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VULCAN 1700 NOMAD
VULCAN 1700 NOMAD ABS
VN1700 CLASSIC TOURER
VN1700 CLASSIC TOURER ABS
Motorcycle
Service Manual
Downloaded free from http://www.vulcanrider.se/

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Table of Contents

   Also See for Kawasaki Vulcan 1700 Nomad

   Summary of Contents for Kawasaki Vulcan 1700 Nomad

  • Page 1 VULCAN 1700 NOMAD VULCAN 1700 NOMAD ABS VN1700 CLASSIC TOURER VN1700 CLASSIC TOURER ABS Motorcycle Service Manual Downloaded free from http://www.vulcanrider.se/...
  • Page 2: 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 3: Country And Area Codes

    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 4: Emission Control Information

    EMISSION CONTROL INFORMATION To protect the environment in which we all live, Kawasaki has incorporated crankcase emis- sion (1) and exhaust emission (2) control systems in compliance with applicable regulations of the United States Environmental Protection Agency and California Air Resources Board. Addi-...
  • Page 5 TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Federal law prohibits the following acts or the causing thereof. (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.
  • Page 6: How To Use This Manual

    Be alert for problems and non-scheduled maintenance. • NOTICE Use proper tools and genuine Kawasaki Mo- torcycle parts. Special tools, gauges, and NOTICE is used to address practices not testers that are necessary when servicing related to personal injury.
  • Page 7 NOTE ○ This note symbol indicates points of par- ticular interest for more efficient and con- venient operation. • Indicates a procedural step or work to be done. ○ Indicates a procedural sub-step or how to do the work of the procedural step it follows. It also precedes the text of a NOTE.
  • Page 8: Table Of Contents

    GENERAL INFORMATION 1-1 General Information Table of Contents Before Servicing ........................Model Identification......................... General Specifications......................1-10 Technical Information-Electronic Throttle Valve (ETV) System ..........1-13 Technical Information-Kawasaki Advanced Coactive-braking Technology Anti-Lock Brake System (K-ACT ABS) ......................1-16 Unit Conversion Table ......................1-20...
  • Page 9: Before Servicing

    1-2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly opera- tion on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustra- tions, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary.
  • Page 10 Replacement Parts Replacement parts must be KAWASAKI genuine or recommended by KAWASAKI. Gaskets, O-rings, oil seals, grease seals, circlips, cotter pins or self-locking nuts must be replaced with new ones whenever disassembled.
  • Page 11 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 12 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 13 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 14: Model Identification

    GENERAL INFORMATION 1-7 Model Identification VN1700C9F ∼ CAF (US and CA Models) Left Side View VN1700C9F ∼ CAF (US and CA Models) Right Side View Frame Number Engine Number...
  • Page 15 1-8 GENERAL INFORMATION Model Identification VN1700C9F (EUR Models) Left Side View VN1700C9F (EUR Models) Right Side View...
  • Page 16 GENERAL INFORMATION 1-9 Model Identification VN1700DAF (EUR Model) Left Side View VN1700DAF (EUR Model) Right Side View...
  • Page 17: General Specifications

    1-10 GENERAL INFORMATION General Specifications VN1700C9F ∼ CAF/DAF Items Dimensions Overall Length 2 500 mm (98.43 in.) Overall Width 1 025 mm (40.35 in.), (AU) 995 mm (39.17 in.) Overall Height 1 465 mm (57.68 in.) Wheelbase 1 665 mm (65.55 in.) Road Clearance 140 mm (5.51 in.) Seat Height...
  • Page 18 GENERAL INFORMATION 1-11 General Specifications VN1700C9F ∼ CAF/DAF Items Exhaust: Open 55° (BBDC) Close 25° (ATDC) Duration 260° Lubrication System Forced lubrication (semi-dry sump) Engine Oil: Type API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2 Viscosity SAE 10W-40 Capacity...
  • Page 19 1-12 GENERAL INFORMATION General Specifications VN1700C9F ∼ CAF/DAF Items Rear Suspension: Type Swingarm Wheel Travel 80 mm (3.2 in.) Brake Type: Front Dual discs Rear Single disc Electrical Equipment Battery 12 V 18 Ah Headlight: Type Semi-sealed beam Bulb 12 V 60/55 W (quartz-halogen) Tail/Brake Light Alternator: Type...
  • Page 20: Technical Information-electronic Throttle Valve (etv) System

    GENERAL INFORMATION 1-13 Technical Information-Electronic Throttle Valve (ETV) System Overview VN1700 series is equipped with the electronically-controlled throttle valve system called the Elec- tronic Throttle Valve (ETV) system. The throttle pulley and the throttle valves of this system are not connected mechanically, and the throttle valves are electrically operated.
  • Page 21 1-14 GENERAL INFORMATION Technical Information-Electronic Throttle Valve (ETV) System System Diagram 1. Accelerator Position Sensor 1 and 2 The accelerator position sensor senses the rider’s intention on throttle operation and transmits it to the ECU as an electrical signal. Each incorporating a built-in variable resistor, the two sensors independently work to detect the position of the pulley shaft.
  • Page 22 GENERAL INFORMATION 1-15 Technical Information-Electronic Throttle Valve (ETV) System D. Throttle Valve Opening Control Section E. ETV Actuator Drive Section F. CPU Monitoring Section 5. Partial Opening Holding Device When the ETV actuator (DC motor) becomes incapable of throttle valve control, this device holds the throttle valve at a predetermined partially-open position by balancing the forces of the return spring and the open spring which pulls...
  • Page 23: Technical Information-kawasaki Advanced Coactive-braking Technology Anti-lock Brake System (k-act Abs)

    Technical Information-Kawasaki Advanced Coactive-braking Technology Anti -Lock Brake System (K-ACT ABS) Overview VN1700D model adopts the Kawasaki Advanced Coactive-braking Technology (K-ACT) that dis- tributes the front-rear braking force in an ideal balance to stabilize the motorcycle behavior during the brake operation.
  • Page 24 GENERAL INFORMATION 1-17 Technical Information-Kawasaki Advanced Coactive-braking Technology Anti -Lock Brake System (K-ACT ABS) 8. K-ACT ABS Kawasaki Diagnostic System Connector Brake Fluid Flow Chart [When K-ACT Operates] Case1) When operating only the front brake lever. Case2) When operating only the rear brake pedal.
  • Page 25 1-18 GENERAL INFORMATION Technical Information-Kawasaki Advanced Coactive-braking Technology Anti -Lock Brake System (K-ACT ABS) Case3*) When operating both the front brake lever and rear brake pedal. *: Under some operating conditions, the K-ACT works on only the front brake or the rear brake.
  • Page 26 GENERAL INFORMATION 1-19 Technical Information-Kawasaki Advanced Coactive-braking Technology Anti -Lock Brake System (K-ACT ABS) (Decreased Mode) (Increased Mode)
  • Page 27: Unit Conversion Table

    1-20 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 28 PERIODIC MAINTENANCE 2-1 Periodic Maintenance Table of Contents Periodic Maintenance Chart ....................Torque and Locking Agent...................... Specifications ......................... 2-13 Special Tools .......................... 2-15 Periodic Maintenance Procedures..................2-16 Fuel System (DFI)........................ 2-16 Throttle Control System Inspection................... 2-16 Idle Speed Inspection ....................... 2-17 Idle Speed Adjustment......................
  • Page 29 2-2 PERIODIC MAINTENANCE Headlight Aiming Inspection ..................... 2-44 Sidestand Switch Operation Inspection ................2-46 Engine Stop Switch Operation Inspection................. 2-47 Others ..........................2-47 Chassis Parts Lubrication ....................2-47 Bolts, Nuts and Fasteners Tightness Inspection............... 2-48 Replacement Parts ......................2-50 Air Cleaner Element Replacement..................2-50 Fuel Hose Replacement ....................
  • Page 30: Periodic Maintenance Chart

    PERIODIC MAINTENANCE 2-3 Periodic Maintenance Chart Dummy Page...
  • Page 31 2-4 PERIODIC MAINTENANCE 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 32 PERIODIC MAINTENANCE 2-5 Periodic Maintenance Chart FREQUENCY Whichever * ODOMETER READING comes × 1 000 km first (× 1 000 mile) Page (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) ITEM Every Final Drive • • • • • • • Drive belt deflection-inspect 2–27 •...
  • Page 33 2-6 PERIODIC MAINTENANCE Periodic Maintenance Chart Periodic Replacement Parts FREQUENCY Whichever * ODOMETER READING come × 1 000 km first (× 1 000 mile) Page (0.6) (7.5) (15) (22.5) (30) ITEM Every Air cleaner element-replace # Every 18 000 km (11 250 mile) 2–50 •...
  • Page 34: Torque And Locking Agent

    PERIODIC MAINTENANCE 2-7 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. L: Apply a non-permanent locking agent.
  • Page 35 2-8 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Cylinder Head Nuts (M12 Used Nuts) (Final) MO, S Cylinder Head Nuts (M10) (First) MO, S Cylinder Head Nuts (M10) (Final) MO, S Cylinder Head Outer Cover Bolts 87 in·lb Cylinder Head Inner Cover Bolts 87 in·lb...
  • Page 36 PERIODIC MAINTENANCE 2-9 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Oil Pressure Switch Terminal Bolt Hand-tighten Oil Pump Cover Bolts 106 in·lb Oil Pump Drive Gear Bolt Oil Screen Plugs Outside Oil Pipe Bolts 87 in·lb Torque Limiter Bearing Retainer Bolt 87 in·lb Engine Removal/Installation Cross Pipe Bolts...
  • Page 37 2-10 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Shift Pedal Pad Screw 0.70 61 in·lb Shift Shaft Return Spring Pin Tie-Rod Locknuts 87 in·lb Lh (1) Wheels/Tires Front Axle 13.0 Front Axle Clamp Bolts Rear Axle Nut 11.0 Rear Air Valve Nuts 0.15...
  • Page 38 PERIODIC MAINTENANCE 2-11 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Steering Handlebar Clamp Bolts O, S Handlebar Holder Nuts Lower Front Fork Clamp Bolts Steering Stem Head Nut Steering Stem Nut Upper Front Fork Clamp Bolts Frame Cross Pipe Bolts Downtube Bolts Front Footboard Bracket Bolts...
  • Page 39 2-12 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Sidestand Switch Mounting Bolt 0.90 78 in·lb Starter Lockout Switch Screw 0.12 11 in·lb Electronic Cruise Control Cancel Switch 0.12 11 in·lb (Clutch) Screw Water Temperature Sensor 106 in·lb Licence Plate Light Lens Screws 0.09...
  • Page 40: Specifications

    PERIODIC MAINTENANCE 2-13 Specifications Item Standard Service Limit Fuel System (DFI) 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Throttle Grip Free Play – – – Idle Speed 950 ±50 r/min (rpm) – – – Air Cleaner Element Viscous paper element –...
  • Page 41 2-14 PERIODIC MAINTENANCE Specifications Item Standard Service Limit Final Drive Drive Belt Deflection: (45 N, 4.6 kgf, 10 lb force) 3.0 ∼ 4.5 mm (0.12 ∼ 0.18 in.) – – – (When installing new belt 3.0 mm (0.12 in.) – – – or engine is remounted) Brakes Brake Fluid:...
  • Page 42: Special Tools

    PERIODIC MAINTENANCE 2-15 Special Tools Inside Circlip Pliers: Oil Filter Wrench: 57001-143 57001-1249 Steering Stem Nut Wrench: Tension Gauge: 57001-1100 57001-1585...
  • Page 43: Periodic Maintenance Procedures

    2-16 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel System (DFI) Throttle Control System Inspection • Check the throttle grip free play [A]. Throttle Grip Free Play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Standard: If the free play is incorrect, adjust the throttle grip free play as follows.
  • Page 44: Idle Speed Inspection

    PERIODIC MAINTENANCE 2-17 Periodic Maintenance Procedures Idle Speed Inspection • Start the engine and warm it up thoroughly. ○ At first the engine will run fast to decrease warm up time (fast idle). ○ Gradually the fast idle will lower to a certain RPM auto- matically.
  • Page 45 2-18 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Push the “S” button [A] of the right switch housing for more than two seconds to display the clock setting mode [B] on the LCD (Liquid Crystal Display).
  • Page 46 PERIODIC MAINTENANCE 2-19 Periodic Maintenance Procedures • Push the “S” button to display the idle speed adjusting mode [A]. NOTE ○ The display change to the clock setting mode [B], aver- age fuel consumption unit setting mode [C], idle speed adjusting mode each time the “S”...
  • Page 47: Fuel Hose Inspection (fuel Leak, Damage, Installation Condition)

    2-20 PERIODIC MAINTENANCE Periodic Maintenance Procedures ○ The idle speed goes up 50 r/min (rpm) at one time by pushing the “MODE-A” switch. ○ When pushing the “MODE-A” switch, the value on the display shows the “+50” [A] (this shows 1 000 r/min (rpm)). ○...
  • Page 48: Evaporative Emission Control System Inspection (cal And Sea Models)

    PERIODIC MAINTENANCE 2-21 Periodic Maintenance Procedures • Check that the fuel hose [A] are routed according to Cable, Wire, and Hose Routing section in the Appendix chapter. Replace the hose if it has been sharply bent or kinked. • Check that the fuel hose joints are securely connected. ○...
  • Page 49: Cooling System

    2-22 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Check the liquid/vapor separator as follows. ○ Remove: Canister Band [A] ○ Disconnect the hoses from the separator [B], and remove the separator. ○ Visually inspect the separator for cracks and other dam- age.
  • Page 50: Radiator Hose And Pipe Inspection (coolant Leak, Damage, Installation Condition)

    PERIODIC MAINTENANCE 2-23 Periodic Maintenance Procedures Radiator Hose and Pipe Inspection (Coolant Leak, Damage, Installation Condition) ○ The high pressure inside the radiator hose can cause coolant to leak [A] or the hose to burst if the line is not properly maintained.
  • Page 51: Clutch

    2-24 PERIODIC MAINTENANCE Periodic Maintenance Procedures Clutch Clutch Operation Inspection • Start the engine and check that the clutch does not slip and that it releases properly. If the clutch operation is insufficiency, inspect the clutch system. WARNING When test riding the vehicle, be aware of surround- ing traffic for your safety.
  • Page 52: Clutch Hose And Pipe Damage And Installation Condition Inspection

    PERIODIC MAINTENANCE 2-25 Periodic Maintenance Procedures Clutch Hose and Pipe Damage and Installation Condition Inspection • The high pressure inside the clutch line can cause fluid to leak [A] or the hose to burst if the line is not properly maintained.
  • Page 53: Wheel Bearing Damage Inspection

    2-26 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Measure the tread depth at the center of the tread with a depth gauge [A]. Since the tire may wear unevenly, take measurement at several places. If any measurement is less than the service limit, replace the tire (see Tire Removal/Installation in the Wheels/Tires chapter).
  • Page 54: Final Drive

    PERIODIC MAINTENANCE 2-27 Periodic Maintenance Procedures Final Drive Drive Belt Deflection Inspection NOTE ○ Belt deflection must be checked and adjusted when the belt is cold (at room temperature). ○ Belt deflection also should be checked at first 1000 km (621.4 mile) ride after belt replacement.
  • Page 55: Drive Belt Deflection Adjustment

    2-28 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Inspect the drive belt deflection at arbitrary position, and record the value [A]. • Turn the rear wheel 90 degrees. • Inspect the drive belt deflection, and record the value [B]. • Decide the belt deflection at the position [C] of one where deflection is large.
  • Page 56 PERIODIC MAINTENANCE 2-29 Periodic Maintenance Procedures • Remove the axle cotter pin [A], and loosen the axle nut [B]. • Raise the rear wheel off the ground (see Rear Wheel Re- moval in the Wheels/Tires chapter). • Loosen the belt adjuster locknuts [C] on the both sides. If the belt is too tight, back out the left and right belt ad- juster nuts [D], and kick the wheel forward until the belt is too loose.
  • Page 57: Wheel Alignment Inspection/adjustment

    2-30 PERIODIC MAINTENANCE Periodic Maintenance Procedures Wheel Alignment Inspection/Adjustment • Check that the notch [A] on the belt adjuster [B] aligns with the same swingarm mark [C] or position that the other side notch aligns with. If they do not, adjust the belt deflection (see Belt Deflec- tion Adjustment) and align the wheel alignment.
  • Page 58 PERIODIC MAINTENANCE 2-31 Periodic Maintenance Procedures Drive Belt Tooth Wear and Damage Patterns A. Belt Cross Section B. Edge Bevel Wear C. Rub Wear D. Stone...
  • Page 59 2-32 PERIODIC MAINTENANCE Periodic Maintenance Procedures Drive Belt Wear and Damage Analysis Pattern Condition Required Action O.K. for continued use, but inspect the belt Internal tooth cracks (slight) periodically. O.K. for continued use, but inspect the belt Scuffing to side of teeth periodically.
  • Page 60: Brakes

    PERIODIC MAINTENANCE 2-33 Periodic Maintenance Procedures Brakes Brake Fluid Leak (Brake Hose and Pipe) Inspection • For K-ACT ABS equipped models, note the following. • Remove: Seats (see Rear/Front Seat Removal in the Frame chap- ter) Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Right Side Cover (see Right Side Cover Removal in the Frame chapter)
  • Page 61: Brake Hose And Pipe Damage And Installation Condition Inspection

    2-34 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Hose and Pipe Damage and Installation Condition Inspection • For K-ACT ABS equipped models, note the following. • Remove: Seats (see Rear/Front Seat Removal in the Frame chap- ter) Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Right Side Cover (see Right Side Cover Removal in the Frame chapter)
  • Page 62: Brake Pad Wear Inspection

    PERIODIC MAINTENANCE 2-35 Periodic Maintenance Procedures If the fluid level is lower than the lower level line, fill the reservoir to the upper level line [A] in the reservoir [B]. • Check that the brake fluid level in the rear brake reservoir [A] is above the lower level line [B].
  • Page 63: Brake Light Switch Operation Inspection

    2-36 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Light Switch Operation Inspection • Turn on the ignition switch. • The brake lights [A] should go on when the brake lever is applied or after the brake pedal is depressed about 10 mm (0.39 in.).
  • Page 64: Suspension

    PERIODIC MAINTENANCE 2-37 Periodic Maintenance Procedures Suspension Front Forks/Rear Shock Absorber Operation Inspection • Pump the forks down and up [A] 4 or 5 times, and inspect the smooth stroke. If the forks does not smoothly or noise is found, inspect the fork oil level or fork clamps (see Front Fork Oil Change in the Suspension chapter).
  • Page 65: Steering

    2-38 PERIODIC MAINTENANCE Periodic Maintenance Procedures Steering Steering Play Inspection • Raise the front wheel off the ground (see Front Wheel Removal in the Wheels/Tires chapter). • 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 66 PERIODIC MAINTENANCE 2-39 Periodic Maintenance Procedures • Remove the lock washer [A]. • Adjust the steering using the steering stem nut wrench [A]. Special Tool - Steering Stem Nut Wrench: 57001-1100 If the steering is too tight, loosen the stem nut [B] a fraction of a turn.
  • Page 67: Steering Stem Bearing Lubrication

    2-40 PERIODIC MAINTENANCE Periodic Maintenance Procedures Steering Stem Bearing Lubrication • Remove the steering stem (see Steering, Stem Bearing Removal in the Steering chapter). • Using a high-flash point solvent, wash the upper and lower ball bearings in the cages, and wipe the upper and lower outer races, which are press-fitted into the frame head pipe, clean off grease and dirt.
  • Page 68: Lights And Switches Operation

    PERIODIC MAINTENANCE 2-41 Periodic Maintenance Procedures Lights and Switches Operation First Step • Turn the ignition switch ON. • The following lights should go on according to below table. United Aus- Models Canada Europe States tralia Position Lights go on go on –...
  • Page 69 2-42 PERIODIC MAINTENANCE Periodic Maintenance Procedures If the light does not go on, inspect or replace the following parts. Battery (see Charging Condition Inspection in the Elec- trical System chapter) Position Light Bulb (see Position Light Bulb Replace- ment in the Electrical System chapter) City Light Bulb (see City Light Bulb Replacement in the Electrical System chapter) Fuel Level Warning Indicator Light (LED) (see Meter Unit...
  • Page 70 PERIODIC MAINTENANCE 2-43 Periodic Maintenance Procedures Second Step • Turn the ignition switch ON. • Push the turn signal switch [A] ON (left or right position). • The left or right turn signal lights [B] (front and rear) ac- cording to the switch position should flash. •...
  • Page 71: Headlight Aiming Inspection

    2-44 PERIODIC MAINTENANCE Periodic Maintenance Procedures Third Step • Turn the ignition switch to ACC position. • Push the turn signal switch [A] ON (left or right position). • The left or right turn signal lights (front and rear) according to the switch position should flash.
  • Page 72 PERIODIC MAINTENANCE 2-45 Periodic Maintenance Procedures Headlight Beam Horizontal Adjustment • Turn the horizontal adjuster [A] on the headlight with a screwdriver in or out until the beam points straight ahead. ○ Turn the adjuster clockwise to face the headlight to the left.
  • Page 73: Sidestand Switch Operation Inspection

    2-46 PERIODIC MAINTENANCE Periodic Maintenance Procedures Sidestand Switch Operation Inspection • Raise the rear wheel off the ground with the jack (see Rear Wheel Removal in the Wheels/Tires chapter). • Inspect the sidestand switch [A] operation accordance to below table. Sidestand Switch Operation Side- Gear...
  • Page 74: Engine Stop Switch Operation Inspection

    PERIODIC MAINTENANCE 2-47 Periodic Maintenance Procedures Engine Stop Switch Operation Inspection First Step • Set the gear position in the neutral position. • Turn the ignition switch ON. • Push the engine stop switch to stop position [A]. • Push the starter button. •...
  • Page 75: Bolts, Nuts And Fasteners Tightness Inspection

    2-48 PERIODIC MAINTENANCE Periodic Maintenance Procedures Cables: Lubricate with Rust Inhibitor 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 76 PERIODIC MAINTENANCE 2-49 Periodic Maintenance Procedures Bolt, Nut and Fastener to be checked Engine: Radiator Bolt Exhaust Pipe Holder Nuts Left and Right Muffler Body Mounting Bolts Clutch Lever Pivot Bolt Nut Clutch Master Cylinder Clamp Bolts Clutch Slave Cylinder Bolts Engine Mounting Bolts and Nuts Engine Bracket Bolts Wheels:...
  • Page 77: Replacement Parts

    Install a new element [A] so that the screen side [B] faces inward. NOTICE Use only the recommended air cleaner element (Kawasaki part number 11013-0031). Using another air cleaner element will wear the engine prema- turely or lower the engine performance. •...
  • Page 78: Fuel Hose Replacement

    PERIODIC MAINTENANCE 2-51 Periodic Maintenance Procedures • Tighten: Torque - Left Air Cleaner Housing Cover Bolts : 4.9 N·m ( 0.50 kgf·m, 43 in·lb) L = 10 mm (0.39 in.) [A] L = 25 mm (0.98 in.) [B] Fuel Hose Replacement •...
  • Page 79: Coolant Change

    2-52 PERIODIC MAINTENANCE Periodic Maintenance Procedures Coolant Change WARNING Coolant can be extremely hot and cause severe burns, is toxic and very slippery. Do not remove the radiator cap or attempt to change the coolant when the engine is hot; allow it cool completely. Immediately wipe any spilled coolant from tires, frame, engine or other painted parts.
  • Page 80 PERIODIC MAINTENANCE 2-53 Periodic Maintenance Procedures Water and Coolant Mixture Ratio (Recommended) Soft Water : 50% Coolant : 50% Freezing Point : –35°C (–31°F) Total Amount : 2.4 L (2.5 US qt) • Fill the coolant into the radiator. NOTE ○...
  • Page 81: Radiator Hose And O-ring Replacement

    2-54 PERIODIC MAINTENANCE Periodic Maintenance Procedures Radiator Hose and O-ring Replacement • Drain the coolant (see Coolant Change). • Remove: Thermostat Housing [A] with Bracket [B] (see Thermo- stat Removal in the Cooling System chapter) Alternator Cover (see Alternator Removal in the Electri- cal System chapter) Left Side Cover (see Left Side Cover Removal in the Frame chapter)
  • Page 82: Engine Oil Change

    PERIODIC MAINTENANCE 2-55 Periodic Maintenance Procedures Engine Oil Change • Situate the motorcycle so that it is vertical after warming up the engine. • Remove the oil filler cap [A] on the crankcase. • Remove the front [A] and rear [B] engine oil drain bolts and drain the oil.
  • Page 83: Oil Filter Replacement

    2-56 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Pour in the specified grade and amount of oil. Recommended Engine Oil Grade: API SG, SH, SJ, SL or SM with JASO MA, MA1, or MA2 Viscosity: SAE 10W-40 Amount: 4.1 L (4.3 US qt) (when filter is not removed) 4.3 L (4.5 US qt) (when filter is removed) 5.0 L (5.3 US qt) (when engine is...
  • Page 84: Brake Hose Replacement

    PERIODIC MAINTENANCE 2-57 Periodic Maintenance Procedures Brake Hose Replacement NOTICE Brake fluid quickly ruins painted plastic surfaces; any spilled fluid should be completely washed away immediately. • Remove the right saddlebag (see Saddlebag Removal in the Frame chapter). • Remove the brake hose banjo bolts [A], clamps [B], bolt [C] and grommets [D].
  • Page 85 2-58 PERIODIC MAINTENANCE Periodic Maintenance Procedures • For K-ACT ABS equipped models, note the following. • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Seats (see Rear/Front Seat Removal in the Frame chap- ter) Left Muffler Body (see Muffler Body Removal in the En- gine Top End chapter) Right Side Cover (see Right Side Cover Removal in the Frame chapter)
  • Page 86 PERIODIC MAINTENANCE 2-59 Periodic Maintenance Procedures...
  • Page 87: Brake Fluid Change

    2-60 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 88 PERIODIC MAINTENANCE 2-61 Periodic Maintenance Procedures • Change the brake fluid as follows. ○ Repeat this operation until fresh brake fluid comes out from the plastic hose or the color of the fluid changes. 1. Open the bleed valve [A]. 2.
  • Page 89: Master Cylinder Rubber Parts Replacement

    2-62 PERIODIC MAINTENANCE 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 reservoir cap [A], plate [B] and diaphragm [C].
  • Page 90: Caliper Rubber Parts Replacement

    PERIODIC MAINTENANCE 2-63 Periodic Maintenance Procedures Master Cylinder Assembly • Before assembly, clean all parts including the master cylinder with brake fluid or alcohol. NOTICE Except for the disc pads and disc, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol for cleaning brake parts.
  • Page 91 2-64 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Remove the dust seals [A] and fluid seals [B]. • Remove the bleed valve [C] and rubber cap [D]. NOTE ○ If compressed air is not available, do as follows with the brake hose connected to the caliper. ○...
  • Page 92 PERIODIC MAINTENANCE 2-65 Periodic Maintenance Procedures NOTE ○ If compressed air is not available, do as follows for both calipers coincidentally, with the brake hose connected to the caliper. ○ Prepare a container for brake fluid, and perform the work above it. ○...
  • Page 93 2-66 PERIODIC MAINTENANCE Periodic Maintenance Procedures Front Caliper Assembly (VN1700D Model) • Clean the caliper parts except for the pads. NOTICE For cleaning the parts, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol. • Install the bleed valve and rubber cap. Torque - Bleed Valves: 7.8 N·m (0.80 kgf·m, 69 in·lb) •...
  • Page 94 PERIODIC MAINTENANCE 2-67 Periodic Maintenance Procedures ○ Pull out the pistons by hand. • Remove the dust seals [A] and fluid seals [B]. • Remove the bleed valves [C] and rubber caps [D]. NOTE ○ If compressed air is not available, do as follows with the brake hose connected to the caliper.
  • Page 95: Clutch Hose And Pipe Replacement

    2-68 PERIODIC MAINTENANCE Periodic Maintenance Procedures Clutch Hose and Pipe Replacement NOTICE Clutch fluid quickly ruins painted plastic surfaces; any spilled fluid should be completely washed away immediately. • When removing the clutch hose, take care not to spill the clutch fluid on the painted or plastic parts.
  • Page 96: Clutch Fluid Change

    PERIODIC MAINTENANCE 2-69 Periodic Maintenance Procedures Clutch Fluid Change • Level the clutch fluid reservoir and remove the reservoir cap. • Remove the engine pulley outer cover (see Engine Pulley Outer Cover Removal in the Final Drive chapter.) and the rubber cap from the bleed valve on the clutch slave cylinder.
  • Page 97: Clutch Master Cylinder Rubber Parts Replacement

    2-70 PERIODIC MAINTENANCE Periodic Maintenance Procedures Clutch Master Cylinder Rubber Parts Replacement • Remove the clutch master cylinder (see Clutch Master Cylinder Removal in the Clutch chapter). • Remove the reservoir cap [A], plate [B] and diaphragm [C], and pour the clutch fluid into a container. •...
  • Page 98: Clutch Slave Cylinder Piston Seal Replacement

    PERIODIC MAINTENANCE 2-71 Periodic Maintenance Procedures Clutch Slave Cylinder Piston Seal Replacement • Remove the engine pulley outer cover (see Engine Pulley Outer Cover Removal in the Final Drive). • Loosen the banjo bolt [A] at the clutch pipe lower end, and tighten it loosely.
  • Page 99 2-72 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Remove the spark plug using a 14 mm (0.55 in.) plug wrench [A] vertically. NOTICE The insulator [A] of the spark plug may break if when the wrench is inclined during loosening. Inclined Spark Plug Wrench [B] Contact (Spark Plug and Plug Wrench) [C] Bad [D] Vertically Spark Plug Wrench [E]...
  • Page 100 FUEL SYSTEM (DFI) 3-1 Fuel System (DFI) Table of Contents Exploded View........................Specifications ......................... Special Tools and Sealant ...................... 3-10 DFI System..........................3-12 DFI Parts Location........................3-18 DFI Servicing Precautions ...................... 3-20 DFI Servicing Precautions ....................3-20 Troubleshooting the DFI System .................... 3-22 Outline ..........................
  • Page 101 3-2 FUEL SYSTEM (DFI) Gear Position Switch Output Voltage Inspection .............. 3-64 Vehicle-down Sensor (Service Code 31)................3-66 Vehicle-down Sensor Removal ..................3-66 Vehicle-down Sensor Installation ..................3-66 Vehicle-down Sensor Input Voltage Inspection..............3-67 Vehicle-down Sensor Output Voltage Inspection .............. 3-68 Oxygen Sensor - not activated (Service Code 33, Equipped Models) ........
  • Page 102 FUEL SYSTEM (DFI) 3-3 Fuel Pump Operating Voltage Inspection ................. 3-96 Pressure Regulator Removal.................... 3-97 Fuel Filter Cleaning......................3-98 Fuel Injectors .......................... 3-99 Fuel Injector Removal ....................... 3-99 Fuel Injector Installation ....................3-100 Fuel Injector Audible Inspection ..................3-100 Fuel Injector Resistance Inspection .................. 3-100 Fuel Injector Output Voltage Inspection ................
  • Page 103: Exploded View

    3-4 FUEL SYSTEM (DFI) Exploded View...
  • Page 104 FUEL SYSTEM (DFI) 3-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Air Cleaner Housing Cover Bolts 0.50 43 in·lb Air Cleaner Element Bolt 0.50 43 in·lb Air Cleaner Housing Bolts 87 in·lb Crankshaft Sensor Bolts 0.60 52 in·lb Delivery Joint Bolts 87 in·lb Fuel Pump Bolts 87 in·lb...
  • Page 105 3-6 FUEL SYSTEM (DFI) Exploded View...
  • Page 106 FUEL SYSTEM (DFI) 3-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Oxygen Sensor (Equipped Models) 2. CAL and SEA Models 3. Canister 4. Separator...
  • Page 107: Specifications

    3-8 FUEL SYSTEM (DFI) Specifications Item Standard Digital Fuel Injection System Idle Speed 950 ±50 r/min (rpm) Throttle Body Assy: Type Two barrel type Bore 42 mm (1.65 in.) ECU: Make MITSUBISHI ELECTRIC Type Digital memory type, with built in IC igniter, sealed with resin Fuel Pressure (High Pressure Line) 294 kPa (3.0 kgf/cm², 43 psi) with engine idling Fuel Pump: Type...
  • Page 108 FUEL SYSTEM (DFI) 3-9 Specifications Item Standard Vehicle-down Sensor: DC 4.75 ∼ 5.25 V Input Voltage With sensor tilted 40 ∼ 50° or more right or left: DC 0.65 Output Voltage ∼ 1.35 V With sensor arrow mark pointed up: DC 3.55 ∼ 4.45 V Oxygen Sensor (Equipped Models): Output Voltage (Rich) DC 0.8 V or more...
  • Page 109: Special Tools And Sealant

    3-10 FUEL SYSTEM (DFI) Special Tools and Sealant Oil Pressure Gauge, 5 kgf/cm²: Needle Adapter Set: 57001-125 57001-1457 Jack: Fuel Pressure Gauge Adapter: 57001-1238 57001-1593 Fork Oil Level Gauge: Fuel Hose: 57001-1290 57001-1607 Vacuum Gauge: Speed Sensor Measuring Adapter: 57001-1369 57001-1667 Hand Tester: Measuring Adapter:...
  • Page 110 FUEL SYSTEM (DFI) 3-11 Special Tools and Sealant Liquid Gasket, TB1211: 56019-120...
  • Page 111: Dfi System

    3-12 FUEL SYSTEM (DFI) DFI System DFI System...
  • Page 112 FUEL SYSTEM (DFI) 3-13 DFI System 1. Fuel Tank 2. FI Indicator LED Light 3. ECU 4. Battery 12 V 18 Ah 5. Pressure Regulator 6. Fuel Pump 7. Water Temperature Sensor 8. Intake Air Pressure Sensor 9. Delivery Joint 10.
  • Page 113 3-14 FUEL SYSTEM (DFI) DFI System DFI System Wiring Diagram...
  • Page 114 35. Battery 36. Starter Relay 37. Main Fuse 30 A 38. Vehicle-down Sensor 39. Crankshaft Sensor 40. Fuel Pump 41. Meter Unit 42. Kawasaki Diagnostic System Connector ○ Color Codes: BK: Black GY: Gray R: Red BL: Blue LB: Light Blue...
  • Page 115 3-16 FUEL SYSTEM (DFI) DFI System Terminal Numbers of ECU Connectors Terminal Names 1. Ignition Coil #2 (Rear Cylinder): BK 2. Fuel Injector #2 (Rear Cylinder): BL/Y 3. Unused 4. Ground for ETV Actuator (to Battery): BK/Y 5. Power Supply to ETV Actuator (from ETV Actuator Relay): G/O 6.
  • Page 116 64. External Communication Line (*KDS): LG 65. Ground for Accelerator Position Sensor 1: BK/O 66. Accelerator Position Sensor 1: G/W 67. Power Supply to Accelerator Position Sensor 1: BL/W 68. Throttle Position Sensor 1: G/R *: KDS (Kawasaki Diagnostic System)
  • Page 117: Dfi Parts Location

    3-18 FUEL SYSTEM (DFI) DFI Parts Location Ignition Coil #1 (Front Cylinder) [A] Air Switching Valve [B] Ignition Coil #2 (Rear Cylinder) [A] Intake Air Pressure Sensor [B] Water Temperature Sensor [A] Fuel Injector #1 (Front Cylinder) [B] Fuel Injector #2 (Rear Cylinder) [C] Intake Air Temperature Sensor [D] Throttle Position Sensor [A] ETV Actuator [B]...
  • Page 118 FUEL SYSTEM (DFI) 3-19 DFI Parts Location Gear Position Switch [A] Speed Sensor [A] Kawasaki Diagnostic System Connector (6-pins Con- nector) [B] ETV Actuator Relay [A] (R/BL, Y/BL, R/BL, G/O Leads) Vehicle-down Sensor [B] Fuse Box 1 [C] (Oxygen Sensor Heater Fuse 10 A...
  • Page 119: Dfi Servicing Precautions

    3-20 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 120 FUEL SYSTEM (DFI) 3-21 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 [A].
  • Page 121: Troubleshooting The Dfi System

    3-22 FUEL SYSTEM (DFI) Troubleshooting the DFI System The warning indicator light (LED) [A] is used for the FI/ETV (Electronic Throttle Valve) indicator, oil pressure warning indicator and water temperature warning indicator. Outline When problem occurs with DFI system, the warning indi- cator light (LED) [A] goes on and the “Error”...
  • Page 122 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 123 3-24 FUEL SYSTEM (DFI) Troubleshooting the DFI System Much of the DFI system troubleshooting work consists of confirming continuity of the wiring. The DFI parts are assembled and adjusted with precision, and it is impossible to disassemble or repair them. •...
  • Page 124 FUEL SYSTEM (DFI) 3-25 Troubleshooting the DFI System • Make sure all connectors in the circuit are clean and tight, and examine wires for signs of burning, fraying, short, etc. Deteriorated wires and bad connections can cause reappearance of problems and unstable operation of the DFI system.
  • Page 125: Inquiries To Rider

    3-26 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 126 FUEL SYSTEM (DFI) 3-27 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 127 3-28 FUEL SYSTEM (DFI) Troubleshooting the DFI System □ Poor running spark plug loose (tighten it). □ or no power at spark plug dirty, broken, or gap maladjusted (remedy it). high speed □ spark plug incorrect (replace it). □ knocking (fuel poor quality or incorrect, → use high-octane gasoline). □...
  • Page 128: Dfi System Troubleshooting Guide

    FUEL SYSTEM (DFI) 3-29 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 129 3-30 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). Intake air pressure sensor trouble Inspect (see chapter 3).
  • Page 130 FUEL SYSTEM (DFI) 3-31 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Intake air temperature sensor trouble Inspect (see chapter 3). Spark plug dirty, broken or gap maladjusted Inspect and replace (see chapter 2). Ignition coil trouble Inspect (see chapter 16). Stumble: Fuel pressure too low Inspect (see chapter 3).
  • Page 131 3-32 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Ignition coil trouble Inspect (see chapter 16). Spark plug dirty, broken or gap maladjusted Inspect and replace (see chapter 2). Spark plug incorrect Replace it with the correct plug (see chapter 2). ECU trouble Inspect (see chapter 3).
  • Page 132 FUEL SYSTEM (DFI) 3-33 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Air cleaner element clogged Clean element (see chapter 2). Fuel pressure too high Inspect (see chapter 3). Fuel injector trouble Inspect (see chapter 3). Water temperature sensor trouble Inspect (see chapter 3).
  • Page 133: Self-diagnosis

    3-34 FUEL SYSTEM (DFI) Self-Diagnosis The warning indicator light (LED) [A] is used for the FI/ETV (Electronic Throttle Valve) indicator, oil pressure warning indicator and water temperature warning indicator. Self-diagnosis Outline The ECU notifies the rider of troubles in DFI system, ig- nition system and ETV system by lighting up or blinking the warning indicator light (LED) [A] and displaying the “Error”...
  • Page 134 FUEL SYSTEM (DFI) 3-35 Self-Diagnosis ○ When problem occurs with ETV (Electronic Throttle Valve) system, the warning indicator light (LED) [A] blinks and the “Error” segments [B], service code [C] and FI warning symbol [D] are displayed on the LCD (Liquid Crystal Display) to alert the rider.
  • Page 135 3-36 FUEL SYSTEM (DFI) Self-Diagnosis • After switching to the normal display, the service code can be displayed again by the following procedures. ○ Push the “S” button of the right switch housing for more than two seconds to display the clock setting mode [A] on the LCD.
  • Page 136 FUEL SYSTEM (DFI) 3-37 Self-Diagnosis Self-Diagnosis Flow Chart...
  • Page 137: Service Code Reading

    3-38 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 138 FUEL SYSTEM (DFI) 3-39 Self-Diagnosis Service Code Table Service System Problems Code Throttle position sensor malfunction, wiring open or short. Intake air pressure sensor malfunction, wiring open or short. Intake air temperature sensor malfunction, wiring open or short. Water temperature sensor malfunction, wiring open or short. Accelerator position sensor malfunction, wiring open or short.
  • Page 139: Backups

    3-40 FUEL SYSTEM (DFI) Self-Diagnosis Backups ○ The ECU takes the following measures to prevent engine damage when the DFI, ignition or ETV system parts have troubles. Service Output Signal Usable Parts Backups by ECU Codes Range or Criteria If both throttle position sensor 1 and 2 fail, Output Voltage Throttle the ECU sets the DFI in the D-J method...
  • Page 140 FUEL SYSTEM (DFI) 3-41 Self-Diagnosis Service Output Signal Usable Parts Backups by ECU Codes Range or Criteria If the ignition coil #1 primary winding has Ignition Coil failures (wiring short or open), the ECU shuts #1 (Front – off the injector #1 to stop fuel to the cylinder Cylinder) #1, though the engine keeps running.
  • Page 141: Throttle Position Sensor (service Code 11)

    3-42 FUEL SYSTEM (DFI) Throttle Position Sensor (Service Code 11) Throttle Position Sensor Removal NOTICE Do not remove throttle position sensor in the gear case [A] since it has been adjusted and set with pre- cision at the factory. Never drop the throttle body assy, especially on a hard surface.
  • Page 142: Throttle Position Sensor Input Voltage Inspection

    FUEL SYSTEM (DFI) 3-43 Throttle Position Sensor (Service Code 11) Throttle Position Sensor Input Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch OFF. • Remove: Front Seat (see Front Seat Removal in the Frame chap- ter) Battery Case Cover (see Battery Removal in the Electri- cal System chapter)
  • Page 143 3-44 FUEL SYSTEM (DFI) Throttle Position Sensor (Service Code 11) Throttle Position Sensor Circuit 1. ECU 2. Throttle Position Sensor/ETV Actuator 3. Throttle Position Sensor 1 4. Throttle Position Sensor 2...
  • Page 144: Intake Air Pressure Sensor (service Code 12)

    FUEL SYSTEM (DFI) 3-45 Intake Air Pressure Sensor (Service Code 12) Intake Air Pressure Sensor Removal NOTICE Never drop the intake air pressure sensor, espe- cially on a hard surface. Such a shock to the sensor can damage it. • Remove: Fuel Tank (see Fuel TankRemoval) Intake Air Pressure Sensor Connector [A]...
  • Page 145: Intake Air Pressure Sensor Output Voltage Inspection

    3-46 FUEL SYSTEM (DFI) Intake 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 connectors. Special Tool - Hand Tester: 57001-1394 ○ Disconnect the ECU and sensor connectors. Wiring Continuity Inspection ECU Connector [A] ←→...
  • Page 146 FUEL SYSTEM (DFI) 3-47 Intake Air Pressure Sensor (Service Code 12) If the reading is within the usable range, remove the ECU and check the wiring for continuity between main harness connector. Special Tool - Hand Tester: 57001-1394 ○ Disconnect the ECU and sensor connectors. Wiring Continuity Inspection ECU Connector [A] ←→...
  • Page 147 3-48 FUEL SYSTEM (DFI) Intake Air Pressure Sensor (Service Code 12) then Pv = Pl – Pg For example, suppose the following data is obtained: Pg = 8 cmHg (Vacuum Gauge Reading) Pl = 70 cmHg (Barometer Reading) Vv = 3.2 V (Digital Meter Reading) then Pv = 70 –...
  • Page 148 FUEL SYSTEM (DFI) 3-49 Intake 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: Intake Air Pressure Sensor Output Voltage (V) (Digital Meter Reading)
  • Page 149 3-50 FUEL SYSTEM (DFI) Intake Air Pressure Sensor (Service Code 12) Intake Air Pressure Sensor Circuit 1. ECU 2. Intake Air Pressure Sensor...
  • Page 150: Intake Air Temperature Sensor (service Code 13)

    FUEL SYSTEM (DFI) 3-51 Intake Air Temperature Sensor (Service Code 13) Intake Air Temperature Sensor Removal/Instal- lation NOTICE Never drop the intake air temperature sensor, espe- cially on a hard surface. Such a shock to the sensor can damage it. •...
  • Page 151: Intake Air Temperature Sensor Resistance Inspection

    3-52 FUEL SYSTEM (DFI) Intake 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 In- spection). If the ground and power supply are good, replace the ECU (see ECU Removal/Installation).
  • Page 152 FUEL SYSTEM (DFI) 3-53 Intake Air Temperature Sensor (Service Code 13) Intake Air Temperature Sensor Circuit 1. ECU 2. Intake Air Temperature Sensor...
  • Page 153: Water Temperature Sensor (service Code 14)

    3-54 FUEL SYSTEM (DFI) Water Temperature Sensor (Service Code 14) Water Temperature Sensor Removal/Installation NOTICE 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) •...
  • Page 154: Water Temperature Sensor Resistance Inspection

    FUEL SYSTEM (DFI) 3-55 Water Temperature Sensor (Service Code 14) • 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 155: Accelerator Position Sensor (service Code 18)

    3-56 FUEL SYSTEM (DFI) Accelerator Position Sensor (Service Code 18) Accelerator Position Sensor Removal NOTICE Do not remove accelerator position sensor [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 156: Accelerator Position Sensor Input Voltage Inspection

    FUEL SYSTEM (DFI) 3-57 Accelerator Position Sensor (Service Code 18) Accelerator Position Sensor Input Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch OFF. • Remove: Front Seat (see Front Seat Removal in the Frame chap- ter) Battery Case Cover (see Battery Removal in the Electri- cal System chapter)
  • Page 157 3-58 FUEL SYSTEM (DFI) Accelerator Position Sensor (Service Code 18) • Connect the digital meter [A] to the terminals of the accel- erator position sensor connector [B]. Accelerator Position Sensor Resistance Connection: (1) BL/W lead terminal → BK/O lead terminal (2) BL/BK lead terminal →...
  • Page 158: Crankshaft Sensor (service Code 21)

    FUEL SYSTEM (DFI) 3-59 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 159 3-60 FUEL SYSTEM (DFI) Crankshaft Sensor (Service Code 21) Crankshaft Sensor Circuit 1. ECU 2. Crankshaft Sensor...
  • Page 160: Speed Sensor (service Code 24)

    FUEL SYSTEM (DFI) 3-61 Speed Sensor (Service Code 24) 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 161: Speed Sensor Output Voltage Inspection

    3-62 FUEL SYSTEM (DFI) Speed Sensor (Service Code 24) Speed Sensor Output Voltage Inspection • Using the jack, raise the rear wheel off the ground (see Rear Wheel Removal in the Wheels/Tires chapter). Special Tool - Jack: 57001-1238 • Measure the output voltage at the speed sensor in the same way as input voltage inspection, note the following.
  • Page 162 FUEL SYSTEM (DFI) 3-63 Speed Sensor (Service Code 24) Speed Sensor Circuit 1. ECU 2. Speed Sensor...
  • Page 163: Gear Position Switch (service Code 25)

    3-64 FUEL SYSTEM (DFI) Gear Position Switch (Service Code 25) Gear Position Switch Removal/Installation • Refer to the Gear Position Switch Removal/Installation in the Electrical System chapter. Gear Position Switch Resistance Inspection • Refer to the Gear Position Switch Inspection in the Elec- trical System chapter.
  • Page 164 FUEL SYSTEM (DFI) 3-65 Gear Position Switch (Service Code 25) • Turn the ignition switch OFF. If the reading is out of the standard, check the wiring for continuity, using the wiring diagram in this section. Special Tool - Hand Tester: 57001-1394 If the wiring is good, check the ECU for its ground and power supply (see ECU Power Supply Inspection).
  • Page 165: Vehicle-down Sensor (service Code 31)

    3-66 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 166: Vehicle-down Sensor Input Voltage Inspection

    FUEL SYSTEM (DFI) 3-67 Vehicle-down Sensor (Service Code 31) Vehicle-down Sensor Input Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Remove the vehicle-down sensor (see Vehicle-down Sensor Removal). • Connect the measuring adapter [A] between the main har- ness connector and vehicle-down sensor connector as shown in the figure.
  • Page 167: Vehicle-down Sensor Output Voltage Inspection

    3-68 FUEL SYSTEM (DFI) Vehicle-down Sensor (Service Code 31) Vehicle-down Sensor Output Voltage Inspection • Measure the output voltage at the vehicle-down sensor in the same way as input voltage inspection, note the follow- ing. ○ Connect the measuring adapter [A] between the main har- ness connector and vehicle-down sensor connector as shown in the figure.
  • Page 168 FUEL SYSTEM (DFI) 3-69 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 con- nectors. Special Tool - Hand Tester: 57001-1394 ○ Disconnect the ECU and sensor connectors. Wiring Continuity Inspection ECU Connector [A] ←→...
  • Page 169: Oxygen Sensor - Not Activated (service Code 33, Equipped Models)

    3-70 FUEL SYSTEM (DFI) Oxygen Sensor - not activated (Service Code 33, 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 170 FUEL SYSTEM (DFI) 3-71 Oxygen Sensor - not activated (Service Code 33, Equipped Models) ○ Do not disconnect the air switching valve connector [A]. • Plug the air switching valve hose ends [A], and shut off the secondary air. • Connect the following parts temporarily.
  • Page 171 3-72 FUEL SYSTEM (DFI) Oxygen Sensor - not activated (Service Code 33, Equipped Models) If the reading is out of the standard (with plugs: 0.8 V or more, without plugs: 0.24 V or less), remove the ECU and check the wiring for continuity between main harness connectors.
  • Page 172: Fuel Pump Relay (service Code 46)

    FUEL SYSTEM (DFI) 3-73 Fuel Pump Relay (Service Code 46) Fuel Pump Relay Removal/Installation ○ The fuel pump relay is built in the relay box [A]. • Refer to the Relay Box Removal in the Electrical System chapter. Fuel Pump Relay Inspection •...
  • Page 173: Return Spring (service Code 49)

    3-74 FUEL SYSTEM (DFI) Return Spring (Service Code 49) Return Spring Removal NOTICE Do not remove return spring in the gear case [A] since it has been set with precision at the factory. Return Spring Inspection • Turn the ignition switch OFF. •...
  • Page 174: Ignition Coils #1, #2 (service Code 51, 52)

    FUEL SYSTEM (DFI) 3-75 Ignition Coils #1, #2 (Service Code 51, 52) Ignition Coil #1 (Front Cylinder): Service Code 51 Ignition Coil #2 (Rear Cylinder): Service Code 52 Ignition Coil Removal/Installation • Refer to the Ignition Coil Removal/Installation in the Elec- trical System chapter.
  • Page 175 3-76 FUEL SYSTEM (DFI) Ignition Coils #1, #2 (Service Code 51, 52) Ignition Coil Circuit 1. ECU 2. Ignition Coil #2 (Rear Cylinder) 3. Ignition Coil #1 (Front Cylinder) 4. Engine Stop Switch 5. Ignition Switch 6. Main Fuse 30 A 7.
  • Page 176: Radiator Fan Relay (service Code 56)

    FUEL SYSTEM (DFI) 3-77 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 177: Etv Acutuator (service Code 58)

    3-78 FUEL SYSTEM (DFI) ETV Acutuator (Service Code 58) ETV Actuator Removal NOTICE Do not remove ETV actuator in the gear case [A] since it has been set with precision at the factory. ETV Actuator Input Voltage Inspection NOTE ○ Be sure the battery is fully charged.
  • Page 178: Etv Actuator Resistance Inspection

    FUEL SYSTEM (DFI) 3-79 ETV Acutuator (Service Code 58) ETV Actuator Resistance Inspection • Remove: Front Seat (see Front Seat Removal in the Frame chap- ter) ETV Actuator Relay [A] • Connect the hand tester [A] and a 12 V battery [B] to the relay [C] as shown in the figure.
  • Page 179: Air Switching Valve (service Code 64)

    3-80 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 180: Oxygen Sensor Heater (service Code 67, Equipped Models)

    FUEL SYSTEM (DFI) 3-81 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 181: Oxygen Sensor Heater Power Source Voltage Inspection

    3-82 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 measuring adapter [A] between these connec- tors as shown in the figure.
  • Page 182 FUEL SYSTEM (DFI) 3-83 Oxygen Sensor Heater (Service Code 67, Equipped Models) Oxygen Sensor Circuit 1. ECU 2. Oxygen Sensor 3. Oxygen Sensor Heater Fuse 10 A 4. Ignition Switch 5. Main Fuse 30 A 6. Battery 7. Engine Ground 8.
  • Page 183: Battery Voltage (service Code 97)

    3-84 FUEL SYSTEM (DFI) Battery Voltage (Service Code 97) Battery Voltage Inspection • Refer to the Charging Condition Inspection in the Electri- cal System chapter for battery voltage inspection. If the battery voltage is good condition, replace the ECU (see ECU Removal/Installation). Battery Monitor Circuit 1.
  • Page 184: Etv Control Circuit (service Code 98)

    FUEL SYSTEM (DFI) 3-85 ETV Control Circuit (Service Code 98) ETV Control Circuit Inspection ○ The ETV control circuit is controlled in the ECU [A]. So, the ETV control circuit cannot be inspected. • When the service code 98 is displayed on the LCD, re- place the ECU (see ECU Removal/Installation).
  • Page 185: Warning Indicator Light (led)

    3-86 FUEL SYSTEM (DFI) Warning Indicator Light (LED) Light (LED) Inspection ○ The warning indicator light (LED) [A] is used for the FI in- dicator, ETV (Electronic Throttle Valve) indicator, oil pres- sure warning indicator and battery warning indicator. ○ In this model, the warning indicator light (LED) goes on or blinks by the data sent from the ECU.
  • Page 186: Ecu

    FUEL SYSTEM (DFI) 3-87 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 can not clear the regulation. ECU Identification Model Part Number [A]...
  • Page 187: Ecu Installation

    3-88 FUEL SYSTEM (DFI) ECU Installation • Install: ECU (in Rubber Protector) ECU Connectors • Fit the hooks [A] of the bracket [B] into the recesses [C] of the battery case. • Install the removed parts. NOTE ○ When the ECU was replaced with a new one, do not remove the battery, fuse or ECU for 6 seconds for the learning control of the ECU after the ignition switch is turned off.
  • Page 188 FUEL SYSTEM (DFI) 3-89 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 189 3-90 FUEL SYSTEM (DFI) ECU Power Source Circuit 1. Ignition Switch 2. Ignition Fuse 10A 3. ECU Fuse 10 A 4. Main Fuse 30 A 5. Battery 6. Engine Ground 7. Frame Ground 3 8. Frame Ground 6 9. ECU...
  • Page 190: Dfi Power Source

    FUEL SYSTEM (DFI) 3-91 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 191: Fuel Line

    3-92 FUEL SYSTEM (DFI) Fuel Line Fuel Pressure Inspection NOTE ○ Be sure the battery is fully charged. • Remove: Fuel 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 192: Fuel Flow Rate Inspection

    FUEL SYSTEM (DFI) 3-93 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 193 3-94 FUEL SYSTEM (DFI) 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 194: Fuel Pump

    FUEL SYSTEM (DFI) 3-95 Fuel Pump Fuel Pump Removal WARNING Gasoline is extremely flammable and can be ex- plosive under certain conditions, creating the potential for serious burns. Make sure the area is well-ventilated and free from any source of flame or sparks;...
  • Page 195: Fuel Pump Installation

    3-96 FUEL SYSTEM (DFI) 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 196: Pressure Regulator Removal

    FUEL SYSTEM (DFI) 3-97 Fuel Pump • Disconnect the fuel pump lead connector and connect the measuring adapter [A] between these connectors as shown in the figure. Main Harness [B] Fuel Pump [C] Special Tool - Measuring Adapter: 57001-1700 • Connect a digital meter [D] to the measuring adapter leads.
  • Page 197: Fuel Filter Cleaning

    3-98 FUEL SYSTEM (DFI) Fuel Pump Fuel Filter Cleaning ○ The fuel filter [A] is built into the pump and can not be cleaned or checked. If the fuel filter is suspected of clogging or being damaged, replace it with the fuel pump as a set. Fuel Pump Circuit 1.
  • Page 198: Fuel Injectors

    FUEL SYSTEM (DFI) 3-99 Fuel Injectors Fuel Injector Removal • Remove: Fuel Tank (see Fuel Tank Removal) Throttle Body Assy (see Throttle Body Assy Removal) Fuel Injector Connectors [A] • Remove: Delivery Joint Bolt [A] Bracket [B] • Remove: Delivery Joint Bolt [A] Bracket [B] •...
  • Page 199: Fuel Injector Installation

    3-100 FUEL SYSTEM (DFI) Fuel Injectors Fuel Injector Installation • Before installing the fuel injector, blow away dirt or dust from the delivery joint by applying compressed air. • Replace the O-rings [A] of each fuel injector with new ones. •...
  • Page 200: Fuel Injector Output Voltage Inspection

    FUEL SYSTEM (DFI) 3-101 Fuel Injectors • Connect the digital meter [A] to the harness connectors [B] with the needle adapter set. Special Tool - Needle Adapter Set: 57001-1457 Fuel Injector Resistance Connection: Fuel Injector #1 Digital Meter → BL/O lead (ECU terminal 27) Digital Meter →...
  • Page 201: Fuel Injector Input Voltage Inspection

    3-102 FUEL SYSTEM (DFI) Fuel Injectors • Turn the ignition switch OFF. If the reading is in the specification, but the injector does not operate, replace the ECU (see ECU Removal/Instal- lation). If the reading is out of the specification, check the input voltage (see Fuel Injector Input Voltage Inspection).
  • Page 202: Fuel Injector Fuel Line Inspection

    FUEL SYSTEM (DFI) 3-103 Fuel Injectors Fuel Injector Fuel Line Inspection • Remove: Fuel Tank (see Fuel Tank Removal) Left Air Cleaner Housing (see Left Air Cleaner Housing Removal) Fuel Hoses (see Fuel Hose Replacement in the Periodic Maintenance chapter) ○...
  • Page 203 3-104 FUEL SYSTEM (DFI) Fuel Injectors Fuel Injector Circuit 1. ECU 2. Engine Stop Switch 3. Fuel Injector #2 4. Fuel Injector #1 5. Ignition Switch 6. Ignition Fuse 10 A 7. ECU Fuse 10 A 8. Main Fuse 30 A 9.
  • Page 204: Throttle Grip And Cables

    FUEL SYSTEM (DFI) 3-105 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 205: Cable Lubrication

    3-106 FUEL SYSTEM (DFI) Throttle Grip and Cables If the stopper of the pulley does not touch, adjust the throt- tle grip free play with the accelerator cable adjuster [A], and then adjust with the decelerator cable adjuster [B] (see Throttle Control System Inspection in the Periodic Maintenance chapter).
  • Page 206: Throttle Body Assy

    FUEL SYSTEM (DFI) 3-107 Throttle Body Assy Idle Speed Inspection/Adjustment • Refer to the Idle Speed Inspection/Adjustment in the Pe- riodic Maintenance chapter. Throttle Body Assy Removal WARNING Gasoline is extremely flammable and can be ex- plosive under certain conditions, creating the potential for serious burns.
  • Page 207: Throttle Body Assy Installation

    3-108 FUEL SYSTEM (DFI) Throttle Body Assy • Remove: Vacuum Hose [A] Electronic Cruise Control Cancel Switch (Throttle) Lead Connector [B] • Remove: Throttle Position Sensor Connector [A] Accelerator Position Sensor Connector [B] Throttle Body Assy Holder Bolts [C] Throttle Body Assy [D] (from Intake Manifold) •...
  • Page 208 FUEL SYSTEM (DFI) 3-109 Throttle Body Assy • Apply a thin coat of grease to the throttle cable upper ends. • Install the upper ends of the throttle cables in the grip. • Fit the projection [A] of the right switch housing into the hole [B] of the handlebar.
  • Page 209: Throttle Body Assy Disassembly

    3-110 FUEL SYSTEM (DFI) Throttle Body Assy • Install: Throttle Body Assy [A] Throttle Body Assy Holder Bolt [B], 75 mm (3.0 in.) Throttle Body Assy Holder Bolts [C], 60 mm (2.4 in.) • Tighten: Torque - Throttle Body Assy Holder Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) •...
  • Page 210: Throttle Body Assy Assembly

    FUEL SYSTEM (DFI) 3-111 Throttle Body Assy Throttle Body Assy Assembly • Apply a non-permanent locking agent to the electronic cruise control cancel switch (throttle) bolt [A]. • Install the switch so that the projection [B] into the hole [C] of the bracket. •...
  • Page 211: Intake Manifold

    3-112 FUEL SYSTEM (DFI) Intake Manifold Intake Manifold Removal • Remove: Throttle Body Assy (see Throttle Body Assy Removal) Fuel Injectors (Fuel Injector Removal) Intake Manifold Bolts [A] Intake Manifold [B] Intake Mnifold Installation • Wipe any carbon off the bores [A] around the intake man- ifold, using a piece of lint-free cloth penetrated with a high-flash point solvent.
  • Page 212: Air Cleaner

    FUEL SYSTEM (DFI) 3-113 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: Air Cleaner Element (see Air Cleaner Element Replace- ment in the Periodic Maintenance chapter) •...
  • Page 213: Left Air Cleaner Housing Installation

    3-114 FUEL SYSTEM (DFI) Air Cleaner • Remove: Breather Hose [A] Left Air Cleaner Housing Installation • When installing the damper [A] and collar [B], install them as shown in the figure. Air Cleaner Housing [C] Engine Side [D] Big Side [E] •...
  • Page 214: Right Air Cleaner Housing Installation

    FUEL SYSTEM (DFI) 3-115 Air Cleaner • Remove: Right Air Cleaner Housing Cover Bolts [A] Right Air Cleaner Housing Cover [B] • Remove: Intake Air temperature Sensor Connector [A] Air Switching Valve Hose [B] • Remove: Air Cleaner Housing Bolts [A] and Washers Right Air Cleaner Housing Center Bolts [B] Right Air Cleaner Housing [C] Right Air Cleaner Housing Installation...
  • Page 215 3-116 FUEL SYSTEM (DFI) Air Cleaner • Install: Right Air Cleaner Housing Air Cleaner Housing Bolts [A] and Washers • Apply a non-permanent locking agent to the right air cleaner housing center bolts [B]. • Tighten: Torque - Right Air Cleaner Housing Center Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) Air Cleaner Housing Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)
  • Page 216: Fuel Tank

    FUEL SYSTEM (DFI) 3-117 Fuel Tank Fuel Tank Removal WARNING Gasoline is extremely flammable and can be ex- plosive under certain conditions, creating the potential for serious burns. Make sure the area is well-ventilated and free from any source of flame or sparks;...
  • Page 217 3-118 FUEL SYSTEM (DFI) Fuel Tank • Disconnect: Fuel Pump Lead Connector [A] • Be sure to place a piece of cloth [A] around the fuel hose joint. • Insert a thin blade screwdriver [B] into the slit [C] on the joint lock [D].
  • Page 218: Fuel Tank Installation

    FUEL SYSTEM (DFI) 3-119 Fuel Tank • For the CAL and SEA models, note the following. NOTICE For the California and Southeast Asia models, if gasoline, solvent, water or any other liquid enters the canister, the canister’s vapor absorbing capac- ity is greatly reduced.
  • Page 219 3-120 FUEL SYSTEM (DFI) Fuel Tank • Check that the dampers [A] are in place on the frame. If the dampers are damaged or deteriorated, replace them. • Install the fuel pump so that the stoppers [A] fit to the dampers [B].
  • Page 220: Fuel Tank Inspection

    FUEL SYSTEM (DFI) 3-121 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 fuel breather pipe [B] in the tank are not clogged.
  • Page 221: Evaporative Emission Control System (cal And Sea Models)

    3-122 FUEL SYSTEM (DFI) Evaporative Emission Control System (CAL and SEA Models) The Evaporative Emission Control System routes fuel va- pors from the fuel system into the running engine or stores the vapors in a canister when the engine is stopped. Al- though no adjustments are required, a thorough visual in- spection must be made at the intervals specified by the Pe- riodic Maintenance Chart.
  • Page 222: Separator Operation Test

    FUEL SYSTEM (DFI) 3-123 Evaporative Emission Control System (CAL and SEA Models) Separator Operation Test WARNING Gasoline is extremely flammable and can be ex- plosive under certain conditions. Turn the ignition switch OFF. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks;...
  • Page 223 3-124 FUEL SYSTEM (DFI) Evaporative Emission Control System (CAL and SEA Models) 1. Fuel Tank 2. Canister 3. Blue Hose (Breather) 4. Green Hose (Purge) 5. Band (for Canister) 6. Bracket (for Canister) 7. Separator 8. Band (for Separator) 9. Fittings 10.
  • Page 224 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 225: Exploded View

    4-2 COOLING SYSTEM Exploded View...
  • Page 226 COOLING SYSTEM 4-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Cross Pipe Bolts Radiator Fan Bolts 0.85 73 in·lb Radiator Hose Clamp Screws 27 in·lb Thermostat Housing Cover Bolts 87 in·lb Water Pipe Bolts 106 in·lb Water Pump Impeller Bolt 106 in·lb 106 in·lb Water Separator Inner Cover Bolts...
  • Page 227: Coolant Flow Chart

    4-4 COOLING SYSTEM Coolant Flow Chart...
  • Page 228 COOLING SYSTEM 4-5 Coolant Flow Chart 1. Radiator Fan 2. Radiator 3. Water Separator Cover 4. Water Pump 5. Reserve Tank 6. Reserve Tank Overflow Hose (VN1700C9F Model) 7. Radiator Overflow Hose 8. Cylinder Jacket 9. Cylinder Head Jacket 10. Thermostat Housing 11.
  • Page 229: Specifications

    4-6 COOLING SYSTEM Specifications Item Standard Coolant provided when shipping Type (Recommended) Permanent type 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) 2.4 L (2.5 US qt) (Reserve tank full level, including...
  • Page 230: Special Tools

    COOLING SYSTEM 4-7 Special Tools Bearing Driver Set: Bearing Remover Head, 10 × 12: 57001-1129 57001-1266 Bearing Remover Shaft, 9: 57001-1265...
  • Page 231: Coolant

    4-8 COOLING SYSTEM Coolant Coolant Deterioration Inspection • Remove the left side cover (see Left Side 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.
  • Page 232: Cooling System Flushing

    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 considerably reduce the effi- ciency of the cooling system.
  • Page 233: Water Pump

    4-10 COOLING SYSTEM Water Pump Water Pump Removal • Drain the coolant (see Coolant Change in the Periodic Maintenance chapter). • Remove: Alternator Cover (see Alternator Cover Removal in the Electrical System chapter) Impeller Bolt [A] and Washer Impeller [B] NOTE ○...
  • Page 234: Mechanical Seal Inspection

    COOLING SYSTEM 4-11 Water Pump Mechanical Seal Inspection • Remove the impeller (see Water Pump Removal). • Visually inspect the mechanical seal. If any one of the parts is damaged, replace the mechani- cal seal as a unit. ○ The sealing seat and rubber seal may be removed easily by hand.
  • Page 235 4-12 COOLING SYSTEM Water Pump • Replace the oil seal and ball bearing with new ones. • Apply grease to the oil seal lips. • Press the oil seal [A] into the hole from the outside of the left crankcase with the bearing driver set so that the spring side of the seal lips is toward the inside of the crankcase.
  • Page 236: Radiator

    COOLING SYSTEM 4-13 Radiator Radiator Removal • Remove: Bracket Bolt [A] Cross Pipe Bolts [B] • Detach the projections of the radiator from the grommet [C] of the cross pipe. • Open the clamp [A] to free the lead. • Disconnect the regulator connectors [B].
  • Page 237: Radiator Installation

    4-14 COOLING SYSTEM Radiator • Remove: Radiator Bolt [A] Radiator [B] NOTICE Do not touch the radiator core. This could damage the radiator fins, resulting in loss of cooling effi- ciency. • Remove: Radiator Fan Bolts [A] Radiator Fan [B] Radiator Installation •...
  • Page 238: Radiator Inspection

    COOLING SYSTEM 4-15 Radiator Radiator Inspection • Remove the radiator (see Radiator Removal). • Check the radiator core. If there are obstructions to air flow, remove them. If the corrugated fins [A] are deformed, carefully straighten them. If the air passages of the radiator core are blocked more than 20% by unremovable obstructions or irreparably de- formed fins, replace the radiator with a new one.
  • Page 239: Radiator Filler Neck Inspection

    4-16 COOLING SYSTEM Radiator Radiator Filler Neck Inspection • Remove the radiator cap (see Coolant Change in the Pe- riodic Maintenance chapter). • Check the radiator filler neck for signs of damage. • Check the condition of the top and bottom sealing seats [A] in the filler neck.
  • Page 240: Thermostat

    COOLING SYSTEM 4-17 Thermostat Thermostat Removal • Drain the coolant (see Coolant Change in the Periodic Maintenance chapter). • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Water Hoses [A] Bracket Bolts [B] Water Temperature Sensor Connector [C] •...
  • Page 241: Thermostat Inspection

    4-18 COOLING SYSTEM Thermostat Thermostat Inspection • Remove the thermostat (see Thermostat Removal). • Inspect the thermostat valve at room temperature. If the valve is open, replace the valve with a new one. • To check valve opening temperature, suspend the ther- mostat [A] and an accurate thermometer [B] in a container of water with the heat-sensitive portions [C] in almost the same depth.
  • Page 242: Hoses And Pipes

    COOLING SYSTEM 4-19 Hoses and Pipes Water Separator Cover Removal • Drain the coolant (see Coolant Change in the Periodic Maintenance chapter) • Remove: Water Separator Outer Cover Bolts [A] Water Separator Outer Cover [B] • Remove: Water Pipe Bolts [A] Upper Water Pipes [B] •...
  • Page 243: Lower Water Pipe Removal (vn1700caf/daf Models)

    4-20 COOLING SYSTEM Hoses and Pipes • Replace the O-rings [A] with new ones. • Apply grease to the new O-rings. • Install the upper water pipes. ○ When installing the upper water pipes, insert the water pipes into the pipe fitting of the cylinder as far as they will •...
  • Page 244: Hose Installation

    COOLING SYSTEM 4-21 Hoses and Pipes Hose Installation • Install the hoses and pipes being careful to follow bend- ing direction. Avoid sharp bending, kinking, flattening, or twisting. • Install the clamps [A] as near as possible to the hose end to clear the raised rib on the fitting.
  • Page 245: Water Temperature Sensor

    4-22 COOLING SYSTEM Water Temperature Sensor Water Temperature Sensor Removal/Installation • Refer to the Water Temperature Sensor Removal/Instal- lation in the Fuel System (DFI) chapter. Water Temperature Sensor Inspection • Refer to the Water Temperature Sensor Inspection in the Electrical System chapter.
  • Page 246 Camshaft Sprocket Removal ..5-31 Clean Air System....... 5-12 Camshaft Sprocket Installation ..5-32 Air Suction Valve Removal... 5-12 KACR (Kawasaki Automatic Air Suction Valve Installation..5-12 Compression Release) ....5-33 Air Suction Valve Inspection ..5-12 KACR Inspection......5-33 Air Switching Valve Removal ..
  • Page 247: Exploded View

    5-2 ENGINE TOP END Exploded View...
  • Page 248 ENGINE TOP END 5-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Breather Check Valve Cover Bolts 87 in·lb Cylinder Head Nuts (M12) (First) Cylinder Head Nuts (M12 New Nuts) (Final) MO, S Cylinder Head Nuts (M12 Used Nuts) (Final) Cylinder Head Nuts (M10) (First) MO, S Cylinder Head Nuts (M10) (Final)
  • Page 249 5-4 ENGINE TOP END Exploded View...
  • Page 250 ENGINE TOP END 5-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Camshaft Chain Tensioner Bolts 106in·lb Camshaft Sprocket Bolts Exhaust Pipe Holder Nuts Muffler Body Mounting Bolt Rear Camshaft Chain Guide Retainer Bolts 87 in·lb 6. HLA (Hydraulic Lash Adjuster) 7.
  • Page 251: Exhaust System Identification

    5-6 ENGINE TOP END Exhaust System Identification Exhaust Pipe Mark Position [A] Left Muffler Body Mark Position [A]...
  • Page 252 ENGINE TOP END 5-7 Exhaust System Identification Right Muffler Body Mark Position [A] Right Muffler Body [A] with Hole [B] for Oxygen Sensor [C] Honeycomb Type Catalyst Positions [A] Left Muffler Body [B] Right Muffler Body [C]...
  • Page 253: Specifications

    5-8 ENGINE TOP END Specifications Item Standard Service Limit Rocker Shafts, Rocker Arms 15.976 ∼ 15.994 mm Rocker Shaft Diameter 15.95 mm (0.6279 in.) (0.6289 ∼ 0.6296 in.) 16.016 ∼ 16.034 mm Rocker Arm Inside Diameter 16.07 mm (0.6326 in.) (0.6305 ∼...
  • Page 254 ENGINE TOP END 5-9 Specifications Item Standard Service Limit Valve Seating Surface: Width: 0.8 ∼ 1.2 mm (0.031 ∼ 0.047 in.) Exhaust – – – 0.8 ∼ 1.2 mm (0.031 ∼ 0.047 in.) Intake – – – Outside Diameter: 34.9 ∼ 35.1 mm (1.374 ∼ 1.382 in.) Exhaust –...
  • Page 255: Special Tools And Sealant

    5-10 ENGINE TOP END Special Tools and Sealant Compression Gauge, 20 kgf/cm²: Valve Seat Cutter, 45° - 41.5: 57001-221 57001-1117 Valve Spring Compressor Assembly: Valve Seat Cutter, 32° - 38.5: 57001-241 57001-1122 Valve Spring Compressor Adapter, 28.2: Valve Seat Cutter, 60° - 41: 57001-243 57001-1124 Valve Guide Arbor, 5.5:...
  • Page 256 ENGINE TOP END 5-11 Special Tools and Sealant Valve Seat Cutter, 45° - 40: Valve Seat Cutter Holder, 6: 57001-1496 57001-1576 Valve Seat Cutter, 55° - 38.5: Valve Guide Reamer, 6: 57001-1497 57001-1596 Valve Seat Cutter, 32°- 44: Compression Gauge Adapter, M12 × 1.25: 57001-1515 57001-1733 Valve Guide Driver:...
  • Page 257: Clean Air System

    5-12 ENGINE TOP END Clean Air System Air Suction Valve Removal Air Suction Valve of Front Cylinder • Remove: Cylinder Head Inner Cover (see Cylinder Head Cover Removal) Air Suction Valve [A] Air Suction Valve of Rear Cylinder • Remove: Engine (see Engine Removal in the Engine Removal/In- stallation chapter) Cylinder Head Inner Cover (see Cylinder Head Cover...
  • Page 258: Air Switching Valve Removal

    ENGINE TOP END 5-13 Clean Air System Air Switching Valve Removal NOTICE Never drop the air switching valve, especially on a hard surface. Such a shock to the air switching valve can damaged it. • Remove the ignition coils (see Ignition Coil Removal in the Electrical System chapter).
  • Page 259: Air Switching Valve Unit Test

    5-14 ENGINE TOP END Clean Air System Air Switching Valve Unit Test • Refer to the Air Switching Valve Unit Test in the Electrical System chapter. Clean Air System Hose Inspection • Be certain that all the hoses are routed without being flat- tened or kinked, and are connected correctly to the air cleaner housing, air switching valve, and fittings on the cylinder head covers.
  • Page 260: Cylinder Head Covers

    ENGINE TOP END 5-15 Cylinder Head Covers Cylinder Head Cover Removal Front Cylinder Head Cover • Remove: Air Switching Valve (see Air Switching Valve Removal) Cylinder Head Outer Cover Bolts [A] with Collars Cylinder Head Outer Covers [B] • Remove: Cylinder Head Inner Cover Bolts [A] with Gaskets Cylinder Head Inner Cover [B] Rear Cylinder Head Cover...
  • Page 261 5-16 ENGINE TOP END Cylinder Head Covers • Replace the cylinder head inner cover gasket [A] with a new one, and install it on the cylinder head inner cover [B]. • Apply silicone sealant to the mating surface of the half -month portion [C], and install the gasket on the cylinder head.
  • Page 262 ENGINE TOP END 5-17 Cylinder Head Covers Rear Cylinder Head Cover • Install the collars [A] on the seating surfaces (shaded por- tions) [B] of the cylinder head outer covers [C] as shown in the figure. • Install the plate [D] so that the tabs [E] fit onto the seating surface of the cylinder head outer cover as shown in the figure.
  • Page 263: Rocker Cases

    5-18 ENGINE TOP END Rocker Cases Rocker Case Removal Front Rocker Case • Remove: Cylinder Head Inner Cover (see Cylinder Head Cover Removal) Alternator Cover (see Alternator Cover Removal in the Electrical System chapter) • Using a wrench on the alternator rotor bolt, turn the crankshaft clockwise [A] until the “FRONT”...
  • Page 264 ENGINE TOP END 5-19 Rocker Cases • Remove the camshaft chain tensioner (see Camshaft Chain Tensioner Removal). • Loosen the M6 and M8 rocker case bolts as shown se- quence [1 ∼ 6] in the figure, and remove them. • Lift the rocker case [A], and remove the front camshaft chain guide [B] from the pin of the case.
  • Page 265: Rocker Case Installation

    5-20 ENGINE TOP END Rocker Cases ○ Using a wrench on the alternator rotor bolt, turn the crankshaft clockwise [A] until the “R” mark line (TDC mark for rear piston) [B] of the balancer chain sprocket [C] is aligned with the line [D] of the crankcase. •...
  • Page 266 ENGINE TOP END 5-21 Rocker Cases • Apply molybdenum disulfide oil solution to all cam parts and journals. • Install the plug hole gasket [A] so that the cutout portions [B] fit onto the ribs [C] of the cylinder head. •...
  • Page 267 5-22 ENGINE TOP END Rocker Cases • Install the camshaft chain tensioner (see Camshaft Chain Tensioner Installation). • After installing the camshaft chain tensioner, check to be sure that the camshaft chain timing is correct. • Turn the crankshaft clockwise and recheck the camshaft chain timing.
  • Page 268: Rocker Shafts, Rocker Arms

    ENGINE TOP END 5-23 Rocker Shafts, Rocker Arms Rocker Shaft and Rocker Arm Removal • Remove: Rocker Case (see Rocker Case Removal) Rocker Shafts [A] Rocker Arms [B] Rocker Shaft and Rocker Arm Installation • Apply molybdenum disulfide oil solution to the rocker shafts.
  • Page 269: Rocker Arm Inspection

    5-24 ENGINE TOP END Rocker Shafts, Rocker Arms Rocker Arm Inspection • Remove the rocker arm (see Rocker Shaft and Rocker Arm Removal). • Inspect the area [A] on the rocker arm where the cam rubs. If the rocker arm is scored, discolored or otherwise dam- aged, replace it.
  • Page 270: Hla (hydraulic Lash Adjuster)

    ENGINE TOP END 5-25 HLA (Hydraulic Lash Adjuster) HLA Removal • Remove the rocker arm (see Rocker Shaft and Rocker Arm Removal). • Pull the HLA (Hydraulic Lash Adjuster) [A] out of the rocker arm with fingers. NOTICE Be careful not to damage or deform an HLA by tap- ping it during removal or installation.
  • Page 271: Camshaft Chain Tensioners

    5-26 ENGINE TOP END Camshaft Chain Tensioners Camshaft Chain Tensioner Removal NOTICE Do not turn over the crankshaft while the tensioner is removed. This could upset the camshaft chain timing, and damage the valves. Front Camshaft Chain Tensioner • Remove the alternator rotor (see Alternator Rotor Re- moval in the Electrical System chapter).
  • Page 272: Camshaft Chain Tensioner Installation

    ENGINE TOP END 5-27 Camshaft Chain Tensioners Camshaft Chain Tensioner Installation If the pin was removed, install it as follows. ○ Push the push rod [A] into the interior of tensioner body [B] while pushing the stopper [C]. NOTICE Be careful the oil remaining in the tensioner body dashes out.
  • Page 273: Camshafts, Camshaft Chains, Camshaft Sprockets

    5-28 ENGINE TOP END Camshafts, Camshaft Chains, Camshaft Sprockets Camshaft Removal NOTE ○ The front and rear camshaft removal are same proce- dures. • Remove: Engine (see Engine Removal in the Engine Removal/In- stallation chapter) Rocker Case (see Rocker Case Removal) •...
  • Page 274 ENGINE TOP END 5-29 Camshafts, Camshaft Chains, Camshaft Sprockets If the rear camshaft chain guide [A] was removed, be sure to install it first. Torque - Rear Camshaft Chain Guide Retainer Bolt : 9.8 N·m (1.0 kgf·m, 87 in·lb) Left Side View [B] ○...
  • Page 275: Camshaft, Rocker Case Wear

    5-30 ENGINE TOP END Camshafts, Camshaft Chains, Camshaft Sprockets Camshaft, Rocker Case Wear • Remove the rocker cases (see Rocker Case Removal). • Cut strips of plastigage to journal width. Place a strip on each journal parallel to the camshaft installed in the correct position.
  • Page 276: Cam Wear

    ENGINE TOP END 5-31 Camshafts, Camshaft Chains, Camshaft Sprockets Cam Wear • Remove the camshaft (see Camshaft Removal). • Measure the height [A] of each cam with a micrometer. If the cams are worn down past the service limit, replace the camshaft.
  • Page 277: Camshaft Sprocket Installation

    5-32 ENGINE TOP END Camshafts, Camshaft Chains, Camshaft Sprockets Camshaft Sprocket Installation • Install the camshaft sprockets as shown in the figure. Exhaust Cam Positions [A] Push Rods of KACR [B] Front Camshaft Sprocket [C] Rear Camshaft Sprocket [D] ○ The front and rear camshaft sprockets are identical.
  • Page 278: Kacr (kawasaki Automatic Compression Release)

    ENGINE TOP END 5-33 KACR (Kawasaki Automatic Compression Release) KACR Inspection The KACR (Kawasaki Automatic Compression Release) momentarily opens the exhaust valves on the compression stroke at very low speeds. In this model, the KACR is oper- ated at 400 ∼ 500 r/min (rpm). This allows some of the com- pression pressure to escape, making it easy to turn over the engine during starting.
  • Page 279: Kacr Installation

    5-34 ENGINE TOP END KACR (Kawasaki Automatic Compression Release) • Insert the suitable wire [A] into the hole of the push rod [B] to hold it in place. • Pull out the shaft [A] from the camshaft, and then remove the push rod [B].
  • Page 280 ENGINE TOP END 5-35 KACR (Kawasaki Automatic Compression Release) • Install the push rod [A], and then insert the shaft [B] to the camshaft. • Pull out the wire [C] from the hole of the push rod. • For front KACR, set the shaft so that the “F” mark [A] is aligned with the “...
  • Page 281 5-36 ENGINE TOP END KACR (Kawasaki Automatic Compression Release) ○ Next, release the hand from the weights [A], and check that the weights and push rod [B] are returned to original position. ○ When releasing the hand from the weights, the push rod must be pushed out [C].
  • Page 282: Cylinder Heads

    ENGINE TOP END 5-37 Cylinder Heads Cylinder Compression Measurement NOTE ○ Use the battery which is fully charged. • Warm up the engine thoroughly. • Stop the engine. • Remove spark plugs (see Spark Plug Replacement in the Periodic Maintenance chapter). •...
  • Page 283: Cylinder Head Removal

    5-38 ENGINE TOP END Cylinder Heads Cylinder Head Removal NOTE ○ The front and rear cylinder head removal are same pro- cedures. • Remove: Camshaft (see Camshaft Removal) Front Camshaft Chain Guide [A] Rear Camshaft Chain Guide Retainer Bolt [B] with Re- tainer [C] Rear Camshaft Chain Guide [D] •...
  • Page 284 ENGINE TOP END 5-39 Cylinder Heads NOTE ○ The front cylinder head gasket has a “F” mark [A] and the rear cylinder head gasket has a “R” mark [B]. Be careful not to mix up these gaskets. • Replace the cylinder head gasket with a new one, and install it.
  • Page 285 5-40 ENGINE TOP END Cylinder Heads • Apply molybdenum disulfide oil solution to the following portions. Threads of M10 Cylinder Head Nuts [A] Threads of M12 Cylinder Head Nuts [B] Both Sides of Washers [C] • Tighten the cylinder head nuts using the following steps. ○...
  • Page 286: Cylinder Head Warp

    ENGINE TOP END 5-41 Cylinder Heads Cylinder Head Warp • Clean the cylinder head. • Lay a straightedge across the lower surface of the cylinder head at several positions. • Use a thickness gauge [A] to measure the space between the straightedge [B] and the head.
  • Page 287: Valves

    5-42 ENGINE TOP END Valves Valve Clearance Inspection/Adjustment NOTE ○ Since the HLA (hydraulic lash adjuster) constantly maintain zero clearance, it is not necessary to inspect or adjust the valve clearance. Valve Removal • Remove the cylinder head (see Cylinder Head Removal). •...
  • Page 288: Valve Guide Installation

    ENGINE TOP END 5-43 Valves Valve Guide Installation • Apply oil to the valve guide outer surface before installa- tion. • Heat the area around the valve guide hole to about 120 ∼ 150°C (248 ∼ 302°F). NOTICE Do not heat the cylinder head with a torch. This will warp the cylinder head.
  • Page 289: Valve Seat Inspection

    5-44 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 290 ENGINE TOP END 5-45 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 291 5-46 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 292 ENGINE TOP END 5-47 Valves If the seat width is too wide, make the 60° or 55° [A] grind described 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°...
  • Page 293 5-48 ENGINE TOP END Valves...
  • Page 294: Cylinders, Pistons

    ENGINE TOP END 5-49 Cylinders, Pistons Cylinder Removal NOTE ○ The front and rear cylinder removal are same proce- dures. • Remove: Cylinder Head (see Cylinder Head Removal) Upper Oil Pipe [A] Cylinder [B] Cylinder Installation NOTE ○ If a new cylinder is used, use new piston ring. ○...
  • Page 295: Piston Removal

    5-50 ENGINE TOP END Cylinders, Pistons • Apply molybdenum disulfide oil solution to the cylinder bore, piston rings and piston skirt. • Using the piston ring compressor assembly [A] with the chamfered side [B] upward, install the cylinder block. For Front Cylinder [C] For Rear Cylinder [D] Special Tools - Piston Ring Compressor Grip : 57001-1095 Piston Ring Compressor Belt, 95 ∼...
  • Page 296: Piston Installation

    ENGINE TOP END 5-51 Cylinders, Pistons • Carefully spread the ring opening with your thumbs and then push up on the opposite side of the ring [A] to remove • Remove the 3-piece oil ring with your thumbs in the same manner.
  • Page 297: Cylinder Wear

    5-52 ENGINE TOP END Cylinders, Pistons • Fit a new piston pin snap ring into the side of the piston so that the ring opening [A] does not coincide with the slit [B] of the piston pin hole. ○ Apply molybdenum disulfide oil solution to the piston pin and piston skirt.
  • Page 298: Piston Ring, Piston Ring Groove Wear

    ENGINE TOP END 5-53 Cylinders, 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 299: Piston Ring End Gap

    5-54 ENGINE TOP END Cylinders, 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 300: Mufflers

    ENGINE TOP END 5-55 Mufflers WARNING The muffler can become extremely hot during nor- mal operation and cause severe burns. Do not re- move the muffler while it is hot. Muffler Body Removal Left Muffler Body • Loosen the muffler body clamp bolt [A]. •...
  • Page 301: Muffler Body Installation

    5-56 ENGINE TOP END Mufflers • Remove: Right Saddlebag (see Saddlebag Removal in the Frame chapter) Muffler Body Mounting Bolts [A] • Pull out the right muffler body [B] backward from the ex- haust pipe. Muffler Body Installation If the left muffler body cover [A] was removed, install it as follows.
  • Page 302: Exhaust Pipe Removal

    ENGINE TOP END 5-57 Mufflers ○ For equipped with the oxygen sensor, run the oxygen sen- sor lead correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). NOTICE Do not pull strongly, twist, or bend the oxygen sen- sor lead.
  • Page 303 5-58 ENGINE TOP END Mufflers • Loosen the middle exhaust pipe cover clamp bolts [A] • Slide the clamp [B] of the rear side backward [C]. • Slide the clamp [D] of the front side forward [E], and re- move the middle exhaust pipe cover [F]. •...
  • Page 304 ENGINE TOP END 5-59 Mufflers Dummy Page...
  • Page 305: Exhaust Pipe Installation

    5-60 ENGINE TOP END Mufflers Exhaust Pipe Installation • Replace the exhaust pipe gaskets [A] with new ones. • Install the exhaust pipe holders [B] so that the “up” mark faces upper side. • Tighten: Torque - Exhaust Pipe Holder Nuts [C] : 17 N·m (1.7 kgf·m, 12 ft·lb) •...
  • Page 306 ENGINE TOP END 5-61 Mufflers • Install the left and right muffler bodies (see Muffler Body Installation). • Thoroughly warm up the engine, wait until the engine cools down, retighten all the bolts and nuts.
  • Page 307 5-62 ENGINE TOP END Mufflers (VN1700CAF/DAF Models) If the insulators [A] of the exhaust covers were removed, install them as follows. ○ Clean off any oil on the exhaust cover to install the insu- lator securely. ○ Install the insulator on the corner [B] of the stay. Front Exhaust Cover [C] Rear Exhaust Cover [D] About 5 mm (0.2 in) [E]...
  • Page 308 CLUTCH 6-1 Clutch Table of Contents Exploded View........................Specifications ......................... Special Tools .......................... Clutch Fluid..........................Clutch Fluid Level Inspection .................... Clutch Fluid Change ......................Clutch Line Bleeding ......................Clutch Hose Removal/Installation ..................Clutch Hose Inspection ..................... Clutch Master Cylinder ......................Clutch Lever Adjustment....................
  • Page 309: Exploded View

    6-2 CLUTCH Exploded View...
  • Page 310 CLUTCH 6-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Cam Damper Bolt Clutch Cover Bolts 106 in·lb Clutch Hose Banjo Bolt Clutch Hub Nut 19.0 MO, R Clutch Lever Pivot Bolt 0.10 8.8 in·lb Clutch Lever Pivot Bolt Locknut 0.60 52 in·lb Clutch Master Cylinder Clamp Bolts...
  • Page 311: Specifications

    6-4 CLUTCH Specifications Item Standard Service Limit Clutch Fluid Grade DOT4 – – – Clutch Lever – – – Clutch Lever Position 8-way adjustable (to suit Rider) Clutch Lever Free Play Non-adjustable – – – Clutch 3.30 ∼ 3.50 mm (0.130 ∼ 0.138 in.) Friction Plate Thickness 3.0 mm (0.12 in.) Friction Plate Warp...
  • Page 312: Special Tools

    CLUTCH 6-5 Special Tools Bearing Driver Set: Grip: 57001-1129 57001-1591 Clutch Holder: Rotor Holder: 57001-1243 57001-1726...
  • Page 313: Clutch Fluid

    6-6 CLUTCH Clutch Fluid Clutch Fluid Level Inspection • Refer to the Clutch Fluid Level Inspection in the Periodic Maintenance chapter. Clutch Fluid Change • Refer to the Clutch Fluid Change in the Periodic Mainte- nance chapter. Clutch Line Bleeding •...
  • Page 314: Clutch Hose Inspection

    CLUTCH 6-7 Clutch Fluid Clutch Hose Inspection • Refer to the Clutch Hose and Pipe Damage and Instal- lation Condition Inspection in the Periodic Maintenance chapter.
  • Page 315: Clutch Master Cylinder

    6-8 CLUTCH Clutch Master Cylinder Clutch Lever Adjustment The adjuster has 8 positions so that the clutch lever posi- tion can be adjusted to suit the operator’s hand. • Push the lever forward and turn the adjuster [A]. Clutch Master Cylinder Removal •...
  • Page 316: Clutch Master Cylinder Inspection

    CLUTCH 6-9 Clutch Master Cylinder Clutch Master Cylinder Inspection • Disassemble the clutch master cylinder (see Clutch Mas- ter Cylinder Rubber Parts Replacement in the Periodic Maintenance chapter). NOTICE Do not remove the secondary cup from the piston since removal will damage it. •...
  • Page 317: Clutch Slave Cylinder

    6-10 CLUTCH Clutch Slave Cylinder Clutch Slave Cylinder Removal • Remove: Engine Pulley Outer Cover (see Engine Pulley Outer Cover Removal in the Final Drive chapter) Banjo Bolt [A] Clutch Slave Cylinder Bolts [B] Slave Cylinder [C] NOTICE Immediately wash away any clutch fluid that spills. •...
  • Page 318: Clutch Slave Cylinder Disassembly/assembly

    CLUTCH 6-11 Clutch Slave Cylinder • Apply a non-permanent locking agent to the threads of the slave cylinder bolts [A]. • Hand-tighten all the clutch slave cylinder bolts evenly. • Remove the band from the clutch lever and release the clutch lever.
  • Page 319: Clutch Cover Removal

    6-12 CLUTCH Clutch Clutch Cover Removal • Drain the engine oil (see Engine Oil Change in the Peri- odic Maintenance chapter). • Remove the exhaust pipe (see Exhaust Pipe Removal in the Engine Top End chapter) • Unscrew the clutch cover bolts (19) [A] Clutch Cover Installation •...
  • Page 320: Clutch Outer Covers Installation

    CLUTCH 6-13 Clutch Clutch Outer Covers Installation • Install the front and rear outer clutch covers. • When installing the rear outer clutch cover [A], set the round mark [B] downward. • Apply a non-permanent locking agent to the threads of the front and rear outer clutch cover bolts, and tighten them.
  • Page 321 6-14 CLUTCH Clutch • Remove: Primary Chain Guide Bolts [A] Primary Chain Guides [B] • Hold the clutch hub [A] steady with the clutch holder [B], and remove the clutch hub nut [C]. Special Tool - Clutch Holder: 57001-1243 • Remove: Spring Washer Washer...
  • Page 322: Clutch Installation

    CLUTCH 6-15 Clutch • Pull out the following parts as a set. Primary Chain [A] Clutch Housing [B] Starter Clutch Gear [C] Damper Cam Sprocket [D] Torque Limiter [E] • Remove the collar [A] and spacer [B] from the input shaft. •...
  • Page 323 6-16 CLUTCH Clutch • Install the spacer [A] to the input shaft so that the stepped side [B] faces inward. • Install the starter clutch gear [A] and collar [B]. ○ Apply molybdenum disulfide oil [C] to the starter clutch gear and collar.
  • Page 324 CLUTCH 6-17 Clutch • Insert the needle bearing [A] to the input shaft while turn- ing counterclockwise [B] the clutch housing. • Install the cam damper [A] while fitting the alignment notch [B] of the splines onto the alignment tooth [C]. •...
  • Page 325 6-18 CLUTCH Clutch • Install the washer [A] and spring washer [B] so that the “OUTSIDE” mark [C] faces outward. • Replace the clutch hub nut with a new one. • Apply molybdenum disulfide oil to seating surface of the hub nut.
  • Page 326 CLUTCH 6-19 Clutch • Install the thrust bearing [A] and washer [B] to the push rod [C]. • Install: Spring Plate [D] Clutch Springs [E] Spring Holders [F] Clutch Spring Bolts [G] Torque - Clutch Spring Bolts: 12 N·m (1.2 kgf·m, 106 in·lb) VN1700C9F [H] VN1700CAF/DAF [I]...
  • Page 327: Clutch Plate, Wear, Damage Inspection

    6-20 CLUTCH Clutch Clutch Plate, Wear, Damage Inspection • Visually inspect the friction and steel plates for signs of seizure, overheating (discoloration), or uneven wear. If any plates show signs of damage, replace the plates. • Measure the thickness of the friction plates [A] at several points.
  • Page 328: Clutch Housing Finger Inspection

    CLUTCH 6-21 Clutch Clutch Housing Finger Inspection • Visually inspect the fingers [A] of the clutch housing where the tangs [B] of the friction plates hit them. If they are badly worn or if there are groove cuts where the tangs hit, replace the housing.
  • Page 330 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 Screen..........................7-10 Oil Screen Removal ......................
  • Page 331: Exploded View

    7-2 ENGINE LUBRICATION SYSTEM Exploded View...
  • Page 332 ENGINE LUBRICATION SYSTEM 7-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Breather Check Valve Cover Bolts 87 in·lb Engine Oil Drain Bolts Inside Oil Pipe Retainer Bolt 87 in·lb Oil Filter Oil Filter Pipe Oil Passage Plug (PT1/8) Oil Pressure Relief Valve Oil Pressure Switch Oil Pressure Switch Terminal Bolt Hand-tighten...
  • Page 333: Engine Oil Flow Chart

    7-4 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart...
  • Page 334 ENGINE LUBRICATION SYSTEM 7-5 Engine Oil Flow Chart 1. Camshaft Chain Tensioner 2. Balancer Chain Tensioner 3. Alternator Rotor Bolt (For Cooling Stator Coil) 4. Crankshaft 5. Piston Oil Jet 6. Drive Shaft 7. Output Shaft 8. Oil Screen for Scavenge Pump 9.
  • Page 335: Specifications

    7-6 ENGINE LUBRICATION SYSTEM Specifications Item Standard Engine Oil Grade API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2 Viscosity SAE 10W-40 Capacity 4.1 L (4.3 US qt) (when filter is not removed) 4.3 L (4.5 US qt) (when filter is removed) 5.0 L (5.3 US qt) (when engine is completely disassembled and dry) Between upper and lower level lines (wait 3 minutes or more after Level...
  • Page 336: Special Tools And Sealant

    ENGINE LUBRICATION SYSTEM 7-7 Special Tools and Sealant Outside Circlip Pliers: Oil Pressure Gauge Adapter, PT1/8: 57001-144 57001-1731 Oil Pressure Gauge, 10 kgf/cm²: Liquid Gasket, TB1211: 57001-164 56019-120 Gear Holder: 57001-1602...
  • Page 337: Engine Oil And Oil Filter

    7-8 ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter Because of the semi-dry sump lubrication system, the en- gine oil level indicated on the dipstick will fluctuate depend- ing on the motorcycle’s position and engine speed when the engine is shut off. To ensure a proper reading of the engine oil level, follow the Oil Level Inspection procedures closely.
  • Page 338: Engine Oil Change

    ENGINE LUBRICATION SYSTEM 7-9 Engine Oil and Oil Filter NOTICE Racing the engine before the oil reaches every part can cause engine seizure. If the engine oil gets extremely low or if the oil pump or oil passages clog up or otherwise do not func- tion properly, the warning indicator light (LED) [A] and oil pressure warning symbol [B] will light.
  • Page 339: Oil Screen

    7-10 ENGINE LUBRICATION SYSTEM Oil Screen Oil Screen Removal Oil Screen for Scavenge Pump • Drain the engine oil (see Engine Oil Change in the Peri- odic Maintenance chapter). • For VN1700C9F model, remove the alternator cover (see Alternator Cover Removal in the Electrical System chap- ter).
  • Page 340: Oil Screen Installation

    ENGINE LUBRICATION SYSTEM 7-11 Oil Screen Oil Screen Installation NOTE ○ Clean the oil screen thoroughly whenever it is removed for any reason. ○ While cleaning the screen, check for any metal particles that might indicate internal engine damage. • Clean the oil screen with a high-flash point solvent and remove any particles stuck to them.
  • Page 341: Oil Pressure Relief Valve

    7-12 ENGINE LUBRICATION SYSTEM Oil Pressure Relief Valve Oil Pressure Relief Valve Removal • Split the crankcase (see Crankcase Splitting in the Crank- shaft/Transmission chapter). • Remove the oil pressure relief valve [A] from the right crankcase half. Oil Pressure Relief Valve Installation •...
  • Page 342: Oil Pump

    ENGINE LUBRICATION SYSTEM 7-13 Oil Pump Oil Pump Gear Removal • Remove: Clutch (see Clutch Removal in the Clutch chapter) Circlip [A] Oil Pump Gear [B] Special Tool - Outside Circlip Pliers: 57001-144 Oil Pump Gear Installation • Check that the pin [A] is in place. •...
  • Page 343: Oil Pump Removal

    7-14 ENGINE LUBRICATION SYSTEM Oil Pump • Apply molybdenum disulfide oil solution to the threads and seating surface of the oil pump drive gear bolt [A]. • Using the gear holder [B], secure the oil pump drive gear [C]. Special Tool - Gear Holder : 57001-1602 •...
  • Page 344: Oil Pump Installation

    ENGINE LUBRICATION SYSTEM 7-15 Oil Pump • Remove: Pin [A] Inner Rotor [B] for Feed Pump Outer Rotor [C] for Feed Pump • Remove: Pin [A] Inner Rotor [B] for Scavenge Pump Oil Pump Shaft [C] Oil Pump Installation • Apply molybdenum disulfide oil solution to the portion [A] of the oil pump shaft as shown.
  • Page 345 7-16 ENGINE LUBRICATION SYSTEM Oil Pump • Install the dowel pin [A]. • Fit the dowel pin into the hole [B] on the oil pump cover [C]. • Tighten: Torque - Oil Pump Cover Bolts: 12 N·m (1.2 kgf·m, 106 in·lb) •...
  • Page 346: Oil Pressure Measurement

    ENGINE LUBRICATION SYSTEM 7-17 Oil Pressure Measurement Oil Pressure Measurement • Remove the oil passage plug (PT1/8) [A] from the bottom of the right crankcase. • 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, PT1/8: 57001 -1731 •...
  • Page 347: Oil Pressure Switch

    7-18 ENGINE LUBRICATION SYSTEM Oil Pressure Switch Oil Pressure Switch Removal • Drain the engine oil (see Engine Oil Change in the Peri- odic Maintenance chapter). • Remove: Front Footboard Right (see Front Footboard Re- moval/Installation in the Frame chapter) Front Exhaust Pipe Cover (see Exhaust Pipe Removal in the Engine Top End chapter) •...
  • Page 348: Oil Pipes

    ENGINE LUBRICATION SYSTEM 7-19 Oil Pipes Oil Pipe Removal Outside Oil Pipe • Remove: Clutch (see Clutch Removal in the Clutch chapter) Outside Oil Pipe Bolt [A] Torque Limiter Bearing Retainer Bolt [B] Torque Limiter Bearing Retainer [C] Washer [D] •...
  • Page 349: Oil Pipe Installation

    7-20 ENGINE LUBRICATION SYSTEM Oil Pipes Oil Pipe Installation • Refer to the Cylinder Installation in the Crankshaft/Trans- mission chapter for upper oil pipe installation procedures. • Replace the O-rings [A] with new ones. • Apply grease to the O-rings. Outside Oil Pipe [B] Inside Oil Pipe [C] Outside Oil Pipe...
  • Page 350: Blowby Gas System

    ENGINE LUBRICATION SYSTEM 7-21 Blowby Gas System Blowby Gas System Inspection • Remove the fuel tank (see Fuel Tank Removal in the Fuel System (DFI) chapter). • Be certain that the breather hose [A] is routed without being flattened or kinked, and is connected correctly to left air cleaner housing.
  • Page 351: Breather Drain Cleaning

    7-22 ENGINE LUBRICATION SYSTEM Blowby Gas System • Replace the O-ring [A] with a new one. • Apply grease to the new O-ring, install it. • Install: Valve Seat [A] Breather Check Valve [B] • Replace the breather check valve cover gasket with a new one.
  • Page 352 ENGINE REMOVAL/INSTALLATION 8-1 Engine Removal/Installation Table of Contents Exploded View........................Special Tools .......................... Engine Removal/Installation ....................Engine Removal........................ Engine Installation......................
  • Page 353: Exploded View

    8-2 ENGINE REMOVAL/INSTALLATION Exploded View...
  • Page 354 ENGINE REMOVAL/INSTALLATION 8-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Cross Pipe Bolts Downtube Bolts Engine Mounting Adjusting Bolt 87 in·lb Engine Mounting Adjusting Bolt Locknut Engine Mounting Bolt (M10) Engine Mounting Bracket Bolts (M6) 87 in·lb Engine Mounting Bracket Bolts (M8) Engine Mounting Bracket Bolts (M10) Engine Mounting Bracket Nuts (M10) Engine Mounting Nut (M10)
  • Page 355: Special Tools

    8-4 ENGINE REMOVAL/INSTALLATION Special Tools Jack: Socket Wrench: 57001-1238 57001-1347...
  • Page 356: Engine Removal/installation

    ENGINE REMOVAL/INSTALLATION 8-5 Engine Removal/Installation Engine Removal • Raise the rear wheel off the ground using the jack. Special Tool - Jack: 57001-1238 • Squeeze the brake lever slowly, and hold it with a band [A]. WARNING Motorcycle may fall over unexpectedly resulting in an accident or injury.
  • Page 357 8-6 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Remove: Vacuum Hose [A] Vacuum Hoses [B] (CAL and SEA Models) • Disconnect the injector connectors [C]. • Disconnect the throttle body connectors [A]. • Disconnect: Crankshaft Sensor Lead Connector [A] Alternator Lead Connectors [B] •...
  • Page 358: Engine Mounting Bolt (m10)

    ENGINE REMOVAL/INSTALLATION 8-7 Engine Removal/Installation • Remove the sidestand switch lead connector [A] from the brake hose clamp [B]. • Remove the starter motor cable [A]. • Open the clamp [B], and free the leads. • Disconnect: Speed Sensor Connector [C] Gear Position Switch Lead Connector [D] •...
  • Page 359: Engine Mounting Bracket Bolts (m6)

    8-8 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Remove the engine mounting bolt and nut (M12) [A]. • Using the socket wrench [A], loosen the engine mounting adjusting bolt locknut [B]. Special Tool - Socket Wrench: 57001-1347 • Using the Hexagon Wrench, turn the engine mounting ad- justing bolt [A] counterclockwise to make the gap between the engine and adjusting bolt.
  • Page 360: Engine Installation

    ENGINE REMOVAL/INSTALLATION 8-9 Engine Removal/Installation • Remove the downtube (see Downtube Removal in the Frame chapter). • Remove the drive belt [A] from the output shaft [B]. • Remove the engine [A] from the motorcycle right side. Engine Installation • Support the engine with a suitable stand.
  • Page 361 8-10 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation ○ Seventh, tighten the engine mounting nut (M12) (lower) [J]. Torque - Engine Mounting Nut (M12): 59 N·m (6.0 kgf·m, 43 ft·lb) ○ Eighth, tighten the engine mounting bracket bolts [C] again to the specified torque. Torque - Engine Mounting Bracket Bolts (M8): 25 N·m (2.5 kgf·m, 18 ft·lb) ○...
  • Page 362 ENGINE REMOVAL/INSTALLATION 8-11 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. • Adjust: Throttle Cables (see Throttle Control System Inspection in the Periodic Maintenance chapter) Drive Belt (see Belt Deflection inspection in the Periodic Maintenance chapter) •...
  • Page 364 CRANKSHAFT/TRANSMISSION 9-1 Crankshaft/Transmission Table of Contents Exploded View........Torque Limiter........9-30 Specifications ........Torque Limiter Removal ....9-30 Special Tools and Sealants ....Torque Limiter Installation .... 9-30 Crankcase ......... Torque Limiter Inspection..... 9-30 Crankcase Splitting ...... Transmission ........9-31 Crankcase Assembly ....
  • Page 365: Exploded View

    9-2 CRANKSHAFT/TRANSMISSION Exploded View...
  • Page 366 CRANKSHAFT/TRANSMISSION 9-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Balancer Chain Tensioner Bolts 106 in·lb Balancer Sprocket Bolts Ball Bearing Retainer Bolts 87 in·lb Ball Bearing Retainer Screws 61 in·lb Connecting Rod Big End Bolts Crankcase Bolts (M10) Crankcase Bolts (M6) 106 in·lb Engine Pulley Plate Bolts 106 in·lb...
  • Page 367 9-4 CRANKSHAFT/TRANSMISSION Exploded View...
  • Page 368 CRANKSHAFT/TRANSMISSION 9-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb External Shift Mechanism Cover Bolts (L = 50 mm) 106 in·lb External Shift Mechanism Cover Bolts (L = 22 mm) 106 in·lb Gear Positioning Lever Nut 0.80 69 in·lb Shift Drum Bearing Retainer Bolts 87 in·lb Shift Drum Cam Bolt 106 in·lb...
  • Page 369: Specifications

    9-6 CRANKSHAFT/TRANSMISSION Specifications Item Standard Service Limit Crankcase, Crankshaft and 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.) 0.08 ∼ 0.30 mm (0.003 ∼ 0.012 in.) Connecting Rod Big End Side 0.5 mm Clearance...
  • Page 370 CRANKSHAFT/TRANSMISSION 9-7 Specifications Connecting Rod Big End Bearing Insert Selection Con-rod Big End Bearing Insert Crankpin Diameter Inside Diameter Marking Size Color Part Number Marking ○ None Brown 92139-0227 None None Black 92139-0226 ○ ○ ○ None Blue 92139-0225...
  • Page 371: Special Tools And Sealants

    9-8 CRANKSHAFT/TRANSMISSION Special Tools and Sealants Outside Circlip Pliers: Rotor Holder: 57001-144 57001-1726 Bearing Driver Set: Liquid Gasket, TB1211F: 57001-1129 92104-0004 Grip: Liquid Gasket, TB1216B: 57001-1591 92104-1064...
  • Page 372: Crankcase

    CRANKSHAFT/TRANSMISSION 9-9 Crankcase 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: Clutch (see Clutch Removal in the Clutch chapter) Balancer Mechanism (see Balancer Mechanism Re- moval) Cylinders (see Cylinder Removal in the Engine Top End...
  • Page 373 9-10 CRANKSHAFT/TRANSMISSION Crankcase • Remove the left crankcase bolts (11) [A]. • Remove the right crankcase bolts, following the specified sequence. ○ First, loosen the M6 bolts (9) [A]. ○ Next, loosen the M10 bolts (3) [B]. • Put the engine so that the right crankcase half [A] faces upside.
  • Page 374: Crankcase Assembly

    CRANKSHAFT/TRANSMISSION 9-11 Crankcase • Using the pry points, split the crankcase halves. Pry Point (Front) [A] Pry Points (Rear) [B] If the crankcase does not split easily, tap the crankcase mating surface lightly with a plastic mallet. ○ Take care not to damage the crankcase. •...
  • Page 375 9-12 CRANKSHAFT/TRANSMISSION Crankcase If the piston oil jet [A] was removed, install it as follows. ○ Replace the O-ring [B] with a new one. ○ Insert the piston oil jet [A] into the hole on the crankcase [B] as shown in the figure. ○...
  • Page 376 CRANKSHAFT/TRANSMISSION 9-13 Crankcase • Apply liquid gasket [A] to the mating surface of the lower crankcase half. Sealant - Liquid Gasket, TB1216B: 92104-1064 NOTE ○ Especially, apply a sealant so that it shall be filled up on the grooves [B]. NOTICE Do not apply liquid gasket around the oil passage hole [C].
  • Page 377 9-14 CRANKSHAFT/TRANSMISSION Crankcase NOTE ○ Be sure to tighten the right crankcase bolts first. • Tighten the right crankcase bolts using the following steps. ○ First, tighten the M10 bolts (3) [A]. Torque - Crankcase Bolts (M10) : 39 N·m (4.0 kgf·m, 29 ft·lb) ○...
  • Page 378 CRANKSHAFT/TRANSMISSION 9-15 Crankcase • Apply grease to the new O-ring [A] and install it on the output shaft as shown in the figure. • Apply grease to oil seal lip. • Install the collar [B] so that the stepped side [C] faces inward.
  • Page 379: Crankshaft And Connecting Rods

    9-16 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods Crankshaft Removal • Split the crankcase (see Crankcase Splitting). • Turn the balancer shafts [A] to clear the balancers [B] from the crankshaft web [C]. • Remove the crankshaft. Crankshaft Installation • Apply molybdenum disulfide oil solution onto the crank- shaft main journal [A] on both sides.
  • Page 380: Connecting Rod Installation

    CRANKSHAFT/TRANSMISSION 9-17 Crankshaft and Connecting Rods Connecting Rod Installation NOTICE To minimize vibration, the connecting rods should have the same weight mark. Big End Cap [A] Connecting Rod [B] “OUT” Mark [C] Weight Mark, Alphabet [D] Diameter Mark [E]: “O” or no mark NOTICE If the connecting rods, big end bearing inserts, or crankshaft are replaced with new ones, select the...
  • Page 381: Crankshaft/connecting Rod Cleaning

    9-18 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods • Be sure the dowel pins [A] on the big end cap [B] are in position. • Install each connecting rod on its original position as fol- lows. ○ Left connecting rod [A] is for the rear cylinder and right connecting rod [B] is for the front cylinder.
  • Page 382: Connecting Rod Twist

    CRANKSHAFT/TRANSMISSION 9-19 Crankshaft and Connecting Rods Connecting Rod Twist • With the big-end arbor [A] still on V block [B], hold the con- necting rod horizontally and measure the amount that the arbor [C] varies from being parallel with the surface plate over a 100 mm (3.94 in.) length of the arbor to determine the amount of connecting rod twist.
  • Page 383 9-20 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods If clearance is within the standard, no bearing replace- ment is required. If clearance is between 0.057 mm (0.0022 in.) and the service limit (0.09 mm, 0.035 in.), replace the bear- ing inserts [A] with inserts painted blue [B]. Check insert/crankpin clearance with the plastigage.
  • Page 384: Crankshaft Side Clearance

    CRANKSHAFT/TRANSMISSION 9-21 Crankshaft and Connecting Rods • Select the proper bearing insert [A] in accordance with the combination of the connecting rod and crankshaft coding. Size Color [B] Connecting Rod Big End Bearing Insert Selection Bearing Insert Con-rod Big End Crankpin Inside Diameter Diameter...
  • Page 385: Crankshaft Main Bearing/main Journal Wear

    9-22 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods Crankshaft Main Bearing/Main Journal Wear • Measure the diameter [A] of the crankshaft main journal. If any journal has worn past the service limit, replace the crankshaft with a new one. Crankshaft Main Journal Diameter 52.986 ∼...
  • Page 386: Balancer

    CRANKSHAFT/TRANSMISSION 9-23 Balancer Balancer Mechanism Removal • Remove the alternator cover (see Alternator Cover Re- moval in the Electrical System chapter). • Loosen the front balancer sprocket bolt [A] and rear bal- ancer sprocket bolt [B] while holding the alternator rotor [C] steady with the rotor holder [D].
  • Page 387: Balancer Mechanism Installation

    9-24 CRANKSHAFT/TRANSMISSION Balancer Balancer Mechanism Installation • Align the line [A] on the following parts with the colored chain links [B] as shown in the figure. Balancer Chain Sprocket [C] Front Balancer Sprocket [D] Rear Balancer Sprocket [E] ○ The front and rear balancer sprockets are identical. •...
  • Page 388 CRANKSHAFT/TRANSMISSION 9-25 Balancer • Engage the first teeth [A] of the ratchet [B] with second groove [C] of the plunger [D]. • Insert the suitable pin [A] into the hole of the tensioner body [B] through the hole of the link plate [C].
  • Page 389 9-26 CRANKSHAFT/TRANSMISSION Balancer • For VN1700C9F model, install the upper balancer chain guide [A]. Torque - Upper Balancer Chain Guide Bolts [B] : 12 N·m (1.2 kgf·m, 106 in·lb) • Install the balancer chain tensioner [C] and lower balancer chain guide [D]. Torque - Balancer Chain Tensioner Bolts [E] : 12 N·m (1.2 kgf·m, 106 in·lb) Lower Balancer Chain Guide Bolts [F] : 12 N·m (1.2...
  • Page 390: Balancer Shaft Removal

    CRANKSHAFT/TRANSMISSION 9-27 Balancer Balancer Shaft Removal NOTE ○ The front and rear balancer shafts are same proce- dures. • Split the crankcase (see Crankcase Splitting). • Turn the balancer shaft [A] to clear the balancer [B] from the crankshaft web [C]. Front Balancer Shaft [D] Rear Balancer Shaft [E] •...
  • Page 391: Starter Clutch

    9-28 CRANKSHAFT/TRANSMISSION Starter Clutch Starter Clutch Removal • Refer to the Clutch Removal in the Clutch chapter. Starter Clutch Installation • Refer to the Clutch Installation in the Clutch chapter. Starter Clutch Disassembly • Remove the clutch housing (see Clutch Removal in the Clutch chapter).
  • Page 392 CRANKSHAFT/TRANSMISSION 9-29 Starter Clutch ○ Examine the starter clutch gear [A] as well. Replace the clutch gear if it is worn or damaged.
  • Page 393: Torque Limiter

    9-30 CRANKSHAFT/TRANSMISSION Torque Limiter Torque Limiter Removal • Refer to the Clutch Removal in the Clutch chapter. NOTICE Do not disassemble the torque limiter [A]. The torque limiter will not function if this is done. Torque Limiter Installation • Refer to the Clutch Installation in the Clutch chapter. Torque Limiter Inspection •...
  • Page 394: Transmission

    CRANKSHAFT/TRANSMISSION 9-31 Transmission Transmission Shaft and Shift Fork Removal • Split the crankcase (see Crankcase Splitting). • Remove: Speed Sensor (see Speed Sensor Removal in the Elec- trical System chapter) Shift Rods [A] Shift Forks [B] • Take out the drive shaft [A] and output shaft [B] as a set. Transmission Shaft and Shift Fork Removal •...
  • Page 395: Transmission Shaft Assembly

    9-32 CRANKSHAFT/TRANSMISSION Transmission Transmission Shaft Assembly • When assembling the transmission shafts, refer to the transmission assembly illustration on ahead too. • Apply engine oil to the bushings and shafts. • Replace any circlips removed with new ones. • Install the circlips [A] so that opening [B] of it is aligned with a spline groove [C].
  • Page 396 CRANKSHAFT/TRANSMISSION 9-33 Transmission 1. Drive Shaft 11. Thrust Washers, Inside Diameter 25.3 mm (1.00 in.) 2. 1st Gear 3. 5th gear 12. Needle Bearing 13. Circlip, Outside Diameter 27.9 mm (1.10 in.) 4. Thrust Washer, Inside Diameter 30.3 mm (1.19 in.) 14.
  • Page 397: Shift Drum Removal

    9-34 CRANKSHAFT/TRANSMISSION Transmission Shift Drum Removal • Split the crankcase (see Crankcase Splitting). • Remove: Shift Forks (see Transmission Shaft and Shift Fork Re- moval) Pin [A] and Spring [B] Shift Drum Bearing Retainer Bolts [C] • Pull out the shift drum [D] while aligning the shift drum cam with the left crankcase hole.
  • Page 398: Shift Drum Assembly

    CRANKSHAFT/TRANSMISSION 9-35 Transmission Shift Drum Assembly If the new pins [A] are installed on the shift drum cam [B], note the following. ○ Install the new pins so that the longest pin [C] is positioned as shown in the figure. Cutout Portion [D] of Shift Drum Cam •...
  • Page 399: Shift Fork Bending

    9-36 CRANKSHAFT/TRANSMISSION Transmission Shift Fork Bending • Visually inspect the shift forks, and replace any fork that is bent. A bent fork could cause difficulty in shifting, or allow the transmission to jump out of gear when under power. 90° [A] Shift Fork/Gear Groove Wear •...
  • Page 400: External Shift Mechanism

    CRANKSHAFT/TRANSMISSION 9-37 External Shift Mechanism Shift Pedal Removal • Remove the front footboard left (Front Footboard Re- moval/Installation in the Frame chapter). • Remove: Front Shift Lever Bolt [A] Front Shift Lever [B] Shift Pedal [C] If the tie-rod is removed from the front and rear shift levers, note the following.
  • Page 401 9-38 CRANKSHAFT/TRANSMISSION External Shift Mechanism • After installation, confirm that the shift pedal [A] is posi- tioned as shown in the figure. 30 ∼ 40 mm (1.18 ∼ 1.57 in.) [B] About 1°[C] About 240.0 mm (9.45 in.) [D] About 7°[E] If the pedal position is different, adjust it as follows.
  • Page 402: External Shift Mechanism Removal

    CRANKSHAFT/TRANSMISSION 9-39 External Shift Mechanism • Be sure the sealing lip of the rubber boot [A] fits into the groove of the ball joint after installing the shift pedal. Correctly Boot Fitting Position [B] Incorrectly Boot Fitting Position [C] External Shift Mechanism Removal •...
  • Page 403: External Shift Mechanism Installation

    9-40 CRANKSHAFT/TRANSMISSION External Shift Mechanism • Remove the shift shaft assembly [A]. • Remove: Gear Positioning Lever Nut [A] Gear Positioning Lever [B] Pin [C] and Spring External Shift Mechanism Installation If the shift shaft return spring pin [A] was removed, install it as follows.
  • Page 404 CRANKSHAFT/TRANSMISSION 9-41 External Shift Mechanism If the shift shaft assembly was disassembled, assemble it as follows. ○ Install the following parts on the shift shaft as a set. Upper Lever [A] Washer [B] Spring [C] Lower Lever [D] ○ Push down [E] the above parts while opening [F] the up- per lever.
  • Page 405 9-42 CRANKSHAFT/TRANSMISSION External Shift Mechanism • Be sure to install the spacer [A] on the shift shaft [B]. • Install the shift shaft assembly [A]. • Be sure to install the spacer [B] on the shift shaft. • Install the dowel pins [C]. •...
  • Page 406 CRANKSHAFT/TRANSMISSION 9-43 External Shift Mechanism • Apply silicone sealant to the gear position switch lead grommet [A]. Sealant - Liquid Gasket, TB1211F : 92104-0004 • Replace the external shift mechanism cover gasket with a new one. • Install the external shift mechanism cover [A]. •...
  • Page 407: Ball Bearing, Needle Bearing And Oil Seal

    9-44 CRANKSHAFT/TRANSMISSION Ball Bearing, Needle Bearing and Oil Seal Bearing and Oil Seal Installation Left Crankcase • Refer to the Mechanical Seal Replacement in the Cooling System chapter for mechanical seal, ball bearing and oil seal of the water pump. •...
  • Page 408: Bearing Wear

    CRANKSHAFT/TRANSMISSION 9-45 Ball Bearing, Needle Bearing and Oil Seal Right Crankcase • Before installing the bearing or race, apply small amount of the engine oil to the outer surface of them. • When the following ball bearings or race are installed in the right crankcase half, press and insert them until they are bottomed.
  • Page 409: Oil Seal Inspection

    9-46 CRANKSHAFT/TRANSMISSION Ball Bearing, Needle Bearing and Oil Seal • Check the needle bearings. ○ The rollers in a needle bearing normally wear very little, and wear is difficult to measure. Instead of measuring, inspect the bearing for abrasion, color change, or other damage.
  • Page 410 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 ....................10-7 Rear Wheel Removal......................10-8 Rear Wheel Installation..................... 10-10 Wheel Inspection ......................10-11 Axle Inspection........................
  • Page 411: Exploded View

    10-2 WHEELS/TIRES Exploded View...
  • Page 412 WHEELS/TIRES 10-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Axle 13.0 Front Axle Clamp Bolts Rear Axle Nut 11.0 Rear Air Valve Nuts 0.15 13 in·lb G: Apply grease. HG: Apply high-temperature grease. R: Replacement Parts S: Follow the specified tightening sequence. WL: Apply soap and water solution or rubber lubricant.
  • Page 413: Specifications

    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 (3.94 in.) TIR 0.03 mm (0.001 in.) or less TIR 0.2 mm (0.008 in.) Wheel Balance 10 g (0.35 oz.) or less...
  • Page 414: Special Tools

    WHEELS/TIRES 10-5 Special Tools Inside Circlip Pliers: Bearing Remover Head, 20 × 22: 57001-143 57001-1293 Bearing Driver Set: Bearing Remover Head, 25 × 28: 57001-1129 57001-1346 Jack: Bearing Remover Shaft, 13: 57001-1238 57001-1377...
  • Page 415: Wheels (rims)

    10-6 WHEELS/TIRES Wheels (Rims) Front Wheel Removal • Remove: Front Wheel Rotation Sensor [A] (K-ACT ABS equipped models) Front Caliper Mounting Bolts [B] (Both Sides) Front Calipers (with the hose installed) [C] (Both Sides) • For K-ACT ABS equipped models, remove the sensor bracket bolt [A].
  • Page 416: Front Wheel Installation

    WHEELS/TIRES 10-7 Wheels (Rims) Front Wheel Installation • Apply high-temperature grease to the grease seal lips. • Fit the collars [A] on both sides of the hub. ○ The collars are identical. ○ For K-ACT ABS equipped models, fit the collar [A] to the right side, and fit the collar with the sensor bracket [B] to the left side.
  • Page 417: Rear Wheel Removal

    10-8 WHEELS/TIRES Wheels (Rims) • For K-ACT ABS equipped models, tighten the sensor bracket bolt [A]. • Install: Front Wheel Rotation Sensor [B] (K-ACT ABS equipped models) Front Calipers [C] (see Caliper Installation in the Brakes chapter) • Check the front brake effectiveness. WARNING After servicing, it takes several applications of the brake lever before the brake pads contact the disc,...
  • Page 418 WHEELS/TIRES 10-9 Wheels (Rims) • Squeeze the brake lever slowly and hold it with a band [A]. NOTICE Be sure to hold the front brake when removing the rear wheel, or the motorcycle may fall over. The motorcycle could be damaged. WARNING Motorcycle may fall over unexpectedly resulting in an accident or injury.
  • Page 419: Rear Wheel Installation

    10-10 WHEELS/TIRES Wheels (Rims) Rear Wheel Installation • Apply high-temperature grease to the grease seal lips on both sides of the hub. • Fit the collars [A] on both sides of the hub. ○ Fit the flange collar onto the right side. •...
  • Page 420: Wheel Inspection

    WHEELS/TIRES 10-11 Wheels (Rims) • Bend the cotter pin [A] over the nut . WARNING A loose axle nut can lead to an accident resulting in serious injury or death. Tighten the axle nut to the proper torque and install a new cotter pin. •...
  • Page 421: Axle Inspection

    10-12 WHEELS/TIRES Wheels (Rims) Axle Inspection • Remove the front and rear axles (see Front/Rear Wheel Removal). • Visually inspect the front and rear axles for damages. If the axle is damaged or bent, replace it. • Place the axle in V blocks that are 100 mm (3.94 in.) [A] apart, and set a dial gauge [B] on the axle at a point halfway between the blocks.
  • Page 422: Balance Weight Installation

    30 g (1.06 oz.) NOTE ○ Balance weights are available from Kawasaki dealers in 10, 20 and 30 g (0.35, 0.71 and 1.06 oz.) sizes. An imbalance of less than 10 g (0.35 oz.) will not usually affect running stability.
  • Page 423: Tires

    10-14 WHEELS/TIRES 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: Wheel (see Front/Rear Wheel Removal) Valve Core (Let out the air) •...
  • Page 424 WHEELS/TIRES 10-15 Tires • Install a new valve in the rim. Front ○ 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 425: Tire Repair

    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 426: Hub Bearing

    WHEELS/TIRES 10-17 Hub Bearing Hub Bearings Removal • Remove the wheel, and take out the following. Front Hub [A] Rear Hub [B] Collars Coupling [C] Grease Seals [D] • Use the bearing remover to remove the hub bearings [A]. NOTICE Do not lay the wheel directly on the ground with the disc facing down.
  • Page 427: Hub Bearings Inspection

    10-18 WHEELS/TIRES Hub Bearing ○ Replace the circlips with new ones. Special Tool - Inside Circlip Pliers: 57001-143 • 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. ○...
  • Page 428 FINAL DRIVE 11-1 Final Drive Table of Contents Exploded View........................11-2 Specifications ......................... 11-4 Special Tools .......................... 11-5 Drive Belt ..........................11-6 Belt Handling Precautions....................11-6 Drive Belt Wear Inspection ....................11-7 Drive Belt Deflection Inspection ..................11-7 Drive Belt Deflection Adjustment ..................11-7 Drive Belt Removal ......................
  • Page 429: Exploded View

    11-2 FINAL DRIVE Exploded View...
  • Page 430 FINAL DRIVE 11-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Engine Pulley Mounting Nut 18.0 Engine Pulley Inner Cover Bolts 106 in·lb Engine Pulley Outer Cover Bolts 87 in·lb Rear Axle Nut 11.0 Rear Coupling Stud Bolts Rear Pulley Mounting Nuts Rear Pulley Plate Bolts 0.70 61 in·lb...
  • Page 431: Specifications

    11-4 FINAL DRIVE Specifications Item Standard Drive Belt Make GATES, 139T 3.0 ∼ 4.5 mm (0.12 ∼ 0.18 in.) Belt Deflection (45 N, 4.6 kgf, 10 lb force) (When installing new belt or engine is remounted) 3.0 mm (0.12 in.)
  • Page 432: Special Tools

    FINAL DRIVE 11-5 Special Tools Inside Circlip Pliers: Pulley Holder: 57001-143 57001-1572 Oil Seal & Bearing Remover: Grip: 57001-1058 57001-1591 Bearing Driver Set: 57001-1129...
  • Page 433: Drive Belt

    11-6 FINAL DRIVE Drive Belt The drive belt must be checked, and adjusted in accor- dance with the Periodic Maintenance Chart for safety and to prevent excessive wear. If the belt becomes badly worn or maladjusted-either too loose or too tight-the belt could jump off the pulley or break.
  • Page 434: Drive Belt Wear Inspection

    FINAL DRIVE 11-7 Drive Belt • Do not twist [A] the drive belt [B] as shown in the figure. ○ This includes coiling the belt to make it smaller for pack- aging. • Do not use tools [A] to pry [B] the drive belt [C] onto the application.
  • Page 435: Drive Belt Installation

    11-8 FINAL DRIVE Drive Belt Drive Belt Installation • Installation is the reverse of removal. Note the following. NOTE ○ Be sure the printed information faces the same direction so the belt rotates in the same direction as originally in- stead.
  • Page 436: Pulley And Coupling

    FINAL DRIVE 11-9 Pulley and Coupling Engine Pulley Outer Cover Removal • Remove: Bolts [A] Engine Pulley Outer Cover [B] Engine Pulley Outer Cover Installation • Install the trim [A] on the engine pulley outer cover [B]. ○ The higher side of the trim faces inside. ○...
  • Page 437: Engine Pulley Removal

    11-10 FINAL DRIVE Pulley and Coupling • Check the installation condition of the pad [A]. ○ Stick the pad securely. • Install the dowel pins [B] as shown in the figure. • Install the engine pulley inner cover [A]. • Tighten: Torque - Engine Pulley Inner Cover Bolts [B] : 12 N·m (1.2 kgf·m, 106 in·lb)
  • Page 438: Engine Pulley Installation

    FINAL DRIVE 11-11 Pulley and Coupling Engine Pulley Installation • Fit the grooves inside the pulley onto the splines on the output shaft. • Replace the washer with a new one. • Apply molybdenum disulfide grease to the threads of the output shaft and seating surface of the engine pulley mounting nut.
  • Page 439: Rear Pulley Coupling Installation

    11-12 FINAL DRIVE Pulley and Coupling Rear Pulley Coupling Installation • Apply grease to the coupling grease seal lips [A]. • Apply grease to the rear pulley coupling internal surface [B]. • Install the sleeve [C]. • Install the coupling dampers [A] so that the projections [B] face to the outside.
  • Page 440: Coupling Bearing Installation

    FINAL DRIVE 11-13 Pulley and Coupling • Remove the circlip [A]. Special Tool - Inside Circlip Pliers: 57001-143 • Remove the sleeve [A]. • Remove the ball bearing [B] by tapping from the wheel side. Special Tool - Oil Seal & Bearing Remover: 57001-1058 Coupling Bearing Installation •...
  • Page 441: Coupling Bearing Lubrication

    11-14 FINAL DRIVE Pulley and Coupling Coupling Bearing Lubrication NOTE ○ Since the coupling bearing is packed with grease and sealed, lubrication is not required. Rubber Damper Inspection • Remove the rear wheel (see Rear Wheel Removal in the Wheels/Tires chapter). •...
  • Page 442 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 443 12-2 BRAKES Brake Hose and Pipe Inspection..................12-31 K-ACT ABS (Equipped Models) ..................... 12-32 K-ACT ABS Servicing Precautions ................... 12-35 K-ACT ABS Troubleshooting Outline ................12-38 Inquiries to Rider....................... 12-41 Self-diagnosis Outline ....................... 12-43 Self-diagnosis Procedures ....................12-43 Service Code Clearing Procedures................... 12-44 How to Read Service Codes.....................
  • Page 444 BRAKES 12-3 Dummy Page...
  • Page 445: Exploded View

    12-4 BRAKES Exploded View VN1700C Model...
  • Page 446 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 8.9 in·lb Brake Lever Pivot Bolt Locknut 0.60 52 in·lb Front Brake Disc Mounting Bolts Front Brake Light Switch Screw 0.12 11 in·lb Front Brake Reservoir Cap Screws...
  • Page 447 12-6 BRAKES Exploded View VN1700C Model...
  • Page 448 BRAKES 12-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Bleed Valves 0.80 69 in·lb Brake Hose Banjo Bolts Brake Pedal Bolt 0.90 78 in·lb Rear Brake Disc Mounting Bolts Rear Caliper Mounting Bolts Rear Master Cylinder Mounting Bolts Rear Master Cylinder Push Rod Locknut 17.2 B: Apply brake fluid.
  • Page 449 12-8 BRAKES Exploded View VN1700D Model...
  • Page 450 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 8.9 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 451 12-10 BRAKES Exploded View VN1700D Model...
  • Page 452 BRAKES 12-11 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Bleed Valves 0.80 69 in·lb Brake Hose Banjo Bolts Brake Pedal Bolt 0.90 78 in·lb Brake Pipe Joint Nuts Rear Brake Disc Mounting Bolts Rear Caliper Mounting Bolts Rear Master Cylinder Mounting Bolts Rear Master Cylinder Push Rod Locknut 17.2 Rear Wheel Rotation Sensor Rotor Mounting Bolts...
  • Page 453: Specifications

    12-12 BRAKES Specifications Item Standard Service Limit Brake Lever, Brake Pedal Brake Lever Position 8-way adjustable (to suit rider) – – – Brake Lever Free Play Non-adjustable – – – Pedal Free Play Non-adjustable – – – Pedal Position About 100 mm (3.94 in.) –...
  • Page 454 BRAKES 12-13 Special Tools Inside Circlip Pliers: Needle Adapter Set: 57001-143 57001-1457 Jack: Measuring Adapter: 57001-1238 57001-1700 Hand Tester: 57001-1394...
  • Page 455: Brake Lever Position Adjustment

    12-14 BRAKES Brake Lever, Brake Pedal Brake Lever Position Adjustment • Push the lever forward and turn the adjuster [A]. Brake Pedal Position Inspection • Check that the brake pedal [A] is in the correct position. Pedal Position Standard: About 100 mm (3.94 in.) [B] (height from pedal top to footboard top [C]) If it is incorrect, adjust the brake pedal position.
  • Page 456: Brake Pedal Installation

    BRAKES 12-15 Brake Lever, Brake Pedal • Remove: Brake Pedal Return Spring [A] Rear Brake Light Switch Spring [B] Bolt [C] Washer [D] Cotter Pin [E] Washer [F] Joint Pin [G] Brake Pedal [H] Brake Pedal Installation • Apply grease to the pivot shaft [A]. •...
  • Page 457: Calipers

    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. NOTICE Do not loosen the caliper assembly bolts [D]. Take out only the caliper mounting bolts for caliper re- moval.
  • Page 458: Caliper Installation

    BRAKES 12-17 Calipers Caliper Installation • Install the caliper and brake hose lower end. ○ Replace the washer on each side of hose fitting with new ones. • Tighten: Torque - Caliper Mounting Bolts: Front: (VN1700C Model) 34 N·m (3.5 kgf·m, 25 ft·lb) (VN1700D Model) 25 N·m (2.5 kgf·m, 18 ft·lb) Rear: 34 N·m (3.5 kgf·m, 25 ft·lb) Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18...
  • Page 459: Caliper Fluid Seal Damage Inspection

    12-18 BRAKES Calipers Caliper Fluid Seal Damage Inspection 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 460: Caliper Dust Seal Damage Inspection

    BRAKES 12-19 Calipers Caliper Dust Seal Damage Inspection • Check that the dust seals [A] are not cracked, worn, swollen, or otherwise damaged. If they show any damage, replace the dust seals with new ones. Pistons [B] Fluid Seals [C] VN1700C Model [D] VN1700D Model [E] Caliper Dust Boot and Friction Boot Damage...
  • Page 461: Caliper Piston And Cylinder Damage Inspection

    12-20 BRAKES Calipers Caliper Piston and Cylinder Damage Inspection • Visually inspect the pistons [A] and cylinder surfaces [B]. Replace the caliper if the cylinder and piston are badly scores or rusty. VN1700C Model [C] VN1700D Model [D] Caliper Holder Shaft Wear Inspection The caliper body must slide smoothly on the caliper holder shafts [A].
  • Page 462: Brake Pads

    BRAKES 12-21 Brake Pads Front Brake Pad Removal (VN1700C Model) • Remove the caliper with the hose installed (see Front Caliper Removal). • Remove: Snap Pin [A] Pad Pin [B] Brake Pads [C] Front Brake Pad Installation (VN1700C Model) • Push the caliper piston in by hand as far as it will go.
  • Page 463: Front Brake Pad Installation (vn1700d Model)

    12-22 BRAKES Brake Pads • Remove: Pad Pin [A] Brake Pads [B] Front Brake Pad Installation (VN1700D Model) • Push the caliper pistons in by hand as far as they will go. • Install: Brake Pads Pad Pin • Tighten: Torque - Front Brake Pad Pin: 15 N·m (1.5 kgf·m, 11 ft·lb) •...
  • Page 464: Rear Brake Pad Installation

    BRAKES 12-23 Brake Pads Rear Brake Pad Installation • Push the caliper piston in by hand as far as it will go. • Install the pad spring in place. • Install the piston side pad [A] first, and then another pad. ○...
  • Page 465: Master Cylinder

    12-24 BRAKES Master Cylinder Front Master Cylinder Removal • Remove the banjo bolt [A] to disconnect the brake hose from the master cylinder (see Brake Hose Replacement in the Periodic Maintenance chapter). • Disconnect the front brake light switch connectors [A] and the electronic cruise control cancel switch (front brake) connectors [B].
  • Page 466: Rear Master Cylinder Removal

    BRAKES 12-25 Master Cylinder Rear Master Cylinder Removal • Remove: Bolt [A] Cover [B] Bolt [C] • Unscrew: Front Guard Mounting Bolt [A] Brake Hose Banjo Bolt [B] Front Footboard Bracket Bolts [C] • Remove: Cotter Pin [A] Joint Pin [B] Rear Master Cylinder Mounting Bolts [C] Rear Master Cylinder Installation •...
  • Page 467: Rear Master Cylinder Disassembly

    12-26 BRAKES Master Cylinder Rear Master Cylinder Disassembly • Refer to the Master Cylinder Rubber Parts Replacement in the Periodic Maintenance chapter. Master Cylinder Assembly • Refer to the Master Cylinder Rubber Parts Replacement in the Periodic Maintenance chapter. Master Cylinder Inspection (Visual Inspection) •...
  • Page 468: Brake Discs

    BRAKES 12-27 Brake Discs Brake Disc Removal • Remove the wheels (see Front/Rear Wheel Removal in the Wheels/Tires chapter). • Unscrew the mounting bolts [A], and take off the disc. Brake Disc Installation • Install the brake disc [A] on the wheel so that the marked side [B] faces out.
  • Page 469: Brake Fluid

    12-28 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 470 BRAKES 12-29 Brake Fluid • Remove the rubber cap from the bleed valve [A] on the caliper [B]. • Attach a clear plastic hose [C] to the bleed valve, and run the other end of the hose into a container. •...
  • Page 471 12-30 BRAKES Brake Fluid NOTE ○ For the rear brake caliper [A], bleed the brake line for two bleed valves [B]. • Tighten the bleed valve, and install the rubber cap. Torque - Bleed Valves: 7.8 N·m (0.80 kgf·m, 69 in·lb) •...
  • Page 472: Brake Hose

    BRAKES 12-31 Brake Hose Brake Hose and Pipe Removal/Installation • Refer to the Brake Hose 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 473: K-act Abs (equipped Models)

    1. K-ACT ABS Indicator Light (LED) 2. Front Wheel Rotation Sensor 3. Front Wheel Rotation Sensor Rotor 4. K-ACT ABS Hydraulic Unit 5. Rear Wheel Rotation Sensor 6. Rear Wheel Rotation Sensor Rotor 7. K-ACT ABS Fuse Box 8. K-ACT ABS Kawasaki Diagnostic System Connector...
  • Page 474 5. K-ACT ABS Hydraulic Unit 15. Fuse Box 1 6. K-ACT ABS Self-diagnosis Terminal 16. Ignition Fuse 10 A 7. K-ACT ABS Kawasaki Diagnostic System 17. Taillight Fuse 10 A Connector 18. Battery 12 V 18 Ah 8. Frame Ground 7 19.
  • Page 475 16. Unused 33. Unused 17. Unused 34. K-ACT ABS Indicator Light (LED) 18. Rear Wheel Rotation Sensor Signal 35. Unused 19. Power Supply to Front Wheel Rotation Sen- 36. K-ACT ABS Kawasaki Diagnostic System Terminal 37. Unused 38. Ground to ECU...
  • Page 476: K-act Abs Servicing Precautions

    BRAKES 12-35 K-ACT ABS (Equipped Models) K-ACT ABS Servicing Precautions There are a number of important precautions that should be followed servicing the K-ACT ABS. ○ K-ACT ABS does not function if the battery is discharged. When driving with an insufficiently charged battery, K-ACT ABS may not function.
  • Page 477 12-36 BRAKES K-ACT ABS (Equipped Models) WARNING Air in the brake lines diminish braking performance and can cause an accident resulting in injury or death. If any of the brake line fittings, including the K-ACT ABS hydraulic unit joint nuts, or the bleed valve is opened at any time, the air must be bled completely from the brake line.
  • Page 478 BRAKES 12-37 K-ACT ABS (Equipped Models) ○ The K-ACT ABS indicator light (LED) [A] may light if the tire pressure is incorrect, a non-recommended tire is in- stalled, 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 K-ACT ABS and can lead to extended...
  • Page 479: K-act Abs Troubleshooting Outline

    12-38 BRAKES K-ACT ABS (Equipped Models) K-ACT ABS Troubleshooting Outline When an abnormality in the system occurs, the K-ACT ABS indicator light (LED) lights up to alert the rider. In ad- dition, the nature of the fault is stored in the memory of the K-ACT ABS hydraulic unit and when in the self-diagnosis mode, the service code [A] is indicated by the number of times the K-ACT ABS indicator light (LED) blinks.
  • Page 480 BRAKES 12-39 K-ACT ABS (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 481 12-40 BRAKES K-ACT ABS (Equipped Models) K-ACT ABS Diagnosis Flow Chart...
  • Page 482: Inquiries To Rider

    BRAKES 12-41 K-ACT ABS (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 483 12-42 BRAKES K-ACT ABS (Equipped Models) Pre-Diagnosis Inspection 1...
  • Page 484: Self-diagnosis Outline

    BRAKES 12-43 K-ACT ABS (Equipped Models) Pre-Diagnosis Inspection 2 Self-diagnosis Outline When the indicator light has blinked or come on, the K-ACT ABS hydraulic unit memorizes and stores the service code (32 codes including “Normal Code”) for the service person to troubleshoot easily.
  • Page 485: Service Code Clearing Procedures

    12-44 BRAKES K-ACT ABS (Equipped Models) • Remove the right side cover (see Right Side Cover Re- moval in the Frame chapter). • Ground the self-diagnosis terminal (gray) [A] to the battery (–) terminal, using a auxiliary lead. • Turn on the ignition switch. ○...
  • Page 486 BRAKES 12-45 K-ACT ABS (Equipped Models) Self-diagnosis Flow Chart...
  • Page 487: How To Read Service Codes

    12-46 BRAKES K-ACT ABS (Equipped Models) How to Read Service Codes ○ Service codes are shown by a series of long and short blinks of the K-ACT ABS indicator light (LED) as shown below. ○ Read 10th digit and unit digit as the K-ACT ABS indicator light (LED) blinks. ○...
  • Page 488 BRAKES 12-47 K-ACT ABS (Equipped Models) Service Code Table Service Light K-ACT ABS Indicator Light (LED) Problems Code State After Start code (not fault) starts, turn off Rear inlet solenoid valve trouble (open, temperature abnormal) Rear outlet solenoid valve trouble (open, temperature abnormal) Front inlet solenoid valve trouble (open, temperature abnormal)
  • Page 489: K-act Abs Indicator Light (led) Inspection

    12-48 BRAKES K-ACT ABS (Equipped Models) Service Light K-ACT ABS Indicator Light (LED) Problems Code State Rear switching valve trouble (open, temperature abnormal) Front switching valve trouble (open, temperature abnormal) Front high pressure switching valve trouble (open, temperature abnormal) Input fluid pressure sensor (front brake) trouble (voltage abnormal, wiring shorted or open) Input fluid pressure sensor (front brake)
  • Page 490: Solenoid Valve Inspection (service Code 13,14,17,18)

    BRAKES 12-49 K-ACT ABS (Equipped Models) • Do the 2nd step test. ○ Check for continuity between the orange/black lead ter- minal of the main harness side connector [A] and ground. Special Tool - Hand Tester: 57001-1394 If there is the continuity in the lead, replace or repair the main harness.
  • Page 491 12-50 BRAKES K-ACT ABS (Equipped Models) • Do the 2nd step test. ○ Disconnect the K-ACT ABS hydraulic unit connector [A]. ○ Check for continuity between the red/black [25] and black/blue [38] lead terminals of the K-ACT ABS hy- draulic unit connector. If there is the continuity in the lead, replace the K-ACT ABS hydraulic unit.
  • Page 492: Front Combine Valve Inspection (service Code 21,22)

    BRAKES 12-51 K-ACT ABS (Equipped Models) • Do the 6th 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 K-ACT ABS indicator light (LED) [A] lit, faulty K-ACT ABS solenoid valve relay in the K-ACT ABS hydraulic unit.
  • Page 493: K-act Abs Motor Relay Inspection (service Code 35)

    12-52 BRAKES K-ACT ABS (Equipped Models) K-ACT ABS Motor Relay Inspection (Service Code • Do the 1st step test. ○ Check the K-ACT ABS motor relay fuse (30 A) [A]. If the fuse blown, proceed the 2nd step. If the fuse correct, proceed the 4th step. •...
  • Page 494: Front Wheel Rotation Sensor Signal Abnormal (service Code 42)

    BRAKES 12-53 K-ACT ABS (Equipped Models) • Do the 5th step test. ○ Check for continuity between the positive cable [A] of the battery and red/white [1] lead terminal of the main harness side connector [B]. If there is the continuity in the lead, proceed the 4th step. If there is not the continuity in the lead, replace or repair the main harness.
  • Page 495: Front Wheel Rotation Sensor Wiring Inspection (service Code 43)

    12-54 BRAKES K-ACT ABS (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 K-ACT ABS indicator light (LED) [A] lit, faulty ECU in the K-ACT ABS hydraulic unit.
  • Page 496: Rear Wheel Rotation Sensor Signal Abnormal (service Code 44)

    BRAKES 12-55 K-ACT ABS (Equipped Models) Rear Wheel Rotation Sensor Signal Abnormal (Service Code 44) • Do the 1st step test. ○ Measure the air gap between the rear wheel rotation sen- sor and sensor rotor. Thickness Gauge [A] Air Gap Standard: 1.0 mm (0.039 in.) If the measurement is over standard, check each part...
  • Page 497: Power Supply Voltage Abnormal (under-voltage) (service Code 52)

    ○ Connect the K-ACT ABS hydraulic unit connector. ○ Check the battery terminal voltage, connect the hand tester to the brown terminal of K-ACT ABS Kawasaki self-diagnosis system connector [A] and ground. Special Tool - Hand Tester: 57001-1394 ○ Turn the ignition switch ON.
  • Page 498: Power Supply Voltage Abnormal (over-voltage) (service Code 53)

    Connect the K-ACT ABS Kawasaki self-diagnosis system connector and K-ACT ABS hydraulic unit connector. ○ Check the battery terminal voltage, connect the hand tester to the brown terminal of K-ACT ABS Kawasaki self-diagnosis system connector [A] and ground. Special Tool - Hand Tester: 57001-1394 ○...
  • Page 499: High Pressure Switching/switching Valve Inspection (service Code 71, 72, 73, 74)

    12-58 BRAKES K-ACT ABS (Equipped Models) • Do the 4th 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 K-ACT ABS indicator light (LED) [A] lit, faulty ECU in the K-ACT ABS hydraulic unit.
  • Page 500: K-act Abs Hydraulic Unit Removal

    BRAKES 12-59 K-ACT ABS (Equipped Models) K-ACT ABS Hydraulic Unit Removal NOTICE The K-ACT ABS hydraulic unit [A] has been ad- justed and set with precision at the factory. There- fore, it should be handled carefully, never struck sharply with a hammer, or allowed to fall on a hard surface.
  • Page 501: K-act Abs Hydraulic Unit Installation

    12-60 BRAKES K-ACT ABS (Equipped Models) • Remove: Brake Hose Banjo Bolts [A] Bolts [B] • Tape the brake line opening to prevent brake fluid leakage or contamination by foreign matter. • Remove the K-ACT ABS hydraulic unit [C] with bracket. NOTICE Brake fluid quickly ruins painted plastic surfaces;...
  • Page 502: K-act Abs Hydraulic Unit Inspection

    BRAKES 12-61 K-ACT ABS (Equipped Models) NOTICE Brake fluid quickly ruins painted plastic surfaces; any spilled fluid should be completely washed away immediately. • When installing the hoses and pipes, avoid sharp bend- ing, kinking, flatting or twisting, and run the hoses accord- ing to Cable, Wire, and Hose Routing section in the Ap- pendix chapter.
  • Page 503: Front Wheel Rotation Sensor Removal

    12-62 BRAKES K-ACT ABS (Equipped Models) • Visually inspect the connector terminals [A]. Replace the K-ACT ABS hydraulic unit or main harness if either of the terminals are cracked, bent, or otherwise damaged. If the K-ACT ABS hydraulic unit connector is clogged with mud or dust, blow it off with compressed air.
  • Page 504: Rear Wheel Rotation Sensor Removal

    BRAKES 12-63 K-ACT ABS (Equipped Models) Rear Wheel Rotation Sensor Removal NOTICE The wheel rotation sensor should be handled care- fully, never struck sharply with a hammer, or al- lowed to fall on a hard surface since the wheel rota- tion sensor is precision made.
  • Page 505: Wheel Rotation Sensor Inspection

    12-64 BRAKES K-ACT ABS (Equipped Models) Wheel Rotation Sensor Inspection • Remove the front wheel rotation sensor [A] from the sen- sor bracket. • 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 506: Rear Wheel Rotation Sensor Rotor Removal

    BRAKES 12-65 K-ACT ABS (Equipped Models) Rear Wheel Rotation Sensor Rotor Removal • Remove: Rear Wheel (see Rear Wheel Removal in the Wheels/Tires chapter) Bolts [A] Wheel Rotation Sensor Rotor [B] Rear Wheel Rotation Sensor Rotor Installation • Installation is the reverse of removal, note the following. Torque - Rear Wheel Rotation Sensor Rotor Mounting Bolts: 6.9 N·m (0.70 kgf·m, 61 in·lb) Wheel Rotation Sensor Rotor Inspection...
  • Page 508 SUSPENSION 13-1 Suspension Table of Contents Exploded View........................13-2 Specifications ......................... 13-6 Special Tools .......................... 13-7 Front Fork ..........................13-9 Fork Oil Change........................ 13-9 Front Fork Removal ......................13-11 Front Fork Installation ....................... 13-13 Front Fork Disassembly ....................13-13 Front Fork Assembly......................13-15 Inner Tube, Outer Tube Inspection ...................
  • Page 509: Exploded View

    13-2 SUSPENSION Exploded View...
  • Page 510 SUSPENSION 13-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Upper Front Fork Clamp Bolts Lower Front Fork Clamp Bolts Fork Cover Clamp Bolts 0.43 37 in·lb Front Fork Bottom Allen Bolts Front Axle Clamp Bolts 6. K-ACT ABS Equipped Models AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque.
  • Page 511 13-4 SUSPENSION Exploded View...
  • Page 512 SUSPENSION 13-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Rear Shock Absorber Nuts Rear Shock Absorber Air Valve 0.56 49 in·lb Swingarm Pivot Shaft Nut 11.0 G: Apply grease. R: Replacement Parts WL: Apply a soap and water solution or rubber lubricant.
  • Page 513: Specifications

    13-6 SUSPENSION Specifications Item Standard Front Fork (per one unit) Fork Inner Tube Diameter 43 mm (1.7 in.) Fork Spring Preload Setting Non-adjustable Air Pressure Atmospheric pressure (Non-adjustable) Damper Setting Non-adjustable Fork Oil: Viscosity SHOWA SS-8 or equivalent SAE 10W Amount (Per Side): When changing oil Approx.
  • Page 514: Special Tools

    SUSPENSION 13-7 Special Tools Inside Circlip Pliers: Front Fork Oil Seal Driver: 57001-143 57001-1219 Fork Cylinder Holder Handle: Jack: 57001-183 57001-1238 Fork Cylinder Holder Adapter: Fork Oil Level Gauge: 57001-1057 57001-1290 Oil Seal & Bearing Remover: Bearing Remover Head, 20 × 22: 57001-1058 57001-1293 Bearing Driver Set:...
  • Page 515 13-8 SUSPENSION Special Tools Needle Bearing Driver, 28: Spacer, 57001-1610 57001-1637...
  • Page 516: Front Fork

    SUSPENSION 13-9 Front Fork Fork Oil Change • Remove the front fork (see Front Fork Removal). • Install the front fork temporary without the upper fork cover for removing the top plug. • Remove the cap [A]. • Push down the top plug [A] with a suitable tool [B]. •...
  • Page 517 13-10 SUSPENSION Front Fork • Fill the front fork with the specified oil. Fork Oil: Viscosity: SHOWA SS-8 or equivalent SAE 10W Amount (Per Side): When changing oil: Approx. 435mL (14.7 US oz.) After disassembly and completely dry: 512 ±2.5 mL (17.3 ±0.085 US oz.) •...
  • Page 518: Front Fork Removal

    SUSPENSION 13-11 Front Fork • Install the fork spring with the smaller end [A] facing down- ward [B]. Upward [C] • Install the front fork temporary without the upper fork cover. • Replace the O-ring [A] and retaining ring with new ones. •...
  • Page 519 13-12 SUSPENSION Front Fork • Disconnect the connectors [A]. • Clear the harness from the clamp [B]. • Remove: Bolts [A] (Both Sides) Headlight Body [B] with Bracket Clamp [C] (K-ACT ABS Equipped models) • Remove: Bolts [A] Turn Signal Light Bracket [B] Stem Cover [C] •...
  • Page 520: Front Fork Installation

    SUSPENSION 13-13 Front Fork Front Fork Installation • Install the rubber dampers onto the upper fork cover [A]. Thin Damper (Part No.: 92161-0604) [B] Thick Damper (Part No.: 92161-0799) [C] • Install the fork together with the upper fork cover [A]. ○...
  • Page 521 13-14 SUSPENSION Front Fork • Take the cylinder unit [A] out of the inner tube [B]. • Remove the dust seal [A]. • Remove the retaining ring [A] from the outer tube. • Separate the inner tube [A] from the outer tube [B] as follows: ○...
  • Page 522: Front Fork Assembly

    SUSPENSION 13-15 Front Fork Front Fork Assembly • Replace the following parts with new ones. Dust Seal [A] Retaining Ring [B] Oil Seal [C] Inner Guide Bushing [D] Outer Guide Bushing [E] Bottom Allen Bolt Gasket [F] • Put the cylinder unit [A] with the spring into the inner tube [B], protruding from the inner tube, and install the cylinder base [C] onto the bottom end of the cylinder unit.
  • Page 523: Inner Tube, Outer Tube Inspection

    13-16 SUSPENSION Front Fork • Install the front fork cover clamp [A] as shown. Inner Tube [B] About 248 mm (9.76 in.) [C] • Tighten: Torque - Fork Cover Clamp Bolt: 4.2 N·m (0.43 kgf·m, 37 in·lb) • Pour in the specified type of oil (see Fork Oil Change). Inner Tube, Outer Tube Inspection •...
  • Page 524: Spring Tension

    SUSPENSION 13-17 Front Fork Spring Tension • Since the spring becomes shorter as it weakens, check its free length [A] to determine its condition. If the spring of either fork leg is shorter than the service limit, it must be replaced. If the length of a replacement spring and that of the re- maining spring vary greatly, the remaining spring should also be replaced in order to keep the fork legs balanced...
  • Page 525: Rear Shock Absorber (air Type)

    13-18 SUSPENSION Rear Shock Absorber (Air Type) Rebound Damping Adjustment The rebound damping force adjuster on each rear shock absorber has 4 positions so that the rebound damping force can be adjusted for different road and loading conditions. The numbers on the adjuster show the setting position. •...
  • Page 526: Rear Shock Absorber Removal

    SUSPENSION 13-19 Rear Shock Absorber (Air Type) • Take off the air valve cap [A] on both shock absorbers. • Check the air pressure with the air pressure gauge. NOTE ○ Do not use tire gauges for checking air pressure. They may not indicate the correct air pressure because of air leakage that occur when the gauge is applied to the valve.
  • Page 527: Rear Shock Absorber Installation

    13-20 SUSPENSION Rear Shock Absorber (Air Type) • Remove the nuts [A], spring washers, and flat washers from both ends of the rear shock absorber [B]. • Pull the rear shock absorber off the frame. Rear Shock Absorber Installation • Install the sleeve [A] so the flange side faces inside.
  • Page 528: Rear Shock Absorber Scrapping

    SUSPENSION 13-21 Rear Shock Absorber (Air Type) Rear Shock Absorber Scrapping • Remove the rear shock absorber (see Rear Shock Ab- sorber Removal). Air Valve [A] WARNING When heated, pressurized air may explode and cause serious injury or death. Since the rear shocks contains air, do not incinerate them.
  • Page 529: Swingarm

    13-22 SUSPENSION Swingarm Swingarm Removal • Remove: Saddlebags (see Saddlebag Removal in the Frame chapter) Saddlebag Stays (see Saddlebag Stay Removal in the Frame chapter) Rear Fender (see Rear Fender Removal in the Frame chapter) Rear Caliper (see Caliper Removal in the Brakes chap- ter) Rear Wheel (see Rear Wheel Removal in the Wheels/Tires chapter)
  • Page 530: Swingarm Installation

    SUSPENSION 13-23 Swingarm • Remove the swingarm pivot nut [A]. • Pull out the swingarm pivot shaft and take off the swingarm. Swingarm Installation • Apply grease to the grease seal lips [A]. • Install the collar [A]. • Insert the swingarm pivot shaft to install the swingarm. •...
  • Page 531: Swingarm Bearing Installation

    13-24 SUSPENSION Swingarm • Remove: Ball Bearing [A] Needle Bearings [B] Special Tools - Bearing Remover Head, 20 × 22: 57001 -1293 Bearing Remover Shaft, 13: 57001-1377 Oil Seal & Bearing Remover: 57001-1058 Swingarm Bearing Installation • Replace the needle bearings, ball bearing, grease seals and circlip with new ones.
  • Page 532: Grease Seal And Needle Bearing Lubrication

    SUSPENSION 13-25 Swingarm • Turn the ball bearing in the swingarm back and forth [A] while checking for plays, roughness or binding. If bearing play, roughness or binding is found, replace the bearing. Grease Seal and Needle Bearing Lubrication • Refer to the Swingarm Pivot Lubrication in the Periodic Maintenance chapter.
  • Page 534