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Kawasaki VULCAN 1600 CLASSIC Service Manual

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VULCAN 1600 CLASSIC
VN1600 CLASSIC
Motorcycle
Service Manual

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  Summary of Contents for Kawasaki VULCAN 1600 CLASSIC

  • Page 1 VULCAN 1600 CLASSIC VN1600 CLASSIC Motorcycle Service Manual...
  • Page 3 Quick Reference Guide General Information Periodic Maintenance Fuel System (DFI Cooling System Engine Top End Clutch Engine Lubrication System Engine Removal/Installation Crankshaft/Transmission Wheels/Tires 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 ­...
  • Page 5 All information contained in this publication is based on the latest product information available at the time of publication. Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts. © 2003 Kawasaki Heavy Industries, Ltd. Second Edition (1) : Aug. 25, 2003 (M)
  • Page 6 LIST OF ABBREVIATIONS ampere(s) pound(s) ABDC after bottom dead center meter(s) alternating current minute(s) ATDC after top dead center newton(s) BBDC before bottom dead center pascal(s) bottom dead center horsepower BTDC before top dead center pound(s) per square inch °C degree(s) Celsius revolution direct current...
  • Page 7: Emission Control Information

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

    • Use proper tools and genuine Kawasaki Mo ­ torcycle parts. Special tools, gauges, and CAUTION testers that are necessary when servicing This caution symbol identifies special...
  • Page 10 NOTE ○ This note symbol indicates points of par ­ ticular interest for more efficient and con ­ venient operation. • Indicates a procedural step or work to be done. ○ Indicates a procedural sub-step or how to do the work of the procedural step it follows. It also precedes the text of a NOTE.
  • Page 11 GENERAL INFORMATION 1-1 General Information Table of Contents Before Servicing ........................Model Identification......................... General Specifications......................1-9 Unit Conversion Table ......................1-11...
  • Page 12: Before Servicing

    1-2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly opera­ tion on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustra- tions, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary.
  • Page 13 Replacement Parts Replacement Parts must be KAWASAKI genuine or recommended by KAWASAKI. Gaskets, O-rings, Oil seals, Grease seals, circlips or cotter pins must be replaced with new ones whenever disassembled.
  • Page 14 1-4 GENERAL INFORMATION Before Servicing Tightening Sequence Bolts, nuts, or screws must be tightened according to the specified sequence to prevent case warpage or deformation which can lead to malfunction. If the specified tightening sequence is not indicated, tighten the fasteners alternating diagonally.
  • Page 15 GENERAL INFORMATION 1-5 Before Servicing Press For items such as bearings or oil seals that must be pressed into place, apply small amount of oil to the con ­ tact area. Be sure to maintain proper alignment and use smooth movements when installing. Ball Bearing and Needle Bearing Do not remove pressed ball or needle unless removal is absolutely necessary.
  • Page 16 1-6 GENERAL INFORMATION Before Servicing Direction of Engine Rotation When rotating the crankshaft by hand, the free play amount of rotating direction will affect the adjustment. Ro ­ tate the crankshaft to positive direction (clockwise viewed from output side). Electrical Wires A two-color wire is identified first by the primary color and then the stripe color.
  • Page 17: Model Identification

    GENERAL INFORMATION 1-7 Model Identification VN1600-A1 (US, and Canada) Left Side View: VN1600-A1 (US, and Canada) Right Side View:...
  • Page 18 1-8 GENERAL INFORMATION Model Identification VN1600-A1 (Europe) Left Side View: VN1600-A1 (Europe) Right Side View:...
  • Page 19: General Specifications

    GENERAL INFORMATION 1-9 General Specifications Items VN1600-A1 Dimensions: Overall length 2 505 mm (98.62 in.) Overall width 1 040 mm (40.9 in.), (AU) 990 mm (39 in.) Overall height 1 130 mm (44.5 in.) Wheelbase 1 680 mm (66.1 in.) Road clearance 130 mm (5.12 in.) Seat height...
  • Page 20 1-10 GENERAL INFORMATION General Specifications Items VN1600-A1 Drive Train: Primary reduction system: Type Gear Reduction ratio 1.517 (85/56) Clutch type Wet multi disc Transmission: Type 5-speed, constant mesh, return shift Gear ratios: 2.500 (40/16) 1.590 (35/22) 1.192 (31/26) 0.965 (28/29) 0.781 (25/32) Final drive system: Type...
  • Page 21: Unit Conversion Table

    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...
  • Page 23: Table Of Contents

    PERIODIC MAINTENANCE 2-1 Periodic Maintenance Table of Contents Periodic Maintenance Chart ....2-2 Final Drive........2-25 Torque and Locking Agent....2-4 Oil Level Inspection...... 2-25 Specifications ........2-10 Oil Change ........2-26 Special Tools ........2-12 Propeller Shaft Joint Lubrication .. 2-26 Periodic Maintenance Procedures..
  • Page 24: Periodic Maintenance Chart

    2-2 PERIODIC MAINTENANCE Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition.The initial maintenance is vitally important and must not be neglected. FREQUENCY Whichever 1 000 km * ODOMETER READING comes...
  • Page 25: Periodic Maintenance Chart

    PERIODIC MAINTENANCE 2-3 Periodic Maintenance Chart FREQUENCY Whichever 1 000 km * ODOMETER READING comes (600 mile) first 6 000 km → (4 000 mile) ↓ 12 000 km (7 500 mile) 18 000 km (12 000 mile) 24 000 km (15 000 mile) 30 000 km (20 000 mile)
  • Page 26: Torque And Locking Agent

    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.
  • Page 27: Periodic Maintenance

    PERIODIC MAINTENANCE 2-5 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Radiator drain bolt 0.75 65 in·lb Water temperature sensor (DFI) Engine Top End: Spark plugs Spark plug retainer 104 in·lb Air suction valve cover bolts 0.75 65 in·lb 95 in·lb Chain tensioner mounting bolts Chain tensioner cap...
  • Page 28 2-6 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Engine Lubrication System: Oil filler cap 0.15 13 in·lb Oil screen plug Engine oil drain plug Oil filter (cartridge type) R, EO Oil filter Pipe Oil pressure relief valve Oil pressure switch terminal screw 0.15 13 in·lb...
  • Page 29 PERIODIC MAINTENANCE 2-7 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Left balancer gear bolt Starter clutch bolt Starter clutch coupling bolts Gear set lever bolt 95 in·lb Shift shaft return spring pin (bolt) Shift pedal clamp bolt Shift pedal clamp bolts (VN1600–A2 ) Rear shift lever clamp bolt 104 in·lb...
  • Page 30 2-8 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Brake lever pivot bolt 0.10 8.7 in·lb Brake lever pivot bolt locknut 0.60 52 in·lb Front brake reservoir cap screws 0.15 13 in·lb Front brake light switch screw 0.12 10 in·lb Front master cylinder clamp bolts...
  • Page 31 PERIODIC MAINTENANCE 2-9 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Alternator outer cover assembly bolts 0.70 61 in·lb Alternator cover bolts 95 in·lb Alternator inner cover bolts 95 in·lb Alternator rotor bolt Alternator stator bolts 113 in·lb Regulator/rectifier bolts 0.66 57 in·lb...
  • Page 32: Specifications

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

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

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

    2-14 PERIODIC MAINTENANCE Periodic Maintenance Procedures 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].
  • Page 37: Air Cleaner Element Cleaning

    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. •...
  • Page 38: Cooling System

    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.
  • Page 39 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.
  • Page 40 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) •...
  • Page 41: Engine Top End

    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.
  • Page 42: Clutch Fluid Level Inspection

    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...
  • Page 43: Clutch Master Cylinder Cup And Dust Seal Replacement

    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. •...
  • Page 44: Clutch Slave Cylinder Piston Seal Replacement

    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.
  • Page 45: Engine Lubrication System

    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...
  • Page 46: Oil Filter Replacement

    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...
  • Page 47: Final Drive

    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).
  • Page 48: Oil Change

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

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

    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.
  • Page 51: Brake Master Cylinder Cup And Dust Seal Replacement

    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].
  • Page 52: Rear Brake Light Switch Check/Adjustment

    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].
  • Page 53: Rear Shock Absorber Oil Leak Inspection

    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 •...
  • Page 54: Steering Adjustment

    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.
  • Page 55: Electrical System

    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.
  • Page 56: Nut, Bolt, And Fastener Tightness

    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.
  • Page 57 PERIODIC MAINTENANCE 2-35 Periodic Maintenance Procedures Engine: Throttle Cable Adjuster Locknuts Engine Mounting Bolts and Nuts Shift Pedal Bolts Muffler Mounting Bolt and Nut Exhaust Pipe Holder Nuts Clutch Master Cylinder Clamp Bolts Clutch Lever Pivot Nut Radiator Mounting Bolt Radiator Bracket Bolts Others: Sidestand Bolt and Nut...
  • Page 59 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)...........
  • Page 60 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 ...
  • Page 62: Exploded View

    3-4 FUEL SYSTEM (DFI) Exploded View...
  • Page 63 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.
  • Page 64 3-6 FUEL SYSTEM (DFI) Exploded View...
  • Page 65 FUEL SYSTEM (DFI) 3-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Fuel pump bolts 87 in·lb S, L Inlet air temperature sensor nut 0.80 69 in·lb ISC pipe bolts 95 in·lb Throttle body assy holder bolts 95 in·lb Spark plug lead holder bolts 95 in·lb Choke cable plate screw 0.30...
  • Page 66: Dfi Parts Location

    3-8 FUEL SYSTEM (DFI) DFI Parts Location...
  • Page 67 FUEL SYSTEM (DFI) 3-9 DFI Parts Location DFI: DFI Parts (this chapter) F: Front 1. Atmospheric Pressure Sensor (DFI) 2. Water Temperature Sensor (DFI) 3. Ignition Coils 4. Ignition Switch (see next page) 5. Starter Motor 6. Water Temperature Switch 7.
  • Page 68 3-10 FUEL SYSTEM (DFI) DFI Parts Location...
  • Page 69 FUEL SYSTEM (DFI) 3-11 DFI Parts Location...
  • Page 70: Dfi System

    3-12 FUEL SYSTEM (DFI) DFI System...
  • Page 71 FUEL SYSTEM (DFI) 3-13 DFI System #1: For Front Cylinder #2: For Rear Cylinder 1. ECU (Electronic Control Unit) 2. Crankshaft Sensor #1 3. Crankshaft Sensor #2 4. Pressure Regulator 5. Throttle Sensor (front view) 6. Atmospheric Pressure Sensor 7. Inlet Air Pressure Sensor 8.
  • Page 72: Dfi Wiring Diagram

    3-14 FUEL SYSTEM (DFI) DFI Wiring Diagram...
  • Page 73 FUEL SYSTEM (DFI) 3-15 DFI Wiring Diagram Terminal Numbers of ECU Connectors Terminal Names #1: Front Cylinder, #2: Rear Cylinder 1. Starter Lockout Switch Signal 2. Interlock Circuit Signal 3. Self-diagnosis Signal (generated by grounding this terminal and shown by FI indicator LED light) 4.
  • Page 74 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]...
  • Page 75: Specifications

    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...
  • Page 76: Special Tools And Sealant

    Special Tools and Sealant Oil Pressure Gauge, 5 kgf/cm² : Filler Cap Driver : 57001–125 57001–1454 Fork Oil Level Gauge : Needle Adapter Set : 57001–1290 57001–1457 Hand Tester : Kawasaki Bond (Silicone Sealant) : 57001–1394 56019–120 Fuel Pressure Gauge Adapter : 57001–1417...
  • Page 77: Dfi Servicing Precautions

    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].
  • Page 78: Troubleshooting The Dfi System

    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).
  • Page 79 ○ 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.
  • Page 80 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. •...
  • Page 81 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.
  • Page 82: Inquiries To Rider

    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.
  • Page 83 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. □ □ □ □ □ □...
  • Page 84 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 □...
  • Page 85: Dfi System Troubleshooting Guide

    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. ○...
  • Page 86 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...
  • Page 87: Poor Running At Low Speed

    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).
  • Page 88 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).
  • Page 89 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).
  • Page 90 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).
  • Page 91: Poor Running Or No Power At High Speed

    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).
  • Page 92 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).
  • Page 93 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).
  • Page 94: Self-Diagnosis

    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].
  • Page 95: Service Code Reading

    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. ○...
  • Page 96: Service Code Erasing

    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.
  • Page 97 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.
  • Page 98 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...
  • Page 99: Throttle Sensor (Service Code 11)

    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.
  • Page 100: Output Voltage Inspection

    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...
  • Page 101: Resistance Inspection

    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] ←→...
  • Page 102: Inlet Air Pressure Sensor (Service Code 12)

    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).
  • Page 103: Output Voltage Inspection

    • Turn the ignition SW OFF and remove the needle adapters. • Apply silicone sealant to the seals of the connector for waterproofing. Silicone Sealant (Kawasaki Bond: 56019-120) - Connector Seals...
  • Page 104 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 ­...
  • Page 105 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 –...
  • Page 106 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...
  • Page 107: Inlet Air Temperature Sensor (Service Code 13)

    ECU and the inlet air temperature sensor. If the wiring is good, check the sensor resistance. • Remove the needle adapters, and apply silicone sealant to the seals of the connector for waterproofing. Silicone Sealant (Kawasaki Bond: 56019-120) - Seals of Connector...
  • Page 108: Sensor Resistance Inspection

    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.
  • Page 109: Water Temperature Sensor (Service Code 14)

    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) •...
  • Page 110: Water Temperature Sensor Resistance Inspection

    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.
  • Page 111: Atmospheric Pressure Sensor (Service Code 15)

    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).
  • Page 112: Output Voltage Inspection

    • Remove the needle adapters. • Apply silicone sealant to the seals of the connector for waterproofing. Silicone Sealant (Kawasaki Bond: 56019-120) - ECU Connector Seals Output Voltage Inspection NOTE ○ The output voltage changes according to the local at ­...
  • Page 113 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).
  • Page 114 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)
  • Page 115: Crankshaft Sensors (#1, #2: Service Code 21, 22)

    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 ○...
  • Page 116: Vehicle-Down Sensor

    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].
  • Page 117: Vehicle-Down Sensor Inspection

    • Remove the needle adapters, and apply silicone sealant to the seals of the connector for waterproofing. Silicone Sealant (Kawasaki Bond: 56019-120) - Seals of Vehicle-down Sensor Connector If the output voltage is out of the specified, replace the vehicle-down sensor.
  • Page 118 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.
  • Page 119: Fuel Injectors

    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.
  • Page 120 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].
  • Page 121 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.
  • Page 122: Audible Inspection

    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.).
  • Page 123: Output Voltage Inspection

    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.
  • Page 124: Injector Resistance Inspection

    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].
  • Page 125 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.
  • Page 126: Fuel Pump (Service Code 45)

    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.
  • Page 127: Pressure Regulator Removal

    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. •...
  • Page 128: Operating Voltage Inspection

    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.
  • Page 129: Power Source Voltage Inspection

    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].
  • Page 130 • 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.
  • Page 131: Ignition Coils

    (see Electrical System chap- ter) in order to check the primary coils. • Remove the needle adapters. • Apply silicone sealant to the seals of the connector for waterproofing. Silicone Sealant (Kawasaki Bond: 56019-120) - ECU Connector Seals...
  • Page 132: Fi Indicator Led Light

    3-74 FUEL SYSTEM (DFI) FI Indicator LED Light Inspection Flow Chart...
  • Page 133: Led Light Inspection

    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.
  • Page 134: Ecu

    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.
  • Page 135 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 ←→...
  • Page 136: Dfi Power Source

    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.
  • Page 137 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.
  • Page 138: Isc Valves

    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).
  • Page 139 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 •...
  • Page 140 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.
  • Page 141: Fuel Line

    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.
  • Page 142 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.
  • Page 143: Fuel Flow Rate Inspection

    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;...
  • Page 144: Throttle Grip And Cables

    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.
  • Page 145: Throttle Body Assy

    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.
  • Page 146 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].
  • Page 147 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] •...
  • Page 148 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.
  • Page 149: Disassembly/Assembly

    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.
  • Page 150 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. ○...
  • Page 151 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.
  • Page 152: Air Cleaner

    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 ­...
  • Page 153: Right Air Cleaner Housing Removal

    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] •...
  • Page 154: Lower Air Cleaner Duct Removal/Installation

    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.
  • Page 155: Fuel Tank

    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.
  • Page 156 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.
  • Page 157 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]. •...
  • Page 158: Fuel Tank Installation

    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.
  • Page 159: Fuel Tank And Cap Inspection

    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. •...
  • Page 160: Fuel Tank Cleaning

    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.
  • Page 161: Evaporative Emission Control System

    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.
  • Page 162: Hose Inspection

    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.
  • Page 163 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 .......................
  • Page 164: Exploded View

    4-2 COOLING SYSTEM Exploded View...
  • Page 165 11 Radiator hose clamp screws 0.25 22 in·lb 12. Mechanical seal 13. Double seal bearing 14. Oil seal 15. Ball bearing 16. Thermostat 17. Radiator cap 18. Radiator R: Replacement parts Lh: Left-hand threads G: Apply grease. SS: Apply silicone sealant (Kawasaki Bond: 56019-120).
  • Page 166: Coolant Flow Chart

    4-4 COOLING SYSTEM Coolant Flow Chart Permanent type antifreeze is used as a coolant to protect the cooling system from rust and corrosion. When the engine starts, the water pump turns and the coolant circulates. The thermostat is a wax pellet type which opens or closes as coolant temperature changes. The thermostat continuously changes its valve opening to keep the coolant temperature at the proper level.
  • Page 167 COOLING SYSTEM 4-5 Coolant Flow Chart 1. Water Pump 9. Radiator 2. Water Jacket 10. Radiator Fan 3. Cylinder Head 11. Throttle Body Assy 4. Water Pipe 12. Front 5. Water Hose 13. Cold Coolant 6. Radiator Cap 14. Hot Coolant 7.
  • Page 168: Specifications

    4-6 COOLING SYSTEM Specifications Coolant provided when shipping: Type (recommended) Permanent type antifreeze (soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators) Color Green Mixed ratio Soft water 50%, coolant 50% Freezing point −...
  • Page 169: Special Tools And Sealant

    COOLING SYSTEM 4-7 Special Tools and Sealant Bearing Driver Set : Kawasaki Bond (Silicone Sealant) : 57001–1129 56019–120 Kawasaki Bond (Silicone Sealant) : Bearing Remover Shaft, 56019–120 57001–1265 Bearing Remover Head, 10 × 12 : 57001–1266...
  • Page 170: Coolant

    4-8 COOLING SYSTEM Coolant Coolant Deterioration Inspection • Remove the right side cover (see Frame chapter). • Visually inspect the coolant [A] in the reserve tank. If whitish cotton-like wafts are observed, aluminum parts in the cooling system are corroded. If the coolant is brown, iron or steel parts are rusting.
  • Page 171: Pressure Testing

    COOLING SYSTEM 4-9 Coolant Pressure Testing • Remove the fuel tank (see Fuel System chapter). • Remove the radiator cap, and install a cooling system pressure tester [A] on the radiator filler neck [B]. NOTE ○ Wet the cap sealing surfaces with water or coolant to prevent pressure leakage.
  • Page 172: Water Pump

    4-10 COOLING SYSTEM Water Pump Water Pump Removal • Drain the coolant (see Coolant Change in the Periodic Maintenance chapter). • Remove: Water Hose Clamp [A] Water Hose [B] Front [C] • Remove: Water Pump Cover Bolts [A] Water Pump Cover [B] •...
  • Page 173: Water Pump Inspection

    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.
  • Page 174 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 ○...
  • Page 175: Radiator

    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.
  • Page 176: Radiator Installation

    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) •...
  • Page 177: Radiator Cap Inspection

    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] •...
  • Page 178: Thermostat

    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.
  • Page 179: Hoses And Pipes

    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.
  • Page 181 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...
  • Page 182 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...
  • Page 183: Specifications

    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...
  • Page 184 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...
  • Page 185 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:...
  • Page 186: Exploded View

    5-6 ENGINE TOP END Exploded View...
  • Page 187 8. Vacuum Switch Valve 9. Air Suction Valves 10. HLA Oil Filters AD: Apply adhesive. EO: Apply engine oil. MO: Apply molybdenum disulfide oil. L: Apply a non-permanent locking agent. S: Follow the specific tightening sequence. SS: Apply silicone sealant (Kawasaki Bond: 56019-120).
  • Page 188 5-8 ENGINE TOP END Exploded View...
  • Page 189 ENGINE TOP END 5-9 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Rocker shafts Exhaust pipe cover clamp screws 0.70 61 in·lb Premuffler chamber bolts Muffler bracket nut Muffler stay mounting bolts, Muffler stay mounting nuts, Muffler bracket bolt 8. Rear Exhaust Pipe 9.
  • Page 190 5-10 ENGINE TOP END Exploded View...
  • Page 191 ENGINE TOP END 5-11 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Cylinder coolant drain plug 95 in·lb Cylinder head nuts Cylinder nuts Chain tensioner cap Chain tensioner lockbolt 0.50 43 in·lb Chain tensioner mounting bolts 95 in·lb Chain guide mounting bolts 95 in·lb Camshaft sprocket bolts 9.
  • Page 192: Special Tools And Sealant

    5-12 ENGINE TOP END Special Tools and Sealant Valve Guide Reamer, 7 : Piston Pin Puller Assembly : 57001–162 57001–910 Valve Guide Reamer, 7 : Compression Gauge Adapter, M12 × 1.25 : 57001–162 57001–1018 Valve Guide Arbor, 7 : Spark Plug Wrench, Hex 18 : 57001–163 57001–1024 Valve Spring Compressor Assembly :...
  • Page 193 ENGINE TOP END 5-13 Special Tools and Sealant Valve Seat Cutter, 32° – 35 : Piston Pin Puller Adapter, 14 : 57001–1121 57001–1211 Valve Seat Cutter, 32° – 38.5 : Valve Seat Cutter, 55° – 35 : 57001–1122 57001–1247 Valve Seat Cutter Holder, Fork Oil Level Gauge : 57001–1126 57001–1290...
  • Page 194 5-14 ENGINE TOP END Special Tools and Sealant Valve Seat Cutter 45° – 40 : Kawasaki Bond (Silicone Sealant) : 57001–1496 56019–120 ○ Compression Gauge Adapter: 57001-1183 Valve Seat Cutter 55° – 38.5 : can also be used. 57001–1497 ○...
  • Page 195: Clean Air System

    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. •...
  • Page 196: Vacuum Switch Valve Removal

    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.
  • Page 197: Clean Air System Hose Inspection

    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.
  • Page 198: Camshaft Chain Tensioner

    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.
  • Page 199 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.
  • Page 200: Rocker Case Cover

    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 •...
  • Page 201: Rocker Case Cover Assembly

    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.
  • Page 202: Rocker Case

    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).
  • Page 203: Rocker Case Installation

    • 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 ­...
  • Page 204: Rocker Arm Assembly

    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) •...
  • Page 205: Hla Removal

    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.
  • Page 206: Camshafts

    5-26 ENGINE TOP END Camshafts Camshaft Removal • Remove the timing inspection cap [A] and rotor bolt cap [B]. Special Tool - Driver-Filler Cap: 57001–1454 [C] • Turn the crankshaft counterclockwise [A] and align the “F” mark [B] (TDC mark for the front piston) with the middle of the notch [C].
  • Page 207 ENGINE TOP END 5-27 Camshafts • Install the KACR on each camshaft. ○ The front KACR [A] and rear KACR [B] are different (inside view). Do not confuse these KACRs. • Fit the pin [A] into the notch [B], and install the KACR [C] onto the camshaft [D].
  • Page 208: Camshaft Sprocket Installation

    5-28 ENGINE TOP END Camshafts • Align the “R” mark [A] (TDC mark for the rear piston) with the middle of the notch [B] (310° turn from the front piston TDC). • Engage the rear camshaft sprocket with the camshaft chain as shown.
  • Page 209 ENGINE TOP END 5-29 Camshafts • Apply molybdenum disulfide oil to the threads and seating surface of 12 mm nuts and both sides of washers. • Tighten the rocker case nuts and bolts temporarily follow ­ ing the tightening sequence shown, and then tighten them to the specified torque.
  • Page 210: Front Camshaft Chain Removal

    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 •...
  • Page 211: Kacr Inspection

    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 ­...
  • Page 212: Cylinder Head

    5-32 ENGINE TOP END Cylinder Head Cylinder Compression Measurement NOTE ○ Be sure the battery is fully charged. • Warm up the engine thoroughly. • Stop the engine. • Remove one spark plug and attach the compression gauge and adapter firmly into the spark plug hole. Do not remove the other spark plug, only the plug lead.
  • Page 213: Cylinder Head Removal

    ENGINE TOP END 5-33 Cylinder Head The following table should be consulted if the obtainable compression reading is not within the us­ able range. Problem Diagnosis Remedy (Action) 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...
  • Page 214: Cylinder Head Installation

    5-34 ENGINE TOP END Cylinder Head • Do not remove the coolant drain plug [A] yet. • Remove the cylinder head nuts [B]. • Take the cylinder head off the cylinder. Cylinder Head Installation ○ The front cylinder head [A] has an F mark while the rear cylinder head [B] has an R mark.
  • Page 215: Valve Clearance Adjustment

    ENGINE TOP END 5-35 Cylinder Head Valve Clearance Adjustment NOTE ○ Since the hydraulic lash adjusters constantly maintain zero clearance, it is not necessary to inspect or adjust the valve clearance. Valve Removal • Remove the cylinder head (see this chapter). •...
  • Page 216: Valve Guide Installation

    5-36 ENGINE TOP END Cylinder Head Valve Guide Installation • Apply engine oil to the valve guide outer surface before installation. • Heat the area around the valve guide hole to about 120 150°C (248 302°F) in the engine oil. •...
  • Page 217: Valve Seat Inspection

    ENGINE TOP END 5-37 Cylinder Head Valve Seat Inspection • Remove the valve (see Valve Removal). • Check the valve seat surface [A] between the valve [B] and valve seat [C]. ○ Measure the outside diameter [D] of the seating pattern on the valve seat with vernier calipers.
  • Page 218 5-38 ENGINE TOP END Cylinder Head Seat Cutter Operation Care: 1. This valve seat cutter is developed to grind the valve for repair. Therefore the cutter must not be used for other purposes than seat repair. Do not drop or shock the valve seat cutter, or the diamond particles may fall off.
  • Page 219 ENGINE TOP END 5-39 Cylinder Head ○ To make the 32° grind, fit a 32° cutter into the holder, and slide it into the valve guide. ○ Turn the holder one turn at a time while pressing down very lightly. Check the seat after each turn. CAUTION The 32°...
  • Page 220 5-40 ENGINE TOP END Cylinder Head...
  • Page 221: Cylinders, Piston

    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].
  • Page 222 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 •...
  • Page 223 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].
  • Page 224: Cylinder Wear

    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).
  • Page 225: Cylinder Boring And Honing

    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.
  • Page 226: Piston Ring Thickness

    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...
  • Page 227: Mufflers

    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. •...
  • Page 228: Lower Muffler Removal(For Other Than U.s.a. And Canadian Models)

    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.
  • Page 229: Chamber Removal(For Other Than U.s.a. And Canadian Models)

    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] •...
  • Page 230: Chamber Identification(For Other Than U.s.a. And Canadian Models)

    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).
  • Page 231 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.
  • Page 232 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) •...
  • Page 233 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 ......................
  • Page 234: Exploded View

    6-2 CLUTCH Exploded View...
  • Page 235 CLUTCH 6-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Clutch reservoir cap screws 0.15 13 in·lb Clutch slave cylinder bleed valve 0.80 69 in·lb Clutch master cylinder clamp bolts 95 in·lb Clutch hose banjo bolt Clutch slave cylinder bolts 0.70 61 in·lb Clutch pipe banjo bolt...
  • Page 236: Specifications

    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)
  • Page 237: Special Tools And Sealant

    CLUTCH 6-5 Special Tools and Sealant Inside Circlip Pliers : Gear Holder, m2.0 : 57001–143 57001–1557 Clutch Spring Compressor : 57001–1162...
  • Page 238: Clutch Fluid

    6-6 CLUTCH Clutch Fluid Clutch Fluid Level Check ○ Refer to Clutch Fluid Level Check in the Periodic Mainte ­ nance Chapter. Clutch Fluid Change ○ Refer to Clutch Fluid Change in the Periodic Maintenance Chapter. Clutch Line Bleeding • Remove: Alternator Outer Cover (see Electrical System chapter) •...
  • Page 239: Clutch Master Cylinder

    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).
  • Page 240: Clutch Master Cylinder Inspection

    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...
  • Page 241: Clutch Slave Cylinder

    CLUTCH 6-9 Clutch Slave Cylinder Clutch Slave Cylinder Removal • Remove: Alternator Outer Cover (see Electrical System chapter) Banjo Bolt [A] Clutch Slave Cylinder Bolts [B] Slave Cylinder [C] CAUTION Immediately wash away any clutch fluid that spills. It may damage painted surfaces. •...
  • Page 242: Clutch Slave Cylinder Disassembly/Assembly

    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.
  • Page 243: Clutch Cover Removal

    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]. ○...
  • Page 244 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.
  • Page 245: Clutch Installation

    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.
  • Page 246: Inner Clutch Hub Disassembly

    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.
  • Page 247 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.).
  • Page 248: Spring Plate Gap Adjustment

    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) ×...
  • Page 249: Clutch Spring Height Measurement

    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 •...
  • Page 251 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......................
  • Page 252: Engine Oil Flow Chart

    7-2 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart...
  • Page 253 ENGINE LUBRICATION SYSTEM 7-3 Engine Oil Flow Chart →: Oil Flow (1 --→: Blowby Gas 1. Oil Screen 2. Oil Pump 3. Relief Valve 4. Oil Filter 5. Bypass Valve 6. Oil Pressure Switch 7. Inside Oil Pipe 8. Banjo Bolts of Right Crankcase Rear 9.
  • Page 254: Exploded View

    7-4 ENGINE LUBRICATION SYSTEM Exploded View...
  • Page 255 20. Oil Screen 21. Crankcase Breather Hose 22. To right air cleaner base 23. Oil Baffle EO: Apply engine oil. G: Apply grease. L: Apply a non-permanent locking agent. Lh: Left-hand Threads R: Replacement Parts SS: Apply silicone sealant (Kawasaki Bond: 56019-120).
  • Page 256: Specifications

    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)
  • Page 257: Special Tools And Sealant

    ENGINE LUBRICATION SYSTEM 7-7 Special Tools and Sealant Oil Pressure Gauge, 5 kgf/cm² : Filler Cap Driver : 57001–125 57001–1454 Oil Pressure Gauge Adapter, PT 1/8 : Kawasaki Bond (Silicone Sealant) : 57001–1033 56019–120 Oil Filter Wrench : 57001–1249...
  • Page 258: Engine Oil And Oil Filter

    7-8 ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter WARNING Motorcycle operation with insufficient, deteri­ orated, or contaminated engine oil will cause accelerated wear and may result in engine or trans ­ mission seizure, accident, and injury. Oil Level Inspection •...
  • Page 259: Oil Pump And Oil Line

    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.
  • Page 260: Oil Hose Installation

    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]. •...
  • Page 261: Inside Oil Pipe Removal

    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. •...
  • Page 262: Inside Oil Pipe Installation

    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.
  • Page 263 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].
  • Page 264: Blowby Gas System Inspection

    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].
  • Page 265: Oil Pressure

    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. •...
  • Page 266: Relief Valve Inspection

    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.
  • Page 267 ENGINE REMOVAL/INSTALLATION 8-1 Engine Removal/Installation Table of Contents Exploded View........................Specifications ......................... 8-4 Engine Removal/Installation ....................8-5 Engine Removal........................ 8-5 Engine Installation......................
  • Page 268: Exploded View

    8-2 ENGINE REMOVAL/INSTALLATION Exploded View...
  • Page 269 ENGINE REMOVAL/INSTALLATION 8-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Downtube bolts and nuts Engine mounting bolts and nuts Engine mounting bracket bolts WL: Apply a soap and water solution or rubber lubricant.
  • Page 270: Specifications

    8-4 ENGINE REMOVAL/INSTALLATION Specifications Jack : 57001–1238 Attachment Jack : 57001–1398...
  • Page 271: Engine Removal/Installation

    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.
  • Page 272 8-6 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Remove: Spark Plug Caps [A] Clamp [B] Throttle Sensor Connector [C] • Remove: Injector Connectors [A] Fuel Hose [B] Connector [C] Vacuum Switch Valve [D] Inlet Air Pressure Sensor Hose • Remove: Spark Plug Caps [A] Horn [B] Regulator/Rectifier Lead Connectors [C] Alternator Lead Connectors [D]...
  • Page 273 ENGINE REMOVAL/INSTALLATION 8-7 Engine Removal/Installation • Remove: Engine Ground Terminal [A] • Remove: Brake Reservoir Cover Bolt [A] Brake Reservoir Cover [B] • Support the engine with a commercially available stand [A]. • Loosen the engine mounting nut [B]. • Remove: Engine Mounting Bracket Bolts [C] Downtube Bolts [D]...
  • Page 274: Engine Installation

    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.
  • Page 275 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). •...
  • Page 277 CRANKSHAFT/TRANSMISSION 9-1 Crankshaft/Transmission Table of Contents Exploded View........9-2 Transmission ........9-30 Specifications ........9-6 Shift Pedal Removal ....9-30 Special Tools and Sealants ....9-8 Shift Pedal Installation ....9-30 Crankcase ......... 9-9 External Shift Mechanism Crankcase Disassembly ....9-9 Removal ........
  • Page 278: Exploded View

    9-2 CRANKSHAFT/TRANSMISSION Exploded View...
  • Page 279 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).
  • Page 280 9-4 CRANKSHAFT/TRANSMISSION Exploded View...
  • Page 281 CRANKSHAFT/TRANSMISSION 9-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Shift shaft return spring pin Shift rod locknuts 95 in·lb Rear shift lever clamp bolt 104 in·lb Gear set lever bolt 95 in·lb Shift drum cam bolt Shift pedal clamp bolts Shift pedal clamp bolts (VN1600–A2 ) Damper cam nut Idle shaft holder bolts...
  • Page 282: Specifications

    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)
  • Page 283 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...
  • Page 284: Special Tools And Sealants

    Outside Circlip Pliers : Flywheel Holder : 57001–144 57001–1410 Damper Cam Holder : Gear Holder, m2.0 : 57001–1025 57001–1557 Bearing Driver Set : Kawasaki Bond (Silicone Sealant) : 57001–1129 56019–120 Flywheel Holder : Kawasaki Bond (Liquid Gasket – Black) : 57001–1313 92104–1064...
  • Page 285: Crankcase

    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) •...
  • Page 286 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].
  • Page 287 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]...
  • Page 288 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] ○...
  • Page 289: Crankcase Assembly

    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.
  • Page 290 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 •...
  • Page 291 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.
  • Page 292 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)
  • Page 293 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.
  • Page 294 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) •...
  • Page 295 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. •...
  • Page 296: Starter Clutch Disassembly

    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.
  • Page 297: Starter Clutch Assembly

    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].
  • Page 298: Starter Torque Limiter Check

    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]...
  • Page 299: Crankshaft/Connecting Rods

    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.
  • Page 300: Crankshaft/Connecting Rod Cleaning

    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]...
  • Page 301: Connecting Rod Big End Side Clearance

    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...
  • Page 302 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.
  • Page 303: Crankshaft Runout

    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 •...
  • Page 304: Primary Gear

    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]...
  • Page 305 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].
  • Page 306: Transmission

    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 •...
  • Page 307: External Shift Mechanism 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.
  • Page 308: Transmission Removal

    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].
  • Page 309: Shift Drum Disassembly/Assembly

    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].
  • Page 310: Transmission Disassembly

    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.
  • Page 311: Shift Fork Bending

    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 •...
  • Page 312 9-36 CRANKSHAFT/TRANSMISSION Transmission 1. Circlip 10. 4th Gear 21. Washer ( 20 × 25.5 × t 1.2) 11. 1st Gear (drive shaft) ( 25.5 × 36 × t 1.0) 2. Needle Bearing 12. Output Shaft 22. 1st Gear 3. Thrust Washer 13.
  • Page 313: Ball Bearing, Needle Bearing, And Oil Seal

    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.
  • Page 314: Oil Seal Inspection

    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.
  • Page 315 WHEELS/TIRES 10-1 Wheels/Tires Table of Contents Exploded View........................10-2 Specifications ......................... 10-4 Special Tools .......................... 10-5 Wheels (Rims) ........................10-6 Front Wheel Removal ....................... 10-6 Front Wheel Installation ....................10-7 Rear Wheel Removal ......................10-8 Rear Wheel Installation..................... 10-9 Wheel Coupling Removal ....................10-10 Wheel Coupling Installation ....................
  • Page 316: Exploded View

    10-2 WHEELS/TIRES Exploded View...
  • Page 317 WHEELS/TIRES 10-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Tire air valve stem nuts 0.15 13 in·lb Air valve cores 0.03 2.6 in·lb Tire air valve caps 0.15 0.015 1.3 in·lb Front axle clamp bolts Front axle 11.0 79.6 Rear axle nut 11.0 79.6...
  • Page 318: Specifications

    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 –...
  • Page 319: Special Tools

    WHEELS/TIRES 10-5 Special Tools Inside Circlip Pliers : Bearing Remover Head, 20 × 22 : 57001–143 57001–1293 Bearing Driver Set : Bearing Remover Shaft, 13 : 57001–1129 57001–1377 Jack : Attachment Jack : 57001–1238 57001–1398...
  • Page 320: Wheels (Rims)

    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] ○...
  • Page 321: Front Wheel Installation

    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. •...
  • Page 322: Rear Wheel Removal

    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...
  • Page 323: Rear Wheel Installation

    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. •...
  • Page 324: Wheel Coupling Removal

    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. ○...
  • Page 325 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 •...
  • Page 326: Wheel Balance

    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.
  • Page 327: Balance Weight Removal

    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.
  • Page 328 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.
  • Page 329: Tires

    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) •...
  • Page 330 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.
  • Page 331: Tire Repair

    Also, permanent (internal) repairs have the advantage of permitting a thorough examination for secondary damage not visible from external inspection of the tire. For these reasons, Kawasaki does not recommend temporary (exter- nal) repair. Only appropriate permanent (internal) repairs are recommended. Repair methods may vary slightly from make to make.
  • Page 332: Hub Bearings (Wheel Bearings)

    10-18 WHEELS/TIRES Hub Bearings (Wheel Bearings) Hub Bearings Removal • Remove the wheel, and take out the following. Collars Grease Seals [A] Circlips [B] Coupling [C] (Out of Rear Hub) Front Hub [D] Rear Hub [E] Special Tool - Inside Circlip Pliers: 57001-143 •...
  • Page 333: Hub Bearings Inspection

    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.
  • Page 335 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 ..
  • Page 336: Exploded View

    11-2 FINAL DRIVE Exploded View...
  • Page 337 FINAL DRIVE 11-3 Exploded View Front Gear Case Torque Fastener Remarks N·m kgf·m ft·lb Oil pipe banjo bolts (front gear) 104 in·lb Front gear case bolts 6 mm 104 in·lb Neutral switch Oil nozzle (front gear) 0.30 26 in·lb Oil nozzle (front gear) Speed sensor bolt 87 in·lb Bearing retainer bolts (front gear)
  • Page 338 11-4 FINAL DRIVE Exploded View...
  • Page 339 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...
  • Page 340: Specifications

    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...
  • Page 341: Special Tools

    FINAL DRIVE 11-7 Special Tools Bearing Puller : Oil Seal & Bearing Remover : 57001–158 57001–1058 Bearing Puller Adapter : Bearing Driver Set : 57001–317 57001–1129 Bearing Driver, 32 : Pinion Gear Holder, m1.9 : 57001–382 57001–1165 Damper Cam Holder : Final Gear Case Holder : 57001–1025 57001–1250...
  • Page 342: Final Gear Case And Oil

    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.
  • Page 343 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 ○...
  • Page 344: Final Gear Case Assembly

    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.
  • Page 345 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. ○...
  • Page 346: Pinion Gear Removal

    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 •...
  • Page 347: Pinion Gear Installation

    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. •...
  • Page 348: Pinion Gear Bearing Preload Adjustment

    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. ○...
  • Page 349 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.
  • Page 350: Bevel Gear Inspection

    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...
  • Page 351: Final Bevel Gear Adjustment

    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.
  • Page 352: Backlash Adjustment

    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...
  • Page 353: Tooth Contact Adjustment

    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.
  • Page 354 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.
  • Page 355: Propeller Shaft

    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.
  • Page 356: Propeller Shaft Inspection

    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.
  • Page 357: Front Bevel Gears

    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].
  • Page 358: Front Gear Case Assembly

    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] ○...
  • Page 359: Driven Gear Disassembly

    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.
  • Page 360: Driven Gear Assembly

    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. •...
  • Page 361: Damper Cam Installation

    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.
  • Page 362: Preload Adjustment

    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 ­...
  • Page 363: Preload Measurement With Spring Scale

    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.
  • Page 364: Backlash Adjustment

    11-30 FINAL DRIVE Front Bevel Gears Bearing Preloading Mechanism 1. Bearing Housing 3. Spacer 5. Tapered Roller Bearing 2. Tapered Roller Bearing 4. Collar Before Tightening [A] Under No Preload [C] Under Preload [E] After Tightening [B] Initial Clearance [D] No Clearance [F] Backlash Adjustment •...
  • Page 365: Tooth Contact Adjustment

    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.
  • Page 366 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.
  • Page 367: Bevel Gear Inspection

    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.
  • Page 368: Bearing And Oil Seal

    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 ○...
  • Page 369: Tapered Roller Bearing Inspection

    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.
  • Page 371 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.
  • Page 372: Exploded View

    12-2 BRAKES Exploded View...
  • Page 373 BRAKES 12-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Brake hose banjo bolts Front brake reservoir cap screws 0.15 13 in·lb Brake lever pivot bolt 0.10 87 in·lb Brake lever pivot bolt locknut 0.60 52 in·lb Front master cylinder clamp bolts 78 in·lb Front brake light switch screw 0.12...
  • Page 374 12-4 BRAKES Exploded View...
  • Page 375 BRAKES 12-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Rear master cylinder mounting bolts Brake hose banjo bolts Rear master cylinder push rod locknut Brake pedal clamp bolt Caliper bleed valves 69 in·lb Rear caliper mounting bolts Rear caliper holder bolt Brake disc bolts B: Apply brake fluid.
  • Page 376: Specifications

    12-6 BRAKES Specifications Item Standard Service Limit Brake Lever, Brake Pedal: Brake lever position No.1 5-way adjustable Brake lever free play Non-adjustable – – – Pedal free play Non-adjustable – – – Pedal position About 110 mm (4.33 in.) – – – (height from pedal top to footpeg top) Brake Fluid: Grade...
  • Page 377: Special Tool

    BRAKES 12-7 Special Tool Inside Circlip Pliers : 57001–143...
  • Page 378: Brake Lever, Brake Pedal

    12-8 BRAKES Brake Lever, Brake Pedal Brake Lever Position Adjustment The brake lever adjuster has 5 positions so that the brake lever position can be adjusted to suit the operator’s hand. • Push the lever forward and turn the adjuster [A] to align the number with the arrow mark [B] on the lever holder.
  • Page 379: Brake Pedal Removal

    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 ±...
  • Page 380: Brake Pedal Installation

    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].
  • Page 381: Calipers

    BRAKES 12-11 Calipers Front Caliper Removal • Loosen the banjo bolt [A] at the brake hose lower end, and tighten it loosely. • Unscrew the caliper mounting bolts [B]. CAUTION Do not loosen the caliper assembly bolt [C]. Take out only the caliper mounting bolts for caliper re ­ moval.
  • Page 382: Front Caliper Disassembly

    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.
  • Page 383: Rear Caliper Disassembly

    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.
  • Page 384: Rear Caliper Assembly

    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. ○...
  • Page 385: Caliper Fluid Seal Damage

    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.
  • Page 386: Brake Pads

    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).
  • Page 387: Rear Brake Pad Installation

    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 •...
  • Page 388: Master Cylinder

    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. •...
  • Page 389: Rear Master Cylinder Removal

    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).
  • Page 390: Rear Master Cylinder Installation

    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. •...
  • Page 391: Rear Master Cylinder Disassembly

    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).
  • Page 392: Master Cylinder Inspection

    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.
  • Page 393: Brake Discs

    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.
  • Page 394: Brake Fluid

    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.
  • Page 395 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: ○...
  • Page 396 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.
  • Page 397: Brake Hoses

    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. •...
  • Page 399 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 ......................
  • Page 400: Exploded View

    13-2 SUSPENSION Exploded View...
  • Page 401 SUSPENSION 13-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Upper front fork clamp bolts Lower front fork clamp bolts Front fork top plugs Front fork bottom allen bolt Front axle clamp bolts L: Apply a non-permanent locking agent. R: Replacement Parts G: Apply grease.
  • Page 402 13-4 SUSPENSION Exploded View...
  • Page 403 SUSPENSION 13-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Rear shock absorber nuts Swingarm pivot shaft 11.0 79.6 G: Apply grease. WL: Apply a soap and water solution or rubber lubricant.
  • Page 404: Specifications

    13-6 SUSPENSION Specifications Item Standard Front Fork (per one unit): Fork inner tube diameter 43 mm ( 1.7 in.) Fork spring setting Non-adjustable Air pressure Atmospheric pressure (Non-adjustable) Rebound damper setting Non-adjustable Fork oil viscosity SAE 10W-20 Fork oil capacity: 521 ±...
  • Page 405: Special Tools

    SUSPENSION 13-7 Special Tools Fork Cylinder Holder Handle : Front Fork Oil Seal Driver : 57001–183 57001–1219 Fork Cylinder Holder Adapter : Jack : 57001–1057 57001–1238 Oil Seal & Bearing Remover : Fork Oil Level Gauge : 57001–1058 57001–1290 Bearing Driver Set : Attachment Jack : 57001–1129 57001–1398...
  • Page 406: Front Fork

    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.
  • Page 407: Front Fork Removal

    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.
  • Page 408: Front Fork Installation

    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.
  • Page 409: Disassembly

    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]...
  • Page 410: Assembly

    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]...
  • Page 411: Inner Tube, Outer Tube Inspection

    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]. •...
  • Page 412: Spring Tension

    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 ­...
  • Page 413: Rear Shock Absorber

    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.
  • Page 414: Rear Shock Absorber Removal

    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].