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Ninja ZX–6R
Ninja ZX-6RR
Motorcycle
Service Manual

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Table of Contents

   Also See for Kawasaki Ninja ZX–6R

   Summary of Contents for Kawasaki Ninja ZX–6R

  • Page 1 Ninja ZX–6R Ninja ZX-6RR Motorcycle Service Manual...
  • Page 3 Quick Reference Guide General Information Periodic Maintenance Fuel System (DFI) Cooling System Engine Top End Clutch Engine Lubrication System Engine Removal/Installation Crankshaft / Transmission Wheels / Tires 10 j Final Drive 11 j Brakes 12 j Suspension 13 j Steering 14 j Frame 15 j...
  • 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. © 2002 Kawasaki Heavy Industries, Ltd. Third Edition (1): Sep. 30, 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: How To Use This Manual

    • However, it contains enough detail and basic in- Use proper tools and genuine Kawasaki Mo- formation to make it useful to the owner who de- torcycle parts. Special tools, gauges, and sires to perform his own basic maintenance and testers that are necessary when servicing repair work.
  • Page 8 Whenever you see these WARNING and In most chapters an exploded view illustration CAUTION symbols, heed their instructions! of the system components follows the Table of Always follow safe operating and maintenance Contents. In these illustrations you will find the practices.
  • Page 9: Table Of Contents

    Technical Information – Air Inlet System ................1-15 Technical Information – New Ignition Interlock Sidestand ............1-18 Technical Information – Tail/Brake Lights Employing LED ............. 1-19 Technical Information – KAWASAKI LOW EXHAUST EMISSION SYSTEM ......1-21 Unit Conversion Table ......................1-22...
  • Page 10: General Information

    1-2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly opera- tion on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustra- tions, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary.
  • Page 11 Replacement Parts Replacement Parts must be KAWASAKI genuine or rec- ommended by KAWASAKI. Gaskets, O rings, Oil seals, Grease seals, circlips or cotter pins must be replaced with new ones whenever disassembled.
  • Page 12 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 13 GENERAL INFORMATION 1-5 Before Servicing Press For items such as bearings or oil seals that must be pressed into place, apply small amount of oil to the con- tact area. Be sure to maintain proper alignment and use smooth movements when installing. Ball Bearing and Needle Bearing Do not remove pressed ball or needle unless removal is absolutely necessary.
  • Page 14 1-6 GENERAL INFORMATION Before Servicing Direction of Engine Rotation When rotating the crankshaft by hand, the free play amount of rotating direction will affect the adjustment. Ro- tate the crankshaft to positive direction (clockwise viewed from output side). Electrical Wires A two-color wire is identified first by the primary color and then the stripe color.
  • Page 15: Model Identification

    GENERAL INFORMATION 1-7 Model Identification ZX636–B1 (Ninja ZX-6R) Left Side View: ZX636–B1 (Ninja ZX-6R) Right Side View:...
  • Page 16 1-8 GENERAL INFORMATION Model Identification ZX600–K1 (Ninja ZX-6RR) Left Side View: ZX600–K1 (Ninja ZX-6RR) Right Side View:...
  • Page 17: General Specifications

    GENERAL INFORMATION 1-9 General Specifications ZX636-B1 ∼ (Ninja ZX-6R) Items Dimensions: Overall length 2 025 mm (79.7 in.) Overall width 720 mm (28.3 in.) Overall height 1 100 mm (43.3 in.) Wheelbase 1 400 mm (55.1 in.) Road clearance 130 mm (5.1 in.) Seat height 825 mm (32.4 in.) Dry mass...
  • Page 18 1-10 GENERAL INFORMATION General Specifications ZX636-B1 ∼ (Ninja ZX-6R) Items Engine oil: Type API SE, SF or SG API SH or SJ with JASO MA Viscosity SAE10W-40 Capacity 4.0 L (4.2 US qt) Drive Train: Primary reduction system: Type Gear Reduction ratio 2.022 (89/44) Clutch type...
  • Page 19 GENERAL INFORMATION 1-11 General Specifications ZX636-B1 ∼ (Ninja ZX-6R) Items 12 V 55 W (quartz-halogen) Tail/brake light 12 V 0.5/3.8 W (LED) (US), (CAL), (CA) 12 V 0.5/5 W (LED) Alternator: Type Three-phase AC Rated output 22.5 A / 14 V @5 000 r/min (rpm) Specifications subject to change without notice, and may not apply to every country.
  • Page 20 1-12 GENERAL INFORMATION General Specifications Items ZX600-K1 (Ninja ZX-6RR) Dimensions: Overall length 2 025 mm (79.7 in.) Overall width 720 mm (28.3 in.) Overall height 1 100 mm (43.3 in.) Wheelbase 1 400 mm (55.1 in.) Road clearance 130 mm (5.1 in.) Seat height 825 mm (32.4 in.) Dry mass...
  • Page 21 GENERAL INFORMATION 1-13 General Specifications Items ZX600-K1 (Ninja ZX-6RR) Viscosity SAE10W-40 Capacity 4.0 L (4.2 US qt) Drive Train: Primary reduction system: Type Gear Reduction ratio 2.022 (89/44) Clutch type Wet multi disc Transmission: Type 6-speed, constant mesh, return shift Gear ratios: 2.923 (38/13) 2.055 (37/18)
  • Page 22 1-14 GENERAL INFORMATION General Specifications Items ZX600-K1 (Ninja ZX-6RR) Alternator: Type Three-phase AC Rated output 22.5 A / 14 V @5 000 r/min (rpm) Specifications subject to change without notice, and may not apply to every country. (US): United States Model (CAL): California Model (CA): Canada Model (FR): France Model...
  • Page 23: Technical Information - Air Inlet System

    GENERAL INFORMATION 1-15 Technical Information – Air Inlet System Center Ram Air Inlet The ram air duct was moved from both left and right side to center of the fairing so that incoming air has a straighter path to the airbox, increasing ram air efficiency. The duct was also designed to maintain optimum airflow despite ex- treme changes in bike attitude, such as during hard accel- eration, braking, and cornering.
  • Page 24 1-16 GENERAL INFORMATION Technical Information – Air Inlet System Subthrottle Control System The ZX636–B1 ∼ and ZX600–K1 utilize large bore throttle bodies to increase power output. How- ever, sudden changes in throttle opening can cause hesitation and jerky throttle response with a single butterfly valve in a large bore.
  • Page 25 GENERAL INFORMATION 1-17 Technical Information – Air Inlet System Operation The subthrottle control system consists of the subthrottle valve, subthrottle valve actuator with a stepping motor built in it, ECU, and subthrottle sensor. The subthrottle valve is built in the each throttle body.
  • Page 26: Technical Information - New Ignition Interlock Sidestand

    1-18 GENERAL INFORMATION Technical Information – New Ignition Interlock Sidestand Outline The New Ignition Interlock Sidestand System applied to ZX636–B1 ∼ and ZX600–K1 models that cannot function if gears are engaged and/or the sidestand is not lifted upward even though clutch lever pulled in, which differs from the traditional one.
  • Page 27: Technical Information - Tail/brake Lights Employing Led

    GENERAL INFORMATION 1-19 Technical Information – Tail/Brake Lights Employing LED Outline This model employs a tail/brake light containing 21 Light Emitting Diodes (LED). The LED emits luminous beams over a longer life span than those emitted from a traditional electric heated bulb (more than 5 times longer), uses lower voltage, expends lower wattage (approx.1/5), and is quicker responsing.
  • Page 28 1-20 GENERAL INFORMATION Technical Information – Tail/Brake Lights Employing LED The emitting color differs according to the materials of semi-conductors. Materials of Semi-Conductor and Emitting Color Materials of Semi-Conductor Emitting Color GaAsP, GaAlAs Green Blue Ga: Gallium As: Arsenic P: Phosphorus N: Nitrogen Al: Aluminum...
  • Page 29: Technical Information - Kawasaki Low Exhaust Emission System

    GENERAL INFORMATION 1-21 Technical Information – KAWASAKI LOW EXHAUST EMISSION SYSTEM Since the emission regulations become more severe, Kawasaki has adopted a type of simplified KAWASAKI LOW EXHAUST EMISSION SYSTEM (KLEEN), which have no catalyst protection sys- tem, according to each regulation of different countries.
  • Page 30: Unit Conversion Table

    1-22 GENERAL INFORMATION 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 ....Tire Wear Check ......2-28 Torque and Locking Agent....Final Drive........2-29 Specifications ........Drive Chain Wear Check ..... 2-29 Special Tools ........2-11 Drive Chain Lubrication....2-32 Maintenance Procedure ....
  • 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. FREQUENCY 1 000 km Whichever * ODOMETER READING comes...
  • Page 33: Periodic Maintenance Chart

    PERIODIC MAINTENANCE 2-3 Periodic Maintenance Chart FREQUENCY 1 000 km Whichever * ODOMETER READING comes (600 mile) first 6 000 km → (4 000 mile) ↓ 12 000 km ( 7 500 mile) 18 000 km (12 000 mile) 24 000 km (15 000 mile) 30 000 km (20 000 mile)
  • Page 34: Torque And Locking Agent

    2-4 PERIODIC MAINTENANCE Torque and Locking Agent The following tables list the tightening torque The table below, relating tightening torque to for the major fasteners requiring use of a non thread diameter, lists the basic torque for the -permanent locking agent or liquid gasket. bolts and nuts.
  • Page 35 PERIODIC MAINTENANCE 2-5 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Coolant By-pass Fitting 0.90 78 in·lb Water Hose Fitting Bolts 106 in·lb Radiator Mounting Bolts 0.70 61 in·lb Radiator Bracket Mounting Bolts 0.70 61 in·lb Coolant Reserve Tank Mounting Screws 0.70 61 in·lb Oil Cooler Bolt...
  • Page 36 2-6 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Oil Pipe Holder Bolts 104 in·lb Oil Pressure Relief Valve Oil Pressure Switch Oil Pressure Switch Terminal Bolt 0.15 13 in·lb Impeller Bolt 87 in·lb Oil Passage Plug Oil Jet Nozzle Bolts 0.70 61 in·lb...
  • Page 37 PERIODIC MAINTENANCE 2-7 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Speed Sensor Mounting Bolt 0.40 35 in·lb Rear Sprocket Nuts Rear Sprocket Studs – – – Brakes: Bleed Valves 0.80 69 in·lb Brake Hose Banjo Bolts Brake Lever Pivot Bolt 0.10 9 in·lb Brake Lever Pivot Bolt Locknut...
  • Page 38 2-8 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Clutch Lever Holder Bolts 0.80 69 in·lb Frame: Footpeg Holder Bolts Side Stand Bolt Footpeg Stay Bolts Side Stand Bracket Bolts Rear Frame Bolts and Nuts Side Stand Switch Bolt 0.90 78 in·lb Wind Shield Mounting Screws...
  • Page 39: Specifications

    PERIODIC MAINTENANCE 2-9 Specifications Item Standard Service Limit Fuel System: 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Throttle grip free play – – – Idle speed 1 300 ± 50 r/min (rpm) – – – Throttle body vacuum: ZX636B 24 ±...
  • Page 40 2-10 PERIODIC MAINTENANCE Specifications Item Standard Service Limit Air pressure: (when cold) Front Up to 180 kg (397 lb) load: – – – 250 kPa (2.5 kgf/cm², 36 psi) Rear Up to 180 kg (397 lb) load: – – – 290 kPa (2.9 kgf/cm², 42 psi) Final Drive: 25 ∼...
  • Page 41: Special Tools

    PERIODIC MAINTENANCE 2-11 Special Tools Steering Stem Nut Wrench: Pilot Screw Adjuster, C: 57001–1100 57001–1292 Jack: Lead Wire-Peak Voltage Adapter: 57001–1238 57001–1449 Oil Filter Wrench: 57001–1249...
  • Page 42: Maintenance Procedure

    2-12 PERIODIC MAINTENANCE Maintenance Procedure Fuel System (DFI) Fuel Hose and Connection Inspection ○ The fuel hose [A] is designed to be used throughout the motorcycle’s life without any maintenance. However, if the motorcycle is not properly handled, the high pressure inside the fuel line can cause fuel to leak or the hose to burst.
  • Page 43: Idle Speed Inspection

    PERIODIC MAINTENANCE 2-13 Maintenance Procedure Throttle Bore Cleaning • Check the throttle bore for cleanliness as follows: ○ Remove: Throttle Body (see Fuel System (DFI) chapter) ○ Check the main throttle valves and throttle bores [A] for carbon deposits by opening the main throttle valves. If any carbon accumulates, wipe the carbon off the throt- tle bores around the throttle bores and the throttle valves, using a cotton pad penetrated with a high-flash point sol-...
  • Page 44: Engine Vacuum Synchronization Inspection

    2-14 PERIODIC MAINTENANCE Maintenance Procedure Engine Vacuum Synchronization Inspection NOTE ○ These procedures are explained on the assumption that the inlet and exhaust systems of the engine are in good condition. • Situate the motorcycle so that it is vertical. •...
  • Page 45 PERIODIC MAINTENANCE 2-15 Maintenance Procedure • Plug: Vacuum Switch Valve Hose [A] and its Air Cleaner Hous- Hole [B] Removed Vacuum Hoses • Install the air cleaner housing [A]. • Start the engine and warm it up thoroughly. • Check the idle speed. If the idle speed is out of the specified range, adjust it.
  • Page 46 2-16 PERIODIC MAINTENANCE Maintenance Procedure If any one vacuum measurement is out of the standard measurement after synchronization, adjust the bypass screws [A]. Special Tool - Pilot Screw Adjuster, C: 57001-1292 • Adjust the lowest vacuum between #1 and #2 to the high- est of 1 and 2.
  • Page 47: Air Cleaner Element Replacement

    PERIODIC MAINTENANCE 2-17 Maintenance Procedure • Back out the same number of turns counted when first turned in. This is to set the screw to its original position. NOTE ○ A throttle body has different “turns out” of the bypass screw for each individual unit.
  • Page 48: Evaporative Emission Control System Inspection (california Model)

    Install a new element [A] with the mesh side facing up- ward. CAUTION Use only the recommended air cleaner element (Kawasaki part number 11013–1301). Using an- other air cleaner element will wear the engine prematurely or lower the engine performance.
  • Page 49: Cooling System

    PERIODIC MAINTENANCE 2-19 Maintenance Procedure • Check the liquid/vapor separator as follows: ○ Remove: Seats (see Frame chapter) ○ Disconnect the hoses from the separator, and remove the separator [A] from the motorcycle right side. ○ Visually inspect the separator for cracks and other dam- age.
  • Page 50 2-20 PERIODIC MAINTENANCE Maintenance Procedure • Remove: Right Inner Cover (see Frame chapter) Radiator Cap [A] ○ Remove the radiator cap 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 51: Engine Top End

    PERIODIC MAINTENANCE 2-21 Maintenance Procedure Water and Coolant Mixture Ratio (Recommended) Soft Water: 50 % Coolant: 50 % Freezing Point: – 35°C (– 31°F) Total Amount: 2.4 L (2.5 US qt) NOTE ○ Choose a suitable mixture ratio by referring to the coolant manufacturer’s directions.
  • Page 52: Valve Clearance Check

    2-22 PERIODIC MAINTENANCE Maintenance Procedure Valve Clearance Check Valve Clearance Inspection NOTE ○ Valve clearance must be checked and adjusted when the engine is cold (at room temperature). • Remove: Lower Fairings (see Frame chapter) Pickup Coil Cover Cylinder Head Cover (see Engine Top End chapter) •...
  • Page 53 PERIODIC MAINTENANCE 2-23 Maintenance Procedure Valve Clearance Adjustment • To change the valve clearance, remove the camshaft chain tensioner, camshafts and valve lifters. Replace the shim with one of a different thickness. NOTE ○ Mark and record the valve lifter and shim locations so they can be reinstalled in their original positions.
  • Page 54 2-24 PERIODIC MAINTENANCE Maintenance Procedure VALVE CLEARANCE ADJUSTMENT CHART INLET VALVE 1. Measure the clearance (when engine is cold). 2. Check present shim size. 3. Match clearance in vertical column with present shim size in horizontal column. 4. Install the shim specified where the lines intersect. This shim will give the proper clearance.
  • Page 55 PERIODIC MAINTENANCE 2-25 Maintenance Procedure VALVE CLEARANCE ADJUSTMENT CHART EXHAUST VALVE 1. Measure the clearance (when engine is cold). 2. Check present shim size. 3. Match clearance in vertical column with present shim size in horizontal column. 4. Install the shim specified where the lines intersect. This shim will give the proper clearance.
  • Page 56: Clutch

    2-26 PERIODIC MAINTENANCE Maintenance Procedure Clutch Clutch Adjustment Check Clutch Lever Free Play Inspection • Pull the clutch lever just enough to take up the free play [A]. • Measure the gap between the lever and the lever holder. If the gap is too wide, the clutch may not release fully. If the gap is too narrow, the clutch may not engage fully.
  • Page 57: Engine Lubrication System

    PERIODIC MAINTENANCE 2-27 Maintenance Procedure Engine Lubrication System Engine Oil Change • Situate the motorcycle so that it is vertical after warming up the engine. • Remove the engine drain plug [A] to drain the oil. ○ The oil in the oil filter can be drained by removing the filter (see Oil Filter Replacement).
  • Page 58: Wheels/tires

    2-28 PERIODIC MAINTENANCE Maintenance Procedure • Install the oil filter clamp so that projection [B] fits the slot [A] of oil cooler. ○ Be sure to place the rubber tube on the projection. • Tighten: Torque - Oil Filter Clamp Bolt [C]: 5.9 N·m (0.60 kgf·m, 52 in·lb) •...
  • Page 59: Final Drive

    PERIODIC MAINTENANCE 2-29 Maintenance Procedure NOTE ○ Most countries may have their own regulations a mini- mum tire tread depth: be sure to follow them. ○ Check and balance the wheel when a tire is replaced with a new one. Air Pressure Inspection/Adjustment •...
  • Page 60 2-30 PERIODIC MAINTENANCE Maintenance Procedure WARNING Misalignment of the wheel will result in abnormal wear and may result in an unsafe riding condition. • Tighten both chain adjuster locknuts securely. • Tighten the axle nut. Torque - Rear Axle Nut: 127 N·m (13.0 kgf·m, 92 ft·lb) •...
  • Page 61 PERIODIC MAINTENANCE 2-31 Maintenance Procedure Drive Chain Wear Inspection • Remove: Chain Cover • Rotate the rear wheel to inspect the drive chain for dam- aged rollers, and loose pins and links. If there is any irregularity, replace the drive chain. Lubricate the drive chain if it appears dry.
  • Page 62: Drive Chain Lubrication

    2-32 PERIODIC MAINTENANCE Maintenance Procedure Drive Chain Lubrication • If a special lubricant is not available, a heavy oil such as SAE 90 is preferred to a lighter oil because it will stay on the chain longer and provide better lubrication. •...
  • Page 63: Caliper Piston Seal And Dust Seal Replacement

    PERIODIC MAINTENANCE 2-33 Maintenance Procedure Brake Light Timing Adjustment Brake light timing is adjusted by changing the position of the rear brake light switch. • Adjust the position of the switch so that the brake light goes on after the specified pedal travel by turning the ad- justing nut [A].
  • Page 64 2-34 PERIODIC MAINTENANCE Maintenance Procedure • Level the brake fluid reservoir. • Remove the reservoir cap. • Remove the rubber cap from the bleed valve [A] on the caliper. • Attach a clear plastic hose [B] to the bleed valve, and run the other end of the hose into a container.
  • Page 65 PERIODIC MAINTENANCE 2-35 Maintenance Procedure Bleeding the Brake Line 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. Air, however, is easily compressed.
  • Page 66 2-36 PERIODIC MAINTENANCE Maintenance Procedure • Follow the procedure below to install the front/rear brake fluid reservoir cap correctly. ○ First, tighten the front/rear brake fluid reservoir cap [B] clockwise [C] by hand until the resistance is felt fully; then, tighten the cap an additional 1/6 turn [D] while holding the brake fluid reservoir [A] body.
  • Page 67: Brake Hoses And Connections Check

    PERIODIC MAINTENANCE 2-37 Maintenance Procedure Brake Hoses and Connections Check • 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 68: Steering

    2-38 PERIODIC MAINTENANCE Maintenance Procedure Steering Steering Check Steering Inspection • Lift the front wheel off the ground using the jack. Special Tool - Jack: 57001–1238 • With the front wheel pointing straight ahead, alternately tap each end of the handlebar. The front wheel should swing fully left and right from the force of gravity until the fork hits the stop.
  • Page 69: Steering Stem Bearing Lubrication

    PERIODIC MAINTENANCE 2-39 Maintenance Procedure NOTE ○ Turn the stem nut 1/8 turn at a time maximum. • Install the lock washer so that claw of washer fit the notch of steering stem nut. • First tighten the steering stem locknut by hand until the resistance is felt fully, then tighten steering stem nut ad- ditional more than two notches so that align the notch of stem nut and stem locknut.
  • Page 70: General Lubrication

    2-40 PERIODIC MAINTENANCE Maintenance Procedure Spark Plug Gap Inspection • Measure the gap [A] with a wire-type thickness gauge. If the gap is incorrect, carefully bend the side electrode [B] with a suitable tool to obtain the correct gap. Spark Plug Gap : 0.7 ∼ 0.8 mm (0.028 ∼ 0.031 in.) CAUTION Use only the recommended spark plugs (special marks ).
  • Page 71 PERIODIC MAINTENANCE 2-41 Maintenance Procedure • With the cable disconnected at both ends, the inner 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 72: Nut, Bolts, And Fasteners Tightness Check

    2-42 PERIODIC MAINTENANCE Maintenance Procedure Nut, Bolts, and Fasteners Tightness Check Tightness Inspection • Check the tightness of the bolts and nuts listed here. Also, check to see that each cotter pin is in place and in good condition. NOTE ○...
  • Page 73 FUEL SYSTEM (DFI) 3-1 Fuel System (DFI) Table of Contents Exploded View........Backups .......... 3-64 Specifications ........3-10 Main Throttle Sensor (Service Code Special Tools ........3-12 11)........... 3-66 DFI System........3-14 Main Throttle Sensor DFI Servicing Precautions ....3-20 Removal/Adjustment ....
  • Page 74 3-2 FUEL SYSTEM (DFI) Output Voltage Inspection.... 3-87 Free Play Adjustment....3-101 Vehicle-down Sensor (Service Code Choke Cable Installation ....3-101 31)........... 3-89 Cable Lubrication ......3-101 Removal........3-89 Throttle Body Assy ......3-102 Installation........3-89 Idle Speed Inspection ....3-102 Inspection........
  • Page 76: Exploded View

    3-4 FUEL SYSTEM (DFI) Exploded View...
  • Page 77: Exploded View

    FUEL SYSTEM (DFI) 3-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Air cleaner housing mounting bolt 0.70 61 in·lb Air inlet duct mounting bolts 0.70 61 in·lb Air cleaner housing clamp bolts 0.25 22 in·lb Parts Remarks Duct (#1, #4) Standard Length 41.3 mm (1.63 in.) Option...
  • Page 78 3-6 FUEL SYSTEM (DFI) Exploded View...
  • Page 79 14. Subthrottle Valve Actuator 15. Injectors 16. Dust Seals 17. Bypass Screw 18. ECU (Electric Control Unit) L: Apply a non-permanent locking agent. G: Apply grease. SS: Apply silicone sealant (Kawasaki Bond: 56019–120). CL: Apply cable lubricant. R: Replacement Parts...
  • Page 80 3-8 FUEL SYSTEM (DFI) Exploded View...
  • Page 81 FUEL SYSTEM (DFI) 3-9 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Fuel pump bolts 87 in·lb 2. Fuel Pump 3. Canister 4. Separator 5. Red 6. Blue 7. Green 8. White L: Apply a non-permanent locking agent. R: Replacement Parts CAL: California model...
  • Page 82: Specifications

    3-10 FUEL SYSTEM (DFI) Specifications Item Standard Digital Fuel Injection System Idle Speed 1 300 ± 50 r/min (rpm) Throttle Assy: Type Four barrel type φ38 mm (1.5 in) Bore Throttle body vacuum: ZX636B 24 ± 1.3 kPa (180 ± 10 mmHg) ZX600K 22 ±...
  • Page 83 FUEL SYSTEM (DFI) 3-11 Specifications Item Standard Vehicle-down Sensor: Detection method Magnetic flux detection method More than 60 ∼ 70° for each bank Detection angle Within 0.5 ∼ 1.0 sec. Detection time with the sensor tilted 60 ∼ 70° or more: 3.7 ∼ 4.4 V Output voltage with sensor arrow mark pointed up: 0.4 ∼...
  • Page 84 3-12 FUEL SYSTEM (DFI) Special Tools Oil Pressure Gauge: Throttle Sensor Setting Adapter: 57001–125 57001–1400 Carburetor Drain Plug Wrench, Hex 3: Fuel Pressure Gauge Adapter: 57001–1269 57001–1417 Fork Oil Level Gauge: Needle Adapter Set: 57001–1290 57001–1457 Pilot Screw Adjuster, C: Throttle Sensor Setting Adapter: 57001–1292 57001–1538...
  • Page 85 FUEL SYSTEM (DFI) 3-13 Special Tools Kawasaki Bond (Silicone Sealant): 56019–120...
  • Page 86: Dfi System

    3-14 FUEL SYSTEM (DFI) DFI System DFI System...
  • Page 87 FUEL SYSTEM (DFI) 3-15 DFI System 1. ECU (Electric Control Unit) 2. Crankshaft Sensor 3. Camshaft Position Sensor 4. Main Throttle Sensor 5. Subthrottle Sensor 6. Subthrottle Valve Actuator 7. Inlet Air Pressure Sensor 8. Atmospheric Pressure Sensor 9. Water Temperature Sensor 10.
  • Page 88 3-16 FUEL SYSTEM (DFI) DFI System DFI System Wiring Diagram...
  • Page 89 FUEL SYSTEM (DFI) 3-17 DFI System Part Name 1. Subthrottle Valve Actuator 2. Injector #1 3. Injector #2 4. Injector #3 5. Injector #4 6. Water Temperature Sensor 7. Speed Sensor 8. Inlet Air Temperature Sensor 9. Atmospheric Pressure Sensor 10.
  • Page 90 3-18 FUEL SYSTEM (DFI) DFI System Terminal Numbers of ECU Connectors...
  • Page 91 FUEL SYSTEM (DFI) 3-19 DFI System Terminal Names 1. Power Supply to Sensors 2. Main Throttle Sensor Output Signal 3. Subthrottle Sensor Output Signal 4. Atmospheric Pressure Sensor Output Signal 5. Water Temperature Sensor Output Signal 6. Unused 7. Ignition Switch Output Signal 8.
  • Page 92: Dfi Servicing Precautions

    3-20 FUEL SYSTEM (DFI) DFI Servicing Precautions There are a number of important precautions that should be followed servicing the DFI system. ○ This DFI system is designed to be used with a 12 V sealed battery as its power source. Do not use any other battery except for a 12 V sealed battery as a power source.
  • Page 93 FUEL SYSTEM (DFI) 3-21 DFI Servicing Precautions ○ The fuel hose [A] is designed to be used through out the motorcycle’s life without any maintenance, however, if the motorcycle is not properly handled, the high pressure in- side the fuel line can cause fuel to leak or the hose to burst.
  • Page 94: Troubleshooting The Dfi System

    3-22 FUEL SYSTEM (DFI) Troubleshooting the DFI System Outline When an abnormality in the system occurs, the FI indica- tor LED (Light Emitting Diode) light goes on to alert the rider on the meter panel. In addition, the condition of the problem is stored in the memory of the ECU (electronic control unit).
  • Page 95 ○ 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 accurate tests of the DFI system.
  • Page 96 3-24 FUEL SYSTEM (DFI) Troubleshooting the DFI System • Pull each connector [A] apart and inspect it for corrosion, dirt, and damage. If the connector is corroded or dirty, clean it carefully. If it is damaged, replace it. Connect the connectors securely. •...
  • Page 97 FUEL SYSTEM (DFI) 3-25 Troubleshooting the DFI System ○ Electrical Connectors: Female Connectors [A] Male Connectors [B]...
  • Page 98 3-26 FUEL SYSTEM (DFI) Troubleshooting the DFI System DFI Diagnosis Flow Chart...
  • Page 99 FUEL SYSTEM (DFI) 3-27 Troubleshooting the DFI System Notes: OK: No problem. NG: Problem exists. 1. Inspection starts. • An abnormality occurs in the DFI system, and the FI indicator LED light goes on to alert the rider. • Bring the motorcycle into the shop. 2.
  • Page 100: Inquiries To Rider

    3-28 FUEL SYSTEM (DFI) Troubleshooting the DFI System Inquiries to Rider ○ Each rider reacts to problems in different ways, so it is important to confirm what kind of symptoms the rider has encountered. ○ Try to find out exactly what problem occurred under exactly what conditions by asking the rider; knowing this information may help you reproduce the problem.
  • Page 101 FUEL SYSTEM (DFI) 3-29 Troubleshooting the DFI System Sample Diagnosis Sheet Rider name: Registration No. (license plate No.): Year of initial registration: Model: Engine No.: Frame No.: Date problem occured: Mileage: Environment when problem occurred. Weather □ fine, □ cloudy, □ rain, □ snow, □ always, □ other: Temperature □...
  • Page 102 3-30 FUEL SYSTEM (DFI) Troubleshooting the DFI System Poor running □ choke lever pulled out fully (push it in fully). at low speed □ very low choke speed. □ very low idle speed, □ very high idle speed, □ rough idle speed. □...
  • Page 103: Dfi System Troubleshooting Guide

    FUEL SYSTEM (DFI) 3-31 DFI System Troubleshooting Guide NOTE ○ This is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties. ○...
  • Page 104 3-32 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or possible Causes Actions (chapter) Ignition and engine stop switches not ON Turn both switches ON . Clutch lever not pulled in and gear not in neutral Pull the lever in and shift the gear in neutral. whether sidestand up or not Though clutch lever pulled in, sidestand up and Sidestand down and clutch lever pulled in...
  • Page 105: Poor Running At Low Speed

    FUEL SYSTEM (DFI) 3-33 DFI System Troubleshooting Guide Symptoms or possible Causes Actions (chapter) Piston ring /groove clearance excessive Inspect and replace (see chapter 5). Cylinder head gasket damaged Replace (see chapter 5). Cylinder head warped Inspect and replace (see chapter 5). No valve clearance Adjust (see chapter 2).
  • Page 106 3-34 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Atmospheric pressure sensor trouble Inspect (see chapter 3). Fuel pressure too low or too high Inspect (see chapter 3). Battery voltage low Inspect and charge (see chapter 16). Incorrect idle speed : Water temperature sensor trouble Inspect (see chapter 3).
  • Page 107 FUEL SYSTEM (DFI) 3-35 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Subthrottle valve actuator trouble Inspect (see chapter 3). Water temperature sensor trouble Inspect (see chapter 3). Atmospheric pressure sensor trouble Inspect (see chapter 3). Inlet air pressure sensor trouble Inspect (see chapter 3).
  • Page 108 3-36 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Too low fuel pressure Inspect (see chapter 3). Fuel pump trouble Inspect (see chapter 3). Main throttle sensor trouble Inspect (see chapter 3). Inlet air temperature sensor trouble Inspect (see chapter 3).
  • Page 109: Poor Running Or No Power At High Speed

    FUEL SYSTEM (DFI) 3-37 DFI System Troubleshooting Guide Poor Running or No Power at High Speed: Symptoms or Possible Causes Actions (chapter) Firing incorrect : Clean spark plug and adjust plug gap (see Spark plug dirty, broken or maladjusted chapter 2). Spark plug cap trouble Inspect stick coil (see chapter 16).
  • Page 110 3-38 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Fuel poor quality or incorrect (Use the gasoline Change fuel (see chapter 3). recommended in the Owner’s Manual) Spark plug incorrect Replace it with the correct plug (see chapter 16). Stick coil trouble Inspect (see chapter 16).
  • Page 111 FUEL SYSTEM (DFI) 3-39 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Too low fuel pressure Inspect fuel line and fuel pump (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 112: Ecu

    3-40 FUEL SYSTEM (DFI) CAUTION Never drop the ECU, especially on a hard surface. Such a shock to the ECU can damage it. ECU Removal • Remove: Seats (see Frame chapter) Seat Cover (see Frame chapter) Battery Leads Bolts [A] Storage Compartments [B] ○...
  • Page 113: Ecu Power Supply Inspection

    FUEL SYSTEM (DFI) 3-41 • Insert the projections [A] of the rear fender front into the slits [B] of the rubber protector. ECU Power Supply Inspection • Visually inspect the terminals [A] of the ECU connectors. If the connector is clogged with mud or dust, blow it off with compressed air.
  • Page 114 3-42 FUEL SYSTEM (DFI) • Check the ECU power source voltage with a tester [A]. ○ Position the terminal in accordance with terminal numbers of ECU connectors [B] in this chapter figure. Battery [C] ECU Power Source Inspection Tester between 13 (W/Y) Terminal and Connections: Battery (–) Terminal between 43 (W) Terminal and...
  • Page 115: Dfi Power Source

    FUEL SYSTEM (DFI) 3-43 DFI Power Source ECU Fuse Removal • Refer to the Electrical System chapter for the ECU fuse removal. ECU Fuse Installation If a fuse fails during operation, inspect the DFI system to determine the cause, and then replace it with a new fuse of proper amperage.
  • Page 116: Fi Indicator Led Light

    3-44 FUEL SYSTEM (DFI) FI Indicator LED Light Inspection Flow Chart...
  • Page 117: Led Light Inspection

    FUEL SYSTEM (DFI) 3-45 FI Indicator LED Light LED Light Inspection • Remove the meter unit (see Electrical System chapter). • Using two auxiliary leads, supply battery power to the FI indicator LED light [A]. 12 V Battery [B] FI Indicator LED Light Check Connector: Meter Connector [C] (disconnected) Connection:...
  • Page 118: Fuel Line

    3-46 FUEL SYSTEM (DFI) Fuel Line Fuel Pressure Inspection NOTE ○ Be sure the battery is fully charged. • Remove: Seats (see Frame chapter) Fuel Tank Bolts (see Fuel Tank Removal) • Be sure to place a piece of cloth around the fuel supply pipe of the throttle body assembly and fuel pump.
  • Page 119: Fuel Flow Rate Inspection

    FUEL SYSTEM (DFI) 3-47 Fuel Line Fuel Pressure (idling) Standard: 304 kPa (3.1 kgf/cm², 44 psi) NOTE ○ The gauge hand will fluctuate. Read the pressure at the average of the maximum and minimum indications. If the fuel pressure is much higher than the specified, re- place the fuel pump.
  • Page 120 3-48 FUEL SYSTEM (DFI) Fuel Line • Connect the prepared fuel hose [A] to the fuel supply pipe of the fuel pump. • Secure the fuel hose with a clamp. • Insert the fuel hose into the measuring cylinder [B]. WARNING Wipe off spilled out fuel immediately.
  • Page 121: Fuel Pump

    FUEL SYSTEM (DFI) 3-49 Fuel Pump Fuel Pump Removal CAUTION Never drop the fuel pump, especially on a hard sur- face. Such a shock to the pump can damage it. WARNING Gasoline is extremely flammable and can be explo- sive under certain conditions. Make sure the area is well-ventilated and free from any source of flame or sparks;...
  • Page 122: Operation Inspection

    3-50 FUEL SYSTEM (DFI) Fuel Pump • Check that the fuel pump terminal [A] and band [B] are in place. [C] Front • 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 tight- ening sequence shown.
  • Page 123 FUEL SYSTEM (DFI) 3-51 Fuel Pump 1. ECU 7. Starter Relay 2. Ignition Switch 8. Battery 3. ECU Main Relay 9. Fuel Pump 4. Fuel Pump Relay 10. Engine Stop Switch 11. Junction Box 5. ECU Fuse 15 A 6. Main Fuse 30 A 12.
  • Page 124: Fuel Pump Relay

    3-52 FUEL SYSTEM (DFI) Fuel Pump Relay Fuel Pump Relay Removal CAUTION Never drop the relay, especially on a hard surface. Such a shock to the relay can damage it. • Remove: Seats (see Frame chapter) • Remove the fuel pump relay [A] from the bracket and dis- connect the connector.
  • Page 125 FUEL SYSTEM (DFI) 3-53 Fuel Pump Relay 1. ECU 7. Main Fuse 30 A 2. Fuel Pump 8. Starter Relay 3. Ignition Switch 9. Battery 4. ECU Main Relay 10. Engine Stop Switch 5. Fuel Pump Relay 11. Ignition Fuse 10 A 6.
  • Page 126: Fuel Injectors

    3-54 FUEL SYSTEM (DFI) Fuel Injectors CAUTION Never drop the injector, especially on a hard sur- face. Such a shock to the injector can damage it. Audible Inspection • Start the engine. • Apply the tip of a screwdriver [A] to the injector [B]. Put the grip end onto your ear, and listen whether the injector is clicking or not.
  • Page 127: Injector Resistance Inspection

    • Disconnect the connector from the injector [A] (see Throt- tle Body Disassembly/Assembly). • Measure the injector resistance with the hand tester [B]. Special Tool - Kawasaki Hand Tester: 57001–1394 Injector Resistance Connections to Injector Meter (+) Meter (–) #1: W/R ←→ BL/R Terminal #2: W/R ←→...
  • Page 128: Injector Voltage Inspection

    3-56 FUEL SYSTEM (DFI) Fuel Injectors Injector Voltage Inspection • Turn the ignition switch OFF. • Remove: Fuel Tank (see Fuel Tank Removal) • Connect a digital voltmeter [A] to the connector [B], with the needle adapter set. Special Tool - Needle Adapter Set: 57001-1457 Injector Power Source Voltage Connector to Injector #1, #2, #3, #4 Meter (+) →...
  • Page 129: Injector Fuel Line Inspection

    FUEL SYSTEM (DFI) 3-57 Fuel Injectors Injector Fuel Line Inspection • Remove the throttle body assy (see this chapter). • Check the injector fuel line for leakage as follows: ○ Connect a commercially available vacuum/pressure pump [A] to the nipple of the delivery pipe [B] with the fuel hose [C] (both ends connected with the clamps [D]) as shown.
  • Page 130 3-58 FUEL SYSTEM (DFI) Fuel Injectors 1. ECU 9. ECU Fuse 15 A 2. Fuel Injector #4 10. Main Fuse 30 A 3. Fuel Injector #3 11. Starter Relay 4. Fuel Injector #2 12. Battery 5. Fuel Injector #1 13. Engine Stop Switch 6.
  • Page 131: Self-diagnosis

    FUEL SYSTEM (DFI) 3-59 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 132: Service Code Clearing Procedures

    3-60 FUEL SYSTEM (DFI) Self-Diagnosis • To enter the self-diagnosis dealer mode 2 repeat opening [B] and grounding [A] the lead more than five times [F] within 2 seconds [C] after the lead is first grounded, and then keep it grounded continuously [D] for more than 2 seconds.
  • Page 133 FUEL SYSTEM (DFI) 3-61 Self-Diagnosis...
  • Page 134: How To Read Service Codes

    3-62 FUEL SYSTEM (DFI) 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. ○ Read 10th digit and unit digit as the FI indicator LED light blinks. ○...
  • Page 135: Service Code Table

    FUEL SYSTEM (DFI) 3-63 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 136: Backups

    3-64 FUEL SYSTEM (DFI) 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 137 FUEL SYSTEM (DFI) 3-65 Self-Diagnosis Service Output Signal Usable Parts Backups by ECU Codes Range or Criteria If the subthrottle sensor system fails (the signal Subthrottle Sensor Subthrottle is out of the usable range, wiring short or open), Output Voltage sensor the actuator locks sub throttle valve at full open 0.15 ∼...
  • Page 138: Main Throttle Sensor Removal/adjustment

    3-66 FUEL SYSTEM (DFI) 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 139 FUEL SYSTEM (DFI) 3-67 Main Throttle Sensor (Service Code 11) • Disconnect the main throttle sensor connector [A] and connect the harness adapter [B] between the harness connector and main throttle sensor connector. • Connect a digital meter to the harness adapter leads. Special Tool - Throttle Sensor Harness Adapter : 57001 -1538 Main Throttle Sensor Input Voltage...
  • Page 140: Output Voltage Inspection

    3-68 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: 57001–1457 Main Throttle Sensor Output Voltage Connections to ECU Meter (+) →...
  • Page 141 FUEL SYSTEM (DFI) 3-69 Main Throttle Sensor (Service Code 11) • Disconnect the main throttle sensor connector [A] and connect the harness adapter [B] between the harness connector and main throttle sensor connector. • Connect a digital meter to the harness adapter leads. Special Tool - Throttle Sensor Harness...
  • Page 142: Resistance Inspection

    3-70 FUEL SYSTEM (DFI) Main Throttle Sensor (Service Code 11) Resistance Inspection • Turn the ignition switch OFF. • Disconnect the main throttle sensor connector. • Connect a digital meter [A] to the main throttle sensor connector [B]. • Measure the main throttle sensor resistance. Main Throttle Sensor Resistance Connections: BL lead [C] ←→...
  • Page 143: Inlet Air Pressure Sensor (service Code 12)

    FUEL SYSTEM (DFI) 3-71 Inlet Air Pressure Sensor (Service Code 12) CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the part can damage it. Removal • Turn the ignition switch off. • Remove: Air Cleaner Housing (see Air Cleaner Housing Removal) Inlet Air Pressure Sensor Connector [A] Inlet Air Pressure Sensor Screw [B] Inlet Air Pressure Sensor [C]...
  • Page 144: Output Voltage Inspection

    3-72 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code 12) If the reading is within the standard range, and check the input voltage again at the sensor connector. Remove the air cleaner housing (see Air Cleaner Housing Removal). • Disconnect the inlet air pressure sensor connector and connect the harness adapter [A] between the sub harness connector and inlet air pressure sensor connector.
  • Page 145 FUEL SYSTEM (DFI) 3-73 Inlet Air Pressure Sensor (Service Code 12) If the output voltage is far out of the usable range, check the output voltage again at the sensor connector [A] (when the lead is open, the output voltage is about 1.8 •...
  • Page 146 3-74 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 147 FUEL SYSTEM (DFI) 3-75 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 148: Inlet Air Temperature Sensor (service Code 13)

    3-76 FUEL SYSTEM (DFI) 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 fuel tank (see Fuel Tank Removal). •...
  • Page 149: Sensor Resistance Inspection

    • Remove the needle adapter set, and apply silicone sealant to the seals of the connector for waterproofing. Silicone Sealant (Kawasaki Bond: 56019-120) - Seals of ECU Connectors If the wiring is good, check the sensor resistance. Sensor Resistance Inspection •...
  • Page 150 3-78 FUEL SYSTEM (DFI) Inlet Air Temperature Sensor (Service Code 13) 1. ECU 2. Inlet Air Temperature Sensor...
  • Page 151: Water Temperature Sensor (service Code 14)

    Such a shock to the sensor can damage it. • Disconnect the sensor connector [A], and unscrew the water temperature sensor [B]. Silicone Sealant (Kawasaki Bond: 56019-120) - Threads of Water Temperature Sensor Torque - Water Temperature Sensor: 25 N·m (2.5 kgf·m, 18 ft·lb) •...
  • Page 152: Sensor Resistance Inspection

    3-80 FUEL SYSTEM (DFI) Water Temperature Sensor (Service Code 14) 1. ECU 2. Meter 3. Water Temperature Sensor Sensor Resistance Inspection • Remove the water temperature sensor (see this section). • Refer to Electrical System chapter for water temperature sensor inspection.
  • Page 153: Atmospheric Pressure Sensor (service Code 15)

    FUEL SYSTEM (DFI) 3-81 Atmospheric Pressure Sensor (Service Code 15) CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. Removal • Turn the ignition switch off. • Remove: Air Cleaner Housing (see Air Cleaner Housing Removal) Atmospheric Pressure Sensor Connector [A] Atmospheric Pressure Sensor Screw [B] Atmospheric Pressure Sensor [C]...
  • Page 154: Output Voltage Inspection

    3-82 FUEL SYSTEM (DFI) Atmospheric Pressure Sensor (Service Code 15) If the reading is within the standard range, remove the seat cover, and check the input voltage again at the sen- sor connector. Remove the air cleaner housing (see Air Cleaner Housing Removal).
  • Page 155 FUEL SYSTEM (DFI) 3-83 Atmospheric Pressure Sensor (Service Code 15) If the output voltage is far out of the usable range, remove the fuel tank, and check the output voltage at the sensor connector [A] (when the wiring is open, the output voltage is about 1.8 V).
  • Page 156 3-84 FUEL SYSTEM (DFI) Atmospheric Pressure Sensor (Service Code 15) 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). And get the usable range of the atmospheric pressure sensor output voltage and check if output voltage is within the standard or not in the same way as Output...
  • Page 157: Crankshaft Sensor

    FUEL SYSTEM (DFI) 3-85 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 158: Camshaft Position Sensor (service Code 23)

    3-86 FUEL SYSTEM (DFI) Camshaft Position Sensor (Service Code 23) 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 camshaft position sensor.
  • Page 159: Speed Sensor (service Code 24, 25)

    FUEL SYSTEM (DFI) 3-87 Speed Sensor (Service Code 24, 25) Speed Sensor Removal/Installation • See the Switches and Sensors section in teh Electrical System chapter. Speed Sensor Inspection • See the Switches and Sensors section in teh Electrical System chapter. Input Voltage Inspection NOTE ○...
  • Page 160 3-88 FUEL SYSTEM (DFI) Speed Sensor (Service Code 24, 25) • Disconnect the speed sensor connector [A] and connect the harness adapter [B] between the harness connector and speed sensor connector. • Connect a digital meter to the harness adapter leads. Special Tool - Throttle Sensor Setting Adapter: 57001 -1400...
  • Page 161: Vehicle-down Sensor (service Code 31)

    FUEL SYSTEM (DFI) 3-89 Vehicle-down Sensor (Service Code 31) This sensor has a weight [A] with two magnets inside, and sends a signal to the ECU. But when the motorcycle banks 60 ∼ 70° or more to either side (in fact falls down), the weight turns and shuts off the signal.
  • Page 162 3-90 FUEL SYSTEM (DFI) Vehicle-down Sensor (Service Code 31) • Connect a digital volt meter [A] to the connector of the vehicle-down sensor [B], with the needle adapter set [C]. Vehicle-down Sensor Power Source Voltage Connections to Sensor Meter (+) → W/Y lead [D] Meter (–) →...
  • Page 163 • Remove the needle adapter set, 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 normal, the wiring is suspect. Check the wiring.
  • Page 164: Subthrottle Sensor (service Code 32)

    3-92 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 165: Output Voltage Inspection

    FUEL SYSTEM (DFI) 3-93 Subthrottle Sensor (Service Code 32) • Disconnect the subthrottle sensor connector [A] and con- nect the harness adapter [B] between the harness con- nector and sub throttle sensor connector. • Connect a digital meter to the harness adapter leads. Special Tool - Throttle Sensor Setting Adapter : 57001 -1538 Subthrottle Sensor Input Voltage...
  • Page 166 3-94 FUEL SYSTEM (DFI) Subthrottle Sensor (Service Code 32) If the output voltage is within the standard range, check the ECU for a good ground, and power supply (see this chapter). If the ground and power supply are good, re- place the ECU.
  • Page 167: Resistance Inspection

    FUEL SYSTEM (DFI) 3-95 Subthrottle Sensor (Service Code 32) • After subthrottle sensor voltage inspection, remove the harness adapter. If the reading is out of the standard range, inspect the throttle sensor resistance. If the output voltage is normal, check the wiring for conti- nuity (see next diagram).
  • Page 168: Stick Coils (#1, #2, #3, #4: Service Code 51, 52, 53, 54)

    3-96 FUEL SYSTEM (DFI) Stick Coils (#1, #2, #3, #4: Service Code 51, 52, 53, 54) Stick Coil #1: Ignition Coil (Service Code 51) Stick Coil #2: Ignition Coil (Service Code 52) Stick Coil #3: Ignition Coil (Service Code 53) Stick Coil #4: Ignition Coil (Service Code 54) Removal/Installation CAUTION...
  • Page 169 FUEL SYSTEM (DFI) 3-97 Stick Coils (#1, #2, #3, #4: Service Code 51, 52, 53, 54) 1. ECU 5. Stick Coil #4 9. Ignition Fuse 10 A 2. Stick Coil #1 6. Ignition Switch 10. Main Fuse 30 A 3. Stick Coil #2 7.
  • Page 170: Subthrottle Valve Actuator (service Code 62)

    3-98 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 171: Input Voltage Inspection

    FUEL SYSTEM (DFI) 3-99 Subthrottle Valve Actuator (Service Code 62) Input Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch OFF. • Connect the peak voltage adaper [A] and a digital meter [B] to the connector [C], using the needle adapter set [D]. Recommended Tool - Peak Voltage Adapter Type: KEK-54–9–B Brand: KOWA SEIKI...
  • Page 172: Throttle Grip And Cables

    3-100 FUEL SYSTEM (DFI) Throttle Grip and Cables Free Play Inspection • Refer to the Throttle Control System Inspection in the Pe- riodic Maintenance chapter. Free Play Adjustment • Refer to the Throttle Control System Inspection in the Pe- riodic Maintenance chapter. Cable Installation •...
  • Page 173: Choke Cable

    FUEL SYSTEM (DFI) 3-101 Choke Cable Free Play Inspection • Push the choke lever [A] all the way to the front. • Check choke cable free paly [B]. ○ Determine the amount of choke cable play at the choke lever. Pull the choke lever till just before the inner cable [C] moves the link lever [D];...
  • Page 174: Throttle Body Assy

    3-102 FUEL SYSTEM (DFI) Throttle Body Assy Idle Speed Inspection • Refer to the Idle Speed Inspection in the Periodic Main- tenance chapter . Throttle Bore Cleaning • Refer to the Throttle Control System Inspection in the Pe- riodic Maintenance chapter. Synchronization Inspection •...
  • Page 175: Throttle Body Assy Installation

    FUEL SYSTEM (DFI) 3-103 Throttle Body Assy • Remove: Choke Cable Lower End [A] • Remove the throttle case to make a throttle cable slack. • Remove: Throttle Cable Lower Ends [B] • After removing the throttle body assy, stuff pieces of lint -free, clean cloths into the throttle body holders.
  • Page 176: Throttle Body Assy Disassembly

    3-104 FUEL SYSTEM (DFI) Throttle Body Assy Throttle Body Assy Disassembly 1. Throttle Body Assy 5. Inlet Air Pressure Sensor Hoses 2. Injectors 6. Bands 3. Injector Connector Harness 4. Delivery Pipe Assy CAUTION Do not remove, disassemble or adjust the main throttle sensor, subthrottle sensor, subthrottle valve actuator, throttle link mechanism and throttle body assy, because they are adjust or set surely at...
  • Page 177: Throttle Body Assy Assembly

    FUEL SYSTEM (DFI) 3-105 Throttle Body Assy • Pull out the injectors [A] from the delivery pipe [B]. NOTE ○ Do not damage the part of insert of the injectors when they are pulled out from the delivery pipe. Throttle Body Assy Assembly •...
  • Page 178: Air Line

    3-106 FUEL SYSTEM (DFI) Air Line Element Removal • Refer to Air Cleaner Element Replacement in the Periodic Maintenance chapter. Element Installation • Refer to Air Cleaner Element Replacement in the Periodic Maintenance chapter. Air Cleaner Element Inspection • Visually check the element [A] for tears or breaks. If the element has any tears or breaks, replace the ele- ment.
  • Page 179: Fuel Tank

    FUEL SYSTEM (DFI) 3-107 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 180: Fuel Tank Installation

    3-108 FUEL SYSTEM (DFI) Fuel Tank • For California Model, note the following: ○ Be sure to plug the evaporative fuel return hose to prevent fuel spilling before fuel tank removal. WARNING For California model, be careful not to spill the gasoline through the return hose.
  • Page 181: Fuel Tank Inspection

    FUEL SYSTEM (DFI) 3-109 Fuel Tank • Connect the fuel pump lead connector [A]. • Insert the fuel hose joint [B] straight onto the delivery pipe until the hose joint clicks. • Push and pull [C] the hose joint [B] back and forth, and make sure it is locked and does not come off.
  • Page 182: Evaporative Emission Control System

    3-110 FUEL SYSTEM (DFI) Evaporative Emission Control System The Evaporative Emission Control System routes fuel va- pors from the fuel system into the running engine or stores the vapors in a canister when the engine is stopped. Al- though no adjustments are required, a thorough visual in- spection must be made at the intervals specified by the Pe- riodic Maintenance Chart.
  • Page 183: Separator Operation Test

    FUEL SYSTEM (DFI) 3-111 Evaporative Emission Control System Separator Operation Test WARNING Gasoline is extremely flammable and can be ex- plosive under certain conditions. Turn the ignition switch OFF. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks;...
  • Page 185 COOLING SYSTEM 4-1 Cooling System Table of Contents Exploded View........................Specifications ......................... Special Tool ..........................Coolant Flow Chart......................... Coolant ........................... Coolant Deterioration Inspection..................Coolant Level Inspection....................Coolant Draining ....................... Coolant Filling ........................Pressure Testing ....................... Cooling System Flushing ....................Coolant Filter Cleaning ..................... Coolant Reserve Tank Removal ..................
  • Page 186: Exploded View

    4-2 COOLING SYSTEM Exploded View...
  • Page 187 12 Radiator bracket mounting bolts 0.70 61 in·lb 13 Coolant reserve tank mounting screws 0.70 61 in·lb 14 Oil cooler bolt 15 Water passage plugs L: Apply a non-permanent locking agent. EO: Apply engine oil. SS: Apply silicone sealant (Kawasaki Bond: 56019–120).
  • Page 188: Specifications

    4-4 COOLING SYSTEM Specifications Item Standard Coolant provided when shipping: Permanent type of antifreeze (soft water and ethylene Type glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators) Color Green Mixed ratio Soft water 50%, coolant 50% Freezing point -35°C (-31°F) Total amount...
  • Page 189: Special Tool

    COOLING SYSTEM 4-5 Special Tool Kawasaki Bond (Silicone Sealant) : 56019–120...
  • Page 190: Coolant Flow Chart

    4-6 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 with coolant temperature changes. The thermostat continuously changes its valve opening to keep the coolant temperature at the proper level.
  • Page 191 COOLING SYSTEM 4-7 Coolant Flow Chart 1. Radiator 5. Drain Plugs 2. Radiator Cap 6. Water Pump 3. Radiator Fan 7. Water Temperature Sensor 4. Fan Switch 8. Oil Cooler 9. Thermostat When the engine is cold, the thermostat is closed so that the coolant flow is restricted through the air bleeder hole, causing the engine to warm up more quickly.
  • Page 192: Coolant

    4-8 COOLING SYSTEM Coolant Coolant Deterioration Inspection • Visually inspect the coolant in the reserve tank. If whitish cotton-like wafts are observed, aluminum parts in the cooling system are corroded. If the coolant is brown, iron or steel parts are rusting. In either case, flush the cooling system.
  • Page 193: Pressure Testing

    COOLING SYSTEM 4-9 Coolant Pressure Testing • Remove: Right Inner Cover (see Frame chapter) • Remove the radiator cap, and install a cooling system pressure tester [A] on the filler neck. NOTE ○ Wet the cap sealing surfaces with water or coolant to prevent pressure leaks.
  • Page 194: Coolant Reserve Tank Removal

    4-10 COOLING SYSTEM Coolant Coolant Reserve Tank Removal • Remove: Coolant Reserve Tank Mounting Screws [A] • Remove: Coolant Reserve Tank Mounting Screws [A] Collar Idle Adjuster Bracket [B] Coolant Reserve Tank [C] Coolant Reserve Tank Installation • Install: Coolant Reserve Tank [A] Collar [B] Idle Adjuster Bracket [C] •...
  • Page 195: Water Pump

    COOLING SYSTEM 4-11 Water Pump Water Pump Removal • Refer to the Oil Pump Removal in Engine Lubrication Sys- tem chapter. Water Pump Installation • Refer to the Oil Pump Installation in Engine Lubrication System chapter. Water Pump Impeller Disassembly/Assembly •...
  • Page 196: Water Pump Housing Assembly

    4-12 COOLING SYSTEM Water Pump • Take the oil seal [A] out of the housing [B] with a hook [C]. Water Pump Housing Assembly CAUTION Do not reuse the mechanical seal and oil seal. • Apply high temperature grease to the oil seal lips [A]. •...
  • Page 197: Radiator, Radiator Fan

    COOLING SYSTEM 4-13 Radiator, Radiator Fan Radiator and Radiator Fan Removal WARNING The radiator fan is connected directly to the bat- tery. The radiator fan may start even if the ignition switch is off. NEVER TOUCH THE RADIATOR FAN UNTIL THE RADIATOR FAN CONNECTOR IS DIS- CONNECTED.
  • Page 198: Radiator And Radiator Fan Installation

    4-14 COOLING SYSTEM Radiator, Radiator Fan Radiator and Radiator Fan Installation • Install: Radiator [A] Dampers [B] (note the direction) Collars [C] Horn [D] Bracket [E] • Tighten: Torque - Radiator Bracket Mounting Bolts (L= 16 mm) [F]: 6.9 N·m (0.70 kgf·m, 61 in·lb) Radiator Mounting Bolts (L= 30 mm) [G]: 6.9 N·m (0.70 kgf·m, 61 in·lb) Radiator Mounting Bolts (L= 25 mm) [H]: 6.9 N·m...
  • Page 199: Radiator Filler Neck Inspection

    COOLING SYSTEM 4-15 Radiator, Radiator Fan • Install the cap [A] on a cooling system pressure tester [B]. NOTE ○ Wet the cap sealing surfaces with water or coolant to prevent pressure leaks. • Watching the pressure gauge, pump the pressure tester to build up the pressure until the relief valve opens: the gauge hand flicks downward.
  • Page 200: Thermostat

    4-16 COOLING SYSTEM Thermostat Thermostat Removal • Remove: Coolant (see Cooling System in the Periodic Maintenance chapter) Seats (see Frame chapter) Fuel Tank (see Fuel System chapter) Thermostat Housing Cover Bolts [A] Bracket [B] Thermostat Housing Cover [C] Thermostat Thermostat Installation •...
  • Page 201: Hose And Pipes

    COOLING SYSTEM 4-17 Hose and Pipes Hose Installation • Install the hoses and pipes being careful to follow bend- ing direction or diameter. Avoid sharp bending, kinking, flattening, or twisting. • Install the clamps [A] as near as possible to the hose end to clear the raised rib or the fitting.
  • Page 202: Radiator Fan Switch, Water Temperature Sensor

    • Apply silicone sealant to the threads of the water temper- ature sensor. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 • Tighten the fan switch and water temperature sensor. Torque - Radiator Fan Switch : 18 N·m (1.8 kgf·m, 13 ft·lb) Water Temperature Sensor : 25 N·m (2.5 kgf·m, 18...
  • Page 203 ENGINE TOP END 5-1 Engine Top End Table of Contents Exploded View........Cylinder Head Warp..... 5-21 Specifications ........Valves ..........5-22 Special Tools and Sealant ....Valve Clearance Inspection ..5-22 Clean Air System....... 5-10 Valve Clearance Adjustment..5-22 Air Suction Valve Removal... 5-10 Valve Removal ......
  • Page 204: Exploded View

    5-2 ENGINE TOP END Exploded View...
  • Page 205 ENGINE TOP END 5-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Air suction valve cover bolts 104 in·lb Cylinder head cover bolts 87 in·lb Spark plugs 113 in·lb Camshaft cap bolts 104 in·lb Cylinder head bolts (9 mm) Cylinder head bolts (6 mm) 104 in·lb Cylinder head jacket plug (upper) 14.5...
  • Page 206 5-4 ENGINE TOP END Exploded View...
  • Page 207 ENGINE TOP END 5-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Water jacket drain bolt 0.90 78 in·lb Exhaust pipe manifold nut Exhaust pipe clamp bolt Muffler body bolt Crankshaft sensor cover bolts 87 in·lb L (1) 6. R marked side face up. 7.
  • Page 208: Specifications

    5-6 ENGINE TOP END Specifications Item Standard Service Limit Clean Air System: Vacuum switch valve closing Open → Close 41 ∼ 49 kPa (310 ∼ 370 mmHg) pressure: Camshafts Cam height: 33.146 ∼ 33.254 mm (1.305 ∼ 1.309 in.) Exhaust 33.05 mm (1.30 in.) 34.146 ∼...
  • Page 209 ENGINE TOP END 5-7 Specifications Item Standard Service Limit Cylinder, Piston: Cylinder inside diameter 68.000 ∼ 68.012 mm (2.677 ∼ 2.678 in.) ZX636 68.10 mm (2.68 in.) 67.000 ∼ 67.012 mm (2.637 ∼ 2.638 in.) ZX600 67.10 mm (2.64 in.) 67.975∼...
  • Page 210: Special Tools And Sealant

    5-8 ENGINE TOP END Special Tools and Sealant Compression Gauge: Valve Seat Cutter, 32° – 25: 57001–221 57001–1118 Valve Spring Compressor Assembly: Valve Seat Cutter, 32° – 28: 57001–241 57001–1119 Piston Pin Puller Assembly: Valve Seat Cutter Holder Bar: 57001–910 57001–1128 Valve Seat Cutter, 45°...
  • Page 211 Compression Gauge Adapter, M10 × 1.0: 57001–1273 57001–1317 Valve Guide Reamer, 4: Valve Seat Cutter, 60° – 25: 57001–1274 57001–1328 Valve Seat Cutter Holder, 4: Valve Seat Cutter, 60° – 27: 57001–1275 57001–1409 Fork Oil Level Gauge: Kawasaki Bond (Silicone Sealant): 57001–1290 56019–120...
  • Page 212: Clean Air System

    5-10 ENGINE TOP END Clean Air System Air Suction Valve Removal • Remove: Seats (see Frame chapter) Fuel Tank, Air Cleaner Housing (see Fuel System (DFI) chapter) • Push out the rubber plate right side [A]. • Separate the hoses [B] from the air suction valve cover. •...
  • Page 213: Vacuum Switch Valve Test

    ENGINE TOP END 5-11 Clean Air System Vacuum Switch Valve Test • Remove: Fuel Tank, Air Cleaner Housing (see Fuel System (DFI) chapter) Vacuum Switch Valve • Connect a vacuum gauge [A] and syringe [B] or fork oil level gauge to the vacuum hoses as shown. Special Tool - Fork Oil Level Gauge: 57001-1290 Air Flow [C] •...
  • Page 214: Cylinder Head Cover

    Cylinder Head Cover Installation • Replace the head cover gasket with a new one if dam- aged. • Apply silicone sealant to the cylinder head as shown [A]. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120...
  • Page 215 ENGINE TOP END 5-13 Cylinder Head Cover • Be sure to install the pins [A] and rubber gaskets [B]. • Install the chain guide [A]. • Install the washer [B] with the metal side faces upward. • Tighten: Torque - Cylinder Head Cover Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) [C] •...
  • Page 216: Camshaft Chain Tensioner

    5-14 ENGINE TOP END Camshaft Chain Tensioner Camshaft Chain Tensioner Removal CAUTION This is a non-return type camshaft chain tensioner. The push rod does not return to its original position once it moves out to take up camshaft chain slack. Observe all the rules listed below: When removing the tensioner, do not take out the mounting bolts only halfway.
  • Page 217: Camshaft, Camshaft Chain

    ENGINE TOP END 5-15 Camshaft, Camshaft Chain Camshaft Removal • Remove: Cylinder Head Cover (see Cylinder Head Cover Removal) Pickup Coil Cover • Position the crankshaft at #1, 4 piston TDC. [A] TDC mark for #1, 4 Pistons [B] Timing Mark (crankcase halves mating surface) •...
  • Page 218 5-16 ENGINE TOP END Camshaft, Camshaft Chain • Position the crankshaft at #1, 4 piston TDC. • Pull the tension side (exhaust side) [A] of the chain taut to install the chain. • Engage the camshaft chain with the camshaft sprockets so that the timing marks on the sprockets are positioned as shown.
  • Page 219: Camshaft, Camshaft Cap Wear

    ENGINE TOP END 5-17 Camshaft, Camshaft Chain Camshaft, Camshaft Cap Wear • Remove the camshaft cap (see Camshaft Removal). • Cut strips of plastigage to journal width. Place a strip on each journal parallel to the camshaft installed in the correct position.
  • Page 220: Camshaft Chain Removal

    5-18 ENGINE TOP END Camshaft, Camshaft Chain Camshaft Chain Removal • Split the crankcase (see Crankshaft/Transmission chap- ter). • Remove the camshaft chain [A] from the crankshaft sprocket. Camshaft and Sprocket Assembly • Inlet and exhaust camshaft sprockets are the same. •...
  • Page 221: Cylinder Head

    ENGINE TOP END 5-19 Cylinder Head Cylinder Compression Measurement NOTE ○ Use the battery which is fully charged. • Warm up the engine thoroughly. • Stop the engine. • Remove: Seats (see Frame chapter) Fuel Tank (see Fuel System (DFI) chapter) Air Cleaner Housing (see Fuel System (DFI) chapter) Stick Coils Spark Plugs...
  • Page 222: Cylinder Head Removal

    5-20 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) Cylinder Carbon accumulation on piston and in Remove the carbon deposits compression is combustion chamber possibly due to and replace damaged parts if higher than usable...
  • Page 223: Cylinder Head Installation

    ENGINE TOP END 5-21 Cylinder Head Cylinder Head Installation NOTE ○ The camshaft cap is machined with the cylinder head, so if a new cylinder head is installed, use the cap that is supplied with the new head. • Install a new cylinder head gasket and knock pins. •...
  • Page 224: Valves

    5-22 ENGINE TOP END Valves Valve Clearance Inspection ○ Refer to the Engine Top End in the Periodic Maintenance chapter. Valve Clearance Adjustment ○ Refer to the Engine Top End in the Periodic Maintenance chapter. Valve Removal • Remove the cylinder head (see Cylinder Head Removal). •...
  • Page 225: Valve Guide Installation

    ENGINE TOP END 5-23 Valves Valve Guide Installation • Apply oil to the valve guide outer surface before installa- tion. • Heat the area around the valve guide hole to about 120 ∼ 150 °C (248 ∼ 302 °F). • Drive the valve guide in from the top of the head using the valve guide arbor.
  • Page 226: Valve Seat Inspection

    5-24 ENGINE TOP END Valves Valve Seat Inspection • Remove the valve (see Valve Removal). • Check the valve seating surface [A] between the valve [B] and valve seat [C]. ○ Measure the outside diameter [D] of the seating pattern on the valve seat.
  • Page 227 ENGINE TOP END 5-25 Valves Seat Cutter Operation Care: 1. This valve seat cutter is developed to grind the valve for repair. Therefore the cutter must not be used for other purposes than seat repair. 2. Do not drop or shock the valve seat cutter, or the dia- mond particles may fall off.
  • Page 228 5-26 ENGINE TOP END Valves • Measure the outside diameter of the seating surface with a vernier caliper. If the outside diameter of the seating surface is too small, repeat the 45° grind [A] until the diameter is within the specified range.
  • Page 229 ENGINE TOP END 5-27 Valves • Lap the valve to the seat, once the seat width and O.D. are within the ranges specified above. ○ Put a little coarse grinding compound on the face of the valve in a number of places around the valve head. ○...
  • Page 230 5-28 ENGINE TOP END Valves...
  • Page 231: Cylinder, Pistons

    ENGINE TOP END 5-29 Cylinder, Pistons Cylinder Removal • Remove: Engine (see Engine Removal/Installation chapter) Cylinder Head (see Cylinder Head Removal) • Remove the cylinder. Cylinder Installation NOTE ○ If a new cylinder is used, use new piston ring. • Install the pins [A] and new cylinder gasket [B].
  • Page 232: Piston Installation

    5-30 ENGINE TOP END Cylinder, Pistons • Remove the piston pins. Special Tool - Piston Pin Puller Assembly: 57001-910 [A] • Carefully spread the ring opening with your thumbs and then push up on the opposite side of the ring [A] to remove •...
  • Page 233: Cylinder Wear

    ENGINE TOP END 5-31 Cylinder, Pistons • Do not mix up the top and second ring. • Install the top ring [A] so that the "R" mark [B] faces up. • Install the second ring [C] so that the "RN" mark [D] faces Cylinder Wear •...
  • Page 234: Piston Ring, Piston Ring Groove Wear

    5-32 ENGINE TOP END Cylinder, Pistons Piston Ring, Piston Ring Groove Wear • Check for uneven groove wear by inspecting the ring seat- ing. The rings should fit perfectly parallel to groove surfaces. If not, replace the piston and all the piston rings. •...
  • Page 235: Piston Ring Thickness

    ENGINE TOP END 5-33 Cylinder, Pistons Piston Ring Thickness • Measure the piston ring thickness. ○ Use the micrometer to measure at several points around the ring. Piston Ring Thickness Standard Service Limit 0.77 ∼ 0.79 mm 0.70 mm (0.028 in.) (0.0303 ∼...
  • Page 236: Throttle Valve Holder

    5-34 ENGINE TOP END Throttle Valve Holder Throttle Valve Holder Installation • Be sure to install the O-rings [A]. • Tighten: Torque - Throttle Body Assembly Holder Bolts [B]: 12 N·m (1.2 kgf·m, 104 in·lb)
  • Page 237: Muffler

    ENGINE TOP END 5-35 Muffler WARNING To avoid a serious burn, do not remove the mufflers when the engine is still hot. Wait until the mufflers cool down. Exhaust Pipe Manifold Removal • Remove: Lower Fairings (see Frame chapter) Muffler Body (see Muffler Body Removal) Radiator [A] (see Cooling System chapter) Exhaust Pipe Manifold Holder Nuts [B] Exhaust Pipe Manifold [C]...
  • Page 239 CLUTCH 6-1 Clutch Table of Contents Exploded View........................Specifications ......................... Special Tool and Sealant ......................Clutch Lever and Cable ......................Lever Free Play Inspection ....................Lever Free Play Adjustment....................Cable Removal ......................... Cable Installation ......................Cable Lubrication ......................Clutch Lever Installation....................Clutch Cover...........................
  • Page 240: Exploded View

    6-2 CLUTCH Exploded View...
  • Page 241 CLUTCH 6-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Clutch lever holder bolts 0.80 69 in·lb Clutch cover bolts 104 in·lb L (2) Clutch hub nut 13.5 Clutch spring bolts 0.90 78 in·lb Clutch sub hub bolt Parts Parts No. Remarks 6 Clutch spring holder STD 39108–1152...
  • Page 242: Specifications

    6-4 CLUTCH Specifications Item Standard Service Limit Clutch: 2.72 ∼ 2.88 mm (0.107 ∼ 0.113 Friction plate thickness 2.2 mm (0.087 in.) in.) Friction and steel plate warp 0.2 mm (0.008 in.) or less 0.3 mm (0.012 in.) Clutch spring free length ZX636 80.6 mm (3.17 in.) 76.7 mm (3.02 in.)
  • Page 243: Special Tool And Sealant

    CLUTCH 6-5 Special Tool and Sealant Clutch Holder: Kawasaki Bond (Silicone Sealant) : 57001–1243 56019–120...
  • Page 244: Clutch Lever And Cable

    6-6 CLUTCH Clutch Lever and Cable Lever Free Play Inspection ○ Refer to the Clutch in the Periodic Maintenance chapter. Lever Free Play Adjustment ○ Refer to the Clutch in the Periodic Maintenance chapter. Cable Removal • Remove the right lower fairing (see Frame chapter). •...
  • Page 245: Clutch Cover

    Clutch Cover Installation • Apply silicone sealant to the area [A] where the mating surface of the crankcase touches the clutch cover gasket. Sealant - Kawasaki Bond (Silicone Sealant): 56019–120 • Replace the cover gasket with a new one. •...
  • Page 246: Clutch Removal

    6-8 CLUTCH Clutch Clutch Removal • Drain the engine oil (see Engine Lubrication System in the Periodic Maintenance chapter). • Remove: Right Lower Fairing (see Frame chapter) Clutch Cover (see Clutch Cover Removal) Clutch Spring Bolts [A] Clutch Spring Holders Clutch Springs Clutch Spring Plate [B] (with thrust bearing and pusher [C], spring and washer)
  • Page 247: Clutch Installation

    CLUTCH 6-9 Clutch Clutch Installation • Inspect the clutch plate assembly length (see Clutch Plate Assembly Inspection). • Install the following parts on the drive shaft. [A] Spacer [B] Sleeve [C] Needle Bearing [D] Clutch Housing [E] Spacer [F] Clutch Hub [G] Washer [H] Nut [I] Sub Clutch Hub...
  • Page 248 6-10 CLUTCH Clutch ZX636: ○ Install the washer [A] so that the OUT SIDE [B] mark faces outward. ZX600: ○ Install the collar [A] so that the groove [B] faces outward. ZX600: • Pile up the four torque limiter springs [A] so that the spring tongues [B] does not faces same direction in the sub clutch hub [C].
  • Page 249 CLUTCH 6-11 Clutch • Install the friction plates and steel plates, starting with a friction plate and alternating them. CAUTION If new dry friction plates and steel plates are in- stalled, apply engine oil to the surfaces of each plate to avoid clutch plate seizure. ○...
  • Page 250: Clutch Plate Assembly Inspection (zx636)

    6-12 CLUTCH Clutch Clutch Plate Assembly Inspection (ZX636) • Inspect the friction plate thickness (see Clutch Plate, Wear, Damage Inspection). • Measure the length [A] of the clutch plate assembly as shown. ZX636: ○ Assemble: Clutch Hub [B] Spring Plate [G] Spring Seat [C] Springs [H] Spring [D]...
  • Page 251: Spring Plate Free Play Measurement (zx600)

    CLUTCH 6-13 Clutch Spring Plate Free Play Measurement (ZX600) Insufficient clutch free play will cause the engine braking effect to be more sudden, resulting in rear wheel hop. On the other hand, if the free play is excessive, the clutch lever may feel “spongy”...
  • Page 252: Spring Plate Play Adjustment (zx600)

    6-14 CLUTCH Clutch Spring Plate Play Adjustment (ZX600) ○ Apply a non permanent locking agent to the thread of sub clutch hub bolts. • Assemble the following parts so that the clutch plate as- sembly length [A] is specified length. Clutch Hub [B] Spring Plate [G] Sub Clutch Hub [C]...
  • Page 253: Clutch Spring Free Length Measurement

    CLUTCH 6-15 Clutch Clutch Spring Free Length Measurement • Measure the free length of the clutch springs [A]. If any spring is shorter than the service limit, it must be replaced. Clutch Spring Free Length Standard: ZX636 80.6 mm (3.17 in.) ZX600 39.85 mm (1.57 in.) Service Limit:...
  • Page 255 ENGINE LUBRICATION SYSTEM 7-1 Engine Lubrication System Table of Contents Exploded View........................Engine Oil Flow Chart......................Specifications ......................... Special Tools and Sealant ...................... Engine Oil and Oil Filter......................Oil Level Inspection......................Engine Oil Change......................Oil Filter Replacement ...................... Oil Pan............................ Oil Pan Removal .......................
  • Page 256: Exploded View

    7-2 ENGINE LUBRICATION SYSTEM Exploded View...
  • Page 257 ENGINE LUBRICATION SYSTEM 7-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Oil jet nozzle bolts 0.70 61 in·lb Oil pressure switch Oil pressure switch terminal bolt 0.15 13 in·lb Oil pipe holder bolts 104 in·lb Oil passage plug Oil filler plug 0.15 13 in·lb Cooling hose clamp...
  • Page 258: Engine Oil Flow Chart

    7-4 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart 1. Oil Pan 12. Drive Shaft 2. Oil Screen 13. Output Shaft 3. Oil Pump 14. Oil Pressure Switch 4. Relief Valve 15. Cylinder Head 5. Oil Filter 16. Camshaft Cap 6. Oil Cooler 17.
  • Page 259: Specifications

    ENGINE LUBRICATION SYSTEM 7-5 Specifications Item Standard Engine Oil: Type API SE, SF or SG API SH or SJ with JASO MA Viscosity SAE 10W-40 Capacity 3.4 L (3.6 US qt, when filter is not removed) 3.6 L (3.8 US qt, when filter is removed) 4.0 L (4.2 US qt, when engine is completely dry) Level Between upper and lower level lines...
  • Page 260: Special Tools And Sealant

    7-6 ENGINE LUBRICATION SYSTEM Special Tools and Sealant Outside Circlip Pliers: Oil Pressure Gauge Adapter, M18 × 1.5: 57001–144 57001–1278 Oil Pressure Gauge, 10 kgf/cm²: Kawasaki Bond (Silicone Sealant): 57001–164 56019–120 Oil Filter Wrench: 57001–1249...
  • Page 261: Engine Oil And Oil Filter

    ENGINE LUBRICATION SYSTEM 7-7 Engine Oil and Oil Filter WARNING Motorcycle operation with insufficient, deteri- orated, or contaminated engine oil will cause accelerated wear and may result in engine or trans- mission seizure, accident, and injury. Oil Level Inspection • Check that the engine oil level is between the upper [A] and lower [B] levels in the gauge.
  • Page 262: Oil Pan

    7-8 ENGINE LUBRICATION SYSTEM Oil Pan Oil Pan Removal • Drain the Engine Oil (see Engine Lubrication System in the Periodic Maintenance chapter). • Remove: Muffler (see Engine Top End chapter) Oil Pan Bolts [A] Oil Pan [B] Oil Pan Installation •...
  • Page 263: Oil Pressure Relief Valve

    ENGINE LUBRICATION SYSTEM 7-9 Oil Pressure Relief Valve Oil Pressure Relief Valve Removal • See Oil Pan Removal. Oil Pressure Relief Valve Installation • See Oil Pan Installation. Oil Pressure Relief Valve Inspection • Check to see if the valve [A] slides smoothly when push- ing it in with a wooden or other soft rod, and see if it comes back to its seat by spring [B] pressure.
  • Page 264: Oil Pump

    7-10 ENGINE LUBRICATION SYSTEM Oil Pump Oil Pump Removal • Drain: Coolant (see Cooling System in the Periodic Mainte- nance chapter) Engine Oil (see Engine Lubrication System in the Peri- odic Maintenance chapter) • Remove: Water Hoses [A] Bolts [B] and Water Pump Cover [C] Impeller Bolt [A] Impeller [B] Water Pump Body [A]...
  • Page 265: Oil Pump Drive Gear Removal

    ENGINE LUBRICATION SYSTEM 7-11 Oil Pump • Install: Pins [A] Water Pump Body [B] • Apply coolant to the surface of the rubber seal on the impeller. • Install the impeller [A] and bolt [B]. Torque - Impeller Bolt: 9.8 N·m (1.0 kgf·m, 87 in·lb) Pins [C] Water Pump Cover [D] •...
  • Page 266: Oil Cooler

    7-12 ENGINE LUBRICATION SYSTEM Oil Cooler Oil Cooler Removal • Remove: Lower Fairing (see Frame chapter) • Drain: Engine Oil (see Engine Lubrication System in the Peri- odic Maintenance chapter) Coolant (see Cooling System in the Periodic Mainte- nance chapter) •...
  • Page 267: Oil Pressure Measurement

    ENGINE LUBRICATION SYSTEM 7-13 Oil Pressure Measurement Oil Pressure Measurement • Remove the lower fairing (see Frame chapter). • Remove the oil passage plug, and attach the gauge [A] and adapter [B] to the plug hole. Special Tools - Oil Pressure Gauge, 10 kgf/cm²: 57001-164 Oil Pressure Gauge Adapter, M18 ×...
  • Page 268: Oil Pressure Switch

    Oil Pressure Switch Installation • Apply silicone sealant to the threads of the oil pressure switch and tighten it. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 Torque - Oil Pressure Switch: 15 N·m (1.5 kgf·m, 11 ft·lb) • Tighten: Torque - Oil Pressure Switch Terminal Bolt: 1.5 N·m (0.15 kgf·m, 13 in·lb)
  • Page 269 ENGINE REMOVAL/INSTALLATION 8-1 Engine Removal/Installation Table of Contents Exploded View........................Special Tools .......................... Engine Removal/Installation ....................Engine Removal........................ Engine Installation......................
  • Page 270: Exploded View

    8-2 ENGINE REMOVAL/INSTALLATION Exploded View...
  • Page 271 ENGINE REMOVAL/INSTALLATION 8-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Engine mounting bolts Engine mounting locknuts Engine mounting nuts Engine mounting adjusting bolts...
  • Page 272: Special Tools

    8-4 ENGINE REMOVAL/INSTALLATION Special Tools Jack: Engine Mount Nut Wrench: 57001–1238 57001–1450...
  • Page 273: Engine Removal/installation

    ENGINE REMOVAL/INSTALLATION 8-5 Engine Removal/Installation Engine Removal • Squeeze the brake lever slowly and hold it with a band [A]. WARNING Be sure to hold the front brake when removing the engine, or the motorcycle may fall over. It could cause an accident and injury.
  • Page 274 8-6 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Pull off the connectors from the engine and free the wiring from the clamps. Pickup Coil Lead Connector [A] Battery Ground Lead [B] Starter Motor Lead [C] Alternator Lead Connector [D] Side Stand Switch Lead Connector [E] Speed Sensor Connector [F] Regulator/Rectifier Lead Connector [G] Stick Coil Harness Connector [A]...
  • Page 275: Engine Installation

    ENGINE REMOVAL/INSTALLATION 8-7 Engine Removal/Installation Engine Installation • Support the engine with a suitable stand. • Hang the drive chain over the output shaft just before moving the engine into its final position in the frame. • Screw the adjusting bolts [A], [B], [C] into the frame. •...
  • Page 276 8-8 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Turn the adjusting bolt [A], [B] until the clearance [X], [Y] between the crankcase and frame come to zero mm (zero in.). Torque - Engine Mounting Adjusting Bolt: 20 N·m (2.0 kgf·m, 14 ft·lb) •...
  • Page 277 CRANKSHAFT / TRANSMISSION 9-1 Crankshaft / Transmission Table of Contents Exploded View........................Specifications ......................... Special Tools and Sealant ...................... Crankcase Splitting......................... Crankcase Splitting ......................Crankcase Assembly ......................Crankshaft and Connecting Rods................... 9-12 Crankshaft Removal ......................9-12 Crankshaft Installation ...................... 9-12 Connecting Rod Removal ....................
  • Page 278: Exploded View

    9-2 CRANKSHAFT / TRANSMISSION Exploded View...
  • Page 279 G: Apply grease. L: Apply a non-permanent locking agent. M: Apply molybdenum disulfide grease. SS: Apply silicone sealant. LG: Apply liquid gasket (Kawasaki Bond: 92104–1064). MO: Apply molybdenum disulfide oil solution. R: Replacement Parts S: Follow the specific tightening sequence.
  • Page 280 9-4 CRANKSHAFT / TRANSMISSION Exploded View...
  • Page 281 CRANKSHAFT / TRANSMISSION 9-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Shift drum cam holder bolt 104 in·lb Neutral switch Gear positioning lever bolt 87 in·lb Shift shaft return spring pin G: Apply grease. L: Apply a non-permanent locking agent. EO: Apply engine oil.
  • Page 282: Specifications

    9-6 CRANKSHAFT / TRANSMISSION Specifications Item Standard Service Limit Crankshaft, Connecting Rods: Connecting rod big end side clearance 0.13 ∼ 0.33 mm 0.5 mm (0.020 in.) (0.0051 ∼ 0.00130 in.) 0.035 ∼ 0.064 mm (0.0014 ∼ 0.0025 Connecting rod big end bearing insert/ 0.10 mm (0.004 in.) crankpin clearance in.)
  • Page 283 CRANKSHAFT / TRANSMISSION 9-7 Specifications Item Standard Service Limit 33.000 ∼ 33.016 mm (1.2992 ∼ Crankcase main bearing bore – – – diameter: 1.2998 in.) 33.000 ∼ 33.008 mm (1.2992 ∼ Marking – – – 1.2995 in.) 33.009 ∼ 33.016 mm (1.2996 ∼ –...
  • Page 284: Special Tools And Sealant

    9-8 CRANKSHAFT / TRANSMISSION Special Tools and Sealant Bearing Puller: Flywheel & Pulley Holder: 57001–135 57001–1343 Outside Circlip Pliers: Kawasaki Bond (Liquid Gasket – gray): 57001–144 92104–1064 Bearing Puller Adapter: 57001–317...
  • Page 285: Crankcase Splitting

    CRANKSHAFT / TRANSMISSION 9-9 Crankcase Splitting Crankcase Splitting • Remove the engine (see Engine Removal/Installation chapter). • Set the engine on a clean surface and hold the engine steady while parts are being removed. • Remove: Crankshaft Sensor (see Electrical System chapter) Clutch (see Clutch chapter) External Shift Mechanism (see External Shift Mecha- nism Removal)
  • Page 286 9-10 CRANKSHAFT / TRANSMISSION Crankcase Splitting • Apply silicone sealant to the breather plate mating surface [A] 1 to 1.5 mm (0.04 to 0.06 in.) thick, and wait until sealant dries. Sealant - Three Bond #1207B and/or equivalent • Install the breather plate [B], and apply a non-permanent locking agent to the threads and tighten the bolts [A].
  • Page 287 CRANKSHAFT / TRANSMISSION 9-11 Crankcase Splitting • Apply liquid gasket [A] to the mating surface of the lower crankcase half. Sealant - Kawasaki Bond (Liquid Gasket – gray): 92104–1064 NOTE ○ Especially, apply a sealant carefully so that it shall be filled up on the grooves.
  • Page 288: Crankshaft And Connecting Rods

    9-12 CRANKSHAFT / TRANSMISSION Crankshaft and Connecting Rods Crankshaft Removal • Split the crankcase (see Crankcase Splitting). • Remove the crankshaft. Crankshaft Installation CAUTION If the crankshaft, bearing inserts, or crankcase halves are replaced with new ones, select the bear- ing inserts and check clearance with a plastigage (press gauge) before assembling engine to be sure the correct bearing inserts are installed.
  • Page 289 CRANKSHAFT / TRANSMISSION 9-13 Crankshaft and Connecting Rods CAUTION If the connecting rods, big end bearing inserts, or crankshaft are replaced with new ones, select the bearing insert and check clearance with a plasti- gage (press gauge) before assembling engine to be sure the correct bearing inserts are installed.
  • Page 290 9-14 CRANKSHAFT / TRANSMISSION Crankshaft and Connecting Rods (1) Bolt Length Measurement Method • Be sure to clean the bolts, nuts, and connecting rods thoroughly with high-flash point solvent, because the new connecting rods, bolts, and nuts are treated with an anti -rust solution.
  • Page 291 CRANKSHAFT / TRANSMISSION 9-15 Crankshaft and Connecting Rods (2) Tightening Torque Method • If you don’t have a point micrometer, you may tighten the nuts using the “Tightening Torque Method”. • Be sure to clean the bolts, nuts, and connecting rods thoroughly with high-flash point solvent, because the new connecting rods, bolts, and nuts are treated with an anti -rust solution.
  • Page 292: Crankshaft/connecting Rod Cleaning

    9-16 CRANKSHAFT / TRANSMISSION Crankshaft and Connecting Rods Crankshaft/Connecting Rod Cleaning • After removing the connecting rods from the crankshaft, clean them with a high-flash point solvent. • Blow the crankshaft oil passages with compressed air to remove any foreign particles or residue that may have accumulated in the passages.
  • Page 293: Connecting Rod Big End Bearing Insert/crankpin Wear

    CRANKSHAFT / TRANSMISSION 9-17 Crankshaft and Connecting Rods Connecting Rod Big End Bearing Insert/Crankpin Wear • Measure the bearing insert/crankpin [B] clearance with plastigage [A]. • Tighten the big end nuts to the specified torque (see Con- necting Rod Installation). NOTE ○...
  • Page 294: Crankshaft Side Clearance

    9-18 CRANKSHAFT / TRANSMISSION Crankshaft and Connecting Rods • Measure the connecting rod big end bore diameter, and mark each connecting rod big end in accordance with the bore diameter. • Tighten the big end nuts to the specified torque (see Con- necting Rod Installation).
  • Page 295: Crankshaft Runout

    CRANKSHAFT / TRANSMISSION 9-19 Crankshaft and Connecting Rods Crankshaft Runout • Measure the crankshaft runout. If the measurement exceeds the service limit, replace the crankshaft. Crankshaft Runout Standard: TIR 0.02 mm (0.0008 in.) or less Service Limit: TIR 0.05 mmm (0.002 in.) Crankshaft Main Bearing Insert/Journal Wear •...
  • Page 296 9-20 CRANKSHAFT / TRANSMISSION Crankshaft and Connecting Rods • Measure the main bearing bore diameter, and mark the upper crankcase half in accordance with the bore diame- ter. A: Crankcase Main Bearing Bore Diameter Marks, " " mark or no mark. NOTE ○...
  • Page 297: Starter Motor Clutch

    CRANKSHAFT / TRANSMISSION 9-21 Starter Motor Clutch Starter Motor Clutch Removal/Installation • Refer to Alternator Rotor Removal and Installation in the Electrical System chapter. Starter Motor Clutch Inspection • Remove: Alternator Cover (see Electrical System chapter) Starter Idle Gear • Turn the starter motor clutch gear [A] by hand.
  • Page 298: Transmission

    9-22 CRANKSHAFT / TRANSMISSION Transmission Shift Pedal Removal • Mark the position of the shift lever on the shift shaft so that it can be installed later in the same position. • Remove the shift lever and shift pedal. Shift Pedal Installation •...
  • Page 299: External Shift Mechanism Inspection

    CRANKSHAFT / TRANSMISSION 9-23 Transmission External Shift Mechanism Inspection • Examine the shift shaft [A] for any damage. If the shaft is bent, straighten or replace it. If the serration are damaged, replace the shaft. If the springs [B] [C] are damaged in any way, replace them.
  • Page 300: Transmission Shaft Disassembly

    9-24 CRANKSHAFT / TRANSMISSION Transmission • Install the drive shaft and output shaft into the upper crankcase half. • Apply engine oil to the sliding surfaces of the gears and bearings. ○ The bearing set pins and rings must match properly with the holes or grooves in the bearing outer races.
  • Page 301 CRANKSHAFT / TRANSMISSION 9-25 Transmission • Install the gear bushing [A] on the shafts with their oil holes [B] aligned. • The drive shaft gears can be recognized by size: the gear with the smallest diameter is 1st gear, and the largest one is 6th gear.
  • Page 302: Shift Drum And Fork Removal

    9-26 CRANKSHAFT / TRANSMISSION Transmission Shift Drum and Fork Removal • Remove: Clutch (see Clutch chapter) Oil Pan (see Engine Lubrication System chapter) External Shift Mechanism (see External Shift Mecha- nism Removal) Gear Positioning Lever [A] Bolt [B] and Screw [C] Shift Drum Bearing Holder [D] •...
  • Page 303: Shift Drum Assembly

    CRANKSHAFT / TRANSMISSION 9-27 Transmission • Remove the holder [A] with a bearing puller [B]. Special Tool - Bearing Puller: 57001–135 Shift Drum Assembly • Be sure to install the dowel pin. • Apply a non-permanent locking agent to the threads of the shift drum cam holder bolt, and tighten it.
  • Page 304: Shift Fork Guide Pin/drum Groove Wear

    9-28 CRANKSHAFT / TRANSMISSION Transmission Shift Fork Guide Pin/Drum Groove Wear • Measure the diameter of each shift fork guide pin [A], and measure the width [B] of each shift drum groove. If the guide pin on any shift fork is less than the service limit, the fork must be replaced.
  • Page 305 CRANKSHAFT / TRANSMISSION 9-29 Transmission 1. 1st Gear 8. Thrust Washer (Thin) 15. Bearing Outer Race 2. 2nd Gear 9. Circlip 16. Bushing 3. 3rd Gear 10. Circlip 17. Ball Bearing 4. 4th Gear 11. Toothed Washer 18. Oil Seal 5.
  • Page 307 WHEELS / TIRES 10-1 Wheels / Tires Table of Contents Exploded View........................10-2 Specifications ......................... 10-4 Special Tools .......................... 10-5 Wheels (Rims) ........................10-6 Front Wheel Removal ....................... 10-6 Front Wheel Installation ....................10-6 Rear Wheel Removal......................10-7 Rear Wheel Installation..................... 10-8 Wheel Inspection ......................
  • Page 308: Exploded View

    10-2 WHEELS / TIRES Exploded View...
  • Page 309 WHEELS / TIRES 10-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front axle clamp bolts 14.5 Front axle nut 13.0 Rear axle nut 13.0 G: Apply grease. R: Replacement Parts WL: Apply soap and water solution or rubber lubricant.
  • Page 310: Specifications

    10-4 WHEELS / TIRES Specifications Item Standard Service Limit Wheels (Rims): Rim runout: Axial – – – 0.5 mm (0.02 in.) Radial – – – 0.8 mm (0.03 in.) Axle runout/100 mm (3.9 in.) 0.05 mm (0.002 in.) or less 0.2 mm (0.01 in.) Wheel balance 10 g or less...
  • Page 311: Special Tools

    WHEELS / TIRES 10-5 Special Tools Inside Circlip Pliers: Bearing Remover Head, 25 × 28 : 57001–143 57001–1346 Bearing Driver Set: Bearing Remover Shaft, 13: 57001–1129 57001–1377 Jack: 57001–1238...
  • Page 312: Wheels (rims)

    10-6 WHEELS / TIRES Wheels (Rims) Front Wheel Removal • Remove: Lower Fairing (see Frame chapter) Front Fender (see Frame chapter) Brake Caliper Mounting Bolts [A] • Loosen: Right Side Axle Clamp Bolts [A] Axle [B] • Raise the front wheel off the ground. Special Tool - Jack: 57001–1238 •...
  • Page 313: Rear Wheel Removal

    WHEELS / TIRES 10-7 Wheels (Rims) • Fit the collars [A] on the both sides of the hub. • Tighten the axle nut [B]. Torque - Front Axle Nut: 127 N·m (13.0 kgf·m, 94 ft·lb) • Before tightening the clamp bolts on the right front fork leg, pump the front fork up and down 4 or 5 times to all on the right front fork leg to seat on the front axle.
  • Page 314: Rear Wheel Installation

    10-8 WHEELS / TIRES Wheels (Rims) • Remove the rear caliper mounting bolts and rear caliper. • Remove the inner fender and chain cover. • Remove the drive chain [A] from the rear sprocket toward the left. • Move the rear wheel back and remove it. CAUTION Do not lay the wheel on the ground with the disc facing down.
  • Page 315: Wheel Inspection

    WHEELS / TIRES 10-9 Wheels (Rims) Wheel Inspection • Raise the front/rear wheel off the ground. Special Tool - Jack: 57001–1238 • Spin the wheel lightly, and check for roughness or binding. If roughness or binding is found, replace the hub bearings. •...
  • Page 316: Balance Adjustment

    10-10 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. • Rotate the wheel 1/4 turn [B], and see whether or not the wheel stops in this position.
  • Page 317 30g (1.06 oz) NOTE ○ Balance weights are available from Kawasaki dealers in 10, 20, and 30 gram (0.35 oz, 0.71 oz, and 1.06 oz) sizes. An imbalance of less than 10 grams (0.35 oz) will not usually affect running stability.
  • Page 318 10-12 WHEELS / TIRES Wheels (Rims) ○ Check that the blade [A] and weight [B] seat fully on the rim flange [C], and that the clip [D] is hooked over the rim ridge [E] and reaches rim flat portion.
  • Page 319: Tires

    WHEELS / TIRES 10-13 Tires Air Pressure Inspection/Adjustment ○ Refer to the Wheels/Tires in the Periodic Maintenance chapter. Tire Inspection ○ Refer to the Wheels/Tires in the Periodic Maintenance chapter. Tire Removal • Remove: Wheel (see this chapter) Disc(s) Valve Core (let out the air) •...
  • Page 320 10-14 WHEELS / TIRES Tires • Install a new valve in the rim. ○ Remove the valve cap, lubricate the stem seal [A] with a soap and water solution or rubber lubricant, and pull the valve stem [B] through the rim from the inside out until it snaps into place.
  • Page 321: 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 322: Hub Bearing

    10-16 WHEELS / TIRES Hub Bearing Hub Bearing Removal • Remove the wheel, and take out the following. Collars Coupling (out of rear hub) Grease Seals Circlips [A] (Rear Hub only) Special Tool - Inside Circlip Pliers: 57001–143 [B] • Use the bearing remover to remove the hub bearing [A].
  • Page 323: Hub Bearing Inspection

    WHEELS / TIRES 10-17 Hub Bearing Hub Bearing Inspection Since the hub bearings are made to extremely close tol- erances, the clearance can not normally be measured. NOTE ○ Do not remove any bearings for inspection. If any bear- ings are removed, they will need to be replaced with new ones.
  • Page 325 FINAL DRIVE 11-1 Final Drive Table of Contents Exploded View ........................11-2 Specifications ........................11-4 Special Tools .......................... 11-5 Drive Chain..........................11-6 Drive Chain Slack Inspection .................... 11-6 Drive Chain Slack Adjustment ..................11-6 Wheel Alignment Inspection/Adjustment ................11-6 Drive Chain Wear Inspection .................... 11-6 Drive Chain Lubrication.....................
  • Page 326: Exploded View

    11-2 FINAL DRIVE Exploded View...
  • Page 327 FINAL DRIVE 11-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Speed sensor bolt 0.40 35 in·lb Engine sprocket cover bolts 0.70 61 in·lb Engine sprocket nut 13.0 Rear axle nut 13.0 Rear sprocket nuts 6. Drive chain joint (ZX636–B2 ∼ ) G: Apply grease.
  • Page 328: Specifications

    11-4 FINAL DRIVE Specifications Item Standard Service Limit Drive Chain: Standard chain Make ENUMA – – – Type EK520MVXL, Endless – – – Link 108 links – – – Sprockets: Rear sprocket warp 0.4 mm (0.016 in.) or less 0.5 mm (0.02 in.)
  • Page 329: Special Tools

    FINAL DRIVE 11-5 Special Tools Inside Circlip Pliers: Jack: 57001–143 57001–1238 Bearing Driver Set: 57001–1129...
  • Page 330: Drive Chain

    11-6 FINAL DRIVE Drive Chain Drive Chain Slack Inspection ○ Refer to the Final Drive in the Periodic Maintenance chap- ter. Drive Chain Slack Adjustment ○ Refer to the Final Drive in the Periodic Maintenance chap- ter. Wheel Alignment Inspection/Adjustment ○...
  • Page 331 FINAL DRIVE 11-7 Drive Chain EK JOINT TOOL #50 Body [A] Handlebar [B] Cutting and Riveting Pin [C] For Cutting [D] For Riveting [E] Plate Holder (A) [F] Plate Holder (B) [G] Gauge [H] • Grind [A] pin head to make it flat. •...
  • Page 332 11-8 FINAL DRIVE Drive Chain • Set plate holder (A) [A] and plate holder (B) [B] on the body. • Fit plate holder (A) to link plate. • Turn pin holder by hand until plate holder (B) touches the other link plate. •...
  • Page 333 FINAL DRIVE 11-9 Drive Chain • Turn wrench clockwise until tip of riveting pin hits of link pin. • Rivet it. • Some work for the other link pin. • After staking, check the staked area of the link pin for cracks.
  • Page 334: Sprocket, Coupling

    11-10 FINAL DRIVE Sprocket, Coupling Engine Sprocket Removal • Remove: Speed Sensor Bolt [A] Speed Sensor [B] Engine Sprocket Cover Bolts [C] Engine Sprocket Cover [D] • Flatten out the bended washer [A]. • Remove the engine sprocket nut [B] and washer. NOTE ○...
  • Page 335: Rear Sprocket Removal

    FINAL DRIVE 11-11 Sprocket, Coupling Rear Sprocket Removal • Remove the rear wheel (see Wheels/Tires chapter). CAUTION Do not lay the wheel on the ground with the disc facing down. This can damage or warp the disc. Place blocks under the wheel so that the disc does not touch the ground.
  • Page 336: Coupling Bearing Installation

    11-12 FINAL DRIVE Sprocket, Coupling Coupling Bearing Installation • Replace the bearing with a new one. • Press in the bearing [A] until it is bottomed. Special Tool - Bearing Driver Set: 57001–1129 [B] • Pack the bearing with high temperature grease. •...
  • Page 337: Sprocket Wear Inspection

    FINAL DRIVE 11-13 Sprocket, Coupling Sprocket Wear Inspection • Visually inspect the engine and rear sprocket teeth for wear and damage. If the teeth are worn as illustrated, replace the sprocket, and inspect the drive chain wear (see Final Drive in the Periodic Maintenance chapter).
  • Page 339 BRAKES 12-1 Brakes Table of Contents Exploded View ........12-2 Rear Brake Pad Installation ..12-16 Specifications ........12-6 Brake Pad Wear Inspection ..12-16 Special Tools ........12-7 Master Cylinder ......... 12-17 Brake Pedal ........12-8 Front Master Cylinder Removal ... 12-17 Brake Lever Position Adjustment.
  • Page 340: Exploded View

    12-2 BRAKES Exploded View...
  • Page 341 BRAKES 12-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Brake lever pivot bolt 0.10 89 in·lb Front master cylinder clamp bolts 0.90 78 in·lb Front brake light switch screw 0.12 10 in·lb Front brake reservoir cap stopper screw 0.12 10 in·lb Brake lever pivot bolt locknut 0.61...
  • Page 342 12-4 BRAKES Exploded View...
  • Page 343 BRAKES 12-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Brake hose banjo bolts Rear master cylinder mounting bolts Rear master cylinder push rod locknut Bleed valve 0.80 69 in·lb Rear brake disc mounting bolts Rear caliper mounting bolts B: Apply brake fluid. G: Apply grease.
  • Page 344: Specifications

    12-6 BRAKES Specifications Item Standard Service Limit Brake Lever, Brake Pedal: Brake lever position 5-way adjustable (to suit rider) - - - Non-adjustable - - - Brake lever free play Pedal free play Non-adjustable - - - Pedal position About 45 mm (1.8 in.) below footpeg top - - - Brake Discs: Thickness...
  • Page 345: Special Tools

    BRAKES 12-7 Special Tools Inside Circlip Pliers: Jack: 57001–143 57001–1238...
  • Page 346: Brake Pedal

    12-8 BRAKES 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 347: Calipers

    BRAKES 12-9 Calipers Front Caliper Removal • Loosen the banjo bolt [A] at the brake hose lower end, and tighten it loosely. • Unscrew the caliper mounting bolts [B], and detach the caliper [C] from the disc. CAUTION Do not loosen the caliper assembly bolts [D]. Take out only the caliper mounting bolts for caliper re- moval.
  • Page 348: Front Caliper Disassembly

    12-10 BRAKES Calipers WARNING Do not attempt to drive the motorcycle until a full brake lever or pedal is obtained by pumping the brake lever or pedal until the pads are against the disc. The brakes will not function on the first appli- cation of the lever or pedal if this is not done.
  • Page 349: Front Caliper Assembly

    BRAKES 12-11 Calipers Front Caliper Assembly • Clean the caliper parts except for the pads. CAUTION For cleaning of the parts, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol. • Install the bleed valve and rubber cap. Torque - Bleed Valve: 7.8 N·m (0.80 kgf·m, 69 in·lb) •...
  • Page 350: Rear Caliper Assembly

    12-12 BRAKES Calipers NOTE ○ If compressed air is not available, do as follows with the brake hose connected to the caliper. ○ Prepare a container for brake fluid, and perform the work above it. ○ Remove the pads and spring (see Rear Brake Pad Re- moval).
  • Page 351: Caliper Fluid Seal Damage

    BRAKES 12-13 Calipers Caliper Fluid Seal Damage The fluid seals [A] around the piston maintain the proper pad/disc clearance. If the seals are not satisfactory, pad wear will increase, and constant pad drag on the disc will raise brake and brake fluid temperature. •...
  • Page 352: Caliper Holder Shaft Wear

    12-14 BRAKES Calipers Caliper Holder Shaft Wear The caliper body must slide smoothly on the caliper holder shafts [A]. If the body does not slide smoothly, one pad will wear more than the other, pad wear will increase, and con- stant drag on the disc will raise brake and brake fluid tem- perature.
  • Page 353: Brake Pads

    BRAKES 12-15 Brake Pads Front Brake Pad Removal • Remove: Pad Spring Bolts [A] Pad Spring [B] • Remove: Brake Pads [A] Front Brake Pad Installation • Push the caliper pistons in by hand as far as they will go. •...
  • Page 354: Rear Brake Pad Installation

    12-16 BRAKES Brake Pads Rear Brake Pad Installation • Push the caliper piston in by hand as far as it will go. • Install the anti-rattle spring in place. • Install the brake pads. • Install the pad pin and clip. The clip must be "outside" of the pads.
  • Page 355: Master Cylinder

    BRAKES 12-17 Master Cylinder Front Master Cylinder Removal • Loosen the reservoir bracket bolts [A]. • Disconnect the front brake light switch connectors. • Remove the banjo bolt [A] to disconnect the brake hose from the master cylinder (see Brake Hose Removal/In- stallation).
  • Page 356: Rear Master Cylinder Installation

    12-18 BRAKES Master Cylinder Rear Master Cylinder Installation • Replace the cotter pin with a new one. • Replace the washers that are on each side of hose fitting with new ones. • Tighten: Torque - Rear Master Cylinder Mounting Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb) Brake Hose Banjo Bolt: 25 N·m (2.5 kgf·m, 18 ft·lb) •...
  • Page 357: Master Cylinder Assembly

    BRAKES 12-19 Master Cylinder 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 of the brake parts.
  • Page 358 12-20 BRAKES Master Cylinder • Check the dust covers [E] for damage. If they are damaged, replace them. • Check the piston return spring [F] for any damage. If the springs are damaged, replace them. • Check that relief port [G] and supply port [H] are not plugged.
  • Page 359: Brake Disc

    BRAKES 12-21 Brake Disc Brake Disc Removal • Remove the wheel (see Wheels/Tires chapter). • Unscrew the mounting bolts, and take off the disc. • Remove the gasket (Front Brake Disc only). Brake Disc Installation • Replace the gasket with a new one (Front Brake Disc only).
  • Page 360: Brake Fluid

    12-22 BRAKES Brake Fluid Level Inspection ○ Refer to the Brakes in the Periodic Maintenance chapter. Brake Fluid Change ○ Refer to the Brakes in the Periodic Maintenance chapter. Bleeding the Brake Line ○ Refer to the Brakes in the Periodic Maintenance chapter.
  • Page 361: Brake Hose

    BRAKES 12-23 Brake Hose Brake Hose Removal/Installation CAUTION Brake fluid quickly ruins painted or plastic sur- faces; any spilled fluid should be completely wiped up immediately with wet cloth. • When removing the brake hose, take care not to spill the brake fluid on the painted or plastic parts.
  • Page 363 SUSPENSION 13-1 Suspension Table of Contents Exploded View........................13-2 Specifications ......................... 13-6 Special Tools .......................... 13-7 Front Fork ..........................13-9 Rebound Damping Force Adjustment................13-9 Compression Damping Force Adjustment ................ 13-9 Spring Preload Adjustment ....................13-10 Front Fork Removal (each fork leg) .................. 13-10 Front Fork Installation .......................
  • Page 364: Exploded View

    13-2 SUSPENSION Exploded View...
  • Page 365 SUSPENSION 13-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front fork top plug Front fork clamp bolts (upper) 14.5 Front fork clamp bolts (lower) 14.5 Front fork bottom allen bolts Front axle clamp bolts 14.5 Piston rod nut AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque. L: Apply a non-permanent locking agent.
  • Page 366 13-4 SUSPENSION Exploded View...
  • Page 367 SUSPENSION 13-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb 1 Rear shock absorber bracket nut 2 Rear shock absorber Nuts (upper and lower) 3 Tie-Rod Nuts 4 Uni-Trak rocker arm nut 5 Swingarm pivot shaft nut 6 Swingarm pivot shaft ZX636 ZX600 7 Swingarm pivot shaft locknut...
  • Page 368: Specifications

    13-6 SUSPENSION Specifications Item Standard Front Fork (per one unit): Fork inner tube diameter 41 mm (1.6 in.) Air Pressure Atmospheric pressure (Non-adjustable) Rebound damper setting 8th click from the first click of the fully clockwise position (Usable Range: 0 ←→ 11 clicks) Compression damper setting 8th click from the first click of the fully clockwise position (Usable Range: 0 ←→...
  • Page 369: Special Tools

    SUSPENSION 13-7 Special Tools Inside Circlip Pliers: Fork Piston Rod Puller, M10 × 1.0: 57001–143 57001–1298 Oil Seal & Bearing Remover: Fork Spring Stopper: 57001–1058 57001–1316 Bearing Driver Set: Hook Wrench: 57001–1129 57001–1522 Jack: Hook Wrench: 57001–1238 57001–1533 Front Fork Oil Seal Driver: Fork Cylinder Holder: 57001–1288 57001–1537...
  • Page 370 13-8 SUSPENSION Special Tools Fork Spring Compressor: Swingarm Pivot Nut Wrench: 57001–1540 57001–1541...
  • Page 371: Front Fork

    SUSPENSION 13-9 Front Fork Rebound Damping Force Adjustment • To adjust the rebound damping force, turn the rebound damping adjuster [A] until you feel a click. ○ The standard adjuster setting for the average-build rider of 68 kg (150 lb) with no passenger and no accessories is the 8th click from the 1st click of the fully clockwise position.
  • Page 372: Spring Preload Adjustment

    13-10 SUSPENSION Front Fork Spring Preload Adjustment • Turn the spring preload adjuster [A] to change spring preload setting. ○ The standard adjuster setting for the average-build rider of 68 kg (150 lb) with no passenger and no accessories is the 14 mm (0.55 in.) [B] from top as shown. Adjuster Protrusion (from top) Standard: 14 mm (0.55 in.)
  • Page 373: Front Fork Installation

    SUSPENSION 13-11 Front Fork Front Fork Installation • Install the fork so that the top end [A] of the outer tube is flush with the upper surface [B] of the steering stem head bracket. • Tighten the lower fork clamp bolts and fork top bolt. Torque - Front Fork Clamp Bolts (Lower): 20 N·m (2.0 kgf·m, 14.5 ft·lb) Front Fork Top Plug: 23 N·m (2.3 kgf·m, 17 ft·lb)
  • Page 374 13-12 SUSPENSION Front Fork • While holding up the top plug by one person, push down the fork spring compressor and insert the fork spring stop- per [A] between the piston rod nut [B] and the clamps [C]. Special Tool - Fork Spring Stopper: 57001–1316 •...
  • Page 375 SUSPENSION 13-13 Front Fork If necessary, measure the oil level as follows. ○ Hold the inner tube vertically in a vise. ○ Pump the inner tube several times to expel air bubbles. ○ Using the piston rod puller [A], move the piston rod [B] up and down more than ten times in order to expel all the air from the fork oil.
  • Page 376 13-14 SUSPENSION Front Fork • Screw the rod nut [B] onto the piston rod [A] as shown. • Insert the rebound damping adjuster rod [C] into the piston rod. • Check the distance [C] between the bottom end [A] of the top plug and rebound damping adjuster [B] with a pair of vernier caliper.
  • Page 377: Front Fork Disassembly

    SUSPENSION 13-15 Front Fork Front Fork Disassembly • Remove the front fork (see Front Fork Removal). • Drain the fork oil (see Front Fork Oil Change). • Hold the front fork in a vise [A]. • Stop the cylinder [B] from turning by using the fork cylinder holder [C].
  • Page 378: Inner Tube Inspection

    13-16 SUSPENSION Front Fork • Install the following parts into the inner tube [A]. Dust Seal [B] Circlip [C] Oil Seal [D] Washer [E] • Insert the inner tube to the outer tube. • After installing the washer, install the oil seal [A] by using the fork oil seal driver [B].
  • Page 379: Dust Seal Inspection

    SUSPENSION 13-17 Front Fork Dust Seal Inspection • Inspect the dust seals [A] for any signs of deterioration or damage. Replace it if necessary. Spring Tension • Since a spring becomes shorter as it weakens, check its free length [A] to determine its condition. If the spring of either fork leg is shorter than the service limit, it must be replaced.
  • Page 380: Rear Shock Absorber

    13-18 SUSPENSION Rear Shock Absorber Rebound Damping Force Adjustment • To adjust the rebound damping force, turn the lower 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 is the turns out from the fully clockwise position.
  • Page 381: Rear Shock Absorber Removal

    SUSPENSION 13-19 Rear Shock Absorber • To adjust the spring preload, turn in the adjusting nut [A] to the desired position and tighten the locknut [B]. [C] Spring Length Spring Preload Setting Standard: Spring length 180 mm (7.0 in.) Spring length 171.5 ∼ 191.5 mm (6.8 Usable Range: ∼...
  • Page 382: Rear Shock Absorber Installation

    13-20 SUSPENSION Rear Shock Absorber • Remove: Lower Shock Absorber Bolt [A] Upper Tie-Rod Bolt [B] • Remove: Upper Shock Absorber Nut [A] Upper Shock Absorber Bolt [B] • Remove the shock absorber upward. Rear Shock Absorber Installation • Pack the rocker arm needle bearings with grease. •...
  • Page 383: Swingarm

    SUSPENSION 13-21 Swingarm Swingarm Removal • Remove: Rear Wheel (see Wheels/Tires chapter) Inner Fender (see Frame chapter) Chain Cover (see Final Drive chapter) Brake Hose Clamps [A] Rear Shock Absorber [B] (see Rear Shock Absorber Re- moval) • Unscrew the swingarm pivot shaft locknut using socket wrench [A].
  • Page 384: Swingarm Bearing Removal

    13-22 SUSPENSION Swingarm • Place the collar [A] on the stopper [B] inside the frame [C]. • Insert the pivot shaft into the frame from the right side. • First, tighten the pivot shaft so that the clearance between the collar and the frame come to zero mm (zero in.) [D]. Torque - Swingarm Pivot Shaft (First): 25 N·m (2.5 kgf·m, 18 ft·lb) •...
  • Page 385: Swingarm Bearing Installation

    SUSPENSION 13-23 Swingarm Swingarm Bearing Installation • Apply plenty of grease to the ball bearing and needle bearings. • Install the needle bearings so that the manufacturer’s marks faces out. • Install the ball bearing so that the manufacturer’s marks faces out.
  • Page 386: Tie-rod, Rocker Arm

    13-24 SUSPENSION Tie-Rod, Rocker Arm Tie-Rod Removal • Remove the lower fairings (see Frame chapter). • Squeeze the brake lever slowly and hold it with a band [A]. • Using the jack, raise the rear wheel off the ground. Special Tool - Jack: 57001–1238 •...
  • Page 387: Rocker Arm/tie-rod Bearing, Sleeve Inspection

    SUSPENSION 13-25 Tie-Rod, Rocker Arm Rocker Arm/Tie-Rod Bearing, Sleeve Inspection CAUTION Do not remove the bearings for inspection. Re- moval may damage them. • Visually inspect the swingarm sleeves and needle bear- ings. • The rollers in a needle bearing normally wear very little, and wear is difficult to measure.
  • Page 389 STEERING 14-1 Steering Table of Contents Exploded View........................14-2 Special Tools .......................... 14-4 Steering ..........................14-5 Steering Inspection ......................14-5 Steering Adjustment......................14-5 Steering Stem......................... 14-6 Stem, Stem Bearing Removal................... 14-6 Stem, Stem Bearing Installation..................14-6 Stem Bearing Lubrication....................14-8 Steering Stem Warp......................
  • Page 390: Exploded View

    14-2 STEERING Exploded View...
  • Page 391 STEERING 14-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Handlebar switch housing screws 0.36 31 in·lb Handlebar bolts Handlebar position bolts 87 in·lb Front fork clamp bolts (Upper) 14.5 Front fork clamp bolts (Lower) 14.5 Steering stem head nut Steering stem nut 14.5 AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque.
  • Page 392: Special Tools

    14-4 STEERING Special Tools Head Pipe Outer Race Press Shaft: Steering Stem Bearing Driver Adapter: 57001–1075 57001–1345 Steering Stem Nut Wrench: Head Pipe Outer Race Driver: 57001–1100 57001–1446 Jack: Head Pipe Outer Race Driver: 57001–1238 57001–1447 Steering Stem Bearing Driver: 57001–1344...
  • Page 393: Steering Inspection

    STEERING 14-5 Steering Steering Inspection ○ Refer to the Steering in the Periodic Maintenance chapter. Steering Adjustment ○ Refer to the Steering in the Periodic Maintenance chapter.
  • Page 394: Steering Stem

    14-6 STEERING Steering Stem Stem, Stem Bearing Removal • Remove: Fairings (see Frame chapter) Fuel Tank (see Fuel System (DFI) chapter) Brake Hose Clamp Bolt [A] Left/Right handlebar Switch Leads Clamp Bolt [A] Clutch Cable Clamp Bolt [B] Front Wheel (see Wheels/Tires chapter) Front Fork (see Suspension chapter) Steering Stem Head Nut and Washer Steering Stem Head and Handlebars...
  • Page 395 STEERING 14-7 Steering Stem • Replace the bearing inner races with new ones. • Install the oil seal [D] on the steering stem, and drive the lower ball bearing inner race [A] applied the grease onto the stem. Special Tools - Steering Stem Bearing Driver: 57001–1344 Steering Stem Bearing Driver Adapter: 57001–1345 [C] •...
  • Page 396: Stem Bearing Lubrication

    14-8 STEERING Steering Stem • Settle the bearings in place as follows: ○ Tighten the steering stem nut with 20 N·m (2.0 kgf·m, 14.5 ft·lb) of torque first, and loosen it a fraction of a turn until it turns lightly. (To tighten the stem nut to the specified torque, hook the wrench on the stem nut, and pull the wrench at the hole by 11.1 kg (24.5 lb) [B] force in the direction shown.) Afterward tighten it again with specified...
  • Page 397: Steering Stem Warp

    STEERING 14-9 Steering Stem Steering Stem Warp • Whenever the steering stem is removed, or if the steering can not be adjusted for smooth action, check the steering stem for straightness. If the steering stem [A] is bent, replace the steering stem.
  • Page 398: Handlebar

    14-10 STEERING Handlebar Handlebar Removal • Remove: Clutch Lever Assembly [A] Left Handlebar Switch Housing [B] Front Brake Master Cylinder [C] Right handlebar Switch Housing [D] Throttle Case [E] • Remove: Weight Bolts [A] Handlebar Weight [B] Fitting [C] Clip [D] •...
  • Page 399 FRAME 15-1 Frame Table of Contents Exploded View........................15-2 Seats ............................15-8 Rear Seat Removal......................15-8 Rear Seat Installation......................15-8 Front Seat Removal ......................15-8 Front Seat Installation ....................... 15-8 Fairings........................... 15-9 Lower Fairing Removal ..................... 15-9 Inner (Upper) Fairing Removal ..................15-9 Inner (Lower) Fairing Removal ..................
  • Page 400: Exploded View

    15-2 FRAME Exploded View...
  • Page 401 FRAME 15-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Footpeg stay bolts Footpeg holder bolts Rear frame bolts Side stand bracket bolts Side stand bolt Side stand switch bolt 0.90 78 in·lb G: Apply grease. L: Apply a non-permanent locking agent.
  • Page 402 15-4 FRAME Exploded View...
  • Page 403 FRAME 15-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Wind shield mounting screws 0.04 3.5 in·lb Front fender mounting bolts 0.40 35 in·lb 3. United States and Canada Models L: Apply a non-permanent locking agent.
  • Page 404 15-6 FRAME Exploded View...
  • Page 405 FRAME 15-7 Exploded View 1. United States and Canada Models...
  • Page 406: Seats

    15-8 FRAME Seats Rear Seat Removal • Insert the ignition switch key into the seat lock [A], turning the key counterclockwise, pulling the rear of the seat [B] up, and pull the seat backward. Rear Seat Installation • Slip the rear seat hooks [A] into the slend holes [B] on the frame.
  • Page 407: Fairings

    FRAME 15-9 Fairings Lower Fairing Removal • Remove: Allen Bolts [A] [B] [C] [D] [E] Rivet Screws [F] • Pull the lower front part of the lower fairing outward to clear the stoppers [G]. • Remove the lower fairing. • Remove the other side lower fairing in the same manner.
  • Page 408 15-10 FRAME Fairings • Remove: Nuts [A] (Left and Right) Rear View Mirrors [B] (Left and Right) • Remove: Headlight Lead Connector [A] Turn Signal Light Lead Connector [B] Upper Fairing...
  • Page 409: Seat Cover

    FRAME 15-11 Seat Cover Seat Cover Removal • Remove: Seats Screws and Washers [A] Rivet Screws [B] (Left and Right) • Pull the seat cover backward to clear the stoppers [C]. Seat Cover Installation • Set the seat cover [A], and insert the rivet screws [B] into the holes in the seat cover and rear fender rear.
  • Page 410: Fenders

    15-12 FRAME Fenders Front Fender Removal • Remove: Brake Hose Clamps [A] (Left and Right) Bolts [B] (Left and Right) • Remove the front fender [C]. Front Fender Installation • Install the front fender to the front fork. • Tighten: Torque - Front Fender Mounting Bolts: 3.9 N·m (0.40 kgf·m, 35 in·lb) •...
  • Page 411: Rear Fender Front Removal

    FRAME 15-13 Fenders Rear Fender Front Removal • Remove: Flap Rear Fender Rear Battery [A] Junction Box [B] Starter Relay Assy [C] Turn Signal Relay [D] Fuel Pump Relay [E] ECU Main Relay [F] ECU Fuse Holder [G] Seat Lock [H] •...
  • Page 412: Rear Frame Removal

    15-14 FRAME Frame Rear Frame Removal • Remove: Fuel Tank (see Fuel System (DFI) chapter) Flap and Rear Fender Rear (see Flap and Rear Fender Rear Removal) Rear Fender Front (see Rear Fender Front Removal) Clamps for Main Harness Frame Bolts and Nuts [A] Rear Step Bracket Bolts [B] Rear Frame Installation •...
  • Page 413: Storage Box

    FRAME 15-15 Storage Box Storage Box Removal • Remove: Seat Cover (see this chapter) Screw [A] • Pulling up the rear part of the box backward. Storage Box Installation • Insert the front part [A] of the box into the rear frame [B]. •...
  • Page 414: Side Stand

    15-16 FRAME Side Stand Side Stand Removal • Raise the rear wheel off the ground with the stand. • Disconnect the side stand switch lead connectors. • Remove: Side Stand Switch Bolt [A] Spring [B] Side Stand Bolt [C] Side Stand [D] Switch Bracket Bolts [E] Side Stand Bracket Bolts [F] Side Stand Installation...
  • Page 415 ELECTRICAL SYSTEM 16-1 Electrical System Table of Contents Exploded View........16-4 Spark Plug Cleaning and Wiring Diagram (United States and Inspection........16-42 Canada) .......... 16-10 Spark Plug Gap Inspection ..16-42 Wiring Diagram (Australia) ....16-12 Camshaft Position Sensor Wiring Diagram (Other than United Removal ........
  • Page 416 16-2 ELECTRICAL SYSTEM Water Temperature Sensor Starter Circuit/Headlight Relay Inspection........16-71 Inspection........16-74 Speed Sensor Removal ....16-71 Diode Circuit Inspection ....16-75 Speed Sensor Installation .... 16-72 Fuse........... 16-77 Speed Sensor Inspection..... 16-72 30 A Main Fuse Removal..... 16-77 Fuel Reserve Switch Inspection Junction Box Fuse Removal ..
  • Page 418: Exploded View

    16-4 ELECTRICAL SYSTEM Exploded View...
  • Page 419 ELECTRICAL SYSTEM 16-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Crankshaft sensor cover bolts 87 in·lb L (1) Spark plugs 113 in·lb Crankshaft sensor bolts 0.60 52 in·lb Timing rotor bolt Tail/Brake light mounting screws 0.12 10 in·lb License light mounting screws 0.12 10 in·lb License light assembly screws...
  • Page 420 16-6 ELECTRICAL SYSTEM Exploded View...
  • Page 421 ELECTRICAL SYSTEM 16-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Alternator cover bolt 104 in·lb Alternator lead holding plate bolts 0.70 61 in·lb Stator coil bolts 110 in·lb Alternator rotor bolt Fuel pump bolts 87 in·lb Neutral switch Oil pressure switch Oil pressure switch terminal bolt 0.15 13 in·lb...
  • Page 422 16-8 ELECTRICAL SYSTEM Exploded View...
  • Page 423 ELECTRICAL SYSTEM 16-9 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Fan switch Water temperature sensor Side Stand Switch Bolt 0.90 78 in·lb Meter screws 0.12 10 in·lb Meter assembly screws 0.12 10 in·lb Engine Ground Lead Terminal Bolt 87 in·lb 7.
  • Page 424: Wiring Diagram (united States And Canada)

    16-10 ELECTRICAL SYSTEM Wiring Diagram (United States and Canada)
  • Page 425 ELECTRICAL SYSTEM 16-11 Wiring Diagram (United States and Canada)
  • Page 426: Wiring Diagram (australia)

    16-12 ELECTRICAL SYSTEM Wiring Diagram (Australia)
  • Page 427 ELECTRICAL SYSTEM 16-13 Wiring Diagram (Australia)
  • Page 428: Wiring Diagram (other Than United States, Canada And Australia)

    16-14 ELECTRICAL SYSTEM Wiring Diagram (Other than United States, Canada and Australia)
  • Page 429 ELECTRICAL SYSTEM 16-15 Wiring Diagram (Other than United States, Canada and Australia)
  • Page 430: Specifications

    16-16 ELECTRICAL SYSTEM Specifications Item Standard Battery: Type Sealed Battery 12 V 8 Ah Capacity Voltage 12.6 V or more Charging System: Type Three–phase AC 42.4 ∼ 63.6 V @4 000 r/min (rpm) Alternator output voltage 0.3 ∼ 0.4 Ω Stator coil resistance Charging voltage 14.2 ∼...
  • Page 431: Special Tools And Sealant

    ELECTRICAL SYSTEM 16-17 Special Tools and Sealant Flywheel Holder: Needle Adapter Set: 57001–1313 57001–1457 Hand Tester: Harness Adapter: 57001–1394 57001–1542 Flywheel Puller Assembly: Kawasaki Bond (Silicone sealant) : 57001–1405 56019–120 Lead Wire – Peak Voltage Adapter: 57001–1449...
  • Page 432: Parts Location

    16-18 ELECTRICAL SYSTEM Parts Location 1. Starter Lockout Switch 8. Radiator Fan Switch 2. Stick Coils 9. Starter Motor 3. Water Temperature Sensor 10. Alternator 4. Vehicle-down Sensor 11. Neutral Switch 5. Battery 12. Speed Sensor 6. Junction Box 13. Side Stand Switch 7.
  • Page 433 ELECTRICAL SYSTEM 16-19 Parts Location 1. Starter Relay and Main Fuse 7. Front Brake Light Switch 2. Turn Signal Relay 8. Rear Brake Light Switch 3. Fuel Pump Relay 9. Regulator/Rectifire 4. ECU Fuse 10. Crankshaft Sensor 5. ECU Main Relay 11.
  • Page 434: Precautions

    16-20 ELECTRICAL SYSTEM Precautions There are a number of important precautions that are musts when servicing electrical systems. Learn and ob- serve all the rules below. ○ Do not reverse the battery lead connections. This will burn out the diodes on the electrical parts. ○...
  • Page 435 ELECTRICAL SYSTEM 16-21 Precautions Male Connectors [B]...
  • Page 436: Electrical Wiring

    16-22 ELECTRICAL SYSTEM Electrical Wiring Wiring Inspection • Visually inspect the wiring for signs of burning, fraying, etc. If any wiring is poor, replace the damaged wiring. • Pull each connector [A] apart and inspect it for corrosion, dirt, and damage. If the connector is corroded or dirty, clean it carefully.
  • Page 437: Battery

    ELECTRICAL SYSTEM 16-23 Battery Battery Removal • Remove the seats (see Frame chapter). • Disconnect the negative (–) lead [A] and then positive (+) lead [B]. CAUTION Be sure to disconnect the negative (–) lead first. • Remove the battery. Electrolyte Filling CAUTION Do not remove the aluminum seal sheet [A] sealing...
  • Page 438: Initial Charge

    16-24 ELECTRICAL SYSTEM Battery • Make sure air bubbles [A] are coming up from all six filler ports. ○ Leave the container this way for 5 minutes or longer. NOTE ○ If no air bubbles are coming up from a filler port, tap [B] the bottom of the container two or three times.
  • Page 439: Interchange

    ELECTRICAL SYSTEM 16-25 Battery When a fast charge is inevitably required, do it following precisely the maximum charge current and time conditions indicated on the battery. CAUTION This battery is designed to sustain no unusual deterioration if refresh-charged according to the method specified above. However, the battery’s performance may be reduced no- ticeably if charged under conditions other than given above.
  • Page 440: Refreshing Charge

    16-26 ELECTRICAL SYSTEM Battery NOTE ○ Measure with a digital voltmeter [A] which can be read to one decimal place voltage. If the reading is below the specified, refreshing charge is required. Battery Terminal Voltage Standard: 12.6 V or more Refreshing Charge •...
  • Page 441 ELECTRICAL SYSTEM 16-27 Battery • Determine battery condition after refreshing charge. ○ Determine the condition of the battery 30 minutes after completion of the charge by measuring the terminal volt- age according to the table below. Criteria Judgement 12.6 V or higher Good 12.0 ∼...
  • Page 442: Charging System

    Apply silicone sealant to the alternator lead grommet and crankcase halves mating surface [A] on the front and rear sides of the cover mount. Sealant - Kawasaki Bond (Silicone Sealant): 56019–120 • Check that knock pins [B] are in place on the crankcase.
  • Page 443: Alternator Rotor Removal

    ELECTRICAL SYSTEM 16-29 Charging System Alternator Rotor Removal • Remove: Alternator Cover (see Alternator Cover Removal) Starter Idle Gear and Shaft • Wipe oil off the outer circumference of the rotor. • Hold the alternator rotor steady with the flywheel holder [A], and remove the rotor bolt [B].
  • Page 444 16-30 ELECTRICAL SYSTEM Charging System • Install the washer [A]. NOTE ○ Confirm the alternator rotor fit or not to the crankshaft before tightening it with specified torque. ○ Alternator bolt fastening process has two steps. both steps are not carried out, the alternator bolt could loosen and the engine could be damaged.
  • Page 445: Alternator Inspection

    ELECTRICAL SYSTEM 16-31 Charging System Alternator Inspection There are three types of alternator failures: short, open (wire burned out), or loss in rotor magnetism. A short or open in one of the coil wires will result in either a low output, or no output at all.
  • Page 446: Regulator/rectifier Inspection

    16-32 ELECTRICAL SYSTEM Charging System If the output voltage shows the value in the table, the al- ternator operates properly. If the output voltage shows a much higher than the value in the table, the regulator/rectifier is damaged. A much lower reading than that given in the table indicates that the alternator is defective.
  • Page 447 ELECTRICAL SYSTEM 16-33 Charging System Rectifier Circuit Check: • Check the rectifier resistance as follows. • Disconnect the regulator/rectifier connector. • Connect the hand tester (special tool) to the regulator/rec- tifier as shown in the table, and check the resistance in both directions of each diode in the rectifier following the table.
  • Page 448 16-34 ELECTRICAL SYSTEM Charging System • Do the 1st step regulator circuit test. ○ Connect the test light and the 12 V battery to the regula- tor/rectifier as shown. ○ Check BK1, BK2, and BK3 terminal respectively. If the test light turns on, the regulator/rectifier is defective. Replace it.
  • Page 449: Charging Voltage Inspection

    ELECTRICAL SYSTEM 16-35 Charging System Charging Voltage Inspection • Check the battery condition (see Battery section). • Warm up the engine to obtain actual alternator operating conditions. • Remove the seats (see Frame chapter). • Check that the ignition switch is turned off, and connect the hand tester [A] as shown in the table.
  • Page 450 16-36 ELECTRICAL SYSTEM Charging System Charging System Circuit 1. Ignition Switch 3. Regulator/Rectifier 5. Main Fuse 30 A 2. Alternator 4. Battery 6. Load...
  • Page 451: Ignition System

    ELECTRICAL SYSTEM 16-37 Ignition System...
  • Page 452: Crankshaft Sensor Removal

    16-38 ELECTRICAL SYSTEM Ignition System WARNING The ignition system produces extremely high volt- age. Do not touch the spark plugs or stick coils while the engine is running, or you could receive a severe electrical shock. CAUTION Do not disconnect the battery leads or any other electrical connections when the ignition switch is on, or while the engine is running.
  • Page 453: Crankshaft Sensor Installation

    Apply silicone sealant [A] to the crankshaft sensor lead grommet and crankcase halves mating surface on the front and rear sides of the crankshaft sensor cover mount. Sealant - Kawasaki Bond (Silicone Sealant): 56019–120 • Apply a non-permanent locking agent to the threads of the crankshaft sensor cover bolt [A].
  • Page 454: Crankshaft Sensor Peak Voltage

    16-40 ELECTRICAL SYSTEM Ignition System Crankshaft Sensor Peak Voltage • Remove: Fuel Tank (see Fuel System chapter) Crankshaft Sensor Lead Connector • Set the Hand Tester [B] to the × 10 V DC range, and connect it a commercially available peak voltage adapter [E] as shown in the diagram.
  • Page 455: Stick Coil Primary Peak Voltage

    ELECTRICAL SYSTEM 16-41 Ignition System Stick Coil (Ignition Coil together with Spark Plug Cap) Inspection • Remove the stick coils (see this chapter). • Measure the primary winding resistance [A] as follows. ○ Connect the hand tester between the coil terminals. ○...
  • Page 456: Spark Plug Removal

    16-42 ELECTRICAL SYSTEM Ignition System WARNING To avoid extremely high voltage shocks, do not touch the spark plugs or tester connections. • Turn the ignition switch and the engine stop switch ON. • Pushing the starter button, turn the engine 4 ∼ 5 seconds with the transmission in neutral to measure the primary peak voltage.
  • Page 457: Camshaft Position Sensor Removal

    ELECTRICAL SYSTEM 16-43 Ignition System Camshaft Position Sensor Removal • Remove the lower fairings (see Frame chapter). • Lift the left side of the baffle plate and take out the camshaft position sensor lead connector. • Remove the left under side radiator bolt. •...
  • Page 458: Camshaft Position Sensor Peak Voltage Inspection

    16-44 ELECTRICAL SYSTEM Ignition System Camshaft Position Sensor Peak Voltage Inspection • Remove: Right Lower Inner Cover (see Frame chapter) Camshaft Position Sensor Lead Connector • Set the commercially available tester [A] to the 10 V DC range. • Connect commercially available peak voltage adapter [B] to the hand tester and camshaft position sensor leads in the terminals.
  • Page 459: Interlock Operation Inspection

    ELECTRICAL SYSTEM 16-45 Ignition System Interlock Operation Inspection • Remove the seats (see Frame chapter). 1st Check • Measure the terminal voltage of the G/BK lead in the junc- tion box connector [A] in accordance with the following procedure. ○ Set the tester [B] to the 25 V DC range, connect it to the G/BK lead and frame ground [C].
  • Page 460: Ic Igniter Inspection

    16-46 ELECTRICAL SYSTEM Ignition System 2nd Check Raise the rear wheel off the ground with a stand. • Set the following conditions. Condition: Transmission Gear → 1st Position Clutch Lever → Release Side Stand → Up • Turn the ignition switch on and push the starter button. If turn the engine, inspect the starter lockout switch, side stand switch and junction box.
  • Page 461 ELECTRICAL SYSTEM 16-47 Ignition System Ignition System Circuit 1. Junction Box 11. Camshaft Position Sensor 2. Ignition Fuse 10A 12. Main Throttle Sensor 3. Ignition Switch 13. Subthrottle Sensor 4. Engine Stop Switch 14. Starter Lockout Switch 5. Starter Button 15.
  • Page 462: Electric Starter System

    16-48 ELECTRICAL SYSTEM Electric Starter System Starter Motor Removal • Remove the fuel tank (see Fuel System (DFI) chapter). • Slide back the rubber cap. • Remove the starter motor terminal bolt [A] and the mount- ing bolts [B]. • Pull out the starter motor [C].
  • Page 463: Brush Inspection

    ELECTRICAL SYSTEM 16-49 Electric Starter System • Press the springs and holding the brush leads with suit- able clips [A] as shown. • Put the armature [B] among the brushes. • Install the O-rings [A] as shown. • Align the groove [A] in the right-hand end cover and the hollow mark [B] on the yoke.
  • Page 464: Commutator Cleaning And Inspection

    16-50 ELECTRICAL SYSTEM Electric Starter System Commutator Cleaning and Inspection • Smooth the commutator surface [A] if necessary with fine emery cloth [B], and clean out the grooves. • Measure the diameter [A] of the commutator [B]. If the commutator diameter is less than the service limit, replace the starter motor with a new one .
  • Page 465: Right-hand End Cover Assembly Inspection

    ELECTRICAL SYSTEM 16-51 Electric Starter System Right–hand End Cover Assembly Inspection • Using the highest hand tester range, measure the resis- tance as shown. [A] Terminal and Right–hand End Cover Special Tool - Hand Tester: 57001–1394 If there is any reading, the right-hand end cover assembly have a short.
  • Page 466 16-52 ELECTRICAL SYSTEM Electric Starter System Electric Starter Circuit 1. Ignition Switch 6. Ignition Fuse 10A 11. Diode 2. Engine Stop Switch 7. Side Stand Switch 12. Starter Relay 3. Starter Button 8. Neutral Switch 13. Main Fuse 30 A 4.
  • Page 467: Lighting System

    ELECTRICAL SYSTEM 16-53 Lighting System This motorcycle adopt the daylight system and have a headlight relay in the junction box. The headlight does not go on when the ignition switch and the engine stop switch are first turned on. The headlight comes on after the starter button is released and stays on until the ignition switch is turned off.
  • Page 468: Headlight Bulb Replacement

    16-54 ELECTRICAL SYSTEM Lighting System Headlight Bulb Replacement • Remove: Headlight Bulb Dust Cover Headlight Connector [A] Hook [B] Headlight Bulb [C] 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 469 ELECTRICAL SYSTEM 16-55 Lighting System Headlight/Tail Light Circuit 1. High Beam Indicator 6. Dimmer Switch 12. Frame Ground Light 7. Passing Button 13. Alternator 2. Ignition Switch 8. Main Fuse 30A 14. Tail Light Fuse 10A 3. Headlight (High Beam) 9.
  • Page 470: Turn Signal Relay Inspection

    16-56 ELECTRICAL SYSTEM Lighting System Turn Signal Relay Inspection • Remove: Seats (see Frame chapter) Turn Signal Relay [A] • Connect one 12 V battery and turn signal lights as indi- cated in the figure, and count how may times the lights flash for one minute.
  • Page 471 ELECTRICAL SYSTEM 16-57 Lighting System Turn Signal Light Circuit 1. Turn Signal Indicator Lights 7. Turn Signal Relay Fuse 10A (Right & Left) 8. Ignition Switch 2. Front Right Turn Signal Light 9. Rear Right Turn Signal Light 3. Front Left Turn Signal Light 10.
  • Page 472: Radiator Fan System

    16-58 ELECTRICAL SYSTEM Radiator Fan System WARNING The radiator fan is connected directly to the bat- tery. The fan may start even if the ignition switch is off. NEVER TOUCH THE RADIATOR FAN UNTIL THE RADIATOR FAN CONNECTOR IS DISCONNECTED. TOUCHING THE FAN BEFORE THE CONNECTOR IS DISCONNECTED COULD CAUSE INJURY FROM THE FAN BLADES.
  • Page 473 ELECTRICAL SYSTEM 16-59 Radiator Fan System Radiator Fan Circuit 1. Radiator Fan 3. Junction Box 5. Main Fuse 30 A 2. Radiator Fan Switch 4. Fan Fuse 10 A 6. Battery...
  • Page 474: Meter

    16-60 ELECTRICAL SYSTEM Meter Meter Assembly Removal • Remove: Upper Fairing (see Frame chapter) Meter Bracket Bolts [A] • Slide the dust cover [A] and remove the wiring connector. • Remove the meter unit by taking off the mounting screws [B] with the washers.
  • Page 475: Meter, Gauge, Indicator Unit

    ELECTRICAL SYSTEM 16-61 Meter, Gauge, Indicator Unit Electronic Combination Meter Assembly Inspection • Remove the meter assembly [A]. [1] Ignition [10] Battery (+) [2] Fuel Reserve Switch [11] Oil Pressure Warning [3] Stop Watch (+) Indicator Light (LED) [4] Lap Time (+) Ground (–) [5] Neutral Indicator Light [12] Speed Sensor Supply (LED) Ground (–)
  • Page 476 16-62 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit ○ The tachometer LCD segments momentarily to it last readings two times and segment movement is reversal. ○ When the terminals are connected, all the LCD segments [A] and LED warning light [B] appear for three seconds. If the LCD segments and LED warning light will not ap- pear, replace the meter assembly.
  • Page 477 ELECTRICAL SYSTEM 16-63 Meter, Gauge, Indicator Unit • In the HOUR setting mode, press the reset button [C] to effect the MINUTE setting mode. ○ The minute display flashes on the display. • Press the mode selector button [A] to set the minute. •...
  • Page 478 16-64 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit Speed Sensor Electric Source Check: • Connect the 12 V battery and terminals in the same man- ner as specified in the "Liquid Crystal Display (LCD) Seg- ments Check". • Set the hand tester to the DC25 V range and connect it to the terminals [12] and [9].
  • Page 479 ELECTRICAL SYSTEM 16-65 Meter, Gauge, Indicator Unit Tachometer Check: • Connect the 12 V battery and terminals in the same man- ner as specified in the "Liquid Crystal Display (LCD) Seg- ments Check". • The revolutions per minute (rpm) equivalent to the input frequency is indicated in the oscillator [A] if the square wave (illustrated as shown) would be input into the termi- nal [7].
  • Page 480 16-66 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit Stop Watch Check: • Connect the 12V battery and terminal in the same man- ner as specified in the “Liquid Crystal Display (LCD) Seg- ments Check”. • Press the mode selector button each time to set the stop watch mode.
  • Page 481 ELECTRICAL SYSTEM 16-67 Meter, Gauge, Indicator Unit FI Indicator Light (LED): Battery Negative (–) Terminal To Terminal [6] Oil Pressure Warning Indicator Light (LED): Battery Negative (–) Terminal To Terminal [11] Right and Left Turn Signal Indicator Light (LED): Battery Positive (+) Terminal to Terminal [13] Battery Positive (+) Terminal to Terminal [14] High Beam Indicator Light (LED): Battery Positive (+) Terminal to Terminal [15]...
  • Page 482 16-68 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit Shift Up Indicator Light (LED): • Connect the 12V battery and terminal in the same man- ner as specified in the “Liquid Crystal Display (LCD) Seg- ments Check”. • The revolutions per minute(rpm)equivalent to the input frequency is indicated in the oscillator [A] if the square wave(illustrated as shown) would be input into the termi- nal [7].
  • Page 483: Switches And Sensors

    ELECTRICAL SYSTEM 16-69 Switches and Sensors Brake Light Timing Inspection ○ Refer to the Brakes in the Periodic Maintenance chapter. Brake Light Timing Adjustment ○ Refer to the Brakes in the Periodic Maintenance chapter. Switch Inspection • Using a hand tester, check to see that only the con- nections shown in the table have continuity (about zero ohms).
  • Page 484: Radiator Fan Switch Inspection

    16-70 ELECTRICAL SYSTEM Switches and Sensors Radiator Fan Switch Inspection • Remove the fan switch (see Cooling System chapter). • Suspend the switch [A] in a container of coolant so that the temperature-sensing projection and threaded portion are submerged. • Suspend an accurate thermometer [B] in the coolant.
  • Page 485: Water Temperature Sensor Inspection

    ELECTRICAL SYSTEM 16-71 Switches and Sensors Water Temperature Sensor Inspection • Remove the water temperature sensor (see Fuel System (DFI) chapter). • Suspend the sensor [A] in a container of coolant so that the temperature-sensing projection [E] and threaded por- tion [E] are submerged.
  • Page 486: Speed Sensor Installation

    16-72 ELECTRICAL SYSTEM Switches and Sensors • Disconnect the speed sensor lead connector [A]. • Remove the speed sensor. Speed Sensor Installation • Install the speed sensor. Torque - Speed Sensor Bolt: 3.9 N·m (0.40 kgf·m, 35 in·lb) Speed Sensor Inspection •...
  • Page 487: Fuel Reserve Switch Inspection (2)

    ELECTRICAL SYSTEM 16-73 Switches and Sensors Fuel Reserve Switch Inspection (2) • Remove: Fuel Pump (see Fuel System (DFI) chapter) • Connect the test light (12 V 3.4 W bulb in a socket with leads) and the 12 V battery to the fuel pump connector as shown.
  • Page 488: Junction Box

    16-74 ELECTRICAL SYSTEM Junction Box The junction box [A] has fuses [B], relays, and diodes. The relays and diodes can not be removed. Junction Box Fuse Circuit Inspection • Remove the seats (see Frame chapter). • Remove the junction box. •...
  • Page 489: Diode Circuit Inspection

    ELECTRICAL SYSTEM 16-75 Junction Box Relay Circuit Inspection (with the battery disconnected) Tester Tester Reading Tester Tester Reading (Ω) Connection (Ω) Connection ∞ ∞ 7 - 8 9 - 11 Headlight 7 - 13 ∞ 12 - 13 ∞ Starter Circuit Relay Relay (+) (-)
  • Page 490 16-76 ELECTRICAL SYSTEM Junction Box Junction Box Internal Circuit A. Accessory Fuse 10 A G. Headlight Relay B. Fan Fuse 10 A H. Headlight Diodes C. Turn Signal Relay Fuse 10 A I. Starter Diode D. Horn Fuse 10 A J.
  • Page 491: Fuse

    ELECTRICAL SYSTEM 16-77 Fuse 30 A Main Fuse Removal • Remove: Seats (see Frame chapter) Starter Relay and 30 A Main Fuse Connector [A] • Pull out the main fuse [B] from the starter relay with needle nose pliers. Junction Box Fuse Removal •...
  • Page 493 APPENDIX 17-1 Appendix Table of Contents Cable, Wire, and Hose Routing ....................17-2 Troubleshooting Guide ......................17-12...
  • Page 494 17-2 APPENDIX Cable, Wire, and Hose Routing 1. Clucth Cable 12. Clamp the throttle cables and clutch cable 2. Choke Cable and run the clutch cable above the throttle 3. Throttle Cables cables. 4. Coolant Reserve Tank Hose 13. Run the clutch cable above the coolant 5.
  • Page 495 APPENDIX 17-3 Cable, Wire, and Hose Routing 1. Seat Lock Cable 2. ECU (Electrical Control Unit) 3. ECU Fuse15A 4. Turn Signal Relay 5. Fuel Pump Relay 6. ECU Main Relay 7. Battery (+) Lead 8. Battery 9. Vehicle-down Sensor 10.
  • Page 496 17-4 APPENDIX Cable, Wire, and Hose Routing 1. Engine Ground 15. Clamp 2. To Side Stand Switch/Neutral Switch, etc 16. To Camshaft Position Sensor 3. To Speed Sensor 17. Clamp the horn lead, ignition switch lead 4. Regulator/Rectifire Lead and right handlebar switch lead. 5.
  • Page 497 APPENDIX 17-5 Cable, Wire, and Hose Routing 1. To Air Radiator Fan Switch 13. Regulator/Rectifire Lead 2. Vacuum Switch Valve 14. Starter Motor Lead 3. Tighten with the ground lead and clamp. 15. Battery (-) Lead 4. Run the subthrottle lead under the vac- 16.
  • Page 498 17-6 APPENDIX Cable, Wire, and Hose Routing 1. Through the clamp to the rubber cover hole, and bend it for hold the rubber cover. 2. Radiator Fan Lead 3. Clamp the radiator fan switch lead. 4. Camshaft Position lead 5. Through the horn lead outside the bracket of radiator upside, and through it between frame and radiator.
  • Page 499 APPENDIX 17-7 Cable, Wire, and Hose Routing 1. Reserve Tank Overflow Hose 2. Fuel Tank Drain Hose 3. Air Cleaner Housing Drain Hose 4. Clamp the air cleaner housing drain hose. 5. Clamp the reserve tank overflow hose and fuel tank drain hose.
  • Page 500 17-8 APPENDIX Cable, Wire, and Hose Routing 1. Brake Hose Clamp 7. Clamp (Installed to the inner fender) 2. Front Master Cylinder 8. Rear Brake Master Cylinder 3. Front Brake Reservoir Tank 9. Rear Brake Reservoir Tank 4. Clamp (Installed to the front fender) 10.
  • Page 501 APPENDIX 17-9 Cable, Wire, and Hose Routing 1. Radiator 2. Reserve Tank Hose 3. Coolant By-pass Hose 4. Face the clamp screw rear and approximately 30° inside. 5. Face the clamp screw downward. 6. Face the white mark forward. 7. To Cylinder Head Fitting 8.
  • Page 502 17-10 APPENDIX Cable, Wire, and Hose Routing 1. Radiator Fan Switch 2. To Radiator 3. Face the clamp screw downward. 4. Cylinder Fitting. 5. Water Pump. 6. Align the mark.
  • Page 503 APPENDIX 17-11 Cable, Wire, and Hose Routing California Evaporative Emission Control System 1. Canister 2. Band 3. Face the hole downward. 4. Separator 5. Fitting 6. Face the claw outside. 7. To Separator (Blue) 8. To Fuel Tank (Red) 9. To Canister (Blue) 10.
  • Page 504: Troubleshooting Guide

    17-12 APPENDIX Troubleshooting Guide NOTE Spark plug dirty, broken, or gap malad- ○ Refer to the Fuel System chapter for most justed of DFI trouble shooting guide. Stick coil shorted or not in good contact ○ This is not an exhaustive list, giving every Stick coil trouble possible cause for each problem listed.
  • Page 505 APPENDIX 17-13 Troubleshooting Guide Air cleaner duct loose Piston ring/groove clearance excessive Compression low: Cylinder head gasket damaged Spark plug loose Cylinder head warped Cylinder head not sufficiently tightened Valve spring broken or weak down Valve not seating properly (valve bent, No valve clearance worn, or carbon accumulation on the Cylinder, piston worn...
  • Page 506: Gear Shifting Faulty

    17-14 APPENDIX Troubleshooting Guide Engine load faulty: Clutch lever play excessive Clutch slipping Clutch release mechanism trouble Engine oil level too high Gear Shifting Faulty: Engine oil viscosity too high Drive train trouble Doesn’t go into gear; shift pedal doesn’t Brake dragging return: Lubrication inadequate:...
  • Page 507: Exhaust Smokes Excessively

    APPENDIX 17-15 Troubleshooting Guide Exhaust pipe leaking at cylinder head con- Oil pressure switch damaged nection Wiring faulty Crankshaft runout excessive Relief valve stuck open Engine mount loose O-ring at the oil passage in the crankcase Crankshaft bearing worn damaged Primary gear worn or chipped Exhaust Smokes Excessively: Camshaft chain tensioner trouble...
  • Page 508: Battery Trouble

    17-16 APPENDIX Troubleshooting Guide Battery Trouble: Tire air pressure too low Front fork oil insufficient and/or leaking Battery discharged: Front fork oil viscosity too low Charge insufficient Rear shock adjustment too soft Battery faulty (too low terminal voltage) Front fork, rear shock absorber spring weak Battery lead making poor contact Rear shock absorber oil leaking Load excessive (e.g., bulb of excessive...
  • Page 509 MODEL APPLICATION Year Model Beginning Frame No. □ JKBZXJB1 3A000001 or 2003 ZX636–B1 JKBZX636BBA000001 □ JKAZX4K1 3A000001 or 2003 ZX600–K1 JKAZX600KKA000001 □ JKBZXJB1 4A023001 or 2004 ZX636–B2 JKBZX636BBA023001 □ :This digit in the frame number changes from one machine to another. Part No.99924-1311-03 Printed in Japan...

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