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Kawasaki VN1600 MEAN STREAK Service Manual

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Table of Contents
VULCAN 1600 MEAN STREAK
VN1600 MEAN STREAK
Motorcycle
Service Manual

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Table of Contents
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  Also See for Kawasaki VN1600 MEAN STREAK

  Summary of Contents for Kawasaki VN1600 MEAN STREAK

  • Page 1 VULCAN 1600 MEAN STREAK VN1600 MEAN STREAK 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 information contained in this publication is based on the latest product information available at the time of publication. Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts. © 2003 Kawasaki Heavy Industries, Ltd. First Edition (1) : Jul. 1, 2003 (M)
  • 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 WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL LAW, THE VIOLATION OF WHICH IS PUNISHABLE BY CIVIL PENALTIES NOT EXCEEDING $10,000 PER VIOLATION. 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...
  • Page 9: How To Use This Manual

    Be alert for problems and non-scheduled ticular interest for more efficient and con- maintenance. • venient operation. Use proper tools and genuine Kawasaki Mo- • torcycle parts. Special tools, gauges, and Indicates a procedural step or work to be testers that are necessary when servicing done.
  • Page 11 GENERAL INFORMATION 1-1 General Information Table of Contents Before Servicing ........................Model Identification......................... General Specifications......................Unit Conversion Table ......................1-12...
  • Page 12: Before Servicing

    1-2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly opera- tion on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustra- tions, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary.
  • Page 13 Replacement Parts Replacement Parts must be KAWASAKI genuine or recommended by KAWASAKI. Gaskets, O-rings, Oil seals, Grease seals, circlips or cotter pins must be replaced with new ones whenever disassembled.
  • Page 14 1-4 GENERAL INFORMATION Before Servicing Tightening Sequence Bolts, nuts, or screws must be tightened according to the specified sequence to prevent case warpage or deformation which can lead to malfunction. If the specified tightening sequence is not indicated, tighten the fasteners alternating diagonally.
  • 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 Direction of Engine Rotation When rotating the crankshaft by hand, the free play amount of rotating direction will affect the adjustment. Ro- tate the crankshaft to positive direction (clockwise viewed from output side). Electrical Wires A two-color wire is identified first by the primary color and then the stripe color.
  • Page 17: Model Identification

    GENERAL INFORMATION 1-7 Model Identification VN1600-B1 (US, and Canada) Left Side View: VN1600-B1 (US, and Canada) Right Side View:...
  • Page 18 1-8 GENERAL INFORMATION Model Identification VN1600-B1 (Europe) Left Side View: VN1600-B1 (Europe) Right Side View:...
  • Page 19: General Specifications

    GENERAL INFORMATION 1-9 General Specifications Items VN1600–B1 Dimensions: Overall length 2 410 mm (94.9 in.) Overall width 850 mm (33.5 in.) Overall height 1 100 mm (43.3 in.) Wheelbase 1 705 mm (67.1 in.) Road clearance 125 mm (4.92 in.) Seat height 700 mm (27.6 in.) Dry mass...
  • Page 20 1-10 GENERAL INFORMATION General Specifications Items VN1600–B1 Capacity 3.5 L (3.7US qt, when engine is completely disassembled and dry) Drive Train: Primary reduction system: Type Gear Reduction ratio 1.517 (85/56) Clutch type Wet multi disc Transmission: Type 5-speed, constant mesh, return shift Gear ratios: (CAL, CA, US) 2.500 (40/16)
  • Page 21 GENERAL INFORMATION 1-11 General Specifications Items VN1600–B1 Electrical Equipment: Battery Capacity 12 V 18 Ah Headlight: Type Semi-sealed beam Bulb 12 V 60/55 W (quartz-halogen) Tail/brake light 12 V 5/21 W Alternator: Type Three-phase AC Rated output 23 A × 14 V @6 000 r/min (rpm) Specifications subject to change without notice, and may not apply to every country.
  • Page 22: Unit Conversion Table

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

    PERIODIC MAINTENANCE 2-1 Periodic Maintenance Table of Contents Periodic Maintenance Chart ....Tire Inspection ......2-24 Torque and Locking Agent....Final Drive........2-25 Specifications ........2-10 Oil Level Inspection...... 2-25 Special Tools ........2-12 Oil Change ........2-26 Periodic Maintenance Procedures..2-13 Brakes..........
  • Page 24: Periodic Maintenance Chart

    2-2 PERIODIC MAINTENANCE Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition.The initial maintenance is vitally important and must not be neglected. FREQUENCY Whichever * ODOMETER READING comes km ×...
  • Page 25 PERIODIC MAINTENANCE 2-3 Periodic Maintenance Chart FREQUENCY Whichever * ODOMETER READING comes km × 1000 (mile × 1000) first CHANGE/REPLACE ITEM Every (0.6) (7.5) (15) (24) (30) Page • • • Spark plug (e) 2–33 • • • • Engine oil # year 2–22 •...
  • Page 26: Torque And Locking Agent

    2-4 PERIODIC MAINTENANCE Torque and Locking Agent The following tables list the tightening torque WL: Apply a soap and water solution or rubber for the major fasteners requiring use of a non lubricant. -permanent locking agent or liquid gasket. The table below, relating tightening torque to thread diameter, lists the basic torque for the Letters used in the “Remarks”...
  • Page 27: Torque And Locking Agent

    PERIODIC MAINTENANCE 2-5 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Radiator fan switch Radiator fan bolts 0.85 74 in·lb Water temperature switch 0.80 69 in·lb Water pump impeller bolt 0.90 78 in·lb Water pump cover bolts 97 in·lb Water pump air bleeder bolt 97 in·lb Water pump drain bolt...
  • Page 28 2-6 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb 0.12 10 in·lb Starter lockout switch screws Push rod guide bolts 95 in·lb Clutch cover bolts 95 in·lb Clutch damper cover bolts 87 in·lb Clutch damper plate bolts 87 in·lb Clutch cover damper screws 0.50...
  • Page 29 PERIODIC MAINTENANCE 2-7 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb 87 in·lb Oil hose banjo bolts Primary gear bolt 0.30 26 in·lb Water pump chain guide spring hook bolt Water pump chain guide bolt 0.85 73 in·lb Idle shaft holder bolts 0.85 73 in·lb...
  • Page 30 2-8 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb – – – Final gear case Studs Final gear case cover bolts: 8 mm 10 mm Pinion gear nut (final gear) MO, St Bearing retainer bolt 0.70 61 in·lb Brakes: Caliper bleed valves...
  • Page 31 PERIODIC MAINTENANCE 2-9 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Sidestand nut Electrical System: Spark plugs Crankshaft sensor screws 0.30 26 in·lb Stator lead holder screw 87 in·lb Crankshaft sensor lead holder bolt 0.30 26 in·lb Alternator outer cover bolts 0.70 61 in·lb Alternator outer cover joint bolts...
  • Page 32: Specifications

    2-10 PERIODIC MAINTENANCE Specifications Item Standard Service Limit Fuel System (DFI): Throttle grip free play 3 mm (0.08 0.12 in.) – – – Idle speed 950 ±50 r/min (rpm) – – – Air cleaner element Paper filter – – – Cooling System: Coolant: Type (recommended)
  • Page 33 PERIODIC MAINTENANCE 2-11 Specifications Item Standard Service Limit Final Drive: Final gear case oil: Grade API Service Classification: GL-5 – – – hypoid gear oil Viscosity when above 5°C (41°F) SAE90 – – – when below 5°C (41°F) SAE80 Oil level Filler opening bottom –...
  • Page 34: Special Tools

    2-12 PERIODIC MAINTENANCE Special Tools Steering Stem Nut Wrench: Attachment Jack: 57001–1100 57001–1398 Jack: Driver-Filler Cap: 57001–1238 57001–1454...
  • Page 35: Periodic Maintenance Procedures

    PERIODIC MAINTENANCE 2-13 Periodic Maintenance Procedures Fuel System (DFI) Fuel Hose and Connection Inspection ○ The fuel hoses are designed to be used throughout the motorcycle’s life without any maintenance, however, if the motorcycle is not properly handled, the high pressure in- side the fuel line can cause fuel to leak [A] or the hose to burst.
  • Page 36: Idle Speed Inspection

    2-14 PERIODIC MAINTENANCE Periodic Maintenance Procedures Idle Speed Inspection • Start the engine and warm it up thoroughly. ○ At first the engine will run fast to decrease warm up time (fast idle). ○ Gradually the fast idle will lower to a certain RPM auto- matically.
  • Page 37: Evaporative Emission Control System Inspection(Cal)

    PERIODIC MAINTENANCE 2-15 Periodic Maintenance Procedures • Clean the element by tapping it lightly to loosen dust. • Blow away the remaining dust by applying compressed air [A] from the inside to the outside (from the clean side to the dirty side). •...
  • Page 38: Cooling System

    2-16 PERIODIC MAINTENANCE Periodic Maintenance Procedures Cooling System Radiator Hose and Connection Inspection ○ The high pressure inside the radiator hose can cause coolant to leak [A] or the hose to burst if the line is not properly maintained. Visually inspect the hoses for signs of deterioration.
  • Page 39 PERIODIC MAINTENANCE 2-17 Periodic Maintenance Procedures • Remove : Right Side Cover (see Frame chapter) Reserve Tank Bolts • Turn over the reserve tank [A], remove the cap [B], and pour the coolant into a suitable container. • Install the reserve tank. •...
  • Page 40: Engine Top End

    2-18 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Fill the radiator up to the filler neck [A] with coolant. • Install the radiator cap. • Tighten the air bleeder bolt [B]. Torque - Thermostat Air Bleeder Bolt: 7.8 N·m (0.80 kgf·m, 69 in·lb) •...
  • Page 41: Clutch

    PERIODIC MAINTENANCE 2-19 Periodic Maintenance Procedures Clutch Clutch Hose and Connection Inspection • The high pressure inside the clutch line can cause fluid to leak [A] or the hose to burst if the line is not properly maintained. Bend and twist the rubber hose while exam- ining it.
  • Page 42: Clutch Fluid Change

    2-20 PERIODIC MAINTENANCE Periodic Maintenance Procedures Clutch Fluid Change • Level the clutch fluid reservoir and remove the reservoir cap. • Remove the alternator outer cover (see Electrical System chapter.) and the rubber cap from the bleed valve on the clutch slave cylinder.
  • Page 43: Clutch Master Cylinder Cup And Dust Sealreplacement

    PERIODIC MAINTENANCE 2-21 Periodic Maintenance Procedures Clutch Master Cylinder Cup and Dust Seal Replacement • Remove the clutch master cylinder (see Clutch chapter). • Remove the reservoir cap [A] and diaphragm [B], and pour the clutch fluid into a container. •...
  • Page 44: Clutch Slave Cylinder Piston Seal Replacement

    2-22 PERIODIC MAINTENANCE Periodic Maintenance Procedures Clutch Slave Cylinder Piston Seal Replacement • Remove the alternator outer cover (see Electrical System chapter) • Loosen the banjo bolt [A] at the clutch pipe lower end, and tighten it loosely. • Unscrew the slave cylinder bolts [B] and detach the slave cylinder with the pipe installed from the engine.
  • Page 45 PERIODIC MAINTENANCE 2-23 Periodic Maintenance Procedures • Remove: Oil Screen Plug [A] • Remove the oil screen [A], the spring [B], and the washer [C]. • Clean the oil screen with a high-flash point solvent and remove any particles stuck to it. •...
  • Page 46: Oil Filter Replacement

    2-24 PERIODIC MAINTENANCE Periodic Maintenance Procedures Engine Oil Type: API SE, SF or SG class API SH or SJ class with JASO MA Viscosity: SAE 10W-40 Amount: 2.9 L (3.1 US qt, when filter is not removed) 3.1 L (3.3 US qt, when filter is removed) 3.5 L (3.7 US qt, when engine is completely disassembled and dry) NOTE...
  • Page 47: Final Drive

    PERIODIC MAINTENANCE 2-25 Periodic Maintenance Procedures • Measure the tread depth at the center of the tread with a depth gauge [A]. Since the tire may wear unevenly, take measurement at several places. If any measurement is less than the service limit, replace the tire (see Wheels/Tires chapter).
  • Page 48: Oil Change

    2-26 PERIODIC MAINTENANCE Periodic Maintenance Procedures • The oil level [A] should come to the bottom of the filler opening. If it is low, first check the final gear case for oil leakage, remedy it if necessary, and add oil through the filler open- ing.
  • Page 49: Brakes

    PERIODIC MAINTENANCE 2-27 Periodic Maintenance Procedures Brakes Brake Pad Wear Inspection • Unscrew the bolts [A] and remove the pad spring [B] (Front Brake Caliper) • Unscrew the bolts [A] and remove the caliper [B] (Rear Brake Caliper). • Check the lining thickness [A] of the pads in each caliper. If the lining thickness of either pad is less than the service limit [B], replace both pads in the caliper as a set (see Brakes chapter).
  • Page 50: Brake Fluid Level Inspection

    2-28 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Fluid Level Inspection • Check that the brake fluid level in the front brake reservoir [A] is above the lower [B] level line. NOTE ○ Hold the reservoir horizontal by turning the handlebar when checking brake fluid level.
  • Page 51: Brake Fluid Change

    PERIODIC MAINTENANCE 2-29 Periodic Maintenance Procedures Brake Fluid Change NOTE ○ The procedure to change the front brake fluid is as fol- lows. Changing the rear brake fluid is almost the same as for the front brake. • Level the brake fluid reservoir. •...
  • Page 52: Brake Master Cylinder Cup And Dust Seal Replacement

    2-30 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Remove the clear plastic hose. • Install the reservoir cap. • Follow the procedure below to install the rear brake fluid reservoir cap correctly. ○ First, tighten the rear brake fluid reservoir cap [B] clock- wise [C] by hand until the 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 53: Suspension

    PERIODIC MAINTENANCE 2-31 Periodic Maintenance Procedures If it does not, adjust the brake light switch. • While holding the switch body, turn the adjusting nut to adjust the switch. Switch Body [A] Adjusting Nut [B] Light sooner as the body rises [C] Light later as the body lowers [D] CAUTION To avoid damaging the electrical connections in-...
  • Page 54: Steering

    2-32 PERIODIC MAINTENANCE Periodic Maintenance Procedures Steering Stem Bearing Lubrication • Remove the steering stem. (see Steering chapter). • Using a high-flash point solvent, wash the upper and lower tapered roller bearings [A] in the cages, and wipe the upper and lower outer races, which are press-fitted into the frame head pipe, clean of grease and dirt.
  • Page 55: Electrical System

    PERIODIC MAINTENANCE 2-33 Periodic Maintenance Procedures • Remove the claw washer. • Tighten the stem nut [A] firmly with the stem nut wrench [B], and loosen it. • Tighten the stem nut again with the specified torque. Special Tool - Steering Stem Nut Wrench: 57001-1100 Torque - Steering Stem Nut: 4.9 N·m (0.50 kgf·m, 43 in·lb) •...
  • Page 56: Nut, Bolt, And Fastener Tightness

    2-34 PERIODIC MAINTENANCE Periodic Maintenance Procedures Points: Lubricate with Grease. Throttle Inner Cable Upper Ends [A] Clutch Lever Pivot (Apply silicone grease) Brake Lever Pivot (Apply silicone grease) Brake Pedal Pivot Sidestand Cable: Lubricate with Cable Lubricant. Choke Cable Throttle Cables •...
  • Page 57 PERIODIC MAINTENANCE 2-35 Periodic Maintenance Procedures Nut, Bolt and Fastener to be checked Wheels: Front Axle Front Axle Clamp Bolts Rear Axle Nut Rear Axle Nut Cotter Pin Final Drive: Final Gear Case Mounting Nuts Brakes: Front Master Cylinder Clamp Bolts Caliper Mounting Bolts Rear Master Cylinder Mounting Bolts Rear Caliper Holder Bolt...
  • Page 59 FUEL SYSTEM (DFI) 3-1 Fuel System (DFI) Table of Contents Exploded View........Crankshaft Sensor DFI Parts Location......Removal/Installation....3-61 DFI System........3-12 Crankshaft Sensor Inspection..3-61 DFI Wiring Diagram ......3-14 Vehicle-down Sensor (Service Code Specifications ........3-17 31)........... 3-62 Special Tools and Sealant ....
  • Page 60 3-2 FUEL SYSTEM (DFI) Resistance Inspection....3-86 Left Air Cleaner Housing Fuel Line..........3-88 Removal/Installation....3-100 Fuel Pressure Inspection ..... 3-88 Right Air Cleaner Housing Pressure Regulator Removal..3-90 Removal ........3-101 Fuel Flow Rate Inspection ... 3-90 Right Air Cleaner Housing Throttle Grip and Cables ....
  • Page 62: Exploded View

    3-4 FUEL SYSTEM (DFI) Exploded View...
  • Page 63 16. Crankcase breather hose 17. Air cleaner drain hose 18. Right air cleaner base 19. Right spark plug lead holder 20. Throttle body assy CAL: California Model L: Apply a non-permanent locking agent. SS: Apply silicone sealant (Kawasaki Bond: 56019–120).
  • Page 64 3-6 FUEL SYSTEM (DFI) Exploded View...
  • Page 65 FUEL SYSTEM (DFI) 3-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Fuel pump bolts 0.70 61 in·lb S, L Inlet air temperature sensor nut 0.80 69 in·lb ISC pipe bolts 97 in·lb Throttle body assy holder bolts 97 in·lb Spark plug lead holder bolts 97 in·lb Choke cable plate screw...
  • Page 66: Dfi Parts Location

    3-8 FUEL SYSTEM (DFI) DFI Parts Location...
  • Page 67 FUEL SYSTEM (DFI) 3-9 DFI Parts Location DFI: DFI parts (this chapter) F: Front 1. Atmospheric pressure sensor (DFI) 2. Water temperature sensor (DFI) 3. Ignition coils 4. Ignition switch 5. Starter motor 6. Water temperature switch 7. Regulator/rectifier 8. Crankshaft sensors 9.
  • Page 68 3-10 FUEL SYSTEM (DFI) DFI Parts Location...
  • Page 69 FUEL SYSTEM (DFI) 3-11 DFI Parts Location DFI: DFI Parts (this chapter) F: Front 1. Atmospheric pressure sensor (DFI) 2. Water temperature sensor (DFI) 3. Ignition coils 4. Ignition switch 5. Starter motor 6. Water temperature switch 7. Regulator/rectifier 8. Crankshaft sensors 9.
  • Page 70: Dfi System

    3-12 FUEL SYSTEM (DFI) DFI System...
  • Page 71 FUEL SYSTEM (DFI) 3-13 DFI System #1: For front cylinder #2: For rear cylinder 1. ECU (electronic control unit) 2. Crankshaft sensor #1 3. Crankshaft sensor #2 4. Pressure regulator 5. Throttle sensor (front view) 6. Atmospheric pressure sensor 7. Inlet air pressure sensor 8.
  • Page 72: Dfi Wiring Diagram

    3-14 FUEL SYSTEM (DFI) DFI Wiring Diagram...
  • Page 73 FUEL SYSTEM (DFI) 3-15 DFI Wiring Diagram DFI and Electrical Parts DFI: DFI parts A. ECU: electronic control unit (DFI) B. Engine stop switch C. Starter button D. Ignition coils E. Crankshaft sensors F. Junction box G. Starter circuit relay H.
  • Page 74 3-16 FUEL SYSTEM (DFI) DFI Wiring Diagram Terminal Numbers of ECU Connectors Terminal Names #1: Front cylinder, #2: Rear Cylinder 1. Starter lockout switch signal 2. Interlock circuit signal 3. Self-diagnosis signal (generated by grounding this terminal and shown by FI indicator LED light) 4.
  • Page 75: Specifications

    FUEL SYSTEM (DFI) 3-17 Specifications Item Standard Throttle Grip Free Play: 3 mm (0.079 0.118 in.) Air Cleaner Element: Paper filter DFI (Digital Fuel Injection) System: Make: Mitsubishi Electric Idle speed: 950 ±50 r/min (rpm) Throttle assy: Type × bore Two barrel type ×...
  • Page 76 3-18 FUEL SYSTEM (DFI) Specifications Item Standard Water temperature sensor: Resistance 2.162 3.112 kΩ at 20° C (68° F) 0.785 1.049 kΩ at 50° C (122° F) 0.207 0.253 kΩ at 100° C (212° F) Vehicle-down sensor: Detection method Magnetic flux detection method Detection angle More than 45°...
  • Page 77: Special Tools And Sealant

    Special Tools and Sealant Oil Pressure Gauge, 5 kg/cm² : Filler Cap Driver : 57001–125 57001–1454 Fork Oil Level Gauge : Needle Adapter Set : 570101–1290 57001–1457 Hand Tester : Kawasaki Bond (Silicone Sealant) : 57001–1394 56019–120 Fuel Pressure Gauge Adapter : 57001–1417...
  • Page 78 3-20 FUEL SYSTEM (DFI) DFI Servicing Precautions There are a number of important precautions that should be followed servicing the DFI system. ○ To maintain the correct fuel-air mixture (F/A), there must be no inlet air leaks in the DFI system. Be sure to install the oil filler cap [A] after filling the engine oil, using the driver-filler cap [B].
  • Page 79: Dfi Servicing Precautions

    FUEL SYSTEM (DFI) 3-21 DFI Servicing Precautions ○ To prevent corrosion and deposits n the fuel system, do not add any fuel antifreeze chemicals to fuel. ○ When any fuel hose is disconnected, do not turn on the ignition SW. Otherwise, the fuel pump will operate and fuel will spout from the fuel hose.
  • Page 80 3-22 FUEL SYSTEM (DFI) DFI Servicing Precautions ○ Fit the outlet hose joint #1 or #2 [A] onto the pipe until the joint clicks [B]. Front [C] ○ Push and pull [A] the hose joint #1 or #2 [B] back and forth more than two times and make sure it is locked and doesn’t come off.
  • Page 81: Troubleshooting The Dfi System

    FUEL SYSTEM (DFI) 3-23 Troubleshooting the DFI System Outline When an abnormality in the system occurs, the FI indica- tor LED light goes on to alert the rider on the meter panel. In addition, the condition of the problem is stored in the mem- ory of the ECU (electronic control unit).
  • Page 82 3-24 FUEL SYSTEM (DFI) Troubleshooting the DFI System ○ There are two ways to inspect the DFI system. One is Voltage Check Method and the other is Resistance Check Method. Voltage Check Method ○ This method is conducted by measuring the input voltage [B] to a sensor [A] first, and then the output voltage [C] from the sensor.
  • Page 83 ○ After measurement, remove the needle adapters and ap- ply silicone sealant to the seals [A] of the connector [B] for waterproofing. Silicone Sealant (Kawasaki Bond: 56019-120) - Seals of Connectors • Always check battery condition before replacing the DFI parts.
  • Page 84 3-26 FUEL SYSTEM (DFI) Troubleshooting the DFI System If any wiring is deteriorated, replace the wiring. • Pull each connector [A] apart and inspect it for corrosion, dirt, and damage. If the connector is corroded or dirty, clean it carefully. If it is damaged, replace it.
  • Page 85: Inquiries To Rider

    FUEL SYSTEM (DFI) 3-27 Troubleshooting the DFI System DFI Diagnosis Flow Chart Inquiries to Rider • Refer to the next sample diagnosis chart. ○ Each rider reacts to problems in different ways, so it is important to confirm what kind of symptoms the rider has encountered.
  • Page 86 3-28 FUEL SYSTEM (DFI) Troubleshooting the DFI System Sample Diagnosis Sheet Rider name: Year of initial registration: Registration No. (license plate No.): Frame No.: Model: Engine No.: Mileage: Date problem occurred: Environment when problem occurred. □ □ □ □ □ □...
  • Page 87 FUEL SYSTEM (DFI) 3-29 Troubleshooting the DFI System □ Poor running choke knob left pulled out fully (push it in fully). □ or no power spark plug loose (tighten it). □ at high speed spark plug dirty, broken, or gap maladjusted (remedy it). □...
  • Page 88: Dfi System Troubleshooting Guide

    3-30 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. ○...
  • Page 89 FUEL SYSTEM (DFI) 3-31 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) No spark or spark weak: Ignition and engine stop switches not ON Turn both switches ON. Clutch lever not pulled in and gear not in neutral Pull the lever in and shift the gear in neutral.
  • Page 90: Poor Running At Low Speed

    3-32 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Cylinder, piston worn Inspect and replace (see chapter 5). Piston ring bad (worn, weak, broken or sticking) Inspect and replace (see chapter 5). Piston ring/groove clearance excessive Inspect and replace (see chapter 5).
  • Page 91 FUEL SYSTEM (DFI) 3-33 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Fuel injector trouble Inspect (see chapter 3). Throttle sensor trouble Inspect (see chapter 3). Inlet air temperature sensor trouble Inspect (see chapter 3). Water temperature sensor trouble Inspect (see chapter 3).
  • Page 92 3-34 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Inlet air temperature sensor trouble Inspect (see chapter 3). Throttle sensor malfunction Inspect (see chapter 3). Water temperature sensor trouble Inspect (see chapter 3). Atmospheric pressure sensor trouble Inspect (see chapter 3).
  • Page 93 FUEL SYSTEM (DFI) 3-35 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Throttle sensor malfunction Inspect (see chapter 3). Inlet air temperature sensor trouble Inspect (see chapter 3). Water temperature sensor trouble Inspect (see chapter 3). Atmospheric pressure sensor trouble Inspect (see chapter 3).
  • Page 94: Poor Running Or No Power At High Speed

    3-36 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Poor Running or No Power at High Speed: Symptoms or Possible Causes Actions (detailed reference) Firing incorrect: Clean spark plug and adjust plug gap (see Spark plug dirty, broken or maladjusted chapter 2). Inspect plug cap and ignition coil (see chapter Spark plug cap or high tension wiring trouble 16).
  • Page 95 FUEL SYSTEM (DFI) 3-37 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (detailed reference) HLA (hydraulic lash adjuster) damaged (worn, Inspect and replace (see chapter 5). seizure or spring broken) Knocking: Carbon buit up in combustion chamber Repair (see chapter 5). Fuel poor quality or incorrect (Use high-octane Change fuel (see chapter 3).
  • Page 96 3-38 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (detailed reference) Air cleaner O-ring damaged Replace (see chapter 3). Too low fuel pressure Inspect (see chapter 3). Water temperature sensor trouble Inspect and replace (see chapter 3). Inlet air temperature sensor trouble Inspect and replace (see chapter 3).
  • Page 97: Self-Diagnosis

    FUEL SYSTEM (DFI) 3-39 Self-Diagnosis Self-diagnosis Conducting ○ When a problem occurs with the DFI system, the DFI in- dicator LED light [A] goes on. • Remove the seat (see Frame chapter). • With the ECU connector joined, the self-diagnosis mode by grounding the self-diagnosis check female connector [C] (yellow lead from ECU [B]) to the battery (−) connector [D], using a wire [E].
  • Page 98 3-40 FUEL SYSTEM (DFI) Self-Diagnosis...
  • Page 99: Service Code Reading

    FUEL SYSTEM (DFI) 3-41 Self-Diagnosis Service Code Reading ○ Service codes are shown by a series of long and short blinks of the FI indicator LED light as shown below. ○ Read 10th digit and unit digit as the FI indicator LED light blinks. ○...
  • Page 100 3-42 FUEL SYSTEM (DFI) Self-Diagnosis Service Code Table Service FI Indicator LED Light Problems (1) Code 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...
  • Page 101 FUEL SYSTEM (DFI) 3-43 Self-Diagnosis Backups ○ The ECU takes the following measures to prevent engine damage when the DFI or the ignition system parts have troubles. Service Output Signal Usable Parts Backups by ECU Codes Range or Criteria If the throttle sensor system fails (the signal is out of the usable range, wiring Throttle Throttle Valve Opening...
  • Page 102 3-44 FUEL SYSTEM (DFI) Self-Diagnosis Service Output Signal Usable Parts Backups by ECU Codes Range or Criteria If the ignition primary winding #1 has The ignition coil primary failures (no signal, wiring short or Ignition Coil winding must send signals open), the ECU shuts off the injector #1 (output voltage) continuously to stop fuel to the cylinder #1, though...
  • Page 103: Throttle Sensor (Service Code 11)

    FUEL SYSTEM (DFI) 3-45 Throttle Sensor (Service Code 11) Throttle Sensor Removal/Adjustment CAUTION Do not remove or adjust the throttle sensor [A] since it has been adjusted and set with precision at the factory. Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it.
  • Page 104: Resistance Inspection

    • After throttle sensor inspection, remove the needle adapters, and apply silicone sealant to the seals [A] of the connector [B] for waterproofing. Silicone Sealant (Kawasaki Bond: 56019-120) - Seals of Connectors Resistance Inspection • Turn the ignition switch OFF.
  • Page 105 FUEL SYSTEM (DFI) 3-47 Throttle Sensor (Service Code 11) A. ECU c. Throttle Sensor...
  • Page 106: Inlet Air Pressure Sensor (Service Code 12)

    3-48 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code 12) Removal CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the part can damage it. • Remove the fuel tank (see Fuel Tank section in this chap- ter).
  • Page 107: Output Voltage Inspection

    If the output voltage is out of the usable range, replace the sensor. • Turn the ignition SW OFF and remove the needle adapters. • Apply silicone sealant to the seals of the connector for waterproofing. Silicone Sealant (Kawasaki Bond: 56019-120) - Connector Seals...
  • Page 108 3-50 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code 12) If the output voltage is normal, check the inlet air pressure sensor output voltage for vacuum other than 76 cmHg (abs) as follows. If the output voltage changes within the usable range as vacuum changes, the sensor is normal and the ECU is suspect.
  • Page 109 FUEL SYSTEM (DFI) 3-51 Inlet Air Pressure Sensor (Service Code 12) Suppose: Pg : Vacuum (gauge) of Throttle Assy Pl : Local Atmospheric Pressure (absolute) measured by a barometer Pv : Vacuum (absolute) of Throttle Assy Vv : Sensor Output Voltage (v) then Pv = Pl –...
  • Page 110 3-52 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code 12) Pv = 55 86 cm Hg Vv: Inlet Air Pressure Sensor Output Voltage (V) (Digital Meter Reading) Pv: Throttle Vacuum (absolute) Ps: Standard Atmospheric Pressure (absolute) ID: Idling TO: Throttle Full Open ST: Standard of Sensor Output Voltage (v) UR: Usable Range of Sensor Output Voltage (v) A.
  • Page 111: Inlet Air Temperature Sensor (Service Code 13)

    ECU and the inlet air temperature sensor. If the wiring is good, check the sensor resistance. • Remove the needle adapters, and apply silicone sealant to the seals of the connector for waterproofing. Silicone Sealant (Kawasaki Bond: 56019-120) - Seals of Connector...
  • Page 112: Sensor Resistance Inspection

    3-54 FUEL SYSTEM (DFI) Inlet Air Temperature Sensor (Service Code 13) Sensor Resistance Inspection • Remove the inlet air temperature sensor (see this sec- tion). • Suspend the sensor [A] in a container of machine oil so that the heat-sensitive portion and threaded portion are submerged.
  • Page 113: Water Temperature Sensor (Service Code 14)

    Cooling System chapter). • Disconnect the sensor connector, and unscrew the water temperature sensor [B]. Top [C] Silicone Sealant (Kawasaki Bond: 56019-120) - Threads of Water Temperature Sensor Torque - Water Temperature Sensor: 18 N·m (1.8 kgf·m, 13 ft·lb) •...
  • Page 114: Sensor Resistance Inspection

    3-56 FUEL SYSTEM (DFI) Water Temperature Sensor (Service Code 14) Sensor Resistance Inspection • Remove the water temperature sensor (see this section). • Suspend the sensor [A] in a container of machine oil so that the heat-sensitive portion and threaded portion are submerged.
  • Page 115: Atmospheric Pressure Sensor (Service Code 15)

    FUEL SYSTEM (DFI) 3-57 Atmospheric Pressure Sensor (Service Code 15) Removal 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 section in this chap- ter).
  • Page 116: Output Voltage Inspection

    • Remove the needle adapters. • Apply silicone sealant to the seals of the connector for waterproofing. Silicone Sealant (Kawasaki Bond: 56019-120) - ECU Connector Seals Output Voltage Inspection NOTE ○ The output voltage changes according to the local at- mospheric pressure.
  • Page 117 FUEL SYSTEM (DFI) 3-59 Atmospheric Pressure Sensor (Service Code 15) A. ECU b. Atmospheric Pressure Sensor If you need to check the atmospheric pressure sensor for various altitudes other than sea level, check the output voltage as follows: ○ Determine the local altitude (elevation). If you know the local atmospheric pressure using a barometer, substitute the atmospheric pressure for Pv (Throttle Vacuum) in the inlet air pressure sensor chart (see Inlet Air Pressure Sensor section in this chapter).
  • Page 118 3-60 FUEL SYSTEM (DFI) Atmospheric Pressure Sensor (Service Code 15) Va: Atmospheric Pressure Sensor Output Voltage (v) H: Altitude (m or feet) SL: Sea Level (0 m) ST: Standard of Sensor Output Voltage (v) UR: Usable Range of Sensor Output Voltage (v)
  • Page 119: Crankshaft Sensors (#1, #2: Service Code 21, 22)

    FUEL SYSTEM (DFI) 3-61 Crankshaft Sensors (#1, #2: Service Code 21, 22) Crankshaft Sensor #1: for Front Cylinder (Service Code Crankshaft Sensor #2: for Rear Cylinder (Service Code Crankshaft Sensor Removal/Installation • See Ignition System section in the Electrical System chapter.
  • Page 120: Vehicle-Down Sensor (Service Code 31)

    3-62 FUEL SYSTEM (DFI) Vehicle-down Sensor (Service Code 31) Removal CAUTION Never drop the down-sensor, especially on a hard surface. Such a shock to the sensor can damage it. • Remove the seat (see Frame chapter). • Remove the bolt [A] and take out the vehicle-down sensor [B].
  • Page 121 • Remove the needle adapters, and apply silicone sealant to the seals of the connector for waterproofing. Silicone Sealant (Kawasaki Bond: 56019-120) - Seals of Vehicle-down Sensor Connector If the output voltage is out of the specified, replace the vehicle-down sensor.
  • Page 122 3-64 FUEL SYSTEM (DFI) Vehicle-down Sensor (Service Code 31) A. ECU N. Ignition Switch Q. Sealed Battery d. Vehicle-down Sensor O. Starter Relay f. Ignition Fuse 10 A F. Junction Box P. Main Fuse 30 A V. DFI Fuse 15A e.
  • Page 123: Fuel Injectors (#1, #2: Service Code 41, 42)

    FUEL SYSTEM (DFI) 3-65 Fuel Injectors (#1, #2: Service Code 41, 42) Fuel Injector #1: Front Fuel Injector for Front Cylinder (Service Code 41) Fuel Injector #2: Rear Fuel Injector for Rear Cylinder (Service Code 42) CAUTION Never drop the injector, especially on a hard sur- face.
  • Page 124: Injector Installation

    3-66 FUEL SYSTEM (DFI) Fuel Injectors (#1, #2: Service Code 41, 42) • If necessary, remove the screws [A] and the fuel hose [B], and then take off the pressure regulator [C]. ○ The screen [A] comes off from the pressure regulator [B]. Delivery Joint [C] Front [D] •...
  • Page 125 FUEL SYSTEM (DFI) 3-67 Fuel Injectors (#1, #2: Service Code 41, 42) • Apply engine oil to the O-ring [A], and install each injector [B] into the delivery joint [C]. • Check that there is no dirt or dust on the injector seating surface [A] of the inlet manifold [B].
  • Page 126 3-68 FUEL SYSTEM (DFI) Fuel Injectors (#1, #2: Service Code 41, 42) • Check the injector fuel line for leakage as follows: ○ Connect a commercially available vacuum/pressure pump [C] and a rubber hose [I] to the fuel hose [B] of the delivery joint [A] as shown.
  • Page 127: Audible Inspection

    FUEL SYSTEM (DFI) 3-69 Fuel Injectors (#1, #2: Service Code 41, 42) • Push and pull [A] the fuel hose joint #2 [B] back and forth more than two times and make sure it is locked and doesn’t come off. When the fuel hose joint #2 is correctly installed, it should slide on the delivery pipe about 5 mm (0.2 in.).
  • Page 128: Output Voltage Inspection

    3-70 FUEL SYSTEM (DFI) Fuel Injectors (#1, #2: Service Code 41, 42) If the power source voltage is incorrect, check the DFI power source (see DFI Power Source in this chapter). If the DFI power source is good, check the ECU for its ground and power supply.
  • Page 129: Injector Signal Test

    FUEL SYSTEM (DFI) 3-71 Fuel Injectors (#1, #2: Service Code 41, 42) 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 (0.013 in.) CAUTION Do not use larger terminals than specified above.
  • Page 130: Injector Unit Test

    3-72 FUEL SYSTEM (DFI) Fuel Injectors (#1, #2: Service Code 41, 42) Injector Unit Test • Use two wires [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 Sealed Battery [D] CAUTION...
  • Page 131: Fuel Pump (Service Code 45)

    FUEL SYSTEM (DFI) 3-73 Fuel Pump (Service Code 45) 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.
  • Page 132: Fuel Pump Installation

    3-74 FUEL SYSTEM (DFI) Fuel Pump (Service Code 45) Fuel Pump Installation • Clean the pump screen (see Pump Filter Cleaning). • Remove dirt or dust from the fuel pump by lightly applying compressed air. • Replace the fuel pump gasket with a new one. •...
  • Page 133: Operation Inspection

    FUEL SYSTEM (DFI) 3-75 Fuel Pump (Service Code 45) • Secure the fuel pump leads [A] with the clamps [B]. • Press the clamps flat by hands against the fuel tank bot- tom. • Make sure that the end of each clamp is covered with a plastic cap [C] and touches the fuel tank bottom.
  • Page 134: Operating Voltage Inspection

    ECU is suspect. Replace the ECU. • After inspection, remove the needle adapter, and apply silicone sealant to the seal of the connector for water- proofing. Silicone Sealant (Kawasaki Bond: 56019-120) - Sealing of Fuel Pump Connector...
  • Page 135 FUEL SYSTEM (DFI) 3-77 Fuel Pump (Service Code 45) A. ECU P. Main Fuse 30 A V. DFI Fuse 15 A F. Junction Box e. DFI Main Relay Q. Sealed Battery N. Ignition Switch U. Fuel Pump f. Ignition Fuse 10 A O.
  • Page 136: Ignition Coils (#1, #2: Service Code 51, 52)

    (see Electrical System chap- ter) in order to check the primary coils. • Remove the needle adapters. • Apply silicone sealant to the seals of the connector for waterproofing. Silicone Sealant (Kawasaki Bond: 56019-120) - ECU Connector Seals...
  • Page 137: Fi Indicator Led Light

    FUEL SYSTEM (DFI) 3-79 FI Indicator LED Light Inspection Flow Chart...
  • Page 138: Led Light Inspection

    3-80 FUEL SYSTEM (DFI) FI Indicator LED Light The FI indicator LED light [A] goes ON when the ignition SW is turned ON and the LED light goes OFF 2 seconds later. This is to ensure that the FI indicator LED light has not burned out and the DFI system and the ignition system function properly.
  • Page 139: Ecu

    FUEL SYSTEM (DFI) 3-81 ECU Identification ○ Most countries have their own regulations, so each ECU has different characteristic of fuel injection according to each country. So, do not confuse ECU’s with each other and use only the ECU’s for your country. Otherwise, the motorcycle could not clear the emission regulation.
  • Page 140: Ecu Power Supply Inspection

    3-82 FUEL SYSTEM (DFI) ECU Power Supply Inspection • Visually inspect the terminals of the ECU connector. If the connector is clogged with mud or dust, blow it off with compressed air. Replace the main harness if the terminals [A] of the main harness connectors are cracked, bent, or otherwise dam- aged.
  • Page 141: Dfi Power Source

    FUEL SYSTEM (DFI) 3-83 DFI Power Source DFI Fuse Removal • Remove the seat (see Frame chapter). • Pull the lock [A] and open the lid [B]. • Pull out the DFI fuse [C] from the case with needle nose pliers.
  • Page 142 3-84 FUEL SYSTEM (DFI) DFI Power Source DFI Power Source Circuit A. ECU Q. Sealed Battery W. ISC Valve #2 F. Junction Box R. Fuel Injector #1 X. ISC Valve #1 N. Ignition SW S. Fuel Injector #2 e. DFI Main Relay O.
  • Page 143: Isc Valves

    FUEL SYSTEM (DFI) 3-85 ISC Valves Removal/Installation CAUTION Never drop the ISC valves, especially on a hard sur- face. Such a shock to the valve can damage it. ○ The ISC valves are removed during right air cleaner hous- ing removal (see this chapter). ○...
  • Page 144: Resistance Inspection

    3-86 FUEL SYSTEM (DFI) ISC Valves Output Voltage Inspection • Check the output voltage at the connectors [A] of the ISC Valves. • Remove the right air cleaner cover (see this chapter). Special Tool - Hand Tester [B] : 57001–1394 •...
  • Page 145 FUEL SYSTEM (DFI) 3-87 ISC Valves A. ECU V. DFI Fuse 15 A F. Junction Box W. ISC Valve #2 N. Ignition Switch X. ISC Valve #1 O. Starter Relay e. DFI Main Relay P. Main Fuse 30 A f. Ignition Fuse 10 A Q.
  • Page 146: Fuel Line

    3-88 FUEL SYSTEM (DFI) Fuel Line Fuel Pressure Inspection NOTE ○ This inspection can detect the faults of the DFI fuel line other than the DFI electronic system. ○ It is preferable to measure the fuel pressure while run- ning the motorcycle when the trouble has occurred in order to know symptom well.
  • Page 147 FUEL SYSTEM (DFI) 3-89 Fuel Line • Turn the ignition SW ON. The fuel pump will turn for 3 seconds, and then stop. • Measure the fuel pressure with the engine stopped. Fuel Pressure right after Ignition SW ON, with pump running: Standard: 310 kPa (3.2 kgf/cm², 46 psi) after 3 seconds from Ignition SW ON,...
  • Page 148: Pressure Regulator Removal

    3-90 FUEL SYSTEM (DFI) Fuel Line • Fit the fuel hose joint #2 [A] onto the pipe (for delivery joint) until the joint clicks [B]. ○ Insert the hose joint straight along the pipe. Front [C] • Push and pull [A] the fuel hose joint #2 [B] back and forth more than two times and make sure it is locked and doesn’t come off.
  • Page 149 FUEL SYSTEM (DFI) 3-91 Fuel Line • Prepare a plastic hose of the inside diameter 7.5 mm × L about 400 mm and a measuring cylinder. • Remove: Seat (see Frame chapter) Indicator Unit (see Fuel Tank Removal in this chapter). Fuel Tank Bolts •...
  • Page 150: Throttle Grip And Cables

    3-92 FUEL SYSTEM (DFI) Throttle Grip and Cables Throttle Grip Free Play Inspection ○ Refer to Throttle Control System Check in the Periodic Maintenance Chapter. Throttle Grip Free Play Adjustment • Loosen the locknuts [A] and screw the adjusters [B] all the way in so as to give the throttle grip plenty of play.
  • Page 151: Throttle Body Assy

    FUEL SYSTEM (DFI) 3-93 Throttle Body Assy Idle Speed Check ○ Refer to Idle Speed Check in the Periodic Maintenance Chapter. Idle Speed Adjustment ○ Refer to Idle Speed Check in the Periodic Maintenance Chapter. High Altitude Performance Adjustment ○ Any modification is not necessary in this model since the atmospheric pressure sensor senses atmospheric pres- sure change due to high altitude and the ECU compen-...
  • Page 152 3-94 FUEL SYSTEM (DFI) Throttle Body Assy • Remove the following from the choke cable holder [A] (left -behind view). Screw [B] Choke Cable Plate [C] • While pushing the choke lever [A] forward, remove the cable housing from the choke cable holder [B] and the inner cable out of the holder slit [C].
  • Page 153 FUEL SYSTEM (DFI) 3-95 Throttle Body Assy • Remove the decelerator cable end [A] from the throttle pulley [B]. • Using needle nose pliers, move the accelerator inner ca- ble outside the engine, and remove the cable end [C] from the pulley.
  • Page 154: Throttle Body Assy Installation

    3-96 FUEL SYSTEM (DFI) Throttle Body Assy • Stuff a piece of lint-free, clean cloth into the throttle body assy, and the inlet ports of the cylinder heads to keep dirt out of the engine. WARNING If dirt or dust is allowed to pass through into the throttle bore, the throttle may become stuck, possi- bly causing an accident.
  • Page 155: Throttle Body Assy Disassembly/Assembly

    FUEL SYSTEM (DFI) 3-97 Throttle Body Assy • Apply a thin coating of grease to the throttle cable upper ends. • Install the upper ends of the throttle cables in the grip. • Fit the projection [A] of the right switch housing into the hole [B] of the handlebar (front view).
  • Page 156 3-98 FUEL SYSTEM (DFI) Throttle Body Assy • Remove the three throttle body flange bolts [A]. • Split the throttle body assy into the throttle body [A] and the inlet manifold [B]. The gasket [C] comes off. • Discard the gasket. ○...
  • Page 157 FUEL SYSTEM (DFI) 3-99 Throttle Body Assy • Remove the delivery joint and injectors (see Injector sec- tion in this chapter). • Open the butterfly valves [A], and wipe any carbon off the throttle bores [B] around the valves, using a piece of lint-free cloth penetrated with a high-flash point solvent.
  • Page 158: Air Cleaner

    3-100 FUEL SYSTEM (DFI) Air Cleaner Air Cleaner Element Removal • Remove: Allen Bolt and Washer [A] Left Air Cleaner Cover [B] Front [C] • Remove the element [A]. • Push a clean, lint-free towel into the lower air cleaner duct to keep dirt or other foreign material from entering.
  • Page 159: Right Air Cleaner Housing Removal

    FUEL SYSTEM (DFI) 3-101 Air Cleaner Right Air Cleaner Housing Removal • Remove: Allen Bolt and Washer [A] Right Air Cleaner Cover [B] Front [C] • Remove: ISC Valve Hoses [A] ISC Valve Lead Connectors [B] Air Cleaner Allen Bolts [C] and Screws [D] Air Cleaner Base Bolt [E] •...
  • Page 160: Lower Air Cleaner Duct Removal/Installation

    3-102 FUEL SYSTEM (DFI) Air Cleaner If the air cleaner drain hose [A] has been removed with it attached to the right air cleaner base, pull the drain hose off the right air cleaner base. Remove the left air cleaner base and insert the drain hose under the lower air cleaner duct.
  • Page 161: Fuel Tank

    FUEL SYSTEM (DFI) 3-103 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 162 3-104 FUEL SYSTEM (DFI) Fuel Tank • Disconnect: Indicator Unit Connector [A] Ignition Switch Connector [B] • Remove: Ignition Switch [C] and Screws [D] Bracket [E] and Bolt [F] Front [G] • Remove the seat (see Frame chapter). • Disconnect the battery (−) terminal [A]. •...
  • Page 163 FUEL SYSTEM (DFI) 3-105 Fuel Tank • Prepare a 8 mm plug ( 7.8 8.0 mm [A] × L 35 mm [B] with a rounded end [C]), and a 7.3 7.5 mm inside diameter fuel hose [D] (e.g. Part No. 92191–1264). ○...
  • Page 164: Fuel Tank Installation

    3-106 FUEL SYSTEM (DFI) Fuel Tank ○ Be careful of fuel spillage from the fuel tank since fuel still remains in the fuel tank and fuel pump. WARNING Store the fuel tank in an area which is well -ventilated and free from any source of flame or sparks.
  • Page 165: Fuel Tank And Cap Inspection

    FUEL SYSTEM (DFI) 3-107 Fuel Tank • Fit the fuel return hose [A] onto the pipe fully and install the plate clamp [B] beyond the raised rib [C]. • Secure the fuel pump leads [A] with the clamps [B]. • Press the clamps flat by hands against the fuel tank bot- tom.
  • Page 166: Fuel Tank Cleaning

    3-108 FUEL SYSTEM (DFI) Fuel Tank Fuel Tank Cleaning WARNING Clean the tank in a well-ventilated area, and take care that there are no sparks or flame anywhere near the working area. Because of the danger of highly flammable liquids, do not use gasoline or low-flash point solvent to clean the tank.
  • Page 167: Evaporative Emission Control System

    FUEL SYSTEM (DFI) 3-109 Evaporative Emission Control System The Evaporative Emission Control System for California Model routes fuel vapors from the fuel system into the run- ning engine or stores the vapors in a canister when the en- gine is stopped. Although no adjustments are required, a thorough visual inspection must be made at the intervals specified by the Periodic Maintenance Chart.
  • Page 168: Hose Inspection (Periodic Inspection)

    3-110 FUEL SYSTEM (DFI) Evaporative Emission Control System Hose Inspection (Periodic Inspection) ○ Refer to Evaporative Emission Control System Check in the Periodic Maintenance Chapter. Separator Operation Test 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 169 COOLING SYSTEM 4-1 Cooling System Table of Contents Exploded View........................Coolant Flow Chart......................... Specifications ......................... Special Tools and Sealant ...................... Coolant ........................... Coolant Deterioration Inspection..................Coolant Level Inspection....................Coolant Draining ....................... Coolant Filling ........................Pressure Testing ....................... Cooling System Flushing ....................Water Pump..........................
  • Page 170: Exploded View

    4-2 COOLING SYSTEM Exploded View...
  • Page 171 12 Thermostat air bleeder bolt 0.80 69 in·lb 13. Mechanical seal 14. Double seal bearing 15. Oil seal 16. Ball bearing 17. Thermostat 18. Radiator cap 19. Radiator R: Replacement parts Lh: Left-hand threads G: Apply grease. SS: Apply silicone sealant (Kawasaki Bond: 56019-120).
  • Page 172: Coolant Flow Chart

    4-4 COOLING SYSTEM Coolant Flow Chart Permanent type antifreeze is used as a coolant to protect the cooling system from rust and corrosion. When the engine starts, the water pump turns and the coolant circulates. The thermostat is a wax pellet type which opens or closes as coolant temperature changes. The thermostat continuously changes its valve opening to keep the coolant temperature at the proper level.
  • Page 173 COOLING SYSTEM 4-5 Coolant Flow Chart 1. Water Pump 9. Radiator 2. Water Jacket 10. Radiator Fan 3. Cylinder Head 11. Throttle Body Assy 4. Water Pipe 12. Front 5. Water Hose 13. Cold Coolant 6. Radiator Cap 14. Hot Coolant 7.
  • Page 174: Specifications

    4-6 COOLING SYSTEM Specifications Coolant provided when shipping: Type (recommended) Permanent type 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 −...
  • Page 175: Special Tools And Sealant

    COOLING SYSTEM 4-7 Special Tools and Sealant Bearing Driver Set : Bearing Remover Head, 10 x 12 : 57001–1129 57001–1266 Bearing Remover Shaft : Kawasaki Bond (Silicone Sealant) : 57001–1265 56019–120...
  • Page 176: Coolant

    4-8 COOLING SYSTEM Coolant Coolant Deterioration Inspection • Remove the right side cover (see Frame chapter). • Visually inspect the coolant [A] 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.
  • Page 177: Pressure Testing

    COOLING SYSTEM 4-9 Coolant Pressure Testing • Remove the fuel tank (see Fuel System chapter). • Remove the radiator cap, and install a cooling system pressure tester [A] on the radiator filler neck [B]. NOTE ○ Wet the cap sealing surfaces with water or coolant to prevent pressure leakage.
  • Page 178: Water Pump

    4-10 COOLING SYSTEM Water Pump Water Pump Removal • Drain the coolant (see Coolant Change in the Periodic Maintenance chapter). • Remove: Water Hose Clamp [A] Water Hose [B] Front [C] • Remove: Water Pump Cover Bolts [A] Water Pump Cover [B] •...
  • Page 179: Water Pump Inspection

    COOLING SYSTEM 4-11 Water Pump • Install the clamp [A] so that the clamp end is about 16 mm (0.63 in.) [B] apart from the pump inlet step. This prevents coolant leakage from the hose end. • Tighten the hose clamp screw securely. Water Pump Inspection •...
  • Page 180 4-12 COOLING SYSTEM Water Pump If the coolant still leaks through the drainage outlet hose, the seal and ball bearings is probably damaged. Replace the mechanical seal, ball bearings, and oil seal by splitting the crankcase. • Split the crankcase (see Crankshaft/Transmission chap- ter).
  • Page 181 COOLING SYSTEM 4-13 Water Pump • Clean both sliding surfaces of a new mechanical seal with a high-flash point solvent (e.g. ethyl alcohol), and apply a little coolant to the sliding surface to give the mechanical seal initial lubrication. • Apply coolant to the surface of the rubber seal [A] and sealing seat [B], and press the rubber seal and sealing seat into the impeller by hand until the seat bottoms out.
  • Page 182: Radiator

    4-14 COOLING SYSTEM Radiator WARNING The radiator fan is connected directly to the bat- tery. The radiator fan may start even if the ignition switch is off. NEVER TOUCH THE RADIATOR FAN UNTIL THE RADIATOR FAN CONNECTOR IS DIS- CONNECTED. TOUCHING THE FAN BEFORE THE CONNECTOR IS DISCONNECTED COULD CAUSE INJURY FROM THE FAN BLADES.
  • Page 183: Radiator Installation

    COOLING SYSTEM 4-15 Radiator • Remove: Radiator Fan Bolts [A] Radiator Fan [B] Radiator Installation • Be sure to install the radiator fan ground lead terminal [A]. Torque - Radiator Fan Bolts and Fan Ground Lead Terminal Bolt: 8.3 N·m (0.85 kgf·m, 74 in·lb) •...
  • Page 184: Radiator Cap Inspection

    4-16 COOLING SYSTEM Radiator Radiator Cap Inspection • Check the condition of the top and bottom valve seals of the radiator cap. If any one of them shows visible damage, replace the cap. Bottom Valve Seal [A] Top Valve Seal [B] Valve Spring [C] •...
  • Page 185: Thermostat

    COOLING SYSTEM 4-17 Thermostat Thermostat Removal • Remove: Coolant : Drain about 200 mL Fuel Tank (see Fuel System chapter) Four Water Hoses [A] Bracket Bolts [B] Water Temperature Sensor Connector [C] • Remove the thermostat housing [D] along with the bracket.
  • Page 186: Hoses And Pipes

    4-18 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. • Install the clamps [A] as near as possible to the hose end to clear the raised rib on the fitting.
  • Page 187 ENGINE TOP END 5-1 Engine Top End Table of Contents Exploded View........Cylinder Head........5-32 Specifications ........Cylinder Compression Special Tools and Sealant ....5-11 Measurement ......5-32 Clean Air System....... 5-14 Cylinder Head Removal ....5-33 Air Suction Valve Removal... 5-14 Cylinder Head Installation ....
  • Page 188: Exploded View

    5-2 ENGINE TOP END Exploded View...
  • Page 189 8. Air switching valve 9. Air suction valves 10. HLA oil filters AD: Apply adhesive. EO: Apply engine oil. MO: Apply molybdenum disulfide oil. L: Apply a non-permanent locking agent. S: Follow the specific tightening sequence. SS: Apply silicone sealant (Kawasaki Bond: 56019-120).
  • Page 190 5-4 ENGINE TOP END Exploded View...
  • Page 191 ENGINE TOP END 5-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Rocker shafts Exhaust pipe cover clamp screws 0.70 61 in·lb Premuffler chamber bolts Upper muffler bracket nut Muffler stay mounting bolts, Upper muffler mounting nuts, 7. Rear exhaust pipe 8.
  • Page 192 5-6 ENGINE TOP END Exploded View...
  • Page 193 ENGINE TOP END 5-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Cylinder head nuts Cylinder nuts Chain tensioner cap Chain tensioner lockbolt 0.50 43 in·lb Chain tensioner mounting bolts 97 in·lb Chain guide mounting bolts 97 in·lb Camshaft sprocket bolts 8.
  • Page 194: Specifications

    5-8 ENGINE TOP END Specifications Item Standard Service Limit Clean Air System: Air switching valve resistance: 18 ~ 22 Ω at 20° (68°F) – – – Camshafts: Cam height: Exhaust 33.741 ~ 33.857 mm 33.64 mm (1.32839 ~ 1.33295 in.) (1.3244 in.) Inlet 33.928 ~ 34.044 mm...
  • Page 195 ENGINE TOP END 5-9 Specifications Item Standard Service Limit Valve stem diameter: Exhaust 6.955 ~ 6.970 mm 6.94 mm (0.2732 in.) (0.27382 ~ 0.27441 in.) Inlet 6.965 ~ 6.980 mm 6.95 mm (0.2736 in.) (0.27421 ~ 0.27480 in.) Valve guide inside diameter: Exhaust 7.000 ~ 7.015 mm 7.08 mm (0.2787 in.)
  • Page 196 5-10 ENGINE TOP END Specifications Item Standard Service Limit Valve seat surface: Valve seat cutting angle 45°, 32°, 55° – – – Outside diameter: Exhaust 31.9 ~ 32.1 mm – – – (1.256 ~ 1.264 in.) Inlet 36.4 ~ 36.6 mm –...
  • Page 197: Special Tools And Sealant

    ENGINE TOP END 5-11 Special Tools and Sealant Valve Guide Reamer, 7 : Piston Pin Puller Assembly : 57001–162 57001–910 Valve Guide Arbor, 7 : Compression Gauge Adapter, M12 x 1.25 : 57001–163 57001–1018 Compression Gauge : Spark Plug Wrench, Hex 18 : 57001–221 57001–1024 Valve Spring Compressor Assembly :...
  • Page 198 5-12 ENGINE TOP END Special Tools and Sealant Valve Seat Cutter, 32° – 35 : Piston Pin Puller Adapter : 57001–1121 57001–1211 Valve Seat Cutter, 32° – 38.5 : Valve Seat Cutter, 55° – 35 : 57001–1122 57001–1247 Valve Seat Cutter Holder, 7 : Hand Tester : 57001–1126 57001–1394...
  • Page 199 ENGINE TOP END 5-13 Special Tools and Sealant Valve Seat Cutter 45° – 40 : Kawasaki Bond (Silicone Sealant) : 57001–1496 56019–120 ○ Compression Gauge Adapter: 57001-1183 Valve Seat Cutter 55° – 38.5 : can also be used. 57001–1497 ○...
  • Page 200: Clean Air System

    5-14 ENGINE TOP END Clean Air System Air Suction Valve Removal • For rear air suction valve removal, remove the rear ex- haust pipe. • Remove the hose [A]. • Unscrew the mounting bolts [B] and remove the rear air suction valve cover [C].
  • Page 201: Air Switching Valve Removal

    ENGINE TOP END 5-15 Clean Air System Air Switching Valve Removal • Remove: Fuel Tank (see Fuel System Chapter) • Pull off the hoses [A] and air switching valve connector [B], and take out the air switching valve [C]. Air Switching Valve Installation •...
  • Page 202: Clean Air System Hose Inspection

    5-16 ENGINE TOP END Clean Air System • Connect the 12 V battery [A] to the air switching valve terminals as shown. • Blow the air to the inlet air duct [A], and make sure does not flow the blown air from the outlet air ducts [B]. •...
  • Page 203: Camshaft Chain Tensioner

    ENGINE TOP END 5-17 Camshaft Chain Tensioner Camshaft Chain Tensioner Removal CAUTION This is a non-return type cam chain tensioner. The push rod does not return to its original position once it moves out to take up camshaft chain slack. Observe all the rules listed below: When removing the tensioner, do not take out the mounting bolts only halfway.
  • Page 204 5-18 ENGINE TOP END Camshaft Chain Tensioner • Install the larger spring [A], and then the ball bearing assy [B]. ○ Fit the ball bearing assy into the body until it bottoms out, using a thin-bladed screwdriver. • Screw in the lockbolt [A] finger-tight to hold the ball bear- ing assy temporarily.
  • Page 205: Rocker Case Cover

    ENGINE TOP END 5-19 Rocker Case Cover Rocker Case Cover Removal • Remove the engine (see Engine Removal/Installation chapter). • Remove the bolts [A] and take off the cover [B] from the rocker case. • Take out the oil filter springs [A] and HLA oil filters [B]. Rocker Case Cover Installation •...
  • Page 206: Rocker Case Cover Assembly

    5-20 ENGINE TOP END Rocker Case Cover Rocker Case Cover Assembly • Apply adhesive to the rubber dampers [A] and install them on the rocker case cover as shown. ○ Insert the projections [B] of the dampers to the holes [C] of the cover.
  • Page 207: Rocker Case

    ENGINE TOP END 5-21 Rocker Case Rocker Case Removal • Remove the engine (see Engine Removal/Installation chapter). • Remove the throttle body assy (see Fuel System (DFI) chapter). • Remove the rocker case covers (see Rocker Case Cover Removal). • Remove the alternator outer cover (see Electrical System chapter).
  • Page 208: Rocker Case Installation

    Torque - Rocker Shafts: 25 N·m (2.5 kgf·m, 18 ft·lb) • Apply silicone sealant [A] to the rocker case mating sur- face and the outer circumference of the plugs as shown. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 ○ Do not apply silicone sealant around the camshaft bear- ing.
  • Page 209 ENGINE TOP END 5-23 Rocker Case • Apply molybdenum disulfide oil to the threads and seating surface of 12 mm nuts and both sides of washers. • Tighten the rocker case nuts and bolts temporarily follow- ing the tightening sequence shown, and then tighten them to the specified torque.
  • Page 210: Rocker Arm Assembly

    5-24 ENGINE TOP END Rocker Case Rocker Arm Assembly • Prepare a flat-end bar [A] and a block [B] with a recess [C]. • Press the oil chamber [D] for the HLA into the rocker arm end [E] until the chamber end is even with the step [F] of the hole.
  • Page 211: Hla Installation

    ENGINE TOP END 5-25 Rocker Case HLA Installation • Check that the HLA plunger is not damaged. If the plunger does damage, replace the HLA. HLA Body [A] O-ring [B] Plunger Spring [C] Pivot Plunger [D] Check Valve [E] Check Valve Spring [F] •...
  • Page 212: Camshafts

    5-26 ENGINE TOP END Camshafts Camshaft Removal • Remove the timing inspection cap [A] and rotor bolt cap [B]. Special Tool - Driver-Filler Cap: 57001–1454 [C] • Turn the crankshaft counterclockwise [A] and align the “F” mark [B] (TDC mark for the front piston) with the middle of the notch [C].
  • Page 213 ENGINE TOP END 5-27 Camshafts • Install the KACR on each camshaft. ○ The front KACR [A] and rear KACR [B] are different (inside view). Do not confuse these KACRs. • Fit the pin [A] into the notch [B], and install the KACR [C] onto the camshaft [D].
  • Page 214: Camshaft Sprocket Installation

    5-28 ENGINE TOP END Camshafts • Align the “R” mark [A] (TDC mark for the rear piston) with the middle of the notch [B] (310° turn from the front piston TDC). • Engage the rear camshaft sprocket with the camshaft chain as shown.
  • Page 215: Front Camshaft Chain Removal

    ENGINE TOP END 5-29 Camshafts • Apply molybdenum disulfide oil to the threads and seating surface of 12 mm nuts and both sides of washers. • Tighten the rocker case nuts and bolts temporarily follow- ing the tightening sequence shown, and then tighten them to the specified torque.
  • Page 216: Rear Camshaft Chain Removal

    Take out the rear camshaft chain [C]. KACR Inspection ○ Due to the simplicity of the KACR (Kawasaki Automatic Compression Release), no periodic maintenance is needed. There are only two symptoms of problems with the KACR mechanism compression is not released dur- ing starting, and compression is released during running.
  • Page 217 ENGINE TOP END 5-31 Camshafts ○ The cylinder compression is released while the engine is running (abnormal): the pin [A] stays out the cam [B] and pushes up the exhaust rocker arm. • Remove the spring [C] and move the weights [D] back and forth.
  • Page 218: Cylinder Head

    5-32 ENGINE TOP END Cylinder Head Cylinder Compression Measurement NOTE ○ Be sure the battery is fully charged. • Warm up the engine thoroughly. • Stop the engine. • Remove one spark plug and attach the compression gauge and adapter firmly into the spark plug hole. Do not remove the other spark plug, only the plug lead.
  • Page 219: Cylinder Head Removal

    ENGINE TOP END 5-33 Cylinder Head The following table should be consulted if the obtainable compression reading is not within the us- able range. Problem Diagnosis Remedy (Action) Remove the carbon deposits Carbon buildup on piston and in combustion chamber possibly due to damaged valve stem, and replace damaged parts if valve guide, stem oil seal and/or damaged necessary.
  • Page 220: Cylinder Head Installation

    5-34 ENGINE TOP END Cylinder Head • Do not remove the coolant drain plug [A] yet. • Remove the cylinder head nuts [B]. • Take the cylinder head off the cylinder. Cylinder Head Installation ○ The front cylinder head [A] has an F mark while the rear cylinder head [B] has an R mark.
  • Page 221: Valve Clearance Adjustment

    ENGINE TOP END 5-35 Cylinder Head Valve Clearance Adjustment NOTE ○ Since the hydraulic lash adjusters constantly maintain zero clearance, it is not necessary to inspect or adjust the valve clearance. Valve Removal • Remove the cylinder head (see Cylinder Head Removal). •...
  • Page 222: Valve Guide Installation

    5-36 ENGINE TOP END Cylinder Head Valve Guide Installation • Apply engine oil to the valve guide outer surface before installation. • Heat the area around the valve guide hole to about 120 ~ 150°C (248 ~ 302°F) in the engine oil. •...
  • Page 223: Valve Seat Inspection

    ENGINE TOP END 5-37 Cylinder Head Valve Seat Inspection • Remove the valve (see Valve Removal). • Check the valve seat surface [A] between the valve [B] and valve seat [C]. ○ Measure the outside diameter [D] of the seating pattern on the valve seat with vernier calipers.
  • Page 224 5-38 ENGINE TOP END Cylinder Head 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. Do not drop or shock the valve seat cutter, or the diamond particles may fall off.
  • Page 225 ENGINE TOP END 5-39 Cylinder Head ○ To make the 32° grind, fit a 32° cutter into the holder, and slide it into the valve guide. ○ Turn the holder one turn at a time while pressing down very lightly. Check the seat after each turn. CAUTION The 32°...
  • Page 226 5-40 ENGINE TOP END Cylinder Head...
  • Page 227: Cylinders, Piston

    ENGINE TOP END 5-41 Cylinders, Piston Cylinder Removal • Remove the cylinder head (see Cylinder Head Removal). • Remove the coolant drain plug [A] and drain the coolant from the cylinder. • Pull out the front camshaft chain guide [B]. •...
  • Page 228 5-42 ENGINE TOP END Cylinders, Piston • Do not mix up the top ring and second ring. • Install the top ring [A] so that the “R” mark [B] faces up. • Install the second ring [C] so that the “RN” mark [D] faces •...