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Ninja ZX-6RR
Motorcycle
Service Manual

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Table of Contents

   Summary of Contents for Kawasaki ninja zx-6rr

  • Page 1 Ninja ZX-6RR 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 rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Quality Division/Consumer Products & Machinery Company/Kawasaki Heavy Industries, Ltd., Japan.
  • 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......................Unit Conversion Table ......................1-12...
  • Page 12: Before Servicing

    1-2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly opera- tion on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustra- tions, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary.
  • Page 13 Replacement Parts Replacement Parts must be KAWASAKI genuine or recommended by KAWASAKI. Gaskets, O-rings, oil seals, grease seals, circlips 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 ZX600-N1 (Europe) Left Side View ZX600-N1 (Europe) Right Side View...
  • Page 18 1-8 GENERAL INFORMATION Model Identification ZX600-N1 (US and Canada) Left Side View ZX600-N1 (US and Canada) Right Side View...
  • Page 19: General Specifications

    GENERAL INFORMATION 1-9 General Specifications Items ZX600-N1, N6F Dimensions Overall Length 2 075 mm (81.7 in.) Overall Width 715 mm (28.1 in.) Overall Height 1 120 mm (44.1 in.) Wheelbase 1 400 mm (55.1 in.) Road Clearance 120 mm (4.7 in.) Seat Height 820 mm (32.3 in.) Dry Mass...
  • Page 20 1-10 GENERAL INFORMATION General Specifications Items ZX600-N1, N6F Duration 264° Lubrication System Forced lubrication (wet sump with cooler) Engine Oil: Type API SE, SF or SG API SH or SJ with JASO MA Viscosity SAE10W-40 Capacity 4.0 L (4.2 US qt) Drive Train Primary Reduction System: Type...
  • Page 21 GENERAL INFORMATION 1-11 General Specifications Items ZX600-N1, N6F Brake Type: Front Dual discs Rear Single disc Electrical Equipment Battery 12 V 8 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:...
  • Page 22: Unit Conversion Table

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

    PERIODIC MAINTENANCE 2-1 Periodic Maintenance Table of Contents Periodic Maintenance Chart (United Chain Guide Wear Inspection ..2-35 States, Canada Models) ....Brakes..........2-35 Periodic Maintenance Chart (Other Brake Fluid Leak (Brake Hose than United States, Canada Model) and Pipe) Inspection ....2-35 Torque and Locking Agent....
  • Page 24 2-2 PERIODIC MAINTENANCE Engine Oil Change....... 2-53 Master Cylinder Rubber Parts Oil Filter Replacement ....2-53 Replacement ......2-56 Brake Hose and Pipe Caliper Rubber Parts Replacement ......2-54 Replacement ......2-57 Brake Fluid Change ..... 2-54 Spark Plug Replacement ..... 2-60...
  • Page 25: Periodic Maintenance Chart (united States, Canada Models)

    PERIODIC MAINTENANCE 2-3 Periodic Maintenance Chart (United States, Canada Models) 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 26: Periodic Maintenance Chart

    2-4 PERIODIC MAINTENANCE Periodic Maintenance Chart (United States, Canada Models) FREQUENCY Whichever * ODOMETER READING comes × 1 000 km first (× 1 000 mile) Page ITEM Every (0.6) (4) (7.5) (12) (15) (20) (24) • • • • • • Brake pad wear-inspect # 2-36 •...
  • Page 27 PERIODIC MAINTENANCE 2-5 Periodic Maintenance Chart (United States, Canada Models) Periodic Replacement Parts FREQUENCY Whichever * ODOMETER READING come × 1 000 km first (× 1 000 mile) Page ITEM Every (0.6) (7.5) (15) (24) (30) Air cleaner element - replace# Every 18 000 km (12 000 mile) 2-49 •...
  • Page 28 2-6 PERIODIC MAINTENANCE Periodic Maintenance Chart (Other than United States, Canada Model) 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...
  • Page 29 PERIODIC MAINTENANCE 2-7 Periodic Maintenance Chart (Other than United States, Canada Model) FREQUENCY Whichever * ODOMETER READING comes × 1 000 km first (× 1 000 mile) Page ITEM Every (0.6) (4) (7.5) (12) (15) (20) (24) • • • • • • • Brake fluid level-inspect 6 months 2-36...
  • Page 30 2-8 PERIODIC MAINTENANCE Periodic Maintenance Chart (Other than United States, Canada Model) Periodic Replacement Parts FREQUENCY Whichever * ODOMETER READING come × 1 000 km first (× 1 000 mile) Page ITEM Every (0.6) (7.5) (15) (24) (30) 2-49 Air cleaner element - replace# Every 18 000 km (12 000 mile) •...
  • Page 31: Torque And Locking Agent

    PERIODIC MAINTENANCE 2-9 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. G: Apply grease.
  • Page 32 2-10 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Water Hose Clamp Screws 0.20 17 in·lb Water Hose Fitting Bolts 104 in·lb Water Pump Cover Bolts 104 in·lb Water Temperature Sensor Engine Top End Air Suction Valve Cover Bolts 104 in·lb Camshaft Cap Bolts 104 in·lb...
  • Page 33 PERIODIC MAINTENANCE 2-11 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Sub Clutch Hub Bolts Engine Lubrication System Coolant Drain Bolt (Water Pump) 0.90 78 in·lb Engine Oil Drain Bolt Impeller Bolt 87 in·lb Oil Cooler Mounting Bolts 104 in·lb Oil Filter EO, R...
  • Page 34 2-12 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Oil Pressure Switch Oil Jet Nozzle Bolts 0.70 61 in·lb Oil Pressure Switch Terminal Bolt 0.15 13 in·lb Plate Screws 0.60 52 in·lb Shift Drum Bearing Holder Bolts 104 in·lb Shift Drum Cam Holder Bolt 104 in·lb...
  • Page 35 PERIODIC MAINTENANCE 2-13 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Front Fork Top Plugs Piston Rod Nuts Rear Shock Absorber Bracket Nut Rear Shock Absorber Nut (Lower) Rear Shock Absorber Nut (Upper) Swingarm Pivot Adjusting Collar Swingarm Pivot Adjusting Collar Locknut Swingarm Pivot Shaft Nut Tie-Rod Nuts Uni-Trak Rocker Arm Nut...
  • Page 36 2-14 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Meter Mounting Screws 0.12 10 in·lb Neutral Switch Rear Turn Signal Light Lens Screws 0.10 9 in·lb Rear Turn Signal Light Mounting Screws 0.12 10 in·lb Regulator/Rectifier Bolts 0.70 61 in·lb Side Stand Switch Bolt...
  • Page 37: Specifications

    PERIODIC MAINTENANCE 2-15 Specifications Item Standard Service Limit Fuel System (DFI) 2 ∼ 3 mm (0.08 ∼ 0.12 in.) – – – Throttle Grip Free Play Idle Speed 1 300 ±50 r/min (rpm) – – – Throttle Body Vacuum 27.3 ±1.3 kPa (205 ±10 mmHg) at idle speed –...
  • Page 38 2-16 PERIODIC MAINTENANCE Specifications Item Standard Service Limit Final Drive 30 ∼ 35 mm (1.2 ∼ 1.4 in.) Drive Chain Slack – – – 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) Drive Chain Wear (20-link 323 mm (12.7 in.) Length) Standard Chain: Make...
  • Page 39: Special Tools

    PERIODIC MAINTENANCE 2-17 Special Tools Inside Circlip Pliers: Pilot Screw Adjuster, C: 57001-143 57001-1292 Steering Stem Nut Wrench: Extension Tube: 57001-1100 57001-1578 Jack: Jack Attachment: 57001-1238 57001-1608 Oil Filter Wrench: 57001-1249...
  • Page 40: Maintenance Procedure

    2-18 PERIODIC MAINTENANCE Maintenance Procedure Fuel System (DFI) Throttle Control System Inspection • Check the throttle grip free play [A]. If the free play is incorrect, adjust the throttle cables. Throttle Grip Free Play Standard: 2 ∼ 3 mm (0.08 ∼ 0.12 in.) •...
  • Page 41 PERIODIC MAINTENANCE 2-19 Maintenance Procedure • Connect a commercially available vacuum gauge [A] to these right fittings of the throttle body as shown. Front [B] • Connect a highly accurate tachometer to one of the stick coil primary leads. • Plug: Vacuum Switch Valve Hose (Thick) and its Air Cleaner Housing Hole...
  • Page 42 2-20 PERIODIC MAINTENANCE Maintenance Procedure NOTE ○ After adjustment, the final vacuum measurement be- tween the lowest throttle valves may not be 165 mmHg (in this example). The goal is to have the lower two vac- uums between the left (#1 and #2) and right (#3 and #4) banks be the same.
  • Page 43: Idle Speed Inspection

    PERIODIC MAINTENANCE 2-21 Maintenance Procedure • Repeat the same procedure for other bypass screws. • Repeat the synchronization. If the vacuums are correct, check the output voltage of the main throttle sensor (see Output Voltage Inspection of the Main Throttle Sensor in the Fuel System (DFI) chapter). Main Throttle Sensor Output Voltage Connections to ECU Meter (+) →...
  • Page 44: Idle Speed Adjustment

    2-22 PERIODIC MAINTENANCE Maintenance Procedure 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: Cooling System

    PERIODIC MAINTENANCE 2-23 Maintenance Procedure • Check the liquid/vapor separator as follows. ○ Remove: Left Center Fairing (see Center Fairing Removal in the Frame chapter) ○ Disconnect the hoses from the separator, and remove the separator [A] from the motorcycle left side. ○...
  • Page 46: Water Hose Damage And Installation Condition Inspection

    2-24 PERIODIC MAINTENANCE Maintenance Procedure Water Hose Damage and Installation Condition Inspection ○ The high pressure inside of the water hose can cause coolant to leak [A] or the hose to burst if the line is not properly maintained. Visually inspect the hoses for signs of deterioration.
  • Page 47: Valve Clearance Adjustment

    PERIODIC MAINTENANCE 2-25 Maintenance Procedure 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 #1 piston TDC at the end of the compression stroke.
  • Page 48 2-26 PERIODIC MAINTENANCE Maintenance Procedure • Clean the shim to remove any dust or oil. • Measure the thickness of the removed shim [A]. • Select a new shim thickness calculation as follows. a + b – c = d [a] Present Shim Thickness [b] Measured Valve Clearance [c] Specified Valve Clearance (Mean Value = 0.195)
  • Page 49 PERIODIC MAINTENANCE 2-27 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 50: Air Suction System Damage Inspection

    2-28 PERIODIC MAINTENANCE 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 51: Wheels/tires

    PERIODIC MAINTENANCE 2-29 Maintenance Procedure WARNING To avoid a serious burn, never touch the engine or exhaust pipe during clutch adjustment. • Turn the adjuster [A] so that 4 ∼ 6 mm (0.16 ∼ 0.24 in.) [B] of threads is visible. •...
  • Page 52: Wheel/tire Damage Inspection

    2-30 PERIODIC MAINTENANCE Maintenance Procedure Wheel/Tire Damage Inspection • Visually inspect the tire for cracks [A] and cuts [B], and re- place the tire if necessary. Swelling or high spots indicate internal damage, requiring tire replacement. • Remove any imbedded stones [C], nail [D] or other foreign particles from the tread.
  • Page 53: Wheel Bearing Damage Inspection

    PERIODIC MAINTENANCE 2-31 Maintenance Procedure WARNING To ensure safe handling and stability, use only the recommended standard tires for replacement, in- flated to the standard pressure. NOTE ○ Most countries may have their own regulations a mini- mum tire tread depth: be sure to follow them. ○...
  • Page 54: Drive Chain Slack Inspection

    2-32 PERIODIC MAINTENANCE Maintenance Procedure CAUTION The O-rings between the side plates seal in the lu- bricant between the pin and the bushing. To avoid damaging the O-rings and resultant loss of lubri- cant, observe the following rules. Use only kerosene or diesel oil for cleaning of the O-ring of the drive chain.
  • Page 55: Drive Chain Slack Adjustment

    PERIODIC MAINTENANCE 2-33 Maintenance Procedure Drive Chain Slack Adjustment • Remove the cotter pin [A], and loosen the axle nut [B]. • Loosen the both chain adjuster locknuts [C]. If the chain is too loose, turn out the left and right chain adjuster [D] evenly.
  • Page 56: Wheel Alignment Inspection

    2-34 PERIODIC MAINTENANCE Maintenance Procedure Wheel Alignment Inspection • Check that the notch [A] on the left alignment indicator [B] aligns with the same swingarm mark or position [C] that the right alignment indicator notch aligns with. If they do not, adjust the chain slack and align the wheel alignment (see Drive Chain Slack Adjustment).
  • Page 57: Chain Guide Wear Inspection

    PERIODIC MAINTENANCE 2-35 Maintenance Procedure Chain Guide Wear Inspection • Remove: Swingarm (see Swingarm Removal in the Suspension chapter) • Visually inspect the chain guide [A]. Replace the chain guide if it shows any signs of abnormal wear or damage. Brakes Brake Fluid Leak (Brake Hose and Pipe) Inspection •...
  • Page 58: Brake Fluid Level Inspection

    2-36 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 59: Brake Light Switch Operation Inspection

    PERIODIC MAINTENANCE 2-37 Maintenance Procedure 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.) of travel. If it does not, adjust the brake light switch.
  • Page 60: Front Fork Oil Leak Inspection

    2-38 PERIODIC MAINTENANCE Maintenance Procedure • 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 or shock absorber clamps (see Rear Shock Absorber Oil Leak Inspection).
  • Page 61: Steering

    PERIODIC MAINTENANCE 2-39 Maintenance Procedure Steering Steering Play Inspection • Remove the lower fairings (see Lower Fairing Removal in the Frame chapter). • Lift the front wheel off the ground using the jack. Special Tools - Jack: 57001-1238 Jack Attachment: 57001-1608 •...
  • Page 62: Steering Stem Bearing Lubrication

    2-40 PERIODIC MAINTENANCE Maintenance Procedure • Install the claw washer [A] so that its bent side [B] faces upward, and engage the bent claws with the grooves of steering stem locknut [C]. • Hand tighten the stem locknut until it touches the claw washer.
  • Page 63: Lights And Switches Operation Inspection

    PERIODIC MAINTENANCE 2-41 Maintenance Procedure • Measure the gap [A] with a wire-type thickness gauge. If the gap is incorrect, carefully bend the side electrode [B] with a suitable tool to obtain the correct gap. Spark Plug Gap : 0.7 ∼ 0.8 mm (0.028 ∼ 0.031 in.) CAUTION Use only the recommended spark plugs (special marks...
  • Page 64 2-42 PERIODIC MAINTENANCE Maintenance Procedure Second Step • Turn the ignition switch to P (Park) position. • The city light, taillight and license plate light should go on. If the light does not go on, inspect or replace the following item.
  • Page 65: Headlight Aiming Inspection

    PERIODIC MAINTENANCE 2-43 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 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 66: Side Stand Switch Operation Inspection

    2-44 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 67: Engine Stop Switch Operation Inspection

    PERIODIC MAINTENANCE 2-45 Maintenance Procedure If the side stand 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 68: Others

    2-46 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 69: Bolts, Nuts And Fasteners Tightness Inspection

    PERIODIC MAINTENANCE 2-47 Maintenance Procedure 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 70: Replacement Parts

    Air Cleaner Element • Install a new element [A]. CAUTION Use only the recommended air cleaner element (Kawasaki part number 11013-0010). Using another air cleaner element will wear the engine prema- turely or lower the engine performance. NOTE ○ Be sure to install the fuel tank drain hose.
  • Page 71 PERIODIC MAINTENANCE 2-49 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 72: Coolant Change

    2-50 PERIODIC MAINTENANCE 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 73 PERIODIC MAINTENANCE 2-51 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 74: Radiator Hose And O-ring Replacement

    2-52 PERIODIC MAINTENANCE Maintenance Procedure Radiator Hose and O-ring Replacement • Drain the coolant (see Coolant Change). • Remove: Lower Fairings (see Lower Fairing Removal in the Frame chapter) Center Fairings (see Center Fairing Removal in the Frame chapter) Throttle Body Assy (see Throttle Body Assy Removal in the Fuel System (DFI) chapter) Thermostat Housing [A] Fitting [B] Hoses [C]...
  • Page 75: Engine Oil Change

    PERIODIC MAINTENANCE 2-53 Maintenance Procedure Engine Oil Change • Remove the lower fairings (see Lower Fairing Removal in the Frame chapter). • Situate the motorcycle so that it is vertical after warming up the engine. • Remove the engine oil drain bolt [A] to drain the oil. ○...
  • Page 76: Brake Hose And Pipe Replacement

    2-54 PERIODIC MAINTENANCE Maintenance Procedure Brake Hose and Pipe Replacement CAUTION Brake fluid quickly ruins painted plastic surfaces; any spilled fluid should be completely washed away immediately. • When removing the brake hose, take care not to spill the brake fluid on the painted or plastic parts. •...
  • Page 77 PERIODIC MAINTENANCE 2-55 Maintenance Procedure • Level the brake fluid reservoir. • Remove the reservoir cap. • Remove the rubber cap from the bleed valve [A] on the caliper. • Attach a clear plastic hose [B] to the bleed valve, and run the other end of the hose into a container.
  • Page 78: Master Cylinder Rubber Parts Replacement

    2-56 PERIODIC MAINTENANCE Maintenance Procedure 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 79: Caliper Rubber Parts Replacement

    PERIODIC MAINTENANCE 2-57 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. • Tighten the brake lever pivot bolt and the locknut. •...
  • Page 80 2-58 PERIODIC MAINTENANCE 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 81 PERIODIC MAINTENANCE 2-59 Maintenance Procedure Rear Caliper Disassembly • Remove the rear caliper (see Rear Caliper Removal in the Brakes chapter). • Remove the pads and pad spring (see Rear Brake Pad Removal in the Brakes chapter). • Using compressed air, remove the piston. ○...
  • Page 82: Spark Plug Replacement

    2-60 PERIODIC MAINTENANCE Maintenance Procedure • Apply brake fluid to the outside of the piston, and push it into the cylinder by hand. • Replace the shaft rubber 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 83 FUEL SYSTEM (DFI) 3-1 Fuel System (DFI) Table of Contents Exploded View........Water Temperature Sensor (Service Specifications ........3-10 Code 14) ......... 3-56 Special Tools and Sealant ....3-12 Water Temperature Sensor DFI Parts Location......3-14 Removal/Installation....3-56 DFI System........3-16 Water Temperature Sensor DFI Servicing Precautions ....
  • Page 84 3-2 FUEL SYSTEM (DFI) Subthrottle Sensor Input Voltage Fuel Injectors ........3-92 Inspection........3-69 Fuel Injector Audible Inspection... 3-92 Subthrottle Sensor Output Voltage Fuel Injector Signal Test....3-92 Inspection........3-70 Fuel Injector Resistance Subthrottle Sensor Resistance Inspection........3-93 Inspection........3-72 Fuel Injector Unit Test ....
  • Page 85: Exploded View

    FUEL SYSTEM (DFI) 3-3 Exploded View Dummy Page...
  • Page 86 3-4 FUEL SYSTEM (DFI) Exploded View...
  • Page 87 FUEL SYSTEM (DFI) 3-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Air Cleaner Housing Clamp Bolts 0.20 17 in·lb Air Cleaner Housing Mounting Bolt 0.70 62 in·lb Air Inlet Duct Mounting Bolts 0.70 62 in·lb 4. Air Cleaner Element 5.
  • Page 88 3-6 FUEL SYSTEM (DFI) Exploded View...
  • Page 89 FUEL SYSTEM (DFI) 3-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Delivery Pipe Mounting Screws (Nozzle Assy) 0.35 30 in·lb Delivery Pipe Mounting Screws (Throttle Body) 0.35 30 in·lb Fuel Hose Mounting Screw 0.50 43 in·lb Nozzle Assy Mounting Bolts 0.70 61 in·lb Throttle Body Assembly Holder Clamp Bolts...
  • Page 90 3-8 FUEL SYSTEM (DFI) Exploded View...
  • Page 91 FUEL SYSTEM (DFI) 3-9 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Camshaft Position Sensor Bolt 104 in·lb Canister Bracket Mounting Bolt (M6) 0.70 61 in·lb Canister Bracket Mounting Bolt (M5) 0.04 4 in·lb Crankshaft Sensor Bolts 0.60 52 in·lb Exhaust Butterfly Valve Actuator Mounting Bolts 0.70 61 in·lb...
  • Page 92: Specifications

    3-10 FUEL SYSTEM (DFI) Specifications Item Standard Digital Fuel Injection System Idle Speed 1 300 ±50 r/min (rpm) Throttle Assy: Type Oval type Bore 38 mm (1.5 in.) Throttle Body Vacuum 27.3 ±1.3 kPa (205 ±10 mmHg) Bypass Screws – – – ECU (Electronic Control Unit): Make Denso...
  • Page 93 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 with sensor arrow mark pointed up: 3.55 ∼ 4.45 V Output Voltage with sensor tilted 60 ∼ 70° or more: 0.65 ∼ 1.35 V Subthrottle Sensor: Non-adjustable and non-removal DC 4.75 ∼...
  • Page 94: Special Tools And Sealant

    3-12 FUEL SYSTEM (DFI) Special Tools and Sealant Oil Pressure Gauge, 5 kgf/cm Needle Adapter Set: 57001-125 57001-1457 Fork Oil Level Gauge: Throttle Sensor Setting Adapter: 57001-1290 57001-1538 Hand Tester: Sensor Harness Adapter: 57001-1394 57001-1561 Throttle Sensor Setting Adapter #1: Fuel Pressure Gauge Adapter: 57001-1400 57001-1593...
  • Page 95 FUEL SYSTEM (DFI) 3-13 Special Tools and Sealant Speed Sensor Measuring Adapter: Kawasaki Bond (Silicone Sealant): 57001-1635 56019-120...
  • Page 96: Dfi Parts Location

    3-14 FUEL SYSTEM (DFI) DFI Parts Location Subthrottle Sensor [A] Subthrottle Valve Actuator [B] Fuel Injectors (Primary) #1, #2, #3, #4 [C] Water Temperature Sensor [A] Main Throttle Sensor [B] Inlet Air Pressure Sensor [C] Stick Coils #1, #2, #3, #4 [D] Subthrottle Valve Actuator [E] Subthrottle Sensor [F] Atmospheric Pressure Sensor [G]...
  • Page 97 FUEL SYSTEM (DFI) 3-15 DFI Parts Location Camshaft Position Sensor [A] Crankshaft Sensor [B] Speed Sensor [A] Neutral Switch [A]...
  • Page 98: Dfi System

    3-16 FUEL SYSTEM (DFI) DFI System DFI System...
  • Page 99 FUEL SYSTEM (DFI) 3-17 DFI System 1. ECU (Electrical Control Unit) 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.
  • Page 100 3-18 FUEL SYSTEM (DFI) DFI System DFI System Wiring Diagram...
  • Page 101 FUEL SYSTEM (DFI) 3-19 DFI System Part Name 1. Engine Stop Switch 2. Starter Button 3. Water Temperature Sensor 4. Vehicle-down Sensor 5. Subthrottle Valve Actuator 6. Primary Fuel Injector #1 7. Primary Fuel Injector #2 8. Primary Fuel Injector #3 9.
  • Page 102 3-20 FUEL SYSTEM (DFI) DFI System Terminal Numbers of ECU Connectors Terminal Names 1. Subthrottle Valve Actuator Output Signal 2 31. Unused 2. Subthrottle Valve Actuator Output Signal 1 32. External Diagnosis System Signal 3. Exhaust Butterfly Valve Actuator (–) 33.
  • Page 103: Dfi Servicing Precautions

    FUEL SYSTEM (DFI) 3-21 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 104: Troubleshooting The Dfi System

    3-22 FUEL SYSTEM (DFI) Troubleshooting the DFI System Outline When an abnormality in the system occurs, the FI indi- cator light (LED) 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 105 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 106 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 107 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 108: 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 109 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 110 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 111: 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 112 3-30 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or possible Causes Actions 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 Side stand down and clutch lever pulled in gear not in neutral whether gear in neutral or not...
  • Page 113 FUEL SYSTEM (DFI) 3-31 DFI System Troubleshooting Guide Symptoms or possible Causes Actions 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 114 3-32 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions 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 115 FUEL SYSTEM (DFI) 3-33 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions 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 116: Poor Running Or No Power At High Speed

    3-34 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions 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 117 FUEL SYSTEM (DFI) 3-35 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions 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 118 3-36 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions Speed sensor trouble Inspect (see chapter 3). Throttle valves won’t fully open Inspect throttle cable and lever linkage (see chapter 3). Brake dragging Inspect caliper fluid seal damage or clogging of master cylinder relief and supply ports (see chapter 12).
  • Page 119: Self-diagnosis

    FUEL SYSTEM (DFI) 3-37 Self-Diagnosis Self-diagnosis Outline The self-diagnosis system has three 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 120: Service Code Clearing Procedures

    3-38 FUEL SYSTEM (DFI) Self-Diagnosis • To enter the self-diagnosis dealer mode 2 repeat opening [B] and grounding [A] the lead more than five times [F] within 2 seconds [C] after the lead is first grounded, and then keep it grounded continuously [D] for more than 2 seconds.
  • Page 121 FUEL SYSTEM (DFI) 3-39 Self-Diagnosis...
  • Page 122: Service Code Reading

    3-40 FUEL SYSTEM (DFI) Self-Diagnosis Service Code Reading ○ Service codes are shown by a series of long and short blinks of the FI indicator light (LED) as shown below. ○ Read 10th digit and unit digit as the FI indicator light (LED) blinks. ○...
  • Page 123 FUEL SYSTEM (DFI) 3-41 Self-Diagnosis Service FI Indicator Light (LED) Problems Codes Camshaft position sensor malfunction, wiring open or short Speed sensor malfunction Vehicle-down sensor malfunction, wiring open or short Subthrottle sensor malfunction, wiring open or short Exhaust butterfly valve sensor malfunction, wiring open or short Stick (Ignition) coil #1 malfunction, wiring open or short...
  • Page 124: Backups

    3-42 FUEL SYSTEM (DFI) Self-Diagnosis Backups ○ The ECU takes the following measures to prevent engine damage when the DFI or the ignition system parts have troubles. Service Output Signal Usable Parts Backups by ECU Codes Range or Criteria If the main throttle sensor system fails (the Main Throttle Sensor signal is out of the usable range, wiring short Main Throttle...
  • Page 125 FUEL SYSTEM (DFI) 3-43 Self-Diagnosis Service Output Signal Usable Parts Backups by ECU Codes Range or Criteria The ignition coil primary If the ignition primary winding #1 has failures Stick Coil winding must send signals (no signal, wiring short or open), the ECU #1 (Ignition (output voltage) 32 or more shuts off the fuel injector #1 to stop fuel to the...
  • Page 126: 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 changes 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 127: Main Throttle Sensor 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: 57001 -1538...
  • Page 128 3-46 FUEL SYSTEM (DFI) Main Throttle Sensor (Service Code 11) CAUTION Do not remove or adjust the main throttle sensor. It has been adjusted and set with precision at the factory. Never drop the throttle body assy, especially on a hard surface.
  • Page 129: Main Throttle Sensor Resistance Inspection

    FUEL SYSTEM (DFI) 3-47 Main Throttle Sensor (Service Code 11) Main Throttle Sensor 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]. •...
  • Page 130: Inlet Air Pressure Sensor (service Code 12)

    3-48 FUEL SYSTEM (DFI) 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. Inlet Air Pressure Sensor Removal • Turn the ignition switch OFF. •...
  • Page 131: Inlet Air Temperature Sensor Output Voltage Inspection

    FUEL SYSTEM (DFI) 3-49 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 132 3-50 FUEL SYSTEM (DFI) 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 V.).
  • Page 133 FUEL SYSTEM (DFI) 3-51 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 134 3-52 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 135: Inlet Air Temperature Sensor (service Code 13)

    FUEL SYSTEM (DFI) 3-53 Inlet Air Temperature Sensor (Service Code 13) Inlet Air Temperature Sensor 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 136: Inlet Air Temperature Sensor Resistance Inspection

    • Remove the needle adapter set, and apply silicone sealant to the seals of the connector for waterproofing. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 If the wiring is good, check the sensor resistance. Inlet Air Temperature Sensor Resistance Inspection •...
  • Page 137 FUEL SYSTEM (DFI) 3-55 Inlet Air Temperature Sensor (Service Code 13) 1. ECU 2. Inlet Air Temperature Sensor...
  • Page 138: Water Temperature Sensor (service Code 14)

    Water Temperature Sensor [A] • Apply silicone sealant to the threads of the water temper- ature sensor and tighten it. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 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 cool- ing system (see Coolant Change in the Periodic Mainte- nance chapter).
  • Page 139: Water Temperature Sensor Resistance Inspection

    • Remove the needle adapter set, and apply silicone sealant to the seals of the connector for waterproofing. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 1. ECU 2. Meter Unit 3. Water Temperature Sensor Water Temperature Sensor Resistance Inspection •...
  • Page 140: Atmospheric Pressure Sensor (service Code 15)

    3-58 FUEL SYSTEM (DFI) 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. Atmospheric Pressure Sensor Removal • Turn the ignition switch OFF. • Remove: Air Cleaner Housing (see Air Cleaner Housing Removal) Atmospheric Pressure Sensor Connector [A]...
  • Page 141: Atmospheric Pressure Sensor Output Voltage Inspection

    FUEL SYSTEM (DFI) 3-59 Atmospheric Pressure Sensor (Service Code 15) If the reading is within the standard range, check the input voltage again at the sensor connector. • Remove the air cleaner housing (see Air Cleaner Housing Removal). • Disconnect the atmospheric pressure sensor connector and connect the harness adapter [A] between the main harness connector and atmospheric pressure sensor con- nector.
  • Page 142 3-60 FUEL SYSTEM (DFI) Atmospheric Pressure Sensor (Service Code 15) If the output voltage is far out of the usable range, check the output voltage at the sensor connector [A] (when the wiring is open, the output voltage is about 1.8 V.). •...
  • Page 143 FUEL SYSTEM (DFI) 3-61 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 Inlet Air Pressure Sensor section). 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 Voltage Inspection of...
  • Page 144: Crankshaft Sensor (service Code 21)

    3-62 FUEL SYSTEM (DFI) Crankshaft Sensor (Service Code 21) Crankshaft Sensor Removal/Installation • See the Crankshaft Sensor Removal/Installation 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 145: Camshaft Position Sensor (service Code 23)

    FUEL SYSTEM (DFI) 3-63 Camshaft Position Sensor (Service Code 23) Camshaft Position Sensor Removal/Installation The camshaft position sensor detects the position of the camshaft, and distinguishes the cylinder. • See the Camshaft Position Sensor Removal/Installation in the Electric System chapter. Camshaft Position Sensor Inspection ○...
  • Page 146: Speed Sensor (service Code 24)

    3-64 FUEL SYSTEM (DFI) Speed Sensor (Service Code 24) Speed Sensor Removal/Installation • See the Speed Sensor Removal/Installation in the Elec- trical System chapter. Speed Sensor Inspection • See the Speed Sensor Inspection in the Electrical System chapter. Speed Sensor Input Voltage Inspection NOTE ○...
  • Page 147 FUEL SYSTEM (DFI) 3-65 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 - Speed Sensor Measuring Adapter: 57001-1635 Speed Sensor Output Voltage...
  • Page 148: Vehicle-down Sensor (service Code 31)

    3-66 FUEL SYSTEM (DFI) Vehicle-down Sensor (Service Code 31) This sensor has a weight [A] with two magnets inside, and sends a signal to the ECU. But when the motorcycle banks 60 ∼ 70° or more to either side (in fact falls down), the weight turns and shuts off the signal.
  • Page 149 FUEL SYSTEM (DFI) 3-67 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 Input Voltage Connections to Sensor Meter (+) → BL lead [D] Meter (–) →...
  • Page 150 • Remove the needle adapter set, and apply silicone sealant to the seals of the connector for waterproofing. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 If the output voltage is out of the specified, replace the vehicle-down sensor. 1. ECU...
  • Page 151: Subthrottle Sensor (service Code 32)

    FUEL SYSTEM (DFI) 3-69 Subthrottle Sensor (Service Code 32) Subthrottle Sensor Removal/Adjustment CAUTION Do not remove or adjust the subthrottle sensor [A] since it has been adjusted and set with precision at the factory. Never drop the throttle body assy, especially on a hard surface.
  • Page 152: Subthrottle Sensor Output Voltage Inspection

    3-70 FUEL SYSTEM (DFI) 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 -1538...
  • Page 153 FUEL SYSTEM (DFI) 3-71 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 ECU Power Supply Inspection). If the ground and power sup- ply are good, replace the ECU (see ECU Removal/Instal- lation).
  • Page 154: Subthrottle Sensor Resistance Inspection

    3-72 FUEL SYSTEM (DFI) 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 155: Exhaust Butterfly Valve Actuator Sensor (service Code 34)

    FUEL SYSTEM (DFI) 3-73 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 156: Stick Coils #1, #2, #3, #4: (service Code 51, 52, 53, 54)

    3-74 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 Coils Removal/Installation CAUTION Never drop the stick coils, especially on a hard sur-...
  • Page 157 FUEL SYSTEM (DFI) 3-75 Stick Coils #1, #2, #3, #4: (Service Code 51, 52, 53, 54) 1. Ignition Switch 2. Engine Stop Switch 3. Stick Coil #1 4. Stick Coil #2 5. Stick Coil #3 6. Stick Coil #4 7. ECU 8.
  • Page 158: Inspection

    3-76 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 159: Subthrottle Valve Actuator Input Voltage Inspection

    FUEL SYSTEM (DFI) 3-77 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. • Connect the peak voltage adapter [A] and a digital meter [B] to the connector [C], using the needle adapter set [D].
  • Page 160: Exhaust Butterfly Valve Actuator (service Code 63)

    3-78 FUEL SYSTEM (DFI) Exhaust Butterfly Valve Actuator (Service Code 63) Exhaust Butterfly Valve Actuator Removal • Remove: Seat Cover (see Seat Cover Removal in the Frame chapter) • Put off the rubber boots of exhaust butterfly valve cables. • Loosen the locknuts [A] and adjuster nut [B].
  • Page 161: Exhaust Butterfly Valve Actuator Inspection

    FUEL SYSTEM (DFI) 3-79 Exhaust Butterfly Valve Actuator (Service Code 63) • Install the actuator [A] on the frame. Collars [B] Washers [C] Exhaust Butterfly Valve Actuator Mounting Bolts [D] • Tighten: Torque - Exhaust Butterfly Valve Actuator Mounting Bolts: 6.9 N·m (0.70 kgf·m, 61 in·lb) •...
  • Page 162: Exhaust Butterfly Valve Actuator Output Voltage Inspection

    3-80 FUEL SYSTEM (DFI) Exhaust Butterfly Valve Actuator (Service Code 63) Exhaust Butterfly Valve Actuator Output Voltage Inspection • Remove: Front Seat (see Front Seat Removal in the Frame chap- ter) • 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 163: Ecu

    FUEL SYSTEM (DFI) 3-81 CAUTION Never drop the ECU, especially on a hard surface. Such a shock to the ECU can damage it. ECU Removal • Remove: Seat Cover (see Seat Cover Removal in the Frame chapter) Bolts [A] Seat Bracket [B] •...
  • Page 164: Ecu Power Supply Inspection

    3-82 FUEL SYSTEM (DFI) 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. Replace the main harness if the terminals of the main harness connectors are cracked, bent, or otherwise dam- aged.
  • Page 165 FUEL SYSTEM (DFI) 3-83 ECU Power Source Circuit 1. Ignition Switch 2. ECU 3. ECU Fuse 15 A 4. ECU Main Relay 5. Main Fuse 30 A 6. Starter Relay 7. Battery 12 V 8 Ah 8. Fuse Box 9. Relay Box...
  • Page 166: Dfi Power Source

    3-84 FUEL SYSTEM (DFI) DFI Power Source ECU Fuse Removal • Refer to the Electrical System chapter for the 15 A 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 167: Fi Indicator Light (led)

    FUEL SYSTEM (DFI) 3-85 FI Indicator Light (LED) Light (LED) Inspection • Remove the meter unit (see Meter Unit Removal in the Electrical System chapter). • Using two auxiliary leads, supply battery power to the FI indicator light (LED) [A]. 12 V Battery [B] FI Indicator Light (LED) Check Connector:...
  • Page 168: Fuel Line

    3-86 FUEL SYSTEM (DFI) Fuel Line Fuel Pressure Inspection NOTE ○ Be sure the battery is fully charged. • Remove: Front Seat (see Front Seat Removal) 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 169: Fuel Flow Rate Inspection

    FUEL SYSTEM (DFI) 3-87 Fuel Line Fuel Pressure (Idling) Standard: 304 kPa (3.1 kgf/cm , 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 (see Fuel Pump Removal/Installa- tion).
  • Page 170 3-88 FUEL SYSTEM (DFI) 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 171: Fuel Pump

    FUEL SYSTEM (DFI) 3-89 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 172: Fuel Pump Operation Inspection

    3-90 FUEL SYSTEM (DFI) Fuel Pump • Check that the fuel pump terminals [A], fuel reserve switch terminal [B] and band [C] are in place. Front [D] • Apply a non-permanent locking agent to the threads of the fuel pump bolts. •...
  • Page 173 FUEL SYSTEM (DFI) 3-91 Fuel Pump 1. ECU 2. Ignition Switch 3. Engine Stop Switch 4. ECU Main Relay 5. Fuel Pump Relay 6. ECU Fuse 15 A 7. Ignition Fuse 10 A 8. Battery 12 V 8 Ah 9. Fuel Pump 10.
  • Page 174: Fuel Injectors

    3-92 FUEL SYSTEM (DFI) Fuel Injectors CAUTION Never drop the fuel injector, especially on a hard surface. Such a shock to the fuel injector can dam- age it. Fuel Injector Audible Inspection Primary Fuel Injector • Start the engine. • Apply the tip of a screwdriver [A] to the fuel injector [B].
  • Page 175: Fuel Injector Resistance Inspection

    FUEL SYSTEM (DFI) 3-93 Fuel Injectors • Remove connectors for fuel injector [A]. • Connect each test light set [B] to the fuel injector sub har- ness connector [C]. • Turn the ignition switch ON. • While cranking the engine with the starter motor, watch the test lights.
  • Page 176: Fuel Injector Unit Test

    3-94 FUEL SYSTEM (DFI) Fuel Injectors Secondary Fuel Injector Resistance Connections to Fuel Injectors Meter (+) Meter (–) #1: W/R ←→ O/R Terminal #2: W/R ←→ O/G Terminal #3: W/R ←→ O/BK Terminal #4: W/R ←→ O/Y Terminal Standard: About 11.1 ∼ 12.3 Ω at 20°C (68°F) If the reading is out of the range, perform the “Fuel Injector Unit Test”...
  • Page 177 FUEL SYSTEM (DFI) 3-95 Fuel Injectors If the power source voltage is less than standard, check the wiring (see wiring diagram), fuel pump relay (see Fuel Pump Relay Inspection) and ECU power source (see ECU Power Supply Inspection). • Turn the ignition switch OFF. •...
  • Page 178: Fuel Injector Fuel Line Inspection

    3-96 FUEL SYSTEM (DFI) Fuel Injectors Fuel Injector Fuel Line Inspection • Remove the throttle body assy (see Throttle Body Assy Removal). • Remove the nozzle assy (see Nozzle Assy Removal). • Check the fuel injector fuel line for leakage as follows: ○...
  • Page 179 FUEL SYSTEM (DFI) 3-97 Fuel Injectors 1. ECU 2. Secondary Fuel Injector #4 3. Secondary Fuel Injector #3 4. Secondary Fuel Injector #2 5. Secondary Fuel Injector #1 6. Primary Fuel Injector #4 7. Primary Fuel Injector #3 8. Primary Fuel Injector #2 9.
  • Page 180: Throttle Grip And Cables

    3-98 FUEL SYSTEM (DFI) Throttle Grip and Cables Throttle Grip Free Play Inspection • Refer to the Throttle Control System Inspection in the Pe- riodic Maintenance chapter. Throttle Grip Free Play Adjustment • Refer to the Throttle Control System Inspection in the Pe- riodic Maintenance chapter.
  • Page 181: Throttle Body Assy

    FUEL SYSTEM (DFI) 3-99 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 Assy (see Throttle Body Assy Removal in the Fuel System (DFI) chapter) ○...
  • Page 182: Throttle Body Assy Installation

    3-100 FUEL SYSTEM (DFI) Throttle Body Assy • Remove: Vacuum Switch Valve Vacuum Hose [A] Vacuum Hose (California Model) • Loosen: Clamp Bolts [B] • Remove the throttle body assy from the holder. CAUTION When removing the throttle body assy, put the main throttle valves in the throttle bore, be careful to damage to valves.
  • Page 183: Throttle Body Assy Disassembly

    FUEL SYSTEM (DFI) 3-101 Throttle Body Assy • Tighten: Torque - Throttle Body Assembly Holder Clamp Bolts: 3.0 N·m (0.30 kgf·m, 27 in·lb) • Install the removed connectors. • Run the vacuum hoses as shown in the Cable, Wire, and Hose Routing section in the Appendix chapter.
  • Page 184: Throttle Body Assy Assembly

    3-102 FUEL SYSTEM (DFI) Throttle Body Assy • Remove the throttle body assy (see Throttle Body Assy Removal). • Remove the fuel injector connectors. • Remove the screws [A] to pull out the fuel injector assys from the throttle body assy together with the delivery pipe [B].
  • Page 185: Nozzle Assy

    FUEL SYSTEM (DFI) 3-103 Nozzle Assy Nozzle Assy Removal • Remove: Fuel Tank (see Fuel Tank Removal) Nozzle Assy Lead Connectors [A] Fuel Hose [B] Nozzle Assy Mounting Bolts [C] Nozzle Assy [D] WARNING Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately.
  • Page 186: Nozzle Assy Assembly

    3-104 FUEL SYSTEM (DFI) Nozzle Assy Nozzle Assy Assembly • Before assembling, blow away dirt or dust from the nozzle and delivery pipe assy [A] by applying compressed air [B]. • Apply engine oil to the new O-rings [A] and the dust seals [B] of fuel each injector.
  • Page 187 FUEL SYSTEM (DFI) 3-105 Nozzle Assy • Tighten the screws [A]. Torque - Delivery Pipe Mounting Screws: 3.4 N·m (0.35 kgf·m, 30 in·lb) Stay Plate [B] • Apply engine oil to the O-ring [A]. • Tighten: Torque - Fuel Hose Mounting Screw [B]: 4.9 N·m (0.50 kgf·m, 43 in·lb) •...
  • Page 188: Air Cleaner

    3-106 FUEL SYSTEM (DFI) Air Cleaner Air Cleaner Element Removal • Refer to the Air Cleaner Element Replacement in the Pe- riodic Maintenance chapter. Air Cleaner Element Installation • Refer to the Air Cleaner Element Replacement in the Pe- riodic Maintenance chapter. Air Cleaner Element Inspection •...
  • Page 189: Air Cleaner Housing Installation

    FUEL SYSTEM (DFI) 3-107 Air Cleaner • Remove the fuel hose [A]. • Remove the engine breather hose [B]. • Remove the drain hose. • Remove the vacuum switch valve hose [A]. Air Cleaner Housing Installation • Install the vacuum switch valve hose to the air cleaner housing.
  • Page 190: Air Cleaner Housing Disassembly

    3-108 FUEL SYSTEM (DFI) Air Cleaner Air Cleaner Housing Disassembly • Remove: Air Cleaner Housing (see Air Cleaner Housing Removal) Ducts [A] Air Cleaner Housing Assembly • Apply adhesive to the hatched area [A] on the duct. Adhesive - Cemedine #540 or equivalent •...
  • Page 191: Fuel Tank

    FUEL SYSTEM (DFI) 3-109 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 192 3-110 FUEL SYSTEM (DFI) Fuel Tank • Be sure to place a piece of cloth around the fuel hose joint [A]. • Push the joint lock claws [B]. • Pull the joint lock [A] as shown. • Pull the fuel hose joint [B] out of the delivery pipe. WARNING Be prepared for fuel spillage;...
  • Page 193: Fuel Tank Installation

    FUEL SYSTEM (DFI) 3-111 Fuel Tank Fuel Tank Installation • Note the above WARNING (see Fuel Tank Removal). • Route the hoses correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). • For California Model, note the following. ○...
  • Page 194: Fuel Tank And Cap Inspection

    3-112 FUEL SYSTEM (DFI) 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 195: Evaporative Emission Control System (california Model)

    FUEL SYSTEM (DFI) 3-113 Evaporative Emission Control System (California Model) 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 196: Separator Operation Test

    3-114 FUEL SYSTEM (DFI) Evaporative Emission Control System (California Model) 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 197 COOLING SYSTEM 4-1 Cooling System Table of Contents Exploded View........................Specifications ......................... Special Tools and Sealant ...................... Coolant Flow Chart......................... Coolant ........................... Coolant Deterioration Inspection..................Coolant Level Inspection....................Coolant Draining ....................... Coolant Filling ........................Pressure Testing ....................... Cooling System Flushing ....................Coolant Reserve Tank Removal ..................
  • Page 198: Exploded View

    4-2 COOLING SYSTEM Exploded View...
  • Page 199 COOLING SYSTEM 4-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Coolant By-pass Fitting Bolt 0.90 78 in·lb Coolant Drain Bolt (Cylinder) 87 in·lb Coolant Drain Bolt (Water Pump) 0.90 78 in·lb Coolant Reserve Tank Mounting Bolts 0.70 61 in·lb Impeller Bolt 87 in·lb Oil Cooler Mounting Bolts...
  • Page 200: Specifications

    4-4 COOLING SYSTEM Specifications Item Standard Coolant Provided when Shipping Type (Recommended) Permanent type of antifreeze (soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators) Color Green Mixed Ratio Soft water 50%, coolant 50% Freezing Point –35°C (–31°F) Total Amount...
  • Page 201: Special Tools And Sealant

    COOLING SYSTEM 4-5 Special Tools and Sealant Bearing Driver, Kawasaki Bond (Silicone Sealant): 57001-382 56019-120 Bearing Driver Set: 57001-1129...
  • Page 202: Coolant Flow Chart

    4-6 COOLING SYSTEM Coolant Flow Chart...
  • Page 203 COOLING SYSTEM 4-7 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 204: Coolant

    4-8 COOLING SYSTEM 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 205: 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 206: 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 Impeller Disassembly/Assembly •...
  • Page 207: 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 208: Radiator

    4-12 COOLING SYSTEM Radiator Radiator and Radiator Fan Removal • Remove: Coolant (Drain, see Coolant Change in the Periodic Maintenance chapter) Air Cleaner Housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter) Radiator Fan Lead Connector [A] •...
  • Page 209: Radiator And Radiator Fan Installation

    COOLING SYSTEM 4-13 Radiator • Remove: Radiator Fan Mounting Bolts [A] Radiator Fan [B] Radiator and Radiator Fan Installation • Insert the plugs [A] in the holes of heat insulation rubber plate [B]. • Install the heat insulation rubber plate [C] on the engine. •...
  • Page 210 4-14 COOLING SYSTEM Radiator • Cover [A] the heat insulation rubber plate on the radiator. • Install the radiator to the projection [B] as shown.
  • Page 211 COOLING SYSTEM 4-15 Radiator • Enchase the heat insulation rubber plate [A] to the radiator stay. • Through the radiator fan lead [B] in the heat insulation rubber plate hole, and clamp the radiator fan lead and horn lead [C] with the radiator clamp [D]. •...
  • Page 212: Radiator Inspection

    4-16 COOLING SYSTEM Radiator • Install the radiator bracket collar [A] as shown. Rubber Damper [B] Radiator [C] Horn [D] Harness Stay [E] Bolt [F] • Tighten: Torque - Radiator Upper Bolt [G]: 12 N·m (1.2 kgf·m, 104 in·lb) Radiator Lower Bolt [H]: 6.9 N·m (0.70 kgf·m, 61 in·lb) •...
  • Page 213: Radiator Cap Inspection

    COOLING SYSTEM 4-17 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 per- pendicular [C] (not oblique [D]) to the core surface.
  • Page 214: Thermostat

    4-18 COOLING SYSTEM Thermostat Thermostat Removal • Drain the coolant (see Coolant Change in the Periodic Maintenance chapter). • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Throttle Body Assy (see Throttle Body Assy Removal in the Fuel System (DFI) chapter) Thermostat Housing Cover Bolts [A] Bracket [B]...
  • Page 215: Thermostat Inspection

    COOLING SYSTEM 4-19 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 216: Hoses And Pipes

    4-20 COOLING SYSTEM 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 217: Water Temperature Sensor

    COOLING SYSTEM 4-21 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 219 ENGINE TOP END 5-1 Engine Top End Table of Contents Exploded View........Valve Clearance Inspection ..5-24 Specifications ........Valve Clearance Adjustment..5-24 Special Tools and Sealant ....Valve Removal ......5-24 Clean Air System....... 5-11 Valve Installation ......5-24 Air Suction Valve Removal...
  • Page 220: Exploded View

    5-2 ENGINE TOP END Exploded View...
  • Page 221 ENGINE TOP END 5-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Air Suction Valve Cover Bolts 104 in·lb Camshaft Cap Bolts 104 in·lb Camshaft Chain Tensioner Cap Bolt Camshaft Chain Tensioner Mounting Bolts 97 in·lb Cam Sprocket Mounting Bolts Coolant Drain Bolt (Cylinder) 87 in·lb Crankshaft Sensor Cover Bolts...
  • Page 222 5-4 ENGINE TOP END Exploded View...
  • Page 223 ENGINE TOP END 5-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Exhaust Butterfly Valve Actuator Mounting Bolts 0.70 61 in·lb Exhaust Butterfly Valve Actuator Pulley Bolt 0.50 43 in·lb Exhaust Butterfly Valve Cable Adjuster Locknuts 0.70 61 in·lb Exhaust Butterfly Valve Cable Locknuts 0.70 61 in·lb Exhaust Butterfly Valve Cover Bolt...
  • Page 224 5-6 ENGINE TOP END Exploded View Manifold Mark Position [A] Muffler Body Mark Position [A]...
  • Page 225: Specifications

    ENGINE TOP END 5-7 Specifications Item Standard Service Limit Clean Air System Vacuum Switch Valve Open → Close – – – 41 ∼ 49 kPa (310 ∼ 370 mmHg) Closing Pressure Camshafts Cam Height: 32.946 ∼ 33.054 mm (1.2970 ∼ 1.3013 in.) Exhaust 32.85 mm (1.293 in.) 34.646 ∼...
  • Page 226 5-8 ENGINE TOP END Specifications Item Standard Service Limit Valve Spring Free Length: Exhaust 39.4 mm (1.551 in.) 38.0 mm (1.496 in.) Inlet 36.7 mm (1.445 in.) 35.2 mm (1.386 in.) Cylinder, Piston 67.000 ∼ 67.012 mm (2.637 ∼ 2.638 in.) Cylinder Inside Diameter 67.10 mm (2.64 in.) 66.950 ∼...
  • Page 227 ENGINE TOP END 5-9 Special Tools and Sealant Compression Gauge, 20 kgf/cm Valve Seat Cutter, 32° - 25: 57001-221 57001-1118 Valve Spring Compressor Assembly: Valve Seat Cutter, 32° - 28: 57001-241 57001-1119 Piston Pin Puller Assembly: Valve Seat Cutter Holder Bar: 57001-910 57001-1128 Valve Seat Cutter, 45°...
  • Page 228 Valve Seat Cutter Holder, 4: Compression Gauge Adapter, M10 × 1.0: 57001-1275 57001-1601 Fork Oil Level Gauge: L-Shape Hose: 57001-1290 57001-1606 Valve Seat Cutter, 60° - 25: Attachment C: 57001-1328 57001-1624 Valve Seat Cutter, 60° - 27: Kawasaki Bond (Silicone Sealant): 57001-1409 92104-0004...
  • Page 229: Air Suction Valve Removal

    ENGINE TOP END 5-11 Clean Air System Air Suction Valve Removal • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Air Cleaner Housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter) • Separate the hoses [A] from the air suction valve cover.
  • Page 230: Vacuum Switch Valve Removal

    5-12 ENGINE TOP END Clean Air System Vacuum Switch Valve Removal • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Air Cleaner Housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter) • Remove the throttle body assembly hose [A], clamp [B] and hoses [C].
  • Page 231: Clean Air System Hose Inspection

    ENGINE TOP END 5-13 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, throttle body, vacuum switch valve and air suction valve covers.
  • Page 232: Cylinder Head Cover

    Remove the cylinder head cover [A] to backward floating it a little up. Cylinder Head Cover Installation • Replace the head cover gasket with a new one. • Apply silicone sealant [A] to the cylinder head as shown. Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004...
  • Page 233 ENGINE TOP END 5-15 Cylinder Head Cover • Install: Dowel Pins [A] Plug Hole Gaskets [B] • Install the washer [A] with the metal side faces upward. • Install the cylinder head cover. • Tighten the cover bolts [A]. Torque - Cylinder Head Cover Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) •...
  • Page 234: Camshaft Chain Tensioner

    5-16 ENGINE TOP END 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 235: Camshaft, Camshaft Chain

    ENGINE TOP END 5-17 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) • Position the crankshaft at #1, 4 piston TDC. TDC mark [A] for #1, 4 Pistons Timing Mark (Crankcase Halves Mating Surface) [B] •...
  • Page 236 5-18 ENGINE TOP END Camshaft, Camshaft Chain • Install the cam sprockets as shown in figure. #4 Cam Positions [A] Inlet Cam Sprocket [B] Exhaust Cam Sprocket [C] • Apply a non-permanent locking agent to the threads and tighten the bolts. Torque - Cam Sprocket Mounting Bolts: 15 N·m (1.5 kgf·m, 11 ft·lb) •...
  • Page 237: Camshaft, Camshaft Cap Wear Inspection

    ENGINE TOP END 5-19 Camshaft, Camshaft Chain Camshaft, Camshaft Cap Wear Inspection • Remove: Camshaft Cap (see Camshaft Removal) • Cut the strips of plastigage to journal width. Place a strip on each journal parallel to the camshaft installed in the correct position.
  • Page 238: Cam Wear Inspection

    5-20 ENGINE TOP END Camshaft, Camshaft Chain Cam Wear Inspection • Remove the camshaft (see Camshaft Removal). • Measure the height [A] of each cam with a micrometer. If the cams are worn down past the service limit, replace the camshaft. Cam Height Standard: 32.946 ∼...
  • Page 239: Cylinder Head

    ENGINE TOP END 5-21 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) Air Cleaner Housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter)
  • Page 240: Cylinder Head Removal

    5-22 ENGINE TOP END Cylinder Head Cylinder Head Removal • Drain the coolant (see Coolant Change in the Periodic Maintenance chapter). • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Air Cleaner Housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter) Throttle Body Assembly (see Throttle Body Assembly Removal in the Fuel System (DFI) chapter)
  • Page 241: Cylinder Head Warp Inspection

    ENGINE TOP END 5-23 Cylinder Head • Tighten the M9 cylinder head bolts following the tightening sequence [1 ∼ 10]. 146 mm (5.75 in.) [1 ∼ 6, 9 ∼ 10] 138 mm (5.43 in.) [7 ∼ 8] Torque - Cylinder Head Bolts (M9): First: 20 N·m (2.0 kgf·m, 15 ft·lb) Final: 39 N·m (4.0 kgf·m, 29 ft·lb) •...
  • Page 242: Valves

    5-24 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 the cylinder head (see Cylinder Head Removal). •...
  • Page 243: Valve Guide Installation

    ENGINE TOP END 5-25 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 244: Valve Seat Inspection

    5-26 ENGINE TOP END 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: 0.09 ∼ 0.16 mm (0.0035 ∼ 0.0063 in.) Exhaust 0.03 ∼ 0.11 mm (0.0012 ∼ 0.0043 in.) Inlet Service Limit: Exhaust...
  • Page 245 ENGINE TOP END 5-27 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 246 5-28 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 247 ENGINE TOP END 5-29 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 248 5-30 ENGINE TOP END Valves...
  • Page 249: Cylinder, Pistons

    ENGINE TOP END 5-31 Cylinder, Pistons Cylinder Removal • Remove: Cylinder Head (see Cylinder Head Removal) Water Hoses [A] • Remove the cylinder [A]. Cylinder Installation NOTE ○ If a new cylinder is used, use new piston ring. • Install the dowel pins [A] and new cylinder gasket [B]. •...
  • Page 250: Piston Removal

    5-32 ENGINE TOP END Cylinder, Pistons • Position the crankshaft at #2, 3 piston TDC. • Prepare two auxiliary head bolts with their head cut. ○ Install the two cylinder head bolts [A] diagonally in the crankcase. • Install the cylinder block [B]. Pistons [C] ○...
  • Page 251: Cylinder Wear Inspection

    ENGINE TOP END 5-33 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 252: Piston Ring, Piston Ring Groove Wear Inspection

    5-34 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 253: Piston Ring End Gap Inspection

    ENGINE TOP END 5-35 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 254: Throttle Body Holder

    5-36 ENGINE TOP END Throttle Body Holder Throttle Body Holder Installation • Be sure to install the O-rings [A]. • Install the clamps [B] as shown. • Apply a non-permanent locking agent to the throttle body holder bolts, and tighten them. Torque - Throttle Body Holder Bolts [C]: 12 N·m (1.2 kgf·m, 104 in·lb) Throttle Body Assy Holder Clamp Bolts [D]: 2.9...
  • Page 255: Muffler

    ENGINE TOP END 5-37 Muffler Muffler Body Removal WARNING To avoid a serious burn, do not remove the muffler when the engine is still hot. Wait until the muffler cool down. • Remove: Seat Cover (see Seat Cover Removal in the Frame chapter) Clamp [A] Connectors [B]...
  • Page 256: Muffler Body Installation

    5-38 ENGINE TOP END Muffler • Slide the dust covers [A]. • Loosen the locknuts [B], and turn the adjuster [C] to give the cable plenty of play. • Loosen the locknuts [D]. • Remove the exhaust butterfly valve cable lower ends from the pulley [E].
  • Page 257: Exhaust Pipe Manifold Removal

    ENGINE TOP END 5-39 Muffler • Install the exhaust butterfly valve cables, and adjust (see Exhaust Butterfly Valve Cable Installation). • Thoroughly warm up the engine, wait until the engine cools down, retighten all the bolts. • Install the removed parts (see appropriate chapters). ○...
  • Page 258: Exhaust Pipe Manifold Installation

    5-40 ENGINE TOP END Muffler • Remove: Exhaust Pipe Clamp Bolt [A] • Remove the exhaust pipe manifold forward. Exhaust Pipe Manifold Installation • Replace the exhaust pipe gaskets [A] and exhaust pipe gasket [B] with new ones and install them. ○...
  • Page 259: Exhaust Butterfly Valve Cable Removal

    ENGINE TOP END 5-41 Muffler Exhaust Butterfly Valve Cable Removal • Remove: Seat Cover (see Seat Cover Removal in the Frame chapter) Seat Bracket [A] (see ECU Removal in the Fuel System chapter) Cover (see Muffler Body Removal) • Slide the dust covers [B]. •...
  • Page 260 5-42 ENGINE TOP END Muffler • Install the exhaust butterfly valve cable upper ends to the pulley of actuator. Exhaust Butterfly Valve Cable (Accelerator) [A] Exhaust Butterfly Valve Cable (Decelerator) [B] • Install the clamp [C]. • Install the exhaust butterfly valve cable lower ends to the pulley of muffler body.
  • Page 261 ENGINE TOP END 5-43 Muffler...
  • Page 263 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 .................. Cable Removal ......................... Cable Installation ......................Cable Lubrication ......................Clutch Lever Installation....................
  • Page 264: Exploded View

    6-2 CLUTCH Exploded View...
  • Page 265 CLUTCH 6-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Clutch Cover Bolt (M6, L = 50 mm) 104 in·lb Clutch Cover Bolts (M6, L = 40 mm) 104 in·lb L (1) Clutch Cover Bolts (M6, L = 30 mm) 104 in·lb L (1) Clutch Hub Nut...
  • Page 266: Specifications

    6-4 CLUTCH Specifications Item Standard Service Limit 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Clutch Lever Free Play – – – Clutch Spring Plate Free Play (Usable Range) 0.05 ∼ 0.70 mm (0.002 ∼ 0.028 in.) – – – Clutch Plate Assembly Length 38.8 mm (1.53 in.) –...
  • Page 267: Special Tool And Sealant

    CLUTCH 6-5 Special Tool and Sealant Clutch Holder: Kawasaki Bond (Silicone Sealant): 57001-1243 92104-0004...
  • Page 268: 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. Cable Removal •...
  • Page 269: 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 270: Release Shaft Installation

    6-8 CLUTCH Clutch Cover Release Shaft Installation • Apply high-temperature grease to the oil seal lips on the upper ridge of the clutch cover. • Apply engine oil to the needle bearings in the hole of the clutch cover. • Apply molybdenum disulfide grease to the pusher-holding portion [A] on the release shaft.
  • Page 271: Clutch Removal

    CLUTCH 6-9 Clutch Clutch Removal • Remove: Clutch Cover (see Clutch Cover Removal) Clutch Spring Bolts [A] Spring Holders Clutch Springs Clutch Spring Plate [B] (with shim, bearing, pusher [C], spring and washer) • Remove: Friction Plates, Steel Plates Clutch Hub Nut [A] ○...
  • Page 272 6-10 CLUTCH Clutch • Install the spacer [A] so that the stepped side [B] faces inward. • Install the clutch housing. • Install the needle bearing and sleeve. • Install the spacer [A] so that the stepped side [B] faces outward.
  • Page 273 CLUTCH 6-11 Clutch ○ Third Torque Limiter Spring Tang [B] ○ Fourth Torque Limiter Spring Tang [B] ○ Replace the clutch hub nut with a new one. • Holding the sub clutch hub, tighten the clutch hub nut. Special Tool - Clutch Holder: 57001-1243 Torque - Clutch Hub Nut: 137 N·m (14 kgf·m, 101 ft·lb) ○...
  • Page 274: Spring Plate Free Play Measurement

    6-12 CLUTCH Clutch • Apply molybdenum disulfide grease to the pusher ends [A] and install the shim [B], bearing [C], pusher [D] in the clutch spring plate [E]. Spring [F] Washer [G] • Align the grooves [A] of the spring plate [B] to the grooves [C] of the sub clutch hub [D] to install the spring plate on the sub clutch hub.
  • Page 275: Spring Plate Play Adjustment

    CLUTCH 6-13 Clutch • Engage the clutch hub with the sub clutch hub. • To measure the free play, set a dial gauge [A] against the raised center [B] of the clutch spring plate. • Move the clutch housing gear back and forth [C]. The dif- ference between the highest and lowest gauge readings is the amount of free play.
  • Page 276: Clutch Plate, Wear, Damage Inspection

    6-14 CLUTCH Clutch Clutch Plate, Wear, Damage Inspection • Visually inspect the friction and steel plates for signs of seizure, overheating (discoloration), or uneven wear. • Measure the thickness of each friction plate [A] at several points. If any plates show signs of damage, or if they have worn past the service limit, replace them with new ones.
  • Page 277 ENGINE LUBRICATION SYSTEM 7-1 Engine Lubrication System Table of Contents Exploded View........................Specifications ......................... Special Tools and Sealant ...................... Engine Oil Flow Chart......................Engine Oil and Oil Filter......................Oil Level Inspection......................Engine Oil Change......................Oil Filter Replacement ...................... Oil Pan............................ Oil Pan Removal .......................
  • Page 278: Exploded View

    7-2 ENGINE LUBRICATION SYSTEM Exploded View...
  • Page 279 ENGINE LUBRICATION SYSTEM 7-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Coolant Drain Bolt (Water Pump) 0.90 78 in·lb Engine Oil Drain Bolt Impeller Bolt 87 in·lb Oil Cooler Mounting Bolts 104 in·lb Oil Filter EO, R Oil Filter Mounting Bolt Oil Jet Nozzle Bolts 0.70 61 in·lb...
  • Page 280: Specifications

    7-4 ENGINE LUBRICATION SYSTEM Specifications Item Standard Engine Oil Type API SE, SF or SG API SH or SJ with JASO MA Viscosity SAE 10W-40 Capacity 3.4 L (3.6 US gt) (when filter is not removed) 3.6 L (3.8 US gt) (when filter is removed) 4.0 L (4.2 US gt) (when engine is completely dry) Level Between upper and lower level lines...
  • Page 281: Special Tools And Sealant

    ENGINE LUBRICATION SYSTEM 7-5 Special Tools and Sealant Outside Circlip Pliers: Oil Pressure Gauge Adapter, M18 × 1.5: 57001-144 57001-1278 Oil Pressure Gauge, 10 kgf/cm Kawasaki Bond (Silicone Sealant): 57001-164 56019-120 Oil Filter Wrench: 57001-1249...
  • Page 282: Engine Oil Flow Chart

    7-6 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart...
  • Page 283 ENGINE LUBRICATION SYSTEM 7-7 Engine Oil Flow Chart...
  • Page 284: Engine Oil And Oil Filter

    7-8 ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter WARNING Motorcycle operation with insufficient, deteri- orated, or contaminated engine oil will cause accelerated wear and may result in engine or trans- mission seizure, accident, and injury. Oil Level Inspection • Check that the engine oil level is between the upper [A] and lower [B] levels in the gauge.
  • Page 285: Oil Pan

    ENGINE LUBRICATION SYSTEM 7-9 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) • Remove the water hose from the oil pan clamp. •...
  • Page 286 7-10 ENGINE LUBRICATION SYSTEM Oil Pan • Install the clamp [A] as shown. Boss [B] • Replace the oil pan gasket with a new one. • Tighten: Torque - Oil Pan Bolts [C] : 9.8 N·m (1.0 kgf·m, 87 in·lb)
  • Page 287: Oil Pressure Relief Valve

    ENGINE LUBRICATION SYSTEM 7-11 Oil Pressure Relief Valve Oil Pressure Relief Valve Removal • See Oil Pan Removal. Oil Pressure Relief Valve Installation • See 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 288: Oil Pump

    7-12 ENGINE LUBRICATION SYSTEM Oil Pump Oil 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] Water Pump Cover Bolts [B] Water Pump Cover •...
  • Page 289: Oil Pump Drive Gear Removal

    ENGINE LUBRICATION SYSTEM 7-13 Oil Pump • Fit the pin [A] of the oil pump cover [B] into the hole [C] in the crankcase. • Install: Pins [A] Water Pump Body [B] • Apply coolant to the surface of the rubber seal on the impeller.
  • Page 290: Oil Pump Drive Gear Installation

    7-14 ENGINE LUBRICATION SYSTEM Oil Pump • Pull the oil pump drive gear [A]. Oil Pump Drive Gear Installation • Apply molybdenum disulfide oil to the journal portions [A] on the oil pump drive gear shaft [B]. • Install: Washer [C] •...
  • Page 291: Oil Cooler

    ENGINE LUBRICATION SYSTEM 7-15 Oil Cooler Oil Cooler Removal • Drain: Coolant (see Coolant Change in the Periodic Mainte- nance chapter) Engine Oil (see Engine Oil Change in the Periodic Main- tenance chapter) • Remove the water hoses [A] from the oil cooler. •...
  • Page 292: Oil Pressure Measurement

    7-16 ENGINE LUBRICATION SYSTEM Oil Pressure Measurement Oil Pressure Measurement • Remove the lower fairings (see Lower Fairing Removal in the Frame chapter). • Remove the oil passage plug, and attach the adapter [A] and gauge [B] to the plug hole. Special Tools - Oil Pressure Gauge, 10 kgf/cm : 57001-164 Oil Pressure Gauge Adapter, M18 ×...
  • Page 293: 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 outward.
  • Page 295 ENGINE REMOVAL/INSTALLATION 8-1 Engine Removal/Installation Table of Contents Exploded View........................Special Tool ..........................Engine Removal/Installation ....................Engine Removal........................ Engine Installation......................
  • Page 296: Exploded View

    8-2 ENGINE REMOVAL/INSTALLATION Exploded View...
  • Page 297 ENGINE REMOVAL/INSTALLATION 8-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Adjusting Collar Locknut Lower Engine Mounting Bolt 87 in·lb Lower Engine Mounting Nut Middle Engine Mounting Bolt 87 in·lb Middle Engine Mounting Nut Upper Engine Mounting Bolts S: Tighten the fasteners following the specified sequence.
  • Page 298: Special Tool

    8-4 ENGINE REMOVAL/INSTALLATION Special Tool Engine Mount Nut Wrench: 57001-1450...
  • Page 299: 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 300 8-6 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Support the engine with a suitable stand [A]. ○ Put a plank [B] onto the suitable stand for engine balance. • Remove: Right and Left Upper Engine Mounting Bolts [A] • Using the nut wrench [A], loosen the locknut [B]. Special Tool - Engine Mount Nut Wrench: 57001-1450 •...
  • Page 301: Engine Installation

    ENGINE REMOVAL/INSTALLATION 8-7 Engine Removal/Installation Engine Installation • Support the engine with a suitable stand. ○ Put a plank onto the suitable stand for engine balance. • Install the engine mounting bolts and nuts, following the specified installing sequence. ○ First, install the adjusting collars [A] to backside of the upper and lower crankcase and right side of the frame.
  • Page 302 8-8 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Run the leads, cable and hoses correctly (see Cable, Wire, and Hose Routing section in the Appendix chap- ter). • Install the removed parts (see appropriate chapters). • Adjust: Throttle Cables (see Throttle Control System Inspection in the Periodic Maintenance chapter) Clutch Cable (see Clutch Operation Inspection in the Pe- riodic Maintenance chapter)
  • Page 303 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 304: Exploded View

    9-2 CRANKSHAFT/TRANSMISSION Exploded View...
  • Page 305 CRANKSHAFT/TRANSMISSION 9-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Breather Plate Bolts 87 in·lb Connecting Rod Big End Nuts see the text ← ← Crankcase Bolts (M8) MO, S Crankcase Bolts (M7, L = 38 mm) Crankcase Bolt (M7, L = 70 mm) Crankcase Bolts (M6, L = 65 mm) 104 in·lb Crankcase Bolts (M6, L = 50 mm)
  • Page 306 9-4 CRANKSHAFT/TRANSMISSION Exploded View...
  • Page 307 CRANKSHAFT/TRANSMISSION 9-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Gear Positioning Lever Bolt 104 in·lb Neutral Switch Shift Drum Cam Holder Bolt 104 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 308: Specifications

    9-6 CRANKSHAFT/TRANSMISSION Specifications Item Standard Service Limit Crankcase, Crankshaft, Connecting Rods Connecting Rod Bend – – – TIR 0.20/100 (0.008/3.94 in.) Connecting Rod Twist – – – TIR 0.20/100 (0.008/3.94 in.) 0.13 ∼ 0.33 mm Connecting Rod Big End Side Clearance 0.53 mm (0.0051 ∼...
  • Page 309 CRANKSHAFT/TRANSMISSION 9-7 Specifications Item Standard Service Limit 34.000 ∼ 34.016 mm Crankcase Main Bearing Inside Diameter: – – – (1.3386 ∼ 1.3392 in.) Marking: ○ 34.000 ∼ 34.008 mm – – – (1.3386 ∼ 1.3389 in.) 34.009 ∼ 34.016 mm None –...
  • Page 310: Special Tools And Sealant

    9-8 CRANKSHAFT/TRANSMISSION Special Tools and Sealant Bearing Puller: Bearing Driver, 32: 57001-135 57001-382 Outside Circlip Pliers: Kawasaki Bond (Silicone Sealant): 57001-144 56019-120 Bearing Puller Adapter: Kawasaki Bond: 57001-317 92104-1064...
  • Page 311: 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) Starter Motor (see Starter Motor Removal in the Electri-...
  • Page 312: Crankcase Splitting

    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 313 CRANKSHAFT/TRANSMISSION 9-11 Crankcase Splitting • Apply liquid gasket to the mating surface of the lower crankcase half. Sealant - Kawasaki Bond: 92104-1064 NOTE ○ Especially, apply a sealant carefully so that it shall be filled up on the grooves. CAUTION Do not apply liquid gasket around the crankshaft main bearing inserts, and oil passage holes.
  • Page 314 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 M8 bolts [1 ∼ 10] with copper plated wash- ers. L = 71 mm (2.80 in.) [1 ∼ 6] L = 94 mm (3.70 in.) [7 ∼...
  • Page 315: Crankshaft And Connecting Rods

    CRANKSHAFT/TRANSMISSION 9-13 Crankshaft and Connecting Rods Crankshaft Removal • See Connecting Rod Removal. 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 316 9-14 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods • Apply molybdenum disulfide oil to the inner surface of the upper and lower bearing inserts [A]. • Apply molybdenum disulfide oil to the threads [B] and seating surface [C] of the connecting rod nuts. •...
  • Page 317 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 318 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, nuts and connecting rods thor- oughly with a high-flash point solvent, because the new connecting rods, bolts and nuts are treated with an anti -rust solution.
  • Page 319: Crankshaft/connecting Rod Cleaning

    CRANKSHAFT/TRANSMISSION 9-17 Crankshaft and Connecting Rods Crankshaft/Connecting Rod Cleaning • After removing the connecting rods from the crankshaft, clean them with a high-flash point solvent. • Blow the crankshaft oil passages with compressed air to remove any foreign particles or residue that may have accumulated in the passages.
  • Page 320: 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 [B] clearance with plastigage [A]. • Tighten the big end nuts to the specified torque (see Con- necting Rod Installation). NOTE ○...
  • Page 321: Crankshaft Side Clearance Inspection

    CRANKSHAFT/TRANSMISSION 9-19 Crankshaft and Connecting Rods Connecting Rod Big End Inside Diameter Marks None: 33.000 ∼ 33.008 mm (1.2992 ∼ 1.2995 in.) ○ 33.009 ∼ 33.016 mm (1.2996 ∼ 1.2998 in.) Big End Cap [A] Connecting Rod [B] Weight Mark, Alphabet [C] ○...
  • Page 322: 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 323 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. ○ [A]: Crankcase Main Bearing Inside Diameter Marks, “ ” mark or no mark. •...
  • Page 324: Transmission

    9-22 CRANKSHAFT/TRANSMISSION Transmission Shift Pedal Removal • Mark [A] the position of the shift lever [B] on the shift shaft so that it can be installed later in the same position. • Remove: Shift Lever Bolt [C] Shift Lever • Remove: Shift Pedal Mounting Bolt [A] Tie-Rod [B]...
  • Page 325: External Shift Mechanism Removal

    CRANKSHAFT/TRANSMISSION 9-23 Transmission External Shift Mechanism Removal • Remove: Engine Oil (Drain, see Engine Oil Change in the Periodic Maintenance chapter) Clutch (see Clutch Removal in the Clutch chapter) Shift Pedal (see Shift Pedal Removal) • Remove the shift shaft assembly [A] while pulling the shift mechanism arm.
  • Page 326: Transmission Shaft Removal

    9-24 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 ring [A] and set pin [B] are in place.
  • Page 327: Transmission Shaft Assembly

    CRANKSHAFT/TRANSMISSION 9-25 Transmission • Remove the ball bearing [A] from each shafts. Special Tools - Bearing Puller [B]: 57001-135 Bearing Puller Adapter [C]: 57001-317 • Discard the bearing. Transmission Shaft Assembly • Install the ball bearing on the drive shaft [A] with the groove [B] toward the clutch side using the bearing driver.
  • Page 328 9-26 CRANKSHAFT/TRANSMISSION Transmission • Fit the steel balls into the 5th gear holes in the output shaft, aligning three oil holes. 5th Gear [A] Output Shaft [B] Steel Balls [C] Oil Holes [D] CAUTION Do not apply grease to the balls to hold them in place.
  • Page 329 CRANKSHAFT/TRANSMISSION 9-27 Transmission 1. Output Shaft 14. Toothed Washer, 34 mm (1.34 in.) 2. Collar 15. Snap Ring 3. Ball Bearing 16. Bushing 4. 2nd Gear 17. Thrust Washer, 30 mm (1.18 in.) 5. 6th (Top) Gear 18. Snap Ring 6.
  • Page 330: Shift Drum And Fork Removal

    9-28 CRANKSHAFT/TRANSMISSION Transmission Shift Drum and Fork Removal • Remove: Lower Crankcase Half (see Crankcase Splitting) External Shift Mechanism (see External Shift Mecha- nism Removal) Bolts [A] Shift Drum Bearing Holder [B] • Pull out the shift rods [C], and take off the shift forks. •...
  • Page 331: Shift Fork/gear Groove Wear Inspection

    CRANKSHAFT/TRANSMISSION 9-29 Transmission Shift Fork/Gear Groove Wear Inspection • Measure the thickness of the shift fork ears [A], and mea- sure the width [B] of the gear grooves. If the thickness of a shift fork ear is less than the service limit, the shift fork must be replaced.
  • Page 333 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 ......................10-9 Axle Inspection........................
  • Page 334: Exploded View

    10-2 WHEELS/TIRES Exploded View...
  • Page 335 WHEELS/TIRES 10-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Axle Clamp Bolts Front Axle Nut Rear Axle Nut AL: Tighten the two clamp bolts alternately two time to ensure even tightening. G: Apply grease. HG: Apply high-temperature grease. R: Replacement Parts WL: Apply soap and water solution or rubber lubricant.
  • Page 336: Specifications

    10-4 WHEELS/TIRES Specifications Item Standard Service Limit Wheels (Rims) Rim Size: Front 17 × 3.50 – – – Rear 17 × 5.50 – – – Rim Runout (with tire installed): Axial TIR 0.5 mm (0.02 in.) or less TIR 1 mm (0.04 in.) Radial TIR 0.8 mm (0.03 in.) or less TIR 1 mm (0.04 in.)
  • Page 337: Special Tools

    WHEELS/TIRES 10-5 Special Tools Bearing Driver Set: Bearing Remover Shaft, 13: 57001-1129 57001-1377 Jack: Jack Attachment: 57001-1238 57001-1608 Bearing Remover Head, 25 × 28: 57001-1346...
  • Page 338: Wheels (rims)

    10-6 WHEELS/TIRES Wheels (Rims) Front Wheel Removal • Remove: Brake Caliper Mounting Bolts [A] Front Brake Calipers [B] • Loosen: Axle Clamp Bolts [A] (Left Side) Axle Nut [B] Axle Clamp Bolts (Right Side) • Remove the lower fairings (see Lower Fairing Removal in the Frame chapter).
  • Page 339: Rear Wheel Removal

    WHEELS/TIRES 10-7 Wheels (Rims) • Apply high-temperature grease to the grease seal lip. • Fit the collars [A] on the both sides of the hub. ○ The collars are identical. • Insert the axle. • Tighten the axle nut [B]. Right Axle Clamp Bolts [C] Left Axle Clamp Bolts [D] Viewed from Rear [E]...
  • Page 340: Rear Wheel Installation

    10-8 WHEELS/TIRES Wheels (Rims) • Remove: Rear Caliper Mounting Bolts [A] Rear Caliper [B] • Remove: Cotter Pin [A] Axle Nut [B] Axle [C] (from Right Side) • Remove the drive chain [A] from the rear sprocket toward the left. •...
  • Page 341: Wheel Inspection

    WHEELS/TIRES 10-9 Wheels (Rims) • Engage the drive chain with the rear sprocket. • Install the caliper bracket [A] onto the swingarm stop [B]. ○ Insert the axle from the right side of the wheel, and tighten the axle nut. Torque - Rear Axle Nut: 127 N·m (13 kgf·m, 94 ft·lb) •...
  • Page 342: Axle Inspection

    10-10 WHEELS/TIRES Wheels (Rims) • Measure the rim runout, radial [B] and axial [A], with a dial gauge. If the rim runout exceeds the service limit, check the hub bearings (see Hub Bearing Inspection). If the problem is not due to the bearings, replace the wheel.
  • Page 343: Balance Adjustment

    30 g (1.06 oz) NOTE ○ Balance weights are available from Kawasaki dealers in 10, 20, and 30 gram (0.35 oz, 0.71 oz, and 1.06 oz) sizes. An imbalance of less than 10 grams (0.35 oz) will not usually affect running stability.
  • Page 344 10-12 WHEELS/TIRES Wheels (Rims) • Slip the balance weight [A] on to the rib [B], by pushing or lightly hammering [C] the clip [D]. Left Side [E] Right Side [F] • Be sure to install the balance weight. ○ Check that the blade [A] and clip [B] are fully seated on the rim [C] and that the clip is hooked over the rib [D].
  • Page 345: Tires

    WHEELS/TIRES 10-13 Tires Air Pressure Inspection/Adjustment • Refer to the Air Pressure Inspection in the Periodic Main- tenance chapter. Tire Inspection • Refer to the Wheel/Tire Damage Inspection in the Peri- odic Maintenance chapter. Tire Removal • Remove: Wheel (see Front/Rear Wheel Removal) Valve Core (Let out the air) •...
  • Page 346 10-14 WHEELS/TIRES Tires • Install a new valve in the rim. ○ Remove the valve cap, lubricate the stem seal [A] with a soap and water solution or rubber lubricant, and pull [B] the valve stem through the rim from the inside out until it snaps into place.
  • Page 347: 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 348: Hub Bearing

    10-16 WHEELS/TIRES Hub Bearing Hub Bearing Removal • Remove the wheel (see Front/Rear Wheel Removal), and take out the following. Collars Coupling (Out of rear hub) Grease Seals • Use the bearing remover to remove the hub bearing [A]. CAUTION Do not lay the wheel on the ground with the disc facing down.
  • Page 349: Hub Bearing Lubrication

    WHEELS/TIRES 10-17 Hub Bearing Hub Bearing Lubrication NOTE ○ Since the hub bearings are packed with grease and sealed, lubrication is not required.
  • Page 351 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 352: Exploded View

    11-2 FINAL DRIVE Exploded View...
  • Page 353 FINAL DRIVE 11-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Chain Cover Bolts 0.50 43 in·lb Engine Sprocket Cover Bolts 0.70 61 in·lb Engine Sprocket Nut Rear Axle Nut Rear Sprocket Nuts G: Apply grease. HG: Apply high-temperature grease. HO: Apply heavy oil.
  • Page 354: Specifications

    11-4 FINAL DRIVE Specifications Item Standard Service Limit Drive Chain Standard Chain: Make ENUMA – – – Type EK520MVXL – – – Link 110 links – – – Sprockets Rear Sprocket Warp TIR 0.4 mm (0.016 in.) or less TIR 0.5 mm (0.02 in.)
  • Page 355: Special Tools

    FINAL DRIVE 11-5 Special Tools Inside Circlip Pliers: Bearing Driver Set: 57001-143 57001-1129...
  • Page 356: 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 357: Drive Chain Installation

    FINAL DRIVE 11-7 Drive Chain • Grind [A] the pin head to make it flat. • Set the cutting and riveting pin [B] as shown. • Screw the pin holder until it touches the link pin. • Be sure that the cutting pin hits center of the link pin. •...
  • Page 358 11-8 FINAL DRIVE Drive Chain • Set the plate holder (a) [A] and plate holder (b) [B] on the body. • Fit the plate holder (a) to the link plate. • Turn the pin holder by hand until the plate holder (b) touches the other link plate.
  • Page 359 FINAL DRIVE 11-9 Drive Chain • Turn the wrench clockwise until the tip of riveting pin con- tact with the link pin. • Rivet it. • Repeat the same procedure for the other link pin. • After staking, check the staked area of the link pin for cracks.
  • Page 360: Sprocket, Coupling

    11-10 FINAL DRIVE Sprocket, Coupling Engine Sprocket Removal • Remove: Engine Sprocket Cover Bolts [A] Engine Sprocket Cover [B] • Flatten out the bended washer [A]. • Remove the engine sprocket nut [B] and washer. NOTE ○ When loosening the engine sprocket nut, hold the rear brake on.
  • Page 361: Rear Sprocket Removal

    FINAL DRIVE 11-11 Sprocket, Coupling • Install the engine sprocket cover. • Install the stay [A] and clamp [B] as shown, and tighten the cover bolts. Torque - Engine Sprocket Cover Bolts: 6.9 N·m (0.70 kgf·m, 61 in·lb) • Bend the end of axle cotter pin surely after tightening the axle nut (see Rear Wheel Installation in the Wheel/Tires chapter).
  • Page 362: Coupling Bearing Removal

    11-12 FINAL DRIVE Sprocket, Coupling • Apply grease to the O-ring [A]. • Install the collar [B] Coupling Bearing Removal • Remove: Coupling Grease Seal Circlip [A] Special Tool - Inside Circlip Pliers [B]: 57001-143 • Remove the bearing [A] by tapping from the wheel side. Special Tool - Bearing Driver Set [B]: 57001-1129 Coupling Bearing Installation •...
  • Page 363: Coupling Bearing Inspection

    FINAL DRIVE 11-13 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 364: Rear Sprocket Warp Inspection

    11-14 FINAL DRIVE Sprocket, Coupling Rear Sprocket Warp Inspection • Raise the rear wheel off the ground so that it will turn freely. • Set a dial gauge [A] against the rear sprocket [B] near the teeth as shown, and rotate [C] the rear wheel to measure the sprocket runout (warp).
  • Page 365 BRAKES 12-1 Brakes Table of Contents Exploded View ........12-2 Front Brake Pad Installation..12-13 Specifications ........12-6 Rear Brake Pad Removal ... 12-14 Special Tools ........12-7 Rear Brake Pad Installation ..12-14 Brake Lever, Brake Pedal....12-8 Brake Pad Wear Inspection ..12-14 Brake Lever Position Adjustment.
  • Page 366: Exploded View

    12-2 BRAKES Exploded View...
  • Page 367 BRAKES 12-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Bleed Valves 0.80 69 in·lb Brake Hose Banjo Bolts Brake Lever Pivot Bolt 0.10 9 in·lb Brake Lever Pivot Bolt Locknut 0.60 52 in·lb Brake Disc Mounting Bolts Front Brake Light Switch Screw 0.12 10 in·lb Front Brake Pad Pins...
  • Page 368 12-4 BRAKES Exploded View...
  • Page 369 BRAKES 12-5 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 0.90 78 in·lb Brake Disc Mounting Bolts Rear Caliper Mounting Bolts Rear Master Cylinder Mounting Bolts Rear Master Cylinder Push Rod Locknut Front Footpeg Bracket Bolts G: Apply brake fluid.
  • Page 370: Specifications

    12-6 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 60 mm (2.4 in.) below top of footpeg –...
  • Page 371: Special Tools

    BRAKES 12-7 Special Tools Inside Circlip Pliers: Jack Attachment: 57001-143 57001-1608 Jack: 57001-1238...
  • Page 372: Brake Lever, Brake Pedal

    12-8 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 373: Brake Pedal Installation

    BRAKES 12-9 Brake Lever, Brake Pedal • Remove: Cotter Pin [A] Joint Pin [B] Rear Brake Light Switch Spring [C] Return Spring [D] • Remove the mounting bolt [E] and take out the brake pedal. Brake Pedal Installation • Apply high-temperature grease to the pivot shaft [A] and install the washer [B].
  • Page 374: Calipers

    12-10 BRAKES Calipers Front Caliper Removal • Loosen the banjo bolt [A] at the brake hose lower end, and tighten it loosely. • Unscrew the caliper mounting bolts [B], and detach the caliper [C] from the disc. CAUTION Do not loosen the caliper assembly bolts [D]. Take out only the caliper mounting bolts for caliper re- moval.
  • Page 375: Front Caliper Disassembly

    BRAKES 12-11 Calipers WARNING Do not attempt to drive the motorcycle until a full brake lever or pedal is obtained by pumping the brake lever or pedal until the pads are against the disc. The brakes will not function on the first appli- cation of the lever or pedal if this is not done.
  • Page 376: Rear Caliper Dust Boot And Rubber Boot Damage Inspection

    12-12 BRAKES Calipers Rear Caliper Dust Boot and Rubber Boot Damage Inspection • Check that the dust boot [A] and rubber boot [B] are not cracked, worn, swollen, or otherwise damaged. If they show any damage, replace it. Caliper Piston and Cylinder Damage Inspection •...
  • Page 377: Brake Pads

    BRAKES 12-13 Brake Pads Front Brake Pad Removal • Loosen: Pad Pins [A] • Remove: Pad Pins [A] Pad Springs [B] Brake Pads [C] Front Brake Pad Installation • Push the caliper pistons in by hand as far as they will go. •...
  • Page 378: Rear Brake Pad Removal

    12-14 BRAKES Brake Pads Rear Brake Pad Removal • Remove the caliper with the hose installed. • Remove: Clip [A] Pad Pin [B] Brake Pads [C] Rear Brake Pad Installation • Push the caliper piston in by hand as far as it will go. •...
  • Page 379: Master Cylinder

    BRAKES 12-15 Master Cylinder Front Master Cylinder Removal • Remove the reservoir bracket nut [A]. • 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 380: Rear Master Cylinder Removal

    12-16 BRAKES Master Cylinder Rear Master Cylinder Removal • Unscrew the brake hose banjo bolt [A] and brake hose [B]. • Remove: Cotter Pin [C] Joint Pin [D] Bolts [E] Foot Guard [F] Rear Master Cylinder • Slide out the clamp [G]. •...
  • Page 381 BRAKES 12-17 Master Cylinder • Check the dust covers [E] for damage. If they are damaged, replace them. • Check the piston return spring [F] for any damage. If the springs are damaged, replace them. • Check that relief port [G] and supply port [H] are not plugged.
  • Page 382: Brake Disc

    12-18 BRAKES Brake Disc Brake Disc Removal • Remove the wheel (see Front/Rear Wheel Removal in the Wheels/Tires chapter). • Unscrew the brake disc mounting bolts, and take off the disc. Brake Disc Installation • Install the brake disc on the wheel so that the marked side [B] faces out.
  • Page 383: Brake Fluid

    BRAKES 12-19 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 384 12-20 BRAKES 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 385 BRAKES 12-21 Brake Fluid • Install: Diaphragm [A] Diaphragm Plate [B] Front Brake Reservoir Cap [C] Clamp [D] Screw [E] • 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 the resistance is felt fully;...
  • Page 386 12-22 BRAKES Brake Fluid WARNING When working with the disc brake, observe the pre- cautions listed below. 1. Never reuse old brake fluid. 2. Do not use fluid from a container that has been left unsealed or that has been open for a long time. 3.
  • Page 387: Brake Hose

    BRAKES 12-23 Brake Hose Brake Hose Removal/Installation • Refer to the Brake Hose and Pipe Replacement in the Periodic Maintenance chapter. Brake Hose Inspection • Refer to the Brake Hose Damage and Installation Condi- tion Inspection in the Periodic Maintenance chapter.
  • Page 389 SUSPENSION 13-1 Suspension Table of Contents Exploded View........................13-2 Specifications ......................... 13-6 Special Tools .......................... 13-7 Front Fork ..........................13-9 Rebound Damping Force Adjustment................13-9 Compression Damping Force Adjustment ................ 13-9 Spring Preload Adjustment ....................13-10 Front Fork Removal (Each Fork Leg) ................13-10 Front Fork Installation .......................
  • Page 390: Exploded View

    13-2 SUSPENSION Exploded View...
  • Page 391 SUSPENSION 13-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Axle Clamp Bolts Front Fork Bottom Allen Bolts Front Fork Clamp Bolts (Lower) Front Fork Clamp Bolts (Upper) Front Fork Top Plugs Piston Rod Nuts AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque. G: Apply grease.
  • Page 392 13-4 SUSPENSION Exploded View...
  • Page 393 SUSPENSION 13-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Rear Shock Absorber Bracket Nut Rear Shock Absorber Nut (Lower) Rear Shock Absorber Nut (Upper) Swingarm Pivot Adjusting Collar Swingarm Pivot Adjusting Collar Locknut Swingarm Pivot Shaft Nut Tie-Rod Nuts Uni-Trak Rocker Arm Nut Chain Guard Bolt 0.50...
  • Page 394: 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 1/4 turns out from the fully clockwise position (Usable range: 0 ←→ 2 1/2 turns out) Compression Damper Setting 2 3/4 turns out from the fully clockwise position (Usable range: 0 ←→...
  • Page 395: Special Tools

    SUSPENSION 13-7 Special Tools Inside Circlip Pliers: Fork Piston Rod Puller, M12 × 1.25: 57001-143 57001-1289 Oil Seal & Bearing Remover: Fork Oil Level Gauge: 57001-1058 57001-1290 Bearing Driver Set: Bearing Remover Head, 20 × 22: 57001-1129 57001-1293 Jack: Bearing Remover Shaft, 13: 57001-1238 57001-1377 Fork Oil Seal Driver, 41:...
  • Page 396 13-8 SUSPENSION Special Tools Hook Wrench T=3.2 R37: Stem Bearing Driver, 28: 57001-1539 57001-1610 Fork Spring Compressor: Clamp: 57001-1587 57001-1626 Swingarm Pivot Nut Wrench: Spacer, 57001-1597 57001-1636 Jack Attachment: Spacer, 57001-1608 57001-1637 Needle Bearing Driver, 17/ 18: Hook Wrench R37: 57001-1609 57001-1641...
  • Page 397: 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 1/4 turns out from the fully clockwise position.
  • Page 398: Spring Preload Adjustment

    13-10 SUSPENSION Front Fork Spring Preload Adjustment • Turn the spring preload adjuster [A] to change spring preload setting. ○ The standard adjuster setting for the average-build rider of 68 kg (150 lb) with no passenger and no accessories is the 20 mm (0.79 in.) [B] from top as shown. Adjuster Protrusion (from top) Standard: 20 mm (0.79 in.)
  • Page 399: Front Fork Installation

    SUSPENSION 13-11 Front Fork Front Fork Installation • Install the front fork so that the outer tube top is flush with the steering stem head. 0 mm (0 in.) [B] • Tighten the lower fork clamp bolts and fork top plug. Torque - Front Fork Clamp Bolts (Lower): 25 N·m (2.5 kgf·m, 18 ft·lb) Front Fork Top Plug: 34 N·m (3.5 kgf·m, 25 ft·lb)
  • Page 400 13-12 SUSPENSION Front Fork • Insert the holder bar [A] into the axle hole of the front fork [B]. • Insert the compression shaft and install the nut. • Insert the lower end of the compression shaft [A] into the hole [B] of the holder bar.
  • Page 401 SUSPENSION 13-13 Front Fork • Holding the piston rod nut with a wrench [A], remove the top plug assy [B] from the piston rod. • Remove: Washer [A] Collar [B] Collar [C] Fork Spring [D] • Drain the fork oil into a suitable container. ○...
  • Page 402 13-14 SUSPENSION Front Fork Oil Level (fully compressed, without spring) Standard: 115 ±2 mm (4.53 ±0.08 in.) (from the top of the outer tube) NOTE ○ Fork oil lever may also be measured using the fork oil level gauge. Special Tool - Fork Oil Level Gauge [A]: 57001-1290 ○...
  • Page 403: Front Fork Disassembly

    SUSPENSION 13-15 Front Fork • Screw in the top plug assy [A] stopped onto the piston rod. • Check the O-ring [B] on the top plug and replace it with a new one if damaged. • Holding the top plug with a wrench, tighten the piston rod nut [C] against the top plug.
  • Page 404: Front Fork Assembly

    13-16 SUSPENSION Front Fork Front Fork Assembly • Replace the following parts with a new one. Oil Seal Bottom Allen Bolt Gasket • Insert the cylinder unit [A] into the inner tube [B]. • Stop the cylinder from turning by using the fork cylinder holder.
  • Page 405: Dust Seal Inspection

    SUSPENSION 13-17 Front Fork CAUTION If the inner tube is badly bent or creased, replace Excessive bending, followed by subsequent straightening, can weaken the inner tube. • Temporarily assemble the inner and outer tubes, and pump them back and forth manually to check for smooth operation.
  • Page 406: Rear Shock Absorber

    13-18 SUSPENSION 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 15 clicks from the fully clockwise position.
  • Page 407: Spring Preload Adjustment

    SUSPENSION 13-19 Rear Shock Absorber Low Speed Compression Damping Adjustment • To adjust the compression damping force, turn the damp- ing adjuster [A] to the desired position 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 10th clicks from the fully clockwise position.
  • Page 408: Rear Shock Absorber Removal

    13-20 SUSPENSION Rear Shock Absorber • To adjust the spring preload, turn in the adjusting nut [A] to the desired position and tighten the locknut [B]. Spring Length [C] Spring Preload Setting Standard: Spring length 173.7 mm (6.84 in.) Spring length 168.7 ∼ 178.7 mm (6.642 Usable Range: ∼...
  • Page 409: 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 410: Swingarm

    13-22 SUSPENSION Swingarm Swingarm Removal • Remove: Bolts [A] Chain Cover [B] Rear Wheel (see Rear Wheel Removal in the Wheels/Tires chapter) Engine Sprocket (see Engine Sprocket Removal in the Final Drive chapter) • Remove: Bolt [A] Brake Hose Clamp [B] •...
  • Page 411: Swingarm Installation

    SUSPENSION 13-23 Swingarm • Unscrew the swingarm pivot collar locknut [A] using the swingarm pivot nut wrench [B]. Special Tool - Swingarm Pivot Nut Wrench: 57001-1597 • Unscrew the swingarm pivot shaft [A] few turns. ○ Turn out the swingarm pivot adjusting collar [B]. •...
  • Page 412: Swingarm Bearing Removal

    13-24 SUSPENSION Swingarm ○ Be sure to install the washer [A]. • Tighten the adjusting collar locknut [A] with the swingarm pivot nut wrench [B]. Special Tool - Swingarm Pivot Nut Wrench: 57001-1597 Torque - Swingarm Pivot Adjusting Collar Locknut: 98 N·m (10 kgf·m, 72 ft·lb) •...
  • Page 413: Swingarm Bearing Installation

    SUSPENSION 13-25 Swingarm Swingarm Bearing Installation • Replace the ball and needle bearings [A] with new ones. • Install the ball and needle bearings so that the manufac- turer’s marks face out. Special Tools - Bearing Driver Set: 57001-1129 Needle Bearing Driver, 28 [B]: 57001-1610 Spacer, 28: 57001-1637 •...
  • Page 414: Chain Guide Inspection

    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 415: Tie-rod, Rocker Arm

    SUSPENSION 13-27 Tie-Rod, Rocker Arm Tie-Rod Removal • Remove the lower fairings (see Lower Fairing Removal in the Frame chapter). • Squeeze the brake lever slowly and hold it with a band [A]. • Using the jack, raise the rear wheel off the ground. Special Tools - Jack: 57001-1238 Jack Attachment: 57001-1608 •...
  • Page 416: Rocker Arm Installation

    13-28 SUSPENSION Tie-Rod, Rocker Arm Rocker Arm Installation • Apply grease to the inside of the grease seals. • Tighten: Torque - Uni-Trak Rocker Arm Nut: 34 N·m (3.5 kgf·m, 25 ft·lb) Tie-Rod Nuts: 59 N·m (6.0 kgf·m, 43 ft·lb) Rear Shock Absorber Nut (Lower): 34 N·m (3.5 kgf·m, 25 ft·lb) Tie-Rod and Rocker Arm Bearing Removal...
  • Page 417 SUSPENSION 13-29 Tie-Rod, Rocker Arm ○ Screw the needle bearing driver [A] into the driver holder [B]. ○ Insert the needle bearing driver into the needle bearing [C] and press the needle bearing into the housing until the driver contacts the end surface of the housing. Bearing Pressing Depth: 5.5 mm (0.22 in.)[D] 5.0 mm (0.20 in.)[E] NOTE...
  • Page 418: Rocker Arm/tie-rod Bearing, Sleeve Inspection

    13-30 SUSPENSION Tie-Rod, Rocker Arm Rocker Arm/Tie-Rod Bearing, Sleeve Inspection CAUTION Do not remove the bearings for inspection. Re- moval may damage them. • Visually inspect the locker arm, or tie-rod sleeves [A] and needle bearings [B]. • The rollers in a needle bearing normally wear very little, and wear is difficult to measure.
  • Page 419 STEERING 14-1 Steering Table of Contents Exploded View........................14-2 Special Tools .......................... 14-4 Steering ..........................14-5 Steering Inspection ......................14-5 Steering Adjustment......................14-5 Steering Stem......................... 14-6 Steering Stem, Steering Stem Bearing Removal.............. 14-6 Steering Stem, Steering Stem Bearing Installation............14-7 Steering Stem Bearing Lubrication ...................
  • Page 420: Exploded View

    14-2 STEERING Exploded View...
  • Page 421 STEERING 14-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Fork Clamp Bolts (Lower) Front Fork Clamp Bolts (Upper) Handlebar Bolts Handlebar Position Bolts 87 in·lb Steering Stem Head Nut Steering Stem Nut Handlebar Switch Housing Screws 0.36 31 in·lb AD: Apply adhesive.
  • Page 422: Special Tools

    14-4 STEERING Special Tools Bearing Puller Adapter: Bearing Driver Set: 57001-136 57001-1129 Bearing Puller: Steering Stem Bearing Driver, 42.5: 57001-158 57001-1344 Head Pipe Outer Race Press Shaft: Steering Stem Bearing Driver Adapter, 41.5: 57001-1075 57001-1345 Steering Stem Nut Wrench: Head Pipe Outer Race Driver, 55: 57001-1100 57001-1446...
  • Page 423: 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 424: Steering Stem

    14-6 STEERING Steering Stem Steering Stem, Steering Stem Bearing Removal • Remove: Upper Fairing (see Upper Fairing Removal in the Frame chapter) Front Wheel (see Front Wheel Removal in the Wheels/Tires chapter) Front Fork (see Front Fork Removal in the Suspension chapter) Brake Hose Clamp Bolt [A] •...
  • Page 425: Steering Stem, Steering Stem Bearing Installation

    STEERING 14-7 Steering Stem • Remove the lower bearing inner race (with its oil seal) [A] which is pressed onto the steering stem [B] with the bearing puller [C] and adapter [D]. Special Tools - Bearing Puller Adapter: 57001-136 Bearing Puller: 57001-158 Steering Stem, Steering Stem Bearing Installation •...
  • Page 426 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 (To tighten the stem nut to the specified torque, hook the wrench on the stem nut, and pull the wrench at the hole by 305 N (31.0 kgf, 69 lb) [B] force in the direction shown.).
  • Page 427: Steering Stem Bearing Lubrication

    STEERING 14-9 Steering Stem NOTE ○ Tighten the upper fork clamp bolts [A] first, next the steering stem head nut [B], last the lower fork clamp bolts [C] and the handlebar bolts [D]. ○ Tighten the two lower fork clamp bolts alternately two times to ensure even tightening torque.
  • Page 428: Handlebar

    14-10 STEERING Handlebar Handlebar Removal • Remove: Clutch Lever Clamp Bolts [A] Clutch Lever Assembly [B] Left Handlebar Switch Housing [C] Handlebar Weight [D] • Remove: Front Brake Master Cylinder [A] (see Front Master Cylin- der Removal in the Brakes chapter) Right Handlebar Switch Housing [B] Throttle Case [C] Handlebar Weight [D]...
  • Page 429 STEERING 14-11 Handlebar • Install the left and right handlebar switch housings. ○ Fit the projection [A] into a small hole [B] in the handlebar. Torque - Handlebar Switch Housing Screws: 3.5 N·m (0.36 kgf·m, 31 in·lb) • Install: Clutch Lever (see Clutch Lever Installation in the Clutch chapter) •...
  • Page 431 FRAME 15-1 Frame Table of Contents Exploded View........................15-2 Seats ............................15-8 Rear Seat Removal......................15-8 Rear Seat Installation......................15-8 Front Seat Removal ......................15-8 Front Seat Installation ....................... 15-8 Fairings........................... 15-9 Lower Fairing Removal ..................... 15-9 Lower Fairing Installation ....................15-9 Center Fairing Removal ....................
  • Page 432: Exploded View

    15-2 FRAME Exploded View...
  • Page 433 FRAME 15-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Footpeg Bracket Bolts Rear Footpeg Bracket Bolts Rear Frame Bolts L (2) Side Stand Bolt Side Stand Bracket Bolts Side Stand Switch Bolt 0.90 78 in·lb Side Stand Switch Bracket Bolt 0.40 G: Apply grease.
  • Page 434 15-4 FRAME Exploded View...
  • Page 435 FRAME 15-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Fender Mounting Bolts 0.40 35 in·lb 2. United States and Canada Models R: Replacement Parts...
  • Page 436 15-6 FRAME Exploded View...
  • Page 437 FRAME 15-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Air Inlet Duct Mounting Bolts 0.70 Windshield Mounting Bolts 0.04 4 in·lb L: Apply a non-permanent locking agent. R: Replacement Parts...
  • Page 438: Seats

    15-8 FRAME Seats Rear Seat Removal • Insert the ignition switch key [A] into the seat lock, turning the key counterclockwise, pulling the front part of the seat [B] up, and pull the seat forward. Rear Seat Installation • Slip the rear seat hook [A] into the brace [B]. •...
  • Page 439: Fairings

    FRAME 15-9 Fairings Lower Fairing Removal • Remove: Bolts [A] with Washers • Clear the hook portion from the slot. • Pull up the core [A] by the thin blade driver. • Remove: Quick Rivets [B] • Separate the right lower fairing from the left lower fairing. Lower Fairing Installation •...
  • Page 440: Center Fairing Installation

    15-10 FRAME Fairings • Remove: Right Turn Signal Lead Connector [A] Center Fairing Installation • Install the separator bracket bolt (California Model). • Connect the turn signal lead connectors. • Insert the hook [A] into the slot [B]. • Install the washers and bolts. Windshield Removal •...
  • Page 441: Upper Fairing Disassembly

    FRAME 15-11 Fairings • Open the clamps [A] (Both Side). • Disconnect the meter lead connector [A]. • Remove: Bolts [A] (Both Side) Upper Fairing ○ Pull out the upper fairing forward. Upper Fairing Disassembly • Remove: Center Inner Fairing (see Center Inner Fairing Removal) Nuts [A] and Rear View Mirrors (Both Side) Meter Unit (see Meter Unit Removal in the Electrical Sys- tem chapter)
  • Page 442: Upper Fairing Installation

    15-12 FRAME Fairings Upper Fairing Installation • Fit the opening [A] of the upper fairing into the ram air duct [B]. • Apply a non-permanent locking agent to the threads and, tighten the bolts. Torque - Air Inlet Duct Mounting Bolts: 6.9 N·m (0.70 kgf·m, 61 in·lb) Upper Inner Fairing Removal •...
  • Page 443: Right And Left Inner Fairing Removal

    FRAME 15-13 Fairings Right and Left Inner Fairing Removal • Remove: Right and Left Center Fairings (see Center Fairing Re- moval) Bolts [A] Inner Fairing [B] Right and Left Inner Fairing Installation • Tighten the bolts [A].
  • Page 444: Side Covers

    15-14 FRAME Side Covers Left Side Cover Removal • Remove: Bolts [A] • Pull out the left side cover [B]. Left Side Cover Installation • Insert the projections [A] of the left side cover into the holes [B]. Right Side Cover Removal •...
  • Page 445: Seat Cover

    FRAME 15-15 Seat Cover Seat Cover Removal • Remove: Seats (see Rear/Front Seat Removal) Bolts [A] • Remove: Rivet Screws [A] • Pull the seat cover backward, and clear the stoppers. • Disconnect: Tail/Brake Light Connector [A] • Remove: Bolts [A] Tail/Brake Light [B] Seat Cover Installation •...
  • Page 446: Fenders

    15-16 FRAME Fenders Front Fender Removal • Remove: Brake Hose Clamps [A] (Both Side) Bolts [B] with Washer (Both Side) • Remove the front fender assy [C]. • Remove: Bolts [A] • Separate the front fender cover [B] and front fender [C]. Front Fender Installation •...
  • Page 447: Flap And Rear Fender Rear Installation

    FRAME 15-17 Fenders • Remove: Nuts [A] Bolts [B] Flap [C] (with License Light) Turn Signal Lights • Remove: Muffler Body and Center Pipe (see Muffler Body Re- moval in the Engine Top End chapter) Battery (see Battery Removal in the Electrical System chapter) Exhaust Butterfly Valve Actuator (see Exhaust Butterfly Valve Actuator Removal in the Fuel System (DFI) chap-...
  • Page 448: Rear Fender Front Removal

    15-18 FRAME Fenders • Install the removed parts (see appropriate chapters). • Install the harness clamp in accordance with Cable, Wire, and Hose Routing section in the Appendix chapter. • Install the flap. If there is a gap between the tire and flap, adjust it using the washer [A].
  • Page 449: Frame

    FRAME 15-19 Frame Rear Frame Removal • Remove: Rear Fender Front (see Rear Fender Front Removal) Frame Bolts [A] and Nuts Rear Footpeg Bracket Bolts [B] and Bracket (Both Side) Rear Frame Installation • Apply a non-permanent locking agent to the threads of rear frame bolt.
  • Page 450: Side Stand

    15-20 FRAME Side Stand Side Stand Removal • Raise the rear wheel off the ground with the stand. • Remove: Lower Fairings (see Lower Fairing Removal) Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) • Disconnect the side stand switch lead connector [A]. •...
  • Page 451 ELECTRICAL SYSTEM 16-1 Electrical System Table of Contents Parts Location........16-3 Stick Coil (Ignition Coil together Exploded View........16-4 with Spark Plug Cap) Removal . 16-39 Wiring Diagram (United States and Stick Coil (Ignition Coil together Canada) .......... 16-10 with Spark Plug Cap) Wiring Diagram (Other than United Installation .........
  • Page 452 16-2 ELECTRICAL SYSTEM Tail/Brake Light (LED) Installation 16-54 Switch Inspection ......16-71 License Plate Light Bulb Water Temperature Sensor Replacement ......16-54 Inspection........16-72 Turn Signal Light Bulb Speed Sensor Removal ....16-72 Replacement ......16-55 Speed Sensor Installation .... 16-72 Turn Signal Relay Inspection ..
  • Page 453: Parts Location

    ELECTRICAL SYSTEM 16-3 Parts Location 1. Starter Lockout Switch 12. Starter Motor 2. Ignition Switch 13. Speed Sensor 3. Stick Coils 14. Side Stand Switch 4. Water Temperature Sensor 15. Neutral Switch 5. Alternator 16. Turn Signal Relay 6. Starter Relay with Main Fuse 17.
  • Page 454: Exploded View

    16-4 ELECTRICAL SYSTEM Exploded View...
  • Page 455 ELECTRICAL SYSTEM 16-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Turn Signal Light Lens Screws 0.10 9 in·lb Front Turn Signal Light Mounting Screws 0.12 10 in·lb Licence Light Assembly Screws 0.09 8 in·lb Licence Light Mounting Screws 0.12 10 in·lb Meter Mounting Screws...
  • Page 456 16-6 ELECTRICAL SYSTEM Exploded View...
  • Page 457 ELECTRICAL SYSTEM 16-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Brake Light Switch Screw 0.12 10 in·lb Starter Motor Clutch Bolts Starter Motor Mounting Bolts 97 in·lb Starter Motor Lead Terminal Bolt 0.28 24 in·lb Starter Relay Lead Terminal Bolts 0.40 35 in·lb Handlebar Switch Housing Screws...
  • Page 458 16-8 ELECTRICAL SYSTEM Exploded View...
  • Page 459 ELECTRICAL SYSTEM 16-9 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Alternator Cover Bolts 104 in·lb Alternator Lead Holding Plate Bolts 0.70 61 in·lb Alternator Rotor Bolt Camshaft Position Sensor Bolt 104 in·lb Crankshaft Sensor Bolts 0.60 52 in·lb Crankshaft Sensor Cover Bolts 87 in·lb L (1) Engine Ground Lead Terminal Bolt...
  • Page 460: Wiring Diagram (united States And Canada)

    16-10 ELECTRICAL SYSTEM Wiring Diagram (United States and Canada)
  • Page 461 ELECTRICAL SYSTEM 16-11 Wiring Diagram (United States and Canada)
  • Page 462: Wiring Diagram (other Than United States And Canada)

    16-12 ELECTRICAL SYSTEM Wiring Diagram (Other than United States and Canada)
  • Page 463 ELECTRICAL SYSTEM 16-13 Wiring Diagram (Other than United States and Canada)
  • Page 464: Wiring Diagram (australia)

    16-14 ELECTRICAL SYSTEM Wiring Diagram (Australia)
  • Page 465 ELECTRICAL SYSTEM 16-15 Wiring Diagram (Australia)
  • Page 466: Specifications

    16-16 ELECTRICAL SYSTEM Specifications Item Standard Battery Type Sealed battery Capacity 12 V 8 Ah Voltage 12.8 V or more Charging System Type Three-phase AC Alternator Output Voltage 42 V or more @4 000 r/min (rpm) 0.3 ∼ 0.4 Ω Stator Coil Resistance 14.2 ∼...
  • Page 467: Special Tools And Sealant

    Special Tools and Sealant Flywheel Holder: Lead Wire - Peak Voltage Adapter: 57001-1313 57001-1449 Hand Tester: Harness Adapter: 57001-1394 57001-1542 Flywheel Puller Assembly, M38 × 1.5/M35 × 1.5: Flywheel & Pulley Holder: 57001-1405 57001-1605 Peak Voltage Adapter: Kawasaki Bond (Silicone Sealant): 57001-1415 92104-0004...
  • Page 468: Precautions

    16-18 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 lead connections. This will burn out the diodes on the electrical parts. ○...
  • Page 469 ELECTRICAL SYSTEM 16-19 Precautions Male Connectors [B]...
  • Page 470: Electrical Wiring

    16-20 ELECTRICAL SYSTEM 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 471: Battery

    ELECTRICAL SYSTEM 16-21 Battery Battery Removal • Remove: Front Seat (see Front Seat Removal in the Frame chap- ter) Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Bolts [A] Connector [B] Fuel Tank Bracket [C] • Slide the caps [A].
  • Page 472 16-22 ELECTRICAL SYSTEM Battery CAUTION Do not remove the aluminum sealing sheet [A] from the filler ports [B] until just prior to use. Be sure to use the dedicated electrolyte container for correct electrolyte volume. • Place the battery on a level surface. •...
  • Page 473 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 474: Precautions

    16-24 ELECTRICAL SYSTEM Battery NOTE ○ To ensure maximum battery life and customer satisfac- tion, it is recommended the battery be load tested at three times its amp-hour rating for 15 seconds. Re-check voltage and if less than 12.8 V repeat the charging cycle and load test.
  • Page 475: Charging Condition Inspection

    ELECTRICAL SYSTEM 16-25 Battery Charging Condition Inspection ○ Battery charging condition can be checked by measuring battery terminal voltage with a digital voltmeter [A]. • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Battery Cable Caps (see Battery Removal) •...
  • Page 476 16-26 ELECTRICAL SYSTEM Battery NOTE ○ Increase the charging voltage to a maximum voltage of 25 V if the battery will not accept current initially. Charge for no more than 5 minutes at the increased voltage then check if the battery is drawing current. If the battery will accept current decrease the voltage and charge by the standard charging method described on the battery case.
  • Page 477: Charging System

    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 478: Alternator Rotor Removal

    16-28 ELECTRICAL SYSTEM Charging System • Secure the alternator lead with a holding plate, and apply a non-permanent locking agent to the threads of the plate bolts and tighten them. Torque - Alternator Lead Holding Plate Bolts: 6.9 N·m (0.70 kgf·m, 61 in·lb) •...
  • Page 479: Alternator Inspection

    ELECTRICAL SYSTEM 16-29 Charging System • Install the alternator rotor [A] while turning [B] it counter- clockwise. • Install the washer [A]. NOTE ○ Confirm the alternator rotor fit or not to the crankshaft before tightening it with specified torque. •...
  • Page 480 16-30 ELECTRICAL SYSTEM Charging System • To check the alternator output voltage, do the following procedures. ○ Turn off the ignition switch. ○ Remove the fuel tank (see Fuel Tank Removal in the Fuel System (DFI) chapter). ○ Disconnect the alternator lead connector [A]. ○...
  • Page 481: Regulator/rectifier Removal

    ELECTRICAL SYSTEM 16-31 Charging System Regulator/Rectifier Removal • Remove: Bolts [A] Regulator/Rectifier [B] • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Connector [A] Regulator/Rectifier Inspection Rectifier Circuit Check • Check the rectifier resistance as follows. •...
  • Page 482 16-32 ELECTRICAL SYSTEM Charging System Regulator Circuit Check To test the regulator out of circuit, use three 12 V batteries and a test light (12 V 3 ∼ 6 W bulb in a socket with leads). CAUTION The test light works as an indicator and also a cur- rent limiter to protect the regulator/rectifier from ex- cessive current.
  • Page 483: Charging Voltage Inspection

    ELECTRICAL SYSTEM 16-33 Charging System Charging Voltage Inspection • Check the battery condition (see Charging Condition In- spection). • Warm up the engine to obtain actual alternator operating conditions. • Remove: Front Seat (see Front Seat Removal in the Frame chap- ter) Caps •...
  • Page 484 16-34 ELECTRICAL SYSTEM Charging System Charging System Circuit 1. Ignition Switch 2. Alternator 3. Regulator/rectifier 4. Main Fuse 30 A 5. Battery 12 V 8 Ah 6. Load...
  • Page 485: Starter Motor Clutch Removal/installation

    ELECTRICAL SYSTEM 16-35 Starter Motor Clutch Starter Motor Clutch Removal/Installation • Refer to the Alternator Rotor Removal and Installation. Starter Motor Clutch Inspection • Remove: Alternator Cover (see Alternator Cover Removal) Starter Idle Gear • Turn the starter motor clutch gear [A] by hand. The starter motor clutch gear should turn clockwise [B] freely, but should not turn counterclockwise [C].
  • Page 486: Ignition System

    16-36 ELECTRICAL SYSTEM Ignition System...
  • Page 487: Crankshaft Sensor Removal

    ELECTRICAL SYSTEM 16-37 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 488: Crankshaft Sensor Installation

    Torque - Crankshaft Sensor Bolts: 5.9 N·m (0.60 kgf·m, 52 in·lb) • Apply silicone sealant. Crankshaft Sensor Lead Grommet (Around) [A] Crankcase Halves Mating Surfaces [B] Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004 • Install the gasket. • Apply a non-permanent locking agent. Crankshaft Sensor Cover Bolt [A] •...
  • Page 489: Timing Rotor Removal

    ELECTRICAL SYSTEM 16-39 Ignition System • Set the hand tester [A] to the DC 10 V range, and connect the peak voltage adapter [B]. • Connect the black lead (–) [D] of the adapter to black/yel- low lead and red lead (+) [C] to black lead in the crankshaft sensor connector [E].
  • Page 490: Stick Coil (ignition Coil Together With Spark Plug Cap) Installation

    16-40 ELECTRICAL SYSTEM Ignition System Stick Coil (Ignition Coil together with Spark Plug Cap) Installation • Connect the connectors [A]. CAUTION Do not tap the coil head while installing the coil. • Run the hoses and harness correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter).
  • Page 491: Stick Coil Primary Peak Voltage

    ELECTRICAL SYSTEM 16-41 Ignition System Stick Coil Primary Peak Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Remove the stick coils (see Stick Coil (Ignition Coil to- gether with Spark Plug Cap) Removal), but do not remove the spark plugs.
  • Page 492: Spark Plug Clean And Inspection

    16-42 ELECTRICAL SYSTEM Ignition System Spark Plug Clean and Inspection • Refer to the Spark Plug Clean and Gap Inspection in the Periodic Maintenance chapter. Spark Plug Gap Inspection • Refer to the Spark Plug Clean and Gap Inspection in the Periodic Maintenance chapter.
  • Page 493: Camshaft Position Sensor Peak Voltage Inspection

    ELECTRICAL SYSTEM 16-43 Ignition System • Set the hand tester to the × 10 Ω range and connect it to the terminals. Special Tool - Hand Tester: 57001-1394 If there is more resistance than the specified value, the sensor coil has an open lead and must be replaced. Much less than this resistance means the sensor coil is shorted, and must be replaced.
  • Page 494: Interlock Operation Inspection

    16-44 ELECTRICAL SYSTEM Ignition System Interlock Operation Inspection • Using the stand [A], raise the rear wheel off the ground. 1st Check • Start the engine to the following conditions. Condition Transmission Gear → 1st Position Clutch Lever → Release Side Stand →...
  • Page 495: Ic Igniter Inspection

    ELECTRICAL SYSTEM 16-45 Ignition System IC Igniter Inspection ○ The IC igniter is built in the ECU [A]. • Refer to the Interlock Operation Inspection, Ignition Sys- tem Troubleshooting chart and Fuel System (DFI) chapter for ECU Power Supply Inspection.
  • Page 496 16-46 ELECTRICAL SYSTEM Ignition System Ignition System Circuit 1. ECU 13. Ignition Switch 2. Side Stand Switch 14. Starter Lockout Switch 3. Crankshaft Sensor 15. ECU Fuse 15 A 4. Main Throttle Sensor 16. Ignition Fuse 10 A 5. Subthrottle Sensor 17.
  • Page 497: Electric Starter System

    ELECTRICAL SYSTEM 16-47 Electric Starter System Starter Motor Removal • Remove the fuel tank (see Fuel Tank Removal in the Fuel System (DFI) chapter). • Slide back the rubber cap. • Remove the starter motor terminal bolt [A] and the mount- ing bolts [B].
  • Page 498: Brush Inspection

    16-48 ELECTRICAL SYSTEM Electric Starter System • Press the springs holding the brush leads with suitable clips [A] as shown. • Put the armature [B] among the brushes. • Install the O-rings [A] as shown. • Align the groove [A] in the right-hand end cover and the hollow mark [B] on the yoke.
  • Page 499: Commutator Cleaning And Inspection

    ELECTRICAL SYSTEM 16-49 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 500: Right-hand End Cover Assembly Inspection

    16-50 ELECTRICAL SYSTEM Electric Starter System Right-hand End Cover Assembly Inspection • Using the highest hand tester range, measure the resis- tance as shown. Terminal and Right-hand End Cover [A] Special Tool - Hand Tester: 57001-1394 If there is any reading, the right-hand end cover assembly have a short.
  • Page 501 ELECTRICAL SYSTEM 16-51 Electric Starter System Electric Starter Circuit 1. Ignition Switch 9. Starter Circuit Relay 2. Engine Stop Switch 10. Ignition Fuse 10 A 3. Starter Button 11. Diode 4. Neutral Switch 12. Starter Lockout Switch 5. Side Stand Switch 13.
  • Page 502: Lighting System

    16-52 ELECTRICAL SYSTEM 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 503: City Light Bulb Replacement (europe Models)

    ELECTRICAL SYSTEM 16-53 Lighting System • Turn the dust cover clockwise, align the mark [A] on the headlight and mark [B] the dust cover. • After installation, adjust the headlight aim (see Headlight Aiming Inspection in the Periodic Maintenance chapter). City Light Bulb Replacement (Europe Models) •...
  • Page 504: Tail/brake Light (led) Removal

    16-54 ELECTRICAL SYSTEM Lighting System Tail/Brake Light (LED) Removal • Remove: Seat Cover (see Seat Cover Removal in the Frame chapter) • Unscrew the mounting bolts [A]. • Remove the tail/brake light (LED) [B]. Tail/Brake Light (LED) Installation • Refer to the Seat Cover Installation in the Frame chapter. License Plate Light Bulb Replacement •...
  • Page 505: Turn Signal Light Bulb Replacement

    ELECTRICAL SYSTEM 16-55 Lighting System Headlight/Tail Light Circuit 10. Headlight Relay 1. Ignition Switch 2. Headlight (High Beam) 11. Relay Box 3. Headlight (Low Beam) 12. Headlight Fuse 10 A 4. Regulator/Rectifier 13. Tail Light Fuse 10 A 5. License Plate Light 14.
  • Page 506 16-56 ELECTRICAL SYSTEM Lighting System • Unscrew: Screw [A] • Remove: Turn Signal Light [B] • Unscrew the screw [A] and removed the signal lens [B]. • Push and turn the bulb counterclockwise and remove it. • 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.
  • Page 507: Turn Signal Relay Inspection

    ELECTRICAL SYSTEM 16-57 Lighting System • Insert the new bulb [A] by aligning its upper and lower pins [B] with the upper and lower grooves [C] in the socket, ant turn the bulb clockwise. Turn Signal Relay Inspection • Remove: Seat Cover (see Seat Cover Removal in the Frame chapter) Turn Signal Relay [A]...
  • Page 508 16-58 ELECTRICAL SYSTEM Lighting System Other than United States and Canada Models • Connect one 12 V battery and turn signal lights as indi- cated in the figure, and count how may times the lights flash for one minute. Turn Signal Relay [A] Turn Signal Lights [B] 12 V Battery [C] If the lights do not flash as specified, replace the turn sig-...
  • Page 509 ELECTRICAL SYSTEM 16-59 Lighting System Turn Signal Light Circuit 1. Meter Unit 7. Turn Signal Relay 2. Ignition Switch 8. Main Fuse 30 A 3. Front Right Turn Signal Light 9. Battery 12 V 8 Ah 4. Front Left Turn Signal Light 10.
  • Page 510: Radiator Fan System

    16-60 ELECTRICAL SYSTEM Radiator Fan System Fan Motor Inspection • Remove the air cleaner housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter). • Disconnect the connector [A]. • Using an auxiliary leads, supply battery power to the fan motor.
  • Page 511: Meter, Gauge, Indicator Unit

    ELECTRICAL SYSTEM 16-61 Meter, Gauge, Indicator Unit Meter Unit Removal • Remove: Upper Fairing (see Upper Fairing Removal in the Frame chapter) Nuts [A] Screws [B] • Remove the bolts [A]. • Remove the screws [A]. CAUTION Place the meter unit so that the face is up. If a meter unit is left upside down or sideways for any length of time, it will malfunction.
  • Page 512: Electronic Combination Meter Unit Inspection

    16-62 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit Electronic Combination Meter Unit Inspection • Remove the meter unit [A] (see Meter Unit Removal in this chapter). [1] Ignition [2] Fuel Reserve Switch [3] Stop Watch (+) [4] Lap Time (+) [5] Neutral Indicator Light (LED) Ground (–) [6] FI Indicator Light (LED) Ground (–) [7] Tachometer Pulse [8] Water Temperature Sensor...
  • Page 513 ELECTRICAL SYSTEM 16-63 Meter, Gauge, Indicator Unit ○ The tachometer LCD segments momentarily to it last readings two times and segment movement is reversal. ○ When the terminals are connected, all the LCD segments [A] and light (LED) [B] appear for three seconds. If the LCD segments and warning light (LED) will not ap- pear, replace the meter unit.
  • Page 514 16-64 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit • In the HOUR setting mode, press the reset button [C] to effect the MINUTE setting mode. ○ The minute display flashes on the display. • Press the mode selector button [A] to set the minute. •...
  • Page 515 ELECTRICAL SYSTEM 16-65 Meter, Gauge, Indicator Unit Speed Sensor Electric Source Check • Connect the 12 V battery and terminals in the same man- ner as specified in the “Liquid Crystal Display (LCD) Seg- ments Check”. • Set the hand tester to the DC 25 V range and connect it to the terminals [12] and [9].
  • Page 516 16-66 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit Tachometer Check • Connect the 12 V battery and terminals in the same man- ner as specified in the “Liquid Crystal Display (LCD) Seg- ments Check”. • The revolutions per minute (rpm) equivalent to the input frequency is indicated in the oscillator [A] if the square wave (illustrated as shown) would be input into the termi- nal [7].
  • Page 517 ELECTRICAL SYSTEM 16-67 Meter, Gauge, Indicator Unit Stop Watch Check • Connect the 12 V battery and terminal in the same man- ner as specified in the “Liquid Crystal Display (LCD) Seg- ments Check”. • Press the mode selector button each time to set the stop watch mode.
  • Page 518 16-68 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit FI Indicator Light (LED) Battery Negative (–) Terminal To Terminal [6] Oil Pressure Warning Indicator Light (LED) Battery Negative (–) Terminal To Terminal [11] Right and Left Turn Signal Indicator Light (LED) Battery Positive (+) Terminal to Terminal [13] Battery Positive (+) Terminal to Terminal [14] High Beam Indicator Light (LED) Battery Positive (+) Terminal to Terminal [15]...
  • Page 519 ELECTRICAL SYSTEM 16-69 Meter, Gauge, Indicator Unit Shift Up Indicator Light (LED) • Connect the 12 V battery and terminal in the same man- ner as specified in the “Liquid Crystal Display (LCD) Seg- ments Check”. • The revolutions per minute (rpm) equivalent to the input frequency is indicated in the oscillator [A] if the square wave (illustrated as shown) would be input into the termi- nal [7].
  • Page 520: Switches And Sensors

    16-70 ELECTRICAL SYSTEM Switches and Sensors Brake Light Timing Inspection • Refer to the Brake Light Switch Operation Inspection in the Periodic Maintenance chapter. Brake Light Timing Adjustment • Refer to the Brake Light Switch Operation Inspection in the Periodic Maintenance chapter. Neutral Switch Replacement CAUTION Never drop the neutral switch, especially on a hard...
  • Page 521: Switch Inspection

    ELECTRICAL SYSTEM 16-71 Switches and Sensors Switch Inspection • Using a hand tester, check to see that only the con- nections shown in the table have continuity (about zero ohms). ○ For the handlebar switches and the ignition switch, refer to the tables in the Wiring Diagram.
  • Page 522: Water Temperature Sensor Inspection

    16-72 ELECTRICAL SYSTEM Switches and Sensors Water Temperature Sensor Inspection • Remove the water temperature sensor (see Water Tem- perature Sensor Removal in the Fuel System (DFI) chap- ter). • Suspend the sensor [A] in a container of coolant so that the temperature-sensing projection [E] and threaded por- tion [E] are submerged.
  • Page 523: Speed Sensor Inspection

    ELECTRICAL SYSTEM 16-73 Switches and Sensors Speed Sensor Inspection • Remove: Speed Sensor (see Speed Sensor Removal) • Connect the speed sensor connector [A] with the battery [B], 10 kΩ resistor [C] and hand tester [D] as shown. • Set the tester to the DC 25 V range. Special Tool - Hand Tester: 57001-1394 •...
  • Page 524: Relay Box

    16-74 ELECTRICAL SYSTEM Relay Box The relay box [A] has relays and diodes. The relays and diodes can not be removed. Relay Box Removal • Remove: Seat Cover (see Seat Cover Removal in the Frame chapter) • Take out the relay box [A] and disconnect the connectors [B].
  • Page 525: Diode Circuit Inspection

    ELECTRICAL SYSTEM 16-75 Relay Box Relay Circuit Inspection (with the battery connected) Battery Tester Tester Connection Connection Reading (Ω) (–) 15-9 11-16 ECU Main Relay 5-10 12-13 Fuel Pump Relay 12-14 Fan Relay 18-20 17-19 Battery Tester Connection Tester Connection DC 25 V Range Reading (V) (–)
  • Page 526 16-76 ELECTRICAL SYSTEM Relay Box A: Headlight Relay B: ECU Main Relay C: Fuel Pump Relay D: Starter Circuit Relay E: Fan Relay...
  • Page 527: Fuse

    ELECTRICAL SYSTEM 16-77 Fuse 30 A Main Fuse Removal • Remove: Left Side Cover (see Left Side Cover Removal in the Frame chapter) 30 A Main Fuse Connector [A] • Pull out the main fuse [A] from the starter relay with needle nose pliers.
  • Page 528: Fuse Installation

    16-78 ELECTRICAL SYSTEM Fuse • Pull the ECU fuse [A] straight out of the fuse box with needle nose pliers. 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.
  • Page 529 APPENDIX 17-1 Appendix Table of Contents Cable, Wire, and Hose Routing ....................17-2 Cable, Wire, and Hose Routing (US Model)................17-4 Cable, Wire, and Hose Routing (Other them US Model)............17-6 Cable, Wire, and Hose Routing ....................17-8 Troubleshooting Guide ......................17-30...
  • Page 530: Cable, Wire, And Hose Routing

    17-2 APPENDIX Cable, Wire, and Hose Routing...
  • Page 531 APPENDIX 17-3 Cable, Wire, and Hose Routing 1. Meter Connector 2. Left Switch Housing Lead Connector 3. Front Right Turn Signal Light Connector 4. Headlight Harness Connector 5. Clamp 6. Right Switch Housing Lead Connector 7. Horn Lead Connectors 8. Clamp the horn lead. 9.
  • Page 532: Cable, Wire, And Hose Routing (us Model)

    17-4 APPENDIX Cable, Wire, and Hose Routing (US Model)
  • Page 533 APPENDIX 17-5 Cable, Wire, and Hose Routing (US Model) 1. Fuel Pump Lead 2. Fuel Tank 3. Frame 4. Clamp 5. Clamp 6. Fuel Pump Lead Connector 7. Vehicle-down Sensor Lead Connector 8. Clamp 9. Self-diagnosis Indicator Terminal 10. Exhaust Butterfly Valve Actuator Lead Connector 11.
  • Page 534: Cable, Wire, And Hose Routing (other Them Us Model)

    17-6 APPENDIX Cable, Wire, and Hose Routing (Other them US Model)
  • Page 535 APPENDIX 17-7 Cable, Wire, and Hose Routing (Other them US Model) 1. Fuel Pump Lead 2. Fuel Tank 3. Frame 4. Clamp 5. Clamp 6. Fuel Pump Lead Connector 7. Vehicle-down Sensor Lead Connector 8. Clamp 9. Self-diagnosis Indicator Terminal 10.
  • Page 536: Cable, Wire, And Hose Routing

    17-8 APPENDIX Cable, Wire, and Hose Routing...
  • Page 537 APPENDIX 17-9 Cable, Wire, and Hose Routing 1. Battery Positive Terminal 2. Starter Relay 3. Battery Negative Terminal 4. Clamp 5. Relay Box 6. Run the seat lock cable into the relay box bracket. 7. Fuse Box 8. Turn Signal Relay 9.
  • Page 538 17-10 APPENDIX Cable, Wire, and Hose Routing...
  • Page 539 APPENDIX 17-11 Cable, Wire, and Hose Routing 1. Meter Connector 2. Clamp the meter connector and front turn signal light connector. 3. Front Left Turn Signal Light Connector 4. Left Handlebar Switch Housing Lead 5. Clamp (United States, Canada and California Model only) 6.
  • Page 540 17-12 APPENDIX Cable, Wire, and Hose Routing...
  • Page 541 APPENDIX 17-13 Cable, Wire, and Hose Routing 1. Reserve Return Hose 2. Clamp 3. Starter Motor Cable 4. Main Harness 5. Run the harnesses under the breather hose. 6. Clamp 7. Clamp 8. Speed Sensor 9. Force the harness into between the bosses of the upper crankcase. 10.
  • Page 542 17-14 APPENDIX Cable, Wire, and Hose Routing...
  • Page 543 APPENDIX 17-15 Cable, Wire, and Hose Routing 1. Insert the holes of heat insulation rubber plate in to the radiator stay. 2. Run the fan lead from the holes of heat insulation rubber plate. 3. After install the holes of heat insulation rubber plate, clamp the lead as shown. 4.
  • Page 544 17-16 APPENDIX Cable, Wire, and Hose Routing...
  • Page 545 APPENDIX 17-17 Cable, Wire, and Hose Routing 1. Front 2. Horn Lead 3. Clamps 4. Fit the clamp to the air suction valve cover. 5. Vacuum Switch Valve 6. Radiator Fan Lead 7. Clamp the together with radiator fan lead and horn lead. 8.
  • Page 546 17-18 APPENDIX Cable, Wire, and Hose Routing...
  • Page 547 APPENDIX 17-19 Cable, Wire, and Hose Routing 1. Radiator 2. Clamp 3. Radiator Over Flow Hose 4. Clamp 5. Radiator Return Hose 6. To the Cylinder Head 7. Install the bolt head of the hose clamp as shown. 8. Insert water hose to the corner position of the radiator pipe. 9.
  • Page 548 17-20 APPENDIX Cable, Wire, and Hose Routing...
  • Page 549 APPENDIX 17-21 Cable, Wire, and Hose Routing 1. Hose Clamp 2. Hose Clamp 3. Hose 4. Oil Cooler 5. Oil Filter 6. White Mark 7. Clamp 8. Hose 9. Clamp 10. Radiator Hose 11. Front View 12. Align the paint mark and embossed line. 13.
  • Page 550 17-22 APPENDIX Cable, Wire, and Hose Routing...
  • Page 551 APPENDIX 17-23 Cable, Wire, and Hose Routing 1. Main Harness 2. Run the clutch cable over the throttle cable. 3. Run the throttle cable over the front master cylinder. 4. Throttle Cables 5. Run the clutch and throttle cable into the clamp. 6.
  • Page 552 17-24 APPENDIX Cable, Wire, and Hose Routing...
  • Page 553 APPENDIX 17-25 Cable, Wire, and Hose Routing 1. Brake Hose 2. Clamp 3. Install the brake hose so that align the mark with the center of opening of the clamp. 4. Mark 5. Clamps 6. Brake Hose 7. Face the paint mark outside. 8.
  • Page 554 17-26 APPENDIX Cable, Wire, and Hose Routing...
  • Page 555 APPENDIX 17-27 Cable, Wire, and Hose Routing 1. Rear Frame 2. Exhaust Butterfly Valve Cable (Accelerator) 3. Exhaust Butterfly Valve Cable (Decelerator) 4. Holder 5. Position the exhaust butterfly valve cable (accelerator) over the exhaust butterfly valve cable (decelerator). 6. Dust Cover 7.
  • Page 556 17-28 APPENDIX Cable, Wire, and Hose Routing California Model Only...
  • Page 557 APPENDIX 17-29 Cable, Wire, and Hose Routing 1. White Marks 2. Hose (Green) 3. View A 4. White Marks 5. Clamp 6. Position the red hose under the blue hose, and clamp the them. 7. Run the green hose over the harness. 8.
  • Page 558: Troubleshooting Guide

    17-30 APPENDIX Troubleshooting Guide NOTE Neutral, starter lockout, or side stand switch ○ Refer to the Fuel System chapter for most trouble of DFI trouble shooting guide. Crankshaft sensor trouble ○ This is not an exhaustive list, giving every Ignition switch or engine stop switch possible cause for each problem listed.
  • Page 559 APPENDIX 17-31 Troubleshooting Guide Piston ring bad (worn, weak, broken, or Knocking: sticking) Carbon built up in combustion chamber Piston ring/groove clearance excessive Fuel poor quality or incorrect Cylinder head warped Spark plug incorrect Cylinder head gasket damaged IC igniter in ECU trouble Valve spring broken or weak Camshaft position sensor trouble Valve not seating properly (valve bent,...
  • Page 560: Over Cooling

    17-32 APPENDIX Troubleshooting Guide Engine oil poor quality or incorrect Gear positioning lever binding Oil cooler incorrect: Shift return spring weak or broken Oil cooler clogged Shift return spring pin loose Gauge incorrect: Shift mechanism arm spring broken Water temperature gauge broken Shift mechanism arm broken Water temperature sensor broken Shift pawl broken...
  • Page 561: Abnormal Drive Train Noise

    APPENDIX 17-33 Troubleshooting Guide Vacuum switch valve damaged Cylinder worn Alternator rotor loose Valve oil seal damaged Catalytic converter melt down due to muffler Valve guide worn overheating (KLEEN) Engine oil level too high Black smoke: Abnormal Drive Train Noise: Air cleaner clogged Brown smoke: Clutch noise:...
  • Page 562 17-34 APPENDIX Troubleshooting Guide Pad or disc worn Brake fluid leakage Disc warped Contaminated pad Brake fluid deteriorated Primary or secondary cup damaged in master cylinder Master cylinder scratched inside Battery Trouble: Battery discharged: Charge insufficient Battery faulty (too low terminal voltage) Battery lead making poor contact Load excessive (e.g., bulb of excessive wattage)
  • Page 563 MODEL APPLICATION Year Model Beginning Frame No. □ JKAZX4N1 5A000001 2005 ZX600-N1 JKAZX600NNA000001 □ 2006 ZX600N6F JKAZX4N1 6A005001 □ :This digit in the frame number changes from one machine to another. Part No.99924-1346-03 Printed in Japan...

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