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Z1000
Z1000 ABS
Motorcycle
Service Manual

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Table of Contents

   Also See for Kawasaki Z1000

   Summary of Contents for Kawasaki Z1000

  • Page 1 Z1000 Z1000 ABS Motorcycle Service Manual...
  • Page 3: General Information

    Quick Reference Guide General Information Periodic Maintenance Fuel System (DFI) Cooling System Engine Top End Clutch Engine Lubrication System Engine Removal/Installation Crankshaft/Transmission Wheels/Tires 10 j Final Drive 11 j Brakes 12 j Suspension 13 j Steering 14 j Frame 15 j Electrical System 16 j Appendix...
  • Page 5 All information contained in this publication is based on the latest product information available at the time of publication. Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts. © 2007 Kawasaki Heavy Industries, Ltd. Third Edition (1) : Jun. 26, 2008 (K)
  • Page 6 LIST OF ABBREVIATIONS ampere(s) pound(s) ABDC after bottom dead center meter(s) alternating current minute(s) ATDC after top dead center newton(s) BBDC before bottom dead center pascal(s) bottom dead center horsepower BTDC before top dead center pound(s) per square inch °C degree(s) Celsius revolution direct current...
  • Page 7: Emission Control Information

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

    Be alert for problems and non-scheduled ticular interest for more efficient and con- maintenance. venient operation. • Use proper tools and genuine Kawasaki Mo- torcycle parts. Special tools, gauges, and • Indicates a procedural step or work to be testers that are necessary when servicing done.
  • Page 11 GENERAL INFORMATION 1-1 General Information Table of Contents Before Servicing ........................Model Identification......................... General Specifications......................1-10 Unit Conversion Table ......................1-13...
  • 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 or cotter pins 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 ZR1000B7F/B8F (United States and Canada) ZR1000B8F (Southeast Asia) Left Side View ZR1000B7F/B8F (United States and Canada) ZR1000B8F (Southeast Asia) Right Side View...
  • Page 18 1-8 GENERAL INFORMATION Model Identification ZR1000B7F/B8F (Europe) Left Side View ZR1000B7F/B8F (Europe) Right Side View...
  • Page 19 GENERAL INFORMATION 1-9 Model Identification ZR1000C7F/C8F Left Side View ZR1000C7F/C8F Right Side View Frame Number Engine Number...
  • Page 20: General Specifications

    1-10 GENERAL INFORMATION General Specifications ZR1000B7F ∼, ZR1000C7F ∼ Items Dimensions Overall Length 2 090 mm (82.28 in.) Overall Width 780 mm (30.71 in.) Overall Height 1 065 mm (41.93 in.) Wheelbase 1 445 mm (56.89 in.) Road Clearance 160 mm (6.30 in.) Seat Height 820 mm (32.28 in.) Dry Mass:...
  • Page 21 GENERAL INFORMATION 1-11 General Specifications ZR1000B7F ∼, ZR1000C7F ∼ Items Valve Timing: Inlet: Open 38° BTDC Close 58° ABDC Duration 276° Exhaust: Open 51° BBDC Close 25° ATDC Duration 256° Lubrication System Forced lubrication (wet sump) Engine Oil: Type API SE, SF or SG API SH, SJ or SL with JASO MA Viscosity SAE 10W-40...
  • Page 22 1-12 GENERAL INFORMATION General Specifications ZR1000B7F ∼, ZR1000C7F ∼ Items Rear Tire: Type Tubeless Size 190/50 ZR17 M/C (73W) Rim Size 17 × 6.00 Front Suspension: Type Telescopic fork Wheel Travel 120 mm (4.72 in.) Rear Suspension: Type Swingarm (uni-trak) Wheel Travel 150 mm (5.91 in.) Brake Type:...
  • Page 23: Unit Conversion Table

    GENERAL INFORMATION 1-13 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 25: Table Of Contents

    PERIODIC MAINTENANCE 2-1 Periodic Maintenance Table of Contents Periodic Maintenance Chart ....................Torque and Locking Agent...................... Specifications ......................... 2-12 Special Tools .......................... 2-14 Periodic Maintenance Procedures..................2-15 Fuel System (DFI)........................ 2-15 Air Cleaner Element Cleaning................... 2-15 Throttle Control System Inspection................... 2-15 Engine Vacuum Synchronization Inspection..............
  • Page 26 2-2 PERIODIC MAINTENANCE Steering Play Inspection ....................2-44 Steering Play Adjustment....................2-44 Steering Stem Bearing Lubrication ................... 2-45 Electrical System ......................... 2-46 Spark Plug Condition Inspection..................2-46 Lights and Switches Operation Inspection................ 2-47 Headlight Aiming Inspection ..................... 2-49 Sidestand Switch Operation Inspection ................2-50 Engine Stop Switch Operation Inspection.................
  • Page 27: Periodic Maintenance Chart

    PERIODIC MAINTENANCE 2-3 Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition.The initial maintenance is vitally important and must not be neglected. Periodic Inspection FREQUENCY Whichever * ODOMETER READING comes ×...
  • Page 28 2-4 PERIODIC MAINTENANCE Periodic Maintenance Chart FREQUENCY Whichever * ODOMETER READING comes × 1 000 km first (× 1 000 mile) Page ITEM Every (0.6) (4) (7.5) (12) (15) (20) (24) Brakes Brake fluid leak (brake hose and pipe) - •...
  • Page 29 PERIODIC MAINTENANCE 2-5 Periodic Maintenance Chart Periodic Replacement Parts FREQUENCY Whichever * ODOMETER READING comes × 1 000 km first (× 1 000 mile) Page ITEM Every (0.6) (7.5) (15) (24) (30) • Air cleaner element # - replace 2-55 •...
  • Page 30: Torque And Locking Agent

    2-6 PERIODIC MAINTENANCE Torque and Locking Agent The following tables list the tightening torque for the major fasteners requiring use of a non-permanent locking agent or silicone sealant etc. Letters used in the “Remarks” column mean: AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque. EO: Apply engine oil.
  • Page 31 PERIODIC MAINTENANCE 2-7 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Thermostat Bracket Bolt 0.70 61 in·lb Thermostat Housing Ground Bolt 0.70 61 in·lb Thermostat Housing Screws 0.60 52 in·lb Water Pipe Bolts 97 in·lb Water Pump Cover Bolts 97 in·lb Water Pump Impeller Bolt 87 in·lb...
  • Page 32 2-8 PERIODIC MAINTENANCE Torque and Locking Agent 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 Oil Filler Plug 0.20 18 in·lb Engine Lubrication System Coolant Drain Bolt (Water Pump) 97 in·lb Engine Oil Drain Bolt Lower Fairing Bracket Bolts...
  • Page 33 PERIODIC MAINTENANCE 2-9 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Shift Drum Cam Holder Bolt 106 in·lb Shift Lever Bolt 0.70 61 in·lb Shift Pedal Mounting Bolt Shift Shaft Return Spring Pin Starter Motor Clutch Bolts 106 in·lb Tie-Rod Locknuts 0.70 61 in·lb...
  • Page 34 2-10 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Piston Rod Nuts Rear Shock Absorber Nut (Lower) Rear Shock Absorber Nut (Upper) Swingarm Pivot Shaft 87 in·lb Swingarm Pivot Shaft Locknut 10.0 72.3 Swingarm Pivot Shaft Nut 11.0 79.7 Tie-Rod Nuts...
  • Page 35 PERIODIC MAINTENANCE 2-11 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Oxygen Sensor (Equipped Models) 44.1 4.50 32.5 Regulator/Rectifier Bolts 0.70 61 in·lb Regulator/Rectifier Bracket Bolts 0.70 61 in·lb Sidestand Switch Bolt 0.90 78 in·lb Spark Plugs 115 in·lb Speed Sensor Bolt 106 in·lb Starter Motor Mounting Bolts...
  • Page 36: Specifications

    2-12 PERIODIC MAINTENANCE 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) – – – Bypass Screws (Turn Out) 2 1/2 (for reference) –...
  • Page 37 PERIODIC MAINTENANCE 2-13 Specifications Item Standard Service Limit Air Pressure (when Cold): Front – – – Up to 180 kg (397 lb) load: 250 kPa (2.5 kgf/cm², 36 psi) Rear Up to 180 kg (397 lb) load: – – – 290 kPa (2.9 kgf/cm², 42 psi) Final Drive 25 ∼...
  • Page 38: Special Tools

    2-14 PERIODIC MAINTENANCE Special Tools Inside Circlip Pliers: Vacuum Gauge: 57001-143 57001-1369 Steering Stem Nut Wrench: Throttle Sensor Setting Adapter: 57001-1100 57001-1538 Jack: Extension Tube: 57001-1238 57001-1578 Oil Filter Wrench: Jack Attachment: 57001-1249 57001-1608...
  • Page 39: Periodic Maintenance Procedures

    PERIODIC MAINTENANCE 2-15 Periodic Maintenance Procedures Fuel System (DFI) Air Cleaner Element Cleaning NOTE ○ In dusty areas, the element should be cleaned more frequently than the recommended interval. ○ After riding through rain or on muddily roads, the ele- ment should be cleaned immediately.
  • Page 40: Engine Vacuum Synchronization Inspection

    2-16 PERIODIC MAINTENANCE Periodic Maintenance Procedures Engine Vacuum Synchronization Inspection NOTE ○ These procedures are explained on the assumption that the inlet and exhaust systems of the engine are in good condition. • Situate the motorcycle so that it is vertical. •...
  • Page 41 PERIODIC MAINTENANCE 2-17 Periodic Maintenance Procedures • Remove the fuel outlet hose (see Fuel Hose Replace- ment). • Connect the following parts temporary. Fuel Pump Lead Connector [A] Fuel Level Sensor Lead Connector [B] Extension Tube [C] Special Tool - Extension Tube: 57001-1578 •...
  • Page 42 2-18 PERIODIC MAINTENANCE Periodic Maintenance Procedures If any one vacuum measurement is out of the specified range after left (#1, #2) and right (#2, #3) synchronization, adjust the bypass screws [A]. Upside View [B] • Adjust the lower vacuum between #1 and #2 to the higher vacuum of #1 and #2.
  • Page 43: Idle Speed Inspection

    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 44: Idle Speed Adjustment

    2-20 PERIODIC MAINTENANCE Periodic Maintenance Procedures Idle Speed Adjustment • Start the engine and warm it up thoroughly. • Turn the adjusting screw [A] until the idle speed is correct. ○ Open and close the throttle a few times to make sure that the idle speed is within the specified range.
  • Page 45: Evaporative Emission Control System (cal And Sea Models) Inspection

    PERIODIC MAINTENANCE 2-21 Periodic Maintenance Procedures • Check that the outlet hose joints are securely connected. ○ Push and pull [A] the hose joint [B] back and forth more than two times, and make sure it is locked and does not come off.
  • Page 46: Cooling System

    2-22 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Check the liquid/vapor separator as follows. ○ Remove the right side cover (see Side Cover Removal in the Frame chapter). ○ Disconnect the hoses from the separator, and remove the separator [A] from the motorcycle right side. ○...
  • Page 47: Radiator Hose And Pipe Inspection (coolant Leak, Damage, Installation Condition)

    PERIODIC MAINTENANCE 2-23 Periodic Maintenance Procedures Radiator Hose and Pipe Inspection (coolant leak, damage, installation condition) ○ The high pressure inside the radiator hose can cause coolant to leak [A] or the hose to burst if the line is not properly maintained.
  • Page 48: Valve Clearance Adjustment

    2-24 PERIODIC MAINTENANCE Periodic Maintenance Procedures NOTE ○ Thickness gauge is horizontally inserted on the valve lifter. Appropriateness [A] Inadequacy [B] Thickness Gauge [C] Horizontally Inserts [D] Cam [E] Valve Lifter [F] Hits the Valve Lifter Ahead [G] ○ When positioning #4 piston TDC at the end of the compression stroke: Inlet Valve Clearance of #2 and #4 Cylinders Exhaust Valve Clearance of #3 and #4 Cylinders...
  • Page 49 PERIODIC MAINTENANCE 2-25 Periodic Maintenance Procedures ○ Besides the standard shims in the valve clearance adjust- ment charts, the following additional shims maybe used. Adjustment Shims Part Number Thickness 92180-0276 3.225 mm 92180-0277 3.275 mm 92180-0278 3.325 mm 92180-1174 2.675 mm 92180-1175 2.725 mm 92180-1176...
  • Page 50 2-26 PERIODIC MAINTENANCE Periodic Maintenance Procedures VALVE CLEARANCE ADJUSTMENT CHART INLET VALVE 1. Measure the clearance (when engine is cold). 2. Check present shim size. 3. Match clearance in vertical column with present shim size in horizontal column. 4. Install the shim specified where the lines intersect. This shim will give the proper clearance. Example: Present shim is 2.95 mm Measured clearance is 0.45 mm...
  • Page 51 PERIODIC MAINTENANCE 2-27 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 52: Exhaust Butterfly Valve Cable Inspection

    2-28 PERIODIC MAINTENANCE Periodic Maintenance Procedures CAUTION Be sure to remeasure the clearance after selecting a shim according to the table. If the clearance is out of the specified range, use the additional shim. ○ If there is no valve clearance, use a shim that is a few sizes smaller, and remeasure the valve clearance.
  • Page 53: Exhaust Butterfly Valve Cable Adjustment

    PERIODIC MAINTENANCE 2-29 Periodic Maintenance Procedures • Check that there is no play in the inner cables [A] by pulling them lightly. If there is play in the inner cables, adjust them (see Ex- haust Butterfly Valve Cable Adjustment). Exhaust Butterfly Valve Cable Adjustment •...
  • Page 54 2-30 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Stretch the open cable (white) [A] first by using the ad- juster [B]. ○ Turn the adjuster counterclockwise until it becomes hard to turn. Locknut of White [C] CAUTION To keep the correct exhaust butterfly valve position, adjust the open cable first.
  • Page 55 PERIODIC MAINTENANCE 2-31 Periodic Maintenance Procedures • Turn the ignition switch ON and wait until the pulley [A] turns fully clockwise [B]. • Turn off the ignition switch when the pulley become fully clockwise position [C] as shown in the figure. ○...
  • Page 56: Air Suction System Damage Inspection

    2-32 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Stretch the open cable (white) by using the adjuster [A]. ○ Turn the adjuster counterclockwise until it becomes hard to turn. Locknut of White [B] CAUTION Do not overstretch. If the adjustment of the exhaust butterfly valve cables are incorrect, the exhaust but- terfly valve actuator does not operate correctly.
  • Page 57: Wheels/tires

    PERIODIC MAINTENANCE 2-33 Periodic Maintenance Procedures WARNING To avoid a serious burn, never touch the engine or exhaust pipe during clutch adjustment. • Turn the adjuster [A] so that 5 ∼ 6 mm (0.20 ∼ 0.24 in.) [B] of threads are visible. •...
  • Page 58: Wheel/tire Damage Inspection

    2-34 PERIODIC MAINTENANCE Periodic Maintenance Procedures Wheel/Tire Damage Inspection • Remove any imbedded stones [A] or other foreign parti- cles [B] from tread. • Visually inspect the tire for cracks and cuts, and replace the tire if necessary. Swelling or high spots indicate inter- nal damage, requiring tire replacement.
  • Page 59: Wheel Bearing Damage Inspection

    PERIODIC MAINTENANCE 2-35 Periodic Maintenance Procedures Wheel Bearing Damage Inspection • Raise the front wheel off the ground with the jack (see Front Wheel Removal in the Wheels/Tires chapter). • Turn the handlebar all the way to the right or left. •...
  • Page 60: Drive Chain Slack Inspection

    2-36 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Apply oil to the sides of the rollers so that oil will penetrate to the rollers and bushings. Apply the oil to the O-rings so that the O-rings will be coated with oil. •...
  • Page 61: Wheel Alignment Inspection

    PERIODIC MAINTENANCE 2-37 Periodic Maintenance Procedures • Insert a new cotter pin [A]. NOTE ○ When inserting the cotter pin, if the slots in the nut do not align with the cotter pin hole in the axle, tighten the nut clockwise [B] up to next alignment. ○...
  • Page 62: Drive Chain Wear Inspection

    2-38 PERIODIC MAINTENANCE Periodic Maintenance Procedures Drive Chain Wear Inspection • Remove the chain cover (see Drive Chain Removal in the Final Drive chapter). • Rotate the rear wheel to inspect the drive chain for dam- aged rollers, and loose pins and links. If there is any irregularity, replace the drive chain.
  • Page 63: Brakes

    PERIODIC MAINTENANCE 2-39 Periodic Maintenance Procedures Brakes Brake Fluid Leak (Brake Hose and Pipe) Inspection • For ABS equipped models; note the following. • Remove the fuel tank (see Fuel Tank Removal in the Fuel System (DFI) chapter). • Apply the brake lever or pedal and inspect the brake fluid leak from the brake hoses [A], pipes [B] (ABS equipped models) and fittings [C].
  • Page 64: Brake Hose And Pipe Damage And Installation Condition Inspection

    2-40 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Hose and Pipe Damage and Installation Condition Inspection • For ABS equipped models; note the following. • Remove the fuel tank (see Fuel Tank Removal in the Fuel System (DFI) chapter). • Inspect the brake hoses, pipes and fittings for deteriora- tion, cracks and signs of leakage.
  • Page 65: Brake Pad Wear Inspection

    PERIODIC MAINTENANCE 2-41 Periodic Maintenance Procedures • Follow the procedure below to install the front brake fluid reservoir cap correctly. ○ First, tighten the front brake fluid reservoir cap [B] clock- wise [C] by hand until slight resistance is felt indicating that the cap is seated on the reservoir body, then tighten the cap an additional 1/6 turn [D] while holding the brake fluid reservoir body [A].
  • Page 66: Brake Light Switch Operation Inspection

    2-42 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Light Switch Operation Inspection • Turn on the ignition switch. • The brake light [A] should go on when the brake lever is applied or after the brake pedal is depressed about 10 mm (0.39 in.).
  • Page 67: Front Fork Oil Leak Inspection

    PERIODIC MAINTENANCE 2-43 Periodic Maintenance Procedures • Pump the seat down and up [A] 4 or 5 times, and inspect the smooth stroke. If the shock absorber does not smoothly stroke or noise is found, inspect the oil leak (see Rear Shock Absorber Oil Leak Inspection).
  • Page 68: Steering

    2-44 PERIODIC MAINTENANCE Periodic Maintenance Procedures Steering Steering Play Inspection • Remove the lower fairings (see Lower Fairing Removal in the Frame chapter). • Raise the front wheel off the ground with the jack. Special Tools - Jack: 57001-1238 Jack Attachment: 57001-1608 •...
  • Page 69: Steering Stem Bearing Lubrication

    PERIODIC MAINTENANCE 2-45 Periodic Maintenance Procedures • Adjust the steering. Special Tool - Steering Stem Nut Wrench [A]: 57001-1100 If the steering is too tight, loosen the stem nut a fraction of a turn. If the steering is too loose, tighten the stem nut a fraction of a turn.
  • Page 70: Electrical System

    2-46 PERIODIC MAINTENANCE Periodic Maintenance Procedures Electrical System Spark Plug Condition Inspection • Remove the spark plugs (see Spark Plug Replacement). • Visually inspect the spark plugs. If the spark plug center electrode [A] and/or side elec- trode [B] are corroded or damaged, or if the insulator [C] is cracked, replace the plug.
  • Page 71: Lights And Switches Operation Inspection

    PERIODIC MAINTENANCE 2-47 Periodic Maintenance Procedures Lights and Switches Operation Inspection First Step • Turn on the ignition switch. • The following lights should go on according to below table. go on City Lights [A] goes on Taillight [B] License Plate Light [C] goes on Meter Panel LCD [D] goes on...
  • Page 72 2-48 PERIODIC MAINTENANCE Periodic Maintenance Procedures Third Step • Turn on the turn signal switch [A] (left or right position). • The left or right turn signal lights [B] (front and rear) ac- cording to the switch position should flash. •...
  • Page 73: Headlight Aiming Inspection

    PERIODIC MAINTENANCE 2-49 Periodic Maintenance Procedures • Set the dimmer switch to high beam position. • The low beam [A] and high beam [B] headlights should go on. • The high beam indicator light (LED) [C] should go on. If the high beam headlight and/or high beam indicator light (LED) does not go on, inspect or replace the following item.
  • Page 74: Sidestand Switch Operation Inspection

    2-50 PERIODIC MAINTENANCE Periodic Maintenance Procedures NOTE ○ For US model, the proper angle is 0.4 degrees below horizontal. This is 50 mm (2 in.) drop at 7.6 m (25 ft) measured from the center of the headlight with the motorcycle on its wheels and the rider seated.
  • Page 75: Engine Stop Switch Operation Inspection

    PERIODIC MAINTENANCE 2-51 Periodic Maintenance Procedures If the sidestand switch operation does not work, inspect or replace the following item. 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 10 A (see Fuse Inspection in the Electrical System chapter)
  • Page 76: Others

    2-52 PERIODIC MAINTENANCE Periodic Maintenance Procedures Others Chassis Parts Lubrication • Before lubricating each part, clean off any rusty spots with rust remover and wipe off any grease, oil, dirt, or grime. • Lubricate the points listed below with indicated lubricant. NOTE ○...
  • Page 77 PERIODIC MAINTENANCE 2-53 Periodic Maintenance Procedures • With the cable disconnected at both ends, the cable should move freely [A] within the cable housing. If cable movement is not free after lubricating, if the cable is frayed [B], or if the cable housing is kinked [C], replace the cable.
  • Page 78: Bolts, Nuts And Fasteners Tightness Inspection

    2-54 PERIODIC MAINTENANCE Periodic Maintenance Procedures Bolts, Nuts and Fasteners Tightness Inspection • Check the tightness of the bolts and nuts listed here. Also, check to see that each cotter pin is in place and in good condition. NOTE ○ For the engine fasteners, check the tightness of them when the engine is cold (at room temperature).
  • Page 79: Replacement Parts

    PERIODIC MAINTENANCE 2-55 Periodic Maintenance Procedures Replacement Parts Air Cleaner Element Replacement NOTE ○ In dusty areas, the element should be replaced more frequently than the recommended interval. ○ After riding through rain or on muddily roads, the ele- ment should be replaced immediately. WARNING If dirt or dust is allowed to pass through into the throttle assy, the throttle may become stuck, possi-...
  • Page 80: Fuel Hose Replacement

    2-56 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Install a new element [A] so that flat side [B] faces forward. • Fit the tongue [C] of the air cleaner duct into the slot [D] of the air cleaner housing. • Tighten: Torque - Air Cleaner Duct Screws: 3.8 N·m (0.39 kgf·m, 34 in·lb) Fuel Hose Replacement...
  • Page 81 PERIODIC MAINTENANCE 2-57 Periodic Maintenance Procedures • Pull the joint lock [A] as shown. • Pull the fuel outlet hose joint [B] out of the delivery pipe. • Install a new fuel inlet hose [A] so that the white mark side [B] faces outlet pipe [C] of the fuel tank.
  • Page 82: Coolant Change

    2-58 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Push and pull [A] the fuel hose joint [B] back and forth more than two times, and make sure it is locked and does not come off. WARNING Make sure the fuel hose joint is installed correctly on the delivery pipe or the fuel could leak.
  • Page 83 PERIODIC MAINTENANCE 2-59 Periodic Maintenance Procedures • Remove: Right Seat Cover (see Seat Cover Removal in the Frame chapter) Hose [A] Reserve Tank Bolts [B] • Turn over the reserve tank, remove the cap, and pour the coolant into a suitable container. •...
  • Page 84: Radiator Hose And O-ring Replacement

    2-60 PERIODIC MAINTENANCE Periodic Maintenance Procedures Radiator Hose and O-ring Replacement • Drain the coolant (see Coolant Change). • Remove: Thermostat Housing [A] (see Thermostat Removal in the Cooling System chapter) Water Pump Cover [B] (see Water Pump Removal in the Cooling System chapter) Oil Cooler [C] (see Oil Cooler Removal in the Engine Lubrication System chapter)
  • Page 85: Oil Filter Replacement

    PERIODIC MAINTENANCE 2-61 Periodic Maintenance Procedures Recommended Engine Oil Type: API SE, SF or SG API SH, SJ or SL with JASO MA, MA1 or Viscosity: SAE 10W-40 Capacity: 3.1 L (3.3 US qt) (when filter is not removed) 3.3 L (3.5 US qt) (when filter is removed) 3.8 L (4.0 US qt) (when engine is completely dry) NOTE...
  • Page 86: Brake Hose And Pipe Replacement

    2-62 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Hose and Pipe Replacement CAUTION Brake fluid quickly ruins painted plastic surfaces; any spilled fluid should be completely washed away immediately. • Remove the brake hose banjo bolts [A]. • When removing the brake hose, take care not to spill the brake fluid on the painted or plastic parts.
  • Page 87 PERIODIC MAINTENANCE 2-63 Periodic Maintenance Procedures • For ABS equipped models; note the following. • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Rear Fender (see Flap and Rear Fender Removal in the Frame chapter) ABS Hydraulic Unit (see ABS Hydraulic Unit Removal in the Brakes chapter) Brake Pipe Joint Nuts [A]...
  • Page 88: Brake Fluid Change

    2-64 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Fluid Change NOTE ○ The procedure to change the front brake fluid is as fol- lows. Changing the rear brake fluid is the same as for the front brake. • Level the brake fluid reservoir. •...
  • Page 89: Master Cylinder Rubber Parts Replacement

    PERIODIC MAINTENANCE 2-65 Periodic Maintenance Procedures Master Cylinder Rubber Parts Replacement Front Master Cylinder Disassembly • Remove the front master cylinder (see Front Master Cylin- der Removal in the Brakes chapter). • Remove the seal cover [A], circlip [B], connector [C] and O-ring [D].
  • Page 90: Caliper Rubber Parts Replacement

    2-66 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Apply brake fluid to the new parts and to the inner wall of the cylinder. • Take care not to scratch the piston or the inner wall of the cylinder. • Apply silicone grease to the brake lever pivot bolt. •...
  • Page 91 PERIODIC MAINTENANCE 2-67 Periodic Maintenance Procedures NOTE ○ If compressed air is not available, do as follows for both calipers coincidentally, with the brake hose connected to the caliper. ○ Prepare a container for brake fluid, and perform the work above it. ○...
  • Page 92 2-68 PERIODIC MAINTENANCE Periodic Maintenance Procedures Rear Caliper Disassembly • Remove the rear brake pad pin plug [A]. • Loosen the rear caliper pad pin and banjo bolt [B], and tighten them loosely. • Remove: Rear Caliper [C] (see Rear Caliper Removal in the Brakes chapter) Brake Pads (see Rear Brake Pad Removal in the Brakes chapter)
  • Page 93: Spark Plug Replacement

    PERIODIC MAINTENANCE 2-69 Periodic Maintenance Procedures • Apply brake fluid to the cylinder bore. • Replace the fluid seal [A] with a new one. ○ Apply silicone grease to the fluid seal, and install it into the cylinder by hand. •...
  • Page 95 FUEL SYSTEM (DFI) 3-1 Fuel System (DFI) Table of Contents Exploded View........................DFI System..........................3-10 DFI Parts Location........................3-18 Specifications ......................... 3-20 Special Tools and Sealant ...................... 3-22 DFI Servicing Precautions ...................... 3-24 DFI Servicing Precautions ....................3-24 Troubleshooting the DFI System .................... 3-26 Outline ..........................
  • Page 96 3-2 FUEL SYSTEM (DFI) Speed Sensor Input Voltage Inspection................3-69 Speed Sensor Output Voltage Inspection ................. 3-70 Vehicle-down Sensor (Service Code 31)................3-72 Vehicle-down Sensor Removal ..................3-72 Vehicle-down Sensor Installation ..................3-72 Vehicle-down Sensor Input Voltage Inspection..............3-73 Vehicle-down Sensor Output Voltage Inspection .............. 3-74 Subthrottle Sensor (Service Code 32)..................
  • Page 97 FUEL SYSTEM (DFI) 3-3 ECU Identification ......................3-109 ECU Removal ........................3-109 ECU Installation ........................ 3-110 ECU Power Supply Inspection..................3-111 DFI Power Source ........................3-114 ECU Fuse Removal ......................3-114 ECU Fuse Installation ....................... 3-114 ECU Fuse Inspection ......................3-114 ECU Main Relay Removal/Installation ................
  • Page 98: Exploded View

    3-4 FUEL SYSTEM (DFI) Exploded View...
  • Page 99 FUEL SYSTEM (DFI) 3-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Throttle Cable Plate Bolt 0.60 52 in·lb Bypass Screws 0.02 1.8 in·lb Delivery Pipe Assy Mounting Screws 0.35 30 in·lb Throttle Link Holder Screws 0.20 18 in·lb Idle Adjusting Cable Clamp Screw 0.35 30 in·lb Throttle Body Assy Holder Clamp Bolts...
  • Page 100 3-6 FUEL SYSTEM (DFI) Exploded View...
  • Page 101 FUEL SYSTEM (DFI) 3-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Water Temperature Sensor Vehicle-down Sensor Bolts 0.61 53 in·lb Camshaft Position Sensor Bolt 106 in·lb Oxygen Sensor (Equipped Models) 44.1 4.50 32.5 Speed Sensor Bolt 106 in·lb Crankshaft Sensor Bolts 0.60 52 in·lb 7.
  • Page 102 3-8 FUEL SYSTEM (DFI) Exploded View...
  • Page 103 FUEL SYSTEM (DFI) 3-9 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Fuel Pump Bolts 87 in·lb L, S Exhaust Butterfly Valve Actuator Mounting Bolts 0.70 61 in·lb Exhaust Butterfly Valve Actuator Bracket Bolt 0.70 61 in·lb Exhaust Butterfly Valve Actuator Pulley Bolt 0.51 44 in·lb 5.
  • Page 104: Dfi System

    3-10 FUEL SYSTEM (DFI) DFI System DFI System...
  • Page 105 FUEL SYSTEM (DFI) 3-11 DFI System 1. ECU 2. Crankshaft Sensor 3. Camshaft Position Sensor 4. Main Throttle Sensor 5. Subthrottle Sensor 6. Subthrottle Valve Actuator 7. Inlet Air Pressure Sensor 8. Atmospheric Pressure Sensor 9. Water Temperature Sensor 10. Inlet Air Temperature Sensor 11.
  • Page 106 3-12 FUEL SYSTEM (DFI) DFI System DFI System Wiring Diagram (ZR1000B7F ∼ B8F/C7F ∼ C8F)
  • Page 107 35. ECU Main Relay 36. Fuel Pump Relay 37. Vehicle-down Sensor 38. Main Fuse 30 A 39. Starter Relay 40. Water-proof Joint B 41. Battery 12 V 8 Ah 42. Fuel Pump 43. Immobilizer (Equipped Models)/Kawasaki Diagnostic System Connector 44. Water-proof Joint C...
  • Page 108 3-14 FUEL SYSTEM (DFI) DFI System DFI System Wiring Diagram (ZR1000B9F/C9F)
  • Page 109 37. Vehicle-down Sensor 38. Main Fuse 30 A 39. Starter Relay 40. Water-proof Joint B 41. Battery 12 V 8 Ah 42. Fuel Pump 43. Immobilizer (Equipped Models)/Kawasaki Diagnostic System Connector 44. Water-proof Joint C ○ Color Codes: BK: Black GY: Gray...
  • Page 110 3-16 FUEL SYSTEM (DFI) DFI System Terminal Numbers of ECU Connectors Terminal Names 1. Subthrottle Valve Actuator: BK/BL 2. Subthrottle Valve Actuator: G 3. Exhaust Butterfly Valve Actuator (+): GY 4. Exhaust Butterfly Valve Actuator (–): G/R 5. Exhaust Butterfly Valve Actuator Sensor: R/BK 6.
  • Page 111 54. Oxygen Sensor Heater (Equipped Models): R 55. Air Switching Valve: R/BL 56. Injector #4: BL/Y 57. Injector #3: BL/BK 58. Ground for Fuel System: BK/Y 59. Ground for Ignition System: BK/Y 60. Stick Coil #4: BK/O *: KDS (Kawasaki Diagnostic System)
  • Page 112: Dfi Parts Location

    3-18 FUEL SYSTEM (DFI) DFI Parts Location Main Throttle Sensor [A] Subthrottle Sensor [B] Fuel Injectors #1, #2, #3, #4 [C] Crankshaft Sensor [A] Oxygen Sensor [B] (Equipped Models) Ignition Key (Transponder, Equipped Models) [A] Ignition Switch [B] Immobilizer Antenna [C] (Equipped Models) Immobilizer Amplifier [D] (Equipped Models) Warning Indicator Light (LED) [E] Stick Coils #1, #2, #3, #4 [A]...
  • Page 113 Relay Box (ECU Main Relay, Radiator Fan Relay, Fuel Pump Relay) [A] ECU [B] Fuse Box 2 (ECU Fuse 10 A, Ignition Fuse 10 A, Radi- ator Fan Fuse 15 A) [C] Vehicle-down Sensor [D] Immobilizer (Equipped Models)/Kawasaki Diagnostic System Connector [E] Fuel Pump [A]...
  • Page 114: Specifications

    3-20 FUEL SYSTEM (DFI) Specifications Item Standard Digital Fuel Injection System Idle Speed 1 100 ±50 r/min (rpm) Throttle Body Assy: Type Four oval type Bore 36 mm (1.42 in.) Throttle Body Vacuum 38.0 ±1.3 kPa (285 ±10 mmHg) Bypass Screws (Turn Out) 2 1/2 (for reference) ECU: Make...
  • Page 115 FUEL SYSTEM (DFI) 3-21 Specifications Item Standard Subthrottle Sensor: DC 4.75 ∼ 5.25 V Input Voltage DC 0.48 ∼ 0.52 V at subthrottle valve full close Output Voltage position DC 3.8 ∼ 4.0 V at subthrottle valve full open position (for reference) 4 ∼...
  • Page 116: Special Tools And Sealant

    3-22 FUEL SYSTEM (DFI) Special Tools and Sealant Oil Pressure Gauge, 5 kgf/cm²: Peak Voltage Adapter: 57001-125 57001-1415 Fork Oil Level Gauge: Needle Adapter Set: 57001-1290 57001-1457 Vacuum Gauge: Throttle Sensor Setting Adapter: 57001-1369 57001-1538 Hand Tester: Sensor Harness Adapter: 57001-1394 57001-1561 Throttle Sensor Setting Adapter #1:...
  • Page 117 FUEL SYSTEM (DFI) 3-23 Special Tools and Sealant Fuel Pressure Gauge Adapter: Oxygen Sensor Measuring Adapter: 57001-1593 57001-1682 Fuel Hose: Measuring Adapter: 57001-1607 57001-1700 Speed Sensor Measuring Adapter: Kawasaki Bond (Silicone Sealant): 57001-1667 56019-120...
  • Page 118: Dfi Servicing Precautions

    3-24 FUEL SYSTEM (DFI) DFI Servicing Precautions DFI Servicing Precautions There are a number of important precautions that should be followed servicing the DFI system. ○ This DFI system is designed to be used with a 12 V sealed battery as its power source. Do not use any other battery except for a 12 V sealed battery as a power source.
  • Page 119 FUEL SYSTEM (DFI) 3-25 DFI Servicing Precautions ○ If the motorcycle is not properly handled, the high pres- sure inside the fuel line can cause fuel to leak or the hose to burst. Remove the fuel tank (see Fuel Tank Removal) and check the fuel hose.
  • Page 120: Troubleshooting The Dfi System

    3-26 FUEL SYSTEM (DFI) Troubleshooting the DFI System The warning indicator light (LED) [A] is used for the FI indicator, immobilizer indicator (equipped models) and oil pressure warning indicator. Outline When a problem occurs with DFI system, the warning in- dicator light (LED) [A] and FI warning symbol [B] blinks to alert the rider.
  • Page 121 But the service codes stored in memory of the ECU are not erased to preserve the problem history. The problem history can be referred using the KDS (Kawasaki Diagnostic System) when solving unstable problems. When the motorcycle is down, the vehicle-down sensor operates and the ECU shuts off the fuel pump relay, fuel in- jectors and ignition system.
  • Page 122 After measurement, remove the needle adapters and ap- ply silicone sealant to the seals [A] of the connector [B] for waterproofing. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 • Always check battery condition before replacing the DFI parts. A fully charged battery is a must for conducting accurate tests of the DFI system.
  • Page 123 FUEL SYSTEM (DFI) 3-29 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 124: Inquiries To Rider

    3-30 FUEL SYSTEM (DFI) Troubleshooting the DFI System DFI Diagnosis Flow Chart Inquiries to Rider ○ Each rider reacts to problems in different ways, so it is important to confirm what kind of symptoms the rider has encountered. ○ Try to find out exactly what problem occurred under exactly what conditions by asking the rider; knowing this information may help you reproduce the problem.
  • Page 125 FUEL SYSTEM (DFI) 3-31 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 126 3-32 FUEL SYSTEM (DFI) Troubleshooting the DFI System □ □ □ Poor running very low idle speed, very high idle speed, rough idle speed. □ at low speed battery voltage is low (charge the battery). □ spark plug loose (tighten it). □...
  • Page 127: Dfi System Troubleshooting Guide

    FUEL SYSTEM (DFI) 3-33 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 128 3-34 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Fuel pressure regulator trouble Inspect fuel pressure and replace fuel pump (see chapter 3). Fuel line clogged Inspect and repair (see chapter 3). Inlet air pressure sensor trouble Inspect (see chapter 3).
  • Page 129 FUEL SYSTEM (DFI) 3-35 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Main throttle sensor trouble Inspect (see chapter 3). Subthrottle sensor trouble Inspect (see chapter 3). Subthrottle valve actuator trouble Inspect (see chapter 3). Inlet air pressure sensor trouble Inspect (see chapter 3).
  • Page 130 3-36 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Inlet air temperature sensor trouble Inspect (see chapter 3). Other: Intermittent any DFI fault and its recovery Check that DFI connectors are clean and tight, and examine leads for signs of burning or fraying (see chapter 3).
  • Page 131 FUEL SYSTEM (DFI) 3-37 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Water temperature sensor trouble Inspect (see chapter 3). Inlet air temperature sensor trouble Inspect (see chapter 3). Miscellaneous: Subthrottle sensor trouble Inspect (see chapter 3). Subthrottle valve actuator trouble Inspect (see chapter 3).
  • Page 132: Self-diagnosis

    3-38 FUEL SYSTEM (DFI) Self-Diagnosis The warning indicator light (LED) [A] is used for the FI indicator, immobilizer indicator (equipped models) and oil pressure warning indicator. Self-diagnosis Outline The self-diagnosis system has two modes and can be switched to another mode by operating the meter unit. User Mode The ECU notifies the rider of troubles in DFI system, ig- nition system and immobilizer system by blinking the warn-...
  • Page 133: Self-diagnosis Procedures

    FUEL SYSTEM (DFI) 3-39 Self-Diagnosis Dealer Mode The LCD (Liquid Crystal Display) display the service code(s) [A] to show the problem(s) which the DFI system, ignition system and immobilizer system has at the moment of diagnosis. Self-diagnosis Procedures ○ When a problem occurs with the DFI system and ignition system, the warning indicator light (LED) [A] and FI warn- ing symbol [B] blinks.
  • Page 134 3-40 FUEL SYSTEM (DFI) Self-Diagnosis • Turn the ignition switch ON. • Push the MODE button [A] to display the odometer. • Push the MODE button [A] for more than two seconds. • The service code [B] is displayed on the LCD by the num- ber of two digits.
  • Page 135 FUEL SYSTEM (DFI) 3-41 Self-Diagnosis Self-Diagnosis Flow Chart...
  • Page 136: Service Code Reading

    3-42 FUEL SYSTEM (DFI) Self-Diagnosis Service Code Reading ○ The service code(s) is displayed on the LCD by the number of two digits. ○ When there are a number of problems, all the service codes can be stored and the display will begin starting from the lowest number service code in the numerical order.
  • Page 137 FUEL SYSTEM (DFI) 3-43 Self-Diagnosis Service Code Table Service Code Problems Main throttle sensor malfunction, wiring open or short Inlet air pressure sensor malfunction, wiring open or short Inlet air temperature sensor malfunction, wiring open or short Water temperature sensor malfunction, wiring open or short Atmospheric pressure sensor malfunction, wiring open or short Crankshaft sensor malfunction, wiring open or short Camshaft position sensor malfunction, wiring open or short...
  • Page 138: Backups

    3-44 FUEL SYSTEM (DFI) Self-Diagnosis Backups ○ The ECU takes the following measures to prevent engine damage when the DFI, ignition or immo- bilizer system parts have troubles. Service Output Signal Usable Parts Backups by ECU Codes Range or Criteria If the main throttle sensor system fails (the output voltage is out of the usable range, Main Throttle...
  • Page 139 FUEL SYSTEM (DFI) 3-45 Self-Diagnosis Service Output Signal Usable Parts Backups by ECU Codes Range or Criteria The oxygen sensor is Oxygen active and sensor must Sensor If the oxygen sensor is not activated, the ECU send signals (output (Equipped stops the feedback mode of the oxygen sensor.
  • Page 140 3-46 FUEL SYSTEM (DFI) Self-Diagnosis Service Output Signal Usable Parts Backups by ECU Codes Range or Criteria The air switching valve controls the flow of the Air Switching secondary air by opening – Valve and shutting the solenoid valve. Oxygen The oxygen sensor heater If the oxygen sensor heater fails (wiring short Sensor...
  • Page 141: Main Throttle Sensor (service Code 11)

    FUEL SYSTEM (DFI) 3-47 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 142: Main Throttle Sensor Output Voltage Inspection

    3-48 FUEL SYSTEM (DFI) Main Throttle Sensor (Service Code 11) If the reading is out of the standard, remove the ECU and check the wiring for continuity between main harness connectors. ○ Disconnect the ECU and sensor connectors. Wiring Inspection ECU Connector [A] ←→...
  • Page 143: Main Throttle Sensor Resistance Inspection

    FUEL SYSTEM (DFI) 3-49 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 0.985 ∼ 1.015 V at idle throttle opening Standard: DC 4.18 ∼...
  • Page 144 3-50 FUEL SYSTEM (DFI) Main Throttle Sensor (Service Code 11) Main Throttle Sensor Circuit 1. ECU 2. Main Throttle Sensor...
  • Page 145: Inlet Air Pressure Sensor (service Code 12)

    FUEL SYSTEM (DFI) 3-51 Inlet Air Pressure Sensor (Service Code 12) Inlet Air Pressure Sensor Removal CAUTION Never drop the inlet air pressure sensor especially on a hard surface. Such a shock to the sensor can damage it. • Remove: Fuel Tank (see Fuel Tank Removal) Water Temperature Sensor Connector [A] Inlet Air Pressure Sensor Connector [B]...
  • Page 146: Inlet Air Pressure Sensor Output Voltage Inspection

    3-52 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code 12) If the reading is out of the standard, remove the ECU and check the wiring for continuity between main harness connectors. ○ Disconnect the ECU and sensor connectors. Wiring Inspection ECU Connector [A] ←→...
  • Page 147 FUEL SYSTEM (DFI) 3-53 Inlet Air Pressure Sensor (Service Code 12) If the wiring is good, check the sensor for various vacuum. • Remove the inlet air pressure sensor [A] and disconnect the vacuum hose from the sensor. • Connect an auxiliary hose [B] to the inlet air pressure sen- sor.
  • Page 148 3-54 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code 12) ID: Idling Ps: Standard Atmospheric Pressure (Absolute) Pv: Throttle Vacuum Pressure (Absolute) ST: Standard of Sensor Output Voltage (V) TO: Throttle Full Open UR: Usable Range of Sensor Output Voltage (V) Vv: Inlet Air Pressure Sensor Output Voltage (V) (Digital Meter Reading)
  • Page 149 FUEL SYSTEM (DFI) 3-55 Inlet Air Pressure Sensor (Service Code 12) Inlet Air Pressure Sensor Circuit 1. ECU 2. Inlet Air Pressure Sensor...
  • Page 150: Inlet Air Temperature Sensor (service Code 13)

    3-56 FUEL SYSTEM (DFI) Inlet Air Temperature Sensor (Service Code 13) Inlet Air Temperature Sensor Removal/Installation CAUTION Never drop the inlet air temperature sensor espe- cially on a hard surface. Such a shock to the sensor can damage it. • Remove the fuel tank (see Fuel Tank Removal).
  • Page 151: Inlet Air Temperature Sensor Resistance Inspection

    FUEL SYSTEM (DFI) 3-57 Inlet Air Temperature Sensor (Service Code 13) • Turn the ignition switch OFF. If the reading is within the standard, check the ECU for its ground, and power supply (see ECU Power Supply Inspection). If the ground and power supply are good, replace the ECU (see ECU Removal/Installation).
  • Page 152 3-58 FUEL SYSTEM (DFI) Inlet Air Temperature Sensor (Service Code 13) Inlet Air Temperature Sensor Circuit 1. ECU 2. Inlet Air Temperature Sensor...
  • Page 153: Water Temperature Sensor (service Code 14)

    FUEL SYSTEM (DFI) 3-59 Water Temperature Sensor (Service Code 14) Water Temperature Sensor Removal/Installation CAUTION Never drop the water temperature sensor especially on a hard surface. Such a shock to the sensor can damage it. • Remove the fuel tank (see Fuel Tank Removal). •...
  • Page 154: Water Temperature Sensor Resistance Inspection

    3-60 FUEL SYSTEM (DFI) Water Temperature Sensor (Service Code 14) If the reading is out of the standard, remove the ECU and check the wiring for continuity between main harness connectors. ○ Disconnect the ECU and sensor connectors. Wiring Inspection ECU Connector [A] ←→...
  • Page 155: Atmospheric Pressure Sensor (service Code 15)

    FUEL SYSTEM (DFI) 3-61 Atmospheric Pressure Sensor (Service Code 15) Atmospheric Pressure Sensor Removal CAUTION Never drop the atmospheric pressure sensor espe- cially on a hard surface. Such a shock to the sensor can damage it. • Remove the left seat cover (see Seat Cover Removal in the Frame chapter).
  • Page 156: Atmospheric Pressure Sensor Output Voltage Inspection

    3-62 FUEL SYSTEM (DFI) Atmospheric Pressure Sensor (Service Code 15) If the input voltage is out of the standard, remove the ECU and check the wiring for continuity between main harness connectors. ○ Disconnect the ECU and sensor connectors. Wiring Inspection ECU Connector [A] ←→...
  • Page 157 FUEL SYSTEM (DFI) 3-63 Atmospheric Pressure Sensor (Service Code 15) If the wiring is good, check the sensor for various vacuum. ○ Determine the local altitude (elevation). If you know the local altitude, use the chart in this section. If you know the local atmospheric pressure using a barometer, substitute the atmospheric pressure for Pv (vacuum pressure) in the inlet air pressure sensor chart (see Inlet Air Pressure Sensor Output Voltage Inspec-...
  • Page 158 3-64 FUEL SYSTEM (DFI) Atmospheric Pressure Sensor (Service Code 15) Atmospheric Pressure/Altitude Relationship...
  • Page 159 FUEL SYSTEM (DFI) 3-65 Atmospheric Pressure Sensor (Service Code 15) Atmospheric Pressure Sensor Circuit 1. ECU 2. Atmospheric Pressure Sensor...
  • Page 160: Crankshaft Sensor (service Code 21)

    3-66 FUEL SYSTEM (DFI) Crankshaft Sensor (Service Code 21) The crankshaft sensor has no power source, and when the engine stops, the crankshaft sensor generates no sig- nals. Crankshaft Sensor Removal/Installation • Refer to the Crankshaft Sensor Removal/Installation in the Electrical System chapter. Crankshaft Sensor Resistance Inspection •...
  • Page 161: Camshaft Position Sensor (service Code 23)

    FUEL SYSTEM (DFI) 3-67 Camshaft Position Sensor (Service Code 23) The camshaft position sensor detects the position of the camshaft, and distinguishes the cylinder. The camshaft position sensor has no power source, and when the engine stops, the camshaft position sensor gen- erates no signals.
  • Page 162 3-68 FUEL SYSTEM (DFI) Camshaft Position Sensor (Service Code 23) Camshaft Position Sensor Circuit 1. ECU 2. Camshaft Position Sensor...
  • Page 163: Speed Sensor (service Code 24, 25)

    FUEL SYSTEM (DFI) 3-69 Speed Sensor (Service Code 24, 25) Speed Sensor Removal/Installation • Refer to the Speed Sensor Removal/Installation in the Electrical System chapter. Speed Sensor Input Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch OFF.
  • Page 164: Speed Sensor Output Voltage Inspection

    3-70 FUEL SYSTEM (DFI) Speed Sensor (Service Code 24, 25) Speed Sensor Output Voltage Inspection • Using the stand, raise the rear wheel off the ground. • Measure the output voltage at the speed sensor in the same way as input voltage inspection, note the following. ○...
  • Page 165 FUEL SYSTEM (DFI) 3-71 Speed Sensor (Service Code 24, 25) Speed Sensor Circuit 1. ECU 2. Speed Sensor...
  • Page 166: Vehicle-down Sensor (service Code 31)

    3-72 FUEL SYSTEM (DFI) Vehicle-down Sensor (Service Code 31) This sensor has a weight [A] with two magnets inside, and sends a signal to the ECU. But when the motorcycle banks 60 ∼ 70° or more to either side (in fact falls down), the weight turns and the signal changes.
  • Page 167: Vehicle-down Sensor Input Voltage Inspection

    FUEL SYSTEM (DFI) 3-73 Vehicle-down Sensor (Service Code 31) Vehicle-down Sensor Input Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch OFF. • Disconnect the vehicle-down sensor connector and con- nect the harness adapter [A] between these connectors as shown.
  • Page 168: Vehicle-down Sensor Output Voltage Inspection

    3-74 FUEL SYSTEM (DFI) Vehicle-down Sensor (Service Code 31) Vehicle-down Sensor Output Voltage Inspection • Remove the vehicle-down sensor. • Connect the harness adapter [A] to the vehicle-down sen- sor connectors as shown. Special Tool - Measuring Adapter: 57001-1700 Main Harness [B] Vehicle-down Sensor [C] •...
  • Page 169 FUEL SYSTEM (DFI) 3-75 Vehicle-down Sensor (Service Code 31) If the reading is within the standard, remove the ECU and check the wiring for continuity between main harness con- nectors. ○ Disconnect the ECU and sensor connectors. Wiring Inspection ECU Connector [A] ←→ Vehicle-down Sensor Connector [B] Y/G lead (ECU terminal 11) [C] BR/BK lead (ECU terminal 28) [D]...
  • Page 170: Subthrottle Sensor (service Code 32)

    3-76 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 171: Subthrottle Sensor Output Voltage Inspection

    FUEL SYSTEM (DFI) 3-77 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 Inspection ECU Connector [A] ←→ Subthrottle Sensor Connector [B] BL lead (ECU terminal 10) [C] BR/BK lead (ECU terminal 28) [D]...
  • Page 172 3-78 FUEL SYSTEM (DFI) Subthrottle Sensor (Service Code 32) • Measure the output voltage with the engine stopped with the connector joined. • Turn the ignition switch ON. • Measure the output voltage when the subthrottle valve is completely closed by turning the lever [A] fully clockwise [B].
  • Page 173: Subthrottle Sensor Resistance Inspection

    FUEL SYSTEM (DFI) 3-79 Subthrottle Sensor (Service Code 32) Subthrottle Sensor Resistance Inspection • Turn the ignition switch OFF. • Disconnect the subthrottle sensor connector. • Connect a digital meter [A] to the subthrottle sensor con- nector [B]. • Measure the subthrottle sensor resistance. Subthrottle Sensor Resistance Connections: BL lead [C] ←→...
  • Page 174: Oxygen Sensor - Not Activated (service Code 33, Equipped Models)

    3-80 FUEL SYSTEM (DFI) Oxygen Sensor - not activated (Service Code 33, Equipped Models) Oxygen Sensor Removal/Installation • Refer to the Oxygen Sensor Removal/Installation in the Electrical System chapter. Oxygen Sensor Inspection • Warm up the engine thoroughly until the radiator fan starts.
  • Page 175 FUEL SYSTEM (DFI) 3-81 Oxygen Sensor - not activated (Service Code 33, Equipped Models) • Remove the connector [A] from the clamp [B]. • Separate the hoses [A] from the air suction valve covers. • Pull the air switching valve [A] and hoses out to the left side of the motorcycle.
  • Page 176 3-82 FUEL SYSTEM (DFI) Oxygen Sensor - not activated (Service Code 33, Equipped Models) • Start the engine, and let it idle. • Measure the output voltage with the connector joined. Output Voltage (with Plugs) Standard: DC 0.7 V or more •...
  • Page 177 FUEL SYSTEM (DFI) 3-83 Oxygen Sensor - not activated (Service Code 33, Equipped Models) Oxygen Sensor Circuit 1. ECU 2. Meter Ground 3. Oxygen Sensor 4. Water-proof Joint C 5. Fuse Box 1 6. Oxygen Sensor Heater Fuse 10 A 7.
  • Page 178: Exhaust Butterfly Valve Actuator Sensor (service Code 34)

    3-84 FUEL SYSTEM (DFI) Exhaust Butterfly Valve Actuator Sensor (Service Code 34) Exhaust Butterfly Valve Actuator Sensor Removal/Installation The exhaust butterfly valve actuator sensor is built in the exhaust butterfly valve actuator. So, the sensor itself can not be removed. Remove the exhaust butterfly valve actu- ator (see Exhaust Butterfly Valve Actuator Removal).
  • Page 179: Exhaust Butterfly Valve Actuator Sensor Output Voltage Inspection

    FUEL SYSTEM (DFI) 3-85 Exhaust Butterfly Valve Actuator Sensor (Service Code 34) Exhaust Butterfly Valve Actuator Sensor Output Voltage Inspection NOTE ○ Before this inspection, confirm the pulley [A] is original position (see Exhaust Butterfly Valve Actuator Installa- tion). • Disconnect: 2 pins Connector [B] 3 pins Connector [C]...
  • Page 180: Exhaust Butterfly Valve Actuator Sensor Resistance Inspection

    3-86 FUEL SYSTEM (DFI) Exhaust Butterfly Valve Actuator Sensor (Service Code 34) Exhaust Butterfly Valve Actuator Sensor Resistance Inspection • Turn the ignition switch OFF. • Disconnect the exhaust butterfly valve actuator sensor connector (3 pins connector) [A]. • Connect a digital meter [B] to the exhaust butterfly valve actuator sensor connector.
  • Page 181: Immobilizer Amplifier (service Code 35, Equipped Models)

    FUEL SYSTEM (DFI) 3-87 Immobilizer Amplifier (Service Code 35, Equipped Models) Antenna Resistance Inspection • Turn the ignition switch OFF. • Remove the fuel tank (see Fuel Tank Removal). • Disconnect the antenna lead connector [A]. • Measure the antenna resistance. Antenna Resistance Connections: BK lead ←→...
  • Page 182: Blank Key Detection (service Code 36, Equipped Models)

    Electrical System chapter). If the service code 36 appears again, the transponder in the key is malfunction, replace it. Immobilizer System Circuit 1. ECU 8. Immobilizer/Kawasaki Di- 13. Warning Indicator Light (LED) 2. Frame Ground agnostic System Connec- (FI/Immobilizer) 3.
  • Page 183: Ecu Communication Error (service Code 39)

    FUEL SYSTEM (DFI) 3-89 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 184: Stick Coils #1, #2, #3, #4 (service Code 51, 52, 53, 54)

    3-90 FUEL SYSTEM (DFI) Stick Coils #1, #2, #3, #4 (Service Code 51, 52, 53, 54) Stick Coil #1: Service Code 51 Stick Coil #2: Service Code 52 Stick Coil #3: Service Code 53 Stick Coil #4: Service Code 54 Stick Coil Removal/Installation •...
  • Page 185 FUEL SYSTEM (DFI) 3-91 Stick Coils #1, #2, #3, #4 (Service Code 51, 52, 53, 54) • Turn the ignition switch OFF. If the input voltage is out of the standard, check the wiring for continuity (see wiring diagram in this section). If the wiring is good, check the ECU for its ground and power supply (see ECU Power Supply Inspection).
  • Page 186: Radiator Fan Relay (service Code 56)

    3-92 FUEL SYSTEM (DFI) Radiator Fan Relay (Service Code 56) Radiator Fan Relay Removal/Installation ○ The radiator fan relay is built in the relay box [A]. • Refer to the Relay Box Removal in the Electrical System chapter. Radiator Fan Relay Inspection •...
  • Page 187 FUEL SYSTEM (DFI) 3-93 Radiator Fan Relay (Service Code 56) Radiator Fan Relay Circuit (ZR1000B9F/C9F) 1. ECU 8. Radiator Fan Relay 2. Frame Ground 9. Ignition Switch 3. Meter Ground 10. Main Fuse 30 A 4. Water-proof Joint C 11. Battery 12 V 8 Ah 5.
  • Page 188: Subthrottle Valve Actuator (service Code 62)

    3-94 FUEL SYSTEM (DFI) Subthrottle Valve Actuator (Service Code 62) Subthrottle Valve Actuator Removal CAUTION Do not remove the subthrottle valve actuator [A] since it has been adjusted and set with precision at the factory. Never drop the throttle body assy especially on a hard surface.
  • Page 189: 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 harness adapter [A] between these connec- tors as shown.
  • Page 190 3-96 FUEL SYSTEM (DFI) Subthrottle Valve Actuator (Service Code 62) Subthrottle Valve Actuator Circuit 1. ECU 2. Subthrottle Valve Actuator...
  • Page 191: Exhaust Butterfly Valve Actuator (service Code 63)

    FUEL SYSTEM (DFI) 3-97 Exhaust Butterfly Valve Actuator (Service Code 63) Exhaust Butterfly Valve Actuator Removal CAUTION Never drop the exhaust butterfly valve actuator es- pecially on a hard surface. Such a shock to the ac- tuator can damage it. •...
  • Page 192: Exhaust Butterfly Valve Actuator Installation

    3-98 FUEL SYSTEM (DFI) Exhaust Butterfly Valve Actuator (Service Code 63) Exhaust Butterfly Valve Actuator Installation • Install the pulley [A] on the actuator as shown. • Tighten the pulley bolt [B] while holding the pulley with the suitable tool [C]. Torque - Exhaust Butterfly Valve Actuator Pulley Bolt: 5.0 N·m (0.51 kgf·m, 44 in·lb) CAUTION...
  • Page 193: Exhaust Butterfly Valve Actuator Inspection

    FUEL SYSTEM (DFI) 3-99 Exhaust Butterfly Valve Actuator (Service Code 63) • Install the bracket [A] on the actuator [B]. Washer [C] Nut [D] Bolt [E] • Tighten: Torque - Exhaust Butterfly Valve Actuator Bracket Bolt: 6.9 N·m (0.70 kgf·m, 61 in·lb) •...
  • Page 194 3-100 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 195: Air Switching Valve (service Code 64)

    FUEL SYSTEM (DFI) 3-101 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 196: Oxygen Sensor Heater (service Code 67, Equipped Models)

    3-102 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 197: Oxygen Sensor Heater Power Source Voltage Inspection

    FUEL SYSTEM (DFI) 3-103 Oxygen Sensor Heater (Service Code 67, Equipped Models) Oxygen Sensor Heater Power Source Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch OFF. • Disconnect the oxygen sensor lead connector and con- nect the harness adapter [A] between these connectors.
  • Page 198 3-104 FUEL SYSTEM (DFI) Oxygen Sensor Heater (Service Code 67, Equipped Models) Oxygen Sensor Circuit 1. ECU 2. Meter Ground 3. Oxygen Sensor 4. Water-proof Joint C 5. Fuse Box 1 6. Oxygen Sensor Heater Fuse 10 A 7. Ignition Switch 8.
  • Page 199: Oxygen Sensor - Incorrect Output Voltage (service Code 94, Equipped Models)

    FUEL SYSTEM (DFI) 3-105 Oxygen Sensor - Incorrect Output Voltage (Service Code 94, Equipped Models) Oxygen Sensor Removal/Installation • Refer to the Oxygen Sensor Removal/Installation in the Electrical System chapter. Oxygen Sensor Inspection • Warm up the engine thoroughly until the radiator fan starts.
  • Page 200 3-106 FUEL SYSTEM (DFI) Oxygen Sensor - Incorrect Output Voltage (Service Code 94, Equipped Models) • Remove the connector [A] from the clamp [B]. • Separate the hoses [A] from the air suction valve covers. • Pull the air switching valve [A] and hoses out to the left side of the motorcycle.
  • Page 201 FUEL SYSTEM (DFI) 3-107 Oxygen Sensor - Incorrect Output Voltage (Service Code 94, Equipped Models) • Start the engine, and let it idle. • Measure the output voltage with the connector joined. Output Voltage (with Plugs) Standard: DC 0.7 V or more •...
  • Page 202: Warning Indicator Light (led)

    3-108 FUEL SYSTEM (DFI) Warning Indicator Light (LED) Light (LED) Inspection ○ The warning indicator light (LED) [A] is used for the FI indicator, immobilizer indicator (immobilizer models) and oil pressure warning indicator. ○ In this model, the warning indicator light (LED) (FI/immo- bilizer) blink by the data sent from the ECU.
  • Page 203: 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] ZR1000B7F ZR1000B8F ZR1000B9F...
  • Page 204: Ecu Installation

    3-110 FUEL SYSTEM (DFI) • Remove the relay box [A]. • Lift up the ECU [A] with rubber protector [B]. • Remove: ECU Connectors [A] ECU [B] ECU Installation • Install: ECU [A] (In rubber protector [B]) ECU Connectors [C] •...
  • Page 205: Ecu Power Supply Inspection

    FUEL SYSTEM (DFI) 3-111 ECU Power Supply Inspection • Remove the rear seat (see Rear Seat Removal in the Frame chapter). • Visually inspect the ECU connectors. If the connector is clogged with mud or dust, blow it off with compressed air. •...
  • Page 206 3-112 FUEL SYSTEM (DFI) If the wiring is good, check the power source voltage of the ECU. NOTE ○ Be sure the battery is fully charged. • Connect the ECU connectors. • Connect a digital meter [A] to the connectors [B] with the needle adapter set.
  • Page 207 FUEL SYSTEM (DFI) 3-113 ECU Power Source Circuit 1. ECU 2. Frame Ground 3. Water-proof Joint C 4. Fuse Box 2 5. ECU Fuse 10 A 6. Water-proof Joint B 7. Ignition Switch 8. Relay Box 9. ECU Main Relay 10.
  • Page 208: Dfi Power Source

    3-114 FUEL SYSTEM (DFI) DFI Power Source ECU Fuse Removal • Refer to the 10 A ECU Fuse Removal in the Electrical System chapter. ECU Fuse Installation If a fuse fails during operation, inspect the DFI system to determine the cause, and then replace it with a new fuse of proper amperage.
  • Page 209: Fuel Line

    FUEL SYSTEM (DFI) 3-115 Fuel Line Fuel Pressure Inspection NOTE ○ Be sure the battery is fully charged. • Remove: Fuel Tank (see Fuel Tank Removal) Fuel Outlet Hose (see Fuel Hose Replacement in the Periodic Maintenance chapter) ○ Be sure to place a piece of cloth around the fuel outlet pipe of the fuel pump and the delivery pipe of the throttle body assy.
  • Page 210: Fuel Flow Rate Inspection

    3-116 FUEL SYSTEM (DFI) Fuel Line NOTE ○ The gauge needle will fluctuate. Read the pressure at the average of the maximum and minimum indications. • Turn the ignition switch OFF. If the fuel pressure is much higher than specified, replace the fuel pump because the fuel pressure regulator in the fuel pump have been clogged or stuck.
  • Page 211 FUEL SYSTEM (DFI) 3-117 Fuel Line • Connect the prepared fuel hose [A] to the fuel outlet pipe. • Secure the fuel hose with a clamp. • Insert the fuel hose into the measuring cylinder [B]. WARNING Wipe off spilled out fuel immediately. Be sure to hold the measuring cylinder vertical.
  • Page 212: Fuel Pump

    3-118 FUEL SYSTEM (DFI) Fuel Pump Fuel Pump Removal WARNING Gasoline is extremely flammable and can be explo- sive under certain conditions. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light.
  • Page 213: Fuel Pump Installation

    FUEL SYSTEM (DFI) 3-119 Fuel Pump Fuel Pump Installation • Remove dirt or dust from the fuel pump [A] by lightly ap- plying compressed air. • Replace the fuel pump gasket with a new one. • Check that the fuel pump terminal [A] and band [B] are in place.
  • Page 214: Fuel Pump Operating Voltage Inspection

    3-120 FUEL SYSTEM (DFI) Fuel Pump Fuel Pump Operating Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch OFF. • Remove the right side cover (see Side Cover Removal in the Frame chapter). •...
  • Page 215: Pressure Regulator Removal

    FUEL SYSTEM (DFI) 3-121 Fuel Pump Pressure Regulator Removal ○ The pressure regulator [A] is built into the fuel pump [B] and can not be removed. Pump Screen, Fuel Filter Cleaning ○ The pump screen [A] and fuel filter [B] are built into the pump and can not be cleaned or checked.
  • Page 216 3-122 FUEL SYSTEM (DFI) Fuel Pump Fuel Pump Circuit 1. ECU 2. Frame Ground 3. Fuel Pump 4. Water-proof Joint B 5. Engine Stop Switch 6. Fuse Box 2 7. ECU Fuse 10A 8. Ignition Fuse 10 A 9. Relay Box 10.
  • Page 217: Fuel Injectors

    FUEL SYSTEM (DFI) 3-123 Fuel Injectors Fuel Injector Removal/Installation • Refer to the Throttle Body Assy Disassembly/Assembly. Fuel Injector Audible Inspection NOTE ○ Be sure the battery is fully charged. • Start the engine, and let it idle. • Apply the tip of a screwdriver [A] to the fuel injector [B]. Put the grip end onto your ear, and listen whether the fuel injector is clicking or not.
  • Page 218: Fuel Injector Power Source Voltage Inspection

    3-124 FUEL SYSTEM (DFI) Fuel Injectors Fuel Injector Power Source Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch OFF. • Disconnect the injector connector and connect the har- ness adapter [A] between these connectors as shown. Main Harness [B] Fuel Injector #1 [C] Special Tool - Measuring Adapter: 57001-1700...
  • Page 219: Fuel Injector Output Voltage Inspection

    FUEL SYSTEM (DFI) 3-125 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 220: Fuel Injector Fuel Line Inspection

    3-126 FUEL SYSTEM (DFI) Fuel Injectors If the reading is out of the specification, remove the ECU and check the wiring for continuity between main harness connectors. ○ Disconnect the ECU and injector connectors. Wiring Inspection ECU Connector [A] ←→ Fuel Injector Connector [B] For Fuel Injector #1 [C] BL/R lead (ECU terminal 44) [D] For Fuel Injector #2...
  • Page 221 FUEL SYSTEM (DFI) 3-127 Fuel Injectors ○ Watch the gauge for at least 6 seconds. If the pressure holds steady, the fuel line is good. If the pressure drops at once or if bubbles are found in the area, the fuel line is leaking. Replace the delivery pipe assy, injectors and related parts.
  • Page 222: 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 223: 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.
  • Page 224 3-130 FUEL SYSTEM (DFI) Throttle Body Assy • Disconnect: Main Throttle Sensor Connector [A] Subthrottle Sensor Connector [B] • Open the clamp [C]. • For the California and Southeast Asia models, pull off the vacuum hoses [D]. • For models equipped with an ABS, remove the bolt [A] and bracket [B].
  • Page 225 FUEL SYSTEM (DFI) 3-131 Throttle Body Assy • Remove the left frame cover (see Frame Cover Removal in the Frame chapter). • Open the clamp [A] and pull the alternator lead connector [B] downward. • Loosen the air duct clamp bolts [A]. •...
  • Page 226: Throttle Body Assy Installation

    3-132 FUEL SYSTEM (DFI) Throttle Body Assy • Remove the bolt [A] and the throttle cable plate [B] from the throttle body assy. • Remove the throttle cable lower ends [A] from the throttle pulley. Throttle Body Assy Installation • Turn the lever [A] fully clockwise, and close the subthrottle valves [B] until completely closed position.
  • Page 227: Throttle Body Assy Disassembly

    FUEL SYSTEM (DFI) 3-133 Throttle Body Assy • Install the air duct clamp bolts in the direction as shown. Bolt Heads [A] • Fit the projections [B] of the holder into the holes in the clamps. • Install the air ducts to the throttle body assy. ○...
  • Page 228: Throttle Body Assy Assembly

    3-134 FUEL SYSTEM (DFI) Throttle Body Assy CAUTION Do not remove, disassemble or adjust the main throttle sensor, subthrottle sensor, subthrottle valve actuator, throttle link mechanism and throttle body assy, because they are adjust or set surely at the manufacturer. Adjustment of these parts could result in poor performance, requiring replacement of the throttle body assy.
  • Page 229 FUEL SYSTEM (DFI) 3-135 Throttle Body Assy • Replace the dust seals [A] with new ones. • Apply engine oil to the new dust seals. • Install the injectors along with the delivery pipe assy to the throttle body. • Tighten: Torque - Delivery Pipe Assy Mounting Screws: 3.4 N·m (0.35 kgf·m, 30 in·lb)
  • Page 230: Air Cleaner

    3-136 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 231: Fuel Tank

    FUEL SYSTEM (DFI) 3-137 Fuel Tank Fuel Tank Removal WARNING Gasoline is extremely flammable and can be explo- sive under certain conditions. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light.
  • Page 232 3-138 FUEL SYSTEM (DFI) Fuel Tank • Disconnect: Fuel Pump Lead Connector [A] Fuel Level Sensor Lead Connector [B] • Be sure to place a piece of cloth [A] around the fuel outlet hose joint [B]. • Push the joint lock claws [C]. •...
  • Page 233: Fuel Tank Installation

    FUEL SYSTEM (DFI) 3-139 Fuel Tank • For the California and Southeast Asia models, note the following. CAUTION For the California and Southeast Asia models, if gasoline, solvent, water or any other liquid enters the canister, the canister’s vapor absorbing capac- ity is greatly reduced.
  • Page 234 3-140 FUEL SYSTEM (DFI) Fuel Tank • For the California and Southeast Asia models, note the following. ○ To prevent the gasoline from flowing into or out of the canister, hold the separator perpendicular to the ground. ○ Connect the hoses according to the diagram of the evap- orative emission control system.
  • Page 235: Fuel Tank Inspection

    FUEL SYSTEM (DFI) 3-141 Fuel Tank Fuel Tank Inspection • Open the tank cap. • Visually inspect the gasket [A] on the tank cap for any damage. Replace the gasket if it is damaged. • Check to see if the water drain pipe [B] and fuel breather pipe [C] (California and Southeast Asia models) in the tank are not clogged.
  • Page 236: Evaporative Emission Control System (cal And Sea Models)

    3-142 FUEL SYSTEM (DFI) Evaporative Emission Control System (CAL and SEA Models) The Evaporative Emission Control System routes fuel va- pors from the fuel system into the running engine or stores the vapors in a canister when the engine is stopped. Al- though no adjustments are required, a thorough visual in- spection must be made at the intervals specified by the Pe- riodic Maintenance Chart.
  • Page 237: Separator Operation Test

    FUEL SYSTEM (DFI) 3-143 Evaporative Emission Control System (CAL and SEA Models) Separator Operation Test WARNING Gasoline is extremely flammable and can be ex- plosive under certain conditions. Do not smoke. Turn the ignition switch OFF. Make sure the area is well-ventilated and free from any source of flame or sparks;...
  • Page 238 3-144 FUEL SYSTEM (DFI) Evaporative Emission Control System (CAL and SEA Models) 1. Fuel Tank 2. Green Hose (Purge) 3. Fitting 4. Clamp 5. White Hose (Vacuum) 6. Blue Hose (Breather) 7. Green Hose (Purge) 8. Band (for Canister) 9. Canister 10.
  • Page 239 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 240: Exploded View

    4-2 COOLING SYSTEM Exploded View...
  • Page 241 COOLING SYSTEM 4-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Coolant Drain Bolt (Cylinder) 87 in·lb Coolant Drain Bolt (Water Pump) 97 in·lb Radiator Bracket Mounting Bolt 0.70 61 in·lb Radiator Lower Bolt 0.70 61 in·lb Radiator Upper Bolts 0.70 61 in·lb Radiator (Water) Hose Clamp Screws...
  • Page 242: Coolant Flow Chart

    4-4 COOLING SYSTEM Coolant Flow Chart...
  • Page 243 COOLING SYSTEM 4-5 Coolant Flow Chart 1. Water Temperature Sensor 10. Cylinder Jacket 2. Thermostat Housing 11. Cylinder Head Jacket 3. Radiator Cap 12. Reserve Tank Hose 4. Radiator 13. Reserve Tank 5. Oil Filter 14. Reserve Tank Overflow Hose 6.
  • Page 244: 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% −35°C (−31°F) Freezing Point Total Amount...
  • Page 245: Special Tools

    COOLING SYSTEM 4-7 Special Tools Bearing Driver Set: Oil Seal Driver: 57001-1129 57001-1660...
  • Page 246: Coolant

    4-8 COOLING SYSTEM Coolant Coolant Deterioration Inspection • Remove the right seat cover (see Seat Cover Removal in the Frame chapter). • Visually inspect the coolant [A] in the reserve tank. If whitish cotton-like wafts are observed, aluminum parts in the cooling system are corroded. If the coolant is brown, iron or steel parts are rusting.
  • Page 247: 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 248: Water Pump

    4-10 COOLING SYSTEM Water Pump Water Pump Removal • Refer to the Oil Pump Removal in the Engine Lubrication System chapter. Water Pump Installation • Refer to the Oil Pump Installation in the Engine Lubrica- tion System chapter. Water Pump Inspection •...
  • Page 249: Water Pump Housing Assembly

    COOLING SYSTEM 4-11 Water Pump • Take the oil seal [A] out of the housing [B] with a hook [C]. Water Pump Housing Assembly CAUTION Do not reuse the mechanical seal and oil seal. • Apply high-temperature grease to the oil seal lips [A]. •...
  • Page 250: Radiator

    4-12 COOLING SYSTEM Radiator Radiator and Radiator Fan Removal WARNING The radiator fan is connected directly to the bat- tery. The radiator fan may start even if the ignition switch is off. NEVER TOUCH THE RADIATOR FAN UNTIL THE RADIATOR FAN MOTOR LEAD CON- NECTOR IS DISCONNECTED.
  • Page 251: Radiator And Radiator Fan Installation

    COOLING SYSTEM 4-13 Radiator Radiator and Radiator Fan Installation • Installation is the reverse of removal. • Run the radiator fan motor lead correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). • Install the radiator bracket collars [A] as shown in the fig- ure.
  • Page 252: Radiator Cap Inspection

    4-14 COOLING SYSTEM Radiator CAUTION When cleaning the radiator with steam cleaner, be careful of the following to prevent radiator damage: Keep the steam gun [A] away more than 0.5 m (1.6 ft) [B] from the radiator core. Hold the steam gun perpendicular [C] (not oblique [D]) to the core surface.
  • Page 253: Thermostat

    COOLING SYSTEM 4-15 Thermostat Thermostat Removal • Remove: Coolant (Drain, see Coolant Change in the Periodic Maintenance chapter) Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Right Center Fairing (see Center Fairing Removal in the Frame chapter) Radiator Hose Clamp Screw [A] (Loosen) Water Hose Clamp Screw [B] (Loosen) •...
  • Page 254: Thermostat Inspection

    4-16 COOLING SYSTEM Thermostat Thermostat Inspection • Remove the thermostat (see Thermostat Removal), and inspect the thermostat valve [A] at room temperature. If the valve is open, replace the thermostat with a new one. • To check valve opening temperature, suspend the ther- mostat [A] in a container of water and raise the tempera- ture of the water.
  • Page 255: Hose And Pipes

    COOLING SYSTEM 4-17 Hose and Pipes Hose Installation • Install the hoses and pipes, being careful to follow bend- ing direction. Avoid sharp bending, kinking, flattening or twisting. • Run the hoses (see Cable, Wire, and Hose Routing sec- tion in the Appendix chapter). •...
  • Page 256: Water Temperature Sensor

    4-18 COOLING SYSTEM Water Temperature Sensor CAUTION The water temperature sensor should never be al- lowed to fall on a hard surface. Such a shock to the water temperature sensor can damage it. Water Temperature Sensor Removal/Installation • Refer to the Water Temperature Sensor Removal/Instal- lation in the Fuel System (DFI) chapter.
  • Page 257 ENGINE TOP END 5-1 Engine Top End Table of Contents Exploded View........Valves ..........5-22 Exhaust System......... Valve Clearance Inspection ..5-22 Specifications ........Valve Clearance Adjustment..5-22 Special Tools and Sealant ....5-10 Valve Removal ......5-22 Clean Air System....... 5-12 Valve Installation ......
  • Page 258: Exploded View

    5-2 ENGINE TOP END Exploded View...
  • Page 259 ENGINE TOP END 5-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Air Suction Valve Cover Bolts 87 in·lb Camshaft Cap Bolts (L = 45 mm) 106 in·lb Camshaft Cap Bolts (L = 40 mm) 106 in·lb Camshaft Chain Tensioner Cap Bolt Camshaft Chain Tensioner Mounting Bolts 97 in·lb Coolant Drain Bolt (Cylinder)
  • Page 260 5-4 ENGINE TOP END Exploded View...
  • Page 261 ENGINE TOP END 5-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Exhaust Butterfly Valve Actuator Bracket Bolt 0.70 61 in·lb Exhaust Butterfly Valve Actuator Mounting Bolts 0.70 61 in·lb Exhaust Butterfly Valve Actuator Pulley Bolt 0.51 44 in·lb Exhaust Butterfly Valve Cable Adjuster Locknuts 0.70 61 in·lb Exhaust Butterfly Valve Cable Locknuts...
  • Page 262: Exhaust System

    5-6 ENGINE TOP END Exhaust System Exhaust System 78.2: Horsepower 78.2 kW (106.3 ps) Full: Full Power H: Honeycomb Type Catalyst...
  • Page 263 ENGINE TOP END 5-7 Exhaust System Manifold Mark Position [A] Muffler Body Mark Position [B] Honey Comb Type Catalyst Position [C] Honeycomb Type Catalyst Position [D] Manifold with Hole [E] for Oxygen Sensor. Oxygen Sensor [F]...
  • Page 264: Specifications

    5-8 ENGINE TOP END Specifications Item Standard Service Limit Camshafts Cam Height: 35.743 ∼ 35.857 mm (1.4072 ∼ 1.4117 in.) Exhaust 35.64 mm (1.403 in.) 35.943 ∼ 36.057 mm (1.4151 ∼ 1.4196 in.) Inlet 35.84 mm (1.411 in.) 0.028 ∼ 0.071 mm (0.0011 ∼ 0.0028 in.) Camshaft Journal, Camshaft 0.16 mm (0.0063 in.) Cap Clearance...
  • Page 265 ENGINE TOP END 5-9 Specifications Item Standard Service Limit Cylinder, Pistons 77.194 ∼ 77.206 mm (3.0391 ∼ 3.0396 in.) 77.30 mm (3.0433 in.) Cylinder Inside Diameter 77.174 ∼ 77.184 mm (3.0383 ∼ 3.0387 in.) 77.02 mm (3.0322 in.) Piston Diameter 0.010 ∼...
  • Page 266: Special Tools And Sealant

    5-10 ENGINE TOP END Special Tools and Sealant Compression Gauge, 20 kgf/cm²: Valve Seat Cutter, 45° - 27.5: 57001-221 57001-1114 Valve Spring Compressor Assembly: Valve Seat Cutter, 45° - 32: 57001-241 57001-1115 Piston Pin Puller Assembly: Valve Seat Cutter, 32° - 28: 57001-910 57001-1119 Piston Ring Compressor Grip:...
  • Page 267 Valve Seat Cutter, 60° - 27: 57001-1199 57001-1409 Compression Gauge Adapter, M10 × 1.0: Compression Gauge Adapter, M10 × 1.0: 57001-1317 57001-1601 Valve Seat Cutter Holder, 4.5: L-Shape Hose: 57001-1330 57001-1606 Valve Guide Arbor, 4.5: Kawasaki Bond (Silicone Sealant): 57001-1331 92104-0004...
  • Page 268: Clean Air System

    5-12 ENGINE TOP END Clean Air System Air Suction Valve Removal • Remove: Right Center Fairing (see Center Fairing Removal in the Frame chapter) Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Connector [A] (from Clamp [B]) Air Suction Valve Cover Bolts [C] and Bracket [D] Air Suction Valve Covers [E] Air Suction Valves...
  • Page 269: Air Switching Valve Removal

    ENGINE TOP END 5-13 Clean Air System Air Switching Valve Removal • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Thermostat Housing (see Thermostat Removal in the Cooling System chapter) Connector [A] (Disconnect) • Separate the hoses [B] from the air suction valve covers and air cleaner housing holder, and remove the air switch- ing valve [C].
  • Page 270: Cylinder Head Cover

    • Replace the head cover gasket with a new one. • Apply silicone sealant [A] to the cylinder head as shown in the figure. Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004 • Install the new head cover gasket. • Install:...
  • Page 271: Camshaft Chain Tensioner

    ENGINE TOP END 5-15 Camshaft Chain Tensioner Camshaft Chain Tensioner Removal CAUTION This is a non-return type camshaft chain tensioner. The push rod does not return to its original position once it moves out to take up camshaft chain slack. Observe all the rules listed below.
  • Page 272: Camshaft, Camshaft Chain

    5-16 ENGINE TOP END Camshaft, Camshaft Chain Camshaft Removal • Remove: Cylinder Head Cover (see Cylinder Head Cover Re- moval) Crankshaft Sensor Cover (see Crankshaft Sensor Re- moval in the Electrical System chapter) • Turn the crankshaft, align the #1, 4 mark on the timing rotor with the crankcase timing mark.
  • Page 273: Camshaft, Camshaft Cap Wear Inspection

    ENGINE TOP END 5-17 Camshaft, Camshaft Chain • Turn the crankshaft, align the #1, 4 mark on the timing rotor with the crankcase timing mark. • Pull the tension side (exhaust side) [A] of the chain taut to install the chain. •...
  • Page 274: Camshaft Runout Inspection

    5-18 ENGINE TOP END Camshaft, Camshaft Chain If any clearance exceeds the service limit, measure the diameter of each camshaft journal with a micrometer. Camshaft Journal Diameter 23.950 ∼ 23.972 mm (0.9429 ∼ 0.9438 in.) Standard: Service Limit: 23.92 mm (0.942 in.) If the camshaft journal diameter is less than the service limit, replace the camshaft with a new one and measure the clearance again.
  • Page 275: Cylinder Head

    ENGINE TOP END 5-19 Cylinder Head Cylinder Compression Measurement NOTE ○ Use the battery which is fully charged. • Warm up the engine thoroughly. • Stop the engine. • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Stick Coils (see Stick Coil Removal in the Electrical Sys- tem chapter)
  • Page 276: Cylinder Head Removal

    5-20 ENGINE TOP END Cylinder Head Cylinder Head Removal • Remove: Coolant (Drain, see Coolant Change in the Periodic Maintenance chapter) Cylinder Head Cover (see Cylinder Head Cover Re- moval) Camshafts (see Camshaft Removal) Throttle Body Assy (see Throttle Body Assy Removal in the Fuel System (DFI) chapter) Exhaust Pipe (see Exhaust Pipe Removal) •...
  • Page 277: Cylinder Head Warp Inspection

    ENGINE TOP END 5-21 Cylinder Head • Install: Front Camshaft Chain Guide [A] Rear Camshaft Chain Guide [B] New O-rings [C] Collar [D] ○ Apply grease to the new O-ring. • Tighten: Torque - Front Camshaft Chain Guide Bolt (Upper) [E]: 25 N·m (2.5 kgf·m, 18 ft·lb) Front Camshaft Chain Guide Bolt (Lower) [F]: 12 N·m (1.2 kgf·m, 106 in·lb)
  • Page 278: Valves

    5-22 ENGINE TOP END Valves Valve Clearance Inspection • Refer to the Valve Clearance Inspection in the Periodic Maintenance chapter. Valve Clearance Adjustment • Refer to the Valve Clearance Adjustment in the Periodic Maintenance chapter. Valve Removal • Remove: Cylinder Head (see Cylinder Head Removal) Valve Lifter and Shim ○...
  • Page 279: Valve Guide Installation

    ENGINE TOP END 5-23 Valves Valve Guide Installation • Apply engine oil to the valve guide outer surface before installation. • Heat the area around the valve guide hole to about 120 ∼ 150°C (248 ∼ 302°F). CAUTION Do not heat the cylinder head with a torch. This will warp the cylinder head.
  • Page 280: Valve Seat Inspection

    5-24 ENGINE TOP END Valves Valve Seat Inspection • Remove the valve (see Valve Removal). • Check the valve seating surface [A] between the valve [B] and valve seat [C]. ○ Measure the outside diameter [D] of the seating pattern on the valve seat.
  • Page 281 ENGINE TOP END 5-25 Valves Seat Cutter Operation Care 1. This valve seat cutter is developed to grind the valve for repair. Therefore the cutter must not be used for other purposes than seat repair. 2. Do not drop or shock the valve seat cutter, or the dia- mond particles may fall off.
  • Page 282 5-26 ENGINE TOP END Valves • Measure the outside diameter of the seating surface with a vernier caliper. If the outside diameter of the seating surface is too small, repeat the 45° grind until the diameter is within the spec- ified range.
  • Page 283 ENGINE TOP END 5-27 Valves If the seat width is too wide, make the 60° [A] grind de- scribed below. If the seat width is within the specified range, lap the valve to the seat as described below. • Grind the seat at a 60° angle until the seat width is within the specified range.
  • Page 284 5-28 ENGINE TOP END Valves...
  • Page 285: Cylinder, Pistons

    ENGINE TOP END 5-29 Cylinder, Pistons Cylinder Removal • Remove: Cylinder Head (see Cylinder Head Removal) Subframe [A] (see Engine Removal in the Engine Re- moval/Installation chapter) • Remove: Water Hose Clamp Screw (Loosen) [A] Water Hose [B] Cylinder [C] Cylinder Installation NOTE ○...
  • Page 286: Piston Removal

    5-30 ENGINE TOP END Cylinder, Pistons Piston Removal • Remove the cylinder (see Cylinder Removal). • Place a clean cloth under the pistons and remove the pis- ton pin snap ring [A] from the outside of each piston. • Remove the piston pins. Special Tool - Piston Pin Puller Assembly [A]: 57001-910 •...
  • Page 287: Cylinder Wear Inspection

    ENGINE TOP END 5-31 Cylinder, Pistons • Do not mix up the top and second ring. • Install the top ring [A] so that the “R” mark [B] faces up. • Install the second ring [C] so that the “RN” mark [D] faces ○...
  • Page 288: Piston Ring, Piston Ring Groove Wear Inspection

    5-32 ENGINE TOP END Cylinder, Pistons Piston Ring, Piston Ring Groove Wear Inspection • Check for uneven groove wear by inspecting the ring seat- ing. The rings should fit perfectly parallel to groove surfaces. If not, replace the piston and all the piston rings. •...
  • Page 289: Piston Ring End Gap Inspection

    ENGINE TOP END 5-33 Cylinder, Pistons Piston Ring End Gap Inspection • Place the piston ring [A] inside the cylinder, using the pis- ton to locate the ring squarely in place. Set it close to the bottom of the cylinder, where cylinder wear is low. •...
  • Page 290: Throttle Body Holder

    5-34 ENGINE TOP END Throttle Body Holder Throttle Body Holder Installation • Apply grease to the O-rings [A]. • Be sure to install the O-rings. • Install the clamps [B] as shown and so that its hole fit on the projection [C] of the holder. •...
  • Page 291: Muffler

    ENGINE TOP END 5-35 Muffler WARNING To avoid a serious burn, do not remove the muffler when the engine is still hot. Wait until the muffler cool down. Muffler Body Removal • Remove: Bolts [A] Cover [B] • Slide the dust covers [A]. •...
  • Page 292: Muffler Body Installation

    5-36 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 clamp bolts [C] [D] as shown in the figure.
  • Page 293: Exhaust Pipe Removal

    ENGINE TOP END 5-37 Muffler • Install the exhaust butterfly valve cables, and adjust them (see Exhaust Butterfly Valve Cable Installation). • Thoroughly warm up the engine, wait until the engine cools down, retighten all the bolts and nuts. • Install the removed parts (see appropriate chapters).
  • Page 294: Exhaust Pipe Installation

    5-38 ENGINE TOP END Muffler • Remove: Clamp Bolt [A] (Loosen) Mounting Bolt [B] • Remove: Exhaust Pipe Manifold Holder Nuts [A] Exhaust Pipe [B] Exhaust Pipe Installation • Replace the exhaust pipe gaskets [A] and muffler body gaskets [B] with new ones and install them. •...
  • Page 295: Exhaust Butterfly Valve Cable Removal

    ENGINE TOP END 5-39 Muffler Exhaust Butterfly Valve Cable Removal • Remove the cover (see Muffler Body Removal). • Slide the dust covers [A]. • Loosen the locknuts [B], and turn the adjusters [C] to give the cable plenty of play. •...
  • Page 296: Exhaust Butterfly Valve Cable Installation

    5-40 ENGINE TOP END Muffler Exhaust Butterfly Valve Cable Installation • Confirm whether pulley [A] is an angle shown in the figure. 41.7° ±7° [B] ○ This position is original position of the pulley. NOTE ○ Correct the position electrically after confirming use is discontinued and there is no damage when differing from the angle of shown in the figure.
  • Page 297 ENGINE TOP END 5-41 Muffler • Stretch the open cable (white) [A] first by using the ad- juster [B]. ○ Turn the adjuster counterclockwise until it becomes hard to turn. Locknut of White [C] CAUTION To keep the correct exhaust butterfly valve position, adjust the open cable first.
  • Page 298 5-42 ENGINE TOP END Muffler • Turn the ignition switch ON and wait until the pulley [A] turns fully clockwise [B]. • Turn off the ignition switch when the pulley become fully clockwise position [C] as shown in the figure. ○...
  • Page 299 ENGINE TOP END 5-43 Muffler • Stretch the open cable (white) by using the adjuster [A]. ○ Turn the adjuster counterclockwise until it becomes hard to turn. Locknut of White [B] CAUTION Do not overstretch. If the adjustment of the exhaust butterfly valve cables are incorrect, the exhaust but- terfly valve actuator does not operate correctly.
  • Page 301 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 302: Exploded View

    6-2 CLUTCH Exploded View...
  • Page 303 CLUTCH 6-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Clutch Cover Mounting Bolts 97 in·lb Clutch Cover Outer Cover Bolts 0.70 61 in·lb Clutch Hub Nut 13.8 99.6 Clutch Lever Clamp Bolts 0.80 69 in·lb Clutch Spring Bolts 0.90 78 in·lb Oil Filler Plug 0.20...
  • Page 304: Specifications

    6-4 CLUTCH Specifications Item Standard Service Limit 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Clutch Lever Free Play – – – Clutch 48.4 ∼ 49.0 mm (1.91 ∼ 1.93 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 305: Special Tool And Sealant

    CLUTCH 6-5 Special Tool and Sealant Clutch Holder: Kawasaki Bond (Silicone Sealant): 57001-1243 92104-0004...
  • Page 306: 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 307: Clutch Cover

    Clutch Cover Installation • Apply silicone sealant to the area [A] where the mating surface of the crankcase touches the clutch cover gasket. Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004 • Replace the clutch cover gasket with a new one. •...
  • Page 308: Clutch Cover Disassembly

    6-8 CLUTCH Clutch Cover • Fit the spring [A] as shown in the figure. Viewed from Rear [B] Release Shaft [C] Clutch Cover [D] Clutch Cover Disassembly • Remove: Oil Seal [A] Needle Bearings [B] Oil Level Gauge Clutch Cover Assembly •...
  • Page 309: Clutch Removal

    CLUTCH 6-9 Clutch Clutch Removal • Remove: Engine Oil (Drain, see Engine Oil Change in the Periodic Maintenance chapter) Clutch Cover (see Clutch Cover Removal) Clutch Spring Bolts [A] Clutch Springs Spring Holder (ZR1000B7F ∼ B8F/C7F ∼ C8F) Clutch Spring Plate [B] (with Washer, Needle Bearing and Pusher [C]) •...
  • Page 310 6-10 CLUTCH Clutch ○ Install the spacer [A] so that the tapered side [B] faces inward. ○ Install the washer [A] so that the “OUTSIDE” mark [B] faces outward. ○ Replace the clutch hub nut with a new one. ○ Holding the clutch hub, tighten the clutch hub nut.
  • Page 311 CLUTCH 6-11 Clutch • Apply molybdenum disulfide grease to the pusher ends [A] and install the pusher [B], needle bearing [C] and washer [D] in the clutch spring plate [E]. ○ Apply engine oil to the needle bearing. • Align the mark [A] of the clutch spring plate [B] with the groove [C] of the clutch hub.
  • Page 312: Clutch Plate Assembly Inspection

    6-12 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 in the figure. ZR1000B7F ∼ B8F/C7F ∼ C8F ○ Assemble: Clutch Hub [B] Spring Seat [C]...
  • Page 313: Clutch Plate Assembly Adjustment

    CLUTCH 6-13 Clutch Clutch Plate Assembly Adjustment • Inspect the clutch plate assembly length, and then re- place the steel plate(s) which brings the length within the specified range. • Remove: Clutch Spring Bolts Spring Holders (ZR1000B7F ∼ B8F/C7F ∼ C8F) Clutch Springs Clutch Spring Plate •...
  • Page 314: Clutch Spring Free Length Measurement

    6-14 CLUTCH Clutch Clutch Spring Free Length Measurement • Measure the free length of the clutch springs [A]. If any spring is shorter than the service limit, it must be replaced. Clutch Spring Free Length (ZR1000B7F ∼ B8F/C7F ∼ C8F) Standard: 85.0 mm (3.35 in.) Service Limit:...
  • Page 315 ENGINE LUBRICATION SYSTEM 7-1 Engine Lubrication System Table of Contents Exploded View........................Engine Oil Flow Chart......................Specifications ......................... Special Tools and Sealant ...................... Engine Oil and Oil Filter......................Oil Level Inspection......................Engine Oil Change......................Oil Filter Replacement ...................... Oil Pan............................ Oil Pan Removal .......................
  • Page 316: Exploded View

    7-2 ENGINE LUBRICATION SYSTEM Exploded View...
  • Page 317 ENGINE LUBRICATION SYSTEM 7-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Coolant Drain Bolt (Water Pump) 97 in·lb Engine Oil Drain Bolt Lower Fairing Bracket Bolts 0.70 61 in·lb Oil Filter G, R Oil Filter Holder Oil Filler Plug 0.20 18 in·lb Oil Pan Bolts...
  • Page 318: Engine Oil Flow Chart

    7-4 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart...
  • Page 319: Specifications

    ENGINE LUBRICATION SYSTEM 7-5 Specifications Item Standard Engine Oil Type API SE, SF or SG API SH, SJ or SL with JASO MA, MA1 or MA2 Viscosity SAE 10W-40 Capacity: 3.1 L (3.3 US gt) (when filter is not removed) 3.3 L (3.5 US gt) (when filter is removed) 3.8 L (4.0 US gt) (when engine is completely dry) Between upper and lower level lines (Wait 2 ∼...
  • Page 320: Special Tools And Sealant

    7-6 ENGINE LUBRICATION SYSTEM Special Tools and Sealant Outside Circlip Pliers: Oil Filter Wrench: 57001-144 57001-1249 Oil Pressure Gauge, 10 kgf/cm²: Kawasaki Bond (Silicone Sealant): 57001-164 56019-120 Oil Pressure Gauge Adapter, PT3/8: 57001-1233...
  • Page 321: Engine Oil And Oil Filter

    ENGINE LUBRICATION SYSTEM 7-7 Engine Oil and Oil Filter WARNING Motorcycle operation with insufficient, deteri- orated, or contaminated engine oil will cause accelerated wear and may result in engine or trans- mission seizure, accident, and injury. Oil Level Inspection • Check that the engine oil level is between the upper [A] and lower [B] levels in the gauge.
  • Page 322: Oil Pan

    7-8 ENGINE LUBRICATION SYSTEM Oil Pan Oil Pan Removal • Remove: Engine Oil (Drain, see Engine Oil Change in the Periodic Maintenance chapter) Exhaust Pipe (see Exhaust Pipe Removal in the Engine Top End chapter) Lower Fairing Bracket Bolts [A] (Both Sides) Lower Fairing Brackets [B] (Both Sides) •...
  • Page 323 ENGINE LUBRICATION SYSTEM 7-9 Oil Pan • Replace the oil pan gasket with a new one. • Install the clamp [A] at an angle of within 45° [B] as shown in the figure. • Install the clamp [C] as shown in the figure (Oxygen Sen- sor Equipped Models).
  • Page 324: Oil Pressure Relief Valve

    7-10 ENGINE LUBRICATION SYSTEM Oil Pressure Relief Valve Oil Pressure Relief Valve Removal • Refer to the Oil Pan Removal. Oil Pressure Relief Valve Installation • Refer to the Oil Pan Installation. Oil Pressure Relief Valve Inspection • Check to see if the valve [A] slides smoothly when push- ing it in with a wooden or other soft rod, and see if it comes back to its seat by spring [B] pressure.
  • Page 325: Oil Pump

    ENGINE LUBRICATION SYSTEM 7-11 Oil Pump Oil Pump Removal • Remove: Coolant (Drain, see Coolant Change in the Periodic Maintenance chapter) Engine Oil (Drain, see Engine Oil Change in the Periodic Maintenance chapter) Water Hose Clamp Screw [A] Water Hose [B] Water Pipe Bolts [C] Water Pipes [D] •...
  • Page 326: Oil Pump Drive Gear Removal

    7-12 ENGINE LUBRICATION SYSTEM Oil Pump • Install: Pins [A] Water Pump Body [B] • Install the impeller [A], washer and bolt [B]. • Tighten: Torque - Water Pump Impeller Bolt: 9.8 N·m (1.0 kgf·m, 87 in·lb) • Install the pins [C] and water pump cover. •...
  • Page 327: Oil Cooler

    ENGINE LUBRICATION SYSTEM 7-13 Oil Cooler Oil Cooler Removal • Remove: Coolant (Drain, see Coolant Change in the Periodic Maintenance chapter) Engine Oil (Drain, see Engine Oil Change in the Periodic Maintenance chapter) Oil Filter (see Oil Filter Replacement in the Periodic Maintenance chapter) Water Hose Clamp Screws (Loosen) [A] Oil Filter Holder [B] and Washer...
  • Page 328: Oil Pressure Measurement

    7-14 ENGINE LUBRICATION SYSTEM Oil Pressure Measurement Oil Pressure Measurement • Remove the oil passage plug, and attach the adapter [A] and gauge [B] to the plug hole. Special Tools - Oil Pressure Gauge, 10 kgf/cm²: 57001-164 Oil Pressure Gauge Adapter, PT3/8: 57001 -1233 •...
  • Page 329: Oil Pressure Switch

    • Apply silicone sealant to the threads of the oil pressure switch and tighten it. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 Torque - Oil Pressure Switch: 15 N·m (1.5 kgf·m, 11 ft·lb) • Install the switch lead direction upward.
  • Page 331 ENGINE REMOVAL/INSTALLATION 8-1 Engine Removal/Installation Table of Contents Exploded View........................Special Tool ..........................Engine Removal/Installation ....................Engine Removal........................ Engine Installation......................
  • Page 332: Exploded View

    8-2 ENGINE REMOVAL/INSTALLATION Exploded View...
  • Page 333 ENGINE REMOVAL/INSTALLATION 8-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Adjusting Collar Lock Bolt Adjusting Collar Locknut Engine Ground Cable Terminal Bolt 87 in·lb Front Engine Mounting Bolts Lower Engine Mounting Nut Middle Engine Mounting Nut Rear Engine Bracket Bolts Subframe Bolts Upper Engine Bracket Bolts S: Follow the specified tightening sequence.
  • Page 334: Special Tool

    8-4 ENGINE REMOVAL/INSTALLATION Special Tool Engine Mount Nut Wrench: 57001-1450...
  • Page 335: 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 Be sure to hold the front brake when removing the engine, or the motorcycle may fall over.
  • Page 336 8-6 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Disconnect: Stick Coil Harness Connector [A] Camshaft Position Sensor Lead Connector (see Camshaft Position Sensor Removal in the Electrical System chapter) • Disconnect: Starter Motor Cable (see Starter Motor Removal in the Electrical System chapter) Alternator Lead Connector (see Alternator Cover Re- moval in the Electrical System chapter) Crankshaft Sensor Lead Connector (see Crankshaft...
  • Page 337: Engine Installation

    ENGINE REMOVAL/INSTALLATION 8-7 Engine Removal/Installation • Using the nut wrench [A], loosen the locknut [B]. Special Tool - Engine Mount Nut Wrench: 57001-1450 • Using the Hexagon Wrench, turn the adjusting collar [A] counterclockwise to make the gap between the engine and adjusting collar.
  • Page 338 8-8 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Install the engine mounting bolts and nuts, following the specified installing sequence. ○ First, hang the drive chain over the output shaft just before moving the engine into its final position in the frame. ○...
  • Page 339 ENGINE REMOVAL/INSTALLATION 8-9 Engine Removal/Installation • Run the leads, cables and hoses correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). • Install the removed parts (see appropriate chapters). Torque - Engine Ground Cable Terminal Bolt: 9.8 N·m (1.0 kgf·m, 87 in·lb) •...
  • Page 341 CRANKSHAFT/TRANSMISSION 9-1 Crankshaft/Transmission Table of Contents Exploded View........................Specifications ......................... Special Tools and Sealant ...................... Crankcase Splitting......................... Crankcase Splitting ......................Crankcase Assembly ......................9-10 Crankshaft and Connecting Rods................... 9-13 Crankshaft Removal ......................9-13 Crankshaft Installation ...................... 9-13 Connecting Rod Removal ....................9-13 Connecting Rod Installation ....................
  • Page 342: Exploded View

    9-2 CRANKSHAFT/TRANSMISSION Exploded View...
  • Page 343 CRANKSHAFT/TRANSMISSION 9-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Breather Plate Bolts (M6) 87 in·lb Breather Plate Bolts (M5) 0.60 52 in·lb ← ← Connecting Rod Big End Nuts see the text Crankcase Bolts (M9) MO, S Crankcase Bolts (M8) Crankcase Bolts (M7) Crankcase Bolts (M6) 106 in·lb...
  • Page 344 9-4 CRANKSHAFT/TRANSMISSION Exploded View...
  • Page 345 CRANKSHAFT/TRANSMISSION 9-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Footpeg Bracket Bolts Gear Positioning Lever Bolt 106 in·lb Neutral Switch Shift Drum Cam Holder Bolt 106 in·lb Shift Lever Bolt 0.70 61 in·lb Shift Pedal Mounting Bolt Shift Shaft Return Spring Pin Tie-Rod Locknuts 0.70 61 in·lb...
  • Page 346: Specifications

    9-6 CRANKSHAFT/TRANSMISSION Specifications Item Standard Service Limit Crankshaft, Connecting Rods Connecting Rod Bend – – – TIR 0.2/100 mm (0.008/3.94 in.) Connecting Rod Twist – – – TIR 0.2/100 mm (0.008/3.94 in.) 0.13 ∼ 0.38 mm Connecting Rod Big End Side Clearance 0.58 mm (0.0051 ∼...
  • Page 347 CRANKSHAFT/TRANSMISSION 9-7 Specifications Item Standard Service Limit 0.020 ∼ 0.044 mm Crankshaft Main Bearing Insert/Journal 0.07 mm (0.0008 ∼ 0.0017 in.) Clearance (0.0028 in.) 32.984 ∼ 33.000 mm Crankshaft Main Journal Diameter: 32.96 mm (1.2986 ∼ 1.2992 in.) (1.2976 in.) 32.984 ∼...
  • Page 348: Special Tools And Sealant

    9-8 CRANKSHAFT/TRANSMISSION Special Tools and Sealant Bearing Puller: Bearing Puller Adapter: 57001-135 57001-317 Outside Circlip Pliers: Kawasaki Bond (Liquid Gasket - Black) : 57001-144 92104-1062...
  • Page 349: 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: Crankshaft Sensor (see Crankshaft Sensor Removal in the Electrical System chapter) Clutch (see Clutch Removal in the Clutch chapter) External Shift Mechanism (see External Shift Mecha-...
  • Page 350: Crankcase Assembly

    9-10 CRANKSHAFT/TRANSMISSION Crankcase Splitting Crankcase Assembly CAUTION The upper and lower crankcase halves are ma- chined at the factory in the assembled state, so the crankcase halves must be replaced as a set. • With a high-flash point solvent, clean off the mating sur- faces of the crankcase halves and wipe dry.
  • Page 351 • Apply liquid gasket [A] to the mating surface of the lower crankcase half. Sealant - Kawasaki Bond (Liquid Gasket - Black): 92104 -1062 NOTE ○ Especially, apply a sealant so that it shall be filled up on the grooves.
  • Page 352 9-12 CRANKSHAFT/TRANSMISSION Crankcase Splitting • Tighten the lower crankcase bolts using the following steps. ○ Following the sequence numbers on the lower crankcase half, tighten the M9 bolts [1 ∼ 6] L= 81 mm (3.19 in.). Torque - Crankcase Bolts (M9): 42 N·m (4.3 kgf·m, 31 ft·lb) ○...
  • Page 353: Crankshaft And Connecting Rods

    CRANKSHAFT/TRANSMISSION 9-13 Crankshaft and Connecting Rods Crankshaft Removal • Split the crankcase (see Crankcase Splitting). • Remove the crankshaft [A]. Crankshaft Installation CAUTION If the crankshaft, bearing inserts, or crankcase halves are replaced with new ones, select the bear- ing inserts and check clearance with a plastigage (press gauge) before assembling engine to be sure the correct bearing inserts are installed.
  • Page 354 9-14 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods • Apply molybdenum disulfide oil solution [A] to the inner surfaces of upper and lower bearing inserts. • Do not apply any grease or oil to the cap inside and cap insert outside [B]. •...
  • Page 355 CRANKSHAFT/TRANSMISSION 9-15 Crankshaft and Connecting Rods (1) Bolt Length Measurement Method • Be sure to clean the bolts, nuts, and connecting rods thoroughly with a high-flash point solvent, because the new connecting rods, bolts, and nuts are treated with an anti-rust solution.
  • Page 356: Crankshaft/connecting Rod Cleaning

    9-16 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods (2) Rotation Angle Method If you don’t have a point micrometer, you may tighten the nuts using the “Rotation Angle Method”. • Be sure to clean the bolts and nuts thoroughly with a high -flash point solvent, because the new bolts and nuts are treated with an anti-rust solution.
  • Page 357: Connecting Rod Bend Inspection

    CRANKSHAFT/TRANSMISSION 9-17 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 358: Connecting Rod Big End Bearing Insert/crankpin Wear Inspection

    9-18 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods Connecting Rod Big End Bearing Insert/Crankpin Wear Inspection • Measure the bearing insert/crankpin [A] clearance with plastigage [B]. • Tighten the big end nuts to the specified torque (see Con- necting Rod Installation). NOTE ○...
  • Page 359: Crankshaft Side Clearance Inspection

    CRANKSHAFT/TRANSMISSION 9-19 Crankshaft and Connecting Rods • Measure the connecting rod big end inside diameter, and mark each connecting rod big end in accordance with the inside diameter. • Tighten the connecting rod big end nuts to the specified torque (see Connecting Rod Installation). NOTE ○...
  • Page 360: Crankshaft Runout Inspection

    9-20 CRANKSHAFT/TRANSMISSION 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 361 CRANKSHAFT/TRANSMISSION 9-21 Crankshaft and Connecting Rods • Measure the main bearing inside diameter, and mark the upper crankcase half in accordance with the inside diam- eter. ○ Crankcase Main Bearing Inside Diameter Marks: “ ” or no mark. • Tighten the crankcase bolts to the specified torque (see Crankcase Assembly).
  • Page 362: Starter Motor Clutch

    9-22 CRANKSHAFT/TRANSMISSION Starter Motor Clutch Starter Motor Clutch Removal/Installation • Refer to the Alternator Rotor Removal/Installation in the Electrical System chapter. Starter Motor Clutch Inspection • Remove: Alternator Cover (see Alternator Cover Removal in the Electrical System chapter) Starter Idle Gear and Shaft •...
  • Page 363: Transmission

    CRANKSHAFT/TRANSMISSION 9-23 Transmission Shift Pedal Removal • Align the mark [A] on the shift shaft with the slit [B] on the shift lever. • Remove: Shift Lever Bolt [C] Shift Lever • Remove: Front Footpeg Bracket Bolts [A] Front Footpeg Bracket [B] •...
  • Page 364: External Shift Mechanism Removal

    9-24 CRANKSHAFT/TRANSMISSION Transmission • Install the front footpeg bracket [A]. • Tighten: Torque - Front Footpeg Bracket Bolts [B]: 25 N·m (2.5 kgf·m, 18 ft·lb) • Install the shift lever [A], aligning the mark (previously marked). • Tighten: Torque - Shift Lever Bolt: 6.9 N·m (0.70 kgf·m, 61 in·lb) •...
  • Page 365: External Shift Mechanism Installation

    CRANKSHAFT/TRANSMISSION 9-25 Transmission • Remove: Oil Pump Drive Gear (see Oil Pump Drive Gear Removal in the Engine Lubrication System chapter) Gear Positioning Lever Bolt [A] Gear Positioning Lever [B] Collar and Spring External Shift Mechanism Installation • Install the gear positioning lever [A] as shown in the figure. Spring [B] Collar [C] Bolt [D]...
  • Page 366: Transmission Shaft Removal

    9-26 CRANKSHAFT/TRANSMISSION Transmission Transmission Shaft Removal • Split the crankcase (see Crankcase Splitting). • Remove the drive shaft [A] and output shaft [B]. Transmission Shaft Installation • Check to see that the set pins [A] and set rings [B] are in place.
  • Page 367: Transmission Shaft Assembly

    CRANKSHAFT/TRANSMISSION 9-27 Transmission • Remove the ball bearing [A] from each shafts. Special Tools - Bearing Puller [B]: 57001-135 Bearing Puller Adapter [C]: 57001-317 • Discard the bearing. Transmission Shaft Assembly • Apply engine oil to the bushings, ball bearings and shafts. •...
  • Page 368 9-28 CRANKSHAFT/TRANSMISSION Transmission NOTE ○ When the toothed washers [28] [29] are assembled onto the output shaft, note the following. ○ When the tangs [A] of the toothed washer [29] shall be assembled, they should be installed into the notch [B] of the toothed washer [28] (see Page 9-29).
  • Page 369 CRANKSHAFT/TRANSMISSION 9-29 Transmission 1. 1st Gear 17. Nut 2. 2nd Gear 18. Bushing 3. 3rd Gear 19. Bushing 4. 4th Gear 20. Circlip, 33 mm (1.30 in.) 5. 5th Gear 21. Ball Bearing 6. 6th (Top) Gear 22. Collar 7. Toothed Washer, 31 mm (1.22 in.) 23.
  • Page 370: Shift Drum And Fork Removal

    9-30 CRANKSHAFT/TRANSMISSION Transmission Shift Drum and Fork Removal • Remove: Lower Crankcase Half (see Crankcase Splitting) Transmission Shafts Gear Positioning Lever [A] (see External Shift Mecha- nism Removal) Bolt [B] and Screw [C] Shift Drum Bearing Holder [D] • Pull out the shift rods [E], and take off the shift forks. •...
  • Page 371: Shift Fork Bending Inspection

    CRANKSHAFT/TRANSMISSION 9-31 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 373 WHEELS/TIRES 10-1 Wheels/Tires Table of Contents Exploded View........................10-2 Specifications ......................... 10-4 Special Tools .......................... 10-5 Wheels (Rims) ........................10-6 Front Wheel Removal ....................... 10-6 Front Wheel Installation ....................10-6 Rear Wheel Removal......................10-7 Rear Wheel Installation..................... 10-8 Wheel Inspection ......................10-10 Axle Inspection........................
  • Page 374: Exploded View

    10-2 WHEELS/TIRES Exploded View...
  • Page 375 WHEELS/TIRES 10-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Axle 13.0 93.7 Front Axle Clamp Bolt Rear Axle Nut 13.0 93.7 4. Caliper Bracket (ABS Equipped Models) HG: Apply high-temperature grease. R: Replacement Parts WL: Apply soap and water solution or rubber lubricant.
  • Page 376: Specifications

    10-4 WHEELS/TIRES Specifications Item Standard Service Limit Wheels (Rims) Rim Runout: Axial TIR 0.5 mm (0.02 in.) or less TIR 1.0 mm (0.04 in.) Radial TIR 0.8 mm (0.03 in.) or less TIR 1.0 mm (0.04 in.) Axle Runout/100 mm TIR 0.03 mm (0.0012 in.) or less TIR 0.2 mm (0.008 in.) (3.94 in.)
  • Page 377: Special Tools

    WHEELS/TIRES 10-5 Special Tools Inside Circlip Pliers: Bearing Remover Head, 25 × 28: 57001-143 57001-1346 Bearing Driver Set: Bearing Remover Shaft, 13: 57001-1129 57001-1377 Jack: Jack Attachment: 57001-1238 57001-1608...
  • Page 378: Wheels (rims)

    10-6 WHEELS/TIRES Wheels (Rims) Front Wheel Removal • Remove: Front Caliper Mounting Bolts [A] (Both Sides) Front Calipers [B] (Both Sides) • Remove: Front Fender (see Front Fender Removal in the Frame chapter) Front Axle Clamp Bolt [A] (Loosen) Front Axle [B] •...
  • Page 379: Rear Wheel Removal

    WHEELS/TIRES 10-7 Wheels (Rims) • Apply high-temperature grease to the grease seal lips. • Fit the collars [A] on the both sides of the hub. ○ The collars are identical. • Insert the front axle. • Tighten: Torque - Front Axle: 127 N·m (13.0 kgf·m, 93.7 ft·lb) •...
  • Page 380: Rear Wheel Installation

    10-8 WHEELS/TIRES Wheels (Rims) • Remove: Cotter Pin [A] Axle Nut [B] Washer [C] Axle [D] (from Left Side) • Remove the rear wheel rotation sensor [E] from the caliper bracket (see Rear Wheel Rotation Sensor Re- moval in the Brakes chapter) (ABS equipped models). •...
  • Page 381 WHEELS/TIRES 10-9 Wheels (Rims) • Bend the cotter pin [A] over the nut. WARNING If the rear axle nut is not securely tightened or the cotter pin is not installed, an unsafe riding condi- tion may result. • Adjust the drive chain slack after installation (see Drive Chain Slack Inspection in the Periodic Maintenance chap- ter).
  • Page 382: Wheel Inspection

    10-10 WHEELS/TIRES Wheels (Rims) Wheel Inspection • Raise the front/rear wheel off the ground. Special Tools - Jack: 57001-1238 Jack Attachment: 57001-1608 • Spin the wheel lightly, and check for roughness or binding. If roughness or binding is found, replace the hub bearings (see Hub Bearing Removal/Installation).
  • Page 383: 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 384: Balance Weight Installation

    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 385 WHEELS/TIRES 10-13 Wheels (Rims) • Check that the blade [A] and weight [B] seat fully on the rim flange [C], and that the clip [D] is hooked over the rim ridge [E] and reaches rim flat portion. • When required total weight exceeds 20 g (0.71 oz.), install balance weight at both sides of rim flange as shown in the figure.
  • Page 386: Tires

    10-14 WHEELS/TIRES Tires Air Pressure Inspection/Adjustment • Refer to the Air Pressure Inspection in the Periodic Main- tenance chapter. Tire Inspection • Refer to the Wheel/Tire Damage Inspection in the Peri- odic Maintenance chapter. Tire Removal • Remove: Wheels (see Front/Rear Wheel Removal) Valve Core (Let out the air) •...
  • Page 387 WHEELS/TIRES 10-15 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 388: 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 389: Hub Bearing

    WHEELS/TIRES 10-17 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] Circlip [D] Front Wheel [E] Rear Wheel [F] Special Tool - Inside Circlip Pliers: 57001-143 •...
  • Page 390: Hub Bearing Inspection

    10-18 WHEELS/TIRES Hub Bearing • Replace the circlip with a new one. Special Tool - Inside Circlip Pliers: 57001-143 • Replace the grease seals with new ones. • Press in the grease seals [A] so that the seal surface flush [B] with the end of the hole.
  • Page 391 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 392: Exploded View

    11-2 FINAL DRIVE Exploded View...
  • Page 393 FINAL DRIVE 11-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Engine Sprocket Cover Bolts 87 in·lb Engine Sprocket Nut 12.7 92.2 Rear Axle Nut 13.0 93.7 Rear Sprocket Nuts G: Apply grease. HG: Apply high-temperature grease. HO: Apply heavy oil. L: Apply a non-permanent locking agent.
  • Page 394: Specifications

    11-4 FINAL DRIVE Specifications Item Standard Service Limit Drive Chain 25 ∼ 30 mm (1.0 ∼ 1.2 in.) Drive Chain Slack – – – Drive Chain Wear (20-link Length) 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) 323 mm (12.7 in.) Standard Chain: Make ENUMA...
  • Page 395: Special Tools

    FINAL DRIVE 11-5 Special Tools Inside Circlip Pliers: Bearing Driver Set: 57001-143 57001-1129...
  • Page 396: 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 397: Drive Chain Installation

    FINAL DRIVE 11-7 Drive Chain • Remove the drive chain [A] from the engine sprocket [B], and take it off the chassis. Drive Chain Installation • Install the drive chain to the engine sprocket. • Install: Swingarm (see Swingarm Installation in the Suspension chapter) Rear Wheel (see Rear Wheel Installation in the Wheels/Tires chapter)
  • Page 398 11-8 FINAL DRIVE Drive Chain • Grind the [A] pin head to make it flat. • Set the cutting and riveting pin [B] as shown in the figure. • Screw the pin holder until it touches chain pin. • Be sure that the cutting pin hits center of chain pin. •...
  • Page 399 FINAL DRIVE 11-9 Drive Chain • Fit the plate holder (A) [A] to link plate. • Turn the pin holder by hand until plate holder (B) [B] touches the other link plate. • Turn the pin holder [A] by wrench clockwise until two pins of link come into groove of plate holders [B].
  • Page 400 11-10 FINAL DRIVE Drive Chain • After staking, check the staked area of the link pin for cracks. • Measure the outside diameter [A] of the link pin and link plates width [B]. Link Pin Outside Diameter 5.6 ∼ 6.0 mm (0.22 ∼ 0.24 in.) Standard: Link Plates Outside Width 19.65 ∼...
  • Page 401: Sprocket, Coupling

    FINAL DRIVE 11-11 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 402: Rear Sprocket Removal

    11-12 FINAL DRIVE Sprocket, Coupling • Install the engine sprocket cover [A]. • Install the clamp [B] as shown in the figure, and tighten the cover bolts [C]. Torque - Engine Sprocket Cover Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) •...
  • Page 403: 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 404: 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 405 BRAKES 12-1 Brakes Table of Contents Exploded View........................12-4 Specifications ......................... 12-12 Special Tools .......................... 12-13 Brake Lever, Brake Pedal....................... 12-14 Brake Lever Position Adjustment..................12-14 Brake Pedal Position Inspection ..................12-14 Brake Pedal Position Adjustment..................12-14 Brake Pedal Removal ....................... 12-14 Brake Pedal Installation ....................
  • Page 406 12-2 BRAKES Inquiries to Rider....................... 12-39 Self-diagnosis Outline ....................... 12-41 Self-diagnosis Procedures ....................12-41 Service Code Clearing Procedures................... 12-42 How to Read Service Codes..................... 12-45 How to Erase Service Codes .................... 12-45 ABS Indicator Light (LED) Inspection ................12-47 ABS Indicator Light (LED) is Unlit (When the Ignition Switch turned to ON) ....12-47 ABS Indicator Light (LED) Lights (When the Motorcycle is Running, - No Service Code) 12-48...
  • Page 407 BRAKES 12-3 Dummy Page...
  • Page 408: Exploded View

    12-4 BRAKES Exploded View...
  • Page 409 BRAKES 12-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Bleed Valves 0.80 69 in·lb Brake Hose Banjo Bolts Brake Lever Pivot Bolt 0.10 9 in·lb Brake Lever Pivot Bolt Locknut 0.60 52 in·lb Front Brake Disc Mounting Bolts Front Brake Light Switch Screw 0.12 11 in·lb Front Brake Pad Pins...
  • Page 410 12-6 BRAKES Exploded View...
  • Page 411 BRAKES 12-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Bleed Valve 0.80 69 in·lb Brake Hose Banjo Bolts Brake Pedal Bolt Rear Brake Disc Mounting Bolts Rear Brake Pad Pin 17.2 Rear Brake Pad Pin Plug 0.25 25 in·lb Rear Caliper Mounting Bolt Rear Caliper Pin Bolt Rear Master Cylinder Mounting Bolts...
  • Page 412 12-8 BRAKES Exploded View ABS Equipped Models...
  • Page 413 BRAKES 12-9 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Bleed Valves 0.80 69 in·lb Brake Hose Banjo Bolts Brake Lever Pivot Bolt 0.10 9 in·lb Brake Lever Pivot Bolt Locknut 0.60 52 in·lb Brake Pipe Joint Nuts Front Brake Disc Mounting Bolts Front Brake Light Switch Screw 0.12 11 in·lb...
  • Page 414 12-10 BRAKES Exploded View ABS Equipped Models...
  • Page 415 BRAKES 12-11 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Bleed Valve 0.80 69 in·lb Brake Hose Banjo Bolts Brake Pedal Bolt Brake Pipe Joint Nuts Rear Brake Disc Mounting Bolts Rear Brake Pad Pin 17.2 Rear Brake Pad Pin Plug 0.25 25 in·lb Rear Caliper Mounting Bolt...
  • Page 416: Specifications

    12-12 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 45 mm (1.77 in.) below footpeg top –...
  • Page 417 BRAKES 12-13 Special Tools Inside Circlip Pliers: Hand Tester: 57001-143 57001-1394 Jack: Jack Attachment: 57001-1238 57001-1608...
  • Page 418: Brake Lever Position Adjustment

    12-14 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 holder.
  • Page 419: Brake Pedal Installation

    BRAKES 12-15 Brake Lever, Brake Pedal • Remove: Cotter Pin [A] Joint Pin [B] Rear Brake Light Switch Spring [C] Return Spring [D] Brake Pedal Bolt [E] Brake Pedal [F] Brake Pedal Installation • Apply grease to the footpeg pivot shaft [A]. •...
  • Page 420: Calipers

    12-16 BRAKES Calipers Front Caliper Removal • Loosen the banjo bolt [A] at the brake hose lower end, and tighten it loosely. • Unscrew the caliper mounting bolts [B], and detach the caliper [C] from the disc. CAUTION Do not loosen the caliper assembly bolts. Take out only the caliper mounting bolts for caliper removal.
  • Page 421: Front Caliper Disassembly

    BRAKES 12-17 Calipers Rear Caliper • Install: Rubber Boot [A] Guide [B] • Fit the rear brake pads [A] to the guide [B]. • Apply silicone grease to the rear caliper pin bolt. • Tighten: Torque - Caliper Mounting Bolts: Front: 34 N·m (3.5 kgf·m, 25 ft·lb) Rear: 22 N·m (2.2 kgf·m, 16 ft·lb) Rear Caliper Pin Bolt: 27 N·m (2.8 kgf·m, 20 ft·lb)
  • Page 422: Caliper Fluid Seal Damage

    12-18 BRAKES Calipers Caliper Fluid Seal Damage The fluid seal (piston seal) [A] is placed around the pis- ton to maintain clearance between the pad and the disc. If the seal is in a poor condition, it could lead the pad to wear excessively or the brake to drag, which may cause the tem- perature of the discs or the brake fluid to increase.
  • Page 423: Caliper Piston And Cylinder Damage

    BRAKES 12-19 Calipers Caliper Piston and Cylinder Damage • Visually inspect the pistons [A] and cylinder surfaces [B]. Replace the caliper if the cylinder and piston are badly scores or rusty.
  • Page 424: Brake Pads

    12-20 BRAKES Brake Pads Front Brake Pad Removal • Loosen the pad pin [A]. • Remove: Pad Pin [A] Pad Spring [B] Brake Pads [C] Front Brake Pad Installation • Push the caliper pistons in by hand as far as they will go. •...
  • Page 425: Rear Brake Pad Removal

    BRAKES 12-21 Brake Pads • Visually inspect the pad spring positions. ○ Be sure the lower portion [A] of the spring is located on the projection [B] of the brake pad. CAUTION The disc comes in contact with spring when the lower portion of the spring gets depressed the re- cess of the brake pad and abnormal noise may oc- cur.
  • Page 426: Rear Brake Pad Installation

    12-22 BRAKES Brake Pads Rear Brake Pad Installation • Push the caliper piston in by hand as far as they will go. • Install the outside pad [A] and insert the pad pin [B] as shown in the figure. • Set: Inside Pad [A] Pad Pin [B]...
  • Page 427: Master Cylinder

    BRAKES 12-23 Master Cylinder Front Master Cylinder Removal • Remove the banjo bolt [A] to disconnect the brake hose from the master cylinder (see Brake Hose Removal/In- stallation). • Unscrew the clamp bolts [B], and take off the master cylin- der [C] as an assembly with the reservoir, brake lever, and brake switch installed.
  • Page 428: Rear Master Cylinder Installation

    12-24 BRAKES Master Cylinder Rear Master Cylinder Installation • Replace the cotter pin with a new one. • Replace the washers that are on each side of hose fitting with new ones. • Tighten: Torque - Rear Master Cylinder Mounting Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb) Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb)
  • Page 429: Brake Disc

    BRAKES 12-25 Brake Disc Brake Disc Removal • Remove the wheels (see Front/Rear Wheel Removal in the Wheels/Tires chapter). • Unscrew the mounting bolts, and take off the disc. ○ Remove the sensor rotor (ABS equipped models). • Remove the gaskets. Brake Disc Installation •...
  • Page 430: Brake Fluid

    12-26 BRAKES Brake Fluid Brake Fluid Level Inspection • Refer to the Brake Fluid Level Inspection in the Periodic Maintenance chapter. Brake Fluid Change • Refer to the Brake Fluid Change in the Periodic Mainte- nance chapter. Brake Line Bleeding The brake fluid has a very low compression coefficient so that almost all the movement of the brake lever or pedal is transmitted directly to the caliper for braking action.
  • Page 431 BRAKES 12-27 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 432 12-28 BRAKES Brake Fluid • Follow the procedure below to install the front/rear brake fluid reservoir cap correctly. ○ First, tighten the brake fluid reservoir cap [B] clockwise [C] by hand until slight resistance is felt indicating that the cap is seated on the reservoir body, then tighten the cap an additional 1/6 turn [D] while holding the brake fluid reservoir body [A].
  • Page 433 BRAKES 12-29 Brake Fluid WARNING When working with the disc brake, observe the pre- cautions listed below. 1. Never reuse old brake fluid. 2. Do not use fluid from a container that has been left unsealed or that has been open for a long time. 3.
  • Page 434: Brake Hose

    12-30 BRAKES Brake Hose Brake Hose and Pipe Removal/Installation • Refer to the Brake Hose and Pipe Replacement in the Periodic Maintenance chapter. Brake Hose and Pipe Inspection • Refer to the Brake Hose and Pipe Damage and Instal- lation Condition Inspection in the Periodic Maintenance chapter.
  • Page 435: Anti-lock Brake System (equipped Models)

    1. Front Wheel Rotation Sensor 2. Front Wheel Rotation Sensor Rotor 3. Rear Wheel Rotation Sensor 4. Rear Wheel Rotation Sensor Rotor 5. ABS Indicator Light (LED) 6. ABS Hydraulic Unit 7. ABS Fuse Box 8. ABS Kawasaki Self-diagnosis System Connector...
  • Page 436 2. Rear Wheel Rotation Sensor 12. Front Brake Switch 3. Front Wheel Rotation Sensor 13. Water-proof Joint A 14. Meter Ground 4. ABS Kawasaki Self-diagnosis System Con- nector 15. Frame Ground 5. ABS Hydraulic Unit 16. Main Fuse 30 A 6.
  • Page 437 6. Unused 7. Unused 8. Power Supply to ABS Solenoid Valve Relay 9. Power Supply to ABS Motor Relay 10. ABS Kawasaki Self-diagnosis System Terminal 11. Unused 12. Power Supply to Front Wheel Rotation Sensor 13. ABS Self-diagnosis Terminal 14. Unused 15.
  • Page 438: Abs Servicing Precautions

    12-34 BRAKES 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 439 BRAKES 12-35 Anti-Lock Brake System (Equipped Models) ○ The ABS indicator light (LED) [A] may light if the tire pres- sure is incorrect, a non-recommended tire is installed, or the wheel is deformed. If the indicator light lights, remedy the problem and clear the service code. WARNING Use of non-recommended tires may cause malfunc- tioning of ABS and can lead to extended braking...
  • Page 440: Abs Troubleshooting Outline

    12-36 BRAKES Anti-Lock Brake System (Equipped Models) ABS Troubleshooting Outline When an abnormality in the system occurs, the ABS in- dicator light (LED) lights up to alert the rider. In addition, the nature of the fault is stored in the memory of the ABS hydraulic unit and when in the self-diagnosis mode, the ser- vice code [A] is indicated by the number of times the ABS indicator light (LED) blinks.
  • Page 441 BRAKES 12-37 Anti-Lock Brake System (Equipped Models) • Visually inspect the wiring for signs of burning or fraying. If any wiring is poor, replace the damaged wiring. • Pull each connector [A] apart and inspect it for corrosion, dirt and damage. If the connector is corroded or dirty, clean it carefully.
  • Page 442 12-38 BRAKES Anti-Lock Brake System (Equipped Models) ABS Diagnosis Flow Chart...
  • Page 443: Inquiries To Rider

    BRAKES 12-39 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 444 12-40 BRAKES Anti-Lock Brake System (Equipped Models) Pre-Diagnosis Inspection 1...
  • Page 445: Self-diagnosis Outline

    BRAKES 12-41 Anti-Lock Brake System (Equipped Models) Pre-Diagnosis Inspection 2 Self-diagnosis Outline When the indicator light has blinked or come on, the ABS hydraulic unit memorizes and stores the service code for the service person to troubleshoot easily. The service code memory is powered directly by the battery and cannot be canceled by the ignition switch.
  • Page 446: Service Code Clearing Procedures

    12-42 BRAKES Anti-Lock Brake System (Equipped Models) • Remove the seats (see Rear/Front Seat Removal in the Frame chapter). • Ground the self-diagnosis terminal [A] (Gray) to the ground terminal [B] (Black/Yellow), using a lead. • Turn on the ignition switch. ○...
  • Page 447 BRAKES 12-43 Anti-Lock Brake System (Equipped Models)
  • Page 448 12-44 BRAKES Anti-Lock Brake System (Equipped Models) Self-diagnosis Flow Chart...
  • Page 449: How To Read Service Codes

    BRAKES 12-45 Anti-Lock Brake System (Equipped Models) How to Read Service Codes ○ Service codes are shown by a series of long and short blinks of the ABS indicator light (LED) as shown below. ○ Read 10th digit and unit digit as the ABS indicator light (LED) blinks. ○...
  • Page 450 12-46 BRAKES Anti-Lock Brake System (Equipped Models) Service Code Table Service ABS Indicator Light (LED) Problems Light State Code Rear inlet solenoid valve trouble (shorted or open, stuck valve (ON)) Rear outlet solenoid valve trouble (shorted or open, stuck valve (ON)) Front inlet solenoid valve trouble (shorted or open, stuck valve (ON)) Front outlet solenoid valve trouble (shorted...
  • Page 451: Abs Indicator Light (led) Inspection

    BRAKES 12-47 Anti-Lock Brake System (Equipped Models) ABS Indicator Light (LED) Inspection • Turn the ignition switch ON. If the ABS indicator light (LED) [A] lights, it is normal. If the ABS indicator light (LED) does not light, go to step “ABS Indicator Light (LED) is Unlit (When the Ignition Switch turned to ON)”.
  • Page 452: Abs Indicator Light (led) Lights (when The Motorcycle Is Running, - No Service Code)

    12-48 BRAKES Anti-Lock Brake System (Equipped Models) • Do the 3rd step test. ○ Disconnect the ABS hydraulic unit connector. ○ Check for continuity between the black/white lead termi- nal of the main harness side connector [A] and black/white lead terminal of the main harness side connector [B]. If there is the continuity in the lead, replace the ABS hy- draulic unit.
  • Page 453 BRAKES 12-49 Anti-Lock Brake System (Equipped Models) • Do the 2nd step test. ○ Disconnect the ABS hydraulic unit connector [A]. ○ Check for continuity between the light green and black/yellow lead terminals of the ABS hydraulic unit connector. If there is the continuity in the lead, replace the ABS hy- draulic unit.
  • Page 454: Front, Rear Wheel Rotation Difference Abnormal (service Code 25)

    12-50 BRAKES Anti-Lock Brake System (Equipped Models) Front, Rear Wheel Rotation Difference Abnormal (Service Code 25) • Do the 1st step test. ○ Check the following and correct the faulty part. Incorrect the tire pressure. Tires not recommended for the motorcycle were installed (incorrect tire size).
  • Page 455: Front Wheel Rotation Sensor Signal Abnormal (service Code 42)

    BRAKES 12-51 Anti-Lock Brake System (Equipped Models) • Do the 4th step test. ○ Check the battery terminal voltage between the red lead terminal of the fuse box [A] and ground. Special Tool - Hand Tester: 57001-1394 Battery Terminal Voltage Standard: Battery Voltage If the battery terminal voltage is not within the specifica-...
  • Page 456: Front Wheel Rotation Sensor Wiring Inspection (service Code 43)

    12-52 BRAKES Anti-Lock Brake System (Equipped Models) • Do the 2nd step test. ○ Check that there is iron or other magnetic deposits be- tween the sensor [A] and sensor rotor [B], and the sensor rotor slots for obstructions. ○ Check the installation condition of the sensor for loose- ness.
  • Page 457: Rear Wheel Rotation Sensor Signal Abnormal (service Code 44)

    BRAKES 12-53 Anti-Lock Brake System (Equipped Models) • Do the 3rd step test. ○ Recheck the service code indication; erase the service code, perform the pre-diagnosis inspection 1 and 2, and retrieve the service code. If the ABS indicator light (LED) [A] lit, faulty ECU in the ABS hydraulic unit.
  • Page 458: Rear Wheel Rotation Sensor Wiring Inspection (service Code 45)

    12-54 BRAKES Anti-Lock Brake System (Equipped Models) Rear Wheel Rotation Sensor Wiring Inspection (Service Code 45) • Do the 1st step test. ○ Disconnect the ABS hydraulic unit connector and rear wheel rotation sensor connector. ○ Short the black and brown/black lead terminals of the main harness side connector [A] with a jumper lead, and check for continuity between the black and brown/black lead terminals of the main harness side connector [B].
  • Page 459: Power Supply Voltage Abnormal (over-voltage) (service Code 53)

    BRAKES 12-55 Anti-Lock Brake System (Equipped Models) • Do the 2nd step test. ○ Connect the ignition switch connector and ABS hydraulic unit connector. ○ Check the battery terminal voltage, connect the hand tester to the brown terminal of ignition switch connector [A] and ground.
  • Page 460: Ecu Inspection (service Code 55)

    12-56 BRAKES Anti-Lock Brake System (Equipped Models) • Do the 2nd step test. ○ Connect the ignition switch connector and ABS hydraulic unit connector. ○ Check the battery terminal voltage, connect the hand tester to the brown terminal of ignition switch connector [A] and ground.
  • Page 461 BRAKES 12-57 Anti-Lock Brake System (Equipped Models) • Remove: Seats (see Rear/Front Seat Removal in the Frame chap- ter) Rear Fender (see Flap and Rear Fender Removal in the Frame chapter) • Clean the ABS hydraulic unit. CAUTION Clean all fittings on the ABS hydraulic unit and the rear master cylinder because dirt around the banjo bolts could contaminate the brake fluid in the line during removal/installation.
  • Page 462: Abs Hydraulic Unit Installation

    12-58 BRAKES Anti-Lock Brake System (Equipped Models) CAUTION The ABS hydraulic unit [A] has been adjusted and set with precision at the factory. Do not try to dis- assemble and repair the ABS hydraulic unit. ABS Hydraulic Unit Installation • Install the ABS hydraulic unit to the bracket.
  • Page 463: Front Wheel Rotation Sensor Removal

    BRAKES 12-59 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 464: Rear Wheel Rotation Sensor Removal

    12-60 BRAKES Anti-Lock Brake System (Equipped Models) Rear Wheel Rotation Sensor Removal CAUTION The wheel rotation sensor should be handled care- fully, never struck sharply, as with a hammer, or al- lowed to fall on a hard surface since the wheel rota- tion sensor is precision made.
  • Page 465: Wheel Rotation Sensor Inspection

    BRAKES 12-61 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 466: Wheel Rotation Sensor Rotor Inspection

    12-62 BRAKES 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 467: Fuse Installation

    BRAKES 12-63 Anti-Lock Brake System (Equipped Models) Fuse Installation • If a fuse fails during operation, inspect the electrical sys- tem to determine the cause, and then replace it with a new fuse of proper amperage (see Fuse Installation in the Electrical System chapter).
  • Page 469 SUSPENSION 13-1 Suspension Table of Contents Exploded View........................13-2 Specifications ......................... 13-6 Special Tools .......................... 13-7 Front Fork ..........................13-9 Rebound Damping Force Adjustment ................13-9 Spring Preload Adjustment ....................13-9 Front Fork Removal (Each Fork Leg) ................13-10 Front Fork Installation ....................... 13-10 Front Fork Oil Change ......................
  • Page 470: Exploded View

    13-2 SUSPENSION Exploded View...
  • Page 471 SUSPENSION 13-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Axle Clamp Bolt Front Fork Bottom Allen Bolts Front Fork Top Plugs Lower Front Fork Clamp Bolts (Middle) Lower Front Fork Clamp Bolts (Upper, Lower) Piston Rod Nuts Upper Front Fork Clamp Bolts 8.
  • Page 472 13-4 SUSPENSION Exploded View...
  • Page 473 SUSPENSION 13-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Rear Shock Absorber Nut (Lower) Rear Shock Absorber Nut (Upper) Swingarm Pivot Shaft 87 in·lb Swingarm Pivot Shaft Locknut 10.0 72.3 Swingarm Pivot Shaft Nut 11.0 79.7 Tie-Rod Nuts Uni-Trak Rocker Arm Nut G: Apply grease.
  • Page 474: Specifications

    13-6 SUSPENSION Specifications Item Standard Front Fork (Per One Unit) Fork Inner Tube Diameter 41 mm (1.6 in.) Air Pressure Atmospheric pressure (Non-adjustable) Rebound Damper Setting 2 3/4 turns out from the fully clockwise position (Usable Range: 0 ←→ 3 2/4 turns out) Fork Spring Preload Setting 7 turns in from the fully counterclockwise position (Usable Range: 0 ←→...
  • Page 475: Special Tools

    SUSPENSION 13-7 Special Tools Inside Circlip Pliers: Fork Oil Level Gauge: 57001-143 57001-1290 Oil Seal & Bearing Remover: Bearing Remover Head, 20 × 22: 57001-1058 57001-1293 Bearing Driver Set: Fork Piston Rod Puller, M10 × 1.0: 57001-1129 57001-1298 Jack: Fork Spring Stopper: 57001-1238 57001-1374 Fork Oil Seal Driver, 41:...
  • Page 476 13-8 SUSPENSION Special Tools Hook Wrench T=3.2 R37: Needle Bearing Driver, 28: 57001-1539 57001-1610 Fork Spring Compressor: Spacer, 57001-1587 57001-1636 Swingarm Pivot Nut Wrench: Spacer 28: 57001-1597 57001-1663 Jack Attachment: Clamp: 57001-1608 57001-1693 Needle Bearing Driver, 17/ 18: Bar: 57001-1609 57001-1694...
  • Page 477: Front Fork

    SUSPENSION 13-9 Front Fork Rebound Damping Force Adjustment • To adjust the rebound damping force, turn the rebound damping adjuster [A] until you feel a click. ○ The standard adjuster setting for the average-build rider of 68 kg (150 lb) with no passenger and no accessories is the 2 3/4 turns out from the fully clockwise position.
  • Page 478: Front Fork Removal (each Fork Leg)

    13-10 SUSPENSION Front Fork Front Fork Removal (Each Fork Leg) • Remove: Upper Fairing (see Upper Fairing Removal in the Frame chapter) Front Wheel (see Front Wheel Removal in the Wheels/Tires chapter) Front Fender (see Front Fender Removal in the Frame chapter) Loosen the upper front fork clamp bolt [A] and fork top plug [B] beforehand if the fork leg is to be disassembled.
  • Page 479 SUSPENSION 13-11 Front Fork • Holding the top plug [A] with a wrench [B], tighten the spring preload adjuster [C]. NOTE ○ After tightening, lift the top plug to make the space. • Install the clamps [A] as shown in the figure. NOTE ○...
  • Page 480 13-12 SUSPENSION Front Fork • Screw the adjust nut [A] onto the compression shaft as shown in the figure. • Screw the locknut [B]. About 20 mm (0.79 in.) [C] • Set the other side compression shaft same process. • Set the holder bar [A] and compression shafts [B].
  • Page 481 SUSPENSION 13-13 Front Fork • Remove: Top Plug with the Rebound Damping Adjuster Rod Damper [A] Slider [B] Collar [C] Fork Spring [D] • Drain the fork oil into a suitable container. ○ Pump the piston rod [A] up and down at least ten times to expel the oil from the fork.
  • Page 482 13-14 SUSPENSION Front Fork Oil Level (fully compressed, without spring) Standard: 100 ±2 mm (3.94 ±0.08 in.) (from the top of the outer tube) NOTE ○ Fork oil level may also be measured using the fork oil level gauge. Special Tool - Fork Oil Level Gauge [A]: 57001-1290 ○...
  • Page 483 SUSPENSION 13-15 Front Fork • Check the distance between the upper end [A] of the spring preload adjuster [B] and rebound damping adjuster [C] with a pair of vernier caliper. 1.5 mm (0.059 in.) [D] • Set the fork spring compressor on the slider [A] using the outer tube as a guide.
  • Page 484: Front Fork Disassembly

    13-16 SUSPENSION Front Fork Front Fork Disassembly • Remove the front fork (see Front Fork Removal). • Drain the fork oil (see Front Fork Oil Change). • Hold the fork leg with a vise. • Unscrew the Allen bolt, then take the bolt and gasket out of the bottom of the inner tube.
  • Page 485: Inner Tube, Outer Tube Inspection

    SUSPENSION 13-17 Front Fork • Insert the inner tube to the outer tube. • Fit the new outer tube guide bushing [A] into the outer tube. NOTE ○ When assembling the new outer tube guide bushing [A], hold the washer against the new outer tube guide bush- ing and tap the washer with the fork oil seal driver [B] until it stops.
  • Page 486: Dust Seal Inspection

    13-18 SUSPENSION Front Fork Dust Seal Inspection • Inspect the dust seal [A] for any signs of deterioration or damage. Replace it if necessary. 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.
  • Page 487: Rear Shock Absorber

    SUSPENSION 13-19 Rear Shock Absorber Rebound Damping Force Adjustment • To adjust the rebound damping force, turn the lower damping adjuster [A] to the desired position, until you feel a click. ○ The standard adjuster setting for an average-build rider of 68 kg (150 lb) with no passenger and no accessories is the 1 1/4 turns out from the fully clockwise position.
  • Page 488: Rear Shock Absorber Removal

    13-20 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 489: Rear Shock Absorber Inspection

    SUSPENSION 13-21 Rear Shock Absorber Rear Shock Absorber Inspection • Remove the rear shock absorber (see Rear Shock Ab- sorber Removal). • Visually inspect the following items. Smooth Stroke Oil Leakage Crack or Dent If there is any damage to the rear shock absorber, replace •...
  • Page 490: Swingarm

    13-22 SUSPENSION Swingarm Swingarm Removal • Remove: Frame Covers (see Frame Cover Removal in the Frame chapter) Chain Cover (see Drive Chain Removal in the Final Drive chapter) Rear Wheel (see Rear Wheel Removal in the Wheels/Tires chapter) • Remove: Bolt [A] Bracket [B] Screw [C]...
  • Page 491: Swingarm Installation

    SUSPENSION 13-23 Swingarm • Unscrew the swingarm pivot shaft nut [A] and the swingarm pivot shaft [B]. • Pull out the pivot shaft and remove the swingarm. Swingarm Installation • Place the collar [A] on the stopper [B] inside the frame [C]. •...
  • Page 492: Swingarm Bearing Removal

    13-24 SUSPENSION Swingarm Swingarm Bearing Removal • Remove: Swingarm (see Swingarm Removal) Collar [A] Oil Seals [B] Sleeve [C] Circlip [D] (Right Side) Special Tool - Inside Circlip Pliers: 57001-143 • Remove the ball bearing and needle bearings. Special Tool - Oil Seal & Bearing Remover [A]: 57001-1058 Swingarm Bearing Installation •...
  • Page 493: Swingarm Bearing, Sleeve Inspection

    SUSPENSION 13-25 Swingarm • Install the needle bearings [A], ball bearing [B] and oil seals [C] position as shown in the figure. Circlip [D] 23.5 mm (0.93 in.) [E] 17 mm (0.67 in.) [F] 0.5 mm (0.02 in.) [G] 6 mm (0.24 in.) [H] Swingarm Bearing, Sleeve Inspection CAUTION Do not remove the bearings for inspection.
  • Page 494: Swingarm Bearing Lubrication

    13-26 SUSPENSION Swingarm • Turn the bearing in the swingarm back and forth [A] while checking for plays, roughness, or binding. If bearing play, roughness, or binding is found, replace the bearing. • Examine the bearing seal [B] for tears or leakage. If the seal is torn or is leaking, replace the bearing.
  • Page 495: Tie-rod, Rocker Arm

    SUSPENSION 13-27 Tie-Rod, Rocker Arm Tie-Rod Removal • Squeeze the brake lever slowly and hold it with a band [A]. • Raise the rear wheel off the ground with the jack. Special Tools - Jack: 57001-1238 Jack Attachment: 57001-1608 • Remove: Upper Tie-Rod Nut and Bolt [A] Lower Tie-Rod Nut and Bolt [B]...
  • Page 496: Tie-rod And Rocker Arm Bearing Removal

    13-28 SUSPENSION Tie-Rod, Rocker Arm Tie-Rod and Rocker Arm Bearing Removal • Remove: Tie-Rods (see Tie-Rod Removal) Rocker Arm (see Rocker Arm Removal) Sleeves [A] Oil Seals [B] Swingarm [C] (see Swingarm Removal) • Remove the needle bearings [D], using the bearing re- mover head and bearing remover shaft.
  • Page 497: Rocker Arm/tie-rod Bearing, Sleeve Inspection

    SUSPENSION 13-29 Tie-Rod, Rocker Arm NOTE ○ Install the needle bearings so that the marked side faces in. Needle Bearings [A] Oil Seals [B] Front [C] Right Side [D] Left Side [E] Rear Shock Absorber [F] Tie-Rods [G] Rocker Arm [H] 7.5 mm (0.30 in.) [I] 5.0 mm (0.20 in.) [J] 5.5 mm (0.22 in.) [K]...
  • Page 499 STEERING 14-1 Steering Table of Contents Exploded View........................14-2 Special Tools .......................... 14-4 Steering ..........................14-5 Steering Inspection ......................14-5 Steering Adjustment......................14-5 Steering Stem......................... 14-6 Stem, Stem Bearing Removal................... 14-6 Stem, Stem Bearing Installation..................14-7 Steering Stem Bearing Lubrication ................... 14-8 Steering Stem Warp......................
  • Page 500: Exploded View

    14-2 STEERING Exploded View...
  • Page 501 STEERING 14-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Handlebar Holder Bolts Handlebar Lower Holder Nuts Lower Front Fork Clamp Bolts (Middle) Lower Front Fork Clamp Bolts (Upper, Lower) Steering Stem Head Bolt 11.0 79.7 Steering Stem Nut Switch Housing Screws 0.36 31 in·lb Upper Front Fork Clamp Bolts...
  • Page 502: Special Tools

    14-4 STEERING Special Tools Head Pipe Outer Race Press Shaft: Steering Stem Bearing Driver, 42.5: 57001-1075 57001-1344 Steering Stem Nut Wrench: Steering Stem Bearing Driver Adapter, 41.5: 57001-1100 57001-1345 Bearing Driver Set: Head Pipe Outer Race Driver, 55: 57001-1129 57001-1446...
  • Page 503: 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 504: Steering Stem

    14-6 STEERING Steering Stem Stem, Stem Bearing Removal • Remove: Inner Covers (see Inner Cover Removal in the Frame chapter) Upper Fairing (see Upper Fairing Removal in the Frame chapter) Upper Fairing Bracket (see Upper Fairing Bracket Re- moval in the Frame chapter) Front Wheel (see Front Wheel Removal in the Wheels/Tires chapter) Handlebar (see Handlebar Removal)
  • Page 505: Stem, Stem Bearing Installation

    STEERING 14-7 Steering Stem • Remove the lower ball bearing inner race (with its oil seal) [A] which is pressed onto the steering stem with a suitable commercially available chisel [B]. Stem, Stem Bearing Installation • Replace the bearing outer races with new ones. •...
  • Page 506: Steering Stem Bearing Lubrication

    14-8 STEERING Steering Stem • Settle the bearings in place as follows. ○ Tighten the steering stem nut with 55 N·m (5.6 kgf·m, 41 ft·lb) of torque first, and loosen it a fraction of a turn until it turns lightly. Afterward tighten it again with specified torque using a steering stem nut wrench [A].
  • Page 507: Steering Stem Warp

    STEERING 14-9 Steering Stem Steering Stem Warp • Whenever the steering stem is removed, or if the steering can not be adjusted for smooth action, check the steering stem for straightness. If the steering stem [A] is bent, replace the steering stem. Stem Cap Deterioration, Damage Replace the stem cap if its oil seal [A] shows damage.
  • Page 508: Handlebar

    14-10 STEERING Handlebar Handlebar Removal • Remove: Clutch Lever Clamp Bolts [A] Clutch Lever Assembly [B] Left Switch Housing [C] Handlebar Weight [D] • Remove: Front Master Cylinder [A] (see Front Master Cylinder Re- moval in the Brakes chapter) Right Switch Housing [B] Throttle Case [C] Handlebar Weight [D] Throttle Grip [E]...
  • Page 509 STEERING 14-11 Handlebar • Align the punch mark [A] on the handlebar and the corner edge [B] on the lower holder. • Tighten the front holder bolts first, and then the rear holder bolts. There will be a gap [A] at the rear part of the holder after tightening.
  • Page 511 FRAME 15-1 Frame Table of Contents Exploded View........................15-2 Seats ............................15-7 Rear Seat Removal......................15-7 Rear Seat Installation......................15-7 Front Seat Removal ......................15-7 Front Seat Installation ....................... 15-7 Fairings........................... 15-8 Lower Fairing Removal ..................... 15-8 Lower Fairing Installation ....................15-8 Center Fairing Removal ....................
  • Page 512: Exploded View

    15-2 FRAME Exploded View...
  • Page 513 FRAME 15-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Fender Bolts 0.40 35 in·lb Windshield Mounting Bolts 0.42 0.043 3.7 in·lb 3. Reflector (US, CA, and AU Models) 4. 2 ∼ 3 mm (0.08 ∼ 0.12 in.) 5. ZR1000B7F/C7F Models...
  • Page 514 15-4 FRAME Exploded View...
  • Page 515 FRAME 15-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Footpeg Bracket Bolts Lower Fairing Mounting Bolts 0.70 61 in·lb Rear Footpeg Bracket Bolts Sidestand Bolt Sidestand Switch Bolt 0.90 78 in·lb 6. Without guard on the side cover: ZR1000B7F/C7F, ZR1000B8F/C8F early models With guard on the side cover: ZR1000B8F/C8F late models, ZR1000B9F/C9F 7.
  • Page 516 15-6 FRAME Exploded View 1. Reflector (US and CA Models)
  • Page 517: Seats

    FRAME 15-7 Seats Rear Seat Removal • Insert the ignition switch key [A] into the seat lock, turning the key clockwise, pulling the front part of the seat [B] up, and pull the seat forward. Rear Seat Installation • Insert the rear seat hook [A] into the bracket [B] of the frame.
  • Page 518: Fairings

    15-8 FRAME Fairings Lower Fairing Removal • Remove: Bolts [A] and Collars Dampers • Pull out the lower fairing [B], and clear the stopper [C]. Lower Fairing Installation • Insert the projection [A] into the hole [B]. • Install the dampers and collars. •...
  • Page 519: Center Fairing Installation

    FRAME 15-9 Fairings Center Fairing Installation • Install the turn signal light to the center fairing and bracket, and tighten the screws. • Install the inner fairing (see Inner Fairing Installation). • Connect the turn signal lead connector. • Insert the projection [A] into the hole [B] (Right Center Fairing only).
  • Page 520: Upper Fairing Disassembly

    15-10 FRAME Fairings Upper Fairing Disassembly • Remove: Upper Fairing (see Upper Fairing Removal) Nuts and Bracket Nuts [A] • Remove: Bolts [A] and Bracket [B] Headlight [C] (see Headlight Removal/Installation in the Electrical System chapter) Bracket • Remove: Bolts [A] and Washer (Both Sides) Side Upper Fairings [B] (Both Sides) Upper Fairing Assembly •...
  • Page 521: Inner Cover Removal

    FRAME 15-11 Fairings Inner Cover Removal • Remove: Windshield (see Windshield Removal) Rivet [A] Clamp (Right Side only) • Remove: Bolt [A] Inner Cover [B] Inner Cover Installation • Installation is the reverse of removal. Upper Fairing Bracket Removal • Remove: Upper Fairing (see Upper Fairing Removal) Meter Unit (see Meter Unit Removal/Installation in the...
  • Page 522: Side Covers

    15-12 FRAME Side Covers Sub Side Cover Removal • Remove the bolt [A]. • Pull the sub side cover [B] to clear the stoppers [C]. Sub Side Cover Installation • Insert the projections [A] into the holes [B]. • Install the bolt. Side Cover Removal •...
  • Page 523: Seat Covers

    FRAME 15-13 Seat Covers Seat Cover Removal • Remove: Seats (see Rear/Front Seat Removal) Side Covers (see Side Cover Removal) Rivet Screws [A] • Remove the bolts [A]. • Pull the front seat cover [B] to clear the stoppers [C]. •...
  • Page 524: Seat Cover Installation

    15-14 FRAME Seat Covers • Remove: Rivets [A] Bolts [B] Brackets [C] Flap [D] (with Turn Signal and License Plate Lights) Bolts and Seat Lock Bracket Lower Seat Cover Seat Cover Installation • Installation is the reverse of removal. • Put the projections [A] into the holes [B] of the center seat cover.
  • Page 525: Fenders

    FRAME 15-15 Fenders Front Fender Removal • Remove: Brake Hose Clamps [A] (Both Sides) Bolts [B] with Washers (Both Sides) Front Fender Assy [C] • Remove the bolts [A]. • Separate the front fender covers [B] and front fender [C]. Front Fender Installation •...
  • Page 526: Flap And Rear Fender Installation

    15-16 FRAME Fenders • Remove the bolts [A]. • Pull out the rear fender [B] backward. Flap and Rear Fender Installation • Installation is the reverse of removal. • Install the removed parts (see appropriate chapters). • Route the cables, leads, harness and hose correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter).
  • Page 527: Frame Inspection

    FRAME 15-17 Frame Frame Inspection • Visually inspect the frame for cracks, dents, bending, or warp. ○ If there is any damage to the frame, replace it. WARNING A repaired frame may fail in use, possibly causing an accident. If the frame is bent, dented, cracked, or warped, replace it.
  • Page 528: Sidestand

    15-18 FRAME Sidestand Sidestand Removal • Raise the rear wheel off the ground with the stand. • Remove: Left Muffler Body (see Muffler Body Removal in the En- gine Top End chapter) Sidestand Switch Bolt [A] Sidestand Switch [B] Spring [C] Sidestand Nut [D] Sidestand Bolt [E] Sidestand [F]...
  • Page 529: Frame Cover

    FRAME 15-19 Frame Cover Frame Cover Removal • Remove: Sub Side Covers (see Sub Side Cover Removal) Bolts [A] • Pull out the frame cover [B], and clear the stopper [C]. Frame Cover Installation • Insert the projection [A] into the hole [B]. •...
  • Page 530: Rear View Mirrors

    15-20 FRAME Rear View Mirrors Rear View Mirrors Removal • Slide the cover [A] upward (ZR1000B8F/C8F models). • Loosen the lower hexagonal area [B] for tightening to re- move the rear view mirror from the holder. CAUTION Do not force to tighten and/or loosen the upper hexagonal area (adapter) [C] with a pair of span- ners.
  • Page 531 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 (ZR1000B7F ∼ B8F (US, CA and SEA Models)) .......... 16-16 Wiring Diagram (Other than ZR1000B7F ∼ B8F (US, CA and SEA Models), ZR1000B9F)... 16-18 Wiring Diagram (ZR1000B9F) ....................
  • Page 532 16-2 ELECTRICAL SYSTEM Starter Motor Removal...................... 16-57 Starter Motor Installation....................16-57 Starter Motor Disassembly....................16-58 Starter Motor Assembly ....................16-58 Brush Inspection ....................... 16-59 Commutator Cleaning and Inspection................16-60 Armature Inspection......................16-60 Brush Lead Inspection ...................... 16-60 Brush Plate and Terminal Bolt Inspection ................. 16-61 Starter Relay Inspection....................
  • Page 533 ELECTRICAL SYSTEM 16-3 Fuse Inspection......................... 16-118...
  • Page 534: Exploded View

    16-4 ELECTRICAL SYSTEM Exploded View...
  • Page 535 ELECTRICAL SYSTEM 16-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Brake Light Switch Screw 0.12 11 in·lb License Plate Light Cover Mounting Screws 0.09 8 in·lb License Plate Light Mounting Screws 0.12 11 in·lb Meter Mounting Screws 0.12 11 in·lb Oxygen Sensor (Equipped Models) 44.1...
  • Page 536 16-6 ELECTRICAL SYSTEM Exploded View...
  • Page 537 ELECTRICAL SYSTEM 16-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Alternator Cover Bolts 97 in·lb Alternator Cover Outer Cover Bolts 0.70 61 in·ib Alternator Lead Holding Plate Bolt 106 in·lb Alternator Rotor Bolt 15.8 Camshaft Position Sensor Bolt 106 in·lb Crankshaft Sensor Bolts 0.60 52 in·lb...
  • Page 538 16-8 ELECTRICAL SYSTEM Exploded View...
  • Page 539 ELECTRICAL SYSTEM 16-9 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Engine Ground Cable Terminal Bolt 87 in·lb Fuel Level Sensor Bolts 0.70 61 in·lb Neutral Switch Regulator/Rectifier Bolts 0.70 61 in·lb Regulator/Rectifier Bracket Bolts 0.70 61 in·lb Sidestand Switch Bolt 0.90 78 in·lb Speed Sensor Bolt...
  • Page 540: Specifications

    16-10 ELECTRICAL SYSTEM Specifications Item Standard Battery Type Sealed Battery Model Name YTX9-BS Capacity 12 V 8 Ah Voltage 12.8 V or more Charging System Type Three-phase AC Alternator Output Voltage 39 V or more at 4 000 rpm 0.18 ∼ 0.28 Ω at 20°C (68°F) Stator Coil Resistance 14.2 ∼...
  • Page 541 ELECTRICAL SYSTEM 16-11 Special Tools and Sealant Hand Tester: Grip: 57001-1394 57001-1591 Flywheel Puller Assembly, M38 × 1.5/M35 × 1.5: Flywheel & Pulley Holder: 57001-1405 57001-1605 Peak Voltage Adapter: Stopper: 57001-1415 57001-1679 Lead Wire - Peak Voltage Adapter: Rotor Holder: 57001-1449 57001-1690 Key Registration Unit:...
  • Page 542: Special Tools And Sealant

    16-12 ELECTRICAL SYSTEM Special Tools and Sealant Kawasaki Bond (Silicone Sealant): 92104-0004...
  • Page 543: Parts Location

    ELECTRICAL SYSTEM 16-13 Parts Location Dummy Page...
  • Page 544 16-14 ELECTRICAL SYSTEM Parts Location...
  • Page 545 8. Fuse Box 1 9. Battery 12 V 8 Ah 10. Starter Relay 11. Turn Signal Relay 12. Fuse Box 2 13. Vehicle-down Sensor 14. Kawasaki Diagnostic System Connector 15. Relay Box 16. ECU 17. Camshaft Position Sensor 18. Alternator 19. Sidestand Switch 20.
  • Page 546: Wiring Diagram (zr1000b7f ~ B8f (us, Ca And Sea Models))

    16-16 ELECTRICAL SYSTEM Wiring Diagram (ZR1000B7F ∼ B8F (US, CA and SEA Models))
  • Page 547 ELECTRICAL SYSTEM 16-17 Wiring Diagram (ZR1000B7F ∼ B8F (US, CA and SEA Models))
  • Page 548: Wiring Diagram (other Than Zr1000b7f ~ B8f (us, Ca And Sea Models), Zr1000b9f)

    16-18 ELECTRICAL SYSTEM Wiring Diagram (Other than ZR1000B7F ∼ B8F (US, CA and SEA Models), ZR1000B9F)
  • Page 549 ELECTRICAL SYSTEM 16-19 Wiring Diagram (Other than ZR1000B7F ∼ B8F (US, CA and SEA Models), ZR1000B9F)
  • Page 550: Wiring Diagram (zr1000b9f)

    16-20 ELECTRICAL SYSTEM Wiring Diagram (ZR1000B9F)
  • Page 551 ELECTRICAL SYSTEM 16-21 Wiring Diagram (ZR1000B9F)
  • Page 552: Wiring Diagram (abs Equipped Models)

    16-22 ELECTRICAL SYSTEM Wiring Diagram (ABS Equipped Models) ZR1000C7F ∼ C8F...
  • Page 553 ELECTRICAL SYSTEM 16-23 Wiring Diagram (ABS Equipped Models) ZR1000C7F ∼ C8F...
  • Page 554 16-24 ELECTRICAL SYSTEM Wiring Diagram (ABS Equipped Models) ZR1000C9F...
  • Page 555 ELECTRICAL SYSTEM 16-25 Wiring Diagram (ABS Equipped Models) ZR1000C9F...
  • Page 556: 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 557: 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 558: Battery

    16-28 ELECTRICAL SYSTEM Battery Battery Removal • Turn off the ignition switch. • Remove: Seats (see Seats section in the Frame chapter) Front Seat Cover (see Seat Cover Removal in the Frame chapter) Bolts [A] and Front Seat Bracket [B] •...
  • Page 559: Battery Activation

    ELECTRICAL SYSTEM 16-29 Battery • Slide in the fuse box [A] into the front seat bracket [B] until the stopper [C] fits in the bracket. • Run the seat lock cable [A] under the front seat bracket [B] and then install the bracket. ○...
  • Page 560 16-30 ELECTRICAL SYSTEM Battery • Remove the electrolyte container from the vinyl bag. • Detach the strip of caps [A] from the container and set aside, these will be used later to seal the battery. NOTE ○ Do not pierce or otherwise open the sealed cells [B] of the electrolyte container.
  • Page 561 Newly activated sealed batteries require an initial charge. Standard Charge: 0.9 A × 5 ∼ 10 hours If using a recommended battery charger, follow the charger’s instructions for newly activated sealed battery. Kawasaki-recommended chargers: Optimate III Yuasa 1.5 Amp Automatic Charger Battery Mate 150-9 If the above chargers are not available, use equivalent one.
  • Page 562: Precautions

    16-32 ELECTRICAL SYSTEM Battery Precautions 1) No need of topping-up No topping-up is necessary in this battery until it ends its life under normal use. Forcibly prying off the seal cap to add water is very dangerous. Never do that. 2) Refreshing charge.
  • Page 563: Charging Condition Inspection

    ELECTRICAL SYSTEM 16-33 Battery Charging Condition Inspection ○ Battery charging condition can be checked by measuring battery terminal voltage with a digital voltmeter [A]. • Remove: Seats (see Seats section in the Frame chapter) Battery (see Battery Removal) • Disconnect the battery terminals. CAUTION Be sure to disconnect the negative (–) cable first.
  • Page 564 16-34 ELECTRICAL SYSTEM Battery Terminal Voltage: 11.5 ∼ less than 12.8 V Standard Charge 0.9 A × 5 ∼ 10 h (see following chart) Quick Charge 4 A × 1 h CAUTION If possible, do not quick charge. If quick charge is done unavoidably, do standard charge later on.
  • Page 565: Charging System

    ELECTRICAL SYSTEM 16-35 Charging System Alternator Cover Removal • Remove: Left Frame Cover (see Frame Cover Removal in the Frame chapter) Left Lower Fairing (see Lower Fairing Removal in the Frame chapter) Engine Sprocket Cover (see Engine Sprocket Removal in the Final Drive chapter) •...
  • Page 566: Alternator Cover Installation

    Apply silicone sealant to the alternator lead grommet and crankcase halves mating surface [A] on the front and rear sides of the cover mount. Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004 • Check that dowel pins [B] are in place on the crankcase.
  • Page 567: Stator Coil Installation

    Apply silicone sealant to the circumference of the alter- nator lead grommet, and fit the grommet into the notch of the cover securely. Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004 • Install the alternator cover (see Alternator Cover Installa- tion).
  • Page 568: Alternator Rotor Installation

    16-38 ELECTRICAL SYSTEM Charging System Alternator Rotor Installation • Using a cleaning fluid, clean off any oil or dirt on the fol- lowing portions and dry them with a clean cloth. Crankshaft Tapered Portion [A] Alternator Rotor Tapered Portion [B] •...
  • Page 569: Alternator Inspection

    ELECTRICAL SYSTEM 16-39 Charging System • Install the washer and alternator rotor bolt [A]. NOTE ○ Confirm the alternator rotor fit or not to the crankshaft before tightening it with specified torque. • Install the rotor bolt and tighten it with 70 N·m (7.0 kgf·m, 52 ft·lb) of torque.
  • Page 570 16-40 ELECTRICAL SYSTEM Charging System • To check the alternator output voltage, do the following procedures. ○ Turn off the ignition switch. ○ Remove the left frame cover (see Frame Cover Removal in the Frame chapter). ○ Disconnect the alternator lead connector [A]. ○...
  • Page 571: Regulator/rectifier Inspection

    ELECTRICAL SYSTEM 16-41 Charging System Regulator/Rectifier Inspection • Remove: Rear Fender (see Flap and Rear Fender Removal in the Frame chapter) Bolts [A] and Bracket [B] Regulator/Rectifier Assembly [C] • Remove: Connector [A] (Disconnect) Regulator/Rectifier [B] Rectifier Circuit Check • Check conductivity of the following pair of terminals.
  • Page 572 16-42 ELECTRICAL SYSTEM Charging System • Do the 1st step regulator circuit test. ○ Connect the test light and the 12 V battery to the regula- tor/rectifier as shown in the figure. ○ Check the BK1, BK2 and BK3 terminal respectively. If the test light turns on, the regulator/rectifier is defective.
  • Page 573: Charging Voltage Inspection

    ELECTRICAL SYSTEM 16-43 Charging System Charging Voltage Inspection • Check the battery condition (see Charging Condition In- spection). • Warm up the engine to obtain actual alternator operating conditions. • Take out the battery from the battery case with the cables connected (see Battery Removal).
  • Page 574 16-44 ELECTRICAL SYSTEM Charging System Charging System Circuit 1. Ignition Switch 2. Alternator 3. Regulator/Rectifier 4. Battery 12 V 8 Ah 5. Main Fuse 30 A 6. Load...
  • Page 575: Ignition System

    ELECTRICAL SYSTEM 16-45 Ignition System WARNING The ignition system produces extremely high volt- age. Do not touch the spark plugs or stick coils while the engine is running, or you could receive a severe electrical shock. CAUTION Do not disconnect the battery cables or any other electrical connections when the ignition switch is ON, or while the engine is running.
  • Page 576: Crankshaft Sensor Installation

    Apply silicone sealant [A] to the crankshaft sensor lead grommet and crankcase halves mating surface on the front and rear sides of the crankshaft sensor cover mount. Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004 • Install the oil pressure switch lead terminal [A] securely.
  • Page 577 ELECTRICAL SYSTEM 16-47 Ignition System • Replace the O-ring in the crankshaft sensor cover [A] with a new one. • Install: Crankshaft Sensor Cover Clamps [B] • Tighten: Torque - Crankshaft Sensor Cover Bolts: 11 N·m (1.1 kgf·m, 97 in·lb) Crankshaft Sensor Inspection •...
  • Page 578: Crankshaft Sensor Peak Voltage Inspection

    16-48 ELECTRICAL SYSTEM Ignition System Crankshaft Sensor Peak Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Remove: Right Frame Cover (see Frame Cover Removal in the Frame chapter) Crankshaft Sensor Lead Connector [A] (see Crankshaft Sensor Removal) •...
  • Page 579: Camshaft Position Sensor Removal

    ELECTRICAL SYSTEM 16-49 Ignition System Camshaft Position Sensor Removal CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Radiator (see Radiator and Radiator Fan Removal in the Cooling System chapter)
  • Page 580: Camshaft Position Sensor Inspection

    16-50 ELECTRICAL SYSTEM Ignition System Camshaft Position Sensor Inspection • Disconnect the camshaft position sensor lead connector [A] (see Camshaft Position Sensor Removal). • Set the hand tester to the × 10 Ω range and connect it to the yellow and white/yellow leads in the connector. Special Tool - Hand Tester: 57001-1394 Camshaft Position Sensor Resistance: 400 ∼...
  • Page 581: Stick Coil Removal

    ELECTRICAL SYSTEM 16-51 Ignition System Stick Coil Removal CAUTION Never drop the stick coils, especially on a hard sur- face. Such a shock to the stick coils can damage it. • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Air Switching Valve Hose [A] (for Stick Coil #2) •...
  • Page 582: Stick Coil Inspection

    16-52 ELECTRICAL SYSTEM Ignition System Stick Coil Inspection • Remove the stick coils (see Stick Coil Removal). • Measure the primary winding resistance [A] as follows. ○ Connect the hand tester between the coil terminals. ○ Set the tester to the × 1 Ω range, and read the tester. •...
  • Page 583: Spark Plug Removal

    ELECTRICAL SYSTEM 16-53 Ignition System WARNING To avoid extremely high voltage shocks, do not touch the spark plugs or tester connections. • Turn the ignition switch and the engine stop switch ON. • Pushing the starter button, turn the engine 4 ∼ 5 seconds with the transmission in neutral to measure the primary peak voltage.
  • Page 584: Ic Igniter Inspection

    16-54 ELECTRICAL SYSTEM Ignition System 2nd Check • Start the engine to the following conditions. Condition: Transmission Gear → 1st Position Clutch Lever → Pulled in Sidestand → Up ○ Turn the ignition switch ON and push the starter button. ○...
  • Page 585 ELECTRICAL SYSTEM 16-55 Ignition System...
  • Page 586 16-56 ELECTRICAL SYSTEM Ignition System Ignition System Circuit 1. Engine Stop Switch 11. ECU 20. Main Fuse 30 A 2. Stick Coils 12. Ignition Fuse 10 A 21. Battery 12 V 8 Ah 3. Spark Plugs 13. ECU Fuse 10 A 22.
  • Page 587: Starter Motor Removal

    ELECTRICAL SYSTEM 16-57 Electric Starter System Starter Motor Removal CAUTION Do not tap the starter motor shaft or body. Tapping the shaft or body could damage the motor. • Remove: Water Pipe (see Alternator Cover Removal) • Slide back the rubber cap [A]. •...
  • Page 588: Starter Motor Disassembly

    16-58 ELECTRICAL SYSTEM Electric Starter System Starter Motor Disassembly • Remove the starter motor (see Starter Motor Removal). • Take off the starter motor through bolts [A] and remove the both end covers [B] and pull the armature out of the yoke [C].
  • Page 589: Brush Inspection

    ELECTRICAL SYSTEM 16-59 Electric Starter System • Install the shims [A] on the armature shaft. • Install the armature [B] among the brushes [A]. • Align the line marks [A] of the end cover with the square mark [B] on the yoke. •...
  • Page 590: Commutator Cleaning And Inspection

    16-60 ELECTRICAL SYSTEM Electric Starter System Commutator Cleaning and Inspection • Smooth the commutator surface [A] if necessary with fine emery cloth [B], and clean out the grooves. • Measure the diameter [A] of the commutator [B]. If the commutator diameter is less than the service limit, replace the starter motor with a new one .
  • Page 591: Brush Plate And Terminal Bolt Inspection

    ELECTRICAL SYSTEM 16-61 Electric Starter System Brush Plate and Terminal Bolt Inspection • Using the highest hand tester range, measure the resis- tance as shown in the figure. Terminal Bolt and Brush Plate [A] Terminal Bolt and Right-hand End Cover [B] Special Tool - Hand Tester: 57001-1394 If there is any reading, the brush holder assembly and/or terminal bolt assembly have a short.
  • Page 592 16-62 ELECTRICAL SYSTEM Electric Starter System Electric Starter Circuit 1. Sidestand Switch 2. Meter Ground 3. Engine Stop Switch 4. Starter Button 5. Fuse Box 2 6. Ignition Fuse 10 A 7. Ignition Switch 8. Water-proof Joint B 9. Neutral Switch 10.
  • Page 593: Lighting System

    ELECTRICAL SYSTEM 16-63 Lighting System This motorcycle adopt the daylight system and have a headlight relay in the relay box. The headlight does not go on when the ignition switch and the engine stop switch are first turned on. The headlight comes on after the starter button is released and stays on until the ignition switch is turned off.
  • Page 594: Headlight Removal/installation

    16-64 ELECTRICAL SYSTEM Lighting System • Replace the headlight bulb. • Fit the projection [A] of the bulb in the hollow [B] of the headlight. • Install the hook [A]. • Fit the dust cover [A] onto the bulb [B] firmly as shown in the figure.
  • Page 595: Tail/brake Light (led) Removal

    ELECTRICAL SYSTEM 16-65 Lighting System • Pull out the bulb [A] straight from the socket. CAUTION Do not turn the bulb. Pull the bulb out to prevent damage to the bulb. Do not use bulb rated for greater wattage then the specified valve. •...
  • Page 596 16-66 ELECTRICAL SYSTEM Lighting System • Push and turn the bulb [A] counterclockwise and remove • Replace the bulb with a new one. • Insert the new bulb [A] by aligning its upper and lower pins [B] with the upper and lower grooves [C] in the socket, and turn the bulb clockwise.