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1400GTR
CONCOURS 14 ABS
CONCOURS 14
Motorcycle
Service Manual

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Table Of Contents

Troubleshooting

   Summary of Contents for Kawasaki 1400GTR

  • Page 1

    1400GTR CONCOURS 14 ABS CONCOURS 14 Motorcycle Service Manual...

  • Page 2

    This product contains the encryption algorithm "MISTY" developed by MITSUBISHI ELECTRIC CORPORATION.

  • 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 Electrical System 16 j Appendix...

  • Page 5

    All information contained in this publication is based on the latest product information available at the time of publication. Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts. © 2007 Kawasaki Heavy Industries, Ltd. First Edition (1): June 29, 2007 (M)

  • Page 6

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

  • Page 7: Emission Control Information

    EMISSION CONTROL INFORMATION To protect the environment in which we all live, Kawasaki has incorporated crankcase emis- sion (1) and exhaust emission (2) control systems in compliance with applicable regulations of the United States Environmental Protection Agency and California Air Resources Board. Addi-...

  • Page 8

    TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Federal law prohibits the following acts or the causing thereof. (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.

  • Page 9: How To Use This Manual

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

  • Page 11: Table Of Contents

    Before Servicing ........................Model Identification......................... General Specifications......................1-10 Technical Information-Variable Valve Timing ................1-13 Technical Information-Electrical Windshield ................1-17 Technical Information-KIPASS (Kawasaki’s Intelligent Proximity Activation Start System) ..1-18 Technical Information-Tetra Lever Shaft Drive System............1-30 Unit Conversion Table ......................1-32...

  • Page 12: Before Servicing

    1-2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly opera- tion on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustra- tions, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary.

  • Page 13

    Replacement Parts Replacement Parts must be KAWASAKI genuine or recommended by KAWASAKI. Gaskets, O-rings, oil seals, grease seals, circlips or cotter pins must be replaced with new ones whenever disassembled.

  • Page 14: Tightening Torque

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

  • Page 15

    GENERAL INFORMATION 1-5 Before Servicing Press For items such as bearings or oil seals that must be pressed into place, apply small amount of oil to the con- tact area. Be sure to maintain proper alignment and use smooth movements when installing. Ball Bearing and Needle Bearing Do not remove pressed ball or needle unless removal is absolutely necessary.

  • Page 16

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

  • Page 17: Model Identification

    GENERAL INFORMATION 1-7 Model Identification ZG1400A8F Left Side View ZG1400A8F Right Side View Frame Number Engine Number...

  • Page 18: General Information

    1-8 GENERAL INFORMATION Model Identification ZG1400A8F (United States and Canada) Left Side View ZG1400A8F (United States and Canada) Right Side View...

  • Page 19

    GENERAL INFORMATION 1-9 Model Identification ZG1400B8F (United States and Canada) Left Side View ZG1400B8F (United States and Canada) Right Side View...

  • Page 20: General Specifications

    1-10 GENERAL INFORMATION General Specifications Items ZG1400A8F, ZG1400B8F Dimensions Overall Length 2 270 mm (89.4 in.) Overall Width 1 000 mm (39.4 in.) Overall Height/High Position 1 290 mm (50.8 in.)/1 405 mm (55.3 in.) Wheelbase 1 520 mm (59.8 in.) Road Clearance 125 mm (4.9 in.) Seat Height...

  • Page 21

    GENERAL INFORMATION 1-11 General Specifications Items ZG1400A8F, ZG1400B8F Exhaust: Open 52° (BBDC) Close 22° (ATDC) Duration 254° Lubrication System Forced lubrication (wet sump with cooler) Engine Oil: Type API SE, SF or SG API SH, SJ or SL with JASO MA Viscosity SAE10W-40 Capacity...

  • Page 22

    1-12 GENERAL INFORMATION General Specifications Items ZG1400A8F, ZG1400B8F Rim Size: Front 17 × 3.50 Rear 17 × 6.00 Front Suspension: Type Telescopic fork (upside-down) Wheel Travel 113 mm (4.4 in.) Rear Suspension: Type Swingarm (uni-trak - tetra lever) Wheel Travel 136 mm (5.3 in.) Brake Type: Front...

  • Page 23

    GENERAL INFORMATION 1-13 Technical Information-Variable Valve Timing Overview The camshafts that are provided in the engine determine the amount of valve overlap, which affects the engine’s characteristics. As a result, some engines are high-speed oriented while others are low -speed oriented. (Generally speaking, engines with a greater valve overlap are high-speed oriented.) Ordinarily, it is difficult for a given engine to deliver both high-speed and low-speed characteristics.

  • Page 24

    1-14 GENERAL INFORMATION Technical Information-Variable Valve Timing Components • Variable Valve Timing Actuator • Oil Control Valve Solenoid Valve Oil Flow of Parts • Variable Valve Timing Actuator...

  • Page 25

    GENERAL INFORMATION 1-15 Technical Information-Variable Valve Timing • Oil Control Solenoid Valve Oil Flow during Control • Retard Position • Advance Position...

  • Page 26

    1-16 GENERAL INFORMATION Technical Information-Variable Valve Timing • Neutral Position • Most Retarded Position Lock Mechanism • During idle, the lock mechanism locks the camshaft at the most retarded position. • When the engine is stopped, the force of the spring returns the solenoid valve to its most retarded position, thus placing the camshaft in the most retarded position.

  • Page 27: Technical Information-electrical Windshield

    GENERAL INFORMATION 1-17 Technical Information-Electrical Windshield Overview Wind protection for rider and passenger is based on a supersport-style design philosophy. Aero- dynamically curving wind around the riders reduces buffeting that occurs when wind curls around windshield that simply "block" the wind. This model is equipped with the electrically adjustable windshield.

  • Page 28

    1-18 GENERAL INFORMATION Technical Information-KIPASS (Kawasaki’s Intelligent Proximity Activation Start System) Overview • For better user convenience, a system to wirelessly start the engine is used instead of the conven- tional mechanical key. This frees the rider from handling the ignition key, a helpful feature in the rain or after putting on gloves.

  • Page 29

    • The key knob can be turned to the ON position when the key knob symbol appears on the LCD meter. Then, the letters "Kawasaki" will appear for 3 seconds on the LCD screen. ○ When the engine operates normally, the turn signal lights in the meter will flash (answer-back) twice to inform the rider of normal operation.

  • Page 30

    1986 to be used as a LAN network linking onboard ECUs (Electric Control Units). *At Kawasaki, this system is already being used on the ZX1400A/B. 1. Uses two communication lines (called bus lines, consisting of high and low voltages) and changes their electric potentials to transmit and receive data.

  • Page 31

    GENERAL INFORMATION 1-21 Technical Information-KIPASS (Kawasaki’s Intelligent Proximity Activation Start System) • Communication Method Outputs electric potentials pivoted on 2.5 V to transmit "1" or "0" data to a terminal resistor. *Hi and Low transmission data are transmitted simultaneously. Electric Potential...

  • Page 32

    1-22 GENERAL INFORMATION Technical Information-KIPASS (Kawasaki’s Intelligent Proximity Activation Start System) CAN Communication Contents Transmission Reception Date Contents Engine speed, water temperature, gear position, DFI ECU → Meter fuel consumption volume, DFI failure data KIPASS failure and warning data, air pressure KIPASS ECU →...

  • Page 33

    GENERAL INFORMATION 1-23 Technical Information-KIPASS (Kawasaki’s Intelligent Proximity Activation Start System) Registering FOB Keys (Additional Registration) *Registration requires one FOB key that is already registered and the KDS3 version kit. • The KIPASS ECU must be replaced if you lose all the registered FOB keys.

  • Page 34

    1-24 GENERAL INFORMATION Technical Information-KIPASS (Kawasaki’s Intelligent Proximity Activation Start System) Replacing KIPASS Parts • Registration status when all parts are new: steering lock unit (hereafter referred to as "SL"), KIPASS ECU, and DFI ECU. *The two FOB keys that come with the KIPASS ECU are already registered.

  • Page 35

    GENERAL INFORMATION 1-29 Technical Information-KIPASS (Kawasaki’s Intelligent Proximity Activation Start System) Replacing a Tire Pressure Measurement Sensor • To replace an pressure measurement sensor, it is necessary to use the KDS3 version kit in order to register the ID for activating the sensor.

  • Page 36: Technical Information-tetra Lever Shaft Drive System

    1-30 GENERAL INFORMATION Technical Information-Tetra Lever Shaft Drive System Tetra Lever Shaft Drive System Reason for use: To improve the running feel when the drive force is applied to the rear wheel. Tetra Lever Shaft Drive System When the drive force is applied to the rear wheel, a reaction force is generated as shown in the diagram.

  • Page 37

    GENERAL INFORMATION 1-31 Technical Information-Tetra Lever Shaft Drive System Comparison to Conventional Shaft Drive System...

  • Page 38: Unit Conversion Table

    1-32 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 Units of Torque milli × 0.001 N·m ×...

  • Page 39: Table Of Contents, Periodic Maintenance, Table Of Contents

    PERIODIC MAINTENANCE 2-1 Periodic Maintenance Table of Contents Periodic Maintenance Chart ....................Torque and Locking Agent...................... Specifications ......................... 2-13 Special Tools .......................... 2-15 Maintenance Procedure ......................2-16 Fuel System (DFI)........................ 2-16 Throttle Control System Inspection................... 2-16 Engine Vacuum Synchronization Inspection..............2-16 Idle Speed Inspection .......................

  • Page 40: Table Of Contents

    2-2 PERIODIC MAINTENANCE Electrical System ......................... 2-39 Lights and Switches Operation Inspection................ 2-39 Headlight Aiming Inspection ..................... 2-41 Sidestand Switch Operation Inspection ................2-43 Engine Stop Switch Operation Inspection................. 2-44 Others ..........................2-44 Chassis Parts Lubrication ....................2-44 Bolts, Nuts and Fasteners Tightness Inspection............... 2-45 Replacement Parts ......................

  • Page 41: Periodic Maintenance Chart

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

  • Page 42

    2-4 PERIODIC MAINTENANCE Periodic Maintenance Chart FREQUENCY Whichever * ODOMETER comes READING first × 1000 km (× 1000 mile) Page 18 24 30 INSPECTION Every (0.6) (4) (7.5) (12) (15) (20) (24) Final Drive • • • Final gear case oil level - inspect 2-32 Brake System Brake fluid leak (brake hose and pipe) -...

  • Page 43: Periodic Maintenance Chart

    PERIODIC MAINTENANCE 2-5 Periodic Maintenance Chart Periodic Replacement Parts FREQUENCY * ODOMETER Whichever READING come × 1000 km first (× 1000 mile) Page CHANGE/REPLACEMENT Every (0.6) (7.5) (15) (24) (30) Air cleaner element # Every 18 000 km (12 000 mile) 2-48 •...

  • Page 44: Torque And Locking Agent

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

  • Page 45

    PERIODIC MAINTENANCE 2-7 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Coolant Fitting Bolt 0.90 78 in·lb Water Temperature Sensor Reserve Tank Bolts 0.40 35 in·lb Cylinder Fitting Bolts 87 in·lb Radiator Stay Bolt 87 in·lb Radiator Lower Bolt 87 in·lb Radiator Upper Bolt Engine Top End...

  • Page 46

    2-8 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Oil Filler Cap – – – Hand -tighten Clutch Reservoir Cap Screws 0.15 13 in·lb Clutch Reservoir Mounting Bolt 0.80 70 in·lb Clutch Reservoir Screw 0.10 8.9 in·lb Starter Lockout Switch Screw 0.07 6.2 in·lb...

  • Page 47

    PERIODIC MAINTENANCE 2-9 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Crankcase Bolts (M6, L = 25 mm) 106 in·lb Shift Drum Bearing Holder Screws 0.50 43 in·lb Bearing Position Plate Screws 0.50 43 in·lb Oil Passage Plug Connecting Rod Big End Nuts see the ←...

  • Page 48

    2-10 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Oil Nozzles 0.30 26 in·lb Pinion Gear Assembly Nut 13.3 95.9 Speed Sensor Bolt 87 in·lb Brakes Bleed Valves 0.80 69 in·lb Brake Caliper Holder Plate Bolt Brake Hose Banjo Bolts Brake Lever Pivot Bolt 0.10...

  • Page 49

    PERIODIC MAINTENANCE 2-11 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Torque Rod Nuts Steering Front Fork Clamp Bolts (Lower) Front Fork Clamp Bolts (Upper) Handlebar Bolts Handlebar Holder Bolts Left Switch Housing Screws 0.36 31 in·lb Right Switch Housing Screws 0.36 31 in·lb Steering Stem Head Bolt...

  • Page 50

    2-12 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Oil Control Valve Bolts 87 in·lb Oil Pressure Switch Oil Pressure Switch Terminal Bolt 0.15 13 in·lb Oxygen Sensors (Equipped Models) Rear Turn Signal Light Mounting Screws 0.12 11 in·lb Regulator/Rectifier Bolts...

  • Page 51: Specifications

    PERIODIC MAINTENANCE 2-13 Specifications Item Standard Service Limit Fuel System 2 ∼ 3 mm (0.08 ∼ 0.12 in.) – – – Throttle Grip Free Play Idle Speed 1 100 ±50 r/min (rpm) – – – Throttle Body Vacuum 33 ±1.33 kPa (250 ±10 mmHg) at idle speed –...

  • Page 52

    2-14 PERIODIC MAINTENANCE Specifications Item Standard Service Limit Final Drive Final Gear Case Oil hypoid gear oil – – – Grade API Service Classification: GL-5 – – – Viscosity When above 5°C (41°F) SAE90 When below 5°C (41°F) SAE80 Oil Level Filler opening top –...

  • Page 53: Special Tools

    PERIODIC MAINTENANCE 2-15 Special Tools Inside Circlip Pliers: Pilot Screw Adjuster, C: 57001-143 57001-1292 Steering Stem Nut Wrench: Vacuum Gauge: 57001-1100 57001-1369 Jack: Pilot Screw Adjuster Adapter, 5: 57001-1238 57001-1372 Oil Filter Wrench: Filler Cap Driver: 57001-1249 57001-1454...

  • Page 54: Maintenance Procedure, Fuel System, Throttle Control System Inspection, Engine Vacuum Synchronization Inspection

    2-16 PERIODIC MAINTENANCE Maintenance Procedure Fuel System (DFI) Throttle Control System Inspection • Check the throttle grip free play [A]. If the free play is incorrect, adjust the throttle cables. Throttle Grip Free Play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Standard: •...

  • Page 55

    PERIODIC MAINTENANCE 2-17 Maintenance Procedure • Remove: Subframe Bolts [A] with Washer Right Fairing Bracket Bolt (Front Side) • Pull off the rubber caps [A] from the fittings of each throttle body. ○ For the rubber cap #2, remove the air cleaner duct. Front [B] •...

  • Page 56

    2-18 PERIODIC MAINTENANCE Maintenance Procedure • Start the engine and warm it up thoroughly. • Check the idle speed, using a highly accurate tachometer [A]. If the idle speed is out of the specified range, adjust it with the adjust screw. CAUTION Do not measure the idle speed by the tachometer of the meter unit.

  • Page 57

    PERIODIC MAINTENANCE 2-19 Maintenance Procedure If a value of measured vacuum pressure is out of the specified range after synchronization, adjust the bypass screws [A]. Special Tool - Pilot Screw Adjuster, C: 57001-1292 Pilot Screw Adjuster Adapter, 5: 57001 -1372 •...

  • Page 58: Idle Speed Inspection, Evaporative Emission Control System

    2-20 PERIODIC MAINTENANCE 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 59: Idle Speed Adjustment, Fuel Hose Inspection (fuel Leak, Damage, Installation Condition)

    PERIODIC MAINTENANCE 2-21 Maintenance Procedure Idle Speed Adjustment • Start the engine and warm it up thoroughly. • Turn the adjusting screw [A] until the idle speed is correct. ○ Open and close the throttle a few times to make sure that the idle speed is within the specified range.

  • Page 60: Cooling System, Coolant Level Inspection, Radiator Hose And Pipe Inspection

    2-22 PERIODIC MAINTENANCE Maintenance Procedure Cooling System Coolant Level Inspection NOTE ○ Check the level when the engine is cold (room or ambi- ent temperature). • Check the coolant level in the reserve tank [A] with the motorcycle held perpendicular (Do not use the sidestand). If the coolant level is lower than the “L”...

  • Page 61: Evaporative Emission Control System (california Model), Evaporative Emission Control System Inspection, Air Suction System

    PERIODIC MAINTENANCE 2-23 Maintenance Procedure Evaporative Emission Control System (California Model) Evaporative Emission Control System Inspection • Remove: Rear Right Middle Fairing (see Middle Fairing Removal in the Frame chapter) Band [A] Canister [B] • Disconnect the hoses from the canister. •...

  • Page 62: Engine Top End, Valve Clearance Inspection

    2-24 PERIODIC MAINTENANCE Maintenance Procedure • Start the engine and run it at idle speed. • Plug [A] the air switching valve hose end with your finger and feel vacuum pulsing in the hose. If there is no vacuum pulsation, check the hose line for leak.

  • Page 63: Valve Clearance Adjustment

    PERIODIC MAINTENANCE 2-25 Maintenance Procedure NOTE ○ Thickness gauge is horizontally inserted on the valve lifter. Appropriateness [A] Inadequacy [B] Thickness Gauge [C] Horizontally Inserts [D] Cam [E] Valve Lifter [F] Hits the Valve Lifter Ahead [G] ○ When positioning #1 piston TDC at the end of the compression stroke: Inlet Valve Clearance of #2 and #4 Cylinders Exhaust Valve Clearance of #3 and #4 Cylinders...

  • Page 64

    2-26 PERIODIC MAINTENANCE Maintenance Procedure • Clean the shim to remove any dust or oil. • Measure the thickness of the removed shim [A]. • Select a new shim thickness calculation as follows. a + b – c = d [a] Present Shim Thickness [b] Measured Valve Clearance [c] Specified Valve Clearance (Mean Value = 0.125 mm...

  • Page 65

    PERIODIC MAINTENANCE 2-27 Maintenance Procedure Adjustment Shims Thickness Part Number Mark 1.750 92180-1212 –25 1.775 92180-0221 –23 1.800 92180-1211 –20 1.825 92180-0222 –18 1.850 92180-1210 –15 1.875 92180-0223 –13 1.900 92180-1209 –10 1.925 92180-0224 –8 1.950 92180-1208 –5 1.975 92180-0225 –3 2.000 92025-1870...

  • Page 66: Clutch And Drive Train, Clutch Operation Inspection, Clutch Fluid Level Inspection, Clutch Fluid Leak Inspection

    2-28 PERIODIC MAINTENANCE Maintenance Procedure Clutch and Drive Train Clutch Operation Inspection • Start the engine and check that the clutch does not slip and that it releases properly. If the clutch operation is insufficiency, inspect the clutch system. WARNING When inspecting by running the vehicle, note a surrounding traffic situation enough in the place of safety.

  • Page 67: Clutch Hose And Pipe Damage And Installation Condition Inspection, Wheels/tires, Air Pressure Inspection

    PERIODIC MAINTENANCE 2-29 Maintenance Procedure Clutch Hose and Pipe Damage and Installation Condition Inspection • Inspect the clutch hoses and fittings for deterioration, cracks, corrosion and signs of leakage. ○ The high pressure inside the clutch line can cause fluid to leak [A] or the hose to burst if the line is not properly maintained.

  • Page 68: Tire Tread Wear Inspection, Wheel Bearing Damage Inspection

    2-30 PERIODIC MAINTENANCE Maintenance Procedure Tire Tread Wear Inspection As the tire tread wears down, the tire becomes more sus- ceptible to puncture and failure. An accepted estimate is that 90% of all tire failures occur during the last 10% of tread life (90% worn).

  • Page 69: Final Drive, Oil Level Inspection

    PERIODIC MAINTENANCE 2-31 Maintenance Procedure • Raise the rear wheel off the ground with the center stand (see Rear Wheel Removal in the Wheels/Tires chapter). • Spin [A] the rear wheel lightly, and check for smoothly turn, roughness, binding or noise. If roughness, binding or noise is found, remove the rear wheel and inspect the wheel bearing (see Hub Bearing Inspection in the Wheels/Tires chapter) and coupling (see...

  • Page 70: Brake System, Brake Fluid Leak (brake Hose And Pipe) Inspection

    2-32 PERIODIC MAINTENANCE Maintenance Procedure Brake System Brake Fluid Leak (Brake Hose and Pipe) Inspection • Apply the brake lever or pedal and inspect the brake fluid leak from the brake hoses [A], pipes (ABS equipped mod- els) [B] and fittings [C]. If the brake fluid leaked from any position, inspect or re- place the problem part.

  • Page 71: Brake Hose And Pipe Damage And Installation Condition Inspection, Brake Operation Inspection

    PERIODIC MAINTENANCE 2-33 Maintenance Procedure Brake Hose and Pipe Damage and Installation Condition Inspection • For ABS equipped models; note the following. • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Battery (see Battery Removal in the Electrical System chapter) •...

  • Page 72: Brake Pad Wear Inspection, Brake Light Switch Operation Inspection

    2-34 PERIODIC MAINTENANCE Maintenance Procedure • Remove the seat (see Seat Removal in the Frame chap- ter). • Check that the brake fluid level in the rear brake reservoir [A] is above the lower level line [B]. If the fluid level is lower than the lower level line, fill the reservoir to the upper level line [C].

  • Page 73: Suspensions, Front Forks/rear Shock Absorber Operation Inspection

    PERIODIC MAINTENANCE 2-35 Maintenance Procedure If it does not, adjust the brake light switch. • While holding the switch body, turn the adjusting nut to adjust the switch. Switch Body [A] Adjusting Nut [B] Light sooner as the body rises [C] Light later as the body lowers [D] CAUTION To avoid damaging the electrical connections in-...

  • Page 74: Front Fork Oil Leak Inspection, Rear Shock Absorber Oil Leak Inspection, Rocker Arm Operation Inspection

    2-36 PERIODIC MAINTENANCE Maintenance Procedure Front Fork Oil Leak Inspection • Visually inspect the front forks [A] for oil leakage. Replace or repair any defective parts, if necessary. Rear Shock Absorber Oil Leak Inspection • Visually inspect the shock absorber [A] for oil leakage. If the oil leakage is found on it, replace the shock absorber with a new one.

  • Page 75: Steering System, Steering Play Inspection, Steering Play Adjustment

    PERIODIC MAINTENANCE 2-37 Maintenance Procedure Steering System Steering Play Inspection • Raise the front wheel off the ground with the jack. Special Tools - 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 76: Steering Stem Bearing Lubrication

    2-38 PERIODIC MAINTENANCE Maintenance Procedure • Install the claw washer [A] so that its bent side [B] faces upward, and engage the bent claws with the grooves of stem locknut [C]. • Hand tighten the stem locknut until it touches the claw washer.

  • Page 77: Electrical System, Lights And Switches Operation Inspection

    PERIODIC MAINTENANCE 2-39 Maintenance Procedure Electrical System Lights and Switches Operation Inspection First Step • Push and turn the key knob to ON. • The following lights should go on according to below table. goes on City Light [A] Taillight [B] goes on goes on License Plate Light [C]...

  • Page 78

    2-40 PERIODIC MAINTENANCE Maintenance Procedure Third Step • Push and turn the key knob to ON. • Turn on the turn signal switch [A] (left or right position). • The left or right turn signal lights [B] (front and rear) ac- cording to the switch position should flash.

  • Page 79: Headlight Aiming Inspection

    PERIODIC MAINTENANCE 2-41 Maintenance Procedure Fourth Step • Set the dimmer switch [A] to low beam position. • Start the engine. • The low beam headlights [B] should go on. If the low beam headlight does not go on, inspect or re- place the following item.

  • Page 80

    2-42 PERIODIC MAINTENANCE Maintenance Procedure Headlight Beam Horizontal Adjustment • Turn the horizontal adjuster [A] in both headlights in or out until the beam points straight ahead. If the headlight beam points too low or high, adjust the vertical beam. Headlight Beam Vertical Adjustment •...

  • Page 81: Sidestand Switch Operation Inspection

    PERIODIC MAINTENANCE 2-43 Maintenance Procedure Sidestand Switch Operation Inspection • Inspect the sidestand switch [A] operation accordance to table the below. Sidestand Switch Operation Gear Clutch Engine Engine Sidestand Position Lever Start Continue Neutral Released Starts running Continue Neutral Pulled in Starts running Doesn’t...

  • Page 82: Engine Stop Switch Operation Inspection, Others, Chassis Parts Lubrication

    2-44 PERIODIC MAINTENANCE Maintenance Procedure Engine Stop Switch Operation Inspection First Step • Push and turn the key knob to ON. • Set the neutral position. • Turn the engine stop switch to stop position [A]. • Push the starter button. •...

  • Page 83: Bolts, Nuts And Fasteners Tightness Inspection

    PERIODIC MAINTENANCE 2-45 Maintenance Procedure Cables: Lubricate with Rust Inhibitor. Throttle Cables • Lubricate the cables by seeping the oil between the cable and housing. ○ The cable may be lubricated by using a commercially available pressure cable lubricator with an aerosol cable lubricant.

  • Page 84: Replacement Parts, Air Cleaner Element Replacement

    2-46 PERIODIC MAINTENANCE Maintenance Procedure Bolt, Nut and Fastener to be checked Engine: Clutch Lever Pivot Bolt Locknut Engine Mounting Bolts and Nut Muffler Clamp Bolts Exhaust Pipe Manifold Holder Nuts Muffler Body Mounting Bolts Wheels: Front Axle Clamp Bolts Front Axle Nut Rear Axle Nut Rear Axle Nut Cotter Pin...

  • Page 85

    Install a new element [A] so that screen side [B] faces upward. CAUTION Use only the recommended air cleaner element (Kawasaki part number 11013-0014). Using another air cleaner element will wear the engine prema- turely or lower the engine performance. •...

  • Page 86: Fuel Hose Replacement

    2-48 PERIODIC MAINTENANCE Maintenance Procedure Fuel Hose Replacement • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Sub Engine Bracket Breather Hose Drain Hose • Be sure to place a piece of cloth [A] around the fuel hose joint.

  • Page 87: Coolant Change

    PERIODIC MAINTENANCE 2-49 Maintenance Procedure • Insert the fuel hose joint [A] straight onto the delivery pipe until the hose joint clicks. • Push [B] the joint lock [C] until the hose joint clicks. • Push and pull the fuel hose joint [A] back and forth [B] more than two times and make sure it is locked and doesn’t come off.

  • Page 88

    2-50 PERIODIC MAINTENANCE Maintenance Procedure • Remove: Left Middle Fairing (see Middle Fairing Removal in the Frame chapter) Left Lower Fairing (see Lower Fairing Removal in the Frame chapter) • Place a containers under the drain plug [A] at the bottom of the water pump cover.

  • Page 89: Radiator Hose And O-ring Replacement

    PERIODIC MAINTENANCE 2-51 Maintenance Procedure • Bleed the air from the cooling system as follows. ○ Start the engine with the radiator cap removed and run it until no more air bubbles [A] can be seen in the coolant. ○ Tap the radiator hoses to force any air bubbles caught inside.

  • Page 90: Engine Oil Change, Oil Filter Replacement

    2-52 PERIODIC MAINTENANCE Maintenance Procedure Engine Oil Change • Situate the motorcycle so that it is vertical after warming up the engine. • Remove the engine oil drain bolt [A] to drain the oil. ○ The oil in the oil filter can be drained by removing the filter (see Oil Filter Replacement).

  • Page 91: Brake Hose And Pipe Replacement

    PERIODIC MAINTENANCE 2-53 Maintenance Procedure Brake Hose and Pipe Replacement CAUTION Brake fluid quickly ruins painted plastic surfaces; any spilled fluid should be completely washed away immediately. • Remove: Radiator Cover (see Steering Stem Removal in the Steering chapter) Brake Hose Banjo Bolts [A] Brake Hose Joint Bolts [B] Brake Hose [C] Brake Hose Clamp Bolt [D]...

  • Page 92: Brake Fluid Change

    2-54 PERIODIC MAINTENANCE Maintenance Procedure • For ABS equipped models; note the following. • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Battery (see Battery Removal in the Electrical System chapter) Upper Fairing (see Upper Fairing Removal in the Frame chapter) Brake Pipe Joint Nuts [A] Bolts [B]...

  • Page 93

    PERIODIC MAINTENANCE 2-55 Maintenance Procedure • 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 94: Master Cylinder Rubber Parts Replacement

    2-56 PERIODIC MAINTENANCE Maintenance Procedure Master Cylinder Rubber Parts Replacement Front Master Cylinder Disassembly • Remove the front master cylinder (see Front Master Cylin- der Removal in the Brakes chapter). • Remove: Screws [A] Cap [B] Diaphragm Plate [C] Diaphragm [D] Float [E] Screw [F] Bolt [G]...

  • Page 95: Caliper Rubber Parts Replacement

    PERIODIC MAINTENANCE 2-57 Maintenance Procedure Master Cylinder Assembly • Before assembly, clean all parts including the master cylinder with brake fluid or alcohol. CAUTION Except for the disc pads and disc, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol for cleaning brake parts.

  • Page 96

    2-58 PERIODIC MAINTENANCE Maintenance Procedure • Using compressed air, remove the pistons. One way to remove the pistons is as follows. ○ Install a rubber gasket [A] and a wooden board [B] more than 10 mm (0.4 in.) thick on the caliper half, and fas- ten them together with a suitable bolt and nut as shown.

  • Page 97

    PERIODIC MAINTENANCE 2-59 Maintenance Procedure • Replace the fluid seals [A] with new ones. ○ Apply silicone grease to the fluid seals, and install them into the cylinders by hand. • Replace the dust seals [B] with new ones if they are dam- aged.

  • Page 98: Rear Caliper Assembly

    2-60 PERIODIC MAINTENANCE Maintenance Procedure • Remove the right side piston as follows. • Using the rear caliper assembly bolt [A], remove the pis- ton [B] as shown in the figure. • Remove the dust seals [A] and fluid seals [B]. •...

  • Page 99: Clutch Hose And Pipe Replacement

    PERIODIC MAINTENANCE 2-61 Maintenance Procedure • Apply brake fluid to the cylinder bores. • Replace the fluid seals [A] with new ones. ○ Apply silicone grease to the fluid seals, and install them into each cylinder by hand. • Replace the dust seals [B] with new ones. •...

  • Page 100

    2-62 PERIODIC MAINTENANCE Maintenance Procedure • Remove: Left Middle Fairing (see Middle Fairing Removal in the Frame chapter) Left Lower Fairing (see Lower Fairing Removal in the Frame chapter) Left Heat Insulation Plate (see Fairing Bracket Removal in the Frame chapter) Banjo Bolts [A] with Washers Fitting Bolt [B] Clamp [C]...

  • Page 101: Rubber Parts Of Clutch Master Cylinder/slave Cylinder Replacement

    PERIODIC MAINTENANCE 2-63 Maintenance Procedure Rubber Parts of Clutch Master Cylinder/Slave Cylinder Replacement Clutch Master Cylinder Cup and Dust Seal Replacement • Remove the clutch master cylinder (see Clutch Master Cylinder Removal in the Clutch chapter). • Remove: Screws [A] Cap [B] Diaphragm Plate [C] Diaphragm [D]...

  • Page 102

    2-64 PERIODIC MAINTENANCE Maintenance Procedure Clutch Slave Cylinder Piston Seal Replacement • Remove: Left Lower Fairing (see Lower Fairing Removal in the Frame chapter) • Loosen the banjo bolt [A] at the clutch pipe lower end, and tighten it loosely. •...

  • Page 103: Clutch Fluid Change, Spark Plug Replacement

    PERIODIC MAINTENANCE 2-65 Maintenance Procedure Clutch Fluid Change • Level the clutch fluid reservoir and remove the reservoir cap. • Remove the rubber cap from the bleed valve on the clutch slave cylinder. • Attach a clear plastic hose [A] to the bleed valve and run the other end of the hose into a container.

  • Page 104: Oil Change

    2-66 PERIODIC MAINTENANCE Maintenance Procedure • Replace the spark plug with a new one. Standard Spark Plug Type: NGK CR9EIA-9 • Insert new spark plug in the plug hole, and finger-tighten it first. • Using the plug wrench [A] vertically, tighten the plug. CAUTION The insulator of the spark plug may break if when the wrench is inclined during tightening.

  • Page 105

    PERIODIC MAINTENANCE 2-67 Maintenance Procedure • Fill the final gear case with the specified oil and quantity. ○ The oil level [A] should come to the top of the filler open- ing. Final Gear Case Oil: Amount: about 160 mL (5.41 US oz) Grade: API GL-5 hypoid gear oil Viscosity:...

  • Page 107: Table Of Contents

    FUEL SYSTEM (DFI) 3-1 Fuel System (DFI) Table of Contents Exploded View........................DFI System..........................3-10 DFI Parts Location........................3-15 Specifications ......................... 3-17 Special Tools and Sealant ...................... 3-19 DFI Servicing Precautions ...................... 3-21 DFI Servicing Precautions ....................3-21 Troubleshooting the DFI System .................... 3-23 Outline ..........................

  • Page 108: Table Of Contents

    3-2 FUEL SYSTEM (DFI) Speed Sensor Input Voltage Inspection................3-68 Speed Sensor Output Voltage Inspection ................. 3-69 Gear Position Switch (Service Code 25) ................3-71 Gear Position Switch Removal/Installation ............... 3-71 Gear Position Switch Inspection ..................3-71 Input Voltage Inspection....................3-71 Vehicle-down Sensor (Service Code 31)................

  • Page 109: Table Of Contents

    FUEL SYSTEM (DFI) 3-3 Light (LED) Inspection ...................... 3-110 Fuel Line..........................3-111 Fuel Pressure Inspection ....................3-111 Fuel Flow Rate Inspection ....................3-113 Fuel Pump ..........................3-115 Fuel Pump Removal ......................3-115 Fuel Pump Installation ...................... 3-115 Fuel Pump Operation Inspection ..................3-116 Operating Voltage Inspection....................

  • Page 110: Exploded View

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

  • Page 111: Exploded View

    FUEL SYSTEM (DFI) 3-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Resonator Mounting Bolts 0.40 35 in·lb Front Air Inlet Duct Mounting Bolts 0.40 35 in·lb Air Inlet Duct Clamp Bolts 0.30 26 in·lb Rear Air Inlet Duct Mounting Bolts 87 in·lb Air Cleaner Element Holder Screws 0.70...

  • Page 112

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

  • Page 113

    FUEL SYSTEM (DFI) 3-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Speed Sensor Bolt 87 in·lb Crankshaft Sensor Bolts 0.60 52 in·lb Gear Position Switch Screws 0.30 26 in·lb Gear Position Switch Lead Clamp Bolts 87 in·lb Vehicle-down Sensor Bolts 0.60 52 in·lb Camshaft Position Sensor Bolts...

  • Page 114

    3-8 FUEL SYSTEM (DFI) Exploded View...

  • Page 115

    FUEL SYSTEM (DFI) 3-9 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Fuel Pump Bolts 87 in·lb L, S Separator Bracket Bolt 87 in·lb Oxygen Sensor (Europe Models) Fuel Level Sensor Bolts 0.70 61 in·lb 5. Canister 6. Separator 7. Fitting 8.

  • Page 116

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

  • Page 117: Dfi System

    FUEL SYSTEM (DFI) 3-11 DFI System 1. ECU 2. Crankshaft Sensor 3. Inlet Camshaft Position Sensor 4. Exhaust Camshaft Position Sensor 5. Main Throttle Sensor 6. Subthrottle Sensor 7. Subthrottle Valve Actuator 8. Inlet Air Pressure Sensor 9. Atmospheric Pressure Sensor 10.

  • Page 118

    3-12 FUEL SYSTEM (DFI) DFI System...

  • Page 119

    FUEL SYSTEM (DFI) 3-13 DFI System Part Name 1. Steering Lock Unit 2. Joint Connector 1 3. Engine Stop Switch 4. Starter Button 5. Inlet Camshaft Position Sensor 6. Exhaust Camshaft Position Sensor 7. Stick Coil #1, #2, #3, #4 8.

  • Page 120

    66. Crankshaft Sensor Output Signal (–) 35. Power Supply to ECU (from Battery) 67. Speed Sensor Output Signal 68. CAN Communication Line (High) KDS (Kawasaki Diagnostic System) KDS that runs on Windows personal computer (PC) diagnostic tool for motorcycle with Kawasaki DFI system.

  • Page 121: Dfi Parts Location

    Water Temperature Sensor [D] Fuel Injectors #1, #2, #3, #4 [A] Vehicle-down Sensor [A] Relay Box (Fuel Pump Relay) [B] Immobilizer/Kawasaki Diagnostic System Connector [C] DFI ECU [D] Atmospheric Pressure Sensor [E] KIPASS ECU [F] Fuse Box (ECU Fuse 15 A) [G]...

  • Page 122

    3-16 FUEL SYSTEM (DFI) DFI Parts Location Exhaust Camshaft Position Sensor [A] Crankshaft Sensor [B] Oil Control Valve Solenoid [C] Oxygen Sensor #1, #2 [D] Speed Sensor [A] Gear Position Switch [B] Key Knob [A] Steering Lock Unit [B] (Immobilizer) Air Switching Valve [A] Subthrottle Valve Actuator [B] Fuel Pump [A]...

  • Page 123

    FUEL SYSTEM (DFI) 3-17 Specifications Item Standard Digital Fuel Injection System Idle Speed 1 100 ±50 r/min (rpm) Throttle Assy: Type Four barrel type Bore 40 mm (1.6 in.) Throttle Body Vacuum 33 ±1.33 kPa (250 ±10 mmHg) Bypass Screws –...

  • Page 124

    3-18 FUEL SYSTEM (DFI) Specifications Item Standard Vehicle-down sensor: Detection Method Magnetic flux detection method More than 60 ∼ 70° for each bank Detection Angle with sensor arrow mark pointed up: 3.55 ∼ 4.45 V Output Voltage with sensor tilted 60 ∼ 70° or more: 0.65 ∼ 1.35 V Subthrottle Sensor: Non-adjustable and non-removal DC 4.75 ∼...

  • Page 125: Special Tools And Sealant

    FUEL SYSTEM (DFI) 3-19 Special Tools and Sealant Oil Pressure Gauge, 5 kgf/cm²: Peak Voltage Adapter: 57001-125 57001-1415 Fork Oil Level Gauge: Needle Adapter Set: 57001-1290 57001-1457 Vacuum Gauge: Throttle Sensor Setting Adapter: 57001-1369 57001-1538 Hand Tester: Sensor Harness Adapter: 57001-1394 57001-1561 Throttle Sensor Setting Adapter #1:...

  • Page 126

    3-20 FUEL SYSTEM (DFI) Special Tools and Sealant Fuel Hose: Kawasaki Bond (Silicone Sealant): 57001-1607 56019-120...

  • Page 127: Dfi Servicing Precautions

    FUEL SYSTEM (DFI) 3-21 DFI Servicing Precautions DFI Servicing Precautions There are a number of important precautions that should be followed servicing the DFI system. ○ This DFI system is designed to be used with a 12 V sealed battery as its power source. Do not use any other battery except for a 12 V sealed battery as a power source.

  • Page 128

    3-22 FUEL SYSTEM (DFI) DFI Servicing Precautions ○ Replace the fuel hose [A] if it has been sharply bent or kinked. ○ The motorcycle is not properly handled, the high pressure inside the fuel line can cause fuel to leak or the hose to burst.

  • Page 129: Troubleshooting The Dfi System

    FUEL SYSTEM (DFI) 3-23 Troubleshooting the DFI System Outline When a problem occurs with DFI system, the warning in- dicator (LED) [A] goes on and FI warning message [B] and FI warning symbol [C] are displayed alternately on the LCD (Liquid Crystal Display) to alert the rider.

  • Page 130

    3-24 FUEL SYSTEM (DFI) Troubleshooting the DFI System With the engine stopped and turned in the self-diagnosis mode, the service code (error code) [A] is displayed on the LCD by the number of two digits. When the service code [A] is displayed, for first ask the rider about the conditions [B] of trouble, and then start to determine the cause [C] of problem.

  • Page 131

    LCD. But the service codes stored in memory of the ECU are not erased to preserve the problem history. The problem history can be referred using the KDS (Kawasaki Diagnostic System) when solving unstable problems Much of the DFI system troubleshooting work consists of confirming continuity of the wiring.

  • Page 132

    3-26 FUEL SYSTEM (DFI) Troubleshooting the DFI System • Always check battery condition before replacing the DFI parts. A fully charged battery is a must for conducting accurate tests of the DFI system. • Trouble may involve one or in some cases all items. Never replace a defective part without determining what CAUSED the problem.

  • Page 133

    FUEL SYSTEM (DFI) 3-27 Troubleshooting the DFI System ○ If both ends of a harness [A] are far apart, ground [B] the one end [C], using a jumper lead [D] and check the con- tinuity between the end [E] and the ground [F]. This en- ables to check a long harness for continuity.

  • Page 134: Inquiries To Rider

    3-28 FUEL SYSTEM (DFI) Troubleshooting the DFI System DFI Diagnosis Flow Chart 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 135

    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 occurred: Mileage: Environment when problem occurred. □ □ □ □ □ □...

  • Page 136

    3-30 FUEL SYSTEM (DFI) Troubleshooting the DFI System □ □ □ Poor running at low very low idle speed, very high idle speed, rough idle speed. □ speed battery voltage is low (charge the battery). □ spark plug loose (tighten it). □...

  • Page 137: Dfi System Troubleshooting Guide, Poor Running At Low Speed

    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 in DFI system.

  • Page 138

    3-32 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Fuel pressure regulator trouble Inspect fuel pressure and replace fuel pump (see chapter 16). Fuel line clogged Inspect and repair (see chapter 3). Inlet air pressure sensor trouble Inspect (see chapter 3).

  • Page 139

    FUEL SYSTEM (DFI) 3-33 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Main throttle sensor trouble Inspect (see chapter 3). Subthrottle sensor trouble Inspect (see chapter 3). Subthrottle valve actuator trouble Inspect (see chapter 3). Inlet air pressure sensor trouble Inspect (see chapter 3).

  • Page 140: Poor Running Or No Power At High Speed

    3-34 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Inlet air temperature sensor trouble Inspect (see chapter 3). Other: Intermittent any DFI fault and its recovery Check that DFI connectors are clean and tight, and examine leads for signs of burning or fraying (see chapter 3).

  • Page 141

    FUEL SYSTEM (DFI) 3-35 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Atmospheric pressure sensor trouble Inspect (see chapter 3). Water temperature sensor trouble Inspect (see chapter 3). Inlet air temperature sensor trouble Inspect (see chapter 3). Miscellaneous: Subthrottle sensor trouble Inspect (see chapter 3).

  • Page 142

    3-36 FUEL SYSTEM (DFI) Self-Diagnosis Self-diagnosis Outline The self-diagnosis system has two modes and can be switched to another mode by operating the meter unit. User Mode The ECU notifies the rider of troubles in DFI system , igni- tion system and KIPASS system by lighting up the warning indicator light (LED) [A] and displaying the warning mes- sage [B] and warning symbol [C] alternately on the LCD (Liquid Crystal Display) when DFI, ignition and KIPASS sys-...

  • Page 143: Self-diagnosis Procedures

    FUEL SYSTEM (DFI) 3-37 Self-Diagnosis Self-diagnosis Procedures ○ When a problem occurs with DFI system and ignition sys- tem, the warning indicator (LED) [A] goes on and FI warn- ing message [B] and FI warning symbol [C] are displayed alternately on the LCD (Liquid Crystal Display) to alert the rider.

  • Page 144

    3-38 FUEL SYSTEM (DFI) Self-Diagnosis • Push and turn the key knob to ON. • Push the upper button [A] and lower button [B] for more than two seconds. • The service code [C] is displayed on the LCD by the num- ber of two digits.

  • Page 145

    FUEL SYSTEM (DFI) 3-39 Self-Diagnosis Self-Diagnosis Flow Chart...

  • Page 146: Service Code Reading, Service Code Erasing

    3-40 FUEL SYSTEM (DFI) Self-Diagnosis Service Code Reading ○ The service code(s) is displayed on the LCD by the number of two digits. ○ When there are a number of problems, all the service codes can be stored and the display will begin starting from the lowest number service code in the numerical order.

  • Page 147

    FUEL SYSTEM (DFI) 3-41 Self-Diagnosis Service Code Table Service Code Problems 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 Atmospheric pressure sensor malfunction, wiring open or short Crankshaft sensor malfunction, wiring open or short Camshaft position sensor (EX) malfunction, wiring open or short...

  • Page 148

    3-42 FUEL SYSTEM (DFI) Self-Diagnosis Backups ○ The ECU takes the following measures to prevent engine damage when the DFI, ignition, KIPASS or immobilizer system parts have troubles. Service Output Signal Usable Parts Backups by ECU Codes Range or Criteria If the main throttle sensor system fails (the Main Throttle Sensor signal is out of the usable range, wiring short...

  • Page 149

    FUEL SYSTEM (DFI) 3-43 Self-Diagnosis Service Output Signal Usable Parts Backups by ECU Codes Range or Criteria Steering lock unit send the Steering date to the KIPASS ECU – Lock Unit with CAN communication line. FI ECU send the date to FI ECU the KIPASS ECU with CAN –...

  • Page 150

    3-44 FUEL SYSTEM (DFI) Self-Diagnosis Service Output Signal Usable Parts Backups by ECU Codes Range or Criteria Oxygen The oxygen sensor heater If the oxygen sensor heater fails (wiring short Sensor raise temperature of or open), the ECU stops the current to the Heater the sensor for its earlier heater, and it stops the feedback mode of the...

  • Page 151: Main Throttle Sensor (service Code), Main Throttle Sensor Removal/adjustment, Main Throttle Sensor Input Voltage Inspection

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

  • Page 152

    3-46 FUEL SYSTEM (DFI) Main Throttle Sensor (Service Code 11) • Remove: Right Middle Fairing (see Middle Fairing Removal in the Frame chapter) Right Subframe (see Sub Frame Removal in the Frame chapter) • Disconnect the main throttle sensor connector [A]. •...

  • Page 153: Main Throttle Sensor Output Voltage Inspection

    FUEL SYSTEM (DFI) 3-47 Main Throttle Sensor (Service Code 11) Main Throttle Sensor Output Voltage Inspection • Measure the output voltage at the ECU in the same way as input voltage inspection. Note the following. Digital Meter [A] Connector [B] Special Tool - Needle Adapter Set: 57001-1457 Main Throttle Sensor Output Voltage Connections to ECU Connector...

  • Page 154

    3-48 FUEL SYSTEM (DFI) Main Throttle Sensor (Service Code 11) NOTE ○ The standard voltage refers to the value when the volt- age reading at the Input Voltage Inspection shows 5 V exactly. ○ When the input voltage reading shows other than 5 V, derive a voltage range as follows.

  • Page 155: Main Throttle Sensor Resistance Inspection

    FUEL SYSTEM (DFI) 3-49 Main Throttle Sensor (Service Code 11) CAUTION Do not remove or adjust the main throttle sensor. It has been adjusted and set with precision at the factory. Never drop the sensor, especially on a hard surface. A shock to the sensor can damage it.

  • Page 156

    3-50 FUEL SYSTEM (DFI) Main Throttle Sensor (Service Code 11) Main Throttle Sensor Circuit 1. ECU 2. Subthrottle Valve Actuator 3. Subthrottle Sensor 4. Main Throttle Sensor 5. Water-proof Joint 2...

  • Page 157

    FUEL SYSTEM (DFI) 3-51 Inlet Air Pressure Sensor (Service Code 12) CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the part can damage it. Inlet Air Pressure Sensor Removal • Remove: Left Subframe (see Subframe Removal in the Frame chapter) Bolts [A] Relay Bracket [B] with Relays [C]...

  • Page 158

    3-52 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code 12) Inlet Air Pressure Sensor Input Voltage Inspection NOTE ○ Be sure the battery is fully charged. ○ The inspection is the same as “Input Voltage Inspection” of the throttle sensor and the atmospheric pressure sen- sor.

  • Page 159

    FUEL SYSTEM (DFI) 3-53 Inlet Air Pressure Sensor (Service Code 12) Output Voltage Inspection • Measure the output voltage at the ECU in the same way as input voltage inspection. Note the following. Digital Meter [A] Connector [B] Special Tool - Needle Adapter Set: 57001-1457 Inlet Air Pressure Sensor Output Voltage Connections to ECU Meter (+) →...

  • Page 160

    3-54 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code 12) Inlet Air Pressure Sensor Circuit 1. ECU 2. Inlet Air Pressure Sensor 3. Water-proof Joint 2 If you need to check the inlet air pressure sensor for vac- uum other than 76 cmHg (abs.), check the output voltage as follows.

  • Page 161

    FUEL SYSTEM (DFI) 3-55 Inlet Air Pressure Sensor (Service Code 12) • Remove the inlet air pressure sensor [A] and disconnect the vacuum hose from the sensor. • Connect an auxiliary hose [B] to the inlet air pressure sen- sor. •...

  • Page 162

    3-56 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code 12) ID: Idling Pv: Throttle Vacuum Pressure (abs.) Ps: Standard Atmospheric Pressure (abs.) ST: Standard of Sensor Output Voltage (v) TO: Throttle Full Open UR: Usable Range of Sensor Output Voltage (v) Vv: Inlet Air Pressure Sensor Output Voltage (V) (Digital Meter Reading)

  • Page 163: Inlet Air Temperature Sensor (service Code), Inlet Air Temperature Sensor Removal

    FUEL SYSTEM (DFI) 3-57 Inlet Air Temperature Sensor (Service Code 13) Inlet Air Temperature Sensor Removal CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. • Remove the fuel tank (see Fuel Tank Removal). •...

  • Page 164

    3-58 FUEL SYSTEM (DFI) Inlet Air Temperature Sensor (Service Code 13) If the output voltage is out of the specified, check the ECU for its ground, and power supply (see ECU Power Supply Inspection). If the ground and power supply are good, replace the ECU (see ECU section).

  • Page 165

    FUEL SYSTEM (DFI) 3-59 Inlet Air Temperature Sensor (Service Code 13) Inlet Air Temperature Sensor Circuit 1. ECU 2. Inlet Air Temperature Sensor 3. Water-proof Joint 2...

  • Page 166: Water Temperature Sensor (service Code), Water Temperature Sensor Removal/installation

    3-60 FUEL SYSTEM (DFI) Water Temperature Sensor (Service Code 14) Water Temperature Sensor Removal/Installation CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. • Drain the coolant (see Coolant Change in the Periodic Maintenance chapter).

  • Page 167

    FUEL SYSTEM (DFI) 3-61 Water Temperature Sensor (Service Code 14) Sensor Resistance Inspection • Refer to the Water Temperature Sensor Inspection in the Electrical System chapter (see Water Temperature Sen- sor Inspection in the Electrical System chapter). Water Temperature Sensor Circuit 1.

  • Page 168: Atmospheric Pressure Sensor (service Code)

    3-62 FUEL SYSTEM (DFI) 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 • Remove: Left Saddlebag (see Saddlebag Removal in the Frame chapter) Seat (see Seat Removal in the Frame chapter) Atmospheric Pressure Sensor Connector [A]...

  • Page 169

    FUEL SYSTEM (DFI) 3-63 Atmospheric Pressure Sensor (Service Code 15) If the reading is within the standard range, remove the seat, and check the input voltage again at the sensor con- nector. • Disconnect the atmospheric pressure sensor connector and connect the harness adapter [A] between the harness connector and atmospheric pressure sensor connector.

  • Page 170

    3-64 FUEL SYSTEM (DFI) Atmospheric Pressure Sensor (Service Code 15) If the output voltage is far out of the usable range, check the output voltage at the sensor connector [A] (when the wiring is open, the output voltage is about 1.8 V). •...

  • Page 171

    FUEL SYSTEM (DFI) 3-65 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 Inlet Air Pressure Sensor section). 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 Voltage Inspection of...

  • Page 172: Crankshaft Sensor (service Code), Crankshaft Sensor Removal/installation

    3-66 FUEL SYSTEM (DFI) Crankshaft Sensor (Service Code 21) Crankshaft Sensor Removal/Installation • Refer to the Crankshaft Sensor Removal/Installation in the Electrical System chapter (see Crankshaft Sensor Re- moval/Installation in the Electrical System chapter). Crankshaft Sensor Inspection ○ The crankshaft have no power source, and when the en- gine stops, the crankshaft generates no signals.

  • Page 173: Camshaft Position Sensor (service Code), Camshaft Position Sensor Removal/installation

    FUEL SYSTEM (DFI) 3-67 Camshaft Position Sensor (Service Code 23, 26) Camshaft Position Sensor Removal/Installation The camshaft position sensor detects the position of the camshaft, and distinguishes the cylinder. • Refer to the Camshaft Position Sensor Removal/Installa- tion in the Electrical System chapter (see Camshaft Posi- tion Sensor Removal/Installation in the Electrical System chapter).

  • Page 174

    3-68 FUEL SYSTEM (DFI) Speed Sensor (Service Code 24) Speed Sensor Removal/Installation • Refer to the Speed Sensor Removal/Installation in the Electrical System chapter (see Speed Sensor Re- moval/Installation in the Electrical System chapter). Speed Sensor Inspection • Refer to the Speed Sensor Inspection in the Electrical System chapter (see Speed Sensor Inspection in the Electrical System chapter).

  • Page 175: Speed Sensor Output Voltage Inspection

    FUEL SYSTEM (DFI) 3-69 Speed Sensor (Service Code 24) Speed Sensor Output Voltage Inspection • Before this inspection, inspect the input voltage (see Speed Sensor Input Voltage Inspection). NOTE ○ Be sure the battery is fully charged. • Turn the key knob to OFF. •...

  • Page 176

    3-70 FUEL SYSTEM (DFI) Speed Sensor (Service Code 24) 1. ECU 2. Speed Sensor 3. Joint Connector 8 4. Meter Unit 5. Frame Ground 6. Frame Ground 7. Battery 12 V 14 Ah...

  • Page 177: Gear Position Switch (service Code), Gear Position Switch Removal/installation

    FUEL SYSTEM (DFI) 3-71 Gear Position Switch (Service Code 25) Gear Position Switch Removal/Installation • Refer to the Gear Position Switch Removal/Installation in the Electrical System chapter (see Gear Position Switch Removal/Installation in the Electrical System chapter). Gear Position Switch Inspection •...

  • Page 178

    3-72 FUEL SYSTEM (DFI) Gear Position Switch (Service Code 25) Gear Position Switch Circuit 1. ECU 2. Gear Position Switch 3. Joint Connector 8 4. Frame Ground 5. Frame Ground 6. Battery 12 V 14 Ah...

  • Page 179: Vehicle-down Sensor (service Code), Vehicle-down Sensor Removal, Vehicle-down Sensor Installation

    FUEL SYSTEM (DFI) 3-73 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 180: Vehicle-down Sensor Inspection

    3-74 FUEL SYSTEM (DFI) Vehicle-down Sensor (Service Code 31) Vehicle-down Sensor Inspection NOTE ○ Be sure the battery is fully charged. • Remove the rear fender (see Rear Fender Removal in the Frame chapter). • Connect a digital meter [A] to the connector of the vehicle -down sensor [B], with the needle adapter set [C].

  • Page 181

    FUEL SYSTEM (DFI) 3-75 Vehicle-down Sensor (Service Code 31) • Turn the key knob to OFF. • Remove the vehicle-down sensor. ○ Do not disconnect the sensor connector. • Connect a digital meter [A] to the connector, with needle adapter set [B]. Special Tool - Needle Adapter Set: 57001-1457 Vehicle-down sensor Output Voltage Connections to Sensor...

  • Page 182: Subthrottle Sensor (service Code), Subthrottle Sensor Removal/adjustment

    3-76 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 183

    FUEL SYSTEM (DFI) 3-77 Subthrottle Sensor (Service Code 32) • Remove: Right Middle Fairing (see Middle Fairing Removal in the Frame chapter). Right Subframe • Disconnect the subthrottle sensor connector [A]. • Connect the harness adapter [A] between the harness connector and subthrottle sensor connector.

  • Page 184

    3-78 FUEL SYSTEM (DFI) Subthrottle Sensor (Service Code 32) Output Voltage Inspection • Measure the output voltage at the ECU in the same way as input voltage inspection. Note the following. Digital Meter [A] Connector [B] Special Tool - Needle Adapter Set: 57001-1457 Subthrottle Sensor Output Voltage Connections to ECU Connector Meter (+) →...

  • Page 185

    FUEL SYSTEM (DFI) 3-79 Subthrottle Sensor (Service Code 32) • Disconnect the subthrottle sensor connector [A] and con- nect the harness adapter [B] between the harness con- nector and subthrottle sensor connector. Special Tool - Throttle Sensor Harness Adapter: 57001 -1538 •...

  • Page 186: Resistance Inspection

    3-80 FUEL SYSTEM (DFI) Subthrottle Sensor (Service Code 32) Resistance Inspection • Turn the key knob to OFF. • Disconnect the subthrottle sensor connector. • Connect a digital meter [A] to the subthrottle sensor con- nector [B]. • Measure the subthrottle sensor resistance. Subthrottle Sensor Resistance Connections: BL lead [C] ←→...

  • Page 187: Oxygen Sensor-not Activated (#1, #2: Service Code 33, 83) - Equipped Models

    FUEL SYSTEM (DFI) 3-81 Oxygen Sensor-not activated (#1, #2: Service Code 33, 83) - Equipped Models Oxygen Sensor #2 Removal/Installation • Refer to the Oxygen Sensor Removal (Equipped Models) in the Electrical System chapter (see Oxygen Sensor Re- moval in the Electrical System chapter). Oxygen Sensor #2 Inspection NOTE ○...

  • Page 188

    0.05 ∼ 0.45 V), the oxygen sensor is good. If the reading is without range, replace the oxygen sensor. • Remove the needle adapter set, and apply silicone sealant to the seals of the connector for waterproofing. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120...

  • Page 189

    FUEL SYSTEM (DFI) 3-83 Oxygen Sensor-not activated (#1, #2: Service Code 33, 83) - Equipped Models Oxygen Sensor Circuit 1. ECU 2. Joint Connector 9 3. Oxygen Sensor #2 4. Oxygen Sensor #1 5. Steering Lock Unit 6. Oxygen Sensor Heater Fuse 15 A 7.

  • Page 190: Steering Lock Unit And Ecu Communication Error (service Code)

    3-84 FUEL SYSTEM (DFI) Steering Lock Unit and ECU Communication Error (Service Code 37, 38) Steering Lock Unit and ECU Communication Line Inspection ○ When the data is not sent from the steering lock unit and ECU to KIPASS ECU, the service code 37, 38 is dis- played.

  • Page 191: Fuel Pump Relay (service Code), Fuel Pump Relay Inspection

    FUEL SYSTEM (DFI) 3-85 Fuel Pump Relay (Service Code 46) Fuel Pump Relay Removal CAUTION Never drop the relay, especially on a hard surface. Such a shock to the relay can damage it. ○ The fuel pump relay is included in the relay box. •...

  • Page 192

    3-86 FUEL SYSTEM (DFI) Fuel Pump Relay (Service Code 46) Fuel Pump Relay Circuit 1. Steering Lock Unit 11. Relay Box 12. Joint Connector 2 2. Joint Connector 1 13. Main Fuse 30 A 3. Engine Stop Switch 14. Starter Relay 4.

  • Page 193: Stick Coils #1, #2, #3, #4: (service Code), Stick Coil Removal/installation

    FUEL SYSTEM (DFI) 3-87 Stick Coils #1, #2, #3, #4: (Service Code 51, 52, 53, 54) Stick Coil #1: Service Code 51 Stick Coil #2: Service Code 52 Stick Coil #3: Service Code 53 Stick Coil #4: Service Code 54 Stick Coil Removal/Installation CAUTION Never drop the stick coils, especially on a hard sur-...

  • Page 194

    3-88 FUEL SYSTEM (DFI) Stick Coils #1, #2, #3, #4: (Service Code 51, 52, 53, 54) Stick Coil Circuit 1. ECU 10. Joint Connector 9 2. Stick Coil #4 11. Main Fuse 30 A 3. Stick Coil #3 12. Starter Relay 4.

  • Page 195: Radiator Fan Relay (service Code), Radiator Fan Relay Removal/installation, Radiator Fan Relay Inspection

    FUEL SYSTEM (DFI) 3-89 Radiator Fan Relay (Service Code 56) Radiator Fan Relay Removal/Installation ○ The radiator fan relay is built in the relay box [A]. • Refer to the Relay Box Removal in the Electrical System chapter. Radiator Fan Relay Inspection •...

  • Page 196: Variable Valve Timing And Oil Control Solenoid Valve (service Code), Oil Control Solenoid Valve Removal/installation

    Using the KDS3 Kit. NOTE ○ Read the OCV Solenoid Test in the Kawasaki Diagnos- tic Software Version 3 Instruction Manual. If the oil control solenoid valve does not function, check it for any tips interlocked or seizure.

  • Page 197

    FUEL SYSTEM (DFI) 3-91 Variable Valve Timing and Oil Control Solenoid Valve (Service Code 59, 65) • Turn the key knob to OFF. If the reading is incorrect, check the following. Battery (see Charging Condition Inspection in the Elec- trical System chapter) Main Fuse 30 A (see Fuse Inspection in the Electrical System chapter) Oxygen Sensor Heater Fuse 15 A (see Fuse Inspection...

  • Page 198: Subthrottle Valve Actuator (service Code), Subthrottle Valve Actuator Removal, Subthrottle Valve Actuator Inspection

    3-92 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 199

    FUEL SYSTEM (DFI) 3-93 Subthrottle Valve Actuator (Service Code 62) Input Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Push and turn the key knob to OFF. • Connect the peak voltage adapter [A] and a digital meter [B] to the connector [C], using the needle adapter set [D].

  • Page 200

    3-94 FUEL SYSTEM (DFI) Subthrottle Valve Actuator (Service Code 62) Subthrottle Valve Actuator Circuit 1. ECU 2. Subthrottle Valve Actuator 3. Subthrottle Sensor 4. Main Throttle Sensor 5. Water-proof Joint 2...

  • Page 201: Air Switching Valve (service Code), Air Switching Valve Removal/installation, Air Switching Valve Inspection

    FUEL SYSTEM (DFI) 3-95 Air Switching Valve (Service Code 64) Air Switching Valve Removal/Installation • Refer to Clean Air System section in the Engine Top End chapter. Air Switching Valve Inspection • Refer to Air Switching Valve Unit Test in the Electrical Sys- tem chapter.

  • Page 202: Oxygen Sensor Heaters (#1 And/or #2: Service Code 67) - Equipped Models

    3-96 FUEL SYSTEM (DFI) Oxygen Sensor Heaters (#1 and/or #2: Service Code 67) - Equipped Models Oxygen Sensor Heaters Removal/Installation The oxygen sensor heater is built in the oxygen sensor. So, the heater itself can not be removed. Remove the oxy- gen sensors (see Oxygen Sensor Removal in the Electrical System chapter).

  • Page 203

    (see ECU Power Supply Inspection). If the ground and power supply are good, replace the ECU (see ECU section). • Remove the needle adapter set, and apply silicone sealant to the connector for water proofing. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120...

  • Page 204

    3-98 FUEL SYSTEM (DFI) Oxygen Sensor Heaters (#1 and/or #2: Service Code 67) - Equipped Models Oxygen Sensor Circuit 1. ECU 2. Joint Connector 9 3. Oxygen Sensor #2 4. Oxygen Sensor #1 5. Steering Lock Unit 6. Oxygen Sensor Heater Fuse 15 A 7.

  • Page 205: Steering Lock Unit (service Code), Steering Lock Unit Inspection

    FUEL SYSTEM (DFI) 3-99 Steering Lock Unit (Service Code 68) Steering Lock Unit Inspection • Remove : Left Inner Cover (see Inner Cover Removal in the Frame chapter) • Turn the key knob to OFF. • Open the rubber cap [A]. •...

  • Page 206

    3-100 FUEL SYSTEM (DFI) Steering Lock Unit (Service Code 68) • Push and turn ON the key knob and check the Voltage. Steering Lock Unit Voltage Connections for Main Harness side Connector Meter (+) → W lead Meter (–) → BK/Y lead Standard Voltage: Battery Voltage Meter (+) →...

  • Page 207: Steering Lock Unit And Dfi Ecu - Identify Authentification Error (service Code)

    FUEL SYSTEM (DFI) 3-101 Steering Lock Unit and DFI ECU - Identify Authentification Error (Service Code 87, 88) ○ When the service code 87, 88 is displayed, perform the registration of KIPASS ID by using the KDS 3. • If KIPASS ID can not be registered, replace the ECU or steering lock unit.

  • Page 208: Ecu Identification, Ecu Removal

    3-102 FUEL SYSTEM (DFI) CAUTION Never drop the ECU, especially on a hard surface. Such a shock to the ECU can damage it. ECU Identification ○ Most countries have their own regulations, so each ECU has different characteristic. So, do not confuse ECU with each other and use only the ECU for your model.

  • Page 209: Ecu Installation

    FUEL SYSTEM (DFI) 3-103 • Remove: Fuse Box [A] Bolts [B] Tool Kit Case [C] • Pull of the connectors [D] • For Europe Models, using a suitable tool cut of the screws [A]. • Remove: Connectors [A] Relay Box [B] •...

  • Page 210: Ecu Power Supply Inspection

    Insert the stopper [C] of the fuse box [D] into the groove of the tool case. • For Europe Models, tighten new screws [A] of the tool kit case use Kawasaki genuine screws of witch treads are coated with locking agent. • Install:...

  • Page 211

    FUEL SYSTEM (DFI) 3-105 • With the ECU connectors [B] connected, check the fol- lowing ground lead for continuity with the key knob OFF, using a digital meter [A] and needle adapter set. Special Tool - Needle Adapter Set: 57001-1457 ECU Grounding Inspection 21, 22, or 52 Terminal ←→...

  • Page 212

    3-106 FUEL SYSTEM (DFI) ECU Power Source Circuit 1. ECU 2. Water-proof Joint 1 3. Steering Lock Unit 4. Joint Connector 9 5. Fuse Box 2 6. ECU Fuse 15 A 7. Main Fuse 30 A 8. Starter Relay 9. Battery 12 V 14 Ah 10.

  • Page 213: Can Communication Line Resistance Inspection

    FUEL SYSTEM (DFI) 3-107 CAN Communication Line Resistance Inspection ○ In this model, resistors for CAN communication line are built in the DFI ECU, KIPASS ECU and meter unit. • Turn the key knob to OFF. • Disconnect the DFI ECU connector [A] and KIPASS ECU connector [B].

  • Page 214

    3-108 FUEL SYSTEM (DFI) CAN Communication Line Circuit 1. Steering Lock Unit 2. Joint Connector 4 3. Joint Connector 5 4. KIPASS ECU 5. Meter Unit 6. Joint Connector 6 7. Joint Connector 7 8. Kawasaki Diagnostic System Connector 9. ECU...

  • Page 215: Dfi Power Source, Ecu Fuse Installation, Ecu Fuse Inspection

    FUEL SYSTEM (DFI) 3-109 DFI Power Source ECU Fuse Removal • Refer to the ECU Fuse 15 A Removal in the Electrical Sys- tem chapter (see ECU Fuse 15 A Removal in the Electri- cal System chapter). 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 216: Warning Indicator Light (led), Light (led) Inspection

    3-110 FUEL SYSTEM (DFI) Warning Indicator Light (LED) Light (LED) Inspection ○ The warning indicator light (LED) [A] is used for the FI indicator and KIPASS indicator. ○ In this model, the warning indicator light (LED) goes on or blinks by the special signal sent from the ECU. •...

  • Page 217: Fuel Line, Fuel Pressure Inspection

    FUEL SYSTEM (DFI) 3-111 Fuel Line Fuel Pressure Inspection NOTE ○ Be sure the battery is fully charged. • Remove the fuel tank bolts [A] (see Fuel Tank Removal). ○ Do not disconnect the fuel pump and fuel level sensor lead connector.

  • Page 218

    3-112 FUEL SYSTEM (DFI) Fuel Line WARNING Do not try to start the engine with the fuel hoses disconnected. • Push and turn the key knob to ON. The fuel pump will turn for 3 seconds, and then stop. CAUTION Do not drive the fuel pump 3 seconds or more with- out the fuel in the fuel tank.

  • Page 219: Fuel Flow Rate Inspection

    FUEL SYSTEM (DFI) 3-113 Fuel Line Fuel Flow Rate Inspection NOTE ○ Be sure the battery is fully charged. WARNING Gasoline is extremely flammable and can be explo- sive under certain conditions. Make sure the area is well-ventilated and free from any source of flame or sparks;...

  • Page 220

    3-114 FUEL SYSTEM (DFI) Fuel Line WARNING Wipe off spilled out fuel immediately. Be sure to hold the measuring cylinder vertical. • Close the fuel tank cap. • With the engine stopped, turn the ignition switch ON. The fuel pump should operate for 3 seconds, and then should stop.

  • Page 221: Fuel Pump, Fuel Pump Removal, Fuel Pump Installation

    FUEL SYSTEM (DFI) 3-115 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 222: Fuel Pump Operation Inspection, Operating Voltage Inspection

    3-116 FUEL SYSTEM (DFI) Fuel Pump • Check that the fuel pump terminals [A], fuel reserve switch terminal [B] and band [C] are in place. Left [D] • Apply a non-permanent locking agent to the threads of the fuel pump bolts. •...

  • Page 223

    FUEL SYSTEM (DFI) 3-117 Fuel Pump Fuel Pump Circuit 11. Relay Box 1. Steering Lock Unit 12. Joint Connector 2 2. Joint Connector 1 3. Engine Stop Switch 13. Main Fuse 30 A 4. Water-proof Joint 1 14. Starter Relay 5.

  • Page 224: Fuel Injectors, Fuel Injector Removal/installation, Power Source Voltage Inspection

    3-118 FUEL SYSTEM (DFI) Fuel Injectors Fuel Injector Removal/Installation • Refer to the Throttle Body Assy Disassembly/Assembly (see Throttle Body Assy Disassembly/Assembly). CAUTION Never drop the injector, especially on a hard sur- face. Such a shock to the injector can damage it. Power Source Voltage Inspection NOTE ○...

  • Page 225: Fuel Injector Output Voltage Inspection

    FUEL SYSTEM (DFI) 3-119 Fuel Injectors • Connect a digital meter [A] to the throttle body subharness connector [B], using the needle adapter set [C]. Special Tool - Needle Adapter Set: 57001-1457 Injector Power Source Voltage at Injector Connections to Injector #1, #2, #3, #4 Meter (+) →...

  • Page 226: Audible Inspection

    3-120 FUEL SYSTEM (DFI) Fuel Injectors If the output voltage is out of the standard, check the out- put voltage at the throttle body subharness connector [B] using a digital meter [A] and needle adapter set [C] (when the lead is open, the output voltage is 0 V). Special Tool - Needle Adapter Set: 57001-1457 Injector Output Voltage at Injector Connections to Injector #1...

  • Page 227: Injector Signal Test, Injector Resistance Inspection

    FUEL SYSTEM (DFI) 3-121 Fuel Injectors Injector Signal Test • Prepare two test light sets with male terminals as shown. Rating of Bulb [A]: 12 V × 3 ∼ 3.4 W Terminal Width [B]: 1.8 mm (0.07 in.) Terminal Thickness [C]: 0.8 mm (0.03 in.) CAUTION Do not use larger terminals than specified above.

  • Page 228: Injector Unit Test, Injector Fuel Line Inspection

    3-122 FUEL SYSTEM (DFI) Fuel Injectors Injector Unit Test • Use two leads [A] and the same test light set [B] as in “Injector Signal Test”. Rating of Bulb [C]: 12 V × (3 ∼ 3.4) W 12 V MF Battery [D] CAUTION Be sure to connect the bulb in series.

  • Page 229

    FUEL SYSTEM (DFI) 3-123 Fuel Injectors Fuel Injector Circuit 1. Steering Lock Unit 2. Ignition Fuse 10 A 3. ECU Fuse 15 A 4. Fuse Box 2 5. Joint Connector 9 6. Engine Stop Switch 7. Fuel Injector #1 8. Fuel Injector #2 9.

  • Page 230: Throttle Grip And Cables, Cable Lubrication, Free Play Inspection, Free Play Adjustment, Cable Installation

    3-124 FUEL SYSTEM (DFI) Throttle Grip and Cables Free Play Inspection • Refer to the Throttle Control System Inspection in the Pe- riodic Maintenance chapter (see Throttle Control System Inspection in the Periodic Maintenance chapter). Free Play Adjustment • Refer to the Throttle Control System Inspection in the Pe- riodic Maintenance chapter (see Throttle Control System Inspection in the Periodic Maintenance chapter).

  • Page 231: Throttle Body Assy, Throttle Bore Cleaning, Synchronization Inspection, Synchronization Adjustment, Throttle Body Assy Removal

    FUEL SYSTEM (DFI) 3-125 Throttle Body Assy Idle Speed Inspection • Refer to the Idle Speed Inspection in the Periodic Mainte- nance chapter (see Idle Speed Inspection in the Periodic Maintenance chapter). Throttle Bore Cleaning • Check the throttle bore for cleanliness as follows. ○...

  • Page 232

    3-126 FUEL SYSTEM (DFI) Throttle Body Assy • Remove: Right Subframe Bolt [A] with Washer Right Fairing Bracket Bolt (Front Side) • Disconnect the throttle body subharness connector [A]. • Remove the connector [A] from the connector bracket. ○ Insert the thin blade screw driver into the connector stop- per portion from the right side of motorcycle.

  • Page 233

    FUEL SYSTEM (DFI) 3-127 Throttle Body Assy • Remove: Fuel Tank (see Fuel Tank Removal) Inlet Air Temperature Sensor [A] Bolts [B] Left and Right Air Cleaner Caps [C] ○ Do not disconnect the inlet air temperature sensor lead connector. •...

  • Page 234: Throttle Body Assy Installation

    3-128 FUEL SYSTEM (DFI) Throttle Body Assy • Remove the adjuster screw [A] from the clamp [B]. • Loosen the throttle body assy holder clamp bolts [A] on both sides. • Pull out the throttle body assy [B] from the holder. •...

  • Page 235

    FUEL SYSTEM (DFI) 3-129 Throttle Body Assy If the grommet [A] was removed, install it. ○ Install the grommet from the inside of the frame. • Insert the duct [B] to the grommet. ○ Apply a soap and water solution or rubber lubricant to the oblique portion [C] on the duct for easy installation.

  • Page 236

    3-130 FUEL SYSTEM (DFI) Throttle Body Assy Throttle Body Assy Disassembly 1. Subthrottle Valve Actuator 2. Subthrottle Sensor 3. Main Throttle Sensor 4. Throttle Body Assy 5. Injector 6. Delivery Pipe 7. Throttle Body Subharness 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 237

    FUEL SYSTEM (DFI) 3-131 Throttle Body Assy • Disconnect the main throttle sensor [A] and subthrottle sensor [B] connector. • Disconnect: Subthrottle Valve Actuator Lead Connector [A] Inlet Air Pressure Sensor Connector [B] • Remove the inlet air pressure sensor [A] with hose [B]. •...

  • Page 238: Throttle Body Assy Assembly

    3-132 FUEL SYSTEM (DFI) Throttle Body Assy Throttle Body Assy Assembly • Before assembling, blow away dirt or dust from the throttle body and delivery pipe by applying compressed air. • Apply daphne oil or engine oil to the new O-rings [A] of each injector, insert them to the delivery pipe [B] and con- firm whether the injectors turn smoothly or not.

  • Page 239: Air Line, Element Removal, Element Installation, Air Cleaner Element Inspection, Air Cleaner Element Holder Removal

    FUEL SYSTEM (DFI) 3-133 Air Line Element Removal • Refer to the Air Cleaner Element Replacement in the Pe- riodic Maintenance chapter (see Air Cleaner Element Re- placement in the Periodic Maintenance chapter). Element Installation • Refer to the Air Cleaner Element Replacement in the Pe- riodic Maintenance chapter (see Air Cleaner Element Re- placement in the Periodic Maintenance chapter).

  • Page 240: Oil Draining, Rear Air Inlet Duct Installation

    3-134 FUEL SYSTEM (DFI) Air Line Oil Draining A drain hose is connected to the bottom of the air cleaner part to drain water or oil accumulated in the cleaner part. • Visually check the catch tank [A] of the drain hose, if the water or oil accumulates in the tank.

  • Page 241: Front Air Inlet Duct Installation

    FUEL SYSTEM (DFI) 3-135 Air Line • Insert the rear air inlet duct [A] until the duct end [B] align the line [C] of middle air inlet duct [D]. • Tighten Torque - Rear Air inlet Duct Mounting Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) •...

  • Page 242: Fuel Tank

    3-136 FUEL SYSTEM (DFI) 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 243

    FUEL SYSTEM (DFI) 3-137 Fuel Tank • Disconnect: Fuel Pump Lead Connector [A] Fuel Level Sensor Lead Connector [B] • Open the fuel tank cap [A] to lower the pressure in the tank. ○ During tank removal, keep the tank cap open to release pressure in the tank.

  • Page 244: Fuel Tank Installation

    3-138 FUEL SYSTEM (DFI) Fuel Tank • For the California Model, note the following. CAUTION For the California model, if gasoline, solvent, water or any other liquid enters the canister, the canister’s vapor absorbing capacity is greatly reduced. If the canister does become contaminated, replace it with a new one.

  • Page 245

    FUEL SYSTEM (DFI) 3-139 Fuel Tank • Pull the joint lock [A] as shown. • Insert the fuel hose joint [A] straight onto the delivery pipe until the hose joint clicks. • Push the joint lock [B] until the hose joint clicks. •...

  • Page 246: Fuel Tank Cleaning

    3-140 FUEL SYSTEM (DFI) Fuel Tank Fuel Tank and Cap Inspection • Visually inspect the gasket [A] on the tank cap for any damage. Replace the gasket if it is damaged. • Check to see if the water drain pipe [B] and fuel breather pipe [C] (California Model) in the tank are not clogged.

  • Page 247: Evaporative Emission Control System, Parts Removal/installation, Separator Inspection

    FUEL SYSTEM (DFI) 3-141 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 248: Separator Operation Test, Canister Inspection

    3-142 FUEL SYSTEM (DFI) 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 249: Table Of Contents

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

  • Page 250

    4-2 COOLING SYSTEM Exploded View...

  • Page 251

    COOLING SYSTEM 4-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Radiator Hose Clamp Screws 0.20 18 in·lb Coolant Drain Plug 106 in·lb Water Pump Cover Bolts 87 in·lb Oil Cooler Mounting Bolts 106 in·lb Thermostat Housing Cover Bolts 0.60 52 in·lb Thermostat Housing Mounting Bolts 87 in·lb...

  • Page 252

    4-4 COOLING SYSTEM Coolant Flow Chart...

  • Page 253: Coolant Flow Chart

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

  • Page 254

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

  • Page 255: Coolant Deterioration Inspection, Coolant Draining, Coolant Filling, Pressure Testing

    COOLING SYSTEM 4-7 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 256: Cooling System Flushing, Coolant Reserve Tank Removal/installation

    4-8 COOLING SYSTEM Coolant Cooling System Flushing Over a period of time, the cooling system accumulates rust, scale, and lime in the water jacket and radiator. When this accumulation is suspected or observed, flush the cool- ing system. If this accumulation is not removed, it will clog up the water passage and considerable reduce the effi- ciency of the cooling system.

  • Page 257: Water Pump, Water Pump Installation

    COOLING SYSTEM 4-9 Water Pump Water Pump Removal • Drain: Coolant (see Coolant Change in the Periodic Mainte- nance chapter) Engine Oil (see Engine Oil Change in the Periodic Main- tenance chapter) • Remove: Lower Fairing (see Lower Fairing Removal in the Frame chapter) •...

  • Page 258: Water Pump Impeller Inspection

    4-10 COOLING SYSTEM Water Pump • Turn the pump drive gear shaft so that the slot [A] in its shaft fits onto the projection [B] of the impeller shaft. • Install: Radiator Hose • Tighten: Torque - Radiator Hose Clamp Screw: 2.0 N·m (0.20 kgf·m, 18 in·lb) •...

  • Page 259

    COOLING SYSTEM 4-11 Radiator Radiator and Radiator Fan Removal • Drain: Coolant (see Coolant Change in the Periodic Mainte- nance chapter) • Remove: Middle Fairings (see Middle Fairing Removal in the Frame chapter) Right Side Radiator Fan Lead Connector [A] Reservoir Tank Hose [B] Air Bleeder Hose [C] for Thermostat Housing Radiator Hose [D]...

  • Page 260: Radiator And Radiator Fan Installation, Radiator Inspection

    4-12 COOLING SYSTEM Radiator Radiator and Radiator Fan Installation • Be sure that the trim seals [A] are in position on the radi- ator as shown. • Install the dampers [B], radiator bracket collars [C] and bolts as shown. Radiator Inspection •...

  • Page 261: Radiator Cap Inspection, Radiator Filler Neck Inspection

    COOLING SYSTEM 4-13 Radiator Radiator Cap Inspection • Remove: Front Right Middle Fairing (see Middle Fairing Removal in the Frame chapter) Radiator Cap [A] • Check the condition of the bottom [A] and top [B] valve seals and valve spring [C]. If any one of them shows visible damage, replace the cap with a new one.

  • Page 262: Thermostat Removal, Thermostat Installation, Thermostat Inspection

    4-14 COOLING SYSTEM Thermostat Thermostat Removal • Drain the coolant (see Coolant Change in the Periodic Maintenance chapter). • Remove: Right Rear Middle Fairing (see Middle Fairing Removal in the Frame chapter) Battery Compartment Cover (see Battery Removal in the Electrical System chapter) Crankshaft Sensor Connector (see Crankshaft Sensor Removal in the Electrical System chapter)

  • Page 263

    COOLING SYSTEM 4-15 Thermostat • To check valve opening temperature, suspend the ther- mostat [A] in a container of water and raise the tempera- ture of the water. ○ The thermostat must be completely submerged and must not touch the container sides or bottom. Suspend an ac- curate thermometer [B] in the water so that the heat sen- sitive portions [C] are located in almost the same depth.

  • Page 264: Hoses And Pipes, Hose Installation

    4-16 COOLING SYSTEM Hoses and Pipes Hose Installation • Install the hoses and pipes, being careful to follow bend- ing direction. Avoid sharp bending, kinking, flattening or twisting. • Run the hoses (see Cable, Wire, and Hose Routing sec- tion in the Appendix chapter). •...

  • Page 265

    COOLING SYSTEM 4-17 Water Temperature Sensor CAUTION The water temperature sensor should never be al- lowed to fall on a hard surface. Such a shock to their parts can damage them. Water Temperature Sensor Removal • Refer to the Water Temperature Sensor Removal in the Fuel System (DFI) chapter.

  • Page 267: Table Of Contents

    ENGINE TOP END 5-1 Engine Top End Table of Contents Exploded View........................Exhaust System........................Specifications ......................... Special Tools and Sealant ...................... Clean Air System........................5-11 Air Suction Valve Removal....................5-11 Air Suction Valve Installation..................... 5-11 Air Suction Valve Inspection ..................... 5-12 Air Switching Valve Removal ....................

  • Page 268

    5-2 ENGINE TOP END Exploded View...

  • Page 269

    M: Apply molybdenum disulfide grease. MO: Apply molybdenum disulfide oil. (mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 : 1) R: Replacement Parts S: Follow the specific tightening sequence. SS: Apply silicone sealant (Kawasaki Bond: 92104-0004).

  • Page 270

    5-4 ENGINE TOP END Exploded View...

  • Page 271

    ENGINE TOP END 5-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Muffler Body Mounting Bolts Crankshaft Sensor Cover Bolts 87 in·lb L (1) Oxygen Sensor (Europe Models) 4. Muffler Body Clamp Bolt 5. Exhaust Pipe Manifold Holder Nuts 6. Europe Models L: Apply a non-permanent locking agent.

  • Page 272: Exhaust System

    5-6 ENGINE TOP END Exhaust System Full: Full Power H: Honeycomb Type Catalyst 78.2: Hosepower 78.2 kW (106.3 ps) Manifold Mark Position [A]...

  • Page 273

    ENGINE TOP END 5-7 Exhaust System Silencer Mark Position [A] Manifold [A] with Holes [B] for Oxygen Sensors [C]. Honeycomb Type Catalysts [A]...

  • Page 274

    5-8 ENGINE TOP END Specifications Item Standard Service Limit Camshafts Cam Height: 33.642 ∼ 33.756 mm (1.3245 ∼ 1.3290 in.) Exhaust 33.54 mm (1.32 in.) 34.243 ∼ 34.357 mm (1.3481 ∼ 1.3526 in.) Inlet 34.14 mm (1.344 in.) 0.038 ∼ 0.081 mm (0.0015 ∼ 0.0032 in.) Camshaft Journal, Camshaft 0.17 mm (0.0067 in.) Cap Clearance...

  • Page 275

    ENGINE TOP END 5-9 Special Tools and Sealant Compression Gauge, 20 kgf/cm²: Valve Seat Cutter, 60° - 30: 57001-221 57001-1123 Valve Spring Compressor Assembly: Valve Seat Cutter Holder Bar: 57001-241 57001-1128 Valve Seat Cutter, 45° - 35: Valve Seat Cutter, 45° - 30: 57001-1116 57001-1187 Valve Seat Cutter, 32°...

  • Page 276

    Valve Seat Cutter Holder, 5: Valve Spring Compressor Adapter, 24: 57001-1208 57001-1586 Valve Seat Cutter, 60° - 33: Valve Guide Driver Attachment, E: 57001-1334 57001-1677 Compression Gauge Adapter, M10 × 1.0: Kawasaki Bond (Silicone Sealant): 57001-1486 92104-0004 Valve Guide Driver: 57001-1564...

  • Page 277: Clean Air System, Air Suction Valve Removal, Air Suction Valve Installation

    ENGINE TOP END 5-11 Clean Air System Air Suction Valve Removal • Remove: Middle Fairings (see Middle Fairing Removal in the Frame chapter) Subframes Engine Bracket • Remove the air switching valve with the hoses [A] (see air switching valve Removal). •...

  • Page 278: Air Suction Valve Inspection, Air Switching Valve Removal

    5-12 ENGINE TOP END Clean Air System Air Suction Valve Inspection • Remove the air suction valve (see Air Suction Valve Re- moval). • Visually inspect the reeds [A] for cracks, folds, warps, heat damage, or other damage. If there is any doubt as to the condition of the reed, replace the air suction valve as an assembly.

  • Page 279

    ENGINE TOP END 5-13 Clean Air System Air Switching Valve Installation • Install the air switching valve so that the air duct [A] faces left side. • Route the hoses correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). Air Switching Valve Operation Test •...

  • Page 280: Cylinder Head Cover, Cylinder Head Cover Removal, Cylinder Head Cover Installation

    Remove the cylinder head cover [A] to the right side of the engine. Cylinder Head Cover Installation • Replace the head cover gasket with a new one. • Apply silicone sealant [A] to the cylinder head as shown. Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004...

  • Page 281

    ENGINE TOP END 5-15 Cylinder Head Cover • Install: Dowel Pins [A] Plug Hole Gaskets [B] • Apply a soap solution to the upper and lower surfaces [A] to the washer. • Install the washer [B] with the metal side faces [C] upward. •...

  • Page 282: Camshaft Chain Tensioner, Camshaft Chain Tensioner Removal, Camshaft Chain Tensioner Installation

    5-16 ENGINE TOP END Camshaft Chain Tensioner Camshaft Chain Tensioner Removal CAUTION Do not turn over the crankshaft while the tensioner is removed. This could upset the camshaft chain timing, and damage the valves. • Remove the right Rear middle fairing (see Middle Fairing Removal in the Frame chapter).

  • Page 283: Camshaft, Camshaft Chain

    ENGINE TOP END 5-17 Camshaft, Camshaft Chain Camshaft Removal • Remove: Cylinder Head Cover (see Cylinder Head Cover Re- moval) • Position the crankshaft at #1, 4 piston TDC. TDC mark [A] for #1, 4 Pistons Timing Mark (crankcase halves mating surface) [B] •...

  • Page 284: Camshaft Installation

    5-18 ENGINE TOP END Camshaft, Camshaft Chain • Remove the variable valve actuator and cam sprocket mounting bolts [A]. • Remove the variable valve actuator and cam sprocket. CAUTION The crankshaft may be turned while the camshafts are removed. Always pull the chain taut while turn- ing the crankshaft.

  • Page 285

    ENGINE TOP END 5-19 Camshaft, Camshaft Chain NOTE ○ The exhaust camshaft has the projection [A] for camshaft position sensor. ○ The inlet camshaft has two projections [B] for camshaft position sensor. • Position the crankshaft at #1, 4 piston TDC. •...

  • Page 286

    5-20 ENGINE TOP END Camshaft, Camshaft Chain • First install the camshaft cap [A] temporary to fix the po- sition of the camshaft. • Next install the camshaft caps, following the identification No. and/or Name [B] and chain guide [C]. ○...

  • Page 287

    ENGINE TOP END 5-21 Camshaft, Camshaft Chain • Be sure to install the following parts. Plug Hole Gaskets [A] Dowel Pins [B] • Install the Cylinder Head Cover (see Cylinder Head Cover Installation). Camshaft, Camshaft Cap Wear • Remove: Camshaft Chain Guide Camshaft Cap (see Camshaft Removal) •...

  • Page 288: Camshaft Runout, Camshaft Chain Removal

    5-22 ENGINE TOP END Camshaft, Camshaft Chain Camshaft Runout • Remove the camshaft (see Camshaft Removal). • Set the camshaft in a camshaft alignment jig or on V blocks. • Measure runout with a dial gauge at the specified place as shown.

  • Page 289: Camshaft Chain Installation

    ENGINE TOP END 5-23 Camshaft, Camshaft Chain Camshaft Chain Installation • Install the camshaft chain from head side. • Install the crankshaft sprocket [A] on the crankshaft [B] with their teeth [C] aligned. • Install: Camshaft Chain Guides (see Cylinder Head Installation) Timing Rotor (see Timing Rotor Installation in the Elec- trical System chapter) Torque - Front Camshaft Chain Guide Bolt (Upper): 25 N·m...

  • Page 290: Cylinder Head, Cylinder Compression Measurement

    5-24 ENGINE TOP END Cylinder Head Cylinder Compression Measurement NOTE ○ Use the battery which is fully charged. • Warm up the engine thoroughly. • Stop the engine. • Remove: Stick Coils (see Stick Coil Removal in the Electrical Sys- tem chapter) Spark Plugs (see Spark Plug Replacement in the Peri- odic Maintenance chapter)

  • Page 291: Cylinder Head Removal

    ENGINE TOP END 5-25 Cylinder Head Cylinder Head Removal • Drain the coolant (see Coolant Change in the Periodic Maintenance chapter). • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Throttle Body Assy (see Throttle Body Assy Removal in the Fuel System (DFI) chapter) Exhaust Pipe (see Exhaust Pipe Removal) Cylinder Head Cover (see Cylinder Head Cover Re-...

  • Page 292: Cylinder Head Installation

    5-26 ENGINE TOP END Cylinder Head Cylinder Head Installation NOTE ○ The camshaft cap is machined with the cylinder head, so if a new cylinder head is installed, use the cap that is supplied with the new head. • Install a new cylinder head gasket [A] and dowel pins [B]. •...

  • Page 293: Cylinder Head Warp

    ENGINE TOP END 5-27 Cylinder Head Cylinder Head Warp • Clean the cylinder head. • Lay a straightedge across the lower surface of the cylinder head at several positions. • Use a thickness gauge [A] to measure the space between the straightedge [B] and the head.

  • Page 294: Valve Removal, Valve Installation, Valve Guide Removal, Valve Guide Installation

    5-28 ENGINE TOP END Valves Valve Clearance Inspection • Refer to the Valve Clearance Inspection in the Periodic Maintenance chapter (see Valve Clearance Inspection the Periodic Maintenance chapter). Valve Removal • Remove the cylinder head (see Cylinder Head Removal). • Remove the valve lifter and shim.

  • Page 295

    ENGINE TOP END 5-29 Valves • Assembly the valve guide driver parts (Holder and attach- ment E). • Insert the rod of the driver into the valve guide bore and hammer the end of the driver until it bottoms. Valve Guide Driver Attachment E [A] Valve Guide Driver (Holder) [B] Valve Guide [C] Cylinder Head [D]...

  • Page 296: Valve Seat Inspection, Valve Seat Repair

    5-30 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 297

    ENGINE TOP END 5-31 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 298

    5-32 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 until the diameter is within the spec- ified range.

  • Page 299

    ENGINE TOP END 5-33 Valves If the seat width is too wide, make the 60° [A] grind de- scribed below. If the seat width is within the specified range, lap the valve to the seat as described below. • Grind the seat at a 60° angle until the seat width is within the specified range.

  • Page 300

    5-34 ENGINE TOP END Valves...

  • Page 301: Throttle Body Holder, Throttle Body Holder Installation

    ENGINE TOP END 5-35 Throttle Body Holder Throttle Body Holder Installation • Be sure to install the O-rings [A]. • Tighten the holder bolts following the tightening sequence [1 ∼ 3]. Torque - Throttle Body Holder Bolts [C]: 9.8 N·m (1.0 kgf·m, 87 in·lb) Throttle Body Assy Holder Clamp Bolts [D]: 2.0 N·m (0.20 kgf·m, 18 in·lb)

  • Page 302: Muffler Body Removal, Muffler Body Installation, Exhaust Pipe Removal

    5-36 ENGINE TOP END Muffler WARNING To avoid a serious burn, do not remove the muffler when the engine is still hot. Wait until the muffler cool down. Muffler Body Removal • Remove: Right Saddlebag (see Saddlebag Removal in the Frame chapter) Muffler Clamp Bolts [A] Muffler Mounting Bolts and Nuts [B]...

  • Page 303: Exhaust Pipe Installation

    ENGINE TOP END 5-37 Muffler • For the oxygen sensor was equipped models as follows. ○ Disconnect the sensor connectors [A]. • Remove the sensor [B]. Exhaust Pipe Installation • Replace the exhaust pipe gaskets [A], muffler gasket with new ones and install them. ○...

  • Page 305: Table Of Contents

    CLUTCH 6-1 Clutch Table of Contents Exploded View........................Specifications ......................... Special Tools and Sealant ...................... Clutch Master Cylinder ......................Clutch Lever Adjustment....................Clutch Master Cylinder Removal ..................Clutch Master Cylinder Installation .................. Clutch Master Cylinder Disassembly ................Clutch Master Cylinder Assembly ..................Clutch Master Cylinder Inspection ..................

  • Page 306

    6-2 CLUTCH Exploded View...

  • Page 307

    CLUTCH 6-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Clutch Lever Pivot Bolt 0.10 8.9 in·lb Clutch Lever Pivot Bolt Locknut 0.60 52 in·lb Clutch Master Cylinder Bleed Valve 0.80 69 in·lb Clutch Reservoir Cap Screws 0.15 13 in·lb Clutch Reservoir Mounting Bolt 0.80 70 in·lb...

  • Page 308

    6-4 CLUTCH Specifications Item Standard Service Limit Clutch Fluid Grade DOT4 – – – Clutch Lever – – – Clutch Lever Position 5-way adjustable (to suit rider) – – – Clutch Lever Free Play Non-adjustable – – – Clutch 2.92 ∼ 3.08 mm (0.115 ∼ 0.121 in.) Friction Plate Thickness 2.7 mm (0.106 in.) (13088-0031)

  • Page 309

    CLUTCH 6-5 Special Tools and Sealant Inside Circlip Pliers: Clutch Holder: 57001-143 57001-1243 Clutch Spring Compressor: Kawasaki Bond (Silicone Sealant): 57001-1162 92104-0004...

  • Page 310: Clutch Master Cylinder, Clutch Lever Adjustment, Clutch Master Cylinder Removal, Clutch Master Cylinder Installation

    6-6 CLUTCH Clutch Master Cylinder Clutch Lever Adjustment ○ The adjuster has 5 positions so that the clutch lever posi- tion can be adjusted to suit the operator’s hand. • Push the lever forward and turn the adjuster [A] to align the number with the triangular mark [B] on the lever holder.

  • Page 311: Clutch Master Cylinder Disassembly, Clutch Master Cylinder Assembly, Clutch Master Cylinder Inspection

    CLUTCH 6-7 Clutch Master Cylinder Clutch Master Cylinder Disassembly • Refer to the Clutch Master Cylinder Cap and Dust Seal Replacement in the Periodic Maintenance chapter. Clutch Master Cylinder Assembly • Refer to the Clutch Master Cylinder Cap and Dust Seal Replacement in the Periodic Maintenance chapter.

  • Page 312: Clutch Slave Cylinder, Clutch Slave Cylinder Removal, Clutch Slave Cylinder Installation

    6-8 CLUTCH Clutch Slave Cylinder Clutch Slave Cylinder Removal • Remove: Left Rear Middle Fairing (see Middle Fairing Removal in the Frame chapter) Left Lower Fairing (see Lower Fairing Removal in the Frame chapter) Banjo Bolt [A] Clutch Slave Cylinder Bolts [B] Slave Cylinder [C] CAUTION Immediately wash away any clutch fluid that spills.

  • Page 313: Clutch Slave Cylinder Disassembly, Clutch Slave Cylinder Assembly

    CLUTCH 6-9 Clutch Slave Cylinder • Apply a non-permanent locking agent to the threads of the slave cylinder bolts [A]. • Finger tighten all the clutch slave cylinder bolts. • Remove the band from the clutch lever and release the clutch lever.

  • Page 314: Clutch Fluid, Bleeding The Clutch Line

    6-10 CLUTCH Clutch Fluid Clutch Fluid Level Inspection • Refer to the Clutch Fluid Level Inspection in the Periodic Maintenance chapter (see Clutch Fluid Level Inspection in the Periodic Maintenance chapter). Clutch Fluid Change • Refer to the Clutch Fluid Change in the Periodic Mainte- nance chapter (see Clutch Fluid Change in the Periodic Maintenance chapter).

  • Page 315: Clutch Hose Removal/installation, Clutch Hose And Connection Inspection

    CLUTCH 6-11 Clutch Fluid • Bleed the clutch line and the master cylinder. ○ Repeat this operation until no more air can be seen com- ing out into the plastic hose. 1. Pump the clutch lever until it becomes hard, and apply the clutch lever and hold it [C].

  • Page 316: Clutch Cover, Clutch Cover Removal, Clutch Cover Installation

    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): 92104-0004 • Replace the clutch cover gasket with a new one. •...

  • Page 317: Clutch Removal

    CLUTCH 6-13 Clutch Clutch Removal • Remove: Right Lower Fairing (see Lower Fairing Removal in the Frame chapter) Clutch Cover (see Clutch Cover Removal) Clutch Spring Bolts [A] with Spring Holder Clutch Springs Clutch Spring Plate [B] (with thrust bearing and washer [C]) •...

  • Page 318: Clutch Installation

    6-14 CLUTCH Clutch • Pull out the sleeve [B] from the clutch housing [D], and remove the housing. ○ If the sleeve does not pull out easily, insert M4 bolts [A] into the threaded hole of the sleeve, and pull out the sleeve and needle bearing [C].

  • Page 319

    CLUTCH 6-15 Clutch • Install the spacer [A] and clutch shaft [B]. ○ Install the clutch shaft so that the tooth side faces [C] in. • If the sub clutch hub bolts was removed, install it. ○ Apply a non-permanent locking agent to the threads of the sub clutch hub bolts, and tighten it.

  • Page 320

    6-16 CLUTCH Clutch ○ Install the friction plates (between the first and outer-end friction plate), that has notches [A] among others. ○ Install outer-end friction plate, that has the thin thickness body [A] among others [B]. • Install the last friction plate [A] fitting the tangs in the grooves in the housing as shown.

  • Page 321: Clutch Hub Disassembly

    CLUTCH 6-17 Clutch Clutch Hub Disassembly • Remove the clutch hub (see Clutch Removal). • Using a press [A], and the clutch spring compressor [B], push the damper spring holder [C] to remove the retaining ring [D]. Special Tool - Clutch Spring Compressor: 57001-1162 •...

  • Page 322: Spring Plate Free Play Adjustment

    6-18 CLUTCH Clutch • Engage the clutch hub with the sub clutch hub. • To measure the free play, set a dial gauge [A] against the raised center [B] of the clutch spring plate. • Move the clutch housing gear back and forth [C]. The dif- ference between the highest and lowest gauge readings is the amount of free play.

  • Page 323: Clutch Plate Warp Inspection

    CLUTCH 6-19 Clutch Clutch Plate Assembly Length (Reference Information) • Inspect the friction plate thickness (see Clutch Plate, Wear, Damage Inspection). • Assemble: Clutch Hub [A] Friction Plates [B] Steel Plates [C] Sub Clutch Hub [D] Spring Plate [E] Clutch Spring [F] Spring Holder [G] Spring Bolts [H] Clutch Hub Bolts [I]...

  • Page 324: Clutch Spring Free Length Measurement, Damper Cam Inspection, Clutch Hub Spline Inspection, Cam Damper Inspection

    6-20 CLUTCH 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: 65.0 mm (2.56 in.) Service Limit: 62.0 mm (2.44 in.) Damper Cam Inspection •...

  • Page 325: Table Of Contents

    ENGINE LUBRICATION SYSTEM 7-1 Engine Lubrication System Table of Contents Exploded View........................Engine Oil Flow Chart......................Specifications ......................... Special Tools and Sealant ...................... Engine Oil and Oil Filter......................Oil Level Inspection......................Engine Oil Change......................Oil Filter Replacement ...................... Oil Pan............................ 7-10 Oil Pan Removal .......................

  • Page 326

    7-2 ENGINE LUBRICATION SYSTEM Exploded View...

  • Page 327

    G: Apply grease. L: Apply a non-permanent locking agent. MO: Apply molybdenum disulfide oil. (mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 : 1) R: Replacement Parts SS: Apply silicone sealant (Kawasaki Bond: 56019-120).

  • Page 328

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

  • Page 329

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

  • Page 330

    7-6 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart...

  • Page 331

    ENGINE LUBRICATION SYSTEM 7-7 Specifications Item Standard Engine Oil Type API SE, SF or SG API SH, SJ or SL with JASO MA Viscosity SAE 10W-40 Capacity 4.0 L (4.2 US gt) (when filter is not removed) 4.4 L (4.7 US gt) (when filter is removed) 4.7 L (5.0 US gt) (when engine is completely dry) Level Between upper and lower level lines...

  • Page 332

    7-8 ENGINE LUBRICATION SYSTEM Special Tools and Sealant Oil Pressure Gauge, 10 kgf/cm²: Oil Filter Wrench: 57001-164 57001-1249 Oil Pressure Gauge Adapter, PT3/8 × 19/in.: Kawasaki Bond (Silicone Sealant): 57001-1233 56019-120...

  • Page 333: Engine Oil And Oil Filter

    ENGINE LUBRICATION SYSTEM 7-9 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 334: Oil Pan

    7-10 ENGINE LUBRICATION SYSTEM Oil Pan Oil Pan Removal • Remove: Engine Oil (Drain, see Engine Oil Change in the Periodic Maintenance chapter) Muffler Bodies (see Muffler Body Removal/Installation in the Engine Top End chapter) Exhaust Pipe (see Exhaust Pipe Removal in the Engine Top End chapter) •...

  • Page 335

    ENGINE LUBRICATION SYSTEM 7-11 Oil Pan • Replace the O-rings with new ones. • Apply grease the oil pipe O-rings [A] and install the oil pipes [B]. If the oil pressure relief valve [C] was removed, install it (see Oil Pressure Relief Valve Installation). •...

  • Page 336: Oil Pressure Relief Valve, Oil Pressure Relief Valve Installation, Oil Pressure Relief Valve Inspection

    7-12 ENGINE LUBRICATION SYSTEM Oil Pressure Relief Valve Oil Pressure Relief Valve Removal • Remove: Oil Pan (see Oil Pan Removal) Oil Pipe (see Oil Pan Removal) • Hold the pipe [A] in a vise [B]. • Remove the oil pressure relief valve [C]. Oil Pressure Relief Valve Installation •...

  • Page 337: Oil Pump, Oil Pump Removal, Oil Pump Installation

    ENGINE LUBRICATION SYSTEM 7-13 Oil Pump Oil Pump Removal • Drain: Engine Oil (see Engine Oil Change in the Periodic Main- tenance chapter) • Remove: Clutch (see Clutch Removal in the Clutch chapter) Oil Pump Cover Bolts [A] Oil Pump Cover [B] Oil Pump Drive Gear Shaft [C] Outer Rotor Inner Rotor...

  • Page 338

    7-14 ENGINE LUBRICATION SYSTEM Oil Pump • After tighten tightening the cover bolts [A], check the fol- lowing. ○ Oil pump drive gear turn freely [B]. Torque - Oil Pump Cover Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)

  • Page 339: Oil Cooler, Oil Cooler Removal, Oil Cooler Installation

    ENGINE LUBRICATION SYSTEM 7-15 Oil Cooler Oil Cooler Removal • Remove: Left Lower Fairings (see Lower Fairing Removal in the Frame chapter) • Drain: Coolant (see Coolant Change in the Periodic Mainte- nance chapter) Engine Oil (see Engine Oil Change in the Periodic Main- tenance chapter) •...

  • Page 340: Oil Pressure Measurement

    7-16 ENGINE LUBRICATION SYSTEM Oil Pressure Measurement Oil Pressure Measurement • Remove the left lower fairing (see Lower Fairing Removal in the Frame chapter). • Remove the oil passage plug, and attach the adapter [A] and gauge [B] to the plug hole. Special Tools - Oil Pressure Gauge, 10 kgf/cm²: 57001-164 Oil Pressure Gauge Adapter, PT3/8 ×...

  • Page 341: Oil Pressure Switch, Oil Pressure Switch Removal, 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) • Install the switch lead direction [A] as shown.

  • Page 342: Vvt (variable Valve Taiming), Oil Pipe Removal, Oil Pipe Installation, Oil Control Solenoid Valve Removal

    7-18 ENGINE LUBRICATION SYSTEM VVT (Variable Valve Taiming) Oil Pipe Removal • Drain the engine oil (see Engine Oil Change in the Peri- odic Maintenance chapter). • Remove: Right Middle Fairings (see Middle Fairing Removal in the Frame chapter) Lower Fairing (see Lower Fairing Removal in the Frame chapter) Bolt [A] •...

  • Page 343

    ENGINE LUBRICATION SYSTEM 7-19 VVT (Variable Valve Taiming) Oil Control Solenoid Valve Installation • Install the gasket [A] as shown. Cylinder Head Mating Surface [B] • Tighten the bolts. Torque - Oil Control Solenoid Valve Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) Variable Valve Taiming Actuator Removal/Instal- lation •...

  • Page 345

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

  • Page 346

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

  • Page 347

    ENGINE REMOVAL/INSTALLATION 8-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Engine Mounting Nuts (M12) Adjusting Collars Front Engine Mounting Bolts (M10) S, R Engine Bracket Bolts (M8) S, R Subframe Bolts M: Apply molybdenum sulfide grease. R: Replacement Parts S: Follow the specified tightening sequence.

  • Page 348

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

  • Page 349

    ENGINE REMOVAL/INSTALLATION 8-5 Engine Removal/Installation • Remove: Pad [A] Right Heat Insulation Cover [B] (see Fairing Bracket Re- moval in the Frame chapter) Right Subframe [C] (see Subframe Removal in the Frame chapter) Bolts [D] Right Engine Bracket [E] Ground Terminals [F] •...

  • Page 350

    8-6 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Disconnect: Fuel Hose [A] on the Delivery Pipe • Remove: Clamp [A] Throttle Cable Lower Ends [B] • Loosen the clamp bolts [C] and pull the ducts [D] upward. • Support the engine with a suitable stand [A]. ○...

  • Page 351

    ENGINE REMOVAL/INSTALLATION 8-7 Engine Removal/Installation • Remove the starter motor cable terminal nut [A]. • Using the stand, take out the engine. Engine Installation • Support the engine with a suitable stand. ○ Put a plank onto the suitable stand for engine balance. •...

  • Page 352

    8-8 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation A: After installation, set the projection in the hole. B: To Water Temperature Sensor C: To Breather Hose D: To Throttle Body Subharness Bracket E: To throttle Body Holder F: To Throttle Pulley G: To Inlet Cam Position Sensor H: To Air Suction Valve and Stick Coils I: Only put the heat insulation rubber plate on the cylinder head cover.

  • Page 353

    ENGINE REMOVAL/INSTALLATION 8-9 Engine Removal/Installation • Before installing the engine. Confirm the routing of the water temperature sensor lead [A] and inlet camshaft po- sition sensor lead [B]. ○ Run [C] the water temperature sensor lead of the sub- harness between the #3 and #4 throttle body holders and connect the water temperature sensor body.

  • Page 354

    8-10 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation ○ Secondly, insert the mounting bolts [A] until they fit [B] in the adjusting collars [C]. ○ Be sure that the collar [D] is in position. NOTE ○ Replace the following bolts with new bolts pre-coated with locking agent.

  • Page 355

    ENGINE REMOVAL/INSTALLATION 8-11 Engine Removal/Installation ○ Fifthly, tighten the left engine bracket bolts [A]. ○ Sixthly, tighten the upper engine mounting nut [B] and then the lower engine mounting nut [C]. ○ Seventhly, install the right engine bracket and tighten the right engine bracket bolts [D] and the right front engine mounting bolt [E].

  • Page 356

    8-12 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Run the leads, cable and hoses correctly (see Cable, Wire, and Hose Routing section in the Appendix chap- ter). • Install the removed parts (see appropriate chapters). • Adjust: Throttle Cables (see Throttle Control System Inspection in the Periodic Maintenance chapter) •...

  • Page 357: Table Of Contents

    CRANKSHAFT/TRANSMISSION 9-1 Crankshaft/Transmission Table of Contents Exploded View........Rear Balancer Removal....9-31 Specifications ........Rear Balancer Installation.... 9-32 Special Tools and Sealants ....Balancer Adjustment....9-33 Crankcase Splitting......9-10 Balancer Damper Inspection..9-34 Crankcase Splitting ...... 9-10 Starter Motor Clutch and Torque Crankcase Assembly ....

  • Page 358

    9-2 CRANKSHAFT/TRANSMISSION Exploded View...

  • Page 359

    27. Do not apply any grease or oil. G: Apply grease. L: Apply a non-permanent locking agent. LG: Apply liquid gasket (Kawasaki Bond: 92104-1064). M: Apply molybdenum disulfide grease. MO: Apply molybdenum disulfide oil. (mixture of engine oil and molybdenum disulfide grease in a weight ratio is 10 : 1) R: Replacement Parts S: Follow the specified tightening sequence.

  • Page 360

    9-4 CRANKSHAFT/TRANSMISSION Exploded View...

  • Page 361

    CRANKSHAFT/TRANSMISSION 9-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Balancer Shaft Clamp Bolts 87 in·lb Balancer Shaft Clamp Lever Bolts Starter Clutch Shaft Bolt 87 in·lb Starter Clutch Shaft Plate Bolt 87 in·lb Torque Limiter Bolt Shift Drum Cam Holder Bolt 106 in·lb Gear Position Switch Screws 0.30...

  • Page 362

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

  • Page 363

    CRANKSHAFT/TRANSMISSION 9-7 Specifications Item Standard Service Limit ○ 41.000 ∼ 41.008 mm Marking – – – (1.6142 ∼ 1.6145 in.) 41.009 ∼ 41.016 mm None – – – (1.6145 ∼ 1.6148 in.) Crankshaft Main Bearing Insert Thickness: 1.490 ∼ 1.494 mm Brown –...

  • Page 364

    9-8 CRANKSHAFT/TRANSMISSION Specifications Connecting Rod Big End Bearing Insert Selection Bearing Insert Con-rod Big End Bore Crankpin Diameter Diameter Marking Marking Size Color Part Number ○ None Brown 92139-0131 None None Black 92139-0130 ○ ○ ○ None Blue 92139-0129 Crankshaft Main Bearing Insert Selection Crankcase Main Crankshaft Main Bearing Insert...

  • Page 365: Special Tools And Sealants

    CRANKSHAFT/TRANSMISSION 9-9 Special Tools and Sealants Piston Ring Compressor Belt, 80 ∼ 91: Bearing Puller: 57001-135 57001-1320 Bearing Puller Adapter: Kawasaki Bond (Silicone Sealant): 57001-317 56019-120 Piston Pin Puller Assembly: Kawasaki Bond: 57001-910 92104-1064 Piston Ring Compressor Grip: 57001-1095...

  • Page 366: Crankcase Splitting

    9-10 CRANKSHAFT/TRANSMISSION Crankcase Splitting Crankcase Splitting • Remove the engine (see Engine Removal/Installation in the Engine Removal/Installation chapter). • Set the engine on a clean surface and hold the engine steady while parts are being removed. • Remove: Clutch (see Clutch Removal in the Clutch chapter) Starter Motor Clutch (see Starter Motor Clutch Removal) Oil Pump (see Oil Pump Removal in the Engine Lubri- cation System chapter)

  • Page 367: Crankcase Assembly

    CRANKSHAFT/TRANSMISSION 9-11 Crankcase Splitting ○ Next, loosen the M10 Bolts [1 ∼10] (sequence numbers). • Tap lightly around the crankcase mating surface with a plastic mallet, and split the crankcase. Take care not to damage the crankcase. If the crankshaft is to be removed [A], remove the pistons (see Piston Removal).

  • Page 368

    9-12 CRANKSHAFT/TRANSMISSION Crankcase Splitting • Install the new drive shaft bearing [A] so that its stepped side [B] faces as shown using a press. • Install the bearing plate [A] with the screws [B]. ○ Install the plate so that the stepped hole side [C] faces outside.

  • Page 369

    [A]. • Apply liquid gasket [A] to the mating surface of the lower crankcase half. Sealant - Kawasaki Bond: 92104-1064 NOTE ○ Aster tightening the crankcase bolts, wipe up the liquid gasket seeping out the output shaft bearing hole [D].

  • Page 370

    9-14 CRANKSHAFT/TRANSMISSION Crankcase Splitting • Tighten the lower crankcase bolts using the following steps. ○ Following the sequence numbers on the lower crankcase half, tighten the M10 bolts [1 ∼ 10] with washers. Torque - Crankcase Bolts (M10): 47 N·m (4.8 kgf·m, 35 ft·lb) ○...

  • Page 371: Crankshaft And Connecting Rods, Crankshaft Installation

    CRANKSHAFT/TRANSMISSION 9-15 Crankshaft and Connecting Rods Crankshaft Removal • Split the crankcase (see Crankcase Splitting). • Remove the crankshaft (see Connecting Rod Removal). 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 372: Connecting Rod Removal, Connecting Rod Installation

    9-16 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods Connecting Rod Removal • Split the crankcase (see Crankcase Splitting). • Remove the connecting rod nuts [A]. • Remove the crankshaft. NOTE ○ Mark and record the locations of the connecting rods and their big end caps so that they can be reassembled in their original positions.

  • Page 373

    CRANKSHAFT/TRANSMISSION 9-17 Crankshaft and Connecting Rods • Install the crankshaft (see Crankshaft Installation). • Install each connecting rod on its original crankpin. ○ The connecting rod big end is bolted using the “plastic region fastening method”. ○ This method precisely achieves the needed clamping force without exceeding it unnecessarily, allowing the use of thinner, lighter bolts further decreasing connecting rod weight.

  • Page 374

    9-18 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods • Install new bolts in reused connecting rods. • Dent both bolt head and bolt tip with a punch as shown. • Before tightening, use a point micrometer to measure the length of new connecting rod bolts and record the values to find the bolt stretch.

  • Page 375: Connecting Rod Bend

    CRANKSHAFT/TRANSMISSION 9-19 Crankshaft and Connecting Rods • Install new bolts in reused connecting rods. • Apply a small amount of molybdenum disulfide oil to the following. Threads [A] of Bolts Seating Surfaces [B] of Nuts on the Connecting Rods • First, tighten the nuts to the specified torque.

  • Page 376: Connecting Rod Twist

    9-20 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods Connecting Rod Twist • With the big-end arbor [A] still on V block [C], hold the connecting rod horizontally and measure the amount that the arbor [B] varies from being paralleled with the surface plate over a 100 mm (3.94 in.) length of the arbor to de- termine the amount of connecting rod twist.

  • Page 377

    CRANKSHAFT/TRANSMISSION 9-21 Crankshaft and Connecting Rods If the clearance is within the standard, no bearing replace- ment is required. If the clearance is between 0.087 mm (0.0034 in.) and the service limit (0.12 mm, 0.0047 in.), replace the bear- ing inserts [A] with inserts painted blue [B]. Check in- sert/crankpin clearance with the plastigage.

  • Page 378: Crankshaft Side Clearance

    9-22 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods • Select the proper bearing insert [A] in accordance with the combination of the connecting rod and crankshaft coding. Size Color [B] Con-rod Big Crankpin Bearing Insert End Inside Diameter Diameter Marking Size Color Part Number Marking ○...

  • Page 379: Crankshaft Runout

    CRANKSHAFT/TRANSMISSION 9-23 Crankshaft and Connecting Rods • Measure the crankshaft #3 main journal width [A]. If the measurement exceeds the standard, replace the crankshaft [B]. Crankshaft #3 Main Journal Width 27.45 ∼ 27.50 mm (1.0807 ∼ 1.0827 in.) Standard: Crankshaft Runout •...

  • Page 380

    9-24 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods Crankshaft Main Journal Diameter 37.984 ∼ 38.000 mm (1.4954 ∼ 1.4961 in.) Standard: Service Limit: 37.96 mm (1.4945 in.) If any journal has worn past the service limit, replace the crankshaft with a new one. If the measured journal diameters are not less than the service limit, but do not coincide with the original diameter markings on the crankshaft, make new marks on it.

  • Page 381

    CRANKSHAFT/TRANSMISSION 9-25 Crankshaft and Connecting Rods Bearing Insert Crankcase Main Bearing Crankshaft Main Journal Inside Diameter Marking Diameter Marking Size Color Part Number Journal Nos. 92139-0134 1, 3, 5 ○ Brown 92139-0137 2, 4 None 92139-0133 1, 3, 5 Black ○...

  • Page 382: Piston Removal

    9-26 CRANKSHAFT/TRANSMISSION Pistons Piston Removal • Split the crankcase (see Crankcase Splitting). • Remove the connecting rod nuts [A]. • Remove the connecting rod big end caps. • Remove the crankshaft. • Remove the piston [A] with connecting rod to the cylinder head side.

  • Page 383: Piston Installation

    CRANKSHAFT/TRANSMISSION 9-27 Pistons Piston Installation • Apply molybdenum disulfide oil solution to the oil ring ex- pander, and install the oil ring expander [A] in the bottom piston ring groove so the ends [B] butt together. • Apply molybdenum disulfide oil solution to the oil ring steel rails, and install the oil ring steel rails, one above the ex- pander and one below it.

  • Page 384: Piston Wear

    9-28 CRANKSHAFT/TRANSMISSION Pistons • Install the piston with its marking IN [A] facing inlet side. • Using the piston ring compressor assy [B] to install the piston from the cylinder head side. Special Tools - Piston Ring Compressor Grip: 57001-1095 80 ∼...

  • Page 385: Piston Ring Groove Width, Piston Ring Thickness, Piston Ring End Gap

    CRANKSHAFT/TRANSMISSION 9-29 Pistons Piston Ring Groove Width • Measure the piston ring groove width. ○ Use a vernier caliper at several points around the piston. Piston Ring Groove Width Standard: 0.92 ∼ 0.94 mm (0.0362 ∼ 0.0370 in.) Top [A] 1.01 ∼...

  • Page 386: Front Balancer Removal, Front Balancer Installation

    9-30 CRANKSHAFT/TRANSMISSION Balancer Front Balancer Removal • Remove: Engine (see Engine Removal in the Engine Removal/In- stallation chapter) • Unscrew: Balancer Shaft Clamp Bolt [A] Balancer Shaft Clamp Lever Bolt [B] Balancer Shaft Clamp Lever [C] • Split the crankcase (see Crankcase Splitting). •...

  • Page 387: Rear Balancer Removal

    CRANKSHAFT/TRANSMISSION 9-31 Balancer • Insert the pin [A] as shown. • Set the front balancer on the upper crankcase half. ○ Align the punch mark [B] on the balancer gear [C] with the mark [D] (crankshaft at 2, 3 position TDC) on the balancer drive gear [E] of crankshaft.

  • Page 388: Rear Balancer Installation

    9-32 CRANKSHAFT/TRANSMISSION Balancer • Unscrew the balancer shaft clamp lever bolt [A]. • Pry off the clamp lever [A] until the oil seal [B] removed. • Pull the balancer shaft [C] out of the crankcase. The bal- ancer weight and gear assembly [D] come off with needle bearings and copper washers.

  • Page 389: Balancer Adjustment

    CRANKSHAFT/TRANSMISSION 9-33 Balancer • Position the crankshaft at # 2, 3 position TDC or at # 1, 4 position TDC. • Aligin the mark [A] on the balancer gear [B] with the mat- ing surface [C] of the upper crankcase half. •...

  • Page 390

    9-34 CRANKSHAFT/TRANSMISSION Balancer Balancer Damper Inspection • Remove the balancer and disassemble the weight and gear assembly. • Visually inspect the rubber dampers [A]. If they appear damaged or deteriorated, replace them.

  • Page 391: Starter Motor Clutch Removal, Starter Motor Clutch Installation, Starter Motor Clutch Disassembly

    CRANKSHAFT/TRANSMISSION 9-35 Starter Motor Clutch and Torque Limiter Starter Motor Clutch Removal • Remove: Engine (see Engine Removal in the Engine Removal/In- stallation chapter) Starter Motor (see Starter Motor Removal in the Electri- cal System chapter) Rear Balancer (see Rear Balancer Removal) •...

  • Page 392: Starter Motor Clutch Assembly, Starter Clutch Inspection, Torque Limiter Removal

    9-36 CRANKSHAFT/TRANSMISSION Starter Motor Clutch and Torque Limiter • Holding the drive gear [A] with a hand, take off the one -way clutch [B] from the gear by using the screw driver [C]. Starter Motor Clutch Assembly • Be sure to install the one-way clutch [A] so that its arrow [B] faces the side of the flat washer.

  • Page 393: Torque Limiter Installation

    CRANKSHAFT/TRANSMISSION 9-37 Starter Motor Clutch and Torque Limiter • Holding the torque limiter [A], remove the torque limiter shaft [B] and the torque limiter. Torque Limiter Installation • Replace the washer with a new one. • Apply molybdenum disulfide grease to the torque limiter shaft and tooths.

  • Page 394: Shift Pedal Removal, Shift Pedal Installation

    9-38 CRANKSHAFT/TRANSMISSION Transmission Shift Pedal Removal • Remove: Shift Lever Bolt [A] Shift Lever [B] • Remove: Shift Pedal Mounting Bolt [A] Shift Pedal [B] with Tie-rod [C] Shift Pedal Installation • Tighten: Torque - Shift Pedal Mounting Bolt [A]: 25 N·m (2.5 kgf·m, 18 ft·lb) Footpeg Bracket [B] Shift Pedal [C]...

  • Page 395

    CRANKSHAFT/TRANSMISSION 9-39 Transmission External Shift Mechanism Removal • Remove: Bolt [A] Shift Lever [B] Snap Ring [C] Washer [D] Clutch (see Clutch Removal in the Clutch chapter) • Remove the shift shaft assembly [A]. • Remove: Gear Positioning Lever Bolt [A] Gear Positioning Lever [B] Collar Spring [C] •...

  • Page 396

    9-40 CRANKSHAFT/TRANSMISSION Transmission • Install the gear positioning lever [A] as shown. Spring [B] Collar [C] Bolt [D] • Tighten: Torque - Gear Positioning Lever Bolt: 12 N·m (1.2 kgf·m, 106 in·lb) • Be sure to install the washer [A]. •...

  • Page 397: Transmission Shaft Removal, Transmission Shaft Installation

    CRANKSHAFT/TRANSMISSION 9-41 Transmission Transmission Shaft Removal • Split the crankcase (see Crankcase Splitting). • Remove the output shaft [A]. • Remove the shift forks (see Shift Drum and Fork Re- moval). • Remove the cover bolts [A] and cover [B]. •...

  • Page 398: Transmission Shaft Disassembly, Transmission Shaft Assembly

    9-42 CRANKSHAFT/TRANSMISSION Transmission Transmission Shaft Disassembly • Remove the transmission shafts (see Transmission Shaft Removal). • Remove the circlips, disassemble the transmission shafts. • The 5th gear [A] on the output shaft has three steel balls assembled into it for the positive neutral finder mecha- nism.

  • Page 399

    CRANKSHAFT/TRANSMISSION 9-43 Transmission • Fit the steel balls into the 5th gear holes in the output shaft, aligning three oil holes [D]. 5th Gear [A] Output Shaft [B] Steel Balls [C] CAUTION Do not apply grease to the balls to hold them in place.

  • Page 400

    9-44 CRANKSHAFT/TRANSMISSION Transmission 1. Drive Shaft 15. Output Shaft 2. Circlip, 33 mm (1.30 in.) 16. Needle Bearing 3. 2nd Gear 17. Dumper Cam Nut 4. Toothed Washer, 37 mm (1.46 in.) 18. Dumper Cam 5. Toothed Washer, 40.5 mm (1.59 in.) 19.

  • Page 401: Shift Drum And Fork Installation, Shift Drum Disassembly

    CRANKSHAFT/TRANSMISSION 9-45 Transmission Shift Drum and Fork Removal • Remove: Lower Crankcase Half (see Crankcase Splitting) External Shift Mechanism (see External Shift Mecha- nism Removal) Screws [A] Shift Drum Bearing Holder [B] • Pull out the shift rods [C], and take off the shift forks. •...

  • Page 402: Shift Drum Assembly, Shift Fork Bending, Shift Fork/gear Groove Wear

    9-46 CRANKSHAFT/TRANSMISSION Transmission 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. Torque - Shift Drum Cam Holder Bolt: 12 N·m (1.2 kgf·m, 106 in·lb) Shift Fork Bending •...

  • Page 403

    CRANKSHAFT/TRANSMISSION 9-47 Transmission Gear Dog and Gear Dog Hole Damage • Visually inspect the gear dogs [A] and gear dog holes [B]. Replace any damaged gears or gears with excessively worn dogs or dog holes.

  • Page 405: Table Of Contents

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

  • Page 406

    10-2 WHEELS/TIRES Exploded View...

  • Page 407

    WHEELS/TIRES 10-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Axle Clamp Bolts Front Axle Nut 13.0 93.7 Front Tire Pressure Measurement Sensor Bolt 0.46 40 in·lb Rear Axle Nut 13.0 93.7 Rear Tire Pressure Measurement Sensor Bolt 0.46 40 in·lb 6.

  • Page 408

    10-4 WHEELS/TIRES Specifications Item Standard Service Limit Wheels (Rims) Rim Runout: Axial TIR 0.5 mm (0.02 in.) or less TIR 1.0 mm (0.04 in.) Radial TIR 0.8 mm (0.03 in.) or less TIR 1.0 mm (0.04 in.) Axle Runout/100 mm (3.94 in.) TIR 0.03 mm (0.0012 in.) or less TIR 0.2 mm (0.01 in.) Wheel Balance 10 g (0.35 oz.) or less...

  • Page 409

    WHEELS/TIRES 10-5 Special Tools Bearing Driver Set: Bearing Remover Head, 25 × 28: 57001-1129 57001-1346 Jack: Bearing Remover Shaft, 13: 57001-1238 57001-1377 Bearing Remover Head, 20 × 22: 57001-1293...

  • Page 410: Wheels (rims), Front Wheel Removal, Front Wheel Installation

    10-6 WHEELS/TIRES Wheels (Rims) Front Wheel Removal • Remove: Front Caliper Mounting Bolts [A] Front Calipers [B] Front Fender [C] (see Front Fender Removal in the Frame chapter) ○ For the ZG1400A Models, remove the bolts [D] and rota- tion sensor [E]. •...

  • Page 411

    WHEELS/TIRES 10-7 Wheels (Rims) • Apply high-temperature grease to the grease seal lip. • Fit the collars [A] on the both sides of the hub. ○ The collars are identical. • Insert the axle from the right side. • Tighten the axle nut [B]. Right Axle Clamp Bolts [C] Left Axle Clamp Bolts [D] Viewed from Rear [E]...

  • Page 412: Rear Wheel Installation

    10-8 WHEELS/TIRES Wheels (Rims) • Remove: Saddlebags (see Rear Caliper Mounting Bolts [A] Rear Caliper [B] Caliper Bracket Bolt [C] • For the ZG1400A Models, remove the bolts [D] and rear wheel rotation sensor [E]. • Remove: Cotter Pin [A] Axle Nut [B] Washer [C] Caliper Bracket [D]...

  • Page 413

    WHEELS/TIRES 10-9 Wheels (Rims) • Pull the axle little and install the caliper bracket [A]. • Temporary install the caliper bracket bolt. • Tighten: Torque - Rear Axle Nut: 127 N·m (13.0 kgf·m, 94 ft·lb) Caliper Bracket Bolt: 64 N·m (6.5 kgf·m, 47 ft·lb) •...

  • Page 414: Wheel Coupling Removal, Wheel Coupling Installation, Wheel Inspection

    10-10 WHEELS/TIRES Wheels (Rims) Wheel Coupling Removal • Remove the rear wheel (see Rear Wheel Removal). • Remove the coupling retaining ring [A]. • Remove the wheel coupling [B] with a bearing puller if necessary. Wheel Coupling Installation • Replace the O-ring [A] and the retaining ring [B]. •...

  • Page 415: Axle Inspection, Coupling Damper Inspection, Balance Inspection, Balance Adjustment

    WHEELS/TIRES 10-11 Wheels (Rims) Axle Inspection • Remove the front and rear axles (see Front/Rear Wheel Removal). • Visually inspect the front and rear axle for damages. If the axle is damaged or bent, replace it. • Place the axle in V blocks that are 100 mm (3.94 in.) [A] apart, and set a dial gauge [B] on the axle at a point halfway between the blocks.

  • Page 416: Balance Weight Removal, Balance Weight Installation

    30 g (1.06 oz.) NOTE ○ Balance weights are available from Kawasaki dealers in 10, 20, and 30 grams (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 417

    WHEELS/TIRES 10-13 Wheels (Rims) • Check that the blade [A] and clip [B] are fully seated on the rim [C] and that the clip is hooked over the rib [D]. Left Side [E] Right Side [F]...

  • Page 418: Air Pressure Inspection/adjustment, Tire Inspection, Tire Removal

    10-14 WHEELS/TIRES Tires Air Pressure Inspection/Adjustment • Refer to the Air Pressure Inspection in the Periodic Main- tenance chapter. Tire Inspection • Refer to the Wheel/Tire Damage Inspection in the Peri- odic Maintenance chapter. Tire Removal • Remove: Wheel (see Front/Rear Wheel Removal) Valve Core (Let out the air) •...

  • Page 419: Tire Installation

    WHEELS/TIRES 10-15 Tires ○ Pull the opposite bead of the tire [A] upward. ○ Unscrew the bolt [B] and remove the tire pressure mea- surement sensor [C], spring and air valve. ○ Step on the side of the tire opposite the air valve, and start plying the tire off the rim near the air valve with tire iron.

  • Page 420

    10-16 WHEELS/TIRES Tires • Lubricate the valve seal with a soap and water solution or rubber lubricant. • Install the air valve [A] and sensor [B]. ○ Install the sensor position parallel to the rim line in either direction. Torque - Tire Pressure Measurement sensor: 4.5 N·m (0.46 kgf·m, 40 in·lb) Replacement Procedure •...

  • Page 421

    WHEELS/TIRES 10-17 Tires • Install the tire bead over the rim flange using a suitable commercially available tire changer. ○ Install the beads of the tire onto the rim followings the steps shown. Tire pressure measurement sensor [A] Opposite side of rim (180° from sensor) [B] Push on the first bead following direction shown in steps 1 and 2 Push on the second bead following direction shown in...

  • Page 422: 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 423: Hub Bearing, Hub Bearing Removal, Hub Bearing Installation, Hub Bearing Inspection

    WHEELS/TIRES 10-19 Hub Bearing Hub Bearing Removal • Remove the wheel (see Front/Rear Wheel Removal), and take out the following. Collars Coupling (Out of rear hub) Grease Seals • Use the bearing remover to remove the hub bearing [A]. CAUTION Do not lay the wheel on the ground with the disc facing down.

  • Page 424

    10-20 WHEELS/TIRES Hub Bearing Hub Bearing Lubrication NOTE ○ Since the hub bearings are packed with grease and sealed, lubrication is not required.

  • Page 425: Table Of Contents

    FINAL DRIVE 11-1 Final Drive Table of Contents Exploded View........11-2 Front Gear Case Disassembly..11-25 Specifications ........11-6 Front Gear Case Assembly..11-26 Special Tools ........11-7 Driven Gear Disassembly .... 11-27 Final Gear Case and Oil ....11-9 Driven Gear Assembly ....

  • Page 426

    11-2 FINAL DRIVE Exploded View...

  • Page 427

    FINAL DRIVE 11-3 Exploded View Front Gear Case Torque Fastener Remarks N·m kgf·m ft·lb Adjuster Locknut Bearing Retainer 55.1 Bearing Retainer Screw 0.71 62 in·lb Filler Plug 0.20 18 in·lb Final Gear Case Cover Bolts (M10) Final Gear Case Cover Bolts (M8) Final Gear Case Outer Cover Bolts 87 in·lb Gear Case Oil Drain Bolt...

  • Page 428

    11-4 FINAL DRIVE Exploded View...

  • Page 429

    FINAL DRIVE 11-5 Exploded View Final Gear Case Torque Fastener Remarks N·m kgf·m ft·lb Bearing Retainer Bolts 0.90 78 in·lb Damper Cam Nut 21.4 MO, R Driven Gear Assy Mounting Bolts 13.3 95.9 Driven Gear Bolt Drive Gear Nut 27.0 MO, S Front Gear Case Bolt (L = 50 mm) Front Gear Case Bolts (L = 95 mm)

  • Page 430

    11-6 FINAL DRIVE Specifications Item Standard Final Gear Case Oil Grade API GL-5 hypoid gear oil Viscosity When above 5°C (41°F) SAE90 When below 5°C (41°F) SAE80 Oil level Filler opening top Amount about 160 mL (5.41 US oz.) 0.10 ∼ 0.20 mm (0.0039 ∼ 0.0079 in.) (at gear hub Final Bevel Gear Backlash splines) Preload for Pinion Gear Bearing...

  • Page 431

    FINAL DRIVE 11-7 Special Tools Bearing Puller: Oil Seal & Bearing Remover: 57001-158 57001-1058 Bearing Puller Adapter: Bearing Driver Set: 57001-317 57001-1129 Bearing Driver, Drive Shaft Holder, m1.25: 57001-382 57001-1702 Damper Cam Holder: Retainer Wrench: 57001-1025 57001-1703 Driven Gear Holder, m2: Base Set: 57001-1027 57001-1704...

  • Page 432

    11-8 FINAL DRIVE Special Tools Bevel Gear Holder: 57001-1706...

  • Page 433: Final Gear Case And Oil

    FINAL DRIVE 11-9 Final Gear Case and Oil Oil Level Inspection • Refer to Final Gear Case Oil Level Inspection in Periodic Maintenance chapter (see Final Gear Case Oil Level In- spection in Periodic Maintenance chapter). Oil Change • Refer to Final Gear Case Oil Change in Periodic Mainte- nance chapter (see Final Gear Case Oil Change in Peri- odic Maintenance chapter).

  • Page 434: Final Gear Case Installation

    11-10 FINAL DRIVE Final Gear Case and Oil • Remove the upper side bolt. • Remove the final gear case [A] by taking off the lower bolts [B]. NOTE ○ If the final gear case is full of oil, place the case so that the breather [A] is on top, and joint portion [B] of the case is upward [C] for pervent the oil leak.

  • Page 435

    FINAL DRIVE 11-11 Final Gear Case and Oil Final Gear Case Disassembly • Drain the oil (see Oil Change). • Remove the final gear case. • Using the hub assembly [A], remove the pinion gear as- sembly nut. ○ Insert the wooden bar [C] between the spokes. CAUTION Do not lay the wheel down on one of the discs.

  • Page 436

    11-12 FINAL DRIVE Final Gear Case and Oil • Remove the sliding joint [A] with washer [B], pinion gear assembly [C] and lock plate. • Remove the lock pin and plug. • Final Gear Case Cover Bolts [A]. • Use three tapped holes [A] to lift the ring gear assy from the gear case.

  • Page 437

    FINAL DRIVE 11-13 Final Gear Case and Oil ○ Remove the small ring gear oil seal if damaged. Special Tool - Oil Seal & Bearing Remover [D]: 57001-1058 • Unscrew the bearing retainer bolt [A] and washer [B]. • Pull out the needle bearing [C]. Special Tool - Oil Seal &...

  • Page 438

    11-14 FINAL DRIVE Final Gear Case and Oil Final Gear Case 1. Sliding Joint 13. Ring Gear Shim(s) 2. Pinion Gear Nut 14. Ring Gear 3. Washer 15. Ball Bearing Retainer 4. O-ring 16. Ball Bearing 5. Pin 17. Pinion Gear Shim(s) 6.

  • Page 439

    FINAL DRIVE 11-15 Final Gear Case and Oil • Replace the needle bearings [A] with new ones. • Apply a hypoid gear oil to the roller parts of the needle bearings. NOTE ○ Install the bearing so that the marked side faces out. ○...

  • Page 440

    11-16 FINAL DRIVE Final Gear Case and Oil • Blow the breather hole [A] in the final gear case clean with compressed air. • Install the shim(s) [A] and final gear case cover [B]. ○ Reinstall the original ring gear shim(s) to keep the gear backlash and the tooth contact unchanged.

  • Page 441: Sliding Joint Inspection, Final Bevel Gear Adjustment

    FINAL DRIVE 11-17 Final Gear Case and Oil • Install the sliding joint [A]. • Using the hub assembly [B], tighten the pinion gear as- sembly nut. ○ Insert the wooden bar [C] between the sporks. Torque - Pinion Gear Assembly Nut: 130 N·m (13.3 kgf·m, 95.9 ft·lb) •...

  • Page 442

    11-18 FINAL DRIVE Final Gear Case and Oil Pinion Gear Shims for Tooth Contact Ring Gear Shims for Backlash Adjustment Adjustment Thickness (mm) Parts Number Thickness (mm) Parts Number 0.15 (0.0059 in.) 92180-0263 0.10 (0.0039 in.) 92025-1733 0.5 (0.02 in.) 92180-0264 0.15 (0.0059 in.) 92025-1734...

  • Page 443

    FINAL DRIVE 11-19 Final Gear Case and Oil • Mount a dial gage [A] on a vise so that the tip of the gage is against the splines of the ring gear hub. • To measure the backlash, turn the ring gear hub [B] back and forth [C].

  • Page 444

    11-20 FINAL DRIVE Final Gear Case and Oil • Remove the ring gear assy and pinion gear assy to check the couvex side pattern and concave side pattern of the bevel gear teeth. Good contact is achieved when the pat- tern of tooth contact is visible in the inside diameter side and center of the tooth flank.

  • Page 445: Propeller Shaft, Propeller Shaft Removal

    FINAL DRIVE 11-21 Propeller Shaft Propeller Shaft Removal • Remove: Final Gear Case (see Final Gear Case Removal) Bolts [A] • Remove the frame side bracket [B] with the footpeg [C] And shift rod [D]. • Open the clamp portion [A] and remove the band [B]. •...

  • Page 446: Propeller Shaft Installation

    11-22 FINAL DRIVE Propeller Shaft ○ Move back the propeller shaft and slip the propeller shaft off the driven gear joint while pushing on the lockpin. Propeller Shaft [A] Universal Joint [B] Lockpin [C] Spring [D] Driven Gear Joint [E] Propeller Shaft Installation •...

  • Page 447: Propeller Shaft Inspection

    FINAL DRIVE 11-23 Propeller Shaft • Pinch the clamp portion [B] of the band [B]. Propeller Shaft Inspection • Check that the universal joints [A] works smoothly without rattling or sticking. If it does not work smoothly, the needle bearings of the universal joint are damaged.

  • Page 448

    11-24 FINAL DRIVE Front Bevel Gears Front Gear Case Removal • Drain the coolant (see Coolant Change in the Periodic Maintenance chapter). • Remove: Propeller Shaft (see Propeller Shaft Removal) Clutch Slave Cylinder (see Clutch Slave Cylinder Re- moval in the Clutch chapter) Water Pump (see Water Pump Removal in the Cooling System chapter) •...

  • Page 449: Front Gear Case Disassembly

    FINAL DRIVE 11-25 Front Bevel Gears • Tighten the front gear case bolts to the specified torque. Bolts M8 × 92 [A] Bolts M8 × 95 [B] [F] Bolts M8 × 35 [C] [D] Bolts M8 × 50 [E] Torque - Front Gear Case Bolts: Bolts [A] [B] [E]: 29 N·m (3.0 kgf·m, 22 ft·lb) Bolts [C] [D] [F] : 20 N·m (2.0 kgf·m, 15 ft·lb) ○...

  • Page 450: Front Gear Case Assembly

    11-26 FINAL DRIVE Front Bevel Gears ○ Unscrew the drive gear nut [A] while holding the drive gear shaft with the drive gear holder [B]. Front Gear Case [C] Vise [D] Special Tool - Drive Gear Holder, m1.25: 57001-1702 • Pull off the drive gear shaft [A], the drive gear [B], and shim(s) [C].

  • Page 451: Driven Gear Disassembly

    FINAL DRIVE 11-27 Front Bevel Gears ○ Stake [A] the nut [B] to secure it in place. CAUTION When staking the nut, be careful not to apply shock to the shaft and its bearing. Such a shock could damage the shaft and/or bearing. •...

  • Page 452: Driven Gear Assembly

    11-28 FINAL DRIVE Front Bevel Gears Driven Gear Assembly • Replace the driven gear bolt with a new one. ○ The drive and driven gears are lapped as a set at the fac- tory to get the best tooth contact. They must be replaced as a set.

  • Page 453: Damper Cam Installation

    FINAL DRIVE 11-29 Front Bevel Gears Damper Cam Installation • Replace the damper cam nut with a new one. • Fit the damper cam holder [A] on the damper cam [B] and touch in to the frame. • Apply molybdenum disulfide oil to the threads and the seating surface of the damper cam nut [C].

  • Page 454: Preload Adjustment

    11-30 FINAL DRIVE Front Bevel Gears Front Bevel Gear Adjustment ○ When any of the backlash-related parts are replaced, or the driven gear bolt is loosened; even if the purpose is not to replace the parts, be sure to check and adjust the bearing preload, the bevel gear backlash, and tooth con- tact by replacing shims.

  • Page 455

    FINAL DRIVE 11-31 Front Bevel Gears Preload Measurement with Spring Scale • Hold the bearing housing in a vise so that the gear shaft axis is vertical. • Hook [C] the spring scale [B] on the driven gear holder [A] at a point 200 mm (7.9 in.) [D] apart from the center of the gear shaft.

  • Page 456

    11-32 FINAL DRIVE Front Bevel Gears Bearing Preloading Mechanism 1. Bearing Housing 5. Tapered Roller Bearing 3. Spacer 2. Tapered Roller Bearing 4. Collar Before Tightening [A] Under No Preload [C] Under Preload [E] After Tightening [B] Initial Clearance [D] No Clearance [F] Backlash Adjustment •...

  • Page 457

    FINAL DRIVE 11-33 Front Bevel Gears • Install a holder [A] with 6 mm bolts and nuts on the front gear case to mount a dial gage. • Set up a dial gage against a drive gear tooth to check gear backlash.

  • Page 458

    11-34 FINAL DRIVE Front Bevel Gears • Turn the driven gear for 3 or 4 revolutions back and forth, while creating a drag on the drive gear. • Check the couvex side pattern and concave side pattern of the bevel gear teeth. Good contact is achieved when pattern of tooth contact is visible in the inside diameter side and center of the tooth flank.

  • Page 459

    FINAL DRIVE 11-35 Front Bevel Gears Cam Damper Inspection • Visually inspect the spring [A], cam follower [B], damper cam [C], and output shaft [D]. Replace the damaged parts.

  • Page 460: Bearing And Oil Seal

    11-36 FINAL DRIVE Bearing and Oil Seal Ball or Needle Bearing Replacement • Using the bearing driver set or the oil seal & bearing re- mover, remove the bearings. Special Tools - Oil Seal & Bearing Remover: 57001-1058 Bearing Driver Set: 57001-1129 NOTE ○...

  • Page 461: Needle Bearing Inspection, Oil Seal Inspection

    FINAL DRIVE 11-37 Bearing and Oil Seal Tapered Roller Bearing Inspection CAUTION Do not remove the tapered roller bearing for inspec- tion. Removal may damage them. • Visually inspect the bearing in the front for abrasion, color change, or other damage. If there is any doubt as to the condition of the bearing, replace it.

  • Page 463: Table Of Contents

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

  • Page 464: Table Of Contents

    12-2 BRAKES Inquiries to Rider....................... 12-39 Self-diagnosis Outline ....................... 12-41 Self-diagnosis Procedures ....................12-41 Service Code Clearing Procedures................... 12-42 How to Read Service Codes..................... 12-44 How to Erase Service Codes .................... 12-44 ABS Indicator Light (LED) Inspection ................12-46 ABS Indicator Light (LED) is Unlit (When the Key Knob turned to ON) ......12-46 ABS Indicator Light (LED) Lights (When the Motorcycle is Running, - No Service Code) 12-47...

  • Page 465

    BRAKES 12-3 Exploded View Dummy Page...

  • Page 466

    12-4 BRAKES Exploded View ZG1400A Models...

  • Page 467

    BRAKES 12-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb 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 0.60 52 in·lb Brake Pipe Joint Nuts Brake Reservoir Bolt 0.80 69 in·lb Brake Reservoir Screw...

  • Page 468

    12-6 BRAKES Exploded View...

  • Page 469

    BRAKES 12-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Bleed Valves 0.80 69 in·lb Brake Caliper Holder Plate Bolt Brake Hose Banjo Bolts Brake Pedal Bolt 0.90 78 in·lb Brake Pipe Joint Nuts Rear Brake Disc Mounting Bolts Rear Brake Pad Pin 17.2 Rear Caliper Assembly Bolts Rear Caliper Mounting Bolts...

  • Page 470

    12-8 BRAKES Exploded View ZG1400B Models...

  • Page 471

    BRAKES 12-9 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb 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 0.60 52 in·lb Brake Reservoir Bolt 0.80 69 in·lb Brake Reservoir Screw 0.13 12 in·lb...

  • Page 472

    12-10 BRAKES Exploded View...

  • Page 473

    BRAKES 12-11 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Bleed Valves 0.80 69 in·lb Brake Caliper Holder Plate Bolt Brake Hose Banjo Bolts Brake Pedal Bolt 0.90 78 in·lb Rear Brake Disc Mounting Bolts Rear Brake Pad Pin 17.2 Rear Caliper Assembly Bolts Rear Caliper Mounting Bolts Rear Master Cylinder Mounting Bolts...

  • Page 474

    12-12 BRAKES Specifications Item Standard Service Limit Brake Lever, Brake Pedal Brake Lever Position 6-way adjustable (to suit rider) – – – Brake Lever Free Play Non-adjustable – – – Pedal Free Play Non-adjustable – – – Pedal Position About 35 mm (1.38 in.) below footpeg top –...

  • Page 475

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

  • Page 476: Brake Lever, Brake Pedal, Brake Lever Position Adjustment, Brake Pedal Position Inspection

    12-14 BRAKES Brake Lever, Brake Pedal Brake Lever Position Adjustment The brake lever adjuster has 6 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 477: Brake Pedal Installation

    BRAKES 12-15 Brake Lever, Brake Pedal • Remove: Hook Bolt [A] Rear Brake Light Switch Spring [B] Return Spring [C] Cotter Pin [D] Joint Pin [E] • Remove the mounting bolt [F] and take out the brake pedal. Brake Pedal Installation •...

  • Page 478

    12-16 BRAKES Calipers Front Caliper Removal • Loosen the banjo bolt [A] at the brake hose lower end, and tighten it loosely. • Unscrew the caliper mounting bolts [B], and detach the caliper [C] from the disc. CAUTION Do not loosen the caliper assembly bolts. Take out only the caliper mounting bolts for caliper removal.

  • Page 479: Caliper Installation, Front Caliper Disassembly, Front Caliper Assembly, Rear Caliper Disassembly

    BRAKES 12-17 Calipers Caliper Installation • Install the caliper and brake hose lower end. ○ Replace the washers on each side of hose fitting with new ones. • Tighten: Torque - Caliper Mounting Bolts Front: 34 N·m (3.5 kgf·m, 25 ft·lb) Rear: 25 N·m (2.5 kgf·m, 18 ft·lb) Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb)

  • Page 480

    12-18 BRAKES Calipers Caliper Fluid Seal Damage The fluid seal (piston seal) [A] is placed around the pis- ton to maintain clearance between the pad and the disc. If the seal is in a poor condition, it could lead the pad to wear excessively or the brake to drag, which may cause the tem- perature of the discs or the brake fluid to increase.

  • Page 481

    BRAKES 12-19 Calipers Caliper Piston and Cylinder Damage • Visually inspect the pistons [A] and cylinder surfaces [B]. Replace the caliper if the cylinder and piston are badly scores or rusty.

  • Page 482: Brake Pads, Front Brake Pad Installation

    12-20 BRAKES Brake Pads Front Brake Pad Removal • Unscrew the pad pins [A]. • Remove: Pad Pins [A] Pad Springs [B] Brake Pads [C] Front Brake Pad Installation • Push the caliper pistons in by hand as far as they will go. •...

  • Page 483: Rear Brake Pad Installation

    BRAKES 12-21 Brake Pads Rear Brake Pad Removal • Remove: Pad Pin [A] Pad Spring [B] Brake Pads [C] Rear Brake Pad Installation • Push the caliper pistons in by hand as far as they will go. • Install the outside pad [A] and insert the pad pin [B] as shown in the figure.

  • Page 484: Master Cylinder, Front Master Cylinder Removal, Front Master Cylinder Installation

    12-22 BRAKES Master Cylinder Front Master Cylinder Removal • Remove the banjo bolt [A] to disconnect the brake hose from the master cylinder (see Brake Hose Removal/In- stallation). • Unscrew the clamp bolts [B], and take off the master cylin- der [C] as an assembly with the reservoir, brake lever, and brake switch installed.

  • Page 485: Rear Master Cylinder Removal, Rear Master Cylinder Installation, Front Master Cylinder Disassembly

    BRAKES 12-23 Master Cylinder Rear Master Cylinder Removal • Unscrew the brake hose banjo bolt [A] and brake hose [B]. • Remove: Bolts [C] Foot Guard [D] Cotter Pin [E] Joint Pin [E] Rear Master Cylinder • Slide out the clamp [G]. •...

  • Page 486

    12-24 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 487: Brake Disc, Brake Disc Removal, Brake Disc Installation

    BRAKES 12-25 Brake Disc Brake Disc Removal • Remove the wheels (see Front/Rear Wheel Removal in the Wheels/Tires chapter). • Unscrew the mounting bolts, and take off the disc. ○ Remove the sensor rotor (ZG1400A Models). Brake Disc Installation • Install the brake disc on the wheel so that the marked side [A] faces out.

  • Page 488: Brake Fluid, Brake Line Bleeding

    12-26 BRAKES Brake Fluid Brake Fluid Level Inspection • Refer to the Brake Fluid Level Inspection in the Periodic Maintenance chapter. Brake Fluid Change • Refer to the Brake Fluid Change in the Periodic Mainte- nance chapter. Brake Line Bleeding The brake fluid has a very low compression coefficient so that almost all the movement of the brake lever or pedal is transmitted directly to the caliper for braking action.

  • Page 489

    BRAKES 12-27 Brake Fluid • Remove the rubber cap from the bleed valve [A] on the front master cylinder. • Attach a clear plastic hose [B] to the bleed valve, and run the other end of the hose into a container. •...

  • Page 490

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

  • Page 491

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

  • Page 492: Brake Hose

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

  • Page 493: Parts Location

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

  • Page 494

    ABS System Wiring Diagram 1. Steering Lock Unit 2. ABS Self-diagnosis Terminal 3. Rear Wheel Rotation Sensor 4. Front Wheel Rotation Sensor 5. ABS Kawasaki Self-diagnosis System Connector 6. ABS Hydraulic Unit 7. Meter Unit 8. Joint Connector 8 9. Joint Connector 9 10.

  • Page 495

    6. Unused 7. Unused 8. Power Supply to ABS Solenoid Valve Relay 9. Power Supply to ABS Motor Relay 10. ABS Kawasaki Self-diagnosis System Terminal 11. Unused 12. Power Supply to Front Wheel Rotation Sensor 13. ABS Self-diagnosis Terminal 14. Unused 15.

  • Page 496: Abs Servicing Precautions

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

  • Page 497

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

  • Page 498: Abs Troubleshooting Outline

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

  • Page 499

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

  • Page 500

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

  • Page 501

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

  • Page 502

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

  • Page 503

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

  • Page 504: Service Code Clearing Procedures

    12-42 BRAKES Anti-Lock Brake System (Equipped Models) • Remove the seat (see Seat Removal in the Frame chap- ter). • Ground the self-diagnosis terminal [A] (Gray) to the ground terminal [B] (Black/Yellow), using a lead. • Push and turn the key knob to ON. ○...

  • Page 505

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

  • Page 506

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

  • Page 507: Service Code Table

    BRAKES 12-45 Anti-Lock Brake System (Equipped Models) Service Code Table Service ABS Indicator Light (LED) Problems Light State Code Rear inlet solenoid valve trouble (shorted or open, stuck valve (ON)) Rear outlet solenoid valve trouble (shorted or open, stuck valve (ON)) Front inlet solenoid valve trouble (shorted or open, stuck valve (ON)) Front outlet solenoid valve trouble (shorted...

  • Page 508: Abs Indicator Light (led) Inspection

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

  • Page 509: Solenoid Valve Inspection (service Code)

    BRAKES 12-47 Anti-Lock Brake System (Equipped Models) • Do the 3rd step test. ○ Disconnect the ABS hydraulic unit connector. ○ Check for continuity between the black/white lead termi- nal of the main harness side connector [A] and black/white lead terminal of the main harness side connector [B]. If there is the continuity in the lead, replace the ABS hy- draulic unit.

  • Page 510

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

  • Page 511

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

  • Page 512

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

  • Page 513

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

  • Page 514

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

  • Page 515

    BRAKES 12-53 Anti-Lock Brake System (Equipped Models) Rear Wheel Rotation Sensor Wiring Inspection (Service Code 45) • Do the 1st step test. ○ Disconnect the ABS hydraulic unit connector and rear wheel rotation sensor connector. ○ Short the black and white/red lead terminals of the main harness side connector [A] with a jumper lead, and check for continuity between the black and white/red lead termi- nals of the main harness side connector [B].

  • Page 516

    12-54 BRAKES Anti-Lock Brake System (Equipped Models) • Do the 2nd step test. ○ Connect the ignition switch connector and ABS hydraulic unit connector. ○ Check the battery terminal voltage, connect the hand tester to the brown terminal of ignition switch connector [A] and ground.

  • Page 517: Abs Hydraulic Unit Removal

    BRAKES 12-55 Anti-Lock Brake System (Equipped Models) • Do the 2nd step test. ○ Connect the steering lock connector and ABS hydraulic unit connector. ○ Check the battery terminal voltage, connect the hand tester to the brown terminal of ignition switch connector [A] and ground.

  • Page 518

    12-56 BRAKES Anti-Lock Brake System (Equipped Models) • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Battery (see Battery Removal in the Electrical System chapter) Bolts [A] Cover [B] • Clean the ABS hydraulic unit. CAUTION Clean all fittings on the ABS hydraulic unit and the rear master cylinder because dirt around the banjo...

  • Page 519: Abs Hydraulic Unit Installation

    BRAKES 12-57 Anti-Lock Brake System (Equipped Models) • Remove the bolts [A] and bracket [B]. CAUTION The ABS hydraulic unit has been adjusted and set with precision at the factory. Do not try to disas- semble and repair the ABS hydraulic unit. ABS Hydraulic Unit Installation •...

  • Page 520: Abs Hydraulic Unit Inspection, Front Wheel Rotation Sensor Removal, Front Wheel Rotation Sensor Installation

    12-58 BRAKES Anti-Lock Brake System (Equipped Models) ABS Hydraulic Unit Inspection • Remove the ABS hydraulic unit (see ABS Hydraulic Unit Removal). • Visually inspect the ABS hydraulic unit. Replace the ABS hydraulic unit if any of them are cracked, or otherwise damaged.

  • Page 521

    BRAKES 12-59 Anti-Lock Brake System (Equipped Models) Rear Wheel Rotation Sensor Removal CAUTION The wheel rotation sensor should be handled care- fully, never struck sharply, as with a hammer, or al- lowed to fall on a hard surface since the wheel rota- tion sensor is precision made.

  • Page 522: Wheel Rotation Sensor Inspection, Wheel Rotation Sensor Air Gap Inspection, Wheel Rotation Sensor Rotor Inspection

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

  • Page 523: Fuse Installation

    BRAKES 12-61 Anti-Lock Brake System (Equipped Models) If the rotor is deformed or damaged (chipped teeth [A]), replace the sensor rotor with a new one. If there is iron or other magnetic deposits [B], remove the deposits. ABS Solenoid Valve Relay Fuse (20 A) Removal •...

  • Page 525: Table Of Contents

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

  • Page 526

    13-2 SUSPENSION Exploded View...

  • Page 527

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

  • Page 528

    13-4 SUSPENSION Exploded View...

  • Page 529

    SUSPENSION 13-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Axle Bracket Locknut 10.0 72.3 Final Gear Case Locknut 10.0 72.3 Rear Shock Absorber Nut (Lower) Rear Shock Absorber Nut (Upper) Rocker Arm Nut Swingarm Pivot Collar Locknut 10.0 72.3 Swingarm Pivot Shaft Swingarm Pivot Shaft Nut 11.0...

  • Page 530

    13-6 SUSPENSION Specifications Item Standard Front Fork (Per One Unit) Fork Inner Tube Diameter 43 mm (1.7 in.) Air Pressure Atmospheric pressure (non-adjustable) Rebound Damper Setting 5th click from the 1st click of the fully clockwise position (Usable range: 0 ←→ 11 clicks) Fork Spring Preload Setting Adjuster protrusion is 14 mm (0.55 in.) (Usable range: 4 ∼...

  • Page 531

    SUSPENSION 13-7 Special Tools Inside Circlip Pliers: Fork Piston Rod Puller, M12 × 1.25: 57001-143 57001-1289 Oil Seal & Bearing Remover: Fork Oil Level Gauge: 57001-1058 57001-1290 Bearing Driver Set: Bearing Remover Head, 20 × 22: 57001-1129 57001-1293 Jack: Bearing Remover Shaft, 13: 57001-1238 57001-1377 Fork Cylinder Holder:...

  • Page 532

    13-8 SUSPENSION Special Tools Fork Spring Compressor: Stem Bearing Driver, 28: 57001-1540 57001-1610 Fork Spring Compressor: Spacer, 57001-1587 57001-1636 Swingarm Pivot Nut Wrench: Spacer 28: 57001-1597 57001-1663 Needle Bearing Driver, 17/ 18: Needle Bearing Driver, 20 & Spacer, 28: 57001-1609 57001-1678...

  • Page 533: 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 5th click from the 1st click of the fully clockwise position.

  • Page 534: Front Fork Installation

    13-10 SUSPENSION Front Fork Front Fork Removal (Each Fork Leg) • Remove: Front Wheel (see Front Wheel Removal in the Wheels/Tires chapter) Front Fender (see Front Fender Removal in the Frame chapter) Loosen the upper fork clamp bolt [A] and fork top plug [B] beforehand if the fork leg is to be disassembled.

  • Page 535

    SUSPENSION 13-11 Front Fork Front Fork Oil Change • Remove the front fork (see Front Fork Removal). • Unscrew the top plug [A] out of the outer tube. • Install the clamps [A] as shown in the figure. NOTE ○ Set the clamps so that the cutout [B] of the upper side does not touch the tongue shape of stopper, pull up the outer tube [C] to hold it by the clamps, and then tighten...

  • Page 536

    13-12 SUSPENSION Front Fork • Screw in nuts [A] come out the piston rod nut. • Holding the piston rod nut with a wrench [A], remove the top plug [B] from the piston rod. • Remove: Washer [A] Collar [B] Rebound Damping Adjuster Rod [C] Fork Spring [D] •...

  • Page 537

    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 538

    13-14 SUSPENSION Front Fork • Set the fork spring compressor on the washer using the outer tube as a guide. Special Tools - Fork Spring Compressor: 57001-1540 Fork Spring Compressor: 57001-1587 NOTE ○ Set the clamps so that the cutout [A] of the upper side does not fit the hole [B] of washer [C], pull up the outer tube to hold it by the clamps, and then tighten the two bolts.

  • Page 539: Front Fork Disassembly

    SUSPENSION 13-15 Front Fork • Check the O-ring [A] on the top plug and replace it with a new one if damaged. • Screw in the top plug [B] stopped onto the piston rod. • Holding the top plug with a wrench [C], tighten the piston rod nut [D] against the top plug.

  • Page 540: Front Fork Assembly

    13-16 SUSPENSION Front Fork Front Fork Assembly • Replace the following parts with a new one. Oil Seal Bottom Allen Bolt Gasket • Insert the cylinder unit [A] into the inner tube [B]. • Stop the cylinder from turning by using the fork cylinder holder.

  • Page 541: Inner Tube Inspection, Dust Seal Inspection, Spring Tension

    SUSPENSION 13-17 Front Fork Inner Tube Inspection • Visually inspect the inner tube [A], and repair any dam- age. • Nicks or rust damage can sometimes be repaired by using a wet-stone to remove sharp edges or raised areas which cause seal damage.

  • Page 542: Rear Shock Absorber, Rear Shock Absorber Removal

    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, until you feel a click. ○ The standard adjuster setting for an average-build rider of 68 kg (150 lb) with no passenger and no accessories is the 1 1/4 turns out from the fully clockwise position.

  • Page 543: Rear Shock Absorber Installation

    SUSPENSION 13-19 Rear Shock Absorber • Remove: Bolts [A] • Clear the hose form the clamp [B]. • Squeeze the brake lever slowly and it with a band [A]. WARNING Be sure to hold the front brake when removing the shock absorber, or the motorcycle may fall over.

  • Page 544

    13-20 SUSPENSION Rear Shock Absorber Rear Shock Absorber Inspection • Remove the rear shock absorber [A] (see Rear Shock Absorber Removal). • Visually inspect the following items. Smooth Stroke Oil Leakage Crack or Dent If there is any damage to the rear shock absorber, replace •...

  • Page 545: Swingarm Removal

    SUSPENSION 13-21 Swingarm Swingarm Removal • Use the center stand to support the motorcycle uptight. • Remove: Rear Wheel (see Rear Wheel Removal in the Wheels/Tires chapter) Propeller Shaft (see Propeller Shaft Removal in the Final Drive chapter) Muffler Body (see Muffler Body Removal in the Engine Tope End chapter) Bolts [A] Clamps [B]...

  • Page 546: Swingarm Installation

    13-22 SUSPENSION Swingarm • Unscrew the swingarm pivot shaft [A] few times. ○ Turn out the swingarm pivot adjusting collar. • Pull out the pivot shaft right side of the motorcycle and remove the swingarm. Swingarm Installation • Apply plenty of grease to the lip of the oil seals [A]. •...

  • Page 547: Swingarm Bearing Removal, Swingarm Bearing Installation

    SUSPENSION 13-23 Swingarm • Tighten the pivot shaft nut [A]. Torque - Swingarm Pivot Shaft Nut: 108 N·m (11.0 kgf·m, 80 ft·lb) • Install the removed parts (see appropriate chapters). Swingarm Bearing Removal • Remove: Swingarm (see Swingarm Removal) Collar [A] Grease Seals [B] Sleeve [C] Circlip [D] (Right Side)

  • Page 548: Swingarm Bearing, Sleeve Inspection

    13-24 SUSPENSION Swingarm • Install the needle bearings [A], ball bearing [B] and oil seals [C] position as shown in the figure. ○ Press in the ball bearing until it is bottomed. Circlip [D] 31.6 ∼ 32.4 mm (1.24 ∼ 1.28 in.) [E] 27.1 ∼...

  • Page 549: Torque Rod Removal, Torque Rod Installation

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

  • Page 550: Torque Rod Bearing Removal, Torque Rod Bearing Installation

    13-26 SUSPENSION Swingarm • Install the front bolt [A] with washer [B]. • Tighten: Torque - Torque Rod Bolts: 59 N·m (6.0 kgf·m, 44 ft·lb) Torque Rod Bearing Removal • Remove: Torque Rod Sleeve [A] Grease Seals [B] Needle Bearing [C] ○...

  • Page 551

    SUSPENSION 13-27 Swingarm NOTE ○ Install the Needle bearing of the frame so that the man- ufacture’s marks side OUT. • Install the needle bearing [A] position as shown in the figure. 5.1 ∼ 5.9 mm (0.20 ∼ 0.23 in.) [B] Sleeve [C] Frame [D] Left Side [E]...

  • Page 552: Tie-rod, Rocker Arm, Tie-rod Removal, Tie-rod Installation, Rocker Arm Removal, Rocker Arm Installation

    13-28 SUSPENSION Tie-Rod, Rocker Arm Tie-Rod Removal • Use the center stand to support the motorcycle upright. • Squeeze the brake lever slowly and hold it with a band [A]. • Remove: Upper Tie-Rod Nut and Bolt [A] Lower Tie-Rod Nut and Bolt [B] Tie-Rods [C] Tie-Rod Installation •...

  • Page 553: Tie-rod And Rocker Arm Bearing Installation

    SUSPENSION 13-29 Tie-Rod, Rocker Arm Tie-Rod and Rocker Arm Bearing Removal • Remove: Tie-Rods (see Tie-Rod Removal) Rocker Arm (see Rocker Arm Removal) Sleeves [A] Grease Seals [B] Swingarm [C] (see Swingarm Removal) • Remove the needle bearings [D], using the bearing re- mover head and bearing remover shaft.

  • Page 554

    13-30 SUSPENSION Tie-Rod, Rocker Arm ○ Screw the needle bearing driver [A] into the driver holder [B]. ○ Insert the needle bearing driver into the needle bearing [C] and press the needle bearing into the housing until the driver contacts the end surface of the housing. Bearing Pressing Depth: 5.5 mm (0.22 in.) [D] 5.0 mm (0.20 in.) [E] NOTE...

  • Page 555

    SUSPENSION 13-31 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 locker arm, or tie-rod sleeves [A] and needle bearings [B]. • The rollers in a needle bearing normally wear very little, and wear is difficult to measure.

  • Page 557

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

  • Page 558

    14-2 STEERING Exploded View...

  • Page 559

    STEERING 14-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Fork Clamp Bolts (Lower) Front Fork Clamp Bolts (Upper) Handlebar Bolts Handlebar Holder Bolts Left Switch Housing Screws 0.36 31 in·lb Right Switch Housing Screws 0.36 31 in·lb Steering Stem Head Bolt 11.0 79.7 Steering Stem Nut...

  • Page 560

    14-4 STEERING Special Tools Head Pipe Outer Race Press Shaft: Steering Stem Bearing Driver, 42.5: 57001-1075 57001-1344 Steering Stem Nut Wrench: Steering Stem Bearing Driver Adapter, 41.5: 57001-1100 57001-1345 Bearing Driver Set: Head Pipe Outer Race Driver, 55: 57001-1129 57001-1446...

  • Page 561

    STEERING 14-5 Steering Steering Inspection • Refer to the Steering Play Inspection in the Periodic Main- tenance chapter (see Steering Play Inspection in the Pe- riodic Maintenance chapter). Steering Adjustment • Refer to the Steering Play Adjustment in the Periodic Maintenance chapter (see Steering Play Adjustment in the Periodic Maintenance chapter).

  • Page 562: Steering Stem

    14-6 STEERING Steering Stem Stem, Stem Bearing Removal • Remove: Inner Cover (see Inner Cover Removal in the Frame chapter) Storage Compartment Cover (see Storage Compart- ment Removal in the Frame chapter) Front Wheel (see Front Wheel Removal in the Wheels/Tires chapter) Handlebars Holders [A] with Handlebar Assemblys (see Handlebar Holder Removal)

  • Page 563

    STEERING 14-7 Steering Stem • Bend the claws [A] of lock washer straighten. • Remove the steering stem locknut [B]. Special Tool - Steering Stem Nut Wrench: 57001-1100 • Remove the lock washer. • Pulling up the stem base, and remove the steering stem nut [A] with stem cap [B].

  • Page 564

    14-8 STEERING Steering Stem • Replace the bearing inner races and oil seal with new ones. • Apply grease to the oil seal. • Install the oil seal [A] on the steering stem, and drive the lower ball bearing inner race [B] applied the grease onto the stem.

  • Page 565

    STEERING 14-9 Steering Stem • First tighten the steering stem locknut by hand until the resistance is felt fully, then tighten the steering stem lock nut so that align the claw [A] of stem lock nut to the notch [B] of stem nut by hand. •...

  • Page 566

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

  • Page 567

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

  • Page 568

    14-12 STEERING Handlebar • Install: Throttle Grip Throttle Cable Tips Throttle Cases ○ Fit the projection [A] into a small hole [B] in the handlebar. • Apply a non-permanent locking agent to the threads of the handlebar weight bolts, and tighten them. Handlebar Holder Removal •...

  • Page 569: Table Of Contents

    FRAME 15-1 Frame Table of Contents Exploded View........15-2 Fenders ..........15-22 Seat ........... 15-10 Front Fender Removal ....15-22 Seat Removal ......15-10 Front Fender Installation ....15-22 Seat Installation ......15-10 Flap and Rear Fender Removal... 15-22 Fairings..........15-11 Flap and Rear Fender Installation 15-24...

  • Page 570

    15-2 FRAME Exploded View...

  • Page 571

    FRAME 15-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Center Stand Bolts Front Footpeg Bracket Bolts Sidestand Bolt Sidestand Bracket Bolts Sidestand Switch Bolt 0.90 78 in·lb G: Apply grease. L: Apply a non-permanent locking agent. R: Replacement Parts...

  • Page 572

    15-4 FRAME Exploded View...

  • Page 573

    FRAME 15-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Carrier Bracket Bolts (M10) Carrier Bracket Bolts (M8) Frame Side Bracket Bolts Hook Bracket Bolts Rear Footpeg Bracket Bolts Rear Frame Bolts G: Apply grease. L: Apply a non-permanent locking agent. R: Replacement Parts...

  • Page 574

    15-6 FRAME Exploded View...

  • Page 575

    FRAME 15-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Fender Cover Screws 0.12 11 in·lb Seat Lock Guard Screws 0.12 11 in·lb 3. License Plate Bracket (CA and US Models) 4. Reflectors (AU, CA and US Models) 5. Reflectors (CA and US Models)

  • Page 576

    15-8 FRAME Exploded View...

  • Page 577

    FRAME 15-9 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Upper Fairing Bracket Nuts 2. Bolts and Washers 3. Canister Bracket (CAL Model)

  • Page 578: Seat Removal, Seat Installation

    15-10 FRAME Seat Seat Removal • Insert the key knob [A] into the seat lock and, turning the key counterclockwise, pulling up on the rear of the seat [B], and pulling the seat backward. Seat Installation • Insert the brackets [A] of the fuel tank into the slots [B] of the seat.

  • Page 579: Lower Fairing Removal, Lower Fairing Installation, Fairing Cover Removal

    FRAME 15-11 Fairings Lower Fairing Removal • Remove: Rear Middle Fairings (see Rear Middle Fairing Removal) ○ Pull up the core by the thin blade driver. ○ Remove the quick rivet [A]. • Remove the bolts [B] with washers. • Clear the hook portion [C] from the slot.

  • Page 580: Middle Fairing Removal

    15-12 FRAME Fairings Middle Fairing Removal • Remove: Storage Compartment Cover (see Storage Compart- ment Removal) Inner Covers (see Inner Cover Removal) Fairing Covers (see Fairing Cover Removal) • For the right side, remove the bolt [A] and sub front right side cover [B].

  • Page 581: Middle Fairing Installation, Windshield Removal

    FRAME 15-13 Fairings Middle Fairing Installation • Install the turn signal light to the front middle fairing, and tighten the screws. • Install the inner fairing (see Inner Fairing Installation). • Connect the turn signal lead connector. • Fit the rear side hook [A] of the fairing first, and then fit the front side.

  • Page 582: Windshield Installation

    15-14 FRAME Fairings • Remove: Rubber Damper [A] Bolts [B] Windshield [C] Windshield Installation • Put the rabber damper [A] onto the shape area of the damper [B]. • Tighten: Upper Fairing Removal • Remove: Inner Cover (see Inner Cover Removal) Windshield Screws [A] Electric Windshield Actuator Cover [B]...

  • Page 583: Upper Fairing Installation

    FRAME 15-15 Fairings • Remove: Bolt [A] Right Resonator [B] • Turn the fittings [A] of the aiming cable counter-clockwise and remove them. • Pull out the upper fairing [A] forward. ○ Pull the both side of the fairing to clear the rear view mirror bracket [B].

  • Page 584

    15-16 FRAME Fairings Upper Fairing Disassembly • Remove: Upper Fairing (see Upper Fairing Removal) Screws [A] Bolts [B] Headlights [C] Upper Fairing Assembly • Set up the and fairing damper bracket [A] inlet fairing [B]. • Install the headlight. • Installation is the reverse of removal.

  • Page 585

    FRAME 15-17 Fairings Upper Inner Fairing Installation • Engage the engage parts [A] of the inner fairing front por- tion and counters [B]. • Install the quick revets. Lower Inner Fairing Removal • Remove: Quick Rivet [A] Bolts [B] • Clear the slots [C] from the hooks.

  • Page 586: Fairing Stay Removal

    15-18 FRAME Fairings Fairing Stay Removal • Remove: Middle Fairings (see Middle Fairing Removal) Bolts [A] Relay Bracket [B] with Pad [C] Bolt [D] Left Heat Insulation Cover [E] • Remove: Bolts [A] Left Fairing stay [B] • For the California Model, Remove the band [A], canister [B], bolt [C] and bracket [D].

  • Page 587: Fairing Stay Installation, Upper Fairing Bracket Removal, Upper Fairing Bracket Installation

    FRAME 15-19 Fairings • Remove: Bolt [A] Right Fan Motor Lead Connector [B] (disconnect) Clamp [C] (open) Right Fairing Stay [D] • For the California Mode, Remove the bolt [A] and sepa- rater [B]. Fairing Stay Installation • Installation is the reverse of removal. Upper Fairing Bracket Removal •...

  • Page 588: Seat Cover, Seat Cover Removal, Seat Cover Installation

    15-20 FRAME Seat Cover Seat Cover Removal • Remove: Seat (see Seat Removal) Screws [A] Center Seat Cover [B] • Remove: Screws [A] • Remove the quick rivets [A]. • Clear the side seat covers [B] from the holders [C] of the saddlebag.

  • Page 589: Tail Cover Removal, Tail Cover Installation

    FRAME 15-21 Seat Cover • Insert the projection [A] of the seat cover [B] into the hole [C] of the tail light cover [D]. • Tighten the screws. Tail Cover Removal • Remove: Tail/Brake Light (see Tail/Brake Light Removal in the Electrical System chapter) Seat Covers Bolts [A]...

  • Page 590: Front Fender Removal, Front Fender Installation

    (DFI) chapter) Seat Covers (see Seat Cover Removal) Tool Kit Case [A] (see ECU Removal in the Fuel System (DFI) chapter) Kawasaki Self-diagnosis System Connections with Holder [B] Relay Box [C] (see Relay Box Removal in the Electrical System chapter)

  • Page 591

    FRAME 15-23 Fenders • Remove: Lisense Plate Light Lead Connector [A] Nuts [B] Flaps [C] • Remove: Band [A] KIPASS ECU [B] Fuse Box [C] Clamps (open) [D] • Remove: Tail/Brake Light (LED) (see Tail/Brake Light (LED) Re- moval In the Electrical System chaoter) Bolts [A] •...

  • Page 592

    15-24 FRAME Fenders • Pull out the rear fender [A] backward and downward. ○ Cleare the fender from the frame brackets [B]. Flap and Rear Fender Installation • Put the front portion [A] of the rear fender on the frame [B].

  • Page 593: Storage Compartment

    FRAME 15-25 Storage Compartment Storage Compartment Removal • Unlock the lid [A] of the storage compartment [B]. ○ Pushing the lever [C] in with holding the button [D] down. • Remove: Screws [A] Storage compartment Cover [B] with Lid [C] •...

  • Page 594

    15-26 FRAME Storage Compartment Storage Compartment Installation • Installe the end of the springs [A] position as shown.

  • Page 595: Rear Frame Installation, Subframe Removal

    FRAME 15-27 Frame Rear Frame Removal • Remove: Frame Side Cover (see Propeller Shaft Removal in the Final Drive chapter) Rear Fender (see Rear Fender Removal) Muffler Body Bolt [A] Rear Footpeg Bracket Bolts [B] and Brackets (Both Sides) Rear Frame Bolts [C] Rear Frame Installation •...

  • Page 596

    15-28 FRAME Frame Frame Inspection • Visually inspect the frame [A] for cracks, dents, bending, or warp. If there is any damage to the frame, replace it. WARNING A repaired frame may fail in use, possibly causing an accident. If the frame is bent, dented, cracked, or warped, replace it.

  • Page 597: Meter Cover Removal, Meter Cover Installation

    FRAME 15-29 Cover Meter Cover Removal • Remove: Meter Unit (see Meter Unit Removal in the Electrical Sys- tem Chapter) • Open the clamp [A]. • Unscrew the bolt [B]. • Turn the fitting [C] of the aiming cable counter-clockwise and remove it.

  • Page 598

    15-30 FRAME Cover • Insert the cap [A] onto the cable [B]. • Install the meter cover [A] and tighten the bolts [B]. • Install the removed parts.

  • Page 599: Center Stand, Sidestand, Center Stand Removal, Center Stand Installation, Sidestand Removal

    FRAME 15-31 Center Stand, Sidestand Center Stand Removal • Remove: Muffler Bodies (see Muffler Body Removal in the Engine Top End chapter) • Using the jack [A] rais the rear wheel off the ground Special Tools - Jack [A]: 57001-1238 Jack Attachment [B]: 57001-1608 •...

  • Page 600: Sidestand Installation

    15-32 FRAME Center Stand, Sidestand Sidestand Installation • Apply grease to the sliding area [A] of the sidestand [B]. • Apply a non-permanent locking agent to the bracket bolts [C]. • Tighten the bolt and lock them with the nut. Torque - Sidestand Bracket Bolts: 49 N·m (5.0 kgf·m, 36 ft·lb) Sidestand Bolt [D]: 44 N·m (4.5 kgf·m, 32 ft·lb)

  • Page 601: Saddlebag Removal, Saddlebag Installation, Saddlebag Disassembly

    FRAME 15-33 Saddlebag Saddlebag Removal • Insert the key knob [A] into the lid lock. • Turn the key knob clockwise. • Pull up the handle [A] on the top of the saddlebag [B]. • Remove the saddlebag by pulling it up. Saddlebag Installation •...

  • Page 602: Saddlebag Assembly

    15-34 FRAME Saddlebag • Unscrew the screws [A] of the saddlebag lock assy. • Remove the saddlebag lock assy. • Unscrew the hinge nuts [A] and separate the lid [B] and case [C]. • Unscrew: Screws [D] • Remove: Hooks [E] Lid Cover [F] •...

  • Page 603: Carrier Removal, Carrier Installation

    FRAME 15-35 Carrier Carrier Removal • Unscrew the bolts [A] and remove the carrier [B]. • Remove: Saddlebags (see saddlebag Removal) Seat Cover (seat cover Removal) Carrier Bolts [A] Right and Left Carrier Bracket [B] • Remove: Bolts [A] Right and Left Hook Brackets [B] Carrier Installation ○...

  • Page 604: Rear View Mirror

    15-36 FRAME Rear View Mirror Rear View Mirror Removal • Remove: Fairing Cover (see Fairing Cover Removal) Rear Middle Fairings (see Middle Fairing Removal) Nuts [A] Rear View Mirror [B] Rear View Mirror Installation • Installation is the reverse of removal.

  • Page 605

    FRAME 15-37 Pads Dummy Page...

  • Page 606

    15-38 FRAME Pads...

  • Page 607

    FRAME 15-39 Pads 1. Fuel Tank 2. Align the pad with plate of the fuel tank. 3. Align the pad with weld of the fuel tank. 4. Pad 5. Pad 6. Pad 7. Pad 8. Pad 9. Guard...

  • Page 608

    15-40 FRAME Pads...

  • Page 609

    FRAME 15-41 Pads 1. Front View 2. Damper 3. Damper 4. Electric Windshield Actuator Cover 5. Left and Right Inner Fairings 6. Pad 7. 0 ∼ 10 mm (0 ∼ 0.39 in.) 8. 10 mm (0.39 in.) 9. Left and Right Front Middle Fairings 10.

  • Page 610

    15-42 FRAME Pads...

  • Page 611

    FRAME 15-43 Pads 1. Left Side 2. Rear Middle Fairing 3. 10 mm (0.39 in.) 4. Pad 5. Pad 6. 0 ∼ 10 mm (0 ∼ 0.39 in.) 7. Pad (Install the pad from the outside.) 8. 10 ∼ 15 mm (0.39 ∼ 0.59 in.) 9.

  • Page 613: Table Of Contents

    ELECTRICAL SYSTEM 16-1 Electrical System Table of Contents Exploded View........................16-4 Parts Location......................... 16-10 Wiring Diagram (ABS Equipped Models) ................16-14 Wiring Diagram (Other than ABS Equipped Models) ............. 16-16 Specifications ......................... 16-18 Special Tools and Sealant ...................... 16-19 Precautions..........................16-21 Electrical Wiring........................

  • Page 614: Table Of Contents

    16-2 ELECTRICAL SYSTEM Starter Motor Disassembly....................16-51 Starter Motor Assembly ....................16-51 Brush Inspection ....................... 16-53 Commutator Cleaning and Inspection................16-53 Armature Inspection......................16-53 Brush Lead Inspection ...................... 16-54 Right-hand End Cover Assembly Inspection ..............16-54 Starter Relay Inspection....................16-54 Lighting System ........................

  • Page 615: Table Of Contents

    ELECTRICAL SYSTEM 16-3 Gear Position Switch Removal ..................16-104 Gear Position Switch Installation ..................16-105 Gear Position Switch Inspection ..................16-105 Oxygen Sensor Removal (Equipped Models)..............16-106 Oxygen Sensor Installation (Equipped Models)..............16-106 Oxygen Sensor Inspection (Equipped Models)..............16-106 Oxygen Sensor Heater Inspection (Equipped Models)............. 16-106 Relay Box and Accessory Relay ....................

  • Page 616

    16-4 ELECTRICAL SYSTEM Exploded View...

  • Page 617

    ELECTRICAL SYSTEM 16-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Adjuster Knob Bracket Screws 0.12 11 in·lb Aiming Bracket Screws 0.12 11 in·lb Front Turn Signal Light Mounting Screws 0.12 11 in·lb License Plate Light Cover Mounting Screws 0.90 0.092 8 in·lb License Plate Light Mounting Screws...

  • Page 618

    16-6 ELECTRICAL SYSTEM Exploded View...

  • Page 619

    ELECTRICAL SYSTEM 16-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Alternator Cover Bolts 87 in·lb Alternator Lead Holding Plate Bolts 0.85 73 in·lb Alternator Rotor Bolt 11.2 81.1 Crankshaft Sensor Bolts 0.60 52 in·lb Crankshaft Sensor Cover Bolts 87 in·lb L (1) Exhaust Camshaft Position Sensor Bolts 87 in·lb...

  • Page 620

    16-8 ELECTRICAL SYSTEM Exploded View...

  • Page 621

    ELECTRICAL SYSTEM 16-9 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Brake Light Switch Screw 0.12 11 in·lb Left Switch Housing Screws 0.36 31 in·lb Right Switch Housing Screws 0.36 31 in·lb Sidestand Switch Bolt 0.90 78 in·lb Speed Sensor Bolt 87 in·lb Starter Clutch Shaft Bolt 87 in·lb...

  • Page 622

    16-10 ELECTRICAL SYSTEM Parts Location...

  • Page 623

    ELECTRICAL SYSTEM 16-11 Parts Location 1. Turn Signal Relay 2. Battery 12 V 14 Ah 3. Frame Ground 4. Water Temperature Sensor 5. Stick Coils 6. Air Switching Valve 7. KIPASS Signal Diode (in Main Harness) 8. Meter Unit 9. Oil Control Solenoid Valve 10.

  • Page 624

    16-12 ELECTRICAL SYSTEM Parts Location...

  • Page 625

    ELECTRICAL SYSTEM 16-13 Parts Location 24. Electric Windshield Motor 25. Steering Lock Unit 26. Headlight Relays (Hi and Lo) 27. KIPASS Signal Relay 28. Accessory Relay 29. Electric Windshield Relays (Up and Down) 30. Fan Motors 31. Exhaust Camshaft Position Sensor 32.

  • Page 626

    16-14 ELECTRICAL SYSTEM Wiring Diagram (ABS Equipped Models)

  • Page 627

    ELECTRICAL SYSTEM 16-15 Wiring Diagram (ABS Equipped Models)

  • Page 628

    16-16 ELECTRICAL SYSTEM Wiring Diagram (Other than ABS Equipped Models)

  • Page 629

    ELECTRICAL SYSTEM 16-17 Wiring Diagram (Other than ABS Equipped Models)

  • Page 630

    16-18 ELECTRICAL SYSTEM Specifications Item Standard Service Limit Battery Type Sealed Battery – – – Model Name FTZ14-BS – – – Capacity 12 V 14 Ah – – – Voltage 12.6 V or more – – – Charging System Type Three-phase AC –...

  • Page 631

    ELECTRICAL SYSTEM 16-19 Special Tools and Sealant Hand Tester: Harness Adapter: 57001-1394 57001-1562 Flywheel Puller Assembly, M38 × 1.5/M35 × 1.5: Grip: 57001-1405 57001-1591 Peak Voltage Adapter: Flywheel & Pulley Holder: 57001-1415 57001-1605 Lead Wire - Peak Voltage Adapter: Rotor Holder: 57001-1449 57001-1672 Needle Adapter Set:...

  • Page 632

    16-20 ELECTRICAL SYSTEM Special Tools and Sealant Kawasaki Bond (Silicone Sealant): 92104-0004...

  • Page 633

    ELECTRICAL SYSTEM 16-21 Precautions There are a number of important precautions that are musts when servicing electrical systems. Learn and ob- serve all the rules below. ○ Do not reverse the battery cable connections. This will burn out the diodes on the electrical parts. ○...

  • Page 634: Electrical Wiring, Wiring Inspection

    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 635

    ELECTRICAL SYSTEM 16-23 Battery Battery Removal • Turn the key knob to OFF. • Remove: Bolt [A] Right Cover [B] ○ Pull out the projection [C] of the cover from the rubber grommet. • Remove: Bolts [A] Battery Compartment Cover [B] ○...

  • Page 636: Battery Installation

    16-24 ELECTRICAL SYSTEM Battery • Disconnect the negative (–) cable [A]. • Remove the battery [B] from the battery tray. Battery Installation • Place the battery in the battery tray [A]. • Connect the negative (–) cable [B] to the battery. •...

  • Page 637: Battery Activation

    ELECTRICAL SYSTEM 16-25 Battery • Install the bracket [A]. ○ Insert the projections on the battery tray into the holes [B] of the bracket. • Tighten the bracket bolts. • Connect the connector [C]. • Install the negative cable (–) terminal [A] to the frame so that the flat surface faces to frame and the terminal touches the stopper [B].

  • Page 638

    16-26 ELECTRICAL SYSTEM Battery CAUTION Do not remove the aluminum sealing sheet [A] from the filler ports [B] until just prior to use. Be sure to use the dedicated electrolyte container for correct electrolyte volume. • Place the battery on a level surface. •...

  • Page 639

    Newly activated sealed batteries require an initial charge. Standard Charge: 1.4 A × 5 ∼ 10 hours If using a recommended battery charger, follow the charger’s instructions for newly activated sealed battery. Kawasaki-recommended chargers: Optimate III Yuasa 1.5 Amp Automatic Charger Battery Mate 150-9 If the above chargers are not available, use equivalent one.

  • Page 640

    16-28 ELECTRICAL SYSTEM Battery NOTE ○ To ensure maximum battery life and customer satisfac- tion, it is recommended the battery be load tested at three times its amp-hour rating for 15 seconds. Re-check voltage and if less than 12.6 volts repeat the charging cycle and load test.

  • Page 641: Charging Condition Inspection, Refreshing Charge

    ELECTRICAL SYSTEM 16-29 Battery Charging Condition Inspection ○ Battery charging condition can be checked by measuring battery terminal voltage with a digital voltmeter [A]. • Remove: Battery (see Battery Removal) • Measure the battery terminal voltage. NOTE ○ Measure with a digital voltmeter which can be read one decimal place voltage.

  • Page 642

    16-30 ELECTRICAL SYSTEM Battery • Determine the battery condition after refresh charge. ○ Determine the condition of the battery left for 30 minutes after completion of the charge by measuring the terminal voltage according to the table below. Criteria Judgement 12.6 V or higher Good 12.0 ∼...

  • Page 643: Charging System, Alternator Cover Removal, Alternator Cover Installation, Stator Coil Removal

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

  • Page 644: Stator Coil Installation, Alternator Rotor Removal, Alternator Rotor Installation

    Apply silicone sealant to the circumference of the alter- nator lead grommet, and fit the grommet into the notch of the cover securely. Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004 • Secure the alternator lead with a holding plate [A], and apply a non-permanent locking agent to the thread of the plate bolts and tighten them.

  • Page 645: Alternator Inspection

    ELECTRICAL SYSTEM 16-33 Charging System • Using a cleaning fluid, clean off any oil or dirt on the washer [A] and dry if with a clean cloth. NOTE ○ Confirm the alternator rotor fit or not to the crankshaft before tightening it with specified torque. •...

  • Page 646

    16-34 ELECTRICAL SYSTEM Charging System • To check the alternator output voltage, do the following procedures. ○ Turn the key knob to OFF. ○ Disconnect the alternator lead connector [A] from the reg- ulator/rectifier. ○ Connect the hand tester [B] as shown in the table 1. Special Tool - Hand Tester: 57001-1394 ○...

  • Page 647: Regulator/rectifier Inspection

    CAUTION Use only Kawasaki Hand Tester 57001-1394 for this test. A tester other than the Kawasaki Hand Tester may show different readings. If a megger or a meter with a large capacity battery is used, the regulator/rectifier will be damaged.

  • Page 648: Charging Voltage Inspection

    16-36 ELECTRICAL SYSTEM Charging System Charging Voltage Inspection • Check the battery condition (see Charging Condition In- spection). • Warm up the engine to obtain actual alternator operating conditions. • Remove the right cover. • Check that the key knob is turned off, and connect the hand tester [A] to the battery (+) terminal and ground.

  • Page 649

    ELECTRICAL SYSTEM 16-37 Charging System Charging System Circuit 1. Steering Lock Unit 2. Regulator/Rectifier 3. Alternator 4. Load 5. Main Fuse 30 A 6. Frame Ground 7. Battery 12 V 14 Ah 8. Frame Ground 9. Engine Ground...

  • Page 650

    16-38 ELECTRICAL SYSTEM Ignition System...

  • Page 651: Ignition System

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

  • Page 652: Crankshaft Sensor Installation, Crankshaft Sensor Inspection, Crankshaft Sensor Peak Voltage Inspection

    [B], and fit the grommet into the notch of the crankcase securely. • Apply silicone sealant to the mating surface [C] of crankcase halves. Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004 • Replace the O-ring [D] with a new one. • Install:...

  • Page 653: Timing Rotor Removal, Timing Rotor Installation, Stick Coil Removal

    ELECTRICAL SYSTEM 16-41 Ignition System • Set the hand tester [A] to the × 25 V DC range, and con- nect the peak voltage adapter [B]. Special Tools - Hand Tester: 57001-1394 Peak Voltage Adapter: 57001-1415 Type: KEK-54-9-B Connections: Crankshaft Sensor Adapter Hand Tester Connector [C]...

  • Page 654

    16-42 ELECTRICAL SYSTEM Ignition System • Remove: Bolt [A] Bracket and Connector [B] • Disconnect the stick coil connectors [C]. • Pull the stick coils [D] off the spark plugs. CAUTION Do not pry the connector part of the coil while re- moving the coil.

  • Page 655: Stick Coil Inspection

    ELECTRICAL SYSTEM 16-43 Ignition System Stick Coil Inspection • Remove the stick coils (see Stick Coil Removal). • Measure the primary winding resistance [A] as follows. ○ Connect the hand tester between the coil terminals. ○ Set the tester to the × 1 Ω range, and read the tester. •...

  • Page 656: Spark Plug Removal, Spark Plug Installation, Spark Plug Condition Inspection, Camshaft Position Sensor Removal

    16-44 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 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 657

    ELECTRICAL SYSTEM 16-45 Ignition System • Disconnect the camshaft position sensor lead connector [A]. • Remove: Quick Rivets [A] Cover [B] Camshaft Position Sensor Bolt [C] Camshaft Position Sensor [D] (Inlet Side) • Loosen the clamps of the throttle body assy and remove the throttle body assy from the throttle body holder (see Throttle Body Assy Removal in the Fuel System (DFI) chapter).

  • Page 658: Camshaft Position Sensor Installation

    16-46 ELECTRICAL SYSTEM Ignition System Camshaft Position Sensor Installation • Replace the O-rings of the camshaft position sensors. • Apply grease to the new O-rings. • Tighten: Torque - Camshaft Position Sensor Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) • Route the camshaft position sensor lead correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter).

  • Page 659: Interlock Operation Inspection

    ELECTRICAL SYSTEM 16-47 Ignition System • Turn the key knob and engine stop switch ON. • Pushing the starter button, run the engine with the trans- mission gear in neutral to measure the camshaft position sensor peak voltage. • Repeat the measurement 5 or more times. Camshaft Position Sensor Peak Voltage Standard: 2.8 V or more...

  • Page 660: Ic Igniter Inspection

    16-48 ELECTRICAL SYSTEM Ignition System IC Igniter Inspection ○ The IC igniter is built in the ECU [A]. • Refer to the following items. Interlock Operation Inspection (see Interlock Operation Inspection) Ignition System Troubleshooting (see Ignition System section) ECU Power Supply Inspection (see ECU Power Supply Inspection in the Fuel System (DFI) chapter)

  • Page 661

    ELECTRICAL SYSTEM 16-49 Ignition System Ignition System Circuit 1. Sidestand Switch 10. Vehicle-down Sensor 23. Battery 12 V 14 Ah 2. Water Temperature Sen- 11. Water-proof Joint 2 24. Frame Ground 12. Subthrotte Sensor 25. Engine Ground 3. Inlet Camshaft Position 13.

  • Page 662: Electric Starter System, Starter Motor Removal, Starter Motor Installation

    16-50 ELECTRICAL SYSTEM Electric Starter System Starter Motor Removal • Remove: Left Rear Middle Fairing (see Middle Fairing Removal in the Frame chapter) Clamp Bolts [A] • Remove: Speed Sensor (see Speed Sensor Removal) Starter Motor Mounting Bolts [A] • Pull out the starter motor [B].

  • Page 663: Starter Motor Disassembly, Starter Motor Assembly

    ELECTRICAL SYSTEM 16-51 Electric Starter System • Install the starter motor cable [A] side by side with starter motor [B]. • Tighten: Torque - Starter Motor Cable Terminal Nut: 5.9 N·m (0.60 kgf·m, 52 in·lb) • Slide back the rubber cap [C] to the original position. Starter Motor Disassembly •...

  • Page 664

    16-52 ELECTRICAL SYSTEM Electric Starter System • Install the brush plate assembly [A] into the right-hand end cover [B]. • Replace the O-ring [C] with a new one. • Install: Insulators [D] Washer [E] • Tighten: Torque - Starter Motor Terminal Locknut [F]: 6.9 N·m (0.70 kgf·m, 61 in·lb) •...

  • Page 665: Brush Inspection, Commutator Cleaning And Inspection, Armature Inspection

    ELECTRICAL SYSTEM 16-53 Electric Starter System Brush Inspection • Measure the length [A] of each brush [B]. If any is worn down to the service limit, replace the brush holder assembly. Starter Motor Brush Length Standard: 10 mm (0.39 in.) Service Limit: 5 mm (0.20 in.) Commutator Cleaning and Inspection •...

  • Page 666: Brush Lead Inspection, Right-hand End Cover Assembly Inspection, Starter Relay Inspection

    16-54 ELECTRICAL SYSTEM Electric Starter System Brush Lead Inspection • Using the × 1 Ω hand tester range, measure the resis- tance as shown. Terminal Bolt and Positive Brush [A] Right-hand End Cover and Negative Brush [B] Special Tool - Hand Tester: 57001-1394 If there is not close to zero ohms, the brush lead has an open.

  • Page 667

    ELECTRICAL SYSTEM 16-55 Electric Starter System Electric Starter Circuit 1. Sidestand Switch 2. Engine Stop Switch 3. Starter Button 4. Fuse Box 2 5. Ignition Fuse 10 A 6. Steering Lock Unit 7. Joint Connector 1 8. Joint Connector 8 9.

  • Page 668: Lighting System

    16-56 ELECTRICAL SYSTEM Lighting System This motorcycle adopts the daylight system and has a headlight relay in the relay box. The headlight does not go on when the ignition switch and the engine stop switch are first turned on. The headlight comes on after the starter button is released and stays on until the ignition switch is turned off.

  • Page 669: City Light Bulb Replacement

    ELECTRICAL SYSTEM 16-57 Lighting System • Install the hook [A]. • Fit the dust cover [A] onto the bulb [B] firmly as shown in the figure. Good [C] Bad [D] • Connect the headlight connector. • After installation, adjust the headlight aim (see Headlight Aiming Inspection in the Periodic Maintenance chapter).

  • Page 670: Headlight Removal/installation, Headlight Relay Inspection

    16-58 ELECTRICAL SYSTEM Lighting System • Insert the socket [A] so that the round side [B] fits the wall [C]. Headlight Removal/Installation • Remove: Upper Fairing (see Upper Fairing Removal in the Frame chapter) Upper Fairing Damper Bracket Screws [A] (Tapping Screws) Headlight Mounting Screws [B] (Tapping Screws) Headlight Mounting Screws [C]...

  • Page 671

    ELECTRICAL SYSTEM 16-59 Lighting System Tail/Brake Light (LED) Removal • Remove: Seat (see Seat Removal in the Frame chapter) ECU (see ECU removal in the Fuel System (DFI) chapter Tail/Brake Light Lead Connector [A] • Open the clamp [B]. • Remove: Bolts [A] Carrier Plate [B]...

  • Page 672: Tail/brake Light (led) Installation, License Plate Light Bulb Replacement

    16-60 ELECTRICAL SYSTEM Lighting System • Remove: Tail Light Cover Bracket Bolts [A] Upper Cover [B] Lower Cover [C] • Remove: Bolts [A] Bracket [B] • Remove: Tail Light Screws [A] Tail Light Bracket [B] Tail/Brake Light (LED) Installation • Installation is basically the reverse of removal.

  • Page 673

    ELECTRICAL SYSTEM 16-61 Lighting System • Push and turn the bulb [A] counterclockwise wise and re- move it. • Replace the bulb with a new one. • Insert the new bulb [A] by aligning its upper and lower pins [B] with the upper and lower grooves [C] in the socket, and turn the bulb clockwise.

  • Page 674

    16-62 ELECTRICAL SYSTEM Lighting System Headlight/Tail Light Circuit 1. Fuse Box 1 15. License Plate Light 12 V 5 W 2. Taillight Fuse 10 A 16. Tail/Brake Light (LED) 13.5 V 0.5/4.1 W 3. Headlight Fuse 10 A 17. Headlight Relay (Lo) 4.

  • Page 675: Turn Signal Light Bulb Replacement

    ELECTRICAL SYSTEM 16-63 Lighting System Turn Signal Light Bulb Replacement Front Turn Signal Light • Remove: Front Middle Fairings (see Middle Fairing Removal in the Frame chapter) • Turn the socket [A] counterclockwise and pull out the socket together with the bulb. •...

  • Page 676: Turn Signal Relay Inspection

    16-64 ELECTRICAL SYSTEM Lighting System • Push and turn the rear turn signal light bulb [A] counter- clockwise and remove it. • Insert the new bulb [A] by aligning its upper and lower pins [B] with the upper and lower grooves [C] in the socket, and turn the bulb clockwise.

  • Page 677

    ELECTRICAL SYSTEM 16-65 Lighting System • Connect one 12 V battery and turn signal lights as indi- cated in the figure, and count how may times the lights flash for one minute. Turn Signal Relay [A] Turn Signal Lights [B] (12 V 21 W × 2) 12 V Battery [C] If the lights do not flash as specified, replace the turn sig- nal relay.

  • Page 678

    16-66 ELECTRICAL SYSTEM Lighting System Turn Signal Light Circuit 1. KIPASS Signal Diode 2. KIPASS Signal Relay 3. KIPASS ECU 4. Joint Connector 9 5. Joint Connector 8 6. Right Turn Signal Indicator Light (LED) 7. Left Turn Signal Indicator Light (LED) 8.

  • Page 679: Air Switching Valve

    ELECTRICAL SYSTEM 16-67 Air Switching Valve Air Switching Valve Operation Test • Refer to the Air Suction System Damage Inspection in the Periodic Maintenance chapter. Air Switching Valve Unit Test • Remove the air switching valve (see Air Switching Valve Removal in the Engine Top End chapter).

  • Page 680

    16-68 ELECTRICAL SYSTEM Air Switching Valve Air Switching Valve Circuit 1. Steering Lock Unit 2. Fuse Box 2 3. Ignition Fuse 10 A 4. Air Switching Valve 5. ECU 6. Main Fuse 30 A 7. Battery 12 V 14 Ah 8.

  • Page 681: Radiator Fan System, Fan Motor Inspection

    ELECTRICAL SYSTEM 16-69 Radiator Fan System Fan Motor Inspection • Remove the front middle fairings (see Middle Fairing Re- moval in the Frame chapter). • Disconnect the connectors. Right Fan Motor Lead Connector [A] Left Fan Motor Lead Connector [B] •...

  • Page 682

    16-70 ELECTRICAL SYSTEM Oil Control Solenoid Valve Oil Control Solenoid Valve Inspection • Remove: Right Rear Middle Fairing (see Middle Fairing Removal in the Frame chapter) • Disconnect the oil control solenoid valve lead connector [A]. • Set the hand tester [A] to ×1 Ω range and connect the tester leads to the terminals in the oil control solenoid valve lead connector [B].

  • Page 683: Electric Windshield

    ELECTRICAL SYSTEM 16-71 Electric Windshield Electric Windshield Assembly Removal • Remove: Upper Fairing (see Upper Fairing Removal in the Frame chapter) • Position the windshield bracket [A] as shown. • Remove: Clamp [B] Bolts [C] • Disconnect the electric windshield motor lead connector [A].

  • Page 684: Electric Windshield Assembly Lubrication

    16-72 ELECTRICAL SYSTEM Electric Windshield Electric Windshield Assembly Lubrication • Remove: Windshield (see Windshield Removal in the Frame chapter) Quick Rivets [A] Screws [B] Electric Windshield Actuator Cover [C] • Apply silicon grease to the right rail [A]. • Apply silicon grease to the left rail [A]. •...

  • Page 685: Electric Windshield Inspection

    ELECTRICAL SYSTEM 16-73 Electric Windshield • Connect the hand tester [A] and 12 V battery [B] to the electric windshield relay [C] as shown. Special Tool - Hand Tester: 57001-1394 If the relay does not work as specified, replace the relay. Testing Relay Hand Tester Range: ×...

  • Page 686

    16-74 ELECTRICAL SYSTEM Electric Windshield Electric Windshield Circuit 1. Electric Windshield Motor 2. Steering Lock Unit 3. Main Fuse 30 A 4. Fuse Box 3 5. Electric Windshield Fuse 30 A 6. Electric Windshield Switch 7. Electric Windshield Relay (Down) 8.

  • Page 687: Meter, Gauge, Indicator Unit, Meter Installation

    ELECTRICAL SYSTEM 16-75 Meter, Gauge, Indicator Unit Meter Unit Removal • Remove: Windshield (see Windshield Removal in the Frame chapter) Quick Rivets [A] Screws [B] Electric Windshield Actuator Cover [C] • Remove: Meter Lead Connector [A] Meter Unit Mounting Nuts [B] and Washers Meter Unit [C] Damper CAUTION...

  • Page 688

    The turn signal light indicator lights (LED) [A] flash two times. ○ The speedometer and tachometer needles [B] momen- tarily point their last readings and back to the minimum position. ○ The K Kawasaki mark [C] appears in the display for three seconds.

  • Page 689

    ELECTRICAL SYSTEM 16-77 Meter, Gauge, Indicator Unit ○ After the K Kawasaki mark appeared, the ordinary indica- tion [A] (Example: N, AVERAGE --.- KM/L), odometer [B] or trip meter, clock [C], water temperature gauge [D], and fuel level gauge [E] appear in the display.

  • Page 690

    16-78 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit • Check that the display changes to the language setting mode [A]. ○ This display is system menu indication. • By pushing the lower button each time, check that the cursor [B] changes on the languages. If the display function does not work, replace the meter assembly.

  • Page 691

    ELECTRICAL SYSTEM 16-79 Meter, Gauge, Indicator Unit • Select the MILEAGE indication. • Push the upper button [A] for more than two seconds. • Check that the unit [B] flashes. • By pushing the lower button each time, check that the display changes as follows.

  • Page 692: Meter Unit Inspection

    16-80 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit • By pushing the lower button, check that the hour and minute display [A] starts flashing. • By pushing the upper button, check that the hour and minute display is decided. • When both hour and minute display flashing, by pushing the lower button, check that the hour display start flashing.

  • Page 693

    ELECTRICAL SYSTEM 16-81 Meter, Gauge, Indicator Unit Check 1: CAN Communication Line Resistance Inspec- tion • Set the hand tester [A] to the ×1 Ω range and connect it to the terminal [17] and [18] in the meter unit. Special Tool - Hand Tester: 57001-1394 CAN Communication Line Resistance (at Meter Unit) 122 ∼...

  • Page 694

    16-82 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit Check 3: KIPASS Flashing Mode Inspection • Connect the leads in the same circuit as Check 2. • Disconnect the terminal [9]. • Check that the warning light (LED) [A] starts flashing (KIPASS Warning Light Flashing Mode). •...

  • Page 695

    ELECTRICAL SYSTEM 16-83 Meter, Gauge, Indicator Unit • Check that the high beam indicator light (LED) [A] goes If the indicator light does not go on, replace the meter assembly. Check 5: Right Turn Signal Indicator Light (LED) In- spection •...

  • Page 696

    16-84 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit Check 7: Oil Pressure Warning Indicator Light (LED) Inspection • Connect the leads in the same circuit as Check 2. • Connect the terminal [2] to the battery (–) terminal. • Check that the oil pressure warning indicator light (LED) [A] goes on.

  • Page 697

    ELECTRICAL SYSTEM 16-85 Meter, Gauge, Indicator Unit • Connect the terminal [6] to the battery (–) terminal. • Check that the ABS indicator light (LED) goes off. If the indicator light does not work, replace the meter as- sembly. Check 10: Speed Sensor Supply Voltage Inspection •...

  • Page 698

    16-86 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit • Push and turn the key knob to ON. • Check that the symbol [A] appears in the water tempera- ture gauge and the three segments [B] for fuel level gauge start flashing. •...

  • Page 699

    ELECTRICAL SYSTEM 16-87 Meter, Gauge, Indicator Unit Check 12: Battery Voltage Inspection • Connect the leads in the same circuit as Check 11. • Push and turn the key knob to ON. • 1st, set the BATTERY display [A]. • Check that the display indicates the battery voltage.

  • Page 700

    16-88 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit Check 13: FI ERROR Inspection • Connect the leads in the same circuit as Check 11. • For example, disconnect the atmospheric pressure sen- sor connector under the seat. • Push and turn the key knob to ON. •...

  • Page 701

    ELECTRICAL SYSTEM 16-89 Meter, Gauge, Indicator Unit • Push the upper and lower buttons for more than two sec- onds, check that the ERROR CODE [A] and numbers ap- pear in the display. ○ The warning indicator light (LED) goes on. •...

  • Page 702

    16-90 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit • After about 5 seconds, check that one segment [A] in the fuel gauge starts flashing. • Check that the FUEL LOW [B] and fuel symbol [C] appear alternately in the display. ○ This display is the warning message indication.

  • Page 703

    ELECTRICAL SYSTEM 16-91 Meter, Gauge, Indicator Unit Check 16: Speedometer Inspection • Connect the leads in the same circuit as Check 11. • The speed equivalent to the input frequency is indicated in the oscillator [A], if the square wave is input into terminal [13].

  • Page 704

    16-92 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit Check 19: Tachometer Inspection • Connect the leads in the same circuit as Check 11. • Start the engine. • Check that the needle in the tachometer moves. If the needle does not move, go to the Check 1 and in- spect the following items.

  • Page 705

    Crankshaft Sensor (see Crankshaft Sensor Inspection) If the above items are good, replace the meter assembly and/or ECU. • Refer to the Technical Infornation-KIPASS (Kawasaki’s Intelligent Proximity Activation Start System) in the Gen- eral Information chapter) for the display of the KIPASS.

  • Page 706

    16-94 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit Meter Unit Circuit 23. Oil Pressure/FI Warning Indicator Light 1. ABS Hydraulic Unit (LED) 2. Oil Pressure Switch 24. ABS Indicator Light (LED) 3. Gear Position Switch 25. Dimmer Switch 4. Speed Sensor 26.

  • Page 707: General Information, Fob Key Operational Cautions, Key Registration

    If FOB key is lost, re-registry at dealer is securely required to prevent the possibility of theft. If all FOB keys are lost, an authorized Kawasaki dealer will have to replace the ECU, and re-register the new FOB key. Key Registration The key can be registered by the KDS 3 version kit.

  • Page 708: Steering Lock Unit Replacement

    16-96 ELECTRICAL SYSTEM KIPASS • Check the KIPASS ECU power source voltage with the hand tester [A]. ○ Position the terminal in accordance with terminal numbers of KIPASS ECU connector [B] in the figure. KIPASS ECU Power Source Inspection Tester Connections: between 7 (LG) Terminal and Frame Ground [C]...

  • Page 709: Kipass Signal Relay Inspection, Kipass Signal Diode Inspection

    ELECTRICAL SYSTEM 16-97 KIPASS • Remove: Steering Stem Head (see Stem, Stem Bearing Removal in the Steering chapter) • Using a small chisel or punch, turn out the Torx bolts [A]. • Remove the steering lock unit [B]. • Tighten a new Torx bolt [A] until the bolt head [B] is broken. [C] Broken Head of Other Side •...

  • Page 710

    16-98 ELECTRICAL SYSTEM KIPASS • Remove: Middle Fairings (see Middle Fairing Removal in the Frame chapter) KIPASS Signal Relay Connector [A] • Connect the hand tester [B] to the blue lead terminal [C] of the KIPASS signal relay connector and front turn signal light lead connector as shown.

  • Page 711

    ELECTRICAL SYSTEM 16-99 KIPASS KIPASS Circuit 1. Steering Lock Unit 9. Rear Right Turn Signal 19. ECU 2. Joint Connector 8 Light 12 V 21 W 20. ECU Fuse 15 A 3. Joint Connector 9 10. Joint Connector 2 21. Ignition Fuse 10 A 4.

  • Page 712: Switches And Sensors, Brake Light Timing Inspection, Brake Light Timing Adjustment, Switch Inspection

    16-100 ELECTRICAL SYSTEM Switches and Sensors Brake Light Timing Inspection • Refer to the Brake Light Switch Operation Inspection in the Periodic Maintenance chapter. Brake Light Timing Adjustment • Refer to the Brake Light Switch Operation Inspection in the Periodic Maintenance chapter. Switch Inspection •...

  • Page 713: Water Temperature Sensor Inspection, Speed Sensor Removal, Speed Sensor Installation

    ELECTRICAL SYSTEM 16-101 Switches and Sensors Water Temperature Sensor Inspection • Remove the water temperature sensor (see Removal/In- stallation in the Water Temperature Sensor (Service Code 14) section in the Fuel System (DFI) chapter). • Suspend the sensor [A] in a container of coolant so that the threaded portion is submerged.

  • Page 714: Fuel Level Sensor Inspection

    16-102 ELECTRICAL SYSTEM Switches and Sensors Speed Sensor Inspection • Remove the speed sensor (see Speed Sensor Removal). • Connect the speed sensor lead connector [A] with the bat- tery [B], 10 kΩ resistor [C] and hand tester [D] as shown. •...

  • Page 715: Fuel Reserve Switch Inspection

    ELECTRICAL SYSTEM 16-103 Switches and Sensors • Install a new gasket [A] on the fuel level sensor as shown. Hollows [B] Front [C] • Apply a non-permanent locking agent to the threads of the level sensor bolts and tighten it. Torque - Fuel Level Sensor Bolts: 6.9 N·m (0.70 kgf·m, 61 in·lb) Fuel Reserve Switch Inspection...

  • Page 716: Gear Position Switch Removal

    16-104 ELECTRICAL SYSTEM Switches and Sensors Gear Position Switch Removal • Remove the lower fairings (see Lower Fairing Removal in the Frame chapter). • Slide out the rubber boot [A]. • Loosen the oil pressure switch terminal bolt [B], and re- move the switch lead [C].

  • Page 717: Gear Position Switch Installation

    ELECTRICAL SYSTEM 16-105 Switches and Sensors Gear Position Switch Installation • Securely place the springs [A] and pins [B] into the holes of the shift drum [C]. • Apply grease to the new O-ring [D]. • Install the gear position switch [E] so that the switch sticks to the engine.

  • Page 718: Oxygen Sensor Removal (equipped Models), Oxygen Sensor Installation (equipped Models), Oxygen Sensor Inspection (equipped Models)

    16-106 ELECTRICAL SYSTEM Switches and Sensors Oxygen Sensor Removal (Equipped Models) NOTE ○ The oxygen sensor itself is the same for #1 [A] and #2 [B], but wiring of the main harness side is different. • Remove the right front middle fairing (see Middle Fairing Removal in the Frame chapter).

  • Page 719: Relay Box And Accessory Relay, Relay Box Removal, Relay Circuit Inspection

    ELECTRICAL SYSTEM 16-107 Relay Box and Accessory Relay Relay Box Removal • Remove: Seat (see Seat Removal in the Frame chapter) Tool Kit Box (see ECU Removal in the Fuel System (DFI) chapter) • Take out the relay box [A] and disconnect the connectors [B].

  • Page 720: Diode Circuit Inspection, Accessory Relay Inspection

    16-108 ELECTRICAL SYSTEM Relay Box and Accessory Relay Diode Circuit Inspection • Remove the relay box (see Relay Box Removal). • Check conductivity of the following pairs of terminals (see Relay Box Internal Circuit). Diode Circuit Inspection 1-11, 2-11, 12-13, 12-15, 12-16, 13-14, Tester Connection 13-15 The resistance should be low in one direction and more...

  • Page 721

    ELECTRICAL SYSTEM 16-109 Fuse 30 A Main Fuse Removal • Remove: Battery (see Battery Removal) Bolts and Cable Terminals [A] • Take out the starter relay assembly [A]. • Disconnect the 30 A main fuse connector [B]. • Pull out the 30 A main fuse [C] from the starter relay as- sembly.

  • Page 722

    16-110 ELECTRICAL SYSTEM Fuse • Pull the fuses [A] straight out of the fuse box with needle nose pliers. Fuse Installation If a fuse fails during operation, inspect the electrical sys- tem to determine the cause, and then replace it with a new fuse of proper amperage.

  • Page 723

    APPENDIX 17-1 Appendix Table of Contents Cable, Wire, and Hose Routing ....................17-2 Troubleshooting Guide ......................17-76...

  • Page 724

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

  • Page 725

    APPENDIX 17-3 Cable, Wire, and Hose Routing 1. Grommet 2. Insert the air switching valve hose into the air cleaner until white paint mark on it is hidden a half. 3. About 41 mm (1.61 in.) 4. Air Switching Valve Hose 5.

  • Page 726

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

  • Page 727

    APPENDIX 17-5 Cable, Wire, and Hose Routing 1. Run the air cleaner drain hose and idle adjusting screw cable through to the outside of the main harness. 2. Air Cleaner Drain Hose 3. Main Harness 4. Idle Adjusting Screw 5. Run the air cleaner drain hose through the front of the clamp. 6.

  • Page 728

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

  • Page 729

    APPENDIX 17-7 Cable, Wire, and Hose Routing 1. Run the reserve tank hose between the air suction valve and bracket. 2. Run the air switching valve lead which is connected to the water temperature sensor lead be- tween the throttle body #3 and #4. 3.

  • Page 730

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

  • Page 731

    APPENDIX 17-9 Cable, Wire, and Hose Routing 1. Run the oil control solenoid valve lead between the cylinder head cover and throttle body assy, and connect it. 2. Hold the crankshaft sensor lead with the clamps. 3. Run the oxygen sensor leads, and close the clamp. 4.

  • Page 732

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

  • Page 733

    APPENDIX 17-11 Cable, Wire, and Hose Routing 1. Radiator 2. Water Hose 3. Water Hose 4. Left Side View 5. Inlet Hose 6. Outlet Hose 7. Oil Cooler 8. Water Hose 9. Air Bleeder Hose for Water Pump 10. Water Pump 11.

  • Page 734

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

  • Page 735

    APPENDIX 17-13 Cable, Wire, and Hose Routing 1. Install the clamp so that knob of the clamp faces right side of the frame as shown in the figure. 2. Reserve Tank 3. Clamp 4. Clamp 5. About 20 mm (0.79 in.) 6.

  • Page 736

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

  • Page 737

    APPENDIX 17-15 Cable, Wire, and Hose Routing 1. Main Harness 2. Fuel Hose 3. 4-pin Connector (Unused) 4. Run the regulator/rectifier lead under the cross bracket. 5. Alternator Lead 6. Alternator Connectors (1-pin × 3) 7. Alternator Lead 8. Put the alternator lead between the frames when the lead remain. 9.

  • Page 738

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

  • Page 739

    APPENDIX 17-17 Ca