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Table of Contents

   Summary of Contents for KAWASAKI ER-5

  • Page 3 Quick Reference Guide General Information Fuel System Cooling System Engine Top End Clutch Engine Lubrication System Engine Removal/Installation Crankshaft/Transmission Wheels/Tires Final Drive 10 j Brakes 11 j Suspension 12 j Steering 13 j Frame 14 j Electrical System 15 j Appendix 16 j This quick reference guide will assist...
  • Page 5 All information contained in this publication is based on the latest product information available at the time of publication. Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts. © 2000 Kawasaki Heavy Industries, Ltd. 4th Edition (1): Aug. 5, 2004 (K)
  • Page 6 LIST OF ABBREVIATIONS ampere(s) pound(s) ABDC after bottom dead center meter(s) alternating current minute(s) ATDC after top dead center newton(s) BBDC before bottom dead center pascal(s) bottom dead center horsepower BTDC before top dead center pound(s) per square inch °C degree(s) Celsius revolution direct current...
  • Page 7: Emission Control Information

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

    GENERAL INFORMATION 1-1 General Information Table of Contents Before Servicing ........................Model Identification......................... General Specifications......................Periodic Maintenance Chart ....................Torque and Locking Agent...................... 1-11 Special Tools and Sealants ....................1-16 Cable, Wire, and Hose Routing ....................1-23...
  • 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 GENERAL INFORMATION 1-3 Before Servicing (10)Liquid Gasket, Locking Agent Clean and prepare surfaces where liquid gasket or non-permanent locking agent will be used. Apply them sparingly. Excessive amount may block engine oil passages and cause serious dam- age. (11) Press When using a press or driver to install a part such as a wheel bearing, apply a small amount of oil to the area where the two parts come in contact to ensure a smooth fit.
  • Page 14 1-4 GENERAL INFORMATION Before Servicing Two-Color Electrical (19)Inspection When parts have been disassembled, visually inspect these parts for the following conditions or other damage. If there is any doubt as to the condition of them, replace them with new ones. Abrasion Crack Hardening...
  • Page 15: Model Identification

    GENERAL INFORMATION 1-5 Model Identification ER500-C1, D1 Left Side View ER500-C1, D1 Right Side View...
  • Page 16: General Specifications

    1-6 GENERAL INFORMATION General Specifications Items EN500-C1 EN500-C3 EN500-D1 Dimensions Overall Length 2 070 mm (81.5 in.) ← ← Overall Width 730 mm (28.74 in.) ← ← Overall Height 1 070 mm (42.13 in.) ← ← Wheelbase 1 430 mm (56.3 in.) ←...
  • Page 17 GENERAL INFORMATION 1-7 General Specifications Items EN500-C1 EN500-C3 EN500-D1 Lubrication System Forced lubrication ← ← Engine Oil: Grade API SE, SF, SG or ← ← API SH or SJ with JASO MA Viscosity SAE10W-40 ← ← Capacity 3.4 L (3.6 us at) ←...
  • Page 18 1-8 GENERAL INFORMATION General Specifications Items EN500-C1 EN500-C3 EN500-D1 Electrical Equipment Battery 12 V 10 Ah ← ← Headlight: Type Semi-sealed beam ← ← Bulb 12 V 60/55 W (quartz-halogen) ← ← Tail/brake Light 12 V 5/21 W × 2 ←...
  • Page 19: Periodic Maintenance Chart

    GENERAL INFORMATION 1-9 Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition. The initial maintenance is vitally important and must not be neglected. FREQUENCY Whichever * ODOMETER READING comes ×...
  • Page 20 1-10 GENERAL INFORMATION Periodic Maintenance Chart FREQUENCY Whichever * ODOMETER READING comes × 1 000 km first (× 1 000 mile) Remarks INSPECTION Every (0.6) (4) (7.5) (12) (15) (20) (24) • • • • • • • Engine oil - change # year •...
  • Page 21: Torque And Locking Agent

    GENERAL INFORMATION 1-11 Torque and Locking Agent Tighten all bolts and nuts to the proper torque using an accurate torque wrench. An insufficiently tightened bolt or nut may become damaged or fall off, possibly resulting in damage to the motorcycle and injury to the rider.
  • Page 22 1-12 GENERAL INFORMATION Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Water Pipe Bolts 87 in·lb Cylinder Head Jacket Plug 87 in·lb Air Suction Valve Cover Bolts 95 in·lb Coolant Drain Plug 95 in·lb Engine Top End Spark Plugs Cylinder Head Cover Bolts 87 in·lb Camshaft Cap Bolts...
  • Page 23 GENERAL INFORMATION 1-13 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Engine Oil Drain Plug Oil Pan Mounting Bolts 95 in·lb Oil Pump Mounting Bolts 95 in·lb Breather Body Bolt 52 in·lb Engine Removal/Installation Downtube Bolts Engine Mounting Bolts and Nuts Engine Mounting Bracket Bolts Crankshaft/Transmission Crankcase Bolts (8 mm)
  • Page 24 1-14 GENERAL INFORMATION Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Front Brake Light Switch Mounting Screw 0.12 10 in·lb Caliper Mounting Bolts Caliper Bleed Valves 69 in·lb Brake Disc Mounting Bolts Brake Pedal Bolt 78 in·lb Torque Link Nuts Brake Cam Lever Bolt 13.5 Suspension...
  • Page 25 GENERAL INFORMATION 1-15 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Starter Clutch Allen Bolts Sidestand Switch Mounting Screw 35 in·lb Sidestand Mounting Bolt Starter Motor Terminal Locknut 0.70 61 in·lb Starter Relay Terminal Bolt 0.50 43 in·lb Headlight Body Screws 0.30 26 in·lb...
  • Page 26: Special Tools And Sealants

    1-16 GENERAL INFORMATION Special Tools and Sealants Piston Ring Pliers: Inside Circlip Pliers: 57001-115 57001-143 Oil Pressure Gauge, 5 kgf/cm²: Outside Circlip Pliers: 57001-125 57001-144 Bearing Puller: Bearing Puller: 57001-135 57001-158 Bearing Puller Adapter: Fork Cylinder Holder Handle: 57001-136 57001-183 Steering Stem Bearing Driver: Compression Gauge, 20 kgf/cm²: 57001-137...
  • Page 27 GENERAL INFORMATION 1-17 Special Tools and Sealants Valve Spring Compressor Assembly: Valve Guide Arbor, 5.5: 57001-241 57001-1021 Bearing Puller Adapter: Spark Plug Wrench, Hex 18: 57001-317 57001-1024 Bearing Driver, Fork Cylinder Holder Adapter: 57001-382 57001-1057 Piston Pin Puller Assembly: Oil Seal & Bearing Remover: 57001-910 57001-1058 Fuel Level Gauge:...
  • Page 28 1-18 GENERAL INFORMATION Special Tools and Sealants Bead Breaker Assembly: Piston Ring Compressor Grip: 57001-1072 57001-1095 Steering Stem Bearing Driver Adapter, 34.5: Piston Ring Compressor Belt, 67 57001-1074 57001-1097 Head Pipe Outer Race Press Shaft: Steering Stem Nut Wrench: 57001-1075 57001-1100 Head Pipe Outer Race Driver, 51.5: Head Pipe Outer Race Driver, 46.5:...
  • Page 29 GENERAL INFORMATION 1-19 Special Tools and Sealants Valve Seat Cutter, 32° - 25: Bearing Driver Set: 57001-1118 57001-1129 Valve Seat Cutter, 32° - 30: Compression Gauge Adapter, M12 × 1.25: 57001-1120 57001-1183 Valve Seat Cutter, 60° - 30: Valve Seat Cutter, 45° - 30: 57001-1123 57001-1187 Valve Seat Cutter Holder, 5.5:...
  • Page 30 1-20 GENERAL INFORMATION Special Tools and Sealants Rotor Puller, M16/M18/M20/M22 × 1.5: Clutch Holder: 57001-1216 57001-1243 Fork Outer Tube Weight: Oil Filter Wrench: 57001-1218 57001-1249 Front Fork Oil Seal Driver: Bearing Remover Head, 15 × 17: 57001-1219 57001-1267 Jack: Carburetor Drain Plug Wrench, Hex 3: 57001-1238 57001-1269 Fork Oil Level Gauge:...
  • Page 31 GENERAL INFORMATION 1-21 Special Tools and Sealants Valve Seat Cutter, 60° - 25: Harness Adapter #1: 57001-1328 57001-1381 Pilot Screw Adjuster Adapter, 5: Hand Tester: 57001-1372 57001-1394 Pilot Screw Adjuster Driver: Flywheel Holder: 57001-1373 57001-1410 Bearing Remover Shaft, 13: Peak Voltage Adapter: 57001-1377 57001-1415 Igniter Checker Assembly:...
  • Page 32 1-22 GENERAL INFORMATION Special Tools and Sealants Kawasaki Bond (Silicone Sealant): Kawasaki Bond (Liquid Gasket - Black) TB1105: 56019-120 92104-1003...
  • Page 33: Cable, Wire, And Hose Routing

    GENERAL INFORMATION 1-23 Cable, Wire, and Hose Routing 1. Vacuum Hose 2. Air Hose 3. Fuel Hose 4. Throttle and Choke Cables 5. Fuel Filters 6. Fuel Tap 7. To the air suction valve. 8. To the vacuum switch valve. 9.
  • Page 34 1-24 GENERAL INFORMATION Cable, Wire, and Hose Routing 1. Throttle Cables 12. Run the ignition switch lead behind and 2. Choke Cable then under the choke cable and above 3. Right Handlebar Switch Leads the clutch cable into the right hole of the 4.
  • Page 35 GENERAL INFORMATION 1-25 Cable, Wire, and Hose Routing 1. Handlebar Switch Harness 15. Starter Relay 2. Main Harness 16. Bands 3. Radiator Fan Switch 17. Run the leads inside the cross pipe. 4. Alternator Connector 18. Run the harness inside the frame. 5.
  • Page 36 1-26 GENERAL INFORMATION Cable, Wire, and Hose Routing 1. Radiator 12. Face the white mark upward and to the 2. Thermostat Housing radiator. 3. Coolant Filter 13. Face the head of the clamp screw up- 4. Carburetor ward. 5. Reserve Tank 14.
  • Page 37 GENERAL INFORMATION 1-27 Cable, Wire, and Hose Routing 1. Reserve Tank 2. Reserve Tank Overflow Hose 3. Clamps...
  • Page 38 1-28 GENERAL INFORMATION Cable, Wire, and Hose Routing 1. Starter Motor 2. Positive Lead 3. Negative Lead 4. Plate 5. Pickup Coil 6. Pickup Coil Mounting Bolts 7. Tighten the starter motor negative lead terminal with the rear starter mounting bolt. 8.
  • Page 39 GENERAL INFORMATION 1-29 Cable, Wire, and Hose Routing 1. #1 Ignition Coil Connectors 9. Radiator Fan Connector 2. Radiator Fan Switch Connector 10. White Tape (position here) 3. Left Handlebar Switch Connectors 11. Right Handlebar Switch Connectors 4. Water Temperature Switch Ground Termi- 12.
  • Page 40 1-30 GENERAL INFORMATION Cable, Wire, and Hose Routing 1. Fuel Tank 10. Bind the edge of the hose bend 2. Fuel Tank Upper Drain Hose 11. About 70 mm 3. Catch Tank 12. Frame Corner 4. Reserve Tank Hose 13. Clips 5.
  • Page 41 FUEL SYSTEM 2-1 Fuel System Table of Contents Exploded View........................Specifications ......................... Throttle Grip and Cables ......................Throttle Cable Inspection ....................Throttle Cable Lubrication....................Choke Cable........................... Free Play Inspection ......................Free Play Adjustment......................Cable Installation ......................Cable Lubrication ......................Carburetors..........................Idle Speed Inspection .......................
  • Page 42: Exploded View

    2-2 FUEL SYSTEM Exploded View 1. Throttle Cable (accelerator) 2. Throttle Cable (decelerator) 3. Choke Cable 4. Pilot Screw 5. Pilot (Slow) Jet 6. Needle Jet 7. Needle Jet Holder 8. Main Jet 9. Jet Needle CL: Apply cable lubricant. G: Apply grease.
  • Page 43 FUEL SYSTEM 2-3 Exploded View 1. Vacuum Switch Valve 2. Air Cleaner Housing 3. Air Cleaner Element T1: 0.8 N·m (0.08 kgf·m, 7 in·lb) T2: 1.0 N·m (0.10 kgf·m, 9 in·lb) T3: 6.9 N·m (0.7 kgf·m, 61 in·lb) T4: 2.5 N·m (0.25 kgf·m, 22 in·lb)
  • Page 44: Specifications

    2-4 FUEL SYSTEM Specifications Item Standard Throttle Grip Free Play 3 mm (0.08 0.12 in.) Choke Cable Free Play 3 mm (0.08 0.12 in.) Carburetors Mark, Type KEIHIN CVK34 Idle Speed 1 200 ±50 r/min (rpm) Pilot Screw (Turns Out) (1 1/4 ±1/4 for reference) 2.7 kPa (2 cmHg) or less difference between two Synchronization Vacuum...
  • Page 45: Throttle Grip And Cables

    FUEL SYSTEM 2-5 Throttle Grip and Cables Throttle Cable Inspection Throttle Grip Free Play Inspection • Check throttle grip play [A] by lightly turning the throttle grip back and forth. If the free play is improper, adjust the throttle cable. Throttle Grip Free Play Standard: 3 mm (0.08...
  • Page 46: Throttle Cable Lubrication

    2-6 FUEL SYSTEM Throttle Grip and Cables • Check that the throttle pulley [A] stops against the idle adjusting screw [B], with the throttle grip released and stops against the carburetor stopper with the throttle grip opened. • Turn the handlebar from side to side while idling the en- gine.
  • Page 47: Choke Cable

    FUEL SYSTEM 2-7 Choke Cable Free Play Inspection • Push the choke lever [A] all the way to the front. • Check choke cable free play [B]. ○ Determine the amount of choke cable play at the choke lever. Pull the choke lever until the starter plunger lever [C] at the carburetor touches the starter plunger [D];...
  • Page 48: Carburetors

    2-8 FUEL SYSTEM Carburetors Idle Speed Inspection Idle Speed Inspection • Start the engine and warm it up thoroughly. • With the engine idling, turn the handlebar to both sides. If handlebar movement changes the idle speed, the throt- tle cable may be improperly adjusted or incorrectly routed, or it may be damaged.
  • Page 49: Carburetor Removal

    FUEL SYSTEM 2-9 Carburetors Carburetor Removal WARNING Gasoline is extremely flammable and can be ex- plosive under certain conditions. Turn the ignition switch OFF. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks;...
  • Page 50: Service Fuel Level Inspection

    2-10 FUEL SYSTEM Carburetors • Install the holder clamps [A] as shown being careful of the screw position and the screw head [B] direction. WARNING Install the clamp screws horizontally as shown. Otherwise the screws could come in contact with the vacuum adjusting screws, resulting in an un- safe riding condition.
  • Page 51: Service Fuel Level Adjustment

    FUEL SYSTEM 2-11 Carburetors • Connect fuel level gauge [A] to the rubber hose. Special Tool - Fuel Level Gauge: 57001-1017 • Hold the gauge vertically against the side of the carburetor body so that the "middle" line [B] is several millimeters higher than the bottom edge [D] of the carburetor body.
  • Page 52: Fuel System Cleanliness Inspection

    2-12 FUEL SYSTEM Carburetors • Bend the tang [A] on the float arm very slightly to change the float height. Increasing the float height lowers the fuel level and decreasing the float height raises the fuel level. Float Height 17.0 ±2.0 mm (0.67 ±0.08 in.) NOTE ○...
  • Page 53 FUEL SYSTEM 2-13 Carburetors • Turn in the pilot screw and count the number of turns until it seats fully but not tightly, and then remove the screw. This is to set the screw to its original position when as- sembling.
  • Page 54: Carburetor Separation/assembly

    2-14 FUEL SYSTEM Carburetors • Slip the jet needle through the hole in the center of the vacuum piston, and put the spring seat [A] on the top of the needle. Turn the seat so that it does not block the hole [B] at the bottom of the vacuum piston.
  • Page 55: Carburetor Inspection

    FUEL SYSTEM 2-15 Carburetors CAUTION Do not use compressed air on an assembled car- buretor, or the floats may be crushed by the pres- sure, and the vacuum piston diaphragms may be damaged. Remove as many rubber or plastic parts from the carburetor as possible before cleaning the carburetor with a cleaning solution.
  • Page 56: Coolant Filter Cleaning

    2-16 FUEL SYSTEM Carburetors • Disassemble the carburetors. • Clean the carburetors. • Check that the O-rings on the float bowl and drain plug and the diaphragm on the vacuum piston are in good con- dition. If any of the O-rings or diaphragms are not in good con- dition, replace them.
  • Page 57: Air Cleaner

    FUEL SYSTEM 2-17 Air Cleaner Element Removal • Remove: Left Side Cover (see Frame chapter) Screws [A] Nut [B] Inlet Pipe [C] • Remove the element [A]. • Push a clean, lint-free towel into the carburetor intake to keep dirt or other foreign material from entering. WARNING If dirt or dust is allowed to pass through into the carburetor, the throttle may become stuck, possibly...
  • Page 58: Air Cleaner Draining

    2-18 FUEL SYSTEM Air Cleaner Air Cleaner Draining A drain hose [A] is provided beneath the air cleaner hos- ing, and catches the water or oil from the bottom of the hose. Usually water or oil does not collect at the bottom of the hose.
  • Page 59: Fuel Tank

    FUEL SYSTEM 2-19 Fuel Tank Fuel Tank Removal WARNING Gasoline is extremely flammable and can be ex- plosive under certain conditions. Turn the ignition switch OFF. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks;...
  • Page 60: Fuel Tank Installation

    2-20 FUEL SYSTEM Fuel Tank • Remove the fuel tank [A]. • Drain the fuel tank. ○ Place a suitable container under the fuel tank. ○ Turn the fuel tap to the PRI position to drain the fuel into the container. Fuel Tank Installation •...
  • Page 61: Fuel Tank And Tap Cleaning

    FUEL SYSTEM 2-21 Fuel Tank Fuel Tank and Tap Cleaning • Remove the fuel tank and drain it. • Pour some high flash-point solvent into the fuel tank and shake the tank to remove dirt and fuel deposits. WARNING Clean the tank in a well-ventilated area, and take care that there are no sparks or flame anywhere near the working area;...
  • Page 62: Fuel Hose

    2-22 FUEL SYSTEM Fuel Hose Fuel Hose and Connection Inspection ○ Check the fuel hose periodically in accordance with the Periodic Maintenance Chart, and if the motorcycle is not properly handled, the inside the fuel line can cause fuel to leak [A] or the hose to burst. Remove the fuel tank and check the fuel hose.
  • Page 63 COOLING SYSTEM 3-1 Cooling System Table of Contents Exploded View........................Specifications ......................... Coolant Flow Chart......................... Coolant ........................... Coolant Deterioration Inspection..................Coolant Level Inspection....................Coolant Draining ....................... Coolant Filling ........................Visual Leak Inspection ...................... Cooling System Pressure Testing ..................Flushing ..........................Coolant Filter Cleaning .....................
  • Page 64: Exploded View

    3-2 COOLING SYSTEM Exploded View 1. Radiator Fan Switch 2. Water Temperature Switch 3. Thermostat 4. Coolant Drain Plug T1: 2.5 N·m (0.25 kgf·m, 22 in·lb) T2: 7.8 N·m (0.8 kgf·m, 69 in·lb) T3: 11 N·m (1.1 kgf·m, 95 in·lb) T4: 9.8 N·m (1.0 kgf·m, 7.0 ft·lb) T5: 18 N·m (1.8 kgf·m, 13.0 ft·lb) T6: 25 N·m (2.5 kgf·m, 18.0 ft·lb)
  • Page 65: Specifications

    123 kPa (0.95 1.25 kgf/cm², 14 18 psi) Thermostat Valve Opening Temperature 80.5 83.5°C (177 182°F) Valve Full Opening Lift 8 mm (0.31 in.) or more @95°C (203°F) Special Tool - Bearing Driver Set: 57001-1129 Sealant - Kawasaki Bond (Silicone Sealant): 56019-120...
  • Page 66: Coolant Flow Chart

    3-4 COOLING SYSTEM Coolant Flow Chart Permanent type antifreeze is used as a coolant to protect the cooling system from rust and corrosion. When the engine starts, the water pump turns and the coolant circulates. The thermostat is a wax pellet type which opens or closes with coolant temperature changes. The thermostat continuously changes its valve opening to keep the coolant temperature at the proper level.
  • Page 67: Coolant

    COOLING SYSTEM 3-5 Coolant Coolant Deterioration Inspection • Visually inspect the coolant in the reservoir tank. ○ If whitish cotton-like wafts are observed, aluminum parts in the cooling system are corroded. If the coolant is brown, iron or steel parts are rusting. In either case flush the cooling system.
  • Page 68: Coolant Filling

    3-6 COOLING SYSTEM Coolant Coolant Filling • Install the drain plug [A]. Always replace the gasket with a new one, if it is damaged. • Tighten the drain plug. Torque - Coolant Drain Plug: 11 N·m (1.1 kgf·m, 95 in·lb) •...
  • Page 69: Visual Leak Inspection

    COOLING SYSTEM 3-7 Coolant • Remove the reserve tank cap. • Fill the reserve tank up to the F level [A] with coolant and install the cap. CAUTION Do not add more coolant above the F level. • Install the fuel tank. •...
  • Page 70: Flushing

    3-8 COOLING SYSTEM Coolant 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 passages and considerably reduce the effi- ciency of the cooling system.
  • Page 71: Water Pump

    Apply silicone sealant to the area [A] where the mating surface of the crankcase contacts the water pump hous- ing gasket. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 • Apply high temperature grease to the lips of the water pump housing oil seal.
  • Page 72: Mechanical Seal Inspection

    3-10 COOLING SYSTEM Water Pump • Be sure to install the water pipe O-rings [A], and apply high temperature grease to them. • Install the water pump cover with the water pipe, being careful of the two knock pins [B]. Torque - Water Pump Cover Bolts: 11 N·m (1.1 kgf·m, 95 in·lb) Mechanical Seal Inspection...
  • Page 73: Impeller Assembly

    COOLING SYSTEM 3-11 Water Pump Impeller Assembly • Clean the sliding surface of the mechanical seal with a high flash-point solvent, and apply a little coolant to the sliding surface to give the mechanical seal initial lubrica- tion. • Apply coolant to the surfaces of the rubber seal [A] and sealing seat [B], and install the rubber seal and sealing seat into the impeller by pressing them by hand until the seat stops at the bottom of the hole.
  • Page 74: Radiator, Radiator Fan

    3-12 COOLING SYSTEM Radiator, Radiator Fan WARNING The radiator fan is connected directly to the bat- tery. The radiator fan may start even if the ignition switch is off. NEVER TOUCH THE RADIATOR FAN UNTIL THE RADIATOR FAN CONNECTOR IS DIS- CONNECTED.
  • Page 75: Filler Neck Inspection

    COOLING SYSTEM 3-13 Radiator, Radiator Fan CAUTION When cleaning the radiator with steam cleaner, be careful of the following to prevent radiator damage. 1) Keep the steam gun [A] away more than 0.5 m (20 in.) [B] from the radiator core. 2) Hold the steam gun perpendicular to the core sur- face.
  • Page 76: Radiator Hose And Connection Inspection

    3-14 COOLING SYSTEM Radiator, Radiator Fan Radiator Hose and Connection Inspection ○ The high pressure inside the radiator hose can cause coolant to leak [A] or the hose to burst if the line is not properly maintained. Visually inspect the hoses for signs of deterioration.
  • Page 77: Thermostat

    COOLING SYSTEM 3-15 Thermostat Thermostat Removal • Remove: Coolant (Draining) Seat (see Frame chapter) Fuel Tank (see Fuel System chapter) • Unscrew the thermostat housing bolts [A]. • Separate the housing from the housing cover [B]. • Pull out the thermostat [A]. Thermostat Installation •...
  • Page 78: Radiator Fan Switch, Water Temperature Switch

    Radiator Fan Switch, Water Temperature Switch Installation • Apply silicone sealant to the threads before mounting the water temperature switch. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 ○ Do not apply silicone sealant to the radiator fan switch on the radiator. •...
  • Page 79 ENGINE TOP END 4-1 Engine Top End Table of Contents Exploded View........Main Oil Pipe Removal ....4-14 Specifications ........Main Oil Pipe Installation ..... 4-14 Clean Air System....... Cylinder Head........4-15 Vacuum Switch Valve Removal ... Compression Measurement..4-15 Vacuum Switch Valve Installation Cylinder Head Removal ....
  • Page 80: Exploded View

    4-2 ENGINE TOP END Exploded View 1. Closed coil end faces downward. 2. Arrow points to the front (ER500-C1 C4). Install the piston so that the circle mark on the top of the piston come to front side of the engine (ER500-C5).
  • Page 81 ENGINE TOP END 4-3 Exploded View T1: 13 N·m (1.3 kgf·m, 9.5 ft·lb) T2: 9.8 N·m (1.0 kgf·m, 87 in·lb) T3: 11 N·m (1.1 kgf·m, 95 in·lb) T4: 12 N·m (1.2 kgf·m, 8.5 ft·lb) T5: 15 N·m (1.5 kgf·m, 11.0 ft·lb) T6: 20 N·m (2.0 kgf·m, 14.5 ft·lb) T7: 25 N·m (2.5 kgf·m, 18.0 ft·lb) T8: 39 N·m (4.0 kgf·m, 29 ft·lb)
  • Page 82: Specifications

    4-4 ENGINE TOP END Specifications Item Standard Service Limit Clean Air System Vacuum Switch Valve Closing Open → Close – – – Pressure 65 kPa (430 490 mmHg) Camshafts Cam Height: Exhaust 35.475 35.591 mm (1.3967 1.4012 in.) 35.38 mm (1.3929 in.) Inlet 35.474 35.590 mm (1.3966 1.4012 in.) 35.37 mm (1.3925 in.) Camshaft, Camshaft Cap...
  • Page 83 Valve Seat Cutter, 45° - 24.5: 57001-1113 Valve Seat Cutter, 32° - 25: 57001-1118 Valve Seat Cutter, 60° - 25: 57001-1328 Piton Pin Puller Assembly: 57001-910 Piston Ring Compressor Grip: 57001-1095 Piston Ring Compressor Belt, 67 79: 57001-1097 Sealant - Kawasaki Bond (Silicone Sealant): 56019-120...
  • Page 84: Clean Air System

    4-6 ENGINE TOP END Clean Air System Vacuum Switch Valve Removal • Remove: Fuel Tank (see Fuel System chapter) • Remove the clamps [A] and take off the vacuum switch valve [B]. Vacuum Switch Valve Installation • Install the vacuum switch valve so that the air hole [A] faces downwards.
  • Page 85: Clean Air System Hose Inspection

    ENGINE TOP END 4-7 Clean Air System Clean Air System Hose Inspection • Be certain that all the hoses are routed without being flat- tened or kinked, and are connected correctly to the air cleaner housing, silencer, vacuum switch valve, carbure- tors, and air suction valve covers.
  • Page 86: Cylinder Head Cover

    • Be sure to install the knock pins [C]. • Apply silicone sealant [D] as shown. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 • Tighten the cover bolts [E]. Torque - Cylinder Head Cover Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)
  • Page 87: Camshaft Chain Tensioner

    ENGINE TOP END 4-9 Camshaft Chain Tensioner Camshaft Chain Tensioner Removal CAUTION This is a non-return type cam chain tensioner. The push rod does not return to its original position once it moves out to take up cam chain slack. Ob- serve all the rules listed below: When removing the tensioner, do not take out the mounting bolts only halfway.
  • Page 88: Camshaft, Camshaft Chain

    4-10 ENGINE TOP END Camshaft, Camshaft Chain Camshaft Removal • Remove the cylinder head cover. • Position the crankshaft at #2 piston TDC. ○ Using a wrench on the crankshaft rotation bolt turn the crankshaft clockwise until the "C" mark line [A] on the rotor is aligned with the notch [B] in the edge of the upper hole in the alternator cover.
  • Page 89: Camshaft And Sprocket Assembly

    ENGINE TOP END 4-11 Camshaft, Camshaft Chain • Engage the camshaft chain with the camshaft sprockets. ○ Pull the tension side [A] (inlet side) of the chain taut to install the chain. ○ The timing marks [B] on the inlet sprocket [C] must be aligned with the cylinder head upper surface [D].
  • Page 90: Camshaft, Camshaft Cap Wear

    4-12 ENGINE TOP END Camshaft, Camshaft Chain Camshaft, Camshaft Cap Wear The journal wear is measured using plastigage (press gauge), which is inserted into the clearance to be mea- sured. The plastigage indicates the clearance by the amount it is compressed and widened when the parts are assembled.
  • Page 91: Rocker Shaft, Rocker Arm

    ENGINE TOP END 4-13 Rocker Shaft, Rocker Arm Rocker Shaft, Rocker Arm Removal • Remove the camshafts (see Camshaft Removal). • Unscrew the rocker shafts [A] and remove the rocker arms [B] and springs [C]. ○ Mark and record the rocker arm locations so that the rocker arm can be reinstalled in their original positions.
  • Page 92: Oil Pipe

    4-14 ENGINE TOP END Oil Pipe Cylinder Head Oil Pipe Removal • Remove the oil pipe mounting bolts [A] and pull the oil pipes [B] and O-rings out of the cylinder head. Cylinder Head Oil Pipe Installation • Flush out the oil pipes with a high flash-point solvent. •...
  • Page 93: Cylinder Head

    ENGINE TOP END 4-15 Cylinder Head Compression Measurement • Remove the seat (see Frame chapter). • Thoroughly warm up the engine so that the engine oil be- tween the piston and cylinder wall will help seal compres- sion as it does during normal running. •...
  • Page 94: Cylinder Head Removal

    4-16 ENGINE TOP END Cylinder Head Cylinder Head Removal • Remove: Cylinder Head Cover (see Cylinder Head Cover Re- moval) Exhaust Pipes and Mufflers (see Crankshaft/Transmis- sion chapter) Cam Chain Tensioner (see Chain Tensioner Removal) Camshafts (see Camshaft Removal) Carburetors (see Fuel System chapter) •...
  • Page 95: Cylinder Head Warp

    ENGINE TOP END 4-17 Cylinder Head • Install a new cylinder head gasket with "UP" [A] marked side positioning to the right. NOTE ○ The camshaft caps are machined with the cylinder head so if a new cylinder head is installed, use the caps that are supplied with the new head.
  • Page 96 4-18 ENGINE TOP END Cylinder Head • Using compressed air, blow out any particles which may obstruct the oil passage [A] in the cylinder head. • Install the valves (see Valve Installation).
  • Page 97: Valves

    ENGINE TOP END 4-19 Valves Valve Clearance Inspection Valve Clearance Inspection NOTE ○ Valve clearance must be checked and adjusted when the engine is cold (room temperature). • Remove the cylinder head cover (see Cylinder Head Cover Removal). • Remove the cylinder head oil pipes (see Cylinder Head Oil Pipe Removal).
  • Page 98: Valve Removal

    4-20 ENGINE TOP END Valves • Measure the clearance of each valve by inserting a thick- ness gauge [A] between the adjusting screw [B] and the valve stem. Valve Clearance (when cold) Inlet 0.13 0.18 mm (0.0051 0.0071 in.) Exhaust 0.18 0.23 mm (0.0070 0.0090 in.)
  • Page 99: Valve Guide Removal

    ENGINE TOP END 4-21 Valves Valve Guide Removal • Remove: Valve (see Valve Removal) Oil Seal Spring Seats • Heat the area around the valve guide to about 120 150°C (248 302°F), and hammer lightly on the valve guide arbor [A] to remove the guide from the top of the head.
  • Page 100: Measuring Valve-to-guide Clearance (wobble Method)

    4-22 ENGINE TOP END Valves If the width is too wide, too narrow or uneven, repair the seat (see Valve Seat Repair). [F] Good [G] Too Wide [H] Too Narrow [J] Uneven Valve Seating Surface Width Inlet 1.0 mm (0.020 0.039 in.) Exhaust 1.0 mm (0.020...
  • Page 101 ENGINE TOP END 4-23 Valves Seat Cutter Operating Cares 1. This valve seat cutter is developed to grind the valve for repair. Therefore the cutter must not be used for other purposes than seat repair. 2. Do not drop or shock the valve seat cutter, or the dia- mond particles may fall off.
  • Page 102 4-24 ENGINE TOP END Valves • Measure the outside diameter (O.D.) of the seating sur- face with a vernier caliper. If the outside diameter of the seating surface is too small, repeat the 45° grind [A] until the diameter is within the specified range.
  • Page 103 ENGINE TOP END 4-25 Valves • Lap the valve to the seat, once the seat width and O.D. 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 104 4-26 ENGINE TOP END Valves...
  • Page 105: Cylinder, Piston

    ENGINE TOP END 4-27 Cylinder, Piston Cylinder Removal • Remove the cylinder head (see Cylinder Head Removal). • Remove the main oil pipe mounting bolt. • Remove the bolts [A] and pull out the water pipe with wa- ter pump cover [B] (see Cooling System chapter). •...
  • Page 106: Piston Installation

    4-28 ENGINE TOP END Cylinder, Piston Piston Installation • Install the oil ring expander [A] in the piston oil ring groove so that the expander ends [B] butt together, never overlap. • Install the upper and lower steel rails. There is no UP or Down to the rails.
  • Page 107: Piston Ring, Piston Ring Groove Wear

    ENGINE TOP END 4-29 Cylinder, Piston Piston Ring, Piston Ring Groove Wear • Check for uneven groove wear by inspecting the ring seat- ing. The rings should fit perfectly parallel to the groove sur- faces. If not, the piston must be replaced. •...
  • Page 108: Piston Diameter

    4-30 ENGINE TOP END Cylinder, Piston Piston Diameter • Measure the outside diameter [A] of each piston 5 mm [B] up from the bottom of the piston at a right angle to the direction of the piston pin. If the measurement is under the service limit, replace the piston.
  • Page 109: Carburetor Holder

    ENGINE TOP END 4-31 Carburetor Holder Carburetor Holder Installation • Install the carburetor holders. The projection [A] faces upwards. • Install the holder clamps [A] as shown being careful of the screw position and the screw head [B] direction. WARNING Install the clamp screws horizontally.
  • Page 110: Muffler

    4-32 ENGINE TOP END Muffler Muffler Removal • Unscrew the muffler mounting bolt and nut [A]. • Remove the exhaust pipe holder nuts [A]. • Take off the muffler [A]. Muffler Installation • Replace the exhaust pipe holder gaskets with new ones. •...
  • Page 111 CLUTCH 5-1 Clutch Table of Contents Exploded View........................Specifications ......................... Clutch Lever and Cable ......................Clutch Adjustment......................Clutch Lever Installation....................Cable Lubrication ......................Right Engine Cover ........................ Clutch Cover Removal ...................... Clutch Cover Installation ....................Clutch Release Removal ....................Clutch Release Installation ....................Clutch .............................
  • Page 112: Exploded View

    5-2 CLUTCH Exploded View 1. Starter Lockout Switch CL: Apply cable lubricant. G: Apply high temperature grease. M: Apply molybdenum disulfide grease. O: Apply engine oil. SS: Apply silicone sealant.
  • Page 113 CLUTCH 5-3 Exploded View T1: 1.5 N·m (0.15 kgf·m, 13 in·lb) T2: 9.3 N·m (0.95 kgf·m, 82 in·lb) T3: 11 N·m (1.1 kgf·m, 95 in·lb) T4: 132 N·m (13.5 kgf·m, 98 ft·lb)
  • Page 114: Specifications

    Friction and Steel Plate Warp 0.2 mm (0.008 in.) or less 0.3 mm (0.012 in.) Clutch Spring Free Length 34.2 mm (1.346 in.) 33.1 mm (1.303 in.) Special Tool - Clutch Holder: 57001-1243 Sealant - Kawasaki Bond (Silicone Sealant): 56019-120...
  • Page 115: Clutch Lever And Cable

    CLUTCH 5-5 Clutch Lever and Cable Due to friction plate wear and clutch cable stretch over a long period of use, the clutch must be adjusted in accor- dance with the Periodic Maintenance Chart. WARNING To avoid a serious burn, never touch the engine or exhaust pipe during clutch adjustment.
  • Page 116: Cable Lubrication

    5-6 CLUTCH Clutch Lever and Cable Cable Lubrication Whenever the clutch cable is removed, lubricate the clutch cable as follows. • Apply a thin coating of grease to the cable upper and lower ends. • Lubricate the cable with a penetrating rust inhibitor.
  • Page 117: Right Engine Cover

    • Apply silicone sealant to the area [A] where the mating surface of the crankcase touches the clutch cover gasket. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 • Install the knock pins [B], and replace the cover gasket with a new one.
  • Page 118: Clutch Release Installation

    5-8 CLUTCH Right Engine Cover • Free the clutch inner cable tip from the clutch release lever [A]. • Turn the release lever toward the rear [B] as shown in the figure. • Pull the lever and shaft assembly out of the clutch cover. Clutch Release Installation CAUTION Always install a new oil seal when the clutch release...
  • Page 119: Clutch Removal

    CLUTCH 5-9 Clutch Clutch Removal • Drain the engine oil (see Engine Lubrication System chapter). • Remove the clutch cover (see Clutch Cover Removal). • Remove the clutch spring bolts [A], washers [B] and springs. • Remove the clutch spring plate [C] with the thrust ball bearing [D] and pusher [E].
  • Page 120: Clutch Plate Wear, Damage Inspection

    5-10 CLUTCH Clutch ○ The grooves [A] on the friction plate surfaces are cut tan- gentially and radially, install the friction plates so that the grooves run toward the center in the direction of the clutch housing rotation (counterclockwise viewed from the en- gine right side).
  • Page 121: Clutch Spring Free Length Measurement

    CLUTCH 5-11 Clutch Clutch Spring Free Length Measurement • Measure the free length of the clutch spring [A]. If any spring is shorter than the service limit, it must be replaced. Clutch Spring Free Length Standard: 34.2 mm (1.346 in.) Service Limit: 33.1 mm (1.303 in.) Clutch Housing Finger Inspection...
  • Page 123 ENGINE LUBRICATION SYSTEM 6-1 Engine Lubrication System Table of Contents Exploded View........................Engine Oil Flow Chart......................Specifications ......................... Engine Oil and Oil Filter......................Engine Oil Level Inspection ....................Engine Oil Change......................Oil Filter Replacement ...................... Oil Pan and Relief Valve......................Oil Pan Removal .......................
  • Page 124: Exploded View

    6-2 ENGINE LUBRICATION SYSTEM Exploded View 1. Oil Filter 2. Main Oil Passage Plug 3. Oil Pump Drive Gear 4. Oil Pump 5. Oil Screen 6. Oil Pressure Relief Valve 7. Oil Pressure Switch 8. Engine Oil Drain Plug...
  • Page 125 ENGINE LUBRICATION SYSTEM 6-3 Exploded View T1: 1.5 N·m (0.15 kgf·m, 13 in·lb) G: Apply high temperature grease. T2: 7.8 N·m (0.80 kgf·m, 69 in·lb) L: Apply a non-permanent locking agent. T3: 11 N·m (1.1 kgf·m, 95 in·lb) O: Apply engine oil. T4: 12 N·m (1.2 kgf·m, 8.5 ft·lb) R: Replacement Parts.
  • Page 126: Engine Oil Flow Chart

    6-4 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart...
  • Page 127: Specifications

    Oil pressure @4 000 r/min (rpm), oil 335 kPa (2.8 3.4 kgf/cm², 40 48 psi) temperature 90°C (194°F) Special Tools - Oil Pressure Gauge, 5 kgf/cm²: 57001-125 Oil Pressure Gauge Adapter, M14 × 1.5: 57001-1209 Oil Filter Wrench: 57001-1249 Sealant - Kawasaki Bond (Silicone Sealant): 56019-120...
  • Page 128: Engine Oil And Oil Filter

    6-6 ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter WARNING Motorcycle operation with insufficient, deteri- orated, or contaminated engine oil will cause accelerated wear and may result in engine or trans- mission seizure, accident, and injury. Engine Oil Level Inspection •...
  • Page 129: Oil Filter Replacement

    ENGINE LUBRICATION SYSTEM 6-7 Engine Oil and Oil Filter • Fill the engine with a good quality motor oil specified in the table. • Check the oil level. Engine Oil Grade: API SE, SF, SG or API SH or SJ with JASO MA Viscosity: SAE 10W40 Capacity:...
  • Page 130: Oil Pan And Relief Valve

    6-8 ENGINE LUBRICATION SYSTEM Oil Pan and Relief Valve Oil Pan Removal • Drain the engine oil (see Engine Oil Change). • Disconnect the oil pressure switch lead. • Remove the oil pan mounting bolts [A] and the oil pan from the crankcase.
  • Page 131: Relief Valve Inspection

    ENGINE LUBRICATION SYSTEM 6-9 Oil Pan and Relief Valve Relief Valve Inspection • Remove the relief valve. • Check to see if the steel ball inside the valve slides smoothly when pushing it in with a wooden or other soft rod, and see if it comes back to its seat by valve spring pressure.
  • Page 132: Oil Pump

    6-10 ENGINE LUBRICATION SYSTEM Oil Pump Oil Pump Removal • Drain the coolant (see Cooling System chapter). • Drain the engine oil (see Engine Oil Change). • Remove the engine (see Engine Removal/Installation chapter). • Remove: Water Pump (see Cooling System chapter) Clutch Cover (see Clutch chapter) Alternator Cover with Gear Change Link and Pedal (see Electrical System chapter)
  • Page 133: Oil Pump Disassembly

    ENGINE LUBRICATION SYSTEM 6-11 Oil Pump • Be sure to install the oil pump and outer oil pipe O-rings [A], and apply engine oil to them. • Install the oil pump outer oil pipe [B] and oil screen. ○ Apply a non-permanent locking agent to the oil pipe bolt and tighten it.
  • Page 134: Oil Pressure Measurement

    6-12 ENGINE LUBRICATION SYSTEM Oil Pressure Measurement Oil Pressure Measurement NOTE ○ Measure the oil pressure after the engine is warmed up. • Remove: Right Footpeg Assembly Oil Passage Plug WARNING If the oil passage plug is removed while the engine is warm, hot engine oil will drain through the oil pas- sage;...
  • Page 135 ENGINE REMOVAL/INSTALLATION 7-1 Engine Removal/Installation Table of Contents Exploded View........................Engine Removal/Installation ....................Engine Removal........................ Engine Installation......................
  • Page 136: Exploded View

    7-2 ENGINE REMOVAL/INSTALLATION Exploded View T1: 44 N·m (4.5 kgf·m, 33 ft·lb) T2: 25 N·m (2.5 kgf·m, 18 ft·lb)
  • Page 137: Engine Removal/installation

    ENGINE REMOVAL/INSTALLATION 7-3 Engine Removal/Installation Engine Removal • Set the motorcycle up on its center stand. • Squeeze the brake lever slowly and hold it with a band [A]. WARNING Be sure to hold the front brake when removing the engine, or the motorcycle may fall over.
  • Page 138: Engine Installation

    7-4 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Remove: Battery Negative Lead [A] Starter Motor Lead [B] • Remove: Oil Pressure Switch Lead [A] Neutral Switch Lead [B] Sidestand Switch Lead Connector [C] • Support the engine with a stand or jack [A]. •...
  • Page 139 ENGINE REMOVAL/INSTALLATION 7-5 Engine Removal/Installation • Insert the rear mounting bolts from the left side of the engine. • Tighten the rear engine upper mounting bolt and nut first to eliminate the gap between the engine and frame bracket, and then the rear engine lower mounting bolt and nut.
  • Page 141 CRANKSHAFT/TRANSMISSION 8-1 Crankshaft/Transmission Table of Contents Exploded View........................Specifications ......................... Crankcase Splitting......................... Crankcase Splitting ......................Crankcase Assembly ......................Clutch Housing/Primary Chain ....................8-10 Clutch Housing/Primary Chain Removal................8-10 Clutch Housing/Primary Chain Installation................ 8-10 Primary Chain Guide Wear ....................8-10 Crankshaft/Connecting Rods....................8-11 Crankshaft Removal ......................
  • Page 142: Exploded View

    8-2 CRANKSHAFT/TRANSMISSION Exploded View 1. 8 mm Bolt (55 mm l.) 2. 6 mm Bolts (60 mm l.) 3. 6 mm Bolts (80 mm l.) 4. 6 mm Bolts (40 mm l.) 5. 8 mm Bolts (80 mm l.) 6. 8 mm Bolts (40 mm l.) 7.
  • Page 143 CRANKSHAFT/TRANSMISSION 8-3 Exploded View G: Apply high temperature grease. L: Apply a non-permanent locking agent. LG: Apply liquid gasket-black. M: Apply a thin coat of molybdenum disulfide grease. O: Apply engine oil. S: Follow the specific tightening sequence. SS: Apply silicone sealant. WL: Apply soap water solution or rubber lubricant.
  • Page 144: Specifications

    8-4 CRANKSHAFT/TRANSMISSION Specifications Item Standard Service Limit Crankshaft, Connecting Rods Connecting Rod Bend – – – 0.2/100 mm (0.0079/4 in.) Connecting Rod Twist – – – 0.2/100 mm 0.0079/4 in.) Connecting Rod Big End Side 0.13 0.38 mm (0.0051 0.0150 in.) 0.50 mm Clearance (0.02 in.)
  • Page 145 CRANKSHAFT/TRANSMISSION 8-5 Specifications Item Standard Service Limit Crankshaft Main Bearing Insert Thickness: Brown 1.490 1.494 mm (0.0587 0.0588 in.) – – – Black 1.494 1.498 mm (0.0588 0.0590 in.) – – – Blue 1.498 1.502 mm (0.0590 0.0591 in.) – – – Crankshaft main bearing insert selection: Crankcase Bearing Insert*...
  • Page 146 *: The bearing inserts for Nos. 2 and 3 journals have oil grooves. Special Tools - Outside Circlip Pliers: 57001-144 Bearing Driver, 32: 57001-382 Bearing Puller: 57001-135 Bearing Puller Adapter: 57001-317 Sealant - Kawasaki Bond (Liquid Gasket - Black) TB1105: 92104-1003...
  • Page 147: Crankcase Splitting

    CRANKSHAFT/TRANSMISSION 8-7 Crankcase Splitting Crankcase Splitting • Remove the engine (see Engine Removal/Installation chapter). • Set the engine on a clean surface and hold the engine steady while parts are being removed. • Remove: Shift Lever (see External Shift Mechanism Removal) Starter Motor (see Electrical System chapter) Water Pump (see Cooling System chapter) Clutch Cover (see Clutch chapter)
  • Page 148: Crankcase Splitting

    • Apply liquid gasket to the mating surface of the lower crankcase half. Sealant - Kawasaki Bond (Liquid Gasket - Black) TB1105: 92104-1003 CAUTION Do not apply liquid gasket [A] around the crankshaft main bearing inserts and balancer shaft inserts.
  • Page 149 CRANKSHAFT/TRANSMISSION 8-9 Crankcase Splitting • Tighten the lower crankcase-half bolts using the following 3 steps: ○ Tighten all lower crankcase-half bolts to a snug fit. Following the sequence numbers on the lower crankcase half, torque the 8 mm bolts first to about one half of the specification, and finally to the specification in the same sequence.
  • Page 150: Clutch Housing/primary Chain

    8-10 CRANKSHAFT/TRANSMISSION Clutch Housing/Primary Chain Clutch Housing/Primary Chain Removal • Remove the engine. • Remove: Cylinder Head, Cylinder and Pistons (see Engine Top End chapter) Starter Clutch Sprocket (see Electrical System chapter) Clutch (except the Clutch Housing) • Split the crankcase. •...
  • Page 151: Crankshaft/connecting Rods

    CRANKSHAFT/TRANSMISSION 8-11 Crankshaft/Connecting Rods Crankshaft Removal • Split the crankcase (see Crankcase Splitting). • Remove the clutch housing and the primary chain. • Remove the crankshaft with the camshaft chain and pri- mary chain. Crankshaft Installation CAUTION If the crankshaft, bearing inserts or crankcase halves are replaced with new ones, select the bear- ing inserts and check clearance with plastigage before assembling engine to be sure the correct...
  • Page 152: Crankshaft/connecting Rod Cleaning

    8-12 CRANKSHAFT/TRANSMISSION Crankshaft/Connecting Rods Big End Cap [A] Connecting Rod [B] Weight Mark, Alphabet [C] Diameter Mark [D] • Apply engine oil to the inner surface of the upper and lower bearing inserts [A]. • Apply a small amount of engine oil to the threads [B] and seating surface [C] of the connecting rod big end cap nuts.
  • Page 153: Connecting Rod Big End Side Clearance

    CRANKSHAFT/TRANSMISSION 8-13 Crankshaft/Connecting Rods • Measure the connecting rod twist. ○ With the big-end arbor [A] still on V blocks [C], hold the connecting rod horizontal and measure the difference in the height of the arbor [B] above the surface plate over a 100 mm (4 in.) length of the arbor to determine the amount of connecting rod twist.
  • Page 154 8-14 CRANKSHAFT/TRANSMISSION Crankshaft/Connecting Rods If the clearance is within the standard, no bearing insert replacement is required. If the clearance is between 0.066 mm and the service limit (0.10 mm, 0.0039 in.), replace the bearing inserts [A] with inserts painted blue [B] Check insert/crankpin clearance with a plastigage.
  • Page 155: Crankshaft Runout

    CRANKSHAFT/TRANSMISSION 8-15 Crankshaft/Connecting Rods • Select the proper bearing insert in accordance with the combination of the connecting rod and crankshaft coding. • Install the new insert in the connecting rod and check in- sert/journal clearance with a plastigage. Connecting Rod Big End Bearing Insert Selection Bearing Insert Con-rod Bore Crankpin...
  • Page 156 8-16 CRANKSHAFT/TRANSMISSION Crankshaft/Connecting Rods If the clearance is within the standard, no bearing insert replacement is required. If the clearance is between 0.044 mm and the service limit (0.08 mm), replace the bearing inserts [A] with in- serts painted blue [B] Check insert/journal clearance with a plastigage.
  • Page 157: Crankshaft Side Clearance

    CRANKSHAFT/TRANSMISSION 8-17 Crankshaft/Connecting Rods Crankshaft Main Bearing Insert Selection Crankcase Main Crankshaft Main Bearing Insert* Bearing Bore Journal Diameter Size Color Part Number Journal Nos Diameter Mark Mark 92028-1102 2, 3 ○ Brown 92028-1274 1, 4 92028-1100 2, 3 None None Blue 92028-1272...
  • Page 158: Balancer

    8-18 CRANKSHAFT/TRANSMISSION Balancer Balancer Removal • Split the crankcase (see Crankcase Splitting). • Pull the balancer shaft with the balancer gear out of the crankcase. Balancer Installation • Apply oil to the inside of the balancer shaft bearing insert. • Align the timing mark [A] on the balancer gear [B] with the timing mark on the balancer drive gear [C] of the crank- shaft.
  • Page 159 CRANKSHAFT/TRANSMISSION 8-19 Balancer If either journal has worn past the service limit, replace the balancer shaft with a new one. If the measured journal diameters are not less than the service limit, but do not coincide with the original diameter markings on the balancer shaft, write new marks on it.
  • Page 160: Transmission

    8-20 CRANKSHAFT/TRANSMISSION Transmission External Shift Mechanism Removal • Remove: Engine Sprocket (see Final Drive chapter) Chain Guard [A] Neutral Switch Lead Connector [B] • Place an oil pan beneath the external shift mechanism cover [A]. • Remove the external shift mechanism cover bolts [B]. •...
  • Page 161: External Shift Mechanism Inspection

    CRANKSHAFT/TRANSMISSION 8-21 Transmission • Apply high temperature grease to the seal lips. • Insert the shift shaft into the cover [A], and then fit the shift mechanism arm [B] to the shift drum [C]. • Tighten the cover bolts. Torque - External Shift Mechanism Cover Bolts: 11 N·m (1.1 kgf·m.
  • Page 162: Transmission Shaft Installation

    8-22 CRANKSHAFT/TRANSMISSION Transmission Transmission Shaft Installation • With a high flash-point solvent, clean off the outer cir- cumferences of the transmission ball bearings and needle bearings, and their bearing housings, and wipe dry. • Check to see that the set rings [A] and set pins [B] are in place in the transmission bearing housings.
  • Page 163: Drive Shaft Assembly

    CRANKSHAFT/TRANSMISSION 8-23 Transmission Drive Shaft Assembly • Apply engine oil liberally to the drive shaft, gears, bear- ings and bushing. • Install the drive shaft ball bearing using the bearing driver [A]. Special Tool - Bearing Driver, 32: 57001-382 • Replace any circlips that were removed with new ones.
  • Page 164: Output Shaft Assembly

    8-24 CRANKSHAFT/TRANSMISSION Transmission Output Shaft Assembly • Assembly is the reverse of disassembly. Note the follow- ing. • Apply engine oil liberally to the output shaft, gears, bear- ings, bushing and O-ring. • Install the output shaft ball bearing, O-ring and collar us- ing the bearing driver.
  • Page 165: Shift Drum And Fork Removal

    CRANKSHAFT/TRANSMISSION 8-25 Transmission • The output shaft gears can be identified by size: the largest diameter gear is 1st gear, and the smallest is 6th. Be sure that all parts are put back in the correct sequence and facing the proper direction, and that all circlips and washers are properly in place.
  • Page 166: Shift Drum And Fork Installation

    8-26 CRANKSHAFT/TRANSMISSION Transmission Shift Drum and Fork Installation • Insert the shift drum [A] into the crankcase part way, install the 3rd/4th shift fork [B] with the longer side [C] facing the neutral switch, i.e., the longer side goes onto the drum first.
  • Page 167: Shift Drum Disassembly

    CRANKSHAFT/TRANSMISSION 8-27 Transmission Shift Drum Disassembly • Remove the screw [A] and the pin plate [B]. • Pull out the shift drum cam [C]. • Take off the ball bearing [D]. • Pull off the dowel pin [E]. Shift Drum Assembly •...
  • Page 168: Ball And Needle Bearing Wear

    8-28 CRANKSHAFT/TRANSMISSION Transmission Ball and Needle Bearing Wear • Check the following ball bearings: shift drum LH, drive shaft RH, and output shaft LH. ○ Since the ball bearings are made to extremely close toler- ances, the wear must be judged by feel rather than mea- surement.
  • Page 169 WHEELS/TIRES 9-1 Wheels/Tires Table of Contents Exploded View........................Specifications ......................... Wheels (Rims) ........................Front Wheel Removal ....................... Front Wheel Installation ....................Rear Wheel Removal......................Rear Wheel Installation..................... Wheel Inspection ......................Axle Inspection........................Wheel Balance........................Balance Inspection......................Balance Adjustment ......................Balance Weight Removal....................Balance Weight Installation....................
  • Page 170: Exploded View

    9-2 WHEELS/TIRES Exploded View T1: 20 N·m (2.0 kgf·m, 14.5 ft·lb) T2: 88 N·m (9.0 kgf·m, 65 ft·lb) T3: 98 N·m (10.0 kgf·m, 72 ft·lb) G: Apply grease. R: Replacement Parts S: Follow the specific tightening sequence. WL: Apply soap and water solution or rubber lubricant.
  • Page 171: Specifications

    WHEELS/TIRES 9-3 Specifications Standard Item Service Limit EN500-C1 C2, D1 EN500-C3 Wheels (Rims) Rim Runout: Radial – – – – – – 0.5 mm (0.02 in.) Axial – – – – – – 0.8 mm (0.03 in.) Axle Runout/100 mm (3.94 in.) 0.1 mm (0.004 in.) or less ←...
  • Page 172: Wheels (rims)

    9-4 WHEELS/TIRES Wheels (Rims) Front Wheel Removal • Remove the speedometer cable lower end [A]. • Loosen the front axle nut [B]. • Raise the front wheel off the ground. Special Tool - Jack: 57001-1238 • Loosen the axle clamp bolt [A]. •...
  • Page 173: Rear Wheel Removal

    WHEELS/TIRES 9-5 Wheels (Rims) Rear Wheel Removal • Remove: Cotter Pin [A] Rear Axle Nut [B] (loosen) • Raise the rear wheel off the ground using the center stand. • Remove: Cotter Pin [A] Torque Link Nut and Bolt [B] Adjuster [C] and Brake Rod [D] Rear Axle Nut •...
  • Page 174: Wheel Inspection

    9-6 WHEELS/TIRES Wheels (Rims) • Insert a new cotter pin [A]. NOTE ○ When inserting the cotter pin, if the slots in the nut do not align with the cotter pin hole in the axel, tighten the nut clockwise [B] up to next alignment. ○...
  • Page 175: Axle Inspection

    WHEELS/TIRES 9-7 Wheels (Rims) Axle Inspection • Visually inspect the front and rear axle for damages. If the axle is damaged or bent, replace it. • Measure the axle runout with a dial gauge. If axle runout exceeds the service limit, replace the axle. Axle Runout/100 mm (3.94 in.) Standard: less than 0.1 mm (0.004 in.)
  • Page 176: Balance Weight Removal

    30 (1.06) NOTE ○ Balance weights are available from Kawasaki dealers in 10, 20 g (0.35, 0.71 US oz), and 30 g (1.06 US oz) sizes. An imbalance of less than 10 grams will not usu- ally affect running stability.
  • Page 177 WHEELS/TIRES 9-9 Wheels (Rims) • Check that the weight [A] and clip [B] are fully seated on the rim [C] and that the clip is hooked over the rib [D]. WARNING If the balance weight has any play on the rim, the clip of the weight has been stretched.
  • Page 178: Tires

    9-10 WHEELS/TIRES Tires Air Pressure Inspection/Adjustment • Measure the tire air pressure with an air pressure gauge [A] when the tires are cold (that is, when the motorcycle has not been ridden more than a mile during the past 3 hours).
  • Page 179: Tire Removal

    WHEELS/TIRES 9-11 Tires Tire Removal CAUTION Do not lay the front 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 180: Tire Installation

    9-12 WHEELS/TIRES Tires Tire Installation • Inspect the rim and the tire, and replace them if neces- sary. • Clean the sealing surfaces of the rim and tire, and smooth the sealing surfaces of the rim with a fine emery cloth if necessary.
  • Page 181: Tire Repair

    For these rea- sons, Kawasaki does not recommend temporary (external) repair. Only appropriate permanent (internal) repair are rec- ommended. Repair methods may vary slightly from make to make.
  • Page 182: Hub Bearing

    9-14 WHEELS/TIRES Hub Bearing Hub Bearing Removal • Remove the wheel, and take out the following. CAUTION 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 183: Hub Bearing Inspection

    WHEELS/TIRES 9-15 Hub Bearing • Replace the circlips with new ones. Special Tool - Inside Circlip Pliers: 57001-143 • Replace the grease seal with new ones. • Press in the grease seals so that the seal surface flush with the end of the hole. ○...
  • Page 184: Speedometer Gear

    9-16 WHEELS/TIRES Speedometer Gear Disassembly and Assembly NOTE ○ It is recommended that the assembly be replaced rather than attempting to repair the components. • Install the speedometer gear so that it fits in the speedometer gear drive notches (see Front Wheel Installation).
  • Page 185 FINAL DRIVE 10-1 Final Drive Table of Contents Exploded View........................10-2 Specifications ......................... 10-3 Drive Chain..........................10-4 Drive Chain Slack Inspection .................... 10-4 Wheel Alignment Inspection/Adjustment ................10-5 Drive Chain Wear Inspection .................... 10-6 Drive Chain Lubrication..................... 10-6 Drive Chain Removal ......................10-7 Drive Chain Installation .....................
  • Page 186: Exploded View

    10-2 FINAL DRIVE Exploded View 1. Drive Chain Joint (ER500-C4 ) T1: 11 N·m (1.1 kgf·m, 95 in·lb) T2: 127 N·m (13.0 kgf·m, 94 ft·lb) T3: 59 N·m (6.0 kgf·m, 43 ft·lb) T4: 98 N·m (10.0 kgf·m, 72 ft·lb) CO: Apply chain oil. G: Apply grease.
  • Page 187: Specifications

    FINAL DRIVE 10-3 Specifications Item Standard Service Limit Drive Chain Chain Slack 40 mm (1.4 1.6 in.) – – – 20-link Length 317.5 318.2 mm (12.50 12.53 in.) 323 mm (12.7 in.) Standard Chain Make Enuma – – – Type EK520SX-O, Endless –...
  • Page 188: Drive Chain

    10-4 FINAL DRIVE Drive Chain Drive Chain Slack Inspection Drive Chain Slack Inspection NOTE ○ Check the slack with the motorcycle setting on its center stand. ○ Clean the chain if it is dirty, and lubricate it if it appears dry.
  • Page 189: Wheel Alignment Inspection/adjustment

    FINAL DRIVE 10-5 Drive Chain • Bend the cotter pin [A] over the nut [B]. • Turn the wheel, measure the chain slack again at the tight- est position, and readjust if necessary. • Tighten the torque link nut. Torque - Torque Link Nut: 34 N·m (3.5 kgf·m, 25 ft·lb) •...
  • Page 190: Drive Chain Wear Inspection

    10-6 FINAL DRIVE Drive Chain Drive Chain Wear Inspection • Remove: Chain Cover • Rotate the rear wheel to inspect the drive chain for dam- aged rollers, loose pins and links. If there is any irregularity, replace the drive chain. Lubricate the drive chain if it appears dry.
  • Page 191: Drive Chain Removal

    FINAL DRIVE 10-7 Drive Chain CAUTION The O-rings between the side plates seal in the lu- bricant between the pin and the bushing. To avoid damaging the O-rings and resultant loss of lubri- cant, observe the following rules: Use only kerosene or diesel oil for cleaning an O -ring drive chain.
  • Page 192 10-8 FINAL DRIVE Drive Chain • Grind [A] pin head to make it flat. • Set cutting and rivetting pin [B] as shown. • Screw pin holder until it touches the link pin. • Be sure that the cutting pin hits center of the link pin. •...
  • Page 193 FINAL DRIVE 10-9 Drive Chain • Fit the plate holder (A) to the link plate. • Turn the pin holder by hand until the plate holder (B) touches the other link plate. • Turn the pin holder by a wrench clockwise until two pins of link come into groove of the plate holder (A).
  • Page 194 10-10 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 Standard: 6.0 mm (0.22 0.24 in.) Link Plates Outside Width Standard:...
  • Page 195: Sprocket, Coupling

    FINAL DRIVE 10-11 Sprocket, Coupling Engine Sprocket Removal • Remove the bolts [A]. • Pull the 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 196: Rear Sprocket Removal

    10-12 FINAL DRIVE Sprocket, Coupling Rear Sprocket Removal • Remove the rear wheel (see Wheel/Tires chapter). • Remove the rear sprocket nuts [A]. • Remove the rear sprocket [B]. Rear Sprocket Installation • Install the sprocket facing the tooth number marking [A] outward.
  • Page 197: Coupling Bearing Removal

    FINAL DRIVE 10-13 Sprocket, Coupling Coupling Bearing Removal • Remove: Coupling Grease Seal [A] • Remove the bearing by tapping from the brake drum side. Special Tool - Bearing Driver Set: 57001-1129 [A] Coupling Bearing Installation • Replace the bearing with a new one. •...
  • Page 198: Coupling Bearing Inspection And Lubrication

    10-14 FINAL DRIVE Sprocket, Coupling Coupling Bearing Inspection and Lubrication NOTE ○ It is not necessary to remove the coupling bearing for inspection and lubrication. If the bearing is removed, it will need to be replaced with a new one. •...
  • Page 199 BRAKES 11-1 Brakes Table of Contents Exploded View........11-2 Brake Disc Warp ......11-12 Specifications ........11-4 Brake Fluid ........11-13 Brake Lever ........11-5 Level Inspection ......11-13 Lever Position Adjustment ... 11-5 Brake Fluid Change ..... 11-13 Caliper ..........11-6 Bleeding the Brake Line....
  • Page 200: Exploded View

    11-2 BRAKES Exploded View T1: 7.8 N·m (0.80 kgf·m, 69 in·lb) T10: 27 N·m (2.8 kgf·m, 20 ft·lb) T2: 25 N·m (2.5 kgf·m, 18.0 ft·lb) T11: 19 N·m (1.9 kgf·m, 13.5 ft·lb) T3: 11 N·m (1.1 kgf·m, 95 in·lb) B: Apply brake fluid. T4: 1.0 N·m (0.10 kgf·m, 9 in·lb) G: Apply grease.
  • Page 201 BRAKES 11-3 Exploded View...
  • Page 202: Specifications

    11-4 BRAKES Specifications Item Standard Service Limit Front Brake Brake Lever Position 4-way adjustable (to suit rider) – – – 5-way adjustable (to suit rider): ER500-C4 Brake Lever Free Play Non-adjustable – – – Pad Lining Thickness 4.5 mm (0.177 in.) 1 mm (0.04 in.) Disc Thickness 5.2 mm (0.189...
  • Page 203: Brake Lever

    BRAKES 11-5 Brake Lever Lever Position Adjustment The adjuster has 4 positions so that the brake 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 Arrow mark [B] on the lever holder. ○...
  • Page 204: Caliper

    11-6 BRAKES Caliper Caliper Removal • Drain the brake fluid. • Loosen the banjo bolt [A] at the brake hose lower end, and tighten it loosely. • Unscrew the caliper mounting bolts [B], and detach the caliper [C] from the disc. •...
  • Page 205: Caliper Assembly

    BRAKES 11-7 Caliper • Insert a wooden board [A] 5 mm thick inside the caliper opening. • Pump the brake lever until the pistons [B] push the wooden board. • Remove the wooden board and pull out the piston by hand.
  • Page 206: Caliper Piston Seal And Dust Seal Inspection

    11-8 BRAKES Caliper • Apply brake fluid to the outside of the piston, and push the piston into the cylinder by hand. Take care that neither the cylinder nor the piston skirt get scratched. • Replace the shaft rubber friction boot [A] and dust cover [B] with new ones if they are damaged.
  • Page 207: Brake Pads

    BRAKES 11-9 Brake Pads Brake Pad Removal • Remove the caliper with the hose installed. • Remove the clip and take off the pad pin. • Remove: Piston Side Pad [A] • Remove the other pad [A]. Brake Pad Installation •...
  • Page 208: Master Cylinder

    11-10 BRAKES Master Cylinder Master Cylinder Removal • Disconnect the front brake switch wires [A]. • Remove the banjo bolt [B] to disconnect the upper brake hose end from the master cylinder [C]. There is a flat washer [D] on each side of the hose fitting. •...
  • Page 209: Master Cylinder Assembly

    BRAKES 11-11 Master Cylinder Master Cylinder Assembly • Before assembly, clean all parts including the master cylinder with brake fluid or alcohol. CAUTION Except for the disc pads and disc, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol, for cleaning brake parts.
  • Page 210: Brake Disc

    11-12 BRAKES Brake Disc Brake Disc Removal • Remove the wheel (see Wheels/Tires chapter). • Unscrew the mounting Allen bolts [A], and take off the disc [B]. Brake Disc Installation • Install the brake disc on the wheel so that the marked side [A] faces out.
  • Page 211: Brake Fluid

    BRAKES 11-13 Brake Fluid Level Inspection • Check that the brake fluid level in the front brake reservoir [A] is above the lower level line [B]. NOTE ○ Hold the reservoir horizontal by turning the handlebar when checking brake fluid level. If the fluid level is lower than the lower level line, fill the reservoir to the upper level line [A] in the reservoir [B].
  • Page 212: Bleeding The Brake Line

    11-14 BRAKES Brake Fluid Bleeding the Brake Line The brake fluid has a very low compression coefficient so that almost all the movement of the brake lever is transmit- ted directly to the caliper for braking action. Air, however, is easily compressed.
  • Page 213 BRAKES 11-15 Brake Fluid • Install the reservoir cap. • Remove the rubber cap from the bleed valve on the caliper. • Attach a clear plastic hose to the bleed valve on the caliper, and run the other end of the hose into a con- tainer.
  • Page 214 11-16 BRAKES Brake Fluid WARNING When working with the disc brake, observe the pre- cautions listed below. 1. Never reuse old brake fluid. 2. Do not use fluid from a container that has been left unsealed or that has been open for a long time. 3.
  • Page 215: Brake Hose

    BRAKES 11-17 Brake Hose Brake Hoses and Connections Inspection • Inspect the brake hose and fittings for deterioration, cracks and signs of leakage. ○ The high pressure inside the brake line can cause fluid to leak [A] or the hose to burst if the line is not properly main- tained.
  • Page 216: Brake Pedal And Cable

    11-18 BRAKES Brake Pedal and Cable Brake Play Inspection Brake Pedal Position Inspection • With the brake pedal [A] in the correct position, inspect the brake pedal position [B] as shown. Footpeg [C] Pedal Position Standard: About 20 mm (0.79 in.) below footpeg (from Top of the footpeg to Top of the brake Pedal) If it is incorrect, adjust the brake pedal position.
  • Page 217: Brake Pedal Removal

    BRAKES 11-19 Brake Pedal and Cable Brake Pedal Removal • Remove: Adjuster [A] Clevis Pin [B] Return Spring [C] • Remove the brake rod rear end. • Loosen the locknut and turn in the adjusting bolt to keep the pedal free from it. •...
  • Page 218: Brake Panel And Drum

    11-20 BRAKES Brake Panel and Drum Brake Lining Wear Inspection • Check that the brake lining wear indicator [A] points within the USABLE RANGE [B] when the rear brake is fully ap- plied. If does not, the shoes must be immediately replaced and the other brake parts examined.
  • Page 219: Brake Panel Removal

    BRAKES 11-21 Brake Panel and Drum Brake Panel Removal • Remove the rear wheel (see Wheels/Tires chapter). • Separate the brake panel [A] from the wheel. Brake Panel Installation • Installation is the reverse of removal. Note the following. • Adjust the brake pedal free play (see Brake Pedal Free Play Adjustment).
  • Page 220: Brake Shoe Lining Wear

    11-22 BRAKES Brake Panel and Drum • Link the brake shoes together with the springs, and push them onto the panel in the reverse of removal. • Put the dust seal over the end of the cam shaft. • Install the return spring. •...
  • Page 221: Brake Camshaft And Camshaft Hole Wear

    BRAKES 11-23 Brake Panel and Drum Brake Camshaft and Camshaft Hole Wear • Remove the brake camshaft (see Brake Panel Disassem- bly). • Measure the shaft diameter [A]. ○ Use a micrometer at the point shown. If any measurement is less than the service limit, replace the camshaft.
  • Page 222 11-24 BRAKES Brake Panel and Drum • Lubricate the brake pedal by applying a multi-purpose grease to the brake shaft pivot groove [A]. • Clean any excess grease from the parts before assembly. • Lubricate the brake cable (see Brake Cable Lubrication).
  • Page 223 SUSPENSION 12-1 Suspension Table of Contents Exploded View........................12-2 Specifications ......................... 12-4 Front Fork ..........................12-5 Fork Oil Change........................ 12-5 Fork Removal........................12-6 Fork Installation......................... 12-6 Fork Disassembly ......................12-6 Fork Assembly ........................12-7 Fork Oil Leak Inspection ....................12-8 Inner Tube, Outer Tube Inspection ...................
  • Page 224: Exploded View

    12-2 SUSPENSION Exploded View FO: Apply fork oil. L: Apply a non-permanent locking agent. R: Replacement Parts S: Follow he specific tightening sequence. T1: 20 N·m (2.0 kgf·m, 14.5 ft·lb) T2: 35 N·m (3.6 kgf·m, 26 ft·lb)
  • Page 225 SUSPENSION 12-3 Exploded View 1. Needle Bearings: Face the manufacturer’s marks out. T3: 34 N·m (3.5 kgf·m, 25 ft·lb) T4: 88 N·m (9.0 kgf·m, 65 ft·lb) G: Apply grease.
  • Page 226: Specifications

    12-4 SUSPENSION Specifications Item Standard Service Limit Front Fork (per one unit) Fork Inner Tube Diameter 37 mm (1.46 in.) Fork Spring Setting Non-adjustable Air Pressure Atmospheric pressure (Non-adjustable) Rebound Damper Setting Non-adjustable Compression Damper Setting Non-adjustable Fork Oil Viscosity SHOWA SS-8 or equivalent Fork Oil Capacity: Completely Dry...
  • Page 227: Front Fork

    SUSPENSION 12-5 Front Fork Fork Oil Change The oil should be changed in accordance with the Periodic Maintenance Chart. • Remove the front fork (see Fork Removal). • Hold the outer tube vertically in a vise. • Remove the cap. •...
  • Page 228: Fork Removal

    12-6 SUSPENSION Front Fork • Install the fork spring with the smaller diameter end [A] facing down. • Install: Fork Spring Seat Spacer • Install the front fork (see Front Fork Installation). • Repeat the same procedure for another front fork. Fork Removal •...
  • Page 229: Fork Assembly

    SUSPENSION 12-7 Front Fork • Hold the front fork horizontally in a vise [A]. • Stop the cylinder unit [B] from turning by using the special tools. • Unscrew the Allen bolt [C], and take the gasket out of the bottom of the outer tube.
  • Page 230: Fork Oil Leak Inspection

    12-8 SUSPENSION Front Fork • Put the cylinder unit [A] with the spring into the inner tube [B] protruding from the inner tube, and install the cylinder base [C] onto the bottom end of the cylinder unit. ○ Install the cylinder base with the tapered end [D] up. •...
  • Page 231: Inner Tube, Outer Tube Inspection

    SUSPENSION 12-9 Front Fork Inner Tube, Outer Tube Inspection • Visually inspect the inner tube [A] for scoring or scratches on the outer surface of it and repair any damage. • Nick or rust damage can sometimes be repaired by using a wet- stone to remove sharp edges or raised areas which cause seal damage.
  • Page 232: Rear Shock Absorber

    12-10 SUSPENSION Rear Shock Absorber Spring Preload Adjustment The spring preload adjuster on each rear shock absorber has 5 positions so that the spring tension can be adjusted for different road and loading conditions. • Using the hook wrench [A], turn the adjuster to adjust the spring tension.
  • Page 233: Bushing Wear

    SUSPENSION 12-11 Rear Shock Absorber Bushing Wear • Visually inspect the rubber bushings [A]. If they show any signs of damage, replace them. Rear Shock Absorber Oil Leak Inspection • Visually inspect the shock absorber for oil leakage. If the oil leakage is found on it, replace the shock absorber with a new one.
  • Page 234: Swingarm

    12-12 SUSPENSION Swingarm CAUTION Do not tap the swingarm pivot shaft when removing or installing. Push or pull the pivot shaft while turn- ing the shaft. Tapping on the shaft could damage the needle bearings in the swingarm. Swingarm Removal •...
  • Page 235: Swingarm Installation

    SUSPENSION 12-13 Swingarm Swingarm Installation • Installation is the reverse of removal. • Tighten the pivot shaft nut. Torque - Swingarm Pivot Nut: 88 N·m (9.0 kgf·m, 65 ft·lb) • Tighten the torque link nut. Torque - Torque Link Nut: 34 N·m (3.5 kgf·m, 25 ft·lb) •...
  • Page 237 STEERING 13-1 Steering Table of Contents Exploded View........................13-2 Specifications ......................... 13-3 Handlebar ..........................13-4 Handlebar Removal ......................13-4 Handlebar Installation ....................... 13-4 Rear View Mirror Removal....................13-4 Rear View Mirrors (Left and Right) Installation ..............13-5 Steering ..........................13-6 Steering Inspection ......................
  • Page 238: Exploded View

    13-2 STEERING Exploded View T1: 44 N·m (4.5 kgf·m, 33 ft·lb) T2: Hand-tight T3: 25 N·m (2.5 kgf·m, 18 ft·lb) T4: 3.4 N·m (0.35 kgf·m, 30 in·lb) T5: 20 N·m (2.0 kgf·m, 14.5 ft·lb) T6: 29 N·m (3.0 kgf·m, 22 ft·lb) AD: Apply adhesive.
  • Page 239: Specifications

    STEERING 13-3 Specifications Special Tools - Jack: 57001-1238 Steering Stem Wrench: 57001-1100 Head Pipe Outer Race Press Shaft: 57001-1075 Bearing Puller: 57001-158 Head Pipe Outer Race Driver, 46.5: 57001-1106 Head Pipe Outer Race Driver, 51.5: 57001-1076 Steering Stem Bearing Driver: 57001-137 Steering Stem Bearing Driver Adapter, 34.5: 57001-1074 Bearing Puller Adapter: 57001-136...
  • Page 240: Handlebar

    13-4 STEERING Handlebar Handlebar Removal • Remove: Clutch Cable Upper End Right and Left Handlebar Switch Housing Throttle Grip Brake Master Cylinder • Unscrew the handlebar mounting bolts [A] and remove the handlebar [B] and clamp [C]. Handlebar Installation • Install the handlebar clamps so that the arrow [A] on the clamp points to the front.
  • Page 241: Rear View Mirrors (left And Right) Installation

    STEERING 13-5 Handlebar Rear View Mirrors (Left and Right) Installation • Screw the mounting area of the right rear view mirror into the holder all the way, and tighten the lower hexagonal area for tightening securely. [A] Lower Hexagonal Area for Tightening [B] Upper Hexagonal Area (Adapter) [C] Rear View Mirror (Right)
  • Page 242: Steering Inspection

    13-6 STEERING Steering Steering Inspection Steering Inspection • Check the steering. ○ Lift the front wheel off the ground using the jack. Special Tool - Jack: 57001-1238 ○ With the front wheel pointing straight ahead, alternately tap each end of the handlebar. The front wheel should swing fully left and right from the force of gravity until the fork hits the stop.
  • Page 243 STEERING 13-7 Steering • Tighten the steering stem head bolt [A] and fork lower clamp bolts [B]. Torque - Steering Stem Head Bolt: 44 N·m (4.5 kgf·m, 33 ft·lb) Fork Lower Clamp Bolts: 29 N·m (3.0 kgf·m, 22 ft·lb) • Check the steering again.
  • Page 244: Steering Stem

    13-8 STEERING Steering Stem Steering Stem Removal • Remove the handlebar. Loosen the stem head bolt [A] Remove the Front Fork [B] (see Suspension chapter) • Remove: Headlight Turn Signal Light Bracket Bolts [A] Headlight Housing Bolts [B] Meter Unit •...
  • Page 245: Steering Stem Warp

    STEERING 13-9 Steering Stem • Install the stem cap [A], and hand tighten the stem nut [B]. Torque - Steering Stem Nut: 4.9 N·m (0.50 kgf·m, 43 in·lb, for reference) NOTE ○ Install the steering stem nut so that the recess side [C] faces down.
  • Page 246: Steering Stem Bearing

    13-10 STEERING Steering Stem Bearing Stem Bearing Removal • Remove the steering stem (see this chapter). • To remove the outer races [A] pressed in the head pipe [B], insert a bar [C] into the head pipe, and hammer evenly around the circumference of the opposite race to drive it out.
  • Page 247: Stem Bearing Lubrication

    STEERING 13-11 Steering Stem Bearing • Settle the inner races in place as follows. ○ Using the steering stem nut wrench, tighten the stem nut 20 N·m (2.0 kgf·m, 14.5 ft·lb) of torque. To tighten the steering stem nut to the specified torque, hook the wrench on the stem nut, and pull the wrench at the hole by 110 N (11.1 kgf, 24.5 lb) of force in the direction shown.
  • Page 249 FRAME 14-1 Frame Table of Contents Exploded View........................14-2 Specifications ........................14-4 Seat ............................14-5 Seat Removal ........................14-5 Seat Installation ....................... 14-5 Side Covers ..........................14-6 Side Cover Removal ......................14-6 Seat Cover..........................14-7 Seat Cover Removal ......................14-7 Fenders ..........................
  • Page 250: Exploded View

    14-2 FRAME Exploded View T1: 34 N·m (3.5 kgf·m, 25 ft·lb) T2: 44 N·m (4.5 kgf·m, 33 ft·lb) T3: 25 N·m (2.5 kgf·m, 18 ft·lb) O: Apply oil. G: Apply grease.
  • Page 251 FRAME 14-3 Exploded View...
  • Page 252: Specifications

    14-4 FRAME Specifications Special Tool - Jack: 57001-1238...
  • Page 253: Seat

    FRAME 14-5 Seat Seat Removal • Insert the ignition switch key [A] into the seat lock. • Turn the ignition switch key clockwise. • Swing open the seat and remove it. Seat Installation • Slip the hook [A] of the seat under the brace [B] on the fuel tank.
  • Page 254: Side Covers

    14-6 FRAME Side Covers Side Cover Removal • Remove the seat (see this chapter). • Remove the screw [A]. • Pull the rear part and front part of the side cover [A] evenly outward to clear the stoppers [B]. • Remove the side cover.
  • Page 255: Seat Cover

    FRAME 14-7 Seat Cover Seat Cover Removal • Remove the seat (see this chapter). • Remove both side covers (see this chapter). • Unscrew the mounting bolts [A] and remove the tail grip [B]. • Remove the screws [A]. • With the tail of the seat covers joined, bend open the seat cover [A] and pull them out backward.
  • Page 256: Fenders

    14-8 FRAME Fenders Front Fender Removal • Remove the front wheel (see Wheels/Tires chapter). • Remove the bolts [A] and take off the front fender [B] rear- ward. Rear Fender Removal • Remove: Seat (see Frame chapter) Battery (see Electrical System chapter) Regulator/Rectifier (see Electrical System chapter) Igniter (see Electrical System chapter) Fuse Box (see Electrical System chapter)
  • Page 257: Frame

    FRAME 14-9 Frame Frame Inspection • Visually inspect the frame [A] for cracks, dents, bending, or warp. If there is any damage to the frame, replace it. WARNING A repaired frame may fail in use, possibly causing an accident. If the frame is bent, dented, cracked, or warped, replace it.
  • Page 259 ELECTRICAL SYSTEM 15-1 Electrical System Table of Contents Parts Location........15-3 Diodes Inspection ......15-41 Exploded View........15-4 Electric Starter System ...... 15-43 Specifications ........15-8 Starter Motor Removal....15-44 ER500-C1 C2, D1 Wiring Diagram Starter Motor Installation....15-44 (other than Australia) ...... 15-10 Starter Motor Disassembly...
  • Page 260 15-2 ELECTRICAL SYSTEM Radiator Fan Switch Inspection ... 15-62 Fuses..........15-66 Water Temperature Switch 30 Ampere Fuse Removal ... 15-66 Inspection........15-63 Fuse Box Fuse Removal....15-66 Fuel Gauge Operation Inspection 15-63 Fuse Installation......15-66 Fuel Level Sensor Inspection..15-64 Fuse Inspection......
  • Page 261: Parts Location

    ELECTRICAL SYSTEM 15-3 Parts Location 1. Starter Lockout Switch 2. Horn 3. Radiator Fan Switch 4. #1 Ignition Coil 5. Spark Plugs 6. Water Temperature Switch 7. Starter Motor 8. MF Battery 9. IC Igniter 10. Fuse Box 11. Alternator 12.
  • Page 262: Exploded View

    15-4 ELECTRICAL SYSTEM Exploded View 1. Starter Lockout Switch 2. Front Brake Light Switch 3. Horns 4. City Light (other than Australia) T1: 1.2 N·m (0.12 kgf·m, 10 in·lb) T2: 3.4 N·m (0.35 kgf·m, 30 in·lb) L: Apply a non-permanent locking agent.
  • Page 263 ELECTRICAL SYSTEM 15-5 Exploded View 1. Regulator/Rectifier 2. Fuse Box 3. Turn Signal Relay 4. Rectifiers 5. IC Igniter 6. Starter Circuit Relay 7. Diode T1: 5.9 N·m (0.6 kgf·m, 52 in·lb)
  • Page 264 15-6 ELECTRICAL SYSTEM Exploded View...
  • Page 265 ELECTRICAL SYSTEM 15-7 Exploded View 1. Ignition Switch 2. Water Temperature Switch 3. Radiator Fan 4. Radiator Fan Switch 5. Ignition Coils 6. Spark Plugs 7. Rear Brake Light Switch 8. Alternator Starter 9. Pickup Coil 10. Starter Motor 11. 30 A Main Fuse 12.
  • Page 266: Specifications

    15-8 ELECTRICAL SYSTEM Specifications Item Standard Service Limit Battery Type Sealed Battery Capacity 12 V 10 Ah Voltage 12.6 V or more Charging System Alternator Type Three-phase AC DC Battery Charging Voltage 15 V @4 000 r/min (rpm) Alternator Output Voltage 64 V @4 000 r/min (rpm) Stator Coil Resistance 0.6 Ω...
  • Page 267 Special Tools - Hand Tester: 57001-1394 Spark Plug Wrench, Hex 18: 57001-1024 Timing Light: 57001-1241 Flywheel Holder: 57001-1313 Rotor Puller, M16/M18/M20/M22 × 1.5: 57001-1216 Igniter Checker Assembly: 57001-1378 Harness Adapter #1: 57001-1381 Needle Adapter Set: 57001-1457 Sealant - Kawasaki Bond (Silicone Sealant): 56019-120...
  • Page 268: Er500-c1 C2, D1 Wiring Diagram (other Than Australia)

    15-10 ELECTRICAL SYSTEM ER500-C1 C2, D1 Wiring Diagram (other than Australia)
  • Page 269 ELECTRICAL SYSTEM 15-11 ER500-C1 C2, D1 Wiring Diagram (other than Australia)
  • Page 270: Er500-c1 , D1 Wiring Diagram (australia)

    15-12 ELECTRICAL SYSTEM ER500-C1 , D1 Wiring Diagram (Australia)
  • Page 271 ELECTRICAL SYSTEM 15-13 ER500-C1 , D1 Wiring Diagram (Australia)
  • Page 272: Er500-c3 Wiring Diagram (other Than Australia)

    15-14 ELECTRICAL SYSTEM ER500-C3 Wiring Diagram (other than Australia)
  • Page 273 ELECTRICAL SYSTEM 15-15 ER500-C3 Wiring Diagram (other than Australia)
  • Page 274: Precautions

    15-16 ELECTRICAL SYSTEM Precautions There are a number of important precautions that are musts when servicing electrical systems. Learn and ob- serve all the rules below. ○ Do not reverse the battery lead connections. This will burn out the diodes in the electrical parts. ○...
  • Page 275 ELECTRICAL SYSTEM 15-17 Precautions Male Connectors [B]...
  • Page 276: Electrical Wiring

    15-18 ELECTRICAL SYSTEM Electrical Wiring Wiring Inspection • Visually inspect the wiring for signs of burning, fraying, etc. If any wiring is in poor condition, replace the damaged wiring. • Pull each connector [A] apart and inspect it for corrosion, dirt, and damage.
  • Page 277: Battery

    ELECTRICAL SYSTEM 15-19 Battery Battery Removal/Installation • Remove: Seat (see Frame Chapter) ○ Remove the battery cover [A] by taking off three screws. • Remove the negative (–) lead [A] from the battery first. • Remove the positive (+) lead [B] from the battery and pull out the battery.
  • Page 278 15-20 ELECTRICAL SYSTEM Battery • Take the electrolyte container out of the vinyl bag. • Detach the seal caps [A] from the container. NOTE ○ Do not discard the seal cap because it is used as the battery plugs later. ○...
  • Page 279: Initial Charge

    ELECTRICAL SYSTEM 15-21 Battery Initial Charge While a sealed battery can be used after only filling with electrolyte, a battery may not be able to sufficiently move a starter motor to start an engine in the cases shown in the table below, where an initial charge is required before use.
  • Page 280: Interchange

    15-22 ELECTRICAL SYSTEM Battery Interchange The sealed battery can fully display its performance only when combined with a proper vehicle elec- tric system. Therefore, replace the sealed battery only on a motorcycle which was originally equipped with the sealed battery. Be careful, if a sealed battery is installed on a motorcycle which had an ordinary battery as original equipment, the sealed battery’s life will be shortened.
  • Page 281 ELECTRICAL SYSTEM 15-23 Battery NOTE ○ If the current does not flow when charging, raise the voltage initially (25 V as maximum), and let down the voltage to charge when the current starts to flow as a yardstick. If ammeter shows no change in current after 5 minutes, you need a new battery.
  • Page 282: Charging System

    15-24 ELECTRICAL SYSTEM Charging System Alternator Rotor/Starter Clutch Removal • Remove the engine sprocket cover (see Final Drive chap- ter). • Loosen the left footpeg mounting bolt and let the footpeg hang down. • Remove the shift pedal. • Remove the circlip and washer from the shift shaft. •...
  • Page 283: Starter Clutch Sprocket Removal

    ELECTRICAL SYSTEM 15-25 Charging System • Holding the rotor [A] steady, remove the Allen bolts [B] to separate the rotor and starter clutch [C]. Starter Clutch Sprocket Removal • Remove: Alternator cover (see Alternator Rotor/Starter Clutch Re- moval) Alternator rotor with Starter Clutch (see Alternator Ro- tor/Starter Clutch Removal) •...
  • Page 284: Alternator Stator Removal

    • Check that knock pins [B] are in place on the crankcase. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 • Apply a non-permanent locking agent to the threads of the alternator cover Allen bolt.
  • Page 285: Alternator Inspection

    ELECTRICAL SYSTEM 15-27 Charging System Alternator Inspection There are three types of alternator failures: short, open (wire burned out), or loss in rotor magnetism. A short or open in one of the coil wires will result in either a low output or no output at all.
  • Page 286: Regulator/rectifier Removal

    15-28 ELECTRICAL SYSTEM Charging System Regulator/Rectifier Removal • Remove the right side cover and disconnect the regula- tor/rectifier connector [A]. • Unscrew two mounting bolts [B] and remove the regula- tor/rectifier [C] from the battery case. Regulator/Rectifier Output Voltage Inspection •...
  • Page 287: Regulator/rectifier Inspection

    ELECTRICAL SYSTEM 15-29 Charging System Regulator/Rectifier Inspection Rectifier circuit check • Remove the right side cover (see Frame chapter). • Disconnect the regulator/rectifier lead connector [A]. White Lead Terminal [A] Brown Lead Terminal [B] Black/Yellow Lead Terminal [C] Yellow 1 Lead Terminal [D] Yellow 2 Lead Terminal [E] Yellow 3 Lead Terminal [F] •...
  • Page 288 15-30 ELECTRICAL SYSTEM Charging System Regulator Circuit Check • Prepare the following: Test Light Bulb: one 12 V 3.4 W bulb Batteries: three 12 V batteries Wires: five wires of appropriate lengths CAUTION The test light works as an indicator and also a cur- rent limiter to protect the regulator/rectifier from ex- cessive current.
  • Page 289 ELECTRICAL SYSTEM 15-31 Charging System Charging System Circuit 1. Ignition Switch 2. Alternator 3. Regulator/Rectifier 4. Battery 5. Main Fuse 30 A 6. Load...
  • Page 290: Ignition System

    15-32 ELECTRICAL SYSTEM Ignition System Ignition System Circuit 1. Diode 9. Ignition Fuse 10 A 2. Fuse Box 10. Neutral Switch 3. Ignition Switch 11. Starter Lockout Switch 4. Engine Stop Switch 12. Sidestand Switch 5. Starter Button 13. Main Fuse 30 A 6.
  • Page 291: Pickup Coil Removal

    ELECTRICAL SYSTEM 15-33 Ignition System WARNING The ignition system produces extremely high volt- age. Do not touch the spark plugs, ignition coils, or spark plug leads while the engine is running, or you could receive a severe electrical shock. CAUTION Do not disconnect the battery leads or any other electrical connections when the ignition switch is on or while the engine is running.
  • Page 292: Ignition Coil Removal/installation

    15-34 ELECTRICAL SYSTEM Ignition System Ignition Coil Removal/Installation • Remove the fuel tank (see Fuel System chapter). • Disconnect the leads and remove the ignition coils. • Install the ignition coils. Note the following. ○ Connect the primary winding leads to the ignition coiled terminals as shown.
  • Page 293: Ignition Timing Inspection

    ELECTRICAL SYSTEM 15-35 Ignition System NOTE ○ The hand tester cannot detect layer shorts and shorts resulting from insulation breakdown under high voltage. • Disconnect the primary leads from the coil terminals. • Measure the primary winding resistance [A] as follows: ○...
  • Page 294: Spark Plug Removal/installation

    15-36 ELECTRICAL SYSTEM Ignition System Spark Plug Removal/Installation • Remove the fuel tank (see Fuel System chapter). • Carefully pull the spark plug cap from the spark plug and unscrew the spark plug. • Using the 18 mm plug wrench [A]. •...
  • Page 295 ELECTRICAL SYSTEM 15-37 Ignition System • To examine the condition of the igniter, connect the igniter checker to the igniter as shown. Special Tools - Igniter Checker Set: 57001-1378 [A] Wiring Harness Adapter, #14: 57001-1381 IC Igniter [B] Battery [D] ○...
  • Page 296 [C] to the tester [B], and connect the adapter terminals to the respective terminals of the ignition coil [D]. ○ Keep the terminals connected. Special Tool - Kawasaki Hand Tester: 57001-1394 Peak Voltage Adapter: 57001-1415 Type: KEK-54-9-B Connect Adapter’s positive (+) → terminal black/white wire terminal [A] Adapter’s negative (–)
  • Page 297 ELECTRICAL SYSTEM 15-39 Ignition System • Turn the ignition switch ON. • Shift the gears to neutral, and run the engine stop switch. • Turn the starter motor for several seconds and read the maximum value on the tester. Ignition Coil Primary Peak Voltage Standard: DC100 V or more WARNING...
  • Page 298 15-40 ELECTRICAL SYSTEM Ignition System Troubleshooting...
  • Page 299: Diodes Inspection

    ○ Connect the peak voltage adapter [A] to the tester, and connect the adapter terminal to the pickup coil connector [B] terminal. Special Tool - Kawasaki Hand Tester: 57001-1394 Needle Adapter Set: 57001-1457 Peak Voltage Adapter: 57001-1415 Type: KEK-54-9-B Connect Adapter’s positive (+) terminal →...
  • Page 300 15-42 ELECTRICAL SYSTEM Ignition System NOTE ○ The actual meter reading varies with the meter used and the individual diode, but, generally speaking, the lower reading should be from zero to one half the scale.
  • Page 301: Electric Starter System

    ELECTRICAL SYSTEM 15-43 Electric Starter System Electric Starter Circuit 1. Ignition Switch 7. Ignition Fuse 10 A 2. Engine Stop Switch 8. Starter Lockout Switch 3. Starter Button 9. Neutral Switch 4. Starter Circuit Relay 10. Starter Motor 5. Starter Circuit Relay 11.
  • Page 302: Starter Motor Removal

    15-44 ELECTRICAL SYSTEM Electric Starter System Starter Motor Removal • Remove the alternator cover. • Remove the starter chain guide screws [A] and remove the starter chain guide [B] with the guide stay [C]. • Disconnect the starter motor lead [A]. •...
  • Page 303: Starter Motor Disassembly

    ELECTRICAL SYSTEM 15-45 Electric Starter System Starter Motor Disassembly • Unscrew the starter motor through bolts [A] and pull off the gear cover [B] and the end cover [C]. • Pull the armature [D] out of the yoke housing [E], and remove the end bracket [F].
  • Page 304: Starter Chain Wear

    15-46 ELECTRICAL SYSTEM Electric Starter System • Make sure that the marks [A] on the covers and yoke housing align with each other. • Tighten the through bolts. Torque - Starter Motor Through Bolts: 6.9 N·m (0.7 kgf·m, 65 in·lb) Starter Chain Wear •...
  • Page 305: Brush Inspection

    ELECTRICAL SYSTEM 15-47 Electric Starter System • Connect the hand tester [A] and 12 V battery [B] to the starter circuit relay [C] as shown. If the relay does not work as specified, the relay is defec- tive. Replace the relay. Testing Relay Tester Range: ×...
  • Page 306: Armature Inspection

    15-48 ELECTRICAL SYSTEM Electric Starter System • Measure the diameter [A] of the commutator [B]. Replace the starter motor with a new one if the commu- tator diameter is less than the service limit. Commutator Diameter Standard: 28 mm (1.10 in.) Service Limit: 27 mm (1.06 in.) Armature Inspection...
  • Page 307: Lighting System

    ELECTRICAL SYSTEM 15-49 Lighting System Headlight Circuit (Australia, ER500-C1 , D1) 1. Ignition Switch 2. High Beam Indicator Light 3. Headlight 4. Engine Stop Switch 5. Starter Button 6. Diode 7. Diode 8. Starter Circuit Relay 9. Diode 10. Headlight Circuit Relay 11.
  • Page 308 15-50 ELECTRICAL SYSTEM Lighting System Headlight Circuit (Other than Australia, ER500-C1 1. Ignition Switch 2. Headlight Switch 3. Fuse Box 4. Taillight Fuse 10 A 5. Headlight Fuse 10 A 6. High Beam Indicator Light 7. Headlight 8. City Light 9.
  • Page 309: Headlight Circuit Relay Inspection (australia)

    ELECTRICAL SYSTEM 15-51 Lighting System Headlight Circuit (Other than Australia, ER500-C3 ) 1. Ignition Switch 2. Headlight Switch 3. Fuse Box 4. Taillight Fuse 10 A 5. Headlight Fuse 10 A 6. High Beam Indicator Light 7. Headlight 8. City Light 9.
  • Page 310: Headlight Beam Horizontal Adjustment

    15-52 ELECTRICAL SYSTEM Lighting System • Connect the hand tester [A] and 12 V battery [B] to the starter circuit relay [C] as shown. If the relay does not work as specified, the relay is defec- tive. Replace the relay. Testing Relay Tester Range: ×...
  • Page 311: Headlight Unit/housing Removal

    ELECTRICAL SYSTEM 15-53 Lighting System • Fit the dust cover [A] with the Top mark upward onto the bulb firmly as shown in the figure. Good [B] Bad [C] • After installation, adjust the headlight aim. Headlight Unit/Housing Removal • Remove the screws [A] on both sides.
  • Page 312: Tail/brake Light Lens Removal/installation

    15-54 ELECTRICAL SYSTEM Lighting System • Insert the new bulb by aligning the pins with the grooves in the walls of the socket so that the pin closest to the bulb base [A] is to the upper right. Tail/Brake Light Lens Removal/Installation •...
  • Page 313 ELECTRICAL SYSTEM 15-55 Lighting System Turn Signal Light Circuit 1. Turn Signal Indicator Light 2. Front Right Turn Signal Light 3. Front Left Turn Signal Light 4. Turn Signal Relay 5. Turn Signal Fuse 10 A 6. Fuse Box 7. Rear Right Turn Signal Light 8.
  • Page 314: Radiator Fan System

    15-56 ELECTRICAL SYSTEM Radiator Fan System Fan System Circuit Inspection • Disconnect leads from the radiator fan switch [A]. • Using an auxiliary wire [B], connect the radiator fan switch leads. If the fan turns, inspect the fan switch. If the fan does not turn, inspect the following. Lead and Connectors Main Fuse and Fan Fuse Fan Motor...
  • Page 315: Meter Unit

    ELECTRICAL SYSTEM 15-57 Meter Unit Meter Unit Removal • Remove the headlight unit and housing. • Remove the speedometer cable upper end [A] and the mounting nuts [B]. • Disconnect the meter connectors and take off the meter unit [C]. CAUTION Place the meter unit so that the face is up.
  • Page 316: Tachometer Inspection

    15-58 ELECTRICAL SYSTEM Meter Unit Tachometer Inspection • Check the tachometer circuit wiring (see Wiring Inspec- tion). If all wiring and components other than the tachometer unit check out good, the unit is suspect. Check the unit as shown. ○ Remove the headlight body.
  • Page 317: Water Temperature Warning System Inspection

    ELECTRICAL SYSTEM 15-59 Meter Unit Tachometer Circuit 1. Tachometer 2. Fuse Box 3. Ignition Fuse 10 A 4. Ignition Switch 5. Main Fuse 30 A 6. Battery 7. IC Igniter Water Temperature Warning System Inspection The water temperature warning light goes on when the ignition switch is turned on and goes off soon after the en- gine starts running (oil pressure switch off) to ensure that its circuit functions properly.
  • Page 318 15-60 ELECTRICAL SYSTEM Meter Unit Water Temperature Warning System 1. Ignition Switch 2. Fuse Box 3. Ignition Fuse 10 A 4. Starter Relay 5. Main Fuse 30 A 6. Water Temperature Warning Light 7. Oil Pressure Warning Light 8. Rectifier 9.
  • Page 319: Switches And Sensors

    ELECTRICAL SYSTEM 15-61 Switches and Sensors Brake Light Switch Ispection Rear Brake Light Timing Inspection • Turn on the ignition switch. • Check the operation of the rear brake light switch by de- pressing the brake pedal. The brake light should go on as specified.
  • Page 320: Radiator Fan Switch Inspection

    15-62 ELECTRICAL SYSTEM Switches and Sensors Oil Pressure Switch Connections* *: Engine lubrication system is in good condition Side Stand Switch Connections* Radiator Fan Switch Inspection • Remove the fan switch (see Cooling System chapter). • Suspend the switch [A] in a container of coolant so that the temperature-sensing projection and threaded portion are submerged.
  • Page 321: Water Temperature Switch Inspection

    ELECTRICAL SYSTEM 15-63 Switches and Sensors Water Temperature Switch Inspection • Remove the water temperature switch (see Cooling Sys- tem chapter). • Suspend the switch [A] in a container of coolant so that the temperature sensing projection and threaded portion are submerged.
  • Page 322: Fuel Level Sensor Inspection

    15-64 ELECTRICAL SYSTEM Switches and Sensors Fuel Gauge Circuit 1. Ignition Switch 2. Fuel Gauge 3. Fuse Box 4. Ignition Fuse 10 A 5. Fuel Level Sensor 6. Battery 7. 30 A Main Fuse 8. Starter Relay Fuel Level Sensor Inspection •...
  • Page 323 ELECTRICAL SYSTEM 15-65 Switches and Sensors • Using a hand tester, measure the resistance across the terminals in the fuel level sensor lead connector [A]. If the tester reading are not as specified, or do not change smoothly according as the float moves up and down, re- place the sensor.
  • Page 324: Fuses

    15-66 ELECTRICAL SYSTEM Fuses 30 Ampere Fuse Removal • Remove the left side cover (see Frame chapter). • Disconnect the 30 ampere fuse connector [A]. • Pull out the main fuse [B] from the starter relay with a pair of needle nose pliers. Fuse Box Fuse Removal •...
  • Page 325 APPENDIX 16-1 Appendix Table of Contents Troubleshooting Guide ......................16-2 General Lubrication ........................ 16-7 Lubrication (Periodic Maintenance) .................. 16-7 Nut, Bolt, and Fastener Tightness ..................16-8 Tightness Inspection ......................16-8 Unit Conversion Table ......................16-9...
  • Page 326: Troubleshooting Guide

    16-2 APPENDIX Troubleshooting Guide NOTE Neutral, starter lockout, or side stand switch ○ This is not an exhaustive list, giving every trouble possible cause for each problem listed. It Pickup coil trouble is meant simply as a rough guide to assist Ignition coil trouble the troubleshooting for some of the more Ignition or engine stop switch shorted...
  • Page 327 APPENDIX 16-3 Troubleshooting Guide Cylinder head not sufficiently tightened Compression low: down Spark plug loose No valve clearance Cylinder head not sufficiently tightened Cylinder, piston worn down Piston ring bad (worn, weak, broken, or No valve clearance sticking) Cylinder, piston worn Piston ring/groove clearance excessive Piston ring bad (worn, weak, broken, or Cylinder head warped...
  • Page 328 16-4 APPENDIX Troubleshooting Guide Brake dragging Shift pawl broken Lubrication inadequate: Jumps out of gear: Engine oil level too low Shift fork ear worn, bent Engine oil poor quality or incorrect Gear groove worn Coolant incorrect: Gear dogs and/or dog holes worn Coolant level too low Shift drum groove worn Coolant deteriorated...
  • Page 329 APPENDIX 16-5 Troubleshooting Guide Abnormal Drive Train Noise: Cylinder worn Clutch noise: Valve oil seal damaged Clutch rubber damper weak or damaged Valve guide worn Clutch housing/friction plate clearance ex- Cylinder head gasket damaged cessive Engine oil level too high Clutch housing gear worn Black smoke: Transmission noise:...
  • Page 330 16-6 APPENDIX Troubleshooting Guide Brake Doesn’t Hold: Oil on brake linings Disc brake: Battery Trouble: Air in the brake line Pad or disc worn Battery discharged: Brake fluid leakage Battery faulty (e.g., plates sulphated, Disc warped shorted through sedimentation, elec- Contaminated pad trolyte insufficient) Brake fluid deteriorated...
  • Page 331: General Lubrication

    APPENDIX 16-7 General Lubrication Lubrication (Periodic Maintenance) • Before lubricating each part, clean off any rusty spots with rust remover and wipe off any grease, oil, dirt, or grime. • Lubricate the points listed below with indicated lubricant. NOTE ○ Whenever the vehicle has been operated under wet or rainy conditions, or especially after using a high-pressure water spray, perform the general lubri-...
  • Page 332: Nut, Bolt, And Fastener Tightness

    16-8 APPENDIX Nut, Bolt, and Fastener Tightness Tightness Inspection • Check the tightness of the bolts and nuts listed here. Also, check to see that each cotter pin is in place and in good condition. NOTE ○ For the engine fasteners, check the tightness of them when the engine is cold (at room temperature).
  • Page 333: Unit Conversion Table

    APPENDIX 16-9 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 334 MODEL APPLICATION Year Model Beginning Frame No. JKAER500ACA051001, or 2001 ER500-C1 □ JKAERVC1 1A000001 2001 ER500-D1 JKAER500ADA051001 □ 2002 ER500-C2 JKAERVC1 2A003001 □ JKAERVC1 3A005001, or 2003 ER500-C3 JKAER500ACA067001 □ JKAERVC1 4A007001, or 2004 ER500-C4 JKAER500ACA072001 □ JKAERVC1 5A009001, or 2005 ER500-C5 JKAER500ACA082001...

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