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Z750
Z750 ABS
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   Also See for KAWASAKI Z750 ABS

   Summary of Contents for KAWASAKI Z750 ABS

  • Page 1

    Z750 Z750 ABS Motorcycle Service Manual...

  • Page 3: General Information

    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...

  • Page 5

    All information contained in this publication is based on the latest product information available at the time of publication. Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts. © 2007 Kawasaki Heavy Industries, Ltd. First Edition (1) : Feb. 28, 2007 (K)

  • Page 6

    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 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 9

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

  • Page 10

    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.

  • Page 11

    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.

  • Page 12

    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 13

    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.

  • Page 14

    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 15

    GENERAL INFORMATION 1-7 Model Identification ZR750L7F (Europe) Left Side View ZR750L7F (Europe) Right Side View...

  • Page 16

    1-8 GENERAL INFORMATION Model Identification ZR750M7F Left Side View ZR750M7F Right Side View Frame Number Engine Number...

  • Page 17

    GENERAL INFORMATION 1-9 General Specifications Items ZR750L7F, ZR750M7F Dimensions Overall Length 2 085 mm (82.09 in.) Overall Width 805 mm (31.69 in.) Overall Height 1 100 mm (43.31 in.) Wheelbase 1 440 mm (56.69 in.) Road Clearance 155 mm (6.10 in.) Seat Height 815 mm (32.09 in.) Dry Mass:...

  • Page 18

    1-10 GENERAL INFORMATION General Specifications Items ZR750L7F, ZR750M7F Exhaust: Open 51° BBDC Close 25° ATDC Duration 256° Lubrication System Forced lubrication (wet sump) Engine Oil: Type API SE, SF or SG API SH, SJ or SL with JASO MA Viscosity SAE 10W-40 Capacity 3.8 L (4.0 US qt)

  • Page 19

    GENERAL INFORMATION 1-11 General Specifications Items ZR750L7F, ZR750M7F Rear Suspension: Type Swingarm (uni-trak) Wheel Travel 125 mm (4.92 in.) Brake Type: Front Dual discs Rear Single disc Electrical Equipment Battery 12 V 8 Ah Headlight: Type Semi-sealed beam Bulb 12 V 55 W × 2/55 W (Hi/Lo) Tail/Brake Light 12 V 0.5/4.1 W (LED) Alternator:...

  • Page 20

    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 21: Table Of Contents, Periodic Maintenance, Table Of Contents

    PERIODIC MAINTENANCE 2-1 Periodic Maintenance Table of Contents Periodic Maintenance Chart ....................Torque and Locking Agent...................... Specifications ......................... 2-12 Special Tools .......................... 2-14 Periodic Maintenance Procedures..................2-15 Fuel System (DFI)........................ 2-15 Air Cleaner Element Cleaning................... 2-15 Throttle Control System Inspection................... 2-15 Engine Vacuum Synchronization Inspection..............

  • Page 22: Table Of Contents, Periodic Maintenance

    2-2 PERIODIC MAINTENANCE Steering Play Inspection ....................2-43 Steering Play Adjustment....................2-43 Steering Stem Bearing Lubrication ................... 2-44 Electrical System ......................... 2-45 Spark Plug Condition Inspection..................2-45 Lights and Switches Operation Inspection................ 2-46 Headlight Aiming Inspection ..................... 2-48 Sidestand Switch Operation Inspection ................2-49 Engine Stop Switch Operation Inspection.................

  • Page 23: Table Of Contents, Periodic Maintenance Chart

    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 ×...

  • Page 24: Periodic Maintenance Chart

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

  • Page 25: Periodic Maintenance, Periodic Maintenance Chart

    PERIODIC MAINTENANCE 2-5 Periodic Maintenance Chart Periodic Replacement Parts FREQUENCY Whichever * ODOMETER READING comes × 1 000 km first (× 1 000 mile) Page CHANGE/REPLACE ITEM Every (0.6) (7.5) (15) (24) (30) • Air cleaner element # 2-53 • Fuel hose 4 years 2-54...

  • Page 26: Torque And Locking Agent, Fuel System

    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. EO: Apply engine oil.

  • Page 27

    PERIODIC MAINTENANCE 2-7 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Thermostat Bracket Bolt 0.70 61 in·lb Thermostat Housing Ground Bolt 0.70 61 in·lb Thermostat Housing Screws 0.60 52 in·lb Water Pipe Bolts 97 in·lb Water Pump Cover Bolts 97 in·lb Water Pump Impeller Bolt 87 in·lb...

  • Page 28

    2-8 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Engine Lubrication System Coolant Drain Bolt (Water Pump) 97 in·lb Engine Oil Drain Bolt Oil Filter G, R Oil Filter Holder Oil Filler Plug 0.20 18 in·lb Oil Jet Nozzle Bolts 0.70 61 in·lb...

  • Page 29

    PERIODIC MAINTENANCE 2-9 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Shift Lever Bolt 0.70 61 in·lb Shift Pedal Mounting Bolt Shift Shaft Return Spring Pin Starter Motor Clutch Bolts 106 in·lb Tie-Rod Locknuts 0.70 61 in·lb Wheels/Tires Front Axle 11.0 79.7...

  • Page 30

    2-10 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Rear Shock Absorber Nut (Lower) Rear Shock Absorber Nut (Upper) Swingarm Pivot Shaft 87 in·lb Swingarm Pivot Shaft Locknut 10.0 72.3 Swingarm Pivot Shaft Nut 11.0 79.7 Tie-Rod Nuts Uni-Trak Rocker Arm Nut Upper Front Fork Clamp Bolts...

  • Page 31

    PERIODIC MAINTENANCE 2-11 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Speed Sensor Bolt 106 in·lb Starter Motor Mounting Bolts 97 in·lb Starter Relay Cable Terminal Bolts 0.40 35 in·lb Stator Coil Bolts 106 in·lb Switch Housing Screws 0.36 31 in·lb Tail/Brake Light Mounting Screws...

  • Page 32: Fuel System

    2-12 PERIODIC MAINTENANCE 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) – – – Bypass Screws (Turn Out) 2 1/2 (for reference) –...

  • Page 33

    PERIODIC MAINTENANCE 2-13 Specifications Item Standard Service Limit Final Drive Drive Chain Slack 40 mm (1.2 1.6 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 ENUMA –...

  • Page 34

    2-14 PERIODIC MAINTENANCE Special Tools Inside Circlip Pliers: Vacuum Gauge: 57001-143 57001-1369 Steering Stem Nut Wrench: Throttle Sensor Setting Adapter: 57001-1100 57001-1538 Jack: Extension Tube: 57001-1238 57001-1578 Oil Filter Wrench: Jack Attachment: 57001-1249 57001-1608...

  • Page 35: Periodic Maintenance Procedures, Fuel System (dfi), Air Cleaner Element Cleaning, Throttle Control System Inspection

    PERIODIC MAINTENANCE 2-15 Periodic Maintenance Procedures Fuel System (DFI) Air Cleaner Element Cleaning NOTE ○ In dusty areas, the element should be cleaned more frequently than the recommended interval. ○ After riding through rain or on muddily roads, the ele- ment should be cleaned immediately.

  • Page 36: Engine Vacuum Synchronization Inspection, Engine Vacuum Synchronization - Inspect

    2-16 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Loosen the locknuts [A], and turn the lower adjusters [B] until the proper amount of throttle grip free play is ob- tained. • Tighten the locknuts against the adjusters securely. If the throttle grip free play can not be adjusted with the lower adjusters, use the adjuster at the upper end of the cable again.

  • Page 37

    PERIODIC MAINTENANCE 2-17 Periodic Maintenance Procedures • Remove the fuel outlet hose (see Fuel Hose Replace- ment). • Connect the following parts temporary. Fuel Pump Lead Connector [A] Fuel Level Sensor Lead Connector [B] Extension Tube [C] Special Tool - Extension Tube: 57001-1578 •...

  • Page 38

    2-18 PERIODIC MAINTENANCE Periodic Maintenance Procedures If any one vacuum measurement is out of the specified range after left (#1, #2) and right (#2, #3) synchronization, adjust the bypass screws [A]. Upside View [B] • Adjust the lower vacuum between #1 and #2 to the higher vacuum of #1 and #2.

  • Page 39: Idle Speed Inspection, Idle Speed - Inspect • • • •

    PERIODIC MAINTENANCE 2-19 Periodic Maintenance Procedures • 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.

  • Page 40: Idle Speed Adjustment, Fuel Hose Inspection (fuel Leak, Damage, Installation Condition)

    2-20 PERIODIC MAINTENANCE Periodic Maintenance Procedures 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.

  • Page 41

    PERIODIC MAINTENANCE 2-21 Periodic Maintenance Procedures • Check that the outlet hose joints are securely connected. ○ Push and pull [A] the hose joint [B] back and forth more than two times, and make sure it is locked and does not come off.

  • Page 42: Cooling System, Coolant Level Inspection, Radiator Hose And Pipe Inspection (coolant Leak, Damage, Installation Condition)

    2-22 PERIODIC MAINTENANCE Periodic Maintenance Procedures Cooling System Coolant Level Inspection NOTE ○ Check the level when the engine is cold (room or ambi- ent temperature). • Remove the front seat (see Front Seat Removal in the Frame chapter). • Check the coolant level in the reserve tank [A] with the motorcycle held perpendicular (Do not use the side- stand.).

  • Page 43: Engine Top End, Valve Clearance Inspection

    PERIODIC MAINTENANCE 2-23 Periodic Maintenance Procedures Engine Top End Valve Clearance Inspection NOTE ○ Valve clearance must be checked and adjusted when the engine is cold (room temperature). • Remove: Crankshaft Sensor Cover (see Crankshaft Sensor Re- moval in the Electrical System chapter) Cylinder Head Cover (see Cylinder Head Cover Re- moval in the Engine Top End chapter) •...

  • Page 44: Valve Clearance Adjustment

    2-24 PERIODIC MAINTENANCE Periodic Maintenance Procedures ○ When positioning #1 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 Measuring Valve [A] ○ When positioning #4 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...

  • Page 45

    PERIODIC MAINTENANCE 2-25 Periodic Maintenance Procedures VALVE CLEARANCE ADJUSTMENT CHART INLET VALVE 1. Measure the clearance (when engine is cold). 2. Check present shim size. 3. Match clearance in vertical column with present shim size in horizontal column. 4. Install the shim specified where the lines intersect. This shim will give the proper clearance. Example: Present shim is 2.95 mm Measured clearance is 0.45 mm...

  • Page 46

    2-26 PERIODIC MAINTENANCE Periodic Maintenance Procedures VALVE CLEARANCE ADJUSTMENT CHART EXHAUST VALVE 1. Measure the clearance (when engine is cold). 2. Check present shim size. 3. Match clearance in vertical column with present shim size in horizontal column. 4. Install the shim specified where the lines intersect. This shim will give the proper clearance. Example: Present shim is 2.95 mm.

  • Page 47: Exhaust Butterfly Valve Cable Inspection

    PERIODIC MAINTENANCE 2-27 Periodic Maintenance Procedures CAUTION Be sure to remeasure the clearance after selecting a shim according to the table. If the clearance is out of the specified range, use the additional shim. ○ If there is no valve clearance, use a shim that is a few sizes smaller, and remeasure the valve clearance.

  • Page 48: Exhaust Butterfly Valve Cable Adjustment

    2-28 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Check that there is no play in the inner cables [A] by pulling them lightly. If there is play in the inner cables, adjust them (see Ex- haust Butterfly Valve Cable Adjustment). Exhaust Butterfly Valve Cable Adjustment •...

  • Page 49

    PERIODIC MAINTENANCE 2-29 Periodic Maintenance Procedures • Stretch the open cable (white) [A] first by using the ad- juster [B]. ○ Turn the adjuster counterclockwise until it becomes hard to turn. Locknut of White [C] CAUTION To keep the correct exhaust butterfly valve position, adjust the open cable first.

  • Page 50

    2-30 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Turn the ignition switch ON and wait until the pulley [A] turns fully clockwise [B]. • Turn off the ignition switch when the pulley become fully clockwise position [C] as shown in the figure. ○...

  • Page 51: Air Suction System, Air Suction System Damage Inspection, Clutch, Clutch Operation Inspection

    PERIODIC MAINTENANCE 2-31 Periodic Maintenance Procedures • Stretch the open cable (white) by using the adjuster [A]. ○ Turn the adjuster counterclockwise until it becomes hard to turn. Locknut of White [B] CAUTION Do not overstretch. If the adjustment of the exhaust butterfly valve cables are incorrect, the exhaust but- terfly valve actuator does not operate correctly.

  • Page 52: Wheels/tires, Air Pressure Inspection

    2-32 PERIODIC MAINTENANCE Periodic Maintenance Procedures WARNING To avoid a serious burn, never touch the engine or exhaust pipe during clutch adjustment. • Turn the adjuster [A] so that 5 6 mm (0.20 0.24 in.) [B] of threads are visible. •...

  • Page 53: Wheel/tire Damage Inspection, Tire Tread Wear Inspection, Wheel/tire Damage - Inspect • • •

    PERIODIC MAINTENANCE 2-33 Periodic Maintenance Procedures Wheel/Tire Damage Inspection • Remove any imbedded stones [A] or other foreign parti- cles [B] from tread. • Visually inspect the tire for cracks and cuts, and replace the tire if necessary. Swelling or high spots indicate inter- nal damage, requiring tire replacement.

  • Page 54: Wheel Bearing Damage Inspection, Drive Train, Drive Chain Lubrication Condition Inspection

    2-34 PERIODIC MAINTENANCE Periodic Maintenance Procedures Wheel Bearing Damage Inspection • Raise the front wheel off the ground with the jack (see Front Wheel Removal in the Wheels/Tires chapter). • Turn the handlebar all the way to the right or left. •...

  • Page 55: Drive Chain Slack Inspection, Drive Chain Slack Adjustment

    PERIODIC MAINTENANCE 2-35 Periodic Maintenance Procedures • Apply oil to the sides of the rollers so that oil will penetrate to the rollers and bushings. Apply the oil to the O-rings so that the O-rings will be coated with oil. •...

  • Page 56: Wheel Alignment Inspection

    2-36 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Insert a new cotter pin [A]. NOTE ○ When inserting the cotter pin, if the slots in the nut do not align with the cotter pin hole in the axle, tighten the nut clockwise [B] up to next alignment. ○...

  • Page 57: Drive Chain Wear Inspection, Chain Guide Wear Inspection

    PERIODIC MAINTENANCE 2-37 Periodic Maintenance Procedures Drive Chain Wear Inspection • Remove the chain cover (see Drive Chain Removal in the Final Drive chapter). • Rotate the rear wheel to inspect the drive chain for dam- aged rollers, and loose pins and links. If there is any irregularity, replace the drive chain.

  • Page 58: Brake System, Brake Fluid Leak (brake Hose And Pipe) Inspection

    2-38 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake System Brake Fluid Leak (Brake Hose and Pipe) Inspection • For ABS equipped models; note the following. • Remove the fuel tank (see Fuel Tank Removal in the Fuel System (DFI) chapter). • Apply the brake lever or pedal and inspect the brake fluid leak from the brake hoses [A], pipes [B] (ABS equipped models) and fittings [C].

  • Page 59: Brake Hose And Pipe Damage And Installation Condition Inspection, Brake Operation Inspection

    PERIODIC MAINTENANCE 2-39 Periodic Maintenance Procedures Brake Hose and Pipe Damage and Installation Condition Inspection • For ABS equipped models; note the following. • Remove the fuel tank (see Fuel Tank Removal in the Fuel System (DFI) chapter). • Inspect the brake hoses, pipes and fittings for deteriora- tion, cracks and signs of leakage.

  • Page 60: Brake Pad Wear Inspection

    2-40 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Follow the procedure below to install the front brake fluid reservoir cap correctly. ○ First, tighten the front brake fluid reservoir cap [B] clock- wise [C] by hand until slight resistance is felt indicating that the cap is seated on the reservoir body, then tighten the cap an additional 1/6 turn [D] while holding the brake fluid reservoir body [A].

  • Page 61: Brake Light Switch Operation Inspection, Suspensions, Front Forks/rear Shock Absorber Operation Inspection

    PERIODIC MAINTENANCE 2-41 Periodic Maintenance Procedures Brake Light Switch Operation Inspection • Turn on the ignition switch. • The brake light [A] should go on when the brake lever is applied or after the brake pedal is depressed about 10 mm (0.39 in.).

  • Page 62: Front Fork Oil Leak Inspection, Rear Shock Absorber Oil Leak Inspection, Rocker Arm Operation Inspection

    2-42 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Pump the seat down and up [A] 4 or 5 times, and inspect the smooth stroke. If the shock absorber does not smoothly stroke or noise is found, inspect the oil leak (see Rear Shock Absorber Oil Leak Inspection).

  • Page 63: Steering System, Steering Play Inspection, Steering Play Adjustment

    PERIODIC MAINTENANCE 2-43 Periodic Maintenance Procedures Steering System Steering Play Inspection • Raise the front wheel off the ground with the jack. Special Tools - Jack: 57001-1238 Jack Attachment: 57001-1608 • With the front wheel pointing straight ahead, alternately tap each end of the handlebar. The front wheel should swing fully left and right from the force of gravity until the fork hits the stop.

  • Page 64: Steering Stem Bearing Lubrication

    2-44 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Adjust the steering. Special Tool - Steering Stem Nut Wrench [A]: 57001-1100 If the steering is too tight, loosen the stem nut a fraction of a turn. If the steering is too loose, tighten the stem nut a fraction of a turn.

  • Page 65: Electrical System, Spark Plug Condition Inspection, Spark Plug Condition - Inspect

    PERIODIC MAINTENANCE 2-45 Periodic Maintenance Procedures Electrical System Spark Plug Condition Inspection • Remove the spark plugs (see Spark Plug Replacement), and visually inspect. • Clean the spark plug, preferably in a sandblasting device, and then clean off any abrasive particles. The plug may also be cleaned using a high-flash point solvent and a wire brush or other suitable tool.

  • Page 66: Lights And Switches Operation Inspection

    2-46 PERIODIC MAINTENANCE Periodic Maintenance Procedures Lights and Switches Operation Inspection First Step • Turn on the ignition switch. • The following lights should go on according to below table. go on City Lights [A] Taillight [B] goes on License Plate Light [C] goes on Meter Panel LCD [D] goes on...

  • Page 67

    PERIODIC MAINTENANCE 2-47 Periodic Maintenance Procedures 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. •...

  • Page 68: Headlight Aiming Inspection

    2-48 PERIODIC MAINTENANCE Periodic Maintenance Procedures • 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 69: Sidestand Switch Operation Inspection

    PERIODIC MAINTENANCE 2-49 Periodic Maintenance Procedures Sidestand Switch Operation Inspection • Inspect the sidestand switch [A] operation accordance to the following table. Sidestand Switch Operation Gear Clutch Engine Engine Sidestand Start Position Lever Continue Neutral Released Starts running Continue Neutral Pulled in Starts running...

  • Page 70: Engine Stop Switch Operation Inspection, Others, Chassis Parts Lubrication

    2-50 PERIODIC MAINTENANCE Periodic Maintenance Procedures Engine Stop Switch Operation Inspection First Step • Turn on the ignition switch. • Set the neutral position. • Turn the engine stop switch to stop position [A]. • Push the starter button. • The engine does not start.

  • Page 71

    PERIODIC MAINTENANCE 2-51 Periodic Maintenance Procedures Cables: Lubricate with Rust Inhibitor. Clutch Cable Throttle Cables • Lubricate the cables by seeping the oil between the cable and housing. ○ The cable may be lubricated by using a commercially available pressure cable lubricator with an aerosol cable lubricant.

  • Page 72: Bolts, Nuts And Fasteners Tightness Inspection

    2-52 PERIODIC MAINTENANCE Periodic Maintenance Procedures Bolts, Nuts and Fasteners Tightness Inspection • Check the tightness of the bolts and nuts listed here. Also, check to see that each cotter pin is in place and in good condition. NOTE ○ For the engine fasteners, check the tightness of them when the engine is cold (at room temperature).

  • Page 73: Replacement Parts, Air Cleaner Element Replacement, Air Cleaner Element #

    PERIODIC MAINTENANCE 2-53 Periodic Maintenance Procedures 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 muddily roads, the ele- ment should be replaced immediately. WARNING If dirt or dust is allowed to pass through into the throttle assy, the throttle may become stuck, possi-...

  • Page 74: Fuel Hose Replacement

    2-54 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Install a new element [A] so that flat side [B] faces forward. • Fit the tongue [C] of the air cleaner duct into the slot [D] of the air cleaner housing. • Tighten: Torque - Air Cleaner Duct Screws: 3.8 N·m (0.39 kgf·m, 34 in·lb) Fuel Hose Replacement...

  • Page 75

    PERIODIC MAINTENANCE 2-55 Periodic Maintenance Procedures • Pull the joint lock [A] as shown in the figure. • Pull the fuel outlet hose joint [B] out of the delivery pipe. • Install a new fuel inlet hose [A] so that the white mark side [B] faces outlet pipe [C] of the fuel tank.

  • Page 76: Coolant Change

    2-56 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Push and pull [A] the fuel hose joint [B] back and forth more than two times, and make sure it is locked and does not come off. WARNING Make sure the fuel hose joint is installed correctly on the delivery pipe or the fuel could leak.

  • Page 77

    PERIODIC MAINTENANCE 2-57 Periodic Maintenance Procedures • Remove: Right Seat Cover (see Seat Cover Removal in the Frame chapter) Hose [A] Reserve Tank Bolts [B] • Turn over the reserve tank, remove the cap, and pour the coolant into a suitable container. •...

  • Page 78: Radiator Hose And O-ring Replacement, Engine Oil Change

    2-58 PERIODIC MAINTENANCE Periodic Maintenance Procedures Radiator Hose and O-ring Replacement • Drain the coolant (see Coolant Change). • Remove: Thermostat Housing [A] (see Thermostat Removal in the Cooling System chapter) Water Pump Cover [B] (see Water Pump Removal in the Cooling System chapter) O-rings [C] Hoses [D]...

  • Page 79: Oil Filter Replacement

    PERIODIC MAINTENANCE 2-59 Periodic Maintenance Procedures Recommended Engine Oil Type: API SE, SF or SG API SH, SJ or SL with JASO MA Viscosity: SAE 10W-40 Capacity: 3.1 L (3.3 US qt) (when filter is not removed) 3.3 L (3.5 US qt) (when filter is removed) 3.8 L (4.0 US qt) (when engine is completely dry) NOTE...

  • Page 80: Brake Hose And Pipe Replacement

    2-60 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Hose and Pipe Replacement CAUTION Brake fluid quickly ruins painted plastic surfaces; any spilled fluid should be completely washed away immediately. • Remove the brake hose banjo bolts [A]. • When removing the brake hose, take care not to spill the brake fluid on the painted or plastic parts.

  • Page 81

    PERIODIC MAINTENANCE 2-61 Periodic Maintenance Procedures • For ABS equipped models; note the following. • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Rear Fender (see Flap and Rear Fender Removal in the Frame chapter) ABS Hydraulic Unit (see ABS Hydraulic Unit Removal in the Brakes chapter) Brake Pipe Joint Nuts [A]...

  • Page 82: Brake Fluid Change

    2-62 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Fluid Change NOTE ○ The procedure to change the front brake fluid is as fol- lows. Changing the rear brake fluid is the same as for the front brake. • Level the brake fluid reservoir. •...

  • Page 83: Master Cylinder Rubber Parts Replacement

    PERIODIC MAINTENANCE 2-63 Periodic Maintenance Procedures 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 84: Caliper Rubber Parts Replacement

    2-64 PERIODIC MAINTENANCE Periodic Maintenance Procedures Master Cylinder Assembly • Before assembly, clean all parts including the master cylinder with brake fluid or alcohol. CAUTION Except for the disc pads and disc, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol for cleaning brake parts.

  • Page 85

    PERIODIC MAINTENANCE 2-65 Periodic Maintenance Procedures WARNING To avoid serious injury, never place your fingers or palm in front of the piston. If you apply compressed air into the caliper, the piston may crush your hand or fingers. ○ Pull out the pistons by hand. •...

  • Page 86

    2-66 PERIODIC MAINTENANCE Periodic Maintenance Procedures Rear Caliper Disassembly • Remove: Rear Caliper (see Rear Caliper Removal in the Brakes chapter) Brake Pads (see Rear Brake Pad Removal in the Brakes chapter) • Using compressed air, remove the piston. ○ Cover the piston area with a wooden board [A].

  • Page 87: Spark Plug Replacement, Spark Plug • • • •

    PERIODIC MAINTENANCE 2-67 Periodic Maintenance Procedures • Apply brake fluid to the cylinder bore. • Replace the fluid seal [A] with a new one. ○ Apply silicone grease to the fluid seal, and install it into the cylinder by hand. •...

  • Page 89

    FUEL SYSTEM (DFI) 3-1 Fuel System (DFI) Table of Contents Exploded View........................DFI System..........................3-10 DFI Parts Location........................3-16 Specifications ......................... 3-18 Special Tools and Sealant ...................... 3-20 DFI Servicing Precautions ...................... 3-22 DFI Servicing Precautions ....................3-22 Troubleshooting the DFI System .................... 3-24 Outline ..........................

  • Page 90

    3-2 FUEL SYSTEM (DFI) Speed Sensor Input Voltage Inspection................3-67 Speed Sensor Output Voltage Inspection ................. 3-68 Vehicle-down Sensor (Service Code 31)................3-70 Vehicle-down Sensor Removal ..................3-70 Vehicle-down Sensor Installation ..................3-70 Vehicle-down Sensor Input Voltage Inspection..............3-71 Vehicle-down Sensor Output Voltage Inspection .............. 3-72 Subthrottle Sensor (Service Code 32)..................

  • Page 91

    FUEL SYSTEM (DFI) 3-3 ECU Identification ......................3-106 ECU Removal ........................3-106 ECU Installation ........................ 3-107 ECU Power Supply Inspection..................3-107 DFI Power Source ........................3-110 ECU Fuse Removal ......................3-110 ECU Fuse Installation ....................... 3-110 ECU Fuse Inspection ......................3-110 ECU Main Relay Removal/Installation ................

  • Page 92

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

  • Page 93

    FUEL SYSTEM (DFI) 3-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Air Cleaner Duct Screws 0.39 34 in·lb Air Cleaner Housing Mounting Bolts 87 in·lb 0.12 11 in·lb Air Cleaner Housing Tapping Screws Air Duct Clamp Bolts 0.20 18 in·lb Bypass Screws 0.02 1.8 in·lb...

  • Page 94

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

  • Page 95

    FUEL SYSTEM (DFI) 3-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Camshaft Position Sensor Bolt 106 in·lb Crankshaft Sensor Bolts 0.60 52 in·lb 44.1 4.50 32.5 Oxygen Sensor (Equipped Models) Speed Sensor Bolt 106 in·lb Vehicle-down Sensor Bolts 0.61 53 in·lb Water Temperature Sensor 7.

  • Page 96

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

  • Page 97

    FUEL SYSTEM (DFI) 3-9 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Exhaust Butterfly Valve Actuator Bracket Bolt 0.70 61 in·lb Exhaust Butterfly Valve Actuator Mounting Bolts 0.70 61 in·lb 0.51 44 in·lb Exhaust Butterfly Valve Actuator Pulley Bolt Fuel Pump Bolts 87 in·lb L, S L: Apply a non-permanent locking agent.

  • Page 98

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

  • Page 99

    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 100

    3-12 FUEL SYSTEM (DFI) DFI System DFI System Wiring Diagram...

  • Page 101

    37. Vehicle-down Sensor 38. Main Fuse 30 A 39. Starter Relay 40. Water-proof Joint B 41. Battery 12 V 8 Ah 42. Fuel Pump 43. Immobilizer (Equipped Models)/Kawasaki Diagnostic System Connector 44. Water-proof Joint C ○ Color Codes: BK: Black PU: Purple...

  • Page 102

    3-14 FUEL SYSTEM (DFI) DFI System Terminal Numbers of ECU Connectors Terminal Names 1. Subthrottle Valve Actuator: BK/BL 2. Subthrottle Valve Actuator: G 3. Exhasut Butterfly Valve Actuator (+): GY 4. Exhasut Butterfly Valve Actuator (–): G/R 5. Exhasut Butterfly Valve Actuator Sensor: R/BK 6.

  • Page 103

    54. Oxygen Sensor Heater (Equipped Models): R 55. Air Switching Valve: R/BL 56. Injector #4: BL/Y 57. Injector #3: BL/BK 58. Ground for Fuel System: BK/Y 59. Ground for Ignition System: BK/Y 60. Stick Coil #4: BK/O *: KDS (Kawasaki Diagnostic System)

  • Page 104

    3-16 FUEL SYSTEM (DFI) DFI Parts Location Main Throttle Sensor [A] Subthrottle Sensor [B] Fuel Injectors #1, #2, #3, #4 [C] Crankshaft Sensor [A] Oxygen Sensor [B] (Equipped Models) Ignition Key (Transponder (Equipped Models)) [A] Ignition Switch [B] Immobilizer Antenna [C] (Equipped Models) Immobilizer Amplifier [D] (Equipped Models) Warning Indicator Light (LED) [E] Stick Coils #1, #2, #3, #4 [A]...

  • Page 105

    Relay Box (ECU Main Relay, Radiator Fan Relay, Fuel Pump Relay) [A] ECU [B] Fuse Box 2 (ECU Fuse 10 A, Ignition Fuse 10 A, Radi- ator Fan Fuse 15 A) [C] Vehicle-down Sensor [D] Immobilizer (Equipped Models)/Kawasaki Diagnostic System Connector [E] Fuel Pump [A]...

  • Page 106

    3-18 FUEL SYSTEM (DFI) Specifications Item Standard Digital Fuel Injection System Idle Speed 1 100 ±50 r/min (rpm) Throttle Body Assy: Type Four oval type Bore 32 mm (1.26 in.) Throttle Body Vacuum 35.3 ±1.3 kPa (265 ±10 mmHg) at idle speed Bypass Screws (Turn Out) 2 1/2 (for reference) ECU:...

  • Page 107

    FUEL SYSTEM (DFI) 3-19 Specifications Item Standard Output Voltage With sensor tilted 60 70° or more right or left: DC 0.65 1.35 V With sensor arrow mark pointed up: DC 3.55 4.45 V Subthrottle Sensor: Input Voltage DC 4.75 5.25 V Output Voltage DC 0.48 0.52 V at idle throttle opening...

  • Page 108

    3-20 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 109

    FUEL SYSTEM (DFI) 3-21 Special Tools and Sealant Fuel Pressure Gauge Adapter: Oxygen Sensor Measuring Adapter: 57001-1593 57001-1682 Fuel Hose: Measuring Adapter: 57001-1607 57001-1700 Speed Sensor Measuring Adapter: Kawasaki Bond (Silicone Sealant): 57001-1667 56019-120...

  • Page 110

    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 111

    FUEL SYSTEM (DFI) 3-23 DFI Servicing Precautions ○ If the motorcycle is not properly handled, the high pres- sure inside the fuel line can cause fuel to leak or the hose to burst. Remove the fuel tank (see Fuel Tank Removal) and check the fuel hose.

  • Page 112

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

  • Page 113

    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. When the motorcycle is down, the vehicle-down sensor operates and the ECU shuts off the fuel pump relay, fuel in- jectors and ignition system.

  • Page 114

    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 • Always check battery condition before replacing the DFI parts. A fully charged battery is a must for conducting accurate tests of the DFI system.

  • Page 115

    FUEL SYSTEM (DFI) 3-27 Troubleshooting the DFI System • Pull each connector [A] apart and inspect it for corrosion, dirt, and damage. If the connector is corroded or dirty, clean it carefully. If it is damaged, replace it. Connect the connectors securely. •...

  • Page 116

    3-28 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 117

    FUEL SYSTEM (DFI) 3-29 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 118

    3-30 FUEL SYSTEM (DFI) Troubleshooting the DFI System □ □ □ Poor running very low idle speed, very high idle speed, rough idle speed. □ at low speed battery voltage is low (charge the battery). □ spark plug loose (tighten it). □...

  • Page 119

    FUEL SYSTEM (DFI) 3-31 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 in DFI system.

  • Page 120

    3-32 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Fuel pressure regulator trouble Inspect fuel pressure and replace fuel pump (see chapter 3). Fuel line clogged Inspect and repair (see chapter 3). Inlet air pressure sensor trouble Inspect (see chapter 3).

  • Page 121

    FUEL SYSTEM (DFI) 3-33 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Main throttle sensor trouble Inspect (see chapter 3). Subthrottle sensor trouble Inspect (see chapter 3). Subthrottle valve actuator trouble Inspect (see chapter 3). Inlet air pressure sensor trouble Inspect (see chapter 3).

  • Page 122

    3-34 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Inlet air temperature sensor trouble Inspect (see chapter 3). Other: Intermittent any DFI fault and its recovery Check that DFI connectors are clean and tight, and examine leads for signs of burning or fraying (see chapter 3).

  • Page 123

    FUEL SYSTEM (DFI) 3-35 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Water temperature sensor trouble Inspect (see chapter 3). Inlet air temperature sensor trouble Inspect (see chapter 3). Miscellaneous: Subthrottle sensor trouble Inspect (see chapter 3). Subthrottle valve actuator trouble Inspect (see chapter 3).

  • Page 124

    3-36 FUEL SYSTEM (DFI) Self-Diagnosis The warning indicator light (LED) [A] is used for the FI indicator, immobilizer indicator (equipped 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 125

    FUEL SYSTEM (DFI) 3-37 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 126

    3-38 FUEL SYSTEM (DFI) Self-Diagnosis • Turn the ignition switch ON. • Push the MODE button [A] to display the odometer. • Push the MODE button [A] for more than two seconds. • The service code [B] is displayed on the LCD by the num- ber of two digits.

  • Page 127

    FUEL SYSTEM (DFI) 3-39 Self-Diagnosis Self-Diagnosis Flow Chart...

  • Page 128

    3-40 FUEL SYSTEM (DFI) 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 129

    FUEL SYSTEM (DFI) 3-41 Self-Diagnosis Service Code Table Service Code Problems Main 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 130

    3-42 FUEL SYSTEM (DFI) 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 output voltage is out of the usable range, Main Throttle...

  • Page 131

    FUEL SYSTEM (DFI) 3-43 Self-Diagnosis Service Output Signal Usable Parts Backups by ECU Codes Range or Criteria The oxygen sensor is Oxygen active and sensor must Sensor If the oxygen sensor is not activated, the ECU send signals (output (Equipped stops the feedback mode of the oxygen sensor.

  • Page 132

    3-44 FUEL SYSTEM (DFI) Self-Diagnosis Service Output Signal Usable Parts Backups by ECU Codes Range or Criteria The air switching valve controls the flow of the Air Switching secondary air by opening – Valve and shutting the solenoid valve. The oxygen sensor heater Oxygen If the oxygen sensor heater fails (wiring short Sensor...

  • Page 133

    FUEL SYSTEM (DFI) 3-45 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 134

    3-46 FUEL SYSTEM (DFI) Main Throttle Sensor (Service Code 11) If the reading is out of the standard, remove the ECU and check the wiring for continuity between main harness side connectors. ○ Disconnect the ECU and sensor connectors. Wiring Inspection ECU Connector [A] ←→...

  • Page 135

    FUEL SYSTEM (DFI) 3-47 Main Throttle Sensor (Service Code 11) • Turn the ignition switch OFF. • Measure the output voltage with the engine stopped, and with the connector joined. • Turn the ignition switch ON. Output Voltage Standard: DC 0.985 1.015 V at idle throttle opening DC 4.18 4.38 V at full throttle opening (for...

  • Page 136

    3-48 FUEL SYSTEM (DFI) Main Throttle Sensor (Service Code 11) Main Throttle Sensor Circuit 1. ECU 2. Main Throttle Sensor...

  • Page 137

    FUEL SYSTEM (DFI) 3-49 Inlet Air Pressure Sensor (Service Code 12) Inlet Air Pressure Sensor Removal CAUTION Never drop the inlet air pressure sensor, especially on a hard surface. Such a shock to the sensor can damage it. • Remove: Fuel Tank (see Fuel Tank Removal) Water Temperature Sensor Connector [A] (Disconnect) Inlet Air Pressure Sensor Connector [B] (Disconnect)

  • Page 138

    3-50 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code 12) If the reading is out of the standard, remove the ECU and check the wiring for continuity between main harness side connectors. ○ Disconnect the ECU and sensor connectors. Wiring Inspection ECU Connector [A] ←→...

  • Page 139

    FUEL SYSTEM (DFI) 3-51 Inlet Air Pressure Sensor (Service Code 12) If the wiring is good, check the sensor for various vacuum. • 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 140

    3-52 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code 12) ID: Idling Ps: Standard Atmospheric Pressure (Absolute) Pv: Throttle Vacuum Pressure (Absolute) 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 141

    FUEL SYSTEM (DFI) 3-53 Inlet Air Pressure Sensor (Service Code 12) Inlet Air Pressure Sensor Circuit 1. ECU 2. Inlet Air Pressure Sensor...

  • Page 142

    3-54 FUEL SYSTEM (DFI) Inlet Air Temperature Sensor (Service Code 13) Inlet Air Temperature Sensor Removal/Installation CAUTION Never drop the inlet air temperature sensor, espe- cially on a hard surface. Such a shock to the sensor can damage it. • Remove the fuel tank (see Fuel Tank Removal).

  • Page 143

    FUEL SYSTEM (DFI) 3-55 Inlet Air Temperature Sensor (Service Code 13) • Turn the ignition switch OFF. If the reading is within the standard, 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/Installation).

  • Page 144

    3-56 FUEL SYSTEM (DFI) Inlet Air Temperature Sensor (Service Code 13) Inlet Air Temperature Sensor Circuit 1. ECU 2. Inlet Air Temperature Sensor...

  • Page 145

    FUEL SYSTEM (DFI) 3-57 Water Temperature Sensor (Service Code 14) Water Temperature Sensor Removal/Installation CAUTION Never drop the water temperature sensor, espe- cially on a hard surface. Such a shock to the sensor can damage it. • Remove: Fuel Tank (see Fuel Tank Removal) Coolant (Drain, see Coolant Change in the Periodic Maintenance chapter) Connector [A] (Disconnect)

  • Page 146

    3-58 FUEL SYSTEM (DFI) Water Temperature Sensor (Service Code 14) If the reading is out of the standard, remove the ECU and check the wiring for continuity between main harness side connectors. ○ Disconnect the ECU and sensor connectors. Wiring Inspection ECU Connector [A] ←→...

  • Page 147

    FUEL SYSTEM (DFI) 3-59 Atmospheric Pressure Sensor (Service Code 15) Atmospheric Pressure Sensor Removal CAUTION Never drop the atmospheric pressure sensor, espe- cially on a hard surface. Such a shock to the sensor can damage it. • Remove: Left Seat Cover (see Seat Cover Removal in the Frame chapter) Sensor Connector [A] (Disconnect) •...

  • Page 148

    3-60 FUEL SYSTEM (DFI) Atmospheric Pressure Sensor (Service Code 15) If the input voltage is out of the standard, remove the ECU and check the wiring for continuity between main harness side connectors. ○ Disconnect the ECU and sensor connectors. Wiring Inspection ECU Connector [A] ←→...

  • Page 149

    FUEL SYSTEM (DFI) 3-61 Atmospheric Pressure Sensor (Service Code 15) If the wiring is good, check the sensor for various vacuum. ○ Determine the local altitude (elevation). If you know the local altitude, use the chart in this section. If you know the local atmospheric pressure using a barometer, substitute the atmospheric pressure for Pv (vacuum pressure) in the inlet air pressure sensor chart (see Inlet Air Pressure Sensor Output Voltage Inspec-...

  • Page 150

    3-62 FUEL SYSTEM (DFI) Atmospheric Pressure Sensor (Service Code 15) Atmospheric Pressure/Altitude Relationship...

  • Page 151

    FUEL SYSTEM (DFI) 3-63 Atmospheric Pressure Sensor (Service Code 15) Atmospheric Pressure Sensor Circuit 1. ECU 2. Atmospheric Pressure Sensor...

  • Page 152

    3-64 FUEL SYSTEM (DFI) Crankshaft Sensor (Service Code 21) The crankshaft sensor has no power source, and when the engine stops, the crankshaft sensor generates no sig- nals. Crankshaft Sensor Removal/Installation • Refer to the Crankshaft Sensor Removal/Installation in the Electrical System chapter. Crankshaft Sensor Resistance Inspection •...

  • Page 153

    FUEL SYSTEM (DFI) 3-65 Camshaft Position Sensor (Service Code 23) The camshaft position sensor detects the position of the camshaft, and distinguishes the cylinder. The camshaft position sensor has no power source, and when the engine stops, the camshaft position sensor gen- erates no signals.

  • Page 154

    3-66 FUEL SYSTEM (DFI) Camshaft Position Sensor (Service Code 23) Camshaft Position Sensor Circuit 1. ECU 2. Camshaft Position Sensor...

  • Page 155

    FUEL SYSTEM (DFI) 3-67 Speed Sensor (Service Code 24, 25) Speed Sensor Removal/Installation • Refer to the Speed Sensor Removal/Installation in the Electrical System chapter. Speed Sensor Input Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch OFF.

  • Page 156

    3-68 FUEL SYSTEM (DFI) Speed Sensor (Service Code 24, 25) Speed Sensor Output Voltage Inspection • Raise the rear wheel off the ground with the stand. • Measure the output voltage at the speed sensor in the same way as input voltage inspection, note the following. ○...

  • Page 157

    FUEL SYSTEM (DFI) 3-69 Speed Sensor (Service Code 24, 25) Speed Sensor Circuit 1. ECU 2. Speed Sensor...

  • Page 158

    3-70 FUEL SYSTEM (DFI) 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 the signal changes.

  • Page 159

    FUEL SYSTEM (DFI) 3-71 Vehicle-down Sensor (Service Code 31) Vehicle-down Sensor Input Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch OFF. • Disconnect the vehicle-down sensor connector and con- nect the harness adapter [A] between these connectors as shown in the figure.

  • Page 160

    3-72 FUEL SYSTEM (DFI) Vehicle-down Sensor (Service Code 31) Vehicle-down Sensor Output Voltage Inspection • Remove the vehicle-down sensor (see Vehicle-down Sensor Removal). • Connect the harness adapter [A] to the vehicle-down sen- sor connectors as shown in the figure. Special Tool - Measuring Adapter: 57001-1700 Main Harness [B] Vehicle-down Sensor [C]...

  • Page 161

    FUEL SYSTEM (DFI) 3-73 Vehicle-down Sensor (Service Code 31) If the reading is within the standard, remove the ECU and check the wiring for continuity between main harness side connectors. ○ Disconnect the ECU and sensor connectors. Wiring Inspection ECU Connector [A] ←→ Vehicle-down Sensor Connector [B] Y/G lead (ECU terminal 11) [C] BR/BK lead (ECU terminal 28) [D]...

  • Page 162

    3-74 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 163

    FUEL SYSTEM (DFI) 3-75 Subthrottle Sensor (Service Code 32) If the reading is out of the standard, remove the ECU and check the wiring for continuity between main harness side connectors. ○ Disconnect the ECU and sensor connectors. Wiring Inspection ECU Connector [A] ←→...

  • Page 164

    3-76 FUEL SYSTEM (DFI) Subthrottle Sensor (Service Code 32) • Measure the output voltage with the engine stopped with the connector joined. • Turn the ignition switch ON. • Measure the output voltage when the subthrottle valve is completely closed by turning the lever [A] fully clockwise [B].

  • Page 165

    FUEL SYSTEM (DFI) 3-77 Subthrottle Sensor (Service Code 32) Subthrottle Sensor Circuit 1. ECU 2. Subthrottle Sensor...

  • Page 166

    3-78 FUEL SYSTEM (DFI) Oxygen Sensor - not activated (Service Code 33 (Equipped Models)) Oxygen Sensor Removal/Installation • Refer to the Oxygen Sensor Removal/Installation in the Electrical System chapter. Oxygen Sensor Inspection • Warm up the engine thoroughly until the radiator fan starts.

  • Page 167

    FUEL SYSTEM (DFI) 3-79 Oxygen Sensor - not activated (Service Code 33 (Equipped Models)) • Remove the connector [A] from the clamp [B]. • Separate the hoses [A] from the air suction valve covers. • Pull the air switching valve [A] and hoses out to the left side of the motorcycle.

  • Page 168

    3-80 FUEL SYSTEM (DFI) Oxygen Sensor - not activated (Service Code 33 (Equipped Models)) • Start the engine, and let it idle. • Measure the output voltage with the connector joined. Output Voltage (with Plugs) Standard: DC 0.7 V or more •...

  • Page 169

    FUEL SYSTEM (DFI) 3-81 Oxygen Sensor - not activated (Service Code 33 (Equipped Models)) Oxygen Sensor Circuit 1. ECU 2. Meter Ground 3. Oxygen Sensor 4. Water-proof Joint C 5. Fuse Box 1 6. Oxygen Sensor Heater Fuse 10 A 7.

  • Page 170

    3-82 FUEL SYSTEM (DFI) Exhaust Butterfly Valve Actuator Sensor (Service Code 34) Exhaust Butterfly Valve Actuator Sensor Removal/Installation The exhaust butterfly valve actuator sensor is built in the exhaust butterfly valve actuator. So, the sensor itself can not be removed. Remove the exhaust butterfly valve actu- ator (see Exhaust Butterfly Valve Actuator Removal).

  • Page 171

    FUEL SYSTEM (DFI) 3-83 Exhaust Butterfly Valve Actuator Sensor (Service Code 34) Exhaust Butterfly Valve Actuator Sensor Output Voltage Inspection NOTE ○ Before this inspection, confirm the pulley [A] is original position (see Exhaust Butterfly Valve Actuator Installa- tion). • Disconnect: 2 pins Connector [B] 3 pins Connector [C]...

  • Page 172

    3-84 FUEL SYSTEM (DFI) Exhaust Butterfly Valve Actuator Sensor (Service Code 34) Exhaust Butterfly Valve Actuator Sensor Resistance Inspection • Turn the ignition switch OFF. • Disconnect the exhaust butterfly valve actuator sensor connector (3 pins connector) [A]. • Connect a digital meter [B] to the exhaust butterfly valve actuator sensor connector.

  • Page 173

    FUEL SYSTEM (DFI) 3-85 Immobilizer Amplifier (Service Code 35 (Equipped Models)) Antenna Resistance Inspection • Turn the ignition switch OFF. • Remove the fuel tank (see Fuel Tank Removal). • Disconnect the antenna lead connector [A]. • Measure the antenna resistance. Antenna Resistance Connections: BK lead ←→...

  • Page 174

    Electrical System chapter). If the service code 36 appears again, the transponder in the key is malfunction, replace it. Immobilizer System Circuit 1. ECU 8. Immobilizer/Kawasaki Di- 13. Warning Indicator Light (LED) 2. Frame Ground agnostic System Connec- (FI/Immobilizer) 3.

  • Page 175

    FUEL SYSTEM (DFI) 3-87 ECU Communication Error (Service Code 39) ECU Communication Line Inspection ○ When the data is not sent from the ECU to the meter unit for more than about 10 seconds, the service code 39 is displayed. ○...

  • Page 176

    3-88 FUEL SYSTEM (DFI) 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 Stick Coil Removal/Installation •...

  • Page 177

    FUEL SYSTEM (DFI) 3-89 Stick Coils #1, #2, #3, #4 (Service Code 51, 52, 53, 54) • Turn the ignition switch OFF. If the input voltage is out of the standard, check the wiring for continuity (see wiring diagram in this section). If the wiring is good, check the ECU for its ground and power supply (see ECU Power Supply Inspection).

  • Page 178

    3-90 FUEL SYSTEM (DFI) Radiator Fan Relay (Service Code 56) Radiator Fan Relay Removal/Installation ○ The radiator fan relay is built in the relay box [A]. • Refer to the Relay Box Removal in the Electrical System chapter. Radiator Fan Relay Inspection •...

  • Page 179

    FUEL SYSTEM (DFI) 3-91 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 throttle body assy, especially on a hard surface.

  • Page 180

    3-92 FUEL SYSTEM (DFI) Subthrottle Valve Actuator (Service Code 62) Subthrottle Valve Actuator Input Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch OFF. • Disconnect the subthrottle valve actuator connector and connect the harness adapter [A] between these connec- tors as shown in the figure.

  • Page 181

    FUEL SYSTEM (DFI) 3-93 Subthrottle Valve Actuator (Service Code 62) Subthrottle Valve Actuator Circuit 1. ECU 2. Subthrottle Valve Actuator...

  • Page 182

    3-94 FUEL SYSTEM (DFI) Exhaust Butterfly Valve Actuator (Service Code 63) Exhaust Butterfly Valve Actuator Removal CAUTION Never drop the exhaust butterfly valve actuator, es- pecially on a hard surface. Such a shock to the ac- tuator can damage it. •...

  • Page 183

    FUEL SYSTEM (DFI) 3-95 Exhaust Butterfly Valve Actuator (Service Code 63) Exhaust Butterfly Valve Actuator Installation • Install the pulley [A] on the actuator as shown in the figure. • Tighten the pulley bolt [B] while holding the pulley with the suitable tool [C].

  • Page 184

    3-96 FUEL SYSTEM (DFI) Exhaust Butterfly Valve Actuator (Service Code 63) • Install the bracket [A] on the actuator [B]. Washer [C] Nut [D] Bolt [E] • Tighten: Torque - Exhaust Butterfly Valve Actuator Bracket Bolt: 6.9 N·m (0.70 kgf·m, 61 in·lb) •...

  • Page 185

    FUEL SYSTEM (DFI) 3-97 Exhaust Butterfly Valve Actuator (Service Code 63) If the reading is in specification, remove the ECU and check the wiring for continuity between main harness side connectors. ○ Disconnect the ECU and actuator connectors. Wiring Inspection ECU Connector [A] ←→...

  • Page 186

    3-98 FUEL SYSTEM (DFI) Air Switching Valve (Service Code 64) Air Switching Valve Removal/Installation • Refer to the Air Switching Valve Removal/Installation in the Engine Top End chapter. Air Switching Valve Inspection • Refer to the Air Switching Valve Unit Test in the Electrical System chapter.

  • Page 187

    FUEL SYSTEM (DFI) 3-99 Oxygen Sensor Heater (Service Code 67 (Equipped Models)) Oxygen Sensor Heater Removal/Installation The oxygen sensor heater is built in the oxygen sensor. So, the heater itself can not be removed. Remove the oxy- gen sensor (see Oxygen Sensor Removal (Equipped Mod- els) in the Electrical System chapter).

  • Page 188

    3-100 FUEL SYSTEM (DFI) Oxygen Sensor Heater (Service Code 67 (Equipped Models)) Oxygen Sensor Heater Power Source Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch OFF. • Disconnect the oxygen sensor lead connector and con- nect the harness adapter [A] between these connectors.

  • Page 189

    FUEL SYSTEM (DFI) 3-101 Oxygen Sensor Heater (Service Code 67 (Equipped Models)) Oxygen Sensor Circuit 1. ECU 2. Meter Ground 3. Oxygen Sensor 4. Water-proof Joint C 5. Fuse Box 1 6. Oxygen Sensor Heater Fuse 10 A 7. Ignition Switch 8.

  • Page 190

    3-102 FUEL SYSTEM (DFI) Oxygen Sensor - Incorrect Output Voltage (Service Code 94 (Equipped Models)) Oxygen Sensor Removal/Installation • Refer to the Oxygen Sensor Removal/Installation (Equipped Models) in the Electrical System chapter. Oxygen Sensor Inspection • Warm up the engine thoroughly until the radiator fan starts.

  • Page 191

    FUEL SYSTEM (DFI) 3-103 Oxygen Sensor - Incorrect Output Voltage (Service Code 94 (Equipped Models)) • Remove the connector [A] from the clamp [B]. • Separate the hoses [A] from the air suction valve covers. • Pull the air switching valve [A] and hoses out to the left side of the motorcycle.

  • Page 192

    3-104 FUEL SYSTEM (DFI) Oxygen Sensor - Incorrect Output Voltage (Service Code 94 (Equipped Models)) • Start the engine, and let it idle. • Measure the output voltage with the connector joined. Output Voltage (with Plugs) Standard: DC 0.7 V or more •...

  • Page 193

    FUEL SYSTEM (DFI) 3-105 Warning Indicator Light (LED) Light (LED) Inspection ○ The warning indicator light (LED) [A] is used for the FI in- dicator, immobilizer indicator (immobilizer equipped mod- els) and oil pressure warning indicator. ○ In this model, the warning indicator light (LED) (FI/immo- bilizer) blink by the data sent from the ECU.

  • Page 194

    3-106 FUEL SYSTEM (DFI) 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. Other- wise, the motorcycle cannot clear the regulation. ECU Identification Part Number [A] Specification...

  • Page 195

    FUEL SYSTEM (DFI) 3-107 ECU Installation • Install: ECU [A] (In Rubber Protector [B]) ECU Connectors [C] (Connect) • Insert the slits of the rubber protector to the projections [A] of the bracket. ECU Power Supply Inspection • Remove the relay box (see Relay Box Removal in the Electrical System chapter).

  • Page 196

    3-108 FUEL SYSTEM (DFI) If the wiring is good, check the power source voltage of the ECU. NOTE ○ Be sure the battery is fully charged. • Connect the ECU connectors. • Connect a digital meter [A] to the connector [B] with the needle adapter set.

  • Page 197

    FUEL SYSTEM (DFI) 3-109 ECU Power Source Circuit 1. ECU 2. Frame Ground 3. Water-proof Joint C 4. Fuse Box 2 5. ECU Fuse 10 A 6. Water-proof Joint B 7. Ignition Switch 8. Relay Box 9. ECU Main Relay 10.

  • Page 198

    3-110 FUEL SYSTEM (DFI) DFI Power Source ECU Fuse Removal • Refer to the 10 A ECU Fuse Removal in the Electrical 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 199

    FUEL SYSTEM (DFI) 3-111 Fuel Line Fuel Pressure Inspection NOTE ○ Be sure the battery is fully charged. • Remove: Fuel Tank (see Fuel Tank Removal) Fuel Outlet Hose (see Fuel Hose Replacement in the Periodic Maintenance chapter) ○ Be sure to place a piece of cloth around the fuel outlet pipe of the fuel pump and the delivery pipe of the throttle body assy.

  • Page 200

    3-112 FUEL SYSTEM (DFI) Fuel Line NOTE ○ The gauge needle will fluctuate. Read the pressure at the average of the maximum and minimum indications. • Turn the ignition switch OFF. If the fuel pressure is much higher than specified, replace the fuel pump because the fuel pressure regulator in the fuel pump have been clogged or stuck.

  • Page 201

    FUEL SYSTEM (DFI) 3-113 Fuel Line • Connect the prepared fuel hose [A] to the fuel outlet pipe. • Secure the fuel hose with a clamp. • Insert the fuel hose into the measuring cylinder [B]. WARNING Wipe off spilled out fuel immediately. Be sure to hold the measuring cylinder vertical.

  • Page 202

    3-114 FUEL SYSTEM (DFI) Fuel Pump Fuel Pump 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 203

    FUEL SYSTEM (DFI) 3-115 Fuel Pump Fuel Pump Installation • Remove dirt or dust from the fuel pump [A] by lightly ap- plying compressed air. • Replace the fuel pump gasket with a new one. • Check that the fuel pump terminal [A] and band [B] are in place.

  • Page 204

    3-116 FUEL SYSTEM (DFI) Fuel Pump Fuel Pump Operating Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch OFF. • Remove the right side cover (see Side Cover Removal in the Frame chapter). •...

  • Page 205

    FUEL SYSTEM (DFI) 3-117 Fuel Pump Pressure Regulator Removal ○ The pressure regulator [A] is built into the fuel pump [B] and can not be removed. Pump Screen, Fuel Filter Cleaning ○ The pump screen [A] and fuel filter [B] are built into the pump and can not be cleaned or checked.

  • Page 206

    3-118 FUEL SYSTEM (DFI) Fuel Pump Fuel Pump Circuit 1. ECU 2. Frame Ground 3. Fuel Pump 4. Water-proof Joint B 5. Engine Stop Switch 6. Fuse Box 2 7. ECU Fuse 10A 8. Ignition Fuse 10 A 9. Relay Box 10.

  • Page 207

    FUEL SYSTEM (DFI) 3-119 Fuel Injectors Fuel Injector Removal/Installation • Refer to the Throttle Body Assy Disassembly/Assembly. Fuel Injector Audible Inspection NOTE ○ Be sure the battery is fully charged. • Start the engine, and let it idle. • Apply the tip of a screwdriver [A] to the fuel injector [B]. Put the grip end onto your ear, and listen whether the fuel injector is clicking or not.

  • Page 208

    3-120 FUEL SYSTEM (DFI) Fuel Injectors Fuel Injector Power Source Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch OFF. • Disconnect the injector connector and connect the har- ness adapter [A] between these connectors as shown in the figure.

  • Page 209

    FUEL SYSTEM (DFI) 3-121 Fuel Injectors Fuel Injector Output Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch OFF. • Remove the ECU (see ECU Removal). ○ Do not disconnect the ECU connector. •...

  • Page 210

    3-122 FUEL SYSTEM (DFI) Fuel Injectors If the reading is out of the specification, remove the ECU and check the wiring for continuity between main harness side connector. ○ Disconnect the ECU and injector connector. Wiring Inspection ECU Connector [A] ←→ Fuel Injector Connector [B] For Fuel Injector #1 [C] BL/R lead (ECU terminal 44) [D] For Fuel Injector #2...

  • Page 211

    FUEL SYSTEM (DFI) 3-123 Fuel Injectors ○ Watch the gauge for at least 6 seconds. If the pressure holds steady, the fuel line is good. If the pressure drops at once or if bubbles are found in the area, the fuel line is leaking. Replace the delivery pipe assy, injectors and related parts.

  • Page 212

    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. Free Play Adjustment • Refer to the Throttle Control System Inspection in the Pe- riodic Maintenance chapter. Cable Installation •...

  • Page 213

    FUEL SYSTEM (DFI) 3-125 Throttle Body Assy Idle Speed Inspection/Adjustment • Refer to the Idle Speed Inspection/Adjustment in the Pe- riodic Maintenance chapter. Synchronization Inspection/Adjustment • Refer to the Engine Vacuum Synchronization Inspection in the Periodic Maintenance chapter. Throttle Body Assy Removal WARNING Gasoline is extremely flammable and can be explo- sive under certain conditions.

  • Page 214

    3-126 FUEL SYSTEM (DFI) Throttle Body Assy • Disconnect: Main Throttle Sensor Connector [A] Subthrottle Sensor Connector [B] • Open the clamp [C]. • For models equipped with an ABS, remove the bolt [A] and bracket [B]. • Remove: Air Cleaner Duct (see Air Cleaner Element Replacement in the Periodic Maintenance chapter) Inlet Air Temperature Sensor (see Inlet Air Temperature Sensor Removal)

  • Page 215

    FUEL SYSTEM (DFI) 3-127 Throttle Body Assy • Remove the left frame cover (see Frame Cover Removal in the Frame chapter). • Open the clamp [A] and pull the alternator lead connector [B] downward. • Loosen the air duct clamp bolts [A]. •...

  • Page 216

    3-128 FUEL SYSTEM (DFI) Throttle Body Assy • Remove the bolt [A] and the throttle cable plate [B] from the throttle body assy. • Remove the throttle cable lower ends [A] from the throttle pulley. Throttle Body Assy Installation • Turn the lever [A] fully clockwise, and close the subthrottle valves [B] until completely closed position.

  • Page 217

    FUEL SYSTEM (DFI) 3-129 Throttle Body Assy • Install the air duct clamp bolts in the direction as shown. Bolt Heads [A] • Fit the projections [B] of the holder into the holes in the clamps. • Install the air ducts to the throttle body assy. ○...

  • Page 218

    3-130 FUEL SYSTEM (DFI) Throttle Body Assy 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 the manufacturer. Adjustment of these parts could result in poor performance, requiring replacement of the throttle body assy.

  • Page 219

    FUEL SYSTEM (DFI) 3-131 Throttle Body Assy • Replace the dust seals [A] with new ones. • Apply engine oil to the new dust seals. • Install the injectors along with the delivery pipe assy to the throttle body. • Tighten: Torque - Delivery Pipe Assy Mounting Screws: 3.4 N·m (0.35 kgf·m, 30 in·lb)

  • Page 220

    3-132 FUEL SYSTEM (DFI) Air Cleaner Air Cleaner Element Removal/Installation • Refer to the Air Cleaner Element Replacement in the Pe- riodic Maintenance chapter. Air Cleaner Element Inspection • Remove the air cleaner element (see Air Cleaner Element Replacement in the Periodic Maintenance chapter). •...

  • Page 221

    FUEL SYSTEM (DFI) 3-133 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 222

    3-134 FUEL SYSTEM (DFI) Fuel Tank • Disconnect: Fuel Pump Lead Connector [A] Fuel Level Sensor Lead Connector [B] • Be sure to place a piece of cloth [A] around the fuel outlet hose joint [B]. • Push the joint lock claws [C]. •...

  • Page 223

    FUEL SYSTEM (DFI) 3-135 Fuel Tank Fuel Tank Installation • Note the above WARNING (see Fuel Tank Removal). • Run the hoses correctly (see Cable, Wire, and Hose Rout- ing in the Appendix chapter). • Check that the dampers [A] are in place on the frame and the fuel tank.

  • Page 224

    3-136 FUEL SYSTEM (DFI) Fuel Tank Fuel Tank Inspection • Visually inspect the gasket [A] on the tank cap for any damage. Replace the gasket if it is damaged. • Check to see if the water drain pipe [B] in the tank are not clogged.

  • Page 225

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

  • Page 226

    4-2 COOLING SYSTEM Exploded View...

  • Page 227

    COOLING SYSTEM 4-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Coolant Drain Bolt (Cylinder) 87 in·lb Coolant Drain Bolt (Water Pump) 97 in·lb Radiator Bracket Mounting Bolt 0.70 61 in·lb Radiator Lower Bolt 0.70 61 in·lb Radiator Upper Bolts 0.70 61 in·lb Radiator (Water) Hose Clamp Screws...

  • Page 228

    4-4 COOLING SYSTEM Coolant Flow Chart...

  • Page 229

    COOLING SYSTEM 4-5 Coolant Flow Chart 1. Water Temperature Sensor 8. Cylinder Head Jacket 2. Thermostat Housing 9. Reserve Tank Hose 3. Radiator Cap 10. Reserve Tank 4. Radiator 11. Reserve Tank Overflow Hose 5. Oil Filter 12. Front 6. Water Pump 13.

  • Page 230

    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 231

    COOLING SYSTEM 4-7 Special Tools Bearing Driver Set: Oil Seal Driver: 57001-1129 57001-1660...

  • Page 232

    4-8 COOLING SYSTEM Coolant Coolant Deterioration Inspection • Remove the right seat cover (see Seat Cover Removal in the Frame chapter). • Visually inspect the coolant [A] 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.

  • Page 233

    COOLING SYSTEM 4-9 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 234

    4-10 COOLING SYSTEM Water Pump Water Pump Removal • Refer to the Oil Pump Removal in the Engine Lubrication System chapter. Water Pump Installation • Refer to the Oil Pump Installation in the Engine Lubrica- tion System chapter. Water Pump Inspection •...

  • Page 235

    COOLING SYSTEM 4-11 Water Pump • Take the oil seal [A] out of the housing [B] with a hook [C]. Water Pump Housing Assembly CAUTION Do not reuse the mechanical seal and oil seal. • Apply high-temperature grease to the oil seal lips [A]. •...

  • Page 236

    4-12 COOLING SYSTEM Radiator Radiator and Radiator Fan Removal WARNING The radiator fan is connected directly to the bat- tery. The radiator fan may start even if the ignition switch is off. NEVER TOUCH THE RADIATOR FAN UNTIL THE RADIATOR FAN MOTOR LEAD CON- NECTOR IS DISCONNECTED.

  • Page 237

    COOLING SYSTEM 4-13 Radiator Radiator and Radiator Fan Installation • Installation is the reverse of removal. • Run the radiator fan motor lead correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). • Install the radiator bracket collars [A] as shown in the fig- ure.

  • Page 238

    4-14 COOLING SYSTEM Radiator CAUTION When cleaning the radiator with steam cleaner, be careful of the following to prevent radiator damage: Keep the steam gun [A] away more than 0.5 m (1.6 ft) [B] from the radiator core. Hold the steam gun perpendicular [C] (not oblique [D]) to the core surface.

  • Page 239

    COOLING SYSTEM 4-15 Thermostat Thermostat Removal • Remove: Coolant (Drain, see Coolant Change in the Periodic Maintenance chapter) Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Right Center Fairing (see Center Fairing Removal in the Frame chapter) Radiator Hose Clamp Screw [A] (Loosen) Water Hose Clamp Screw [B] (Loosen) •...

  • Page 240

    4-16 COOLING SYSTEM Thermostat Thermostat Inspection • Remove the thermostat (see Thermostat Removal), and inspect the thermostat valve [A] at room temperature. If the valve is open, replace the thermostat with a new one. • To check valve opening temperature, suspend the ther- mostat [A] in a container of water and raise the tempera- ture of the water.

  • Page 241

    COOLING SYSTEM 4-17 Hose 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 (see Cable, Wire, and Hose Routing sec- tion in the Appendix chapter). •...

  • Page 242

    4-18 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 the water temperature sensor can damage it. Water Temperature Sensor Removal/Installation • Refer to the Water Temperature Sensor Removal/Instal- lation in the Fuel System (DFI) chapter.

  • Page 243

    ENGINE TOP END 5-1 Engine Top End Table of Contents Exploded View........Valves ..........5-22 Exhaust System......... Valve Clearance Inspection ..5-22 Specifications ........Valve Clearance Adjustment..5-22 Special Tools and Sealant ....5-10 Valve Removal ......5-22 Clean Air System....... 5-12 Valve Installation ......

  • Page 244

    5-2 ENGINE TOP END Exploded View...

  • Page 245

    ENGINE TOP END 5-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Air Suction Valve Cover Bolts 87 in·lb Camshaft Cap Bolts (L = 45 mm) 106 in·lb Camshaft Cap Bolts (L = 40 mm) 106 in·lb Camshaft Chain Tensioner Cap Bolt Camshaft Chain Tensioner Mounting Bolts 97 in·lb Coolant Drain Bolt (Cylinder)

  • Page 246

    5-4 ENGINE TOP END Exploded View...

  • Page 247

    ENGINE TOP END 5-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Exhaust Butterfly Valve Actuator Bracket Bolt 0.70 61 in·lb Exhaust Butterfly Valve Actuator Mounting Bolts 0.70 61 in·lb Exhaust Butterfly Valve Actuator Pulley Bolt 0.51 44 in·lb Exhaust Butterfly Valve Cable Adjuster Locknuts 0.70 61 in·lb Exhaust Butterfly Valve Cable Locknuts...

  • Page 248

    5-6 ENGINE TOP END Exhaust System Exhaust System Full: Full Power H: Honeycomb Type Catalyst Manifold Mark Position [A] Muffler Body Mark Position [B] Honeycomb Type Catalyst Position [C]...

  • Page 249

    ENGINE TOP END 5-7 Exhaust System Manifold with Hole [D] for Oxygen Sensor. Oxygen Sensor [E]...

  • Page 250

    5-8 ENGINE TOP END Specifications Item Standard Service Limit Camshafts Cam Height: Exhaust 35.743 35.857 mm (1.4072 1.4117 in.) 35.64 mm (1.403 in.) Inlet 35.943 36.057 mm (1.4151 1.4196 in.) 35.84 mm (1.411 in.) Camshaft Journal, Camshaft 0.028 0.071 mm (0.0011 0.0028 in.) 0.16 mm (0.0063 in.) Cap Clearance...

  • Page 251

    ENGINE TOP END 5-9 Specifications Item Standard Service Limit Cylinder, Pistons Cylinder Inside Diameter 68.400 68.412 mm (2.6929 2.6934 in.) 68.50 mm (2.6969 in.) Piston Diameter 68.345 68.360 mm (2.6907 2.6913 in.) 68.20 mm (2.6850 in.) Piston/Cylinder Clearance 0.040 0.067 mm (0.0016 0.0026 in.) –...

  • Page 252

    5-10 ENGINE TOP END Special Tools and Sealant Compression Gauge, 20 kgf/cm²: Valve Seat Cutter, 32° - 30: 57001-221 57001-1120 Valve Spring Compressor Assembly: Valve Seat Cutter, 60° - 30: 57001-241 57001-1123 Piston Pin Puller Assembly: Valve Seat Cutter Holder Bar: 57001-910 57001-1128 Valve Seat Cutter, 45°...

  • Page 253

    Valve Seat Cutter, 60° - 25: 57001-1273 57001-1328 Valve Guide Reamer, 4: Compression Gauge Adapter, M10 × 1.0: 57001-1274 57001-1601 Valve Seat Cutter Holder, 4: L-Shape Hose: 57001-1275 57001-1606 Compression Gauge Adapter, M10 × 1.0: Kawasaki Bond (Silicone Sealant): 57001-1317 92104-0004...

  • Page 254

    5-12 ENGINE TOP END Clean Air System Air Suction Valve Removal • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Connector [A] (from Clamp [B]) Air Suction Valve Cover Bolts [C] and Bracket [D] Air Suction Valve Covers [E] Air Suction Valves Air Suction Valve Installation •...

  • Page 255

    ENGINE TOP END 5-13 Clean Air System Air Switching Valve Removal • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Thermostat Housing (see Thermostat Removal in the Cooling System chapter) Connector [A] (Disconnect) • Separate the hoses [B] from the air suction valve covers and air cleaner housing holder, and remove the air switch- ing valve [C].

  • Page 256

    • Replace the head cover gasket with a new one. • Apply silicone sealant [A] to the cylinder head as shown in the figure. Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004 • Install the new head cover gasket. • Install:...

  • Page 257

    ENGINE TOP END 5-15 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.

  • Page 258

    5-16 ENGINE TOP END Camshaft, Camshaft Chain Camshaft Removal • Remove: Cylinder Head Cover (see Cylinder Head Cover Re- moval) Crankshaft Sensor Cover (see Crankshaft Sensor Re- moval in the Electrical System chapter) • Position the crankshaft at #1, 4 piston TDC. TDC mark [A] for #1, 4 Pistons Timing Mark (Crankcase Halves Mating Surface) [B] •...

  • Page 259

    ENGINE TOP END 5-17 Camshaft, Camshaft Chain • Position the crankshaft at #1, 4 piston TDC. • Pull the tension side (exhaust side) [A] of the chain taut to install the chain. • Engage the camshaft chain with the camshaft sprockets so that the timing marks on the sprockets are positioned as shown in the figure.

  • Page 260

    5-18 ENGINE TOP END Camshaft, Camshaft Chain If any clearance exceeds the service limit, measure the diameter of each camshaft journal with a micrometer. Camshaft Journal Diameter Standard: 23.950 23.972 mm (0.9429 0.9438 in.) Service Limit: 23.92 mm (0.942 in.) If the camshaft journal diameter is less than the service limit, replace the camshaft with a new one and measure the clearance again.

  • Page 261

    ENGINE TOP END 5-19 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) Stick Coils (see Stick Coil Removal in the Electrical Sys- tem chapter)

  • Page 262

    5-20 ENGINE TOP END Cylinder Head Cylinder Head Removal • Remove: Coolant (Drain, see Coolant Change in the Periodic Maintenance chapter) Cylinder Head Cover (see Cylinder Head Cover Re- moval) Camshafts (see Camshaft Removal) Throttle Body Assy (see Throttle Body Assy Removal in the Fuel System (DFI) chapter) Exhaust Pipe (see Exhaust Pipe Removal) •...

  • Page 263

    ENGINE TOP END 5-21 Cylinder Head • Install: Front Camshaft Chain Guide [A] Rear Camshaft Chain Guide [B] New O-rings [C] Collar [D] ○ Apply grease to the new O-ring. • Tighten: Torque - Front Camshaft Chain Guide Bolt (Upper) [E]: 25 N·m (2.5 kgf·m, 18 ft·lb) Front Camshaft Chain Guide Bolt (Lower) [F]: 12 N·m (1.2 kgf·m, 106 in·lb)

  • Page 264

    5-22 ENGINE TOP END Valves Valve Clearance Inspection • Refer to the Valve Clearance Inspection in the Periodic Maintenance chapter. Valve Clearance Adjustment • Refer to the Valve Clearance Adjustment in the Periodic Maintenance chapter. Valve Removal • Remove: Cylinder Head (see Cylinder Head Removal) Valve Lifter and Shim ○...

  • Page 265

    ENGINE TOP END 5-23 Valves Valve Guide Installation • Apply engine oil to the valve guide outer surface before installation. • 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 266

    5-24 ENGINE TOP END Valves Valve Seat Inspection • Remove the valve (see Valve Removal). • Check the valve seating surface [A] between the valve [B] and valve seat [C]. ○ Measure the outside diameter [D] of the seating pattern on the valve seat.

  • Page 267

    ENGINE TOP END 5-25 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 268

    5-26 ENGINE TOP END 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 269

    ENGINE TOP END 5-27 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 270

    5-28 ENGINE TOP END Valves...

  • Page 271

    ENGINE TOP END 5-29 Cylinder, Pistons Cylinder Removal • Remove: Cylinder Head (see Cylinder Head Removal) Subframe [A] (see Engine Removal in the Engine Re- moval/Installation chapter) • Remove: Water Hose Clamp Screw (Loosen) [A] Water Hose [B] Cylinder [C] Cylinder Installation NOTE ○...

  • Page 272

    5-30 ENGINE TOP END Cylinder, Pistons Piston Removal • Remove the cylinder (see Cylinder Removal). • Place a clean cloth under the pistons and remove the pis- ton pin snap ring [A] from the outside of each piston. • Remove the piston pins. Special Tool - Piston Pin Puller Assembly [A]: 57001-910 •...

  • Page 273

    ENGINE TOP END 5-31 Cylinder, Pistons • Do not mix up the top and second ring. • Install the top ring [A] so that the “1T” mark [B] faces up. • Install the second ring [C] so that the “2T” mark [D] faces ○...

  • Page 274

    5-32 ENGINE TOP END Cylinder, Pistons Piston Ring, Piston Ring Groove Wear • Check for uneven groove wear by inspecting the ring seat- ing. The rings should fit perfectly parallel to groove surfaces. If not, replace the piston and all the piston rings. •...

  • Page 275

    ENGINE TOP END 5-33 Cylinder, Pistons Piston Ring End Gap • Place the piston ring [A] inside the cylinder, using the pis- ton to locate the ring squarely in place. Set it close to the bottom of the cylinder, where cylinder wear is low. •...

  • Page 276

    5-34 ENGINE TOP END Throttle Body Holder Throttle Body Holder Installation • Apply grease to the O-rings [A]. • Be sure to install the O-rings. • Install the clamps [B] as shown and so that its hole fit on the projection [C] of the holder. •...

  • Page 277

    ENGINE TOP END 5-35 Muffler WARNING To avoid a serious burn, do not remove the muffler when the engine is still hot. Wait until the muffler cool down. Muffler Body Removal • Slide the dust covers [A]. • Loosen the locknuts [B], and turn the adjusters [C] to give the cable plenty of play.

  • Page 278

    5-36 ENGINE TOP END Muffler Muffler Body Installation • Replace the muffler body gasket [A] with a new one. • Install the muffler body gasket until it is bottomed so that the inside chamfer side faces rear [B]. • Install the muffler body clamp bolt [C] as shown in the figure.

  • Page 279

    ENGINE TOP END 5-37 Muffler • Install the exhaust butterfly valve cables, and adjust them (see Exhaust Butterfly Valve Cable Installation). • Thoroughly warm up the engine, wait until the engine cools down, retighten all the bolts and nut. • Install the removed parts (see appropriate chapters).

  • Page 280

    5-38 ENGINE TOP END Muffler • Loosen the clamp bolt [A]. • Remove: Exhaust Pipe Manifold Holder Nuts [A] Exhaust Pipe [B] Exhaust Pipe Installation • Replace the exhaust pipe gaskets [A] and muffler body gasket [B] with new ones and install them. •...

  • Page 281

    ENGINE TOP END 5-39 Muffler Exhaust Butterfly Valve Cable Removal • Slide the dust covers [A]. • Loosen the locknuts [B], and turn the adjusters [C] to give the cable plenty of play. • Remove: Left Side Cover (see Side Cover Removal in the Frame chapter) Clamp [A] Exhaust Butterfly Valve Cable Upper Ends [B]...

  • Page 282

    5-40 ENGINE TOP END Muffler Exhaust Butterfly Valve Cable Installation • Confirm whether pulley [A] is an angle shown in the figure. 41.7° ±7° [B] ○ This position is original position of the pulley. NOTE ○ Correct the position electrically after confirming use is discontinued and there is no damage when differing from the angle of shown in the figure.

  • Page 283

    ENGINE TOP END 5-41 Muffler • Stretch the open cable (white) [A] first by using the ad- juster [B]. ○ Turn the adjuster counterclockwise until it becomes hard to turn. Locknut of White [C] CAUTION To keep the correct exhaust butterfly valve position, adjust the open cable first.

  • Page 284

    5-42 ENGINE TOP END Muffler • Turn the ignition switch ON and wait until the pulley [A] turns fully clockwise [B]. • Turn off the ignition switch when the pulley become fully clockwise position [C] as shown in the figure. ○...

  • Page 285

    ENGINE TOP END 5-43 Muffler • Stretch the open cable (white) by using the adjuster [A]. ○ Turn the adjuster counterclockwise until it becomes hard to turn. Locknut of White [B] CAUTION Do not overstretch. If the adjustment of the exhaust butterfly valve cables are incorrect, the exhaust but- terfly valve actuator does not operate correctly.

  • Page 287

    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 .................. Clutch Cable Removal ...................... Clutch Cable Installation ....................Clutch Cable Lubrication....................

  • Page 288

    6-2 CLUTCH Exploded View...

  • Page 289

    CLUTCH 6-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Clutch Cover Mounting Bolts 97 in·lb Clutch Hub Nut 13.8 99.6 Clutch Lever Clamp Bolts 0.80 69 in·lb Clutch Spring Bolts 0.90 78 in·lb Oil Filler Plug 0.20 18 in·lb CL: Apply cable lubricant.

  • Page 290

    6-4 CLUTCH Specifications Item Standard Service Limit Clutch Lever Free Play 3 mm (0.08 0.12 in.) – – – Clutch Clutch Plate Assembly Length 37.7 38.3 mm (1.48 1.51 in.) – – – Friction Plate Thickness 2.72 2.88 mm (0.107 0.113 in.) 2.4 mm (0.094 in.) Friction and Steel Plate Warp...

  • Page 291

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

  • Page 292

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

  • Page 293

    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 • Replace the clutch cover gasket with a new one. •...

  • Page 294

    6-8 CLUTCH Clutch Cover • Fit the spring [A] as shown in the figure. Viewed from Rear [B] Release Shaft [C] Clutch Cover [D] Clutch Cover Disassembly • Remove: Oil Seal [A] Needle Bearings [B] Oil Level Gauge Clutch Cover Assembly •...

  • Page 295

    CLUTCH 6-9 Clutch Clutch Removal • Remove: Engine Oil (Drain, see Engine Oil Change in the Periodic Maintenance chapter) Clutch Cover (see Clutch Cover Removal) Clutch Spring Bolts [A] Clutch Springs and Spring Holders Clutch Spring Plate [B] (with Thrust Bearing, Pusher [C], Spring and Washer) •...

  • Page 296

    6-10 CLUTCH Clutch ○ Install the spacer [A] so that the tapered side [B] faces inward. ○ Install the washer [A] so that the “OUTSIDE” mark [B] faces outward. ○ Replace the clutch hub nut with a new one. ○ Holding the clutch hub, tighten the clutch hub nut.

  • Page 297

    CLUTCH 6-11 Clutch • Align the mark [A] of the clutch spring plate [B] with the groove [C] of the clutch hub. • Install the clutch spring plate, springs and spring holders, and tighten the clutch spring bolts. Torque - Clutch Spring Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb) •...

  • Page 298

    6-12 CLUTCH Clutch Clutch Plate, Wear, Damage Inspection • Visually inspect the friction and steel plates for signs of seizure, overheating (discoloration), or uneven wear. • Measure the thickness of each friction plate [A] at several points. If any plates show signs of damage, or if they have worn past the service limit, replace them with new ones.

  • Page 299

    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 300

    7-2 ENGINE LUBRICATION SYSTEM Exploded View...

  • Page 301

    ENGINE LUBRICATION SYSTEM 7-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Coolant Drain Bolt (Water Pump) 97 in·lb Engine Oil Drain Bolt Oil Filter G, R Oil Filter Holder Oil Filler Plug 0.20 18 in·lb Oil Jet Nozzle Bolts 0.70 61 in·lb Oil Pan Bolts...

  • Page 302

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

  • Page 303

    ENGINE LUBRICATION SYSTEM 7-5 Specifications Item Standard Engine Oil Type API SE, SF or SG API SH, SJ or SL with JASO MA Viscosity SAE 10W-40 Capacity: 3.1 L (3.3 US gt) (when filter is not removed) 3.3 L (3.5 US gt) (when filter is removed) 3.8 L (4.0 US gt) (when engine is completely dry) Level Between upper and lower level lines (Wait 2...

  • Page 304

    7-6 ENGINE LUBRICATION SYSTEM Special Tools and Sealant Outside Circlip Pliers: Oil Filter Wrench: 57001-144 57001-1249 Oil Pressure Gauge, 10 kgf/cm²: Kawasaki Bond (Silicone Sealant): 57001-164 56019-120 Oil Pressure Gauge Adapter, PT3/8: 57001-1233...

  • Page 305

    ENGINE LUBRICATION SYSTEM 7-7 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 306

    7-8 ENGINE LUBRICATION SYSTEM Oil Pan Oil Pan Removal • Remove: Engine Oil (Drain, see Engine Oil Change in the Periodic Maintenance chapter) Exhaust Pipe (see Exhaust Pipe Removal in the Engine Top End chapter) Oil Pan Bolts [A] and Clamps Oil Pan [B] and Gasket [C] •...

  • Page 307

    ENGINE LUBRICATION SYSTEM 7-9 Oil Pressure Relief Valve Oil Pressure Relief Valve Removal • Refer to the Oil Pan Removal. Oil Pressure Relief Valve Installation • Refer to the Oil Pan Installation. Oil Pressure Relief Valve Inspection • 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 308

    7-10 ENGINE LUBRICATION SYSTEM Oil Pump Oil Pump Removal • Remove: Coolant (Drain, see Coolant Change in the Periodic Maintenance chapter) Engine Oil (Drain, see Engine Oil Change in the Periodic Maintenance chapter) Water Pipe Bolts [A] Water Pipes [B] •...

  • Page 309

    ENGINE LUBRICATION SYSTEM 7-11 Oil Pump • Install: Pins [A] Water Pump Body [B] • Install the impeller [A], washer and bolt [B]. • Tighten: Torque - Water Pump Impeller Bolt: 9.8 N·m (1.0 kgf·m, 87 in·lb) • Install the pins [C] and water pump cover. •...

  • Page 310

    7-12 ENGINE LUBRICATION SYSTEM Oil Pressure Measurement Oil Pressure Measurement • Remove the oil passage plug, and 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 311

    • Apply silicone sealant to the threads of the oil pressure switch and tighten it. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 Torque - Oil Pressure Switch: 15 N·m (1.5 kgf·m, 11 ft·lb) • Install the switch lead direction upward.

  • Page 313

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

  • Page 314

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

  • Page 315

    ENGINE REMOVAL/INSTALLATION 8-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Adjusting Collar Lock Bolt Adjusting Collar Locknut Engine Ground Cable Terminal Bolt 87 in·lb Front Engine Mounting Bolts Lower Engine Mounting Nut Middle Engine Mounting Nut Rear Engine Bracket Bolts Subframe Bolts Upper Engine Bracket Bolts S: Follow the specified tightening sequence.

  • Page 316

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

  • Page 317

    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 318

    8-6 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Disconnect: Stick Coil Harness Connector [A] Camshaft Position Sensor Lead Connector (see Camshaft Position Sensor Removal in the Electrical System chapter) • Disconnect: Starter Motor Cable (see Starter Motor Removal in the Electrical System chapter) Alternator Lead Connector (see Alternator Cover Re- moval in the Electrical System chapter) Crankshaft Sensor Lead Connector (see Crankshaft...

  • Page 319

    ENGINE REMOVAL/INSTALLATION 8-7 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 320

    8-8 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Install the engine mounting bolts and nuts, following the specified installing sequence. ○ First, hang the drive chain over the output shaft just before moving the engine into its final position in the frame. ○...

  • Page 321

    ENGINE REMOVAL/INSTALLATION 8-9 Engine Removal/Installation • Run the leads, cables and hoses correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). • Install the removed parts (see appropriate chapters). Torque - Engine Ground Cable Terminal Bolt: 9.8 N·m (1.0 kgf·m, 87 in·lb) •...

  • Page 323

    CRANKSHAFT/TRANSMISSION 9-1 Crankshaft/Transmission Table of Contents Exploded View........................Specifications ......................... Special Tools and Sealant ...................... Crankcase Splitting......................... Crankcase Splitting ......................Crankcase Assembly ......................Crankshaft and Connecting Rods................... 9-13 Crankshaft Removal ......................9-13 Crankshaft Installation ...................... 9-13 Connecting Rod Removal ....................9-13 Connecting Rod Installation ....................

  • Page 324

    9-2 CRANKSHAFT/TRANSMISSION Exploded View...

  • Page 325

    CRANKSHAFT/TRANSMISSION 9-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Breather Plate Bolts (M6) 87 in·lb Breather Plate Bolts (M5) 0.60 52 in·lb see the text ← ← Connecting Rod Big End Nuts Crankcase Bolts (M9) MO, S Crankcase Bolts (M8) Crankcase Bolts (M7) Crankcase Bolts (M6) 106 in·lb...

  • Page 326

    9-4 CRANKSHAFT/TRANSMISSION Exploded View...

  • Page 327

    CRANKSHAFT/TRANSMISSION 9-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Footpeg Bracket Bolts Gear Positioning Lever Bolt 106 in·lb Neutral Switch Shift Drum Cam Holder Bolt 106 in·lb Shift Lever Bolt 0.70 61 in·lb Shift Pedal Mounting Bolt Shift Shaft Return Spring Pin Tie-Rod Locknuts 0.70 61 in·lb...

  • Page 328

    9-6 CRANKSHAFT/TRANSMISSION Specifications Item Standard Service Limit 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 Clearance 0.13 0.38 mm 0.58 mm (0.0051 0.0150 in.)

  • Page 329

    CRANKSHAFT/TRANSMISSION 9-7 Specifications Item Standard Service Limit Crankshaft Main Bearing Insert/Journal 0.020 0.044 mm 0.07 mm (0.0008 0.0017 in.) (0.0028 in.) Clearance Crankshaft Main Journal Diameter: 32.984 33.000 mm 32.96 mm (1.2986 1.2992 in.) (1.2976 in.) Marking None 32.984 32.992 mm –...

  • Page 330

    9-8 CRANKSHAFT/TRANSMISSION Special Tools and Sealant Bearing Puller: Bearing Puller Adapter: 57001-135 57001-317 Outside Circlip Pliers: Kawasaki Bond (Liquid Gasket - Black) : 57001-144 92104-1062...

  • Page 331

    CRANKSHAFT/TRANSMISSION 9-9 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) Clutch (see Clutch Removal in the Clutch chapter) External Shift Mechanism (see External Shift Mecha-...

  • Page 332

    9-10 CRANKSHAFT/TRANSMISSION Crankcase Splitting • Apply liquid gasket to the breather plate mating surface [A] 1 mm (0.04 in.) or more thick, and then install the breather plate. 22 mm (0.87 in.) [B] Sealant - Three Bond: TB1207B NOTE ○ Make the application finish within 7 minutes when the liquid gasket to the mating surface of the breather plate is applied.

  • Page 333

    • Apply liquid gasket [A] to the mating surface of the lower crankcase half. Sealant - Kawasaki Bond (Liquid Gasket - Black): 92104 -1062 NOTE ○ Especially, apply a sealant so that it shall be filled up on the grooves.

  • Page 334

    9-12 CRANKSHAFT/TRANSMISSION Crankcase Splitting • The M9 bolts (L = 95 mm, 3.74 in.) [A] has a copper plated washer [B], replace it with a new one. • Apply molybdenum disulfide oil solution to the seating sur- face [C] on the lower crankcase for the M9 bolts (L = 95 mm, 3.74 in.).

  • Page 335

    CRANKSHAFT/TRANSMISSION 9-13 Crankshaft and Connecting Rods Crankshaft Removal • Split the crankcase (see Crankcase Splitting). • Remove the crankshaft [A]. Crankshaft Installation CAUTION If the crankshaft, bearing inserts, or crankcase halves are replaced with new ones, select the bear- ing inserts and check clearance with a plastigage (press gauge) before assembling engine to be sure the correct bearing inserts are installed.

  • Page 336

    9-14 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods • Apply molybdenum disulfide oil solution [A] to the inner surfaces of upper and lower bearing inserts. • Do not apply any grease or oil to the cap inside and cap insert outside [B]. •...

  • Page 337

    CRANKSHAFT/TRANSMISSION 9-15 Crankshaft and Connecting Rods (1) Bolt Length Measurement Method • Be sure to clean the bolts, nuts, and connecting rods thoroughly with a high-flash point solvent, because the new connecting rods, bolts, and nuts are treated with an anti-rust solution.

  • Page 338

    9-16 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods (2) Rotation Angle Method If you don’t have a point micrometer, you may tighten the nuts using the “Rotation Angle Method”. • Be sure to clean the bolts and nuts thoroughly with a high -flash point solvent, because the new bolts and nuts are treated with an anti-rust solution.

  • Page 339

    CRANKSHAFT/TRANSMISSION 9-17 Crankshaft and Connecting Rods Connecting Rod Bend • Remove the connecting rod big end bearing inserts, and reinstall the connecting rod big end cap. • Select an arbor [A] of the same diameter as the connect- ing rod big end, and insert the arbor through the connect- ing rod big end.

  • Page 340

    9-18 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods Connecting Rod Big End Bearing Insert/Crankpin Wear • Measure the bearing insert/crankpin [A] clearance with plastigage [B]. • Tighten the big end nuts to the specified torque (see Con- necting Rod Installation). NOTE ○ Do not move the connecting rod and crankshaft during clearance measurement.

  • Page 341

    CRANKSHAFT/TRANSMISSION 9-19 Crankshaft and Connecting Rods • Measure the connecting rod big end inside diameter, and mark each connecting rod big end in accordance with the inside diameter. • Tighten the connecting rod big end nuts to the specified torque (see Connecting Rod Installation). NOTE ○...

  • Page 342

    9-20 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods Crankshaft Runout • Measure the crankshaft runout. If the measurement exceeds the service limit, replace the crankshaft. Crankshaft Runout Standard: TIR 0.02 mm (0.0008 in.) or less Service Limit: TIR 0.05 mm (0.0020 in.) Crankshaft Main Bearing Insert/Journal Wear •...

  • Page 343

    CRANKSHAFT/TRANSMISSION 9-21 Crankshaft and Connecting Rods • Measure the main bearing inside diameter, and mark the upper crankcase half in accordance with the inside diam- eter. ○ Crankcase Main Bearing Inside Diameter Marks: “ ” or no mark. • Tighten the crankcase bolts to the specified torque (see Crankcase Assembly).

  • Page 344

    9-22 CRANKSHAFT/TRANSMISSION Starter Motor Clutch Starter Motor Clutch Removal/Installation • Refer to the Alternator Rotor Removal/Installation in the Electrical System chapter. Starter Motor Clutch Inspection • Remove: Alternator Cover (see Alternator Cover Removal in the Electrical System chapter) Starter Idle Gear and Shaft •...

  • Page 345

    CRANKSHAFT/TRANSMISSION 9-23 Transmission Shift Pedal Removal • Align the mark [A] on the shift shaft with the slit [B] on the shift lever. • Remove: Shift Lever Bolt [C] Shift Lever • Remove: Front Footpeg Bracket Bolts [A] Front Footpeg Bracket [B] •...

  • Page 346

    9-24 CRANKSHAFT/TRANSMISSION Transmission • Install the front footpeg bracket [A]. • Tighten: Torque - Front Footpeg Bracket Bolts [B]: 25 N·m (2.5 kgf·m, 18 ft·lb) • Install the shift lever [A], aligning the mark (previously marked). • Tighten: Torque - Shift Lever Bolt: 6.9 N·m (0.70 kgf·m, 61 in·lb) •...

  • Page 347

    CRANKSHAFT/TRANSMISSION 9-25 Transmission • Remove: Oil Pump Drive Gear (see Oil Pump Drive Gear Removal in the Engine Lubrication System chapter) Gear Positioning Lever Bolt [A] Gear Positioning Lever [B] Collar and Spring External Shift Mechanism Installation • Install the gear positioning lever [A] as shown in the figure. Spring [B] Collar [C] Bolt [D]...

  • Page 348

    9-26 CRANKSHAFT/TRANSMISSION Transmission Transmission Shaft Removal • Split the crankcase (see Crankcase Splitting). • Remove the drive shaft [A] and output shaft [B]. Transmission Shaft Installation • Check to see that the set pins [A] and set rings [B] are in place.

  • Page 349

    CRANKSHAFT/TRANSMISSION 9-27 Transmission • Remove the ball bearing [A] from each shafts. Special Tools - Bearing Puller [B]: 57001-135 Bearing Puller Adapter [C]: 57001-317 • Discard the bearing. Transmission Shaft Assembly • Apply engine oil to the bushings, ball bearings and shafts. •...

  • Page 350

    9-28 CRANKSHAFT/TRANSMISSION Transmission NOTE ○ When the toothed washers [28] [29] are assembled onto the output shaft, note the following. ○ When the tangs [A] of the toothed washer [29] shall be assembled, they should be installed into the notch [B] of the toothed washer [28] (see Page 9-29).

  • Page 351

    CRANKSHAFT/TRANSMISSION 9-29 Transmission 1. 1st Gear 17. Nut 2. 2nd Gear 18. Bushing 3. 3rd Gear 19. Bushing 4. 4th Gear 20. Circlip, 33 mm (1.30 in.) 5. 5th Gear 21. Ball Bearing 6. 6th (Top) Gear 22. Collar 7. Toothed Washer, 31 mm (1.22 in.) 23.

  • Page 352

    9-30 CRANKSHAFT/TRANSMISSION Transmission Shift Drum and Fork Removal • Remove: Lower Crankcase Half (see Crankcase Splitting) Transmission Shafts Gear Positioning Lever [A] (see External Shift Mecha- nism Removal) Bolt [B] and Screw [C] Shift Drum Bearing Holder [D] • Pull out the shift rods [E], and take off the shift forks. •...

  • Page 353

    CRANKSHAFT/TRANSMISSION 9-31 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 355

    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......................10-7 Rear Wheel Installation..................... 10-8 Wheel Inspection ......................10-10 Axle Inspection........................

  • Page 356

    10-2 WHEELS/TIRES Exploded View...

  • Page 357

    WHEELS/TIRES 10-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Axle 11.0 79.7 Front Axle Clamp Bolt Rear Axle Nut 11.0 79.7 4. Caliper Bracket (ABS Equipped Models) G: Apply grease. HG: Apply high-temperature grease. R: Replacement Parts WL: Apply soap and water solution or rubber lubricant.

  • Page 358

    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 (0.008 in.) (3.94 in.)

  • Page 359

    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 360

    10-6 WHEELS/TIRES Wheels (Rims) Front Wheel Removal • Remove: Front Caliper Mounting Bolts [A] (Both Sides) Front Calipers [B] (Both Sides) • Remove: Front Fender (see Front Fender Removal in the Frame chapter) Front Axle Clamp Bolt [A] (Loosen) Front Axle [B] •...

  • Page 361

    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 front axle. • Tighten: Torque - Front Axle: 108 N·m (11.0 kgf·m, 79.7 ft·lb) •...

  • Page 362

    10-8 WHEELS/TIRES Wheels (Rims) • Remove: Cotter Pin [A] Axle Nut [B] Washer [C] Axle [D] (from Right Side) • Remove the rear wheel rotation sensor from the caliper bracket (see Rear Wheel Rotation Sensor Removal in the Brakes chapter) (ABS equipped models). •...

  • Page 363

    WHEELS/TIRES 10-9 Wheels (Rims) • Bend the cotter pin [A] over the nut. WARNING If the rear axle nut is not securely tightened or the cotter pin is not installed, an unsafe riding condi- tion may result. • Adjust the drive chain slack after installation (see Drive Chain Slack Inspection in the Periodic Maintenance chap- ter).

  • Page 364

    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 (see Hub Bearing Removal/Installation).

  • Page 365

    WHEELS/TIRES 10-11 Wheels (Rims) Balance Inspection • Remove the front and rear wheels (see Front/Rear Wheel Removal). • 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 366

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

  • Page 367

    WHEELS/TIRES 10-13 Tires Air Pressure Inspection/Adjustment • Refer to the Air Pressure Inspection in the Periodic Main- tenance chapter. Tire Inspection • Refer to the Wheel/Tire Damage Inspection in the Peri- odic Maintenance chapter. Tire Removal • Remove: Wheels (see Front/Rear Wheel Removal) Valve Core (Let out the air) •...

  • Page 368

    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 369

    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 370

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

  • Page 371

    WHEELS/TIRES 10-17 Hub Bearing • Replace the grease seals with new ones. • Press in the grease seals [A] so that the seal surface is flush [B] with the end of the hole. ○ Apply high-temperature grease to the grease seal lips. Special Tool - Bearing Driver Set [C]: 57001-1129 Hub Bearing Inspection Since the hub bearings are made to extremely close tol-...

  • Page 373

    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 374

    11-2 FINAL DRIVE Exploded View...

  • Page 375

    FINAL DRIVE 11-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Engine Sprocket Cover Bolts 87 in·lb Engine Sprocket Cover Plate Bolts 87 in·lb Engine Sprocket Nut 12.7 92.2 Rear Axle Nut 11.0 79.7 Rear Sprocket Nuts G: Apply grease. HG: Apply high-temperature grease.

  • Page 376

    11-4 FINAL DRIVE Specifications Item Standard Service Limit Drive Chain Drive Chain Slack 40 mm (1.2 1.6 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 ENUMA –...

  • Page 377

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

  • Page 378

    11-6 FINAL DRIVE Drive Chain Drive Chain Slack Inspection • Refer to the Drive Chain Slack Inspection in the Periodic Maintenance chapter. Drive Chain Slack Adjustment • Refer to the Drive Chain Slack Adjustment in the Periodic Maintenance chapter. Wheel Alignment Inspection/Adjustment •...

  • Page 379

    FINAL DRIVE 11-7 Drive Chain CAUTION For safety, if the drive chain shall be replaced, re- place it using a recommended tool. Recommended Tool - Type: EK Joint Tool #50 Brand: ENUMA Body [A] Handlebar [B] Cutting and Riveting Pin [C] For Cutting [D] For Riveting [E] Plate Holder (A) [F]...

  • Page 380

    11-8 FINAL DRIVE Drive Chain • Replace the link pin, link plate and grease seals. • Apply grease to the link pins [A] and grease seals [B] [C]. • Engage the drive chain on the engine and rear sprockets. • Insert the link pins in the drive chain ends.

  • Page 381

    FINAL DRIVE 11-9 Drive Chain • Turn the pin holder until riveting pin touches link pin. • Turn the wrench clockwise until tip of riveting pin hits of link pin. • Rivet it. • Same work for the other link pin. •...

  • Page 382

    11-10 FINAL DRIVE Sprocket, Coupling Engine Sprocket Removal • Remove: Engine Sprocket Cover Bolts [A] Engine Sprocket Cover [B] • Flatten out the bended washer [A]. • Remove the engine sprocket nut [B] and washer. NOTE ○ When loosening the engine sprocket nut, hold the rear brake on.

  • Page 383

    FINAL DRIVE 11-11 Sprocket, Coupling • Install the engine sprocket cover [A]. • Install the clamp [B] as shown in the figure, and tighten the cover bolts [C]. Torque - Engine Sprocket Cover Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) •...

  • Page 384

    11-12 FINAL DRIVE Sprocket, Coupling • Grease the following. Wheel Flange Portion [A] O-ring [B] • Install the collar [C]. Coupling Bearing Removal • Remove: Coupling Grease Seal Circlip [A] Special Tool - Inside Circlip Pliers: 57001-143 • Remove the bearing [A] by tapping from the wheel side. Special Tool - Bearing Driver Set [B]: 57001-1129 Coupling Bearing Installation •...

  • Page 385

    FINAL DRIVE 11-13 Sprocket, Coupling Coupling Bearing Inspection Since the coupling bearing is made to extremely close tolerances, the clearance can not normally be measured. NOTE ○ It is not necessary to remove the coupling bearing for inspection. If the bearing is removed, it will need to be replaced with a new one.

  • Page 386

    11-14 FINAL DRIVE Sprocket, Coupling Rear Sprocket Warp Inspection • Raise the rear wheel off the ground with the stand so that it will turn freely. • Set a dial gauge [A] against the rear sprocket [B] near the teeth as shown in the figure, and rotate [C] the rear wheel to measure the sprocket runout (warp).

  • Page 387

    BRAKES 12-1 Brakes Table of Contents Exploded View........................12-4 Specifications ......................... 12-12 Special Tools .......................... 12-13 Brake Lever, Brake Pedal....................... 12-14 Brake Lever Position Adjustment..................12-14 Brake Pedal Position Inspection ..................12-14 Brake Pedal Position Adjustment..................12-14 Brake Pedal Removal ....................... 12-14 Brake Pedal Installation ....................

  • Page 388

    12-2 BRAKES ABS Servicing Precautions ....................12-33 ABS Troubleshooting Outline.................... 12-35 Inquiries to Rider....................... 12-38 Self-diagnosis Outline ....................... 12-40 Self-diagnosis Procedures ....................12-40 Service Code Clearing Procedures................... 12-41 How to Read Service Codes..................... 12-44 How to Erase Service Codes .................... 12-44 ABS Indicator Light (LED) Inspection ................

  • Page 389

    BRAKES 12-3 Dummy Page...

  • Page 390

    12-4 BRAKES Exploded View...

  • Page 391

    BRAKES 12-5 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 Locknut 0.60 52 in·lb Front Brake Disc Mounting Bolts 0.12 11 in·lb Front Brake Light Switch Screw Front Brake Pad Pin Plugs...

  • Page 392

    12-6 BRAKES Exploded View...

  • Page 393

    BRAKES 12-7 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 Rear Brake Disc Mounting Bolts Rear Brake Pad Pin 17.2 Rear Brake Pad Pin Plug 0.25 25 in·lb Rear Caliper Mounting Bolt Rear Caliper Pin Bolt Rear Master Cylinder Mounting Bolts...

  • Page 394

    12-8 BRAKES Exploded View ABS Equipped Models...

  • Page 395

    BRAKES 12-9 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 Locknut 0.60 52 in·lb Brake Pipe Joint Nuts Front Brake Disc Mounting Bolts Front Brake Light Switch Screw 0.12 11 in·lb...

  • Page 396

    12-10 BRAKES Exploded View ABS Equipped Models...

  • Page 397

    BRAKES 12-11 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 Brake Pipe Joint Nuts Rear Brake Disc Mounting Bolts Rear Brake Pad Pin 17.2 Rear Brake Pad Pin Plug 0.25 25 in·lb Rear Caliper Mounting Bolt...

  • Page 398

    12-12 BRAKES Specifications Item Standard Service Limit Brake Lever, Brake Pedal Brake Lever Position 5-way adjustable (to suit rider) – – – Brake Lever Free Play Non-adjustable – – – Pedal Free Play Non-adjustable – – – Pedal Position About 45 mm (1.77 in.) below footpeg top –...

  • Page 399

    BRAKES 12-13 Special Tools Inside Circlip Pliers: Hand Tester: 57001-143 57001-1394 Jack: Jack Attachment: 57001-1238 57001-1608...

  • Page 400

    12-14 BRAKES Brake Lever, Brake Pedal Brake Lever Position Adjustment The brake lever adjuster has 5 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 401

    BRAKES 12-15 Brake Lever, Brake Pedal • Remove: Cotter Pin [A] Joint Pin [B] Rear Brake Light Switch Spring [C] Return Spring [D] Brake Pedal Bolt [E] Brake Pedal [F] Brake Pedal Installation • Apply grease to the footpeg pivot shaft [A]. •...

  • Page 402

    12-16 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. • Unscrew the banjo bolt and remove the brake hoses [D] from the caliper (see Brake Hose Removal/Installation).

  • Page 403

    BRAKES 12-17 Calipers • Fit the rear brake pads [A] to the guide [B]. • Apply silicone grease to the rear caliper pin bolt. • Tighten: Torque - Caliper Mounting Bolts: Front: 25 N·m (2.5 kgf·m, 18 ft·lb) Rear: 22 N·m (2.2 kgf·m, 16 ft·lb) Rear Caliper Pin Bolt: 27 N·m (2.8 kgf·m, 20 ft·lb) Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb)

  • Page 404

    12-18 BRAKES Calipers Caliper Fluid Seal Damage The fluid seal (piston seal) [A] is placed around the pis- ton to maintain clearance between the pad and the disc. If the seal is in a poor condition, it could lead the pad to wear excessively or the brake to drag, which may cause the tem- perature of the discs or the brake fluid to increase.

  • Page 405

    BRAKES 12-19 Calipers Caliper Piston and Cylinder Damage • Visually inspect the pistons [A] and cylinder surfaces [B]. Replace the caliper if the cylinder and piston are badly scores or rusty. Front Caliper Holder Shaft Wear The caliper body must slide smoothly on the caliper holder shaft [A].

  • Page 406

    12-20 BRAKES Brake Pads Front Brake Pad Removal • Unscrew the pad pin plug [A]. • Loosen the pad pin [A]. • Unscrew the bolts [B]. • Remove the caliper with the hose installed. • Remove: Pad Pin [A] Brake Pads [B] Front Brake Pad Installation •...

  • Page 407

    BRAKES 12-21 Brake Pads Rear Brake Pad Removal • Unscrew the pad pin plug [A]. • Loosen the pad pin [A]. • Unscrew the bolts [B]. • Remove the caliper with the hose installed. • Remove: Pad Pin [A] Brake Pads [B] Rear Brake Pad Installation •...

  • Page 408

    12-22 BRAKES Brake Pads Brake Pad Wear Inspection • Refer to the Brake Pad Wear Inspection in the Periodic Maintenance chapter.

  • Page 409

    BRAKES 12-23 Master Cylinder Front Master Cylinder Removal • 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 410

    12-24 BRAKES Master Cylinder Rear Master Cylinder Installation • Replace the cotter pin with a new one. • Replace the washers that are on each side of hose fitting with new ones. • Tighten: Torque - Rear Master Cylinder Mounting Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb) Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb)

  • Page 411

    BRAKES 12-25 Brake Disc Brake Disc Removal • Remove the wheels (see Front/Rear Wheel Removal in the Wheels/Tires chapter). • Unscrew the mounting bolts, and take off the disc. ○ Remove the sensor rotor (ABS equipped models). • Remove the gaskets. Brake Disc Installation •...

  • Page 412

    12-26 BRAKES Brake Fluid Brake Fluid Level Inspection • Refer to the Brake Fluid Level Inspection in the Periodic Maintenance chapter. Brake Fluid Change • Refer to the Brake Fluid Change in the Periodic Mainte- nance chapter. Brake Line Bleeding The brake fluid has a very low compression coefficient so that almost all the movement of the brake lever or pedal is transmitted directly to the caliper for braking action.

  • Page 413

    BRAKES 12-27 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 414

    12-28 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 415

    BRAKES 12-29 Brake Hose Brake Hose and Pipe Removal/Installation • Refer to the Brake Hose and Pipe Replacement in the Periodic Maintenance chapter. Brake Hose and Pipe Inspection • Refer to the Brake Hose and Pipe Damage and Instal- lation Condition Inspection in the Periodic Maintenance chapter.

  • Page 416

    1. Front Wheel Rotation Sensor 2. Front Wheel Rotation Sensor Rotor 3. Rear Wheel Rotation Sensor 4. Rear Wheel Rotation Sensor Rotor 5. ABS Indicator Light (LED) 6. ABS Hydraulic Unit 7. ABS Fuse Box 8. ABS Kawasaki Self-diagnosis System Connector...

  • Page 417

    11. Meter Unit 2. Rear Wheel Rotation Sensor 12. Front Brake Switch 13. Water-proof Joint A 3. Front Wheel Rotation Sensor 4. ABS Kawasaki Self-diagnosis System Con- 14. Meter Ground 15. Frame Ground nector 5. ABS Hydraulic Unit 16. Main Fuse 30 A 17.

  • Page 418

    6. Unused 7. Unused 8. Power Supply to ABS Solenoid Valve Relay 9. Power Supply to ABS Motor Relay 10. ABS Kawasaki Self-diagnosis System Terminal 11. Unused 12. Power Supply to Front Wheel Rotation Sensor 13. ABS Self-diagnosis Terminal 14. Unused 15.

  • Page 419

    BRAKES 12-33 Anti-Lock Brake System (Equipped Models) ABS Servicing Precautions There are a number of important precautions that should be followed servicing the ABS system. ○ This ABS 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 420

    12-34 BRAKES Anti-Lock Brake System (Equipped Models) ○ The ABS indicator light (LED) [A] may light if the tire pres- sure is incorrect, a non-recommended tire is installed, or the wheel is deformed. If the indicator light lights, remedy the problem and clear the service code. WARNING Use of non-recommended tires may cause malfunc- tioning of ABS and can lead to extended braking...

  • Page 421

    BRAKES 12-35 Anti-Lock Brake System (Equipped Models) ABS Troubleshooting Outline When an abnormality in the system occurs, the ABS in- dicator light (LED) lights up to alert the rider. In addition, the nature of the fault is stored in the memory of the ABS hydraulic unit and when in the self-diagnosis mode, the ser- vice code [A] is indicated by the number of times the ABS indicator light (LED) blinks.

  • Page 422

    12-36 BRAKES Anti-Lock Brake System (Equipped Models) • Visually inspect the wiring for signs of burning or fraying. 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 423

    BRAKES 12-37 Anti-Lock Brake System (Equipped Models) ABS Diagnosis Flow Chart...

  • Page 424

    12-38 BRAKES Anti-Lock Brake System (Equipped Models) Inquiries to Rider ○ Each rider reacts to problems in different ways, so it is important to confirm what kind of condition the rider is dissatisfied with. ○ Try to find out exactly what problem occurs under exactly what conditions by asking the rider; know- ing this information may help you reproduce the problem in the shop.

  • Page 425

    BRAKES 12-39 Anti-Lock Brake System (Equipped Models) Pre-Diagnosis Inspection 1...

  • Page 426

    12-40 BRAKES Anti-Lock Brake System (Equipped Models) Pre-Diagnosis Inspection 2 Self-diagnosis Outline When the indicator light has blinked or come on, the ABS hydraulic unit memorizes and stores the service code for the service person to troubleshoot easily. The service code memory is powered directly by the battery and cannot be canceled by the ignition switch.

  • Page 427

    BRAKES 12-41 Anti-Lock Brake System (Equipped Models) • Remove the seats (see Rear/Front Seat Removal in the Frame chapter). • Ground the self-diagnosis terminal [A] (Gray) to the ground terminal [B] (Black/Yellow), using a lead. • Turn on the ignition switch. ○...

  • Page 428

    12-42 BRAKES Anti-Lock Brake System (Equipped Models)

  • Page 429

    BRAKES 12-43 Anti-Lock Brake System (Equipped Models) Self-diagnosis Flow Chart...

  • Page 430

    12-44 BRAKES Anti-Lock Brake System (Equipped Models) How to Read Service Codes ○ Service codes are shown by a series of long and short blinks of the ABS indicator light (LED) as shown below. ○ Read 10th digit and unit digit as the ABS indicator light (LED) blinks. ○...

  • Page 431

    BRAKES 12-45 Anti-Lock Brake System (Equipped Models) Service Code Table Service ABS Indicator Light (LED) Problems Light State Code Rear inlet solenoid valve trouble (shorted or open, stuck valve (ON)) Rear outlet solenoid valve trouble (shorted or open, stuck valve (ON)) Front inlet solenoid valve trouble (shorted or open, stuck valve (ON)) Front outlet solenoid valve trouble (shorted...

  • Page 432

    12-46 BRAKES Anti-Lock Brake System (Equipped Models) ABS Indicator Light (LED) Inspection • Turn the ignition switch ON. If the ABS indicator light (LED) [A] lights, it is normal. If the ABS indicator light (LED) does not light, go to step “ABS Indicator Light (LED) is Unlit (When the Ignition Switch turned to ON)”.

  • Page 433

    BRAKES 12-47 Anti-Lock Brake System (Equipped Models) • Do the 3rd step test. ○ Disconnect the ABS hydraulic unit connector. ○ Check for continuity between the black/white lead termi- nal of the main harness side connector [A] and black/white lead terminal of the main harness side connector [B]. If there is the continuity in the lead, replace the ABS hy- draulic unit.

  • Page 434

    12-48 BRAKES Anti-Lock Brake System (Equipped Models) • Do the 2nd step test. ○ Disconnect the ABS hydraulic unit connector [A]. ○ Check for continuity between the light green and black/yellow lead terminals of the ABS hydraulic unit connector. If there is the continuity in the lead, replace the ABS hy- draulic unit.

  • Page 435

    BRAKES 12-49 Anti-Lock Brake System (Equipped Models) Front, Rear Wheel Rotation Difference Abnormal (Service Code 25) • Do the 1st step test. ○ Check the following and correct the faulty part. Incorrect the tire pressure. Tires not recommended for the motorcycle were installed (incorrect tire size).

  • Page 436

    12-50 BRAKES Anti-Lock Brake System (Equipped Models) • Do the 4th step test. ○ Check the battery terminal voltage between the red lead terminal of the fuse box [A] and ground. Special Tool - Hand Tester: 57001-1394 Battery Terminal Voltage Standard: Battery Voltage If the battery terminal voltage is not within the specifica-...

  • Page 437

    BRAKES 12-51 Anti-Lock Brake System (Equipped Models) • Do the 2nd step test. ○ Check that there is iron or other magnetic deposits be- tween the sensor [A] and sensor rotor [B], and the sensor rotor slots for obstructions. ○ Check the installation condition of the sensor for loose- ness.

  • Page 438

    12-52 BRAKES Anti-Lock Brake System (Equipped Models) • Do the 3rd step test. ○ Recheck the service code indication; erase the service code, perform the pre-diagnosis inspection 1 and 2, and retrieve the service code. If the ABS indicator light (LED) [A] lit, faulty ECU in the ABS hydraulic unit.

  • Page 439

    BRAKES 12-53 Anti-Lock Brake System (Equipped Models) Rear Wheel Rotation Sensor Wiring Inspection (Service Code 45) • Do the 1st step test. ○ Disconnect the ABS hydraulic unit connector and rear wheel rotation sensor connector. ○ Short the black and brown/black lead terminals of the main harness side connector [A] with a jumper lead, and check for continuity between the black and brown/black lead terminals of the main harness side connector [B].

  • Page 440

    12-54 BRAKES Anti-Lock Brake System (Equipped Models) • Do the 2nd step test. ○ Connect the ignition switch connector and ABS hydraulic unit connector. ○ Check the battery terminal voltage, connect the hand tester to the brown terminal of ignition switch connector [A] and ground.

  • Page 441

    BRAKES 12-55 Anti-Lock Brake System (Equipped Models) • Do the 2nd step test. ○ Connect the ignition switch connector and ABS hydraulic unit connector. ○ Check the battery terminal voltage, connect the hand tester to the brown terminal of ignition switch connector [A] and ground.

  • Page 442

    12-56 BRAKES Anti-Lock Brake System (Equipped Models) • Remove: Seats (see Rear/Front Seat Removal in the Frame chap- ter) Rear Fender (see Flap and Rear Fender Removal in the Frame chapter) • Clean the ABS hydraulic unit. CAUTION Clean all fittings on the ABS hydraulic unit and the rear master cylinder because dirt around the banjo bolts could contaminate the brake fluid in the line during removal/installation.

  • Page 443

    BRAKES 12-57 Anti-Lock Brake System (Equipped Models) CAUTION The ABS hydraulic unit [A] has been adjusted and set with precision at the factory. Do not try to dis- assemble and repair the ABS hydraulic unit. ABS Hydraulic Unit Installation • Install the ABS hydraulic unit to the bracket.

  • Page 444

    12-58 BRAKES Anti-Lock Brake System (Equipped Models) • Visually inspect the connector terminals [A]. Replace the ABS hydraulic unit or main harness if either of the terminals are cracked, bent, or otherwise damaged. If the ABS hydraulic unit connector is clogged with mud or dust, blow it off with compressed air.

  • Page 445

    BRAKES 12-59 Anti-Lock Brake System (Equipped Models) Rear Wheel Rotation Sensor Removal CAUTION The wheel rotation sensor should be handled care- fully, never struck sharply, as with a hammer, or al- lowed to fall on a hard surface since the wheel rota- tion sensor is precision made.

  • Page 446

    12-60 BRAKES Anti-Lock Brake System (Equipped Models) Wheel Rotation Sensor Inspection • Remove the front wheel rotation sensor [A] from the front fork. • Remove the rear wheel rotation sensor [B] from the caliper bracket. • Visually inspect the wheel rotation sensors. Replace the wheel rotation sensor if it is cracked, bent, or otherwise damaged.

  • Page 447

    BRAKES 12-61 Anti-Lock Brake System (Equipped Models) Wheel Rotation Sensor Rotor Inspection • Remove: Wheels (see Front/Rear Wheel Removal in the Wheels/Tires chapter) Brake Disc Mounting Bolts [A] Sensor Rotor [B] Front Wheel [C] Rear Wheel [D] • Visually inspect the wheel rotation sensor rotor. If the rotor is deformed or damaged (chipped teeth [A]), replace the sensor rotor with a new one.

  • Page 448

    12-62 BRAKES Anti-Lock Brake System (Equipped Models) 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 (see Fuse Installation in the Electrical System chapter).

  • Page 449

    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 Spring Preload Adjustment ....................13-9 Front Fork Removal (Each Fork Leg) ................13-10 Front Fork Installation ....................... 13-10 Front Fork Oil Change ......................

  • Page 450

    13-2 SUSPENSION Exploded View...

  • Page 451

    SUSPENSION 13-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Axle Clamp Bolt Front Fork Bottom Allen Bolts Front Fork Top Plugs Lower Front Fork Clamp Bolts Piston Rod Nuts Upper Front Fork Clamp Bolts 7. Inner Tube (ABS Equipped Models) AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque.

  • Page 452

    13-4 SUSPENSION Exploded View...

  • Page 453

    SUSPENSION 13-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Rear Shock Absorber Nut (Lower) Rear Shock Absorber Nut (Upper) Swingarm Pivot Shaft 87 in·lb Swingarm Pivot Shaft Locknut 10.0 72.3 Swingarm Pivot Shaft Nut 11.0 79.7 Tie-Rod Nuts Uni-Trak Rocker Arm Nut G: Apply grease.

  • Page 454

    13-6 SUSPENSION Specifications Item Standard Front Fork (Per One Unit) Fork Inner Tube Diameter 41 mm (1.6 in.) Air Pressure Atmospheric pressure (Non-adjustable) Rebound Damper Setting (Only 7th click from the 1st click of the fully clockwise position Right Fork Leg) (Usable Range: 0 ←→...

  • Page 455

    SUSPENSION 13-7 Special Tools Inside Circlip Pliers: Fork Oil Level Gauge: 57001-143 57001-1290 Oil Seal & Bearing Remover: Bearing Remover Head, 20 × 22: 57001-1058 57001-1293 Bearing Driver Set: Fork Piston Rod Puller, M10 × 1.0: 57001-1129 57001-1298 Jack: Fork Spring Stopper: 57001-1238 57001-1374 Fork Oil Seal Driver, 41:...

  • Page 456

    13-8 SUSPENSION Special Tools Fork Cylinder Holder, Hex 24: Needle Bearing Driver, 28: 57001-1537 57001-1610 Hook Wrench R=35 Spacer, 57001-1580 57001-1636 Swingarm Pivot Nut Wrench: Spacer 28: 57001-1597 57001-1663 Jack Attachment: Fork Spring Compressor: 57001-1608 57001-1685 Needle Bearing Driver, 17/ 18: 57001-1609...

  • Page 457

    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 7th click from the 1st click of the fully clockwise position.

  • Page 458

    13-10 SUSPENSION Front Fork Front Fork Removal (Each Fork Leg) • Remove: Upper Fairing (see Upper Fairing Removal in the Frame chapter) Front Wheel (see Front Wheel Removal in the Wheels/Tires chapter) Front Fender (see Front Fender Removal in the Frame chapter) Loosen the upper front fork clamp bolt [A] and fork top plug [B] beforehand if the fork leg is to be disassembled.

  • Page 459

    SUSPENSION 13-11 Front Fork • Install the fork spring compressor as shown in the figure. NOTE ○ Set the fork spring compressor so that the end of the handle [A] passes the upper side hole on the spacer [B] by screwing the handle in the holder [C] to the bottom. Special Tool - Fork Spring Compressor: 57001-1685 •...

  • Page 460

    13-12 SUSPENSION Front Fork • Drain the fork oil into a suitable container. ○ Pump the piston rod [A] up and down at least ten times to expel the oil from the fork. Special Tool - Fork Piston Rod Puller, M10 × 1.0 [B]: 57001 -1298 •...

  • Page 461

    SUSPENSION 13-13 Front Fork Oil Level (fully compressed, without spring) Standard: Right Fork Leg: 106 ±2 mm (4.17 ±0.08 in.) (from the top of the outer tube) Left Fork Leg: 100 ±2 mm (3.94 ±0.08 in.) (from the top of the outer tube) NOTE ○...

  • Page 462

    13-14 SUSPENSION 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 463

    SUSPENSION 13-15 Front Fork • Check the O-ring [A] on the top plug and replace it with a new one if damaged. ○ Apply grease to the new O-ring. • Holding the spring preload adjuster [B] with a wrench [C], tighten the piston rod nut [D] against the top plug.

  • Page 464

    13-16 SUSPENSION Front Fork Front Fork Assembly • Replace the following parts with a new one. Oil Seal Bottom Allen Bolt Gasket • Insert the cylinder unit into the inner tube. • Stop the cylinder from turning by using the fork cylinder holder.

  • Page 465

    SUSPENSION 13-17 Front Fork Inner Tube, Outer Tube Inspection • Visually inspect the inner tube [A], and repair any dam- age. • Nicks or rust damage can sometimes be repaired by using a wet-stone to remove sharp edges or raised areas which cause seal damage.

  • Page 466

    13-18 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 1 2/4 turns out from the fully clockwise position.

  • Page 467

    SUSPENSION 13-19 Rear Shock Absorber Rear Shock Absorber Removal • Raise the rear wheel off the ground with the jack. Special Tools - Jack: 57001-1238 Jack Attachment: 57001-1608 • Squeeze the brake lever slowly and hold it with a band [A].

  • Page 468

    13-20 SUSPENSION Swingarm Swingarm Removal • Remove: Frame Covers (see Frame Cover Removal in the Frame chapter) Chain Cover (see Drive Chain Removal in the Final Drive chapter) Rear Wheel (see Rear Wheel Removal in the Wheels/Tires chapter) • Remove: Screw [A] Clamps [B] [C] •...

  • Page 469

    SUSPENSION 13-21 Swingarm • Unscrew the swingarm pivot shaft nut [A] and the swingarm pivot shaft [B]. • Pull out the pivot shaft and remove the swingarm. Swingarm Installation • Place the collar [A] on the stopper [B] inside the frame [C]. •...

  • Page 470

    13-22 SUSPENSION Swingarm Swingarm Bearing Removal • Remove: Swingarm (see Swingarm Removal) Collar [A] Oil Seals [B] Sleeve [C] Circlip [D] (Right Side) Special Tool - Inside Circlip Pliers: 57001-143 • Remove the ball bearing and needle bearings. Special Tool - Oil Seal & Bearing Remover [A]: 57001-1058 Swingarm Bearing Installation •...

  • Page 471

    SUSPENSION 13-23 Swingarm • Install the needle bearings [A], ball bearing [B] and oil seals [C] position as shown in the figure. Circlip [D] 23.5 mm (0.93 in.) [E] 17 mm (0.67 in.) [F] 6 mm (0.24 in.) [G] Swingarm Bearing, Sleeve Inspection CAUTION Do not remove the bearings for inspection.

  • Page 472

    13-24 SUSPENSION Swingarm Swingarm Bearing Lubrication NOTE ○ Since the bearings are packed with grease and sealed, lubrication is not required. Chain Guide Inspection • Refer to the Chain Guide Wear Inspection in the Periodic Maintenance chapter.

  • Page 473

    SUSPENSION 13-25 Tie-Rod, Rocker Arm Tie-Rod Removal • Squeeze the brake lever slowly and hold it with a band [A]. • Raise the rear wheel off the ground with the jack. Special Tools - Jack: 57001-1238 Jack Attachment: 57001-1608 • Remove: Upper Tie-Rod Nut and Bolt [A] Lower Tie-Rod Nut and Bolt [B]...

  • Page 474

    13-26 SUSPENSION Tie-Rod, Rocker Arm Tie-Rod and Rocker Arm Bearing Removal • Remove: Tie-Rods (see Tie-Rod Removal) Rocker Arm (see Rocker Arm Removal) Sleeves [A] Oil Seals [B] Swingarm [C] (see Swingarm Removal) • Remove the needle bearings [D], using the bearing re- mover head and bearing remover shaft.

  • Page 475

    SUSPENSION 13-27 Tie-Rod, Rocker Arm NOTE ○ Install the needle bearings so that the marked side faces in. Needle Bearings [A] Oil Seals [B] Front [C] Right Side [D] Left Side [E] Rear Shock Absorber [F] Tie-Rods [G] Rocker Arm [H] 7.5 mm (0.30 in.) [I] 5.0 mm (0.20 in.) [J] 5.5 mm (0.22 in.) [K]...

  • Page 477

    STEERING 14-1 Steering Table of Contents Exploded View........................14-2 Special Tools .......................... 14-4 Steering ..........................14-5 Steering Inspection ......................14-5 Steering Adjustment......................14-5 Steering Stem......................... 14-6 Stem, Stem Bearing Removal................... 14-6 Stem, Stem Bearing Installation..................14-7 Steering Stem Bearing Lubrication ................... 14-8 Steering Stem Warp......................

  • Page 478

    14-2 STEERING Exploded View...

  • Page 479

    STEERING 14-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Handlebar Holder Bolts Handlebar Lower Clamp Nuts Lower Front Fork Clamp Bolts Steering Stem Head Bolt 11.0 79.7 Steering Stem Nut Switch Housing Screws 0.36 31 in·lb Upper Front Fork Clamp Bolts AD: Apply adhesive.

  • Page 480

    14-4 STEERING Special Tools Head Pipe Outer Race Press Shaft: Steering Stem Bearing Driver, 42.5: 57001-1075 57001-1344 Steering Stem Nut Wrench: Steering Stem Bearing Driver Adapter, 41.5: 57001-1100 57001-1345 Bearing Driver Set: Head Pipe Outer Race Driver, 55: 57001-1129 57001-1446...

  • Page 481

    STEERING 14-5 Steering Steering Inspection • Refer to the Steering Play Inspection in the Periodic Main- tenance chapter. Steering Adjustment • Refer to the Steering Play Adjustment in the Periodic Maintenance chapter.

  • Page 482

    14-6 STEERING Steering Stem Stem, Stem Bearing Removal • Remove: Inner Cover (see Inner Cover Removal in the Frame chapter) Upper Fairing (see Upper Fairing Removal in the Frame chapter) Upper Fairing Bracket (see Upper Fairing Bracket Re- moval in the Frame chapter) Front Wheel (see Front Wheel Removal in the Wheels/Tires chapter) Handlebar (see Handlebar Removal)

  • Page 483

    STEERING 14-7 Steering Stem • Remove the lower ball bearing inner race (with its oil seal) [A] which is pressed onto the steering stem with a suitable commercially available chisel [B]. Stem, Stem Bearing Installation • Replace the bearing outer races with new ones. •...

  • Page 484

    14-8 STEERING Steering Stem • Settle the bearings in place as follows. ○ Tighten the steering stem nut with 55 N·m (5.6 kgf·m, 41 ft·lb) of torque first, and loosen it a fraction of a turn until it turns lightly. Afterward tighten it again with specified torque using a steering stem nut wrench [A].

  • Page 485

    STEERING 14-9 Steering Stem 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. If the steering stem [A] is bent, replace the steering stem. Stem Cap Deterioration, Damage Replace the stem cap if its oil seal [A] shows damage.

  • Page 486

    14-10 STEERING Handlebar Handlebar Removal • Remove: Clutch Lever Clamp Bolts [A] Clutch Lever Assembly [B] Left Switch Housing [C] Handlebar Weight [D] • Remove: Front Master Cylinder [A] (see Front Master Cylinder Re- moval in the Brakes chapter) Right Switch Housing [B] Handlebar Weight [C] Throttle Grip [D] •...

  • Page 487

    STEERING 14-11 Handlebar • Align the punch mark [A] on the handlebar and the corner edge [B] on the lower clamp. • Tighten the front holder bolts first, and then the rear holder bolts. There will be a gap [A] at the rear part of the holder after tightening.

  • Page 489

    FRAME 15-1 Frame Table of Contents Exploded View........................15-2 Seats ............................15-7 Rear Seat Removal......................15-7 Rear Seat Installation......................15-7 Front Seat Removal ......................15-7 Front Seat Installation ....................... 15-7 Fairings........................... 15-8 Center Fairing Removal ....................15-8 Center Fairing Installation ....................15-8 Upper Fairing Removal .....................

  • Page 490

    15-2 FRAME Exploded View...

  • Page 491: Au Model

    FRAME 15-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Fender Bolts 0.40 35 in·lb 2. Reflector (AU Model) 3. 2 3 mm (0.08 0.12 in.) L: Apply a non-permanent locking agent.

  • Page 492

    15-4 FRAME Exploded View...

  • Page 493

    FRAME 15-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Footpeg Bracket Bolts Rear Footpeg Bracket Bolts Sidestand Bolt Sidestand Switch Bolt 0.90 78 in·lb 5. With guard on the side cover: Frame No.; Without guard on the side cover: Frame No.; G: Apply grease.

  • Page 494

    15-6 FRAME Exploded View...

  • Page 495

    FRAME 15-7 Seats Rear Seat Removal • Insert the ignition switch key [A] into the seat lock, turning the key clockwise, pulling the front part of the seat [B] up, and pull the seat forward. Rear Seat Installation • Insert the rear seat hook [A] into the bracket [B] of the frame.

  • Page 496

    15-8 FRAME Fairings Center Fairing Removal • Remove: Bolts [A] Center Fairing [B] • Remove: Inner Fairing (see Inner Fairing Removal) Bracket Center Fairing Installation • Installation is the reverse of removal. Upper Fairing Removal • Remove: Inner Cover (see Inner Cover Removal) Bolts [A] (Both Sides) •...

  • Page 497

    FRAME 15-9 Fairings Upper Fairing Installation • Connect: City Light Lead Connectors Headlight Lead Connectors • Fit the projections [A] on the upper fairing bracket into the holes [B] of the headlight. • Tighten the bolts. Inner Cover Removal • Push the central pin, and then remove the quick rivets [A].

  • Page 498

    15-10 FRAME Side Covers Sub Side Cover Removal • Remove the bolt [A]. • Pull the sub side cover [B] to clear the stoppers [C]. Sub Side Cover Installation • Insert the projections [A] into the holes [B]. • Tighten the bolt. Side Cover Removal •...

  • Page 499

    FRAME 15-11 Seat Covers Seat Cover Removal • Remove: Seats (see Rear/Front Seat Removal) Side Covers (see Side Cover Removal) Rivet Screws [A] • Remove the bolts [A]. • Pull the front seat cover [B] to clear the stoppers [C]. •...

  • Page 500

    15-12 FRAME Seat Covers • Remove: Rivets [A] Bolts [B] Brackets [C] Flap [D] (with Turn Signal and License Plate Lights) Bolts and Seat Lock Bracket Lower Seat Cover Seat Cover Installation • Installation is the reverse of removal. • Put the projections [A] into the holes [B] of the center seat cover.

  • Page 501

    FRAME 15-13 Fenders Front Fender Removal • Remove: Brake Hose Clamps [A] (Both Sides) Bolts [B] with Washers (Both Sides) Front Fender [C] Front Fender Installation • Install the front fender to the front fork. • Tighten: Torque - Front Fender Bolts: 3.9 N·m (0.40 kgf·m, 35 in·lb) •...

  • Page 502

    15-14 FRAME Frame Frame Inspection • Visually inspect the frame for cracks, dents, bending, or warp. ○ If there is any damage to the frame, replace it. WARNING A repaired frame may fail in use, possibly causing an accident. If the frame is bent, dented, cracked, or warped, replace it.

  • Page 503

    FRAME 15-15 Sidestand Sidestand Removal • Raise the rear wheel off the ground with the stand. • Remove: Sidestand Switch Bolt [A] Sidestand Switch [B] Spring [C] Sidestand Nut [D] Sidestand Bolt [E] Sidestand [F] Sidestand Installation • Apply grease to the sliding area [A] of the sidestand [B]. •...

  • Page 504

    15-16 FRAME Frame Cover Frame Cover Removal • Remove: Sub Side Covers (see Sub Side Cover Removal) Bolts [A] • Pull out the frame cover [B], and clear the stopper [C]. Frame Cover Installation • Insert the projection [A] into the hole [B]. •...

  • Page 505

    FRAME 15-17 Rear View Mirrors Rear View Mirrors Removal • Loosen the lower hexagonal area [A] for tightening to re- move the rear view mirror from the holder. CAUTION Do not force to tighten and/or loosen the upper hexagonal area (adapter) [B] with a pair of span- ners.

  • Page 507

    ELECTRICAL SYSTEM 16-1 Electrical System Table of Contents Exploded View........................16-3 Specifications ......................... 16-10 Special Tools and Sealant ...................... 16-11 Parts Location......................... 16-13 Wiring Diagram........................16-16 Wiring Diagram (ABS Equipped Models) ................16-18 Precautions..........................16-20 Electrical Wiring........................16-21 Wiring Inspection ......................16-21 Battery ............................

  • Page 508

    16-2 ELECTRICAL SYSTEM Starter Motor Disassembly....................16-51 Starter Motor Assembly ....................16-51 Brush Inspection ....................... 16-52 Commutator Cleaning and Inspection................16-53 Armature Inspection......................16-53 Brush Lead Inspection ...................... 16-53 Brush Plate and Terminal Bolt Inspection ................. 16-54 Starter Relay Inspection....................16-54 Lighting System ........................

  • Page 509

    ELECTRICAL SYSTEM 16-3 Exploded View Dummy Page...

  • Page 510

    16-4 ELECTRICAL SYSTEM Exploded View...

  • Page 511

    ELECTRICAL SYSTEM 16-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Brake Light Switch Screw 0.12 11 in·lb License Plate Light Cover Mounting Screws 0.09 8 in·lb License Plate Light Mounting Screws 0.12 11 in·lb Meter Mounting Screws 0.12 11 in·lb Oxygen Sensor (Equipped Models) 44.1...

  • Page 512

    16-6 ELECTRICAL SYSTEM Exploded View...

  • Page 513

    ELECTRICAL SYSTEM 16-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Alternator Cover Bolts 97 in·lb Alternator Lead Holding Plate Bolt 106 in·lb Alternator Rotor Bolt 15.8 Camshaft Position Sensor Bolt 106 in·lb Crankshaft Sensor Bolts 0.60 52 in·lb Crankshaft Sensor Cover Bolts 97 in·lb Oil Pressure Switch Oil Pressure Switch Terminal Bolt...

  • Page 514

    16-8 ELECTRICAL SYSTEM Exploded View...

  • Page 515

    ELECTRICAL SYSTEM 16-9 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Engine Ground Cable Terminal Bolt 87 in·lb Fuel Level Sensor Bolts 0.70 61 in·lb Neutral Switch Regulator/Rectifier Bolts 0.70 61 in·lb Regulator/Rectifier Bracket Bolts 0.70 61 in·lb Sidestand Switch Bolt 0.90 78 in·lb Speed Sensor Bolt...

  • Page 516

    16-10 ELECTRICAL SYSTEM Specifications Item Standard Battery Type Sealed Battery Model Name YTX9-BS Capacity 12 V 8 Ah Voltage 12.8 V or more Charging System Type Three-phase AC Alternator Output Voltage 39 V or more at 4 000 r/min (rpm) Stator Coil Resistance 0.18 0.28 Ω...

  • Page 517

    ELECTRICAL SYSTEM 16-11 Special Tools and Sealant Hand Tester: Grip: 57001-1394 57001-1591 Flywheel Puller Assembly, M38 × 1.5/M35 × 1.5: Flywheel & Pulley Holder: 57001-1405 57001-1605 Peak Voltage Adapter: Stopper: 57001-1415 57001-1679 Lead Wire - Peak Voltage Adapter: Rotor Holder: 57001-1449 57001-1690 Key Registration Unit:...

  • Page 518

    16-12 ELECTRICAL SYSTEM Special Tools and Sealant Kawasaki Bond (Silicone Sealant): 92104-0004...

  • Page 519

    ELECTRICAL SYSTEM 16-13 Parts Location Dummy Page...

  • Page 520

    16-14 ELECTRICAL SYSTEM Parts Location...

  • Page 521

    8. Fuse Box 1 9. Starter Relay 10. Battery 12 V 8 Ah 11. Turn Signal Relay 12. Fuse Box 2 13. Vehicle-down Sensor 14. Kawasaki Diagnostic System Connector 15. Relay Box 16. ECU 17. Camshaft Position Sensor 18. Alternator 19. Sidestand Switch 20.

  • Page 522

    16-16 ELECTRICAL SYSTEM Wiring Diagram...

  • Page 523

    ELECTRICAL SYSTEM 16-17 Wiring Diagram...

  • Page 524

    16-18 ELECTRICAL SYSTEM Wiring Diagram (ABS Equipped Models)

  • Page 525

    ELECTRICAL SYSTEM 16-19 Wiring Diagram (ABS Equipped Models)

  • Page 526

    16-20 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 cable connections. This will burn out the diodes on the electrical parts. ○...

  • Page 527

    ELECTRICAL SYSTEM 16-21 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

    16-22 ELECTRICAL SYSTEM Battery Battery Removal • Turn off the ignition switch. • Remove: Seats (see Rear/Front Seat Removal in the Frame chap- ter) Front Seat Cover (see Seat Cover Removal in the Frame chapter) Bolts [A] and Front Seat Bracket [B] •...

  • Page 529

    ELECTRICAL SYSTEM 16-23 Battery • Slide in the fuse box [A] into the front seat bracket [B] until the stopper [C] fits in the bracket. • Run the seat lock cable [A] under the front seat bracket [B] and then install the bracket. ○...

  • Page 530

    16-24 ELECTRICAL SYSTEM Battery • Remove the electrolyte container from the vinyl bag. • Detach the strip of caps [A] from the container and set aside, these will be used later to seal the battery. NOTE ○ Do not pierce or otherwise open the sealed cells [B] of the electrolyte container.

  • Page 531

    Standard Charge: 0.9 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 532

    16-26 ELECTRICAL SYSTEM Battery Precautions 1) No need of topping-up No topping-up is necessary in this battery until it ends its life under normal use. Forcibly prying off the seal cap to add water is very dangerous. Never do that. 2) Refreshing charge.

  • Page 533

    ELECTRICAL SYSTEM 16-27 Battery If the reading is 12.8 V or more, no refresh charge is re- quired, however, if the read is below the specified, refresh charge is required. Battery Terminal Voltage Standard: 12.8 V or more Terminal Voltage (V) [A] Battery Charge Rate (%) [B] Good [C] Refresh charge is required [D]...

  • Page 534

    16-28 ELECTRICAL SYSTEM Charging System Alternator Cover Removal • Remove: Left Frame Cover (see Frame Cover Removal in the Frame chapter) Engine Sprocket Cover (see Engine Sprocket Removal in the Final Drive chapter) Coolant (Drain, see Coolant Change in the Periodic Maintenance chapter) •...

  • Page 535

    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 536

    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 • Install the alternator cover (see Alternator Cover Installa- tion).

  • Page 537

    ELECTRICAL SYSTEM 16-31 Charging System Alternator Rotor Installation • Using a cleaning fluid, clean off any oil or dirt on the fol- lowing portions and dry them with a clean cloth. Crankshaft Tapered Portion [A] Alternator Rotor Tapered Portion [B] •...

  • Page 538

    16-32 ELECTRICAL SYSTEM Charging System • Install the washer and alternator rotor bolt [A]. NOTE ○ Confirm the alternator rotor fit or not to the crankshaft before tightening it with specified torque. • Install the rotor bolt and tighten it with 70 N·m (7.0 kgf·m, 52 ft·lb) of torque.

  • Page 539

    ELECTRICAL SYSTEM 16-33 Charging System • To check the alternator output voltage, do the following procedures. ○ Turn off the ignition switch. ○ Remove the left frame cover (see Frame Cover Removal in the Frame chapter). ○ Disconnect the alternator lead connector [A]. ○...

  • Page 540

    16-34 ELECTRICAL SYSTEM Charging System Regulator/Rectifier Inspection • Remove: Bolts [A] and Bracket [B] Regulator/Rectifier Assembly [C] • Remove: Connector [A] (Disconnect) Regulator/Rectifier [B] Rectifier Circuit Check • Check conductivity of the following pair of terminals. Rectifier Circuit Inspection W-BK1, W-BK2, W-BK3 Tester connection...

  • Page 541

    ELECTRICAL SYSTEM 16-35 Charging System • Do the 1st step regulator circuit test. ○ Connect the test light and the 12 V battery to the regula- tor/rectifier as shown in the figure. ○ Check the BK1, BK2 and BK3 terminal respectively. If the test light turns on, the regulator/rectifier is defective.

  • Page 542

    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. • Take out the battery from the rear fender with the cables connected (see Battery Removal).

  • Page 543

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

  • Page 544

    16-38 ELECTRICAL SYSTEM Ignition System WARNING The ignition system produces extremely high volt- age. Do not touch the spark plugs or stick coils while the engine is running, or you could receive a severe electrical shock. CAUTION Do not disconnect the battery cables or any other electrical connections when the ignition switch is ON, or while the engine is running.

  • Page 545

    Apply silicone sealant [A] to the crankshaft sensor lead grommet and crankcase halves mating surface on the front and rear sides of the crankshaft sensor cover mount. Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004 • Install the oil pressure switch lead terminal [A] securely.

  • Page 546

    16-40 ELECTRICAL SYSTEM Ignition System • Replace the O-ring in the crankshaft sensor cover [A] with a new one. • Install: Crankshaft Sensor Cover Clamps [B] • Tighten: Torque - Crankshaft Sensor Cover Bolts: 11 N·m (1.1 kgf·m, 97 in·lb) Crankshaft Sensor Inspection •...

  • Page 547

    ELECTRICAL SYSTEM 16-41 Ignition System Crankshaft Sensor Peak Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Remove: Right Frame Cover (see Frame Cover Removal in the Frame chapter) Crankshaft Sensor Lead Connector [A] (see Crankshaft Sensor Removal) •...

  • Page 548

    16-42 ELECTRICAL SYSTEM Ignition System Camshaft Position Sensor Removal CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Radiator (see Radiator and Radiator Fan Removal in the Cooling System chapter)

  • Page 549

    ELECTRICAL SYSTEM 16-43 Ignition System Camshaft Position Sensor Inspection • Disconnect the camshaft position sensor lead connector [A] (see Camshaft Position Sensor Removal). • Set the hand tester to the × 10 Ω range and connect it to the yellow and white/yellow leads in the connector. Special Tool - Hand Tester: 57001-1394 Camshaft Position Sensor Resistance: 460 Ω...

  • Page 550

    16-44 ELECTRICAL SYSTEM Ignition System Stick Coil Removal CAUTION Never drop the stick coils, especially on a hard sur- face. Such a shock to the stick coils can damage it. • Remove the fuel tank (see Fuel Tank Removal in the Fuel System (DFI) chapter).

  • Page 551

    ELECTRICAL SYSTEM 16-45 Ignition System Stick Coil Inspection • Remove the stick coils (see Stick Coil Removal). • Measure the primary winding resistance [A] as follows. ○ Connect the hand tester between the coil terminals. ○ Set the tester to the × 1 Ω range, and read the tester. •...

  • Page 552

    16-46 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 the 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 553

    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 554

    16-48 ELECTRICAL SYSTEM Ignition System...

  • Page 555

    ELECTRICAL SYSTEM 16-49 Ignition System Ignition System Circuit 1. Engine Stop Switch 11. ECU 20. Main Fuse 30 A 2. Stick Coils 12. Ignition Fuse 10 A 21. Battery 12 V 8 Ah 3. Spark Plugs 13. ECU Fuse 10 A 22.

  • Page 556

    16-50 ELECTRICAL SYSTEM Electric Starter System Starter Motor Removal CAUTION Do not tap the starter motor shaft or body. Tapping the shaft or body could damage the motor. • Remove the water pipe (see Alternator Cover Removal). • Slide back the rubber cap [A]. •...

  • Page 557

    ELECTRICAL SYSTEM 16-51 Electric Starter System Starter Motor Disassembly • Remove the starter motor (see Starter Motor Removal). • Take off the starter motor through bolts [A] and remove the both end covers [B] and pull the armature out of the yoke [C].

  • Page 558

    16-52 ELECTRICAL SYSTEM Electric Starter System • Install the shims [A] on the armature shaft. • Install the armature [A] among the brushes [B]. • Align the line marks [A] of the end cover with the square mark [B] on the yoke. •...

  • Page 559

    ELECTRICAL SYSTEM 16-53 Electric Starter System Commutator Cleaning and Inspection • Smooth the commutator surface [A] if necessary with fine emery cloth [B], and clean out the grooves. • Measure the diameter [A] of the commutator [B]. If the commutator diameter is less than the service limit, replace the starter motor with a new one.

  • Page 560

    16-54 ELECTRICAL SYSTEM Electric Starter System Brush Plate and Terminal Bolt Inspection • Using the highest hand tester range, measure the resis- tance as shown in the figure. Terminal Bolt and Brush Plate [A] Terminal Bolt and Right-hand End Cover [B] Special Tool - Hand Tester: 57001-1394 If there is any reading, the brush holder assembly and/or terminal bolt assembly have a short.

  • Page 561

    ELECTRICAL SYSTEM 16-55 Electric Starter System Electric Starter Circuit 1. Sidestand Switch 2. Meter Ground 3. Engine Stop Switch 4. Starter Button 5. Fuse Box 2 6. Ignition Fuse 10 A 7. Ignition Switch 8. Water-proof Joint B 9. Neutral Switch 10.

  • Page 562

    16-56 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 563

    ELECTRICAL SYSTEM 16-57 Lighting System • Replace the headlight bulb. • Fit the projection [A] of the bulb in the hollow [B] of the headlight. • Install the hook [A]. • Fit the dust cover [A] onto the bulb [B] firmly as shown in the figure.

  • Page 564

    16-58 ELECTRICAL SYSTEM Lighting System • Install the bracket [A]; noting the letters “L” [B] and “R” [C]. City Light Bulb Replacement • Remove the upper fairing (see Upper Fairing Removal in the Frame chapter). • Turn the socket [A] counterclockwise and remove it with the bulb.

  • Page 565

    ELECTRICAL SYSTEM 16-59 Lighting System Tail/Brake Light (LED) Removal • Remove: Center Seat Cover (see Seat Cover Removal in the Frame chapter) Tail/Brake Light Mounting Screws [A] Tail/Brake Light (LED) [B] Tail/Brake Light (LED) Installation • Installation is the reverse of removal. •...

  • Page 566

    16-60 ELECTRICAL SYSTEM Lighting System Headlight/Tail Light Circuit 1. Fuse Box 2 10. Ignition Switch 18. Passing Button 2. Headlight Fuse 10 A 19. Relay Box 11. Meter Unit 3. Taillight Fuse 10 A 12. High Beam Indicator Light 20. Headlight Circuit Relay 4.

  • Page 567

    ELECTRICAL SYSTEM 16-61 Lighting System • Push and turn the bulb [A] counterclockwise and remove • 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.

  • Page 568

    16-62 ELECTRICAL SYSTEM Lighting System Turn Signal Light Circuit 1. Fuse Box 2 2. Turn Signal Relay Fuse 10 A 3. Water-proof Joint A 4. Water-proof Joint B 5. Meter Ground 6. Frame Ground 7. Ignition Switch 8. Meter Unit 9.

  • Page 569

    ELECTRICAL SYSTEM 16-63 Air Switching Valve Air Switching Valve Operation Test • Refer to the Air Suction System Damage Inspection in the Periodic Maintenance chapter. Air Switching Valve Unit Test • Remove the air switching valve (see Air Switching Valve Removal in the Engine Top End chapter).

  • Page 570

    16-64 ELECTRICAL SYSTEM Air Switching Valve Air Switching Valve Circuit 1. Engine Stop Switch 2. Air Switching Valve 3. Water-proof Joint B 4. Frame Ground 5. Water-proof Joint C 6. ECU 7. Ignition Switch 8. Fuse Box 2 9. ECU Fuse 10 A 10.

  • Page 571

    ELECTRICAL SYSTEM 16-65 Radiator Fan System Fan Motor Inspection • Remove the fuel tank (see Fuel Tank Removal in the Fuel System (DFI) chapter). • Disconnect the connector [A]. • Using an auxiliary leads, supply battery power to the fan motor.

  • Page 572

    16-66 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit Meter Unit Removal/Installation • Remove: Upper Fairing (see Upper Fairing Removal in the Frame chapter) • Slide the dust cover [A] and disconnect the connector. • Remove the meter unit by taking off the mounting screws [B] with the washers and two clamps.

  • Page 573

    ELECTRICAL SYSTEM 16-67 Meter, Gauge, Indicator Unit Electronic Combination Meter Unit Inspection • Remove the meter unit [A]. [1] Left Turn Signal Indicator Light (LED) (+) [2] Unused [3] Unused [4] Unused [5] Unused [6] Unused [7] Water Temperature Sensor [8] High Beam Indicator Light (LED) [9] Right Turn Signal Light (LED) (+) [10] Neutral Indicator Light (LED) Ground (–)

  • Page 574

    16-68 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit • Connect the terminal [15] to the battery (+) terminal. • Check the following items. ○ The tachometer needle momentarily points their last read- ings and back to the minimum position. ○ The following LCD (Liquid Crystal Display) will display the action (1, 2, 3) within about 1.5 seconds.

  • Page 575

    ELECTRICAL SYSTEM 16-69 Meter, Gauge, Indicator Unit • Disconnect the terminal [15]. ○ All the LCD segments and LED warning lights disappear. If the meter unit does not work, replace the meter assem- bly. Check 2: Meter Communication Line (Service Code 39) Check •...

  • Page 576

    16-70 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit Check 3: MODE Button Operation Check • Connect the leads in the same circuit as Check 1. • By pushing the MODE button [A] each time, check that the display [B] changes as follows. If the display function does not work, replace the meter assembly.

  • Page 577

    ELECTRICAL SYSTEM 16-71 Meter, Gauge, Indicator Unit Check 5: Clock Setting Check • Connect the leads in the same circuit as Check 1. • Set the ODO mode [A] by pushing the MODE button [B]. • Push the REST button [C] for more than two seconds. ○...

  • Page 578

    16-72 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit Check 6: Immobilizer Flashing Mode Inspection (Equipped Models) • Connect the leads in the same circuit as Check 1. • Disconnect the terminal [15]. • Check that the warning light (LED) [A] starts flashing (Im- mobilizer Warning Light Flashing Mode).

  • Page 579

    ELECTRICAL SYSTEM 16-73 Meter, Gauge, Indicator Unit Check 7: Left Turn Signal Indicator Light (LED) Inspec- tion • Connect the leads in the same circuit as Check 1. • Connect the terminal [1] to the battery (+) terminal. • Check that the left turn signal indicator light (LED) [A] goes on.

  • Page 580

    16-74 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit • Check that the right turn signal indicator light (LED) [A] goes on. If the indicator light (LED) does not go on, replace the meter assembly. Check 10: Neutral Indicator Light (LED) Inspection •...

  • Page 581

    ELECTRICAL SYSTEM 16-75 Meter, Gauge, Indicator Unit Check 12: Oil Pressure Warning Indicator Light (LED) Inspection • Connect the leads in the same circuit as Check 1. • Connect the terminal [20] to the battery (–) terminal. • Check that the oil symbol [A] and oil pressure warning indicator light (LED) [B] flash.

  • Page 582

    16-76 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit • Check that the display of the water temperature meter [A] indicates approximately 50 °C (122 °F). If the water temperature meter does not indicate temper- ature, replace the meter assembly. Check 14: Fuel Gauge Inspection •...

  • Page 583

    ELECTRICAL SYSTEM 16-77 Meter, Gauge, Indicator Unit Check 16: Odometer Inspection • Connect the leads in the same circuit as Check 15. • Set the ODO mode [A] by pushing the MODE button [B]. • Raise the input frequency of the oscillator to see the result of this inspection.

  • Page 584

    16-78 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit • Disconnect the terminal [15]. • Check that the tachometer needle [A] back to the mini- mum (0) position. If the meter unit does not work, replace the meter assem- bly. Fuel Level Sensor Line Self-Diagnosis Mode Inspection NOTE ○...

  • Page 585

    ELECTRICAL SYSTEM 16-79 Meter, Gauge, Indicator Unit Meter Circuit 1. Water Temperature Sensor 17. Clock 2. Neutral Switch 18. Odometer/Trip Meter 3. Fuel Level Sensor 19. Water Temperature Meter 4. Meter Ground 20. Fuel Gauge 5. Water-proof Joint C 21. Tachometer 6.

  • Page 586

    • Remove: Rear Seat (see Rear Seat Removal in the Frame chap- ter) • Disconnect the immobilizer/Kawasaki diagnostic system connector [A]. • Connect the connection cable [A] and key registration unit [B]. Special Tools - Key Registration Unit: 57001-1582...

  • Page 587

    ELECTRICAL SYSTEM 16-81 Immobilizer System (Equipped Models) • Insert the master key to the ignition switch and turn it ON. Verified ○ The warning indicator light (LED) [A] blinks to display the registration mode (go to the next step). Not Verified ○...

  • Page 588

    16-82 ELECTRICAL SYSTEM Immobilizer System (Equipped Models) ○ If there is any problem in the registration, the warning indicator light (LED) [A] blinks to display the collation error. Immobilizer Amplifier Failure When Registered User Key is Inserted. User Key Collation Error •...

  • Page 589

    ELECTRICAL SYSTEM 16-83 Immobilizer System (Equipped Models) • Insert the user key 2 to the ignition switch and turn it ON. ○ If there is any problem in the registration, the warning indicator light (LED) [A] blinks to display the collation error. Immobilizer Amplifier Failure When Registered User Key is Inserted.

  • Page 590

    Immobilizer System (Equipped Models) • Warning indicator light (LED) [A] goes off. • 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 591

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

  • Page 592

    Ignition Switch and Immobilizer Antenna (see Immobi- lizer System Parts Replacement) Rear Seat (see Rear Seat Removal in the Frame chap- ter) • Disconnect the immobilizer/Kawasaki diagnostic system connector. • Connect the connection cable [A] and key registration unit [B].

  • Page 593

    ELECTRICAL SYSTEM 16-87 Immobilizer System (Equipped Models) Verified ○ The warning indicator light (LED) [A] blinks to display the ECU is in the registration mode (go to the next step). Not Verified ○ The warning indicator light (LED) [A] blinks to display the collation error.

  • Page 594

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

  • Page 595

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

  • Page 596

    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 597

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

  • Page 598

    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) [A] blinks 2 times and stops for 1 second and then repeats this cycle to indicate successful registration of user key.

  • Page 599

    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) [A] blinks 3 times and stops for 1 second and then repeats this cycle to indicate successful registration of user key 2.

  • Page 600

    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 ECU re- placement.

  • Page 601

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

  • Page 602

    16-96 ELECTRICAL SYSTEM Immobilizer System (Equipped Models) Immobilizer System Parts Replacement Immobilizer Antenna Replacement • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) • Disconnect the lead connectors [A]. • Remove: Handlebar (see Handlebar Removal in the Steering chapter) Steering Stem Head (see Stem, Stem Bearing Removal in the Steering chapter)

  • Page 603

    ELECTRICAL SYSTEM 16-97 Immobilizer System (Equipped Models) • Remove: Connector [A] (Disconnect) Bolt [B] and Holder [C] Immobilizer Amplifier [D] • When the holder [A] installing, contact the projection [B] to bracket [C]. ECU (Electronic Control Unit) Replacement (for Immo- bilizer Models) CAUTION Never drop the ECU, especially on a hard surface.

  • Page 604

    Install the lower and upper [A] guard to the ECU. CAUTION Do not pinch the leads. • Tighten the new screws [B] using the Kawasaki genuine screws of which threads are coated with locking agent. • Install the pads [A] over the guard as shown in the figure.

  • Page 605

    ELECTRICAL SYSTEM 16-99 Immobilizer System (Equipped Models) Immobilizer Relational Parts Replacement Chart Failed or Lost Part Master User Ignition Ampli- Switch tenna fier (Red) (Black) Master • (Red) User • ○ (Black) Ignition • Switch • tenna Ampli- • fier ○...

  • Page 606

    10. Meter Unit 11. Oil Pressure/FI/Immobilizer Warning Indicator Light (LED) 12. Relay Box 13. ECU Main Relay 14. Water-proof Joint B 15. Main Fuse 30 A 16. Battery 12 V 8 Ah 17. Water-proof Joint C 18. Kawasaki Diagnostic System Connector...

  • Page 607

    ELECTRICAL SYSTEM 16-101 Switches and Sensors Brake Light Timing Inspection • Refer to the 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. Switch Inspection •...

  • Page 608

    16-102 ELECTRICAL SYSTEM Switches and Sensors Water Temperature Sensor Inspection • Remove the water temperature sensor (see Water Tem- perature Sensor Removal/Installation in the Fuel System (DFI) chapter). • Suspend the sensor [A] in a container of coolant so that the threaded portion is submerged.

  • Page 609

    ELECTRICAL SYSTEM 16-103 Switches and Sensors Speed Sensor Installation • Apply grease to the O-ring [A] on the speed sensor [B]. • Tighten: Torque - Speed Sensor Bolt: 12 N·m (1.2 kgf·m, 106 in·lb) • Install the removed parts (see appropriate chapters). Speed Sensor Inspection •...

  • Page 610

    16-104 ELECTRICAL SYSTEM Switches and Sensors Oxygen Sensor Installation (Equipped Models) CAUTION Never drop the oxygen sensor [A], especially on a hard surface. Such a shock to the unit can damage it. Do not touch the sensing part [B] and filter holes [C] of the sensor to prevent oil contact.

  • Page 611

    ELECTRICAL SYSTEM 16-105 Switches and Sensors • Install a new gasket [A] on the fuel level sensor as shown in the figure. Hollows [B] Front [C] • Apply a non-permanent locking agent to the threads of the fuel level sensor bolts and tighten them. Torque - Fuel Level Sensor Bolts: 6.9 N·m (0.70 kgf·m, 61 in·lb)

  • Page 612

    16-106 ELECTRICAL SYSTEM Relay Box The relay box [A] has relays and diodes. The relays and diodes can not be removed. Relay Box Removal CAUTION Never drop the relay box, especially on a hard sur- face. Such a shock to the relay box can damage it. •...

  • Page 613

    ELECTRICAL SYSTEM 16-107 Relay Box Relay Circuit Inspection (with the battery connected) Battery Tester Tester Connection Connection Reading (Ω) (–) 2-11 ECU Main Relay Fuel Pump Relay 9-10 Fan Relay 18-19 17-20 Battery Tester Connection Tester Connection DC 25 V Range Reading (V) (–) (–)

  • Page 614

    16-108 ELECTRICAL SYSTEM Relay Box Relay Box Internal Circuit A: Headlight Relay B: ECU Main Relay C: Fuel Pump Relay D: Starter Circuit Relay E: Fan Relay...

  • Page 615

    ELECTRICAL SYSTEM 16-109 Fuse 30 A Main Fuse Removal • Remove: Rear Seat Bracket (see Relay Box Removal) 30 A Main Fuse Connector [A] (Disconnect) • Pull out the main fuse [A] from the starter relay with a needle nose pliers. Fuse Box Fuse Removal •...

  • Page 616

    16-110 ELECTRICAL SYSTEM Fuse 10 A ECU Fuse Removal • Remove the rear seat (see Rear Seat Removal in the Frame chapter) • Unlock the hook to lift up the lid [A]. • Pull out the ECU fuse [B] from the fuse box 2. Fuse Installation •...

  • Page 617

    APPENDIX 17-1 Appendix Table of Contents Cable, Wire, and Hose Routing ....................17-2 Troubleshooting Guide ......................17-60...

  • Page 618

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

  • Page 619

    APPENDIX 17-3 Cable, Wire, and Hose Routing 1. Viewed A 2. Viewed B 3. After installing the heat insulation rubber plate, run the radiator fan motor lead under the rivet of the left side. 4. Run the reserve tank hose and main harness into the clamp. 5.

  • Page 620

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

  • Page 621

    APPENDIX 17-5 Cable, Wire, and Hose Routing 1. Viewed A 2. Radiator Hose (From Thermostat Housing to Radiator) 3. Align the white paint of the radiator hose (from thermostat housing to radiator) with projection of the thermostat housing. 4. Align the white paint of the water hose (from cylinder head to thermostat housing) with rib of the thermostat housing.

  • Page 622

    17-6 APPENDIX Cable, Wire, and Hose Routing 1. White Paint 2. Air Switching Valve Hose (From Air Switching Valve to Air Cleaner Housing) 3. Inlet Air Temperature Sensor 4. Clamp 5. Clamp 6. Main Harness (Main Throttle and Subthrottle Sensor Leads) 7.

  • Page 623

    APPENDIX 17-7 Cable, Wire, and Hose Routing 1. Hold the fuel tank drain hose with the left side clamp of the fuel tank. 2. Run the fuel tank drain hose between the air cleaner housing and frame. 3. Air Cleaner Drain Hose 4.

  • Page 624

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

  • Page 625

    APPENDIX 17-9 Cable, Wire, and Hose Routing 1. Put the alternator lead connector to the inside of the left frame cover and left subframe. 2. Left Frame Cover 3. Left Subframe 4. Run the alternator lead over the frame cross pipe. 5.

  • Page 626

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

  • Page 627

    APPENDIX 17-11 Cable, Wire, and Hose Routing 1. Frame Cross Pipe 2. Run the starter motor cable and battery negative cable under the frame cross pipe. 3. Frame Cross Pipe 4. Run the sidestand switch lead under the frame cross pipe. 5.

  • Page 628

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

  • Page 629

    APPENDIX 17-13 Cable, Wire, and Hose Routing 1. Air Switching Valve Hose (From Air Switching Valve to Air Cleaner Housing) 2. Subthrottle Valve Actuator Lead Connector 3. Run the subthrottle valve actuator and fuel injector leads under the air switching valve hose (from air switching valve to air cleaner housing).

  • Page 630

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

  • Page 631

    APPENDIX 17-15 Cable, Wire, and Hose Routing 1. Put the rear brake light switch lead connector to the inside of the right sub side cover. 2. Put the rear wheel rotation sensor lead connector to the inside of the right frame cover. 3.

  • Page 632

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

  • Page 633

    APPENDIX 17-17 Cable, Wire, and Hose Routing 1. Oxygen Sensor Lead Connector 2. Oil Pressure Switch/Crankshaft Sensor Lead Connector 3. Install the oxygen sensor and oil pressure switch/crankshaft sensor lead connectors to the bracket. 4. After installing the connectors to the bracket, tighten the bolt to the bracket and subframe. 5.

  • Page 634

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

  • Page 635

    APPENDIX 17-19 Cable, Wire, and Hose Routing 1. Left Front Turn Signal Light Lead (Run the right and left front turn signal light leads inside the fairing bracket). 2. Run the horn lead inside the radiator hose. 3. Horn Lead 4.

  • Page 636

    17-20 APPENDIX Cable, Wire, and Hose Routing...

  • Page 637

    APPENDIX 17-21 Cable, Wire, and Hose Routing 1. Fuel Outlet Hose 2. Run the fuel pump lead to the outside of the fuel outlet hose. 3. Fuel Pump Lead Connector 4. Fuel Tank Bottom 5. Install the fuel inlet hose so that the white mark side faces outlet pipe of the fuel tank. 6.

  • Page 638

    17-22 APPENDIX Cable, Wire, and Hose Routing...

  • Page 639

    APPENDIX 17-23 Cable, Wire, and Hose Routing 1. Put the rubber cover to the inside of the frame as shown in the figure. 2. Run the throttle cables under the immobilizer antenna and stick coil leads. 3. Run the immobilizer antenna, ignition switch and radiator fan motor leads under the left side of the thermostat housing and over the main harness.

  • Page 640

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

  • Page 641

    4. Run the main harness (to fuse box 1) under the fuel tank bracket and frame cross pipe. 5. Fuse Box 1 6. Put the ABS Kawasaki self-diagnosis system connector under the fuse box 1. 7. Main Harness (To Fuse Box 1)

  • Page 642

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

  • Page 643

    APPENDIX 17-27 Cable, Wire, and Hose Routing 1. Main Harness (To Fuse Box 1) 2. Run the main harness (to fuse box 1) over the frame. 3. Hold the main harness (to fuse box 1) and reserve tank hose. 4. Run the main harness (to fuse box 1) under the frame and over the reserve tank hose. 5.

  • Page 644

    17-28 APPENDIX Cable, Wire, and Hose Routing...

  • Page 645

    1. Turn Signal Relay (Position the turn signal relay lead in the lower side.) 2. Fuse Box 2 3. Tail/Brake Light (LED) Lead Connector 4. Immobilizer/Kawasaki Diagnostic System Connector 5. Run the tail/brake light (LED) lead over the reserve tank overflow hose (from fitting). 6. Vehicle-down Sensor 7.

  • Page 646

    17-30 APPENDIX Cable, Wire, and Hose Routing...

  • Page 647

    APPENDIX 17-31 Cable, Wire, and Hose Routing 1. Ground Lead Connector 2. Battery Positive Lead Connector 3. Battery Positive Cable 4. Battery Negative Cable 5. Run the battery negative cable and starter motor cable into the clamp. 6. Run the battery negative cable and starter motor cable to the outside of the brake hose.

  • Page 648

    17-32 APPENDIX Cable, Wire, and Hose Routing...

  • Page 649

    APPENDIX 17-33 Cable, Wire, and Hose Routing 1. Rear Seat Lock Cable 2. Run the rear seat lock cable under the front seat bracket. 3. Front Seat Lock Cables 4. Bracket 5. Run the reserve tank hose to the inside of the bracket. 6.

  • Page 650

    17-34 APPENDIX Cable, Wire, and Hose Routing...

  • Page 651

    APPENDIX 17-35 Cable, Wire, and Hose Routing 1. Rear Seat Lock Cable 2. Right Rear Turn Signal Light Lead 3. After inserting the dampers in the brackets, run the right and left turn signal light leads into the dampers. 4. Left Rear Turn Signal Light Lead...

  • Page 652

    17-36 APPENDIX Cable, Wire, and Hose Routing...

  • Page 653

    APPENDIX 17-37 Cable, Wire, and Hose Routing 1. Clamp (Install the clamp with the meter mounting screw and hold the right and left switch housing leads.) 2. Left Switch Housing Lead Connector 3. Position the left switch housing lead connector inside the clamp. 4.

  • Page 654

    17-38 APPENDIX Cable, Wire, and Hose Routing...

  • Page 655

    APPENDIX 17-39 Cable, Wire, and Hose Routing 1. Clutch Cable 2. Main Harness 3. Ignition Switch and Immobilizer Antenna Leads 4. Throttle Cables 5. From head pipe side, run the clutch cable, ignition switch and immobilizer antenna leads, throttle cables and main harness. 6.

  • Page 656

    17-40 APPENDIX Cable, Wire, and Hose Routing...

  • Page 657

    APPENDIX 17-41 Cable, Wire, and Hose Routing 1. Clutch Cable 2. Run the clutch cable and left switch housing lead inside the guide of the upper fairing bracket. Run the left switch housing lead to the front of the clutch cable. 3.

  • Page 658

    17-42 APPENDIX Cable, Wire, and Hose Routing...

  • Page 659

    APPENDIX 17-43 Cable, Wire, and Hose Routing 1. Run the throttle cables under the upper fairing bracket. 2. Run the brake hose outside the guide of the upper fairing bracket. 3. Run the throttle cables and right switch housing lead inside the guide of the upper fairing bracket. 4.

  • Page 660

    17-44 APPENDIX Cable, Wire, and Hose Routing...

  • Page 661

    APPENDIX 17-45 Cable, Wire, and Hose Routing 1. Clamps 2. Brake Hose (From Front Master Cylinder to Right Front Caliper) 3. Brake Hose (From Right Front Caliper to Left Front Caliper) 4. Viewed Front Side 5. Bracket 6. Brake Hose (From Rear Master Cylinder to Rear Caliper) 7.

  • Page 662

    17-46 APPENDIX Cable, Wire, and Hose Routing ABS Equipped Models...

  • Page 663

    APPENDIX 17-47 Cable, Wire, and Hose Routing 1. Brake Hose (From Front Master Cylinder to ABS Hydraulic Unit) 2. Clamps 3. Brake Pipes 4. Front Wheel Rotation Sensor Lead 5. Brake Hose (From Right Front Caliper to Left Front Caliper) 6.

  • Page 664

    17-48 APPENDIX Cable, Wire, and Hose Routing ABS Equipped Models...

  • Page 665

    APPENDIX 17-49 Cable, Wire, and Hose Routing 1. ABS Hydraulic Unit 2. Clamps 3. Brake Hose (From ABS Hydraulic Unit to Rear Caliper) 4. Rear Wheel Rotation Sensor Lead 5. Rear Wheel Rotation Sensor...

  • Page 666

    17-50 APPENDIX Cable, Wire, and Hose Routing ABS Equipped Models...

  • Page 667

    APPENDIX 17-51 Cable, Wire, and Hose Routing 1. Clamps 2. Bands 3. To Rear Master Cylinder 4. To Rear Caliper 5. To Front Master Cylinder 6. To Right Front Caliper 7. ABS Hydraulic Unit 8. Viewed Front Side 9. Left Side 10.

  • Page 668

    17-52 APPENDIX Cable, Wire, and Hose Routing ABS Equipped Models...

  • Page 669

    APPENDIX 17-53 Cable, Wire, and Hose Routing 1. Clamps 2. Brake Hose (From ABS Hydraulic Unit to Right Front Caliper) 3. Brake Hose (From Right Front Caliper to Left Front Caliper) 4. Clamp (Hold the brake hose (from right front caliper to left front caliper) and front wheel rotation sensor lead on the white tape.)

  • Page 670

    17-54 APPENDIX Cable, Wire, and Hose Routing ABS Equipped Models...

  • Page 671

    APPENDIX 17-55 Cable, Wire, and Hose Routing 1. Run the brake hose (from front master cylinder to ABS hydraulic unit) between the steering stem head and guide of the upper fairing bracket. 2. Clamps 3. Brake Hose (From ABS Hydraulic Unit to Right Front Caliper) 4.

  • Page 672

    17-56 APPENDIX Cable, Wire, and Hose Routing ABS Equipped Models...

  • Page 673

    APPENDIX 17-57 Cable, Wire, and Hose Routing 1. Clamps 2. Brake Pipe 3. One White Paint Mark 4. One Blue Paint Mark 5. Bracket 6. Brake Pipe 7. Brake Hoses (One White Paint Mark) 8. Bands 9. Grommets 10. Clamp 11.

  • Page 674

    17-58 APPENDIX Cable, Wire, and Hose Routing ABS Equipped Models...

  • Page 675

    APPENDIX 17-59 Cable, Wire, and Hose Routing 1. Bracket 2. Brake Pipe (One White Paint Mark) 3. Clamps 4. Brake Hose (Two Blue Paint Marks) 5. Brake Hose (Two White Paint Marks) 6. Grommets 7. Bands 8. Brake Pipe (Two White Paint Marks) 9.

  • Page 676

    17-60 APPENDIX Troubleshooting Guide NOTE Stick coil trouble ○ Refer to the Fuel System chapter for most ECU trouble of DFI trouble shooting guide. Camshaft position sensor trouble ○ This is not an exhaustive list, giving every Neutral, starter lockout, or sidestand switch possible cause for each problem listed.

  • Page 677

    APPENDIX 17-61 Troubleshooting Guide Compression low: Cylinder head not sufficiently tightened Spark plug loose down Cylinder head not sufficiently tightened No valve clearance down Cylinder, piston worn No valve clearance Piston ring bad (worn, weak, broken, or Cylinder, piston worn sticking) Piston ring bad (worn, weak, broken, or Piston ring/groove clearance excessive...

  • Page 678

    17-62 APPENDIX Troubleshooting Guide Air cleaner clogged Clutch release mechanism trouble Compression high: Gear Shifting Faulty: Carbon built up in combustion chamber Engine load faulty: Doesn’t go into gear; shift pedal doesn’t Clutch slipping return: Engine oil level too high Clutch not disengaging Engine oil viscosity too high Shift fork bent or seized...

  • Page 679

    APPENDIX 17-63 Troubleshooting Guide Exhaust pipe leaking at cylinder head con- Crankshaft bearing worn nection Oil pressure switch damaged Crankshaft runout excessive Wiring faulty Engine mount loose Relief valve stuck open Crankshaft bearing worn O-ring at the oil passage in the crankcase Primary gear worn or chipped damaged Camshaft chain tensioner trouble...

  • Page 680

    17-64 APPENDIX Troubleshooting Guide Front fork oil insufficient and/or leaking Front fork oil viscosity too low 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...

  • Page 681

    MODEL APPLICATION Year Model Beginning Frame No. □ JKAZRDL1 7A000001 2007 ZR750L7F JKAZR750LLA000001 ZR750L-000001 2007 ZR750M7F JKAZR750LMA000001 □ :This digit in the frame number changes from one machine to another. Part No.99924-1381-01 Printed in Japan...

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