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Versys
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Service Manual

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   Also See for Kawasaki Versys

   Summary of Contents for Kawasaki Versys

  • Page 1

    Versys Motorcycle Service Manual...

  • Page 3: General Information

    Quick Reference Guide General Information Periodic Maintenance Fuel System (DFI) Cooling System Engine Top End Clutch Engine Lubrication System Engine Removal/Installation Crankshaft/Transmission Wheels/Tires 10 j Final Drive 11 j Brakes 12 j Suspension 13 j Steering 14 j Frame 15 j Electrical System 16 j Appendix...

  • Page 5

    All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Quality Division/Consumer Products & Machinery Company/Kawasaki Heavy Industries, Ltd., Japan.

  • Page 6

    LIST OF ABBREVIATIONS ampere(s) pound(s) ABDC after bottom dead center meter(s) alternating current minute(s) ATDC after top dead center newton(s) BBDC before bottom dead center pascal(s) bottom dead center horsepower BTDC before top dead center pound(s) per square inch °C degree(s) Celsius revolution direct current...

  • Page 7: How To Use This Manual

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

  • Page 9

    GENERAL INFORMATION 1-1 General Information Table of Contents Before Servicing ........................Model Identification......................... General Specifications......................Unit Conversion Table ......................1-11...

  • Page 10: 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 11

    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 12: Tightening Torque

    1-4 GENERAL INFORMATION Before Servicing Tightening Sequence Generally, when installing a part with several bolts, nuts, or screws, start them all in their holes and tighten them to a snug fit. Then tighten them according to the specified se- quence to prevent case warpage or deformation which can lead to malfunction.

  • Page 13

    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 14

    1-6 GENERAL INFORMATION Before Servicing Lubrication It is important to lubricate rotating or sliding parts during assembly to minimize wear during initial operation. Lubri- cation points are called out throughout this manual, apply the specific oil or grease as specified. Direction of Engine Rotation When rotating the crankshaft by hand, the free play amount of rotating direction will affect the adjustment.

  • Page 15: Model Identification

    GENERAL INFORMATION 1-7 Model Identification KLE650B7F Left Side View KLE650B7F Right Side View Frame Number Engine Number...

  • Page 16: General Specifications

    1-8 GENERAL INFORMATION General Specifications Items KLE650A7F, KLE650B7F Dimensions Overall Length 2 125 mm (83.7 in.) Overall Width 840 mm (33.1 in.) Overall Height 1 315 mm (51.8 in.) Wheelbase 1 415 mm (55.7 in.) Road Clearance 180 mm (7.1 in.) Seat Height 840 mm (33.1 in.) Dry Mass:...

  • Page 17

    GENERAL INFORMATION 1-9 General Specifications Items KLE650A7F, KLE650B7F Valve Timing: Inlet: Open 25° (BTDC) Close 54° (ABDC) Duration 260° Exhaust: Open 47° (BBDC) Close 25° (ATDC) Duration 252° Lubrication System Forced lubrication (sem-dry sump) Engine Oil: Type API SE, SF or SG API SH, SJ or SL with JASO MA Viscosity SAE 10W-40...

  • Page 18

    1-10 GENERAL INFORMATION General Specifications Items KLE650A7F, KLE650B7F Rim Size: Front 17 × 3.50 Rear 17 × 4.50 Front Suspension: Type Telescopic fork (upside-down) Wheel Travel 150 mm (5.9 in.) Rear Suspension: Type Swingarm (uni-trak) Wheel Travel 145 mm (5.7 in.) Brake Type: Front Dual discs...

  • Page 19: Unit Conversion Table, Units Of Force

    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 Units of Torque: milli × 0.001 N·m ×...

  • Page 21: Table Of Contents

    PERIODIC MAINTENANCE 2-1 Periodic Maintenance Table of Contents Periodic Maintenance Chart ....................Torque and Locking Agent...................... Specifications ......................... 2-11 Special Tools .......................... 2-13 Periodic Maintenance Procedures..................2-14 Fuel System (DFI)........................ 2-14 Air Cleaner Element Cleaning................... 2-14 Throttle Control System Inspection................... 2-15 Engine Vacuum Synchronization Inspection..............

  • Page 22: Table Of Contents

    2-2 PERIODIC MAINTENANCE Lights and Switches Operation Inspection................ 2-37 Headlight Aiming Inspection ..................... 2-39 Sidestand Switch Operation Inspection ................2-40 Engine Stop Switch Operation Inspection................. 2-41 Others ..........................2-42 Chassis Parts Lubrication ....................2-42 Bolts, Nuts and Fasteners Tightness Inspection............... 2-43 Replacement Parts ......................

  • Page 23: Table Of Contents

    PERIODIC MAINTENANCE 2-3 Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition.The initial maintenance is vitally important and must not be neglected. Periodic Inspection FREQUENCY Whichever * ODOMETER READING comes ×...

  • Page 24

    2-4 PERIODIC MAINTENANCE Periodic Maintenance Chart FREQUENCY Whichever * ODOMETER READING comes × 1 000 km first (× 1 000 mile) Page (0.6) (7.5) (12) (15) (20) (24) INSPECTION Every • • • • • • • Brake hose and pipe damage - inspect year 2-31 Brake hose and pipe installation condition -...

  • Page 25: Periodic Maintenance Chart, Periodic Replacement Parts

    PERIODIC MAINTENANCE 2-5 Periodic Maintenance Chart Periodic Replacement Parts FREQUENCY Whichever * ODOMETER READING comes × 1 000 km first (× 1 000 mile) Page (0.6) (7.5) (15) (24) (30) CHANGE/REPLACE ITEM Every Air cleaner element # 2 years 2-44 •...

  • Page 26: Torque And Locking Agent, Fuel System

    2-6 PERIODIC MAINTENANCE Torque and Locking Agent The following tables list the tightening torque for the major fasteners requiring use of a non-permanent locking agent or silicone sealant etc. Letters used in the “Remarks” column mean: AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque. EO: Apply engine oil.

  • Page 27

    PERIODIC MAINTENANCE 2-7 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Throttle Body Assy Holder Bolts 106 in·lb Cylinder Bolt (M8) 27.5 MO,S Cylinder Nut (M10) MO, S Cylinder Bolts (M6) 106 in·lb Exhaust Pipe Manifold Holder Nuts Muffler Body Mounting Bolt (Front) Muffler Body Mounting Bolt (Rear) Clutch...

  • Page 28

    2-8 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Crankcase Bolt (M6, L = 32 mm) 19.6 Crankcase Bolts (M6, L = 38 mm) 19.6 Crankcase Bolts (M6, L = 45 mm) 19.6 Crankcase Bolts (M8, L = 50 mm) 27.5 Crankcase Bolts (M8, L = 60 mm) MO, S...

  • Page 29

    PERIODIC MAINTENANCE 2-9 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Front Brake Reservoir Cap Screws 0.15 13 in·lb Front Caliper Mounting Bolts Front Master Cylinder Clamp Bolts 0.90 78 in·lb Bleed Valve 0.80 69 in·lb Brake Hose Banjo Bolts Brake Pedal Bolt 0.90 78 in·lb...

  • Page 30

    2-10 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Turn Signal Light Lens Screws 0.10 9 in·lb Alternator Cover Bolts 87 in·lb Alternator Lead Holding Plate Bolt 87 in·lb Alternator Rotor Bolt 15.8 Engine Ground Cable Terminal Bolt 87 in·lb Front Brake Light Switch Screw 0.12...

  • Page 31: Specifications

    PERIODIC MAINTENANCE 2-11 Specifications Item Standard Service Limit Fuel System (DFI) – – – Throttle Grip Free Play 3 mm (0.08 0.12 in.) Idle Speed 1 300 ±50 r/min (rpm) – – – Bypass Screws (Turn Out) 0 2 1/2 (for reference) –...

  • Page 32

    2-12 PERIODIC MAINTENANCE Specifications Item Standard Service Limit Final Drive Drive Chain Slack 35 mm (1.0 1.4 in.) – – – Drive Chain Wear (20-link 317.5 318.2 mm (12.50 12.53 in.) 323 mm (12.7 in.) Length) Standard Chain: Make ENUMA –...

  • Page 33: Special Tools

    PERIODIC MAINTENANCE 2-13 Special Tools Inside Circlip Pliers: Throttle Sensor Setting Adapter: 57001-143 57001-1538 Steering Stem Nut Wrench: Extension Tube: 57001-1100 57001-1578 Oil Filter Wrench: Pilot Screw Adjuster, E: 57001-1249 57001-1603 Vacuum Gauge: 57001-1369...

  • Page 34: Periodic Maintenance Procedures, Fuel System (dfi), Air Cleaner Element Cleaning

    2-14 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel System (DFI) 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 muddily roads, the ele- ment should be cleaned immediately.

  • Page 35: Throttle Control System Inspection

    PERIODIC MAINTENANCE 2-15 Periodic Maintenance Procedures WARNING Clean the element in a well-ventilated area, and make sure that there are no sparks or flame any- where near the working area. Because of the danger of highly flammable liquids, do not use gasoline or a low-flash point solvent to clean the element.

  • Page 36: Engine Vacuum Synchronization Inspection, Engine Vacuum Synchronization - Inspect

    2-16 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Loosen the locknut [A] at the middle of the decelerator cable. • Turn the adjuster [B] until there is no play when the throttle grip is completely closed. • Tighten the locknut. • Turn the accelerator cable adjuster until the proper amount of throttle grip free play is obtained.

  • Page 37

    PERIODIC MAINTENANCE 2-17 Periodic Maintenance Procedures If any one vacuum is not within the specification, turn in the bypass screws until it seats fully but not tightly. Special Tool - Pilot Screw Adjuster, E [A]: 57001-1603 CAUTION Do not over tighten them. They could be damaged, requiring replacement.

  • Page 38: Idle Speed Inspection, Idle Speed Adjustment, Fuel Hose Inspection (fuel Leak, Damage, Installation Condition)

    2-18 PERIODIC MAINTENANCE Periodic Maintenance Procedures Idle Speed Inspection • Start the engine and warm it up thoroughly. • With the engine idling, turn the handlebar to both sides [A]. If handlebar movement changes the idle speed, the throttle cables may be improperly adjusted or incorrectly routed or damaged.

  • Page 39: Cooling System, Coolant Level Inspection, Radiator Hose Damage And Installation Condition Inspection

    PERIODIC MAINTENANCE 2-19 Periodic Maintenance Procedures • Check that the hose joints are securely connected. ○ Push and pull [A] the hose joint [B] back and forth more than two times, and make sure it is locked. If it does not locked, reinstall the hose joint. WARNING Make sure the hose joint is installed correctly on the delivery pipe by sliding the joint, or the fuel could...

  • Page 40: Valve Clearance Inspection, Air Suction System, Air Suction System Damage Inspection, Engine Top End

    2-20 PERIODIC MAINTENANCE Periodic Maintenance Procedures Air Suction System Air Suction System Damage Inspection • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System chapter) Fuel Hose (see Fuel Hose Replacement) • Connect the following parts temporary. Fuel Pump Lead Connector [A] Fuel Level Sensor Lead Connector [B] Extension Tube [C] Special Tool - Extension Tube: 57001-1578...

  • Page 41: Valve Clearance Adjustment

    PERIODIC MAINTENANCE 2-21 Periodic Maintenance Procedures ○ Measure the valve clearance of the valves for which the cams [A] are turned away from each other. • Using the thickness gauge [A], measure the valve clear- ance between cam and valve lifter. Valve Clearance Standard: Exhaust 0.22...

  • Page 42

    2-22 PERIODIC MAINTENANCE Periodic Maintenance Procedures NOTE ○ Mark and record the valve lifter and shim locations so they can be reinstalled in their original positions. ○ If there is no clearance, select a shim which is several sizes smaller and then measure the clearance. •...

  • Page 43

    PERIODIC MAINTENANCE 2-23 Periodic Maintenance Procedures VALVE CLEARANCE ADJUSTMENT CHART INLET VALVE 1. Measure the clearance (when engine is cold). 2. Check present shim size. 3. Match clearance in vertical column with present shim size in horizontal column. 4. Install the shim specified where the lines intersect. This shim will give the proper clearance. Example: Present shim is 2.95 mm.

  • Page 44

    2-24 PERIODIC MAINTENANCE Periodic Maintenance Procedures VALVE CLEARANCE ADJUSTMENT CHART EXHAUST VALVE 1. Measure the clearance (when engine is cold). 2. Check present shim size. 3. Match clearance in vertical column with present shim size in horizontal column. 4. Install the shim specified where the lines intersect. This shim will give the proper clearance. Example: Present shim is 2.95 mm.

  • Page 45: Clutch, Clutch Operation Inspection, Wheels/tires, Air Pressure Inspection

    PERIODIC MAINTENANCE 2-25 Periodic Maintenance Procedures Clutch Clutch Operation Inspection • Pull the clutch lever just enough to take up the free play [A]. • Measure the gap between the lever and the lever holder. If the gap is too wide, the clutch may not release fully. If the gap is too narrow, the clutch may not engage fully.

  • Page 46: Wheel/tire Damage Inspection, Tire Tread Wear, Abnormal Wear Inspection

    2-26 PERIODIC MAINTENANCE Periodic Maintenance Procedures Wheel/Tire Damage Inspection • Remove any imbedded stones [A] or other foreign parti- cles [B] from tread. • Visually inspect the tire for cracks and cuts, and replace the tire if necessary. Swelling or high spots indicate inter- nal damage, requiring tire replacement.

  • Page 47: Wheel Bearing Damage Inspection, Drive Train, Drive Chain Lubrication Condition Inspection

    PERIODIC MAINTENANCE 2-27 Periodic Maintenance Procedures Wheel Bearing Damage Inspection • Raise the front wheel off the ground with jack (see Front Wheel Removal in the Wheels/Tires chapter). • Turn the handlebar all the way to the right or left. •...

  • Page 48: Drive Chain Slack Inspection, Drive Chain Slack Adjustment

    2-28 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Apply oil to the sides of the rollers so that oil will penetrate to the rollers and bushings. Apply the oil to the O-rings so that the O-rings will be coated with oil. •...

  • Page 49: Wheel Alignment Inspection

    PERIODIC MAINTENANCE 2-29 Periodic Maintenance Procedures • Insert a new cotter pin [A]. NOTE ○ When inserting the cotter pin, if the slots in the nut do not align with the cotter pin hole in the axle, tighten the nut clockwise [B] up to next alignment. ○...

  • Page 50: Drive Chain Wear Inspection, Chain Guide Inspection

    2-30 PERIODIC MAINTENANCE Periodic Maintenance Procedures Drive Chain Wear Inspection • Remove the chain cover (see Swingarm Removal in the Suspension chapter). • Rotate the rear wheel to inspect the drive chain for dam- aged rollers, and loose pins and links. If there is any irregularity, replace the drive chain.

  • Page 51: Brake System, Brake Fluid Leak (brake Hose And Pipe) Inspection

    PERIODIC MAINTENANCE 2-31 Periodic Maintenance Procedures Brake System Brake Fluid Leak (Brake Hose and Pipe) Inspection • For models equipped with an ABS, remove the rear fender front (see Rear Fender Front Removal in the Frame chap- ter). • Apply the brake lever or pedal and inspect the brake fluid leak from the brake hoses [A], pipes (ABS equipped mod- els) [B] and fittings [C].

  • Page 52: Brake Operation Inspection, Brake Fluid Level Inspection

    2-32 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Operation Inspection • Inspect the operation of the front and rear brake by run- ning the vehicle on the dry road. If the brake operation is insufficiency, inspect the brake system. WARNING When inspecting by running the vehicle, note a surrounding traffic situation enough in the place of safety.

  • Page 53: Brake Pad Wear Inspection, Brake Light Switch Operation Inspection, Brake Pad Wear - Inspect #

    PERIODIC MAINTENANCE 2-33 Periodic Maintenance Procedures • Follow the procedure below to install the rear brake fluid reservoir cap correctly. ○ First, tighten the rear brake fluid reservoir cap [B] clock- wise [C] by hand until slight resistance is felt indicating that the cap is seated on the reservoir body, then tighten the cap an additional 1/6 turn [D] while holding the brake fluid reservoir body [A].

  • Page 54: Suspensions, Front Forks/rear Shock Absorber Operation Inspection, Front Fork Oil Leak Inspection

    2-34 PERIODIC MAINTENANCE Periodic Maintenance Procedures Suspensions Front Forks/Rear Shock Absorber Operation Inspection • Pump the forks down and up [A] 4 or 5 times, and inspect the smooth stroke. If the forks do not smoothly or noise is found, inspect the fork oil level or fork clamps (see Front Fork Oil Change in the Suspension chapter).

  • Page 55: Steering System, Steering Play Inspection, Steering Play Adjustment

    PERIODIC MAINTENANCE 2-35 Periodic Maintenance Procedures Steering System Steering Play Inspection • Raise the front wheel off the ground with jack (see Front Wheel Removal in the Wheels/Tires chapter). • With the front wheel pointing straight ahead, alternately tap each end of the handlebar. The front wheel should swing fully left and right from the force of gravity until the fork hits the stop.

  • Page 56: Steering Stem Bearing Lubrication

    2-36 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Install the claw washer [A] so that its bent side [B] faces upward, and engage the bent claws with the grooves of stem locknut [C]. • Hand tighten the stem locknut until it touches the claw washer.

  • Page 57: Electrical System, Lights And Switches Operation Inspection

    PERIODIC MAINTENANCE 2-37 Periodic Maintenance Procedures Electrical System Lights and Switches Operation Inspection First Step • Turn on the ignition switch. • The following lights should go on according to below table. goes on City Lights [A] Taillight [B] goes on goes on License Plate Light [C] Meter Panel Illumination Light (LED) [D]...

  • Page 58

    2-38 PERIODIC MAINTENANCE Periodic Maintenance Procedures Second Step • Turn the ignition switch to P (Park) position. • The city light, taillight and license plate light should go on. If the light does not go on, inspect or replace the following item.

  • Page 59: Headlight Aiming Inspection

    PERIODIC MAINTENANCE 2-39 Periodic Maintenance Procedures • Set the dimmer switch to high beam position. • The low beam [A] and high beam [B] headlights should go on. • The high beam indicator light (LED) [C] should go on. If the high beam headlight and/or high beam indicator light (LED) does not go on, inspect or replace the following item.

  • Page 60: Sidestand Switch Operation Inspection

    2-40 PERIODIC MAINTENANCE Periodic Maintenance Procedures NOTE ○ ON high beam, the brightest points should be slightly below horizontal with the motorcycle on its wheels and the rider seated. Adjust the headlight to the proper an- gle according to local regulations. Low Beam [A] Height of Headlight Center [B] High Beam [C]...

  • Page 61: Engine Stop Switch Operation Inspection

    PERIODIC MAINTENANCE 2-41 Periodic Maintenance Procedures If the sidestand switch operation does not work, inspect or replace the following item. Battery (see Charging Condition Inspection in the Elec- trical System chapter) Main Fuse 30 A (see Fuse Inspection in the Electrical System chapter) Ignition Fuse 10 A (see Fuse Inspection in the Electrical System chapter)

  • Page 62: Others, Chassis Parts Lubrication

    2-42 PERIODIC MAINTENANCE Periodic Maintenance Procedures Others Chassis Parts Lubrication • Before lubricating each part, clean off any rusty spots with rust remover and wipe off any grease, oil, dirt, or grime. • Lubricate the points listed below with indicated lubricant. NOTE ○...

  • Page 63: Bolts, Nuts And Fasteners Tightness Inspection

    PERIODIC MAINTENANCE 2-43 Periodic Maintenance Procedures Bolts, Nuts and Fasteners Tightness Inspection • Check the tightness of the bolts and nuts listed here. Also, check to see that each cotter pin is in place and in good condition. NOTE ○ For the engine fasteners, check the tightness of them when the engine is cold (at room temperature).

  • Page 64: Replacement Parts, Air Cleaner Element Replacement, Fuel Hose Replacement

    2-44 PERIODIC MAINTENANCE Periodic Maintenance Procedures Replacement Parts Air Cleaner Element Replacement • Refer to the Air Cleaner Element Cleaning. Fuel Hose Replacement CAUTION When removing and installing the fuel hose joint, do not apply strong force to the outlet pipe on the fuel pump and delivery pipe on the throttle body assy.

  • Page 65: Coolant Change

    PERIODIC MAINTENANCE 2-45 Periodic Maintenance Procedures Coolant Change WARNING To avoid burns, do not remove the radiator cap or try to change the coolant when the engine is still hot. Wait until it cools down. Coolant on tires will make them slippery and can cause an accident and injury.

  • Page 66

    2-46 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Place a container under the water pump drain bolt [A], then remove the drain bolt. • Remove the radiator cap [A] in two steps. First turn the cap counterclockwise to the first stop. Then push and turn it further in the same direction and remove the cap.

  • Page 67: Radiator Hose And O-ring Replacement

    PERIODIC MAINTENANCE 2-47 Periodic Maintenance Procedures • Fill the radiator up to the filler neck [A] with coolant. NOTE ○ Pour in the coolant slowly so that it can expel the air from the engine and radiator. • Check the cooling system for leaks. •...

  • Page 68: Engine Oil Change, Oil Filter Replacement

    2-48 PERIODIC MAINTENANCE Periodic Maintenance Procedures Engine Oil Change • Situate the motorcycle so that it is vertical after warming up the engine. • Unscrew the oil filler plug [A]. • Place on oil pan beneath the engine. • Remove the engine oil drain bolt [A] to drain the oil. ○...

  • Page 69: Brake Hose And Pipe Replacement

    PERIODIC MAINTENANCE 2-49 Periodic Maintenance Procedures • Replace the filter with a new one. • Apply engine oil to the gasket [A] before installation. • Tighten the filter with the oil filter wrench. Torque - Oil Filter: 17.5 N·m (1.8 kgf·m, 13 ft·lb) NOTE ○...

  • Page 70: Brake Fluid Change

    2-50 PERIODIC MAINTENANCE Periodic Maintenance Procedures • For models equipped with an ABS, note the following. ○ Remove: Rear Fender Front (see Rear Fender Front Removal in the Frame chapter) Air Cleaner Housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter) Right Rear Frame Cover (see Rear Frame Cover Re- moval in the Frame chapter) ○...

  • Page 71

    PERIODIC MAINTENANCE 2-51 Periodic Maintenance Procedures • Level the brake fluid reservoir. • Remove the reservoir cap and diaphragm. • Remove the rubber cap from the bleed valve [A] on the caliper. • Attach a clear plastic hose [B] to the bleed valve, and run the other end of the hose into a container.

  • Page 72: Master Cylinder Rubber Parts Replacement

    2-52 PERIODIC MAINTENANCE Periodic Maintenance Procedures Master Cylinder Rubber Parts Replacement Front Master Cylinder Disassembly • Remove the front master cylinder (see Front Master Cylin- der Removal in the Brakes chapter). • Remove the reservoir cap and diaphragm, and pour the brake fluid into a container.

  • Page 73: Caliper Rubber Parts Replacement

    PERIODIC MAINTENANCE 2-53 Periodic Maintenance Procedures • Apply brake fluid to the new parts and to the inner wall of the cylinder. • Take care not to scratch the piston or the inner wall of the cylinder. • Tighten the brake lever pivot bolt and locknut. •...

  • Page 74

    2-54 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Replace the fluid seals [A] with new ones. ○ Apply brake fluid to the fluid seals, and install them into the cylinders by hand. • Replace the dust seals [B] with new ones if they are dam- aged.

  • Page 75: Spark Plug Replacement, Spark Plug • • • •

    PERIODIC MAINTENANCE 2-55 Periodic Maintenance Procedures Rear Caliper Assembly • Clean the caliper parts except for the pads. CAUTION For cleaning of the parts, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol. • Install the bleed valve and rubber cap. Torque - Bleed Valve: 7.8 N·m (0.80 kgf·m, 69 in·lb) •...

  • Page 76

    2-56 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Insert the spark plug [A] vertically into the plug hole with the spark plug installed in the plug wrench [B]. Owner’s Tool - Spark Plug Wrench, 16 mm: 92110-1132 CAUTION The insulator of the spark plug may break if when the wrench is inclined during tightening.

  • Page 77: Table Of Contents

    FUEL SYSTEM (DFI) 3-1 Fuel System (DFI) Table of Contents Exploded View........................DFI System..........................DFI System..........................3-10 DFI Parts Location........................3-13 Specifications ......................... 3-14 Special Tools and Sealant ...................... 3-16 DFI Servicing Precautions ...................... 3-18 DFI Servicing Precautions ....................3-18 Troubleshooting the DFI System ....................

  • Page 78: Table Of Contents

    3-2 FUEL SYSTEM (DFI) Speed Sensor (Service Code 24, 25)..................3-56 Speed Sensor Removal/Installation.................. 3-56 Speed Sensor Inspection....................3-56 Speed Sensor Input Voltage Inspection................3-56 Speed Sensor Output Voltage Inspection ................. 3-57 Vehicle-down Sensor (Service Code 31)................3-59 Vehicle-down Sensor Removal ..................3-59 Vehicle-down Sensor Installation ..................

  • Page 79: Table Of Contents

    FUEL SYSTEM (DFI) 3-3 Fuel Injector Power Source Voltage Inspection ..............3-92 Fuel Injector Output Voltage Inspection ................3-93 Injector Signal Test......................3-94 Injector Resistance Inspection ..................3-95 Injector Unit Test ....................... 3-95 Injector Fuel Line Inspection ..................... 3-95 Throttle Grip and Cables ......................3-98 Throttle Grip Free Play Inspection ..................

  • Page 80

    3-4 FUEL SYSTEM (DFI) Exploded View...

  • Page 81: Exploded View

    FUEL SYSTEM (DFI) 3-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Fuel Pump Bolts 87 in·lb L, S Right Switch Housing Screws 0.36 31 in·lb Sidestand Switch Bolt 0.40 35 in·lb 4. Injectors 5. Throttle Body Assy 6. Throttle Cable (Accelerator) 7.

  • Page 82

    3-6 FUEL SYSTEM (DFI) Exploded View...

  • Page 83

    FUEL SYSTEM (DFI) 3-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Crankshaft Sensor Bolts 0.61 53 in·lb Oxygen Sensor (Europe Models) 44.1 Spark Plugs Speed Sensor Bolt 0.80 69 in·lb Timing Rotor Bolt Water Temperature Sensor 106 in·lb 5. Air Switching Valve 6.

  • Page 84

    3-8 FUEL SYSTEM (DFI) DFI System DFI System...

  • Page 85

    FUEL SYSTEM (DFI) 3-9 DFI System 1. Inlet Air Pressure Sensor 2. Crankshaft Sensor 3. Injector 4. Main Throttle Sensor 5. Delivery Pipe 6. Subthrottle Sensor 7. Subthrottle Valve 8. Main Throttle Valve 9. Subthrottle Valve Actuator 10. Fuel Pump 11.

  • Page 86

    3-10 FUEL SYSTEM (DFI) DFI System DFI System Wiring Diagram...

  • Page 87: Dfi System

    33. Radiator Fan Relay 34. ECU Main Relay 35. Fuel Pump Relay 36. Relay Box 37. Main Fuse 30 A 38. Battery 12 V 10 Ah 39. Fuel Pump 40. Kawasaki Self-diagnosis System Connector 41. Self-diagnosis Terminal 42. Joint Connector 43. ECU...

  • Page 88

    3-12 FUEL SYSTEM (DFI) DFI System Terminal Names 1. Subthrottle Valve Actuator Drive Signal 2 28. Ground to Sensors 2. Subthrottle Valve Actuator Drive Signal 1 29. Oxygen Sensor Heater Signal (Europe 3. Water Temperature Warning Light Signal Models) 4. Unused 30.

  • Page 89: Dfi Parts Location

    18. Stick Coils 7. Relay Box (ECU Main Relay, Fuel Pump 19. Inlet Air Pressure Sensor Relay, Radiator Fan Relay) 20. Kawasaki Self-diagnosis System Con- 8. Fuse Box (ECU Fuse 15 A, Oxygen Sen- nector sor Heater Fuse 10 A) 21.

  • Page 90

    3-14 FUEL SYSTEM (DFI) Specifications Item Standard Digital Fuel Injection System Idle Speed 1 300 ±50 r/min (rpm) Throttle Body Assy: Type Two barrel type Bore 38 mm (1.50 in.) ECU (Electronic Control Unit): Make DENSO Type Digital memory type, with built in IC igniter, sealed with resin Usable Engine Speed 10 650 r/min (rpm)

  • Page 91

    FUEL SYSTEM (DFI) 3-15 Specifications Item Standard Subthrottle Sensor: Non-adjustable and non-removal Input Voltage DC 4.75 5.25 V between BL and BR/BK leads Output Voltage at Idle Throttle Opening DC 0.4 0.6 V between BL/W and BR/BK leads Output Voltage at Full Throttle Opening DC 3.825 3.975 V between BL/W and BR/BK leads Resistance...

  • Page 92: Special Tools And Sealant

    3-16 FUEL SYSTEM (DFI) Special Tools and Sealant Oil Pressure Gauge, 5 kgf/cm²: Needle Adapter Set: 57001-125 57001-1457 Fork Oil Level Gauge: Throttle Sensor Setting Adapter: 57001-1290 57001-1538 Hand Tester: Sensor Harness Adapter: 57001-1394 57001-1561 Throttle Sensor Setting Adapter #1: Fuel Pressure Gauge Adapter: 57001-1400 57001-1593...

  • Page 93

    FUEL SYSTEM (DFI) 3-17 Special Tools and Sealant Oxygen Sensor Measuring Adapter: Kawasaki Bond (Silicone Sealant): 57001-1682 56019-120...

  • Page 94: Dfi Servicing Precautions

    3-18 FUEL SYSTEM (DFI) DFI Servicing Precautions DFI Servicing Precautions There are a number of important precautions that should be followed servicing the DFI system. ○ This DFI system is designed to be used with a 12 V sealed battery as its power source. Do not use any other battery except for a 12 V sealed battery as a power source.

  • Page 95

    FUEL SYSTEM (DFI) 3-19 DFI Servicing Precautions ○ To maintain the correct fuel/air mixture (F/A), there must be no inlet air leaks in the DFI system. Be sure to install the oil filler plug [A] after filling the engine oil. Clutch Cover [B] Torque - Oil Filler Plug: Hand-tighten...

  • Page 96: Troubleshooting The Dfi System

    3-20 FUEL SYSTEM (DFI) Troubleshooting the DFI System Outline Outline When an abnormality in the DFI system occurs, the FI indicator light (LED) goes on to alert the rider on the meter panel. In addition, the condition of the problem is stored in the memory of the ECU (electronic control unit).

  • Page 97

    After measurement, remove the needle adapters and ap- ply silicone sealant to the seals [A] of the connector [B] for waterproofing. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 • Always check battery condition before replacing the DFI parts. A fully charged battery is a must for conducting accurate tests of the DFI system.

  • Page 98

    3-22 FUEL SYSTEM (DFI) Troubleshooting the DFI System • Pull each connector [A] apart and inspect it for corrosion, dirt, and damage. If the connector is corroded or dirty, clean it carefully. If it is damaged, replace it. Connect the connectors securely. •...

  • Page 99

    FUEL SYSTEM (DFI) 3-23 Troubleshooting the DFI System ○ There are two ways to inspect the DFI system. One is voltage Check Method and the other is Resistance Check Method. (Voltage Check Method) ○ This method is conducted by measuring the input voltage [B] to a sensor [A] first, and then the output voltage [C] from the sensor.

  • Page 100: Inquiries To Rider

    3-24 FUEL SYSTEM (DFI) Troubleshooting the DFI System DFI Diagnosis Flow Chart Inquiries to Rider Inquiries to Rider ○ Each rider reacts to problems in different ways, so it is important to confirm what kind of symptoms the rider has encountered. ○...

  • Page 101

    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 102

    3-26 FUEL SYSTEM (DFI) Troubleshooting the DFI System □ other □ Poor running spark plug loose (tighten it) □ or no power at spark plug dirty, broken, or gap maladjusted (remedy it) high speed □ spark plug incorrect (replace it) □...

  • Page 103: 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 104

    3-28 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or possible Causes Actions (chapter) 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, sidestand up and Sidestand down and clutch lever pulled in gear not in neutral whether gear in neutral or not...

  • Page 105: Poor Running At Low Speed

    FUEL SYSTEM (DFI) 3-29 DFI System Troubleshooting Guide Symptoms or possible Causes Actions (chapter) No valve clearance Adjust (see chapter 2). Valve guide worn Inspect and replace (see chapter 5). Valve spring broken or weak Inspect and replace (see chapter 5). Valve not seating properly (valve bent, worn or Inspect and repair or replace (see chapter 5).

  • Page 106

    3-30 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Engine stalls easily: Fuel pump trouble Inspect (see chapter 3). Fuel injector trouble Inspect (see chapter 3). Main throttle sensor trouble Inspect (see chapter 3). Fuel pressure too low or too high Inspect (see chapter 3).

  • Page 107

    FUEL SYSTEM (DFI) 3-31 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Loose terminal of battery (–) cable or engine Inspect and repair (see chapter 16). ground lead Delay of ignition timing Inspect crankshaft sensor and IC igniter in ECU (see chapter 16).

  • Page 108: Poor Running Or No Power At High Speed

    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). Inlet air pressure sensor trouble Inspect (see chapter 3). Fuel injector trouble Inspect (see chapter 3).

  • Page 109

    FUEL SYSTEM (DFI) 3-33 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Throttle body assy O-ring damaged Replace (see chapter 3). Fuel tank air vent obstructed Inspect and repair (see chapter 3). Fuel line clogged Inspect and repair (see chapter 3). Fuel pump operates intermittently and often DFI Pump bearings may wear.

  • Page 110

    3-34 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Drive train trouble Inspect drive chain (see chapter 2) and sprockets (see chapter 11). Camshaft cam worn Inspect and replace (see chapter 5). Air switching valve trouble Inspect and replace (see chapter 5).

  • Page 111: Self-diagnosis Outline/procedures, Self-diagnosis Procedures

    FUEL SYSTEM (DFI) 3-35 Self-Diagnosis Self-diagnosis Outline Self-diagnosis Outline The self-diagnosis system has three modes and can be switched to another mode by grounding the self-diagnosis terminal. User Mode The ECU notifies the rider of troubles in DFI system and ignition system by lighting the FI indicator when DFI system and ignition system parts are faulty, and initiates fail-safe function.

  • Page 112: Service Code Clearing Procedures

    3-36 FUEL SYSTEM (DFI) Self-Diagnosis • To enter the self-diagnosis dealer mode 2, open [B] and ground [A] the lead more than five times [F] within 2 sec- onds [C] after the lead is first grounded, and then keep it grounded continuously [D] for more than 2 seconds.

  • Page 113

    FUEL SYSTEM (DFI) 3-37 Self-Diagnosis...

  • Page 114: How To Read Service Codes, How To Erase Service Codes

    3-38 FUEL SYSTEM (DFI) Self-Diagnosis How to Read Service Codes How to Read Service Codes ○ Service codes are shown by a series of long and short blinks of the FI indicator light (LED) as shown below. ○ Read 10th digit and unit digit as the FI indicator light (LED) blinks. ○...

  • Page 115: Service Code Table

    FUEL SYSTEM (DFI) 3-39 Self-Diagnosis Service Code Table Service Code Table Service FI Indicator Light (LED) Problems Code Main throttle sensor malfunction, wiring open or short Inlet air pressure sensor malfunction, wiring open or short Inlet air temperature sensor malfunction, wiring open or short Water temperature sensor malfunction, wiring open or short Crankshaft sensor malfunction, wiring...

  • Page 116

    3-40 FUEL SYSTEM (DFI) Self-Diagnosis Backups Backups ○ The ECU takes the following measures to prevent engine damage when the DFI or the ignition system parts have troubles. Service Output Signal Usable Parts Backups by ECU Codes Range or Criteria If the main throttle sensor system fails (the signal is out of the usable range, wiring short or open), the ECU locks ignition timing into the...

  • Page 117

    FUEL SYSTEM (DFI) 3-41 Self-Diagnosis Service Output Signal Usable Parts Backups by ECU Codes Range or Criteria The stick coil primary If the ignition primary winding #1 has failures winding must send Stick Coil #1 (no signal, wiring short or open), the ECU signals (output voltage) (Ignition Coil)* shuts off the injector #1 to stop fuel to the...

  • Page 118: Main Throttle Sensor (service Code), Main Throttle Sensor Removal/adjustment, Main Throttle Sensor Input Voltage Inspection

    3-42 FUEL SYSTEM (DFI) Main Throttle Sensor (Service Code 11) Main Throttle Sensor Removal/Adjustment CAUTION Do not remove or adjust the main throttle sensor [A] since it has been adjusted and set with precision at the factory. Never drop the throttle body assy, especially on a hard surface.

  • Page 119: Main Throttle Sensor Output Voltage Inspection

    FUEL SYSTEM (DFI) 3-43 Main Throttle Sensor (Service Code 11) • If the input voltage is less than the standard, remove the ECU and check the wiring between these connectors. ○ Disconnect the ECU and sensor connectors. Wiring Connection ECU Connector [A] ←→ Main Throttle Sensor Connector [B] BL lead (ECU terminal 10) BR/BK lead (ECU terminal 28)

  • Page 120: Main Throttle Sensor Resistance Inspection

    3-44 FUEL SYSTEM (DFI) Main Throttle Sensor (Service Code 11) If the output voltage is normal, check the wiring for conti- nuity. ○ Disconnect the ECU and sensor connectors. Wiring Connection ECU Connector [A] ←→ Main Throttle Sensor Connector [B] Y/W lead (ECU terminal 7) BR/BK lead (ECU terminal 28) If the wiring is good, check the ECU for its ground and...

  • Page 121

    FUEL SYSTEM (DFI) 3-45 Main Throttle Sensor (Service Code 11) Main Throttle Sensor Circuit 1. ECU 2. Water-proof Joint E 3. Water-proof Joint D 4. Main Throttle Sensor...

  • Page 122: Inlet Air Pressure Sensor (service Code), Inlet Air Pressure Sensor Removal

    3-46 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code 12) CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the part can damage it. Inlet Air Pressure Sensor Removal • Remove the left middle fairing (see Middle Fairing Re- moval in the Frame chapter).

  • Page 123

    FUEL SYSTEM (DFI) 3-47 Inlet Air Pressure Sensor (Service Code 12) Inlet Air Pressure Sensor Output Voltage Inspection NOTE ○ The output voltage changes according to the local at- mospheric pressure. • Measure the output voltage at the ECU in the same way as input voltage inspection.

  • Page 124

    3-48 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code 12) Suppose: Pg: Vacuum Pressure (gauge) to Sensor Pl: Local Atmospheric Pressure (absolute) measured by a barometer Pv: Vacuum Pressure (absolute) to Sensor Vv: Sensor Output Voltage (V) then Pv = Pl – Pg For example, suppose the following data is obtained: Pg = 8 cmHg (Vacuum gauge reading) Pl = 70 cmHg (Varometer reading)

  • Page 125

    FUEL SYSTEM (DFI) 3-49 Inlet Air Pressure Sensor (Service Code 12) Pv = 55 86 cmHg ID: Idling Ps: Standard Atmospheric Pressure (Absolute) Pv: Throttle Vacuum Pressure (Absolute) ST: Standard of Sensor Output Voltage (V) TO: Throttle Full Open UR: Usable Range of Sensor Output Voltage (V) Vv: Inlet Air Pressure Sensor Output Voltage (V) (Digital Meter Reading)

  • Page 126

    3-50 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code 12) Inlet Air Pressure Sensor Circuit 1. ECU 2. Water-proof Joint E 3. Water-proof Joint D 4. Inlet Air Pressure Sensor...

  • Page 127: Inlet Air Temperature Sensor (service Code), Inlet Air Temperature Sensor Removal/installation

    FUEL SYSTEM (DFI) 3-51 Inlet Air Temperature Sensor (Service Code 13) Inlet Air Temperature Sensor Removal/Installation CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. • Remove the fuel tank (see Fuel Tank Removal). •...

  • Page 128

    3-52 FUEL SYSTEM (DFI) Inlet Air Temperature Sensor (Service Code 13) Inlet Air Temperature Sensor Resistance Inspection • Remove the inlet air temperature sensor (see Inlet Air Temperature Sensor Removal/Installation). • Suspend the sensor [A] in a container of machine oil so that the heat-sensitive portion is submerged.

  • Page 129: Water Temperature Sensor (service Code), Water Temperature Sensor Removal/installation

    FUEL SYSTEM (DFI) 3-53 Water Temperature Sensor (Service Code 14) Water Temperature Sensor Removal/Installation CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. • Drain the coolant (see Coolant Change in the Periodic Maintenance chapter).

  • Page 130

    3-54 FUEL SYSTEM (DFI) Water Temperature Sensor (Service Code 14) Water Temperature Sensor Resistance Inspection • Refer to the Water Temperature Sensor Inspection in the Electrical System chapter. Water Temperature Sensor Circuit 1. ECU 2. Water Temperature Sensor 3. Water-proof Joint E 4.

  • Page 131: Crankshaft Sensor (service Code), Crankshaft Sensor Removal/installation

    FUEL SYSTEM (DFI) 3-55 Crankshaft Sensor (Service Code 21) Start the engine and switch the diagnosis mode to Dealer 1 mode to know all the problem that the DFI system has at the time of self-diagnosis. If the engine cannot be started, the self-diagnosis system does not detect dynamic condi- tion of the crankshaft sensor.

  • Page 132: Speed Sensor (service Code), Speed Sensor Removal/installation, Speed Sensor Input Voltage Inspection

    3-56 FUEL SYSTEM (DFI) Speed Sensor (Service Code 24, 25) Speed Sensor Removal/Installation • Refer to the Speed Sensor Removal/Installation in the Electrical System chapter. Speed Sensor Inspection • Refer to the Speed Sensor Inspection in the Electrical System chapter. Speed Sensor Input Voltage Inspection NOTE ○...

  • Page 133: Speed Sensor Output Voltage Inspection

    FUEL SYSTEM (DFI) 3-57 Speed Sensor (Service Code 24, 25) Speed Sensor Output Voltage Inspection • Before this inspection, inspect the input voltage (see Speed Sensor Input Voltage Inspection). NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch OFF. •...

  • Page 134

    3-58 FUEL SYSTEM (DFI) Speed Sensor (Service Code 24, 25) Speed Sensor Circuit 1. ECU 2. Speed Sensor 3. Meter Unit 4. Water-proof Joint B 5. Frame Ground 6. Joint Connector...

  • Page 135: Vehicle-down Sensor (service Code)

    FUEL SYSTEM (DFI) 3-59 Vehicle-down Sensor (Service Code 31) Vehicle-down Sensor Removal CAUTION Never drop the vehicle-down sensor, especially on a hard surface. Such a shock to the sensor can damage it. • Remove: Bolts [A] Connector [B] Vehicle-down Sensor [C] Vehicle-down Sensor Installation •...

  • Page 136

    3-60 FUEL SYSTEM (DFI) Vehicle-down Sensor (Service Code 31) • Remove the vehicle-down sensor (see Vehicle-down Sensor Removal). ○ Do not disconnect the sensor connector. • Connect a digital meter [A] to the connector with needle adapter set [B]. Special Tool - Needle Adapter Set: 57001-1457 Vehicle-down Sensor Output Voltage Connections to Sensor Connector Meter (+) →...

  • Page 137

    FUEL SYSTEM (DFI) 3-61 Vehicle-down Sensor (Service Code 31) Vehicle-down Sensor Circuit 1. ECU 2. Water-proof Joint E 3. Vehicle-down Sensor 4. Water-proof Joint D...

  • Page 138: Subthrottle Sensor (service Code), Subthrottle Sensor Removal/adjustment, Subthrottle Sensor Input Voltage Inspection

    3-62 FUEL SYSTEM (DFI) Subthrottle Sensor (Service Code 32) Subthrottle Sensor Removal/Adjustment CAUTION Do not remove or adjust the subthrottle sensor [A] since it has been adjusted and set with precision at the factory. Never drop the throttle body assy, especially on a hard surface.

  • Page 139: Subthrottle Sensor Output Voltage Inspection

    FUEL SYSTEM (DFI) 3-63 Subthrottle Sensor (Service Code 32) If the input voltage is normal, check the sensor output voltage. If the input voltage is less than the standard, remove the ECU and check the wiring between these connectors. ○ Disconnect the ECU and sensor connectors.

  • Page 140: Subthrottle Sensor Resistance Inspection

    3-64 FUEL SYSTEM (DFI) Subthrottle Sensor (Service Code 32) If the output voltage is normal, check the wiring for conti- nuity. ○ Disconnect the ECU and sensor connectrs. Wiring Connection ECU Connector [A] ←→ Subthrottle Sensor Connector [B] BL/W lead (terminal 24) BR/BK lead (terminal 28) If the wiring is good, check the ECU for its ground and power supply (see ECU Power Supply Inspection).

  • Page 141

    FUEL SYSTEM (DFI) 3-65 Subthrottle Sensor (Service Code 32) Subthrottle Sensor Circuit 1. ECU 2. Water-proof Joint E 3. Water-proof Joint D 4. Subthrottle Sensor...

  • Page 142: Oxygen Sensor-not Activated (service Code 33) (europe Models)

    3-66 FUEL SYSTEM (DFI) Oxygen Sensor-not activated (Service Code 33) (Europe Models) Oxygen Sensor Removal/Installation • Refer to the Oxygen Sensor Removal/Installation in the Electrical System chapter. Oxygen Sensor Inspection • Warm up the engine thoroughly until the radiator fan starts.

  • Page 143

    FUEL SYSTEM (DFI) 3-67 Oxygen Sensor-not activated (Service Code 33) (Europe Models) Oxygen Sensor Circuit 1. ECU 2. Oxygen Sensor 3. Water-proof Joint E 4. Water-proof Joint C 5. Oxygen Sensor Heater Fuse 10 A 6. Main Fuse 30 A 7.

  • Page 144: Stick Coils #1, #2: (service Code), Stick Coil Removal/installation, Stick Coil Input Voltage Inspection

    3-68 FUEL SYSTEM (DFI) Stick Coils #1, #2: (Service Code 51, 52) Stick Coil #1: Service Code 51 Stick Coil #2: Service Code 52 Stick Coil Removal/Installation CAUTION Never drop the stick coils, especially on a hard sur- face. Such a shock to the stick coil can damage it. •...

  • Page 145

    FUEL SYSTEM (DFI) 3-69 Stick Coils #1, #2: (Service Code 51, 52) Stick Coil Circuit 1. ECU 2. Water-proof Joint C 3. Stick Coils 4. Engine Stop Switch 5. Ignition Switch 6. Ignition Fuse 10 A 7. Main Fuse 30 A 8.

  • Page 146: Radiator Fan Relay (service Code), Radiator Fan Relay Removal/installation, Radiator Fan Relay Inspection

    3-70 FUEL SYSTEM (DFI) Radiator Fan Relay (Service Code 56) Radiator Fan Relay Removal/Installation • Radiator fan relay is built in the relay box [A]. • Remove the relay box (see Relay Box Removal in the Electrical System chapter). Radiator Fan Relay Inspection •...

  • Page 147: Subthrottle Valve Actuator (service Code), Subthrottle Valve Actuator Removal, Subthrottle Valve Actuator Audible Inspection

    FUEL SYSTEM (DFI) 3-71 Subthrottle Valve Actuator (Service Code 62) Subthrottle Valve Actuator Removal CAUTION Do not remove the subthrottle valve actuator [A] since it has been adjusted and set with precision at the factory. Never drop the throttle body assy, especially on a hard surface.

  • Page 148

    3-72 FUEL SYSTEM (DFI) Subthrottle Valve Actuator (Service Code 62) Subthrottle Valve Actuator Input Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch OFF. • Connect the peak voltage adapter [A] and a digital meter [B] to the connector [C], using the needle adapter set [D].

  • Page 149: Air Switching Valve (service Code), Air Switching Valve Removal/installation, Air Switching Valve Inspection

    FUEL SYSTEM (DFI) 3-73 Air Switching Valve (Service Code 64) Air Switching Valve Removal/Installation • Refer to the Air Switching Valve Removal/Installation in the Engine Top End chapter. Air Switching Valve Inspection • Refer to the Air Switching Valve Operation Test/Unit Test in the Electrical System chapter.

  • Page 150: Oxygen Sensor Heater (service Code 67) (europe Models), Oxygen Sensor Heater Removal/installation

    3-74 FUEL SYSTEM (DFI) Oxygen Sensor Heater (Service Code 67) (Europe Models) Oxygen Sensor Heater Removal/Installation The oxygen sensor heater is bult in the oxygen sensor. So, the heater itself can not be removed. Remove the oxy- gen sensor (see Oxygen Sensor Removal in the Electrical System chapter).

  • Page 151

    FUEL SYSTEM (DFI) 3-75 Oxygen Sensor Heater (Service Code 67) (Europe Models) If the tester reading is specified, check the power source voltage Inspection. NOTE ○ Be sure the battery is fully charged. • Disconnect the oxygen sensor connector and connect the harness adapter [A] between these connectors.

  • Page 152

    3-76 FUEL SYSTEM (DFI) Oxygen Sensor Heater (Service Code 67) (Europe Models) Oxygen Sensor Circuit 1. ECU 2. Oxygen Sensor 3. Water-proof Joint E 4. Water-proof Joint C 5. Oxygen Sensor Heater Fuse 10 A 6. Main Fuse 30 A 7.

  • Page 153: Oxygen Sensor-incorrect Output Voltage (service Code 94) (europe Models)

    FUEL SYSTEM (DFI) 3-77 Oxygen Sensor-Incorrect Output Voltage (Service Code 94) (Europe Models) Oxygen Sensor Removal/Installation • Refer to the Oxygen Sensor Removal/Installation in the Electrical System chapter. Oxygen Sensor Inspection • Warm up the engine thoroughly until the radiator fan starts.

  • Page 154

    3-78 FUEL SYSTEM (DFI) Oxygen Sensor-Incorrect Output Voltage (Service Code 94) (Europe Models) Oxygen Sensor Circuit 1. ECU 2. Oxygen Sensor 3. Water-proof Joint E 4. Water-proof Joint C 5. Oxygen Sensor Heater Fuse 10 A 6. Main Fuse 30 A 7.

  • Page 155

    FUEL SYSTEM (DFI) 3-79 FI Indicator Light (LED) Inspection Flow Chart...

  • Page 156: Fi Indicator Light (led), Fi Indicator Light (led) Inspection

    3-80 FUEL SYSTEM (DFI) FI Indicator Light (LED) FI Indicator Light (LED) Inspection • Remove the meter unit (see Meter Unit Removal in the Electrical System chapter). • Using two auxiliary leads, supply battery power to the FI indicator light (LED) [A]. 12 V Battery [B] FI Indicator Light (LED) Check Connector:...

  • Page 157: Ecu Removal

    FUEL SYSTEM (DFI) 3-81 CAUTION Never drop the ECU, especially on a hard surface. Such a shock to the ECU can damage it. ECU Removal • Remove the seat covers (see Seat Cover Removal in the Frame chapter). • Open the clamps [A]. •...

  • Page 158: Ecu Installation, Ecu Power Supply Inspection

    3-82 FUEL SYSTEM (DFI) • Disconnect the ECU connectors [A] and remove the ECU [B]. ECU Installation • Install: ECU [A] (In rubber protector [B]) ECU Connectors [C] • Fit [A] the bracket on the ECU as shown. • Install the removed parts (see appropriate chapters). ECU Power Supply Inspection •...

  • Page 159

    FUEL SYSTEM (DFI) 3-83 • Check the ECU power source voltage with a digital meter [A]. ○ Position the terminal in accordance with terminal numbers of ECU connector [B] in this chapter figure. Battery [C] ECU Power Source Inspection Meter Connections: Between Terminal 16 (BR/W) and Battery (–) Terminal Between Terminal 17 (W/BK) and Battery (–) Terminal Ignition Switch OFF:...

  • Page 160

    3-84 FUEL SYSTEM (DFI) ECU Power Source Circuit 1. ECU 2. Water-proof Joint C 3. Ignition Switch 4. Water-proof Joint A 5. ECU Main Fuse 15 A 6. ECU Main Relay 7. Relay Box 8. Main Fuse 30 A 9. Battery 10.

  • Page 161: Fuel Line, Fuel Pressure Inspection

    FUEL SYSTEM (DFI) 3-85 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 just when trouble occurred in order to know symptom well.

  • Page 162: Fuel Flow Rate Inspection

    3-86 FUEL SYSTEM (DFI) Fuel Line • Start the engine, and let it idle. • Measure the fuel pressure with the engine idling. Fuel Pressure (Idling) Standard: 294 kPa (3.0 kgf/cm², 43 psi) NOTE ○ The gauge needle will fluctuate. Read the pressure at the average of the maximum and minimum indications.

  • Page 163

    FUEL SYSTEM (DFI) 3-87 Fuel Line • Open the fuel tank cap [A] to lower the pressure in the tank. • Be sure to place a piece of cloth around the fuel pump outlet pipe. • Remove the fuel hose from the fuel pump (see Fuel Tank Removal).

  • Page 164: Fuel Pump, Fuel Pump Removal, Fuel Pump Installation

    3-88 FUEL SYSTEM (DFI) Fuel Pump Fuel Pump Removal CAUTION Never drop the fuel pump, especially on a hard sur- face. Such a shock to the pump can damage it. WARNING Gasoline is extremely flammable and can be explo- sive under certain conditions. Make sure the area is well-ventilated and free from any source of flame or sparks;...

  • Page 165: Fuel Pump Operation Inspection, Fuel Pump Operating Voltage Inspection

    FUEL SYSTEM (DFI) 3-89 Fuel Pump • Replace the fuel pump gasket [A] with a new one. • Apply a non-permanent locking agent to the threads of the fuel pump bolts. • Tighten the fuel pump bolts to a snug fit, tighten them alternating diagonally.

  • Page 166: Pressure Regulator Removal

    3-90 FUEL SYSTEM (DFI) Fuel Pump • Connect the hand tester (× DC 25 V) to the fuel pump connector [A] with needle adapter set. Special Tools - Hand Tester: 57001-1394 Needle Adapter Set: 57001-1457 Pump Operating Voltage at Pump Connections to Pump Connectors Tester (+) →...

  • Page 167

    FUEL SYSTEM (DFI) 3-91 Fuel Pump Fuel Pump Circuit 1. ECU 2. Water-proof Joint C 3. Engine Stop Switch 4. Ignition Switch 5. Water-proof Joint A 6. ECU Fuse 15 A 7. Ignition Fuse 10 A 8. ECU Main Relay 9.

  • Page 168: Fuel Injectors, Audible Inspection, Fuel Injector Power Source Voltage Inspection

    3-92 FUEL SYSTEM (DFI) Fuel Injectors Removal/Installation • Refer to the Throttle Body Assy Disassembly/Assembly. Audible Inspection • Start the engine. • Apply the tip of a screwdriver [A] to the injector [B]. Put the grip end onto your ear, and listen whether the injector is clicking or not.

  • Page 169: Fuel Injector Output Voltage Inspection

    FUEL SYSTEM (DFI) 3-93 Fuel Injectors If the meter doesn’t read as specified, check the following. Main Fuse 30 A (see Fuse Inspection in the Electrical System chapter) Fuel Pump Relay (see Relay Circuit Inspection in the Electrical System chapter) Power Source Wiring (see wiring diagram below) ○...

  • Page 170: Injector Signal Test

    3-94 FUEL SYSTEM (DFI) Fuel Injectors Injector Signal Test • Prepare two test light sets with terminals as shown. Rating of Bulb [A]: 12 V × 3 3.4 W Terminal Width [B]: 1.8 mm (0.071 in.) Terminal Thickness [C]: 0.8 mm (0.031 in.) CAUTION Do not use larger terminals than specified above.

  • Page 171: Injector Resistance Inspection, Injector Unit Test, Injector Fuel Line Inspection

    FUEL SYSTEM (DFI) 3-95 Fuel Injectors Injector Resistance Inspection • Remove: Fuel Tank (see Fuel Tank Removal) Air Cleaner Housing (see Air Cleaner Housing Removal) • Disconnect the connector from the injector [A]. • Measure the injector resistance with the hand tester [B]. Special Tool - Hand Tester: 57001-1394 Injector Resistance Connections to Injector Connector...

  • Page 172

    3-96 FUEL SYSTEM (DFI) Fuel Injectors • 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 the clamps [D]) as shown.

  • Page 173

    FUEL SYSTEM (DFI) 3-97 Fuel Injectors Fuel Injector Circuit 1. ECU 2. Fuel Injectors 3. Water-proof Joint C 4. Engine Stop Switch 5. Ignition Switch 6. Water-proof Joint A 7. ECU Fuse 15 A 8. Ignition Fuse 10 A 9. ECU Main Relay 10.

  • Page 174: Throttle Grip And Cables

    3-98 FUEL SYSTEM (DFI) Throttle Grip and Cables Throttle Grip Free Play Inspection • Refer to the Throttle Control System Inspection in the Pe- riodic Maintenance chapter. Throttle Grip Free Play Adjustment • Refer to the Throttle Control System Inspection in the Pe- riodic Maintenance chapter.

  • Page 175: Throttle Body Assy

    FUEL SYSTEM (DFI) 3-99 Throttle Body Assy Idle Speed Inspection • Refer to the Idle Speed Inspection in the Periodic Main- tenance chapter. Engine Vacuum Synchronization Inspection/Ad- justment • Refer to the Engine Vacuum Synchronization Inspection in the Periodic Maintenance chapter. Throttle Body Assy Removal WARNING Gasoline is extremely flammable and can be ex-...

  • Page 176: Throttle Body Assy Installation

    3-100 FUEL SYSTEM (DFI) Throttle Body Assy • Remove the throttle case [A] to make a throttle cable slack. • Remove the throttle cable lower ends [A] from the throttle pulley. • Pull off the throttle body assy from the holder. •...

  • Page 177

    FUEL SYSTEM (DFI) 3-101 Throttle Body Assy • Fit the accelerator cable end [A] and the decelerator cable end [B] into the throttle pulley. • Check fuel leakage from the throttle body assy. WARNING Fuel spilled from the carburetors is hazardous. •...

  • Page 178: Throttle Body Assy Assembly

    3-102 FUEL SYSTEM (DFI) Throttle Body Assy • Remove: Throttle Body Assy (see Throttle Body Assy Removal) Screws [A] Delivery Pipe [B] Fuel Injectors [C] Throttle Body Assy Assembly • Replace the O-rings [A] and seals [B] with the new ones. •...

  • Page 179: Air Cleaner, Air Cleaner Element Removal/installation, Air Cleaner Element Inspection, Air Cleaner Oil Draining

    FUEL SYSTEM (DFI) 3-103 Air Cleaner Air Cleaner Element Removal/Installation • Refer to the Air Cleaner Element Replacement in the Pe- riodic Maintenance chapter. Air Cleaner Element Inspection • Remove the air cleaner element (see Air Cleaner Element Replacement in the Periodic Maintenance chapter). •...

  • Page 180: Air Cleaner Housing Installation

    3-104 FUEL SYSTEM (DFI) Air Cleaner • Unscrew the bolts [A] and remove the air cleaner housing [B]. Air Cleaner Housing Installation • Install the clamp on the breather hose [A] so that its pinch heads [B] face the left.

  • Page 181: Fuel Tank

    FUEL SYSTEM (DFI) 3-105 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 182

    3-106 FUEL SYSTEM (DFI) Fuel Tank • Disconnect: Fuel Pump Lead Connector [A] Fuel Level Sensor Lead Connector [B] • Remove the fuel drain hose [C]. • Be sure to place a piece of cloth [A] around the fuel hose joint.

  • Page 183: Fuel Tank Installation

    FUEL SYSTEM (DFI) 3-107 Fuel Tank Fuel Tank Installation • Note the above WARNING (see Fuel Tank Removal). • Route the hoses correctly (see Cable, Wire, and Hose Routing in the Appendix chapter). • Check that the rubber dampers [A] are on the frame and the fuel tank.

  • Page 184: Fuel Tank Cleaning

    3-108 FUEL SYSTEM (DFI) Fuel Tank Fuel Tank and Cap Inspection • Visually inspect the gasket [A] on the tank cap for any damage. Replace the gasket if it is damaged. • Check to see if the water drain pipe [B] and fuel breather pipe [C] in the tank is not clogged.

  • Page 185: Table Of Contents

    COOLING SYSTEM 4-1 Cooling System Table of Contents Exploded View........................Coolant Flow Chart......................... Specifications ......................... Special Tools .......................... Coolant ........................... Coolant Deterioration Inspection..................Coolant Level Inspection....................Coolant Draining ....................... Coolant Filling ........................Pressure Testing ....................... Cooling System Flushing ....................Coolant Reserve Tank Removal/Installation ..............Water Pump..........................

  • Page 186

    4-2 COOLING SYSTEM Exploded View...

  • Page 187

    COOLING SYSTEM 4-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Baffle Plate Bolts 0.60 52 in·lb Radiator Bolt Radiator Hose Clamp Screws 0.20 18 in·lb Thermostat Housing Bolts 87 in·lb Water Pump Cover Bolts 87 in·lb Water Pump Drain Bolt 87 in·lb Water Pump Impeller Bolt 87 in·lb...

  • Page 188

    4-4 COOLING SYSTEM Coolant Flow Chart...

  • Page 189: Coolant Flow Chart

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

  • Page 190

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

  • Page 191

    COOLING SYSTEM 4-7 Special Tools Bearing Driver Set: Oil Seal Driver: 57001-1129 57001-1660...

  • Page 192: Coolant Deterioration Inspection, Coolant Draining, Coolant Filling, Pressure Testing

    4-8 COOLING SYSTEM Coolant Coolant Deterioration Inspection • Remove the right middle fairing (see Middle Fairing Re- moval in the 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.

  • Page 193: Cooling System Flushing, Coolant Reserve Tank Removal/installation

    COOLING SYSTEM 4-9 Coolant Cooling System Flushing Over a period of time, the cooling system accumulates rust, scale, and lime in the water jacket and radiator. When this accumulation is suspected or observed, flush the cool- ing system. If this accumulation is not removed, it will clog up the water passage and considerable reduce the effi- ciency of the cooling system.

  • Page 194: Water Pump, Water Pump Installation

    4-10 COOLING SYSTEM Water Pump Water Pump Removal • Drain the coolant (see Coolant Change in the Periodic Maintenance chapter). • Remove: Radiator Hose [A] Water Pump Cover Bolts [B] Right Lower Fairing Bracket [C] Water Pump Cover [D] • Shift the transmission into 1st gear.

  • Page 195: Mechanical Seal Inspection, Water Pump Housing Disassembly

    COOLING SYSTEM 4-11 Water Pump • Install the water pump cover, being careful of the two dowel pins [A]. • Install the right lower fairing bracket and tighten the water pump cover bolts. Torque - Water Pump Cover Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) Mechanical Seal Inspection •...

  • Page 196: Water Pump Housing Assembly, Impeller Assembly, Pump Impeller Inspection

    4-12 COOLING SYSTEM Water Pump • Press the mechanical seal [A] out of the housing with a bearing driver [B]. Special Tool - Bearing Driver Set: 57001-1129 Water Pump Housing Assembly • Apply high-temperature grease [A] to the new oil seal [B]. •...

  • Page 197

    COOLING SYSTEM 4-13 Radiator Radiator and Radiator Fan Removal • Drain the coolant (see Coolant Change in the Periodic Maintenance chapter). • Remove the left front frame cover (see Front Frame Cover Removal in the Frame chapter). • Open the clamp [A]. •...

  • Page 198: Radiator And Radiator Fan Installation

    4-14 COOLING SYSTEM Radiator Radiator and Radiator Fan Installation If the radiator guard [A] was removed, install it. • Install the radiator fan [B]. • Install the rubber dampers [C] and collar [D] to the radiator and frame. • Align the projections [E] on the frame with the holes [F] on the dampers.

  • Page 199: Radiator Inspection, Radiator Cap Inspection

    COOLING SYSTEM 4-15 Radiator Radiator Inspection • Remove the radiator (see Radiator and Radiator Fan Re- moval). • Check the radiator core. If there are obstructions to air flow, remove them. If the corrugated fins [A] are deformed, carefully straighten them. If the air passages of the radiator core are blocked more than 20% by unremovable obstructions or irreparably de- formed fins, replace the radiator with a new one.

  • Page 200: Radiator Filler Neck Inspection

    4-16 COOLING SYSTEM Radiator Radiator Filler Neck Inspection • Remove the radiator cap (see Coolant Change in the Pe- riodic Maintenance chapter). • Check the radiator filler neck for signs of damage. • Check the condition of the top and bottom sealing seats [A] in the filler neck.

  • Page 201: Thermostat Removal, Thermostat Installation

    COOLING SYSTEM 4-17 Thermostat Thermostat Removal • Drain the coolant (see Coolant Change in the Periodic Maintenance chapter). • Remove the left front frame cover (see Front Frame Cover Removal in the Frame chapter). • Disconnect the horn leads [A]. •...

  • Page 202: Thermostat Inspection

    4-18 COOLING SYSTEM Thermostat • Align the line [A] of the thermostat housing and the red mark [B] of the radiator hose [C]. • Install the radiator hose clamp [D] as shown. • Tighten: Torque - Radiator Hose Clamp Screws: 2.0 N·m (0.20 kgf·m, 18 in·lb) •...

  • Page 203: Hose And Pipes, Hose Installation, Hose Inspection

    COOLING SYSTEM 4-19 Hose and Pipes Hose Installation • Install the hoses and pipes, being careful to follow bend- ing direction. Avoid sharp bending, kinking, flattening or twisting. • Run the hoses (see Cable, Wire, and Hose Routing sec- tion in the Appendix chapter). •...

  • Page 204

    4-20 COOLING SYSTEM Water Temperature Sensor CAUTION The water temperature sensor should never be al- lowed to fall on a hard surface. Such a shock to the water temperature sensor can damage it. Water Temperature Sensor Removal/Installation • Refer to the Water Temperature Sensor Removal/Instal- lation in the Fuel System (DFI) chapter.

  • Page 205: Table Of Contents

    ENGINE TOP END 5-1 Engine Top End Table of Contents Exploded View........................Exhaust System Identification ....................Specifications ......................... 5-10 Special Tools and Sealant ...................... 5-12 Clean Air System........................5-14 Air Suction Valve Removal....................5-14 Air Suction Valve Installation..................... 5-14 Air Suction Valve Inspection ..................... 5-15 Air Switching Valve Removal ....................

  • Page 206: Table Of Contents

    5-2 ENGINE TOP END Piston Ring Thickness ...................... 5-43 Piston Ring End Gap ......................5-44 Throttle Body Assy Holder...................... 5-45 Throttle Body Assy Holder Removal ................. 5-45 Throttle Body Assy Holder Installation ................5-45 Muffler............................. 5-46 Muffler Body Removal....................... 5-46 Exhaust Pipe Removal......................

  • Page 207

    ENGINE TOP END 5-3 Exploded View Dummy Page...

  • Page 208

    5-4 ENGINE TOP END Exploded View...

  • Page 209

    ENGINE TOP END 5-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Air Suction Valve Cover Bolts 87 in·lb Baffle Plate Bolts 0.60 52 in·lb Camshaft Cap Bolts 106 in·lb Camshaft Chain Tensioner Cap Bolt Camshaft Chain Tensioner Mounting Bolts 87 in·lb Camshaft Sprocket Bolts Cylinder Head Bolts (M10)

  • Page 210

    5-6 ENGINE TOP END Exploded View...

  • Page 211

    ENGINE TOP END 5-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Cylinder Bolt (M8) 27.5 MO,S Cylinder Nut (M10) MO, S Cylinder Bolts (M6) 106 in·lb Exhaust Pipe Manifold Holder Nuts Muffler Body Mounting Bolt (Front) Muffler Body Mounting Bolt (Rear) MO: Apply molybdenum disulfide oil solution.

  • Page 212: Exhaust System Identification

    5-8 ENGINE TOP END Exhaust System Identification Exhaust System KLE650A7F, KLE650B7F Full: Full Power H: Honeycomb Type Catalyst Silencer [A] with Hole [B] for Oxygen Sensor [C]...

  • Page 213

    ENGINE TOP END 5-9 Exhaust System Identification Muffler Body Mark Position [A] Manifold Mark Position [A]...

  • Page 214

    5-10 ENGINE TOP END Specifications Item Standard Service Limit Camshafts Cam Height: 35.343 35.457 mm Exhaust 35.24 mm (1.387 in.) (1.3915 1.3959 in.) Inlet 35.843 35.957 mm 35.74 mm (1.407 in.) (1.4111 1.4156 in.) Camshaft Journal, Camshaft 0.028 0.071 mm (0.0011 0.0028 in.) 0.16 mm (0.0063 in.) Cap Clearance...

  • Page 215

    ENGINE TOP END 5-11 Specifications Item Standard Service Limit Valve Spring Free Length: Exhaust 41.9 mm (1.65 in.) 40.3 mm (1.587 in.) Inlet 41.9 mm (1.65 in.) 40.3 mm (1.587 in.) Cylinder, Pistons Cylinder Inside Diameter 82.994 83.006 mm 83.10 mm (3.272 in.) (3.2675 3.2679 in.) Piston Diameter...

  • Page 216

    5-12 ENGINE TOP END Special Tools and Sealant Compression Gauge, 20 kgf/cm²: Valve Seat Cutter, 60° - 30: 57001-221 57001-1123 Valve Spring Compressor Assembly: Valve Seat Cutter Holder Bar: 57001-241 57001-1128 Valve Seat Cutter, 45° - 35: Valve Seat Cutter, 45° - 30: 57001-1116 57001-1187 Valve Seat Cutter, 32°...

  • Page 217

    Special Tools and Sealant Compression Gauge Adapter, M10 × 1.0: Piston Pin Puller: 57001-1317 57001-1568 Valve Seat Cutter Holder, 4.5: Piston Pin Puller Adapter C: 57001-1330 57001-1657 Valve Guide Arbor, 4.5: Kawasaki Bond (Silicone Sealant): 57001-1331 92104-0004 Valve Guide Reamer, 4.5: 57001-1333...

  • Page 218: Clean Air System, Air Suction Valve Removal, Air Suction Valve Installation

    5-14 ENGINE TOP END Clean Air System Air Suction Valve Removal • Remove: Air Switching Valve (see Air Switching Valve Removal) Air Suction Valve Cover Bolts [A] Clamp [B] Air Suction Valve Cover [C] • Remove the air suction valve [A]. Air Suction Valve Installation •...

  • Page 219: Air Suction Valve Inspection, Air Switching Valve Removal, Air Switching Valve Installation

    ENGINE TOP END 5-15 Clean Air System Air Suction Valve Inspection • Remove the air suction valve (see Air Suction Valve Re- moval). • Visually inspect the reeds [A] for cracks, folds, warps, heat damage or other damage. If there is any doubt as to the condition of the reeds, re- place the air suction valve as an assembly.

  • Page 220

    5-16 ENGINE TOP END Clean Air System Air Switching Valve Unit Test • Refer to the Air Switching Valve Unit Test in the Electrical System chapter. Clean Air System Hose Inspection • Be certain that all the hoses are routed without being flat- tened or kinked, and are connected correctly to the air cleaner housing, air switching valve and air suction valve cover.

  • Page 221: Cylinder Head Cover, Cylinder Head Cover Removal

    ENGINE TOP END 5-17 Cylinder Head Cover Cylinder Head Cover Removal • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Air Cleaner Housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter) Air Suction Valve (see Air Suction Valve Removal) Stick Coils (see Stick Coil (Ignition Coil together with Spark Plug Cap) Removal in the Electrical System chap- ter).

  • Page 222: Cylinder Head Cover Installation

    • Replace the head cover gasket [A] with a new one. • Apply silicone sealant [B] to the cylinder head as shown. Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004 • Replace the plug hole gaskets [A] with new ones. •...

  • Page 223

    ENGINE TOP END 5-19 Cylinder Head Cover • Be sure that the dampers [A] of the baffle plate is in posi- tion. • Tighten: Torque - Baffle Plate Bolts: 5.9 N·m (0.60 kgf·m, 52 in·lb)

  • Page 224: Camshaft Chain Tensioner

    5-20 ENGINE TOP END Camshaft Chain Tensioner Camshaft Chain Tensioner Removal CAUTION This is a non-return type camshaft 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 225: Camshaft Chain Tensioner Installation

    ENGINE TOP END 5-21 Camshaft Chain Tensioner Camshaft Chain Tensioner Installation • Replace the O-ring [A] with a new one. • Apply grease to the new O-ring. • Release the stopper [B] and push the push rod [C] into the tensioner body [D]. •...

  • Page 226: Camshaft, Camshaft Chain, Camshaft Removal

    5-22 ENGINE TOP END Camshaft, Camshaft Chain Camshaft Removal • Remove: Cylinder Head Cover (see Cylinder Head Cover Re- moval) Timing Inspection Cap [A] Timing Rotor Bolt Cap [B] • Using a wrench on the timing rotor bolt, turn the crank- shaft clockwise until the 2/T mark line [A] on the timing rotor is aligned with the notch [B] in the edge of the timing inspection hole [C] in the clutch cover.

  • Page 227

    ENGINE TOP END 5-23 Camshaft, Camshaft Chain • Remove the camshaft chain tensioner (see Camshaft Chain Tensioner Removal). • Loosen the camshaft cap bolts as shown sequence [1 12 ] in the figure, and remove them. • Remove: Camshaft Caps [A] Camshafts [B] CAUTION The crankshaft may be turned while the camshafts...

  • Page 228: Camshaft Installation

    5-24 ENGINE TOP END Camshaft, Camshaft Chain Camshaft Installation • Replace the plug hole gaskets [A] with new ones. • Be sure to install the following parts. Plug Hole Gaskets Dowel Pins [B] • Install the cam sprockets so that the marked (“IN" and “EX”) side faces to the outward.

  • Page 229

    ENGINE TOP END 5-25 Camshaft, Camshaft Chain • Using a wrench on the timing rotor bolt, turn the crank- shaft clockwise until the 2/T mark line [A] on the timing rotor is aligned with the notch [B] in the edge of the timing inspection hole [C] in the clutch cover.

  • Page 230

    5-26 ENGINE TOP END Camshaft, Camshaft Chain • Before installing the camshaft caps, install the camshaft chain tensioner body temporally (see Camshaft Chain Tensioner Installation). • Install the camshaft caps as shown. NOTE ○ The exhaust cap has a “EX” mark [A] and the inlet cap has a “IN”...

  • Page 231: Camshaft Runout

    ENGINE TOP END 5-27 Camshaft, Camshaft Chain Camshaft, Camshaft Cap Wear • Remove the camshaft caps (see Camshaft Removal). • Cut strips of plastigage to journal width. Place a strip on each journal parallel to the camshaft installed in the correct position.

  • Page 232

    5-28 ENGINE TOP END Camshaft, Camshaft Chain Camshaft Chain Removal • Split the crankcase (see Crankcase Splitting in the Crank- shaft/Transmission chapter). • Remove the camshaft chain [A] from the crankshaft sprocket.

  • Page 233: Cylinder Head, Cylinder Compression Measurement

    ENGINE TOP END 5-29 Cylinder Head Cylinder Compression Measurement NOTE ○ Use the battery which is fully charged. • Warm up the engine thoroughly. • Stop the engine. • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Air Cleaner Housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter)

  • Page 234: Cylinder Head Removal

    5-30 ENGINE TOP END Cylinder Head Cylinder Head Removal • Drain the coolant (see Coolant Change in the Periodic Maintenance chapter). • Remove: Exhaust Pipes (see Exhaust Pipe Removal) Cylinder Head Cover (see Cylinder Head Cover Re- moval) Camshafts (see Camshaft Removal) Throttle Body Assy (see Throttle Body Assy Removal in the Fuel System (DFI) chapter) Throttle Body Assy Holders [A] (see Throttle Body Assy...

  • Page 235: Cylinder Head Installation

    ENGINE TOP END 5-31 Cylinder Head Cylinder Head Installation NOTE ○ The camshaft cap is machined with the cylinder head, so if a new cylinder head is installed, use the cap that is supplied with the new head. • Install a new cylinder head gasket [A] and dowel pins [B]. •...

  • Page 236: Cylinder Head Warp

    5-32 ENGINE TOP END Cylinder Head • Tighten the M6 cylinder head bolts and M6 cylinder bolts [A]. Torque - Cylinder Head Bolts (M6): 12 N·m (1.2 kgf·m, 106 in·lb) Cylinder Bolts (M6): 12 N·m (1.2 kgf·m, 106 in·lb) • Install the front camshaft chain guide [A].

  • Page 237: Valve Removal, Valve Installation, Valve Guide Removal

    ENGINE TOP END 5-33 Valves Valve Clearance Inspection • Refer to the Valve Clearance Inspection in the Periodic Maintenance chapter. Valve Clearance Adjustment • Refer to the Valve Clearance Adjustment in the Periodic Maintenance chapter. Valve Removal • Remove cylinder head (see Cylinder Head Removal). •...

  • Page 238: Valve Guide Installation

    5-34 ENGINE TOP END Valves 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). • Drive the valve guide in from the top of the head using the valve guide arbor.

  • Page 239: Valve Seat Inspection, Valve Seat Repair

    ENGINE TOP END 5-35 Valves Valve Seat Inspection • Remove the valve (see Valve Removal). • Check the valve seating surface [A] between the valve [B] and valve seat [C]. ○ Measure the outside diameter [D] of the seating pattern on the valve seat.

  • Page 240

    5-36 ENGINE TOP END Valves Seat Cutter Operation Care 1. This valve seat cutter is developed to grind the valve for repair. Therefore the cutter must not be used for other purposes than seat repair. 2. Do not drop or shock the valve seat cutter, or the dia- mond particles may fall off.

  • Page 241

    ENGINE TOP END 5-37 Valves • Measure the outside diameter of the seating surface with a vernier caliper. If the outside diameter of the seating surface is too small, repeat the 45° grind until the diameter is within the spec- ified range.

  • Page 242

    5-38 ENGINE TOP END Valves If the seat width is too wide, make the 60° or 55° [A] grind described below. If the seat width is within the specified range, lap the valve to the seat as described below. • Grind the seat at a 60°...

  • Page 243

    ENGINE TOP END 5-39 Valves...

  • Page 244: Cylinder, Pistons, Cylinder Removal, Cylinder Installation, Piston Removal

    5-40 ENGINE TOP END Cylinder, Pistons Cylinder Removal • Remove: Cylinder Head (see Cylinder Head Removal) Front Engine Mounting Bolts (Both Sides) [A] (see En- gine Removal in the Engine Removal/Installation chap- ter) Front Engine Brackets (Both Sides) [B] (see Engine Re- moval in the Engine Removal/Installation chapter) Cylinder [C] Cylinder Installation...

  • Page 245: Piston Installation

    ENGINE TOP END 5-41 Cylinder, Pistons • Remove the piston pins. Special Tools - Piston Pin Puller [A]: 57001-1568 Piston Pin Puller Adapter C [D]: 57001-1657 Center Bolt [B] Shell of Piston [C] • Remove the pistons. • Carefully spread the ring opening with your thumbs and then push up on the opposite side of the ring [A] to remove •...

  • Page 246: Cylinder Wear, Piston Wear

    5-42 ENGINE TOP END Cylinder, Pistons NOTE ○ If a new piston is used, use new piston ring. • Install the piston with its marking hollow [A] facing forward. • Fit a new piston pin snap ring into the side of the piston so that the ring opening [A] does not coincide with the slit [B] of the piston pin hole.

  • Page 247: Piston Ring Groove Width, Piston Ring Thickness

    ENGINE TOP END 5-43 Cylinder, Pistons Piston Ring, Piston Ring Groove Wear • Check for uneven groove wear by inspecting the ring seat- ing. The rings should fit perfectly parallel to groove surfaces. If not, replace the piston and all the piston rings. •...

  • Page 248

    5-44 ENGINE TOP END Cylinder, Pistons Piston Ring End Gap • Place the piston ring [A] inside the cylinder, using the pis- ton to locate the ring squarely in place. Set it close to the bottom of the cylinder, where cylinder wear is low. •...

  • Page 249: Throttle Body Assy Holder, Throttle Body Assy Holder Removal, Throttle Body Assy Holder Installation

    ENGINE TOP END 5-45 Throttle Body Assy Holder Throttle Body Assy Holder Removal • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Air Cleaner Housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter) Throttle Body Assy (see Throttle Body Assy Removal in the Fuel System (DFI) chapter) Clamps [A]...

  • Page 250: Muffler Body Removal, Exhaust Pipe Removal

    5-46 ENGINE TOP END Muffler Muffler Body Removal WARNING To avoid a serious burn, do not remove the muffler when the engine is still hot. Wait until the muffler cool down. • Remove: Right Rear Frame Cover (see Rear Frame Cover Re- moval in the Frame chapter) Lower Fairings (see Lower Fairing Removal in the Frame chapter)

  • Page 251: Muffler Body And Exhaust Pipe Installation

    ENGINE TOP END 5-47 Muffler • Loosen the muffler body clamp bolt [A]. • Remove the exhaust pipe to forward. Muffler Body and Exhaust Pipe Installation • Replace the exhaust pipe gaskets [A] and muffler body gasket [B] with new ones and install them. ○...

  • Page 253: Table Of Contents

    CLUTCH 6-1 Clutch Table of Contents Exploded View........................Specifications ......................... Special Tool and Sealant ......................Clutch Lever and Cable ......................Clutch Lever Free Play Inspection ..................Clutch Lever Free Play Adjustment .................. Clutch Cable Removal ...................... Clutch Cable Installation ....................Clutch Cable Lubrication....................

  • Page 254

    6-2 CLUTCH Exploded View...

  • Page 255

    CLUTCH 6-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Clutch Cable Clamp Bolt 87 in·lb Clutch Cable Holder Bolts 87 in·lb Clutch Cover Mounting Bolts 87 in·lb Clutch Hub Nut 13.3 Clutch Lever Clamp Bolts 0.80 69 in·lb Clutch Spring Bolts 87 in·lb Timing Rotor Bolt Cap 0.50...

  • Page 256

    6-4 CLUTCH Specifications Item Standard Service Limit Clutch Lever Free Play 3 mm (0.08 0.12 in.) – – – Clutch Friction Plate Thickness 2.92 3.08 mm (0.115 0.121 in.) 2.8 mm (0.110 in.) Friction Plate Warp 0.15 mm (0.16 in.) or less 0.3 mm (0.012 in.) Steel Plate Warp 0.2 mm (0.008 in.) or less...

  • Page 257: Special Tool And Sealant

    CLUTCH 6-5 Special Tool and Sealant Clutch Holder: Kawasaki Bond (Silicone Sealant): 57001-1243 92104-0004...

  • Page 258: Clutch Lever And Cable, Clutch Lever Free Play Inspection, Clutch Lever Free Play Adjustment

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

  • Page 259: Clutch Lever Installation, Clutch Lever Adjustment

    CLUTCH 6-7 Clutch Lever and Cable Clutch Lever Installation • Install the clutch lever so that the mating surface [B] of the clutch lever clamp is aligned with the punch mark [A]. • Tighten the upper clamp bolt first, and then the lower clamp bolt.

  • Page 260: Clutch Cover, Clutch Cover Removal, Clutch Cover Installation, Release Shaft Removal, Release Shaft Installation

    Apply silicone sealant to the areas [A] where the mating surface of the crankcase touches the clutch cover gasket and to the crankshaft sensor lead grommet [B]. Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004 • Be sure that the dowel pins [C] are in position.

  • Page 261: Clutch Cover Disassembly, Clutch Cover Assembly

    CLUTCH 6-9 Clutch Cover • Fit the spring [A] as shown. Release Shaft [B] Clutch Cover [C] Clutch Cover Disassembly • Remove: Clutch Cover (see Clutch Cover Removal) Release Leer and Shaft Assembly (see Release Shaft Removal) Oil Seal [A] Needle Bearings [B] •...

  • Page 262: Clutch Removal

    6-10 CLUTCH Clutch Clutch Removal • Remove: Clutch Cover (see Clutch Cover Removal) Clutch Spring Bolts [A] Clutch Springs Clutch Spring Plate [B] (with bearing) Pusher [C] • Remove: Friction Plates Steel Plates • Hold the clutch hub [A] steady with the clutch holder [B], and remove the clutch hub nut [C] and washer [D].

  • Page 263: Clutch Installation

    CLUTCH 6-11 Clutch Clutch Installation • Engage the oil pump chain guide [A] to the groove of the shift rod [B], and apply a non-permanent locking agent to the upper chain guide bolt [C] and tighten the chain guide bolts. Torque - Oil Pump Chain Guide Bolts: 12 N·m (1.2 kgf·m, 106 in·lb) •...

  • Page 264

    6-12 CLUTCH Clutch • Install the washer so that the OUT SIDE mark [A] faces outward. • Replace the clutch hub nut [A] with a new one. • Hold the clutch hub [B] steady with the clutch holder [C], and tighten the clutch hub nut. Special Tool - Clutch Holder: 57001-1243 Torque - Clutch Hub Nut: 130 N·m (13.3 kgf·m, 96 ft·lb) •...

  • Page 265: Clutch Plate Warp Inspection, Clutch Spring Free Length Measurement

    CLUTCH 6-13 Clutch • Apply engine oil to the sliding surfaces of the bearing [A]. • Install the spring plate [B] on the clutch hub [C]. • Install the clutch springs, and tighten the clutch spring bolts. Torque - Clutch Spring Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) •...

  • Page 266: Clutch Housing Finger Inspection, Clutch Housing Spline Inspection

    6-14 CLUTCH Clutch Clutch Housing Finger Inspection • Visually inspect the clutch housing fingers [A] where the friction plate tangs [B] hit them. If they are badly worn or if there are groove cuts where the tangs hit, replace the housing. Also, replace the friction plates if their tangs are damaged.

  • Page 267: Table Of Contents

    ENGINE LUBRICATION SYSTEM 7-1 Engine Lubrication System Table of Contents Exploded View........................Engine Oil Flow Chart......................Specifications ......................... Special Tools and Sealant ...................... Engine Oil and Oil Filter......................Oil Level Inspection......................Engine Oil Change......................Oil Filter Replacement ...................... Oil Pan............................ Oil Pan Removal .......................

  • Page 268

    7-2 ENGINE LUBRICATION SYSTEM Exploded View...

  • Page 269

    ENGINE LUBRICATION SYSTEM 7-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Engine Oil Drain Bolt Filter Plate Bolts 87 in·lb Holder Mounting Bolt Lower Fairing Bracket Bolts 106 in·lb Oil Filter 17.5 EO, R Oil Pan Bolts 106 in·lb Oil Passage Plug Oil Pipe Plate Bolt 87 in·lb...

  • Page 270

    7-4 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart...

  • Page 271

    ENGINE LUBRICATION SYSTEM 7-5 Engine Oil Flow Chart...

  • Page 272

    7-6 ENGINE LUBRICATION SYSTEM Specifications Item Standard Engine Oil Type API SE, SF or SG API SH, SJ or SL with JASO MA Viscosity SAE 10W-40 Capacity: 1.7 L (1.8 US gt) (when filter is not removed) 1.9 L (2.0 US gt) (when filter is removed) 2.4 L (2.5 US gt) (when engine is completely dry) Level Between upper and lower level lines...

  • Page 273

    ENGINE LUBRICATION SYSTEM 7-7 Special Tools and Sealant Oil Pressure Gauge, 10 kgf/cm²: Kawasaki Bond (Silicone Sealant): 57001-164 56019-120 Oil Pressure Gauge Adapter, PT3/8: 57001-1233...

  • Page 274: Engine Oil And Oil Filter, Oil Level Inspection

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

  • Page 275: Oil Pan

    ENGINE LUBRICATION SYSTEM 7-9 Oil Pan Oil Pan Removal • Drain the engine oil (see Engine Oil Change in the Peri- odic Maintenance chapter). • Remove: Exhaust Pipe (see Exhaust Pipe Removal in the Engine Top End chapter) Muffler Body (see Muffler Body Removal in the Engine Top End chapter) •...

  • Page 276: Oil Pan Installation

    7-10 ENGINE LUBRICATION SYSTEM Oil Pan Oil Pan Installation • Apply grease to the O-rings on the oil pipes [A]. • Install the oil pipe plate [B] so that its guide portion fits the oil pipe as shown. • Apply a non-permanent locking agent to the oil pipe plate bolt.

  • Page 277: Oil Pressure Relief Valve, Oil Pressure Relief Valve Installation, Oil Pressure Relief Valve Inspection

    ENGINE LUBRICATION SYSTEM 7-11 Oil Pressure Relief Valve Oil Pressure Relief Valve Removal • Remove: Oil Pan (see Oil Pan Removal) Oil Pressure Relief Valve [A] Oil Pressure Relief Valve Installation • Apply a non-permanent locking agent to the threads of the oil pressure relief valve, and tighten it.

  • Page 278: Oil Pump, Oil Pump Removal

    7-12 ENGINE LUBRICATION SYSTEM Oil Pump Oil Pump Removal • Remove: Clutch (see Clutch Removal in the Clutch chapter) Oil Pump Cover Bolts [A] • Temporarily install the oil pump sprocket bolt [A]. NOTE ○ The oil pump sprocket bolt has a left-hand threads. •...

  • Page 279: Oil Pump Installation

    ENGINE LUBRICATION SYSTEM 7-13 Oil Pump • Remove: Inner Rotor [A] for Scavenge Pump Outer Rotor [B] for Scavenge Pump • Remove the pin [A]. • Remove: Pin [A] Inner Rotor for Feed Pump [B] Oil Pump Shaft [C] Oil Pump Installation •...

  • Page 280

    7-14 ENGINE LUBRICATION SYSTEM Oil Pump • Install: Dowel Pin [A] Outer Rotor [B] for Feed Pump • Fit the pin of the crankcase into the hole [C] in the oil pump body. ○ Turn the oil pump shaft so that the inner rotor [D] fits into the outer rotor.

  • Page 281: Oil Pressure Measurement

    ENGINE LUBRICATION SYSTEM 7-15 Oil Pressure Measurement Oil Pressure Measurement • Remove: Right Lower Fairing (see Lower Fairing Removal in the Frame chapter) Oil Passage Plug [A] • Attach the adapter [A] and gauge [B] to the plug hole. Special Tools - Oil Pressure Gauge, 10 kgf/cm²: 57001-164 Oil Pressure Gauge Adapter, PT3/8: 57001 -1233 •...

  • Page 282: Oil Pressure Switch, Oil Pressure Switch Removal, Oil Pressure Switch Installation

    • Apply silicone sealant to the threads of the oil pressure switch [A] and tighten it. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 Torque - Oil Pressure Switch: 15 N·m (1.5 kgf·m, 11 ft·lb) • Install the switch lead [B] direction downward.

  • Page 283

    ENGINE REMOVAL/INSTALLATION 8-1 Engine Removal/Installation Table of Contents Exploded View........................Engine Removal/Installation ....................Engine Removal........................ Engine Installation......................

  • Page 284

    8-2 ENGINE REMOVAL/INSTALLATION Exploded View...

  • Page 285

    ENGINE REMOVAL/INSTALLATION 8-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Engine Mounting Bracket Bolts Front Engine Mounting Bolts Rear Engine Mounting Nuts 4. Collar 5. Engine Mounting Brackets S: Follow the specified tightening sequence.

  • Page 286

    8-4 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation Engine Removal • Support the rear part of the swingarm with a stand. • Squeeze the brake lever slowly and hold it with a band [A]. WARNING Be sure to hold the front brake when removing the engine, or the motorcycle may fall over.

  • Page 287

    ENGINE REMOVAL/INSTALLATION 8-5 Engine Removal/Installation • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Air Switching Valve (see Air Switching Valve Removal in the Engine Top End chapter) Air Cleaner Housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter) Throttle Body Assy (see Throttle Body Assy Removal in the Fuel System (DFI) chapter)

  • Page 288

    8-6 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Open the clamp [A]. • Disconnect the horn leads [B]. • Support the engine with a suitable stand [A]. ○ Put a plank [B] onto the suitable stand for engine balance. • Remove: Front Engine Mounting Bolts [C] (Both Sides) Engine Mounting Bracket Bolts [D] (Both Sides) Rear Engine Mounting Nuts [E] •...

  • Page 289: Engine Installation

    ENGINE REMOVAL/INSTALLATION 8-7 Engine Removal/Installation Engine Installation • Firstly, insert the rear engine mounting bolts [A] from the left side of the engine. • Secondly, temporally tighten the right engine mounting bracket bolts [B] and then the right front engine mounting bolt [C].

  • Page 291: Table Of Contents

    CRANKSHAFT/TRANSMISSION 9-1 Crankshaft/Transmission Table of Contents Exploded View........................Specifications ......................... Special Tools and Sealants ....................Crankcase Splitting......................... 9-10 Crankcase Splitting ......................9-10 Crankcase Assembly ......................9-12 Crankshaft and Connecting Rods................... 9-18 Crankshaft Removal ......................9-18 Crankshaft Installation ...................... 9-18 Connecting Rod Removal ....................9-18 Connecting Rod Installation ....................

  • Page 292

    9-2 CRANKSHAFT/TRANSMISSION Exploded View...

  • Page 293

    CRANKSHAFT/TRANSMISSION 9-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Breather Plate Bolts 87 in·lb Race Holder Screw 0.50 43 in·lb Connecting Rod Big End Nuts see Text ← ← Crankcase Bolt (M8, L = 110 mm) 27.5 Crankcase Bolt (M6, L = 32 mm) 19.6 Crankcase Bolts (M6, L = 38 mm) 19.6...

  • Page 294

    9-4 CRANKSHAFT/TRANSMISSION Exploded View...

  • Page 295

    CRANKSHAFT/TRANSMISSION 9-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Drive Shaft Bearing Holder Screw 0.50 43 in·lb Gear Positioning Lever Bolt 106 in·lb Neutral Switch Neutral Switch Holder Screw 0.50 43 in·lb Oil Jet Nozzle 0.30 26 in·lb Shift Drum Bearing Holder Screws 0.50 43 in·lb Shift Drum Cam Bolt...

  • Page 296

    9-6 CRANKSHAFT/TRANSMISSION Specifications Item Standard Service Limit Crankshaft, Connecting Rods Connecting Rod Bend – – – TIR 0.2/100 mm (0.008/3.94 in.) Connecting Rod Twist – – – TIR 0.2/100 mm (0.008/3.94 in.) Connecting Rod Big End Side Clearance 0.13 0.38 mm 0.58 mm (0.0051 0.0150 in.)

  • Page 297

    CRANKSHAFT/TRANSMISSION 9-7 Specifications Item Standard Service Limit Crankshaft Runout TIR 0.02 mm (0.0008 in.) TIR 0.05 mm or less (0.0020 in.) Crankshaft Main Bearing Insert/Journal Clearance 0.012 0.036 mm 0.07 mm (0.0005 0.0014 in.) (0.0028 in.) Crankshaft Main Journal Diameter: 37.984 38.000 mm 37.96 mm...

  • Page 298

    9-8 CRANKSHAFT/TRANSMISSION Specifications Item Standard Service Limit Crankcase Bearing Bore Diameter: 31.000 31.016 mm – – – (1.2205 1.2228 in.) Marking: ○ 31.000 31.008 mm – – – (1.2205 1.2208 in.) None 31.009 31.016 mm – – – (1.2208 1.2211 in.) Balancer Shaft Bearing Insert Thickness: Brown 1.490...

  • Page 299: Special Tools And Sealants

    CRANKSHAFT/TRANSMISSION 9-9 Special Tools and Sealants Outside Circlip Pliers: Kawasaki Bond (Silicone Sealant): 57001-144 92104-0004 Bearing Driver Set: Kawasaki Bond: 57001-1129 92104-1064...

  • Page 300: Crankcase Splitting

    9-10 CRANKSHAFT/TRANSMISSION Crankcase Splitting Crankcase Splitting • Remove the engine (see Engine Removal in the Engine Removal/Installation chapter) • Set the engine on a clean surface and hold the engine steady while parts are being removed. • Remove: Cylinder Head (see Cylinder Head Removal in the En- gine Top End chapter) Cylinder (see Cylinder Removal in the Engine Top End chapter)

  • Page 301

    CRANKSHAFT/TRANSMISSION 9-11 Crankcase Splitting • Remove the oil pan, oil screen and oil pipes (see Oil Pan Removal in the Engine Lubrication System chapter). • Remove the lower crankcase bolts, following the specified sequence. ○ Firstly, loosen the M6 bolts [A]. ○...

  • Page 302: Crankcase Assembly

    Apply silicone sealant to the portions [E] on the upper crankcase half, and insert [F] the new oil plug until it is bottomed. Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004 ○ Press and insert the new race until it is bottomed.

  • Page 303

    CRANKSHAFT/TRANSMISSION 9-13 Crankcase Splitting • Apply silicone sealant to the breather plate mating surface [A] 1 mm (0.04 in.) or more thick, and then install the breather plate. Sealant - Three Bond: TB1207B NOTE ○ Make the application finish within 7 minutes when the liquid gasket to the mating surface of the breather plate is applied.

  • Page 304

    9-14 CRANKSHAFT/TRANSMISSION Crankcase Splitting • Install the crankshaft and the balancer shaft on the upper crankcase half. ○ Align [A] the timing mark on the balancer gear [B] with the timing mark on the balancer drive gear [C] of the crank- shaft.

  • Page 305

    CRANKSHAFT/TRANSMISSION 9-15 Crankcase Splitting • Apply liquid gasket [A] to the mating surface of the lower crankcase half. Sealant - Kawasaki Bond: 92104-1064 NOTE ○ Especially, apply a liquid gasket carefully so that it shall be filled up on the grooves.

  • Page 306

    9-16 CRANKSHAFT/TRANSMISSION Crankcase Splitting • Fit the lower crankcase half to the upper crankcase half. ○ Insert [A] the breather pipe [B] on the upper crankcase half through the hole [C] on the lower crankcase half. NOTE ○ Make the application finish within 20 minutes when the liquid gasket to the mating surface of the lower crankcase half is applied.

  • Page 307

    CRANKSHAFT/TRANSMISSION 9-17 Crankcase Splitting • Tighten the lower crankcase bolts using the following steps. ○ Following the sequence numbers on the lower crankcase half, tighten the M9 bolts [1, 2] L= 113 mm (4.45 in.) with washers. Torque - Crankcase Bolts (M9): 44 N·m (4.5 kgf·m, 32 ft·lb) ○...

  • Page 308: Crankshaft And Connecting Rods, Crankshaft Installation

    9-18 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods Crankshaft Removal • Split the crankcase (see Crankcase Splitting). • Remove: Camshaft Chain [A] Crankshaft [B] Crankshaft Installation NOTE ○ If the crankshaft is replaced with a new one, refer to the Connecting Rod Big End Bearing/Crankshaft Main Bearing Insert Selection in the Specifications.

  • Page 309: Connecting Rod Installation

    CRANKSHAFT/TRANSMISSION 9-19 Crankshaft and Connecting Rods Connecting Rod Installation CAUTION To minimize vibration, the connecting rods should have the same weight mark. Big End Cap [A] Connecting Rod [B] Weight Mark, Alphabet [C] ○ Diameter Mark [D]: “ ” or no mark CAUTION If the connecting rods, big end bearing inserts, or crankshaft are replaced with new ones, select the...

  • Page 310

    9-20 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods • Install the crankshaft (see Crankshaft Installation). • Install each connecting rod on its original crankpin. NOTE ○ Install each connecting rod so that its oil jet [A] faces the exhaust side (the front [B]) (see Engine Oil Flow Chart in the Engine Lubrication System chapter).

  • Page 311

    CRANKSHAFT/TRANSMISSION 9-21 Crankshaft and Connecting Rods • Install new bolts in reused connecting rods. • Dent both bolt head and bolt tip with a punch as shown. • Before tightening, use a point micrometer to measure the length of new connecting rod bolts and record the values to find the bolt stretch.

  • Page 312: Crankshaft/connecting Rod Cleaning, Connecting Rod Bend

    9-22 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods • Install new bolts in reused connecting rods. • Apply a small amount of molybdenum disulfide oil solution to the following. Threads [A] of Nuts and Bolts Seating Surfaces [B] of Nuts and Con-rods •...

  • Page 313: Connecting Rod Twist, Connecting Rod Big End Bearing Insert/crankpin Wear

    CRANKSHAFT/TRANSMISSION 9-23 Crankshaft and Connecting Rods Connecting Rod Twist • With the big-end arbor [A] still on V block [C], hold the connecting rod horizontally and measure the amount that the arbor [B] varies from being paralleled with the surface plate over a 100 mm (3.94 in.) length of the arbor to de- termine the amount of connecting rod twist.

  • Page 314

    9-24 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods If the clearance is within the standard, no bearing replace- ment is required. If the clearance is between 0.042 mm (0.00165 in.) and the service limit (0.08 mm, 0.0031 in.), replace the bear- ing inserts [A] with inserts painted blue [B]. Check in- sert/crankpin clearance with the plastigage.

  • Page 315: Crankshaft Side Clearance, Crankshaft Runout, Crankshaft Main Bearing Insert/journal Wear

    CRANKSHAFT/TRANSMISSION 9-25 Crankshaft and Connecting Rods • Select the proper bearing insert [A] in accordance with the combination of the connecting rod and crankshaft coding. Size Color [B] Con-rod Big End Crankpin Bearing Insert Inside Diameter Diameter Size Color Part Number Marking Marking ○...

  • Page 316

    9-26 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods Crankshaft Main Bearing Insert/Journal Clearance Standard: 0.012 0.036 mm (0.0005 0.0014 in.) Service Limit: 0.07 mm (0.0028 in.) If the clearance is within the standard, no bearing replace- ment is required. If the clearance is between 0.037 mm (0.0015 in.) and the service limit (0.07 mm, 0.0028 in.), replace the bearing in- serts [A] with inserts painted blue [B].

  • Page 317

    CRANKSHAFT/TRANSMISSION 9-27 Crankshaft and Connecting Rods • Select the proper bearing insert [A] in accordance with the combination of the crankcase and crankshaft coding. Size Color [B] Bearing Insert* Crankcase Main Bearing Crankshaft Main Journal Inside Diameter Marking Diameter Marking Size Color Part Number ○...

  • Page 318: Balancer Removal, Balancer Installation, Balancer Shaft Bearing Insert/journal Clearance

    9-28 CRANKSHAFT/TRANSMISSION Balancer Balancer Removal • Split the crankcase (see Crankcase Splitting). • Pull the balancer shaft [A] with the balancer gear out of the crankcase. Balancer Installation • Apply molybdenum disulfide oil solution to the inside of the balancer shaft bearing insert. •...

  • Page 319

    CRANKSHAFT/TRANSMISSION 9-29 Balancer NOTE ○ Do not turn the balancer shaft during clearance mea- surement. ○ Remove the lower crankcase half and measure the plas- tigage width [A] to determine the bearing insert/journal [B] clearance. Balancer Shaft Bearing Insert/Journal Clearance Standard: 0.011 0.033 mm (0.0004...

  • Page 320

    9-30 CRANKSHAFT/TRANSMISSION Balancer • Put the lower crankcase half on the upper crankcase half without bearing inserts, and tighten the case bolts to the specified torque and sequence (see Crankcase Assem- bly). • Measure the crankcase bearing bore diameter for the bal- ancer shaft, and mark the upper crankcase half in accor- dance with the bore diameter.

  • Page 321: Shift Pedal Removal, Shift Pedal Installation

    CRANKSHAFT/TRANSMISSION 9-31 Transmission Shift Pedal Removal • Remove: Shift Lever Bolt [A] Shift Lever [B] Bolts [C] Left Front Footpeg Stay [D] with Shift Pedal [E] • Remove: Footpeg Holder Bolt [A] Footpeg [B] Shift Pedal [C] Shift Pedal Installation •...

  • Page 322: External Shift Mechanism Removal

    9-32 CRANKSHAFT/TRANSMISSION Transmission • Align the mark [A] on the shift shaft with the mark [B] on the shift lever. • Tighten the shift lever bolt [C] securely. • Be sure the shift pedal [A] position is as shown. Shift Pedal Damper [B] About 136.1 mm (5.36 in.) [C] ○...

  • Page 323: External Shift Mechanism Installation

    CRANKSHAFT/TRANSMISSION 9-33 Transmission • Remove: Clutch (see Clutch Removal in the Clutch chapter) Gear Positioning Lever Bolt [A] Spacer [B] Gear Positioning Lever [C] Washer and Spring External Shift Mechanism Installation • Install the gear positioning lever [A] as shown. Spring [B] Washer [C] Spacer [D]...

  • Page 324: External Shift Mechanism Inspection

    9-34 CRANKSHAFT/TRANSMISSION Transmission • When the new needle bearing [A] is installed in the shift shaft cover [B], press and insert the new needle bearing until it is bottomed. Special Tool - Bearing Driver Set: 57001-1129 • When the new oil seal [C] is installed in the shift cover, press and insert the new oil seal so that its surface is flush with the end of the hole.

  • Page 325: Transmission Assy Removal

    CRANKSHAFT/TRANSMISSION 9-35 Transmission • Check the gear positioning lever [A] and its spring for breaks or distortion. If the lever or spring are damaged in any way, replace them. • Visually inspect the shift drum cam [B]. If they are badly worn or if they show any damage, replace Transmission Assy Removal •...

  • Page 326: Transmission Assy Installation

    9-36 CRANKSHAFT/TRANSMISSION Transmission Transmission Assy Installation • Be sure that the dowel pins [A] are in position. • Apply grease to the new O-ring [B] on the oil pipe [C]. • Install the transmission assy on the crankcase. • Tighten: Torque - Transmission Case Bolts: 20 N·m (2.0 kgf·m, 15 ft·lb) If the gear positioning lever [A] was removed, install it (see...

  • Page 327: Transmission Assy Disassembly, Transmission Assy Assembly

    CRANKSHAFT/TRANSMISSION 9-37 Transmission Transmission Assy Disassembly • Remove the transmission assy (see Transmission Assy Removal). • Remove the following from the transmission case [A]. Shift Rods [B] Shift Forks [C] Drive Shaft [D] Output Shaft [E] • Remove: Shift Drum Cam Bolt [A] Shift Drum [B] and Pin Shift Drum [C] Transmission Assy Assembly...

  • Page 328

    9-38 CRANKSHAFT/TRANSMISSION Transmission • Install the drive shaft bearing holder [A]. • Apply a non-permanent locking agent to the threads of the drive shaft bearing holder screw [B] and tighten it. Torque - Drive Shaft Bearing Holder Screw: 4.9 N·m (0.50 kgf·m, 43 in·lb) •...

  • Page 329: Transmission Shaft Installation

    CRANKSHAFT/TRANSMISSION 9-39 Transmission Transmission Shaft Removal • Refer to the Transmission Assy Disassembly. Transmission Shaft Installation • Refer to the Transmission Assy Assembly. Transmission Shaft Disassembly • Remove the transmission shafts (see Transmission Assy Disassembly). • Remove the circlips, disassemble the transmission shafts.

  • Page 330

    9-40 CRANKSHAFT/TRANSMISSION Transmission • The drive shaft gears can be recognized by size: the gear with the smallest diameter is 1st gear, and the largest one is 6th gear. Be sure that all parts are put back in the cor- rect sequence and all circlips and washers are properly in place.

  • Page 331

    CRANKSHAFT/TRANSMISSION 9-41 Transmission 1. Drive Shaft 2. 1st Gear 3. 2nd Gear 4. 3rd Gear 5. 4th Gear 6. 5th Gear 7. 6th (Top) Gear 8. Bushing 9. Toothed Washer, 34 mm (1.34 in.) 10. Circlip 11. Bushing 12. Thrust Washer, 30 mm (1.18 in.) 13.

  • Page 332: Shift Drum And Fork Installation, Shift Drum Disassembly, Shift Drum Assembly, Shift Fork Bending

    9-42 CRANKSHAFT/TRANSMISSION Transmission Shift Drum and Fork Removal • Refer to the Transmission Assy Disassembly. Shift Drum and Fork Installation • Refer to the Transmission Assy Assembly. Shift Drum Disassembly • Refer to the Transmission Assy Disassembly. Shift Drum Assembly •...

  • Page 333

    CRANKSHAFT/TRANSMISSION 9-43 Transmission Gear Dog and Gear Dog Hole Damage • Visually inspect the gear dogs [A] and gear dog holes [B]. Replace any damaged gears or gears with excessively worn dogs or dog holes.

  • Page 334: Ball Bearing, Needle Bearing, And Oil Seal, Oil Seal Inspection

    9-44 CRANKSHAFT/TRANSMISSION Ball Bearing, Needle Bearing, and Oil Seal Ball and Needle Bearing Replacement CAUTION Do not remove the ball or needle bearings unless it is necessary. Removal may damage them. • Using a press or puller, remove the ball bearing and/or needle bearings.

  • Page 335: Table Of Contents

    WHEELS/TIRES 10-1 Wheels/Tires Table of Contents Exploded View........................10-2 Specifications ......................... 10-4 Special Tools .......................... 10-5 Wheels (Rims) ........................10-6 Front Wheel Removal ....................... 10-6 Front Wheel Installation ....................10-6 Rear Wheel Removal......................10-8 Rear Wheel Installation..................... 10-9 Wheel Inspection ......................10-10 Axle Inspection........................

  • Page 336

    10-2 WHEELS/TIRES Exploded View...

  • Page 337

    WHEELS/TIRES 10-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Axle 11.0 Front Axle Clamp Bolt Rear Axle Nut 11.0 4. Caliper Bracket (KLE650B Models) G: Apply grease. HG: Apply high-temperature grease. R: Replacement Parts WL: Apply soap and water solution or rubber lubricant.

  • Page 338

    10-4 WHEELS/TIRES Specifications Item Standard Service Limit Wheels (Rims) Rim Runout: Axial TIR 0.5 mm (0.02 in.) or less TIR 1.0 mm (0.04 in.) Radial TIR 0.8 mm (0.03 in.) or less TIR 1.0 mm (0.04 in.) Axle Runout/100 mm (3.94 in.) TIR 0.03 mm (0.0012 in.) or less TIR 0.2 mm (0.008 in.) Wheel Balance...

  • Page 339

    WHEELS/TIRES 10-5 Special Tools Bearing Driver Set: Bearing Remover Shaft, 13: 57001-1129 57001-1377 Jack: Jack Attachment: 57001-1238 57001-1608 Bearing Remover Head, 20 × 22: 57001-1293...

  • Page 340: Wheels (rims), Front Wheel Removal, Front Wheel Installation

    10-6 WHEELS/TIRES Wheels (Rims) Front Wheel Removal • Remove: Brake Caliper Mounting Bolts [A] (Both Side) Front Brake Calipers [B] • Loosen: Axle Clamp Bolt [A] Front Axle [B] • Remove the lower fairing (see Lower Fairing Removal in the Frame chapter). •...

  • Page 341

    WHEELS/TIRES 10-7 Wheels (Rims) • Apply high-temperature grease to the grease seal lips. • Fit the collars [A] on the both sides of the hub. • Insert the front axle, and tighten the axle. Torque - Front Axle: 108 N·m (11.0 kgf·m, 80 ft·lb) •...

  • Page 342

    10-8 WHEELS/TIRES Wheels (Rims) Rear Wheel Removal • Raise the rear wheel off the ground with stand [A]. • Remove: Brake Caliper Mounting Bolts [A] Rear Brake Caliper [B] • For models eqquipped with an ABS, remove the rear wheel rotation sensor from the caliper bracket (see Rear Wheel Rotation Sensor Removal in the Brakes chapter).

  • Page 343: Rear Wheel Installation

    WHEELS/TIRES 10-9 Wheels (Rims) Rear Wheel Installation • Apply high-temperature grease to the grease seal lips. • Fit the collars [A] on the both sides of the hub. • Engage the drive chain with the rear sprocket. • Install the caliper bracket [A] onto the stopper [B] of the swingarm.

  • Page 344: Wheel Inspection, Axle Inspection

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

  • Page 345: Balance Inspection, Balance Adjustment, Balance Weight Removal, Balance Weight Installation

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

  • Page 346

    30 g (1.06 oz.) NOTE ○ Balance weights are available from Kawasaki dealers in 10, 20, and 30 grams (0.35, 0.71, and 1.06 oz.) sizes. An imbalance of less than 10 grams (0.35 oz.) will not usually affect running stability.

  • Page 347: Air Pressure Inspection/adjustment, Tire Inspection, Tire Removal, Tire Installation

    WHEELS/TIRES 10-13 Tires Air Pressure Inspection/Adjustment • Refer to the Air Pressure Inspection in the Periodic Main- tenance chapter. Tire Inspection • Refer to the Wheel/Tire Damage Inspection in the Peri- odic Maintenance chapter. Tire Removal • Remove: Wheel (see Front/Rear Wheel Removal) Valve Core (Let out the air) •...

  • Page 348

    10-14 WHEELS/TIRES Tires • Install a new valve in the rim. ○ Remove the valve cap, lubricate the stem seal [A] with a soap and water solution or rubber lubricant, and pull [B] the valve stem through the rim from the inside out until it snaps into place.

  • Page 349: 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 350: Hub Bearing, Hub Bearing Removal, Hub Bearing Installation, Hub Bearing Inspection

    10-16 WHEELS/TIRES Hub Bearing Hub Bearing Removal • Remove the wheel (see Front/Rear Wheel Removal), and take out the following. Collars Coupling (Out of Rear Hub) Grease Seals • Use the bearing remover to remove the hub bearings [A]. CAUTION Do not lay the wheel on the ground with the disc facing down.

  • Page 351

    WHEELS/TIRES 10-17 Hub Bearing Hub Bearing Lubrication NOTE ○ Since the hub bearings are packed with grease and sealed, lubrication is not required.

  • Page 353: Table Of Contents

    FINAL DRIVE 11-1 Final Drive Table of Contents Exploded View........................11-2 Specifications ......................... 11-4 Special Tools .......................... 11-5 Drive Chain..........................11-6 Drive Chain Slack Inspection .................... 11-6 Drive Chain Slack Adjustment ..................11-6 Wheel Alignment Inspection/Adjustment ................11-6 Drive Chain Wear Inspection .................... 11-6 Drive Chain Lubrication.....................

  • Page 354

    11-2 FINAL DRIVE Exploded View...

  • Page 355

    FINAL DRIVE 11-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Engine Sprocket Nut 12.7 Rear Axle Nut 11.0 Rear Sprocket Nuts Speed Sensor Bolt 0.80 69 in·lb Speed Sensor Bracket Bolts 87 in·lb G: Apply grease. HG: Apply high-temperature grease. HO: Apply heavy oil.

  • Page 356

    11-4 FINAL DRIVE Specifications Item Standard Service Limit Drive Chain Drive Chain Slack 35 mm (1.0 1.4 in.) – – – Drive Chain Wear (20-link Length) 317.5 318.2 mm (12.50 12.53 in.) 323 mm (12.7 in.) Standard Chain: Make ENUMA –...

  • Page 357

    FINAL DRIVE 11-5 Special Tools Inside Circlip Pliers: Bearing Driver Set: 57001-143 57001-1129...

  • Page 358: Drive Chain, Wheel Alignment Inspection/adjustment, Drive Chain Lubrication, Drive Chain Removal

    11-6 FINAL DRIVE Drive Chain Drive Chain Slack Inspection • Refer to the Drive Chain Slack Inspection in the Periodic Maintenance chapter. Drive Chain Slack Adjustment • Refer to the Drive Chain Slack Adjustment in the Periodic Maintenance chapter. Wheel Alignment Inspection/Adjustment •...

  • Page 359: Drive Chain Installation

    FINAL DRIVE 11-7 Drive Chain • Grind [A] the pin head to make it flat. • Set the cutting and riveting pin [B] as shown. • Screw the pin holder until it touches chain pin. • Be sure that the cutting pin hits center of chain pin. •...

  • Page 360

    11-8 FINAL DRIVE Drive Chain • Set the plate holder (a) [A] and plate holder (b) [B] on the body. • Fit the plate holder (a) to link plate. • Turn the pin holder by hand until plate holder (b) touches the other link plate.

  • Page 361

    FINAL DRIVE 11-9 Drive Chain • Turn the wrench clockwise until tip of riveting pin hits of link pin. • Rivet it. • Same work for the other link pin. • After staking, check the staked area of the link pin for cracks.

  • Page 362: Sprocket, Coupling, Engine Sprocket Removal

    11-10 FINAL DRIVE Sprocket, Coupling Engine Sprocket Removal • Remove: Engine Sprocket Cover Bolts [A] Engine Sprocket Cover [B] • Remove: Speed Sensor Bracket Bolts [A] Speed Sensor Bracket [B] • Flatten out the bended washer [A]. • Remove the engine sprocket nut [B] and washer. NOTE ○...

  • Page 363: Engine Sprocket Installation, Rear Sprocket Removal, Rear Sprocket Installation

    FINAL DRIVE 11-11 Sprocket, Coupling Engine Sprocket Installation • Replace the sprocket washer with a new one. • Install the engine sprocket [A] so that “OUT SIDE” letters [B] face outward. • Apply molybdenum disulfide oil solution to the threads of the output shaft and seating surface of the engine sprocket nut.

  • Page 364: Coupling Installation, Coupling Bearing Removal, Coupling Bearing Installation

    11-12 FINAL DRIVE Sprocket, Coupling Coupling Installation • Apply high-temperature grease to the coupling grease seal lips [A]. • Apply grease to the coupling internal surface [B]. • Apply grease to the new O-ring [A]. • Install the collar [B]. Coupling Bearing Removal •...

  • Page 365: Coupling Bearing Inspection, Coupling Bearing Lubrication, Coupling Damper Inspection, Sprocket Wear Inspection

    FINAL DRIVE 11-13 Sprocket, Coupling • Replace the grease seal with a new one. • Press in the grease seal so that the seal surface is flush with the end of the hole. ○ Apply high-temperature grease to the grease seal lips. Special Tool - Bearing Driver Set: 57001-1129 Coupling Bearing Inspection Since the coupling bearing is made to extremely close...

  • Page 366: Rear Sprocket Warp Inspection

    11-14 FINAL DRIVE Sprocket, Coupling Rear Sprocket Warp Inspection • Raise the rear wheel off the ground with stand so that it will turn freely. • Set a dial gauge [A] against the rear sprocket [B] near the teeth as shown, and rotate [C] the rear wheel to measure the sprocket runout (warp).

  • Page 367: Table Of Contents

    BRAKES 12-1 Brakes Table of Contents Exploded View........................12-3 Specifications ......................... 12-12 Special Tools .......................... 12-13 Brake Lever, Brake Pedal....................... 12-14 Brake Lever Position Adjustment..................12-14 Brake Pedal Position Inspection ..................12-14 Brake Pedal Position Adjustment..................12-14 Brake Pedal Removal ....................... 12-15 Brake Pedal Installation ....................

  • Page 368: Table Of Contents

    12-2 BRAKES ABS Troubleshooting Outline.................... 12-36 Inquiries to Rider....................... 12-39 Self-diagnosis Outline ....................... 12-41 Self-diagnosis Procedures ....................12-41 Service Code Clearing Procedures................... 12-42 How to Read Service Codes..................... 12-44 How to Erase Service Codes .................... 12-44 ABS Indicator Light (LED) Inspection ................12-46 Solenoid Valve Inspection (Service Code 13,14,17,18)............

  • Page 369

    BRAKES 12-3 Exploded View Dummy Page...

  • Page 370

    12-4 BRAKES Exploded View...

  • Page 371

    BRAKES 12-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Bleed Valve 0.80 69 in·lb Brake Hose Banjo Bolts Brake Lever Pivot Bolt 0.10 9 in·lb Brake Lever Pivot Bolt Locknut 0.60 52 in·lb Front Brake Disc Mounting Bolts Front Brake Light Switch Screw 0.10 9 in·lb Front Brake Reservoir Cap Screws...

  • Page 372

    12-6 BRAKES Exploded View...

  • Page 373

    BRAKES 12-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Bleed Valve 0.80 69 in·lb Brake Hose Banjo Bolts Brake Pedal Bolt 0.90 78 in·lb Rear Brake Disc Mounting Bolts Rear Caliper Mounting Bolts Rear Master Cylinder Mounting Bolts Rear Master Cylinder Push Rod Locknut B: Apply brake fluid.

  • Page 374

    12-8 BRAKES Exploded View KLE650B Models...

  • Page 375

    BRAKES 12-9 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Bleed Valve 0.80 69 in·lb Brake Hose Banjo Bolts Brake Lever Pivot Bolt 0.10 9 in·lb Brake Lever Pivot Bolt Locknut 0.60 52 in·lb Brake Pipe Joint Nuts Front Brake Disc Mounting Bolts Front Brake Light Switch Screw 0.10 9 in·lb...

  • Page 376

    12-10 BRAKES Exploded View KLE650B Models...

  • Page 377

    BRAKES 12-11 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Bleed Valve 0.80 69 in·lb Brake Hose Banjo Bolts Brake Pedal Bolt 0.90 78 in·lb Brake Pipe Joint Nuts Rear Brake Disc Mounting Bolts Rear Caliper Mounting Bolts Rear Master Cylinder Mounting Bolts Rear Master Cylinder Push Rod Locknut B: Apply brake fluid.

  • Page 378

    12-12 BRAKES Specifications Item Standard Service Limit Brake Lever, Brake Pedal Brake Lever Position 5-way adjustable (to suit rider) – – – Brake Lever Free Play Non-adjustable – – – Pedal Free Play Non-adjustable – – – Pedal Position About 50 mm (2.0 in.) below top of footpeg –...

  • Page 379

    BRAKES 12-13 Special Tools Inside Circlip Pliers: Hand Tester: 57001-143 57001-1394 Jack: Jack Attachment: 57001-1238 57001-1608...

  • Page 380: Brake Lever, Brake Pedal, Brake Lever Position Adjustment, Brake Pedal Position Inspection

    12-14 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 381: Brake Pedal Removal, Brake Pedal Installation

    BRAKES 12-15 Brake Lever, Brake Pedal Brake Pedal Removal • Remove: Right Rear Frame Cover (see Rear Frame Cover Re- moval in the Frame chapter) Bolts [A] Right Front Footpeg Stay [B] • Remove: Cotter Pin [A] Joint Pin [B] Rear Brake Light Switch Spring [C] Return Spring [D] •...

  • Page 382

    12-16 BRAKES Brake Lever, Brake Pedal • Install: Right Front Footpeg Stay [A] Washer [B] • Tighten: Torque - Front Footpeg Stay Bolts [C]: 25 N·m (2.5 kgf·m, 18 ft·lb) • Check the brake pedal position (see Brake Pedal Position Inspection).

  • Page 383: Front Caliper Removal, Rear Caliper Removal

    BRAKES 12-17 Calipers Front Caliper Removal • Loosen the banjo bolt [A] at the brake hose lower end, and tighten it loosely. • Unscrew the caliper mounting bolts [B], and detach the caliper [C] from the disc. • Unscrew the banjo bolt and remove the brake hose(s) [D] from the caliper (see Brake Hose and Pipe Replacement in the Periodic Maintenance chapter).

  • Page 384: Caliper Installation, Front Caliper Disassembly, Front Caliper Assembly, Rear Caliper Disassembly, Rear Caliper Assembly

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

  • Page 385: Caliper Piston And Cylinder Damage

    BRAKES 12-19 Calipers Caliper Fluid Seal Damage The fluid seal (piston seal) [A] is placed around the pis- ton to maintain clearance between the pad and the disc. If the seal is in a poor condition, it could lead the pad to wear excessively or the brake to drag, which may cause the tem- perature of the discs or the brake fluid to increase.

  • Page 386: Rear Caliper Holder Shaft Wear

    12-20 BRAKES Calipers Rear Caliper Holder Shaft Wear The caliper body must slide smoothly on the caliper holder shafts [A]. If the body does not slide smoothly, one pad will wear more than the other, pad wear will increase, and con- stant drag on the disc will raise brake and brake fluid tem- perature.

  • Page 387: Brake Pads, Front Brake Pad Installation, Rear Brake Pad Installation

    BRAKES 12-21 Brake Pads Front Brake Pad Removal • Remove the front caliper with the hose installed (see Front Caliper Removal). • Draw out the holder shaft pin [A], and take off the holder shaft [B]. • Remove the pad [C] of the jaw side from the holder shaft [D].

  • Page 388: Master Cylinder, Front Master Cylinder Removal, Front Master Cylinder Installation

    12-22 BRAKES Master Cylinder Front Master Cylinder Removal • Remove the banjo bolt [A] to disconnect the brake hose from the master cylinder [B] (see Brake Hose and Pipe Replacement in the Periodic Maintenance chapter). • Disconnect the front brake light switch connectors [A]. •...

  • Page 389: Rear Master Cylinder Removal

    BRAKES 12-23 Master Cylinder • The master cylinder clamp must be installed with the ar- row mark [A] upward. • Tighten the upper clamp bolt [B] first, and then the lower clamp bolt [C]. ○ There will be a gap at the lower part of the clamp after tightening.

  • Page 390: Rear Master Cylinder Installation, Front Master Cylinder Disassembly, Rear Master Cylinder Disassembly, Master Cylinder Assembly

    12-24 BRAKES Master Cylinder Rear Master Cylinder Installation • Replace the cotter pin [A] with a new one. • Replace the washers on each side of hose fitting with new ones. • Tighten the following bolts. Torque - Rear Master Cylinder Mounting Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb) Brake Hose Banjo Bolt: 25 N·m (2.5 kgf·m, 18 ft·lb) NOTE...

  • Page 391: Master Cylinder Inspection

    BRAKES 12-25 Master Cylinder Master Cylinder Inspection • Remove the master cylinders (see Front/Rear Master Cylinder Removal). • 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].

  • Page 392: Brake Disc, Brake Disc Removal, Brake Disc Installation

    12-26 BRAKES Brake Disc Brake Disc Removal • Remove the wheel (see Front/Rear Wheel Removal in the Wheels/Tires chapter). • Unscrew the mounting bolts, and take off the disc. • Remove the gaskets. Brake Disc Installation • Replace the gaskets with new ones. •...

  • Page 393: Brake Fluid, Brake Line Bleeding

    BRAKES 12-27 Brake Fluid Brake Fluid Level Inspection • Refer to the Brake Fluid Level Inspection in the Periodic Maintenance chapter. Brake Fluid Change • Refer to the Brake Fluid Change in the Periodic Mainte- nance chapter. Brake Line Bleeding The brake fluid has a very low compression coefficient so that almost all the movement of the brake lever or pedal is transmitted directly to the caliper for braking action.

  • Page 394

    12-28 BRAKES Brake Fluid • Bleed the brake line and the caliper. ○ Repeat this operation until no more air can be seen com- ing out into the plastic hose. 1. Pump the brake lever until it becomes hard, and apply the brake and hold it [A].

  • Page 395

    BRAKES 12-29 Brake Fluid WARNING When working with the disc brake, observe the pre- cautions listed below. 1. Never reuse old brake fluid. 2. Do not use fluid from a container that has been left unsealed or that has been open for a long time. 3.

  • Page 396: Brake Hose

    12-30 BRAKES Brake Hose Brake Hose Removal/Installation • Refer to the Brake Hose and Pipe Replacement in the Periodic Maintenance chapter. Brake Hose Inspection • Refer to the Brake Hose Damage and Installation Condi- tion Inspection in the Periodic Maintenance chapter.

  • Page 397: Parts Location

    2. Front Wheel Rotation Sensor Rotor 3. Rear Wheel Rotation Sensor 4. Rear Wheel Rotation Sensor Rotor 5. ABS Indicator Light (LED) 6. ABS Hydraulic Unit 7. ABS Self-diagnosis Terminal 8. ABS Kawasaki Self-diagnosis System Connector 9. ABS Fuse Boxes...

  • Page 398

    ABS System Wiring Diagram 1. Ignition Switch 2. ABS Hydraulic Unit 3. ABS Self-diagnosis Terminal 4. ABS Kawasaki Self-diagnosis System Connector 5. Front Wheel Rotation Sensor 6. Rear Wheel Rotation Sensor 7. ABS Solenoid Valve Relay Fuse 25 A 8. ABS Motor Relay Fuse 30 A 9.

  • Page 399

    6. Unused 7. Power Supply to Rear Wheel Rotation Sensor 8. Unused 9. Unused 10. Unused 11. ABS Kawasaki Self-diagnosis System Terminal 12. ABS Indicator Light (LED) 13. Unused 14. Unused 15. Unused 16. Power Supply to Front Wheel Rotation Sensor 17.

  • Page 400: Abs Servicing Precautions

    12-34 BRAKES Anti-Lock Brake System (Equipped Models) ABS Servicing Precautions There are a number of important precautions that should be followed servicing the ABS system. ○ This ABS system is designed to be used with a 12 V sealed battery as its power source. Do not use any other battery except for a 12 V sealed battery as a power source.

  • Page 401

    BRAKES 12-35 Anti-Lock Brake System (Equipped Models) ○ The ABS indicator light (LED) [A] may light if the tire pres- sure is incorrect, a non-recommended tire is installed, or the wheel is deformed. If the indicator light lights, remedy the problem and clear the service code. WARNING Use of non-recommended tires may cause malfunc- tioning of ABS and can lead to extended braking...

  • Page 402: Abs Troubleshooting Outline

    12-36 BRAKES Anti-Lock Brake System (Equipped Models) ABS Troubleshooting Outline When an abnormality in the system occurs, the ABS in- dicator light (LED) lights up to alert the rider. In addition, the nature of the fault is stored in the memory of the ABS hydraulic unit and when in the self-diagnosis mode, the ser- vice code [A] is indicated by the number of times the ABS indicator light (LED) blinks.

  • Page 403

    BRAKES 12-37 Anti-Lock Brake System (Equipped Models) • Visually inspect the wiring for signs of burning or fraying. If any wiring is poor, replace the damaged wiring. • Pull each connector [A] apart and inspect it for corrosion, dirt and damage. If the connector is corroded or dirty, clean it carefully.

  • Page 404

    12-38 BRAKES Anti-Lock Brake System (Equipped Models) ABS Diagnosis Flow Chart...

  • Page 405

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

  • Page 406

    12-40 BRAKES Anti-Lock Brake System (Equipped Models) Pre-Diagnosis Inspection 1...

  • Page 407

    BRAKES 12-41 Anti-Lock Brake System (Equipped Models) Pre-Diagnosis Inspection 2 Self-diagnosis Outline When the indicator light has blinked or come on, the ABS hydraulic unit memorizes and stores the service code (15 codes including “Normal Code”) for the service person to troubleshoot easily. The service code memory is powered directly by the battery and cannot be canceled by the ignition switch.

  • Page 408

    12-42 BRAKES Anti-Lock Brake System (Equipped Models) • Remove the seat (see Seat Removal in the Frame chap- ter). • Ground the self-diagnosis terminal [A] (Gray) to the bat- tery (–) terminal or battery (–) lead connector, using a lead. •...

  • Page 409

    BRAKES 12-43 Anti-Lock Brake System (Equipped Models) Self-diagnosis Flow Chart...

  • Page 410

    12-44 BRAKES Anti-Lock Brake System (Equipped Models) How to Read Service Codes ○ Service codes are shown by a series of long and short blinks of the ABS indicator light (LED) as shown below. ○ Read 10th digit and unit digit as the ABS indicator light (LED) blinks. ○...

  • Page 411

    BRAKES 12-45 Anti-Lock Brake System (Equipped Models) Service Code Table Service ABS Indicator Light (LED) Problems Light State Code After starts, Start code (not fault) turn off Rear Inlet solenoid valve trouble (open, temperature abnormal) Rear outlet solenoid valve trouble (open, temperature abnormal) Front Inlet solenoid valve trouble (open, temperature abnormal)

  • Page 412: Abs Indicator Light (led) Inspection

    12-46 BRAKES Anti-Lock Brake System (Equipped Models) ABS Indicator Light (LED) Inspection • Turn the ignition switch ON. If the ABS indicator light (LED) [A] lights, it is normal. If the ABS indicator light (LED) does not light, go to step “ABS Indicator Light (LED) is Unlit (When the Ignition Switch turned to ON)”.

  • Page 413: Solenoid Valve Inspection (service Code)

    BRAKES 12-47 Anti-Lock Brake System (Equipped Models) ABS Indicator Light (LED) Lights (When the Motorcycle is Running, - No Service Code) • Do the 1st step test. ○ Check the terminal voltage between the orange/black and black/yellow lead terminals of the meter connector [A]. Special Tool - Hand Tester: 57001-1394 Terminal Voltage Standard:...

  • Page 414

    12-48 BRAKES Anti-Lock Brake System (Equipped Models) • Do the 2nd step test. ○ Disconnect the ABS hydraulic unit connector [A]. ○ Check for continuity between the white/red and black/yel- low lead terminals of the ABS hydraulic unit connector. If there is the continuity in the lead, replace the ABS hy- draulic unit.

  • Page 415

    BRAKES 12-49 Anti-Lock Brake System (Equipped Models) Front, Rear Wheel Rotation Difference Abnormal (Service Code 25) • Do the 1st step test. ○ Check the following and correct the faulty part. Incorrect the tire pressure. Tires not recommended for the motorcycle were installed (incorrect tire size).

  • Page 416

    12-50 BRAKES Anti-Lock Brake System (Equipped Models) • Do the 4th step test. ○ Check the battery terminal voltage between the red/white lead terminal of the fuse box [A] and ground. Special Tool - Hand Tester: 57001-1394 Battery Terminal Voltage Standard: Battery Voltage If the battery terminal voltage is not within the specifica-...

  • Page 417

    BRAKES 12-51 Anti-Lock Brake System (Equipped Models) • Do the 2nd step test. ○ Check that there is iron or other magnetic deposits be- tween the sensor [A] and sensor rotor [B], and the sensor rotor slots for obstructions. ○ Check the installation condition of the sensor for loose- ness.

  • Page 418

    12-52 BRAKES Anti-Lock Brake System (Equipped Models) • Do the 3rd step test. ○ Recheck the service code indication; erase the service code, perform the pre-diagnosis inspection 1 and 2, and retrieve the service code. If the ABS indicator light (LED) [A] lit, faulty ECU in the ABS hydraulic unit.

  • Page 419

    (Service Code 52) • Do the 1st step test. ○ Disconnect the ABS Kawasaki self-diagnosis system con- nector and ABS hydraulic unit connector. ○ Check for continuity between the brown lead terminal of the main harness side connector [A] and brown lead ter- minal of the main harness side [B].

  • Page 420

    ABS hydraulic unit connector. ○ Check the battery terminal voltage, connect the hand tester to the brown terminal of ABS Kawasaki self-diagnosis system connector [A] and ground. Special Tool - Hand Tester: 57001-1394 ○ Turn the ignition switch ON.

  • Page 421: Abs Hydraulic Unit Removal

    BRAKES 12-55 Anti-Lock Brake System (Equipped Models) • Do the 3rd step test. ○ Check the battery condition and regulator/rectifier (see Charging Condition Inspection, Regulator/Rectifier In- spection in the Electrical System chapter). • Do the 4th step test. ○ Recheck the service code indication; erase the service code, perform the pre-diagnosis inspection 1 and 2, and retrieve the service code.

  • Page 422

    12-56 BRAKES Anti-Lock Brake System (Equipped Models) • Clean the ABS hydraulic unit [A]. CAUTION Clean all fittings on the ABS hydraulic unit and the rear master cylinder because dirt around the banjo bolts could contaminate the brake fluid in the line during removal/installation.

  • Page 423: Abs Hydraulic Unit Installation, Abs Hydraulic Unit Inspection, Front Wheel Rotation Sensor Removal

    BRAKES 12-57 Anti-Lock Brake System (Equipped Models) ABS Hydraulic Unit Installation • Install the ABS hydraulic unit to the bracket. CAUTION Brake fluid quickly ruins painted plastic surfaces; any spilled fluid should be completely washed away immediately. • Route the lead correctly, and join connector [A] securely. ○...

  • Page 424

    12-58 BRAKES Anti-Lock Brake System (Equipped Models) • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Bolt [A] Clamps [B] • Disconnect the connector [A]. • Remove: Bolt [A] Front Wheel Rotation Sensor [B] Front Wheel Rotation Sensor Installation •...

  • Page 425

    BRAKES 12-59 Anti-Lock Brake System (Equipped Models) • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Air Cleaner Housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter) • Disconnect the connector [A]. •...

  • Page 426: Wheel Rotation Sensor Inspection, Wheel Rotation Sensor Air Gap Inspection, Wheel Rotation Sensor Rotor Inspection

    12-60 BRAKES Anti-Lock Brake System (Equipped Models) Wheel Rotation Sensor Inspection • Remove the front wheel rotation sensor [A] from the front fork. • Remove the rear wheel rotation sensor [B] from the caliper bracket. • Visually inspect the wheel rotation sensors. Replace the wheel rotation sensor if it is cracked, bent, or otherwise damaged.

  • Page 427

    BRAKES 12-61 Anti-Lock Brake System (Equipped Models) Brake Hose and Pipe Inspection • Refer to the Brake Hose and Pipe Damage and Instal- lation Condition Inspection in the Periodic Maintenance chapter. 25 A ABS Solenoid Valve Relay Fuse Removal • Remove the seat (see Seat Removal in the Frame chap- ter).

  • Page 428

    12-62 BRAKES Anti-Lock Brake System (Equipped Models) Fuse Inspection • Remove the fuse (see 25 A ABS Solenoid Valve Relay/30 A ABS Motor Relay Fuse Removal). • Inspect the fuse element. If it is blown out, replace the fuse. Before replacing a blown fuse, always check the amperage in the affected circuit.

  • Page 429: Table Of Contents

    SUSPENSION 13-1 Suspension Table of Contents Exploded View........................13-2 Specifications ......................... 13-6 Special Tools .......................... 13-7 Front Fork ..........................13-9 Rebound Damping Force Adjustment (Only Right Fork Leg) ........... 13-9 Spring Preload Adjustment ....................13-9 Front Fork Removal (Each Fork Leg) ................13-10 Front Fork Installation .......................

  • Page 430

    13-2 SUSPENSION Exploded View...

  • Page 431

    SUSPENSION 13-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Axle Clamp Bolt Front Fork Bottom Allen Bolts Front Fork Clamp Bolts (Lower) Front Fork Clamp Bolts (Upper) Front Fork Top Plugs Piston Rod Nuts AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque. G: Apply grease.

  • Page 432

    13-4 SUSPENSION Exploded View...

  • Page 433

    SUSPENSION 13-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Rear Shock Absorber Bolt (Upper) Rear Shock Absorber Nut (Lower) Swingarm Pivot Shaft Nut 11.0 G: Apply grease. R: Replacement Parts...

  • Page 434

    13-6 SUSPENSION Specifications Item Standard Front Fork (Per One Unit) Fork Inner Tube Diameter 41 mm (1.6 in.) Air Pressure Atmospheric pressure (Non-adjustable) Rebound Damper Setting (Only 1 3/4 turns out from the fully clockwise position Right Fork Leg) (Usable Range: 0 ←→ 3 turns out) Fork Spring Preload Setting 7 turns out from the fully clockwise position (Usable Range: 0 ←→...

  • Page 435

    SUSPENSION 13-7 Special Tools Inside Circlip Pliers: Fork Oil Level Gauge: 57001-143 57001-1290 Oil Seal & Bearing Remover: Fork Piston Rod Puller, M10 × 1.0: 57001-1058 57001-1298 Bearing Driver Set: Fork Spring Stopper: 57001-1129 57001-1374 Jack: Jack Attachment: 57001-1238 57001-1608 Fork Oil Seal Driver, 41: Needle Bearing Driver, 28: 57001-1288...

  • Page 436

    13-8 SUSPENSION Special Tools Spacer, Fork Spring Compressor: 57001-1663 57001-1685...

  • Page 437: Front Fork, Rebound Damping Force Adjustment, Spring Preload Adjustment

    SUSPENSION 13-9 Front Fork Rebound Damping Force Adjustment (Only Right Fork Leg) • To adjust the rebound damping force, turn the rebound damping adjuster [A] on top of the right front fork leg to the desired position. ○ The standard adjuster setting for the average-build rider of 68 kg (150 lb) with no passenger and no accessories is 1 3/4 turns out from the fully clockwise position.

  • Page 438: Front Fork Installation

    13-10 SUSPENSION Front Fork Front Fork Removal (Each Fork Leg) • Remove: Middle Fairings (see Middle Fairing Removal in the Frame chapter) Inner Cover (see Inner Cover Removal in the Frame chapter) Front Wheel (see Front Wheel Removal in the Wheels/Tires chapter) Front Fender (see Front Fender Removal in the Frame chapter)

  • Page 439: Fork Oil Change

    SUSPENSION 13-11 Front Fork Fork Oil Change • Remove the front fork (see Front Fork Removal). • Hold the inner tube lower end in a vice. • Unscrew the top plug [A] out of the outer tube. • Install the fork spring compressor as shown in the figure. NOTE ○...

  • Page 440

    13-12 SUSPENSION Front Fork • Remove: Slider [A] Spacer [B] Damper [C] Fork Spring [D] NOTE ○ The right fork leg spacer [A] is shorter than the left fork leg spacer [B]. • Drain the fork oil into a suitable container. ○...

  • Page 441

    SUSPENSION 13-13 Front Fork If necessary, measure the oil level as follows. ○ Hold the inner tube vertically in a vise. ○ Using the piston rod puller [A], move the piston rod [B] up and down more than ten times in order to expel all the air from the fork oil.

  • Page 442

    13-14 SUSPENSION Front Fork • Screw the fork piston rod puller onto the end of the rod. Special Tool - Fork Piston Rod Puller, M10 × 1.0: 57001 -1298 • Install the fork spring [A] with the smaller end [B] facing upward.

  • Page 443: Front Fork Disassembly

    SUSPENSION 13-15 Front Fork • While holding up the piston rod puller [A] by one person, push down [B] the fork spring compressor, and insert the fork spring stopper [C] between the piston rod nut [D] and the spacer [E]. Special Tool - Fork Spring Stopper: 57001-1685 •...

  • Page 444: Front Fork Assembly

    13-16 SUSPENSION Front Fork • Take the cylinder unit and center ring plate [A] out of the inner tube. ○ Do not disassemble the cylinder unit. Cylinder Unit [B] for Right Fork Leg Cylinder Unit [C] for Left Fork Leg •...

  • Page 445

    SUSPENSION 13-17 Front Fork • Insert the inner tube to the outer tube. • Fit the new outer guide bush [A] into the outer tube. NOTE ○ When assembling the new outer tube guide bushing [A], hold the washer against the new outer tube guide bush- ing and tap the washer with the fork oil seal driver [B] until it stops.

  • Page 446: Dust Seal Inspection, Spring Tension Inspection

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

  • Page 447: Rear Shock Absorber, Rebound Damping Force Adjustment

    SUSPENSION 13-19 Rear Shock Absorber Rebound Damping Force Adjustment • To adjust the rebound damping force, turn the rebound damping adjuster [A] until you feel a click. ○ The standard adjuster setting for an average-build rider of 68 kg (150 lb) with no passenger and no accessories is the 5th click (white mark position) from the 1st click of the fully clockwise position.

  • Page 448: Rear Shock Absorber Removal, Rear Shock Absorber Installation

    13-20 SUSPENSION Rear Shock Absorber Rear Shock Absorber Removal • Remove: Right Rear Frame Cover (see Rear Frame Cover Re- moval in the Frame chapter) Muffler Body (see Muffler Body Removal in the Engine Top End chapter) • Raise the rear wheel off the ground with jack. Special Tools - Jack: 57001-1238 Jack Attachment: 57001-1608 •...

  • Page 449: Rear Shock Absorber Inspection

    SUSPENSION 13-21 Rear Shock Absorber Rear Shock Absorber Inspection • Remove the rear shock absorber (see Rear Shock Ab- sorber Removal). • Visually inspect the following items. Smooth Stroke Oil Leakage Crack or Dent If there is any damage to the rear shock absorber, replace •...

  • Page 450: Swingarm Removal, Swingarm Installation

    13-22 SUSPENSION Swingarm Swingarm Removal • Remove: Muffler Body (see Muffler Body Removal in the Engine Top End chapter) Engine Sprocket (see Engine Sprocket Removal in the Final Drive chapter) Rear Wheel (see Rear Wheel Removal in the Wheels/Tiers chapter) •...

  • Page 451: Swingarm Bearing Removal, Swingarm Bearing Installation

    SUSPENSION 13-23 Swingarm Swingarm Bearing Removal • Remove: Swingarm (see Swingarm Removal) Collar [A] Oil Seals [B] Sleeve [C] Circlip [D] Special Tool - Inside Circlip Pliers: 57001-143 • Remove the ball bearing and needle bearings. Special Tool - Oil Seal & Bearing Remover [A]: 57001-1058 Swingarm Bearing Installation •...

  • Page 452: Swingarm Bearing, Sleeve Inspection

    13-24 SUSPENSION Swingarm • Replace the circlip with a new one. • Install the needle bearings [A], ball bearing [B] and oil seals [C] position as shown. Circlip [D] 25 mm (0.98 in.) [E] 17 mm (0.67 in.) [F] 1 mm (0.04 in.) [G] 0.5 mm (0.02 in.) [H] 1 mm (0.04 in.) [I] 23.5 mm (0.93 in.) [J]...

  • Page 453: Swingarm Bearing Lubrication

    SUSPENSION 13-25 Swingarm • Turn the bearing in the swingarm back and forth [A] while checking for plays, roughness, or binding. If the bearing play, roughness, or binding is found, replace the bearing. • Examine the bearing seal [B] for tears or leakage. If the seal is torn or is leaking, replace the bearing.

  • Page 455

    STEERING 14-1 Steering Table of Contents Exploded View........................14-2 Special Tools .......................... 14-4 Steering ..........................14-5 Steering Inspection ......................14-5 Steering Adjustment......................14-5 Steering Stem......................... 14-6 Stem, Stem Bearing Removal................... 14-6 Stem, Stem Bearing Installation..................14-7 Stem Bearing Lubrication....................14-9 Steering Stem Warp......................

  • Page 456

    14-2 STEERING Exploded View...

  • Page 457

    STEERING 14-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Fork Clamp Bolts (Lower) Front Fork Clamp Bolts (Upper) Upper Handlebar Holder Bolts Lower Handlebar Holder Bolts Left Switch Housing Screws 0.36 31 in·lb Right Switch Housing Screws 0.36 31 in·lb Steering Stem Head Bolt 11.0...

  • Page 458

    14-4 STEERING Special Tools Steering Stem Nut Wrench: Steering Stem Bearing Driver, 42.5: 57001-1100 57001-1344 Bearing Driver Set: Steering Stem Bearing Driver Adapter, 41.5: 57001-1129 57001-1345...

  • Page 459

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

  • Page 460: Steering Stem

    14-6 STEERING Steering Stem Stem, Stem Bearing Removal • Remove: Middle Fairings (see Middle Fairing Removal in the Frame chapter) Inner Cover (see Inner Cover Removal in the Frame chapter) Bolt [A] Clamp [B] • Remove: Bolt [A] Clamp [B] •...

  • Page 461

    STEERING 14-7 Steering Stem • Pushing up the stem base, and remove the steering stem nut [A] with stem cap [B]. Special Tool - Steering Stem Nut Wrench [C]: 57001-1100 • Remove the steering stem [D] under side. • Remove the upper stem bearing inner race [A] and bear- ing [B].

  • Page 462

    14-8 STEERING Steering Stem • Replace the bearing inner races and oil seal with new ones. • Apply grease to the oil seal. • Drive the lower ball bearing inner race applied the grease onto the stem. Special Tools - Steering Stem Bearing Driver, 42.5 [A]: 57001-1344 Steering Stem Bearing Driver Adapter,...

  • Page 463

    STEERING 14-9 Steering Stem • Install the claw washer [A] so that its bent side [B] faces upward, and engage the bent claws with the grooves of stem locknut [C]. • Hand tighten the stem locknut until it touches the claw washer.

  • Page 464

    14-10 STEERING Steering Stem Stem Cap Deterioration, Damage Replace the stem cap if its oil seal [A] shows damage.

  • Page 465

    STEERING 14-11 Handlebar Handlebar Removal • Remove: Clutch Lever Assembly [A] Left Switch Housing [B] Left Handlebar Weight [C] Left Handlebar Grip [D] Clamp [E] • Remove: Front Brake Master Cylinder [A] (see Front Master Cylin- der Removal in the Brakes chapter) Right Switch Housing [B] Right Handlebar Weight [C] Throttle Grip [D]...

  • Page 466

    14-12 STEERING Handlebar • Tighten the front holder bolts [A] first, and then the rear holder bolts [B]. ○ There will be a gap [C] at the rear part of the handlebar holder after tightening. Torque - Upper Handlebar Holder Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb) •...

  • Page 467: Table Of Contents

    FRAME 15-1 Frame Table of Contents Exploded View........................15-2 Seat ............................15-8 Seat Removal ........................15-8 Seat Installation ........................ 15-8 Fairings........................... 15-9 Lower Fairing Removal ..................... 15-9 Lower Fairing Installation ....................15-9 Middle Fairing Removal ....................15-9 Middle Fairing Installation ....................15-9 Middle Fairing Bracket Removal ..................

  • Page 468

    15-2 FRAME Exploded View...

  • Page 469

    FRAME 15-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Footpeg Holder Bolts Front Footpeg Stay Bolts Rear Footpeg Stay Bolts Sidestand Bolt Sidestand Switch Bolt 0.40 35 in·lb 6. Canada Model G: Apply grease. L: Apply a non-permanent locking agent. R: Replacement Parts...

  • Page 470

    15-4 FRAME Exploded View...

  • Page 471

    FRAME 15-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Lower Fairing Mounting Bolts 0.90 78 in·lb Windshield Mounting Bolts 0.40 0.041 3.5 in·lb 3. Canada Model S: Follow the specified tightening sequence.

  • Page 472

    15-6 FRAME Exploded View...

  • Page 473

    FRAME 15-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Tandem Grip Mounting Bolts 2. KLE650B Models...

  • Page 474: Seat Removal, Seat Installation

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

  • Page 475: Lower Fairing Installation, Middle Fairing Installation

    FRAME 15-9 Fairings Lower Fairing Removal • Remove the mounting bolts [A] and lower fairing [B]. Lower Fairing Installation • Tighten: Torque - Lower Fairing Mounting Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb) Middle Fairing Removal • Remove: Windshield (see Windshield Removal) Bolts [A] •...

  • Page 476: Middle Fairing Bracket Removal, Middle Fairing Bracket Installation

    15-10 FRAME Fairings • Tighten the middle fairing mounting bolts as shown se- quence [1 6] in the figure Middle Fairing Bracket Removal • Remove: Middle Fairings (see Middle Fairing Removal) Windshield Brackets (see Windshield Bracket Removal) Inner Cover (see Inner Cover Removal) Headlight Assy (see Headlight Removal in the Electrical System chapter) Meter Unit (see Meter Unit Removal in the Electrical Sys-...

  • Page 477

    FRAME 15-11 Fairings Inner Cover Removal • Remove the middle fairings (see Middle Fairing Re- moval). • Push the central pin, and then remove the quick rivets [A]. • Remove: Bolts [B] Inner Cover [C] Inner Cover Installation • Installation is the reverse of removal. ○...

  • Page 478: Side Covers

    15-12 FRAME Side Covers Side Cover Removal • Remove: Seat (see Seat Removal) Screw [A] • Pull the side cover [B] evenly outward to clear the stop- pers [C]. Side Cover Installation • Installation is the reverse of removal. ○ Insert the projection [A] into the grommets [B] on the fuel tank and frame.

  • Page 479: Seat Covers, Seat Cover Removal, Seat Cover Installation

    FRAME 15-13 Seat Covers Seat Cover Removal • Remove: Seat (see Seat Removal) Screw [A] (Both Sides) • Push the central pin, and then remove the quick rivet [B] on both sides. • Remove the front seat cover [C] forward. •...

  • Page 480

    15-14 FRAME Fenders Front Fender Removal • Remove: Brake Hose Clamps [A] Bolts [B] (Both Sides) • Remove the front fender [C] upward. Front Fender Installation • Installation is the reverse of removal. ○ Install the brake hose clamps to the front fender holes. Flap and Rear Fender Rear Removal •...

  • Page 481

    FRAME 15-15 Fenders • Remove: Tail/Brake Light [A] (see Tail/Brake Light Removal in the Electrical System chapter) Owner’s Tool [B] For models equipped with an ABS, remove the ABS fuse boxes [C]. • Push the center pin, and then remove the quick rivet [A]. •...

  • Page 482: Rear Fender Front Installation

    15-16 FRAME Fenders • Remove: Battery (see Battery Removal in the Electrical System chapter) Relay Box (see Relay Box Removal in the Electrical Sys- tem chapter) Starter Relay (see Starter Relay Inspection in the Elec- trical System chapter) Fuse Box [A] Clamp [B] •...

  • Page 483

    FRAME 15-17 Frame Frame Inspection • Visually inspect the frame [A] for cracks, dents, bending or warp. ○ If there is any damage to the frame, replace it. WARNING A repaired frame may fail in use, possibly causing an accident. If the frame is bent, dented, cracked, or warped, replace it.

  • Page 484: Windshield Installation

    15-18 FRAME Windshield Windshield Height Adjustment ○ The windshield can be adjusted within 3 positions in height to suit the rider’s preference. • Remove the windshield (see Windshield Removal). • Move the position of the dampers [A] evenly and adjust the windshield height.

  • Page 485: Sidestand Removal, Sidestand Installation

    FRAME 15-19 Sidestand Sidestand Removal • Raise the rear wheel off the ground with stand [A]. • Remove: Sidestand Switch Bolt [A] Clamp [B] Sidestand Switch [C] • Remove: Spring [A] Sidestand Nut [B] Sidestand Bolt [C] Sidestand [D] Sidestand Installation •...

  • Page 486: Frame Cover, Front Frame Cover Removal, Front Frame Cover Installation, Rear Frame Cover Installation

    15-20 FRAME Frame Cover Front Frame Cover Removal • Remove: Middle Fairings (see Middle Fairing Removal) Bolts [A] • Pull the front frame cover [B] outward to clear the stopper [C]. • Disconnect the turn signal light lead connector [A]. Front Frame Cover Installation •...

  • Page 487: Rear View Mirrors

    FRAME 15-21 Rear View Mirrors Rear View Mirrors Removal • Loosen the lower hexagonal area [A] for tightening to re- move the rear view mirror from the holder. CAUTION Do not force to tighten and/or loosen the upper hexagonal area (adapter) [B] with a pair of span- ners.

  • Page 489: Table Of Contents

    ELECTRICAL SYSTEM 16-1 Electrical System Table of Contents Exploded View........................16-3 Specifications ......................... 16-10 Special Tools and Sealant ...................... 16-11 Parts Location......................... 16-12 Wiring Diagram (Other than Canada, New Zealand and Malaysia) ........16-14 Wiring Diagram (Canada, New Zealand and Malaysia) ............16-16 Wiring Diagram (KLE650B Models)..................

  • Page 490: Table Of Contents

    16-2 ELECTRICAL SYSTEM Starter Motor Removal...................... 16-48 Starter Motor Installation....................16-48 Starter Motor Disassembly....................16-49 Starter Motor Assembly ....................16-49 Brush Inspection ....................... 16-51 Commutator Cleaning and Inspection................16-51 Armature Inspection......................16-52 Brush Lead Inspection ...................... 16-52 Right-hand End Cover Inspection ..................16-52 Starter Relay Inspection....................

  • Page 491

    ELECTRICAL SYSTEM 16-3 Exploded View Dummy Page...

  • Page 492

    16-4 ELECTRICAL SYSTEM Exploded View...

  • Page 493

    ELECTRICAL SYSTEM 16-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Tail/Brake Light Mounting Bolts 0.12 11 in·lb License Plate Light Cover Screws 0.90 0.090 8 in·lb License Plate Light Mounting Screws 0.12 11 in·lb Turn Signal Light Lens Screws 0.10 9 in·lb...

  • Page 494

    16-6 ELECTRICAL SYSTEM Exploded View...

  • Page 495

    ELECTRICAL SYSTEM 16-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Alternator Cover Bolts 87 in·lb Alternator Lead Holding Plate Bolt 87 in·lb Alternator Rotor Bolt 15.8 Engine Ground Cable Terminal Bolt 87 in·lb Front Brake Light Switch Screw 0.12 11 in·lb Left Switch Housing Screws 0.36...

  • Page 496

    16-8 ELECTRICAL SYSTEM Exploded View...

  • Page 497

    ELECTRICAL SYSTEM 16-9 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Crankshaft Sensor Bolts 0.61 53 in·lb Neutral Switch Oil Pressure Switch Oxygen Sensor (Europe Models) 44.1 4.50 32.5 Spark Plugs Speed Sensor Bolt 0.80 69 in·lb Timing Rotor Bolt Water Temperature Sensor 106 in·lb Fuel Level Sensor Bolts...

  • Page 498

    16-10 ELECTRICAL SYSTEM Specifications Item Standard Battery Type Sealed Battery Model Name YTX12-BS Capacity 12 V 10 Ah Voltage 12.8 V or more Charging System Type Three-phase AC Alternator Output Voltage 42 V or more at 4 000 r/min (rpm) Stator Coil Resistance 0.18 0.27 Ω...

  • Page 499

    Special Tools and Sealant Hand Tester: Rotor Holder: 57001-1394 57001-1567 Flywheel Puller Assembly, M38 × 1.5/M35 × 1.5: Grip: 57001-1405 57001-1591 Peak Voltage Adapter: Rotor Holder: 57001-1415 57001-1658 Lead Wire - Peak Voltage Adapter: Kawasaki Bond (Silicone Sealant): 57001-1449 92104-0004...

  • Page 500

    16-12 ELECTRICAL SYSTEM Parts Location...

  • Page 501

    ELECTRICAL SYSTEM 16-13 Parts Location 1. Air Switching Valve 2. Alternator 3. Battery 12 V 10 Ah 4. Crankshaft Sensor 5. ECU 6. Fan Motor 7. Front Brake Light Switch 8. Fuse Box with ECU Main Fuse 9. Ignition Switch 10.

  • Page 502

    16-14 ELECTRICAL SYSTEM Wiring Diagram (Other than Canada, New Zealand and Malaysia)

  • Page 503

    ELECTRICAL SYSTEM 16-15 Wiring Diagram (Other than Canada, New Zealand and Malaysia)

  • Page 504

    16-16 ELECTRICAL SYSTEM Wiring Diagram (Canada, New Zealand and Malaysia)

  • Page 505

    ELECTRICAL SYSTEM 16-17 Wiring Diagram (Canada, New Zealand and Malaysia)

  • Page 506

    16-18 ELECTRICAL SYSTEM Wiring Diagram (KLE650B Models)

  • Page 507

    ELECTRICAL SYSTEM 16-19 Wiring Diagram (KLE650B Models)

  • Page 508

    16-20 ELECTRICAL SYSTEM Precautions There are a number of important precautions that are musts when servicing electrical systems. Learn and ob- serve all the rules below. ○ Do not reverse the battery cable connections. This will burn out the diodes on the electrical parts. ○...

  • Page 509: Electrical Wiring, Wiring Inspection

    ELECTRICAL SYSTEM 16-21 Electrical Wiring Wiring Inspection • Visually inspect the wiring for signs of burning, fraying, etc. If any wiring is poor, replace the damaged wiring. • Pull each connector [A] apart and inspect it for corrosion, dirt, and damage. If the connector is corroded or dirty, clean it carefully.

  • Page 510: Battery Installation, Battery Removal, Battery Activation

    16-22 ELECTRICAL SYSTEM Battery Battery Removal • Remove the seat (see Seat Removal in the Frame chap- ter). • Slide the black [A] and red [B] caps out. • Disconnect the negative (–) cable [A] and then positive (+) cable [B]. CAUTION Be sure to disconnect the negative (–) cable first.

  • Page 511

    ELECTRICAL SYSTEM 16-23 Battery CAUTION Do not remove the aluminum sealing sheet [A] from the filler ports [B] until just prior to use. Be sure to use the dedicated electrolyte container for correct electrolyte volume. • Place the battery on a level surface. •...

  • Page 512

    Standard Charge: 1.2 A × 5 10 hours If using a recommended battery charger, follow the charger’s instructions for newly activated sealed battery. Kawasaki-recommended chargers Optimate III Yuasa 1.5 Amp Automatic Charger Battery Mate 150-9 If the above chargers are not available, use equivalent one.

  • Page 513

    ELECTRICAL SYSTEM 16-25 Battery NOTE ○ To ensure maximum battery life and customer satisfac- tion, it is recommended the battery be load tested at three times its amp-hour rating for 15 seconds. Re-check voltage and if less than 12.8 V repeat the charging cycle and load test.

  • Page 514: Charging Condition Inspection, Refreshing Charge

    16-26 ELECTRICAL SYSTEM Battery Charging Condition Inspection ○ Battery charging condition can be checked by measuring battery terminal voltage with a digital meter [A]. • Remove: Seat (see Seat Removal in the Frame chapter) Battery Cable Caps (see Battery Removal) •...

  • Page 515

    ELECTRICAL SYSTEM 16-27 Battery Terminal Voltage: 11.5 less than 12.8 V Standard Charge 1.2 A × 5 10 h (see following chart) Quick Charge 5 A × 1 h CAUTION If possible, do not quick charge. If quick charge is done unavoidably, do standard charge later on.

  • Page 516: Charging System, Alternator Cover Removal, Alternator Cover Installation, Stator Coil Removal

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

  • Page 517: Stator Coil Installation, Alternator Rotor Removal

    Apply silicone sealant to the circumference of the alter- nator lead grommet, and fit the grommet into the notch of the cover securely. Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004 • Install the alternator cover (see Alternator Cover Installa- tion).

  • Page 518: Alternator Rotor Installation

    16-30 ELECTRICAL SYSTEM Charging System Alternator Rotor Installation • Using a cleaning fluid, clean off any oil or dirt on the fol- lowing portions and dry them with a clean cloth. Crankshaft Tapered Portion [A] Alternator Rotor Tapered Portion [B] •...

  • Page 519: Alternator Inspection

    ELECTRICAL SYSTEM 16-31 Charging System • Install the rotor bolt and washer. • Tighten the alternator rotor bolt [A] while holding the alter- nator rotor steady with the rotor holder [B]. Special Tools - Grip: 57001-1591 Rotor Holder: 57001-1658 Torque - Alternator Rotor Bolt: 155 N·m (15.8 kgf·m, 114 ft·lb) •...

  • Page 520

    16-32 ELECTRICAL SYSTEM Charging System • To check the alternator output voltage, do the following procedures. ○ Turn off the ignition switch. ○ Disconnect the alternator lead connector [A]. ○ Connect the hand tester as shown in the table 1. ○...

  • Page 521: Regulator/rectifier Inspection

    ELECTRICAL SYSTEM 16-33 Charging System Regulator/Rectifier Inspection KLE650A Models • Remove: Left Rear Frame Cover (see Rear Frame Cover Removal in the Frame chapter) Bolts [A] • Disconnect the connector [A]. • Remove: Bolts [A] Regulator/Rectifier [B] KLE650B Models • Remove: Muffler Body (see Muffler Body Removal in the Engine Top End chapter)

  • Page 522

    16-34 ELECTRICAL SYSTEM Charging System Rectifier Circuit Check • Check conductivity of the following pair of terminals. Rectifier Circuit Inspection W/BL-BK1, W/BL-BK2, W/BL-BK3 Tester connection BK/Y-BK1, BK/Y-BK2, BK/Y-BK3 The resistance should be low in one direction and more than ten times as much in the other direction. If any two leads are low or high in both directions, the rectifier is defective and the regulator/rectifier must be replaced.

  • Page 523

    ELECTRICAL SYSTEM 16-35 Charging System • Do the 3rd step regulator circuit test. ○ Connect the test light and the 12 V battery in the same manner as specified in the “Regulator Circuit Test-1st Step”. ○ Momentarily apply 24 V to the voltage BR terminal by adding a 12 V battery.

  • Page 524: Charging Voltage Inspection

    16-36 ELECTRICAL SYSTEM Charging System Charging Voltage Inspection • Check the battery condition (see Charging Condition In- spection). • Warm up the engine to obtain actual alternator operating conditions. • Remove the seat (see Seat Removal in the Frame chap- ter).

  • Page 525

    ELECTRICAL SYSTEM 16-37 Charging System Charging System Circuit 1. Ignition Switch 2. Alternator 3. Regulator/Rectifier 4. Water-proof Joint C 5. Main Fuse 30 A 6. Battery 12 V 10 Ah 7. Load...

  • Page 526: Starter Motor Clutch, Starter Motor Clutch Removal/installation, Starter Motor Clutch Inspection, Starter Motor Clutch Disassembly

    16-38 ELECTRICAL SYSTEM Starter Motor Clutch Starter Motor Clutch Removal/Installation • Refer to the Alternator Rotor Removal/Installation. Starter Motor Clutch Inspection • Remove: Alternator Cover (see Alternator Cover Removal) Starter Idle Gear and Torque Limiter (see Alternator Re- moval) • Turn the starter motor clutch gear [A] by hand.

  • Page 527: Ignition System

    ELECTRICAL SYSTEM 16-39 Ignition System WARNING The ignition system produces extremely high volt- age. Do not touch the spark plugs or stick coils while the engine is running, or you could receive a severe electrical shock. CAUTION Do not disconnect the battery cables or any other electrical connections when the ignition switch is on, or while the engine is running.

  • Page 528: Crankshaft Sensor Installation

    Torque - Crankshaft Sensor Bolts: 6.0 N·m (0.61 kgf·m, 53 in·lb) • Apply silicone sealant [A] to the crankshaft sensor lead grommet. Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004 • Install the removed parts (see appropriate chapters). Crankshaft Sensor Inspection •...

  • Page 529: Crankshaft Sensor Peak Voltage Inspection, Timing Rotor Removal, Timing Rotor Installation

    ELECTRICAL SYSTEM 16-41 Ignition System Crankshaft Sensor Peak Voltage Inspection NOTE ○ Be sure the battery is fully charged. ○ Using the peak voltage adapter [A] is a more reliable way to determine the condition of the crankshaft sen- sor than crankshaft sensor internal resistance measure- ments.

  • Page 530

    16-42 ELECTRICAL SYSTEM Ignition System Stick Coil (Ignition Coil together with Spark Plug Cap) Removal • Remove the air cleaner housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter). • Open the clamp [A]. • Disconnect the stick coil connectors [B]. •...

  • Page 531: Spark Plug Removal, Spark Plug Installation

    ELECTRICAL SYSTEM 16-43 Ignition System • Remove the stick coils (see Stick Coil (Ignition Coil to- gether with Spark Plug Cap) Removal). ○ Do not remove the spark plugs. • Measure the primary peak voltage as follows. ○ Install the new spark plug [A] into each stick coil [B], and ground them onto the engine.

  • Page 532: Spark Plug Condition Inspection, Interlock Operation Inspection

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

  • Page 533: Ic Igniter Inspection

    ELECTRICAL SYSTEM 16-45 Ignition System 3rd Check • Inspect the engine for its secure stop after the following operations are completed. • Run the engine to the following conditions. Condition Transmission Gear → 1st Position Clutch Lever → Pulled in Sidestand →...

  • Page 534

    16-46 ELECTRICAL SYSTEM Ignition System...

  • Page 535

    ELECTRICAL SYSTEM 16-47 Ignition System Ignition System Circuit 1. Ignition Switch 11. Water-proof Joint E 21. Fuse Box 2. Engine Stop Switch 12. Water Temperature Sensor 22. ECU Main Relay 3. Spark Plugs 13. Neutral Switch 23. Relay Box 4. Stick Coils 14.

  • Page 536: Electric Starter System, Starter Motor Removal, Starter Motor Installation

    16-48 ELECTRICAL SYSTEM Electric Starter System Starter Motor Removal CAUTION Do not tap the starter motor shaft or body. Tapping the shaft or body could damage the motor. • Remove the throttle body assy (see Throttle Body Assy Removal in the Fuel System (DFI) chapter). •...

  • Page 537: Starter Motor Disassembly, Starter Motor Assembly

    ELECTRICAL SYSTEM 16-49 Electric Starter System Starter Motor Disassembly • Remove the starter motor (see Starter Motor Removal). • Take off the starter motor through bolts [A] and remove the both end covers [B]. • Pull out the armature [A] out of the yoke [B]. NOTE ○...

  • Page 538

    16-50 ELECTRICAL SYSTEM Electric Starter System • Align the stoppers [A] of the negative brush assy [B] to the grooves [C] of the brush holder [D]. • Tighten the screw securely. • Align the stoppers [A] of the positive brush assy [B] to the grooves [C] of the brush holder [D].

  • Page 539: Brush Inspection, Commutator Cleaning And Inspection

    ELECTRICAL SYSTEM 16-51 Electric Starter System • Replace the O-rings [A] with new ones. • Insert the armature [B] so that commutator side [C] faces hollow side [D] of the yoke [E]. • Align the marks [A] to assembly the yoke and the end covers [B].

  • Page 540: Armature Inspection, Brush Lead Inspection, Right-hand End Cover Inspection, Starter Relay Inspection

    16-52 ELECTRICAL SYSTEM Electric Starter System Armature Inspection • Using the × 1 Ω hand tester range, measure the resis- tance between any two commutator segments [A]. Special Tool - Hand Tester: 57001-1394 If there is a high resistance or no reading (∞) between any two segments, a winding is open and the starter motor must be replaced.

  • Page 541

    ELECTRICAL SYSTEM 16-53 Electric Starter System • Disconnect the connector [A]. • Disconnect the starter motor cable [B] and battery positive (+) cable [C] from the starter relay [D]. • Connect the hand tester [A] and 12 V battery [B] to the starter relay [C] as shown.

  • Page 542

    16-54 ELECTRICAL SYSTEM Electric Starter System Electric Starter Circuit 1. Ignition Switch 2. Water-proof Joint B 3. Starter Lockout Switch 4. Ignition Fuse 10 A 5. Fuse Box 6. Starter Circuit Relay 7. Relay Box 8. Starter Motor 9. Starter Relay 10.

  • Page 543: Lighting System

    ELECTRICAL SYSTEM 16-55 Lighting System This motorcycle adopt the daylight system and have a headlight relay in the relay box. The headlight does not go on when the ignition switch and the engine stop switch are first turned on. The headlight comes on after the starter button is released and stays on until the ignition switch is turned off.

  • Page 544: Headlight Removal/installation

    16-56 ELECTRICAL SYSTEM Lighting System • Fit the dust cover [A] with the “Top” mark upward onto the bulb [B] firmly as shown. Good [C] Bad [D] Top Mark [E] • After installation, adjust the headlight aim (see Headlight Aiming Inspection in the Periodic Maintenance chapter). ○...

  • Page 545: Tail/brake Light Removal, Tail/brake Light Installation

    ELECTRICAL SYSTEM 16-57 Lighting System • Disconnect the headlight connectors [A] and city light con- nectors [B]. • Remove the headlight assy. • Installation is the reverse of removal. ○ Insert the hook [A] of the inner cover into the slot [B] of the headlight assy.

  • Page 546: License Plate Light Bulb Replacement

    16-58 ELECTRICAL SYSTEM Lighting System License Plate Light Bulb Replacement • Remove: Screws [A] License Plate Light Cover [B] • Push and turn the bulb [A] counterclockwise and remove • Insert the new bulb [A] by aligning its upper and lower pins [B] with the upper and lower grooves [C] in the socket, and turn the bulb clockwise.

  • Page 547

    ELECTRICAL SYSTEM 16-59 Lighting System Headlight/Tail Light Circuit 13. Main Fuse 30 A 1. Ignition Switch 2. Water-proof Joint A 14. Battery 12 V 10 Ah 3. Water-proof Joint B 15. Frame Ground 4. Right City Right 16. Tail/Brake Light 5.

  • Page 548: Turn Signal Light Bulb Replacement, Turn Signal Relay Inspection

    16-60 ELECTRICAL SYSTEM Lighting System Turn Signal Light Bulb Replacement • Remove: Screw [A] Turn Signal Light Lens [B] • Push and turn the bulb [A] counterclockwise and remove • Insert the new bulb [A] by aligning its upper and lower pins [B] with the upper and lower grooves [C] in the socket, and turn the bulb clockwise.

  • Page 549

    ELECTRICAL SYSTEM 16-61 Lighting System • Connect one 12 V battery and turn signal lights as indi- cated in the figure, and count how may times the lights flash for one minute. Turn Signal Relay [A] Turn Signal Lights [B] 12 V Battery [C] If the lights do not flash as specified, replace the turn sig- nal relay.

  • Page 550

    16-62 ELECTRICAL SYSTEM Lighting System Turn Signal Light Circuit 1. Meter Unit 2. Water-proof Joint A 3. Water-proof Joint B 4. Front Right Turn Signal Light 5. Front Left Turn Signal Light 6. Turn Signal Relay 7. Hazard Button 8. Turn Signal Switch 9.

  • Page 551: Air Switching Valve

    ELECTRICAL SYSTEM 16-63 Air Switching Valve Air Switching Valve Operation Test • Refer to the Air Suction System Damage Inspection in the Periodic Maintenance chapter. Air Switching Valve Unit Test • Remove the air switching valve (see Air Switching Valve Removal in the Engine Top End chapter).

  • Page 552: Radiator Fan System, Fan Motor Inspection

    16-64 ELECTRICAL SYSTEM Radiator Fan System Fan Motor Inspection • Disconnect the connector [A]. • Using an auxiliary leads, supply battery power to the fan motor. If the fan does not rotate, the fan motor is defective and must be replaced. Radiator Fan Circuit 1.

  • Page 553: Oil Pressure Warning System

    ELECTRICAL SYSTEM 16-65 Oil Pressure Warning System Motorcycle operation with low engine oil level, even if it is higher than the lower level line, will cause oil level change when sudden acceleration, or deceleration, and may lead flicker of the oil pressure warning indicator light (LED) because of too rapid response of the oil pressure switch.

  • Page 554: Oil Pressure Warning System Inspection

    16-66 ELECTRICAL SYSTEM Oil Pressure Warning System Oil Pressure Warning Indicator Light (LED) Delay Unit Removal • Remove the right middle fairing (see Middle Fairing Re- moval in the Frame chapter). • Disconnect the connector [A] and remove the delay unit [B].

  • Page 555

    ELECTRICAL SYSTEM 16-67 Oil Pressure Warning System • Do the 4th step test. ○ Disconnect the oil pressure switch lead [A] (see Oil pres- sure Switch Removal in the Engine Lubrication System chapter). ○ Ground the oil pressure switch lead to the engine, using an auxiliary wire [B].

  • Page 556: Meter, Gauge, Indicator Unit

    16-68 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit Meter Unit Removal • Remove the headlight assy (see Headlight Removal/In- stallation). • Disconnect the connector [A]. • Remove the meter unit by taking off the mounting screws [B] with the washers. CAUTION Place the meter unit so that the face is up.

  • Page 557: Electronic Combination Meter Unit Inspection

    ELECTRICAL SYSTEM 16-69 Meter, Gauge, Indicator Unit Electronic Combination Meter Unit Inspection • Remove the meter unit [A] (see Meter Unit Removal). [1] Battery (+) [2] Ignition [3] Ground (–) [4] Fuel Lever Sensor [5] Speed Sensor Signal [6] Tachometer Signal [7] Water Temperature Sensor (–) [8] Oil Pressure Warning Indicator Light (LED) (–) [9] Fuel Reserve Switch...

  • Page 558

    16-70 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit ○ When the terminals are connected, all the LCD segment [A] appear for three seconds. If the LCD segments will not appear, replace the meter assembly. • Disconnect the terminal [2]. ○ All the LCD segments disappear. If the segment do not disappear, replace the meter as- sembly.

  • Page 559

    ELECTRICAL SYSTEM 16-71 Meter, Gauge, Indicator Unit • In the HOUR/MINUTE setting mode, press the RESET button again to effect the HOUR setting mode. ○ The hour display flashes on the display. • Press the MODE button to set the hour. •...

  • Page 560

    16-72 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit Speed Sensor Electric Source Check • Connect the 12 V battery and terminals in the same man- ner as specified in the “Liquid Crystal Display (LCD) Seg- ments Check”. • Set the hand tester to the DC 25 V range and connect it to the terminals [10] and [3].

  • Page 561

    ELECTRICAL SYSTEM 16-73 Meter, Gauge, Indicator Unit Fuel Level Gauge Check • Connect the 12 V battery and terminals in the same man- ner way as specified in the “Liquid Crystal Display (LCD) Segments Check”. • Connect the variable resistor [A] to the terminal [4] as shown.

  • Page 562

    16-74 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit Lights (LED) Inspection Neutral Indicator Light (LED) [A] FI Indicator Light (LED) [B] Oil Pressure Wiring Indicator Light (LED) [C] Water Temperature Warning Indicator Light (LED) [D] Right Turn Signal Indicator Light (LED) [E] Left Turn Signal Indicator Light (LED) [F] High Beam Indicator Light (LED) [G] Illumination Light (LED) [H]...

  • Page 563

    ELECTRICAL SYSTEM 16-75 Meter, Gauge, Indicator Unit High Beam Indicator Light (LED) Battery Positive (+) Terminal to Terminal [11] Neutral Indicator Light (LED) Battery Negative (–) Terminal to Terminal [12] Right and Left Turn Signal Indicator Light (LED) For Right Turn Signal Indicator Light (LED) Battery Positive (+) Terminal to Terminal [14] For Left Turn Signal Indicator Light (LED) Battery Positive (+) Terminal to Terminal [15]...

  • Page 564

    16-76 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit • Connect the battery negative (–) terminal to the terminal [13]. ○ When the terminal are connected, the ABS warning indi- cator light (LED) should goes off. If the ABS warning indicator light (LED) does not go off, replace the meter assembly.

  • Page 565

    ELECTRICAL SYSTEM 16-77 Meter, Gauge, Indicator Unit Meter Circuit 1. ABS Hydraulic Unit (LE650B Models) 13. Fuel Reserve Switch 2. Oil Pressure Warning Indicator Light (LED) 14. Joint Connector Delay Unit 15. ECU 3. Frame Ground 16. Oil Pressure Switch 4.

  • Page 566: Switches And Sensors, Brake Light Timing Inspection, Brake Light Timing Adjustment, Switch Inspection

    16-78 ELECTRICAL SYSTEM Switches and Sensors Brake Light Timing Inspection • Refer to the Brake Light Switch Operation Inspection in the Periodic Maintenance chapter. Brake Light Timing Adjustment • Refer to the Brake Light Switch Operation Inspection in the Periodic Maintenance chapter. Switch Inspection •...

  • Page 567: Water Temperature Sensor Inspection, Speed Sensor Removal, Speed Sensor Installation

    ELECTRICAL SYSTEM 16-79 Switches and Sensors Water Temperature Sensor Inspection • Remove the water temperature sensor (see Removal/In- stallation in the Fuel System (DFI) chapter). • Suspend the sensor [A] in a container of coolant so that the threaded portion is submerged. •...

  • Page 568: Fuel Level Sensor Inspection

    16-80 ELECTRICAL SYSTEM Switches and Sensors Speed Sensor Inspection • Remove the speed sensor (see Speed Sensor Removal). • Connect the speed sensor connector [A] with the battery [B], 10 kΩ resistor [C] and hand tester [D] as shown. • Set the tester to the DC 25 V range.

  • Page 569: Oxygen Sensor Removal (europe Models), Oxygen Sensor Installation (europe Models), Oxygen Sensor Inspection (europe Models)

    ELECTRICAL SYSTEM 16-81 Switches and Sensors • Install a new gasket [A] on the fuel level sensor as shown. Hollows [B] Front [C] • Apply a non-permanent locking agent to the threads of the level sensor bolts and tighten it. Torque - Fuel Level Sensor Bolts: 6.9 N·m (0.70 kgf·m, 61 in·lb) Oxygen Sensor Removal (Europe Models)

  • Page 570: Fuel Reserve Switch Inspection

    16-82 ELECTRICAL SYSTEM Switches and Sensors Fuel Reserve Switch Inspection • Fill the fuel tank with fuel. • Close the fuel tank cap surely. • Remove the fuel tank (see Fuel Tank Removal in the Fuel System (DFI) chapter). • Connect the test light [A] (12 V 3.4 W bulb a socket with leads) and the 12 V battery [B] to the fuel pump connector [C].

  • Page 571

    ELECTRICAL SYSTEM 16-83 Relay Box The relay box [A] has relays and diodes. The relays and diodes can not be removed. Relay Box Removal • Remove the fuel tank (see Fuel Tank Removal in the Fuel System (DFI) chapter. • Open the clamps [A].

  • Page 572: Diode Circuit Inspection

    16-84 ELECTRICAL SYSTEM Relay Box Relay Circuit Inspection (with the battery disconnected) Tester Connection Tester Reading (Ω) Headlight Relay ∞ ∞ ECU Main Relay Not ∞* ∞ Fuel Pump Relay 9-10 Not ∞* 11-16 ∞ Starter Circuit Relay ∞ 11-12 17-20 ∞...

  • Page 573

    ELECTRICAL SYSTEM 16-85 Relay Box Relay Box Internal Circuit A: Headlight Relay B: ECU Main Relay C: Fuel Pump Relay D: Starter Circuit Relay E: Fan Relay...

  • Page 574

    16-86 ELECTRICAL SYSTEM Fuse 30 A Main Fuse Removal • Remove: Right Rear Frame Cover (see Rear Frame Cover Re- moval in the Frame chapter) Bolt [A] Cover [B] • Disconnect the connector [A]. • Pull out the main fuse [A] from the starter relay with needle nose pliers.

  • Page 575: Fuse Inspection

    ELECTRICAL SYSTEM 16-87 Fuse 15 A ECU Fuse Removal • Remove: Seat (see Seat Removal in the Frame chapter) • Unlock the hook [A] to pull the lid [B]. • Pull out the ECU fuse [A] from the fuse box. Fuse Installation •...

  • Page 577

    APPENDIX 17-1 Appendix Table of Contents Cable, Wire, and Hose Routing ....................17-2 Troubleshooting Guide ......................17-46...

  • Page 578

    17-2 APPENDIX Cable, Wire, and Hose Routing...

  • Page 579

    APPENDIX 17-3 Cable, Wire, and Hose Routing 1. Radiator 2. Reserver Tank 3. Reserver Tank Hose 4. Reserver Tank Overflow Hose 5. Outlet Hose 6. Water pump Cover 7. Thermostat Housing 8. Inlet Hose 9. Through the overflow hose as shown. 10.

  • Page 580

    17-4 APPENDIX Cable, Wire, and Hose Routing...

  • Page 581

    APPENDIX 17-5 Cable, Wire, and Hose Routing 1. Clamps 2. Clamp (Insert the clamp in the bracket.) 3. Clamps (Insert the clamps in the frame.) 4. Clamps (Insert the clamps from air cleaner housing side.) 5. Clamp (Insert the clamp from opening part turn to the body side.) 6.

  • Page 582

    17-6 APPENDIX Cable, Wire, and Hose Routing...

  • Page 583

    3. Run the harness through the cutout of the rear fender and between the frame pipes. 4. Frame Ground 5. Kawasaki Self-diagnosis System Connector (Insert the connector to the bracket.) 6. Clamp (Insert the clamp in the rear fender front.) 7.

  • Page 584

    17-8 APPENDIX Cable, Wire, and Hose Routing...

  • Page 585

    APPENDIX 17-9 Cable, Wire, and Hose Routing 1. Install the clamp together with the rear fender rear (Clamp the turn signal leads and license plate light lead.). 2. Run the turn signal leads and license plate light lead into the frame hook. 3.

  • Page 586

    17-10 APPENDIX Cable, Wire, and Hose Routing...

  • Page 587

    APPENDIX 17-11 Cable, Wire, and Hose Routing 1. To Vehicle-down Sensor, Rear Brake Light Switch and Crankshaft Sensor 2. Battery Negative Lead Connector 3. Fuel Pump Lead 4. Fuel Level Sensor Lead 5. Clamp the main harness, and insert it in the rear fender front. 6.

  • Page 588

    17-12 APPENDIX Cable, Wire, and Hose Routing...

  • Page 589

    APPENDIX 17-13 Cable, Wire, and Hose Routing 1. Through the main harness to the rear fender front opening. 2. Clamp (Insert the clamp to the frame.) 3. Vehicle-down Sensor 4. Rear Brake Hose (To Rear Master Cylinder) 5. Through the leads of the rear brake light switch and vehicle-down sensor from forward of the rear shock absorber mounting portion.

  • Page 590

    17-14 APPENDIX Cable, Wire, and Hose Routing...

  • Page 591

    APPENDIX 17-15 Cable, Wire, and Hose Routing 1. Subthrottle Valve Actuator Lead 2. Clamp (Push the subthrottle valve actuator lead under the clamp, and clamp the subthrottle sensor lead and subthrottle valve actuator lead to the delivery pipe.) 3. Clamp (clamp the harness.) 4.

  • Page 592

    17-16 APPENDIX Cable, Wire, and Hose Routing...

  • Page 593

    APPENDIX 17-17 Cable, Wire, and Hose Routing 1. Clamp (Insert the clamp in the frame.) 2. Clamp (Insert the clamp in the horn bracket.) 3. Insert the horn lead terminal from the under. 4. Battery Negative Cable 5. Battery Positive Cable 6.

  • Page 594

    17-18 APPENDIX Cable, Wire, and Hose Routing...

  • Page 595

    APPENDIX 17-19 Cable, Wire, and Hose Routing 1. Fuel Tank Drain Hose (Through the drain hose between main harness and air cleaner housing.) 2. Air Cleaner Drain Hose 3. Fuel Tank Drain Hose 4. Clamp (Through the sidestand switch lead, oxygen sensor lead (europe models), and fuel tank drain hose in the clamp.) 5.

  • Page 596

    17-20 APPENDIX Cable, Wire, and Hose Routing...

  • Page 597

    APPENDIX 17-21 Cable, Wire, and Hose Routing 1. Headlight (low) connector with green tape on the headlight lead. 2. Clamp (Insert the clamp to the handle.) 3. Turn Signal Relay Lead 4. Left City Light Connector 5. Run the main harness between the clamp and pipe. 6.

  • Page 598

    17-22 APPENDIX Cable, Wire, and Hose Routing...

  • Page 599

    APPENDIX 17-23 Cable, Wire, and Hose Routing 1. Clamp (Insert the clamp to the handlebar.) 2. Through the brake hose, right switch housing lead, and throttle cables in the upper and lower clamps. 3. Right Switch Housing Lead 4. Throttle Cable (Accelerator) 5.

  • Page 600

    17-24 APPENDIX Cable, Wire, and Hose Routing...

  • Page 601

    APPENDIX 17-25 Cable, Wire, and Hose Routing 1. Seat Lock Cable 2. Seat Lock 3. Through the seat lock cable to the space of the frame bracket. 4. Install the hook faces downward.

  • Page 602

    17-26 APPENDIX Cable, Wire, and Hose Routing...

  • Page 603

    APPENDIX 17-27 Cable, Wire, and Hose Routing 1. Clamp 2. Clamp 3. Brake Hose 4. Bracket 5. Brake Hose...

  • Page 604

    17-28 APPENDIX Cable, Wire, and Hose Routing...

  • Page 605

    APPENDIX 17-29 Cable, Wire, and Hose Routing 1. Clamp 2. Clamp 3. Brake Hose 4. Face the paint mark outside. 5. Viewed A...

  • Page 606

    17-30 APPENDIX Cable, Wire, and Hose Routing KLE650B Models...

  • Page 607

    APPENDIX 17-31 Cable, Wire, and Hose Routing 1. ABS Hydraulic Unit 2. Brake Hose 3. Brake Hose 4. Damper 5. Clamp 6. Clamp 7. Bracket 8. Brake Hose 9. Front Wheel Rotation Sensor Lead 10. Front Wheel Rotation Sensor 11. Front Wheel Rotation Sensor Rotor 12.

  • Page 608

    17-32 APPENDIX Cable, Wire, and Hose Routing KLE650B Models...

  • Page 609

    APPENDIX 17-33 Cable, Wire, and Hose Routing 1. Through the front wheel rotation sensor lead to the outside of the main harness. 2. Through the front wheel rotation sensor lead inside the right switch housing lead and ignition switch lead, and outside of the head pipe. 3.

  • Page 610

    17-34 APPENDIX Cable, Wire, and Hose Routing KLE650B Models...

  • Page 611

    APPENDIX 17-35 Cable, Wire, and Hose Routing 1. Run the brake hose between the throttle cables and left switch housing lead. 2. Front Wheel Rotation Sensor Lead 3. Clamp 4. Clamps (Insert the clamps in the baffle plate.) 5. Front Wheel Rotation Sensor Lead (Front Side)

  • Page 612

    17-36 APPENDIX Cable, Wire, and Hose Routing KLE650B Models...

  • Page 613

    APPENDIX 17-37 Cable, Wire, and Hose Routing 1. Brake Hose 2. Clamp (Clamp the right switch housing lead, throttle cables, and brake hose.) 3. Throttle Cable (Decelerator) 4. Throttle Cable (Accelerator) 5. Right Switch Housing Lead 6. Install the clamp to the frame, and clamp the right switch housing lead connector.

  • Page 614

    17-38 APPENDIX Cable, Wire, and Hose Routing KLE650B Models...

  • Page 615

    APPENDIX 17-39 Cable, Wire, and Hose Routing 1. ABS Hydraulic Unit 2. Brake Hose 3. Rear Wheel Rotation Sensor Lead 4. Clamps 5. Band 6. Brake Hose 7. Brake Hose 8. Rear Wheel Rotation Sensor 9. Face the paint mark outside. 10.

  • Page 616

    17-40 APPENDIX Cable, Wire, and Hose Routing KLE650B Models...

  • Page 617

    APPENDIX 17-41 Cable, Wire, and Hose Routing 1. Clamp (Clamp the brake hose and front wheel rotation sensor lead, and insert the clamp from the outside.) 2. Clamp the brake hose and rear wheel rotation sensor lead with the band to the frame bracket (Position the band so that the edge of the band faces outward of the motorcycle.).

  • Page 618

    17-42 APPENDIX Cable, Wire, and Hose Routing KLE650B Models...

  • Page 619

    2. ABS Pump Motor Relay Fuse 30A (Insert the connector from the bottom in the rear fender side bracket.) 3. Battery Positive Cable 4. ABS Kawasaki Self-diagnosis System Connector (Insert the connector to the bracket.) 5. Battery Positive Lead (To main harness) 6. After connecting the battery positive lead connector, and insert the connector in the clamp.

  • Page 620

    17-44 APPENDIX Cable, Wire, and Hose Routing...

  • Page 621

    APPENDIX 17-45 Cable, Wire, and Hose Routing 1. Through the ECU lead to the forward of the frame cross pipe. 2. ABS Hydraulic Unit...

  • Page 622: Troubleshooting Guide

    17-46 APPENDIX Troubleshooting Guide NOTE Spark plug dirty, broken, or gap malad- ○ Refer to the Fuel System chapter for most justed of DFI trouble shooting guide. Stick coil shorted or not in good contact ○ This is not an exhaustive list, giving every Stick coil trouble possible cause for each problem listed.

  • Page 623

    APPENDIX 17-47 Troubleshooting Guide Compression low: Cylinder head gasket damaged Spark plug loose Cylinder head warped Cylinder head not sufficiently tightened Valve spring broken or weak down Valve not seating properly (valve bent, No valve clearance worn, or carbon accumulation on the Cylinder, piston worn seating surface) Piston ring bad (worn, weak, broken, or...

  • Page 624: Gear Shifting Faulty, Over Cooling, Abnormal Engine Noise, Clutch Operation Faulty

    17-48 APPENDIX Troubleshooting Guide Gear Shifting Faulty: Engine oil viscosity too high Drive train trouble Doesn’t go into gear; shift pedal doesn’t Brake dragging return: Lubrication inadequate: Clutch not disengaging Engine oil level too low Shift fork bent or seized Engine oil poor quality or incorrect Gear stuck on the shaft Gauge incorrect:...

  • Page 625: Exhaust Smokes Excessively, Abnormal Drive Train Noise, Abnormal Frame Noise

    APPENDIX 17-49 Troubleshooting Guide Engine mount loose O-ring at the oil passage in the crankcase Crankshaft bearing worn damaged Primary gear worn or chipped Exhaust Smokes Excessively: Camshaft chain tensioner trouble Camshaft chain, sprocket, guide worn White smoke: Air suction valve damaged Piston oil ring worn Air switching valve damaged Cylinder worn...

  • Page 626: Battery Trouble

    17-50 APPENDIX Troubleshooting Guide Battery Trouble: Rear shock adjustment too soft Front fork, rear shock absorber spring weak Battery discharged: Rear shock absorber oil leaking Charge insufficient Battery faulty (too low terminal voltage) Brake Doesn’t Hold: Battery lead making poor contact Load excessive (e.g., bulb of excessive Air in the brake line wattage)

  • Page 627

    MODEL APPLICATION Year Model Beginning Frame No. □ JKALEEA1 7A000001 2007 KLE650A7F JKALE650AAA000001 LE650A-000001 2007 KLE650B7F JKALE650ABA000001 □ :This digit in the frame number changes from one machine to another. Part No.99924-1369-01 Printed in Japan...

This manual also for:

Versys kle650

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  • mo jin sa Oct 28, 2016 08:09:
    2015款川​崎Versys 650拥有
  • mojinsa Oct 28, 2016 08:38:
    2015款川​崎Versys 650拥有
  • mo Oct 28, 2016 08:02:
    2015-Kawas​aki-Versys​-Service-M​anual.pdf
  • mojin sa Oct 28, 2016 08:42:
    2015-Kawas​aki-Versys​-Service-M​anual.pdf
  • Speed Jan 13, 2016 06:01:
    Thanks for the service manual, Very Helpful