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VERSYS 1000

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Table of Contents

   Also See for Kawasaki Versys 1000

   Summary of Contents for Kawasaki Versys 1000

  • Page 1 VERSYS 1000...
  • Page 3 Quick Reference Guide General Information Periodic Maintenance Fuel System (DFI) Cooling System Engine Top End Clutch Engine Lubrication System Engine Removal/Installation Crankshaft/Transmission Wheels/Tires 10 j Final Drive 11 j Brakes 12 j Suspension 13 j Steering 14 j Frame 15 j Electrical System 16 j Appendix...
  • Page 5 All 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) inch(es) ABDC after bottom dead center km/h kilometers per hour antilock brake system KTRC Kawasaki traction control system alternating current liter(s) ampere hour liquid crystal display ATDC after top dead center light emitting diode BBDC before bottom dead center...
  • Page 7: Emission Control Information

    EMISSION CONTROL INFORMATION To protect the environment in which we all live, Kawasaki has incorporated crankcase emis- sion (1) and exhaust emission (2) control systems in compliance with applicable regulations of the United States Environmental Protection Agency and California Air Resources Board. Addi-...
  • Page 8 TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Federal law prohibits the following acts or the causing thereof. (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.
  • Page 9 • the vehicle. Use proper tools and genuine Kawasaki Mo- torcycle parts. Special tools, gauges, and • Indicates a procedural step or work to be testers that are necessary when servicing done.
  • Page 11 GENERAL INFORMATION 1-1 General Information Table of Contents Before Servicing ........................Model Identification......................... General Specifications......................Unit Conversion Table ......................1-11...
  • Page 12: Before Servicing

    1-2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly opera- tion on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustra- tions, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary.
  • Page 13 Replacement Parts Replacement parts must be KAWASAKI genuine or recommended by KAWASAKI. Gaskets, O-rings, oil seals, grease seals, circlips, cotter pins or self-locking nuts must be replaced with new ones whenever disassembled.
  • Page 14 1-4 GENERAL INFORMATION Before Servicing Tightening Sequence Generally, when installing a part with several bolts, nuts, or screws, start them all in their holes and tighten them to a snug fit. Then tighten them according to the specified se- quence to prevent case warpage or deformation which can lead to malfunction.
  • Page 15 GENERAL INFORMATION 1-5 Before Servicing Press For items such as bearings or oil seals that must be pressed into place, apply small amount of oil to the con- tact area. Be sure to maintain proper alignment and use smooth movements when installing. Ball Bearing and Needle Bearing Do not remove pressed ball or needle unless removal is absolutely necessary.
  • Page 16 1-6 GENERAL INFORMATION Before Servicing Lubrication It is important to lubricate rotating or sliding parts during assembly to minimize wear during initial operation. Lubri- cation points are called out throughout this manual, apply the specific oil or grease as specified. Direction of Engine Rotation When rotating the crankshaft by hand, the free play amount of rotating direction will affect the adjustment.
  • Page 17: Model Identification

    GENERAL INFORMATION 1-7 Model Identification KLZ1000BF Left Side View KLZ1000BF Right Side View Frame Number Engine Number...
  • Page 18: General Specifications

    1-8 GENERAL INFORMATION General Specifications Items KLZ1000BF Dimensions Overall Length 2 240 mm (88.19 in.) Overall Width 895 mm (35.2 in.) Overall Height/High Position 1 400 mm (55.12 in.)/1 465 mm (57.68 in.) Wheelbase 1 520 mm (59.84 in.) Road Clearance 150 mm (5.91 in.) Seat Height 840 mm (33.1 in.)
  • Page 19 GENERAL INFORMATION 1-9 General Specifications Items KLZ1000BF Ignition Timing From 10° BTDC @1 100 r/min (rpm) to 40.2° BTDC @5 200 r/min (rpm) Spark Plug NGK CR9EIA-9 Cylinder Numbering Method Left to right, 1-2-3-4 Firing Order 1-2-4-3 Valve Timing: Intake: Open 24°...
  • Page 20 1-10 GENERAL INFORMATION General Specifications Items KLZ1000BF Front Tire: Type Tubeless Size 120/70 ZR17 M/C (58W) Rim Size J17M/C × MT3.50 Rear Tire: Type Tubeless Size 180/55 ZR17 M/C (73W) Rim Size J17M/C × MT5.50 Front Suspension: Type Telescopic fork (upside-down) Wheel Travel 150 mm (5.91 in.) Rear Suspension:...
  • Page 21: 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 23: Table Of Contents

    PERIODIC MAINTENANCE 2-1 Periodic Maintenance Table of Contents Periodic Maintenance Chart ....................Torque and Locking Agent...................... Specifications ......................... 2-13 Special Tools .......................... 2-15 Periodic Maintenance Procedures..................2-16 Fuel System (DFI)........................ 2-16 Air Cleaner Element Replacement..................2-16 Idle Speed Inspection ....................... 2-17 Idle Speed Adjustment......................
  • Page 24 2-2 PERIODIC MAINTENANCE Suspension .......................... 2-55 Suspension System Inspection..................2-55 Steering ..........................2-57 Steering Play Inspection ....................2-57 Steering Play Adjustment....................2-57 Steering Stem Bearing Lubrication ................... 2-59 Electrical System ......................... 2-60 Lights and Switches Operation Inspection................ 2-60 Headlight Aiming Inspection ..................... 2-62 Side Stand Switch Operation Inspection................
  • Page 25: Periodic Maintenance Chart

    PERIODIC MAINTENANCE 2-3 Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition.The initial maintenance is vitally important and must not be neglected. Periodic Inspection *A: Service at number of years shown or indicated odometer reading intervals, whichever comes first.
  • Page 26 2-4 PERIODIC MAINTENANCE Periodic Maintenance Chart Odometer Reading (*B) × 1 000 km (× 1 000 mile) year (*A) Page Items (0.6) (3.8) (7.6) (11.4) (15.2) Wheel bearing damage 2-38 Final Drive Drive chain lubrication condition (*C) 2-39 : every 600 km (400 mile) Drive chain slack (*C) 2-40 : every 1 000 km (600 mile)
  • Page 27: Torque And Locking Agent

    PERIODIC MAINTENANCE 2-5 Torque and Locking Agent The following tables list the tightening torque for the major fasteners requiring use of a non-permanent locking agent or silicone sealant etc. All of the values are for use with dry solvent - cleaned threads unless otherwise indicated.
  • Page 28 2-6 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Water Pump Cover Bolts 97 in·lb Coolant Drain Bolt 97 in·lb Engine Top End Air Suction Valve Cover Bolts 87 in·lb Spark Plugs 115 in·lb Cylinder Head Cover Bolts 89 in·lb Camshaft Cap Bolts 106 in·lb...
  • Page 29 PERIODIC MAINTENANCE 2-7 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Oil Pressure Relief Valve Oil Filter G, R Oil Filter Pipe Engine Oil Drain Bolt Lower Fairing Bracket Bolts 106 in·lb Oil Pan Bolts 106 in·lb Engine Removal/Installation Upper Engine Bracket Bolts Lower Engine Bracket Bolts Upper Adjusting Collar...
  • Page 30 2-8 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Shift Lever Bolt 0.70 61 in·lb Shift Pedal Mounting Bolt Wheels/Tires Front Axle Clamp Bolt Front Axle 13.3 95.9 Rear Axle Nut 11.2 81.1 Final Drive Engine Sprocket Nut 15.0 Engine Sprocket Cover Bolts 0.71...
  • Page 31 PERIODIC MAINTENANCE 2-9 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Rear Brake Pad Pin Rear Brake Pad Pin Plug 0.25 22 in·lb Rear Caliper Mounting Bolt Rear Wheel Rotation Sensor Lead Bracket Bolt 0.82 71 in·lb Rear Wheel Rotation Sensor Bolt Rear Brake Disc Mounting Bolts Suspension Upper Front Fork Clamp Bolts...
  • Page 32 2-10 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Socket Cover Screws 0.12 11 in·lb Windshield Adjuster Knob Bolts 0.46 40 in·lb Windshield Bolts 0.43 0.044 38 in·lb Windshield Bracket Nuts 0.82 71 in·lb Middle Fairing Inner Cover Screws 0.12 11 in·lb Middle Fairing Bolts...
  • Page 33 PERIODIC MAINTENANCE 2-11 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Lower Mud Guard Bolts (M5) 0.50 0.05 4.4 in·lb Reflector Bracket Bolts 0.82 71 in·lb Reflector Nuts (US, CA, CAL and CN Models) 0.46 40 in·lb Center Stand Bracket Bolts (Other than CN Model) Center Stand Bolts (Other than CN Model) Center Stand Nuts (Other than CN Model) R, S...
  • Page 34 2-12 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Horn Bolt 0.82 71 in·lb Regulator/Rectifier Bolts 0.70 61 in·lb Side Stand Bracket Nut 0.82 71 in·lb Side Stand Switch Bolt 0.92 80 in·lb Neutral Switch The table below, relating tightening torque to thread diameter, lists the basic torque for the bolts and nuts.
  • Page 35: Specifications

    PERIODIC MAINTENANCE 2-13 Specifications Item Standard Service Limit Fuel System (DFI) 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Throttle Grip Free Play – – – Idle Speed 1 100 ±50 r/min (rpm) – – – Throttle Body Vacuum 40.7 ±1.3 kPa (305 ±10 mmHg) at idle speed –...
  • Page 36 2-14 PERIODIC MAINTENANCE Specifications Item Standard Service Limit Final Drive 25 ∼ 35 mm (1.0 ∼ 1.4 in.) Drive Chain Slack – – – 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) Drive Chain Wear (20-link 319 mm (12.6 in.) Length) Standard Chain: Make...
  • Page 37: Special Tools

    PERIODIC MAINTENANCE 2-15 Special Tools Inside Circlip Pliers: Vacuum Gauge: 57001-143 57001-1369 Jack: Throttle Sensor Setting Adapter: 57001-1238 57001-1538 Pilot Screw Adjuster, A: Extension Tube: 57001-1239 57001-1578 Oil Filter Wrench: Jack Attachment: 57001-1249 57001-1608 Attachment Jack: Socket Wrench, 57001-1252 57001-1828...
  • Page 38: Periodic Maintenance Procedures

    2-16 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel System (DFI) Air Cleaner Element Replacement NOTE ○ In dusty areas, the element should be replaced more frequently than the recommended interval. WARNING If dirt or dust is allowed to pass through into the throttle body assy, the throttle may become stuck, possibly causing accident.
  • Page 39: Idle Speed Inspection

    PERIODIC MAINTENANCE 2-17 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 40: Engine Vacuum Synchronization Inspection

    2-18 PERIODIC MAINTENANCE Periodic Maintenance Procedures Engine Vacuum Synchronization Inspection NOTE ○ These procedures are explained on the assumption that the intake and exhaust systems of the engine are in good condition. • Situate the motorcycle so that it is vertical. •...
  • Page 41 PERIODIC MAINTENANCE 2-19 Periodic Maintenance Procedures • Install the air cleaner housing (see Air Cleaner Housing Installation in the Fuel System (DFI) chapter). • Connect the following parts temporarily. Fuel Pump Lead Connector [A] Extension Tube [B] Special Tool - Extension Tube: 57001-1578 •...
  • Page 42 2-20 PERIODIC MAINTENANCE Periodic Maintenance Procedures If any vacuum is not within specifications, adjust the by- pass screws [A]. View from Rear [B] Special Tool - Pilot Screw Adjuster, A [C]: 57001-1239 • Adjust the each vacuum (#1 ∼ #4) to the standard value. •...
  • Page 43: Fuel System Inspection

    PERIODIC MAINTENANCE 2-21 Periodic Maintenance Procedures • Back out the same number of turns counted when first turned in. This is to set the screw to its original position. NOTE ○ A throttle body has different “turns out” of the bypass screw for each individual unit.
  • Page 44: Fuel Hose Replacement

    2-22 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Check that the fuel hose joints are securely connected. ○ Push and pull [A] the fuel hose joint [B] back and forth more than two times, and make sure it is locked. WARNING Leaking fuel can cause a fire or explosion resulting in serious burns.
  • Page 45 PERIODIC MAINTENANCE 2-23 Periodic Maintenance Procedures • Remove the vinyl bag on the pipe. • Check that there are no flaws, burrs, and adhesion of foreign materials on the delivery pipe [A]. • Replace the fuel hose with a new one. •...
  • Page 46: Evaporative Emission Control System Inspection (other Than Us, Ca, Id And Sea-b2 Models)

    2-24 PERIODIC MAINTENANCE Periodic Maintenance Procedures Evaporative Emission Control System Inspection (Other than US, CA, ID and SEA-B2 Models) • Inspect the canister as follows. ○ Remove the meter cover (see Meter Cover Removal in the Frame chapter). ○ Slide the clamps [A]. ○...
  • Page 47: Cooling System

    PERIODIC MAINTENANCE 2-25 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 48 2-26 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Remove: Left Lower Fairing (see Lower Fairing Removal in the Frame chapter) • Place a container under the drain bolt [A] of the water pump cover. • Remove: Right Fuel Tank Cover (see Fuel Tank Cover Removal in the Frame chapter) •...
  • Page 49 PERIODIC MAINTENANCE 2-27 Periodic Maintenance Procedures • Fill the radiator up to the filler neck [A] with coolant. NOTE ○ Pour in the coolant slowly so that it can expel the air from the engine and radiator. • Check the cooling system for leaks. •...
  • Page 50: Water Hose And O-ring Replacement

    2-28 PERIODIC MAINTENANCE Periodic Maintenance Procedures Water Hose and O-ring Replacement • Drain the coolant (see Coolant Change). • Remove: Oil Passage Cover [A] Thermostat Housing Cover [B] (see Thermostat Re- moval in the Cooling System chapter) Water Pump Housing [C] (see Water Pump Removal in the Cooling System chapter) •...
  • Page 51: Engine Top End

    PERIODIC MAINTENANCE 2-29 Periodic Maintenance Procedures Engine Top End Valve Clearance Inspection NOTE ○ Valve clearance must be checked and adjusted when the engine is cold (at room temperature). • Remove: Cylinder Head Cover (see Cylinder Head Cover Re- moval in the Engine Top End chapter) Crankshaft Sensor Cover (see Crankshaft Sensor Re- moval in the Electrical System chapter) •...
  • Page 52: Valve Clearance Adjustment

    2-30 PERIODIC MAINTENANCE Periodic Maintenance Procedures ○ When positioning #1 piston TDC at the end of the compression stroke: Intake Valve Clearance of #1 and #3 Cylinders Exhaust Valve Clearance of #1 and #2 Cylinders Measuring Valve [A] ○ When positioning #4 piston TDC at the end of the compression stroke: Intake Valve Clearance of #2 and #4 Cylinders Exhaust Valve Clearance of #3 and #4 Cylinders...
  • Page 53 PERIODIC MAINTENANCE 2-31 Periodic Maintenance Procedures ○ Besides the standard shims in the valve clearance adjust- ment charts, the following shims may be installed at the factory. Although they are not available as spare parts, they can be used to adjust valve clearance. Adjustment Shims Thickness 2.675 mm...
  • Page 54 2-32 PERIODIC MAINTENANCE Periodic Maintenance Procedures VALVE CLEARANCE ADJUSTMENT CHART INTAKE VALVE 1. Measure the clearance (when engine is cold). 2. Check present shim size. 3. Match clearance in vertical column with present shim size in horizontal column. 4. Install the shim specified where the lines intersect. This shim will give the proper clearance. Example: Present shim is 2.95 mm Measured clearance is 0.45 mm...
  • Page 55 PERIODIC MAINTENANCE 2-33 Periodic Maintenance Procedures VALVE CLEARANCE ADJUSTMENT CHART EXHAUST VALVE 1. Measure the clearance (when engine is cold). 2. Check present shim size. 3. Match clearance in vertical column with present shim size in horizontal column. 4. Install the shim specified where the lines intersect. This shim will give the proper clearance. Example: Present shim is 2.95 mm.
  • Page 56: Air Suction System Damage Inspection

    2-34 PERIODIC MAINTENANCE Periodic Maintenance Procedures NOTICE Be sure to remeasure the clearance after selecting a shim according to the table. If the clearance is out of the specified range, use the additional shim. ○ If there is no valve clearance, use a shim that is a few sizes smaller, and remeasure the valve clearance.
  • Page 57: Clutch

    PERIODIC MAINTENANCE 2-35 Periodic Maintenance Procedures Clutch Clutch Operation Inspection • Pull the clutch lever just enough to take up the free play [A]. • Measure the gap between the lever and the lever holder. If the gap is too wide, the clutch may not release fully. If the gap is too narrow, the clutch may not engage fully.
  • Page 58: Engine Lubrication System

    2-36 PERIODIC MAINTENANCE Periodic Maintenance Procedures Engine Lubrication System Engine Oil Change • Situate the motorcycle so that it is vertical after warming up the engine. • Remove the engine oil drain bolt [A] to drain the oil. ○ The oil in the oil filter can be drained by removing the filter (see Oil Filter Replacement).
  • Page 59: Oil Filter Replacement

    PERIODIC MAINTENANCE 2-37 Periodic Maintenance Procedures Oil Filter Replacement • Drain the engine oil (see Engine Oil Change). • Remove: Left Lower Fairing (see Lower Fairing Removal in the Frame chapter) • Remove the oil filter with the oil filter wrench [A]. Special Tool - Oil Filter Wrench: 57001-1249 •...
  • Page 60: Wheel Bearing Damage Inspection

    2-38 PERIODIC MAINTENANCE Periodic Maintenance Procedures Tire Tread Wear Inspection As the tire tread wears down, the tire becomes more sus- ceptible to puncture and failure. An accepted estimate is that 90% of all tire failures occur during the last 10% of tread life (90% worn).
  • Page 61: Final Drive

    PERIODIC MAINTENANCE 2-39 Periodic Maintenance Procedures • Raise the rear wheel off the ground with the stand (see Rear Wheel Removal in the Wheels/Tires chapter). • Inspect the roughness of the rear wheel bearing by push- ing and pulling [A] the wheel. •...
  • Page 62: Drive Chain Slack Inspection

    2-40 PERIODIC MAINTENANCE Periodic Maintenance Procedures Drive Chain Slack Inspection NOTE ○ Check the slack with the motorcycle setting on its side stand. ○ Clean the chain if it is dirty, and lubricate it if it appears dry. • Check the wheel alignment (see Wheel Alignment Inspec- tion).
  • Page 63: Wheel Alignment Inspection

    PERIODIC MAINTENANCE 2-41 Periodic Maintenance Procedures • Bend the cotter pin [A] over the nut [B]. WARNING A loose axle nut can lead to an accident resulting in serious injury or death. Tighten the axle nut to the proper torque and install a new cotter pin. Wheel Alignment Inspection •...
  • Page 64: Chain Guide Wear Inspection

    2-42 PERIODIC MAINTENANCE Periodic Maintenance Procedures WARNING A chain that breaks or jumps off the sprockets could snag on the engine sprocket or lock the rear wheel, severely damaging the motorcycle and causing it to go out of control. Inspect the chain for damage and proper adjustment before each ride.
  • Page 65: Brakes

    PERIODIC MAINTENANCE 2-43 Periodic Maintenance Procedures Brakes Brake System Inspection Brake Fluid Leak (Brake Hose and Pipe) Inspection • Remove the air cleaner housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter). • Apply the brake lever or pedal and inspect the brake fluid leak from the brake hoses [A], pipes [B] and fittings [C].
  • Page 66: Brake Operation Inspection

    2-44 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Hose and Pipe Damage and Installation Condi- tion Inspection • Remove the air cleaner housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter). • Inspect the brake hoses, pipes and fittings for deteriora- tion, cracks and signs of leakage.
  • Page 67: Brake Fluid Change

    PERIODIC MAINTENANCE 2-45 Periodic Maintenance Procedures • Remove the seat (see Seat Removal in the Frame chap- ter). • Check that the brake fluid level in the rear brake fluid reservoir [A] is above the lower level line [B]. If the fluid level is lower than the lower level line, fill the reservoir to the upper level line [C].
  • Page 68 2-46 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Change the brake fluid. ○ Repeat this operation until fresh brake fluid comes out from the plastic hose or the color of the fluid changes. 1. Open the bleed valve [A]. 2. Apply the brake and hold it [B]. 3.
  • Page 69 PERIODIC MAINTENANCE 2-47 Periodic Maintenance Procedures This page intentionally left blank.
  • Page 70: Brake Hose And Pipe Replacement

    2-48 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Hose and Pipe Replacement NOTICE Brake fluid quickly ruins painted plastic surfaces; any spilled fluid should be completely washed away immediately. NOTE ○ When removing the brake pipes and hoses on the hy- draulic unit, remove them with the flare nut wrench ac- cording to each assembly of the exploded view in the Brakes chapter.
  • Page 71 PERIODIC MAINTENANCE 2-49 Periodic Maintenance Procedures...
  • Page 72: Master Cylinder Rubber Parts Replacement

    2-50 PERIODIC MAINTENANCE Periodic Maintenance Procedures Master Cylinder Rubber Parts Replacement Front Master Cylinder Disassembly • Remove the front master cylinder (see Front Master Cylin- der Removal in the Brakes chapter). • Remove: Front Brake Fluid Reservoir Cap Screws [A] Reservoir Cap [B] Diaphragm Plate [C] Diaphragm [D]...
  • Page 73: Caliper Rubber Parts Replacement

    PERIODIC MAINTENANCE 2-51 Periodic Maintenance Procedures Master Cylinder Assembly • Before assembly, clean all parts including the master cylinder with brake fluid or alcohol. NOTICE Except for the disc pads and disc, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol for cleaning brake parts.
  • Page 74 2-52 PERIODIC MAINTENANCE Periodic Maintenance Procedures WARNING The piston in the brake caliper can crush hands and fingers. Never place your hand or fingers in front of the piston. ○ Pull out the pistons by hand. • Remove the dust seals [A] and fluid seals [B]. •...
  • Page 75 PERIODIC MAINTENANCE 2-53 Periodic Maintenance Procedures Rear Caliper Disassembly • Remove: Rear Caliper (see Rear Caliper Removal in the Brakes chapter) Brake Pads (see Rear Brake Pad Removal in the Brakes chapter) Pad Spring [A] Dust Boot [B] Sleeve [C] •...
  • Page 76: Brake Pad Wear Inspection

    2-54 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Install the pad spring [A] in the caliper as shown. • Apply brake fluid to the outside of the piston [B], and push it into the cylinder by hand. • Replace the dust boot [C]. •...
  • Page 77: Suspension

    PERIODIC MAINTENANCE 2-55 Periodic Maintenance Procedures If it does not, adjust the brake light switch. • Remove the front footpeg bracket bolts [A] and washers. • Pull the right footpeg bracket [B] outward. • While holding the switch body, turn the adjusting nut to adjust the switch.
  • Page 78 2-56 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Pump the seat down and up [A] 4 or 5 times, and inspect the smooth stroke. If the shock absorber does not smoothly stroke or noise is found, inspect the oil leak (see Rear Shock Absorber Oil Leak Inspection).
  • Page 79: Steering

    PERIODIC MAINTENANCE 2-57 Periodic Maintenance Procedures Steering Steering Play Inspection • Raise the front wheel off the ground with the jack (see Front Wheel Removal in the Wheels/Tires chapter). Special Tools - Jack: 57001-1238 Attachment Jack: 57001-1252 Jack Attachment: 57001-1608 •...
  • Page 80 2-58 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Remove: Steering Stem Head Bolt Plug [A] Steering Stem Head Bolt [B] and Washer • Loosen the upper front fork clamp bolts [C]. • Remove the stem head [D]. • Bend the claws [A] of the claw washer straighten. •...
  • Page 81: Steering Stem Bearing Lubrication

    PERIODIC MAINTENANCE 2-59 Periodic Maintenance Procedures • Install the claw washer [A] so that its bent side [B] faces upward, and engage the bent claws with the grooves of stem locknut [C]. • Hand tighten the stem locknut until it touches the claw washer.
  • Page 82: Electrical System

    2-60 PERIODIC MAINTENANCE Periodic Maintenance Procedures Electrical System Lights and Switches Operation Inspection First Step • Set the gear position in the neutral position. • Turn the ignition switch on. • The following lights should go on according to below table. City Lights [A] Go on Taillight (LED) [B]...
  • Page 83 PERIODIC MAINTENANCE 2-61 Periodic Maintenance Procedures Second Step (Other than US, CA and CAL Models) • Turn the ignition switch to hazard position. • The all lights should go off. If the light goes on, inspect or replace the following item. Ignition Switch (see Switch Inspection in the Electrical System chapter) Third Step...
  • Page 84: Headlight Aiming Inspection

    2-62 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Set the dimmer switch to high beam position. • The low beam [A] and high beam [B] headlights should go on. • The blue high beam indicator light (LED) [C] should goes If the high beam headlight and/or blue high beam indicator light (LED) does not go on, inspect or replace the following parts.
  • Page 85: Side Stand Switch Operation Inspection

    PERIODIC MAINTENANCE 2-63 Periodic Maintenance Procedures NOTE ○ ON high beam, the brightest points should be slightly below horizontal with the motorcycle on its wheels and the rider seated. Adjust the headlight to the proper an- gle according to local regulations. ○...
  • Page 86: Engine Stop Switch Operation Inspection

    2-64 PERIODIC MAINTENANCE Periodic Maintenance Procedures If the side stand switch operation does not work, inspect or replace the following parts. Battery (see Charging Condition Inspection in the Elec- trical System chapter) Main Fuse 30 A (see Fuse Inspection in the Electrical System chapter) Ignition Fuse 15 A (see Fuse Inspection in the Electrical System chapter)
  • Page 87: Spark Plug Replacement

    PERIODIC MAINTENANCE 2-65 Periodic Maintenance Procedures Spark Plug Replacement • Remove the stick coils (see Stick Coil Removal in the Electrical System chapter). • Remove the spark plugs using the 16 mm (0.63 in.) plug wrench [A] vertically. • Replace the spark plugs with new ones. Standard Spark Plug Type: NGK CR9EIA-9...
  • Page 88: Condition Of Bolts, Nuts And Fasteners Tightness Inspection

    2-66 PERIODIC MAINTENANCE Periodic Maintenance Procedures Cables: Lubricate with Rust Inhibitor. Clutch Cable Throttle Cables • Lubricate the cables by seeping the oil between the cable and housing. ○ The cable may be lubricated by using a commercially available pressure cable lubricator with an aerosol cable lubricant.
  • Page 89 PERIODIC MAINTENANCE 2-67 Periodic Maintenance Procedures Bolt, Nut and Fastener to be checked Engine: Clutch Lever Pivot Bolt Locknut Engine Mounting Bolts and Nuts Exhaust Pipe Holder Nuts Muffler Body Clamp Bolts Muffler Body Mounting Bolt and Nut Premuffler Chamber Mounting Bolt Radiator Bolts Wheels: Front Axle Clamp Bolt...
  • Page 91 FUEL SYSTEM (DFI) 3-1 Fuel System (DFI) Table of Contents Exploded View........................DFI System..........................3-10 DFI Components Naming ....................3-12 DFI Parts Location........................3-18 Specifications ......................... 3-21 Special Tools and Sealant ...................... 3-23 DFI Servicing Precautions ...................... 3-25 DFI Servicing Precautions ....................3-25 Troubleshooting the DFI System ....................
  • Page 92 3-2 FUEL SYSTEM (DFI) Front Wheel Rotation Sensor Signal Inspection ............... 3-73 Vehicle-down Sensor (Service Code 31) (DTC C0064) ............3-75 Vehicle-down Sensor Removal ..................3-75 Vehicle-down Sensor Installation ..................3-75 Vehicle-down Sensor Inspection (Service Code 31/DTC C0064)........3-76 Subthrottle Sensor (Service Code 32) (DTC P0220, P0223) ..........3-79 Subthrottle Sensor Removal/Adjustment ................
  • Page 93 FUEL SYSTEM (DFI) 3-3 ECU Fuse Removal ......................3-111 ECU Fuse Installation ....................... 3-111 ECU Fuse Inspection ......................3-111 ECU Main Relay Removal/Installation ................3-111 ECU Main Relay Inspection ....................3-111 Fuel Line..........................3-112 Fuel Pressure Inspection ....................3-112 Fuel Flow Rate Inspection ....................3-113 Fuel Line Leak Inspection ....................
  • Page 94: Exploded View

    3-4 FUEL SYSTEM (DFI) Exploded View...
  • Page 95 FUEL SYSTEM (DFI) 3-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Air Cleaner Housing Assembly Screws 0.11 10 in·lb Air Cleaner Housing Plate Screws 0.11 10 in·lb Air Cleaner Housing Bolt 0.70 61 in·lb Throttle Body Assy Holder Clamp Bolts 0.30 26 in·lb Delivery Pipe Assy Mounting Screws...
  • Page 96 3-6 FUEL SYSTEM (DFI) Exploded View...
  • Page 97 FUEL SYSTEM (DFI) 3-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Vehicle-down Sensor Bolts 0.60 52 in·lb Intake Air Temperature Sensor Screw 0.12 11 in·lb Spark Plugs 115 in·lb Crankshaft Sensor Bolts 0.60 52 in·lb Oxygen Sensor Water Temperature Sensor 106 in·lb ECU Bracket Screws 0.41...
  • Page 98 3-8 FUEL SYSTEM (DFI) Exploded View...
  • Page 99 FUEL SYSTEM (DFI) 3-9 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Fuel Tank Cap Bolts 0.46 40 in·lb Fuel Tank Bolts 0.82 71 in·lb Fuel Tank Bracket Bolts 0.82 71 in·lb Fuel Pump Bolts 89 in·lb L, S Canister Bracket Bolts 0.70 61 in·lb 6.
  • Page 100: Dfi System

    3-10 FUEL SYSTEM (DFI) DFI System DFI System...
  • Page 101 FUEL SYSTEM (DFI) 3-11 DFI System 1. ECU 2. Battery 12 V 8 Ah 3. Front Wheel Rotation Sensor 4. Rear Wheel Rotation Sensor 5. ABS Hydraulic Unit 6. Vehicle-down Sensor 7. Pressure Regulator 8. Fuel Pump 9. Fuel Filter 10.
  • Page 102: Dfi Components Naming

    DFI Components Naming The terms used in the European regulation for DFI components are sometimes different from those used by Kawasaki. Use this table to cross reference terms which may appear in a generic scan tool when diagnosing the DFI system.
  • Page 103 FUEL SYSTEM (DFI) 3-13 DFI System This page intentionally left blank.
  • Page 104 3-14 FUEL SYSTEM (DFI) DFI System DFI System Wiring Diagram...
  • Page 105 FUEL SYSTEM (DFI) 3-15 DFI System Part Names 1. ECU 2. Rear Wheel Rotation Sensor 3. Immobilizer (Equipped Models)/Kawasaki Diagnostic System Connector 4. Fuel Pump 5. ABS Hydraulic Unit 6. Frame Ground 4 7. Frame Ground 3 8. Frame Ground 2 9.
  • Page 106 3-16 FUEL SYSTEM (DFI) DFI System Terminal Numbers of ECU Connectors Terminal Names 1. Subthrottle Valve Actuator: P/BL 2. Unused 3. Unused 4. Power Supply to Sensors: BL 5. Fuel Pump Relay: BR/Y 6. Power Supply to ECU (from Battery): BR/W 7.
  • Page 107 60. External Communication Line (Immobilizer System (Equipped Models)/*KDS): BR/Y 61. Meter Unit (Tachometer): LB 62. Radiator Fan Relay: Y/BL 63. Air Switching Valve: R/BL 64. Oxygen Sensor Heater: P/BK 65. Ground for Ignition System: BK/Y 66. Stick Coil #3: BK/O *: KDS (Kawasaki Diagnostic System)
  • Page 108: Dfi Parts Location

    3-18 FUEL SYSTEM (DFI) DFI Parts Location Main Throttle Sensor [A] Subthrottle Sensor [B] Subthrottle Valve Actuator [C] Intake Air Pressure Sensor #2 [D] Stick Coils #1, #2, #3, #4 [E] Intake Air Pressure Sensor #1 [F] Fuel Injectors #1, #2, #3, #4 [G] Air Switching Valve [A] Water Temperature Sensor [A] Intake Air Temperature Sensor [A]...
  • Page 109 FUEL SYSTEM (DFI) 3-19 DFI Parts Location Fuse Box 1 [A] Battery 12 V 8 Ah [B] Immobilizer (Equipped Models)/Kawasaki Diagnostic System Connector [C] Relay Box [D] (ECU Main Relay, Fuel Pump Relay, Ra- diator Fan Relay) ECU [E] Main Fuse 30 A [A]...
  • Page 110 3-20 FUEL SYSTEM (DFI) DFI Parts Location Front Wheel Rotation Sensor [A] Rear Wheel Rotation Sensor [A] Purge Valve [A] (Other than US, CA, ID and SEA-B2 Models) Vehicle-down Sensor [B]...
  • Page 111: Specifications

    FUEL SYSTEM (DFI) 3-21 Specifications Item Standard Digital Fuel Injection System Idle Speed 1 100 ±50 r/min (rpm) Throttle Body Assy: Throttle Valve Dual throttle valve Bore 38 mm (1.5 in.) Throttle Body Vacuum 40.7 ±1.3 kPa (305 ±10 mmHg) Bypass Screws (Turn Out) 2 1/2 (for reference) ECU:...
  • Page 112 3-22 FUEL SYSTEM (DFI) Specifications Item Standard Oxygen Sensor: Output Voltage (Rich) DC 0.7 V or more Output Voltage (Lean) DC 0.2 V or less 11.7 ∼ 14.5 kΩ @20°C (68°F) Heater Resistance Immobilizer Antenna (Equipped Models): About 3.0 ∼ 4.6 Ω Resistance Purge Valve (Other than US, CA, ID and SEA-B2 Models):...
  • Page 113: Special Tools And Sealant

    FUEL SYSTEM (DFI) 3-23 Special Tools and Sealant Oil Pressure Gauge, 5 kgf/cm²: Throttle Sensor Setting Adapter: 57001-125 57001-1538 Carburetor Drain Plug Wrench, Hex 3: Extension Tube: 57001-1269 57001-1578 Fork Oil Level Gauge: Fuel Pressure Gauge Adapter: 57001-1290 57001-1593 Vacuum Gauge: Fuel Hose: 57001-1369 57001-1607...
  • Page 114 3-24 FUEL SYSTEM (DFI) Special Tools and Sealant Liquid Gasket, TB1211: 56019-120...
  • Page 115: Dfi Servicing Precautions

    FUEL SYSTEM (DFI) 3-25 DFI Servicing Precautions DFI Servicing Precautions There are a number of important precautions that should be followed servicing the DFI system. ○ This DFI system is designed to be used with a 12 V sealed battery as its power source. Do not use any other battery except for a 12 V sealed battery as a power source.
  • Page 116 3-26 FUEL SYSTEM (DFI) DFI Servicing Precautions ○ If the motorcycle is not properly handled, the high pres- sure inside the fuel line can cause fuel to leak or the hose to burst. Remove the fuel tank (see Fuel Tank Removal) and check the fuel hose [A].
  • Page 117: Troubleshooting The Dfi System

    FUEL SYSTEM (DFI) 3-27 Troubleshooting the DFI System Outline When a problem occurs with DFI system, the yellow en- gine warning indicator light (LED) [A] goes on to alert the rider. ○ When a problem occurs with KTRC system, the yellow KTRC warning indicator light (LED) [B] goes on, the KTRC and POWER mode indicators [C] blinking on the LCD.
  • Page 118 3-28 FUEL SYSTEM (DFI) Troubleshooting the DFI System With the engine stopped and turned in the self-diagnosis mode, the service code [A] is displayed on the LCD (Liquid Crystal Display) by the number of two digits. If the problem is with the following parts, the ECU can not recognize these problem.
  • Page 119 But the service codes stored in memory of the ECU are not erased to preserve the problem history. The problem his- tory can be referred using the KDS (Kawasaki Diagnostic System) when solving unstable problems or other proce- dures (see Service Code Erasing).
  • Page 120 3-30 FUEL SYSTEM (DFI) Troubleshooting the DFI System ○ After measurement, remove the needle adapters and ap- ply silicone sealant to the seals [A] of the connector [B] for waterproofing. Sealant - Liquid Gasket, TB1211: 56019-120 • Always check battery condition before replacing the DFI parts.
  • Page 121 FUEL SYSTEM (DFI) 3-31 Troubleshooting the DFI System ○ When checking a harness [A] for short circuit, open one end [B] and check the continuity between the other end [C] and ground [D]. If there is continuity, the harness has a short circuit to ground, and it must be repaired or re- placed.
  • Page 122: Inquiries To Rider

    3-32 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 123 FUEL SYSTEM (DFI) 3-33 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 124 3-34 FUEL SYSTEM (DFI) Troubleshooting the DFI System □ □ □ Poor running very low idle speed, very high idle speed, rough idle speed. at low speed □ battery voltage is low (charge the battery). □ spark plug loose (tighten it). □...
  • Page 125: Dfi System Troubleshooting Guide

    FUEL SYSTEM (DFI) 3-35 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 126 3-36 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 #1 trouble Inspect (see chapter 3).
  • Page 127 FUEL SYSTEM (DFI) 3-37 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Subthrottle sensor trouble Inspect (see chapter 3). Subthrottle valve actuator trouble Inspect (see chapter 3). Intake air pressure sensor #1 trouble Inspect (see chapter 3). Intake air pressure sensor #2 trouble Inspect (see chapter 3).
  • Page 128 3-38 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Other: Intermittent any DFI fault and its recovery Check that DFI connectors are clean and tight, and examine leads for signs of burning or fraying (see chapter 3). Poor Running or No Power at High Speed Symptoms or Possible Causes Actions (chapter)
  • Page 129 FUEL SYSTEM (DFI) 3-39 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Intake air temperature sensor trouble Inspect (see chapter 3). Miscellaneous: Subthrottle sensor trouble Inspect (see chapter 3). Subthrottle valve actuator trouble Inspect (see chapter 3). Throttle valves will not fully open Inspect throttle cables and lever linkage (see chapter 3).
  • Page 130: Self-diagnosis

    3-40 FUEL SYSTEM (DFI) Self-Diagnosis Self-Diagnosis Outline The self-diagnosis system is monitoring the following mechanisms. DFI System and Ignition System KTRC System Immobilizer System (Equipped Models) The following indicator lights (LED) are used for warning indicators of below table. LED Color Warning Indicators Oil Pressure Battery...
  • Page 131: Self-diagnosis Procedures

    FUEL SYSTEM (DFI) 3-41 Self-Diagnosis Self-Diagnosis Procedures NOTE ○ Use a fully charged battery when conducting self-diagnosis. Otherwise, the warning indicator light (LED) and indicator do not light or blink. • Turn the ignition switch on. ○ When a problem occurs with DFI system and ignition sys- tem, the yellow engine warning indicator light (LED) [A] goes on to alert the rider.
  • Page 132 3-42 FUEL SYSTEM (DFI) Self-Diagnosis • Push the upper meter button [A] the for more than two seconds. • The service code [B] is displayed on the LCD by the num- ber of two digits. • Any of the following procedures ends self-diagnosis. ○...
  • Page 133 FUEL SYSTEM (DFI) 3-43 Self-Diagnosis Self-Diagnosis Flow Chart...
  • Page 134: Service Code Reading

    (16→33→56)→(16→33→56)→· · ·(repeated) Service Code Erasing • The service codes stored in memory of the ECU can be erased using Kawasaki Diagnostic System (KDS Ver.3). If the Kawasaki Diagnostic System (KDS Ver.3) is not available, do the following procedures.
  • Page 135 FUEL SYSTEM (DFI) 3-45 Self-Diagnosis Service (Diagnostic System Problems Code Trouble Code) Water temperature sensor malfunction, wiring open or short P0115 to power supply wire Water temperature sensor malfunction, wiring short to P0117 ground Intake air pressure sensor #2 malfunction, wiring open or P2226 short to power supply wire P2227...
  • Page 136: Backups

    When no service code is displayed, the electrical parts of the DFI system has no fault, and the mechanical parts of the DFI system and the engine are suspect. ○ DTC (Diagnostic Trouble Code) is displayed on the Kawasaki Diagnostic System (KDS Ver.3) and the Generic Scan Tool (GST). Backups ○...
  • Page 137 FUEL SYSTEM (DFI) 3-47 Self-Diagnosis Service Parts or Output Signal Usable Backups by ECU Function Codes Range or Criteria Crankshaft sensor must Crankshaft If the crankshaft sensor fails, the engine stops send 22 signals to the ECU Sensor by itself. at the 1 cranking.
  • Page 138 3-48 FUEL SYSTEM (DFI) Self-Diagnosis Service Parts or Output Signal Usable Backups by ECU Codes Function Range or Criteria If the injector #4 fails (no signal, wiring short The injector must send Fuel Injector or open), the ECU shuts off the signal to the signals continuously to the injector.
  • Page 139 FUEL SYSTEM (DFI) 3-49 Self-Diagnosis Note: (1): D-J Method: When the engine load is light like at idling or low speed, the ECU determines the injection quantity by calculating from the throttle vacuum (vacuum sensor output voltage) and engine speed (crankshaft sensor output voltage). This method is called D-J method. (2): α-N Method: As the engine speed increases, and the engine load turns middle to heavy, the ECU determines the injection quantity by calculating from the throttle opening (throttle sensor output voltage) and the engine speed.
  • Page 140: Main Throttle Sensor (service Code 11) (dtc P0120, P0123)

    3-50 FUEL SYSTEM (DFI) Main Throttle Sensor (Service Code 11) (DTC P0120, P0123) • When only the service code is available, follow all inspec- tion procedures in this section. • When the DTC (Diagnostic Trouble Code) is available, fol- low inspection procedures that have the DTC in the head- line in this section.
  • Page 141: Main Throttle Sensor Inspection (service Code 11/dtc P0123)

    FUEL SYSTEM (DFI) 3-51 Main Throttle Sensor (Service Code 11) (DTC P0120, P0123) (Checking wire for short circuit to ground) • Check the wiring for short circuit to ground by check- ing the continuity between the sensor connector [A] and frame ground [B].
  • Page 142 3-52 FUEL SYSTEM (DFI) Main Throttle Sensor (Service Code 11) (DTC P0120, P0123) If the reading is DC 5 V or more, check the following part resistance. ○ Disconnect the throttle setting adapter [A] from the main harness side. Main Throttle Sensor [B] Part Resistance Inspection Connections to Adapter: Digital Meter (+) →...
  • Page 143: Intake Air Pressure Sensor #1 (service Code 12) (dtc P0105, P0107)

    FUEL SYSTEM (DFI) 3-53 Intake Air Pressure Sensor #1 (Service Code 12) (DTC P0105, P0107) • When only the service code is available, follow all inspec- tion procedures in this section. • When the DTC (Diagnostic Trouble Code) is available, fol- low inspection procedures that have the DTC in the head- line in this section.
  • Page 144: Intake Air Pressure Sensor #1 Inspection (service Code 12/dtc P0105)

    3-54 FUEL SYSTEM (DFI) Intake Air Pressure Sensor #1 (Service Code 12) (DTC P0105, P0107) Intake Air Pressure Sensor #1 Inspection (Service Code 12/DTC P0105) (Checking wire for open circuit) • Disconnect: ECU Connectors (see ECU Removal) Intake Air Pressure Sensor #1 Connector (see Intake Air Pressure Sensor #1 Removal) •...
  • Page 145: Intake Air Pressure Sensor #1 Inspection (service Code 12/dtc P0107)

    FUEL SYSTEM (DFI) 3-55 Intake Air Pressure Sensor #1 (Service Code 12) (DTC P0105, P0107) Intake Air Pressure Sensor #1 Inspection (Service Code 12/DTC P0107) (Checking wire for short circuit to ground) • Disconnect: ECU Connectors (see ECU Removal) Intake Air Pressure Sensor #1 Connector (see Intake Air Pressure Sensor #1 Removal) •...
  • Page 146 3-56 FUEL SYSTEM (DFI) Intake Air Pressure Sensor #1 (Service Code 12) (DTC P0105, P0107) then Pv = 70 – 8 = 62 cmHg (Absolute) Plot this Pv (62 cmHg) at a point [1] on the chart and draw a vertical line through the point.
  • Page 147 FUEL SYSTEM (DFI) 3-57 Intake Air Pressure Sensor #1 (Service Code 12) (DTC P0105, P0107) ID: Idling Ps: Standard Atmospheric Pressure (Absolute) Pv: Throttle Vacuum Pressure (Absolute) ST: Standard of Sensor Output Voltage (V) TO: Throttle Full Open UR: Usable Range of Sensor Output Voltage (V) Vv: Intake Air Pressure Sensor #1 Output Voltage (V) (Digital Meter Reading)
  • Page 148 3-58 FUEL SYSTEM (DFI) Intake Air Pressure Sensor #1 (Service Code 12) (DTC P0105, P0107) Intake Air Pressure Sensor #1 Circuit 1. ECU 2. Intake Air Pressure Sensor #1 3. Intake Air Pressure Sensor #2...
  • Page 149: Intake Air Temperature Sensor (service Code 13) (dtc P0110, P0112)

    FUEL SYSTEM (DFI) 3-59 Intake Air Temperature Sensor (Service Code 13) (DTC P0110, P0112) • When only the service code is available, follow all inspec- tion procedures in this section. • When the DTC (Diagnostic Trouble Code) is available, follow inspection procedures that has have the DTC in the headline in this section.
  • Page 150: Intake Air Temperature Sensor Inspection (service Code 13/dtc P0112)

    3-60 FUEL SYSTEM (DFI) Intake Air Temperature Sensor (Service Code 13) (DTC P0110, P0112) (Checking wire for short circuit to power supply wire) • Connect the ECU connectors. • Connect the measuring adapter [A] between the harness connector and intake air temperature sensor. Main Harness [B] Intake Air Temperature Sensor [C] Special Tool - Measuring Adapter: 57001-1700...
  • Page 151 FUEL SYSTEM (DFI) 3-61 Intake Air Temperature Sensor (Service Code 13) (DTC P0110, P0112) (Checking sensor for internal short circuit) • Remove the intake air temperature sensor (see Intake Air Temperature Sensor Removal/Installation). • Suspend the sensor [A] in a container of machine oil so that the heat-sensitive portion is submerged.
  • Page 152: Water Temperature Sensor (service Code 14) (dtc P0115, P0117)

    3-62 FUEL SYSTEM (DFI) Water Temperature Sensor (Service Code 14) (DTC P0115, P0117) • When only the service code is available, follow all inspec- tion procedures in this section. • When the DTC (Diagnostic Trouble Code) is available, follow inspection procedures that has have the DTC in the headline in this section.
  • Page 153: Water Temperature Sensor Inspection (service Code 14/dtc P0117)

    FUEL SYSTEM (DFI) 3-63 Water Temperature Sensor (Service Code 14) (DTC P0115, P0117) (Checking wire for short circuit to power supply wire) • Connect the ECU connectors. • Connect the measuring adapter [A] between the harness connector and water temperature sensor as shown. Sub Harness [B] Water Temperature Sensor [C] Special Tool - Measuring Adapter: 57001-1700...
  • Page 154 3-64 FUEL SYSTEM (DFI) Water Temperature Sensor (Service Code 14) (DTC P0115, P0117) Water Temperature Sensor Circuit 1. ECU 2. Water Temperature Sensor...
  • Page 155: Intake Air Pressure Sensor #2 (service Code 16) (dtc P2226, P2227, P2228)

    FUEL SYSTEM (DFI) 3-65 Intake Air Pressure Sensor #2 (Service Code 16) (DTC P2226, P2227, P2228) • When only the service code is available, follow all inspec- tion procedures in this section. • When the DTC (Diagnostic Trouble Code) is available, fol- low inspection procedures that have the DTC in the head- line in this section.
  • Page 156: Intake Air Pressure Sensor #2 Inspection (service Code 16/dtc P2226)

    3-66 FUEL SYSTEM (DFI) Intake Air Pressure Sensor #2 (Service Code 16) (DTC P2226, P2227, P2228) Intake Air Pressure Sensor #2 Inspection (Service Code 16/DTC P2226) (Checking wire for open circuit) • Disconnect: ECU Connectors (see ECU Removal) Intake Air Pressure Sensor #2 Connector (see Intake Air Pressure Sensor #2 Removal) •...
  • Page 157: Intake Air Pressure Sensor #2 Inspection (service Code 16/dtc P2227)

    FUEL SYSTEM (DFI) 3-67 Intake Air Pressure Sensor #2 (Service Code 16) (DTC P2226, P2227, P2228) Intake Air Pressure Sensor #2 Inspection (Service Code 16/DTC P2227) (Checking sensor for various vacuum) • Remove the intake air pressure sensor #2 [A] and dis- connect the vacuum hose from the sensor (see Intake Air Pressure Sensor #2 Removal).
  • Page 158 3-68 FUEL SYSTEM (DFI) Intake Air Pressure Sensor #2 (Service Code 16) (DTC P2226, P2227, P2228) ID: Idling Ps: Standard Atmospheric Pressure (Absolute) Pv: Throttle Vacuum Pressure (Absolute) ST: Standard of Sensor Output Voltage (V) TO: Throttle Full Open UR: Usable Range of Sensor Output Voltage (V) Vv: Intake Air Pressure Sensor #2 Output Voltage (V) (Digital Meter Reading)
  • Page 159: Intake Air Pressure Sensor #2 Inspection (service Code 16/dtc P2228)

    FUEL SYSTEM (DFI) 3-69 Intake Air Pressure Sensor #2 (Service Code 16) (DTC P2226, P2227, P2228) Intake Air Pressure Sensor #2 Inspection (Service Code 16/DTC P2228) (Checking wire for short circuit to ground) • Disconnect: ECU Connectors (see ECU Removal) Intake Air Pressure Sensor #2 Connector (see Intake Air Pressure Sensor #2 Removal) •...
  • Page 160: Crankshaft Sensor (service Code 21) (dtc P0335)

    3-70 FUEL SYSTEM (DFI) Crankshaft Sensor (Service Code 21) (DTC P0335) 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.
  • Page 161: Rear Wheel Rotation Sensor Signal (service Code 24) (dtc P2158)

    FUEL SYSTEM (DFI) 3-71 Rear Wheel Rotation Sensor Signal (Service Code 24) (DTC P2158) Rear Wheel Rotation Sensor Signal Inspection • Inspect the wheel rotation sensor (see Wheel Rotation Sensor Inspection in the Brakes chapter). • Inspect the wheel rotation sensor air gap (see Wheel Ro- tation Sensor Air Gap Inspection in the Brakes chapter).
  • Page 162 3-72 FUEL SYSTEM (DFI) Rear Wheel Rotation Sensor Signal (Service Code 24) (DTC P2158) Wheel Rotation Sensor Circuit 1. ECU 2. Rear Wheel Rotation Sensor 3. ABS Hydraulic Unit 4. Front Wheel Rotation Sensor...
  • Page 163: Front Wheel Rotation Sensor Signal (service Code 27) (dtc P0500)

    FUEL SYSTEM (DFI) 3-73 Front Wheel Rotation Sensor Signal (Service Code 27) (DTC P0500) Front Wheel Rotation Sensor Signal Inspection • Inspect the wheel rotation sensor (see Wheel Rotation Sensor Inspection in the Brakes chapter). • Inspect the wheel rotation sensor air gap (see Wheel Ro- tation Sensor Air Gap Inspection in the Brakes chapter).
  • Page 164 3-74 FUEL SYSTEM (DFI) Front Wheel Rotation Sensor Signal (Service Code 27) (DTC P0500) Wheel Rotation Sensor Circuit 1. ECU 2. Rear Wheel Rotation Sensor 3. ABS Hydraulic Unit 4. Front Wheel Rotation Sensor...
  • Page 165: Vehicle-down Sensor (service Code 31) (dtc C0064)

    FUEL SYSTEM (DFI) 3-75 Vehicle-down Sensor (Service Code 31) (DTC C0064) This sensor has a weight [A] with two magnets inside, and sends a signal to the ECU. But when the motorcycle banks 60 ∼ 70° or more to either side (in fact falls down), the weight turns and the signal changes.
  • Page 166: Vehicle-down Sensor Inspection (service Code 31/dtc C0064)

    3-76 FUEL SYSTEM (DFI) Vehicle-down Sensor (Service Code 31) (DTC C0064) • The UP mark [A] of the sensor should face upward. WARNING Incorrect installation of the vehicle-down sensor could cause sudden loss of engine power. The rider could lose balance during certain riding situ- ations for an accident resulting in injury or death.
  • Page 167 FUEL SYSTEM (DFI) 3-77 Vehicle-down Sensor (Service Code 31) (DTC C0064) (Checking wire for short circuit to power supply wire) • Connect the ECU connectors. • Connect the measuring adapter [A] between the harness connector and vehicle-down sensor as shown. Main Harness [B] Vehicle-down Sensor [C] Special Tool - Measuring Adapter: 57001-1700...
  • Page 168 3-78 FUEL SYSTEM (DFI) Vehicle-down Sensor (Service Code 31) (DTC C0064) Vehicle-down Sensor Circuit 1. ECU 2. Vehicle-down Sensor...
  • Page 169: Subthrottle Sensor (service Code 32) (dtc P0220, P0223)

    FUEL SYSTEM (DFI) 3-79 Subthrottle Sensor (Service Code 32) (DTC P0220, P0223) • When only the service code is available, follow all inspec- tion procedures in this section. • When the DTC (Diagnostic Trouble Code) is available, fol- low inspection procedures that have the DTC in the head- line in this section.
  • Page 170: Subthrottle Sensor Inspection (service Code 32/dtc P0223)

    3-80 FUEL SYSTEM (DFI) Subthrottle Sensor (Service Code 32) (DTC P0220, P0223) (Checking wire for short circuit to ground) • Check the wiring for short circuit to ground by checking continuity between the sensor connector [A] and frame ground [B]. Wiring Continuity Inspection BL/W lead (ECU terminal 28) [C] ←...
  • Page 171 FUEL SYSTEM (DFI) 3-81 Subthrottle Sensor (Service Code 32) (DTC P0220, P0223) • Measure the output voltage with the engine stopped and with the connector joined. • Turn the ignition switch on. Output Voltage DC 1.08 ∼ 1.12 V at subthrottle valve full Standard: close position DC 4.28 ∼...
  • Page 172: Oxygen Sensor (service Code 33) (dtc P0130, P0132)

    3-82 FUEL SYSTEM (DFI) Oxygen Sensor (Service Code 33) (DTC P0130, P0132) • When only the service code is available, follow all inspec- tion procedures in this section. • When the DTC (Diagnostic Trouble Code) is available, fol- low inspection procedures that have the DTC in the head- line in this section.
  • Page 173: Oxygen Sensor Inspection (service Code 33/dtc P0132)

    FUEL SYSTEM (DFI) 3-83 Oxygen Sensor (Service Code 33) (DTC P0130, P0132) Oxygen Sensor Inspection (Service Code 33/DTC P0132) (Checking wire for short circuit to power supply wire) • Remove: Oxygen Sensor Lead Connector (see Oxygen Sensor Removal in the Electrical System chapter) •...
  • Page 174 3-84 FUEL SYSTEM (DFI) Oxygen Sensor (Service Code 33) (DTC P0130, P0132) • Remove the air switching valve [A] (see Air Switching Valve Removal in the Engine Top End chapter). ○ Do not disconnect the air switching valve connector [B]. •...
  • Page 175 FUEL SYSTEM (DFI) 3-85 Oxygen Sensor (Service Code 33) (DTC P0130, P0132) • Turn the ignition switch off. • Remove the air cleaner housing (see Air Cleaner Housing Removal). • Remove the plugs from the fittings [A]. WARNING The engine gets extremely hot during normal oper- ation and can cause serious burns.
  • Page 176 3-86 FUEL SYSTEM (DFI) Oxygen Sensor (Service Code 33) (DTC P0130, P0132) Oxygen Sensor Circuit 1. ECU 2. Frame Ground 2 3. Engine Ground 4. Battery 12 V 8 Ah 5. Main Fuse 30 A 6. ECU Fuse 15 A 7.
  • Page 177: Immobilizer Amplifier (service Code 35, Equipped Models)

    FUEL SYSTEM (DFI) 3-87 Immobilizer Amplifier (Service Code 35, Equipped Models) Antenna Resistance Inspection • Turn the ignition switch off. • Remove the left side cover (see Side Cover Removal in the Frame chapter). • Slide the dust cover [A]. •...
  • Page 178: Blank Key Detection (service Code 36, Equipped Models)

    If the service code 36 appears again, the transponder in the key is malfunction, replace it. Immobilizer System Circuit 1. ECU 6. Starter Relay 11. Immobilizer Antenna 2. Immobilizer/Kawasaki 7. Main Fuse 30 A 12. Immobilizer Amplifier Diagnostic System 8. Frame Ground 6 13.
  • Page 179: Ecu Communication Error (service Code 39)

    FUEL SYSTEM (DFI) 3-89 ECU Communication Error (Service Code 39) ECU Communication Line Inspection ○ When the data is not sent from the ECU to the meter unit for more than about 10 seconds, the service code 39 is displayed. ○...
  • Page 180: Fuel Injectors #1, #2, #3, #4 (service Code 41, 42, 43, 44) (dtc P0201, P0202, P0203, P0204)

    3-90 FUEL SYSTEM (DFI) Fuel Injectors #1, #2, #3, #4 (Service Code 41, 42, 43, 44) (DTC P0201, P0202, P0203, P0204) Inspect the eligible injector according to the following ser- vice code or DTC. Service Code 41/DTC P0201 → Fuel Injector #1 Service Code 42/DTC P0202 →...
  • Page 181: Fuel Injector Power Source Voltage Inspection

    FUEL SYSTEM (DFI) 3-91 Fuel Injectors #1, #2, #3, #4 (Service Code 41, 42, 43, 44) (DTC P0201, P0202, P0203, P0204) Fuel Injector Power Source Voltage Inspection • Turn the ignition switch off. • Remove: Air Cleaner Housing (see Air Cleaner Housing Removal) •...
  • Page 182: Fuel Injector Output Voltage Inspection

    3-92 FUEL SYSTEM (DFI) Fuel Injectors #1, #2, #3, #4 (Service Code 41, 42, 43, 44) (DTC P0201, P0202, P0203, P0204) Fuel Injector Output Voltage Inspection • Turn the ignition switch off. • Remove the ECU (see ECU Removal). ○ Do not disconnect the ECU connector.
  • Page 183 FUEL SYSTEM (DFI) 3-93 Fuel Injectors #1, #2, #3, #4 (Service Code 41, 42, 43, 44) (DTC P0201, P0202, P0203, P0204) Fuel Injector Circuit 1. ECU 2. Frame Ground 3 3. Engine Ground 4. Battery 12 V 8 Ah 5. Starter Relay 6.
  • Page 184: Stick Coils #1, #2, #3, #4 (service Code 51, 52, 53, 54) (dtc P0351, P0352, P0353, P0354)

    3-94 FUEL SYSTEM (DFI) Stick Coils #1, #2, #3, #4 (Service Code 51, 52, 53, 54) (DTC P0351, P0352, P0353, P0354) Inspect the eligible stick coil according to the following service code or DTC. Service Code 51/DTC P0351 → Stick Coil #1 Service Code 52/DTC P0352 →...
  • Page 185 FUEL SYSTEM (DFI) 3-95 Stick Coils #1, #2, #3, #4 (Service Code 51, 52, 53, 54) (DTC P0351, P0352, P0353, P0354) Stick Coil Circuit 1. ECU 2. Frame Ground 3 3. Engine Ground 4. Battery 12 V 8 Ah 5. Starter Relay 6.
  • Page 186: Radiator Fan Relay (service Code 56) (dtc P0480)

    3-96 FUEL SYSTEM (DFI) Radiator Fan Relay (Service Code 56) (DTC P0480) Radiator Fan Relay Removal/Installation ○ The radiator fan relay is built in the relay box [A]. • Refer to the Relay Box Removal in the Electrical System chapter. Radiator Fan Relay Inspection •...
  • Page 187: Subthrottle Valve Actuator (service Code 62) (dtc P2100)

    FUEL SYSTEM (DFI) 3-97 Subthrottle Valve Actuator (Service Code 62) (DTC P2100) Subthrottle Valve Actuator Removal NOTICE Do not remove the subthrottle valve actuator [A] since it has been adjusted and set with precision at the factory. Never drop the throttle body assy especially on a hard surface.
  • Page 188 3-98 FUEL SYSTEM (DFI) Subthrottle Valve Actuator (Service Code 62) (DTC P2100) (Checking power supply to actuator) • Connect the ECU connectors. • Connect the measuring adapter [A] between the harness connector and subthrottle valve actuator. Main Harness [B] Subthrottle Valve Actuator [C] Special Tool - Measuring Adapter: 57001-1700 •...
  • Page 189 FUEL SYSTEM (DFI) 3-99 Subthrottle Valve Actuator (Service Code 62) (DTC P2100) Subthrottle Valve Actuator Circuit 1. ECU 2. Subthrottle Valve Actuator...
  • Page 190: Air Switching Valve (service Code 64) (dtc P0410)

    3-100 FUEL SYSTEM (DFI) Air Switching Valve (Service Code 64) (DTC P0410) Air Switching Valve Removal/Installation • Refer to the Air Switching Valve Removal/Installation in the Engine Top End chapter. Air Switching Valve Inspection • Refer to the Air Switching Valve Unit Test in the Electrical System chapter.
  • Page 191: Oxygen Sensor Heater (service Code 67) (dtc P0030)

    FUEL SYSTEM (DFI) 3-101 Oxygen Sensor Heater (Service Code 67) (DTC P0030) 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 192 3-102 FUEL SYSTEM (DFI) Oxygen Sensor Heater (Service Code 67) (DTC P0030) (Checking wire for open circuit) • Disconnect: Measuring Adapter ECU Connectors (see ECU Removal) • Check the wiring for continuity between the ECU harness connector and sensor connector. Wiring Continuity Inspection ECU Harness Connector [A] ←...
  • Page 193 FUEL SYSTEM (DFI) 3-103 Oxygen Sensor Heater (Service Code 67) (DTC P0030) Oxygen Sensor Circuit 1. ECU 2. Frame Ground 2 3. Engine Ground 4. Battery 12 V 8 Ah 5. Main Fuse 30 A 6. ECU Fuse 15 A 7.
  • Page 194: Purge Valve (service Code 3a) (dtc P0443) (other Than Us, Ca, Id And Sea-b2 Models)

    3-104 FUEL SYSTEM (DFI) Purge Valve (Service Code 3A) (DTC P0443) (Other than US, CA, ID and SEA-B2 Models) Purge Valve Removal/Installation • Remove: Upper Fairing (see Upper Fairing Removal in the Frame chapter) Nut [A] • Remove the purge valve from the bracket. •...
  • Page 195 FUEL SYSTEM (DFI) 3-105 Purge Valve (Service Code 3A) (DTC P0443) (Other than US, CA, ID and SEA-B2 Models) • Disconnect the 12 V battery. • Blow the air to the intake air duct [A] again, and make sure that the air does not flow from the outlet air duct [B]. If the purge valve does not operate as described, replace it with a new one.
  • Page 196: Warning Indicator Light (led)

    3-106 FUEL SYSTEM (DFI) Warning Indicator Light (LED) Yellow Engine Warning/Red Warning Indicator Light (LED) Inspection Yellow Engine Warning Indicator Light (LED) [A] Red Warning Indicator Light (LED) [B] ○ In this model, the above mentioned warning indicator lights (LED) go on or blink by the data sent from the ECU. •...
  • Page 197: Ecu

    Cut the band [A]. • Disconnect: Connector [B] • Remove: ABS Kawasaki Diagnosis System Connector [C] Fuel Pump Lead Connector [D] ECU Bracket Screws [E] • Pull up the ECU bracket assembly. • Remove the relay box [A] from the rubber protector [B].
  • Page 198: Ecu Installation

    3-108 FUEL SYSTEM (DFI) • For WVTA (78.2 H) and GB WVTA (FULL H) models, re- move the ECU connector guard. • Disconnect: ECU Connectors [A] • Remove: ECU [B] ECU Installation • For WVTA (78.2 H) and GB WVTA (FULL H) models, in- stall the new ECU connector guard.
  • Page 199 FUEL SYSTEM (DFI) 3-109 If the wiring is good, check the power source voltage of the ECU. • Connect the ECU connectors. • Connect a digital meter [A] to the connector (black) [B] with the needle adapter set. Special Tool - Needle Adapter Set: 57001-1457 ECU Power Supply Inspection Connections: (I) Digital Meter (+) →...
  • Page 200 3-110 FUEL SYSTEM (DFI) ECU Power Source Circuit 1. ECU 2. Frame Ground 4 3. Frame Ground 3 4. Frame Ground 2 5. Engine Ground 6. Battery 12 V 8 Ah 7. Starter Relay 8. Main Fuse 30 A 9. ECU Fuse 15 A 10.
  • Page 201: Dfi Power Source

    FUEL SYSTEM (DFI) 3-111 DFI Power Source ECU Fuse Removal • Refer to the 30 A Main/15 A ECU Fuse Removal in the Electrical System chapter. ECU Fuse Installation If a fuse fails during operation, inspect the DFI system to determine the cause, and then replace it with a new fuse of proper amperage.
  • Page 202: Fuel Line

    3-112 FUEL SYSTEM (DFI) Fuel Line Fuel Pressure Inspection • Remove: 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 delivery pipe of the throttle body assy.
  • Page 203: Fuel Flow Rate Inspection

    FUEL SYSTEM (DFI) 3-113 Fuel Line NOTE ○ The gauge needle will fluctuate. Read the pressure at the average of the maximum and minimum indications. • Turn the ignition switch off. If the fuel pressure is much higher than specified, replace the fuel pump because the fuel pressure regulator in the fuel pump have been clogged or stuck.
  • Page 204: Fuel Line Leak Inspection

    3-114 FUEL SYSTEM (DFI) Fuel Line • Connect the prepared fuel hose [A] to the fuel outlet pipe. • Secure the fuel hose with a clamp. • Insert the fuel hose into the measuring cylinder [B]. WARNING Wipe off spilled out fuel immediately. Be sure to hold the measuring cylinder vertical.
  • Page 205 FUEL SYSTEM (DFI) 3-115 Fuel Line • Check the fuel injector fuel line for leakage as follows. ○ Connect a commercially available vacuum/pressure pump [A] to the nipple of the delivery pipe [B] with the fuel hose [C] (both ends with the clamps [D]) as shown. Rear Side View [E] ○...
  • Page 206: Fuel Pump

    3-116 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 207: Fuel Pump Installation

    FUEL SYSTEM (DFI) 3-117 Fuel Pump Fuel Pump Installation • Remove dirt or dust from the fuel pump [A] by lightly ap- plying compressed air. • Replace the fuel pump gasket with a new one. NOTE ○ Be careful not to bend the fuel level sensor arm. •...
  • Page 208: Fuel Pump Operating Voltage Inspection

    3-118 FUEL SYSTEM (DFI) Fuel Pump Fuel Pump Operating Voltage Inspection • Turn the ignition switch off. • Remove the seat (see Seat Removal in the Frame chap- ter). • Disconnect the fuel pump lead connector and connect the measuring adapter [A] between these connectors as shown.
  • Page 209: Pump Screen, Fuel Filter Cleaning

    FUEL SYSTEM (DFI) 3-119 Fuel Pump Pump Screen, Fuel Filter Cleaning ○ The pump screen [A] and fuel filter [B] are built into the fuel pump and can not be cleaned or checked. If the pump screen or fuel filter is suspected of clogging or being damaged, replace it with the fuel pump as a set.
  • Page 210 3-120 FUEL SYSTEM (DFI) Fuel Pump Fuel Pump Circuit 1. ECU 2. Fuel Pump 3. Frame Ground 3 4. Engine Ground 5. Battery 12 V 8 Ah 6. Starter Relay 7. Main Fuse 30 A 8. ECU Fuse 15 A 9.
  • Page 211: Throttle Grip And Cables

    FUEL SYSTEM (DFI) 3-121 Throttle Grip and Cables Free Play Inspection • Refer to the Throttle Control System Inspection in the Pe- riodic Maintenance chapter. Free Play Adjustment • Refer to the Throttle Control System Inspection in the Pe- riodic Maintenance chapter. Cable Installation •...
  • Page 212: Throttle Body Assy

    3-122 FUEL SYSTEM (DFI) Throttle Body Assy Idle Speed Inspection/Adjustment • Refer to the Idle Speed Inspection/Adjustment in the Pe- riodic Maintenance chapter. Synchronization Inspection/Adjustment • Refer to the Engine Vacuum Synchronization Inspection in the Periodic Maintenance chapter. Throttle Body Assy Removal WARNING Gasoline is extremely flammable and can be explo- sive under certain conditions, creating the potential...
  • Page 213 FUEL SYSTEM (DFI) 3-123 Throttle Body Assy • Loosen the locknuts [A]. • Turn the adjusters [B] to give the more free play. • Remove the adjuster screw [A] from the bracket. • Remove: Throttle Cable Holder Clamp [A] Throttle Cable Lower Ends [B] •...
  • Page 214: Throttle Body Assy Installation

    3-124 FUEL SYSTEM (DFI) Throttle Body Assy • Remove the throttle body assy. • After removing the throttle body assy, stuff pieces of lint -free, clean cloth into the throttle body assy holders. NOTICE If dirt gets into the engine, excessive engine wear and possible engine damage will occur.
  • Page 215: Throttle Body Assy Disassembly

    FUEL SYSTEM (DFI) 3-125 Throttle Body Assy Throttle Body Assy Disassembly 1. Throttle Body Assy 2. Subthrottle Valve Actuator 3. Main Throttle Sensor 4. Subthrottle Sensor 5. Fuel Injectors 6. Delivery Pipe Assy 7. Intake Air Pressure Sensor #1 8. Intake Air Pressure Sensor #2 NOTICE Do not remove, disassemble or adjust the main throttle sensor, subthrottle sensor, subthrottle...
  • Page 216: Throttle Body Assy Assembly

    3-126 FUEL SYSTEM (DFI) Throttle Body Assy • Remove the fuel injectors [A] from the delivery pipe assy [B]. NOTE ○ Do not damage the insertion portions of the injectors when they are pulled out from the delivery pipe assy. NOTICE Never drop the fuel injector especially on a hard surface.
  • Page 217: Air Cleaner

    FUEL SYSTEM (DFI) 3-127 Air Cleaner Air Cleaner Element Removal/Installation • Refer to the Air Cleaner Element Replacement in the Pe- riodic Maintenance chapter. Air Cleaner Element Inspection • Remove the air cleaner element (see Air Cleaner Element Replacement in the Periodic Maintenance chapter). •...
  • Page 218: Air Cleaner Housing Installation

    3-128 FUEL SYSTEM (DFI) Air Cleaner • Loosen the air cleaner housing clamp bolt [A] on both sides. • Lift up the air cleaner housing, and disconnect the air switching valve hose [A]. • After removing the air cleaner housing, cover the clean cloth on the throttle body assy.
  • Page 219: Fuel Tank

    FUEL SYSTEM (DFI) 3-129 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 220 3-130 FUEL SYSTEM (DFI) Fuel Tank • Remove: Rivet [A] (Both Sides) • Disconnect: Fuel Pump Lead Connector [A] • Remove: Fuel Tank Bracket Bolts [B] Plate [C] • Remove: Fuel Tank Bolts [A] • Open the fuel tank cap [A] to lower the pressure in the tank.
  • Page 221 FUEL SYSTEM (DFI) 3-131 Fuel Tank • Slide the clamp [A]. • Disconnect: Fuel Tank Breather Hose [B] • Clear the left side tab [A] of the fuel tank from the meter cover [B] first, and then clear the right side tab of the fuel tank.
  • Page 222 3-132 FUEL SYSTEM (DFI) Fuel Tank When removing with flat tip screwdriver • Insert the flat tip screwdriver [A] into slit on the joint lock [B]. • Turn the driver to disconnect the joint lock. When removing with fingers • Open and push up [C] the joint lock with your fingers.
  • Page 223: Fuel Tank Installation

    FUEL SYSTEM (DFI) 3-133 Fuel Tank Fuel Tank Installation • Note the above WARNING (see Fuel Tank Removal). • Check that the dampers [A], pads [B] and trim [C] are in place on the frame and fuel tank. 4 mm (0.16 in.) [D] 60 ∼...
  • Page 224: Fuel Tank And Cap Inspection

    3-134 FUEL SYSTEM (DFI) Fuel Tank • Insert the fuel hose joint [A] straight onto the fuel outlet pipe until the hose joint clicks. • Push [B] the joint lock [C] until the hose joint clicks. • Push and pull [A] the hose joint [B] back and forth more than two times, and make sure it is locked does not come off.
  • Page 225: Fuel Tank Cleaning

    FUEL SYSTEM (DFI) 3-135 Fuel Tank Fuel Tank Cleaning WARNING Gasoline and low flash-point solvents can be flammable and/or explosive and cause severe burns. Clean the tank in a well-ventilated area, and take care that there are no sparks or flame any- where near the working area.
  • Page 226: Evaporative Emission Control System (other Than Us, Ca, Id And Sea-b2 Models)

    3-136 FUEL SYSTEM (DFI) Evaporative Emission Control System (Other than US, CA, ID and SEA-B2 Mod- els) The Evaporative Emission Control System routes fuel va- pors from the fuel system into the running engine or stores the vapors in a canister when the engine is stopped. Al- though no adjustments are required, a thorough visual in- spection must be made at the intervals specified by the Pe- riodic Maintenance Chart.
  • Page 227 COOLING SYSTEM 4-1 Cooling System Table of Contents Exploded View........................Coolant Flow Chart......................... Specifications ......................... Special Tools ......................... Coolant ........................... Coolant Deterioration Inspection..................Coolant Level Inspection....................Coolant Draining ....................... Coolant Filling ........................Pressure Testing ....................... Cooling System Flushing ....................4-10 Coolant Reserve Tank Removal ..................
  • Page 228: Exploded View

    4-2 COOLING SYSTEM Exploded View...
  • Page 229 COOLING SYSTEM 4-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Coolant Reserve Tank Bolts 0.70 61 in·lb Radiator Cap Housing Bolt 0.70 61 in·lb Water Hose Clamp Screws 0.31 27 in·lb Fitting Bolt 0.90 78 in·lb Radiator Bolts 0.70 61 in·lb Thermostat Housing Bolts 0.60...
  • Page 230: Coolant Flow Chart

    4-4 COOLING SYSTEM Coolant Flow Chart 1. Radiator 9. Outlet Pipe 2. Radiator Fan 10. Water Pump 3. Radiator Overflow Hose 11. Intake Pipe 4. Radiator Cap 12. Cylinder Jacket 5. Reserve Tank 13. Cylinder Head Jacket 6. Reserve Tank Overflow Hose 14.
  • Page 231 COOLING SYSTEM 4-5 Coolant Flow Chart Permanent type antifreeze is used as a coolant to protect the cooling system from rust and corro- sion. When the engine starts, the water pump turns and the coolant circulates. The thermostat is a wax pellet type which opens or closes with coolant temperature changes. The thermostat continuously changes its valve opening to keep the coolant temperature at the proper level.
  • Page 232: Specifications

    4-6 COOLING SYSTEM Specifications Item Standard Coolant Provided when Shipping Type (Recommended) Permanent type of antifreeze (soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators) Color Green Mixed Ratio Soft water 50%, coolant 50% Freezing Point −35°C (−31°F) Total Amount...
  • Page 233: Special Tools

    COOLING SYSTEM 4-7 Special Tools Bearing Driver Set: Oil Seal Driver 37.5: 57001-1129 57001-1660...
  • Page 234: Coolant

    4-8 COOLING SYSTEM Coolant Coolant Deterioration Inspection • Remove the right fuel tank cover (see Fuel Tank Cover 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.
  • Page 235 COOLING SYSTEM 4-9 Coolant • Pull the right side cover [A] outward to clear the projec- tions [B] from the grommets. • Put the clean cloth [A] to prevent damage to the frame. • Slide the clamp [A]. • To prevent the coolant from flowing out from the reserve tank, disconnect the radiator overflow hose [B] from the radiator filler neck and hold the hose end higher than the reserve tank using a band [C].
  • Page 236: Cooling System Flushing

    4-10 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 237: Water Pump

    COOLING SYSTEM 4-11 Water Pump Water Pump Removal • Drain: Coolant (see Coolant Change in the Periodic Mainte- nance chapter) Engine Oil (see Engine Oil Change in the Periodic Main- tenance chapter) • Remove: Engine Sprocket Cover (see Engine Sprocket Removal in the Final Drive chapter) •...
  • Page 238 4-12 COOLING SYSTEM Water Pump • Be sure to install the dowel pins [A]. • Install: Water Pump Housing [A] Water Pump Impeller [B] • Replace the washer with a new one, and install it. • Tighten: Torque - Water Pump Impeller Bolt [C]: 9.8 N·m (1.0 kgf·m, 87 in·lb) •...
  • Page 239: Water Pump Inspection

    COOLING SYSTEM 4-13 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 240: Water Pump Housing Assembly

    4-14 COOLING SYSTEM Water Pump • Take the oil seal [A] out of the housing [B] with a hook [C]. Water Pump Housing Assembly NOTICE Do not reuse the mechanical seal and oil seal. • Apply high-temperature grease to the oil seal lips [A]. •...
  • Page 241: Radiator

    COOLING SYSTEM 4-15 Radiator Radiator and Radiator Fan Removal • Drain: Coolant (see Coolant Change in the Periodic Mainte- nance chapter) • Remove: Middle Fairings (see Middle Fairing Removal in the Frame chapter) Seat (see Seat Removal in the Frame chapter) Bolts [A], Collars and Washers Quick Rivet [B] •...
  • Page 242 4-16 COOLING SYSTEM Radiator • Loosen the water hose clamp screw [A]. • Disconnect the water hose [B]. • Remove: Radiator Bolt (Lower) [A] • Loosen the water hose clamp screw [A]. • Disconnect the water hose [B] from the radiator filler neck. •...
  • Page 243: Radiator And Radiator Fan Installation

    COOLING SYSTEM 4-17 Radiator • Clear the heat insulation rubber plate [A] from the radiator [B] and radiator fan motor lead [C]. NOTICE Do not touch the radiator core. This could damage the radiator fins, resulting in loss of cooling effi- ciency.
  • Page 244: Radiator Inspection

    4-18 COOLING SYSTEM Radiator • Cover the heat insulation rubber plate [A] on the radiator [B] as shown. Slits [C] of Heat Insulation Rubber Plate • Run the radiator fan motor lead [D] into the slit. • Insert the upper right mounting bracket [A] to the frame projection [B].
  • Page 245: Radiator Cap Inspection

    COOLING SYSTEM 4-19 Radiator Radiator Cap Inspection • Remove: Right Middle Fairing (see Middle Fairing Removal in the Frame chapter) Radiator Cap • Check the condition of the bottom [A] and top [B] valve seals and valve spring [C]. If any one of them shows visible damage, replace the cap with a new one.
  • Page 246 4-20 COOLING SYSTEM Radiator • Pull the right side cover [A] outward to clear the projection [B] from the grommets. • Put the clean cloth [A] to prevent damage to the frame. • Slide the clamp [A]. • To prevent the coolant from flowing out from the reserve tank, disconnect the radiator overflow hose [B] from the radiator filler neck and hold the hose end higher than the reserve tank using a band [C].
  • Page 247: Thermostat

    COOLING SYSTEM 4-21 Thermostat Thermostat Removal • Drain: Coolant (see Coolant Change in the Periodic Mainte- nance chapter) • Remove: Throttle Body Assy (see Throttle Body Assy Removal in the Fuel System (DFI) chapter) Clamp [A] • Slide the clamp [B]. •...
  • Page 248: Thermostat Inspection

    4-22 COOLING SYSTEM Thermostat Thermostat Inspection • Remove the thermostat (see Thermostat Removal). • Inspect the thermostat valve [A] at room temperature. If the valve is open, replace the thermostat with a new one. • To check valve opening temperature, suspend the ther- mostat [A] in a container of water and raise the tempera- ture of the water.
  • Page 249: Hose And Pipes

    COOLING SYSTEM 4-23 Hose and Pipes Hose Installation • Install the hoses and pipes, being careful to follow bend- ing direction. Avoid sharp bending, kinking, flattening or twisting. • Run the hoses (see Cable, Wire, and Hose Routing sec- tion in the Appendix chapter). •...
  • Page 250: Water Temperature Sensor

    4-24 COOLING SYSTEM Water Temperature Sensor NOTICE The water temperature sensor should never be al- lowed to fall on a hard surface. Such a shock to the water temperature sensor can damage it. Water Temperature Sensor Removal/Installation • Refer to the Water Temperature Sensor Removal/Instal- lation in the Fuel System (DFI) chapter.
  • Page 251 ENGINE TOP END 5-1 Engine Top End Table of Contents Exploded View........Cylinder Head Warp Inspection ... 5-29 Exhaust System Identification ... Valves ..........5-30 Specifications ........Valve Clearance Inspection ..5-30 Special Tools and Sealants ....5-10 Valve Clearance Adjustment..5-30 Clean Air System.......
  • Page 252: Exploded View

    5-2 ENGINE TOP END Exploded View...
  • Page 253 ENGINE TOP END 5-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Air Suction Valve Cover Bolts 87 in·lb Spark Plugs 115 in·lb Cylinder Head Cover Bolts 89 in·lb Camshaft Cap Bolts 106 in·lb Upper Camshaft Chain Guide Bolts 106 in·lb Cylinder Head Bolts (M10) (First) S, MO Cylinder Head Bolts (M10) (Final)
  • Page 254 5-4 ENGINE TOP END Exploded View...
  • Page 255 ENGINE TOP END 5-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Muffler Cover Bolts 0.82 71 in·lb Muffler Body Mounting Bolt Muffler Body Clamp Bolt Muffler Body End Cover Bolts 89 in·lb Exhaust Pipe Holder Nuts Premuffler Chamber Mounting Bolt Premuffler Chamber Cover Bolt (L = 14 mm) 0.82 71 in·lb...
  • Page 256: Exhaust System Identification

    5-6 ENGINE TOP END Exhaust System Identification Exhaust Pipe Mark Position [A] Muffler Body Mark Position [A]...
  • Page 257 ENGINE TOP END 5-7 Exhaust System Identification Exhaust Pipe [A] with Hole [B] for Oxygen Sensor [C] Honeycomb Type Catalyst Positions [A]...
  • Page 258: Specifications

    5-8 ENGINE TOP END Specifications Item Standard Service Limit Camshafts Cam Height: 32.943 ∼ 33.057 mm (1.2970 ∼ 1.3015 in.) Exhaust 32.84 mm (1.293 in.) 32.943 ∼ 33.057 mm (1.2970 ∼ 1.3015 in.) Intake 32.84 mm (1.293 in.) 0.038 ∼ 0.081 mm (0.0015 ∼ 0.0032 in.) Camshaft Journal, Camshaft 0.17 mm (0.0067 in.) Cap Clearance...
  • Page 259 ENGINE TOP END 5-9 Specifications Item Standard Service Limit Cylinder, Pistons 76.994 ∼ 77.006 mm (3.0313 ∼ 3.0317 in.) Cylinder Inside Diameter 77.09 mm (3.035 in.) 76.974 ∼ 76.984 mm (3.0305 ∼ 3.0309 in.) Piston Diameter 76.82 mm (3.024 in.) 0.010 ∼...
  • Page 260: Special Tools And Sealants

    5-10 ENGINE TOP END Special Tools and Sealants Compression Gauge, 20 kgf/cm²: Valve Seat Cutter, 32° - 28: 57001-221 57001-1119 Valve Spring Compressor Assembly: Valve Seat Cutter Holder Bar: 57001-241 57001-1128 Piston Pin Puller Assembly: Valve Seat Cutter, 32° - 33: 57001-910 57001-1199 Valve Seat Cutter, 45°...
  • Page 261 ENGINE TOP END 5-11 Special Tools and Sealants Valve Guide Reamer, 4.5: Valve Spring Compressor Adapter, 24: 57001-1333 57001-1586 Valve Seat Cutter, 60° - 33: Compression Gauge Adapter, M10 × 1.0: 57001-1334 57001-1601 Valve Seat Cutter, 60° - 27: L-Shape Hose: 57001-1409 57001-1606 Engine Mount Nut Wrench:...
  • Page 262 5-12 ENGINE TOP END Special Tools and Sealants Liquid Gasket, TB1216B: 92104-1064...
  • Page 263: Clean Air System

    ENGINE TOP END 5-13 Clean Air System Air Suction Valve Removal • Remove: Air Switching Valve (see Air Switching Valve Removal) Bolts • Remove the connector [A] from the bracket [B]. • Remove: Air Suction Valve Cover Bolts [C] (Both Sides) Connector Bracket Air Suction Valve Cover [D] (Both Sides) •...
  • Page 264: Air Suction Valve Inspection

    5-14 ENGINE TOP END Clean Air System Air Suction Valve Inspection • Remove the air suction valve (see Air Suction Valve Re- moval). • Visually inspect the reeds [A] for cracks, folds, warps, heat damage or other damage. If there is any doubt as to the condition of the reeds, re- place the air suction valve as an assembly.
  • Page 265: Air Switching Valve Installation

    ENGINE TOP END 5-15 Clean Air System Air Switching Valve Installation • Install the air switching valve [A] with hoses as shown. Left Side View [B] About 40° [C] • Install the removed parts (see appropriate chapters). Air Switching Valve Operation Test •...
  • Page 266: Cylinder Head Cover

    5-16 ENGINE TOP END Cylinder Head Cover Cylinder Head Cover Removal • Remove: Stick Coils (see Stick Coil Removal in the Electrical Sys- tem chapter) Air Suction Valves (see Air Suction Valve Removal) Radiator Cap Housing Bolt [A] and Collar •...
  • Page 267 ENGINE TOP END 5-17 Cylinder Head Cover • Using a high flash-point solvent, clean off any oil or dirt that may be on the liquid gasket coating area. Dry them with a clean cloth. • Apply liquid gasket [A] to the cylinder head as shown. Sealant - Liquid Gasket, TB1216B: 92104-1064 NOTE ○...
  • Page 268 5-18 ENGINE TOP END Cylinder Head Cover • Tighten the cylinder head cover bolts following the speci- fied tightening sequence [1 ∼ 6]. Torque - Cylinder Head Cover Bolts: 10 N·m (1.0 kgf·m, 89 in·lb) • Install the removed parts (see appropriate chapters).
  • Page 269: Camshaft Chain Tensioner

    ENGINE TOP END 5-19 Camshaft Chain Tensioner Camshaft Chain Tensioner Removal NOTICE This is a non-return type camshaft chain tensioner. The push rod does not return to its original position once it moves out to take up camshaft chain slack. Observe all the rules listed below.
  • Page 270: Camshaft, Camshaft Chain

    5-20 ENGINE TOP END Camshaft, Camshaft Chain Camshaft Removal • Remove: Cylinder Head Cover (see Cylinder Head Cover Re- moval) Crankshaft Sensor Cover (see Crankshaft Sensor Re- moval in the Electrical System chapter) • Using a wrench on the timing rotor bolt [A], turn the crank- shaft clockwise until the line [B] (TDC mark for #1, 4 pis- tons) on the timing rotor is aligned with the mating surface [C] of the crankcase.
  • Page 271: Camshaft Installation

    ENGINE TOP END 5-21 Camshaft, Camshaft Chain Camshaft Installation • Be sure to install the following parts. Plug Hole Gaskets [A] Dowel Pins [B] NOTE ○ The exhaust camshaft has a 1169 EX mark [A] and the intake camshaft has a 1169 IN mark [B]. Be careful not to mix up these shafts.
  • Page 272 5-22 ENGINE TOP END Camshaft, Camshaft Chain • Pull the tension side (exhaust side) [A] of the chain taut to install the chain. • Engage the camshaft chain with the sprockets so that tim- ing marks on the sprockets are positioned as shown. ○...
  • Page 273 ENGINE TOP END 5-23 Camshaft, Camshaft Chain • Before installing the camshaft caps and upper chain guide, install the camshaft chain tensioner body tem- porarily (see Camshaft Chain Tensioner Installation). • Install the camshaft caps and upper camshaft chain guide [A] as shown.
  • Page 274: Camshaft, Camshaft Cap Wear Inspection

    5-24 ENGINE TOP END Camshaft, Camshaft Chain Camshaft, Camshaft Cap Wear Inspection • Remove: Camshaft Caps (see Camshaft Removal) • Cut the strips of plastigage (press gauge) to journal width. Place a strip on each journal parallel to the camshaft in- stalled in the correct position.
  • Page 275: Cam Wear Inspection

    ENGINE TOP END 5-25 Camshaft, Camshaft Chain Cam Wear Inspection • Remove the camshafts (see Camshaft Removal). • Measure the height [A] of each cam with a micrometer. If the cams are worn down past the service limit, replace the camshaft. Cam Height Standard: 32.943 ∼...
  • Page 276: Cylinder Head

    5-26 ENGINE TOP END Cylinder Head Cylinder Compression Measurement NOTE ○ Use the battery which is fully charged. • Warm up the engine thoroughly. • Stop the engine. • Remove: Spark Plugs (see Spark Plug Replacement in the Peri- odic Maintenance chapter) •...
  • Page 277: Cylinder Head Removal

    ENGINE TOP END 5-27 Cylinder Head Cylinder Head Removal • Drain: Coolant (see Coolant Change in the Periodic Mainte- nance chapter) • Remove: Camshafts (see Camshaft Removal) Throttle Body Assy (see Throttle Body Assy Removal in the Fuel System (DFI) chapter) Exhaust Pipe (see Exhaust Pipe Removal) Timing Rotor (see Timing Rotor Removal in the Electrical System chapter)
  • Page 278: Cylinder Head Installation

    5-28 ENGINE TOP END Cylinder Head • Loosen: Upper Engine Mounting Bolt (Left) [A] • Remove: Upper Engine Mounting Bolt (Right) [B] • Loosen: Upper Adjusting Collar Locknut [C] Special Tool - Engine Mount Nut Wrench [D]: 57001-1450 • Loosen: Upper Adjusting Collar [E] •...
  • Page 279: Cylinder Head Warp Inspection

    ENGINE TOP END 5-29 Cylinder Head • Tighten the M10 cylinder head bolts following the tighten- ing sequence [1 ∼ 10]. Torque - Cylinder Head Bolts (M10): First 30 N·m (3.1 kgf·m, 22 ft·lb) Final 52 N·m (5.3 kgf·m, 38 ft·lb) •...
  • Page 280: Valves

    5-30 ENGINE TOP END Valves Valve Clearance Inspection • Refer to the Valve Clearance Inspection in the Periodic Maintenance chapter. Valve Clearance Adjustment • Refer to the Valve Clearance Adjustment in the Periodic Maintenance chapter. Valve Removal • Remove: Cylinder Head (see Cylinder Head Removal) Valve Lifter and Shim NOTE ○...
  • Page 281: Valve Guide Installation

    ENGINE TOP END 5-31 Valves Valve Guide Installation • Apply oil to the valve guide outer surface before installa- tion. • Heat the area around the valve guide hole to about 120 ∼ 150°C (248 ∼ 302°F). NOTICE Do not heat the cylinder head with a torch. This Will warp the cylinder head.
  • Page 282: Valve-to-guide Clearance Measurement (wobble Method)

    5-32 ENGINE TOP END Valves Valve-to-Guide Clearance Measurement (Wobble Method) If a small bore gauge is not available, inspect the valve guide wear by measuring the valve to valve guide clearance with the wobble method as indicated below. • Insert a new valve [A] into the guide [B] and set a dial gauge against the stem perpendicular to it as close as possible to the cylinder head mating surface.
  • Page 283: Valve Seat Repair

    ENGINE TOP END 5-33 Valves Valve Seat Repair • Repair the valve seat with the valve seat cutters [A]. Special Tools - Valve Seat Cutter Holder Bar [B]: 57001 -1128 Valve Seat Cutter Holder, 4.5 [C]: 57001 -1330 [For Exhaust Valve Seat] Valve Seat Cutter, 45°...
  • Page 284 5-34 ENGINE TOP END Valves Operating Procedures • Clean the seat area carefully. • Coat the seat with machinist’s dye. • Fit a 45° cutter into the holder and slide it into the valve guide. • Press down lightly on the handle and turn it right or left. Grind the seating surface only until it is smooth.
  • Page 285 ENGINE TOP END 5-35 Valves If the outside diameter [A] of the seating surface is too large, make the 32° [B] grind described below. If the outside diameter of the seating surface is within the specified range, measure the seat width as described be- low.
  • Page 286 5-36 ENGINE TOP END Valves • Lap the valve to the valve seat, once the seat width and outside diameter are within the ranges specified above. ○ Put a little coarse grinding compound on the face of the valve in a number of places around the valve head. ○...
  • Page 287 ENGINE TOP END 5-37 Valves...
  • Page 288: Cylinder, Pistons

    5-38 ENGINE TOP END Cylinder, Pistons Cylinder Removal • Remove: Cylinder Head (see Cylinder Head Removal) Radiator Bracket Bolt [A] Radiator Bracket [B] • Slide the clamp [A]. • Disconnect the water hose [B]. • Remove: Upper Engine Mounting Bolt (Left) [C] •...
  • Page 289: Piston Removal

    ENGINE TOP END 5-39 Cylinder, Pistons • Position the crankshaft at #2, 3 piston TDC. • Prepare two auxiliary head bolts with their head cut. ○ Install the two cylinder head bolts [A] diagonally in the crankcase. • Install the cylinder block [B]. Pistons [C] ○...
  • Page 290: Piston Installation

    5-40 ENGINE TOP END Cylinder, Pistons Piston Installation NOTE ○ If a new piston is used, use new piston ring. • Apply molybdenum disulfide oil solution to the oil ring ex- pander, and install the oil ring expander [A] in the bottom piston ring groove so the ends [B] not butt together.
  • Page 291: Piston Wear Inspection

    ENGINE TOP END 5-41 Cylinder, Pistons Piston Wear Inspection • Measure the outside diameter [A] of each piston 11 mm (0.43 in.) [B] up from the bottom of the piston at a right angle to the direction of the piston pin. If the measurement is under service limit, replace the pis- ton.
  • Page 292: Piston Ring Thickness Inspection

    5-42 ENGINE TOP END Cylinder, Pistons Piston Ring Thickness Inspection • Measure the piston ring thickness. ○ Use the micrometer to measure at several points around the ring. Piston Ring Thickness Standard: 0.77 ∼ 0.79 mm (0.0303 ∼ 0.0311 in.) Top [A] 0.77 ∼...
  • Page 293: Throttle Body Assy Holder

    ENGINE TOP END 5-43 Throttle Body Assy Holder Throttle Body Assy Holder Removal • Remove: Throttle Body Assy (see Throttle Body Assy Removal in the Fuel System (DFI) chapter) Clamps [A] Throttle Body Assy Holder Bolts [B] Throttle Body Assy Holders [C] Throttle Body Assy Holder Installation •...
  • Page 294: Muffler

    5-44 ENGINE TOP END Muffler WARNING The exhaust pipe or muffler body can become ex- tremely hot during normal operation and cause se- vere burns. Do not remove the exhaust pipe or muf- fler body while it is hot. Muffler Body Removal •...
  • Page 295: Muffler Body Installation

    ENGINE TOP END 5-45 Muffler Muffler Body Installation • Replace the muffler body gaskets [A] with new ones. • Install the muffler body gaskets until it is bottomed so that the inside chamfer side faces rear [B]. • Install the muffler body clamp [C] so that the projection [D] fits into the clamp slit [E].
  • Page 296: Exhaust Pipe Removal

    5-46 ENGINE TOP END Muffler • Install the muffler cover [A] and tighten the muffler cover bolts [B]. Torque - Muffler Cover Bolts: 8.0 N·m (0.82 kgf·m, 71 in·lb) Exhaust Pipe Removal • Remove: Muffler Body (see Muffler Body Removal) Oxygen Sensor (see Oxygen Sensor Removal in the Electrical System chapter) •...
  • Page 297 ENGINE TOP END 5-47 Muffler • Replace the exhaust pipe gaskets [A] with new ones. • Apply grease to the exhaust pipe gaskets and install them. • Install the exhaust pipe. • Tighten the exhaust pipe holder nuts [B] and premuffler chamber mounting bolt [C].
  • Page 299 CLUTCH 6-1 Clutch Table of Contents Exploded View........................Specifications ......................... Special Tool and Sealant ......................Clutch Lever and Cable ......................Clutch Lever Free Play Inspection ..................Clutch Lever Free Play Adjustment .................. Clutch Cable Removal ...................... Clutch Cable Installation ....................Clutch Cable Lubrication....................
  • Page 300: Exploded View

    6-2 CLUTCH Exploded View...
  • Page 301 CLUTCH 6-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Clutch Lever Clamp Bolts 0.80 69 in·lb Clutch Stopper Bolts 0.90 78 in·lb Clutch Hub Nut 13.8 Clutch Cover Bolts 87 in·lb Hand Oil Filler Plug – – – -tighten CL: Apply cable lubricant.
  • Page 302: Specifications

    6-4 CLUTCH Specifications Item Standard Service Limit Clutch Lever and Cable 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Clutch Lever Free Play – – – Clutch 45.6 ∼ 46.4 mm (1.80 ∼ 1.83 in.) Clutch Plate Assembly Length – – – 2.72 ∼...
  • Page 303: Special Tool And Sealant

    CLUTCH 6-5 Special Tool and Sealant Clutch Holder: Liquid Gasket, TB1211F: 57001-1243 92104-0004...
  • Page 304: Clutch Lever And Cable

    6-6 CLUTCH Clutch Lever and Cable Clutch Lever Free Play Inspection • Refer to the Clutch Operation Inspection in the Periodic Maintenance chapter. Clutch Lever Free Play Adjustment • Refer to the Clutch Operation Inspection in the Periodic Maintenance chapter. Clutch Cable Removal •...
  • Page 305: Clutch Lever Assembly Installation

    CLUTCH 6-7 Clutch Lever and Cable Clutch Lever Assembly Installation • Install the clutch lever so that the mating surface [A] of the clutch lever clamp is aligned with the punch mark [B]. • Tighten the upper clamp bolt first, and then the lower clamp bolt.
  • Page 306: Clutch Lever Adjustment

    6-8 CLUTCH Clutch Lever and Cable Clutch Lever Adjustment The adjuster has 5 positions so that the clutch lever posi- tion 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 holder.
  • Page 307: Clutch Cover

    CLUTCH 6-9 Clutch Cover Clutch Cover Removal • Drain the engine oil (see Engine Oil Change in the Peri- odic Maintenance chapter). • Remove: Right Lower Fairing (see Lower Fairing Removal in the Frame chapter) Clutch Cable Lower End (see Clutch Cable Removal) Clutch Cover Bolts [A] Brackets [B] •...
  • Page 308: Release Shaft Installation

    6-10 CLUTCH Clutch Cover Release Shaft Installation • Apply grease to the oil seal lips on the upper ridge of the clutch cover. • Apply engine oil to the needle bearings in the hole of the clutch cover. • Apply molybdenum disulfide grease to the pusher-holding portion [A] on the release shaft.
  • Page 309: Clutch Cover Assembly

    CLUTCH 6-11 Clutch Cover Clutch Cover Assembly • Replace the needle bearings and oil seal with new ones. NOTE ○ Install the needle bearings so that the manufacture’s mark face out. • Apply soap and water solution to the oil seal. •...
  • Page 310: Clutch Removal

    6-12 CLUTCH Clutch Clutch Removal • Remove: Clutch Cover (see Clutch Cover Removal) • Loosen the three clutch stopper bolts [A] alternately with little by little (1/4 turn at a time) to prevent tilting the clutch stopper plate [B]. NOTICE Do not loosen the one or two clutch stopper bolt at once to prevent clutch stopper plate from warpage by the spring force.
  • Page 311: Clutch Installation

    CLUTCH 6-13 Clutch • Remove: Clutch Hub [A] Spacer [B] • Using the two 4 mm (0.16 in.) bolts [A], pull out the sleeve [B], needle bearing [C] and clutch housing [D]. • Remove the spacer. Clutch Installation • Install the spacer [A] so that the tapered side [B] faces inward.
  • Page 312 6-14 CLUTCH Clutch • Install: Clutch Hub [A] Washer [B] • Install the washer [C] so that the “OUT SIDE” mark faces outward. • Replace the clutch hub nut [A] with a new one. • Hold the sub clutch hub [B] steady with the clutch holder [C], and tighten the clutch hub nut.
  • Page 313 CLUTCH 6-15 Clutch • Put the last friction plate [A] and steel plate [B] on the clutch pressure plate [C] and install them. • Install the last friction plate so that the tangs [A] fit into the grooves in the housing as shown. NOTE ○...
  • Page 314: Clutch Plate Assembly Length Measurement

    6-16 CLUTCH Clutch Clutch Plate Assembly Length Measurement • Assemble the following parts. Clutch Hub [A] Friction Plates [B] Steel Plates [C] Clutch Pressure Plate [D] Spring Seats [E] Clutch Springs [F] Clutch Stopper Plate [G] Clutch Stopper Bolts [H] Torque - Clutch Stopper Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb) •...
  • Page 315: Clutch Spring Free Length Measurement

    CLUTCH 6-17 Clutch Clutch Spring Free Length Measurement • Measure the free length of the clutch springs [A]. If any spring is shorter than the service limit, it must be replaced. Clutch Spring Free Length Standard: 49.47 mm (1.948 in.) Service Limit: 47.6 mm (1.87 in.) Clutch Housing Finger Inspection •...
  • Page 317 ENGINE LUBRICATION SYSTEM 7-1 Engine Lubrication System Table of Contents Exploded View........................Engine Oil Flow Chart......................Specifications ......................... Special Tools and Sealants ....................Engine Oil and Oil Filter......................Oil Level Inspection......................Engine Oil Change......................Oil Filter Replacement ...................... Oil Pan............................ Oil Pan Removal .......................
  • Page 318: Exploded View

    7-2 ENGINE LUBRICATION SYSTEM Exploded View...
  • Page 319 ENGINE LUBRICATION SYSTEM 7-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Oil Passage Cover Bolts 106 in·lb Oil Filler Plug – – – Hand-tighten Oil Passage Plugs Oil Passage Plug 87 in·lb Oil Pressure Switch Oil Pressure Switch Terminal Bolt 0.20 18 in·lb Oil Pressure Relief Valve...
  • Page 320: Engine Oil Flow Chart

    7-4 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart 1. Balancer Oil Passage 2. Camshaft Oil Passage 3. Crankshaft Oil Passage 4. Drive Shaft Oil Passage 5. Output Shaft Oil Passage 6. Oil Pump 7. Oil Pipe 8. Oil Screen 9. Oil Pressure Relief Valve 10.
  • Page 321: Specifications

    ENGINE LUBRICATION SYSTEM 7-5 Specifications Item Standard Engine Oil Type API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2 Viscosity SAE 10W-40 Capacity: 3.2 L (3.4 US qt) (when filter is not removed) 3.8 L (4.0 US qt) (when filter is removed) 4.0 L (4.2 US qt) (when engine is completely dry) Level Between upper and lower level lines (Wait several minutes after...
  • Page 322: Special Tools And Sealants

    7-6 ENGINE LUBRICATION SYSTEM Special Tools and Sealants Outside Circlip Pliers: Liquid Gasket, TB1211: 57001-144 56019-120 Oil Pressure Gauge, 10 kgf/cm²: Liquid Gasket, TB1207B: 57001-164 92104-2068 Oil Pressure Gauge Adapter, PT3/8: 57001-1233...
  • Page 323: 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 324: Oil Pan

    7-8 ENGINE LUBRICATION SYSTEM Oil Pan Oil Pan Removal • Remove: Exhaust Pipe (see Exhaust Pipe Removal in the Engine Top End chapter) Oil Filter (see Oil Filter Replacement in the Periodic Maintenance chapter) Oil Pan Bolts [A] • Remove the oil pan [A] using the three pry points [B]. •...
  • Page 325 ENGINE LUBRICATION SYSTEM 7-9 Oil Pan • Using a high flash-point solvent, clean off any oil or dirt that may be on the liquid gasket coating area. Dry them with a clean cloth. • Apply liquid gasket [A] to the mating surface of the oil pan. Sealant - Liquid Gasket, TB1207B: 92104-2068 NOTE ○...
  • Page 326 7-10 ENGINE LUBRICATION SYSTEM Oil Pan • Tighten the oil pan bolts following sequence [1 ∼ 22]. Torque - Oil Pan Bolts: 12 N·m (1.2 kgf·m, 106 in·lb) • Install the removed parts (see appropriate chapters).
  • Page 327: Oil Screen

    ENGINE LUBRICATION SYSTEM 7-11 Oil Screen Oil Screen Removal • Remove: Oil Pan (see Oil Pan Removal) Oil Screen [A] Oil Screen Installation • Clean the oil screen (see Oil Screen Cleaning). • Replace the O-ring [A] with a new one, and install it. •...
  • Page 328: Oil Pressure Relief Valve

    7-12 ENGINE LUBRICATION SYSTEM Oil Pressure Relief Valve Oil Pressure Relief Valve Removal • Remove: Oil Screen (see Oil Screen Removal) Oil Pressure Relief Valve [A] Oil Pressure Relief Valve Installation • Apply a non-permanent locking agent to the threads of the oil pressure relief valve, and tighten it.
  • Page 329: Oil Pump

    ENGINE LUBRICATION SYSTEM 7-13 Oil Pump Oil Pump Removal • Remove: Water Pump (see Water Pump Removal in the Cooling System chapter) Oil Pump Cover [A] • Remove: Oil (Water) Pump Shaft [A] with Inner Rotor [B] Outer Rotor [C] Oil Pump Installation •...
  • Page 330: Oil Pump Drive Gear Removal

    7-14 ENGINE LUBRICATION SYSTEM Oil Pump • Pack grease into the cavity [A] between the inner rotor and outer rotor for improve the oil pump initial priming. • Install the dowel pin [B]. • Install the oil pump cover [C] so that the dowel pin fits into the hole [D] of the oil pump cover.
  • Page 331: Oil Pressure Measurement

    ENGINE LUBRICATION SYSTEM 7-15 Oil Pressure Measurement Oil Pressure Measurement • Remove: Right Lower Fairing (see Lower Fairing Removal in the Frame chapter) Oil Passage Plug [A] • Attach the adapter [A] and gauge [B] to the plug hole. Special Tools - Oil Pressure Gauge, 10 kgf/cm²: 57001-164 Oil Pressure Gauge Adapter, PT3/8: 57001 -1233 •...
  • Page 332: Oil Pressure Switch

    7-16 ENGINE LUBRICATION SYSTEM Oil Pressure Switch Oil Pressure Switch Removal • Drain the engine oil (see Engine Oil Change in the Peri- odic Maintenance chapter). • Remove the left lower fairing (see Lower Fairing Removal in the Frame chapter). •...
  • Page 333: Oil Pipe

    ENGINE LUBRICATION SYSTEM 7-17 Oil Pipe Oil Pipe Removal • Remove: Oil Pan (see Oil Pan Removal) Oil Pipe [A] Oil Pipe Installation • Replace the O-rings [A] with new ones. • Apply grease to the O-rings, and install them. •...
  • Page 335 ENGINE REMOVAL/INSTALLATION 8-1 Engine Removal/Installation Table of Contents Exploded View........................Special Tool ..........................Engine Removal/Installation ....................Engine Removal........................ Engine Installation......................
  • Page 336: Exploded View

    8-2 ENGINE REMOVAL/INSTALLATION Exploded View...
  • Page 337 ENGINE REMOVAL/INSTALLATION 8-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Upper Engine Bracket Bolts Lower Engine Bracket Bolts Upper Adjusting Collar 0.51 44 in·lb S, 2T Upper Adjusting Collar Locknut Upper Engine Mounting Bolt (L = 65 mm) Upper Engine Mounting Bolt (L = 54 mm) Rear Engine Bracket Bolts Lower Engine Mounting Nut Lower Adjusting Collar Locknut...
  • Page 338: Special Tool

    8-4 ENGINE REMOVAL/INSTALLATION Special Tool Engine Mount Nut Wrench: 57001-1450...
  • Page 339: Engine Removal/installation

    ENGINE REMOVAL/INSTALLATION 8-5 Engine Removal/Installation Engine Removal • Support the rear part of the swingarm with a stand. • Squeeze the brake lever slowly and hold it with a band [A]. WARNING Motorcycle may fall over unexpectedly resulting in an accident or injury. Be sure to hold the front brake when removing the engine.
  • Page 340 8-6 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Disconnect the side stand switch connector [A]. • Remove the connector [A] from the bracket on the air suc- tion valve cover and disconnect the connector. • Remove the clamps [A]. • Remove the drive chain [B] from the output shaft [C]. •...
  • Page 341 ENGINE REMOVAL/INSTALLATION 8-7 Engine Removal/Installation • Open the clamp [A]. • Release the crankshaft sensor lead [B] from the clamp [C] and guide [D]. • Remove the clamp [A] and left lower fairing bracket [B]. • Release the lead [C] from the right lower fairing bracket [D] and remove the right lower fairing bracket.
  • Page 342 8-8 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Remove: (Right Side) Radiator Cap Housing Bolt [A] and Collar • Loosen the water hose clamp screw [B]. • Disconnect the water hose [C]. • Free the clutch cable [D] from the clamps [E]. •...
  • Page 343: Engine Installation

    ENGINE REMOVAL/INSTALLATION 8-9 Engine Removal/Installation • Using the nut wrench [A], loosen the lower adjusting collar locknut [B]. Special Tool - Engine Mount Nut Wrench: 57001-1450 • Remove the lower engine mounting bolt [C]. • Using the Hexagon Wrench, turn the adjusting collar [D] counterclockwise to make the gap between the engine and adjusting collar.
  • Page 344 8-10 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Install the engine mounting bolts and nuts, following the specified installing sequence. ○ First, hang the drive chain over the output shaft just before moving the engine into its final position in the frame. ○...
  • Page 345 ENGINE REMOVAL/INSTALLATION 8-11 Engine Removal/Installation • Run the leads, cables and hoses correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). • Install the removed parts (see appropriate chapters). • Adjust: Throttle Cables (see Throttle Control System Inspection in the Periodic Maintenance chapter) Clutch Cable (see Clutch Operation Inspection in the Pe- riodic Maintenance chapter)
  • Page 347 CRANKSHAFT/TRANSMISSION 9-1 Crankshaft/Transmission Table of Contents Exploded View........Starter Motor Clutch Disassembly 9-29 Specifications ........Starter Motor Clutch Assembly ..9-30 Special Tools and Sealants ....External Shift Mechanism....9-31 Crankcase Splitting......Shift Pedal Removal ....9-31 Crankcase Splitting ...... Shift Pedal Installation ....
  • Page 348: Exploded View

    9-2 CRANKSHAFT/TRANSMISSION Exploded View...
  • Page 349 CRANKSHAFT/TRANSMISSION 9-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Balancer Shaft Clamp Bolt 87 in·lb Balancer Shaft Clamp Lever Bolt Connecting Rod Big End Nuts see the text ← ← Breather Side Plate Bolt 0.60 52 in·lb Breather Plate Bolts 87 in·lb Starter Motor Clutch Bolts 106 in·lb...
  • Page 350 9-4 CRANKSHAFT/TRANSMISSION Exploded View...
  • Page 351 CRANKSHAFT/TRANSMISSION 9-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Gear Positioning Lever Bolt 106 in·lb Shift Drum Bearing Holder Bolts 106 in·lb Shift Drum Cam Holder Bolt 106 in·lb Shift Shaft Return Spring Pin Neutral Switch Shift Lever Bolt 0.70 61 in·lb Shift Pedal Mounting Bolt...
  • Page 352: Specifications

    9-6 CRANKSHAFT/TRANSMISSION Specifications Item Standard Service Limit Crankcase, Crankshaft, Connecting Rods Connecting Rod Bend – – – TIR 0.2/100 mm (0.008/3.94 in.) Connecting Rod Twist – – – TIR 0.2/100 mm (0.008/3.94 in.) 0.13 ∼ 0.38 mm (0.0051 ∼ 0.0150 in.) Connecting Rod Big End Side 0.58 mm Clearance...
  • Page 353 CRANKSHAFT/TRANSMISSION 9-7 Specifications Item Standard Service Limit Crankshaft Main Bearing Insert Thickness: 1.491 ∼ 1.495 mm (0.0587 ∼ 0.0589 in.) Brown – – – 1.495 ∼ 1.499 mm (0.0589 ∼ 0.0590 in.) Black – – – 1.499 ∼ 1.503 mm (0.0590 ∼ 0.0592 in.) Blue –...
  • Page 354: Special Tools And Sealants

    9-8 CRANKSHAFT/TRANSMISSION Special Tools and Sealants Bearing Puller: Bearing Driver Set: 57001-135 57001-1129 Outside Circlip Pliers: Flywheel Holder: 57001-144 57001-1313 Bearing Puller Adapter: Liquid Gasket, TB1216B: 57001-317 92104-1064 Bearing Driver, 32: Liquid Gasket, TB1207B: 57001-382 92104-2068...
  • Page 355: Crankcase Splitting

    CRANKSHAFT/TRANSMISSION 9-9 Crankcase Splitting Crankcase Splitting • Remove the engine (see Engine Removal in the Engine Removal/Installation chapter). • Set the engine on a clean surface and hold the engine steady while parts are being removed. • Remove: Cylinder (see Cylinder Removal in the Engine Top End chapter) Clutch (see Clutch Removal in the Clutch chapter) External Shift Mechanism (see External Shift Mecha-...
  • Page 356 9-10 CRANKSHAFT/TRANSMISSION Crankcase Splitting • Remove the upper crankcase bolts, following the speci- fied sequence. ○ Firstly, loosen the M6 bolts [A]. ○ Secondly, loosen the M7 bolts [B]. ○ Lastly, loosen the M8 bolts [C]. • Remove: Oil Passage Bolts [A] Oil Passage Cover [B] •...
  • Page 357: Crankcase Assembly

    CRANKSHAFT/TRANSMISSION 9-11 Crankcase Splitting Crankcase Assembly NOTICE The upper and lower crankcase halves are ma- chined at the factory in the assembled state, so the crankcase halves must be replaced as a set. • With a high flash-point solvent, clean off the mating sur- faces of the crankcase halves and wipe dry.
  • Page 358 9-12 CRANKSHAFT/TRANSMISSION Crankcase Splitting • Press the fitting [A] in the upper crankcase [B] until it is bottomed. Special Tool - Bearing Driver Set: 57001-1129 • Press the plug [C] in the upper crankcase so that the plug is deeper than crankcase surface. •...
  • Page 359 CRANKSHAFT/TRANSMISSION 9-13 Crankcase Splitting • Using a high flash-point solvent, clean off any oil or dirt that may be on the liquid gasket coating area. Dry them with a clean cloth. • Apply liquid gasket [A] to the mating surface of the lower crankcase half.
  • Page 360 9-14 CRANKSHAFT/TRANSMISSION Crankcase Splitting • The M9 bolts [A] have copper plated washers [B], replace them with new ones. • Apply molybdenum disulfide oil solution to both sides [C] of the copper plated washer and threads [D] of the M9 bolts.
  • Page 361 CRANKSHAFT/TRANSMISSION 9-15 Crankcase Splitting • Tighten the upper crankcase bolts using the following steps. ○ Tighten the M8 bolts [A]. Torque - Crankcase Bolts (M8): 27 N·m (2.8 kgf·m, 20 ft·lb) ○ Replace the washer [B] with a new one. ○...
  • Page 362: Crankshaft And Connecting Rods

    9-16 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods Crankshaft Removal • Split the crankcase (see Crankcase Splitting). • Remove: Connecting Rods [A] (see Connecting Rod Removal) Balancer [B] (see Balancer Removal) Camshaft Chain [C] Crankshaft [D] Crankshaft Installation NOTICE If the crankshaft, bearing inserts, or crankcase halves are replaced with new ones, select the bear- ing inserts and check clearance with a plastigage (press gauge) before assembling engine to be sure...
  • Page 363: Connecting Rod Installation

    CRANKSHAFT/TRANSMISSION 9-17 Crankshaft and Connecting Rods Connecting Rod Installation NOTICE To minimize vibration, the connecting rods should have the same weight mark. Big End Cap [A] Connecting Rod [B] Weight Mark, Alphabet [C] ○ Diameter Mark [D]: “ ” or no mark NOTICE If the connecting rods, big end bearing inserts, or crankshaft are replaced with new ones, select the...
  • Page 364 9-18 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods • Install each connecting rod on its original crankpin. ○ The connecting rod big end is bolted using the “plastic region fastening method.” ○ This method precisely achieves the needed clamping force without exceeding it unnecessarily, allowing the use of thinner, lighter bolts further decreasing connecting rod weight.
  • Page 365 CRANKSHAFT/TRANSMISSION 9-19 Crankshaft and Connecting Rods • Install new bolts and nuts in reused connecting rod. If the connecting rod assy was replaced, use the bolts and nuts attached to the new connecting rod assy. • Apply a small amount of molybdenum disulfide oil solution to the following portions.
  • Page 366: Crankshaft/connecting Rod Cleaning

    9-20 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods • Install new bolts and nuts in reused connecting rods. If the connecting rod assy was replaced, use the bolts and nuts attached to the new connecting rod assy. • Apply a small amount of molybdenum disulfide oil solution to the following portions.
  • Page 367: Connecting Rod Bend Inspection

    CRANKSHAFT/TRANSMISSION 9-21 Crankshaft and Connecting Rods Connecting Rod Bend Inspection • Remove the connecting rod big end bearing inserts, and reinstall the connecting rod big end cap. • Select an arbor [A] of the same diameter as the connect- ing rod big end, and insert the arbor through the connect- ing rod big end.
  • Page 368: Connecting Rod Big End Bearing Insert/crankpin Wear Inspection

    9-22 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods Connecting Rod Big End Bearing Insert/Crankpin Wear Inspection • Remove the connecting rod big end (see Connecting Rod Removal). • Cut strips of plastigage (press gauge) to crankpin width. Place a strip on the crankpin parallel to the crankshaft installed in the correct position.
  • Page 369: Crankshaft Side Clearance Inspection

    CRANKSHAFT/TRANSMISSION 9-23 Crankshaft and Connecting Rods • Measure the connecting rod big end inside diameter, and mark each connecting rod big end in accordance with the inside diameter. • Tighten the connecting rod big end nuts to the specified torque (see Connecting Rod Installation). NOTE ○...
  • Page 370: Crankshaft Runout Inspection

    9-24 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods Crankshaft Runout Inspection • Measure the crankshaft runout. If the measurement exceeds the service limit, replace the crankshaft. Crankshaft Runout Standard: TIR 0.02 mm (0.0008 in.) or less Service Limit: TIR 0.05 mm (0.0020 in.) Crankshaft Main Bearing Insert/Journal Wear Inspection •...
  • Page 371 CRANKSHAFT/TRANSMISSION 9-25 Crankshaft and Connecting Rods Crankshaft Main Journal Diameter 34.984 ∼ 35.000 mm (1.3773 ∼ 1.3780 in.) Standard: Service Limit: 34.96 mm (1.376 in.) If any journal has worn past the service limit, replace the crankshaft with a new one. If the measured journal diameters [A] are not less than the service limit, but do not coincide with the original diameter markings [B] on the crankshaft, make new marks on it.
  • Page 372 9-26 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods Crankcase Main Crankshaft Main Bearing Insert* Bearing Inside Journal Diameter Diameter Marking Marking Size Color Part Number Journal Nos. 92139-0034 2, 4 ○ Brown 92139-0219 1, 3, 5 None 92139-0033 2, 4 Black ○ None 92139-0218 1, 3, 5...
  • Page 373: Balancer

    CRANKSHAFT/TRANSMISSION 9-27 Balancer Balancer Removal • Split the crankcase (see Crankcase Splitting). • Remove: Oil Seal [A] Balancer [B] Balancer Installation • Check that the rubber dampers [A] are in place as shown. • Apply molybdenum disulfide oil solution to the damper contact portions of the balancer weight [A].
  • Page 374: Balancer Adjustment

    9-28 CRANKSHAFT/TRANSMISSION Balancer • Assemble the crankcase (see Crankcase Assembly). • Fill the oil seal lips with grease. • Install the new oil seal [A] so that its surface is flush with the surface of the crankcase. • Install the balancer shaft clamp lever [B]. •...
  • Page 375: Starter Motor Clutch

    CRANKSHAFT/TRANSMISSION 9-29 Starter Motor Clutch Starter Motor Clutch Removal/Installation • Refer to the Starter Motor Clutch Disassembly/Assembly. Starter Motor Clutch Inspection • Remove: Alternator Cover (see Alternator Cover Removal in the Electrical System chapter) Starter Idle Gear [A] and Shaft [B] •...
  • Page 376: Starter Motor Clutch Assembly

    9-30 CRANKSHAFT/TRANSMISSION Starter Motor Clutch • Remove: Starter Motor Clutch Housing [A] Starter Motor Clutch [B] Starter Motor Clutch Assembly • Install the starter motor clutch to the housing so that the flange [A] fit to the housing groove [B]. •...
  • Page 377: External Shift Mechanism

    CRANKSHAFT/TRANSMISSION 9-31 External Shift Mechanism Shift Pedal Removal • Remove: Shift Lever Bolt [A] Shift Lever [B] If the tie-rod is removed from the shift pedal and shift lever, note the following. ○ The following portions have left-hand threads. Locknut [C] of Shift Lever Side Ball Joint [D] of Shift Lever •...
  • Page 378: External Shift Mechanism Removal

    9-32 CRANKSHAFT/TRANSMISSION External Shift Mechanism External Shift Mechanism Removal • Remove: Shift Lever (see Shift Pedal Removal) Clutch (see Clutch Removal in the Clutch chapter) Circlip [A] Washer [B] Special Tool - Outside Circlip Pliers: 57001-144 • Remove: Shift Shaft Assembly [A] •...
  • Page 379: External Shift Mechanism Inspection

    CRANKSHAFT/TRANSMISSION 9-33 External Shift Mechanism • Apply grease to the lips of the oil seal [A]. • Install the shift shaft [A] so that the return spring pin [B] fits between the spring [C]. • Install the washer [A]. • Replace the circlip [B] with a new one, and install it.
  • Page 380 9-34 CRANKSHAFT/TRANSMISSION External Shift Mechanism • Check the gear positioning lever [A] and its spring for breaks or distortion. If the lever or spring are damaged in any way, replace them. • Visually inspect the shift drum cam [B]. If it is badly worn or shows any damage, replace it.
  • Page 381: Transmission

    CRANKSHAFT/TRANSMISSION 9-35 Transmission Transmission Shaft Removal • Split the crankcase (see Crankcase Splitting). • Remove the drive shaft [A] and output shaft [B]. Transmission Shaft Installation • Check to see that the set pins [A] and set rings [B] are in place.
  • Page 382: Transmission Shaft Assembly

    9-36 CRANKSHAFT/TRANSMISSION Transmission • Remove the ball bearing [A] from each shafts. Special Tools - Bearing Puller [B]: 57001-135 Bearing Puller Adapter [C]: 57001-317 • Discard the bearing. Transmission Shaft Assembly • Install the new ball bearing [A] on the each shaft, using the bearing driver.
  • Page 383 CRANKSHAFT/TRANSMISSION 9-37 Transmission • The drive shaft gears can be recognized by size: the gear with the smallest diameter is 1st gear, and the largest one is 6th gear. Be sure that all parts are put back in the cor- rect sequence and all circlips and washers are properly in place.
  • Page 384 9-38 CRANKSHAFT/TRANSMISSION Transmission...
  • Page 385 CRANKSHAFT/TRANSMISSION 9-39 Transmission 1. Output Shaft 2. Collar 3. Ball Bearings 4. Bushing 5. 2nd Gear (39 T) 6. Washer ( 34 × 28.1) 7. Circlips ( 33 × 25.9) 8. Top Gear (23 T) 9. Toothed Washer ( 34) 10.
  • Page 386: Shift Drum And Fork Removal

    9-40 CRANKSHAFT/TRANSMISSION Transmission Shift Drum and Fork Removal • Remove: Lower Crankcase Half (see Crankcase Splitting) Transmission Shafts (see Transmission Shaft Removal) Gear Positioning Lever (see External Shift Mechanism Removal) Shift Drum Bearing Holder Bolts [A] Shift Drum Bearing Holder [B] •...
  • Page 387: Shift Fork Bending Inspection

    CRANKSHAFT/TRANSMISSION 9-41 Transmission Shift Fork Bending Inspection • Visually inspect the shift forks, and replace any fork that is bent. A bent fork could cause difficulty in shifting, or allow the transmission to jump out of gear when under power. 90°...
  • Page 388: Ball Bearing, Needle Bearing, And Oil Seal

    9-42 CRANKSHAFT/TRANSMISSION Ball Bearing, Needle Bearing, and Oil Seal Ball and Needle Bearing Replacement NOTICE Do not remove the ball or needle bearings unless it is necessary. Removal may damage them. • Using a press or puller, remove the ball bearing and/or needle bearings.
  • Page 389 WHEELS/TIRES 10-1 Wheels/Tires Table of Contents Exploded View........................10-2 Specifications ......................... 10-4 Special Tools .......................... 10-5 Wheels (Rims) ........................10-6 Front Wheel Removal ....................... 10-6 Front Wheel Installation ....................10-6 Rear Wheel Removal......................10-7 Rear Wheel Installation..................... 10-8 Wheel Inspection ......................10-10 Axle Inspection........................
  • Page 390: Exploded View

    10-2 WHEELS/TIRES Exploded View...
  • Page 391 WHEELS/TIRES 10-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Axle Clamp Bolt Front Axle 13.3 95.9 Rear Axle Nut 11.2 81.1 G: Apply grease. HG: Apply high-temperature grease. R: Replacement Parts WL: Apply soap and water solution or rubber lubricant.
  • Page 392: Specifications

    10-4 WHEELS/TIRES Specifications Item Standard Service Limit Wheels (Rims) Rim Runout: Axial TIR 0.5 mm (0.02 in.) or less TIR 1.0 mm (0.04 in.) Radial TIR 0.8 mm (0.03 in.) or less TIR 1.0 mm (0.04 in.) Axle Runout/100 mm TIR 0.03 mm (0.0012 in.) or less TIR 0.2 mm (0.008 in.) (3.94 in.)
  • Page 393: Special Tools

    WHEELS/TIRES 10-5 Special Tools Bearing Driver Set: Bearing Remover Head, 20 × 22: 57001-1129 57001-1293 Jack: Bearing Remover Shaft, 13: 57001-1238 57001-1377 Attachment Jack: Jack Attachment: 57001-1252 57001-1608...
  • Page 394: Wheels (rims)

    10-6 WHEELS/TIRES Wheels (Rims) Front Wheel Removal • Free the brake hose [A] from the clamp [B]. • Remove: Right Lower Fairing (see Lower Fairing Removal in the Frame chapter) Front Caliper Mounting Bolts [C] (Both Sides) Front Caliper [D] (Both Sides) Bolt [E] Front Wheel Rotation Sensor [F] •...
  • Page 395: Rear Wheel Removal

    WHEELS/TIRES 10-7 Wheels (Rims) • Apply high-temperature grease to the grease seal lips. • Fit the collars [A] on the both sides of the hub. ○ The collars are identical. • Apply a thin coat of grease [A] to the front axle [B] for rust prevention.
  • Page 396: Rear Wheel Installation

    10-8 WHEELS/TIRES Wheels (Rims) • Remove: Bolt [A] Rear Wheel Rotation Sensor [B] • Remove: Chain Cover (see Drive Chain Removal in the Final Drive chapter) Cotter Pin [A] Rear Axle Nut [B] Washer [C] Axle [D] (from Right Side) •...
  • Page 397 WHEELS/TIRES 10-9 Wheels (Rims) • Apply a thin coat of grease [A] to the rear axle [B] for rust prevention. About 10 mm (0.4 in.) [C] About 70 mm (2.8 in.) [D] NOTE ○ Do not apply grease to the threads of the axle. •...
  • Page 398: Wheel Inspection

    10-10 WHEELS/TIRES Wheels (Rims) Wheel Inspection • Raise the front/rear wheel off the ground. Special Tools - Jack: 57001-1238 Attachment Jack: 57001-1252 Jack Attachment: 57001-1608 • Spin the wheel lightly, and check for roughness or binding. If roughness or binding is found, replace the hub bearings (see Hub Bearing Removal/Installation).
  • Page 399: Balance Inspection

    WHEELS/TIRES 10-11 Wheels (Rims) Balance Inspection • Remove the front and rear wheels (see Front/Rear Wheel Removal). • Support the wheel so that it can be spun freely. • Spin the wheel lightly, and mark [A] the wheel at the top when the wheel stops.
  • Page 400 30 g (1.06 oz.) NOTE ○ Balance weights are available from Kawasaki dealers in 10, 20 and 30 grams (0.35, 0.71 and 1.06 oz.) sizes. An imbalance of less than 10 grams (0.35 oz.) will not usually affect running stability.
  • Page 401: Tires

    WHEELS/TIRES 10-13 Tires Air Pressure Inspection/Adjustment • Refer to the Air Pressure Inspection in the Periodic Main- tenance chapter. Tire Inspection • Refer to the Wheel/Tire Damage Inspection in the Peri- odic Maintenance chapter. Tire Removal • Remove: Wheels (see Front/Rear Wheel Removal) Valve Core (Let out the air) •...
  • Page 402 10-14 WHEELS/TIRES Tires • Install a new valve in the rim. ○ Remove the valve cap, lubricate the stem seal [A] with a soap and water solution or rubber lubricant, and pull [B] the valve stem through the rim from the inside out until it snaps into place.
  • Page 403: 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 404: Hub Bearing

    10-16 WHEELS/TIRES Hub Bearing Hub Bearing Removal • Remove the wheels (see Front/Rear Wheel Removal), and take out the following. Collars [A] Coupling [B] (Out of rear hub) Grease Seals [C] • Use the bearing remover to remove the hub bearings [A]. NOTICE Do not lay the wheel on the ground with the disc facing down.
  • Page 405: Hub Bearing Inspection

    WHEELS/TIRES 10-17 Hub Bearing • Replace the grease seals with new ones. • Press in the grease seals [A] so that the seal surface flush [B] with the end of the hole. ○ Apply high-temperature grease to the grease seal lips. Special Tool - Bearing Driver Set [C]: 57001-1129 Hub Bearing Inspection Since the hub bearings are made to extremely close tol-...
  • Page 407 FINAL DRIVE 11-1 Final Drive Table of Contents Exploded View........................11-2 Specifications ......................... 11-4 Special Tools .......................... 11-5 Drive Chain..........................11-6 Drive Chain Slack Inspection .................... 11-6 Drive Chain Slack Adjustment ..................11-6 Wheel Alignment Inspection/Adjustment ................11-6 Drive Chain Wear Inspection .................... 11-6 Drive Chain Lubrication.....................
  • Page 408: Exploded View

    11-2 FINAL DRIVE Exploded View...
  • Page 409 FINAL DRIVE 11-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Engine Sprocket Nut 15.0 Engine Sprocket Cover Bolts 0.71 62 in·lb Engine Sprocket Outer Cover Screws 0.31 27 in·lb Chain Guide Bolts 87 in·lb Lower Mud Guard Bolts (M6) 0.41 35 in·lb Upper Mud Guard Bolts...
  • Page 410: Specifications

    11-4 FINAL DRIVE Specifications Item Standard Service Limit Drive Chain 25 ∼ 35 mm (1.0 ∼ 1.4 in.) Drive Chain Slack – – – 317.5 ∼ 318.2 mm (12.50 ∼ Drive Chain Wear (20-link Length) 319 mm (12.6 in.) 12.53 in.) Standard Chain: Make ENUMA...
  • Page 411: Special Tools

    FINAL DRIVE 11-5 Special Tools Inside Circlip Pliers: Bearing Driver Set: 57001-143 57001-1129...
  • Page 412: Drive Chain

    11-6 FINAL DRIVE Drive Chain Drive Chain Slack Inspection • Refer to the Drive Chain Slack Inspection in the Periodic Maintenance chapter. Drive Chain Slack Adjustment • Refer to the Drive Chain Slack Adjustment in the Periodic Maintenance chapter. Wheel Alignment Inspection/Adjustment •...
  • Page 413: Drive Chain Installation

    FINAL DRIVE 11-7 Drive Chain Drive Chain Installation • Engage the drive chain on the engine sprocket. • Install: Swingarm (see Swingarm Installation in the Suspension chapter) Rear Wheel (see Rear Wheel Installation in the Wheels/Tires chapter) Engine Sprocket Cover (see Engine Sprocket Installa- tion) •...
  • Page 414 11-8 FINAL DRIVE Drive Chain • Screw the pin holder until it touches chain pin. • Be sure that the cutting pin hits center of chain pin. • Screw the handlebar [A] into body. • Turn the pin holder with wrench [B] clockwise to extract chain pin.
  • Page 415 FINAL DRIVE 11-9 Drive Chain • Turn the pin holder [A] by wrench clockwise until two pins of link come into groove of plate holders [B]. • Take off the plate holder. • Set the plate holder (B) [A] and cutting and riveting pin [B] as shown.
  • Page 416 11-10 FINAL DRIVE Drive Chain • After staking, check the staked area of the link pin for cracks. • Measure the outside diameter [A] of the link pin and link plates width [B]. Link Pin Outside Diameter 5.6 ∼ 6.0 mm (0.22 ∼ 0.24 in.) Standard: Link Plates Outside Width 19.15 ∼...
  • Page 417: Sprocket, Coupling

    FINAL DRIVE 11-11 Sprocket, Coupling Engine Sprocket Removal • Remove: Engine Sprocket Cover Bolts [A] Engine Sprocket Cover [B] • Flatten out the bended washer [A]. • Remove the engine sprocket nut [B] and washer. NOTE ○ When loosening the engine sprocket nut, hold the rear brake on.
  • Page 418: Engine Sprocket Cover Disassembly

    11-12 FINAL DRIVE Sprocket, Coupling • Install: Dowel Pins [A] • Install: Engine Sprocket Cover [A] • Tighten the engine sprocket cover bolts. ○ First tighten the two bolts [B] at the dowel pin positions. Torque - Engine Sprocket Cover Bolts: 7.0 N·m (0.71 kgf·m, 62 in·lb) Engine Sprocket Cover Disassembly •...
  • Page 419: Rear Sprocket Removal

    FINAL DRIVE 11-13 Sprocket, Coupling Rear Sprocket Removal • Remove the rear wheel (see Rear Wheel Removal in the Wheels/Tires chapter). NOTICE Do not lay the wheel on the ground with the disc facing down. This can damage or warp the disc. Place blocks under the wheel so that the disc does not touch the ground.
  • Page 420: Coupling Bearing Removal

    11-14 FINAL DRIVE Sprocket, Coupling Coupling Bearing Removal • Remove: Coupling Grease Seal Circlip [A] Special Tool - Inside Circlip Pliers: 57001-143 • Remove the bearing [A] by tapping from the wheel side. Special Tool - Bearing Driver Set [B]: 57001-1129 Coupling Bearing Installation •...
  • Page 421: Coupling Damper Inspection

    FINAL DRIVE 11-15 Sprocket, Coupling Coupling Damper Inspection • Remove the rear wheel coupling, and inspect the rubber dampers [A]. • Replace the damper if it appears damaged or deterio- rated. Sprocket Wear Inspection • Visually inspect the engine and rear sprocket teeth for wear and damage.
  • Page 423 BRAKES 12-1 Brakes Table of Contents Exploded View........................12-3 Specifications ......................... 12-8 Special Tools .......................... 12-9 Brake Lever, Brake Pedal....................... 12-10 Brake Lever Position Adjustment..................12-10 Brake Pedal Position Inspection ..................12-10 Brake Pedal Position Adjustment..................12-10 Brake Pedal Removal ....................... 12-10 Brake Pedal Installation ....................
  • Page 424 12-2 BRAKES Parts Location ........................12-26 ABS Servicing Precautions ....................12-30 ABS Troubleshooting Outline.................... 12-32 Inquiries to Rider....................... 12-35 Self-diagnosis Outline ....................... 12-37 Self-diagnosis Procedures ....................12-37 Service Code Clearing Procedures................... 12-38 How to Read Service Codes..................... 12-41 How to Erase Service Codes .................... 12-41 Yellow ABS Indicator Light (LED) Inspection ..............
  • Page 425: Exploded View

    BRAKES 12-3 Exploded View This page intentionally left blank.
  • Page 426 12-4 BRAKES Exploded View...
  • Page 427 BRAKES 12-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Brake Hose Banjo Bolts Front Brake Fluid Reservoir Cap Screws 0.15 13 in·lb Brake Lever Pivot Bolt 0.10 8.9 in·lb Brake Hose Bolts 0.82 71 in·lb Brake Lever Pivot Bolt Locknut 0.60 52 in·lb Front Wheel Rotation Sensor Bolt...
  • Page 428 12-6 BRAKES Exploded View...
  • Page 429 BRAKES 12-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Brake Pipe Joint Nuts Brake Hose Banjo Bolts Bracket Bolt 0.82 71 in·lb Brake Hose Clamp Bolt 0.82 71 in·lb Rear Master Cylinder Mounting Bolts Brake Hose Bolt 0.82 71 in·lb Brake Pedal Bolt 0.92 80 in·lb...
  • Page 430: Specifications

    12-8 BRAKES Specifications Item Standard Service Limit Brake Lever, Brake Pedal Brake Lever Position 6-way adjustable (to suit rider) – – – Brake Lever Free Play Non-adjustable – – – Pedal Free Play Non-adjustable – – – Pedal Position About 54 mm (2.1 in.) below top of footpeg –...
  • Page 431: Special Tools

    BRAKES 12-9 Special Tools Jack: Jack Attachment: 57001-1238 57001-1608 Attachment Jack: 57001-1252...
  • Page 432: Brake Lever, Brake Pedal

    12-10 BRAKES Brake Lever, Brake Pedal Brake Lever Position Adjustment The brake lever adjuster has 6 positions so that the brake lever position can be adjusted to suit the operator’s hand. • Push the lever forward and turn the adjuster [A] to align the number with the arrow mark [B] on the lever.
  • Page 433: Brake Pedal Installation

    BRAKES 12-11 Brake Lever, Brake Pedal • Remove: Cotter Pin [A] Joint Pin [B] Rear Brake Light Switch Spring [C] Return Spring [D] Brake Pedal Bolt [E] Brake Pedal [F] Brake Pedal Installation • Apply grease to the footpeg pivot shaft [A]. •...
  • Page 434: Calipers

    12-12 BRAKES Calipers Front Caliper Removal • Remove the clamp [A] (Left Side Only). • Loosen the banjo bolt [B] at the brake hose lower end, and tighten it loosely. • Remove the caliper mounting bolts [C], and detach the caliper [D] from the disc.
  • Page 435: Front Caliper Disassembly

    BRAKES 12-13 Calipers • Fit the rear brake pads [A] to the guide [B]. • Apply silicone grease to the rear caliper pin bolt. • Tighten: Torque - Caliper Mounting Bolts Front: 25 N·m (2.5 kgf·m, 18 ft·lb) Rear: 22 N·m (2.2 kgf·m, 16 ft·lb) Rear Caliper Pin Bolt: 27 N·m (2.8 kgf·m, 20 ft·lb) Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb)
  • Page 436: Caliper Fluid Seal Damage Inspection

    12-14 BRAKES 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 437: Caliper Piston And Cylinder Damage Inspection

    BRAKES 12-15 Calipers 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. Rear Caliper Holder Wear Inspection The caliper body must slide smoothly on the rear caliper pin bolt [A] and sleeve [B].
  • Page 438: Brake Pads

    12-16 BRAKES Brake Pads Front Brake Pad Removal • Remove: Pad Spring Bolts [A] Pad Spring [B] Pad Pin [C] • Remove the brake pads [A]. Front Brake Pad Installation • Push the caliper pistons in by hand as far as they will go. •...
  • Page 439: Rear Brake Pad Installation

    BRAKES 12-17 Brake Pads • Pull up the caliper, remove the pad pin [A] and brake pads [B]. Rear Brake Pad Installation • Check that the pad spring [A] and guide [B] are in place on the caliper or bracket. •...
  • Page 440: Master Cylinder

    12-18 BRAKES Master Cylinder Front Master Cylinder Removal • Remove the banjo bolt to disconnect the brake hose from the master cylinder (see Brake Hose Replacement in the Periodic Maintenance chapter). • Unscrew the clamp bolts [A], and take off the master cylin- der [B] as an assembly with the reservoir, brake lever, and brake switch installed.
  • Page 441: Rear Master Cylinder Installation

    BRAKES 12-19 Master Cylinder • Remove: Cotter Pin [A] Joint Pin [B] NOTE ○ Pull off the joint pin while pressing down the brake pedal. Rear Master Cylinder Installation • Replace the cotter pin [A] with a new one. • Insert the joint pin [B].
  • Page 442: Master Cylinder Inspection (visual Inspection)

    12-20 BRAKES Master Cylinder Master Cylinder Inspection (Visual Inspection) • Remove the master cylinders (see Front/Rear Master Cylinder Removal). • Disassemble the front and rear master cylinders (see Master Cylinder Rubber Parts Replacement in the Peri- odic Maintenance chapter). • Check that there are no scratches, rust or pitting on the inner wall [A] of each master cylinder and on the outside of each piston [B].
  • Page 443: Brake Disc

    BRAKES 12-21 Brake Disc Brake Disc Removal • Remove the wheels (see Front/Rear Wheel Removal in the Wheels/Tires chapter). • Unscrew the mounting bolts [A], and take off the disc [B]. • Remove the gaskets (Front Only). Brake Disc Installation •...
  • Page 444: Brake Fluid

    12-22 BRAKES Brake Fluid Brake Fluid Level Inspection • Refer to the Brake Fluid Level Inspection in the Periodic Maintenance chapter. Brake Fluid Change • Refer to the Brake Fluid Change in the Periodic Mainte- nance chapter. Brake Line Bleeding The brake fluid has a very low compression coefficient so that almost all the movement of the brake lever or pedal is transmitted directly to the caliper for braking action.
  • Page 445 BRAKES 12-23 Brake Fluid • Bleed the brake line and the caliper. ○ Repeat this operation until no more air can be seen com- ing out into the plastic hose. 1. Pump the brake lever until it becomes hard, and apply the brake and hold it [A].
  • Page 446 12-24 BRAKES 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 447: Brake Hose

    BRAKES 12-25 Brake Hose Brake Hose Removal/Installation • Refer to the Brake Hose Replacement in the Periodic Maintenance chapter. Brake Hose and Pipe Inspection • Refer to the Brake System Inspection in the Periodic Maintenance chapter.
  • Page 448: Anti-lock Brake System

    12-26 BRAKES Anti-Lock Brake System 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 2 [A]...
  • Page 449 BRAKES 12-27 Anti-Lock Brake System ABS Kawasaki Diagnosis System Connector [A] ABS Self-diagnosis Terminal [B]...
  • Page 450 12-28 BRAKES Anti-Lock Brake System ABS System Wiring Diagram 1. Ignition Switch 13. ABS Kawasaki Diagnosis System Connec- 2. Front Wheel Rotation Sensor 3. Front Brake Light Switch 14. ABS Self-diagnosis Terminal 4. Fuse Box 1 15. ABS Hydraulic Unit 5.
  • Page 451 2. Unused 3. Front Wheel Rotation Sensor Signal Input: BK/W 4. Power Supply: BR/W 5. ABS Kawasaki Diagnosis System Terminal: P 6. Front and Rear Brake Light Switch Signal: BL/R 7. ABS Self-Diagnosis Terminal: GY 8. Front Wheel Rotation Sensor Signal Output: G/Y 9.
  • Page 452: Abs Servicing Precautions

    12-30 BRAKES Anti-Lock Brake System 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 453 BRAKES 12-31 Anti-Lock Brake System WARNING Air in the brake lines diminish braking performance and can cause an accident resulting in injury or death. If any of the brake line fittings, including the ABS hydraulic unit joint nuts, or the bleed valve is opened at any time, the air must be bled completely from the brake line.
  • Page 454: Abs Troubleshooting Outline

    12-32 BRAKES Anti-Lock Brake System ○ The yellow ABS indicator light (LED) may come on if the engine is run with the motorcycle on its stand and the transmission in gear. If the indicator light comes on, just turn the ignition switch OFF, then clear service code 42, which indicates a “Faulty front wheel rotation sensor”.
  • Page 455 BRAKES 12-33 Anti-Lock Brake System Even when the ABS is operating normally, the yellow ABS indicator light (LED) may light up under the conditions listed below. Turn the ignition switch OFF to stop the indicator light. If the motorcycle runs without erasing the service code, the light may light up again.
  • Page 456 12-34 BRAKES Anti-Lock Brake System ABS Diagnosis Flow Chart...
  • Page 457: Inquiries To Rider

    BRAKES 12-35 Anti-Lock Brake System 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 458 12-36 BRAKES Anti-Lock Brake System Pre-Diagnosis Inspection 1...
  • Page 459: Self-diagnosis Outline

    BRAKES 12-37 Anti-Lock Brake System Pre-Diagnosis Inspection 2 Self-diagnosis Outline When the yellow ABS indicator light (LED) has blinked or come on, the ABS hydraulic unit memorizes and stores the service code (19 codes including “Normal Code”) for the service person to troubleshoot easily.
  • Page 460: Service Code Clearing Procedures

    12-38 BRAKES Anti-Lock Brake System • Remove the seat (see Seat Removal in the Frame chap- ter). • Ground the self-diagnosis terminal [A] (Gray) to the bat- tery (–) terminal, using a suitable lead. • Turn the ignition switch to ON. ○...
  • Page 461 BRAKES 12-39 Anti-Lock Brake System...
  • Page 462 12-40 BRAKES Anti-Lock Brake System Self-diagnosis Flow Chart...
  • Page 463: How To Read Service Codes

    BRAKES 12-41 Anti-Lock Brake System How to Read Service Codes ○ Service codes are shown by a series of long and short blinks of the yellow ABS indicator light (LED) as shown below. ○ Read 10th digit and unit digit as the yellow ABS indicator light (LED) blinks. ○...
  • Page 464 12-42 BRAKES Anti-Lock Brake System Service Code Table Service Light Problems Yellow ABS Indicator Light (LED) Code State After Start code (not fault) starts, turn off Rear intake solenoid valve trouble (shorted or open, stuck valve) Rear outlet solenoid valve trouble (shorted or open, stuck valve) Front intake solenoid valve trouble (shorted or open, stuck valve)
  • Page 465 BRAKES 12-43 Anti-Lock Brake System Service Light Yellow ABS Indicator Light (LED) Problems State Code Output fluid pressure sensor (front brake) trouble (offset abnormal) Power supply voltage for fluid pressure sensor abnormal (voltage abnormal, wiring shorted or open)
  • Page 466: Yellow Abs Indicator Light (led) Inspection

    12-44 BRAKES Anti-Lock Brake System Yellow ABS Indicator Light (LED) Inspection ○ In this model, the yellow ABS indicator light (LED) [A] goes on or blinks by the control of the ABS hydraulic unit. • Turn the ignition switch on. If the yellow ABS indicator light (LED) lights, it is normal.
  • Page 467: Front, Rear Wheel Rotation Difference Abnormal (service Code 25)

    BRAKES 12-45 Anti-Lock Brake System If the fuse is good, check the wiring continuity between the positive (+) terminal [A] of the battery and R/BK lead terminal [B] in the ABS Hydraulic Unit Lead Connector [C]. If the wiring is open, replace or repair the harness (see ABS System Wiring Diagram).
  • Page 468: Abs Motor Relay Inspection (service Code 35)

    12-46 BRAKES Anti-Lock Brake System ABS Motor Relay Inspection (Service Code 35) • Remove: Seat (see Seat Removal in the Frame chapter) • Check the ABS motor relay fuse (25 A) [A] (see Fuse Inspection in the Electrical System chapter). If the fuse is good, check the wiring continuity between the positive (+) terminal [A] of the battery and R/W lead terminal [B] in the ABS hydraulic unit lead connector [C].
  • Page 469: Front Wheel Rotation Sensor Wiring Inspection (service Code 43)

    BRAKES 12-47 Anti-Lock Brake System • Recheck the service code indication; erase the service code, perform the pre-diagnosis inspection 1 and 2, and retrieve the service code. If the yellow ABS indicator light (LED) [A] lights, the ABS hydraulic unit has trouble. Replace the ABS hydraulic unit.
  • Page 470: Rear Wheel Rotation Sensor Wiring Inspection (service Code 45)

    12-48 BRAKES Anti-Lock Brake System • 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 471: Power Supply Voltage Abnormal (over-voltage) (service Code 53)

    BRAKES 12-49 Anti-Lock Brake System • Recheck the service code indication; erase the service code, perform the pre-diagnosis inspection 1 and 2, and retrieve the service code. If the yellow ABS indicator light (LED) [A] lights, the ABS hydraulic unit has trouble. Replace the ABS hydraulic unit.
  • Page 472: Output Fluid Pressure Sensor (front Brake) Wiring Inspection (service Code 83)

    12-50 BRAKES Anti-Lock Brake System Output Fluid Pressure Sensor (Front Brake) Wiring Inspection (Service Code 83) ○ The Output Fluid Pressure Sensor is built in the ABS Hy- draulic Unit. Therefore the sensor cannot be checked di- rectly. • Perform the Pre-Diagnosis Inspection 1 and 2 (see In- quiries to Rider).
  • Page 473 BRAKES 12-51 Anti-Lock Brake System • Remove: Rear Fender (see Flap and Rear Fender Removal in the Frame chapter) Brake Hose Lower Ends (see Brake Hose Replacement in the Periodic maintenance chapter) • Clean the ABS hydraulic unit. NOTICE Clean all fittings on the ABS hydraulic unit and the rear master cylinder because dirt around the banjo bolts could contaminate the brake fluid in the line during removal/installation.
  • Page 474: Abs Hydraulic Unit Installation

    12-52 BRAKES Anti-Lock Brake System NOTICE The ABS hydraulic unit [A] has been adjusted and set with precision at the factory. Do not try to dis- assemble and repair the ABS hydraulic unit. ABS Hydraulic Unit Installation • Check the pad [A] are in place on the ABS hydraulic unit. •...
  • Page 475: Front Wheel Rotation Sensor Removal

    BRAKES 12-53 Anti-Lock Brake System • Visually inspect the connector terminals [A]. Replace the ABS hydraulic unit or main harness if either of the terminals are cracked, bent, or otherwise damaged. If the ABS hydraulic unit connector is clogged with mud or dust, blow it off with compressed air.
  • Page 476: Rear Wheel Rotation Sensor Removal

    12-54 BRAKES Anti-Lock Brake System Rear Wheel Rotation Sensor Removal NOTICE The wheel rotation sensor should be handled care- fully, never struck sharply, as with a hammer, or al- lowed to fall on a hard surface since the wheel rota- tion sensor is precision made.
  • Page 477: Wheel Rotation Sensor Inspection

    BRAKES 12-55 Anti-Lock Brake System Wheel Rotation Sensor Inspection • Remove the front wheel rotation sensor [A] from the front fork. • Remove the rear wheel rotation sensor [B] from the caliper bracket. • Visually inspect the wheel rotation sensors. Replace the wheel rotation sensor if it is cracked, bent, or otherwise damaged.
  • Page 478: Wheel Rotation Sensor Rotor Inspection

    12-56 BRAKES Anti-Lock Brake System 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 479: Fuse Inspection

    BRAKES 12-57 Anti-Lock Brake System Fuse Inspection • Remove the fuses (see ABS Solenoid Valve Relay Fuse (15 A)/ABS Motor Relay Fuse (25 A) Removal). • Refer to the Fuse Inspection in the Electrical System chapter.
  • Page 481 SUSPENSION 13-1 Suspension Table of Contents Exploded View........................13-2 Specifications ......................... 13-6 Special Tools .......................... 13-7 Front Fork ..........................13-9 Rebound Damping Force Adjustment (Right Front Fork Only) ......... 13-9 Spring Preload Adjustment ....................13-9 Front Fork Removal (Each Fork Leg) ................13-10 Front Fork Installation .......................
  • Page 482: Exploded View

    13-2 SUSPENSION Exploded View...
  • Page 483 SUSPENSION 13-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Upper Front Fork Clamp Bolts Front Fork Top Plugs 22.5 2.29 16.6 Lower Front Fork Clamp Bolts 20.5 2.09 15.1 Piston Rod Nuts Front Axle Clump Bolt Front Fork Bottom Allen Bolts AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque.
  • Page 484 13-4 SUSPENSION Exploded View...
  • Page 485 SUSPENSION 13-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Spring Preload Adjuster Bolts 0.82 71 in·lb Rear Shock Absorber Bolt (Upper) Swingarm Pivot Adjusting Collar Locknut 10.2 73.8 Swingarm Pivot Adjusting Collar Swingarm Pivot Shaft Nut 11.2 81.1 Tie-Rod Nut (Lower) Tie-Rod Nut (Upper) Rear Shock Absorber Nut (Lower) Rocker Arm Nut...
  • Page 486: Specifications

    Adjuster protrusion is 14 mm (0.55 in.) Fork Spring Preload Setting (Usable range: 4 ∼ 19 mm (0.16 ∼ 0.75 in.)) Suspension Oil Kawasaki KHL 15-10 or equivalent Amount: Right Front Fork Approx. 450 mL (15.2 US oz.) (when changing oil) 533 ±4 mL (18.0 ±0.14 US oz.) (after disassembly...
  • Page 487: Special Tools

    SUSPENSION 13-7 Special Tools Inside Circlip Pliers: Fork Piston Rod Puller, M10 × 1.0: 57001-143 57001-1298 Oil Seal & Bearing Remover: Fork Spring Stopper: 57001-1058 57001-1374 Bearing Driver Set: Fork Oil Seal Driver, 43: 57001-1129 57001-1530 Jack: Fork Cylinder Holder, Hex 24: 57001-1238 57001-1537 Fork Oil Level Gauge:...
  • Page 488 13-8 SUSPENSION Special Tools Fork Spring Compressor: Bar: 57001-1587 57001-1694 Swingarm Pivot Nut Wrench: Fork Spring Compressor: 57001-1597 57001-1771 Fork Oil Seal Driver Weight, 26 ∼ 46: Jack Attachment: 57001-1608 57001-1795 Fork Oil Seal Driver Attachment, 36 ∼ 46: Needle Bearing Driver, 17/ 18: 57001-1609 57001-1798 Needle Bearing Driver, 28:...
  • Page 489: Front Fork

    SUSPENSION 13-9 Front Fork Rebound Damping Force Adjustment (Right Front Fork Only) • To adjust the rebound damping force, turn the rebound damping adjuster [A] until you feel a click. ○ The standard adjuster setting is the 7 clicks from the fully clockwise position.
  • Page 490: Front Fork Removal (each Fork Leg)

    13-10 SUSPENSION Front Fork Front Fork Removal (Each Fork Leg) • Remove: Upper Fairing (see Upper Fairing Removal in the Frame chapter) Front Wheel (see Front Wheel Removal in the Wheels/Tires chapter) • Loosen the upper front fork clamp bolt [A] and lower front fork clamp bolts [B].
  • Page 491 SUSPENSION 13-11 Front Fork • Holding the top plug [A] with a wrench [B], tighten the spring preload adjuster [C]. NOTE ○ After tightening, lift the top plug to make the space. • Install the clamps [A] as shown. NOTE ○...
  • Page 492 13-12 SUSPENSION Front Fork • Insert the projection of the protector [A] into the front fork bottom hole [B]. ○ For right front fork, remove the front axle clamp bolt. • Lift up the suitable jack until the piston rod nut comes out. •...
  • Page 493 SUSPENSION 13-13 Front Fork • Hold the fork tube upright, press the outer tube [A] and the piston rod all the way down. • Pour in the type and amount of fork oil specified. Suspension Oil - KHL15-10 (1 L): 44091-0004 KHL15-10 (4 L): 44091-0013 Amount (Per Side): When changing oil (for reference):...
  • Page 494 13-14 SUSPENSION Front Fork • Screw the rod nut [A] onto the piston rod [B] as shown. 14 mm (0.55 in.) or more [C] • Screw the fork piston rod puller onto the end of the piston rod. Special Tool - Fork Piston Rod Puller, M10 × 1.0: 57001 -1298 •...
  • Page 495 SUSPENSION 13-15 Front Fork • While holding up the piston rod puller, insert the fork spring stopper between the piston rod nut and the holder. Special Tool - Fork Spring Stopper: 57001-1374 • Remove the piston rod puller. • Insert the rebound damping adjuster rod into the holes of the piston rod (Right Front Fork Only).
  • Page 496 13-16 SUSPENSION Front Fork • Insert the holder bar [A] into the axle hole of the front fork [B]. Special Tool - Bar: 57001-1694 (For Left Fork Leg) ○ Position the bar left and right and evenly. • Insert the compression shaft and install the nut. •...
  • Page 497 SUSPENSION 13-17 Front Fork • While holding up the top plug [A], insert the fork spring stopper [B] between the piston rod nut [C] and the slider. Special Tool - Fork Spring Stopper: 57001-1374 • Holding the top plug [A] with a wrench [B], loosen the piston rod nut [C].
  • Page 498 13-18 SUSPENSION Front Fork If necessary, measure the oil level as follows. ○ Hold the inner tube vertically in a vise. ○ Using the piston rod puller [A], move the piston rod [B] up and down more than ten times in order to expel all the air from the fork oil.
  • Page 499 SUSPENSION 13-19 Front Fork • Screw the fork piston rod puller onto the end of the piston rod. Special Tool - Fork Piston Rod Puller, M10 × 1.0: 57001 -1298 • Install the fork spring [A] with the smaller end [B] facing upward.
  • Page 500: Front Fork Disassembly

    13-20 SUSPENSION Front Fork • Replace the O-ring [A] on the top plug with a new one. • Apply grease to the new O-ring. • Screw in the top plug until it stops onto the piston rod. • Holding the top plug [B] with a wrench [C], tighten the piston rod nut [D] against the top plug.
  • Page 501: Front Fork Assembly

    SUSPENSION 13-21 Front Fork • Remove the inner tube guide bushing [A], outer tube guide bushing [B], washer [C], oil seal [D] from the inner tube. • Remove the piston rod nut. • Hold the inner tube lower end in a vice. •...
  • Page 502: Inner Tube, Outer Tube Inspection

    13-22 SUSPENSION Front Fork • Hold the inner tube lower end in a vice. • Insert the cylinder unit [A] into the inner tube. • Stop the cylinder unit from turning by using the fork cylin- der holder [B]. Special Tool - Fork Cylinder Holder, Hex 24: 57001-1537 •...
  • Page 503: Rear Shock Absorber

    SUSPENSION 13-23 Rear Shock Absorber Rebound Damping Force Adjustment • To adjust the rebound damping force, turn the lower damping adjuster [A] to the desired position, until you feel a click. ○ The standard adjuster setting is the 1 1/4 turns out from the fully clockwise position.
  • Page 504 13-24 SUSPENSION Rear Shock Absorber • Squeeze the brake lever slowly and hold it with a band [A]. • Loosen: Rear Shock Absorber Nut and Bolt (Lower) [A] Rear Shock Absorber Bolt (Upper) [B] • Raise the rear wheel off the ground with the jack. Special Tools - Jack Attachment [A]: 57001-1608 Jack [B]: 57001-1238 WARNING...
  • Page 505: Rear Shock Absorber Installation

    SUSPENSION 13-25 Rear Shock Absorber • Remove: Rear Shock Absorber Nut and Bolt (Lower) [A] Rear Shock Absorber Bolt (Upper) [B] • Remove the rear shock absorber [C] from rearside. • Turn up the heat insulation rubber plate. • Remove the rear shock absorber nut (upper) [A]. Rear Shock Absorber Installation •...
  • Page 506: Rear Shock Absorber Scrapping

    13-26 SUSPENSION Rear Shock Absorber Rear Shock Absorber Scrapping WARNING Since the rear shock absorber contains nitrogen gas, do not incinerate the rear shock absorber with- out first releasing the gas or it may explode. Before a rear shock absorber is scrapped, drill a hole at the point [A] shown to release the nitrogen gas com- pletely.
  • Page 507: Swingarm

    SUSPENSION 13-27 Swingarm Swingarm Removal • Remove: Muffler Body (see Muffler Body Removal in the Engine Top End chapter) Rear Wheel (see Rear Wheel Removal in the Wheels/Tires chapter) Mud Guards (see Mad Guard Removal in the Frame chapter) Rocker Arm (see Rocker Arm Removal) •...
  • Page 508 13-28 SUSPENSION Swingarm • Apply grease to the lips of the grease seals [A]. • Be sure to install the grease seals and sleeve [B] to the swingarm. • Fit the collar [C] on the grease seal of the left side. •...
  • Page 509: Swingarm Bearing Removal

    SUSPENSION 13-29 Swingarm Swingarm Bearing Removal • Remove: Swingarm (see Swingarm Removal) Collar [A] Grease Seals [B] Sleeve [C] Circlip (Right Side) [D] Special Tool - Inside Circlip Pliers: 57001-143 • Remove the ball bearing and needle bearings. Special Tool - Oil Seal & Bearing Remover [A]: 57001-1058 Swingarm Bearing Installation •...
  • Page 510: Swingarm Bearing, Sleeve Inspection

    13-30 SUSPENSION Swingarm Swingarm Bearing, Sleeve Inspection NOTICE Do not remove the bearings for inspection. Re- moval may damage them. • Inspect the needle bearings [A] and ball bearing [B] in- stalled in the swingarm. ○ The rollers and ball in a bearing normally wear very little, and wear is difficult to measure.
  • Page 511: Tie-rod, Rocker Arm

    SUSPENSION 13-31 Tie-Rod, Rocker Arm Tie-Rod Removal • Remove: Upper Mud Guard (see Upper Mud Guard Removal in the Frame chapter) • Squeeze the brake lever slowly and hold it with a band [A]. • Raise the rear wheel off the ground with the jack (see Rear Shock Absorber Removal).
  • Page 512: Rocker Arm Installation

    13-32 SUSPENSION Tie-Rod, Rocker Arm Rocker Arm Installation • Apply grease to the inside of the oil seals. • Replace the rocker arm nut, tie-rod nut (upper) and rear shock absorber nut (lower) with new ones. • Install the rocker arms so that the marked side faces left side.
  • Page 513: Tie-rod And Rocker Arm Bearing Installation

    SUSPENSION 13-33 Tie-Rod, Rocker Arm Tie-Rod and Rocker Arm Bearing Installation • Replace the needle bearing [A] and oil seals with new ones. • Install the needle bearings position as shown. ○ Screw the needle bearing driver into the driver holder. ○...
  • Page 515 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 ................... 14-9 Steering Stem Warp Inspection ..................
  • Page 516: Exploded View

    14-2 STEERING Exploded View...
  • Page 517 STEERING 14-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Handlebar Holder Bolts Left Switch Housing Screws 0.36 31 in·lb Handlebar Weight Bolts Right Switch Housing Screws 0.36 31 in·lb Upper Front Fork Clamp Bolts Steering Stem Head Bolt 11.0 79.7 Guide Bolts 0.82...
  • Page 518: Special Tools

    14-4 STEERING Special Tools Head Pipe Outer Race Press Shaft: Steering Stem Bearing Driver Adapter, 41.5: 57001-1075 57001-1345 Head Pipe Outer Race Driver, 54.5: Head Pipe Outer Race Driver, 55: 57001-1077 57001-1446 Steering Stem Bearing Driver, 42.5: Socket Wrench, 52: 57001-1344 57001-1828...
  • Page 519: 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 520: Steering Stem

    14-6 STEERING Steering Stem Stem, Stem Bearing Removal • Remove: Upper Fairing (see Upper Fairing Removal in the Frame chapter) Meter Cover (see Meter Cover Removal in the Frame chapter) Handlebars (see Handlebar Removal) Steering Stem Head Bolt Plug [A] •...
  • Page 521 STEERING 14-7 Steering Stem • Remove: Steering Stem Head Bolt [A] and Washer Steering Stem Head [B] • Bend the claws [A] of claw washer back. • Remove the steering stem locknut [B]. Special Tool - Socket Wrench, 52: 57001-1828 •...
  • Page 522: Stem, Stem Bearing Installation

    14-8 STEERING Steering Stem Stem, Stem Bearing Installation • Replace the bearing outer races with new ones. • Drive them into the head pipe at the same time. Special Tools - Head Pipe Outer Race Press Shaft [A]: 57001-1075 Head Pipe Outer Race Driver, 54.5 [B]: 57001-1077 Head Pipe Outer Race Driver,...
  • Page 523: Steering Stem Bearing Lubrication

    STEERING 14-9 Steering Stem • Install the claw washer [A] so that its bent side [B] faces upward, and engage the bent claws with the grooves of stem locknut [C]. • Hand tighten the stem locknut until the claw washer touches the steering stem nut.
  • Page 524: Stem Cap Deterioration, Damage Inspection

    14-10 STEERING Steering Stem Stem Cap Deterioration, Damage Inspection Replace the stem cap if its oil seal [A] shows damage.
  • Page 525: Handlebar

    STEERING 14-11 Handlebar Handlebar Removal • Remove: Clamp [A] Clutch Lever Holder Clamp Bolts [B] Clutch Lever Holder [C] Left Switch Housing [D] Handlebar Weight [E] Handlebar Grip [F] • Remove: Front Master Cylinder [A] (see Front Master Cylinder Re- moval in the Brakes chapter) Clamp [B] Right Switch Housing [C]...
  • Page 526: Handlebar Installation

    14-12 STEERING Handlebar • Remove: Pin [A] (Both Sides) Handlebar Holder Mounting Nut [B] (Both Sides) Washer [C] (Both Sides) Damper [D] (Both Sides) • Remove: Lower Handlebar Holder [A] Dampers [B] Handlebar Installation • Install: Dampers [A] Lower Handlebar Holder [B] •...
  • Page 527 STEERING 14-13 Handlebar • Install: Throttle Grip Throttle Cable Tips [A] Right Switch Housing ○ Fit the projection [B] into a hole [C] in the handlebars. • Tighten: Torque - Right Switch Housing Screws: 3.5 N·m (0.36 kgf·m, 31 in·lb) •...
  • Page 529 FRAME 15-1 Frame Table of Contents Exploded View........15-2 Carrier..........15-22 Seats ..........15-8 Carrier Removal......15-22 Seat Removal ......15-8 Carrier Installation......15-22 Seat Installation ......15-8 Fenders ..........15-23 Fairings..........15-9 Front Fender Removal ....15-23 Lower Fairing Removal ....15-9 Front Fender Installation ....
  • Page 530: Exploded View

    15-2 FRAME Exploded View...
  • Page 531 FRAME 15-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Fender Bolts 0.41 35 in·lb Upper Fairing Bolts 0.41 35 in·lb Fuel Tank Cover Bolts 0.50 0.05 4.4 in·lb Side Cover Bolts 0.50 0.05 4.4 in·lb Side Cover Bolts (with Collars) 0.31 27 in·lb Upper Fairing Right Cover Screws...
  • Page 532 15-4 FRAME Exploded View...
  • Page 533 FRAME 15-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Main Harness Guide Bolt 0.82 71 in·lb Rear View Mirror Locknuts (Upper) Rear View Mirror Nuts (Lower) Rear Frame Bolts Front Footpeg Bracket Bolts Bank Sensors 0.82 71 in·lb Front Footpeg Screws 0.31 27 in·lb Carrier Bolts...
  • Page 534 15-6 FRAME Exploded View...
  • Page 535 FRAME 15-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Seat Cover Bolts 0.31 27 in·lb Rear Fender Bolts (L = 12 mm) 0.82 71 in·lb Rear Flap Nut 0.82 71 in·lb Seat Lock Bolts 0.82 71 in·lb Rear Fender Bolts (L = 18 mm) 0.10 8.9 in·lb Upper Mud Guard Bolts...
  • Page 536: Seats

    15-8 FRAME Seats Seat Removal • Insert the ignition key [A] into the seat lock, turning the key clockwise, pulling up on the rear part of the seat [B], and pull the seat backward. Seat Installation • Insert the tabs [A] at the front part of the seat under the fuel tank bracket [B].
  • Page 537: Fairings

    FRAME 15-9 Fairings Lower Fairing Removal • Remove: Lower Fairing Bolts [A] Lower Fairing [B] Lower Fairing Installation • Installation is the reverse of removal. Torque - Lower Fairing Bolts (M6): 8.0 N·m (0.82 kgf·m, 71 in·lb) Lower Fairing Bolts (M5): 0.50 N·m (0.05 kgf·m, 4.4 in·lb) •...
  • Page 538: Middle Fairing Installation

    15-10 FRAME Fairings • Pull the middle fairing [A] outward to clear the projections [B]. • Disconnect the turn signal light lead connector [A], and remove the middle fairing. Middle Fairing Installation • Installation is the reverse of removal. • Be sure install the damper [A].
  • Page 539: Middle Fairing Assembly

    FRAME 15-11 Fairings • Remove: Middle Fairing Bracket Screws [A] and Washer Middle Fairing Bracket [B] Middle Fairing Assembly • Assembly is the reverse of disassembly. Torque - Middle Fairing Bracket Screws: 1.2 N·m (0.12 kgf·m, 11 in·lb) Middle Fairing Inner Cover Screws: 1.2 N·m (0.12 kgf·m, 11 in·lb) Upper Fairing Removal •...
  • Page 540: Upper Fairing Installation

    15-12 FRAME Fairings • Disconnect the headlight lead connector [A] on both sides. • Remove (Both Sides): Quick Rivets [B] Upper Fairing Bolt [C] • Pull the upper fairing [A] forward to clear the projections [B] of the upper fairing from the grommets [C] of the upper fairing bracket.
  • Page 541: Upper Fairing Disassembly

    FRAME 15-13 Fairings Upper Fairing Disassembly • Remove: Upper Fairing (see Upper Fairing Removal) • Open the Clamps [A]. • Remove: Headlight Screws [B] Headlight Bolts [C] Headlight Unit [D] Upper Fairing Disassembly • Assembly is the reverse of disassembly. Torque - Headlight Screws: 1.2 N·m (0.12 kgf·m, 11 in·lb) Headlight Bolts: 8.0 N·m (0.82 kgf·m, 71 in·lb) Fuel Tank Cover Removal...
  • Page 542: Fuel Tank Cover Installation

    15-14 FRAME Fairings • Clear the hooks [A] of fuel tank cover [B] outward while pushing them. • Pull the fuel tank cover [A] outward to clear the projections [B]. • Remove the fuel tank cover. Fuel Tank Cover Installation •...
  • Page 543: Meter Cover Removal

    FRAME 15-15 Fairings • Insert the hooks [A] of the fuel tank cover into the slots of the upper fairing while pushing them. • Tighten: Torque - Fuel Tank Cover Bolt: 0.50 N·m (0.05 kgf·m, 4.4 in·lb) Meter Cover Removal •...
  • Page 544: Meter Cover Installation

    15-16 FRAME Fairings Meter Cover Installation • Fit the projection [A] of the socket cover [B] in the groove [C] of the meter cover. • Install the bracket [D] and tighten the socket cover screw [E]. Torque - Socket Cover Screw: 1.2 N·m (0.12 kgf·m, 11 in·lb) •...
  • Page 545: Windshield Installation

    FRAME 15-17 Fairings • Remove: Windshield Adjuster Knob Bolts [A] and Washers Adjusting Nuts [B], Plate, Bolts and Washers Windshield Assembly [C] • Remove: Bolts [A] Washers [B] Brackets [C] with Wellnuts Windshield [D] Windshield Installation • Installation is reverse of removal. •...
  • Page 546: Upper Fairing Bracket Removal

    15-18 FRAME Fairings Upper Fairing Bracket Removal • Remove: Upper Fairing (see Upper fairing Removal) Meter Cover (see Meter Cover Removal) Coolant Reserve Tank (see Coolant Change in the Peri- odic Maintenance chapter) Regulator/Rectifier (see Regulator/Rectifier Removal in the Electrical System chapter) Bands [A] •...
  • Page 547: Side Covers

    FRAME 15-19 Side Covers Side Cover Removal • Remove: Seat (see Seat Removal) Upper Fairing (see Upper Fairing Removal) Bolts [A], Collars and Washers Bolts [B] and Washers • Pull the side cover [C] outward to clear the projections [D]. Side Cover Installation •...
  • Page 548: Seat Covers

    15-20 FRAME Seat Covers Seat Cover Removal Tabs [A] Hooks [B] Slots [C] Damper [D] • Remove: Seat (see Seat Removal) Carrier (see Carrier Removal) Seat Cover Bolts [A] and Washers • Clear the tabs [B] of the seat cover [C] from the slots of the rear fender on both sides.
  • Page 549: Seat Cover Installation

    FRAME 15-21 Seat Covers Seat Cover Installation • Check that the damper [A] is in place on the rear brake light. • Insert the hooks [B] of the seat cover into the tabs [C] of the rear fender. • Insert the tabs [A] of the seat cover into the slots [B] of rear fender on both sides.
  • Page 550: Carrier

    15-22 FRAME Carrier Carrier Removal • Remove: Seat (see Seat Removal) Grab Rail Bolts [A] and Collars Carrier Assembly [B] • Remove: Carrier Bolts [A] and Washers Carrier [B] Grab Rail Assemblies [C] • Remove: Grab Rail Stay Bolts [A] Rear Grab Rail [B] Front Grab Rail [C] Carrier Installation...
  • Page 551: Fenders

    Starter Relay [C] Fuse Box 1 [D] Fuse Box 2 [E] Bracket [F] Rear Brake Reservoir Bracket Bolt [G] Rear Fender Bolts (L = 12 mm) [H] Immobilizer (Equipped Models)/Kawasaki Diagnostic System Connector [I] • Remove the clamps [A]. • Disconnect:...
  • Page 552: Flap And Rear Fender Installation

    15-24 FRAME Fenders • Pull up [A] front side of the rear fender [B], remove the rear fender rearward [C]. • Remove: Pad [A] Rear Flap Nut [B] Plate [C] with Pad Rear Flap Bolt [D] Flap [E] Flap and Rear Fender Installation •...
  • Page 553: Frame

    FRAME 15-25 Frame Frame Inspection • Visually inspect the frame for cracks, dents, bending, or warp. ○ If there is any damage to the frame, replace it. WARNING A repaired frame may fail in use, possibly causing an accident resulting in injury or death. If the frame is bent, dented, cracked, or warped, replace it.
  • Page 554: Rear Footpeg Bracket Installation

    15-26 FRAME Frame Rear Footpeg Bracket Installation • Installation is the reverse of removal. • Apply a non-permanent locking agent to the thread of the rear footpeg bracket bolt (lower). • Replace the rear footpeg bracket nuts with new ones. •...
  • Page 555: Guard

    FRAME 15-27 Guard Upper Mud Guard Removal • Remove: Right Front Footpeg Bracket Bolts [A] • Remove: Quick Rivets [A] • Remove: Upper Mud Guard Bolt [A] • Remove: Quick Rivet [A] Upper Mud Guard Bolts [B] Upper Mud Guard [C] Upper Mud Guard Installation •...
  • Page 556: Lower Mud Guard Removal

    15-28 FRAME Guard Lower Mud Guard Removal • Remove: Upper Mud Guard (see Upper Mud Guard Removal) Lower Mud Guard Bolts [A] Lower Mud Guard [B] Lower Mud Guard Installation • Installation is the reverse of removal. • Apply a non-permanent locking agent to the thread of the lower mud guard bolts (M6) [A].
  • Page 557: Side Stand, Center Stand

    FRAME 15-29 Side Stand, Center Stand Side Stand Removal • Raise the rear wheel off the ground with the stand. • Remove: Side Stand Switch Bolt [A] Nut [B] Side Stand Switch [C] • Remove: Spring [A] Side Stand Nut [B] Side Stand Bolt [C] Side Stand [D] Side Stand Installation...
  • Page 558: Center Stand Installation (other Than Cn Model)

    15-30 FRAME Side Stand, Center Stand • Remove: Center Stand Bracket Bolts [A] Center Stand Nuts [B] Collars [C] Bolts [D] Center Stand Brackets [E] Damper [F] Center Stand [G] Center Stand Installation (Other than CN Model) • Apply grease to the sliding area [A] of the center stand [B].
  • Page 559: Rear View Mirrors

    FRAME 15-31 Rear View Mirrors Rear View Mirror Removal • Slide the dust cover [A]. • Loosen the rear view mirror locknut (upper) [B], and re- move the rear view mirror stay [C] from the rear view mir- ror nut (lower) [D]. ○...
  • Page 561 ELECTRICAL SYSTEM 16-1 Electrical System Table of Contents Exploded View........16-4 Electric Starter System ...... 16-50 Specifications ........16-10 Starter Motor Removal....16-50 Special Tools and Sealant ....16-11 Starter Motor Installation....16-50 Parts Location........16-13 Starter Motor Disassembly... 16-51 Wiring Diagram (US, CA and CAL Starter Motor Assembly ....
  • Page 562 16-2 ELECTRICAL SYSTEM Immobilizer System Inspection ..16-103 Outside Temperature Sensor Switches and Sensors ....... 16-105 Inspection........16-108 Brake Light Timing Inspection..16-105 Fuel Level Sensor Inspection..16-108 Brake Light Timing Adjustment ..16-105 Relay Box .......... 16-109 Switch Inspection ......16-105 Relay Box Removal/Installation ...
  • Page 563 ELECTRICAL SYSTEM 16-3 This page intentionally left blank.
  • Page 564: Exploded View

    16-4 ELECTRICAL SYSTEM Exploded View...
  • Page 565 ELECTRICAL SYSTEM 16-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Meter Unit Mounting Screws 0.12 11 in·lb Meter Assembly Screws 0.12 11 in·lb Front Turn Signal Light Mounting Screws 0.12 11 in·lb Headlight Screws 0.12 11 in·lb Left Switch Housing Screws 0.36 31 in·lb Right Switch Housing Screw...
  • Page 566 16-6 ELECTRICAL SYSTEM Exploded View...
  • Page 567 ELECTRICAL SYSTEM 16-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Outside Temperature Sensor Screw 0.31 27 in·ib Spark Plugs 115 in·lb Crankshaft Sensor Cover Bolts 106 in·lb Water Temperature Sensor 106 in·lb Timing Rotor Bolt Crankshaft Sensor Bolts 0.60 52 in·lb Starter Motor Cable Terminal Nut 0.60...
  • Page 568 16-8 ELECTRICAL SYSTEM Exploded View...
  • Page 569 ELECTRICAL SYSTEM 16-9 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Frame Ground Bolts 0.82 71 in·lb Connector Bracket Bolt 0.82 71 in·lb Engine Ground Cable Terminal Bolt 87 in·lb ECU Bracket Screws 0.41 35 in·lb Regulator/Rectifier Bracket Bolts 0.70 61 in·lb Horn Bolt 0.82...
  • Page 570: Specifications

    16-10 ELECTRICAL SYSTEM Specifications Item Standard Battery Type Sealed Battery Model Name YTX9-BS Capacity 12 V 8 Ah (10 HR) Voltage 12.8 V or more Gross Weight 2.9 kg (6.4 lb) Electrolyte Volume 0.40 L (24 cu in.) Charging System Type Three-phase AC Alternator Output Voltage...
  • Page 571: Special Tools And Sealant

    ELECTRICAL SYSTEM 16-11 Special Tools and Sealant Peak Voltage Adapter: Flywheel & Pulley Holder: 57001-1415 57001-1605 Lead Wire - Peak Voltage Adapter: Flywheel Puller Assembly, M38 × 1.5/M35 × 1.5: 57001-1449 57001-1615 Needle Adapter Set: Stopper: 57001-1457 57001-1679 Key Registration Unit: Rotor Holder: 57001-1582 57001-1690...
  • Page 572 16-12 ELECTRICAL SYSTEM Special Tools and Sealant Rotor Holder: Liquid Gasket, TB1211F: 57001-1757 92104-0004...
  • Page 573: Parts Location

    ELECTRICAL SYSTEM 16-13 Parts Location Timing Rotor [A] Crankshaft Sensor [B] Oxygen Sensor [C] Horn [A] Outside Temperature Sensor [B] Regulator/Rectifier [A] Turn Signal Relay [B] Immobilizer Amplifier (Immobilizer Equipped Models) [C] Rear Brake Light Switch [A] Radiator Fan Motor [A] Water Temperature Sensor [B] Starter Motor [C] Alternator [D]...
  • Page 574 16-14 ELECTRICAL SYSTEM Parts Location Oil Pressure Switch [A] Neutral Switch [B] Side Stand Switch [C] Fuse Box 1 [A] Fuse Box 2 [B] Starter Relay [C] Battery 12 V 10 Ah [D] Relay Box [E] ECU [F] Air Switching Valve [A] Stick Coils [B] Spark Plugs [C] Meter Unit [A]...
  • Page 575 ELECTRICAL SYSTEM 16-15 Parts Location This page intentionally left blank.
  • Page 576: Wiring Diagram (us, Ca And Cal Models)

    16-16 ELECTRICAL SYSTEM Wiring Diagram (US, CA and CAL Models)
  • Page 577 ELECTRICAL SYSTEM 16-17 Wiring Diagram (US, CA and CAL Models)
  • Page 578: Wiring Diagram (other Than Us, Ca, Cal And Br Models)

    16-18 ELECTRICAL SYSTEM Wiring Diagram (Other than US, CA, CAL and BR Models)
  • Page 579 ELECTRICAL SYSTEM 16-19 Wiring Diagram (Other than US, CA, CAL and BR Models)
  • Page 580: Wiring Diagram (br Model)

    16-20 ELECTRICAL SYSTEM Wiring Diagram (BR Model)
  • Page 581 ELECTRICAL SYSTEM 16-21 Wiring Diagram (BR Model)
  • Page 582: Precautions

    16-22 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 583: Electrical Wiring

    ELECTRICAL SYSTEM 16-23 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 584: Battery

    16-24 ELECTRICAL SYSTEM Battery Battery Removal • Turn the ignition switch off. • Remove: Seat (see Seat Removal in the Frame chapter) • Disconnect the negative (–) cable [A]. NOTICE Be sure to disconnect the negative (–) cable first. • Slide out the positive (+) terminal cap [B] and disconnect the positive (+) cable [C].
  • Page 585 ELECTRICAL SYSTEM 16-25 Battery NOTICE Do not remove the aluminum sealing sheet [A] from the filler ports [B] until just prior to use. Be sure to use the dedicated electrolyte container for correct electrolyte volume. DANGER Sulfuric acid in battery electrolyte can cause severe burns.
  • Page 586 16-26 ELECTRICAL SYSTEM Battery • Check the electrolyte flow. If no air bubbles [A] are coming up from the filler ports, or if the container cells have not emptied completely, tap the container [B] a few times. NOTE ○ Be careful not to have the battery fall down. •...
  • Page 587: 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 588: Interchange

    16-28 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 589 ELECTRICAL SYSTEM 16-29 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 590: Charging System

    16-30 ELECTRICAL SYSTEM Charging System Alternator Cover Removal • Drain: Engine Oil (see Engine Oil Change in the Periodic Main- tenance chapter) • Remove: Left Side Cover (see Side Cover Removal in the Frame chapter) Left Lower Fairing (see Lower Fairing Removal in the Frame chapter) •...
  • Page 591: Stator Coil Removal

    ELECTRIC