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ZZR 1400
ZZR1400 ABS
Ninja ZX-14
Motorcycle
Service Manual

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Table of Contents

   Also See for KAWASAKI NINJA ZX-14

   Summary of Contents for KAWASAKI NINJA ZX-14

  • Page 1 ZZR 1400 ZZR1400 ABS Ninja ZX-14 Motorcycle Service Manual...
  • Page 3 Quick Reference Guide General Information Periodic Maintenance Fuel System (DFI) Cooling System Engine Top End Clutch Engine Lubrication System Engine Removal/Installation Crankshaft/Transmission Wheels/Tires 10 j Final Drive 11 j Brakes 12 j Suspension 13 j Steering 14 j Frame 15 j Electrical System 16 j Appendix...
  • Page 5 All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Quality Division/Consumer Products & Machinery Company/Kawasaki Heavy Industries, Ltd., Japan.
  • Page 6 LIST OF ABBREVIATIONS ampere(s) pound(s) ABDC after bottom dead center meter(s) alternating current minute(s) ATDC after top dead center newton(s) BBDC before bottom dead center pascal(s) bottom dead center horsepower BTDC before top dead center pound(s) per square inch °C degree(s) Celsius revolution direct current...
  • Page 7: Emission Control Information

    EMISSION CONTROL INFORMATION To protect the environment in which we all live, Kawasaki has incorporated crankcase emis- sion (1) and exhaust emission (2) control systems in compliance with applicable regulations of the United States Environmental Protection Agency and California Air Resources Board. Addi-...
  • Page 8 TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Federal law prohibits the following acts or the causing thereof. (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.
  • Page 9: How To Use This Manual

    Be alert for problems and non-scheduled ticular interest for more efficient and con- maintenance. • venient operation. Use proper tools and genuine Kawasaki Mo- • torcycle parts. Special tools, gauges, and Indicates a procedural step or work to be testers that are necessary when servicing done.
  • Page 11: Table Of Contents

    GENERAL INFORMATION 1-1 General Information Table of Contents Before Servicing ........................Model Identification......................... General Specifications......................1-12 Technical Information-CAN (Controller Area Network) Communication System ....1-15 Unit Conversion Table ......................1-18...
  • Page 12: Before Servicing

    1-2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly opera- tion on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustra- tions, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary.
  • Page 13 Replacement Parts Replacement Parts must be KAWASAKI genuine or recommended by KAWASAKI. Gaskets, O-rings, oil seals, grease seals, circlips or cotter pins must be replaced with new ones whenever disassembled.
  • Page 14: Tightening Torque

    1-4 GENERAL INFORMATION Before Servicing Tightening Sequence Generally, when installing a part with several bolts, nuts, or screws, start them all in their holes and tighten them to a snug fit. Then tighten them according to the specified se- quence to prevent case warpage or deformation which can lead to malfunction.
  • Page 15 GENERAL INFORMATION 1-5 Before Servicing Press For items such as bearings or oil seals that must be pressed into place, apply small amount of oil to the con- tact area. Be sure to maintain proper alignment and use smooth movements when installing. Ball Bearing and Needle Bearing Do not remove pressed ball or needle unless removal is absolutely necessary.
  • Page 16 1-6 GENERAL INFORMATION Before Servicing Lubrication It is important to lubricate rotating or sliding parts during assembly to minimize wear during initial operation. Lubri- cation points are called out throughout this manual, apply the specific oil or grease as specified. Direction of Engine Rotation When rotating the crankshaft by hand, the free play amount of rotating direction will affect the adjustment.
  • Page 17: Model Identification

    GENERAL INFORMATION 1-7 Model Identification ZX1400A6F (Europe) Left Side View ZX1400A6F (Europe) Right Side View Frame Number Engine Number...
  • Page 18 1-8 GENERAL INFORMATION Model Identification ZX1400A6F (United States and Canada) Left Side View ZX1400A6F (United States and Canada) Right Side View...
  • Page 19 GENERAL INFORMATION 1-9 Model Identification ZX1400A6F (Malaysia) Left Side View ZX1400A6F (Malaysia) Right Side View...
  • Page 20 1-10 GENERAL INFORMATION Model Identification ZX1400B6F (Europe) Left Side View ZX1400B6F (Europe) Right Side View...
  • Page 21 GENERAL INFORMATION 1-11 Model Identification ZX1400B6F (Malaysia) Left Side View ZX1400B6F (Malaysia) Right Side View...
  • Page 22: General Specifications

    1-12 GENERAL INFORMATION General Specifications Items ZX1400A6F, ZX1400B6F Dimensions Overall Length 2 170 mm (85.4 in.) Overall Width 760 mm (29.9 in.) Overall Height 1 170 mm (46.1 in.) Wheelbase 1 460 mm (57.4 in.) Road Clearance 125 mm (4.9 in.) Seat Height 800 mm (31.5 in.) Dry Mass:...
  • Page 23 GENERAL INFORMATION 1-13 General Specifications Items ZX1400A6F, ZX1400B6F Valve Timing: Inlet: Open 41° (BTDC) Close 71° (ABDC) Duration 292° Exhaust: Open 64° (BBDC) Close 34° (ATDC) Duration 278° Lubrication System Forced lubrication (wet sump with cooler) Engine Oil: Type API SE, SF or SG API SH, SJ or SL with JASO MA Viscosity SAE10W-40...
  • Page 24 1-14 GENERAL INFORMATION General Specifications Items ZX1400A6F, ZX1400B6F Rim Size: Front 17 × 3.50 Rear 17 × 6.00 Front Suspension: Type Telescopic fork (upside-down) Wheel Travel 117 mm (4.6 in.) Rear Suspension: Type Swingarm (uni-trak) Wheel Travel 122 mm (4.8 in.) Brake Type: Front Dual discs...
  • Page 25: Technical Information-can (controller Area Network) Communication System

    GENERAL INFORMATION 1-15 Technical Information-CAN (Controller Area Network) Communication System Overview The CAN communication system is used for transmitting and receiving data that is sent to the meter unit and ECU. A LCD (liquid crystal display) display in the meter unit displays information such as bat- tery voltage, fuel consumption, and service codes in addition to the conventional indicator functions.
  • Page 26 1-16 GENERAL INFORMATION Technical Information-CAN (Controller Area Network) Communication System Structure and Function 1. In the CAN communication system, anti-noise twisted pair leads are used (two leads). Twisted Pair Leads [A] (In the main harness) 2. Data is transmitted from the two nodes-the ECU and meter unit-on the CAN bus and does not contain specific bus addresses of either node.
  • Page 27 GENERAL INFORMATION 1-17 Technical Information-CAN (Controller Area Network) Communication System System failure and maintenance 1. Detection of a system failure When the DFI or immobilizer system fails, the information will be shown on the LCD under the "ig- nition switch ON" condition. 2.
  • Page 28: Unit Conversion Table

    1-18 GENERAL INFORMATION Unit Conversion Table Prefixes for Units Units of Length × 0.6214 mile Prefix Symbol Power × 3.281 mega × 1 000 000 × 0.03937 kilo × 1 000 centi × 0.01 Units of Torque milli × 0.001 N·m ×...
  • Page 29 PERIODIC MAINTENANCE 2-1 Periodic Maintenance Table of Contents Periodic Maintenance Chart ....................Torque and Locking Agent...................... Specifications ......................... 2-12 Special Tools .......................... 2-14 Maintenance Procedure ......................2-15 Fuel System (DFI)........................ 2-15 Throttle Control System Inspection................... 2-15 Engine Vacuum Synchronization Inspection..............2-15 Idle Speed Inspection .......................
  • Page 30 2-2 PERIODIC MAINTENANCE Steering System ........................2-39 Steering Play Inspection ....................2-39 Steering Play Adjustment....................2-39 Steering Stem Bearing Lubrication ................... 2-40 Electrical System ......................... 2-41 Lights and Switches Operation Inspection................ 2-41 Headlight Aiming Inspection ..................... 2-44 Sidestand Switch Operation Inspection ................2-45 Engine Stop Switch Operation Inspection.................
  • Page 31: Periodic Maintenance Chart

    PERIODIC MAINTENANCE 2-3 Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition.The initial maintenance is vitally important and must not be neglected. FREQUENCY Whichever * ODOMETER comes READING first ×...
  • Page 32 2-4 PERIODIC MAINTENANCE Periodic Maintenance Chart FREQUENCY Whichever * ODOMETER comes READING first × 1000 km (× 1000 mile) Page 18 24 30 INSPECTION Every (0.6) (4) (7.5) (12) (15) (20) (24) Final Drive Drive chain lubrication condition - inspect # Every 600 km (400 mile) after driving in rain 2-30 Drive chain slack - inspect # Every 1 000 km (600 mile)
  • Page 33: Periodic Maintenance Chart

    PERIODIC MAINTENANCE 2-5 Periodic Maintenance Chart Periodic Replacement Parts FREQUENCY Whichever * ODOMETER READING come × 1000 km first (× 1000 mile) Page CHANGE/REPLACEMENT Every (0.6) (7.5) (12) (15) (24) (30) Air cleaner element # Every 18 000 km (12 000 mile) 2-48 •...
  • Page 34: Torque And Locking Agent

    2-6 PERIODIC MAINTENANCE Torque and Locking Agent The following tables list the tightening torque for the major fasteners requiring use of a non-permanent locking agent or silicone sealant etc. Letters used in the “Remarks” column mean: AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque. G: Apply grease to the threads.
  • Page 35 PERIODIC MAINTENANCE 2-7 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Engine Top End Air Suction Valve Cover Bolts 87 in·lb Camshaft Cap Bolts 106 in·lb Camshaft Chain Guide Bolts 106 in·lb Camshaft Chain Tensioner Mounting Bolts 87 in·lb Camshaft Position Sensor Bolt 87 in·lb Cam Sprocket Mounting Bolts...
  • Page 36 2-8 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Oil Pressure Switch Oil Pressure Switch Terminal Bolt 0.15 13 in·lb Oil Pump Cover Bolts 87 in·lb Engine Removal/Installation Adjusting Collars Engine Bracket Bolts (M8) S, R Engine Mounting Nuts (M12) Front Engine Mounting Bolts (M10) S, R...
  • Page 37 PERIODIC MAINTENANCE 2-9 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Wheels/Tires Front Axle Clamp Bolts Front Axle Nut 13.0 Rear Axle Nut 13.0 Final Drive Chain Guide Bolt 106 in·lb Chain Guide Bolts 87 in·lb Engine Sprocket Cover Bolts 87 in·lb Engine Sprocket Nut 13.0...
  • Page 38 2-10 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Swingarm Pivot Adjusting Collar Swingarm Pivot Adjusting Collar Locknut 10.0 Swingarm Pivot Shaft Nut 11.0 Tie-Rod Nuts Uni-Trak Rocker Arm Nut Steering Front Fork Clamp Bolts (Upper) Front Fork Clamp Bolts (Lower) Handlebar Bolts Handlebar Holder Bolts...
  • Page 39 PERIODIC MAINTENANCE 2-11 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Licence Plate Light Cover Mounting Screws 0.09 8 in·lb Licence Plate Light Mounting Screws 0.12 11 in·lb Rear Turn Signal Light Mounting Screws 0.12 11 in·lb RegulatorRectifier Bolts 87 in·lb Right Switch Housing Screws 0.36...
  • Page 40: Specifications

    2-12 PERIODIC MAINTENANCE Specifications Item Standard Service Limit Fuel System Throttle Grip Free Play 3 mm (0.08 0.12 in.) – – – Idle Speed 1 100 ±50 r/min (rpm) – – – Throttle Body Vacuum 39 ±1.33 kPa (293 ±10 mmHg) at idle speed –...
  • Page 41 PERIODIC MAINTENANCE 2-13 Specifications Item Standard Service Limit Final Drive Drive Chain Slack 38 mm (1.3 1.5 in.) – – – Drive Chain Wear (20-link 317.5 318.2 mm (12.50 12.53 in.) 323 mm (12.7 in.) Length) Standard Chain: Make DAIDO –...
  • Page 42: Special Tools

    2-14 PERIODIC MAINTENANCE Special Tools Inside Circlip Pliers: Pilot Screw Adjuster, C: 57001-143 57001-1292 Steering Stem Nut Wrench: Vacuum Gauge: 57001-1100 57001-1369 Jack: Pilot Screw Adjuster Adapter, 5: 57001-1238 57001-1372 Oil Filter Wrench: Jack Attachment: 57001-1249 57001-1608...
  • Page 43: Maintenance Procedure

    PERIODIC MAINTENANCE 2-15 Maintenance Procedure Fuel System (DFI) Throttle Control System Inspection • Check the throttle grip free play [A]. If the free play is incorrect, adjust the throttle cables. Throttle Grip Free Play Standard: 3 mm (0.08 0.12 in.) •...
  • Page 44 2-16 PERIODIC MAINTENANCE Maintenance Procedure • For the California Model, pull off the vacuum hoses [A]. • Pull off the air switching valve hose [A] from the air cleaner housing. • Plug the air switching valve hose end and air cleaner housing hole.
  • Page 45 PERIODIC MAINTENANCE 2-17 Maintenance Procedure If any vacuum is not within specifications, first synchro- nize the balance of the left (#1, #2 throttle valves) and right (#3, #4 throttle valves) assemblies. Example: #1: 260 mmHg #2: 290 mmHg #3: 250 mmHg #4: 270 mmHg •...
  • Page 46 2-18 PERIODIC MAINTENANCE Maintenance Procedure • Turn in the bypass screw [A] with counting the number of turns until it seals fully but not tightly. Record the number of turns. Torque - Bypass Screw: 0.2 N·m (0.02 kgf·m, 1.8 in·lb) CAUTION Do not over tighten them.
  • Page 47: Idle Speed Inspection

    PERIODIC MAINTENANCE 2-19 Maintenance Procedure Idle Speed Inspection • Start the engine and warm it up thoroughly. • With the engine idling, turn the handlebar to both sides [A]. If handlebar movement changes the idle speed, the throttle cables may be improperly adjusted or incorrectly routed, or damaged.
  • Page 48: Cooling System

    2-20 PERIODIC MAINTENANCE Maintenance Procedure • Check that the hose joints are securely connected. ○ Push and pull [A] the hose joint [B] back and forth more than two times, and make sure it is locked. If it does not locked, reinstall the hose joint. WARNING Make sure the hose joint is installed correctly on the delivery pipe by sliding the joint, or the fuel could...
  • Page 49: Evaporative Emission Control System (california Model)

    PERIODIC MAINTENANCE 2-21 Maintenance Procedure Evaporative Emission Control System (California Model) Evaporative Emission Control System Inspection • Inspect the canister as follows. ○ Remove the seat (see Seat Removal in the Frame chap- ter). ○ Remove the canister [A], and disconnect the hoses from the canister.
  • Page 50: Engine Top End

    2-22 PERIODIC MAINTENANCE Maintenance Procedure Engine Top End Valve Clearance Inspection Valve Clearance Inspection NOTE ○ Valve clearance must be checked and adjusted when the engine is cold (at room temperature). • Remove: Lower Fairings (see Lower Fairing Removal in the Frame chapter) Middle Fairings (see Middle Fairing Removal in the Frame chapter)
  • Page 51 PERIODIC MAINTENANCE 2-23 Maintenance Procedure ○ When positioning #1 piston TDC at the end of the compression stroke: Inlet Valve Clearance of #1 and #3 Cylinders Exhaust Valve Clearance of #1 and #2 Cylinders Measuring Valve [A] ○ When positioning #4 piston TDC at the end of the compression stroke: Inlet Valve Clearance of #2 and #4 Cylinders Exhaust Valve Clearance of #3 and #4 Cylinders...
  • Page 52 2-24 PERIODIC MAINTENANCE Maintenance Procedure ○ Bisides the standard shims in the valve clearance adjust- ment charts, the following additional shims maybe used. Adjustment Shims Part Number Thickness 92025-1982 2.425 mm 92025-1983 2.475 mm 92025-1984 2.525 mm 92025-1985 2.575 mm 92180-1058 2.375 mm 92180-1059...
  • Page 53 PERIODIC MAINTENANCE 2-25 Maintenance Procedure EXHAUST- VALVE CLEARANCE ADJUSTMENT CHART 1. Measure the clearance (with engine cold). 2. Check present shim size. 3. Match clearance in vertical column with present shim size in horizontal column. 4. Install the shim specified where the lines intersect. This shim will give the proper clearance.
  • Page 54 2-26 PERIODIC MAINTENANCE Maintenance Procedure INLET- VALVE CLEARANCE ADJUSTMENT CHART 1. Measure the clearance (with engine cold). 2. Check present shim size. 3. Match clearance in vertical column with present shim size in horizontal column. 4. Install the shim specified where the lines intersect. This shim will give the proper clearance.
  • Page 55: Clutch And Drive Train

    PERIODIC MAINTENANCE 2-27 Maintenance Procedure CAUTION Be sure to remeasure the clearance after selecting a shim according to the table. If the clearance is out of the specified rage, use the additional shim. ○ If there is no valve clearance, use a shim that is a few sizes smaller, and remeaasure the valve clearance.
  • Page 56: Clutch Fluid Leak Inspection

    2-28 PERIODIC MAINTENANCE Maintenance Procedure • Follow the procedure below to instal the clutch fluid reser- voir cap correctly. ○ First, tighten the clutch fluid reservoir cap [B] clockwise [C] by hand until the resistance is felt fully; then, tighten the cap an additional 1/6 turn [D] while holding the clutch fluid reservoir body [A].
  • Page 57: Wheels/tires

    PERIODIC MAINTENANCE 2-29 Maintenance Procedure Wheels/Tires Air Pressure Inspection • Remove the air valve cap. • 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 58: Wheel Bearing Damage Inspection

    2-30 PERIODIC MAINTENANCE Maintenance Procedure WARNING To ensure safe handling and stability, use only the recommended standard tires for replacement, in- flated to the standard pressure. NOTE ○ Most countries may have their own regulations a mini- mum tire tread depth: be sure to follow them. ○...
  • Page 59: Drive Chain Slack Inspection

    PERIODIC MAINTENANCE 2-31 Maintenance Procedure • Apply oil to the sides of the rollers so that oil will penetrate to the rollers and bushings. Apply the oil to the O-rings so that the O-rings will be coated with oil. • Wipe off any excess oil.
  • Page 60: Wheel Alignment Inspection

    2-32 PERIODIC MAINTENANCE Maintenance Procedure • Insert a new cotter pin [A]. NOTE ○ When inserting the cotter pin, if the slots in the nut do not align with the cotter pin hole in the axle, tighten the nut clockwise [B] up to next alignment. ○...
  • Page 61: Chain Guide Wear Inspection

    PERIODIC MAINTENANCE 2-33 Maintenance Procedure WARNING If the drive chain wear exceeds the service limit, re- place the chain or an unsafe riding condition may result. A chain that breaks or jumps off the sprock- ets could snag on the engine sprocket or lock the rear wheel, severely damaging the motorcycle and causing it to go out of control.
  • Page 62: Brake System

    2-34 PERIODIC MAINTENANCE Maintenance Procedure Brake System Brake Fluid Leak (Brake Hose and Pipe) Inspection • For ABS equipped models; note the following. • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Battery (see Battery Removal in the Electrical System chapter) •...
  • Page 63: Brake Hose And Pipe Damage And Installation Condition Inspection

    PERIODIC MAINTENANCE 2-35 Maintenance Procedure Brake Hose and Pipe Damage and Installation Condition Inspection • For ABS equipped models; note the following. • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Battery (see Battery Removal in the Electrical System chapter) •...
  • Page 64: Brake Pad Wear Inspection

    2-36 PERIODIC MAINTENANCE Maintenance Procedure • Follow the procedure below to install the front brake fluid reservoir cap correctly. ○ First, tighten the front brake fluid reservoir cap [B] clock- wise [C] by hand until slight resistance is felt indicating that the cap is seated on the reservoir body, then tighten the cap an additional 1/6 turn [D] while holding the brake fluid reservoir body [A].
  • Page 65: Brake Light Switch Operation Inspection

    PERIODIC MAINTENANCE 2-37 Maintenance Procedure Brake Light Switch Operation Inspection • Turn on the ignition switch. • The brake light [A] should go on when the brake lever is applied or after the brake pedal is depressed about 10 mm (0.39 in.). If it does not, adjust the brake light switch.
  • Page 66: Front Fork Oil Leak Inspection

    2-38 PERIODIC MAINTENANCE Maintenance Procedure • Pump the seat down and up [A] 4 or 5 times, and inspect the smooth stroke. If the shock absorber does not smoothly stroke or noise is found, inspect the oil leak (see Rear Shock Absorber Oil Leak Inspection).
  • Page 67: Steering System

    PERIODIC MAINTENANCE 2-39 Maintenance Procedure Steering System Steering Play Inspection • Remove the lower fairings (see Lower Fairing Removal in the Frame chapter). • Raise the front wheel off the ground with the jack. Special Tools - Jack: 57001-1238 Jack Attachment: 57001-1608 •...
  • Page 68: Steering Stem Bearing Lubrication

    2-40 PERIODIC MAINTENANCE Maintenance Procedure • Adjust the steering. Special Tool - Steering Stem Nut Wrench [A]: 57001-1100 If the steering is too tight, loosen the stem nut a fraction of a turn. If the steering is too loose, tighten the stem nut a fraction of a turn.
  • Page 69: Electrical System

    PERIODIC MAINTENANCE 2-41 Maintenance Procedure Electrical System Lights and Switches Operation Inspection First Step • Turn on the ignition switch. • The following lights should go on according to below table. goes on City Light [A] Taillight [B] goes on goes on License Plate Light [C] Meter Panel Illumination Light (LED) [D]...
  • Page 70 2-42 PERIODIC MAINTENANCE Maintenance Procedure Second Step • Turn the ignition switch to P (Park) position. • The city light, taillight and license plate light should go on. If the light does not go on, inspect or replace the following item.
  • Page 71 PERIODIC MAINTENANCE 2-43 Maintenance Procedure Fourth Step • Set the dimmer switch [A] to low beam position. • Start the engine. • The low beam headlights [B] should go on. If the low beam headlight does not go on, inspect or re- place the following item.
  • Page 72: Headlight Aiming Inspection

    2-44 PERIODIC MAINTENANCE Maintenance Procedure Headlight Aiming Inspection • Inspect the headlight beam for aiming. If the headlight beam points to one side rather than straight ahead, adjust the horizontal beam. Headlight Beam Horizontal Adjustment • Turn the horizontal adjuster [A] in both headlights in or out until the beam points straight ahead.
  • Page 73: Sidestand Switch Operation Inspection

    PERIODIC MAINTENANCE 2-45 Maintenance Procedure Sidestand Switch Operation Inspection • Inspect the sidestand switch [A] operation accordance to table the below. Sidestand Switch Operation Gear Clutch Engine Engine Sidestand Position Lever Start Continue Neutral Released Starts running Continue Neutral Pulled in Starts running Doesn’t...
  • Page 74: Engine Stop Switch Operation Inspection

    2-46 PERIODIC MAINTENANCE Maintenance Procedure Engine Stop Switch Operation Inspection First Step • Turn on the ignition switch. • Set the neutral position. • Turn the engine stop switch to stop position [A]. • Push the starter button. • The engine does not start. If the engine starts, inspect or replace the following item.
  • Page 75: Bolts, Nuts And Fasteners Tightness Inspection

    PERIODIC MAINTENANCE 2-47 Maintenance Procedure Cables: Lubricate with Rust Inhibitor. Throttle Cables • Lubricate the cables by seeping the oil between the cable and housing. ○ The cable may be lubricated by using a commercially available pressure cable lubricator with an aerosol cable lubricant.
  • Page 76: Replacement Parts

    2-48 PERIODIC MAINTENANCE Maintenance Procedure Bolt, Nut and Fastener to be checked Engine: Clutch Lever Pivot Bolt Locknut Engine Mounting Bolts Muffler Clamp Bolts Exhaust Pipe Manifold Holder Nuts Muffler Body Mounting Bolts Wheels: Front Axle Clamp Bolts Front Axle Nut Rear Axle Nut Rear Axle Nut Cotter Pin Brakes:...
  • Page 77: Fuel Hose Replacement

    Install a new element [A] so that screen side [B] faces upward. CAUTION Use only the recommended air cleaner element (Kawasaki part number 11013-0014). Using another air cleaner element will wear the engine prema- turely or lower the engine performance. •...
  • Page 78 2-50 PERIODIC MAINTENANCE Maintenance Procedure • Pull the joint lock [A] as shown. • Pull the fuel hose joint [B] out of the delivery pipe. • Remove the throttle body assy (see Throttle Body Assy Removal in the Fuel System (DFI) chapter). •...
  • Page 79: Coolant Change

    PERIODIC MAINTENANCE 2-51 Maintenance Procedure Coolant Change WARNING To avoid burns, do not remove the radiator cap or try to change the coolant when the engine is still hot. Wait until it cools down. Coolant on tires will make them slippery and can cause an accident and injury.
  • Page 80 2-52 PERIODIC MAINTENANCE Maintenance Procedure • Fill the radiator up to the radiator filler neck [A] with coolant, and install the radiator cap. NOTE ○ Pour in the coolant slowly so that it can expel the air from the engine and radiator. •...
  • Page 81: Radiator Hose And O-ring Replacement

    PERIODIC MAINTENANCE 2-53 Maintenance Procedure Radiator Hose and O-ring Replacement • Drain the coolant (see Coolant Change). • Remove: Lower Fairings (see Lower Fairing Removal in the Frame chapter) Middle Fairings (see Middle Fairing Removal in the Frame chapter) Throttle Body Assy (see Throttle Body Assy Removal in the Fuel System (DFI) chapter) Thermostat Housing [A] Fitting [B]...
  • Page 82: Oil Filter Replacement

    2-54 PERIODIC MAINTENANCE Maintenance Procedure Recommended Engine Oil Type: API SE, SF or SG API SH, SJ or SL with JASO MA Viscosity: SAE 10W-40 Capacity: 3.7 L (3.9 US qt) (when filter is not removed) 4.1 L (4.3 US qt) (when filter is removed) 4.5 L (4.8 US qt) (when engine is completely dry) NOTE...
  • Page 83: Brake Hose And Pipe Replacement

    PERIODIC MAINTENANCE 2-55 Maintenance Procedure Brake Hose and Pipe Replacement CAUTION Brake fluid quickly ruins painted plastic surfaces; any spilled fluid should be completely washed away immediately. • Remove the brake hose banjo bolts [A]. • When removing the brake hose, take care not to spill the brake fluid on the painted or plastic parts.
  • Page 84 2-56 PERIODIC MAINTENANCE Maintenance Procedure • For ABS equipped models; note the following. • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Battery (see Battery Removal in the Electrical System chapter) Upper Fairing (see Upper Fairing Removal in the Frame chapter) Brake Pipe Joint Nuts [A] Bolts [B]...
  • Page 85: Brake Fluid Change

    PERIODIC MAINTENANCE 2-57 Maintenance Procedure Brake Fluid Change NOTE ○ The procedure to change the front brake fluid is as fol- lows. Changing the rear brake fluid is the same as for the front brake. • Level the brake fluid reservoir. •...
  • Page 86: Master Cylinder Rubber Parts Replacement

    2-58 PERIODIC MAINTENANCE Maintenance Procedure • Tighten: Torque - Front Brake Reservoir Cap Stopper Screw: 1.2 N·m (0.12 kgf·m, 11 in·lb) • Tighten the bleed valve, and install the rubber cap. Torque - Bleed Valve: 7.8 N·m (0.80 kgf·m, 69 in·lb) •...
  • Page 87: Caliper Rubber Parts Replacement

    PERIODIC MAINTENANCE 2-59 Maintenance Procedure 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 88 2-60 PERIODIC MAINTENANCE Maintenance Procedure WARNING To avoid serious injury, never place your fingers or palm in front of the piston. If you apply compressed air into the caliper, the piston may crush your hand or fingers. ○ Pull out the pistons by hand. •...
  • Page 89 PERIODIC MAINTENANCE 2-61 Maintenance Procedure • Install the pads (see Front Brake Pad Installation in the Brakes chapter). • Wipe up any spilled brake fluid on the caliper with wet cloth. Rear Caliper Disassembly • Loosen the rear caliper pad pin [A] and banjo bolt [B], and tighten them loosely.
  • Page 90: Rear Caliper Assembly

    2-62 PERIODIC MAINTENANCE Maintenance Procedure • Remove the dust seals [A] and fluid seals [B]. • Remove the bleed valves [C] and rubber caps [D]. NOTE ○ If compressed air is not available, do as follows with the brake hose connected to the caliper. ○...
  • Page 91: Clutch Hose And Pipe Replacement

    PERIODIC MAINTENANCE 2-63 Maintenance Procedure • Replace the O-ring [A]. • Apply brake fluid to the outside of the pistons, and push them into each cylinder by hand. • Be sure to install the O-ring. • Apply a non-permanent locking agent to the threads of the rear caliper assembly bolts, and tighten them.
  • Page 92: Rubber Parts Of Clutch Master Cylinder/slave Cylinder Replacement

    2-64 PERIODIC MAINTENANCE Maintenance Procedure Rubber Parts of Clutch Master Cylinder/Slave Cylinder Replacement Clutch Master Cylinder Cup and Dust Seal Replacement • Remove the clutch master cylinder (see Clutch Master Cylinder Removal in the Clutch chapter). • Remove the seal cover [A], circlip [B], connector [C] and O-ring [D].
  • Page 93 PERIODIC MAINTENANCE 2-65 Maintenance Procedure Clutch Slave Cylinder Piston Seal Replacement • Remove the left lower fairing (see Lower Fairing Removal in the Frame chapter). • Remove the coolant reserve tank. • Loosen the banjo bolt [A] at the clutch pipe lower end, and tighten it loosely.
  • Page 94: Clutch Fluid Change

    2-66 PERIODIC MAINTENANCE Maintenance Procedure Clutch Fluid Change • Level the clutch fluid reservoir and remove the reservoir cap. • Remove the left lower fairing (see Frame chapter). • Remove the rubber cap from the bleed valve on the clutch slave cylinder.
  • Page 95 PERIODIC MAINTENANCE 2-67 Maintenance Procedure • Replace the spark plug with a new one. Standard Spark Plug Type: NGK CR9EIA-9 • Insert new spark plug in the plug hole, and finger-tighten it first. • Using the plug wrench [A] vertically, tighten the plug. CAUTION The insulator of the spark plug may break if when the wrench is inclined during tightening.
  • Page 97 FUEL SYSTEM (DFI) 3-1 Fuel System (DFI) Table of Contents Exploded View........................DFI System..........................3-10 DFI Parts Location........................3-16 Specifications ......................... 3-18 Special Tools and Sealant ...................... 3-20 DFI Servicing Precautions ...................... 3-22 DFI Servicing Precautions ....................3-22 Troubleshooting the DFI System .................... 3-24 Outline ..........................
  • Page 98 3-2 FUEL SYSTEM (DFI) Output Voltage Inspection....................3-69 Gear Position Switch (Service Code 25) ................3-71 Gear Position Switch Removal/Installation ............... 3-71 Gear Position Switch Inspection ..................3-71 Input Voltage Inspection....................3-71 Vehicle-down Sensor (Service Code 31)................3-73 Removal..........................3-73 Installation.........................
  • Page 99 FUEL SYSTEM (DFI) 3-3 Injector Signal Test......................3-109 Injector Resistance Inspection ..................3-109 Injector Unit Test ....................... 3-110 Injector Fuel Line Inspection ..................... 3-110 Throttle Grip and Cables ......................3-112 Free Play Inspection ......................3-112 Free Play Adjustment......................3-112 Cable Installation ......................3-112 Cable Lubrication ......................
  • Page 100: Exploded View

    3-4 FUEL SYSTEM (DFI) Exploded View...
  • Page 101 FUEL SYSTEM (DFI) 3-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Air Inlet Duct Mounting Bolts 87 in·lb Middle Air Inlet Duct Mounting Bolts 87 in·lb Middle Air Inlet Duct Clamp Bolts 0.30 26 in·lb Rear Air Inlet Duct Mounting Bolts 87 in·lb Air Cleaner Element Holder Screws 0.70...
  • Page 102 3-6 FUEL SYSTEM (DFI) Exploded View...
  • Page 103 FUEL SYSTEM (DFI) 3-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Speed Sensor Bolt 0.40 35 in·lb Crankshaft Sensor Bolts 0.60 52 in·lb Gear Position Switch Screws 0.30 26 in·lb Gear Position Switch Lead Clamp Bolts 87 in·lb Vehicle-down Sensor Bolts 0.60 52 in·lb Camshaft Position Sensor Bolt...
  • Page 104 3-8 FUEL SYSTEM (DFI) Exploded View...
  • Page 105 FUEL SYSTEM (DFI) 3-9 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Fuel Pump Bolts 87 in·lb L, S 2. Canister 3. Separator 4. Fitting 5. Red Hose 6. Blue Hose 7. Green Hose 8. White Hose 9. Damper (ZX1400B Models) L: Apply a non-permanent locking agent.
  • Page 106: Dfi System

    3-10 FUEL SYSTEM (DFI) DFI System DFI System...
  • Page 107 FUEL SYSTEM (DFI) 3-11 DFI System 1. ECU 2. Crankshaft Sensor 3. Camshaft Position Sensor 4. Main Throttle Sensor 5. Subthrottle Sensor 6. Subthrottle Valve Actuator 7. Inlet Air Pressure Sensor 8. Atmospheric Pressure Sensor 9. Water Temperature Sensor 10. Inlet Air Temperature Sensor 11.
  • Page 108 3-12 FUEL SYSTEM (DFI) DFI System...
  • Page 109 FUEL SYSTEM (DFI) 3-13 DFI System Part Name 1. Ignition Switch 2. Joint Connector 1 3. Engine Stop Switch 4. Starter Button 5. Camshaft Position Sensor 6. Stick Coil #1, #2, #3, #4 7. Speed Sensor 8. Water Temperature Sensor 9.
  • Page 110 3-14 FUEL SYSTEM (DFI) DFI System Terminal Numbers of ECU Connectors Terminal Names 1. CAN Communication Line (High) 2. Subthrottle Valve Actuator 3. Subthrottle Valve Actuator 4. Gear Position Switch 5. Crankshaft Sensor (–) 6. Speed Sensor 7. Power Supply to Sensors 8.
  • Page 111 54. Unused 55. Ground 56. Unused 57. Injector #4 58. Ignition Coil #4 59. Injector #2 60. Ignition Coil #2 KDS (Kawasaki Diagnostic System) KDS that runs on Windows personal computer (PC) diagnostic tool for motorcycle with Kawasaki DFI system.
  • Page 112: Dfi Parts Location

    Water Temperature Sensor [D] Battery [E] Fuel Injectors #1, #2, #3, #4 [A] Relay Box (Fuel Pump Relay) [A] Immobilizer/Kawasaki Diagnostic System Connector [B] Atmospheric Pressure Sensor [C] ECU [D] Fuse Box (ECU Fuse 15 A) [E] Stick Coils #1, #2, #3, #4 [A]...
  • Page 113 FUEL SYSTEM (DFI) 3-17 DFI Parts Location Camshaft Position Sensor [A] Crankshaft Sensor [B] Speed Sensor [A] Gear Position Switch [B] Ignition Key [A] (Transponder, Immobilizer Models) Ignition Switch [B] Immobilizer Antenna [C] (Immobilizer Models) Immobilizer Amplifier [D] (Immobilizer Models) Vehicle-down [E] Inlet Air Pressure Sensor [A] Fuel Pump [A]...
  • Page 114: Specifications

    3-18 FUEL SYSTEM (DFI) Specifications Item Standard Digital Fuel Injection System Idle Speed 1 100 ±50 r/min (rpm) Throttle Assy: Type Four barrel type Bore 44 mm (1.7 in.) Throttle Body Vacuum 39 ±1.33 kPa (293 ±10 mmHg) Bypass Screws –...
  • Page 115 FUEL SYSTEM (DFI) 3-19 Specifications Item Standard Vehicle-down sensor: Detection Method Magnetic flux detection method Detection Angle More than 60 70° for each bank Output Voltage with sensor arrow mark pointed up: 3.55 4.45 V with sensor tilted 60 70° or more: 0.65 1.35 V Subthrottle Sensor: Non-adjustable and non-removal...
  • Page 116: Special Tools And Sealant

    3-20 FUEL SYSTEM (DFI) Special Tools and Sealant Oil Pressure Gauge, 5 kgf/cm²: Peak Voltage Adapter: 57001-125 57001-1415 Fork Oil Level Gauge: Needle Adapter Set: 57001-1290 57001-1457 Vacuum Gauge: Throttle Sensor Setting Adapter: 57001-1369 57001-1538 Hand Tester: Sensor Harness Adapter: 57001-1394 57001-1561 Throttle Sensor Setting Adapter #1:...
  • Page 117 FUEL SYSTEM (DFI) 3-21 Special Tools and Sealant Fuel Hose: Kawasaki Bond (Silicone Sealant): 57001-1607 56019-120...
  • Page 118 3-22 FUEL SYSTEM (DFI) DFI Servicing Precautions DFI Servicing Precautions There are a number of important precautions that should be followed servicing the DFI system. ○ This DFI system is designed to be used with a 12 V sealed battery as its power source. Do not use any other battery except for a 12 V sealed battery as a power source.
  • Page 119: Dfi Servicing Precautions

    FUEL SYSTEM (DFI) 3-23 DFI Servicing Precautions ○ Before removing the fuel system parts, blow the outer sur- faces of these parts clean with compressed air. ○ When any fuel hose is disconnected, fuel may spout out by residual pressure in the fuel line. Cover the hose joint with a piece of clean cloth to prevent fuel spillage.
  • Page 120: Troubleshooting The Dfi System

    3-24 FUEL SYSTEM (DFI) Troubleshooting the DFI System Outline When a problem occurs with DFI system, the warning in- dicator (LED) [A] goes on and FI warning message [B] and FI warning symbol [C] are displayed alternately on the LCD (Liquid Crystal Display) to alert the rider.
  • Page 121 FUEL SYSTEM (DFI) 3-25 Troubleshooting the DFI System With the engine stopped and turned in the self-diagnosis mode, the service code (error code) [A] is displayed on the LCD by the number of two digits. When the service code [A] is displayed, for first ask the rider about the conditions [B] of trouble, and then start to determine the cause [C] of problem.
  • Page 122 LCD. But the service codes stored in memory of the ECU are not erased to preserve the problem history. The problem history can be referred using the KDS (Kawasaki Diagnostic System) when solving unstable problems Much of the DFI system troubleshooting work consists of confirming continuity of the wiring.
  • Page 123 FUEL SYSTEM (DFI) 3-27 Troubleshooting the DFI System • Always check battery condition before replacing the DFI parts. A fully charged battery is a must for conducting accurate tests of the DFI system. • Trouble may involve one or in some cases all items. Never replace a defective part without determining what CAUSED the problem.
  • Page 124 3-28 FUEL SYSTEM (DFI) Troubleshooting the DFI System ○ If both ends of a harness [A] are far apart, ground [B] the one end [C], using a jumper lead [D] and check the con- tinuity between the end [E] and the ground [F]. This en- ables to check a long harness for continuity.
  • Page 125: Inquiries To Rider

    FUEL SYSTEM (DFI) 3-29 Troubleshooting the DFI System DFI Diagnosis Flow Chart Inquiries to Rider ○ Each rider reacts to problems in different ways, so it is important to confirm what kind of symptoms the rider has encountered. ○ Try to find out exactly what problem occurred under exactly what conditions by asking the rider; knowing this information may help you reproduce the problem.
  • Page 126 3-30 FUEL SYSTEM (DFI) Troubleshooting the DFI System Sample Diagnosis Sheet Rider name: Registration No. (license plate No.): Year of initial registration: Model: Engine No.: Frame No.: Date problem occurred: Mileage: Environment when problem occurred. □ □ □ □ □ □...
  • Page 127 FUEL SYSTEM (DFI) 3-31 Troubleshooting the DFI System □ □ □ Poor running at low very low idle speed, very high idle speed, rough idle speed. □ speed battery voltage is low (charge the battery). □ spark plug loose (tighten it). □...
  • Page 128: Dfi System Troubleshooting Guide

    3-32 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide NOTE ○ This is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties in DFI system.
  • Page 129 FUEL SYSTEM (DFI) 3-33 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Fuel pressure regulator trouble Inspect fuel pressure and replace fuel pump (see chapter 16). Fuel line clogged Inspect and repair (see chapter 3). Inlet air pressure sensor trouble Inspect (see chapter 3).
  • Page 130 3-34 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Main throttle sensor trouble Inspect (see chapter 3). Subthrottle sensor trouble Inspect (see chapter 3). Subthrottle valve actuator trouble Inspect (see chapter 3). Inlet air pressure sensor trouble Inspect (see chapter 3).
  • Page 131: Poor Running Or No Power At High Speed

    FUEL SYSTEM (DFI) 3-35 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Inlet air temperature sensor trouble Inspect (see chapter 3). Other: Intermittent any DFI fault and its recovery Check that DFI connectors are clean and tight, and examine leads for signs of burning or fraying (see chapter 3).
  • Page 132 3-36 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Water temperature sensor trouble Inspect (see chapter 3). Inlet air temperature sensor trouble Inspect (see chapter 3). Miscellaneous: Subthrottle sensor trouble Inspect (see chapter 3). Subthrottle valve actuator trouble Inspect (see chapter 3).
  • Page 133: Self-diagnosis

    FUEL SYSTEM (DFI) 3-37 Self-Diagnosis Self-diagnosis Outline The self-diagnosis system has two modes and can be switched to another mode by operating the meter unit. User Mode The ECU notifies the rider of troubles in DFI system , igni- tion system and immobilizer system by lighting up or blink- ing the warning indicator light (LED) [A] and displaying the warning message [B] and warning symbol [C] alternately on the LCD (Liquid Crystal Display) when DFI, ignition and...
  • Page 134: Self-diagnosis Procedures

    3-38 FUEL SYSTEM (DFI) Self-Diagnosis Self-diagnosis Procedures ○ When a problem occurs with DFI system and ignition sys- tem, the warning indicator (LED) [A] goes on and FI warn- ing message [B] and FI warning symbol [C] are displayed alternately on the LCD (Liquid Crystal Display) to alert the rider.
  • Page 135 FUEL SYSTEM (DFI) 3-39 Self-Diagnosis • Turn the ignition switch ON. • Push the MODE button [A] and RESET button [B] for more than two seconds. • The service code [C] is displayed on the LCD by the num- ber of two digits. ○...
  • Page 136 3-40 FUEL SYSTEM (DFI) Self-Diagnosis Self-Diagnosis Flow Chart...
  • Page 137: Service Code Reading

    FUEL SYSTEM (DFI) 3-41 Self-Diagnosis Service Code Reading ○ The service code(s) is displayed on the LCD by the number of two digits. ○ When there are a number of problems, all the service codes can be stored and the display will begin starting from the lowest number service code in the numerical order.
  • Page 138 3-42 FUEL SYSTEM (DFI) Self-Diagnosis Service Code Table Service Code Problems Main throttle sensor malfunction, wiring open or short Inlet air pressure sensor malfunction, wiring open or short Inlet air temperature sensor malfunction, wiring open or short Water temperature sensor malfunction, wiring open or short Atmospheric pressure sensor malfunction, wiring open or short Crankshaft sensor malfunction, wiring open or short Camshaft position sensor malfunction, wiring open or short...
  • Page 139: Backups

    FUEL SYSTEM (DFI) 3-43 Self-Diagnosis Backups ○ The ECU takes the following measures to prevent engine damage when the DFI, ignition or immo- bilizer system parts have troubles. Service Output Signal Usable Parts Backups by ECU Codes Range or Criteria If the main throttle sensor system fails (the Main Throttle Sensor signal is out of the usable range, wiring short...
  • Page 140 3-44 FUEL SYSTEM (DFI) Self-Diagnosis Service Output Signal Usable Parts Backups by ECU Codes Range or Criteria When the relay ON Fuel Pump condition, battery monitor If the relay fails, battery monitor voltage 12 V. Relay voltage 5 V or more The ignition coil primary If the ignition primary winding #1 has failures Stick Coil...
  • Page 141: Main Throttle Sensor (service Code 11)

    FUEL SYSTEM (DFI) 3-45 Main Throttle Sensor (Service Code 11) The main throttle sensor is a rotating variable resistor that change output voltage according to throttle operating. The ECU senses this voltage change and determines fuel injec- tion quantity, and ignition timing according to engine rpm, and throttle opening.
  • Page 142 3-46 FUEL SYSTEM (DFI) Main Throttle Sensor (Service Code 11) • Remove the right fairing cover (see Fairing Cover Re- moval in the Frame chapter). • Disconnect the main throttle sensor connector [A]. • Connect the harness adapter [A] between the harness connector and main throttle sensor connector.
  • Page 143: Output Voltage Inspection

    FUEL SYSTEM (DFI) 3-47 Main Throttle Sensor (Service Code 11) Output Voltage Inspection • Measure the output voltage at the ECU in the same way as input voltage inspection. Note the following. Digital Meter [A] Connector [B] Special Tool - Needle Adapter Set: 57001-1457 Main Throttle Sensor Output Voltage Connections to ECU Connector Meter (+) →...
  • Page 144 3-48 FUEL SYSTEM (DFI) Main Throttle Sensor (Service Code 11) NOTE ○ The standard voltage refers to the value when the volt- age reading at the Input Voltage Inspection shows 5V exactly. ○ When the input voltage reading shows other than 5V, derive a voltage range as follows.
  • Page 145 FUEL SYSTEM (DFI) 3-49 Main Throttle Sensor (Service Code 11) • Disconnect the main throttle sensor connector and con- nect the harness adapter [A] between the harness con- nector and main throttle sensor connector. Special Tool - Throttle Sensor Setting Adapter: 57001 -1538 •...
  • Page 146: Resistance Inspection

    3-50 FUEL SYSTEM (DFI) Main Throttle Sensor (Service Code 11) Resistance Inspection • Turn the ignition switch OFF. • Disconnect the main throttle sensor connector. • Connect a digital meter [A] to the main throttle sensor connector [B]. • Measure the main throttle sensor resistance. Main Throttle Sensor Resistance Connections: BL lead [C] ←→BR/BK lead [D] Standard:...
  • Page 147: Inlet Air Pressure Sensor (service Code 12)

    FUEL SYSTEM (DFI) 3-51 Inlet Air Pressure Sensor (Service Code 12) CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the part can damage it. Removal • Remove: Fuel Tank Cover (see Fuel Tank Removal) Bolt [A] Bracket [B] •...
  • Page 148: Input Voltage Inspection

    3-52 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code 12) Input Voltage Inspection NOTE ○ Be sure the battery is fully charged. ○ The inspection is the same as “Input Voltage Inspection” of the throttle sensor and the atmospheric pressure sen- sor.
  • Page 149: Output Voltage Inspection

    FUEL SYSTEM (DFI) 3-53 Inlet Air Pressure Sensor (Service Code 12) Output Voltage Inspection • Measure the output voltage at the ECU in the same way as input voltage inspection. Note the following. Digital Meter [A] Connector [B] Special Tool - Needle Adapter Set: 57001-1457 Inlet Air Pressure Sensor Output Voltage Connections to ECU Meter (+) →...
  • Page 150 3-54 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code 12) Inlet Air Pressure Sensor Circuit 1. ECU 2. Inlet Air Pressure Sensor 3. Water-proof Joint 2 If you need to check the inlet air pressure sensor for vac- uum other than 76 cmHg (abs.), check the output voltage as follows.
  • Page 151 FUEL SYSTEM (DFI) 3-55 Inlet Air Pressure Sensor (Service Code 12) • Remove the inlet air pressure sensor [A] and disconnect the vacuum hose from the sensor. • Connect an auxiliary hose [B] to the inlet air pressure sen- sor. •...
  • Page 152 3-56 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code 12) ID: Idling Pv: Throttle Vacuum Pressure (abs.) Ps: Standard Atmospheric Pressure (abs.) ST: Standard of Sensor Output Voltage (v) TO: Throttle Full Open UR: Usable Range of Sensor Output Voltage (v) Vv: Inlet Air Pressure Sensor Output Voltage (V) (Digital Meter Reading)
  • Page 153: Inlet Air Temperature Sensor (service Code 13)

    FUEL SYSTEM (DFI) 3-57 Inlet Air Temperature Sensor (Service Code 13) Removal/Installation CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. • Remove the fuel tank (see Fuel Tank Removal). •...
  • Page 154: Sensor Resistance Inspection

    3-58 FUEL SYSTEM (DFI) Inlet Air Temperature Sensor (Service Code 13) If the output voltage is out of the specified, check the ECU for its ground, and power supply (see ECU Power Supply Inspection). If the ground and power supply are good, replace the ECU (see ECU section).
  • Page 155 FUEL SYSTEM (DFI) 3-59 Inlet Air Temperature Sensor (Service Code 13) Inlet Air Temperature Sensor Circuit 1. ECU 2. Inlet Air Temperature Sensor 3. Water-proof Joint 2...
  • Page 156: Water Temperature Sensor (service Code 14)

    3-60 FUEL SYSTEM (DFI) Water Temperature Sensor (Service Code 14) Removal/Installation CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. • Drain the coolant (see Coolant Change in the Periodic Maintenance chapter).
  • Page 157: Sensor Resistance Inspection

    FUEL SYSTEM (DFI) 3-61 Water Temperature Sensor (Service Code 14) Sensor Resistance Inspection • Refer to the Water Temperature Sensor Inspection in the Electrical System chapter (see Water Temperature Sen- sor Inspection in the Electrical System chapter). Water Temperature Sensor Circuit 1.
  • Page 158: Atmospheric Pressure Sensor (service Code 15)

    3-62 FUEL SYSTEM (DFI) Atmospheric Pressure Sensor (Service Code 15) CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. Removal • Remove: Seat (see Seat Removal in the Frame chapter) Atmospheric Pressure Sensor Connector [A] Damper [B] Atmospheric Pressure Sensor [C]...
  • Page 159: Output Voltage Inspection

    FUEL SYSTEM (DFI) 3-63 Atmospheric Pressure Sensor (Service Code 15) If the reading is within the standard range, remove the seat, and check the input voltage again at the sensor con- nector. • Disconnect the atmospheric pressure sensor connector and connect the harness adapter [A] between the harness connector and atmospheric pressure sensor connector.
  • Page 160 3-64 FUEL SYSTEM (DFI) Atmospheric Pressure Sensor (Service Code 15) If the output voltage is far out of the usable range, check the output voltage at the sensor connector [A] (when the wiring is open, the output voltage is about 1.8 V). •...
  • Page 161 FUEL SYSTEM (DFI) 3-65 Atmospheric Pressure Sensor (Service Code 15) If you know the local atmospheric pressure using a barometer, substitute the atmospheric pressure for throt- tle vacuum pressure in the inlet air pressure sensor chart (see Inlet Air Pressure Sensor section). And get the usable range of the atmospheric pressure sensor output voltage and check if output voltage is within the standard or not in the same way as Output Voltage Inspection of...
  • Page 162: Crankshaft Sensor (service Code 21)

    3-66 FUEL SYSTEM (DFI) Crankshaft Sensor (Service Code 21) Crankshaft Sensor Removal/Installation • Refer to the Crankshaft Sensor Removal/Installation in the Electrical System chapter (see Crankshaft Sensor Re- moval/Installation in the Electrical System chapter). Crankshaft Sensor Inspection ○ The crankshaft have no power source, and when the en- gine stops, the crankshaft generates no signals.
  • Page 163: Camshaft Position Sensor (service Code 23)

    FUEL SYSTEM (DFI) 3-67 Camshaft Position Sensor (Service Code 23) Camshaft Position Sensor Removal/Installation The camshaft position sensor detects the position of the camshaft, and distinguishes the cylinder. • Refer to the Camshaft Position Sensor Removal/Installa- tion in the Electrical System chapter (see Camshaft Posi- tion Sensor Removal/Installation in the Electrical System chapter).
  • Page 164: Speed Sensor (service Code 24)

    3-68 FUEL SYSTEM (DFI) Speed Sensor (Service Code 24) Speed Sensor Removal/Installation • Refer to the Speed Sensor Removal/Installation in the Electrical System chapter (see Speed Sensor Re- moval/Installation in the Electrical System chapter). Speed Sensor Inspection • Refer to the Speed Sensor Inspection in the Electrical System chapter (see Speed Sensor Inspection in the Electrical System chapter).
  • Page 165: Output Voltage Inspection

    FUEL SYSTEM (DFI) 3-69 Speed Sensor (Service Code 24) Output Voltage Inspection • Before this inspection, inspect the input voltage (see Input Voltage Inspection in this section). NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch OFF. •...
  • Page 166 3-70 FUEL SYSTEM (DFI) Speed Sensor (Service Code 24) 1. ECU 2. Meter Unit 3. Speed Sensor 4. Frame Ground 1...
  • Page 167: Gear Position Switch (service Code 25)

    FUEL SYSTEM (DFI) 3-71 Gear Position Switch (Service Code 25) Gear Position Switch Removal/Installation • Refer to the Gear Position Switch Removal/Installation in the Electrical System chapter (see Gear Position Switch Removal/Installation in the Electrical System chapter). Gear Position Switch Inspection •...
  • Page 168 3-72 FUEL SYSTEM (DFI) Gear Position Switch (Service Code 25) Gear Position Switch Circuit 1. ECU 2. Gear Position Switch 3. Joint Connector 1 4. Joint Connector 2 5. Frame Ground 1...
  • Page 169: Vehicle-down Sensor (service Code 31)

    FUEL SYSTEM (DFI) 3-73 Vehicle-down Sensor (Service Code 31) This sensor has a weight [A] with two magnets inside, and sends a signal to the ECU. But when the motorcycle banks 60 70° or more to either side (in fact falls down), the weight turns and shuts off the signal.
  • Page 170: Inspection

    3-74 FUEL SYSTEM (DFI) Vehicle-down Sensor (Service Code 31) Inspection NOTE ○ Be sure the battery is fully charged. • Remove the Windshield (see Windshield Removal in the Frame chapter). • Connect a digital meter [A] to the connector of the vehicle -down sensor [B], with the needle adapter set [C].
  • Page 171 FUEL SYSTEM (DFI) 3-75 Vehicle-down Sensor (Service Code 31) • Turn the ignition switch OFF. • Remove the vehicle-down sensor. ○ Do not disconnect the sensor connector. • Connect a digital meter [A] to the connector, with needle adapter set [B]. Special Tool - Needle Adapter Set: 57001-1457 Vehicle-down sensor Output Voltage Connections to Sensor...
  • Page 172: Subthrottle Sensor (service Code 32)

    3-76 FUEL SYSTEM (DFI) Subthrottle Sensor (Service Code 32) The subthrottle sensor is a rotating variable resistor that change output voltage according to throttle operating. The ECU senses this voltage change and determines fuel injec- tion quantity, and ignition timing according to engine rpm, and throttle opening.
  • Page 173 FUEL SYSTEM (DFI) 3-77 Subthrottle Sensor (Service Code 32) • Remove the right fairing cover (see Fairing Cover Re- moval in the Frame chapter). • Disconnect the subthrottle sensor connector [A]. • Connect the harness adapter [A] between the harness connector and subthrottle sensor connector.
  • Page 174: Output Voltage Inspection

    3-78 FUEL SYSTEM (DFI) Subthrottle Sensor (Service Code 32) Output Voltage Inspection • Measure the output voltage at the ECU in the same way as input voltage inspection. Note the following. Digital Meter [A] Connector [B] Special Tool - Needle Adapter Set: 57001-1457 Subthrottle Sensor Output Voltage Connections to ECU Connector Meter (+) →...
  • Page 175 FUEL SYSTEM (DFI) 3-79 Subthrottle Sensor (Service Code 32) • Disconnect the subthrottle sensor connector [A] and con- nect the harness adapter [B] between the harness con- nector and subthrottle sensor connector. Special Tool - Throttle Sensor Harness Adapter: 57001 -1538 •...
  • Page 176: Resistance Inspection

    3-80 FUEL SYSTEM (DFI) Subthrottle Sensor (Service Code 32) Resistance Inspection • Turn the ignition switch OFF. • Disconnect the subthrottle sensor connector. • Connect a digital meter [A] to the subthrottle sensor con- nector [B]. • Measure the subthrottle sensor resistance. Subthrottle Sensor Resistance Connections: BL lead [C] ←→...
  • Page 177: Immobilizer Amplifier (service Code 35)

    FUEL SYSTEM (DFI) 3-81 Immobilizer Amplifier (Service Code 35) Antenna Resistance Inspection • Remove the left inner cover (see Inner Cover Removal in the Frame chapter). • Disconnect the antenna lead connector [A]. • Measure the resistance of the antenna coil in the ignition switch as follows.
  • Page 178: Blank Key Detection (service Code 36)

    14. Battery 12 V 14 Ah 6. Fuse Box × 2 15. Frame Ground 1 7. ECU Fuse 15 A 16. Frame Ground 2 8. Ignition Fuse 10 A 17. Immobilizer/Kawasaki Diagnostic System 9. Main Relay Connector 18. Water-proof Joint 1 19. ECU...
  • Page 179: Fuel Pump Relay (service Code 46)

    FUEL SYSTEM (DFI) 3-83 Fuel Pump Relay (Service Code 46) Fuel Pump Relay Removal CAUTION Never drop the relay, especially on a hard surface. Such a shock to the relay can damage it. ○ The fuel pump relay is included in the relay box. •...
  • Page 180 3-84 FUEL SYSTEM (DFI) Fuel Pump Relay (Service Code 46) Fuel Pump Relay Circuit 1. Ignition Switch 10. Fuel Pump Relay 2. Joint Connector 1 11. Relay Box 3. Engine Stop Switch 12. Joint Connector 2 4. Water-proof Joint 1 13.
  • Page 181: Stick Coils #1, #2, #3, #4: (service Code 51, 52, 53, 54)

    FUEL SYSTEM (DFI) 3-85 Stick Coils #1, #2, #3, #4: (Service Code 51, 52, 53, 54) Stick Coil #1: Service Code 51 Stick Coil #2: Service Code 52 Stick Coil #3: Service Code 53 Stick Coil #4: Service Code 54 Removal/Installation CAUTION Never drop the stick coils, especially on a hard sur-...
  • Page 182 3-86 FUEL SYSTEM (DFI) Stick Coils #1, #2, #3, #4: (Service Code 51, 52, 53, 54) Stick Coil Circuit 1. ECU 9. Ignition Fuse 10 A 2. Stick Coil #4 10. Starter Relay 3. Stick Coil #3 11. Main Fuse 30 A 4.
  • Page 183: Subthrottle Valve Actuator (service Code 62)

    FUEL SYSTEM (DFI) 3-87 Subthrottle Valve Actuator (Service Code 62) Subthrottle Valve Actuator Removal CAUTION Do not remove the subthrottle valve actuator [A] since it has been adjusted and set with precision at the factory. Never drop the actuator , especially on a hard sur- face.
  • Page 184: Input Voltage Inspection

    3-88 FUEL SYSTEM (DFI) Subthrottle Valve Actuator (Service Code 62) Input Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch OFF. • Connect the peak voltage adapter [A] and a digital meter [B] to the connector [C], using the needle adapter set [D]. Special Tools - Peak Voltage Adapter: 57001-1415 Type: KEK-54-9-B Needle Adapter Set: 57001-1457...
  • Page 185 FUEL SYSTEM (DFI) 3-89 Subthrottle Valve Actuator (Service Code 62) Subthrottle Valve Actuator Circuit 1. ECU 2. Subthrottle Valve Actuator 3. Subthrottle Sensor 4. Main Throttle Sensor 5. Water-proof Joint 2...
  • Page 186: Ecu Main Relay (service Code 75)

    3-90 FUEL SYSTEM (DFI) ECU Main Relay (Service Code 75) ECU Main Relay Inspection ○ The ECU main relay function is included in the ECU [A]. So, the ECU main relay function cannot be inspected. • When the service code 75 is displayed on the LCD, re- place the ECU (see ECU section).
  • Page 187: Ecu

    FUEL SYSTEM (DFI) 3-91 CAUTION Never drop the ECU, especially on a hard surface. Such a shock to the ECU can damage it. ECU Identification ○ Most countries have their own regulations, so each ECU has different characteristic. So, do not confuse ECU with each other and use only the ECU for your model.
  • Page 188: Ecu Installation

    3-92 FUEL SYSTEM (DFI) • Remove: Fuse Box [A] Bolts [B] Tool Kit Case [C] • Remove the relay box [A]. • Lift up the ECU [B] with rubber protector [C]. • Remove: ECU Connectors [A] ECU [B] • Refer to the Immobilizer System Parts Replacement in the Electrical System chapter for the immobilizer models (see Immobilizer System Parts Replacement in the Electrical System chapter).
  • Page 189: Ecu Power Supply Inspection

    FUEL SYSTEM (DFI) 3-93 • Install: Connector Holder [A] Relay Box [B] • Install the plate [A] to the tool kit case [B] and tighten the bolts [C]. • Insert the stopper [D] of the fuse box [E] into the groove of the tool case.
  • Page 190 3-94 FUEL SYSTEM (DFI) • Check the ECU power source voltage with a digital meter [A]. ○ Position the terminal in accordance with terminal numbers of ECU connectors [B] in the figure. ECU Power Source Inspection Tester Connections: between 33 (BR) Terminal and Frame Ground 2 [C] between 15 (W/BK) Terminal and Frame Ground 2 [C]...
  • Page 191: Can Communication Line Resistance Inspection

    FUEL SYSTEM (DFI) 3-95 ECU Power Source Circuit 1. ECU 2. Water-proof Joint 1 3. Ignition Switch 4. ECU Fuse 15 A 5. Fuse Box 2 6. Starter Relay 7. Main Fuse 30 A 8. Battery 12 V 14 Ah 9.
  • Page 192 3-96 FUEL SYSTEM (DFI) • Connect a digital meter [A] to the ECU connector [B]. • Measure the resistance of the CAN communication line resistor. CAN Communication Line Resistance (at ECU Connector) Connections: Terminal 1 ←→Terminal 18 Standard: 114 126 Ω If the reading is out of the range, replace the ECU (see ECU section).
  • Page 193: Dfi Power Source

    FUEL SYSTEM (DFI) 3-97 DFI Power Source ECU Fuse Removal • Refer to the ECU Fuse 15 A Removal in the Electrical Sys- tem chapter (see 15 A ECU Fuse Removal in the Electri- cal System chapter). ECU Fuse Installation If a fuse fails during operation, inspect the DFI system to determine the cause, and then replace it with a new fuse of proper amperage.
  • Page 194: Warning Indicator Light (led)

    3-98 FUEL SYSTEM (DFI) Warning Indicator Light (LED) Light (LED) Inspection ○ The warning indicator light (LED) [A] is used for the FI indicator and immobilizer indicator (immobilizer models). ○ In this model, the warning indicator light (LED) goes on or blinks by the special signal sent from the ECU.
  • Page 195: Fuel Line

    FUEL SYSTEM (DFI) 3-99 Fuel Line Fuel Pressure Inspection NOTE ○ Be sure the battery is fully charged. • Remove the fuel tank (see Fuel Tank Removal). • Be sure to place a piece of cloth around the fuel supply pipe of the throttle body assy.
  • Page 196: Fuel Flow Rate Inspection

    3-100 FUEL SYSTEM (DFI) Fuel Line • Start the engine, and let it idle. • Measure the fuel pressure with the engine idling. Fuel Pressure (idling) Standard: 304 kPa (3.1 kgf/cm², 44 psi) NOTE ○ The gauge hand will fluctuate. Read the pressure at the average of the maximum and minimum indications.
  • Page 197 FUEL SYSTEM (DFI) 3-101 Fuel Line • Remove the fuel tank bolts [A]. • Open the fuel tank cap [A] to lower the pressure in the tank. • Be sure to place a piece of cloth around the fuel supply pipe of the fuel pump.
  • Page 198 3-102 FUEL SYSTEM (DFI) Fuel Line WARNING Wipe off spilled out fuel immediately. Be sure to hold the measuring cylinder vertical. • Close the fuel tank cap. • With the engine stopped, turn the ignition switch ON. The fuel pump should operate for 3 seconds, and then should stop.
  • Page 199: Fuel Pump

    FUEL SYSTEM (DFI) 3-103 Fuel Pump Fuel Pump Removal CAUTION Never drop the fuel pump, especially on a hard sur- face. Such a shock to the pump can damage it. WARNING Gasoline is extremely flammable and can be explo- sive under certain conditions. Make sure the area is well-ventilated and free from any source of flame or sparks;...
  • Page 200: Operation Inspection

    3-104 FUEL SYSTEM (DFI) Fuel Pump • Check that the fuel pump terminals [A], fuel reserve switch terminal [B] and band [C] are in place. Front [D] • Apply a non-permanent locking agent to the threads of the fuel pump bolts. •...
  • Page 201 FUEL SYSTEM (DFI) 3-105 Fuel Pump Fuel Pump Circuit 1. Ignition Switch 10. Fuel Pump Relay 2. Joint Connector 1 11. Relay Box 3. Engine Stop Switch 12. Joint Connector 2 4. Water-proof Joint 1 13. Main Fuse 30 A 5.
  • Page 202: Fuel Injectors

    3-106 FUEL SYSTEM (DFI) Fuel Injectors Removal/Installation • Refer to the Throttle Body Assy Disassembly/Assembly (see Throttle Body Assy Disassembly/Assembly). CAUTION Never drop the injector, especially on a hard sur- face. Such a shock to the injector can damage it. Power Source Voltage Inspection NOTE ○...
  • Page 203: Output Voltage Inspection

    FUEL SYSTEM (DFI) 3-107 Fuel Injectors • Connect a digital meter [A] to the throttle body subharness connector [B], using the needle adapter set [C]. Special Tool - Needle Adapter Set: 57001-1457 Injector Power Source Voltage at Injector Connections to Injector #1, #2, #3, #4 Meter (+) →...
  • Page 204: Audible Inspection

    3-108 FUEL SYSTEM (DFI) Fuel Injectors If the output voltage is out of the standard, check the out- put voltage at the throttle body subharness connector [B] using a digital meter [A] and needle adapter set [C] (when the lead is open, the output voltage is 0 V). Special Tool - Needle Adapter Set: 57001-1457 Injector Output Voltage at Injector Connections to Injector #1...
  • Page 205: Injector Signal Test

    FUEL SYSTEM (DFI) 3-109 Fuel Injectors Injector Signal Test • Prepare two test light sets with male terminals as shown. Rating of Bulb [A]: 12 V × 3 ~ 3.4 W Terminal Width [B]: 1.8 mm (0.07 in.) Terminal Thickness [C]: 0.8 mm (0.03 in.) CAUTION Do not use larger terminals than specified above.
  • Page 206: Injector Unit Test

    3-110 FUEL SYSTEM (DFI) Fuel Injectors Injector Unit Test • Use two leads [A] and the same test light set [B] as in “Injector Signal Test”. Rating of Bulb [C]: 12 V × (3 3.4) W 12 V MF Battery [D] CAUTION Be sure to connect the bulb in series.
  • Page 207 FUEL SYSTEM (DFI) 3-111 Fuel Injectors Fuel Injector Circuit 1. Ignition Switch 12. Fuse Box 2 2. Joint Connector 1 13. Main Relay 3. Engine Stop Switch 14. Fuel Pump Relay 4. Fuel Injector #4 15. Relay Box 5. Fuel Injector #3 16.
  • Page 208: Throttle Grip And Cables

    3-112 FUEL SYSTEM (DFI) Throttle Grip and Cables Free Play Inspection • Refer to the Throttle Control System Inspection in the Pe- riodic Maintenance chapter (see Throttle Control System Inspection in the Periodic Maintenance chapter). Free Play Adjustment • Refer to the Throttle Control System Inspection in the Pe- riodic Maintenance chapter (see Throttle Control System Inspection in the Periodic Maintenance chapter).
  • Page 209: Throttle Body Assy

    FUEL SYSTEM (DFI) 3-113 Throttle Body Assy Idle Speed Inspection • Refer to the Idle Speed Inspection in the Periodic Mainte- nance chapter (see Idle Speed Inspection in the Periodic Maintenance chapter). Throttle Bore Cleaning • Check the throttle bore for cleanliness as follows. ○...
  • Page 210 3-114 FUEL SYSTEM (DFI) Throttle Body Assy • Disconnect the throttle body subharness connector [A]. • Remove the connector [A] from the connector bracket. ○ Insert the thin blade screw driver into the connector stop- per portion from the right side of motorcycle. •...
  • Page 211 FUEL SYSTEM (DFI) 3-115 Throttle Body Assy • Remove: Fuel Tank (see Fuel Tank Removal) Inlet Air Temperature Sensor [A] Bolts [B] Left and Right Air Cleaner Caps [C] ○ Do not disconnect the inlet air temperature sensor lead connector. •...
  • Page 212: Throttle Body Assy Installation

    3-116 FUEL SYSTEM (DFI) Throttle Body Assy • Remove the adjuster screw [A] from the clamp [B]. • Loosen the throttle body assy holder clamp bolts [A] on both sides. • Pull out the throttle body assy [B] from the holder. •...
  • Page 213 FUEL SYSTEM (DFI) 3-117 Throttle Body Assy If the grommet [A] was removed, install it. ○ Install the grommet from the inside of the frame. • Insert the duct [B] to the grommet. ○ Apply a soap and water solution or rubber lubricant to the oblique portion [C] on the duct for easy installation.
  • Page 214: Throttle Body Assy Disassembly

    3-118 FUEL SYSTEM (DFI) Throttle Body Assy Throttle Body Assy Disassembly 1. Subthrottle Valve Actuator 2. Subthrottle Sensor 3. Main Throttle Sensor 4. Throttle Body Assy 5. Injector 6. Delivery Pipe 7. Throttle Body Subharness CAUTION Do not remove, disassemble or adjust the main throttle sensor, subthrottle sensor, subthrottle valve actuator, throttle link mechanism and throttle body assy, because they are adjust or set surely at...
  • Page 215: Throttle Body Assy Assembly

    FUEL SYSTEM (DFI) 3-119 Throttle Body Assy • Disconnect the main throttle sensor [A] and subthrottle sensor [B] connector. • Disconnect: Subthrottle Valve Actuator Lead Connector [A] Inlet Air Pressure Sensor Connector [B] • Separete the hoses [A] from the throttle body fittings and inlet air pressure sensor.
  • Page 216 3-120 FUEL SYSTEM (DFI) Throttle Body Assy • Apply daphne oil or engine oil to the new dust seals [A], and insert the injectors into the throttle body, which in- stalled to the delivery pipe. NOTE ○ Replace the dust seals of the throttle body to new ones. •...
  • Page 217: Air Line

    FUEL SYSTEM (DFI) 3-121 Air Line Element Removal • Refer to the Air Cleaner Element Replacement in the Pe- riodic Maintenance chapter (see Air Cleaner Element Re- placement in the Periodic Maintenance chapter). Element Installation • Refer to the Air Cleaner Element Replacement in the Pe- riodic Maintenance chapter (see Air Cleaner Element Re- placement in the Periodic Maintenance chapter).
  • Page 218: Oil Draining

    3-122 FUEL SYSTEM (DFI) Air Line Oil Draining A drain hose is connected to the bottom of the air cleaner part to drain water or oil accumulated in the cleaner part. • Visually check the catch tank of the drain hose [A], if the water or oil accumulates in the tank.
  • Page 219: Front And Middle Air Inlet Duct Removal

    FUEL SYSTEM (DFI) 3-123 Air Line • Install the clamp bolts [A] so that bolt heads [B] faces direction as shown. Left Clamp [C] Right Clamp [D] About 30° [E] Rear View [F] • Tighten: Torque - Middle Air inlet Duct Clamp Bolts: 2.9 N·m (0.30 kgf·m, 26 in·lb) Front and Middle Air Inlet Duct Removal •...
  • Page 220 3-124 FUEL SYSTEM (DFI) Air Line • Insert the middle air inlet duct [A] until the line [B] align the duct end [C] of rear air inlet duct [D]. • Tighten: Torque - Middle Air Inlet Duct Mounting Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) •...
  • Page 221: Fuel Tank

    FUEL SYSTEM (DFI) 3-125 Fuel Tank Fuel Tank Removal WARNING Gasoline is extremely flammable and can be explo- sive under certain conditions. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light.
  • Page 222 3-126 FUEL SYSTEM (DFI) Fuel Tank • Disconnect: Fuel Pump Lead Connector [A] Fuel Level Sensor Lead Connector [B] • Open the fuel tank cap [A] to lower the pressure in the tank. ○ During tank removal, keep the tank cap open to release pressure in the tank.
  • Page 223: Fuel Tank Installation

    FUEL SYSTEM (DFI) 3-127 Fuel Tank • For the California Model, note the following. CAUTION For the California model, if gasoline, solvent, water or any other liquid enters the canister, the canister’s vapor absorbing capacity is greatly reduced. If the canister does become contaminated, replace it with a new one.
  • Page 224 3-128 FUEL SYSTEM (DFI) Fuel Tank • Pull the joint lock [A] as shown. • Insert the fuel hose joint [A] straight onto the delivery pipe until the hose joint clicks. • Push the joint lock [B] until the hose joint clicks. •...
  • Page 225: Fuel Tank And Cap Inspection

    FUEL SYSTEM (DFI) 3-129 Fuel Tank • Fit the dampers [A] of the fuel tank into the slots [B] of the fuel tank cover [C]. Fuel Tank and Cap Inspection • Visually inspect the gasket [A] on the tank cap for any damage.
  • Page 226: Evaporative Emission Control System

    3-130 FUEL SYSTEM (DFI) Evaporative Emission Control System The Evaporative Emission Control System routes fuel va- pors from the fuel system into the running engine or stores the vapors in a canister when the engine is stopped. Al- though no adjustments are required, a thorough visual in- spection must be made at the intervals specified by the Pe- riodic Maintenance Chart.
  • Page 227: Separator Operation Test

    FUEL SYSTEM (DFI) 3-131 Evaporative Emission Control System Separator Operation Test WARNING Gasoline is extremely flammable and can be ex- plosive under certain conditions. Turn the ignition switch OFF. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks;...
  • Page 228 3-132 FUEL SYSTEM (DFI) Evaporative Emission Control System 1. Fuel Tank 2. White Hose (Vacuum) 3. Throttle Body Assy 4. Green Hose (Purge) 5. Canister 6. Band (for Canister) 7. Red Hose (Right, Return) 8. Fitting 9. Bracket (for Separator) 10.
  • Page 229 COOLING SYSTEM 4-1 Cooling System Table of Contents Exploded View........................Coolant Flow Chart......................... Specifications ......................... Coolant ........................... Coolant Deterioration Inspection..................Coolant Level Inspection....................Coolant Draining ....................... Coolant Filling ........................Pressure Testing ....................... Cooling System Flushing ....................Coolant Reserve Tank Removal/Installation ..............Water Pump..........................
  • Page 230: Exploded View

    4-2 COOLING SYSTEM Exploded View...
  • Page 231 COOLING SYSTEM 4-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Radiator Hose Clamp Screws 0.20 18 in·lb Coolant Drain Plug 106 in·lb Water Pump Cover Bolts 87 in·lb Oil Cooler Mounting Bolts 106 in·lb Thermostat Housing Cover Bolts 0.60 52 in·lb Thermostat Housing Mounting Bolts 87 in·lb...
  • Page 232: Coolant Flow Chart

    4-4 COOLING SYSTEM Coolant Flow Chart...
  • Page 233 COOLING SYSTEM 4-5 Coolant Flow Chart Permanent type antifreeze is used as a coolant to protect the cooling system from rust and corrosion. When the engine starts, the water pump turns and the coolant circulates. The thermostat is a wax pellet type which opens or closes with coolant temperature changes. The thermostat continuously changes its valve opening to keep the coolant temperature at the proper level.
  • Page 234: Specifications

    4-6 COOLING SYSTEM Specifications Item Standard Coolant Provided when Shipping Type (Recommended) Permanent type of antifreeze (soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators) Color Green Mixed Ratio Soft water 50%, coolant 50% Freezing Point –35°C (–31°F) Total Amount...
  • Page 235: Coolant

    COOLING SYSTEM 4-7 Coolant Coolant Deterioration Inspection • Visually inspect the coolant in the reserve tank. If whitish cotton-like wafts are observed, aluminum parts in the cooling system are corroded. If the coolant is brown, iron or steel parts are rusting. In either case, flush the cooling system.
  • Page 236: Cooling System Flushing

    4-8 COOLING SYSTEM Coolant Cooling System Flushing Over a period of time, the cooling system accumulates rust, scale, and lime in the water jacket and radiator. When this accumulation is suspected or observed, flush the cool- ing system. If this accumulation is not removed, it will clog up the water passage and considerable reduce the effi- ciency of the cooling system.
  • Page 237: Water Pump

    COOLING SYSTEM 4-9 Water Pump Water Pump Removal • Drain: Coolant (see Coolant Change in the Periodic Mainte- nance chapter) Engine Oil (see Engine Oil Change in the Periodic Main- tenance chapter) • Remove: Clutch Slave Cylinder (see Clutch Slave Cylinder Re- moval in the Clutch chapter) Engine Sprocket Cover (see Engine Sprocket Removal in the Final Drive chapter)
  • Page 238: Water Pump Impeller Inspection

    4-10 COOLING SYSTEM Water Pump • Install the water pump cover [A]. • Tighten: Torque - Water Pump Cover Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) • Install the water hose [B] as shown. Water Pump Impeller Inspection • Visually inspect the water pump impeller [A]. If the surface is corroded or if the blades are damaged, replace the water pump assy.
  • Page 239: Radiator

    COOLING SYSTEM 4-11 Radiator Radiator and Radiator Fan Removal • Remove: Middle Fairings (see Middle Fairing Removal in the Frame chapter) Coolant (Drain, see Coolant Change in the Periodic Maintenance chapter) Reservoir Tank Hose [A] Air Bleeder Hose [B] for Thermostat Housing Radiator Hose [C] Oil Cooler Outlet Hose [D] Radiator Upper Bolt [E]...
  • Page 240: Radiator And Radiator Fan Installation

    4-12 COOLING SYSTEM Radiator Radiator and Radiator Fan Installation • Be sure that the trim seals [A] are in position on the radi- ator as shown. • Install the dampers [B], radiator bracket collars [C] and bolts as shown. Radiator Inspection •...
  • Page 241: Radiator Cap Inspection

    COOLING SYSTEM 4-13 Radiator Radiator Cap Inspection • Remove: Right Middle Fairing (see Middle Fairing Removal in the Frame chapter) Radiator Cap • Check the condition of the bottom [A] and top [B] valve seals and valve spring [C]. If any one of them shows visible damage, replace the cap with a new one.
  • Page 242: Thermostat

    4-14 COOLING SYSTEM Thermostat Thermostat Removal • Drain the coolant (see Coolant Change in the Periodic Maintenance chapter). • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Throttle Body Assy (see Throttle Body Assy Removal in the Fuel System (DFI) chapter) Thermostat Housing Mounting Bolts [A] Radiator Hose [B]...
  • Page 243 COOLING SYSTEM 4-15 Thermostat • To check valve opening temperature, suspend the ther- mostat [A] in a container of water and raise the tempera- ture of the water. ○ The thermostat must be completely submerged and must not touch the container sides or bottom. Suspend an ac- curate thermometer [B] in the water so that the heat sen- sitive portions [C] are located in almost the same depth.
  • Page 244: Hoses And Pipes

    4-16 COOLING SYSTEM Hoses and Pipes Hose Installation • Install the hoses and pipes, being careful to follow bend- ing direction. Avoid sharp bending, kinking, flattening or twisting. • Run the hoses (see Cable, Wire, and Hose Routing sec- tion in the Appendix chapter). •...
  • Page 245: Water Temperature Sensor

    COOLING SYSTEM 4-17 Water Temperature Sensor CAUTION The water temperature sensor should never be al- lowed to fall on a hard surface. Such a shock to their parts can damage them. Water Temperature Sensor Removal • Refer to the Water Temperature Sensor Removal in the Fuel System (DFI) chapter.
  • Page 247 ENGINE TOP END 5-1 Engine Top End Table of Contents Exploded View........................Exhaust System........................Specifications ......................... Special Tools and Sealant ...................... Clean Air System........................5-11 Air Suction Valve Removal....................5-11 Air Suction Valve Installation..................... 5-11 Air Suction Valve Inspection ..................... 5-12 Air Switching Valve Removal ....................
  • Page 248: Exploded View

    5-2 ENGINE TOP END Exploded View...
  • Page 249 M: Apply molybdenum disulfide grease. MO: Apply molybdenum disulfide oil. (mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 : 1) R: Replacement Parts S: Follow the specific tightening sequence. SS: Apply silicone sealant (Kawasaki Bond: 92104-0004).
  • Page 250 5-4 ENGINE TOP END Exploded View...
  • Page 251 ENGINE TOP END 5-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Muffler Body Mounting Bolts Crankshaft Sensor Cover Bolts 87 in·lb L (1) 3. Muffler Body Clamp Bolts 4. Exhaust Pipe Manifold Holder Nuts L: Apply a non-permanent locking agent. R: Replacement Parts...
  • Page 252: Exhaust System

    5-6 ENGINE TOP END Exhaust System Full: Full Power H: Honeycomb Type Catalyst 78.2: Hosepower 78.2 kW (106.3 ps) Manifold Mark Position [A]...
  • Page 253 ENGINE TOP END 5-7 Exhaust System Silencer Mark Position [A] Honeycomb Type Catalyst [A]...
  • Page 254: Specifications

    5-8 ENGINE TOP END Specifications Item Standard Service Limit Camshafts Cam Height: Exhaust 34.442 34.556 mm (1.3560 1.3605 in.) 34.34 mm (1.352 in.) Inlet 34.943 35.057 mm (1.3757 1.3802 in.) 34.84 mm (1.372 in.) Camshaft Journal, Camshaft 0.038 0.081 mm (0.0015 0.0032 in.) 0.17 mm (0.0067 in.) Cap Clearance...
  • Page 255: Special Tools And Sealant

    ENGINE TOP END 5-9 Special Tools and Sealant Compression Gauge, 20 kgf/cm²: Valve Seat Cutter, 60° - 30: 57001-221 57001-1123 Valve Spring Compressor Assembly: Valve Seat Cutter Holder Bar: 57001-241 57001-1128 Valve Seat Cutter, 45° - 35: Valve Seat Cutter, 45° - 30: 57001-1116 57001-1187 Valve Seat Cutter, 32°...
  • Page 256 Valve Seat Cutter Holder, 5: Compression Gauge Adapter, M10 × 1.0: 57001-1208 57001-1601 Valve Seat Cutter, 60° - 33: L-Shape Hose: 57001-1334 57001-1606 Valve Guide Driver: Valve Guide Driver Attachment, E: 57001-1564 57001-1677 Valve Spring Compressor Adapter, 24: Kawasaki Bond (Silicone Sealant): 57001-1586 92104-0004...
  • Page 257: Clean Air System

    ENGINE TOP END 5-11 Clean Air System Air Suction Valve Removal • Remove: Middle Fairings (see Middle Fairing Removal in the Frame chapter) • Pull out the hoses [A]. • Disconnect the connector [B]. • Remove the air switching valve [C] with the hoses. •...
  • Page 258: Air Suction Valve Inspection

    5-12 ENGINE TOP END Clean Air System Air Suction Valve Inspection • Remove the air suction valve (see Air Suction Valve Re- moval). • Visually inspect the reeds [A] for cracks, folds, warps, heat damage, or other damage. If there is any doubt as to the condition of the reed, replace the air suction valve as an assembly.
  • Page 259: Cylinder Head Cover

    Cylinder Head Cover Installation • Replace the head cover gasket with a new one. • Apply silicone sealant [A] to the cylinder head as shown. Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004 • Install: Dowel Pins [A] Plug Hole Gaskets [B]...
  • Page 260 5-14 ENGINE TOP END Cylinder Head Cover • Install the washer [A] with the metal side faces upward. • Tighten the cover bolts, following the sequence numbers on the cover. Torque - Cylinder Head Cover Bolts [B]: 9.8 N·m (1.0 kgf·m, 87 in·lb) •...
  • Page 261: Camshaft Chain Tensioner

    ENGINE TOP END 5-15 Camshaft Chain Tensioner Camshaft Chain Tensioner Removal CAUTION Do not turn over the crankshaft while the tensioner is removed. This could upset the camshaft chain timing, and damage the valves. • Remove the right middle fairing (see Middle Fairing Re- moval in the Frame chapter).
  • Page 262 5-16 ENGINE TOP END Camshaft Chain Tensioner • Lightly hit the push rod head [A] with a minus screw driver [B] to move out the push rod. NOTE ○ You hear of the sound from which the push rod moves out.
  • Page 263: Camshaft, Camshaft Chain

    ENGINE TOP END 5-17 Camshaft, Camshaft Chain Camshaft Removal • Remove: Cylinder Head Cover (see Cylinder Head Cover Re- moval) Crankshaft Sensor Cover • Position the crankshaft at #1, 4 piston TDC. TDC mark [A] for #1, 4 Pistons Timing Mark (crankcase halves mating surface) [B] •...
  • Page 264 5-18 ENGINE TOP END Camshaft, Camshaft Chain • Apply engine oil to all cam parts and journals. • If a new camshaft is to be used, apply a thin coat of molyb- denum disulfide grease to the cam surfaces. NOTE ○...
  • Page 265 ENGINE TOP END 5-19 Camshaft, Camshaft Chain ○ The timing marks must be aligned with the cylinder head upper surface [A]. EX mark [B] IN mark [C]...
  • Page 266: Camshaft, Camshaft Cap Wear

    5-20 ENGINE TOP END Camshaft, Camshaft Chain • Install the camshaft cap, following the identification No. [A] and chain guide [B]. ○ First tighten the camshaft cap and all chain guide bolts evenly to seat the camshaft in place, then tighten all bolts following the specified tightening sequence.
  • Page 267: Camshaft Runout

    ENGINE TOP END 5-21 Camshaft, Camshaft Chain If any clearance exceeds the service limit, measure the diameter of each camshaft journal with a micrometer. Camshaft Journal Diameter Standard: 23.940 23.962 mm (0.9425 0.9434 in.) Service Limit: 23.91 mm (0.941 in.) If the camshaft journal diameter is less than the service limit, replace the camshaft with a new one and measure the clearance again.
  • Page 268: Camshaft Chain Installation

    5-22 ENGINE TOP END Camshaft, Camshaft Chain • Remove the crankshaft sprocket [A]. • Pull out the camshaft chain [B] from downward. Camshaft Chain Installation • Install the camshaft chain from head side. • Install the crankshaft sprocket [A] on the crankshaft [B] with their teeth [C] aligned.
  • Page 269: Cylinder Head

    ENGINE TOP END 5-23 Cylinder Head Cylinder Compression Measurement NOTE ○ Use the battery which is fully charged. • Warm up the engine thoroughly. • Stop the engine. • Remove: Stick Coils (see Stick Coil (Ignition Coil together with Spark Plug Cap) Removal in the Electrical System chap- ter) Spark Plugs (see Spark Plug Replacement in the Peri- odic Maintenance chapter)
  • Page 270: Cylinder Head Removal

    5-24 ENGINE TOP END Cylinder Head Cylinder Head Removal • Drain the coolant (see Coolant Change in the Periodic Maintenance chapter). • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Throttle Body Assy (see Throttle Body Assy Removal in the Fuel System (DFI) chapter) Exhaust Pipe (see Exhaust Pipe Removal) Cylinder Head Cover (see Cylinder Head Cover Re-...
  • Page 271: Cylinder Head Warp

    ENGINE TOP END 5-25 Cylinder Head • Tighten the M11 cylinder head bolts following the tighten- ing sequence [1 10]. Torque - Cylinder Head Bolts (M11): First: 39 N·m (4.0 kgf·m, 29 ft·lb) Final: 71 N·m (7.2 kgf·m, 52 ft·lb) •...
  • Page 272: Valves

    5-26 ENGINE TOP END Valves Valve Clearance Inspection • Refer to the Valve Clearance Inspection in the Periodic Maintenance chapter. Valve Removal • Remove the cylinder head (see Cylinder Head Removal). • Remove the valve lifter and shim. ○ Mark and record the valve lifter and shim locations so they can be installed in their original positions.
  • Page 273: Valve Guide Installation

    ENGINE TOP END 5-27 Valves Valve Guide Installation • Apply oil to the valve guide outer surface before installa- tion. • Heat the area around the valve guide hole to about 120 150°C (248 302°F). CAUTION Do not heat the cylinder head with a torch. This Will warp the cylinder head.
  • Page 274: Valve-to-guide Clearance Measurement (wobble Method)

    5-28 ENGINE TOP END Valves Valve-to-Guide Clearance Measurement (Wobble Method) If a small bore gauge is not available, inspect the valve guide wear by measuring the valve to valve guide clearance with the wobble method as indicated below. • Insert a new valve [A] into the guide [B] and set a dial gauge against the stem perpendicular to it as close as possible to the cylinder head mating surface.
  • Page 275: Valve Seat Inspection

    ENGINE TOP END 5-29 Valves Valve Seat Inspection • Remove the valve (see Valve Removal). • Check the valve seating surface [A] between the valve [B] and valve seat [C]. ○ Measure the outside diameter [D] of the seating pattern on the valve seat.
  • Page 276 5-30 ENGINE TOP END Valves Seat Cutter Operation Care 1. This valve seat cutter is developed to grind the valve for repair. Therefore the cutter must not be used for other purposes than seat repair. 2. Do not drop or shock the valve seat cutter, or the dia- mond particles may fall off.
  • Page 277 ENGINE TOP END 5-31 Valves • Measure the outside diameter of the seating surface with a vernier caliper. If the outside diameter of the seating surface is too small, repeat the 45° grind until the diameter is within the spec- ified range.
  • Page 278 5-32 ENGINE TOP END Valves If the seat width is too wide, make the 60° [A] grind de- scribed below. If the seat width is within the specified range, lap the valve to the seat as described below. • Grind the seat at a 60° angle until the seat width is within the specified range.
  • Page 279 ENGINE TOP END 5-33 Valves...
  • Page 280: Throttle Body Holder

    5-34 ENGINE TOP END Throttle Body Holder Throttle Body Holder Installation • Be sure to install the O-rings [A]. • Install the clamps [B] as shown. • Tighten the holder bolts following the tightening sequence Torque - Throttle Body Holder Bolts [C]: 9.8 N·m (1.0 kgf·m, 87 in·lb) Throttle Body Assy Holder Clamp Bolts [D]: 2.0 N·m (0.20 kgf·m, 18 in·lb)
  • Page 281: Muffler

    ENGINE TOP END 5-35 Muffler WARNING To avoid a serious burn, do not remove the muffler when the engine is still hot. Wait until the muffler cool down. Muffler Body Removal/Installation • Remove: Lower Fairings (see Lower Fairing Removal in the Frame chapter) Rear Fairing (see Rear Fairing Removal in the Frame chapter)
  • Page 282: Exhaust Pipe Removal

    5-36 ENGINE TOP END Muffler • Align [A] the projections on the muffler bodies with the hoses on the muffler clamps. • Tighten: Torque - Muffler Body Mounting Bolts: 34 N·m (3.5 kgf·m, 25 ft·lb) Exhaust Pipe Removal • Remove: Radiator (see Radiator Removal in the Cooling System chapter) Right and Left Muffler Body (see Muffler Body Re-...
  • Page 283 CLUTCH 6-1 Clutch Table of Contents Exploded View........................Specifications ......................... Special Tools and Sealant ...................... Clutch Master Cylinder ......................Clutch Lever Adjustment....................Clutch Master Cylinder Removal ..................Clutch Master Cylinder Installation .................. Clutch Master Cylinder Disassembly ................Clutch Master Cylinder Assembly ..................Clutch Master Cylinder Inspection ..................
  • Page 284: Exploded View

    6-2 CLUTCH Exploded View...
  • Page 285 CLUTCH 6-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Clutch Lever Pivot Bolt 0.10 8.9 in·lb Clutch Lever Pivot Bolt Locknut 0.60 52 in·lb Clutch Master Cylinder Bleed Valve 0.80 69 in·lb Clutch Slave Cylinder Bleed Valve 0.80 69 in·lb Clutch Slave Cylinder Bolts –...
  • Page 286: Specifications

    6-4 CLUTCH Specifications Item Standard Service Limit Clutch Fluid: Grade DOT4 – – – Clutch Lever: – – – Clutch Lever Position 5-way adjustable (to suit rider) – – – Clutch Lever Free Play Non-adjustable – – – Clutch: Friction Plate Thickness 2.92 3.08 mm (0.115 0.121 in.)
  • Page 287: Special Tools And Sealant

    CLUTCH 6-5 Special Tools and Sealant Inside Circlip Pliers: Clutch Gear Setting Screw: 57001-143 57001-1671 Clutch Holder: Kawasaki Bond (Silicone Sealant): 57001-1243 92104-0004...
  • Page 288: Clutch Master Cylinder

    6-6 CLUTCH Clutch Master Cylinder Clutch Lever Adjustment ○ The adjuster has 5 positions so that the clutch lever posi- tion can be adjusted to suit the operator’s hand. • Push the lever forward and turn the adjuster [A] to align the number with the triangular mark [B] on the lever holder (front view).
  • Page 289: Clutch Master Cylinder Disassembly

    CLUTCH 6-7 Clutch Master Cylinder • Install the master cylinder clamp with the triangular mark [A] up. • Tighten the upper clamp bolt [B] first, and then the lower clamp bolt [C]. There will be a gap at the lower part of the clamp after tightening.
  • Page 290: Clutch Slave Cylinder

    6-8 CLUTCH Clutch Slave Cylinder Clutch Slave Cylinder Removal • Remove: Left Lower Fairing (see Lower Fairing Removal Frame chapter) Left Middle Fairing (see Middle Fairing Removal in the Frame chapter) Banjo Bolt [A] Clutch Slave Cylinder Bolts [B] Slave Cylinder [C] CAUTION Immediately wash away any clutch fluid that spills.
  • Page 291: Clutch Slave Cylinder Installation

    CLUTCH 6-9 Clutch Slave Cylinder Clutch Slave Cylinder Installation • Apply molybdenum disulfide grease to either end [A] of the push rod, and install the push rod so that the greased end faces in. • Replace the spacer [B] of the clutch slave cylinder with a new one.
  • Page 292: Clutch Fluid

    6-10 CLUTCH Clutch Fluid Clutch Fluid Level Inspection • Refer to the Clutch Fluid Level Inspection in the Periodic Maintenance chapter. Clutch Fluid Change • Refer to the Clutch Fluid Change in the Periodic Mainte- nance chapter. Bleeding the Clutch Line WARNING Be sure to bleed the air from the clutch line when- ever clutch lever action feels soft or spongy after...
  • Page 293: Clutch Hose Removal/installation

    CLUTCH 6-11 Clutch Fluid • Bleed the clutch line and the master cylinder. ○ Repeat this operation until no more air can be seen com- ing out into the plastic hose. 1. Pump the clutch lever until it becomes hard, and apply the clutch lever and hold it [C].
  • Page 294: Clutch Cover

    Clutch Cover Installation • Apply silicone sealant to the area [A] where the mating surface of the crankcase touches the clutch cover gasket. Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004 • Replace the clutch cover gasket with a new one. •...
  • Page 295: Clutch Removal

    CLUTCH 6-13 Clutch Clutch Removal • Remove: Right Lower Fairing (see Lower Fairing Removal in the Frame chapter) Clutch Cover (see Clutch Cover Removal) Clutch Spring Bolts [A] Clutch Springs Clutch Spring Plate [B] (with thrust bearing, pusher [C] and washer) •...
  • Page 296: Clutch Installation

    6-14 CLUTCH Clutch Clutch Installation • Install the thrust washer [A] by facing its chamfered side [B] towards the crankcase. • Align the teeth of the clutch housing gears by the gear setting screw [A]. ○ Install the clutch housing so that the hole position forward of the engine.
  • Page 297 CLUTCH 6-15 Clutch • Install the spring seat [A], spring [B], friction plates [C] [D] [E] and steel plates [F] as shown. NOTE ○ The inside diameter of first friction plates are larger than the others because the spring seat and spring are equipped to decrease the judder noise as shown.
  • Page 298: Clutch Plate Assembly Inspection

    6-16 CLUTCH Clutch Clutch Plate Assembly Inspection • Inspect the friction plate thickness (see Clutch Plate, Wear, Damage Inspection). • Measure the length [A] of the clutch plate assembly as shown. ○ Assemble: Clutch Hub [B] Spring Seat [C] Spring [D] Friction Plates [E] [F] [G] Steel Plates [H] Spring Plate [J]...
  • Page 299: Clutch Plate, Wear, Damage Inspection

    CLUTCH 6-17 Clutch Clutch Plate, Wear, Damage Inspection • Visually inspect the friction and steel plates for signs of seizure, overheating (discoloration), or uneven wear. • Measure the thickness of each friction plate [A] at several points. If any plates show signs of damage, or if they have worn past the service limit, replace them with new ones.
  • Page 301 ENGINE LUBRICATION SYSTEM 7-1 Engine Lubrication System Table of Contents Exploded View........................Engine Oil Flow Chart......................Specifications ......................... Special Tools and Sealant ...................... Engine Oil and Oil Filter......................Oil Level Inspection......................Engine Oil Change......................Oil Filter Replacement ...................... Oil Pan............................ Oil Pan Removal .......................
  • Page 302: Exploded View

    7-2 ENGINE LUBRICATION SYSTEM Exploded View...
  • Page 303 G: Apply grease. L: Apply a non-permanent locking agent. MO: Apply molybdenum disulfide oil. (mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 : 1) R: Replacement Parts SS: Apply silicone sealant (Kawasaki Bond: 56019-120).
  • Page 304: Engine Oil Flow Chart

    7-4 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart...
  • Page 305 ENGINE LUBRICATION SYSTEM 7-5 Engine Oil Flow Chart...
  • Page 306: Specifications

    7-6 ENGINE LUBRICATION SYSTEM Specifications Item Standard Engine Oil Type API SE, SF or SG API SH, SJ or SL with JASO MA Viscosity SAE 10W-40 Capacity 3.7 L (3.9 US gt) (when filter is not removed) 4.1 L (4.3 US gt) (when filter is removed) 4.5 L (4.8 US gt) (when engine is completely dry) Level Between upper and lower level lines...
  • Page 307: Special Tools And Sealant

    ENGINE LUBRICATION SYSTEM 7-7 Special Tools and Sealant Oil Pressure Gauge, 10 kgf/cm²: Oil Filter Wrench: 57001-164 57001-1249 Oil Pressure Gauge Adapter, PT3/8 × 19/in.: Kawasaki Bond (Silicone Sealant): 57001-1233 56019-120...
  • Page 308: Engine Oil And Oil Filter

    7-8 ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter WARNING Motorcycle operation with insufficient, deteri- orated, or contaminated engine oil will cause accelerated wear and may result in engine or trans- mission seizure, accident, and injury. Oil Level Inspection • Check that the engine oil level is between the upper [A] and lower [B] levels in the gauge.
  • Page 309: Oil Pan

    ENGINE LUBRICATION SYSTEM 7-9 Oil Pan Oil Pan Removal • Remove: Engine Oil (Drain, see Engine Oil Change in the Periodic Maintenance chapter) Muffler Bodies (see Muffler Body Removal/Installation in the Engine Top End chapter) Exhaust Pipe (see Exhaust Pipe Removal in the Engine Top End chapter) •...
  • Page 310 7-10 ENGINE LUBRICATION SYSTEM Oil Pan • Put new O-ring [A] on the lower crankcase [B] as shown. Oil Pipe [C] • Install the brackets [A] as shown. • Replace the oil pan gasket [B] with a new one. • Tighten: Torque - Oil Pan Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)
  • Page 311: Oil Pressure Relief Valve

    ENGINE LUBRICATION SYSTEM 7-11 Oil Pressure Relief Valve Oil Pressure Relief Valve Removal • See Oil Pan Removal. Oil Pressure Relief Valve Installation • See Oil Pan Installation. Oil Pressure Relief Valve Inspection • Check to see if the valve [A] slides smoothly when push- ing it in with a wooden or other soft rod, and see if it comes back to its seat by spring [B] pressure.
  • Page 312: Oil Pump

    7-12 ENGINE LUBRICATION SYSTEM Oil Pump Oil Pump Removal • Drain: Coolant (see Coolant Change in the Periodic Mainte- nance chapter) Engine Oil (see Engine Oil Change in the Periodic Main- tenance chapter) • Remove: Clutch (see Clutch Removal in the Clutch chapter) •...
  • Page 313 ENGINE LUBRICATION SYSTEM 7-13 Oil Pump • Install the oil pump shaft with inner rotor. ○ Turn the pump shaft [A] so that the projection [B] in its shaft fits onto the slot [C] of the water pump shaft [D]. ○...
  • Page 314: Oil Cooler

    7-14 ENGINE LUBRICATION SYSTEM Oil Cooler Oil Cooler Removal • Remove: Lower Fairings (see Lower Fairing Removal in the Frame chapter) • Drain: Coolant (see Coolant Change in the Periodic Mainte- nance chapter) Engine Oil (see Engine Oil Change in the Periodic Main- tenance chapter) •...
  • Page 315: Oil Pressure Measurement

    ENGINE LUBRICATION SYSTEM 7-15 Oil Pressure Measurement Oil Pressure Measurement • Remove the left lower fairing (see Lower Fairing Removal in the Frame chapter). • Remove the oil passage plug, and attach the adapter [A] and gauge [B] to the plug hole. Special Tools - Oil Pressure Gauge, 10 kgf/cm²: 57001-164 Oil Pressure Gauge Adapter, PT3/8 ×...
  • Page 316: Oil Pressure Switch

    • Apply silicone sealant to the threads of the oil pressure switch and tighten it. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 Torque - Oil Pressure Switch: 15 N·m (1.5 kgf·m, 11 ft·lb) • Install the switch lead direction [A] upward.
  • Page 317 ENGINE REMOVAL/INSTALLATION 8-1 Engine Removal/Installation Table of Contents Exploded View........................Engine Removal/Installation ....................Engine Removal........................ Engine Installation......................
  • Page 318: Exploded View

    8-2 ENGINE REMOVAL/INSTALLATION Exploded View...
  • Page 319 ENGINE REMOVAL/INSTALLATION 8-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Engine Mounting Nuts (M12) Adjusting Collars Front Engine Mounting Bolts (M10) S, R Engine Bracket Bolts (M8) S, R Subframe Bolts M: Apply molybdenum sulfide grease. R: Replacement Parts S: Follow the specified tightening sequence.
  • Page 320: Engine Removal/installation

    8-4 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation Engine Removal • Support the rear part of the swingarm with a stand. • Squeeze the brake lever slowly and hold it with a band [A]. WARNING Be sure to hold the front brake when removing the engine, or the motorcycle may fall over.
  • Page 321 ENGINE REMOVAL/INSTALLATION 8-5 Engine Removal/Installation • Disconnect the alternator lead conductor [A]. • Remove: Connector [A] of Subharness for Sensor and Valve (dis- connect) Subframe Bolts [B] Subframe Bracket Bolt [C] • Remove the subframe [D] with the clutch pipe [E]. •...
  • Page 322: Engine Installation

    8-6 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Remove the engine sprocket [A] (see Engine Sprocket Removal in the Final Drive chapter). • Support the engine with a suitable stand [B]. ○ Put a plank [C] onto the suitable stand for engine balance. •...
  • Page 323 ENGINE REMOVAL/INSTALLATION 8-7 Engine Removal/Installation A: After installation, set the projection in the hole. B: To Water Temperature Sensor C: To Breather Hose D: To Throttle Body Subharness Bracket E: To throttle Body Holder F: To Throttle Pulley G: To Air Suction Valve and Stick Coils H: Only put the heat insulation rubber plate on the cylinder head cover.
  • Page 324 8-8 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Before installing the engine. Confirm the routing of the water temperature sensor lead [A]. ○ Run [B] the water temperature sensor lead between the #3 and #4 cylinder and connect the water temperature sensor body. •...
  • Page 325 ENGINE REMOVAL/INSTALLATION 8-9 Engine Removal/Installation ○ Secondly, insert the mounting bolts [A] until they fit [B] in the adjusting collars [C]. ○ Be sure that the collar [D] is in position. NOTE ○ Replace the following bolts with new bolts pre-coated with locking agent.
  • Page 326 8-10 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation ○ Fifthly, tighten the left engine bracket bolts [A]. ○ Sixthly, tighten the upper engine mounting nut [B] and then the lower engine mounting nut [C]. ○ Seventhly, install the right engine bracket and tighten the right engine bracket bolts [D] and the right front engine mounting bolt [E].
  • Page 327 ENGINE REMOVAL/INSTALLATION 8-11 Engine Removal/Installation • Run the leads, cable and hoses correctly (see Cable, Wire, and Hose Routing section in the Appendix chap- ter). • Install the removed parts (see appropriate chapters). • Adjust: Throttle Cables (see Throttle Control System Inspection in the Periodic Maintenance chapter) Drive Chain (see Drive Chain Slack Inspection in the Periodic Maintenance chapter)
  • Page 329 CRANKSHAFT/TRANSMISSION 9-1 Crankshaft/Transmission Table of Contents Exploded View........Rear Balancer Removal....9-31 Specifications ........Rear Balancer Installation.... 9-32 Special Tools and Sealants ....Balancer Adjustment....9-34 Crankcase Splitting......9-10 Balancer Damper Inspection..9-34 Crankcase Splitting ...... 9-10 Starter Motor Clutch and Torque Crankcase Assembly ....
  • Page 330: Exploded View

    9-2 CRANKSHAFT/TRANSMISSION Exploded View...
  • Page 331 27. Do not apply any grease or oil. G: Apply grease. L: Apply a non-permanent locking agent. LG: Apply liquid gasket (Kawasaki Bond: 92104-1064). M: Apply molybdenum disulfide grease. MO: Apply molybdenum disulfide oil. (mixture of engine oil and molybdenum disulfide grease in a weight ratio is 10 : 1) R: Replacement Parts S: Follow the specified tightening sequence.
  • Page 332 9-4 CRANKSHAFT/TRANSMISSION Exploded View...
  • Page 333 CRANKSHAFT/TRANSMISSION 9-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Balancer Shaft Clamp Bolts 87 in·lb Balancer Shaft Clamp Lever Bolts Starter Clutch Shaft Bolt 87 in·lb Starter Clutch Shaft Plate Bolt 87 in·lb Torque Limiter Bolt Shift Drum Cam Holder Bolt 106 in·lb Gear Position Switch Screws 0.30...
  • Page 334: Specifications

    9-6 CRANKSHAFT/TRANSMISSION Specifications Item Standard Service Limit Crankcase, Crankshaft, Connecting Rods Connecting Rod Bend – – – TIR 0.2/100 mm (0.008/3.94 in.) Connecting Rod Twist – – – TIR 0.2/100 mm (0.008/3.94 in.) Connecting Rod Big End Side 0.13 0.38 mm 0.58 mm Clearance (0.0051...
  • Page 335 CRANKSHAFT/TRANSMISSION 9-7 Specifications Item Standard Service Limit ○ Marking 41.000 41.008 mm – – – (1.6142 1.6145 in.) None 41.009 41.016 mm – – – (1.6145 1.6148 in.) Crankshaft Main Bearing Insert Thickness: Brown 1.490 1.494 mm – – – (0.0587 0.0588 in.) Black...
  • Page 336 9-8 CRANKSHAFT/TRANSMISSION Specifications Connecting Rod Big End Bearing Insert Selection Bearing Insert Con-rod Big End Bore Crankpin Diameter Diameter Marking Marking Size Color Part Number ○ None Brown 92139-0131 None None Black 92139-0130 ○ ○ ○ None Blue 92139-0129 Crankshaft Main Bearing Insert Selection Crankcase Main Crankshaft Main Bearing Insert...
  • Page 337: Special Tools And Sealants

    CRANKSHAFT/TRANSMISSION 9-9 Special Tools and Sealants Bearing Puller: Piston Ring Compressor Belt, 80 57001-135 57001-1320 Bearing Puller Adapter: Kawasaki Bond (Silicone Sealant): 57001-317 56019-120 Piston Pin Puller Assembly: Kawasaki Bond: 57001-910 92104-1064 Piston Ring Compressor Grip: 57001-1095...
  • Page 338: Crankcase Splitting

    9-10 CRANKSHAFT/TRANSMISSION Crankcase Splitting Crankcase Splitting • Remove the engine (see Engine Removal/Installation in the Engine Removal/Installation chapter). • Set the engine on a clean surface and hold the engine steady while parts are being removed. • Remove: Clutch (see Clutch Removal in the Clutch chapter) Starter Motor (see Starter Motor Removal in the Electri- cal System chapter) Oil Pump (see Oil Pump Removal in the Engine Lubri-...
  • Page 339: Crankcase Assembly

    CRANKSHAFT/TRANSMISSION 9-11 Crankcase Splitting ○ Next, loosen the M10 Bolts [1 10] (sequence numbers). If the crankshaft is to be removed, remove the pistons (see Piston Removal). • Tap lightly around the crankcase mating surface with a plastic mallet, and split the crankcase. Take care not to damage the crankcase.
  • Page 340 • Apply liquid gasket [A] to the mating surface of the lower crankcase half. Sealant - Kawasaki Bond: 92104-1064 NOTE ○ Aster tightening the crankcase bolts, wipe up the liquid gasket seeping out the output shaft bearing hole [D].
  • Page 341 CRANKSHAFT/TRANSMISSION 9-13 Crankcase Splitting • Fit the lower crankcase half to the upper crankcase half. • Be sure that the breather hole [A] on the upper crankcase [B] is not plugged with liquid gasket. • The M10 bolts have washers, replace them with new ones.
  • Page 342 9-14 CRANKSHAFT/TRANSMISSION Crankcase Splitting • Tighten the upper crankcase bolts in the order listed. ○ The M8 bolts have washers, replace them with new ones. ○ Tighten: M8 Bolts with Washers [A] M7 Bolt with the clamp [B] M7 Bolt [C] M6 Bolts [D] Torque - Crankcase Bolts (M8): 27 N·m (2.8 kgf·m, 20 ft·lb) Crankcase Bolts (M7): 20 N·m (2.0 kgf·m, 15 ft·lb)
  • Page 343: Crankshaft And Connecting Rods

    CRANKSHAFT/TRANSMISSION 9-15 Crankshaft and Connecting Rods Crankshaft Removal • Split the crankcase (see Crankcase Splitting). • Remove the crankshaft (see Connecting Rod Removal). Crankshaft Installation CAUTION If the crankshaft, bearing inserts, or crankcase halves are replaced with new ones, select the bear- ing inserts and check clearance with a plastigage (press gauge) before assembling engine to be sure the correct bearing inserts are installed.
  • Page 344: Connecting Rod Removal

    9-16 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods Connecting Rod Removal • Split the crankcase (see Crankcase Splitting). • Remove the connecting rod nuts [A]. • Remove the crankshaft. NOTE ○ Mark and record the locations of the connecting rods and their big end caps so that they can be reassembled in their original positions.
  • Page 345 CRANKSHAFT/TRANSMISSION 9-17 Crankshaft and Connecting Rods • Install the crankshaft (see Crankshaft Installation). • Install each connecting rod on its original crankpin. ○ The connecting rod big end is bolted using the “plastic region fastening method”. ○ This method precisely achieves the needed clamping force without exceeding it unnecessarily, allowing the use of thinner, lighter bolts further decreasing connecting rod weight.
  • Page 346 9-18 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods • Install new bolts in reused connecting rods. • Dent both bolt head and bolt tip with a punch as shown. • Before tightening, use a point micrometer to measure the length of new connecting rod bolts and record the values to find the bolt stretch.
  • Page 347: Crankshaft/connecting Rod Cleaning

    CRANKSHAFT/TRANSMISSION 9-19 Crankshaft and Connecting Rods • Install new bolts in reused connecting rods. • Apply a small amount of molybdenum disulfide oil to the following. Threads [A] of Nuts and Bolts Seating Surfaces [B] of Nuts and Connecting Rods •...
  • Page 348: Connecting Rod Twist

    9-20 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods Connecting Rod Twist • With the big-end arbor [A] still on V block [C], hold the connecting rod horizontally and measure the amount that the arbor [B] varies from being paralleled with the surface plate over a 100 mm (3.94 in.) length of the arbor to de- termine the amount of connecting rod twist.
  • Page 349 CRANKSHAFT/TRANSMISSION 9-21 Crankshaft and Connecting Rods If the clearance is within the standard, no bearing replace- ment is required. If the clearance is between 0.087 mm (0.0034 in.) and the service limit (0.12 mm, 0.0047 in.), replace the bear- ing inserts [A] with inserts painted blue [B]. Check in- sert/crankpin clearance with the plastigage.
  • Page 350: Crankshaft Side Clearance

    9-22 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods • Select the proper bearing insert [A] in accordance with the combination of the connecting rod and crankshaft coding. Size Color [B] Con-rod Big Crankpin Bearing Insert End Inside Diameter Diameter Marking Size Color Part Number Marking ○...
  • Page 351: Crankshaft Runout

    CRANKSHAFT/TRANSMISSION 9-23 Crankshaft and Connecting Rods If the thrust washers (t = 4.0 mm, 0.1575 in.) are installed on the upper crankcase half, replace them with new thrust washer (t = 4.0 mm, 0.1575 in.) as a set. Thrust Washer Thickness Edge Colar P/No.
  • Page 352 9-24 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods Crankshaft Main Bearing Insert/Journal Clearance Standard: 0.031 0.063 mm (0.0012 0.0025 in.) Service Limit: 0.09 mm (0.0035 in.) If the clearance is within the standard, no bearing replace- ment is required. If the clearance is between 0.064 mm (0.0025 in.) and the service limit (0.09 mm, 0.0035 in.), replace the bearing in- serts [A] with inserts painted blue [B].
  • Page 353 CRANKSHAFT/TRANSMISSION 9-25 Crankshaft and Connecting Rods Bearing Insert Crankcase Main Bearing Crankshaft Main Journal Inside Diameter Marking Diameter Marking Size Color Part Number Journal Nos. 92139-0134 1, 3, 5 ○ Brown 92139-0137 2, 4 None 92139-0133 1, 3, 5 Black ○...
  • Page 354: Pistons

    9-26 CRANKSHAFT/TRANSMISSION Pistons Piston Removal • Split the crankcase (see Crankcase Splitting). • Remove the connecting rod nuts [A]. • Remove the connecting rod big end caps. • Remove the crankshaft. • Remove the piston to the cylinder head side. •...
  • Page 355: Piston Installation

    CRANKSHAFT/TRANSMISSION 9-27 Pistons Piston Installation • Apply molybdenum disulfide oil solution to the oil ring ex- pander, and install the oil ring expander [A] in the bottom piston ring groove so the ends [B] butt together. • Apply molybdenum disulfide oil solution to the oil ring steel rails, and install the oil ring steel rails, one above the ex- pander and one below it.
  • Page 356: Cylinder Wear (upper Crankcase)

    9-28 CRANKSHAFT/TRANSMISSION Pistons • Install the piston with its marking hollow facing exhaust side. • Using the piston ring compressor assy [A] to install the piston from the cylinder head side. Special Tools - Piston Ring Compressor Grip: 57001-1095 Piston Ring Compressor Belt, 57001-1320 •...
  • Page 357: Piston Ring Groove Width

    CRANKSHAFT/TRANSMISSION 9-29 Pistons Piston Ring Groove Width • Measure the piston ring groove width. ○ Use a vernier caliper at several points around the piston. Piston Ring Groove Width Standard: Top [A] 0.92 0.94 mm (0.0362 0.0370 in.) Second [B] 1.01 1.03 mm (0.0398 0.0406 in.)
  • Page 358: Balancer

    9-30 CRANKSHAFT/TRANSMISSION Balancer Front Balancer Removal • Split the crankcase (see Crankcase Splitting). • Unscrew: Balancer Shaft Clamp Bolt [A] Balancer Shaft Clamp Lever Bolt [B] • Remove the front balancer [C] from the lower crankcase half [D] Front Balancer Installation •...
  • Page 359: Rear Balancer Removal

    CRANKSHAFT/TRANSMISSION 9-31 Balancer • Position the crankshaft at 2, 3 position TDC. • Insert the pin [A] as shown. • Set the front balancer on the upper crankcase half. ○ Align the punch mark [B] on the balancer gear [C] with the mark [D] on the balancer drive gear [E] of crankshaft.
  • Page 360: Rear Balancer Installation

    9-32 CRANKSHAFT/TRANSMISSION Balancer • Unscrew the balancer shaft clamp bolt [A], and balancer shaft clamp lever bolt [B], and pull off the clamp lever [C]. • Pull the balancer shaft [D] out of the crankcase. The bal- ancer weight and gear assembly [E] come off with needle bearings and copper washers.
  • Page 361 CRANKSHAFT/TRANSMISSION 9-33 Balancer • Position the crankshaft at # 2, 3 position TDC or at # 1, 4 position TDC. • Aligin the mark [A] on the balancer gear [B] with the mat- ing surface [C] of the upper crankcase half. •...
  • Page 362: Balancer Adjustment

    9-34 CRANKSHAFT/TRANSMISSION Balancer Balancer Adjustment • First, adjust the front balancer [A], next the rear balancer [B]. ○ For the front balancer adjustment, remove the lower fair- ing (see Lower Fairing Removal in the Frame chapter). • Start the engine and warm it up thoroughly. •...
  • Page 363: Starter Motor Clutch And Torque Limiter

    CRANKSHAFT/TRANSMISSION 9-35 Starter Motor Clutch and Torque Limiter Starter Motor Clutch Removal • Remove the engine (see Engine Removal in the Engine Removal/Installation chapter). • Remove the rear balancer (see Rear Balancer Removal). • Unscrew the starter clutch shaft plate bolt [A]. •...
  • Page 364: Starter Motor Clutch Assembly

    9-36 CRANKSHAFT/TRANSMISSION Starter Motor Clutch and Torque Limiter • Holding the drive gear [A] with a hand, take off the one -way clutch [B] from the gear by using the screw driver [C]. Starter Motor Clutch Assembly • Be sure to install the one-way clutch [A] so that its arrow [B] faces the side of the flat washer.
  • Page 365: Torque Limiter Installation

    CRANKSHAFT/TRANSMISSION 9-37 Starter Motor Clutch and Torque Limiter • Holding the torque limiter [A], remove the torque limiter shaft [B] and the torque limiter. Torque Limiter Installation • Replace the O-ring with a new one. • Apply engine oil to the new O-ring. •...
  • Page 366: Transmission

    9-38 CRANKSHAFT/TRANSMISSION Transmission Shift Pedal Removal • Remove: Shift Lever Bolt [A] Shift Lever [B] Shift Pedal Installation • Install the shift pedal. ○ Align [A] the punch mark [B] on the shift shaft with the upper surface [C] of shift lever slit. ○...
  • Page 367: External Shift Mechanism Installation

    CRANKSHAFT/TRANSMISSION 9-39 Transmission External Shift Mechanism Installation • Install the gear positioning lever [A] as shown. Spring [B] Collar [C] Bolt [D] • Tighten: Torque - Gear Positioning Lever Bolt: 12 N·m (1.2 kgf·m, 106 in·lb) External Shift Mechanism Inspection •...
  • Page 368: Transmission Shaft Installation

    9-40 CRANKSHAFT/TRANSMISSION Transmission • Remove the cover bolts [A] and cover [B]. • Remove the shift forks (see Shift Drum and Fork Re- moval). • Pull out the drive shaft. Transmission Shaft Installation • Check to see that the set pin [A] and set ring [B] are in place.
  • Page 369: Transmission Shaft Assembly

    CRANKSHAFT/TRANSMISSION 9-41 Transmission • Remove the ball bearing [A] from each shafts. Special Tools - Bearing Puller [B]: 57001-135 Bearing Puller Adapter [C]: 57001-317 • Discard the bearing. Transmission Shaft Assembly • Apply engine oil to the bushings, ball bearings and shafts. •...
  • Page 370 9-42 CRANKSHAFT/TRANSMISSION Transmission • Fit the steel balls into the 5th gear holes in the output shaft, aligning three oil holes [D]. 5th Gear [A] Output Shaft [B] Steel Balls [C] CAUTION Do not apply grease to the balls to hold them in place.
  • Page 371 CRANKSHAFT/TRANSMISSION 9-43 Transmission 1. Output Shaft 13. 5th Gear 2. Collar 14. Thrust Washer, 35 mm (1.38 in.) 3. Ball Bearing 15. 1st Gear 4. Bushing 16. Needle Bearing 5. 2nd Gear 17. Bearing Outer Race 6. Toothed Washer, 30 mm (1.18 in.) 18.
  • Page 372: Shift Drum And Fork Removal

    9-44 CRANKSHAFT/TRANSMISSION Transmission Shift Drum and Fork Removal • Remove: Lower Crankcase Half (see Crankcase Splitting) External Shift Mechanism (see External Shift Mecha- nism Removal) Screws [A] Shift Drum Bearing Holder [B] • Pull out the shift rods [C], and take off the shift forks. •...
  • Page 373: Shift Fork Bending

    CRANKSHAFT/TRANSMISSION 9-45 Transmission Shift Fork Bending • Visually inspect the shift forks, and replace any fork that is bent. A bent fork could cause difficulty in shifting, or allow the transmission to jump out of gear when under power. 90° [A] Shift Fork/Gear Groove Wear •...
  • Page 375 WHEELS/TIRES 10-1 Wheels/Tires Table of Contents Exploded View........................10-2 Specifications ......................... 10-4 Special Tools .......................... 10-5 Wheels (Rims) ........................10-6 Front Wheel Removal ....................... 10-6 Front Wheel Installation ....................10-6 Rear Wheel Removal......................10-7 Rear Wheel Installation..................... 10-8 Wheel Inspection ......................10-10 Axle Inspection........................
  • Page 376: Exploded View

    10-2 WHEELS/TIRES Exploded View...
  • Page 377 WHEELS/TIRES 10-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Axle Clamp Bolts Front Axle Nut 13.0 Rear Axle Nut 13.0 4. Caliper Bracket (ZX1400B Models) AL: Tighten the two clamp bolts alternately two time to ensure even tightening. G: Apply grease.
  • Page 378: Specifications

    10-4 WHEELS/TIRES Specifications Item Standard Service Limit Wheels (Rims) Rim Runout: Axial TIR 0.5 mm (0.02 in.) or less TIR 1.0 mm (0.04 in.) Radial TIR 0.8 mm (0.03 in.) or less TIR 1.0 mm (0.04 in.) Axle Runout/100 mm (3.94 in.) TIR 0.03 mm (0.0012 in.) or less TIR 0.2 mm (0.01 in.) Wheel Balance 10 g (0.35 oz.) or less...
  • Page 379: Special Tools

    WHEELS/TIRES 10-5 Special Tools Bearing Driver Set: Bearing Remover Shaft, 13: 57001-1129 57001-1377 Jack: Jack Attachment: 57001-1238 57001-1608 Bearing Remover Head, 25 × 28: 57001-1346...
  • Page 380: Wheels (rims)

    10-6 WHEELS/TIRES Wheels (Rims) Front Wheel Removal • Remove: Front Caliper Mounting Bolts [A] Front Calipers [B] • Loosen: Axle Clamp Bolts [A] (Left Side) Axle Nut [B] Axle Clamp Bolts (Right Side) • Remove the lower fairings (see Lower Fairing Removal in the Frame chapter).
  • Page 381: Rear Wheel Removal

    WHEELS/TIRES 10-7 Wheels (Rims) • Apply high-temperature grease to the grease seal lip. • Fit the collars [A] on the both sides of the hub. ○ The collars are identical. • Insert the axle from the right side. • Tighten the axle nut [B]. Right Axle Clamp Bolts [C] Left Axle Clamp Bolts [D] Viewed from Rear [E]...
  • Page 382: Rear Wheel Installation

    10-8 WHEELS/TIRES Wheels (Rims) • Remove: Rear Caliper Mounting Bolts [A] Rear Caliper [B] • Remove the rear wheel rotation sensor from the caliper bracket (see Rear Wheel Rotation Sensor Removal in the Brakes chapter) (ZX1400B Models). • Remove: Cotter Pin [A] Axle Nut [B] Washer [C] Axle [D] (from Left Side)
  • Page 383 WHEELS/TIRES 10-9 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 axle, tighten the nut clockwise [B] up to next alignment. ○...
  • Page 384: Wheel Inspection

    10-10 WHEELS/TIRES Wheels (Rims) Wheel Inspection • Raise the front/rear wheel off the ground. Special Tools - Jack: 57001-1238 Jack Attachment: 57001-1608 • Spin the wheel lightly, and check for roughness or binding. If roughness or binding is found, replace the hub bearings (see Hub Bearing Removal/Installation).
  • Page 385: Balance Inspection

    WHEELS/TIRES 10-11 Wheels (Rims) Balance Inspection • Remove the front and rear wheels (see Front/Rear Wheel Removal). • Support the wheel so that it can be spun freely. • Spin the wheel lightly, and mark [A] the wheel at the top when the wheel stops.
  • Page 386: Balance Weight Installation

    30 g (1.06 oz.) NOTE ○ Balance weights are available from Kawasaki dealers in 10, 20, and 30 grams (0.35 oz., 0.71 oz., and 1.06 oz.) sizes. An imbalance of less than 10 grams (0.35 oz.) will not usually affect running stability.
  • Page 387 WHEELS/TIRES 10-13 Wheels (Rims) • Slip the balance weight [A] on to the rib [B], by pushing or lightly hammering [C] the clip [D]. ○ Install the balance weight at the left side of the motorcycle. Left Side [E] Right Side [F] •...
  • Page 388: Tires

    10-14 WHEELS/TIRES Tires Air Pressure Inspection/Adjustment • Refer to the Air Pressure Inspection in the Periodic Main- tenance chapter. Tire Inspection • Refer to the Wheel/Tire Damage Inspection in the Peri- odic Maintenance chapter. Tire Removal • Remove: Wheel (see Front/Rear Wheel Removal) Valve Core (Let out the air) •...
  • Page 389 WHEELS/TIRES 10-15 Tires • Install a new valve in the rim. ○ Remove the valve cap, lubricate the stem seal [A] with a soap and water solution or rubber lubricant, and pull [B] the valve stem through the rim from the inside out until it snaps into place.
  • Page 390: Tire Repair

    Also, permanent (internal) repairs have the advantage of permitting a thorough examination for secondary damage not visible from external inspection of the tire. For these reasons, Kawasaki does not recommend temporary (exter- nal) repair. Only appropriate permanent (internal) repairs are recommended. Repair methods may vary slightly from make to make.
  • Page 391: Hub Bearing

    WHEELS/TIRES 10-17 Hub Bearing Hub Bearing Removal • Remove the wheel (see Front/Rear Wheel Removal), and take out the following. Collars Coupling (Out of rear hub) Grease Seals • Use the bearing remover to remove the hub bearing [A]. CAUTION Do not lay the wheel on the ground with the disc facing down.
  • Page 392: Hub Bearing Lubrication

    10-18 WHEELS/TIRES Hub Bearing Hub Bearing Lubrication NOTE ○ Since the hub bearings are packed with grease and sealed, lubrication is not required.
  • Page 393 FINAL DRIVE 11-1 Final Drive Table of Contents Exploded View ........................11-2 Specifications ........................11-4 Special Tools .......................... 11-5 Drive Chain..........................11-6 Drive Chain Slack Inspection .................... 11-6 Drive Chain Slack Adjustment ..................11-6 Wheel Alignment Inspection/Adjustment ................11-6 Drive Chain Wear Inspection .................... 11-6 Drive Chain Lubrication.....................
  • Page 394: Exploded View

    11-2 FINAL DRIVE Exploded View...
  • Page 395 FINAL DRIVE 11-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Chain Guide Bolt 106 in·lb Chain Guide Bolts 87 in·lb Engine Sprocket Cover Bolts 87 in·lb Engine Sprocket Nut 13.0 Rear Axle Nut 13.0 Rear Sprocket Nuts Speed Sensor Bolt 0.40 35 in·lb Stud Bolts...
  • Page 396: Specifications

    11-4 FINAL DRIVE Specifications Item Standard Service Limit Drive Chain Drive Chain Slack 38 mm (1.3 1.5 in.) – – – Drive Chain Wear (20-link Length) 317.5 318.2 mm (12.50 12.53 in.) 323 mm (12.7 in.) Standard Chain: Make DAIDO –...
  • Page 397: Special Tools

    FINAL DRIVE 11-5 Special Tools Inside Circlip Pliers: Bearing Driver Set: 57001-143 57001-1129...
  • Page 398: Drive Chain

    11-6 FINAL DRIVE Drive Chain Drive Chain Slack Inspection • Refer to the Drive Chain Slack Inspection in the Periodic Maintenance chapter. Drive Chain Slack Adjustment • Refer to the Drive Chain Slack Adjustment in the Periodic Maintenance chapter. Wheel Alignment Inspection/Adjustment •...
  • Page 399: Sprocket, Coupling

    FINAL DRIVE 11-7 Sprocket, Coupling Engine Sprocket Removal • Remove: Left Lower Fairing (see Lower Fairing Removal in the Frame chapter) Speed Sensor [A] (see Speed Sensor Removal in the Electrical System chapter) Clutch Slave Cylinder [B] (see Clutch Slave Cylinder in the Clutch chapter) Engine Sprocket Cover Bolts [C] Engine Sprocket Cover [D]...
  • Page 400: Rear Sprocket Removal

    11-8 FINAL DRIVE Sprocket, Coupling • Install the engine sprocket cover. • Install the clamp [A] as shown in the figure, and tighten the cover bolts. Torque - Engine Sprocket Cover Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) • Bend the end of axle cotter pin surely after tightening the axle nut (see Rear Wheel Installation in the Wheels/Tires chapter).
  • Page 401: Coupling Bearing Removal

    FINAL DRIVE 11-9 Sprocket, Coupling • Install the collar [A]. • Install the coupling. Coupling Bearing Removal • Remove: Coupling Grease Seal Circlip [A] Special Tool - Inside Circlip Pliers: 57001-143 • Remove the bearing [A] by tapping from the wheel side. Special Tool - Bearing Driver Set [B]: 57001-1129 Coupling Bearing Installation •...
  • Page 402: Coupling Bearing Inspection

    11-10 FINAL DRIVE Sprocket, Coupling Coupling Bearing Inspection Since the coupling bearing is made to extremely close tolerances, the clearance can not normally be measured. NOTE ○ It is not necessary to remove the coupling bearing for inspection. If the bearing is removed, it will need to be replaced with a new one.
  • Page 403: Rear Sprocket Warp Inspection

    FINAL DRIVE 11-11 Sprocket, Coupling Rear Sprocket Warp Inspection • Raise the rear wheel off the ground with the stand so that it will turn freely. • Set a dial gauge [A] against the rear sprocket [B] near the teeth as shown in the figure, and rotate [C] the rear wheel to measure the sprocket runout (warp).
  • Page 405 BRAKES 12-1 Brakes Table of Contents Exploded View ........................12-3 Specifications ........................12-12 Special Tools .......................... 12-13 Brake Lever, Brake Pedal....................... 12-14 Brake Lever Position Adjustment..................12-14 Brake Pedal Position Inspection ..................12-14 Brake Pedal Position Adjustment ..................12-14 Brake Pedal Removal ....................... 12-14 Brake Pedal Installation ....................
  • Page 406 12-2 BRAKES Inquiries to Rider....................... 12-39 Self-diagnosis Outline ....................... 12-41 Self-diagnosis Procedures ....................12-41 Service Code Clearing Procedures................... 12-42 How to Read Service Codes..................... 12-45 How to Erase Service Codes .................... 12-45 ABS Indicator Light (LED) Inspection ................12-47 ABS Indicator Light (LED) is Unlit (When the Ignition Switch turned to ON) ....12-47 ABS Indicator Light (LED) Lights (When the Motorcycle is Running, - No Service Code) 12-48...
  • Page 407: Exploded View

    BRAKES 12-3 Exploded View Dummy Page...
  • Page 408 12-4 BRAKES Exploded View ZX1400A Models...
  • Page 409 BRAKES 12-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Bleed Valves 0.80 69 in·lb Brake Hose Banjo Bolts Brake Lever Pivot Bolt 0.10 9 in·lb Brake Lever Pivot Bolt Locknut 0.60 52 in·lb Front Brake Disc Mounting Bolts Front Brake Light Switch Screw 0.12 11 in·lb Front Brake Pad Pins...
  • Page 410 12-6 BRAKES Exploded View...
  • Page 411 BRAKES 12-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Bleed Valves 0.80 69 in·lb Brake Hose Banjo Bolts Brake Pedal Bolt 0.90 78 in·lb Rear Brake Disc Mounting Bolts Rear Brake Pad Pin 17.2 Rear Caliper Assembly Bolts Rear Caliper Mounting Bolts Rear Master Cylinder Mounting Bolts Rear Master Cylinder Push Rod Locknut 17.2...
  • Page 412 12-8 BRAKES Exploded View ZX1400B Models...
  • Page 413 BRAKES 12-9 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Bleed Valves 0.80 69 in·lb Brake Hose Banjo Bolts Brake Lever Pivot Bolt 0.10 9 in·lb Brake Lever Pivot Bolt Locknut 0.60 52 in·lb Brake Pipe Joint Nuts Front Brake Disc Mounting Bolts Front Brake Light Switch Screw 0.12 11 in·lb...
  • Page 414 12-10 BRAKES Exploded View...
  • Page 415 BRAKES 12-11 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Bleed Valves 0.80 69 in·lb Brake Hose Banjo Bolts Brake Pedal Bolt 0.90 78 in·lb Brake Pipe Joint Nuts Rear Brake Disc Mounting Bolts Rear Brake Pad Pin 17.2 Rear Caliper Assembly Bolts Rear Caliper Mounting Bolts Rear Master Cylinder Mounting Bolts 10 Rear Master Cylinder Push Rod Locknut...
  • Page 416: Specifications

    12-12 BRAKES Specifications Item Standard Service Limit Brake Lever, Brake Pedal Brake Lever Position 6-way adjustable (to suit rider) – – – Brake Lever Free Play Non-adjustable – – – Pedal Free Play Non-adjustable – – – Pedal Position About 45 mm (1.8 in.) below footpeg top –...
  • Page 417: Special Tools

    BRAKES 12-13 Special Tools Inside Circlip Pliers: Hand Tester: 57001-143 57001-1394 Jack: Jack Attachment: 57001-1238 57001-1608...
  • Page 418: Brake Lever, Brake Pedal

    12-14 BRAKES Brake Lever, Brake Pedal Brake Lever Position Adjustment The brake lever adjuster has 6 positions so that the brake lever position can be adjusted to suit the operator’s hand. • Push the lever forward and turn the adjuster [A] to align the number with the arrow mark [B] on the lever holder.
  • Page 419: Brake Pedal Installation

    BRAKES 12-15 Brake Lever, Brake Pedal • Remove: Cotter Pin [A] Joint Pin [B] Rear Brake Light Switch Spring [C] Return Spring [D] • Remove the mounting bolt [E] and take out the brake pedal. Brake Pedal Installation • Apply grease to the pivot shaft [A] and install the washer [B].
  • Page 420: Calipers

    12-16 BRAKES Calipers Front Caliper Removal • Loosen the banjo bolt [A] at the brake hose lower end, and tighten it loosely. • Unscrew the caliper mounting bolts [B], and detach the caliper [C] from the disc. CAUTION Do not loosen the caliper assembly bolts. Take out only the caliper mounting bolts for caliper removal.
  • Page 421: Caliper Installation

    BRAKES 12-17 Calipers Caliper Installation • Install the caliper and brake hose lower end. ○ Replace the washers on each side of hose fitting with new ones. • Tighten: Torque - Caliper Mounting Bolts Front: 34 N·m (3.5 kgf·m, 25 ft·lb) Rear: 25 N·m (2.5 kgf·m, 18 ft·lb) Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb)
  • Page 422: Caliper Fluid Seal Damage

    12-18 BRAKES Calipers Caliper Fluid Seal Damage The fluid seal (piston seal) [A] is placed around the pis- ton to maintain clearance between the pad and the disc. If the seal is in a poor condition, it could lead the pad to wear excessively or the brake to drag, which may cause the tem- perature of the discs or the brake fluid to increase.
  • Page 423: Caliper Piston And Cylinder Damage

    BRAKES 12-19 Calipers Caliper Piston and Cylinder Damage • Visually inspect the pistons [A] and cylinder surfaces [B]. Replace the caliper if the cylinder and piston are badly scores or rusty.
  • Page 424: Brake Pads

    12-20 BRAKES Brake Pads Front Brake Pad Removal • Loosen the pad pins [A]. • Remove: Pad Pins [A] Pad Springs [B] Brake Pads [C] Front Brake Pad Installation • Push the caliper pistons in by hand as far as they will go. •...
  • Page 425: Rear Brake Pad Removal

    BRAKES 12-21 Brake Pads Rear Brake Pad Removal • Loosen the pad pin [A]. • Unscrew the caliper mounting bolts [B]. • Remove the caliper with the hose installed. • Remove: Pad Pin [A] Pad Spring [B] Brake Pads [C] Rear Brake Pad Installation •...
  • Page 426: Master Cylinder

    12-22 BRAKES Master Cylinder Front Master Cylinder Removal • Remove the reservoir bracket bolt [A]. • Remove the banjo bolt [B] to disconnect the brake hose from the master cylinder (see Brake Hose Removal/In- stallation). • Unscrew the clamp bolts [C], and take off the master cylin- der [D] as an assembly with the reservoir, brake lever, and brake switch installed.
  • Page 427: Rear Master Cylinder Installation

    BRAKES 12-23 Master Cylinder Rear Master Cylinder Installation • Replace the cotter pin with a new one. • Replace the washers that are on each side of hose fitting with new ones. • Tighten: Torque - Rear Master Cylinder Mounting Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb) Brake Hose Banjo Bolt: 25 N·m (2.5 kgf·m, 18 ft·lb) •...
  • Page 428 12-24 BRAKES Master Cylinder • Check the dust covers [E] for damage. If they are damaged, replace them. • Check the piston return spring [F] for any damage. If the springs are damaged, replace them. • Check that relief port [G] and supply port [H] are not plugged.
  • Page 429: Brake Disc

    BRAKES 12-25 Brake Disc Brake Disc Removal • Remove the wheels (see Front/Rear Wheel Removal in the Wheels/Tires chapter). • Unscrew the mounting bolts, and take off the disc. ○ Remove the sensor rotor (ZX1400B Models). Brake Disc Installation • Install the brake disc on the wheel so that the marked side [A] faces out.
  • Page 430: Brake Fluid

    12-26 BRAKES Brake Fluid Brake Fluid Level Inspection • Refer to the Brake Fluid Level Inspection in the Periodic Maintenance chapter. Brake Fluid Change • Refer to the Brake Fluid Change in the Periodic Mainte- nance chapter. Brake Line Bleeding The brake fluid has a very low compression coefficient so that almost all the movement of the brake lever or pedal is transmitted directly to the caliper for braking action.
  • Page 431 BRAKES 12-27 Brake Fluid • Bleed the brake line and the master cylinder. ○ Repeat this operation until no more air can be seen com- ing out into the plastic hose. 1. Pump the brake lever until it becomes hard, and apply the brake and hold it [A].
  • Page 432 12-28 BRAKES Brake Fluid • Install: Diaphragm Diaphragm Plate Front Brake Reservoir Cap [A] Clamp [B] Screw [C] • Follow the procedure below to install the front/rear brake fluid reservoir cap correctly. ○ First, tighten the brake fluid reservoir cap [B] clockwise [C] by hand until slight resistance is felt indicating that the cap is seated on the reservoir body, then tighten the cap an additional 1/6 turn [D] while holding the brake fluid...
  • Page 433 BRAKES 12-29 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 434: Brake Hose

    12-30 BRAKES Brake Hose Brake Hose and Pipe Removal/Installation • Refer to the Brake Hose and Pipe Replacement in the Periodic Maintenance chapter. Brake Hose and Pipe Inspection • Refer to the Brake Hose and Pipe Damage and Instal- lation Condition Inspection in the Periodic Maintenance chapter.
  • Page 435: Anti-lock Brake System (equipped Models)

    1. Front Wheel Rotation Sensor 2. Front Wheel Rotation Sensor Rotor 3. Rear Wheel Rotation Sensor 4. Rear Wheel Rotation Sensor Rotor 5. ABS Indicator Light (LED) 6. ABS Hydraulic Unit 7. ABS Fuse Box 8. ABS Kawasaki Self-diagnosis System Connector...
  • Page 436 15. ABS ECU Fuse 10 A 16. Ignition Fuse 10 A 17. Fuse Box 2 18. Meter Unit 19. ABS Hydraulic Unit 20. ABS Kawasaki Self-diagnosis System Connector 21. Front Wheel Rotation Sensor 22. Rear Wheel Rotation Sensor 23. ABS Self-diagnosis Terminal...
  • Page 437 6. Unused 7. Unused 8. Power Supply to ABS Solenoid Valve Relay 9. Power Supply to ABS Motor Relay 10. ABS Kawasaki Self-diagnosis System Terminal 11. Unused 12. Power Supply to Front Wheel Rotation Sensor 13. ABS Self-diagnosis Terminal 14. Unused 15.
  • Page 438: Abs Servicing Precautions

    12-34 BRAKES Anti-Lock Brake System (Equipped Models) ABS Servicing Precautions There are a number of important precautions that should be followed servicing the ABS system. ○ This ABS system is designed to be used with a 12 V sealed battery as its power source. Do not use any other battery except for a 12 V sealed battery as a power source.
  • Page 439 BRAKES 12-35 Anti-Lock Brake System (Equipped Models) ○ The ABS indicator light (LED) [A] may light if the tire pres- sure is incorrect, a non-recommended tire is installed, or the wheel is deformed. If the indicator light lights, remedy the problem and clear the service code. WARNING Use of non-recommended tires may cause malfunc- tioning of ABS and can lead to extended braking...
  • Page 440: Abs Troubleshooting Outline

    12-36 BRAKES Anti-Lock Brake System (Equipped Models) ABS Troubleshooting Outline When an abnormality in the system occurs, the ABS in- dicator light (LED) lights up to alert the rider. In addition, the nature of the fault is stored in the memory of the ABS hydraulic unit and when in the self-diagnosis mode, the ser- vice code [A] is indicated by the number of times the ABS indicator light (LED) blinks.
  • Page 441 BRAKES 12-37 Anti-Lock Brake System (Equipped Models) • Visually inspect the wiring for signs of burning or fraying. If any wiring is poor, replace the damaged wiring. • Pull each connector [A] apart and inspect it for corrosion, dirt and damage. If the connector is corroded or dirty, clean it carefully.
  • Page 442 12-38 BRAKES Anti-Lock Brake System (Equipped Models) ABS Diagnosis Flow Chart...
  • Page 443: Inquiries To Rider

    BRAKES 12-39 Anti-Lock Brake System (Equipped Models) Inquiries to Rider ○ Each rider reacts to problems in different ways, so it is important to confirm what kind of condition the rider is dissatisfied with. ○ Try to find out exactly what problem occurs under exactly what conditions by asking the rider; know- ing this information may help you reproduce the problem in the shop.
  • Page 444 12-40 BRAKES Anti-Lock Brake System (Equipped Models) Pre-Diagnosis Inspection 1...
  • Page 445: Self-diagnosis Outline

    BRAKES 12-41 Anti-Lock Brake System (Equipped Models) Pre-Diagnosis Inspection 2 Self-diagnosis Outline When the indicator light has blinked or come on, the ABS hydraulic unit memorizes and stores the service code for the service person to troubleshoot easily. The service code memory is powered directly by the battery and cannot be canceled by the ignition switch.
  • Page 446: Service Code Clearing Procedures

    12-42 BRAKES Anti-Lock Brake System (Equipped Models) • Remove the seat (see Seat Removal in the Frame chap- ter). • Ground the self-diagnosis terminal [A] (Gray) to the ground terminal [B] (Black/Yellow), using a lead. • Turn on the ignition switch. ○...
  • Page 447 BRAKES 12-43 Anti-Lock Brake System (Equipped Models)
  • Page 448 12-44 BRAKES Anti-Lock Brake System (Equipped Models) Self-diagnosis Flow Chart...
  • Page 449: How To Read Service Codes

    BRAKES 12-45 Anti-Lock Brake System (Equipped Models) How to Read Service Codes ○ Service codes are shown by a series of long and short blinks of the ABS indicator light (LED) as shown below. ○ Read 10th digit and unit digit as the ABS indicator light (LED) blinks. ○...
  • Page 450: Service Code Table

    12-46 BRAKES Anti-Lock Brake System (Equipped Models) Service Code Table Service ABS Indicator Light (LED) Problems Light State Code Rear inlet solenoid valve trouble (shorted or open, stuck valve (ON)) Rear outlet solenoid valve trouble (shorted or open, stuck valve (ON)) Front inlet solenoid valve trouble (shorted or open, stuck valve (ON)) Front outlet solenoid valve trouble (shorted...
  • Page 451: Abs Indicator Light (led) Inspection

    BRAKES 12-47 Anti-Lock Brake System (Equipped Models) ABS Indicator Light (LED) Inspection • Turn the ignition switch ON. If the ABS indicator light (LED) [A] lights, it is normal. If the ABS indicator light (LED) does not light, go to step “ABS Indicator Light (LED) is Unlit (When the Ignition Switch turned to ON)”.
  • Page 452: Abs Indicator Light (led) Lights (when The Motorcycle Is Running, - No Service Code)

    12-48 BRAKES Anti-Lock Brake System (Equipped Models) • Do the 3rd step test. ○ Disconnect the ABS hydraulic unit connector. ○ Check for continuity between the black/white lead termi- nal of the main harness side connector [A] and black/white lead terminal of the main harness side connector [B]. If there is the continuity in the lead, replace the ABS hy- draulic unit.
  • Page 453 BRAKES 12-49 Anti-Lock Brake System (Equipped Models) • Do the 2nd step test. ○ Disconnect the ABS hydraulic unit connector [A]. ○ Check for continuity between the light green and black/yellow lead terminals of the ABS hydraulic unit connector. If there is the continuity in the lead, replace the ABS hy- draulic unit.
  • Page 454: Front, Rear Wheel Rotation Difference Abnormal (service Code 25)

    12-50 BRAKES Anti-Lock Brake System (Equipped Models) Front, Rear Wheel Rotation Difference Abnormal (Service Code 25) • Do the 1st step test. ○ Check the following and correct the faulty part. Incorrect the tire pressure. Tires not recommended for the motorcycle were installed (incorrect tire size).
  • Page 455: Front Wheel Rotation Sensor Signal Abnormal (service Code 42)

    BRAKES 12-51 Anti-Lock Brake System (Equipped Models) • Do the 4th step test. ○ Check the battery terminal voltage between the red lead terminal of the fuse box [A] and ground. Special Tool - Hand Tester: 57001-1394 Battery Terminal Voltage Standard: Battery Voltage If the battery terminal voltage is not within the specifica-...
  • Page 456: Front Wheel Rotation Sensor Wiring Inspection (service Code 43)

    12-52 BRAKES Anti-Lock Brake System (Equipped Models) • Do the 2nd step test. ○ Check that there is iron or other magnetic deposits be- tween the sensor [A] and sensor rotor [B], and the sensor rotor slots for obstructions. ○ Check the installation condition of the sensor for loose- ness.
  • Page 457: Rear Wheel Rotation Sensor Signal Abnormal (service Code 44)

    BRAKES 12-53 Anti-Lock Brake System (Equipped Models) • Do the 3rd step test. ○ Recheck the service code indication; erase the service code, perform the pre-diagnosis inspection 1 and 2, and retrieve the service code. If the ABS indicator light (LED) [A] lit, faulty ECU in the ABS hydraulic unit.
  • Page 458: Rear Wheel Rotation Sensor Wiring Inspection (service Code 45)

    12-54 BRAKES Anti-Lock Brake System (Equipped Models) Rear Wheel Rotation Sensor Wiring Inspection (Service Code 45) • Do the 1st step test. ○ Disconnect the ABS hydraulic unit connector and rear wheel rotation sensor connector. ○ Short the black and white/red lead terminals of the main harness side connector [A] with a jumper lead, and check for continuity between the black and white/red lead termi- nals of the main harness side connector [B].
  • Page 459: Power Supply Voltage Abnormal (over-voltage) (service Code 53)

    BRAKES 12-55 Anti-Lock Brake System (Equipped Models) • Do the 2nd step test. ○ Connect the ignition switch connector and ABS hydraulic unit connector. ○ Check the battery terminal voltage, connect the hand tester to the brown terminal of ignition switch connector [A] and ground.
  • Page 460: Ecu Inspection (service Code 55)

    12-56 BRAKES Anti-Lock Brake System (Equipped Models) • Do the 2nd step test. ○ Connect the ignition switch connector and ABS hydraulic unit connector. ○ Check the battery terminal voltage, connect the hand tester to the brown terminal of ignition switch connector [A] and ground.
  • Page 461 BRAKES 12-57 Anti-Lock Brake System (Equipped Models) • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Battery (see Battery Removal in the Electrical System chapter) Bolts [A] Cover [B] • Clean the ABS hydraulic unit. CAUTION Clean all fittings on the ABS hydraulic unit and the rear master cylinder because dirt around the banjo...
  • Page 462: Abs Hydraulic Unit Installation

    12-58 BRAKES Anti-Lock Brake System (Equipped Models) • Remove the bolts [A] and bracket [B]. CAUTION The ABS hydraulic unit has been adjusted and set with precision at the factory. Do not try to disas- semble and repair the ABS hydraulic unit. ABS Hydraulic Unit Installation •...
  • Page 463: Abs Hydraulic Unit Inspection

    BRAKES 12-59 Anti-Lock Brake System (Equipped Models) ABS Hydraulic Unit Inspection • Remove the ABS hydraulic unit (see ABS Hydraulic Unit Removal). • Visually inspect the ABS hydraulic unit. Replace the ABS hydraulic unit if any of them are cracked, or otherwise damaged.
  • Page 464: Rear Wheel Rotation Sensor Removal

    12-60 BRAKES Anti-Lock Brake System (Equipped Models) Rear Wheel Rotation Sensor Removal CAUTION The wheel rotation sensor should be handled care- fully, never struck sharply, as with a hammer, or al- lowed to fall on a hard surface since the wheel rota- tion sensor is precision made.
  • Page 465: Wheel Rotation Sensor Inspection

    BRAKES 12-61 Anti-Lock Brake System (Equipped Models) Wheel Rotation Sensor Inspection • Remove the front wheel rotation sensor [A] from the front fork. • Remove the rear wheel rotation sensor [B] from the caliper bracket. • Visually inspect the wheel rotation sensors. Replace the wheel rotation sensor if it is cracked, bent, or otherwise damaged.
  • Page 466: Wheel Rotation Sensor Rotor Inspection

    12-62 BRAKES Anti-Lock Brake System (Equipped Models) Wheel Rotation Sensor Rotor Inspection • Remove: Wheels (see Front/Rear Wheel Removal in the Wheels/Tires chapter) Brake Disc Mounting Bolts [A] Sensor Rotor [B] • Visually inspect the wheel rotation sensor rotor. If the rotor is deformed or damaged (chipped teeth [A]), replace the sensor rotor with a new one.
  • Page 467: Fuse Installation

    BRAKES 12-63 Anti-Lock Brake System (Equipped Models) Fuse Installation • If a fuse fails during operation, inspect the electrical sys- tem to determine the cause, and then replace it with a new fuse of proper amperage (see Fuse Installation in the Electrical System chapter).
  • Page 469 SUSPENSION 13-1 Suspension Table of Contents Exploded View........................13-2 Specifications ......................... 13-6 Special Tools .......................... 13-7 Front Fork ..........................13-9 Rebound Damping Force Adjustment................13-9 Compression Damping Force Adjustment ................ 13-9 Spring Preload Adjustment ....................13-10 Front Fork Removal (Each Fork Leg) ................13-10 Front Fork Installation .......................
  • Page 470: Exploded View

    13-2 SUSPENSION Exploded View...
  • Page 471 SUSPENSION 13-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Axle Clamp Bolts Front Fork Bottom Allen Bolts Front Fork Clamp Bolts (Lower) Front Fork Clamp Bolts (Upper) Front Fork Top Plugs Piston Rod Nuts AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque. G: Apply grease.
  • Page 472 13-4 SUSPENSION Exploded View...
  • Page 473 SUSPENSION 13-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Rear Shock Absorber Nut (Lower) Rear Shock Absorber Nut (Upper) Swingarm Pivot Adjusting Collar Swingarm Pivot Adjusting Collar Locknut 10.0 Swingarm Pivot Shaft Nut 11.0 Tie-Rod Nuts Uni-Trak Rocker Arm Nut G: Apply grease.
  • Page 474: Specifications

    13-6 SUSPENSION Specifications Item Standard Front Fork (Per One Unit) Fork Inner Tube Diameter 43 mm (1.7 in.) Air Pressure Atmospheric pressure (non-adjustable) Rebound Damper Setting 5th click from the 1st click of the fully clockwise position (Usable range: 0 ←→ 11 clicks) Compression Damper Setting 10th click from the 1st click of the fully clockwise position (Usable range: 0 ←→...
  • Page 475: Special Tools

    SUSPENSION 13-7 Special Tools Inside Circlip Pliers: Fork Piston Rod Puller, M12 × 1.25: 57001-143 57001-1289 Oil Seal & Bearing Remover: Fork Oil Level Gauge: 57001-1058 57001-1290 Bearing Driver Set: Bearing Remover Head, 20 × 22: 57001-1129 57001-1293 Jack: Bearing Remover Shaft, 13: 57001-1238 57001-1377 Fork Cylinder Holder:...
  • Page 476 13-8 SUSPENSION Special Tools Fork Oil Seal Driver, 43: Needle Bearing Driver, 17/ 18: 57001-1530 57001-1609 Fork Spring Compressor: Stem Bearing Driver, 28: 57001-1540 57001-1610 Fork Spring Compressor: Spacer, 57001-1587 57001-1636 Swingarm Pivot Nut Wrench: Spacer 28: 57001-1597 57001-1663 Jack Attachment: Needle Bearing Driver, 20 &...
  • Page 477: Front Fork

    SUSPENSION 13-9 Front Fork Rebound Damping Force Adjustment • To adjust the rebound damping force, turn the rebound damping adjuster [A] until you feel a click. ○ The standard adjuster setting for the average-build rider of 68 kg (150 lb) with no passenger and no accessories is the 5th click from the 1st click of the fully clockwise position.
  • Page 478: Spring Preload Adjustment

    13-10 SUSPENSION Front Fork Spring Preload Adjustment • Turn the spring preload adjuster [A] to change spring preload setting. ○ The standard adjuster setting for the average-build rider of 68 kg (150 lb) with no passenger and no accessories is the 15 mm (0.59 in.) [B] from top as shown in the figure.
  • Page 479: Front Fork Installation

    SUSPENSION 13-11 Front Fork Front Fork Installation • Install the fork so that the top end [A] of the outer tube as shown in the figure. 21.5 mm (0.85 in.) [B] • Tighten the lower fork clamp bolts and fork top plug. Torque - Front Fork Clamp Bolts (Lower): 30 N·m (3.1 kgf·m, 22 ft·lb) Front Fork Top Plug: 22 N·m (2.2 kgf·m, 16 ft·lb)
  • Page 480 13-12 SUSPENSION Front Fork • Insert the holder bar [A] into the axle hole of the front fork [B]. • Insert the compression shaft and install the nut. • Insert the lower end of the compression shaft [A] into the hole [B] of the holder bar.
  • Page 481 SUSPENSION 13-13 Front Fork • Holding the piston rod nut with a wrench [A], remove the top plug [B] from the piston rod. • Remove: Washer [A] Collar [B] Rebound Damping Adjuster Rod [C] Fork Spring [D] • Drain the fork oil into a suitable container. ○...
  • Page 482 13-14 SUSPENSION Front Fork If necessary, measure the oil level as follows. ○ Hold the inner tube vertically in a vise. ○ Pump the inner tube several times to expel air bubbles. ○ Using the piston rod puller [A], move the piston rod [B] up and down more than ten times in order to expel all the air from the fork oil.
  • Page 483 SUSPENSION 13-15 Front Fork • Screw the rod nut [A] onto the piston rod [B] as shown in the figure. 11 mm (0.43 in.) [C] • Check the distance between the bottom end [A] of the top plug and rebound damping adjuster [B] with a pair of vernier caliper.
  • Page 484: Front Fork Disassembly

    13-16 SUSPENSION Front Fork • Raise the outer tube and screw the top plug into it and install it to the steering stem. • Screw in the spring preload adjuster [A] of the top plug so that the distance between the adjuster top and the top plug surface is 15 mm (0.59 in.) [B].
  • Page 485: Inner Tube Inspection

    SUSPENSION 13-17 Front Fork • Install the following parts into the inner tube [A]. Dust Seal [B] Retaining Ring [C] Oil Seal [D] Washer [E] • Insert the inner tube to the outer tube. • After installing the washer, install the oil seal [A] by using the fork oil seal driver [B].
  • Page 486: Dust Seal Inspection

    13-18 SUSPENSION Front Fork Dust Seal Inspection • Inspect the dust seal [A] for any signs of deterioration or damage. Replace it if necessary. Spring Tension • Since a spring becomes shorter as it weakens, check its free length [A] to determine its condition. If the spring of either fork leg is shorter than the service limit, it must be replaced.
  • Page 487: Rear Shock Absorber

    SUSPENSION 13-19 Rear Shock Absorber Rebound Damping Force Adjustment • To adjust the rebound damping force, turn the lower damping adjuster [A] to the desired position, until you feel a click. ○ The standard adjuster setting for an average-build rider of 68 kg (150 lb) with no passenger and no accessories is the 1 2/4 turns out from the fully clockwise position.
  • Page 488: Rear Shock Absorber Removal

    13-20 SUSPENSION Rear Shock Absorber • To adjust the spring preload, turn in the adjusting nut [A] to the desired position and tighten the locknut [B]. Spring Length [C] Spring Preload Setting Standard: Spring length 175.5 mm (6.9 in.) Usable Range: Spring length 175.5 191.5 mm (6.909...
  • Page 489: Rear Shock Absorber Installation

    SUSPENSION 13-21 Rear Shock Absorber • Squeeze the brake lever slowly and it with a band [A]. WARNING Be sure to hold the front brake when removing the shock absorber, or the motorcycle may fall over. It could cause an accident and injury. •...
  • Page 490: Rear Shock Absorber Scrapping

    13-22 SUSPENSION Rear Shock Absorber Rear Shock Absorber Scrapping WARNING Since the reservoir tank of the rear shock absorber contains nitrogen gas, do not incinerate the reser- voir tank without first releasing the gas or it may explode. • Remove the rear shock absorber (see Rear Shock Ab- sorber Removal).
  • Page 491: Swingarm

    SUSPENSION 13-23 Swingarm Swingarm Removal • Remove: Chain Cover (see Drive Chain Removal in the Final Drive chapter) Rear Wheel (see Rear Wheel Removal in the Wheels/Tires chapter) Bolts [A] Brackets [B] • Remove: Upper Tie-Rod Nut and Bolt [A] Rear Shock Absorber [B] (see Rear Shock Absorber Re- moval) •...
  • Page 492: Swingarm Installation

    13-24 SUSPENSION Swingarm Swingarm Installation • Apply plenty of grease to the lip of the oil seals [A]. • Install the collar. • Place the adjusting collar [A] the frame [B] as shown in the figure. 11 mm (0.43 in.) [C] •...
  • Page 493: Swingarm Bearing Removal

    SUSPENSION 13-25 Swingarm Swingarm Bearing Removal • Remove: Swingarm (see Swingarm Removal) Collar [A] Oil Seals [B] Sleeve [C] Circlip [D] (Right Side) Special Tool - Inside Circlip Pliers: 57001-143 • Remove the ball bearing and needle bearings. Special Tool - Oil Seal & Bearing Remover [A]: 57001-1058 Swingarm Bearing Installation •...
  • Page 494: Swingarm Bearing, Sleeve Inspection

    13-26 SUSPENSION Swingarm • Install the needle bearings [A], ball bearing [B] and oil seals [C] position as shown in the figure. Circlip [D] 32 mm (1.26 in.) [E] 17 mm (0.67 in.) [F] 27.5 mm (1.08 in.) [G] 9.5 mm (0.37 in.) [H] Swingarm Bearing, Sleeve Inspection CAUTION Do not remove the bearings for inspection.
  • Page 495: Chain Guide Inspection

    SUSPENSION 13-27 Swingarm • Turn the bearing in the swingarm back and forth [A] while checking for plays, roughness, or binding. If bearing play, roughness, or binding is found, replace the bearing. • Examine the bearing seal [B] for tears or leakage. If the seal is torn or is leaking, replace the bearing.
  • Page 496: Tie-rod, Rocker Arm

    13-28 SUSPENSION Tie-Rod, Rocker Arm Tie-Rod Removal • Squeeze the brake lever slowly and hold it with a band [A]. • Remove: Lower Fairings (see Lower Fairing Removal in the Frame chapter) Rear Fairing (see Rear Fairing Removal in the Frame chapter) Bracket (see Rear Shock Absorber Removal) •...
  • Page 497: Rocker Arm Installation

    SUSPENSION 13-29 Tie-Rod, Rocker Arm Rocker Arm Installation • Apply grease to the inside of the grease seals. • Tighten: Torque - Uni-Trak Rocker Arm Nut: 34 N·m (3.5 kgf·m, 25 ft·lb) Tie-Rod Nuts: 59 N·m (6.0 kgf·m, 44 ft·lb) Rear Shock Absorber Nut (Lower): 34 N·m (3.5 kgf·m, 25 ft·lb) Tie-Rod and Rocker Arm Bearing Removal...
  • Page 498 13-30 SUSPENSION Tie-Rod, Rocker Arm ○ Screw the needle bearing driver [A] into the driver holder [B]. ○ Insert the needle bearing driver into the needle bearing [C] and press the needle bearing into the housing until the driver contacts the end surface of the housing. Bearing Pressing Depth: 5.5 mm (0.22 in.) [D] 5.0 mm (0.20 in.) [E] NOTE...
  • Page 499: Rocker Arm/tie-rod Bearing, Sleeve Inspection

    SUSPENSION 13-31 Tie-Rod, Rocker Arm Rocker Arm/Tie-Rod Bearing, Sleeve Inspection CAUTION Do not remove the bearings for inspection. Re- moval may damage them. • Visually inspect the locker arm, or tie-rod sleeves [A] and needle bearings [B]. • The rollers in a needle bearing normally wear very little, and wear is difficult to measure.
  • Page 501 STEERING 14-1 Steering Table of Contents Exploded View........................14-2 Special Tools .......................... 14-4 Steering ..........................14-5 Steering Inspection ......................14-5 Steering Adjustment......................14-5 Steering Stem......................... 14-6 Stem, Stem Bearing Removal................... 14-6 Stem, Stem Bearing Installation..................14-7 Steering Stem Bearing Lubrication ................... 14-9 Steering Stem Warp......................
  • Page 502: Exploded View

    14-2 STEERING Exploded View...
  • Page 503 STEERING 14-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Fork Clamp Bolts (Lower) Front Fork Clamp Bolts (Upper) Handlebar Bolts Handlebar Holder Bolts Steering Stem Head Nut Steering Stem Nut Switch Housing Screws 0.36 31 in·lb AD: Apply adhesive. AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque.
  • Page 504: Special Tools

    14-4 STEERING Special Tools Head Pipe Outer Race Press Shaft: Steering Stem Bearing Driver, 42.5: 57001-1075 57001-1344 Steering Stem Nut Wrench: Steering Stem Bearing Driver Adapter, 41.5: 57001-1100 57001-1345 Bearing Driver Set: Head Pipe Outer Race Driver, 55: 57001-1129 57001-1446...
  • Page 505: Steering Inspection

    STEERING 14-5 Steering Steering Inspection • Refer to the Steering Play Inspection in the Periodic Main- tenance chapter. Steering Adjustment • Refer to the Steering Play Adjustment in the Periodic Maintenance chapter.
  • Page 506: Steering Stem

    14-6 STEERING Steering Stem Stem, Stem Bearing Removal • Remove: Upper Fairing (see Upper Fairing Removal in the Frame chapter) Front Wheel (see Front Wheel Removal in the Wheels/Tires chapter) Handlebars (see Handlebar Removal) Front Forks (see Front Fork Removal in the Suspension chapter) Bracket Bolts [A] Cover Bolts [B] and Cover [C]...
  • Page 507: Stem, Stem Bearing Installation

    STEERING 14-7 Steering Stem • Remove the lower ball bearing inner race (with its oil seal) [A] which is pressed onto the steering stem with a suitable commercially available chisel [B]. Stem, Stem Bearing Installation • Replace the bearing outer races with new ones. •...
  • Page 508 14-8 STEERING Steering Stem • Settle the bearings in place as follows. ○ Tighten the steering stem nut with 55 N·m (5.6 kgf·m, 41 ft·lb) of torque first, and loosen it a fraction of a turn until it turns lightly. Afterward tighten it again with specified torque using a steering stem nut wrench [A].
  • Page 509: Steering Stem Bearing Lubrication

    STEERING 14-9 Steering Stem NOTE ○ Tighten the upper front fork clamp bolts [A] first, next the stem head nut [B], last the lower front fork clamp bolts [C]. ○ Tighten the two lower fork clamp bolts alternately two times to ensure even tightening torque. Torque - Front Fork Clamp Bolts (Upper): 20 N·m (2.0 kgf·m, 15 ft·lb) Steering Stem Head Nut: 78 N·m (8.0 kgf·m, 58...
  • Page 510: Handlebar

    14-10 STEERING Handlebar Handlebar Removal • Remove: Clutch Lever Clamp Bolts [A] Clutch Lever Assembly [B] Left Switch Housing [C] Handlebar Weight [D] • Remove: Front Master Cylinder [A] (see Front Master Cylinder Re- moval in the Brakes chapter) Right Switch Housing [B] Throttle Case [C] Handlebar Weight [D] Throttle Grip [E]...
  • Page 511 STEERING 14-11 Handlebar • Install the handlebar holder with handlebar on the steering stem head. • Tighten the handlebar holder bolts. NOTE ○ Tighten the handlebar holder bolt [A] first, next the han- dlebar holder bolt [B]. ○ Tighten the two handlebar holder bolts alternately two times to ensure even tightening torque.
  • Page 513 FRAME 15-1 Frame Table of Contents Exploded View........................15-2 Seat ............................15-10 Seat Removal ........................15-10 Seat Installation ........................ 15-10 Fairings........................... 15-11 Lower Fairing Removal ..................... 15-11 Lower Fairing Installation ....................15-11 Fairing Cover Removal ..................... 15-11 Middle Fairing Removal ....................15-11 Middle Fairing Installation ....................
  • Page 514: Exploded View

    15-2 FRAME Exploded View...
  • Page 515 FRAME 15-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Center Stand Bolts Front Footpeg Bracket Bolts Sidestand Bolt Sidestand Bracket Bolts Sidestand Switch Bolt 0.90 78 in·lb 6. Center Stand (Equipped Models) G: Apply grease. L: Apply a non-permanent locking agent. R: Replacement Parts...
  • Page 516 15-4 FRAME Exploded View...
  • Page 517 FRAME 15-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Rear Fender Mounting Screws 0.12 11 in·lb Rear Footpeg Bracket Bolts Rear Frame Bolts Rear Frame Pipe Bolts Rear Frame Pipe Nuts 6. Center Stand Grip (Equipped Models) G: Apply grease. L: Apply a non-permanent locking agent.
  • Page 518 15-6 FRAME Exploded View...
  • Page 519 FRAME 15-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Grab Rail Mounting Bolts Seat Lock Bracket Screws 0.12 11 in·lb 3. Reflector (United States and Canada Models) 4. Grab Rail (Equipped Models) 5. Seat Cover (Equipped Models)
  • Page 520 15-8 FRAME Exploded View...
  • Page 521 FRAME 15-9 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Windshield Mounting Bolts 0.42 0.043 3.7 in·lb...
  • Page 522: Seat

    15-10 FRAME Seat Seat Removal • Insert the ignition switch key [A] into the seat lock, turning the key counterclockwise, pulling up on the rear of the seat [B], and pulling the seat backward. • For seat cover equipped models; note the following. •...
  • Page 523: Fairings

    FRAME 15-11 Fairings Lower Fairing Removal • Pull up the core by the thin blade driver. • Remove the quick rivet [A]. • Remove the bolts [B] with washers. • Clear the hook portions from the slots. • Separate the left lower fairing from the right lower fairing. Lower Fairing Installation •...
  • Page 524: Middle Fairing Installation

    15-12 FRAME Fairings • Remove: Bolts [A] with Washers Turn Signal Lead Connector • Remove each middle fairing. ○ Clear the hook [B] from the bracket. • Remove: Inner Fairing (see Inner Fairing Removal) Screws Bracket Turn Signal Light Middle Fairing Installation •...
  • Page 525: Windshield Installation

    FRAME 15-13 Fairings Windshield Installation • Put the front tongue [A] into the hollow [B]. • Tighten: Torque - Windshield Mounting Bolts: 0.42 N·m (0.043 kgf·m, 3.7 in·lb) Upper Fairing Removal • Remove: Lower Fairings (see Lower Fairing Removal) Fairing Covers (see Fairing Cover Removal) Inner Covers (see Inner Cover Removal) Middle Fairings (see Middle Fairing Removal) Windshield (see Windshield Removal)
  • Page 526: Upper Fairing Installation

    15-14 FRAME Fairings Upper Fairing Installation • Installation is the reverse of removal. Inner Cover Removal • Remove the bolts [A]. • Remove the inner cover [B]. ○ Pull the inner cover backward, and clear the hooks. Inner Cover Installation •...
  • Page 527: Upper Inner Fairing Installation

    FRAME 15-15 Fairings Upper Inner Fairing Installation • Insert the slots [A] of the upper inner fairing into the hooks [B] of the upper fairing. • Tighten the bolt. Upper Fairing Bracket Removal • Remove: Upper Fairing (see Upper Fairing Removal) Front and Middle Inlet Ducts (see Front and Middle Inlet Duct Removal in the Fuel System (DFI) chapter) Rear Inlet Ducts (see Rear Inlet Duct Removal in the...
  • Page 528: Seat Cover

    15-16 FRAME Seat Cover Seat Cover Removal • Remove: Seat (see Seat Removal) Bolts [A] Screws [B] Grab Rail [C] (Equipped Models) Center Seat Cover [D] • Remove the quick rivets [A]. • Remove the bolts [A]. • Clear the side seat covers [B] from the rear fender. •...
  • Page 529 FRAME 15-17 Seat Cover • Insert the projection [A] into the hole [B]. • Tighten the screws. • Install the grab rail (equipped models). • Tighten: Torque - Grab Rail Mounting Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb)
  • Page 530: Fenders

    15-18 FRAME Fenders Front Fender Removal • Remove: Brake Hose Clamps [A] (Both Sides) Bolts [B] with Washer (Both Sides) Bracket [C] (ZX1400B Models) • Remove the front fender assy [D]. • Remove the screws [A]. • Separate the front fender covers [B] and front fender [C]. Front Fender Installation •...
  • Page 531: Flap And Rear Fender Installation

    FRAME 15-19 Fenders • Remove: Nuts [A] License Light Connector (Disconnect) Flap (with License Light) Tail/Brake Light (LED) (see Tail/Brake Light (LED) Re- moval in the Electrical System chapter) • Pull out the rear fender [B] backward and downward. Flap and Rear Fender Installation •...
  • Page 532: Rear Frame Removal

    15-20 FRAME Frame Rear Frame Removal • Remove: Rear Fender (see Rear Fender Removal) Regulator/Rectifier [A] (see Regulator/Rectifier Inspec- tion in the Electrical System chapter) Tail/Brake Light (see Tail/Brake Light Removal in the Electrical System chapter) Bolts [B] (Both Sides) Rear Footpeg Bracket Bolts [C] and Brackets (Both Sides) Frame Bolts [D]...
  • Page 533: Center Stand, Sidestand

    FRAME 15-21 Center Stand, Sidestand Center Stand Removal (Equipped Models) • Remove: Muffler Bodies (see Muffler Body Removal in the Engine Top End chapter) Spring [A] Bolts [B] Bolts [C] and Nuts Center Stand [D] Center Stand Installation (Equipped Models) •...
  • Page 535 ELECTRICAL SYSTEM 16-1 Electrical System Table of Contents Exploded View........................16-4 Parts Location......................... 16-10 Wiring Diagram (United States, Canada, New Zealand and Colombia)......... 16-12 Wiring Diagram (Other than United States, Canada, New Zealand and Colombia)....16-14 Wiring Diagram (ZX1400B Models)..................16-16 Specifications .........................
  • Page 536 16-2 ELECTRICAL SYSTEM Starter Motor Assembly ....................16-47 Brush Inspection ....................... 16-48 Commutator Cleaning and Inspection................16-49 Armature Inspection......................16-49 Brush Lead Inspection ...................... 16-49 Right-hand End Cover Assembly Inspection ..............16-50 Starter Relay Inspection....................16-50 Lighting System ........................16-52 Headlight Beam Horizontal Vertical Adjustment ...............
  • Page 537 ELECTRICAL SYSTEM 16-3 Fuse Inspection......................... 16-111...
  • Page 538: Exploded View

    16-4 ELECTRICAL SYSTEM Exploded View...
  • Page 539 ELECTRICAL SYSTEM 16-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Headlight Mounting Screws 0.12 11 in·lb Front Turn Signal Light Mounting Screws 0.12 11 in·lb Rear Turn Signal Light Mounting Screws 0.12 11 in·lb License Plate Light Mounting Screws 0.12 11 in·lb Tail/Brake Light Mounting Screws...
  • Page 540 16-6 ELECTRICAL SYSTEM Exploded View...
  • Page 541 ELECTRICAL SYSTEM 16-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Camshaft Position Sensor Bolt 87 in·lb Water Temperature Sensor Gear Position Switch Screws 0.30 26 in·lb Gear Position Switch Lead Clamp Bolts 87 in·lb Spark Plugs 115 in·lb Stator Coil Bolts 106 in·lb Alternator Rotor Bolt (First) Alternator Rotor Bolt (Final)
  • Page 542 16-8 ELECTRICAL SYSTEM Exploded View...
  • Page 543 ELECTRICAL SYSTEM 16-9 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Brake Light Switch Screw 0.12 11 in·lb Right Switch Housing Screws 0.36 31 in·lb Left Switch Housing Screws 0.36 31 in·lb Starter Motor Mounting Bolts 87 in·lb Sidestand Switch Bolt 0.90 78 in·lb Starter Motor Cable Mounting Bolt...
  • Page 544: Parts Location

    16-10 ELECTRICAL SYSTEM Parts Location...
  • Page 545 ELECTRICAL SYSTEM 16-11 Parts Location 1. Headlight Relay (High) 2. Immobilizer Amplifier (Immobilizer Models) 3. Ignition Switch with Immobilizer Antenna (Immobilizer Models) 4. Starter Lockout Switch 5. Fan Motor 6. Starter Relay with Main Fuse 30 A 7. Alternator 8. Speed Senor 9.
  • Page 546: Wiring Diagram (united States, Canada, New Zealand And Colombia)

    16-12 ELECTRICAL SYSTEM Wiring Diagram (United States, Canada, New Zealand and Colombia)
  • Page 547 ELECTRICAL SYSTEM 16-13 Wiring Diagram (United States, Canada, New Zealand and Colombia)
  • Page 548: Wiring Diagram (other Than United States, Canada, New Zealand And Colombia)

    16-14 ELECTRICAL SYSTEM Wiring Diagram (Other than United States, Canada, New Zealand and Colombia)
  • Page 549 ELECTRICAL SYSTEM 16-15 Wiring Diagram (Other than United States, Canada, New Zealand and Colombia)
  • Page 550: Wiring Diagram (zx1400b Models)

    16-16 ELECTRICAL SYSTEM Wiring Diagram (ZX1400B Models)
  • Page 551 ELECTRICAL SYSTEM 16-17 Wiring Diagram (ZX1400B Models)
  • Page 552: Specifications

    16-18 ELECTRICAL SYSTEM Specifications Item Standard Battery Type Sealed battery Model Name FTZ14-BS Capacity 12 V 14 Ah Voltage 12.6 V or more Charging System Type Three-phase AC Alternator Output Voltage 51 V or more @4 000 r/min (rpm) Stator Coil Resistance 0.05 0.5 Ω...
  • Page 553 ELECTRICAL SYSTEM 16-19 Special Tools and Sealant Hand Tester: Harness Adapter: 57001-1394 57001-1562 Flywheel Puller Assembly, M38 × 1.5/M35 × 1.5: Key Registration Unit: 57001-1405 57001-1582 Peak Voltage Adapter: Grip: 57001-1415 57001-1591 Lead Wire - Peak Voltage Adapter: Rotor Holder: 57001-1449 57001-1672 Needle Adapter Set:...
  • Page 554: Special Tools And Sealant

    16-20 ELECTRICAL SYSTEM Special Tools and Sealant Kawasaki Bond (Silicone Sealant): 92104-0004...
  • Page 555: Precautions

    ELECTRICAL SYSTEM 16-21 Precautions There are a number of important precautions that are musts when servicing electrical systems. Learn and ob- serve all the rules below. ○ Do not reverse the battery cable connections. This will burn out the diodes on the electrical parts. ○...
  • Page 556: Electrical Wiring

    16-22 ELECTRICAL SYSTEM Electrical Wiring Wiring Inspection • Visually inspect the wiring for signs of burning, fraying, etc. If any wiring is poor, replace the damaged wiring. • Pull each connector [A] apart and inspect it for corrosion, dirt, and damage. If the connector is corroded or dirty, clean it carefully.
  • Page 557: Battery

    ELECTRICAL SYSTEM 16-23 Battery Battery Removal • Turn off the ignition switch. • Remove: Right Fairing Cover (see Fairing Cover Removal in the Frame chapter) Bolt [A] Battery Compartment Cover [B] ○ Clear the stoppers from the frame. • Remove: Bolt [A] Bracket Bolts [B] Bracket [C]...
  • Page 558: Battery Installation

    16-24 ELECTRICAL SYSTEM Battery Battery Installation • Place the battery in the tray. • Connect the negative (–) cable to the battery. • Apply a light coat of grease on the terminals to prevent corrosion. • Insert the battery tray along with the battery into the bat- tery compartment.
  • Page 559 ELECTRICAL SYSTEM 16-25 Battery • Remove the electrolyte container from the vinyl bag. • Detach the strip of caps [A] from the container and set aside, these will be used later to seal the battery. NOTE ○ Do not pierce or otherwise open the sealed cells [B] of the electrolyte container.
  • Page 560 Standard Charge: 1.4 A × 5 10 hours If using a recommended battery charger, follow the charger’s instructions for newly activated sealed battery. Kawasaki-recommended chargers: Optimate III Yuasa 1.5 Amp Automatic Charger Battery Mate 150-9 If the above chargers are not available, use equivalent one.
  • Page 561: Precautions

    ELECTRICAL SYSTEM 16-27 Battery Precautions 1) No need of topping-up No topping-up is necessary in this battery until it ends its life under normal use. Forcibly prying off the seal cap to add water is very dangerous. Never do that. 2) Refreshing charge If an engine will not start, a horn sounds weak, or lamps are dim, it indicates the battery has been discharged.
  • Page 562: Refreshing Charge

    16-28 ELECTRICAL SYSTEM Battery If the reading is 12.6 V or more, no refresh charge is re- quired, however, if the read is below the specified, refresh charge is required. Battery Terminal Voltage Standard: 12.6 V or more Refreshing Charge •...
  • Page 563: Charging System

    Apply silicone sealant to the alternator lead grommet and crankcase halves mating surface [A] on the front and rear sides of the cover mount. Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004 • Check that dowel pins [B] are in place on the crankcase.
  • Page 564: Stator Coil Installation

    Apply silicone sealant to the circumference of the alter- nator lead grommet, and fit the grommet into the notch of the cover securely. Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004 • Secure the alternator lead with a holding plate [A], and apply a non-permanent locking agent to the thread of the plate bolts and tighten them.
  • Page 565: Alternator Inspection

    ELECTRICAL SYSTEM 16-31 Charging System • Using a cleaning fluid, clean off any oil or dirt on the washer [A] and dry if with a clean cloth. • Install the washer so that its chamfer side [B] faces the rotor bolt [C]. NOTE ○...
  • Page 566 16-32 ELECTRICAL SYSTEM Charging System • To check the alternator output voltage, do the following procedures. ○ Turn off the ignition switch. ○ Remove the right seat cover (see Seat Cover Removal in the Frame chapter). ○ Disconnect the alternator lead connector [A]. ○...
  • Page 567: Regulator/rectifier Inspection

    CAUTION Use only Kawasaki Hand Tester 57001-1394 for this test. A tester other than the Kawasaki Hand Tester may show different readings. If a megger or a meter with a large capacity battery is used, the regulator/rectifier will be damaged.
  • Page 568: Charging Voltage Inspection

    16-34 ELECTRICAL SYSTEM Charging System Charging Voltage Inspection • Check the battery condition (see Charging Condition In- spection). • Warm up the engine to obtain actual alternator operating conditions. • Remove the right fairing cover (see Fairing Cover Re- moval in the Frame chapter). •...
  • Page 569 ELECTRICAL SYSTEM 16-35 Charging System Charging System Circuit 1. Ignition Switch 2. Regulator/Rectifier 3. Alternator 4. Load 5. Main Fuse 30 A 6. Frame Ground 1 7. Battery 12 V 14 Ah 8. Joint Connector 1 9. Frame Ground 2 10.
  • Page 570: Ignition System

    16-36 ELECTRICAL SYSTEM Ignition System...
  • Page 571: Crankshaft Sensor Removal

    ELECTRICAL SYSTEM 16-37 Ignition System WARNING The ignition system produces extremely high volt- age. Do not touch the spark plugs or stick coils while the engine is running, or you could receive a severe electrical shock. CAUTION Do not disconnect the battery cables or any other electrical connections when the ignition switch is on, or while the engine is running.
  • Page 572: Crankshaft Sensor Installation

    • Apply silicone sealant to the mating surface [C] of crankcase halves. Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004 • Replace the O-ring [D] with a new one. • Install the crankshaft sensor cover.
  • Page 573: Stick Coil (ignition Coil Together With Spark Plug Cap) Removal

    ELECTRICAL SYSTEM 16-39 Ignition System • Set the hand tester [A] to the × 25 V DC range, and con- nect the peak voltage adapter [B]. Special Tools - Hand Tester: 57001-1394 Peak Voltage Adapter: 57001-1415 Type: KEK-54-9-B Connections: Crankshaft Sensor Adapter Hand Tester Connector [C]...
  • Page 574: Stick Coil (ignition Coil Together With Spark Plug Cap) Inspection

    16-40 ELECTRICAL SYSTEM Ignition System Stick Coil (Ignition Coil together with Spark Plug Cap) Inspection • Remove the stick coils (see Stick Coil (Ignition Coil to- gether with Spark Plug Cap) Removal). • Measure the primary winding resistance [A] as follows. ○...
  • Page 575: Spark Plug Removal

    ELECTRICAL SYSTEM 16-41 Ignition System WARNING To avoid extremely high voltage shocks, do not touch the spark plugs or tester connections. • Turn the ignition switch and engine stop switch ON. • Pushing the starter button, turn the engine 4 5 seconds with the transmission in neutral to measure the primary peak voltage.
  • Page 576: Camshaft Position Sensor Removal

    16-42 ELECTRICAL SYSTEM Ignition System Camshaft Position Sensor Removal • Remove: Fuel Tank Cover (see Fuel Tank Removal in the Fuel System (DFI) chapter) Right Middle Fairing (see Middle Fairing Removal in the Frame chapter) • Disconnect the camshaft position sensor lead connector [A].
  • Page 577: Camshaft Position Sensor Peak Voltage Inspection

    ELECTRICAL SYSTEM 16-43 Ignition System Camshaft Position Sensor Peak Voltage Inspection • Disconnect the camshaft position sensor lead connector [A] (see Camshaft Position Sensor Removal). • Connect the harness adapter [B] between the camshaft position sensor lead connector and harness connector [C].
  • Page 578: Ic Igniter Inspection

    16-44 ELECTRICAL SYSTEM Ignition System 2nd Check • Start the engine to the following conditions. Condition: Transmission Gear → 1st Position Clutch Lever → Pulled in Sidestand → Up ○ Turn the ignition switch ON and push the starter button. ○...
  • Page 579 ELECTRICAL SYSTEM 16-45 Ignition System Ignition System Circuit 1. Sidestand Switch 14. Ignition Fuse 10 A 2. Camshaft Position Sensor 15. ECU Fuse 15 A 3. Joint Connector 1 16. Ignition Switch 4. Joint Connector 2 17. Main Fuse 30 A 5.
  • Page 580: Electric Starter System

    16-46 ELECTRICAL SYSTEM Electric Starter System Starter Motor Removal • Remove: Engine Sprocket Cover (see Engine Sprocket Removal in the Final Drive chapter) • Take off the heat insulation rubber plate [A]. • Slide out the rubber cap [B]. • Remove the starter motor cable terminal nut [C].
  • Page 581: Starter Motor Disassembly

    ELECTRICAL SYSTEM 16-47 Electric Starter System Starter Motor Disassembly • Remove the starter motor (see Starter Motor Removal). • Take off the starter motor through bolts [A] and remove both end covers [B]. • Pull the armature [A] out of the yoke [B]. •...
  • Page 582: Brush Inspection

    16-48 ELECTRICAL SYSTEM Electric Starter System • Install the armature [A] into the yoke [B]. • Install thrust washer [C]. • Replace the O-rings [D] with new ones. • Put the armature [E] among the brushes [F]. • Align the marks [A] to assembly the yoke and the end covers.
  • Page 583: Commutator Cleaning And Inspection

    ELECTRICAL SYSTEM 16-49 Electric Starter System Commutator Cleaning and Inspection • Smooth the commutator surface [A] if necessary with fine emery cloth [B], and clean out the grooves. • Measure the diameter [A] of the commutator [B]. If the commutator diameter is less than the service limit, replace the starter motor with a new one.
  • Page 584: Right-hand End Cover Assembly Inspection

    16-50 ELECTRICAL SYSTEM Electric Starter System Right-hand End Cover Assembly Inspection • Using the highest hand tester range, measure the resis- tance as shown. Terminal and Right-hand End Cover [A] Special Tool - Hand Tester: 57001-1394 If there is any reading, the right-hand end cover assembly have a short.
  • Page 585 ELECTRICAL SYSTEM 16-51 Electric Starter System Electric Starter Circuit 1. Sidestand Switch 2. Engine Stop Switch 3. Starter Button 4. Fuse Box 2 5. Ignition Fuse 10 A 6. Ignition Switch 7. Joint Connector 1 8. Joint Connector 2 9. Gear Position Switch 10.
  • Page 586: Lighting System

    16-52 ELECTRICAL SYSTEM Lighting System This motorcycle adopt the daylight system and have a headlight relay in the relay box. The headlight does not go on when the ignition switch and the engine stop switch are first turned on. The headlight comes on after the starter button is released and stays on until the ignition switch is turned off.
  • Page 587: City Light Bulb Replacement

    ELECTRICAL SYSTEM 16-53 Lighting System City Light Bulb Replacement • Remove the inner covers (see Inner Cover Removal in the Frame chapter). • Unscrew the screw [A]. • Disconnect the city light connector [B]. • Turn the city light bulb counterclockwise and pull out the socket [A] together with the bulb.
  • Page 588: Headlight Relay Inspection

    CAUTION Use only Hand Tester 57001-1394 for this test. An ohmmeter other than the Kawasaki Hand Tester may show different readings. If a megger or a meter with a large-capacity battery is used, the headlight relay will be damaged.
  • Page 589: Tail/brake Light (led) Installation

    ELECTRICAL SYSTEM 16-55 Lighting System Tail/Brake Light (LED) Installation • Connect the connector. • Insert the projections [A] of the tail/brake light into the holes [B] of the rear fender. Torque - Tail/Brake Light Mounting Screws: 1.2 N·m (0.12 kgf·m, 11 in·lb) •...
  • Page 590: Turn Signal Light Bulb Replacement

    16-56 ELECTRICAL SYSTEM Lighting System Headlight/Tail Light Circuit 1. Ignition Switch 15. Headlight Fuse (Low) 10 A 2. Joint Connector 1 16. Fuse Box 1 3. High Beam Indicator Light (LED) 17. Relay Box 4. Right City Light 18. Headlight Circuit Relay 5.
  • Page 591 ELECTRICAL SYSTEM 16-57 Lighting System • Push and turn the front turn signal light bulb [A] counter- clockwise and remove it. • Replace the bulb with new ones. • Insert the new bulb [A] by aligning its upper and lower pins [B] with the upper and lower grooves [C] in the socket, and turn the bulb clockwise.
  • Page 592: Turn Signal Relay Inspection

    16-58 ELECTRICAL SYSTEM Lighting System • Insert the new bulb [A] by aligning its upper and lower pins [B] with the upper and lower grooves [C] in the socket, and turn the bulb clockwise. ○ Turn the bulb about 15°. •...
  • Page 593 ELECTRICAL SYSTEM 16-59 Lighting System Turn Signal Light Circuit 1. Ignition Switch 2. Joint Connector 1 3. Turn Signal Indicator Light (LED) (Right) 4. Turn Signal Indicator Light (LED) (Left) 5. Front Right Turn Signal Light 6. Front Left Turn Signal Light 7.
  • Page 594: Air Switching Valve

    16-60 ELECTRICAL SYSTEM Air Switching Valve Air Switching Valve Operation Test • Refer to the Air Suction System Damage Inspection in the Periodic Maintenance chapter. Air Switching Valve Unit Test • Remove the air switching valve (see Air Switching Valve Removal in the Engine Top End chapter).
  • Page 595: Radiator Fan System

    ELECTRICAL SYSTEM 16-61 Radiator Fan System Fan Motor Inspection • Remove the left fairing cover (see Fairing Cover Removal in the Frame chapter). • Disconnect the connector [A]. • Using an auxiliary leads, supply battery power to the fan motor. If the fan does not rotate, the fan motor is defective and must be replaced.
  • Page 596: Meter, Gauge, Indicator Unit

    16-62 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit Meter Unit Removal • Remove: Windshield (see Windshield Removal in the Frame chapter) Immobilizer Amplifier [A] (Equipped Models) • Remove: Immobilizer Amplifier Bracket and Bolt [A] (Equipped Models) Vehicle-down Sensor Bracket and Bolt [B] Meter Lead Connector [C] •...
  • Page 597: Meter Unit Disassembly

    ELECTRICAL SYSTEM 16-63 Meter, Gauge, Indicator Unit Meter Unit Disassembly • Remove: Meter Unit (see Meter Unit Removal) Screws [A] Lower Meter Cover [B] • Separate: Upper Meter Cover [A] Middle Meter Cover [B] Meter Assembly [C] Meter Unit Inspection •...
  • Page 598 The speedometer and tachometer needles momentarily point their last readings and back to the minimum position. ○ The ABS indicator light (LED) [A] (equipped models) should go on. ○ The K Kawasaki mark [B] in the LCD appears for three seconds.
  • Page 599 ELECTRICAL SYSTEM 16-65 Meter, Gauge, Indicator Unit ○ After the K Kawasaki mark appeared, the TRIP A/B meter [A], water temperature gauge [B], fuel level gauge [C], odometer and clock appear in the display [D]. ○ The ABS indicator light (LED) [E] (equipped models) should go on.
  • Page 600 16-66 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit • By pushing the MODE button each time at the language setting mode, check that the display [A] selects as follows. If the display function does not work, replace the meter assembly. • Select the MILEAGE [A] indication.
  • Page 601 ELECTRICAL SYSTEM 16-67 Meter, Gauge, Indicator Unit • Select the LAMP MODE [A] indication. • Push the MODE button for m