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Table of Contents

   Also See for Kawasaki J300

   Summary of Contents for Kawasaki J300

  • Page 1 J300 J300 ABS...
  • Page 3: General Information

    Quick Reference Guide General Information Periodic Maintenance Fuel System (DFI) Cooling System Engine Top End Converter System Engine Lubrication System Engine Removal/Installation Crankcase/Crankshaft Wheels/Tires 10 j Final Drive 11 j Brakes 12 j Suspension 13 j Steering 14 j Frame 15 j Electrical System 16 j...
  • 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 Assurance Division/Motorcycle & Engine Company/Kawasaki Heavy Industries, Ltd., Japan.
  • Page 6 LIST OF ABBREVIATIONS ampere(s) (mass) ABDC after bottom dead center (force) alternating current km/h kilometers per hour ampere hour liter(s) ATDC after top dead center pound(s) BBDC before bottom dead center meter(s) bottom dead center minute(s) BTDC before top dead center newton(s) °C degree(s) Celsius...
  • Page 7: How To Use This Manual

    • the vehicle. Use proper tools and genuine Kawasaki Mo- torcycle parts. Special tools, gauges, and • Indicates a procedural step or work to be testers that are necessary when servicing done.
  • Page 9 GENERAL INFORMATION 1-1 General Information Table of Contents Before Servicing ........................Model Identification......................... General Specifications......................Unit Conversion Table ......................1-11...
  • Page 10: 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 11 Replacement Parts Replacement Parts must be KAWASAKI genuine or recommended by KAWASAKI. Gaskets, O-rings, oil seals, grease seals, circlips, cotter pins or self-locking nuts must be replaced with new ones whenever disassembled.
  • Page 12 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 13 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 14 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 15: Model Identification

    GENERAL INFORMATION 1-7 Model Identification SC300AE Left Side View SC300AE Right Side View...
  • Page 16 1-8 GENERAL INFORMATION Model Identification SC300BE Left Side View SC300BE Right Side View Frame Number Engine Number...
  • Page 17: General Specifications

    GENERAL INFORMATION 1-9 General Specifications SC300AE ∼ AF/BE ∼ BF Items Dimensions Overall Length 2 235 mm (87.99 in.) Overall Width 775 mm (30.51 in.) Overall Height 1 260 mm (49.61 in.) Wheelbase 1 555 mm (61.22 in.) Road Clearance 145 mm (5.71 in.) Seat Height 775 mm (30.5 in.)
  • Page 18 1-10 GENERAL INFORMATION General Specifications SC300AE ∼ AF/BE ∼ BF Items Engine Oil: Type API SJ, SL or SM with JASO MA, MA1 or MA2 Viscosity SAE 5W-50 Capacity 1.5 L (1.6 US qt) Drive Train Driving System V-Matic continuously variable 2.220 ∼...
  • Page 19: Unit Conversion Table

    GENERAL INFORMATION 1-11 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 21: Table Of Contents

    PERIODIC MAINTENANCE 2-1 Periodic Maintenance Table of Contents Periodic Maintenance Chart ....Drive Belt Wear Inspection ..2-25 Torque and Locking Agent....Drive Belt Replacement ....2-25 Specifications ........Final Drive........2-27 Special Tools ........2-10 Final Gear Case Oil Change..2-27 Periodic Maintenance Procedures..
  • Page 22: Periodic Maintenance Chart

    *: Should be serviced by your Kawasaki dealer, unless you have the proper tools, service data and are technically qualified. **: In the interest of safety, we recommend these items be serviced only by your Kawasaki dealer. Kawasaki recommends that your Kawasaki dealer road test your scooter after each periodic maintenance service is completed.
  • Page 23 PERIODIC MAINTENANCE 2-3 Periodic Maintenance Chart FREQUENCY Whichever *Odometer Reading comes × 1 000 km (× 1 000 mile) first Page (0.6) (12) (15) (18) ITEM MONTH Chassis parts 2-43 Condition of bolts, nuts and 2-44 fasteners...
  • Page 24: Torque And Locking Agent

    2-4 PERIODIC MAINTENANCE Torque and Locking Agent Tighten all bolts and nuts to the proper torque using an accurate torque wrench. If insufficiently tightened, a bolt or nut may become damaged, strip an internal thread, or break and then fall out. The following table lists the tightening torque for the major bolts and nuts, and the parts requiring use of a non-permanent locking agent or silicone grease etc.
  • Page 25 PERIODIC MAINTENANCE 2-5 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Cylinder Head Cover Bolts 87 in·lb Intake Manifold Mounting Nuts 87 in·lb Valve Adjusting Screw Locknuts 0.90 78 in·lb Muffler Body Mounting Bolts Exhaust Pipe Manifold Holder Nuts Converter System Left Crankcase Cover Bolts 87 in·lb...
  • Page 26 2-6 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Brake Pad Pin Rear Caliper Mounting Bolts ABS Hydraulic Unit Mounting Nuts 0.80 69 in·lb Suspension Front Fork Clamp Bolts Front Fork Bottom Allen Bolts Upper Rear Shock Absorber Nuts Lower Rear Shock Absorber Bolts Sub Frame Bolts Steering...
  • Page 27 PERIODIC MAINTENANCE 2-7 Torque and Locking Agent The table below, relating tightening torque to thread diameter, lists the basic torque for the bolts and nuts. Use this table for only the bolts and nuts which do not require a specific torque value. All of the values are for use with dry solvent-cleaned threads.
  • Page 28: Specifications

    2-8 PERIODIC MAINTENANCE Specifications Item Standard Service Limit Fuel System (DFI) 2 ∼ 6 mm (0.08 ∼ 0.24 in.) Throttle Grip Free Play – – – Idle Speed 1 600 ±100 r/min (rpm) – – – Air Cleaner Element Wet paper element –...
  • Page 29 PERIODIC MAINTENANCE 2-9 Specifications Item Standard Service Limit Brake Light Timing: Front Pulled ON – – – Rear Pulled ON – – – Electrical System Spark Plug: Type NGK CR7E – – – 0.7 ∼ 0.8 mm (0.028 ∼ 0.031 in.) –...
  • Page 30: Special Tools

    2-10 PERIODIC MAINTENANCE Special Tools Inside Circlip Pliers: Jack: 57001-143 57001-1238 Steering Stem Nut Wrench: Flywheel & Pulley Holder: 57001-1100 57001-1605 Valve Adjusting Screw Holder: 57001-1217...
  • Page 31: Periodic Maintenance Procedures

    PERIODIC MAINTENANCE 2-11 Periodic Maintenance Procedures Fuel System (DFI) Air Cleaner Element Replacement NOTE ○ In dusty areas, the element should be replaced more frequently than the recommended interval. WARNING If dirt or dust is allowed to pass through into the throttle body assy, the throttle may become stuck, possibly causing accident.
  • Page 32: Idle Speed Inspection

    2-12 PERIODIC MAINTENANCE Periodic Maintenance Procedures Idle Speed Inspection • Start the engine and warm it up thoroughly. • With the engine idling, turn the handlebars to both sides [A]. If handlebars movement changes the idle speed, the throttle cables may be improperly adjusted or incorrectly routed, or damaged.
  • Page 33: Fuel System

    PERIODIC MAINTENANCE 2-13 Periodic Maintenance Procedures If necessary, adjust the throttle cable as follows. • Slide the dust cover [A]. • Loosen the locknut [A]. • Turn the adjuster [B] until the proper amount of throttle grip play is obtained. •...
  • Page 34: Fuel Hose Replacement

    2-14 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Check that the fuel hose clamps are securely installed. ○ Push and pull [A] the fuel hose [B] back and forth, and make sure it is locked. WARNING Leaking fuel can cause a fire or explosion resulting in serious burns.
  • Page 35 PERIODIC MAINTENANCE 2-15 Periodic Maintenance Procedures • Clean the fuel pipe [A]. • If the new hose is not installed soon, cover the fuel pipe with the vinyl bag [B] to keep it clean. • Remove the vinyl bag on the pipe. •...
  • Page 36: Cooling System

    2-16 PERIODIC MAINTENANCE Periodic Maintenance Procedures Cooling System Coolant Level Inspection NOTE ○ Check the level when the engine is cold (room or ambi- ent temperature). • Check the coolant level in the reserve tank [A] with the motorcycle held perpendicular (Do not use the side stand).
  • Page 37 PERIODIC MAINTENANCE 2-17 Periodic Maintenance Procedures • Remove: Front Center Cover (see Front Center Cover Removal in the Frame chapter) Storage Box (see Storage Box Removal in the Frame chapter) Radiator Cap [A] ○ Remove the radiator cap in two steps. First turn the cap counterclockwise to the first stop.
  • Page 38 2-18 PERIODIC MAINTENANCE Periodic Maintenance Procedures • When filling the coolant, choose a suitable mixture ratio by referring to the coolant manufacturer’s directions. NOTICE Soft or distilled water must be used with the an- tifreeze in the cooling system. If hard water is used in the system, it causes scales accumulation in the water passages, and consider- ably reduces the efficiency of the cooling system.
  • Page 39: Engine Top End

    PERIODIC MAINTENANCE 2-19 Periodic Maintenance Procedures Engine Top End Valve Clearance Inspection NOTICE If valve clearance is left unadjusted, the wear will eventually cause the valves to remain partly open, which lowers performance, burns the valves and the valve seats, and may cause serious engine dam- age.
  • Page 40: Valve Clearance Adjustment

    2-20 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Using a thickness gauge [A], measure the valve clearance between the adjusting screw and valve stem. ○ Measure the both valves at a time. Valve Clearance Standard: Exhaust 0.10 mm (0.0039 in.) Intake 0.10 mm (0.0039 in.) If the valve clearance is not within the specified range, adjust it.
  • Page 41 PERIODIC MAINTENANCE 2-21 Periodic Maintenance Procedures • Remove the engine oil drain bolt [A] from the bottom of the engine, and let the oil drain completely. • Replace the drain bolt assy with a new one. • Install the new drain bolt. •...
  • Page 42: Oil Service Indicator Light Reset

    2-22 PERIODIC MAINTENANCE Periodic Maintenance Procedures Oil Service Indicator Light Reset NOTE ○ The yellow oil service indicator light (LED) [A] goes on for changing the engine oil when the distance of the service mode [B] reaches 5 000 km (3 107 mile). The yellow oil service indicator light (LED) goes off when the oil service mode is reset.
  • Page 43: Oil Screen Inspection

    PERIODIC MAINTENANCE 2-23 Periodic Maintenance Procedures Oil Screen Inspection • Remove the both right and left oil screens (see Oil Screen Removal in the Engine Lubrication System chapter). • Check the oil screens [A] carefully for any damage, holes, and broken wires. If the screen is damaged, replace it.
  • Page 44: Wheels And Tires

    2-24 PERIODIC MAINTENANCE Periodic Maintenance Procedures Wheels and Tires Wheel/Tire Damage Inspection • Remove any imbedded stones [A] or other foreign parti- cles [B] from tread. • Visually inspect the tire for cracks and cuts, and replace the tire if necessary. Swelling or high spots indicate inter- nal damage, requiring tire replacement.
  • Page 45: Converter

    PERIODIC MAINTENANCE 2-25 Periodic Maintenance Procedures • Raise the rear wheel off the ground with the center stand. • Inspect the roughness of the rear wheel bearing by push- ing and pulling [A] the wheel. • Spin [B] the rear wheel lightly, and check for smoothly turn, roughness, binding or noise.
  • Page 46 2-26 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Hold the clutch outer [A] with the flywheel & pulley holder [B], and remove the clutch outer nut [C]. Special Tool - Flywheel & Pulley Holder: 57001-1605 • Remove: Collar [D] Clutch Outer •...
  • Page 47: Final Drive

    PERIODIC MAINTENANCE 2-27 Periodic Maintenance Procedures • Hold the drive pulley using the flywheel & pulley holder [A]. Special Tool - Flywheel & Pulley Holder: 57001-1605 • Tighten the drive face nut [B]. Torque - Drive Face Nut: 93 N·m (9.5 kgf·m, 69 ft·lb) Final Drive WARNING Motorcycle operation with insufficient, deterio-...
  • Page 48: Brakes

    2-28 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brakes Brake System Brake Fluid Leak Inspection • For ABS equipped model, remove the front fairing (see Front Fairing Removal in the Frame chapter). • Apply the brake lever and inspect the brake fluid leak from the brake hoses [A] and fittings [B].
  • Page 49: Brake Fluid Level Inspection

    PERIODIC MAINTENANCE 2-29 Periodic Maintenance Procedures Brake Hose Installation Condition Inspection • For ABS equipped model, remove the front fairing (see Front Fairing Removal in the Frame chapter). • Inspect the brake hoses and fittings for deterioration, cracks and signs of leakage. ○...
  • Page 50: Brake Fluid Change

    2-30 PERIODIC MAINTENANCE Periodic Maintenance Procedures WARNING Mixing brands and types of brake fluid can reduce the brake system’s effectiveness and cause an ac- cident resulting in injury or death. Do not mix two brands of brake fluid. Change the brake fluid in the brake line completely if the brake fluid must be re- filled but the type and brand of the brake fluid that is already in the reservoir are unidentified.
  • Page 51: Brake Hose Replacement

    PERIODIC MAINTENANCE 2-31 Periodic Maintenance Procedures Brake Hose Replacement NOTICE Brake fluid quickly ruins painted plastic surfaces; any spilled fluid should be completely washed away immediately. • Remove: Upper Handlebar Cover (see Handlebar Cover Removal in the Frame chapter) Leg Shield (see Leg Shield Removal in the Frame chap- ter) Brake Hose Clamps [A] Brake Hose Banjo Bolts [B]...
  • Page 52: Master Cylinder Rubber Parts Replacement

    2-32 PERIODIC MAINTENANCE Periodic Maintenance Procedures Master Cylinder Rubber Parts Replacement Master Cylinder Disassembly • Remove the master cylinder (see Master Cylinder Re- moval in the Brakes chapter). • Unscrew the locknut and pivot bolt, and remove the brake lever. •...
  • Page 53 PERIODIC MAINTENANCE 2-33 Periodic Maintenance Procedures • Using compressed air, remove the pistons. ○ Cover the caliper opening with a clean heavy cloth [A]. ○ Blow compressed air [B] into the hole for the banjo bolt to remove the piston. WARNING The piston in the brake caliper can crush hands and fingers.
  • Page 54 2-34 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Install the pad springs [A]. • Install the pads (see Front Brake Pad Installation in the Brakes chapter). • Wipe up any spilled brake fluid on the caliper with wet cloth. Rear Caliper Disassembly •...
  • Page 55: Brake Pad Wear Inspection

    PERIODIC MAINTENANCE 2-35 Periodic Maintenance Procedures • Replace the fluid seals [A] and the dust seals [B] with new ones. ○ Apply brake fluid to the seals, and install them into the cylinders by hand. • Apply brake fluid to the outside of the pistons, and push them into each cylinder by hand.
  • Page 56: Brake Light Switch Operation Inspection

    2-36 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Light Switch Operation Inspection • Turn the ignition switch on. • The brake light (LED) [A] should go on when the brake lever is applied. If it does not go on, inspect or replace the following parts. Battery (see Charging Condition Inspection in the Elec- trical System chapter) Brake Light (LED) (see Tail/Brake Light (LED) Removal...
  • Page 57: Steering

    PERIODIC MAINTENANCE 2-37 Periodic Maintenance Procedures Front Fork Oil Leak Inspection • Visually inspect the front forks [A] for oil leakage. Replace or repair any defective parts, if necessary. Rear Shock Absorber Oil Leak Inspection • Visually inspect the shock absorber [A] for oil leakage. If the oil leakage is found on it, replace the shock absorber with a new one.
  • Page 58: Steering Stem Bearing Lubrication

    2-38 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Adjust the steering using the steering stem nut wrench [A]. Special Tool - Steering Stem Nut Wrench: 57001-1100 If the steering is too tight, loosen the stem nut [B] a fraction of a turn. If the steering is too loose, tighten the stem nut a fraction of a turn.
  • Page 59: Electrical System

    PERIODIC MAINTENANCE 2-39 Periodic Maintenance Procedures Electrical System Lights and Switches Operation Inspection First Step • Set the motorcycle with the center stand. • Put the side stand up. • Turn the ignition switch on. • The following lights should go on according to below table. City Lights (LED) [A] Go on Headlights [B]...
  • Page 60 2-40 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Turn the ignition switch off. • The all lights should go off. If the light does not go off, replace the ignition switch. Second Step • Turn the ignition switch on. • Turn on the turn signal switch [A] (left or right position). •...
  • Page 61: Headlight Aiming Inspection

    PERIODIC MAINTENANCE 2-41 Periodic Maintenance Procedures Third Step • Set the dimmer switch [A] to high beam position. • The high beam headlights [B] should go on. • The blue high beam indicator light (LED) [C] should go on. If the high beam headlight and/or blue high beam indicator light (LED) does not go on, inspect or replace the following parts.
  • Page 62: Engine Stop Switch Operation Inspection

    2-42 PERIODIC MAINTENANCE Periodic Maintenance Procedures Engine Stop Switch Operation Inspection First Step • Turn the ignition switch on. • Set the motorcycle with the center stand. • Put the side stand up. • Turn the engine stop switch to stop position [A]. •...
  • Page 63: Others

    PERIODIC MAINTENANCE 2-43 Periodic Maintenance Procedures Others Chassis Parts Lubrication • Before lubricating each part, clean off any rusty spots with rust remover and wipe off any grease, oil, dirt, or grime. • Lubricate the points listed below with indicated lubricant. NOTE ○...
  • Page 64: Condition Of Bolts, Nuts And Fasteners Tightness Inspection

    2-44 PERIODIC MAINTENANCE Periodic Maintenance Procedures Condition of 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 ○...
  • Page 65 FUEL SYSTEM (DFI) 3-1 Fuel System (DFI) Table of Contents Exploded View........................DFI System..........................DFI Parts Location........................3-11 Specifications ......................... 3-13 Special Tools and Sealant ...................... 3-14 DFI Servicing Precautions ...................... 3-15 DFI Servicing Precautions ....................3-15 Troubleshooting the DFI System .................... 3-17 Outline ..........................
  • Page 66 3-2 FUEL SYSTEM (DFI) Ignition Coil Input Voltage Inspection................3-56 Fuel Pump Relay (Service Code 41) ..................3-58 Fuel Pump Relay Removal ....................3-58 Fuel Pump Relay Inspection ..................... 3-58 Radiator Fan Relay (Service Code 43)................... 3-60 Radiator Fan Relay Removal.................... 3-60 Radiator Fan Relay Inspection..................
  • Page 67 FUEL SYSTEM (DFI) 3-3 Air Cleaner Element Inspection ..................3-84 Engine Breather Box Oil Draining ..................3-84 Air Cleaner Box Removal....................3-84 Air Cleaner Box Installation....................3-85 Fuel Tank ..........................3-86 Fuel Tank Removal ......................3-86 Fuel Tank Installation ......................3-87 Fuel Tank Cleaning ......................
  • Page 68: Exploded View

    3-4 FUEL SYSTEM (DFI) Exploded View...
  • Page 69 FUEL SYSTEM (DFI) 3-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Oxygen Sensor Fuel Injector Mounting Bolt 87 in·lb Water Temperature Sensor (ECU) 106 in·lb Fuel Pump Mounting Screws 0.35 30 in·lb 5. ECU 6. ECU Relay 7. Vehicle-down Sensor 8.
  • Page 70: Dfi System

    3-6 FUEL SYSTEM (DFI) DFI System DFI System...
  • Page 71 FUEL SYSTEM (DFI) 3-7 DFI System 1. ECU 2. Vehicle-down Sensor 3. Ignition Coil 4. Fuel Pump Relay 5. Fuel Pump 6. Idle Speed Control Valve Actuator 7. Intake Air Pressure Sensor 8. Fuel Injector 9. Throttle Senor 10. Water Temperature Sensor (ECU) 11.
  • Page 72 3-8 FUEL SYSTEM (DFI) DFI System DFI System Wiring Diagram...
  • Page 73 FUEL SYSTEM (DFI) 3-9 DFI System Part Names 1. ECU 2. Crankshaft Sensor 3. Ignition Coil 4. Spark Plug 5. Water Temperature Sensor (ECU) 6. Fuel Pump 7. Meter Unit 8. Yellow Engine Warning Indicator Light (LED) 9. Vehicle-down Sensor 10.
  • Page 74 3-10 FUEL SYSTEM (DFI) DFI System Terminal Numbers of ECU Connectors Terminal Names 1. Ignition Power: BK 2. Ground: G/P 3. Oxygen Sensor: GY/W 4. Ground for Sensors: G/P 5. Throttle Sensor: V/BK 6. Power Supply to Sensors: V/R 7. Battery: R/W 8.
  • Page 75: Dfi Parts Location

    FUEL SYSTEM (DFI) 3-11 DFI Parts Location Throttle Sensor [A] Idle Speed Control Valve Actuator [B] Intake Air Pressure Sensor [C] Water Temperature Sensor (ECU) [D] Fuel Injector [E] ECU Relay [A] Vehicle-down Sensor [B] ECU [C] Crankshaft Sensor [A] Oxygen Sensor [A] Fuel Pump [A]...
  • Page 76 3-12 FUEL SYSTEM (DFI) DFI Parts Location Speed Sensor (Front Wheel Rotation Sensor) [A] Battery [A] Fuse Box (Charging/ECU Fuse 30 A) [B] Ignition Coil [A]...
  • Page 77: Specifications

    FUEL SYSTEM (DFI) 3-13 Specifications Item Standard Digital Fuel Injection System Idle Speed 1 600 ±100 r/min (rpm) Throttle Body Assy: Throttle Valve Single throttle valve Bore 34 mm (1.34 in.) ECU: Make KEIHIN Type Digital memory type, with built in IC igniter, sealed with resin Fuel Pressure (High Pressure Line) 294 ±6 kPa (3.0 ±0.06 kgf/cm², 43 ±0.87 psi) with engine...
  • Page 78: Special Tools And Sealant

    3-14 FUEL SYSTEM (DFI) Special Tools and Sealant Oil Pressure Gauge, 5 kgf/cm²: Fuel Pressure Gauge Adapter: 57001-125 57001-1593 Peak Voltage Adapter: Fuel Hose: 57001-1415 57001-1607 Needle Adapter Set: Measuring Adapter: 57001-1457 57001-1700 Throttle Sensor Setting Adapter: Liquid Gasket, TB1211: 57001-1538 56019-120...
  • Page 79: Dfi Servicing Precautions

    FUEL SYSTEM (DFI) 3-15 DFI Servicing Precautions DFI Servicing Precautions There are a number of important precautions that should be followed servicing the DFI system. ○ This DFI system is designed to be used with a 12 V sealed battery as its power source. Do not use any other battery except for a 12 V sealed battery as a power source.
  • Page 80 3-16 FUEL SYSTEM (DFI) DFI Servicing Precautions ○ If the motorcycle is not properly handled, the high pres- sure inside the fuel line can cause fuel to leak or the hose to burst. Check the fuel hose [A] (see Fuel Hose Inspec- tion (fuel leak, damage, installation condition) in the Peri- odic Maintenance chapter).
  • Page 81: Troubleshooting The Dfi System

    FUEL SYSTEM (DFI) 3-17 Troubleshooting the DFI System Outline When a problem occurs with DFI system, the yellow en- gine warning indicator light (LED) [A] blinks on to alert the rider. And the engine warning symbol [A] and the service code (error code) [B] are displayed on the LCD by the number of two digits.
  • Page 82 3-18 FUEL SYSTEM (DFI) Troubleshooting the DFI System • When checking the DFI parts, use a tester which can be read two decimal place voltage or resistance. ○ The DFI part connectors [A] have seals [B], including the ECU. When measuring the input or output voltage with the connector joined, use the needle adapter set [C].
  • Page 83 FUEL SYSTEM (DFI) 3-19 Troubleshooting the DFI System • Pull each connector 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 84: Inquiries To Rider

    3-20 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 85 FUEL SYSTEM (DFI) 3-21 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 86 3-22 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 87: Dfi System Troubleshooting Guide

    FUEL SYSTEM (DFI) 3-23 DFI System Troubleshooting Guide NOTE ○ This is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties in DFI system.
  • Page 88 3-24 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Fuel pressure regulator trouble Inspect fuel pressure and replace fuel pump (see chapter 3). Fuel line clogged Inspect and repair (see chapter 3). Intake air pressure sensor trouble Inspect (see chapter 3).
  • Page 89: Poor Running Or No Power At High Speed

    FUEL SYSTEM (DFI) 3-25 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Throttle sensor trouble Inspect (see chapter 3). Intake air pressure sensor trouble Inspect (see chapter 3). Water temperature sensor trouble Inspect (see chapter 3). Surge: Unstable fuel pressure Fuel pressure regulator trouble (Inspect and replace fuel pump) or kinked fuel line (Inspect and replace fuel pump) (see chapter 3).
  • Page 90 3-26 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Fuel pump trouble Inspect (see chapter 3). Intake air pressure sensor trouble Inspect (see chapter 3). Cracked or obstructed intake air pressure sensor Inspect and repair or replace (see chapter 3). vacuum hose Water temperature sensor trouble Inspect (see chapter 3).
  • Page 91: Self-diagnosis

    FUEL SYSTEM (DFI) 3-27 Self-Diagnosis Self-Diagnosis Outline The self-diagnosis system is monitoring the DFI system and ignition system. The ECU notifies the rider of troubles in DFI system and ignition system by blinking the yellow engine warning in- dicator light (LED) [A] when DFI and ignition system parts are faulty, and initiates fail-safe function.
  • Page 92 3-28 FUEL SYSTEM (DFI) Self-Diagnosis • Turn the ignition switch on. ○ When a problem occurs with DFI system and ignition sys- tem, the yellow engine warning indicator light (LED) [A] blinks to alert the rider. ○ And the engine warning symbol [A] and service code [B] are displayed at the end of the blinking of the yellow en- gine warning indicator light (LED).
  • Page 93: Self-diagnosis Flow Chart

    FUEL SYSTEM (DFI) 3-29 Self-Diagnosis Self-Diagnosis Flow Chart...
  • Page 94: How To Read Service Codes

    3-30 FUEL SYSTEM (DFI) Self-Diagnosis How to Read Service Codes ○ Service codes are shown by a series of long and short blinks of the yellow engine warning indicator light (LED), and the number of two digits on the display, as shown below. ○...
  • Page 95: How To Erase Service Code

    FUEL SYSTEM (DFI) 3-31 Self-Diagnosis How to Erase Service Code The service code stored in memory of the ECU continues to be display on the meter unit until it is erased. Erase the service code after the repair has done. Service Code Erasing Procedure 1.
  • Page 96 3-32 FUEL SYSTEM (DFI) Self-Diagnosis Service Code Table Service Yellow Engine Warning Problems Code Indicator Light (LED) Throttle sensor malfunction, wiring open or short Intake air pressure sensor malfunction, wiring open or short Water temperature sensor malfunction, wiring open or short Vehicle-down sensor malfunction, wiring open or short Oxygen sensor inactivation, wiring open or short...
  • Page 97: Symptoms

    FUEL SYSTEM (DFI) 3-33 Self-Diagnosis Symptoms Service Output Signal Usable Range Parts or Function Symptoms Codes or Criteria Output Voltage Throttle Sensor Engine operates normally 0.3 ∼ 4.5 V Intake Air Pressure Output Voltage Engine operates normally 1.0 ∼ 4.2 V Sensor –20°C: 18.8 kΩ...
  • Page 98: Throttle Sensor Position And Idle Speed Control Valve Actuator Position Reset

    3-34 FUEL SYSTEM (DFI) Throttle Sensor Position and Idle Speed Control Valve Actuator Position Reset How to Reset Throttle Sensor Position and Idle Speed Control Valve Actuator Position The ECU records the throttle sensor position and idle speed control valve actuator position. Therefore, the throt- tle sensor position and idle speed control valve actuator po- sition have to be reset when throttle body, intake air pres- sure sensor, idle speed control valve actuator or ECU has...
  • Page 99: Throttle Sensor (service Code 06)

    FUEL SYSTEM (DFI) 3-35 Throttle Sensor (Service Code 06) The throttle sensor is a rotating variable resistor that change output voltage according to throttle operating. The ECU senses this voltage change and determines fuel injection quantity, and ignition timing according to engine rpm, and throttle opening.
  • Page 100: Throttle Sensor Resistance Inspection

    3-36 FUEL SYSTEM (DFI) Throttle Sensor (Service Code 06) If the reading is out of the standard, remove the ECU and check the wiring for continuity between harness connec- tors. ○ Disconnect the ECU and sensor connectors. Wiring Continuity Inspection ECU Connector [A] ←→...
  • Page 101 FUEL SYSTEM (DFI) 3-37 Throttle Sensor (Service Code 06) • Start the engine and warm it up thoroughly. • Check idle speed to ensure the throttle opening is correct (see Idle Speed Inspection in the Periodic Maintenance chapter). Idle Speed Standard: 1 600 ±100 r/min (rpm) •...
  • Page 102 3-38 FUEL SYSTEM (DFI) Throttle Sensor (Service Code 06) Throttle Sensor Circuit 1. ECU 2. Throttle Sensor...
  • Page 103: Intake Air Pressure Sensor (service Code 09)

    FUEL SYSTEM (DFI) 3-39 Intake Air Pressure Sensor (Service Code 09) Intake Air Pressure Sensor Removal NOTICE Never drop the intake air pressure sensor espe- cially on a hard surface. Such a shock to the sensor can damage it. • Remove the storage box (see Storage Box Removal in the Frame chapter).
  • Page 104: Intake Air Pressure Sensor Input Voltage Inspection

    3-40 FUEL SYSTEM (DFI) Intake Air Pressure Sensor (Service Code 09) Intake Air Pressure Sensor Input Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch off. • Remove the storage box (see Storage Box Removal in the Frame chapter).
  • Page 105: Intake Air Pressure Sensor Output Voltage Inspection

    FUEL SYSTEM (DFI) 3-41 Intake Air Pressure Sensor (Service Code 09) Intake Air Pressure Sensor Output Voltage Inspection • Measure the output voltage at the intake air pressure sen- sor in the same way as input voltage inspection, note the following.
  • Page 106 3-42 FUEL SYSTEM (DFI) Intake Air Pressure Sensor (Service Code 09) Intake Air Pressure Sensor Circuit 1. ECU 2. Intake Air Pressure Sensor...
  • Page 107: Water Temperature Sensor (service Code 12)

    FUEL SYSTEM (DFI) 3-43 Water Temperature Sensor (Service Code 12) Water Temperature Sensor (ECU) Removal/Installation NOTICE Never drop the water temperature sensor especially on a hard surface. Such a shock to the sensor can damage it. • Remove the storage box (see Storage Box Removal in the Frame chapter).
  • Page 108: Vehicle-down Sensor (service Code 15)

    3-44 FUEL SYSTEM (DFI) Vehicle-down Sensor (Service Code 15) This sensor has a weight [A] with two magnets inside, and sends a signal to the ECU. But when the motorcycle banks 65° or more to either side (in fact falls down), the weight turns and the signal changes.
  • Page 109: Vehicle-down Sensor Input Voltage Inspection

    FUEL SYSTEM (DFI) 3-45 Vehicle-down Sensor (Service Code 15) Vehicle-down Sensor Input Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch off. • Remove the front center cover (see Front Center Cover Removal in the Frame chapter). •...
  • Page 110: Vehicle-down Sensor Output Voltage Inspection

    3-46 FUEL SYSTEM (DFI) Vehicle-down Sensor (Service Code 15) Vehicle-down Sensor Output Voltage Inspection • Remove the vehicle-down sensor. • Connect the measuring adapter [A] to the vehicle-down sensor connectors. Special Tool - Measuring Adapter: 57001-1700 Main Harness [B] Vehicle-down Sensor [C] •...
  • Page 111 FUEL SYSTEM (DFI) 3-47 Vehicle-down Sensor (Service Code 15) If the reading is within the standard, remove the ECU and check the wiring for continuity between main harness con- nectors. ○ Disconnect the ECU and sensor connectors. Wiring Continuity Inspection ECU Connector [A] ←→...
  • Page 112: Oxygen Sensor - Not Activated (service Code 17, Equipped Models)

    3-48 FUEL SYSTEM (DFI) Oxygen Sensor - not activated (Service Code 17, Equipped Models) Oxygen Sensor Removal/Installation • Refer to the Oxygen Sensor Removal/Installation in the Electrical System chapter. Oxygen Sensor Inspection • Remove: Storage Box (see Storage Box Removal in the Frame chapter) Oxygen Sensor Lead Connector [A] •...
  • Page 113 FUEL SYSTEM (DFI) 3-49 Oxygen Sensor - not activated (Service Code 17, Equipped Models) If the reading is out of the standard, remove the ECU and check the wiring for continuity between harness connec- tors. ○ Disconnect the ECU and sensor connectors. Wiring Continuity Inspection ECU Connector [A] ←→...
  • Page 114 3-50 FUEL SYSTEM (DFI) Oxygen Sensor - not activated (Service Code 17, Equipped Models) Oxygen Sensor Circuit 1. ECU 2. Engine Stop Switch 3. Fuse Box 4. Ignition Fuse 15 A 5. Charging/ECU Fuse 30 A 6. Ignition Switch 7. Side Stand Switch 8.
  • Page 115: Fuel Injector (service Code 33)

    FUEL SYSTEM (DFI) 3-51 Fuel Injector (Service Code 33) Fuel Injector Removal WARNING Gasoline is extremely flammable and can be explo- sive under certain conditions, creating the potential for serious burns. Make sure the area is well venti- lated and free from any source of flame or sparks; this includes any appliance with a pilot light.
  • Page 116: Fuel Injector Installation

    3-52 FUEL SYSTEM (DFI) Fuel Injector (Service Code 33) Fuel Injector Installation • Replace the O-ring [A] and dust seal [B] with new ones. • Apply engine oil to the O-ring and dust seal. • Install the fuel injector to the fuel pipe. •...
  • Page 117: Fuel Injector Power Supply Voltage Inspection

    FUEL SYSTEM (DFI) 3-53 Fuel Injector (Service Code 33) Fuel Injector Power Supply Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch off. • Remove the storage box (see Storage Box Removal in the Frame chapter).
  • Page 118: Fuel Injector Output Voltage Inspection

    3-54 FUEL SYSTEM (DFI) Fuel Injector (Service Code 33) Fuel Injector Output Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch off. • Remove the ECU (see ECU Removal). ○ Do not disconnect the ECU connector. •...
  • Page 119 FUEL SYSTEM (DFI) 3-55 Fuel Injector (Service Code 33) Fuel Injector Circuit 1. ECU 2. Engine Stop Switch 3. Fuse Box 4. Ignition Fuse 15 A 5. Charging/ECU Fuse 30 A 6. Ignition Switch 7. Side Stand Switch 8. Fuel Pump Relay 9.
  • Page 120: Ignition Coil (service Code 37)

    3-56 FUEL SYSTEM (DFI) Ignition Coil (Service Code 37) Ignition Coil Removal/Installation • Refer to the Ignition Coil Removal/Installation in the Elec- trical System chapter. Ignition Coil Input Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch off.
  • Page 121 FUEL SYSTEM (DFI) 3-57 Ignition Coil (Service Code 37) Ignition Coil Circuit 1. ECU 2. Spark Plug 3. Ignition Coil 4. Engine Stop Switch 5. Fuse Box 6. Ignition Fuse 15 A 7. Charging/ECU Fuse 30 A 8. Ignition Switch 9.
  • Page 122: Fuel Pump Relay (service Code 41)

    3-58 FUEL SYSTEM (DFI) Fuel Pump Relay (Service Code 41) Fuel Pump Relay Removal NOTICE Never drop the fuel pump relay especially on a hard surface. Such a shock to the relay can damage it. • Remove the front fairing (see Front Fairing Removal in the Frame chapter).
  • Page 123 FUEL SYSTEM (DFI) 3-59 Fuel Pump Relay (Service Code 41) Fuel Pump Relay Circuit 1. ECU 2. Fuel Pump 3. Engine Stop Switch 4. Fuse Box 5. Ignition Fuse 15 A 6. Charging/ECU Fuse 30 A 7. Ignition Switch 8. Side Stand Switch 9.
  • Page 124: Radiator Fan Relay (service Code 43)

    3-60 FUEL SYSTEM (DFI) Radiator Fan Relay (Service Code 43) Radiator Fan Relay Removal NOTICE Never drop the radiator fan relay especially on a hard surface. Such a shock to the relay can dam- age it. • Remove the front fairing (see Front Fairing Removal in the Frame chapter).
  • Page 125: Oxygen Sensor Heater (service Code 45)

    FUEL SYSTEM (DFI) 3-61 Oxygen Sensor Heater (Service Code 45) Oxygen Sensor Heater Removal/Installation The oxygen sensor heater is built in the oxygen sensor. So, the heater itself can not be removed. Remove the oxy- gen sensor (see Oxygen Sensor Removal) in the Electrical System chapter).
  • Page 126: Oxygen Sensor Heater Power Source Voltage Inspection

    3-62 FUEL SYSTEM (DFI) Oxygen Sensor Heater (Service Code 45) Oxygen Sensor Heater Power Source Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch off. • Remove the storage box (see Storage Box Removal in the Frame chapter).
  • Page 127 FUEL SYSTEM (DFI) 3-63 Oxygen Sensor Heater (Service Code 45) Oxygen Sensor Circuit 1. ECU 2. Engine Stop Switch 3. Fuse Box 4. Ignition Fuse 15 A 5. Charging/ECU Fuse 30 A 6. Ignition Switch 7. Side Stand Switch 8. Battery 9.
  • Page 128: Idle Speed Control Valve Actuator (service Code 49)

    3-64 FUEL SYSTEM (DFI) Idle Speed Control Valve Actuator (Service Code 49) Idle Speed Control Valve Actuator Removal NOTICE Never drop the idle speed control valve actuator es- pecially on a hard surface. Such a shock to the ac- tuator can damage it. •...
  • Page 129: Idle Speed Control Valve Actuator Input Voltage Inspection

    FUEL SYSTEM (DFI) 3-65 Idle Speed Control Valve Actuator (Service Code 49) Idle Speed Control Valve Actuator Input Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch off. • Disconnect the idle speed control valve actuator connec- tor and connect the measuring adapter [A] between these connectors.
  • Page 130 3-66 FUEL SYSTEM (DFI) Idle Speed Control Valve Actuator (Service Code 49) Idle Speed Control Valve Actuator Circuit 1. ECU 2. Idle Speed Control Valve Actuator...
  • Page 131: Crankshaft Sensor (service Code 66)

    FUEL SYSTEM (DFI) 3-67 Crankshaft Sensor (Service Code 66) The crankshaft sensor has no power source, and when the engine stops, the crankshaft sensor generates no sig- nals. Crankshaft Sensor Removal/Installation • Refer to the Crankshaft Sensor Removal/Installation in the Electrical System chapter. Crankshaft Sensor Resistance Inspection •...
  • Page 132: Yellow Engine Warning Indicator Light (led)

    3-68 FUEL SYSTEM (DFI) Yellow Engine Warning Indicator Light (LED) Yellow Engine Warning Indicator Light (LED) Inspection ○ In this model, the yellow engine warning indicator light (LED) [A] goes on or blinks by the data sent from the ECU. •...
  • Page 133: Ecu

    FUEL SYSTEM (DFI) 3-69 ECU Removal NOTICE Never drop the ECU especially on a hard surface. Such a shock to the ECU can damage it. • Remove: Front Fairing (see Front Fairing Removal in the Frame chapter) Nuts [A] Bracket [B] ECU [C] •...
  • Page 134 3-70 FUEL SYSTEM (DFI) If the wiring is good, check the power source voltage of the ECU. NOTE ○ Be sure the battery is fully charged. • Connect the ECU connectors. • Connect a digital meter [A] to the connector [B] with the needle adapter set.
  • Page 135 FUEL SYSTEM (DFI) 3-71 ECU Power Source Circuit 1. ECU 2. Engine Stop Switch 3. Fuse Box 4. Ignition Fuse 15 A 5. Charging/ECU Fuse 30 A 6. Ignition Switch 7. Side Stand Switch 8. Battery 9. Engine Ground 10. Frame Ground 1 11.
  • Page 136: Dfi Power Source

    3-72 FUEL SYSTEM (DFI) DFI Power Source ECU Fuse Removal • Refer to the Fuse Box Fuse Removal in the Electrical Sys- tem chapter. ECU Fuse Installation If a fuse fails during operation, inspect the DFI system to determine the cause, and then replace it with a new fuse of proper amperage.
  • Page 137: Fuel Line

    FUEL SYSTEM (DFI) 3-73 Fuel Line Fuel Pressure Inspection NOTE ○ Be sure the battery is fully charged. • Remove the fuel hose (see Fuel Hose Replacement in the Periodic Maintenance chapter). ○ Be sure to place a piece of cloth around the fuel outlet pipe of the fuel pump and the fuel pipe of the intake manifold.
  • Page 138: Fuel Flow Rate Inspection

    3-74 FUEL SYSTEM (DFI) Fuel Line • Start the engine, and let it idle. • Measure the fuel pressure with the engine idling. Fuel Pressure (with Engine Idling) Standard: 294 ±6 kPa (3.0 ±0.06 kgf/cm², 43 ±0.87 psi) NOTE ○ The gauge needle will fluctuate.
  • Page 139 FUEL SYSTEM (DFI) 3-75 Fuel Line • Disconnect the fuel hose from the fuel pump (see Fuel Hose Replacement in the Periodic Maintenance chapter). ○ Be sure to place a piece of cloth around the fuel outlet pipe of the fuel pump. WARNING Fuel is flammable and explosive under certain con- ditions and can cause severe burns.
  • Page 140: Fuel Pump

    3-76 FUEL SYSTEM (DFI) Fuel Pump Fuel Pump Removal WARNING Gasoline is extremely flammable and can be explo- sive under certain conditions, creating the potential for serious burns. Make sure the area is well venti- lated and free from any source of flame or sparks; this includes any appliance with a pilot light.
  • Page 141: Fuel Pump Operating Voltage Inspection

    FUEL SYSTEM (DFI) 3-77 Fuel Pump Fuel Pump Operating Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch off. • Remove the fuel tank cap cover (see Fuel Tank Cap Cover Removal in the Frame chapter). •...
  • Page 142: Pressure Regulator Removal

    3-78 FUEL SYSTEM (DFI) Fuel Pump Pressure Regulator Removal ○ The pressure regulator [A] is built into the fuel pump and can not be removed. Fuel Filter Cleaning • Remove the fuel pump (see Fuel Pump Removal). • Wash the fuel filter [A] in non-flammable of high flash -point solvent.
  • Page 143 FUEL SYSTEM (DFI) 3-79 Fuel Pump Fuel Pump Circuit 1. ECU 2. Fuel Pump 3. Engine Stop Switch 4. Fuse Box 5. Ignition Fuse 15 A 6. Charging/ECU Fuse 30 A 7. Ignition Switch 8. Side Stand Switch 9. Fuel Pump Relay 10.
  • Page 144: Throttle Grip And Cables

    3-80 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 145: Cable Lubrication

    FUEL SYSTEM (DFI) 3-81 Throttle Grip and Cables Cable Lubrication • Refer to the Chassis Parts Lubrication in the Periodic Maintenance chapter.
  • Page 146: Throttle Body Assy

    3-82 FUEL SYSTEM (DFI) Throttle Body Assy Idle Speed Inspection • Refer to the Idle Speed Inspection in the Periodic Main- tenance chapter. Throttle Bore Cleaning • Check the throttle bore for cleanliness as follows. ○ Remove the throttle body assy (see Throttle Body Assy Removal).
  • Page 147: Throttle Body Assy Installation

    FUEL SYSTEM (DFI) 3-83 Throttle Body Assy Throttle Body Assy Installation • Installation is the reverse of the removal. • Install the throttle body assy so that the rib [A] of the throt- tle body assy fits the groove [B] of the intake manifold. •...
  • Page 148: Air Cleaner

    3-84 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 149: Air Cleaner Box Installation

    FUEL SYSTEM (DFI) 3-85 Air Cleaner • Remove the bolts [A]. • Open the clamp and disconnect the breather hose [A]. • Remove the air cleaner box [B]. Air Cleaner Box Installation • Installation is the reverse of removal.
  • Page 150: Fuel Tank

    3-86 FUEL SYSTEM (DFI) Fuel Tank Fuel Tank Removal WARNING Gasoline is extremely flammable and can be explo- sive under certain conditions, creating the potential for serious burns. Make sure the area is well venti- lated and free from any source of flame or sparks; this includes any appliance with a pilot light.
  • Page 151: Fuel Tank Installation

    FUEL SYSTEM (DFI) 3-87 Fuel Tank • Remove: Nuts [A] (Both Sides) Bracket [B] (Both Sides) Guard [C] • Remove: Nuts [A] Fuel Tank [B] Fuel Tank Installation • Installation is the reverse of removal. • Be sure that the pad [A] is in position. Fuel Tank Cleaning WARNING Gasoline and low flash-point solvents can be...
  • Page 153 COOLING SYSTEM 4-1 Cooling System Table of Contents Exploded View........................Coolant Flow Chart......................... Specifications ......................... Special Tools and Sealant ...................... Coolant ........................... Coolant Deterioration Inspection..................Coolant Level Inspection....................Coolant Draining ....................... Coolant Filling ........................Pressure Testing ....................... Cooling System Flushing ....................Coolant Reserve Tank Removal ..................
  • Page 154: Exploded View

    4-2 COOLING SYSTEM Exploded View...
  • Page 155 COOLING SYSTEM 4-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Water Hose Clamp Screws 0.45 39 in·lb Water Pump Cover Bolts 87 in·lb Water Pump Impeller 106 in·lb Water Temperature Sensor (ECU) 106 in·lb Water Temperature Sensor (Meter) 0.75 65 in·lb Thermostat Housing Cover Bolts 0.75...
  • Page 156: Coolant Flow Chart

    4-4 COOLING SYSTEM Coolant Flow Chart 1. Hot Coolant 2. Cold Coolant 3. Reserve Tank Overflow Hose 4. Reserve Tank 5. Radiator Overflow Hose 6. Water Bypass Hose 7. Thermostat 8. Radiator Cap 9. Radiator 10. Water Pump...
  • Page 157: Specifications

    COOLING SYSTEM 4-5 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 158: Special Tools And Sealant

    4-6 COOLING SYSTEM Special Tools and Sealant Outside Circlip Pliers: Oil Seal Driver 37.5: 57001-144 57001-1660 Bearing Driver Set: Liquid Gasket, TB1211F: 57001-1129 92104-0004...
  • Page 159: Coolant

    COOLING SYSTEM 4-7 Coolant Coolant Deterioration Inspection • Remove the front fairing (see Front Fairing Removal in the Frame chapter). • Visually inspect the coolant in the reserve tank [A]. If whitish cotton-like wafts are observed, aluminum parts in the cooling system are corroded. If the coolant is brown, iron or steel parts are rusting.
  • Page 160: Cooling System Flushing

    4-8 COOLING SYSTEM Coolant Cooling System Flushing Over a period of time, the cooling system accumulates rust, scale, and lime in the water jacket and radiator. When this accumulation is suspected or observed, flush the cool- ing system. If this accumulation is not removed, it will clog up the water passage and considerable reduce the effi- ciency of the cooling system.
  • Page 161: Water Pump

    COOLING SYSTEM 4-9 Water Pump Water Pump Cover Removal • Drain the coolant (see Coolant Change in the Periodic Maintenance chapter). • Remove: Right Lower Fairing (see Lower Fairing Removal in the Frame chapter) Exhaust Pipe (see Exhaust Pipe Removal in the Engine Top chapter) •...
  • Page 162: Water Pump Inspection

    4-10 COOLING SYSTEM Water Pump Water Pump Inspection • Check the drainage outlet passage [A] at the bottom of the water pump housing for coolant leaks. • If a coolant leak or ooze is found, start the engine and check if the coolant leaks continuously. ○...
  • Page 163: Mechanical Seal Removal

    COOLING SYSTEM 4-11 Water Pump Mechanical Seal Removal • Remove: Alternator Cover (see Alternator Cover Removal in the Electrical System chapter) Water Pump Impeller (see Water Pump Impeller Re- moval/Installation) Circlip [A] and Washer Water Pump Shaft [B] Special Tool - Outside Circlip Pliers: 57001-144 •...
  • Page 164: Radiator

    4-12 COOLING SYSTEM Radiator Radiator and Radiator Fan Removal • Drain the coolant (see Coolant Change in the Periodic Maintenance chapter). • Remove: Front Fairing (see Front Fairing Removal in the Frame chapter) Side Fairing (see Side Fairing Removal in the Frame chapter) Radiator Cover (see Radiator Cover Removal in the Frame chapter)
  • Page 165: Radiator And Radiator Fan Installation

    COOLING SYSTEM 4-13 Radiator Radiator and Radiator Fan Installation • Installation is the reverse of removal. • Insert the projection [A] of the frame into the grommet [B] of the radiator. • Tighten: Torque - Water Hose Clamp Screws: 4.4 N·m (0.45 kgf/cm, 39 in·lb) •...
  • Page 166: Radiator Filler Neck Inspection

    4-14 COOLING SYSTEM Radiator • Install the cap [A] on a cooling system pressure tester [B]. NOTE ○ Wet the cap sealing surfaces with water or coolant to prevent pressure leaks. • Watching the pressure gauge, pump the pressure tester to build up the pressure until the relief valve opens: the gauge needle flicks downward.
  • Page 167: Thermostat

    COOLING SYSTEM 4-15 Thermostat Thermostat Removal • Drain the coolant (see Coolant Change in the Periodic Maintenance chapter). • Remove the storage box (see Storage Box Removal in the Frame chapter) • Loosen the water hose clamp screw [A]. • Disconnect the water hose [B].
  • Page 168: Hoses And Pipes

    4-16 COOLING SYSTEM Hoses and Pipes Hose Installation • Install the hoses, being careful to follow bending direction. Avoid sharp bending, kinking, flattening or twisting. • Run the hoses (see Cable, Wire, and Hose Routing sec- tion in the Appendix chapter). •...
  • Page 169: Water Temperature Sensor

    COOLING SYSTEM 4-17 Water Temperature Sensor Water Temperature Sensor (ECU) Removal/Installation • Refer to the Water Temperature Sensor (ECU) Re- moval/Installation in the Fuel System (DFI) chapter. Water Temperature Sensor (Meter) Removal • Remove the intake manifold (see Intake Manifold Re- moval in the Engine Top End chapter).
  • Page 171 ENGINE TOP END 5-1 Engine Top End Table of Contents Exploded View........Cylinder Head Warp Inspection ... 5-21 Specifications ........Valves ..........5-22 Special Tools and Sealant ....Valve Clearance Inspection ..5-22 Cylinder Head Cover ......5-10 Valve Clearance Adjustment..5-22 Cylinder Head Cover Removal ..
  • Page 172: Exploded View

    5-2 ENGINE TOP END Exploded View...
  • Page 173 ENGINE TOP END 5-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Upper Camshaft Chain Guide Bolt 87 in·lb Intake Manifold Mounting Nuts 87 in·lb Camshaft Sprocket Bolts 106 in·lb Rocker Shaft Stopper Bolt 0.90 78 in·lb Valve Adjusting Screw Locknuts 0.90 78 in·lb Intake Manifold Stud Bolts...
  • Page 174 5-4 ENGINE TOP END Exploded View...
  • Page 175 ENGINE TOP END 5-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Muffler Body Mounting Bolts Exhaust Pipe Manifold Holder Nuts R: Replacement Parts S: Follow the specified tightening sequence.
  • Page 176: Specifications

    5-6 ENGINE TOP END Specifications Item Standard Service Limit Camshaft Cam Height: Exhaust 34.1721 mm (1.34535 in.) – – – Intake 34.2987 mm (1.35033 in.) – – – Rocker Arm Inside Diameter 10.000 ∼ 10.015 mm (0.3937 ∼ 0.3943 in.) –...
  • Page 177 ENGINE TOP END 5-7 Specifications Item Standard Service Limit Cylinder, Piston 72.705 ∼ 72.715 mm (2.8624 ∼ 2.8628 in.) Cylinder Inside Diameter 72.80 mm (2.866 in.) 72.67 ∼ 72.69 mm (2.8610 ∼ 2.8618 in.) Piston Diameter 72.70 mm (2.862 in.) 0.010 ∼...
  • Page 178: Special Tools And Sealant

    5-8 ENGINE TOP END Special Tools and Sealant Compression Gauge, 20 kgf/cm²: Valve Seat Cutter, 60° - 30: 57001-221 57001-1123 Valve Spring Compressor Assembly: Valve Seat Cutter Holder Bar: 57001-241 57001-1128 Valve Seat Cutter, 45° - 24.5: Valve Seat Cutter, 45° - 30: 57001-1113 57001-1187 Valve Seat Cutter, 32°...
  • Page 179 ENGINE TOP END 5-9 Special Tools and Sealant Compression Gauge Adapter, M10 × 1.0: Liquid Gasket, TB1216: 57001-1317 92104-1063 Valve Seat Cutter, 60° - 25: 57001-1328...
  • Page 180: Cylinder Head Cover

    5-10 ENGINE TOP END Cylinder Head Cover Cylinder Head Cover Removal • Remove the storage box (see Storage Box Removal in the Frame chapter). • Open the clamp and disconnect the breather hose [A]. • Loosen the bolt and remove the fuel hose bracket [B]. •...
  • Page 181: Camshaft Chain Tensioner

    ENGINE TOP END 5-11 Camshaft Chain Tensioner Camshaft Chain Tensioner Removal NOTICE This is a non-return type camshaft chain tensioner. The push rod does not return to its original position once it moves out to take up cam chain slack. Ob- serve all the rules listed below.
  • Page 182 5-12 ENGINE TOP END Camshaft Chain Tensioner • Replace the chain tensioner gasket with a new one. • Install: Camshaft Chain Tensioner Clamp [A] Camshaft Chain Tensioner Mounting Bolts [B] Torque - Camshaft Chain Tensioner Mounting Bolts: 12 N·m (1.2 kgf·m, 106 in·lb) •...
  • Page 183: Camshaft

    ENGINE TOP END 5-13 Camshaft Camshaft Removal • Remove: Camshaft Sprocket (see Camshaft Sprocket Removal) Rocker Arms (see Rocker Arm Removal) Camshaft [A] Camshaft Installation • Clean the camshaft with the high flash-point solvent. • Apply molybdenum disulfide oil solution to all cam parts, journal and bearing.
  • Page 184: Camshaft Sprocket Removal

    5-14 ENGINE TOP END Camshaft Camshaft Sprocket Removal • Bring the piston to the TDC of the compression stroke (see Valve Clearance Inspection in the Periodic Mainte- nance chapter). • Remove: Right Side Fairing (see Side Fairing Removal in the Frame chapter) Cylinder Head Cover (see Cylinder Head Cover Re- moval)
  • Page 185: Camshaft Chain Removal

    ENGINE TOP END 5-15 Camshaft Camshaft Chain Removal • Remove: Camshaft Sprocket (see Camshaft Sprocket Removal) Oil Pump Drive Chain (see Oil Pump Removal in the Engine Lubrication System chapter) Upper Camshaft Chain Guide Bolt [A] Upper Camshaft Chain Guide [B] Camshaft Chain [C] Camshaft Chain Installation •...
  • Page 186: Rocker Arm, Rocker Shaft

    5-16 ENGINE TOP END Rocker Arm, Rocker Shaft Rocker Arm Removal • Remove: Camshaft Sprocket (see Camshaft Sprocket Removal) Rocker Shaft Stopper Bolt [A] Rocker Shaft Stopper [B] • Using the 5 mm (0.20 in.) bolt [A], remove the rocker shafts [B] and rocker arms [C].
  • Page 187 ENGINE TOP END 5-17 Rocker Arm, Rocker Shaft • Measure the outside diameter [A] of each rocker shaft where the rocker fits. Rocker Shaft Diameter 9.972 ∼ 9.987 mm (0.3926 ∼ 0.3932 in.) Standard: If the diameter is less than the standard, replace the rocker shaft.
  • Page 188: Cylinder Head

    5-18 ENGINE TOP END Cylinder Head Cylinder Compression Measurement • Remove the left side fairing (see Side Fairing Removal in the Frame chapter). • Warm up the engine thoroughly. • Stop the engine. • Remove the spark plug (see Spark Plug Replacement in the Periodic Maintenance chapter).
  • Page 189: Cylinder Head Installation

    ENGINE TOP END 5-19 Cylinder Head • Loosen the clamp screw and disconnect the water hose [A]. • Open the clamp and disconnect the water bypass hose [B]. • Disconnect: Water Temperature Sensor (Meter) Connectors [C] Spark Plug Cap [D] •...
  • Page 190: Cylinder Head Cleaning

    5-20 ENGINE TOP END Cylinder Head • Install the cylinder head. • First, tighten the cylinder head nuts (M10) [A]. Torque - Cylinder Head Nuts (M10): First 20 N·m (2.0 kgf·m, 15 ft·lb) Final 37 N·m (3.8 kgf·m, 27 ft·lb) •...
  • Page 191: Cylinder Head Warp Inspection

    ENGINE TOP END 5-21 Cylinder Head Cylinder Head Warp Inspection • Clean the cylinder head (see Cylinder Head Cleaning). • Lay a straightedge [A] across the lower surface of the cylinder head at several positions. • Use a thickness gauge [B] to measure the space between the straightedge and the cylinder head.
  • Page 192: Valves

    5-22 ENGINE TOP END Valves Valve Clearance Inspection • Refer to the Valve Clearance Inspection in the Periodic Maintenance chapter. Valve Clearance Adjustment • Refer to the Valve Clearance Adjustment in the Periodic Maintenance chapter. Valve Removal • Remove: Cylinder Head (see Cylinder Head Removal) Rocker Arms and Rocker Shafts (see Rocker Arm Re- moval) Camshaft (see Camshaft Removal)
  • Page 193: Valve Seat Inspection

    ENGINE TOP END 5-23 Valves Valve Seat Inspection • Remove the valve (see Valve Removal). • Check the valve seating surface [A] between the valve [B] and valve seat [C]. ○ Measure the outside diameter [D] of the seating pattern on the valve seat.
  • Page 194 5-24 ENGINE TOP END Valves Seat Cutter Operation Care 1. This valve seat cutter is developed to grind the valve for repair. Therefore the cutter must not be used for other purposes than seat repair. 2. Do not drop or shock the valve seat cutter, or the dia- mond particles may fall off.
  • Page 195 ENGINE TOP END 5-25 Valves • Measure the outside diameter of the seating surface with a vernier caliper. If the outside diameter of the seating surface is too small, repeat the 45° grind until the diameter is within the spec- ified range.
  • Page 196 5-26 ENGINE TOP END Valves If the seat width is too wide, make the 60° [A] grind de- scribed below. If the seat width is within the specified range, lap the valve to the seat as described below. • Grind the seat at a 60° angle until the seat width is within the specified range.
  • Page 197 ENGINE TOP END 5-27 Valves...
  • Page 198: Cylinder, Piston

    5-28 ENGINE TOP END Cylinder, Piston Cylinder Removal • Remove the cylinder head (see Cylinder Head Removal). • Loosen the water hose clamp screw and disconnect the water hose [A]. • Remove: Lower Camshaft Chain Guide [A] Cylinder Bolts [B] Cylinder [C] and Gasket Cylinder Installation NOTE...
  • Page 199: Piston Removal

    ENGINE TOP END 5-29 Cylinder, Piston • Apply molybdenum disulfide oil solution to the piston and cylinder bore. • Apply molybdenum disulfide oil solution to the piston rings (see Piston Installation). • Install the cylinder while compressing the piston rings with your fingers.
  • Page 200: Cylinder Wear Inspection

    5-30 ENGINE TOP END Cylinder, Piston • Apply molybdenum disulfide oil solution to the piston rings. • Do not mix up the top and second ring. • Install the top ring [A] so that the “R” mark [B] faces up. •...
  • Page 201: Piston Wear Inspection

    ENGINE TOP END 5-31 Cylinder, Piston Piston Wear Inspection • Measure the outside diameter [A] at a right angle to the direction of the piston pin. If the measurement is less than the service limit, replace the piston. Piston Diameter 72.67 ∼...
  • Page 202: Piston Ring Groove Width Inspection

    5-32 ENGINE TOP END Cylinder, Piston Piston Ring Groove Width Inspection • Measure the piston ring groove width. ○ Use a vernier caliper at several points around the piston. Piston Ring Groove Width Standard: 1.00 ∼ 1.02 mm (0.039 ∼ 0.040 in.) Top [A] Second [B] 1.00 ∼...
  • Page 203: Piston, Piston Pin, Connecting Rod Wear Inspection

    ENGINE TOP END 5-33 Cylinder, Piston Piston, Piston Pin, Connecting Rod Wear Inspection • Measure the diameter [A] of the piston pin with a microm- eter. Piston Pin Diameter 14.994 ∼ 15.000 mm (0.59031 ∼ 0.59055 Standard: in.) Service Limit: 14.96 mm (0.5890 in.) If the piston pin diameter is less than the service limit at any point, replace the piston pin.
  • Page 204: Intake Manifold

    5-34 ENGINE TOP END Intake Manifold Intake Manifold Removal • Remove: Throttle Body Assy (see Throttle Body Assy Removal in the Fuel System (DFI) chapter) Fuel Injector (see Fuel Injector Removal in the Fuel Sys- tem (DFI) chapter) • Disconnect the water temperature sensor connector [A]. •...
  • Page 205: Muffler

    ENGINE TOP END 5-35 Muffler WARNING The muffler can become extremely hot during nor- mal operation and cause severe burns. Do not re- move the muffler while it is hot. Muffler Body Removal • Remove Bolts [A] and Washer Muffler End Cover [B] •...
  • Page 206: Exhaust Pipe Removal

    5-36 ENGINE TOP END Muffler • Install the muffler body side cover and tighten the bolts together with the washers. • Install the muffler end cover [A] and tighten its bolt to- gether with the washers as shown specified sequence [1 ∼...
  • Page 207 CONVERTER SYSTEM 6-1 Converter System Table of Contents Exploded View........................Specifications ......................... Special Tools .......................... Left Crankcase Cover......................Left Crankcase Cover Removal ..................Left Crankcase Cover Installation ..................Left Crankcase Cover Bearing Replacement..............Converter Air Filter Inspection ..................Drive Pulley ..........................Drive Pulley Removal......................
  • Page 208: Exploded View

    6-2 CONVERTER SYSTEM Exploded View...
  • Page 209 CONVERTER SYSTEM 6-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Clutch Drive Plate Nut Clutch Outer Nut Drive Face Nut Left Crankcase Cover Bolts 87 in·lb G: Apply grease. R: Replacement Parts...
  • Page 210: Specifications

    6-4 CONVERTER SYSTEM Specifications Item Standard Service Limit Drive Belt Drive Belt Width 25.2 mm (0.992 in.) 23.7 mm (0.933 in.) Drive Pulley 27.01 ∼ 27.04 mm Movable Drive Face Bushing Inside 27.07 mm (1.063 ∼ 1.065 in.) Diameter (1.091 in.) 26.985 ∼...
  • Page 211: Special Tools

    CONVERTER SYSTEM 6-5 Special Tools Inside Circlip Pliers: Flywheel & Pulley Holder: 57001-143 57001-1605 Oil Seal & Bearing Remover: Clutch Drive Nut Fitting: 57001-1058 57001-Y022 Bearing Driver Set: Clutch Spring Compressor: 57001-1129 57001-Y023...
  • Page 212: Left Crankcase Cover

    6-6 CONVERTER SYSTEM Left Crankcase Cover Left Crankcase Cover Removal • Remove: Left Lower Fairing (see Lower Fairing Removal in the Frame chapter) Left Crankcase Outer Cover Bolts [A] Left Crankcase Outer Cover [B] • Remove: Left Crankcase Cover Bolts [A] Left Crankcase Cover [B] and Gasket Left Crankcase Cover Installation •...
  • Page 213: Converter Air Filter Inspection

    CONVERTER SYSTEM 6-7 Left Crankcase Cover • Replace the left crankcase cover bearing with a new one. • Press the crankcase cover bearing until it is bottomed. Special Tool - Bearing Driver Set [A]: 57001-1129 • Replace the circlip with a new one. •...
  • Page 214: Drive Pulley

    6-8 CONVERTER SYSTEM Drive Pulley Drive Pulley Removal • Remove the left crankcase cover (see Left Crankcase Cover Removal). • Hold the drive pulley using the flywheel & pulley holder [A], and remove the drive face nut [B] and washer. Special Tool - Flywheel &...
  • Page 215: Drive Pulley Disassembly

    CONVERTER SYSTEM 6-9 Drive Pulley • Hold the drive pulley using the flywheel & pulley holder [A], and tighten the drive face nut [B]. Special Tool - Flywheel & Pulley Holder: 57001-1605 Torque - Drive Face Nut: 93 N·m (9.5 kgf·m, 69 ft·lb) NOTE ○...
  • Page 216 6-10 CONVERTER SYSTEM Drive Pulley • Check the drive pulley collar for damage. If there is any damaged part, replace it. • Measure the outside diameter [A] of the drive pulley collar sliding surface. If the collar is worn over the service limit, replace it. Drive Pulley Collar Outside Diameter 26.985 ∼...
  • Page 217: Clutch/driven Pulley

    CONVERTER SYSTEM 6-11 Clutch/Driven Pulley Clutch/Driven Pulley Removal • Remove the drive pulley (see Drive Pulley Removal). • Hold the clutch outer [A] with the flywheel & pulley holder [B], and remove the clutch outer nut [C]. Special Tool - Flywheel & Pulley Holder: 57001-1605 •...
  • Page 218: Clutch/driven Pulley Disassembly

    6-12 CONVERTER SYSTEM Clutch/Driven Pulley Clutch/Driven Pulley Disassembly • Hold the clutch/driven pulley assembly [A] with the clutch spring compressor [B]. Special Tools - Clutch Drive Nut Fitting [C], [D]: 57001-Y022 Clutch Spring Compressor: 57001-Y023 • Set the clutch spring compressor in a vise and remove the clutch drive plate nut.
  • Page 219: Clutch Disassembly

    CONVERTER SYSTEM 6-13 Clutch/Driven Pulley • Set the driven pulley assembly [A], driven face spring [B], collar [C] and clutch assembly [D] onto the clutch spring compressor. • Compress the clutch spring compressor [A] and install the clutch drive plate nut. Special Tools - Clutch Drive Nut Fitting [B], [C]: 57001-Y022 Clutch Spring Compressor: 57001-Y023 •...
  • Page 220: Driven Pulley Face Bearing Replacement

    6-14 CONVERTER SYSTEM Clutch/Driven Pulley • Measure the driven face spring free length [A]. Driven Face Spring Free Length Service Limit: 136 mm (5.35 in.) • Check the driven face for damage. If there is any damaged part, replace it. •...
  • Page 221 CONVERTER SYSTEM 6-15 Clutch/Driven Pulley • Remove the outer bearing by tapping with a suitable bar [A]. • Replace the bearings with new ones. • Press the outer bearing until it is bottomed. Special Tool - Bearing Driver Set [A]: 57001-1129 ○...
  • Page 223 ENGINE LUBRICATION SYSTEM 7-1 Engine Lubrication System Table of Contents Exploded View........................Engine Oil Flow Chart......................Specifications ......................... Special Tool ..........................Engine Oil and Oil Filter......................Oil Level Inspection......................Engine Oil Change......................Oil Filter Replacement ...................... Oil Screen Removal ......................Oil Screen Installation .......................
  • Page 224: Exploded View

    7-2 ENGINE LUBRICATION SYSTEM Exploded View...
  • Page 225 ENGINE LUBRICATION SYSTEM 7-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Oil Separator Cover Bolts 87 in·lb Oil Pump Screws 87 in·lb Oil Pressure Switch Engine Oil Drain Bolt Oil Screen Plug 0.95 82 in·lb Oil Filter Cap 0.95 82 in·lb EO: Apply engine oil.
  • Page 226: Engine Oil Flow Chart

    7-4 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart...
  • Page 227: Specifications

    ENGINE LUBRICATION SYSTEM 7-5 Specifications Item Standard Engine Oil Type API SJ, SL or SM with JASO MA, MA1 or MA2 Viscosity SAE 5W-50 Capacity 1.3 L (1.4 US qt) 1.5 L (1.6 US qt) (when engine is completely dry) Level Between upper and lower level lines (Wait 2 ∼...
  • Page 228: Special Tool

    7-6 ENGINE LUBRICATION SYSTEM Special Tool Outside Circlip Pliers: 57001-144...
  • Page 229: Engine Oil And Oil Filter

    ENGINE LUBRICATION SYSTEM 7-7 Engine Oil and Oil Filter WARNING Vehicle operation with insufficient, deteriorated, or contaminated engine oil will cause accelerated wear and may result in engine seizure, accident, and injury. Check the oil level before each use and change the oil and filter according to the periodic maintenance chart.
  • Page 230: Oil Screen Removal

    7-8 ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter Oil Screen Removal Oil Screen (Left) • Drain the engine oil (see Engine Oil Change in the Peri- odic Maintenance chapter). • Remove the oil screen plug [A]. • Remove the oil screen [A]. Oil Screen (Right) •...
  • Page 231: Oil Pressure Relief Valve

    ENGINE LUBRICATION SYSTEM 7-9 Oil Pressure Relief Valve Oil Pressure Relief Valve Removal • Remove: Alternator Cover (see Alternator Cover Removal in the Electrical System chapter) Oil Pressure Relief Valve [A] Oil Pressure Relief Valve Installation • Replace the O-ring [A] with a new one. •...
  • Page 232: Oil Pump

    7-10 ENGINE LUBRICATION SYSTEM Oil Pump Oil Pump Removal • Remove: Alternator Rotor (see Alternator Rotor Removal in the Electrical System chapter) Starter Motor Clutch Gear (see Starter Motor Clutch Gear and Starter Idle Gear Removal in the Crankcase/Crankshaft chapter) •...
  • Page 233: Oil Pump Disassembly

    ENGINE LUBRICATION SYSTEM 7-11 Oil Pump Oil Pump Disassembly • Remove: Oil Pump Assembly (see Oil Pump Removal) Screw [A] Oil Pump Cover [B] • Remove: Inner Rotor [A] Outer Rotor [B] Oil Pump Assembly • Assembly is the reverse of disassembly. Oil Pump Inspection •...
  • Page 234: Oil Pipe

    7-12 ENGINE LUBRICATION SYSTEM Oil Pipe Oil Pressure Switch Removal • Remove the right lower fairing (see Lower Fairing Re- moval in the Frame chapter). • Slide the switch cover [A], and disconnect the oil pressure switch connector [B]. • Remove the oil pressure switch [C].
  • Page 235 ENGINE REMOVAL/INSTALLATION 8-1 Engine Removal/Installation Table of Contents Exploded View........................Engine Removal/Installation ....................Engine Removal........................ Engine Installation......................
  • Page 236: Exploded View

    8-2 ENGINE REMOVAL/INSTALLATION Exploded View...
  • Page 237 ENGINE REMOVAL/INSTALLATION 8-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Engine Hanger Nuts Engine Mounting Nut R: Replacement Parts...
  • Page 238: Engine Removal/installation

    8-4 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation Engine Removal • Use the center stand to support the motorcycle upright. • Squeeze the front brake lever slowly and hold it with a band [A]. WARNING Motorcycle may fall over unexpectedly resulting in an accident or injury. Be sure to hold the front brake when removing the engine.
  • Page 239 ENGINE REMOVAL/INSTALLATION 8-5 Engine Removal/Installation • Loosen the clamp screw and disconnect the water hose [A]. • Open the clamp and disconnect the water bypass hose [B]. • Clear the water bypass hose from the clamp [C]. • Disconnect the water temperature sensor connectors [D]. •...
  • Page 240: Engine Installation

    8-6 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Remove the left lower rear shock absorber bolt [A]. • Remove: Engine Mounting Bolt [A] and Nut Engine Hanger Bolt [B] and Nut (Both Sides) Engine Hanger [C] • Remove the engine [A] backward. Engine Installation •...
  • Page 241 CRANKCASE/CRANKSHAFT 9-1 Crankcase/Crankshaft Table of Contents Exploded View........................Specifications ......................... Special Tools and Sealant ...................... Crankcase ..........................Crankcase Splitting ......................Crankcase Assembly ......................Crankshaft Bearing Replacement ..................Crankshaft, Connecting Rod ....................Crankshaft Removal ......................Crankshaft Installation ...................... Crankshaft Disassembly ....................Connecting Rod Big End Radial Clearance Inspection.............
  • Page 242: Exploded View

    9-2 CRANKCASE/CRANKSHAFT Exploded View...
  • Page 243 CRANKCASE/CRANKSHAFT 9-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Starter Motor Clutch Bolts Engine Stud Bolts 106 in·lb Crankcase Bolts 87 in·lb EO: Apply engine oil. G: Apply grease. L: Apply a non-permanent locking agent. LG: Apply liquid gasket.
  • Page 244: Specifications

    9-4 CRANKCASE/CRANKSHAFT Specifications Item Standard Service Limit Crankshaft, Connecting Rod Connecting Rod: 0 ∼ 0.008 mm (0 ∼ 0.0003 in.) Big End Radial Clearance 0.05 mm (0.002 in.) 0.15 ∼ 0.35 mm (0.0059 ∼ 0.0138 in.) Big End Side Clearance 0.6 mm (0.024 in.) Crankshaft Runout TIR 0.03 mm (0.0012 in.) or less...
  • Page 245: Special Tools And Sealant

    CRANKCASE/CRANKSHAFT 9-5 Special Tools and Sealant Bearing Driver Set: Flywheel Holder: 57001-1129 57001-1313 Liquid Gasket, TB1215: 92104-1065...
  • Page 246: Crankcase

    9-6 CRANKCASE/CRANKSHAFT Crankcase Crankcase Splitting • Remove the engine (see Engine Removal in the Engine Removal/Installation chapter). • Set the engine on a clean surface and hold the engine steady while parts are being removed. • Remove: Cylinder (see Cylinder Removal in the Engine Top End chapter) Piston (see Piston Removal in the Engine Top End chap- ter)
  • Page 247: Crankcase Assembly

    CRANKCASE/CRANKSHAFT 9-7 Crankcase • Remove the crankshaft [A] from the left crankcase. NOTE ○ Avoid damaging the bearing. ○ Avoid damaging the crankcase mating surfaces. Crankcase Assembly WARNING Gasoline and low flash-point solvents can be flammable and/or explosive and cause severe burns.
  • Page 248: Crankshaft Bearing Replacement

    9-8 CRANKCASE/CRANKSHAFT Crankcase Crankshaft Bearing Replacement • Remove the crankshaft bearing [A]. Special Tool - Bearing Driver Set [B]: 57001-1129 • Replace the crankshaft bearings with new ones. • Select the new bearing, refer to the following. Crankshaft Bearing Color [A] Crankcase Mark [B] Crankshaft Mark [C] Black...
  • Page 249: Crankshaft, Connecting Rod

    CRANKCASE/CRANKSHAFT 9-9 Crankshaft, Connecting Rod Crankshaft Removal • Refer to the Crankcase Splitting. Crankshaft Installation • Refer to the Crankcase Assembly. Crankshaft Disassembly If the crankshaft is damaged, replace it as a set. Not for sale to each part of the crankshaft. Connecting Rod Big End Radial Clearance Inspection •...
  • Page 250: Starter Motor Clutch

    9-10 CRANKCASE/CRANKSHAFT Starter Motor Clutch Starter Motor Clutch Removal • Refer to the Starter Motor Clutch Disassembly. Starter Motor Clutch Installation • Refer to the Starter Motor Clutch Assembly. Starter Motor Clutch Inspection • Remove: Alternator Cover (see Alternator Cover Removal in the Electrical System chapter) Starter Motor (see Starter Motor Removal in the Electri- cal System chapter)
  • Page 251: Starter Motor Clutch Gear And Starter Idle Gear Removal

    CRANKCASE/CRANKSHAFT 9-11 Starter Motor Clutch Starter Motor Clutch Gear and Starter Idle Gear Removal • Remove: Alternator Rotor (see Alternator Rotor Removal in the Electrical System chapter) Starter Motor Clutch Gear [A] Shaft [B] Starter Idle Gear [C] Starter Motor Clutch Gear and Starter Idle Gear Installation •...
  • Page 253 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 ......................10-8 Front Axle Inspection ......................
  • Page 254: Exploded View

    10-2 WHEELS/TIRES Exploded View...
  • Page 255 WHEELS/TIRES 10-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Axle Rear Axle Nut 12.0 87.0 Sub Frame Bolts HG: Apply high-temperature grease. R: Replacement Parts WL: Apply soap and water solution or rubber lubricant.
  • Page 256: Specifications

    10-4 WHEELS/TIRES Specifications Item Standard Service Limit Wheels (Rims) Rim Runout: Axial – – – TIR 2.0 mm (0.08 in.) Radial – – – TIR 2.0 mm (0.08 in.) Axle Runout/100 mm (3.94 in.) – – – TIR 0.2 mm (0.008 in.) Rim Size: Front J 14 ×...
  • Page 257: Special Tools

    WHEELS/TIRES 10-5 Special Tools Inside Circlip Pliers: Bearing Remover Shaft, 9: 57001-143 57001-1265 Bearing Driver Set: Bearing Remover Head, 15 × 17: 57001-1129 57001-1267 Jack: 57001-1238...
  • Page 258: Wheels (rims)

    10-6 WHEELS/TIRES Wheels (Rims) Front Wheel Removal • Remove: Front Fender (see Front Fender Removal in the Frame chapter) Bolt [A] Front Wheel Rotation Sensor (Speed Sensor) [B] • Loosen: Front Axle Clamp Bolt [A] Front Axle [B] • Remove the lower cover (see Lower Cover Removal in the Frame chapter).
  • Page 259: Rear Wheel Removal

    WHEELS/TIRES 10-7 Wheels (Rims) • Install the removed parts (see appropriate chapters). • Check the front brake effectiveness (see Brake Operation Inspection in the Periodic Maintenance chapter). WARNING After servicing, it takes several applications of the brake lever before the brake pads contact the disc, which could result in increased stopping distance and cause an accident resulting in injury or death.
  • Page 260: Rear Wheel Installation

    10-8 WHEELS/TIRES Wheels (Rims) Rear Wheel Installation • Installation is the reverse of removal. • Replace the rear axle nut with a new one. • Tighten: Torque - Sub Frame Bolts: 34 N·m (3.5 kgf·m, 25 ft·lb) Rear Axle Nut: 118 N·m (12.0 kgf·m, 87.0 ft·lb) •...
  • Page 261: Front Axle Inspection

    WHEELS/TIRES 10-9 Wheels (Rims) • Measure the rim runout, axial [A] and radial [B], with a dial gauge. If rim runout exceeds the service limit, check the following. Hub Bearings/Sub Frame Bearing (see Hub Bear- ing/Sub Frame Bearing Inspection) Bearings of Final Shaft (see Final Gear Case Inspection in the Final Drive chapter) If the problem is not due to the bearings, replace the wheel.
  • Page 262: Balance Adjustment (front Wheel Only)

    10-10 WHEELS/TIRES Wheels (Rims) Balance Adjustment (Front Wheel Only) • If the wheel always stops in one position, provisionally attach a balance weight [A] on the rim at the marking using adhesive tape. • Rotate the wheel 1/4 turn [B], and see whether or not the wheel stops in this position.
  • Page 263: Tires

    WHEELS/TIRES 10-11 Tires Air Pressure Inspection/Adjustment • Refer to the Air Pressure Inspection in the Periodic Main- tenance chapter. Tire Inspection • Refer to the Wheel/Tire Damage Inspection in the Peri- odic Maintenance chapter. Tire Removal • Remove: Wheels (see Front/Rear Wheel Removal) Valve Core (Let out the air) •...
  • Page 264 10-12 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 265: 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 266: Hub Bearing

    10-14 WHEELS/TIRES Hub Bearing Hub Bearing Removal • Remove the front wheel (see Front Wheel Removal), and take out the following. Collars Grease Seals • Use the bearing remover to remove the hub bearings [A]. NOTICE Do not lay the wheel on the ground with the disc facing down.
  • Page 267: Sub Frame Bearing Installation

    WHEELS/TIRES 10-15 Hub Bearing • Remove: Collar [A] Grease Seal [B] (Both Sides) • Remove the circlip [A]. Special Tool - Inside Circlip Pliers: 57001-143 • Remove the bearing [A] by tapping from the wheel side. Special Tool - Bearing Driver Set [B]: 57001-1129 Sub Frame Bearing Installation •...
  • Page 268: Hub Bearing/sub Frame Bearing Inspection

    10-16 WHEELS/TIRES Hub Bearing Hub Bearing/Sub Frame Bearing Inspection Since the bearings are made to extremely close toler- ances, the clearance can not normally be measured. NOTE ○ Do not remove any bearings for inspection. If any bear- ings are removed, they will need to be replaced with new ones.
  • Page 269 FINAL DRIVE 11-1 Final Drive Table of Contents Exploded View ........................11-2 Specifications ........................11-4 Special Tools .......................... 11-5 Final Gear Case ........................11-6 Final Gear Case Disassembly ..................11-6 Final Gear Case Assembly ....................11-6 Final Gear Case Inspection ....................11-7 Final Gear Bearing Replacement..................
  • Page 270: Exploded View

    11-2 FINAL DRIVE Exploded View...
  • Page 271 FINAL DRIVE 11-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Oil Filler Bolt 87 in·lb Final Gear Case Oil Drain Bolt 87 in·lb Final Gear Case Cover Bolts G: Apply grease. R: Replacement Parts...
  • Page 272: Specifications

    11-4 FINAL DRIVE Specifications Item Standard Service Limit Final Drive Final Gear Case Oil: Viscosity SAE 90 – – – Capacity 0.23 L (0.24 US qt) at disassembly – – – 0.21 L (0.22 US qt) at change – – –...
  • Page 273: Special Tools

    FINAL DRIVE 11-5 Special Tools Bearing Driver Set: Oil Seal & Bearing Remover: 57001-1129 57001-Y024...
  • Page 274: Final Gear Case

    11-6 FINAL DRIVE Final Gear Case Final Gear Case Disassembly NOTE ○ Do not remove the final gear case cover except for nec- essary part replacement. ○ When replacing the drive shaft, also replace the bearing and oil seal. • Remove: Rear Wheel (see Rear Wheel Removal in the Wheels/Tires chapter)
  • Page 275: Final Gear Case Inspection

    FINAL DRIVE 11-7 Final Gear Case • Replace the oil seal [A] on the left crankcase with a new one. • Apply grease to the oil seal lips, and install the oil seal to the left crankcase. • Install: Countershaft [A] Final Shaft [B] •...
  • Page 276: Final Gear Bearing Replacement

    11-8 FINAL DRIVE Final Gear Case • Inspect the drive shaft [A] and gear [B] for wear or dam- age. If there is any damage, replace it. NOTE ○ When replacing the drive shaft, also replace the bearing and oil seal. •...
  • Page 277 BRAKES 12-1 Brakes Table of Contents Exploded View ........................12-3 Specifications ........................12-10 Special Tool ..........................12-11 Brake Lever, Brake Pedal....................... 12-12 Brake Lever Position Adjustment..................12-12 Calipers ..........................12-13 Front Caliper Removal ...................... 12-13 Rear Caliper Removal....................... 12-13 Caliper Installation ......................12-14 Front Caliper Disassembly....................
  • Page 278 12-2 BRAKES ABS Motor Relay Inspection ..................... 12-37 Wheel Rotation Sensor Signal Abnormal................12-37 Front Wheel Rotation Sensor Wiring Inspection ............... 12-38 Rear Wheel Rotation Sensor Wiring Inspection..............12-38 ABS Hydraulic Unit Removal .................... 12-39 ABS Hydraulic Unit Installation ..................12-40 ABS Hydraulic Unit Inspection ..................
  • Page 279: Exploded View

    BRAKES 12-3 Exploded View This page intentionally left blank.
  • Page 280 12-4 BRAKES Exploded View...
  • Page 281 BRAKES 12-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Brake Reservoir Cap Screws 0.16 14 in·lb Brake Lever Pivot Bolt 0.20 18 in·lb Master Cylinder Clamp Bolts 106 in·lb Brake Lever Pivot Bolt Locknut 87 in·lb Brake Light Switch Screw 0.10 8.9 in·lb Brake Hose Banjo Bolts...
  • Page 282 12-6 BRAKES Exploded View...
  • Page 283 BRAKES 12-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Brake Reservoir Cap Screws 0.16 14 in·lb Master Cylinder Clamp Bolts 106 in·lb Brake Lever Pivot Bolt 0.20 18 in·lb Brake Hose Banjo Bolts Brake Lever Pivot Bolt Locknut 87 in·lb Brake Light Switch Screw 0.10 8.9 in·lb...
  • Page 284 12-8 BRAKES Exploded View ABS Equipped Model...
  • Page 285 BRAKES 12-9 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Brake Hose Banjo Bolts ABS Hydraulic Unit Mounting Nuts 0.80 69 in·lb 3. Rear Wheel Rotation Sensor R: Replacement Parts...
  • Page 286: Specifications

    12-10 BRAKES Specifications Item Standard Service Limit Brake Lever Brake Lever Position 4-way adjustable (to suit rider) – – – Brake Lever Free Play Non-adjustable – – – Brake Pads Lining Thickness: Front 5 mm (0.20 in.) 1 mm (0.04 in.) Rear 5.8 mm (0.23 in.) 1 mm (0.04 in.)
  • Page 287: Special Tool

    BRAKES 12-11 Special Tool Jack: 57001-1238...
  • Page 288: Brake Lever, Brake Pedal

    12-12 BRAKES Brake Lever, Brake Pedal Brake Lever Position Adjustment The brake lever adjuster has 4 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 mark [B] on the lever.
  • Page 289: Calipers

    BRAKES 12-13 Calipers Front Caliper Removal • Remove the clamp [A]. • Loosen the banjo bolt [B] at the brake hose lower end, and tighten it loosely. • Remove the caliper mounting bolts [C], and remove the caliper [D] from the disc. •...
  • Page 290: Caliper Installation

    12-14 BRAKES Calipers Caliper Installation • Install the caliper and brake hose lower end. ○ Replace the washers on each side of hose fitting with new ones. • Apply a non-permanent locking agent to the caliper mounting bolts. • Tighten: Torque - Front Caliper Mounting Bolts: 34 N·m (3.5 kgf·m, 25 ft·lb) Rear Caliper Mounting Bolts: 34 N·m (3.5 kgf·m,...
  • Page 291: Caliper Fluid Seal Damage Inspection

    BRAKES 12-15 Calipers Caliper Fluid Seal Damage Inspection The fluid seal (piston seal) [A] is placed around the pis- ton to maintain clearance between the pad and the disc. If the seal is in a poor condition, it could lead the pad to wear excessively or the brake to drag, which may cause the tem- perature of the discs or the brake fluid to increase.
  • Page 292: Caliper Friction Boot Damage Inspection

    12-16 BRAKES Calipers Caliper Friction Boot Damage Inspection • Check that the friction boots [A] are not cracked, worn, swollen, or otherwise damaged. If they show any damage, replace them. Caliper Piston and Cylinder Damage Inspection • Visually inspect the pistons [A] and cylinder surfaces [B]. Replace the caliper if the cylinder and piston are badly scores or rusty.
  • Page 293: Caliper Holder Shaft Wear Inspection

    BRAKES 12-17 Calipers Caliper Holder Shaft Wear Inspection The caliper body must slide smoothly on the caliper holder shafts [A]. If the body does not slide smoothly, one pad will wear more than the other, pad wear will increase, and con- stant drag on the disc will raise brake and brake fluid tem- perature.
  • Page 294: Brake Pads

    12-18 BRAKES Brake Pads Front Brake Pad Removal • Remove: Pad Pin [A] Brake Pads [B] Front Brake Pad Installation • Push the caliper pistons in by hand as far as they will go. • Check that the pad spring [A] is in place on the caliper. •...
  • Page 295: Rear Brake Pad Installation

    BRAKES 12-19 Brake Pads Rear Brake Pad Installation • Push the caliper pistons in as far as they will go. • Check that the pad springs are in place on the caliper. • Install: Brake Pads Rear Brake Caliper • Apply silicone grease to the shaft [A] of the caliper holder pins.
  • Page 296: Master Cylinder Removal

    12-20 BRAKES Master Cylinder Master Cylinder Removal • Remove: Rear View Mirror (see Rear View Mirror Removal in the Frame chapter) Upper Handlebar Cover (see Handlebar Cover Removal in the Frame chapter) • Remove the brake hose banjo bolt [A] and remove the brake hose from the master cylinder.
  • Page 297: Master Cylinder Disassembly

    BRAKES 12-21 Master Cylinder • Install the master cylinder to the handlebars. ○ Fit the projection [A] into a hole [B] in the handlebars. • Tighten the upper clamp bolt first, and then lower clamp bolt. Torque - Master Cylinder Clamp Bolts: 12 N·m (1.2 kgf·m, 106 in·lb) •...
  • Page 298: Brake Disc

    12-22 BRAKES Brake Disc Brake Disc Removal • Remove the wheels (see Front/Rear Wheel Removal in the Wheels/Tires chapter). • Remove the brake disc mounting bolts [A], and take off the disc [B]. • Remove the wheel rotation sensor (speed sensor) rotor [C].
  • Page 299: Brake Fluid

    BRAKES 12-23 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 300 12-24 BRAKES Brake Fluid • Remove the rubber cap [A] from the bleed valve on the caliper. • Attach a clear plastic hose [B] to the bleed valve, and run the other end of the hose into a container. • Bleed the brake line and the caliper.
  • Page 301 BRAKES 12-25 Brake Fluid WARNING When working with the disc brake, observe the pre- cautions listed below. • Never reuse old brake fluid. • Do not use fluid from a container that has been left unsealed or that has been open for a long time. •...
  • Page 302: Brake Hose

    12-26 BRAKES 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 and Pipe Damage and Instal- lation Condition Inspection in the Periodic Maintenance chapter.
  • Page 303: Anti-lock Brake System (equipped Model)

    BRAKES 12-27 Anti-Lock Brake System (Equipped Model) Parts Location Front Wheel Rotation Sensor [A] Front Wheel Rotation Sensor Rotor [B] Rear Wheel Rotation Sensor [A] Rear Wheel Rotation Sensor Rotor [B] Yellow ABS Indicator Light [A] ABS Hydraulic Unit [A] Fuse Box [A] (ABS Motor Relay Fuse 40 A, ABS Sole- noid Valve Relay Fuse 25 A)
  • Page 304 12-28 BRAKES Anti-Lock Brake System (Equipped Model) ABS System Wiring Diagram 1. Front Wheel Rotation Sensor 9. Ignition Switch 2. ABS Hydraulic Unit 10. Battery 12 V 10 Ah 3. Rear Wheel Rotation Sensor 11. Engine Ground 4. Fuse Box 12.
  • Page 305 BRAKES 12-29 Anti-Lock Brake System (Equipped Model) ABS Hydraulic Unit Terminal Names 1. Power Supply to ABS Motor Relay: R/BK 21. Power Supply to Front Wheel Rotation Sen- 2. Unused sor: R/G 3. Unused 22. Front Wheel Rotation Sensor Signal Out- 4.
  • Page 306: Abs Servicing Precautions

    12-30 BRAKES Anti-Lock Brake System (Equipped Model) ABS Servicing Precautions There are a number of important precautions that should be followed servicing the ABS system. ○ This ABS system is designed to be used with a 12 V sealed battery as its power source. Do not use any other battery except for a 12 V sealed battery as a power source.
  • Page 307: Abs Troubleshooting Outline

    BRAKES 12-31 Anti-Lock Brake System (Equipped Model) ○ The Yellow ABS indicator light (LED) [A] may light if the tire pressure is incorrect, a non-recommended tire is in- stalled, or the wheel is deformed. If the indicator light lights, remedy the problem. WARNING Use of non-recommended tires may cause malfunc- tioning of ABS and can lead to extended braking...
  • Page 308 12-32 BRAKES Anti-Lock Brake System (Equipped Model) • Visually inspect the wiring for signs of burning or fraying. If any wiring is poor, replace the damaged wiring. • Pull each connector apart and inspect it for corrosion, dirt and damage. If the connector is corroded or dirty, clean it carefully.
  • Page 309 BRAKES 12-33 Anti-Lock Brake System (Equipped Model) ABS Diagnosis Flow Chart...
  • Page 310: Inquiries To Rider

    12-34 BRAKES Anti-Lock Brake System (Equipped Model) Inquiries to Rider ○ Each rider reacts to problems in different ways, so it is important to confirm what kind of condition the rider is dissatisfied with. ○ Try to find out exactly what problem occurs under exactly what conditions by asking the rider; know- ing this information may help you reproduce the problem in the shop.
  • Page 311 BRAKES 12-35 Anti-Lock Brake System (Equipped Model) Preliminary Inspection 1...
  • Page 312: Yellow Abs Indicator Light (led) Inspection

    12-36 BRAKES Anti-Lock Brake System (Equipped Model) Preliminary Inspection 2 Yellow ABS Indicator Light (LED) Inspection ○ In this model, the yellow ABS indicator light (LED) [A] goes on by the control of the ABS hydraulic unit. • Refer to the meter operation Inspection in the Electrical System chapter.
  • Page 313: Front, Rear Wheel Rotation Difference Abnormal (deviation Between Wheel Speeds)

    BRAKES 12-37 Anti-Lock Brake System (Equipped Model) If the fuse is good, check the wiring continuity between the positive (+) terminal [A] of the battery and R/BK lead terminal [B] in the ABS Hydraulic Unit Connector [C]. ○ Disconnect the ABS hydraulic unit connector. If the wiring is open, replace or repair the harness (see ABS System Wiring Diagram).
  • Page 314: Front Wheel Rotation Sensor Wiring Inspection

    12-38 BRAKES Anti-Lock Brake System (Equipped Model) • Check that there is iron or other magnetic deposits be- tween the sensor [A] and sensor rotor [B], and the sensor rotor slots for obstructions. • Check the installation condition of the sensor for loose- ness.
  • Page 315: Abs Hydraulic Unit Removal

    BRAKES 12-39 Anti-Lock Brake System (Equipped Model) ABS Hydraulic Unit Removal NOTICE The ABS hydraulic unit [A] has been adjusted and set with precision at the factory. Therefore, it should be handled carefully, never struck sharply, as with a hammer, or allowed to fall on a hard surface.
  • Page 316: Abs Hydraulic Unit Installation

    12-40 BRAKES Anti-Lock Brake System (Equipped Model) • Remove: ABS Hydraulic Unit Mounting Nuts [A] Clamp [B] Bracket [C] NOTICE The ABS hydraulic unit has been adjusted and set with precision at the factory. Do not try to disas- semble and repair the ABS hydraulic unit. ABS Hydraulic Unit Installation NOTICE Brake fluid quickly ruins painted plastic surfaces;...
  • Page 317: Power Supply Inspection

    BRAKES 12-41 Anti-Lock Brake System (Equipped Model) Power Supply Inspection • When the supply voltage is too low voltage or too high voltage, check the ABS hydraulic unit connector (see ABS Hydraulic Unit Inspection). If the connector is good, check the battery condition (see Charging Condition Inspection in the Electrical System chapter).
  • Page 318: Front Wheel Rotation Sensor Installation

    12-42 BRAKES Anti-Lock Brake System (Equipped Model) • Clear the sensor lead from the clamps [A]. • Remove the clamp bolt [B], and open the clamp. • Remove: Bolt [C] Front Wheel Rotation Sensor [D] Front Wheel Rotation Sensor Installation •...
  • Page 319: Wheel Rotation Sensor Inspection

    BRAKES 12-43 Anti-Lock Brake System (Equipped Model) Wheel Rotation Sensor Inspection • Remove the front wheel rotation sensor [A] from the front fork (see Front Wheel Rotation Sensor Removal). • Remove the sub frame to inspect the rear wheel rotation sensor [B] (see Rear Wheel Removal in the Wheels/Tires chapter).
  • Page 320: Wheel Rotation Sensor Rotor Inspection

    12-44 BRAKES Anti-Lock Brake System (Equipped Model) Wheel Rotation Sensor Rotor Inspection • Remove: Wheels (see Front/Rear Wheel Removal in the Wheels/Tires chapter) Brake Disc Mounting Bolts [A] Sensor Rotor [B] Front Wheel [C] Rear Wheel [D] • Visually inspect the wheel rotation sensor rotor. If the rotor is deformed or damaged (chipped teeth [A]), replace the sensor rotor with a new one.
  • Page 321 SUSPENSION 13-1 Suspension Table of Contents Exploded View........................13-2 Specifications ......................... 13-6 Special Tools .......................... 13-7 Front Fork ..........................13-8 Front Fork Removal (Each Fork Leg) ................13-8 Front Fork Installation (Each Fork Leg) ................13-8 Front Fork Oil Change ...................... 13-8 Front Fork Disassembly ....................
  • Page 322: Exploded View

    13-2 SUSPENSION Exploded View...
  • Page 323 SUSPENSION 13-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Fork Clamp Bolts Front Fork Bottom Allen Bolts AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque. G: Apply grease. L: Apply a non-permanent locking agent. R: Replacement Parts...
  • Page 324 13-4 SUSPENSION Exploded View...
  • Page 325 SUSPENSION 13-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Upper Rear Shock Absorber Nuts Lower Rear Shock Absorber Bolts Sub Frame Bolts R: Replacement Parts...
  • Page 326: Specifications

    Damper Setting Non-adjustable Fork Spring Setting Non-adjustable Suspension Oil: Recommended Oil Kawasaki SS-8 or equivalent Amount Approx. 157 mL (5.31 US oz.) (when changing oil) 185 ±1 mL (6.25 ±0.03 US oz.) (after disassembly and completely dry) Fork Oil Level 82 ±2 mm (3.2 ±0.08 in.) (below from inner tube top with...
  • Page 327: Special Tools

    SUSPENSION 13-7 Special Tools Fork Cylinder Holder Handle: Fork Oil Level Gauge: 57001-183 57001-1290 Bearing Driver Set: Oil Seal & Bearing Remover: 57001-1129 57001-Y024 Front Fork Oil Seal Driver: 57001-1219...
  • Page 328: Front Fork

    13-8 SUSPENSION Front Fork Front Fork Removal (Each Fork Leg) • Remove: Front Fairing (see Front Fairing Removal in the Frame chapter) Front Wheel (see Front Wheel Removal in the Wheel/Tires chapter) • Loosen the front fork clamp bolt [A]. •...
  • Page 329 Hold the fork tube upright, press the inner tube. • Pour in the type and amount of fork oil specified. Suspension Oil Recommended Oil: Kawasaki SS-8 or equivalent Amount (Per Side): When changing oil: Approx. 157 mL (5.31 US oz.) After disassembly and completely dry: 185 ±1 mL (6.25 ±0.03 US oz.)
  • Page 330 13-10 SUSPENSION Front Fork If the oil is above or below the specified level, remove or add oil and recheck the oil level. NOTE ○ Fork oil level may also be measured using the fork oil level gauge [A] as follows. Special Tool - Fork Oil Level Gauge: 57001-1290 ○...
  • Page 331: Front Fork Disassembly

    SUSPENSION 13-11 Front Fork Front Fork Disassembly • Remove the front fork and drain the fork oil (see Front Fork Oil Change). • Hold the fork leg horizontally in a vise [A]. • Loosen the front fork bottom Allen bolt [B] while holding the cylinder unit [C] with a commercially available 19 mm Allen socket [D] and fork cylinder holder handle [E].
  • Page 332: Front Fork Assembly

    13-12 SUSPENSION Front Fork • Remove the oil seal [A], washer [B] and bushing [C] as a set. Special Tool - Oil Seal & Bearing Remover [D]: 57001-Y024 Front Fork Assembly • Replace the following parts with new ones. Bushing [A] Oil Seal [B] Bottom Allen Bolt Gasket [C] •...
  • Page 333 SUSPENSION 13-13 Front Fork • Apply a non-permanent locking agent to the threads of the front fork bottom Allen bolt [A] and screw it to the cylinder unit [B] with the new gasket [C]. • Hold the front fork horizontally in a vise [D]. •...
  • Page 334: Inner Tube, Outer Tube Inspection

    13-14 SUSPENSION Front Fork Inner Tube, Outer Tube Inspection • Visually inspect the inner tube [A]. If there is any damage, replace the inner tube. Since damage to the inner tube damages the oil seal and dust seal, replace the oil seal and dust seal whenever the inner tube is replaced.
  • Page 335: Rear Shock Absorber

    SUSPENSION 13-15 Rear Shock Absorber Spring Preload Adjustment • Set the motorcycle up on its center stand. • Using the hook wrench [A], turn the adjuster [B] to adjust the spring preload. Spring Preload Setting Standard Position: 3rd position 1st ∼ 5th position Adjustable Range: NOTICE Always adjust the spring preload adjuster in se-...
  • Page 336: Rear Shock Absorber Installation

    13-16 SUSPENSION Rear Shock Absorber • Remove: Upper Rear Shock Absorber Bolt [A] and Nut Rear Shock Absorber [B] ○ Remove the right rear shock absorber in the same way. Rear Shock Absorber Installation • Replace the upper rear shock absorber nut with a new one.
  • Page 337 STEERING 14-1 Steering Table of Contents Exploded View........................14-2 Special Tools .......................... 14-4 Steering ..........................14-5 Steering Inspection ......................14-5 Steering Adjustment......................14-5 Steering Stem......................... 14-6 Stem, Stem Bearing Removal................... 14-6 Stem, Stem Bearing Installation..................14-8 Steering Stem Bearing Lubrication ................... 14-10 Steering Stem Warp Inspection ..................
  • Page 338: Exploded View

    14-2 STEERING Exploded View...
  • Page 339 STEERING 14-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Steering Stem Nut Steering Stem Lock Nut Handlebar Mounting Nut AD: Apply adhesive. G: Apply grease. R: Replacement Parts...
  • Page 340: Special Tools

    14-4 STEERING Special Tools Head Pipe Outer Race Press Shaft: Head Pipe Outer Race Remover ID > 37 mm: 57001-1075 57001-1107 Head Pipe Outer Race Driver, 54.5: Steering Stem Bearing Driver Adapter, 41.5: 57001-1077 57001-1345 Steering Stem Nut Wrench: Case Assembly Tool, 50.8: 57001-1100 57001-1353 Head Pipe Outer Race Driver, 46.5:...
  • Page 341: 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 342: Steering Stem

    14-6 STEERING Steering Stem Stem, Stem Bearing Removal • Remove: Front Forks (see Front Fork Removal in the Suspension chapter) Upper Handlebar Cover (see Handlebar Cover Removal in the Frame chapter) Leg Shield Cover (see Leg Shield Removal in the Frame chapter) •...
  • Page 343 STEERING 14-7 Steering Stem • Remove the cap [A]. • Remove the steering stem locknut [A] with the steering stem locknut wrench [B]. Special Tool - Steering Stem Locknut Wrench, 32 mm: 57001-Y014 • Remove the washer. • Pushing up the stem base [A], and remove the steering stem nut [B].
  • Page 344: Stem, Stem Bearing Installation

    14-8 STEERING Steering Stem • Remove the lower ball bearing [A] from the steering stem. • Remove the lower bearing inner race [A] (with its grease seal) which is pressed onto the steering stem with a suit- able commercially available chisel [B]. Stem, Stem Bearing Installation •...
  • Page 345 STEERING 14-9 Steering Stem • Install: Upper Ball Bearing [A] Upper Ball Bearing Inner Race [B] Stem Cap [C] • Install: Steering Stem [A] Steering Stem Nut [B] Special Tool - Steering Stem Nut Wrench [C]: 57001-1100 • Settle the bearings in place as follows. ○...
  • Page 346: Steering Stem Bearing Lubrication

    14-10 STEERING Steering Stem • Replace the handlebar mounting nut [A] with a new one. • Install: Handlebars [B] Collar [C] Handlebar Mounting Bolt and Nut Torque - Handlebar Mounting Nut: 44 N·m (4.5 kgf·m, 32 ft·lb) WARNING If the handlebars do not turn to the steering stop, they may cause an accident resulting in injury or death.
  • Page 347: Handlebar

    STEERING 14-11 Handlebar Handlebar Removal • Remove: Rear View Mirrors [A] (see Rear View Mirror Removal in the Frame chapter) Handlebar Cover [B] (see Handlebar Cover Removal in the Frame chapter) Master Cylinders [C] (see Master Cylinder Removal in the Brakes chapter) Right Switch Housing [D] (see Throttle Cable Removal in the Fuel System (DFI) chapter) Left Switch Housing [E]...
  • Page 348 14-12 STEERING Handlebar • Install the left switch housing. ○ Fit the projection [A] of the left switch housing into a hole [B] of the handlebars. • Install the removed parts (see appropriate chapters).
  • Page 349 FRAME 15-1 Frame Table of Contents Exploded View........15-2 Lower Cover Removal ....15-19 Seat ........... 15-6 Lower Cover Installation ....15-19 Seat Removal ......15-6 Handlebar Cover Removal... 15-19 Seat Installation ......15-6 Handlebar Cover Installation..15-20 Storage Box Removal ....15-6 Fenders ..........
  • Page 350: Exploded View

    15-2 FRAME Exploded View R: Replacement Parts G: Apply grease.
  • Page 351 FRAME 15-3 Exploded View...
  • Page 352 15-4 FRAME Exploded View...
  • Page 353 FRAME 15-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Grab Rail Mounting Bolts...
  • Page 354: Seat

    15-6 FRAME Seat Seat Removal • Open the seat. • Remove the nuts [A]. • Remove: Nuts [A] Seat Assy [B] Seat Installation • Installation is the reverse of removal. Storage Box Removal • Remove: Seat (see Seat Removal) Bolts [A] Nuts [B] •...
  • Page 355: Fairings

    FRAME 15-7 Fairings Lower Fairing Removal • Remove: Floor Mat Rear Fairing Cover (see Rear Faring Cover Removal) Screws [A] • Remove the quick rivets [A]. • Remove the bolt [A]. • Pull the rear side of the lower fairing outward [B] to clear the hooks [C], and then pull the front side of the lower fairing.
  • Page 356: Lower Fairing Installation

    15-8 FRAME Fairings Lower Fairing Installation • Insert the hooks [A] into the slots [B]. • Install: Screws and Bolt Quick Rivets Rear Fairing Cover (see Rear Fairing Cover Installation) Floor Mat Front Fairing Removal • Remove: Front Center Cover (see Front Center Cover Removal) Lower Fairing (see Lower Fairing Removal) Quick Rivets [A] (Both Sides) Screw [B] (Both Sides)
  • Page 357: Front Fairing Installation

    FRAME 15-9 Fairings • Pull the lower side of the front fairing outward [A] to clear the hooks [B], and then pull the front fairing [C] forward [D] to clear the hooks [E]. • Disconnect the headlight lead connectors [A] and remove the front fairing.
  • Page 358: Front Fairing Disassembly

    15-10 FRAME Fairings Front Fairing Disassembly • Remove: Screws [A] Fitting [B] Inner Cover [C] • Disconnect the front turn signal light lead connectors [A]. • Remove: Screws [B] Headlight Assy [C] • Remove the screws [A] and separate the front fairings. Rear Fairing Removal •...
  • Page 359: Rear Fairing Installation

    FRAME 15-11 Fairings • Disconnect the tail/brake light lead connector [A] and re- move the rear fairing. Rear Fairing Installation • Connect the tail/brake light lead connector. • Insert the hooks [A] into the slots [B]. • Install the removed parts (see appropriate chapters). Rear Fairing Disassembly •...
  • Page 360: Side Fairing Installation

    15-12 FRAME Fairings • Pull the side fairing [A] upward [B] to clear the hooks [C]. ○ Clear the plate [A] of the leg shield from bolt hole [B] of the side fairing. • Remove the side fairing. • If necessary, separate the side fairing [A], inner cover [B] and floor board [C] by removing the screws [D].
  • Page 361: Covers

    FRAME 15-13 Covers Front Center Cover Removal • Remove: Windshield (see Windshield Removal) Quick Rivets [A] • Pull the front center cover [B] forward [C] to clear the hooks [D] and remove the front center cover. Front Center Cover Installation •...
  • Page 362: Fuel Tank Cap Cover Removal

    15-14 FRAME Covers Fuel Tank Cap Cover Removal • Remove the storage box (see Storage Box Removal). • Slide the fuel tank cap cover [A] backward [B], and then pull the fuel tank cap cover upward [C] to clear the hooks [D].
  • Page 363: Meter Cover Installation

    FRAME 15-15 Covers • Remove the security shutter assy [A]. • Clear the leg shield [A] from the bolt hole rib [B] of the frame to free the leg shield. • Pull the meter assy [C] forward [D] to clear the hooks [E]. •...
  • Page 364: Leg Shield Removal

    15-16 FRAME Covers • Insert the projection [A] of the meter unit into the grommet [B]. • Fit the projections [A] of the ignition switch to the slits [B] of the security shutter assy and tighten the security shutter assy mounting screw. Leg Shield Removal •...
  • Page 365: Leg Shield Installation

    FRAME 15-17 Covers • Disconnect the accessory socket lead connector [A]. • Remove the bolts [A] (both sides). • Open the fuel tank cap [A]. • Remove the leg shield [B] backward. • Install the fuel tank cap. Leg Shield Installation •...
  • Page 366: Radiator Cover Removal

    15-18 FRAME Covers • Remove the screws [A] and separate the leg shields [B] and glove box [C]. • Remove: Screws [A] Quick Rivets [B] Leg Shield Cover [C] Radiator Cover Removal • Remove: Front Fairing (see Front Fairing Removal) Screws [A] •...
  • Page 367: Lower Cover Removal

    FRAME 15-19 Covers Lower Cover Removal • Remove: Lower Fairing (see Lower Fairing Removal) Screws [A] • Remove: Bolts [A] (Both Sides) Lower Cover [B] Lower Cover Installation • Installation is the reverse of removal. Handlebar Cover Removal • Remove: Rear View Mirrors (see Rear View Mirror Removal) Screws [A] •...
  • Page 368: Handlebar Cover Installation

    15-20 FRAME Covers • Remove the screws [A]. • Remove the lower handlebar cover [B]. • When removing the lower handlebar cover [A] from the handlebar completely, remove the throttle cables [B] from the right switch housing (see Throttle Cable Removal in the Fuel System (DFI) chapter).
  • Page 369: Fenders

    FRAME 15-21 Fenders Front Fender Removal • Remove: Bolts [A] (Both Sides) Bracket [B] Front Fender [C] Front Fender Installation • Installation is the reverse of removal. Flap/Rear Fender Removal/Installation • Refer to the Rear Fairing Disassembly.
  • Page 370: Sub Frame Removal

    15-22 FRAME Frame Sub Frame Removal • Refer to the Rear Wheel Removal in the Wheels/Tires chapter. Sub Frame Installation • Refer to the Rear Wheel Installation in the Wheels/Tires chapter. Footpeg Removal • Remove: Clip [A] Pin [B] Washers [C] Footpeg [D] Guide [E] •...
  • Page 371: Windshield

    FRAME 15-23 Windshield Windshield Removal • Remove: Bolts [A] Windshield [B] Windshield Installation • Installation is the reverse of removal.
  • Page 372: Guard

    15-24 FRAME Guard Mud Guard Removal • Remove: Bolts [A] Mud Guard [B] ○ Remove the bolts [A], and free the air cleaner box to re- move the mud guard. Mud Guard Installation • Installation is the reverse of removal. •...
  • Page 373: Grab Rail Installation

    FRAME 15-25 Guard • Remove: Grab Rail Mounting Bolts [A] Grab Rail [B] Grab Rail Installation • Install the grab rail and tighten its bolts. Torque - Grab Rail Mounting Bolts: 24 N·m (2.4 kgf·m, 18 ft·lb) • Install: Cover Quick Rivets Screws ○...
  • Page 374: Center Stand, Side Stand

    15-26 FRAME Center Stand, Side Stand Center Stand Removal • Remove: Spring [A] Center Stand Bolts [B] and Nut (Both Sides) Center Stand [C] Center Stand Installation • Be sure that the collars [A] are in position. • Apply grease to the inside of the collars. If the damper [B] is damaged, replace it.
  • Page 375: Rear View Mirror

    FRAME 15-27 Rear View Mirror Rear View Mirror Removal • Slide the rubber cover [A]. • Loosen the locknut [B] and remove the rear view mirror [C]. Rear View Mirror Installation • Install the rear view mirror and tighten the locknut [A]. •...
  • Page 377 ELECTRICAL SYSTEM 16-1 Electrical System Table of Contents Exploded View........................16-3 Specifications ......................... 16-6 Special Tools and Sealant ...................... 16-7 Parts Location......................... 16-8 Wiring Diagram........................16-10 Wiring Diagram (ABS Equipped Model) ................. 16-12 Precautions..........................16-14 Electrical Wiring........................16-15 Wiring Inspection ......................16-15 Battery ............................
  • Page 378 16-2 ELECTRICAL SYSTEM Tail/Brake Light (LED) Removal/Installation..............16-39 License Plate Light Bulb Replacement ................16-40 Turn Signal Light Bulb Replacement ................16-42 Turn Signal Relay Inspection .................... 16-43 Hazard Control Unit Removal ................... 16-43 Hazard Control Unit Installation ..................16-43 Hazard Control Unit Inspection ..................
  • Page 379: Exploded View

    ELECTRICAL SYSTEM 16-3 Exploded View...
  • Page 380 16-4 ELECTRICAL SYSTEM Exploded View...
  • Page 381 ELECTRICAL SYSTEM 16-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Alternator Cover Center Cap (SC300AE/BE) 0.45 39 in·lb Alternator Cover Center Cap (SC300AF 87 in·lb ∼/BF ∼) Timing Inspection Cap 0.45 39 in·lb Alternator Cover Bolts 87 in·lb Brake Light Switch Screws 0.10 8.9 in·lb Alternator Rotor Nut...
  • Page 382: Specifications

    16-6 ELECTRICAL SYSTEM Specifications Item Standard Battery Type Sealed Battery Model Name YT12A-BS Capacity 12 V 10 Ah (10 HR) Voltage 12.8 V or more Gross Weight 3.5 kg (7.7 lb) Electrolyte Volume 0.47 L (29 cu in.) Charging System Type Three-phase AC AC 70 ∼...
  • Page 383: Special Tools And Sealant

    ELECTRICAL SYSTEM 16-7 Special Tools and Sealant Rotor Puller M18 × 1.5, M16 × 1.5: Flywheel Puller, M28 × 1.0: 57001-1099 57001-1471 Flywheel Holder: Liquid Gasket, TB1211F: 57001-1313 92104-0004 Peak Voltage Adapter: 57001-1415...
  • Page 384: Parts Location

    16-8 ELECTRICAL SYSTEM Parts Location Meter Unit [A] Front Brake Light Switch [B] Rear Brake Light Switch [C] Ignition Switch [D] Horn [A] High Beam Headlight Relay [B] Low Beam Headlight Relay [C] Starter Relay 1 [D] Fan Relay [E] Fuel Pump/Fuel Level Sensor [A] Fan Motor [B] Speed Sensor (Front Wheel Rotation Sensor) [A]...
  • Page 385 ELECTRICAL SYSTEM 16-9 Parts Location Ignition Coil [A] Spark Plug [B] Side Stand Switch [C] Oil Pressure Switch [D] Starter Relay 2 [A] Regulator/Rectifier [B] Starter Motor [A] Alternator [B] Crankshaft Sensor [C] Oxygen Sensor [D] Fuse Box [A] Battery [B]...
  • Page 386: Wiring Diagram

    16-10 ELECTRICAL SYSTEM Wiring Diagram...
  • Page 387 ELECTRICAL SYSTEM 16-11 Wiring Diagram...
  • Page 388: Wiring Diagram (abs Equipped Model)

    16-12 ELECTRICAL SYSTEM Wiring Diagram (ABS Equipped Model)
  • Page 389 ELECTRICAL SYSTEM 16-13 Wiring Diagram (ABS Equipped Model)
  • Page 390: Precautions

    16-14 ELECTRICAL SYSTEM Precautions There are a number of important precautions that are musts when servicing electrical systems. Learn and ob- serve all the rules below. ○ Do not reverse the battery cable connections. This will burn out the diodes on the electrical parts. ○...
  • Page 391: Electrical Wiring

    ELECTRICAL SYSTEM 16-15 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 392: Battery

    16-16 ELECTRICAL SYSTEM Battery Battery Removal • Turn the ignition switch off. • Open the seat. • Remove: Screws [A] Battery Cover [B] • Remove: Bolts [A] Battery Case Cover [B] • Slide the red cap [A]. • Disconnect the negative (–) cable [B] and then positive (+) cable [C].
  • Page 393: Battery Activation

    ELECTRICAL SYSTEM 16-17 Battery Battery Activation Electrolyte Filling • Make sure that the model name [A] of the electrolyte con- tainer matches the model name [B] of the battery. These names must be the same. Battery Model Name SC300A/B: YT12A-BS NOTICE Each battery comes with its own specific elec- trolyte container;...
  • Page 394 16-18 ELECTRICAL SYSTEM Battery • Place the electrolyte container upside down with the six sealed cells into the filler ports of the battery. Hold the container level, push down to break the seals of all six cells. You will see air bubbles rising into each cell as the ports fill.
  • Page 395: Precautions

    Newly activated sealed batteries require an initial charge. Standard Charge: 1.2 A × 5 ∼ 10 hours If using a recommended battery charger, follow the charger’s instructions for newly activated sealed battery. Kawasaki-recommended chargers: Battery Mate 150-9 OptiMate PRO 4-S/PRO S/PRO2 Yuasa MB-2040/2060...
  • Page 396: Interchange

    16-20 ELECTRICAL SYSTEM Battery DANGER Batteries produce an explosive gas mixture of hydrogen and oxygen that can cause seri- ous injury and burns if ignited. Keep the battery away from sparks and open flames during charging. When using a battery charger, connect the battery to the charger before turning on the charger.
  • Page 397 ELECTRICAL SYSTEM 16-21 Battery Terminal Voltage: 11.5 ∼ less than 12.8 V Standard Charge 1.2 A × 5 ∼ 10 h (see following chart) Quick Charge 5 A × 1 h NOTICE If possible, do not quick charge. If quick charge is done unavoidably, do standard charge later on.
  • Page 398: Charging System

    16-22 ELECTRICAL SYSTEM Charging System Alternator Cover Removal • Drain: Engine Oil (see Engine Oil Change in the Periodic Main- tenance chapter) Coolant (see Coolant Change in the Periodic Mainte- nance chapter) • Remove: Storage Box (see Storage Box Removal in the Frame chapter) Lower Fairing (see Lower Fairing Removal In the Frame chapter)
  • Page 399: Stator Coil Removal

    ELECTRICAL SYSTEM 16-23 Charging System • Check that the dowel pins [A] are in place on the crankcase. • Replace the alternator cover gasket with a new one. • Tighten the alternator cover bolts together with the clamps. Torque - Alternator Cover Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) •...
  • Page 400: Alternator Rotor Installation

    16-24 ELECTRICAL SYSTEM Charging System • Using the flywheel puller [A] and rotor puller [B], remove the alternator rotor from the crankshaft. Special Tools - Rotor Puller M18 × 1.5, M16 × 1.5: 57001 -1099 Flywheel Puller, M28 × 1.0: 57001-1471 NOTICE Do not attempt to strike the alternator rotor itself.
  • Page 401: Charging Voltage Inspection

    ELECTRICAL SYSTEM 16-25 Charging System Charging Voltage Inspection • Check the battery condition (see Charging Condition In- spection). • Warm up the engine to obtain actual alternator operating conditions. • Remove the battery case cover (see Battery Removal). • Check that the ignition switch is turned off, and connect a digital meter [A] to the battery terminals [B].
  • Page 402 16-26 ELECTRICAL SYSTEM Charging System • To check the alternator output voltage, do the following procedures. ○ Turn the ignition switch off. ○ Remove the storage box (see Storage Box Removal in the Frame chapter). ○ Remove the band [A] and slide the dust cover [B]. ○...
  • Page 403: Regulator/rectifier Removal

    ELECTRICAL SYSTEM 16-27 Charging System Regulator/Rectifier Removal • Remove the rear fairing (see Rear Fairing Removal in the Frame chapter). • Remove the band [A] and slide the dust cover [B]. • Disconnect the regulator/rectifier lead connector [C]. • Remove the band [D]. •...
  • Page 404 16-28 ELECTRICAL SYSTEM Charging System...
  • Page 405 ELECTRICAL SYSTEM 16-29 Charging System Charging System Circuit 1. Alternator 2. Regulator/Rectifier 3. Load 4. Fuse Box 5. Charging/ECU Fuse 30 A 6. Battery 12 V 10 Ah 7. Engine Ground 8. Frame Ground 1...
  • Page 406: Ignition System

    16-30 ELECTRICAL SYSTEM Ignition System WARNING The ignition system produces extremely high volt- age. Do not touch the spark plug, ignition coil or ig- nition coil lead while the engine is running, or you could receive a severe electrical shock. NOTICE Do not disconnect the battery cables or any other electrical connections when the ignition switch is...
  • Page 407: Crankshaft Sensor Peak Voltage Inspection

    ELECTRICAL SYSTEM 16-31 Ignition System Crankshaft Sensor Peak Voltage Inspection NOTE ○ Be sure the battery is fully charged. ○ Using the peak voltage adapter [A] is more reliable way to determine the condition of the crankshaft sensor than crankshaft sensor internal resistance measurements. •...
  • Page 408: Ignition Coil Installation

    16-32 ELECTRICAL SYSTEM Ignition System Ignition Coil Installation • Install the ignition coil and tighten its nuts. Torque - Ignition Coil Mounting Nuts: 12 N·m (1.2 kgf·m, 106 in·lb) • Connect the ignition coil lead connectors. BK Lead [A] G/BR Lead [B] •...
  • Page 409: Spark Plug Removal

    ELECTRICAL SYSTEM 16-33 Ignition System WARNING To avoid extremely high voltage shocks, do not touch the spark plugs or tester connections. • Turn the ignition switch on. • Pushing the starter button, turn the engine 4 ∼ 5 seconds to measure the primary peak voltage. •...
  • Page 410 16-34 ELECTRICAL SYSTEM Ignition System Ignition System Troubleshooting...
  • Page 411 ELECTRICAL SYSTEM 16-35 Ignition System Ignition System Circuit 1. Vehicle-down Sensor 2. Engine Stop Switch 3. Fuse Box 4. Ignition Fuse 10 A 5. Charging/ECU Fuse 30 A 6. Ignition Switch 7. Side Stand Switch 8. Intake Air Pressure Sensor 9.
  • Page 412: Electric Starter System

    16-36 ELECTRICAL SYSTEM Electric Starter System Starter Motor Removal • Remove: Storage Box (see Storage Box Removal in the Frame chapter) Air Cleaner Box (see Air Cleaner Box Removal in the Fuel System (DFI) chapter) • Slide the rubber cap [A]. •...
  • Page 413: Starter Motor Inspection

    ELECTRICAL SYSTEM 16-37 Electric Starter System Starter Motor Inspection • Turn the engine stop switch to run position. • Turn the ignition switch on and push the starter button. If the starter motor does not turn, check the following. Charging/ECU Fuse 30 A (see Fuse Inspection) Ignition Fuse 10 A (see Fuse Inspection) Battery Condition (see Charging Condition Inspection) Starter Relays (see Starter Relay Inspection)
  • Page 414 16-38 ELECTRICAL SYSTEM Electric Starter System Electric Starter Circuit 1. Rear Brake Light Switch 2. Front Brake Light Switch 3. Engine Stop Switch 4. Starter Button 5. Fuse Box 6. Ignition Fuse 10 A 7. Charging/ECU Fuse 30 A 8. Ignition Switch 9.
  • Page 415: Lighting System

    ELECTRICAL SYSTEM 16-39 Lighting System Headlight Aiming Inspection • Refer to the Headlight Aiming Inspection in the Periodic Maintenance chapter. Headlight Bulb Replacement • Remove: Front Fairing (see Front Fairing Removal in the Frame chapter) Dust Cover [A] • Disconnect the headlight connector [A]. •...
  • Page 416: License Plate Light Bulb Replacement

    16-40 ELECTRICAL SYSTEM Lighting System License Plate Light Bulb Replacement • Remove: License Plate Light Cover Screws [A] License Plate Light Cover [B] • Pull the bulb [A] out of the socket [B]. NOTICE Do not turn the bulb. Pull the bulb out to prevent damage to the bulb.
  • Page 417 ELECTRICAL SYSTEM 16-41 Lighting System Headlight/Tail Light Circuit 1. Left City Light (LED) 12. Ignition Switch 2. Left Headlight 12 V 33 W/35 W 13. Battery 12 V 10 Ah 3. Right Headlight 12 V 33 W/35 W 14. Engine Ground 4.
  • Page 418: Turn Signal Light Bulb Replacement

    16-42 ELECTRICAL SYSTEM Lighting System Turn Signal Light Bulb Replacement Front Turn Signal Light • Remove: Front Fairing (see Front Fairing Removal in the Frame chapter) Front Turn Signal Light Socket Screws [A] Front Turn Signal Light Socket [B] • Push and turn the front turn signal light bulb [A] counter- clockwise and remove it.
  • Page 419: Turn Signal Relay Inspection

    ELECTRICAL SYSTEM 16-43 Lighting System • Fit the large projection [A] of the socket into the large groove [B] of the turn signal light. • Turn the rear turn signal light bulb clockwise. Turn Signal Relay Inspection • Remove the front center cover (see Front Center Cover Removal in the Frame chapter).
  • Page 420: Hazard Control Unit Inspection

    16-44 ELECTRICAL SYSTEM Lighting System Hazard Control Unit Inspection • Turn the ignition switch on. • Turn the hazard switch on. • The left and right turn signal lights (front and rear) should blink. If turn signal light does not blink, inspect or replace the following parts.
  • Page 421 ELECTRICAL SYSTEM 16-45 Lighting System Turn Signal Light Circuit 1. Front Left Turn Signal Light 12 V 10 W 2. Front Right Turn Signal Light 12 V 10 W 3. Green Left Turn Signal Indicator Light (LED) 4. Green Right Turn Signal Indicator Light (LED) 5.
  • Page 422: Storage Box Light/storage Box Light Switch Removal

    16-46 ELECTRICAL SYSTEM Lighting System Storage Box Light/Storage Box Light Switch Removal • Remove: Storage Box (see Storage Box Removal in the Frame chapter) • Cut the band [A] • Disconnect: Storage Box Light Lead Connectors [B] • Remove: Lock Nuts [C] Storage Box Light [D] Storage Box Light Switch [E] Storage Box Light/Storage Box Light Switch...
  • Page 423: Storage Box Light Switch Inspection

    ELECTRICAL SYSTEM 16-47 Lighting System • Disconnect the storage box light lead connectors [A] and using the auxiliary leads, connect the 12 V battery to the storage box light lead connectors as follows. ○ Connect the battery positive (+) terminal to the green/red lead.
  • Page 424 16-48 ELECTRICAL SYSTEM Lighting System Storage Box Light Circuit 1. Charging/ECU Fuse 30 A 2. Battery 3. Engine Ground 4. Storage Box Light Switch 5. Storage Box Light...
  • Page 425: Radiator Fan System

    ELECTRICAL SYSTEM 16-49 Radiator Fan System Fan Motor Inspection • Remove the right side fairing (see Side Fairing Removal in the Frame chapter). • Disconnect the radiator fan lead connector [A]. • Using an auxiliary leads, supply battery power to the fan motor.
  • Page 426: Oil Pressure Warning System

    16-50 ELECTRICAL SYSTEM Oil Pressure Warning System Oil Pressure Warning Indicator Light Controller Removal • Remove the front fairing (see Front Fairing Removal in the Frame chapter). • Disconnect the connector [A]. • Remove the oil pressure warning indicator light controller [B].
  • Page 427 ELECTRICAL SYSTEM 16-51 Oil Pressure Warning System Third Step • Disconnect the oil pressure switch connector [A] (see Oil Pressure Switch Removal in the Engine Lubrication Sys- tem chapter) • Ground the oil pressure switch connector to the engine, using an auxiliary lead [B]. •...
  • Page 428 16-52 ELECTRICAL SYSTEM Oil Pressure Warning System Oil Pressure Warning System Circuit 1. Meter Unit 2. to Ignition Switch 3. Oil Pressure Warning Indicator Light Controller 4. Engine Ground 5. Oil Pressure Switch 6. Red Oil Pressure Warning Indicator Light (LED)
  • Page 429: Meter, Gauge, Indicator Unit

    ELECTRICAL SYSTEM 16-53 Meter, Gauge, Indicator Unit Meter Unit Removal/Installation • Refer to the Meter Cover Removal/Installation in the Frame chapter. NOTICE 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 430: Electronic Combination Meter Unit Inspection

    16-54 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit Electronic Combination Meter Unit Inspection • Remove the meter unit with the meter cover installed (see Meter Unit Removal/Installation). [1] Red Oil Pressure Switch (–) [2] Meter Illumination Light (LED) (+) [3] Water Temperature Sensor (+) [4] Battery (+) [5] Blue High Beam Indicator Light (LED) (+) [6] Unused...
  • Page 431 ELECTRICAL SYSTEM 16-55 Meter, Gauge, Indicator Unit • Connect the terminal [8] to the battery (+) terminal. • Check the following items. ○ The speedometer and tachometer needles momentarily point their last readings and back to the minimum position. ○ All the LCD (Liquid Crystal Display) segments [A] go on for a few seconds.
  • Page 432 16-56 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit Check 3: Clock Setting Check • Connect the leads in the same circuit as Check 1. • Set the ODO mode [A] by pushing the ADJ button [B] for 2 seconds. • Push the MODE button [C] and ADJ button simultane- ously for more than 2 seconds to adjust the clock [D].
  • Page 433 ELECTRICAL SYSTEM 16-57 Meter, Gauge, Indicator Unit • Check that the green turn signal indicator light (LED) [A] goes on. If the indicator light (LED) does not go on, replace the meter unit. Check 5: Blue High Beam Indicator Light (LED) Inspec- tion •...
  • Page 434 16-58 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit Check 7: Red Oil Pressure Warning Indictor Light (LED) Inspection • Connect the leads in the same circuit as Check 1. • Connect the terminal [1] to the battery (–) terminal. • Check that the red oil pressure warning indicator light (LED) [A] goes on.
  • Page 435 ELECTRICAL SYSTEM 16-59 Meter, Gauge, Indicator Unit Check 10: Trip A/Trip B Meter Check • Check the trip meter with the speedometer in the same way. If value indicated in the trip meter is not added, replace the meter unit. •...
  • Page 436 16-60 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit Check 13: Yellow ABS Indicator Light (LED) Inspection (ABS Equipped Model) • Connect the leads in the same circuit as Check 1. • Connect the terminal [14] to the battery (–) terminal. • Check that the yellow ABS indicator light (LED) [A] goes If the indicator light (LED) does not go on, replace the meter unit.
  • Page 437 ELECTRICAL SYSTEM 16-61 Meter, Gauge, Indicator Unit Meter Circuit 1. Meter Unit 11. Battery 12 V 10 Ah 2. Oil Pressure Warning Indicator Light Con- 12. Engine Ground troller 13. ECU 3. Engine Stop Switch 14. Crankshaft Sensor 4. Speed Sensor 15.
  • Page 438 16-62 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit Meter Circuit (ABS Equipped Model) 1. Meter Unit 12. Battery 12 V 10 Ah 2. Oil Pressure Warning Indicator Light Con- 13. Engine Ground troller 14. Frame Ground 1 3. Engine Stop Switch 15.
  • Page 439: Switches And Sensors

    ELECTRICAL SYSTEM 16-63 Switches and Sensors Brake Light Timing Inspection • Refer to the Brake Light Switch Operation Inspection in the Periodic Maintenance chapter. Switch Inspection • Using a tester, check to see that only the connections shown in the table have continuity. ○...
  • Page 440: Water Temperature Sensor Inspection

    16-64 ELECTRICAL SYSTEM Switches and Sensors Water Temperature Sensor Inspection • Remove: Water Temperature Sensor (ECU) (see Water Temper- ature Sensor (ECU) Removal in the Fuel System (DFI) chapter) Water Temperature Sensor (Meter) (see Water Temper- ature Sensor (Meter) Removal in the Cooling System chapter) •...
  • Page 441: Fuel Level Sensor Inspection

    ELECTRICAL SYSTEM 16-65 Switches and Sensors Fuel Level Sensor Inspection • Remove the fuel pump (see Fuel Pump Removal in the Fuel System (DFI) chapter). • Connect a digital meter to the fuel pump connector. • Measure the fuel level sensor resistance. Fuel Level Sensor Resistance Connections: Y/W lead terminal [A] ←...
  • Page 442: Oxygen Sensor Installation

    16-66 ELECTRICAL SYSTEM Switches and Sensors Oxygen Sensor Installation NOTICE Never drop the oxygen sensor [A] especially on a hard surface. Such a shock to the unit can damage it. Do not touch the sensing part [B] to prevent oil contact.
  • Page 443: Relay Inspection

    ELECTRICAL SYSTEM 16-67 Switches and Sensors Relay Inspection • Remove the front fairing (see Front Fairing Removal in the Frame chapter). • Disconnect the relay connectors, and remove the relays. Fan Relay [A] Starter Relay 1 [B] High Beam Headlight Relay [C] Low Beam Headlight Relay [D] ECU Relay [E] Fuel Pump Relay [F]...
  • Page 444: Fuse

    16-68 ELECTRICAL SYSTEM Fuse Fuse Box Fuse Removal • Remove the battery cover (see Battery Removal). • Unlock the hooks [A] to remove the lid. • Pull the fuses [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...
  • Page 445 APPENDIX 17-1 Appendix Table of Contents Cable, Wire, and Hose Routing ....................17-2 Troubleshooting Guide ......................17-26...
  • Page 446 17-2 APPENDIX Cable, Wire, and Hose Routing...
  • Page 447 APPENDIX 17-3 Cable, Wire, and Hose Routing 1. Right Switch Housing Lead 2. Left Switch Housing Lead 3. Throttle Cable (Accelerator) 4. Throttle Cable (Decelerator) 5. Front Brake Hose 6. Rear Brake Hose 7. Clamp (Hold the main harness and fairing bracket.) 8.
  • Page 448 17-4 APPENDIX Cable, Wire, and Hose Routing...
  • Page 449 APPENDIX 17-5 Cable, Wire, and Hose Routing 1. Clamp (Hold the left headlight leads and left city light leads.) 2. Clamp (Hold the right headlight leads and right city light leads.) 3. Front Left Turn Signal Light Lead Connector 4. Left Headlight 5.
  • Page 450 17-6 APPENDIX Cable, Wire, and Hose Routing...
  • Page 451 APPENDIX 17-7 Cable, Wire, and Hose Routing 1. Ignition Switch 2. Seat Lock Cable 3. Fuel Pump Relay 4. ECU Relay 5. Horn 6. Clamp (Hold the speed sensor (front wheel rotation sensor) lead connector and main harness.) 7. Clamps (Hold the water hose and main harness.) 8.
  • Page 452 17-8 APPENDIX Cable, Wire, and Hose Routing...
  • Page 453 APPENDIX 17-9 Cable, Wire, and Hose Routing 1. Fan Relay 2. Starter Relay 1 3. High Beam Headlight Relay 4. Low Beam Headlight Relay 5. Throttle Cables 6. Rear Brake Hose 7. Run the throttle cables and left switch housing lead to the inside of the guide. 8.
  • Page 454 17-10 APPENDIX Cable, Wire, and Hose Routing...
  • Page 455 APPENDIX 17-11 Cable, Wire, and Hose Routing 1. Run the fuel overflow hose into the hole of bracket. 2. Fuel Overflow Hose 3. Hold the main harness with the hook of the frame. 4. Main Harness 5. Rear Brake Hose 6.
  • Page 456 17-12 APPENDIX Cable, Wire, and Hose Routing...
  • Page 457 APPENDIX 17-13 Cable, Wire, and Hose Routing 1. Regulator/Rectifier 2. Aluminum Plate 3. Clamps (Hold the main harness and frame.) 4. Main Harness 5. Alternator Lead 6. Starter Motor Cable 7. Frame Ground Terminal (on the upper) 8. Frame Ground Terminal (on the lower) 9.
  • Page 458 17-14 APPENDIX Cable, Wire, and Hose Routing...
  • Page 459 APPENDIX 17-15 Cable, Wire, and Hose Routing 1. Run the main harness to the inside of the frame. 2. Run the battery (+) cable to the outside of the frame. 3. Battery (+) Cable 4. Band (Hold the battery (+) cable and main harness.) 5.
  • Page 460 17-16 APPENDIX Cable, Wire, and Hose Routing...
  • Page 461 APPENDIX 17-17 Cable, Wire, and Hose Routing 1. Main Harness 2. Regulator/Rectifier Lead 3. Starter Motor Cable 4. Frame 5. View from A 6. Band (Hold the main harness, regulator/rectifier lead and starter motor cable.) 7. Clamp (Hold the alternator lead and starter motor cable.) 8.
  • Page 462 17-18 APPENDIX Cable, Wire, and Hose Routing 1. Band (Hold the main harness.) 2. Clamps (Hold the main harness.) 3. Main Harness 4. Frame Ground Terminal (on the upper) 5. Battery (–) Cable 6. Clamps (Hold the main harness and battery (–) cable.) 7.
  • Page 463 APPENDIX 17-19 Cable, Wire, and Hose Routing 1. Fuse Box 2. Battery (+) Cable 3. Battery (–) Cable 4. Battery 5. Tail/Brake Light Lead Connector 6. Hazard Control Unit...
  • Page 464 17-20 APPENDIX Cable, Wire, and Hose Routing...
  • Page 465 APPENDIX 17-21 Cable, Wire, and Hose Routing 1. Fuel Hose 2. Water Bypass Hose 3. Fuel Injector 4. Clamp (Hold the fuel hose.) 5. Water Temperature Sensor (ECU) 6. Water Temperature Sensor (Meter) Lead 7. Oil Pressure Switch Lead 8. Run the water temperature sensor (meter) lead under the water bypass hose. 9.
  • Page 466 17-22 APPENDIX Cable, Wire, and Hose Routing 1. Water Hose Clamps 2. Radiator...
  • Page 467 APPENDIX 17-23 Cable, Wire, and Hose Routing 1. Front Brake Hose 2. Clamps (Hold the speed sensor (front wheel rotation sensor) lead and front brake hose.) 3. Speed Sensor (Front Wheel Rotation Sensor) Lead 4. Speed Sensor (Front Wheel Rotation Sensor) 5.
  • Page 468 17-24 APPENDIX Cable, Wire, and Hose Routing ABS Equipped Model...
  • Page 469 APPENDIX 17-25 Cable, Wire, and Hose Routing 1. To Rear Master Cylinder 2. To Rear Caliper 3. To Front Master Cylinder 4. To Front Caliper 5. ABS Hydraulic Unit 6. ABS Hydraulic Unit Lead 7. Clamp (Hold the ABS hydraulic unit lead.) 8.
  • Page 470: Troubleshooting Guide

    17-26 APPENDIX Troubleshooting Guide NOTE Spark plug incorrect ○ Refer to the Fuel System chapter for most ECU trouble of DFI trouble shooting guide. Side stand switch trouble ○ This is not an exhaustive list, giving every Crankshaft sensor trouble possible cause for each problem listed.
  • Page 471 APPENDIX 17-27 Troubleshooting Guide Valve spring broken or weak Knocking: Valve not seating properly (valve bent, Carbon built up in combustion chamber worn, or carbon accumulation on the Fuel poor quality or incorrect seating surface) Spark plug incorrect Camshaft cam warn ECU trouble Run-on (dieseling): Crankshaft sensor trouble...
  • Page 472: Abnormal Drive Train Noise

    17-28 APPENDIX Troubleshooting Guide Abnormal Drive Train Noise: Fan motor broken Fan blade damaged Final gear case noise: Water pump not turning Bearing worn Water pump impeller damaged Metal chip jammed in gear teeth Gears worn or chipped CVT Faulty: Gear oil insufficient or too thin Engine starts but motorcycle won’t move: Abnormal Frame Noise:...
  • Page 473 APPENDIX 17-29 Troubleshooting Guide Steering stem nut too tight Rear shock adjustment too soft Steering stem bearing damaged Front fork, rear shock absorber spring weak Steering stem bearing lubrication inade- Rear shock absorber oil leaking quate Brake Doesn’t Hold: Steering stem bent Tire air pressure too low Air in the brake line Handlebar shakes or excessively vibrates:...
  • Page 474 Part No.99924-1481-02 MODEL APPLICATION Year Model Beginning Frame No. 2014 SC300AE RGSC40000E1000001 2014 SC300BE RGSC40000E1100001 2015 SC300AF RGSC40000F1000101 2015 SC300BF RGSC40000F1100101...

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