Download  Print this page
   
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
146
147
148
149
150
151
152
153
154
155
156
157
158
159
160
161
162
163
164
165
166
167
168
169
170
171
172
173
174
175
176
177
178
179
180
181
182
183
184
185
186
187
188
189
190
191
192
193
194
195
196
197
198
199
200
201
202
203
204
205
206
207
208
209
210
211
212
213
214
215
216
217
218
219
220
221
222
223
224
225
226
227
228
229
230
231
232
233
234
235
236
237
238
239
240
241
242
243
244
245
246
247
248
249
250
251
252
253
254
255
256
257
258
259
260
261
262
263
264
265
266
267
268
269
270
271
272
273
274
275
276
277
278
279
280
281
282
283
284
285
286
287
288
289
290
291
292
293
294
295
296
297
298
299
300
301
302
303
304
305
306
307
308
309
310
311
312
313
314
315
316
317
318
319
320
321
322
323
324
325
326
327
328
329
330
331
332
333
334
335
336
337
338
339
340
341
342
343
344
345
346
347
348
349
350
351
352
353
354
355
356
357
358
359
360
361
362
363
364
365
366
367
368
369
370
371
372
373
374
375
376
377
378
379
380
381
382
383
384
385
386
387
388
389
390
391
392
393
394
395
396
397
398
399
400
401
402
403
404
405
406
407
408
409
410
411
412
413
414
415
416
417
418
419
420
421
422
423
424
425
426
427
428
429
430
431
432
433
434
435
436
437
438
439
440
441
442
443
444
445
446
447
448
449
450
451
452
453
454
455
456
457
458
459
460
461
462
463
464
465
466
467
468
469
470
471
472
473
474
475
476
477
478
479
480
481
482
483
484
485
486
487
488
489
490
491
492
493
494
495
496
497
498
499
500
501
502
503
504
505
506
507
508
509
510
511
512
513
514
515
516
517
518
519
520
521
522
523
524
525
526
527
528
529
530
531
532
533
534
535
536
537
538
539
540
541
542
543
544
545
546
547
548
549
550
551
552
553
554
555
556
557
558
559
560
561
562
563
564
565
566
567
568
569
570
571
572
573
574
575
576
577
578
579
580
581
582
583
584
585
586
587
588
589
590
591
592
593
594
595
596
597
598
599
600
601
602
603
604
605
606
607
608
609
610
611
612
613
614
615
616
617
618
619
620
621
622
623
624
625
626
627
628
629
630
631
632
633
634
635
636
637
638
639
640
641
642
643
644
645
646
647
648
649
650
651
652
653
654
655
656
657
658
659
660
661
662

Advertisement

VULCAN 1700 NOMAD
VN1700 CLASSIC TOURER
Motorcycle
Service Manual

Advertisement

Table of Contents

   Also See for Kawasaki VULCAN 1700 NOMAD

   Summary of Contents for Kawasaki VULCAN 1700 NOMAD

  • Page 1 VULCAN 1700 NOMAD VN1700 CLASSIC TOURER Motorcycle Service Manual...
  • Page 3: General Information

    Quick Reference Guide General Information Periodic Maintenance Fuel System (DFI) Cooling System Engine Top End Clutch Engine Lubrication System Engine Removal/Installation Crankshaft/Transmission Wheels/Tires 10 j Final Drive 11 j Brakes 12 j Suspension 13 j Steering 14 j Frame 15 j Electrical System 16 j Appendix...
  • Page 5 All information contained in this publication is based on the latest product information available at the time of publication. Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts. © 2009 Kawasaki Heavy Industries, Ltd. First Edition (1) : Jan. 30, 2009 (M)
  • Page 6: Country And Area Codes

    LIST OF ABBREVIATIONS ampere(s) pound(s) ABDC after bottom dead center meter(s) alternating current minute(s) ATDC after top dead center newton(s) BBDC before bottom dead center pascal(s) bottom dead center horsepower BTDC before top dead center pound(s) per square inch °C degree(s) Celsius revolution direct current...
  • Page 7: Emission Control Information

    EMISSION CONTROL INFORMATION To protect the environment in which we all live, Kawasaki has incorporated crankcase emis- sion (1) and exhaust emission (2) control systems in compliance with applicable regulations of the United States Environmental Protection Agency and California Air Resources Board. Addi-...
  • Page 8 TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Federal law prohibits the following acts or the causing thereof. (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.
  • Page 9: How To Use This Manual

    Be alert for problems and non-scheduled ticular interest for more efficient and con- maintenance. venient operation. • Use proper tools and genuine Kawasaki Mo- torcycle parts. Special tools, gauges, and • Indicates a procedural step or work to be testers that are necessary when servicing done.
  • Page 11: Table Of Contents

    GENERAL INFORMATION 1-1 General Information Table of Contents Before Servicing ........................Model Identification......................... General Specifications......................Electrical Throttle Valve (ETV) System................... 1-12 Unit Conversion Table ......................1-15...
  • Page 12: 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 13 Replacement Parts Replacement parts must be KAWASAKI genuine or recommended by KAWASAKI. Gaskets, O-rings, oil seals, grease seals, circlips, cotter pins or locknuts must be replaced with new ones whenever disassembled.
  • Page 14 1-4 GENERAL INFORMATION Before Servicing Tightening Sequence Generally, when installing a part with several bolts, nuts, or screws, start them all in their holes and tighten them to a snug fit. Then tighten them according to the specified se- quence to prevent case warpage or deformation which can lead to malfunction.
  • Page 15 GENERAL INFORMATION 1-5 Before Servicing Press For items such as bearings or oil seals that must be pressed into place, apply small amount of oil to the con- tact area. Be sure to maintain proper alignment and use smooth movements when installing. Ball Bearing and Needle Bearing Do not remove pressed ball or needle unless removal is absolutely necessary.
  • Page 16 1-6 GENERAL INFORMATION Before Servicing Lubrication It is important to lubricate rotating or sliding parts during assembly to minimize wear during initial operation. Lubri- cation points are called out throughout this manual, apply the specific oil or grease as specified. Direction of Engine Rotation When rotating the crankshaft by hand, the free play amount of rotating direction will affect the adjustment.
  • Page 17: Model Identification

    GENERAL INFORMATION 1-7 Model Identification VN1700C9F (US and CA Models) Left Side View VN1700C9F (US and CA Models) Right Side View...
  • Page 18 1-8 GENERAL INFORMATION Model Identification VN1700C9F (EUR Models) Left Side View VN1700C9F (EUR Models) Right Side View Frame Number Engine Number...
  • Page 19: General Specifications

    GENERAL INFORMATION 1-9 General Specifications Items VN1700C9F Dimensions Overall Length 2 500 mm (98.43 in.) Overall Width 1 025 mm (40.35 in.), (AU) 995 mm (39.17 in.) Overall Height 1 465 mm (57.68 in.) Wheelbase 1 665 mm (65.55 in.) Road Clearance 140 mm (5.51 in.) Seat Height...
  • Page 20 1-10 GENERAL INFORMATION General Specifications Items VN1700C9F Lubrication System Forced lubrication (semi-dry sump) Engine Oil: Type API SE, SF or SG API SH, SJ, SL or SM with JASO MA, MA1 or MA2 Viscosity SAE 10W-40 Capacity 5.0 L (5.3 US qt) Drive Train Primary Reduction System: Type...
  • Page 21 GENERAL INFORMATION 1-11 General Specifications Items VN1700C9F Brake Type: Front Dual discs Rear Single disc Electrical Equipment Battery 12 V 18 Ah Headlight: Type Semi-sealed beam Bulb 12 V 60/55 W (quartz-halogen) Tail/Brake Light Alternator: Type Three-phase AC Rated Output 46.8 A/14 V @5 000 r/min (rpm) Specifications are subject to change without notice, and may not apply to every country.
  • Page 22: Electrical Throttle Valve (etv) System

    1-12 GENERAL INFORMATION Electrical Throttle Valve (ETV) System General Description VN1700 series is equipped with the electronically-controlled throttle valve system called the Elec- trical Throttle Valve (ETV) system. The throttle pulley and the throttle valves of this system are not connected mechanically, and the throttle valves are electrically operated.
  • Page 23 GENERAL INFORMATION 1-13 Electrical Throttle Valve (ETV) System System Diagram 1. Accelerator Position Sensor #1 and #2 The accelerator position sensor senses the rider’s intention on throttle operation and transmits it to the ECU as an electrical signal. Each incorporating a built-in variable resistor, the two sensors independently work to detect the position of the pulley shaft.
  • Page 24 1-14 GENERAL INFORMATION Electrical Throttle Valve (ETV) System D. Throttle Valve Opening Control Section E. Motor Drive Section F. CPU Monitoring Section 5. Partial Opening Holding Device When the actuator (DC motor) becomes incapable of throttle valve control, this device holds the throttle valve at a predetermined partially-open position by balancing the forces of the return spring and the open spring which pulls...
  • Page 25: Unit Conversion Table

    GENERAL INFORMATION 1-15 Unit Conversion Table Prefixes for Units: Units of Length: × 0.6214 mile Prefix Symbol Power × 3.281 mega × 1 000 000 × 0.03937 kilo × 1 000 centi × 0.01 Units of Torque: milli × 0.001 N·m ×...
  • Page 27 PERIODIC MAINTENANCE 2-1 Periodic Maintenance Table of Contents Periodic Maintenance Chart ....................Torque and Locking Agent...................... Specifications ......................... 2-13 Special Tools .......................... 2-15 Periodic Maintenance Procedures..................2-16 Fuel System (DFI)........................ 2-16 Throttle Control System Inspection................... 2-16 Idle Speed Inspection ....................... 2-17 Idle Speed Adjustment......................
  • Page 28 2-2 PERIODIC MAINTENANCE Headlight Aiming Inspection ..................... 2-44 Sidestand Switch Operation Inspection ................2-46 Engine Stop Switch Operation Inspection................. 2-47 Others ..........................2-47 Chassis Parts Lubrication ....................2-47 Bolts, Nuts and Fasteners Tightness Inspection............... 2-48 Replacement Parts ......................2-50 Air Cleaner Element Replacement..................2-50 Fuel Hose Replacement ....................
  • Page 29: Periodic Maintenance Chart

    PERIODIC MAINTENANCE 2-3 Periodic Maintenance Chart Dummy Page...
  • Page 30 2-4 PERIODIC MAINTENANCE Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition.The initial maintenance is vitally important and must not be neglected. Periodic Inspection FREQUENCY Whichever * ODOMETER READING comes ×...
  • Page 31 PERIODIC MAINTENANCE 2-5 Periodic Maintenance Chart FREQUENCY Whichever * ODOMETER READING comes × 1 000 km first (× 1 000 mile) Page (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) ITEM Every Final Drive • • • • • • • Drive belt deflection-inspect 2–27 •...
  • Page 32 2-6 PERIODIC MAINTENANCE Periodic Maintenance Chart Periodic Replacement Parts FREQUENCY Whichever * ODOMETER READING come × 1 000 km first (× 1 000 mile) Page (0.6) (7.5) (15) (22.5) (30) ITEM Every Air cleaner element-replace # Every 18 000 km (11 250 mile) 2–50 •...
  • Page 33: Torque And Locking Agent

    PERIODIC MAINTENANCE 2-7 Torque and Locking Agent The following tables list the tightening torque for the major fasteners requiring use of a non-permanent locking agent or silicone sealant etc. Letters used in the “Remarks” column mean: AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque. L: Apply a non-permanent locking agent.
  • Page 34 2-8 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Cylinder Head Nuts (M12 Used Nuts) (Final) MO, S Cylinder Head Nuts (M10) (First) MO, S Cylinder Head Nuts (M10) (Final) MO, S Cylinder Head Outer Cover Bolts 87 in·lb Cylinder Head Inner Cover Bolts 87 in·lb...
  • Page 35 PERIODIC MAINTENANCE 2-9 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Oil Pump Cover Bolts 106 in·lb Oil Pump Drive Gear Bolt Oil Screen Plugs Out Side Oil Pipe Bolts 87 in·lb Torque Limiter Bearing Retainer Bolt 87 in·lb Engine Removal/Installation Cross Pipe Bolts Downtube Bolts...
  • Page 36 2-10 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Shift Shaft Return Spring Pin Tie-Rod Locknuts 87 in·lb Lh (1) Wheels/Tires Front Axle 13.0 Front Axle Clamp Bolts Rear Axle Nut 11.0 Rear Air Valve Nuts 0.15 13 in·lb Final Drive...
  • Page 37 PERIODIC MAINTENANCE 2-11 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Steering Stem Head Nut Steering Stem Nut Upper Front Fork Clamp Bolts Frame Cross Pipe Bolts Downtube Bolts Front Footboard Bracket Bolts Rear Footboard Bracket Bolts Sidestand Mounting Bolt Sidestand Mounting Nut Sidestand Switch Mounting Bolt 0.90...
  • Page 38 2-12 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Water Temperature Sensor 106 in·lb Licence Plate Light Lens Screws 0.09 8 in·lb The table below, relating tightening torque to thread diameter, lists the basic torque for the bolts and nuts.
  • Page 39: Specifications

    PERIODIC MAINTENANCE 2-13 Specifications Item Standard Service Limit Fuel System (DFI) 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Throttle Grip Free Play – – – Idle Speed 950 ±50 r/min (rpm) – – – Air Cleaner Element Viscous paper element –...
  • Page 40 2-14 PERIODIC MAINTENANCE Specifications Item Standard Service Limit Final Drive Drive Belt Deflection: (45 N, 4.6 kgf, 10 lb force) 3.0 ∼ 4.5 mm (0.12 ∼ 0.18 in.) – – – (When installing new belt 3.0 mm (0.12 in.) – – – or engine is remounted) Brakes Brake Fluid:...
  • Page 41: Special Tools

    PERIODIC MAINTENANCE 2-15 Special Tools Inside Circlip Pliers: Oil Filter Wrench: 57001-143 57001-1249 Steering Stem Nut Wrench: Tension Gauge: 57001-1100 57001-1585...
  • Page 42: Periodic Maintenance Procedures

    2-16 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel System (DFI) Throttle Control System Inspection • Check the throttle grip free play [A]. Throttle Grip Free Play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Standard: If the free play is incorrect, adjust the throttle grip free play as follows.
  • Page 43: Idle Speed Inspection

    PERIODIC MAINTENANCE 2-17 Periodic Maintenance Procedures Idle Speed Inspection • Start the engine and warm it up thoroughly. ○ At first the engine will run fast to decrease warm up time (fast idle). ○ Gradually the fast idle will lower to a certain RPM auto- matically.
  • Page 44 2-18 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Push the “S” button [A] of the right switch housing for more than two seconds to display the clock setting mode [B] on the LCD (Liquid Crystal Display).
  • Page 45 PERIODIC MAINTENANCE 2-19 Periodic Maintenance Procedures • Push the “S” button to display the idle speed adjusting mode [A]. NOTE ○ The display change to the clock setting mode [B], aver- age fuel consumption unit setting mode [C], idle speed adjusting mode each time the “S”...
  • Page 46: Fuel Hose Inspection (fuel Leak, Damage, Installation Condition)

    2-20 PERIODIC MAINTENANCE Periodic Maintenance Procedures ○ The idle speed goes up 50 r/min (rpm) at one time by pushing the “MODE-A” switch. ○ When pushing the “MODE-A” switch, the value on the display shows the “+50” [A] (this shows 1 000 r/min (rpm)). ○...
  • Page 47: Evaporative Emission Control System Inspection (cal And Sea Models)

    PERIODIC MAINTENANCE 2-21 Periodic Maintenance Procedures • Check that the fuel hose [A] are routed according to Cable, Wire, and Hose Routing section in the Appendix chapter. Replace the hose if it has been sharply bent or kinked. • Check that the fuel hose joints are securely connected. ○...
  • Page 48: Cooling System

    2-22 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Check the liquid/vapor separator as follows. ○ Remove: Canister Band [A] ○ Disconnect the hoses from the separator [B], and remove the separator. ○ Visually inspect the separator for cracks and other dam- age.
  • Page 49: Radiator Hose And Pipe Inspection (coolant Leak, Damage, Installation Condition)

    PERIODIC MAINTENANCE 2-23 Periodic Maintenance Procedures Radiator Hose and Pipe Inspection (Coolant Leak, Damage, Installation Condition) ○ The high pressure inside the radiator hose can cause coolant to leak [A] or the hose to burst if the line is not properly maintained.
  • Page 50: Clutch

    2-24 PERIODIC MAINTENANCE Periodic Maintenance Procedures Clutch Clutch Operation Inspection • Start the engine and check that the clutch does not slip and that it releases properly. If the clutch operation is insufficiency, inspect the clutch system. WARNING When inspecting by running the vehicle, note a surrounding traffic situation enough in the place of safety.
  • Page 51: Clutch Hose And Pipe Damage And Installation Condition Inspection

    PERIODIC MAINTENANCE 2-25 Periodic Maintenance Procedures Clutch Hose and Pipe Damage and Installation Condition Inspection • The high pressure inside the clutch line can cause fluid to leak [A] or the hose to burst if the line is not properly maintained.
  • Page 52: Wheel Bearing Damage Inspection

    2-26 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Measure the tread depth at the center of the tread with a depth gauge [A]. Since the tire may wear unevenly, take measurement at several places. If any measurement is less than the service limit, replace the tire (see Tire Removal/Installation in the Wheels/Tires chapter).
  • Page 53: Final Drive

    PERIODIC MAINTENANCE 2-27 Periodic Maintenance Procedures Final Drive Drive Belt Deflection Inspection NOTE ○ Belt deflection must be checked and adjusted when the belt is cold (at room temperature). ○ Belt deflection also should be checked at first 1000 km (621.4 mile) ride after belt replacement.
  • Page 54: Drive Belt Deflection Adjustment

    2-28 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Inspect the drive belt deflection at arbitrary position, and record the value [A]. • Turn the rear wheel 90 degrees. • Inspect the drive belt deflection, and record the value [B]. • Decide the belt deflection at the position [C] of one where deflection is large.
  • Page 55 PERIODIC MAINTENANCE 2-29 Periodic Maintenance Procedures • Remove the axle cotter pin [A], and loosen the axle nut [B]. • Raise the rear wheel off the ground (see Rear Wheel Re- moval in the Wheels/Tires chapter). • Loosen the belt adjuster locknuts [C] on the both sides. If the belt is too tight, back out the left and right belt ad- juster nuts [D], and kick the wheel forward until the belt is too loose.
  • Page 56: Wheel Alignment Inspection/adjustment

    2-30 PERIODIC MAINTENANCE Periodic Maintenance Procedures Wheel Alignment Inspection/Adjustment • Check that the notch [A] on the belt adjuster [B] aligns with the same swingarm mark [C] or position that the other side notch aligns with. If they do not, adjust the belt deflection (see Belt Deflec- tion Adjustment) and align the wheel alignment.
  • Page 57 PERIODIC MAINTENANCE 2-31 Periodic Maintenance Procedures Drive Belt Tooth Wear and Damage Patterns A. Belt Cross Section B. Edge Bevel Wear C. Rub Wear D. Stone...
  • Page 58 2-32 PERIODIC MAINTENANCE Periodic Maintenance Procedures Drive Belt Wear and Damage Analysis Pattern Condition Required Action O.K. for continued use, but inspect the belt Internal tooth cracks (slight) periodically. O.K. for continued use, but inspect the belt Scuffing to side of teeth periodically.
  • Page 59: Brakes

    PERIODIC MAINTENANCE 2-33 Periodic Maintenance Procedures Brakes Brake Fluid Leak (Brake Hose and Pipe) Inspection • Apply the brake lever or pedal and inspect the brake fluid leak from the brake hoses [A] and fittings [B]. If the brake fluid leaked from any position, inspect or re- place the problem part.
  • Page 60: Brake Hose And Pipe Damage And Installation Condition Inspection

    2-34 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Hose and Pipe Damage and Installation Condition Inspection • Inspect the brake hoses 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 61: Brake Pad Wear Inspection

    PERIODIC MAINTENANCE 2-35 Periodic Maintenance Procedures • Check that the brake fluid level in the rear brake reservoir [A] is above the lower level line [B]. If the fluid level is lower than the lower level line, fill the reservoir to the upper level line [C]. WARNING Do not mix two brands of fluid.
  • Page 62: Suspension

    2-36 PERIODIC MAINTENANCE Periodic Maintenance Procedures If it does not, adjust the brake light switch. • Remove the front guard mounting bolt [A] and front foot- board bracket bolts [B]. • Slide the front guard forward. • While holding the switch body, turn the adjusting nut to adjust the switch.
  • Page 63: Front Fork Oil Leak Inspection

    PERIODIC MAINTENANCE 2-37 Periodic Maintenance Procedures • Pump the rear seat down and up [A] 4 or 5 times, and inspect the smooth stroke. If the shock absorber does not smoothly or noise is found, inspect the oil leak (see Rear Shock Absorber Oil Leak Inspection).
  • Page 64: Steering

    2-38 PERIODIC MAINTENANCE Periodic Maintenance Procedures Steering Steering Play Inspection • Raise the front wheel off the ground (see Front Wheel Removal in the Wheels/Tires chapter). • With the front wheel pointing straight ahead, alternately tap each end of the handlebar. The front wheel should swing fully left and right from the force of gravity until the fork hits the stop.
  • Page 65 PERIODIC MAINTENANCE 2-39 Periodic Maintenance Procedures • Remove the lock washer [A]. • Adjust the steering using the steering stem nut wrench [A]. Special Tool - Steering Stem Nut Wrench: 57001-1100 If the steering is too tight, loosen the stem nut [B] a fraction of a turn.
  • Page 66: Steering Stem Bearing Lubrication

    2-40 PERIODIC MAINTENANCE Periodic Maintenance Procedures Steering Stem Bearing Lubrication • Remove the steering stem (see Steering, Stem Bearing Removal in the Steering chapter). • Using a high-flash point solvent, wash the upper and lower ball bearings in the cages, and wipe the upper and lower outer races, which are press-fitted into the frame head pipe, clean off grease and dirt.
  • Page 67: Lights And Switches Operation

    PERIODIC MAINTENANCE 2-41 Periodic Maintenance Procedures Lights and Switches Operation First Step • Turn the ignition switch ON. • The following lights should go on according to below table. United Aus- Models Canada Europe States tralia Position Lights go on go on –...
  • Page 68 2-42 PERIODIC MAINTENANCE Periodic Maintenance Procedures If the light does not go on, inspect or replace the following parts. Battery (see Charging Condition Inspection in the Elec- trical System chapter) Position Light Bulb (see Position Light Bulb Replace- ment in the Electrical System chapter) City Light Bulb (see City Light Bulb Replacement in the Electrical System chapter) Fuel Level Warning Indicator Light (LED) (see Meter Unit...
  • Page 69 PERIODIC MAINTENANCE 2-43 Periodic Maintenance Procedures Second Step • Turn the ignition switch ON. • Push the turn signal switch [A] ON (left or right position). • The left or right turn signal lights [B] (front and rear) ac- cording to the switch position should flash. •...
  • Page 70: Headlight Aiming Inspection

    2-44 PERIODIC MAINTENANCE Periodic Maintenance Procedures Third Step • Turn the ignition switch to ACC position. • Push the turn signal switch [A] ON (left or right position). • The left or right turn signal lights (front and rear) according to the switch position should flash.
  • Page 71 PERIODIC MAINTENANCE 2-45 Periodic Maintenance Procedures Headlight Beam Horizontal Adjustment • Turn the horizontal adjuster [A] on the headlight with a screwdriver in or out until the beam points straight ahead. ○ Turn the adjuster clockwise to face the headlight to the left.
  • Page 72: Sidestand Switch Operation Inspection

    2-46 PERIODIC MAINTENANCE Periodic Maintenance Procedures Sidestand Switch Operation Inspection • Raise the rear wheel off the ground with the jack (see Rear Wheel Removal in the Wheels/Tires chapter). • Inspect the sidestand switch [A] operation accordance to below table. Sidestand Switch Operation Side- Gear...
  • Page 73: Engine Stop Switch Operation Inspection

    PERIODIC MAINTENANCE 2-47 Periodic Maintenance Procedures Engine Stop Switch Operation Inspection First Step • Set the gear position in the neutral position. • Turn the ignition switch ON. • Push the engine stop switch to stop position [A]. • Push the starter button. •...
  • Page 74: Bolts, Nuts And Fasteners Tightness Inspection

    2-48 PERIODIC MAINTENANCE Periodic Maintenance Procedures Cables: Lubricate with Rust Inhibitor Throttle Cables • Lubricate the cables by seeping the oil between the cable and housing. ○ The cable may be lubricated by using a commercially available pressure cable lubricator with an aerosol cable lubricant.
  • Page 75 PERIODIC MAINTENANCE 2-49 Periodic Maintenance Procedures Bolt, Nut and Fastener to be checked Engine: Radiator Bolt Exhaust Pipe Holder Nuts Left and Right Muffler Body Mounting Bolts Clutch Lever Pivot Bolt Nut Clutch Master Cylinder Clamp Bolts Clutch Slave Cylinder Bolts Engine Mounting Bolts and Nuts Engine Bracket Bolts Wheels:...
  • Page 76: Replacement Parts

    Install a new element [A] so that the screen side [B] faces inward. CAUTION Use only the recommended air cleaner element (Kawasaki part number 11013-0031). Using another air cleaner element will wear the engine prema- turely or lower the engine performance. •...
  • Page 77: Fuel Hose Replacement

    PERIODIC MAINTENANCE 2-51 Periodic Maintenance Procedures • Tighten: Torque - Left Air Cleaner Housing Cover Bolts : 4.9 N·m ( 0.50 kgf·m, 43 in·lb) L = 10 mm (0.39 in.) [A] L = 25 mm (0.98 in.) [B] Fuel Hose Replacement •...
  • Page 78: Coolant Change

    2-52 PERIODIC MAINTENANCE Periodic Maintenance Procedures Coolant Change WARNING To avoid burns, do not remove the radiator cap or try to change the coolant when the engine is still hot. Wait until it cools down. Coolant on tires will make them slippery, and can cause an accident and injury.
  • Page 79 PERIODIC MAINTENANCE 2-53 Periodic Maintenance Procedures Water and Coolant Mixture Ratio (Recommended) : 50% Soft Water Coolant : 50% Freezing Point : –35°C (–31°F) Total Amount : 2.4 L (2.5 US qt) • Fill the coolant into the radiator. NOTE ○...
  • Page 80: Radiator Hose And O-ring Replacement

    2-54 PERIODIC MAINTENANCE Periodic Maintenance Procedures Radiator Hose and O-ring Replacement • Drain the coolant (see Coolant Change). • Remove: Thermostat Housing [A] with Bracket [B] (see Thermo- stat Removal in the Cooling System chapter) Alternator Cover (see Alternator Removal in the Electri- cal System chapter) Left Side Cover (see Left Side Cover Removal in the Frame chapter)
  • Page 81: Engine Oil Change

    PERIODIC MAINTENANCE 2-55 Periodic Maintenance Procedures Engine Oil Change • Situate the motorcycle so that it is vertical after warming up the engine. • Remove the oil filler cap [A] on the crankcase. • Remove the front [A] and rear [B] engine oil drain bolts and drain the oil.
  • Page 82: Oil Filter Replacement

    2-56 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Pour in the specified grade and amount of oil. Recommended Engine Oil Grade: API SE, SF or SG API SH, SJ, SL or SM with JASO MA, MA1, or MA2 Viscosity: SAE 10W-40 Amount: 4.1 L (4.3 US qt) (when filter is not removed)
  • Page 83: Brake Hose And Pipe Replacement

    PERIODIC MAINTENANCE 2-57 Periodic Maintenance Procedures Brake Hose and Pipe Replacement CAUTION Brake fluid quickly ruins painted plastic surfaces; any spilled fluid should be completely washed away immediately. • Remove the right saddlebag (see Saddlebag Removal in the Frame chapter). •...
  • Page 84 2-58 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Remove the rubber cap from the bleed valve [A] on the caliper [B]. • Attach a clear plastic hose [C] to the bleed valve, and run the other end of the hose into a container. •...
  • Page 85: Master Cylinder Rubber Parts Replacement

    PERIODIC MAINTENANCE 2-59 Periodic Maintenance Procedures • Follow the procedure below to install the rear brake fluid reservoir cap correctly. ○ First, tighten the rear brake fluid reservoir cap [B] clock- wise [C] by hand until slight resistance is felt indicating that the cap is seated on the reservoir body, then tighten the cap an additional 1/6 turn [D] while holding the brake fluid reservoir body [A].
  • Page 86 2-60 PERIODIC MAINTENANCE Periodic Maintenance Procedures Rear Master Cylinder Disassembly • Remove the rear master cylinder (see Rear Master Cylin- der Removal in the Brakes chapter). • Remove the reservoir cap [A], plate [B] and diaphragm [C]. • Remove the circlip [D], connector [E] and O-ring [F]. Special Tool - Inside Circlip Pliers: 57001-143 •...
  • Page 87: Caliper Rubber Parts Replacement

    PERIODIC MAINTENANCE 2-61 Periodic Maintenance Procedures Caliper Rubber Parts Replacement Front Caliper Disassembly • Remove: Front Caliper (see Front Caliper Removal in the Brakes chapter) Front Brake Pads (see Front Brake Pad Removal in the Brakes chapter) Caliper Holder [A] Pad Spring [B] •...
  • Page 88 2-62 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Replace the fluid seals [A] with new ones. ○ Apply silicone grease to the fluid seals, and install them into the cylinders by hand. • Replace the dust seals [B] with new ones. ○...
  • Page 89 PERIODIC MAINTENANCE 2-63 Periodic Maintenance Procedures ○ Pull out the pistons by hand. • Remove the dust seals [A] and fluid seals [B]. • Remove the bleed valves [C] and rubber caps [D]. NOTE ○ If compressed air is not available, do as follows with the brake hose connected to the caliper.
  • Page 90: Clutch Hose And Pipe Replacement

    2-64 PERIODIC MAINTENANCE Periodic Maintenance Procedures Clutch Hose and Pipe Replacement CAUTION Clutch fluid quickly ruins painted plastic surfaces; any spilled fluid should be completely washed away immediately. • When removing the clutch hose, take care not to spill the clutch fluid on the painted or plastic parts.
  • Page 91: Clutch Fluid Change

    PERIODIC MAINTENANCE 2-65 Periodic Maintenance Procedures Clutch Fluid Change • Level the clutch fluid reservoir and remove the reservoir cap. • Remove the engine pulley outer cover (see Engine Pulley Outer Cover Removal in the Final Drive chapter.) and the rubber cap from the bleed valve on the clutch slave cylinder.
  • Page 92: Clutch Master Cylinder Rubber Parts Replacement

    2-66 PERIODIC MAINTENANCE Periodic Maintenance Procedures Clutch Master Cylinder Rubber Parts Replacement • Remove the clutch master cylinder (see Clutch Master Cylinder Removal in the Clutch chapter). • Remove the reservoir cap [A], plate [B] and diaphragm [C], and pour the clutch fluid into a container. •...
  • Page 93: Clutch Slave Cylinder Piston Seal Replacement

    PERIODIC MAINTENANCE 2-67 Periodic Maintenance Procedures Clutch Slave Cylinder Piston Seal Replacement • Remove the engine pulley outer cover (see Engine Pulley Outer Cover Removal in the Final Drive). • Loosen the banjo bolt [A] at the clutch pipe lower end, and tighten it loosely.
  • Page 94 2-68 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Remove the spark plug using a 14 mm (0.55 in.) plug wrench [A] vertically. CAUTION The insulator [A] of the spark plug may break if when the wrench is inclined during loosening. Inclined Spark Plug Wrench [B] Contact (Spark Plug and Plug Wrench) [C] Bad [D] Vertically Spark Plug Wrench [E]...
  • Page 95 FUEL SYSTEM (DFI) 3-1 Fuel System (DFI) Table of Contents Exploded View........................Specifications ......................... Special Tools and Sealant ...................... 3-10 DFI System..........................3-12 DFI Parts Location........................3-18 DFI Servicing Precautions ...................... 3-20 DFI Servicing Precautions ....................3-20 Troubleshooting the DFI System .................... 3-22 Outline ..........................
  • Page 96 3-2 FUEL SYSTEM (DFI) Gear Position Switch Output Voltage Inspection .............. 3-64 Vehicle-down Sensor (Service Code 31)................3-66 Vehicle-down Sensor Removal ..................3-66 Vehicle-down Sensor Installation ..................3-67 Vehicle-down Sensor Input Voltage Inspection..............3-67 Vehicle-down Sensor Output Voltage Inspection .............. 3-68 Oxygen Sensor - not activated (Service Code 33, Equipped Models) ........
  • Page 97 FUEL SYSTEM (DFI) 3-3 Fuel Pump Operating Voltage Inspection ................. 3-96 Pressure Regulator Removal.................... 3-97 Fuel Filter Cleaning......................3-98 Fuel Injectors .......................... 3-99 Fuel Injector Removal ....................... 3-99 Fuel Injector Installation ....................3-100 Fuel Injector Audible Inspection ..................3-100 Fuel Injector Resistance Inspection .................. 3-100 Fuel Injector Output Voltage Inspection ................
  • Page 98: Exploded View

    3-4 FUEL SYSTEM (DFI) Exploded View...
  • Page 99 FUEL SYSTEM (DFI) 3-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Air Cleaner Housing Cover Bolts 0.50 43 in·lb Air Cleaner Element Bolt 0.50 43 in·lb Air Cleaner Housing Bolts 87 in·lb Crankshaft Sensor Bolts 0.60 52 in·lb Delivery Joint Bolts 87 in·lb Fuel Pump Bolts 87 in·lb...
  • Page 100 3-6 FUEL SYSTEM (DFI) Exploded View...
  • Page 101 FUEL SYSTEM (DFI) 3-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Oxygen Sensor (Equipped Models) 2. CAL and SEA Models 3. Canister 4. Separator...
  • Page 102: Specifications

    3-8 FUEL SYSTEM (DFI) Specifications Item Standard Digital Fuel Injection System Idle Speed 950 ±50 r/min (rpm) Throttle Body Assy: Type Two barrel type Bore 42 mm (1.65 in.) ECU: Make MITSUBISHI ELECTRIC Type Digital memory type, with built in IC igniter, sealed with resin Fuel Pressure (High Pressure Line) 294 kPa (3.0 kgf/cm², 43 psi) with engine idling Fuel Pump: Type...
  • Page 103 FUEL SYSTEM (DFI) 3-9 Specifications Item Standard Vehicle-down Sensor: DC 4.75 ∼ 5.25 V Input Voltage With sensor tilted 40 ∼ 50° or more right or left: DC 0.65 Output Voltage ∼ 1.35 V With sensor arrow mark pointed up: DC 3.55 ∼ 4.45 V Oxygen Sensor (Equipped Models): Output Voltage (Rich) DC 0.8 V or more...
  • Page 104: Special Tools And Sealant

    3-10 FUEL SYSTEM (DFI) Special Tools and Sealant Oil Pressure Gauge, 5 kgf/cm²: Needle Adapter Set: 57001-125 57001-1457 Jack: Fuel Pressure Gauge Adapter: 57001-1238 57001-1593 Fork Oil Level Gauge: Fuel Hose: 57001-1290 57001-1607 Vacuum Gauge: Speed Sensor Measuring Adapter: 57001-1369 57001-1667 Hand Tester: Measuring Adapter:...
  • Page 105 FUEL SYSTEM (DFI) 3-11 Special Tools and Sealant Kawasaki Bond (Silicone Sealant): 56019-120...
  • Page 106: Dfi System

    3-12 FUEL SYSTEM (DFI) DFI System DFI System...
  • Page 107 FUEL SYSTEM (DFI) 3-13 DFI System 1. Fuel Tank 2. FI Indicator LED Light 3. ECU 4. Battery 12 V 18 Ah 5. Pressure Regulator 6. Fuel Pump 7. Water Temperature Sensor 8. Inlet Air Pressure Sensor 9. Delivery Joint 10.
  • Page 108 3-14 FUEL SYSTEM (DFI) DFI System DFI System Wiring Diagram...
  • Page 109 35. Battery 36. Starter Relay 37. Main Fuse 30 A 38. Vehicle-down Sensor 39. Crankshaft Sensor 40. Fuel Pump 41. Meter Unit 42. Kawasaki Diagnostic System Connector ○ Color Codes: BK: Black GY: Gray R: Red BL: Blue LB: Light Blue...
  • Page 110 3-16 FUEL SYSTEM (DFI) DFI System Terminal Numbers of ECU Connectors Terminal Names 1. Ignition Coil #2 (Rear Cylinder): BK 2. Fuel Injector #2 (Rear Cylinder): BL/Y 3. Unused 4. Ground for ETV Actuator (to Battery): BK/Y 5. Power Supply to ETV Actuator (from ETV Actuator Relay): G/O 6.
  • Page 111 64. External Communication Line (*KDS): LG 65. Ground for Accelerator Position Sensor 1: BK/O 66. Accelerator Position Sensor 1: G/W 67. Power Supply to Accelerator Position Sensor 1: BL/W 68. Throttle Position Sensor 1: G/R *: KDS (Kawasaki Diagnostic System)
  • Page 112: Dfi Parts Location

    3-18 FUEL SYSTEM (DFI) DFI Parts Location Ignition Coil #1 (Front Cylinder) [A] Air Switching Valve [B] Ignition Coil #2 (Rear Cylinder) [A] Inlet Air Pressure Sensor [B] Water Temperature Sensor [A] Fuel Injector #1 (Front Cylinder) [B] Fuel Injector #2 (Rear Cylinder) [C] Inlet Air Temperature Sensor [D] Throttle Position Sensor [A] ETV Actuator [B]...
  • Page 113 FUEL SYSTEM (DFI) 3-19 DFI Parts Location Gear Position Switch [A] Speed Sensor [A] Kawasaki Diagnostic System Connector (6 Pins Con- nector) [B] ETV Actuator Relay [A] (R/BL, Y/BL, R/BL, G/O Leads) Vehicle-down Sensor [B] Fuse Box 1 [C] (Oxygen Sensor Heater Fuse 10 A...
  • Page 114: Dfi Servicing Precautions

    3-20 FUEL SYSTEM (DFI) DFI Servicing Precautions DFI Servicing Precautions There are a number of important precautions that should be followed servicing the DFI system. ○ This DFI system is designed to be used with a 12 V sealed battery as its power source. Do not use any other battery except for a 12 V sealed battery as a power source.
  • Page 115 FUEL SYSTEM (DFI) 3-21 DFI Servicing Precautions ○ If the motorcycle is not properly handled, the high pres- sure inside the fuel line can cause fuel to leak or the hose to burst. Remove the fuel tank (see Fuel Tank Removal) and check the fuel hose [A].
  • Page 116: Troubleshooting The Dfi System

    3-22 FUEL SYSTEM (DFI) Troubleshooting the DFI System The warning indicator light (LED) [A] is used for the FI/ETV (Electrical Throttle Valve) indicator, oil pressure warning indicator and water temperature warning indicator. Outline When problem occurs with DFI system, the warning indi- cator light (LED) [A] goes on and the “Error”...
  • Page 117 But the service codes stored in memory of the ECU are not erased to preserve the problem history. The problem history can be referred using the KDS (Kawasaki Diagnostic System) when solving unstable problems. When the motorcycle is down, the vehicle-down sensor operates and the ECU shuts off the fuel pump relay, fuel in- jectors and ignition system.
  • Page 118 After measurement, remove the needle adapters and ap- ply silicone sealant to the seals [A] of the connector [B] for waterproofing. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 • Always check battery condition before replacing the DFI parts. A fully charged battery is a must for conducting accurate tests of the DFI system.
  • Page 119 FUEL SYSTEM (DFI) 3-25 Troubleshooting the DFI System • Make sure all connectors in the circuit are clean and tight, and examine wires for signs of burning, fraying, short, etc. Deteriorated wires and bad connections can cause reappearance of problems and unstable operation of the DFI system.
  • Page 120: Inquiries To Rider

    3-26 FUEL SYSTEM (DFI) Troubleshooting the DFI System DFI Diagnosis Flow Chart Inquiries to Rider ○ Each rider reacts to problems in different ways, so it is important to confirm what kind of symptoms the rider has encountered. ○ Try to find out exactly what problem occurred under exactly what conditions by asking the rider; knowing this information may help you reproduce the problem.
  • Page 121 FUEL SYSTEM (DFI) 3-27 Troubleshooting the DFI System Sample Diagnosis Sheet Rider name: Registration No. (license plate No.): Year of initial registration: Model: Engine No.: Frame No.: Date problem occurred: Mileage: Environment when problem occurred. □ □ □ □ □ □...
  • Page 122 3-28 FUEL SYSTEM (DFI) Troubleshooting the DFI System □ Poor running spark plug loose (tighten it). □ or no power at spark plug dirty, broken, or gap maladjusted (remedy it). high speed □ spark plug incorrect (replace it). □ knocking (fuel poor quality or incorrect, → use high-octane gasoline). □...
  • Page 123: Dfi System Troubleshooting Guide

    FUEL SYSTEM (DFI) 3-29 DFI System Troubleshooting Guide NOTE ○ This is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties in DFI system.
  • Page 124 3-30 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Fuel pressure regulator trouble Inspect fuel pressure and replace fuel pump (see chapter 3). Fuel line clogged Inspect and repair (see chapter 3). Inlet air pressure sensor trouble Inspect (see chapter 3).
  • Page 125 FUEL SYSTEM (DFI) 3-31 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Inlet air temperature sensor trouble Inspect (see chapter 3). Spark plug dirty, broken or gap maladjusted Inspect and replace (see chapter 2). Ignition coil trouble Inspect (see chapter 16). Stumble: Fuel pressure too low Inspect (see chapter 3).
  • Page 126 3-32 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Ignition coil trouble Inspect (see chapter 16). Spark plug dirty, broken or gap maladjusted Inspect and replace (see chapter 2). Spark plug incorrect Replace it with the correct plug (see chapter 2). ECU trouble Inspect (see chapter 3).
  • Page 127 FUEL SYSTEM (DFI) 3-33 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Air cleaner element clogged Clean element (see chapter 2). Fuel pressure too high Inspect (see chapter 3). Fuel injector trouble Inspect (see chapter 3). Water temperature sensor trouble Inspect (see chapter 3).
  • Page 128: Self-diagnosis

    3-34 FUEL SYSTEM (DFI) Self-Diagnosis The warning indicator light (LED) [A] is used for the FI/ETV (Electrical Throttle Valve) indicator, oil pressure warning indicator and water temperature warning indicator. Self-diagnosis Outline The ECU notifies the rider of troubles in DFI system, ig- nition system and EVT system by lighting up or blinking the warning indicator light (LED) [A] and displaying the “Error”...
  • Page 129 FUEL SYSTEM (DFI) 3-35 Self-Diagnosis ○ When problem occurs with ETV (Electrical Throttle Valve) system, the warning indicator light (LED) [A] blinks and the “Error” segments [B], service code [C] and FI warning symbol [D] are displayed on the LCD (Liquid Crystal Dis- play) to alert the rider.
  • Page 130 3-36 FUEL SYSTEM (DFI) Self-Diagnosis • After switching to the normal display, the service code can be displayed again by the following procedures. ○ Push the “S” button of the right switch housing for more than two seconds to display the clock setting mode [A] on the LCD.
  • Page 131 FUEL SYSTEM (DFI) 3-37 Self-Diagnosis Self-Diagnosis Flow Chart...
  • Page 132: Service Code Reading

    3-38 FUEL SYSTEM (DFI) Self-Diagnosis Service Code Reading ○ The service code(s) is displayed on the LCD by the number of two digits. ○ When there are a number of problems, all the service codes can be stored and the display will begin starting from the lowest number service code in the numerical order.
  • Page 133 FUEL SYSTEM (DFI) 3-39 Self-Diagnosis Service Code Table Service System Problems Code Throttle position 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. Accelerator position sensor malfunction, wiring open or short.
  • Page 134: Backups

    3-40 FUEL SYSTEM (DFI) Self-Diagnosis Backups ○ The ECU takes the following measures to prevent engine damage when the DFI, ignition or ETV system parts have troubles. Service Output Signal Usable Parts Backups by ECU Codes Range or Criteria If both throttle position sensor 1 and 2 fail, Output Voltage Throttle the ECU sets the DFI in the D-J method(*1)
  • Page 135 FUEL SYSTEM (DFI) 3-41 Self-Diagnosis Service Output Signal Usable Parts Backups by ECU Codes Range or Criteria If the ignition coil #1 primary winding has Ignition Coil failures (wiring short or open), the ECU shuts #1 (Front — off the injector #1 to stop fuel to the cylinder Cylinder) #1, though the engine keeps running.
  • Page 136: Throttle Position Sensor (service Code 11)

    3-42 FUEL SYSTEM (DFI) Throttle Position Sensor (Service Code 11) Throttle Position Sensor Removal CAUTION Do not remove throttle position sensor in the gear case [A] since it has been adjusted and set with pre- cision at the factory. Never drop the throttle body assy, especially on a hard surface.
  • Page 137: Throttle Position Sensor Input Voltage Inspection

    FUEL SYSTEM (DFI) 3-43 Throttle Position Sensor (Service Code 11) Throttle Position Sensor Input Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch OFF. • Remove: Front Seat (see Front Seat Removal in the Frame chap- ter) Battery Case Cover (see Battery Removal in the Electri- cal System chapter)
  • Page 138 3-44 FUEL SYSTEM (DFI) Throttle Position Sensor (Service Code 11) Throttle Position Sensor Circuit 1. ECU 2. Throttle Position Sensor/ETV Actuator 3. Throttle Position Sensor 1 4. Throttle Position Sensor 2...
  • Page 139: Inlet Air Pressure Sensor (service Code 12)

    FUEL SYSTEM (DFI) 3-45 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 TankRemoval) Inlet Air Pressure Sensor Connector [A] Inlet Air Pressure Sensor Bolt [B]...
  • Page 140: Inlet Air Pressure Sensor Output Voltage Inspection

    3-46 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 connectors. Special Tool - Hand Tester: 57001-1394 ○ Disconnect the ECU and sensor connectors. Wiring Continuity Inspection ECU Connector [A] ←→...
  • Page 141 FUEL SYSTEM (DFI) 3-47 Inlet Air Pressure Sensor (Service Code 12) If the reading is within the usable range, remove the ECU and check the wiring for continuity between main harness connector. Special Tool - Hand Tester: 57001-1394 ○ Disconnect the ECU and sensor connectors. Wiring Continuity Inspection ECU Connector [A] ←→...
  • Page 142 3-48 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code 12) then Pv = Pl – Pg For example, suppose the following data is obtained: Pg = 8 cmHg (Vacuum Gauge Reading) Pl = 70 cmHg (Barometer Reading) Vv = 3.2 V (Digital Meter Reading) then Pv = 70 –...
  • Page 143 FUEL SYSTEM (DFI) 3-49 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 144 3-50 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code 12) Inlet Air Pressure Sensor Circuit 1. ECU 2. Inlet Air Pressure Sensor...
  • Page 145: Inlet Air Temperature Sensor (service Code 13)

    FUEL SYSTEM (DFI) 3-51 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: Right Air Cleaner Housing (see Air Cleaner Housing Re- moval)
  • Page 146: Inlet Air Temperature Sensor Resistance Inspection

    3-52 FUEL SYSTEM (DFI) Inlet Air Temperature Sensor (Service Code 13) • Turn the ignition switch OFF. If the reading is within the standard, check the ECU for its ground and power supply (see ECU Power Supply In- spection). If the ground and power supply are good, replace the ECU (see ECU Removal/Installation).
  • Page 147 FUEL SYSTEM (DFI) 3-53 Inlet Air Temperature Sensor (Service Code 13) Inlet Air Temperature Sensor Circuit 1. ECU 2. Inlet Air Temperature Sensor...
  • Page 148: Water Temperature Sensor (service Code 14)

    3-54 FUEL SYSTEM (DFI) Water Temperature Sensor (Service Code 14) Water Temperature Sensor Removal/Installation CAUTION Never drop the water temperature sensor, espe- cially on a hard surface. Such a shock to the sensor can damage it. • Remove: Fuel Tank (see Fuel Tank Removal) •...
  • Page 149: Water Temperature Sensor Resistance Inspection

    FUEL SYSTEM (DFI) 3-55 Water Temperature Sensor (Service Code 14) • Turn the ignition switch OFF. If the reading is within the standard, check the ECU for its ground, and power supply (see ECU Power Supply Inspection). If the ground and power supply are good, replace the ECU (see ECU Removal/Installation).
  • Page 150: Accelerator Position Sensor (service Code 18)

    3-56 FUEL SYSTEM (DFI) Accelerator Position Sensor (Service Code 18) Accelerator Position Sensor Removal CAUTION Do not remove accelerator position sensor [A] since it has been adjusted and set with precision at the factory. Never drop the throttle body assy, especially on a hard surface.
  • Page 151: Accelerator Position Sensor Input Voltage Inspection

    FUEL SYSTEM (DFI) 3-57 Accelerator Position Sensor (Service Code 18) Accelerator Position Sensor Input Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch OFF. • Remove: Front Seat (see Front Seat Removal in the Frame chap- ter) Battery Case Cover (see Battery Removal in the Electri- cal System chapter)
  • Page 152 3-58 FUEL SYSTEM (DFI) Accelerator Position Sensor (Service Code 18) • Connect the digital meter [A] to the terminals of the accel- erator position sensor connector [B]. Accelerator Position Sensor Resistance Connection: (1) BL/W lead terminal → BK/O lead terminal (2) BL/BK lead terminal →...
  • Page 153: Crankshaft Sensor (service Code 21)

    FUEL SYSTEM (DFI) 3-59 Crankshaft Sensor (Service Code 21) The crankshaft sensor has no power source, and when the engine stops, the crankshaft sensor generates no sig- nals. Crankshaft Sensor Removal/Installation • Refer to the Crankshaft Sensor Removal/Installation in the Electrical System chapter. Crankshaft Sensor Resistance Inspection •...
  • Page 154 3-60 FUEL SYSTEM (DFI) Crankshaft Sensor (Service Code 21) Crankshaft Sensor Circuit 1. ECU 2. Crankshaft Sensor...
  • Page 155: Speed Sensor (service Code 24)

    FUEL SYSTEM (DFI) 3-61 Speed Sensor (Service Code 24) Speed Sensor Removal/Installation • Refer to the Speed Sensor Removal/Installation in the Electrical System chapter. Speed Sensor Input Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch OFF. •...
  • Page 156: Speed Sensor Output Voltage Inspection

    3-62 FUEL SYSTEM (DFI) Speed Sensor (Service Code 24) Speed Sensor Output Voltage Inspection • Using the jack, raise the rear wheel off the ground (see Rear Wheel Removal in the Wheels/Tires chapter). Special Tool - Jack: 57001-1238 • Measure the output voltage at the speed sensor in the same way as input voltage inspection, note the following.
  • Page 157 FUEL SYSTEM (DFI) 3-63 Speed Sensor (Service Code 24) Speed Sensor Circuit 1. ECU 2. Speed Sensor...
  • Page 158: Gear Position Switch (service Code 25)

    3-64 FUEL SYSTEM (DFI) Gear Position Switch (Service Code 25) Gear Position Switch Removal/Installation • Refer to the Gear Position Switch Removal/Installation in the Electrical System chapter. Gear Position Switch Resistance Inspection • Refer to the Gear Position Switch Inspection in the Elec- trical System chapter.
  • Page 159 FUEL SYSTEM (DFI) 3-65 Gear Position Switch (Service Code 25) • Turn the ignition switch OFF. If the reading is out of the standard, check the wiring for continuity, using the wiring diagram in this section. Special Tool - Hand Tester: 57001-1394 If the wiring is good, check the ECU for its ground and power supply (see ECU Power Supply Inspection).
  • Page 160: Vehicle-down Sensor (service Code 31)

    3-66 FUEL SYSTEM (DFI) Vehicle-down Sensor (Service Code 31) This sensor has a weight [A] with two magnets inside, and sends a signal to the ECU. But when the motorcycle banks 60 ∼ 70° or more to either side (in fact falls down), the weight turns and the signal changes.
  • Page 161: Vehicle-down Sensor Installation

    FUEL SYSTEM (DFI) 3-67 Vehicle-down Sensor (Service Code 31) Vehicle-down Sensor Installation • The UP mark [A] of the sensor should face upward. • Tighten the vehicle-down senor bolts securely. WARNING Incorrect installation of the vehicle-down sensor could cause sudden loss of engine power. The rider could lose balance during certain riding situ- ations like leaning over in a turn with the potential for an accident resulting in injury or death.
  • Page 162: Vehicle-down Sensor Output Voltage Inspection

    3-68 FUEL SYSTEM (DFI) Vehicle-down Sensor (Service Code 31) If the reading is out of the standard, remove the ECU and check the wiring for continuity between main harness connectors. Special Tool - Hand Tester: 57001-1394 ○ Disconnect the ECU and sensor connectors. Wiring Continuity Inspection ECU Connector [A] ←→...
  • Page 163 FUEL SYSTEM (DFI) 3-69 Vehicle-down Sensor (Service Code 31) • Hold the sensor vertically. • Measure the output voltage with the engine stopped, and with the connector joined. • Turn the ignition switch ON. • Tilt the sensor 40 ∼ 50° or more [A] right or left, then hold the sensor almost vertical with the arrow mark pointed up [B], and measure the output voltage.
  • Page 164 3-70 FUEL SYSTEM (DFI) Vehicle-down Sensor (Service Code 31) Vehicle-down Sensor Circuit 1. ECU 2. Vehicle-down Sensor...
  • Page 165: Oxygen Sensor - Not Activated (service Code 33, Equipped Models)

    FUEL SYSTEM (DFI) 3-71 Oxygen Sensor - not activated (Service Code 33, Equipped Models) Oxygen Sensor Removal/Installation • Refer to the Oxygen Sensor Removal/Installation (Equipped Models) in the Electrical System chapter. Oxygen Sensor Inspection • Warm up the engine thoroughly until the radiator fan starts.
  • Page 166 3-72 FUEL SYSTEM (DFI) Oxygen Sensor - not activated (Service Code 33, Equipped Models) ○ Do not disconnect the air switching valve connector [A]. • Plug the air switching valve hose ends [A], and shut off the secondary air. • Connect the following parts temporarily.
  • Page 167 FUEL SYSTEM (DFI) 3-73 Oxygen Sensor - not activated (Service Code 33, Equipped Models) If the reading is out of the standard (with plugs: 0.8 V or more, without plugs: 0.24 V or less), remove the ECU and check the wiring for continuity between main harness connectors.
  • Page 168: Fuel Pump Relay (service Code 46)

    3-74 FUEL SYSTEM (DFI) Fuel Pump Relay (Service Code 46) Fuel Pump Relay Removal/Installation ○ The fuel pump relay is built in the relay box [A]. • Refer to the Relay Box Removal in the Electrical System chapter. Fuel Pump Relay Inspection •...
  • Page 169: Return Spring (service Code 49)

    FUEL SYSTEM (DFI) 3-75 Return Spring (Service Code 49) Return Spring Removal CAUTION Do not remove return spring in the gear case [A] since it has been set with precision at the factory. Return Spring Inspection • Turn the ignition switch OFF. •...
  • Page 170: Ignition Coils #1, #2 (service Code 51, 52)

    3-76 FUEL SYSTEM (DFI) Ignition Coils #1, #2 (Service Code 51, 52) Ignition Coil #1 (Front Cylinder): Service Code 51 Ignition Coil #2 (Rear Cylinder): Service Code 52 Ignition Coil Removal/Installation • Refer to the Ignition Coil Removal/Installation in the Elec- trical System chapter.
  • Page 171 FUEL SYSTEM (DFI) 3-77 Ignition Coils #1, #2 (Service Code 51, 52) Ignition Coil Circuit 1. ECU 2. Ignition Coil #2 (Rear Cylinder) 3. Ignition Coil #1 (Front Cylinder) 4. Engine Stop Switch 5. Ignition Switch 6. Main Fuse 30 A 7.
  • Page 172: Radiator Fan Relay (service Code 56)

    3-78 FUEL SYSTEM (DFI) Radiator Fan Relay (Service Code 56) Radiator Fan Relay Removal/Installation ○ The radiator fan relay is built in the relay box [A]. • Refer to the Relay Box Removal in the Electrical System chapter. Radiator Fan Relay Inspection •...
  • Page 173: Etv Acutuator (service Code 58)

    FUEL SYSTEM (DFI) 3-79 ETV Acutuator (Service Code 58) ETV Actuator Removal CAUTION Do not remove ETV actuator in the gear case [A] since it has been set with precision at the factory. ETV Actuator Input Voltage Inspection NOTE ○ Be sure the battery is fully charged.
  • Page 174: Etv Actuator Resistance Inspection

    3-80 FUEL SYSTEM (DFI) ETV Acutuator (Service Code 58) ETV Actuator Resistance Inspection • Remove: Front Seat (see Front Seat Removal in the Frame chap- ter) ETV Actuator Relay [A] • Connect the hand tester [A] and a 12 V battery [B] to the relay [C] as shown in the figure.
  • Page 175: Air Switching Valve (service Code 64)

    FUEL SYSTEM (DFI) 3-81 Air Switching Valve (Service Code 64) Air Switching Valve Removal/Installation • Refer to the Air Switching Valve Removal/Installation in the Engine Top End chapter. Air Switching Valve Inspection • Refer to the Air Switching Valve Unit Test in the Electrical System chapter.
  • Page 176: Oxygen Sensor Heater (service Code 67, Equipped Models)

    3-82 FUEL SYSTEM (DFI) Oxygen Sensor Heater (Service Code 67, Equipped Models) Oxygen Sensor Heater Removal/Installation The oxygen sensor heater is built in the oxygen sensor. So, the heater itself can not be removed. Remove the oxy- gen sensor (see Oxygen Sensor Removal (Equipped Mod- els) in the Electrical System chapter).
  • Page 177: Oxygen Sensor Heater Power Source Voltage Inspection

    FUEL SYSTEM (DFI) 3-83 Oxygen Sensor Heater (Service Code 67, Equipped Models) Oxygen Sensor Heater Power Source Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch OFF. • Disconnect the oxygen sensor lead connector and con- nect the measuring adapter [A] between these connec- tors as shown in the figure.
  • Page 178 3-84 FUEL SYSTEM (DFI) Oxygen Sensor Heater (Service Code 67, Equipped Models) Oxygen Sensor Circuit 1. ECU 2. Oxygen Sensor 3. Oxygen Sensor Heater Fuse 10 A 4. Ignition Switch 5. Main Fuse 30 A 6. Battery 7. Engine Ground 8.
  • Page 179: Battery Voltage (service Code 97)

    FUEL SYSTEM (DFI) 3-85 Battery Voltage (Service Code 97) Battery Voltage Inspection • Refer to the Charging Condition Inspection in the Electri- cal System chapter for battery voltage inspection. If the battery voltage is good condition, replace the ECU (see ECU Removal/Installation). Battery Monitor Circuit 1.
  • Page 180: Etv Control Circuit (service Code 98)

    3-86 FUEL SYSTEM (DFI) ETV Control Circuit (Service Code 98) ETV Control Circuit Inspection ○ The ETV control circuit is controlled in the ECU [A]. So, the ETV control circuit cannot be inspected. • When the service code 98 is displayed on the LCD, re- place the ECU (see ECU Removal/Installation).
  • Page 181: Warning Indicator Light (led)

    FUEL SYSTEM (DFI) 3-87 Warning Indicator Light (LED) Light (LED) Inspection ○ The warning indicator light (LED) [A] is used for the FI in- dicator, ETV (Electrical Throttle Valve) indicator, oil pres- sure warning indicator and battery warning indicator. ○ In this model, the warning indicator light (LED) goes on or blinks by the data sent from the ECU.
  • Page 182: Ecu

    3-88 FUEL SYSTEM (DFI) ECU Identification ○ Most countries have their own regulations, so each ECU has different characteristic. So, do not confuse ECU with each other and use only the ECU for your model. Other- wise, the motorcycle can not clear the regulation. ECU Identification Part Number [A] Specification...
  • Page 183: Ecu Power Supply Inspection

    FUEL SYSTEM (DFI) 3-89 ECU Power Supply Inspection • Remove: Front Seat (see Front Seat Removal in the Frame chap- ter) Battery Case Cover (see Battery Removal in the Electri- cal System chapter) • Visually inspect the ECU connectors. If the connector is clogged with mud or dust, blow it off with compressed air.
  • Page 184 3-90 FUEL SYSTEM (DFI) If the reading is out of the specification, check the follow- ing. Main Fuse 30 A (see Fuse Inspection in the Electrical System chapter) ECU Fuse 10 A (see Fuse Inspection Electrical System chapter) Power Source Wiring (see ECU Power Source Circuit) If the fuse and wiring are good, replace the ECU (see ECU Removal/Installation).
  • Page 185: Dfi Power Source

    FUEL SYSTEM (DFI) 3-91 DFI Power Source ECU Fuse Removal • Refer to the 10 A ECU Fuse Removal in the Electrical System chapter. ECU Fuse Installation If a fuse fails during operation, inspect the DFI system to determine the cause, and then replace it with a new fuse of proper amperage.
  • Page 186: Fuel Line

    3-92 FUEL SYSTEM (DFI) Fuel Line Fuel Pressure Inspection NOTE ○ Be sure the battery is fully charged. • Remove: Fuel Hose (see Fuel Hose Replacement in the Periodic Maintenance chapter) ○ Be sure to place a piece of cloth around the fuel outlet pipe of the fuel pump and the delivery pipe of the throttle body assy.
  • Page 187: Fuel Flow Rate Inspection

    FUEL SYSTEM (DFI) 3-93 Fuel Line NOTE ○ The gauge needle will fluctuate. Read the pressure at the average of the maximum and minimum indications. • Turn the ignition switch OFF. If the fuel pressure is much higher than specified, replace the fuel pump because the fuel pressure regulator in the fuel pump have been clogged or stuck.
  • Page 188 3-94 FUEL SYSTEM (DFI) Fuel Line • Connect the prepared fuel hose [A] to the fuel outlet pipe. • Secure the fuel hose with a clamp. • Insert the fuel hose into the measuring cylinder [B]. WARNING Wipe off spilled out fuel immediately. Be sure to hold the measuring cylinder vertical.
  • Page 189: Fuel Pump

    FUEL SYSTEM (DFI) 3-95 Fuel Pump Fuel Pump Removal WARNING Gasoline is extremely flammable and can be explo- sive under certain conditions. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light.
  • Page 190: Fuel Pump Installation

    3-96 FUEL SYSTEM (DFI) Fuel Pump Fuel Pump Installation • Remove dirt or dust from the fuel pump [A] by lightly ap- plying compressed air. • Replace the fuel pump gasket with a new one. • Check that the fuel pump terminal [A] and band [B] are in place.
  • Page 191: Pressure Regulator Removal

    FUEL SYSTEM (DFI) 3-97 Fuel Pump • Disconnect the fuel pump lead connector and connect the measuring adapter [A] between these connectors as shown in the figure. Main Harness [B] Fuel Pump [C] Special Tool - Measuring Adapter: 57001-1700 • Connect a digital meter [D] to the measuring adapter leads.
  • Page 192: Fuel Filter Cleaning

    3-98 FUEL SYSTEM (DFI) Fuel Pump Fuel Filter Cleaning ○ The fuel filter [A] is built into the pump and can not be cleaned or checked. If the fuel filter is suspected of clogging or being damaged, replace it with the fuel pump as a set. Fuel Pump Circuit 1.
  • Page 193: Fuel Injectors

    FUEL SYSTEM (DFI) 3-99 Fuel Injectors Fuel Injector Removal • Remove: Fuel Tank (see Fuel Tank Removal) Throttle Body Assy (see Throttle Body Assy Removal) Fuel Injector Connectors [A] • Remove: Delivery Joint Bolt [A] Bracket [B] • Remove: Delivery Joint Bolt [A] Bracket [B] •...
  • Page 194: Fuel Injector Installation

    3-100 FUEL SYSTEM (DFI) Fuel Injectors Fuel Injector Installation • Before installing the fuel injector, blow away dirt or dust from the delivery joint by applying compressed air. • Replace the O-rings [A] of each fuel injector with new ones. •...
  • Page 195: Fuel Injector Output Voltage Inspection

    FUEL SYSTEM (DFI) 3-101 Fuel Injectors • Connect the digital meter [A] to the harness connectors [B] with the needle adapter set. Special Tool - Needle Adapter Set: 57001-1457 Fuel Injector Resistance Connection: Fuel Injector #1 Digital Meter → BL/O lead (ECU terminal 27) Digital Meter →...
  • Page 196: Fuel Injector Input Voltage Inspection

    3-102 FUEL SYSTEM (DFI) Fuel Injectors • Turn the ignition switch OFF. If the reading is in the specification, but the injector does not operate, replace the ECU (see ECU Removal/Instal- lation). If the reading is out of the specification, check the input voltage (see Fuel Injector Input Voltage Inspection).
  • Page 197: Fuel Injector Fuel Line Inspection

    FUEL SYSTEM (DFI) 3-103 Fuel Injectors Fuel Injector Fuel Line Inspection • Remove: Fuel Tank (see Fuel Tank Removal) Left Air Cleaner Housing (see Left Air Cleaner Housing Removal) Fuel Hoses (see Fuel Hose Replacement in the Periodic Maintenance chapter) ○...
  • Page 198 3-104 FUEL SYSTEM (DFI) Fuel Injectors Fuel Injector Circuit 1. ECU 2. Engine Stop Switch 3. Fuel Injector #2 4. Fuel Injector #1 5. Ignition Switch 6. Ignition Fuse 10 A 7. ECU Fuse 10 A 8. Main Fuse 30 A 9.
  • Page 199: Throttle Grip And Cables

    FUEL SYSTEM (DFI) 3-105 Throttle Grip and Cables Free Play Inspection • Refer to the Throttle Control System Inspection in the Pe- riodic Maintenance chapter. Free Play Adjustment • Refer to the Throttle Control System Inspection in the Pe- riodic Maintenance chapter. Cable Installation •...
  • Page 200: Cable Lubrication

    3-106 FUEL SYSTEM (DFI) Throttle Grip and Cables If the stopper of the pulley does not touch, adjust the throttle grip free play with the accelerator cable adjuster [A] and then use the decelerator cable adjuster [B] (see Throttle Control System Inspection in the Periodic Main- tenance chapter).
  • Page 201: Throttle Body Assy

    FUEL SYSTEM (DFI) 3-107 Throttle Body Assy Idle Speed Inspection/Adjustment • Refer to the Idle Speed Inspection/Adjustment in the Pe- riodic Maintenance chapter. Throttle Body Assy Removal WARNING Gasoline is extremely flammable and can be explo- sive under certain conditions. Make sure the area is well-ventilated and free from any source of flame or sparks;...
  • Page 202: Throttle Body Assy Installation

    3-108 FUEL SYSTEM (DFI) Throttle Body Assy • Remove: Vacuum Hose [A] Cruise Control Cancel Switch (Throttle) Lead Connector [B] • Remove: Throttle Position Sensor Connector [A] Accelerator Position Sensor Connector [B] Throttle Body Assy Holder Bolts [C] Throttle Body Assy [D] (from Inlet Manifold) •...
  • Page 203 FUEL SYSTEM (DFI) 3-109 Throttle Body Assy • Apply a thin coat of grease to the throttle cable upper ends. • Install the upper ends of the throttle cables in the grip. • Fit the projection [A] of the right switch housing into the hole [B] of the handlebar.
  • Page 204: Throttle Body Assy Disassembly

    3-110 FUEL SYSTEM (DFI) Throttle Body Assy • Install: Throttle Body Assy [A] Throttle Body Assy Holder Bolt [B], 75 mm (3.0 in.) Throttle Body Assy Holder Bolts [C], 60 mm (2.4 in.) • Tighten: Torque - Throttle Body Assy Holder Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) •...
  • Page 205: Throttle Body Assy Assembly

    FUEL SYSTEM (DFI) 3-111 Throttle Body Assy Throttle Body Assy Assembly • Apply a non-permanent locking agent to the cruise control cancel switch (throttle) bolt [A]. • Install the switch so that the projection [B] into the hole [C] of the bracket. •...
  • Page 206: Inlet Manifold

    3-112 FUEL SYSTEM (DFI) Inlet Manifold Inlet Manifold Removal • Remove: Throttle Body Assy (see Throttle Body Assy Removal) Fuel Injectors (Fuel Injector Removal) Inlet Manifold Bolts [A] Inlet Manifold [B] Inlet Mnifold Installation • Wipe any carbon off the bores [A] around the inlet man- ifold, using a piece of lint-free cloth penetrated with a high-flash point solvent.
  • Page 207: Air Cleaner

    FUEL SYSTEM (DFI) 3-113 Air Cleaner Air Cleaner Element Removal/Installation • Refer to the Air Cleaner Element Replacement in the Pe- riodic Maintenance chapter. Air Cleaner Element Inspection • Remove: Air Cleaner Element (see Air Cleaner Element Replace- ment in the Periodic Maintenance chapter) •...
  • Page 208: Left Air Cleaner Housing Installation

    3-114 FUEL SYSTEM (DFI) Air Cleaner • Remove: Breather Hose [A] Left Air Cleaner Housing Installation • When installing the damper [A] and collar [B], install them as shown in the figure. Air Cleaner Housing [C] Engine Side [D] Big Side [E] •...
  • Page 209: Right Air Cleaner Housing Installation

    FUEL SYSTEM (DFI) 3-115 Air Cleaner • Remove: Right Air Cleaner Housing Cover Bolts [A] Right Air Cleaner Housing Cover [B] • Remove: Inlet Air temperature Sensor Connector [A] Air Switching Valve Hose [B] • Remove: Air Cleaner Housing Bolts [A] and Washers Right Air Cleaner Housing Center Bolts [B] Right Air Cleaner Housing [C] Right Air Cleaner Housing Installation...
  • Page 210 3-116 FUEL SYSTEM (DFI) Air Cleaner • Install: Right Air Cleaner Housing Air Cleaner Housing Bolts [A] and Washers • Apply a non-permanent locking agent to the right air cleaner housing center bolts [B]. • Tighten: Torque - Right Air Cleaner Housing Center Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) Air Cleaner Housing Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)
  • Page 211: Fuel Tank

    FUEL SYSTEM (DFI) 3-117 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 212 3-118 FUEL SYSTEM (DFI) Fuel Tank • Disconnect: Fuel Pump Lead Connector [A] • Be sure to place a piece of cloth [A] around the fuel hose joint. • Insert a thin blade screwdriver [B] into the slit [C] on the joint lock [D].
  • Page 213: Fuel Tank Installation

    FUEL SYSTEM (DFI) 3-119 Fuel Tank • For the CAL and SEA models, note the following. CAUTION For the California and Southeast Asia models, if gasoline, solvent, water or any other liquid enters the canister, the canister’s vapor absorbing capac- ity is greatly reduced.
  • Page 214 3-120 FUEL SYSTEM (DFI) Fuel Tank • Check that the dampers [A] are in place on the frame. If the dampers are damaged or deteriorated, replace them. • Install the fuel pump so that the stoppers [A] fit to the dampers [B].
  • Page 215: Fuel Tank Inspection

    FUEL SYSTEM (DFI) 3-121 Fuel Tank Fuel Tank Inspection • Visually inspect the gasket [A] on the tank cap for any damage. Replace the gasket if it is damaged. • Check to see if the fuel breather pipe [B] in the tank are not clogged.
  • Page 216: Evaporative Emission Control System (cal And Sea Models)

    3-122 FUEL SYSTEM (DFI) Evaporative Emission Control System (CAL and SEA Models) The Evaporative Emission Control System routes fuel va- pors from the fuel system into the running engine or stores the vapors in a canister when the engine is stopped. Al- though no adjustments are required, a thorough visual in- spection must be made at the intervals specified by the Pe- riodic Maintenance Chart.
  • Page 217: Separator Operation Test

    FUEL SYSTEM (DFI) 3-123 Evaporative Emission Control System (CAL and SEA Models) Separator Operation Test WARNING Gasoline is extremely flammable and can be ex- plosive under certain conditions. Do not smoke. Turn the ignition switch OFF. Make sure the area is well-ventilated and free from any source of flame or sparks;...
  • Page 218 3-124 FUEL SYSTEM (DFI) Evaporative Emission Control System (CAL and SEA Models) 1. Fuel Tank 2. Canister 3. Blue Hose (Breather) 4. Green Hose (Purge) 5. Band (for Canister) 6. Bracket (for Canister) 7. Separator 8. Band (for Separator) 9. Fittings 10.
  • Page 219 COOLING SYSTEM 4-1 Cooling System Table of Contents Exploded View........................Coolant Flow Chart......................... Specifications ......................... Special Tools .......................... Coolant ........................... Coolant Deterioration Inspection..................Coolant Level Inspection....................Coolant Draining ....................... Coolant Filling ........................Pressure Testing ....................... Cooling System Flushing ....................Coolant Reserve Tank Removal/Installation ..............Water Pump..........................
  • Page 220: Exploded View

    4-2 COOLING SYSTEM Exploded View...
  • Page 221 COOLING SYSTEM 4-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Cross Pipe Bolts Radiator Fan Bolts 0.85 73 in·lb Radiator Hose Clamp Screws 0.20 18 in·lb Thermostat Housing Cover Bolts 87 in·lb Water Pipe Bolts 106 in·lb Water Pump Impeller Bolt 106 in·lb 106 in·lb Water Separator Inner Cover Bolts...
  • Page 222: Coolant Flow Chart

    4-4 COOLING SYSTEM Coolant Flow Chart...
  • Page 223 COOLING SYSTEM 4-5 Coolant Flow Chart 1. Radiator Fan 2. Radiator 3. Water Separator Cover 4. Water Pump 5. Reserve Tank 6. Reserve Tank Overflow Hose 7. Radiator Overflow Hose 8. Cylinder Jacket 9. Cylinder Head Jacket 10. Thermostat Housing 11.
  • Page 224: Specifications

    4-6 COOLING SYSTEM Specifications Item Standard Coolant provided when shipping Type (Recommended) Permanent type antifreeze (soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators) Color Green Mixed Ratio Soft water 50%, coolant 50% Freezing Point −35°C (−31°F) 2.4 L (2.5 US qt) (Reserve tank full level, including...
  • Page 225: Special Tools

    COOLING SYSTEM 4-7 Special Tools Bearing Driver Set: Bearing Remover Head, 10 × 12: 57001-1129 57001-1266 Bearing Remover Shaft, 9: 57001-1265...
  • Page 226: Coolant

    4-8 COOLING SYSTEM Coolant Coolant Deterioration Inspection • Remove the left side cover (see Left Side Cover Removal in the Frame chapter). • Visually inspect the coolant [A] in the reserve tank. If whitish cotton-like wafts are observed, aluminum parts in the cooling system are corroded.
  • Page 227: Cooling System Flushing

    COOLING SYSTEM 4-9 Coolant Cooling System Flushing Over a period of time, the cooling system accumulates rust, scale, and lime in the water jacket and radiator. When this accumulation is suspected or observed, flush the cool- ing system. If this accumulation is not removed, it will clog up the water passage and considerably reduce the effi- ciency of the cooling system.
  • Page 228: Water Pump

    4-10 COOLING SYSTEM Water Pump Water Pump Removal • Drain the coolant (see Coolant Change in the Periodic Maintenance chapter). • Remove: Alternator Cover (see Alternator Cover Removal in the Electrical System chapter) Impeller Bolt [A] and Washer Impeller [B] NOTE ○...
  • Page 229: Mechanical Seal Inspection

    COOLING SYSTEM 4-11 Water Pump Mechanical Seal Inspection • Remove the impeller (see Water Pump Removal). • Visually inspect the mechanical seal. If any one of the parts is damaged, replace the mechani- cal seal as a unit. ○ The sealing seat and rubber seal may be removed easily by hand.
  • Page 230 4-12 COOLING SYSTEM Water Pump • Replace the oil seal and ball bearing with new ones. • Apply grease to the oil seal lips. • Press the oil seal [A] into the hole from the outside of the left crankcase with the bearing driver set so that the spring side of the seal lips is toward the inside of the crankcase.
  • Page 231: Radiator

    COOLING SYSTEM 4-13 Radiator Radiator Removal • Remove: Bracket Bolt [A] Cross Pipe Bolts [B] • Detach the projections of the radiator from the grommet [C] of the cross pipe. • Open the clamp [A] to free the lead. • Disconnect the regulator connectors [B].
  • Page 232: Radiator Installation

    4-14 COOLING SYSTEM Radiator • Remove: Radiator Bolt [A] Radiator [B] CAUTION Do not touch the radiator core. This could damage the radiator fins, resulting in loss of cooling effi- ciency. • Remove: Radiator Fan Bolts [A] Radiator Fan [B] Radiator Installation •...
  • Page 233: Radiator Inspection

    COOLING SYSTEM 4-15 Radiator Radiator Inspection • Remove the radiator (see Radiator Removal). • Check the radiator core. If there are obstructions to air flow, remove them. If the corrugated fins [A] are deformed, carefully straighten them. If the air passages of the radiator core are blocked more than 20% by unremovable obstructions or irreparably de- formed fins, replace the radiator with a new one.
  • Page 234: Radiator Filler Neck Inspection

    4-16 COOLING SYSTEM Radiator Radiator Filler Neck Inspection • Remove the radiator cap (see Coolant Change in the Pe- riodic Maintenance chapter). • Check the radiator filler neck for signs of damage. • Check the condition of the top and bottom sealing seats [A] in the filler neck.
  • Page 235: Thermostat

    COOLING SYSTEM 4-17 Thermostat Thermostat Removal • Drain the coolant (see Coolant Change in the Periodic Maintenance chapter). • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Water Hoses [A] Bracket Bolts [B] Water Temperature Sensor Connector [C] •...
  • Page 236: Thermostat Inspection

    4-18 COOLING SYSTEM Thermostat Thermostat Inspection • Remove the thermostat (see Thermostat Removal). • Inspect the thermostat valve at room temperature. If the valve is open, replace the valve with a new one. • To check valve opening temperature, suspend the ther- mostat [A] and an accurate thermometer [B] in a container of water with the heat-sensitive portions [C] in almost the same depth.
  • Page 237: Hoses And Pipes

    COOLING SYSTEM 4-19 Hoses and Pipes Water Separator Cover Removal • Drain the coolant (see Coolant Change in the Periodic Maintenance chapter) • Remove: Water Separator Outer Cover Bolts [A] Water Separator Outer Cover [B] • Remove: Water Pipe Bolts [A] Upper Water Pipes [B] •...
  • Page 238: Hose Installation

    4-20 COOLING SYSTEM Hoses and Pipes • Replace the O-rings [A] with new ones. • Apply grease to the new O-rings. • Install the upper water pipes. ○ When installing the upper water pipes, insert the water pipes into the pipe fitting of the cylinder as far as they will •...
  • Page 239: Water Temperature Sensor

    COOLING SYSTEM 4-21 Water Temperature Sensor Water Temperature Sensor Removal/Installation • Refer to the Water Temperature Sensor Removal/Instal- lation in the Fuel System (DFI) chapter. Water Temperature Sensor Inspection • Refer to the Water Temperature Sensor Inspection in the Electrical System chapter.
  • Page 241 Camshaft Sprocket Removal ..5-31 Clean Air System....... 5-12 Camshaft Sprocket Installation ..5-32 Air Suction Valve Removal... 5-12 KACR (Kawasaki Automatic Air Suction Valve Installation..5-12 Compression Release) ....5-33 Air Suction Valve Inspection ..5-12 KACR Inspection......5-33 Air Switching Valve Removal ..
  • Page 242: Exploded View

    5-2 ENGINE TOP END Exploded View...
  • Page 243 ENGINE TOP END 5-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Breather Check Valve Cover Bolts 87 in·lb Cylinder Head Nuts (M12) (First) Cylinder Head Nuts (M12 New Nuts) (Final) MO, S Cylinder Head Nuts (M12 Used Nuts) (Final) Cylinder Head Nuts (M10) (First) MO, S Cylinder Head Nuts (M10) (Final)
  • Page 244 5-4 ENGINE TOP END Exploded View...
  • Page 245 ENGINE TOP END 5-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Camshaft Chain Tensioner Bolts 106in·lb Camshaft Sprocket Bolts Exhaust Pipe Holder Nuts Muffler Body Mounting Bolt Rear Camshaft Chain Guide Retainer Bolts 87 in·lb 6. HLA (Hydraulic Lash Adjuster) 7.
  • Page 246: Exhaust System Identification

    5-6 ENGINE TOP END Exhaust System Identification Exhaust Pipe Mark Position [A] Left Muffler Body Mark Position [A]...
  • Page 247 ENGINE TOP END 5-7 Exhaust System Identification Right Muffler Body Mark Position [A] Right Muffler Body [A] with Hole [B] for Oxygen Sensor [C] Honeycomb Type Catalyst Positions [A] Left Muffler Body [B] Right Muffler Body [C]...
  • Page 248: Specifications

    5-8 ENGINE TOP END Specifications Item Standard Service Limit Rocker Shafts, Rocker Arms 15.976 ∼ 15.994 mm Rocker Shaft Diameter 15.95 mm (0.6279 in.) (0.6289 ∼ 0.6296 in.) 16.016 ∼ 16.034 mm Rocker Arm Inside Diameter 16.07 mm (0.6326 in.) (0.6305 ∼...
  • Page 249 ENGINE TOP END 5-9 Specifications Item Standard Service Limit Valve Seating Surface: Width: 0.8 ∼ 1.2 mm (0.031 ∼ 0.047 in.) Exhaust – – – 0.8 ∼ 1.2 mm (0.031 ∼ 0.047 in.) Inlet – – – Outside Diameter: 34.9 ∼ 35.1 mm (1.374 ∼ 1.382 in.) Exhaust –...
  • Page 250: Special Tools And Sealant

    5-10 ENGINE TOP END Special Tools and Sealant Compression Gauge, 20 kgf/cm²: Valve Seat Cutter, 45° - 41.5: 57001-221 57001-1117 Valve Spring Compressor Assembly: Valve Seat Cutter, 32° - 38.5: 57001-241 57001-1122 Valve Spring Compressor Adapter, 28.2: Valve Seat Cutter, 60° - 41: 57001-243 57001-1124 Valve Guide Arbor, 5.5:...
  • Page 251 57001-1496 57001-1576 Valve Seat Cutter, 55° - 38.5: Valve Guide Reamer, 6: 57001-1497 57001-1596 Valve Seat Cutter, 32°- 44: Compression Gauge Adapter, M12 × 1.25: 57001-1515 57001-1733 Valve Guide Driver: Kawasaki Bond (Silicone Sealant): 57001-1564 92104-0004 Piston Pin Puller: 57001-1568...
  • Page 252: Clean Air System

    5-12 ENGINE TOP END Clean Air System Air Suction Valve Removal Air Suction Valve of Front Cylinder • Remove: Cylinder Head Inner Cover (see Cylinder Head Cover Removal) Air Suction Valve [A] Air Suction Valve of Rear Cylinder • Remove: Engine (see Engine Removal in the Engine Removal/In- stallation chapter) Cylinder Head Inner Cover (see Cylinder Head Cover...
  • Page 253: Air Switching Valve Removal

    ENGINE TOP END 5-13 Clean Air System Air Switching Valve Removal CAUTION Never drop the air switching valve, especially on a hard surface. Such a shock to the air switching valve can damaged it. • Remove the ignition coils (see Ignition Coil Removal in the Electrical System chapter).
  • Page 254: Air Switching Valve Unit Test

    5-14 ENGINE TOP END Clean Air System Air Switching Valve Unit Test • Refer to the Air Switching Valve Unit Test in the Electrical System chapter. Clean Air System Hose Inspection • Be certain that all the hoses are routed without being flat- tened or kinked, and are connected correctly to the air cleaner housing, air switching valve, and fittings on the cylinder head covers.
  • Page 255: Cylinder Head Covers

    ENGINE TOP END 5-15 Cylinder Head Covers Cylinder Head Cover Removal Front Cylinder Head Cover • Remove: Air Switching Valve (see Air Switching Valve Removal) Cylinder Head Outer Cover Bolts [A] with Collars Cylinder Head Outer Covers [B] • Remove: Cylinder Head Inner Cover Bolts [A] with Gaskets Cylinder Head Inner Cover [B] Rear Cylinder Head Cover...
  • Page 256 Apply silicone sealant to the mating surface of the half -month portion [C], and install the gasket on the cylinder head. Sealant - Kawasaki Bond (Silicone Sealant) : 92104-0004 • After installation, wipe up the silicone sealant that seeps out around the mating surface.
  • Page 257 ENGINE TOP END 5-17 Cylinder Head Covers Rear Cylinder Head Cover • Install the collars [A] on the seating surfaces (shaded por- tions) [B] of the cylinder head outer covers [C] as shown in the figure. • Install the plate [D] so that the tabs [E] fit onto the seating surface of the cylinder head outer cover as shown in the figure.
  • Page 258: Rocker Cases

    5-18 ENGINE TOP END Rocker Cases Rocker Case Removal Front Rocker Case • Remove: Cylinder Head Inner Cover (see Cylinder Head Cover Removal) Alternator Cover (see Alternator Cover Removal in the Electrical System chapter) • Using a wrench on the alternator rotor bolt, turn the crankshaft clockwise [A] until the “FRONT”...
  • Page 259 ENGINE TOP END 5-19 Rocker Cases • Remove the camshaft chain tensioner (see Camshaft Chain Tensioner Removal). • Loosen the M6 and M8 rocker case bolts as shown se- quence [1 ∼ 6] in the figure, and remove them. • Lift the rocker case [A], and remove the front camshaft chain guide [B] from the pin of the case.
  • Page 260: Rocker Case Installation

    5-20 ENGINE TOP END Rocker Cases ○ Using a wrench on the alternator rotor bolt, turn the crankshaft clockwise [A] until the “R” mark line (TDC mark for rear piston) [B] of the balancer chain sprocket [C] is aligned with the line [D] of the crankcase. •...
  • Page 261 ENGINE TOP END 5-21 Rocker Cases • Apply molybdenum disulfide oil solution to all cam parts and journals. • Install the plug hole gasket [A] so that the cutout portions [B] fit onto the ribs [C] of the cylinder head. •...
  • Page 262 5-22 ENGINE TOP END Rocker Cases • Install the camshaft chain tensioner (see Camshaft Chain Tensioner Installation). • After installing the camshaft chain tensioner, check to be sure that the camshaft chain timing is correct. • Turn the crankshaft clockwise and recheck the camshaft chain timing.
  • Page 263: Rocker Shafts, Rocker Arms

    ENGINE TOP END 5-23 Rocker Shafts, Rocker Arms Rocker Shaft and Rocker Arm Removal • Remove: Rocker Case (see Rocker Case Removal) Rocker Shafts [A] Rocker Arms [B] Rocker Shaft and Rocker Arm Installation • Apply molybdenum disulfide oil solution to the rocker shafts.
  • Page 264: Rocker Arm Inspection

    5-24 ENGINE TOP END Rocker Shafts, Rocker Arms Rocker Arm Inspection • Remove the rocker arm (see Rocker Shaft and Rocker Arm Removal). • Inspect the area [A] on the rocker arm where the cam rubs. If the rocker arm is scored, discolored or otherwise dam- aged, replace it.
  • Page 265: Hla (hydraulic Lash Adjuster)

    ENGINE TOP END 5-25 HLA (Hydraulic Lash Adjuster) HLA Removal • Remove the rocker arm (see Rocker Shaft and Rocker Arm Removal). • Pull the HLA (Hydraulic Lash Adjuster) [A] out of the rocker arm with fingers. CAUTION Be careful not to damage or deform an HLA by tap- ping it during removal or installation.
  • Page 266: Camshaft Chain Tensioners

    5-26 ENGINE TOP END Camshaft Chain Tensioners Camshaft Chain Tensioner Removal CAUTION Do not turn over the crankshaft while the tensioner is removed. This could upset the camshaft chain timing, and damage the valves. Front Camshaft Chain Tensioner • Remove the alternator rotor (see Alternator Rotor Re- moval in the Electrical System chapter).
  • Page 267: Camshaft Chain Tensioner Installation

    ENGINE TOP END 5-27 Camshaft Chain Tensioners Camshaft Chain Tensioner Installation If the pin was removed, install it as follows. ○ Push the push rod [A] into the interior of tensioner body [B] while pushing the stopper [C]. CAUTION Be careful the oil remaining in the tensioner body dashes out.
  • Page 268: Camshafts, Camshaft Chains, Camshaft Sprockets

    5-28 ENGINE TOP END Camshafts, Camshaft Chains, Camshaft Sprockets Camshaft Removal NOTE ○ The front and rear camshaft removal are same proce- dures. • Remove: Engine (see Engine Removal in the Engine Removal/In- stallation chapter) Rocker Case (see Rocker Case Removal) •...
  • Page 269 ENGINE TOP END 5-29 Camshafts, Camshaft Chains, Camshaft Sprockets If the rear camshaft chain guide [A] was removed, be sure to install it first. Torque - Rear Camshaft Chain Guide Retainer Bolt : 9.8 N·m (1.0 kgf·m, 87 in·lb) Left Side View [B] ○...
  • Page 270: Camshaft, Rocker Case Wear

    5-30 ENGINE TOP END Camshafts, Camshaft Chains, Camshaft Sprockets Camshaft, Rocker Case Wear • Remove the rocker cases (see Rocker Case Removal). • Cut strips of plastigage to journal width. Place a strip on each journal parallel to the camshaft installed in the correct position.
  • Page 271: Cam Wear

    ENGINE TOP END 5-31 Camshafts, Camshaft Chains, Camshaft Sprockets Cam Wear • Remove the camshaft (see Camshaft Removal). • Measure the height [A] of each cam with a micrometer. If the cams are worn down past the service limit, replace the camshaft.
  • Page 272: Camshaft Sprocket Installation

    5-32 ENGINE TOP END Camshafts, Camshaft Chains, Camshaft Sprockets Camshaft Sprocket Installation • Install the camshaft sprockets as shown in the figure. Exhaust Cam Positions [A] Push Rods of KACR [B] Front Camshaft Sprocket [C] Rear Camshaft Sprocket [D] ○ The front and rear camshaft sprockets are identical.
  • Page 273: Kacr (kawasaki Automatic Compression Release)

    ENGINE TOP END 5-33 KACR (Kawasaki Automatic Compression Release) KACR Inspection The KACR (Kawasaki Automatic Compression Release) momentarily opens the exhaust valves on the compression stroke at very low speeds. In this model, the KACR is oper- ated at 400 ∼ 500 r/min (rpm). This allows some of the com- pression pressure to escape, making it easy to turn over the engine during starting.
  • Page 274: Kacr Installation

    5-34 ENGINE TOP END KACR (Kawasaki Automatic Compression Release) • Insert the suitable wire [A] into the hole of the push rod [B] to hold it in place. • Pull out the shaft [A] from the camshaft, and then remove the push rod [B].
  • Page 275 ENGINE TOP END 5-35 KACR (Kawasaki Automatic Compression Release) • Install the push rod [A], and then insert the shaft [B] to the camshaft. • Pull out the wire [C] from the hole of the push rod. • For front KACR, set the shaft so that the “F” mark [A] is aligned with the “...
  • Page 276 5-36 ENGINE TOP END KACR (Kawasaki Automatic Compression Release) ○ Next, release the hand from the weights [A], and check that the weights and push rod [B] are returned to original position. ○ When releasing the hand from the weights, the push rod must be pushed out [C].
  • Page 277: Cylinder Heads

    ENGINE TOP END 5-37 Cylinder Heads Cylinder Compression Measurement NOTE ○ Use the battery which is fully charged. • Warm up the engine thoroughly. • Stop the engine. • Remove spark plugs (see Spark Plug Replacement in the Periodic Maintenance chapter). •...
  • Page 278: Cylinder Head Removal

    5-38 ENGINE TOP END Cylinder Heads Cylinder Head Removal NOTE ○ The front and rear cylinder head removal are same pro- cedures. • Remove: Camshaft (see Camshaft Removal) Front Camshaft Chain Guide [A] Rear Camshaft Chain Guide Retainer Bolt [B] with Re- tainer [C] Rear Camshaft Chain Guide [D] •...
  • Page 279 ENGINE TOP END 5-39 Cylinder Heads NOTE ○ The front cylinder head gasket has a “F” mark [A] and the rear cylinder head gasket has a “R” mark [B]. Be careful not to mix up these gaskets. • Replace the cylinder head gasket with a new one, and install it.
  • Page 280 5-40 ENGINE TOP END Cylinder Heads • Apply molybdenum disulfide oil solution to the following portions. Threads of M10 Cylinder Head Nuts [A] Threads of M12 Cylinder Head Nuts [B] Both Sides of Washers [C] • Tighten the cylinder head nuts using the following steps. ○...
  • Page 281: Cylinder Head Warp

    ENGINE TOP END 5-41 Cylinder Heads Cylinder Head Warp • Clean the cylinder head. • Lay a straightedge across the lower surface of the cylinder head at several positions. • Use a thickness gauge [A] to measure the space between the straightedge [B] and the head.
  • Page 282: Valves

    5-42 ENGINE TOP END Valves Valve Clearance Inspection/Adjustment NOTE ○ Since the HLA (hydraulic lash adjuster) constantly maintain zero clearance, it is not necessary to inspect or adjust the valve clearance. Valve Removal • Remove the cylinder head (see Cylinder Head Removal). •...
  • Page 283: Valve Guide Installation

    ENGINE TOP END 5-43 Valves Valve Guide Installation • Apply oil to the valve guide outer surface before installa- tion. • Heat the area around the valve guide hole to about 120 ∼ 150°C (248 ∼ 302°F). CAUTION Do not heat the cylinder head with a torch. This will warp the cylinder head.
  • Page 284: Valve Seat Inspection

    5-44 ENGINE TOP END Valves Valve Seat Inspection • Remove the valve (see Valve Removal). • Check the valve seating surface [A] between the valve [B] and valve seat [C]. ○ Measure the outside diameter [D] of the seating pattern on the valve seat.
  • Page 285 ENGINE TOP END 5-45 Valves Seat Cutter Operation Care 1. This valve seat cutter is developed to grind the valve for repair. Therefore the cutter must not be used for other purposes than seat repair. 2. Do not drop or shock the valve seat cutter, or the dia- mond particles may fall off.
  • Page 286 5-46 ENGINE TOP END Valves • Measure the outside diameter of the seating surface with a vernier caliper. If the outside diameter of the seating surface is too small, repeat the 45° grind until the diameter is within the spec- ified range.
  • Page 287 ENGINE TOP END 5-47 Valves If the seat width is too wide, make the 60° or 55° [A] grind described below. If the seat width is within the specified range, lap the valve to the seat as described below. • Grind the seat at a 60°...
  • Page 288 5-48 ENGINE TOP END Valves...
  • Page 289: Cylinders, Pistons

    • Apply silicone sealant to the are [B] where the mating sur- face of the crankcase touches the cylinder gasket. Sealant - Kawasaki Bond (Silicone Sealant) : 92104-0004 • Replace the cylinder gasket with a new one, and install it.
  • Page 290: Piston Removal

    5-50 ENGINE TOP END Cylinders, Pistons • Apply molybdenum disulfide oil solution to the cylinder bore, piston rings and piston skirt. • Using the piston ring compressor assembly [A] with the chamfered side [B] upward, install the cylinder block. For Front Cylinder [C] For Rear Cylinder [D] Special Tools - Piston Ring Compressor Grip : 57001-1095 Piston Ring Compressor Belt, 95 ∼...
  • Page 291: Piston Installation

    ENGINE TOP END 5-51 Cylinders, Pistons • Carefully spread the ring opening with your thumbs and then push up on the opposite side of the ring [A] to remove • Remove the 3-piece oil ring with your thumbs in the same manner.
  • Page 292: Cylinder Wear

    5-52 ENGINE TOP END Cylinders, Pistons • Fit a new piston pin snap ring into the side of the piston so that the ring opening [A] does not coincide with the slit [B] of the piston pin hole. ○ Apply molybdenum disulfide oil solution to the piston pin and piston skirt.
  • Page 293: Piston Ring, Piston Ring Groove Wear

    ENGINE TOP END 5-53 Cylinders, Pistons Piston Ring, Piston Ring Groove Wear • Check for uneven groove wear by inspecting the ring seat- ing. The rings should fit perfectly parallel to groove surfaces. If not, replace the piston and all the piston rings. •...
  • Page 294: Piston Ring End Gap

    5-54 ENGINE TOP END Cylinders, Pistons Piston Ring End Gap • Place the piston ring [A] inside the cylinder, using the pis- ton to locate the ring squarely in place. Set it close to the bottom of the cylinder, where cylinder wear is low. •...
  • Page 295: Mufflers

    ENGINE TOP END 5-55 Mufflers WARNING To avoid a serious burn, do not remove the muffler when the engine is still hot. Wait until the muffler cool down. Muffler Body Removal Left Muffler Body • Loosen the muffler body clamp bolt [A]. •...
  • Page 296: Muffler Body Installation

    5-56 ENGINE TOP END Mufflers • Remove: Right Saddlebag (see Saddlebag Removal in the Frame chapter) Muffler Body Mounting Bolts [A] • Pull out the right muffler body [B] backward from the ex- haust pipe. Muffler Body Installation If the left muffler body cover [A] was removed, install it as follows.
  • Page 297: Exhaust Pipe Removal

    ENGINE TOP END 5-57 Mufflers ○ For equipped with the oxygen sensor, run the oxygen sen- sor lead correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). CAUTION Do not pull strongly, twist, or bend the oxygen sen- sor lead.
  • Page 298 5-58 ENGINE TOP END Mufflers • Loosen the middle exhaust pipe cover clamp bolts [A] • Slide the clamp [B] of the rear side backward [C]. • Slide the clamp [D] of the front side forward [E], and re- move the middle exhaust pipe cover [F]. •...
  • Page 299 ENGINE TOP END 5-59 Mufflers Dummy Page...
  • Page 300: Exhaust Pipe Installation

    5-60 ENGINE TOP END Mufflers Exhaust Pipe Installation • Replace the exhaust pipe gaskets [A] with new ones. • Install the exhaust pipe holders [B] so that the “up” mark faces upper side. • Tighten: Torque - Exhaust Pipe Holder Nuts [C] : 17 N·m (1.7 kgf·m, 12 ft·lb) •...
  • Page 301 ENGINE TOP END 5-61 Mufflers • Install the left and right muffler bodies (see Muffler Body Installation). • Thoroughly warm up the engine, wait until the engine cools down, retighten all the bolts and nuts.
  • Page 303 CLUTCH 6-1 Clutch Table of Contents Exploded View........................Specifications ......................... Special Tools .......................... Clutch Fluid..........................Clutch Fluid Level Inspection .................... Clutch Fluid Change ......................Clutch Line Bleeding ......................Clutch Hose Removal/Installation ..................Clutch Hose Inspection ..................... Clutch Master Cylinder ......................Clutch Lever Adjustment....................
  • Page 304: Exploded View

    6-2 CLUTCH Exploded View...
  • Page 305 CLUTCH 6-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Cam Damper Bolt Clutch Cover Bolts 106 in·lb Clutch Hose Banjo Bolt Clutch Hub Nut 19.0 MO, R Clutch Lever Pivot Bolt 0.10 8.8 in·lb Clutch Lever Pivot Bolt Locknut 0.60 52 in·lb Clutch Master Cylinder Clamp Bolts...
  • Page 306: Specifications

    6-4 CLUTCH Specifications Item Standard Service Limit Clutch Fluid Grade DOT4 – – – Clutch Lever – – – Clutch Lever Position 8-way adjustable (to suit Rider) Clutch Lever Free Play Non-adjustable – – – Clutch 3.30 ∼ 3.50 mm (0.130 ∼ 0.138 in.) Friction Plate Thickness 3.0 mm (0.12 in.) Friction Plate Warp...
  • Page 307: Special Tools

    CLUTCH 6-5 Special Tools Bearing Driver Set: Grip: 57001-1129 57001-1591 Clutch Holder: Rotor Holder: 57001-1243 57001-1726...
  • Page 308: Clutch Fluid

    6-6 CLUTCH Clutch Fluid Clutch Fluid Level Inspection • Refer to the Clutch Fluid Level Inspection in the Periodic Maintenance chapter. Clutch Fluid Change • Refer to the Clutch Fluid Change in the Periodic Mainte- nance chapter. Clutch Line Bleeding •...
  • Page 309: Clutch Master Cylinder

    CLUTCH 6-7 Clutch Master Cylinder Clutch Lever Adjustment The adjuster has 8 positions so that the clutch lever posi- tion can be adjusted to suit the operator’s hand. • Push the lever forward and turn the adjuster [A]. Clutch Master Cylinder Removal •...
  • Page 310: Clutch Master Cylinder Inspection

    6-8 CLUTCH Clutch Master Cylinder Clutch Master Cylinder Inspection • Disassemble the clutch master cylinder (see Clutch Mas- ter Cylinder Rubber Parts Replacement in the Periodic Maintenance chapter). CAUTION Do not remove the secondary cup from the piston since removal will damage it. •...
  • Page 311: Clutch Slave Cylinder

    CLUTCH 6-9 Clutch Slave Cylinder Clutch Slave Cylinder Removal • Remove: Engine Pulley Outer Cover (see Engine Pulley Outer Cover Removal in the Final Drive chapter) Banjo Bolt [A] Clutch Slave Cylinder Bolts [B] Slave Cylinder [C] CAUTION Immediately wash away any clutch fluid that spills. •...
  • Page 312: Clutch Slave Cylinder Disassembly/assembly

    6-10 CLUTCH Clutch Slave Cylinder • Apply a non-permanent locking agent to the threads of the slave cylinder bolts [A]. • Hand-tighten all the clutch slave cylinder bolts evenly. • Remove the band from the clutch lever and release the clutch lever.
  • Page 313: Clutch Cover Removal

    CLUTCH 6-11 Clutch Clutch Cover Removal • Drain the engine oil (see Engine Oil Change in the Peri- odic Maintenance chapter). • Remove the exhaust pipe (see Exhaust Pipe Removal in the Engine Top End chapter) • Unscrew the clutch cover bolts (19) [A] Clutch Cover Installation •...
  • Page 314: Clutch Outer Covers Installation

    6-12 CLUTCH Clutch Clutch Outer Covers Installation • Install the front and rear outer clutch covers. • When installing the rear outer clutch cover [A], set the round mark [B] downward. • Apply a non-permanent locking agent to the threads of the front and rear outer clutch cover bolts, and tighten them.
  • Page 315 CLUTCH 6-13 Clutch • Remove: Primary Chain Guide Bolts [A] Primary Chain Guides [B] • Hold the clutch hub [A] steady with the clutch holder [B], and remove the clutch hub nut [C]. Special Tool - Clutch Holder: 57001-1243 • Remove: Spring Washer Washer...
  • Page 316: Clutch Installation

    6-14 CLUTCH Clutch • Pull out the following parts as a set. Primary Chain [A] Clutch Housing [B] Starter Clutch Gear [C] Damper Cam Sprocket [D] Torque Limiter [E] • Remove the collar [A] and spacer [B] from the input shaft. •...
  • Page 317 CLUTCH 6-15 Clutch • Install the spacer [A] to the input shaft so that the stepped side [B] faces inward. • Install the starter clutch gear [A] and collar [B]. ○ Apply molybdenum disulfide oil [C] to the starter clutch gear and collar.
  • Page 318 6-16 CLUTCH Clutch • Insert the needle bearing [A] to the input shaft while turn- ing counterclockwise [B] the clutch housing. • Install the cam damper [A] while fitting the alignment notch [B] of the splines onto the alignment tooth [C]. •...
  • Page 319 CLUTCH 6-17 Clutch • Install: Inner End Friction Plate [A] Friction Plates [B] Outer End Friction Plate [C] Steel Plates [D] Spring [E] Spring Seat [F] CAUTION If new dry friction plates and steel plates are in- stalled, apply engine oil to the surfaces of each plate to avoid clutch plate seizure.
  • Page 320: Clutch Plate, Wear, Damage Inspection

    6-18 CLUTCH Clutch Clutch Plate, Wear, Damage Inspection • Visually inspect the friction and steel plates for signs of seizure, overheating (discoloration), or uneven wear. If any plates show signs of damage, replace the plates. • Measure the thickness of the friction plates [A] at several points.
  • Page 321: Clutch Hub Spline Inspection

    CLUTCH 6-19 Clutch Clutch Hub Spline Inspection • Visually inspect where the teeth [B] on the steel plates wear against the splines [A] of the clutch hub. If there are notches worn into the splines, replace the outer clutch hub. Also, replace the steel plate with a new one of the same thickness if their teeth are damaged.
  • Page 323 ENGINE LUBRICATION SYSTEM 7-1 Engine Lubrication System Table of Contents Exploded View........................Engine Oil Flow Chart......................Specifications ......................... Special Tools and Sealant ...................... Engine Oil and Oil Filter......................Oil Level Inspection......................Engine Oil Change......................Oil Filter Replacement ...................... Oil Screen..........................7-10 Oil Screen Removal ......................
  • Page 324: Exploded View

    7-2 ENGINE LUBRICATION SYSTEM Exploded View...
  • Page 325 ENGINE LUBRICATION SYSTEM 7-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Breather Check Valve Cover Bolts 87 in·lb Engine Oil Drain Bolts Inside Oil Pipe Retainer Bolt 87 in·lb Oil Filter Oil Filter Pipe Oil Passage Plug (PT1/8) Oil Pressure Relief Valve Oil Pressure Switch Oil Pressure Switch Terminal Bolt Hand-tighten...
  • Page 326: Engine Oil Flow Chart

    7-4 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart...
  • Page 327 ENGINE LUBRICATION SYSTEM 7-5 Engine Oil Flow Chart 1. Camshaft Chain Tensioner 2. Balancer Chain Tensioner 3. Alternator Rotor Bolt (For Cooling Stator Coil) 4. Crankshaft 5. Piston Oil Jet 6. Drive Shaft 7. Output Shaft 8. Oil Screen for Scavenge Pump 9.
  • Page 328: Specifications

    7-6 ENGINE LUBRICATION SYSTEM Specifications Item Standard Engine Oil Grade API SE, SF or SG API SH, SJ, SL or SM with JASO MA, MA1 or MA2 Viscosity SAE 10W-40 Capacity 4.1 L (4.3 US qt) (when filter is not removed) 4.3 L (4.5 US qt) (when filter is removed) 5.0 L (5.3 US qt) (when engine is completely disassembled and dry) Between upper and lower level lines (wait 3 minutes or more after...
  • Page 329: Special Tools And Sealant

    ENGINE LUBRICATION SYSTEM 7-7 Special Tools and Sealant Outside Circlip Pliers: Oil Pressure Gauge Adapter, PT1/8: 57001-144 57001-1731 Oil Pressure Gauge, 10 kgf/cm²: Kawasaki Bond (Silicone Sealant): 57001-164 56019-120 Gear Holder: 57001-1602...
  • Page 330: Engine Oil And Oil Filter

    7-8 ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter Because of the semi-dry sump lubrication system, the en- gine oil level indicated on the dipstick will fluctuate depend- ing on the motorcycle’s position and engine speed when the engine is shut off. To ensure a proper reading of the engine oil level, follow the Oil Level Inspection procedures closely.
  • Page 331: Engine Oil Change

    ENGINE LUBRICATION SYSTEM 7-9 Engine Oil and Oil Filter Engine Oil Change • Refer to Engine Oil Change in the Periodic Maintenance Chapter. Oil Filter Replacement • Refer to Oil Filter Replacement in the Periodic Mainte- nance Chapter.
  • Page 332: Oil Screen

    7-10 ENGINE LUBRICATION SYSTEM Oil Screen Oil Screen Removal Oil Screen for Scavenge Pump • Remove: Alternator Cover (see Alternator Cover Removal in the Electrical System chapter) Oil Screen Plug [A] • Remove: Oil Screen [A] Spring [B] Oil Screen for Feed Pump •...
  • Page 333: Oil Screen Installation

    ENGINE LUBRICATION SYSTEM 7-11 Oil Screen Oil Screen Installation NOTE ○ Clean the oil screen thoroughly whenever it is removed for any reason. ○ While cleaning the screen, check for any metal particles that might indicate internal engine damage. • Clean the oil screen with a high-flash point solvent and remove any particles stuck to them.
  • Page 334: Oil Pressure Relief Valve

    7-12 ENGINE LUBRICATION SYSTEM Oil Pressure Relief Valve Oil Pressure Relief Valve Removal • Split the crankcase (see Crankcase Splitting in the Crank- shaft/Transmission chapter). • Remove the oil pressure relief valve [A] from the right crankcase half. Oil Pressure Relief Valve Installation •...
  • Page 335: Oil Pump

    ENGINE LUBRICATION SYSTEM 7-13 Oil Pump Oil Pump Gear Removal • Remove: Clutch (see Clutch Removal in the Clutch chapter) Circlip [A] Oil Pump Gear [B] Special Tool - Outside Circlip Pliers: 57001-144 Oil Pump Gear Installation • Check that the pin [A] is in place. •...
  • Page 336: Oil Pump Removal

    7-14 ENGINE LUBRICATION SYSTEM Oil Pump • Apply molybdenum disulfide oil solution to the threads and seating surface of the oil pump drive gear bolt [A]. • Using the gear holder [B], secure the oil pump drive gear [C]. Special Tool - Gear Holder : 57001-1602 •...
  • Page 337: Oil Pump Installation

    ENGINE LUBRICATION SYSTEM 7-15 Oil Pump • Remove: Pin [A] Inner Rotor [B] for Feed Pump Outer Rotor [C] for Feed Pump • Remove: Pin [A] Inner Rotor [B] for Scavenge Pump Oil Pump Shaft [C] Oil Pump Installation • Apply molybdenum disulfide oil solution to the portion [A] of the oil pump shaft as shown.
  • Page 338 7-16 ENGINE LUBRICATION SYSTEM Oil Pump • Install the dowel pin [A]. • Fit the dowel pin into the hole [B] on the oil pump cover [C]. • Tighten: Torque - Oil Pump Cover Bolts: 12 N·m (1.2 kgf·m, 106 in·lb) •...
  • Page 339: Oil Pressure Measurement

    ENGINE LUBRICATION SYSTEM 7-17 Oil Pressure Measurement Oil Pressure Measurement • Remove the oil passage plug (1/8) [A] from the bottom of the right crankcase. • Attach the adapter [A] and gauge [B] to the plug hole. Special Tools - Oil Pressure Gauge, 10 kgf/cm²: 57001-164 Oil Pressure Gauge Adapter, PT1/8: 57001 -1731 •...
  • Page 340: Oil Pressure Switch

    • Apply silicone sealant to the threads of the oil pressure switch [A] and tighten it. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 Torque - Oil Pressure Switch: 15 N·m (1.5 kgf·m, 11 ft·lb) • Apply grease to the switch terminal [B].
  • Page 341: Oil Pipes

    ENGINE LUBRICATION SYSTEM 7-19 Oil Pipes Oil Pipe Removal Outside Oil Pipe • Remove: Clutch (see Clutch Removal in the Clutch chapter) Outside Oil Pipe Bolt [A] Torque Limiter Bearing Retainer Bolt [B] Torque Limiter Bearing Retainer [C] Washer [D] •...
  • Page 342: Oil Pipe Installation

    7-20 ENGINE LUBRICATION SYSTEM Oil Pipes Oil Pipe Installation • Refer to the Cylinder Installation in the Crankshaft/Trans- mission chapter for upper oil pipe installation procedures. • Replace the O-rings [A] with new ones. • Apply grease to the O-rings. Outside Oil Pipe [B] Inside Oil Pipe [C] Outside Oil Pipe...
  • Page 343: Blowby Gas System

    ENGINE LUBRICATION SYSTEM 7-21 Blowby Gas System Blowby Gas System Inspection • Remove the fuel tank (see Fuel Tank Removal in the Fuel System (DFI) chapter). • Be certain that the breather hose [A] is routed without being flattened or kinked, and is connected correctly to left air cleaner housing.
  • Page 344: Breather Drain Cleaning

    7-22 ENGINE LUBRICATION SYSTEM Blowby Gas System • Replace the O-ring [A] with a new one. • Apply grease to the new O-ring, install it. • Install: Valve Seat [A] Breather Check Valve [B] • Replace the breather check valve cover gasket with a new one.
  • Page 345 ENGINE REMOVAL/INSTALLATION 8-1 Engine Removal/Installation Table of Contents Exploded View........................Special Tools .......................... Engine Removal/Installation ....................Engine Removal........................ Engine Installation......................
  • Page 346: Exploded View

    8-2 ENGINE REMOVAL/INSTALLATION Exploded View...
  • Page 347 ENGINE REMOVAL/INSTALLATION 8-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Cross Pipe Bolts Downtube Bolts Engine Mounting Adjusting Bolt 87 in·lb Engine Mounting Adjusting Bolt Locknut Engine Mounting Bolt (M10) Engine Mounting Bracket Bolts (M6) 87 in·lb Engine Mounting Bracket Bolts (M8) Engine Mounting Bracket Bolts (M10) Engine Mounting Bracket Nuts (M10) Engine Mounting Nut (M10)
  • Page 348: Special Tools

    8-4 ENGINE REMOVAL/INSTALLATION Special Tools Jack: Socket Wrench: 57001-1238 57001-1347...
  • Page 349: Engine Removal/installation

    ENGINE REMOVAL/INSTALLATION 8-5 Engine Removal/Installation Engine Removal • Raise the rear wheel off the ground using the jack. Special Tool - Jack: 57001-1238 • Squeeze the brake lever slowly, and hold it with a band [A]. WARNING Be sure to hold the front brake when removing the engine, or the motorcycle may fall over.
  • Page 350 8-6 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Remove: Vacuum Hose [A] Vacuum Hoses [B] (CAL and SEA Models) • Disconnect the injector connectors [C]. • Disconnect the throttle body connectors [A]. • Disconnect: Crankshaft Sensor Lead Connector [A] Alternator Lead Connectors [B] •...
  • Page 351 ENGINE REMOVAL/INSTALLATION 8-7 Engine Removal/Installation • Remove the side stand switch lead connector [A] from the brake hose clamp [B]. • Remove the starter motor cable [A]. • Open the clamp [B], and free the leads. • Disconnect: Speed Sensor Connector [C] Gear Position Switch Lead Connector [D] •...
  • Page 352 8-8 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Remove the engine mounting bolt and nut (M12) [A]. • Using the socket wrench [A], loosen the engine mounting adjusting bolt locknut [B]. Special Tool - Socket Wrench: 57001-1347 • Using the Hexagon Wrench, turn the engine mounting ad- justing bolt [A] counterclockwise to make the gap between the engine and adjusting bolt.
  • Page 353: Engine Installation

    ENGINE REMOVAL/INSTALLATION 8-9 Engine Removal/Installation • Remove the downtube (see Downtube Removal in the Frame chapter). • Remove the drive belt [A] from the output shaft [B]. • Remove the engine [A] from the motorcycle right side. Engine Installation • Support the engine with a suitable stand.
  • Page 354 8-10 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation ○ Seventh, tighten the engine mounting nut (M12) (lower) [J]. Torque - Engine Mounting Nut (M12): 59 N·m (6.0 kgf·m, 43 ft·lb) ○ Eighth, tighten the engine mounting bracket bolts [C] again to the specified torque. Torque - Engine Mounting Bracket Bolts (M8): 25 N·m (2.5 kgf·m, 18 ft·lb) ○...
  • Page 355 ENGINE REMOVAL/INSTALLATION 8-11 Engine Removal/Installation • Run the leads, cables and hoses correctly (see Cable, Wire and Hose Routing section in the Appendix chapter). • Install the removed parts. • Adjust: Throttle Cables (see Throttle Control System Inspection in the Periodic Maintenance chapter) Drive Belt (see Belt Deflection inspection in the Periodic Maintenance chapter) •...
  • Page 357 CRANKSHAFT/TRANSMISSION 9-1 Crankshaft/Transmission Table of Contents Exploded View........Torque Limiter........9-30 Specifications ........Torque Limiter Removal ....9-30 Special Tools and Sealants ....Torque Limiter Installation .... 9-30 Crankcase ......... Torque Limiter Inspection..... 9-30 Crankcase Splitting ...... Transmission ........9-31 Crankcase Assembly ....
  • Page 358: Exploded View

    9-2 CRANKSHAFT/TRANSMISSION Exploded View...
  • Page 359 CRANKSHAFT/TRANSMISSION 9-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Balancer Chain Tensioner Bolts 106 in·lb Balancer Sprocket Bolts Ball Bearing Retainer Bolts 87 in·lb Ball Bearing Retainer Screws 87 in·lb Connecting Rod Big End Bolts Crankcase Bolts (M10) Crankcase Bolts (M6) 106 in·lb Engine Pulley Plate Bolts 106 in·lb...
  • Page 360 9-4 CRANKSHAFT/TRANSMISSION Exploded View...
  • Page 361 CRANKSHAFT/TRANSMISSION 9-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb External Shift Mechanism Cover Bolts (L = 50 mm) 106 in·lb External Shift Mechanism Cover Bolts (L = 22 mm) 106 in·lb Gear Positioning Lever Nut 0.80 69 in·lb Shift Drum Bearing Retainer Bolts 87 in·lb Shift Drum Cam Bolt 106 in·lb...
  • Page 362: Specifications

    9-6 CRANKSHAFT/TRANSMISSION Specifications Item Standard Service Limit Crankcase, Crankshaft and Connecting Rods Connecting Rod Bend – – – TIR 0.2/100 mm (0.008/3.94 in.) Connecting Rod Twist – – – TIR 0.2/100 mm (0.008/3.94 in.) 0.08 ∼ 0.30 mm (0.003 ∼ 0.012 in.) Connecting Rod Big End Side 0.5 mm Clearance...
  • Page 363 CRANKSHAFT/TRANSMISSION 9-7 Specifications Connecting Rod Big End Bearing Insert Selection Con-rod Big End Bearing Insert Crankpin Diameter Inside Diameter Marking Size Color Part Number Marking ○ None Brown 92139-0227 None None Black 92139-0226 ○ ○ ○ None Blue 92139-0225...
  • Page 364: Special Tools And Sealants

    9-8 CRANKSHAFT/TRANSMISSION Special Tools and Sealants Outside Circlip Pliers: Rotor Holder: 57001-144 57001-1726 Bearing Driver Set: Kawasaki Bond (Silicone Sealant): 57001-1129 92104-0004 Grip: Kawasaki Bond (Liquid Gasket - Black): 57001-1591 92104-1064...
  • Page 365: Crankcase

    CRANKSHAFT/TRANSMISSION 9-9 Crankcase Crankcase Splitting • Remove the engine (see Engine Removal in the Engine Removal/Installation chapter). • Set the engine on a clean surface and hold the engine steady while parts are being removed. • Remove: Clutch (see Clutch Removal in the Clutch chapter) Balancer Mechanism (see Balancer Mechanism Re- moval) Cylinders (see Cylinder Removal in the Engine Top End...
  • Page 366 9-10 CRANKSHAFT/TRANSMISSION Crankcase • Remove the left crankcase bolts (11) [A]. • Remove the right crankcase bolts, following the specified sequence. ○ First, loosen the M6 bolts (9) [A]. ○ Next, loosen the M10 bolts (3) [B]. • Put the engine so that the right crankcase half [A] faces upside.
  • Page 367: Crankcase Assembly

    CRANKSHAFT/TRANSMISSION 9-11 Crankcase • Using the pry points, split the crankcase halves. Pry Point (Front) [A] Pry Points (Rear) [B] If the crankcase does not split easily, tap the crankcase mating surface lightly with a plastic mallet. ○ Take care not to damage the crankcase. •...
  • Page 368 9-12 CRANKSHAFT/TRANSMISSION Crankcase ○ Insert the piston oil jet [A] into the hole on the crankcase [B] as shown in the figure. ○ Apply a non-permanent locking agent to the threads of the piston oil jet bolt [C], and tighten it. Torque - Piston Oil Jet Bolt : 6.9 N·m (0.70 kgf·m, 61 in·lb) •...
  • Page 369 CRANKSHAFT/TRANSMISSION 9-13 Crankcase • Apply liquid gasket [A] to the mating surface of the lower crankcase half. Sealant - Kawasaki Bond (Liquid Gasket - Black): 92104 -1064 NOTE ○ Especially, apply a sealant so that it shall be filled up on the grooves [B].
  • Page 370 9-14 CRANKSHAFT/TRANSMISSION Crankcase NOTE ○ Be sure to tighten the right crankcase bolts first. • Tighten the right crankcase bolts using the following steps. ○ First, tighten the M10 bolts (3) [A]. Torque - Crankcase Bolts (M10) : 39 N·m (4.0 kgf·m, 29 ft·lb) ○...
  • Page 371 CRANKSHAFT/TRANSMISSION 9-15 Crankcase • Apply grease to the new O-ring [A] and install it on the output shaft as shown in the figure. • Apply grease to oil seal lip. • Install the collar [B] so that the stepped side [C] faces inward.
  • Page 372: Crankshaft And Connecting Rods

    9-16 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods Crankshaft Removal • Split the crankcase (see Crankcase Splitting). • Turn the balancer shafts [A] to clear the balancers [B] from the crankshaft web [C]. • Remove the crankshaft. Crankshaft Installation • Apply molybdenum disulfide oil solution onto the crank- shaft main journal [A] on both sides.
  • Page 373: Connecting Rod Installation

    CRANKSHAFT/TRANSMISSION 9-17 Crankshaft and Connecting Rods Connecting Rod Installation CAUTION To minimize vibration, the connecting rods should have the same weight mark. Big End Cap [A] Connecting Rod [B] “OUT” Mark [C] Weight Mark, Alphabet [D] Diameter Mark [E]: “O” or no mark CAUTION If the connecting rods, big end bearing inserts, or crankshaft are replaced with new ones, select the...
  • Page 374: Crankshaft/connecting Rod Cleaning

    9-18 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods • Be sure the dowel pins [A] on the big end cap [B] are in position. • Install each connecting rod on its original position as fol- lows. ○ Left connecting rod [A] is for the rear cylinder and right connecting rod [B] is for the front cylinder.
  • Page 375: Connecting Rod Twist

    CRANKSHAFT/TRANSMISSION 9-19 Crankshaft and Connecting Rods Connecting Rod Twist • With the big-end arbor [A] still on V block [B], hold the con- necting rod horizontally and measure the amount that the arbor [C] varies from being parallel with the surface plate over a 100 mm (3.94 in.) length of the arbor to determine the amount of connecting rod twist.
  • Page 376 9-20 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods If clearance is within the standard, no bearing replace- ment is required. If clearance is between 0.057 mm (0.0022 in.) and the service limit (0.09 mm, 0.035 in.), replace the bear- ing inserts [A] with inserts painted blue [B]. Check insert/crankpin clearance with the plastigage.
  • Page 377: Crankshaft Side Clearance

    CRANKSHAFT/TRANSMISSION 9-21 Crankshaft and Connecting Rods • Select the proper bearing insert [A] in accordance with the combination of the connecting rod and crankshaft coding. Size Color [B] Connecting Rod Big End Bearing Insert Selection Bearing Insert Con-rod Big End Crankpin Inside Diameter Diameter...
  • Page 378: Crankshaft Main Bearing/main Journal Wear

    9-22 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods Crankshaft Main Bearing/Main Journal Wear • Measure the diameter [A] of the crankshaft main journal. If any journal has worn past the service limit, replace the crankshaft with a new one. Crankshaft Main Journal Diameter 52.986 ∼...
  • Page 379: Balancer

    CRANKSHAFT/TRANSMISSION 9-23 Balancer Balancer Mechanism Removal • Remove the alternator cover (see Alternator Cover Re- moval in the Electrical System chapter). • Loosen the front balancer sprocket bolt [A] and rear bal- ancer sprocket bolt [B] while holding the alternator rotor [C] steady with the rotor holder [D].
  • Page 380: Balancer Mechanism Installation

    9-24 CRANKSHAFT/TRANSMISSION Balancer Balancer Mechanism Installation • Align the line [A] on the following parts with the colored chain links [B] as shown in the figure. Balancer Chain Sprocket [C] Front Balancer Sprocket [D] Rear Balancer Sprocket [E] ○ The front and rear balancer sprockets are identical. •...
  • Page 381 CRANKSHAFT/TRANSMISSION 9-25 Balancer • Engage the first teeth [A] of the ratchet [B] with second groove [C] of the plunger [D]. • Insert the suitable pin [A] into the hole of the tensioner body [B] through the hole of the link plate [C].
  • Page 382 9-26 CRANKSHAFT/TRANSMISSION Balancer • Install the upper balancer chain guide [A]. Torque - Upper Balancer Chain Guide Bolts [B] : 12 N·m (1.2 kgf·m, 106 in·lb) • Install the balancer chain tensioner [C] and lower balancer chain guide [D]. Torque - Balancer Chain Tensioner Bolts [E] : 12 N·m (1.2 kgf·m, 106 in·lb) Lower Balancer Chain Guide Bolts [F] : 12 N·m (1.2 kgf·m, 106 in·lb)
  • Page 383: Balancer Shaft Removal

    CRANKSHAFT/TRANSMISSION 9-27 Balancer Balancer Shaft Removal NOTE ○ The front and rear balancer shafts are same proce- dures. • Split the crankcase (see Crankcase Splitting). • Turn the balancer shaft [A] to clear the balancer [B] from the crankshaft web [C]. Front Balancer Shaft [D] Rear Balancer Shaft [E] •...
  • Page 384: Starter Clutch

    9-28 CRANKSHAFT/TRANSMISSION Starter Clutch Starter Clutch Removal • Refer to the Clutch Removal in the Clutch chapter. Starter Clutch Installation • Refer to the Clutch Installation in the Clutch chapter. Starter Clutch Disassembly • Remove the clutch housing (see Clutch Removal in the Clutch chapter).
  • Page 385 CRANKSHAFT/TRANSMISSION 9-29 Starter Clutch ○ Examine the starter clutch gear [A] as well. Replace the clutch gear if it is worn or damaged.
  • Page 386: Torque Limiter

    9-30 CRANKSHAFT/TRANSMISSION Torque Limiter Torque Limiter Removal • Refer to the Clutch Removal in the Clutch chapter. CAUTION Do not disassemble the torque limiter [A]. The torque limiter will not function if this is done. Torque Limiter Installation • Refer to the Clutch Installation in the Clutch chapter. Torque Limiter Inspection •...
  • Page 387: Transmission

    CRANKSHAFT/TRANSMISSION 9-31 Transmission Transmission Shaft and Shift Fork Removal • Split the crankcase (see Crankcase Splitting). • Remove: Speed Sensor (see Speed Sensor Removal in the Elec- trical System chapter) Shift Rods [A] Shift Forks [B] • Take out the drive shaft [A] and output shaft [B] as a set. Transmission Shaft and Shift Fork Removal •...
  • Page 388: Transmission Shaft Assembly

    9-32 CRANKSHAFT/TRANSMISSION Transmission Transmission Shaft Assembly • When assembling the transmission shafts, refer to the transmission assembly illustration on ahead too. • Apply engine oil to the bushings and shafts. • Replace any circlips removed with new ones. • Install the circlips [A] so that opening [B] of it is aligned with a spline groove [C].
  • Page 389 CRANKSHAFT/TRANSMISSION 9-33 Transmission 1. Drive Shaft 10. 2nd Gear 2. 1st Gear 11. Thrust Washers, Inside Diameter 25.3 mm 3. 5th gear (1.00 in.) 4. Thrust Washer, Inside Diameter 30.3 mm 12. Needle Bearing (1.19 in.) 13. Circlip, Outside Diameter 27.9 mm (1.10 in.) 5.
  • Page 390: Shift Drum Removal

    9-34 CRANKSHAFT/TRANSMISSION Transmission Shift Drum Removal • Split the crankcase (see Crankcase Splitting). • Remove: Shift Forks (see Transmission Shaft and Shift Fork Re- moval) Pin [A] and Spring [B] Shift Drum Bearing Retainer Bolts [C] • Pull out the shift drum [D] while aligning the shift drum cam with the left crankcase hole.
  • Page 391: Shift Drum Assembly

    CRANKSHAFT/TRANSMISSION 9-35 Transmission Shift Drum Assembly If the new pins [A] are installed on the shift drum cam [B], note the following. ○ Install the new pins so that the longest pin [C] is positioned as shown in the figure. Cutout Portion [D] of Shift Drum Cam •...
  • Page 392: Shift Fork Bending

    9-36 CRANKSHAFT/TRANSMISSION Transmission Shift Fork Bending • Visually inspect the shift forks, and replace any fork that is bent. A bent fork could cause difficulty in shifting, or allow the transmission to jump out of gear when under power. 90° [A] Shift Fork/Gear Groove Wear •...
  • Page 393: External Shift Mechanism

    CRANKSHAFT/TRANSMISSION 9-37 External Shift Mechanism Shift Pedal Removal • Remove the front footboard left (Front Footboard Re- moval/Installation in the Frame chapter). • Remove: Front Shift Lever Bolt [A] Front Shift Lever [B] Shift Pedal [C] If the tie-rod is removed from the front and rear shift levers, note the following.
  • Page 394 9-38 CRANKSHAFT/TRANSMISSION External Shift Mechanism • After installation, confirm that the shift pedal [A] is posi- tioned as shown in the figure. 30 ∼ 40 mm (1.18 ∼ 1.57 in.) [B] About 1°[C] About 240.0 mm (9.45 in.) [D] About 7°[E] If the pedal position is different, adjust it as follows.
  • Page 395: External Shift Mechanism Removal

    CRANKSHAFT/TRANSMISSION 9-39 External Shift Mechanism • Be sure the sealing lip of the rubber boot [A] fits into the groove of the ball joint after installing the shift pedal. Correctly Boot Fitting Position [B] Incorrectly Boot Fitting Position [C] External Shift Mechanism Removal •...
  • Page 396: External Shift Mechanism Installation

    9-40 CRANKSHAFT/TRANSMISSION External Shift Mechanism • Remove the shift shaft assembly [A]. • Remove: Gear Positioning Lever Nut [A] Gear Positioning Lever [B] Pin [C] and Spring External Shift Mechanism Installation If the shift shaft return spring pin [A] was removed, install it as follows.
  • Page 397 CRANKSHAFT/TRANSMISSION 9-41 External Shift Mechanism If the shift shaft assembly was disassembled, assemble it as follows. ○ Install the following parts on the shift shaft as a set. Upper Lever [A] Washer [B] Spring [C] Lower Lever [D] ○ Push down [E] the above parts while opening [F] the up- per lever.
  • Page 398 9-42 CRANKSHAFT/TRANSMISSION External Shift Mechanism • Be sure to install the spacer [A] on the shift shaft [B]. • Install the shift shaft assembly [A]. • Be sure to install the spacer [B] on the shift shaft. • Install the dowel pins [C]. •...
  • Page 399 CRANKSHAFT/TRANSMISSION 9-43 External Shift Mechanism • Apply silicone sealant to the gear position switch lead grommet [A]. Sealant - Kawasaki Bond (Silicone Sealant) : 92104-0004 • Replace the external shift mechanism cover gasket with a new one. • Install the external shift mechanism cover [A].
  • Page 400: Ball Bearing, Needle Bearing And Oil Seal

    9-44 CRANKSHAFT/TRANSMISSION Ball Bearing, Needle Bearing and Oil Seal Bearing and Oil Seal Installation Left Crankcase • Refer to the Mechanical Seal Replacement in the Cooling System chapter for mechanical seal, ball bearing and oil seal of the water pump. •...
  • Page 401: Bearing Wear

    CRANKSHAFT/TRANSMISSION 9-45 Ball Bearing, Needle Bearing and Oil Seal Right Crankcase • Before installing the bearing or race, apply small amount of the engine oil to the outer surface of them. • When the following ball bearings or race are installed in the right crankcase half, press and insert them until they are bottomed.
  • Page 402: Oil Seal Inspection

    9-46 CRANKSHAFT/TRANSMISSION Ball Bearing, Needle Bearing and Oil Seal • Check the needle bearings. ○ The rollers in a needle bearing normally wear very little, and wear is difficult to measure. Instead of measuring, inspect the bearing for abrasion, color change, or other damage.
  • Page 403 WHEELS/TIRES 10-1 Wheels/Tires Table of Contents Exploded View........................10-2 Specifications ......................... 10-4 Special Tools .......................... 10-5 Wheels (Rims) ........................10-6 Front Wheel Removal ....................... 10-6 Front Wheel Installation ....................10-7 Rear Wheel Removal......................10-8 Rear Wheel Installation..................... 10-9 Wheel Inspection ......................10-11 Axle Inspection........................
  • Page 404: Exploded View

    10-2 WHEELS/TIRES Exploded View...
  • Page 405 WHEELS/TIRES 10-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Axle 13.0 Front Axle Clamp Bolts Rear Axle Nut 11.0 Rear Air Valve Nuts 0.15 13 in·lb G: Apply grease. HG: Apply high-temperature grease. R: Replacement Parts S: Follow the specified tightening sequence. WL: Apply soap and water solution or rubber lubricant.
  • Page 406: Specifications

    10-4 WHEELS/TIRES Specifications Item Standard Service Limit Wheels (Rims) Rim Runout: Axial TIR 0.5 mm (0.02 in.) or less TIR 1.0 mm (0.04 in.) Radial TIR 0.8 mm (0.03 in.) or less TIR 1.0 mm (0.04 in.) Axle Runout/100 mm (3.94 in.) TIR 0.03 mm (0.001 in.) or less TIR 0.2 mm (0.008 in.) Wheel Balance 10 g (0.35 oz.) or less...
  • Page 407: Special Tools

    WHEELS/TIRES 10-5 Special Tools Inside Circlip Pliers: Bearing Remover Head, 20 × 22: 57001-143 57001-1293 Bearing Driver Set: Bearing Remover Head, 25 × 28: 57001-1129 57001-1346 Jack: Bearing Remover Shaft, 13: 57001-1238 57001-1377...
  • Page 408: Wheels (rims)

    10-6 WHEELS/TIRES Wheels (Rims) Front Wheel Removal • Remove: Front Caliper Mounting Bolts [A] (Both Sides) Front Caliper (with the hose installed) [B] (Both Sides) • Loosen: Front Axle Clamp Bolts [A] Front Axle [B] • Using the jack [A] under the frame pipe, and a commer- cially available jack [B] under the engine, lift the front wheel off the ground until the rear wheel touches the ground.
  • Page 409: Front Wheel Installation

    WHEELS/TIRES 10-7 Wheels (Rims) Front Wheel Installation • Apply high-temperature grease to the grease seal lips. • Fit the collars [A] on both sides of the hub. ○ The collars are identical. • Install the front wheel, and insert the front axle. •...
  • Page 410: Rear Wheel Removal

    10-8 WHEELS/TIRES Wheels (Rims) Rear Wheel Removal • Remove: Saddlebags (see Saddlebag Removal in the Frame chapter) Saddlebag Stays (see Saddlebag Stay Removal in the Frame chapter) Right Muffler Body (see Muffler Body Removal in the Engine Top End chapter) Rear Fender (see Rear Fender Removal in the Frame chapter) •...
  • Page 411: Rear Wheel Installation

    WHEELS/TIRES 10-9 Wheels (Rims) • Remove: Bolt [A] and Brake Hose Guide [B] Rear Caliper Mounting Bolts [C] Rear Caliper (with the hose installed) [D] • Remove: Cotter Pin [A] Rear Axle Nut [B] Washer [C] • Loosen: Belt Adjuster Locknuts [D] (Both Sides) Belt Adjuster Nuts [E] (Both Sides) •...
  • Page 412 10-10 WHEELS/TIRES Wheels (Rims) • Install the caliper bracket [A] onto the swingarm stop [B]. • Engage the drive belt [A] with the rear pulley [B]. • Insert the axle from the left side. • Adjust the belt deflection before tightening the axle nut (see Belt Deflection Adjustment in the Periodic Mainte- nance chapter).
  • Page 413: Wheel Inspection

    WHEELS/TIRES 10-11 Wheels (Rims) Wheel Inspection • Raise the wheel off the ground with the jack. Special Tool - Jack: 57001-1238 • Spin the wheel lightly, and check for roughness or binding. If roughness or binding is found, replace the hub bearings. •...
  • Page 414: Balance Inspection

    10-12 WHEELS/TIRES Wheels (Rims) Balance Inspection • Remove the front and rear wheels (see Front/Rear Wheel Removal). • Support the wheel so that it can be spun freely. • Spin the wheel lightly, and mark [A] the wheel at the top when the wheel stops.
  • Page 415 30 g (1.06 oz.) NOTE ○ Balance weights are available from Kawasaki dealers in 10, 20 and 30 g (0.35, 0.71 and 1.06 oz.) sizes. An imbalance of less than 10 g (0.35 oz.) will not usually affect running stability.
  • Page 416: Tires

    10-14 WHEELS/TIRES Tires Air Pressure Inspection/Adjustment • Refer to the Air Pressure Inspection in the Periodic Main- tenance chapter. Tire Inspection • Refer to the Wheel/Tire Damage Inspection in the Peri- odic Maintenance chapter. Tire Removal • Remove: Wheel (see Front/Rear Wheel Removal) Valve Core (Let out the air) •...
  • Page 417 WHEELS/TIRES 10-15 Tires • Install a new valve in the rim. Front ○ Remove the valve cap, lubricate the stem seal [A] with a soap and water solution or rubber lubricant, and pull [B] the valve stem through the rim from the inside out until it snaps into place.
  • Page 418: Tire Repair

    Also, permanent (internal) repairs have the advantage of permitting a thorough examination for secondary damage not visible from external inspection of the tire. For these reasons, Kawasaki does not recommend temporary (exter- nal) repair. Only appropriate permanent (internal) repairs are recommended. Repair methods may vary slightly from make to make.
  • Page 419: Hub Bearing

    WHEELS/TIRES 10-17 Hub Bearing Hub Bearings Removal • Remove the wheel, and take out the following. Front Hub [A] Rear Hub [B] Collars Coupling [C] Grease Seals [D] • Use the bearing remover to remove the hub bearings [A]. CAUTION Do not lay the wheel directly on the ground with the disc facing down.
  • Page 420: Hub Bearings Inspection

    10-18 WHEELS/TIRES Hub Bearing ○ Replace the circlips with new ones. Special Tool - Inside Circlip Pliers: 57001-143 • Replace the grease seals with new ones. • Press in the grease seals [A] so that the seal surface is flush [B] with the end of the hole. ○...
  • Page 421 FINAL DRIVE 11-1 Final Drive Table of Contents Exploded View........................11-2 Specifications ......................... 11-4 Special Tools .......................... 11-5 Drive Belt ..........................11-6 Belt Handling Precautions....................11-6 Drive Belt Wear Inspection ....................11-7 Drive Belt Deflection Inspection ..................11-7 Drive Belt Deflection Adjustment ..................11-7 Drive Belt Removal ......................
  • Page 422: Exploded View

    11-2 FINAL DRIVE Exploded View...
  • Page 423 FINAL DRIVE 11-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Engine Pulley Mounting Nut 18.0 Engine Pulley Inner Cover Bolts 106 in·lb Engine Pulley Outer Cover Bolts 87 in·lb Rear Axle Nut 11.0 Rear Coupling Stud Bolts Rear Pulley Mounting Nuts Rear Pulley Plate Bolts 0.70 61 in·lb...
  • Page 424: Specifications

    11-4 FINAL DRIVE Specifications Item Standard Drive Belt Make GATES, 139T 3.0 ∼ 4.5 mm (0.12 ∼ 0.18 in.) Belt Deflection (45 N, 4.6 kgf, 10 lb force) (When installing new belt or engine is remounted) 3.0 mm (0.12 in.)
  • Page 425: Special Tools

    FINAL DRIVE 11-5 Special Tools Inside Circlip Pliers: Pulley Holder: 57001-143 57001-1572 Oil Seal & Bearing Remover: Grip: 57001-1058 57001-1591 Bearing Driver Set: 57001-1129...
  • Page 426: Drive Belt

    11-6 FINAL DRIVE Drive Belt The drive belt must be checked, and adjusted in accor- dance with the Periodic Maintenance Chart for safety and to prevent excessive wear. If the belt becomes badly worn or maladjusted-either too loose or too tight-the belt could jump off the pulley or break.
  • Page 427: Drive Belt Wear Inspection

    FINAL DRIVE 11-7 Drive Belt • Do not twist [A] the drive belt [B] as shown in the figure. ○ This includes coiling the belt to make it smaller for pack- aging. • Do not use tools [A] to pry [B] the drive belt [C] onto the application.
  • Page 428: Drive Belt Installation

    11-8 FINAL DRIVE Drive Belt Drive Belt Installation • Installation is the reverse of removal. Note the following. NOTE ○ Be sure the printed information faces the same direction so the belt rotates in the same direction as originally in- stead.
  • Page 429: Pulley And Coupling

    FINAL DRIVE 11-9 Pulley and Coupling Engine Pulley Outer Cover Removal • Remove: Bolts [A] Engine Pulley Outer Cover [B] Engine Pulley Outer Cover Installation • Install the trim [A] on the engine pulley outer cover [B]. ○ The higher side of the trim faces inside. ○...
  • Page 430: Engine Pulley Removal

    11-10 FINAL DRIVE Pulley and Coupling • Check the installation condition of the pad [A]. ○ Stick the pad securely. • Install the dowel pins [B] as shown in the figure. • Install the engine pulley inner cover [A]. • Tighten: Torque - Engine Pulley Inner Cover Bolts [B] : 12 N·m (1.2 kgf·m, 106 in·lb)
  • Page 431: Engine Pulley Installation

    FINAL DRIVE 11-11 Pulley and Coupling Engine Pulley Installation • Fit the grooves inside the pulley onto the splines on the output shaft. • Replace the washer with a new one. • Apply molybdenum disulfide grease to the threads of the output shaft and seating surface of the engine pulley mounting nut.
  • Page 432: Rear Pulley Coupling Installation

    11-12 FINAL DRIVE Pulley and Coupling Rear Pulley Coupling Installation • Apply grease to the coupling grease seal lips [A]. • Apply grease to the rear pulley coupling internal surface [B]. • Install the sleeve [C]. • Install the coupling dampers [A] so that the projections [B] face to the outside.
  • Page 433: Coupling Bearing Installation

    FINAL DRIVE 11-13 Pulley and Coupling • Remove the circlip [A]. Special Tool - Inside Circlip Pliers: 57001-143 • Remove the sleeve [A]. • Remove the ball bearing [B] by tapping from the wheel side. Special Tool - Oil Seal & Bearing Remover: 57001-1058 Coupling Bearing Installation •...
  • Page 434: Coupling Bearing Lubrication

    11-14 FINAL DRIVE Pulley and Coupling Coupling Bearing Lubrication NOTE ○ Since the coupling bearing is packed with grease and sealed, lubrication is not required. Rubber Damper Inspection • Remove the rear wheel (see Rear Wheel Removal in the Wheels/Tires chapter). •...
  • Page 435 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 Position Adjustment..................12-8 Brake Pedal Position Inspection ..................12-8 Brake Pedal Position Adjustment..................12-8 Brake Pedal Removal ....................... 12-8 Brake Pedal Installation ....................
  • Page 436: Exploded View

    12-2 BRAKES Exploded View...
  • Page 437 BRAKES 12-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Bleed Valves 0.80 69 in·lb Brake Hose Banjo Bolts Brake Lever Pivot Bolt 0.10 8.9 in·lb Brake Lever Pivot Bolt Locknut 0.60 52 in·lb Front Brake Disc Mounting Bolts Front Brake Light Switch Screw 0.12 11 in·lb Front Brake Reservoir Cap Screws...
  • Page 438 12-4 BRAKES Exploded View...
  • Page 439 BRAKES 12-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Bleed Valves 0.80 69 in·lb Brake Hose Banjo Bolts Brake Pedal Bolt 0.90 78 in·lb Rear Brake Disc Mounting Bolts Rear Caliper Mounting Bolts Rear Master Cylinder Mounting Bolts Rear Master Cylinder Push Rod Locknut 17.2 B: Apply brake fluid.
  • Page 440: Specifications

    12-6 BRAKES Specifications Item Standard Service Limit Brake Lever, Brake Pedal Brake Lever Position 8-way adjustable (to suit rider) – – – Brake Lever Free Play Non-adjustable – – – Pedal Free Play Non-adjustable – – – Pedal Position About 100 mm (3.94 in.) –...
  • Page 441 BRAKES 12-7 Special Tool Jack: 57001-1238...
  • Page 442: Brake Lever Position Adjustment

    12-8 BRAKES Brake Lever, Brake Pedal Brake Lever Position Adjustment • Push the lever forward and turn the adjuster [A]. Brake Pedal Position Inspection • Check that the brake pedal [A] is in the correct position. Pedal Position Standard: About 100 mm (3.94 in.) [B] (height from pedal top to footboard top [C]) If it is incorrect, adjust the brake pedal position.
  • Page 443: Brake Pedal Installation

    BRAKES 12-9 Brake Lever, Brake Pedal • Remove: Brake Pedal Return Spring [A] Rear Brake Light Switch Spring [B] Bolt [C] Washer [D] Cotter Pin [E] Washer [F] Joint Pin [G] Brake Pedal [H] Brake Pedal Installation • Apply grease to the pivot shaft [A]. •...
  • Page 444: Calipers

    12-10 BRAKES Calipers Front Caliper Removal • Loosen the banjo bolt [A] at the brake hose lower end, and tighten it loosely. • Unscrew the caliper mounting bolts [B], and detach the caliper [C] from the disc. • Unscrew the banjo bolt and remove the brake hose [D] from the caliper (see Brake Hose and Pipe Replacement in the Periodic Maintenance chapter).
  • Page 445: Caliper Installation

    BRAKES 12-11 Calipers Caliper Installation • Install the caliper and brake hose lower end. ○ Replace the washer on each side of hose fitting with new ones. • Tighten: Torque - Caliper Mounting Bolts: 34 N·m (3.5 kgf·m, 25 ft·lb) Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb) •...
  • Page 446: Caliper Fluid Seal Damage Inspection

    12-12 BRAKES Calipers Caliper Fluid Seal Damage Inspection The fluid seal (piston seal) [A] is placed around the pis- ton to maintain clearance between the pad and the disc. If the seal is in a poor condition, it could lead the pad to wear excessively or the brake to drag, which may cause the tem- perature of the discs or the brake fluid to increase.
  • Page 447: Caliper Dust Boot And Friction Boot Damage Inspection

    BRAKES 12-13 Calipers Caliper Dust Boot and Friction Boot Damage Inspection • Check that the dust boot [A] and friction boot [B] are not cracked, worn, swollen, or otherwise damaged. If they show any damage, replace it. Caliper Piston and Cylinder Damage Inspection •...
  • Page 448: Caliper Holder Shaft Wear Inspection

    12-14 BRAKES Calipers Caliper Holder Shaft Wear Inspection 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 449: Brake Pads

    BRAKES 12-15 Brake Pads Front Brake Pad Removal • Remove the front caliper with the hose installed (see Front Caliper Removal). • Remove: Snap Pin [A] Pad Pin [B] Brake Pads [C] Front Brake Pad Installation • Push the caliper piston in by hand as far as it will go. •...
  • Page 450: Master Cylinder

    12-16 BRAKES Master Cylinder Front Master Cylinder Removal • Remove the banjo bolt [A] to disconnect the brake hose from the master cylinder (see Brake Hose Replacement in the Periodic Maintenance chapter). • Disconnect the front brake light switch connectors [A] and the cruise control cancel switch connectors [B].
  • Page 451: Rear Master Cylinder Removal

    BRAKES 12-17 Master Cylinder Rear Master Cylinder Removal • Remove: Bolt [A] Cover [B] Bolt [C] • Unscrew: Front Guard Mounting Bolt [A] Brake Hose Banjo Bolt [B] Front Footboard Bracket Bolts [C] • Slide the front guard forward. • Remove: Cotter Pin [A] Joint Pin [B]...
  • Page 452: Master Cylinder Assembly

    12-18 BRAKES Master Cylinder Master Cylinder Assembly • Refer to the Master Cylinder Rubber Parts Replacement in the Periodic Maintenance chapter. Master Cylinder Inspection (Visual Inspection) • Remove the master cylinders (see Front/Rear Master Cylinder Removal). • Disassemble the front and rear master cylinders (see Master Cylinder Rubber Parts Replacement in the Peri- odic Maintenance chapter).
  • Page 453: Brake Discs

    BRAKES 12-19 Brake Discs Brake Disc Removal • Remove the wheels (see Front/Rear Wheel Removal in the Wheels/Tires chapter). • Unscrew the mounting bolts [A], and take off the disc. Brake Disc Installation • Install the brake disc [A] on the wheel so that the marked side [B] faces out.
  • Page 454: Brake Fluid

    12-20 BRAKES Brake Fluid Brake Fluid Level Inspection • Refer to the Brake Fluid Level Inspection in the Periodic Maintenance chapter. Brake Fluid Change • Refer to the Brake Fluid Change in the Periodic Mainte- nance chapter. Brake Line Bleeding The brake fluid has a very low compression coefficient so that almost all the movement of the brake lever or pedal is transmitted directly to the caliper for braking action.
  • Page 455 BRAKES 12-21 Brake Fluid • Remove the rubber cap from the bleed valve [A] on the caliper [B]. • Attach a clear plastic hose [C] to the bleed valve, and run the other end of the hose into a container. •...
  • Page 456 12-22 BRAKES Brake Fluid NOTE ○ For the rear brake caliper [A], bleed the brake line for two bleed valves [B]. • Tighten the bleed valve, and install the rubber cap. Torque - Bleed Valves: 7.8 N·m (0.80 kgf·m, 69 in·lb) •...
  • Page 457: Brake Hose

    BRAKES 12-23 Brake Hose Brake Hose and Pipe Removal/Installation • Refer to the Brake Hose and Pipe Replacement in the Periodic Maintenance chapter. Brake Hose and Pipe Inspection • Refer to the Brake Hose and Pipe Damage and Instal- lation Condition Inspection in the Periodic Maintenance chapter.
  • Page 459 SUSPENSION 13-1 Suspension Table of Contents Exploded View........................13-2 Specifications ......................... 13-6 Special Tools .......................... 13-7 Front Fork ..........................13-9 Fork Oil Change........................ 13-9 Front Fork Removal ......................13-11 Front Fork Installation ....................... 13-13 Front Fork Disassembly ....................13-13 Front Fork Assembly......................13-15 Inner Tube, Outer Tube Inspection ...................
  • Page 460: Exploded View

    13-2 SUSPENSION Exploded View...
  • Page 461 SUSPENSION 13-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Upper Front Fork Clamp Bolts Lower Front Fork Clamp Bolts Fork Cover Clamp Bolts 0.43 37 in·lb Front Fork Bottom Allen Bolts Front Axle Clamp Bolts AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque. L: Apply a non-permanent locking agent.
  • Page 462 13-4 SUSPENSION Exploded View...
  • Page 463 SUSPENSION 13-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Rear Shock Absorber Nuts Rear Shock Absorber Air Valve 0.56 49 in·lb Swingarm Pivot Shaft Nut 11.0 G: Apply grease. R: Replacement Parts WL: Apply a soap and water solution or rubber lubricant.
  • Page 464: Specifications

    13-6 SUSPENSION Specifications Item Standard Front Fork (per one unit) Fork Inner Tube Diameter 43 mm (1.7 in.) Fork Spring Preload Setting Non-adjustable Air Pressure Atmospheric pressure (Non-adjustable) Damper Setting Non-adjustable Fork Oil: Viscosity SHOWA SS-8 or equivalent SAE 10W Amount (Per Side): When changing oil Approx.
  • Page 465: Special Tools

    SUSPENSION 13-7 Special Tools Inside Circlip Pliers: Front Fork Oil Seal Driver: 57001-143 57001-1219 Fork Cylinder Holder Handle: Jack: 57001-183 57001-1238 Fork Cylinder Holder Adapter: Fork Oil Level Gauge: 57001-1057 57001-1290 Oil Seal & Bearing Remover: Bearing Remover Head, 20 × 22: 57001-1058 57001-1293 Bearing Driver Set:...
  • Page 466 13-8 SUSPENSION Special Tools Needle Bearing Driver, 28: Spacer, 57001-1610 57001-1637...
  • Page 467: Front Fork

    SUSPENSION 13-9 Front Fork Fork Oil Change • Remove the front fork (see Front Fork Removal). • Install the front fork temporary without the upper fork cover for removing the top plug. • Remove the cap [A]. • Push down the top plug [A] with a suitable tool [B]. •...
  • Page 468 13-10 SUSPENSION Front Fork • Fill the front fork with the specified oil. Fork Oil: Viscosity: SHOWA SS-8 or equivalent SAE 10W Amount (Per Side): When changing oil: Approx. 435mL (14.7 US oz.) After disassembly and completely dry: 512 ±2.5 mL (17.3 ±0.085 US oz.) •...
  • Page 469: Front Fork Removal

    SUSPENSION 13-11 Front Fork • Install the fork spring with the smaller end [A] facing down- ward [B]. Upward [C] • Install the front fork temporary without the upper fork cover. • Replace the O-ring [A] and retaining ring with new ones. •...
  • Page 470 13-12 SUSPENSION Front Fork • Disconnect the connectors [A]. • Clear the harness from the clamp [B]. • Remove: Bolts [A] (Both Sides) Headlight Body [B] with Bracket • Remove: Bolts [A] Turn Signal Light Bracket [B] Stem Cover [C] •...
  • Page 471: Front Fork Installation

    SUSPENSION 13-13 Front Fork Front Fork Installation • Install the rubber dampers onto the upper fork cover [A]. Thin Damper (Part No.: 92161-0604) [B] Thick Damper (Part No.: 92161-0799) [C] • Install the fork together with the upper fork cover [A]. ○...
  • Page 472 13-14 SUSPENSION Front Fork • Take the cylinder unit [A] out of the inner tube [B]. • Remove the dust seal [A]. • Remove the retaining ring [A] from the outer tube. • Separate the inner tube [A] from the outer tube [B] as follows: ○...
  • Page 473: Front Fork Assembly

    SUSPENSION 13-15 Front Fork Front Fork Assembly • Replace the following parts with new ones. Dust Seal [A] Retaining Ring [B] Oil Seal [C] Inner Guide Bushing [D] Outer Guide Bushing [E] Bottom Allen Bolt Gasket [F] • Put the cylinder unit [A] with the spring into the inner tube [B], protruding from the inner tube, and install the cylinder base [C] onto the bottom end of the cylinder unit.
  • Page 474: Inner Tube, Outer Tube Inspection

    13-16 SUSPENSION Front Fork • Install the front fork cover clamp [A] as shown. Inner Tube [B] About 248 mm (9.76 in.) [C] • Tighten: Torque - Fork Cover Clamp Bolt: 4.2 N·m (0.43 kgf·m, 37 in·lb) • Pour in the specified type of oil (see Fork Oil Change). Inner Tube, Outer Tube Inspection •...
  • Page 475: Spring Tension

    SUSPENSION 13-17 Front Fork Spring Tension • Since the spring becomes shorter as it weakens, check its free length [A] to determine its condition. If the spring of either fork leg is shorter than the service limit, it must be replaced. If the length of a replacement spring and that of the re- maining spring vary greatly, the remaining spring should also be replaced in order to keep the fork legs balanced...
  • Page 476: Rear Shock Absorber (air Type)

    13-18 SUSPENSION Rear Shock Absorber (Air Type) Rebound Damping Adjustment The rebound damping force adjuster on each rear shock absorber has 4 positions so that the rebound damping force can be adjusted for different road and loading conditions. The numbers on the adjuster show the setting position. •...
  • Page 477: Rear Shock Absorber Removal

    SUSPENSION 13-19 Rear Shock Absorber (Air Type) • Take off the air valve cap [A] on both shock absorbers. • Check the air pressure with the air pressure gauge. NOTE ○ Do not use tire gauges for checking air pressure. They may not indicate the correct air pressure because of air leakage that occur when the gauge is applied to the valve.
  • Page 478: Rear Shock Absorber Installation

    13-20 SUSPENSION Rear Shock Absorber (Air Type) • Remove the nuts [A], spring washers, and flat washers from both ends of the rear shock absorber [B]. • Pull the rear shock absorber off the frame. Rear Shock Absorber Installation • Install the sleeve [A] so the flange side faces inside.
  • Page 479: Rear Shock Absorber Scrapping

    SUSPENSION 13-21 Rear Shock Absorber (Air Type) Rear Shock Absorber Scrapping • Remove the rear shock absorber (see Rear Shock Ab- sorber Removal). WARNING Since the rear shock absorber contains air, do not incinerate the rear shock absorber without first re- leasing the air or it may explode.
  • Page 480: Swingarm

    13-22 SUSPENSION Swingarm Swingarm Removal • Remove: Saddlebags (see Saddlebag Removal in the Frame chapter) Saddlebag Stays (see Saddlebag Stay Removal in the Frame chapter) Rear Fender (see Rear Fender Removal in the Frame chapter) Rear Caliper (see Caliper Removal in the Brakes chap- ter) Rear Wheel (see Rear Wheel Removal in the Wheels/Tires chapter)
  • Page 481: Swingarm Installation

    SUSPENSION 13-23 Swingarm Swingarm Installation • Apply grease to the grease seal lips [A]. • Install the collar [A]. • Insert the swingarm pivot shaft to install the swingarm. • Tighten: Torque - Swingarm Pivot Shaft Nut: 108 N·m (11.0 kgf·m, 80 ft·lb) •...
  • Page 482: Swingarm Bearing, Sleeve Inspection

    13-24 SUSPENSION Swingarm • Install the needle bearings [A] as shown in the figure. ○ Apply grease a little to the outer surface of the bearings. ○ Turn the marked side of the bearings toward out. Special Tools - Needle Bearing Driver, 28: 57001-1610 Spacer, 28: 57001-1637 Left Side [B] 24 ~ 27 mm (0.9 ~ 1.1 in.) [C]...
  • Page 483 STEERING 14-1 Steering Table of Contents Exploded View........................14-2 Special Tools .......................... 14-4 Handlebar ..........................14-5 Handlebar Removal ......................14-5 Handlebar Installation ....................... 14-5 Steering ..........................14-7 Handlebar Holder Installation.................... 14-7 Steering Inspection ......................14-7 Steering Adjustment......................14-7 Steering Stem......................... 14-8 Steering Stem Removal ....................
  • Page 484: Exploded View

    14-2 STEERING Exploded View...
  • Page 485 STEERING 14-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Handlebar Clamp Bolts O, S Upper Front Fork Clamp Bolts Steering Stem Head Nut Handlebar Holder Nuts Steering Stem Nut Lower Front Fork Clamp Bolts AD: Apply adhesive. AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque. G: Apply grease.
  • Page 486: Special Tools

    14-4 STEERING Special Tools Head Pipe Outer Race Press Shaft: Head Pipe Outer Race Remover ID > 37 mm: 57001-1075 57001-1107 Head Pipe Outer Race Driver, 54.5: Steering Stem Bearing Driver, 42.5: 57001-1077 57001-1344 Steering Stem Nut Wrench: Steering Stem Bearing Driver Adapter, 41.5: 57001-1100 57001-1345...
  • Page 487: Handlebar

    STEERING 14-5 Handlebar Handlebar Removal • Remove: Clamps [A] Clutch Master Cylinder [B] (see Clutch Master Cylinder Removal in the Clutch chapter) Left Handlebar Switch Housing [C] • Remove the left grip end cap [A] from the handlebar [B]. ○ The left grip end cap has left-hand threads.
  • Page 488 14-6 STEERING Handlebar • Install the handlebar clamps [A] so that the cut side [B] on the clamp points at the rear. • Apply 2-stroke oil to the threads of the handlebar clamp bolts [C]. • Tighten: Torque - Handlebar Clamp Bolts: 34 N·m (3.5 kgf·m, 25 ft·lb) ○...
  • Page 489: Handlebar Holder Installation

    STEERING 14-7 Steering Handlebar Holder Installation • When the rubber bushings [A] are installed in the steering stem head [B], apply soap and water solution or rubber lubricant to the outer surface first, and then press and insert them until rubber bush end is about 1.0 mm (0.039 in.) [C] from the steering stem head surface.
  • Page 490: Steering Stem

    14-8 STEERING Steering Stem Steering Stem Removal • Remove: Windshield (see Windshield Removal in the Frame chapter) Headlight Unit (see Headlight Body Removal in the Elec- trical System chapter) • Disconnect the connectors [A]. • Clear the harness from the clamp [B]. •...
  • Page 491: Steering Stem Installation

    STEERING 14-9 Steering Stem • Remove: Steering Stem Head Nut [A] Washer [B] Front Fork (see Front Fork Removal in the Suspension chapter) Steering Stem Head [C] • Remove: Lock Washer [A] • Hold the steering stem base [A] by hand. •...
  • Page 492: Steering Stem Warp

    14-10 STEERING Steering Stem • Install the front fork temporary. • Install the washer [A] and the steering stem head nut [B]. Torque - Steering Stem Head Nut: 88 N·m (9.0 kgf·m, 65 ft·lb) • Install the removed parts (see appropriate chapters). •...
  • Page 493: Steering Stem Bearing

    STEERING 14-11 Steering Stem Bearing Stem Bearing Removal • Remove the steering stem (see Steering Stem Removal in this chapter). • Remove the upper stem bearing inner race [A] and bear- ing [B]. • Drive out the bearing outer races from the head pipe. Special Tool - Head Pipe Outer Race Remover ID >...
  • Page 494: Stem Bearing Lubrication

    14-12 STEERING Steering Stem Bearing • Replace the bearing inner races and oil seal with new ones. • Apply grease to the oil seal. • Drive the lower ball bearing inner race [A] applied the grease onto the stem. Special Tools - Steering Stem Bearing Driver, 42.5 [B]: 57001-1344 Steering Stem Bearing Driver Adapter,...
  • Page 495 FRAME 15-1 Frame Table of Contents Exploded View........15-2 Windshield and Deflector Special Tool ........15-8 Installation ......... 15-20 Seats ..........15-9 Windshield Assembly....15-20 Rear Seat Removal...... 15-9 Deflector Assembly ...... 15-21 Rear Seat Installation....15-9 Saddlebags........15-22 Front Seat Removal ..... 15-9 Saddlebag Lid Unlocking .....
  • Page 496: Exploded View

    15-2 FRAME Exploded View...
  • Page 497 FRAME 15-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Cross Pipe Bolts Downtube Bolts Front Footboard Bracket Bolts Rear Footboard Bracket Bolts Sidestand Mounting Bolt Sidestand Mounting Nut 0.90 78 in·lb Sidestand Switch Mounting Bolt 8. Trim (EUR Models) G: Apply grease.
  • Page 498 15-4 FRAME Exploded View...
  • Page 499 FRAME 15-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Rear Fender Allen Bolts 2. Other than EUR and AU Models...
  • Page 500 15-6 FRAME Exploded View...
  • Page 501 FRAME 15-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Cross Bar Mounting Bolts Front Guard Mounting Bolts Rear Guard Mounting Bolts Saddlebag Stay Bolts 5. Other than EUR and AU Models 6. EUR and SEA Models 7. US, CA, CAL and AU Models...
  • Page 502: Special Tool

    15-8 FRAME Special Tool Jack: 57001-1238...
  • Page 503: Seats

    FRAME 15-9 Seats Rear Seat Removal • Insert the ignition key into the seat lock [A], and turn it counterclockwise. • Pull up the front part of the rear seat [B], and remove the rear seat forward. Rear Seat Installation •...
  • Page 504: Side Covers

    15-10 FRAME Side Covers CAUTION Be careful not to scratch the painted surface during removal or installation. Left Side Cover Removal • Remove: Seats (see Front/Rear Seat Removal) Screw [A] • Detach the projections [B], and remove the upper side cover [C].
  • Page 505: Right Side Cover Removal

    FRAME 15-11 Side Covers • Insert the projections [A] of upper side cover into the grommets [B]. • Tighten the screw. Right Side Cover Removal • Remove: Seats (see Front/Rear Seat Removal) Screw [A] • Detach the projections [B], and remove the upper side cover [C].
  • Page 506: Fenders

    15-12 FRAME Fenders CAUTION Be careful not to scratch the painted surface during removal or installation. Front Fender Removal • Remove: Front Wheel (see Front Wheel Removal in the Wheels/Tires chapter) Front Fender Bolts [A] Brake Hose Brackets [B] Front Fender [C] Rear Fender Removal •...
  • Page 507: Rear Fender Installation

    FRAME 15-13 Fenders Rear Fender Installation • Install the grommet [A] so that its taper side faces inside. • Fit the grommet of the rear fender onto the stopper [B]. • Tighten: Torque - Rear Fender Allen Bolts [A]: 25 N·m (2.5 kgf·m, 18 ft·lb) •...
  • Page 508: Battery Case

    15-14 FRAME Battery Case Battery Case Removal • Remove: Seats (see Front/Rear Seat Removal) Rear Fender (see Rear Fender Removal) Battery (see Battery Removal in the Electrical System chapter) • Pull the following out from the battery case. ECU [A] Turn Signal Control Relay [B] Fuse Boxes [C] ETV Actuator Relay [D]...
  • Page 509: Footboard

    FRAME 15-15 Footboard Front Footboard Removal/Installation Left Side • Remove: Rear Shift Lever Bolt [A] Rear Shift Lever [B] • Remove: Front Footboard Bracket Bolt [A] (Tighten with Front Guard) Front Footboard Bracket Bolt [B] Front Footboard Left [C] • Installation is the reverse of removal;...
  • Page 510: Front Footboard Disassembly

    15-16 FRAME Footboard • Open the clamp [A], and free the lead. • Disconnect: Rear Brake Light Switch Lead Connector [B] Cruise Control Cancel Switch Lead Connector [C] If necessary, remove the rear brake master cylinder and brake pedal (see Brake Pedal Removal in the Brakes chapter).
  • Page 511: Rear Footboard Removal/installation

    FRAME 15-17 Footboard • Install the dampers [A] onto the front footboard brackets [B]. • Put the footboards [C] and the brackets together. ○ Apply grease to the sliding surface of the front footboards. ○ Insert the pins [D] from the front. ○...
  • Page 512: Rear Footboard Assembly

    15-18 FRAME Footboard Rear Footboard Assembly • Replace the circlips with new ones. • Install the following onto the rear footboards [A]. Inner Dampers [B] Outer Dampers [C] Rear Footboard Covers [D] and Bolts [E] • Install the spring [A] and steel ball [B] into the hole [C] of the footboard.
  • Page 513: Side Stand

    FRAME 15-19 Side Stand Side Stand Removal • Raise the rear wheel off the ground using the jack. Special Tool - Jack: 57001-1238 • Remove: Side Stand Switch Bolt [A] Side Stand Switch [B] • Remove: Spring [A] Side Stand Nut [B] Side Stand Bolt [C] Side Stand [D] Side Stand Installation...
  • Page 514: Windshield

    15-20 FRAME Windshield Windshield Height Adjustment ○ The windshield can be adjusted within 50 mm (2.0 in.) in height to suit the rider’s preference. • Loosen the windshield bolts [A] on both sides. • Slide the windshield up or down [B]. •...
  • Page 515: Deflector Assembly

    FRAME 15-21 Windshield • Install the following with the bolts and nuts to the wind- shield. Outer Side Plates [A] and Dampers [B] Dampers (D = 50 mm (2.0 in.)) [C] Subwindshield [D] Dampers (D = 35 mm (1.4 in.)) [E] Windshield Stays [F] ○...
  • Page 516: Saddlebags

    15-22 FRAME Saddlebags Saddlebag Lid Unlocking • Insert the ignition key into the lid lock [A], and turn it coun- terclockwise. • Take hold of the knob [B], and open the lid. Saddlebag Lid Locking • Close the lid until lock with a click. •...
  • Page 517: Saddlebag Stay Removal

    FRAME 15-23 Saddlebags • Install the saddlebag onto the saddlebag stay. ○ Fit the side hook [A] and the bottom stoppers [B] to the saddlebag stay. Saddlebag Stay Removal • Remove: Seats (see Front/Rear Seat Removal) Saddlebag (see Saddlebag Removal) •...
  • Page 518 15-24 FRAME Saddlebags Saddlebag Stay Installation • Installation is the reverse of removal; note the following. ○ Tighten: Torque - Saddlebag Stay Bolts [A]: 25 N·m (2.5 kgf·m, 18 ft·lb) Muffler Mounting Bolts [B]: 25 N·m (2.5 kgf·m, 18 ft·lb) Cross Bar Mounting Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb)
  • Page 519: Guards

    FRAME 15-25 Guards Front Guard Removal/Installation Left Side • Remove: Front Guard Mounting Bolt [A] Front Footboard Bracket Bolt [B] Left Front Guard [C] • Apply a non-permanent locking agent to the front foot- board bracket bolt. • Tighten: Torque - Front Footboard Bracket Bolt: 34 N·m (3.5 kgf·m, 25 ft·lb) Front Guard Mounting Bolt: 34 N·m (3.5 kgf·m, 25 ft·lb)
  • Page 520: Rear View Mirrors

    15-26 FRAME Rear View Mirrors Rear View Mirror Removal (Other than EUR and SEA Models) • Remove the bolt [A] and nut on both sides. • Tilt the windshield [B] forward. • Loosen the locknut [A]. • Turn the rear view mirror stay [B] counterclockwise to re- move the rear view mirror from the holder [C].
  • Page 521: Rear View Mirror Installation (eur And Sea Models)

    FRAME 15-27 Rear View Mirrors • Loosen the lower hexagonal area [A]. • Turn the rear view mirror stay [B] counterclockwise to re- move the rear view mirror from the holder [C]. CAUTION Do not force to tighten and/or loosen the upper hexagonal area (adapter) [A] with a pair of span- ners or wrench.
  • Page 522: Downtube

    15-28 FRAME Downtube Downtube Removal • Raise the rear wheel off the ground using the jack. Special Tool - Jack: 57001-1238 • Remove: Right Front Guard (see Front Guard Removal/Installa- tion) Front Footboard Right (see Front Footboard Re- moval/Installation) Exhaust Pipes (see Exhaust Pipe Removal in the Engine Top End chapter) •...
  • Page 523: Tandem Grip

    FRAME 15-29 Tandem Grip Tandem Grip Removal • Remove: Seats (see Front/Rear Seat Removal) Saddlebags (see Saddlebag Removal) • Remove the screw [A] and bolts [B], and take off the rear fender cover front [C] (Both Sides). • Remove the bolts [A], and take off the tandem grip inner cover [B] (Both Sides).
  • Page 524: Frame Inspection

    15-30 FRAME Frame Frame Inspection • Visually inspect the frame [A] for cracks, dents, bending, or warp. If there is any damage to the frame, replace it. WARNING A repaired frame may fail in use, possibly causing an accident. If the frame is bent, dented, cracked, or warped, replace it.
  • Page 525 ELECTRICAL SYSTEM 16-1 Electrical System Table of Contents Exploded View........16-4 Commutator Cleaning and Specifications ........16-10 Inspection........16-47 Special Tools and Sealant ....16-11 Armature Inspection..... 16-47 Electrical Parts Location ....16-12 Brush Lead Inspection ....16-48 Wiring Diagram........16-14 Right-hand End Cover Inspection 16-48...
  • Page 526 16-2 ELECTRICAL SYSTEM Speed Sensor Installation .... 16-85 Rear Brake Light Switch Speed Sensor Inspection..... 16-85 Check/Adjustment ..... 16-87 Oxygen Sensor Removal Switch Inspection ......16-88 (Equipped Models) ....16-85 Relay Box .......... 16-89 Oxygen Sensor Installation Relay Box Removal ..... 16-89 (Equipped Models) ....
  • Page 527 ELECTRICAL SYSTEM 16-3 Dummy Page...
  • Page 528: Exploded View

    16-4 ELECTRICAL SYSTEM Exploded View...
  • Page 529 ELECTRICAL SYSTEM 16-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Alternator Cover Bolts 106 in·lb Alternator Harness Clamp Bolt 87 in·lb Alternator Rotor Bolt 15.3 Alternator Stator Coil Lead Connector Stay 87 in·lb Bolt 106 in·lb Alternator Stator Coil Mounting Bolts Crankshaft Sensor Bolts 0.60 52 in·lb...
  • Page 530 16-6 ELECTRICAL SYSTEM Exploded View...
  • Page 531 ELECTRICAL SYSTEM 16-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Engine Ground Mounting Bolt 87 in·lb Front Brake Light Switch Screw 0.12 11 in·lb Fuel Pump Bolts 87 in·lb L, S Sidestand Switch Mounting Bolt 0.90 78 in·lb Starter Lockout Switch Screw 0.12 11 in·lb Cruise Control Cancel Switch (Clutch)
  • Page 532 16-8 ELECTRICAL SYSTEM Exploded View...
  • Page 533 ELECTRICAL SYSTEM 16-9 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Licence Plate Light Lens Screws 0.09 8 in·lb 2. EUR Models L: Apply a non-permanent locking agent.
  • Page 534: Specifications

    16-10 ELECTRICAL SYSTEM Specifications Item Standard Battery Type Sealed Battery Model Name FTZ16-BS Capacity 12 V 18 Ah Voltage 12.6 V or more Charging System Alternator Type Three-phase AC 14.0 ∼ 15.0 V at 5 000 r/min (rpm) Battery Charging Voltage Alternator Output Voltage (No Load) 76 V or more at 4 000 r/min (rpm) 0.23 ∼...
  • Page 535: Special Tools And Sealant

    ELECTRICAL SYSTEM 16-11 Special Tools and Sealant Jack: Grip: 57001-1238 57001-1591 Hand Tester: Rotor Holder: 57001-1394 57001-1726 Peak Voltage Adapter: Kawasaki Bond (Silicone Sealant): 57001-1415 92104-0004 Needle Adapter Set: 57001-1457...
  • Page 536: Electrical Parts Location

    16-12 ELECTRICAL SYSTEM Electrical Parts Location Fuel Pump and Fuel Level Sensor [A] Speed Sensor [B] Crankshaft Sensor [C] Alternator [D] Gear Position Switch [E] Sidestand Switch [F] Meter Unit [A] Ignition Switch [B] Meter Unit Switch [C] Cruise Control ON/OFF Button [D] Cruise Control Switch [E] Oil Pressure Switch [A] Rear Brake Light Switch [B]...
  • Page 537 ELECTRICAL SYSTEM 16-13 Electrical Parts Location Front Brake Light Switch [A] Cruise Control Cancel Switch (Front Brake) [B] Starter Lockout Switch [A] Cruise Control Cancel Switch (Clutch) [B] Cruise Control Cancel Switch (Throttle) [A] Frame Ground [A] Accessory Relay [B] ETV Actuator Relay [C] Starter Relay [D] Main Fuse 30 A [E]...
  • Page 538: Wiring Diagram

    16-14 ELECTRICAL SYSTEM Wiring Diagram...
  • Page 539 ELECTRICAL SYSTEM 16-15 Wiring Diagram...
  • Page 540 16-16 ELECTRICAL SYSTEM Wiring Diagram...
  • Page 541 ELECTRICAL SYSTEM 16-17 Wiring Diagram...
  • Page 542: Servicing Precautions

    16-18 ELECTRICAL SYSTEM Servicing Precautions There are a number of important precautions that are musts when servicing electrical systems. Learn and ob- serve all the rules below. ○ Do not reverse the battery cable connections. This will burn out the diodes on the electrical parts. ○...
  • Page 543: Electrical Wiring

    ELECTRICAL SYSTEM 16-19 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 544: Battery

    16-20 ELECTRICAL SYSTEM Battery Battery Removal CAUTION Do not remove the battery cables and fuses for 6 seconds after turning off the ignition switch. • Turn the ignition switch OFF. • Remove: Front Seat (see Front Seat Removal) Connector [A] Screws [B] Battery Case Cover [C] •...
  • Page 545: Battery Activation

    ELECTRICAL SYSTEM 16-21 Battery • Install the battery case cover [A]. NOTE ○ Run each harness [B] under the battery case cover, and do not run them over the frame pipe [C]. • Install the removed parts (see appropriate chapters). Battery Activation Electrolyte Filling •...
  • Page 546 1.8 A × 5 ∼ 10 hours Standard Charge If using a recommended battery charger, follow the charger’s instructions for newly activated sealed battery. Kawasaki-recommended Chargers Optimate III Yuasa 1.5 Amp Automatic Charger Battery Mate 150-9 If the above chargers are not available, use equivalent one.
  • Page 547: Precautions

    ELECTRICAL SYSTEM 16-23 Battery • After charging is completed, press down firmly with both hands to seat the strip of caps [A] into the battery (don’t pound or hammer). When properly installed, the strip of the caps will be level with the top of the battery. CAUTION Once the strip of the caps [A] is installed onto the battery, never remove the caps, nor add water or...
  • Page 548: Interchange

    16-24 ELECTRICAL SYSTEM Battery WARNING Keep the battery away from sparks and open flames during charging, since the battery gives off an explosive gas mixture of hydrogen and oxygen. When using a battery charger, connect the battery to the charger before turning on the charger. This procedure prevents sparks at the battery terminals which could ignite any battery gases.
  • Page 549 ELECTRICAL SYSTEM 16-25 Battery Terminal Voltage: 11.5 ∼ less than 12.6 V 1.8 A × 5 ∼ 10 h (see following Standard Charge chart) Quick Charge 9 A × 1 h CAUTION If possible, do not quick charge. If quick charge is done unavoidably, do standard charge later on.
  • Page 550: Charging System

    16-26 ELECTRICAL SYSTEM Charging System Alternator Cover Removal • Drain: Engine Oil (see Engine Oil Change in the Periodic Main- tenance chapter) Coolant (see Coolant Change in the Periodic Mainte- nance chapter) • Remove: Front Footboard Right (see Front Footboard Removal in the Frame chapter) Front Exhaust Pipe Cover (see Exhaust Pipe Removal in the Engine Top End chapter)
  • Page 551: Alternator Cover Installation

    Alternator Cover Installation • Apply silicone sealant to around grommets [A] of the al- ternator lead and crankshaft sensor lead. Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004 • Check that dowel pins [A] are in place on the crankcase. •...
  • Page 552: Alternator Stator Coil Removal

    16-28 ELECTRICAL SYSTEM Charging System • Replace the O-ring [A] of the water pipe [B] with a new one. • Apply soap and water solution to the new O-ring. • Insert the water pipe [A] into the alternator cover [B] and install the cover.
  • Page 553: Alternator Stator Coil Installation

    Torque - Stator Lead Holding Plate Bolts: 5.9 N·m (0.60 kgf·m, 52 in·lb) • Apply silicone sealant to around grommet [C] of the alter- nator lead. Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004 • Install: Alternator Cover (see Alternator Cover Installation) Alternator Rotor Removal •...
  • Page 554: Charging Voltage Inspection

    16-30 ELECTRICAL SYSTEM Charging System Charging Voltage Inspection • Check the battery condition (see Charging Condition In- spection). • Warm up the engine to obtain actual alternator operating conditions. • Remove the front seat (see Front Seat Removal in the Frame chapter).
  • Page 555 ELECTRICAL SYSTEM 16-31 Charging System ○ Disconnect the alternator lead connectors [A]. ○ Connect the hand tester [A] to each connector [B] as shown in the table 1. Special Tool - Hand Tester: 57001-1394 ○ Connect the crankshaft sensor lead connector. ○...
  • Page 556: Regulator/rectifier Removal

    16-32 ELECTRICAL SYSTEM Charging System Regulator/Rectifier Removal • Remove: Connector Bracket Bolt [A] Bolts [B] and Cross Pipe [C] • Pull out the cross pipe from the projections [D] of the ra- diator. • Disconnect: Regulator/Rectifier Lead Connectors [A] • Remove: Regulator/Rectifier Bolts [B] and Nuts Regulator/Rectifiers [C]...
  • Page 557: Regulator/rectifier Inspection

    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 me- ter with a large capacity battery is used, the regula- tor/rectifier will be damaged.
  • Page 558 16-34 ELECTRICAL SYSTEM Charging System Charging System Circuit 1. Ignition Switch 2. Load 3. Frame Ground 1 4. Frame Ground 2 5. Regulator/Rectifier #1 6. Regulator/Rectifier #2 7. Alternator 8. Starter Relay 9. Main Fuse 30 A 10. Battery...
  • Page 559: Ignition System

    ELECTRICAL SYSTEM 16-35 Ignition System WARNING The ignition system produces extremely high volt- age. Do not touch the spark plugs, ignition coils, or spark plug high-tension cables while the engine is running, or you could receive a severe electrical shock. CAUTION Do not disconnect the battery cables or any other electrical connections when the ignition switch is...
  • Page 560: Ignition Coil Installation

    16-36 ELECTRICAL SYSTEM Ignition System Ignition Coil Installation • Run the high-tension cables according to the Cable, Wire, and Hose Routing section in the Appendix chapter. • Connect the primary leads to the ignition coil [A]. Ignition Coil #1 (Front Cylinder) R/G Lead [B] to Green Terminal Cover [C] BK/O Lead [D] to Black Terminal Cover [E] Ignition Coil #2 (Rear Cylinder)
  • Page 561: Spark Plug Removal

    ELECTRICAL SYSTEM 16-37 Ignition System • Measure the primary winding resistance [A] as follows. ○ Connect the hand tester between the coil terminals. ○ Set the tester to the × 1 Ω range, and read the tester. • Measure the secondary winding resistance [B] as follows. ○...
  • Page 562: Ignition Coil Primary Peak Voltage

    16-38 ELECTRICAL SYSTEM Ignition System Ignition Coil Primary Peak Voltage NOTE ○ Be sure the battery is fully charged. • Remove the fuel tank (see Fuel Tank Removal in the Fuel System (DFI) chapter). • Remove all the spark plug caps but do not remove the spark plugs.
  • Page 563: Crankshaft Sensor Removal

    Apply silicone sealant to the circumference of the crank- shaft sensor lead grommet [C], and fit the grommet into the notch of the cover securely. Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004 • Secure the crankshaft sensor lead with the holding plate...
  • Page 564: Crankshaft Sensor Peak Voltage Inspection

    16-40 ELECTRICAL SYSTEM Ignition System Crankshaft Sensor Peak Voltage Inspection NOTE ○ Be sure the battery is fully charged. ○ Using the peak voltage adapter is more reliable way to determine the condition of the crankshaft sensor than crankshaft sensor internal resistance measurements. •...
  • Page 565: Ic Igniter Inspection

    ELECTRICAL SYSTEM 16-41 Ignition System 2nd Check • Start the engine to the following conditions. Condition: Transmission Gear → 1st Position Clutch Lever → Pulled in Sidestand → Up ○ Turn the ignition switch to ON and push the starter button. ○...
  • Page 566 16-42 ELECTRICAL SYSTEM Ignition System Ignition System Troubleshooting...
  • Page 567 ELECTRICAL SYSTEM 16-43 Ignition System Ignition System Circuit 1. Engine Stop Switch 9. Throttle Position Sen- 19. Vehicle-down Sensor 2. Starter Button sor/ETV Actuator 20. Starter Relay 3. Spark Plug #1 (Front 10. Throttle Position Sensor 21. Main Fuse 30A Cylinder) 22.
  • Page 568: Starter Motor

    16-44 ELECTRICAL SYSTEM Starter Motor Starter Motor Removal • Remove: Engine Pulley Inner Cover (see Engine Pulley Inner Cover Removal in the Final Drive chapter) Starter Motor Terminal Nut [A] and Cable [B] Starter Motor Mounting Bolts [C] • Pull out the starter motor [D]. CAUTION Never drop the starter motor, especially on a hard surface.
  • Page 569: Starter Motor Disassembly

    ELECTRICAL SYSTEM 16-45 Starter Motor Starter Motor Disassembly • Remove the starter motor (see Starter Motor Removal). • Take off the starter motor through bolts [A] and remove the both end covers [B]. • Pull out the armature [A] out of the yoke [B]. NOTE ○...
  • Page 570 16-46 ELECTRICAL SYSTEM Starter Motor • Replace the O-ring [A] with a new one. • Install the starter motor terminal [B] together with the fol- lowing parts. New O-ring Collar [C] Washer [D] Starter Motor Terminal Locknut [E] ○ Install the collar so that stepped side faces outward. •...
  • Page 571: Brush Inspection

    ELECTRICAL SYSTEM 16-47 Starter Motor • Replace the O-rings [A] with new ones. • Install the end cover [B] and tighten the through bolts [C]. Torque - Starter Motor Through Bolts: 5.0 N·m (0.51 kgf·m, 44 in·lb) Brush Inspection • Measure the length of each brush [A].
  • Page 572: Brush Lead Inspection

    16-48 ELECTRICAL SYSTEM Starter Motor Brush Lead Inspection • Using the × 1 Ω hand tester range, measure the resis- tance as shown. Terminal Bolt and Positive Brushes [A] End Cover and Negative Brushes [B] Special Tool - Hand Tester: 57001-1394 If there is not close to zero ohms, the brush lead has an open.
  • Page 573 ELECTRICAL SYSTEM 16-49 Starter Motor Electric Starter Circuit 1. Engine Stop Switch 2. Starter Button 3. Gear Position Switch 4. Ignition Switch 5. Starter Lockout Switch 6. Sidestand Switch 7. Starter Motor 8. Starter Relay 9. Main Fuse 30 A 10.
  • Page 574: Lighting System

    16-50 ELECTRICAL SYSTEM Lighting System This motorcycle adopts the daylight system and has a headlight relay in the relay box. The headlight does not go on when the ignition switch and the engine stop switch are first turned on. The headlight comes on after the starter button is released and stays on until the ignition switch is turned off.
  • Page 575: Headlight Body Removal

    ELECTRICAL SYSTEM 16-51 Lighting System • Replace the headlight bulb. • Fit the projections [A] of the bulb in the hollows [B] of the headlight. • Install the hook [A]. • Fit the dust cover [A] with the TOP mark [B] upward onto the bulb [C] firmly as shown.
  • Page 576: Tail/brake Light (led) Removal

    16-52 ELECTRICAL SYSTEM Lighting System City Light Bulb Replacement (EUR Models) • Remove the headlight unit (see Headlight Bulb Replase- ment). • Pull out the socket [A] together with the bulb. • Remove the wedge-base type bulb [A], pull the bulb straight out of the socket [B].
  • Page 577: Licence Plate Light Bulb Replacemrnt

    ELECTRICAL SYSTEM 16-53 Lighting System Licence Plate Light Bulb Replacemrnt • Remove: Bolts [A] Cover [B] • Remove: License Plate Light Lens Screws [A] License Plate Light Lens [B] • Push and turn the bulb [A] counterclockwise [B] and re- move it.
  • Page 578 16-54 ELECTRICAL SYSTEM Lighting System Headlight/Tail Light Circuit 1. Ignition Switch 2. Joint Connector 1 3. Frame Ground 1 4. Tail/Brake Lights (LED) 5. License Plate Light 12 V 5 W 6. Frame Ground 4 7. Frame Ground 5 8. Frame Ground 3 9.
  • Page 579: Automatic Turn Signal Canceling System

    ELECTRICAL SYSTEM 16-55 Automatic Turn Signal Canceling System Automobiles use a turn signal canceling system actuated by steering wheel turn. But, motorcycles turn with a bank additionally, and so have a smaller steer angle. This makes difficult to adopt an automobile type turn signal canceling system because of inaccurate operation in motorcycles.
  • Page 580: Distance Sensor System Inspection

    16-56 ELECTRICAL SYSTEM Automatic Turn Signal Canceling System Distance Sensor System Inspection • Remove: Battery Case Cover (see Battery Removal) Turn Signal Control Relay ○ Do not disconnect the connector. • Use the jack to lift the rear wheel (see Rear Wheel Re- moval in the Wheel/Tires chapter).
  • Page 581 ELECTRICAL SYSTEM 16-57 Automatic Turn Signal Canceling System • Remove: Screw [A] Socket Assembly [B] • Push and turn the bulb [A] counterclockwise [B] and re- move it. • Replace the bulb with a new one. • Insert the new bulb [A] by aligning its upper and lower pins [B] with the upper and lower grooves [C] in the socket, and turn the bulb clockwise about 15°.
  • Page 582 16-58 ELECTRICAL SYSTEM Automatic Turn Signal Canceling System • Insert the lens [A] by aligning projections [B] with the grooves [C] and turn the lens clockwise until it is stopped. • Tighten the screw.
  • Page 583 ELECTRICAL SYSTEM 16-59 Automatic Turn Signal Canceling System Turn Signal Cancelling System Circuit 1. Ignition Switch 2. Joint Connector 1 3. Frame Ground 1 4. Hazard Button 5. Speed Sensor 6. Front Left Turn Signal Light 12 V 21 W 7.
  • Page 584: Air Switching Valve

    16-60 ELECTRICAL SYSTEM Air Switching Valve Air Switching Valve Operation Test • Refer to the Air Suction System Damage Inspection in the Periodic Maintenance chapter. Air Switching Valve Unit Test • Remove the air switching valve (see Air Switching Valve Removal in the Engine Top End chapter).
  • Page 585 ELECTRICAL SYSTEM 16-61 Air Switching Valve Air Switching Valve Circuit 1. ECU 2. Air Switching Valve 3. Engine Stop Switch 4. Ignition Switch 5. Ignition Fuse 10 A 6. ECU Fuse 10 A 7. Main Fuse 30 A 8. Battery 9.
  • Page 586: Radiator Fan System

    16-62 ELECTRICAL SYSTEM Radiator Fan System Fan System Circuit Inspection • Remove: Front Seat (see Front Seat Removal in the Frame chap- ter) Battery Case Cover (see Battery Removal) • Take out the relay box [A] from battery case. • Disconnect the 4-pin connector [B] •...
  • Page 587 ELECTRICAL SYSTEM 16-63 Radiator Fan System Radiator Fan Circuit 1. Ignition Switch 2. Joint Connector 1 3. Frame Ground 1 4. Fan Motor 5. Water Temperature Sensor 6. ECU 7. Fan Relay 8. Relay Box 9. Ignition Fuse 10 A 10.
  • Page 588: Meter, Gauge

    16-64 ELECTRICAL SYSTEM Meter, Gauge Meter Unit Removal • Remove: Key Cylinder Cover [A] Bolts [B] Meter Cover [C] with Meter Unit • Side the dust cover [A] and disconnect the meter unit con- nector. • Remove the screws [A] and separate the meter unit [B] and cover.
  • Page 589: Meter Operation Inspection

    ELECTRICAL SYSTEM 16-65 Meter, Gauge • Separate the meter base assembly [A] and cover [B]. Meter Operation Inspection NOTE ○ Be sure the battery is fully charged. ○ Be sure the ignition switch and meter unit switch are normality (see Switch Inspection). ○...
  • Page 590 16-66 ELECTRICAL SYSTEM Meter, Gauge • By pushing the meter unit switch [A] to MODE-A position [B] each time, check that the display [C] changes as fol- lows. ○ This display is ordinary indication. • By pushing the meter unit switch [A] to MODE-B position [B] each time, check that the display [C] changes as fol- lows.
  • Page 591 ELECTRICAL SYSTEM 16-67 Meter, Gauge • Check that the display changes to the setting mode [A]. • By pushing the meter unit switch each time, check that the display changes as follows. • Push and hold the meter unit switch more than two sec- onds.
  • Page 592 16-68 ELECTRICAL SYSTEM Meter, Gauge • Push the meter unit switch to MODE-A position, and check that the minute display is decided. If the display function does not work, replace the meter base (see Meter Unit Disassembly). • Set to the setting mode, and push the meter unit switch [A].
  • Page 593: Can Communication Item Inspection

    ELECTRICAL SYSTEM 16-69 Meter, Gauge Can Communication Item Inspection Cruise Control Indicator Light (LED) Inspection • Turn the ignition switch to ON. • Push the cruise control ON/OFF button [A]. • Check that the cruise control indicator light (LED) [A] goes •...
  • Page 594 16-70 ELECTRICAL SYSTEM Meter, Gauge • Push and hold the meter unit switch [A] more than two seconds. • Check that the display changes to the ordinary indication. If the display function does not work, replace the meter base and/or ECU. •...
  • Page 595 ELECTRICAL SYSTEM 16-71 Meter, Gauge Gear Position Indication Inspection • Turn the ignition switch to ON in the neutral position. • The N mark [A] appears and the neutral indicator light [B] (LED) goes on in the display. • Set the low gear position, check that the display changes to 1 mark.
  • Page 596: Meter Unit Inspection

    16-72 ELECTRICAL SYSTEM Meter, Gauge Meter Unit Inspection • Remove the meter unit (see Meter Unit Removal). [1] Right Turn Signal Indicator Light (LED) (+) [2] High Beam Indicator Light (LED) (+) [3] Unused [4] Unused [5] Unused [6] CAN Communication Line (High) [7] CAN Communication Line (Low) [8] Unused [9] Left Turn Signal Indicator Light (LED) (+)
  • Page 597 ELECTRICAL SYSTEM 16-73 Meter, Gauge • Check the following items. ○ The needle [A] of the speedometer momentarily points its last reading and back to the minimum position. If the meter unit does not work, replace the meter base (see Meter Unit Disassembly). NOTE ○...
  • Page 598 16-74 ELECTRICAL SYSTEM Meter, Gauge Check 4: High Beam Indicator Light (LED) Inspection • Connect the leads in the same circuit as Check 2. • Connect the terminal [2] to the battery (+) terminal. • Check that the high beam indicator light (LED) [A] goes If the indicator light does not go on, replace the meter base (see Meter Unit Disassembly).
  • Page 599 ELECTRICAL SYSTEM 16-75 Meter, Gauge • Check that the neutral indicator light (LED) [A] goes on. If the indicator light does not go on, replace the meter base (see Meter Unit Disassembly). Check 7: Oil Pressure Warning Symbol Inspection • Connect the leads in the same circuit as Check 2.
  • Page 600 16-76 ELECTRICAL SYSTEM Meter, Gauge Check 9: Fuel Level Warning Inspection • Connect the leads in the same circuit as Check 2. • Connect the variable rheostat [A] (about 213 Ω) to the terminal [10] and the battery (–) terminal. •...
  • Page 601 ELECTRICAL SYSTEM 16-77 Meter, Gauge Check 11: Odometer Inspection • Connect the leads in the same circuit as Check 10. • Set the odometer mode by connecting the terminal [16] to the battery (+) terminal each time. • Raise the input frequency of the oscillator to see the result of odometer inspection.
  • Page 602 16-78 ELECTRICAL SYSTEM Meter, Gauge Meter Unit Circuit 1. Ignition Switch 17. Oil Pressure Switch 2. Meter Unit Switch 18. Fuel Level Sensor 3. Water Temperature Sensor 19. to Turn Signal Switch 4. Gear Position Switch 20. to Dimmer Switch 5.
  • Page 603: Cruise Control System Switches

    ELECTRICAL SYSTEM 16-79 Cruise Control System Switches Cruise Control System Switch Inspection NOTE ○ Refer to the Fuel System (DFI) chapter for the informa- tion of the cruise control system parts. ○ The inspection of cruise control system switches can check by the following the cancel switch inspection mode and the operating of each switch.
  • Page 604 16-80 ELECTRICAL SYSTEM Cruise Control System Switches • Shift the transmission to 1st gear. • While pushing in meter swit