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Kawasaki ninja zx-10r Service Manual

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Table of Contents
Ninja ZX-10R
Motorcycle
Service Manual

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Table of Contents
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  Summary of Contents for Kawasaki ninja zx-10r

  • Page 1 Ninja ZX-10R Motorcycle Service Manual...
  • Page 3 Quick Reference Guide General Information Periodic Maintenance Fuel System (DFI) Cooling System Engine Top End Clutch Engine Lubrication System Engine Removal/Installation Crankshaft/Transmission Wheels/Tires 10 j Final Drive 11 j Brakes 12 j Suspension 13 j Steering 14 j Frame 15 j Electrical System 16 j Appendix...
  • Page 5 All information contained in this publication is based on the latest product information available at the time of publication. Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts. © 2004 Kawasaki Heavy Industries, Ltd. Second Edition (1): Jul. 22, 2004 (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: Table Of Contents

    GENERAL INFORMATION 1-1 General Information Table of Contents Before Servicing ........................Model Identification......................... General Specifications......................Technical Information-Immobilizer System ................1-12 Technical Information-Exhaust Device System ..............1-15 Technical Information......................1-16 Unit Conversion Table ......................1-17...
  • 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 ZX1000-C1 (Europe) Left Side View ZX1000-C1 (Europe) Right Side View...
  • Page 18 1-8 GENERAL INFORMATION Model Identification ZX1000-C1 (US and Canada) Left Side View ZX1000-C1 (US and Canada) Right Side View...
  • Page 19: General Specifications

    GENERAL INFORMATION 1-9 General Specifications ZX1000-C1 ∼ Items Dimensions Overall Length 2 045 mm (80.5 in.) Overall Width 705 mm (27.8 in.) Overall Height 1 115 mm (43.9 in.) Wheelbase 1 385 mm (54.5 in.) Road Clearance 125 mm (4.9 in.) Seat Height 825 mm (32.5 in.) Dry Mass...
  • Page 20 1-10 GENERAL INFORMATION General Specifications ZX1000-C1 ∼ Items Engine Oil: Type API SE, SF or SG API SH or SJ with JASO MA Viscosity SAE10W-40 Capacity 3.7 L (3.9 US qt) Drive Train Primary Reduction System: Type Gear Reduction Ratio 1.611 (87/54) Clutch Type Wet multi disc...
  • Page 21 GENERAL INFORMATION 1-11 General Specifications ZX1000-C1 ∼ Items Electrical Equipment Battery 12 V 10 Ah Headlight: Type Semi-sealed beam Bulb: High 12 V 55 W (quartz-halogen) × 2 12 V 55 W (quartz-halogen) Tail/Brake Light 12 V 0.5/4.1 W (LED) Alternator: Type Three-phase AC...
  • Page 22: Technical Information-Immobilizer System

    4. FI Indicator Light 11. Relay Box 5. Immobilizer Antenna 12. Fuse Box 6. Ignition Switch 13. Immobilizer/Kawasaki Diagnostic System 7. Immobilizer Amplifier Connector Master Key (1 piece) The master key (colored red) has an inbuilt transponder, containing a master key code. These codes are unique to each key.
  • Page 23 13. Starter Relay 5. Meter Unit 14. Main Fuse 30 A 6. FI Indicator Light 15. Battery 12 V 10 Ah 7. Immobilizer Amplifier 16. Immobilizer/Kawasaki Diagnostic System 8. Fuse Box Connector 9. Ignition Fuse 10 A 17. Electronic Control Unit (ECU)
  • Page 24 1-14 GENERAL INFORMATION Technical Information-Immobilizer System Sequence of Operation 1. Turn ON the ignition switch, the ECU, amplifier and antenna start working, and the meter assembly FI indicator lights up. 2. The transponder excited by radio waves transmitted from the antenna receives the ciphered code from the ECU.
  • Page 25: Technical Information-Exhaust Device System

    GENERAL INFORMATION 1-15 Technical Information-Exhaust Device System Exhaust Device System The exhaust device system consists of the ECU, exhaust butterfly valve, exhaust butterfly valve actuator and exhaust device cables. Exhaust butterfly valve is installed in the exhaust pipe end. Exhaust butterfly valve actuator is un- der the seat.
  • Page 26: Technical Information

    1-16 GENERAL INFORMATION Technical Information Crankcase Upper Crankcase upper and cylinder are a one piece casting, permitting light weight and compact engine. High-speed Generator The high-speed generator is located behind the cylinder, atop the transmission. Although small in diameter it is wider and is driven at twice the crank speed by the clutch to gen- erate ample output at lower rpm.
  • Page 27: Unit Conversion Table

    GENERAL INFORMATION 1-17 Unit Conversion Table Prefixes for Units: Units of Length: Prefix Symbol Power × 0.6214 mile mega × 1 000 000 × 3.281 kilo × 1 000 × 0.03937 centi × 0.01 milli × 0.001 Units of Torque: micro µ...
  • Page 29 PERIODIC MAINTENANCE 2-1 Periodic Maintenance Table of Contents Periodic Maintenance Chart ....Brake Fluid Level Inspection..2-32 Torque and Locking Agent....Brake Pad Wear Inspection ..2-32 Specifications ........2-11 Brake Light Switch Operation ..2-33 Special Tools ........2-13 Suspensions ........
  • Page 30: Periodic Maintenance Chart

    2-2 PERIODIC MAINTENANCE Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition.The initial maintenance is vitally important and must not be neglected. FREQUENCY Whichever * ODOMETER READING comes ×...
  • Page 31: Periodic Maintenance

    PERIODIC MAINTENANCE 2-3 Periodic Maintenance Chart FREQUENCY Whichever * ODOMETER READING comes × 1000 km first (× 1000 mile) Page INSPECTION Every (0.6) (4) (7.5) (12) (15) (20) (24) • • • • • • • Brake light switch operation-inspect 2-33 Suspensions Front forks/rear shock absorber operation...
  • Page 32: Periodic Maintenance Chart

    2-4 PERIODIC MAINTENANCE Periodic Maintenance Chart Periodic Replacement Parts FREQUENCY Whichever * ODOMETER READING come × 1000 km first (× 1000 mile) Page CHANGE/REPLACEMENT Every (0.6) (7.5) (12) (15) (24) (30) • Fuel hose 4 years 2-44 • • Air cleaner element # 2-46 •...
  • Page 33: Torque And Locking Agent

    PERIODIC MAINTENANCE 2-5 Torque and Locking Agent The following tables list the tightening torque for the major fasteners requiring use of a non-permanent locking agent or liquid gasket. Letters used in the “Remarks” column mean: AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque. G: Apply grease to the threads.
  • Page 34 2-6 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Exhaust Butterfly Valve Actuator Mounting Nuts 0.70 62 in·lb Exhaust Butterfly Valve Actuator Pulley Bolt 0.50 43 in·lb Exhaust Butterfly Valve Cover Bolts 0.90 78 in·lb Fuel Pump Bolts 87 in·lb L, S Separator Mounting Bolt...
  • Page 35 PERIODIC MAINTENANCE 2-7 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Muffler Body Mounting Bolts Crankshaft Sensor Cover Bolts 87 in·lb Muffler Body Assembly Nuts Exhaust Butterfly Valve Cable Locknuts 0.71 62 in·lb Exhaust Butterfly Valve Cover Bolts 0.90 80 in·lb Exhaust Butterfly Valve Cable Adjuster Locknuts...
  • Page 36 2-8 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Crankshaft/Transmission Breather Plate Bolts 87 in·lb Crankcase Bolts (M9) MO, S Crankcase Bolts (M8, L = 90 mm) Crankcase Bolt (M8, L = 45 mm) Crankcase Bolt (M7, L = 85 mm) Crankcase Bolt (M7, L = 50 mm) Crankcase Bolts (M7, L = 45 mm) Crankcase Bolts (M7, L = 32 mm)
  • Page 37 PERIODIC MAINTENANCE 2-9 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Brakes 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 0.61 53 in·lb Front Brake Reservoir Cap Stopper Screw 0.12 11 in·lb Front Brake Light Switch Screw...
  • Page 38 2-10 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Side Stand Switch Bolt 0.90 78 in·lb Wind Shield Mounting Screws 0.40 0.04 3.5 in·lb Front Fender Mounting Bolts 0.40 35 in·lb Inner Fender Mounting Bolts 0.25 1.8 in·lb Electrical System Alternator Shaft Lever Bolt...
  • Page 39: Specifications

    PERIODIC MAINTENANCE 2-11 Specifications Item Standard Service Limit Fuel System 2 ∼ 3 mm (0.08 ∼ 0.12 in.) – – – Throttle Grip Free Play Idle Speed 1 100 ±50 r/min (rpm) – – – Throttle Body Vacuum 30 ±1.3 kPa (225 ±10 mmHg) at idle speed –...
  • Page 40 2-12 PERIODIC MAINTENANCE Specifications Item Standard Service Limit Final Drive 35 ∼ 45 mm (1.4 ∼ 1.8 in.) Drive Chain Slack – – – Drive Chain Wear (20-link 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) 323 mm (12.7 in.) Length) Standard Chain: Make...
  • Page 41: Special Tools

    PERIODIC MAINTENANCE 2-13 Special Tools Inside Circlip Pliers: Lead Wire - Peak Voltage Adapter: 57001-143 57001-1449 Steering Stem Nut Wrench: Extension Tube: 57001-1100 57001-1578 Jack: Pilot Screw Adjuster, D: 57001-1238 57001-1588 Oil Filter Wrench: 57001-1249...
  • Page 42: Maintenance Procedure

    2-14 PERIODIC MAINTENANCE Maintenance Procedure Fuel System (DFI) Throttle Cable Inspection Throttle Grip Free Play Inspection • Check the throttle grip free play [A]. If the free play is incorrect, adjust the throttle cables. Throttle Grip Free Play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Standard: •...
  • Page 43 PERIODIC MAINTENANCE 2-15 Maintenance Procedure • Plug the engine breather hose end [A]. • Connect a commercially available vacuum gauge and hoses [A] to the fittings on the throttle body. • Connect a highly accurate tachometer to one of the stick coil primary leads using the adapter [B].
  • Page 44 2-16 PERIODIC MAINTENANCE Maintenance Procedure If any vacuum is not within specifications, first synchro- nize the balance of the left (#1, #2 throttle valves) and right (#3, #4 throttle valves) assemblies. Example: #1: 210 mmHg #2: 240 mmHg #3: 200 mmHg #4: 220 mmHg •...
  • Page 45 PERIODIC MAINTENANCE 2-17 Maintenance Procedure • Turn in the bypass screw [A] with counting the number of turns until it seals fully but not tightly. Record the number of turns. Torque - Bypass Screw: 0.2 N·m (0.02 kgf·m, 1.7 in·lb) CAUTION Do not over tighten them.
  • Page 46: Idle Speed Inspection

    2-18 PERIODIC MAINTENANCE Maintenance Procedure Idle Speed Inspection Idle Speed Inspection • Start the engine and warm it up thoroughly. • With the engine idling, turn the handlebar to both sides [A]. If handlebar movement changes the idle speed, the throttle cables may be improperly adjusted or incorrectly routed, or damaged.
  • Page 47: Cooling System

    PERIODIC MAINTENANCE 2-19 Maintenance Procedure Cooling System Coolant Level Inspection NOTE ○ Check the level when the engine is cold (room or ambi- ent temperature). • Check the coolant level in the reserve tank [A] with the motorcycle held perpendicular (Do not use the sidestand). If the coolant level is lower than the “L”...
  • Page 48: Evaporative Emission Control System (California Model)

    2-20 PERIODIC MAINTENANCE Maintenance Procedure Evaporative Emission Control System (California Model) Evaporative Emission Control System Function Inspection • Inspect the canister as follow: ○ Remove: Right Lower Fairing (see Frame chapter) Right Middle Fairing (see Frame chapter) ○ Remove the canister [A], and disconnect the hoses from the canister.
  • Page 49: Air Suction System

    PERIODIC MAINTENANCE 2-21 Maintenance Procedure Air Suction System Air Suction Valve Inspection • Remove the air suction valve (see Engine Top End chap- ter). • Visually inspect the reeds [A] for cracks, folds, warps, heat damage, or other damage. If there is any doubt as to the condition of the reed, replace the air suction valve as an assembly.
  • Page 50 2-22 PERIODIC MAINTENANCE Maintenance Procedure • Using a thickness gauge [A], measure the valve clearance between the cam and the valve lifter. Valve Clearance Standard: 0.17 ∼ 0.22 mm (0.0067 ∼ 0.0087 in.) Exhaust 0.15 ∼ 0.24 mm (0.0059 ∼ 0.0094 in.) Inlet NOTE ○...
  • Page 51 PERIODIC MAINTENANCE 2-23 Maintenance Procedure Valve Clearance Adjustment • To change the valve clearance, remove the camshaft chain tensioner, camshafts and valve lifters. Replace the shim with one of a different thickness. NOTE ○ Mark and record the locations of the valve lifters and shims so that they can be reinstalled in their original positions.
  • Page 52 2-24 PERIODIC MAINTENANCE Maintenance Procedure Adjustment Shims Thickness Part Number Mark 1.300 92180-0108 1.325 92180-0109 1.350 92180-0110 1.375 92180-0111 1.400 92180-0112 1.425 92180-0113 1.450 92180-0114 1.475 92180-0115 1.500 92180-0116 1.525 92180-0117 1.550 92180-0118 1.575 92180-0119 1.600 92180-0120 1.625 92180-0121 1.650 92180-0122 1.675 92180-0123...
  • Page 53: Clutch And Drive Train

    PERIODIC MAINTENANCE 2-25 Maintenance Procedure CAUTION Be sure to remeasure the clearance after selecting a shim. The clearance can be out of the specified range because of the shim tolerance. ○ If there is no valve clearance, use a shim that is a few sizes smaller, and remeasure the valve clearance.
  • Page 54: Drive Chain Lubrication Condition Inspection

    2-26 PERIODIC MAINTENANCE Maintenance Procedure • Slide the dust cover [A] at the clutch cable lower end out of place. • Loosen both adjusting nuts [B] at the clutch cover as far as they will go. • Pull the clutch outer cable [C] tight and tighten the adjust- ing nuts against the bracket [D].
  • Page 55: Drive Chain Slack Inspection

    PERIODIC MAINTENANCE 2-27 Maintenance Procedure • 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. • Wipe off any excess oil.
  • Page 56: Drive Chain Wear Inspection

    2-28 PERIODIC MAINTENANCE Maintenance Procedure • 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 57: Drive Chain Guide Wear Inspection

    PERIODIC MAINTENANCE 2-29 Maintenance Procedure WARNING If the drive chain wear exceeds the service limit, re- place the chain or an unsafe riding condition may result. A chain that breaks or jumps off the sprock- ets could snag on the engine sprocket or lock the rear wheel, severely damaging the motorcycle and causing it to go out of control.
  • Page 58: Tire Tread Wear Inspection

    2-30 PERIODIC MAINTENANCE Maintenance Procedure Tire Tread Wear Inspection As the tire tread wears down, the tire becomes more sus- ceptible to puncture and failure. An accepted estimate is that 90% of all tire failures occur during the last 10% of tread life (90% worn).
  • Page 59: Brake System

    PERIODIC MAINTENANCE 2-31 Maintenance Procedure • Using a jack and attachment, raise the rear wheel off the ground (see Wheels/Tires chapter). • Inspect the roughness of the rear wheel bearing by push- ing and pulling [A] the wheel. • Spin [B] the rear wheel lightly, and check for smoothly turn, roughness, binding or noise.
  • Page 60: Brake Fluid Level Inspection

    2-32 PERIODIC MAINTENANCE Maintenance Procedure Brake Fluid Level Inspection • Check that the brake fluid level in the front brake reservoir [A] is above the lower level line [B]. NOTE ○ Hold the reservoir horizontal by turning the handlebar when checking brake fluid level. If the fluid level is lower than the lower level line, fill the reservoir to the upper level line [C].
  • Page 61: Brake Light Switch Operation

    PERIODIC MAINTENANCE 2-33 Maintenance Procedure Brake Light Switch Operation • 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.). If it does not, adjust the brake light switch.
  • Page 62: Suspensions

    2-34 PERIODIC MAINTENANCE Maintenance Procedure Suspensions Front Forks/Rear Shock Absorber Operation Inspection • Pump the forks down and up [A] 4 or 5 times, and inspect the smooth stroke. If the forks do not smoothly or noise is found, inspect the fork oil level or fork clamps (see Suspension chapter).
  • Page 63: Tie-Rod Operation Inspection

    PERIODIC MAINTENANCE 2-35 Maintenance Procedure Tie-rod Operation Inspection • Remove the lower fairings (see Frame chapter). • Pump the seat down and up 4 or 5 times, and inspect the smooth stroke. If the tie-rods [A] do not smoothly stroke or noise is found, inspect the fasteners and tie-rod bearings (see Suspen- sion chapter).
  • Page 64: Steering Stem Bearing Lubrication

    2-36 PERIODIC MAINTENANCE Maintenance Procedure • Adjust the steering. Special Tool - Steering Stem Nut Wrench: 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 65: Electrical System

    PERIODIC MAINTENANCE 2-37 Maintenance Procedure Electrical System Lights and Switches Operation Inspection First Step • Turn on the ignition switch. • The following lights should go on according to below table. goes on City Light [A] Taillight [B] goes on goes on License Plate Light [C] Meter Panel LCD [D]...
  • Page 66 2-38 PERIODIC MAINTENANCE Maintenance Procedure 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. • The turn signal indicator LED [C] in the meter unit should flash.
  • Page 67: Headlight Aiming Inspection

    PERIODIC MAINTENANCE 2-39 Maintenance Procedure • Set the dimmer switch to high beam position. • The low beam [A] and high beam [B] headlights should go on. • The high beam indicator LED [C] should go on. If the high beam headlight and/or high beam indicator LED does not go on, inspect or replace the following item.
  • Page 68: Side Stand Switch Operation Inspection

    2-40 PERIODIC MAINTENANCE Maintenance Procedure NOTE ○ ON high beam, the brightest points should be slightly below horizontal with the motorcycle on its wheels and the rider seated. Adjust the headlight to the proper an- gle according to local regulations. ○...
  • Page 69: Engine Stop Switch Operation Inspection

    PERIODIC MAINTENANCE 2-41 Maintenance Procedure If the side stand switch operation does not work, inspect or replace the following item. Battery (see Electrical System chapter) Main Fuse 30 A (see Electrical System chapter) Ignition Fuse 10 A (see Electrical System chapter) Ignition Switch (see Electrical System chapter) Side Stand Switch (see Electrical System chapter) Engine Stop Switch (see Electrical System chapter)
  • Page 70: Others

    2-42 PERIODIC MAINTENANCE Maintenance Procedure 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 71: Bolts, Nuts And Fasteners Tightness Inspection

    PERIODIC MAINTENANCE 2-43 Maintenance Procedure • With the cable disconnected at both ends, the inner 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 72: Replacement Parts

    2-44 PERIODIC MAINTENANCE Maintenance Procedure Bolt, Nut and Fastener to be checked Wheels: Front Axle Nut Front Axle Clamp Bolt Rear Axle Nut Rear Axle Nut Cotter Pin Brakes: Front Master Cylinder Clamp Bolts Caliper Mounting Bolts Rear Master Cylinder Mounting Bolts Brake Lever Pivot Nut Brake Pedal Bolt Brake Rod Joint Cotter Pin...
  • Page 73 PERIODIC MAINTENANCE 2-45 Maintenance Procedure • Pull the joint lock [A] as shown. • Pull the fuel hose joint [B] out of the delivery pipe. WARNING Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately. When the fuel hose is disconnected, fuel spills out from the hose and the pipe.
  • Page 74: Air Cleaner Element Replacement

    Install a new element [A] so that the element ends [B] insert along the rib [C] in the housing. CAUTION Use only the recommended air cleaner element (Kawasaki part number 11013-0004). Using another air cleaner element will wear the engine prema- turely or lower the engine performance.
  • Page 75: Coolant Change

    PERIODIC MAINTENANCE 2-47 Maintenance Procedure Coolant Change WARNING To avoid burns, do not remove the radiator cap or try to change the coolant when the engine is still hot. Wait until it cools down. Coolant on tires will make them slippery and can cause an accident and injury.
  • Page 76 2-48 PERIODIC MAINTENANCE Maintenance Procedure • Fill the radiator up to the radiator filler neck [A] with coolant, and install the radiator cap. NOTE ○ Pour in the coolant slowly so that it can expel the air from the engine and radiator. •...
  • Page 77: Radiator Hose And O-Ring Replacement

    PERIODIC MAINTENANCE 2-49 Maintenance Procedure Radiator Hose and O-ring Replacement • Drain the coolant (see Coolant Change). • Remove: Lower Fairings (see Frame chapter) Middle Fairings (see Frame chapter) Throttle Body Assy (see Fuel System (DFI) chapter) Thermostat Housing [A] Fitting [B] Hoses [C] O-rings [D]...
  • Page 78: Oil Filter Replacement

    2-50 PERIODIC MAINTENANCE Maintenance Procedure Recommended Engine Oil Type: API SE, SF or SG API SH or SJ with JASO MA Viscosity: SAE 10W-40 Capacity: 2.7 L (2.9 US qt) (when filter is not removed) 3.0 L (3.2 US qt) (when filter is removed) 3.7 L (3.9 US qt) (when engine is completely dry) NOTE...
  • Page 79: Brake Fluid Change

    PERIODIC MAINTENANCE 2-51 Maintenance Procedure • When installing the hoses [A], avoid sharp bending, kink- ing, flatting or twisting, and route the hoses according to Cable, Wire, and Hose Routing section in Appendix chap- ter. • Fill the brake line after installing the brake hose (see Brake Fluid Change).
  • Page 80 2-52 PERIODIC MAINTENANCE Maintenance Procedure • Change the brake fluid. ○ Repeat this operation until fresh brake fluid comes out from the plastic hose or the color of the fluid changes. 1. Open the bleed valve [A]. 2. Apply the brake and hold it [B]. 3.
  • Page 81: Master Cylinder Rubber Parts Replacement

    PERIODIC MAINTENANCE 2-53 Maintenance Procedure Master Cylinder Rubber Parts Replacement Front Master Cylinder Disassembly • Remove the front master cylinder (see Brakes chapter). • Remove the seal cover [A], circlip [B], connector [C] and O-ring [D]. Special Tool - Inside Circlip Pliers: 57001-143 •...
  • Page 82: Caliper Rubber Parts Replacement

    2-54 PERIODIC MAINTENANCE Maintenance Procedure • 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. CAUTION Do not remove the secondary cup from the piston since removal will damage it.
  • Page 83 PERIODIC MAINTENANCE 2-55 Maintenance Procedure 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 84 2-56 PERIODIC MAINTENANCE Maintenance Procedure Rear Caliper Disassembly • Remove the rear caliper. • Remove the pads and anti-rattle spring (see Brakes chap- ter). • Using compressed air, remove the piston. ○ Cover the caliper opening with a clean, heavy cloth [A]. ○...
  • Page 85: Spark Plug Replacement

    PERIODIC MAINTENANCE 2-57 Maintenance Procedure • Apply brake fluid to the outside of the piston, and push it into the cylinder by hand. • Replace the shaft rubber friction boot [A] and dust boot [B]. • Apply a thin coat of PBC (Poly Butyl Cuprysil) grease to the caliper holder shafts [C] and holder holes [D] (PBC is a special high temperature, water-resistance grease).
  • Page 87 FUEL SYSTEM (DFI) 3-1 Fuel System (DFI) Table of Contents Exploded View........Crankshaft Sensor (Service Code Specifications ........3-10 21)........... 3-63 Special Tools and Sealant ....3-12 Crankshaft Sensor DFI Parts Location......3-14 Removal/Installation....3-63 DFI System........3-16 Crankshaft Sensor Inspection..3-63 DFI Servicing Precautions ....
  • Page 88 3-2 FUEL SYSTEM (DFI) Fuel Injectors #1, #2, #3, #4: (Service Fuel Line..........3-101 Code 41, 42, 43, 44) ....... 3-79 Fuel Pressure Inspection ..... 3-101 Power Source Voltage Inspection 3-79 Fuel Flow Rate Inspection ... 3-102 Output Voltage Inspection.... 3-80 Fuel Pump .........
  • Page 89: Exploded View

    FUEL SYSTEM (DFI) 3-3 Exploded View Dummy Page...
  • Page 90 3-4 FUEL SYSTEM (DFI) Exploded View...
  • Page 91 FUEL SYSTEM (DFI) 3-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Air Inlet Duct Mounting Bolts 0.70 62 in·lb Air Cleaner Element Cover Screws 0.11 9.7 in·lb Air Cleaner Housing Holder Clamp Screws 0.50 43 in·lb 4. Air Inlet Duct 5.
  • Page 92 3-6 FUEL SYSTEM (DFI) Exploded View...
  • Page 93 19. Main throttle Valve Sensor 20. Bypass Screw 21. Injector 22. Stick Coil CL: Apply cable lubricant. EO: Apply engine oil. G: Apply grease. L: Apply a non-permanent locking agent. R: Replacement Parts SS: Apply silicone sealant (Kawasaki Bond: 56019-120).
  • Page 94 3-8 FUEL SYSTEM (DFI) Exploded View...
  • Page 95 FUEL SYSTEM (DFI) 3-9 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Exhaust Butterfly Valve Actuator Mounting Nuts 0.70 62 in·lb Exhaust Butterfly Valve Actuator Pulley Bolt 0.50 43 in·lb Exhaust Butterfly Valve Cover Bolts 0.90 78 in·lb Fuel Pump Bolts 87 in·lb L, S Separator Mounting Bolt...
  • Page 96: Specifications

    3-10 FUEL SYSTEM (DFI) Specifications Item Standard Digital Fuel Injection System Idle Speed 1 100 ±50 r/min (rpm) Throttle Assy: Type Four barrel type Bore 43 mm (1.7 in.) Throttle Body Vacuum 30 ±1.3 kPa (225 ±10 mmHg) Bypass Screws –...
  • Page 97 FUEL SYSTEM (DFI) 3-11 Specifications Item Standard Vehicle-down-Sensor: Detection Method Magnetic flux detection method More than 60 ∼ 70° for each bank Detection Angle Within 1.0 ∼ 1.5 sec. Detection Time with sensor arrow mark pointed up: 3.55 ∼ 4.45 V Output Voltage with sensor tilted 60 ∼...
  • Page 98: Special Tools And Sealant

    3-12 FUEL SYSTEM (DFI) Special Tools and Sealant Oil Pressure Gauge, 5 kgf/cm²: Throttle Sensor Setting Adapter: 57001-125 57001-1521 Fork Oil Level Gauge: Sensor Harness Adapter: 57001-1290 57001-1561 Hand Tester: Pilot Screw Adjuster, D: 57001-1394 57001-1588 Throttle Sensor Setting Adapter #1: Fuel Pressure Gauge Adapter: 57001-1400 57001-1593...
  • Page 99 FUEL SYSTEM (DFI) 3-13 Special Tools and Sealant Kawasaki Bond (Silicone Sealant): 56019-120...
  • Page 100: Dfi Parts Location

    Subthrottle Valve Actuator [E] Subthrottle Sensor [F] Battery [A] Relay Box [B] Exhaust Butterfly Valve Actuator [C] ECU (Electronic Control Unit) [D] Self-diagnosis Terminal [A] Kawasaki Diagnosis System Connector [B] Atmospheric Pressure Sensor [C] Vehicle-down-Sensor [D] Inlet Air Temperature Sensor [A]...
  • Page 101 FUEL SYSTEM (DFI) 3-15 DFI Parts Location Camshaft Position Sensor [A] Crankshaft Sensor [B] Speed Sensor [A] Gear Position Switch [B] Gear Position Switch [A] Ignition Key [A] (Transponder) Ignition Switch [B] Immobilizer Antenna [C] Immobilizer Amplifier [D] Immobilizer Amplifier [A] (Headlight [B])
  • Page 102: Dfi System

    3-16 FUEL SYSTEM (DFI) DFI System DFI System Wiring Diagram...
  • Page 103 FUEL SYSTEM (DFI) 3-17 DFI System Part Name 1. Joint Connector 4 2. Joint Connector 1 3. Joint Connector 2 4. Ignition Switch 5. Engine Stop Switch 6. Starter Button 7. Stick Coil #1, #2, #3, #4 8. Camshaft Position Sensor 9.
  • Page 104 3-18 FUEL SYSTEM (DFI) DFI System Terminal Numbers of ECU Connectors Terminal Names 1. External Communication Line 2. Side Stand Switch 3. Crankshaft Sensor (–) 4. Vehicle-down-Sensor 5. Main Throttle Sensor 6. Subthrottle Sensor 7. Exhaust Butterfly Valve Sensor 8. Engine Stop Switch 9.
  • Page 105 FUEL SYSTEM (DFI) 3-19 DFI System 24. Ignition Switch 25. External Communication Line (Mode Switch) 26. Self-diagnosis Terminal 27. Stick Coil #4 28. Stick Coil #1 29. Injector #1 30. Exhaust Butterfly Valve Actuator (+) 31. Exhaust Butterfly Valve Actuator (–) 32.
  • Page 106: Dfi Servicing Precautions

    3-20 FUEL SYSTEM (DFI) 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 107 FUEL SYSTEM (DFI) 3-21 DFI Servicing Precautions ○ The fuel hose [A] is designed to be used through out the motorcycle’s life without any maintenance, however, if the motorcycle is not properly handled, the high pressure in- side the fuel line can cause fuel to leak or the hose to burst.
  • Page 108: Troubleshooting The Dfi System

    3-22 FUEL SYSTEM (DFI) Troubleshooting the DFI System Outline When an abnormality in the system occurs, the FI indica- tor LED (Light Emitting Diode) light goes on to alert the rider on the meter panel. In addition, the condition of the problem is stored in the memory of the ECU (electronic control unit).
  • Page 109 ○ After measurement, remove the needle adapters and ap- ply silicone sealant to the seals [A] of the connector [B] for waterproofing. Silicone Sealant (Kawasaki Bond: 56019-120) Seals of Connector • 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 110 3-24 FUEL SYSTEM (DFI) Troubleshooting the DFI System • Pull each connector [A] apart and inspect it for corrosion, dirt, and damage. If the connector is corroded or dirty, clean it carefully. If it is damaged, replace it. Connect the connectors securely. •...
  • Page 111 FUEL SYSTEM (DFI) 3-25 Troubleshooting the DFI System • Narrow down suspicious locations by repeating the con- tinuity tests from the ECU connectors. If no abnormality is found in the wiring or connectors, the DFI parts are the next likely suspects. Check the part, starting with input and output voltages.
  • Page 112: Inquiries To Rider

    3-26 FUEL SYSTEM (DFI) Troubleshooting the DFI System DFI Diagnosis Flow Chart Inquiries to Rider ○ Each rider reacts to problems in different ways, so it is important to confirm what kind of symptoms the rider has encountered. ○ Try to find out exactly what problem occurred under exactly what conditions by asking the rider; knowing this information may help you reproduce the problem.
  • Page 113 FUEL SYSTEM (DFI) 3-27 Troubleshooting the DFI System Sample Diagnosis Sheet Rider name: Registration No. (license plate No.): Year of initial registration: Model: Engine No.: Frame No.: Date problem occurred: Mileage: Environment when problem occurred. □ □ □ □ □ □...
  • Page 114 3-28 FUEL SYSTEM (DFI) Troubleshooting the DFI System □ □ □ Poor running at low very low idle speed, very high idle speed, rough idle speed. □ speed battery voltage is low (charge the battery). □ spark plug loose (tighten it). □...
  • Page 115: Dfi System Troubleshooting Guide

    FUEL SYSTEM (DFI) 3-29 DFI System Troubleshooting Guide NOTE ○ This is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties. ○...
  • Page 116 3-30 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or possible Causes Actions (chapter) Clutch lever not pulled in and gear not in neutral Pull the lever in and shift the gear in neutral. whether sidestand up or not Though clutch lever pulled in, sidestand up and Sidestand down and clutch lever pulled in gear not in neutral whether gear in neutral or not...
  • Page 117 FUEL SYSTEM (DFI) 3-31 DFI System Troubleshooting Guide Symptoms or possible Causes Actions (chapter) Cylinder head warped Inspect and replace (see chapter 5). No valve clearance Adjust (see chapter 2). Valve guide worn Inspect and replace (see chapter 5). Valve spring broken or weak Inspect and replace (see chapter 5).
  • Page 118 3-32 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Incorrect idle speed: Water temperature sensor trouble Inspect (see chapter 3). Main throttle sensor trouble Inspect (see chapter 3). Engine stalls easily: Fuel pump trouble Inspect (see chapter 3). Fuel injector trouble Inspect (see chapter 3).
  • Page 119 FUEL SYSTEM (DFI) 3-33 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Inlet air pressure sensor trouble Inspect (see chapter 3). Loose injector connectors Remedy (see chapter 3). Crankshaft sensor trouble Inspect and repair or replace (see chapter 16). Stick coil trouble Inspect and repair or replace (see chapter 16).
  • Page 120: Poor Running Or No Power At High Speed

    3-34 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Inlet air pressure sensor trouble Inspect (see chapter 3). Vacuum switch valve broken Inspect and replace (see chapter 5). Air suction valve trouble Inspect and replace (see chapter 5). After fire: Crankshaft sensor trouble Inspect (see chapter 16).
  • Page 121 FUEL SYSTEM (DFI) 3-35 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Stick coil trouble Inspect (see chapter 16). Fuel/air mixture incorrect: Air cleaner clogged, poorly sealed, or missing Clean element or inspect sealing (see chapter 3). Air cleaner duct loose Reinstall (see chapter 3).
  • Page 122 3-36 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Speed sensor trouble Inspect (see chapter 3). Inspect throttle cable and lever linkage (see Throttle valves won’t fully open chapter 3). Inspect caliper fluid seal damage or clogging Brake dragging of master cylinder relief and supply ports (see chapter 12).
  • Page 123: Self-Diagnosis

    FUEL SYSTEM (DFI) 3-37 Self-Diagnosis Self-diagnosis Outline The self-diagnosis system has two modes and can be switched to another mode by grounding the self-diagnosis terminal [A]. User Mode The ECU notifies the rider of troubles in DFI system and ignition system by lighting the FI indicator when DFI system and ignition system parts are faulty, and initiates fail-safe function.
  • Page 124: Service Code Reading

    3-38 FUEL SYSTEM (DFI) Self-Diagnosis Service Code Reading ○ Service codes are shown by a series of long and short blinks of the FI indicator LED light as shown below. ○ Read 10th digit and unit digit as the FI indicator LED light blinks. ○...
  • Page 125: Service Code Erasing

    FUEL SYSTEM (DFI) 3-39 Self-Diagnosis Service Code Erasing ○ When the repair has been done, the LED light will not show fault codes any more. But even if the repair has been done, the ignition SW is turned OFF, or the battery is disconnected, all the fault codes remain in the ECU, which need not be absolutely erased.
  • Page 126 3-40 FUEL SYSTEM (DFI) Self-Diagnosis Service FI Indicator LED Light Problems Code Injector #1 malfunction, wiring open or short Injector #2 malfunction, wiring open or short Injector #3 malfunction, wiring open or short Injector #4 malfunction, wiring open or short Fuel pump relay malfunction, wiring open Fuel pump relay malfunction, relay is stuck Stick (Ignition) coil #1 malfunction, wiring open or...
  • Page 127: Backups

    FUEL SYSTEM (DFI) 3-41 Self-Diagnosis Backups ○ The ECU takes the following measures to prevent engine damage when the DFI or the ignition system parts have troubles. Service Output Signal Usable Parts Backups by ECU Codes Range or Criteria If the main throttle sensor system fails (the Main Throttle Sensor signal is out of the usable range, wiring short Main Throttle...
  • Page 128 3-42 FUEL SYSTEM (DFI) Self-Diagnosis Service Output Signal Usable Parts Backups by ECU Codes Range or Criteria Master or The user or master key If the blank key or broken key is used, the User Key must use register key. vehicle is no start and run.
  • Page 129 FUEL SYSTEM (DFI) 3-43 Self-Diagnosis Service Output Signal Usable Parts Backups by ECU Codes Range or Criteria The actuator operates Subthrottle If the sub throttle actuator fails (the signal is open and close of the Valve out to the usable range, wiring short or open), subthrottle valve by the Actuator the ECU stops the current to the actuator.
  • Page 130: Main Throttle Sensor (Service Code 11)

    3-44 FUEL SYSTEM (DFI) Main Throttle Sensor (Service Code 11) The main throttle sensor is a rotating variable resistor that change output voltage according to throttle operating. The ECU senses this voltage change and determines fuel injec- tion quantity, and ignition timing according to engine rpm, and throttle opening.
  • Page 131: Output Voltage Inspection

    FUEL SYSTEM (DFI) 3-45 Main Throttle Sensor (Service Code 11) • Disconnect the main throttle sensor connector and con- nect the harness adapter [A] between the harness con- nector and main throttle sensor connector. • Connect a digital meter to the harness adapter leads. Special Tool - Throttle Sensor Setting Adapter #1: 57001 -1400 Main Throttle Sensor Input Voltage...
  • Page 132 3-46 FUEL SYSTEM (DFI) Main Throttle Sensor (Service Code 11) NOTE ○ The throttle sensor is operating correctly if the following voltages are obtained: • 0.66 VDC (or slightly higher) with the throttle at the idle position. • 4.62 VDC (or slightly lower) with the throttle at the fully open position.
  • Page 133 FUEL SYSTEM (DFI) 3-47 Main Throttle Sensor (Service Code 11) • Disconnect the main throttle sensor connector and con- nect the harness adapter [A] between the harness con- nector and main throttle sensor connector. • Connect a digital meter to the harness adapter leads. Special Tool - Throttle Sensor Setting Adapter #1: 57001 -1400 Throttle Sensor Output Voltage...
  • Page 134: Resistance Inspection

    3-48 FUEL SYSTEM (DFI) Main Throttle Sensor (Service Code 11) Resistance Inspection • Turn the ignition switch OFF. • Disconnect the main throttle sensor connector. • Connect a digital meter [A] to the main throttle sensor connector [B]. • Measure the main throttle sensor resistance. Main Throttle Sensor Resistance Connections: BL lead [C] ←→...
  • Page 135: Inlet Air Pressure Sensor (Service Code 12)

    FUEL SYSTEM (DFI) 3-49 Inlet Air Pressure Sensor (Service Code 12) CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the part can damage it. Removal • Turn the ignition switch off. • Remove: Air Cleaner Housing (see Air Cleaner Housing Removal) Inlet Air Pressure Sensor Connector [A] Inlet Air Pressure Sensor Screw [B] Inlet Air Pressure Sensor [C]...
  • Page 136: Output Voltage Inspection

    3-50 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code 12) If the reading is within the standard range, and check the input voltage again at the sensor connector. • Remove the air cleaner housing (see Air Cleaner Housing Removal). •...
  • Page 137 FUEL SYSTEM (DFI) 3-51 Inlet Air Pressure Sensor (Service Code 12) If the output voltage is far out of the usable range, check the output voltage again at the sensor connector [A] (when the lead is open, the output voltage is about 1.8 •...
  • Page 138 3-52 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code 12) • Remove the inlet air pressure sensor [A] and disconnect the vacuum hose from the sensor. ○ Do not disconnect the sensor connector. • Connect an auxiliary hose [B] to the inlet air pressure sen- sor.
  • Page 139 FUEL SYSTEM (DFI) 3-53 Inlet Air Pressure Sensor (Service Code 12) Vv: Inlet Air Pressure Sensor Output Voltage (V) (Digital Meter Reading) Pv: Throttle Vacuum Pressure (absolute) Ps: Standard Atmospheric Pressure (absolute) ID: Idling TO: Throttle Full Open ST: Standard of Sensor Output Voltage (v) UR: Usable Range of Sensor Output Voltage (v)
  • Page 140: Inlet Air Temperature Sensor (Service Code 13)

    3-54 FUEL SYSTEM (DFI) Inlet Air Temperature Sensor (Service Code 13) Removal/Installation CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. • Remove the fuel tank (see Fuel Tank Removal). •...
  • Page 141: Sensor Resistance Inspection

    • Remove the needle adapter set, and apply silicone sealant to the seals of the connector for waterproofing. Silicone Sealant (Kawasaki Bond: 56019-120) - Seals of ECU Connectors If the wiring is good, check the sensor resistance. Sensor Resistance Inspection •...
  • Page 142 3-56 FUEL SYSTEM (DFI) Inlet Air Temperature Sensor (Service Code 13) 1. ECU 2. Inlet Air Temperature Sensor...
  • Page 143: Water Temperature Sensor (Service Code 14)

    • Remove: Water Temperature Sensor [A] • Install the water temperature sensor. Silicone Sealant (Kawasaki Bond: 56019-120) - Threads of Water Temperature Sensor Torque - Water Temperature Sensor: 25 N·m (2.5 kgf·m, 18 ft·lb) • Fill the engine with coolant and bleed the air from the cooling system (see Coolant Filling in the Cooling System chapter).
  • Page 144: Sensor Resistance Inspection

    If the wiring is good, check the water temperature sensor resistance. • Remove the needle adapter set, and apply silicone sealant to the seals of the connector for waterproofing. Silicone Sealant (Kawasaki Bond: 56019-120) - Seals of ECU Connectors 1. ECU 2. Meter 3. Water Temperature Sensor Sensor Resistance Inspection •...
  • Page 145: Atmospheric Pressure Sensor (Service Code 15)

    FUEL SYSTEM (DFI) 3-59 Atmospheric Pressure Sensor (Service Code 15) CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. Removal • Turn the ignition switch off. • Remove: Seat (see Frame chapter) Atmospheric Pressure Sensor Connector [A] Damper [B] Atmospheric Pressure Sensor [C]...
  • Page 146: Output Voltage Inspection

    3-60 FUEL SYSTEM (DFI) Atmospheric Pressure Sensor (Service Code 15) If the reading is within the standard range, remove the seat cover, and check the input voltage again at the sen- sor connector. • Remove the air cleaner housing (see Air Cleaner Housing Removal).
  • Page 147 FUEL SYSTEM (DFI) 3-61 Atmospheric Pressure Sensor (Service Code 15) If the output voltage is far out of the usable range, remove the fuel tank, and check the output voltage at the sensor connector [A] (when the wiring is open, the output voltage is about 1.8 V).
  • Page 148 3-62 FUEL SYSTEM (DFI) Atmospheric Pressure Sensor (Service Code 15) If you know the local atmospheric pressure using a barometer, substitute the atmospheric pressure for throt- tle vacuum pressure in the inlet air pressure sensor chart (see intake Air Pressure Sensor section in this chapter). And get the usable range of the atmospheric pressure sensor output voltage and check if output voltage is within the standard or not in the same way as Output...
  • Page 149: Crankshaft Sensor (Service Code 21)

    FUEL SYSTEM (DFI) 3-63 Crankshaft Sensor (Service Code 21) Crankshaft Sensor Removal/Installation • See the Ignition System section in the Electrical System chapter. Crankshaft Sensor Inspection ○ The crankshaft have no power source, and when the en- gine stops, the crankshaft generates no signals. •...
  • Page 150: Camshaft Position Sensor (Service Code 23)

    3-64 FUEL SYSTEM (DFI) Camshaft Position Sensor (Service Code 23) Camshaft Position Sensor Removal/Installation 1. Inspection starts. • The camshaft position sensor detects the position of the camshaft, and distinguishes the cylinder. • See the Ignition system section in the Electric System chapter.
  • Page 151: Speed Sensor (Service Code 24)

    FUEL SYSTEM (DFI) 3-65 Speed Sensor (Service Code 24) Speed Sensor Removal/Installation • See the Switches and Sensors section in the Electrical System chapter. Speed Sensor Inspection • See the Switches and Sensors section in the Electrical System chapter. Input Voltage Inspection NOTE ○...
  • Page 152 3-66 FUEL SYSTEM (DFI) Speed Sensor (Service Code 24) • Disconnect the speed sensor connector [A] and connect the harness adapter [B] between the harness connector and speed sensor connector. • Connect a digital meter to the harness adapter leads. Special Tool - Throttle Sensor Setting Adapter #1: 57001 -1400 Speed Sensor Output Voltage...
  • Page 153: Gear Position Switch (Service Code 25)

    FUEL SYSTEM (DFI) 3-67 Gear Position Switch (Service Code 25) Gear Position Switch Removal/Installation • See the Switches and Sensors section in the Electrical System chapter. Gear Position Switch Inspection • See the Switches and Sensors section in the Electrical System chapter.
  • Page 154 3-68 FUEL SYSTEM (DFI) Gear Position Switch (Service Code 25) 1. Joint Connector 1 2. Joint Connector 2 3. Gear Position Switch 4. ECU...
  • Page 155: Vehicle-Down-Sensor (Service Code 31)

    FUEL SYSTEM (DFI) 3-69 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 shuts off the signal.
  • Page 156 3-70 FUEL SYSTEM (DFI) Vehicle-down-sensor (Service Code 31) • Connect a digital volt meter [A] to the connector of the vehicle-down-sensor [B], with the needle adapter set [C]. Vehicle-down-sensor Power Source Voltage Connections to Sensor Meter (+) → BL lead [D] Meter (–) →...
  • Page 157 • Remove the needle adapter set, and apply silicone sealant to the seals of the connector for waterproofing. Silicone Sealant (Kawasaki Bond: 56019-120) - Seals of Vehicle-down-sensor Connector If the output voltage is out of the specified, replace the vehicle-down-sensor.
  • Page 158: Subthrottle Sensor (Service Code 32)

    3-72 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 159: Output Voltage Inspection

    FUEL SYSTEM (DFI) 3-73 Subthrottle Sensor (Service Code 32) • Disconnect the subthrottle sensor connector [A] and con- nect the harness adapter [B] between the harness con- nector and sub throttle sensor connector. • Connect a digital meter to the harness adapter leads. Special Tool - Throttle Sensor Setting Adapter: 57001 -1521...
  • Page 160 3-74 FUEL SYSTEM (DFI) Subthrottle Sensor (Service Code 32) If the output voltage is within the standard range, check the ECU for a good ground, and power supply (see this chapter). If the ground and power supply are good, re- place the ECU.
  • Page 161: Resistance Inspection

    FUEL SYSTEM (DFI) 3-75 Subthrottle Sensor (Service Code 32) • After subthrottle sensor voltage inspection, remove the harness adapter. If the reading is out of the standard range, inspect the throttle sensor resistance. If the output voltage is normal, check the wiring for conti- nuity (see next diagram).
  • Page 162: Exhaust Butterfly Valve Actuator Sensor (Service Code 34)

    3-76 FUEL SYSTEM (DFI) Exhaust Butterfly Valve Actuator Sensor (Service Code 34) Exhaust Butterfly Valve Actuator Sensor Inspection • Turn the ignition switch OFF. • Disconnect the exhaust butterfly valve actuator sensor connector. • Connect a digital meter [A] to the exhaust butterfly valve actuator sensor connector [B].
  • Page 163: Immobilizer Amplifier (Service Code 35)

    FUEL SYSTEM (DFI) 3-77 Immobilizer Amplifier (Service Code 35) Antenna Resistance Inspection • Remove: Left Lower Fairing (see Frame chapter) • Disconnect: Antenna Lead Connector [A] • Measure the resistance of the antenna coil in the ignition switch as follows. Antenna Resistance Connections to Antenna Meter →...
  • Page 164: Blank Key Detection (Service Code 36)

    7. Immobilizer Amplifier 8. Fuse Box 9. Ignition Fuse 10 A 10. ECU Fuse 15 A 11. Relay Box 12. ECU Main Relay 13. Starter Relay 14. Main Fuse 30 A 15. Battery 16. Immobilizer/Kawasaki Diagnostic System Connector 17. ECU...
  • Page 165: Fuel Injectors #1, #2, #3, #4: (Service Code 41, 42, 43, 44)

    FUEL SYSTEM (DFI) 3-79 Fuel Injectors #1, #2, #3, #4: (Service Code 41, 42, 43, 44) Fuel Injector #1: (Service Code 41) Fuel Injector #2: (Service Code 42) Fuel Injector #3: (Service Code 43) Fuel Injector #4: (Service Code 44) CAUTION Never drop the injector, especially on a hard sur- face.
  • Page 166: Output Voltage Inspection

    3-80 FUEL SYSTEM (DFI) Fuel Injectors #1, #2, #3, #4: (Service Code 41, 42, 43, 44) If the reading is normal, remove the air cleaner housing, and check the power source voltage at the injector con- nector [B], with a digital volt meter [A]. •...
  • Page 167 FUEL SYSTEM (DFI) 3-81 Fuel Injectors #1, #2, #3, #4: (Service Code 41, 42, 43, 44) If the output voltage is normal, check the ECU for its ground, and power supply (see this chapter). If the ground and power supply are good, replace the ECU. If the output voltage is out of the standard, remove the air cleaner housing, and check the output voltage at the injector connector [B] using a digital meter [A] and needle...
  • Page 168: Audible Inspection

    3-82 FUEL SYSTEM (DFI) Fuel Injectors #1, #2, #3, #4: (Service Code 41, 42, 43, 44) Audible Inspection • Remove: Air Cleaner Housing (see Air Cleaner Housing Removal) • Connect the following parts temporary. Fuel Pump Connector Extension Tube Special Tool - Extension Tube: 57001-1578 •...
  • Page 169: Injector Resistance Inspection

    FUEL SYSTEM (DFI) 3-83 Fuel Injectors #1, #2, #3, #4: (Service Code 41, 42, 43, 44) Injector Resistance Inspection • Remove the throttle body assy (see Throttle Body Assy Removal). • Disconnect the connector from the injector [A] (see Throt- tle Body Disassembly/Assembly).
  • Page 170: Injector Fuel Line Inspection

    3-84 FUEL SYSTEM (DFI) Fuel Injectors #1, #2, #3, #4: (Service Code 41, 42, 43, 44) Injector Fuel Line Inspection • Remove the throttle body assy (see this chapter). • Check the injector fuel line for leakage as follows: ○ Connect a commercially available vacuum/pressure pump [A] to the nipple of the delivery pipe [B] with the fuel hose [C] (both ends connected with the clamps [D])
  • Page 171 FUEL SYSTEM (DFI) 3-85 Fuel Injectors #1, #2, #3, #4: (Service Code 41, 42, 43, 44) 1. Joint Connector 4 2. Joint Connector 2 3. Ignition Switch 4. Engine Stop Switch 5. Fuel Injector #1 6. Fuel Injector #2 7. Fuel Injector #3 8.
  • Page 172: Fuel Pump Relay (Service Code 45, 46)

    3-86 FUEL SYSTEM (DFI) Fuel Pump Relay (Service Code 45, 46) Service code 45 is open to the fuel pump relay system. Service code 46 is stuck ON to the fuel pump relay system. Fuel Pump Relay Removal CAUTION Never drop the relay, especially on a hard surface. Such a shock to the relay can damage it.
  • Page 173 FUEL SYSTEM (DFI) 3-87 Fuel Pump Relay (Service Code 45, 46) 1. Joint Connector 4 2. Joint Connector 2 3. Ignition Switch 4. Engine Stop Switch 5. ECU 6. ECU Fuse 15 A 7. Ignition Fuse 10 A 8. ECU Main Relay 9.
  • Page 174: Stick Coils #1, #2, #3, #4: (Service Code 51, 52, 53, 54)

    3-88 FUEL SYSTEM (DFI) Stick Coils #1, #2, #3, #4: (Service Code 51, 52, 53, 54) Stick Coil #1: Ignition Coil (Service Code 51) Stick Coil #2: Ignition Coil (Service Code 52) Stick Coil #3: Ignition Coil (Service Code 53) Stick Coil #4: Ignition Coil (Service Code 54) Removal/Installation CAUTION...
  • Page 175 FUEL SYSTEM (DFI) 3-89 Stick Coils #1, #2, #3, #4: (Service Code 51, 52, 53, 54) 1. Joint Connector 4 2. Joint Connector 2 3. Ignition Switch 4. Engine Stop Switch 5. Stick Coil #1 6. Stick Coil #2 7. Stick Coil #3 8.
  • Page 176: Subthrottle Valve Actuator (Service Code 62)

    3-90 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 actuator , especially on a hard sur- face.
  • Page 177 FUEL SYSTEM (DFI) 3-91 Subthrottle Valve Actuator (Service Code 62) 1. ECU 2. Subthrottle Valve Actuator 3. Subthrottle Sensor 4. Main Throttle Sensor...
  • Page 178: Exhaust Butterfly Valve Actuator (Service Code 63)

    3-92 FUEL SYSTEM (DFI) Exhaust Butterfly Valve Actuator (Service Code 63) Exhaust Butterfly Valve Actuator Removal • Remove: Seats (see Frame chapter) • Put off the rubber boots [A]. • Loosen the locknuts [A] and adjuster nut [B]. • Remove: Wire Stopper [C] Exhaust Butterfly Valve Cables [D] Connectors [E]...
  • Page 179: Exhaust Butterfly Valve Actuator Inspection

    FUEL SYSTEM (DFI) 3-93 Exhaust Butterfly Valve Actuator (Service Code 63) • Confirm the pulley angle [A] (41.7° ±7°) as shown. It is original position of the pulley [B]. If the angle is not within the specified angle, adjust the actuator as follows.
  • Page 180: Output Voltage Inspection

    3-94 FUEL SYSTEM (DFI) Exhaust Butterfly Valve Actuator (Service Code 63) Output Voltage Inspection • Remove: Seats (see Frame chapter) • Measure the output voltage at the 3 pins connector of the exhaust butterfly valve actuator [A] when the pulley is original position as follows.
  • Page 181: Ecu Main Relay (Service Code 75)

    FUEL SYSTEM (DFI) 3-95 ECU Main Relay (Service Code 75) ECU Main Relay Removal CAUTION Never drop the relay box, especially on a hard sur- face. Such a shock to the relay can damage it. ○ The ECU main relay is included in the relay box. •...
  • Page 182: Ecu

    3-96 FUEL SYSTEM (DFI) CAUTION Never drop the ECU, especially on a hard surface. Such a shock to the ECU can damage it. 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.
  • Page 183: Ecu Installation

    FUEL SYSTEM (DFI) 3-97 ECU Installation • Install: ECU [A] (In rubber protector [B]) ECU Lead Connectors • Insert the projections [A] of the rear fender front into the slits of the rubber protector. ECU Power Supply Inspection • Visually inspect the terminals [A] of the ECU connectors. If the connector is clogged with mud or dust, blow it off with compressed air.
  • Page 184 3-98 FUEL SYSTEM (DFI) • Check the ECU power source voltage with a tester [A]. ○ Position the terminal in accordance with terminal numbers of ECU connectors [B] in this chapter figure. Battery [C] ECU Power Source Inspection Tester Connections: between 24 (BR) Terminal and Battery (–) Terminal between 47 (Y/BK) Terminal and...
  • Page 185: Dfi Power Source

    FUEL SYSTEM (DFI) 3-99 DFI Power Source ECU Fuse Removal • Refer to the Electrical System chapter for the ECU fuse removal. ECU Fuse Installation If a fuse fails during operation, inspect the DFI system to determine the cause, and then replace it with a new fuse of proper amperage.
  • Page 186: Fi Indicator Led Light

    3-100 FUEL SYSTEM (DFI) FI Indicator LED Light LED Light Inspection • Remove the meter unit (see Electrical System chapter). • Using two auxiliary leads, supply battery power to the FI indicator LED light [A]. 12 V Battery [B] FI Indicator LED Light Check Connector: Meter Connector [C] (disconnected) Connection:...
  • Page 187: Fuel Line

    FUEL SYSTEM (DFI) 3-101 Fuel Line Fuel Pressure Inspection NOTE ○ Be sure the battery is fully charged. • Remove: Seats (see Frame chapter) Fuel Tank Bolts (see Fuel Tank Removal) • Be sure to place a piece of cloth around the fuel supply pipe of the throttle body assembly and fuel pump.
  • Page 188: Fuel Flow Rate Inspection

    3-102 FUEL SYSTEM (DFI) Fuel Line Fuel Pressure (idling) Standard: 304 kPa (3.1 kgf/cm², 44 psi) NOTE ○ The gauge hand will fluctuate. Read the pressure at the average of the maximum and minimum indications. If the fuel pressure is much higher than the specified, re- place the fuel pump.
  • Page 189 FUEL SYSTEM (DFI) 3-103 Fuel Line • Connect the prepared fuel hose [A] to the fuel supply pipe of the fuel pump. • Secure the fuel hose with a clamp. • Insert the fuel hose into the measuring cylinder [B]. WARNING Wipe off spilled out fuel immediately.
  • Page 190: Fuel Pump

    3-104 FUEL SYSTEM (DFI) Fuel Pump Fuel Pump Removal CAUTION Never drop the fuel pump, especially on a hard sur- face. Such a shock to the pump can damage it. WARNING Gasoline is extremely flammable and can be explo- sive under certain conditions. Make sure the area is well-ventilated and free from any source of flame or sparks;...
  • Page 191: Operation Inspection

    FUEL SYSTEM (DFI) 3-105 Fuel Pump • Check that the fuel pump terminals [A], fuel reserve switch terminal [B] and band [C] are in place. [D] Front • Apply a non-permanent locking agent to the threads of the fuel pump bolts. •...
  • Page 192 3-106 FUEL SYSTEM (DFI) Fuel Pump 1. Joint Connector 4 2. Joint Connector 1 3. Ignition Switch 4. Engine Stop Switch 5. ECU 6. ECU Fuse 15 A 7. Ignition Fuse 10 A 8. ECU Main Relay 9. Fuel Pump Relay 10.
  • Page 193: Throttle Grip And Cables

    FUEL SYSTEM (DFI) 3-107 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 194: Throttle Body Assy

    3-108 FUEL SYSTEM (DFI) Throttle Body Assy Idle Speed Inspection • Refer to the Idle Speed Inspection in the Periodic Main- tenance chapter . Throttle Bore Cleaning • Check the throttle bore for cleanliness as follows: ○ Remove: Throttle Body (see Fuel System (DFI) chapter) ○...
  • Page 195: Throttle Body Assy Installation

    FUEL SYSTEM (DFI) 3-109 Throttle Body Assy • Remove: Vacuum Switch Valve Vacuum Hose [A] Four Connectors [B] Vacuum Hose (California Model) • Remove: Middle Fairings (see Frame chapter) • Loosen: Clamp Bolts [A] (both side) • Remove the throttle body assembly with cables from holder.
  • Page 196: Throttle Body Assy Disassembly

    3-110 FUEL SYSTEM (DFI) Throttle Body Assy Throttle Body Assy Disassembly 1. Subthrottle Valve Actuator 2. Subthrottle Valve 3. Main Throttle Valve 4. Throttle Body Assy 5. Injector 6. Delivery Pipe Assy 7. Injector Connector Harness 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...
  • Page 197: Throttle Body Assy Assembly

    FUEL SYSTEM (DFI) 3-111 Throttle Body Assy • Pull out the injectors [A] from the delivery pipe [B]. NOTE ○ Do not damage the part of insert of the injectors when they are pulled out from the delivery pipe. Throttle Body Assy Assembly •...
  • Page 198: Air Line

    3-112 FUEL SYSTEM (DFI) Air Line Element Removal • Refer to the Air Cleaner Element Replacement in the Pe- riodic Maintenance chapter. Element Installation • Refer to the Air Cleaner Element Replacement in the Pe- riodic Maintenance chapter. Air Cleaner Element Inspection •...
  • Page 199: Air Cleaner Housing Installation

    FUEL SYSTEM (DFI) 3-113 Air Line • Turn the air cleaner housing [A] counterclockwise [B] and remove it. Air Cleaner Housing Installation • Confirm the air ducts [A] fit in the frame [B]. • Insert the air cleaner housing [C] inside the frame as shown.
  • Page 200: Air Cleaner Housing Disassembly

    3-114 FUEL SYSTEM (DFI) Air Line Air Cleaner Housing Disassembly • Remove: Air Cleaner Housing (Air Cleaner Housing Removal) Air Cleaner Housing Screws [A] Lower Housing [B] Duct Holder Screws [C] Ducts and Duct Holders Filter Air Cleaner Housing Assembly •...
  • Page 201: Air Inlet Duct Removal

    FUEL SYSTEM (DFI) 3-115 Air Line Air Inlet Duct Removal • Remove: Upper Fairing (see Frame chapter) Mounting Bolts [A] Air Inlet Duct [B] Air Inlet Duct Installation • Tighten: Torque - Air Inlet Duct Mounting Bolts: 7.0 N·m (0.70 kgf·m, 62 in·lb)
  • Page 202: Fuel Tank

    3-116 FUEL SYSTEM (DFI) 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 203 FUEL SYSTEM (DFI) 3-117 Fuel Tank • Disconnect the fuel pump lead connector [A]. • Be sure to place a piece of cloth [A] around the fuel hose joint [B]. • Push [C] the joint lock claws [D]. • Pull [A] the joint lock [B] as shown. •...
  • Page 204: Fuel Tank Installation

    3-118 FUEL SYSTEM (DFI) Fuel Tank Fuel Tank Installation • Note the above WARNING (see Fuel Tank Removal). • Route the hoses correctly (see Appendix chapter). • Check that the dampers [A] and pad [B] are in place on the fuel tank as well. If the dampers are damaged or deteriorated, replace them.
  • Page 205: Fuel Tank And Cap Inspection

    FUEL SYSTEM (DFI) 3-119 Fuel Tank Fuel Tank and Cap Inspection • Visually inspect the gasket [A] on the tank cap for any damage. Replace the gasket if it is damaged. • Check to see if the water drain pipe [B] and fuel breather pipe [C] (California model) in the tank are not clogged.
  • Page 206: Evaporative Emission Control System

    3-120 FUEL SYSTEM (DFI) Evaporative Emission Control System 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 207: Separator Operation Test

    FUEL SYSTEM (DFI) 3-121 Evaporative Emission Control System Separator Operation Test WARNING Gasoline is extremely flammable and can be ex- plosive under certain conditions. Turn the ignition switch OFF. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks;...
  • Page 209 COOLING SYSTEM 4-1 Cooling System Table of Contents Exploded View........................Coolant Flow Chart......................... Specifications ......................... Coolant ........................... Coolant Deterioration Inspection..................Coolant Level Inspection....................Coolant Draining ....................... Coolant Filling ........................Pressure Testing ....................... Cooling System Flushing ....................Coolant Reserve Tank Removal/Installation ..............Water Pump..........................
  • Page 210: Exploded View

    4-2 COOLING SYSTEM Exploded View...
  • Page 211 COOLING SYSTEM 4-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Water Hose Clamp Screws 0.20 17 in·lb Coolant Drain Plug (Water Pump) 87 in·lb Coolant Drain Plug (Cylinder) 87 in·lb Coolant Drain Plug (Lower Crankcase) 87 in·lb Water Pump Cover Bolts 87 in·lb Oil Cooler Mounting Bolts Water Passage Plugs...
  • Page 212: Coolant Flow Chart

    4-4 COOLING SYSTEM Coolant Flow Chart...
  • Page 213 COOLING SYSTEM 4-5 Coolant Flow Chart Permanent type antifreeze is used as a coolant to protect the cooling system from rust and corrosion. When the engine starts, the water pump turns and the coolant circulates. The thermostat is a wax pellet type which opens or closes with coolant temperature changes. The thermostat continuously changes its valve opening to keep the coolant temperature at the proper level.
  • Page 214: Specifications

    4-6 COOLING SYSTEM Specifications Item Standard Coolant Provided when Shipping Type (Recommended) Permanent type of antifreeze (soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators) Color Green Mixed Ratio Soft water 50%, coolant 50% Freezing Point –...
  • Page 215: Coolant

    COOLING SYSTEM 4-7 Coolant Coolant Deterioration Inspection • Visually inspect the coolant 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. In either case, flush the cooling system.
  • Page 216: Cooling System Flushing

    4-8 COOLING SYSTEM 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 217: Water Pump

    COOLING SYSTEM 4-9 Water Pump Water Pump Removal • Drain: Coolant (see Coolant Change in the Periodic Mainte- nance chapter) Engine Oil (see Engine Oil Change in the Periodic Main- tenance chapter) • Remove: Water Hoses [A] • Remove: Water Pump Cover Bolts [A] Water Pump Cover [B] •...
  • Page 218: Water Pump Impeller Inspection

    4-10 COOLING SYSTEM Water Pump • Install the water pump cover [A]. • Tighten: Torque - Water Pump Cover Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) • Install the water hoses [B] as shown. Water Pump Impeller Inspection • Visually inspect the water pump impeller [A]. If the surface is corroded or if the blades are damaged, replace the water pump assy.
  • Page 219: Radiator

    COOLING SYSTEM 4-11 Radiator Radiator and Radiator Fan Removal • Remove: Upper Fairing (see Frame chapter) Coolant (Drain, see Coolant Change in the Periodic Maintenance chapter) Radiator Hoses [A] • Remove: Radiator Upper Bolt [A] • Remove: Radiator Lower Bolt [A] Radiator Fan Lead Connector [B] Radiator Hose [C] •...
  • Page 220: Radiator And Radiator Fan Installation

    4-12 COOLING SYSTEM Radiator Radiator and Radiator Fan Installation • Install the radiator in the projection [A] as shown. • Install the radiator bracket collar [A] as shown. Rubber Damper [B] Radiator [C] • Tighten: Torque - Radiator Lower Bolt [D]: 7.0 N·m (0.70 kgf·m, 61 in·lb) Radiator Upper Bolt [E]: 7.0 N·m (0.70 kgf·m, 61 in·lb)
  • Page 221: Radiator Inspection

    COOLING SYSTEM 4-13 Radiator Radiator Inspection • Check the radiator core. If there are obstructions to air flow, remove them. If the corrugated fins [A] are deformed, carefully straighten them. If the air passages of the radiator core are blocked more than 20% by unremovable obstructions or irreparably de- formed fins, replace the radiator with a new one.
  • Page 222: Radiator Filler Neck Inspection

    4-14 COOLING SYSTEM Radiator Radiator Filler Neck Inspection • Remove the upper fairing (see Frame chapter). • Remove the radiator cap. • Check the radiator filler neck for signs of damage. • Check the condition of the top and bottom sealing seats [A] in the filler neck.
  • Page 223: Thermostat

    COOLING SYSTEM 4-15 Thermostat Thermostat Removal • Drain the coolant (see Coolant Change in the Periodic Maintenance chapter). • Remove: Fuel Tank (see Fuel System (DFI) chapter) Air Cleaner Housing (see Fuel System (DFI) chapter) Throttle Body Assy (see Fuel System (DFI) chapter) Thermostat Housing Mounting Bolts [A] Water Hoses [B] •...
  • Page 224 4-16 COOLING SYSTEM Thermostat • To check valve opening temperature, suspend the ther- mostat [A] in a container of water and raise the tempera- ture of the water. ○ The thermostat must be completely submerged and must not touch the container sides or bottom. Suspend an ac- curate thermometer [B] in the water so that the heat sen- sitive portions [C] are located in almost the same depth.
  • Page 225: Hoses And Pipes

    COOLING SYSTEM 4-17 Hoses 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 in accordance with the Cable, Wire, and Hose Routing section in the Appendix chapter. •...
  • Page 226: 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 their parts can damage them. Water Temperature Sensor Removal • Refer to the Water Temperature Sensor Removal in the Fuel System (DFI) chapter.
  • Page 227 ENGINE TOP END 5-1 Engine Top End Table of Contents Exploded View........Camshaft Chain Installation ..5-17 Specifications ........Cylinder Head........5-18 Special Tools ........Cylinder Compression Clean Air System....... Measurement ......5-18 Air Suction Valve Removal... Cylinder Head Removal ....5-19 Air Suction Valve Installation..
  • Page 228: Exploded View

    5-2 ENGINE TOP END Exploded View...
  • Page 229 M: Apply molybdenum disulfide grease. MO: Apply molybdenum disulfide oil. (mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 : 1) R: Replacement Parts S: Follow the specific tightening sequence. SS: Apply silicone sealant (Kawasaki Bond: 56019-120).
  • Page 230 5-4 ENGINE TOP END Exploded View...
  • Page 231 ENGINE TOP END 5-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Coolant Drain Plug (Cylinder) 87 in·lb Exhaust Pipe Manifold Holder Nuts Muffler Body Clamp Bolt Muffler Body Mounting Bolts Crankshaft Sensor Cover Bolts 87 in·lb Muffler Body Assembly Nuts Exhaust Butterfly Valve Cable Locknuts 0.71 62 in·lb...
  • Page 232: Specifications

    5-6 ENGINE TOP END Specifications Item Standard Service Limit Camshafts Cam Height: 34.942 ∼ 35.058 mm (1.3757 ∼ 1.3802 in.) Exhaust 34.84 mm (1.372 in.) 35.342 ∼ 35.458 mm (1.3914 ∼ 1.3960 in.) Inlet 35.24 mm (1.387 in.) 0.038 ∼ 0.081 mm (0.0015 ∼ 0.0032 in.) Camshaft Journal, Camshaft 0.17 mm (0.0067 in.) Cap Clearance...
  • Page 233: Special Tools

    ENGINE TOP END 5-7 Special Tools Compression Gauge, 20 kgf/cm²: Valve Seat Cutter Holder Bar: 57001-221 57001-1128 Valve Spring Compressor Assembly: Valve Seat Cutter, 32° - 33: 57001-241 57001-1199 Valve Seat Cutter, 45° - 27.5: Fork Oil Level Gauge: 57001-1114 57001-1290 Valve Seat Cutter, 45°...
  • Page 234 5-8 ENGINE TOP END Special Tools Valve Guide Arbor, 4.5: Valve Spring Compressor Adapter, 24: 57001-1331 57001-1586 Valve Guide Reamer, 4.5: Compression Gauge Adapter, M10 × 1.0: 57001-1333 57001-1601 Valve Seat Cutter, 60° - 33: L-Shape Hose: 57001-1334 57001-1606 Valve Guide Driver: Washer: 57001-1564 57001-1612...
  • Page 235: Clean Air System

    ENGINE TOP END 5-9 Clean Air System Air Suction Valve Removal • Remove: Fuel Tank (see Fuel System (DFI) chapter) Air Cleaner Housing (see Fuel System (DFI) chapter) • Separate the hoses [A] from the air suction valve cover. • Remove: Air Suction Valve Cover Bolts [B] Air Suction Valve Cover [C]...
  • Page 236: Clean Air System Hose Inspection

    5-10 ENGINE TOP END Clean Air System Clean Air System Hose Inspection • Be certain that all the hoses are routed without being flat- tened or kinked, and are connected correctly to the air cleaner housing, air switching valve and air suction valve covers.
  • Page 237: Cylinder Head Cover

    ENGINE TOP END 5-11 Cylinder Head Cover Cylinder Head Cover Removal • Remove: Upper Fairing (see Frame chapter) Fuel Tank (see Fuel System (DFI) chapter) Air Cleaner Housing (see Fuel System (DFI) chapter) Throttle Body Assembly (see Fuel System (DFI) chapter) Air Switching Valve [A] (see Air Switching Valve Re- moval) •...
  • Page 238 5-12 ENGINE TOP END Cylinder Head Cover • Install: Dowel Pins [A] Plug Hole Gaskets [B] • Install the washer [A] with the metal side faces upward. • Tighten the cover bolts. Torque - Cylinder Head Cover Bolts [B]: 9.8 N·m (1.0 kgf·m, 87 in·lb) •...
  • Page 239: Camshaft Chain Tensioner

    ENGINE TOP END 5-13 Camshaft Chain Tensioner Camshaft Chain Tensioner Removal CAUTION This is a non-return type camshaft chain tensioner. The push rod does not return to its original position once it moves out to take up camshaft chain slack. Observe all the rules listed below: When removing the tensioner, do not take out the mounting bolts only halfway.
  • Page 240: Camshaft, Camshaft Chain

    5-14 ENGINE TOP END Camshaft, Camshaft Chain Camshaft Removal • Remove: Cylinder Head Cover (see Cylinder Head Cover Re- moval) Crankshaft Sensor Cover • Position the crankshaft at #1, 4 piston TDC. TDC mark [A] for #1, 4 Pistons Timing Mark (crankcase halves mating surface) [B] •...
  • Page 241: Camshaft, Camshaft Cap Wear

    ENGINE TOP END 5-15 Camshaft, Camshaft Chain • Apply engine oil to all cam parts and journals. • If a new camshaft is to be used, apply a thin coat of molyb- denum disulfide grease to the cam surfaces. NOTE ○...
  • Page 242: Camshaft Runout

    5-16 ENGINE TOP END Camshaft, Camshaft Chain • Tighten: Torque - Camshaft Cap Bolts: 12 N·m (1.2 kgf·m, 104 in·lb) Camshaft Chain Guide Bolts: 12 N·m (1.2 kgf·m, 104 in·lb) (see Camshaft Installation) NOTE ○ Do not turn the camshaft when the plastigage is be- tween the journal and camshaft cap.
  • Page 243: Camshaft Chain Removal

    ENGINE TOP END 5-17 Camshaft, Camshaft Chain Camshaft Chain Removal • Remove: Camshafts (see Camshaft Removal) Timing Rotor (see Electrical System chapter) Crankshaft Sensor [A] (see Electrical System chapter) Lower Front Camshaft Chain Guide Bolt [B] • Remove the upper front camshaft chain guide bolt [A]. •...
  • Page 244: Cylinder Head

    5-18 ENGINE TOP END Cylinder Head Cylinder Compression Measurement NOTE ○ Use the battery which is fully charged. • Warm up the engine thoroughly. • Stop the engine. • Remove: Fuel Tank (see Fuel System (DFI) chapter) Air Cleaner Housing (see Fuel System (DFI) chapter) Stick Coils (see Electrical System chapter) Spark Plugs (see Electrical System chapter) Owner’s Tool - Spark Plug Wrench: 92110-1132...
  • Page 245: Cylinder Head Removal

    ENGINE TOP END 5-19 Cylinder Head Cylinder Head Removal • Drain the coolant (see Coolant Change in the Periodic Maintenance chapter). • Remove: Fuel Tank (see Fuel System (DFI) chapter) Air Cleaner Housing (see Fuel System (DFI) chapter) Throttle Body Assembly (see Fuel System (DFI) chapter) Exhaust Pipe (see Exhaust Pipe Removal) Cylinder Head Cover (see Cylinder Head Cover Re- moval)
  • Page 246: Cylinder Head Warp

    5-20 ENGINE TOP END Cylinder Head • Install: Front Camshaft Chain Guide [A] O-ring [B] Collar [C] Washer [D] • Tighten: Torque - Front Camshaft Chain Guide Bolt (Upper) [E]: 25 N·m (2.5 kgf·m, 18 ft·lb) Front Camshaft Chain Guide Bolt (Lower) [F]: 12 N·m (1.2 kgf·m, 104 in·lb) •...
  • Page 247: Valves

    ENGINE TOP END 5-21 Valves Valve Clearance Inspection • Refer to the Valve Clearance Inspection in the Periodic Maintenance chapter. Valve Removal • Remove the cylinder head (see Cylinder Head Removal). • Remove the valve lifter and shim. ○ Mark and record the valve lifter and shim locations so they can be installed in their original positions.
  • Page 248: Valve Guide Installation

    5-22 ENGINE TOP END Valves Valve Guide Installation • Apply oil to the valve guide outer surface before installa- tion. • Heat the area around the valve guide hole to about 120 ∼ 150°C (248 ∼ 302°F). CAUTION Do not heat the cylinder head with a torch. This Will warp the cylinder head.
  • Page 249: Valve Seat Inspection

    ENGINE TOP END 5-23 Valves NOTE ○ The reading is not actual valve/valve guide clearance because the measuring point is above the guide. Valve/Valve Guide Clearance (Wobble Method) Standard: 0.05 ∼ 0.13 mm (0.0020 ∼ 0.0051 in.) Exhaust 0.03 ∼ 0.11 mm (0.0012 ∼ 0.0043 in.) Inlet Service Limit: Exhaust...
  • Page 250 5-24 ENGINE TOP END 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 251 ENGINE TOP END 5-25 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 252 5-26 ENGINE TOP END 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 253 ENGINE TOP END 5-27 Valves...
  • Page 254: Throttle Body Holder

    5-28 ENGINE TOP END Throttle Body Holder Throttle Body Holder Installation • Be sure to install the O-rings [A]. • Install the clamps [B] as shown. • Tighten the holder bolts following the tightening sequence [1 ∼ 3]. Torque - Throttle Body Holder Bolts [C]: 9.8 N·m (1.0 kgf·m, 87 in·lb) Throttle Body Assy Holder Clamp Bolts [D]: 2.0 N·m (0.20 kgf·m, 17 in·lb)
  • Page 255: Muffler

    ENGINE TOP END 5-29 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/Installation • Remove: Muffler Body Assembly Nuts [A] Muffler Body Mounting Bolt [B] •...
  • Page 256 5-30 ENGINE TOP END Muffler • Remove the clamp [A]. • Remove the exhaust butterfly valve cable upper ends [B] from the pulley [C]. • Remove the exhaust pipe manifold holder nuts [A]. • Remove the muffler body mounting bolts [A]. •...
  • Page 257: Exhaust Pipe Installation

    ENGINE TOP END 5-31 Muffler • Remove the cover bolts [A] and cover [B]. • Loosen the locknuts [A]. • Remove the exhaust butterfly valve cable lower ends [B] from the pulley. • Remove the muffler body clamp bolt. • Remove the muffler body (see Muffler Body Removal).
  • Page 258 5-32 ENGINE TOP END Muffler • Install the exhaust butterfly valve cable lower ends to the pulley of exhaust pipe. Open Cable (Yellow) [A] Close Cable (Dark Green) [B] 6 mm (0.24 in.) [C] about 45° [D] • Tighten: Torque - Exhaust Butterfly Valve Cable Locknuts [E]: 7.0 N·m (0.71 kgf·m, 62 in·lb)
  • Page 259: Exhaust Butterfly Valve Cable Removal

    ENGINE TOP END 5-33 Muffler • Install the exhaust butterfly valve cover. • Tighten: Torque - Exhaust Butterfly Valve Cover Bolts [A]: 8.8 N·m (0.90 kgf·m, 78 in·lb) • Install the muffler assy to the chassis. • Tighten: Torque - Exhaust Pipe Manifold Holder Nuts: 17 N·m (1.7 kgf·m, 12 ft·lb) Muffler Body mounting Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb)
  • Page 260 5-34 ENGINE TOP END Muffler • Remove the clamps [A]. • Remove the cover bolts [A] and cover [B]. • Loosen the locknuts [A]. • Remove the exhaust butterfly valve cable lower ends [B] from the pulley. • Remove the exhaust butterfly valve cable.
  • Page 261: Exhaust Butterfly Valve Cable Installation

    ENGINE TOP END 5-35 Muffler Exhaust Butterfly Valve Cable Installation • Install the exhaust butterfly valve cable lower ends to the pulley of exhaust pipe. Open Cable (Yellow) [A] Close Cable (Dark Gree