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VULCAN900 CLASSIC
VULCAN900 CLASSIC LT
VN900 CLASSIC
Motorcycle
Service Manual

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Table of Contents

   Summary of Contents for KAWASAKI VN900 CLASSIC

  • Page 1 VULCAN900 CLASSIC VULCAN900 CLASSIC LT VN900 CLASSIC 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) pounds(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 correctly followed, could result in per- maintenance. sonal injury, or loss of life. • Use proper tools and genuine Kawasaki Mo- torcycle parts. Special tools, gauges, and CAUTION testers that are necessary when servicing This caution symbol identifies special...
  • Page 10 NOTE ○ This note symbol indicates points of par- ticular interest for more efficient and con- venient operation. • Indicates a procedural step or work to be done. ○ Indicates a procedural sub-step or how to do the work of the procedural step it follows. It also precedes the text of a NOTE.
  • Page 11 GENERAL INFORMATION 1-1 General Information Table of Contents Before Servicing ........................Model Identification......................... General Specifications......................1-10 Unit Conversion Table ......................1-13...
  • 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: Vn900b6f Left/right Side View

    GENERAL INFORMATION 1-7 Model Identification VN900B6F (US and Canada) Left Side View: VN900B6F (US and Canada) Right Side View: Frame Number Engine Number [A] Frame Number [A] Engine Number [B] Front Fork (Right side) [B] Right Engine Cover...
  • Page 18 1-8 GENERAL INFORMATION Model Identification VN900B6F (Europe and Australia) Left Side View: VN900B6F (Europe and Australia) Right Side View:...
  • Page 19 GENERAL INFORMATION 1-9 Model Identification VN900D6F (US and Canada) Left Side View: VN900D6F (US and Canada) Right Side View:...
  • Page 20: General Specifications

    1-10 GENERAL INFORMATION General Specifications Items VN900B6F/D6F Dimensions Overall Length 2 465 mm (97.05 in.) Overall Width 1 005 mm (39.57 in.), (AU) 980 mm (38.6 in.) Overall Height (VN900B) 1 065 mm (41.93 in.) (VN900D) 1 480 mm (58.27 in.) Wheelbase 1 645 mm (64.76 in.) Road Clearance...
  • Page 21 GENERAL INFORMATION 1-11 General Specifications Items VN900B6F/D6F Valve Timing: Inlet open 40° BTDC close 40° ABDC duration 260° Exhaust Open 55° BBDC Close 25° ATDC Duration 260° Lubrication System Forced lubrication (wet sump) Engine Oil: Type API SE, SF or SG class API SH or SJ class with JASO MA Viscosity SAE10W-40...
  • Page 22 1-12 GENERAL INFORMATION General Specifications Items VN900B6F/D6F Front Suspension: Type Telescopic fork Wheel Travel 150 mm (5.90 in.) Rear Suspension: Type Swingarm (uni-trak) Wheel Travel 103 mm (4.06 in.) Brake Type: Front Single disc Rear Single disc Electrical Equipment Battery: Capacity 12 V 10 Ah Headlight:...
  • Page 23: Unit Conversion Table

    GENERAL INFORMATION 1-13 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 25: Table Of Contents

    PERIODIC MAINTENANCE 2-1 Periodic Maintenance Table of Contents Periodic Maintenance Chart ....................Torque and Locking Agent...................... Specifications ......................... 2-11 Special Tools .......................... 2-13 Periodic Maintenance Procedures..................2-14 Fuel System (DFI)........................ 2-14 Fuel Hose Inspection (fuel leak, damage, installation condition) ........2-14 Throttle Control System Inspection...................
  • Page 26 2-2 PERIODIC MAINTENANCE Electrical System ......................... 2-39 Lights and Switches Operation Inspection................ 2-39 Headlight Aiming Inspection ..................... 2-41 Sidestand Switch Operation Inspection ................2-42 Engine Stop Switch Operation Inspection................. 2-43 Others ..........................2-44 Chassis Parts Lubrication ....................2-44 Bolts, Nuts and Fasteners Tightness Inspection............... 2-45 Evaporative Emission Control SystemInspection (CAL)............
  • Page 27: Periodic Maintenance Chart

    PERIODIC MAINTENANCE 2-3 Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition.The initial maintenance is vitally important and must not be neglected. Periodic Inspection FREQUENCY Whichever * ODOMETER READING comes ×...
  • Page 28 2-4 PERIODIC MAINTENANCE Periodic Maintenance Chart FREQUENCY Whichever * ODOMETER READING comes × 1 000 km first (× 1 000 mile) Page INSPECTION Every (0.6) (4) (7.5) (12) (15) (20) (24) • • • • • • • Brake hose damage - inspect year 2-32 •...
  • Page 29 PERIODIC MAINTENANCE 2-5 Periodic Maintenance Chart Periodic Replacement Parts FREQUENCY Whichever * ODOMETER READING comes × 1 000 km first (× 1 000 mile) Page CHANGE/REPLACE ITEM Every (0.6) (7.5) (15) (24) (30) Air cleaner element # Every 18 000 km (12 000 mile) 2-47 •...
  • Page 30: 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 liquid gasket. Letters used in the “Remarks” column mean: 2T: Apply 2-stroke oil. L: Apply a non-permanent locking agent to the threads. Lh: Left-hand threads M: Apply molybdenum disulfide grease.
  • Page 31 PERIODIC MAINTENANCE 2-7 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Cylinder Head Cover Bolts 106 in·lb Cylinder Head Outer Cover Bolts 87 in·lb Plug (PT1/4) Plug (PT1/2) Muffler Mounting Bolts Muffler Mounting Nut Muffler Joint Clamp Bolt Exhaust Pipe Cover Clamp Bolts 0.70 61 in·lb...
  • Page 32 2-8 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Rear Shift Lever Clamp Bolt 106 in·lb Shift Pedal Clamp Bolt 106 in·lb Shift Rod Locknut (Front) 87 in·lb Oil Nozzle 0.40 34 in·lb Shift Rod Locknut (Rear) 87 in·lb Rear Shift Pedal Pad Screw 0.70...
  • Page 33 PERIODIC MAINTENANCE 2-9 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Suspension Swingarm Pivot Shaft Nut Rear Shock Absorber Nuts Lower Tie-Rod Nut Upper Tie-Rod Nut 11.0 Rocker Arm Pivot Shaft Nut Upper Front Fork Clamp Bolts Lower Front Fork Clamp Bolts Front Fork Bottom Allen Bolts Front Fork Upper Cover Stopper Bolts 0.43...
  • Page 34 2-10 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Spark Plugs 13 in·lb Sidestand Switch Mounting Bolts 0.90 78 in·lb The table below, relating tightening torque to thread diameter, lists the basic torque for the bolts and nuts.
  • Page 35: Specifications

    PERIODIC MAINTENANCE 2-11 Specifications Item Standard Service Limit Fuel System – – – Throttle Grip Free Play 3 mm (0.08 0.12 in.) Idle Speed 1 000 ±50 r/min (rpm) – – – Air Cleaner Element Polyurethane Foam – – – Cooling System Coolant: Type (recommended)
  • Page 36 2-12 PERIODIC MAINTENANCE Specifications Item Standard Service Limit Final Drive Drive Belt Deflection: – – – (45 N, 4.6 kgf, 10 lb fprce) 1.5 4.0 mm (0.059 0.16 in.) – – – When Installing New Belt 1.5 mm (0.059 in.) –...
  • Page 37: Special Tools

    PERIODIC MAINTENANCE 2-13 Special Tools Inside Circlip Pliers: Oil Filter Wrench: 57001-143 57001-1249 Steering Stem Nut Wrench: Spark Plug Wrench, Hex 16: 57001-1100 57001-1262 Jack: Tension Gauge: 57001-1238 57001-1585...
  • Page 38: Periodic Maintenance Procedures

    2-14 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel System (DFI) Fuel Hose Inspection (fuel leak, damage, installation condition) ○ The fuel hose is designed to be used throughout the mo- torcycle’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 39: Idle Speed Inspection

    PERIODIC MAINTENANCE 2-15 Periodic Maintenance Procedures • If necessary, adjust the throttle cable as follows: ○ Loosen the locknuts [A] and screw the adjusters [B] all the way in so as to give the throttle grip plenty of play. ○ Turn out the adjuster of the decelerator cable [D] until there is no play.
  • Page 40: Cooling System

    2-16 PERIODIC MAINTENANCE Periodic Maintenance Procedures Cooling System Coolant Level Inspection NOTE ○ Check the level when the engine is cold (room or ambi- ent temperature). • Check the coolant level in the reserve tank [A] with the motorcycle held upright. If the coolant level is lower than the “L”...
  • Page 41: Air Suction System

    PERIODIC MAINTENANCE 2-17 Periodic Maintenance Procedures Air Suction System Air Suction System Damage Inspection • Pull the air switching valve hose [A] out of the right air cleaner housing. • Start the engine and run it at idle speed. • Plug the air switching valve hose end with your finger and feel vacuum pulsing in the hose.
  • Page 42 2-18 PERIODIC MAINTENANCE Periodic Maintenance Procedures • To select a new shim which brings the valve clearance within the specified range, refer to the Valve Clearance Adjustment Charts. • Remeasure any valve clearance that was adjusted. Readjust if necessary. CAUTION Do not put shim stock under the shim.
  • Page 43 PERIODIC MAINTENANCE 2-19 Periodic Maintenance Procedures VALVE CLEARANCE ADJUSTMENT CHART INLET VALVE 1. Measure the clearance (when engine is cold). 2. Check present shim size. 3. Match clearance in vertical column with present shim size in horizontal column. 4. Install the shim specified where the lines intersect. This shim will give the proper clearance. Example: Present shim is 2.60 mm (0.102 in.) Measured clearance is 0.25 mm (0.010 in.)
  • Page 44 2-20 PERIODIC MAINTENANCE Periodic Maintenance Procedures VALVE CLEARANCE ADJUSTMENT CHART EXHAUST VALVE 1. Measure the clearance (when engine is cold). 2. Check present shim size. 3. Match clearance in vertical column with present shim size in horizontal column. 4. Install the shim specified where the lines intersect. This shim will give the proper clearance. Example: Present shim is 2.55 mm (0.100 in.) Measured clearance is 0.50 mm (0.020 in.)
  • Page 45: Clutch

    PERIODIC MAINTENANCE 2-21 Periodic Maintenance Procedures Clutch Clutch Operation Inspection Clutch Lever Free Play Inspection • Pull the clutch lever just enough to take up the free play [A]. • Measure the gap between the lever and the lever holder. If the gap is too wide, the clutch may not release fully.
  • Page 46: Wheels And Tires

    2-22 PERIODIC MAINTENANCE Periodic Maintenance Procedures Wheels and Tires Tire Air Pressure Inspection • 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 47: Wheel Bearing Damage Inspection

    PERIODIC MAINTENANCE 2-23 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.
  • Page 48: Spoke Tightness And Rim Runout Inspection

    2-24 PERIODIC MAINTENANCE Periodic Maintenance Procedures Spoke Tightness and Rim Runout Inspection • Check that all the spokes are tightened evenly. If spoke tightness is uneven or loose, tighten the spoke nipples evenly. Torque - Spoke Nipples: 5.2 N·m (0.53 kgf·m, 46 in·lb) •...
  • Page 49: Drive Train

    PERIODIC MAINTENANCE 2-25 Periodic Maintenance Procedures Drive Train Belt Deflection Inspection NOTE ○ Belt deflection must be checked and adjusted when the belt is cold (at room temperature). ○ Belt deflection also should be checked at first 1000 km ride after belt replacement. •...
  • Page 50 2-26 PERIODIC MAINTENANCE Periodic Maintenance Procedures NOTE ○ Push the belt by the gauge until the top surface [A] of the stopper comes to the 45 N loaded scale [B], marked “45N”. ○ Push up on the center of the belt. An inaccurate reading will occur if the edge of the belt is pushed up.
  • Page 51: Belt Deflection Adjustment

    PERIODIC MAINTENANCE 2-27 Periodic Maintenance Procedures • Decide the belt deflection at the position [C] of one where deflection is large. Drive Belt Deflection (with 45 N, 4.6 kgf, 10 lb force) Standard: 1.5 4.0 mm (0.059 0.16 in.) Drive Belt Deflection (with 45 N, 4.6 kgf, 10 lb force, when installing new belt or engine remounted) Standard: 1.5 mm (0.059 in.) If the deflection is out of the specification, adjust it.
  • Page 52: Wheel Alignment Inspection/adjustment

    2-28 PERIODIC MAINTENANCE Periodic Maintenance Procedures • 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 53 PERIODIC MAINTENANCE 2-29 Periodic Maintenance Procedures • Visually inspect the belt [A] for wear and damage. If the nylon fabric facing of any portion is worn off, and the polyurethane compound is exposed, or belt is damaged, replace the belt immediately with a new one. •...
  • Page 54 2-30 PERIODIC MAINTENANCE Periodic Maintenance Procedures Drive Belt Tooth Wear and Damage Patterns A. Belt Cross Section B. Edge Bevel Wear C. Rub Wear D. Stone...
  • Page 55: Brake System

    PERIODIC MAINTENANCE 2-31 Periodic Maintenance Procedures Drive Belt Wear and Damage Analysis Pattern Condition Required Action O.K. for continued use, but inspect the Internal tooth cracks (slight) belt periodically. O.K. for continued use, but inspect the Scuffing to side of teeth belt periodically.
  • Page 56: Brake Hose Damage And Installation Condition Inspection

    2-32 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Hose Damage and Installation Condition Inspection • Inspect the brake hoses and fittings for deterioration, cracks and signs of leakage. ○ The high pressure inside the brake line can cause fluid to leak [A] or the hose to burst if the line is not properly main- tained.
  • Page 57: Brake Pad Wear Inspection

    PERIODIC MAINTENANCE 2-33 Periodic Maintenance Procedures • Check that the brake fluid level in the rear brake reservoir [A] is above the lower level line [B]. If the fluid level is lower than the lower level line, fill the reservoir to the upper level line [C]. WARNING Change the brake fluid in the brake line completely if the brake fluid must be refilled but the type and...
  • Page 58: Suspensions

    2-34 PERIODIC MAINTENANCE Periodic Maintenance Procedures If it does not, adjust the brake light switch. • While holding the switch body, turn the adjusting nut [A] to adjust the switch. CAUTION To avoid damaging the electrical connections in- side the switch, be sure that the switch body does not turn during adjustment.
  • Page 59: Front Fork Oil Leak Inspection

    PERIODIC MAINTENANCE 2-35 Periodic Maintenance Procedures Front Fork Oil Leak Inspection • Visually inspect the front forks [A] for oil leakage. Replace or repair any defective parts, if necessary. Rear Shock Absorber Oil Leak Inspection • Remove the left side cover (see Left Side Cover Removal in the Frame chapter).
  • Page 60: Uni-trak Linkage Lubrication

    2-36 PERIODIC MAINTENANCE Periodic Maintenance Procedures Uni-trak Linkage Lubrication • Remove: Tie-Rod (see Tie-Rod Removal in the Suspension chap- ter) • Apply grease to the inner surfaces of the needle bearings • For the rocker arm it has grease nipples [A] on the rocker arm for lubrication.
  • Page 61 PERIODIC MAINTENANCE 2-37 Periodic Maintenance Procedures • Straighten the claws [A] of the claw washer. • Remove the steering stem locknut [B] and claw washer [C]. • Adjust the steering. Special Tool - Steering Stem Nut Wrench [A]: 57001-1100 If the steering is too tight, loosen the stem nut [B] a fraction of a turn.
  • Page 62: Steering Stem Bearing Lubrication

    2-38 PERIODIC MAINTENANCE Periodic Maintenance Procedures Steering Stem Bearing Lubrication • Remove the steering stem (see Steering Stem Removal in the Steering chapter). • Using a high flash-point solvent, wash the upper and lower ball bearings in the cages, and wipe the upper and lower outer races, which are press-fitted into the frame head pipe, clean off grease and dirt.
  • Page 63: Electrical System

    PERIODIC MAINTENANCE 2-39 Periodic Maintenance Procedures Electrical System Lights and Switches Operation Inspection First Step • Turn on the ignition switch. • The following lights should go on according to below table. Position Lights [A] ( US and Canada goes on Models) City Light [B] (Europe Models) goes on...
  • Page 64 2-40 PERIODIC MAINTENANCE Periodic Maintenance Procedures Third Step • Turn on the turn signal switch [A] (left or right position). • The left or right turn signal lights [B] (front and rear) ac- cording to the switch position should flash. •...
  • Page 65: Headlight Aiming Inspection

    PERIODIC MAINTENANCE 2-41 Periodic Maintenance Procedures • Set the dimmer switch to high beam position. • The high beam should go on. • The high beam indicator light (LED) [A] should go on. If the high beam headlight and/or high beam indicator light (LED) does not go on, inspect or replace the following item.
  • Page 66: Sidestand Switch Operation Inspection

    2-42 PERIODIC MAINTENANCE Periodic Maintenance Procedures NOTE ○ For US model, the proper angle is 0.4 degrees below horizontal. This is 50 mm (2 in.) drop at 7.6 m (25 ft.) measured from the center of the headlight with the motorcycle on its wheels and the rider seated.
  • Page 67: Engine Stop Switch Operation Inspection

    PERIODIC MAINTENANCE 2-43 Periodic Maintenance Procedures If the sidestand switch operation does not work, inspect or replace the following item. Battery (see Charging Condition Inspection in the Elec- trical System chapter) Main Fuse 30 A (see Fuse Inspection in the Electrical System chapter) Ignition Fuse 10 A (see Fuse Inspection in the Electrical System chapter)
  • Page 68: Others

    2-44 PERIODIC MAINTENANCE Periodic Maintenance Procedures Others Chassis Parts Lubrication • Before lubricating each part, clean off any rusty spots with rust remover and wipe off any grease, oil, dirt, or grime. • Lubricate the points listed below with indicated lubricant. NOTE ○...
  • Page 69: Bolts, Nuts And Fasteners Tightness Inspection

    PERIODIC MAINTENANCE 2-45 Periodic Maintenance Procedures Bolts, Nuts and Fasteners Tightness Inspection • Check the tightness of the bolts and nuts listed here. Also, check to see that each cotter pin is in place and in good condition. NOTE ○ For the engine fasteners, check the tightness of them when the engine is cold (at room temperature).
  • Page 70: Evaporative Emission Control Systeminspection (cal)

    2-46 PERIODIC MAINTENANCE Periodic Maintenance Procedures Evaporative Emission Control System Inspection (CAL) Evaporative Emission Control System Inspection • Inspect the canister as follows: ○ Remove: Muffler (see Muffler Removal in the Engine Top End chapter) ○ Remove the bolts [A]. ○...
  • Page 71: Replacement Parts

    Install a new element [A] with the mesh side facing up -ward. CAUTION Use only the recommended air cleaner element (Kawasaki part number 11013-0015). Using another air cleaner element will wear the engine prema- turely or lower the engine performance. Torque - Air Cleaner Element Screw: 4.9 N·m (0.50 kgf·m,...
  • Page 72: Engine Oil Change

    2-48 PERIODIC MAINTENANCE Periodic Maintenance Procedures Engine Oil Change • Situate the motorcycle so that it is vertical after warning up the engine. • Remove: Oil Filler Cap [A] Special Tool - Filler Cap Driver: 57001-1454 • Remove the engine drain plug [A] to drain the oil. ○...
  • Page 73: Oil Filter Replacement

    PERIODIC MAINTENANCE 2-49 Periodic Maintenance Procedures Oil Filter Replacement • Drain the engine oil (see Engine Oil Change). • Remove: Regulator/Rectifier (see Regulator/Rectifier Removal in the Electrical System chapter) Bolts [A] Bracket [B] • Remove the oil filter [A] with the oil filter wrench [B] and discard the oil filter.
  • Page 74 2-50 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Twist the driver to disconnect the joint lock [A]. • Pull [B] the fuel hose joint [C] out of the delivery pipe. WARNING Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately. When the fuel hose is disconnected, fuel spills out from the hose and the pipe.
  • Page 75: Coolant Change

    PERIODIC MAINTENANCE 2-51 Periodic Maintenance Procedures 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 76 2-52 PERIODIC MAINTENANCE Periodic Maintenance Procedures Water and Coolant Mixture Ratio (when recommended) Soft Water Coolant Freezing Point : −35°C (−31°F) Total Amount 2.2 L (2.3 US gt.) • Tighten: Torque - Coolant Drain Bolt: 9.8 N·m (1.0 kgf·m, 87 in·lb) •...
  • Page 77: Radiator Hose And O-ring Replacement

    PERIODIC MAINTENANCE 2-53 Periodic Maintenance Procedures Radiator Hose and O-ring Replacement • Drain the coolant (see Coolant Change). • Remove: Thermostat Bracket [A] (see Thermostat Removal in the Cooling System chapter) • Loosen the radiator hose clamps and remove the hoses [B].
  • Page 78: Brake Fluid Change

    2-54 PERIODIC MAINTENANCE Periodic Maintenance Procedures • When installing the hoses [A], avoid sharp bending, kink- ing, flattening or twisting, and route the hoses according to Cable, Wire and Hose Routing section in the Appendix chapter. • Fill the brake line after installing the brake hose (see Brake Fluid Change).
  • Page 79 PERIODIC MAINTENANCE 2-55 Periodic Maintenance Procedures ○ Repeat this operation until fresh brake fluid comes out from the plastic hose or the color of the fluid changes. Open the bleed valve [A]. Pump the brake lever and hold it [B]. Close the bleed valve [C].
  • Page 80: Master Cylinder Rubber Parts Replacement

    2-56 PERIODIC MAINTENANCE Periodic Maintenance Procedures Master Cylinder Rubber Parts Replacement Front Master Cylinder Disassembly • Remove the front master cylinder (see Front Master Cylin- der Removal in the Brakes chapter). • Remove the reservoir cap [A], plate [B], and diaphragm [C].
  • Page 81: Caliper Rubber Parts Replacement

    PERIODIC MAINTENANCE 2-57 Periodic Maintenance Procedures 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 82 2-58 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Using compressed air, remove the piston. WARNING To avoid serious injury, never place your fingers or palm inside the caliper opening. If you apply com- pressed air into the caliper, the piston may crush your hand or fingers.
  • Page 83 PERIODIC MAINTENANCE 2-59 Periodic Maintenance Procedures • Apply brake fluid to the inside of the cylinders and to the outside of the pistons and push the pistons [A] into the cylinders. • Check the friction boot [B] and dust boot [C] and replace them with new ones if they are damaged.
  • Page 84: Spark Plug Replacement

    2-60 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Remove: Antirattle Spring [A] Dust Seals [B] and Fluid Seals [C] Rubber Friction Boots [D] Bleed Valves [E] and Rubber Caps [F] Rear Caliper Assembly • Tighten the bleed valve. Torque - Rear Caliper Bleed Valves: 7.8 N·m (0.80 kgf·m, 69 in·lb) ○...
  • Page 85 PERIODIC MAINTENANCE 2-61 Periodic Maintenance Procedures CAUTION The insulator [A] of the spark plug may break if when the wrench is inclined during loosening. Inclined Spark Plug Wrench [B] Contact (Spark Plug and Plug Wrench) [C] Bad [D] Vertically Spark Plug Wrench [E] Good [F] •...
  • Page 87 FUEL SYSTEM (DFI) 3-1 Fuel System (DFI) Table of Contents Exploded View........................DFI Parts Location........................Specifications ......................... 3-11 Special Tools and Sealant ...................... 3-13 DFI System..........................3-14 DFI Servicing Precautions ...................... 3-22 DFI Servicing Precautions ....................3-22 Troubleshooting the DFI System .................... 3-24 Outline ..........................
  • Page 88 3-2 FUEL SYSTEM (DFI) Speed Sensor Removal ....................3-63 Speed Sensor Installation ....................3-63 Speed Sensor Inspection....................3-63 Input Voltage Inspection....................3-63 Output Voltage Inspection....................3-64 Vehicle-down Sensor (Service Code 31)................3-66 Vehicle-down Sensor Removal ..................3-66 Vehicle-down Sensor Installation ..................3-66 Vehicle-down Sensor Inspection..................
  • Page 89 FUEL SYSTEM (DFI) 3-3 Audible Inspection......................3-106 Fuel Injector Power Source Voltage Inspection ..............3-106 Output Voltage Inspection....................3-107 Injector Signal Test......................3-108 Injector Resistance Inspection ..................3-108 Injector Unit Test ....................... 3-109 Throttle Grip and Cables ......................3-112 Throttle Grip Free Play Inspection ..................3-112 Throttle Grip Free Play Adjustment...................
  • Page 90: Exploded View

    3-4 FUEL SYSTEM (DFI) Exploded View...
  • Page 91 FUEL SYSTEM (DFI) 3-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Fuel Pump Bolts 87 in·lb Air Cleaner Housing Bolts 87 in·lb Air Cleaner Cover Bolts 0.50 43 in·lb Throttle Body Assy Holder Bolts 87 in·lb Inlet Manifold Bolts 87 in·lb Delivery Joint Bolts 87 in·lb...
  • Page 92 3-6 FUEL SYSTEM (DFI) Exploded View...
  • Page 93 FUEL SYSTEM (DFI) 3-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Fuel Level Sensor Mounting Bolts 0.70 61 in·lb 2. California Model 3. Breather Hose (Other than California Models) L: Apply a non-permanent locking agent. R: Replacement Parts...
  • Page 94: Dfi Parts Location

    3-8 FUEL SYSTEM (DFI) DFI Parts Location 1. Ignition Coil #1 12. Injector #1 2. Fuel Pump 13. Water Temperature Sensor 3. Ignition Coil #2 14. Main Throttle Sensor 4. Main Fuse 30 A 15. Subthrottle Sensor 5. Relay Box 16.
  • Page 95 FUEL SYSTEM (DFI) 3-9 DFI Parts Location...
  • Page 96 3-10 FUEL SYSTEM (DFI) DFI Parts Location...
  • Page 97: Specifications

    FUEL SYSTEM (DFI) 3-11 Specifications Item Standard Throttle Grip Free Play 3 mm (0.08 0.12 in.) Air Cleaner Element Viscous paper element DFI System Make Denso Idle Speed 1 000 ±50 r/min (rpm) Throttle Body Assy: Type × Bore Two barrel type × 34 mm (1.34 in.) ECU (Electronic Control Unit): Type Digital memory type, with built in IC igniter, sealed...
  • Page 98 3-12 FUEL SYSTEM (DFI) Specifications Item Standard Subthrottle Sensor: Non-adjustable and non-removable Input Voltage 4.75 5.25 V DC between BL and BR/BK leads Output Voltage 0.93 4.59 V DC between BL/W and BR/BK leads (at idle throttle opening to full throttle opening) Resistance 6 kΩ...
  • Page 99: Special Tools And Sealant

    Oil Pressure Gauge, 5 kgf/cm²: Needle Adapter Set: 57001-125 57001-1457 Fork Oil Level Gauge: Fuel Pressure Gauge Adapter: 57001-1290 57001-1593 Hand Tester: Fuel Hose: 57001-1394 57001-1607 Peak Voltage Adapter: Speed Sensor Measuring Adapter: 57001-1415 57001-1667 Filler Cap Driver: Kawasaki Bond (Silicone Sealant): 57001-1454 56019-120...
  • Page 100: Dfi System

    3-14 FUEL SYSTEM (DFI) DFI System DFI System...
  • Page 101 FUEL SYSTEM (DFI) 3-15 DFI System 1. Battery 2. ECU 3. Injector 4. Fuel Pump 5. Fuel Tank 6. Subthrottle Valve Actuator 7. Air Cleaner 8. Subthrottle Sensor 9. Main Throttle Sensor 10. Inlet Air Temperature Sensor 11. Water Temperature Sensor 12.
  • Page 102 3-16 FUEL SYSTEM (DFI) DFI System DFI System Wiring Diagram (Other than Europe Models)
  • Page 103 FUEL SYSTEM (DFI) 3-17 DFI System Part Name 1. ECU 2. Diagnosis Connector 3. Self-diagnosis Terminal 4. Fuel Pump 5. Vehicle-down Sensor 6. Frame Ground 7. Battery 8. Main Fuse 30 A 9. Relay Box 10. Fuel Pump Relay 11. ECU Main Relay 12.
  • Page 104 3-18 FUEL SYSTEM (DFI) DFI System DFI System Wiring Diagram (Europe Models)
  • Page 105 FUEL SYSTEM (DFI) 3-19 DFI System Part Name 1. ECU 2. Diagnosis Connector 3. Self-diagnosis Terminal 4. Fuel Pump 5. Vehicle-down Sensor 6. Frame Ground 7. Battery 8. Main Fuse 30 A 9. Relay Box 10. Fuel Pump Relay 11. ECU Main Relay 12.
  • Page 106 3-20 FUEL SYSTEM (DFI) DFI System Other than Europe Models Terminal Names 1. Subthrottle Valve Actuator Drive Signal 2 23. Unused 2. Subthrottle Valve Actuator Drive Signal 1 24. Crankshaft Sensor (–) Signal 3. Water Temperature Warning Light Signal 25. Unused 4.
  • Page 107 FUEL SYSTEM (DFI) 3-21 DFI System Europe Model Terminal Names 1. Subthrottle Valve Actuator Drive Signal 2 27. Unused 2. Subthrottle Valve Actuator Drive Signal 1 28. Ground to Sensors 3. Water Temperature Warning Light Signal 29. Oxygen Sensor Heater Signal 4.
  • Page 108: Dfi Servicing Precautions

    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 109 FUEL SYSTEM (DFI) 3-23 DFI Servicing Precautions ○ 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 plug [A] after filling the engine oil. Alternator Cover [B] Special Tool - Filler Cap Driver: 57001-1454...
  • Page 110: Troubleshooting The Dfi System

    3-24 FUEL SYSTEM (DFI) Troubleshooting the DFI System Outline Outline When an abnormality in the system occurs, the FI indica- tor LED (Light Emitting Diode) light goes on to alert the rider on the meter panel. In addition, the condition of the problem is stored in the memory of the ECU (electronic control unit).
  • Page 111 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 Vehicle-down Sensor Connector • Always check battery condition before replacing the DFI parts.
  • Page 112 3-26 FUEL SYSTEM (DFI) Troubleshooting the DFI System • 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. Connect the connectors securely. •...
  • Page 113 FUEL SYSTEM (DFI) 3-27 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 114: Inquiries To Rider

    3-28 FUEL SYSTEM (DFI) Troubleshooting the DFI System DFI Diagnosis Flow Chart Inquiries to Rider 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. ○...
  • Page 115 FUEL SYSTEM (DFI) 3-29 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 116 3-30 FUEL SYSTEM (DFI) Troubleshooting the DFI System □ engine overheating. □ clutch slipping. □ other: □ Poor running spark plug loose (tighten it). or no power at □ spark plug dirty, broken, or gap maladjusted (remedy it). high speed □...
  • Page 117: Dfi System Troubleshooting Guide

    FUEL SYSTEM (DFI) 3-31 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 118 3-32 FUEL SYSTEM (DFI) 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 119: Poor Running At Low Speed

    FUEL SYSTEM (DFI) 3-33 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) 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). Cylinder head gasket damaged Replace (see chapter 5).
  • Page 120 3-34 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Incorrect idle speed Water temperature sensor trouble Inspect (see chapter 3). Throttle sensor trouble Inspect (see chapter 3). Throttle valves or actuator trouble Inspect (see chapter 3). Engine stalls easily Fuel pump trouble Inspect (see chapter 3).
  • Page 121 FUEL SYSTEM (DFI) 3-35 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Delay of ignition timing Inspect crankshaft sensor and IC igniter in ECU (see chapter 16). Poor acceleration Too low fuel pressure Inspect (see chapter 3). Water or foreign matter in fuel Change fuel.
  • Page 122: Poor Running Or No Power At High Speed

    3-36 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Fuel injector trouble Inspect (see chapter 3). Run-on (dieseling) Ignition switch trouble Inspect and replace (see chapter 16). Engine switch trouble Inspect and repair or replace (see chapter 16). Fuel injector trouble Inspect (see chapter 3).
  • Page 123 FUEL SYSTEM (DFI) 3-37 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (detailed reference) Inlet air temperature sensor trouble Inspect (see chapter 3). Throttle sensor malfunction Inspect (see chapter 3). Inlet air pressure sensor trouble Inspect (see chapter 3). Cracked or obstructed inlet air pressure sensor Inspect and repair or replace (see chapter 3) hose...
  • Page 124 3-38 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (detailed reference) Cylinder worn Inspect and replace (see chapter 5). Valve oil seal damaged Replace (see chapter 5). Valve guide worn Replace the guide (see chapter 5). Engine oil level too high Repair (see chapter 7).
  • Page 125: Self-diagnosis

    FUEL SYSTEM (DFI) 3-39 Self-Diagnosis Self-diagnosis Outline Self-diagnosis Outline The self-diagnosis system has three modes and can be switched to another mode by grounding the self-diagnosis terminal. User Mode The ECU notifies the rider of troubles in DFI system and ignition system by lighting the FI indicator when DFI system and ignition system parts are faulty, and initiates fail-safe function.
  • Page 126: Service Code Clearing Procedures

    3-40 FUEL SYSTEM (DFI) Self-Diagnosis • To enter the self-diagnosis dealer mode 2, open [B] and ground [A] the lead more than five times [F] within 2 sec- onds [C] after the lead is first grounded, and then keep it grounded continuously [D] for more than 2 seconds.
  • Page 127 FUEL SYSTEM (DFI) 3-41 Self-Diagnosis...
  • Page 128: How To Read Service Codes

    3-42 FUEL SYSTEM (DFI) Self-Diagnosis How to Read Service Codes How to Read Service Codes ○ Service codes are shown by a series of long and short blinks of the FI indicator light (LED) as shown below. ○ Read 10th digit and unit digit as the FI indicator light (LED) blinks. ○...
  • Page 129: Service Code Table

    FUEL SYSTEM (DFI) 3-43 Self-Diagnosis Service Code Table Service Code Table Service FI Indicator Light (LED) Problems Code 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...
  • Page 130 3-44 FUEL SYSTEM (DFI) Self-Diagnosis Notes: ○ The ECU may be involved in these problems. If all the parts and circuits checked out good, be sure to check the ECU for ground and power supply. If the ground and power supply are checked good, replace the ECU.
  • Page 131: Backups

    FUEL SYSTEM (DFI) 3-45 Self-Diagnosis Backups 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 main throttle sensor system fails (the signal is out of the usable range, wiring short or open), the ECU locks ignition timing into the...
  • Page 132 3-46 FUEL SYSTEM (DFI) Self-Diagnosis Service Output Signal Usable Parts Backups by ECU Codes Range or Criteria The stick coil primary If the ignition primary winding #1 has failures winding must send (no signal, wiring short or open), the ECU Ignition Coil #1* signals (output voltage) shuts off the injector #1 to stop fuel to the...
  • Page 133: Main Throttle Sensor (service Code 11)

    FUEL SYSTEM (DFI) 3-47 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 134: Output Voltage Inspection

    3-48 FUEL SYSTEM (DFI) Main Throttle Sensor (Service Code 11) Output Voltage Inspection • Measure the output voltage at the ECU in the same way as input voltage inspection. Special Tool - Needle Adapter Set: 57001-1457 Main Throttle Sensor Output Voltage Connections to ECU (Other than Europe Models [A]) Meter (+) →...
  • Page 135: Resistance Inspection

    FUEL SYSTEM (DFI) 3-49 Main Throttle Sensor (Service Code 11) NOTE ○ The standard voltage marked with an asterisk refers to the value when the voltage reading at the Input Voltage Inspection shows 5 V exactly. ○ When the input voltage reading shows other than 5 V, derive a voltage range as follows.
  • Page 136 3-50 FUEL SYSTEM (DFI) Main Throttle Sensor (Service Code 11) Main Throttle Sensor Circuit (Other than Europe Models) Main Throttle Sensor Circuit (Europe Models) 1. ECU 2. Main Throttle Sensor 3. Joint Connector B...
  • Page 137: Inlet Air Pressure Sensor (service Code 12)

    FUEL SYSTEM (DFI) 3-51 Inlet Air Pressure Sensor (Service Code 12) Inlet Air Pressure Sensor Removal CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the part can damage it. • Remove: Fuel Tank (see Fuel Tank Removal) Bolt [A] •...
  • Page 138: Output Voltage Inspection

    3-52 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code 12) If the reading is within the standard range, remove the fuel tank, and check wiring from ECU to the inlet pressure sensor for continuity. If wiring is good, check the output voltage of the inlet air pressure sensor.
  • Page 139 FUEL SYSTEM (DFI) 3-53 Inlet Air Pressure Sensor (Service Code 12) • Remove the inlet air pressure sensor [A] and disconnect the vacuum hose from the sensor. ○ Do not disconnect the sensor connector. • Connect an auxiliary hose [B] to the inlet air pressure sen- sor.
  • Page 140 3-54 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code 12) ID: Idling Ps: Standard Atmospheric Pressure (absolute) Pv: Throttle Vacuum Pressure (absolute) ST: Standard of Sensor Output Voltage (v) TO: Throttle Full Open UR: Usable Range of Sensor Output Voltage (v) Vv: Inlet Air Pressure Sensor Output Voltage (v) (Digital Meter Reading)
  • Page 141 FUEL SYSTEM (DFI) 3-55 Inlet Air Pressure Sensor (Service Code 12) Inlet Air Pressure Sensor Circuit (Other than Europe Models) Inlet Air Pressure Sensor Circuit (Europe Models) 1. ECU 2. Inlet Air Pressure Sensor 3. Joint Connector B...
  • Page 142: Inlet Air Temperature Sensor (service Code 13)

    3-56 FUEL SYSTEM (DFI) Inlet Air Temperature Sensor (Service Code 13) Inlet Air Temperature Sensor Removal/Installation CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. • Remove the air cleaner housing (see Air Cleaner Housing Removal).
  • Page 143: Sensor Resistance Inspection

    FUEL SYSTEM (DFI) 3-57 Inlet Air Temperature Sensor (Service Code 13) Sensor Resistance Inspection • Remove the inlet air temperature sensor (see Inlet Air Temperature Sensor Removal). • Suspend the sensor [A] in a container of machine oil so that the heat-sensitive portion is submerged. •...
  • Page 144 3-58 FUEL SYSTEM (DFI) Inlet Air Temperature Sensor (Service Code 13) Inlet Air Temperature Sensor Circuit (Other than Europe Models) Inlet Air Temperature Sensor Circuit (Europe Models) 1. ECU 2. Inlet Air Temperature Sensor 3. Joint Connector B...
  • Page 145: Water Temperature Sensor (service Code 14)

    FUEL SYSTEM (DFI) 3-59 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. • Remove the fuel tank (see Fuel Tank Removal). • Drain the coolant (see Coolant Change in the Periodic Maintenance chapter).
  • Page 146 3-60 FUEL SYSTEM (DFI) Water Temperature Sensor (Service Code 14) Water Temperature Sensor Circuit (Other than Europe Models) Water Temperature Sensor Circuit (Europe Models) 1. ECU 2. Water Temperature Sensor 3. Joint Connector B...
  • Page 147: Crankshaft Sensor (service Code 21)

    FUEL SYSTEM (DFI) 3-61 Crankshaft Sensor (Service Code 21) Start the engine and switch the diagnosis mode to Dealer 1 mode to know all the problem that the DFI system has at the time of self-diagnosis. If the engine cannot be started, the self-diagnosis system does not detect dynamic condi- tion of the crankshaft sensor.
  • Page 148 3-62 FUEL SYSTEM (DFI) Crankshaft Sensor (Service Code 21) Crankshaft Sensor Circuit (Other than Europe Models) Crankshaft Sensor Circuit (Europe Models) 1. ECU 2. Crankshaft Sensor...
  • Page 149: Speed Sensor (service Code 24, 25)

    FUEL SYSTEM (DFI) 3-63 Speed Sensor (Service Code 24, 25) Speed Sensor Removal • Refer to the Speed Sensor Removal in the Electrical Sys- tem chapter. Speed Sensor Installation • Refer to the Speed Sensor Installation in the Electrical System chapter. Speed Sensor Inspection •...
  • Page 150: Output Voltage Inspection

    3-64 FUEL SYSTEM (DFI) Speed Sensor (Service Code 24, 25) Output Voltage Inspection • Before this inspection, inspect the input voltage (see Input Voltage Inspection in the Speed Sensor section). NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch OFF.
  • Page 151 FUEL SYSTEM (DFI) 3-65 Speed Sensor (Service Code 24, 25) Speed Sensor Circuit (Other than Europe Models) Speed Sensor Circuit (Europe Models) 1. ECU 2. Meter Unit 3. Joint Connector B 4. Speed Sensor...
  • Page 152: Vehicle-down Sensor (service Code 31)

    3-66 FUEL SYSTEM (DFI) Vehicle-down Sensor (Service Code 31) Vehicle-down Sensor Removal • Remove: Tool Box (see Tool Box Removal in the Frame chapter) Bolts [A] Vehicle-down Sensor [B] Connector [C] (disconnect) Vehicle-down Sensor Installation • Install the vehicle-down sensor [A] in the original position. The arrow mark [B] on the sensor must be on the rear and point upward.
  • Page 153 • 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 154 3-68 FUEL SYSTEM (DFI) Vehicle-down Sensor (Service Code 31) Vehicle-down Sensor Circuit (Other than Europe Models) Vehicle-down Sensor Circuit (Europe Models) 1. ECU 2. Vehicle-down Sensor 3. Joint Connector B...
  • Page 155: Subthrottle Sensor (service Code 32)

    FUEL SYSTEM (DFI) 3-69 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 156: Output Voltage Inspection

    3-70 FUEL SYSTEM (DFI) Subthrottle Sensor (Service Code 32) • Turn the ignition switch OFF. If the reading of input voltage is less than the standard, check the ECU for its ground, power supply and wiring shorted. If the input voltage is within the standard range, remove the fuel tank, and check wiring from ECU to the subthrottle sensor for continuity.
  • Page 157: Resistance Inspection

    FUEL SYSTEM (DFI) 3-71 Subthrottle Sensor (Service Code 32) NOTE ○ The standard voltage marked with an asterisk refers to the value when the voltage reading at the Input Voltage Inspection shows 5 V exactly. ○ When the input voltage reading shows other than 5 V, derive a voltage range as follows.
  • Page 158 3-72 FUEL SYSTEM (DFI) Subthrottle Sensor (Service Code 32) Subthrottle Sensor Circuit (Other than Europe Models) Subthrottle Sensor Circuit (Europe Models) 1. ECU 2. Subthrottle Sensor 3. Joint Connector B...
  • Page 159: Oxygen Sensor-not Activated (#1, #2: Service Code 33, 83)-europe Models

    FUEL SYSTEM (DFI) 3-73 Oxygen Sensor-not activated (#1, #2: Service Code 33, 83)-Europe Models Oxygen Sensor #1: Service Code 33 Oxygen Sensor #2: Service Code 83 Oxygen Sensor Removal/Installation • Refer to Oxygen Sensor Removal and Installation in the Electrical System chapter. Oxygen Sensor Inspection NOTE ○...
  • Page 160 If the reading is without range, replace the oxygen sensor. • Remove the needle adapter set, and apply silicone sealant to the seals of the connector for waterproofing. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 Oxygen Sensor Circuit 1. ECU 2. Oxygen Sensor #1 3.
  • Page 161: Ignition Coils (#1, #2: Service Code 51, 52)

    FUEL SYSTEM (DFI) 3-75 Ignition Coils (#1, #2: Service Code 51, 52) Ignition Coil #1: Ignition Coil for Front Cylinder (Service Code 51) Ignition Coil #2: Ignition Coil for Rear Cylinder (Service Code 52) Ignition Coil Removal/Installation CAUTION Never drop the ignition coils, especially on a hard surface.
  • Page 162 3-76 FUEL SYSTEM (DFI) Ignition Coils (#1, #2: Service Code 51, 52) If the reading is out of the standard, check the ECU for its ground and power supply (see ECU Power Supply In- spection). If the reading is good remove the fuel tank and check the wiring between the ECU and the primary lead terminals at the ignition coils.
  • Page 163: Radiator Fan Relay (service Code 56)

    FUEL SYSTEM (DFI) 3-77 Radiator Fan Relay (Service Code 56) Radiator Fan Relay Removal/Installation • Radiator fan relay is bult in the relay box. • Remove the relay box (see Relay Box Removal in the Electrical System chapter). Radiator Fan Relay Inspection •...
  • Page 164 3-78 FUEL SYSTEM (DFI) Radiator Fan Relay (Service Code 56) Radiator Fan Relay Circuit 1. Ignition Switch 2. Radiator Fan 3. Joint Connector B 4. Water Temperature Sensor 5. ECU 6. Frame Ground 7. Battery 8. Main Fuse 30 A 9.
  • Page 165: Subthrottle Valve Actuator (service Code 62)

    FUEL SYSTEM (DFI) 3-79 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 166: Input Voltage Inspection

    3-80 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. • Remove the fuel tank (see Fuel Tank Removal). • Connect the peak voltage adapter [A] and a digital meter [B] to the connector (main harness side) [C], using the needle adapter set [D].
  • Page 167 FUEL SYSTEM (DFI) 3-81 Subthrottle Valve Actuator (Service Code 62) Subthrottle Valve Actuator Circuit (Other than Europe Models) Subthrottle Valve Actuator Circuit (Europe Models) 1. ECU 2. Subthrottle Valve Actuator...
  • Page 168: Air Switching Valve (service Code 64)

    3-82 FUEL SYSTEM (DFI) Air Switching Valve (Service Code 64) Air Switching Valve Removal/Installation • See Clean Air System section in the Engine Top End chapter. Air Switching Valve Inspection • See Air Switching Valve Unit Test in the Electrical System chapter.
  • Page 169 FUEL SYSTEM (DFI) 3-83 Air Switching Valve (Service Code 64) Air Switching Valve Circuit (Europe Models) 1. ECU 2. Engine Stop Switch 3. Ignition Switch 4. Ignition Fuse 10 A 5. ECU Fuse 15 A 6. Fuse Box 7. ECU Main Relay 8.
  • Page 170: Oxygen Sensor Heaters (#1, #2: Service Code 67)-europe Models

    3-84 FUEL SYSTEM (DFI) Oxygen Sensor Heaters (#1, #2: Service Code 67)-Europe Models Oxygen Sensor Heater Removal/Installation The oxygen sensor heater is bult in the oxygen sensor. So, the heater itself can not be removed. Remove the oxy- gen sensor (see Switch and Sensors section in the Electri- cal System chapter).
  • Page 171 ECU (see ECU section). • Remove the needle adapter set, and apply silicone sealant to the connector for water proofing. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 Oxygen Sensor Circuit 1. ECU 2. Oxygen Sensor #1 3. Oxygen Sensor #2 4.
  • Page 172: Oxygen Sensors-incorrect Output Voltage (#1, #2: Service Code 94, 95)-europe Models

    3-86 FUEL SYSTEM (DFI) Oxygen Sensors-Incorrect Output Voltage (#1, #2: Service Code 94, 95)-Europe Models Oxygen Sensor #1: Service Code 94 Oxygen Sensor #2: Service Code 95 Oxygen Sensor Removal/Installation • Refer to Oxygen Sensor Removal and Installation in the Electrical System chapter.
  • Page 173 • Remove the needle adapter set, and apply silicone sealant to the seals of the connector for waterproofing. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 Oxygen Sensor Circuit 1. ECU 2. Oxygen Sensor #1 3. Oxygen Sensor #2 4.
  • Page 174: Fi Indicator Led Light

    3-88 FUEL SYSTEM (DFI) FI Indicator LED Light Inspection Flow Chart...
  • Page 175: Led Light Inspection

    FUEL SYSTEM (DFI) 3-89 FI Indicator LED Light LED Light Inspection ○ The FI indicator LED light [A] goes ON when the ignition switch is turned ON and the LED light goes OFF when the engine oil pressure is high enough (the engine is running). 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 176 3-90 FUEL SYSTEM (DFI) FI Indicator LED Light FI Indicator LED Light Circuit (Other than Europe Models) FI Indicator LED Light Circuit (Europe Models) 1. ECU 2. Ignition Switch 3. Meter Unit 4. FI Indicator LED Light 5. Main Fuse 30 A 6.
  • Page 177: Ecu

    FUEL SYSTEM (DFI) 3-91 ECU Removal CAUTION Never drop the ECU, especially on a hard surface. Such a shock to the ECU can damage it. • Remove: Seat (see Seat Removal in the Frame chapter) Tool Box (see Tool Box Removal in the Frame chapter) •...
  • Page 178 3-92 FUEL SYSTEM (DFI) • Check the ECU power source voltage with a digital meter. ○ Position the terminal in accordance with terminal numbers of ECU connectors in this chapter figure. ECU Power Source Inspection Meter Connections: (Other than Europe Models [A]) Between Terminal 12 (BR/W) and Battery (–) Terminal Between Terminal 27 (W/BK) and Battery (–)
  • Page 179: Fuel Line

    FUEL SYSTEM (DFI) 3-93 Fuel Line Fuel Pressure Inspection NOTE ○ This inspection can determine which trouble the DFI system has, mechanical or electrical trouble. ○ 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 180 3-94 FUEL SYSTEM (DFI) Fuel Line • Turn the ignition switch 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 Switch ON, with pump running: Standard: 304 kPa (3.1 kgf/cm², 44 psi) after 3 seconds from Ignition Switch ON, with pump stopped:...
  • Page 181: Fuel Flow Rate Inspection

    FUEL SYSTEM (DFI) 3-95 Fuel Line • Insert the fuel hose joint [A] straight onto the delivery pipe. • Push [B] the joint lock [C] until the hose joint clicks. • Push and pull [A] the fuel hose joint [B] back and forth more than two times and make sure it is locked and doesn’t come off.
  • Page 182 3-96 FUEL SYSTEM (DFI) Fuel Line • Prepare a plastic hose of the inside diameter 7.5 mm × L = about 400 mm and a measuring cylinder. • Remove: Seat (see Seat Removal in the Frame chapter) Fuel Tank Bolts •...
  • Page 183: Fuel Pump

    FUEL SYSTEM (DFI) 3-97 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 184: Pump Screen, Fuel Filter Cleaning

    3-98 FUEL SYSTEM (DFI) Fuel Pump • Check that the terminals [A] and band [B] are in place. • Apply a non-permanent locking agent to the threads of the fuel pump bolts. • Tighten the fuel pump bolts [C] to a snug fit. •...
  • Page 185: Operating Voltage Inspection

    FUEL SYSTEM (DFI) 3-99 Fuel Pump Operating Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch OFF. • Remove the ignition coil cover (see Ignition Coil Removal in the Electrical System chapter). • Connect the hand tester (25 V DC) to the fuel pump con- nector [A] with needle adapter set.
  • Page 186: Power Source Voltage Inspection

    3-100 FUEL SYSTEM (DFI) Fuel Pump Power Source Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Remove the ignition coil cover (see Ignition Coil Removal in the Electrical System chapter). • Connect a digital voltmeter [A] to the fuel pump connector [B] (3P), using the needle adapter [C].
  • Page 187 FUEL SYSTEM (DFI) 3-101 Fuel Pump Fuel Pump Circuit (Other than Europe Models) 1. ECU 2. Engine Stop Switch 3. Ignition Switch 4. Ignition Fuse 10 A 5. ECU Fuse 15 A 6. Fuse Box 7. ECU Main Relay 8. Fuel Pump Relay 9.
  • Page 188 3-102 FUEL SYSTEM (DFI) Fuel Pump Fuel Pump Circuit (Europe Models) 1. ECU 2. Engine Stop Switch 3. Ignition Switch 4. Ignition Fuse 10 A 5. ECU Fuse 15 A 6. Fuse Box 7. ECU Main Relay 8. Fuel Pump Relay 9.
  • Page 189: Fuel Injectors

    FUEL SYSTEM (DFI) 3-103 Fuel Injectors CAUTION Never drop the injector, especially on a hard sur- face. Such a shock to the injector can damage it. Injector Removal WARNING Gasoline is extremely flammable and can be ex- plosive under certain conditions. Turn the ignition switch OFF.
  • Page 190: Injector Installation

    3-104 FUEL SYSTEM (DFI) Fuel Injectors • Unscrew the delivery joint bolts [A], and lift up the delivery joint [B] with the injectors [C]. • Remove the injectors from the delivery joint. Injector Installation ○ The front and rear injectors are the same. •...
  • Page 191: Injector Fuel Line Inspection

    FUEL SYSTEM (DFI) 3-105 Fuel Injectors Injector Fuel Line Inspection • Remove: Fuel Tank (see Fuel Tank Removal) Fuel Hose (see Fuel Hose Replacement in the Periodic Maintenance chapter) • Check the injector fuel line for leakage as follows: ○ Connect a commercially available vacuum/pressure pump [A] to the nipple of the delivery pipe [B] with a high-pressure fuel hose [C] (both ends connected with...
  • Page 192: Audible Inspection

    3-106 FUEL SYSTEM (DFI) Fuel Injectors Audible Inspection • Start the engine. • Insert a screwdriver from the engine right side between the fuel tank bottom end and the engine top end. • Apply the tip of a screwdriver [A] to the injector [B]. Put the grip end onto your ear, and listen whether the injector is clicking or not.
  • Page 193: Output Voltage Inspection

    FUEL SYSTEM (DFI) 3-107 Fuel Injectors Output Voltage Inspection • Turn the ignition switch OFF. • Remove the ECU (see ECU Removal). Do not disconnect the ECU connector. • Connect a digital voltmeter to the connector, using the needle adapter set. Special Tool - Needle Adapter Set: 57001-1457 Injector Output Voltage at ECU (Other than Europe Models [A])
  • Page 194: Injector Signal Test

    3-108 FUEL SYSTEM (DFI) 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 Terminal Thickness [C]: 0.8 mm CAUTION Do not use larger terminals than specified above.
  • Page 195: Injector Unit Test

    FUEL SYSTEM (DFI) 3-109 Fuel Injectors 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 Battery [D] CAUTION Be sure to connect the bulb in series.
  • Page 196 3-110 FUEL SYSTEM (DFI) Fuel Injectors Fuel Injector Circuit (Other than Europe Models) 1. ECU 2. Engine Stop Switch 3. Ignition Switch 4. Ignition Fuse 10 A 5. ECU Fuse 15 A 6. Fuse Box 7. ECU Main Relay 8. Fuel Pump Relay 9.
  • Page 197 FUEL SYSTEM (DFI) 3-111 Fuel Injectors Fuel Injector Circuit (Other than Europe Models) 1. ECU 2. Engine Stop Switch 3. Ignition Switch 4. Ignition Fuse 10 A 5. ECU Fuse 15 A 6. Fuse Box 7. ECU Main Relay 8. Fuel Pump Relay 9.
  • Page 198: Throttle Grip And Cables

    3-112 FUEL SYSTEM (DFI) Throttle Grip and Cables Throttle Grip Free Play Inspection • Refer to Throttle Control System Inspection in the Peri- odic 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 199: Throttle Body Assy

    FUEL SYSTEM (DFI) 3-113 Throttle Body Assy Idle Speed Inspection • Refer to Idle Speed Inspection in the Periodic Mainte- nance Chapter. Idle Speed Adjustment • Refer to Idle Speed Adjustment in the Periodic Mainte- nance Chapter. Throttle Bore Cleaning •...
  • Page 200 3-114 FUEL SYSTEM (DFI) Throttle Body Assy • Remove the screws and take off the right switch housing. • Remove the accelerator cable end [A] and decelerator cable end [B] at the throttle grip. • Disconnect the injector connectors [A]. •...
  • Page 201: Throttle Body Assy And Intake Manifold Installation

    FUEL SYSTEM (DFI) 3-115 Throttle Body Assy ○ Be careful not to damage (dent, nick, flaw, and crack) the flange mating surface and the plastic parts. ○ Do not drop the throttle body assy, especially on a hard surface. WARNING The throttle body assy should never be allowed to fall.
  • Page 202 3-116 FUEL SYSTEM (DFI) Throttle Body Assy • Before Installation, visually inspect the mating surfaces [A] for any damage, like dent, nick, rust, flaw, and crack. • Nick or rust damage can sometimes be repaired by using emery paper (first No. 200, then 400) to remove sharp edges or raised areas.
  • Page 203 FUEL SYSTEM (DFI) 3-117 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.
  • Page 204: Air Cleaner

    3-118 FUEL SYSTEM (DFI) Air Cleaner Air Cleaner Element Removal/Installation • Refer to the Air Cleaner Element Replacement in the Pe- riodic Maintenance chapter. Air Cleaner Housing Removal • Remove the air cleaner housing bolts [A]. • Clear the idle speed screw [A] from the recess on the air cleaner housing.
  • Page 205 FUEL SYSTEM (DFI) 3-119 Air Cleaner • Fit the idle speed screw [A] in the recess on the air cleaner housing. • Be sure the dampers [A] and collars [B] are in position. ○ Install the damper [A] into the air cleaner housing [C] as shown.
  • Page 206: Fuel Tank

    3-120 FUEL SYSTEM (DFI) 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 207 FUEL SYSTEM (DFI) 3-121 Fuel Tank • Remove: Seat (see Seat Removal in the Frame chapter) Fuel Tank Bolts [A] • Disconnect (California Model): Fuel Return Hose (Red) [A] • Unscrew the screw [A], and pull out the ignition coil cover [B].
  • Page 208 3-122 FUEL SYSTEM (DFI) Fuel Tank • Place a cloth around the fuel hose joint. • Insert a minus screw driver [A] into the slit on the joint lock [B]. • Turn the driver to disconnect the joint lock. • Pull [C] the fuel hose joint [D] out of the outlet pipe.
  • Page 209: Fuel Tank Installation

    FUEL SYSTEM (DFI) 3-123 Fuel Tank Fuel Tank Installation • Read the above WARNING. • Route the hoses correctly (see Cable, Wire and Hose Routing section in the Appendix chapter). • For California model, note the following: ○ To prevent the gasoline from flowing into or out of the canister, hold the separator perpendicular to the ground.
  • Page 210: Fuel Tank And Cap Inspection

    3-124 FUEL SYSTEM (DFI) Fuel Tank Fuel Tank and Cap Inspection • Visually inspect the gasket [A] on the tank cap for any damage. Replace the gasket if it is damaged. • Check to see if the breather pipe [B] in the tank is not clogged.
  • Page 211 FUEL SYSTEM (DFI) 3-125 Fuel Tank • 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 pressure of the spring [B]. NOTE ○...
  • Page 212: Evaporative Emission Control System

    3-126 FUEL SYSTEM (DFI) 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 213: Separator Operation Test

    FUEL SYSTEM (DFI) 3-127 Evaporative Emission Control System 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; this includes any appliance with a pilot light.
  • Page 214 3-128 FUEL SYSTEM (DFI) Evaporative Emission Control System 1. Fuel Tank 2. Throttle Body 3. Canister 4. Separator 5. Breather Check Valve 6. Breather Hose 7. Breather Hose (Blue) 8. Vacuum Hose (White) 9. Fuel Return Hose (Red) 10. Purge Hose (Green) 11.
  • Page 215 COOLING SYSTEM 4-1 Cooling System Table of Contents Exploded View........................Specifications ......................... Special Tools and Sealant ...................... Coolant Flow Chart......................... Coolant ........................... Coolant Deterioration Inspection..................Coolant Level Inspection....................Coolant Draining ....................... Coolant Filling ........................Pressure Testing ....................... Reserve Tank Removal..................... Water Pump..........................
  • Page 216: Exploded View

    4-2 COOLING SYSTEM Exploded View...
  • Page 217 COOLING SYSTEM 4-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Water Pump Impeller Bolt 87 in·lb Water Hose Fitting Bolts 87 in·lb Water (Radiator) Hose Clamp Screws 0.20 18 in·lb Thermostat Housing Cover Bracket Bolts 0.70 61 in·lb Thermostat Housing Cover Bolts 0.50 43 in·lb Radiator Bolts...
  • Page 218: Specifications

    4-4 COOLING SYSTEM Specifications Item Standard Service Limit Coolant Provided When Shipping Type 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% –...
  • Page 219: Special Tools And Sealant

    COOLING SYSTEM 4-5 Special Tools and Sealant Bearing Driver Set: Bearing Remover Head, 10 × 12: 57001-1129 57001-1266 Bearing Remover Shaft, 9: Kawasaki Bond (Silicone Sealant): 57001-1265 56019-120...
  • Page 220: Coolant Flow Chart

    4-6 COOLING SYSTEM Coolant Flow Chart...
  • Page 221 COOLING SYSTEM 4-7 Coolant Flow Chart 1. Thermostat 2. Radiator Cap 3. Cylinder Head Jacket 4. Radiator Fan 5. Radiator 6. Cylinder Jacket 7. Water Pump 8. Reserve Tank 9. Hot Coolant 10. Cold Coolant 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.
  • Page 222: Coolant

    4-8 COOLING SYSTEM 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 223: Reserve Tank Removal

    COOLING SYSTEM 4-9 Coolant Reserve Tank Removal • Remove: Left Side Cover (see Left Side Cover Removal in the Frame chapter) Bolt [A] Reserve Tank Cover [B] • Remove: Bolts [A] Cap [B] • Drain the coolant to the suitable container. •...
  • Page 224: Water Pump

    4-10 COOLING SYSTEM Water Pump Water Pump Impeller Removal • Drain: Engine Oil (see Engine Oil Change in the Periodic Main- tenance chapter) Coolant (see Coolant Change in the Periodic Mainte- nance chapter) • Remove: Right Engine Cover (see Right Engine Cover Removal in the Clutch chapter) Bolt [A] and Washer Impeller [B]...
  • Page 225 COOLING SYSTEM 4-11 Water Pump If the seal and ball bearing are damaged, replace the me- chanical seal, ball bearing, and oil seal by splitting the crankcase. • Split the crankcase (see Crankcase Splitting in the Crank- shaft/Transmission chapter). • Take the bearing [A] out of the right crankcase, using the bearing remover.
  • Page 226: Water Pump Inspection

    4-12 COOLING SYSTEM Water Pump Water Pump Inspection • Check the drainage outlet passage [A] at the bottom of the right crankcase for coolant leaks. If the mechanical seal is damaged, the coolant leaks through the seal and drains through the passage. Re- place the mechanical seal with a new one.
  • Page 227: Radiator, Radiator Fan

    COOLING SYSTEM 4-13 Radiator, Radiator Fan Radiator and Radiator Fan Removal WARNING The radiator fan is connected directly to the bat- tery. The radiator fan may start even if the ignition switch is off. NEVER TOUCH THE RADIATOR FAN UNTIL THE RADIATOR FAN CONNECTOR IS DIS- CONNECTED.
  • Page 228: Radiator Fan Installation

    4-14 COOLING SYSTEM Radiator, Radiator Fan • Remove: Radiator Fan Connector [A] Radiator • Remove: Radiator Fan Mounting Bolts [A] Radiator Fan [B] CAUTION Do not touch the radiator core. This could damage the radiator fins, resulting in loss of cooling effi- ciency.
  • Page 229: Radiator Cap Inspection

    COOLING SYSTEM 4-15 Radiator, Radiator Fan Radiator Cap Inspection • Check the condition of the top [A] and bottom [B] valve seals and valve spring [C]. If any one of them shows visible damage, replace the cap with a new one. •...
  • Page 230: Thermostat

    4-16 COOLING SYSTEM Thermostat Thermostat Removal • Drain: Coolant (about 200 mL) • Remove: Seat (see Seat Removal in the Frame chapter) Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Reserve Tank Hose [A] Radiator Hose Clamp [B] (Loosen) Water Temperature Connector [C] Bolt [D] •...
  • Page 231 COOLING SYSTEM 4-17 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 232: Hose And Pipes

    4-18 COOLING SYSTEM Hose and Pipes Hose Installation • Install the hoses and pipes being careful to follow bend- ing direction or diameter. Avoid sharp bending, kinking, flattening, or twisting. • Install the clamps [A] as near as possible to the hose end to clear the raised rib or the fitting.
  • Page 233: Water Temperature Sensor

    COOLING SYSTEM 4-19 Water Temperature Sensor Water Temperature Sensor Removal/Installation CAUTION The water temperature sensor should never be al- lowed to fall on a hard surface. Such a shock to water temperature sensor can damage it. • Refer to the Water Temperature Sensor Removal/Instal- lation in the Fuel System (DFI) chapter.
  • Page 235 ENGINE TOP END 5-1 Engine Top End Table of Contents Exploded View........................Exploded Veiw ........................Specifications ......................... Special Tools .......................... 5-11 Clean Air System........................5-13 Air Suction Valve Removal....................5-13 Air Suction Valve Installation..................... 5-13 Air Suction Valve Inspection ..................... 5-13 Air Switching Valve Removal ....................
  • Page 236 5-2 ENGINE TOP END Piston Wear ........................5-35 Piston/Cylinder Clearance ....................5-36 Piston Ring, Piston Ring Groove Wear................5-36 Piston Ring Groove Width....................5-36 Piston Ring Thickness ..................... 5-37 Piston Ring End Gap ......................5-37 Muffler............................. 5-38 Muffler Removal........................ 5-38 Muffler Installation......................
  • Page 237 ENGINE TOP END 5-3 Dummy Page...
  • Page 238: Exploded View

    5-4 ENGINE TOP END Exploded View...
  • Page 239 ENGINE TOP END 5-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Cylinder Head nuts(M10)(First) S, MO Cylinder Head nuts(M10)(Final) S, MO Cylinder Head nuts(M8) Camshaft Cap Bolts Cylinder Head Cover Bolts 106 in·lb Cylinder Head Outer Cover Bolts 87 in·lb Plug (PT1/4) Plug (PT1/2) EO: Apply oil.
  • Page 240 5-6 ENGINE TOP END Exploded View...
  • Page 241 ENGINE TOP END 5-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Muffler Mounting Bolts Muffler Mounting Nut Muffler Joint Clamp Bolt Exhaust Pipe Cover Clamp Bolts 0.70 61 in·lb Exhaust Pipe Cover Bolts 0.70 61 in·lb Exhaust Pipe Holder Nuts Camshaft Sprocket Bolts Camshaft Chain Tensioner Cap Bolts Camshaft Chain Guide Bolts...
  • Page 242: Exploded Veiw

    5-8 ENGINE TOP END Exploded Veiw Exhaust System UK: U.K Model FULL: Full Power H: Honeycomb Type Catalyst Silensor [A] without Boss [A] for Oxygen Sensor Silensor with Boss [B] for Oxygen Sensor...
  • Page 243: Specifications

    ENGINE TOP END 5-9 Specifications Item Standard Service Limit Camshafts Cam Height: Exhaust 35.030 35.144 mm (1.3791 1.3836 in.) 34.93 mm (1.375 in.) Inlet 35.302 35.416 mm (1.3898 1.3943 in.) 35.20 mm (1.386 in.) Camshaft Journal, Camshaft 0.028 0.071 mm (0.0011 0.0028 in.) 0.16 mm (0.0063 in.) Cap Clearance...
  • Page 244 5-10 ENGINE TOP END Specifications Item Standard Service Limit Cylinder, Piston Cylinder Inside Diameter 88.000 88.012 mm (3.4646 3.4650 in.) 88.10 mm (3.468 in.) Piston Diameter 87.955 87.970 mm (3.4628 3.4634 in.) 87.80 mm (3.457 in.) Piston/Cylinder Clearance 0.030 0.057 mm (0.0012 0.0022 in.) –...
  • Page 245: Special Tools

    ENGINE TOP END 5-11 Special Tools 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 Piston Pin Puller Assembly: Valve Seat Cutter, 45° - 30: 57001-910 57001-1187 Valve Seat Cutter, 45°...
  • Page 246 5-12 ENGINE TOP END Special Tools Valve Guide Arbor, 5: Spark Plug Wrench, Hex 16: 57001-1203 57001-1262 Valve Guide Reamer, 5: Compression Gauge Adapter, M10 × 1.0: 57001-1204 57001-1317 Valve Seat Cutter Holder, 5: Valve Seat Cutter, 60° - 33: 57001-1208 57001-1334 NOTE...
  • Page 247: Clean Air System

    ENGINE TOP END 5-13 Clean Air System Air Suction Valve Removal • Remove: Cylinder Head Covers (see Cylinder Head Cover Re- moval) Air Suction Valves [A] Air Suction Valve Installation • Install each air suction valve so that stopper side [A] of the reed faces downward.
  • Page 248: Clean Air System Hose Inspection

    5-14 ENGINE TOP END Clean Air System Clean Air System Hose Inspection • Be certain that all the hoses are routed without being flat- tened or kinked, and are connected correctly to the right air cleaner base, air switching valve, and fittings on the rocker case covers If they are not, correct them.
  • Page 249: Cylinder Head Cover

    ENGINE TOP END 5-15 Cylinder Head Cover Cylinder Head Cover Removal • Remove: Seat (see Seat Removal in the Frame chapter) Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) • Slide [A] the air switching valve [B] forward to clear the clamp.
  • Page 250: Cylinder Head Cover Installation

    5-16 ENGINE TOP END Cylinder Head Cover • Remove: Dampers [A] Cylinder Head Cover Bolts [B] and washers Cylinder Head Cover [C] Cylinder Head Cover Gasket ○ Just move everything that is between the cylinder head cover and the frame out of the may to make room. Then as a lift the cover up, make sure the spark plug pipe [A] stays all the way down in the cylinder head.
  • Page 251: Camshaft Chain Tensioner

    ENGINE TOP END 5-17 Camshaft Chain Tensioner Camshaft Chain Tensioner Removal • Remove: Engine (see Engine Removal/Installation chapter) Camshaft (see Camshaft Removal) Cylinder Head (see Cylinder Head Removal) • Remove the camshaft chain tensioner body from the cylinder. Camshaft Chain Tensioner Installation •...
  • Page 252: Camshaft, Camshaft Chain

    5-18 ENGINE TOP END Camshaft, Camshaft Chain Camshaft Removal • Remove: Cylinder Head Cover (see Cylinder Head Cover Re- moval) Ignition Coil Cover (For Front Cylinder)(see Ignition Coil Removal in the Electrical System chapter) Tensioner Cap Bolt [A], Washer [B] and Spring CAUTION Do not turn over the crankshaft while the tensioner cap bolt is removed, The tensioner body is loose...
  • Page 253: Camshaft Installation

    ENGINE TOP END 5-19 Camshaft, Camshaft Chain Camshaft Installation • Apply engine oil to all cam parts and journals. NOTE ○ The front and rear camshafts are different. The rear camshaft [A] has a groove [B]. • Remove: Alternator Outer Cover (see Alternator Outer Cover Re- moval in the Electrical System chapter) Bolts [A] Timing Inspection Plate [B]...
  • Page 254: Camshaft/camshaft Cap Wear

    5-20 ENGINE TOP END Camshaft, Camshaft Chain NOTE ○ Installing the rear camshaft is the same as for the front camshaft. But noting the following. • Set the rear piston at TDC. ○ Align the rear piston TDC mark [A] and timing mark [B] by turning the crankshaft counterclockwise [C] 305°...
  • Page 255: Camshaft Runout

    ENGINE TOP END 5-21 Camshaft, Camshaft Chain Camshaft Runout • Remove the camshaft (see Camshaft Removal). • Set the camshaft in a camshaft alignment jig or on V blocks. • Measure runout with a dial gauge at the specified place as shown.
  • Page 256: Camshaft And Sprocket Assembly

    5-22 ENGINE TOP END Camshaft, Camshaft Chain Camshaft and Sprocket Assembly • Clean the sprocket bolt [A] and threads of the camshaft. • Be sure to install the pin [B]. • Apply a non-permanent locking agent to the threads of the camshaft sprocket bolt, and tighten it.
  • Page 257: Rocker Shaft, Rocker Arm

    ENGINE TOP END 5-23 Rocker Shaft, Rocker Arm Rocker Shaft, Rocker Arm Removal • Remove: Cylinder Head Cover (see Cylinder Head Cover Re- moval) Camshaft Cap (see Camshaft Removal) Rocker Shafts [A] Rocker Arms [B] and Springs [C] Rocker Shaft, Rocker Arm Installation •...
  • Page 258: Cylinder Head

    5-24 ENGINE TOP END Cylinder Head Cylinder Compression Measurement NOTE ○ Use the battery which is fully charged. • Warm up the engine thoroughly. • Stop the engine. • Remove: Seat (see Seat Removal in the Frame chapter) Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Spark Plugs Special Tool - Spark Plug Wrench, Hex 16: 57001-1262...
  • Page 259: Cylinder Head Removal

    ENGINE TOP END 5-25 Cylinder Head Cylinder Head Removal • Remove: Engine (see Engine Removal in the Engine Removal/In- stallation chapter) Camshaft (see Camshaft Removal) • Remove the cylinder head nuts following sequence [1 • Remove: Cylinder Head Cylinder Head Installation NOTE ○...
  • Page 260: Valves

    5-26 ENGINE TOP END Valves Valve Clearance Inspection • Refer to the Valve Clearance Inspection in the Periodic Maintenance chapter. Valve Clearance Adjustment • Refer to the Valve Clearance Adjustment in the Periodic Maintenance chapter. Valve Removal • Remove the cylinder head (see Cylinder Head Removal). •...
  • Page 261: 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) (see Valve Guide Removal). • Drive the valve guide in from the top of the head using the valve guide arbor [A].
  • Page 262: Valve Seat Inspection

    5-28 ENGINE TOP END 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 263 ENGINE TOP END 5-29 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 264 5-30 ENGINE TOP END Valves • Measure the outside diameter (O.D.) of the seating sur- face with a vernier caliper. If the outside diameter of the seating surface is too small, repeat the 45° grind [A] until the diameter is within the specified range.
  • Page 265 ENGINE TOP END 5-31 Valves • Lap the valve to the seat, once the seat width and O.D. are within the ranges specified above. ○ Put a little coarse grinding compound on the face of the valve in a number of places around the valve head. ○...
  • Page 266 5-32 ENGINE TOP END Valves...
  • Page 267: Cylinders, Pistons

    ENGINE TOP END 5-33 Cylinders, Pistons Cylinder Removal • Drain the coolant (see Coolant Change in the Periodic Maintenance chapter). • Remove the cylinder head (see Cylinder Head Removal). • Pull out the front camshaft chain guide [A] and oil pipe [B]. •...
  • Page 268 5-34 ENGINE TOP END Cylinders, Pistons • 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 •...
  • Page 269: Cylinder Wear

    ENGINE TOP END 5-35 Cylinders, Pistons NOTE ○ If a new piston or cylinder is used, check piston to cylin- der clearance (see Piston/Cylinder Clearance), and use new piston ring. • Replace the cylinder base gasket with a new one. •...
  • Page 270: Piston/cylinder Clearance

    5-36 ENGINE TOP END Cylinders, Pistons Piston/Cylinder Clearance • Subtract the piston diameter from the cylinder inside di- ameter to get the piston/cylinder clearance. Piston/Cylinder Clearance Standard: 0.030 0.057 mm (0.0012 0.0022 in.) If the piston/cylinder clearance is less than the specified range, use a smaller piston or increase the cylinder inside diameter by honing.
  • Page 271: Piston Ring Thickness

    ENGINE TOP END 5-37 Cylinders, Pistons Piston Ring Thickness • Measure the piston ring thickness. ○ Use a micrometer to measure at several points around the ring. Piston Ring Thickness Standard: Top and Second 0.97 0.99 mm (0.038 0.039 in.) Service Limit: Top and Second 0.90 mm (0.035 in.) If any of the measurements is less than the service limit...
  • Page 272: Muffler

    5-38 ENGINE TOP END Muffler Muffler Removal • Remove: Clamp Screws (Loosen) [A] Bolt [B] Rear Muffler Cover [C] • Remove: Clamp Screws (Loosen) [A] Bolt [B] Front Muffler Cover [C] • Remove: Muffler Mounting Nut [A], Collar and Damper Muffler Mounting Bolt [B] •...
  • Page 273: Muffler Installation

    ENGINE TOP END 5-39 Muffler • Remove: Rear Exhaust Holder Nuts [A] • Remove the upper and lower muffler jointed. Muffler Installation • Joint the upper and lower muffler. • Temporary tighten the muffler joint clamp bolt [A]. • Install the muffler. •...
  • Page 275 CLUTCH 6-1 Clutch Table of Contents Exploded View........................Specifications ......................... Special Tool ..........................Clutch Lever and Cable ......................Clutch Lever Free Play Inspection ..................Clutch Lever Free Play Adjustment .................. Clutch Cable Removal ...................... Clutch Cable Installation ....................Cable Lubrication ......................Clutch Lever Installation....................
  • Page 276: Exploded View

    6-2 CLUTCH Exploded View...
  • Page 277 CLUTCH 6-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Right Engine Cover Bolts 87 in·lb L (1) Clutch Hub Nut 13.2 95.9 Clutch Spring Bolts 87 in·lb CL: Apply cable lubricate. EO: Apply engine oil. G: Apply grease. L: Apply a non-permanent locking agent. MO: Apply molybdenum disulfide oil.
  • Page 278: Specifications

    6-4 CLUTCH Specifications Item Standard Service Limit Clutch Lever Free Play 3 mm (0.08 0.12 in.) Clutch Friction Plate Thickness 3.1 mm (0.114 0.122 in.) 2.8 mm (0.110 in.) Friction and Steel Plate Warp 0.2 mm (0.008 in.) or less 0.3 mm (0.01 in.) Clutch Spring Free Length 33.6 mm (1.32 in.)
  • Page 279: Special Tool

    CLUTCH 6-5 Special Tool Clutch Holder: 57001-1243...
  • Page 280: Clutch Lever And Cable

    6-6 CLUTCH Clutch Lever and Cable Clutch Lever Free Play Inspection • Refer to the Clutch Operation Inspection in the Periodic Maintenance chapter. Clutch Lever Free Play Adjustment • Refer to the Clutch Operation Inspection in the Periodic Maintenance chapter. Clutch Cable Removal •...
  • Page 281: Clutch Lever Installation

    CLUTCH 6-7 Clutch Lever and Cable Clutch Lever Installation • Install the clutch lever so that the mating surface [A] of the lever holder is aligned with the punch mark [B] of the handlebar.
  • Page 282: Right Engine Cover

    6-8 CLUTCH Right Engine Cover Right Engine Cover Removal • Drain: Engine Oil (see Engine Oil Change in the Periodic Main- tenance chapter) Coolant (see Coolant Change in the Periodic Mainte- nance chapter) • Remove: Brake Pedal (see Brake Pedal Removal in the Brakes chapter) Right Footboard (see Footboard Removal/Installation in the Frame chapter)
  • Page 283: Release Shaft Removal

    CLUTCH 6-9 Right Engine Cover Release Shaft Removal CAUTION Do not remove the clutch release lever and shaft assembly unless it is absolutely necessary. If re- moved, the oil seal replacement may be required. • Remove the right engine cover (see Right Engine Cover Removal).
  • Page 284: Clutch Removal

    6-10 CLUTCH Clutch Clutch Removal • Remove: Right Engine Cover (see Right Engine Cover Removal) Clutch Spring Bolts [A] Clutch Springs Clutch Spring Plate [B] (with thrust bearing and pusher [C]) • Remove: Friction Plates, Steel Plates Clutch Hub Nut [A] •...
  • Page 285: Clutch Plate, Wear, Damage Inspection

    CLUTCH 6-11 Clutch • Install the washer so that the OUTSIDE mark [A] faces outward. • Replace the clutch hub nut with a new one. • Apply molybdenum disulfide oil to seating surface of the hub nut. • Holding the clutch hub, tighten the clutch hub nut. Special Tool - Clutch Holder: 57001-1243 Torque - Clutch Hub Nut: 130 N·m (13.3 kgf·m, 95.9 ft·lb) •...
  • Page 286: Clutch Plate Warp Inspection

    6-12 CLUTCH Clutch Clutch Plate Warp Inspection • Place each friction plate or steel plate on a surface plate and measure the gap between the surface plate [A] and each friction plate or steel plate [B] with a thickness gauge [C].
  • Page 287 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 Change ....................... Oil Screen Cleaning ......................Oil Pressure Relief Valve......................
  • Page 288: Exploded View

    7-2 ENGINE LUBRICATION SYSTEM Exploded View...
  • Page 289 ENGINE LUBRICATION SYSTEM 7-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Engine Oil Drain Plug Oil Pump Cover Bolts 87 in·lb Oil Pump Drive Chain Guide Bolt 87 in·lb Oil Filter Oil Filter Plate Bolts 0.80 69 in·lb Oil Screen Plug Oil Pressure Relief Valve Oil Pressure Switch Oil Pressure Switch Adapter...
  • Page 290: Engine Oil Flow Chart

    7-4 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart 1. Rocker Arm 5. Oil Screen 9. Oil Filter 2. Oil Pipe 6. Oil Pump 10. Oil Pressure Relief Valve 3. Output Shaft 7. Crankshaft 4. Drive Shaft 8. Oil Pressure Switch...
  • Page 291: Specifications

    ENGINE LUBRICATION SYSTEM 7-5 Specifications Item Standard Engine Oil Type API SE, SFor SG API SH, SJ or SL with JASO MA Viscosity SAE 10W-40 Capacity 3.0 L (3.2 us qt) (when filter is not removed) 3.2 L (3.4 us qt) (when filter is removed) 3.7 L (3.9 us qt) (when engine is completely dry) Level (After warm-up or driving) Between upper and lower level lines...
  • Page 292: Special Tools And Sealant

    7-6 ENGINE LUBRICATION SYSTEM Special Tools and Sealant Oil Pressure Gauge, 10 kgf/cm²: Kawasaki Bond (Silicone Sealant): 57001-164 56019-120 Oil Pressure Gauge Adapter, M10 × 1.25: 57001-1182...
  • Page 293: Engine Oil And Oil Filter

    ENGINE LUBRICATION SYSTEM 7-7 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] level lines next to the gauge [C].
  • Page 294 7-8 ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter • Pull out the oil screen [A]. • Clean the screen with high flash-point solvent. WARNING Clean the screen in a well-ventilated area, and take care that there is no spark or frame anywhere near the working area.
  • Page 295: Oil Pressure Relief Valve

    ENGINE LUBRICATION SYSTEM 7-9 Oil Pressure Relief Valve Oil Pressure Relief Valve Removal/Installation • Split the crankcase (see Crankcase Splitting in the Crank- shaft/Transmission chapter). • Remove the relief valve [A] from the right crankcase. • Apply a non-permanent locking agent to the threads of the relief valve, and tighten it.
  • Page 296: Oil Pump, Oil Pump Drive Chain

    7-10 ENGINE LUBRICATION SYSTEM Oil Pump, Oil Pump Drive Chain Oil Pump Removal • Split the crankcase (see Crankcase Splitting in the Crank- shaft/Transmission chapter). • Remove: Water Pump Impeller (see Water Pump Impeller Re- moval in the Cooling System chapter) Crankshaft (see Crankshaft Removal in the Crank- shaft/Transmission chapter) Oil Pipes (see Oil Pipe (Crankcase Inside) Removal)
  • Page 297: Oil Pump Drive Chain Guide Installation

    ENGINE LUBRICATION SYSTEM 7-11 Oil Pump, Oil Pump Drive Chain Oil Pump Drive Chain Guide Installation • Install the chain guide [A] to the left crankcase. • Apply a non-permanent locking agent to the threads of the chain guide bolt [B], and tighten it. Torque - Oil Pump Drive Chain Guide Bolt: 9.8 N·m (1.0 kgf·m, 87 in·lb)
  • Page 298: Oil Pressure Measurement

    7-12 ENGINE LUBRICATION SYSTEM Oil Pressure Measurement Oil Pressure Measurement • Remove: • Regulator/Rectifier (see Regulator/Rectifier Removal in the Electrical System chapter) • Remove the oil pressure switch together with the adapter (see Oil Pressure Switch Removal) without draining the engine oil.
  • Page 299: Oil Pressure Switch

    Oil Pressure Switch Installation • 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) • Tighten the terminal bolt securely.
  • Page 300: Oil Pipe And Oil Hose

    7-14 ENGINE LUBRICATION SYSTEM Oil Pipe and Oil Hose Oil Pipe (Crankcase Outside) Removal • Remove: Alternator Cover (see Alternator Cover Removal in the Electrical System chapter) Oil Pipe Mounting Bolts [A] Oil Pipe [B] Oil Pipe (Crankcase Outside) Installation •...
  • Page 301: Blowby Gas System Inspection

    ENGINE LUBRICATION SYSTEM 7-15 Oil Pipe and Oil Hose • Install the oil return pipe [A]. • Tighten: Torque - Oil Return Pipe Bolts [B]: 9.8 N·m (1.0 kgf·m, 87 in·lb) Blowby Gas System Inspection • Remove: Ignition Coil with the bracket (see Ignition Coil Removal in the Electrical System chapter) •...
  • Page 303 ENGINE REMOVAL/INSTALLATION 8-1 Engine Removal/Installation Table of Contents Exploded View........................Special Tool ..........................Engine Removal/Installation ....................Engine Removal........................ Engine Installation......................
  • Page 304: Exploded View

    8-2 ENGINE REMOVAL/INSTALLATION Exploded View...
  • Page 305 ENGINE REMOVAL/INSTALLATION 8-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Engine Mounting Nuts Engine Mounting Bracket Bolts (M10) Engine Mounting Bracket Bolts (M8) Downtube Mounting Bolts WL: Apply a soap and water solution.
  • Page 306: Special Tool

    8-4 ENGINE REMOVAL/INSTALLATION Special Tool Jack: 57001-1238...
  • Page 307: Engine Removal/installation

    ENGINE REMOVAL/INSTALLATION 8-5 Engine Removal/Installation Engine Removal • Drain: Engine Oil (see Engine Oil Change in the Periodic Main- tenance chapter) Coolant (see Coolant Change in the Periodic Mainte- nance chapter) • Remove: Seat (see Seat Removal in the Frame chapter) Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Muffler (see Muffler Removal in the Engine Top End...
  • Page 308 8-6 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Remove: Speed Sensor Connector [A] • Remove: Water Temperature sensor Connector [A] Water Hoses [B] Thermostat Housing Cover Bracket Bolt [C] • Remove: Cap [A] and Bolt Ignition Switch [B] • Disconnect: Alternator Lead Connector [A] •...
  • Page 309 ENGINE REMOVAL/INSTALLATION 8-7 Engine Removal/Installation • Support the frame with the jack. Special Tool - Jack: 57001-1238 • 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 310: Engine Removal

    8-8 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation Engine Installation • When installing the rubber dampers into the bracket, lu- bricate the outer surface of the dampers with a soap and water solution. CAUTION Do not lubricate the rubber damper with engine oil or petroleum distillates because they will deterio- rate the rubbers.
  • Page 311 CRANKSHAFT/TRANSMISSION 9-1 Crankshaft/Transmission Table of Contents Exploded View........................Specifications ......................... Special Tools and Sealants ....................Crankcase Splitting......................... Crankcase Splitting ......................Crankcase Assembly ......................9-10 Crankshaft/Connecting Rods....................9-13 Crankshaft Removal ......................9-13 Crankshaft Installation ...................... 9-13 Connecting Rod Removal ....................9-13 Connecting Rod Installation ....................
  • Page 312: Exploded View

    9-2 CRANKSHAFT/TRANSMISSION Exploded View...
  • Page 313 CRANKSHAFT/TRANSMISSION 9-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Crankcase Bolts (M6) 87 in·lb Crankcase Bolts (M10) Connecting Rod Big End Bolts Primary Gear Bolt Balancer Gear Bolt Starter Motor Clutch Gear Bolt Balancer Shaft Bearing Stopper Plate Bolts 87 in·lb Bearing Retainer Bolts 87 in·lb...
  • Page 314 9-4 CRANKSHAFT/TRANSMISSION Exploded View...
  • Page 315 CRANKSHAFT/TRANSMISSION 9-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Shift Drum Cam Bolt 106 in·lb Rear Shift Lever Clamp Bolt 106 in·lb Shift Return Spring Pin Shift Drum Position Lever Bolt 87 in·lb Shift Pedal Clamp Bolt 106 in·lb Shift Rod Locknut (Front) 87 in·lb Shift Rod Locknut (Rear)
  • Page 316: Specifications

    9-6 CRANKSHAFT/TRANSMISSION Specifications Item Standard Service Limit Crankshaft, Connecting Rods Connecting Rod Big End Side Clearance 0.08 0.3 mm 0.5 mm (0.003 0.01 in.) (0.02 in.) 0.026 0.054 mm 0.09 mm Connecting Rod Big End Bearing Insert/Crankpin Clearance (0.0010 0.0021 in.) (0.035 in.) Crankpin Diameter: 42.984...
  • Page 317 CRANKSHAFT/TRANSMISSION 9-7 Specifications Item Standard Service Limit Crankshaft Main Journal Diameter 44.984 45.000 mm 44.96 mm (1.7710 1.7716 in.) (1.770 in.) Crankcase Main Bearing Bore Diameter 45.025 mm 45.041 mm 45.07 mm (1.7726 1.7733 in.) (1.774 in.) Transmission Shift Fork Ear Thickness 5.0 mm 4.8 mm (0.193...
  • Page 318: Special Tools And Sealants

    9-8 CRANKSHAFT/TRANSMISSION Special Tools and Sealants Outside Circlip Pliers: Rotor Holder: 57001-144 57001-1674 Bearing Driver Set: Kawasaki Bond (Silicone Sealant): 57001-1129 92104-0004 Grip: Kawasaki Bond (Liquid Gasket - Black): 57001-1591 92104-1064...
  • Page 319: Crankcase Splitting

    CRANKSHAFT/TRANSMISSION 9-9 Crankcase Splitting Crankcase Splitting • Remove the engine (see Engine Removal in the Engine Removal/Installation chapter). • Set the engine on a clean surface and hold the engine steady while parts are being removed. • Remove: Starter Motor (see Starter Motor Removal in the Electri- cal System chapter) Oil Filter (see Oil Filter Replacement in the Periodic Maintenance chapter)
  • Page 320: Crankcase Assembly

    9-10 CRANKSHAFT/TRANSMISSION Crankcase Splitting • Put the engine so that the left crankcase is down. • Pry the points [A] to split the crankcase halves apart, and remove the right crankcase half. ○ Tap lightly around the crankcase joint with a plastic mallet, and split the crankcase.
  • Page 321 Crankcase Splitting • Apply liquid gasket [A] to the mating surface of the right crankcase half. Sealant - Kawasaki Bond (Liquid Gasket - Black): 92104 -1064 CAUTION Do not apply liquid gasket to the oil passage [B] and hole [C].
  • Page 322 9-12 CRANKSHAFT/TRANSMISSION Crankcase Splitting • Apply silicone sealant to the crankcace mating surface [A] as shown. Sealant - Kawasaki Bond (Silicon Sealant): 92104-0004...
  • Page 323: Crankshaft/connecting Rods

    CRANKSHAFT/TRANSMISSION 9-13 Crankshaft/Connecting Rods Crankshaft Removal • Split the crankcase (see Crankcase Splitting). • Remove the crankshaft. Crankshaft Installation • Insert the crankshaft tapered end in to the left crankcase [A]. • Install the left connecting rod [B] into the rear cylinder opening [C], and right connecting rod [D] into the front cylinder opening [E].
  • Page 324: Crankshaft/connecting Rod Cleaning

    9-14 CRANKSHAFT/TRANSMISSION Crankshaft/Connecting Rods ○ When installing the inserts [A], be careful not to damage the insert surface with the edge of the connecting rod [B] or the cap [C]. One way to install inserts is as follows: Installation [D] to Cap Installation [E] to Connecting Rod Push [F] Dowel Pin [G]...
  • Page 325: Connecting Rod Bend

    CRANKSHAFT/TRANSMISSION 9-15 Crankshaft/Connecting Rods Connecting Rod Bend • Remove the connecting rod big end bearing insets, and reinstall the connecting rod big end cap. • Select an arbor [A] of the same diameter as the connect- ing rod big end, and insert the arbor through the connect- ing rod big end.
  • Page 326 9-16 CRANKSHAFT/TRANSMISSION Crankshaft/Connecting Rods If clearance is within the standard, no bearing replace- ment is required. If clearance is between 0.054 mm (0.0021 in.) and the service limit (0.09 mm, 0.035 in.), replace the bear- ing inserts [A] with inserts painted blue [B]. Check insert/crankpin clearance with the plastigage.
  • Page 327: Crankshaft Side Clearance

    CRANKSHAFT/TRANSMISSION 9-17 Crankshaft/Connecting Rods • Select the proper bearing insert [A] in accordance with the combination of the connecting rod and crankshaft coding. Size Color [B] Connecting Rod Big End Bearing Insert Selection Con-rod Big End Crankpin Bearing Insert Bore Diameter Diameter Size Color Part Number...
  • Page 328: Crankshaft Main Bearing/main Journal Wear

    9-18 CRANKSHAFT/TRANSMISSION Crankshaft/Connecting Rods Crankshaft Main Bearing/Main Journal Wear • Measure the diameter [A] of the crankshaft main journal. If any journal has worn past the service limit, replace the crankshaft with a new one. Crankshaft Main Journal Diameter Standard: 44.984 45.000 mm (1.7710 1.7716 in.) Service Limit: 44.96 mm (1.770 in.) •...
  • Page 329: Balancer, Starter Motor Clutch

    CRANKSHAFT/TRANSMISSION 9-19 Balancer, Starter Motor Clutch Left Balancer Removal • Remove the alternator cover (see Alternator Cover Re- moval in the Electrical System chapter). • Wipe oil off the outer circumference of the alternator rotor. • Hold the alternator rotor steady with the rotor holder [A], and remove the balancer gear bolt [B] and washer [C].
  • Page 330: Right Balancer And Starter Motor Clutch Installation

    9-20 CRANKSHAFT/TRANSMISSION Balancer, Starter Motor Clutch • Remove: Starter Motor Clutch Gear Bolt [A] Washers [B] • Remove: Starter Motor Clutch Gear [A] Torque Limiter [B] Needle Bearing [C] Collar [D] Starter Motor Clutch Assembly [E] Washer If the assembly is hard to remove, use a suitable puller. •...
  • Page 331: Starter Motor Clutch Inspection

    CRANKSHAFT/TRANSMISSION 9-21 Balancer, Starter Motor Clutch • Install: Torque Limiter Washer Collar [A] and Needle Bearing [B] • Install the starter motor clutch gear [C] while turning [D] the gear. • Install the alternator rotor (see Alternator Rotor Installa- tion in the Electrical System chapter). •...
  • Page 332: Torque Limiter

    9-22 CRANKSHAFT/TRANSMISSION Torque Limiter Torque Limiter Removal • Remove: Right Engine Cover (see Right Engine Cover Removal in the Clutch chapter) Washer [A] Starter Motor Clutch Gear [B] (see Right Balancer and Starter Motor Clutch Removal) Torque Limiter [C] CAUTION Do not disassemble the torque limiter.
  • Page 333: Primary Gear

    CRANKSHAFT/TRANSMISSION 9-23 Primary Gear Primary Gear Removal • Remove the alternator cover (see Alternator Cover Re- moval in the Electrical System chapter). • Wipe oil off the outer circumference of the alternator rotor. • Hold the alternator rotor steady with the rotor holder [A]. Special Tools - Rotor Holder: 57001-1674 Grip [B]: 57001-1591 ○...
  • Page 334: Transmission

    9-24 CRANKSHAFT/TRANSMISSION Transmission Shift Pedal Removal • Remove: Shift Pedal Clamp Bolt [A] • Remove: Footboard Bracket Bolts [A] Footboard [B] together with the Shift Pedal [C] • Separate the shift pedal from the footboard. Shift Pedal Installation • Apply grease to the shift pedal shaft. •...
  • Page 335: External Shift Mechanism Installation

    CRANKSHAFT/TRANSMISSION 9-25 Transmission • Remove: Front and Rear Shift Levers [A] • Remove: Bolts [A] External Shift Mechanism Cover [B] together with the Shift Shaft [C] ○ Remove the these bolts [D] with the cover. • Remove: Bolt [A] Spring [B] Gear Set Lever [C] External Shift Mechanism Installation •...
  • Page 336: External Shift Mechanism Inspection

    9-26 CRANKSHAFT/TRANSMISSION Transmission • Install the front shift lever [A] to the shift pedal shaft so that the punched mark [B] on the shaft is aligned with the punched marked [C] on the front shift lever. • Install the rear shift lever [A] on the shift shaft so that the punched mark [B] on the shaft is aligned with the punched mark [C] on the rear shift lever.
  • Page 337: Transmission Shaft And Shift Fork Removal

    CRANKSHAFT/TRANSMISSION 9-27 Transmission • Check the return spring pin [A] is not loose. If it is loose, unscrew it, apply a non-permanent locking agent to the threads, and tighten it. Torque - Shift Shaft Return spring Pin: 29 N·m (3.0 kgf·m, 21 ft·lb) •...
  • Page 338: Transmission Shaft Assembly

    9-28 CRANKSHAFT/TRANSMISSION Transmission Transmission Shaft Assembly • Install the 5th gear [A] on the output shaft with its oil hole [B] aligned with the shaft oil hole [C]. • Fit the steel balls into the 4th gear holes as shown. (This illustration shows "section A-A"...
  • Page 339: Shift Drum Installation

    CRANKSHAFT/TRANSMISSION 9-29 Transmission Shift Drum Installation • While aligning the shift drum cam [A] with the left crankcase hole, install the shift drum. • Tighten: Torque - Shift Drum Bearing Stopper Bolts 9.8 N·m (1.0 kgf·m, 87 in·lb) Shift Drum Disassembly •...
  • Page 340 9-30 CRANKSHAFT/TRANSMISSION Transmission 1. Drive Shaft 9. Thrust Washer (20 × 41 × 1) 2. Output Shaft 10. Circlip 3. 1st Gear 11. Thrust Washer (25.3 × 30 × 1) 4. 2nd Gear 12. Circlip 5. 3rd Gear 13. Toothed Washer 6.
  • Page 341: Shift Drum Assembly

    CRANKSHAFT/TRANSMISSION 9-31 Transmission Shift Drum Assembly • Assemble: Dowel Pin (Shorter) [A] Shift Drum Holder [B] Spring [C] Circlip [D] Special Tool - Outside Circlip Pliers: 57001-144 • Assemble: Dowel Pin (Longer) [E] Bearing [F] Shift Drum Cam [G] Shift Drum [I] •...
  • Page 342: Gear Dog And Gear Dog Hole Damage

    9-32 CRANKSHAFT/TRANSMISSION Transmission Gear Dog and Gear Dog Hole Damage • Visually inspect the gear dogs [A] and gear dog holes [B]. Replace any damaged gears or gears with excessively worn dogs or dog holes.
  • Page 343: Ball Bearing And Oil Seal

    CRANKSHAFT/TRANSMISSION 9-33 Ball Bearing and Oil Seal Bearing and Oil Seal Installation • When installing a bearing other than the following parts, press it in with the marked side facing out. Special Tool - Bearing Driver Set: 57001-1129 Right Crankcase •...
  • Page 345 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 ....................10-7 Rear Wheel Removal......................10-7 Rear Wheel Installation..................... 10-9 Rim and Spokes Removal ....................10-11 Rim and Spokes Installation .....................
  • Page 346: Exploded View

    10-2 WHEELS/TIRES Exploded View...
  • Page 347 WHEELS/TIRES 10-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Axle Nut 11.0 79.7 Front Axle Clamp Bolt Rear Axle Nut 11.0 79.7 Spoke Nipples 0.53 46 in·lb 5. Axle Cap (Europe Models) G: Apply grease. R: Replacement Parts WL: Apply sorp and water solution or rubber lubricant.
  • Page 348: Specifications

    10-4 WHEELS/TIRES Specifications Item Standard Service Limit Wheels (Rims) Rim Runout: Radial TIR 0.8 mm (0.03 in.) 2.0 mm (0.079 in.) Axial 0.8 mm (0.03 in.) 2.0 mm (0.079 in.) Axle Runout/100 mm (3.94 in.) Front less than 0.05 mm (0.002 in.) 0.2 mm (0.008 in.) Rear less than 0.03 mm (0.001 in.)
  • Page 349: Special Tools

    WHEELS/TIRES 10-5 Special Tools Rim Protector: Bearing Remover Shaft, 9: 57001-1063 57001-1265 Bead Breaker Assembly: Bearing Remover Head, 15 × 17: 57001-1072 57001-1267 Bearing Driver Set: Bearing Remover Head, 20 × 22: 57001-1129 57001-1293 Jack: 57001-1238...
  • Page 350: Wheels (rims)

    10-6 WHEELS/TIRES Wheels (Rims) Front Wheel Removal • Unscrew the front brake caliper mounting bolts [A] and remove the brake caliper [B] with the brake hose installed. • For the Europe Models, remove the axle caps. • Loosen: Front Axle Clamp Bolt [A] Front Axle [B] •...
  • Page 351: Front Wheel Installation

    WHEELS/TIRES 10-7 Wheels (Rims) Front Wheel Installation • Apply grease to the seal lips. • Fit the collars [A] on the both side of the hub. The collars are identical. • Insert the axle from the right side of the wheel. •...
  • Page 352 10-8 WHEELS/TIRES Wheels (Rims) • Squeeze the brake lever slowly and hold it with a band [A]. CAUTION Be sure to hold the front brake when removing the rear wheel, or the motorcycle may fall over. The motorcycle could be damaged. WARNING Be sure to hold the front brake when removing the rear wheel, or the motorcycle may fall over.
  • Page 353: Rear Wheel Installation

    WHEELS/TIRES 10-9 Wheels (Rims) • Place the suitable stand (about 30 mm (1.2 in.) thickness) [A] under the rear tire. • Reduce the jack until the rear axle shaft pull out easily, and remove the axle shaft. • Incline the rear wheel to the right diagonally. •...
  • Page 354 10-10 WHEELS/TIRES Wheels (Rims) • Install the rear wheel so that the grove [A] of the caliper bracket fit onto the swingarm stop [B]. • Reduce the jack until the rear axle install easily. • Engage the drive belt [A] with the pully [B]. •...
  • Page 355: Rim And Spokes Removal

    WHEELS/TIRES 10-11 Wheels (Rims) Rim and Spokes Removal • Remove the tire and tube. • Remove the rubber band. • Tape or wire all the spokes intersections so that the spokes don’t get mixed up, and unscrew the nipples from all the spokes with a screwdriver, separate the rim from the spokes and hub.
  • Page 356: Balance Inspection

    10-12 WHEELS/TIRES Wheels (Rims) Balance Inspection • Remove the wheel. • 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. ○ Repeat this procedure several times. If the wheel stops of its own accord in various positions, it is well balanced.
  • Page 357: Tires

    WHEELS/TIRES 10-13 Tires Air Pressure Inspection/Adjustment • Refer to the Tire Air Pressure Inspection in the Periodic Maintenance chapter. Tire Tread Inspection • Refer to the Tire Tread Wear Inspection in the Periodic Maintenance chapter. Tire Removal CAUTION Do not lay the wheel on the ground with the disc facing down.
  • Page 358: Tire Installation

    10-14 WHEELS/TIRES Tires Tire Installation WARNING Use the same manufacture’s tires on both front and rear wheels. • Check the tire rotation mark [A] on the front/rear tire and install it on the rim accordingly. NOTE ○ The direction of the tire rotation is shown by an arrow on the tire sidewall.
  • Page 359: Hub Bearing

    WHEELS/TIRES 10-15 Hub Bearing Hub Bearing Removal • Remove the wheel, and take out the following. CAUTION Do not lay the wheel on the ground with the disc facing down. This can damage or warp the disc. Place blocks under the wheel so that the disc does not touch the ground.
  • Page 360: Hub Bearing Inspection

    10-16 WHEELS/TIRES Hub Bearing • Replace the grease seals with new ones. • Press in the grease seal [A] so that the seal surface is flush [B] with the end of the hole. ○ Apply high temperature grease to the grease seal lips. Special Tool - Bearing Driver Set: 57001-1129 [C] Hub Bearing Inspection ○...
  • Page 361 FINAL DRIVE 11-1 Final Drive Table of Contents Exploded View........................11-2 Specifications ......................... 11-4 Special Tools .......................... 11-5 Drive Belt ..........................11-6 Belt Handling Precautions....................11-6 Drive Belt Wear Inspection ....................11-7 Drive Belt Deflection Inspection ..................11-7 Drive Belt Deflection Adjustment ..................11-7 Drive Belt Removal ......................
  • Page 362: Exploded View

    11-2 FINAL DRIVE Exploded View...
  • Page 363 FINAL DRIVE 11-3 Exploded View Front Gear Case Torque Fastener Remarks N·m kgf·m ft·lb Rear Pulley Mounting Nuts Rear Pulley Plate Bolts 0.70 61 in·lb Engine Pulley Mounting Nut 13.0 93.7 Engine Pulley Plate Bolts 87 in·lb Engine Pulley Cover Bolts 87 in·lb Engine Pulley Cover Clamp Mounting Bolt 87 in·lb...
  • Page 364: Specifications

    11-4 FINAL DRIVE Specifications Item Standard Service Limit Drive Belt Make GATES, 153T – – – Belt Deflection (45 N, 4.6 kgf, 10 lb force) 4.0 mm (0.059 0.16 in.) – – – (When installing new belt or engine is 1.5 mm (0.059 in.) –...
  • Page 365: Special Tools

    FINAL DRIVE 11-5 Special Tools Inside Circlip Pliers: Pulley Holder: 57001-143 57001-1572 Oil Seal & Bearing Remover: Grip: 57001-1058 57001-1591 Bearing Driver Set: 57001-1129...
  • Page 366: Drive Belt

    11-6 FINAL DRIVE Drive Belt The drive belt must be checked, and adjusted in accor- dance with the Periodic Maintenance Chart for safety and to prevent excessive wear. If the belt becomes badly worn or maladjusted-either too loose or too tight-the belt could jump off the pulley or break.
  • Page 367: Drive Belt Wear Inspection

    FINAL DRIVE 11-7 Drive Belt • Do not twist [A] the drive belt [B] as shown. ○ This includes coiling the belt to make it smaller for pack- aging. • Do not use tools [A] to pry [B] the drive belt [C] onto the application.
  • Page 368: Drive Belt Installation

    11-8 FINAL DRIVE Drive Belt Drive Belt Installation • Installation is reverse of removal. Note the following. NOTE ○ Be sure the printed information faces the same direction so the belt rotates in the same direction as originally in- stead. When installing a new belt, install it so the printed information can be read from left side of the motorcycle.
  • Page 369: Pulley And Coupling

    FINAL DRIVE 11-9 Pulley and Coupling Engine Pulley Cover Removal • Remove: Alternator Outer Cover (see Alternator Outer Cover Re- moval in the Electrical System chapter) Bolt [A] Clamp [B] Bolts [C] Engine Pully Cover [D] Engine Pulley Cover Installation •...
  • Page 370: Engine Pulley Installation

    11-10 FINAL DRIVE Pulley and Coupling • Hold the engine pulley [A] steady with the pulley holder [B], and remove the pulley mounting nut [C]. Special Tools - Pulley Holder: 57001-1572 Grip: 57001-1591 • Pull out the engine pulley from the output shaft. Engine Pulley Installation •...
  • Page 371: Rear Pulley Coupling Removal

    FINAL DRIVE 11-11 Pulley and Coupling Rear Pulley Coupling Removal • Remove: Rear Wheel (see Rear Wheel Removal in the Wheels/Tires chapter) • Loosen (lightly): Rear Pulley Mounting Nuts [A] • Remove the rear pulley [B] with the rear pulley coupling from the wheel.
  • Page 372: Coupling Bearing Removal

    11-12 FINAL DRIVE Pulley and Coupling Coupling Bearing Removal • Remove: Rear Pulley Coupling (see Rear Pulley Coupling Re- moval) Sleeve [A] • Remove: Collar [A] Grease Seal [B] • Remove: Circlip [A] Special Tool - Inside Circlip Pliers [B]: 57001-143 •...
  • Page 373: Coupling Bearing Inspection

    FINAL DRIVE 11-13 Pulley and Coupling Coupling Bearing Inspection Since the coupling bearing [A] is made to extremely close tolerances, the clearance cannot normally be measured. • Wash the bearing with a high-flash point solvent, dry it (do not spin it while it is dry), and oil it. •...
  • Page 374: Belt Adjuster

    11-14 FINAL DRIVE Belt Adjuster Belt Adjuster Removal • Remove the left and right belt adjuster locknuts [A] and belt adjuster nuts [B]. • Remove the belt adjuster [C] from the swingarm. Belt Adjuster Installation • Apply 2-stroke oil to the inside of the belt adjuster sliding surface.
  • Page 375 BRAKES 12-1 Brakes Table of Contents Exploded View........................12-2 Specifications ......................... 12-6 Special Tool ..........................12-7 Brake Lever, Brake Pedal....................... 12-8 Brake Lever Position Adjustment..................12-8 Brake Pedal Position Adjustment..................12-8 Brake Pedal Removal ....................... 12-9 Brake Pedal Installation ....................12-10 Calipers ..........................
  • Page 376: Exploded View

    12-2 BRAKES Exploded View...
  • Page 377 BRAKES 12-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Brake Lever Pivot Bolt 0.10 8.8 in·lb Brake Lever Pivot Bolt Locknut 0.60 52 in·lb Front Brake Disc Bolts Front Brake Hose Banjo Bolts Front Brake Light Switch Screw 0.12 11 in·lb Front Brake Reservoir Cap Screws 0.15...
  • Page 378 12-4 BRAKES Exploded View...
  • Page 379 BRAKES 12-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Brake Pedal Clamp Bolt Rear Brake Disc Bolts Rear Brake Hose Banjo Bolts Rear Caliper Bleed Valves 0.80 69 in·lb Rear Caliper Mounting Bolts Rear Master Cylinder Mounting Bolts Rear Master Cylinder Push Rod Locknut B: Apply brake fluid.
  • Page 380: Specifications

    12-6 BRAKES Specifications Item Standard Service Limit Brake Lever, Brake Pedal Brake Lever Position No.1 5-way adjustable Brake Lever Free Play Non-adjustable – – – Pedal Free Play Non-adjustable – – – Pedal Position About 130 mm (5.12 in.) – – – (height from pedal top to footpeg top) Brake Fluid Grade...
  • Page 381: Special Tool

    BRAKES 12-7 Special Tool Inside Circlip Pliers: 57001-143...
  • Page 382: Brake Lever, Brake Pedal

    12-8 BRAKES Brake Lever, Brake Pedal Brake Lever Position Adjustment The brake lever adjuster has 5 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 383: Brake Pedal Removal

    BRAKES 12-9 Brake Lever, Brake Pedal • Loosen the locknut [A] and turn the push rod with the hex head [B] to achieve the correct pedal position. If the length [C] is 70 ±1 mm (2.8 ±0.04 in.), the pedal position will be within the standard range.
  • Page 384: Brake Pedal Installation

    12-10 BRAKES Brake Lever, Brake Pedal Brake Pedal Installation • Apply grease to the brake pedal shaft. • Install the brake pedal [A] so that the punched mark on the pedal is aligned [B] with the punched mark on the brake lever [C].
  • Page 385: Calipers

    BRAKES 12-11 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]. • Take off the caliper [C] from the disc. • Unscrew the banjo bolt, and remove the brake hose from the caliper.
  • Page 386: Rear Caliper Disassembly

    12-12 BRAKES Calipers Rear Caliper Disassembly • Refer to the Caliper Rubber Parts Replacement in the Pe- riodic Maintenance chapter. Rear Caliper Assembly • Refer to the Caliper Rubber Parts Replacement in the Pe- riodic Maintenance chapter. 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.
  • Page 387: Brake Pads

    BRAKES 12-13 Brake Pads Front Brake Pad Removal • Remove the front caliper with the hose installed (see Front Caliper Removal). • Remove: Snap Pin [A] Pad Pin [B] • Remove the jaw side pad [A], and then remove the piston side pad [B].
  • Page 388: Rear Brake Pad Installation

    12-14 BRAKES Brake Pads • Remove the jaw side pad [A], and then remove the piston side pad [B]. Jaw [C] Rear Brake Pad Installation • Before installation, clean the pads with a high-flash point solvent. • Push the caliper pistons [A] in by hand as far as they will •...
  • Page 389: Master Cylinder

    BRAKES 12-15 Master Cylinder Front Master Cylinder Removal • Disconnect the front brake light switch connectors [A]. • Remove the banjo bolt [B] to disconnect the brake hose from the master cylinder (see Brake Hose Replacement in the Periodic Maintenance chapter). •...
  • Page 390: Rear Master Cylinder Removal

    12-16 BRAKES Master Cylinder Rear Master Cylinder Removal • Remove the brake fluid reservoir (see Brake Pedal Posi- tion Adjustment). • Unscrew the brake hose banjo bolt [A] on the master cylin- der. • Loosen the rear master cylinder mounting bolts [B]. •...
  • Page 391: Master Cylinder Inspection

    BRAKES 12-17 Master Cylinder Master Cylinder Inspection • Disassemble the front and rear master cylinders (see Master Cylinder Rubber Parts Replacement in the Peri- odic Maintenance chapter). CAUTION Do not remove the secondary cup from the piston since removal will damage it. •...
  • Page 392: Brake Discs

    12-18 BRAKES Brake Discs Brake Disc Removal • Remove the wheel (see Wheels (Rims) section in the Wheels/Tires chapter). • Unscrew the mounting bolts [A], and take off the disc. Brake Disc Installation • Install the brake disc [A] on the wheel so that the marked side [B] faces out.
  • Page 393: Brake Fluid

    BRAKES 12-19 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 394 12-20 BRAKES Brake Fluid • Bleed the brake line and the caliper. ○ Repeat this operation until no more air can be seen com- ing out into the plastic hose. 1. Pump the brake lever until it becomes hard, and apply the brake lever and hold it [A].
  • Page 395 BRAKES 12-21 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 396: Brake Hoses

    12-22 BRAKES Brake Hoses Brake Hose Removal/Installation • Refer to the Brake Hose Replacement in the Periodic Maintenance chapter.
  • Page 397 SUSPENSION 13-1 Suspension Table of Contents Exploded View........................13-2 Specifications ......................... 13-6 Special Tools .......................... 13-7 Front Fork ..........................13-8 Front Fork Removal (each fork leg) .................. 13-8 Front Fork Installation ....................... 13-9 Front Fork Oil Change ...................... 13-9 Front Fork Disassembly ....................13-10 Front Fork Assembly......................
  • Page 398: Exploded View

    13-2 SUSPENSION Exploded View...
  • Page 399 SUSPENSION 13-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Upper Front Fork Clamp Bolts Lower Front Fork Clamp Bolts Front Fork Bottom Allen Bolts Front Fork Upper Cover Stopper Bolts 0.43 37 in·lb G: Apply grease. L: Apply a non-permanent Locking agent. R: Replacement Parts...
  • Page 400 13-4 SUSPENSION Exploded View...
  • Page 401 SUSPENSION 13-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Rear Shock Absorber Nuts Swing Arm Pivot Shaft Nut Rocker Arm Pivot Shaft Nut Lower Tie-Rod Nuts Upper Tie-Rod Nuts 11.0 79.7 G: Apply grease. R: Replacement Parts...
  • Page 402: Specifications

    13-6 SUSPENSION Specifications Item Standard Service Limit Front Fork (per one unit) Fork Inner Tube Diameter 41 mm ( 1.6 in.) – – – Fork Oil: Type SHOWA SS-8 or equivalent – – – Capacity: When changing oil Approx. 355 mL (12.0 US oz.) –...
  • Page 403: Special Tools

    SUSPENSION 13-7 Special Tools Inside Circlip Pliers: Fork Outer Tube Weight: 57001-143 57001-1218 Fork Cylinder Holder Handle: Front Fork Oil Seal Driver: 57001-183 57001-1219 Fork Cylinder Holder Adapter: Jack: 57001-1057 57001-1238 Bearing Driver Set: Fork Oil Level Gauge: 57001-1129 57001-1290...
  • Page 404: Front Fork

    13-8 SUSPENSION Front Fork Front Fork Removal (each fork leg) • Loosen the front axle nut (see Front Wheel Removal in the Wheels/Tires chapter). • Using the jack [A] under the frame pipes, and a com- mercially available jack [B] under the engine, lift the front wheel off the ground until the rear wheel touches the ground.
  • Page 405: Front Fork Installation

    SUSPENSION 13-9 Front Fork Front Fork Installation • Install the stopper [A] so that the distance between the fork top end [B] and the upper surface [C] of the stopper is 250.6 mm (9.866 in.) [D]. Torque - Front Fork Upper Cover Stopper Bolt: 4.2 N·m (0.43 kgf·m, 37 in·lb) •...
  • Page 406: Front Fork Disassembly

    13-10 SUSPENSION Front Fork • Wait for about five minutes so that any suspended air bub- bles can surface. • Measure the oil level, using the fork oil level gauge [A]. Special Tool - Fork Oil level Gauge: 57001-1290 ○ Set the gauge stopper [B] so that its lower side shows the oil level distance specified [C].
  • Page 407: Front Fork Assembly

    SUSPENSION 13-11 Front Fork • Remove the cylinder unit [A] and short spring [B] from the inner tube. • Separate the inner tube from the outer tube as follows: ○ Slide up the dust seal [A]. ○ Remove the retaining ring [B] from the outer tube. ○...
  • Page 408 13-12 SUSPENSION Front Fork • Insert the cylinder unit [A] into the inner tube [B]. • Install the cylinder base [C] on the cylinder unit so that the tapered end face the upward. • Insert the inner tube, cylinder unit, cylinder base as a set into the outer tube [D].
  • Page 409: Inner Tube Inspection

    SUSPENSION 13-13 Front Fork Inner Tube Inspection • Visually inspect the inner tube, and repair any damage. • Nicks or rust damage can sometimes be repaired by using a wet-stone to remove sharp edges or raised areas which cause seal damage. If the damage is not repairable, replace the inner tube.
  • Page 410: Rear Shock Absorber

    13-14 SUSPENSION Rear Shock Absorber Spring Preload Adjustment • Remove: Reserve Tank (see Reserve Tank Removal in the Cool- ing System chapter) • Hang the under part of the reserve tank to the holder [A] of the frame as shown. •...
  • Page 411: Rear Shock Absorber Installation

    SUSPENSION 13-15 Rear Shock Absorber • Remove: Lower Shock Absorber Bolt [A] Lower Tie-Rod Bolt [B] Upper Shock Absorber Bolt [C] Rear Shock Absorber Rear Shock Absorber Installation • Pack the rocker arm needle bearings with grease. • Install the rear shock absorber so that the CAUTION label [A] faces left side.
  • Page 412: Swingarm

    13-16 SUSPENSION Swingarm Swingarm Removal • Remove: Rear Wheel (see Rear Wheel Removal in the Wheels/Tires chapter) Rear Brake Caliper (see Rear Caliper Removal in the Brakes chapter) Rear Shock Absorber (see Rear Shock Absorber Re- moval) Bolts [A] Rear Wheel Mad Guard [B] •...
  • Page 413: Swingarm Installation

    SUSPENSION 13-17 Swingarm Swingarm Installation • Apply plenty of grease to the needle bearings and grease seals. • Install: Collar [A] • Install the tie-rod to the swingarm. • Install the swingarm and insert the swingarm pivot shaft from the right side. •...
  • Page 414: Swingarm Bearing Installation

    13-18 SUSPENSION Swingarm • Remove the ball bearing [A] and needle bearing with the available bearing remover [B]. • Remove: Sleeve Right Side • Remove: Grease Seal • Remove the needle bearing [A] with the available bearing remover. Swingarm Bearing Installation •...
  • Page 415: Swingarm Bearing, Sleeve Inspection

    SUSPENSION 13-19 Swingarm Swingarm Bearing, Sleeve Inspection CAUTION Do not remove the bearings for inspection. Remove may damage them. • Inspect the swingarm sleeve [A], needle bearings [B] and ball bearing [C] installed in the swingarm. • The rollers and balls in the bearing normally wear very lit- tle, and wear is difficult to measure.
  • Page 416: Tie-rod, Rocker Arm

    13-20 SUSPENSION Tie-Rod, Rocker Arm Tie-Rod Removal • Tie-rod is removed together with the swingarm. Refer to the Swingarm Removal. Tie-Rod Installation • Refer to the Swingarm Installation. Rocker Arm Removal • Remove: Muffler (see Muffler Removal in the Engine Top End chapter) •...
  • Page 417: Tie-rod And Rocker Arm Bearing Removal

    SUSPENSION 13-21 Tie-Rod, Rocker Arm Tie-rod and Rocker Arm Bearing Removal • Remove: Tie-rod (see Swingarm Removal) Rocker Arm [A] (see Rocker Arm Removal) Sleeves [B] Grease Seal [C] • Remove the needle bearings [D], using the available bearing remover. Tie-rod and Rocker Arm Bearing Installation •...
  • Page 418 13-22 SUSPENSION Tie-Rod, Rocker Arm NOTE ○ Install the needle bearings so that the marked side faces out. Needle Bearing [A] Grease Seals [B] Front [C] Left Side [D] Right Side [E] Rocker Arm [F] Tie-rod [G] 6 ±1 mm (0.24 ±0.04 in.) [H] 11.5 ±1 mm (0.453 ±0.04 in.) [I] 5.5 ±1 mm (0.22 ±0.04 in.) [J] 6.5 ±2 mm (0.26 ±0.08 in.) [K]...
  • Page 419 STEERING 14-1 Steering Table of Contents Exploded View........................14-2 Special Tools .......................... 14-4 Handlebar ..........................14-5 Handlebar Removal ......................14-5 Handlebar Installation ....................... 14-5 Steering ..........................14-7 Steering Inspection ......................14-7 Steering Adjustment......................14-7 Steering Stem......................... 14-8 Steering Stem Removal ....................14-8 Steering Stem Installation ....................
  • Page 420: Exploded View

    14-2 STEERING Exploded View...
  • Page 421 STEERING 14-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Handlebar Clamp Bolts O, S Handlebar Holder Nuts Steering Stem Head Nut Upper Front Fork Clamp Bolts Steering Stem Nut 0.50 43 in·lb Lower Front Fork Clamp Bolts AD: Apply adhesive. G: Apply grease.
  • Page 422: Special Tools

    14-4 STEERING Special Tools Bearing Puller: Steering Stem Nut Wrench: 57001-135 57001-1100 Steering Stem Bearing Driver: Head Pipe Outer Race Driver, 46.5: 57001-137 57001-1106 Steering Stem Bearing Driver Adapter, 34.5: Head Pipe Outer Race Remover, ID > 37 mm: 57001-1074 57001-1107 Head Pipe Outer Race Press Shaft: Bearing Puller:...
  • Page 423: Handlebar

    STEERING 14-5 Handlebar Handlebar Removal • Remove: Clutch Lever Assembly [A] Left Handlebar Switch Housing [B] • Remove: Front Master Cylinder [A] (see Front Master Cylinder Re- moval in the Brakes chapter) Right Handlebar Switch Housing [B] Throttle Grip [C] •...
  • Page 424 14-6 STEERING Handlebar ○ The front half of the right handlebar switch housing has a small projection [A]. • Fit the projection into the small hole [B] in the handlebar, and install the housing. • Set the left handlebar switch housing [A] to match its mat- ing surface [B] to the punched mark [C] of the handlebar.
  • Page 425: Steering Inspection

    STEERING 14-7 Steering Steering Inspection • Refer to the Steering Inspection in the Periodic Mainte- nance chapter. Steering Adjustment • Refer to the Steering Adjustment in the Periodic Mainte- nance chapter.
  • Page 426: Steering Stem

    14-8 STEERING Steering Stem Steering Stem Removal • Remove the front wheel (see Front Wheel Removal in the Wheels/Tires chapter). CAUTION Be sure to put the rear wheel on the ground when removing the steering, or the motorcycle may fall over.
  • Page 427: Steering Stem Installation

    STEERING 14-9 Steering Stem • Remove: Steering Stem Head Nut [A] and Washer Front Forks (see Front Fork Removal (each fork leg) in the Suspension chapter) Steering Stem Head [B] • Bend the claws [A] of the claw washer straighten. •...
  • Page 428 14-10 STEERING Steering Stem • Replace the claw washer [A] with a new one. • Install the claw washer so that its bent side [B] faces up- ward, and engage the bent claws with the grooves of stem locknut [C]. •...
  • Page 429: Steering Stem Warp

    STEERING 14-11 Steering Stem Steering Stem Warp • Whenever the steering stem is removed, or if the steering cannot be adjusted for smooth action, check the steering stem for straightness. If the steering stem [A] is bent, replace the steering stem.
  • Page 430: Steering Stem Bearing

    14-12 STEERING Steering Stem Bearing Stem Bearing Removal • Remove the steering stem (see Steering Stem Removal). • Drive out the bearing outer races from the head pipe. Special Tool - Head Pipe Outer Race Remover, ID > 37 mm [A]: 57001-1107 NOTE ○...
  • Page 431: Stem Bearing Lubrication

    STEERING 14-13 Steering Stem Bearing ○ Check that there is no play and the steering stem turns smoothly without rattles. If not, the steering stem bearings may be damaged. Stem Bearing Lubrication In accordance with the Periodic Maintenance Chart, lubri- cate the steering stem bearings.
  • Page 433 FRAME 15-1 Frame Table of Contents Exploded View........................15-2 Special Tool ..........................15-7 Seats ............................15-8 Seat Removal ........................15-8 Seat Installation ........................ 15-8 Side Covers ..........................15-9 Left Side Cover Removal ....................15-9 Left Side Cover Installation ....................15-9 Right Side Cover Removal....................
  • Page 434: Exploded View

    15-2 FRAME Exploded View...
  • Page 435 FRAME 15-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Downtube Bolts Footboard Bracket Bolts Sidestand Mounting Nut Lower Muffler Bracket Bolts Upper Muffler Bracket Bolts Sidestand Mounting Bolt Footpeg Bracket Bolts G: Apply grease. R: Replacement Parts CAL: California Model...
  • Page 436 15-4 FRAME Exploded View...
  • Page 437 FRAME 15-5 Exploded View 1. other than Europe Models...
  • Page 438 15-6 FRAME Exploded View VN900D Models...
  • Page 439: Special Tool

    FRAME 15-7 Special Tool Jack: 57001-1238...
  • Page 440: Seats

    15-8 FRAME Seats Seat Removal • Insert the ignition switch key [A] into the seat lock, turning the key clockwise, pulling up on the rear of the seat [B], and pulling the seat backward. Seat Installation • Slip the seat hook [A] under the brace [B] on the fuel tank bracket.
  • Page 441: Side Covers

    FRAME 15-9 Side Covers Left Side Cover Removal • Remove: Seat (see Seat Removal) Screw [A] • Pull [A] the left side cover evenly, and remove it. Left Side Cover Installation • Put the front stoppers [A] into the grommets [B] first, then put the rear stopper [C] into the grommet [D].
  • Page 442: Right Side Cover Installation

    15-10 FRAME Side Covers Right Side Cover Installation • Put the stoppers [A] into the grommets [B]. • Tighten the screw.
  • Page 443: Fenders

    FRAME 15-11 Fenders Front Fender Removal CAUTION Be careful not to scratch the painted surface during removal or installation. • Remove the mounting bolts [A] and washers on both sides to separate the fender from the front fork. • Move the fender forwards with the wheel installed and remove it.
  • Page 444: Rear Fender Installation

    15-12 FRAME Fenders • Remove: Bolt [A] Seat Lock Cable Lower End [B] • Remove the rear fender bolts [A] on both sides. • Remove the rear fender [B] rearwards. • Remove: Bolts [A] Screws [B] Reinforce [C] Rear Fender Installation •...
  • Page 445: Battery Case

    FRAME 15-13 Battery Case Battery Case Removal • Remove: Seat (see Seat Removal) Battery (see Battery Removal in the Electrical System chapter) ECU [A] (see ECU Removal in the Fuel System (DFI) chapter) Relay Box (see Relay Box Removal in the Electrical Sys- tem chapter) Fuse Box (see Electrical System chapter) Vechicle-down Sensor [B] (see Vechicle-down Sensor...
  • Page 446: Tool Box

    15-14 FRAME Tool Box Tool Box Removal • Clear the seat lock cable [A] from the hook [B]. • Remove: Seat (see Seat Removal) Screws [C] Tool Box [D]...
  • Page 447: Footboard

    FRAME 15-15 Footboard Footboard Removal/Installation Left Side: • Remove: Shift Pedal Clamp Bolt [A] Footboard Bracket Bolts [B] Left Footboard Assembly [C] • Install the shift pedal to the front shift lever so that the punch mark [A] on the pedal align to the punch mark [B] on the shift lever.
  • Page 448: Footboard Disassembly

    15-16 FRAME Footboard • Install: Right Footboard Assembly • Tighten: Torque - Footboard Bracket Bolts: 34 N·m (3.5 kgf·m, 25 ft·lb) Rear Master Cylinder Mounting Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb) • Install the brake pedal so that the punch mark [A] on the brake lever shaft align to the brake lever punch mark [B].
  • Page 449: Sidestand

    FRAME 15-17 Sidestand Sidestand Removal • Raise the rear wheel [A] off the ground, using the jack [B]. Special Tool - Jack: 57001-1238 • Remove the alternator outer cover (see Alternator Outer Cover Removal in the Electrical System chapter). • Disconnect the sidestand switch lead connector [A].
  • Page 450: Windshield (vn900d Models)

    15-18 FRAME Windshield (VN900D Models) Windshield Height Adjustment ○ The windshield [A] can be adjusted within 50 mm (2.0 in.) in height to suit the rider’s preference. • Loosen the upper and lower bolts [B] on both sides and slide the windshield up or down. •...
  • Page 451 FRAME 15-19 Windshield (VN900D Models) • Install: Brackets (Both Sides) [A] Bolts [B] • Install the windshield [A] on the brackets with the bolt [B].
  • Page 452: Saddlebags (vn900d Models)

    15-20 FRAME Saddlebags (VN900D Models) Saddlebag Removal • Open the lid. • Remove: Bolt [A] Nuts [B] Saddlebag Saddlebag Installation • Be sure that the washers [A] are in place. • Install: Saddlebag • Tighten: Nuts [A] Bolt [B]...
  • Page 453: Rear View Mirrors

    FRAME 15-21 Rear View Mirrors Rear View Mirror Removal (Other than Europe Models) • Loosen the locknut [A]. • Turn the rear view mirror stay [B] counterclockwise to re- move the rear view mirror from the holder [C]. Rear View Mirror Removal (Europe Models) •...
  • Page 454: Rear View Mirror Installation (europe Models)

    15-22 FRAME Rear View Mirrors Rear View Mirror Installation (Europe Models) • Screw the mounting area of the rear view mirror [A] into the holder [B] all the way, and tighten the lower hexagonal area [C] securely. CAUTION Do not force to tighten and/or loosen the upper hexagonal area (adapter) [A] with a pair of span- ners or wrench.
  • Page 455: Downtube

    FRAME 15-23 Downtube Downtube Removal • Raise the rear wheel [A] off the ground, using the jack [B]. Special Tool - Jack: 57001-1238 • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) • Disconnect the rear brake light switch connector [A]. •...
  • Page 456: Downtube Installation

    15-24 FRAME Downtube • Clear the brake hose [A] from the clamps [B]. • Remove: Radiator Mounting Bolt [A] • Remove: Regulator/Rectifier (see Regulator/Rectifier Removal in the Electrical System chapter) Front Cross Pipe Bolts [A] Front Cross Pipe [B] • Remove: Engine Mounting Bracket Bolts [A] Caps [B] and Down Tube Bolts...
  • Page 457: Back Rest (vn900d Models)

    FRAME 15-25 Back Rest (VN900D Models) Back Rest Removal/Installation • Remove: Bolts (Both Sides) [A] Back Rest Assy [B] • Remove: Bolts [A] Plate [B] Back Rest Pad [C] • Install: Back Rest Side Stays (Both Sides) [A] Saddlebag Brackets (Both Sides) [B] •...
  • Page 458: Frame Inspection

    15-26 FRAME Frame Frame Inspection • Visually inspect the frame [A] for cracks, dents, bending, or warp. If there is any damage to the frame, replace it. WARNING A repaired frame may fail in use, possibly causing an accident. If the frame is bent, dented, cracked, or warped, replace it.
  • Page 459 ELECTRICAL SYSTEM 16-1 Electrical System Table of Contents Exploded View........................16-3 Electrical Parts Location ......................16-10 Wiring Diagram........................16-13 Specifications ......................... 16-20 Special Tools and Sealant ...................... 16-21 Precautions..........................16-22 Electrical Wiring........................16-24 Wiring Inspection ......................16-24 Battery ............................ 16-25 Battery Removal .......................
  • Page 460 16-2 ELECTRICAL SYSTEM Armature Inspection......................16-53 Brush Lead Inspection ...................... 16-53 Brush Plate and Terminal Bolt Inspection ................. 16-53 Starter Relay Inspection....................16-53 Lighting System ........................16-56 Headlight Beam Horizontal Adjustment ................16-56 Headlight Beam Vertical Adjustment................. 16-56 Headlight Bulb Replacement .................... 16-56 Headlight Body Removal ....................
  • Page 461: Exploded View

    ELECTRICAL SYSTEM 16-3 Exploded View Dummy Page...
  • Page 462 16-4 ELECTRICAL SYSTEM Exploded View...
  • Page 463 ELECTRICAL SYSTEM 16-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Alternator Outer Cover Bolts 87 in·lb Alternator Cover Bolts 87 in·lb Timing Inspection Plate Bolts 87 in·lb Alternator Lead Holder Plate Bolts 0.60 52 in·lb Sator Coil Bolts 106 in·lb Alternator Rotor Bolt (First) S, MO Alternator Rotor Bolt (Final)
  • Page 464 16-6 ELECTRICAL SYSTEM Exploded View...
  • Page 465 ELECTRICAL SYSTEM 16-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Tail/Brake Light Unit Mounting Nuts 0.60 52 in·lb Headlight Rim Screws 0.30 26 in·lb...
  • Page 466 16-8 ELECTRICAL SYSTEM Exploded View...
  • Page 467 ELECTRICAL SYSTEM 16-9 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Sidestand Switch Mounting Bolt 0.90 78 in·lb Fuel Level Sensor Mounting Bolts 0.70 61 in·lb L: Apply a non-permanent locking agent. R: Replacement Parts...
  • Page 468: Electrical Parts Location

    16-10 ELECTRICAL SYSTEM Electrical Parts Location Left Handlebar Switches [A] Starter Lockout Switch [B] Headlight [C] Front Brake Light Switch [D] Right Handlebar Switches [E] Meter Unit [F] Spark Plug [A] (Front) Fuel Pump [B] Ignition Coil [C] (Front) Ignition Coil [D] (Rear) Spark Plug [E] (Rear) Radiator Fan [A] Horn [B]...
  • Page 469 ELECTRICAL SYSTEM 16-11 Electrical Parts Location Speed Sensor [A] Battery [A] ECU (Electronic Control Unit) [B] Turn Signal Control Relay [C] Relay Box [A] Starter Relay and Main Fuse 30 A [B] Frame Ground Terminal [C] Natural Switch [A] Air Switching Valve [A]...
  • Page 470 16-12 ELECTRICAL SYSTEM Electrical Parts Location Fuel Level Sensor [A] Rear Brake Light Switch [A] Water Temperature Sensor [A] Sidestand Switch [A]...
  • Page 471: Wiring Diagram

    ELECTRICAL SYSTEM 16-13 Wiring Diagram Dummy Page...
  • Page 472 16-14 ELECTRICAL SYSTEM Wiring Diagram United States and Canada Models...
  • Page 473 ELECTRICAL SYSTEM 16-15 Wiring Diagram...
  • Page 474 16-16 ELECTRICAL SYSTEM Wiring Diagram Europe Models...
  • Page 475 ELECTRICAL SYSTEM 16-17 Wiring Diagram...
  • Page 476 16-18 ELECTRICAL SYSTEM Wiring Diagram Australia Model...
  • Page 477 ELECTRICAL SYSTEM 16-19 Wiring Diagram...
  • Page 478: Specifications

    16-20 ELECTRICAL SYSTEM Specifications Item Standard Service Limit Battery Type Sealed Battery – – – Model Name YTX12-BS – – – Capacity 12 V 10 Ah – – – Voltage 12.8 V or more – – – Charging System Type Three-phase AC –...
  • Page 479: Special Tools And Sealant

    Rotor Puller, M16/M18/M20/M22 × 1.5: Peak Voltage Adapter: 57001-1216 57001-1415 Jack: Needle Adapter Set: 57001-1238 57001-1457 Spark Plug Wrench, Hex 16: Grip: 57001-1262 57001-1591 Hand Tester: Rotor Holder: 57001-1394 57001-1674 Flywheel Puller Assembly, M38 × 1.5/M35 × 1.5: Kawasaki Bond (Silicone Sealant): 57001-1405 92104-0004...
  • Page 480: Precautions

    16-22 ELECTRICAL SYSTEM Precautions There are a number of important precautions that are musts when servicing electrical systems. Learn and ob- serve all the rules below. ○ Do not reverse the battery cable connections. This will burn out the diodes on the electrical parts. ○...
  • Page 481 ELECTRICAL SYSTEM 16-23 Precautions ○ Electrical Connectors Female Connectors [A] Male Connectors [B]...
  • Page 482: Electrical Wiring

    16-24 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 483: Battery

    ELECTRICAL SYSTEM 16-25 Battery Battery Removal • Remove: Tool Box (see Tool Box Removal in the Frame chapter) • Disconnect the negative (–) cable [A]. • Slide out the positive (+) terminal cap [B] and then discon- nect the positive (+) cable. CAUTION Be sure to disconnect the negative (–) cable first.
  • Page 484 16-26 ELECTRICAL SYSTEM 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 485 Standard Charge: 1.2 A × 5 10 hours If using a recommended battery charger, follow the charger’s instructions for newly activated sealed battery. Kawasaki-recommended chargers Optimate III Yuasa 1.5 Amp Automatic Charger Battery Mate 150-9 If the above chargers are not available, use equivalent one.
  • Page 486: Precautions

    16-28 ELECTRICAL SYSTEM 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.
  • Page 487: Charging Condition Inspection

    ELECTRICAL SYSTEM 16-29 Battery Charging Condition Inspection ○ Battery charging condition can be checked by measuring battery terminal voltage with a digital voltmeter [A]. • Remove: Seat (see Seat Removal in the Frame chapter) Battery Cable Cap (see Battery Removal) •...
  • Page 488 16-30 ELECTRICAL SYSTEM Battery Terminal Voltage: 11.5 less than 12.8 V Standard Charge 1.2 A × 5 10 h (see following chart) Quick Charge 5 A × 1 h CAUTION If possible, do not quick charge. If quick charge is done unavoidably, do standard charge later on.
  • Page 489: Charging System

    ELECTRICAL SYSTEM 16-31 Charging System Alternator Outer Cover Removal • Remove: Bolts [A] Alternator Outer Cover [B] Alternator Outer Cover Installation • Install the alternator outer cover. • Tighten: Torque - Alternator Outer Cover Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) Alternator Cover Removal •...
  • Page 490: Alternator Cover Installation

    Apply silicone sealant to the circumference of the alterna- tor lead and crankshaft sensor lead grommets, and fit the grommets into the notch of the cover securely. Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004 ○ First install the alternator lead grommet and then crank- shaft sensor lead grommets.
  • Page 491: Alternator Rotor Removal

    ELECTRICAL SYSTEM 16-33 Charging System Alternator Rotor Removal • Remove: Alternator Cover (see Alternator Cover Removal). • Wipe oil off the outer circumference of the rotor. • Hold the alternator rotor steady with the rotor holder [A], and remove the rotor bolt [B]. Special Tools - Rotor Holder: 57001-1674 Grip [C]: 57001-1591 ○...
  • Page 492: Alternator Inspection

    16-34 ELECTRICAL SYSTEM Charging System • When installing the alternator rotor, align the rotor mark [A] with the left crankcase projection [B]. • Apply molybdenum disulfide oil solution to the threads and seating surface of the alternator rotor bolt. • Install the washer.
  • Page 493 ELECTRICAL SYSTEM 16-35 Charging System • To check the alternator output voltage, do the following procedures. ○ Remove the regulator/rectifier and disconnect the con- nector [A]. ○ Connect the hand tester to the connector as shown. Special Tool - Hand Tester: 57001-1394 ○...
  • Page 494: Regulator/rectifier Removal

    16-36 ELECTRICAL SYSTEM Charging System Regulator/Rectifier Removal • Remove: Bolts [A] Regulator/Rectifier Cover [B] • Remove: Bolts [A] Regulator/Rectifier [B] Connector [C] (disconnect) Regulator/Rectifier Inspection Rectifier Circuit Check • Remove the regulator/rectifier (see Regulator/Rectifier Removal). • Check conductivity of the following pair of terminals. Rectifier Circuit Inspection R-W1, R-W2,...
  • Page 495 ELECTRICAL SYSTEM 16-37 Charging System • Do the 1st step regulator circuit test. ○ Connect the test light and the 12 V battery to the regula- tor/rectifier as shown. ○ Check W1, W2 and W3 terminal respectively. If the test light turns on, the regulator/rectifier is defective. Replace it.
  • Page 496: Charging Voltage Inspection

    16-38 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: Seat (see Seat Removal in the Frame chapter) Tool Box (see Tool Box Removal in the Frame chapter) •...
  • Page 497 ELECTRICAL SYSTEM 16-39 Charging System Charging System Circuit 1. Ignition Switch 2. Regulator/Rectifier 3. Alternator 4. Frame Ground 5. Battery 6. Main Fuse 30 A 7. Load...
  • Page 498: Ignition System

    16-40 ELECTRICAL SYSTEM Ignition System...
  • Page 499: Ignition Coil Removal

    ELECTRICAL SYSTEM 16-41 Ignition System WARNING The ignition system produces extremely high volt- age. Do not touch the spark plugs, ignition coils, or spark plug high-tension cables 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...
  • Page 500: Ignition Coil Installation

    16-42 ELECTRICAL SYSTEM Ignition System Ignition Coil Installation • Connect the primary leads to the ignition coil terminals and run the secondary cables according to the Cable, Wire and Hose Routing section in the Appendix chapter. [A] Front Ignition Coil [B] Rear Ignition Coil [C] Dampers [D] Bracket...
  • Page 501: Spark Plug Removal

    ELECTRICAL SYSTEM 16-43 Ignition System • Measure the primary winding resistance as follows. ○ Connect the hand tester between the coil terminals. ○ Set the tester to the × 1 Ω range, and read the tester. • Measure the secondary winding resistance as follows. ○...
  • Page 502: Spark Plug Condition Inspection

    16-44 ELECTRICAL SYSTEM Ignition System Spark Plug Condition Inspection • Remove the spark plugs (see Spark Plug Removal). • Visually inspect the spark plugs. If the spark plug center electrode [A] and/or side elec- trode [B] are corroded or damaged, or if the insulator [C] is cracked, replace the plug.
  • Page 503: Crankshaft Sensor Removal

    ELECTRICAL SYSTEM 16-45 Ignition System WARNING To avoid extremely high voltage shocks, do not touch the spark plugs or tester connections. • Turn the ignition switch and the 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 504: Crankshaft Sensor Inspection

    16-46 ELECTRICAL SYSTEM Ignition System Crankshaft Sensor Inspection • Remove: Alternator Outer Cover (see Alternator Outer Cover Re- moval) Crankshaft Sensor Lead Connector [A] (Disconnect) • Set the hand tester to the × 100 Ω range and connect it between the terminals in the connector. Special Tool - Hand Tester: 57001-1394 If there is more resistance than the specified value, the coil has an open lead and must be replaced.
  • Page 505: Crankshaft Sensor Peak Voltage Inspection

    ELECTRICAL SYSTEM 16-47 Ignition System Crankshaft Sensor Peak Voltage Inspection • Remove: Alternator Outer Cover (see Alternator Outer Cover Re- moval) • Remove all the spark plug caps but do not remove the spark plugs. • Disconnect the crankshaft sensor lead connector. •...
  • Page 506: Ic Igniter Inspection

    16-48 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 507 ELECTRICAL SYSTEM 16-49 Ignition System Ignition System Circuit 1. Ignition Switch 13. Vehicle-down Sensor 2. Engine Stop Switch 14. Frame Ground 3. Spark Plugs 15. Battery 4. Ignition Coil #1 (front cylinder) 16. Main Fuse 30 A 5. Ignition Coil #2 (rear cylinder) 17.
  • Page 508: Electric Starter System

    16-50 ELECTRICAL SYSTEM Electric Starter System Starter Motor Removal • Remove: Regulator/Rectifier (see Regulator/Rectifier Removal) Bolts [A] Front Cross Pipe [B] • Drain the engine oil (see Engine Oil Change in the Peri- odic Maintenance chapter). • Remove the starter motor cable nut [A] and the mounting bolts [B].
  • Page 509: Starter Motor Assembly

    ELECTRICAL SYSTEM 16-51 Electric Starter System • Remove: Terminal Locknut and Washers O-ring • Remove the brush plate assy [A] from the yoke [B]. • Remove the brush plate [A] from the terminal bolt assem- bly [B]. NOTE ○ Do not remove the negative carbon brushes form the brush plate.
  • Page 510: Brush Inspection

    16-52 ELECTRICAL SYSTEM Electric Starter System • Install the new O-ring [A] as shown. • Install: Washers [B] and Terminal Locknut [C] • Tighten: Torque - Starter Motor Terminal Locknut: 11 N·m (1.1 kgf·m, 97 in·lb) • Align the lines [A] on the yoke with the end cover lines [B]. •...
  • Page 511: Armature Inspection

    ELECTRICAL SYSTEM 16-53 Electric Starter System Armature Inspection • Using the × 1 Ω hand tester range, measure the resis- tance between any two commutator segments [A]. Special Tool - Hand Tester: 57001-1394 If there is a high resistance or no reading (∞) between any two segments, a winding is open and the starter motor must be replaced.
  • Page 512 16-54 ELECTRICAL SYSTEM Electric Starter System • Disconnect the connector [A]. • Disconnect the starter motor cable [B] and battery positive (+) cable [C] from the starter relay [D]. CAUTION The battery positive (+) cable with the rubber cap is connected directly to the battery positive (+) termi- nal even when the ignition switch off, so take care not to short the removed cable to chassis ground.
  • Page 513 ELECTRICAL SYSTEM 16-55 Electric Starter System Electric Starter Circuit 1. Ignition Switch 2. Engine Stop Switch 3. Starter Button 4. Neutral Switch 5. Sidestand Switch 6. ECU 7. Battery 8. Main Fuse 30 A 9. Starter Relay 10. Starter Motor 11.
  • Page 514: Lighting System

    16-56 ELECTRICAL SYSTEM Lighting System This models adopt the daylight system and has a head- light 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 515: Headlight Body Removal

    ELECTRICAL SYSTEM 16-57 Lighting System • Take out the bulb [A]. CAUTION When handling the quartz-halogen bulb, never touch the glass portion with bare hands. Always use a clean cloth. Oil contamination from hands or dirty rags can reduce bulb life or cause the bulb to explode.
  • Page 516: Tail/brake Light Removal/installation

    16-58 ELECTRICAL SYSTEM Lighting System • Remove the wedge-base type bulb [A], pull the bulb straight out of the socket [B]. • Replace the bulb with a new one. CAUTION Do not turn the bulb. Pull the bulb out to prevent damage to the bulb.
  • Page 517: Licence Plate Light Bulb Replacement

    ELECTRICAL SYSTEM 16-59 Lighting System • With the front pin [A] up and the rear pin [B] down, in- sert the new bulb by aligning the front pin with the upper groove [C] in the walls of the socket [D]. •...
  • Page 518 16-60 ELECTRICAL SYSTEM Lighting System • Insert the new bulb [A] by aligning the pins [B] with the groove in the walls of the socket [C]. Headlight/Taillight Circuit 1. Ignition Switch 10. Tail Light Fuse 10 A 2. Rear Brake Switch 11.
  • Page 519: Turn Signal Light Bulb Replacement

    ELECTRICAL SYSTEM 16-61 Lighting System Turn Signal Light Bulb Replacement • Remove the turn signal light lens screws [A] and remove the lens [B]. • Push the bulb [A] in the socket and turn the bulb counter- clockwise. • Replace the bulb. Turn Signal Relay Inspection •...
  • Page 520 16-62 ELECTRICAL SYSTEM Lighting System Turn Signal Light Circuit 1. Ignition Switch 2. Frame Ground 3. Main Fuse 30 A 4. Battery 5. Rear Right Turn Signal Light 6. Rear Left Turn Signal Light 7. Turn Signal Relay 8. Turn Signal Lights Fuse 10 A 9.
  • Page 521: Radiator Fan System

    ELECTRICAL SYSTEM 16-63 Radiator Fan System Fan Motor Inspection • Remove the fuel tank (see Fuel Tank Removal in the Fuel System (DFI) chapter). • Disconnect the 2-pin connector [A] in the fan motor leads. • Using two auxiliary wires, supply battery [B] power to the fan motor.
  • Page 522: Meter Unit

    16-64 ELECTRICAL SYSTEM Meter Unit Meter Unit Removal • Remove the bolt [A], and lift up the tail of the cover [B]. • Push the cover forward a little, and remove the meter cover. • Remove the meter unit [A]. ○...
  • Page 523 ELECTRICAL SYSTEM 16-65 Meter Unit • Remove the screw [A] on the lower cover to free the speedometer. • Remove the screw [A] on the indicator panel to remove the panel.
  • Page 524: Meter Unit Assembly

    16-66 ELECTRICAL SYSTEM Meter Unit • Lifting the speedometer [A] with the indicator panel [B] attached, pull out the FI indicator LED light [C] and oil pressure warning LED light [D] from the lower cover [E]. NOTE ○ The water temperature warning LED light, oil pressure warning LED light and FI indicator LED light can not be exchanged.
  • Page 525: Meter Unit Inspection

    ELECTRICAL SYSTEM 16-67 Meter Unit • Fit the speedometer and indicator panel onto the lower cover. ○ Put the holes [B] onto the projections [A] of the lower cover. • Tighten the screws. • Install the upper cover. Meter Unit Inspection Mode Selection and Reset Button Checks •...
  • Page 526 16-68 ELECTRICAL SYSTEM Meter Unit • Push the mode select button to CLOCK. • Push the reset button [A] more than 2 seconds, then the display turns to the HOUR/MINUTE mode [B]. ○ In the HOUR/MINUTE mode, the numbers flash on the display.
  • Page 527 ELECTRICAL SYSTEM 16-69 Meter Unit LCD Segment Inspection • Remove the meter unit [A] (see Meter Unit Removal). CAUTION Do not drop the meter unit. Such a shock to the meter unit can damage it. Place the meter facing up. If a meter is left upside down or sideways for any length of time, it will malfunction.
  • Page 528 16-70 ELECTRICAL SYSTEM Meter Unit Speedometer Inspection • If an oscillator is unavailable, check the speedometer as follows. ○ Install the meter unit. ○ Use the jack to lift the rear wheel. Special Tool - Jack: 57001-1238 ○ Turn the ignition switch ON. ○...
  • Page 529 ELECTRICAL SYSTEM 16-71 Meter Unit TRIP Meter Inspection • Turn the display [A] into TRIP. • During the speedometer inspection with an oscillator, ver- ify that the trip meter reading increases. • Stop the short wave form, press the reset button more than 2 seconds and check that the display shows “0.0”.
  • Page 530 16-72 ELECTRICAL SYSTEM Meter Unit Oil Pressure Warning LED Light Connections Battery Negative Wire (–) to Terminal [3] • Connect the terminal [3]. ○ The oil pressure warning LED light lights. • Disconnect the terminal [3]. ○ The oil pressure warning LED light disappears. If there is any problem, replace the speedometer assem- bly.
  • Page 531 ELECTRICAL SYSTEM 16-73 Meter Unit Turn Signal Indicator Lights Connections Battery Positive Wire (+) to Terminal [17] or [18] • Connect the terminal [17] or [18]. ○ The turn signal indicator light lights. • Disconnect the terminal [17] or [18]. ○...
  • Page 532 16-74 ELECTRICAL SYSTEM Meter Unit If there is any problem, inspect the bulb, bulb socket [A] and wiring of the indicator panel [B] for continuity. If they are normal, replace the speedometer assembly. Special Tools - Hand Tester: 57001-1394 Needle Adapter Set: 57001-1457...
  • Page 533 ELECTRICAL SYSTEM 16-75 Meter Unit 1. Ignition Switch 16. Neutral Indicator Light 2. Fuel Level Sensor 17. Turn Signal Indicator Light 3. Speed Sensor 18. High Beam Indicator Light 4. Joint Connector B 19. Reset Button 5. Water Temperature Sensor 20.
  • Page 534: Fuel Gauge Operation Inspection

    16-76 ELECTRICAL SYSTEM Meter Unit Fuel Gauge Operation Inspection • Remove: Fuel Tank Bolts (see Fuel Tank Removal in the Fuel Sys- tem (DFI) chapter) • Lift the fuel tank front part a little and pull the fuel gauge connector forward. •...
  • Page 535: Air Switching Valve

    ELECTRICAL SYSTEM 16-77 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 536: Switch And Sensors

    16-78 ELECTRICAL SYSTEM Switch and Sensors Fuel Level Sensor Inspection • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) • Open the clamps on the fuel tank. • Remove: Bolts [A] Fuel Level Sensor [B] •...
  • Page 537: Fuel Reserve Switch Inspection

    ELECTRICAL SYSTEM 16-79 Switch and Sensors Fuel Reserve Switch Inspection • Fill the fuel tank with fuel. • Close the fuel tank cap surely. • Remove: Ignition Coil Cover (see Ignition Coil Removal) Fuel Pump Lead Connector [A] • Connect the test light [B] (12 V 3.4 W bulb in a socket with leads) and the 12 V battery [C] to the fuel level sensor lead connector.
  • Page 538: Speed Sensor Installation

    16-80 ELECTRICAL SYSTEM Switch and Sensors Speed Sensor Installation • Apply grease to the O-ring [A] on the speed sensor [B]. • Tighten: Torque - Speed Sensor Mounting Bolt: 9.8 N·m (1.0 kgf·m, 87 in·lb) Speed Sensor Inspection • Remove: Speed Sensor (see Speed Sensor Removal) •...
  • Page 539: Oxygen Sensor Installation (europe Models)

    ELECTRICAL SYSTEM 16-81 Switch and Sensors Oxygen Sensor Installation (Europe Models) CAUTION Never drop the Oxygen Sensor [A], especially on a hard surface. Such a shock to the unit can damage Do not touch the sensing part [B] to prevent oil con- tact.
  • Page 540: Water Temperature Sensor Inspection

    16-82 ELECTRICAL SYSTEM Switch and Sensors Water Temperature Sensor Inspection • Remove the water temperature sensor (see Water Tem- perature Sensor Removal). • Suspend the sensor [A] in a container of machine oil so that the heat-sensitive portion and threaded portion are submerged.
  • Page 541: Switch Inspection

    ELECTRICAL SYSTEM 16-83 Switch and Sensors Switch Inspection • Using the hand tester, check to see that only the con- nections shown in the table have continuity (about zero ohms). ○ For the handlebar switches and the ignition switch, refer to the tables in the Wiring Diagram.
  • Page 542: Relay Box

    16-84 ELECTRICAL SYSTEM Relay Box The relay box [A] has relays and diodes. The relays and diodes can not be removed. Relay Box Removal • Remove: Right Side Cover (see Right Side Cover Removal in the Frame chapter) • Take out the relay box [A] and disconnect the connectors [B].
  • Page 543: Diode Circuit Inspection

    ELECTRICAL SYSTEM 16-85 Relay Box Relay Circuit Inspection (with the battery connected) Battery Tester Tester Connection Connection Reading (Ω) (–) 2-11 ECU Main Relay Fuel Pump Relay 9-10 Fan Relay 18-19 17-20 Battery Tester Tester Connection Connection DC 25 V Range Reading (V) (–) Starter...
  • Page 544 16-86 ELECTRICAL SYSTEM Relay Box Relay Box Internal Circuit A: Headlight Relay B: ECU Main Relay C: Fuel Pump Relay D: Starter Circuit Relay E: Fan Relay...
  • Page 545: Fuse

    ELECTRICAL SYSTEM 16-87 Fuse 30 A Main Fuse Removal • Remove: Right Side Cover (see Right Side Cover Removal in the Frame chapter) Connector [A] • Pull out the main fuse [B] from the starter relay with needle nose pliers. Fuse Box Fuse Removal •...
  • Page 546: Fuse Installation

    16-88 ELECTRICAL SYSTEM Fuse 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. • Install the fuse box fuses on the original position as spec- ified on the lid.
  • Page 547 APPENDIX 17-1 Appendix Table of Contents Cable, Wire and Hose Routing ....................17-2 Troubleshooting Guide ......................17-37...
  • Page 548 17-2 APPENDIX Cable, Wire and Hose Routing...
  • Page 549 APPENDIX 17-3 Cable, Wire and Hose Routing 1. Right Switch Housing Harness 2. Left Switch Housing Harness 3. Clutch Cable 4. Clamp the right switch housing harness. 5. Through the clutch cable and left switch housing harness. 6. Run the clutch cable through the brake hose front side. 7.
  • Page 550 17-4 APPENDIX Cable, Wire and Hose Routing...
  • Page 551 APPENDIX 17-5 Cable, Wire and Hose Routing 1. Clamp the left and right switch housing harness and clutch cable. 2. Run the water temperature sensor connector over the reserve tank hose. 3. Run the clutch cable between the frame and radiator hose. 4.
  • Page 552 17-6 APPENDIX Cable, Wire and Hose Routing...
  • Page 553 APPENDIX 17-7 Cable, Wire and Hose Routing 1. Right Switch Housing Harness Connector 2. Left Switch Housing Harness Connector 3. Left Switch Housing Harness Connector 4. Radiator Fan Harness Connector 5. Rear Brake Light Switch Lead Connector 6. Clamp the main harness. 7.
  • Page 554 17-8 APPENDIX Cable, Wire and Hose Routing...
  • Page 555 APPENDIX 17-9 Cable, Wire and Hose Routing 1. Subthrottle Valve Actuator Connector 2. Subthrottle Sensor Connector 3. Injector #2 Connector 4. Injector #1 Connector 5. Inlet Air Pressure Sensor Hose 6. Inlet Air Temperature Sensor Lead 7. Vacuum Hose (California Model) 8.
  • Page 556 17-10 APPENDIX Cable, Wire and Hose Routing...
  • Page 557 APPENDIX 17-11 Cable, Wire and Hose Routing 1. Run the alternator lead and sidestand switch lead through the clamp of the engine bracket. 2. Fuse box 3. Run the seat lock cable through the guide of the tool box. 4. Seat Lock Cable 5.
  • Page 558 17-12 APPENDIX Cable, Wire and Hose Routing...
  • Page 559 APPENDIX 17-13 Cable, Wire and Hose Routing 1. Fuel Pump Lead Connector 2. Black/Green Lead 3. Red Lead 4. Black Lead 5. Red Lead 6. Clamp the ignition coil #2 lead connector with the air switching valve hose clamp. 7. Air Switching Valve Hose...
  • Page 560 17-14 APPENDIX Cable, Wire and Hose Routing...
  • Page 561 APPENDIX 17-15 Cable, Wire and Hose Routing 1. Speed Sensor Connector 2. Neutral Switch Connector 3. Run the starter motor lead through the engine bracket clamp.
  • Page 562 17-16 APPENDIX Cable, Wire and Hose Routing...
  • Page 563 1. Connect the battery negative (–) lead connector to the main harness. 2. Vehicle-down Sensor 3. ECU 4. Ignition Switch Lead Connector 5. Kawasaki Diagnostic System Connector 6. Battery 7. Turn Signal Relay 8. Insert the harness attached clamp to the battery case.
  • Page 564 17-18 APPENDIX Cable, Wire and Hose Routing...
  • Page 565 3. Run the rear fender harness through the guide of the frame. 4. Rear Fender Harness 5. Seat Lock Cable 6. Run the seat lock cable through the guide of the frame. 7. Starter Relay 8. Relay Box 9. Clamp (for Oxygensensor #2) 10. Kawasaki Diagnostic System Connector...
  • Page 566 17-20 APPENDIX Cable, Wire and Hose Routing...
  • Page 567 APPENDIX 17-21 Cable, Wire and Hose Routing 1. Reserve Tank Hose 2. Breather Hose 3. Breather Check Valve 4. Other than Europe Models 5. Run the breather hose to the inside of the engine bracket and frame cross pipe front. 6.
  • Page 568 17-22 APPENDIX Cable, Wire and Hose Routing...
  • Page 569 APPENDIX 17-23 Cable, Wire and Hose Routing 1. View from the outside 2. Roll the taillight lead to the pin. 3. Through the rear fender harness to the fender hole. 4. Through the rear fender harness to the guide. 5. Clamp the rear fender harness with the reinforce attached clamps. 6.
  • Page 570 17-24 APPENDIX Cable, Wire and Hose Routing 1. Clamps (Clamp the sidestand switch lead.)
  • Page 571 APPENDIX 17-25 Cable, Wire and Hose Routing 1. Starter Motor Lead 2. Clamp 3. Clamp (Bent the clamp as shown.)
  • Page 572 17-26 APPENDIX Cable, Wire and Hose Routing 1. Air Switching Valve 2. Face the white mark right side. 3. Clamp (for Ignition Coil #2 Lead) 4. Air Switching Valve Hose...
  • Page 573 APPENDIX 17-27 Cable, Wire and Hose Routing 1. Stator Coil Lead 2. Oil Pressure switch Lead 3. Clamp the stator coil lead and oil pressure switch lead. After installed, bend the clamp to the alternator cover. 4. Clamp the sidestand switch lead only. 5.
  • Page 574 17-28 APPENDIX Cable, Wire and Hose Routing 1. Main Harness 2. Clamp (Wrap the connectors.) 3. Sidestand Switch Lead 4. Oil Pressure Switch Lead 5. Crankshaft Sensor Lead 6. Engine Pulley Cover...
  • Page 575 APPENDIX 17-29 Cable, Wire and Hose Routing 1. Clamp the stator coil lead and main harness. 2. Stator Coil Lead...
  • Page 576 17-30 APPENDIX Cable, Wire and Hose Routing 1. Reserve Tank Hose 2. Inlet Air Pressure Sensor Hose 3. Air Switching Valve Hose 4. Run the inlet air pressure hose over the air switching valve hose. 5. Run the reserve tank hose into the frame hose. 6.
  • Page 577 APPENDIX 17-31 Cable, Wire and Hose Routing 1. Clamp 2. Reserve Tank Hose 3. Reserve Tank...
  • Page 578 17-32 APPENDIX Cable, Wire and Hose Routing...
  • Page 579 APPENDIX 17-33 Cable, Wire and Hose Routing 1. Front Caliper 2. Brake Hose 3. Clamp (Insert the clamp in to the handlebar.) 4. Clamp 5. Through the brake hose. 6. Front Master Cylinder...
  • Page 580 17-34 APPENDIX Cable, Wire and Hose Routing...
  • Page 581 APPENDIX 17-35 Cable, Wire and Hose Routing 1. Rear Caliper 2. Brake Hose 3. Clamp 4. Rear Master Cylinder 5. Reservoir Tank 6. Swingarm 7. Cotter Pin 8. Brake Hose Holder 9. Run the brake hose between the swingarm and frame.
  • Page 582 17-36 APPENDIX Cable, Wire and Hose Routing California Model 1. Reserve Tank Hose 2. Clamp the air switching valve hose, vacuum hose (White) and purge hose (Green). 3. Breather Hose 4. Purge Hose (Green) 5. Fuel Return Hose (Red) 6. Vacuum Hose (White) 7.
  • Page 583: Troubleshooting Guide

    APPENDIX 17-37 Troubleshooting Guide NOTE Spark plug dirty, broken, or gap malad- ○ Refer to the Fuel System chapter for most justed of DFI trouble shooting guide. Spark plug dirty, broken, or gap malad- ○ This is not an exhaustive list, giving every justed possible cause for each problem listed.
  • Page 584 17-38 APPENDIX Troubleshooting Guide Air cleaner duct loose Cylinder head not sufficiently tightened Compression low: down Spark plug loose No valve clearance Cylinder head not sufficiently tightened Cylinder, piston worn down Piston ring bad (worn, weak, broken, or No valve clearance sticking) Cylinder, piston worn Piston ring/groove clearance excessive...
  • Page 585: Gear Shifting Faulty

    APPENDIX 17-39 Troubleshooting Guide Air cleaner O-ring damaged Clutch lever play excessive Air cleaner clogged Clutch release mechanism trouble Compression high: Gear Shifting Faulty: Carbon built up in combustion chamber Engine load faulty: Doesn’t go into gear; shift pedal doesn’t Clutch slipping return: Engine oil level too high...
  • Page 586: Exhaust Smokes Excessively

    17-40 APPENDIX Troubleshooting Guide Exhaust pipe leaking at cylinder head con- Relief valve stuck open nection O-ring at the oil passage in the crankcase Crankshaft runout excessive damaged Engine mount loose Exhaust Smokes Excessively: Crankshaft bearing worn Primary gear worn or chipped White smoke: Camshaft chain tensioner trouble Piston oil ring worn...
  • Page 587: Battery Trouble

    APPENDIX 17-41 Troubleshooting Guide Battery Trouble: Front fork oil viscosity too low Rear shock adjustment too soft Battery discharged: Front fork, rear shock absorber spring weak Charge insufficient Rear shock absorber oil leaking Battery faulty (too low terminal voltage) Battery lead making poor contact Brake Doesn’t Hold: Load excessive (e.g., bulb of excessive wattage)
  • Page 588 MODEL APPLICATION Year Model Beginning Frame No. □ JKAVN2B1 6A000001 or 2006 VN900B6F JKAVN900BBA000001 2006 VN900D6F JKAVN900BBA000001 □ :This digit in the frame number changes from one machine to another. Part No.99924-1366-01 Printed in Japan...

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Vulcan900 classic lt

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  • Gregory Polk May 27, 2019 11:06:
    This manual is good but not great because lots of things that you need it for it omits altogether​. For the amount of money this manual costs it go go into more detail but it fails to do so. Even being a mechanic still had to take bike to dealer to have minor work done that it never explains. I am disappoint​ed!
  • Alexandre Nov 24, 2016 12:02:
    Meu email pra retorno e o ale.santan​a73@gmail.​com
  • Alexandre Nov 24, 2016 12:30:
    Bom dia, em primeiro lugar, gostaria de parabeniza​los pelo excelente serviço prestado, em segundo, gostaria de pedir que se possível, me enviassem o manual de servicos da kawasaki vulcan 900 Classic Lt , ano 2011/ 12 em portugues.