58 PERIODIC MAINTENANCE Maintenance Procedure NOTE ○ If compressed air is not available, do as follows for both calipers coincidentally, with the brake hose connected to the caliper. ○ Prepare a container for brake fluid, and perform the work above it. ○...

  • Page 80

    PERIODIC MAINTENANCE 2-59 Maintenance Procedure Rear Caliper Disassembly • Remove the rear caliper (see Rear Caliper Removal in the Brakes chapter). • Remove the pads and pad spring (see Rear Brake Pad Removal in the Brakes chapter). • Using compressed air, remove the piston. ○...

  • Page 81

    2-60 PERIODIC MAINTENANCE Maintenance Procedure • Apply brake fluid to the outside of the piston, and push it into the cylinder by hand. • Replace the shaft rubber friction boot [A] and dust boot [B]. • Apply a thin coat of PBC (Poly Butyl Cuprysil) grease to the caliper holder shafts [C] and holder holes [D] (PBC is a special high temperature, water-resistance grease).

  • Page 82

    FUEL SYSTEM (DFI) 3-1 Fuel System (DFI) Table of Contents Exploded View........................DFI System..........................3-10 Specifications ......................... 3-12 Special Tools and Sealant ...................... 3-14 DFI Parts Location........................3-16 DFI System..........................3-18 DFI Servicing Precautions ...................... 3-22 DFI Servicing Precautions ....................3-22 Troubleshooting the DFI System ....................

  • Page 83

    3-2 FUEL SYSTEM (DFI) Output Voltage Inspection....................3-73 Gear Position Switch (Service Code 25) ................3-75 Gear Position Switch Removal/Installation ............... 3-75 Gear Position Switch Inspection ..................3-75 Input Voltage Inspection....................3-75 Vehicle-down Sensor (Service Code 31)................3-77 Removal..........................3-77 Installation.........................

  • Page 84

    FUEL SYSTEM (DFI) 3-3 Warning Indicator Light (LED) ....................3-111 Light (LED) Inspection ...................... 3-111 Fuel Line..........................3-112 Fuel Pressure Inspection ....................3-112 Fuel Flow Rate Inspection ....................3-113 Fuel Pump ..........................3-115 Fuel Pump Removal ......................3-115 Fuel Pump Installation ...................... 3-115 Operation Inspection......................

  • Page 85

    3-4 FUEL SYSTEM (DFI) Exploded View...

  • Page 86

    Air Cleaner Housing Mounting Bolts 0.71 62 in·lb 5. Air Cleaner Element 6. Air Inlet Duct 7. Air Switching Valve L: Apply a non-permanent locking agent. LG: Apply liquid gasket (Kawasaki Bond: 92104-0002). WL: Apply a soap and water solution.

  • Page 87

    3-6 FUEL SYSTEM (DFI) Exploded View...

  • Page 88

    20. Relay Box 21. ECU 22. Stick Coils CL: Apply cable lubricant. EO: Apply engine oil. G: Apply grease. L: Apply a non-permanent locking agent. R: Replacement Parts S: Follow the specified tightening sequence. SS: Apply silicone sealant (Kawasaki Bond: 92104-0004).

  • Page 89

    3-8 FUEL SYSTEM (DFI) Exploded View...

  • Page 90

    FUEL SYSTEM (DFI) 3-9 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Exhaust Butterfly Valve Actuator Mounting Bolts 0.08 7 in·lb Exhaust Butterfly Valve Actuator Pulley Bolt 0.50 44 in·lb Fuel Pump Bolts 89 in·lb L, S Canister Bracket Mounting Bolt (M5) 0.44 38 in·lb Canister Bracket Mounting Screws (M5)

  • Page 91

    3-10 FUEL SYSTEM (DFI) DFI System DFI System...

  • Page 92

    FUEL SYSTEM (DFI) 3-11 DFI System 1. ECU 2. Crankshaft Sensor 3. Camshaft Position Sensor 4. Main Throttle Sensor 5. Subthrottle Sensor 6. Subthrottle Valve Actuator 7. Inlet Air Pressure Sensor 8. Atmospheric Pressure Sensor 9. Water Temperature Sensor 10. Inlet Air Temperature Sensor 11.

  • Page 93

    3-12 FUEL SYSTEM (DFI) Specifications Item Standard Digital Fuel Injection System Idle Speed 1 100 ±50 r/min (rpm) Throttle Assy: Type Four barrel type Bore 43 mm (1.7 in.) Throttle Body Vacuum 31.5 ±1.3 kPa (236 ±10 mmHg) Bypass Screws –...

  • Page 94

    FUEL SYSTEM (DFI) 3-13 Specifications Item Standard Vehicle-down sensor: Detection Method Magnetic flux detection method Detection Angle More than 60 70° for each bank Output Voltage with sensor arrow mark pointed up: 3.55 4.45 V with sensor tilted 60 70° or more: 0.65 1.35 V Subthrottle Sensor: Non-adjustable and non-removal...

  • Page 95

    3-14 FUEL SYSTEM (DFI) Special Tools and Sealant Oil Pressure Gauge, 5 kgf/cm²: Peak Voltage Adapter: 57001-125 57001-1415 Fork Oil Level Gauge: Needle Adapter Set: 57001-1290 57001-1457 Vacuum Gauge: Throttle Sensor Setting Adapter: 57001-1369 57001-1538 Hand Tester: Sensor Harness Adapter: 57001-1394 57001-1561 Throttle Sensor Setting Adapter #1:...

  • Page 96

    FUEL SYSTEM (DFI) 3-15 Special Tools and Sealant Fuel Pressure Gauge Adapter: Kawasaki Bond (Silicone Sealant): 57001-1593 56019-120 Fuel Hose: Kawasaki Bond (Liquid Gasket - Black): 57001-1607 92104-0002 Speed Sensor Measuring Adapter: Kawasaki Bond (Silicone Sealant): 57001-1667 92104-0004...

  • Page 97

    Stick Coils #1, #2, #3, #4 [E] Water Temperature Sensor [A] Fuel Injectors #1, #2, #3, #4 [B] Battery [A] Relay Box (Fuel Pump Relay) [B] Immobilizer/Kawasaki Diagnostic System Connector [C] ECU [D] Exhaust Butterfly Valve Actuator [A] Atmospheric Pressure Sensor [B] Vehicle-down Sensor [C]...

  • Page 98

    FUEL SYSTEM (DFI) 3-17 DFI Parts Location Camshaft Position Sensor [A] Crankshaft Sensor [B] Speed Sensor [A] Gear Position Switch [B] Ignition Key [A] (Transponder, Immobilizer Models) Ignition Switch [B] Immobilizer Antenna [C] (Immobilizer Models) Immobilizer Amplifier [D] (Immobilizer Models) Oxygen Sensor #1 [A] (Europe Models) Oxygen Sensor #2 [B] (Europe Models)

  • Page 99

    3-18 FUEL SYSTEM (DFI) DFI System DFI System Wiring Diagram...

  • Page 100

    FUEL SYSTEM (DFI) 3-19 DFI System Part Name 1. Ignition Switch 2. Engine Stop Switch 3. Starter Button 4. Stick Coil #1,#2,#3,#4 5. Camshaft Position Sensor 6. Injector #1 7. Injector #2 8. Injector #3 9. Injector #4 10. Crankshaft Sensor 11.

  • Page 101

    3-20 FUEL SYSTEM (DFI) DFI System Terminal Numbers of ECU Connectors Terminal Names 1. Unused 2. Subthrottle Valve Actuator 3. Subthrottle Valve Actuator 4. Gear Position Switch 5. Crankshaft Sensor (–) 6. Speed Sensor 7. Power Supply to Sensors 8. Inlet Air Temperature Sensor 9.

  • Page 102

    55. Ground 56. Oxygen Sensor Heater 57. Injector #4 58. Stick Coil #4 59. Injector #2 60. Stick Coil #2 KDS (Kawasaki Diagnostic System) KDS that runs on Windows personal computer (PC) diagnostic tool for motorcycle with Kawasaki DFI system.

  • Page 103

    3-22 FUEL SYSTEM (DFI) DFI Servicing Precautions DFI Servicing Precautions There are a number of important precautions that should be followed servicing the DFI system. ○ This DFI system is designed to be used with a 12 V sealed battery as its power source. Do not use any other battery except for a 12 V sealed battery as a power source.

  • Page 104

    FUEL SYSTEM (DFI) 3-23 DFI Servicing Precautions ○ Before removing the fuel system parts, blow the outer sur- faces of these parts clean with compressed air. ○ When any fuel hose is disconnected, fuel may spout out by residual pressure in the fuel line. Cover the hose joint with a piece of clean cloth to prevent fuel spillage.

  • Page 105

    3-24 FUEL SYSTEM (DFI) Troubleshooting the DFI System The warning indicator light (LED) [A] is used for the FI indicator, immobilizer indicator (immobilizer models) and oil pressure warning indicator. Outline When a problem occurs with DFI system, the warning indicator light (LED) [A] and FI warning symbol [B] blinks to alert the rider.

  • Page 106

    When the repair has been done, the FI warning symbol goes off. But the service codes stored in memory of the ECU are not erased to preserve the problem history. The problem history can be referred using the KDS (Kawasaki Diagnostic System) when solving unstable problems...

  • Page 107

    ○ After measurement, remove the needle adapters and ap- ply silicone sealant to the seals [A] of the connector [B] for waterproofing. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 -Seals of Connector...

  • Page 108

    FUEL SYSTEM (DFI) 3-27 Troubleshooting the DFI System • Always check battery condition before replacing the DFI parts. A fully charged battery is a must for conducting accurate tests of the DFI system. • Trouble may involve one or in some cases all items. Never replace a defective part without determining what CAUSED the problem.

  • Page 109

    3-28 FUEL SYSTEM (DFI) Troubleshooting the DFI System ○ If both ends of a harness [A] are far apart, ground [B] the one end [C], using a jumper lead [D] and check the con- tinuity between the end [E] and the ground [F]. This en- ables to check a long harness for continuity.

  • Page 110

    FUEL SYSTEM (DFI) 3-29 Troubleshooting the DFI System ○ Electrical Connectors: Female Connectors [A] Male Connectors [B]...

  • Page 111

    3-30 FUEL SYSTEM (DFI) Troubleshooting the DFI System DFI Diagnosis Flow Chart Inquiries to Rider ○ Each rider reacts to problems in different ways, so it is important to confirm what kind of symptoms the rider has encountered. ○ Try to find out exactly what problem occurred under exactly what conditions by asking the rider; knowing this information may help you reproduce the problem.

  • Page 112

    FUEL SYSTEM (DFI) 3-31 Troubleshooting the DFI System Sample Diagnosis Sheet Rider name: Registration No. (license plate No.): Year of initial registration: Model: Engine No.: Frame No.: Date problem occurred: Mileage: Environment when problem occurred. □ □ □ □ □ □...

  • Page 113

    3-32 FUEL SYSTEM (DFI) Troubleshooting the DFI System □ □ □ Poor running at low very low idle speed, very high idle speed, rough idle speed. □ speed battery voltage is low (charge the battery). □ spark plug loose (tighten it). □...

  • Page 114

    FUEL SYSTEM (DFI) 3-33 DFI System Troubleshooting Guide NOTE ○ This is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties. ○...

  • Page 115

    3-34 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or possible Causes Actions (chapter) Clutch lever not pulled in and gear not in neutral Pull the lever in and shift the gear in neutral. whether sidestand up or not Though clutch lever pulled in, sidestand up and Sidestand down and clutch lever pulled in gear not in neutral whether gear in neutral or not...

  • Page 116

    FUEL SYSTEM (DFI) 3-35 DFI System Troubleshooting Guide Symptoms or possible Causes Actions (chapter) Cylinder head warped Inspect and replace (see chapter 5). No valve clearance Adjust (see chapter 2). Valve guide worn Inspect and replace (see chapter 5). Valve spring broken or weak Inspect and replace (see chapter 5).

  • Page 117

    3-36 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Incorrect idle speed: Water temperature sensor trouble Inspect (see chapter 3). Main throttle sensor trouble Inspect (see chapter 3). Engine stalls easily: Fuel pump trouble Inspect (see chapter 3). Fuel injector trouble Inspect (see chapter 3).

  • Page 118

    FUEL SYSTEM (DFI) 3-37 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Inlet air pressure sensor trouble Inspect (see chapter 3). Loose injector connectors Remedy (see chapter 3). Crankshaft sensor trouble Inspect and repair or replace (see chapter 16). Stick coil trouble Inspect and repair or replace (see chapter 16).

  • Page 119

    3-38 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Inlet air pressure sensor trouble Inspect (see chapter 3). Air switching valve broken Inspect and replace (see chapter 5). Air suction valve trouble Inspect and replace (see chapter 5). After fire: Crankshaft sensor trouble Inspect (see chapter 16).

  • Page 120

    FUEL SYSTEM (DFI) 3-39 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Stick coil trouble Inspect (see chapter 16). Fuel/air mixture incorrect: Air cleaner clogged, poorly sealed, or missing Clean element or inspect sealing (see chapter 3). Air cleaner duct loose Reinstall (see chapter 3).

  • Page 121

    3-40 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Speed sensor trouble Inspect (see chapter 3). Throttle valves won’t fully open Inspect throttle cable and lever linkage (see chapter 3). Brake dragging Inspect caliper fluid seal damage or clogging of master cylinder relief and supply ports (see chapter 12).

  • Page 122

    FUEL SYSTEM (DFI) 3-41 Self-Diagnosis The warning indicator light (LED) [A] is used for the FI indicator, immobilizer indicator (immobilizer models) and oil pressure warning indicator. Self-diagnosis Outline The self-diagnosis system has two modes and can be switched to another mode by operating the meter unit. User Mode The ECU notifies the rider of troubles in DFI system , ig- nition system and immobilizer system by blinking the warn-...

  • Page 123

    3-42 FUEL SYSTEM (DFI) Self-Diagnosis Dealer Mode The LCD (Liquid Crystal Display) display the service code(s) [A] to show the problem(s) which the DFI system, ignition system and immobilizer system has at the moment of diagnosis. Self-diagnosis Procedures ○ When a problem occurs with the DFI system and ignition system, the warning indicator light (LED) [A] and FI warn- ing symbol [B] blinks.

  • Page 124

    FUEL SYSTEM (DFI) 3-43 Self-Diagnosis • Turn the ignition switch ON. • Push the Mode button [A] to display the odometer. • Push the RESET button [A] for more than two seconds. • The service code [B] is displayed on the LCD by the num- ber of two digits.

  • Page 125

    3-44 FUEL SYSTEM (DFI) Self-Diagnosis Self-Diagnosis Flow Chart...

  • Page 126

    FUEL SYSTEM (DFI) 3-45 Self-Diagnosis Service Code Reading ○ The service code(s) is displayed on the LCD by the number of two digits. ○ When there are a number of problems, all the service codes can be stored and the display will begin starting from the lowest number service code in the numerical order.

  • Page 127

    3-46 FUEL SYSTEM (DFI) Self-Diagnosis Service Code Table Service Code Problems Throttle sensor malfunction, wiring open or short Inlet Air Pressure sensor malfunction, wiring open or short Inlet air temperature sensor malfunction, wiring open or short Water temperature sensor malfunction, wiring open or short Atmospheric pressure sensor malfunction, wiring open or short Crankshaft sensor malfunction, wiring open or short Camshaft position sensor malfunction, wiring open or short...

  • Page 128

    FUEL SYSTEM (DFI) 3-47 Self-Diagnosis Backups ○ The ECU takes the following measures to prevent engine damage when the DFI, ignition or immo- bilizer system parts have troubles. Service Output Signal Usable Parts Backups by ECU Codes Range or Criteria If the main throttle sensor system fails (the Main Throttle Sensor signal is out of the usable range, wiring short...

  • Page 129

    3-48 FUEL SYSTEM (DFI) Self-Diagnosis Service Output Signal Usable Parts Backups by ECU Codes Range or Criteria Exhaust If the exhaust butterfly valve system fails (the Exhaust Butterfly Valve Butterfly signal is out of the usable range, wiring short Output Voltage Valve or open), the actuator locks exhaust butterfly 4.8 V...

  • Page 130

    FUEL SYSTEM (DFI) 3-49 Self-Diagnosis Service Output Signal Usable Parts Backups by ECU Codes Range or Criteria When the relay OFF ECU Main condition, the main relay is – Relay open. The oxygen sensor #2 is Oxygen active and sensor must If the oxygen sensor #2 is not activated, the Sensor #2 send signals (output...

  • Page 131

    3-50 FUEL SYSTEM (DFI) Main Throttle Sensor (Service Code 11) The main throttle sensor is a rotating variable resistor that change output voltage according to throttle operating. The ECU senses this voltage change and determines fuel injec- tion quantity, and ignition timing according to engine rpm, and throttle opening.

  • Page 132

    FUEL SYSTEM (DFI) 3-51 Main Throttle Sensor (Service Code 11) • Remove the throttle body assy temporarily (see Throttle Body Assy Removal). • Disconnect the main throttle sensor connector [A]. • Connect the harness adapter [A] between the harness connector and main throttle sensor connector. •...

  • Page 133

    3-52 FUEL SYSTEM (DFI) Main Throttle Sensor (Service Code 11) Output Voltage Inspection • Measure the output voltage at the ECU in the same way as input voltage inspection. Note the following. Digital Meter [A] Connector [B] Special Tool - Needle Adapter Set: 57001-1457 Main Throttle Sensor Output Voltage Connections to ECU Connector Meter (+) →...

  • Page 134

    FUEL SYSTEM (DFI) 3-53 Main Throttle Sensor (Service Code 11) NOTE ○ The standard voltage refers to the value when the volt- age reading at the Input Voltage Inspection shows 5V exactly. ○ When the input voltage reading shows other than 5V, derive a voltage range as follows.

  • Page 135

    3-54 FUEL SYSTEM (DFI) Main Throttle Sensor (Service Code 11) • Disconnect the main throttle sensor connector and con- nect the harness adapter [A] between the harness con- nector and main throttle sensor connector. Special Tool - Throttle Sensor Setting Adapter: 57001 -1538 •...

  • Page 136

    FUEL SYSTEM (DFI) 3-55 Main Throttle Sensor (Service Code 11) Resistance Inspection • Turn the ignition switch OFF. • Disconnect the main throttle sensor connector. • Connect a digital meter [A] to the main throttle sensor connector [B]. • Measure the main throttle sensor resistance. Main Throttle Sensor Resistance Connections: BL lead [C] ←→BR/BK lead [D] Standard:...

  • Page 137

    3-56 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code 12) CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the part can damage it. Removal • Turn the ignition switch OFF. • Remove: Air Cleaner Housing (see Air Cleaner Housing Removal) Inlet Air Pressure Sensor Connector [A] Inlet Air Pressure Sensor [B] Vacuum Hose...

  • Page 138

    FUEL SYSTEM (DFI) 3-57 Inlet Air Pressure Sensor (Service Code 12) If the reading is within the standard range, and check the input voltage again at the sensor connector. • Remove the air cleaner housing (see Air Cleaner Housing Removal). •...

  • Page 139

    3-58 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code 12) If the output voltage is far out of the usable range, check the output voltage again at the sensor connector [A] (when the lead is open, the output voltage is about 1.8 •...

  • Page 140

    FUEL SYSTEM (DFI) 3-59 Inlet Air Pressure Sensor (Service Code 12) • Remove the inlet air pressure sensor [A] and disconnect the vacuum hose from the sensor. • Connect an auxiliary hose [B] to the inlet air pressure sen- sor. •...

  • Page 141

    3-60 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code 12) ID: Idling Pv: Throttle Vacuum Pressure (abs.) Ps: Standard Atmospheric Pressure (abs.) ST: Standard of Sensor Output Voltage (v) TO: Throttle Full Open UR: Usable Range of Sensor Output Voltage (v) Vv: Inlet Air Pressure Sensor Output Voltage (V) (Digital Meter Reading)

  • Page 142

    FUEL SYSTEM (DFI) 3-61 Inlet Air Temperature Sensor (Service Code 13) Removal/Installation CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. • Remove the fuel tank (see Fuel Tank Removal). •...

  • Page 143

    • Remove the needle adapter set, and apply silicone sealant to the seals of the ECU connector for waterproof- ing. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 If the wiring is good, check the sensor resistance. Sensor Resistance Inspection •...

  • Page 144

    FUEL SYSTEM (DFI) 3-63 Inlet Air Temperature Sensor (Service Code 13) Inlet Air Temperature Sensor Circuit 1. ECU 2. Inlet Air Temperature Sensor 3. Water-proof Joint 2...

  • Page 145

    Water Temperature Sensor [B] • Apply silicone sealant to the threads of the water temper- ature sensor and tighten it. Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004 Torque - Water Temperature Sensor: 25 N·m (2.5 kgf·m, 18 ft·lb) • Fill the engine with coolant and bleed the air from the cooling system (see Coolant Filling in the Cooling System chapter).

  • Page 146

    • Remove the needle adapter set, and apply silicone sealant to the seals of the ECU connector for waterproof- ing. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 Sensor Resistance Inspection • Refer to the Water Temperature Sensor Inspection in the Electrical System chapter (see Water Temperature Sen- sor Inspection in the Electrical System chapter).

  • Page 147

    3-66 FUEL SYSTEM (DFI) Atmospheric Pressure Sensor (Service Code 15) CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. Removal • Turn the ignition switch OFF. • Remove: Seat Cover (see Seat Cover Removal in the Frame chapter) Atmospheric Pressure Sensor Connector [A] Damper [B]...

  • Page 148

    FUEL SYSTEM (DFI) 3-67 Atmospheric Pressure Sensor (Service Code 15) If the reading is within the standard range, remove the seat cover, and check the input voltage again at the sen- sor connector. • Disconnect the atmospheric pressure sensor connector and connect the harness adapter [A] between the harness connector and atmospheric pressure sensor connector.

  • Page 149

    3-68 FUEL SYSTEM (DFI) Atmospheric Pressure Sensor (Service Code 15) If the output voltage is far out of the usable range, remove the seat cover, and check the output voltage at the sensor connector [A] (when the wiring is open, the output voltage is about 1.8 V).

  • Page 150

    FUEL SYSTEM (DFI) 3-69 Atmospheric Pressure Sensor (Service Code 15) If you know the local atmospheric pressure using a barometer, substitute the atmospheric pressure for throt- tle vacuum pressure in the inlet air pressure sensor chart (see Inlet Air Pressure Sensor section). And get the usable range of the atmospheric pressure sensor output voltage and check if output voltage is within the standard or not in the same way as Output Voltage Inspection of...

  • Page 151

    3-70 FUEL SYSTEM (DFI) Crankshaft Sensor (Service Code 21) Crankshaft Sensor Removal/Installation • Refer to the Crankshaft Sensor Removal/Installation in the Electrical System chapter (see Crankshaft Sensor Re- moval/Installation in the Electrical System chapter). Crankshaft Sensor Inspection ○ The crankshaft have no power source, and when the en- gine stops, the crankshaft generates no signals.

  • Page 152

    FUEL SYSTEM (DFI) 3-71 Camshaft Position Sensor (Service Code 23) Camshaft Position Sensor Removal/Installation The camshaft position sensor detects the position of the camshaft, and distinguishes the cylinder. • Refer to the Camshaft Position Sensor Removal/Installa- tion in the Electric System chapter (see Camshaft Position Sensor Removal/Installation in the Electric System chap- ter).

  • Page 153

    3-72 FUEL SYSTEM (DFI) Speed Sensor (Service Code 24) Speed Sensor Removal/Installation • Refer to the Speed Sensor Removal/Installation in the Electrical System chapter (see Speed Sensor Re- moval/Installation in the Electrical System chapter). Input Voltage Inspection NOTE ○ Be sure the battery is fully charged. ○...

  • Page 154

    FUEL SYSTEM (DFI) 3-73 Speed Sensor (Service Code 24) • Connect the harness adapter [A] between the harness connector and speed sensor connector. Special Tool - Speed Sensor Measuring Adapter: 57001 -1667 • Connect a digital meter to the harness adapter leads. Speed Sensor Input Voltage Connections to Adapter Meter (+) →...

  • Page 155

    3-74 FUEL SYSTEM (DFI) Speed Sensor (Service Code 24) • Connect a digital meter to the harness adapter leads. Speed Sensor Output Voltage Connections to Adapter Meter (+) → BL/Y lead [A] Meter (–) → BK lead [B] • Measure the output voltage with the engine stopped, and with the connectors joined.

  • Page 156

    FUEL SYSTEM (DFI) 3-75 Gear Position Switch (Service Code 25) Gear Position Switch Removal/Installation • Refer to the Gear Position Switch Removal/Installation in the Electrical System chapter (see Gear Position Switch Removal/Installation in the Electrical System chapter). Gear Position Switch Inspection •...

  • Page 157

    3-76 FUEL SYSTEM (DFI) Gear Position Switch (Service Code 25) Gear Position Switch Circuit 1. ECU 2. Gear Position Switch 3. Joint Connector 1 4. Joint Connector 2 5. Frame Ground...

  • Page 158

    FUEL SYSTEM (DFI) 3-77 Vehicle-down Sensor (Service Code 31) This sensor has a weight [A] with two magnets inside, and sends a signal to the ECU. But when the motorcycle banks 60 70° or more to either side (in fact falls down), the weight turns and shuts off the signal.

  • Page 159

    3-78 FUEL SYSTEM (DFI) Vehicle-down Sensor (Service Code 31) • Connect a digital meter [A] to the connector of the vehicle -down sensor [B], with the needle adapter set [C]. Special Tool - Needle Adapter Set: 57001-1457 Vehicle-down sensor Power Source Voltage Connections to Sensor Meter (+) →...

  • Page 160

    Remove the needle adapter set, and apply silicone sealant to the seals of sensor the connector for water- proofing. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 If the output voltage is out of the specified, replace the vehicle-down sensor. Vehicle-down Sensor Circuit 1.

  • Page 161

    3-80 FUEL SYSTEM (DFI) Subthrottle Sensor (Service Code 32) The subthrottle sensor is a rotating variable resistor that change output voltage according to throttle operating. The ECU senses this voltage change and determines fuel injec- tion quantity, and ignition timing according to engine rpm, and throttle opening.

  • Page 162

    FUEL SYSTEM (DFI) 3-81 Subthrottle Sensor (Service Code 32) • Disconnect the subthrottle sensor connector [A] and con- nect the harness adapter [B] between the harness con- nector and subthrottle sensor connector. Special Tool - Throttle Sensor Setting Adapter: 57001 -1538 •...

  • Page 163

    3-82 FUEL SYSTEM (DFI) Subthrottle Sensor (Service Code 32) If the output voltage is within the standard range, check the ECU for its ground, and power supply (see ECU Power Supply Inspection). If the ground and power supply are good, replace the ECU (see ECU Removal). If the output voltage is far out of the standard range (e.g.

  • Page 164

    FUEL SYSTEM (DFI) 3-83 Subthrottle Sensor (Service Code 32) • After subthrottle sensor voltage inspection, remove the harness adapter. If the reading is out of the standard range, inspect the subthrottle sensor resistance. If the output voltage is normal, check the wiring for conti- nuity (see wiring diagram in this section).

  • Page 165

    3-84 FUEL SYSTEM (DFI) Oxygen Sensor #1-not activated (Service Code 33) - Europe Models Oxygen Sensor #1 Removal/Installation • Refer to the Oxygen Sensor Removal (Europe Models) in the Electrical System chapter (see Oxygen Sensor Re- moval (Europe Models) in the Electrical System chapter). Oxygen Sensor #1 Inspection NOTE ○...

  • Page 166

    0.45 V), the oxygen sensor is good. If the reading is without range, replace the oxygen sensor • Remove the needle adapter set, and apply silicone sealant to the seals of the connector for waterproofing. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120...

  • Page 167

    3-86 FUEL SYSTEM (DFI) Oxygen Sensor #1-not activated (Service Code 33) - Europe Models Oxygen Sensor Circuit 1. ECU 2. Water-proof Joint 2 3. Oxygen Sensor #2 4. Oxygen Sensor #1 5. Ignition Switch 6. Oxygen Sensor Heater Fuse 10 A 7.

  • Page 168

    FUEL SYSTEM (DFI) 3-87 Exhaust Butterfly Valve Actuator Sensor (Service Code 34) Exhaust Butterfly Valve Actuator Sensor Inspection • Turn the ignition switch OFF. • Remove the seat cover (see Seat Cover Removal in the Frame chapter). • Disconnect the exhaust butterfly valve actuator sensor connector.

  • Page 169

    3-88 FUEL SYSTEM (DFI) Immobilizer Amplifier (Service Code 35) Antenna Resistance Inspection • Remove the left upper inner fairing (see Upper Inner Fair- ing Removal in the Frame chapter). • Disconnect the antenna lead connector [A]. • Measure the resistance of the antenna coil in the ignition switch as follows.

  • Page 170

    8. Ignition Fuse 15 A 9. Main Fuse 30 A 10. Starter Relay 11. Battery 12 V 10 Ah 12. Joint Connector 2 13. Joint Connector 3 14. Immobilizer/Kawasaki Diagnostic System Connector 15. ECU 16. Water-proof Joint 1 17. Frame Ground...

  • Page 171

    3-90 FUEL SYSTEM (DFI) Fuel Pump Relay (Service Code 46) Fuel Pump Relay Removal CAUTION Never drop the relay, especially on a hard surface. Such a shock to the relay can damage it. ○ The fuel pump relay is included in the relay box. •...

  • Page 172

    FUEL SYSTEM (DFI) 3-91 Stick Coils #1, #2, #3, #4: (Service Code 51, 52, 53, 54) Stick Coil #1: Service Code 51 Stick Coil #2: Service Code 52 Stick Coil #3: Service Code 53 Stick Coil #4: Service Code 54 Removal/Installation CAUTION Never drop the stick coils, especially on a hard sur-...

  • Page 173

    3-92 FUEL SYSTEM (DFI) Stick Coils #1, #2, #3, #4: (Service Code 51, 52, 53, 54) Stick Coil Circuit 1. ECU 2. Stick Coil #4 3. Stick Coil #3 4. Stick Coil #2 5. Stick Coil #1 6. Engine Stop Switch 7.

  • Page 174

    FUEL SYSTEM (DFI) 3-93 Subthrottle Valve Actuator (Service Code 62) Subthrottle Valve Actuator Removal CAUTION Do not remove the subthrottle valve actuator [A] since it has been adjusted and set with precision at the factory. Never drop the actuator , especially on a hard sur- face.

  • Page 175

    3-94 FUEL SYSTEM (DFI) Subthrottle Valve Actuator (Service Code 62) Input Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch OFF. • Connect the peak voltage adapter [A] and a digital meter [B] to the connector [C], using the needle adapter set [D]. Special Tools - Peak Voltage Adapter: 57001-1415 Type: KEK-54-9-B Needle Adapter Set: 57001-1457...

  • Page 176

    FUEL SYSTEM (DFI) 3-95 Subthrottle Valve Actuator (Service Code 62) Subthrottle Valve Actuator Circuit 1. ECU 2. Subthrottle Valve Actuator 3. Subthrottle Sensor 4. Main Throttle Sensor 5. Water-proof Joint 2...

  • Page 177

    3-96 FUEL SYSTEM (DFI) Exhaust Butterfly Valve Actuator (Service Code 63) Exhaust Butterfly Valve Actuator Removal • Remove the seat cover (see Seat Cover Removal in the Frame chapter) • Slide the dust covers [A]. • Loosen the locknuts [B], and turn the adjuster to give the cable plenty of play [C].

  • Page 178

    FUEL SYSTEM (DFI) 3-97 Exhaust Butterfly Valve Actuator (Service Code 63) • Confirm the pulley angle [A] (41.7° ±7°) as shown. It is original position of the pulley [B]. If the angle is not within the specified angle, adjust the actuator as follows.

  • Page 179

    3-98 FUEL SYSTEM (DFI) Exhaust Butterfly Valve Actuator (Service Code 63) Output Voltage Inspection • Remove the seat cover (see Seat Cover Removal in the Frame chapter). • Turn the ignition switch ON and wait until the pulley stops. • Turn the ignition switch OFF and wait until the pulley stops.

  • Page 180

    FUEL SYSTEM (DFI) 3-99 Oxygen Sensor Heaters (#1 and/or #2: Service Code 67) - Europe Models Oxygen Sensor Heaters Removal/Installation The oxygen sensor heater is built in the oxygen sensor. So, the heater itself can not be removed. Remove the oxy- gen sensors (see Oxygen Sensor Removal in the Electrical System chapter).

  • Page 181

    (see ECU Power Supply Inspection). If the ground and power supply are good, replace the ECU (see ECU section). • Remove the needle adapter set, and apply silicone sealant to the connector for water proofing. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120...

  • Page 182

    FUEL SYSTEM (DFI) 3-101 Oxygen Sensor Heaters (#1 and/or #2: Service Code 67) - Europe Models Oxygen Sensor Circuit 1. ECU 2. Water-proof Joint 2 3. Oxygen Sensor #2 4. Oxygen Sensor #1 5. Ignition Switch 6. Oxygen Sensor Heater Fuse 10 A 7.

  • Page 183

    3-102 FUEL SYSTEM (DFI) ECU Main Relay (Service Code 75) ECU Main Relay Inspection ○ The ECU main relay function is included in the ECU [A]. So, the ECU main relay function cannot inspect. • When the service code 75 is displayed on the LCD, re- place the ECU (see ECU sectionl).

  • Page 184

    FUEL SYSTEM (DFI) 3-103 Oxygen Sensor #2-not activated (Service Code 83) - Europe Models Oxygen Sensor #2 Removal/Installation • Refer to the Oxygen Sensor Removal (Europe Models) in the Electrical System chapter (see Oxygen Sensor Re- moval (Europe Models) in the Electrical System chapter). Oxygen Sensor #2 Inspection NOTE ○...

  • Page 185

    0.45 V), the oxygen sensor is good. If the reading is without range, replace the oxygen sensor. • Remove the needle adapter set, and apply silicone sealant to the seals of the connector for waterproofing. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120...

  • Page 186

    FUEL SYSTEM (DFI) 3-105 Oxygen Sensor #2-not activated (Service Code 83) - Europe Models Oxygen Sensor Circuit 1. ECU 2. Water-proof Joint 2 3. Oxygen Sensor #2 4. Oxygen Sensor #1 5. Ignition Switch 6. Oxygen Sensor Heater Fuse 10 A 7.

  • Page 187

    3-106 FUEL SYSTEM (DFI) CAUTION Never drop the ECU, especially on a hard surface. Such a shock to the ECU can damage it. ECU Identification ○ Most countries have their own regulations, so each ECU has different characteristic. So, do not confuse ECU with each other and use only the ECU for your model.

  • Page 188

    FUEL SYSTEM (DFI) 3-107 ECU Installation • Install: ECU [A] (In rubber protector [B]) ECU Connectors • Insert the slits of the rubber protector to the projections [A] of the rear fender front. ECU Power Supply Inspection • Remove the ECU (see ECU Removal). •...

  • Page 189

    3-108 FUEL SYSTEM (DFI) • Check the ECU power source voltage with a digital meter [A]. ○ Position the terminal in accordance with terminal numbers of ECU connectors [B] in the figure. Battery [C] ECU Power Source Inspection Tester Connections: between 33 (BR) Terminal and Battery (–) Terminal between 15 (W/BK) Terminal and...

  • Page 190

    FUEL SYSTEM (DFI) 3-109 ECU Power Source Circuit 1. ECU 2. Water-proof Joint 1 3. Ignition Switch 4. ECU Fuse 15 A 5. Starter Relay 6. Main Fuse 30 A 7. Battery 12 V 10 Ah 8. Joint Connector 3...

  • Page 191

    3-110 FUEL SYSTEM (DFI) DFI Power Source ECU Fuse Removal • Refer to the 15 A ECU Fuse Removal in the Electrical Sys- tem chapter (see 15 A ECU Fuse Removal in the Electri- cal System chapter). ECU Fuse Installation If a fuse fails during operation, inspect the DFI system to determine the cause, and then replace it with a new fuse of proper amperage.

  • Page 192

    FUEL SYSTEM (DFI) 3-111 Warning Indicator Light (LED) Light (LED) Inspection ○ The warning indicator light (LED) [A] is used for the FI indicator, immobilizer indicator (immobilizer models) and oil pressure warning indicator. ○ In this model, the warning indicator light (LED) (FI/immo- bilizer) blink by the special signal sent from the ECU.

  • Page 193

    3-112 FUEL SYSTEM (DFI) Fuel Line Fuel Pressure Inspection NOTE ○ Be sure the battery is fully charged. • Remove: Front Seat (see Front Seat Removal in the Frame chap- ter) Steering Damper (see Steering Damper Removal in the Steering chapter) Fuel Tank Bolts [A] •...

  • Page 194

    FUEL SYSTEM (DFI) 3-113 Fuel Line • Start the engine, and let it idle. • Measure the fuel pressure with the engine idling. Fuel Pressure (idling) Standard: 304 kPa (3.1 kgf/cm², 44 psi) NOTE ○ The gauge hand will fluctuate. Read the pressure at the average of the maximum and minimum indications.

  • Page 195

    3-114 FUEL SYSTEM (DFI) Fuel Line • Open the fuel tank cap [A] to lower the pressure in the tank. • Be sure to place a piece of cloth around the fuel supply pipe of the fuel pump. • Remove the fuel hose from the fuel pump (see Fuel Tank Removal).

  • Page 196

    FUEL SYSTEM (DFI) 3-115 Fuel Pump Fuel Pump Removal CAUTION Never drop the fuel pump, especially on a hard sur- face. Such a shock to the pump can damage it. WARNING Gasoline is extremely flammable and can be explo- sive under certain conditions. Make sure the area is well-ventilated and free from any source of flame or sparks;...

  • Page 197

    3-116 FUEL SYSTEM (DFI) Fuel Pump • Check that the fuel pump terminals [A], fuel reserve switch terminal [B] and band [C] are in place. Front [D] • Apply a non-permanent locking agent to the threads of the fuel pump bolts. •...

  • Page 198

    FUEL SYSTEM (DFI) 3-117 Fuel Pump Fuel Pump Circuit 1. ECU 2. Water-proof Joint 1 3. Engine Stop Switch 4. Ignition Switch 5. Fuel Pump Relay 6. ECU Fuse 15 A 7. Ignition Fuse 15 A 8. Starter Replay 9. Main Fuse 30 A 10.

  • Page 199

    3-118 FUEL SYSTEM (DFI) Fuel Injectors Removal/Installation • Refer to the Throttle Body Assy Disassembly/Assembly (see Throttle Body Assy Disassembly/Assembly). CAUTION Never drop the injector, especially on a hard sur- face. Such a shock to the injector can damage it. Power Source Voltage Inspection NOTE ○...

  • Page 200

    FUEL SYSTEM (DFI) 3-119 Fuel Injectors If the reading is normal, remove the fuel tank (see Fuel Tank Removal), and check the power source voltage at the injector connector [B], with a digital meter [A]. • Measure the power source voltage with the engine stopped, and the connector joined, with a digital meter and needle adapter set [C].

  • Page 201

    3-120 FUEL SYSTEM (DFI) Fuel Injectors If the output voltage is out of the standard, remove the air cleaner housing, and check the output voltage at the injector connector [B] using a digital meter [A] and needle adapter set [C] (when the lead is open, the output voltage is 0 V).

  • Page 202

    FUEL SYSTEM (DFI) 3-121 Fuel Injectors Injector Signal Test • Prepare two test light sets with male terminals as shown. Rating of Bulb [A]: 12 V × 3 ~ 3.4 W Terminal Width [B]: 1.8 mm (0.07 in.) Terminal Thickness [C]: 0.8 mm (0.03 in.) CAUTION Do not use larger terminals than specified above.

  • Page 203

    3-122 FUEL SYSTEM (DFI) Fuel Injectors Injector Unit Test • Use two leads [A] and the same test light set [B] as in “Injector Signal Test”. Rating of Bulb [C]: 12 V × (3 3.4) W 12 V MF Battery [D] CAUTION Be sure to connect the bulb in series.

  • Page 204

    FUEL SYSTEM (DFI) 3-123 Fuel Injectors Fuel Injector Circuit 1. ECU 2. Frame Ground 3. Joint Connector 1 4. Joint Connector 2 5. Fuel Pump 6. Water-proof Joint 1 7. Fuel Injector #4 8. Fuel Injector #3 9. Fuel Injector #2 10.

  • Page 205

    3-124 FUEL SYSTEM (DFI) Throttle Grip and Cables Free Play Inspection • Refer to the Throttle Control System Inspection in the Pe- riodic Maintenance chapter (see Throttle Control System Inspection in the Periodic Maintenance chapter). Free Play Adjustment • Refer to the Throttle Control System Inspection in the Pe- riodic Maintenance chapter (see Throttle Control System Inspection in the Periodic Maintenance chapter).

  • Page 206

    FUEL SYSTEM (DFI) 3-125 Throttle Body Assy Idle Speed Inspection • Refer to the Idle Speed Inspection in the Periodic Mainte- nance chapter (see Idle Speed Inspection in the Periodic Maintenance chapter). Throttle Bore Cleaning • Check the throttle bore for cleanliness as follows. ○...

  • Page 207

    3-126 FUEL SYSTEM (DFI) Throttle Body Assy • Remove: Air Switching Valve Hose [A] Vacuum Hoses [B] (California Model) • Remove the middle fairings (see Middle Fairing Removal in the Frame chapter). • Loosen the throttle body assy holder clamp bolts [A] on both sides.

  • Page 208

    FUEL SYSTEM (DFI) 3-127 Throttle Body Assy • After removing the throttle body assy, stuff pieces of lint -free, clean cloths into the throttle body assy holders. CAUTION If dirt gets into the engine, excessive engine wear and possible engine damage will occur. If the throttle body assy is to be disassembly, loosen the air cleaner housing holder clamp bolts [A], and remove the air cleaner housing holder [B].

  • Page 209

    3-128 FUEL SYSTEM (DFI) Throttle Body Assy Throttle Body Assy Disassembly 1. Subthrottle Valve Actuator 2. Subthrottle Sensor 3. Main Throttle Sensor 4. Throttle Body Assy 5. Injector 6. Delivery Pipe 7. Injector Connector Harness CAUTION Do not remove, disassemble or adjust the main throttle sensor, subthrottle sensor, subthrottle valve actuator, throttle link mechanism and throttle body assy, because they are adjust or set surely at...

  • Page 210

    FUEL SYSTEM (DFI) 3-129 Throttle Body Assy • Disconnect the main throttle sensor [A] and subthrottle sensor [B] connector. • Disconnect: Subthrottle Valve Actuator Lead Connector [A] Inlet Air Pressure Sensor Connector [B] • Separete the hoses [A] from the throttle body fittings and inlet air pressure sensor.

  • Page 211

    3-130 FUEL SYSTEM (DFI) Throttle Body Assy • Apply daphne oil or engine oil to the new dust seals [A], and insert the injectors into the throttle body, which in- stalled to the delivery pipe. NOTE ○ Replace the dust seals of the throttle body to new ones. •...

  • Page 212

    FUEL SYSTEM (DFI) 3-131 Air Line Element Removal • Refer to the Air Cleaner Element Replacement in the Pe- riodic Maintenance chapter (see Air Cleaner Element Re- placement in the Periodic Maintenance chapter). Element Installation • Refer to the Air Cleaner Element Replacement in the Pe- riodic Maintenance chapter (see Air Cleaner Element Re- placement in the Periodic Maintenance chapter).

  • Page 213

    3-132 FUEL SYSTEM (DFI) Air Line • Turn the air cleaner housing [A] counterclockwise [B] and remove it. • Pull off the air ducts [A] from the frame. Air Cleaner Housing Installation • Confirm the air ducts [A] fit in the frame [B]. •...

  • Page 214

    Insert the seal [A] into the groove in the lower housing [B]. • Apply liquid gasket to the mesh patterns [C] on the lower housing. Sealant - Kawasaki Bond (Liquid Gasket - Black): 92104 -0002 ○ Wipe off any protruding liquid gasket.

  • Page 215

    3-134 FUEL SYSTEM (DFI) Air Line Air Inlet Duct Removal • Remove: Upper Fairing (see Upper Fairing Removal in the Frame chapter) Mounting Bolts [A] (Both Sides) Air Inlet Duct [B] Air Inlet Duct Installation • Install the gasket [A]. •...

  • Page 216

    FUEL SYSTEM (DFI) 3-135 Fuel Tank Fuel Tank Removal WARNING Gasoline is extremely flammable and can be explo- sive under certain conditions. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light.

  • Page 217

    3-136 FUEL SYSTEM (DFI) Fuel Tank • Draw the fuel out from the fuel tank with a commercially available pump [A]. ○ Use a soft plastic hose [B] as a pump inlet hose in order to insert the hose smoothly. ○...

  • Page 218

    FUEL SYSTEM (DFI) 3-137 Fuel Tank • For the California Model, note the following. CAUTION For the California model, if gasoline, solvent, water or any other liquid enters the canister, the canister’s vapor absorbing capacity is greatly reduced. If the canister does become contaminated, replace it with a new one.

  • Page 219

    3-138 FUEL SYSTEM (DFI) Fuel Tank • Insert the fuel hose joint [A] straight onto the delivery pipe until the hose joint clicks. • Push [B] the joint lock [C] until the hose joint clicks. • Push and pull [A] the hose joint [B] back and forth more than two times and make sure it is locked and doesn’t come off.

  • Page 220

    FUEL SYSTEM (DFI) 3-139 Evaporative Emission Control System The Evaporative Emission Control System routes fuel va- pors from the fuel system into the running engine or stores the vapors in a canister when the engine is stopped. Al- though no adjustments are required, a thorough visual in- spection must be made at the intervals specified by the Pe- riodic Maintenance Chart.

  • Page 221

    3-140 FUEL SYSTEM (DFI) Evaporative Emission Control System Separator Operation Test WARNING Gasoline is extremely flammable and can be ex- plosive under certain conditions. Turn the ignition switch OFF. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks;...

  • Page 222

    COOLING SYSTEM 4-1 Cooling System Table of Contents Exploded View........................Coolant Flow Chart......................... Specifications ......................... Coolant ........................... Coolant Deterioration Inspection..................Coolant Level Inspection....................Coolant Draining ....................... Coolant Filling ........................Pressure Testing ....................... Cooling System Flushing ....................Coolant Reserve Tank Removal ..................Coolant Reserve Tank Installation ..................

  • Page 223

    4-2 COOLING SYSTEM Exploded View...

  • Page 224

    COOLING SYSTEM 4-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Water Hose Clamp Screws 0.20 18 in·lb Coolant Drain Bolt (Cylinder) 89 in·lb Water Pump Cover Bolts 89 in·lb Water Temperature Sensor Coolant Reserve Tank Mounting Bolts 0.71 62 in·lb Coolant By-pass Fitting Bolt 0.92 80 in·lb...

  • Page 225

    4-4 COOLING SYSTEM Coolant Flow Chart...

  • Page 226

    COOLING SYSTEM 4-5 Coolant Flow Chart 1. Radiator 2. Radiator Fan 3. Radiator Cap 4. Radiator Overflow Hose 5. Reserve Tank 6. Reserve Tank Overflow Hose 7. Oil Cooler 8. Outlet Hose 9. Cylinder Head Jacket 10. Cylinder Jacket 11. Thermostat Housing 12.

  • Page 227

    4-6 COOLING SYSTEM Specifications Item Standard Coolant Provided when Shipping Type (Recommended) Permanent type of antifreeze (soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators) Color Green Mixed Ratio Soft water 50%, coolant 50% Freezing Point –35°C (–31°F) Total Amount...

  • Page 228

    COOLING SYSTEM 4-7 Coolant Coolant Deterioration Inspection • Visually inspect the coolant in the reserve tank. If whitish cotton-like wafts are observed, aluminum parts in the cooling system are corroded. If the coolant is brown, iron or steel parts are rusting. In either case, flush the cooling system.

  • Page 229

    4-8 COOLING SYSTEM Coolant Cooling System Flushing Over a period of time, the cooling system accumulates rust, scale, and lime in the water jacket and radiator. When this accumulation is suspected or observed, flush the cool- ing system. If this accumulation is not removed, it will clog up the water passage and considerable reduce the effi- ciency of the cooling system.

  • Page 230

    COOLING SYSTEM 4-9 Coolant Coolant Reserve Tank Installation • Install the following to the coolant reserve tank [A]. Rubber Dampers [B] Collars [C] Gasket [D] Cap [E] • Tighten: Torque - Coolant Reserve Tank Mounting Bolts [F]: 7.0 N·m (0.71 kgf·m, 62 in·lb) •...

  • Page 231

    4-10 COOLING SYSTEM Water Pump Water Pump Removal • Drain: Coolant (see Coolant Change in the Periodic Mainte- nance chapter) Engine Oil (see Engine Oil Change in the Periodic Main- tenance chapter) • Remove the water hoses [A]. • Remove: Water Pump Cover Bolts [A] Water Pump Cover [B] •...

  • Page 232

    COOLING SYSTEM 4-11 Water Pump • Turn the impeller shaft so that the slot [A] in its shaft fits onto the projection [B] of the oil pump gear shaft. CAUTION Do not pinch the gear position switch lead. • Install the water hose [A] and hose clamp [B] as shown. White Mark [C] •...

  • Page 233

    4-12 COOLING SYSTEM Radiator Radiator and Radiator Fan Removal • Drain the coolant (see Coolant Change in the Periodic Maintenance chapter). • Remove: Right Middle Fairing (see Middle Fairing Removal in the Frame chapter) Separator [A] (California Model) Clamp [B] (California Model) Radiator Cap [C] Radiator Hoses [D] Radiator Upper Bolt [E]...

  • Page 234

    COOLING SYSTEM 4-13 Radiator Radiator and Radiator Fan Installation • Install the radiator fan [A]. • Install the rubber dampers [B] and collars [C] as shown. • Remove the radiator cap [A] temporarily. • Cover the heat insulation rubber plate [B] on the radiator [C] as shown.

  • Page 235

    4-14 COOLING SYSTEM Radiator If the radiator bracket [A] was removed, install it. Torque - Radiator Bracket Mounting Bolt [B]: 7.0 N·m (0.71 kgf·m, 62 in·lb) • Tighten: Torque - Radiator Lower Bolt [C]: 7.0 N·m (0.71 kgf·m, 62 in·lb) Radiator Upper Bolt [D]: 7.0 N·m (0.71 kgf·m, 62 in·lb) Horn [E]...

  • Page 236

    COOLING SYSTEM 4-15 Radiator • Fill the radiator with coolant (see Coolant Change in the Periodic Maintenance chapter). • Install the middle fairings (see Middle Fairings Installation in the Frame chapter). • After installation, note the following. ○ Run the main harness [A] over the heat insulation rubber plate [B].

  • Page 237

    4-16 COOLING SYSTEM Radiator Radiator Inspection • Remove the radiator (see Radiator and Radiator Fan Re- moval). • Check the radiator core. If there are obstructions to air flow, remove them. If the corrugated fins [A] are deformed, carefully straighten them. If the air passages of the radiator core are blocked more than 20% by unremovable obstructions or irreparably de- formed fins, replace the radiator with a new one.

  • Page 238

    COOLING SYSTEM 4-17 Radiator Radiator Filler Neck Inspection • Remove the radiator cap (see Pressure Testing). • Check the radiator filler neck for signs of damage. • Check the condition of the top and bottom sealing seats [A] in the filler neck. They must be smooth and clean for the radiator cap to function properly.

  • Page 239

    4-18 COOLING SYSTEM Thermostat Thermostat Removal • Drain the coolant (see Coolant Change in the Periodic Maintenance chapter). • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Air Cleaner Housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter) Throttle Body Assy (see Throttle Body Assy Removal in the Fuel System (DFI) chapter)

  • Page 240

    COOLING SYSTEM 4-19 Thermostat • Replace the O-rings [A] with a new one. • Apply grease to the new O-rings. • Install a new O-rings into the thermostat housing [B] and Cover [C]. If the coolant by-pass fitting bolt [D] was removed, install ○...

  • Page 241

    4-20 COOLING SYSTEM Thermostat • To check valve opening temperature, suspend the ther- mostat [A] in a container of water and raise the tempera- ture of the water. ○ The thermostat must be completely submerged and must not touch the container sides or bottom. Suspend an ac- curate thermometer [B] in the water so that the heat sen- sitive portions [C] are located in almost the same depth.

  • Page 242

    COOLING SYSTEM 4-21 Hoses and Pipes Hose Installation • Install the hoses and pipes, being careful to follow bend- ing direction. Avoid sharp bending, kinking, flattening or twisting. • Run the hoses in accordance with the Cable, Wire, and Hose Routing section in the Appendix chapter. •...

  • Page 243

    4-22 COOLING SYSTEM Water Temperature Sensor CAUTION The water temperature sensor should never be al- lowed to fall on a hard surface. Such a shock to their parts can damage them. Water Temperature Sensor Removal • Refer to the Water Temperature Sensor Removal in the Fuel System (DFI) chapter (Water Temperature Sensor Removal in the Fuel System (DFI) chapter).

  • Page 244

    ENGINE TOP END 5-1 Engine Top End Table of Contents Exploded View........................Exhaust System........................Specifications ......................... 5-11 Special Tools and Sealant ...................... 5-12 Clean Air System........................5-14 Air Suction Valve Removal....................5-14 Air Suction Valve Installation..................... 5-14 Air Suction Valve Inspection ..................... 5-14 Air Switching Valve Removal ....................

  • Page 245

    5-2 ENGINE TOP END Exhaust Butterfly Valve Cable Removal ................5-45 Exhaust Butterfly Valve Cable Installation ................ 5-46...

  • Page 246

    ENGINE TOP END 5-3 Exploded View Dummy Page...

  • Page 247

    5-4 ENGINE TOP END Exploded View...

  • Page 248

    M: Apply molybdenum disulfide grease. MO: Apply molybdenum disulfide oil solution. (mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 : 1) R: Replacement Parts S: Follow the specified tightening sequence. SS: Apply silicone sealant (Kawasaki Bond: 92104-0004).

  • Page 249

    5-6 ENGINE TOP END Exploded View...

  • Page 250

    ENGINE TOP END 5-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Exhaust Pipe Holder Nuts Muffler Body Assembly Nuts Muffler Body Mounting Bolts Middle Exhaust Pipe Clamp Bolt Rear Exhaust Pipe Clamp Bolt Muffler Body Cover Bolts 0.71 62 in·lb Exhaust Butterfly Valve Cable Locknuts 0.71...

  • Page 251

    5-8 ENGINE TOP END Exhaust System Exhaust System ZX1000D6F 78.2: Horsepower 78.2 kW (106.3 ps) Full: Full Power H: Honeycomb Type Catalyst...

  • Page 252

    ENGINE TOP END 5-9 Exhaust System Manifold Mark Position [A] Silencer Mark Position [A] Manifold [A] with Holes [B] for Oxygen Sensors. Oxygen Sensor #1 [C] Oxygen Sensor #2 [D]...

  • Page 253

    5-10 ENGINE TOP END Exhaust System...

  • Page 254

    ENGINE TOP END 5-11 Specifications Item Standard Service Limit Camshafts Cam Height: Exhaust 34.443 34.557 mm (1.3560 1.3605 in.) 34.34 mm (1.352 in.) Inlet 35.043 35.157 mm (1.3796 1.3841 in.) 34.94 mm (1.376 in.) Camshaft Journal, Camshaft 0.038 0.081 mm (0.0015 0.0032 in.) 0.17 mm (0.0067 in.) Cap Clearance...

  • Page 255

    5-12 ENGINE TOP END Special Tools and Sealant Compression Gauge, 20 kgf/cm²: Valve Seat Cutter, 32° - 35: 57001-221 57001-1121 Valve Spring Compressor Assembly: Valve Seat Cutter Holder Bar: 57001-241 57001-1128 Valve Seat Cutter, 45° - 27.5: Valve Seat Cutter, 60° - 25: 57001-1114 57001-1328 Valve Seat Cutter, 45°...

  • Page 256

    Special Tools and Sealant Valve Guide Reamer, 4.5: Compression Gauge Adapter, M10 × 1.0: 57001-1333 57001-1601 Valve Seat Cutter, 60° - 33: L-Shape Hose: 57001-1334 57001-1606 Valve Guide Driver: Washer: 57001-1564 57001-1612 Valve Spring Compressor Adapter, 24: Kawasaki Bond (Silicone Sealant): 57001-1586 92104-0004...

  • Page 257

    5-14 ENGINE TOP END Clean Air System Air Suction Valve Removal • Remove: Air Switching Valve (see Air Switching Valve Removal) Air Suction Valve Cover Bolts [A] Air Suction Valve Covers [B] • Remove the air suction valves [A]. Air Suction Valve Installation •...

  • Page 258

    ENGINE TOP END 5-15 Clean Air System Air Switching Valve Removal • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Air Cleaner Housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter) • Disconnect the connector [A].

  • Page 259

    • Replace the head cover gasket [A] with a new one. • Apply silicone sealant [B] to the cylinder head as shown. Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004 • Be sure to install the following parts. Dowel Pins [A]...

  • Page 260

    ENGINE TOP END 5-17 Cylinder Head Cover • Replace the washer [A] with new ones. • Install the new washer with the metal side faces upward. • Install the cylinder head cover. • Tighten the cover bolts [A]. Torque - Cylinder Head Cover Bolts: 10 N·m (1.0 kgf·m, 89 in·lb) •...

  • Page 261

    5-18 ENGINE TOP END Camshaft Chain Tensioner Camshaft Chain Tensioner Removal CAUTION This is a non-return type camshaft chain tensioner. The push rod does not return to its original position once it moves out to take up camshaft chain slack. Observe all the rules listed below: When removing the tensioner, do not take out the mounting bolts only halfway.

  • Page 262

    ENGINE TOP END 5-19 Camshaft Chain Tensioner • Remove the mounting bolts [A] and take off the camshaft chain tensioner body [B]. Camshaft Chain Tensioner Installation • Replace the O-ring [A] with a new one. • Apply grease to the new O-ring. •...

  • Page 263

    5-20 ENGINE TOP END Camshaft, Camshaft Chain Camshaft Removal • Remove the cylinder head cover (see Cylinder Head Cover Removal). • Remove the timing inspection cap [A] and starter clutch bolt cap [B] on the starter clutch cover [C]. • Using a wrench on the starter clutch bolt [A], turn the crankshaft clockwise until the line [B] (TDC mark for #1,4 pistons) on the starter clutch is aligned with the notch [C]...

  • Page 264

    ENGINE TOP END 5-21 Camshaft, Camshaft Chain • Remove the camshaft chain tensioner (see Camshaft Chain Tensioner Removal). • Loosen the upper chain guid bolts and camshaft cap bolts as shown sequence [1 20] in the figure, and remove them. •...

  • Page 265

    5-22 ENGINE TOP END Camshaft, Camshaft Chain • Install the cam sprockets as shown in figure. #4 Cam Positions [A] Inlet Cam Sprocket [B] Exhaust Cam Sprocket [C] • Apply a non-permanent locking agent to the threads and tighten the bolts. Torque - Cam Sprocket Mounting Bolts: 15 N·m (1.5 kgf·m, 11 ft·lb) •...

  • Page 266

    ENGINE TOP END 5-23 Camshaft, Camshaft Chain • Pull the tension side (exhaust side) [A] of the chain taut to install the chain. • Engage the camshaft chain with the sprockets so that tim- ing marks on the sprockets are positioned as shown. ○...

  • Page 267

    5-24 ENGINE TOP END Camshaft, Camshaft Chain • Before installing the camshaft caps and upper chain guide, install the camshaft chain tensioner body tempo- rally (see Camshaft Chain Tensioner Installation). • Install the camshaft caps and upper camshaft chain guide [A] as shown.

  • Page 268

    ENGINE TOP END 5-25 Camshaft, Camshaft Chain Camshaft, Camshaft Cap Wear • Remove the camshaft cap (see Camshaft Removal). • Cut strips of plastigage to journal width. Place a strip on each journal parallel to the camshaft installed in the correct position.

  • Page 269

    5-26 ENGINE TOP END Camshaft, Camshaft Chain Cam Wear • Remove the camshaft (see Camshaft Removal). • Measure the height [A] of each cam with a micrometer. If the cams are worn down past the service limit, replace the camshaft. Cam Height Standard: Exhaust...

  • Page 270

    ENGINE TOP END 5-27 Cylinder Head Cylinder Compression Measurement NOTE ○ Use the battery which is fully charged. • Warm up the engine thoroughly. • Stop the engine. • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Air Cleaner Housing (Air Cleaner Housing Removal in the Fuel System (DFI) chapter)

  • Page 271

    5-28 ENGINE TOP END Cylinder Head Cylinder Head Removal • Drain the coolant (see Coolant Change in the Periodic Maintenance chapter). • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Air Cleaner Housing (Air Cleaner Housing Removal in the Fuel System (DFI) chapter) Throttle Body Assy (see Throttle Body Assy Removal in the Fuel System (DFI) chapter)

  • Page 272

    ENGINE TOP END 5-29 Cylinder Head Cylinder Head Installation NOTE ○ The camshaft cap is machined with the cylinder head, so if a new cylinder head is installed, use the cap that is supplied with the new head. • Install the dowel pins. •...

  • Page 273

    5-30 ENGINE TOP END Cylinder Head Cylinder Head Warp • Clean the cylinder head. • Lay a straightedge across the lower surface of the cylinder head at several positions. • Use a thickness gauge [A] to measure the space between the straightedge [B] and the head.

  • Page 274

    ENGINE TOP END 5-31 Valves Valve Clearance Inspection • Refer to the Valve Clearance Inspection in the Periodic Maintenance chapter (see Valve Clearance Inspection in the Periodic Maintenance chapter). Valve Removal • Remove the cylinder head (see Cylinder Head Removal). •...

  • Page 275

    5-32 ENGINE TOP END Valves Valve Guide Installation • Apply oil to the valve guide outer surface before installa- tion. • Heat the area around the valve guide hole to about 120 150°C (248 302°F). CAUTION Do not heat the cylinder head with a torch. This Will warp the cylinder head.

  • Page 276

    ENGINE TOP END 5-33 Valves NOTE ○ The reading is not actual valve/valve guide clearance because the measuring point is above the guide. Valve/Valve Guide Clearance (Wobble Method) Standard: Exhaust 0.04 0.12 mm (0.0016 0.0047 in.) Inlet 0.03 0.10 mm (0.0012 0.0039 in.) Service Limit: Exhaust...

  • Page 277

    5-34 ENGINE TOP END Valves Seat Cutter Operation Care 1. This valve seat cutter is developed to grind the valve for repair. Therefore the cutter must not be used for other purposes than seat repair. 2. Do not drop or shock the valve seat cutter, or the dia- mond particles may fall off.

  • Page 278

    ENGINE TOP END 5-35 Valves • Measure the outside diameter of the seating surface with a vernier caliper. If the outside diameter of the seating surface is too small, repeat the 45° grind until the diameter is within the spec- ified range.

  • Page 279

    5-36 ENGINE TOP END Valves If the seat width is too wide, make the 60° [A] grind de- scribed below. If the seat width is within the specified range, lap the valve to the seat as described below. • Grind the seat at a 60° angle until the seat width is within the specified range.

  • Page 280

    ENGINE TOP END 5-37 Valves...

  • Page 281

    5-38 ENGINE TOP END Throttle Body Assy Holder Throttle Body Assy Holder Removal • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Air Cleaner Housing (Air Cleaner Housing Removal in the Fuel System (DFI) chapter) Throttle Body Assy (Throttle Body Assy Removal in the Fuel System (DFI) chapter) Clamps [A]...

  • Page 282

    ENGINE TOP END 5-39 Muffler WARNING To avoid a serious burn,do not remove the muffler when the engine is still hot.What until the muffler cool down. Muffler Body Removal • Remove: Seat Cover (see Seat Cover Removal in the Frame chapter) Bolts [A] Right Rear Footpeg Bracket [B] with Cover [C]...

  • Page 283

    5-40 ENGINE TOP END Muffler Muffler Body Installation If the muffler body cover [A] was removed, install it. ○ Fit the dampers [B] of the muffler body into the slots [C] in the muffler cover. Torque - Muffler Body Cover Bolts [D]: 7.0 N·m (0.70 kgf·m, 62 in·lb) •...

  • Page 284

    ENGINE TOP END 5-41 Muffler Middle and Rear Exhaust Pipe Removal • Remove the left muffler body (see Muffler Body Removal). • Loosen the rear exhaust pipe clamp bolt [A]. • Remove the rear exhaust pipe [B] from left side of motor- cycle.

  • Page 285

    5-42 ENGINE TOP END Muffler Middle and Rear Exhaust Pipe Installation • Replace the middle exhaust pipe gasket [A] with a new one. ○ Install the middle exhaust pipe gasket until it is bottomed so that the chamfer side (inner) faces front exhaust pipe [B].

  • Page 286

    ENGINE TOP END 5-43 Muffler • Install the exhaust butterfly valve cable, and adjust (see Exhaust Butterfly Valve Cable Installation). • Throughly warm up the engine, wait until the engine cools down, retighten all the bolts. • Install the removed parts (see appropriate chapters). Front Exhaust Pipe Removal •...

  • Page 287

    5-44 ENGINE TOP END Muffler Front Exhaust Pipe Installation • Replace the front exhaust pipe gaskets [A] with new ones. • Replace the middle exhaust pipe gasket [B] with a new one. ○ Install the middle exhaust pipe gasket until it is bottomed so that the chamfer side (inner) faces front exhaust pipe.

  • Page 288

    ENGINE TOP END 5-45 Muffler Exhaust Butterfly Valve Cable Removal • Remove the seat cover (see Seat Cover Removal in the Frame chapter). • Slide the dust covers [A]. • Loosen the locknuts [B], and turn the adjusters [C] to give the cable plenty of paly.

  • Page 289

    5-46 ENGINE TOP END Muffler • Remove: Bolts [A] Lower Cover [B] • Loosen the locknuts [A]. • Remove the exhaust butterfly valve cable lower ends [B] from the pulley [C]. • Pull the exhaust butterfly valve cables out of frame. Front View [D] Exhaust Butterfly Valve Cable Installation •...

  • Page 290

    ENGINE TOP END 5-47 Muffler CAUTION To keep the correct exhaust butterfly valve position, adjust the open cable first. • Install the close cable (green) [A]. • Install the open cable (yellow) [B] and adjust the adjuster [C] until the clearance of part [D] of figure come to 0 mm (0 in.).

  • Page 292

    CLUTCH 6-1 Clutch Table of Contents Exploded View........................Specifications ......................... Special Tool and Sealant ......................Clutch Lever and Cable ......................Clutch Lever Free Play Inspection ..................Clutch Lever Free Play Adjustment .................. Cable Removal ......................... Cable Installation ......................Cable Lubrication ......................Clutch Lever Installation....................

  • Page 293

    6-2 CLUTCH Exploded View...

  • Page 294

    CLUTCH 6-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Clutch Lever Clamp Bolts 0.80 69 in·lb Clutch Cover Mounting Bolts 89 in·lb Oil Filler Plug – – – Hand-tighten Clutch Spring Bolts 87 in·lb Clutch Hub Nut 13.3 Sub Clutch Hub Bolts CL: Apply cable lubricant.

  • Page 295

    6-4 CLUTCH Specifications Item Standard Service Limit Clutch Lever Free Play 3 mm (0.08 0.12 in.) – – – Clutch Spring Plate Free Play (Usable Range) 0.05 0.70 mm (0.002 0.028 in.) – – – Clutch Plate Assembly Length (Reference) 53.5 mm (2.11 in.) –...

  • Page 296

    CLUTCH 6-5 Special Tool and Sealant Clutch Holder: Kawasaki Bond (Silicone Sealant): 57001-1243 92104-0004...

  • Page 297

    6-6 CLUTCH Clutch Lever and Cable Clutch Lever Free Play Inspection • Refer to the Clutch Adjustment Inspection in the Periodic Maintenance chapter (see Clutch Adjustment Inspection in the Periodic Maintenance chapter). Clutch Lever Free Play Adjustment • Refer to the Clutch Adjustment Inspection in the Periodic Maintenance chapter (see Clutch Adjustment Inspection in the Periodic Maintenance chapter).

  • Page 298

    Clutch Cover Installation • Apply silicone sealant to the area [A] where the mating surface of the crankcase touches the clutch cover gasket. Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004 • Install the dowel pins [B]. • Replace the clutch cover gasket with a new one.

  • Page 299

    6-8 CLUTCH Clutch Cover Release Shaft Installation • Apply high-temperature grease to the oil seal lips on the upper ridge of the clutch cover. • Apply oil to the needle bearings in the hole of the clutch cover. • Apply molybdenum disulfide grease to the pusher-holding portion [A] on the release shaft.

  • Page 300

    CLUTCH 6-9 Clutch Cover Clutch Cover Assembly • Replace the needle bearings and oil seal with new ones. NOTE ○ Install the needle bearings so that the manufacture’s make face out. • Install the needle bearings [A] and oil seal [B] position as shown.

  • Page 301

    6-10 CLUTCH Clutch Clutch Removal • Remove: Clutch Cover (see Clutch Cover Removal) Clutch Spring Bolts [A] Clutch Springs (with Clutch Spring Holders) Clutch Spring Plate [B] (with Bearing ) Pusher [C] • Remove: Friction Plates (10) [A] Steel Plates (9) [B] Spring [C] Spring Seat [D] •...

  • Page 302

    CLUTCH 6-11 Clutch • Remove: Torque Limiter Springs [A] Sub Clutch Hub [B] Clutch Hub [C] Spacer [D] ○ Remove the sub clutch hub bolts [E] as necessary. • Using the two 4 mm (0.16 in.) screws [A], pull out the sleeve [B], needle bearing [C] and clutch housing [D].

  • Page 303

    6-12 CLUTCH Clutch Clutch Installation • Install the spacer [A] so that the circle mark [B] faces out- ward. • Engage the clutch housing gear [A] and oil pump drive gear [B] with the crankshaft primary gear [C] and oil pump gear [D].

  • Page 304

    CLUTCH 6-13 Clutch ○ Second Torque Limiter Spring Tang [B] ○ Third Torque Limiter Spring Tang [B] ○ Fourth Torque Limiter Spring Tang [B] • Replace the clutch hub nut [A] with a new one. • Hold the sub clutch hub [B] steady with the clutch holder [C], and tighten the clutch hub nut.

  • Page 305

    6-14 CLUTCH Clutch • Install the following as shown. Friction Plates (9) [A] Steel Plates (9) [B] Spring Seat [C] Spring [D] ○ Install the spring seat and spring between first steel plate and second steel plate. CAUTION If new dry friction plates and steel plates are in- stalled, apply engine oil to the surface of each plate to avoid clutch plate seizure.

  • Page 306

    CLUTCH 6-15 Clutch Spring Plate Free Play Measurement Insufficient clutch free play will cause the engine braking effect to be more sudden, resulting in rear wheel hop. On the other hand, if the free play is excessive, the clutch lever may feel “spongy”...

  • Page 307

    6-16 CLUTCH Clutch Spring Plate Free Play Adjustment NOTE ○ The free play adjustment is performed by replacing the steel plate(s). • Measure the clutch spring plate free play (see Clutch Spring Plate Free Play Measurement), and then replace the steel plate(s) which brings the free play within the usable range.

  • Page 308

    CLUTCH 6-17 Clutch Clutch Plate Warp Inspection • Place each friction plate or steel plate on a surface plate and measure the gap between the surface plate [A] and each friction plate or steel plate [B] with a thickness gauge [C].

  • Page 310

    ENGINE LUBRICATION SYSTEM 7-1 Engine Lubrication System Table of Contents Exploded View........................Engine Oil Flow Chart......................Specifications ......................... Special Tools and Sealant ...................... Engine Oil and Oil Filter......................Oil Level Inspection......................Engine Oil Change......................Oil Filter Replacement ...................... Oil Pan............................ Oil Pan Removal .......................

  • Page 311

    7-2 ENGINE LUBRICATION SYSTEM Exploded View...

  • Page 312

    G: Apply grease. L: Apply a non-permanent locking agent. MO: Apply molybdenum disulfide oil solution. (mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 : 1) R: Replacement Parts SS: Apply silicone sealant (Kawasaki Bond: 92104-0004).

  • Page 313

    7-4 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart...

  • Page 314

    ENGINE LUBRICATION SYSTEM 7-5 Engine Oil Flow Chart 1. Inlet Camshaft 2. Exhaust Camshaft 3. Oil Cooler 4. Oil Filter 5. Oil Pressure Switch 6. Main Oil Passage 7. Relief Valve 8. Oil Pump 9. Oil Screen 10. Camshaft Oil Passage 11.

  • Page 315

    7-6 ENGINE LUBRICATION SYSTEM Specifications Item Standard Engine Oil Type API SE, SF or SG API SH, SJ or SL with JASO MA Viscosity SAE 10W-40 Capacity 3.2 L (3.4 US gt) (when filter is not removed) 3.7 L (3.9 US gt) (when filter is removed) 4.0 L (4.2 US gt) (when engine is completely dry) Level Between upper and lower level lines...

  • Page 316

    ENGINE LUBRICATION SYSTEM 7-7 Special Tools and Sealant Oil Pressure Gauge, 10 kgf/cm²: Gear Holder: 57001-164 57001-1599 Oil Pressure Gauge Adapter, PT3/8: Kawasaki Bond (Silicone Sealant): 57001-1233 92104-0004 Oil Filter Wrench: 57001-1249...

  • Page 317

    7-8 ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter WARNING Motorcycle operation with insufficient, deteri- orated, or contaminated engine oil will cause accelerated wear and may result in engine or trans- mission seizure, accident, and injury. Oil Level Inspection • Check that the engine oil level is between the upper [A] and lower [B] levels in the gauge.

  • Page 318

    ENGINE LUBRICATION SYSTEM 7-9 Oil Pan Oil Pan Removal • Drain the engine oil (see Engine Oil Change in the Peri- odic Maintenance chapter). • Remove: Front Exhaust Pipe (see Front Exhaust Pipe Removal in the Engine Top End chapter) Oil Pan Bolts [A] Clamps [B] Oil Pan [C]...

  • Page 319

    7-10 ENGINE LUBRICATION SYSTEM Oil Pressure Relief Valve Oil Pressure Relief Valve Removal • Remove: Oil Pan (see Oil Pan Removal) Oil Screen [A] • Remove the oil pressure relief valve [A]. Oil Pressure Relief Valve Installation • Apply a non-permanent locking agent to the threads of the oil pressure relief valve [A], and tighten it.

  • Page 320

    ENGINE LUBRICATION SYSTEM 7-11 Oil Pressure Relief Valve Oil Pressure Relief Valve Inspection • Remove the oil pressure relief valve (see Oil Pressure Relief Valve Removal). • Check to see if the valve [A] slides smoothly when push- ing it in with a wooden or other soft rod, and see if it comes back to its seat by spring [B] pressure.

  • Page 321

    7-12 ENGINE LUBRICATION SYSTEM Oil Pump Oil Pump Removal • Remove: Oil Pump Gear (see Oil Pump Gear Removal) Oil Pump Cover Bolts [A] • Remove the oil pump cover [A] with oil pump gear shaft [B]. ○ Stuff the cloth [C] on the hole of the crankcase so that pin [D] close not drop into the crankcase bottom.

  • Page 322

    ENGINE LUBRICATION SYSTEM 7-13 Oil Pump • Install the outer rotor [A] on the inner rotor. ○ Apply engine oil to the outer rotor. • Install the dowel pin [B]. • Fit the pin of the oil pump cover into the hole [C] in the crankcase.

  • Page 323

    7-14 ENGINE LUBRICATION SYSTEM Oil Pump • Apply a non-permanent locking agent to the threads of the oil pump gear bolts [A]. • Hold the oil pump gear [B] steady with the gear holder [C], and tighten the bolts. Special Tool - Gear Holder: 57001-1599 Torque - Oil Pump Gear Bolts: 10 N·m (1.0 kgf·m, 89 in·lb) •...

  • Page 324

    ENGINE LUBRICATION SYSTEM 7-15 Oil Cooler Oil Cooler Removal • Drain: Coolant (see Coolant Change in the Periodic Mainte- nance chapter) Engine Oil (see Engine Oil Change in the Periodic Main- tenance chapter) • Remove: Water Hoses [A] Oil Cooler Mounting Bolts [B] Oil Cooler [C] Oil Cooler Installation •...

  • Page 325

    7-16 ENGINE LUBRICATION SYSTEM Oil Cooler Oil Cooler/Oil Filter Case Installation • Replace the O-ring [A] with a new one. • Apply grease to the new O-ring. If the oil filter pipe [B] was removed, install it. ○ Apply a non-permanent locking agent to the threads of the oil filter pipe, and tighten it.

  • Page 326

    ENGINE LUBRICATION SYSTEM 7-17 Oil Pressure Measurement Oil Pressure Measurement • Remove: Lower Fairings (see Lower Fairing Removal in the Frame chapter) Oil Passage Plug [A] • Attach the adapter [A] and gauge [B] to the plug hole. Special Tools - Oil Pressure Gauge, 10 kgf/cm²: 57001-164 Oil Pressure Gauge Adapter, PT3/8: 57001 -1233 •...

  • Page 327

    • Apply silicone sealant to the threads of the oil pressure switch [A] and tighten it. Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004 Torque - Oil Pressure Switch: 15 N·m (1.5 kgf·m, 11 ft·lb) • Install the switch lead [B] direction downward.

  • Page 328

    ENGINE REMOVAL/INSTALLATION 8-1 Engine Removal/Installation Table of Contents Exploded View........................Special Tool ..........................Engine Removal/Installation ....................Engine Removal........................ Engine Installation .......................

  • Page 329

    8-2 ENGINE REMOVAL/INSTALLATION Exploded View...

  • Page 330

    ENGINE REMOVAL/INSTALLATION 8-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Adjusting Collar Locknut Lef Front Engine Mounting Bolt (M10, L = 42) Right Front Engine Mounting Bolt (M10, L = 67) Middle Engine Mounting Bolt 87 in·lb Middle Engine Mounting Nut Lower Engine Mounting Bolt 87 in·lb Lower Engine Mounting Nut...

  • Page 331

    8-4 ENGINE REMOVAL/INSTALLATION Special Tool Engine Mount Nut Wrench: 57001-1450...

  • Page 332

    ENGINE REMOVAL/INSTALLATION 8-5 Engine Removal/Installation Engine Removal • Support the rear part of the swingarm with a stand. • Squeeze the brake lever slowly and hold it with a band [A]. WARNING Be sure to hold the front brake when removing the engine, or the motorcycle may fall over.

  • Page 333

    8-6 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Disconnect the sidestand switch lead connector [A]. • Remove: Gear Position Switch Lead Connector [A] Alternator Lead Connector [B] • Remove: Engine Ground Cable Terminal Bolt [A] Starter Motor Cable [B] • Support the engine with a suitable stand [A]. ○...

  • Page 334

    ENGINE REMOVAL/INSTALLATION 8-7 Engine Removal/Installation • Remove: Left Engine Bracket Bolts [A] Left Engine Bracket [B] • Remove: Right Upper Inner Fairing Bracket Bolts [A] Right Upper Inner Fairing Bracket [B] • Remove: Right Engine Bracket Bolts [A] Right Engine Bracket [B] •...

  • Page 335

    8-8 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Using the nut wrench [A], loosen the locknut [B]. Special Tool - Engine Mount Nut Wrench: 57001-1450 • Using the Hexagon Wrench, turn the adjusting collar [A] counterclockwise to make the gap between the engine and adjusting collar.

  • Page 336

    ENGINE REMOVAL/INSTALLATION 8-9 Engine Removal/Installation A: White Mark K: Crankshaft Sensor Lead B: To Radiator L: Through the water hose under the heat insu- C: To Right Engine Bracket (Cylinder Head lation rubber plate Side) M: Through the starter motor cable under the D: Through the left engine bracket bolt.

  • Page 337

    8-10 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Install the engine mounting bolts and nuts, following the specified installing sequence. ○ Apply molybdenum disulfide grease to the threads of the adjusting collars [A]. ○ Apply 2-stroke oil to the threads of the adjusting collar [B]. ○...

  • Page 338

    ENGINE REMOVAL/INSTALLATION 8-11 Engine Removal/Installation ○ Fifth, tighten the middle engine mounting nut [H], and then lower engine mounting nut [I]. Torque - Middle Engine Mounting Nut: 44 N·m (4.5 kgf·m, 32 ft·lb) Lower Engine Mounting Nut: 44 N·m (4.5 kgf·m, 32 ft·lb) ○...

  • Page 339

    8-12 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Install the left [A] and right [B] engine bracket, following the specified installing sequence. ○ First, install the adjusting collar [C] to the right engine bracket [B]. ○ Second, install the bolts [D] [E] [F] [G] temporally as shown sequence [1 8] in the figure.

  • Page 340

    ENGINE REMOVAL/INSTALLATION 8-13 Engine Removal/Installation • Install the left and right upper inner fairing brackets. • Run the leads, cable and hoses correctly (see Cable, Wire and Hose Routing section in Appendix chapter). • Install the removed parts (see appropriate chapters). •...

  • Page 342

    CRANKSHAFT/TRANSMISSION 9-1 Crankshaft/Transmission Table of Contents Exploded View........................Specifications ......................... Special Tools and Sealants ....................Crankcase Splitting......................... 9-10 Crankcase Splitting ......................9-10 Crankcase Assembly ......................9-11 Crankshaft and Connecting Rods................... 9-16 Crankshaft Removal ......................9-16 Crankshaft Installation ...................... 9-16 Connecting Rod Removal ....................9-16 Connecting Rod Installation ....................

  • Page 343

    9-2 CRANKSHAFT/TRANSMISSION Exploded View...

  • Page 344

    G: Apply grease. HG: Apply high-temperature grease. L: Apply a non-permanent locking agent. LG: Apply liquid gasket (Kawasaki Bond: 92104-1064). MO: Apply molybdenum disulfide oil solution. (mixture of engine oil and molybdenum disulfide grease in a weight ratio is 10 : 1) R: Replacement Parts S: Follow the specified tightening sequence.

  • Page 345

    9-4 CRANKSHAFT/TRANSMISSION Exploded View...

  • Page 346

    CRANKSHAFT/TRANSMISSION 9-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Shift Pedal Mounting Bolt Gear Position Lever Bolt 106 in·lb Shift Shaft Return Spring Pin Shift Drum Cam Holder Bolt 106 in·lb Shift Lever Bolt 0.71 62 in·lb Tie-Rod Locknuts 0.71 62 in·lb Gear Position Switch Screws...

  • Page 347

    9-6 CRANKSHAFT/TRANSMISSION Specifications Item Standard Service Limit Crankcase, Crankshaft, Connecting Rods Connecting Rod Bend – – – TIR 0.2/100 mm (0.008/3.94 in.) Connecting Rod Twist – – – TIR 0.2/100 mm (0.008/3.94 in.) Connecting Rod Big End Side 0.13 0.38 mm (0.0051 0.0150 in.) 0.58 mm Clearance...

  • Page 348

    CRANKSHAFT/TRANSMISSION 9-7 Specifications Item Standard Service Limit Crankshaft Main Bearing Insert Thickness: Brown 1.491 1.495 mm (0.0587 0.0589 in.) – – – Black 1.495 1.499 mm (0.0589 0.0590 in.) – – – Blue 1.499 1.503 mm (0.0590 0.0592 in.) – – – Pistons Cylinder (Upper Crankcase) Inside 75.990 76.006 mm (2.9917 2.9924 in.)

  • Page 349

    9-8 CRANKSHAFT/TRANSMISSION Specifications Connecting Rod Big End Bearing Insert Selection Bearing Insert Con-rod Big End Bore Crankpin Diameter Diameter Marking Marking Size Color Part Number ○ None Brown 92139-0028 None None Black 92139-0027 ○ ○ ○ None Blue 92139-0026 Crankshaft Main Bearing Insert Selection Crankcase Main Crankshaft Main Bearing Insert...

  • Page 350

    CRANKSHAFT/TRANSMISSION 9-9 Special Tools and Sealants Bearing Puller: Piston Pin Puller Assembly: 57001-135 57001-910 Outside Circlip Pliers: Piston Ring Compressor Grip: 57001-144 57001-1095 Bearing Puller Adapter: Piston Ring Compressor Belt, 67 57001-317 57001-1097 Bearing Driver, Kawasaki Bond: 57001-382 92104-1064...

  • Page 351

    9-10 CRANKSHAFT/TRANSMISSION Crankcase Splitting Crankcase Splitting • Remove the engine (see Engine Removal in the Engine Removal/Installation chapter). • Set the engine on a clean surface and hold the engine steady while parts are being removed. • Remove: Crankshaft Sensor (see Crankshaft Sensor Removal in the Electrical System chapter) Starter Clutch (see Starter Clutch Removal in the Elec- trical System chapter)

  • Page 352

    CRANKSHAFT/TRANSMISSION 9-11 Crankcase Splitting • Remove the lower crankcase bolts, following the specified sequence. ○ First, loosen the M6 bolts [A]. ○ Second, loosen the M7 bolts [B]. ○ Lastly, loosen the M9 bolts as shown sequence [1 10] in the figure. •...

  • Page 353

    9-12 CRANKSHAFT/TRANSMISSION Crankcase Splitting • Apply a non-permanent locking agent to the treads of the breather plate bolts [A] and tighten it. Torque - Breather Plate Bolts: 10 N·m (1.0 kgf·m, 89 in·lb) • Install the following in the upper crankcase. Output Shaft [A] (see Transmission Shaft Installation) Crankshaft [B] (see Crankshaft Installation) Pistons and Connecting Rods [C] (see Connecting Rod...

  • Page 354

    CRANKSHAFT/TRANSMISSION 9-13 Crankcase Splitting • Apply liquid gasket [A] to the mating surface of the lower crankcase half. Sealant - Kawasaki Bond: 92104-1064 NOTE ○ Especially, apply a sealant so that it shall be filled up on the grooves. CAUTION Do not apply liquid gasket around the crankshaft main bearing inserts, and oil passage hole.

  • Page 355

    9-14 CRANKSHAFT/TRANSMISSION Crankcase Splitting • Tighten the lower crankcase bolts using the following steps. ○ Following the sequence numbers on the lower crankcase half, M9 bolts [1 10] with copper plated washers. Torque - Crankcase Bolts (M9): 39 N·m (4.0 kgf·m, 29 ft·lb) ○...

  • Page 356

    CRANKSHAFT/TRANSMISSION 9-15 Crankcase Splitting • Tighten the upper crankcase bolts using the following steps. ○ The M8 bolts [A] has a washer, replace it with a new one. ○ Tighten the M8 bolts with washers. Torque - Crankcase Bolts (M8): 27 N·m (2.8 kgf·m, 20 ft·lb) ○...

  • Page 357

    9-16 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods Crankshaft Removal • Refer to the Connecting Rod Removal (see Connecting Rod Removal). Crankshaft Installation NOTE ○ If the crankshaft is replaced with a new one, refer to the Connecting Rod Big End Bearing/Crankshaft Main Bearing Insert Selection in the Specifications.

  • Page 358

    CRANKSHAFT/TRANSMISSION 9-17 Crankshaft and Connecting Rods Connecting Rod Installation CAUTION To minimize vibration, the connecting rods should have the same weight mark. Big End Cap [A] Connecting Rod [B] Weight Mark, Alphabet [C] ○ Diameter Mark [D]: “ ” or no mark CAUTION If the connecting rods, big end bearing inserts, or crankshaft are replaced with new ones, select the...

  • Page 359

    9-18 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods CAUTION The connecting rod bolts are designed to stretch when tightened. Never reuse the connecting rod bolts. See the table below for correct bolt and nut usage. CAUTION Be careful not to overtighten the nuts. The bolts must be positioned on the seating surface correctly to prevent the bolt heads from hitting the crankcase.

  • Page 360

    CRANKSHAFT/TRANSMISSION 9-19 Crankshaft and Connecting Rods • Install new bolts in reused connecting rods. • Dent both bolt head and bolt tip with a punch as shown. • Before tightening, use a point micrometer to measure the length of new connecting rod bolts and record the values to find the bolt stretch.

  • Page 361

    9-20 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods • Install new bolts in reused connecting rods. • Apply a small amount of molybdenum disulfide oil solution to the following. Threads [A] of Nuts and Bolts Seating Surfaces [B] of Nuts and Connecting Rods •...

  • Page 362

    CRANKSHAFT/TRANSMISSION 9-21 Crankshaft and Connecting Rods Connecting Rod Twist • With the big-end arbor [A] still on V block [C], hold the connecting rod horizontally and measure the amount that the arbor [B] varies from being paralleled with the surface plate over a 100 mm (3.94 in.) length of the arbor to de- termine the amount of connecting rod twist.

  • Page 363

    9-22 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods If the clearance is within the standard, no bearing replace- ment is required. If the clearance is between 0.061 mm (0.0024 in.) and the service limit (0.10 mm, 0.0039 in.), replace the bear- ing inserts [A] with inserts painted blue [B]. Check in- sert/crankpin clearance with the plastigage.

  • Page 364

    CRANKSHAFT/TRANSMISSION 9-23 Crankshaft and Connecting Rods Connecting Rod Big End Inside Diameter Marks None 37.500 37.508 mm (1.4764 1.4766 in.) ○ 37.509 37.516 mm (1.4767 1.4770 in.) Big End Cap [A] Connecting Rod [B] Weight Mark, Alphabet [C] ○ Diameter Mark (Around Weight Mark) [D]: “ ”...

  • Page 365

    9-24 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods Crankshaft Main Bearing Insert/Journal Wear • Using a plastigage (press gauge) [A], measure the bear- ing insert/journal [B] clearance. NOTE ○ Tighten the crankcase bolts to the specified torque (see Crankcase Assembly). ○ Do not turn the crankshaft during clearance measure- ment.

  • Page 366

    CRANKSHAFT/TRANSMISSION 9-25 Crankshaft and Connecting Rods • Measure the main bearing inside diameter, and mark the upper crankcase half in accordance with the inside diam- eter. ○ A: Crankcase Main Bearing Inside Diameter Marks, “ ” mark or no mark. •...

  • Page 367

    9-26 CRANKSHAFT/TRANSMISSION Pistons Piston Removal • Split the crankcase (see Crankcase Splitting). • Remove the connecting rod nuts [A] and big end caps [B]. NOTE ○ Mark and record the locations of the connecting rods and their big end caps so that they can be reassembled in their original positions.

  • Page 368

    CRANKSHAFT/TRANSMISSION 9-27 Pistons Piston Installation • Apply molybdenum disulfide oil solution to the oil ring ex- pander, and install the oil ring expander [A] in the bottom piston ring groove so the ends [B] butt together. • Apply molybdenum disulfide oil solution to the oil ring steel rails, and install the oil ring steel rails, one above the ex- pander and one below it.

  • Page 369

    9-28 CRANKSHAFT/TRANSMISSION Pistons • Apply molybdenum disulfide oil solution to the cylinder bore and piston skirt. • Install the piston with its marking hollow [A] facing exhaust side. • Using the piston ring compressor assembly [B] to install the piston from the cylinder head side. Special Tools - Piston Ring Compressor Grip: 57001-1095 Piston Ring Compressor Belt, 57001-1097...

  • Page 370

    CRANKSHAFT/TRANSMISSION 9-29 Pistons Piston Ring Groove Width • Measure the piston ring groove width. ○ Use a vernier caliper at several points around the piston. Piston Ring Groove Width Standard: Top [A] 0.82 0.84 mm (0.0323 0.0331 in.) Second [B] 0.82 0.84 mm (0.0323 0.0331 in.) Service Limit:...

  • Page 371

    9-30 CRANKSHAFT/TRANSMISSION Transmission Shift Pedal Removal • Mark [A] the position of the shift lever [B] on the shift shaft so that it can be installed later in the same position. • Remove: Left Lower Fairing (see Lower Fairing Removal in the Frame chapter) Shift Lever Bolt [C] Shift Lever...

  • Page 372

    CRANKSHAFT/TRANSMISSION 9-31 Transmission • Remove: Gear Positioning Lever Bolt [A] Gear Positioning Lever [B] Washer and Spring External Shift Mechanism Installation • Install the gear positioning lever [A] as shown. Spring [B] Washer [C] Bolt [D] • Tighten: Torque - Gear Positioning Lever Bolt: 12 N·m (1.2 kgf·m, 106 in·lb) External Shift Mechanism Inspection •...

  • Page 373

    9-32 CRANKSHAFT/TRANSMISSION Transmission Transmission Shaft Removal • Split the crankcase (see Crankcase Splitting). • Remove the output shaft [A]. • Discard the oil seal [B] • Remove: Water Pump (see Water Pump Removal in the Cooling System chapter) Shift Forks (see Shift Drum and Shift Forks Removal) Bolts [A] Drive Shaft Cover [B] •...

  • Page 374

    CRANKSHAFT/TRANSMISSION 9-33 Transmission • Assemble the crankcase (see Crankcase Assembly). • Press in the new oil seal [A] onto collar [B] so that the surface of the oil seal is flush with the counterbore bottom surface [C] of the crankcase. ○...

  • Page 375

    9-34 CRANKSHAFT/TRANSMISSION Transmission • Apply engine oil to the bushings, ball bearings and shafts. • Install the gear bushings [A] on the shaft with their holes [B] aligned. • Replace any circlips removed with new ones. • Install the circlips [A] so that the opening [B] of it is aligned with spline grooves [C].

  • Page 376

    CRANKSHAFT/TRANSMISSION 9-35 Transmission • Fit the steel balls into the 5th gear holes in the output shaft, aligning three oil holes [D]. 5th Gear [A] Output Shaft [B] Steel Balls [C] CAUTION Do not apply grease to the balls to hold them in place.

  • Page 377

    9-36 CRANKSHAFT/TRANSMISSION Transmission 1. Output Shaft 13. Bushing 2. Collar 14. Thrust Washer, 34 mm (1.34 in.) 3. Ball Bearing 15. Snap Ring 4. 2nd Gear 16. Bushing 5. 6th (Top) Gear 17. Toothed Washer, 34 mm (1.34 in.) 6. 4th Gear 18.

  • Page 378

    CRANKSHAFT/TRANSMISSION 9-37 Transmission Shift Drum and Fork Removal • Split the crankcase (see Crankcase Splitting). • Remove: Gear Position Switch (see Gear Position Switch Re- moval in the Electrical System chapter) Bolt [A] Shift Fork Holder [B] Screws [C] Shift Drum Bearing Holder [D] •...

  • Page 379

    9-38 CRANKSHAFT/TRANSMISSION Transmission Shift Fork Bending • Visually inspect the shift forks, and replace any fork that is bent. A bent fork could cause difficulty in shifting, or allow the transmission to jump out of gear when under power. 90° [A] Shift Fork/Gear Groove Wear •...

  • Page 380

    WHEELS/TIRES 10-1 Wheels/Tires Table of Contents Exploded View........................10-2 Specifications ......................... 10-4 Special Tools .......................... 10-5 Wheels (Rims) ........................10-6 Front Wheel Removal ....................... 10-6 Front Wheel Installation ....................10-6 Rear Wheel Removal......................10-8 Rear Wheel Installation..................... 10-8 Wheel Inspection ......................10-10 Axle Inspection........................

  • Page 381

    10-2 WHEELS/TIRES Exploded View...

  • Page 382

    WHEELS/TIRES 10-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Axle Clamp Bolts Front Axle Nut 13.0 Rear Axle Nut 11.0 AL: Tighten the two clamp bolts alternately two times to ensure even tightening. G: Apply grease. HG: Apply high-temperature grease. R: Replacement Parts WL: Apply soap and water solution or rubber lubricant.

  • Page 383

    10-4 WHEELS/TIRES Specifications Item Standard Service Limit Wheels (Rims) Rim Runout: Axial TIR 0.5 mm (0.02 in.) or less TIR 1.0 mm (0.04 in.) Radial TIR 0.8 mm (0.03 in.) or less TIR 1.0 mm (0.04 in.) Axle Runout/100 mm TIR 0.03 mm (0.0012 in.) or less TIR 0.2 mm (0.01 in.) Wheel Balance...

  • Page 384

    WHEELS/TIRES 10-5 Special Tools Bearing Driver Set: Bearing Remover Shaft, 13: 57001-1129 57001-1377 Jack: Jack Attachment: 57001-1238 57001-1608 Bearing Remover Head, 20 × 22: 57001-1293...

  • Page 385

    10-6 WHEELS/TIRES Wheels (Rims) Front Wheel Removal • Remove: Brake Caliper Mounting Bolts [A] Front Brake Calipers [B] (Left and Right) • Loosen: Left Side Axle Clamp Bolts [A] Axle Nut [B] Right Side Axle Clamp Bolts • Remove the lower fairings (see Lower Fairing Removal in the Frame chapter).

  • Page 386

    WHEELS/TIRES 10-7 Wheels (Rims) • Apply high-temperature grease to the grease seal lips. • Fit the collars [A] on the both sides of the hub. ○ The collars are identical. • Insert the axle. • Tighten the axle nut [B]. Right Axle Clamp Bolts [C] Left Axle Clamp Bolts [D] 4.1 mm (0.028...

  • Page 387

    10-8 WHEELS/TIRES Wheels (Rims) Rear Wheel Removal • Raise the rear wheel off the ground with the stand [A]. • Remove: Rear Caliper Mounting Bolts [A] Rear Caliper [B] • Remove: Cotter Pin [A] Axle Nut [B] Axle [C] (from Right Side) •...

  • Page 388

    WHEELS/TIRES 10-9 Wheels (Rims) ○ If the coupling [A] is removed from the rear wheel, apply the grease [B] as shown. Wheel Flange Portion [C] O-ring [D] • Engage the drive chain with the rear sprocket. • Install the caliper bracket [A] onto the swingarm stop [B]. ○...

  • Page 389

    10-10 WHEELS/TIRES Wheels (Rims) Wheel Inspection • Raise the front/rear wheel off the ground. Special Tools - Jack: 57001-1238 Jack Attachment: 57001-1608 • Spin the wheel lightly, and check for roughness or binding. If roughness or binding is found, replace the hub bearings. •...

  • Page 390

    WHEELS/TIRES 10-11 Wheels (Rims) Balance Inspection • Remove the wheel (see wheels (Rims) section). • Support the wheel so that it can be spun freely. • Spin the wheel lightly, and mark [A] the wheel at the top when the wheel stops. ○...

  • Page 391

    30 g (1.06 oz.) NOTE ○ Balance weights are available from Kawasaki dealers in 10, 20, and 30 gram (0.35 oz., 0.71 oz., and 1.06 oz.) sizes. An imbalance of less than 10 grams (0.35 oz.) will not usually affect running stability.

  • Page 392

    WHEELS/TIRES 10-13 Tires Air Pressure Inspection/Adjustment • Refer to the Tires Air Pressure Inspection in the Periodic Maintenance chapter (see Tires Air Pressure Inspection in the Periodic Maintenance chapter). Tire Inspection • Refer to the Wheels/Tires Damage Inspection in the Pe- riodic Maintenance chapter (see Wheels/Tires Damage Inspection in the Periodic Maintenance chapter).

  • Page 393

    10-14 WHEELS/TIRES Tires • Install a new valve in the rim. ○ Remove the valve cap, lubricate the stem seal [A] with a soap and water solution or rubber lubricant, and pull [B] the valve stem through the rim from the inside out until it snaps into place.

  • Page 394

    Also, permanent (internal) repairs have the advantage of permitting a thorough examination for secondary damage not visible from external inspection of the tire. For these reasons, Kawasaki does not recommend temporary (exter- nal) repair. Only appropriate permanent (internal) repairs are recommended. Repair methods may vary slightly from make to make.

  • Page 395

    10-16 WHEELS/TIRES Hub Bearing Hub Bearing Removal • Remove the wheel, and take out the following. Collars Coupling (out of rear hub) Grease Seals • Use the bearing remover to remove the hub bearing [A]. CAUTION Do not lay the wheel on the ground with the disc facing down.

  • Page 396

    WHEELS/TIRES 10-17 Hub Bearing Hub Bearing Lubrication NOTE ○ Since the hub bearings are packed with grease and sealed, lubrication is not required.

  • Page 398

    FINAL DRIVE 11-1 Final Drive Table of Contents Exploded View ........................11-2 Specifications ........................11-4 Special Tools .......................... 11-5 Drive Chain..........................11-6 Drive Chain Slack Inspection .................... 11-6 Drive Chain Slack Adjustment ..................11-6 Wheel Alignment Inspection/Adjustment ................11-6 Drive Chain Wear Inspection .................... 11-6 Drive Chain Lubrication.....................

  • Page 399

    11-2 FINAL DRIVE Exploded View...

  • Page 400

    FINAL DRIVE 11-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Rear Axle Nut 11.0 Rear Sprocket Nuts Engine Sprocket Nut 12.7 Engine Sprocket Cover Bolts 89 in·lb G: Apply grease. HG: Apply high-temperature grease. HO: Apply heavy oil. L: Apply a non-permanent locking agent. MO: Apply molybdenum disulfide oil solution.

  • Page 401

    11-4 FINAL DRIVE Specifications Item Standard Service Limit Drive Chain Drive Chain Slack 35 mm (1.2 1.4 in.) – – – Drive Chain Wear (20-link Length) 317.5 318.2 mm (12.50 12.53 in.) 323 mm (12.7 in.) Standard Chain Make RK EXCEL –...

  • Page 402

    FINAL DRIVE 11-5 Special Tools Inside Circlip Pliers: Bearing Driver Set: 57001-143 57001-1129...

  • Page 403

    11-6 FINAL DRIVE Drive Chain Drive Chain Slack Inspection • Refer to the Drive Chain Slack Inspection in the Periodic Maintenance chapter (see Drive Chain Slack Inspection in the Periodic Maintenance chapter). Drive Chain Slack Adjustment • Refer to the Drive Chain Slack Inspection in the Periodic Maintenance chapter (see Drive Chain Slack Inspection in the Periodic Maintenance chapter).

  • Page 404

    FINAL DRIVE 11-7 Drive Chain • Using a suitable tool [A], cut the drive chain by removing the link pins. Recommended Tool: RK EXCEL 70 Tool (RK-700) CAUTION Read the Tool Manual before removing. Pressure Bolt (A) [A] Pressure Bolt (B) [B] Handle Lever [C] Pressure Holder [D] Guide Plate [E]...

  • Page 405

    11-8 FINAL DRIVE Drive Chain ○ Screw in the pressure bolt assy [A] in the pressure bolt (A) [B]. ○ Install the handle lever [C] to the pressure bolt assy. ○ Turn in the handle lever until the link pin [D] removed at the link plate [E].

  • Page 406

    FINAL DRIVE 11-9 Drive Chain ○ Install the link plate so that the gold painted [A] faces out. ○ Fit the link plate [A] in the pressure holder [B]. ○ Fit the link plates of the chain into the wedge holder and wedge pin [D].

  • Page 407

    11-10 FINAL DRIVE Drive Chain • After staking, measure the outside diameter [A] of the link pin and link plates width [B]. Link Pin Outside Diameter Standard: 5.60 5.90 mm (0.22 0.23 in.) Link Plates Outside Width Standard: 19.70 20.00 mm (0.775 0.787 in.) If the reading exceeds the specified length, cut and rejoin the chain again.

  • Page 408

    FINAL DRIVE 11-11 Sprocket, Coupling Engine Sprocket Removal • Remove: Lower Fairings (see Lower Fairing Removal in the Frame chapter) Shift Lever Bolt [A] • Pull the shift lever [B]. • Remove: Engine Sprocket Cover Bolts [A] Engine Sprocket Cover [B] •...

  • Page 409

    11-12 FINAL DRIVE Sprocket, Coupling • Install the guide [A] into the sprocket cover [B] so that the hook [C] of the guide fits into the receiver [D]. • Install the engine sprocket cover [A] with the guide [B]. ○ Install the pins [C] into the holes [D].

  • Page 410

    FINAL DRIVE 11-13 Sprocket, Coupling Coupling Installation • Grease the following and install the coupling. Coupling Grease Seal Lips [A] Coupling Internal Surface [B] • Apply grease to the O-ring [A]. • Install the collar [B]. Coupling Bearing Removal • Remove: Coupling Grease Seal...

  • Page 411

    11-14 FINAL DRIVE Sprocket, Coupling • Replace the grease seal with a new one. • Press in the grease seal so that the seal surface is flush with the end of the hole. ○ Apply high-temperature grease to the grease seal lips. Special Tool - Bearing Driver Set: 57001-1129 Coupling Bearing Inspection Since the coupling bearing is made to extremely close...

  • Page 412

    FINAL DRIVE 11-15 Sprocket, Coupling Rear Sprocket Warp Inspection • Raise the rear wheel off the ground (see Rear Wheel Removal in the Wheels/Tires chapter) so that it will turn freely. • Set a dial gauge [A] against the rear sprocket [B] near the teeth as shown, and rotate [C] the rear wheel to measure the sprocket runout (warp).

  • Page 414

    BRAKES 12-1 Brakes Table of Contents Exploded View ........................12-2 Specifications ........................12-6 Special Tools .......................... 12-7 Brake Lever, Brake Pedal....................... 12-8 Brake Lever Position Adjustment..................12-8 Brake Pedal Position Inspection ..................12-8 Brake Pedal Position Adjustment ..................12-8 Brake Pedal Removal ....................... 12-8 Brake Pedal Installation ....................

  • Page 415

    12-2 BRAKES Exploded View...

  • Page 416

    BRAKES 12-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Bleed Valves 0.80 69 in·lb Brake Hose Banjo Bolts Brake Lever Pivot Bolt 0.10 9 in·lb Brake Lever Pivot Bolt Nut 0.60 52 in·lb Front Brake Disc Mounting Bolts Front Brake Light Switch Screw 0.12 11 in·lb Front Brake Pad Pins...

  • Page 417

    12-4 BRAKES Exploded View...

  • Page 418

    BRAKES 12-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Bleed Valve 0.80 69 in·lb Brake Hose Banjo Bolts Brake Pedal Bolt 0.90 78 in·lb Rear Brake Disc Mounting Bolts Rear Caliper Mounting Bolts Rear Master Cylinder Mounting Bolts Rear Master Cylinder Push Rod Locknut B: Apply brake fluid.

  • Page 419

    12-6 BRAKES Specifications Item Standard Service Limit Brake Lever, Brake Pedal Brake Lever Position 6-way adjustable (to suit rider) – – – Brake Lever Free Play Non-adjustable – – – Pedal Free Play Non-adjustable – – – Pedal Position About 90 mm (3.5 in.) below footpeg top –...

  • Page 420

    BRAKES 12-7 Special Tools Inside Circlip Pliers: Jack Attachment: 57001-143 57001-1608 Jack: 57001-1238...

  • Page 421

    12-8 BRAKES Brake Lever, Brake Pedal Brake Lever Position Adjustment The brake lever adjuster has 6 positions so that the brake lever position can be adjusted to suit the operator’s hand. • Push the lever forward and turn the adjuster [A] to align the number with the arrow mark [B] on the lever holder.

  • Page 422

    BRAKES 12-9 Brake Lever, Brake Pedal • Remove: Cotter Pin [A] Joint Pin [B] Rear Brake Light Switch Spring [C] Return Spring [D] • Remove the mounting bolt [E] and take out the brake pedal. Brake Pedal Installation • Apply grease to the pivot shaft [A] and install the washer [B].

  • Page 423

    12-10 BRAKES Calipers Front Caliper Removal • Loosen the banjo bolt [A] at the brake hose lower end, and tighten it loosely. • Unscrew the caliper mounting bolts [B], and detach the caliper [C] from the disc. CAUTION Do not loosen the caliper assembly bolts [D]. Take out only the caliper mounting bolts for caliper re- moval.

  • Page 424

    BRAKES 12-11 Calipers WARNING Do not attempt to drive the motorcycle until a full brake lever or pedal is obtained by pumping the brake lever or pedal until the pads are against the disc. The brakes will not function on the first appli- cation of the lever or pedal if this is not done.

  • Page 425

    12-12 BRAKES Calipers Rear Caliper Dust Boot and Friction Boot Damage • Check that the dust boot [A] and friction boot [B] are not cracked, worn, swollen, or otherwise damaged. If they show any damage, replace it. Caliper Piston and Cylinder Damage •...

  • Page 426

    BRAKES 12-13 Brake Pads Front Brake Pad Removal • Loosen: Pad Pins [A] • Remove: Pad Pins [A] Pad Springs [B] Brake Pads [C] Front Brake Pad Installation • Push the caliper pistons in by hand as far as they will go. •...

  • Page 427

    12-14 BRAKES Brake Pads Rear Brake Pad Removal • Remove the caliper with the hose installed. • Remove: Clip [A] Pad Pin [B] Brake Pads [C] Rear Brake Pad Installation • Push the caliper piston in by hand as far as it will go. •...

  • Page 428

    BRAKES 12-15 Master Cylinder Front Master Cylinder Removal • Remove the reservoir bracket nut [A]. • Remove the banjo bolt [A] to disconnect the brake hose from the master cylinder (see Brake Hose Removal/In- stallation). • Unscrew the clamp bolts [B], and take off the master cylin- der [C] as an assembly with the reservoir, brake lever, and brake switch installed.

  • Page 429

    12-16 BRAKES Master Cylinder Rear Master Cylinder Removal • Unscrew the brake hose banjo bolt [A] and brake hose [B]. • Remove: Cotter Pin [C] Joint Pin [D] Bolts [E] Foot Guard [F] Rear Master Cylinder • Slide out the clamp [G]. •...

  • Page 430

    BRAKES 12-17 Master Cylinder Master Cylinder Inspection (Visual Inspection) • Remove the master cylinders (see Front/Rear Master Cylinder Removal). • Disassemble the front and rear master cylinders (see Master Cylinder Rubber Parts Replacement in the Peri- odic Maintenance chapter). • Check that there are no scratches, rust or pitting on the inner wall [A] of each master cylinder and on the outside of each piston [B].

  • Page 431

    12-18 BRAKES Brake Disc Brake Disc Removal • Remove the wheel (see Wheels (Rims) section in the Wheels/Tires chapter). • Unscrew the mounting bolts, and take off the disc. Brake Disc Installation • Install the brake disc on the wheel so that the marked side [B] faces out.

  • Page 432

    BRAKES 12-19 Brake Fluid Brake Fluid Level Inspection • Refer to the Brake Fluid Level Inspection in the Periodic Maintenance chapter (see Brake Fluid Level Inspection in the Periodic Maintenance chapter). Brake Fluid Change • Refer to the Brake Fluid Change in the Periodic Mainte- nance chapter (see Brake Fluid Change in the Periodic Maintenance chapter).

  • Page 433

    12-20 BRAKES Brake Fluid • Remove the rubber cap from the bleed valve on the front master cylinder. • Attach a clear plastic hose [A] to the bleed valve, and run the other end of the hose into a container. •...

  • Page 434

    BRAKES 12-21 Brake Fluid • Bleed the brake line and the caliper. ○ Repeat this operation until no more air can be seen com- ing out into the plastic hose. 1. Pump the brake lever until it becomes hard, and apply the brake and hold it [A].

  • Page 435

    12-22 BRAKES Brake Fluid WARNING When working with the disc brake, observe the pre- cautions listed below. 1. Never reuse old brake fluid. 2. Do not use fluid from a container that has been left unsealed or that has been open for a long time. 3.

  • Page 436

    BRAKES 12-23 Brake Hose Brake Hose Removal/Installation • Refer to the Brake Hose and Pipe Replacement in the Periodic Maintenance chapter (see Brake Hose and Pipe Replacement in the Periodic Maintenance chapter). Brake Hose Inspection • Refer to the Brake Hose Damage and Installation Condi- tion Inspection in the Periodic Maintenance chapter (see Brake Hose Damage and Installation Condition Inspec- tion in the Periodic Maintenance chapter).

  • Page 438

    SUSPENSION 13-1 Suspension Table of Contents Exploded View........................13-2 Specifications ......................... 13-6 Special Tools .......................... 13-7 Front Fork ..........................13-9 Rebound Damping Force Adjustment................13-9 Compression Damping Force Adjustment ................ 13-9 Spring Preload Adjustment ....................13-10 Front Fork Removal (each fork leg) .................. 13-10 Front Fork Installation .......................

  • Page 439

    13-2 SUSPENSION Exploded View...

  • Page 440

    SUSPENSION 13-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Axle Clamp Bolts Front Fork Bottom Allen Bolts Front Fork Clamp Bolts (Lower) Front Fork Clamp Bolts (Upper) Front Fork Top Plugs Piston Rod Nuts AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque. G: Apply grease.

  • Page 441

    13-4 SUSPENSION Exploded View...

  • Page 442

    SUSPENSION 13-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Rear Shock Absorber Bracket Nut Rear Shock Absorber Nut (Lower) Rear Shock Absorber Nut (Upper) Uni-Trak Rocker Arm Nut Swingarm Pivot Adjusting Shaft Swingarm Pivot Adjusting Collar Locknut 10.0 Swingarm Pivot Shaft Nut 11.0 Tie-Rod Nuts G: Apply or add grease.

  • Page 443

    13-6 SUSPENSION Specifications Item Standard Front Fork (Per One Unit) Fork Inner Tube Diameter 43 mm (1.7 in.) Air Pressure Atmospheric pressure (non-adjustable) Rebound Damper Setting 10th click from the first click of the fully clockwise position (Usable range: 0 ←→ 11 clicks) Compression Damper Setting 10th click from the first click of the fully clockwise position...

  • Page 444

    SUSPENSION 13-7 Special Tools Inside Circlip Pliers: Fork Cylinder Holder: 57001-143 57001-1287 Oil Seal & Bearing Remover: Fork Oil Level Gauge: 57001-1058 57001-1290 Hook Wrench R37.5, R42: Bearing Remover Head, 20 × 22: 57001-1101 57001-1293 Bearing Driver Set: Fork Piston Rod Puller, M10 × 1.0: 57001-1129 57001-1298 Jack:...

  • Page 445

    13-8 SUSPENSION Special Tools Fork Oil Seal Driver, 43: Needle Bearing Driver, 17/ 18: 57001-1530 57001-1609 Fork Spring Compressor: Stem Bearing Driver, 28: 57001-1587 57001-1610 Swingarm Pivot Nut Wrench: Clamp: 57001-1597 57001-1626 Jack Attachment: Spacer, 57001-1608 57001-1636...

  • Page 446

    SUSPENSION 13-9 Front Fork Rebound Damping Force Adjustment • To adjust the rebound damping force, turn the rebound damping adjuster [A] until you feel a click. ○ The standard adjuster setting for the average-build rider of 68 kg (150 lb) with no passenger and no accessories is the 10th click from the 1st click of the fully clockwise position.

  • Page 447

    13-10 SUSPENSION Front Fork Spring Preload Adjustment • Turn the spring preload adjuster [A] to change spring preload setting. ○ The standard adjuster setting for the average-build rider of 68 kg (150 lb) with no passenger and no accessories is the 17 mm (0.67 in.) [B] from the top plug nut surface as shown.

  • Page 448

    SUSPENSION 13-11 Front Fork • Loosen the handlebar bolt [A], upper fork clamp bolt [B] and lower fork clamp bolts [C]. • With a twisting motion, work the fork leg down and out. Front Fork Installation • Install the fork so that the top end [A] of the outer tube is flush with the upper surface [B] of the steering stem head bracket.

  • Page 449

    13-12 SUSPENSION Front Fork • Install the clamps [A] as shown. NOTE ○ Set the clamps so that the cutout [B] of the upper side does not touch the tongue shape of stopper, pull up the outer tube [C] to hold it by the clamps, and then tighten the two bolts [D].

  • Page 450

    SUSPENSION 13-13 Front Fork • Screw the adjust nut [A] onto the compression shaft as shown. 20 mm (0.79 in.) [B] • Screw the locknut [C]. • Set the other side compression shaft same process. • Screw in one side nut [A] come out the piston rod nut. •...

  • Page 451

    13-14 SUSPENSION Front Fork • Hold the fork tube upright, press the inner tube [A] and the piston rod all the way down. • Pour in the type and amount of fork oil specified. Fork Oil Viscosity: KHL15-10 (KAYABA) or equivalent Amount (per side): When changing oil: Approx.

  • Page 452

    SUSPENSION 13-15 Front Fork • Screw the fork piston rod puller onto the end of the piston rod. Special Tool - Fork Piston Rod Puller, M10 × 1.0: 57001 -1298 • Pull the puller up above the outer tube top. •...

  • Page 453

    13-16 SUSPENSION Front Fork • Set the holder bar [B], and compression shafts [A]. • Hold the piston rod nut [A]. • Remove the piston rod puller [B]. • Install the rebound damping adjuster rod [A]. • Screw in the top plug [A] stopped onto the piston rod. •...

  • Page 454

    SUSPENSION 13-17 Front Fork Front Fork Disassembly • Remove the front fork (see Front Fork Removal). • Drain the fork oil (see Front Fork Oil Change). • Hold the front fork in a vise [A]. • Stop the cylinder [B] from turning by using the fork cylinder holder [C].

  • Page 455

    13-18 SUSPENSION Front Fork • Install the following parts into the inner tube [A]. Dust Seal [B] Circlip [C] Oil Seal [D] Washer [E] • Insert the inner tube to the outer tube. • After installing the washer, install the oil seal [A] by using the fork oil seal driver [B].

  • Page 456

    SUSPENSION 13-19 Front Fork Dust Seal Inspection • Inspect the dust seals [A] for any signs of deterioration or damage. Replace it if necessary. Spring Tension • Since a spring becomes shorter as it weakens, check its free length [A] to determine its condition. If the spring of either fork leg is shorter than the service limit, it must be replaced.

  • Page 457

    13-20 SUSPENSION Rear Shock Absorber Rebound Damping Force Adjustment • To adjust the rebound damping force, turn the lower damping adjuster [A] to the desired position, until you feel a click. ○ The standard adjuster setting for an average-build rider of 68 kg (150 lb) with no passenger and no accessories is the 2 turns out from the fully clockwise position.

  • Page 458

    SUSPENSION 13-21 Rear Shock Absorber • To adjust the spring preload, turn in the adjusting nut [A] to the desired position and tighten the locknut [B]. Spring Length [C] Spring Preload Setting Standard: Spring length 179 mm (7.0 in.) Usable Range: Spring length 179 191.5 mm (7.047 7.539 in.) ○...

  • Page 459

    13-22 SUSPENSION Rear Shock Absorber • Squeeze the brake lever slowly and it with a band [A]. WARNING Be sure to hold the front brake when removing the shock absorber, or the motorcycle may fall over. It could cause an accident and injury. •...

  • Page 460

    SUSPENSION 13-23 Swingarm Swingarm Removal • Remove: Rear Wheel (see Rear Wheel Removal in the Wheels/Tires chapter) Middle Exhaust Pipe (see Middle and Rear Exhaust Pipe Removal in the Engine Top End chapter) Engine Sprocket (see Engine Sprocket Removal in the Final Drive chapter) Bolts [A] Chain Cover [B]...

  • Page 461

    13-24 SUSPENSION Swingarm Swingarm Installation • Apply plenty of grease to the lip [A] of the oil seals. • Install the collar. • Place the adjusting collar [A] into the frame [B] as shown. • Insert the pivot adjusting shaft [A] into the frame from the right side.

  • Page 462

    SUSPENSION 13-25 Swingarm Swingarm Bearing Removal • Remove: Swingarm (see Swingarm Removal) Collar [A] Oil Seals [B] Sleeve [C] Circlip (Right Side) [D] Special Tool - Inside Circlip Pliers: 57001-143 • Remove the ball bearing and needle bearings. Special Tools - Oil Seal & Bearing Remover [A]: 57001-1058 Bearing Remover Head: 57001-1293 Bearing Remover Shaft: 57001-1377 Swingarm Bearing Installation...

  • Page 463

    13-26 SUSPENSION Swingarm Swingarm Bearing, Sleeve Inspection CAUTION Do not remove the bearings for inspection. Re- moval may damage them. • Inspect the needle bearings [A] and ball bearing installed in the swingarm. ○ The rollers and ball in a bearing normally wear very little, and wear is difficult to measure.

  • Page 464

    SUSPENSION 13-27 Tie-Rod, Rocker Arm Tie-Rod Removal • Remove: Lower Fairings (see Lower Fairing Removal in the Frame chapter) Middle Exhaust Pipe (see Middle and Rear Exhaust Pipe Removal in the Engine Top End chapter) • Squeeze the brake lever slowly and hold it with a band [A].

  • Page 465

    13-28 SUSPENSION Tie-Rod, Rocker Arm Rocker Arm Installation • Apply grease to the inside of the grease seals. • Tighten: Torque - Uni-Trak Rocker Arm Nut: 34 N·m (3.5 kgf·m, 25 ft·lb) Tie-Rod Nuts: 59 N·m (6.0 kgf·m, 44 ft·lb) Rear Shock Absorber Nuts: 34 N·m (3.5 kgf·m, 25 ft·lb) Tie-Rod and Rocker Arm Bearing Removal...

  • Page 466

    SUSPENSION 13-29 Tie-Rod, Rocker Arm ○ Screw the needle bearing driver [A] into the driver holder [B]. ○ Insert the needle bearing driver into the needle bearing [C] and press the needle bearing into the housing until the driver contacts the end surface of the housing. Bearing’s Pressing Depth: 5.5 mm (0.22 in.) [D] 5.0 mm (0.20 in.) [E] NOTE...

  • Page 467

    13-30 SUSPENSION Tie-Rod, Rocker Arm Rocker Arm/Tie-Rod Bearing, Sleeve Inspection CAUTION Do not remove the bearings for inspection. Re- moval may damage them. • Visually inspect the rocker arm, or tie-rod sleeves [A] and needle bearings [B]. • The rollers in a needle bearing normally wear very little, and wear is difficult to measure.

  • Page 468

    STEERING 14-1 Steering Table of Contents Exploded View........................14-2 Special Tools .......................... 14-5 Steering ..........................14-6 Steering Inspection ......................14-6 Steering Adjustment......................14-6 Steering Damper ........................14-7 Steering Damper Removal....................14-7 Steering Damper Installation..................... 14-7 Damping Force Adjustment ....................14-7 Steering Damper Oil Leak Inspection ................

  • Page 469

    14-2 STEERING Exploded View...

  • Page 470

    STEERING 14-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Handlebar Switch Housing Screws 0.36 31 in·lb Handlebar Bolts Handlebar Position Bolts 87 in·lb Steering Stem Head Nut Front Fork Clamp Bolts (Upper) Steering Stem Locknut – – – Hand-tighten Steering Stem Nut Front Fork Clamp Bolts (Lower) 9.

  • Page 471

    14-4 STEERING Exploded View Item Standard Steering Damper Damper Set 18 turns out from the fully clockwise position (Usable range: 0 ←→ 18 tuns out)

  • Page 472

    STEERING 14-5 Special Tools Bearing Puller Adapter: Bearing Driver Set: 57001-136 57001-1129 Bearing Puller: Steering Stem Bearing Driver, 42.5: 57001-158 57001-1344 Head Pipe Outer Race Press Shaft: Steering Stem Bearing Driver Adapter, 41.5: 57001-1075 57001-1345 Steering Stem Nut Wrench: Head Pipe Outer Race Driver, 55: 57001-1100 57001-1446...

  • Page 473

    14-6 STEERING Steering Steering Inspection • Refer to the Steering Play Inspection in the Periodic Main- tenance chapter (see Steering Play Inspection in the Pe- riodic Maintenance chapter). Steering Adjustment • Refer to the Steering Play Adjustment in the Periodic Maintenance chapter (see Steering Play Adjustment in the Periodic Maintenance chapter).

  • Page 474

    STEERING 14-7 Steering Damper Steering Damper Removal • Remove the TORX bolt [A] and washer [B]. • Remove the bolt [C], washer, collar and steering damper [D]. Steering Damper Installation • Install the steering damper [F] and parts as shown. Collar [A] Washer [B] Fuel Tank Bracket [C]...

  • Page 475

    14-8 STEERING Steering Stem Stem, Stem Bearing Removal • Remove: Steering Damper (see Steering Damper Removal) Steering Stem Head Nut [A] and Washer [B] Steering Stem Head [C] Handlebars [D] • Remove: Brake Hose Clamp [A] Right Switch Housing Lead Clamp [B] •...

  • Page 476

    STEERING 14-9 Steering Stem • Remove the lock washer [A]. • Pushing up the stem base, and remove the steering stem nut with stem cap [A]. • Remove: Steering Stem [C] Upper Ball Bearing Inner Race Special Tool - Steering Stem Nut Wrench [B]: 57001-1100 •...

  • Page 477

    14-10 STEERING Steering Stem • Replace the bearing inner races with new ones. • Install the oil seal [D] on the steering stem, and drive the lower ball bearing inner race [A] applied the grease onto the stem. Special Tools - Steering Stem Bearing Driver [B]: 57001 -1344 Steering Stem Bearing Driver Adapter [C]: 57001-1345...

  • Page 478

    STEERING 14-11 Steering Stem • Install the lock washer [A] so that claw [B] of washer fit the notch [C] of steering stem locknut [D]. • First tighten the steering stem locknut by hand until the resistance is felt fully, then tighten the steering stem lock- nut so that align the claw [A] of stem locknut to the notch [B] of stem nut by hand.

  • Page 479

    14-12 STEERING Steering Stem Steering Stem Bearing Lubrication • Refer to the Steering Stem Bearing Lubrication in the Pe- riodic Maintenance chapter (see Steering Stem Bearing Lubrication in the Periodic Maintenance chapter). Steering Stem Warp • Whenever the steering stem is removed, or if the steering can not be adjusted for smooth action, check the steering stem for straightness.

  • Page 480

    STEERING 14-13 Handlebar Handlebar Removal • Remove: Steering Damper (see Steering Damper Removal) Clutch Lever Clamp Bolts [A] Clutch Lever Assembly [B] Left Switch Housing [C] Handlebar Weight [D] • Remove: Front Brake Reservoir Bracket Nut [A] Front Brake Master Cylinder [B] Front Brake Light Switch Connector [C] Right Switch Housing [D] Throttle Case [E]...

  • Page 481

    14-14 STEERING Handlebar • Install the left and right switch housings. ○ Fit the projection [A] into a small hole [B] in the handlebar. Torque - Handlebar Switch Housing Screws: 3.5 N·m (0.36 kgf·m, 31 in·lb) • Connect the front brake light switch connector. •...

  • Page 482

    FRAME 15-1 Frame Table of Contents Exploded View........................15-2 Seats ............................15-8 Rear Seat Removal......................15-8 Rear Seat Installation......................15-8 Front Seat Removal ......................15-8 Front Seat Installation ....................... 15-8 Fairings........................... 15-9 Lower Fairing Removal ..................... 15-9 Lower Fairing Installation ....................15-9 Middle Fairing Removal ....................

  • Page 483

    15-2 FRAME Exploded View...

  • Page 484

    FRAME 15-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Footpeg Bracket Bolts Rear Footpeg Bracket Bolts Rear Frame Bolts Rear Master Cylinder Mounting Bolts Sidestand Bolt Sidestand Switch Bolt 0.90 78 in·lb Sidestand Bracket Bolts 8. Immobilizer Models G: Apply grease.

  • Page 485

    15-4 FRAME Exploded View...

  • Page 486

    FRAME 15-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Fender Mounting Bolts 0.40 35 in·lb 2. United States and Canada Models 3. Australian Models...

  • Page 487

    15-6 FRAME Exploded View...

  • Page 488

    FRAME 15-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Windshield Mounting Bolts 0.04 4 in·lb...

  • Page 489

    15-8 FRAME Seats Rear Seat Removal • Insert the ignition switch key [A] into the seat lock, turning the key counterclockwise, pulling the front part of the seat [B] up, and pull the seat forward. Rear Seat Installation • Put the rear seat hook [A] on the rib [B]. •...

  • Page 490

    FRAME 15-9 Fairings Lower Fairing Removal • Pull up the core [A] by the thin blade driver [B]. • Remove: Quick Rivets [A] Bolts [B] with Washers Screws [C] • Separate the right lower fairing [D] from the left lower fair- ing.

  • Page 491

    15-10 FRAME Fairings For the California Model ○ Remove: Band [A] Canister [B] ○ Clear the right switch housing lead from the clamp [A]. ○ Disconnect the right turn signal lead connector [B]. • Disconnect the left turn signal lead connector [A]. •...

  • Page 492

    FRAME 15-11 Fairings Windshield Installation • Put the front tongue [A] into the hollow [B]. Torque - Windshield Mounting Bolts: 0.4 N·m (0.04 kgf·m, 4 in·lb) Upper Fairing Removal • Remove: Lower Fairings (see Lower Fairing Removal) Upper Inner Fairings (see Upper Inner Fairing Removal) Windshield (see Windshield Removal) Middle Fairings (see Middle Fairing Removal) Bolts [A]...

  • Page 493

    15-12 FRAME Fairings Upper Inner Fairing Removal • Remove the bolts [A] with washers. • Remove the upper inner fairing [B]. ○ Remove the upper inner fairing by pulling the rear of it up and upward to clear the projection from the stopper [C]. ○...

  • Page 494

    FRAME 15-13 Fairings Right and Left Inner Fairing Removal • Remove: Right and Left Middle Fairings (see Middle Fairing Re- moval) Bolts [A] Inner Fairing [B] Right and Left Inner Fairing Installation • Tighten the bolts [A].

  • Page 495

    15-14 FRAME Side Covers Side Cover Removal • Remove: Bolt and Washer [A] • Pull out the side cover [B]. Side Cover Installation • Insert the projections [A] into the holes [B]. • Tighten the bolt with washer.

  • Page 496

    FRAME 15-15 Seat Cover Seat Cover Removal • Remove: Seats (see Seats section) Bolts [A] Quick Rivets [B] • Pull the seat cover backward, and clear the projections from the holes. • Disconnect: Tail/Brake Light Lead Connector [A] Turn Signal Light Lead Connectors [B] •...

  • Page 497

    15-16 FRAME Seat Cover • Remove: Screws [A] Seat Lock Assy [B] Seat Cover Installation • Install the seat lock assy with screws. • Connect the tail/brake light lead connector. • Install the tail/brake light [A] inserting the hooks [B] into the stoppers [C].

  • Page 498

    FRAME 15-17 Fenders Front Fender Removal • Remove: Brake Hose Clamps [A] (Left and Right) Bolts [B] with Washers (Left and Right) • Remove the front fender assy [C]. • Remove: Bolts [A] • Separate the front fender cover [B] and front fender [C]. Front Fender Installation •...

  • Page 499

    15-18 FRAME Fenders • Pull out the rear fender rear [A] assembled turn signal lights and license plate light downward. Rear Fender Rear Installation • Install the harness clamp in accordance with Harness Routing section in Appendix chapter. Rear Fender Front Removal •...

  • Page 500

    FRAME 15-19 Fenders • Remove: Bolts and Nuts [A] Collars [B] Dampers [C] Upper Heat Guard [D] • Remove: Bolt [E] Bolts [F] Fender Bracket [G] • Remove: Rivet [H] Nut [I] Bolt [J] Rear Fender Front [K] Front [L] Viewed from Upside [M] Rear Fender Front Installation •...

  • Page 501

    15-20 FRAME Frame Rear Frame Removal • Remove: Vehicle-down Sensor (see Vehicle-down Sensor Re- moval in the Fuel System (DFI) chapter) Seat Cover (see Seat Cover Removal) Rear Fender Front (see Rear Fender Front Removal) Clamps for Main Harness Frame Bolts [A] Rear Frame Installation •...

  • Page 502

    FRAME 15-21 Sidestand Sidestand Removal • Raise the rear wheel off the ground with the stand. • Remove: Lower Fairings (see Lower Fairing Removal) • Disconnect the sidestand switch lead connector [A] and clear the lead from the clamps [B]. •...

  • Page 504

    ELECTRICAL SYSTEM 16-1 Electrical System Table of Contents Exploded View........................16-4 Parts Location......................... 16-10 Wiring Diagram (United States, Canada, New Zealand, Colombia and Taiwan)....16-11 Wiring Diagram (Other than United States, Canada, New Zealand, Colombia, Taiwan, Australia and Malaysia) ....................... 16-14 Wiring Diagram (Australia) .....................

  • Page 505

    16-2 ELECTRICAL SYSTEM Starter Idle Gear Installation ..................... 16-49 Starter Clutch Removal..................... 16-51 Starter Clutch Installation ....................16-51 Starter Clutch Disassembly....................16-52 Starter Clutch Assembly ....................16-52 Starter Clutch Inspection....................16-52 Starter Motor Removal...................... 16-53 Starter Motor Installation....................16-54 Starter Motor Disassembly....................16-54 Starter Motor Assembly ....................

  • Page 506

    ELECTRICAL SYSTEM 16-3 Relay Box ..........................16-107 Relay Box Removal ......................16-107 Relay Circuit Inspection ....................16-107 Diode Circuit Inspection ....................16-108 Fuse............................16-110 30 A Main Fuse Removal....................16-110 Fuse Box Fuse Removal....................16-110 15 A ECU Fuse Removal....................16-110 Fuse Installation........................

  • Page 507

    16-4 ELECTRICAL SYSTEM Exploded View...

  • Page 508

    ELECTRICAL SYSTEM 16-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Meter Unit Mounting Screws 0.12 11 in·lb Headlight Mounting Screws 0.12 11 in·lb Front Turn Signal Light Mounting Screws 0.12 11 in·lb Rear Turn Signal Light Mounting Screws 0.12 11 in·lb Rear Turn Signal Light Lens Screws 0.12...

  • Page 509

    16-6 ELECTRICAL SYSTEM Exploded View...

  • Page 510

    ELECTRICAL SYSTEM 16-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Camshaft Position Sensor Bolt 89 in·lb Water Temperature Sensor Oxygen Sensors (Europe Models) Vehicle-down Sensor Bolts 0.61 53 in·lb Gear Position Switch Screws 0.31 27 in·lb Spark Plugs 115 in·lb Stator Coil Bolts 106 in·lb Alternator Rotor Bolt...

  • Page 511

    16-8 ELECTRICAL SYSTEM Exploded View...

  • Page 512

    ELECTRICAL SYSTEM 16-9 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Brake Light Switch Screw 0.12 11 in·lb Right Handlebar Switch Housing Screws (M5, L = 45) 0.36 31 in·lb Left Handlebar Switch Housing Screws (M5, L = 25) 0.36 31 in·lb Starter Clutch Bolt...

  • Page 513

    16-10 ELECTRICAL SYSTEM Parts Location 1. Starter Lockout Switch 14. Sidestand Switch 2. Ignition Switch with Immobilizer Antenna (Im- 15. Gear Position Switch mobilizer Models) 16. Turn Signal Relay 3. Stick Coils 17. Regulator/Rectifier 4. Water Temperature Sensor 18. Air Switching Valve 5.

  • Page 514

    ELECTRICAL SYSTEM 16-11 Wiring Diagram (United States, Canada, New Zealand, Colombia and Taiwan) Dummy Page...

  • Page 515

    16-12 ELECTRICAL SYSTEM Wiring Diagram (United States, Canada, New Zealand, Colombia and Taiwan)

  • Page 516

    ELECTRICAL SYSTEM 16-13 Wiring Diagram (United States, Canada, New Zealand, Colombia and Taiwan)

  • Page 517

    16-14 ELECTRICAL SYSTEM Wiring Diagram (Other than United States, Canada, New Zealand, Colombia, Tai- wan, Australia and Malaysia)

  • Page 518

    ELECTRICAL SYSTEM 16-15 Wiring Diagram (Other than United States, Canada, New Zealand, Colombia, Tai- wan, Australia and Malaysia)

  • Page 519

    16-16 ELECTRICAL SYSTEM Wiring Diagram (Australia)

  • Page 520

    ELECTRICAL SYSTEM 16-17 Wiring Diagram (Australia)

  • Page 521

    16-18 ELECTRICAL SYSTEM Wiring Diagram (Malaysia)

  • Page 522

    ELECTRICAL SYSTEM 16-19 Wiring Diagram (Malaysia)

  • Page 523

    16-20 ELECTRICAL SYSTEM Specifications Item Standard Battery Type Sealed battery Model Name YT12B-BS Capacity 12 V 10 Ah Voltage 12.8 V or more Charging System Type Three-phase AC Alternator Output Voltage 60 V or more @4 000 r/min (rpm) Stator Coil Resistance 0.2 Ω...

  • Page 524

    Hand Tester: Grip: 57001-1394 57001-1591 Flywheel Puller Assembly, M38 × 1.5/M35 × 1.5: Rotor Holder: 57001-1405 57001-1658 Peak Voltage Adapter: Rotor Holder: 57001-1415 57001-1666 Lead Wire - Peak Voltage Adapter: Kawasaki Bond (Silicone Sealant): 57001-1449 92104-0004 Key Registration Unit: 57001-1582...

  • Page 525

    16-22 ELECTRICAL SYSTEM Precautions There are a number of important precautions that are musts when servicing electrical systems. Learn and ob- serve all the rules below. ○ Do not reverse the battery lead connections. This will burn out the diodes on the electrical parts. ○...

  • Page 526

    ELECTRICAL SYSTEM 16-23 Precautions Male Connectors [B]...

  • Page 527

    16-24 ELECTRICAL SYSTEM Electrical Wiring Wiring Inspection • Visually inspect the wiring for signs of burning, fraying, etc. If any wiring is poor, replace the damaged wiring. • Pull each connector [A] apart and inspect it for corrosion, dirt, and damage. If the connector is corroded or dirty, clean it carefully.

  • Page 528

    ELECTRICAL SYSTEM 16-25 Battery Battery Removal • Remove: Front Seat (see Front Seat Removal in the Frame chap- ter) Relay Box [A] • Slide the black and red caps [A] out. • Disconnect the negative (–) cable [B] and then positive (+) cable [C].

  • Page 529

    16-26 ELECTRICAL SYSTEM Battery Battery Activation Electrolyte Filling • Make sure that the model name [A] of the electrolyte con- tainer matches the model name [B] of the battery. These names must be the same. Battery Model Name for ZX1000D: YT12B-BS CAUTION Be sure to use the electrolyte container with the same model name as the battery since the elec-...

  • Page 530

    Standard Charge: 1.2 A × 5 10 hours If using a recommended battery charger, follow the charger’s instructions for newly activated sealed battery. Kawasaki-recommended chargers: Optimate III Yuasa 1.5 Amp Automatic Charger Battery Mate 150-9 If the above chargers are not available, use equivalent one.

  • Page 531

    16-28 ELECTRICAL SYSTEM Battery • After charging is completed, press down firmly with both hands to seat the strip of caps [A] into the battery (don’t pound or hammer). When properly installed, the strip of the caps will be level with the top of the battery. CAUTION Once the strip of the caps [A] is installed onto the battery, never remove the caps, nor add water or...

  • Page 532

    ELECTRICAL SYSTEM 16-29 Battery WARNING Keep the battery away from sparks and open flames during charging, since the battery gives off an explosive gas mixture of hydrogen and oxygen. When using a battery charger, connect the battery to the charger before turning on the charger. This procedure prevents sparks at the battery terminals which could ignite any battery gases.

  • Page 533

    16-30 ELECTRICAL SYSTEM Battery Terminal Voltage: 11.5 less than 12.8 V Standard Charge 1.2 A × 5 10 h (see following chart) Quick Charge 5 A × 1 h CAUTION If possible, do not quick charge. If quick charge is done unavoidably, do standard charge later on.

  • Page 534

    Apply silicone sealant to the alternator lead grommet and crankcase halves mating surface [A] on the front and rear sides of the cover mount. Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004 • Check that dowel pins [B] are in place on the crankcase.

  • Page 535

    Apply silicone sealant to the circumference of the alter- nator lead grommet, and fit the grommet into the notch of the cover securely. Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004 • Secure the alternator lead with a holding plate, and apply a non-permanent locking agent to the thread of the plate bolt and tighten it.

  • Page 536

    ELECTRICAL SYSTEM 16-33 Charging System • Using a cleaning fluid, clean off any oil or dirt on the washer [A] and dry if with a clean cloth. • Install the washer. NOTE ○ Confirm the alternator rotor fit or not to the crankshaft before tightening it with specified torque.

  • Page 537

    16-34 ELECTRICAL SYSTEM Charging System • To check the alternator output voltage, do the following procedures. ○ Turn off the ignition switch. ○ Remove the fuel tank (see Fuel Tank Removal in the Fuel System (DFI) chapter). ○ Disconnect the alternator lead connector [A]. ○...

  • Page 538

    CAUTION Use only Kawasaki Hand Tester 57001-1394 for this test. A tester other than the Kawasaki Hand Tester may show different readings. If a megger or a meter with a large capacity battery is used, the regulator/rectifier will be damaged.

  • Page 539

    16-36 ELECTRICAL SYSTEM Charging System Charging Voltage Inspection • Check the battery condition (see Charging Condition In- spection). • Warm up the engine to obtain actual alternator operating conditions. • Remove the Front seat (see Front Seat Removal in the Frame chapter).

  • Page 540

    ELECTRICAL SYSTEM 16-37 Charging System Charging System Circuit 1. Ignition Switch 2. Main Fuse 30 A 3. Starter Relay 4. Battery 12 V 10 Ah 5. Frame Ground 6. Load 7. Alternator 8. Regulator/Rectifier...

  • Page 541

    16-38 ELECTRICAL SYSTEM Ignition System...

  • Page 542

    Apply silicone sealant to the circumference of the crank- shaft sensor lead grommet [B], and fit the grommet into the notch of the crankcase securely. Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004 • Install the starter clutch cover (see Starter Clutch Instal- lation).

  • Page 543

    16-40 ELECTRICAL SYSTEM Ignition System Crankshaft Sensor Inspection • Disconnect the crankshaft sensor lead connector (see Crankshaft Sensor Removal). • Set the hand tester [A] to the × 100 Ω range and connect it to the crankshaft sensor lead connector [B]. Special Tool - Hand Tester: 57001-1394 Crankshaft Sensor Resistance: 380 570 Ω...

  • Page 544

    ELECTRICAL SYSTEM 16-41 Ignition System • Disconnect the stick coil connectors [A]. • Pull the stick coils #2, #3 [B] off the spark plugs. CAUTION Do not pry the connector part of the coil while re- moving the coil. • For remove the stick coil #1 as follows.

  • Page 545

    16-42 ELECTRICAL SYSTEM Ignition System ○ Remove: Right Engine Bracket Bolts [A] Right Engine Bracket [B] ○ Pull out the stick coil #4 [A] to forward. Stick Coil (Ignition Coil together with Spark Plug Cap) Installation • Apply grease to the stick coils. •...

  • Page 546

    ELECTRICAL SYSTEM 16-43 Ignition System Stick Coil (Ignition Coil together with Spark Plug Cap) Inspection • Remove the stick coils (see Stick Coil (Ignition Coil to- gether with Spark Plug Cap) Removal). • Measure the primary winding resistance [A] as follows. ○...

  • Page 547

    16-44 ELECTRICAL SYSTEM Ignition System WARNING To avoid extremely high voltage shocks, do not touch the spark plugs or tester connections. • Turn the ignition switch and engine stop switch ON. • Pushing the starter button, turn the engine 4 5 seconds with the transmission in neutral to measure the primary peak voltage.

  • Page 548

    ELECTRICAL SYSTEM 16-45 Ignition System Camshaft Position Sensor Removal • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Air Cleaner Housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter) • Disconnect the camshaft position sensor lead connector [A].

  • Page 549

    16-46 ELECTRICAL SYSTEM Ignition System Camshaft Position Sensor Peak Voltage Inspection • Disconnect the camshaft position sensor connector (see Camshaft Position Sensor Removal). • Set the hand tester [A] to the 10 V DC range. • Connect the peak voltage adapter [B] to the hand tester and camshaft position sensor leads in the terminals.

  • Page 550

    ELECTRICAL SYSTEM 16-47 Ignition System 2nd Check • Start the engine to the following conditions. Condition: Transmission Gear → 1st Position Clutch Lever → Pulled in Sidestand → Up ○ Turn the ignition switch ON and push the starter button. ○...

  • Page 551

    16-48 ELECTRICAL SYSTEM Ignition System Ignition System Circuit 1. Ignition Switch 12. Frame Ground 23. Fuel Injector #3 2. Joint Connector 1 13. Fuel Pump 24. Fuel Injector #2 3. Starter Lockout Switch 14. Vehicle-down Sensor 25. Main Fuse 30 A 4.

  • Page 552

    ELECTRICAL SYSTEM 16-49 Electric Starter System Starter Idle Gear Removal • Remove: Right Middle Fairing (see Right Middle Fairing Removal in the Frame chapter) Bolts [A] Idle Gear Cover [B] • Pull out the idle gear (starter motor side) [A] with the shaft [B].

  • Page 553

    • Apply silicone sealant to the following portion. Crankshaft Sensor Lead Grommet [B] Crankcase Halves Mating Surfaces [C] Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004 • Install the dowel pin [D] and new gasket. • Apply grease to the O-rings of starter motor.

  • Page 554

    ELECTRICAL SYSTEM 16-51 Electric Starter System Starter Clutch Removal • Remove: Starter Clutch Cover (see Idle Gear Removal) Idle Gear (Starter Clutch Side, see Idle Gear Removal) • Unscrew the starter clutch bot [A], while holding the al- ternator rotor steady with the rotor holder (see Alternator Rotor Removal).

  • Page 555

    16-52 ELECTRICAL SYSTEM Electric Starter System • Push [A] the starter clutch gear [B] in and turn it counter- clockwise [C] and install it. • Install the washer [A]. • Tighten the starter clutch bot [B], while holding the alterna- tor rotor steady with the rotor holder (see Alternator Rotor Installation).

  • Page 556

    ELECTRICAL SYSTEM 16-53 Electric Starter System • Disassemble the starter clutch (see Starter Clutch Disas- sembly), and visually inspect the clutch parts. One-way Clutch [A] Starter Clutch Case [B] If there is any worn or damaged part, replace it. ○ Examine the starter clutch gear [C] as well.

  • Page 557

    16-54 ELECTRICAL SYSTEM Electric Starter System • Remove the starter motor mounting bolts [A]. • Pull out the starter motor from the right side. Starter Motor Installation CAUTION Do not tap the starter motor shaft or body. Tapping the shaft or body could damage the motor. •...

  • Page 558

    ELECTRICAL SYSTEM 16-55 Electric Starter System • Pull the armature [A] out of the yoke [B]. • Remove: Brush Plate Terminal Nut [A] Brush Plate Assembly [B] Starter Motor Assembly • Pry the spring end [A] and insert the brush [B]. •...

  • Page 559

    16-56 ELECTRICAL SYSTEM Electric Starter System • Replace the O-rings [A] with new ones. • Put the armature [B] among the brushes [C]. • Apply a thin coat of grease to the oil seal [A]. • Fit the toothed washer [B] into the left-hand end cover. •...

  • Page 560

    ELECTRICAL SYSTEM 16-57 Electric Starter System Brush Inspection • Measure the length [A] of each brush [B]. If any is worn down to the service limit, replace the brush holder assembly. Starter Motor Brush Length Standard: 10 mm (0.39 in.) Service Limit: 5.0 mm (0.20 in.) Commutator Cleaning and Inspection •...

  • Page 561

    16-58 ELECTRICAL SYSTEM Electric Starter System Brush Lead Inspection • Using the × 1 Ω hand tester range, measure the resis- tance as shown. Terminal Bolt and Positive Brush [A] Right-hand End Cover and Negative Brush [B] Special Tool - Hand Tester: 57001-1394 If there is not close to zero ohms, the brush lead has an open.

  • Page 562

    ELECTRICAL SYSTEM 16-59 Electric Starter System Electric Starter Circuit 1. Ignition Switch 2. Joint Connector 1 3. Starter Lockout Switch 4. Fuse Box 5. Ignition Fuse 15 A 6. Relay Box 7. Starter Circuit Relay 8. Starter Motor 9. Main Fuse 30 A 10.

  • Page 563

    16-60 ELECTRICAL SYSTEM Lighting System This motorcycle adopt the daylight system and have a headlight relay in the relay box. The headlight does not go on when the ignition switch and the engine stop switch are first turned on. The headlight comes on after the starter button is released and stays on until the ignition switch is turned off.

  • Page 564

    ELECTRICAL SYSTEM 16-61 Lighting System • Turn the headlight bulb [A] clockwise. • Connect the headlight connector. • After installation, adjust the headlight aim (see Headlight Aiming Inspection in the Periodic Maintenance chapter). City Light Bulb Replacement • Remove the upper inner fairing (see Upper Inner Fairing Removal in the Frame chapter).

  • Page 565

    16-62 ELECTRICAL SYSTEM Lighting System Tail/Brake Light (LED) Removal • Refer to the Seat Cover Removal in the Frame chapter (see Seat Cover Removal in the Frame chapter). Tail/Brake Light (LED) Installation • Refer to the Seat Cover Installation in the Frame chapter (see Seat Cover Installation in the Frame chapter).

  • Page 566

    ELECTRICAL SYSTEM 16-63 Lighting System Headlight/Tail Light Circuit 12. Fuse Box 1. Ignition Switch 2. High Beam Indicator Light (LED) 13. Relay Box 3. Joint Connector 1 14. Headlight Relay 4. Right City Light 15. Starter Relay 6. Headlight (High Beam) 16.

  • Page 567

    16-64 ELECTRICAL SYSTEM Lighting System • Push and turn the front turn signal light bulb [A] counter- clockwise and remove it. • Replace the bulb with new ones. • Insert the new bulb [A] by aligning its upper and lower pins [B] with the upper and lower grooves [C] in the soket, and turn the bulb clockwise.

  • Page 568

    ELECTRICAL SYSTEM 16-65 Lighting System • Insert the new bulb [A] by aligning its upper and lower pins [B] with the upper and lower grooves [C] in the socket, and turn the bulb clockwise. ○ Turn the bulb about 15° degrees. •...

  • Page 569

    16-66 ELECTRICAL SYSTEM Lighting System Turn Signal Light Circuit 1. Ignition Switch 2. Turn Signal Indicator Lights (Right and Left) 3. Joint Connector 1 4. Front Right Turn Signal Light 5. Front Left Turn Signal Light 6. Turn Signal Switch 7.

  • Page 570

    ELECTRICAL SYSTEM 16-67 Air Switching Valve Air Switching Valve Operation Test • Refer to the Air Suction System Damage Inspection in the Periodic Maintenance chapter (see Air Suction System Damage Inspection in the Periodic Maintenance chapter). Air Switching Valve Unit Test •...

  • Page 571

    16-68 ELECTRICAL SYSTEM Radiator Fan System Fan Motor Inspection • Remove the left upper inner fairing (see Upper Inner Fair- ing Removal in the Frame chapter). • Disconnect the connector [A]. • Using an auxiliary leads, supply battery power to the fan motor.

  • Page 572

    ELECTRICAL SYSTEM 16-69 Meter, Gauge, Indicator Unit Meter Unit Removal/Installation • Remove: Upper Fairing (see Upper Fairing Removal in the Frame chapter) Screws [A] with Washers CAUTION Place the meter unit so that the face is up. If a meter unit is left upside down or sideways for any length of time, it will malfunction.

  • Page 573

    16-70 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit Electronic Combination Meter Unit Inspection • Remove the meter unit (see Meter Unit Removal) [A]. [1] Ignition [2] Fuel Level Warning Indicator Light (LED) (–) [3] Stop Watch (+) [4] Lap Time (+) [5] Neutral Indicator Light (LED) (–) [6] ECU Communication Signal [7] Tachometer Signal...

  • Page 574

    ELECTRICAL SYSTEM 16-71 Meter, Gauge, Indicator Unit ○ When the terminals are connected, all the LCD segments [A] appear for three seconds. If the LCD segments will not appear, replace the meter assembly. • Disconnect the terminal [1]. ○ All the LCD segments disappear. If the segments do not disappear, replace the meter as- sembly.

  • Page 575

    16-72 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit • In the HOUR setting mode, press the REST button to ef- fect the MINUTE setting mode. ○ The minute display flashes on the display. • Press the MODE button to set the minute. •...

  • Page 576

    ELECTRICAL SYSTEM 16-73 Meter, Gauge, Indicator Unit • If the oscillator is not available, the speedometer can be checked as follows. ○ Install the meter unit. ○ Raise the rear wheel off the ground, using the jack. ○ Turn on the ignition switch. ○...

  • Page 577

    16-74 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit Tachometer Check • Connect the 12 V battery and terminals in the same man- ner as specified in the "Liquid Crystal Display (LCD) Seg- ments Check". ○ When the terminals are connected, the tachometer nee- dle momentary points to the last reading, and then return to the 0 position.

  • Page 578

    ELECTRICAL SYSTEM 16-75 Meter, Gauge, Indicator Unit Stop Watch Check • Connect the 12 V battery and terminal in the same man- ner as specified in the “Liquid Crystal Display (LCD) Seg- ments Check”. • Press the MODE button each time to set the stop watch mode.

  • Page 579

    16-76 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit Neutral Indicator Light (LED) Inspection ○ Connect the 12 V battery and terminals in the same man- ner as specified in the “Liquid Crystal Display (LCD) Seg- ments check.” • Using the insulated auxiliary lead, 12 V battery to the me- ter unit connector as follows.

  • Page 580

    ELECTRICAL SYSTEM 16-77 Meter, Gauge, Indicator Unit High Beam Indicator Light (LED) ○ Connect the 12 V battery and terminals in the same man- ner as specified in the “Liquid Crystal Display (LCD) Seg- ments check.” • Using the insulated auxiliary lead, 12 V battery to the me- ter unit connector as follows.

  • Page 581

    16-78 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit Shift Up Indicator Light (LED) ○ Connect the 12 V battery and terminal in the same man- ner as specified in the “Liquid Crystal Display (LCD) Seg- ments Check”. • The revolutions per minute (rpm) equivalent to the input frequency is indicated in the oscillator [A] if the square wave (illustrated as shown) would be input into the termi- nal [7].

  • Page 582

    ELECTRICAL SYSTEM 16-79 Meter, Gauge, Indicator Unit Meter Unit Circuit 1. Ignition Switch 14. Lap Switch 2. Turn Signal Indicator Light (LED) 15. Fuse Box 3. High Beam Indicator Light (LED) 16. Ignition Fuse 15 A 4. Neutral Indicator Light (LED) 17.

  • Page 583

    Prepare a new spare user key. • Cut the key in accordance with the shape of the current user key. • Remove the front seat (see Front Seat Removal in the Frame). • Disconnect the immobilizer/Kawasaki diagnostic system connector [A].

  • Page 584

    ELECTRICAL SYSTEM 16-81 Immobilizer System (Equipped Models) • Connect the key registration unit [A]. Special Tool - Key Registration Unit: 57001-1582 • Insert the master key to the ignition switch and turn it ON. Verified ○ The warning indicator light (LED) and immobilizer warning symbol [A] blinks to display the registration mode (go to the next step).

  • Page 585

    16-82 ELECTRICAL SYSTEM Immobilizer System (Equipped Models) • Insert the user key 1 to the ignition switch and turn it ON. NOTE ○ Keep the other user key away from the immobilizer an- tenna. ○ If there is any problem in the registration, the warning indicator light (LED) and immobilizer warning symbol [A] blinks to display the collation error.

  • Page 586

    ELECTRICAL SYSTEM 16-83 Immobilizer System (Equipped Models) • Turn the user key 1 OFF and remove the user key 1. ○ The warning indicator light (LED) [A] blinks to display the registration mode. NOTE ○ Turn off the ignition switch and wait for the period of 15 seconds or more.

  • Page 587

    The registration mode automatically ends. • Warning indicator light (LED) goes off [A]. • Remove the key registration unit and connect the immo- bilizer/Kawasaki diagnostic system connector. NOTE ○ Turn the ignition switch ON with the registered user key. ○...

  • Page 588

    ELECTRICAL SYSTEM 16-85 Immobilizer System (Equipped Models) Spare User Key Registration Flow Chart...

  • Page 589

    Ignition Switch and Immobilizer Antenna (see Immobi- lizer System Parts Replacement) Front Seat (see Front Seat Removal in the Frame chap- ter) • Disconnect the immobilizer/Kawasaki diagnostic system connector. • Connect the key registration unit [A]. Special Tool - Key Registration Unit: 57001-1582 •...

  • Page 590

    ELECTRICAL SYSTEM 16-87 Immobilizer System (Equipped Models) Not Verified ○ The warning indicator light (LED) and immobilizer warning symbol [A] blinks to display the collation error. Immobilizer Amplifier Failure Master Key Collation Error • Turn OFF and remove the new user key 1. •...

  • Page 591

    16-88 ELECTRICAL SYSTEM Immobilizer System (Equipped Models) ○ If there is any problem in the registration, the warning indicator light (LED) and immobilizer warning symbol [A] blinks to display the collation error. Immobilizer Amplifier Failure When Registered User Key is Inserted. User Key Collation Error •...

  • Page 592

    ELECTRICAL SYSTEM 16-89 Immobilizer System (Equipped Models) ○ If there is any problem in the registration, the warning indicator light (LED) and immobilizer warning symbol [A] blinks to display the collation error. Immobilizer Amplifier Failure When Registered User Key is Inserted. User Key Collation Error •...

  • Page 593

    16-90 ELECTRICAL SYSTEM Immobilizer System (Equipped Models) • Remove the key registration unit and connect the immo- bilizer/Kawasaki diagnostic system connector. NOTE ○ Turn the ignition switch ON with the registered user key. ○ Check that the engine can be started using all regis- tered user keys.

  • Page 594

    ELECTRICAL SYSTEM 16-91 Immobilizer System (Equipped Models) • The master key is registered in the ECU. ○ The warning indicator light (LED) and immobilizer warning symbol [A] blinks 1 time and stops for 1 second and the repeats this cycle to indicate successful registration of the master key.

  • Page 595

    16-92 ELECTRICAL SYSTEM Immobilizer System (Equipped Models) User Key Collation Error • The user key 1 is registered in the ECU. ○ The warning indicator light (LED) and immobilizer warn- ing symbol [A] blinks 2 times and stops for 1 second and then repeats this cycle to indicate successful registration of user key.

  • Page 596

    ELECTRICAL SYSTEM 16-93 Immobilizer System (Equipped Models) When Registered User Key is Inserted. User Key Collation Error • The user key 2 is registered in the ECU. ○ The warning indicator light (LED) and immobilizer warn- ing symbol [A] blinks 3 times and stops for 1 second and then repeats this cycle to indicate successful registration of user key 2.

  • Page 597

    16-94 ELECTRICAL SYSTEM Immobilizer System (Equipped Models) • Prepare a new ECU [A], new master key [B] and current user keys [C]. NOTE ○ The key registration unit is not required. ○ The key registration process is same as the electric con- trol unit replacement.

  • Page 598

    ELECTRICAL SYSTEM 16-95 Immobilizer System (Equipped Models) All Keys Initial Registration Flow Chart...

  • Page 599

    16-96 ELECTRICAL SYSTEM Immobilizer System (Equipped Models) Immobilizer System Parts Replacement Immobilizer Antenna • Remove the left middle fairing (see Middle Faring Re- moval in the Frame chapter). • Disconnect the lead connectors [A]. • Remove: Steering Stem Head (see Stem, Stem Bearing Removal in the Steering chapter) Handlebar (see Handlebar Removal in the Steering chapter)

  • Page 600

    ELECTRICAL SYSTEM 16-97 Immobilizer System (Equipped Models) ECU (Electric Control Unit) Replacement (for Immobi- lizer Models) • Remove: Front Seat (see Front Seat Removal in the Frame chap- ter) Relay Box [A] • Using a small chisel or other suitable tool, cut off the screws [A].

  • Page 601

    Lower Guard Bracket [A] Upper Guard Bracket [B] CAUTION Do not pinch the leads. • Tighten new screws [C] use Kawasaki genuine screws of which threads are coated with locking agent. Immobilizer Relational Parts Replacement Chart Failed or Lost Part Master...

  • Page 602

    8. Ignition Fuse 15 A 9. Main Fuse 30 A 10. Starter Relay 11. Battery 12 V 10 Ah 12. Joint Connector 2 13. Joint Connector 3 14. Immobilizer/Kawasaki Diagnostic System Connector 15. ECU 16. Water-proof Joint 1 17. Frame Ground...

  • Page 603

    16-100 ELECTRICAL SYSTEM Switches and Sensors Brake Light Timing Inspection • Refer to the Brake Light Switch Operation Inspection in the Periodic Maintenance chapter (see Brake Light Switch Operation Inspection in the Periodic Maintenance chapter). Brake Light Timing Adjustment • Refer to the Brake Light Switch Operation Inspection in the Periodic Maintenance chapter (see Brake Light Switch Operation Inspection in the Periodic Maintenance...

  • Page 604

    ELECTRICAL SYSTEM 16-101 Switches and Sensors Water Temperature Sensor Inspection • Remove the water temperature sensor (see Removal/In- stallation in the Fuel System (DFI) chapter). • Suspend the sensor [A] in a container of coolant so that the temperature-sensing projection [E] and threaded por- tion [E] are submerged.

  • Page 605

    16-102 ELECTRICAL SYSTEM Switches and Sensors • Disconnect the connector [A]. • Remove: Bolt [A] Speed Senor [B] Speed Sensor Installation • Apply grease to the new O-ring [A]. • Set the speed sensor bolt [B]. • Tighten: Torque - Speed Sensor Bolt: 10 N·m (1.0 kgf·m, 89 in·lb) •...

  • Page 606

    ELECTRICAL SYSTEM 16-103 Switches and Sensors • Remove the fuel pump (see Fuel Pump Removal in the Fuel System (DFI) chapter). • Connect the test light (12 V 3.4 W bulb in a socket with leads) and the 12 V battery to the fuel pump connector as shown.

  • Page 607

    16-104 ELECTRICAL SYSTEM Switches and Sensors • Remove: Front Exhaust Pipe (see Front Exhaust Pipe Removal in the Engine Top End chapter) Oxygen Sensor #2 [A] Oxygen Sensor Installation (Europe Models) CAUTION Never drop the oxygen sensor [A], especially on a hard surface.

  • Page 608

    ELECTRICAL SYSTEM 16-105 Switches and Sensors • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel Tank Re- moval in the Fuel System (DFI) chapter) Air Cleaner Housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter) •...

  • Page 609

    16-106 ELECTRICAL SYSTEM Switches and Sensors Gear Position Switch Inspection NOTE ○ Be sure the transmission mechanism is good condition. • Remove the fuel tank (see Fuel Tank Removal in the Fuel System (DFI) chapter). • Disconnect the connector [A]. •...

  • Page 610

    ELECTRICAL SYSTEM 16-107 Relay Box The relay box [A] has relays and diodes. The relays and diodes can not be removed. Relay Box Removal • Remove the front seat (see Front Seat Removal in the Frame chapter). • Take out the relay box [A] and disconnect the connectors [B].

  • Page 611

    16-108 ELECTRICAL SYSTEM Relay Box Relay Circuit Inspection (with the battery connected) Battery Tester Tester Connection Connection Reading (Ω) (–) Fuel Pump Relay Fan Relay 15-16 14-17 Battery Tester Connection Tester Connection DC 25 V Range Reading (V) (–) Starter Circuit Battery 13-9 Relay...

  • Page 612

    ELECTRICAL SYSTEM 16-109 Relay Box Relay Box Internal Circuit A. Headlight Relay B. Fuel Pump Relay C. Starter Circuit Relay D. Fan Relay...

  • Page 613

    16-110 ELECTRICAL SYSTEM Fuse 30 A Main Fuse Removal • Remove: Front Seat (see Front Seat Removal in the Frame chap- ter) Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) 30 A Main Fuse Connector [A] •...

  • Page 614

    ELECTRICAL SYSTEM 16-111 Fuse • Pull the ECU fuse [A] straight out of the fuse box with needle nose pliers. Fuse Installation If a fuse fails during operation, inspect the electrical sys- tem to determine the cause, and then replace it with a new fuse of proper amperage.

  • Page 616

    APPENDIX 17-1 Appendix Table of Contents Cable, Wire, and Hose Routing ....................17-2 Troubleshooting Guide ......................17-30...

  • Page 617

    17-2 APPENDIX Cable, Wire, and Hose Routing...

  • Page 618

    APPENDIX 17-3 Cable, Wire, and Hose Routing 1. Throttle Cables 2. Clamp 3. Meter Connector 4. Clamp the right switch housing lead. 5. Right Switch Housing Lead 6. City Light Connector 7. Right Headlight Connector 8. Right Turn Signal Light Connector 9.

  • Page 619

    17-4 APPENDIX Cable, Wire, and Hose Routing...

  • Page 620

    APPENDIX 17-5 Cable, Wire, and Hose Routing 1. Throttle Cable (Accelerator) 2. Throttle Cable (Decelerator) 3. Run the throttle cables above the harness and hose, and under the ignition switch lead. 4. Clutch Cable 5. Clamp 6. Throttle Cables 7. Viewed A 8.

  • Page 621

    17-6 APPENDIX Cable, Wire, and Hose Routing...

  • Page 622

    APPENDIX 17-7 Cable, Wire, and Hose Routing 1. Right Headlight Connector 2. Right City Light Connector 3. Right Turn Signal Light Connector 4. Right Switch Housing Lead 5. Clamp the right switch housing lead. 6. Horn 7. Engine Subharness Joint Connector (To the Throttle Assy) 8.

  • Page 623

    17-8 APPENDIX Cable, Wire, and Hose Routing...

  • Page 624

    APPENDIX 17-9 Cable, Wire, and Hose Routing 1. Battery Positive (+) Terminal 2. Relay Box 3. Immobilizer/Kawasaki Diagnostic System Connector 4. Fuse Box 5. Turn Signal Relay 6. Right Turn Signal Light Connector 7. Tail/Brake Light Connector 8. Clamp (The clamp attached on the main harness.) 9.

  • Page 625

    17-10 APPENDIX Cable, Wire, and Hose Routing...

  • Page 626

    APPENDIX 17-11 Cable, Wire, and Hose Routing 1. Left City Light Connector 2. Meter Connector 3. Clamp 4. Headlight Connector 5. Clamp 6. Run the fan motor lead connector above the main harness. 7. Immobilizer Amplifier 8. Joint Connector for the stick coil and air switching valve leads (Install it into the bracket). 9.

  • Page 627

    17-12 APPENDIX Cable, Wire, and Hose Routing...

  • Page 628

    APPENDIX 17-13 Cable, Wire, and Hose Routing 1. Insert the radiator coolant return hose to the corner portion of the radiator pipe. 2. Clamp 3. Radiator Overflow Hose 4. Clamp 5. Run the radiator coolant return hose inside the engine mount. 6.

  • Page 629

    17-14 APPENDIX Cable, Wire, and Hose Routing...

  • Page 630

    APPENDIX 17-15 Cable, Wire, and Hose Routing 1. Clamp 2. Air Cleaner Drain Hose 3. Breather Hose 4. Joint Connector (Water Temperature Sensor Lead, Gear Position Sensor Lead, Speed Sensor Lead, and Oil Pressure Switch Lead) 5. Right Side 6. Front 7.

  • Page 631

    17-16 APPENDIX Cable, Wire, and Hose Routing...

  • Page 632

    APPENDIX 17-17 Cable, Wire, and Hose Routing 1. Stick Coil #1 2. Stick Coil #2 3. Stick Coil #3 4. Stick Coil #4 5. Air Switching Valve 6. Evaporative Hose (White) 7. Evaporative Hose (Green) 8. Clamp 9. Through the crankshaft sensor lead into the clamp (attached on the air switching valve). 10.

  • Page 633

    17-18 APPENDIX Cable, Wire, and Hose Routing...

  • Page 634

    APPENDIX 17-19 Cable, Wire, and Hose Routing 1. Install the air switching valve after installing the heat insulation rubber plate. 2. Throttle Body Assy 3. Hang down the shaded portions of the heat insultaion rubber plate. 4. For Left Engine Bracket Bolt 5.

  • Page 635

    17-20 APPENDIX Cable, Wire, and Hose Routing 1. Heat Insulation Rubber Plate 2. Run the starter motor cable into the hole of the heat insulation rubber plate. 3. Run the starter motor cable under the adjusting collar. 4. Engine Ground Cable 5.

  • Page 636

    APPENDIX 17-21 Cable, Wire, and Hose Routing 1. Ignition Coil Lead 2. Run the ignition coil lead. 3. Do not pinch the ignition coil lead. 4. Idle Adjusting Cable 5. Radiator Hose 6. Install the idle adjuster screw direction as shown. 7.

  • Page 637

    17-22 APPENDIX Cable, Wire, and Hose Routing 1. Fuel Tank Drain Hose 2. Run the drain hose inside the radiator hose. 3. Run the drain hose inside the water hose. 4. Put the hose through the cut hole of the under fairing. 5.

  • Page 638

    APPENDIX 17-23 Cable, Wire, and Hose Routing 1. Air Switching Valve 10. Run the water hose through the clamp. 2. Face the paint mark upward. 11. Water Hose 3. Air Switching Valve Hose 12. Install the upper crankcase bolt with the 4.

  • Page 639

    17-24 APPENDIX Cable, Wire, and Hose Routing...

  • Page 640

    APPENDIX 17-25 Cable, Wire, and Hose Routing 1. Brake Hose 2. Clamp 3. Clamps 4. Brake Hoses 5. Face the paint mark outside. 6. Viewed Right Side 7. Viewed Left Side 8. Brake Hose 9. Rubber Dumper 10. Clamps 11. Brake Hose 12.

  • Page 641

    17-26 APPENDIX Cable, Wire, and Hose Routing California Model...

  • Page 642

    APPENDIX 17-27 Cable, Wire, and Hose Routing 1. Front 2. To the Fuel Tank 3. Hose (Blue) 4. Hose (Red) 5. Hose (White) 6. To the fitting of the Throttle Body #3 (Run the hose over the subthrottle valve actuator connector.) 7.

  • Page 643

    17-28 APPENDIX Cable, Wire, and Hose Routing California Model 1. Fuel Tank 9. Throttle Bodies 2. Clamps 10. Hose (Blue) 3. Hose (Red) 11. Hose (Blue) 4. Canister 12. Separator 5. Clamp 13. Hose (Green) 6. To the Fitting of the Throttle Body #3 14.

  • Page 644

    APPENDIX 17-29 Cable, Wire, and Hose Routing 1. Adjusters 2. Closing Cable 3. Yellow 4. Dark Green 5. Rear Frame 6. Dust Covers 7. Opening Cable 8. Clamp 9. Exhaust Butterfly Valve Actuator 10. 41.7° ±7° (Original Position of Pulley) 11.

  • Page 645

    17-30 APPENDIX Troubleshooting Guide NOTE Camshaft position sensor trouble ○ Refer to the Fuel System chapter for most Neutral, starter lockout, or sidestand switch of DFI trouble shooting guide. trouble ○ This is not an exhaustive list, giving every Crankshaft sensor trouble possible cause for each problem listed.

  • Page 646

    APPENDIX 17-31 Troubleshooting Guide No valve clearance Valve not seating properly (valve bent, Cylinder, piston worn worn, or carbon accumulation on the Piston ring bad (worn, weak, broken, or seating surface.) sticking) Knocking: Piston ring/groove clearance excessive Carbon built up in combustion chamber Cylinder head warped Fuel poor quality or incorrect Cylinder head gasket damaged...

  • Page 647

    17-32 APPENDIX Troubleshooting Guide Gear Shifting Faulty: Brake dragging Lubrication inadequate: Doesn’t go into gear; shift pedal doesn’t Engine oil level too low return: Engine oil poor quality or incorrect Clutch not disengaging Oil cooler incorrect: Shift fork bent or seized Oil cooler clogged Gear stuck on the shaft Gauge incorrect:...

  • Page 648

    APPENDIX 17-33 Troubleshooting Guide Engine mount loose O-ring at the oil passage in the crankcase Crankshaft bearing worn damaged Primary gear worn or chipped Exhaust Smokes Excessively: Camshaft chain tensioner trouble Camshaft chain, sprocket, guide worn White smoke: Air suction valve damaged Piston oil ring worn Air switching valve damaged Cylinder worn...

  • Page 649

    17-34 APPENDIX Troubleshooting Guide Rear shock adjustment too soft Front fork, rear shock absorber spring weak Rear shock absorber oil leaking Brake Doesn’t Hold: Air in the brake line Pad or disc worn Brake fluid leakage Disc warped Contaminated pad Brake fluid deteriorated Primary or secondary cup damaged in master cylinder...

  • Page 650

    MODEL APPLICATION Year Model Beginning Frame No. □ JKAZXCD1 6A000001 2006 ZX1000D6F JKAZXT00DDA000001 ZXT00D-000001 □ :This digit in the frame number changes from one machine to another. Part No.99924-1365-02 Printed in Japan...

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