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KX450F
Motorcycle
Service Manual

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Table of Contents

   Also See for Kawasaki kx450f

   Summary of Contents for Kawasaki kx450f

  • Page 1 KX450F Motorcycle Service Manual...
  • Page 3 Quick Reference Guide General Information Periodic Maintenance Fuel System (DFI) Cooling System Engine Top End Clutch Engine Lubrication System Engine Removal/Installation Crankshaft/Transmission Wheels/Tires 10 j Final Drive 11 j Brakes 12 j Suspension 13 j Steering 14 j Frame 15 j Electrical System 16 j Appendix...
  • Page 5 All information contained in this publication is based on the latest product information available at the time of publication. Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts. © 2008 Kawasaki Heavy Industries, Ltd. First Edition (2) : Jul. 18, 2008 (M)
  • Page 6 LIST OF ABBREVIATIONS ampere(s) pound(s) ABDC after bottom dead center meter(s) alternating current minute(s) ATDC after top dead center newton(s) BBDC before bottom dead center pascal(s) bottom dead center horsepower BTDC before top dead center pound(s) per square inch °C degree(s) Celsius revolution direct current...
  • Page 7: How To Use This Manual

    NOTE maintenance. ○ This note symbol indicates points of par- • Use proper tools and genuine Kawasaki Mo- ticular interest for more efficient and con- torcycle parts. Special tools, gauges, and venient operation. testers that are necessary when servicing Kawasaki motorcycles are introduced by the •...
  • Page 9 GENERAL INFORMATION 1-1 General Information Table of Contents Before Servicing ........................Model Identification......................... General Specifications......................Unit Conversion Table ......................1-10...
  • Page 10: 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 11 Replacement Parts Replacement Parts must be KAWASAKI genuine or recommended by KAWASAKI. Gaskets, O-rings, Oil seals, Grease seals, circlips or cotter pins must be replaced with new ones whenever disassembled.
  • Page 12 1-4 GENERAL INFORMATION Before Servicing Tightening Torque Incorrect torque applied to a bolt, nut, or screw may lead to serious damage. Tighten fasteners to the specified torque using a good quality torque wrench. Often, the tightening sequence is followed twice-initial tightening and final tightening with torque wrench.
  • Page 13 GENERAL INFORMATION 1-5 Before Servicing Ball Bearing and Needle Bearing Do not remove pressed ball or needle unless removal is absolutely necessary. Replace with new ones whenever removed. Press bearings with the manufacturer and size marks facing out. Press the bearing into place by putting pressure on the correct bearing race as shown.
  • Page 14 1-6 GENERAL INFORMATION Before Servicing Direction of Engine Rotation When rotating the crankshaft by hand, the free play amount of rotating direction will affect the adjustment. Ro- tate the crankshaft to positive direction (clockwise viewed from output side). Electrical Leads A two-color lead is identified first by the primary color and then the stripe color.
  • Page 15: Model Identification

    GENERAL INFORMATION 1-7 Model Identification KX450E9F Left Side View KX450E9F Right Side View Frame Number Engine Number...
  • Page 16: General Specifications

    1-8 GENERAL INFORMATION General Specifications Items KX450E9F Dimensions Overall Length 2 185 mm (86.02 in.) Overall Width 820 mm (32.3 in.) Overall Height 1 280 mm (50.39 in.) Wheelbase 1 480 mm (58.27 in.) Road Clearance 340 mm (13.4 in.) Seat Height 965 mm (38.0 in.) Curb Mass:...
  • Page 17 GENERAL INFORMATION 1-9 General Specifications Items KX450E9F Transmission: Type 5-speed, constant wesh, return shift Gear ratios: 1.750 (28/16) 1.412 (24/17) 1.188 (19/16) 1.000 (19/19) 0.875 (21/24) Final Drive System: Type Chain drive Reduction Ratio 3.846 (50/13) Overall Drive Ratio 9.178 @Top gear Frame Type Tubular, semi-double cradle...
  • Page 18: Unit Conversion Table

    1-10 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 milli × 0.001 Units of Torque: µ...
  • Page 19: Table Of Contents

    PERIODIC MAINTENANCE 2-1 Periodic Maintenance Table of Contents Periodic Maintenance Chart ....................Torque and Locking Agent...................... Specifications ......................... Special Tools .......................... 2-11 Periodic Maintenance Procedures..................2-12 Fuel System......................... 2-12 Fuel Hose and Connections Inspection ................2-12 Throttle Grip (Throttle Cable) Free Play Inspection ............2-12 Throttle Grip (Throttle Cable) Free Play Adjustment............
  • Page 20 2-2 PERIODIC MAINTENANCE Rear Sprocket Warp (Runout) Inspection ................. 2-34 Brakes..........................2-34 Brake Lever and Pedal Position Adjustment..............2-34 Brake Fluid Level Inspection..................... 2-36 Brake Fluid Change ......................2-37 Brake Pad Wear Inspection ....................2-39 Brake Master Cylinder Cup and Dust Cover Replacement..........2-39 Brake Caliper Fluid Seal and Dust Seal Replacement .............
  • Page 21: Periodic Maintenance Chart

    PERIODIC MAINTENANCE 2-3 Periodic Maintenance Chart The maintenance must be done in accordance with this chart to keep the motorcycle in good running condition. FREQUENCY Every Every Each Every 3 races race or 6 races or 7.5 races or Page 2.5 hr or 15 hr OPERATION...
  • Page 22 2-4 PERIODIC MAINTENANCE Periodic Maintenance Chart FREQUENCY Every Every Each Every 3 races race or 6 races or 7.5 races or Page 2.5 hr or 15 hr OPERATION 30 hr • Wheels/tires-inspect 2-29 • Rear sprocket-inspect † 2-34 • Front fork-inspect and clean 2-46 •...
  • Page 23: Torque And Locking Agent

    PERIODIC MAINTENANCE 2-5 Torque and Locking Agent Tighten all bolts and nuts to the proper torque using an accurate torque wrench. If insufficiently tightened, a bolt or nut may become damaged, strip an internal thread, or break and then fall out. The following table lists the tightening toque for the major bolts and nuts, and the parts requiring use of a non-permanent locking agent or liquid gasket.
  • Page 24 2-6 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Camshaft Chain Tensioner Cap Bolt 0.51 44 in·lb Cylinder Bolt 106 in·lb Exhaust Pipe Cover Bolts 106 in·lb Exhaust Pipe Holder Nuts Muffler Mounting Bolts Muffler Clamp Bolt Clutch Clutch Spring Bolts 0.90...
  • Page 25 PERIODIC MAINTENANCE 2-7 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb 0.90 78 in·lb Gear Positioning Lever Nut Shift Drum Cam Bolt Balancer Weight Mounting Nut Primary Gear Nut Wheels/Tires Front Axle Front Axle Clamp Bolts AL, S Rear Axle Nut 11.2 81.1...
  • Page 26 2-8 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Steering Steering Stem Head Nut Steering Stem Nut 0.50 43 in·lb Handlebar Clamp Bolts 2T, AL Frame Rear Frame Mounting Bolts Upper Footpeg Bracket Bolts Radiator Shroud Bolts 87 in·lb Electrical System Gear Position Switch Screws...
  • Page 27: Specifications

    PERIODIC MAINTENANCE 2-9 Specifications Item Standard Service Limit Fuel System 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Throttle Grip Free Play – – – Idle Speed 2 000± 50 r/min (rpm) – – – Air Cleaner Element Oil High quality foam air filter oil –...
  • Page 28 2-10 PERIODIC MAINTENANCE Specifications Item Standard Service Limit Standard Tire: Front: Size 90/100-21 57M – – – Make DUNLOP Type D742F, Tube Rear: – – – Size 120/80-19 63M Make DUNLOP Type D756, Tube Final Drive 52 ∼ 58 mm (2.0 ∼ 2.3 in.) Drive Chain Slack –...
  • Page 29: Special Tools

    PERIODIC MAINTENANCE 2-11 Special Tools Inside Circlip Pliers: Filler Cap Driver: 57001-143 57001-1454 Steering Stem Nut Wrench: Top Plug Wrench, 49 mm: 57001-1100 57001-1653 Jack: Top Plug Wrench, 36 mm: 57001-1238 57001-1705 Spark Plug Wrench, Hex 16: 57001-1262...
  • Page 30: Periodic Maintenance Procedures

    2-12 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel System Fuel Hose and Connections Inspection ○ If the motorcycle is not properly handled, the high pres- sure inside the fuel line can cause fuel to leak [A] or the hose burst. Replace the fuel hose if any fraying, cracks [B] or bulges [C] are noticed.
  • Page 31: Throttle Body Cleaning

    PERIODIC MAINTENANCE 2-13 Periodic Maintenance Procedures Throttle Body Cleaning • Check the throttle bore for cleanliness as follows. ○ Remove the throttle body assy (see Throttle Body Assy Removal in the Fuel System (DFI) chapter). ○ Check the throttle bore [A] at the throttle valve for carbon deposits by opening the throttle valve.
  • Page 32: Idle Speed Inspection

    2-14 PERIODIC MAINTENANCE Periodic Maintenance Procedures Idle Speed Inspection CAUTION This motorcycle is designed for competition use only. Therefore, the radiator does not incorporate a coolant reserve tank or cooling fan. Prolonged idling of the engine with no airflow through the radiator can cause coolant loss and engine over- heating resulting in possible engine damage.
  • Page 33: Air Cleaner Element Cleaning And Inspection

    PERIODIC MAINTENANCE 2-15 Periodic Maintenance Procedures Air Cleaner Element Cleaning and Inspection NOTE ○ In dusty areas, the element should be cleaned more frequently than recommended interval. ○ After riding through rain or on muddy roads, the element should be cleaned immediately. ○...
  • Page 34 2-16 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Clean the element [A] in a bath of a high-flash point sol- vent using a soft bristle brush. • Squeeze it dry in a clean towel [A]. Do not wring the ele- ment or blow it dry; the element can be damaged. •...
  • Page 35: Fuel Tank Cleaning

    PERIODIC MAINTENANCE 2-17 Periodic Maintenance Procedures Fuel Tank Cleaning WARNING Clean the fuel tank in a well-ventilated area, and take care that there is no sparks or flame anywhere near the working area. Because of the danger of highly flammable liquids, do not use gasoline or low flash-point solvent to clean the tank.
  • Page 36: Coolant Deterioration Inspection

    2-18 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Check the coolant level. The coolant level [A] should be at the bottom of the filler neck [B]. If the coolant level is low, add coolant through the filler opening to the bottom of the filler neck. Install the cap. Recommended coolant: Permanent type of antifreeze (soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for...
  • Page 37: Water Hoses And Connections Inspection

    PERIODIC MAINTENANCE 2-19 Periodic Maintenance Procedures Water Hoses and Connections Inspection ○ The high pressure inside the water hoses [A] can cause coolant to leak [B] or the hose to burst if the line is not properly maintained. Visually inspect the hoses for signs of deterioration.
  • Page 38: Valve Clearance Adjustment

    2-20 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Using a thickness gauge [A], measure the clearance be- tween each cam lob and valve lifter for all four valves. ○ For the purpose of adjusting the valve clearances, record the measured values. Valve clearance: between cam and valve lifter Standard: 0.17 ∼...
  • Page 39 PERIODIC MAINTENANCE 2-21 Periodic Maintenance Procedures Adjustment shims Thick- Thick- P/No. Mark P/No. Mark ness ness 2.00 92025-1870 2.55 92025-1881 2.05 92025-1871 2.575 92025-1985 2.10 92025-1872 2.60 92025-1882 2.15 92025-1873 2.625 92180-1059 2.20 92025-1874 2.625 92025-1883 2.25 92025-1875 2.675 92180-1194 2.30 92025-1876 2.70...
  • Page 40: Cylinder Head Warp Inspection

    2-22 PERIODIC MAINTENANCE Periodic Maintenance Procedures Cylinder Head Warp Inspection • Remove the cylinder head (see Cylinder Head Removal in the Engine Top End chapter). • Lay a straightedge [A] across the lower surface of the head at several different points, and measure warp by inserting a thickness gauge [B] between the straightedge and the head.
  • Page 41: Piston/cylinder Clearance Inspection

    PERIODIC MAINTENANCE 2-23 Periodic Maintenance Procedures Piston/Cylinder Clearance Inspection The piston-to-cylinder clearance is measured whenever a piston or cylinder is replaced with a new one. The standard piston-to-cylinder clearance must be adhered to whenever the cylinder is replaced. If only a piston is replaced, the clearance may exceed the standard slightly.
  • Page 42 2-24 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Pull off the old muffler baffle assembly [A]. • Clean the adhered silicone sealant. • Install the new muffler baffle assembly [A] into the inner pipe [B]. • While suppressing the muffler baffle for shrink, install the muffler body [C].
  • Page 43: Clutch

    PERIODIC MAINTENANCE 2-25 Periodic Maintenance Procedures Clutch Clutch Lever (Clutch Cable) Free Play Inspection • Slide the clutch lever dust cover [A] out of place. • Check that the clutch cable upper end is fully seated in the adjusting bolt [B]. •...
  • Page 44: Clutch Plates Inspection

    2-26 PERIODIC MAINTENANCE Periodic Maintenance Procedures Clutch Plates Inspection • Remove the clutch plates (see Clutch Removal in the Clutch chapter). • Visually inspect the friction and steel plates to see if they show any signs of seizure, or uneven wear. If any plates show signs of damage, replace the friction plates and steel plates as a set.
  • Page 45: Oil Filter Change

    PERIODIC MAINTENANCE 2-27 Periodic Maintenance Procedures Recommended Engine Type Castrol “POWER1 R4 Racing” 5W-40 or API SG API SH, SJ or SL with JASO MA, MA1 or Viscosity SAE 10W-30, 10W-40, 10W-50 Capacity 0.96 L (1.01 US qt.) (when filter is not removed) 0.98 L (1.03 US qt.) (when filter is remove) 1.2 L (1.3 US qt.) (when engine is...
  • Page 46: Breather Hose Inspection

    2-28 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Apply grease to the grommet [A]. • Install the filter to the filter cover [B] so that the grommet faces outside. CAUTION Inside out installation stop oil flow, causing engine seizure. • Replace the oil filter cover O-rings [A] with new ones. •...
  • Page 47: Wheel/tires

    PERIODIC MAINTENANCE 2-29 Periodic Maintenance Procedures Wheel/Tires Air Pressure Inspection/Adjustment • Using tire air pressure gauge [A], measure the tire pres- sure when the tires are cold. Adjust the tire air pressure to suit track conditions and rider preference, but do not stray too far from the recom- mended pressure.
  • Page 48: Spoke Tightness Inspection

    2-30 PERIODIC MAINTENANCE Periodic Maintenance Procedures Spoke Tightness Inspection • Check that all the spokes are tightened evenly. If spoke tightness is uneven or loose, tighten the spoke nipples evenly. Torque - Spoke Nipples: 2.2 N·m (0.22 kgf·m, 19 in·lb) WARNING If any spoke breaks, it should be replaced immedi- ately.
  • Page 49: Wheel Bearing Inspection

    PERIODIC MAINTENANCE 2-31 Periodic Maintenance Procedures Wheel Bearing Inspection • Raise the front/rear wheel off the ground. Special Tool - Jack: 57001-1238 • Spin the wheel lightly, and check for roughness, binding or noise. If roughness, binding, abnormal noise is found, replace the hub bearing.
  • Page 50: Drive Chain Slack Adjustment

    2-32 PERIODIC MAINTENANCE Periodic Maintenance Procedures Drive Chain Slack Adjustment • Loosen the left and right chain adjuster locknuts [A]. • Remove the cotter pin [B] and loosen the axle nut [C]. If the chain is too tight, back out the left and right chain adjusting bolts [D] evenly, and push the wheel forward until the chain is too loose.
  • Page 51: Drive Chain Wear Inspection

    PERIODIC MAINTENANCE 2-33 Periodic Maintenance Procedures Drive Chain Wear Inspection • Rotate the rear wheel to inspect the drive chain for dam- aged rollers, and loose pins and links. If there is any irregularity, replace the drive chain. Lubricate the drive chain if it appears dry. [A] Bushing [B] Roller [C] Pin...
  • Page 52: Sprocket Wear Inspection

    2-34 PERIODIC MAINTENANCE Periodic Maintenance Procedures • If a special lubricant is not available, a heavy oil such as SAE90 is preferred to a lighter oil because it will stay on the chain longer and provide better lubrication. • Apply oil to the sides of the rollers so that oil will penetrate into the rollers and bushings.
  • Page 53 PERIODIC MAINTENANCE 2-35 Periodic Maintenance Procedures NOTE ○ Usually it is not necessary to adjust the pedal position, but always adjust it when the master cylinder is disas- sembled or pedal position is incorrect. ○ Usually it is not necessary to adjust the pedal position, but alway adjust it when the push rod locknut has been loosened.
  • Page 54: Brake Fluid Level Inspection

    2-36 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Fluid Level Inspection • Check the brake fluid level in the front or rear brake reser- voir [A] and the front or rear reservoir must be kept above the lower level line [B]. If the fluid level in front or rear reservoir is lower than the lower level line, fill the reservoir to the upper level line.
  • Page 55: Brake Fluid Change

    PERIODIC MAINTENANCE 2-37 Periodic Maintenance Procedures Brake Fluid Change WARNING When working with the disc brake, observe the pre- cautions listed below. 1. Never reuse old brake fluid. 2. Do not use fluid from a container that has been left unsealed or that has been open for a long time.
  • Page 56 2-38 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Remove the rubber cap [A] on the bleed valve [B]. • Attach a clear plastic hose [A] to the bleed valve on the caliper, and run the other end of the hose into a container. •...
  • Page 57: Brake Pad Wear Inspection

    PERIODIC MAINTENANCE 2-39 Periodic Maintenance Procedures Brake Pad Wear Inspection • Remove the front brake caliper (see Caliper Removal in the Brakes chapter). • Check the lining thickness and condition of the pads in each caliper. If either pad is damaged, replace both pads in the caliper as a set.
  • Page 58: Brake Caliper Fluid Seal And Dust Seal Replacement

    2-40 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Remove the reservoir cap and diaphragm, and pour the brake fluid into a container. • Slide the dust cover [A] on the push rod [B] out of place, and remove the circlip [C]. Special Tool - Inside Circlip Pliers: 57001-143 •...
  • Page 59 PERIODIC MAINTENANCE 2-41 Periodic Maintenance Procedures • Remove the caliper holder [A] from the caliper [B] and remove the anti-rattle spring [C]. • Using compressed air, remove the pistons. One way to remove the pistons is as follows. ○ Cover the caliper opening with a clean, heavy cloth [A]. ○...
  • Page 60 2-42 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Using compressed air, remove the piston. ○ Cover the caliper opening with a clean, heavy cloth [A]. ○ Remove the piston by lightly applying compressed air [B] to where the brake line fits into the caliper. WARNING To avoid serious injury, never place your fingers or palm inside the caliper opening.
  • Page 61 PERIODIC MAINTENANCE 2-43 Periodic Maintenance Procedures • Install the anti-rattle springs [A] in the caliper as shown. • Replace the shaft rubber boot [A] and dust boot [B] if they are damaged. • Apply a thin coat of PBC (Poly Butyl Cuprysil) grease to the caliper holder shafts [C] and holder holes (PBC is a special high temperature, water-resistance grease).
  • Page 62: Brake Hoses And Connections Inspection

    2-44 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Hoses and Connections Inspection • Inspect the brake hose and fittings for deterioration, cracks and signs of leakage. ○ The high pressure inside the brake line can cause fluid to leak [A] or the hose to burst if the line is not properly main- tained.
  • Page 63 PERIODIC MAINTENANCE 2-45 Periodic Maintenance Procedures Rear Brake • Remove: Brake Hose Clamps [A] • Remove: Rear Master Cylinder Mounting Bolts [A] • Slide the rear master cylinder [A] backward. • Remove: Banjo Bolt [B] Washers [C] • Remove: Bolts [A] Rear Caliper Guard [B]...
  • Page 64: Suspension

    2-46 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Remove: Banjo Bolt [A] Washers [B] Brake Hose [C] • There are washers on each side of the brake hose fitting. Replace them with new ones when installing. • When installing the hoses, avoid sharp bending, kink- ing, flatting or twisting, and route the hoses according to Cable, Wire, and Hose Routing section in the Appendix chapter.
  • Page 65 PERIODIC MAINTENANCE 2-47 Periodic Maintenance Procedures • Turn the handlebar to one side, and loosen the fork top plug [A]. Special Tool - Top Plug Wrench, 49 mm: 57001-1653 [B] • Remove: Front Fork (see Front Fork Removal in the Suspension chapter) NOTE ○...
  • Page 66 2-48 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Raise the outer tube and temporarily install the fork top plug [A] (subtank) to the outer tube [B] with the top plug wrench [C]. Special Tool - Top Plug Wrench, 49 mm: 57001-1653 •...
  • Page 67 PERIODIC MAINTENANCE 2-49 Periodic Maintenance Procedures • With the outer tube compressed by hands, remove the top plug wrench [A]. CAUTION Removing the locknut and pushing the piston rod thread into the cylinder unit will damage the oil seal. Do not remove the locknut from the piston rod. •...
  • Page 68 2-50 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Drain the fork oil [A] from the cylinder unit [B] by pumping the piston rod several times. ○ Plug the two oil holes on the subtank [C] with fingers. • Hold the front fork inverted position for more than 20 min- utes to allow the fork oil to fully drain.
  • Page 69 PERIODIC MAINTENANCE 2-51 Periodic Maintenance Procedures • Pump [A] the piston rod [B] slowly several times to expel air. • With the piston rod held immovable in fully compressed position [A], gently install the base valve assembly [B] to the subtank. •...
  • Page 70 2-52 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Drain the extra oil from the subtank oil hole [A]. • With the cylinder unit in horizontal position, move [A] the piston rod [B] by hand to inspect it if operating smoothly. ○ If the piston rod is not extend, remove the base valve assembly and perform the air bleeding (pour the specified amount fork oil and discharge an excess of oil).
  • Page 71 PERIODIC MAINTENANCE 2-53 Periodic Maintenance Procedures • Compress the outer tube by hands and install the top plug wrench [A] between the axle holder bottom and locknut. Special Tool - Top Plug Wrench, 49 mm: 57001-1653 WARNING Be careful of reaction force in spring and fix surely so that special tool should not come off.
  • Page 72 2-54 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Apply a non-permanent locking agent to the threads of a adjuster assembly. • Torque the adjuster assembly [A]. Torque - Adjuster Assembly: 55 N·m (5.6 kgf·m, 40 ft·lb) • Loosen and remove the fork top plug (subtank) from the outer tube and slowly slide down the outer tube.
  • Page 73: Rear Shock Absorber Inspection

    PERIODIC MAINTENANCE 2-55 Periodic Maintenance Procedures The torque of fork top plug is specified to 30 N·m (3.0 kgf·m, 22 ft·lb) however, when you use the top plug wrench (special tool) [A], reduce the torque to 90% of the spec- ified value [27 N·m (2.8 kgf·m, 20 ft·lb)] due to the dis- tance [B] between the center of the square hole, where the torque wrench is fitted, and that of the octagonal hole of the...
  • Page 74 2-56 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Adjust the gas reservoir damping adjusters [A] to the soft- est position. • Pry or tap [A] at the gaps [B] in the stop [C] with suitable tools to free the stop from the rear shock body [D]. •...
  • Page 75 PERIODIC MAINTENANCE 2-57 Periodic Maintenance Procedures • Pour KYB K2-C oil into the gas reservoir to 30 mm (1.2 in.) [A] from the rear shock body upper end [B]. Push the piston rod assembly and seal downward again into the place where circlip is installed, and then fit the circlip [C] into the rear shock groove securely.
  • Page 76 2-58 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Press the reservoir cap [A] assembly downward slowly into the gas reservoir to 10 mm (0.4 in.) [B] from the gas reservoir upper end. CAUTION Ensure that no air remains in the system. •...
  • Page 77 PERIODIC MAINTENANCE 2-59 Periodic Maintenance Procedures • Pour KYB K2-C oil into the rear shock body to 50 mm (2.0 in.) [A] from the lower end of the rear shock body [B]. Recommended Oil: K2-C (KAYABA) or equivalent • Insert the piston end [A] of the piston rod assembly into the rear shock body [C] slowly.
  • Page 78: Swingarm And Uni-trak Linkage Inspection

    2-60 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Insert a suitable jig to center of the reservoir cap, and operate the piston rod assembly after poor 98kPa (1.0 kgf/cm², 14 psi) nitrogen gas, and then push out to the place where the reservoir cap hits the circlip. Now, check that the edge of the reservoir cap is pushed out to 2 mm (0.08 in.) deeper than the edge of the gas reservoir.
  • Page 79: Steering

    PERIODIC MAINTENANCE 2-61 Periodic Maintenance Procedures Steering Steering Inspection • Using the jack, raise the front wheel off the ground. Special Tool - Jack: 57001-1238 • With the front wheel pointing straight ahead, alternately nudge 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 80: Steering Adjustment

    2-62 PERIODIC MAINTENANCE Periodic Maintenance Procedures Steering Adjustment • Using the jack, raise the front wheel off the ground. Special Tool - Jack: 57001-1238 • Remove number plate (see Number Plate Removal in the Frame chapter). • Remove the handlebar pad [A]. •...
  • Page 81: Steering Stem Bearing Lubrication

    PERIODIC MAINTENANCE 2-63 Periodic Maintenance Procedures • Install the steering stem head to the front fork. • Tighten the steering stem head nut. Torque - Steering Stem Head Nut: 98 N·m (10 kgf·m, 72 ft·lb) • Tighten the loosened front fork clamp bolts. Torque - Upper Front Fork Clamp Bolts: 20 N·m (2.0 kgf·m, 15 ft·lb) NOTE...
  • Page 82: Frame

    2-64 PERIODIC MAINTENANCE Periodic Maintenance Procedures Frame Frame Inspection • Clean the frame with steam cleaner. • Visually inspect the frame and rear frame for cracks, dents, bending, or warp. If there is any damage to the frame, replace it. WARNING A repaired frame may fail in use, possibly causing an accident.
  • Page 83: Spark Plug Replacement

    PERIODIC MAINTENANCE 2-65 Periodic Maintenance Procedures • Fit the spark plug cap [A] so that align it to the rised line [B] on the head cover. ○ Pull the plug cap to make sure the installation of the spark plug cap. Spark Plug Replacement •...
  • Page 84: Cable Inspection

    2-66 PERIODIC MAINTENANCE Periodic Maintenance Procedures Cable Inspection • With the cable disconnected at the both ends, the cable should move freely [A] within the cable housing. If cable movement is not free after lubricating, if the cable is frayed [B], or if the cable housing is kinked [C], replace the cable.
  • Page 85 PERIODIC MAINTENANCE 2-67 Periodic Maintenance Procedures Brakes: Front Master Cylinder Clamp Bolts Front Caliper Mounting Bolts Brake Lever Pivot Nut Brake Pedal Mounting Bolt Rear Master Cylinder Push Rod Cotter Pin Rear Caliper Holder Shaft Rear Master Cylinder Mounting Bolts Suspension: Front Fork Clamp Bolts Rear Shock Absorber Mounting Bolts, Nuts...
  • Page 87 FUEL SYSTEM (DFI) 3-1 Fuel System (DFI) Table of Contents Exploded View........................DFI System..........................DFI Parts Location........................3-14 Specifications ......................... 3-16 Special Tools and Sealant ...................... 3-17 DFI Servicing Precautions ...................... 3-18 DFI Servicing Precautions ....................3-18 Troubleshooting the DFI System .................... 3-19 Outline..........................
  • Page 88 3-2 FUEL SYSTEM (DFI) Fuel Injector Removal ....................... 3-60 Fuel Injector Installation ....................3-61 Fuel Injector Audible Inspection..................3-62 Fuel Injector Resistance Inspection .................. 3-62 Fuel Injector Power Supply Voltage Inspection..............3-63 Fuel Injector Output Voltage Inspection ................3-64 Injector Fuel Line Inspection ..................... 3-65 Fuel Pump (Service Code 46) ....................
  • Page 89 FUEL SYSTEM (DFI) 3-3 Dummy Page...
  • Page 90: Exploded View

    3-4 FUEL SYSTEM (DFI) Exploded View...
  • Page 91 FUEL SYSTEM (DFI) 3-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Throttle Pulley Cover Bolts 0.71 62 in·lb Throttle Cable Mounting Bolts 0.71 62 in·lb Air Cleaner Duct Mounting Bolt 0.20 18 in·lb Air Cleaner Duct Mounting Nuts 0.30 26 in·lb Air Cleaner Housing Bolts 87 in·lb...
  • Page 92 3-6 FUEL SYSTEM (DFI) Exploded View...
  • Page 93 FUEL SYSTEM (DFI) 3-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Fuel Pump Bolts 87 in·lb L, S Water Temperature Sensor 106 in·lb Gear Position Switch Screws 0.30 26 in·lb 4. Fuel Pump 5. Vehicle-down Sensor 6. Capacitor 7. Ignition Coil 8.
  • Page 94: Dfi System

    3-8 FUEL SYSTEM (DFI) DFI System DFI System...
  • Page 95 FUEL SYSTEM (DFI) 3-9 DFI System 1. Capacitor 2. ECU 3. Gear Position Switch 4. Water Temperature Sensor 5. Crankshaft Sensor 6. Vehicle-down Sensor 7. Ignition Coil 8. Fuel Tank 9. Fuel Pump 10. Pressure Regulator 11. Inlet Air Pressure Sensor 12.
  • Page 96 3-10 FUEL SYSTEM (DFI) DFI System DFI System Wiring Diagram...
  • Page 97 10. Frame Ground 11. Fuel Pump 12. Vehicle-down Sensor 13. Capacitor 14. Crankshaft Sensor 15. Gear Position Switch 16. Engine Stop Switch 17. Kawasaki Diagnostic System Connector ○ Color Codes: BK: Black GY: Gray PU: Purple BL: Blue LB: Light Blue...
  • Page 98 3-12 FUEL SYSTEM (DFI) DFI System Terminal Numbers of ECU Connectors Terminal Names 1. Power Supply to ECU 2. Vehicle-down Sensor 3. Crankshaft Sensor (+) 4. Gear Position Switch 5. Main Throttle Sensor 6. Inlet Air Pressure Sensor 7. Unused 8.
  • Page 99 FUEL SYSTEM (DFI) 3-13 DFI System 35. Ground for ECU 36. Ground for ECU *: KDS (Kawasaki Diagnostic System)
  • Page 100: Dfi Parts Location

    3-14 FUEL SYSTEM (DFI) DFI Parts Location ECU [A] Kawasaki Diagnostic System Connector [B] Fuel Pump [A] Throttle Body Assy [B] Inlet Air Temperature Sensor [A] Throttle Sensor [A] Water Temperature Sensor [B] Crankshaft Sensor [C] Vehicle-down Sensor [A] Ignition Coil [B]...
  • Page 101 FUEL SYSTEM (DFI) 3-15 DFI Parts Location Fuel Injector [A] Inlet Air Pressure Sensor [B] FI Indicator Light Harness Connector [A]...
  • Page 102: Specifications

    3-16 FUEL SYSTEM (DFI) Specifications Item Standard Digital Fuel Injection System Idle Speed 2 000 ±50 r/min (rpm) Throttle Body Assy: Type Single barrel Bore 43 (1.69 in.) ECU: Make KEIHIN 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 103: Special Tools And Sealant

    Oil Pressure Gauge, 5 kgf/cm²: Sensor Harness Adapter: 57001-125 57001-1561 Fork Oil Level Gauge: Fuel Pressure Gauge Adapter: 57001-1290 57001-1593 Vacuum Gauge: Fuel Hose: 57001-1369 57001-1607 Hand Tester: Measuring Adapter: 57001-1394 57001-1700 Needle Adapter Set: Kawasaki Bond (Silicone Sealant): 57001-1457 56019-120...
  • Page 104: Dfi Servicing Precautions

    3-18 FUEL SYSTEM (DFI) DFI Servicing Precautions DFI Servicing Precautions There are a number of important precautions that should be followed servicing the DFI system. ○ Connect these connectors until they click [A]. ○ Never any of the DFI electrical connectors are discon- nected.
  • Page 105: Troubleshooting The Dfi System

    FUEL SYSTEM (DFI) 3-19 Troubleshooting the DFI System Outline When an abnormality in the system occurs, the condition of the problem is stored in the memory of the ECU (Elec- tronic Control Unit). With the engine stopped and conduct a self-diagnosis inspection, the service code [A] is indicated by the number of times the FI indicator light blinks.
  • Page 106 After measurement, remove the needle adapters and ap- ply silicone sealant to the seals [A] of the connector [B] for waterproofing. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 • Always check the connected battery condition before re- placing the DFI parts. A fully charged battery is a must for conducting accurate tests of the DFI system.
  • Page 107 FUEL SYSTEM (DFI) 3-21 Troubleshooting the DFI System ○ When checking a harness [A] for short circuit, open one end [B] and check the continuity between the other end [C] and ground [D]. If there is continuity, the harness has a short circuit to ground, and it must be repaired or re- placed.
  • Page 108: Inquiries To Rider

    3-22 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 109 FUEL SYSTEM (DFI) 3-23 Troubleshooting the DFI System Sample Diagnosis Sheet Rider name Model Engine No. Frame No. Date problem occurred Environment when problem occurred. □ □ □ □ □ □ Weather fine, cloudy, rain, snow, always, other: □ □ □...
  • Page 110 3-24 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). □...
  • Page 111: Dfi System Troubleshooting Guide

    FUEL SYSTEM (DFI) 3-25 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 112 3-26 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Water temperature sensor trouble Inspect (see chapter 3). Inlet air temperature sensor trouble Inspect (see chapter 3). Throttle sensor trouble Inspect (see chapter 3). Unstable (rough) idling: Fuel pressure too low or too high Inspect (see chapter 3).
  • Page 113 FUEL SYSTEM (DFI) 3-27 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Surge: Unstable fuel pressure Fuel pressure regulator trouble (Inspect and replace fuel pump) or kinked fuel line (Inspect and replace fuel pump) (see chapter 3). Fuel Injector trouble Inspect (see chapter 3).
  • Page 114 3-28 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Water temperature sensor trouble Inspect (see chapter 3). Inlet air temperature sensor trouble Inspect (see chapter 3). Throttle sensor trouble Inspect (see chapter 3). Knocking: Fuel poor quality or incorrect Fuel charge (Use the gasoline recommended in the Owner’s Manual).
  • Page 115: Self-diagnosis

    FUEL SYSTEM (DFI) 3-29 Self-Diagnosis Self-diagnosis Outline The self-diagnosis system has two modes and can be switched to another mode by grounding the self-diagnosis terminal. User Mode The ECU connected FI indicator light goes on when DFI system and ignition system parts are faulty. In case of seri- ous troubles, the ECU stops the injection/ignition operation.
  • Page 116 3-30 FUEL SYSTEM (DFI) Self-Diagnosis • Keep the FI indicator light assy (option P/No. 23016 -0034) GY/R lead [A] ground. ○ Count the blinks of the light to read the service code. Keep the lead ground until you finish reading the service code.
  • Page 117 FUEL SYSTEM (DFI) 3-31 Self-Diagnosis Self-Diagnosis Flow Chart...
  • Page 118: How To Read Service Codes

    3-32 FUEL SYSTEM (DFI) Self-Diagnosis How to Read Service Codes ○ Service codes are shown by a series of long and short blinks of the FI indicator light as shown below. ○ Read 10th digit and unit digit as the FI indicator light blinks. ○...
  • Page 119: Service Code Table

    FUEL SYSTEM (DFI) 3-33 Self-Diagnosis Service Code Table Service FI Indicator Light Problems Code Throttle sensor malfunction, wiring open or short Inlet air pressure sensor malfunction, wiring open or short Inlet air temperature sensor malfunction, wiring open or short Water temperature sensor malfunction, wiring open or short Crankshaft sensor malfunction, wiring open or short...
  • Page 120: Backups

    3-34 FUEL SYSTEM (DFI) Self-Diagnosis Backups ○ The ECU takes the following measures to prevent engine damage when the DFI or the ignition system parts have troubles. Service Output Signal Usable Parts Backups by ECU Codes Range or Criteria If the throttle sensor system fails (the signal is out of the usable range, wiring short or open), the ECU locks ignition timing into the ignition Throttle Sensor Output...
  • Page 121: Throttle Sensor (service Code 11)

    FUEL SYSTEM (DFI) 3-35 Throttle Sensor (Service Code 11) The throttle sensor is a rotating variable resistor that change output voltage according to throttle operating. The ECU senses this voltage change and determines fuel injection quantity, and ignition timing according to engine rpm, and throttle opening.
  • Page 122 3-36 FUEL SYSTEM (DFI) Throttle Sensor (Service Code 11) • Remove: Left Radiator Shroud (see Radiator Shroud Removal in the Frame chapter) Capacitor Lead Connector [A] • Connect the power supply harness (option P/No. 26011 -0246) [A] to the capacitor lead connector [B] of the main harness.
  • Page 123: Throttle Sensor Output Voltage Inspection

    FUEL SYSTEM (DFI) 3-37 Throttle Sensor (Service Code 11) Throttle Sensor Output Voltage Inspection • Measure the output voltage at the throttle sensor in the same way as input voltage inspection, note the following. ○ Disconnect the throttle sensor connector and connect the measuring adapter [A] between these connectors.
  • Page 124: Throttle Sensor Resistance Inspection

    3-38 FUEL SYSTEM (DFI) Throttle Sensor (Service Code 11) If the reading is within the standard, remove the ECU and check the wiring for continuity between main harness and sub harness connectors. ○ Disconnect the ECU and sensor connectors. Wiring Inspection ECU Connector [A] ←→...
  • Page 125 FUEL SYSTEM (DFI) 3-39 Throttle Sensor (Service Code 11) Throttle Sensor Circuit 1. ECU 2. Throttle Sensor...
  • Page 126: Inlet Air Pressure Sensor (service Code 12)

    3-40 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code 12) Inlet Air Pressure Sensor Removal CAUTION Never drop the inlet air pressure sensor, especially on a hard surface. Such a shock to the sensor can damage it. • Remove: Fuel Tank (see Fuel Tank Removal) Inlet Air Pressure Sensor Connector [A] Screws [B]...
  • Page 127: Inlet Air Pressure Sensor Input Voltage Inspection

    FUEL SYSTEM (DFI) 3-41 Inlet Air Pressure Sensor (Service Code 12) • Tighten the screws [A] securely. • Connect the inlet air pressure sensor connector [B]. Inlet Air Pressure Sensor Input Voltage Inspection NOTE ○ Be sure the battery is fully charged. •...
  • Page 128: Inlet Air Pressure Sensor Output Voltage Inspection

    3-42 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code 12) If the reading is out of the standard, remove the ECU and check the wiring for continuity between main harness and sub harness connectors. ○ Disconnect the ECU and sensor connectors. Wiring Inspection ECU Connector [A] ←→...
  • Page 129 FUEL SYSTEM (DFI) 3-43 Inlet Air Pressure Sensor (Service Code 12) If the wiring is good, check the sensor for various vacuum. • Remove the inlet air pressure sensor [A] and disconnect the vacuum hose from the sensor. • Connect an auxiliary hose [B] to the inlet air pressure sen- sor.
  • Page 130 3-44 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code 12) ID: Idling Ps: Standard Atmospheric Pressure (Absolute) Pv: Throttle Vacuum Pressure (Absolute) ST: Standard of Sensor Output Voltage (V) TO: Throttle Full Open UR: Usable Range of Sensor Output Voltage (V) Vv: Inlet Air Pressure Sensor Output Voltage (V) (Digital Meter Reading)
  • Page 131 FUEL SYSTEM (DFI) 3-45 Inlet Air Pressure Sensor (Service Code 12) Inlet Air Pressure Sensor Circuit 1. ECU 2. Inlet Air Pressure Sensor...
  • Page 132: Inlet Air Temperature Sensor (service Code 13)

    3-46 FUEL SYSTEM (DFI) Inlet Air Temperature Sensor (Service Code 13) Inlet Air Temperature Sensor Removal/Installation CAUTION Never drop the inlet air temperature sensor, espe- cially on a hard surface. Such a shock to the sensor can damage it. • Remove the seat (see Seat Removal in the Frame chap- ter).
  • Page 133 FUEL SYSTEM (DFI) 3-47 Inlet Air Temperature Sensor (Service Code 13) • Remove: Left Radiator Shroud (see Radiator Shroud Removal in the Frame chapter) Capacitor Lead Connector [A] • Connect the power supply harness (option P/No. 26011 -0246) [A] to the capacitor lead connector [B] of the main harness.
  • Page 134: Inlet Air Temperature Sensor Resistance Inspection

    3-48 FUEL SYSTEM (DFI) Inlet Air Temperature Sensor (Service Code 13) Inlet Air Temperature Sensor Resistance Inspection • Remove the inlet air temperature sensor (see Inlet Air Temperature Sensor Removal/Installation). • Suspend the sensor [A] in a container of machine oil so that the heat-sensitive portion is submerged.
  • Page 135: Water Temperature Sensor (service Code 14)

    FUEL SYSTEM (DFI) 3-49 Water Temperature Sensor (Service Code 14) Water Temperature Sensor Removal/Installation CAUTION Never drop the water temperature sensor, espe- cially on a hard surface. Such a shock to the sensor can damage it. • Drain the coolant (see Coolant Draining in the Cooling System chapter).
  • Page 136 3-50 FUEL SYSTEM (DFI) Water Temperature Sensor (Service Code 14) • Connect the power supply harness (option P/No. 26011 -0246) [A] to the capacitor lead connector [B] of the main harness. • Connect the power supply harness (option P/No. 26011 -0246) to the 12 V battery [C] as shown.
  • Page 137: Water Temperature Sensor Inspection

    FUEL SYSTEM (DFI) 3-51 Water Temperature Sensor (Service Code 14) Water Temperature Sensor Inspection • Remove the water temperature sensor (see Water Tem- perature Sensor Removal/Installation). • Suspend the sensor [A] in a container of machine oil so that the heat-sensitive portion and threaded portion are submerged.
  • Page 138: Crankshaft Sensor (service Code 21)

    3-52 FUEL SYSTEM (DFI) Crankshaft Sensor (Service Code 21) The crankshaft sensor has no power source, and when the engine stops, the crankshaft sensor generates no sig- nals. Crankshaft Sensor Removal/Installation • Refer to the Starter Coil Removal/Installation in the Elec- trical System chapter.
  • Page 139: Gear Position Switch (service Code 25)

    FUEL SYSTEM (DFI) 3-53 Gear Position Switch (Service Code 25) Gear position Switch Removal • Remove: Shift Pedal (External Shift Mechanism Removal in the Crankshaft/Transmission chapter) • Remove the gear position switch connector [A]. • Open the clamps [A]. • Remove: Screws [A] Gear Position Switch [B]...
  • Page 140: Gear Position Switch Inspection

    3-54 FUEL SYSTEM (DFI) Gear Position Switch (Service Code 25) Gear Position Switch Inspection NOTE ○ Be sure the transmission mechanism is good condition. • Remove the left radiator shroud (see Radiator shroud Re- moval in the Frame chapter). • Disconnect the gear position switch lead connector [A].
  • Page 141 FUEL SYSTEM (DFI) 3-55 Gear Position Switch (Service Code 25) Gear Position Switch Circuit 1. ECU 2. Frame Ground 3. Gear Position Switch...
  • Page 142: Vehicle-down Sensor (service Code 31)

    3-56 FUEL SYSTEM (DFI) Vehicle-down Sensor (Service Code 31) When motorcycle is down, if opening of the throttle valve is 3/8 or more, stop the engine after 3 seconds. If throt- tle valve opening is 3/8 or less, hold the engine speed at 3000rpm for 3 seconds after the motorcycle fell over the 3 seconds, then stop the engine.
  • Page 143 FUEL SYSTEM (DFI) 3-57 Vehicle-down Sensor (Service Code 31) • Remove: Capacitor Lead Connector [A] • Connect the power supply harness (option P/No. 26011 -0246) [A] to the capacitor lead connector [B] of the main harness. • Connect the power supply harness (option P/No. 26011 -0246) to the 12 V battery [C] as shown.
  • Page 144: Vehicle-down Sensor Output Voltage Inspection

    3-58 FUEL SYSTEM (DFI) Vehicle-down Sensor (Service Code 31) Vehicle-down Sensor Output Voltage Inspection • Remove the vehicle-down sensor. ○ Remove the vehicle-down sensor, and connect the mea- suring adapter [A]. Special Tool - Measuring Adapter: 57001-1700 Main Harness [B] Vehicle-down Sensor [C] •...
  • Page 145 FUEL SYSTEM (DFI) 3-59 Vehicle-down Sensor (Service Code 31) Vehicle-down Sensor Circuit 1. ECU 2. Vehicle-down Sensor...
  • Page 146: Fuel Injector (service Code 41)

    3-60 FUEL SYSTEM (DFI) Fuel Injector (Service Code 41) CAUTION Never drop the fuel injector, especially on a hard surface. Such a shock to the injector can damage Fuel Injector Removal • Remove: Rear Frame (see Rear Frame Removal in the Frame chapter) Fuel Tank (see Fuel Tank Removal) •...
  • Page 147: Fuel Injector Installation

    FUEL SYSTEM (DFI) 3-61 Fuel Injector (Service Code 41) Fuel Injector Installation • Replace the O-ring [A] and dust seal [B] with a new one. • Assemble the delivery pipe [A] and the fuel injector [B]. • Fit the projections [A] on the delivery pipe to the hollows [B] of the throttle body assy.
  • Page 148: Fuel Injector Audible Inspection

    3-62 FUEL SYSTEM (DFI) Fuel Injector (Service Code 41) Fuel Injector Audible Inspection NOTE ○ Be sure the battery is fully charged. • Remove: Fuel Tank (see Fuel Tank Removal) Fuel Hose (see Fuel Injector Removal) • Connect the following parts. Fuel Pump Lead Connector Fuel Hose [A] Special Tool - Fuel Hose: 57001-1607...
  • Page 149: Fuel Injector Power Supply Voltage Inspection

    FUEL SYSTEM (DFI) 3-63 Fuel Injector (Service Code 41) Fuel Injector Power Supply Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Disconnect the injector connector and connect the mea- suring adapter [A] between these connector. Main Harness [B] Fuel Injector [C] Special Tool - Measuring Adapter: 57001-1700 •...
  • Page 150: Fuel Injector Output Voltage Inspection

    3-64 FUEL SYSTEM (DFI) Fuel Injector (Service Code 41) Fuel Injector Output Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Remove the ECU (see ECU Removal). ○ Do not disconnect the ECU connector. • Connect the power supply harness (option P/No. 26011 -0246) and 12 V battery to the capacitor lead connector (see Fuel Injector Power Supply Voltage Inspection).
  • Page 151: Injector Fuel Line Inspection

    FUEL SYSTEM (DFI) 3-65 Fuel Injector (Service Code 41) Injector Fuel Line Inspection • Remove: Fuel Tank (see Fuel Tank Removal) Fuel Hose (see Fuel Injector Removal) ○ Be sure to place a piece of cloth around the fuel outlet pipe of fuel pump and delivery pipe of throttle body assy.
  • Page 152 3-66 FUEL SYSTEM (DFI) Fuel Injector (Service Code 41) Fuel Injector Circuit 1. ECU 2. Fuel Injector 3. Frame Ground 4. Capacitor 5. Engine Stop Switch...
  • Page 153: Fuel Pump (service Code 46)

    FUEL SYSTEM (DFI) 3-67 Fuel Pump (Service Code 46) Fuel Pump Removal WARNING Gasoline is extremely flammable and can be explo- sive under certain conditions. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light.
  • Page 154: Fuel Pump Installation

    3-68 FUEL SYSTEM (DFI) Fuel Pump (Service Code 46) Fuel Pump Installation • Remove the dirt or dust from the fuel pump [A] by lightly applying compressed air. • Replace the fuel pump gasket with a new one. • Apply a non-permanent locking agent to the threads of the fuel pump bolts.
  • Page 155: Fuel Pump Operation Inspection

    FUEL SYSTEM (DFI) 3-69 Fuel Pump (Service Code 46) Fuel Pump Operation Inspection NOTE ○ Be sure the battery is fully charged. • Remove: Left Radiator Shroud (see Radiator Shroud Removal in the Frame chapter) Capacitor Lead Connector [A] • Connect the power supply harness (option P/No.
  • Page 156: Fuel Pump Operating Voltage Inspection

    3-70 FUEL SYSTEM (DFI) Fuel Pump (Service Code 46) Fuel Pump Operating Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Remove the left radiator shroud (see Radiator Shroud Re- moval in the Frame chapter). • Disconnect the fuel pump lead connector and connect the harness adapter [A] between these connectors as shown.
  • Page 157: Pressure Regulator Removal

    FUEL SYSTEM (DFI) 3-71 Fuel Pump (Service Code 46) Pressure Regulator Removal ○ The pressure regulator [A] is built into the fuel pump and can not be removed. Fuel Filter Cleaning ○ The fuel filter [A] is built into the pump and can not be cleaned or checked.
  • Page 158: Ignition Coil (service Code 51)

    3-72 FUEL SYSTEM (DFI) Ignition Coil (Service Code 51) Ignition Coil Removal/Installation • Refer to the Ignition Coil Removal/Installation in the Elec- trical System chapter. Ignition Coil Input Voltage Inspection • Refer to the Ignition Coil Peak Voltage Inspection in the Electrical System chapter.
  • Page 159: Ecu

    FUEL SYSTEM (DFI) 3-73 CAUTION Never drop the ECU, especially on a hard surface. Such a shock to the ECU can damage it. ECU Removal • Remove: Number Plate (see Number Plate Removal in the Frame chapter) Bolt [A] Connector Bracket [B] ECU Connector [C] •...
  • Page 160: Ecu Power Supply Inspection

    3-74 FUEL SYSTEM (DFI) ECU Power Supply Inspection • Remove the number plate (see Number Plate Removal in the Frame chapter). • Visually inspect the ECU connectors. If the connector is clogged with mud or dust, blow it off with compressed air. •...
  • Page 161 FUEL SYSTEM (DFI) 3-75 • Connect the power supply harness (option P/No. 26011 -0246) [A] to the capacitor lead connector [B] of the main harness. • Connect the power supply harness (option P/No. 26011 -0246) to the 12 V battery [C] as shown. •...
  • Page 162: Fuel Line

    3-76 FUEL SYSTEM (DFI) Fuel Line Fuel Pressure Inspection NOTE ○ Be sure the battery is fully charged. • Remove: Left Radiator Shroud (see Radiator Shroud Removal in the Frame chapter) Fuel Tank (see Fuel Tank Removal) Fuel Hose (see Fuel Injector Removal) ○...
  • Page 163 FUEL SYSTEM (DFI) 3-77 Fuel Line • Connect the power supply harness (option P/No. 26011 -0246) [A] to the capacitor lead connector [B] of the main harness. • Connect the power supply harness (option P/No. 26011 -0246) to the 12 V battery [C] as shown. NOTE ○...
  • Page 164: Fuel Flow Rate Inspection

    3-78 FUEL SYSTEM (DFI) Fuel Line Fuel Flow Rate Inspection WARNING Gasoline is extremely flammable and can be explo- sive under certain conditions. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light.
  • Page 165 FUEL SYSTEM (DFI) 3-79 Fuel Line • Disconnect: Capacitor Lead Connector [A] • Connect the power supply harness (option P/No. 26011 -0246) [A] to the capacitor lead connector [B] of the main harness. • Connect the power supply harness (option P/No. 26011 -0246) to the 12 V battery [C] as shown then, drive the fuel pump and fuel goes out.
  • Page 166: Throttle Grip And Cable

    3-80 FUEL SYSTEM (DFI) Throttle Grip and Cable If the throttle grip has excessive free play due to cable stretch or misadjustment, there will be a delay in throttle re- sponse. Also, the throttle valve may not open fully at full throttle.
  • Page 167: Throttle Cable Lubrication

    FUEL SYSTEM (DFI) 3-81 Throttle Grip and Cable • Loosen the mounting bolts [A]. • Remove the cables [B] from the throttle body assy. • Free the tips [C] from the pulley. • Pull out the cables from the frame. •...
  • Page 168: Throttle Body Assy

    3-82 FUEL SYSTEM (DFI) Throttle Body Assy Idle Speed Inspection • Refer to the Idle Speed Inspection in the Periodic Main- tenance chapter. Throttle Bore Cleaning • Refer to the Throttle Body Cleaning in the Periodic Main- tenance chapter. Throttle Body Assy Removal WARNING Gasoline is extremely flammable and can be explo- sive under certain conditions.
  • Page 169: Throttle Body Assy Installation

    FUEL SYSTEM (DFI) 3-83 Throttle Body Assy Throttle Body Assy Installation • Install the throttle body assy so that fit the projection [B] on throttle body assy and groove [A] of the throttle body holder. • Install the removed parts (see appropriate chapters). •...
  • Page 170: Throttle Body Assy Assembly

    3-84 FUEL SYSTEM (DFI) Throttle Body Assy • Remove the screw [A] to pull out the injector from the throttle body assy together with the delivery pipe assy [B]. NOTE ○ Do not damage the insertion portions of the injector when they are pulled out from the throttle body.
  • Page 171 FUEL SYSTEM (DFI) 3-85 Throttle Body Assy • Tighten the delivery pipe mounting screw [A] securely. • Install the inlet air pressure sensor [A] to the vacuum hose. • Install the plate so that fit the hollow [A] on the plate and projection [B] on the throttle body assy.
  • Page 172: Air Cleaner

    3-86 FUEL SYSTEM (DFI) Air Cleaner Air Cleaner Housing Removal • Remove the rear frame (see Rear Frame Removal in the Frame chapter). • Unscrew the bolts [A]. • Remove the air cleaner housing [B] from the rear frame. Air Cleaner Housing Installation •...
  • Page 173: Fuel Tank

    FUEL SYSTEM (DFI) 3-87 Fuel Tank Fuel Tank Removal WARNING Gasoline is extremely flammable and can be explo- sive under certain conditions. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light.
  • Page 174: Fuel Tank Installation

    3-88 FUEL SYSTEM (DFI) Fuel Tank • Be sure to place a piece of cloth around the fuel hose joint [A]. • Insert a minus screw driver [B] into the slit on the joint lock [C]. • Turn the driver to disconnect the joint look. •...
  • Page 175: Fuel Tank Cleaning

    FUEL SYSTEM (DFI) 3-89 Fuel Tank • Insert the fuel hose joint [A] straight onto the fuel outlet pipe until the hose joint clicks. • Push the joint lock [B] until the hose joint clicks. • Push and pull [B] the hose joint [A] back and forth more than two times, and make sure it is locked and does not come off.
  • Page 177 COOLING SYSTEM 4-1 Cooling System Table of Contents Exploded View........................Specifications ......................... Special Tool ..........................Coolant ........................... Coolant Level Inspection....................Coolant Deterioration Inspection..................Coolant Draining ....................... Coolant Filling ........................Air Bleeding........................Cooling System Pressure Testing ..................Cooling System Flushing ....................Water Pump..........................
  • Page 178: Exploded View

    4-2 COOLING SYSTEM Exploded View...
  • Page 179 COOLING SYSTEM 4-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Water Pump Cover Bolts 87 in·lb Coolant Drain Bolt 0.70 61 in·lb Water Pump Impeller Bolt 87 in·lb Water Hose Clamp Screws 0.15 13 in·lb Radiator Mounting Bolts 87 in·lb Radiator Screen Bolts 87 in·lb G: Apply grease.
  • Page 180: Specifications

    4-4 COOLING SYSTEM Specifications Item Service Limit Coolant Type Permanent type antifreeze for aluminum engines and radiators Color Green Mixed Ratio Soft water 50%, antifreeze 50% Freezing Point -35°C (-31°F) Total Amount 1.1 L (1.2 US qt.) Radiator 112 ∼ 142 kPa (1.14 ∼ 1.45 kgf/cm², 16.2 ∼ 20.6 psi) Cap Relief Pressure...
  • Page 181: Special Tool

    COOLING SYSTEM 4-5 Special Tool Bearing Driver Set: 57001-1129...
  • Page 182: Coolant

    4-6 COOLING SYSTEM Coolant Coolant Level Inspection • Refer to the Coolant Level Inspection in the Periodic Main- tenance chapter. Coolant Deterioration Inspection • Refer to the Coolant Deterioration Inspection in the Peri- odic Maintenance chapter. Coolant Draining WARNING To avoid burns, do not remove the radiator cap or try to change the coolant when the engine is still hot.
  • Page 183: Coolant Filling

    COOLING SYSTEM 4-7 Coolant Coolant Filling CAUTION Use coolant containing corrosion inhibitors made specifically for aluminum engines and radiators in accordance with the instruction of the manufac- ture’s. Soft or distilled water must be used with the antifreeze (see below for antifreeze) in the cooling system.
  • Page 184: Cooling System Pressure Testing

    4-8 COOLING SYSTEM Coolant Cooling System Pressure Testing CAUTION During pressure testing, do not exceed the pres- sure for which the system is designed to work. The maximum pressure is 123 kPa (1.25 kgf/cm², 18 psi). • Remove the radiator cap, and install a cooling system pressure tester [A] and adapter [B] on the radiator filler neck [C].
  • Page 185: Water Pump

    COOLING SYSTEM 4-9 Water Pump Water Pump Cover Removal • Drain the coolant (see Coolant Draining). • Loosen the clamp screw [A], and remove the water hose [B] from the water pump cover. • Unscrew the cover bolts [C]. • Using the pry points [A], remove the pump cover [B].
  • Page 186: Impeller Removal

    4-10 COOLING SYSTEM Water Pump Impeller Removal • Drain: Coolant (see Coolant Draining) • Remove: Water Pump Cover (see Water Pump Cover Removal) Impeller Bolt [A] Impeller [B] Impeller Installation • Install: Impeller [A] • Tighten: Torque - Water Pump Impeller Bolt [B]: 9.8 N·m (1.0 kgf·m, 87 in·lb) •...
  • Page 187: Oil Seal And Bearing Installation

    COOLING SYSTEM 4-11 Water Pump • Insert a bar [A] into the water pump shaft hole from the outside of the right engine cover, and remove the ball bearing [B] by tapping [C] evenly around the bearing in- ner race. •...
  • Page 188: Radiator

    4-12 COOLING SYSTEM Radiator Radiator Removal • Drain the coolant (see Coolant Draining). • Remove: Radiator Shrouds (see Radiator Shroud Removal in the Frame chapter) Regulator/Rectifier (see Regulator/Rectifier Removal in the Electrical System chapter) • Loosen: Clamp Screws [A] • Remove: Clamp [B] Water Hoses [C]...
  • Page 189: Radiator Installation

    COOLING SYSTEM 4-13 Radiator Radiator Installation • Fit the projections [A] of the screen in the holes [B] of the radiator. Torque - Water Hose Clamp Screws: 1.5 N·m (0.15 kgf·m, 13 in·lb) Radiator Mounting Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) Radiator Screen Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) •...
  • Page 190: Filler Neck Inspection

    4-14 COOLING SYSTEM Radiator • Wet the top and bottom valve seals with water or coolant to prevent pressure leaks. • Install the cap [A] on a cooling system pressure tester [B]. • Watching the pressure gauge, slowly pump the pressure tester to build up the pressure.
  • Page 191 ENGINE TOP END 5-1 Engine Top End Table of Contents Exploded View........Valve Guide Installation ....5-25 Specifications ........Valve/Valve Guide Clearance Special Tools and Sealant ....Measurement (Wobble Method) 5-26 Cylinder Head Cover ......5-11 Valve Seat Inspection ....5-26 Cylinder Head Cover Removal ..
  • Page 192: Exploded View

    5-2 ENGINE TOP END Exploded View...
  • Page 193 ENGINE TOP END 5-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Cylinder Head Cover Bolts 87 in·lb Cylinder Head Bolts (M10) S, MO Cylinder Head Bolts (M6) 106 in·lb Camshaft Cap Bolts 87 in·lb S, MO Camshaft Sprocket Bolts 106 in·lb Throttle Body Assy Holder Bolts 87 in·lb...
  • Page 194 5-4 ENGINE TOP END Exploded View...
  • Page 195 ENGINE TOP END 5-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Exhaust Pipe Cover Bolts 106 in·lb Exhaust Pipe Holder Nuts Muffler Mounting Bolts Cylinder Bolt 106 in·lb Muffler Clamp Bolt Camshaft Chain Tensioner Mounting Bolts 87 in·lb Camshaft Chain Tensioner Cap Bolt 0.51 44 in·lb EO: Apply engine oil.
  • Page 196: Specifications

    5-6 ENGINE TOP END Specifications Item Standard Service Limit Camshafts Cam Height: 36.943 ∼ 37.057 mm (1.4544 ∼ 1.4589 in.) Exhaust 36.84 mm (1.450 in.) 37.743 ∼ 37.857 mm (1.4859 ∼ 1.4904 in.) Inlet 37.64 mm (1.482 in.) 0.020 ∼ 0.062 mm (0.00079 ∼ 0.0024 in.) Camshaft Journal/Camshaft 0.15 mm (0.0059 in.) Cap Clearance...
  • Page 197 ENGINE TOP END 5-7 Specifications Item Standard Service Limit Inlet Outer 39.28 mm (1.546 in.) 37.8 mm (1.49 in.) Inner 36.05 mm (1.419 in.) 34.5 mm (1.36 in.) Cylinder and Pistons 96.000 ∼ 96.012 mm (3.7795 ∼ 3.7800 in.) Cylinder Inside Diameter 96.10 mm (3.783 in.) 95.970 ∼...
  • Page 198: Special Tools And Sealant

    5-8 ENGINE TOP END Special Tools and Sealant Compression Gauge, 20 kgf/cm²: Valve Seat Cutter, 45° - 35: 57001-221 57001-1116 Valve Spring Compressor Assembly: Valve Seat Cutter, 32° - 35: 57001-241 57001-1121 Valve Guide Arbor, 5.5: Valve Seat Cutter, 32° - 38.5: 57001-1021 57001-1122 Valve Guide Reamer, 5.5:...
  • Page 199 ENGINE TOP END 5-9 Special Tools and Sealant Valve Seat Cutter, 55° - 35: Valve Seat Cutter, 45° - 40: 57001-1247 57001-1496 Spark Plug Wrench, Hex 16: Valve Seat Cutter, 55° - 38.5: 57001-1262 57001-1497 Compression Gauge Adapter, M10 × 1.0: Valve Guide Driver: 57001-1317 57001-1564...
  • Page 200 5-10 ENGINE TOP END Special Tools and Sealant Valve Guide Driver Attachment D: Kawasaki Bond (Silicone Sealant): 57001-1659 92104-0004 Valve Guide Driver Attachment G: 57001-1728...
  • Page 201: Cylinder Head Cover

    Cylinder Head Cover [C] Cylinder Head Cover Installation • Apply silicon sealant [A] to the cylinder head as shown. Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004 • Replace the head cover gasket [A] with a new one. • Install the head cover gasket on the cylinder head.
  • Page 202 5-12 ENGINE TOP END Cylinder Head Cover • Install the spark plug cap [A] so that align it to the rised line [B] on the head cover. ○ Pull up the spark plug cap lightly to make sure of the in- stallation of the spark plug cap.
  • Page 203: Camshaft Chain Tensioner

    ENGINE TOP END 5-13 Camshaft Chain Tensioner Camshaft Chain Tensioner Removal CAUTION This is a non-return type camshaft chain tensioner. The push rod does not return to its original position once it moves out to take up camshaft chain slack. Observe all the rules listed below: When removing the tensioner, do not take out the mounting bolts only halfway.
  • Page 204 5-14 ENGINE TOP END Camshaft Chain Tensioner • Replace the chain tensioner gasket with a new one. • Tighten: Torque - Camshaft Chain Tensioner Mounting Bolts [A]: 9.8 N·m (1.0 kgf·m, 87 in·lb) • Take out the holder plate [B]. •...
  • Page 205: Camshaft

    ENGINE TOP END 5-15 Camshaft Camshaft Removal • Remove: Cylinder Head Cover (see Cylinder Head Cover Re- moval) Timing Inspection Cap [A] Flywheel Nut Cap[B] Special Tool - Filler Cap Driver: 57001-1454 • First, bring the piston to the TDC (of either the compres- sion or exhaust stroke).
  • Page 206: Camshaft Installation

    5-16 ENGINE TOP END Camshaft • Remove: Bolts [A] Auto-Decompressor [B] (with the sprocket) • Remove: Circlips [A] Camshaft Installation • Assemble the auto-decompressor weights [A] and spring [B] to install it to the sprocket [C]. • Replace the circlips [D] with new ones, and install them. •...
  • Page 207 ENGINE TOP END 5-17 Camshaft 1st Pin [A] Mark (exhaust) [D] 2nd Pin [B] Punch Mark (inlet) [E] 29th Pin [C] Cylinder Head Upper Surface [F] • Plug the oil passage and camshaft chain tunnel with a clean cloth for prevent the any parts from dropping in the crankcase.
  • Page 208: Camshaft Chain Removal

    5-18 ENGINE TOP END Camshaft • Uniformly tighten all bolts and after the camshaft has set- tled, uniformly tighten all the bolts. ○ Following the sequence numbers on the camshaft caps. Tighten the cap bolts [1 ∼ 8] after applying molybdenum disulfide oil to the thread of them.
  • Page 209: Camshaft And Camshaft Cap Wear Inspection

    ENGINE TOP END 5-19 Camshaft Camshaft and Camshaft Cap Wear Inspection • Measure each clearance between the camshaft journal and camshaft cap using plastigauge (press gauge) [A]. • Install the camshaft caps (see Camshaft Installation) NOTE ○ Do not turn the camshaft when the plastigauge is be- tween the journal and camshaft cap.
  • Page 210: Cylinder Head

    5-20 ENGINE TOP END Cylinder Head Cylinder Compression Measurement • Start the engine. • Thoroughly warm up the engine so that the engine oil be- tween the piston and cylinder wall will help seal compres- sion as it does during normal running. •...
  • Page 211: Cylinder Head Removal

    ENGINE TOP END 5-21 Cylinder Head Problem Diagnosis Remedy (Action) The cylinder Carbon accumulation on piston and in Remove the carbon deposits and replace compression is cylinder head (combustion chamber) is damaged parts if necessary. higher than the suspected due to damaged valve stem usable range or piston oil rings.
  • Page 212: Cylinder Head Installation

    5-22 ENGINE TOP END Cylinder Head • Remove the cylinder head bolts (M6) [A] and loosen the cylinder bolt [B] for prevent damage. • Remove the cylinder head bolts (M10) following the loos- ening sequence as shown. • Remove the cylinder head [A]. NOTE ○...
  • Page 213: Cylinder Head Cleaning

    ENGINE TOP END 5-23 Cylinder Head • Install: Dowel Pins [A] New Cylinder Head Gasket [B] • Install the cylinder head. ○ The camshaft caps are machined with the cylinder head; therefore, if a new cylinder head is installed, use the caps that are supplied with the new head.
  • Page 214: Valves

    5-24 ENGINE TOP END Valves Valve Clearance Inspection • Refer to the Valve Clearance Inspection in the Periodic Maintenance chapter. Valve Removal • Remove the cylinder head (see Cylinder Head Removal). • Remove the valve lifter and the shim from the valve. NOTE ○...
  • Page 215: Valve Guide Installation

    ENGINE TOP END 5-25 Valves • Hammer lightly on the valve guide arbor [A] to remove the guide. Special Tool - Valve Guide Arbor, 5.5: 57001-1021 Valve Guide Installation • Apply a thin coat of oil to the outer surface of the valve guide.
  • Page 216: Valve/valve Guide Clearance

    5-26 ENGINE TOP END Valves Valve/Valve Guide Clearance Measurement (Wobble Method) ○ If a small bore gauge is not available, inspect the valve guide wear by measuring the valve/valve guide clearance with the wobble method as indicated below. • Insert a new valve [A] into the guide [B] and set a dial gauge against the stem perpendicular to it as close as possible to the cylinder head mating surface.
  • Page 217: Valve Seat Repair

    ENGINE TOP END 5-27 Valves Valve Seat Repair • For the instructions on how to use the valve seat cutter [A], follow the operation manual provided by the manu- facturer. Special Tools - Valve Seat Cutter Holder, 5.5: 57001-1125 Valve Seat Cutter Holder Bar: 57001-1128 Exhaust: Valve Seat Cutter, 45°...
  • Page 218 5-28 ENGINE TOP END Valves Marks Stamped on the Cutter The marks stamped on the back of the cutter [A] represent the following. 60° ......Cutter Angle [B] 37.5 ....... Cutter Outer Diameter [C] Repair Operating Procedures • Clean the seat area carefully. •...
  • Page 219 ENGINE TOP END 5-29 Valves If the outside diameter [A] of the seating surface is too large, make the 32° grind described below. If the outside diameter of the seating surface is within the specified range, measure the seat width as described be- low.
  • Page 220 5-30 ENGINE TOP END Valves Valve Seat Repair...
  • Page 221: Cylinder And Piston

    ENGINE TOP END 5-31 Cylinder and Piston Cylinder Removal • Remove: Cylinder Head (see Cylinder Head Removal) Front Camshaft Chain Guide [A] Cylinder Bolt [B] Water Temperature Sensor Connector [C] • Tap lightly up with a plastic mallet to separate the cylinder from the crankcase.
  • Page 222 5-32 ENGINE TOP END Cylinder and Piston • Install the top ring [A] so that the "R" mark [B] faces up. NOTE ○ If a new piston or cylinder is used, check piston to cylin- der clearance (see Piston/Cylinder Clearance), and use new piston rings.
  • Page 223: Cylinder Wear Inspection

    ENGINE TOP END 5-33 Cylinder and Piston • Apply engine oil to the cylinder bore. • Determine the position of the piston ring ends. • Install the cylinder while compressing the piston rings with your fingers or the special tool [A]. Special Tools - Piston Ring Compressor Grip: 57001-1095 95 ∼...
  • Page 224: Piston Ring Groove Width Inspection

    5-34 ENGINE TOP END Cylinder and Piston Piston Ring Groove Width Inspection • Measure the groove width at several points around the piston with a vernier caliper. Piston Ring Groove Width Standard: 1.03 ∼ 1.05 mm (0.0406 ∼ 0.0413 in.) Service Limit: 1.13 mm (0.0445 in.) If any of the groove widths exceeds the service limit, re-...
  • Page 225: Piston, Piston Pin, Connecting Rod Wear Inspection

    ENGINE TOP END 5-35 Cylinder and Piston Piston, Piston Pin, Connecting Rod Wear Inspection • Visually inspect the snap rings [A] still fitted in place. If the ring shows weakness or deformation, replace the ring. Also if the pin hole groove shows excessive wear, replace the piston.
  • Page 226: Throttle Body Assy Holder

    5-36 ENGINE TOP END Throttle Body Assy Holder Throttle Body Assy Holder Removal • Remove: Throttle Body Assy (see Throttle Body Assy Removal in the Fuel System (DFI) chapter) Throttle Body Assy Holder Bolts [A] Throttle Body Assy Holder [B] Throttle Body Assy Holder Installation •...
  • Page 227: Muffler

    ENGINE TOP END 5-37 Muffler WARNING To avoid a serious burn, do not remove the muffler when the engine is still hot. Wait until the muffler cools down. Muffler Removal • Loosen the muffler clamp bolt [A]. • Remove the exhaust pipe holder nuts [B]. •...
  • Page 228: Muffler Baffle Replacement

    5-38 ENGINE TOP END Muffler Muffler Baffle Replacement • Refer to the Muffler Baffle Change in the Periodic Main- tenance chapter.
  • Page 229 CLUTCH 6-1 Clutch Table of Contents Exploded View........................Specifications ......................... Special Tools .......................... Clutch Lever and Clutch Cable....................Clutch Lever (Clutch Cable) Free Play Inspection ............Clutch Lever (Clutch Cable) Free Play Adjustment ............Clutch Lever Installation....................Clutch Cable Removal ...................... Clutch Cable Installation ....................
  • Page 230: Exploded View

    6-2 CLUTCH Exploded View...
  • Page 231 CLUTCH 6-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Clutch Cover Bolts 87 in·lb Right Engine Cover Bolts 87 in·lb Clutch Spring Bolts 0.90 78 in·lb Clutch Hub Nut 5. Friction Plates (The lining blocks are many.) 6. Friction Plates (The lining blocks are little.) 7.
  • Page 232: Specifications

    6-4 CLUTCH Specifications Item Standard Service Limit Clutch Lever 8 ∼ 13 mm (0.3 ∼ 0.5 in.) Clutch Lever Free Play – – – Clutch 2.92 ∼ 3.08 mm (0.115 ∼ 0.121 in.) Friction Plate Thickness 2.6 mm (0.10 in.) Friction Plate Warp 0.15 mm (0.0059 in.) or less 0.3 mm (0.01 in.)
  • Page 233: Special Tools

    CLUTCH 6-5 Special Tools Inside Circlip Pliers: Clutch Holder: 57001-143 57001-1243 Bearing Driver Set: 57001-1129...
  • Page 234: Clutch Lever And Clutch Cable

    6-6 CLUTCH Clutch Lever and Clutch Cable Due to friction plate wear and clutch cable stretch over a long period of use, the clutch must be adjusted in accor- dance with the Periodic Maintenance Chart. WARNING To avoid a serious burn, never touch the hot engine or exhaust chamber during clutch adjustment.
  • Page 235: Clutch Cable Installation

    CLUTCH 6-7 Clutch Lever and Clutch Cable • Loosen the adjusting nuts [A] fully. • Free the clutch inner cable tip [B] from the clutch release lever [C]. CAUTION Do not remove the clutch release shaft unless it is absolutely necessary. If removed, release shaft oil seal must be replaced with a new one.
  • Page 236: Clutch Cover And Right Engine Cover

    6-8 CLUTCH Clutch Cover and Right Engine Cover Clutch Cover Removal • Drain the engine oil (see Engine Oil Change in the Peri- odic Maintenance chapter). • Remove the brake pedal (see Brake Pedal Removal in the Brakes chapter). • Remove: Clutch Cover Bolts [A] Clutch Cover [B]...
  • Page 237: Right Engine Cover Installation

    CLUTCH 6-9 Clutch Cover and Right Engine Cover Right Engine Cover Installation • Three dowel pins [A] are installed at the mating surface between the crankcase and the right engine cover. • Apply grease to the O-rings [B], and install them to the crankcase.
  • Page 238 6-10 CLUTCH Clutch Cover and Right Engine Cover • Press the kick shaft oil seal [B] so that the bearing surface flush with the right engine cover surface [A]. Special Tool - Bearing Driver Set: 57001-1129 • Apply grease to the oil seal lip.
  • Page 239: Clutch Removal

    CLUTCH 6-11 Clutch Clutch Removal • Drain the engine oil (see Engine Oil Change in the Peri- odic Maintenance chapter). • Remove the clutch cover (see Clutch Cover Removal). • Remove: Clutch Spring Bolts [A] Clutch Spring Clutch Spring Plate [B] •...
  • Page 240: Clutch Installation

    6-12 CLUTCH Clutch Clutch Installation • Check the clutch plate assembly free play (see Clutch Plate Assembly Free Play Inspection/Adjustment). • Apply molybdenum disulfide oil to the inside of the clutch housing. • Install: Clutch Housing [A] Toothed Washer [B] •...
  • Page 241 CLUTCH 6-13 Clutch • Install the clutch spring plate [A]. • Tighten: Torque - Clutch Spring Bolts [B]: 8.8 N·m (0.90 kgf·m, 78 in·lb) • Install the clutch cover (see Clutch Cover Installation). • Check the release shaft lever positions. ○...
  • Page 242: Clutch Plate Assembly Free Play Inspection/adjustment

    6-14 CLUTCH Clutch Clutch Plate Assembly Free Play Inspection/Ad- justment • Assemble the following parts. Clutch Hub [A] Friction Plates [B] Steel Plates [C] Friction Plates [D] Spring Plates [E] Spring [F] Bolts [G] ○ The friction plates [B] have many lining blocks than other plates [D].
  • Page 243: Clutch Housing Finger Damage Inspection

    CLUTCH 6-15 Clutch Clutch Housing Finger Damage Inspection • Visually inspect the clutch housing fingers [A] that come in contact with the friction plate tangs. If they are damaged or if there are groove cuts in the areas that come in contact with the tangs, replace the housing. Replace the friction plates if their tangs are damaged as well.
  • Page 244: Release Shaft Installation

    6-16 CLUTCH Clutch Release Shaft Installation • Replace the oil seal with a new one. • Apply grease to the oil seal lip. • Apply engine oil to the bearing in the hole of the crankcase. • Apply grease to the part where the push rod comes in contact.
  • Page 245 ENGINE LUBRICATION SYSTEM 7-1 Engine Lubrication System Table of Contents Exploded View........................Lubrication System Chart ....................... Specifications ......................... Special Tools .......................... Engine Oil and Oil Filter......................Engine Oil Level Inspection ....................Engine Oil Change......................Oil Filter Change ....................... Oil Screen (Scavenge) Removal..................Oil Screen (Scavenge) Installation..................
  • Page 246: Exploded View

    7-2 ENGINE LUBRICATION SYSTEM Exploded View...
  • Page 247 ENGINE LUBRICATION SYSTEM 7-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Engine Oil Drain Bolt (M10) Engine Oil Drain Bolt (M6) 0.71 62 in·lb Oil Pump (Scavenge) Cover Bolts 87 in·lb Oil Pump (Feed) Cover Bolts 87 in·lb Oil Filter Cover (Right Engine Cover) Bolt 87 in·lb Oil Filter Cover Bolt 87 in·lb...
  • Page 248: Lubrication System Chart

    7-4 ENGINE LUBRICATION SYSTEM Lubrication System Chart...
  • Page 249 ENGINE LUBRICATION SYSTEM 7-5 Lubrication System Chart 1. Oil Screen (feed) 2. Oil Pump (feed) 3. Oil Pressure Relief Valve 4. Right Engine Cover Oil Passage (from Feed Oil Pump to Oil filter) 5. Oil Filter 6. Right Engine Cover Oil Passage (from Oil filter to Crankshaft) 7.
  • Page 250: Specifications

    7-6 ENGINE LUBRICATION SYSTEM Specifications Item Standard Engine Oil Grade Castrol “POWER1 R4 Racing” 5W-40 or API SG API SH, SJ or SL with JASO MA, MA1 or MA2 Viscosity SAE 10W-30, 10W-40, or 10W-50 Capacity Oil Change - when filter is not removed 0.96 L (1.01 US qt) Oil Change - when filter is removed 0.98 L (1.03 US qt)
  • Page 251: Special Tools

    ENGINE LUBRICATION SYSTEM 7-7 Special Tools Oil Pressure Gauge, 5 kgf/cm²: Oil Pressure Gauge Adapter, M10 × 1.25: 57001-125 57001-1182 Outside Circlip Pliers: Oil Pressure Cap: 57001-144 57001-1656...
  • Page 252: Engine Oil And Oil Filter

    7-8 ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter WARNING Motorcycle operation with insufficient, deteri- orated, or contaminated engine oil will cause accelerated wear and may result in engine or trans- mission seizure, accident, and injury. The engine oil level indicated in the right engine cover oil level gauge is very sensitive to the motorcycle’s posi- tion and engine rpm at time of shut down.
  • Page 253: Oil Filter Change

    ENGINE LUBRICATION SYSTEM 7-9 Engine Oil and Oil Filter Oil Filter Change • Refer to the Oil Filter Change in the Periodic Maintenance chapter. Oil Screen (Scavenge) Removal • Remove the oil pump (scavenge) cover (see Oil Pump (Scavenge) Cover Removal). •...
  • Page 254: Oil Screen (scavenge) Cleaning

    7-10 ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter • Install the oil screen [A], and tighten the bolts [B]. Torque - Oil Screen (Feed) Mounting Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) Oil Screen (Scavenge) Cleaning • Remove the oil screen (see Oil Screen (Scavenge) Re- moval).
  • Page 255: Oil Screen (feed) Cleaning

    ENGINE LUBRICATION SYSTEM 7-11 Engine Oil and Oil Filter Oil Screen (Feed) Cleaning • Remove the oil screen (see Oil Screen (Feed) Removal) • Clean the oil screen with a high-flash point solvent and remove the particles stuck. • Blow away the particles by applying compressed air [A] from the inside to the outside (from the clean side to the dirty side).
  • Page 256: Oil Pressure Relief Valve

    7-12 ENGINE LUBRICATION SYSTEM Oil Pressure Relief Valve Oil Pressure Relief Valve Removal • Remove: Right Engine Cover (see Right Engine Cover Removal in the Clutch chapter) • Remove the oil pressure relief valve [A]. Oil Pressure Relief Valve Installation •...
  • Page 257: Oil Pump

    ENGINE LUBRICATION SYSTEM 7-13 Oil Pump Oil Pump (Scavenge) Removal • Drain: Engine Oil (see Engine Oil Change in the Periodic Main- tenance chapter) • Remove: Flywheel (see Flywheel Removal in the Electrical Sys- tem chapter) • Remove: Oil Pump Cover Bolts [A] Lower Camshaft Chain Guide [B] Oil Pump Cover [C] •...
  • Page 258: Oil Pump (feed) Removal

    7-14 ENGINE LUBRICATION SYSTEM Oil Pump • Install: Oil Pump Cover [A] Lower Camshaft Chain Guide [B] • While pushing the oil pump cover, tighten the oil pump cover bolts [C]. Torque - Oil Pump (Scavenge) Cover Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) Oil Pump (Feed) Removal •...
  • Page 259: Oil Pump Inspection

    ENGINE LUBRICATION SYSTEM 7-15 Oil Pump • While pushing the oil pump cover [A], tighten the oil pump cover bolts. [B] L = 20mm [C] L = 16mm Torque - Oil Pump (Feed) Cover Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) •...
  • Page 260: Oil Pressure

    7-16 ENGINE LUBRICATION SYSTEM Oil Pressure Oil Pressure Measurement • Remove: Oil Filter Cover Bolts [A] Oil Filter Cover [B] • Install the O-rings to the oil pressure cap. Special Tool - Oil Pressure Cap: 57001–1656 • Install the oil pressure cap. •...
  • Page 261 ENGINE REMOVAL/INSTALLATION 8-1 Engine Removal/Installation Table of Contents Exploded View........................Special Tool ..........................Engine Removal/Installation ....................Engine Removal........................ Engine Installation......................
  • Page 262: Exploded View

    8-2 ENGINE REMOVAL/INSTALLATION Exploded View...
  • Page 263 ENGINE REMOVAL/INSTALLATION 8-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Middle Engine Mounting Nut Middle Engine Bracket Nuts Upper Engine Mounting Bolts Upper Engine Bracket Bolts Lower Engine Mounting Nut Swingarm Pivot Shaft Nut S: Follow the specified tightening sequence.
  • Page 264: Special Tool

    8-4 ENGINE REMOVAL/INSTALLATION Special Tool Jack: 57001-1238...
  • Page 265: Engine Removal/installation

    ENGINE REMOVAL/INSTALLATION 8-5 Engine Removal/Installation Engine Removal • Raise the rear wheel off the ground with the jack [A]. Special Tool - Jack: 57001-1238 WARNING For engine removal, the swingarm pivot shaft must be pulled out, causing the swingarm and rear wheel assembly to become detached.
  • Page 266 8-6 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Remove: Water Hoses [A] Right Engine Guard [B] • Remove the bolts [C], and remove the brake pedal [D] and rear master cylinder [E] as a set. • Remove: Upper Engine Bracket Bolts (Left and Right) [A] Upper Engine Mounting Bolts and Nuts (Left and Right) Upper Engine Brackets (Left and Right) [C] Middle Engine Bracket Bolts and Nuts [D]...
  • Page 267: Engine Installation

    ENGINE REMOVAL/INSTALLATION 8-7 Engine Removal/Installation Engine Installation • Install the engine. ○ First, insert the front portion of the engine, and then install the rear portion. • Install the swingarm pivot shaft, all engine bracket and mounting bolts temporarily. ○ Insert the swingarm pivot shaft from the right side.
  • Page 269 CRANKSHAFT/TRANSMISSION 9-1 Crankshaft/Transmission Table of Contents Exploded View........................Specifications ......................... Special Tools and Sealant ...................... Crankcase ..........................Crankcase Disassembly ....................Crankcase Assembly ......................9-10 Crankshaft ..........................9-16 Crankshaft Removal ......................9-16 Crankshaft Installation ...................... 9-16 Crankshaft Disassembly ....................9-16 Crankshaft Assembly ......................9-16 Crankshaft Inspection .......................
  • Page 270: Exploded View

    9-2 CRANKSHAFT/TRANSMISSION Exploded View...
  • Page 271 CRANKSHAFT/TRANSMISSION 9-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb 1 Crankcase Bolts (M6) 106 in·lb 2 Crankcase Bolts (M7) 3 Engine Oil Drain Bolt (M10) 4 Engine Oil Drain Bolt (M6) 0.71 62 in·lb 5 Piston Oil Nozzle 0.30 26 in·lb 6 Piston Oil Nozzle Bolt 0.71...
  • Page 272 9-4 CRANKSHAFT/TRANSMISSION Exploded View...
  • Page 273 CRANKSHAFT/TRANSMISSION 9-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Ratchet Guide Bolt 0.90 78 in·lb Kick Pedal Bolt 87 in·lb Shift Pedal Bolt Upper Ratchet Plate Mounting Bolt 87 in·lb Lower Ratchet Plate Mounting Bolt L, S Gear Positioning Lever Nut 0.90 78 in·lb Shift Drum Cam Bolt...
  • Page 274: Specifications

    9-6 CRANKSHAFT/TRANSMISSION Specifications Item Standard Service Limit Crankshaft 0.002 ∼ 0.014 mm Connecting Rod Big End Radial 0.06 mm (0.002 in.) (0.00008 ∼ 0.00055 in.) Clearance 0.25 ∼ 0.35 mm Connecting Rod Big End Side 0.6 mm (0.02 in.) (0.0098 ∼ 0.014 in.) Clearance Crankshaft Runout TIR 0.03 mm (0.0012 in.) or less...
  • Page 275: Special Tools And Sealant

    Special Tools and Sealant Inside Circlip Pliers: Gear Holder, m2.0: 57001-143 57001-1557 Outside Circlip Pliers: Grip: 57001-144 57001-1591 Bearing Driver Set: Rotor Holder: 57001-1129 57001-1730 Crankshaft Jig: Kawasaki Bond (Liquid Gasket - Gray): 57001-1174 92104-1063 Crankcase Splitting Tool Assembly: 57001-1362...
  • Page 276: Crankcase

    9-8 CRANKSHAFT/TRANSMISSION Crankcase Crankcase Disassembly • Remove the engine from the frame (see Engine Removal in the Engine Removal/Installation chapter). • Set the engine on clean surface while parts are being re- moved. • Remove: Piston (see Piston Removal in the Engine Top End chap- ter) Right Engine Cover (see Right Engine Cover Removal in the Clutch chapter)
  • Page 277 CRANKSHAFT/TRANSMISSION 9-9 Crankcase • Remove: Circlip [A] Balancer Drive Gear [B] • Remove the crankcase bolts [A]. • Pry a pry point [A] at the crankcase mating surface, and split the crankcase. If crankcase splitting can not easily, split the crankcase according to the following procedures.
  • Page 278: Crankcase Assembly

    9-10 CRANKSHAFT/TRANSMISSION Crankcase CAUTION Do not remove the bearings and the oil seals unless it is necessary. Removal may damage them. Crankcase Assembly CAUTION Right and left crankcase halves are machined at the factory in the assembled state, so if replaced, they must be replaced as a set.
  • Page 279 CRANKSHAFT/TRANSMISSION 9-11 Crankcase • Press the new drive shaft bearing [A] in the right crankcase [B] half so that the stepped side [C] faces inside of the engine. Special Tool - Bearing Driver Set: 57001-1129 • Press the new crankshaft bearings [A] in the left and right crankcase halves [B] so that the stepped side [C] faces inside of the engine.
  • Page 280 9-12 CRANKSHAFT/TRANSMISSION Crankcase • Replace the oil seals, if removed. • Press the output shaft, shift shaft and release shaft oil seals [C] so that oil seal lip [A] face to the engine outside and oil seal surface flush with the left crankcase surface [B].
  • Page 281: Crankshaft

    Dowel Pins [B] O-ring • Apply liquid gasket to the mating surface [A] of the left crankshaft half. Sealant - Kawasaki Bond (Liquid Gasket - Gray): 92104 -1063 NOTE ○ Make the application finish within 30 minutes when the liquid gasket to the mating surface of the left crankcase half is applied.
  • Page 282 9-14 CRANKSHAFT/TRANSMISSION Crankcase • Using a plastic hammer, press the rear portion of the crankcase, and tap the area around the crankshaft of the left crankcase half. While maintaining the mating sur- faces of the right and left crankcase halves constantly par- allel, mate the crankcase halves evenly.
  • Page 283 CRANKSHAFT/TRANSMISSION 9-15 Crankcase • Replace the O-ring [A] on the output shaft with new ones. • Install O-ring on the grinding faces of the output shaft while expanding the O-ring by the hand. • Apply grease to the inside of the output shaft collar [B]. •...
  • Page 284: Crankshaft Removal

    9-16 CRANKSHAFT/TRANSMISSION Crankshaft Crankshaft Removal • Disassemble the crankcase (see Crankcase Disassem- bly). • Using the hand pull out the crankshaft [A] from the right crankcase half [B]. Crankshaft Installation • Apply grease to the outer side of the crankshaft bearings and use the bearing driver set [C] to face the stepped side [A] to the engine inside and drive the bearing to the bottom of the crankcase [B].
  • Page 285: Crankshaft Inspection

    CRANKSHAFT/TRANSMISSION 9-17 Crankshaft • Carefully align the oil passage hole in the right flywheel [A] with the one in the crankpin [B] at rebuilding of the crankshaft as shown. Crankshaft Inspection Connecting Rod Big End Radial Clearance Inspection • Set the crankshaft on V blocks, and place a dial gauge [A] against the connecting rod big end.
  • Page 286: Connecting Rod Bend Inspection

    9-18 CRANKSHAFT/TRANSMISSION Crankshaft • Next, correct the vertical misalignment by either driving a wedge [A] in between the crank halves or by squeezing them in a vice, depending on the nature of the misalign- ment. CAUTION Do not hammer the crank half at the point [B]. If flywheel misalignment cannot be corrected by the above method, replace the crank pin or the crankshaft itself.
  • Page 287: Connecting Rod Twist Inspection

    CRANKSHAFT/TRANSMISSION 9-19 Crankshaft Connecting Rod Twist Inspection • With the big-end arbor [A] still on the V block [C], hold the connecting rod horizontally and measure the amount that the arbor [B] varies from being parallel with the surface plate over a 100 mm length of the arbor to determine the amount of connecting rod twist.
  • Page 288: Transmission

    9-20 CRANKSHAFT/TRANSMISSION Transmission Transmission Shaft Removal • Disassemble the crankcase (see Crankcase Disassem- bly). • Pull out the shift rods [A] allowing the shift fork guide pins to free from the shift drum [B]. • Remove the shift forks [C]. •...
  • Page 289: Transmission Shaft Disassembly

    CRANKSHAFT/TRANSMISSION 9-21 Transmission Transmission Shaft Disassembly • Remove the transmission shafts. • Remove the circlips, washers, then gears. Special Tool - Outside Circlip Pliers: 57001-144 • Do not reuse the removed circlips. Transmission Shaft Assembly • Apply engine oil liberally to the transmission shaft, gears and bearings.
  • Page 290 9-22 CRANKSHAFT/TRANSMISSION Transmission 1. 2nd Gear (17T) 9. Drive Shaft 2. Circlip 10. Output Shaft 3. Toothed Washer 11. 1st Gear (28T) 4. Bushing 12. 5th Gear (21T) 5. 4th Gear (19T) 13. 3rd Gear (19T) 6. 3rd Gear (16T) 14.
  • Page 291: Shift Fork Bending Inspection

    CRANKSHAFT/TRANSMISSION 9-23 Transmission Shift Fork Bending Inspection • Visually inspect the shift forks, and replace any fork that is bent. A bent fork may cause difficulty in shifting, or allow the transmission to jump out of gear when under power. 90°...
  • Page 292: Balancer

    9-24 CRANKSHAFT/TRANSMISSION Balancer Balancer Removal • Hold the flywheel [A] with the rotor holder [B] to loosen the balancer weight mounting nut [C] Special Tools - Grip [D]: 57001-1591 Rotor Holder: 57001-1730 • Remove: Right Engine Cover (see Right Engine Cover Removal in the Clutch chapter) Magneto Cover (see Magneto Cover Removal in the Electrical System chapter)
  • Page 293: Primary Gear

    CRANKSHAFT/TRANSMISSION 9-25 Primary Gear Primary Gear Removal • Remove: Right Engine Cover (see Right Engine Cover Removal in the Clutch chapter) Clutch (see Clutch Removal in the Clutch chapter) • Temporarily install the clutch housing [A]. • Remove: Oil Pump Drive Shaft [B] Oil Pump Gear [C] •...
  • Page 294: External Shift Mechanism

    9-26 CRANKSHAFT/TRANSMISSION External Shift Mechanism Shift Pedal Removal • Remove: Shift Pedal Bolt [A] Shift Pedal [B] Shift Pedal Installation • Install the shift pedal so that the split portion [A] on the pedal align with the punch mark [B] on the shift shaft. •...
  • Page 295: External Shift Mechanism Installation

    CRANKSHAFT/TRANSMISSION 9-27 External Shift Mechanism External Shift Mechanism Installation • Install the gear positioning lever [A]. ○ Fit each end of the spring [B] or original positions. ○ Install the color and washer [C]. • Tighten: Torque - Gear Positioning Lever Nut [D]: 8.8 N·m (0.90 kgf·m, 78 in·lb) •...
  • Page 296: External Shift Mechanism Inspection

    9-28 CRANKSHAFT/TRANSMISSION External Shift Mechanism • Before installing the shift shaft, apply grease to the oil seal lips and shift shaft splines. • Insert the shift shaft [A]. • Replace the circlip [B] with a new one. • Install the oil pump driver gear [C]. •...
  • Page 297: Kickstarter

    CRANKSHAFT/TRANSMISSION 9-29 Kickstarter Kick Pedal Assy Removal • Remove: Mounting Bolt [A] Kick Pedal Assy [B] Kick Pedal Assy Installation • Install the kick pedal assy [A] as shown. 15.6 ∼ 25.6mm (0.614 ∼ 1.00 in.) [B] • Apply a non-permanent locking agent to the kick pedal bolt.
  • Page 298: Idle Gear Installation

    9-30 CRANKSHAFT/TRANSMISSION Kickstarter Idle Gear Installation • Make sure to position the circlip [A] in original position. Replace it, if removed. • Apply molybdenum disulfide oil to the inside [B] of the idle gear. • Replace the circlip [A] with a new one. •...
  • Page 299: Kick Shaft Assembly Disassembly/assembly

    CRANKSHAFT/TRANSMISSION 9-31 Kickstarter • Install the ratchet guide [A]. • Tighten: Torque - Ratchet Guide Bolt: 8.8 N·m (0.90 kgf·m, 78 in·lb) • Insert the kick shaft assembly [B] into the crankcase. ○ Securely engage the stopper portion [C] of the ratchet gear with the guide.
  • Page 300 9-32 CRANKSHAFT/TRANSMISSION Kickstarter • Fit the spring end [A] and hollow [B] on the spring guide.
  • Page 301: Bearings/oil Seals

    CRANKSHAFT/TRANSMISSION 9-33 Bearings/Oil Seals Bearing Replacement CAUTION Do not remove the ball bearings unless it is neces- sary. Removal may damaged them. • Remove the ball bearing and/or needle bearing outer race using a press or puller. NOTE ○ In the absence of the above mentioned tools, satisfac- tory results may be obtained by heating the case to ap- proximately 93°C (200°F) max, and tapping the bearing in or out.
  • Page 302: Oil Seal Inspection

    9-34 CRANKSHAFT/TRANSMISSION Bearings/Oil Seals • Check the needle bearing. ○ 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. If there is any doubt as to the condition of a needle bear- ing, replace it.
  • Page 303 WHEELS/TIRES 10-1 Wheels/Tires Table of Contents Exploded View........................10-2 Specifications ......................... 10-4 Special Tools .......................... 10-5 Wheels (Rims) ........................10-6 Front Wheel Removal ....................... 10-6 Front Wheel Installation ....................10-6 Rear Wheel Removal......................10-7 Rear Wheel Installation..................... 10-8 Wheels Inspection......................10-10 Spoke Tightness Inspection ....................
  • Page 304: Exploded View

    10-2 WHEELS/TIRES Exploded View...
  • Page 305 WHEELS/TIRES 10-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Not less than Not less than Not less than Spoke Nipples 0.22 19 in·lb Front Axle Nut Front Axle Clamp Bolts AL, S Rear Axle Nut 11.2 81.1 AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque. G: Apply grease.
  • Page 306: Specifications

    10-4 WHEELS/TIRES Specifications Item Standard Service Limit Wheels (Rims) Rim Runout (with tire installted): Axial TIR 1.0 mm (0.039 in.) or less TIR 2 mm (0.08 in.) Radial TIR 1.0 mm (0.039 in.) or less TIR 2 mm (0.08 in.) Axle Runout/100 mm (3.94 in.) TIR 0.1 mm (0.004 in.) or less TIR 0.2 mm (0.008 in.)
  • Page 307: Special Tools

    WHEELS/TIRES 10-5 Special Tools Inside Circlip Pliers: Jack: 57001-143 57001-1238 Rim Protector: Bearing Remover Head, 20 × 22: 57001-1063 57001-1293 Bead Breaker Assembly: Bearing Remover Head, 25 × 28: 57001-1072 57001-1346 Bearing Driver Set: Bearing Remover Shaft, 13: 57001-1129 57001-1377...
  • Page 308: Wheels (rims)

    10-6 WHEELS/TIRES Wheels (Rims) Front Wheel Removal • Unscrew the axle nut [A]. • Loosen the left and right axle clamp bolts [B]. • Using the jack under the frame, and raise the front wheel off the ground. • Special Tool - Jack: 57001-1238 •...
  • Page 309: Rear Wheel Removal

    WHEELS/TIRES 10-7 Wheels (Rims) • Tighten the axle nut [A]. • Tighten the left axle clamp bolts [B]. Torque - Front Axle Nut: 79 N·m (8.0 kgf·m, 58 ft·lb) Left Front Axle Clamp Bolts: 20 N·m (2.0 kgf·m, 15 ft·lb) NOTE ○...
  • Page 310: Rear Wheel Installation

    10-8 WHEELS/TIRES Wheels (Rims) • Squeeze the front brake lever, and hold it with a band [A] to prevent the motorcycle from running forward. WARNING Be sure to hold the front brake when removing the rear wheel, or the motorcycle may fall over. It could cause an accident and injury.
  • Page 311 WHEELS/TIRES 10-9 Wheels (Rims) • Fit the projection [A] on the cap to the groove [B] on the collar. ○ The collars are identical. • Apply grease to the grease seal lips of the rear hub. • Fit the collars [A] and caps [B] on the both sides of the rear hub.
  • Page 312: Wheels Inspection

    10-10 WHEELS/TIRES Wheels (Rims) NOTE ○ When inserting the cotter pin, if the slots in the nut do not align with the cotter pin hole in the axle shaft, tighten the nut clockwise [A] up to next alignment. ○ It should be within 30 degree. ○...
  • Page 313: Tires

    WHEELS/TIRES 10-11 Tires Air Pressure Inspection/Adjustment • Refer to the Air Pressure Inspection/Adjustment in the Pe- riodic Maintenance chapter. Tire Removal • Remove the wheel from the motorcycle. CAUTION Do not lay the wheel on the ground with the disc facing down.
  • Page 314: Tire Installation

    10-12 WHEELS/TIRES Tires • Step on the side of the tire opposite valve stem, pry the tire off the rim with the tire irons [A] of the bead breaker protecting the rim with rim protectors [B]. • Begin to remove the tire beads from the rim, and com- pletely remove the tire beads that are valve stem of the opposite side, and then remove the tire beads slowly.
  • Page 315 WHEELS/TIRES 10-13 Tires • Tighten the bead protector nut [A] and valve stem nut [B], and put on the valve cap [C]. ○ Check and adjust the air pressure after installing.
  • Page 316: Hub Bearing

    10-14 WHEELS/TIRES Hub Bearing Front Hub Bearing Removal • Remove Front Wheel (see Front Wheel Removal) Grease Seals [A] • Use the bearing remover to remove the hub bearings [A]. CAUTION Do not lay the wheel on the ground with the disc facing down.
  • Page 317: Hub Bearing Installation

    WHEELS/TIRES 10-15 Hub Bearing • Using a suitable bar [A], tap the around of the bearing inner race evenly to remove the bearings [B]. Hub Bearing Installation • Before installing the hub bearings, blow any dirt or foreign particles out of the hub with compressed air to prevent contamination of the bearings.
  • Page 318: Hub Bearing Inspection

    10-16 WHEELS/TIRES Hub Bearing Hub Bearing Inspection Since the hub bearings are made to extremely close tol- erances, the clearance can not normally be measured. NOTE ○ Do not remove any bearings for inspection. If any bear- ings are removed, they will need to be replaced with new ones.
  • Page 319 FINAL DRIVE 11-1 Final Drive Table of Contents Exploded View........................11-2 Specifications ......................... 11-4 Drive Chain..........................11-5 Drive Chain Slack Inspection .................... 11-5 Drive Chain Slack Adjustment ..................11-5 Wheel Alignment Inspection ..................... 11-5 Wheel Alignment Adjustment.................... 11-5 Drive Chain Wear Inspection .................... 11-5 Drive Chain Lubrication.....................
  • Page 320: Exploded View

    11-2 FINAL DRIVE Exploded View...
  • Page 321 FINAL DRIVE 11-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Rear Sprocket Nuts Engine Sprocket Nut Engine Sprocket Cover Bolts 87 in·lb G: Apply grease. HO: Apply heavy oil. L: Apply a non-permanent locking agent. R: Replacement Parts...
  • Page 322: Specifications

    11-4 FINAL DRIVE Specifications Item Standard Service Limit Drive Chain 52 ∼ 58 mm (2.0 ∼ 2.3 in.) Chain Slack – – – 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) Chain 20-link Length 323 mm (12.7 in.) Standard Chain: Make DAIDO –...
  • Page 323: Drive Chain Slack Inspection

    FINAL DRIVE 11-5 Drive Chain Drive Chain Slack Inspection • Refer to the Drive Chain Slack Inspection in the Periodic Maintenance chapter. Drive Chain Slack Adjustment • Refer to the Drive Chain Slack Adjustment in the Periodic Maintenance chapter. Wheel Alignment Inspection •...
  • Page 324 11-6 FINAL DRIVE Drive Chain • Install the clip [A] so that the closed end [B] of the "U" pointed in the direction of chain rotation [C]. • Adjust the drive chain slack (see Drive Chain Slack Ad- justment). • Check the rear brake effectiveness.
  • Page 325: Sprockets

    FINAL DRIVE 11-7 Sprockets Engine Sprocket Removal • Remove: Engine Sprocket Cover Bolts [A] Engine Sprocket Cover [B] Drive Chain Guide [C] • Flatten the bended sprocket washer [A]. • Remove: Engine Sprocket Nut [B] Washer • Remove the drive chain [D] from the engine sprocket [C]. Engine Sprocket Installation •...
  • Page 326: Rear Sprocket Installation

    11-8 FINAL DRIVE Sprockets Rear Sprocket Installation • Install the rear sprocket [A] so that the marked side [B] faces out. • Tighten: Torque - Rear Sprocket Nuts: 34 N·m (3.5 kgf·m, 25 ft·lb) Sprocket Wear Inspection • Refer to the Sprocket Wear Inspection in the Periodic Maintenance chapter.
  • Page 327 BRAKES 12-1 Brakes Table of Contents Exploded View........................12-2 Specifications ......................... 12-6 Special Tool ..........................12-7 Brake Lever, Brake Pedal....................... 12-8 Brake Lever Adjustment....................12-8 Brake Pedal Position Adjustment..................12-8 Brake Pedal Removal ....................... 12-8 Brake Pedal Installation ....................12-8 Brake Fluid ..........................
  • Page 328: Exploded View

    12-2 BRAKES Exploded View...
  • Page 329 BRAKES 12-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Master Cylinder Clamp Bolts 0.90 78 in·lb Brake Hose Banjo Bolts Brake Pad Pin 0.80 69 in·lb Caliper Bleed Valve Front Caliper Mounting Bolts Front Brake Disc Mounting Bolts 88 in·lb Brake Lever Pivot Bolt Locknut 0.60...
  • Page 330 12-4 BRAKES Exploded View...
  • Page 331 BRAKES 12-5 Exploded View Torque Fastener marks N·m kgf·m ft·lb Brake Hose Banjo Bolts Rear Master Cylinder Mounting Bolts 88 in·lb Rear Master Cylinder Push Rod Locknut Caliper Bleed Valve 0.80 69 in·lb Brake Pad Pin Rear Brake Pad Pin Plug 0.25 22 in·lb Rear Caliper Holder Shaft...
  • Page 332: Specifications

    12-6 BRAKES Specifications Item Standard Service Limit Brake adjustment Lever Play Adjustable (to suit rider) – – – Brake Fluid Recommended Disc Brake Fluid: – – – Type Front DOT3 or DOT4 – – – Rear DOT4 Brake Pads Lining thickness: Front 4.0 mm (0.16 in.) 1 mm (0.04 in.)
  • Page 333: Special Tool

    BRAKES 12-7 Special Tool Jack: 57001-1238...
  • Page 334: Brake Lever, Brake Pedal

    12-8 BRAKES Brake Lever, Brake Pedal Brake Lever Adjustment • Refer to the Brake Lever and Pedal Position Adjustment in the Periodic Maintenance chapter. Brake Pedal Position Adjustment • Refer to the Brake Lever and Pedal Position Adjustment in the Periodic Maintenance chapter. Brake Pedal Removal •...
  • Page 335 BRAKES 12-9 Brake Lever, Brake Pedal • Install the joint pin [A], washer [B] and a new cotter pin [C]. ○ Bend the ends [D] of the cotter pin. • Adjust the brake pedal position (see Brake Lever and Pedal Position Adjustment in the Periodic Maintenance chapter).
  • Page 336: Brake Fluid

    12-10 BRAKES Brake Fluid WARNING When working with the disc brake, observe the pre- cautions listed below. 1. Never reuse old brake fluid. 2. Do not use fluid from a container that has been left unsealed or that has been open for a long time. 3.
  • Page 337: Bleeding The Brake Line

    BRAKES 12-11 Brake Fluid Bleeding the Brake Line 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. Air, however, is easily compressed. When air enters the brake lines, brake lever or pedal movement will be partially used in compressing the air.
  • Page 338 12-12 BRAKES Brake Fluid • Repeat this operation until no more air can be seen com- ing out into the plastic hose. 1. Pump the brake lever until it becomes hard, and apply the brake and hold it [A]. 2. Quickly open and close the bleed valve while holding the brake applied [B].
  • Page 339: Calipers

    BRAKES 12-13 Calipers Caliper Removal Front Brake • Loosen the banjo bolt [A] on the caliper side once, and tighten again lightly. • Loosen the brake pad pin [B] before the caliper removal if the caliper is to be disassembled. •...
  • Page 340: Caliper Disassembly

    12-14 BRAKES Calipers • Bleed the brake line (see Bleeding the Brake Line). • Check the brake for good braking power, no brake drag, and no fluid leakage. WARNING Do not attempt to drive the motorcycle until a full brake lever or pedal is obtained by pumping the brake lever or pedal until the pads are against the disc.
  • Page 341: Caliper Dust Boot And Friction Boot Damage

    BRAKES 12-15 Calipers Caliper Dust Boot and Friction Boot Damage • Check that the dust boot [A] and friction boot [B] are not cracked, worn, swollen, or other wise damaged. If they show any damage, replace it. [C] Front Caliper [D] Rear Caliper Caliper Piston and Cylinder Damage •...
  • Page 342: Caliper Holder Shaft Wear

    12-16 BRAKES Calipers Caliper Holder Shaft Wear The caliper body must slide smoothly on the caliper holder shafts [A]. If the body does not slide smoothly, one pad will wear more than the other, pad wear will increase, and con- stant drag on the disc will raise brake and brake fluid tem- perature.
  • Page 343: Brake Pad

    BRAKES 12-17 Brake Pad Brake Pad Removal Front Brake • Unscrew the pad pin [A]. • Take the piston side pad [B]. • Remove another pad [C] from the caliper holder. Rear Brake • Remove: Pad Pin Plug [A] • Unscrew the pad pin[A].
  • Page 344: Master Cylinder

    12-18 BRAKES Master Cylinder CAUTION Brake fluid quickly ruins painted or plastic sur- faces; any spilled fluid should be completely wiped up immediately. Front Master Cylinder Removal • Remove the banjo bolt [A] to disconnect the upper brake hose [B] from the master cylinder [C]. •...
  • Page 345: Rear Master Cylinder Removal

    BRAKES 12-19 Master Cylinder Rear Master Cylinder Removal • Remove the brake pedal joint pin (see Brake Pedal Re- moval). • Unscrew the master cylinder mounting bolts [A], and re- move the master cylinder [B] backward. • Unscrew the brake hose banjo bolt [C]. •...
  • Page 346: Master Cylinder Inspection (visual Inspection)

    12-20 BRAKES Master Cylinder Master Cylinder Inspection (Visual Inspection) • Disassemble the front and rear master cylinders. • Check that there are no scratches, rust or pitting on the inner wall of each master cylinder [A] and on the outside of each piston [B].
  • Page 347: Brake Disc

    BRAKES 12-21 Brake Disc Brake Disc Removal • Remove the wheel (see Front/Rear Wheel Removal in the Wheels/Tires chapter). • Unscrew the mounting bolts [A], and take off the disc [B]. Brake Disc Installation • Install the brake disc on the wheel so that the marked side [A] faces out.
  • Page 348: Brake Hose

    12-22 BRAKES Brake Hose Brake Hose Removal/Installation • Refer to the Brake Hose Replacement in the Periodic Maintenance chapter. Brake Hose Inspection • Refer to the Brake Hoses and Connections Inspection in the Periodic Maintenance chapter.
  • Page 349 SUSPENSION 13-1 Suspension Table of Contents Exploded View........................13-2 Specifications ......................... 13-6 Special Tools .......................... 13-7 Front Fork ..........................13-8 Air Pressure ........................13-8 Compression Damping Adjustment .................. 13-8 Rebound Damping Adjustment ..................13-8 Oil Change (each fork leg) ....................13-9 Front Fork Removal ......................
  • Page 350: Exploded View

    13-2 SUSPENSION Exploded View...
  • Page 351 SUSPENSION 13-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Base Valve Assembly Front Fork Top Plugs Upper Front Fork Clamp Bolts Lower Front Fork Clamp Bolts Adjuster Assembly Locknut Adjuster Assembly AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque. L: Apply a non-permanent locking agent to the threads.
  • Page 352 13-4 SUSPENSION Exploded View...
  • Page 353 SUSPENSION 13-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Swingarm Pivot Shaft Nut Rocker Arm Pivot Nut Tie-rod Mounting Nuts Upper Rear Shock Absorber Mounting Nut Lower Rear Shock Absorber Mounting Nut 2T: Apply 2-stroke oil. G: Apply grease L: Apply a non-permanent locking agent.
  • Page 354: Specifications

    13-6 SUSPENSION Specifications Item Standard Service Limit Front Fork Air Pressure Atmospheric pressure – – – (Adjustable Range) Rebound Damping Adjustment 13 clicks counterclockwise 20 clicks (from the seated position adjuster turned fully clockwise) (Adjustable Range) Compression Damping Adjustment 11 clicks counterclockwise 22 clicks (from the seated position adjuster (EUR) 12 clicks conterclockwise...
  • Page 355: Special Tools

    SUSPENSION 13-7 Special Tools Oil Seal & Bearing Remover: Bearing Remover Head, 20 × 22: 57001-1058 57001-1293 Steering Stem Nut Wrench: Bearing Remover Shaft, 13: 57001-1100 57001-1377 Hook Wrench R37.5, R42: Fork Oil Seal Driver, 48: 57001-1101 57001-1509 Bearing Driver Set: Hook Wrench: 57001-1129 57001-1641...
  • Page 356: Front Fork

    13-8 SUSPENSION Front Fork Air Pressure If you felt that a front fork is strong during a driving, place the jack under the frame so that the front wheel off the ground, and remove the screw [A] at the top of the front fork top plugs to let the air pressure equalize.
  • Page 357: Oil Change (each Fork Leg)

    SUSPENSION 13-9 Front Fork Seated positions adjuster turned fully clockwise [A]. Rebound Damping Adjuster Setting Standard: 13 clicks [B] Softer (Counterclockwise) [C] Harder (Clockwise) [D] *: Although you can turn the adjuster beyond the ad- justable range, effecting no changes to damping force, use it within the adjustable range.
  • Page 358: Front Fork Installation

    13-10 SUSPENSION Front Fork • Remove the front fork. ○ With a twisting motion [A], work the fork leg [B] down and out. Front Fork Installation • Install the fork so that the distance between the top end of the outer tube and the upper surface of the steering stem head is specified dimension.
  • Page 359: Front Fork Assembly

    SUSPENSION 13-11 Front Fork • Grasp the outer tube and stroke [A] the inner tube several times. The shock to fork seal separates the inner tube from the outer tube. • Remove the following parts from the inner tube. [A] Guide Bushes [B] Washer [C] Oil Seal [D] Retaining Ring...
  • Page 360: Adjuster Assembly Inspection

    13-12 SUSPENSION Front Fork • Install the oil seal by using the fork oil seal driver [A]. Special Tool - Fork Oil Seal Driver, 48: 57001-1509 • Install the retaining ring to the outer tube. • Push the dust seal into the outer tube, and put the spring band on the dust seal.
  • Page 361: Guide Bush Inspection

    SUSPENSION 13-13 Front Fork • Temporarily assemble the inner [A] and outer tubes [B], and pump them back and forth manually to check for smooth operation. CAUTION If the inner tube is badly bent or creased, replace Excessive bending, followed by subsequent straightening, can weaken the inner tube.
  • Page 362: Rear Shock Absorber

    13-14 SUSPENSION Rear Shock Absorber To suit to various riding conditions, the spring preload of the shock absorber can be adjusted or the spring can be replaced with an optional one. Also the damping force can be adjusted easily so changing oil viscosity unnecessary. Rebound Damping Adjustment •...
  • Page 363: Spring Preload Adjustment

    SUSPENSION 13-15 Rear Shock Absorber Seated position: adjuster turned fully clockwise [A]. Low Speed Compression Damping Standard: 12 clicks [B] (EUR) 11 clicks [C] Softer (counterclockwise) [D] Harder (clockwise) [E] * : Although you can turn the adjuster beyond the ad- justable range, effecting no changes to damping force, use it within the adjustable range.
  • Page 364: Spring Tension Inspection

    13-16 SUSPENSION Rear Shock Absorber • Using the stem nut wrench [A], turn the adjusting nut [B] as required. Turning the adjusting nut downward marks the spring action harder and upward softer. Special Tool - Steering Stem Nut Wrench: 57001-1100 Spring Preload Adjustment (Adjusting nut position at the lower surface [A] from the center of the mounting hole)
  • Page 365: Rear Shock Absorber Installation

    SUSPENSION 13-17 Rear Shock Absorber Remove the rear shock absorber upper mounting bolt [A], nut, and pull out the rear shock absorber [B] down and out. Rear Shock Absorber Installation • Pack the rocker arm needle bearings with grease. • Apply the tie-rod mounting bolts (rear) to the 2-stroke oil.
  • Page 366: Rear Shock Absorber Disassembly (oil Change)

    13-18 SUSPENSION Rear Shock Absorber • Remove the rear shock absorber from the vise. • Slide up the rubber bumper [A]. • Remove the spring guides [B] from the shock absorber and lift off the spring [C]. • Exchange the spring for an optional part. ○...
  • Page 367: Swingarm

    SUSPENSION 13-19 Swingarm Swingarm Removal • Remove: Rear Wheel (see Rear Wheel Removal in the Wheels/Tires chapter) Rear Flap (see Rear Fender Flap Removal in the Frame chapter) Brake Hose Clamps [A] • Remove: Bolts [A] and Nuts [B] Chain Guide Plate [C] Chain Guide [D] •...
  • Page 368: Swingarm Installation

    13-20 SUSPENSION Swingarm • Remove the screws [A] • Remove the chain slipper [B] from the swingarm. Swingarm Installation • Apply plenty of grease to the inside of the needle bear- ings, sleeves, and grease seals. • Install the collars to the both sides of the swingarm. •...
  • Page 369: Swingarm Bearing, Sleeve Inspection

    SUSPENSION 13-21 Swingarm Swingarm Bearing, Sleeve Inspection CAUTION Do not remove the bearings for inspection. Re- moval may damage them. • Inspect the needle bearings installed in the swingarm. ○ The rollers in a bearing normally wear very little, and wear is difficult to measure.
  • Page 370: Tie-rod, Rocker Arm

    13-22 SUSPENSION Tie-Rod, Rocker Arm Tie-Rod Removal • Using the jack under the frame, raise the rear wheel off the ground. Special Tool - Jack: 57001-1238 • Unscrew the nut [A] and remove the chain guide roller [B]. CAUTION When pulling out the mounting bolts, lift the rear wheel slightly.
  • Page 371: Rocker Arm Installation

    SUSPENSION 13-23 Tie-Rod, Rocker Arm Rocker Arm Installation • Apply plenty of grease to the inside of the rocker arm, needle bearings, grease seals and outside of the sleeve. • Tighten: Torque - Rocker Arm Pivot Nut: 59 N·m (6.0 kgf·m, 44 ft·lb) Lower Rear Shock Absorber Mounting Nut: 34 N·m (3.5 kgf·m, 25 ft·lb) Tie-rod Mounting Nut (Rear): 59 N·m (6.0 kgf·m, 44...
  • Page 372: Tie-rod And Rocker Arm Bearing Installation

    13-24 SUSPENSION Tie-Rod, Rocker Arm Tie-Rod and Rocker Arm Bearing Installation • Replace the needle bearing and grease seals with new ones. • Apply plenty of grease to the grease seal and needle bearings [A]. NOTE ○ Install the grease seals so that the deep groove side of the rip out-ward.
  • Page 373: Uni-trak Maintenance

    SUSPENSION 13-25 Uni-Trak Maintenance Uni-Trak Linkage Inspection • Refer to the Uni-Trak Linkage Inspection in the Periodic Maintenance chapter. Tie-Rod and Rocker Arm Sleeve Wear Inspection • Pull out the sleeves [A] of the tie-rod and rocker arm and measure the outside diameter of the sleeve. If the sleeve is worn past the service limit, replace the sleeve.
  • Page 375 STEERING 14-1 Steering Table of Contents Exploded View........................14-2 Special Tools .......................... 14-4 Steering ..........................14-5 Steering Inspection ......................14-5 Steering Adjustment......................14-5 Steering Stem......................... 14-6 Steering Stem, Stem Bearing Removal ................14-6 Steering Stem, Stem Bearing Installation ................. 14-7 Stem Bearing Lubrication....................
  • Page 376: Exploded View

    14-2 STEERING Exploded View...
  • Page 377 STEERING 14-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Handlebar Clamp Bolts 2T, AL Steering Stem Head Nut Steering Stem Nut 0.50 43 in·lb Upper Front Fork Clamp Bolts Lower Front Fork Clamp Bolts AD: Apply adhesive cement. AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque. G: Apply grease.
  • Page 378: Special Tools

    14-4 STEERING Special Tools Bearing Puller: Head Pipe Outer Race Driver, 54.5: 57001-135 57001-1077 Steering Stem Bearing Driver: Steering Stem Nut Wrench: 57001-137 57001-1100 Steering Stem Bearing Driver Adapter, 34.5: Head Pipe Outer Race Remover ID > 37 mm: 57001-1074 57001-1107 Head Pipe Outer Race Press Shaft: Bearing Puller:...
  • Page 379: Steering Inspection

    STEERING 14-5 Steering Steering Inspection • Refer to the Steering Inspection in the Periodic Mainte- nance chapter. Steering Adjustment • Refer to the Steering Adjustment in the Periodic Mainte- nance chapter.
  • Page 380: Steering Stem

    14-6 STEERING Steering Stem Steering Stem, Stem Bearing Removal • Remove: Front Wheel (see Front Wheel Removal in the Wheels/Tires chapter) Front Fender (see Front Fender Removal in the Frame chapter) Number Plate (see Number Plate Removal in the Frame chapter) Handlebar Pad [A] Breather Hose [B] (Pull out)
  • Page 381: Steering Stem, Stem Bearing Installation

    STEERING 14-7 Steering Stem • Take off the upper stem bearing inner race (tapered roller bearing) [A]. • Drive out the bearing outer races from the head pipe. ○ Remove the outer races pressed into the head pipe, using the head pipe outer race remover [A], and hammer the head pipe outer race remover to drive it out.
  • Page 382 14-8 STEERING Steering Stem • Replace the lower inner races with new ones. ○ Apply grease to the lower tapered roller bearing [A], and drive it onto the stem using the steering stem bearing driver [B] and adapter [C]. Special Tools - Steering Stem Bearing Driver: 57001-137 Steering Stem Bearing Driver Adapter, 34.5: 57001-1074 •...
  • Page 383: Stem Bearing Lubrication

    STEERING 14-9 Steering Stem • Install the parts removed (see the appropriate chapter). WARNING Do not impede the handlebar turning by routing the cables, wires, and hoses improperly (see Cable, Wire, and Hose Routing in the Appendix chapter). • Check and Adjust: Steering Front Brake Clutch Cable...
  • Page 384: Handlebar

    14-10 STEERING Handlebar Handlebar Removal • Remove: Number Plate (see Number Plate Removal in the Frame chapter) Clutch Holder [A] Engine Stop Switch [B] Clamps [C] Left Handlebar Grip [D] • Remove: Throttle Grip Assy [A] (see Throttle Cable Replacement in the Fuel System (DFI) chapter) Master Cylinder [B] (see Front Master Cylinder Removal in the Brakes chapter)
  • Page 385 STEERING 14-11 Handlebar • Apply grease to the throttle cable upper end and clutch cable upper end. • Apply a 2-stroke oil to the edge (slash area) of the han- dlebar. [A] 120mm (4.72in.) • Install the throttle grip assy so that the grip [A] is in as far as it will go.
  • Page 387 FRAME 15-1 Frame Table of Contents Exploded View........................15-2 Frame ............................. 15-4 Frame Inspection ......................15-4 Rear Frame Removal......................15-4 Rear Frame Installation..................... 15-4 Engine Guard Installation....................15-5 Seat ............................15-6 Seat Removal ........................15-6 Seat Installation ........................ 15-6 Side Cover..........................15-7 Side Cover Removal ......................
  • Page 388: Exploded View

    15-2 FRAME Exploded View...
  • Page 389 FRAME 15-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Rear Frame Mounting Bolts Upper Footpeg Bracket Bolts Radiator Shroud Bolts 87 in·lb G: Apply grease. L: Apply a non-permanent locking agent. R: Replacement Parts...
  • Page 390: Frame Inspection

    15-4 FRAME Frame Frame Inspection • Refer to the Frame Inspection in the Periodic Mainte- nance chapter. Rear Frame Removal • Remove: Seat (see Seat Removal) Right and Left Side Cover (see Side Cover Removal) Muffler (see Muffler Removal in the Engine Top End chapter) Rear Fender (see Rear Fender Removal) Inlet Air Temperature Sensor Connector [A]...
  • Page 391: Engine Guard Installation

    FRAME 15-5 Frame Engine Guard Installation • Install the engine guard as shown. Right Engine Guard [A] Collar [B] Bolt [C] Engine Guard [D] Bolts [E]...
  • Page 392: Seat

    15-6 FRAME Seat Seat Removal • Remove the bolts [A]. • Pull the seat [B] out from the back. Seat Installation • Insert the hooks [A] of the seat under the flange collar [B] and brackets [C]. • Tighten the seat mounting bolts.
  • Page 393: Side Cover

    FRAME 15-7 Side Cover Side Cover Removal • Remove: Bolts [A] Side Cover [B] • Remove the other side according to similar procedure. Side Cover Installation • Stick the pad [A] on the inside of the right side cover [B]. •...
  • Page 394: Radiator Shroud

    15-8 FRAME Radiator Shroud Radiator Shroud Removal • Remove: Bolts [A] Radiator Shroud [B] Radiator Shroud Installation • Install: Radiator shroud [A] Bolts (L = 12) [B] Bolt (L = 16) [C]...
  • Page 395: Number Plate

    FRAME 15-9 Number Plate Number Plate Removal • Remove the bolt [A]. • Remove the band [B] from the handlebar. • Remove the number plate [C] upward. Number Plate Installation • Insert the projections [A] of the number plate into the holes [B] of the steering stem.
  • Page 396: Fender

    15-10 FRAME Fender Front Fender Removal • Unscrew the bolts [A] and remove the front fender [B]. Rear Fender Removal • Remove: Seat (see Seat Removal) Sidecover (see Side Cover Removal) • Unscrew the bolts [A] and remove the rear fender [B]. Rear Flap Removal •...
  • Page 397 ELECTRICAL SYSTEM 16-1 Electrical System Table of Contents Exploded View........................16-2 Specifications ......................... 16-4 Special Tools and Sealant ...................... 16-5 Wiring Diagram........................16-8 Precautions..........................16-10 Electrical Wiring........................16-11 Wiring Inspection ......................16-11 Flywheel Magneto ........................16-12 Magneto Cover Removal ....................16-12 Magneto Cover Installation ....................
  • Page 398: Exploded View

    16-2 ELECTRICAL SYSTEM Exploded View...
  • Page 399 ELECTRICAL SYSTEM 16-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Gear Position Switch Screws 0.30 26 in·lb Flywheel Nut Stator Coil Bolts 87 in·lb Spark Plug 115 in·lb Magneto Cover Bolts 87 in·lb Crankshaft Sensor Bolts 0.71 62 in·lb Ignition Coil Bolts 87 in·lb Breather Fitting...
  • Page 400: Specifications

    16-4 ELECTRICAL SYSTEM Specifications Item Standard Magneto Magneto Output Voltage 37 V or more at 4 000 r/min (rpm) 0.4 ∼ 1.1 Ω (at 20°C (68°F)) Stator Coil Resistance Ignition System Ignition Timing 10° BTDC @2 000 r/min (rpm) Ignition Coil: 3 Needle Arcing Distance 7 mm (0.26 in.) or more 0.28 ∼...
  • Page 401: Special Tools And Sealant

    ELECTRICAL SYSTEM 16-5 Special Tools and Sealant Bearing Driver Set: Filler Cap Driver: 57001-1129 57001-1454 Rotor Puller, M16/M18/M20/M22 × 1.5: Needle Adapter Set: 57001-1216 57001-1457 Timing Light: Flywheel Puller, M28 × 1.0: 57001-1241 57001-1471 Hand Tester: Grip: 57001-1394 57001-1591 Peak Voltage Adapter: Rotor Holder: 57001-1415 57001-1730...
  • Page 402 16-6 ELECTRICAL SYSTEM Special Tools and Sealant Kawasaki Bond (Silicone Sealant): 92104-0004...
  • Page 403 ELECTRICAL SYSTEM 16-7 Special Tools and Sealant Dummy Page...
  • Page 404: Wiring Diagram

    16-8 ELECTRICAL SYSTEM Wiring Diagram...
  • Page 405 ELECTRICAL SYSTEM 16-9 Wiring Diagram...
  • Page 406: Precautions

    16-10 ELECTRICAL SYSTEM Precautions There are numbers of important precautions that are musts when servicing electrical systems. Learn and ob- serve all the rules below. ○ The electrical parts should never be struck sharply, as with a hammer, or allowed to fall on a hard surface. Such a shock to the parts can damage them.
  • Page 407: Electrical Wiring

    ELECTRICAL SYSTEM 16-11 Electrical Wiring Wiring Inspection • Visually inspect the wiring for signs of burning, fraying, etc. If any wiring is poor, replace the damaged wiring. • Pull each connector [A] apart and inspect it for corrosion, dirt, and damage. If the connector is corroded or dirty, clean it carefully.
  • Page 408: Flywheel Magneto

    Be sure to install the dowel pins [B]. • Apply silicone sealant to the area [A] to the magneto lead grommet. Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004 • Put in the magneto lead to the lead holder [A]. •...
  • Page 409: Magneto Cover Assembly

    ELECTRICAL SYSTEM 16-13 Flywheel Magneto Magneto Cover Assembly • If removed, the oil seal replacement may be required. • Press the balancer shaft oil seal [B] so that the magneto cover end [A] is flushed as shown. Special Tool - Bearing Driver Set: 57001-1129 •...
  • Page 410: Flywheel Installation

    16-14 ELECTRICAL SYSTEM Flywheel Magneto Flywheel Installation • Using a high-flash point solvent, clean off any oil or dirt that may be on the crankshaft taper [A] or in the hole [B] of the flywheel. Dry them with a clean cloth. •...
  • Page 411: Stator Coil Installation

    Torque - Crankshaft Sensor Bolts: 7.0 N·m (0.71 kgf·m, 62 in·lb) • Apply silicone sealant around the circumference of the wiring grommet [D]. Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004 • Set the stator wiring grommet securely in the notch. • Install the magneto cover (see Magneto Cover Installa- tion).
  • Page 412 16-16 ELECTRICAL SYSTEM Flywheel Magneto Table 2 Stator Coil Resistance Connections Tester Reading Range Tester (+) to Tester (–) to Another yellow 0.4 ∼ 1.1Ω × 1 Ω One yellow lead lead If there is more resistance than shown in the table, or no hand tester reading (infinity), the stator has an open lead and must be replaced.
  • Page 413: Charging System

    CAUTION Use only Kawasaki Hand Tester 57001-1394 for this test. A tester other than the Kawasaki Hand Tester may show different readings. If a megger or a meter with a large capacity battery is used, the regulator/rectifier will be damaged.
  • Page 414: Capacitor Removal

    16-18 ELECTRICAL SYSTEM Charging System Capacitor Removal • Remove: Left Radiator Shroud (see Radiator Shroud Removal in the Frame chapter) • Remove the connector [A], and pull the capacitor [B] up- ward. Capacitor Installation • Face the lead of the capacitor upward, and insert to the bracket.
  • Page 415: Ignition Timing

    ELECTRICAL SYSTEM 16-19 Ignition Timing Ignition Timing Inspection • Remove the timing inspection cap[A]. Special Tool - Filler Cap Driver: 57001-1454 • Attach the timing light [A] to the ignition coil lead in the manner prescribed by the manufacturer. Special Tool - Timing Light: 57001-1241 •...
  • Page 416: Ignition System

    16-20 ELECTRICAL SYSTEM Ignition System Safety Instructions WARNING The ignition system produces extremely high volt- age. Do not touch the spark plug, ignition coil, or high tension lead while the engine is running, or you could receive a severe electrical shock. Ignition Coil Removal •...
  • Page 417: Ignition Coil Inspection

    ELECTRICAL SYSTEM 16-21 Ignition System • Install the spark plug cap [A] aligned with the line [B] of the cylinder head cover. Ignition Coil Inspection Measuring arcing distance The most accurate test for determining the condition of the ignition coil is made by measuring arcing distance using the coil tester for the 3-needle method.
  • Page 418: Spark Plug Cleaning And Inspection

    16-22 ELECTRICAL SYSTEM Ignition System Measuring Coil Resistance If the arcing tester is not available, the coil can be checked for a broken or badly shorted winding with an ohmmeter. However, an ohmmeter cannot detect layer shorts and shorts resulting from insulation breakdown under high voltage.
  • Page 419: Ignition Coil Primary Peak Voltage Check

    ELECTRICAL SYSTEM 16-23 Ignition System Ignition Coil Primary Peak Voltage Check • Disconnect the spark plug cap from the spark plug, but do not remove the spark plug. • Connect the good spark plug [A] to the spark plug cap, then touch the engine with it.
  • Page 420 16-24 ELECTRICAL SYSTEM Ignition System...
  • Page 421: Crankshaft Sensor Peak Voltage Check

    ELECTRICAL SYSTEM 16-25 Ignition System Crankshaft Sensor Peak Voltage Check • To check the peak voltage, do the following procedures. ○ Disconnect the connector of the magneto lead connector from the main harness. NOTE ○ Measure the voltage with each lead connected cor- rectly.
  • Page 422: Crankshaft Sensor Inspection

    16-26 ELECTRICAL SYSTEM Ignition System Crankshaft Sensor Inspection • Remove: Magneto Lead Connector (see Magneto Cover Re- moval). • Set the hand tester [A] to the × 100 Ω range and connect it to the Green/White [B] and White/Yellow [C] Leads in the connector.
  • Page 423: Switches

    ELECTRICAL SYSTEM 16-27 Switches Engine Stop Switch Inspection • Using the hand tester, check to see that only the con- nections shown in the table have continuity (about zero ohms). Special Tool - Hand Tester: 57001-1394 If the switch has an open or short, repair it or replace it with a new one.
  • Page 425 APPENDIX 17-1 Appendix Table of Contents Cable, Wire, and Hose Routing ....................17-2 Troubleshooting Guide ......................17-12...
  • Page 426 17-2 APPENDIX Cable, Wire, and Hose Routing 1. Throttle Cables 6. Clamp (Clamp the clutch cable and en- 2. Marked (AAA) cable is accelerator side. gine stop switch lead.) 3. Bands (Hold the engine stop switch lead.) 7. Clamp (Clamp the throttle cables.) 4.
  • Page 427 APPENDIX 17-3 Cable, Wire, and Hose Routing 1. Clutch Cable 10. Engine Stop Switch Lead 2. Kawasaki Diagnostic System Connector 11. Run the throttle cables over the radiator 3. ECU hose. 4. Main Harness 12. Run the throttle cables through the side of 5.
  • Page 428 17-4 APPENDIX Cable, Wire, and Hose Routing 1. Sub-harness connector (Black) 2. Sub-harness connector (Gray) 3. Bracket 4. Insert the sub-harness connectors into the bracket. 5. Regulator/Rectifier Connector 6. Sub-harness 7. Water Temperature Sensor Connector...
  • Page 429 APPENDIX 17-5 Cable, Wire, and Hose Routing 1. Engine Stop Switch Lead 2. Radiator Hose 3. Capacitor 4. Engine Stop Switch Lead Connector 5. Clamp the engine stop switch lead and regulator/rectifier lead with the frame pipe at the blue tape portion.
  • Page 430 17-6 APPENDIX Cable, Wire, and Hose Routing 1. Spark Plug Cap 7. Breather Hose 2. 45° 8. Install the clamp as shown. 3. Gear Position Switch Lead 9. Align the white mark on the breather hose 4. Clamp the gear position switch lead. and embossed mark.
  • Page 431 APPENDIX 17-7 Cable, Wire, and Hose Routing 1. Left Radiator 7. Clamp (Position the clamp claw left side.) 2. Right Radiator 8. Clamp (Position the clamp claw down- 3. Radiator Hose (to cylinder head) ward.) 4. Radiator Hose (to water pump) 9.
  • Page 432 17-8 APPENDIX Cable, Wire, and Hose Routing 1. To Main Harness 5. To Water Temperature Sensor 2. Clamp the sub-harness at the blue tape 6. Throttle Sensor Connector portion. 7. Injector Connector 3. To Intake Air Temperature Sensor 8. Inlet Air Pressure Sensor Connector 4.
  • Page 433 APPENDIX 17-9 Cable, Wire, and Hose Routing 1. Intake Air Temperature Sensor Lead 2. Run the intake air temperature sensor lead through the hole of the guide as shown. 3. Do not touch the intake air temperature sensor lead and rear shock absorber. 4.
  • Page 434 17-10 APPENDIX Cable, Wire, and Hose Routing 1. To Spark Plug Cap 2. To Main Harness (Black) 3. Vehicle-down Sensor 4. Ignition Coil 5. Capacitor 6. Do not touch the high tension lead and engine ground lead. 7. To Main Harness (Green) 8.
  • Page 435 APPENDIX 17-11 Cable, Wire, and Hose Routing 1. Brake Lever 10. Rear Brake Master Cylinder 2. Front Brake Master Cylinder 11. Rear Brake Hose 3. Front Brake Hose 12. Clamps 4. Clamp 13. Rear Brake Caliper 5. Viewed 14. Rear Brake Caliper Guard 6.
  • Page 436 17-12 APPENDIX Troubleshooting Guide NOTE Piston ring/groove clearance excessive ○ Refer to the Fuel System (DFI) chapter for Cylinder head gasket damaged most of DFI trouble shooting guide. Cylinder head warped ○ This is not an exhaustive list, giving every Valve spring broken or weak possible cause for each problem listed.
  • Page 437 APPENDIX 17-13 Troubleshooting Guide Poor Running or No Power at High Engine Overheating: Speed: Firing incorrect: Firing incorrect: Spark plug dirty, broken, or maladjusted Spark plug dirty, broken, or gap malad- Spark plug incorrect justed ECU trouble Spark plug cap or high tension wiring trou- Fuel/air mixture incorrect: Throttle body holder loose Spark plug cap shorted or not in good con-...
  • Page 438 17-14 APPENDIX Troubleshooting Guide Abnormal Drive Train Noise: Shift return spring weak or broken Shift shaft lever broken Clutch noise: Pawl guide plate broken Clutch housing finger and friction plate tang Shift pawl broken worn Shift pawl spring tension lose Clutch housing gear worn Gear seized Metal chips jammed in clutch housing gear...
  • Page 439 APPENDIX 17-15 Troubleshooting Guide Handling and/or Stability Right and left front fork oil level uneven Unsatisfactory: Suspension operation trouble: Handlebar hard to turn: (Too hard) Cable, hose, wire routing incorrect Tire air pressure too high Steering stem nut too tight Front fork oil excessive Steering stem bearing damaged Front fork oil viscosity too high...
  • Page 440 MODEL APPLICATION Year Model Beginning Frame No. □ JKAKXGEC 9A000001 or 2009 KX450E9F JKAKX450EEA000001 □ :This digit in the frame number changes from one machine to another. Part No.99924-1410-01 Printed in Japan...

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