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Table of Contents

   Also See for Kawasaki Z1000

   Summary of Contents for Kawasaki Z1000

  • Page 1 Z1000 Z1000 ABS...
  • 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 Z1000 Z1000 ABS Motorcycle Service Manual 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.
  • Page 6 LIST OF ABBREVIATIONS ampere(s) integrated circuit ABDC after bottom dead center inch(es) antilock brake system km/h kilometers per hour alternating current liter(s) ampere hour liquid crystal display ATDC after top dead center light emitting diode BBDC before bottom dead center pound(s) bottom dead center meter(s)
  • 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

    • the vehicle. 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 GENERAL INFORMATION 1-1 General Information Table of Contents Before Servicing ........................Model Identification......................... General Specifications......................Unit Conversion Table ......................1-12...
  • 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 self-locking nuts 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 ZR1000FE Left Side View ZR1000FE Right Side View Frame Number Engine Number...
  • Page 18 1-8 GENERAL INFORMATION Model Identification ZR1000GE Left Side View ZR1000GE Right Side View...
  • Page 19: General Specifications

    GENERAL INFORMATION 1-9 General Specifications ZR1000FE ∼ FF/GE ∼ GF Items Dimensions Overall Length 2 045 mm (80.51 in.) Overall Width 790 mm (31.10 in.) Overall Height 1 055 mm (41.54 in.) Wheelbase 1 435 mm (56.50 in.) Road Clearance 125 mm (4.92 in.) Seat Height 815 mm (32.09 in.)
  • Page 20 1-10 GENERAL INFORMATION General Specifications ZR1000FE ∼ FF/GE ∼ GF Items Cylinder Numbering Method Left to right, 1-2-3-4 Firing Order 1-2-4-3 Valve Timing: Intake: Open 25° BTDC Close 65° ABDC Duration 270° Exhaust: Open 58° BBDC Close 18° ATDC Duration 256°...
  • Page 21 GENERAL INFORMATION 1-11 General Specifications ZR1000FE ∼ FF/GE ∼ GF Items Rear Tire: Type Tubeless Size 190/50 ZR17 M/C (73W) Rim Size J17M/C × MT6.00 Front Suspension: Type Telescopic fork (upside-down) Wheel Travel 120 mm (4.72 in.) Rear Suspension: Type Swingarm Wheel Travel 122 mm (4.80 in.)
  • Page 22: Unit Conversion Table

    1-12 GENERAL INFORMATION Unit Conversion Table Prefixes for Units: Units of Length: × 0.6214 mile Prefix Symbol Power × 3.281 mega × 1 000 000 × 0.03937 kilo × 1 000 centi × 0.01 Units of Torque: milli × 0.001 N·m ×...
  • Page 23: Table Of Contents

    PERIODIC MAINTENANCE 2-1 Periodic Maintenance Table of Contents Periodic Maintenance Chart ....................Torque and Locking Agent...................... Specifications ......................... 2-11 Special Tools .......................... 2-13 Periodic Maintenance Procedures..................2-14 Fuel System (DFI)........................ 2-14 Air Cleaner Element Replacement..................2-14 Idle Speed Inspection ....................... 2-15 Idle Speed Adjustment......................
  • Page 24 2-2 PERIODIC MAINTENANCE Suspension .......................... 2-54 Suspension System ......................2-54 Steering ..........................2-55 Steering Play Inspection ....................2-55 Steering Play Adjustment....................2-55 Steering Stem Bearing Lubrication ................... 2-57 Electrical System ......................... 2-58 Lights and Switches Operation Inspection................ 2-58 Headlight Aiming Inspection ..................... 2-60 Side Stand Switch Operation Inspection................
  • Page 25: Periodic Maintenance Chart

    PERIODIC MAINTENANCE 2-3 Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition.The initial maintenance is vitally important and must not be neglected. Periodic Inspection *A: Service at number of years shown or indicated odometer reading intervals, whichever comes first.
  • Page 26 2-4 PERIODIC MAINTENANCE Periodic Maintenance Chart Odometer Reading (*B) × 1 000 km (× 1 000 mile) year (*A) Page Items (0.6) (3.8) (7.6) (11.4) (15.2) Wheel bearing damage 2-36 Final Drive Drive chain lubrication condition (*C) 2-37 : every 600 km (400 mile) Drive chain slack (*C) 2-38 : every 1 000 km (600 mile)
  • Page 27: Torque And Locking Agent

    PERIODIC MAINTENANCE 2-5 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. All of the values are for use with dry solvent - cleaned threads unless otherwise indicated.
  • Page 28 2-6 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Cylinder Head Bolts (M10) (Final) S, MO Cylinder Head Jacket Plugs 19.6 2.00 14.5 Cylinder Head Bolts (M6) 106 in·lb Throttle Body Assy Holder Bolts 106 in·lb Throttle Body Assy Holder Clamp Bolts 0.30 26 in·lb...
  • Page 29 PERIODIC MAINTENANCE 2-7 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Lower Engine Mounting Nut Lower Adjusting Collar Locknut Middle Engine Mounting Nut Middle Engine Bracket Bolts L, S Lower Adjusting Collar 87 in·lb Upper Engine Mounting Bolt (L = 40 mm) Crankshaft/Transmission Balancer Shaft Clamp Bolt 87 in·lb...
  • Page 30 2-8 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Front Brake Light Switch Screw 0.12 11 in·lb Front Master Cylinder Clamp Bolts 97 in·lb Brake Hose Banjo Bolts Bleed Valves 0.80 69 in·lb Front Brake Pad Pins Front Caliper Mounting Bolts Front Brake Disc Mounting Bolts L, S...
  • Page 31 PERIODIC MAINTENANCE 2-9 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Upper Fairing Screws 0.12 11 in·lb Front Fender Mounting Bolts 0.40 35 in·lb Rear Frame Bracket Bolts Front Footpeg Bracket Bolts Side Stand Switch Bolt 0.90 78 in·lb Side Stand Bracket Bolts Side Stand Bolt Side Stand Nut...
  • Page 32 2-10 PERIODIC MAINTENANCE Torque and Locking Agent The table below, relating tightening torque to thread diameter, lists the basic torque for the bolts and nuts. Use this table for only the bolts and nuts which do not require a specific torque value. All of the values are for use with dry solvent-cleaned threads.
  • Page 33: Specifications

    PERIODIC MAINTENANCE 2-11 Specifications Item Standard Service Limit Fuel System (DFI) 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Throttle Grip Free Play – – – Idle Speed 1 100 ±50 r/min (rpm) – – – Throttle Body Vacuum 40.7 ±1.3 kPa (305 ±10 mmHg) at idle speed –...
  • Page 34 2-12 PERIODIC MAINTENANCE Specifications Item Standard Service Limit Final Drive 20 ∼ 30 mm (0.8 ∼ 1.2 in.) Drive Chain Slack – – – 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) Drive Chain Wear (20-link 319 mm (12.6 in.) Length) Standard Chain: Make...
  • Page 35: Special Tools

    PERIODIC MAINTENANCE 2-13 Special Tools Inside Circlip Pliers: Attachment Jack: 57001-143 57001-1252 Steering Stem Nut Wrench: Vacuum Gauge: 57001-1100 57001-1369 Jack: Throttle Sensor Setting Adapter: 57001-1238 57001-1538 Pilot Screw Adjuster, A: Extension Tube: 57001-1239 57001-1578 Oil Filter Wrench: Jack Attachment: 57001-1249 57001-1608...
  • Page 36: Periodic Maintenance Procedures

    2-14 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel System (DFI) Air Cleaner Element Replacement NOTE ○ In dusty areas, the element should be replaced more frequently than the recommended interval. WARNING If dirt or dust is allowed to pass through into the throttle body assy, the throttle may become stuck, possibly causing accident.
  • Page 37: Idle Speed Inspection

    PERIODIC MAINTENANCE 2-15 Periodic Maintenance Procedures Idle Speed Inspection • Start the engine and warm it up thoroughly. • With the engine idling, turn the handlebars to both sides [A]. If handlebars movement changes the idle speed, the throttle cables may be improperly adjusted or incorrectly routed, or damaged.
  • Page 38: Engine Vacuum Synchronization Inspection

    2-16 PERIODIC MAINTENANCE Periodic Maintenance Procedures If the free play is incorrect, adjust the throttle cable as follows. • Slide the dust covers. • Loosen the locknuts [A] [B]. • Screw both throttle cable adjusters [C] [D] to give the throttle grip plenty of play.
  • Page 39 PERIODIC MAINTENANCE 2-17 Periodic Maintenance Procedures • Plug the air switching valve hose end [A] and air cleaner housing fitting [B]. • Install the air cleaner housing (see Air Cleaner Housing Installation in the Fuel System (DFI) chapter). • Connect the following parts temporarily. Fuel Pump Lead Connector [A] Extension Tube [B] Special Tool - Extension Tube: 57001-1578...
  • Page 40 2-18 PERIODIC MAINTENANCE Periodic Maintenance Procedures If any vacuum is not within specifications, adjust the by- pass screws [A]. View from Rear [B] Special Tool - Pilot Screw Adjuster, A [C]: 57001-1239 • Adjust the each vacuum (#1 ∼ #4) to the standard value. •...
  • Page 41: Fuel System

    PERIODIC MAINTENANCE 2-19 Periodic Maintenance Procedures • Back out the same number of turns counted when first turned in. This is to set the screw to its original position. NOTE ○ A throttle body has different “turns out” of the bypass screw for each individual unit.
  • Page 42: Fuel Hose Replacement

    2-20 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Check that the fuel hose is routed according to Cable, Wire, and Hose Routing section in the Appendix chapter. Replace the hose if it has been sharply bent or kinked. Hose Joints [A] Fuel Hose [B] •...
  • Page 43 PERIODIC MAINTENANCE 2-21 Periodic Maintenance Procedures • Pull the fuel hose joint [A] out of the delivery pipe [B]. WARNING Fuel is flammable and explosive under certain con- ditions and can cause severe burns. Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately.
  • Page 44: Evaporative Emission Control System Inspection (cal, Sea-b1 And Th Models)

    2-22 PERIODIC MAINTENANCE Periodic Maintenance Procedures Evaporative Emission Control System Inspection (CAL, SEA-B1 and TH Models) • Inspect the canister as follows. ○ Remove the front seat (see Front Seat Removal in the Frame chapter). ○ Pull the canister [A] out of the rear fender. ○...
  • Page 45: Cooling System

    PERIODIC MAINTENANCE 2-23 Periodic Maintenance Procedures Cooling System Water Hose and Pipe Inspection (coolant leak, damage, installation condition) ○ The high pressure inside the water hose can cause coolant to leak [A] or the hose to burst if the line is not properly maintained.
  • Page 46 2-24 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Remove: Lower Rear Shock Absorber Nut and Bolt [A] (see Rear Shock Absorber Removal in the Suspension chapter) • Remove: Coolant Reserve Tank Bolts [A] Collars • Pull up the coolant reserve tank [A]. •...
  • Page 47 PERIODIC MAINTENANCE 2-25 Periodic Maintenance Procedures • Fill the radiator up to the filler neck [A] with coolant. NOTE ○ Pour in the coolant slowly so that it can expel the air from the engine and radiator. • Check the cooling system for leaks. •...
  • Page 48: Water Hose And O-ring Replacement

    2-26 PERIODIC MAINTENANCE Periodic Maintenance Procedures Water Hose and O-ring Replacement • Drain the coolant (see Coolant Change). • Remove: Middle Fairing (see Middle Fairing Removal in the Frame chapter) Oil Cooler [A] (see Oil Cooler Removal in the Engine Lubrication System chapter) Thermostat Housing Cover [B] (see Thermostat Re- moval in the Cooling System chapter)
  • Page 49: Engine Top End

    PERIODIC MAINTENANCE 2-27 Periodic Maintenance Procedures Engine Top End Valve Clearance Inspection NOTE ○ Valve clearance must be checked and adjusted when the engine is cold (at room temperature). • Remove: Cylinder Head Cover (see Cylinder Head Cover Re- moval in the Engine Top End chapter) Crankshaft Sensor Cover (see Crankshaft Sensor Re- moval in the Electrical System chapter) •...
  • Page 50: Valve Clearance Adjustment

    2-28 PERIODIC MAINTENANCE Periodic Maintenance Procedures ○ When positioning #1 piston TDC at the end of the compression stroke: Intake Valve Clearance of #1 and #3 Cylinders Exhaust Valve Clearance of #1 and #2 Cylinders Measuring Valve [A] ○ When positioning #4 piston TDC at the end of the compression stroke: Intake Valve Clearance of #2 and #4 Cylinders Exhaust Valve Clearance of #3 and #4 Cylinders...
  • Page 51 PERIODIC MAINTENANCE 2-29 Periodic Maintenance Procedures ○ Besides the standard shims in the valve clearance adjust- ment charts, the following shims may be installed at the factory. Although they are not available as spare parts, they can be used to adjust valve clearance. Adjustment Shims Thickness 2.675 mm...
  • Page 52 2-30 PERIODIC MAINTENANCE Periodic Maintenance Procedures VALVE CLEARANCE ADJUSTMENT CHART INTAKE VALVE 1. Measure the clearance (when engine is cold). 2. Check present shim size. 3. Match clearance in vertical column with present shim size in horizontal column. 4. Install the shim specified where the lines intersect. This shim will give the proper clearance. Example: Present shim is 2.95 mm Measured clearance is 0.45 mm...
  • Page 53 PERIODIC MAINTENANCE 2-31 Periodic Maintenance Procedures VALVE CLEARANCE ADJUSTMENT CHART EXHAUST VALVE 1. Measure the clearance (when engine is cold). 2. Check present shim size. 3. Match clearance in vertical column with present shim size in horizontal column. 4. Install the shim specified where the lines intersect. This shim will give the proper clearance. Example: Present shim is 2.95 mm.
  • Page 54: Air Suction System Damage Inspection

    2-32 PERIODIC MAINTENANCE Periodic Maintenance Procedures NOTICE Be sure to remeasure the clearance after selecting a shim according to the table. If the clearance is out of the specified range, use the additional shim. ○ If there is no valve clearance, use a shim that is a few sizes smaller, and remeasure the valve clearance.
  • Page 55: Clutch

    PERIODIC MAINTENANCE 2-33 Periodic Maintenance Procedures Clutch Clutch Operation Inspection • Pull the clutch lever just enough to take up the free play [A]. • Measure the gap between the lever and the lever holder. If the gap is too wide, the clutch may not release fully. If the gap is too narrow, the clutch may not engage fully.
  • Page 56: Engine Lubrication System

    2-34 PERIODIC MAINTENANCE Periodic Maintenance Procedures Engine Lubrication System Engine Oil Change • Situate the motorcycle so that it is vertical after warming up the engine. • Remove the engine oil drain bolt [A] to drain the oil. ○ The oil in the oil filter can be drained by removing the filter (see Oil Filter Replacement).
  • Page 57: Oil Filter Replacement

    PERIODIC MAINTENANCE 2-35 Periodic Maintenance Procedures Oil Filter Replacement • Drain the engine oil (see Engine Oil Change). • Remove the oil filter with the oil filter wrench [A]. Special Tool - Oil Filter Wrench: 57001-1249 • Replace the filter with a new one. •...
  • Page 58: Wheel Bearing Damage Inspection

    2-36 PERIODIC MAINTENANCE Periodic Maintenance Procedures Tire Tread Wear Inspection As the tire tread wears down, the tire becomes more sus- ceptible to puncture and failure. An accepted estimate is that 90% of all tire failures occur during the last 10% of tread life (90% worn).
  • Page 59: Final Drive

    PERIODIC MAINTENANCE 2-37 Periodic Maintenance Procedures • Raise the rear wheel off the ground with the stand (see Rear Wheel Removal in the Wheels/Tires chapter). • Inspect the roughness of the rear wheel bearing by push- ing and pulling [A] the wheel. •...
  • Page 60: Drive Chain Slack Inspection

    2-38 PERIODIC MAINTENANCE Periodic Maintenance Procedures Drive Chain Slack Inspection NOTE ○ Check the slack with the motorcycle setting on its side stand. ○ Clean the chain if it is dirty, and lubricate it if it appears dry. • Check the wheel alignment (see Wheel Alignment Inspec- tion).
  • Page 61: Wheel Alignment Adjustment

    PERIODIC MAINTENANCE 2-39 Periodic Maintenance Procedures Wheel Alignment Adjustment • Remove the right retaining ring [A]. • Loosen the axle nut [B]. • Loosen the right chain adjuster clamp bolt [C], and turn the right chain adjuster [D] so that the left and right notches on the swingarm may point to the same marks or positions on the left and right adjusters.
  • Page 62: Chain Guide Wear Inspection

    2-40 PERIODIC MAINTENANCE Periodic Maintenance Procedures Chain Guide Wear Inspection • Remove the swingarm (see Swingarm Removal in the Suspension chapter). • Visually inspect the chain guide [A]. Replace the chain guide if it shows any signs of abnormal wear or damage. Brakes Brake System Brake Fluid Leak (Brake Hose and Pipe) Inspection...
  • Page 63: Brake Operation Inspection

    PERIODIC MAINTENANCE 2-41 Periodic Maintenance Procedures Brake Hose and Pipe Damage and Installation Condi- tion Inspection • For ABS equipped models, remove the air cleaner hous- ing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter). • Inspect the brake hoses, pipe and fittings for deteriora- tion, cracks and signs of leakage.
  • Page 64: Brake Fluid Change

    2-42 PERIODIC MAINTENANCE 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]. ○...
  • Page 65 PERIODIC MAINTENANCE 2-43 Periodic Maintenance Procedures • Change the brake fluid. ○ Repeat this operation until fresh brake fluid comes out from the plastic hose or the color of the fluid changes. 1. Open the bleed valve [A]. 2. Apply the brake and hold it [B]. 3.
  • Page 66: Brake Hose And Pipe Replacement

    2-44 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Hose and Pipe Replacement NOTICE Brake fluid quickly ruins painted plastic surfaces; any spilled fluid should be completely washed away immediately. • Remove: Upper Fairing Cover (see Upper Fairing Removal in the Frame chapter) Brake Hose Fitting Bolt [A] Brake Hose Banjo Bolts [B] Bolts [C]...
  • Page 67 PERIODIC MAINTENANCE 2-45 Periodic Maintenance Procedures This page intentionally left blank.
  • Page 68 2-46 PERIODIC MAINTENANCE Periodic Maintenance Procedures • For ABS equipped models; note the following. NOTE ○ When removing the brake pipes and hoses on the hy- draulic unit, remove them with the flare nut wrench ac- cording to each assembly of the exploded view in the Brakes chapter.
  • Page 69 PERIODIC MAINTENANCE 2-47 Periodic Maintenance Procedures...
  • Page 70: Master Cylinder Rubber Parts Replacement

    2-48 PERIODIC MAINTENANCE Periodic Maintenance Procedures Master Cylinder Rubber Parts Replacement Front Master Cylinder Disassembly • Remove the front master cylinder (see Front Master Cylin- der Removal in the Brakes chapter). • Remove: Front Brake Reservoir Cap Bolts [A] Reservoir Cap [B] Diaphragm Plate [C] Diaphragm [D] Float [E]...
  • Page 71: Caliper Rubber Parts Replacement

    PERIODIC MAINTENANCE 2-49 Periodic Maintenance Procedures Master Cylinder Assembly • Before assembly, clean all parts including the master cylinder with brake fluid or alcohol. NOTICE Except for the disc pads and disc, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol for cleaning brake parts.
  • Page 72 2-50 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Hold the pistons nearest the oil passage [A] with the bands [B]. • Using compressed air, remove the pistons. ○ Cover the caliper opening with a clean heavy cloth [A]. ○ Lightly apply compressed air [B] to the oil passage. WARNING The piston in the brake caliper can crush hands and fingers.
  • Page 73 PERIODIC MAINTENANCE 2-51 Periodic Maintenance Procedures • Apply brake fluid to the outside of the pistons, and push them into each cylinder by hand. • Install the removed parts (see appropriate chapters). • Wipe up any spilled brake fluid on the caliper with wet cloth.
  • Page 74: Brake Pad Wear Inspection

    2-52 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Replace the fluid seal [A] with a new one. ○ Apply silicone grease to the fluid seal, and install it into the cylinder by hand. • Replace the dust seal [B] with a new one. ○...
  • Page 75: Brake Light Switch Operation Inspection

    PERIODIC MAINTENANCE 2-53 Periodic Maintenance Procedures Brake Light Switch Operation Inspection • Turn the ignition switch on. • The brake light (LED) [A] should go on when the brake lever is applied or after the brake pedal is depressed about 10 mm (0.39 in.). If it does not, adjust the brake light switch.
  • Page 76: Suspension

    2-54 PERIODIC MAINTENANCE Periodic Maintenance Procedures Suspension Suspension System Front Forks/Rear Shock Absorber Operation Inspec- tion • Pump the forks down and up [A] 4 or 5 times, and inspect the smooth stroke. If the forks do not smoothly or noise is found, inspect the fork oil level or fork clamps (see Front Fork Oil Change in the Suspension chapter).
  • Page 77: Steering

    PERIODIC MAINTENANCE 2-55 Periodic Maintenance Procedures Tie-Rod Operation Inspection • Pump the seat down and up 4 or 5 times, and inspect the smooth stroke. If the tie-rod [A] do not smoothly stroke or noise is found, inspect the fasteners and tie-rod bearings (see Rocker Arm/Tie-Rod Bearing, Sleeve Inspection in the Suspen- sion chapter).
  • Page 78 2-56 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Bend the claws [A] of the claw washer straighten. • Remove: Steering Stem Locknut [B] Claw Washer • 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 79: Steering Stem Bearing Lubrication

    PERIODIC MAINTENANCE 2-57 Periodic Maintenance Procedures Steering Stem Bearing Lubrication • Remove the steering stem (see Stem, Stem Bearing Re- moval in the Steering chapter). • Using a high flash-point solvent, wash the upper and lower ball bearings [A] 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 80: Electrical System

    2-58 PERIODIC MAINTENANCE Periodic Maintenance Procedures Electrical System Lights and Switches Operation Inspection First Step • Set the gear position in the neutral position. • Turn the ignition switch on. • The following lights should go on according to below table. City Light (LED) [A] Goes on Taillight (LED) [B]...
  • Page 81 PERIODIC MAINTENANCE 2-59 Periodic Maintenance Procedures • Turn the ignition switch off. • The all lights should go off. ○ For models equipped with an immobilizer system, red warning indicator (LED) will blinks. Refer to the Immobi- lizer System (Equipped Models) section in the Electrical System chapter).
  • Page 82: Headlight Aiming Inspection

    2-60 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fourth Step • Set the dimmer switch [A] to low beam position. • Start the engine. • The low beam headlights should go on. If the low beam headlights do not go on, inspect or replace the following parts.
  • Page 83: Side Stand Switch Operation Inspection

    PERIODIC MAINTENANCE 2-61 Periodic Maintenance Procedures Headlight Beam Horizontal Adjustment • Turn the horizontal adjuster [A] in both headlights in or out until the beam points straight ahead. If the headlight beam points too low or high, adjust the vertical beam. Headlight Beam Vertical Adjustment •...
  • Page 84: Engine Stop Switch Operation Inspection

    2-62 PERIODIC MAINTENANCE Periodic Maintenance Procedures If the side stand switch operation does not work, inspect or replace the following parts. Battery (see Charging Condition Inspection in the Elec- trical System chapter) Main Fuse 30 A (see Fuse Inspection in the Electrical System chapter) Ignition Fuse 15 A (see Fuse Inspection in the Electrical System chapter)
  • Page 85: Spark Plug Replacement

    PERIODIC MAINTENANCE 2-63 Periodic Maintenance Procedures Spark Plug Replacement • Remove the stick coils (see Stick Coil Removal in the Electrical System chapter). • Remove the spark plugs using the 16 mm (0.63 in.) plug wrench [A] vertically. • Replace the spark plugs with new ones. Standard Spark Plug Type: NGK CR9EIA-9...
  • Page 86: Condition Of Bolts, Nuts And Fasteners Tightness Inspection

    2-64 PERIODIC MAINTENANCE Periodic Maintenance Procedures Cables: Lubricate with Rust Inhibitor. Clutch Cable Throttle Cables • Lubricate the cables by seeping the oil between the cable and housing. ○ The cable may be lubricated by using a commercially available pressure cable lubricator with an aerosol cable lubricant.
  • Page 87 PERIODIC MAINTENANCE 2-65 Periodic Maintenance Procedures Bolt, Nut and Fastener to be checked Engine: Clutch Lever Pivot Bolt Locknut Engine Mounting Bolts and Nuts Exhaust Pipe Holder Nuts Muffler Body Clamp Bolts Muffler Body Mounting Bolts and Nuts Premuffler Chamber Mounting Bolt Radiator Bolts Wheels: Front Axle Clamp Bolts...
  • Page 89 FUEL SYSTEM (DFI) 3-1 Fuel System (DFI) Table of Contents Exploded View........................DFI System..........................3-10 DFI Parts Location........................3-20 Specifications ......................... 3-23 Special Tools and Sealant ...................... 3-25 DFI Servicing Precautions ...................... 3-27 DFI Servicing Precautions ....................3-27 Troubleshooting the DFI System .................... 3-29 Outline ..........................
  • Page 90 3-2 FUEL SYSTEM (DFI) Vehicle-down Sensor Installation ..................3-74 Vehicle-down Sensor Input Voltage Inspection..............3-74 Vehicle-down Sensor Output Voltage Inspection .............. 3-75 Subthrottle Sensor (Service Code 32)..................3-78 Subthrottle Sensor Removal/Adjustment ................3-78 Subthrottle Sensor Input Voltage Inspection..............3-78 Subthrottle Sensor Output Voltage Inspection ..............3-79 Subthrottle Sensor Resistance Inspection ................
  • Page 91 FUEL SYSTEM (DFI) 3-3 ECU Removal ........................3-109 ECU Installation ........................ 3-110 ECU Power Supply Inspection..................3-110 DFI Power Source ........................3-113 ECU Fuse Removal ......................3-113 ECU Fuse Installation ....................... 3-113 ECU Fuse Inspection ......................3-113 ECU Main Relay Removal/Installation ................3-113 ECU Main Relay Inspection ....................
  • Page 92: Exploded View

    3-4 FUEL SYSTEM (DFI) Exploded View...
  • Page 93 FUEL SYSTEM (DFI) 3-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Throttle Body Assy Holder Clamp Bolts 0.30 26 in·lb Delivery Pipe Assy Mounting Screws 3.43 0.35 30 in·lb Air Cleaner Housing Assembly Screws 0.11 10 in·lb Air Cleaner Housing Plate Screws 0.11 10 in·lb Throttle Case Bolts...
  • Page 94 3-6 FUEL SYSTEM (DFI) Exploded View...
  • Page 95 FUEL SYSTEM (DFI) 3-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Oxygen Sensor (Equipped Models) Water Temperature Sensor 106 in·lb Exhaust Butterfly Valve Actuator Pulley Bolt 0.51 44 in·lb Exhaust Butterfly Valve Actuator Mounting 0.12 11 in·lb Screws Vehicle-down Sensor Mounting Bolts 0.60 52 in·lb Crankshaft Sensor Bolts...
  • Page 96 3-8 FUEL SYSTEM (DFI) Exploded View...
  • Page 97 FUEL SYSTEM (DFI) 3-9 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Fuel Pump Bolts 87 in·lb L, S 2. Purge Valve 3. Canister 4. Other than CAL, SEA-B1 and TH Models 5. CAL, SEA-B1 and TH Models L: Apply a non-permanent locking agent. R: Replacement Parts S: Follow the specified tightening sequence.
  • Page 98: Dfi System

    3-10 FUEL SYSTEM (DFI) DFI System DFI System...
  • Page 99 FUEL SYSTEM (DFI) 3-11 DFI System 1. ECU 2. Battery 12 V 10 Ah 3. Vehicle-down Sensor 4. Pressure Regulator 5. Fuel Pump 6. Fuel Filter 7. Intake Air Temperature Sensor 8. Delivery Pipe Assy 9. Fuel Injectors 10. Wheel Rotation Sensors 11.
  • Page 100 3-12 FUEL SYSTEM (DFI) DFI System DFI System Wiring Diagram...
  • Page 101 DFI System Part Names 1. ECU 2. Rear Wheel Rotation Sensor 3. Joint Connector E 4. Immobilizer (Equipped Models)/Kawasaki Diagnostic System Connector 5. Exhaust Butterfly Valve Actuator 6. Fuel Pump 7. Frame Ground 4 8. Frame Ground 2 9. Frame Ground 1 10.
  • Page 102 3-14 FUEL SYSTEM (DFI) DFI System DFI System Wiring Diagram (ABS Equipped Models)
  • Page 103 DFI System Part Names 1. ECU 2. Rear Wheel Rotation Sensor 3. Joint Connector E 4. Immobilizer (Equipped Models)/Kawasaki Diagnostic System Connector 5. Exhaust Butterfly Valve Actuator 6. Fuel Pump 7. ABS Hydraulic Unit 8. Frame Ground 5 9. Frame Ground 2 10.
  • Page 104 3-16 FUEL SYSTEM (DFI) DFI System ○ Color Codes: BK: Black GY: Gray PU: Purple BL: Blue LB: Light Blue R: Red BR: Brown V: Violet LG: Light Green CH: Chocolate O: Orange W: White DG: Dark Green P: Pink Y: Yellow G: Green...
  • Page 105 FUEL SYSTEM (DFI) 3-17 DFI System This page intentionally left blank.
  • Page 106 3-18 FUEL SYSTEM (DFI) DFI System Terminal Numbers of ECU Connectors Terminal Names 1. Subthrottle Valve Actuator: P/BL 2. Exhaust Butterfly Valve Actuator (–): W/R 3. Unused 4. Power Supply to Sensors: BL 5. Fuel Pump Relay: BR/Y 6. Power Supply to ECU (from Battery): BR/W 7.
  • Page 107 60. External Communication Line (Immobilizer System (Equipped Models)/*KDS): GY/BL 61. Meter Unit (Tachometer): LB 62. Radiator Fan Relay: Y/BL 63. Air Switching Valve: R/BL 64. Oxygen Sensor Heater (Equipped Models): P/BK 65. Ground for Ignition System: BK/Y 66. Stick Coil #3: BK/O *: KDS (Kawasaki Diagnostic System)
  • Page 108: Dfi Parts Location

    3-20 FUEL SYSTEM (DFI) DFI Parts Location Main Throttle Sensor [A] Subthrottle Sensor [B] Subthrottle Valve Actuator [C] Intake Air Pressure Sensor #2 [D] Stick Coils #1, #2, #3, #4 [E] Intake Air Pressure Sensor #1 [F] Fuel Injectors #1, #2, #3, #4 [G] Air Switching Valve [A] Water Temperature Sensor [A] Intake Air Temperature Sensor [A]...
  • Page 109 Main Fuse 30 A [A] ECU Fuse 15 A [B] ECU [A] Relay Box [B] (ECU Main Relay, Fuel Pump Relay, Ra- diator Fan Relay) Immobilizer (Equipped Models)/Kawasaki Diagnostic System Connector [C] Fuel Pump [A] Ignition Key [A] (Transponder, Immobilizer System Equipped Models)
  • Page 110 3-22 FUEL SYSTEM (DFI) DFI Parts Location Immobilizer Amplifier [A] (Equipped Models) Front Wheel Rotation Sensor [A] (ABS Equipped Mod- els) Rear Wheel Rotation Sensor [A] Purge Valve [A] (CAL, SEA-B1 and TH Models)
  • Page 111: Specifications

    FUEL SYSTEM (DFI) 3-23 Specifications Item Standard Digital Fuel Injection System Idle Speed 1 100 ±50 r/min (rpm) Throttle Body Assy: Throttle Valve Dual throttle valve Bore 38 mm (1.42 in.) Throttle Body Vacuum 40.7 ±1.3 kPa (305 ±10 mmHg) Bypass Screws (Turn Out) 2 1/2 (for reference) ECU:...
  • Page 112 3-24 FUEL SYSTEM (DFI) Specifications Item Standard Subthrottle Sensor: DC 4.75 ∼ 5.25 V Input Voltage DC 1.08 ∼ 1.12 V at subthrottle valve full close Output Voltage position DC 4.2 ∼ 4.4 V at subthrottle valve full open position (for reference) 4 ∼...
  • Page 113: Special Tools And Sealant

    FUEL SYSTEM (DFI) 3-25 Special Tools and Sealant Oil Pressure Gauge, 5 kgf/cm²: Peak Voltage Adapter: 57001-125 57001-1415 Carburetor Drain Plug Wrench, Hex 3: Needle Adapter Set: 57001-1269 57001-1457 Fork Oil Level Gauge: Throttle Sensor Setting Adapter: 57001-1290 57001-1538 Vacuum Gauge: Extension Tube: 57001-1369 57001-1578...
  • Page 114 3-26 FUEL SYSTEM (DFI) Special Tools and Sealant Fuel Hose: Liquid Gasket, TB1211: 57001-1607 56019-120 Measuring Adapter: 57001-1700...
  • Page 115: Dfi Servicing Precautions

    FUEL SYSTEM (DFI) 3-27 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 116 3-28 FUEL SYSTEM (DFI) 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 117: Troubleshooting The Dfi System

    FUEL SYSTEM (DFI) 3-29 Troubleshooting the DFI System Outline When a problem occurs with DFI system, the yellow en- gine warning indicator (LED) [A] goes on to alert the rider. For models equipped with an immobilizer system, the red warning indicator (LED) [A] and immobilizer warning indica- tor [B] blink, when a problem occurs in the system.
  • Page 118 (LED) goes off. But the service codes stored in memory of the ECU are not erased to preserve the prob- lem 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 injectors and ignition system.
  • Page 119 FUEL SYSTEM (DFI) 3-31 Troubleshooting the DFI System • When checking the DFI parts, use a digital meter which can be read two decimal place voltage or resistance. ○ The DFI part connectors [A] have seals [B], including the ECU. When measuring the input or output voltage with the connector joined, use the needle adapter set [C].
  • Page 120 3-32 FUEL SYSTEM (DFI) Troubleshooting the DFI System • Pull each connector [A] apart and inspect it for corrosion, dirt, and damage. If the connector is corroded or dirty, clean it carefully. If it is damaged, replace it. Connect the connectors securely. •...
  • Page 121: Inquiries To Rider

    FUEL SYSTEM (DFI) 3-33 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 122 3-34 FUEL SYSTEM (DFI) 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 123 FUEL SYSTEM (DFI) 3-35 Troubleshooting the DFI System □ □ □ Poor running very low idle speed, very high idle speed, rough idle speed. at low speed □ battery voltage is low (charge the battery). □ spark plug loose (tighten it). □...
  • Page 124: Dfi System Troubleshooting Guide

    3-36 FUEL SYSTEM (DFI) 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 125 FUEL SYSTEM (DFI) 3-37 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Fuel pressure regulator trouble Inspect fuel pressure and replace fuel pump (see chapter 3). Fuel line clogged Inspect and repair (see chapter 3). Intake air pressure sensor #1 trouble Inspect (see chapter 3).
  • Page 126 3-38 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Subthrottle sensor trouble Inspect (see chapter 3). Subthrottle valve actuator trouble Inspect (see chapter 3). Intake air pressure sensor #1 trouble Inspect (see chapter 3). Intake air pressure sensor #2 trouble Inspect (see chapter 3).
  • Page 127: Poor Running Or No Power At High Speed

    FUEL SYSTEM (DFI) 3-39 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Other: Intermittent any DFI fault and its recovery Check that DFI connectors are clean and tight, and examine leads for signs of burning or fraying (see chapter 3). Poor Running or No Power at High Speed Symptoms or Possible Causes Actions (chapter)
  • Page 128 3-40 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Intake air temperature sensor trouble Inspect (see chapter 3). Miscellaneous: Subthrottle sensor trouble Inspect (see chapter 3). Subthrottle valve actuator trouble Inspect (see chapter 3). Throttle valves will not fully open Inspect throttle cables and lever linkage (see chapter 3).
  • Page 129: Self-diagnosis

    FUEL SYSTEM (DFI) 3-41 Self-Diagnosis Self-Diagnosis Outline The self-diagnosis system is monitoring the following mechanisms. DFI System and Ignition System Immobilizer System (Equipped Models) The following indicators (LED) are used for warning indi- cators of below table. LED Color Warning Indicators Oil Pressure Battery Red [A]...
  • Page 130: Self-diagnosis Procedures

    3-42 FUEL SYSTEM (DFI) Self-Diagnosis Self-Diagnosis Procedures NOTE ○ Use a fully charged battery when conducting self-diagnosis. Otherwise, the warning indicator (LED) and indicator do not light or blink. • Turn the ignition switch on. ○ When a problem occurs with DFI system and ignition sys- tem, the yellow engine warning indicator (LED) [A] goes on to alert the rider.
  • Page 131 FUEL SYSTEM (DFI) 3-43 Self-Diagnosis • Any of the following procedures ends self-diagnosis. ○ When the service code is displayed on the LCD, push the upper button for more than two seconds. The display will return to the previous display. ○...
  • Page 132: Service Code Reading

    When repair has been done, yellow engine warning indicator (LED) or red warning indicator (LED) and immobilizer warning indicator go off and service code is not displayed. The service codes stored in memory of the ECU can be erased using Kawasaki Diagnostic System (KDS Ver.3).
  • Page 133: Backups

    FUEL SYSTEM (DFI) 3-45 Self-Diagnosis Service System Problems Code Immobilizer Immobilizer amplifier malfunction (Equipped Models) Immobilizer Blank key detection (Equipped Models) ECU communication error Stick coil #1 malfunction, wiring open or short Stick coil #2 malfunction, wiring open or short Stick coil #3 malfunction, wiring open or short Stick coil #4 malfunction, wiring open or short Radiator fan relay malfunction, wiring open or short...
  • Page 134 3-46 FUEL SYSTEM (DFI) Self-Diagnosis Service Parts or Output Signal Usable Backups by ECU Codes Function Range or Criteria Crankshaft sensor must Crankshaft If the crankshaft sensor fails, the engine stops send 22 signals to the ECU Sensor by itself. at the 1 cranking.
  • Page 135 FUEL SYSTEM (DFI) 3-47 Self-Diagnosis Service Parts or Output Signal Usable Backups by ECU Function Codes Range or Criteria The ECU sends If the stick coil #2 primary winding has failures signals (output voltage) (no signal, wiring short or open), the ECU Stick Coil #2* continuously to the stick shuts off the injector #2 to stop fuel to the...
  • Page 136: Main Throttle Sensor (service Code 11)

    3-48 FUEL SYSTEM (DFI) Main Throttle Sensor (Service Code 11) The main throttle sensor is a rotating variable resistor that change output voltage according to throttle operating. The ECU senses this voltage change and determines fuel injec- tion quantity, and ignition timing according to engine rpm, and throttle opening.
  • Page 137: Main Throttle Sensor Resistance Inspection

    FUEL SYSTEM (DFI) 3-49 Main Throttle Sensor (Service Code 11) If the reading is out of the standard, remove the ECU and check the wiring for continuity between main harness connectors. ○ Disconnect the ECU and sensor connectors. Wiring Continuity Inspection ECU Connector [A] ←→...
  • Page 138 3-50 FUEL SYSTEM (DFI) Main Throttle Sensor (Service Code 11) • Turn the ignition switch off. • Measure the output voltage with the engine stopped and with the connector joined. • Turn the ignition switch on. Output Voltage DC 1.02 ∼ 1.06 V at idle throttle opening Standard: DC 4.22 ∼...
  • Page 139 FUEL SYSTEM (DFI) 3-51 Main Throttle Sensor (Service Code 11) Main Throttle Sensor Circuit 1. Main Throttle Sensor 2. Subthrottle Sensor 3. ECU...
  • Page 140: Intake Air Pressure Sensor #1 (service Code 12)

    3-52 FUEL SYSTEM (DFI) Intake Air Pressure Sensor #1 (Service Code 12) Intake Air Pressure Sensor #1 Removal NOTICE Never drop the intake air pressure sensor #1 espe- cially on a hard surface. Such a shock to the sensor can damage it. •...
  • Page 141: Intake Air Pressure Sensor #1 Input Voltage Inspection

    FUEL SYSTEM (DFI) 3-53 Intake Air Pressure Sensor #1 (Service Code 12) Intake Air Pressure Sensor #1 Input Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch off. • Remove the air cleaner housing (see Air Cleaner Housing Removal).
  • Page 142: Intake Air Pressure Sensor #1 Output Voltage Inspection

    3-54 FUEL SYSTEM (DFI) Intake Air Pressure Sensor #1 (Service Code 12) Intake Air Pressure Sensor #1 Output Voltage Inspection • Measure the output voltage at the intake air pressure sen- sor #1 in the same way as input voltage inspection, note the following.
  • Page 143 FUEL SYSTEM (DFI) 3-55 Intake Air Pressure Sensor #1 (Service Code 12) If the wiring is good, check the sensor for various vacuum. • Remove the intake air pressure sensor #1 [A] and discon- nect the vacuum hose from the sensor. •...
  • Page 144 3-56 FUEL SYSTEM (DFI) Intake Air Pressure Sensor #1 (Service Code 12) ID: Idling Ps: Standard Atmospheric Pressure (Absolute) Pv: Throttle Vacuum Pressure (Absolute) ST: Standard of Sensor Output Voltage (V) TO: Throttle Full Open UR: Usable Range of Sensor Output Voltage (V) Vv: Intake Air Pressure Sensor #1 Output Voltage (V) (Digital Meter Reading)
  • Page 145 FUEL SYSTEM (DFI) 3-57 Intake Air Pressure Sensor #1 (Service Code 12) Intake Air Pressure Sensor #1 Circuit 1. Intake Air Pressure Sensor #2 2. Intake Air Pressure Sensor #1 3. ECU...
  • Page 146: Intake Air Temperature Sensor (service Code 13)

    3-58 FUEL SYSTEM (DFI) Intake Air Temperature Sensor (Service Code 13) Intake Air Temperature Sensor Removal/Instal- lation NOTICE Never drop the intake air temperature sensor espe- cially on a hard surface. Such a shock to the sensor can damage it. •...
  • Page 147: Intake Air Temperature Sensor Resistance Inspection

    FUEL SYSTEM (DFI) 3-59 Intake Air Temperature Sensor (Service Code 13) • Turn the ignition switch off. If the reading is within the standard, check the ECU for its ground, and power supply (see ECU Power Supply Inspection). If the ground and power supply are good, replace the ECU (see ECU Removal/Installation).
  • Page 148 3-60 FUEL SYSTEM (DFI) Intake Air Temperature Sensor (Service Code 13) Intake Air Temperature Sensor Circuit 1. Intake Air Temperature Sensor 2. ECU...
  • Page 149: Water Temperature Sensor (service Code 14)

    FUEL SYSTEM (DFI) 3-61 Water Temperature Sensor (Service Code 14) Water Temperature Sensor Removal/Installation NOTICE Never drop the water temperature sensor especially on a hard surface. Such a shock to the sensor can damage it. • Drain the coolant (see Coolant Change in the Periodic Maintenance chapter).
  • Page 150: Water Temperature Sensor Resistance Inspection

    3-62 FUEL SYSTEM (DFI) Water Temperature Sensor (Service Code 14) If the reading is out of the standard, remove the ECU and check the wiring for continuity between main and sub harness connectors. ○ Disconnect the ECU and sensor connectors. Wiring Continuity Inspection ECU Connector [A] ←→...
  • Page 151: Intake Air Pressure Sensor #2 (service Code 16)

    FUEL SYSTEM (DFI) 3-63 Intake Air Pressure Sensor #2 (Service Code 16) Intake Air Pressure Sensor #2 Removal NOTICE Never drop the intake air pressure sensor #2 espe- cially on a hard surface. Such a shock to the sensor can damage it. •...
  • Page 152: Intake Air Pressure Sensor #2 Input Voltage Inspection

    3-64 FUEL SYSTEM (DFI) Intake Air Pressure Sensor #2 (Service Code 16) Intake Air Pressure Sensor #2 Input Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch off. • Remove the air cleaner housing (see Air Cleaner Housing Removal).
  • Page 153: Intake Air Pressure Sensor #2 Output Voltage Inspection

    FUEL SYSTEM (DFI) 3-65 Intake Air Pressure Sensor #2 (Service Code 16) Intake Air Pressure Sensor #2 Output Voltage Inspection • Measure the output voltage at the intake air pressure sen- sor #2 in the same way as input voltage inspection, note the following.
  • Page 154 3-66 FUEL SYSTEM (DFI) Intake Air Pressure Sensor #2 (Service Code 16) Intake Air Pressure Sensor #2 Circuit 1. Intake Air Pressure Sensor #2 2. Intake Air Pressure Sensor #1 3. ECU...
  • Page 155: Crankshaft Sensor (service Code 21)

    FUEL SYSTEM (DFI) 3-67 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 156: Rear Wheel Rotation Sensor Signal (service Code 24, 25)

    3-68 FUEL SYSTEM (DFI) Rear Wheel Rotation Sensor Signal (Service Code 24, 25) Rear Wheel Rotation Sensor Signal Inspection ○ The rear wheel rotation sensor sends the signal to the ECU through the ABS hydraulic unit (ABS equipped mod- els). For other than ABS equipped models, the signal is sent directly to the ECU.
  • Page 157 FUEL SYSTEM (DFI) 3-69 Rear Wheel Rotation Sensor Signal (Service Code 24, 25) If the wiring is good, check the ECU for its ground and power supply (see ECU Power Supply Inspection in the Fuel System (DFI) chapter). If the ground and power supply are good, replace the ECU (see ECU Removal/Installation in the Fuel System (DFI) chapter).
  • Page 158 3-70 FUEL SYSTEM (DFI) Rear Wheel Rotation Sensor Signal (Service Code 24, 25) Wheel Rotation Sensor Circuit (other than ABS Equipped Models) 1. ECU 2. Rear Wheel Rotation Sensor...
  • Page 159: Front Wheel Rotation Sensor Signal (service Code 27, Abs Equipped Models)

    FUEL SYSTEM (DFI) 3-71 Front Wheel Rotation Sensor Signal (Service Code 27, ABS Equipped Models) Front Wheel Rotation Sensor Signal Inspection ○ The front wheel rotation sensor sends the signal to the ECU through the ABS hydraulic unit. ○ The service code 27 is detected with the ECU. •...
  • Page 160 3-72 FUEL SYSTEM (DFI) Front Wheel Rotation Sensor Signal (Service Code 27, ABS Equipped Models) Wheel Rotation Sensor Circuit 1. Front Wheel Rotation Sensor 2. Rear Wheel Rotation Sensor 3. ECU 4. ABS Hydraulic Unit...
  • Page 161: Vehicle-down Sensor (service Code 31)

    FUEL SYSTEM (DFI) 3-73 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 162: Vehicle-down Sensor Installation

    3-74 FUEL SYSTEM (DFI) Vehicle-down Sensor (Service Code 31) Vehicle-down Sensor Installation • Be sure to install the rubber dampers [A] and collars [B] on the battery case. • The UP mark [A] of the sensor should face upward. WARNING Incorrect installation of the vehicle-down sensor could cause sudden loss of engine power.
  • Page 163: Vehicle-down Sensor Output Voltage Inspection

    FUEL SYSTEM (DFI) 3-75 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. ○ Disconnect the ECU and sensor connectors. Wiring Continuity Inspection ECU Connector [A] ←→...
  • Page 164 3-76 FUEL SYSTEM (DFI) 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 60 ∼ 70° 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 165 FUEL SYSTEM (DFI) 3-77 Vehicle-down Sensor (Service Code 31) Vehicle-down Sensor Circuit 1. Vehicle-down Sensor 2. ECU...
  • Page 166: Subthrottle Sensor (service Code 32)

    3-78 FUEL SYSTEM (DFI) Subthrottle Sensor (Service Code 32) The subthrottle sensor is a rotating variable resistor that change output voltage according to throttle operating. The ECU senses this voltage change and determines fuel injec- tion quantity, and ignition timing according to engine rpm, and throttle opening.
  • Page 167: Subthrottle Sensor Output Voltage Inspection

    FUEL SYSTEM (DFI) 3-79 Subthrottle Sensor (Service Code 32) If the reading is out of the standard, remove the ECU and check the wiring for continuity between main harness connectors. ○ Disconnect the ECU and sensor connectors. Wiring Continuity Inspection ECU Connector [A] ←→...
  • Page 168 3-80 FUEL SYSTEM (DFI) Subthrottle Sensor (Service Code 32) • Measure the output voltage with the engine stopped with the connector joined. • Turn the ignition switch on. • Measure the output voltage when the subthrottle valves [A] are fully opened by hand. Output Voltage DC 1.08 ∼...
  • Page 169: Subthrottle Sensor Resistance Inspection

    FUEL SYSTEM (DFI) 3-81 Subthrottle Sensor (Service Code 32) Subthrottle Sensor Resistance Inspection • Turn the ignition switch off. • Disconnect the subthrottle sensor connector. • Connect the setting adapter [A] to the sensor connector only. Special Tool - Throttle Sensor Setting Adapter: 57001 -1538 •...
  • Page 170: Oxygen Sensor - Not Activated (service Code 33, Equipped Models)

    3-82 FUEL SYSTEM (DFI) Oxygen Sensor - not activated (Service Code 33, Equipped Models) Oxygen Sensor Removal/Installation • Refer to the Oxygen Sensor Removal/Installation (Equipped Models) in the Electrical System chapter. Oxygen Sensor Inspection • Turn the ignition switch off. •...
  • Page 171 FUEL SYSTEM (DFI) 3-83 Oxygen Sensor - not activated (Service Code 33, Equipped Models) • Install the suitable plugs [A] on the fitting of the air suction valve covers, and shut off the secondary air. • Remove the fuel hose (see Fuel Hose Replacement in the Periodic Maintenance chapter).
  • Page 172 3-84 FUEL SYSTEM (DFI) Oxygen Sensor - not activated (Service Code 33, Equipped Models) If the reading is out of the standard (with plugs: DC 0.7 V or more, without plugs: DC 0.2 V or less), remove the ECU and check the wiring for continuity between main harness connectors.
  • Page 173: Exhaust Butterfly Valve Actuator Sensor (service Code 34)

    FUEL SYSTEM (DFI) 3-85 Exhaust Butterfly Valve Actuator Sensor (Service Code 34) Exhaust Butterfly Valve Actuator Sensor Removal/Installation The exhaust butterfly valve actuator sensor is built in the exhaust butterfly valve actuator. So, the sensor itself can not be removed. Remove the exhaust butterfly valve actu- ator (see Exhaust Butterfly Valve Actuator Removal in the Engine Top End chapter).
  • Page 174: Exhaust Butterfly Valve Actuator Sensor Output Voltage Inspection

    3-86 FUEL SYSTEM (DFI) Exhaust Butterfly Valve Actuator Sensor (Service Code 34) Exhaust Butterfly Valve Actuator Sensor Output Voltage Inspection NOTE ○ Before this inspection, confirm the pulley is original po- sition (see Exhaust Butterfly Valve Cable Installation in the Engine Top End chapter). •...
  • Page 175: Exhaust Butterfly Valve Actuator Sensor Resistance Inspection

    FUEL SYSTEM (DFI) 3-87 Exhaust Butterfly Valve Actuator Sensor (Service Code 34) Exhaust Butterfly Valve Actuator Sensor Resistance Inspection • Turn the ignition switch off. • Disconnect the exhaust butterfly valve actuator sensor connector (3 pins connector) [A] (see Exhaust Butterfly Valve Actuator Sensor Input Voltage Inspection).
  • Page 176: Immobilizer Amplifier (service Code 35, Equipped Models)

    3-88 FUEL SYSTEM (DFI) Immobilizer Amplifier (Service Code 35, Equipped Models) Antenna Resistance Inspection • Turn the ignition switch off. • Remove the left middle fairing (see Middle Fairing Re- moval in the Frame chapter). • Slide the dust cover [A]. •...
  • Page 177: Blank Key Detection (service Code 36, Equipped Models)

    11. Fuse Box 1 1. Ignition Switch 5. Frame Ground 1 2. ECU 6. Engine Ground 12. Ignition Fuse 15 A 3. Immobilizer/Kawasaki 7. Battery 12 V 10 Ah 13. Joint Connector C Diagnostic System 8. Starter Relay 14. Immobilizer Antenna Connector 9.
  • Page 178: Ecu Communication Error (service Code 39)

    3-90 FUEL SYSTEM (DFI) ECU Communication Error (Service Code 39) ECU Communication Line Inspection ○ When the data is not sent from the ECU to the meter unit for more than about 10 seconds, the service code 39 is displayed. ○...
  • Page 179: Stick Coils #1, #2, #3, #4 (service Code 51, 52, 53, 54)

    FUEL SYSTEM (DFI) 3-91 Stick Coils #1, #2, #3, #4 (Service Code 51, 52, 53, 54) Stick Coil #1: Service Code 51 Stick Coil #2: Service Code 52 Stick Coil #3: Service Code 53 Stick Coil #4: Service Code 54 Stick Coil Removal/Installation •...
  • Page 180 3-92 FUEL SYSTEM (DFI) Stick Coils #1, #2, #3, #4 (Service Code 51, 52, 53, 54) • Turn the ignition switch off. If the input voltage is out of the standard, check the wiring for continuity (see Stick Coil Circuit). If the wiring is good, check the ECU for its ground and power supply (see ECU Power Supply Inspection).
  • Page 181: Radiator Fan Relay (service Code 56)

    FUEL SYSTEM (DFI) 3-93 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 182: Subthrottle Valve Actuator (service Code 62)

    3-94 FUEL SYSTEM (DFI) Subthrottle Valve Actuator (Service Code 62) Subthrottle Valve Actuator Removal NOTICE Do not remove the subthrottle valve actuator [A] since it has been adjusted and set with precision at the factory. Never drop the throttle body assy especially on a hard surface.
  • Page 183: Subthrottle Valve Actuator Input Voltage Inspection

    FUEL SYSTEM (DFI) 3-95 Subthrottle Valve Actuator (Service Code 62) Subthrottle Valve Actuator Input Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch off. • Disconnect the subthrottle valve actuator connector and connect the measuring adapter [A] between these con- nectors as shown.
  • Page 184 3-96 FUEL SYSTEM (DFI) Subthrottle Valve Actuator (Service Code 62) Subthrottle Valve Actuator Circuit 1. Subthrottle Valve Actuator 2. ECU...
  • Page 185: Exhaust Butterfly Valve Actuator (service Code 63)

    FUEL SYSTEM (DFI) 3-97 Exhaust Butterfly Valve Actuator (Service Code 63) Exhaust Butterfly Valve Actuator Removal • Refer to the Exhaust Butterfly Valve Actuator Removal in the Engine Top End chapter. Exhaust Butterfly Valve Actuator Installation • Refer to the Exhaust Butterfly Valve Actuator Installation in the Engine Top End chapter.
  • Page 186 3-98 FUEL SYSTEM (DFI) Exhaust Butterfly Valve Actuator (Service Code 63) If the reading is in specification, remove the ECU and check the wiring for continuity between main harness con- nectors. ○ Disconnect the ECU and actuator connectors. Wiring Inspection ECU Connector [A] ←→...
  • Page 187: Air Switching Valve (service Code 64)

    FUEL SYSTEM (DFI) 3-99 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 188: Oxygen Sensor Heater (service Code 67, Equipped Models)

    3-100 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 189: Oxygen Sensor Heater Power Source Voltage Inspection

    FUEL SYSTEM (DFI) 3-101 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.
  • Page 190 3-102 FUEL SYSTEM (DFI) Oxygen Sensor Heater (Service Code 67, Equipped Models) Oxygen Sensor Circuit 1. Ignition Switch 2. Fuse Box 1 3. Ignition Fuse 15 A 4. Oxygen Sensor 5. ECU 6. Joint Connector E 7. Frame Ground 5 8.
  • Page 191: Oxygen Sensor - Incorrect Output Voltage (service Code 94, Equipped Models)

    FUEL SYSTEM (DFI) 3-103 Oxygen Sensor - Incorrect Output Voltage (Service Code 94, Equipped Models) Oxygen Sensor Removal/Installation • Refer to the Oxygen Sensor Removal/Installation (Equipped Models) in the Electrical System chapter. Oxygen Sensor Inspection • Turn the ignition switch off. •...
  • Page 192 3-104 FUEL SYSTEM (DFI) Oxygen Sensor - Incorrect Output Voltage (Service Code 94, Equipped Models) • Install the suitable plugs [A] on the fitting of the air suction valve covers, and shut off the secondary air. • Remove the fuel hose (see Fuel Hose Replacement in the Periodic Maintenance chapter).
  • Page 193 FUEL SYSTEM (DFI) 3-105 Oxygen Sensor - Incorrect Output Voltage (Service Code 94, Equipped Models) If the reading is out of the standard (with plugs: DC 0.7 V or more, without plugs: DC 0.2 V or less), check the following. Fuel Pressure (see Fuel Pressure Inspection) Fuel Injector (see Fuel Injectors section) If the fuel pressure and fuel injectors are good, replace...
  • Page 194: Purge Valve (service Code 3a) (cal, Sea-b1 And Th Models)

    3-106 FUEL SYSTEM (DFI) Purge Valve (Service Code 3A) (CAL, SEA-B1 and TH Models) Purge Valve Removal/Installation • Remove: Battery Case (see Battery Case Removal in the Frame chapter) • Disconnect the purge valve lead connector [A]. • Remove the nut [B]. •...
  • Page 195 FUEL SYSTEM (DFI) 3-107 Purge Valve (Service Code 3A) (CAL, SEA-B1 and TH Models) • Disconnect the 12 V battery. • Blow the air to the intake air duct [A] again, and make sure that the air does not flow from the outlet air duct [B]. If the purge valve dose not operate as described, replace it with a new one.
  • Page 196: Warning Indicator Light (led)

    3-108 FUEL SYSTEM (DFI) Warning Indicator Light (LED) Yellow Engine Warning/Red Warning Indicator (LED) Inspection Yellow Engine Warning Indicator (LED) [A] Red Warning Indicator (LED) [B] ○ In this model, the above mentioned warning indicators (LED) go on or blink by the data sent from the ECU. •...
  • Page 197: Ecu

    FUEL SYSTEM (DFI) 3-109 ECU Identification ○ Most countries have their own regulations, so each ECU has different characteristic. So, do not confuse ECU with each other and use only the ECU for your model. Other- wise, the motorcycle cannot clear the regulation. ECU Identification Part Number [A] Specification...
  • Page 198: Ecu Installation

    3-110 FUEL SYSTEM (DFI) • Lift up the ECU [A] with rubber protector [B] to clear the projections. • Remove the relay box [C] from the rubber protector. • Disconnect the ECU connectors [D]. • Remove: ECU (with Rubber Protector) ECU Installation •...
  • Page 199 FUEL SYSTEM (DFI) 3-111 If the wiring is good, check the power source voltage of the ECU. NOTE ○ Be sure the battery is fully charged. • Connect the ECU connectors. • Connect a digital meter [A] to the connector (black) [B] with the needle adapter set.
  • Page 200 3-112 FUEL SYSTEM (DFI) ECU Power Source Circuit 1. Ignition Switch 2. Fuse Box 1 3. Ignition Fuse 15 A 4. Joint Connector C 5. Joint Connector D 6. ECU 7. Joint Connector E 8. Frame Ground 5 9. Frame Ground 2 10.
  • Page 201: Dfi Power Source

    FUEL SYSTEM (DFI) 3-113 DFI Power Source ECU Fuse Removal • Refer to the 30 A Main/15 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 202: Fuel Line

    3-114 FUEL SYSTEM (DFI) Fuel Line Fuel Pressure Inspection NOTE ○ Be sure the battery is fully charged. • Remove: Seat Cover (see Seat Cover Removal in the Frame chapter) Fuel Tank Bolts [A] Fuel Hose (see Fuel Hose Replacement in the Periodic Maintenance chapter) ○...
  • Page 203: Fuel Flow Rate Inspection

    FUEL SYSTEM (DFI) 3-115 Fuel Line • Start the engine, and let it idle. • Measure the fuel pressure with the engine idling. Fuel Pressure (with Engine Idling) Standard: 294 kPa (3.0 kgf/cm², 43 psi) NOTE ○ The gauge needle will fluctuate. Read the pressure at the average of the maximum and minimum indications.
  • Page 204 3-116 FUEL SYSTEM (DFI) Fuel Line • Open the fuel tank cap [A] to lower the pressure in the tank. • Remove the fuel hose from the fuel pump (see Fuel Tank Removal). ○ Be sure to place a piece of cloth around the fuel outlet pipe of the fuel pump.
  • Page 205: Fuel Pump

    FUEL SYSTEM (DFI) 3-117 Fuel Pump Fuel Pump Removal WARNING Gasoline is extremely flammable and can be explo- sive under certain conditions, creating the potential for serious burns. Make sure the area is well venti- lated and free from any source of flame or sparks; this includes any appliance with a pilot light.
  • Page 206: Fuel Pump Installation

    3-118 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. NOTE ○ Be careful not to bend the fuel level sensor arm. •...
  • Page 207: Fuel Pump Operating Voltage Inspection

    FUEL SYSTEM (DFI) 3-119 Fuel Pump Fuel Pump Operating Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch off. • Remove the front seat (see Front Seat Removal in the Frame chapter). • Disconnect the fuel pump lead connector and connect the measuring adapter [A] between these connectors as shown.
  • Page 208: Pressure Regulator Removal

    3-120 FUEL SYSTEM (DFI) Fuel Pump Pressure Regulator Removal ○ The pressure regulator [A] is built into the fuel pump [B] and can not be removed. Pump Screen, Fuel Filter Cleaning ○ The pump screen [A] and fuel filter [B] are built into the fuel pump and can not be cleaned or checked.
  • Page 209 FUEL SYSTEM (DFI) 3-121 Fuel Pump Fuel Pump Circuit 1. Ignition Switch 2. Engine Stop Switch 3. Fuse Box 1 4. Ignition Fuse 15 A 5. Joint Connector D 6. ECU 7. Fuel Pump 8. Frame Ground 2 9. Engine Ground 10.
  • Page 210: Fuel Injectors

    3-122 FUEL SYSTEM (DFI) Fuel Injectors Fuel Injector Removal/Installation • Refer to the Throttle Body Assy Disassembly/Assembly. Fuel Injector Audible Inspection NOTE ○ Be sure the battery is fully charged. • Start the engine, and let it idle. • Apply the standard tip screwdriver [A] to the fuel injector [B].
  • Page 211: Fuel Injector Power Source Voltage Inspection

    FUEL SYSTEM (DFI) 3-123 Fuel Injectors Fuel Injector Power Source Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch off. • Remove the throttle body assy with the connectors in- stalled (see Throttle Body Assy Removal). •...
  • Page 212: Fuel Injector Output Voltage Inspection

    3-124 FUEL SYSTEM (DFI) Fuel Injectors Fuel Injector Output Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch off. • Remove the ECU (see ECU Removal). ○ Do not disconnect the ECU connector. •...
  • Page 213: Fuel Injector Fuel Line Inspection

    FUEL SYSTEM (DFI) 3-125 Fuel Injectors If the reading is out of the specification, remove the ECU and check the wiring for continuity between main harness connectors. ○ Disconnect the ECU and injector connector. Wiring Continuity Inspection ECU Connector (Gray) Fuel Injector Connector ←→...
  • Page 214 3-126 FUEL SYSTEM (DFI) Fuel Injectors • Check the fuel injector fuel line for leakage as follows. ○ Connect a commercially available vacuum/pressure pump [A] to the nipple of the delivery pipe [B] with the fuel hose [C] (both ends with the clamps [D]) as shown. Rear Side View [E] ○...
  • Page 215 FUEL SYSTEM (DFI) 3-127 Fuel Injectors Fuel Injector Circuit 1. Ignition Switch 2. Engine Stop Switch 3. Fuse Box 1 4. Ignition Fuse 15 A 5. Joint Connector D 6. Fuel Injector #1 7. Fuel Injector #2 8. Fuel Injector #3 9.
  • Page 216: Throttle Grip And Cables

    3-128 FUEL SYSTEM (DFI) Throttle Grip and Cables Free Play Inspection • Refer to the Throttle Control System Inspection in the Pe- riodic Maintenance chapter. Free Play Adjustment • Refer to the Throttle Control System Inspection in the Pe- riodic Maintenance chapter. Cable Installation •...
  • Page 217: Throttle Body Assy

    FUEL SYSTEM (DFI) 3-129 Throttle Body Assy Idle Speed Inspection/Adjustment • Refer to the Idle Speed Inspection/Adjustment in the Pe- riodic Maintenance chapter. Synchronization Inspection/Adjustment • Refer to the Engine Vacuum Synchronization Inspection in the Periodic Maintenance chapter. Throttle Body Assy Removal WARNING Gasoline is extremely flammable and can be explo- sive under certain conditions, creating the potential...
  • Page 218 3-130 FUEL SYSTEM (DFI) Throttle Body Assy • Remove: Bolts [A] Throttle Pulley Cover [B] • Remove: Throttle Cable Holder Clamp [A] Throttle Cable Lower Ends [B] • Loosen the throttle body assy holder clamp bolts [A]. Special Tool - Carburetor Drain Plug Wrench, Hex 3: 57001-1269 •...
  • Page 219: Throttle Body Assy Installation

    FUEL SYSTEM (DFI) 3-131 Throttle Body Assy Throttle Body Assy Installation • Be sure to position the throttle body assy holder clamp in original position (see Throttle Body Assy Holder Installa- tion in the Engine Top End chapter). • Connect the fuel injector connectors [A]. •...
  • Page 220: Throttle Body Assy Disassembly

    3-132 FUEL SYSTEM (DFI) Throttle Body Assy Throttle Body Assy Disassembly 1. Throttle Body Assy 2. Subthrottle Valve Actuator 3. Main Throttle Sensor 4. Subthrottle Sensor 5. Fuel Injectors 6. Delivery Pipe Assy 7. Intake Air Pressure Sensor #1 8. Intake Air Pressure Sensor #2 NOTICE Do not remove, disassemble or adjust the main throttle sensor, subthrottle sensor, subthrottle...
  • Page 221: Throttle Body Assy Assembly

    FUEL SYSTEM (DFI) 3-133 Throttle Body Assy • Remove the fuel injectors [A] from the delivery pipe assy [B]. NOTE ○ Do not damage the insertion portions of the injectors when they are pulled out from the delivery pipe assy. NOTICE Never drop the fuel injector especially on a hard surface.
  • Page 222: Air Cleaner

    3-134 FUEL SYSTEM (DFI) Air Cleaner Air Cleaner Element Removal/Installation • Refer to the Air Cleaner Element Replacement in the Pe- riodic Maintenance chapter. Air Cleaner Element Inspection • Remove the air cleaner element (see Air Cleaner Element Replacement in the Periodic Maintenance chapter). •...
  • Page 223: Air Cleaner Housing Installation

    FUEL SYSTEM (DFI) 3-135 Air Cleaner • Loosen the air cleaner housing clamp bolt [A] on both sides. • Lift up the air cleaner housing, and disconnect the air switching valve hose [A]. • After removing the air cleaner housing, cover the clean cloth on the throttle body assy.
  • Page 224: Fuel Tank

    3-136 FUEL SYSTEM (DFI) Fuel Tank Fuel Tank Removal WARNING Gasoline is extremely flammable and can be explo- sive under certain conditions, creating the potential for serious burns. Make sure the area is well venti- lated and free from any source of flame or sparks; this includes any appliance with a pilot light.
  • Page 225 FUEL SYSTEM (DFI) 3-137 Fuel Tank • Draw the fuel out from the fuel tank with a commercially available pump [A]. ○ Use a soft plastic hose [B] as a pump intake hose in order to insert the hose smoothly. ○...
  • Page 226: Fuel Tank Installation

    3-138 FUEL SYSTEM (DFI) Fuel Tank • Pull [A] the fuel hose joint [B] out of the outlet pipe. WARNING Fuel is flammable and explosive under certain con- ditions and can cause severe burns. Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately.
  • Page 227: Fuel Tank And Cap Inspection

    FUEL SYSTEM (DFI) 3-139 Fuel Tank • Remove the vinyl bag on the pipe and fuel hose joint. • Check the joint lock for deformation and wear. If the joint lock is deformed, replace the fuel hose with a new one. •...
  • Page 228: Fuel Tank Cleaning

    3-140 FUEL SYSTEM (DFI) Fuel Tank Fuel Tank Cleaning WARNING Gasoline and low flash-point solvents can be flammable and/or explosive and cause severe burns. Clean the tank in a well-ventilated area, and take care that there are no sparks or flame any- where near the working area.
  • Page 229: Evaporative Emission Control System (cal, Sea-b1 And Th Models)

    FUEL SYSTEM (DFI) 3-141 Evaporative Emission Control System (CAL, SEA-B1 and TH 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 231 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 232: Exploded View

    4-2 COOLING SYSTEM Exploded View...
  • Page 233 COOLING SYSTEM 4-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Water Hose Clamp Screws 0.31 27 in·lb Fitting Bolt 0.90 78 in·lb Thermostat Housing Bolts 0.60 52 in·lb Water Pipe Bolts 106 in·lb Water Pump Impeller Bolt 87 in·lb Water Pump Cover Bolts 97 in·lb Coolant Drain Bolt...
  • Page 234: Coolant Flow Chart

    4-4 COOLING SYSTEM Coolant Flow Chart 1. Radiator 10. Reserve Tank 2. Radiator Fan 11. Water Pump 3. Water Temperature Sensor 12. Intake Pipe 4. Air Bleeder Hose 13. Cylinder Jacket 5. Radiator Overflow Hose 14. Oil Cooler 6. Radiator Cap 15.
  • Page 235 COOLING SYSTEM 4-5 Coolant Flow Chart Permanent type antifreeze is used as a coolant to protect the cooling system from rust and corro- sion. When the engine starts, the water pump turns and the coolant circulates. The thermostat is a wax pellet type which opens or closes with coolant temperature changes. The thermostat continuously changes its valve opening to keep the coolant temperature at the proper level.
  • Page 236: Specifications

    4-6 COOLING SYSTEM Specifications Item Standard Coolant Provided when Shipping Type (Recommended) Permanent type of antifreeze (soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators) Color Green Mixed Ratio Soft water 50%, coolant 50% Freezing Point −35°C (−31°F) Total Amount...
  • Page 237: Special Tools

    COOLING SYSTEM 4-7 Special Tools Bearing Driver Set: Oil Seal Driver 37.5: 57001-1129 57001-1660...
  • Page 238: Coolant

    4-8 COOLING SYSTEM Coolant Coolant Deterioration Inspection • Visually inspect the coolant in the reserve tank [A]. If whitish cotton-like wafts are observed, aluminum parts in the cooling system are corroded. If the coolant is brown, iron or steel parts are rusting. In either case, flush the cooling system.
  • Page 239: 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 considerable reduce the effi- ciency of the cooling system.
  • Page 240: Water Pump

    4-10 COOLING SYSTEM Water Pump Water Pump Removal • Drain: Coolant (see Coolant Change in the Periodic Mainte- nance chapter) Engine Oil (see Engine Oil Change in the Periodic Main- tenance chapter) • Remove: Left Lower Fairing (see Lower Fairing Removal in the Frame chapter) Engine Sprocket Cover (see Engine Sprocket Removal in the Final Drive chapter)
  • Page 241 COOLING SYSTEM 4-11 Water Pump • Be sure to install the dowel pins [A]. • Install: Water Pump Housing [A] Water Pump Impeller [B] • Replace the washer with a new one, and install it. • Tighten: Torque - Water Pump Impeller Bolt [C]: 9.8 N·m (1.0 kgf·m, 87 in·lb) •...
  • Page 242: Water Pump Inspection

    4-12 COOLING SYSTEM Water Pump Water Pump Inspection • Check the drainage outlet passage [A] at the bottom of the water pump housing for coolant leaks. • If a coolant leak or ooze is found, start the engine and check if the coolant leaks continuously. ○...
  • Page 243: Water Pump Housing Assembly

    COOLING SYSTEM 4-13 Water Pump • Take the oil seal [A] out of the housing [B] with a hook [C]. Water Pump Housing Assembly NOTICE Do not reuse the mechanical seal and oil seal. • Apply high-temperature grease to the oil seal lips [A]. •...
  • Page 244: Radiator

    4-14 COOLING SYSTEM Radiator Radiator and Radiator Fan Removal • Drain: Coolant (see Coolant Change in the Periodic Mainte- nance chapter) • Remove: Air Cleaner Housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter) Bolts [A] • Disconnect the connectors [B], and remove the horn [C].
  • Page 245: Radiator And Radiator Fan Installation

    COOLING SYSTEM 4-15 Radiator • Move the radiator rightward [A] to clear the frame projec- tion [B]. • Remove: Radiator [C] NOTICE Do not touch the radiator core. This could damage the radiator fins, resulting in loss of cooling effi- ciency.
  • Page 246: Radiator Inspection

    4-16 COOLING SYSTEM Radiator • Fit the slits [A] of the heat insulation rubber plate to the up- per mounting brackets [B] and fan bracket [C] as shown. • Run the radiator fan motor lead [D] into the slit. • Insert the upper right mounting bracket [A] to the frame projection [B].
  • Page 247: Radiator Filler Neck Inspection

    COOLING SYSTEM 4-17 Radiator • Install the cap [A] on a cooling system pressure tester [B]. NOTE ○ Wet the cap sealing surfaces with water or coolant to prevent pressure leaks. • Watching the pressure gauge, pump the pressure tester to build up the pressure until the relief valve opens: the gauge needle flicks downward.
  • Page 248: Thermostat

    4-18 COOLING SYSTEM Thermostat Thermostat Removal • Drain: Coolant (see Coolant Change in the Periodic Mainte- nance chapter) • Remove: Engine Sprocket Cover (see Engine Sprocket Removal in the Final Drive chapter) Harness Holder Clamp [A] • Loosen the water hose clamp screw [B]. •...
  • Page 249: Thermostat Inspection

    COOLING SYSTEM 4-19 Thermostat • Replace the O-ring [A] with a new one. • Apply grease to the O-ring, and install it. • Install the thermostat housing cover. NOTE ○ Note that the thermostat does not move at the place when installing the thermostat housing cover.
  • Page 250 4-20 COOLING SYSTEM Thermostat • To check valve opening temperature, suspend the ther- mostat [A] in a container of water and raise the tempera- ture of the water. ○ The thermostat must be completely submerged and must not touch the container sides or bottom. Suspend an ac- curate thermometer [B] in the water so that the heat sen- sitive portions [C] are located in almost the same depth.
  • Page 251: Hose And Pipes

    COOLING SYSTEM 4-21 Hose and Pipes Hose Installation • Install the hoses and pipes, being careful to follow bend- ing direction. Avoid sharp bending, kinking, flattening or twisting. • Run the hoses (see Cable, Wire, and Hose Routing sec- tion in the Appendix chapter). •...
  • Page 252: Water Temperature Sensor

    4-22 COOLING SYSTEM Water Temperature Sensor NOTICE The water temperature sensor should never be al- lowed to fall on a hard surface. Such a shock to the water temperature sensor can damage it. Water Temperature Sensor Removal/Installation • Refer to the Water Temperature Sensor Removal/Instal- lation in the Fuel System (DFI) chapter.
  • Page 253 ENGINE TOP END 5-1 Engine Top End Table of Contents Exploded View........Valve Installation ......5-30 Exhaust System Identification ... Valve Guide Removal ....5-30 Specifications ........Valve Guide Installation ....5-31 Special Tools and Sealants ....5-10 Valve-to-Guide Clearance Clean Air System.......
  • Page 254: Exploded View

    5-2 ENGINE TOP END Exploded View...
  • Page 255 ENGINE TOP END 5-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Air Suction Valve Cover Bolts 87 in·lb Spark Plugs 115 in·lb Cylinder Head Cover Bolts 89 in·lb Camshaft Cap Bolts 106 in·lb Upper Camshaft Chain Guide Bolts 106 in·lb Cylinder Head Bolts (M10) (First) S, MO Cylinder Head Bolts (M10) (Final)
  • Page 256 5-4 ENGINE TOP END Exploded View...
  • Page 257 ENGINE TOP END 5-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Exhaust Pipe Cover Bracket Bolts 89 in·lb Exhaust Buttery Valve Actuator Pulley Bolt 0.51 44 in·lb Exhaust Battery Valve Actuator Mounting 0.12 11 in·lb Screws Muffler Body Mounting Bolts Premuffler Chamber Mounting Bolt Muffler Body Clamp Bolts G: Apply grease.
  • Page 258: Exhaust System Identification

    5-6 ENGINE TOP END Exhaust System Identification Exhaust Pipe Mark Position [A] Left Muffler Body Mark Position [A]...
  • Page 259 ENGINE TOP END 5-7 Exhaust System Identification Right Muffler Body Mark Position [A] Exhaust Pipe [A] with Hole [B] for Oxygen Sensor [C] (Equipped Models) Honeycomb Type Catalyst Positions [A]...
  • Page 260: Specifications

    5-8 ENGINE TOP END Specifications Item Standard Service Limit Camshafts Cam Height: 33.743 ∼ 33.857 mm (1.3285 ∼ 1.3330 in.) Exhaust 33.64 mm (1.324 in.) 34.443 ∼ 34.557 mm (1.3560 ∼ 1.3605 in.) Intake 34.34 mm (1.352 in.) 0.038 ∼ 0.081 mm (0.0015 ∼ 0.0032 in.) Camshaft Journal, Camshaft 0.17 mm (0.0067 in.) Cap Clearance...
  • Page 261 ENGINE TOP END 5-9 Specifications Item Standard Service Limit Cylinder, Pistons 76.994 ∼ 77.006 mm (3.0313 ∼ 3.0317 in.) Cylinder Inside Diameter 77.09 mm (3.035 in.) 76.974 ∼ 76.984 mm (3.0305 ∼ 3.0309 in.) Piston Diameter 76.82 mm (3.024 in.) 0.010 ∼...
  • Page 262: Special Tools And Sealants

    5-10 ENGINE TOP END Special Tools and Sealants Compression Gauge, 20 kgf/cm²: Valve Seat Cutter, 32° - 28: 57001-221 57001-1119 Valve Spring Compressor Assembly: Valve Seat Cutter Holder Bar: 57001-241 57001-1128 Piston Pin Puller Assembly: Valve Seat Cutter, 32° - 33: 57001-910 57001-1199 Valve Seat Cutter, 45°...
  • Page 263 ENGINE TOP END 5-11 Special Tools and Sealants Valve Guide Reamer, 4.5: Valve Spring Compressor Adapter, 24: 57001-1333 57001-1586 Valve Seat Cutter, 60° - 33: Compression Gauge Adapter, M10 × 1.0: 57001-1334 57001-1601 Valve Seat Cutter, 60° - 27: L-Shape Hose: 57001-1409 57001-1606 Engine Mount Nut Wrench:...
  • Page 264 5-12 ENGINE TOP END Special Tools and Sealants Liquid Gasket, TB1216B: 92104-1064...
  • Page 265: Clean Air System

    ENGINE TOP END 5-13 Clean Air System Air Suction Valve Removal • Remove: Air Switching Valve (see Air Switching Valve Removal) Bolts [A] • Disconnect the connectors [B], and remove the horn [C]. • Slide the dust cover [A]. • Disconnect the radiator fan motor lead connector [B].
  • Page 266: Air Suction Valve Installation

    5-14 ENGINE TOP END Clean Air System • Move the radiator rightward [A] to clear the frame projec- tion [B], and remove it. • Disconnect the stick coil connectors. • Turn up the heat insulation rubber plate. • Install the radiator temporarily to prevent damage the ra- diator core.
  • Page 267: Air Suction Valve Inspection

    ENGINE TOP END 5-15 Clean Air System Air Suction Valve Inspection • Remove the air suction valve (see Air Suction Valve Re- moval). • Visually inspect the reeds [A] for cracks, folds, warps, heat damage or other damage. If there is any doubt as to the condition of the reeds, re- place the air suction valve as an assembly.
  • Page 268: Clean Air System Hose Inspection

    5-16 ENGINE TOP END Clean Air System 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 air suction valve covers.
  • Page 269: Cylinder Head Cover

    ENGINE TOP END 5-17 Cylinder Head Cover Cylinder Head Cover Removal • Remove: Air Cleaner Housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter) Stick Coils (see Stick Coil Removal in the Electrical Sys- tem chapter) Air Suction Valves (see Air Suction Valve Removal) Bracket Bolt [A] Bracket [B] •...
  • Page 270 5-18 ENGINE TOP END Cylinder Head Cover • Replace the head cover gasket with a new one. • Using a high flash-point solvent, clean off any oil or dirt that may be on the liquid gasket coating area. Dry them with a clean cloth.
  • Page 271: Camshaft Chain Tensioner

    ENGINE TOP END 5-19 Camshaft Chain Tensioner Camshaft Chain Tensioner Removal NOTICE This is a non-return type camshaft chain tensioner. The push rod does not return to its original position once it moves out to take up camshaft chain slack. Observe all the rules listed below.
  • Page 272: Camshaft, Camshaft Chain

    5-20 ENGINE TOP END Camshaft, Camshaft Chain Camshaft Removal • Remove: Cylinder Head Cover (see Cylinder Head Cover Re- moval) Crankshaft Sensor Cover (see Crankshaft Sensor Re- moval in the Electrical System chapter) • Using a wrench on the timing rotor bolt [A], turn the crank- shaft clockwise until the line [B] (TDC mark for #1, 4 pis- tons) on the timing rotor is aligned with the mating surface [C] of the crankcase.
  • Page 273: Camshaft Installation

    ENGINE TOP END 5-21 Camshaft, Camshaft Chain Camshaft Installation • Be sure to install the following parts. Plug Hole Gaskets [A] Dowel Pins [B] NOTE ○ The exhaust camshaft has a 8943 EX mark [A] and the intake camshaft has a 8943 IN mark [B]. Be careful not to mix up these shafts.
  • Page 274 5-22 ENGINE TOP END Camshaft, Camshaft Chain • Pull the tension side (exhaust side) [A] of the chain taut to install the chain. • Engage the camshaft chain with the sprockets so that tim- ing marks on the sprockets are positioned as shown. ○...
  • Page 275 ENGINE TOP END 5-23 Camshaft, Camshaft Chain • Before installing the camshaft caps and upper chain guide, install the camshaft chain tensioner body tem- porarily (see Camshaft Chain Tensioner Installation). • Install the camshaft caps and upper camshaft chain guide [A] as shown.
  • Page 276: Camshaft, Camshaft Cap Wear Inspection

    5-24 ENGINE TOP END Camshaft, Camshaft Chain Camshaft, Camshaft Cap Wear Inspection • Remove: Camshaft Caps (see Camshaft Removal) • Cut the strips of plastigage (press gauge) to journal width. Place a strip on each journal parallel to the camshaft in- stalled in the correct position.
  • Page 277: Cam Wear Inspection

    ENGINE TOP END 5-25 Camshaft, Camshaft Chain Cam Wear Inspection • Remove the camshafts (see Camshaft Removal). • Measure the height [A] of each cam with a micrometer. If the cams are worn down past the service limit, replace the camshaft. Cam Height Standard: 33.743 ∼...
  • Page 278: Cylinder Head

    5-26 ENGINE TOP END Cylinder Head 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 Peri- odic Maintenance chapter) •...
  • Page 279: Cylinder Head Removal

    ENGINE TOP END 5-27 Cylinder Head Cylinder Head Removal • Drain: Coolant (see Coolant Change in the Periodic Mainte- nance chapter) • Remove: Camshafts (see Camshaft Removal) Throttle Body Assy (see Throttle Body Assy Removal in the Fuel System (DFI) chapter) Exhaust Pipe (see Exhaust Pipe Removal) Radiator (Radiator and Radiator Fan Removal in the Cooling System)
  • Page 280: Cylinder Head Installation

    5-28 ENGINE TOP END Cylinder Head • Remove the M6 cylinder head bolts [A]. • Loosen the M10 cylinder head bolts as shown sequence [1 ∼ 10], and remove them with washers and spring wash- ers. • Remove the cylinder head. Cylinder Head Installation NOTE ○...
  • Page 281: Cylinder Head Warp Inspection

    ENGINE TOP END 5-29 Cylinder Head • Install: Front Camshaft Chain Guide [A] Rear Camshaft Chain Guide [B] New O-rings [C] Collar [D] • Tighten: Torque - Front Camshaft Chain Guide Bolt (Upper) [E]: 25 N·m (2.5 kgf·m, 18 ft·lb) Front Camshaft Chain Guide Bolt (Lower) [F]: 12 N·m (1.2 kgf·m, 106 in·lb) Rear Camshaft Chain Guide Bolt [G]: 25 N·m (2.5...
  • Page 282: Valves

    5-30 ENGINE TOP END Valves Valve Clearance Inspection • Refer to the Valve Clearance Inspection in the Periodic Maintenance chapter. Valve Clearance Adjustment • Refer to the Valve Clearance Adjustment in the Periodic Maintenance chapter. Valve Removal • Remove: Cylinder Head (see Cylinder Head Removal) Valve Lifter and Shim NOTE ○...
  • Page 283: Valve Guide Installation

    ENGINE TOP END 5-31 Valves Valve Guide Installation • Apply oil to the valve guide outer surface before installa- tion. • Heat the area around the valve guide hole to about 120 ∼ 150°C (248 ∼ 302°F). NOTICE Do not heat the cylinder head with a torch. This Will warp the cylinder head.
  • Page 284: Valve-to-guide Clearance Measurement (wobble Method)

    5-32 ENGINE TOP END Valves Valve-to-Guide Clearance Measurement (Wobble Method) If a small bore gauge is not available, inspect the valve guide wear by measuring the valve to valve guide clearance with the wobble method as indicated below. • Insert a new valve [A] into the guide [B] and set a dial gauge against the stem perpendicular to it as close as possible to the cylinder head mating surface.
  • Page 285: Valve Seat Repair

    ENGINE TOP END 5-33 Valves Valve Seat Repair • Repair the valve seat with the valve seat cutters [A]. Special Tools - Valve Seat Cutter Holder Bar [B]: 57001 -1128 Valve Seat Cutter Holder, 4.5 [C]: 57001 -1330 [For Exhaust Valve Seat] Valve Seat Cutter, 45°...
  • Page 286 5-34 ENGINE TOP END Valves Operating Procedures • Clean the seat area carefully. • Coat the seat with machinist’s dye. • Fit a 45° cutter into the holder and slide it into the valve guide. • Press down lightly on the handle and turn it right or left. Grind the seating surface only until it is smooth.
  • Page 287 ENGINE TOP END 5-35 Valves If the outside diameter [A] of the seating surface is too large, make the 32° [B] grind described below. If the outside diameter of the seating surface is within the specified range, measure the seat width as described be- low.
  • Page 288 5-36 ENGINE TOP END Valves • Lap the valve to the valve seat, once the seat width and outside diameter are within the ranges specified above. ○ Put a little coarse grinding compound on the face of the valve in a number of places around the valve head. ○...
  • Page 289 ENGINE TOP END 5-37 Valves...
  • Page 290: Cylinder, Pistons

    5-38 ENGINE TOP END Cylinder, Pistons Cylinder Removal • Remove: Cylinder Head (see Cylinder Head Removal) Engine Bracket (see Engine Removal in the Engine Re- moval/Installation chapter) Radiator Bracket Bolt [A] Radiator Bracket [B] • Loosen the water hose clamp screw [A]. •...
  • Page 291: Piston Removal

    ENGINE TOP END 5-39 Cylinder, Pistons • The piston ring openings must be positioned as shown. The openings of the oil ring steel rails must be about 30 ∼ 40° of angle from the opening of the top ring. Top Ring [A] Second Ring [B] Upper Oil Ring Steel Rail [C] Oil Ring Expander [D]...
  • Page 292: Piston Installation

    5-40 ENGINE TOP END Cylinder, 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 293: Cylinder Wear Inspection

    ENGINE TOP END 5-41 Cylinder, Pistons Cylinder Wear Inspection • Since there is a difference in cylinder wear in different di- rections, take a side-to-side and a front-to-back measure- ment at each of the two locations (total of four measure- ments) as shown.
  • Page 294: Piston Ring Thickness Inspection

    5-42 ENGINE TOP END Cylinder, Pistons Piston Ring Thickness Inspection • Measure the piston ring thickness. ○ Use the micrometer to measure at several points around the ring. Piston Ring Thickness Standard: 0.77 ∼ 0.79 mm (0.0303 ∼ 0.0311 in.) Top [A] 0.77 ∼...
  • Page 295: Throttle Body Assy Holder

    ENGINE TOP END 5-43 Throttle Body Assy Holder Throttle Body Assy Holder Removal • Remove: Throttle Body Assy (see Throttle Body Assy Removal in the Fuel System (DFI) chapter) Clamps [A] Throttle Body Assy Holder Bolts [B] Throttle Body Assy Holders [C] Throttle Body Assy Holder Installation •...
  • Page 296: Muffler

    5-44 ENGINE TOP END Muffler WARNING The exhaust pipe or muffler body can become ex- tremely hot during normal operation and cause se- vere burns. Do not remove the exhaust pipe or muf- fler body while it is hot. Muffler Body Removal Left Muffler Body •...
  • Page 297 ENGINE TOP END 5-45 Muffler • Loosen the locknuts [A]. • Remove the cable lower ends [B]. • Remove the bolts [A] and collars. • Clear the hook [B], and remove the exhaust pipe cover [C]. • Loosen the muffler body clamp bolt [A]. •...
  • Page 298: Muffler Body Installation

    5-46 ENGINE TOP END Muffler Muffler Body Installation • Replace the muffler body gaskets [A] with new ones. • Install the muffler body gaskets until it is bottomed so that the inside chamfer side faces rear [B]. • Install the muffler body clamps [C] so that the projection [D] fits into the clamp slit [E].
  • Page 299 ENGINE TOP END 5-47 Muffler • After installation, make sure that the clearance [A] of both side mufflers are 12 mm (0.47 in.) or more. Muffler Body [B] Swingarm [C] • Install the exhaust pipe cover, and tighten its bolts to- gether with the collars.
  • Page 300 5-48 ENGINE TOP END Muffler • When installing the muffler covers, note the following. • Install the pads [A] to the muffler covers as shown. • Install the dampers [B], collars [C] and pads [D] as shown. ○ Align the center line of the pad aligns with the edge [E] of the bracket.
  • Page 301: Exhaust Pipe Removal

    ENGINE TOP END 5-49 Muffler Exhaust Pipe Removal • Remove: Muffler Bodies (see Muffler Body Removal) Oxygen Sensor (Equipped Models) (see Oxygen Sen- sor Removal (Equipped Models) in the Electrical System chapter) • Support the premuffler chamber with the suitable stand [A].
  • Page 302 5-50 ENGINE TOP END Muffler • Slide the dust covers [A] off the adjusters [B]. • Loosen the locknuts [C], and turn the adjusters to give the cable plenty of play. • Remove: Bolts [A] Exhaust Butterfly Valve Pulley Cover [B] •...
  • Page 303: Exhaust Butterfly Valve Cable Installation

    ENGINE TOP END 5-51 Muffler Exhaust Butterfly Valve Cable Installation • Before installing the exhaust butterfly valve cables, con- firm that the exhaust valve actuator pulley [A] is in the original position as shown. ○ The pulley edge [B] and housing screw [C] are on the same line.
  • Page 304: Exhaust Butterfly Valve Actuator Removal

    5-52 ENGINE TOP END Muffler • After adjusting the cables, turn the ignition switch on and make sure that the pulley turns clockwise, then counter- clockwise and then returns slightly clockwise as shown. NOTE ○ The stop position [A] of the pulley is changed by the cables tension and the closed position of the exhaust butterfly valve.
  • Page 305: Exhaust Butterfly Valve Actuator Installation

    ENGINE TOP END 5-53 Muffler • When replacing the pulley, note the following. • Remove the pulley bolt while holding the pulley [A] with the suitable tool [B]. NOTICE If the pulley bolt is removed without holding, the actuator damage will occur. •...
  • Page 306: Exhaust Butterfly Valve Actuator Adjustment

    5-54 ENGINE TOP END Muffler Exhaust Butterfly Valve Actuator Adjustment Pulley Position Electrically Adjustment • Turn the ignition switch off. • Disconnect the exhaust butterfly valve actuator connec- tors. • Connect the exhaust butterfly valve actuator connector (2 pins) to the battery to turn the pulley as follows. Connection for counterclockwise [A] Connection for clockwise [B] •...
  • Page 307 CLUTCH 6-1 Clutch Table of Contents Exploded View........................Specifications ......................... Special Tool and Sealant ......................Clutch Lever and Cable ......................Clutch Lever Free Play Inspection ..................Clutch Lever Free Play Adjustment .................. Clutch Cable Removal ...................... Clutch Cable Installation ....................Clutch Cable Lubrication....................
  • Page 308: Exploded View

    6-2 CLUTCH Exploded View...
  • Page 309 CLUTCH 6-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Clutch Lever Clamp Bolts 0.80 69 in·lb Clutch Spring Bolts 0.90 78 in·lb Clutch Hub Nut 13.8 Clutch Cover Bolts 87 in·lb Oil Filler Plug 0.20 18 in·lb CL: Apply cable lubricant. EO: Apply engine oil.
  • Page 310: Specifications

    6-4 CLUTCH Specifications Item Standard Service Limit 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Clutch Lever Free Play – – – Clutch 51.1 ∼ 51.7 mm (2.01 ∼ 2.04 in.) Clutch Plate Assembly Length – – – 2.72 ∼ 2.88 mm (0.107 ∼ 0.113 in.) Friction Plate Thickness 2.4 mm (0.094 in.) Friction and Steel Plate Warp...
  • Page 311: Special Tool And Sealant

    CLUTCH 6-5 Special Tool and Sealant Clutch Holder: Liquid Gasket, TB1211F: 57001-1243 92104-0004...
  • Page 312: Clutch Lever And Cable

    6-6 CLUTCH Clutch Lever and Cable Clutch Lever Free Play Inspection • Refer to the Clutch Operation Inspection in the Periodic Maintenance chapter. Clutch Lever Free Play Adjustment • Refer to the Clutch Operation Inspection in the Periodic Maintenance chapter. Clutch Cable Removal •...
  • Page 313: Clutch Lever Installation

    CLUTCH 6-7 Clutch Lever and Cable Clutch Lever Installation WARNING If the starter lockout switch pin has been damaged the starter lockout system will not work properly. This allows the motorcycle to be started in gear with the clutch lever released (clutch engaged), creat- ing sudden forward movement that can result in an accident or injury.
  • Page 314: Clutch Cover

    6-8 CLUTCH Clutch Cover Clutch Cover Removal • Drain the engine oil (see Engine Oil Change in the Peri- odic Maintenance chapter). • Remove: Right Lower Fairing (see Lower Fairing Removal in the Frame chapter) Clutch Cable Lower End (see Clutch Cable Removal) Clutch Cover Bolts [A] Bracket [B] •...
  • Page 315: Release Shaft Installation

    CLUTCH 6-9 Clutch Cover Release Shaft Installation • Apply grease to the oil seal lips on the upper ridge of the clutch cover. • Apply engine oil to the needle bearings in the hole of the clutch cover. • Apply molybdenum disulfide grease to the pusher-holding portion [A] on the release shaft.
  • Page 316: Clutch Cover Assembly

    6-10 CLUTCH Clutch Cover Clutch Cover Assembly • Replace the needle bearings and oil seal with new ones. NOTE ○ Install the needle bearings so that the manufacture’s mark face out. • Apply soap and water solution to the oil seal. •...
  • Page 317: Clutch Removal

    CLUTCH 6-11 Clutch Clutch Removal • Remove: Clutch Cover (see Clutch Cover Removal) Clutch Spring Bolts [A] Clutch Springs Clutch Spring Plate [B] (with Washer, Needle Bearing and Pusher [C]) Friction Plates and Steel Plates Spring and Spring Seat NOTE ○...
  • Page 318 6-12 CLUTCH Clutch • Install the clutch housing [A] to the drive shaft. • While holding the clutch housing, install the needle bear- ing [B] and sleeve [C]. ○ The holes [D] of the sleeve face outward. • Install the following parts to the drive shaft. Spacer ( 47 ×...
  • Page 319 CLUTCH 6-13 Clutch • Install the friction plates and steel plates, starting with a friction plate and alternating them. NOTE ○ Install the both ends marked two friction plates at dis- assembled to the their original position. ○ When replace the friction plates with new ones, mark the both ends two friction plates so that the two kinds of friction plates do not mix up at opening the package.
  • Page 320: Clutch Plate Assembly Inspection

    6-14 CLUTCH Clutch Clutch Plate Assembly Inspection • Inspect the friction plate thickness (see Clutch Plate, Wear, Damage Inspection). • Measure the length [A] of the clutch plate assembly as shown. ○ Assemble: Clutch Hub [B] Spring Seat [C] Spring [D] Friction Plates [E] Steel Plates [F] Clutch Spring Plate [G]...
  • Page 321: Clutch Plate, Wear, Damage Inspection

    CLUTCH 6-15 Clutch Clutch Plate, Wear, Damage Inspection • Visually inspect the friction and steel plates for signs of seizure, overheating (discoloration), or uneven wear. • Measure the thickness of each friction plate [A] at several points. If any plates show signs of damage, or if they have worn past the service limit, replace them with new ones.
  • Page 323 ENGINE LUBRICATION SYSTEM 7-1 Engine Lubrication System Table of Contents Exploded View........................Engine Oil Flow Chart......................Specifications ......................... Special Tools and Sealants ....................Engine Oil and Oil Filter......................Oil Level Inspection......................Engine Oil Change......................Oil Filter Replacement ...................... Oil Pan............................ Oil Pan 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 Oil Cooler Bolts 106 in·lb Oil Filler Plug 0.20 18 in·lb Oil Passage Plugs Oil Passage Plug 87 in·lb Oil Pressure Switch Oil Pressure Switch Terminal Bolt 0.20 18 in·lb Oil Pressure Relief Valve Oil Filter...
  • Page 326: Engine Oil Flow Chart

    7-4 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart 1. Balancer Oil Passage 9. Oil Pressure Relief Valve 2. Camshaft Oil Passage 10. Oil Cooler 3. Crankshaft Oil Passage 11. Oil Filter 4. Drive Shaft Oil Passage 12. Main Oil Passage 5.
  • Page 327: Specifications

    ENGINE LUBRICATION SYSTEM 7-5 Specifications Item Standard Engine Oil Type API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2 Viscosity SAE 10W-40 Capacity: 3.2 L (3.4 US qt) (when filter is not removed) 3.8 L (4.0 US qt) (when filter is removed) 4.0 L (4.2 US qt) (when engine is completely dry) Level Between upper and lower level lines (Wait several minutes after...
  • Page 328: Special Tools And Sealants

    7-6 ENGINE LUBRICATION SYSTEM Special Tools and Sealants Outside Circlip Pliers: Liquid Gasket, TB1211: 57001-144 56019-120 Oil Pressure Gauge, 10 kgf/cm²: Liquid Gasket, TB1207B: 57001-164 92104-2068 Oil Pressure Gauge Adapter, PT3/8: 57001-1233...
  • Page 329: Engine Oil And Oil Filter

    ENGINE LUBRICATION SYSTEM 7-7 Engine Oil and Oil Filter WARNING Vehicle operation with insufficient, deteriorated, or contaminated engine oil will cause accelerated wear and may result in engine seizure, accident, and injury. Check the oil level before each use and change the oil and filter according to the periodic maintenance chart.
  • Page 330: Oil Pan

    7-8 ENGINE LUBRICATION SYSTEM Oil Pan Oil Pan Removal • Remove: Exhaust Pipe (see Exhaust Pipe Removal in the Engine Top End chapter) Oil Filter (see Oil Filter Replacement in the Periodic Maintenance chapter) Oil Pan Bolts [A] Oil Pan [B] •...
  • Page 331 ENGINE LUBRICATION SYSTEM 7-9 Oil Pan NOTE ○ Make the application finish within 7 minutes when the liquid gasket to the mating surface of the oil pan is ap- plied. ○ Moreover fit the oil pan and tighten the bolts just after application of the liquid gasket.
  • Page 332: Oil Screen

    7-10 ENGINE LUBRICATION SYSTEM Oil Screen Oil Screen Removal • Remove: Oil Pan (see Oil Pan Removal) Oil Screen [A] Oil Screen Installation • Clean the oil screen (see Oil Screen Cleaning). • Replace the O-ring [A] with a new one, and install it. •...
  • Page 333: Oil Pressure Relief Valve

    ENGINE LUBRICATION SYSTEM 7-11 Oil Pressure Relief Valve Oil Pressure Relief Valve Removal • Remove: Oil Screen (see Oil Screen Removal) Oil Pressure Relief Valve [A] Oil Pressure Relief Valve Installation • Apply a non-permanent locking agent to the threads of the oil pressure relief valve, and tighten it.
  • Page 334: Oil Pump

    7-12 ENGINE LUBRICATION SYSTEM Oil Pump Oil Pump Removal • Remove: Water Pump (see Water Pump Removal in the Cooling System chapter) Oil Pump Cover [A] • Remove: Oil (Water) Pump Shaft [A] with Inner Rotor [B] Outer Rotor [C] Oil Pump Installation •...
  • Page 335: Oil Pump Drive Gear Removal

    ENGINE LUBRICATION SYSTEM 7-13 Oil Pump • Pack grease into the cavity [A] between the inner rotor and outer rotor for improve the oil pump initial priming. • Install the dowel pin [B]. • Install the oil pump cover [C] so that the dowel pin fits into the hole [D] of the oil pump cover.
  • Page 336: Oil Cooler

    7-14 ENGINE LUBRICATION SYSTEM Oil Cooler Oil Cooler Removal • Drain: Coolant (see Coolant Change in the Periodic Mainte- nance chapter) Engine Oil (see Engine Oil Change in the Periodic Main- tenance chapter) • Loosen the water hose clamp screws [A]. •...
  • Page 337: Oil Pressure Measurement

    ENGINE LUBRICATION SYSTEM 7-15 Oil Pressure Measurement Oil Pressure Measurement • Remove: Right Lower Fairing (see Lower Fairing Removal in the Frame chapter) Oil Passage Plug [A] • Attach the adapter [A] and gauge [B] to the plug hole. Special Tools - Oil Pressure Gauge, 10 kgf/cm²: 57001-164 Oil Pressure Gauge Adapter, PT3/8: 57001 -1233 •...
  • Page 338: Oil Pressure Switch

    7-16 ENGINE LUBRICATION SYSTEM Oil Pressure Switch Oil Pressure Switch Removal • Drain the engine oil (see Engine Oil Change in the Peri- odic Maintenance chapter). • Remove the left lower fairing (see Lower Fairing Removal in the Frame chapter). •...
  • Page 339: Oil Pipe

    ENGINE LUBRICATION SYSTEM 7-17 Oil Pipe Oil Pipe Removal • Remove: Oil Pan (see Oil Pan Removal) Oil Pipe [A] Oil Pipe Installation • Replace the O-rings [A] with new ones. • Apply grease to the O-rings, and install them. •...
  • Page 341 ENGINE REMOVAL/INSTALLATION 8-1 Engine Removal/Installation Table of Contents Exploded View........................Special Tool ..........................Engine Removal/Installation ....................Engine Removal........................ Engine Installation......................
  • Page 342: Exploded View

    8-2 ENGINE REMOVAL/INSTALLATION Exploded View...
  • Page 343 ENGINE REMOVAL/INSTALLATION 8-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Upper Engine Bracket Bolts Lower Engine Bracket Bolts Upper Adjusting Collar 0.51 44 in·lb 2T, S Upper Adjusting Collar Locknut Upper Engine Mounting Bolt (L = 65 mm) Lower Engine Mounting Nut Lower Adjusting Collar Locknut Middle Engine Mounting Nut Middle Engine Bracket Bolts...
  • Page 344: Special Tool

    8-4 ENGINE REMOVAL/INSTALLATION Special Tool Engine Mount Nut Wrench: 57001-1450...
  • Page 345: Engine Removal/installation

    ENGINE REMOVAL/INSTALLATION 8-5 Engine Removal/Installation Engine Removal • Support the rear part of the swingarm with a stand. • Squeeze the brake lever slowly and hold it with a band [A]. WARNING Motorcycle may fall over unexpectedly resulting in an accident or injury. Be sure to hold the front brake when removing the engine.
  • Page 346 8-6 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Slide the clamp [A]. • Disconnect the air bleeder hose [B]. • Remove the heat insulation rubber plate. • Loosen the water hose clamp screw [A]. • Disconnect: Water Hose [B] Water Temperature Sensor Connector [C] •...
  • Page 347 ENGINE REMOVAL/INSTALLATION 8-7 Engine Removal/Installation • Remove the drive chain [A] from the output shaft [B]. • Remove: Clamp [A] Upper Engine Bracket Bolts [B] Middle Fairing Bracket [C] Lower Engine Bracket Bolt [D] and Washer Engine Bracket [E] • Free the clutch cable [A] from the guide and clamp.
  • Page 348: Engine Installation

    8-8 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Remove: Upper Engine Mounting Bolt [A] (Both Sides) Middle Engine Mounting Nut [B] and Bolt Lower Engine Mounting Nut [C] • Using the nut wrench [A], loosen the upper adjusting collar locknut [B]. Special Tool - Engine Mount Nut Wrench: 57001-1450 •...
  • Page 349 ENGINE REMOVAL/INSTALLATION 8-9 Engine Removal/Installation This page intentionally left blank.
  • Page 350 8-10 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Install the engine mounting bolts and nuts, following the specified installing sequence. ○ First, hang the drive chain over the output shaft just before moving the engine into its final position in the frame. ○...
  • Page 351 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 (see appropriate chapters). • Adjust: Throttle Cables (see Throttle Control System Inspection in the Periodic Maintenance chapter) Clutch Cable (see Clutch Operation Inspection in the Pe- riodic Maintenance chapter)
  • Page 353 CRANKSHAFT/TRANSMISSION 9-1 Crankshaft/Transmission Table of Contents Exploded View........Starter Motor Clutch Disassembly 9-28 Specifications ........Starter Motor Clutch Assembly ..9-28 Special Tools and Sealants ....External Shift Mechanism....9-29 Crankcase Splitting......Shift Pedal Removal ....9-29 Crankcase Splitting ...... Shift Pedal Installation ....
  • Page 354: Exploded View

    9-2 CRANKSHAFT/TRANSMISSION Exploded View...
  • Page 355 CRANKSHAFT/TRANSMISSION 9-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Balancer Shaft Clamp Bolt 87 in·lb Balancer Shaft Clamp Lever Bolt Connecting Rod Big End Nuts see the text ← ← Breather Side Plate Bolt 0.60 52 in·lb Breather Plate Bolts 87 in·lb Starter Motor Clutch Bolts 106 in·lb...
  • Page 356 9-4 CRANKSHAFT/TRANSMISSION Exploded View...
  • Page 357 CRANKSHAFT/TRANSMISSION 9-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Gear Positioning Lever Bolt 106 in·lb Shift Drum Bearing Holder Bolts 106 in·lb Shift Drum Cam Holder Bolt 106 in·lb Shift Shaft Return Spring Pin Shift Pedal Mounting Bolt Neutral Switch EO: Apply engine oil.
  • Page 358: Specifications

    9-6 CRANKSHAFT/TRANSMISSION Specifications Item Standard Service Limit Crankcase, Crankshaft, Connecting Rods Connecting Rod Bend – – – TIR 0.2/100 mm (0.008/3.94 in.) Connecting Rod Twist – – – TIR 0.2/100 mm (0.008/3.94 in.) 0.13 ∼ 0.38 mm (0.0051 ∼ 0.0150 in.) Connecting Rod Big End Side 0.58 mm Clearance...
  • Page 359 CRANKSHAFT/TRANSMISSION 9-7 Specifications Item Standard Service Limit Crankshaft Main Bearing Insert Thickness: 1.491 ∼ 1.495 mm (0.0587 ∼ 0.0589 in.) Brown – – – 1.495 ∼ 1.499 mm (0.0589 ∼ 0.0590 in.) Black – – – 1.499 ∼ 1.503 mm (0.0590 ∼ 0.0592 in.) Blue –...
  • Page 360: Special Tools And Sealants

    9-8 CRANKSHAFT/TRANSMISSION Special Tools and Sealants Bearing Puller: Bearing Driver Set: 57001-135 57001-1129 Outside Circlip Pliers: Flywheel Holder: 57001-144 57001-1313 Bearing Puller Adapter: Liquid Gasket, TB1216B: 57001-317 92104-1064 Bearing Driver, 32: Liquid Gasket, TB1207B: 57001-382 92104-2068...
  • Page 361: Crankcase Splitting

    CRANKSHAFT/TRANSMISSION 9-9 Crankcase Splitting Crankcase Splitting • Remove the engine (see Engine Removal in the Engine Removal/Installation chapter). • Set the engine on a clean surface and hold the engine steady while parts are being removed. • Remove: Cylinder (see Cylinder Removal in the Engine Top End chapter) Clutch (see Clutch Removal in the Clutch chapter) External Shift Mechanism (see External Shift Mecha-...
  • Page 362: Crankcase Assembly

    9-10 CRANKSHAFT/TRANSMISSION Crankcase Splitting • Remove the lower crankcase bolts, following the specified sequence. ○ Firstly, loosen the M7 bolts [A]. ○ Lastly, loosen the M9 bolts as shown sequence [1 ∼ 10]. • Tap lightly around the crankcase mating surface with a plastic mallet, and split the crankcase.
  • Page 363 CRANKSHAFT/TRANSMISSION 9-11 Crankcase Splitting • Apply a non-permanent locking agent to the threads of the breather plate bolts [A] and tighten them. Torque - Breather Plate Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) • Install the breather side plate [A] so that the plate hole [B] fit the projection [C] of the upper crankcase.
  • Page 364 9-12 CRANKSHAFT/TRANSMISSION Crankcase Splitting • Install: Crankshaft (see Crankshaft Installation) Connecting Rods (see Connecting Rod Installation) Balancer (see Balancer Installation) Transmission Shafts (see Transmission Shaft Installa- tion) Dowel Pins [A] Shift Drum (see Shift Drum and Fork Installation) Shift Forks and Shift Rods (see Shift Drum and Fork In- stallation) •...
  • Page 365 CRANKSHAFT/TRANSMISSION 9-13 Crankcase Splitting • Fit the lower crankcase to the upper crankcase. NOTE ○ Make the application finish within 20 minutes when the liquid gasket to the mating surface of the lower crankcase half is applied. ○ Moreover fit the case and tighten the bolts just after application of the liquid gasket.
  • Page 366 9-14 CRANKSHAFT/TRANSMISSION Crankcase Splitting • Tighten the upper crankcase bolts using the following steps. ○ Tighten the M8 bolts [A]. Torque - Crankcase Bolts (M8): 27 N·m (2.8 kgf·m, 20 ft·lb) ○ Replace the washer [B] with a new one. ○...
  • Page 367: Crankshaft And Connecting Rods

    CRANKSHAFT/TRANSMISSION 9-15 Crankshaft and Connecting Rods Crankshaft Removal • Split the crankcase (see Crankcase Splitting). • Remove: Connecting Rods (see Connecting Rod Removal) Balancer (see Balancer Removal) Crankshaft [A] Crankshaft Installation NOTICE If the crankshaft, bearing inserts, or crankcase halves are replaced with new ones, select the bear- ing inserts and check clearance with a plastigage (press gauge) before assembling engine to be sure the correct bearing inserts are installed.
  • Page 368: Connecting Rod Installation

    9-16 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods Connecting Rod Installation NOTICE To minimize vibration, the connecting rods should have the same weight mark. Big End Cap [A] Connecting Rod [B] Weight Mark, Alphabet [C] ○ Diameter Mark [D]: “ ” or no mark NOTICE If the connecting rods, big end bearing inserts, or crankshaft are replaced with new ones, select the...
  • Page 369 CRANKSHAFT/TRANSMISSION 9-17 Crankshaft and Connecting Rods • Install each connecting rod on its original crankpin. ○ The connecting rod big end is bolted using the “plastic region fastening method.” ○ This method precisely achieves the needed clamping force without exceeding it unnecessarily, allowing the use of thinner, lighter bolts further decreasing connecting rod weight.
  • Page 370 9-18 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods • Install new bolts and nuts in reused connecting rod. If the connecting rod assy was replaced, use the bolts and nuts attached to the new connecting rod assy. • Apply a small amount of molybdenum disulfide oil solution to the following portions.
  • Page 371: Crankshaft/connecting Rod Cleaning

    CRANKSHAFT/TRANSMISSION 9-19 Crankshaft and Connecting Rods • Install new bolts and nuts in reused connecting rods. If the connecting rod assy was replaced, use the bolts and nuts attached to the new connecting rod assy. • Apply a small amount of molybdenum disulfide oil solution to the following portions.
  • Page 372: Connecting Rod Bend Inspection

    9-20 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods Connecting Rod Bend Inspection • Remove the connecting rod big end bearing inserts, and reinstall the connecting rod big end cap. • Select an arbor [A] of the same diameter as the connect- ing rod big end, and insert the arbor through the connect- ing rod big end.
  • Page 373: Connecting Rod Big End Bearing Insert/crankpin Wear Inspection

    CRANKSHAFT/TRANSMISSION 9-21 Crankshaft and Connecting Rods Connecting Rod Big End Bearing Insert/Crankpin Wear Inspection • Remove the connecting rod big end (see Connecting Rod Removal). • Cut strips of plastigage (press gauge) to crankpin width. Place a strip on the crankpin parallel to the crankshaft installed in the correct position.
  • Page 374: Crankshaft Side Clearance Inspection

    9-22 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods • Measure the connecting rod big end inside diameter, and mark each connecting rod big end in accordance with the inside diameter. • Tighten the connecting rod big end nuts to the specified torque (see Connecting Rod Installation). NOTE ○...
  • Page 375: Crankshaft Runout Inspection

    CRANKSHAFT/TRANSMISSION 9-23 Crankshaft and Connecting Rods Crankshaft Runout Inspection • Measure the crankshaft runout. If the measurement exceeds the service limit, replace the crankshaft. Crankshaft Runout Standard: TIR 0.02 mm (0.0008 in.) or less Service Limit: TIR 0.05 mm (0.0020 in.) Crankshaft Main Bearing Insert/Journal Wear Inspection •...
  • Page 376 9-24 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods Crankshaft Main Journal Diameter 34.984 ∼ 35.000 mm (1.3773 ∼ 1.3780 in.) Standard: Service Limit: 34.96 mm (1.376 in.) If any journal has worn past the service limit, replace the crankshaft with a new one. If the measured journal diameters [A] are not less than the service limit, but do not coincide with the original diameter markings [B] on the crankshaft, make new marks on it.
  • Page 377 CRANKSHAFT/TRANSMISSION 9-25 Crankshaft and Connecting Rods Crankcase Main Crankshaft Main Bearing Insert* Bearing Inside Journal Diameter Diameter Marking Marking Size Color Part Number Journal Nos. 92139-0034 2, 4 ○ Brown 92139-0219 1, 3, 5 None 92139-0033 2, 4 Black ○ None 92139-0218 1, 3, 5...
  • Page 378: Balancer

    9-26 CRANKSHAFT/TRANSMISSION Balancer Balancer Removal • Split the crankcase (see Crankcase Splitting). • Remove: Oil Seal [A] Balancer [B] Balancer Installation • Check that the rubber dampers [A] are in place as shown. • Apply molybdenum disulfide oil solution to the damper contact portions of the balancer weight [A].
  • Page 379: Balancer Adjustment

    CRANKSHAFT/TRANSMISSION 9-27 Balancer • Assemble the crankcase (see Crankcase Assembly). • Fill the oil seal lips with grease. • Install the new oil seal [A] so that its surface is flush with the surface of the crankcase. • Install the balancer shaft clamp lever [B]. •...
  • Page 380: Starter Motor Clutch

    9-28 CRANKSHAFT/TRANSMISSION Starter Motor Clutch Starter Motor Clutch Removal/Installation • Refer to the Starter Motor Clutch Disassembly/Assembly. Starter Motor Clutch Inspection • Remove: Alternator Cover (see Alternator Cover Removal in the Electrical System chapter) Starter Idle Gear and Shaft • Turn the starter motor clutch gear [A] by hand.
  • Page 381: External Shift Mechanism

    CRANKSHAFT/TRANSMISSION 9-29 External Shift Mechanism Shift Pedal Removal • Remove: Shift Lever Bolt [A] Shift Lever [B] If the tie-rod is removed from the shift pedal and shift lever, note the following. ○ The following portions have left-hand threads. Locknut [C] of Shift Lever Side Ball Joint [D] of Shift Lever •...
  • Page 382: External Shift Mechanism Removal

    9-30 CRANKSHAFT/TRANSMISSION External Shift Mechanism External Shift Mechanism Removal • Remove: Shift Lever (see Shift Pedal Removal) Clutch (see Clutch Removal in the Clutch chapter) Circlip [A] Washer [B] Special Tool - Outside Circlip Pliers: 57001-144 • Remove: Shift Shaft Assembly [A] •...
  • Page 383: External Shift Mechanism Inspection

    CRANKSHAFT/TRANSMISSION 9-31 External Shift Mechanism • Apply grease to the lips of the oil seal [A]. • Install the shift shaft [A] so that the return spring pin [B] fits between the spring [C]. • Install the washer [A]. • Replace the circlip [B] with a new one, and install it.
  • Page 384 9-32 CRANKSHAFT/TRANSMISSION External Shift Mechanism • Check the gear positioning lever [A] and its spring for breaks or distortion. If the lever or spring are damaged in any way, replace them. • Visually inspect the shift drum cam [B]. If it is badly worn or shows any damage, replace it.
  • Page 385: Transmission

    CRANKSHAFT/TRANSMISSION 9-33 Transmission Transmission Shaft Removal • Split the crankcase (see Crankcase Splitting). • Remove the drive shaft [A] and output shaft [B]. Transmission Shaft Installation • Check to see that the set pins [A] and set rings [B] are in place.
  • Page 386: Transmission Shaft Assembly

    9-34 CRANKSHAFT/TRANSMISSION Transmission • Remove the ball bearing [A] from each shafts. Special Tools - Bearing Puller [B]: 57001-135 Bearing Puller Adapter [C]: 57001-317 • Discard the bearing. Transmission Shaft Assembly • Install the new ball bearing [A] on the each shaft, using the bearing driver.
  • Page 387 CRANKSHAFT/TRANSMISSION 9-35 Transmission • The drive shaft gears can be recognized by size: the gear with the smallest diameter is 1st gear, and the largest one is 6th gear. Be sure that all parts are put back in the cor- rect sequence and all circlips and washers are properly in place.
  • Page 388 9-36 CRANKSHAFT/TRANSMISSION Transmission...
  • Page 389 CRANKSHAFT/TRANSMISSION 9-37 Transmission 1. Output Shaft 2. Collar 3. Ball Bearings 4. Bushing 5. 2nd Gear (39 T) 6. Washer ( 34 × 28.1) 7. Circlips ( 33 × 25.9) 8. Top Gear (31 T) 9. Toothed Washer ( 34) 10.
  • Page 390: Shift Drum And Fork Removal

    9-38 CRANKSHAFT/TRANSMISSION Transmission Shift Drum and Fork Removal • Remove: Lower Crankcase Half (see Crankcase Splitting) Transmission Shafts (see Transmission Shaft Removal) Gear Positioning Lever (see External Shift Mechanism Removal) Shift Drum Bearing Holder Bolts [A] Shift Drum Bearing Holder [B] •...
  • Page 391: Shift Fork Bending Inspection

    CRANKSHAFT/TRANSMISSION 9-39 Transmission Shift Fork Bending Inspection • 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°...
  • Page 392: Ball Bearing, Needle Bearing, And Oil Seal

    9-40 CRANKSHAFT/TRANSMISSION Ball Bearing, Needle Bearing, and Oil Seal Ball and Needle Bearing Replacement NOTICE Do not remove the ball or needle bearings unless it is necessary. Removal may damage them. • Using a press or puller, remove the ball bearing and/or needle bearings.
  • Page 393 WHEELS/TIRES 10-1 Wheels/Tires Table of Contents Exploded View........................10-2 Specifications ......................... 10-4 Special Tools .......................... 10-5 Wheels (Rims) ........................10-6 Front Wheel Removal ....................... 10-6 Front Wheel Installation ....................10-6 Rear Wheel Removal......................10-7 Rear Wheel Installation..................... 10-9 Wheel Inspection ......................10-10 Axle Inspection........................
  • Page 394: Exploded View

    10-2 WHEELS/TIRES Exploded View...
  • Page 395 WHEELS/TIRES 10-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Axle Clamp Bolts Front Axle 11.0 79.7 Rear Axle Nut 10.0 AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque. HG: Apply high-temperature grease. R: Replacement Parts WL: Apply soap and water solution or rubber lubricant.
  • Page 396: 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 0.3 mm (0.01 in.) or less TIR 1.0 mm (0.04 in.) Axle Runout/100 mm (3.94 in.): Front TIR 0.03 mm (0.0012 in.) or less TIR 0.2 mm (0.008 in.)
  • Page 397: Special Tools

    WHEELS/TIRES 10-5 Special Tools Bearing Driver Set: Bearing Remover Head, 20 × 22: 57001-1129 57001-1293 Jack: Bearing Remover Shaft, 13: 57001-1238 57001-1377 Attachment Jack: Jack Attachment: 57001-1252 57001-1608...
  • Page 398: Wheels (rims)

    10-6 WHEELS/TIRES Wheels (Rims) Front Wheel Removal • For the ABS equipped models, remove the bolt [A] and front wheel rotation sensor [B]. • Remove: Front Caliper Mounting Bolts [C] (Both Sides) Front Caliper [D] (Both Sides) • Loosen: Front Axle Clamp Bolts [A] Front Axle [B] •...
  • Page 399: Rear Wheel Removal

    WHEELS/TIRES 10-7 Wheels (Rims) • Apply high-temperature grease to the grease seal lips. • Fit the collar [A] on the both sides of the hub. ○ The collars are identical. • Insert the front axle from the right side. • Tighten: Torque - Front Axle: 108 N·m (11.0 kgf·m, 79.7 ft·lb) •...
  • Page 400 10-8 WHEELS/TIRES Wheels (Rims) • Loosen the torque link nuts [A] lightly to turn the chain adjuster easily. • Remove: Bolt [A] Clamp [B] Rear Wheel Rotation Sensor [C] Rear Caliper Mounting Bolts [D] Rear Caliper [E] • Loosen the chain adjuster clamp bolt [A] on both sides. •...
  • Page 401: Rear Wheel Installation

    WHEELS/TIRES 10-9 Wheels (Rims) Rear Wheel Installation • Apply high-temperature grease to the grease seal lips. • Fit the collars on the both sides of the hub. Left Side Collar [A] ( 40 × 35) Right Side Collar [B] ( 41 × 28) •...
  • Page 402: Wheel Inspection

    10-10 WHEELS/TIRES Wheels (Rims) Wheel Inspection • Raise the front/rear wheel off the ground. Special Tools - Jack: 57001-1238 Attachment Jack: 57001-1252 Jack Attachment: 57001-1608 • Spin the wheel lightly, and check for roughness or binding. If roughness or binding is found, replace the hub bearings (see Hub Bearing Removal/Installation).
  • Page 403: Balance Inspection

    WHEELS/TIRES 10-11 Wheels (Rims) Balance Inspection • Remove the front and rear wheels (see Front/Rear Wheel Removal). • Support the wheel so that it can be spun freely. • Spin the wheel lightly, and mark [A] the wheel at the top when the wheel stops.
  • Page 404 30 g (1.06 oz.) NOTE ○ Balance weights are available from Kawasaki dealers in 10, 20 and 30 grams (0.35, 0.71 and 1.06 oz.) sizes. An imbalance of less than 10 grams (0.35 oz.) will not usually affect running stability.
  • Page 405: Tires

    WHEELS/TIRES 10-13 Tires Air Pressure Inspection/Adjustment • Refer to the Air Pressure Inspection in the Periodic Main- tenance chapter. Tire Inspection • Refer to the Wheel/Tire Damage Inspection in the Peri- odic Maintenance chapter. Tire Removal • Remove: Wheels (see Front/Rear Wheel Removal) Valve Core (Let out the air) •...
  • Page 406 10-14 WHEELS/TIRES Tires • Install a new valve in the rim. ○ Remove the valve cap, lubricate the stem seal [A] with a soap and water solution or rubber lubricant, and pull [B] the valve stem through the rim from the inside out until it snaps into place.
  • Page 407: 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 408: Hub Bearing

    10-16 WHEELS/TIRES Hub Bearing Hub Bearing Removal • Remove the wheels (see Front/Rear Wheel Removal), and take out the following. Collars [A] Coupling [B] (Out of rear hub) Grease Seals [C] • Use the bearing remover to remove the hub bearings [A]. NOTICE Do not lay the wheel on the ground with the disc facing down.
  • Page 409: Hub Bearing Inspection

    WHEELS/TIRES 10-17 Hub Bearing • Replace the grease seals with new ones. • Press in the grease seals [A] so that the seal surface is flush [B] with the end of the hole. ○ Apply high-temperature grease to the grease seal lips. Special Tool - Bearing Driver Set [C]: 57001-1129 •...
  • Page 411 FINAL DRIVE 11-1 Final Drive Table of Contents Exploded View........................11-2 Specifications ......................... 11-4 Special Tools .......................... 11-5 Drive Chain..........................11-6 Drive Chain Slack Inspection .................... 11-6 Drive Chain Slack Adjustment ..................11-6 Wheel Alignment Inspection/Adjustment ................11-6 Drive Chain Wear Inspection .................... 11-6 Drive Chain Lubrication.....................
  • Page 412: Exploded View

    11-2 FINAL DRIVE Exploded View...
  • Page 413 FINAL DRIVE 11-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Chain Guide Bolts 87 in·lb Engine Sprocket Outer Cover Screws 0.70 0.07 6.2 in·lb Engine Sprocket Nut 12.7 92.2 Rear Sprocket Nuts R, S Chain Adjuster Clamp Bolts HG: Apply high-temperature grease. HO: Apply heavy oil.
  • Page 414: Specifications

    11-4 FINAL DRIVE Specifications Item Standard Service Limit Drive Chain 20 ∼ 30 mm (0.8 ∼ 1.2 in.) Drive Chain Slack – – – Drive Chain Wear (20-link Length) 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) 319 mm (12.6 in.) Standard Chain: Make ENUMA...
  • Page 415: Special Tools

    FINAL DRIVE 11-5 Special Tools Inside Circlip Pliers: Bearing Driver Set: 57001-143 57001-1129...
  • Page 416: Drive Chain

    11-6 FINAL DRIVE Drive Chain Drive Chain Slack Inspection • Refer to the Drive Chain Slack Inspection in the Periodic Maintenance chapter. Drive Chain Slack Adjustment • Refer to the Drive Chain Slack Adjustment in the Periodic Maintenance chapter. Wheel Alignment Inspection/Adjustment •...
  • Page 417 FINAL DRIVE 11-7 Drive Chain Body [A] Handlebar [B] Cutting and Riveting Pin [C] For Cutting [D] For Riveting [E] Plate Holder (A) [F] Plate Holder (B) [G] Gauge [H] • Grind [A] the pin head to make it flat. •...
  • Page 418 11-8 FINAL DRIVE Drive Chain • Set the plate holder (A) [A] and plate holder (B) [B] on the body. • Fit the plate holder (A) [A] to the link plate. • Turn the pin holder by hand until the plate holder (B) [B] touches the other link plate.
  • Page 419 FINAL DRIVE 11-9 Drive Chain • Turn the wrench clockwise until the tip of riveting pin hits to the link pin. • Rivet it. • Same work for the other link pin. • After staking, check the staked area of the link pin for cracks.
  • Page 420: Sprocket, Coupling

    11-10 FINAL DRIVE Sprocket, Coupling Engine Sprocket Removal • Remove: Engine Sprocket Cover Bolts [A] Engine Sprocket Cover [B] • Flatten out the bended washer [A]. • Remove the engine sprocket nut [B] and washer. NOTE ○ When loosening the engine sprocket nut, hold the rear brake on.
  • Page 421: Engine Sprocket Cover Disassembly

    FINAL DRIVE 11-11 Sprocket, Coupling • Install: Dowel Pins [A] • Install: Engine Sprocket Cover [A] • Tighten the engine sprocket cover bolts. ○ First tighten the two bolts [B] at the dowel pin positions. Engine Sprocket Cover Disassembly • Remove: Engine Sprocket Cover (see Engine Sprocket Removal) Chain Guide Bolts [A]...
  • Page 422: Rear Sprocket Removal

    11-12 FINAL DRIVE Sprocket, Coupling Rear Sprocket Removal • Remove the rear wheel (see Rear Wheel Removal in the Wheels/Tires chapter). NOTICE Do not lay the wheel on the ground with the disc facing down. This can damage or warp the disc. Place blocks under the wheel so that the disc does not touch the ground.
  • Page 423: Coupling Bearing Removal

    FINAL DRIVE 11-13 Sprocket, Coupling • Install: Collar [A] Coupling [B] Coupling Bearing Removal • Remove: Coupling Grease Seal Circlip [A] Special Tool - Inside Circlip Pliers: 57001-143 • Remove the bearing [A] by tapping from the wheel side. Special Tool - Bearing Driver Set [B]: 57001-1129 Coupling Bearing Installation •...
  • Page 424: Coupling Bearing Inspection

    11-14 FINAL DRIVE Sprocket, Coupling Coupling Bearing Inspection Since the coupling bearing is made to extremely close tolerances, the clearance can not normally be measured. NOTE ○ It is not necessary to remove the coupling bearing for inspection. If the bearing is removed, it will need to be replaced with a new one.
  • Page 425: Rear Sprocket Warp Inspection

    FINAL DRIVE 11-15 Sprocket, Coupling Rear Sprocket Warp Inspection • Raise the rear wheel off the ground with the stand so that it will turn freely. • Set a dial gauge [A] against the rear sprocket [B] near the teeth as shown, and rotate [C] the rear wheel to measure the sprocket runout (warp).
  • Page 427 BRAKES 12-1 Brakes Table of Contents Exploded View........................12-3 Specifications ......................... 12-10 Special Tools .......................... 12-11 Brake Lever, Brake Pedal....................... 12-12 Brake Lever Position Adjustment..................12-12 Brake Pedal Position Inspection ..................12-12 Brake Pedal Position Adjustment..................12-12 Brake Pedal Removal ....................... 12-12 Brake Pedal Installation ....................
  • Page 428 12-2 BRAKES Parts Location ........................12-29 ABS Servicing Precautions ....................12-33 ABS Troubleshooting Outline.................... 12-35 Inquiries to Rider....................... 12-38 Self-diagnosis Outline ....................... 12-40 Self-diagnosis Procedures ....................12-40 Service Code Clearing Procedures................... 12-41 How to Read Service Codes..................... 12-44 How to Erase Service Codes .................... 12-44 Yellow ABS Indicator (LED) Inspection ................
  • Page 429: Exploded View

    BRAKES 12-3 Exploded View This page intentionally left blank.
  • Page 430 12-4 BRAKES Exploded View...
  • Page 431 BRAKES 12-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Brake Reservoir Cap Bolts 0.15 13 in·lb Front Brake Reservoir Inner Bolt 0.12 11 in·lb Front Brake Reservoir Bolt 0.80 69 in·lb Brake Lever Pivot Bolt 0.10 8.9 in·lb Front Master Cylinder Bleed Valve 0.55 48 in·lb...
  • Page 432 12-6 BRAKES Exploded View...
  • Page 433 BRAKES 12-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Brake Hose Banjo Bolts Rear Master Cylinder Mounting Bolts Brake Pedal Bolt 0.90 78 in·lb Rear Master Cylinder Push Rod Locknut Rear Wheel Rotation Sensor Bolt Bleed Valve 0.80 69 in·lb Rear Brake Disc Mounting Bolts L, S Rear Caliper Mounting Bolts...
  • Page 434 12-8 BRAKES Exploded View ABS Equipped Models...
  • Page 435 BRAKES 12-9 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Brake Hose Banjo Bolts Brake Pipe Joint Nuts Front Wheel Rotation Sensor Bolt 4. ABS Hydraulic Unit R: Replacement Parts NOTE ○ When disassembling the brake hose and pipe, disassemble them by the unit as shown in the exploded view.
  • Page 436: Specifications

    12-10 BRAKES Specifications Item Standard Service Limit Brake Lever, Brake Pedal Brake Lever Position 6-way adjustable (to suit rider) – – – Brake Lever Free Play Non-adjustable – – – Pedal Free Play Non-adjustable – – – Pedal Position About 62 mm (2.4 in.) below footpeg top –...
  • Page 437: Special Tools

    BRAKES 12-11 Special Tools Jack: Needle Adapter Set: 57001-1238 57001-1457 Attachment Jack: Jack Attachment: 57001-1252 57001-1608...
  • Page 438: Brake Lever, Brake Pedal

    12-12 BRAKES Brake Lever, Brake Pedal Brake Lever Position Adjustment The brake lever adjuster has 6 positions so that the brake lever position can be adjusted to suit the operator’s hand. • Push the lever forward and turn the adjuster [A] to align the number with the arrow mark [B] on the lever.
  • Page 439: Brake Pedal Installation

    BRAKES 12-13 Brake Lever, Brake Pedal • Remove: Cotter Pin [A] Joint Pin [B] Rear Brake Light Switch Spring [C] Return Spring [D] Brake Pedal Bolt [E] and Washer Brake Pedal [F] Brake Pedal Installation • Apply grease to the footpeg pivot shaft [A]. •...
  • Page 440: Calipers

    12-14 BRAKES Calipers Front Caliper Removal • Remove (ABS Equipped Models): Bolt [A] Front Wheel Rotation Sensor [B] • Loosen the banjo bolt [C] at the brake hose lower end, and tighten it loosely. • Remove the caliper mounting bolts [D], and detach the caliper [E] from the disc.
  • Page 441: Front Caliper Assembly

    BRAKES 12-15 Calipers Front Caliper Assembly • Refer to the Caliper Rubber Parts Replacement in the Pe- riodic Maintenance chapter. Rear Caliper Disassembly • Refer to the Caliper Rubber Parts Replacement in the Pe- riodic Maintenance chapter. Rear Caliper Assembly •...
  • Page 442: Rear Caliper Dust Boot And Friction Boot Damage Inspection

    12-16 BRAKES Calipers Rear 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 443: Brake Pads

    BRAKES 12-17 Brake Pads Front Brake Pad Removal • Loosen the pad pins [A]. • Remove the front caliper with the hose installed (see Front Caliper Removal). • Remove: Pad Pins Brake Pads Front Brake Pad Installation • Check that the pad spring [A] is in place on the caliper. •...
  • Page 444: Rear Brake Pad Installation

    12-18 BRAKES Brake Pads Rear Brake Pad Installation • Check that the pad spring [A], guide [B] and insulator [C] are in place on the caliper and holder. • Push the caliper piston in by hand as far as it will go. •...
  • Page 445: Master Cylinder

    BRAKES 12-19 Master Cylinder Front Master Cylinder Removal • Remove the rear view mirror (see Rear View Mirror Re- moval in the Frame chapter). • Remove the banjo bolt [A] to disconnect the brake hose from the master cylinder. • Unscrew the clamp bolts [B], and take off the master cylin- der [C] as an assembly with the reservoir, brake lever, and brake light switch installed.
  • Page 446: Rear Master Cylinder Installation

    12-20 BRAKES Master Cylinder • Remove: Cotter Pin [A] Joint Pin [B] • Slide the clamp [C]. • Disconnect the reservoir hose lower end, and drain the brake fluid into a container. Rear Master Cylinder Installation • Replace the cotter pin [A] with a new one. •...
  • Page 447: Master Cylinder Inspection (visual Inspection)

    BRAKES 12-21 Master Cylinder Master Cylinder Inspection (Visual Inspection) • Remove the master cylinders (see Front/Rear Master Cylinder Removal). • Disassemble the front and rear master cylinders (see Master Cylinder Rubber Parts Replacement in the Peri- odic Maintenance chapter). • Check that there are no scratches, rust or pitting on the inner wall [A] of each master cylinder and on the outside of each piston [B].
  • Page 448: Brake Disc

    12-22 BRAKES Brake Disc Brake Disc Removal • Remove the wheels (see Front/Rear Wheel Removal in the Wheels/Tires chapter). • Remove the brake disc mounting bolts [A], and take off the disc [B]. • Remove the wheel rotation sensor rotor [C] (Front, ABS equipped models).
  • Page 449: Brake Disc Warp Inspection

    BRAKES 12-23 Brake Disc Brake Disc Warp Inspection • Raise the front/rear wheel off the ground. Special Tools - Jack: 57001-1238 Attachment Jack: 57001-1252 Jack Attachment: 57001-1608 ○ For front disc inspection, turn the handlebars fully to one side. • Set up a dial gauge against the disc [A] as shown and measure disc runout, while turning [B] the wheel by hand.
  • Page 450: Brake Fluid

    12-24 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 451 BRAKES 12-25 Brake Fluid • Bleed the brake line and the master cylinder. ○ Repeat this operation until no more air can be seen com- ing out into the plastic hose. 1. Pump the brake lever until it becomes hard, and apply the brake and hold it [A].
  • Page 452 12-26 BRAKES Brake Fluid • Bleed the brake line and the caliper. ○ Repeat this operation until no more air can be seen com- ing out into the plastic hose. 1. Pump the brake lever until it becomes hard, and apply the brake and hold it [A].
  • Page 453 BRAKES 12-27 Brake Fluid WARNING When working with the disc brake, observe the pre- cautions listed below. • Never reuse old brake fluid. • Do not use fluid from a container that has been left unsealed or that has been open for a long time. •...
  • Page 454: Brake Hose

    12-28 BRAKES Brake Hose Brake Hose 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 455: Anti-lock Brake System (equipped Models)

    BRAKES 12-29 Anti-Lock Brake System (Equipped Models) Parts Location Front Wheel Rotation Sensor [A] Front Wheel Rotation Sensor Rotor [B] NOTE ○ The rear wheel rotation sensor and rotor are standard parts of this motorcycle. Rear Wheel Rotation Sensor [A] Rear Wheel Rotation Sensor Rotor [B] Yellow ABS Indicator (LED) [A] ABS Hydraulic Unit [A]...
  • Page 456 12-30 BRAKES Anti-Lock Brake System (Equipped Models) ABS Kawasaki Diagnosis System Connector [A] ABS Self-diagnosis Terminal [B]...
  • Page 457 4. ABS Hydraulic Unit 16. Front Brake Light Switch 5. ABS Self-diagnosis Terminal 17. Fuse Box 1 6. ABS Kawasaki Diagnosis System Connector 18. Ignition Fuse 15 A 7. Frame Ground 4 19. Brake Light/Horn Fuse 7.5 A 8. Frame Ground 1 20.
  • Page 458 2. Unused 3. Front Wheel Rotation Sensor Signal Input: BK/W 4. Power Supply: BR/W 5. ABS Kawasaki Diagnosis System Terminal: P 6. Front and Rear Brake Light Switch Signal: BL/R 7. ABS Self-diagnosis Terminal: GY 8. Front Wheel Rotation Sensor Signal Output: G/Y 9.
  • Page 459: Abs Servicing Precautions

    BRAKES 12-33 Anti-Lock Brake System (Equipped Models) ABS Servicing Precautions There are a number of important precautions that should be followed servicing the ABS system. ○ This ABS system is designed to be used with a 12 V sealed battery as its power source. Do not use any other battery except for a 12 V sealed battery as a power source.
  • Page 460 12-34 BRAKES Anti-Lock Brake System (Equipped Models) WARNING Air in the brake lines diminish braking performance and can cause an accident resulting in injury or death. If any of the brake line fittings, including the ABS hydraulic unit joint nuts, or the bleed valve is opened at any time, the air must be bled completely from the brake line.
  • Page 461: Abs Troubleshooting Outline

    BRAKES 12-35 Anti-Lock Brake System (Equipped Models) ○ The yellow ABS indicator (LED) may come on if the en- gine is run with the motorcycle on its stand and the trans- mission in gear. If the indicator comes on, just turn the ignition switch off, then clear service code 42, which indi- cates a “Faulty front wheel rotation sensor.”...
  • Page 462 12-36 BRAKES Anti-Lock Brake System (Equipped Models) Even when the ABS is operating normally, the yellow ABS indicator (LED) may light up under the conditions listed be- low. Turn the ignition switch off to stop the indicator light. If the motorcycle runs without erasing the service code, the indicator may light up again.
  • Page 463 BRAKES 12-37 Anti-Lock Brake System (Equipped Models) ABS Diagnosis Flow Chart...
  • Page 464: Inquiries To Rider

    12-38 BRAKES Anti-Lock Brake System (Equipped Models) Inquiries to Rider ○ Each rider reacts to problems in different ways, so it is important to confirm what kind of condition the rider is dissatisfied with. ○ Try to find out exactly what problem occurs under exactly what conditions by asking the rider; know- ing this information may help you reproduce the problem in the shop.
  • Page 465 BRAKES 12-39 Anti-Lock Brake System (Equipped Models) Pre-Diagnosis Inspection 1...
  • Page 466: Self-diagnosis Outline

    12-40 BRAKES Anti-Lock Brake System (Equipped Models) Pre-Diagnosis Inspection 2 Self-diagnosis Outline When the yellow ABS indicator light (LED) has blinked or goes on, the ABS hydraulic unit memorizes and stores the service code (19 codes including “Normal Code”) for the service person to troubleshoot easily.
  • Page 467: Service Code Clearing Procedures

    BRAKES 12-41 Anti-Lock Brake System (Equipped Models) • Remove the front seat (see Front Seat Removal in the Frame chapter). • Ground the self-diagnosis terminal [A] (Gray) to the bat- tery (–) terminal, using a suitable lead. • Turn the ignition switch on. ○...
  • Page 468 12-42 BRAKES Anti-Lock Brake System (Equipped Models)
  • Page 469 BRAKES 12-43 Anti-Lock Brake System (Equipped Models) Self-diagnosis Flow Chart...
  • Page 470: How To Read Service Codes

    12-44 BRAKES Anti-Lock Brake System (Equipped Models) How to Read Service Codes ○ Service codes are shown by a series of long and short blinks of the yellow ABS indicator light (LED) as shown below. ○ Read 10th digit and unit digit as the yellow ABS indicator light (LED) blinks. ○...
  • Page 471: Service Code Table

    BRAKES 12-45 Anti-Lock Brake System (Equipped Models) Service Code Table Service Light Yellow ABS Indicator Light (LED) Problems Code State After Start code (not fault) starts, turn off Rear inlet solenoid valve trouble (shorted or open, stuck valve) Rear outlet solenoid valve trouble (shorted or open, stuck valve) Front inlet solenoid valve trouble (shorted or open, stuck valve)
  • Page 472 12-46 BRAKES Anti-Lock Brake System (Equipped Models) Service Light Yellow ABS Indicator Light (LED) Problems Code State Output fluid pressure sensor (front brake) trouble (offset abnormal) Power supply voltage for fluid pressure sensor abnormal (voltage abnormal, wiring shorted or open)
  • Page 473: Yellow Abs Indicator (led) Inspection

    BRAKES 12-47 Anti-Lock Brake System (Equipped Models) Yellow ABS Indicator (LED) Inspection ○ In this model, the yellow ABS indicator (LED) [A] goes on or blinks by the control of the ABS hydraulic unit. • Turn the ignition switch on. If the yellow ABS indicator (LED) lights, it is normal.
  • Page 474: Front, Rear Wheel Rotation Difference Abnormal (service Code 25)

    12-48 BRAKES Anti-Lock Brake System (Equipped Models) If the fuse is good, check the wiring continuity between the positive (+) terminal [A] of the battery and R/BK lead terminal [B] in the ABS hydraulic unit lead connector [C]. If there is not the continuity in the lead, replace or repair the main harness.
  • Page 475: Abs Motor Relay Inspection (service Code 35)

    BRAKES 12-49 Anti-Lock Brake System (Equipped Models) ABS Motor Relay Inspection (Service Code 35) • Remove: Front Seat (see Front Seat Removal in the Frame chap- ter) • Check the ABS motor relay fuse (25 A) [A] (see Fuse Inspection in the Electrical System chapter). If the fuse is good, check the wiring continuity between the positive (+) terminal [A] of the battery and R/W lead terminal [B] in the ABS hydraulic unit lead connector [C].
  • Page 476: Front Wheel Rotation Sensor Wiring Inspection (service Code 43)

    12-50 BRAKES Anti-Lock Brake System (Equipped Models) • Recheck the service code indication; erase the service code, perform the pre-diagnosis inspection 1 and 2, and retrieve the service code. If the yellow ABS indicator (LED) [A] lights, the ABS hy- draulic unit has trouble.
  • Page 477: Rear Wheel Rotation Sensor Wiring Inspection (service Code 45)

    BRAKES 12-51 Anti-Lock Brake System (Equipped Models) • Check that there is iron or other magnetic deposits be- tween the sensor [A] and sensor rotor [B], and the sensor rotor slots for obstructions. • Check the installation condition of the sensor for loose- ness.
  • Page 478: Power Supply Voltage Abnormal [over-voltage] (service Code 53)

    12-52 BRAKES Anti-Lock Brake System (Equipped Models) • Recheck the service code indication; erase the service code, perform the pre-diagnosis inspection 1 and 2, and retrieve the service code. If the yellow ABS indicator (LED) [A] lights, the ABS hy- draulic unit has trouble.
  • Page 479: Output Fluid Pressure Sensor (front Brake) Wiring Inspection (service Code 83)

    BRAKES 12-53 Anti-Lock Brake System (Equipped Models) Output Fluid Pressure Sensor (Front Brake) Wiring Inspection (Service Code 83) • Perform the Pre-Diagnosis Inspection 1 and 2 (see In- quiries to Rider). If the yellow ABS indicator (LED) [A] lights, the ABS hy- draulic unit has trouble.
  • Page 480 12-54 BRAKES Anti-Lock Brake System (Equipped Models) • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Battery Case (see Battery Case Removal in the Frame chapter) • Clean the ABS hydraulic unit. NOTICE Clean all fittings on the ABS hydraulic unit and the rear master cylinder because dirt around the banjo bolts could contaminate the brake fluid in the line during removal/installation.
  • Page 481: Abs Hydraulic Unit Installation

    BRAKES 12-55 Anti-Lock Brake System (Equipped Models) • Remove: Bolts [A] Bracket [B] • Pull up the ABS hydraulic unit [A]. • Remove: Bolts [B] ABS Hydraulic Unit NOTICE The ABS hydraulic unit has been adjusted and set with precision at the factory. Do not try to disas- semble and repair the ABS hydraulic unit.
  • Page 482: Front Wheel Rotation Sensor Removal

    12-56 BRAKES Anti-Lock Brake System (Equipped Models) • Visually inspect the connector terminals [A]. Replace the ABS hydraulic unit or main harness if either of the terminals are cracked, bent, or otherwise damaged. If the ABS hydraulic unit connector is clogged with mud or dust, blow it off with compressed air.
  • Page 483: Rear Wheel Rotation Sensor Removal

    BRAKES 12-57 Anti-Lock Brake System (Equipped Models) Rear Wheel Rotation Sensor Removal NOTICE The wheel rotation sensor should be handled care- fully, never struck sharply, as with a hammer, or al- lowed to fall on a hard surface since the wheel rota- tion sensor is precision made.
  • Page 484: Wheel Rotation Sensor Inspection

    12-58 BRAKES Anti-Lock Brake System (Equipped Models) Wheel Rotation Sensor Inspection • Remove the front wheel rotation sensor [A] from the front fork. • Remove the rear wheel rotation sensor [B] from the caliper bracket. • Visually inspect the wheel rotation sensors. Replace the wheel rotation sensor if it is cracked, bent, or otherwise damaged.
  • Page 485: Wheel Rotation Sensor Rotor Inspection

    BRAKES 12-59 Anti-Lock Brake System (Equipped Models) Wheel Rotation Sensor Rotor Inspection • Remove: Wheels (see Front/Rear Wheel Removal in the Wheels/Tires chapter) Brake Disc Mounting Bolts [A] Sensor Rotor [B] Front Wheel [C] Rear Wheel [D] • Visually inspect the wheel rotation sensor rotor. If the rotor is deformed or damaged (chipped teeth [A]), replace the sensor rotor with a new one.
  • Page 486: Fuse Inspection

    12-60 BRAKES Anti-Lock Brake System (Equipped Models) Fuse Inspection • Remove the fuses (see ABS Solenoid Valve Relay Fuse (15 A)/ABS Motor Relay Fuse (25 A) Removal). • Refer to the Fuse Inspection in the Electrical System chapter.
  • Page 487 SUSPENSION 13-1 Suspension Table of Contents Exploded View........................13-2 Specifications ......................... 13-6 Special Tools .......................... 13-7 Front Fork ..........................13-9 Rebound Damping Force Adjustment................13-9 Compression Damping Force Adjustment ................ 13-9 Spring Preload Adjustment ....................13-10 Front Fork Removal (Each Fork Leg) ................13-10 Front Fork Installation (Each Fork Leg) ................
  • Page 488: Exploded View

    13-2 SUSPENSION Exploded View...
  • Page 489 SUSPENSION 13-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Upper Front Fork Clamp Bolts Lower Front Fork Clamp Bolts Front Fork Top Plugs Piston Rod Guide Case Front Axle Clamp Bolts AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque. G: Apply grease.
  • Page 490 13-4 SUSPENSION Exploded View...
  • Page 491 SUSPENSION 13-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Upper Rear Shock Absorber Bolt Swingarm Pivot Shaft Nut 11.0 79.7 Swingarm Pivot Shaft Swingarm Pivot Adjusting Collar Locknut 10.0 Tie-Rod Nuts Lower Rear Shock Absorber Nut Rocker Arm Nut Torque Link Nuts G: Apply grease.
  • Page 492: Specifications

    Fork Spring Preload Setting 6 1/4 turns in from the fully counterclockwise position (Usable Range: 0 ←→ 20 turns in) Suspension Oil Kawasaki SS-47 or equivalent Amount: Right Front Fork Approx. 430 mL (14.5 US oz.) (when changing oil) 503 ±2.5 mL (17.0 ±0.085 US oz.) (after disassembly and...
  • Page 493: Special Tools

    SUSPENSION 13-7 Special Tools Inside Circlip Pliers: Fork Oil Level Gauge: 57001-143 57001-1290 Oil Seal & Bearing Remover: Hook Wrench T=3.2 R37: 57001-1058 57001-1539 Bearing Driver Set: Swingarm Pivot Nut Wrench: 57001-1129 57001-1597 Jack: Jack Attachment: 57001-1238 57001-1608 Fork Oil Seal Driver, 41: Needle Bearing Driver, 17/ 18: 57001-1288 57001-1609...
  • Page 494 13-8 SUSPENSION Special Tools Fork Oil Seal Driver Weight, 26 ∼ 46: Needle Bearing Driver, 28: 57001-1610 57001-1795 Fork Oil Seal Driver Attachment, 36 ∼ 46: Top Plug Wrench (45 mm): 57001-1741 57001-1798 Rod Guide Case Wrench, 33 mm: 57001-1744...
  • Page 495: Front Fork

    SUSPENSION 13-9 Front Fork Rebound Damping Force Adjustment • To adjust the rebound damping force, turn the rebound damping force adjuster [A]. ○ The standard adjuster setting is the 2 1/2 turns out from the fully clockwise position. ○ The damping force can be left soft for average riding. But it should be adjusted harder for high speed riding or riding with a passenger.
  • Page 496: Spring Preload Adjustment

    13-10 SUSPENSION Front Fork Spring Preload Adjustment • To adjust the spring preload, turn the spring preload ad- juster [A]. ○ The standard adjuster setting is the 6 1/4 turns in from the fully counterclockwise position. ○ The spring preload can be left soft for average riding. But it should be adjusted harder for high speed riding or riding with a passenger.
  • Page 497 SUSPENSION 13-11 Front Fork NOTE ○ Tighten the front fork top plug before tightening the han- dlebar clamp bolt and upper front fork clamp bolt. ○ The torque of front fork top plug is specified to 35 N·m (3.6 kgf·m, 26 ft·lb) however, when you use the top plug wrench (special tool: 57001-1741) [A], reduce the torque to 90% of the specified value [31 N·m (3.2 kgf·m, 23 ft·lb)] due to the distance [B] between the center of...
  • Page 498: Front Fork Oil Change

    13-12 SUSPENSION Front Fork Front Fork Oil Change Right Front Fork • Remove the front fork (see Front Fork Removal (Each Fork Leg)). • Hold the inner tube lower end in a vise. • Using the wrench [A], unscrew the top plug [B] out of the outer tube.
  • Page 499 SUSPENSION 13-13 Front Fork • Remove: Piston Rod Assy [A] Collar [B] Fork Spring [C] • Drain the fork oil into a suitable container [A]. ○ Pump the inner tube up and down at least 10 times to expel the oil from the fork. •...
  • Page 500 13-14 SUSPENSION Front Fork • Hold the inner tube bottom by a vise. • Using the rod guide case wrench [A], tighten the piston rod guide case to the inner tube. Special Tool - Rod Guide Case Wrench, 33 mm: 57001 -1744 Torque - Piston Rod Guide Case: 90 N·m (9.2 kgf·m, 66 ft·lb) NOTE...
  • Page 501 SUSPENSION 13-15 Front Fork • Replace the O-ring [A] with a new one. • Apply grease to the new O-ring. • Install the top plug [B] to the piston rod. • Holding the top plug with a wrench [C], tighten the piston rod nut against the top plug.
  • Page 502 13-16 SUSPENSION Front Fork Left Front Fork • Remove the front fork (see Front Fork Removal (Each Fork Leg)). • Turn the spring preload adjuster fully counterclockwise for removing the piston rod assy easily. • Hold the inner tube lower end in a vise. •...
  • Page 503 SUSPENSION 13-17 Front Fork • Remove: Piston Rod [A] Collar [B] Fork Spring [C] • Drain the fork oil into a suitable container [A]. ○ Pump the inner tube up and down at least 10 times to expel the oil from the fork. •...
  • Page 504 13-18 SUSPENSION Front Fork • Insert the piston rod into the inner tube. • Hold the inner tube bottom by a vise. • Using rod guide case wrench [A], tighten the piston rod guide case to the inner tube. Special Tool - Rod Guide Case Wrench, 33 mm: 57001 -1744 Torque - Piston Rod Guide Case: 90 N·m (9.2 kgf·m, 66 ft·lb) NOTE...
  • Page 505 SUSPENSION 13-19 Front Fork • Replace the O-ring [A] with a new one. • Apply grease to the new O-ring. • Install the top plug [B] to the piston rod. • Holding the top plug with the wrench [C], tighten the piston rod nut against the top plug.
  • Page 506: Front Fork Disassembly

    13-20 SUSPENSION Front Fork Front Fork Disassembly • Remove the front fork (see Front Fork Removal (Each Fork Leg)). • Drain the fork oil (see Front Fork Oil Change). • Remove the dust seal [A] from the outer tube. • Remove the circlip [B].
  • Page 507: Inner Tube Inspection

    SUSPENSION 13-21 Front Fork • Insert the inner tube to the outer tube. • After installing the washer, install the oil seal [A] by using the fork oil seal driver [B]. Special Tools - Fork Oil Seal Driver, 41: 57001-1288 26 ∼...
  • Page 508: Spring Tension Inspection

    13-22 SUSPENSION Front Fork Spring Tension Inspection • Since a spring becomes shorter as it weakens, check its free length [A] to determine its condition. If the spring of either fork leg is shorter than the service limit, it must be replaced. If the length of a replacement spring and that of the remaining spring vary greatly, the remaining spring should also be replaced in order to keep the fork legs balanced for motorcycle stability.
  • Page 509: Rear Shock Absorber

    SUSPENSION 13-23 Rear Shock Absorber Rebound Damping Force Adjustment • To adjust the rebound damping force, turn the rebound damping force adjuster [A] to the desired position. ○ The standard adjuster setting is the 3/4 turns out from the fully clockwise position. Rebound Damping Force Adjustment Adjuster Damping...
  • Page 510: Rear Shock Absorber Removal

    13-24 SUSPENSION Rear Shock Absorber • To adjust the spring preload, turn in the adjusting nut to the desired position and tighten the locknut by using hook wrenches [A] with the rear shock absorber attached the frame. Special Tool - Hook Wrench T=3.2 R37: 57001-1539 If the spring action feels too soft or too stiff, adjust it.
  • Page 511: Rear Shock Absorber Installation

    SUSPENSION 13-25 Rear Shock Absorber • Remove: Lower Rear Shock Absorber Nut and Bolt [A] Upper Rear Shock Absorber Bolt [B] • Remove the rear shock absorber [C] rearward. Rear Shock Absorber Installation • Replace the rear shock absorber nuts with new ones. •...
  • Page 512: Rear Shock Absorber Bearing Removal

    13-26 SUSPENSION Rear Shock Absorber Rear Shock Absorber Bearing Removal • Remove: Rear Shock Absorber (see Rear Shock Absorber Re- moval) Sleeve [A] Grease Seals [B] • Remove the needle bearing, using a suitable tool. Rear Shock Absorber Bearing Installation •...
  • Page 513: Swingarm

    SUSPENSION 13-27 Swingarm Swingarm Removal • Remove: Rear Brake Hose Lower End (see Rear Caliper Removal in the Brakes chapter) Rear Wheel (see Rear Wheel Removal in the Wheels/Tires chapter) Mud Guard (see Mud Guard Removal in the Frame chapter) Chain Cover (see Drive Chain Replacement in the Final Drive chapter) Rocker Arm (see Rocker Arm Removal)
  • Page 514: Swingarm Installation

    13-28 SUSPENSION Swingarm • Turn the swingarm pivot shaft [A] counterclockwise to free the adjusting collar from the swingarm. ○ Make the gap between the adjusting collar and swingarm. • Pull out the pivot shaft to the right side and remove the swingarm.
  • Page 515: Swingarm Bearing Removal

    SUSPENSION 13-29 Swingarm • Tighten the swingarm pivot shaft nut. Torque - Swingarm Pivot Shaft Nut: 108 N·m (11.0 kgf·m, 79.7 ft·lb) • Move the swingarm up and down to check for abnormal friction. • Install the removed parts (see appropriate chapters). Swingarm Bearing Removal •...
  • Page 516: Swingarm Bearing, Sleeve Inspection

    13-30 SUSPENSION Swingarm Swingarm Bearing, Sleeve Inspection NOTICE Do not remove the bearings for inspection. Re- moval may damage them. • Inspect the needle bearings [A] and ball bearing [B] in- stalled in the swingarm. ○ The rollers and ball in a bearing normally wear very little, and wear is difficult to measure.
  • Page 517: Tie-rod, Rocker Arm

    SUSPENSION 13-31 Tie-Rod, Rocker Arm Tie-Rod Removal • Remove: Mud Guard (see Mud Guard Removal in the Frame chapter) • Squeeze the brake lever slowly and hold it with a band [A]. • Raise the rear wheel off the ground with the jack (see Rear Shock Absorber Removal).
  • Page 518: Rocker Arm Installation

    13-32 SUSPENSION Tie-Rod, Rocker Arm • Raise the rear wheel off the ground with the jack (see Rear Shock Absorber Removal). Special Tools - Jack: 57001-1238 Jack Attachment: 57001-1608 WARNING When raising the rear wheel off the ground with the jack and removing part(s) from the motorcycle, be sure to hold the front brake, or the motorcycle may fall over.
  • Page 519: Tie-rod And Rocker Arm Bearing Removal

    SUSPENSION 13-33 Tie-Rod, Rocker Arm Tie-Rod and Rocker Arm Bearing Removal • Remove: Tie-Rod (see Tie-Rod Removal) Rocker Arms (see Rocker Arm Removal) Swingarm [A] (see Swingarm Removal) Sleeves [B] Grease Seals [C] • Remove the needle bearings [D], using a suitable tool. Tie-Rod and Rocker Arm Bearing Installation •...
  • Page 520: Rocker Arm/tie-rod Bearing, Sleeve Inspection

    13-34 SUSPENSION Tie-Rod, Rocker Arm Rocker Arm/Tie-Rod Bearing, Sleeve Inspection NOTICE Do not remove the bearings for inspection. Re- moval may damage them. • Visually inspect the rocker arm, or tie-rod sleeves [A] and needle bearings [B]. • The rollers in a needle bearing normally wear very little, and wear is difficult to measure.
  • Page 521 STEERING 14-1 Steering Table of Contents Exploded View........................14-2 Special Tools .......................... 14-4 Steering ..........................14-5 Steering Inspection ......................14-5 Steering Adjustment......................14-5 Steering Stem......................... 14-6 Stem, Stem Bearing Removal................... 14-6 Stem, Stem Bearing Installation..................14-7 Steering Stem Bearing Lubrication ................... 14-9 Steering Stem Warp Inspection ..................
  • Page 522: Exploded View

    14-2 STEERING Exploded View...
  • Page 523 STEERING 14-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Handlebar Holder Bolts Right Switch Housing Bolts 0.36 31 in·lb Throttle Case Bolts 0.36 31 in·lb Left Switch Housing Bolts 0.36 31 in·lb Steering Stem Head Bolt 11.0 79.7 Upper Front Fork Clamp Bolts Steering Stem Nut Lower Front Fork Clamp Bolts AD: Apply adhesive.
  • Page 524: Special Tools

    14-4 STEERING Special Tools Head Pipe Outer Race Press Shaft: Steering Stem Bearing Driver, 42.5: 57001-1075 57001-1344 Head Pipe Outer Race Driver, 54.5: Steering Stem Bearing Driver Adapter, 41.5: 57001-1077 57001-1345 Steering Stem Nut Wrench: Head Pipe Outer Race Driver, 55: 57001-1100 57001-1446...
  • Page 525: Steering Inspection

    STEERING 14-5 Steering Steering Inspection • Refer to the Steering Play Inspection in the Periodic Main- tenance chapter. Steering Adjustment • Refer to the Steering Play Adjustment in the Periodic Maintenance chapter.
  • Page 526: Steering Stem

    14-6 STEERING Steering Stem Stem, Stem Bearing Removal • Remove: Front Wheel (see Front Wheel Removal in the Wheels/Tires chapter) Front Fender (see Front Fender Removal in the Frame chapter) Upper Fairing (see Upper Fairing Removal in the Frame chapter) Handlebars (see Handlebar Removal) Clamp [A] Bolts [B]...
  • Page 527: Stem, Stem Bearing Installation

    STEERING 14-7 Steering Stem • Pushing up the stem base, and remove the steering stem nut [A]. Special Tool - Steering Stem Nut Wrench [B]: 57001-1100 • Remove: Steering Stem Stem Cap [C] Upper Ball Bearing Inner Race and Ball Bearing •...
  • Page 528 14-8 STEERING Steering Stem • Apply grease to the lower ball bearing [A], and install it onto the steering stem. ○ The lower and upper ball bearings are identical. • Apply grease to the upper ball bearing [B] and inner race [C].
  • Page 529: Steering Stem Bearing Lubrication

    STEERING 14-9 Steering Stem NOTE ○ Tighten the upper front fork clamp bolts first, next the stem head bolt, last the lower front fork clamp bolts. ○ Tighten the two lower front fork clamp bolts alternately two times to ensure even tightening torque. Torque - Upper Front Fork Clamp Bolts: 20 N·m (2.0 kgf·m, 15 ft·lb) Steering Stem Head Bolt: 108 N·m (11.0 kgf·m,...
  • Page 530: Handlebar

    14-10 STEERING Handlebar Handlebar Removal • Remove: Rear View Mirror [A] (see Rear View Mirror Removal in the Frame chapter) Clutch Lever Clamp Bolts [B] Clutch Lever Assembly [C] Left Switch Housing [D] Handlebar Weight [E] Left Handlebar Grip [F] •...
  • Page 531 STEERING 14-11 Handlebar • Install the handlebar holder [A]. • Tighten the front holder bolts [B] first, and then tighten the rear holder bolts [C]. There will be a gap [D] at the rear part of the holder after tightening. Torque - Handlebar Holder Bolt: 25 N·m (2.5 kgf·m, 18 ft·lb) •...
  • Page 533 FRAME 15-1 Frame Table of Contents Exploded View........15-2 Seat Cover Removal....15-16 Seats ..........15-8 Seat Cover Installation....15-16 Front Seat Removal ..... 15-8 Fenders ..........15-18 Front Seat Installation ....15-8 Front Fender Removal ....15-18 Rear Seat Removal...... 15-8 Front Fender Installation ....
  • Page 534: Exploded View

    15-2 FRAME Exploded View...
  • Page 535 FRAME 15-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Rear View Mirror Locknut (Upper) Rear View Mirror Nut (Lower) Middle Fairing Screws 0.12 11 in·lb Upper Fairing Screws 0.12 11 in·lb Front Fender Mounting Bolts 0.40 35 in·lb 6. US, CA, CAL, AU and MY Models Lh: Left-hand Threads S: Follow the specified tightening sequence.
  • Page 536 15-4 FRAME Exploded View...
  • Page 537 FRAME 15-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Rear Frame Bracket Bolts Front Footpeg Bracket Bolts Side Stand Switch Bolt 0.90 78 in·lb Side Stand Bracket Bolts Side Stand Bolt Side Stand Nut R, S Rear Footpeg Bracket Bolts G: Apply grease.
  • Page 538 15-6 FRAME Exploded View...
  • Page 539 FRAME 15-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Rear Frame Bolts Rear Frame End Cover Screws 0.12 11 in·lb Flap Screws 0.12 11 in·lb 4. AU Model 5. US, CA, and CAL Models L: Apply a non-permanent locking agent.
  • Page 540: Seats

    15-8 FRAME Seats Front Seat Removal • Insert the ignition switch key [A] into the seat lock. • Pull up the rear part of the front seat [B] while turning the key clockwise, and remove it backward. Front Seat Installation •...
  • Page 541: Fairings

    FRAME 15-9 Fairings Upper Fairing Removal WARNING The cooling fins [A] at the rear of headlight become hot during normal operation and can cause serious burns. To prevent burns, never touch the cooling fins at the rear of headlight while the engine is run- ning or shortly after it has been stopped.
  • Page 542: Upper Fairing Installation

    15-10 FRAME Fairings Upper Fairing Installation • Installation is the reverse of removal. • Insert the projections [A] into the holes [B]. • Hold the turn signal light leads with the clamps [C]. • Insert the hooks [A] into the slots [B]. •...
  • Page 543: Upper Fairing Assembly

    FRAME 15-11 Fairings Upper Fairing Assembly • Assembly is the reverse of disassembly. Torque - Upper Fairing Screws: 1.2 N·m (0.12 kgf·m, 11 in·lb) Headlight (LED) Assembly Mounting Screws: 1.2 N·m (0.12 kgf·m, 11 in·lb) Headlight Control Unit Bracket Screws: 1.2 N·m (0.12 kgf·m, 11 in·lb) Fuel Tank Cover Removal •...
  • Page 544: Middle Fairing Removal

    15-12 FRAME Fairings Middle Fairing Removal • Remove: Fuel Tank Cover (see Fuel Tank Cover Removal) Bolt [A] (L = 16 mm) and Washer Bolt [B] (L = 10 mm) and Washer Bolt [C] (L = 20 mm) and Washer •...
  • Page 545: Middle Fairing Disassembly

    FRAME 15-13 Fairings Middle Fairing Disassembly • Remove: Middle Fairing (see Middle Fairing Removal) Quick Rivet [A] Middle Fairing Screws [B] • Clear the projections [C], and remove the cover [D]. • Remove: Middle Fairing Screws [A] Middle Fairing Screws [B] and Washers Cover [C] Brackets [D] •...
  • Page 546: Ignition Switch Cover Removal

    15-14 FRAME Fairings Ignition Switch Cover Removal • Remove: Fuel Tank Cover (see Fuel Tank Cover Removal) Bolts [A] and Washers • Remove the bolts [A] while pulling the middle fairing [B] outward. • Remove the ignition switch cover [C]. Ignition Switch Cover Installation •...
  • Page 547: Side Covers

    FRAME 15-15 Side Covers Side Cover Removal • Remove: Middle Fairing (see Middle Fairing Removal) Bolts [A] and Washers Bolt [B] and Collar (Only on Left Side Cover) • Pull the side cover [C] outward to clear the projection [D] and the hooks [E], and remove the side cover.
  • Page 548: Seat Covers

    15-16 FRAME Seat Covers Seat Cover Removal • Remove: Seats (see Front/Rear Seat Removal) Side Covers (see Side Cover Removal) Bolt [A] and Washer • Pull the seat cover [B] outward to clear the projection [C]. • Clear the hook [A] with the standard tip screwdriver [B]. ○...
  • Page 549 FRAME 15-17 Seat Covers • Insert the hooks [A] into the slots [B]. • Insert the projection [A] into the hole [B]. • Be sure to insert the hooks [A].
  • Page 550: Fenders

    15-18 FRAME Fenders Front Fender Removal • Clear the brake hose from the clamps [A]. • For ABS equipped models, clear the front wheel rotation sensor lead from the clamp [B]. • Remove: Bolts [C] and Washers Front Fender [D] Front Fender Installation •...
  • Page 551 FRAME 15-19 Fenders • Open the clamp [A]. • Remove: Bolts [B] Guide [C] • Remove: Connector Bracket Screws [A] Connector Bracket [B] Flap Screws [C] Flap [D] Rear Fender [E] Flap and Rear Fender Installation • Installation is the reverse of removal. Torque - Rear Frame End Cover Screws: 1.2 N·m (0.12 kgf·m, 11 in·lb) Flap Screws: 1.2 N·m (0.12 kgf·m, 11 in·lb)
  • Page 552: Frame Inspection

    15-20 FRAME Frame Frame Inspection • Visually inspect the frame for cracks, dents, bending, or warp. If there is any damage to the frame, replace it. WARNING A repaired frame may fail in use, possibly causing an accident resulting in injury or death. If the frame is bent, dented, cracked, or warped, replace it.
  • Page 553: Rear Frame Bracket Installation

    FRAME 15-21 Frame • Remove: Rear Footpeg Bracket Bolts [A] (Both Sides) Rear Frame Bracket Bolts [B] (Both Sides) Rear Frame Brackets [C] Rear Frame Bracket Installation • Tighten: Torque - Rear Frame Bracket Bolts: 44 N·m (4.5 kgf·m, 32 ft·lb) Rear Footpeg Bracket Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb)
  • Page 554: Battery Case

    15-22 FRAME Battery Case Battery Case Removal • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Battery (see Battery Removal in the Electrical System chapter) Bolts [A] Fuel Tank Bracket [B] • Remove: Rivet [A] Clamp [B] •...
  • Page 555: Guard

    FRAME 15-23 Guard Mud Guard Removal • Remove: Mud Guard Mounting Bolts [A] • Remove: Right Front Footpeg Bracket Bolts [A] • Remove: Quick Rivets [A] Mud Guard Mounting Bolt [B] Bracket [C] Mud Guard [D] Mud Guard Installation • Installation is the reverse of removal.
  • Page 556: Side Stand

    15-24 FRAME Side Stand Side Stand Removal • Raise the rear wheel off the ground with a stand. • Remove: Side Stand Switch Bolt [A] Side Stand Switch [B] • Remove: Spring [A] Side Stand Nut [B] Side Stand Bolt [C] Collar Side Stand [D] Side Stand Installation...
  • Page 557: Rear View Mirrors

    FRAME 15-25 Rear View Mirrors Rear View Mirror Removal • Remove: Bolt [A] Cover [B] • Loosen the rear view mirror locknut (upper) [A], and re- move the rear view mirror stay [B] from the rear view mir- ror nut (lower) [C]. ○...
  • Page 559 ELECTRICAL SYSTEM 16-1 Electrical System Table of Contents Exploded View........................16-4 Specifications ......................... 16-10 Special Tools and Sealant ...................... 16-11 Parts Location......................... 16-13 Wiring Diagram (SEA-B1 Model).................... 16-16 Wiring Diagram (Other than SEA-B1 Model)................16-18 Wiring Diagram (ABS Equipped Models: US, CA and CAL Models) ........16-20 Wiring Diagram (ABS Equipped Models: SEA-B1 and TH Models)........
  • Page 560 16-2 ELECTRICAL SYSTEM Starter Motor Removal...................... 16-53 Starter Motor Installation....................16-53 Starter Motor Disassembly....................16-53 Starter Motor Assembly ....................16-54 Brush Inspection ....................... 16-55 Commutator Cleaning and Inspection................16-55 Armature Inspection......................16-55 Brush Lead Inspection ...................... 16-56 Right-hand End Cover Assembly Inspection ..............16-56 Starter Relay Inspection....................
  • Page 561 ELECTRICAL SYSTEM 16-3 Fuse Installation........................ 16-113 Fuse Inspection......................... 16-113...
  • Page 562: Exploded View

    16-4 ELECTRICAL SYSTEM Exploded View...
  • Page 563 ELECTRICAL SYSTEM 16-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Meter Cover Bolts 0.40 0.04 3.5 in·lb City Light Mounting Screws 0.12 11 in·lb Headlight (LED) Assembly Mounting Screws 0.12 11 in·lb Headlight Control Unit Bracket Screws 0.12 11 in·lb Turn Signal Light Screws 0.12 11 in·lb...
  • Page 564 16-6 ELECTRICAL SYSTEM Exploded View...
  • Page 565 ELECTRICAL SYSTEM 16-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Left Switch Housing Bolts 0.36 31 in·ib Right Switch Housing Bolts 0.36 31 in·lb Front Brake Light Switch Screw 0.12 11 in·lb Side Stand Switch Bolt 0.90 78 in·lb Oil Pressure Switch Oil Pressure Switch Terminal Bolt 0.20...
  • Page 566 16-8 ELECTRICAL SYSTEM Exploded View...
  • Page 567 ELECTRICAL SYSTEM 16-9 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Spark Plugs 115 in·lb Water Temperature Sensor 106 in·lb Fuel Pump Bolts 87 in·lb L, S Engine Ground Cable Terminal Bolt 87 in·lb Oxygen Sensor (Equipped Models) 6. WVTA (78.2 H) and GB WVTA (FULL H) Models L: Apply a non-permanent locking agent.
  • Page 568: Specifications

    16-10 ELECTRICAL SYSTEM Specifications Item Standard Battery Type Sealed Battery Model Name YT12A-BS Capacity 12 V 10 Ah (10 HR) Voltage 12.8 V or more Gross Weight 3.5 kg (7.7 lb) Electrolyte Volume 0.47 L (29 cu in.) Charging System Type Three-phase AC Alternator Output Voltage...
  • Page 569: Special Tools And Sealant

    ELECTRICAL SYSTEM 16-11 Special Tools and Sealant Peak Voltage Adapter: Flywheel & Pulley Holder: 57001-1415 57001-1605 Lead Wire - Peak Voltage Adapter: Flywheel Puller Assembly, M38 × 1.5/M35 × 1.5: 57001-1449 57001-1615 Needle Adapter Set: Stopper: 57001-1457 57001-1679 Key Registration Unit: Rotor Holder: 57001-1582 57001-1690...
  • Page 570 16-12 ELECTRICAL SYSTEM Special Tools and Sealant Key Registration Adapter: Liquid Gasket, TB1211F: 57001-1746 92104-0004 Rotor Holder: 57001-1757...
  • Page 571: Parts Location

    ELECTRICAL SYSTEM 16-13 Parts Location Timing Rotor [A] Crankshaft Sensor [B] Oxygen Sensor (Equipped Models) [C] Horn [A] Regulator/Rectifier [B] Relay Box [A] ECU [B] Turn Signal Relay [C] Rear Brake Light Switch [A] Immobilizer Amplifier (Immobilizer Equipped Models) [A]...
  • Page 572 16-14 ELECTRICAL SYSTEM Parts Location Water Temperature Sensor [A] Alternator [B] Radiator Fan Motor [C] Stater Motor [D] Neutral Switch [A] Oil Pressure Switch [B] Side Stand Switch [C] Battery 12 V 10 Ah [A] Starter Relay [B] Fuse Box 1 [C] Fuse Box 2 [D] Air Switching Valve [A] Stick Coils [B]...
  • Page 573 ELECTRICAL SYSTEM 16-15 Parts Location This page intentionally left blank.
  • Page 574: Wiring Diagram (sea-b1 Model)

    16-16 ELECTRICAL SYSTEM Wiring Diagram (SEA-B1 Model)
  • Page 575 ELECTRICAL SYSTEM 16-17 Wiring Diagram (SEA-B1 Model)
  • Page 576: Wiring Diagram (other Than Sea-b1 Model)

    16-18 ELECTRICAL SYSTEM Wiring Diagram (Other than SEA-B1 Model)
  • Page 577 ELECTRICAL SYSTEM 16-19 Wiring Diagram (Other than SEA-B1 Model)
  • Page 578: Wiring Diagram (abs Equipped Models: Us, Ca And Cal Models)

    16-20 ELECTRICAL SYSTEM Wiring Diagram (ABS Equipped Models: US, CA and CAL Models)
  • Page 579 ELECTRICAL SYSTEM 16-21 Wiring Diagram (ABS Equipped Models: US, CA and CAL Models)
  • Page 580: Wiring Diagram (abs Equipped Models: Sea-b1 And Th Models)

    16-22 ELECTRICAL SYSTEM Wiring Diagram (ABS Equipped Models: SEA-B1 and TH Models)
  • Page 581 ELECTRICAL SYSTEM 16-23 Wiring Diagram (ABS Equipped Models: SEA-B1 and TH Models)
  • Page 582: Wiring Diagram (abs Equipped Models: Other Than Us, Ca, Cal, Sea-b1 And Th Models)

    16-24 ELECTRICAL SYSTEM Wiring Diagram (ABS Equipped Models: Other than US, CA, CAL, SEA-B1 and TH Models)
  • Page 583 ELECTRICAL SYSTEM 16-25 Wiring Diagram (ABS Equipped Models: Other than US, CA, CAL, SEA-B1 and TH Models)
  • Page 584: Precautions

    16-26 ELECTRICAL SYSTEM Precautions There are a number of important precautions that are musts when servicing electrical systems. Learn and ob- serve all the rules below. ○ Do not reverse the battery cable connections. This will burn out the diodes on the electrical parts. ○...
  • Page 585: Electrical Wiring

    ELECTRICAL SYSTEM 16-27 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 586: Battery

    16-28 ELECTRICAL SYSTEM Battery Battery Removal • Turn the ignition switch off. • Remove: Front Seat (see Front Seat Removal in the Frame chap- ter) • Disconnect the negative (–) cable [A]. NOTICE Be sure to disconnect the negative (–) cable first. •...
  • Page 587 ELECTRICAL SYSTEM 16-29 Battery NOTICE Do not remove the aluminum sealing sheet [A] from the filler ports [B] until just prior to use. Be sure to use the dedicated electrolyte container for correct electrolyte volume. DANGER Sulfuric acid in battery electrolyte can cause severe burns.
  • Page 588 16-30 ELECTRICAL SYSTEM Battery • Check the electrolyte flow. If no air bubbles [A] are coming up from the filler ports, or if the container cells have not emptied completely, tap the container [B] a few times. NOTE ○ Be careful not to have the battery fall down. •...
  • Page 589: Precautions

    Newly activated sealed batteries require an initial charge. Standard Charge: 1.2 A × 5 ∼ 10 hours If using a recommended battery charger, follow the charger’s instructions for newly activated sealed battery. K