Summary of Contents for KAWASAKI VULCAN 1600 CLASSIC
VULCAN 1600 CLASSIC VN1600 CLASSIC Motorcycle Service Manual...
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 Final Dr Brakes Suspension Steering 14 j Frame Electrical System 16 j Appendix 17 j This quick reference guide will assist you in locating a desired topic or pro ...
LIST OF ABBREVIATIONS ampere(s) pound(s) ABDC after bottom dead center meter(s) alternating current minute(s) ATDC after top dead center newton(s) BBDC before bottom dead center pascal(s) bottom dead center horsepower BTDC before top dead center pound(s) per square inch °C degree(s) Celsius revolution direct current...
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 ...
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.
• 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...
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.
GENERAL INFORMATION 1-1 General Information Table of Contents Before Servicing ........................Model Identification......................... General Specifications......................1-9 Unit Conversion Table ......................1-11...
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.
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.
1-4 GENERAL INFORMATION Before Servicing Tightening Sequence Bolts, nuts, or screws must be tightened according to the specified sequence to prevent case warpage or deformation which can lead to malfunction. If the specified tightening sequence is not indicated, tighten the fasteners alternating diagonally.
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.
1-6 GENERAL INFORMATION Before Servicing Direction of Engine Rotation When rotating the crankshaft by hand, the free play amount of rotating direction will affect the adjustment. Ro tate the crankshaft to positive direction (clockwise viewed from output side). Electrical Wires A two-color wire is identified first by the primary color and then the stripe color.
GENERAL INFORMATION 1-11 Unit Conversion Table Prefixes for Units: Units of Length: × 0.6214 mile Prefix Symbol Power × 3.281 mega × 1 000 000 × 0.03937 kilo × 1 000 centi × 0.01 milli × 0.001 Units of Torque: micro µ...
2-2 PERIODIC MAINTENANCE Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition.The initial maintenance is vitally important and must not be neglected. FREQUENCY Whichever 1 000 km * ODOMETER READING comes...
2-4 PERIODIC MAINTENANCE Torque and Locking Agent The following tables list the tightening torque The table below, relating tightening torque to for the major fasteners requiring use of a non thread diameter, lists the basic torque for the -permanent locking agent or liquid gasket. bolts and nuts.
PERIODIC MAINTENANCE 2-13 Periodic Maintenance Procedures Fuel System (DFI) Fuel Hose and Connection Inspection ○ The fuel hoses are designed to be used throughout the motorcycle’s life without any maintenance, however, if the motorcycle is not properly handled, the high pressure in side the fuel line can cause fuel to leak [A] or the hose to burst.
2-14 PERIODIC MAINTENANCE Periodic Maintenance Procedures Throttle Bore Cleaning • Check the thrott e bore for cleanliness as follows: ○ Remove the a r c eaner cover A en bolt A] and take off the right a r c eaner cover [B].
PERIODIC MAINTENANCE 2-15 Periodic Maintenance Procedures Air Cleaner Element Cleaning NOTE ○ In dusty areas, the element should be cleaned more frequently than the recommended interval. ○ After riding through rain or on muddy roads, the element should be cleaned immediately. •...
2-16 PERIODIC MAINTENANCE Periodic Maintenance Procedures ○ Run the purge hose (green) [A] above the canister breather hose (blue) [B] through the hole [C] into the tool case [D]. ○ Do not run these hoses side by side on the battery side of the canister.
PERIODIC MAINTENANCE 2-17 Periodic Maintenance Procedures Coo ant 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.
2-18 PERIODIC MAINTENANCE Periodic Maintenance Procedures Water and Coolant Mixture Ratio (when shipping) Soft Water 50 % Coolant 50 % Freezing Point − 35°C (− 31°F) Total Amount 2.3 L (2.4 US qt) • Tighten the drain bolts. Torque - Radiator Drain Bolt: 7.4 N·m (0.75 kgf·m, 65 in·lb) Water Pump Drain Bolt: 11 N·m (1.1 kgf·m, 95 in·lb) •...
PERIODIC MAINTENANCE 2-19 Periodic Maintenance Procedures Engine Top End Air Suction Valve Inspection • Remove the air suction valve (see Engine Top End chap ter). • Visually inspect the reeds for cracks, folds, warps, heat damage or other damage. If there is any doubt as to the condition of the reeds [A], replace the air suction valve as an assembly.
2-20 PERIODIC MAINTENANCE Periodic Maintenance Procedures Clutch Fluid Leve Inspection • Hold the clutch f luid reservoir horizontal. • Check that the c utch fluid evel o the clutch reservoir between the ower [A] and the upper [B] level lines. If the fluid leve l is l ower than the...
PERIODIC MAINTENANCE 2-21 Periodic Maintenance Procedures • After changing the fluid, check the clutch for good clutch power and no fluid leakage. If necessary, bleed the air from the lines (see Clutch Line Bleeding in the Clutch chapter). • Remove the clear plastic hose. •...
2-22 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Apply clutch fluid to the parts removed and to the inner wall of the cylinder. • Take care not to scratch the piston or the inner wall of the cylinder. • Install the push rod with the dust seal fitted into the groove.
PERIODIC MAINTENANCE 2-23 Periodic Maintenance Procedures Engine Lubrication System Engine Oi Change • tuate the motorcycle so that it i s vertical after warming up the engine. • Remove the engine oi drain plug and drain the oil. • Remove: Oil Screen Plug [A] ( Engine r ght s...
2-24 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Remove the oil filler cap [A] with the driver-filler cap [B] and pour in the specified type and amount of oil. Clutch Cover [C] Special Tool - Driver-Filler Cap: 57001–1454 Torque - Oil Filler Cap: 1.5 N·m (0.15 kgf·m, 13 in·lb) Engine Oil Type: API SE, SF or SG class...
PERIODIC MAINTENANCE 2-25 Periodic Maintenance Procedures • Measure the tread depth at the center of the tread depth gauge [A]. S nce the t re may wear unevenly, take measurement at several places. If any measurement s less than the service limi t, replace the tire see Wheels/T res chapter).
2-26 PERIODIC MAINTENANCE Periodic Maintenance Procedures • The oil level [A] should come to the bottom of the filler opening. If it is low, first check the final gear case for oil leakage, remedy it if necessary, and add oil through the filler open ing.
PERIODIC MAINTENANCE 2-27 Periodic Maintenance Procedures Brakes Brake Pad Wear Inspection • Check the lining thickness [A] of the pads in each caliper. If the lining thickness of either pad is less than the service limit [B], replace both pads in the caliper as a set (see Brakes chapter).
2-28 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Check that the brake fluid level in the rear brake reservoir [A] is between the upper [B] and the lower [C] level lines. If the fluid level is lower than the lower level line, fill the reservoir to the upper level line.
PERIODIC MAINTENANCE 2-29 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].
2-30 PERIODIC MAINTENANCE Periodic Maintenance Procedures Rear Brake Light Switch Check/Adjustment • Turn on the ignition switch. • Check the operation of the rear brake light switch by de pressing the brake pedal [A]. The brake light should go on after about 10 mm (0.39 in.) of the pedal travel [B].
PERIODIC MAINTENANCE 2-31 Periodic Maintenance Procedures Rear Shock Absorber Oil Leak Inspection • Visually inspect the shock absorbers [A] for oil leakage. If they are oil leaked, one unit feels weaker than the other, replace both shock absorber as a set. Swingarm Pivot Lubrication •...
2-32 PERIODIC MAINTENANCE Periodic Maintenance Procedures ○ Feel for steering ooseness by pushing and pulling fork. If you feel looseness, the steer ng s too loose. NOTE ○ The cables and wiring w have some effect on the mo tion of the fork which must be taken nto account.
PERIODIC MAINTENANCE 2-33 Periodic Maintenance Procedures Electrical System Spark Plug Cleaning/Inspection • Clean the spark plug, preferably in a sandblasting device, and then clean off any abrasive particles. The plug may also be cleaned using a high-flash point solvent and a wire brush or other tool.
2-34 PERIODIC MAINTENANCE Periodic Maintenance Procedures • With the cable disconnected at both ends, the cable should move freely [A] within the cable housing. If cable movement is not free after lubricating, if the cable is frayed [B], or if the cable housing is kinked [C], replace the cable.
FUEL SYSTEM (DFI) 3-1 Fuel System (DFI) Table of Contents Exploded View........3-4 Crankshaft Sensor DFI Parts Location......3-8 Removal/Installation....3-57 DFI System........3-12 Crankshaft Sensor Inspection..3-57 DFI Wiring Diagram ......3-14 Vehicle-down Sensor (Service Code Specifications ........3-17 31)...........
3-2 FUEL SYSTEM (DFI) Power Source Voltage Inspection 3-80 Element Removal......3-94 Output Voltage Inspection.... 3-81 Element Cleaning......3-94 Resistance Inspection....3-81 Left Air Cleaner Housing Fuel Line..........3-83 Removal/Installation....3-94 Fuel Pressure Inspection ..... 3-83 Right Air Cleaner Housing Fuel Flow Rate Inspection ...
17. Air cleaner drain hose 18. Right air cleaner base 19. Right spark plug lead holder 20. Throttle body assy CA: California Model CN: Canadian Model U.S.: United States Model SS: Apply silicone sealant (Kawasaki Bond: 56019–120). L: Apply a non-permanent locking agent.
FUEL SYSTEM (DFI) 3-9 DFI Parts Location DFI: DFI Parts (this chapter) F: Front 1. Atmospheric Pressure Sensor (DFI) 2. Water Temperature Sensor (DFI) 3. Ignition Coils 4. Ignition Switch (see next page) 5. Starter Motor 6. Water Temperature Switch 7.
3-10 FUEL SYSTEM (DFI) DFI Parts Location...
FUEL SYSTEM (DFI) 3-11 DFI Parts Location...
FUEL SYSTEM (DFI) 3-15 DFI Wiring Diagram Terminal Numbers of ECU Connectors Terminal Names #1: Front Cylinder, #2: Rear Cylinder 1. Starter Lockout Switch Signal 2. Interlock Circuit Signal 3. Self-diagnosis Signal (generated by grounding this terminal and shown by FI indicator LED light) 4.
3-16 FUEL SYSTEM (DFI) DFI Wiring Diagram 44. Ignition Coil #1 Signal DFI and Electrical Parts DFI: DFI Parts ECU [A]: Electronic Control Unit (DFI) Engine Stop Switch [B] Starter Button [C] Ignition Coils [D] Crankshaft Sensors (Crankshaft Sensors) [E] Junction Box [F] Starter Circuit Relay [G] Interlock Diodes [H]...
FUEL SYSTEM (DFI) 3-17 Specifications Item Standard Throttle Grip Free Play: 3 mm (0.08 0.12 in.) Air Cleaner Element: Paper filter DFI System: Make: Mitsubishi Electric Idle Speed: 950 ± 50 r/min (rpm) Throttle Body Assy: Type × Bore Two barrel type × 36 mm (1.42 in.) ECU (Electronic Control Unit): Type...
FUEL SYSTEM (DFI) 3-19 DFI Servicing Precautions There are a number of important precautions that should be followed servicing the DFI system. ○ To maintain the correct fuel-air mixture (F/A), there must be no inlet air leaks in the DFI system. Be sure to install the oil filler cap [A] after filling the engine oil, using the driver-filler cap [B].
3-20 FUEL SYSTEM (DFI) Troubleshooting the DFI System Outline When an abnormality in the system occurs, the FI indica tor LED light [A] and FI symbol [B] go 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).
○ After measurement, remove the needle adapters and ap ply silicone sealant to the seals [A] of the connector [B] for waterproofing. (Kawasaki Bond: 56019–120)-Seals Silicone Sealant- of Connector • Always check battery condition before replacing the DFI parts.
3-22 FUEL SYSTEM (DFI) Troubleshooting the DFI System Resistance Check Method ○ This method is simple. No need for a fully charged battery and the needle adapter. Just do the following especially when a sensor [A] is suspect. • Turn the ignition SW OFF and disconnect the connectors. •...
FUEL SYSTEM (DFI) 3-23 Troubleshooting the DFI System ○ If both ends of a harness [A] are far apart, ground [B] the one end [C], using an auxiliary wire [D] and check the continuity between the end [E] and the ground [F]. This enables to check a long harness for continuity.
3-24 FUEL SYSTEM (DFI) Troubleshooting the DFI System DFI Diagnosis Flow Chart Inquiries to Rider • Refer to the next sample diagnosis chart. ○ Each rider reacts to problems in different ways, so it is important to confirm what kind of symptoms the rider has encountered.
FUEL SYSTEM (DFI) 3-25 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. □ □ □ □ □ □...
3-26 FUEL SYSTEM (DFI) Troubleshooting the DFI System □ brake dragging. □ engine overheating. □ clutch slipping. □ other: □ Poor running choke knob left pulled out fully (push it in fully). or no power at □ spark plug loose (tighten it). high speed □...
FUEL SYSTEM (DFI) 3-27 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. ○...
3-28 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. whether sidestand up or not Though clutch lever pulled in but sidestand up Sidestand down and clutch lever pulled in...
FUEL SYSTEM (DFI) 3-29 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Cylinder, piston worn Inspect and replace (see chapter 5). Piston ring bad (worn, weak, broken or sticking) Inspect and replace (see chapter 5). Piston ring/groove clearance excessive Inspect and replace (see chapter 5).
3-30 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Throttle sensor trouble Inspect (see chapter 3). Inlet air temperature sensor trouble Inspect (see chapter 3). Water temperature sensor trouble Inspect (see chapter 3). Atmospheric pressure sensor trouble Inspect (see chapter 3).
FUEL SYSTEM (DFI) 3-31 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Throttle sensor malfunction Inspect (see chapter 3). Water temperature sensor trouble Inspect (see chapter 3). Atmospheric pressure sensor trouble Inspect (see chapter 3). Inlet air pressure sensor trouble Inspect (see chapter 3).
3-32 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Inlet air temperature sensor trouble Inspect (see chapter 3). Water temperature sensor trouble Inspect (see chapter 3). Atmospheric pressure sensor trouble Inspect (see chapter 3). Inlet air pressure sensor trouble Inspect (see chapter 3).
FUEL SYSTEM (DFI) 3-33 DFI System Troubleshooting Guide Poor Running or No Power at High Speed: Symptoms or Possible Causes Actions (detailed reference) Firing incorrect: Spark plug dirty, broken or maladjusted Clean spark plug and adjust plug gap (see chapter 2). Spark plug cap or high tension wiring trouble Inspect plug cap and ignition coil (see chapter 16).
3-34 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (detailed reference) HLA ( hydraulic lash adjuster) damaged (worn, Inspect and replace (see chapter 5). seizure or spring broken) Knocking: Carbon buit up in combustion chamber Repair (see chapter 5). Fuel poor quality or incorrect (Use high-octone Change fuel (see chapter 3).
FUEL SYSTEM (DFI) 3-35 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (detailed reference) Air cleaner O-ring damaged Replace (see chapter 3). Too low fuel pressure Inspect (see chapter 3). Water temperature sensor trouble Inspect and replace (see chapter 3). Inlet air temperature sensor trouble Inspect and replace (see chapter 3).
3-36 FUEL SYSTEM (DFI) Self-Diagnosis Self-diagnosis Procedures ○ When a problem occurs with the DFI system, the FI indi cator LED light [A] and FI symbol [B] go on. • Remove the rear and front seats (see Frame chapter). • Ground [A] the self-diagnosis terminal [B] (yellow lead) to the battery (–) terminal [C], using a wire [D].
FUEL SYSTEM (DFI) 3-37 Self-Diagnosis Service Code Reading ○ Service codes are shown by a series of long and short blinks of the FI indicator LED light as shown below. ○ Read 10th digit and unit digit as the FI indicator LED light blinks. ○...
3-38 FUEL SYSTEM (DFI) Self-Diagnosis ○ Each service code is conti nuously repeated three times until the gnit ion SW is turned OFF. Service Code Erasing ○ When the repair has been done, the LED light will not show fault codes any more. But even if the repair has been done, the ignition SW is turned OFF, or the battery is disconnected, all the fault codes remain in the ECU, which need not be absolutely erased.
FUEL SYSTEM (DFI) 3-39 Self-Diagnosis Service FI Indicator LED Light Problems (1) Code Injector #2 malfunction, wiring open or short Fuel pump malfunction, wiring open or short Ignition coil primary winding #1 malfunction, wiring open or short Ignition coil primary winding #2 malfunction, wiring open or short Footnotes: (1) The ECU may be involved in these problems.
3-40 FUEL SYSTEM (DFI) Self-Diagnosis Service Output Signal Usable Parts Backups by ECU Codes Range or Criteria Either crankshaft sensor If either crankshaft sensor generates Crankshaft must send signals 8 or more signals, the ECU runs Sensor #1 (output voltage) the engine by the signal of the good crankshaft sensor, but neither Crankshaft...
FUEL SYSTEM (DFI) 3-41 Throttle Sensor (Service Code 11) Throttle Sensor Removal/Adjustment CAUTION Do not remove or adjust the throttle sensor [A] since it has been adjusted and set with precision at the factory. Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it.
If the reading is out of the standard range, inspect the throttle sensor resistance. • After throttle sensor inspection, remove the needle adapters, and apply silicone sealant to the seals [A] of the connector [B] for waterproofing. Silicone Sealant (Kawasaki Bond: 56019-120) - Seals of Connectors...
FUEL SYSTEM (DFI) 3-43 Throttle Sensor (Service Code 11) Resistance Inspection • Turn the ignition switch OFF. • Disconnect the throttle sensor connector. • Connect a digital meter [A] to the throttle sensor connector [B]. • Measure the throttle sensor resistance. Throttle Sensor Resistance Connections: BL/W lead [C] ←→...
3-44 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code 12) Removal CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the part can damage it. • Remove the fuel tank (see Fuel Tank section in this chap ter).
• Turn the ignition SW OFF and remove the needle adapters. • Apply silicone sealant to the seals of the connector for waterproofing. Silicone Sealant (Kawasaki Bond: 56019-120) - Connector Seals...
3-46 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code 12) If the output voltage is normal, check the inlet air pressure sensor itself. ○ Check the output voltage for vacuum as follows. If the output voltage changes within the usable range as vac uum changes, the sensor is normal and the ECU is sus ...
FUEL SYSTEM (DFI) 3-47 Inlet Air Pressure Sensor (Service Code 12) Suppose: Pg : Vacuum (gauge) of Throttle Assy Pl : Local Atmospheric Pressure (absolute) measured by a barometer Pv : Vacuum (absolute) of Throttle Assy Vv : Sensor Output Voltage (v) then Pv = Pl –...
3-48 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code 12) Pv = 55 86 cm Hg Vv: Inlet Air Pressure Sensor Output Voltage (V) TO: Throttle Full Open (Digital Meter Reading) ST: Standard of Sensor Output Pv: Throttle Vacuum (absolute) Voltage (v) Ps: Standard Atmospheric Pressure (absolute) UR: Usable Range of Sensor Output...
ECU and the inlet air temperature sensor. If the wiring is good, check the sensor resistance. • Remove the needle adapters, and apply silicone sealant to the seals of the connector for waterproofing. Silicone Sealant (Kawasaki Bond: 56019-120) - Seals of Connector...
3-50 FUEL SYSTEM (DFI) Inlet Air Temperature Sensor (Service Code 13) Sensor Resistance Inspection • Remove the inlet air temperature sensor (see this sec tion). • Suspend the sensor [A] in a container of machine oil so that the heat-sensitive portion and threaded portion are submerged.
Cooling System chapter). • Disconnect the sensor connector [B], and unscrew the water temperature sensor [C]. Silicone Sealant (Kawasaki Bond: 56019-120) - Threads of Water Temperature Sensor Torque - Water Temperature Sensor: 18 N·m (1.8 kgf·m, 13 ft·lb) •...
3-52 FUEL SYSTEM (DFI) Water Temperature Sensor (Service Code 14) Water Temperature Sensor Resistance Inspection • Remove the water temperature sensor (see this section). • Suspend the sensor [A] in a container of machine oil so that the heat-sensitive portion and threaded portion are submerged.
FUEL SYSTEM (DFI) 3-53 Atmospheric Pressure Sensor (Service Code 15) Removal CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. • Remove the fuel tank (see Fuel Tank section in this chap ter).
• Remove the needle adapters. • Apply silicone sealant to the seals of the connector for waterproofing. Silicone Sealant (Kawasaki Bond: 56019-120) - ECU Connector Seals Output Voltage Inspection NOTE ○ The output voltage changes according to the local at ...
FUEL SYSTEM (DFI) 3-55 Atmospheric Pressure Sensor (Service Code 15) A. ECU b. Atmospheric Pressure Sensor If you need to check the atmospheric pressure sensor for various altitudes other than sea level, check the output voltage as follows: ○ Determine the local altitude (elevation). If you know the local atmospheric pressure using a barometer, substitute the atmospheric pressure for Pv (Throttle Vacuum) in the inlet air pressure sensor chart (see Inlet Air Pressure Sensor section in this chapter).
3-56 FUEL SYSTEM (DFI) Atmospheric Pressure Sensor (Service Code 15) Va: Atmospheric Pressure Sensor Output Voltage (v) H: Altitude (m or feet) SL: Sea Level (0 m) ST: Standard of Sensor Output Voltage (v) UR: Usable Range of Sensor Output Voltage (v)
FUEL SYSTEM (DFI) 3-57 Crankshaft Sensors (#1, #2: Service Code 21, 22) Crankshaft Sensor #1: for Front Cylinder (Service Code 21) Crankshaft Sensor #2: for Rear Cylinder (Service Code 22) Crankshaft Sensor Removal/Installation • See Ignition System section in the Electrical System chapter. Crankshaft Sensor Inspection ○...
3-58 FUEL SYSTEM (DFI) Vehicle-down Sensor (Service Code 31) Vehicle-down Sensor Removal CAUTION Never drop the down-sensor, especially on a hard surface. Such a shock to the sensor can damage it. • Remove the fuel tank (see this chapter). • Remove the bolts [A] and take out the covers [B].
• 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.
3-60 FUEL SYSTEM (DFI) Vehicle-down Sensor (Service Code 31) A. ECU N. Ignition Switch Q. Sealed Battery d. Vehicle-down Sensor O. Starter Relay q. Frame Earth F. Junction Box P. Main Fuse 30 A × 32 V f. Ignition Fuse 10 A × 32 V e.
FUEL SYSTEM (DFI) 3-61 Fuel Injectors (#1, #2: Service Code 41, 42) Fuel Injector #1: Front Fuel Injector for Front Cylinder (Service Code 41) Fuel Injector #2: Rear Fuel Injector for Rear Cylinder (Service Code 42) CAUTION Never drop the injector, especially on a hard sur face.
3-62 FUEL SYSTEM (DFI) Fuel Injectors (#1, #2: Service Code 41, 42) • Apply engine oil to the O-ring [A], and install each injector [B] into the delivery joint [C]. • Check that there is no dirt or dust on the injector seating surface [A] of the inlet manifold [B].
FUEL SYSTEM (DFI) 3-63 Fuel Injectors (#1, #2: Service Code 41, 42) • 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 clamps [D]) as shown.
3-64 FUEL SYSTEM (DFI) Fuel Injectors (#1, #2: Service Code 41, 42) • Push and pull [A] the fuel hose joint #2 [B] back and forth more than two times and make sure it is locked and doesn’t come off. When the fuel hose joint #2 is correctly installed, it should slide on the delivery pipe about 5 mm (0.2 in.).
FUEL SYSTEM (DFI) 3-65 Fuel Injectors (#1, #2: Service Code 41, 42) If the power source voltage is incorrect, check the DFI power source (see DFI Power Source in this chapter). If the DFI power source is good, check the ECU for its ground and power supply.
3-66 FUEL SYSTEM (DFI) Fuel Injectors (#1, #2: Service Code 41, 42) • Remove the fuel tank (see this chapter). • Plug the fuel hose ends. • Remove connectors for injector [A]. • Connect each test light set [B] to the injector main harness connector [C].
FUEL SYSTEM (DFI) 3-67 Fuel Injectors (#1, #2: Service Code 41, 42) A. ECU R. Fuel Injector #1 F. Junction Box S. Fuel Injector #2 N. Ignition Switch V. DFI Fuse 15 A × 32 V O. Starter Relay e. DFI Main Relay P.
3-68 FUEL SYSTEM (DFI) Fuel Pump (Service Code 45) Fuel Pump Removal CAUTION Never drop the fuel pump, especially on a hard sur face. Such a shock to the pump can damage it. WARNING Gasoline is extremely flammable and can be explo sive under certain conditions.
FUEL SYSTEM (DFI) 3-69 Fuel Pump (Service Code 45) • Check that the fuel pump (–) terminals [A] and band [B] are in place. Front [C] • Apply a non-permanent locking agent to the threads of the fuel pump bolts. •...
3-70 FUEL SYSTEM (DFI) Fuel Pump (Service Code 45) Operating Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch OFF. • Remove the seat (see Frame chapter). • Connect the hand tester (25 V DC) to the fuel pump con- nector [A] with needle adapter set.
FUEL SYSTEM (DFI) 3-71 Fuel Pump (Service Code 45) Power Source Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Remove the seat (see Frame chapter). • Connect a digital voltmeter [A] to the fuel pump connector [B] (2P), using the needle adapter [C].
• After inspection, remove the needle adapter, and apply silicone sealant to the seal of the connector for water proofing. Silicone Sealant (Kawasaki Bond: 56019-120) - Sealing of Fuel Pump Connector A. ECU Q. Sealed Battery F. Junction Box U.
(see Electrical System chap- ter) in order to check the primary coils. • Remove the needle adapters. • Apply silicone sealant to the seals of the connector for waterproofing. Silicone Sealant (Kawasaki Bond: 56019-120) - ECU Connector Seals...
FUEL SYSTEM (DFI) 3-75 FI Indicator LED Light LED Light Inspection ○ The FI indicator LED light [A] goes ON when the ignition SW 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.
3-76 FUEL SYSTEM (DFI) ECU Identification ○ Most countries have their own regulations, so each ECU has different characteristic of fuel injection according to each country. So, do not confuse ECU’s with each other and use only the ECU’s for your country. Otherwise, the motorcycle could not clear the emission regulation.
FUEL SYSTEM (DFI) 3-77 ECU • With the ECU connector [A] joined, check the following ground leads for continuity with the ignition SW ON or OFF, using a digital voltmeter [D]. ECU Grounding Inspection Meter Connections: 10, 20, 32, or 42 (BK/Y) ←→ Battery (–) Terminal Terminal 21 (BR/BK) Terminal ←→...
3-78 FUEL SYSTEM (DFI) DFI Power Source DFI Fuse Removal • Remove the seat (see Frame chapter). • Pull the lock [A] and open the lid [B]. • Pull out the DFI fuse [C] from the case with needle nose pliers.
FUEL SYSTEM (DFI) 3-79 DFI Power Source DFI Power Source Circuit A. ECU Q. Sealed Battery W. ISC Valve #1 F. Junction Box R. Fuel Injector #1 X. ISC Valve #2 N. Ignition SW S. Fuel Injector #2 e. DFI Main Relay O.
3-80 FUEL SYSTEM (DFI) ISC Valves Removal/Installation CAUTION Never drop the ISC valves, especially on a hard sur face. Such a shock to the valve can damage it. ○ The ISC valves are removed during right air cleaner hous- ing removal (see this chapter).
FUEL SYSTEM (DFI) 3-81 ISC Valves Output Voltage Inspection • Check the output voltage at the connectors [A] of the ISC Valves. • Remove the right air cleaner cover (see this chapter). Special Tool - Hand Tester [B] : 57001–1394 •...
3-82 FUEL SYSTEM (DFI) ISC Valves A. ECU V. DFI Fuse 15 A × 32 V F. Junction Box W. ISC Valve #1 N. Ignition Switch X. ISC Valve #2 O. Starter Relay e. DFI Main Relay P. Main Fuse 30 A × 32 V f.
FUEL SYSTEM (DFI) 3-83 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.
3-84 FUEL SYSTEM (DFI) Fuel Line • Start the engine, and let it idle. • Measure the fuel pressure with the engine idling. Fuel Pressure (idling) Standard: 304 kPa (3.1 kgf/cm², 44 psi) NOTE ○ The gauge needle will fluctuate. Read the pressure at the average of the maximum and minimum indications.
FUEL SYSTEM (DFI) 3-85 Fuel Line Fuel Flow Rate Inspection NOTE ○ Be sure the battery is fully charged. 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;...
3-86 FUEL SYSTEM (DFI) Throttle Grip and Cables Throttle Grip Free Play Inspection • Refer to Throttle Control System Check in the Periodic Maintenance Chapter. Throttle Grip Free Play Adjustment • Loosen the locknuts [A] and screw the adjusters [B] all the way in so as to give the throttle grip plenty of play.
FUEL SYSTEM (DFI) 3-87 Throttle Body Assy Idle Speed Check • Refer to Idle Speed Check in the Periodic Maintenance Chapter. Idle Speed Adjustment • Refer to Idle Speed Check in the Periodic Maintenance Chapter. Throttle Bore Cleaning • Refer to Throttle Control System Check in the Periodic Maintenance Chapter.
3-88 FUEL SYSTEM (DFI) Throttle Body Assy • Disconnect the front and rear injector connectors [A]. Front [B] • Remove the following from the choke cable holder [A]. Screw [B] Choke Cable Plate [C] • While pushing the choke lever [A] forward, remove the cable housing from the choke cable holder [B] and the inner cable out of the holder slit [C].
FUEL SYSTEM (DFI) 3-89 Throttle Body Assy • Pinch the lock of the fuel hose joint #2 [A] with your fin gers, pull the joint #2 out along the pipe (for delivery joint), and take out the fuel hose assy [B]. Front [C] •...
3-90 FUEL SYSTEM (DFI) Throttle Body Assy Throttle Assy Insta ation • Instal the ower a r cleaner duct between cylinders. • Replace the flange seal [A] with a new one. • With a h gh-flash point solvent, c ean off the f ange sur face of the cylinder head and w pe dry.
FUEL SYSTEM (DFI) 3-91 Throttle Body Assy • Fit the fuel hose joint #2 [A] onto the pipe (for delivery joint) until the joint clicks [B]. ○ Insert the hose joint straight along the pipe. Front [C] • Push and pull [A] the fuel hose joint #2 [B] back and forth more than two times and make sure it is locked and doesn’t come off.
3-92 FUEL SYSTEM (DFI) Throttle Body Assy • Remove the three throttle body flange bolts [A]. • Split the throttle assy into the throttle body [B] and the inlet manifold [C]. The gasket [D] comes off. • Discard the gasket. ○...
FUEL SYSTEM (DFI) 3-93 Throttle Body Assy • Remove the delivery joint and injectors (see Injector sec tion in this chapter). • Open the butterfly valves [A], and wipe any carbon off the throttle bores [B] around the valves, using a piece of lint-free cloth penetrated with a high-flash point solvent.
3-94 FUEL SYSTEM (DFI) Air Cleaner Element Removal • Remove: Allen Bolt and Washer [A] Left Air Cleaner Cover [B] Front [C] • Remove the element [A]. • Push a clean, lint-free towel into the lower air cleaner duct to keep dirt or other foreign material from entering. WARNING If dirt or dust is allowed to pass through into the throttle assy, the throttle may become stuck, possi ...
FUEL SYSTEM (DFI) 3-95 Air Cleaner Right Air Cleaner Housing Removal • Remove: Allen Bolt and Washer [A] Right Air Cleaner Cover [B] Front [C] • Remove: ISC Valve Hoses [A] ISC Valve Lead Connectors [B] Air Cleaner Allen Bolts [C] and Screws [D] Air Cleaner Base Bolt [E] •...
3-96 FUEL SYSTEM (DFI) Air Cleaner If the air cleaner drain hose [A] has been removed with it attached to the right air cleaner base, pull the drain hose off the right air cleaner base. Remove the left air cleaner base and insert the drain hose under the lower air cleaner duct.
FUEL SYSTEM (DFI) 3-97 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.
3-98 FUEL SYSTEM (DFI) Fuel Tank • Remove the Allen bolts [A] and take out the meter unit [B]. CAUTION Place the meter so that the face is up. If a meter is left upside down or sideways for any length of time, it will malfunction.
FUEL SYSTEM (DFI) 3-99 Fuel Tank • Prepare rubber hoses of the inside diameter 5 5.8 mm (0.20 0.23 in.) [e.g. Rubber Tube: Part No. 92191 -1272] × L 80 mm (3.1 in.) and make plug hoses [A] of the rubber hose with one end tied with a wire [B]. •...
3-100 FUEL SYSTEM (DFI) Fuel Tank • Close the fuel tank cap. • Remove the fuel tank from the vehicle, and place it on a flat surface. CAUTION For California model, if gasoline, solvent, water or any other liquid enters the canister, the canister’s vapor absorbing capacity is greatly reduced.
FUEL SYSTEM (DFI) 3-101 Fuel Tank • Check that the rubber dampers [A] are in place. If the dampers are damaged or deteriorated, replace them. ○ Remove the plug hoses, and 8 mm plug, then quickly install the fuel hoses one by one. •...
3-102 FUEL SYSTEM (DFI) Fuel Tank Fuel Tank Cleaning WARNING Clean the tank in a well-ventilated area, and take care that there are no sparks or flame anywhere near the working area. Because of the danger of highly flammable liquids, do not use gasoline or low-flash point solvent to clean the tank.
FUEL SYSTEM (DFI) 3-103 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.
3-104 FUEL SYSTEM (DFI) Evaporative Emission Control System Hose Inspection (Periodic Inspection) • Refer to Evaporative Emission Control System Check in the Periodic Maintenance Chapter (chapter 2). Separator Operation Test WARNING Gasoline is extremely flammable and can be explo sive under certain conditions.
COOLING SYSTEM 4-1 Cooling System Table of Contents Exploded View........................Coolant Flow Chart......................... 4-4 Specifications ......................... 4-6 Special Tools and Sealant ...................... 4-7 Coolant ........................... Coolant Deterioration Inspection..................4-8 Coolant Level Inspection....................4-8 Coolant Draining ....................... Coolant Filling ........................4-8 Pressure Testing .......................
4-4 COOLING SYSTEM Coolant Flow Chart Permanent type antifreeze is used as a coolant to protect the cooling system from rust and corrosion. When the engine starts, the water pump turns and the coolant circulates. The thermostat is a wax pellet type which opens or closes as coolant temperature changes. The thermostat continuously changes its valve opening to keep the coolant temperature at the proper level.
COOLING SYSTEM 4-5 Coolant Flow Chart 1. Water Pump 9. Radiator 2. Water Jacket 10. Radiator Fan 3. Cylinder Head 11. Throttle Body Assy 4. Water Pipe 12. Front 5. Water Hose 13. Cold Coolant 6. Radiator Cap 14. Hot Coolant 7.
4-6 COOLING SYSTEM Specifications Coolant provided when shipping: Type (recommended) Permanent type antifreeze (soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators) Color Green Mixed ratio Soft water 50%, coolant 50% Freezing point −...
4-8 COOLING SYSTEM Coolant Coolant Deterioration Inspection • Remove the right side cover (see Frame chapter). • Visually inspect the coolant [A] in the reserve tank. If whitish cotton-like wafts are observed, aluminum parts in the cooling system are corroded. If the coolant is brown, iron or steel parts are rusting.
COOLING SYSTEM 4-9 Coolant Pressure Testing • Remove the fuel tank (see Fuel System chapter). • Remove the radiator cap, and install a cooling system pressure tester [A] on the radiator filler neck [B]. NOTE ○ Wet the cap sealing surfaces with water or coolant to prevent pressure leakage.
4-10 COOLING SYSTEM Water Pump Water Pump Removal • Drain the coolant (see Coolant Change in the Periodic Maintenance chapter). • Remove: Water Hose Clamp [A] Water Hose [B] Front [C] • Remove: Water Pump Cover Bolts [A] Water Pump Cover [B] •...
COOLING SYSTEM 4-11 Water Pump Water Pump Inspection • Check the water pump drainage outlet hose [A] at the bottom of the water pump for coolant leakage. If the mechanical seal is damaged, the coolant leaks through the seal and drain through the passage. Replace the mechanical seal.
4-12 COOLING SYSTEM Water Pump • Using a thin-bladed screwdriver, pry out the oil seal. • Press out the mechanical seal [A] and ball bearing [B] from the inside of the right crankcase with the bearing driver set [C]. Special Tool - Bearing Driver Set: 57001-1129 ○...
COOLING SYSTEM 4-13 Radiator WARNING The radiator fan is connected directly to the bat tery. The radiator fan may start even if the ignition switch is off. NEVER TOUCH THE RADIATOR FAN UNTIL THE RADIATOR FAN CONNECTOR IS DIS- CONNECTED. TOUCHING THE FAN BEFORE THE CONNECTOR IS DISCONNECTED COULD CAUSE INJURY FROM THE FAN BLADES.
4-14 COOLING SYSTEM Radiator • Remove: Radiator Fan Bolts [A] Radiator Fan [B] Radiator Installation • Be sure to install the radiator fan ground lead terminal [A]. Torque - Radiator Fan Bolts and Fan Ground Lead Terminal Bolt: 8.3 N·m (0.85 kgf·m, 74 in·lb) •...
COOLING SYSTEM 4-15 Radiator Radiator Cap Inspection • Check the condition of the top and bottom valve seals of the radiator cap. If any one of them shows visible damage, replace the cap. Bottom Valve Seal [A] Top Valve Seal [B] Valve Spring [C] •...
4-16 COOLING SYSTEM Thermostat Thermostat Removal • Remove: Coolant : Drain about 200 mL Fuel Tank (see Fuel System chapter) Three Water Hoses [A] Bracket Bolts [B] One Water Hose (from #1 cylinder) Water Temperature Sensor Connector [C] • Remove the thermostat housing [D] along with the bracket.
COOLING SYSTEM 4-17 Hoses and Pipes Hose Installation • Install the hoses and pipes being careful to follow bend ing direction. Avoid sharp bending, kinking, flattening, or twisting. • Install the clamps [A] as near as possible to the hose end to clear the raised rib on the fitting.
ENGINE TOP END 5-1 Engine Top End Table of Contents Specifications ........5-3 Valve Removal ......5-35 Exploded View........5-6 Valve Installation ......5-35 Special Tools and Sealant ....5-12 Valve Guide Removal ....5-35 Clean Air System....... 5-15 Valve Guide Installation ....5-36 Air Suction Valve Removal...
5-2 ENGINE TOP END Front Exhaust Pipe Muffler Removal (U.S.A. and Removal(U.S.A. and Canadian Canadian Models) ..... 5-51 Models) ........5-50 Muffler, Exhaust Pipe Rear Exhaust Pipe Installation(U.S.A. and Removal(U.S.A. and Canadian Canadian Models) ..... 5-51 Models) ........5-51...
ENGINE TOP END 5-3 Specifications Item Standard Service Limit Clean Air System: Vacuum switch valve closing pressure: Open → Close 49.3 65.3 kPa – – – (370 490 mm Hg) Camshafts: Cam height: Exhaust 33.741 33.857 mm 33.64 mm (1.32839 1.33295 in.) (1.3244 in.) Inlet...
5-4 ENGINE TOP END Specifications Item Standard Service Limit Inlet 6.965 6.980 mm 6.95 mm (0.2736 in.) (0.27421 0.27480 in.) Valve guide inside diameter: Exhaust 7.000 7.015 mm 7.08 mm (0.2787 in.) (0.27559 0.27618 in.) Inlet 7.000 7.015 mm 7.08 mm (0.2787 in.) (0.27559 0.27618 in.) Valve/valve guide clearance...
ENGINE TOP END 5-5 Specifications Item Standard Service Limit Valve seat surface: Valve seat cutting angle 45°, 32°, 55° – – – Outside diameter: Exhaust 29.9 30.1 mm – – – (1.295 1.303 in.) Inlet 32.9 33.1 mm – – – (1.177 1.185 in.) Width:...
ENGINE TOP END 5-15 Clean Air System Air Suction Valve Removal • For rear air suction valve removal, remove the hose [A]. • Unscrew the mounting bolts [B] and remove the rear air suction valve cover [C]. • Remove the rear air suction valve. •...
5-16 ENGINE TOP END Clean Air System Vacuum Switch Valve Removal • Remove: Fuel Tank (see Fuel System Chapter) • Pull off the hoses [A] and take out the vacuum switch valve [B]. Vacuum Switch Valve Installation • Install the vacuum switch valve [A] so that the inlet vac uum hose [B] faces rear side.
ENGINE TOP END 5-17 Clean Air System • Gradually raise the vacuum (lower the pressure) applied to the vacuum switch valve, and check the valve opera tion. When the vacuum is low, the vacuum switch valve should permit air to flow. When the vacuum raises to valve closing pressure, it should stop air flow.
5-18 ENGINE TOP END Camshaft Chain Tensioner Camshaft Chain Tensioner Removal CAUTION This is a non-return type cam chain tensioner. The push rod does not return to its original position once it moves out to take up camshaft chain slack. Observe all the rules listed below: When removing the tensioner, do not take out the mounting bolts only halfway.
ENGINE TOP END 5-19 Camshaft Chain Tensioner • Install the larger spring [A], and then the ball bearing assy [B]. ○ Fit the ball bearing assy into the body until it bottoms out, using a thin-bladed screwdriver. • Screw in the lockbolt [A] finger-tight to hold the ball bear ing assy temporarily.
5-20 ENGINE TOP END Rocker Case Cover Rocker Case Cover Removal • Remove the engine (see Engine Removal/Installation chapter). • Remove the bolts [A] and take off the cover [B] from the rocker case. • Take out the oil filter springs [A] and HLA oil filters [B]. Rocker Case Cover Installation •...
ENGINE TOP END 5-21 Rocker Case Cover Rocker Case Cover Assembly • Apply adhesive to the rubber dampers [A] and install them on the rocker case cover as shown. ○ Insert the projections [B] of the dampers to the holes [C] of the cover.
5-22 ENGINE TOP END Rocker Case Rocker Case Removal • Remove the engine (see Engine Removal/Installation chapter). • Remove the throttle body assy (see Fuel System (DFI) chapter). • Remove the rocker case covers (see this chapter). • Remove the alternator outer cover (see Electrical System chapter).
• Apply silicone sealant [A] to the rocker case mating sur face and the outer circumference of the plugs as shown. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 ○ Do not apply silicone sealant around the camshaft bear ...
5-24 ENGINE TOP END Rocker Case • Replace the HLA oil filters [A] with new ones. • After installing the rocker case, fill the oil reservoir [B] with engine oil. • Tighten: Torque - Oil Hose Flange Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) •...
ENGINE TOP END 5-25 Rocker Case HLA Removal • Remove the rocker case (see this chapter). • Remove the rocker arms. • Pull the HLA (hydraulic lash adjuster) [B] out of the rocker arm [A] with your fingers. CAUTION Be careful not to damage or deform an HLA by tap ping it during removal or installation.
5-26 ENGINE TOP END Camshafts Camshaft Removal • Remove the timing inspection cap [A] and rotor bolt cap [B]. Special Tool - Driver-Filler Cap: 57001–1454 [C] • Turn the crankshaft counterclockwise [A] and align the “F” mark [B] (TDC mark for the front piston) with the middle of the notch [C].
ENGINE TOP END 5-27 Camshafts • Install the KACR on each camshaft. ○ The front KACR [A] and rear KACR [B] are different (inside view). Do not confuse these KACRs. • Fit the pin [A] into the notch [B], and install the KACR [C] onto the camshaft [D].
5-28 ENGINE TOP END Camshafts • Align the “R” mark [A] (TDC mark for the rear piston) with the middle of the notch [B] (310° turn from the front piston TDC). • Engage the rear camshaft sprocket with the camshaft chain as shown.
ENGINE TOP END 5-29 Camshafts • Apply molybdenum disulfide oil to the threads and seating surface of 12 mm nuts and both sides of washers. • Tighten the rocker case nuts and bolts temporarily follow ing the tightening sequence shown, and then tighten them to the specified torque.
5-30 ENGINE TOP END Camshafts Front Camshaft Chain Removal • Remove: Front Camshaft [A] (see this chapter) Spark Plug (left side, see Cylinder Compression Mea surement) Spark Plug Retainer [B] (left side) Special Tool - Hexagon Wrench, Hex 27 [C]: 57001-1210 •...
ENGINE TOP END 5-31 Camshafts KACR Inspection ○ Due to the simplicity of the KACR (Kawasaki Automatic Compression Release), no periodic maintenance is needed. There are only two symptoms of problems with the KACR mechanism compression is not released dur ...
5-32 ENGINE TOP END Cylinder Head Cylinder Compression Measurement NOTE ○ Be sure the battery is fully charged. • Warm up the engine thoroughly. • Stop the engine. • Remove one spark plug and attach the compression gauge and adapter firmly into the spark plug hole. Do not remove the other spark plug, only the plug lead.
ENGINE TOP END 5-33 Cylinder Head The following table should be consulted if the obtainable compression reading is not within the us able range. Problem Diagnosis Remedy (Action) Cylinder Carbon buildup on piston and in combustion Remove the carbon deposits chamber possibly due to damaged valve stem, and replace damaged parts if compression is higher than valve guide, stem oil seal and/or damaged...
5-34 ENGINE TOP END Cylinder Head • Do not remove the coolant drain plug [A] yet. • Remove the cylinder head nuts [B]. • Take the cylinder head off the cylinder. Cylinder Head Installation ○ The front cylinder head [A] has an F mark while the rear cylinder head [B] has an R mark.
ENGINE TOP END 5-35 Cylinder Head Valve Clearance Adjustment NOTE ○ Since the hydraulic lash adjusters constantly maintain zero clearance, it is not necessary to inspect or adjust the valve clearance. Valve Removal • Remove the cylinder head (see this chapter). •...
5-36 ENGINE TOP END Cylinder Head Valve Guide Installation • Apply engine oil to the valve guide outer surface before installation. • Heat the area around the valve guide hole to about 120 150°C (248 302°F) in the engine oil. •...
ENGINE TOP END 5-37 Cylinder Head Valve Seat Inspection • Remove the valve (see Valve Removal). • Check the valve seat surface [A] between the valve [B] and valve seat [C]. ○ Measure the outside diameter [D] of the seating pattern on the valve seat with vernier calipers.
5-38 ENGINE TOP END Cylinder Head Seat Cutter Operation Care: 1. This valve seat cutter is developed to grind the valve for repair. Therefore the cutter must not be used for other purposes than seat repair. Do not drop or shock the valve seat cutter, or the diamond particles may fall off.
ENGINE TOP END 5-39 Cylinder Head ○ To make the 32° grind, fit a 32° cutter into the holder, and slide it into the valve guide. ○ Turn the holder one turn at a time while pressing down very lightly. Check the seat after each turn. CAUTION The 32°...
ENGINE TOP END 5-41 Cylinders, Piston Cylinder Removal • Remove the cylinder head (see this chapter). • Remove the coolant drain plug [A] and drain the coolant from the cylinder. • Pull out the front camshaft chain guide [B]. • Remove the cylinder nuts [C].
5-42 ENGINE TOP END Cylinders, Piston • Do not mix up the top ring and second ring. • Install the top ring [A] so that the “R” mark [B] faces up. • Install the second ring [C] so that the “RN” mark [D] faces •...
ENGINE TOP END 5-43 Cylinders, Piston 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 [A] with a new one, and install the gaskets aligning the holes with the crankcase water passages [B].
5-44 ENGINE TOP END Cylinders, Piston • Install the front cylinder in the same way. ○ Position the front piston at TDC. ○ Tighten the cylinder nuts temporarily (These nuts are tightened to the specified torque after rocker case instal lation).
ENGINE TOP END 5-45 Cylinders, Piston Cylinder Boring and Honing ○ There is an oversize piston available. The oversize piston requires oversize rings. Oversize Piston and Rings: 0.5 mm (0.02 in.) oversize • Before boring a cylinder [A], first measure the exact di ameter of the oversize piston, and then, according to the standard clearance in the Specifications, determine the rebore diameter.
5-46 ENGINE TOP END Cylinders, Piston Piston Ring Thickness • Measure the thickness of the top [A] and second [B] rings. ○ Use a micrometer to measure at several points around the ring. Piston Ring Thickness Standard Service Limit 1.17 1.19 mm 1.10 mm (0.04606...
ENGINE TOP END 5-47 Mufflers Exhaust Pipe Removal (For other than U.S.A. and Canadian Models) WARNING To avoid a serious burn, do not remove the exhaust pipe or muffler when the engine is still hot. Wait until the muffler cools down. •...
5-48 ENGINE TOP END Mufflers Lower Muffler Removal (For other than U.S.A. and Canadian Models) • Remove: Lower Front Exhaust Pipe Cover (see above) Chamber Flange Nuts [A] Muffler Bracket Bolts [B] • Remove the lower muffler [C]. NOTE ○ If the chamber flange nuts are difficult to remove, spray a penetrating oil on the studs and nuts.
ENGINE TOP END 5-49 Mufflers Chamber Removal (For other than U.S.A. and Canadian Models) • Remove: Bolts [A] Rear Regulator/Rectifier Bracket [B] • Remove: Front Exhaust Pipe [A] Rear Exhaust Pipe [B] Lower and Upper Mufflers [C] Right and Left Chamber Bolts [D] •...
5-50 ENGINE TOP END Mufflers Chamber Identification (For other than U.S.A. and Canadian Models) ○ The this models have a premuffler chamber (Identification No. KHI M 091) with a honeycomb type catalytic con verter and without any catalyst protection system. Do not mix up this chamber with the other type chamber (espe- cially with a non-catalyst chamber).
ENGINE TOP END 5-51 Mufflers Rear Exhaust Pipe Removal (U.S.A. and Canadian Models) • Loosen the clamp screws [A] on the rear exhaust pipe cover [B]. • Detach the upper clamp [C] by sliding it up. • Detach the middle [D] and lower clamp [E] by sliding it back.
5-52 ENGINE TOP END Mufflers • Tighten the front exhaust pipe cover clamp screws [A] with its head inclined at 50° or less to horizontal as shown. This prevents the screw from touching ground when bank ing. Front Exhaust Pipe [B] Torque - Exhaust Pipe Cover Clamp Screws: 6.9 N·m (0.70 kgf·m, 61 in·lb) •...
CLUTCH 6-1 Clutch Table of Contents Exploded View........................Specifications ......................... 6-4 Special Tools and Sealant ...................... 6-5 Clutch Fluid..........................Clutch Fluid Level Check ....................6-6 Clutch Fluid Change ......................Clutch Line Bleeding ......................Clutch Hose Removal/Installation ..................6-6 Clutch Hose and Connection Check ................. Clutch Master Cylinder ......................
6-4 CLUTCH Specifications Item Standard Service Limit Clutch Fluid Grade DOT4 (provided when shipping) – – – Clutch Lever Position No. 1 (to suit rider) 5-way adjustable Clutch Lever Free Play Non-adjustable – – – Clutch Clutch spring free height 4.3 mm (0.235 in) 4.0 mm (0.16 in) Spring plate gap (usable range)
CLUTCH 6-7 Clutch Master Cylinder Clutch Lever Adjustment The adjuster has 5 positions so that the clutch lever posi tion can be adjusted to suit the operator’s hand. • Push the lever forward and turn the adjuster [A] to align the number with the arrow mark [B] on the lever holder (front view).
6-8 CLUTCH Clutch Master Cylinder Clutch Master Cylinder Inspection • Disassemble the clutch master cylinder. • Check that there are no scratches, rust or pitting on the inside of the master cylinder [A] and on the outside of the piston [B]. If the master cylinder or piston shows any damage, re...
6-10 CLUTCH Clutch Slave Cylinder • Tighten the bolts [A]. Torque - Clutch Slave Cylinder Bolts: 6.9 N·m (0.70 kgf·m, 61 in·lb) ○ Put the clamp [B] together the clutch slave cylinder bolt and bend along the slave cylinder with the end of the clamp straight to the engine side as shown in the figure.
CLUTCH 6-11 Clutch Clutch Cover Removal • Raise the rear wheel off the ground. Special Tools - Jack: 57001–1238 Attachment Jack: 57001–1398 • Drain the engine oil (see Periodic Maintenance chapter). • Support the engine with a suitable stand [A]. ○...
6-12 CLUTCH Clutch • Unscrew the clutch hub nut [A] by using an air impact wrench. • Take the clutch spring [B], and the clutch spring holder [C] out of the clutch hub. • Take the back torque limiter springs [A], and the clutch spring plate out of the clutch housing.
CLUTCH 6-13 Clutch Clutch Installation When replacing any one of the following parts, check the spring plate gap (see Spring Plate Gap Measurement). Spring Plate [A] Friction Plates [B] Steel Plates [C] • When installing the clutch housing, mesh the oil pump drive gear [A] with the oil pump gear [B] so that the pump gear turns smoothly.
6-14 CLUTCH Clutch • The spring plate pusher [A] into the clutch hub. Squeeze the clutch lever slowly and hold it with a band. ○ Install the needle bearing [B] and the washer onto the pusher. • Pushing [A] the operating plate [B] into the clutch hub, and insert the retaining ring [C] by hand.
CLUTCH 6-15 Clutch • Prepare sheet gum (chewing gum) or about 5 g (0.176 oz) clay [A]. • Make an about 2.5 mm (0.10 in.) thick sheet [B] of gum or clay, using a press and two thickness gauges [C] which are overlapped to about 2.5 mm (0.10 in.).
6-16 CLUTCH Clutch Spring Plate Gap Adjustment If the plate gap is out of the usable range, change one of the steel plates [A] to a thicker or thinner one to get the correct gap. ○ Use the standard steel plates (2.0 mm, 0.079 in. thick) ×...
CLUTCH 6-17 Clutch Clutch Spring Height Measurement • Measure the height [B] of the clutch spring [A]. If the spring height is less than the service limit, it must be replaced. Clutch Spring Height Standard: 4.3 mm (0.235 in) Service Limit: 4.0 mm (0.16 in) Clutch Housing Finger Inspection •...
ENGINE LUBRICATION SYSTEM 7-1 Engine Lubrication System Table of Contents Engine Oil Flow Chart......................Exploded View........................Specifications ......................... 7-6 Special Tools and Sealant ...................... 7-7 Engine Oil and Oil Filter......................Oil Level Inspection......................7-8 Engine Oil Change......................Oil Filter Replacement ...................... 7-8 Oil Pump and Oil Line......................
7-6 ENGINE LUBRICATION SYSTEM Specifications Item Standard Engine Oil: Type API Service Classification : SE, SF or SG class API Service Classification : SH or SJ class with JASO MA Viscosity SAE 10W-40 Capacity 2.9 L (3.1 US qt, when filter is not removed) 3.1 L (3.3 US qt, when filter is removed) 3.5 L (3.7 US qt, when engine is completely disassembled and dry)
7-8 ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter WARNING Motorcycle operation with insufficient, deteri orated, or contaminated engine oil will cause accelerated wear and may result in engine or trans mission seizure, accident, and injury. Oil Level Inspection •...
ENGINE LUBRICATION SYSTEM 7-9 Oil Pump and Oil Line Oil Pump Removal • Remove the engine (see Engine Removal/Installation chapter). • Split the crankcase (see Crankshaft/Transmission chap ter). • Remove the oil pump mounting bolts [A], and take off the pump [B] out of the right crankcase.
7-10 ENGINE LUBRICATION SYSTEM Oil Pump and Oil Line • Remove: Left Air Cleaner Housing (see Fuel System (DFI) chap- ter) Oil Hose Flange Bolts [A] on Front and Rear Rocker Cases ○ For the front oil hose [B], remove the clamps [C]. •...
ENGINE LUBRICATION SYSTEM 7-11 Oil Pump and Oil Line • Install each bottom end of the oil hoses on the right crankcase behind the rear cylinder as shown. Front Oil Hose [A] Rear Oil Hose [B] Front [C] ○ Face the paint marks [D] rearward. •...
7-12 ENGINE LUBRICATION SYSTEM Oil Pump and Oil Line • Remove: Oil Pipe Clamp Bolt [A] Oil Pipe Holder Bolt [B] • Remove the inside oil pipe [C] and the oil return pipe [D] from the left crankcase [E]. ○ Pull out the large size fittings [F] first, and remove the small size fitting [G] upward.
ENGINE LUBRICATION SYSTEM 7-13 Oil Pump and Oil Line • Install the inside oil pipe [A], separator [B] and the oil re turn pipe [C] to left crankcase [D] as shown. ○ Do not apply silicone sealant to the groove of the grommet and the mating surface of the grommet [E].
7-14 ENGINE LUBRICATION SYSTEM Oil Pump and Oil Line • Install the inside oil pipe [A], separator [B], and the oil return pipe [C] to the right crankcase [D]. ○ Do not apply silicone sealant to the groove of the grommet and the mating surface of the grommet [E].
ENGINE LUBRICATION SYSTEM 7-15 Oil Pressure Oil Pressure Measurement • Slide out the rubber boot [A]. • Disconnect the oil pressure switch lead [B] from the ter minal screw [C]. • Unscrew the oil pressure switch [D]. NOTE ○ Measure the oil pressure after the engine is warmed up. •...
7-16 ENGINE LUBRICATION SYSTEM Oil Pressure Relief Valve Inspection • Split the crankcase (see Crankshaft/Transmission chap ter). • Remove the relief valve [A] from the oil pump [B]. • Check to see if the valve slides smoothly when pushing it in with a wooden or other soft rod, and see if it comes back to its seat by spring pressure.
ENGINE REMOVAL/INSTALLATION 8-5 Engine Removal/Installation Engine Remova • Support the rear part of the frame on the ack and the attachment ack [B]. Special Tools - Jack: 57001-1238 Attachment Jack: 57001-1398 ○ Fit the ribs of the frame nto the groove C] of the attach ments.
8-8 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Disengage the propeller shaft from the engine. ○ Pull off the rubber boot [A] and push on the lockpin [B] a little with a pin. ○ Move the engine forward [C] to free it from the rear pro peller shaft.
ENGINE REMOVAL/INSTALLATION 8-9 Engine Removal/Installation • Connect the engine ground lead [A] down to the engine as shown. Torque - Engine Ground Terminal Bolt: 7.8 N·m (0.80 kgf·m, 69 in·lb) • Install the removed parts (see appropriate chapters). • Adjust the throttle cables (see Fuel System chapter). •...
23. Oil Baffle EO: Apply engine oil. L: Apply a non-permanent locking agent. LG: Apply liquid gasket (Kawasaki Bond: 92104-1064). Lh: Left-hand Threads MO: Apply molybdenum disulfide oil to the threads and the seating surface. The molybdenum disul fide oil is a mixture of engine oil and molybdenum disulfide grease with a weight ratio (10 : 1).
9-6 CRANKSHAFT/TRANSMISSION Specifications Item Standard Service Limit Crankshaft, Connecting Rods: Connecting rod bend – – – TIR 0.2/100 mm (0.08/3.94 in) Connecting rod twist – – – TIR 0.2/100 mm (0.08/3.94 in) Connecting rod big end side clearance 0.16 0.46 mm 0.7 mm (0.0062 0.0181 in)
CRANKSHAFT/TRANSMISSION 9-7 Specifications Item Standard Service Limit Crankshaft runout TIR 0.02 mm TIR 0.05 mm (0.0008 in) or less (0.0020 in) Crankshaft main bearing/journal clearance 0.025 0.052 mm 0.10 mm (0.00098 0.00205 in) (0.00394 in) Crankshaft main journal diameter 54.986 55.000 mm 54.96 mm (2.1648...
CRANKSHAFT/TRANSMISSION 9-9 Crankcase Crankcase Disassembly • Drain the engine oil (see Periodic Maintenance chapter). • Remove: Engine (see Engine Removal/Installation chapter) Cylinder Blocks (see Engine Top End chapter) Pistons (see Engine Top End chapter) Clutch (see Clutch chapter) Front Gear Case (see Final Drive chapter) •...
9-10 CRANKSHAFT/TRANSMISSION Crankcase • Remove Alternator Cover (see Electrical System chapter) Alternator Inner Cover (see Electrical System chapter) • Loosen the left balancer gear bolt [A], using the flywheel holder [B]. The left balancer gear bolt has right-hand threads. Special Tool - Flywheel Holder: 57001-1410 Remove the alternator rotor bolt [C] and the alternator rotor [D].
CRANKSHAFT/TRANSMISSION 9-11 Crankcase • Pull the primary gear [A] out of the crankshaft. • Remove the idle shaft sprocket [B] with the flat washer from the water pump chain [C]. • Remove the following with the cylinder head removed. Lower Chain Guide Bolts [A] Lower Chain Guide [B] Rear Camshaft Chain [C] Rear Chain Guide Bolts [D]...
9-12 CRANKSHAFT/TRANSMISSION Crankcase • Remove the oil filter [A] with the oil filter wrench [B]. Special Tool - Oil Filter Wrench: 57001–1249 • Remove the oil pressure switch [C]. • Remove the right crankcase bolts. 8 mm Bolts (5) [A] ○...
CRANKSHAFT/TRANSMISSION 9-13 Crankcase • Remove the following from the left crankcase. Crankshaft [A] Transmission Gear Assy [B] (see Transmission Re moval) Balancer Shaft [C] CAUTION The right and left crankcase halves are machined at the factory in the assembled state, so the crankcase halves must be replaced as a set.
9-14 CRANKSHAFT/TRANSMISSION Crankcase ○ Apply silicone sealant [A] to the step of the oil separating chamber [B] in the left crankcase [C]. ○ Install the oil baffle [D] on the chamber. Front [E] Torque - Oil Baffle Bolt: 11 N·m (1.1 kgf·m, 95 in·lb) Sealant - Silicone Sealant: 56019–120 •...
Water Pump Chain Guide [E] • Apply liquid gasket [A] to the mating surface of the right crankcase [B]. Sealant - Kawasaki Bond (Liquid Gasket-Black): 92104 -1064 ○ Do not apply liquid gasket to the area [C] around the hole of the oil screen.
9-16 CRANKSHAFT/TRANSMISSION Crankcase • Tighten the crankcase bolts as follows. ○ Lightly tighten all the bolts to a snug fit. ○ Tighten the 8 mm and 10 mm bolts in the order shown, and then tighten the 6 mm bolts to the specified torque. Torque - 8 mm Crankcase Bolts (1 6): 21 N·m (2.1 kgf·m, 15 ft·lb)
CRANKSHAFT/TRANSMISSION 9-17 Crankcase • Install the balancer dampers [A] so that each damper hole [B] is positioned alternately. • Install the left balancer [A] on the balancer shaft in the engine left side while fitting the alignment tooth [B] onto the alignment notch [C] of the splines.
9-18 CRANKSHAFT/TRANSMISSION Crankcase ○ Be sure to align the balancer gear mark with the alternator mark (shorter line mark) [A] while keeping the front piston on its top dead center. Top Mark for Rear Piston [B] (longer mark) Top Mark for Front Piston [C] (longer mark) •...
CRANKSHAFT/TRANSMISSION 9-19 Crankcase • Install: Washer [A] Idle Shaft Sprocket [B] ○ Fit the pin [C] into the slots [D] of the idle shaft sprocket. • Install the primary gear [A] with the boss [B] facing toward the engine inside. •...
9-20 CRANKSHAFT/TRANSMISSION Crankcase • Install the collar [A], copper washer [B], and needle bear- ing [C] in the order listed. ○ The copper washer must be on the collar. • Install the starter torque limiter [D]. • Push the starter clutch gear [A] in and turn it clockwise [B] and install it.
CRANKSHAFT/TRANSMISSION 9-21 Crankcase • Pull the coupling [A] out of the right balancer [B]. • Take the one-way clutch [C] out of the coupling. Starter Clutch Assembly • Install the one way clutch [A] so that its groove [B] faces outward and its flange [C] fits between the right balancer [D] and the coupling [E].
9-22 CRANKSHAFT/TRANSMISSION Crankcase Starter Torque Limiter Check • Remove the torque limiter (see Crankcase Disassembly) and visually inspect it. If the limiter has wear, discoloration, or other damage, replace it as a set. Gear [A] Friction Plates [B] Spring [C] Pinion [D]...
CRANKSHAFT/TRANSMISSION 9-23 Crankshaft/Connecting Rods Connecting Rod Removal • Remove the crankshaft. • Remove the connecting rod big end nuts, and take off the rod and cap along with the bearing inserts from the crankshaft [A]. NOTE ○ Mark and record the locations of the connecting rods [B] and their big end caps [C] with the bearing inserts left attached so that they can be installed in their original positions.
9-24 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]...
CRANKSHAFT/TRANSMISSION 9-25 Crankshaft/Connecting Rods Connecting Rod Big End Side Clearance • Measure the side clearance [B] of the connecting rod big end [A]. ○ Insert a thickness gauge between the big end and either crank web to determine clearance. Connecting Rod Big End Side Clearance Standard: 0.16 0.46 mm (0.0062...
9-26 CRANKSHAFT/TRANSMISSION Crankshaft/Connecting Rods If the clearance exceeds the service limit, measure the diameter of the crankpin [A]. Crankpin Diameter Standard: 54.981 55.000 mm (2.1646 2.1654 in) Service Limit: 54.97 mm (2.1642 in) If the crankpin has worn past the service limit, replace the crankshaft with a new one.
CRANKSHAFT/TRANSMISSION 9-27 Crankshaft/Connecting Rods Crankshaft Runout • Measure the crankshaft runout. If the measurement exceeds the service limit, replace the crankshaft. Crankshaft Runout Standard: TIR 0.02 mm (0.0008 in) or less Service Limit: TIR 0.05 mm (0.0020 in) Crankshaft Main Bearing/Journal Wear •...
9-28 CRANKSHAFT/TRANSMISSION Primary Gear Primary Gear Removal • Remove: Clutch Cover (see Clutch chapter) Starter Clutch Gear (see this chapter) • Using the gear holder [A] to loosen the primary gear bolt [B]. Special Tool - Gear Holder: 57001–1557 • Install: Clutch (see Clutch chapter) Bolts [A]...
CRANKSHAFT/TRANSMISSION 9-29 Primary Gear • Fit the pin [A] into the slot [B] of the water pump drive sprocket boss and install the sprockets. • Install: Dowel Pins [A] Washer [B] • Pulling the chain guide [C] and install the idle shaft holder [D].
9-30 CRANKSHAFT/TRANSMISSION Transmission Shift Pedal Removal • Unscrew the rear shift pedal clamp bolt [A] and take off the rear shift pedal [B]. • Unscrew the front shift pedal clamp bolt [C] and pull out the front shift pedal [D]. Shift Pedal Installation •...
CRANKSHAFT/TRANSMISSION 9-31 Transmission External Shift Mechanism Installation • Install the gear set lever [A] and the spring [B] in the crankcase and tighten the bolt [C]. Torque - Gear Set Lever Bolt: 11 N·m (1.1 kgf·m, 95 in·lb) • Install the shift mechanism arm assy. Be sure to install the washer [D] onto the shift shaft.
9-32 CRANKSHAFT/TRANSMISSION Transmission Transmission Removal • Remove the engine (see Engine Removal/Installation chapter). • Split the crankcase (see this chapter). • Remove the crankshaft. • First, remove the oil pipe [A] (see Engine Lubrication Sys tem chapter), and then remove the shift drum bearing holder bolts and holder [B].
CRANKSHAFT/TRANSMISSION 9-33 Transmission ○ Each output shaft shift fork has an identification number. Do not confuse them. • Install the shift forks with each number faced left as shown. Shift Fork (No. 270, 5th gear) [A] Shift Fork (No. 293, 4th gear) [B] Front [C].
9-34 CRANKSHAFT/TRANSMISSION Transmission Transmission Disassembly • Remove the transmission shafts (see this chapter). Using the circlip pliers (special tool), remove the circlips, and disassemble the transmission shaft. Special Tool - Outside Circlip Pliers: 57001-144 The 4th gear [A] on the output shaft has three steel balls for the positive neutral finder mechanism.
CRANKSHAFT/TRANSMISSION 9-35 Transmission Shift Fork Bending • Visually inspect the shift forks, and replace any fork that is bend. A bent fork could cause difficulty in shifting, or allow the transmission to jump out of gear under load. 90° [A] Shift Fork/Gear Groove Wear •...
CRANKSHAFT/TRANSMISSION 9-37 Ball Bearing, Needle Bearing, and Oil Seal Ball Bearing and Outer Race Replacement CAUTION Do not remove the ball bearing or needle bearing outer race unless it is necessary. Removal may damage them. • Using a press or puller, remove the ball bearing and/or needle bearing outer race.
9-38 CRANKSHAFT/TRANSMISSION Ball Bearing, Needle Bearing, and Oil Seal Oil Seal Inspection • Inspect the oil seal. Replace it if the lips are misshapen, discolored (indicating that the rubber has deteriorated), hardened or otherwise damaged.
10-4 WHEELS/TIRES Specifications Item Standard Service Limit Wheels (Rims): Rim runout: Axial TIR 0.5 mm (0.02 in.) Radial TIR 0.8 mm (0.03 in.) Axle runout/100 mm TIR 0.05 mm (0.002 in.) or less TIR 0.2 mm (0.008 in.) Wheel balance 10 g (0.35 oz.) or less –...
10-6 WHEELS/TIRES Wheels (Rims) Front Wheel Removal • Unscrew the front brake caliper mounting bolts [A] and remove the brake calipers [B] with the hose installed. • For the European Model, remove the cap. • Loosen: Front Axle Clamp Bolts [A] Front Axle [B] ○...
WHEELS/TIRES 10-7 Wheels (Rims) Front Wheel Installat on • Apply grease to the seal ps. • Fit the col ars A] on the both de of the hub. ○ The collars are dentical. • Insert the axle from the right side of the wheel. •...
10-8 WHEELS/TIRES Wheels (Rims) Rear Whee Removal • Using the jack [A] and attachment ack under the frame pipe r ibs [ C], ft the rear wheel [D] off the ground unt il the front wheel [E] touches the ground. CAUTION Be sure to put the front wheel ON the ground when removing the rear wheel, or the motorcycle may fall...
WHEELS/TIRES 10-9 Wheels (Rims) • Remove: Cali per Ho der Bolt Axle Nut Cotter P n [B Axle Nut ○ Pu the s encer out side and straighten the cotter p n. • Temporari ly i nstal the rear shock absorber. •...
10-10 WHEELS/TIRES Wheels (Rims) • Insert a new cotter pin [A]. NOTE ○ When inserting the cotter pin, if the slots in the nut do not align with the cotter pin hole in the axle, tighten the nut clockwise [B] up to next alignment. ○...
WHEELS/TIRES 10-11 Wheels (Rims) Whee Coupl ng Installat on • Replace the O-r ing [A] and the reta ning ring B]. • Grease the fol ow ing: Bosses [ C] of Rear Drum Hub • Install: Rubber Damper Coupling Retaining Ring Whee Inspect on •...
10-12 WHEELS/TIRES Wheels (Rims) Ax e Inspection • Visually i nspect the front and rear axles for damage. If the ax le i s damaged or bent, replace • Place the axle n V b ocks that are 100 mm [A] apart, and set a dial gauge on the axle at a point halfway between the blocks.
41075–1016 30 (1.1 oz.) NOTE ○ Balance weights are available from Kawasaki Dealers in 10, 20, and 30 gram (0.35, 0.71 and 1.1 ounce) sizes. An imbalance of less than 10 grams (0.35 ounce) will not usually affect running stability.
10-14 WHEELS/TIRES Wheels (Rims) • Lubricate the balance weight blade, tire bead, and rim flange with a soap and water solution or rubber lubricant. This helps the balance weight slip onto the rim flange. CAUTION Do not lubricate the tire bead with engine oil or pe troleum distillates because they will deteriorate the tire.
WHEELS/TIRES 10-15 Tires Air Pressure Inspection/Adjustment • Refer to Tire Inspection in the Periodic Maintenance chap ter. Tire Inspection • Refer to Tire Inspection in the Periodic Maintenance chap ter. Tire Removal • Remove the following. Wheel (see this chapter) Brake Disc (see Brakes chapter) Valve Core (let out the air) •...
10-16 WHEELS/TIRES Tires ○ Insert the new air valve in the rear wheel rim. Valve Cap [A] Valve Body [B] Valve Nuts [C] Valve Washer [D] Rim [E] Valve Grommet [F] Coupling Damper Side [G] ○ Remove the valve cap, valve nuts, valve washer and in sert the valve stem through the rim from the inside out.
Also, permanent (internal) repairs have the advantage of permitting a thorough examination for secondary damage not visible from external inspection of the tire. For these reasons, Kawasaki does not recommend temporary (exter- nal) repair. Only appropriate permanent (internal) repairs are recommended. Repair methods may vary slightly from make to make.
WHEELS/TIRES 10-19 Hub Bearings (Wheel Bearings) ○ Replace the circlips with new ones. Special Tool - Inside Circlip Pliers: 57001-143 • Replace the grease seals with new ones. • Press in the grease seals [A] so that the seal surface is flush [B] with the end of the hole.
FINAL DRIVE 11-1 Final Drive Table of Contents Exploded View........11-2 Front Bevel Gears ......11-23 Specifications ........11-6 Front Gear Case Removal ... 11-23 Special Tools ........11-7 Front Gear Case Installation ..11-23 Final Gear Case and Oil ....11-8 Front Gear Case Disassembly ..
FINAL DRIVE 11-5 Exploded View Final Gear Case Torque Fastener Remarks N·m kgf·m ft·lb Final gear case mounting nuts Pinion gear nut (final gear) MO, St Final gear case cover bolts 10 mm Final gear case cover bolts 8 mm Bearing retainer bolt 61 in·lb Final gear case drain plug...
11-6 FINAL DRIVE Specifications Item Standard Final Gear Case Oil: Grade API Service Classification: GL-5 hypoid gear oil Viscosity When above 5°C (41°F) SAE90 When below 5°C (41°F) SAE80 Oil level Filler opening bottom Amount 200 mL (6.76 US oz.) 0.06 0.09 mm (0.0024 0.0035 in.) (at gear hub...
11-8 FINAL DRIVE Final Gear Case and Oil Oil Level Inspection • Refer to Oil Level Inspection in Periodic Maintenance chapter. Oil Change • Refer to Oil Change in Periodic Maintenance chapter. Final Gear Case Removal If the final gear case is to be disassembled, drain the final gear case oil.
FINAL DRIVE 11-9 Final Gear Case and Oil • Remove the final gear case cover bolts [A]. • Use three tapped holes [B] to lift the ring gear assy from the gear case. The shim(s) comes off with the assy. NOTE ○...
11-10 FINAL DRIVE Final Gear Case and Oil Final Gear Case 1. Pinion Gear Nut 13. Studs 2. Washer 14. Pinion Gear Shim(s) 3. Shim(s) for Preload 15. O-ring 4. Pinion Gear Joint 16. Oil Seal 5. O-ring 17. Tapered Roller Bearings 6.
FINAL DRIVE 11-11 Final Gear Case and Oil • Replace the needle bearings [A] with new ones. • Apply a hypoid gear oil to the roller parts of the needle bearings. NOTE ○ Install the bearing so that the marked side faces out. ○...
11-12 FINAL DRIVE Final Gear Case and Oil Pinion Gear Removal • Pry open the staking [A] on the pinion gear nut [B]. • Unscrew the nut [A] while holding the pinion gear assem- bly [B] with the pinion gear holder [C]. Special Tool - Pinion Gear Holder: 57001-1165 •...
FINAL DRIVE 11-13 Final Gear Case and Oil Pinion Gear Installation • The pinion gear and ring gear are lapped as a set in the factory to get the best tooth contact. They must be re placed as a set. •...
11-14 FINAL DRIVE Final Gear Case and Oil • Replace the oil seal with a new one. • Drive the oil seal [A] using the bearing driver set [B]. Special Tool - Bearing Driver Set: 57001–1129 [C] • Reinstall the above removed parts. ○...
FINAL DRIVE 11-15 Final Gear Case and Oil • Apply a little hypoid gear oil to the bearings, and turn the gear shaft more than 5 turns to allow the bearings to seat. • Measure the bearing preload. Bearing preload is defined as the force or torque which is needed to start the gear shaft turning.
11-16 FINAL DRIVE Final Gear Case and Oil 1. Washer 5. Tapered Roller Bearing Initial Clearance [C] 2. Shim(s) 6. Tapered Roller Bearing Under No Preload [D] 3. Pinion Gear Joint Before Tightening [A] No Clearance [E] 4. Bearing Housing After Tightening [B] Under Preload [F] Bevel Gear Inspection...
FINAL DRIVE 11-17 Final Gear Case and Oil Final Bevel Gear Adjustment ○ The backlash and tooth contact pattern of the bevel gears must be correct to prevent the gears from making noise and being damaged. • After replacing any of the backlash-related parts, be sure to check and adjust the backlash and tooth contact of the bevel gears.
11-18 FINAL DRIVE Final Gear Case and Oil Ring Gear Shims for Backlash Adjustment Pinion Gear Shims for Tooth Contact Adjustment Parts Number Parts Number Thickness (mm) Thickness (mm) 0.15 (0.0059 in.) 92025-1783 0.15 (0.0059 in.) 92180-0009 0.5 (0.02 in.) 92025-1784 0.5 (0.02 in.) 92180-0010...
FINAL DRIVE 11-19 Final Gear Case and Oil Tooth Contact Adjustment • Clean any dirt and oil off the bevel gear teeth with a high -flash point solvent. • Apply checking compound to 4 or 5 teeth of the pinion gear.
11-20 FINAL DRIVE Final Gear Case and Oil Correct Tooth Contact Pattern: No adjustment is required. Heel [A] Bottom [B] Top [C] Toe [D] Incorrect Tooth Contact Patterns (Example 1) ○ Decrease the thickness of the pinion gear shim(s) by 0.05 mm (0.002 in.) to correct the pattern shown above.
FINAL DRIVE 11-21 Propeller Shaft Propeller Shaft Removal • Remove: Final Gear Case (see this chapter) Swingarm (see Suspension chapter) • Remove the propeller shaft from the front driven gear joint. ○ Turn the propeller shaft so that the lockpin access hole [A] in the propeller shaft comes outside.
11-22 FINAL DRIVE Propeller Shaft Propeller Shaft Inspection • Check that the universal joint [A] works smoothly without rattling or sticking. If it does not work smoothly, the needle bearings of the universal joint are damaged. Replace the propeller shaft assy with a new one.
FINAL DRIVE 11-23 Front Bevel Gears Front Gear Case Removal • Remove: Engine (see Engine Removal/Installation chapter) Rear Shift Lever [A] ○ The speed sensor connector [B] is disconnected during engine removal. • Unscrew the front gear case bolts [C] and remove the front gear case [D].
11-24 FINAL DRIVE Front Bevel Gears • Remove the drive gear assy as follows. ○ Pry off the gear case cap [A] with a tool. ○ Pry open the drive gear nut [A] with a small chisel. ○ Install: Damper Spring Cam Follower [B] ○...
FINAL DRIVE 11-25 Front Bevel Gears • Be sure to check and adjust the bearing preload, the bevel gear backlash, and tooth contact, when any of the back- lash-related parts are replaced (see Front Bevel Gear Ad justment). • After completing all adjustment, reassemble the front gear case.
11-26 FINAL DRIVE Front Bevel Gears • Remove the driven gear joint [A] with the O-ring [B]. • Remove the driven gear from the bearing housing. • Remove the oil seal from the housing with a hook, and pull the tapered roller bearing out of the housing. •...
FINAL DRIVE 11-27 Front Bevel Gears Damper Cam Installation • Replace the damper cam nut with a new one. • Remove the clutch push rod guide [A] and bolts, and crankcase bearing lower retainer and bolts. • Insert the bolt ( 12 mm, L100 mm 0.47 in., L3.94 in.) [B] into the engine mounting bolt hole.
11-28 FINAL DRIVE Front Bevel Gears Front Bevel Gear Adjustment ○ When any of the backlash-related parts are replaced, or the driven gear bolt is loosened; even if the purpose is not to replace the parts, be sure to check and adjust the bearing preload, the bevel gear backlash, and tooth con ...
FINAL DRIVE 11-29 Front Bevel Gears Preload Measurement with Spring Scale • Hold the bearing housing in a vise so that the gear shaft axis is vertical. • Hook [C] the spring scale [B] on the driven gear holder [A] at a point 200 mm (7.9 in.) [D] apart from the center of the gear shaft.
FINAL DRIVE 11-31 Front Bevel Gears • Install a holder [A] with 6 mm bolts and nuts on the front gear case to mount a dial gage. • Set up a dial gage against a drive gear tooth to check gear backlash.
11-32 FINAL DRIVE Front Bevel Gears • Turn the driven gear for 3 or 4 revolutions in the drive and reverse (coast) directions, while creating a drag on the drive gear. • Check the drive pattern and coast pattern of the bevel gear teeth.
FINAL DRIVE 11-33 Front Bevel Gears Incorrect Tooth Contact Patterns (Example 2): • Decrease the thickness of the drive gear shim(s) by 0.05 mm (0.002 in.), and/or decrease the thickness of the driven gear shim(s) by 0.05 mm (0.002 in.) to correct the pattern shown below.
11-34 FINAL DRIVE Bearing and Oil Seal Ball or Needle Bearing Replacement • Using the bearing driver set or the oil seal & bearing re mover, remove the bearings. Special Tools - Oil Seal & Bearing Remover: 57001-1058 Bearing Driver Set: 57001-1129 NOTE ○...
FINAL DRIVE 11-35 Bearing and Oil Seal Tapered Roller Bearing Inspection CAUTION Do not remove the tapered roller bearing for inspec tion. Removal may damage them. • Visually inspect the bearing in the front and final gear cases for abrasion, color change, or other damage. If there is any doubt as to the condition of the bearing, replace it.
BRAKES 12-1 Brakes Table of Contents Exploded View........12-2 Rear Brake Pad Removal .... 12-16 Specifications ........12-6 Rear Brake Pad Installation ..12-17 Special Tool ........12-7 Brake Pad Wear Inspection ..12-17 Brake Lever, Brake Pedal....12-8 Master Cylinder ......... 12-18 Brake Lever Position Adjustment.
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 110 mm (4.33 in.) – – – (height from pedal top to footpeg top) Brake Fluid: Grade...
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.
BRAKES 12-9 Brake Lever, Brake Pedal • Remove the right front footboard bracket bolts [A] and turn over the footpeg [B]. • 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 80 ±...
12-10 BRAKES Brake Lever, Brake Pedal • Pull out the brake pedal [A] from the r ght footboard bracket [B]. Brake Pedal Instal at on • Apply grease to the brake pedal shaft. • Instal the pedal shaft so that the punched mark on the shaft s a gned [B] w th the punched mark on the brake lever [C].
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]. CAUTION Do not loosen the caliper assembly bolt [C]. Take out only the caliper mounting bolts for caliper re moval.
12-12 BRAKES Calipers Front Caliper Disassembly • Remove: Caliper (see Front Caliper Removal) Cotter Pin [A] Pin [B] Pads [C] • Push the piston in. • Remove: Pad Springs [A] Caliper Holder [B] • Using compressed air, remove the piston. WARNING To avoid serious injury, never place your fingers or palm inside the caliper opening.
BRAKES 12-13 Calipers • Replace the fluid seals [A] with new ones, apply brake fluid to them, and install them in the caliper body. Either side of the fluid seal may face outboard. • Check the dust seals [B] and replace them with new ones if they are damaged.
12-14 BRAKES Calipers • Insert a wooden board [A] 5 mm (0.2 in.) thick inside the caliper opening. • Pump the brake pedal until the pistons [B] push the wooden board. • Remove the board and pull out the pistons [A] by hand. ○...
BRAKES 12-15 Calipers • Install the anti-rattle spring [A] in the caliper as shown. • Apply brake fluid to the cylinders, pistons, and fluid seals (piston seals), and push the pistons into the cylinders by hand. Take care that neither the cylinder nor the piston skirt gets scratched.
12-16 BRAKES Brake Pads Front Brake Pad Remova NOTE ○ The procedure to remove the front cal iper i s as fol ows. The rear caliper pad removal s the same as for the front cali per. • Remove the caliper with the hose nstalled see Ca liper Removal).
BRAKES 12-17 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 [A] the caliper pistons in by hand as far as they will •...
12-18 BRAKES Master Cylinder Front Master Cylinder Removal • Disconnect the front brake light switch connectors [A]. • Draw out the brake fluid from the reservoir with a means like the fork oil level gage. • Pull the bolt caps out. •...
BRAKES 12-19 Master Cylinder Rear Master Cylinder Removal • Remove the brake fluid reservoir cover (see Brake Pedal Position Adjustment). • Draw out the brake fluid from the reservoir with a means like the fork oil level gage. • Remove the brake fluid reservoir (see Brake Pedal Posi tion Adjustment).
12-20 BRAKES Master Cylinder Rear Master Cyl nder Instal ation • Replace the cotter pin with a new one. • Insert the cotter pin [A] to the hole of the nt p in [B] and separate C] the cotter p n ends. •...
BRAKES 12-21 Master Cylinder Rear Master Cylinder Disassembly NOTE ○ Do not remove the push rod clevis [A] for master cylin der disassembly since removal requires brake pedal po sition adjustment. • Remove the rear master cylinder (see Rear Master Cylin der Removal).
12-22 BRAKES Master Cylinder Master Cylinder Inspection • Disassemble the front and rear master cylinders. • Check that there are no scratches, rust or pitting on the inner wall [A] of each master cylinder and on the outside of each piston [B]. If a master cylinder or piston shows any damage, replace them.
BRAKES 12-23 Brake Discs Brake Disc Removal • Remove the wheel (see 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.
12-24 BRAKES Brake Fluid Brake Fluid Level Inspection • Refer to Brake Fluid Level Inspection in Periodic Mainte nance chapter. Brake Fluid Change • Refer to Brake Fluid Change in Periodic Maintenance 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.
BRAKES 12-25 Brake Fluid • Remove the rubber cap from the bleed valve on the caliper. • Attach a clear plastic hose to the bleed valve, and run the other end of the hose into a container. • Bleed the brake line and the caliper as follows: ○...
12-26 BRAKES Brake Fluid WARNING When working with the disc brake, observe the pre cautions listed below. 1. Never reuse old brake fluid. 2. Do not use fluid from a container that has been left unsealed or that has been open for a long time. 3.
BRAKES 12-27 Brake Hoses Brake Hose Removal/Installation CAUTION Brake fluid quickly ruins painted surfaces; any spilled fluid should be completely washed away immediately. • When removing the brake hose, take care not to spill the brake fluid on the painted or plastic parts. •...
SUSPENSION 13-1 Suspension Table of Contents Exploded View........................13-2 Specifications ......................... 13-6 Special Tools .......................... 13-7 Front Fork ..........................13-8 Fork Oil Change........................ 13-8 Front Fork Removal ......................13-9 Front Fork Installation ....................... 13-10 Disassembly........................13-11 Assembly .......................... 13-12 Inner Tube, Outer Tube Inspection ................... 13-13 Dust Seal Inspection ......................
13-8 SUSPENSION Front Fork Fork Oil Change • Remove the front fork (see Front Fork Removal). • Hold the outer tube vertically in a vise. • Remove: Top Plug [D] (with O-ring [E]) Collar [C] Washer [B] Spring [A] • Pour out the fork oil [A] with the fork upside down.
SUSPENSION 13-9 Front Fork • Install: Fork Spring [A] Washer [B] Spacer [C] Top Plug [D] with O-ring [E] Front Fork Removal • Using the jack [A] and attachment jack [B] under the frame pipe ribs [C], and a commercially available jack [D] under the engine [E], lift the front wheel [F] OFF the ground until the rear wheel [G] touches the ground.
13-10 SUSPENSION Front Fork • Remove: Bolts [A] (both side) Front fork center cover [B] • Remove: Front fork clamp bolts [A] Front fork inner cover Front fork [B] Front Fork Installation • Install the fork so that the top end [A] of the inner tube is flush with the upper surface [B] of the steering stem head bracket.
SUSPENSION 13-11 Front Fork Disassembly • Remove the front fork (see Front Fork Removal in this chapter). • Drain the fork oil (see Fork Oil Change in this chapter). ○ The following parts are removed during draining the fork oil. Top Plug [D] with O-ring [E] Spacer [C] Washer [B]...
13-12 SUSPENSION Front Fork • Remove the inner tube guide bushing [A], outer tube guide bushing [B], washer [C], and oil seal [D] from the inner tube. Assembly • Replace the following parts with new ones after removal. Dust Seal [A] Retaining Ring [B] Oil Seal [C] Inner Guide Bushing [D]...
SUSPENSION 13-13 Front Fork • Apply a non-permanent ocking agent to the threads of the Allen bolt and screw the A en bolt nto the bottom of the outer tube. • Ho d the front fork horizonta lly i n a v se A]. •...
13-14 SUSPENSION Front Fork Spring Tension • Since the spring becomes shorter as it weakens, check its free length [A] to determine its condition. If the spring of either fork leg is shorter than the service limit, it must be replaced. If the length of a replacement spring and that of the re ...
SUSPENSION 13-15 Rear Shock Absorber Rebound Damp ng Ad ustment The rebound damp ng force adjuster on each rear shock absorber has 4 positions so that the rebound damping force can be adjusted for different road and oading conditions. The numbers on the adjuster show the sett ng posit ion.
13-16 SUSPENSION Rear Shock Absorber Rear Shock Absorber Removal • Lift the rear wheel off the ground, using the jack and the attachment jack. Special Tools - Jack: 57001-1238 Attachment Jack: 57001-1398 • Squeeze the brake lever slowly and hold it with a band [A].
SUSPENSION 13-17 Rear Shock Absorber • Visually inspect the shock absorber sleeves [A] and nee dle bearings [B]. • The roller in a needle bearing normally wear very little, and wear is difficult to measure. Instead of measuring, inspect the bearing in the shock absorber for abrasion, color change, or other damage.
13-18 SUSPENSION Swingarm Swingarm Removal • Remove: Bolts ngarm Cover [B] • Remove the rear exhaust p pe see Engine Top End chap • Loosen: Right Muffler Chamber Bolt Front Exhaust Pipe C amp Bolt • Remove: ngarm P vot Cap •...
SUSPENSION 13-19 Swingarm • Remove: Rear Wheel (see Wheels/Tires chapter) Final Gear Case (see Final Drive chapter) • Remove the right rear shock absorber. • Unscrew the pivot shaft [A], and pull it out while turning. • Pull the swingarm [B] rearward, and take it off. CAUTION Do not tap the swingarm pivot shaft when removing or installing.
13-20 SUSPENSION Swingarm Swingarm Bearing Removal • Remove: Swingarm (see this chapter) Propeller Shaft (see Final Drive chapter) Right and Left Sleeves [A] Right and Left Grease Seals [B] • Remove the needle bearings, using the oil seal & bearing remover [A].
STEERING 14-7 Steering Stem Steer ng Stem Removal • Using the ack and attachment ack under the frame pipe r bs [C], and a commercially available jack [D] under the engine E], ft the front wheel [F] OFF the ground unti the rear wheel touches the ground.
14-10 STEERING Steering Stem • Install the fork leg [A] and push it up tightly against the stem bottom. • Temporarily tighten the lower fork clamp bolts. • Install: Steering Stem Head [B] with Handlebar O-ring [C] Washer [D] Stem Head Nut [E] •...
STEERING 14-11 Steering Stem Bearing Stem Bearing Removal • Remove the steering stem (see this chapter). • Drive out the bearing outer races from the head pipe. Special Tool - Head Pipe Outer Race Remover: 57001-1107 [A] NOTE ○ If either steering stem bearing is damaged, it is recom mended that both the upper and lower bearings (includ- ing outer races) be replaced with new ones.
14-12 STEERING 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. • Remove the stem nut. • Install the O-rings and adjust the steering (see Periodic Maintenance chapter).
FRAME 15-1 Frame Table of Contents Exploded View........................15-2 Special Tools .......................... 15-6 Seats ............................15-7 Rear Seat Removal......................15-7 Rear Seat Installation......................15-7 Front Seat Removal ......................15-7 Front Seat Installation ....................... 15-7 Side Covers ..........................15-8 Left Side Cover Removal ....................15-8 Left Side Cover Installation ....................
FRAME 15-7 Seats Rear Seat Removal • Remove the rear seat bolt [A] and move the rear seat backwards [B] and remove it (left view). Rear Seat Installation • Slip the hook [A] of the rear seat into the bracket [B] on the rear fender.
15-8 FRAME Side Covers Left Side Cover Removal • Insert the ignition switch key [A] into the left side cover, and turn the key clockwise until the key slot is vertical. • Pull [B] the rear part of the left side cover, push [C] the left side cover slightly forward, and remove it.
FRAME 15-9 Fenders Front Fender Removal CAUTION Be careful not to scratch the painted surface during removal or installation. • Remove the mounting bolts [A] on both sides to separate the fender from the front fork (right side view). • Move the fender forwards with the wheel installed and remove it.
15-10 FRAME Battery Case/Tool Box Battery Case Removal • Remove (left view): Front and Rear Seats (see this chapter) Bolts [A] and Battery Holder [B] Battery [C] (see Electrical System chapter) ECU [D] (see Fuel System (DFI) chapter) • Pull the following upwards: Oil Pressure Light Delay Unit [A] DFI Main Relay [B] Turn Signal Control Unit [C]...
FRAME 15-11 Front Footboard, Sidestand Footboard Removal • Unscrew the bolts [A] and remove the left front footboard [B]. ○ The right front footboard is removed during brake pedal removal (see Brakes chapter). Footboard Disassembly • Remove the front footboard. •...
15-12 FRAME Frame Downtube Removal • Using the jack and the attachment jack, raise the rear wheel off the ground (see Wheels/Tires chapter). Special Tools - Jack: 57001-1238 Attachment Jack: 57001-1398 • Remove the brake reservoir cover [A] and reservoir (see Brakes chapter).
FRAME 15-13 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 repaired frame may fail in use, possibly causing an accident. If the frame is bent, dented, cracked, or warped, replace it.
ELECTRICAL SYSTEM 16-1 Electrical System Table of Contents Exploded View........16-4 Ignition Coil Removal ....16-43 Specifications ........16-12 Ignition Coil Installation ....16-43 Special Tools ........16-13 Ignition Coil Inspection....16-44 Wiring Diagram (United States and Spark Plug Removal ....16-44 Canada) ..........
16-2 ELECTRICAL SYSTEM Turn Signal Light Bulb Speed Sensor Inspection..... 16-88 Replacement ......16-66 Front Brake Light Switch Radiator Fan System......16-69 Inspection........16-88 Fan System Circuit Inspection ..16-69 Rear Brake Light Switch Fan Motor Inspection ....16-69 Check/Adjustment ..... 16-88 Oil Pressure Warning System ...
20. Regulator/Rectifier (other than United State and Canada models) L: Apply a non-permanent locking agent. G: Apply grease. EO: Apply engine oil. SS: Apply silicone sealant (Kawasaki Bond: 56019-120). Si: Apply silicone grease. WL: Apply a soap and water solution or rubber lubricant.
16-12 ELECTRICAL SYSTEM Specifications Item Standard Battery: Type Sealed Battery Model name FTZ16-BS Capacity 12 V 18 Ah Voltage 12.6 V or more Charging System: Alternator type Three-phase AC with delta connection, and rare-earth single magnet rotor Battery charging voltage 14.2 15.2 V @3 000 r/min (rpm) Alternator output voltage (no load)
16-20 ELECTRICAL SYSTEM Electrical Parts Location Left Handlebar Switches [A] Starter Lockout Switch [B] Ignition Switch [C] Front Brake Light Switch [D] Right Handlebar Switches [E] Meter Unit [F] Fuel Pump with Fuel Reserve Switch [G] Water Temperature Sensor [A] Inlet Air Pressure Sensor [B] Vehicle-down Sensor [C] Throttle Sensor [D]...
ELECTRICAL SYSTEM 16-21 Electrical Parts Location Atmospheric Pressure Sensor [A] Ignition Coil [B] Frame Ground Terminal [C] Spark Plugs [D] Injectors [E] Horn [A] Radiator Fan [B] Water Temperature Switch [C] Radiator Fan Switch [D] Starter Motor [E] Regulator/Rectifier [F] Regulator/Rectifier [G] (US and Canada Models) Alternator [H] Crankshaft Sensors [I]...
16-22 ELECTRICAL SYSTEM Servicing Precautions There are a number of important precautions that should be followed servicing electrical systems. ○ Do not reverse the battery cable connections. This will burn out the diodes on the electrical parts. ○ Always check battery condition before condemning other parts of an electrical system.
ELECTRICAL SYSTEM 16-23 Servicing Precautions ○ Electrical Connectors Female Connectors [A] Male Connectors [B]...
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.
ELECTRICAL SYSTEM 16-25 Battery Battery Removal CAUTION Do not disconnect the battery cables or any other electrical connections when the ignition switch in ON, as this could damage the ECU (Electronic Con trol Unit). Never reverse the connections of the battery, this could damage the ECU.
16-26 ELECTRICAL SYSTEM Battery • Put the battery holder [A] on the battery. • Tighten the bolts securely. • Connect: Connectors [B] Battery (–) Lead Connector [C] • Install the seats (see Frame chapter). Electrolyte Filling • Make sure that the model name [A] of the electrolyte con tainer matches the model name [B] of the battery.
ELECTRICAL SYSTEM 16-27 Battery • Place the electrolyte container upside down aligning the six seals with the six battery filler ports. • Push the container down strongly enough to break the seals. Now the electrolyte should start to flow into the battery.
16-28 ELECTRICAL SYSTEM Battery Initial Charge While a sealed battery can be used after only filling with electrolyte, a battery may not be able to sufficiently move a starter motor to start an engine in the cases shown in the table below, where an initial charge is required before use.
ELECTRICAL SYSTEM 16-29 Battery Interchange The sealed battery can fully display its performance only when combined with a proper vehicle elec tric system. Therefore, replace the sealed battery only on a motorcycle which was originally equipped with the sealed battery. Be careful, if the sealed battery is installed on a motorcycle which had an ordinary battery as original equipment, the sealed battery’s life wil l be shortened.
16-30 ELECTRICAL SYSTEM Battery Terminal Voltage: 11.5 less than 12.6 V Standard Charge 1.8 A × 5 10 h (see following chart) 9 A × 1 h Quick Charge CAUTION If possible, do not quick charge. If quick charge is done unavoidably, do standard charge later on.
ELECTRICAL SYSTEM 16-31 Charging System Alternator Outer Cover Removal • Remove: Left Front Footboard [A] (see Crankshaft/Transmission chapter) Rear Shift Pedal [B] (see Crankshaft/Transmission chapter) Front Shift Pedal [C] (see Crankshaft/Transmission chapter) • Unscrew the bolts [A] and take off the alternator outer cover [B].
ELECTRICAL SYSTEM 16-33 Charging System • Remove the front engine mounting bolt [A]. • Loosen the rear engine mounting bolt [B]. • Lift up [A] the front part of the engine, using the jack until the lower part of the alternator inner cover clears the lower frame [B].
16-34 ELECTRICAL SYSTEM Charging System • Apply molybdenum disulfide oil to the threads of the alter nator rotor bolt. ○ The molybdenum disulfide oil is a mixture of engine oil and molybdenum disulfide grease with a weight ratio (10 : 1). •...
16-36 ELECTRICAL SYSTEM Charging System Alternator Inside Stator Installation • Install the inside stator with the BK leads on the left crankcase. Non-permanent Locking Agent - Inside Stator Holder Bolts Torque - Inside Stator Holder Bolts: 11 N·m (1.1 kgf·m, 95 in·lb) •...
ELECTRICAL SYSTEM 16-37 Charging System • To check the alternator output voltage, do the following procedures. ○ Remove the alternator outer cover and disconnect the outside alternator connector [A]. ○ Connect the hand tester to the outer as shown. Special Tool - Hand Tester: 57001-1394 ○...
16-38 ELECTRICAL SYSTEM Charging System Regulator/Rectifier Removal US and Canada Models: • Remove: Alternator Cover (see Alternator Cover Removal) Regulator/Rectifier Lead Connectors [A] • Remove: Regulator/Rectifier Bolts [A] Regulator/Rectifiers [B] Except US and Canada Models: • Remove: Alternator Cover (see Alternator Cover Removal) Regulator/Rectifier Lead Connectors [A] Front Side: •...
ELECTRICAL SYSTEM 16-39 Charging System • Remove: Regulator/Rectifier Bolts [A] Regulator/Rectifier [B] Regulator/Rectifier Installation • Run the regulator/rectifier leads according to the Cable, Wire, and Hose Routing section in the Appendix chapter. • Tighten: Torque - Regulator/Rectifier Bolts: 6.5 N·m (0.66 kgf·m, 57 in·lb) Rectifier Inspection •...
16-40 ELECTRICAL SYSTEM Charging System Regulator Inspection ○ To test the regulator out of circuit, use three 12 V batteries and a test light (12 V 3 6 W bulb in a socket with leads). CAUTION The test light works as an indicator and also as a current limiter to protect the regulator/rectifier from excessive current.
ELECTRICAL SYSTEM 16-41 Charging System Charging System Circuit 1. Ignition Switch 6. Battery 2. Alternator #2 (inside stator) 7. Joint Connector 3. Regulator/Rectifier #2 8. Main Fuse 30 A 4. Alternator #1 (outside stator) 9. Starter Relay 5. Regulator/Rectifier #1 10.
ELECTRICAL SYSTEM 16-43 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.
16-44 ELECTRICAL SYSTEM Ignition System Ignition Coil Inspection • Remove the ignition coils (see this chapter). • Measure the arcing distance with a commercially avail able coil tester [A] to check the condition of the ignition coil [B]. • Connect the ignition coil (with the spark plug cap left at ...
ELECTRICAL SYSTEM 16-45 Ignition System Spark Plug Installation • Insert the spark plug vertically into the plug hole with the plug installed in the plug wrench [A]. • Tighten the plugs. Special Tool - Spark Plug Wrench, Hex 18: 57001-1024 Torque - Spark Plugs: 18 N·m (1.8 kgf·m, 13 ft·lb) •...
16-46 ELECTRICAL SYSTEM 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.
ELECTRICAL SYSTEM 16-47 Ignition System • Connect a commercially available peak voltage adapter [A] to the hand tester [B]. Recommended Tool: Peak Voltage Adapter Type: KEK-54-9-B Brand: KOWA SEIKI Special Tool - Hand Tester: 57001-1394 • Insert the adapter probes into the connector [C] of the crankshaft sensor [D] as shown.
16-48 ELECTRICAL SYSTEM Ignition System • Set the hand tester [A] to the × 100 Ω range and wire it to the crankshaft sensor lead connector [B]. Connections: Tester Connections Front Crankshaft Sensor: BK/Y ←→ Rear Crankshaft Sensor: BK/R ←→ BK/W If there is more resistance than the specified value, the coil has an open wire and must be replaced.
ELECTRICAL SYSTEM 16-49 Ignition System Interlock Operation Inspection • Remove: Right Side Cover (see Frame chapter) ○ Do not disconnect the connectors. 1st Check • Measure the terminal voltage of the R/W lead in the junc tion box connector [A] in accordance with the following procedure.
16-50 ELECTRICAL SYSTEM Ignition System IC Igniter Inspection ○ The IC igniter is built in the ECU [A]. Damper [B] Battery Case [C] Groove [D] Front [E] ○ Refer to Fuel System chapter for ECU Inspection.
ELECTRICAL SYSTEM 16-51 Ignition System...
16-52 ELECTRICAL SYSTEM Ignition System Ignition System Circuit 1. Ignition Switch 8. Crankshaft Sensor #2 17. Battery 2. Engine Stop Switch (rear cylinder) 18. Junction Box 3. Starter Button 9. DFI Fuse 15 A 19. Ignition Fuse 10 A 4. Spark Plugs 10.
ELECTRICAL SYSTEM 16-53 Starter Motor Starter Motor Removal • Unscrew the bracket bolts [A] and take off the regula- tor/rectifier [B] with its bracket [C]. • Remove: Starter Motor Bolts [A] • Pull the starter motor [A] toward the left. •...
16-54 ELECTRICAL SYSTEM Starter Motor • Replace the O-ring [A] with a new one. • Apply a small amount of engine oil to the O-ring. Torque - Starter Motor Mounting Bolts: 11 N·m (1.1 kgf·m, 95 in·lb) Starter Motor Terminal Nut: 4.9 N·m (0.50 kgf·m, 43 in·lb) Starter Motor Disassembly •...
ELECTRICAL SYSTEM 16-55 Starter Motor Starter Motor Assembly • Holding the springs [A] with plastic washers [B], insert the brushes. ○ Fit the brush wire into the holder groove. • Align the tang [C] with the terminal bolt [D]. • Put the armature [A] among the brushes, and remove the plastic washers [B].
16-56 ELECTRICAL SYSTEM Starter Motor ○ The line on the yoke should align [A] with the line on the left cover. Torque - Starter Motor Assembly Bolts: 4.9 N·m (0.50 kgf·m, 43 in·lb) Brush Inspection • Measure the length [A] of each brush. If any is worn down to the service limit, replace the carbon brush holder assy [B] and the terminal bolt assy [C].
ELECTRICAL SYSTEM 16-57 Starter Motor NOTE ○ Even if the foregoing checks show the armature to be good, it may be defective in some manner not readily detectable with the hand tester. If all other starter mo tor components and starter motor circuit components check good, but the starter motor still does not turn over or only turns over weakly, replace the starter motor with a new one.
16-58 ELECTRICAL SYSTEM Starter Motor Electric Starter Circuit 1. Ignition Switch 6. Ignition Fuse 10 A 11. Starter Motor 2. Engine Stop Switch 7. Starter Lockout Switch 12. Starter Relay 3. Starter Button 8. Side Stand Switch 13. Main Fuse 30 A 4.
ELECTRICAL SYSTEM 16-59 Lighting System This model adopts the daylight system and has a head light relay in the junction box. The headlight does not go on when the ignition switch and the engine stop switch are first turned on. The headlight comes on when the engine starts running and stays on even if the engine stalls.
16-60 ELECTRICAL SYSTEM Lighting System • Pull the headlight unit [A] and drop it out. • Pull the headlight connector [B]. • Remove the headlight dust cover [C]. • Push the hook [A] to unlock. • Take out the bulb [A]. CAUTION When handling the quartz-halogen bulb, never touch the glass portion with bare hands.
ELECTRICAL SYSTEM 16-61 Lighting System Headlight Body Removal • Remove the headlight rim screws [A]. • Pull the headlight unit [B] and drop it out. • Remove: Rubber Cover [A] Clamp [B] Connectors [C] • Remove the headlight body bolts [A], then take off the body [B].
16-62 ELECTRICAL SYSTEM Lighting System Tail/Brake Light Bulb Replacement • Unscrew the screws [A] in the taillight lens. • Pull the lens [B] off. • Push the bulb [A] in, turn it counterclockwise [B], and pull it out. • Replace the bulb with a new one. •...
ELECTRICAL SYSTEM 16-63 Lighting System Headlight/Tail Light Circuit 16. Main Fuse 30A 1. Ignition Switch 8. Headlight 2. Alternator 9. License Plate Light 17. Battery 3. Headlight Relay 10. Tail/Brake Lights 18. Running Position Lights 4. Headlight Fuse 10 A 11.
16-64 ELECTRICAL SYSTEM Automatic Turn Signal Canceling System Automobiles use a turn signal canceling system actuated by steering wheel turn. But, motorcycles turn with a bank additionally, and so have a smaller steer angle. This makes difficult to adopt an automobile type turn signal canceling system because of inaccurate operation in motorcycles.
ELECTRICAL SYSTEM 16-65 Automatic Turn Signal Canceling System Distance Sensor Inspection • Remove the right side cover (see this chapter). • Remove the turn signal control relay [A]. ○ Do not disconnect the connector [B]. • Use the jack and the attachment jack to lift the rear wheel. Special Tools - Jack: 57001–1238 Attachment Jack: 57001–1398 •...
16-66 ELECTRICAL SYSTEM Automatic Turn Signal Canceling System • Connect one 12 V battery and turn signal lights as indi cated in the figure, and count how many times the lights flash for one minute. Turn Signal Control Relay Connector [A] Turn Signal Lights [B] 12 V Battery [C] If the lights do not flash as specified, replace the turn sig ...
ELECTRICAL SYSTEM 16-67 Automatic Turn Signal Canceling System • Insert the new bulb [A] by aligning the pins [B] with the groove in the walls of the socket [C]. • Fit the projection [A] in the recess [B] of the lens. •...
16-68 ELECTRICAL SYSTEM Automatic Turn Signal Canceling System Turn Signal Cancelling System Circuit 1. Ignition Switch 9. Front Right Turn Signal Light 2. Junction Box 10. Rear Left Turn Signal Light 3. Turn Signal Control Relay Fuse 10 A 11. Rear Right Turn Signal Light 4.
ELECTRICAL SYSTEM 16-69 Radiator Fan System WARNING The radiator fan is connected directly to the bat tery. The fan may start even if the ignition switch is off. NEVER TOUCH THE RADIATOR FAN UNTIL THE RADIATOR FAN CONNECTOR IS DISCONNECTED. TOUCHING THE FAN BEFORE THE CONNECTOR IS DISCONNECTED COULD CAUSE INJURY FROM THE FAN BLADES.
16-70 ELECTRICAL SYSTEM Oil Pressure Warning System Motorcycle operation with low engine oil level, even if it is higher than the lower level line, will cause oil level change when sudden acceleration, or deceleration, and may lead flicker of the oil pressure warning light because of too rapid response of the oil pressure switch.
ELECTRICAL SYSTEM 16-71 Oil Pressure Warning System • Turn the ignition switch ON. • Ground the oil pressure switch lead to the engine, then the oil pressure warning LED light should be lit with a delay. • Measure this delay time from grounding of the switch lead to lighting of the warning LED light.
16-72 ELECTRICAL SYSTEM Meter, Gauge Meter Unit Removal • Remove: Bolts [A] and Washers Nuts [B] Meter Cover [C] • Remove: Cover [A] Ignition Switch Lead Connector [B] Meter Unit Lead Connector [C] • Remove the connector [D] from the bracket. •...
16-74 ELECTRICAL SYSTEM Meter, Gauge • Turn out the socket [A] counterclockwise. ○ These sockets are for the high beam indicator light, turn signal indicator light and neutral indicator light. Meter Unit Assembly • Insert the bulb [A] so that the projections [B] align with the grooves [C] in the panel, and turn in the socket clockwise.
ELECTRICAL SYSTEM 16-75 Meter, Gauge Meter Unit Inspection LCD Segment Inspection: • Remove the meter unit (see Meter Unit Removal). [A] Meter Unit Lead Connector CAUTION Do not drop the meter unit. Such a shock to the meter unit can damage it. Place the meter facing up.
16-76 ELECTRICAL SYSTEM Meter, Gauge Check 2 : • Using the auxiliary lead, connect the battery positive ter minal to terminal . • Verify that all the LCD segments (the letters and num bers of the liquid crystal display) to appear for 3 seconds, and the speedometer needle momentary points to the last reading and then return to the 0 position.
ELECTRICAL SYSTEM 16-77 Meter, Gauge • Push the mode button [A] to CLOCK. • Push the reset button [B] more than 2 seconds, then the display turns to the HOUR/MINUTE mode [C]. ○ In the HOUR/MINUTE mode, the numbers flash on the display.
16-78 ELECTRICAL SYSTEM Meter, Gauge • Set the minute, push the reset button to return to the HOUR/MINUTE mode. • Push the mode button to complete the time setting process. ○ The clock starts counting the seconds as soon as the mode button is pushed.
ELECTRICAL SYSTEM 16-79 Meter, Gauge Speed Sensor Power Supply Voltage Inspection: • Connect the leads in the same circuit as for the LCD Seg ment Inspection, Check 2. • Set the hand tester [A] to DC25 V, check the voltage be tween terminal  and battery negative lead.
16-80 ELECTRICAL SYSTEM Meter, Gauge LED Light Inspection • Connect the leads in the same circuit as for the LCD Seg ments Inspection, Check 2. Fuel Level Warning Indicator LED Light: • Connect an about 30 Ω resistor [A] to the terminal  and battery negative lead.
ELECTRICAL SYSTEM 16-81 Meter, Gauge FI Indicator LED Light and LCD Symbol: • Connect the lead to the terminal  and battery negative lead. FI Indicator LED Light Connections: Battery Negative Lead (–) to Terminal  ○ The FI indicator LED light [A] and symbol [B] in the LCD should go on.
16-82 ELECTRICAL SYSTEM Meter, Gauge Neutral Indicator Light: • Connect the lead to the terminal  and battery negative lead. Neutral Indicator Light Connections: Battery Negative Lead (–) to Terminal  ○ The neutral indicator light [A] should go on. If the indicator light does not go on, inspect the bulb.
ELECTRICAL SYSTEM 16-83 Meter, Gauge High Beam Indicator Light: • Connect the lead to the terminal  and battery positive lead. High Beam Indicator Light Connections: Battery Positive Lead (+) to Terminal  ○ The high beam indicator light [A] should go on. If the indicator light does not go on, inspect the bulb.
16-84 ELECTRICAL SYSTEM Meter, Gauge Meter Unit Circuit 1. Meter Unit 15. Fuel Level Sensor 2. Odometer/Trip Meter/Clock LCD 16. Fuel Reserve Switch 3. Speedometer 17. Turn Signal Control Relay 4. Fuel Meter 18. Frame Ground 5. Illuminator LED 19. Water Temperature Switch 6.
ELECTRICAL SYSTEM 16-85 Water Temperature Warning System Water Temperature Warning System Check The water temperature warning LED light goes on when the ignition switch is turned on and goes off soon to ensure that its circuit functions properly and the warning LED light has not burned out.
16-86 ELECTRICAL SYSTEM Switch and Sensors Fuel Level Sensor Inspection • Remove: Fuel Tank (see Fuel System (DFI) chapter) • Open the clamps [A]. • Remove: Bolts [B] Fuel Level Sensor [C] • Check that the float moves up and down smoothly without binding.
ELECTRICAL SYSTEM 16-87 Switch and Sensors Fuel Reserve Switch Inspection • Fill the fuel tank with fuel. • Close the fuel tank cap surely. • Remove: Seats (see Frame chapter) Fuel Level Sensor 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.
Water Temperature Switch Installation • Apply silicone sealant to the threads of the water temper ature switch. Sealant - Kawasaki Bond: 59019–120 Torque - Water Temperature Switch: 7.8 N·m (0.80 kgf·m, 69 in·lb) • Fill the engine with coolant and bleed the air from the cooling system (see Coolant Filling in the Cooling System chapter).
16-90 ELECTRICAL SYSTEM Switch and Sensors Water Temperature Switch Inspection • Remove the water temperature switch. • Suspend the switch [A] in a container of machine oil so that the heat-sensitive portion and threaded portion are submerged. • Suspend an accurate thermometer [B] with heat-sensitive portions [C] located in almost the same depth.
ELECTRICAL SYSTEM 16-91 Switch and Sensors Side Stand Switch Connections Neutral Switch Connections Oil Pressure Switch Connections* *: Engine lubrication system is in good condition...
16-92 ELECTRICAL SYSTEM Junction Box The junction box [A] has fuses [B], relays, and diodes. The relays and diodes can not be removed. Junction Box Fuse Circuit Inspection • Remove the right side cover (see Frame chapter). • Remove the junction box. •...
16-94 ELECTRICAL SYSTEM Junction Box Junction Box Internal Circuit A. Accessory Fuse 10 A D. Horn Fuse 10 A I. Starter Diode B. Fan Fuse 10 A E. Ignition Fuse 10 A J. Starter Circuit Relay Fan Fuse 15 A (After F.
ELECTRICAL SYSTEM 16-95 Fuse Main Fuse Removal • Remove the right side cover (see Frame chapter). • Remove the coolant reserve tank bolts and hanging the reserve tank. • Remove the starter relay [A]. • Pull out the main fuse [B] from the starter relay with needle nose pliers.
APPENDIX 17-1 Appendix Table of Contents Cable, Wire, and Hose Routing ....................17-2 Troubleshooting Guide (except DFI) ..................17-28...
17-2 APPENDIX Cable, Wire, and Hose Routing...
APPENDIX 17-3 Cable, Wire, and Hose Routing F: Front 1. Fuel Tank 2. Ignition Coil for Rear Spark Plugs 3. Fuel Tank Water Drain Hose 4. Run the hose over the cooling hose. 5. Plastic Snap-on Clamps (rear brake light switch and radiator fan leads) 6.
17-4 APPENDIX Cable, Wire, and Hose Routing...
APPENDIX 17-5 Cable, Wire, and Hose Routing F: Front 14. Ignition Coil for Front 27. Plastic Clamp: Align the 1. Right Rear Spark Plug Spark Plugs clamp with the mark . Lead 15. Plastic Clamp 28. Rear Oil Hose into the 2.
17-6 APPENDIX Cable, Wire, and Hose Routing F: Front 10. Rear Oil Hose 1. Ignition Coil for Front Spark Plugs 11. Radiator 2. Inlet Air Pressure Sensor Hose 12. Fuel Pump Outlet Hose 3. Front Coolant Hose 13. Wire Clamp 4.
APPENDIX 17-7 Cable, Wire, and Hose Routing F: Front 30. Coolant Reserve Tank 20. Front Oil Hose 31. Coolant Reserve Tank Overflow Hose 21. Right Air Cleaner Base 32. Clamp 22. Radiator Outlet Hose (right) 33. Holder 23. Rear Cylinder Head 34.
17-8 APPENDIX Cable, Wire, and Hose Routing...
APPENDIX 17-9 Cable, Wire, and Hose Routing F: Front ←: Air Flow 1. Top 2. Locate the glued joint of the gasket  within the angle. 3. Gasket 4. Right Air Cleaner Cover Allen Bolt 5. Clamp (lead ) 6. Inlet Air Temperature Sensor and ISC Valve Leads 7.
17-10 APPENDIX Cable, Wire, and Hose Routing...
APPENDIX 17-11 Cable, Wire, and Hose Routing F: Front R: Rear View 1. Fuel Pump with the fuel filter and screen belt in 2. Fuel Pump Bolts 3. Fuel Hose Joint (delivery joint) 4. Fuel Tank 5. O-ring 6. Left Air Cleaner Cover 7.
17-12 APPENDIX Cable, Wire, and Hose Routing...
APPENDIX 17-13 Cable, Wire, and Hose Routing F: Front 1. Rear View 2. Rear Fender 3. Grommets 4. Five Clamps 5. Rear Fender Harness 6. Plastic Cover 7. Run the harness  into the cut of plastic cover  8. Connector for  and  9.
17-14 APPENDIX Cable, Wire, and Hose Routing F: Front 7. 1. Rear Regulator/Rectifier Connector Connect the following connectors in the 8. Sidestand Switch Connector order numbered and locate them as 9. Starter Motor Lead shown. 10. Speed Sensor 1. Front Regulator/Rectifier Connector 11.
APPENDIX 17-15 Cable, Wire, and Hose Routing F: Front T: Top 5. Fuel Pump 11. Fuel Level Sensor Lead 1. Ignition Switch Connec 6. Run the hose  be 12. Inside of Fuel Tank tor: Push the lock to dis tween the pump  and 13.
17-16 APPENDIX Cable, Wire, and Hose Routing...
APPENDIX 17-17 Cable, Wire, and Hose Routing F: Front ←→: Vacuum Pulsation →: Bypass Air Flow #1: For Front Cylinder #2: For Rear Cylinder 1. Top View 2. Rear View 3. Bottom View 4. Delivery Joint 5. Fuel Injector #2 6.
17-18 APPENDIX Cable, Wire, and Hose Routing F: Front 6. Run the brake hose between the engine 1. Rear Brake Caliper mounting bracket bosses and the oil filter, 2. Hose Holders and then along the downtube towards the 3. Rear Brake Hose front.
APPENDIX 17-19 Cable, Wire, and Hose Routing 8. Rear Brake Reservoir 13. Rear Brake Reservoir Cover 9. Rear Master Cylinder 14. Downtube 10. Brake Pedal 15. Swingarm 11. Bend both ends of the cotter pin  as 16. Cotter Pin shown.
17-20 APPENDIX Cable, Wire, and Hose Routing F: Front 10. Fuel Tank Breather Hose 17. Lower Air Cleaner Duct 1. Throttle Body Assy (blue, rear) 18. Canister Purge Hose 2. Decelerator Cable 11. Fuel Tank Return Hose (green) 3. Accelerator Cable (red, front) 19.
APPENDIX 17-21 Cable, Wire, and Hose Routing F: Front L: Left 8. Clutch Hose 15. Fuel Tank Water Drain 1. Left Handlebar Switch 9. Run the throttle cables in Hose Connectors side the clutch hose . 16. Horn Leads 2. Accessory Lead Connec 10.
17-22 APPENDIX Cable, Wire, and Hose Routing F: Front 28. ECU: Fit it into the battery 32. Main Harness 24. Sidestand Switch Leads: case behind the case rib 33. Strap (main harness Run the leads through on the bottom.  and California purge the front and rear hooks 29.
APPENDIX 17-23 Cable, Wire, and Hose Routing 1. Snap-on Straps 7. Brake Hoes Joint 2. Front Brake Hose Holders 8. Run the hose  through the steering 3. Front Brake Hose Assembly stem bracket. 4. Front Brake Calipers 9. Clamp 5.
17-24 APPENDIX Cable, Wire, and Hose Routing...
APPENDIX 17-25 Cable, Wire, and Hose Routing F: Front 24. Fit the straps into the frame pipe 1. Main Harness: Run it into the headlight 25. White Tape for Identification body and inside the brake hose . 26. Battery (–) Lead from engine ground lead 2.
17-26 APPENDIX Cable, Wire, and Hose Routing F: Front 7. To the inside of the alter 16. Band (Fix the main har T: Top nator outer cover ness and frame joint part 1. Main Harness 8. Through the alternator only.
APPENDIX 17-27 Cable, Wire, and Hose Routing 20. Insert the sub harness connector to the 26. Plastic Snap-on Clamps ( 15 mm, rear frame. brake light switch and radiator fan leads) 21. Vehcle-down Sensor Connector 27. Plastic Snap-on Clamps ( 15 mm, rear 22.
17-28 APPENDIX Troubleshooting Guide (except DFI) NOTE Battery voltage low ○ Refer to Fuel System chapter for most of Spark plug dirty, broken, or gap malad DFI troubleshooting guide. justed ○ This is not an exhaustive list, giving every Spark plug cap or high tension wiring trou possible cause for each problem listed.
APPENDIX 17-29 Troubleshooting Guide (except DFI) Choke knob left pulled out (DFI) Fuel to injector insufficient (DFI) Throttle body assy O-ring damage Fuel tank air vent obstructed Air cleaner duct loose Fuel line clogged Air cleaner O-ring damaged Fuel pump trouble (DFI) Fuel pump (DFI) trouble Compression low: Compression low:...
17-30 APPENDIX Troubleshooting Guide (except DFI) For KLEEN, do not start the engine under Clutch slave cylinder trouble misfire due to spark plug fouling or poor Clutch hub or housing unevenly worn connection of the spark plug Clutch master cylinder trouble For KLEEN, do not coast the motorcycle Clutch not disengaging properly: with the ignition switch off (Turn the igni...
APPENDIX 17-31 Troubleshooting Guide (except DFI) Connecting rod bent Rear wheel coupling damaged Piston pin, piston pin hole worn Final gear case oil level too low or oil too Valve noise: thin Engine not sufficiently warmed up after HLA Insufficient grease in propeller shaft joint installation Abnormal Frame Noise: HLA damaged (worn, seizure, or spring bro...
17-32 APPENDIX Troubleshooting Guide (except DFI) Steering stem nut too tight Rear shock adjustment too soft Steering stem bearing damaged Front fork, rear shock absorber spring weak Steering stem bearing lubrication inade Rear shock absorber oil leaking quate Brake Doesn’t Hold: Steering stem bent Tire air pressure too low Air in the brake line...
MODEL APPLICATION Year Model Beginning Frame No. □ JKBVNKA1 3A000001 or 2003 VN1600-A1 JKBVNT60AAA000001 □ JKBVNKA1 4A009001 or 2004 VN1600-A2 JKBVNT60AAA009001 □ :This digit in the frame number changes from one machine to another. Part No.99924-1309-02 Printed in Japan...