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VULCAN 2000
VN2000

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Table of Contents

   Also See for Kawasaki VN2000

   Summary of Contents for Kawasaki VN2000

  • Page 1 VULCAN 2000 VN2000...
  • 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 information contained in this publication is based on the latest product information available at the time of publication. Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts. © 2003 Kawasaki Heavy Industries, Ltd. Second Edition (1) : Jan. 8, 2003 (K)
  • Page 6 LIST OF ABBREVIATIONS ampere(s) pound(s) ABDC after bottom dead center meter(s) alternating current minute(s) ATDC after top dead center newton(s) BBDC before bottom dead center pascal(s) bottom dead center horsepower BTDC before top dead center pound(s) per square inch °C degree(s) Celsius revolution direct current...
  • Page 7: Emission Control Information

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

    Be alert for problems and non-scheduled correctly followed, could result in per- maintenance. sonal injury, or loss of life. • Use proper tools and genuine Kawasaki Mo- torcycle parts. Special tools, gauges, and CAUTION testers that are necessary when servicing This caution symbol identifies special...
  • Page 10 NOTE ○ This note symbol indicates points of par- ticular interest for more efficient and con- venient operation. • Indicates a procedural step or work to be done. ○ Indicates a procedural sub-step or how to do the work of the procedural step it follows. It also precedes the text of a NOTE.
  • Page 11: Table Of Contents

    GENERAL INFORMATION 1-1 General Information Table of Contents Before Servicing ........................Model Identification......................... General Specifications......................Technical Information – Oxygen Sensor................. 1-11 Technical Information – Electric Solenoid Operated Decompressor ........1-16 Technical Information – Dual Balancer Shaft System............. 1-17 Unit Conversion Table ......................1-19...
  • Page 12: Before Servicing

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

    GENERAL INFORMATION 1-7 Model Identification VN2000-A1 (US, and Canada) Left Side View: VN2000-A1 (US, and Canada) Right Side View:...
  • Page 18 1-8 GENERAL INFORMATION Model Identification VN2000-A1 (Europe) Left Side View: VN2000-A1 (Europe) Right Side View:...
  • Page 19: General Specifications

    176 kg (388 lb) Rear 195 kg (429 lb) Fuel tank capacity 21 L (5.5 US gal) Fuel Unleaded and high-octane gasoline (see VN2000-A1 Owner’s Manual) Performance: Minimum turning radius 3.2 m (10.5 ft) Engine: Type 4-stroke, OHV, V2-cylinder Cooling system...
  • Page 20 1-10 GENERAL INFORMATION General Specifications Items VN2000-A1 Drive Train: Primary reduction system: Type Chain Reduction ratio 1.500 (48/32) Clutch type Wet multi disc Transmission: Type 5-speed, constant mesh, return shift Gear ratios: 2.550 (51/20) 1.629 (44/27) 1.218 (39/32) 0.939 (31/33) 0.729 (27/37)
  • Page 21: Technical Information - Oxygen Sensor

    GENERAL INFORMATION 1-11 Technical Information – Oxygen Sensor Overview Kawasaki has adopted an oxygen sensor [A] for the Euro- pean and California models in addition to the secondary air injection system and honeycomb catalyst. This helps Ka- sawaki keep the motorcycle with cleaner exhaust gas and cope with the emission regulations.
  • Page 22 1-12 GENERAL INFORMATION Technical Information – Oxygen Sensor Construction and Operation The oxygen sensor uses, a solid electrolyte called zirco- nia. An electrolyte is a substance that has positive (+) and negative (−) ions and can move freely in a liquid. For explanation purposes, picture a solid electrolyte plate as a wall and chambers A and B are divided by this wall.
  • Page 23 GENERAL INFORMATION 1-13 Technical Information – Oxygen Sensor The sensor, uses the fresh air as the oxygen reference, and consists of a passageway to lead the fresh air inside the tubular element. Installed in this passageway is, a air permeable filter that allows the fresh air to pass through, but won’t allow moisture through.
  • Page 24 1-14 GENERAL INFORMATION Technical Information – Oxygen Sensor Figure 5 shows how the sensor operates the controlling factors. There is a sharp voltage drop of about 1V (in reality, about 0.9 V) the sensor uses for control (a standard reference). By utilizing this voltage and using 0.45 V as the reference line, an output larger than the line indicates that exhaust gas is in the lean zone.
  • Page 25 GENERAL INFORMATION 1-15 Technical Information – Oxygen Sensor Maintenance 1) Periodic Inspections Periodic inspections or special maintenance is not re- quired for the sensor. 2) Oxygen Sensor Removal and Installation Handle the oxygen sensor with care. Be careful not to damage sensor wires. Do not service the oxygen sensor while it is hot and not use an inpact wrench while removing or installing the oxygen sensor.
  • Page 26: Technical Information - Electric Solenoid Operated Decompressor

    1-16 GENERAL INFORMATION Technical Information – Electric Solenoid Operated Decompressor An automatic decompressor (Automatic Compression Reliese) system is installed to the right side of the engine. This decompressor is activated by an electric solenoid to make starting engine easy. When the ignition is switched on and the starter button depressed, the solenoid pulls a fulcrum-mounted link that depresses push rods in each camshaft.
  • Page 27: Technical Information - Dual Balancer Shaft System

    Technical Information – Dual Balancer Shaft System Dual balancers harmonize primary balance and reduce vibration. The VN2000-A1 engine applied two balancer shafts, one [1] is located in front of the front cylinder and another one [2] is behind the rear cylinder.
  • Page 28 1-18 GENERAL INFORMATION Technical Information – Dual Balancer Shaft System 1. Front Balancer Shaft 6. Balancer Drive Sprocket 9. Chain Guide (under 2. Rear Balancer Shaft 7. Hydraulic Chain Ten- Crankshaft) 3. Front and Rear Balancer sioner 10. Front Sprocket 8.
  • Page 29: Unit Conversion Table

    GENERAL INFORMATION 1-19 Unit Conversion Table Prefixes for Units: Units of Length: × 0.6214 mile Prefix Symbol Power × 3.281 mega × 1 000 000 × 0.03937 kilo × 1 000 centi × 0.01 milli × 0.001 Units of Torque: micro µ...
  • Page 31 PERIODIC MAINTENANCE 2-1 Periodic Maintenance Table of Contents Periodic Maintenance Chart ....Headlight Aiming Inspection ..2-30 Torque and Locking Agent....Side Stand Switch Operation Specifications ........2-11 Inspection........2-31 Special Tools ........2-13 Engine Stop Switch Operation Periodic Maintenance Procedures..2-14 Inspection........
  • Page 32: Periodic Maintenance Chart

    2-2 PERIODIC MAINTENANCE Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition.The initial maintenance is vitally important and must not be neglected. Periodic Inspection: FREQUENCY Whichever * ODOMETER READING comes ×...
  • Page 33 PERIODIC MAINTENANCE 2-3 Periodic Maintenance Chart FREQUENCY Whichever * ODOMETER READING comes × 1000 km first ( × 1000 mile) INSPECTION Every (0.6) (4) (7.5) (12) (15) (20) (24) Page Fuel System: Throttle control system (play, smooth • • • •...
  • Page 34 2-4 PERIODIC MAINTENANCE Periodic Maintenance Chart Periodic Replacement Parts: FREQUENCY Whichever * ODOMETER READING comes × 1000 km first ( × 1000 mile) CHANGE/REPLACE ITEM Every (0.6) (7.5) (15) (24) (30) Page • Brake hoses and pipes 4 year 2–39 •...
  • Page 35: Torque And Locking Agent

    PERIODIC MAINTENANCE 2-5 Torque and Locking Agent The following tables list the tightening torque The table below, relating tightening torque to for the major fasteners requiring use of a non thread diameter, lists the basic torque for the -permanent locking agent or liquid gasket. bolts and nuts.
  • Page 36: Periodic Maintenance

    2-6 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Engine Top End: Rocker case cover bolts 104 in·lb S, AL Rocker case bolts Oil pipe banjo bolts Oil pipe bolts 87 in·lb Upper cylinder head nuts, 10 mm first, S, MO Upper cylinder head nuts, 10 mm final, S, MO...
  • Page 37 PERIODIC MAINTENANCE 2-7 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Engine Lubrication System: Rocker shaft oil pipe bolts 87 in·lb Cylinder head oil pipe banjo bolts Oil filter 17.5 1.75 12.5 Oil passage bolt Oil passage adapter drain plug 87 in·lb Relief valve Camshaft oil pipe bolt...
  • Page 38 2-8 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Upper balancer chain guide bolts 104 in·lb Lower balancer chain guide bolts 104 in·lb Balance chain tensioner bolts 104 in·lb Bearing retainer screws at output shaft 61 in·lb Bearing retainer bolts –...
  • Page 39 PERIODIC MAINTENANCE 2-9 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Front caliper mounting bolts Front caliper assembly bolts Front brake pad pins Caliper bleed valves 0.80 69 in·lb Front brake pad spring bolts 0.30 26 in·lb Rear master cylinder mounting bolts Rear master cylinder push rod locknut Brake pedal clamp bolt Rear caliper mounting bolts...
  • Page 40 2-10 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Alternator stator coil mounting bolts 104 in·lb Crankshaft sensor mounting bolts 0.70 61 in·lb Oil pressure switch Speed sensor mounting bolt 87 in·lb Gear position switch mounting bolts 0.50 43 in·lb Gear position switch lead clamp bolts...
  • Page 41: Specifications

    PERIODIC MAINTENANCE 2-11 Specifications Item Standard Service Limit Fuel System (DFI): Throttle grip free play 2 ~ 3 mm (0.08 ~ 0.12 in.) – – – Idle speed 900 ± 50 r/min (rpm) – – – Air cleaner element Viscous paper element –...
  • Page 42 2-12 PERIODIC MAINTENANCE Specifications Item Standard Service Limit Final Drive: Drive belt deflection: – – – (44.1 N, 4.5 kgf, 10 lb force) 2.5 ~ 4.0 mm (0.10 ~ 0.16 in.) – – – when installing new belt or – – – 2.5 mm (0.10 in.) engine remounted Brakes:...
  • Page 43: Special Tools

    PERIODIC MAINTENANCE 2-13 Special Tools Inside Circlip Pliers: Spark Plug Wrench, Hex 16: 57001–143 57001–1262 Steering Stem Nut Wrench: Jack Attachment : 57001–1100 57001–1571 Jack: Drive Belt Tension Gauge: 57001–1238 57001– 1585 Oil Filter Wrench: 57001–1249...
  • Page 44: Periodic Maintenance Procedures

    2-14 PERIODIC MAINTENANCE Periodic Maintenance Procedures Steering System: Steering Play Inspection • Check steering as follows. ○ Use the jack [A] and jack attachment [B] under the frame pipe, and a commercially available jack [C] under the en- gine to lift the front wheel off the ground. Special Tools - Jack: 57001-1238 Jack Attachment: 57001-1571 ○...
  • Page 45: Steering Stem Bearing Lubrication

    PERIODIC MAINTENANCE 2-15 Periodic Maintenance Procedures • Remove the claw washer. • Adjust the stem nut [A] with the stem nut wrench [B] by tightening to the specified torque. Special Tool - Steering Stem Nut Wrench: 57001-1100 Torque - Steering Stem Nut: 4.9 N·m (0.50 kgf·m, 43 in·lb) •...
  • Page 46: Brake Hose Damage And Installation Connection Inspection

    2-16 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Hose Damage and Installation Connection Inspection • Inspect the brake hose and fittings for deterioration, cracks and signs of leakage. ○ The high pressure inside the brake line can cause fluid to leak [A] or the hose to burst if the line is not properly main- tained.
  • Page 47: Brake Pad Wear Inspection

    PERIODIC MAINTENANCE 2-17 Periodic Maintenance Procedures • Check that the brake fluid level in the rear brake reservoir [A] is between the upper [B] and the lower [C] level lines. If the fluid level is lower than the lower level line, fill the reservoir to the upper level line.
  • Page 48: Wheel And Tires

    2-18 PERIODIC MAINTENANCE Periodic Maintenance Procedures If it does not go on, inspect or replace the following item. Battery (see Electrical System chapter) Brake Light Bulb (see Electrical System chapter) Main Fuse 30 A and Taillight Fuse 10 A (see Electrical System chapter) Front Brake Light Switch [A] (see Electrical System chapter)
  • Page 49: Wheel Bearing Damage Inspection

    PERIODIC MAINTENANCE 2-19 Periodic Maintenance Procedures • Measure the tread depth at the center of the tread with a depth gauge [A]. Since the tire may wear unevenly, take measurement at several places. If any measurement is less than the service limit, replace the tire (see Wheels/Tires chapter).
  • Page 50: Front Fork Oil Leak Inspection

    2-20 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Pump the seat down and up [A] 4 or 5 times, and inspect the smooth stroke. If the shock absorber does not smoothly or noise is found, inspect the oil leak (see Rear Shock Absorber Oil Leak Inspection) or shock absorber clamps (see Suspension chapter).
  • Page 51: Clutch And Drive Train

    PERIODIC MAINTENANCE 2-21 Periodic Maintenance Procedures Clutch and Drive Train: Clutch Operation • 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 52 2-22 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Using the jack and jack attachment under the frame pipe ribs, lift the rear wheel off the ground (see Rear Wheel Removal in the Wheels/Tires chapter). • Visually inspect the belt for damage (see Belt Wear and Damage Inspection).
  • Page 53: Belt Deflection Adjustment

    PERIODIC MAINTENANCE 2-23 Periodic Maintenance Procedures • Inspect the drive belt deflection, and record the value [B]. • Decide the belt deflection at the position [C] of one where deflection is large. Drive Belt Deflection (with 45 N, 4.5 kgf, 10 lb force) Standard: 2.5 ~ 4.0 mm (0.10 0.16 in.) Drive Belt Deflection (with 45 N, 4.5 kgf, 10 lb force,...
  • Page 54: Wheel Alignment Inspection/adjustment

    2-24 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Tighten both belt adjuster locknuts. WARNING Misalignment of the wheel will result in abnormal wear, and may result in an unsafe riding condition. Tighten both belt adjuster locknuts, and make sure the axle stays aligned. •...
  • Page 55: Belt Wear And Damage Inspection

    PERIODIC MAINTENANCE 2-25 Periodic Maintenance Procedures Belt Wear and Damage Inspection • Using the jack and jack attachment under the frame pipe ribs, lift the rear wheel off the ground (see Rear Wheel Removal in the Wheels/Tires chapter). • Remove: Bolts [A] and Washers Upper Belt Cover [B] •...
  • Page 56 2-26 PERIODIC MAINTENANCE Periodic Maintenance Procedures Drive Belt Tooth Wear and Damage Patterns A. Belt Cross Section B. Edge Bevel Wear C. Rub Wear D. Stone...
  • Page 57: Electrical System

    PERIODIC MAINTENANCE 2-27 Periodic Maintenance Procedures Drive Belt Wear and Damage Analysis Pattern Condition Required Action O.K. for continued use, but inspect the Internal tooth cracks (slight) belt periodically. O.K. for continued use, but inspect the Scuffing to side of teeth belt periodically.
  • Page 58: Lights And Switches Operation

    2-28 PERIODIC MAINTENANCE Periodic Maintenance Procedures Lights and Switches Operation First Step: • Turn on the ignition switch. • The following lights should go on according to below table. Neutral Position City Tail- cense Indicator Models Lights Light light Plate light [E] in Light meter unit...
  • Page 59 PERIODIC MAINTENANCE 2-29 Periodic Maintenance Procedures Third Step: • Turn on the turn signal switch [A] (left or right position). • The left or right turn signal lights [B] (front and rear) ac- cording to the switch position should flash. •...
  • Page 60: Headlight Aiming Inspection

    2-30 PERIODIC MAINTENANCE 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 [C] should go on. If the high beam headlight and/or high beam indicator light does not go on, inspect or replace the following item.
  • Page 61: Side Stand Switch Operation Inspection

    PERIODIC MAINTENANCE 2-31 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. ○...
  • Page 62: Engine Stop Switch Operation Inspection

    2-32 PERIODIC MAINTENANCE Periodic Maintenance Procedures Engine Stop Switch Operation Inspection First Step: • Turn on the ignition switch. • Set the neutral position. • Turn the engine stop switch to stop position. • Push the start button. • The engine does not start. If the engine starts, inspect or replace the following item.
  • Page 63: Idle Speed Inspection

    PERIODIC MAINTENANCE 2-33 Periodic Maintenance Procedures Idle Speed Inspection • Start the engine and warm it up thoroughly. ○ At first the engine will run fast to decrease warm up time (fast idle). ○ Gradually the fast idle will lower to a certain RPM auto- matically.
  • Page 64: Cooling System

    2-34 PERIODIC MAINTENANCE Periodic Maintenance Procedures Cooling System Coolant Level Inspection NOTE ○ Check the level when the engine is cold (room or ambi- ent temperature). • Check the coolant level in the reserve tank with the motor- cycle held upright. The coolant level should be between the “F”...
  • Page 65: Evaporative Emission Control System Inspection(cal)

    PERIODIC MAINTENANCE 2-35 Periodic Maintenance Procedures Evaporative Emission Control System Inspection (CAL): Evaporative Emission Control System Inspection • Inspect the canister as follows: ○ Remove the rear inner cover (see Frame chapter). ○ Remove the holder [A] and take out the canister [B]. ○...
  • Page 66: Air Suction System

    2-36 PERIODIC MAINTENANCE Periodic Maintenance Procedures Air Suction System: Air Switching Valve Operation Test • Pull the air switching valve hose [A] out of the right air cleaner base. • Start the engine and run it at idle speed. • Plug the air switching valve hose end with your finger and feel vacuum pulsing in the hose.
  • Page 67: Bolts And Nuts Tightness Inspection

    PERIODIC MAINTENANCE 2-37 Periodic Maintenance Procedures • With the cable disconnected at both ends, the cable should move freely [A] within the cable housing. If cable movement is not free after lubricating, if the cable is frayed [B], or if the cable housing is kinked [C], replace the cable.
  • Page 68 2-38 PERIODIC MAINTENANCE Periodic Maintenance Procedures Nut, Bolt and Fastener to be checked Wheels: Front Axle Front Axle Clamp Bolts Rear Axle Nut Rear Axle Nut Cotter Pin Brakes: Front Master Cylinder Clamp Bolts Caliper Mounting Bolts Rear Master Cylinder Mounting Bolts Brake Lever Pivot Nut Brake Pedal Bolt Brake Rod Joint Cotter Pin...
  • Page 69: Replacement Parts

    PERIODIC MAINTENANCE 2-39 Periodic Maintenance Procedures Replacement Parts: Brake Hose and Pipe Replacement CAUTION Brake fluid quickly ruins painted surfaces; any spilled fluid should be completely washed away immediately. • When removing the brake hose [A], take care not to spill the brake fluid on the painted or plastic parts.
  • Page 70 2-40 PERIODIC MAINTENANCE 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 71: Master Cylinder Rubber Parts Replacement

    PERIODIC MAINTENANCE 2-41 Periodic Maintenance Procedures ○ For the rear brake caliper [A], change the brake fluid for two bleed valves [B]. • After changing the fluid, check the brake for good braking power, no brake drag, and no fluid leakage. If necessary, bleed the air from the lines (see Brakes chapter).
  • Page 72: Caliper Rubber Parts Replacement

    2-42 PERIODIC MAINTENANCE Periodic Maintenance Procedures Master Cylinder Assembly: • Before assembly, clean all parts including the master cylinder with brake fluid or alcohol. CAUTION Except for the disc pads and disc, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol for cleaning brake parts.
  • Page 73 PERIODIC MAINTENANCE 2-43 Periodic Maintenance Procedures WARNING To avoid serious injury, never place your fingers or palm in front of the piston. If you apply compressed air into the caliper, the piston may crush your hand or fingers. ○ Pull out the pistons by hand. •...
  • Page 74 2-44 PERIODIC MAINTENANCE Periodic Maintenance Procedures Rear Caliper Disassembly: • Remove the caliper with the hose installed (see Brakes chapter). • Remove the pads (see Brakes chapter). • Pull out the caliper holder [A]. • Insert a wooden board [A] 5 mm (0.2 in.) thick inside the caliper opening.
  • Page 75: Spark Plug Replacement

    PERIODIC MAINTENANCE 2-45 Periodic Maintenance Procedures Rear Caliper Assembly: • Tighten the bleed valve. Torque - Caliper Bleed Valve: 7.8 N·m (0.80 kgf·m, 69 in·lb) ○ It is recommended that the fluid seal (piston seal) which is removed, be replaced with a new one. •...
  • Page 76: Air Cleaner Element Replacement

    2-46 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Insert new spark plug in the plug hole, and finger-tighten it first. • Using the plug wrench [A] vertically, tighten the plug. CAUTION The insulator of the spark plug may break if when the wrench is inclined during tightening.
  • Page 77: Engine Oil Change

    Install a new element [A] with the mesh side facing up -ward. CAUTION Use only the recommended air cleaner element (Kawasaki part number 11013–0002). Using an- other air cleaner element will wear the engine prematurely or lower the engine performance.
  • Page 78 2-48 PERIODIC MAINTENANCE Periodic Maintenance Procedures Replace the O-ring [A] for drain plug [B] on the outside clutch cover [C]. • Tighten the drain plugs. Torque - Left Oil Pan Drain Plug: 15 N·m (1.5 kgf·m, 11 ft·lb) Right Oil Pan Drain Plug: 20 N·m (2.0 kgf·m, 15 ft·lb) Clutch Drain Plug: 20 N·m (2.0 kgf·m, 15 ft·lb) •...
  • Page 79: Oil Filter Replacement

    PERIODIC MAINTENANCE 2-49 Periodic Maintenance Procedures Oil Filter Replacement • Drain the engine oil (see Engine Oil Change in this sec- tion). • Remove the oil filter [A] with the oil filter wrench [B] and discard the oil filter. Special Tool - Oil Filter Wrench: 57001-1249 NOTE ○...
  • Page 80: Coolant Change

    2-50 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Install the new fuel hose. • Pull [A] the joint lock [B] fully as shown. • Insert the fuel hose joint [A] straight onto the delivery pipe. • Push [B] the joint lock [C] until the hose joint clicks. •...
  • Page 81 PERIODIC MAINTENANCE 2-51 Periodic Maintenance Procedures • Remove the fuel tank (see Fuel System chapter). • 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 82 2-52 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Loosen the air bleeder bolt [A] on the thermostat housing. Front [B] • Replenish the coolant into the radiator until the coolant begins to flow out the air bleeder bolt hole (that is, all the remaining air is forced out).
  • Page 83: Radiator Hose And O-ring Replacement

    PERIODIC MAINTENANCE 2-53 Periodic Maintenance Procedures Radiator Hose and O-ring Replacement • Drain the coolant (see Coolant Change in the Periodic Maintenance chapter). • Remove: Thermostat [A] Bracket [B] (see Thermostat Removal in the Cooling System chapter) Upper Engine Bracket [C] (see Engine Removal/Instal- lation chapter) •...
  • Page 85 FUEL SYSTEM (DFI) 3-1 Fuel System (DFI) Table of Contents Exploded View........Input Voltage Inspection....3-57 DFI Parts Location......Output Voltage Inspection.... 3-58 Specifications ........3-11 Crankshaft Sensor (Service Code Special Tools and Sealant ....3-13 21)........... 3-61 DFI System........3-14 Crankshaft Sensor DFI Servicing Precautions ....
  • Page 86 3-2 FUEL SYSTEM (DFI) Injector Installation ....... 3-75 Oxygen Sensor Heater Audible Inspection......3-78 Inspection........3-95 Power Source Voltage Inspection 3-78 Oxygen Sensor Heater Output Voltage Inspection.... 3-79 Inspection........3-96 Injector Signal Test....... 3-79 Subthrottle Motor Driver (Service Injector Resistance Inspection ..3-80 Code 85) .........
  • Page 87: Fuel System (dfi)

    FUEL SYSTEM (DFI) 3-3 Separator Inspection (Periodic Separator Operation Test..... 3-123 Inspection)......... 3-122 Hose Inspection (Periodic Inspection)......... 3-122...
  • Page 88: Exploded View

    3-4 FUEL SYSTEM (DFI) Exploded View...
  • Page 89 FUEL SYSTEM (DFI) 3-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Fuel pump bolts 87 in·lb S, L Water temperature sensor 104 in·lb Oxygen sensor Gear position switch mounting bolts 61 in·lb Gear position switch lead clamp bolts 61 in·lb Camshaft position sensor bolt 87 in·lb 7.
  • Page 90 3-6 FUEL SYSTEM (DFI) Exploded View...
  • Page 91 FUEL SYSTEM (DFI) 3-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Fuel level sensor mounting bolts 0.70 61 in·lb Speed sensor mounting bolt 87 in·lb Delivery joint bolts 87 in·lb Throttle body assy holder bolts 87 in·lb Inlet manifold bolts 87 in·lb Air cleaner housing bolts 87 in·lb...
  • Page 92: Dfi Parts Location

    3-8 FUEL SYSTEM (DFI) DFI Parts Location 1. Ignition Coil #1 11. Crankshaft Sensor 20. Camshaft Position Sen- 2. Fuel Pump 12. Air Switching Valve 3. Ignition Coil #2 13. Injector #2 21. Inlet Temperature 4. Atmospheric Pressure 14. Injector #1 Sensor Sensor 15.
  • Page 93 FUEL SYSTEM (DFI) 3-9 DFI Parts Location...
  • Page 94 3-10 FUEL SYSTEM (DFI) DFI Parts Location...
  • Page 95: Specifications

    FUEL SYSTEM (DFI) 3-11 Specifications Item Standard Throttle Grip Free Play: 2 ~ 3 mm (0.08 ~ 0.12 in.) Air Cleaner Element: Viscous paper element DFI System: Make: Denso Idle Speed: 900 ± 50 r/min (rpm) Throttle Body Assy: Type × Bore Two barrel type ×...
  • Page 96 3-12 FUEL SYSTEM (DFI) Specifications Item Standard Subthrottle Valve Actuator: Resistance about 5 ~ 7 Ω Input Voltage about 8.5 ~ 10.5 V DC Oxygen Sensor: Output Voltage (rich) 0.7 ~ 0.8 V Output Voltage (lean) approx. 0.1 V Heater Resistance 14.1 ~ 19.3 Ω...
  • Page 97: Special Tools And Sealant

    FUEL SYSTEM (DFI) 3-13 Special Tools and Sealant Oil Pressure Gauge, 5 kg/cm² : Needle Adapter Set : 57001–125 57001–1457 Fork Oil Level Gauge : Kawasaki Bond (Silicone Sealant) : 570101–1290 56019–120 Hand Tester : Throttle Sensor Setting Adapter: 57001–1394 57001–1400...
  • Page 98: Dfi System

    3-14 FUEL SYSTEM (DFI) DFI System DFI System Wiring Diagram...
  • Page 99 FUEL SYSTEM (DFI) 3-15 DFI System Part Name 1. FI Indicator LED Light 2. Speedometer 3. Ignition Switch 4. Engine Stop Switch 5. Starter Button 6. Ignition Coil #1 7. Ignition Coil #2 8. Air Switching Valve 9. Atmospheric Pressure Sensor 10.
  • Page 100 3-16 FUEL SYSTEM (DFI) DFI System...
  • Page 101 FUEL SYSTEM (DFI) 3-17 DFI System Terminal Names 1. Power Supply to Sensors 2. Unused 3. Radiator Fan Signal 4. Subthrottle Valve Actuator Signal 3 5. Subthrottle Valve Actuator Signal 1 6. Unused 7. Engine Stop Switch Output Signal 8. Unused 9.
  • Page 102: Dfi Servicing Precautions

    3-18 FUEL SYSTEM (DFI) DFI Servicing Precautions There are a number of important precautions that should be followed servicing the DFI system. ○ To maintain the correct fuel-air mixture (F/A), there must be no inlet air leaks in the DFI system. Be sure to install the oil filler cap/oil level gauge [A] after filling the engine oil.
  • Page 103: Troubleshooting The Dfi System

    FUEL SYSTEM (DFI) 3-19 Troubleshooting the DFI System Outline When an abnormality in the system occurs, the FI indica- tor LED light [A] and FI symbol [B] go on to alert the rider on the meter panel. In addition, the condition of the problem is stored in the memory of the ECU (electronic control unit).
  • Page 104 ○ After measurement, remove the needle adapters and ap- ply silicone sealant to the seals [A] of the connector [B] for waterproofing. Silicone Sealant- (Kawasaki Bond: 56019–120)-Seals of Connector • Always check battery condition before replacing the DFI parts. A fully charged battery is a must for conducting...
  • Page 105 FUEL SYSTEM (DFI) 3-21 Troubleshooting the DFI System Resistance Check Method ○ This method is simple. No need for a fully charged battery and the needle adapter. Just do the following especially when a sensor [A] is suspect. • Turn the ignition SW OFF and disconnect the connectors. •...
  • Page 106 3-22 FUEL SYSTEM (DFI) Troubleshooting the DFI System ○ If both ends of a harness [A] are far apart, ground [B] the one end [C], using an auxiliary wire [D] and check the continuity between the end [E] and the ground [F]. This enables to check a long harness for continuity.
  • Page 107: Inquiries To Rider

    FUEL SYSTEM (DFI) 3-23 Troubleshooting the DFI System DFI Diagnosis Flow Chart Inquiries to Rider • Refer to the next sample diagnosis chart. ○ Each rider reacts to problems in different ways, so it is important to confirm what kind of symptoms the rider has encountered.
  • Page 108 3-24 FUEL SYSTEM (DFI) 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. Weather □ fine, □ cloudy, □ rain, □ snow, □ always, □ other: Temperature □...
  • Page 109 FUEL SYSTEM (DFI) 3-25 Troubleshooting the DFI System □ hesitation when acceleration. □ engine oil viscosity too high. □ brake dragging. □ engine overheating. □ clutch slipping. □ other: Poor running □ spark plug loose (tighten it). or no power □ spark plug dirty, broken, or gap maladjusted (remedy it). at high speed □...
  • Page 110: Dfi System Troubleshooting Guide

    3-26 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide NOTE ○ This is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties. ○...
  • Page 111 FUEL SYSTEM (DFI) 3-27 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) (see chapter 2). Starting technique faulty When flooded, don’t crank engine with throttle fully opened. No spark or spark weak: Ignition and engine stop switches not ON Turn both switches ON.
  • Page 112: Poor Running At Low Speed

    3-28 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). Throttle valves or actuator trouble Inspect (see chapter 3). Crankshaft sensor trouble Inspect (see chapter 3).
  • Page 113 FUEL SYSTEM (DFI) 3-29 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Throttle body assy O-ring damage Replace (see chapter 3). Throttle valves or actuator trouble Push in (see chapter 3). Fuel filter or pump screen clogged Inspect and replace fuel pump (see chapter 3). Fuel pressure regulator clogged Inspect fuel pressure and replace fuel pump (see chapter 3).
  • Page 114 3-30 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Valve guide worn or stem seal damaged 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 115 FUEL SYSTEM (DFI) 3-31 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Too low fuel pressure Inspect (see chapter 3). Fuel injector trouble Inspect (see chapter 3). Throttle sensor malfunction Inspect (see chapter 3). Water temperature sensor trouble Inspect (see chapter 3).
  • Page 116 3-32 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Drive belt trouble Inspect and replace (se chapter 11). Brake dragging Inspect caliper fluid seal damage or clogging of master cylinder relief and supply ports (see chapter 12). Clutch slipping Inspect friction plates for wear (see chapter 6).
  • Page 117: Poor Running Or No Power At High Speed

    FUEL SYSTEM (DFI) 3-33 DFI System Troubleshooting Guide Poor Running or No Power at High Speed: Symptoms or Possible Causes Actions (detailed reference) Firing incorrect: Spark plug dirty, broken or maladjusted Clean spark plug and adjust plug gap (see chapter 2). Spark plug cap or high tension wiring trouble Inspect plug cap and ignition coil (see chapter 16).
  • Page 118 3-34 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (detailed reference) Valve not seating properly (valve bent , worn Inspect and repair or replace (see chapter 5). or carbon accumulating on the seating surface) Compression release mechanism sticks open Inspect and repair or replace (see chapter 5).
  • Page 119 FUEL SYSTEM (DFI) 3-35 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (detailed reference) Too high fuel pressure Inspect (see chapter 3). Injection stuck open Inspect (see chapter 3). Water temperature sensor trouble Inspect and replace (see chapter 3). Inlet air temperature sensor trouble Inspect and replace (see chapter 3).
  • Page 120: Self-diagnosis

    3-36 FUEL SYSTEM (DFI) Self-Diagnosis Self-diagnosis Outline The self-diagnosis system has three modes and can be switched to another mode by grounding the self-diagnosis terminal [A]. 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 121: Service Code Clearing Procedures

    FUEL SYSTEM (DFI) 3-37 Self-Diagnosis • Turn the ignition SW ON. • Push the MODE button [A] and display the odometer. • Push the RESET button [B] for more than two seconds. The LCD FI characters [C] are displayed. • Count the blinks of the LED light [D] to read the service code after entering the self-diagnosis mode 1 or 2.
  • Page 122 3-38 FUEL SYSTEM (DFI) Self-Diagnosis • Repeat opening [B] and grounding [A] the lead (self-diagnosis terminal) more than five times [E] within 2 seconds [C] after the lead is grounded, and then keep it grounded continuously [D] for more than 2 seconds.
  • Page 123: How To Read Service Codes

    FUEL SYSTEM (DFI) 3-39 Self-Diagnosis How to Read Service Codes ○ Service codes are shown by a series of long or short blinks of the FI indicator LED light as shown below.
  • Page 124: How To Erase Service Codes

    3-40 FUEL SYSTEM (DFI) Self-Diagnosis ○ Read 10th digit and unit digit as the FI indicator LED light blinks. ○ When there are a number of problems, all the service codes can be stored and the display will begin starting from the lowest number service code in the numerical order. Then after completing all codes, the display is repeated until the self-diagnosis indicator terminal is open.
  • Page 125: Service Code Table

    FUEL SYSTEM (DFI) 3-41 Self-Diagnosis Service Code Table Service FI Indicator LED Light Problems (1) Code Main throttle sensor malfunction, wiring open or short Inlet air pressure sensor malfunction, wiring open or short Inlet air temperature sensor malfunction, wiring open or short Water temperature sensor malfunction, wiring open or short...
  • Page 126 3-42 FUEL SYSTEM (DFI) Self-Diagnosis Service FI Indicator LED Light Problems (1) Code Air switching valve malfunction, wiring open or short Decompression solenoid malfunction, wiring open or short Oxygen sensor heater malfunction, wiring open or short Subthrottle stepping driver malfunction, wiring open or short Oxygen sensor malfunction, wiring open or short Footnotes:...
  • Page 127: Backups

    FUEL SYSTEM (DFI) 3-43 Self-Diagnosis Backups ○ The ECU takes the following measures to prevent engine damage when the DFI or the ignition system parts have troubles. Service Output Signal Usable Parts Backups by ECU Codes Range or Criteria If the main throttle sensor system fails (the signal is out of the usable range, wiring short or open), the ECU locks ignition timing into the ignition Main...
  • Page 128 3-44 FUEL SYSTEM (DFI) Self-Diagnosis Service Output Signal Usable Parts Backups by ECU Codes Range or Criteria The oxygen sensor is active and sensor must Oxygen If the oxygen Sensor is not activated, the ECU send signals (output Sensor stops oxygen Sensor feedback mode. voltage) continuously to the ECU.
  • Page 129: Main Throttle Sensor (service Code 11)

    FUEL SYSTEM (DFI) 3-45 Main Throttle Sensor (Service Code 11) The main throttle sensor is a rotating variable resistor that change output voltage according to throttle operating. The ECU senses this voltage change and determines fuel injec- tion quantity, and ignition timing according to engine rpm, and throttle opening.
  • Page 130: Output Voltage Inspection

    3-46 FUEL SYSTEM (DFI) Main Throttle Sensor (Service Code 11) Output Voltage Inspection • Measure the output voltage at the ECU in the same way as input voltage inspection. Note the following. Digital Voltmeter [A] Connector [B] Special Tool - Needle Adapter Set [C]: 57001–1457 Main Throttle Sensor Output Voltage Connections to ECU Meter (+) →...
  • Page 131: Resistance Inspection

    FUEL SYSTEM (DFI) 3-47 Main Throttle Sensor (Service Code 11) If the output voltage is within the standard range, check the wiring for continuity (see next diagram). If the output voltage is far out of the standard range (e.g. when the wiring is open, the reading is 0 V), check the throttle sensor resistance.
  • Page 132: Inlet Air Pressure Sensor (service Code 12)

    3-48 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code 12) Removal CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the part can damage it. • Remove the fuel tank (see Fuel Tank section in this chap- ter).
  • Page 133: Output Voltage Inspection

    FUEL SYSTEM (DFI) 3-49 Inlet Air Pressure Sensor (Service Code 12) If the reading is within the standard range, remove the fuel tank, and check wiring from ECU to the inlet pressure sensor for continuity. If wiring is good, check the output voltage of the inlet air pressure sensor.
  • Page 134 3-50 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code 12) • Remove the inlet air pressure sensor [A] and disconnect the vacuum hose from the sensor. ○ Do not disconnect the sensor connector. • Connect an auxiliary hose [B] to the inlet air pressure sen- sor.
  • Page 135 FUEL SYSTEM (DFI) 3-51 Inlet Air Pressure Sensor (Service Code 12) Vv: Inlet Air Pressure Sensor Output Volt- ID: Idling age (V) (Digital Meter Reading) TO: Throttle Full Open Pv: Throttle Vacuum Pressure (absolute) ST: Standard of Sensor Output Voltage (v) Ps: Standard Atmospheric Pressure (abso- UR: Usable Range of Sensor Output Voltage (v) lute)
  • Page 136 3-52 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code 12) 1. ECU 2. Inlet Air Pressure Sensor...
  • Page 137: Inlet Air Temperature Sensor (service Code 13)

    FUEL SYSTEM (DFI) 3-53 Inlet Air Temperature Sensor (Service Code 13) Removal/Installation CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. • Remove the air cleaner housing (see Air Cleaner Housing Removal in this chapter).
  • Page 138: Sensor Resistance Inspection

    3-54 FUEL SYSTEM (DFI) Inlet Air Temperature Sensor (Service Code 13) Sensor Resistance Inspection • Remove the inlet air temperature sensor (see this sec- tion). • Suspend the sensor [A] in a container of machine oil so that the heat-sensitive portion is submerged. •...
  • Page 139: Water Temperature Sensor (service Code 14)

    FUEL SYSTEM (DFI) 3-55 Water Temperature Sensor (Service Code 14) Removal/Installation CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. • Remove the fuel tank (see this chapter). • Disconnect the sensor connector [A], and unscrew the water temperature sensor [B].
  • Page 140: Water Temperature Sensor Resistance Inspection

    3-56 FUEL SYSTEM (DFI) Water Temperature Sensor (Service Code 14) Water Temperature Sensor Resistance Inspection • Remove the water temperature sensor (see this section). • Suspend the sensor [A] in a container of machine oil so that the heat-sensitive portion and threaded portion are submerged.
  • Page 141: Atmospheric Pressure Sensor (service Code 15)

    FUEL SYSTEM (DFI) 3-57 Atmospheric Pressure Sensor (Service Code 15) Removal CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. • Turn the ignition switch OFF. • Remove the left side cover (see Frame chapter). •...
  • Page 142: Output Voltage Inspection

    3-58 FUEL SYSTEM (DFI) Atmospheric Pressure Sensor (Service Code 15) Output Voltage Inspection • Measure the output voltage at the ECU in the same way as input voltage inspection. Note the following. Digital Meter [A] ECU Connector [B] Atmospheric Pressure Sensor Output Voltage Connections to ECU Meter (+) →...
  • Page 143 FUEL SYSTEM (DFI) 3-59 Atmospheric Pressure Sensor (Service Code 15) If you need to check the atmospheric pressure sensor for various altitudes other than sea level, check the output voltage as follows: ○ Determine the local altitude (elevation). If you know the local atmospheric pressure using a barometer, substitute the atmospheric pressure for throt- tle vacuum pressure in the inlet air pressure sensor chart (see intake Air Pressure Sensor section in this chapter).
  • Page 144 3-60 FUEL SYSTEM (DFI) Atmospheric Pressure Sensor (Service Code 15) Atmospheric Pressure/Altitude Relationship...
  • Page 145: Crankshaft Sensor (service Code 21)

    FUEL SYSTEM (DFI) 3-61 Crankshaft Sensor (Service Code 21) Start the engine and switch the diagnosis mode to Dealer 1 mode to know all the problem that the DFI system has at the time of self-diagnosis. If the engine cannot be started, the self-diagnosis system does not detect dynamic condi- tion of the crankshaft sensor.
  • Page 146: Camshaft Position Sensor (service Code 23)

    3-62 FUEL SYSTEM (DFI) Camshaft Position Sensor (Service Code 23) Camshaft Position Sensor Removal/Installation • See the Ignition System section in the Electrical System chapter. Camshaft Position Sensor Inspection • See the Ignition System section in the Electrical System chapter. NOTE ○...
  • Page 147 FUEL SYSTEM (DFI) 3-63 Camshaft Position Sensor (Service Code 23) 1. ECU 3. Camshaft Position Sensor...
  • Page 148: Speed Sensor (service Code 24)

    3-64 FUEL SYSTEM (DFI) Speed Sensor (Service Code 24) Speed Sensor Removal/Installation • See the Switches and Sensors section in the Electrical System chapter. Speed Sensor Inspection • See the Switches and Sensors section in the Electrical System chapter. Input Voltage Inspection NOTE ○...
  • Page 149 FUEL SYSTEM (DFI) 3-65 Speed Sensor (Service Code 24) • Connect a digital meter [A] to the connector [A], using the needle adapter set [E]. Special Tool - Needle Adapter Set: 57001-1457 Throttle Sensor Output Voltage Connections to Sensor Meter (+) → P lead [C] Meter (–) →...
  • Page 150: Gear Position Switch (service Code 25)

    3-66 FUEL SYSTEM (DFI) Gear Position Switch (Service Code 25) Gear Position Switch Removal/Installation • See the Switches and Sensors section in the Electrical System chapter. Gear Position Switch Inspection • See the Switches and Sensors section in the Electrical System chapter.
  • Page 151 FUEL SYSTEM (DFI) 3-67 Gear Position Switch (Service Code 25) 1. ECU 2. Gear Position Switch 3. Frame Ground...
  • Page 152: Vehicle-down Sensor (service Code 31)

    3-68 FUEL SYSTEM (DFI) Vehicle-down Sensor (Service Code 31) Vehicle-down Sensor Removal • Remove the battery (see Frame chapter). • Unscrew the screws [A] and disconnect the connector [B]. • Remove the vehicle down sensor [C]. Installation • Install the vehicle-down sensor [A] and washer in the orig- inal position.
  • Page 153 • Remove the needle adapters, and apply silicone sealant to the seals of the connector for waterproofing. Silicone Sealant (Kawasaki Bond: 56019-120) - Seals of Vehicle-down Sensor Connector If the output voltage is out of the specified, replace the vehicle-down sensor.
  • Page 154: Subthrottle Sensor (service Code 32)

    3-70 FUEL SYSTEM (DFI) Subthrottle Sensor (Service Code 32) The subthrottle sensor is a rotating variable resistor that change output voltage according to throttle operating. The ECU senses this voltage change and determines fuel injec- tion quantity, and ignition timing according to engine rpm, and throttle opening.
  • Page 155: Output Voltage Inspection

    FUEL SYSTEM (DFI) 3-71 Subthrottle Sensor (Service Code 32) Output Voltage Inspection • Measure the output voltage at the ECU in the same way as input voltage inspection. Note the following. Digital Voltmeter [A] Connector [B] Special Tool - Needle Adapter Set: 57001–1457 Subthrottle Sensor Output Voltage Connections to ECU Meter (+) →...
  • Page 156: Resistance Inspection

    3-72 FUEL SYSTEM (DFI) Subthrottle Sensor (Service Code 32) Resistance Inspection • Turn the ignition switch OFF. • Disconnect the subthrottle sensor connector. • Connect a digital meter [A] to the subthrottle sensor con- nector [B]. • Measure the subthrottle sensor resistance. Throttle Sensor Resistance Connections: BL lead [C] ←→...
  • Page 157: Oxygen Sensor-not Activated (service Code 33)

    FUEL SYSTEM (DFI) 3-73 Oxygen Sensor-not activated (Service Code 33) Oxygen Sensor Removal/Installation • Refer to Oxygen Sensor Removal and Installation in the Electrical System chapter. Oxygen Sensor Inspection • Warm up the engine thoroughly. • Turn the ignition SW OFF. •...
  • Page 158: Oxygen Sensor Heater Inspection

    3-74 FUEL SYSTEM (DFI) Oxygen Sensor-not activated (Service Code 33) 1. ECU 5. Battery 2. Oxygen Sensor 6. Joint Connector 3. Decompression Fuse 10A 7. Frame Ground 4. ECU Main Fuse 30A Oxygen Sensor Heater Inspection • Set the hand tester [A] to the × 1Ω range and connect it to the terminals in the oxygen sensor lead connector [B].
  • Page 159: Fuel Injectors (#1, #2: Service Code 41, 42)

    FUEL SYSTEM (DFI) 3-75 Fuel Injectors (#1, #2: Service Code 41, 42) Fuel Injector #1: Front Fuel Injector for Front Cylinder (Service Code 41) Fuel Injector #2: Rear Fuel Injector for Rear Cylinder (Service Code 42) CAUTION Never drop the injector, especially on a hard sur- face.
  • Page 160 3-76 FUEL SYSTEM (DFI) Fuel Injectors (#1, #2: Service Code 41, 42) • Apply engine oil to the O-ring [A], and install each injector [B] into the delivery joint [C]. • Check that there is no dirt or dust on the injector seating surface [A] of the inlet manifold [B].
  • Page 161 FUEL SYSTEM (DFI) 3-77 Fuel Injectors (#1, #2: Service Code 41, 42) • Check the injector fuel line for leakage as follows: ○ Connect a commercially available vacuum/pressure pump [A] to the nipple of the delivery pipe [B] with a high-pressure fuel hose [C] (both ends connected with clamps [D]) as shown.
  • Page 162: Audible Inspection

    3-78 FUEL SYSTEM (DFI) Fuel Injectors (#1, #2: Service Code 41, 42) Audible Inspection • Start the engine. • Insert a screwdriver from the engine right side between the fuel tank buttom end and the engine top end. • Apply the tip of a screwdriver [A] to the injector [C]. Put the grip end onto your ear, and listen whether the injector is clicking or not.
  • Page 163: Output Voltage Inspection

    FUEL SYSTEM (DFI) 3-79 Fuel Injectors (#1, #2: Service Code 41, 42) Output Voltage Inspection • Turn the ignition switch OFF. • Remove the ECU (see ECU section in this chapter). Do not disconnect the ECU connector. • Connect a digital voltmeter [A] to the connector [B], using the needle adapter set [C].
  • Page 164: Injector Resistance Inspection

    3-80 FUEL SYSTEM (DFI) Fuel Injectors (#1, #2: Service Code 41, 42) • Remove: Fuel Tank (see this chapter) Air Switching Valve with Hoses (see Engine Top End chapter) Vacuum Hoses on Throttle Body Assy • Remove connectors for injector [A]. •...
  • Page 165: Injector Unit Test

    FUEL SYSTEM (DFI) 3-81 Fuel Injectors (#1, #2: Service Code 41, 42) Injector Unit Test • Use two wires [A] and the same test light set [B] as in “Injector Signal Test”. Rating of Bulb [C]: 12 V × (3 ~ 3.4) W 12 V Sealed Battery [D] CAUTION Be sure to connect the bulb in series.
  • Page 166: Fuel Pump (service Code 45)

    3-82 FUEL SYSTEM (DFI) Fuel Pump (Service Code 45) Fuel Pump Removal CAUTION Never drop the fuel pump, especially on a hard sur- face. Such a shock to the pump can damage it. WARNING Gasoline is extremely flammable and can be explo- sive under certain conditions.
  • Page 167: Pressure Regulator Removal

    FUEL SYSTEM (DFI) 3-83 Fuel Pump (Service Code 45) • Check that the terminals [A] and band [B] are in place. • Apply a non-permanent locking agent to the threads of the fuel pump bolts. • Tighten the fuel pump bolts to a snug fit, following the tightening sequence shown.
  • Page 168: Operating Voltage Inspection

    3-84 FUEL SYSTEM (DFI) Fuel Pump (Service Code 45) Operating Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch OFF. • Remove the ignition coil bracket cover (see Frame chap- ter). • Connect the hand tester (25 V DC) to the fuel pump con- nector [A] with needle adapter set.
  • Page 169: Power Source Voltage Inspection

    If the measurement is normal, replace the fuel pump. • After inspection, remove the needle adapter, and apply silicone sealant to the seal of the connector for water- proofing. Silicone Sealant (Kawasaki Bond: 56019-120) - Sealing of Fuel Pump Connector...
  • Page 170 3-86 FUEL SYSTEM (DFI) Fuel Pump (Service Code 45) 1. ECU 7. Ignition Fuse 10A 12. Starter Relay 2. Joint Connector 8. Relay Box 13. Battery 3. Engine Stop Switch 9. ECU Main Relay 14. Fuse 30A 4. Ignition Switch 10.
  • Page 171: Ignition Coils (#1, #2: Service Code 51, 52)

    FUEL SYSTEM (DFI) 3-87 Ignition Coils (#1, #2: Service Code 51, 52) Ignition Coil #1: Ignition Coil for Front Cylinder (Service Code 51) Ignition Coil #2: Ignition Coil for Rear Cylinder (Service Code 52) Removal/Installation CAUTION Never drop the ignition coils, especially on a hard surface.
  • Page 172: Starter Control Relay (service Code 55)

    3-88 FUEL SYSTEM (DFI) Starter Control Relay (Service Code 55) Starter Control Relay Removal and Installation • Refer to Starter Control Relay Inspection in the Electrical System chapter. Starter Control Relay Inspection • Refer to Starter Control Relay Inspection and Electric Starter Circuit in the Electrical System chapter.
  • Page 173: Radiator Fan Relay (service Code 56)

    FUEL SYSTEM (DFI) 3-89 Radiator Fan Relay (Service Code 56) Radiator Fan Relay Removal/Installation • Radiator fan relay is bult in the relay box. • Remove the relay box (see Electrical System chapter). Radiator Fan Relay Inspection • See Relay Circuit Inspection in the Electrical System chapter.
  • Page 174: Subthrottle Valve Actuator (service Code 62)

    3-90 FUEL SYSTEM (DFI) Subthrottle Valve Actuator (Service Code 62) Subthrottle Valve Actuator Removal CAUTION Do not remove the subthrottle valve actuator [A] since it has been adjusted and set with precision at the factory. Never drop the actuator , especially on a hard sur- face.
  • Page 175: Input Voltage Inspection

    FUEL SYSTEM (DFI) 3-91 Subthrottle Valve Actuator (Service Code 62) Input Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch OFF. • Remove the fuel tank (see this chapter). • Connect the peak voltage adaper [A] and a digital meter [B] to the connector [C], using the needle adapter set [D].
  • Page 176 3-92 FUEL SYSTEM (DFI) Subthrottle Valve Actuator (Service Code 62) 1. ECU 2. Subthrottle Valve Actuator...
  • Page 177: Air Switching Valve (service Code 64)

    FUEL SYSTEM (DFI) 3-93 Air Switching Valve (Service Code 64) Air Switching Valve Removal/Instalation • See the Engine Top End chapter. Air Switching Valve Inspection • See the Air Switching Valve Unit Test in the Electrical Sys- tem chapter. • Remove the fuel tank and check the wiring continuity, us- ing the following diagram.
  • Page 178: Decompression Solenoid (service Code 66)

    3-94 FUEL SYSTEM (DFI) Decompression Solenoid (Service Code 66) Decompression Solenoid Removal/Installation • See Decompression Release Mechanism Removal and Installation section in the Engine Top End chapter. Decompression Solenoid Inspection • Remove the outer camshaft cover (see Decompression Mechanism Removal in the Engine Top End chapter). •...
  • Page 179: Oxygen Sensor Heater (service Code 67)

    FUEL SYSTEM (DFI) 3-95 Oxygen Sensor Heater (Service Code 67) 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/Installation in the Electrical System chapter).
  • Page 180: Oxygen Sensor Heater Inspection

    3-96 FUEL SYSTEM (DFI) Oxygen Sensor Heater (Service Code 67) 1. ECU 5. Battery 2. Oxygen Sensor 6. Joint Connector 3. Decompression Fuse 10A 7. Frame Ground 4. ECU Main Fuse 30A Oxygen Sensor Heater Inspection • Set the hand tester [A] to the × 1Ω range and connect it to the terminals in the oxygen sensor lead connector [B].
  • Page 181: Subthrottle Motor Driver (service Code 85)

    FUEL SYSTEM (DFI) 3-97 Subthrottle Motor Driver (Service Code 85) Subthrottle Motor Driver Removal/Installation • Subthrottle motor driver is the internal circuit of the ECU. Subthrottle motor driver itself can not be removed from the ECU. Subthrottle Motor Driver Inspection •...
  • Page 182: Oxygen Sensor - Incorrect Output Voltage (service Code 94)

    3-98 FUEL SYSTEM (DFI) Oxygen Sensor – Incorrect Output Voltage (Service Code 94) Oxygen Sensor Removal/Installation • Refer to Oxygen Sensor Removal and Installation in the Electrical System chapter. Oxygen Sensor Inspection • Warm up the engine thoroughly. • Turn the ignition SW OFF. •...
  • Page 183: Oxygen Sensor Heater Inspection

    FUEL SYSTEM (DFI) 3-99 Oxygen Sensor – Incorrect Output Voltage (Service Code 94) 1. ECU 5. Battery 2. Oxygen Sensor 6. Joint Connector 3. Decompression Fuse 10A 7. Frame Ground 4. ECU Main Fuse 30A Oxygen Sensor Heater Inspection • Set the hand tester [A] to the ×...
  • Page 184: Fi Indicator Led Light

    3-100 FUEL SYSTEM (DFI) FI Indicator LED Light Inspection Flow Chart...
  • Page 185: Led Light Inspection

    FUEL SYSTEM (DFI) 3-101 FI Indicator LED Light LED Light Inspection ○ The FI indicator LED light [A] goes ON when the ignition SW is turned ON and the LED light goes OFF when the engine oil pressure is high enough (the engine is running). This is to ensure that the FI indicator LED light has not burned out and the DFI system and the ignition system function properly.
  • Page 186: Ecu

    3-102 FUEL SYSTEM (DFI) ECU Removal CAUTION Never drop the ECU, especially on a hard surface. Such a shock to the ECU can damage it. • Remove: Seats (see Frame chapter) Rear Shock Absorber (see Suspension chapter) Tool Case (see Frame chapter) •...
  • Page 187 FUEL SYSTEM (DFI) 3-103 • Check the power source voltage of the ECU with a digital voltmeter. ECU Power Source Inspection Meter Connection: between 13 (W/Y) Terminal and Battery (–) Terminal Ignition SW OFF: Ignition SW ON: Battery Voltage (12.5 V or more) If the voltmeter does not read as specified, check the fol- lowing: Power Source Wiring (see wiring diagram of DFI Power...
  • Page 188: Fuel Line

    3-104 FUEL SYSTEM (DFI) Fuel Line Fuel Pressure Inspection NOTE ○ This inspection can determine which trouble the DFI system has, mechanical or electrical trouble. ○ It is preferable to measure the fuel pressure while run- ning the motorcycle when the trouble has occurred in order to know symptom well.
  • Page 189 FUEL SYSTEM (DFI) 3-105 Fuel Line • Install the fuel pressure gauge adapter [A] (special tool) between the fuel tank outlet pipe [B] and the inlet pipe [C] to the delivery joint [D]. ○ Put the fuel pressure gauge adapter outside the frame. •...
  • Page 190 3-106 FUEL SYSTEM (DFI) Fuel Line • Start the engine, and let it idle. • Measure the fuel pressure with the engine idling. Fuel Pressure (idling) Standard: 304 kPa (3.1 kgf/cm², 44 psi) NOTE ○ The gauge needle will fluctuate. Read the pressure at the average of the maximum and minimum indications.
  • Page 191: Fuel Flow Rate Inspection

    FUEL SYSTEM (DFI) 3-107 Fuel Line • Push and pull [A] the fuel hose joint [B] back and forth more than two times and make sure it is locked and doesn’t come off. WARNING Make sure the fuel hose joint is installed correctly on the delivery pipe or the fuel could leak.
  • Page 192 3-108 FUEL SYSTEM (DFI) Fuel Line • Prepare a plastic hose of the inside diameter 7.5 mm × L about 400 mm and a measuring cylinder. • Remove: Seat (see Frame chapter) Fuel Tank Bolts • Raise the fuel tank. •...
  • Page 193: Throttle Grip And Cables

    FUEL SYSTEM (DFI) 3-109 Throttle Grip and Cables Throttle Grip Free Play Inspection • Refer to Throttle Control System Check in the Periodic Maintenance Chapter. Throttle Grip Free Play Adjustment • Loosen the locknuts [A] and screw the adjusters [B] all the way in so as to give the throttle grip plenty of play.
  • Page 194: Throttle Body Assy

    3-110 FUEL SYSTEM (DFI) Throttle Body Assy Idle Speed Check • Refer to Idle Speed Check in the Periodic Maintenance Chapter. Idle Speed Adjustment • Refer to Idle Speed Check in the Periodic Maintenance Chapter. Throttle Bore Cleaning • Check the throttle bore for cleanliness as follows: ○...
  • Page 195 FUEL SYSTEM (DFI) 3-111 Throttle Body Assy • Remove the screws and take off the right switch housing. • Remove the accelerator cable end [A] and decelerator cable end [B] at the throttle grip. • Disconnect the injection connectors [A]. •...
  • Page 196: Throttle Body Assy And Intake Manifold Installation

    3-112 FUEL SYSTEM (DFI) Throttle Body Assy ○ Be careful not to damage (dent, nick, flaw, and crack) the flange mating surface and the plastic parts. ○ Do not drop the throttle body assy, especially on a hard surface. WARNING The throttle body assy should never be allowed to fall.
  • Page 197 FUEL SYSTEM (DFI) 3-113 Throttle Body Assy • Before Installation, visually inspect the mating surfaces [A] for any damage, like dent, nick, rust, flaw, and crack. • Nick or rust damage can sometimes be repaired by using emery paper (first No. 200, then 400) to remove sharp edges or raised areas.
  • Page 198 3-114 FUEL SYSTEM (DFI) Throttle Body Assy • Apply a thin coating of grease to the throttle cable upper ends. • Install the upper ends of the throttle cables in the grip. • Fit the projection [A] of the right switch housing into the hole [B] of the handlebar (front view).
  • Page 199: Air Cleaner

    FUEL SYSTEM (DFI) 3-115 Air Cleaner Element Removal • Remove: Air Cleaner Cover Screws [A] Air Cleaner Cover [B] • Unscrew the air cleaner element scerw [A] and remove the air cleaner element [B]. WARNING If dirt or dust is allowed to pass through into the throttle assy, the throttle may become stuck, possi- bly causing an accident.
  • Page 200: Air Cleaner Housing Installation

    3-116 FUEL SYSTEM (DFI) Air Cleaner Air Cleaner Housing Installation • Check that oil is in the breather drain cap [A]. If necessary, drain the oil in the cap. • Fit the idle speed screw [A] in the recess [B] on the air cleaner housing.
  • Page 201: Fuel Tank

    FUEL SYSTEM (DFI) 3-117 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 202 3-118 FUEL SYSTEM (DFI) Fuel Tank • Unscrew the screw [A] and pull [B] out the cover [C]. • Disconnect: Fuel Level Sensor Connector [A] Meter Connector [B] Fuel Pump Connector [C] • Free the leads from the clamps [D]. •...
  • Page 203: Fuel Tank Installation

    FUEL SYSTEM (DFI) 3-119 Fuel Tank • Close the fuel tank cap. • Remove the fuel tank from the vehicle, and place it on a flat surface. CAUTION For California model, if gasoline, solvent, water or any other liquid enters the canister, the canister’s vapor absorbing capacity is greatly reduced.
  • Page 204 3-120 FUEL SYSTEM (DFI) Fuel Tank • Check that the rubber dampers [A] are in place. If the dampers are damaged or deteriorated, replace them. • Pull [A] the joint lock [B] fully as shown. • Insert the fuel hose joint [A] straight onto the tank outlet pipe [B].
  • Page 205: Fuel Tank And Cap Inspection

    FUEL SYSTEM (DFI) 3-121 Fuel Tank • Push and pull [A] the hose joint [B] up and down more than two times and make sure it is locked and doesn’t come off. WARNING Make sure the hose joint is installed correctly on the delivery pipe, or the fuel could leak.
  • Page 206: Evaporative Emission Control System

    3-122 FUEL SYSTEM (DFI) Evaporative Emission Control System The Evaporative Emission Control System for California Model routes fuel vapors from the fuel system into the run- ning engine or stores the vapors in a canister when the en- gine is stopped. Although no adjustments are required, a thorough visual inspection must be made at the intervals specified by the Periodic Maintenance Chart.
  • Page 207 FUEL SYSTEM (DFI) 3-123 Evaporative Emission Control System Separator Operation Test WARNING Gasoline is extremely flammable and can be explo- sive under certain conditions. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light.
  • Page 208 3-124 FUEL SYSTEM (DFI) Evaporative Emission Control System...
  • Page 209 COOLING SYSTEM 4-1 Cooling System Table of Contents Exploded View........................Coolant Flow Chart......................... Specifications ......................... Special Tools and Sealant ...................... Coolant ........................... Coolant Deterioration Inspection..................Coolant Level Inspection....................Coolant Draining ....................... Coolant Filling ........................Pressure Testing ....................... Cooling System Flushing ....................Water Pump..........................
  • Page 210: Exploded View

    4-2 COOLING SYSTEM Exploded View...
  • Page 211 COOLING SYSTEM 4-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Water temperature sensor (DFI) 104 in·lb Water pipe bolts 87 in·lb Radiator fan bolts 0.85 74 in·lb Reserve tank bolts 0.70 61 in·lb Radiator cover bolts 97 in·lb Water pump impeller bolt 104 in·lb Water pipe drain bolt 87 in·lb...
  • Page 212: Coolant Flow Chart

    4-4 COOLING SYSTEM Coolant Flow Chart Permanent type antifreeze is used as a coolant to protect the cooling system from rust and corrosion. When the engine starts, the water pump turns and the coolant circulates. The thermostat is a wax pellet type which opens or closes as coolant temperature changes. The thermostat continuously changes its valve opening to keep the coolant temperature at the proper level.
  • Page 213 COOLING SYSTEM 4-5 Coolant Flow Chart 1. Water Pump 8. Radiator Fan 2. Water Hose 9. Reserve Tank 3. Water Pipe 10. Cylinder 4. Thermostat 11. Water Jacket 5. Radiator Cap 12. Cylinder Head 6. Reserve Tank Hose 13. Cold Coolant 7.
  • Page 214: Specifications

    4-6 COOLING SYSTEM Specifications Coolant provided when shipping: Type (recommended) Permanent type antifreeze (soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators) Color Green Mixed ratio Soft water 50%, coolant 50% Freezing point −...
  • Page 215: Special Tools And Sealant

    COOLING SYSTEM 4-7 Special Tools and Sealant Bearing Driver Set : Bearing Remover Head, 10 x 12 : 57001–1129 57001–1266 Bearing Remover Shaft : 57001–1265...
  • Page 216: Coolant

    4-8 COOLING SYSTEM Coolant Coolant Deterioration Inspection • Visually inspect the coolant [A] in the coolant level hose [B] (In the photo, the muffler have been removed for clar- ity). If whitish cotton-like wafts are observed, aluminum parts in the cooling system are corroded. If the coolant is brown, iron or steel parts are rusting.
  • Page 217: Cooling System Flushing

    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 considerably reduce the effi- ciency of the cooling system.
  • Page 218: Water Pump

    4-10 COOLING SYSTEM Water Pump Water Pump Removal • Drain the coolant (see Coolant Change in the Periodic Maintenance chapter). • Remove: Muffler (see Engine Top End chapter) Exhaust Pipe (see Engine Top End chapter) Outer Transmission Cover (see Crankshaft/Transmis- sion chapter) Inner Transmission Cover (see Crankshaft/Transmis- sion chapter)
  • Page 219: Mechanical Seal Replacement

    COOLING SYSTEM 4-11 Water Pump Mechanical Seal Replacement • Remove the water pump impeller (see Water Pump Re- moval in this chapter). • Pry the mechanical seal flange off with a small chisel [A]. • Pull the mechanical seal out of the right crankcase with needle nose pliers.
  • Page 220 4-12 COOLING SYSTEM Water Pump ○ Be sure to replace the mechanical seal, oil seal, O-ring, and ball bearings with new ones because these parts will be damaged by removal. • Apply plenty of high temperature grease to the oil seal lips.
  • Page 221: Radiator

    COOLING SYSTEM 4-13 Radiator WARNING The radiator fan is connected directly to the bat- tery. The radiator fan may start even if the ignition switch is off. NEVER TOUCH THE RADIATOR FAN UNTIL THE RADIATOR FAN CONNECTOR IS DIS- CONNECTED. TOUCHING THE FAN BEFORE THE CONNECTOR IS DISCONNECTED COULD CAUSE INJURY FROM THE FAN BLADES.
  • Page 222: Radiator Installation

    4-14 COOLING SYSTEM Radiator • Lift up the radiator to clear the stoppers. • Remove the radiator. CAUTION Do not touch the radiator core. This could damage the radiator fins, resulting in loss of cooling effi- ciency. • Remove: Radiator Fan Bolts [A] Radiator Fan [B] Radiator Installation •...
  • Page 223: Radiator Cap Inspection

    COOLING SYSTEM 4-15 Radiator Radiator Cap Inspection • Check the condition of the top and bottom valve seals of the radiator cap. If any one of them shows visible damage, replace the cap. Bottom Valve Seal [A] Top Valve Seal [B] Valve Spring [C] •...
  • Page 224: Thermostat

    4-16 COOLING SYSTEM Thermostat Thermostat Removal • Remove: Coolant : Drain about 200 mL Fuel Tank (see Fuel System chapter) • Pull back throttle body harness connector [A] out of the bracket [B], pushing the thin plate [C] to right side. Water Hoses [D] Bracket Bolts [E] Water Temperature Sensor Connector [F]...
  • Page 225: Thermostat Inspection

    COOLING SYSTEM 4-17 Thermostat Thermostat Inspection • Remove the thermostat, and inspect the thermostat valve at room temperature. If the valve is open, replace the valve with a new one. • To check valve opening temperature, suspend the ther- mostat [A] and an accurate thermometer [B] in a container of water with the heat-sensitive portions [C] in almost the same depth.
  • Page 226: Hoses And Pipes

    4-18 COOLING SYSTEM Hoses and Pipes Hose Installation • Install the hoses and pipes being careful to follow bend- ing direction. Avoid sharp bending, kinking, flattening, or twisting. • Install the clamps [A] as near as possible to the hose end to clear the raised rib on the fitting.
  • Page 227 ENGINE TOP END 5-1 Engine Top End Table of Contents Exploded View........Ball Bearing and Outer Race Specifications ........Replacement ......5-29 Special Tools and Sealant ....5-11 Ball Bearing Wear ......5-29 Clean Air System....... 5-13 Cam Wear........5-30 Air Suction Valve Removal...
  • Page 228 5-2 ENGINE TOP END Exploded View...
  • Page 229 ENGINE TOP END 5-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Rocker case cover bolts 104 in·lb S, AL Rocker case bolts Oil pipe banjo bolts Oil pipe bolts 87 in·lb Upper cylinder head nuts, 10 mm first, S, MO Upper cylinder head nuts, 10 mm final, S, MO Upper cylinder head nuts, 12 mm...
  • Page 230 5-4 ENGINE TOP END Exploded View...
  • Page 231 ENGINE TOP END 5-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Rocker shaft bolts 104 in·lb Cylinder mounting bolts Coolant drain bolt 87 in·lb Push rod cover bolts 104 in·lb Camshaft chain guide bolts 104 in·lb Camshaft chain tensioner bolts 104 in·lb Inner camshaft cover bolts 104 in·lb...
  • Page 232 5-6 ENGINE TOP END Exploded View...
  • Page 233 ENGINE TOP END 5-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Muffler bracket bolts Muffler cover clamp screws 61 in·lb R: Replacement Parts CAL: California Model EU: Europian Models...
  • Page 234 5-8 ENGINE TOP END Specifications Item Standard Service Limit Push Rod: Push rod length 295.18 mm (11.6212 in.) – – – Push rod bend TIR 0.2 mm (0.008 in.) – – – Camshafts: Cam height: Front Exhaust 37.351 ~ 37.467 mm 37.25 mm (1.47051 ~ 1.47508 in.) (1.4665 in.)
  • Page 235 ENGINE TOP END 5-9 Specifications Item Standard Service Limit Valve guide inside diameter: Exhaust 6.000 ~ 6.012 mm 6.08 mm (0.2394 in.) (0.23622 ~ 0.23669 in.) Inlet 6.000 ~ 6.012 mm 6.08 mm (0.2394 in.) (0.23622 ~ 0.23669 in.) Valve/valve guide clearance (wobble method): Exhaust 0.07 ~ 0.12 mm...
  • Page 236 5-10 ENGINE TOP END Specifications Item Standard Service Limit Valve seat surface: Valve seat cutting angle 45°, 32°, 60° – – – Outside diameter: Exhaust 34.9 ~ 35.1 mm – – – (1.374 ~ 1.382 in.) Inlet 38.9 ~ 39.1 mm –...
  • Page 237 ENGINE TOP END 5-11 Special Tools and Sealant Valve Guide Reamer, 6 : Compression Gauge Adapter, M14 x 1.25 : 57001–1596 57001–1590 Valve Guide Arbor, 5.7 : Spark Plug Wrench, Hex 16 : 57001–1564 57001–1262 Compression Gauge : Piston Ring Compressor Grip : 57001–221 57001–1095 Valve Spring Compressor Assembly :...
  • Page 238 5-12 ENGINE TOP END Special Tools and Sealant Valve Seat Cutter, 60° – 41 : Valve Seat Cutter 45° – 40 : 57001–1124 57001–1496 Valve Seat Cutter Holder, 6 : Valve Seat Cutter 32° – 44 : 57001–1576 57001–1515 Piston Pin Puller Assembly: Valve Seat Cutter Holder Bar : 57001–1568 57001–1128...
  • Page 239: Clean Air System

    ENGINE TOP END 5-13 Clean Air System Air Suction Valve Removal • Remove the rocker case covers (see this chapter). • Remove the air suction valves. Front Rocker Case [A] Front Air Suction Valve [B] Air Suction Valve Installation • Install each air suction valve so that its wider side [A] of the reed faces left.
  • Page 240 5-14 ENGINE TOP END Clean Air System Clean Air System Hose Inspection • Be certain that all the hoses are routed without being flat- tened or kinked, and are connected correctly to the right air cleaner base, air switching valve, and fittings on the rocker case covers If they are not, correct them.
  • Page 241 ENGINE TOP END 5-15 Rocker Case Cover Rocker Case Cover Removal • Remove the engine (see Engine Removal/Installation chapter). • Remove the rocker case cover bolts and take off the rocker case cover from the rocker case. Front Rocker Case Cover Bolts [A] and Washers [B] Front Rocker Case Cover [C] Front [D] Rocker Case Cover Installation...
  • Page 242 5-16 ENGINE TOP END Rocker Case Rocker Case Removal • Remove the engine (see Engine Removal/Installation chapter). • Remove the throttle body assy (see Fuel System (DFI) chapter). • Remove the rocker case covers (see this chapter). • Position the #1 or #2 piston TDC as follows. ○...
  • Page 243 ENGINE TOP END 5-17 Rocker Case ○ Another way to position each piston at TDC is as follows. ○ Remove the outer camshaft cover and camshaft end cover (see Decompression Mechanism Removal in this chapter). ○ Turn the crankshaft couterclockwise and position #1 pis- ton at TDC, aligning [A] the projection [B] on the middle camshaft cover with the front decompression pin [C].
  • Page 244 5-18 ENGINE TOP END Rocker Case NOTE ○ Mark and record the rocker shafts so that they can be reinstalled in their original positions. If the rocker shaft does not be pulled out easily, pull it out by tightening the removed rocker shaft bolt [A] into the shaft [B].
  • Page 245 ENGINE TOP END 5-19 Rocker Case • Replace the O-rings [A] on each oil pipe [B] with new ones and grease them. • Torque the oil pipe bolts. Torque - Oil Pipe Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) • Be sure the dowel pins [A] on each cylinder head are in position.
  • Page 246 5-20 ENGINE TOP END Rocker Case ○ Another way to position each piston at TDC is as follows. ○ Remove the outer camshaft cover and camshaft end cover (see Decompression Mechanism Removal in this chapter). ○ Turn the crankshaft couterclockwise and position #1 pis- ton at TDC, aligning [A] the projection [B] on the middle camshaft cover with the front decompression pin [C].
  • Page 247 ENGINE TOP END 5-21 Rocker Case Rocker Arm Assembly • Prepare a flat-end bar [A] and a block [B] with a recess [C]. • Press the oil chamber [D] for the HLA into the rocker arm end [E] until the chamber end is even with the step [F] of the hole.
  • Page 248 5-22 ENGINE TOP END Rocker Case HLA Installation • Check that the HLA plunger is not damaged. If the plunger does damage, replace the HLA. HLA Body [A] O-ring [B] Plunger Spring [C] Pivot Plunger [D] Check Valve Spring [F] •...
  • Page 249 ENGINE TOP END 5-23 Decompression Mechanism Decompression Mechanism Removal • Remove the right side cover (see Frame chapter). • Loosen the clamps [A]. • Disconnect the decompression solenoid lead connector [B]. • Unscrew the outer camshaft cover bolts [A] and remove the outer camshaft cover [B].
  • Page 250 5-24 ENGINE TOP END Decompression Mechanism Decompression Mechanism Installation • Be sure the dowel pins [A] are in position. • Apply molybdenum disulfide oil to the rubbing surfaces [A] of the decompression shaft ends [B]. Holder [C] Spring [D] Front Camshaft [E] Rear Camshaft [F] •...
  • Page 251 ENGINE TOP END 5-25 Decompression Mechanism • Be sure that the decompression lever [A] moves back end forth [B] smoothly. • Position the grommet [A] and route the decompression solenoid leads [B] and bend [C] the clamp. • Install the outer camshaft cover. Torque - Outer Camshaft Cover Bolts: 12 N·m (1.2 kgf·m, 104 in·lb) Oil Seal Inspection...
  • Page 252 5-26 ENGINE TOP END Camshafts Camshaft Removal • Remove the engine (see Engine Removal/Installation chapter). • Remove the rocker cases (see this chapter). • Remove: Push Rods [A] Pipes [B] • Remove the outer camshaft cover and camshaft end cover (see Compression Release Mechanism Removal in this chapter).
  • Page 253 ENGINE TOP END 5-27 Camshafts Camshaft Installation • Push [A] the chain tensioner ratchet [B] and push down [C] the tensioner shoe [D]. CAUTION Be careful the oil remaining in the tensioner body dashes out. • Engage the first teeth [A] of the ratchet [B] with second groove [C] of the plunger [D].
  • Page 254 5-28 ENGINE TOP END Camshafts • Install the front [A] and rear [B] camshafts. • Install the camshaft chain [C]. ○ Align the crankshaft timing mark [D] with the middle link of three blue colored links [E] and camshaft timing marks [F] with the blue colored links [G].
  • Page 255: Engine Top End

    ENGINE TOP END 5-29 Camshafts • Be sure the dowel pins [A] are in position. • Install the new gasket [B]. NOTE ○ Pull the stopper pin [C] after installing the middle camshaft cover (see below). • Install the middle camshaft cover [A]. Torque - Middle Camshaft Cover Bolts (Length: 95 mm, 105mm): 12 N·m (1.2kgf·m, 104 in·lb) Middle Camshaft Cover Bolts (Length: 35 mm): 12...
  • Page 256 5-30 ENGINE TOP END Camshafts Cam Wear • Remove the camshaft (see Camshaft Removal). • Measure the height [A] of each cam with a micrometer. If the cams are worn down past the service limit, replace the camshaft. Cam Height Inlet (Front) Exhaust (Front) Standard:...
  • Page 257: Cylinder Head

    ENGINE TOP END 5-31 Cylinder Head Cylinder Compression Measurement NOTE ○ Be sure the battery is fully charged. • Warm up the engine thoroughly. • Stop the engine. • Remove the fuel tank (see Fuel System (DFI) chapter). • Remove one spark plug and attach the compression gauge and adapter firmly into the spark plug hole.
  • Page 258 5-32 ENGINE TOP END Cylinder Head The following table should be consulted if the obtainable compression reading is not within the us- able range. Problem Diagnosis Remedy (Action) Carbon buildup on piston and in combustion Remove the carbon deposits chamber possibly due to damaged valve stem, and replace damaged parts if valve guide, stem oil seal and/or damaged necessary.
  • Page 259 ENGINE TOP END 5-33 Cylinder Head • Remove the lower cylinder head nuts [A]. • Take the cylinder heads [B] off the cylinders [C]. Cylinder Head Installation CAUTION The cylinder head and rocker case are machined in the assembled state, so they must be used as a set. •...
  • Page 260 5-34 ENGINE TOP END Cylinder Head • Be sure the dowel pins [A] are in position. • Replace the cylinder head gaskets [B]. ○ The front gasket has an “F” mark [C] while the rear gasket has an “R” mark [D]. ○...
  • Page 261 ENGINE TOP END 5-35 Cylinder Head Valve Removal • Remove the cylinder head (see this chapter). • Swing open the rocker arm. • Using the valve spring compressor assembly, remove the valve. Special Tools - Valve Spring Compressor Assembly: 57001 -241 [A] Valve Spring Compressor Adapter, 28.2:...
  • Page 262 5-36 ENGINE TOP END Cylinder Head Valve Guide Wear (Wobble Method) ○ If a small bore gauge is not available, inspect the valve guide wear by measuring the valve-to-guide clearance with the wobble method as indicated below. The reading is not actual valve-to-guide clearance because the mea- suring point is above the guide.
  • Page 263 ENGINE TOP END 5-37 Cylinder Head ○ The marks stamped on the back of the cutter [A] represent the following. 55° ......Cutter Angle [B] 37.5 ......Outer Diameter of Cutter [C] If the manufacturer’s instructions are not available, use the following procedure.
  • Page 264 5-38 ENGINE TOP END Cylinder Head • Measure the outside diameter [A] of the seat surface (seat O.D.) with vernier calipers. If the seat O.D. is too small, repeat the 45° grind [B] until the diameter is within the specified range. Ground Voluum [C] NOTE ○...
  • Page 265 ENGINE TOP END 5-39 Cylinder Head • Lap the valve to the seat, once the seat width and O.D. are within the ranges specified above. ○ Put a little coarse grinding compound on the face of the valve in a number of places around the valve head. ○...
  • Page 266 5-40 ENGINE TOP END Cylinder Head...
  • Page 267 ENGINE TOP END 5-41 Cylinders, Piston Cylinder Removal • Remove the cylinder head (see this chapter). • Remove the coolant drain plug [A] and washer [B] to drain the coolant from the front cylinder [C]. • Remove the cylinder mounting bolt [A]. •...
  • Page 268 5-42 ENGINE TOP END Cylinders, Piston Cylinder, Piston Installation NOTE ○ The oil ring rails have no “top” or “bottom”. • Install the oil ring expander [A] in the bottom piston ring groove so the ends [B] butt together. • Install the oil ring steel rails, one above the expander and one below it.
  • Page 269 ENGINE TOP END 5-43 Cylinders, Piston • 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. • Apply molybdenum disulfide oil to the outer surface of the piston pin.
  • Page 270 5-44 ENGINE TOP END Cylinders, Piston Cylinder Wear • Since there is a difference in cylinder wear in different di- rections, take a side-to-side and a front-to-back measure- ment at each of the three locations (total of six measure- ments) shown in the figure. If any of the cylinder inside diameter measurements ex- ceeds the service limit, replace the cylinder.
  • Page 271 ENGINE TOP END 5-45 Cylinders, Piston Piston Ring Groove Width • Measure the width of the top [A] and second [B] ring grooves. ○ Use vernier calipers at several points around the piston. Piston Ring Groove Width Standard Service Limit 1.225 ~ 1.240 mm 1.32 mm (0.048228 ~ 0.048819 in.) (0.05197 in.)
  • Page 272 5-46 ENGINE TOP END Mufflers Upper Muffler Removal • Remove: Right Side Cover [A] (see Frame chapter) Clamp Screws [B] (Loosen) Clamp Bolt [C] • Detach the clamps [D] by sliding them up or forward. • Remove the upper exhaust pipe cover [E]. •...
  • Page 273 ENGINE TOP END 5-47 Mufflers • Free the O sensor lead [A] from the clamps [B] and dis- connect the O sensor lead connector [C] (California, Eu- rope and UK model). • Remove the exhaust pipe holder nuts [A]. • Remove the exhaust pipe [B].
  • Page 274 5-48 ENGINE TOP END Mufflers • Be sure that the tabs on the muffler are fitted [A] into the slots on the clamps. • Install the claws [A] on the exhaust pipe cover ends [B] into the slots [C] on the clamps [D]. •...
  • Page 275 CLUTCH 6-1 Clutch Table of Contents Exploded View........................Specifications ......................... Special Tools and Sealant ...................... Clutch Lever and Cable ......................Lever Free Play Inspection ....................Clutch Cable Removal ...................... Clutch Cable Installation ....................Clutch Cable Lubrication....................Clutch Lever Installation....................Clutch ............................. Outer Clutch Cover Removal ....................
  • Page 276: Exploded View

    6-2 CLUTCH Exploded View...
  • Page 277 L: Apply a non-permanent locking agent. G: Apply grease. MO: Apply molybdenum disulfide oil. R: Replacement Parts S: Follow the specific tightening sequence. Si: Apply silicone grease or PBC grease. LG: Apply liquid gasket (Kawasaki Bond: 56019-120). CL: Apply cable lubricant.
  • Page 278: Specifications

    6-4 CLUTCH Specifications Item Standard Service Limit Clutch Lever Free Play 3 mm (0.08 0.12 in.) – – – Clutch Clutch spring free length 81.17 mm (3.20 in.) 77.5 mm (3.05 in.) Clutch plate assembly length 51.32 52.32 mm (2.02 ~ 2.06 in.) –...
  • Page 279: Special Tools And Sealant

    CLUTCH 6-5 Special Tools and Sealant Clutch Holder: Flywheel & Pulley Holder Adapter: 57001–1243 57001–1547 Flywheel & Pulley Holder: Kawasaki Bond (Liquid Gasket-Black): 57001–1343 92104–1064...
  • Page 280: Clutch Lever And Cable

    6-6 CLUTCH Clutch Lever and Cable Lever Free Play Inspection • Refer to Clutch in the Periodic Maintenance chapter. Clutch Cable Removal • Free the clutch cable [A] from the clamps [B]. • Loosen the locknut [A] at the middle of the clutch cable. •...
  • Page 281: Outer Clutch Cover Removal

    CLUTCH 6-7 Clutch Outer Clutch Cover Removal • Drain the engine oil (see Engine Lubrication System in the Periodic Maintenance chapter). • Remove the left footboard (see Frame chapter). • Remove: Clutch Cable (see this chapter). Release Lever Bolt [A] Release Lever [B] Outer Clutch Cover Bolts [C] Outer Clutch Cover [D]...
  • Page 282: Release Shaft Removal

    6-8 CLUTCH Clutch • Turn the release shaft [A] clockwise [B] (viewed from H) until it stops. • Insert the release lever [C] to the release shaft. ○ Align the projection [D] on the outer clutch cover [E] with the slit [F] of the release lever. •...
  • Page 283: Clutch Removal

    CLUTCH 6-9 Clutch Clutch Removal • Drain the engine oil (see Engine Lubrication System in the Periodic Maintenance chapter). • Remove the outer clutch cover (see this chapter). • Remove: Plate Bolts [A] Plate [B] Oil Pipe [C] • Remove: Clutch Spring Bolts [A] Clutch Spring Plate [B] (with Springs) •...
  • Page 284 6-10 CLUTCH Clutch • Remove the spacer [A] from the drive shaft [B]. • Remove the outside and middle covers on the inside cover [A] (see Final Drive chapter). • Remove the left downtube (see Frame chapter). • Remove: Inner Clutch Cover Bolts [B] Inner Clutch Cover [C] •...
  • Page 285 CLUTCH 6-11 Clutch • Remove: Spring Retainer [A] Holder [B] and Springs [C] (as a set) • Remove the damper cam [A] from the crankshaft. • Pull [A] the clutch housing [B] and the sprocket [C] with the primary reduction chain [D]. •...
  • Page 286: Clutch Installation

    6-12 CLUTCH Clutch Clutch Installation • Install the washer [A] to the crankshaft [B]. ○ Align the punch mark [C] on the washer with the punch mark [D] on the crankshaft. • Apply molybdenum disulfide oil to the hatched portion [E] of the washer.
  • Page 287 CLUTCH 6-13 Clutch • Put the spacer [A] on the sprocket [B] so that its dint [C] side faces outward as shown. ○ To prevent the spacer from dropping when the sprocket installing, apply grease to the spacer. Do not grease the oil passages [D].
  • Page 288 6-14 CLUTCH Clutch • Apply [A] molybdenum disulfide oil to the X-mark portions of the cam damper [B] and install it to the crankshaft [C]. • Install: Spring Holder [D] and Springs [E] Spring Retainer [F] and Cam Damper Bolt [G] •...
  • Page 289 Apply liquid gasket [A] to the mating surface of the inner clutch cover [B]. NOTE ○ Make the application finish 20 minutes when the liquid gasket to the mating surface of the inner clutch cover is applied. Sealant - Kawasaki Bond (Liquid Gasket-Black): 92104–1064...
  • Page 290 6-16 CLUTCH Clutch • Install the inner clutch cover. • Tighten the inner clutch cover bolts to a snug fit. • First, torque the No.1 bolt and torque from the No.2 to the No.14, following the tightening order. • For the No.9, 10, 11, bolts, torque them again. NOTE ○...
  • Page 291: Starter Clutch Disassembly

    CLUTCH 6-17 Clutch Starter Clutch Disassembly • Remove the clutch housing with the one-way clutch (see this chapter). • Remove the following from the clutch housing [A]. Plate [B] One-way Clutch [C] Washer [D] Needle Bearing [E] Starter Clutch Assembly •...
  • Page 292: Starter Torque Limiter Check

    6-18 CLUTCH Clutch Starter Torque Limiter Check • Remove the torque limiter (see Clutch Removal in this chapter) and visually inspect it. If the limiter has wear, discoloration, or other damage, replace it as a set. Gear [A] Friction Plates [B] Spring [C] Pinion [D] Primary Chain Wear...
  • Page 293: Clutch Plate Assembly Adjustment

    CLUTCH 6-19 Clutch Clutch Plate Assembly Adjustment • Inspect the clutch plate assembly length, and then re- place the steel plate(s) which brings the length within the specified range. ○ Remove: Spring Bolts Spring Holders Springs Spring Plate ○ Replace the following steel plate(s). Part No.
  • Page 294: Clutch Housing Finger Inspection

    6-20 CLUTCH Clutch Clutch Housing Finger Inspection • Visually inspect the fingers [A] of the clutch housing where the tangs [B] of the friction plates hit them. If they are badly worn or if there are groove cuts where the tangs hit, replace the housing.
  • Page 295 ENGINE LUBRICATION SYSTEM 7-1 Engine Lubrication System Table of Contents Engine Oil Flow Chart......................Exploded View........................Specifications ......................... Special Tools and Sealant ...................... Engine Oil and Oil Filter......................Oil Level Inspection......................Engine Oil Change......................Oil Filter Replacement ...................... Oil Pump and Oil Line......................7-10 Oil Pump Removal ......................
  • Page 296: Engine Oil Flow Chart

    7-2 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart...
  • Page 297 ENGINE LUBRICATION SYSTEM 7-3 Engine Oil Flow Chart A. Feeding Oil Flow B. Scavenging Oil Flow 1. Oil in Transmission Room 2. Oil Screen 3. Feed Pump 4. Oil Pressure Switch 5. Oil Filter 6. Relief Valve 7. To Left Side Crankshaft 8.
  • Page 298: Exploded View

    7-4 ENGINE LUBRICATION SYSTEM Exploded View...
  • Page 299 28. Feed pump EO: Apply engine oil. G: Apply grease. L: Apply a non-permanent locking agent. MO: Apply molybdenum disulfide oil. R: Replacement Parts SS: Apply silicone sealant (Kawasaki Bond: 56019-120 for oil pressure switch). (Three Bond: TB1211F for oil pan)
  • Page 300: Specifications

    7-6 ENGINE LUBRICATION SYSTEM Specifications Item Standard Engine Oil: Type API Service Classification : SE, SF or SG class API Service Classification : SH or SJ class with JASO MA Viscosity SAE 10W-40 Capacity 4.4 L (4.7 US qt, when filter is not removed) 4.6 L (4.9 US qt, when filter is removed) 5.5 L (5.8 US qt, when engine is completely disassembled and dry)
  • Page 301: Special Tools And Sealant

    ENGINE LUBRICATION SYSTEM 7-7 Special Tools and Sealant Oil Pressure Gauge, 5 kg/cm² : Oil Filter Wrench : 57001–125 57001–1249 Oil Pressure Gauge Adapter, PT 1/8 : Kawasaki Bond (Silicone Sealant) : 57001–1033 56019–120...
  • Page 302: Engine Oil And Oil Filter

    7-8 ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter Because of the semi-dry sump lubrication system, the en- gine oil level indicated on the dipstick will fluctuate depend- ing on the motorcycle’s position and engine speed when the engine is shut off. To ensure a proper reading of the engine oil level, follow the Oil Level Inspection procedures closely.
  • Page 303: Oil Filter Replacement

    ENGINE LUBRICATION SYSTEM 7-9 Engine Oil and Oil Filter Oil Filter Replacement • Refer to Oil Filter Replacement in the Periodic Mainte- nance Chapter.
  • Page 304: Oil Pump And Oil Line

    7-10 ENGINE LUBRICATION SYSTEM Oil Pump and Oil Line Oil Pump Removal • Remove the engine (see Engine Removal/Installation chapter). • Split the crankcase (see Crankshaft/Transmission chap- ter). • Remove: Circlip [A] Oil Pump Sprocket [B] Pin [C] Washer [D] Oil Pump Cover Bolts [E] Oil Pump Cover [F] CIrclip [G]...
  • Page 305 ENGINE LUBRICATION SYSTEM 7-11 Oil Pump and Oil Line • Install the scavenge oil pump for the clutch room oil. ○ Install the outer rotor [A], pin [B] and inner rotor [C]. • Install the oil pump body [A]. ○ Be sure the dowel pin [B] is in position.
  • Page 306: Oil Pan

    7-12 ENGINE LUBRICATION SYSTEM Oil Pan Oil Pan Removal • Drain the engine oil (see Engine Lubrication System in the Periodic Maintenance chapter). • Disconnect the oil pressure switch lead from the terminal screw (see Oil Pressure Measurement). • Remove: Oil Pan Bolts [A] Oil Pan [B] Front [C]...
  • Page 307 ENGINE LUBRICATION SYSTEM 7-13 Oil Pan • Install the oil screen for crankcase room [A]. ○ Install the holder [B] to the oil pan [C],noting holder direc- tion. ○ Torque the oil screen bolt. Torque - Oil Screen Bolt: 9.8 N·m (1.0 kgf·m, 87 in·lb) •...
  • Page 308: Blowby Gas System Inspection

    7-14 ENGINE LUBRICATION SYSTEM Oil Pan Blowby Gas System Inspection • Be certain that the hose is routed without being flattened or kinked, and is connected correctly to the air cleaner base. If it is not, correct it. • Inspect the breather hose [A], breather pipe [B], and the air cleaner drain cap for damage or signs of deterioration.
  • Page 309: Oil Pressure

    When installing the oil pressure switch, apply silicone sealant to the threads of the switch, and tighten it to the specified torque. Torque - Oil Pressure Switch: 15 N·m (1.5 kgf·m, 11 ft·lb) Sealant - Silicone Sealant (Kawasaki Bond: 56019-120)
  • Page 310: Relief Valve Inspection

    7-16 ENGINE LUBRICATION SYSTEM Oil Pressure Relief Valve Inspection • Split the crankcase (see Crankshaft/Transmission chap- ter). • Remove the relief valve [A] from the left crankcase half [B]. • Check to see if the valve slides smoothly when pushing it in with a wooden or other soft rod, and see if it comes back to its seat by spring pressure.
  • Page 311 ENGINE REMOVAL/INSTALLATION 8-1 Engine Removal/Installation Table of Contents Exploded View........................Specifications ......................... Engine Removal/Installation ....................Engine Removal........................ Engine Installation......................8-10...
  • Page 312: Exploded View

    8-2 ENGINE REMOVAL/INSTALLATION Exploded View...
  • Page 313 ENGINE REMOVAL/INSTALLATION 8-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front downtube nuts S, AL Upper adjusting bolt 87 in·lb Lower adjusting bolt 87 in·lb Upper adjusting bolt locknut Lower adjusting bolt locknut Upper rear engine mounting nut Lower rear engine mounting nut Upper engine bracket nuts S, AL Upper engine mounting bolts...
  • Page 314: Specifications

    8-4 ENGINE REMOVAL/INSTALLATION Specifications Jack : Jack Attachment: 57001–1238 57001–1571 Socket Wrench: 57001–1347...
  • Page 315: Engine Removal/installation

    ENGINE REMOVAL/INSTALLATION 8-5 Engine Removal/Installation Engine Removal • Support the rear part of the frame on the jack [A] and the attachment jack [B]. Special Tools - Jack: 57001-1238 Jack Attachment : 57001-1571 • Squeeze the brake lever slowly and hold it with a band [A].
  • Page 316 8-6 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Remove: Spark Plug Caps [A] Clamp [B] Ignition Coil Bracket [C] (Place it on the frame.) Engine Bracket Bolts [D] Engine Bracket [E] • Disconnect the horn lead connectors [A]. • Disconnect: Alternator Lead Connector [A] Crankshaft Sensor Lead Connector [B] Side Stand Switch Lead Connector [C] Oil Pressure Switch Terminal [D]...
  • Page 317 ENGINE REMOVAL/INSTALLATION 8-7 Engine Removal/Installation • Unscrew the Allen bolt [A] and disconnect the starter mo- tor lead terminal [B]. • Disconnect: Rear Brake Switch Connector [A] Regulator/Rectifier Connectors [B] • Support the engine with a commercially available stand [A]. •...
  • Page 318 8-8 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Remove: Clamp [A] Radiator Hose Pipe Bolts [B] Radiator Hose Pipe [C] • Remove the bolts [A] holding the ower’s tool box [B] and move it to left side. • Remove: Rear Engine Mounting Bolts and Nuts [A] •...
  • Page 319 ENGINE REMOVAL/INSTALLATION 8-9 Engine Removal/Installation • Move [A] the engine forward a little. • Disconnect the following hoses. Canister Purge Hose [A] (Green, California Model, to Air Switching Valve Hose) Reserve Tank Hose [B] (Brown, to Thermostat Housing) Fuel Tank Breather Hose [C] (Blue) Fuel Tank Return Hose [D] (Red, California Model) Vacuum Hose [E] (White, California Model, to Throttle Body Assy)
  • Page 320: Engine Installation

    8-10 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation Engine Installation • Support the engine with a suitable stand. • Set the collar [A] and insert the lower rear engine mount- ing bolt. • Torque the fasteners following the specified sequence. Torque - Front Downtube Nuts [1]: 88 N·m (9.0 kgf·m, 65 ft·lb) Upper Adjusting Bolt [2]: 9.8 N·m (1.0 kgf·m, 87 in·lb)
  • Page 321 ENGINE REMOVAL/INSTALLATION 8-11 Engine Removal/Installation • Install the removed parts (see appropriate chapters). • Adjust the throttle cables (see Fuel System chapter). • Fill the engine with engine oil (see Periodic Maintenance chapter). • Fill the engine with coolant and bleed the air from the cooling system (see Periodic Maintenance chapter).
  • Page 323 CRANKSHAFT/TRANSMISSION 9-1 Crankshaft/Transmission Table of Contents Exploded View........Transmission ........9-30 Specifications ........Shift Pedal Removal ....9-30 Special Tools and Sealants ....Shift Pedal Installation ....9-30 Crankcase ......... External Shift Mechanism CrankcaseDisassembly ....Removal ........9-31 Crankcase Assembly ....9-11 External Shift Mechanism Starter Clutch Disassembly..
  • Page 324 9-2 CRANKSHAFT/TRANSMISSION Exploded View...
  • Page 325 EO: Apply engine oil. L: Apply a non-permanent locking agent. LG: Apply liquid gasket (Kawasaki Bond: 92104-1064). MO: Apply molybdenum disulfide oil to the threads and the seating surface. The molybdenum disul- fide oil is a mixture of engine oil and molybdenum disulfide grease with a weight ratio (10 : 1).
  • Page 326 9-4 CRANKSHAFT/TRANSMISSION Exploded View...
  • Page 327 CRANKSHAFT/TRANSMISSION 9-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Outer transmission cover bolts 104 in·lb S, see text Inner transmission cover bolts 104 in·lb S, see text Transfer gear nut (Output shaft) 20.0 R, MO, Lh Transfer gear nut (Pulley shaft) R, MO Gear set lever nut 69 in·lb...
  • Page 328 9-6 CRANKSHAFT/TRANSMISSION Specifications Item Standard Service Limit Crankshaft, Connecting Rods: Connecting rod bend – – – TIR 0.2/100 mm (0.08/3.94 in.) Connecting rod twist – – – TIR 0.2/100 mm (0.08/3.94 in.) Connecting rod big end side clearance 0.08 ~ 0.30 mm 0.5 mm (0.0031 ~ 0.0118 in.) (0.0197 in.)
  • Page 329 CRANKSHAFT/TRANSMISSION 9-7 Specifications Item Standard Service Limit Transmission Shift fork ear thickness 6.9 ~ 7.0 mm 6.8 mm (0.272 ~ 0.276 in.) (0.268 in.) Gear shift fork groove width 7.05 ~ 7.15 mm 7.3 mm (0.278 ~ 0.281 in.) (0.287 in.) Shift fork guide pin diameter 5.9 ~ 6.0 mm 5.8 mm...
  • Page 330: Special Tools And Sealants

    9-8 CRANKSHAFT/TRANSMISSION Special Tools and Sealants Outside Circlip Pliers : Flywheel & Pulley Holder : 57001–144 57001–1343 Gear Holder : Kawasaki Bond (Liquid Gasket – Black) : 57001–1574 92104–1064 Bearing Driver Set : Flywheel & Pulley Holder Adapter 57001–1129 57001–1547...
  • Page 331 CRANKSHAFT/TRANSMISSION 9-9 Crankcase Crankcase Disassembly • Drain the engine oil (see Periodic Maintenance chapter). • Remove: Engine (see Engine Removal/Installation chapter) Cylinder Blocks (see Engine Top End chapter) Pistons (see Engine Top End chapter) Starter Motor (see Electrical System chapter) Camshafts (see Engine Top End chapter) Balancer Mechanism (see this chapter) External Shift Mechanism (see this chapter)
  • Page 332 9-10 CRANKSHAFT/TRANSMISSION Crankcase • Remove the left crankcase bolts. 8 mm Bolts (1) [A] 6 mm Bolts (12) [B] • Remove the right crankcase bolts. 8 mm Bolts (1) [A] 6 mm Bolts (12) [B] • Turn the right crankcase down. •...
  • Page 333 CRANKSHAFT/TRANSMISSION 9-11 Crankcase • Remove the following from the right crankcase. Balancer Shafts [A] Crankshaft [B] Transmission Gear Assy [C] (see Transmission Re- moval) Pulley Shaft [D] Water Pump Shaft [E] (see Cooling System chapter) • Remove the following from the left crankcase. Oil Pump Shaft [F] (see Engine Lubrication System chapter) Relief Valve [G] (see Engine Lubrication System chap-...
  • Page 334 9-12 CRANKSHAFT/TRANSMISSION Crankcase ○ For the drive shaft bearing [A], press [B] the bearing on the left crankcase [C] so that its sealed side [D] faces downward. • Press the needle bearing with manufacturer’s mark facing out into hole on the left side of the left crankcase. Push the needle bearing outer race until the face of the bearing is even with the end of the hole, using a driver.
  • Page 335 CRANKSHAFT/TRANSMISSION 9-13 Crankcase • Install the bearing retainer. Bearing Retainer [A] Bearing Retainer Bolts [B] Left Crankcase Half (Inside) [C] • Install the relief valve [D]. • Apply a non-permanent locking agent to the thread of the relief valve and torque it. Torque - Relief Valve: 9.8 N·m (1.0 kgf·m, 87 in·lb) •...
  • Page 336 9-14 CRANKSHAFT/TRANSMISSION Crankcase ○ Position the right side connecting rod [A] to the front and left side connecting rod [B] to the rear as shown. ○ Install the front [A] and rear [B] balancers so that their splined shaft ends face downward (toward the right crankcase half), noting the shapes [C] of their opposite shaft end.
  • Page 337 CRANKSHAFT/TRANSMISSION 9-15 Crankcase • Apply liquid gasket [A] to the mating surface of the left crankcase [B]. Sealant - Kawasaki Bond (Liquid Gasket-Black): 92104-1064 ○ Be sure liquid gasket is applied to the lower ends [C] in- dicated in the figure.
  • Page 338 9-16 CRANKSHAFT/TRANSMISSION Crankcase • Tighten the right crankcase bolts as follows. ○ First, tighten the 8 mm bolts [A], and next, 6 mm bolts [B] temporarily. ○ First, torque the 8 mm bolts, and next, 6 mm bolts. Torque - 8 mm Crankcase Bolts: 29 N·m (3.0 kgf·m, 22 ft·lb) 6 mm Crankcase Bolts: 12 N·m (1.2 kgf·m, 8.8 ft·lb) •...
  • Page 339 CRANKSHAFT/TRANSMISSION 9-17 Crankcase ○ Check that the positive neutral finder operates propely: While spinning [A] the output shaft [B] using an air impact wrench, gears shift smoothly from the 1st, 2nd • • • 5th gear , and 5th, 4th • • • 1st. When the output shaft stays still, the gear can be shifted to only the 1st gear or neutral.
  • Page 340 9-18 CRANKSHAFT/TRANSMISSION Crankcase • Install: Oil Pan (see Engine Lubrication System) Oil Filter (see Periodic Maintenance chapter) Alternator Rotor (see Electrical System chapter) Clutch (see Clutch chapter) Exhaust Shift Mechanism (see this chapter) Balancer Mechanism (see this chapter) Camshaft (see Engine Top End chapter) Starter Motor (see Electrical System chapter) Pistons (see Engine Top End chapter) Engine (see Engine Removal/Installation chapter)
  • Page 341 CRANKSHAFT/TRANSMISSION 9-19 Crankshaft/Connecting Rods Connecting Rod Removal • Remove the crankshaft. • Remove the connecting rod big end bolts, and take off the rod and cap along with the bearing inserts from the crankshaft [A]. NOTE ○ Mark and record the locations of the connecting rods [B] and their big end caps [C] with the bearing inserts left attached so that they can be installed in their original positions.
  • Page 342 9-20 CRANKSHAFT/TRANSMISSION Crankshaft/Connecting Rods ○ When installing the inserts [A], be careful not to damage the insert surface with the edge of the connecting rod [B] or the cap [C]. One way to install inserts is as follows: Installation [D] to Cap Installation [E] to Connecting Rod Push [F] Dowel Pin [G]...
  • Page 343 CRANKSHAFT/TRANSMISSION 9-21 Crankshaft/Connecting Rods Connecting Rod Bend • Remove the connecting rod big end bearing inserts, and reinstall the connecting rod big end cap. • Select an arbor [A] of the same diameter as the connect- ing rod big end, and insert the arbor through the connect- ing rod big end.
  • Page 344 9-22 CRANKSHAFT/TRANSMISSION Crankshaft/Connecting Rods Connecting Rod Big End Bearing Wear • Remove the big end cap and place a strip of plastigage on the crankpin [A]. • Tighten the big end nuts to the specified torque to com- press the plastigage and measure the plastigage width [B] to determine the bearing insert/crankpin clearance (see Camshaft/Rocker Case Wear in the Engine Top End chapter).
  • Page 345 CRANKSHAFT/TRANSMISSION 9-23 Crankshaft/Connecting Rods • Temporarily, install the big end cap and tighten the big end bolts to the specified torque. Molybdenum Disulfide Oil - Threads and Flanged Portion of Big End Bolts Torque - Connecting Rod Big End Bolts: 59 N·m (6.0 kgf·m, 43 ft·lb) •...
  • Page 346 9-24 CRANKSHAFT/TRANSMISSION Crankshaft/Connecting Rods Crankshaft Main Bearing/Journal Wear • Measure the diameter [A] of the crankshaft main journal. Crankshaft Main Journal Diameter Standard: 56.986 ~ 57.000 mm (2.2435 ~ 2.2441 in) Service Limit: 56.96 mm (2.2425 in) If any journal has worn past the service limit, replace the crankshaft with a new one.
  • Page 347 CRANKSHAFT/TRANSMISSION 9-25 Balancer Mechanism Balancer Mechanism Removal • Drain the engine oil (see Periodic Maintenance chapter). • Remove: Engine (see Engine Removal/Installation chapter) Rocker Cases (see Engine Top End chapter) Camshafts (see Engine Top End chapter) Inner Clutch Cover (see Clutch chapter) •...
  • Page 348 9-26 CRANKSHAFT/TRANSMISSION Balancer Mechanism • Remove the balancer chain sprocket [A] and balancer sprockets [B] with the chain [C]. Balancer Mechanism Installation • Align the marks [A] on the following with the colored chain link [B] as shown. Balancer Chain Sprocket [C] Front Balancer Sprocket [D] Rear Balancer Sprocket [E] •...
  • Page 349 CRANKSHAFT/TRANSMISSION 9-27 Balancer Mechanism • Temporally tighten the balancer chain sprocket nut [A] and balancer sprocket bolts [B]. ○ Put the washers [C] to the balancer shafts [D]. ○ Put the washer [E] to the crankshaft so that its “OUT SIDE”...
  • Page 350 9-28 CRANKSHAFT/TRANSMISSION Balancer Mechanism • Install: Chain Guides [A] Chain Tensioner [B] Torque - Upper and Lower Balancer Chain Guide Bolts [C]: 12 N·m (1.2 kgf·m, 8.7 ft·lb) Balancer Chain Tensioner Bolts [D]: 12 N·m (1.2 kgf·m, 8.7 ft·lb) • Pull the stopper pin [E] out of the chain tensioner body.
  • Page 351 CRANKSHAFT/TRANSMISSION 9-29 Balancer Mechanism • Torque the camshaft oil pipe bolt [A]. Torque - Camshaft Oil Pipe Bolt: 9.8 N·m (1.0 kgf·m, 87 in·lb) • Be sure the following are in position. Spacer [B] O-ring [C] Dowel Pins [D] • Install the inner camshaft cover and torque the inner camshaft cover bolts.
  • Page 352 9-30 CRANKSHAFT/TRANSMISSION Transmission Shift Pedal Removal • Unscrew the rear shift pedal clamp bolt [A] and take off the rear shift pedal [B]. • Unscrew the bolts [A] and remove the left footboard [B]. • Unscrew the rear shift lever bolt [A] and remove the front shift pedal [B] with the shift rod [C].
  • Page 353 CRANKSHAFT/TRANSMISSION 9-31 Transmission • Install the front the rear shift pedal on the front shift pedal shaft so that the punched mark [A] on the rear shift pedal boss is aligned with the punched mark [B] on the front shift pedal shaft.
  • Page 354 9-32 CRANKSHAFT/TRANSMISSION Transmission • Unscrew the bolts [A] and remove the water pipes [B]. • Remove the bolts [C] and pull down the rear master cylin- der [D] with the hoses. • Remove: Reserver Tank Cap Gear Position Sensor Lead Connector Inner Transmission Cover Bolts [E] Inner Transmission Cover [F] •...
  • Page 355 CRANKSHAFT/TRANSMISSION 9-33 Transmission ○ Apply the spring end [A] to the wall [B] of water pump room. • Put the washer [A] on the shift shaft [B] and install the shift mechanism assy [C]. • Be sure that the spring [A] and pin [B] are in position. •...
  • Page 356 9-34 CRANKSHAFT/TRANSMISSION Transmission • Apply grease to the O-rings and install the water pipes. Torque - Water Pipe Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) • Be sure the dowel pins [A] are in position. • Replace the gasket with a new one. •...
  • Page 357 CRANKSHAFT/TRANSMISSION 9-35 Transmission External Shift Mechanism Inspection • Examine the shift shaft [A] for any damage. If the shaft is bent, straighten or replace it. If the serrations [B] are damaged, replace the shaft. If the spring [C] [D] is damaged in any way, replace it. If the shift mechanism arm [E] is damaged in any way, replace the arm with the shaft.
  • Page 358 9-36 CRANKSHAFT/TRANSMISSION Transmission ○ Instal the shift forks as shown. ○ Position the one with larger rib [A] on the drive shaft and place the pin in the center groove in the shift drum [B]. ○ The two forks [C] on the output shaft are identical. ○...
  • Page 359 CRANKSHAFT/TRANSMISSION 9-37 Transmission Transmission Assembly • Install the gear bushing [A] on the shafts with their oil holes [B] aligned. CAUTION Do not apply grease to the steel balls to hold them in place. This will cause the positive neutral finder mechanism to malfunction.
  • Page 360 9-38 CRANKSHAFT/TRANSMISSION Transmission Shift Fork/Gear Groove Wear • Measure the thickness of the shift fork ears [A], and mea- sure the width [B] of the gear grooves. If the thickness of a shift fork ear is less than the service limit, the shift fork must be replaced.
  • Page 361 CRANKSHAFT/TRANSMISSION 9-39 Transmission 1. Drive Shaft 10. Five Circlips 2. Low (1st) Gear (26.9 × 32.2 × t1.5) 3. 3rd Gear 11. Bushing (Top Gear) 4. 4th Gear 12. Four Splined Washers 5. Top (5th) Gear (30.3 × 40 × t1.5) 6.
  • Page 362 9-40 CRANKSHAFT/TRANSMISSION Ball Bearing, Needle Bearing, and Oil Seal Ball Bearing and Outer Race Replacement CAUTION Do not remove the ball bearing or needle bearing outer race unless it is necessary. Removal may damage them. • Using a press or puller, remove the ball bearing and/or needle bearing outer race.
  • Page 363 CRANKSHAFT/TRANSMISSION 9-41 Ball Bearing, Needle Bearing, and Oil Seal Oil Seal Inspection • Inspect the oil seal. Replace it if the lips are misshapen, discolored (indicating that the rubber has deteriorated), hardened or otherwise damaged.
  • Page 365 WHEELS/TIRES 10-1 Wheels/Tires Table of Contents Exploded View........................10-2 Specifications ......................... 10-4 Special Tools .......................... 10-5 Wheels (Rims) ........................10-6 Front Wheel Removal ....................... 10-6 Front Wheel Installation ....................10-7 Rear Wheel Removal......................10-8 Rear Wheel Installation..................... 10-9 Wheel Inspection ......................10-10 Axle Inspection........................
  • Page 366: Exploded View

    10-2 WHEELS/TIRES Exploded View...
  • Page 367 WHEELS/TIRES 10-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front axle nut Front axle clamp bolts Rear axle nut Tire air valve caps 0.15 0.015 1.3 in·lb Tire air valve nuts 0.15 13 in·lb G: Apply grease. R: Replacement Parts AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque.
  • Page 368: Specifications

    10-4 WHEELS/TIRES Specifications Item Standard Service Limit Wheels (Rims): Rim runout: Axial – – – TIR 0.5 mm (0.02 in.) Radial – – – TIR 0.8 mm (0.03 in.) Axle runout/100 mm TIR 0.05 mm (0.002 in.) or less TIR 0.2 mm (0.008 in.) Wheel balance 10 g (0.35 oz.) or less –...
  • Page 369: Special Tools

    WHEELS/TIRES 10-5 Special Tools Inside Circlip Pliers : Bearing Remover Head, 25 x 28 : 57001–143 57001–1346 Bearing Driver Set : Bearing Remover Shaft, 13 : 57001–1129 57001–1377 Jack : Jack Attachment : 57001–1238 57001–1571 Bearing Remover Head, 20 x 22 : 57001–1293...
  • Page 370: Wheels (rims)

    10-6 WHEELS/TIRES Wheels (Rims) Front Wheel Removal • Unscrew the front brake caliper mounting bolts [A] and remove the brake calipers [B] with the hose installed. • Loosen: Front Axle Clamp Bolts (Right Side Only) [A] Front Axle [B] ○ Using the special tool jack [A] and the jack attachment [B] under the frame pipe, and a commercially available jack [C] under the engine, lift the front wheel off the ground...
  • Page 371: Front Wheel Installation

    WHEELS/TIRES 10-7 Wheels (Rims) Front Wheel Installation • Apply grease to the seal lips. • Fit the collars [A] on the both side of the hub. The collars are identical. • Insert the axle from the right side of the wheel. •...
  • Page 372: Rear Wheel Removal

    10-8 WHEELS/TIRES Wheels (Rims) Rear Wheel Removal • Remove: Muffler (see Engine Top End chapter) Rear Fender (see Frame chapter) Upper Belt Cover (see Frame chapter) • Using the jack [A] and jack attachment [B] under the frame pipe, lift the rear wheel off the ground. CAUTION Be sure to put the front wheel ON the ground when removing the rear wheel, or the motorcycle may fall...
  • Page 373: Rear Wheel Installation

    WHEELS/TIRES 10-9 Wheels (Rims) • Pull out the axle, and move the rear wheel toward the front [A] to disengage the wheel from the drive belt [B]. • Move the rear wheel back and remove it. CAUTION Do not lay the wheel directly on the ground with the disc facing down.
  • Page 374: Wheel Inspection

    10-10 WHEELS/TIRES Wheels (Rims) • Bend the cotter pin [A] over the nut as shown. • Visually inspect the tire for stuck any grease. If any grease have stuck to the surface of the tire, wash the tire clean with soap and water solution. •...
  • Page 375: Axle Inspection

    WHEELS/TIRES 10-11 Wheels (Rims) • Remove the wheel, and support it without the tire by the axle. • Measure the rim runout, radiator [A] and axial [B], with a dial gauge. If the rim runout exceeds the service limit, check the hub bearings.
  • Page 376: Balance Adjustment

    10-12 WHEELS/TIRES Wheels (Rims) Balance Adjustment If the wheel always stops in one position, provisionally attach a balance weight [A] on the rim at the marking using adhesive tape. WARNING Use only the genuine balance weights. • Rotate the wheel 1/4 turn [B], and see whether or not the wheel stops in this position.
  • Page 377: Balance Weight Installation

    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 378: Tires

    10-14 WHEELS/TIRES Tires Air Pressure Inspection/Adjustment • Refer to Tire Inspection in the Periodic Maintenance chap- ter. Tire Inspection • Refer to Tire Inspection in the Periodic Maintenance chap- ter. Tire Removal • Remove the following. Wheel (see Front Wheel Removal, Rear Wheel Re- moval) Brake Disc (see Brakes chapter) Valve Core (let out the air)
  • Page 379 WHEELS/TIRES 10-15 Tires • Install a new valve in the front wheel rim. ○ Remove the valve cap, lubrication the stem seal [A] with a soap and water solution or rubber lubricant, and pull the valve stem [B] through the rim [C] from the inside out until it snaps into place.
  • Page 380 10-16 WHEELS/TIRES Tires • Apply a soap and water solution, or rubber lubricant to the rim flange and tire beads. CAUTION Never lubricate with mineral oil (engine oil) or gaso- line because they will cause deterioration of the tire. • Check the tire rotation mark on the front and rear tires and install them on the rim accordingly.
  • Page 381: 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 382: Hub Bearings (wheel Bearings)

    10-18 WHEELS/TIRES Hub Bearings (Wheel Bearings) Hub Bearings Removal • Remove the wheel, and take out the following. Collars Grease Seals [A] Circlips [B] Coupling [C] (Out of Rear Hub) Front Hub [D] Rear Hub [E] Special Tool - Inside Circlip Pliers: 57001-143 •...
  • Page 383: Hub Bearings Inspection

    WHEELS/TIRES 10-19 Hub Bearings (Wheel Bearings) ○ Replace the circlips with new ones. Special Tool - Inside Circlip Pliers: 57001-143 • Replace the grease seals with new ones. • Press in the grease seals [A] so that the seal surface is flush [B] with the end of the hole.
  • Page 385 FINAL DRIVE 11-1 Final Drive Table of Contents Exploded View........................11-2 Specifications ......................... 11-4 Special Tools .......................... 11-5 Drive Belt ..........................11-6 Belt Handling Precautions....................11-6 Drive Belt Wear Inspection ....................11-7 Drive Belt Deflection Inspection ..................11-7 Drive Belt Deflection Adjustment ..................11-7 Drive Belt Removal ......................
  • Page 386: Exploded View

    11-2 FINAL DRIVE Exploded View...
  • Page 387 FINAL DRIVE 11-3 Exploded View Front Gear Case Torque Fastener Remarks N·m kgf·m ft·lb Engine pulley inside cover bolts 104 in·lb Engine pulley mounting nut Rear axle nut Rear coupling stud bolts Ring screws 0.70 61 in·lb Rear pulley mounting nuts G: Apply grease.
  • Page 388: Specifications

    11-4 FINAL DRIVE Specifications Item Standard Service Limit Drive Belt: Make – – – GATES, 133T Belt deflection (44.1 N, 4.5 kgf force) 4.0 mm (0.10 0.16 in.) – – – (When installing new belt or engine is 2.5 mm (0.10 in.) –...
  • Page 389: Special Tools

    FINAL DRIVE 11-5 Special Tools Inside Circlip Priers : Pulley Holder : 57001–143 57001–1572 Oil Seal & Bearing Remover: Grip : 57001–1058 57001–1591 Bearing Driver Set : 57001–1129...
  • Page 390: Drive Belt

    11-6 FINAL DRIVE Drive Belt The drive belt must be checked, and adjusted in accor- dance with the Periodic Maintenance Chart for safety and to prevent excessive wear. If the belt becomes badly worn or maladjusted – either too loose or too tight – the belt could jump off the pulley or break.
  • Page 391: Drive Belt Wear Inspection

    FINAL DRIVE 11-7 Drive Belt • Do not twist [A] the drive belt [B] as shown. ○ This includes coiling the belt to make it smaller for pack- aging. • Do not use tools [A] to pry [B] the drive belt [C] onto the application.
  • Page 392: Drive Belt Installation

    11-8 FINAL DRIVE Drive Belt Drive Belt Installation • Installation is reverse of removal. Note the following NOTE ○ Be sure the printed information faces the same direction so the belt rotates in the same direction as originally in- stead. When installing a new belt, install it so the printed information can be read from left side of the motorcycle.
  • Page 393: Pulley And Coupling

    FINAL DRIVE 11-9 Pulley and Coupling Engine Pulley Cover Removal • Remove: Bolt [A] Outside Cover [B] • Remove: Bolts [A], Washers and Dampers Middle Cover [B] • Remove: Bolts [A] Inside Cover [B] and Guide Engine Pulley Cover Installation •...
  • Page 394: Engine Pulley Removal

    11-10 FINAL DRIVE Pulley and Coupling • Confirm the position of the damper [A] in the middle cover [B] as shown. • Install: Middle Cover [A] Dampers [B] Washers [C] Bolts [D] • Confirm the position of the damper [A] in the middle cover [B] as shown.
  • Page 395: Engine Pulley Installation

    FINAL DRIVE 11-11 Pulley and Coupling • Hold the engine pulley [A] steady with the pulley holder [B], and remove the pulley mounting nut [C], Special Tool - Pulley Holder: 57001–1572 Grip: 57001–1591 • Pull out the engine pulley from the output shaft. Engine Pulley Installation •...
  • Page 396: Rear Pulley Coupling Removal

    11-12 FINAL DRIVE Pulley and Coupling Rear Pulley Coupling Removal • Remove: Rear Wheel (see Wheels/Tires chapter) • Loosen (lightly): Rear Pulley Mounting Nuts [A] • Remove the rear pulley [B] with the rear pulley coupling from the wheel. • Remove: Rear Pulley Mounting Nuts and Washers •...
  • Page 397: Pulley Wear Inspection

    FINAL DRIVE 11-13 Pulley and Coupling Pulley Wear Inspection • Visually inspect the engine and rear pulley teeth for wear and damage. If the teeth are worn, damage, or loss of the chrome plat- ing exists, replace the pulley, and inspect the drive belt wear (see Drive Belt Wear Inspection in Periodic Mainte- nance chapter).
  • Page 398: Coupling Bearing Installation

    11-14 FINAL DRIVE Pulley and Coupling Coupling Bearing Installation • Apply grease to the new ball bearing. • Press the ball bearing until it is bottomed. Special Tool - Bearing Driver Set: 57001-1129 • Install: Circlip Special Tool - Inside Circlip Pliers: 57001-143 •...
  • Page 399 BRAKES 12-1 Brakes Table of Contents Exploded View........12-2 Rear Brake Pad Removal .... 12-13 Specifications ........12-6 Rear Brake Pad Installation ..12-13 Special Tool ........12-7 Brake Pad Wear Inspection ..12-13 Brake Lever, Brake Pedal....12-8 Master Cylinder ......... 12-14 Brake Lever Position Adjustment.
  • Page 400 12-2 BRAKES Exploded View...
  • Page 401 BRAKES 12-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Brake hose banjo bolts Front brake reservoir cap screws 0.15 13 in·lb Brake lever pivot bolt 0.10 87 in·lb Brake lever pivot bolt locknut 0.60 52 in·lb Front brake light switch screw 0.12 10 in·lb Front master cylinder clamp bolts...
  • Page 402 12-4 BRAKES Exploded View...
  • Page 403 BRAKES 12-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Rear master cylinder mounting bolts Rear master cylinder push rod locknut Brake hose banjo bolts Brake pedal clamp bolt Caliper bleed valves 69 in·lb Rear caliper mounting bolts Brake disc bolts B: Apply brake fluid.
  • Page 404 12-6 BRAKES Specifications Item Standard Service Limit Brake Lever, Brake Pedal: Brake lever position No.1 5-way adjustable Brake lever free play Non-adjustable – – – Pedal free play Non-adjustable – – – Pedal position About 117 mm (4.61 in.) – – – (height from pedal top to footboard top) Brake Fluid: Grade...
  • Page 405 BRAKES 12-7 Special Tool Inside Circlip Pliers: 57001–143...
  • Page 406 12-8 BRAKES Brake Lever, Brake Pedal Brake Lever Position Adjustment The brake lever adjuster has 5 positions so that the brake lever position can be adjusted to suit the operator’s hand. • Push the lever forward and turn the adjuster [A] to align the number with the arrow mark [B] on the lever holder.
  • Page 407 BRAKES 12-9 Brake Lever, Brake Pedal • Remove: Right Footboard Bracket Front Bolt [A] Right Footboard Bracket Rear Bolt [B] Right Footboard Bracket Assembly [C] • Remove: Brake Lever Bolt [A] Brake Lever [B] Brake Pedal Return Spring [C] Brake Switch Return Spring [D] •...
  • Page 408 12-10 BRAKES Calipers Front Caliper Removal • Loosen the banjo bolt [A] at the brake hose lower end, and tighten it loosely. • Unscrew the caliper mounting bolts [B]. CAUTION Do not loosen the caliper assembly bolt [C]. Take out only the caliper mounting bolts for caliper re- moval.
  • Page 409 BRAKES 12-11 Calipers Rear Caliper Disassembly • Refer to Caliper Rubber Parts Replacement in the Peri- odic Maintenance chapter. Rear Caliper Assembly • Refer to Caliper Rubber Parts Replacement in Periodic Maintenance chapter. Caliper Fluid Seal Damage The fluid seal (piston seal) [A] is placed around the pis- ton to maintain clearance between the pad and the disc.
  • Page 410: Brake Pads

    12-12 BRAKES Brake Pads Front Brake Pad Removal • Loosen the front brake pad pin [A] lightly. • Remove the caliper mounting bolts [B] with the hose in- stalled. • Remove: Caliper [C] (with the hose installed) • Remove: Pad Spring Bolts [A] Pad Spring [B] •...
  • Page 411 BRAKES 12-13 Brake Pads Rear Brake Pad Removal • Remove the caliper with the hose installed (see Caliper Removal). • Remove: Snap Pin [A] Pad Pin [B] • Remove the jaw side pad [A], and then remove the piston side pad [B]. Jaw [C] Rear Brake Pad Installation •...
  • Page 412 12-14 BRAKES Master Cylinder Front Master Cylinder Removal • Disconnect the front brake light switch connector [A]. • Draw out the brake fluid from the reservoir with a means like the fork oil level gage. • Pull the bolt caps out. •...
  • Page 413 BRAKES 12-15 Master Cylinder Rear Master Cylinder Removal • Remove: Right Footboard (see Frame chapter) Muffler and Exhaust Manifold (see Engine Top End chapter) Rear Brake Light Switch Lead Connector (disconnect) Right Footboard Bracket Front Bolt [A] Right Footboard Bracket Rear Bolt [B] Right Footboard Bracket Assembly [C] •...
  • Page 414 12-16 BRAKES Master Cylinder Rear Master Cylinder Installation • Replace the cotter pin with a new one. • Install the washer [A]. • Insert the cotter pin [B] to the hole of the joint pin [C] and separate [D] the cotter pin ends. •...
  • Page 415 BRAKES 12-17 Master Cylinder Master Cylinder Inspection • Disassemble the front and rear master cylinders (see Pe- riodic Maintenance chapter). Special Tool - Inside CIrclip Pliers: 57001–143 • 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 416: Brake Discs

    12-18 BRAKES Brake Discs Brake Disc Removal • Remove the wheel (see Wheels/Tires chapter). • Unscrew the mounting bolts [A], and take off the disc. Brake Disc Installation • Install the brake disc [A] on the wheel so that the marked side [B] faces out.
  • Page 417: Brake Fluid

    BRAKES 12-19 Brake Fluid Brake Fluid Level Inspection • Refer to Brake Fluid Level Inspection in Periodic Mainte- nance chapter. Brake Fluid Change • Refer to Brake Fluid Change in Periodic Maintenance chapter. Brake Line Bleeding The brake fluid has a very low compression coefficient so that almost all the movement of the brake lever or pedal is transmitted directly to the caliper for braking action.
  • Page 418 12-20 BRAKES Brake Fluid • Remove the rubber cap from the bleed valve on the caliper. • Attach a clear plastic hose to the bleed valve, and run the other end of the hose into a container. • Bleed the brake line and the caliper as follows: ○...
  • Page 419 BRAKES 12-21 Brake Fluid WARNING When working with the disc brake, observe the pre- cautions listed below. 1. Never reuse old brake fluid. 2. Do not use fluid from a container that has been left unsealed or that has been open for a long time. 3.
  • Page 420 12-22 BRAKES Brake Hoses Brake Hose Removal/Installation CAUTION Brake fluid quickly ruins painted surfaces; any spilled fluid should be completely washed away immediately. • When removing the brake hose, take care not to spill the brake fluid on the painted or plastic parts. •...
  • Page 421 SUSPENSION 13-1 Suspension Table of Contents Exploded View........................13-2 Specifications ......................... 13-6 Special Tools .......................... 13-7 Front Fork ..........................13-8 Fork Oil Change........................ 13-8 Front Fork Removal ......................13-11 Front Fork Installation ....................... 13-11 Front Fork Disassembly ....................13-12 Front Fork Assembly......................13-13 Inner Tube, Outer Tube Inspection ...................
  • Page 422: Exploded View

    13-2 SUSPENSION Exploded View...
  • Page 423 SUSPENSION 13-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Upper front fork clamp bolts Lower front fork clamp bolts Cover stopper bolts 0.43 37 in·lb Front axle clamp bolts Front fork bottom Allen bolts L: Apply a non-permanent locking agent. R: Replacement Parts G: Apply grease.
  • Page 424 13-4 SUSPENSION Exploded View...
  • Page 425 SUSPENSION 13-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Rear shock absorber bolt and nut Swingarm pivot shaft nut G: Apply grease. R: Replacement Parts...
  • Page 426: Specifications

    13-6 SUSPENSION Specifications Item Standard Front Fork (per one unit): Fork inner tube diameter 49 mm ( 1.9 in.) Fork spring setting Non-adjustable Air pressure Atmospheric pressure (Non-adjustable) Rebound damper setting Non-adjustable Fork oil viscosity SAE 10W-20 Fork oil capacity: 605 ±...
  • Page 427: Special Tools

    SUSPENSION 13-7 Special Tools Inside Circlip Pliers: Jack : 57001–143 57001–1238 Fork Cylinder Holder Handle : Fork Oil Level Gauge : 57001–183 570101–1290 Fork Cylinder Holder Adapter : Jack Attachment : 57001–1057 57001–1571 Oil Seal & Bearing Remover : Hook Wrench : 57001–1058 57001–1580 Bearing Driver Set :...
  • Page 428: Front Fork

    13-8 SUSPENSION Front Fork Fork Oil Change • Remove: Front Wheel (see Wheels/Tires chapter) Front Fender (see Frame chapter) Nacelle (see Frame chapter) Handlebar (from handlebar clamp) • Loosen the front fork upper clamp bolt [A]. • Remove the cap [B]. •...
  • Page 429 SUSPENSION 13-9 Front Fork • Remove: Washer [A] Spring [B] • Drain the fork oil [A] into a suitable container. ○ Pump the inner tube up and down at least ten times to expel the oil from the fork. • Fill the front fork with the specified oil.
  • Page 430 13-10 SUSPENSION Front Fork • Install the fork spring with the smaller diameter end [A] facing down [B]. • Install: Washer • Install the front fork in the fork clamps, and tighten the lower fork clamp bolt only. Torque - Lower Front Fork Clamp Bolt: 34 N·m (3.5 kgf·m, 25 ft·lb) NOTE ○...
  • Page 431: Front Fork Removal

    SUSPENSION 13-11 Front Fork Front Fork Removal • Using the jack [A] and jack attachment [B] under the frame pipes, and a commercially available jack [C] under the engine, lift the front wheel off the ground until the rear wheel touches the ground. Special Tools - Jack: 57001-1238 Jack Attachment: 57001-1571 CAUTION...
  • Page 432: Front Fork Disassembly

    13-12 SUSPENSION Front Fork • Install the removed parts and tighten: Torque - Front Axle Nut: 127 N·m (13 kgf·m, 94 ft·lb) Front Axle Clamp Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb) Front Caliper Mounting Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb) NOTE ○...
  • Page 433: Front Fork Assembly

    SUSPENSION 13-13 Front Fork • Separate the inner tube from the outer tube as follows: ○ Remove the spring band [A] and dust seal [B] from the outer tube. ○ Remove the retaining ring [A] from the outer tube. ○ Holding the outer tube [A] by hand, pull the inner tube [B] several times to pull out the inner tube.
  • Page 434 13-14 SUSPENSION Front Fork • Put the cylinder unit [A] with the spring into the inner tube [B], protruding from the inner tube, and install the cylinder base [C] onto the bottom end of the cylinder unit. ○ Install the cylinder base with the tapered end [D] up. •...
  • Page 435: Inner Tube, Outer Tube Inspection

    SUSPENSION 13-15 Front Fork Inner Tube, Outer Tube Inspection • Visually inspect the inner tube [A] and repair any damage. • Nick or rust damage can sometimes be repaired by using a wet- stone to remove sharp edges or raised areas which cause seal damage.
  • Page 436: Rear Shock Absorber

    13-16 SUSPENSION Rear Shock Absorber Rebound Damping Force Adjustment • Remove the seats (see Frame chapter). • To adjust the rebound damping force, turn the rebound damping adjuster [A] to the desired position. ○ The standard adjuster setting for an average-build rider of 68 kg (150 lb) with no passenger and no accessories 6 clicks turns out of the fully clockwise position.
  • Page 437: Rear Shock Absorber Removal

    SUSPENSION 13-17 Rear Shock Absorber • Using the hook wrenches [A], Adjust the spring preload. Special Tool - Hook Wrench: 57001-1580 Spring Adjustment Spring Position Load Terrain Setting Speed Force 27.5 mm Weak Soft Light Smooth (1.08 in.) ↑ ↑ ↑...
  • Page 438: Rear Shock Absorber Installation

    13-18 SUSPENSION Rear Shock Absorber • Remove: Rear Shock Absorber Rear Mounting Bolt [A] and Nut ○ Lifting up the rear wheel a little, pull out the rear mounting bolt. • Remove: Rear Shock Absorber [B] Rear Shock Absorber Installation •...
  • Page 439: Swingarm

    SUSPENSION 13-19 Swingarm Swingarm Removal • Remove: Rear Wheel (see Wheels/Tires chapter) Rear Shock Absorber (see Rear Shock Absorber Re- moval) Rear Brake Caliper (see Brakes chapter) Mud Guard (see Frame chapter) Drive Belt Lower Cover (see Frame chapter) • Remove: Swingarm Pivot Shaft Nut [A] •...
  • Page 440: Swingarm Bearing Removal

    13-20 SUSPENSION Swingarm Swingarm Bearing Removal • Remove: Swingarm (see Swingarm Removal) Sleeve [A] and Collar [B] Left Side: • Remove: Oil Seal [A] • Remove: Circlip [A] Special Tool - Inside Circlip Pliers [B]: 57001-143 • Remove: Ball Bearing [A] Needle Bearing Special Tool - Oil Seal &...
  • Page 441: Swingarm Bearing Installation

    SUSPENSION 13-21 Swingarm Right Side: • Remove: Oil Seal [A] • Remove: Needle Bearing [A] Special Tool - Oil Seal & Bearing Remover [B]: 57001-1058 Upper Side: • Remove: Sleeve [A] Oil Seals [B] • Remove: Needle Bearing [A] Special Tool - Oil Seal & Bearing Remover [B]: 57001-1058 Swingarm Bearing Installation •...
  • Page 442: Swingarm Bearing, Sleeve Inspection

    13-22 SUSPENSION Swingarm Left Side: [A] Swingarm [B] Needle Bearing [C] 24 ± 0.4 mm (0.94 ± 0.016 in.) [D] Ball Bearing (until bottom end) [E] Circlip [F] Oil Seal [G] 1.5 ± 0.4 mm (0.059 ± 0.016 in.) [H] Collar Right Side: [A] Swingarm [B] Needle Bearing...
  • Page 443 STEERING 14-1 Steering Table of Contents Exploded View........................14-2 Special tools ........................... 14-4 Handlebar ..........................14-5 Handlebar Removal ......................14-5 Handlebar Installation ....................... 14-5 Steering ..........................14-7 Steering Check ......................... 14-7 Steering Adjustment......................14-7 Steering Stem......................... 14-8 Steering Stem Removal ....................14-8 Steering Stem Installation ....................
  • Page 444: Exploded View

    14-2 STEERING Exploded View...
  • Page 445 STEERING 14-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Handlebar clamp bolts O, S Handlebar holder nuts Steering stem head nut Upper front fork clamp bolts Steering stem nut 0.50 43 in·lb Lower front fork clamp bolts G: Apply grease. O: Apply 2 stroke oil.
  • Page 446: Special Tools

    14-4 STEERING Special tools Head Pipe Outer Race Press Shaft : Steering Stem Nut Wrench : 57001–1075 57001–1100 Head Pipe Outer Race Driver : Steering Stem Bearing Driver : 57001–1077 57001–1344 Head Pipe Outer Race Remover : Steering Stem Bearing Driver Adapter : 57001–1107 57001–1345...
  • Page 447: Handlebar

    STEERING 14-5 Handlebar Handlebar Removal • Remove: Headlight Upper Cover Bolts [A] Headlight Upper Cover [B] • Remove: Clutch Lever Assembly [A] Left Handlebar Switch Housing [B] • Remove: Front Brake Master Cylinder [A] Right Handlebar Switch Housing [B] Throttle Grip [C] •...
  • Page 448 14-6 STEERING Handlebar • Set the left handlebar switch housing [A] to match its mat- ing surface [B] to the punched mark [C] of the handlebar. • Install the handlebar switch housing. • Set the clutch lever assembly [A] to mutch its mating sur- face [B] to the punched mark [C] of the handlebar.
  • Page 449: Steering Check

    STEERING 14-7 Steering Steering Check • Refer to Steering Check in the Periodic Maintenance chapter. Steering Adjustment • Refer to Steering Adjustment in the Periodic Maintenance chapter.
  • Page 450: Steering Stem

    14-8 STEERING Steering Stem Steering Stem Removal • Remove the front wheel (see Tires/Wheels chapter). CAUTION Be sure to put the rear wheel on the ground when removing the steering, or the motorcycle may fall over. The motorcycle could be damaged. WARNING Be sure to put the rear wheel on the ground when removing the steering, or the motorcycle may fall...
  • Page 451: Steering Stem Installation

    STEERING 14-9 Steering Stem • Remove: Claw Washer [A] • Remove: Steering Stem Nut [A] Special Tool - Steering Stem Nut Wrench [B]: 57001-1100 • Remove: Oil Seal [C] • Remove: O-ring [A] NOTE ○ Be sure to remove the O-ring for removal of the steering stem.
  • Page 452: Steering Stem Warp

    14-10 STEERING Steering Stem • Install the claw washer. • Install the fork legs [A] and push it up tightly against the stem bottom. • Temporarily tighten the lower fork clamp bolts. • Install: Steering Stem Head [B] with Handlebar O-ring [C] Washer [D] Stem Head Nut [E]...
  • Page 453: Steering Stem Bearing

    STEERING 14-11 Steering Stem Bearing Stem Bearing Removal • Remove the steering stem (see this chapter). • Drive out the bearing outer races from the head pipe. Special Tool - Head Pipe Outer Race Remover [A]: 57001 -1107 NOTE ○ If either steering stem bearing is damaged, it is recom- mended that both the upper and lower bearings (includ- ing outer races) be replaced with new ones.
  • Page 454: Stem Cap Deterioration, Damage

    14-12 STEERING Steering Stem Bearing Stem Cap Deterioration, Damage Replace the stem cap if its grease seal [A] shows dam- age.
  • Page 455 FRAME 15-1 Frame Table of Contents Exploded View........................15-2 Special Tools .......................... 15-10 Seats ............................15-11 Rear Seat Removal......................15-11 Rear Seat Installation......................15-11 Front Seat Removal ......................15-11 Front Seat Installation ....................... 15-11 Side Covers ..........................15-12 Right Side Cover Removal....................15-12 Right Side Cover Installation.....................
  • Page 456: Exploded View

    15-2 FRAME Exploded View...
  • Page 457 FRAME 15-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front downtube nuts Upper engine bracket nuts Upper engine mounting bolts Lower engine bracket bolts Rear downtube bolts Side stand mounting bolt Side stand mounting nut Adjust bolts 87 in·lb Footboard bracket bolts Front engine mounting nut Adjusting bolt locknuts...
  • Page 458 15-4 FRAME Exploded View...
  • Page 459 FRAME 15-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Footpeg bracket bolts G: Apply grease.
  • Page 460 15-6 FRAME Exploded View...
  • Page 461 FRAME 15-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Muffler bracket mounting bolts CAL: California model...
  • Page 462 15-8 FRAME Exploded View...
  • Page 463 FRAME 15-9 Exploded View S: Follow the specific tightening sequence.
  • Page 464: Special Tools

    15-10 FRAME Special Tools Jack: 57001–1238 Jack Attachment: 57001–1571...
  • Page 465: Seats

    FRAME 15-11 Seats Rear Seat Removal • Remove: Right Side Cover (see Right Side Cover Removal) • Remove the rear seat [A] by pulling the looped seat latch [B] and then pulling the rear seat up to the front. Rear Seat Installation •...
  • Page 466: Side Covers

    15-12 FRAME Side Covers Right Side Cover Removal • Insert the ignition key [C] into the right side cover [A], and turn the key clockwise [B] until the key slot is vertical. • Pull the right side cover forward [D] to clear the hook [F], and then remove the side cover pulling it outward to clear the projections [E].
  • Page 467: Ignition Coil Bracket Cover Removal

    FRAME 15-13 Side Covers Ignition Coil Bracket Cover Removal • Remove: Ignition Coil Bracket Cover Screw [A] • Pull [B] the ignition coil bracket cover [C] evenly outward to clear the stoppers and remove the cover. Ignition Coil Bracket Cover Installation •...
  • Page 468: Fenders

    15-14 FRAME Fenders Front Fender Removal CAUTION Be careful not to scratch the painted surface during removal or installation. • Remove: Front Wheel (see Wheels/Tire chapter) Front Fender Bolts [A] Front Fender [B] Rear Fender Removal CAUTION Be careful not to scratch the painted surface during removal or installation.
  • Page 469: Battery Case/tool Case

    Tool Case Removal • Remove: Seats (see Front/Rear Seats Removal) Connector [A] Battery Cover Screws [B] Battery Cover [C] • Remove: Kawasaki Diagnostic System Connector [A] Partition Bolt [B] Partition [C] • Remove: Seat Lock Cable Connectors [A] • Remove:...
  • Page 470: Battery Case Removal

    15-16 FRAME Battery Case/Tool Case • Remove: Connector Bracket [A] • Remove: Tool Case [A] Battery Case Removal • Remove: Seats (see Front/Rear Seats Removal) Battery (see Electrical System chapter) Battery Damper [A] • Disconnect: Ground Lead Connector [A] White Lead Connector [B] Starter Relay Lead Connector [C] Atmospheric Pressure Sensor Lead Connector [D] •...
  • Page 471 FRAME 15-17 Battery Case/Tool Case • Remove: Relay Box [A] Turn Signal Control Relay [B] Starter Control Relay [C] • Remove: Vehicle-down Sensor Bolts [A] Vehicle-down Sensor [B] • Remove: Rear Fender (see Rear Fender Removal) Rear Wheel (see Wheels/Tires chapter) Swingarm (see Suspension chapter) Battery Case Bolts [A] •...
  • Page 472: Footboard And Sidestand

    15-18 FRAME Footboard and Sidestand Right Footboard Removal • Remove: Footboard Bracket Bolts [A] Footboard [B] Right Footboard Installation • Tighten: Torque - Footboard Bracket Bolts: 34 N·m (3.5 kgf·m, 25 ft·lb) Right Footboard Disassembly • Remove: Right Footboard (see Right Footboard Removal) Spring [A] Circlip [B] Pin [C]...
  • Page 473: Left Footboard Removal

    FRAME 15-19 Footboard and Sidestand Left Footboard Removal • Remove: Footboard Bracket Bolts [A] Footboard [B] Left Footboard Installation • Instal the shift pedal. • Tighten: Torque - Footboard Bracket Bolts: 34 N·m (3.5 kgf·m, 25 ft·lb) Left Footboard Disassembly •...
  • Page 474: Side Stand Installation

    15-20 FRAME Footboard and Sidestand Side Stand Installation • Apply grease to the contact surface of the frame and side stand. • Install: Side Stand [A] Side Stand Mounting Bolt [B] and Nut [C] • Tighten: Torque - Side Stand Mounting Bolt, Nut: 44 N·m (4.5 kgf·m, 33 ft·lb) •...
  • Page 475: Downtube

    FRAME 15-21 Downtube Downtube Removal • Using the jack and the jack attachment, raise the rear wheel off the ground (see Wheels/Tires chapter). Special Tools - Jack: 57001-1238 Jack Attachment: 57001-1571 Right Side: • Remove: Muffler and Exhaust Pipes (see Engine Top End chapter) Right Footboard (see Footboard Removal) Brake Pedal and Rear Master Cylinder (see Brake Sys- tem chapter)
  • Page 476: Downtube Installation

    15-22 FRAME Downtube Downtube Installation • Tighten the bolts to the specified torque following the tight- ening sequence. 1. Front Downtube Nuts [A] 2. Lower Engine Bracket Bolts [B] 3. Front Engine Mounting Nut [C] 4. Rear Downtube Bolts [D] •...
  • Page 477: Headlight Cover

    FRAME 15-23 Headlight Cover Headlight Cover Removal • Remove: Headlight Unit (see Electrical System chapter) Headlight Upper Cover Bolts [A] and Washers Headlight Upper Cover [B] • Remove: Headlight Holder Bolts [A] Headlight Holder [B] • Remove: Headlight Cover Bolts [A] (both sides) Headlight Cover Bolts [B] Headlight Covers [C] (both sides) Headlight Cover Installation...
  • Page 478: Frame Inspection

    15-24 FRAME Frame Frame Inspection • Visually inspect the frame [A] for cracks, dents, bending, or warp. If there is any damage to the frame, replace it. WARNING A repaired frame may fail in use, possibly causing an accident. If the frame is bent, dented, cracked, or warped, replace it.
  • Page 479 ELECTRICAL SYSTEM 16-1 Electrical System Table of Contents Exploded View........16-4 Camshaft Position Sensor Specifications ........16-12 Removal ........16-47 Special Tools ........16-13 Camshaft Position Sensor Wiring Diagram (United States and Installation ......... 16-47 Canada) .......... 16-14 Camshaft Position Sensor Wiring Diagram (California) ....
  • Page 480 16-2 ELECTRICAL SYSTEM Meter Unit Disassembly ....16-68 Rear Brake Light Switch Meter Unit Assembly....16-69 Check/Adjustment ..... 16-86 Meter Unit Inspection ....16-70 Water Temperature Sensor LED Light Inspection....16-75 Removal ........16-86 Indicator Light Inspection ..... 16-76 Water Temperature Sensor Air Switching Valve ......
  • Page 482 16-4 ELECTRICAL SYSTEM Exploded View...
  • Page 483 ELECTRICAL SYSTEM 16-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Spark plugs Alternator stator coil mounting bolts 104 in·lb Crankshaft sensor mounting bolts 0.70 61 in·lb Oil pressure switch Speed sensor mounting bolt 87 in·lb Gear position switch mounting bolts 0.50 43 in·lb Gear position switch lead clamp bolts...
  • Page 484 16-6 ELECTRICAL SYSTEM Exploded View...
  • Page 485 ELECTRICAL SYSTEM 16-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Oxygen sensor Water temperature sensor 104 in·lb Camshaft position sensor bolt 87 in·lb 4. Fuse Box 5. ECU (Electronic Control Unit) 6. Starter Control Relay 7. Inlet Air Pressure Sensor 8.
  • Page 486 16-8 ELECTRICAL SYSTEM Exploded View...
  • Page 487 ELECTRICAL SYSTEM 16-9 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Decompression solenoid bolts 87 in·lb Starter lockout switch screw 0.12 10 in·lb Front brake light switch screw 0.12 10 in·lb Fuel level sensor mounting bolts 0.70 61 in·lb Fuel pump mounting bolts 87 in·lb L, S Starter motor terminal nut...
  • Page 488 16-10 ELECTRICAL SYSTEM Exploded View...
  • Page 489 ELECTRICAL SYSTEM 16-11 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Turn signal light lens screws 0.10 8.7 in·lb Front turn signal light screws 0.70 61 in·lb Tail/brake light unit mounting nuts 0.60 52 in·lb Rear turn signal light screws 0.70 61 in·lb License plate light lens mounting screws...
  • Page 490 16-12 ELECTRICAL SYSTEM Specifications Item Standard Battery: Type Sealed Battery Model name FTZ16-BS Capacity 12 V 18 Ah Voltage 12.6 V or more Charging System: Alternator type Three-phase AC with delta connection, and rare-earth single magnet rotor Battery charging voltage 14.2 ~ 15.2 V @3 000 r/min (rpm) Alternator output voltage (no load) 70 ~ 95 V @3 000 r/min (rpm)
  • Page 491 ELECTRICAL SYSTEM 16-13 Special Tools Spark Plug Wrench, Hex 16 : Filler Cap Driver : 57001–1262 57001–1454 Jack : Needle Adapter Set: 57001–1238 57001–1457 Hand Tester : Flywheel & Pulley Holder Adapter: 57001–1394 57001–1547 Flywheel & Pulley Holder: Jack Attachment : 57001–1343 57001–1571...
  • Page 492 16-14 ELECTRICAL SYSTEM Wiring Diagram (United States and Canada)
  • Page 493 ELECTRICAL SYSTEM 16-15 Wiring Diagram (United States and Canada)
  • Page 494 16-16 ELECTRICAL SYSTEM Wiring Diagram (California)
  • Page 495 ELECTRICAL SYSTEM 16-17 Wiring Diagram (California)
  • Page 496 16-18 ELECTRICAL SYSTEM Wiring Diagram (Australia and Malaysia)
  • Page 497 ELECTRICAL SYSTEM 16-19 Wiring Diagram (Australia and Malaysia)
  • Page 498 16-20 ELECTRICAL SYSTEM Wiring Diagram (Other than United States, Canada, Australia and Malaysia)
  • Page 499 ELECTRICAL SYSTEM 16-21 Wiring Diagram (Other than United States, Canada, Australia and Malaysia)
  • Page 500 Oil Pressure Switch [E] Side Stand Switch [F] Atmospheric Pressure Sensor [A] ECU Fuse 30 A [B] Starter Relay and Main Fuse 30 A [C] Fuse Box [D] Battery [E] Vehicle-down Sensor [A] Self-diagnosis Terminal [B] Kawasaki Diagnostic System Connector [C] Battery [D]...
  • Page 501 ELECTRICAL SYSTEM 16-23 Electrical Parts Location ECU (Electronic Control Unit) [A] Frame Ground Terminal [A] Turn Signal Control Relay [B] Starter Control Relay [C] Relay Box [D] Speed Sensor [A] Engine Ground Terminal [B] Starter Motor [C] Oxygen Sensor [D] Gear Position Switch [E] Frame Ground Terminal [A] Inlet Air Pressure Sensor [B]...
  • Page 502 16-24 ELECTRICAL SYSTEM Electrical Parts Location Sub Throttle Sensor [A] Sub Throttle Sensor Actuator [B] Main Throttle Sensor [C] Inlet Air Temperature Sensor [A] Decompression Solenoid [B] Camshaft Position Sensor [C] Rear Brake Light Switch [D] Regulator/Rectifier [E]...
  • Page 503 ELECTRICAL SYSTEM 16-25 Servicing Precautions There are a number of important precautions that should be followed servicing electrical systems. ○ Do not reverse the battery cable connections. This will burn out the diodes on the electrical parts. ○ Always check battery condition before condemning other parts of an electrical system.
  • Page 504 16-26 ELECTRICAL SYSTEM Servicing Precautions Male Connectors [B]...
  • Page 505: Electrical Wiring

    ELECTRICAL SYSTEM 16-27 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 506 16-28 ELECTRICAL SYSTEM Battery Battery Removal CAUTION Do not disconnect the battery cables or any other electrical connections when the ignition switch in ON, as this could damage the ECU (Electronic Con- trol Unit). Never reverse the connections of the battery, this could damage the ECU.
  • Page 507 Make sure that the model name [A] of the electrolyte con- tainer matches the model name [B] of the battery. These names must be the same. Battery Model Name for VN2000-A1: FTZ16-BS CAUTION Be sure to use the electrolyte container with the...
  • Page 508 1.8 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 509 ELECTRICAL SYSTEM 16-31 Battery • After charging is completed, press down firmly with both hands to seat the strip of caps [A] into the battery (don’t pound or hammer). When properly installed, the strip of the caps will be level with the top of the battery. CAUTION Once the strip of the caps [A] is installed onto the battery, never remove the caps, nor add water or...
  • Page 510 16-32 ELECTRICAL SYSTEM Battery system. Therefore, replace a sealed battery only on a motorcycle which was originally equipped with a sealed battery. Be careful, if a sealed battery is installed on a motorcycle which had an ordinary battery as original equipment, the sealed battery’s life will be shortened.
  • Page 511 ELECTRICAL SYSTEM 16-33 Battery Terminal Voltage: 11.5 ~ less than 12.6 V Standard Charge 1.8 A × 5 ~ 10 h (see following chart) Quick Charge 9 A × 1 h CAUTION If possible, do not quick charge. If quick charge is done unavoidably, do standard charge later on.
  • Page 512: Charging System

    16-34 ELECTRICAL SYSTEM Charging System Alternator Rotor Removal • Remove: Clutch and Damper Cam (see Clutch chapter) Washer [A] • Install suitable 2 bolts (M8) [A] in the rotor [B], and remove the rotor. Alternator Rotor Installation • Align the punch mark [A] on the crankshaft with the punch mark [B] on the rotor.
  • Page 513 ELECTRICAL SYSTEM 16-35 Charging System Alternator Stator Installation • Install the alternator stator coil so that the hole [A] faces rearward. • Apply a non-permanent locking agent to the alternator stator coil mounting bolts. • Tighten: Torque - Alternator Stator Coil Mounting Bolts: 12 N·m (1.2 kgf·m, 104 in·lb) •...
  • Page 514 16-36 ELECTRICAL SYSTEM Charging System Alternator Inspection There are three types of alternator failures: short, open (lead burned out), or loss in rotor magnetism. A short or open in one of the stator coil lead will result in either a low output, or no output at all.
  • Page 515 ELECTRICAL SYSTEM 16-37 Charging System • Check the stator coil resistance as follows: ○ Turn off the ignition switch. ○ Connect the hand tester [A] to the connector as shown in the table. ○ Note the resistance readings. Stator Coil Resistance Tester Connections Reading...
  • Page 516 CAUTION Use only Kawasaki Hand Tester 57001-1394 for this test. A tester other than the Kawasaki Hand Tester may show different readings. If a megger or a meter with a large capacity battery is used, the regulator/rectifier will be damaged.
  • Page 517 ELECTRICAL SYSTEM 16-39 Charging System Charging System Circuit 1. Ignition Switch 5. Main Fuse 30 A 2. Alternator 6. Starter Relay 3. Regulator/Rectifier 7. Battery 4. Joint Connector 8. Load...
  • Page 518 16-40 ELECTRICAL SYSTEM Ignition System...
  • Page 519: Ignition System

    ELECTRICAL SYSTEM 16-41 Ignition System WARNING The ignition system produces extremely high volt- age. Do not touch the spark plugs, ignition coils, or spark plug high-tension cables while the engine is running, or you could receive a severe electrical shock. CAUTION Do not disconnect the battery cables or any other electrical connections when the ignition switch is...
  • Page 520 16-42 ELECTRICAL SYSTEM Ignition System Ignition Coil Installation • Connect the primary leads to the ignition coil terminals and run the secondary cables according to the Cable, Wire, and Hose Routing section in the Appendix chapter. Front Ignition Coil R/G Lead → (+) BK Lead →...
  • Page 521 ELECTRICAL SYSTEM 16-43 Ignition System • To determine which part is defective, measure the arcing distance again with the spark plug caps removed from the ignition coil. Remove the caps by turning them counter- clockwise. If the arcing distance is subnormal as before, the trouble is with the ignition coil itself.
  • Page 522 16-44 ELECTRICAL SYSTEM Ignition System Spark Plug Installation • Insert the spark plug in the plug hole, and finger-tighten it first. • Using the plug wrench [A] vertically, tighten the plug. CAUTION The insulator of the spark plug may break if when the wrench is inclined during tightening.
  • Page 523 ELECTRICAL SYSTEM 16-45 Ignition System WARNING To avoid extremely high voltage shocks, do not touch the spark plugs or tester connections. • Turn the ignition switch and the engine stop switch ON. • Pushing the starter button, turn the engine 4 ~ 5 seconds with the transmission in neutral to measure the primary peak voltage.
  • Page 524 16-46 ELECTRICAL SYSTEM Ignition System • Connect a commercially available peak voltage adapter [A] to the hand tester [B]. Recommended Tool: Peak Voltage Adapter Type: KEK-54-9-B Brand: KOWA SEIKI Special Tool - Hand Tester: 57001-1394 • Insert the adapter probes into the connector [C] of the crankshaft sensor [D] as shown.
  • Page 525 ELECTRICAL SYSTEM 16-47 Ignition System Camshaft Position Sensor Removal • Remove: Right Engine Cover Bolts Right Engine Cover Camshaft Position Sensor Connector [A] (disconnect) Camshaft Position Sensor Bolt [B] Camshaft Position Sensor [C] Camshaft Position Sensor Installation • Apply grease to the O-ring on the camshaft position sen- sor.
  • Page 526 16-48 ELECTRICAL SYSTEM Ignition System 1st Check • Start the engine to the following conditions. Condition: Transmission Gear → 1st position Clutch Lever → Release Side Stand → Down or Up ○ Turn the ignition switch on and push the starter button. ○...
  • Page 527 ELECTRICAL SYSTEM 16-49 Ignition System Ignition System Circuit 1. Engine Stop Switch 16. Battery Sub Throttle Sensor 2. Spark Plugs 10. Camshaft Position Sensor 17. Frame Ground 3. Ignition Coil #1 (front cylinder) 11. Crankshaft Sensor 18. Joint Connector 4. Ignition Coil #2 (rear cylinder) 12.
  • Page 528: Starter Motor

    16-50 ELECTRICAL SYSTEM Starter Motor Starter Motor Removal • Remove: Rear Exhaust Pipe (see Engine Top End chapter) Starter Motor Terminal Nut [A] and Lead Starter Motor Bolts [B] • Pull the starter Motor [C] toward the right. CAUTION Never drop the starter motor, especially on a hard surface.
  • Page 529 ELECTRICAL SYSTEM 16-51 Starter Motor • Unscrew the terminal locknut [A] and remove the terminal bolt [B]. • Take the positive carbon brushes and wire assy [C] out of the yoke. NOTE ○ Do not remove the negative carbon brushes [A] from the brush plate [B].
  • Page 530 16-52 ELECTRICAL SYSTEM Starter Motor • Apply a thin coat of grease to the oil seal [A] in the right end cover [B]. • Apply a thin coat of grease to the left bearing [A]. • Fit shims onto the right end cover. ○...
  • Page 531 ELECTRICAL SYSTEM 16-53 Starter Motor • Measure the diameter [A] of the commutator [B]. Replace the starter motor with a new one if the commu- tator diameter is less than the service limit. Commutator Diameter Standard: 28 mm (1.10 in.) Service Limit: 27 mm (1.06 in.) Armature Inspection...
  • Page 532 16-54 ELECTRICAL SYSTEM Starter Motor Starter Relay Inspection • Remove the right side covers (see Frame chapter). • Remove the coolant reserve tank, then the starter relay. • Connect the hand tester [A] and 12 V battery [B] to the starter relay [C] as shown.
  • Page 533 ELECTRICAL SYSTEM 16-55 Starter Motor Electric Starter Circuit 1. Fuse Box 7. Gear Position Switch 13. Starter Lockout Switch 2. Ignition Fuse 10 A 8. Relay Box 14. Side Stand Switch 3. Engine Stop Switch 9. Starter Circuit Relay 15. Starter Relay 4.
  • Page 534: Lighting System

    16-56 ELECTRICAL SYSTEM Lighting System This model adopts the daylight system and has a head- light relay in the relay box. The headlight does not go on when the ignition switch and the engine stop switch are first turned on. The headlight comes on when the engine starts running and stays on even if the engine stalls.
  • Page 535 ELECTRICAL SYSTEM 16-57 Lighting System • Take out the low beam bulb [A]. CAUTION When handling the quartz-halogen bulb, never touch the glass portion with bare hands. Always use a clean cloth. Oil contamination from hands or dirty rags can reduce bulb life or cause the bulb to explode.
  • Page 536 16-58 ELECTRICAL SYSTEM Lighting System City Light Bulb Replacement (Europe Model) • Remove the headlight unit (see Headlight Bulb Replace- ment). • Pull out the socket [A] together with the bulb. • Remove the wedge-base type bulb [A], pull the bulb straight out of the socket [B].
  • Page 537 ELECTRICAL SYSTEM 16-59 Lighting System • Turn the license light bulb socket [A] counterclockwise [B] and pull it out. • Remove the wedge-base type bulb [A], pull the bulb straight out of the socket [B]. CAUTION Do not turn the bulb. Pull the bulb out to prevent damage to the bulb.
  • Page 538 16-60 ELECTRICAL SYSTEM Lighting System Headlight/Tail Light Circuit 1. Ignition Switch 9. Alternator 18. Main Fuse 30A 2. Joint Connector 10. Relay Box 19. Battery 3. High Beam Indicator 11. Headlight Relay 20. Running Position Lights Light 12. License Plate Light (US and Canada Models) 4.
  • Page 539 ELECTRICAL SYSTEM 16-61 Automatic Turn Signal Canceling System Automobiles use a turn signal canceling system actuated by steering wheel turn. But, motorcycles turn with a bank additionally, and so have a smaller steer angle. This makes difficult to adopt an automobile type turn signal canceling system because of inaccurate operation in motorcycles.
  • Page 540 16-62 ELECTRICAL SYSTEM Automatic Turn Signal Canceling System Turn Signal Switch Inspection • Open the headlight housing. • Unplug the 9-pin connectors [A] that leads to the left han- dlebar switch. • Check the turn signal switch connections according to the table.
  • Page 541 ELECTRICAL SYSTEM 16-63 Automatic Turn Signal Canceling System • Connect one 12 V battery and turn signal lights as indi- cated in the figure, and count how many times the lights flash for one minute. Turn Signal Control Relay Connector [A] Turn Signal Lights [B] 12 V Battery [C] If the lights do not flash as specified, replace the turn sig-...
  • Page 542 16-64 ELECTRICAL SYSTEM Automatic Turn Signal Canceling System • Insert the new bulb [A] by aligning the pins [B] with the groove in the walls of the socket [C]. • Fit the projection [A] in the recess [B] of the lens. •...
  • Page 543 ELECTRICAL SYSTEM 16-65 Automatic Turn Signal Canceling System Turn Signal Cancelling System Circuit 1. Ignition Switch 9. Front Right Turn Signal Light 2. Fuse Box 10. Rear Left Turn Signal Light 3. Turn Signal Control Relay Fuse 10 A 11. Rear Right Turn Signal Light 4.
  • Page 544: Radiator Fan System

    16-66 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.
  • Page 545 ELECTRICAL SYSTEM 16-67 Radiator Fan System Radiator Fan Circuit 1. Relay Box 2. Radiator Fan Relay 3. Electronic Control Unit 4. Water Temperature Sensor 5. Joint Connector 6. Radiator Fan 7. Joint Connector 8. Fuse Box 9. Fan Fuse 10A 10.
  • Page 546: Meter Unit Disassembly

    16-68 ELECTRICAL SYSTEM Meter, Gauge Meter Unit Removal • Remove: Fuel Tank (see Fuel System chapter) Bolt [A] • Remove the meter assembly [B] backward [C]. • Remove: Bolts [A] Meter Unit [B] CAUTION Never drop the meter unit, especially on a hard sur- face.
  • Page 547: Meter Unit Assembly

    ELECTRICAL SYSTEM 16-69 Meter, Gauge • Remove: Screws [A] Holder [B] • Remove the grommet [C] from the lower meter cover [D]. NOTE ○ The water temperature warning LED light, oil pressure warning LED light and FI indicator LED light can not be exchanged.
  • Page 548: Meter Unit Inspection

    16-70 ELECTRICAL SYSTEM Meter, Gauge Meter Unit Inspection LCD Segment Inspection: • Remove the meter unit (see Meter Unit Removal). [A] Meter Unit Lead Connector CAUTION Do not drop the meter unit. Such a shock to the meter unit can damage it. Place the meter facing up.
  • Page 549 ELECTRICAL SYSTEM 16-71 Meter, Gauge Check 2 : • Using the auxiliary lead, connect the battery positive ter- minal to terminal [8]. • Verify that all the LCD segments (the letters and num- bers of the liquid crystal display) to appear for 3 seconds, and the speedometer needle momentary points to the last reading and then return to the 0 position.
  • Page 550 16-72 ELECTRICAL SYSTEM Meter, Gauge • Push the mode button [A] to CLOCK. • Push the reset button [B] more than 2 seconds, then the display turns to the HOUR/MINUTE mode [C]. ○ In the HOUR/MINUTE mode, the numbers flash on the display.
  • Page 551 ELECTRICAL SYSTEM 16-73 Meter, Gauge • Set the minute, push the reset button to return to the HOUR/MINUTE mode. • Push the mode button to complete the time setting process. ○ The clock starts counting the seconds as soon as the mode button is pushed.
  • Page 552 16-74 ELECTRICAL SYSTEM Meter, Gauge Speed Sensor Power Supply Voltage Inspection: • Connect the leads in the same circuit as for the LCD Seg- ment Inspection, Check 2. • Set the hand tester [A] to DC25 V, check the voltage be- tween terminal [10] and battery negative lead.
  • Page 553: Led Light Inspection

    ELECTRICAL SYSTEM 16-75 Meter, Gauge LED Light Inspection • Connect the leads in the same circuit as for the LCD Seg- ments Inspection, Check 2. Fuel Level Warning Indicator LED Light: • Connect an about 30 Ω resistor [A] to the terminal [15] and battery negative lead.
  • Page 554: Indicator Light Inspection

    16-76 ELECTRICAL SYSTEM Meter, Gauge FI Indicator LED Light and LCD Symbol: • Connect the lead to the terminal [2] and battery negative lead. FI Indicator LED Light Connections: Battery Negative Lead (–) to Terminal [2] ○ The FI indicator LED light [A] and symbol [B] in the LCD should go on.
  • Page 555 ELECTRICAL SYSTEM 16-77 Meter, Gauge Neutral Indicator Light: • Connect the lead to the terminal [1] and battery negative lead. Neutral Indicator Light Connections: Battery Negative Lead (–) to Terminal [1] ○ The neutral indicator light [A] should go on. If the indicator light does not go on, inspect the bulb.
  • Page 556 16-78 ELECTRICAL SYSTEM Meter, Gauge High Beam Indicator Light: • Connect the lead to the terminal [16] and battery positive lead. High Beam Indicator Light Connections: Battery Positive Lead (+) to Terminal [16] ○ The high beam indicator light [A] should go on. If the indicator light does not go on, inspect the bulb.
  • Page 557 ELECTRICAL SYSTEM 16-79 Meter, Gauge Meter Unit Circuit 1. Meter Unit 15. Turn Signal Control Relay 2. Odometer/Trip Meter/Clock LCD 16. Fuel Reserve Switch 3. Speedometer 17. Oil Pressure Warning Light 4. Fuel Meter Switch 5. Illuminator LED 18. Joint Connector 6.
  • Page 558: Air Switching Valve

    16-80 ELECTRICAL SYSTEM Air Switching Valve Air Switching Valve Operation Test • Pull the air switching valve hose [A] out of the right air cleaner base. • Start the engine and run it at idle speed. • Plug the air switching valve hose end with your finger and feel vacuum pulsing in the hose.
  • Page 559 ELECTRICAL SYSTEM 16-81 Air Switching Valve • Disconnect the 12 V battery. • Blow the air to the inlet air duct [A] again, and make sure flow the blown air from the outlet air ducts [B]. If the air switching valve dose not operate as described, replace it with a new one.
  • Page 560: Decompression Solenoid

    16-82 ELECTRICAL SYSTEM Decompression Solenoid Decompression Solenoid Inspection • Remove: Seats (see Frame chapter) Right Cover (see Frame chapter) • Disconnect the decompression solenoid lead connector [A]. • Set the hand tester [A] to the ×1 Ω range and connect it to the terminals in the decompression solenoid lead con- nector [B].
  • Page 561: Switch And Sensors

    ELECTRICAL SYSTEM 16-83 Switch and Sensors Fuel Level Sensor Inspection • Remove: Fuel Tank (see Fuel System chapter) • Open the clamps. • Remove: Bolts [A] Fuel Level Sensor [B] • Check that the float moves up and down smoothly without binding.
  • Page 562: Fuel Reserve Switch Inspection

    16-84 ELECTRICAL SYSTEM Switch and Sensors Fuel Reserve Switch Inspection • Fill the fuel tank with fuel. • Close the fuel tank cap surely. • Remove: Left Engine Cover (see Frame chapter) Fuel Pump Lead Connector [A] • Connect the test light [B] (12 V 3.4 W bulb in a socket with leads) and the 12 V battery [C] to the fuel level sensor lead connector.
  • Page 563: Speed Sensor Inspection

    ELECTRICAL SYSTEM 16-85 Switch and Sensors Speed Sensor Inspection • Remove: Speed Sensor (see Speed Sensor Removal) • Connect the speed sensor connector [A] with a battery [B], 10 kΩ resistor [C] and hand tester [D] as shown. • Set the tester to the DC 25 V range. Special Tool - Hand Tester : 57001–1394 •...
  • Page 564: Oxygen Sensor Installation

    16-86 ELECTRICAL SYSTEM Switch and Sensors Oxygen Sensor Installation (California and Europe models) CAUTION Never drop the Oxygen Sensor [A], especially on a hard surface. Such a shock to the unit can damage Do not touch the sensing part [B] and filter holes [C] of the sensor to prevent oil contact.
  • Page 565: Water Temperature Sensor Installation

    ELECTRICAL SYSTEM 16-87 Switch and Sensors Water Temperature Sensor Installation • Tighten: Torque - Water Temperature Sensor: 12 N·m (1.2 kgf·m, 104 in·lb) • Fill the engine with coolant and bleed the air from the cooling system (see Coolant Filling in the Cooling System chapter).
  • Page 566: Gear Position Switch Installation

    16-88 ELECTRICAL SYSTEM Switch and Sensors Gear Position Switch Installation • Apply silicone sealant to the gear position switch lead grommet. Sealant - Three Bond: TB1211F • Apply a non-permanent locking agent: Gear Position Switch Mounting Bolts Gear Position Switch Lead Clamp Bolts •...
  • Page 567: Switch Inspection

    ELECTRICAL SYSTEM 16-89 Switch and Sensors Gear Position Switch Resistance Connections Gear 2 - Ground 3 - Ground Ground Position about Neutral – – 0 Ω – 3.00 3.32 kΩ 11.63 12.87 kΩ – 1.70 1.89 kΩ 10.33 11.44 kΩ –...
  • Page 568: Relay Box

    16-90 ELECTRICAL SYSTEM Relay Box The relay box [A] has relays and diodes. The relays and diodes can not be removed. Relay Box Removal • Remove: Battery (See Battery Removal) ECU (see Fuel System chapter) • Take out the relay box [A] and disconnect the connectors [B].
  • Page 569: Diode Circuit Inspection

    ELECTRICAL SYSTEM 16-91 Relay Box Relay Circuit Inspection (with the battery disconnected) Tester Connection Tester Reading (Ω) Headlight Relay 11 – 16 ∞ 12 – 13 ∞ ECU Main Relay 5 – 10 Not ∞* 12 – 14 ∞ Fuel Pump Relay 1 –...
  • Page 570 16-92 ELECTRICAL SYSTEM Relay Box Relay Box Internal Circuit A. Headlight Relay B. ECU Main Relay C. Fuel Pump Relay D. Starter Circuit Relay E. Fan Relay...
  • Page 571: Fuse

    ELECTRICAL SYSTEM 16-93 Fuse Main Fuse Removal • Remove the left side cover (see Frame chapter). • Disconnect the starter relay connector [A]. • Pull out the main fuse [B] from the starter relay with needle nose pliers. ECU Fuse Removal •...
  • Page 573 APPENDIX 17-1 Appendix Table of Contents Cable, Wire, and Hose Routing ....................17-2 Troubleshooting Guide (except DFI) ..................17-56...
  • Page 574 17-2 APPENDIX Cable, Wire, and Hose Routing...
  • Page 575 APPENDIX 17-3 Cable, Wire, and Hose Routing 1. Insert the end of the grip up to the punch mark. 2. Align the mating surface with the punch mark. After the installation, confirm the punch mark. 3. Left Switch Housing Lead 4.
  • Page 576 17-4 APPENDIX Cable, Wire, and Hose Routing...
  • Page 577 APPENDIX 17-5 Cable, Wire, and Hose Routing 1. Clamps 2. Main Harness 3. Regulator/Rectifier 4. Oil Filter 5. Oil Pressure Warning Light Switch 6. Insert the alternator lead conector in the bracket. 7. Main Harness 8. Main Harness 9. Alternator Lead 10.
  • Page 578 17-6 APPENDIX Cable, Wire, and Hose Routing...
  • Page 579 APPENDIX 17-7 Cable, Wire, and Hose Routing 1. Clutch Cable 2. Run the clutch cable the front side of the steering stem head. 3. Clamp 4. Bolt 5. Clamps 6. Clamp ( 15) 7. Clamp ( 10) 8. Install the rubber boot to the metal fitting. 9.
  • Page 580 17-8 APPENDIX Cable, Wire, and Hose Routing...
  • Page 581 APPENDIX 17-9 Cable, Wire, and Hose Routing 1. Front 2. Frame Ground Terminal 3. Clamp 4. Frame Ground Terminal Lead 5. Put the frame ground terminal so that the flat side faces downward. 6. Accessory Lead Terminals 7. Inlet Air Pressure Sensor 8.
  • Page 582 17-10 APPENDIX Cable, Wire, and Hose Routing...
  • Page 583 APPENDIX 17-11 Cable, Wire, and Hose Routing 1. Front 2. Main Harness 3. Clamp ( 20) 4. Clamp ( 15) 5. Breather Tube 6. Starter Relay 7. Engine Ground Terminal 8. Starter Motor Lead 9. Run the starter motor lead and engine ground lead between the engine mount and frame bracket.
  • Page 584 17-12 APPENDIX Cable, Wire, and Hose Routing...
  • Page 585 APPENDIX 17-13 Cable, Wire, and Hose Routing 1. Front Ignition Coil Secondary Lead 2. Fuel Level Sensor Lead Connector 3. Meter Unit Lead Connector 4. Fuel Pump Lead Connector 5. Run the leads outside of the clamp. 6. Insert the clamp in the bracket. 7.
  • Page 586 17-14 APPENDIX Cable, Wire, and Hose Routing...
  • Page 587 APPENDIX 17-15 Cable, Wire, and Hose Routing 1. Seat Lock Cable 2. Rear Harness 3. Clamp 4. Fit the rear harness connector in battery case. 5. Accessory Lead Terminals 6. Decompression Solenoid/Camshaft Sensor Lead Connector 7. Gear Position Switch Lead Connector 8.
  • Page 588 17-16 APPENDIX Cable, Wire, and Hose Routing...
  • Page 589 APPENDIX 17-17 Cable, Wire, and Hose Routing 1. Vacuum Tube (White, California Model) 2. Insert the throttle body lead connector in the thermostat bracket. 3. Throttle Body Lead 4. Clamp (Air Tube) 5. Tube (Green, California Model) 6. Air Switching Valve 7.
  • Page 590 17-18 APPENDIX Cable, Wire, and Hose Routing...
  • Page 591 APPENDIX 17-19 Cable, Wire, and Hose Routing 1. Front 2. Main Harness 3. Install the frame ground terminal so that it is parallel to seat rail. 4. Insert the clamp in the bracket. 5. Fit the seat lock cable in the bracket. 6.
  • Page 592 17-20 APPENDIX Cable, Wire, and Hose Routing...
  • Page 593 Cable, Wire, and Hose Routing 1. Main Harness (Left Side) 2. Damper (Inside of Battery Cover) 3. Fit the Kawasaki Diagnostic System connector in the battery cover. 4. Put the accessory terminals under the rear harness connector. 5. To Frame Ground 6.
  • Page 594 17-22 APPENDIX Cable, Wire, and Hose Routing...
  • Page 595 APPENDIX 17-23 Cable, Wire, and Hose Routing 1. Front 2. Vehicle-down Sensor 3. Main Harness (Left Side) 4. Insert the clamp in the battery case. 5. Fit the relay box in the tab of the battery case. 6. Relay Box 7.
  • Page 596 17-24 APPENDIX Cable, Wire, and Hose Routing...
  • Page 597 APPENDIX 17-25 Cable, Wire, and Hose Routing 1. Install the grommet in the rear fender. 2. Run the rear harness between the rear fender and fender brace. 3. Fit the rear harness in the recess of the cover. 4. Grommet 5.
  • Page 598 17-26 APPENDIX Cable, Wire, and Hose Routing...
  • Page 599 APPENDIX 17-27 Cable, Wire, and Hose Routing 1. Position the mark of the hose at right side, and tighten the clamp. 2. Water Hose (First Install the hose to thermostat.) 3. Clamp 4. Radiator Assembly 5. Clamp 6. Position the mark of the hose at right side, and tighten the clamp. 7.
  • Page 600 17-28 APPENDIX Cable, Wire, and Hose Routing...
  • Page 601 APPENDIX 17-29 Cable, Wire, and Hose Routing 1. Clamp 2. Align the marks and tighten the clamp. 3. Clamp 4. Align the marks and tighten the clamp. 5. Clamp 6. Water Temperature Sensor 7. Thermostat 8. Clamp 9. Align the marks and tighten the clamp. 10.
  • Page 602 17-30 APPENDIX Cable, Wire, and Hose Routing...
  • Page 603 APPENDIX 17-31 Cable, Wire, and Hose Routing 1. Coolant Hose 2. Clamp 3. Clamp 4. Coolant Level Gauge Tube 5. Frame Bracket 6. Clamp 7. Clamp 8. Coolant Reservoir 9. Front...
  • Page 604 17-32 APPENDIX Cable, Wire, and Hose Routing...
  • Page 605 APPENDIX 17-33 Cable, Wire, and Hose Routing 1. Front Brake Fluid Reservoir 2. 6 mm (0.24 in.) 3. Brake Hose 4. Clamp 5. White Paint Mark...
  • Page 606 17-34 APPENDIX Cable, Wire, and Hose Routing...
  • Page 607 APPENDIX 17-35 Cable, Wire, and Hose Routing 1. Clamp 2. Clamps 3. Brake Hose 4. Right Side 5. Engine Side 6. Insert the clamp in the regulator bracket. 7. Rear Brake Light Switch 8. Rear Master Cylinder 9. Insert the clamp in the coolant reservoir bracket. 10.
  • Page 608 17-36 APPENDIX Cable, Wire, and Hose Routing...
  • Page 609 APPENDIX 17-37 Cable, Wire, and Hose Routing 1. Frame Ground Terminal Bolt 2. Clamp 3. Vacuum Tube (White, California Model) 4. Air Tube 5. Insert the clamp of harness in the frame. 6. Throttle Body Lead Connector 7. Water Temperature Sensor 8.
  • Page 610 17-38 APPENDIX Cable, Wire, and Hose Routing...
  • Page 611 APPENDIX 17-39 Cable, Wire, and Hose Routing 1. Fuel Tank 2. Meter Unit 3. Meter Unit Lead 4. Run the meter unit lead beside the fuel level sensor. 5. Fuel Pump Lead 6. Fuel Pump 7. Fuel Level Sensor 8. Fuel Level Sensor Lead 9.
  • Page 612 17-40 APPENDIX Cable, Wire, and Hose Routing...
  • Page 613 APPENDIX 17-41 Cable, Wire, and Hose Routing 1. To Thermostat 2. Clamp 3. Clamp 4. Align the marks and install the coolant tube until the center of the paint mark, and then tighten the clamp. 5. Pipe Assembly 6. Clamp 7.
  • Page 614 17-42 APPENDIX Cable, Wire, and Hose Routing...
  • Page 615 APPENDIX 17-43 Cable, Wire, and Hose Routing 1. Air Cleaner Housing 2. Rear Cylinder Fitting 3. Front Cylinder Fitting 4. To Rear Cylinder Fitting 5. Red Paint Marks 6. Throttle Cables 7. White Paint Marks 8. To Air Cleaner Housing Fitting 9.
  • Page 616 17-44 APPENDIX Cable, Wire, and Hose Routing...
  • Page 617 APPENDIX 17-45 Cable, Wire, and Hose Routing 1. California Model 2. Red Tube 3. Blue Tube 4. To Red Fitting of Fuel Tank 5. To Blue Fitting of Fuel Tank 6. To Thermostat 7. To Air Switching Valve 8. To Throttle Body 9.
  • Page 618 17-46 APPENDIX Cable, Wire, and Hose Routing...
  • Page 619 APPENDIX 17-47 Cable, Wire, and Hose Routing 1. Except California Model 2. Pipe Assembly 3. Starter Motor Lead 4. Blue Stripe 5. Clamp 6. Blue Paint Mark 7. Center Line of Paint Mark 8. Clamp 9. Brown Paint Mark...
  • Page 620 17-48 APPENDIX Cable, Wire, and Hose Routing...
  • Page 621 APPENDIX 17-49 Cable, Wire, and Hose Routing 1. Coolant Reservoir Tube (Black) (Brown Pipe ~ Thermostat Cap) 2. Throttle Cables 3. Breather Tube 4. Fuel Tank Breather Tube (Blue) (Blue Pipe ~ Blue Fitting of Fuel Tank, California Model) 5. Fuel Tank Return Tube (Red) (Red Pipe ~ Red Fitting of Fuel Tank, California Model) 6.
  • Page 622 17-50 APPENDIX Cable, Wire, and Hose Routing...
  • Page 623 APPENDIX 17-51 Cable, Wire, and Hose Routing 1. California Model 2. Front 3. Starter Motor Lead 4. Clamp 5. To Red Fitting of Fuel Tank 6. To Blue Fitting of Fuel Tank 7. To Thermostat 8. To Air Switching Valve 9.
  • Page 624 17-52 APPENDIX Cable, Wire, and Hose Routing...
  • Page 625 APPENDIX 17-53 Cable, Wire, and Hose Routing 1. California Model 2. Front 3. Canister 4. Clamp 5. Green Tube 6. Clamp 7. Coolant Reservoir 8. Band 9. Clamp 10. Blue Tube 11. about 35° 12. Clamps 13. Clamps 14. Blue Tube 15.
  • Page 626 17-54 APPENDIX Cable, Wire, and Hose Routing...
  • Page 627 APPENDIX 17-55 Cable, Wire, and Hose Routing 1. California Model 2. Air Switching Valve 3. Hold the tube in the clamp of the frame 4. Run the green tubes under the white tube. 5. Run the white tube between the damper and frame. 6.
  • Page 628 17-56 APPENDIX Troubleshooting Guide (except DFI) NOTE Battery voltage low ○ Refer to Fuel System chapter for most of Spark plug dirty, broken, or gap malad- DFI troubleshooting guide. justed ○ This is not an exhaustive list, giving every Spark plug cap or high tension wiring trou- possible cause for each problem listed.
  • Page 629 APPENDIX 17-57 Troubleshooting Guide (except DFI) Throttle body assy O-ring damage Fuel line clogged Air cleaner duct loose Fuel pump trouble (DFI) Air cleaner O-ring damaged Compression low: Fuel pump (DFI) trouble Spark plug loose Compression low: Cylinder head not sufficiently tightened Spark plug loose down Cylinder head not sufficiently tightened...
  • Page 630: Gear Shifting Faulty

    17-58 APPENDIX Troubleshooting Guide (except DFI) For KLEEN, do not coast the motorcycle Clutch not disengaging properly: with the ignition switch off (Turn the igni- Clutch plate warped or too rough tion switch ON and run the engine) Spring plate free play maladjustment IC igniter in ECU trouble Clutch spring compression uneven Fuel/air mixture incorrect:...
  • Page 631: Exhaust Smokes Excessively

    APPENDIX 17-59 Troubleshooting Guide (except DFI) HLA aeration due to low oil level Pad surface glazed Air in HLA Disc warped Metal chips or dust jammed in HLA Caliper trouble Engine operated in red zone Master cylinder damaged Valve spring broken or weak Other noise: Camshaft bearing portion worn Bracket, nut, bolt, etc.
  • Page 632: Battery Trouble

    17-60 APPENDIX Troubleshooting Guide (except DFI) Brake Doesn’t Hold: Handlebar pulls to one side: Frame bent Air in the brake line Swingarm bent or twisted Pad or disc worn Swingarm pivot shaft runout excessive Brake fluid leakage Steering maladjusted Disc warped Front fork bent Contaminated pad Right and/or left front fork oil level incorrect...
  • Page 633 MODEL APPLICATION Year Model Beginning Frame No. JKBVNMA1□4A000001 or 2004 VN2000-A1 JKBVNW00AAA000001 or VNW00A-000001 □ :This digit in the frame number changes from one machine to another. Part No.99924-1320-02 Printed in Japan...

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Vulcan 2000

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