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Ninja ZX-6R
Motorcycle
Service Manual

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Table of Contents

   Summary of Contents for Kawasaki Ninja ZX-6R

  • Page 1 Ninja ZX-6R Motorcycle Service Manual...
  • Page 3: General Information

    Quick Reference Guide General Information Periodic Maintenance Fuel System (DFI) Cooling System Engine Top End Clutch Engine Lubrication System Engine Removal/Installation Crankshaft/Transmission Wheels/Tires 10 j Final Drive 11 j Brakes 12 j Suspension 13 j Steering 14 j Frame 15 j Electrical System 16 j Appendix...
  • Page 5 All 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. Second Edition (1): Jun. 21, 2007 (K)
  • Page 6 LIST OF ABBREVIATIONS ampere(s) pound(s) ABDC after bottom dead center meter(s) alternating current minute(s) ATDC after top dead center newton(s) BBDC before bottom dead center pascal(s) bottom dead center horsepower BTDC before top dead center pound(s) per square inch °C degree(s) Celsius revolution direct current...
  • Page 7: Emission Control Information

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

    Be alert for problems and non-scheduled 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 GENERAL INFORMATION 1-1 General Information Table of Contents Before Servicing ........................Model Identification......................... General Specifications......................Unit Conversion Table ......................1-12...
  • 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: General Information

    GENERAL INFORMATION 1-7 Model Identification ZX600P7F (Europe) Left Side View ZX600P7F (Europe) Right Side View Frame Number Engine Number...
  • Page 18 1-8 GENERAL INFORMATION Model Identification ZX600P7F (US and Canada) Left Side View ZX600P7F (US and Canada) Right Side View...
  • Page 19: General Specifications

    GENERAL INFORMATION 1-9 General Specifications ZX600P7F ∼ Items Dimensions Overall Length 2 105 mm (82.9 in.) Overall Width 720 mm (28.3 in.) Overall Height 1 125 mm (44.3 in.) Wheelbase 1 405 mm (55.3 in.) Road Clearance 125 mm (4.7 in.) Seat Height 820 mm (32.3 in.) Dry Mass...
  • Page 20 1-10 GENERAL INFORMATION General Specifications ZX600P7F ∼ Items Duration 266° 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 3.8 L (4.0 US qt) Drive Train Primary Reduction System: Type...
  • Page 21 GENERAL INFORMATION 1-11 General Specifications ZX600P7F ∼ Items Brake Type: Front Dual discs Rear Single disc Electrical Equipment Battery 12 V 8 Ah Headlight: Type Semi-sealed beam Bulb: High 12 V 55 W + 65 W (quartz-halogen) 12 V 55 W (quartz-halogen) Tail/Brake Light 12 V 0.1/1.6 W (LED) Alternator:...
  • Page 22: Unit Conversion Table

    1-12 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 23: Table Of Contents

    PERIODIC MAINTENANCE 2-1 Periodic Maintenance Table of Contents Periodic Maintenance Chart ....................Torque and Locking Agent...................... Specifications ......................... 2-12 Special Tools .......................... 2-14 Maintenance Procedure ......................2-15 Fuel System (DFI)........................ 2-15 Throttle Control System Inspection................... 2-15 Engine Vacuum Synchronization Inspection..............2-15 Idle Speed Inspection .......................
  • Page 24 2-2 PERIODIC MAINTENANCE Lights and Switches Operation Inspection................ 2-38 Headlight Aiming Inspection ..................... 2-40 Side Stand Switch Operation Inspection................2-41 Engine Stop Switch Operation Inspection................. 2-42 Others ..........................2-43 Chassis Parts Lubrication ....................2-43 Bolts, Nuts and Fasteners Tightness Inspection............... 2-44 Replacement Parts ......................
  • Page 25: 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. Periodic Inspection FREQUENCY Whichever * ODOMETER READING comes ×...
  • Page 26 2-4 PERIODIC MAINTENANCE Periodic Maintenance Chart FREQUENCY Whichever * ODOMETER READING comes × 1 000 km first (× 1 000 mile) ITEM Every (0.6) (4) (7.5) (12) (15) (20) (24) Brakes Brake fluid leak (brake hose and • • • • • • • year pipe)-inspect •...
  • Page 27: Periodic Maintenance Chart

    PERIODIC MAINTENANCE 2-5 Periodic Maintenance Chart Periodic Replacement Parts FREQUENCY Whichever * ODOMETER READING come × 1 000 km first (× 1 000 mile) ITEM Every (0.6) (7.5) (15) (24) (30) Air cleaner element - replace# Every 18 000 km (12 000 mile) •...
  • Page 28: 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 29 PERIODIC MAINTENANCE 2-7 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Water Pump Cover Bolts 106 in·lb Water Temperature Sensor Engine Top End Air Suction Valve Cover Bolts 87 in·lb Camshaft Cap Bolts 106 in·lb Camshaft Chain Tensioner Cap Bolt Camshaft Chain Tensioner Mounting Bolts 97 in·lb Cam Sprocket Mounting Bolts...
  • Page 30 2-8 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Engine Oil Drain Bolt Oil Cooler/Oil Filter Case Mounting Bolts Oil Pump Gear Bolt 87 in·lb Oil Cooler Mounting Bolts Oil Filter G, R Oil Filter Guard Bolts 0.41 35 in·lb Oil Filter Holder Bolt...
  • Page 31 PERIODIC MAINTENANCE 2-9 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Oil Pressure Switch Terminal Bolt – – – Hand-tighten Bearing Holder Screws 0.50 43 in·lb Shift Drum Cam Holder Bolt 104 in·lb Shift Lever Bolt 0.70 61 in·lb Shift Pedal Mounting Bolt Shift Shaft Return Spring Pin Shift Tie-Rod Locknuts...
  • Page 32 2-10 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Front Fork Clamp Bolts (Lower) Front Fork Clamp Bolts (Upper) Front Fork Top Plugs Piston Rod Nuts Rear Shock Absorber Bracket Nut Rear Shock Absorber Nut (Lower) Rear Shock Absorber Nut (Upper) Swingarm Pivot Adjusting Collar Swingarm Pivot Adjusting Collar Locknut...
  • Page 33 PERIODIC MAINTENANCE 2-11 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Rear Turn Signal Light Lens Screws 0.10 9 in·lb Rear Turn Signal Light Mounting Screws 0.12 10 in·lb Regulator/Rectifier Bolts 0.70 61 in·lb Regulator/Rectifier Bracket Nuts 0.70 61 in·lb Side Stand Switch Bolt 0.90...
  • Page 34: Specifications

    2-12 PERIODIC MAINTENANCE Specifications Item Standard Service Limit Fuel System (DFI) 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Throttle Grip Free Play – – – Idle Speed 1 300 ±50 r/min (rpm) – – – Throttle Body Vacuum 27.3 ±1.333 kPa (205 ±10 mmHg) at idle speed –...
  • Page 35 PERIODIC MAINTENANCE 2-13 Specifications Item Standard Service Limit Final Drive 30 ∼ 40 mm (1.2 ∼ 1.6 in.) Drive Chain Slack – – – 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) Drive Chain Wear (20-link 323 mm (12.7 in.) Length) Standard Chain: Make...
  • Page 36: Special Tools

    2-14 PERIODIC MAINTENANCE Special Tools Inside Circlip Pliers: Oil Filter Wrench: 57001-143 57001-1249 Steering Stem Nut Wrench: Vacuum Gauge: 57001-1100 57001-1369 Jack: Extension Tube: 57001-1238 57001-1578 Pilot Screw Adjuster, A: Jack Attachment: 57001-1239 57001-1608...
  • Page 37: Maintenance Procedure

    PERIODIC MAINTENANCE 2-15 Maintenance Procedure Fuel System (DFI) Throttle Control System Inspection • Check that the throttle grip [B] moves smoothly from full open to close, and the throttle closes quickly and com- pletely by the return spring in all steering positions. If the throttle grip does not return properly, check the throt- tle cables routing, grip free play, and cable damage.
  • Page 38 2-16 PERIODIC MAINTENANCE Maintenance Procedure • Connect a vacuum gauge (special tool) and hoses [A] to the fittings on the throttle body. Special Tool - Vacuum Gauge: 57001-1369 • Connect a highly accurate tachometer lead [B] to one of the stick coil primary lead. •...
  • Page 39 PERIODIC MAINTENANCE 2-17 Maintenance Procedure If any vacuum is not within the specifications, first syn- chronize the balance of the left (#1, #2 throttle valves) and right (#3, #4 throttle valves) assemblies. Example: #1: 165 mmHg #2: 190 mmHg #3: 170 mmHg #4: 200 mmHg •...
  • Page 40: Idle Speed Inspection

    2-18 PERIODIC MAINTENANCE Maintenance Procedure • Remove the bypass screw [A], spring [B], washer [C] and O-ring [D]. ○ Check the bypass screw and its hole for carbon deposits. If any carbon accumulates, wipe the carbon off the bypass screw and the hole, using a cotton pad penetrated with a high-flash point solvent.
  • Page 41: Idle Speed Adjustment

    PERIODIC MAINTENANCE 2-19 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 42: Engine Top End

    2-20 PERIODIC MAINTENANCE Maintenance Procedure • Check the liquid/vapor separator as follows. ○ Remove: Left Middle Fairing (see Middle Fairing Removal in the Frame chapter) ○ Disconnect the hoses from the separator, and remove the separator [A] from the motorcycle left side. ○...
  • Page 43 PERIODIC MAINTENANCE 2-21 Maintenance Procedure • Using a thickness gauge [A], measure the valve clearance between the cam and the valve lifter. Valve Clearance Standard: Exhaust 0.24 ∼ 0.31 mm (0.0094 ∼ 0.0122 in.) 0.13 ∼ 0.19 mm (0.0051 ∼ 0.0075 in.) Inlet NOTE ○...
  • Page 44: Valve Clearance Adjustment

    2-22 PERIODIC MAINTENANCE Maintenance Procedure Valve Clearance Adjustment • To change the valve clearance, remove the camshaft chain tensioner, camshafts and valve lifters. Replace the shim with one of a different thickness. NOTE ○ Mark and record the locations of the valve lifters and shims so that they can be reinstalled in their original positions.
  • Page 45 PERIODIC MAINTENANCE 2-23 Maintenance Procedure Adjustment Shims Thickness Part Number Mark 1.300 92180-0108 1.325 92180-0109 1.350 92180-0110 1.375 92180-0111 1.400 92180-0112 1.425 92180-0113 1.450 92180-0114 1.475 92180-0115 1.500 92180-0116 1.525 92180-0117 1.550 92180-0118 1.575 92180-0119 1.600 92180-0120 1.625 92180-0121 1.650 92180-0122 1.675 92180-0123...
  • Page 46: Air Suction System Damage Inspection

    2-24 PERIODIC MAINTENANCE Maintenance Procedure CAUTION Be sure to remeasure the clearance after selecting a shim. The clearance can be out of the specified range because of the shim tolerance. ○ If there is no valve clearance, use a shim that is a few sizes smaller, and remeasure the valve clearance.
  • Page 47: Cooling System

    PERIODIC MAINTENANCE 2-25 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 side stand).
  • Page 48: Clutch

    2-26 PERIODIC MAINTENANCE Maintenance Procedure Clutch Clutch Operation Inspection • Pull the clutch lever just enough to take up the free play [A]. • Measure the gap between the lever and the lever holder. If the gap is too wide, the clutch may not release fully. If the gap is too narrow, the clutch may not engage fully.
  • Page 49: Wheels/tires

    PERIODIC MAINTENANCE 2-27 Maintenance Procedure Wheels/Tires Air Pressure Inspection • Remove the air valve cap. • Measure the tire air pressure with an air pressure gauge [A] when the tires are cold (that is, when the motorcycle has not been ridden more than a mile during the past 3 hours).
  • Page 50: Wheel Bearing Damage Inspection

    2-28 PERIODIC MAINTENANCE Maintenance Procedure WARNING To ensure safe handling and stability, use only the recommended standard tires for replacement, in- flated to the standard pressure. NOTE ○ Most countries may have their own regulations a mini- mum tire tread depth: be sure to follow them. ○...
  • Page 51: Final Drive

    PERIODIC MAINTENANCE 2-29 Maintenance Procedure Final Drive Drive Chain Lubrication Condition Inspection • If a special lubricant is not available, a heavy oil such as SAE 90 is preferred to a lighter oil because it will stay on the chain longer and provide better lubrication. •...
  • Page 52: Drive Chain Slack Adjustment

    2-30 PERIODIC MAINTENANCE Maintenance Procedure Drive Chain Slack Adjustment • Remove the cotter pin [A], and loosen the axle nut [B]. • Loosen the both chain adjuster locknuts [C]. If the chain is too loose, turn out the left and right chain adjuster [D] evenly.
  • Page 53: Wheel Alignment Inspection

    PERIODIC MAINTENANCE 2-31 Maintenance Procedure Wheel Alignment Inspection • Check that the notch [A] on the left alignment indicator [B] aligns with the same swingarm mark or position [C] that the right alignment indicator notch aligns with. If they do not, adjust the chain slack and align the wheel alignment (see Drive Chain Slack Adjustment).
  • Page 54: Chain Guide Wear Inspection

    2-32 PERIODIC MAINTENANCE Maintenance Procedure Chain Guide Wear Inspection • Remove: Swingarm (see Swingarm Removal in the Suspension chapter) • Visually inspect the chain guide [A]. Replace the chain guide if it shows any signs of abnormal wear or damage. Brakes Brake Fluid Leak (Brake Hose and Pipe) Inspection •...
  • Page 55: Brake Operation Inspection

    PERIODIC MAINTENANCE 2-33 Maintenance Procedure Brake Operation Inspection • Inspect the operation of the front and rear brake by run- ning the vehicle on the dry road. If the brake operation is insufficiency, inspect the brake system. WARNING When inspecting by running the vehicle, note a surrounding traffic situation enough in the place of safety.
  • Page 56: Brake Pad Wear Inspection

    2-34 PERIODIC MAINTENANCE Maintenance Procedure Brake Pad Wear Inspection • Check the lining thickness of the pads in each caliper. Pad Lining Thickness Standard: Front [A] 4.0 mm (0.16 in.) Rear [B] 5.0 mm (0.20 in.) Service Limit [C]: 1 mm (0.04 in.) If the lining thickness of either pad is less than the service limit, replace both pads in the caliper as a set.
  • Page 57: Suspensions

    PERIODIC MAINTENANCE 2-35 Maintenance Procedure If it does not go on, inspect or replace the following items. Battery (see Charging Condition Inspection in the Elec- trical System chapter) Brake Light (see Tail/Brake Light Removal in the Electri- cal System chapter) Main Fuse 30 A and Taillight Fuse 10 A (see Fuse In- spection in the Electrical System chapter) Front Brake Light Switch [A] (see Switch Inspection in...
  • Page 58: Rear Shock Absorber Oil Leak Inspection

    2-36 PERIODIC MAINTENANCE Maintenance Procedure 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. Rocker Arm Operation Inspection •...
  • Page 59: Steering Play Adjustment

    PERIODIC MAINTENANCE 2-37 Maintenance Procedure Steering Play Adjustment • Raise the front wheel off the ground with the jack. • Remove: Upper End of Clutch Cable Upper End of Throttle Cables Stem Head Nut [A] and Washer [B] Handlebar Position Bolts [C] •...
  • Page 60: Steering Stem Bearing Lubrication

    2-38 PERIODIC MAINTENANCE Maintenance Procedure Steering Stem Bearing Lubrication • Remove the steering stem (see Stem, Stem Bearing Re- moval in the Steering chapter). • Using a high-flash point solvent, wash the upper and lower ball bearings in the cages, and wipe the upper and lower outer races, which are press-fitted into the frame head pipe, clean off grease and dirt.
  • Page 61 PERIODIC MAINTENANCE 2-39 Maintenance Procedure Second Step • Turn the ignition switch to P (Park) position. • The city light, tail/brake light (LED) and license plate light should go on. If the light does not go on, inspect or replace the following item.
  • Page 62: Headlight Aiming Inspection

    2-40 PERIODIC MAINTENANCE Maintenance Procedure • Set the dimmer switch to high beam position. • The low beam [A] and high beam [B] headlights should go on. • The high beam indicator light (LED) [C] should go on. If the high beam headlight and/or high beam indicator light (LED) does not go on, inspect or replace the following item.
  • Page 63: Side Stand Switch Operation Inspection

    PERIODIC MAINTENANCE 2-41 Maintenance Procedure NOTE ○ For US model, the proper angle is 0.4 degrees below horizontal. This is 50 mm (2 in.) drop at 7.6 m (25 ft) measured from the center of the headlight with the motorcycle on its wheels and the rider seated. 50 mm (2 in.) [A] Center of Brightest Spot [B] 7.6 m (25 ft) [C]...
  • Page 64: Engine Stop Switch Operation Inspection

    2-42 PERIODIC MAINTENANCE Maintenance Procedure If the side stand switch operation does not work, inspect or replace the following item. Battery (see Charging Condition Inspection in the Elec- trical System chapter) Main Fuse 30 A (see Fuse Inspection in the Electrical System chapter) Ignition Fuse 10 A (see Fuse Inspection in the Electrical System chapter)
  • Page 65: Others

    PERIODIC MAINTENANCE 2-43 Maintenance Procedure Others Chassis Parts Lubrication • Before lubricating each part, clean off any rusty spots with rust remover and wipe off any grease, oil, dirt, or grime. • Lubricate the points listed below with indicated lubricant. NOTE ○...
  • Page 66: Bolts, Nuts And Fasteners Tightness Inspection

    2-44 PERIODIC MAINTENANCE Maintenance Procedure Bolts, Nuts and Fasteners Tightness Inspection • Check the tightness of the bolts and nuts listed here. Also, check to see that each cotter pin is in place and in good condition. NOTE ○ For the engine fasteners, check the tightness of them when the engine is cold (at room temperature).
  • Page 67: Replacement Parts

    PERIODIC MAINTENANCE 2-45 Maintenance Procedure Replacement Parts Air Cleaner Element Replacement NOTE ○ In dusty areas, the element should be replaced more frequently than the recommended interval. ○ After riding through rain or on muddy roads, the element should be replaced immediately. WARNING If dirt or dust is allowed to pass through into the throttle body assy, the throttle may become stuck,...
  • Page 68: Fuel Hose Replacement

    Torque - Air Cleaner Housing Screws: 1.1 N·m (0.11 kgf·m, 9.7 in·lb) CAUTION Use only the recommended air cleaner element (Kawasaki part number 11013-0016). Using another air cleaner element will wear the engine prema- turely or lower the engine performance. •...
  • Page 69 PERIODIC MAINTENANCE 2-47 Maintenance Procedure For Primary Fuel Hose • Be sure to place a piece of cloth [A] around the fuel hose joint [B]. • Insert the (–) screw driver into the slot [C] of the joint lock. • Pull the joint lock [A] as shown.
  • Page 70 2-48 PERIODIC MAINTENANCE Maintenance Procedure For Secondary Fuel Hose • Set up the fuel tank (see Air Cleaner Element Replace- ment). • Be sure to place a piece of cloth [A] around the fuel hose joint [B]. • Push the joint lock claws [C]. •...
  • Page 71: Coolant Change

    PERIODIC MAINTENANCE 2-49 Maintenance Procedure Coolant Change WARNING To avoid burns, do not remove the radiator cap or try to change the coolant when the engine is still hot. Wait until it cools down. Coolant on tires will make them slippery and can cause an accident and injury.
  • Page 72 2-50 PERIODIC MAINTENANCE Maintenance Procedure • Fill the radiator up to the radiator filler neck [A] with coolant, and install the radiator cap. NOTE ○ Pour in the coolant slowly so that it can expel the air from the engine and radiator. •...
  • Page 73: Radiator Hose And O-ring Replacement

    PERIODIC MAINTENANCE 2-51 Maintenance Procedure Radiator Hose and O-ring Replacement • Drain the coolant (see Coolant Change). • Remove: Middle Fairings (see Middle Fairing Removal in the Frame chapter) Throttle Body Assy (see Throttle Body Assy Removal in the Fuel System (DFI) chapter) Thermostat Housing Cover [A] (see Thermostat Re- moval in the Cooling System chapter) Fitting [B]...
  • Page 74: Engine Oil Change

    2-52 PERIODIC MAINTENANCE Maintenance Procedure Engine Oil Change • Remove the left lower fairing (see Lower Fairing Removal in the Frame chapter). • Situate the motorcycle so that it is vertical after warming up the engine. • Remove the engine oil drain bolt [A] to drain the oil. ○...
  • Page 75: 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 the brake hose banjo bolts [A] and washers. • When removing the brake hose, take care not to spill the brake fluid on the painted or plastic parts.
  • Page 76 2-54 PERIODIC MAINTENANCE Maintenance Procedure • Change the brake fluid. ○ Repeat this operation until fresh brake fluid comes out from the plastic hose or the color of the fluid changes. 1. Open the bleed valve [A]. 2. Apply the brake and hold it [B]. 3.
  • Page 77: Master Cylinder Rubber Parts Replacement

    PERIODIC MAINTENANCE 2-55 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 the seal cover [A], circlip [B], connector [C] and O-ring [D].
  • Page 78: Caliper Rubber Parts Replacement

    2-56 PERIODIC MAINTENANCE Maintenance Procedure • Apply brake fluid to the new parts and to the inner wall of the cylinder. • Take care not to scratch the piston or the inner wall of the cylinder. • Tighten the brake lever pivot bolt and the locknut. Silicone Grease - Brake Lever Pivot Bolt Torque - Brake Lever Pivot Bolt: 1.0 N·m (0.10 kgf·m, 9...
  • Page 79 PERIODIC MAINTENANCE 2-57 Maintenance Procedure NOTE ○ If compressed air is not available, do as follows for both calipers coincidentally, with the brake hose connected to the caliper. ○ Prepare a container for brake fluid, and perform the work above it. ○...
  • Page 80 2-58 PERIODIC MAINTENANCE Maintenance Procedure Rear Caliper Disassembly • Remove the rear caliper (see Rear Caliper Removal in the Brakes chapter). • Remove the pads and pad springs (see Rear Brake Pad Removal in the Brakes chapter). • Using compressed air, remove the piston. ○...
  • Page 81: Spark Plug Replacement

    PERIODIC MAINTENANCE 2-59 Maintenance Procedure • Install the pad spring [A] in the caliper as shown. • Apply brake fluid to the outside of the piston [B], and push it into the cylinder by hand. • Replace the shaft rubber friction boot [C] and dust boot [D].
  • Page 83 FUEL SYSTEM (DFI) 3-1 Fuel System (DFI) Table of Contents Exploded View........Water Temperature Sensor Specifications ........3-10 Resistance Inspection ....3-55 Special Tools and Sealant ....3-12 Atmospheric Pressure Sensor DFI Parts Location......3-14 (Service Code 15)......3-56 DFI System........3-16 Atmospheric Pressure Sensor DFI Servicing Precautions ....
  • Page 84 3-2 FUEL SYSTEM (DFI) Subthrottle Sensor Output Voltage Exhaust Butterfly Valve Actuator Inspection........3-71 Inspection........3-91 Resistance Inspection....3-73 Exhaust Butterfly Valve Actuator Oxygen Sensor-not activated (#1, #2: Output Voltage Inspection ..3-91 Service Code 33, 83)-Equipped Air Switching Valve (Service Code Models ..........
  • Page 85 FUEL SYSTEM (DFI) 3-3 Cable Lubrication ......3-116 Air Cleaner Housing Removal..3-124 Throttle Body Assy ......3-117 Air Cleaner Housing Installation... 3-125 Idle Speed Inspection ....3-117 Air Cleaner Housing Disassembly 3-126 Synchronization Inspection ..3-117 Air Cleaner Housing Assembly ..3-126 Synchronization Adjustment ..
  • Page 86: Exploded View

    3-4 FUEL SYSTEM (DFI) Exploded View...
  • Page 87 FUEL SYSTEM (DFI) 3-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Vehicle-down Sensor Bolts 0.60 52 in·lb Air Inlet Duct Mounting Bolts 87 in·lb Air Cleaner Housing Mounting Bolt 0.70 61 in·lb Air Cleaner Housing Screws 0.11 9.7 in·lb Air Cleaner Housing Clamp Bolts 0.20 17 in·lb...
  • Page 88 3-6 FUEL SYSTEM (DFI) Exploded View...
  • Page 89 FUEL SYSTEM (DFI) 3-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Delivery Pipe Mounting Screws (Nozzle Assy) 0.35 30 in·lb Nozzle Assy Mounting Bolts 0.70 61 in·lb Throttle Cable Holder Plate Bolt 0.40 35 in·lb Nozzle Assy Fuel Hose Screw 0.50 43 in·lb Delivery Pipe Mounting Screws (Throttle Body)
  • Page 90 3-8 FUEL SYSTEM (DFI) Exploded View...
  • Page 91 FUEL SYSTEM (DFI) 3-9 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Separator Bracket Mounting Bolt 0.08 7 in·lb Spark Plugs 113 in·lb Camshaft Position Sensor Bolt 87 in·lb Water Temperature Sensor Crankshaft Sensor Bolts 0.60 52 in·lb Fuel Pump Bolts 87 in·lb L, S Exhaust Butterfly Valve Actuator Mounting Nuts...
  • Page 92: Specifications

    3-10 FUEL SYSTEM (DFI) Specifications Item Standard Digital Fuel Injection System Idle Speed 1 300 ±50 r/min (rpm) Throttle Assy: Type Oval type Bore 38 mm (1.5 in.) Throttle Body Vacuum 27.3 ±1.0 kPa (205 ±10 mmHg) Bypass Screws – – – ECU (Electronic Control Unit): Make Denso...
  • Page 93 FUEL SYSTEM (DFI) 3-11 Specifications Item Standard Vehicle-down Sensor: Detection Method Magnetic flux detection method More than 60 ∼ 70° for each bank Detection Angle with in 1.0 ∼ 1.5 sec. Detection Time with sensor arrow mark pointed up: 3.55 ∼ 4.45 V Output Voltage with sensor tilted 60 ∼...
  • Page 94: Special Tools And Sealant

    3-12 FUEL SYSTEM (DFI) Special Tools and Sealant Oil Pressure Gauge, 5 kgf/cm²: Needle Adapter Set: 57001-125 57001-1457 Carburetor Drain Plug Wrench, Hex 3: Throttle Sensor Setting Adapter: 57001-1269 57001-1538 Fork Oil Level Gauge: Sensor Harness Adapter: 57001-1290 57001-1561 Hand Tester: Fuel Pressure Gauge Adapter: 57001-1394 57001-1593...
  • Page 95 FUEL SYSTEM (DFI) 3-13 Special Tools and Sealant Kawasaki Bond (Silicone Sealant): 56019-120...
  • Page 96: Dfi Parts Location

    Throttle Body Assy [D] Subthrottle Sensor [A] Main Throttle Sensor [B] Water Temperature Sensor [C] Battery [A] Kawasaki Self-Diagnosis System (KDS) Connector [B] Exhaust Butterfly Valve Actuator [C] Atmospheric Pressure Sensor [D] ECU (Electronic Control Unit) [E] Exhaust Butterfly Valve [A]...
  • Page 97 FUEL SYSTEM (DFI) 3-15 DFI Parts Location Camshaft Position Sensor [A] Crankshaft Sensor [B] Gear Position Switch [A] Speed Sensor [B] Fuse Box with ECU Main Fuse [A] Relay Box [B] Ignition Key [A] (Transponder, Equipped Models) Immobilizer Antenna [B] (Equipped Models) Ignition Switch [C] Immobilizer Amplifier [D] (Equipped Models) Vehicle-down Sensor [E]...
  • Page 98: Dfi System

    3-16 FUEL SYSTEM (DFI) DFI System DFI System...
  • Page 99 FUEL SYSTEM (DFI) 3-17 DFI System 1. ECU (Electrical Control Unit) 2. Battery 12 V 8 Ah 3. Air Flow 4. Air Cleaner Element 5. Inlet Air Temperature Sensor 6. Inlet Air Pressure Sensor 7. Subthrottle Valve Actuator 8. Subthrottle Sensor 9.
  • Page 100 3-18 FUEL SYSTEM (DFI) DFI System DFI System Wiring Diagram...
  • Page 101 12. Frame Ground 13. Battery 12 V 8 Ah 14. Fuel Pump 15. Vehicle-down Sensor 16. Kawasaki Self-diagnostic System (KDS) Connector 17. Engine Stop Switch 18. Starter Button 19. Oxygen Sensor (#1, Equipped Models) 20. Oxygen Sensor (#2, Equipped Models) 21.
  • Page 102 3-20 FUEL SYSTEM (DFI) DFI System Terminal Numbers of ECU Connectors Terminal Names 1. Subthrottle Valve Actuator Drive Signal 3 35. Oxygen Sensor Output Signal 2. Subthrottle Valve Actuator Drive Signal 1 (Equipped Models) 3. Exhaust Butterfly Valve Actuator (–) 36.
  • Page 103: Dfi Servicing Precautions

    FUEL SYSTEM (DFI) 3-21 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 104 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 105: Troubleshooting The Dfi System

    FUEL SYSTEM (DFI) 3-23 Troubleshooting the DFI System The warning indicator light (LED) [A] is used for the FI indicator, immobilizer indicator (immobilizer models) and oil pressure warning indicator. Outline When a problem occurs with DFI system, the warning in- dicator light (LED) [A] and FI warning symbol [B] blinks to alert the rider.
  • Page 106 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. When the motorcycle is down, the vehicle-down sensor is turned OFF and the ECU shuts off the fuel pump relay, fuel injectors and ignition system.
  • Page 107 After measurement, remove the needle adapters and ap- ply silicone sealant to the seals [A] of the connector [B] for waterproofing. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 • Always check battery condition before replacing the DFI parts. A fully charged battery is a must for conducting accurate tests of the DFI system.
  • Page 108 3-26 FUEL SYSTEM (DFI) Troubleshooting the DFI System • Pull each connector [A] apart and inspect it for corrosion, dirt, and damage. If the connector is corroded or dirty, clean it carefully. If it is damaged, replace it. Connect the connectors securely. •...
  • Page 109: Inquiries To Rider

    FUEL SYSTEM (DFI) 3-27 Troubleshooting the DFI System ○ Lead Color Codes: BK: Black G: Green P: Pink BL: Blue GY: Gray PU: Purple BR: Brown LB: Light Blue R: Red CH: Chocolate LG: Light Green W: White DG: Dark Green O: Orange Y: Yellow DFI Diagnosis Flow Chart...
  • Page 110 3-28 FUEL SYSTEM (DFI) Troubleshooting the DFI System Sample Diagnosis Sheet Rider name: Registration No. (license plate No.): Year of initial registration: Model: Engine No.: Frame No.: Date problem occurred: Mileage: Environment when problem occurred. □ □ □ □ □ □...
  • Page 111 FUEL SYSTEM (DFI) 3-29 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 112: Dfi System Troubleshooting Guide

    3-30 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide NOTE ○ This is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties in DFI system.
  • Page 113 FUEL SYSTEM (DFI) 3-31 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Fuel pressure regulator trouble Inspect fuel pressure and replace fuel pump (see chapter 3). Fuel line clogged Inspect and repair (see chapter 3). Inlet air pressure sensor trouble Inspect (see chapter 3).
  • Page 114 3-32 FUEL SYSTEM (DFI) 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 115: Poor Running Or No Power At High Speed

    FUEL SYSTEM (DFI) 3-33 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 116 3-34 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) 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). Subthrottle valve actuator trouble Inspect (see chapter 3).
  • Page 117: Self-diagnosis

    FUEL SYSTEM (DFI) 3-35 Self-Diagnosis The warning indicator light (LED) [A] is used for the FI indicator, immobilizer indicator (immobilizer models) and oil pressure warning indicator. 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, ig- nition system and immobilizer system by blinking the warn-...
  • Page 118: Self-diagnosis Procedures

    3-36 FUEL SYSTEM (DFI) Self-Diagnosis Self-diagnosis Procedures ○ When a problem occurs with the DFI system and ignition system, the warning indicator light (LED) [A] and FI warn- ing symbol [B] blinks. ○ For models equipped with an immobilizer system, when a problem occurs with the system, the warning indicator light (LED) and immobilizer warning symbol [C] blinks.
  • Page 119 FUEL SYSTEM (DFI) 3-37 Self-Diagnosis • Push the MODE button [A] for more than two seconds. • The service code [B] is displayed on the LCD by the num- ber of two digits. Immobilizer Models [C] • Any of the following procedures ends self-diagnosis. ○...
  • Page 120: Service Code Reading

    3-38 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 121 FUEL SYSTEM (DFI) 3-39 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 malfunction, wiring open or short...
  • Page 122: Backups

    3-40 FUEL SYSTEM (DFI) Self-Diagnosis Backups ○ The ECU takes the following measures to prevent engine damage when the DFI, ignition or immo- bilizer system parts have troubles. Service Output Signal Usable Parts Backups by ECU Codes Range or Criteria If the main throttle sensor system fails (the output voltage is out of the usable range, wiring Main Throttle...
  • Page 123 FUEL SYSTEM (DFI) 3-41 Self-Diagnosis Service Output Signal Usable Parts Backups by ECU Codes Range or Criteria The oxygen sensor #1 is active and Oxygen Sensor sensor must send If the oxygen sensor is not activated, the ECU #1 (Equipped signals (output voltage) stops the feedback mode of the oxygen sensor.
  • Page 124 3-42 FUEL SYSTEM (DFI) Self-Diagnosis Service Output Signal Usable Parts Backups by ECU Codes Range or Criteria The actuator operates If the exhaust butterfly valve actuator fails (the Exhaust open and close of the signal is out to the usable range, wiring short Butterfly Valve exhaust butterfly valve or open), the ECU stops the current to the...
  • Page 125: Main Throttle Sensor (service Code 11)

    FUEL SYSTEM (DFI) 3-43 Main Throttle Sensor (Service Code 11) The main throttle sensor is a rotating variable resistor that changes 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 126: Main Throttle Sensor Output Voltage Inspection

    3-44 FUEL SYSTEM (DFI) Main Throttle Sensor (Service Code 11) • Disconnect the main throttle sensor connector and con- nect the setting adapter [A] between the harness connec- tor and main throttle sensor connector. • Connect a digital meter [B] to the setting adapter leads. Special Tool - Throttle Sensor Setting Adapter: 57001 -1538...
  • Page 127: Main Throttle Sensor Resistance Inspection

    FUEL SYSTEM (DFI) 3-45 Main Throttle Sensor (Service Code 11) If the output voltage is within the standard range, check the ECU for a good ground, and power supply (see ECU Power Supply Inspection). If the ground and power sup- ply are good, replace the ECU.
  • Page 128 3-46 FUEL SYSTEM (DFI) Main Throttle Sensor (Service Code 11) Main Throttle Sensor Circuit 1. ECU 2. Main Throttle Sensor 3. Subthrottle Sensor...
  • Page 129: Inlet Air Pressure Sensor (service Code 12)

    FUEL SYSTEM (DFI) 3-47 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 • Turn the ignition switch OFF. •...
  • Page 130: Inlet Air Pressure Sensor Output Voltage Inspection

    3-48 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code 12) If the reading is within the standard range, and check the input voltage again at the sensor connector. • Disconnect the inlet air pressure sensor connector and connect the harness adapter [A] between the sub harness connector and inlet air pressure sensor connector.
  • Page 131 FUEL SYSTEM (DFI) 3-49 Inlet Air Pressure Sensor (Service Code 12) If the output voltage is far out of the usable range, check the output voltage again at the sensor connector [A] (when the lead is open, the output voltage is about 1.8 V.).
  • Page 132 3-50 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code 12) • Remove the inlet air pressure sensor [A] and disconnect the vacuum hose from the sensor. ○ Do not disconnect the sensor connector. • Connect an auxiliary hose [B] to the inlet air pressure sen- sor.
  • Page 133 FUEL SYSTEM (DFI) 3-51 Inlet Air Pressure Sensor (Service Code 12) ID: Idling Ps: Standard Atmospheric Pressure (Absolute) Pv: Throttle Vacuum Pressure (Absolute) ST: Standard of Sensor Output Voltage (V) TO: Throttle Full Open UR: Usable Range of Sensor Output Voltage (V) Vv: Inlet Air Pressure Sensor Output Voltage (V) (Digital Meter Reading)
  • Page 134: Inlet Air Temperature Sensor (service Code 13)

    3-52 FUEL SYSTEM (DFI) Inlet Air Temperature Sensor (Service Code 13) Inlet Air Temperature Sensor Removal/Installation CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. • Set up the fuel tank (see Air Cleaner Housing Removal). •...
  • Page 135: Inlet Air Temperature Sensor Resistance Inspection

    • Remove the needle adapter set, and apply silicone sealant to the seals of the connector for waterproofing. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 If the wiring is good, check the sensor resistance. Inlet Air Temperature Sensor Resistance Inspection •...
  • Page 136: Water Temperature Sensor (service Code 14)

    Replace the gasket with new one. • Apply silicone sealant to the threads of the water temper- ature sensor and tighten it. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 Torque - Water Temperature Sensor: 25 N·m (2.5 kgf·m, 18 ft·lb) •...
  • Page 137: Water Temperature Sensor Resistance Inspection

    If the wiring is good, check the water temperature sensor resistance. • Remove the needle adapter set, and apply silicone sealant to the seals of the connector for waterproofing. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 Water Temperature Sensor Circuit 1. ECU 2. Meter Unit 3. Water Temperature Sensor Water Temperature Sensor Resistance Inspection •...
  • Page 138: Atmospheric Pressure Sensor (service Code 15)

    3-56 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. Atmospheric Pressure Sensor Removal • Turn the ignition switch OFF. • Remove: Seat (see Seat Removal in the Frame chapter) Atmospheric Pressure Sensor Connector [A]...
  • Page 139: Atmospheric Pressure Sensor Output Voltage Inspection

    FUEL SYSTEM (DFI) 3-57 Atmospheric Pressure Sensor (Service Code 15) If the reading is within the standard range, check the input voltage again at the sensor connector. • Remove the seat cover (see Seat Cover Removal in the Frame chapter). •...
  • Page 140 3-58 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 141 FUEL SYSTEM (DFI) 3-59 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 142: Crankshaft Sensor (service Code 21)

    3-60 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 143: Camshaft Position Sensor (service Code 23)

    FUEL SYSTEM (DFI) 3-61 Camshaft Position Sensor (Service Code 23) 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 144: Speed Sensor (service Code 24)

    3-62 FUEL SYSTEM (DFI) Speed Sensor (Service Code 24) Speed Sensor Removal/Installation • See the Speed Sensor Removal/Installation in the Elec- trical System chapter. Speed Sensor Inspection • See the Speed Sensor Inspection in the Electrical System chapter. Speed Sensor Input Voltage Inspection NOTE ○...
  • Page 145 FUEL SYSTEM (DFI) 3-63 Speed Sensor (Service Code 24) • Disconnect the speed sensor connector, and connect the setting adapter [A] between the harness connector [B] and speed sensor connector [C]. • Connect a digital meter to the setting adapter leads. Special Tool - Throttle Sensor Setting Adapter #1: 57001 -1400 Speed Sensor Output Voltage...
  • Page 146: Gear Position Switch (service Code 25)

    3-64 FUEL SYSTEM (DFI) 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 147 FUEL SYSTEM (DFI) 3-65 Gear Position Switch (Service Code 25) Gear Position Switch Circuit 1. ECU 2. Gear Position Switch 3. Battery 12 V 8 Ah 4. Frame Ground...
  • Page 148: Vehicle-down Sensor (service Code 31)

    3-66 FUEL SYSTEM (DFI) 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 149: Vehicle-down Sensor Inspection

    FUEL SYSTEM (DFI) 3-67 Vehicle-down Sensor (Service Code 31) Vehicle-down Sensor Inspection NOTE ○ Be sure the battery is fully charged. • Remove: Windshield (see Windshield Removal in the Frame chapter) Rubber Cover (pry open) • Connect a digital volt meter [A] to the connector of the vehicle-down sensor [B], with the needle adapter set [C].
  • Page 150 Turn the ignition switch OFF. • Remove the needle adapter set, and apply silicone sealant to the seals of the connector for waterproofing. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 If the output voltage is out of the specified, replace the vehicle-down sensor.
  • Page 151 FUEL SYSTEM (DFI) 3-69 Vehicle-down Sensor (Service Code 31) Vehicle-down Sensor Circuit 1. ECU 2. Vehicle-down Sensor...
  • Page 152: Subthrottle Sensor (service Code 32)

    3-70 FUEL SYSTEM (DFI) Subthrottle Sensor (Service Code 32) Subthrottle Sensor Removal/Adjustment CAUTION Do not remove or adjust the subthrottle sensor [A] since it has been adjusted and set with precision at the factory. Never drop the throttle body assy, especially on a hard surface.
  • Page 153: Subthrottle Sensor Output Voltage Inspection

    FUEL SYSTEM (DFI) 3-71 Subthrottle Sensor (Service Code 32) • Disconnect the subthrottle sensor connector [A] and con- nect the setting adapter [B] between the harness connec- tor and sub throttle sensor connector. • Connect a digital meter to the setting adapter leads. Special Tool - Throttle Sensor Setting Adapter: 57001 -1538...
  • Page 154 3-72 FUEL SYSTEM (DFI) Subthrottle Sensor (Service Code 32) If the output voltage is within the standard range, check the ECU for a good ground, and power supply (see ECU Power Supply Inspection). If the ground and power sup- ply are good, replace the ECU (see ECU Removal/Instal- lation).
  • Page 155: Resistance Inspection

    FUEL SYSTEM (DFI) 3-73 Subthrottle Sensor (Service Code 32) Resistance Inspection • Turn the ignition switch OFF. • Disconnect the subthrottle sensor connector. • Connect a digital meter [A] to the subthrottle sensor con- nector [B]. • Measure the subthrottle sensor resistance. Subthrottle Sensor Resistance Connections: BL lead [C] ←→...
  • Page 156: Oxygen Sensor-not Activated (#1, #2: Service Code 33, 83)-equipped Models

    3-74 FUEL SYSTEM (DFI) Oxygen Sensor-not activated (#1, #2: Service Code 33, 83)-Equipped Models Oxygen Sensor #1: Service Code 33 Oxygen Sensor #2: Service Code 83 Oxygen Sensor Removal/Installation • Refer to Oxygen Sensor Removal and Installation in the Electrical System chapter (see Oxygen Sensor Removal in the Electrical System chapter).
  • Page 157 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 Oxygen Sensor Circuit 1. ECU 2. Oxygen Sensor #1 3.
  • Page 158: Exhaust Butterfly Valve Actuator Sensor (service Code 34)

    3-76 FUEL SYSTEM (DFI) Exhaust Butterfly Valve Actuator Sensor (Service Code 34) Exhaust Butterfly Valve Actuator Sensor Removal/Installation The exhaust butterfly valve actuator sensor is built in the exhaust butterfly valve actuator. So, the sensor itself can not be removed. Remove the exhaust butterfly valve actu- ator (see Exhaust Butterfly Valve Actuator Removal).
  • Page 159: Exhaust Butterfly Valve Actuator Sensor Output Voltage Inspection

    FUEL SYSTEM (DFI) 3-77 Exhaust Butterfly Valve Actuator Sensor (Service Code 34) Exhaust Butterfly Valve Actuator Sensor Output Voltage Inspection NOTE ○ Before this inspection, confirm the pulley [A] is original position (see Exhaust Butterfly Valve Actuator Installa- tion). • Remove: Exhaust Butterfly Valve Actuator (see Exhaust Butterfly Valve Actuator Removal)
  • Page 160: Exhaust Butterfly Valve Actuator Sensor Inspection

    3-78 FUEL SYSTEM (DFI) Exhaust Butterfly Valve Actuator Sensor (Service Code 34) Exhaust Butterfly Valve Actuator Sensor Inspection • Remove: Seat Cover (see Seat Cover Removal in the Frame chapter) Bolts [A] Screw [B] • Pull out the exhaust butterfly valve actuator [C]. •...
  • Page 161: Immobilizer Amplifier (service Code 35)-equipped Models

    FUEL SYSTEM (DFI) 3-79 Immobilizer Amplifier (Service Code 35)-Equipped Models Antenna Resistance Inspection • Remove: Left Inner Cover (see Inner Cove Removal in the Frame chapter) • Disconnect: Antenna Lead Connector [A] • Measure the resistance of the antenna coil in the ignition switch as follows.
  • Page 162: Blank Key Detection (service Code 36)

    3-80 FUEL SYSTEM (DFI) Blank Key Detection (Service Code 36) This code appears in the following conditions. ○ The transponder [A] in the master and/or user key is mal- function. ○ When the spare key of unregistration is used. ○ When the master key is registered in the registered ECU.
  • Page 163 9. ECU Fuse 10 A 10. Ignition Fuse 10 A 11. Fuse Box 12. Relay Box 13. ECU Main Relay 14. Frame Ground 15. Main Fuse 30 A 16. Starter Relay 17. Battery 12 V 8 Ah 18. Immobilizer/Kawasaki Diagnostic System Connector...
  • Page 164: Ecu Communication Error (service Code 39)

    3-82 FUEL SYSTEM (DFI) ECU Communication Error (Service Code 39) ECU Communication Line Inspection ○ When the data is not sent from the ECU to the meter unit for more than about 10 seconds, the service code 39 is displayed. ○...
  • Page 165: Stick Coils #1, #2, #3, #4: (service Code 51, 52, 53, 54)

    FUEL SYSTEM (DFI) 3-83 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 166 3-84 FUEL SYSTEM (DFI) Stick Coils #1, #2, #3, #4: (Service Code 51, 52, 53, 54) Stick Coil Circuit 1. Ignition Switch 2. Engine Stop Switch 3. Stick Coil #1 4. Stick Coil #2 5. Stick Coil #3 6. Stick Coil #4 7.
  • Page 167: Radiator Fan Relay (service Code 56)

    FUEL SYSTEM (DFI) 3-85 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 168 3-86 FUEL SYSTEM (DFI) Radiator Fan Relay (Service Code 56) Radiator Fan Relay Circuit 1. ECU 10. ECU Fuse 10 A 2. Water Temperature Sensor 11. Ignition Fuse 10 A 3. Radiator Fan 12. Fuse Box 4. Joint Connector C 13.
  • Page 169: Subthrottle Valve Actuator (service Code 62)

    FUEL SYSTEM (DFI) 3-87 Subthrottle Valve Actuator (Service Code 62) Subthrottle Valve Actuator Removal CAUTION Do not remove the subthrottle valve actuator [A] since it has been adjusted and set with precision at the factory. Never drop the throttle body assy, especially on a hard surface.
  • Page 170: Subthrottle Valve Actuator Input Voltage Inspection

    3-88 FUEL SYSTEM (DFI) Subthrottle Valve Actuator (Service Code 62) Subthrottle Valve Actuator Input Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch OFF. • Connect the peak voltage adapter [A] and a digital meter [B] to the connector [C], using the needle adapter set [D].
  • Page 171: Exhaust Butterfly Valve Actuator (service Code 63)

    FUEL SYSTEM (DFI) 3-89 Exhaust Butterfly Valve Actuator (Service Code 63) Exhaust Butterfly Valve Actuator Removal • Remove: Seat Cover (see Seat Cover Removal in the Frame chapter) • Put off the rubber boots of exhaust butterfly valve cables. • Loosen the locknuts [A] and adjuster nut [B].
  • Page 172 3-90 FUEL SYSTEM (DFI) Exhaust Butterfly Valve Actuator (Service Code 63) • Fit the hole side [A] of the pulley to the groove side [B] of the actuator. • Install the pulley [A] on the actuator. • Hold the pulley with a suitable tool [B] and tighten the bolt. Torque - Exhaust Butterfly Valve Actuator Pulley Bolt: 4.9 N·m (0.50 kgf·m, 43 in·lb) CAUTION...
  • Page 173: Exhaust Butterfly Valve Actuator Inspection

    FUEL SYSTEM (DFI) 3-91 Exhaust Butterfly Valve Actuator (Service Code 63) Exhaust Butterfly Valve Actuator Inspection NOTE ○ Be sure to the battery in fully charged. • Remove: Seat Cover (see Seat Cover Removal in the Frame chapter) • Turn the ignition switch ON. •...
  • Page 174 3-92 FUEL SYSTEM (DFI) Exhaust Butterfly Valve Actuator (Service Code 63) Exhaust Butterfly Valve Actuator Circuit 1. ECU 2. Exhaust Butterfly Valve Actuator...
  • Page 175: Air Switching Valve (service Code 64)

    FUEL SYSTEM (DFI) 3-93 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 176: Oxygen Sensor Heaters (#1, #2: Service Code 67)-equipped Models

    3-94 FUEL SYSTEM (DFI) Oxygen Sensor Heaters (#1, #2: Service Code 67)-Equipped Models Oxygen Sensor Heater Removal/Installation The oxygen sensor heater is bult in the oxygen sensor. So, the heater itself can not be removed. Remove the oxy- gen sensor (see Oxygen Sensor Removal in the Electrical System chapter).
  • Page 177 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 Oxygen Sensor Circuit 1. ECU 2. Oxygen Sensor #1 3. Oxygen Sensor #2 4.
  • Page 178: Oxygen Sensors-incorrect Output

    3-96 FUEL SYSTEM (DFI) Oxygen Sensors-Incorrect Output Voltage (#1, #2: Service Code 94, 95)-Equipped Models Oxygen Sensor #1: Service Code 94 Oxygen Sensor #2: Service Code 95 Oxygen Sensor Removal/Installation • Refer to Oxygen Sensor Removal and Installation in the Electrical System chapter.
  • Page 179: Oxygen Sensor Inspection

    • Remove the needle adapter set, and apply silicone sealant to the seals of the connector for waterproofing. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 Oxygen Sensor Circuit 1. ECU 2. Oxygen Sensor #1 3. Oxygen Sensor #2 4.
  • Page 180: Ecu

    3-98 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 181: Ecu Installation

    FUEL SYSTEM (DFI) 3-99 ECU Installation • Install: ECU [A] (In rubber protector [B]) ECU Lead Connectors [C] • Insert the slots [A] of the protector onto the brackets [B]. ECU Power Supply Inspection • Visually inspect the terminals [A] of the ECU connectors. If the connector is clogged with mud or dust, blow it off with compressed air.
  • Page 182 3-100 FUEL SYSTEM (DFI) • Check the ECU power source voltage with a tester [A]. ○ Position the terminal in accordance with terminal numbers of ECU connectors in this chapter figure. Battery [B] ECU Power Source Inspection Tester Connections: between 16 (W/Y) Terminal and Battery (–) Terminal between 17 (W/BK) Terminal and Battery (–) Terminal Ignition Switch OFF: 16 (W/Y) Terminal 0 V,...
  • Page 183: Dfi Power Source

    FUEL SYSTEM (DFI) 3-101 DFI Power Source ECU Fuse Removal • Refer to the Electrical System chapter for the 10 A ECU Fuse Removal. ECU Fuse Installation If a fuse fails during operation, inspect the DFI system to determine the cause, and then replace it with a new fuse of proper amperage.
  • Page 184: Warning Indicator Light (led)

    3-102 FUEL SYSTEM (DFI) Warning Indicator Light (LED) Warning Indicator Light (LED) Inspection ○ The warning indicator light (LED) [A] is used for the FI indicator, immobilizer indicator (immobilizer models) and oil pressure warning indicator. ○ In this model, the warning indicator light (LED) (FI/immo- bilizer) blink by the data sent from the ECU.
  • Page 185: Fuel Line

    FUEL SYSTEM (DFI) 3-103 Fuel Line Fuel Pressure Inspection NOTE ○ Be sure the battery is fully charged. • Remove: Front Seat (see Front Seat Removal in the Frame chap- ter) • Set up the fuel tank (see Air Cleaner Housing Removal). •...
  • Page 186: Fuel Flow Rate Inspection

    3-104 FUEL SYSTEM (DFI) Fuel Line Fuel Pressure (Idling) Standard: 294 kPa (3.0 kgf/cm², 43 psi) NOTE ○ The gauge hand will fluctuate. Read the pressure at the average of the maximum and minimum indications. If the fuel pressure is much higher than the specified, the fuel pressure regulator in the fuel pump have been clogged or stuck.
  • Page 187 FUEL SYSTEM (DFI) 3-105 Fuel Line • Open the fuel tank cap [A] to lower the pressure in the tank. • Be sure to place a piece of cloth around the fuel supply pipe of the fuel pump. • Remove the fuel hose from the fuel supply pipe of the fuel pump (see Fuel Tank Removal).
  • Page 188: Fuel Pump

    3-106 FUEL SYSTEM (DFI) Fuel Pump Fuel Pump Removal CAUTION Never drop the fuel pump, especially on a hard sur- face. Such a shock to the pump can damage it. WARNING Gasoline is extremely flammable and can be explo- sive under certain conditions. Make sure the area is well-ventilated and free from any source of flame or sparks;...
  • Page 189: Fuel Pump Operation Inspection

    FUEL SYSTEM (DFI) 3-107 Fuel Pump • Check that the fuel pump terminals [A], fuel reserve switch terminal [B] and band [C] are in place. Front [D] • Apply a non-permanent locking agent to the threads of the fuel pump bolts. •...
  • Page 190 3-108 FUEL SYSTEM (DFI) Fuel Pump If the reading stays on battery voltage, and never shows 0 V. Check the ECU and fuel pump relay. If the voltage is in specification, but the pump doesn’t work, replace the pump (see Fuel Pump Removal/Instal- lation).
  • Page 191: Fuel Pump Relay

    FUEL SYSTEM (DFI) 3-109 Fuel Pump Relay Fuel Pump Relay Removal CAUTION Never drop the relay, especially on a hard surface. Such a shock to the relay can damage it. ○ The fuel pump relay is included in the relay box. •...
  • Page 192: Fuel Injectors

    3-110 FUEL SYSTEM (DFI) Fuel Injectors CAUTION Never drop the injector, especially on a hard sur- face. Such a shock to the injector can damage it. Audible Inspection • Set up the fuel tank (see Air Cleaner Housing Removal). • Start the engine.
  • Page 193: Injector Resistance Inspection

    FUEL SYSTEM (DFI) 3-111 Fuel Injectors ○ Injector signals can be also confirmed by connecting the hand tester (AC 10 V) instead of the test light set to the injector main harness connector. Crank the engine with the starter motor, and check to see if the hand oscillates at regular intervals.
  • Page 194: Injector Unit Test

    3-112 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 Battery [D] CAUTION Be sure to connect the bulb in series.
  • Page 195 FUEL SYSTEM (DFI) 3-113 Fuel Injectors Secondary Fuel Injector Output Voltage Connections to Injector #1 Meter (+) → O/R lead Meter (–) → Battery (–) Terminal Connections to Injector #2 Meter (+) → O/G lead Meter (–) → Battery (–) Terminal Connections to Injector #3 Meter (+) →...
  • Page 196: Injector Fuel Line Inspection

    3-114 FUEL SYSTEM (DFI) Fuel Injectors Injector Fuel Line Inspection • Remove the nozzle assy (see Nozzle Assy Removal). • Remove the throttle body assy (see Throttle Body Assy). • Check the injector fuel line for leakage as follows: ○ Connect a commercially available vacuum/pressure pump [A] to the nipple of the delivery pipe [B] with the fuel hose [C] (both ends connected with the clamps [D])
  • Page 197 FUEL SYSTEM (DFI) 3-115 Fuel Injectors Fuel Injector Circuit 1. ECU 2. Secondary Fuel Injector #1 3. Secondary Fuel Injector #2 4. Secondary Fuel Injector #3 5. Secondary Fuel Injector #4 6. Primary Fuel Injector #1 7. Primary Fuel Injector #2 8.
  • Page 198: Throttle Grip And Cables

    3-116 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 199: Throttle Body Assy

    FUEL SYSTEM (DFI) 3-117 Throttle Body Assy Idle Speed Inspection • Refer to the Idle Speed Inspection in the Periodic Main- tenance chapter . Synchronization Inspection • Refer to the Engine Vacuum Synchronization Inspection in the Periodic Maintenance chapter. Synchronization Adjustment •...
  • Page 200: Throttle Body Assy Installation

    3-118 FUEL SYSTEM (DFI) Throttle Body Assy • Remove the throttle case [A] to make a throttle cable slack. • Remove: Bolt [A] Holding Plate [B] Throttle Cables [C] • After removing the throttle body assy, stuff pieces of lint -free, clean cloths into the throttle body holders.
  • Page 201: Throttle Body Assy Disassembly

    FUEL SYSTEM (DFI) 3-119 Throttle Body Assy • Adjust: Throttle Grip Free Play (see Throttle Control System In- spection in the Periodic Maintenance chapter) Idle Speed (see Idle Speed Adjustment in the Periodic Maintenance chapter) Throttle Body Assy Disassembly 1. Subthrottle Valve Actuator 2.
  • Page 202: Throttle Body Assy Assembly

    3-120 FUEL SYSTEM (DFI) Throttle Body Assy • Pull out the injectors [A] from the delivery pipe [B]. NOTE ○ Do not damage the part of insert of the injectors when they are pulled out from the delivery pipe. • Separate the delivery pipes.
  • Page 203: Nozzle Assy

    FUEL SYSTEM (DFI) 3-121 Nozzle Assy Nozzle Assy Removal • Set up the fuel tank (see Air Cleaner Housing Removal). • Be sure to place a piece of cloth [A] around the fuel hose joint [B]. • Push the joint lock claws [C]. •...
  • Page 204: Nozzle Assy Disassembly

    3-122 FUEL SYSTEM (DFI) Nozzle Assy Nozzle Assy Disassembly • Remove the nozzle assy (see Nozzle Assy Removal). • Remove the screws [A] to pull out the injector assys from the stay plate comp together with the delivery pipe assy. NOTE ○...
  • Page 205 FUEL SYSTEM (DFI) 3-123 Nozzle Assy • Apply engine oil to the new O-rings [A]. • Fit the connector portion [B] of the injector to the slot [C] of delivery pipe. • Apply engine oil to the new dust seals [A]. •...
  • Page 206: Air Cleaner

    3-124 FUEL SYSTEM (DFI) Air Cleaner Air Cleaner 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). Air Cleaner 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 207: Air Cleaner Housing Installation

    FUEL SYSTEM (DFI) 3-125 Air Cleaner • Loosen: Air Cleaner Housing Clamp Bolts [A] • Remove: Clamp [A] Engine Breather Hose [B] Clamp [C] Drain Hose [D] • Remove the air switching valve hose [A]. Air Cleaner Housing Installation • Install the vacuum switch valve hose to the air cleaner housing.
  • Page 208: Air Cleaner Housing Disassembly

    3-126 FUEL SYSTEM (DFI) Air Cleaner • Install: Inlet Air Temperature Sensor [A] Inlet Air Pressure Sensor [B] Hooks [C] • Run the harness and hose as shown. Air Cleaner Housing Disassembly • Remove: Air Cleaner Housing (see Air Cleaner Housing Removal) Inlet Air Temperature Sensor Nozzle Assy [A] (see Nozzle Assy Removal) Clamps [B]...
  • Page 209: Oil Draining

    FUEL SYSTEM (DFI) 3-127 Air Cleaner 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 end, if the water or oil accu- mulates in the tank.
  • Page 210: Fuel Tank

    3-128 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 211 FUEL SYSTEM (DFI) 3-129 Fuel Tank • Be sure to place a piece of cloth [A] around the fuel hose joint [B]. • Insert the (–) screw driver into the slot [C] of the joint lock. • Pull the joint lock [A] as shown. •...
  • Page 212: Fuel Tank Installation

    3-130 FUEL SYSTEM (DFI) Fuel Tank Fuel Tank Installation • Note the above WARNING (see Fuel Tank Removal). • Route the hoses correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). • For California Model, note the following. ○...
  • Page 213: Fuel Tank Cleaning

    FUEL SYSTEM (DFI) 3-131 Fuel Tank Fuel Tank Cleaning WARNING Clean the tank in a well-ventilated area, and take care that there are no sparks or flame anywhere near the working area. Because of the danger or highly flammable liquids, do not use gasoline or low-flash point solvents to clean the tank.
  • Page 214: Evaporative Emission Control System (california Model)

    3-132 FUEL SYSTEM (DFI) Evaporative Emission Control System (California Model) 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 215: Separator Operation Test

    FUEL SYSTEM (DFI) 3-133 Evaporative Emission Control System (California Model) 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 217 COOLING SYSTEM 4-1 Cooling System Table of Contents Exploded View........................Specifications ......................... Special Tools .......................... Coolant Flow Chart......................... Coolant ........................... Coolant Deterioration Inspection..................Coolant Level Inspection....................Coolant Draining ....................... Coolant Filling ........................Pressure Testing ....................... Cooling System Flushing ....................Coolant Reserve Tank Removal ..................Coolant Reserve Tank Installation ..................
  • Page 218: Exploded View

    4-2 COOLING SYSTEM Exploded View...
  • Page 219 COOLING SYSTEM 4-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Coolant By-pass Fitting Bolt 0.90 78 in·lb Coolant Drain Bolt (Cylinder) 87 in·lb Coolant Drain Bolt (Water Pump) 0.90 78 in·lb Coolant Reserve Tank Mounting Bolts 0.70 61 in·lb Impeller Bolt 87 in·lb Oil Cooler Mounting Bolts...
  • Page 220: Specifications

    4-4 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 221: Special Tools

    COOLING SYSTEM 4-5 Special Tools Bearing Driver, Bearing Driver Set: 57001-382 57001-1129...
  • Page 222: Coolant Flow Chart

    4-6 COOLING SYSTEM Coolant Flow Chart...
  • Page 223 COOLING SYSTEM 4-7 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 224: Coolant

    4-8 COOLING SYSTEM Coolant Coolant Deterioration Inspection • Visually inspect the coolant in the reserve tank. If whitish cotton-like wafts are observed, aluminum parts in the cooling system are corroded. If the coolant is brown, iron or steel parts are rusting. In either case, flush the cooling system.
  • Page 225: Cooling System Flushing

    COOLING SYSTEM 4-9 Coolant Cooling System Flushing Over a period of time, the cooling system accumulates rust, scale, and lime in the water jacket and radiator. When this accumulation is suspected or observed, flush the cool- ing system. If this accumulation is not removed, it will clog up the water passage and considerable reduce the effi- ciency of the cooling system.
  • Page 226: Coolant Reserve Tank Installation

    4-10 COOLING SYSTEM Coolant Coolant Reserve Tank Installation • Be sure that the pad [A] is in position on the coolant re- serve tank [B]. • Install the following to the coolant reserve tank. Rubber Dampers [C] Collars [D] Gasket [E] Cap [F] •...
  • Page 227: Water Pump

    COOLING SYSTEM 4-11 Water Pump Water Pump Removal • Refer to the Oil Pump Removal in the Engine Lubrication System chapter. Water Pump Installation • Refer to the Oil Pump Installation in the Engine Lubrica- tion System chapter. Water Pump Impeller Disassembly/Assembly •...
  • Page 228: Water Pump Housing Assembly

    4-12 COOLING SYSTEM Water Pump • Take the oil seal [A] out of the housing [B] with a hook [C]. Water Pump Housing Assembly CAUTION Do not reuse the mechanical seal and oil seal. • Apply high-temperature grease to the oil seal lips [A]. •...
  • Page 229: Radiator

    COOLING SYSTEM 4-13 Radiator Radiator and Radiator Fan Removal • Drain the coolant (see Coolant Change in the Periodic Maintenance chapter). • Remove: Right Middle Fairing (see Middle Fairing Removal in the Frame chapter) Water Hoses [A] Radiator Fan Lead Connector [B] •...
  • Page 230: Radiator And Radiator Fan Installation

    4-14 COOLING SYSTEM Radiator ○ Remove the bolt [A] and radiator bracket [B] as necessary. • Remove: Radiator Fan Mounting Bolts [A] Radiator Fan [B] Radiator and Radiator Fan Installation • Install the radiator fan [A]. • Install the rubber dampers [B] and collars [C] as shown.
  • Page 231 COOLING SYSTEM 4-15 Radiator If the radiator bracket [A] was removed, install it. Torque - Radiator Bracket Mounting Bolt [B]: 9.8 N·m (1.0 kgf·m, 87 in·lb) • Install the horn [C]. • Tighten: Torque - Radiator Upper Bolts [D]: 9.8 N·m (1.0 kgf·m, 87 in·lb) Radiator Lower Bolt [E]: 6.9 N·m (0.70 kgf·m, 61 in·lb)
  • Page 232: Radiator Inspection

    4-16 COOLING SYSTEM Radiator Radiator Inspection • Remove the radiator (see Radiator and Radiator Fan Re- moval). • Check the radiator core. If there are obstructions to air flow, remove them. If the corrugated fins [A] are deformed, carefully straighten them. If the air passages of the radiator core are blocked more than 20% by unremovable obstructions or irreparably de- formed fins, replace the radiator with a new one.
  • Page 233: Radiator Filler Neck Inspection

    COOLING SYSTEM 4-17 Radiator Radiator Filler Neck Inspection • Remove the radiator cap (see Pressure Testing). • Check the radiator filler neck for signs of damage. • Check the condition of the top and bottom sealing seats [A] in the filler neck. They must be smooth and clean for the radiator cap to function properly.
  • Page 234: Thermostat

    4-18 COOLING SYSTEM Thermostat Thermostat Removal • Remove: Oil Cooler (see Oil Cooler Removal in the Engine Lubri- cation System chapter) Water Hose [A] • Remove: Thermostat Housing Cover Bolts [A] Bracket [B] Thermostat Housing Cover [C] Thermostat Thermostat Installation •...
  • Page 235: Thermostat Inspection

    COOLING SYSTEM 4-19 Thermostat • Install the water hose clamp [A] as shown. Upside View [B] • Tighten: Torque - Water Hose Clamp Screw: 2.0 N·m (0.20 kgf·m, 17 in·lb) • Install the oil cooler (see Oil Cooler Installation in the En- gine Lubrication System chapter).
  • Page 236: Hoses And Pipes

    4-20 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 in accordance with the Cable, Wire, and Hose Routing section in the Appendix chapter. •...
  • Page 237: Water Temperature Sensor

    COOLING SYSTEM 4-21 Water Temperature Sensor Water Temperature Sensor Removal • Refer to the Water Temperature Sensor Removal in the Fuel System (DFI) chapter. Water Temperature Sensor Inspection • Refer to the Water Temperature Sensor Inspection in the Electrical System chapter.
  • Page 239 ENGINE TOP END 5-1 Engine Top End Table of Contents Exploded View........Cylinder Head Removal ....5-24 Exhaust System......... Cylinder Head Installation .... 5-24 Specifications ........Cylinder Head Warp..... 5-25 Special Tools and Sealant ....Valves ..........5-26 Clean Air System....... 5-11 Valve Clearance Inspection ..
  • Page 240: Exploded View

    5-2 ENGINE TOP END Exploded View...
  • Page 241 ENGINE TOP END 5-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Air Suction Valve Cover Bolts 87 in·lb Camshaft Cap Bolts 106 in·lb Camshaft Chain Tensioner Cap Bolt Camshaft Chain Tensioner Mounting Bolts 97 in·lb Cam Sprocket Mounting Bolts Water Passage Plugs Cylinder Head Bolts (M9) (First) MO, S...
  • Page 242 5-4 ENGINE TOP END Exploded View...
  • Page 243 ENGINE TOP END 5-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Exhaust Butterfly Valve Actuator Mounting Nuts 0.70 61 in·lb Exhaust Butterfly Valve Actuator Pulley Bolt 0.50 43 in·lb Exhaust Butterfly Valve Cable Adjuster Locknuts 0.70 61 in·lb Exhaust Butterfly Valve Cable Locknuts 0.70 61 in·lb Exhaust Butterfly Valve Cover Bolt...
  • Page 244: Exhaust System

    5-6 ENGINE TOP END Exhaust System WVTA (FULL H) WVTA Model with Honeycomb Catalytic Converter (Full Power) GB WVTA (FULL H) WVTA Model with Honeycomb Catalytic Converter (Left Side Traffic, Full Power) WVTA (78.2 H) WVTA Model with Honeycomb Catalytic Converter (78.2 Kw Power)
  • Page 245 ENGINE TOP END 5-7 Exhaust System Manifold Mark Position [A] Muffler Body Mark Position [A] • Manifold [A] with Holes [B] for Oxygen Sensors (Equipped Models). Oxygen Sensor #1 [C] Oxygen Sensor #2 [D]...
  • Page 246: Specifications

    5-8 ENGINE TOP END Specifications Item Standard Service Limit Camshafts Cam Height: 33.443 ∼ 33.557 mm (1.3167 ∼ 1.3211 in.) Exhaust 33.34 mm (1.313 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 247: Special Tools And Sealant

    ENGINE TOP END 5-9 Special Tools and Sealant Compression Gauge, 20 kgf/cm²: Valve Seat Cutter Holder Bar: 57001-221 57001-1128 Valve Spring Compressor Assembly: Valve Spring Compressor Adapter, 20: 57001-241 57001-1154 Valve Seat Cutter, 45° - 24.5: Valve Seat Cutter, 45° - 30: 57001-1113 57001-1187 Valve Seat Cutter, 32°...
  • Page 248 Valve Guide Driver: 57001-1275 57001-1564 Compression Gauge Adapter, M10 × 1.0: Valve Spring Compressor Adapter, 24: 57001-1317 57001-1586 Valve Seat Cutter, 60° - 25: Attachment C: 57001-1328 57001-1624 Valve Seat Cutter, 60° - 27: Kawasaki Bond (Silicone Sealant): 57001-1409 92104-0004...
  • Page 249: Clean Air System

    ENGINE TOP END 5-11 Clean Air System Air Suction Valve Removal • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Air Cleaner Housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter) • Separate the hoses [A] from the air suction valve cover.
  • Page 250: Air Switching Valve Removal

    5-12 ENGINE TOP END Clean Air System Air Switching Valve Removal • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Air Cleaner Housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter) • Disconnect the connector [A].
  • Page 251: Cylinder Head Cover

    • Replace the head cover gasket [A] with a new one. • Apply silicone sealant [B] to the cylinder head as shown. Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004 • Be sure to install the following parts. Dowel Pins [A] Plug Hole Gaskets [B] ○...
  • Page 252 5-14 ENGINE TOP END Cylinder Head Cover • Replace the washer [A] with new ones. • Install the new washer with the metal side faces upward. • Install the cylinder head cover. • Tighten the cylinder head cover bolts [A]. Torque - Cylinder Head Cover Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) •...
  • Page 253: Camshaft Chain Tensioner

    ENGINE TOP END 5-15 Camshaft Chain Tensioner Camshaft Chain Tensioner Removal CAUTION This is a non-return type camshaft chain tensioner. The push rod does not return to its original position once it moves out to take up camshaft chain slack. Observe all the rules listed below: When removing the tensioner, do not take out the mounting bolts only halfway.
  • Page 254: Camshaft, Camshaft Chain

    5-16 ENGINE TOP END Camshaft, Camshaft Chain Camshaft Removal • Remove the cylinder head cover (see Cylinder Head Cover Removal). • Remove the timing inspection cap [A] and starter clutch bolt cap [B] on the starter clutch cover [C]. • Using a wrench on the starter clutch bolt [A], turn the crankshaft clockwise until the line [B] (TDC mark for #1,4 pistons) on the starter clutch is aligned with the notch [C]...
  • Page 255 ENGINE TOP END 5-17 Camshaft, Camshaft Chain • Remove the cam sprocket mounting bolts [A]. • Remove the cam sprocket. CAUTION The crankshaft may be turned while the camshafts are removed. Always pull the chain taut while turn- ing the crankshaft. This avoids kinking the chain on the lower (crankshaft) sprocket.
  • Page 256: Camshaft

    5-18 ENGINE TOP END Camshaft Camshaft Installation NOTE ○ The exhaust camshaft has a 4516 EX mark [A] and the inlet camshaft has a 4516 IN mark [B]. Be careful not to mix up these shafts. • Install the cam sprockets as shown in the figure. #4 Cam Positions [A] Inlet Cam Sprocket [B] Exhaust Cam Sprocket [C]...
  • Page 257 ENGINE TOP END 5-19 Camshaft If the starter clutch cover is removed, perform the next procedure. ○ Using a wrench on the starter clutch bolt [A], turn the crankshaft clockwise until the line [B] (TDC mark for #1,4 pistons) on the starter clutch [C] is aligned with the mating surface [D] of crankcase rear side.
  • Page 258 5-20 ENGINE TOP END Camshaft • Apply molybdenum disulfide oil solution [A]: All Cam Lobes, Journals and Thrust Journals • Apply engine oil [B]: #1 ∼ #4 Cam Lobes of EX and IN Camshafts • Install: O-rings [A] Dowel Pins [B] O-rings [C] Dowel Pins [D] •...
  • Page 259: Camshaft, Camshaft Cap Wear

    ENGINE TOP END 5-21 Camshaft • Install the camshaft chain tensioner (see Camshaft Chain Tensioner Installation). • Turn the crankshaft 2 turns clockwise to allow the ten- sioner to expand and recheck the camshaft chain timing. • Check the valve clearance (see Valve Clearance Inspec- tion in the Periodic Maintenance chapter).
  • Page 260: Camshaft Runout

    5-22 ENGINE TOP END Camshaft If any clearance exceeds the service limit, measure the diameter of each camshaft journal with a micrometer. Camshaft Journal Diameter 23.940 ∼ 23.962 mm (0.9425 ∼ 0.9434 in.) Standard: Service Limit: 23.91 mm (0.941 in.) If the camshaft journal diameter is less than the service limit, replace the camshaft with a new one and measure the clearance again.
  • Page 261: Cylinder Head

    ENGINE TOP END 5-23 Cylinder Head Cylinder Compression Measurement NOTE ○ Use the battery which is fully charged. • Warm up the engine thoroughly. • Stop the engine. • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Air Cleaner Housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter)
  • Page 262: Cylinder Head Removal

    5-24 ENGINE TOP END Cylinder Head Cylinder Head 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: Engine (see Engine Removal in the Engine Removal/In- stallation chapter) Cylinder Head Cover (see Cylinder Head Cover Re- moval)
  • Page 263: Cylinder Head Warp

    ENGINE TOP END 5-25 Cylinder Head • Tighten the M9 cylinder head bolts following the tightening sequence [1 ∼ 10]. Torque - Cylinder Head Bolts (M9): First: 15 N·m (1.5 kgf·m, 11 ft·lb) Final: 39 N·m (4.0 kgf·m, 29 ft·lb) •...
  • Page 264: Valves

    5-26 ENGINE TOP END Valves Valve Clearance Inspection • Refer to the Valve Clearance Inspection in the Periodic Maintenance chapter. Valve Clearance Adjustment • Refer to the Valve Clearance Adjustment in the Periodic Maintenance chapter. Valve Removal • Remove the cylinder head (see Cylinder Head Removal). •...
  • Page 265: Valve Guide Removal

    ENGINE TOP END 5-27 Valves Valve Guide Removal • Remove: Valve (see Valve Removal) Oil Seal Spring Seat • Heat the area around the valve guide to 120 ∼ 150°C (248 ∼ 302°F), and hammer lightly on the valve guide arbor [A] to remove the guide from the top of the head.
  • Page 266: Valve-to-guide Clearance Measurement (wobble Method)

    5-28 ENGINE TOP END Valves Valve-to-Guide Clearance Measurement (Wobble Method) If a small bore gauge is not available, inspect the valve guide wear by measuring the valve to valve guide clearance with the wobble method as indicated below. • Insert a new valve [A] into the guide [B] and set a dial gauge against the stem perpendicular to it as close as possible to the cylinder head mating surface.
  • Page 267: Valve Seat Inspection

    ENGINE TOP END 5-29 Valves Valve Seat Inspection • Remove the valve (see Valve Removal in this chapter). • 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 268 5-30 ENGINE TOP END Valves Seat Cutter Operation Care 1. This valve seat cutter is developed to grind the valve for repair. Therefore the cutter must not be used for other purposes than seat repair. 2. Do not drop or shock the valve seat cutter, or the dia- mond particles may fall off.
  • Page 269 ENGINE TOP END 5-31 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 270 5-32 ENGINE TOP END 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 271 ENGINE TOP END 5-33 Valves...
  • Page 272: Throttle Body Assy Holder

    5-34 ENGINE TOP END Throttle Body Assy Holder Throttle Body Assy Holder Removal • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Air Cleaner Housing (Air Cleaner Housing Removal in the Fuel System (DFI) chapter) Throttle Body Assy (Throttle Body Assy Removal in the Fuel System (DFI) chapter) Clamps [A]...
  • Page 273: Muffler

    ENGINE TOP END 5-35 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: Seat Cover (see Seat Cover Removal in the Frame chapter) Flap (see Flap and Rear Fender Removal in the Frame chapter)
  • Page 274: Muffler Body Installation

    5-36 ENGINE TOP END Muffler Muffler Body Installation If the muffler body covers were removed, install them. Muffler Body Upper Cover [A] Muffler Body Rear Cover [B] Dampers [C] ○ Tighten: Torque - Muffler Body Upper Cover Bolts [D]: 6.9 N·m (0.70 kgf·m, 61 in·lb) Muffler Body Rear Cover Bolts [E]: 6.9 N·m (0.70 kgf·m, 61 in·lb) •...
  • Page 275: Rear Exhaust Pipe Removal

    ENGINE TOP END 5-37 Muffler • Install the exhaust butterfly valve cable, and adjust (see Exhaust Butterfly Valve Cable installation). • Throughly warm up the engine, wait until the engine cools down, retighten all the bolts. • Install the removed parts (see appropriate chapters). Rear Exhaust Pipe Removal •...
  • Page 276: Rear Exhaust Pipe Installation

    5-38 ENGINE TOP END Muffler Rear Exhaust Pipe Installation • Replace the rear exhaust pipe gasket [A] with a new one. • Install the rear exhaust pipe gasket until it is bottomed so that the chamfer side [B] faces to the rear exhaust pipe [C].
  • Page 277: Front Exhaust Pipe Removal

    ENGINE TOP END 5-39 Muffler Front Exhaust Pipe Removal • Remove: Radiator Lower Bolt [A] (see Radiator and Radiator Fan Removal in the Cooling System chapter) • Loosen the radiator upper bolts. • Remove: Oxygen Sensor Lead Connectors (see Oxygen Sensor Removal (Equipped Models) in the Electrical System chapter) Front Exhaust Pipe Holder Nuts [B]...
  • Page 278: Front Exhaust Pipe Installation

    5-40 ENGINE TOP END Muffler Front Exhaust Pipe Installation • Replace the front exhaust pipe gaskets [A] with new ones. • Replace the rear exhaust pipe gasket [B] with a new one. ○ Install the rear exhaust pipe gasket until it is bottomed so that the chamfer side [C] faces to the rear exhaust pipe [D].
  • Page 279: Exhaust Butterfly Valve Cable Removal

    ENGINE TOP END 5-41 Muffler Exhaust Butterfly Valve Cable Removal • Remove: Seat Cover (see Seat Cover Removal in the Frame chapter) Bolt [A] Exhaust Butterfly Valve Cover [B] • Slide the dust covers [A]. • Loosen the adjuster locknuts [B], and turn the adjuster [C] to give the cable plenty of play.
  • Page 280: Exhaust Butterfly Valve Cable Installation

    5-42 ENGINE TOP END Muffler Exhaust Butterfly Valve Cable Installation • Install the exhaust butterfly valve cable lower ends to the pulley of muffler body. Open Cable (White) [A] Close Cable (Black) [B] • Tighten: Torque - Exhaust Butterfly Valve Cable Locknuts: 6.9 N·m (0.70 kgf·m, 61 in·lb) •...
  • Page 281 ENGINE TOP END 5-43 Muffler • Stretch the open cable (white) first by using the adjuster [A]. ○ Turn the adjuster counterclockwise until the play of the open cable becomes no play. CAUTION To keep the correct exhaust butterfly valve position, adjust the open cable first.
  • Page 282 5-44 ENGINE TOP END Muffler • Tighten: Torque - Exhaust Butterfly Valve Cable Adjuster Locknut: 6.9 N·m (0.70 kgf·m, 61 in·lb) • Cover the dust covers. • Install the removed parts (see appropriate chapters). • Confirm the operation of the pulley as follows. ○...
  • Page 283 CLUTCH 6-1 Clutch Table of Contents Exploded View........................Specifications ......................... Special Tool and Sealant ......................Clutch Lever and Cable ......................Clutch Lever Free Play Inspection ..................Clutch Lever Free Play Adjustment .................. Cable Removal ......................... Cable Installation ......................Cable Lubrication ......................Clutch Lever Installation....................
  • Page 284: Exploded View

    6-2 CLUTCH Exploded View...
  • Page 285 CLUTCH 6-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Clutch Cover Bolts (M6, L = 25 mm) 87 in·lb Clutch Cover Bolts (M6, L = 40 mm) 87 in·lb Clutch Hub Nut Clutch Lever Clamp Bolts 0.80 69 in·lb Clutch Spring Bolts 0.90 78 in·lb...
  • Page 286: Specifications

    6-4 CLUTCH Specifications Item Standard Service Limit 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Clutch Lever Free Play – – – Clutch Spring Plate Free Play (Usable Range) 0.05 ∼ 0.70 mm (0.002 ∼ 0.028 in.) – – – Clutch Plate Assembly Length (Reference) –...
  • Page 287: Special Tool And Sealant

    CLUTCH 6-5 Special Tool and Sealant Clutch Holder: Kawasaki Bond (Silicone Sealant): 57001-1243 92104-0004...
  • Page 288: Clutch Lever And Cable

    6-6 CLUTCH Clutch Lever and Cable Clutch Lever Free Play Inspection • Refer to the Clutch Operation Inspection in the Periodic Maintenance chapter. Clutch Lever Free Play Adjustment • Refer to the Clutch Operation Inspection in the Periodic Maintenance chapter. Cable Removal •...
  • Page 289: 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 • Be sure that the dowel pins [B] are in position. •...
  • Page 290: Release Shaft Installation

    6-8 CLUTCH Clutch Cover Release Shaft Installation • Apply grease to the oil seal lips on the upper ridge of the clutch cover. • Apply engine oil to the needle bearings in the hole of the clutch cover. • Apply molybdenum disulfide grease to the pusher-holding portion [A] on the release shaft.
  • Page 291: Clutch Cover Assembly

    CLUTCH 6-9 Clutch Cover Clutch Cover Assembly • Replace the needle bearings and oil seal with new ones. NOTE ○ Install the needle bearings so that the manufacture’s mark face out. • Install the needle bearings [A] and oil seal [B] as shown. ○...
  • Page 292: Clutch Removal

    6-10 CLUTCH Clutch Clutch Removal • Remove: Clutch Cover (see Clutch Cover Removal) Clutch Spring Bolts [A] Clutch Springs (with Spring Holders) Clutch Spring Plate [B] (with Shim, Bearing, Pusher [C], Spring and Washer) • Remove: Friction Plates, Steel Plates Spring, Spring Seat •...
  • Page 293 CLUTCH 6-11 Clutch • Install: Clutch Housing [A] Needle Bearing [B] • Install the sleeve [C] so that holes [D] face outward. ○ Apply engine oil to the sleeve and needle bearing. • Install the spacer [A] so that the stepped side [B] faces outward.
  • Page 294 6-12 CLUTCH Clutch ○ Third Torque Limiter Spring [A] Tang [B] ○ Fourth Torque Limiter Spring [A] Tang [B] • Replace the clutch hub nut with a new one. • Hold the sub clutch hub steady with the clutch holder, and tighten the clutch hub nut.
  • Page 295: Spring Plate Free Play Measurement

    CLUTCH 6-13 Clutch • Install the last friction plate (36 lining blocks) [A] fitting the tangs in the grooves in the housing as shown. • Apply molybdenum disulfide grease to the pusher ends [A]. • Install the washer [B], spring [C], bearing [D] and shim [E] to the pusher.
  • Page 296: Spring Plate Free Play Adjustment

    6-14 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 297: Clutch Plate, Wear, Damage Inspection

    CLUTCH 6-15 Clutch Clutch Plate Assembly Length (Reference Information) • Assemble the following parts. Clutch Hub [A] Spring Seat [B] Spring [C] Sub Clutch Hub [D] Sub Clutch Hub Bolts [E] New Friction Plates [F] Steel Plates [G] Spring Plate [H] Clutch Springs [I] Clutch Spring Holders [J] Clutch Spring Bolts [K]...
  • Page 298: Clutch Spring Free Length Measurement

    6-16 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: 41.6 mm (1.64 in.) Service Limit: 40.1 mm (1.58 in.) Damper Cam Inspection •...
  • Page 299 ENGINE LUBRICATION SYSTEM 7-1 Engine Lubrication System Table of Contents Exploded View........................Specifications ......................... Special Tools and Sealant ...................... Engine Oil Flow Chart......................Engine Oil and Oil Filter......................Oil Level Inspection......................Engine Oil Change......................Oil Filter Replacement ...................... Oil Pan............................ Oil Pan Removal .......................
  • Page 300: Exploded View

    7-2 ENGINE LUBRICATION SYSTEM Exploded View...
  • Page 301 ENGINE LUBRICATION SYSTEM 7-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Coolant Drain Bolt (Water Pump) 0.90 78 in·lb Engine Oil Drain Bolt Impeller Bolt 87 in·lb Oil Cooler Mounting Bolts Oil Filter G, R Oil Filter Holder Bolt Piston Oil Nozzles 0.30 26 in·lb...
  • Page 302: Specifications

    7-4 ENGINE LUBRICATION SYSTEM Specifications Item Standard Engine Oil Type API SE, SF or SG API SH, SJ or SL with JASO MA Viscosity SAE 10W-40 Capacity 2.9 L (3.1 US gt) (when filter is not removed) 3.2 L (3.4 US gt) (when filter is removed) 3.8 L (4.0 US gt) (when engine is completely dry) Level Between upper and lower level lines...
  • Page 303: Special Tools And Sealant

    ENGINE LUBRICATION SYSTEM 7-5 Special Tools and Sealant Outside Circlip Pliers: Oil Pressure Gauge Adapter, PT3/8: 57001-144 57001-1233 Oil Pressure Gauge, 10 kgf/cm²: Kawasaki Bond (Silicone Sealant): 57001-164 56019-120...
  • Page 304: Engine Oil Flow Chart

    7-6 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart...
  • Page 305 ENGINE LUBRICATION SYSTEM 7-7 Engine Oil Flow Chart...
  • Page 306: Engine Oil And Oil Filter

    7-8 ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter WARNING Motorcycle operation with insufficient, deteri- orated, or contaminated engine oil will cause accelerated wear and may result in engine or trans- mission seizure, accident, and injury. Oil Level Inspection • Check that the engine oil level is between the upper [A] and lower [B] levels in the gauge.
  • Page 307: Oil Pan

    ENGINE LUBRICATION SYSTEM 7-9 Oil Pan Oil Pan Removal • Drain the engine oil (see Engine Oil Change in the Peri- odic Maintenance chapter). • Remove: Front Exhaust Pipe (see Front Exhaust Pipe Removal in the Engine Top End chapter) Oil Pan Bolts [A] Clamp [B] Oil Pan [C]...
  • Page 308 7-10 ENGINE LUBRICATION SYSTEM Oil Pan • Tighten the oil pan bolts as shown sequence [1 ∼ 20] in the figure. Torque - Oil Pan Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)
  • Page 309: Oil Pressure Relief Valve

    ENGINE LUBRICATION SYSTEM 7-11 Oil Pressure Relief Valve Oil Pressure Relief Valve Removal • Remove: Oil Pan (see Oil Pan Removal) Oil Screen [A] • Remove the oil pressure relief valve [A]. Oil Pressure Relief Valve Installation • Apply a non-permanent locking agent to the threads of the oil pressure relief valve [A], and tighten it.
  • Page 310: Oil Pressure Relief Valve Inspection

    7-12 ENGINE LUBRICATION SYSTEM Oil Pressure Relief Valve Oil Pressure Relief Valve Inspection • Remove the oil pressure relief valve (see Oil Pressure Relief Valve Removal). • Check to see if the valve [A] slides smoothly when push- ing it in with a wooden or other soft rod, and see if it comes back to its seat by spring [B] pressure.
  • Page 311: Oil Pump

    ENGINE LUBRICATION SYSTEM 7-13 Oil Pump Oil 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: Water Pump Cover Bolts [A] Water Pump Cover [B] Water Hose [C] •...
  • Page 312: Oil Pump Installation

    7-14 ENGINE LUBRICATION SYSTEM Oil Pump Oil Pump Installation • Install the outer rotor [A] into the crankcase. • Install the pin [B] and inner rotor [C] to the oil (water) pump shaft [D], and install the assy. ○ Turn the pump shaft so that the slot [E] in its shaft fits onto the projection [F] of the pump drive gear shaft.
  • Page 313: Oil Pump Gear Removal

    ENGINE LUBRICATION SYSTEM 7-15 Oil Pump • Align the line [A] of the water pump cover and the white mark [B] of the water hose [C]. • Install the water hose clamp [D] as shown. • Tighten: Torque - Water Hose Clamp Screw: 2.0 N·m (0.20 kgf·m, 17 in·lb) •...
  • Page 314: Oil Pump Gear Shaft Removal

    7-16 ENGINE LUBRICATION SYSTEM Oil Pump Oil Pump Gear Shaft Removal • Remove: Oil Pump Gear (see Oil Pump Gear Removal) Oil Pan (see Oil Pan Removal) Circlip [A] Washer [B] Oil Pump Gear Shaft [C] Special Tool - Outside Circlip Pliers: 57001-144 Oil Pump Gear Shaft Installation •...
  • Page 315: Oil Cooler

    ENGINE LUBRICATION SYSTEM 7-17 Oil Cooler Oil Cooler 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: Starter Motor (see Starter Motor Removal in the Electri- cal System chapter) Clutch Cable Lower End (see Cable Removal in the Clutch chapter)
  • Page 316: Oil Cooler/oil Filter Case Removal

    7-18 ENGINE LUBRICATION SYSTEM Oil Cooler Oil Cooler/Oil Filter Case Removal • Remove: Oil Filter (see Oil Filter Replacement in the Periodic Maintenance chapter) Oil Cooler (see Oil Cooler Removal) Bolt [A] • Pull the oil filter guard [A] forward as shown. •...
  • Page 317: Oil Cooler/oil Filter Case Installation

    ENGINE LUBRICATION SYSTEM 7-19 Oil Cooler Oil Cooler/Oil Filter Case Installation If the crankcase was disassembled, pour the engine oil into the oil passages [A] until O-ring insert portions [B] of the upper crankcase. NOTE ○ Pour the engine oil into the oil passages because of quick supply of the engine oil to the cylinder head.
  • Page 318: Oil Pressure Measurement

    7-20 ENGINE LUBRICATION SYSTEM Oil Pressure Measurement Oil Pressure Measurement • Remove: Lower Fairings (see Lower Fairing Removal in the Frame chapter) Oil Passage Plug [A] • Attach the adapter [A] and gauge [B] to the plug hole. Special Tools - Oil Pressure Gauge, 10 kgf/cm²: 57001-164 Oil Pressure Gauge Adapter, PT3/8: 57001 -1233 •...
  • Page 319: Oil Pressure Switch

    • Apply silicone sealant to the threads of the oil pressure switch [A] and tighten it. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 Torque - Oil Pressure Switch: 15 N·m (1.5 kgf·m, 11 ft·lb) • Install the switch lead [B] direction as shown.
  • Page 321 ENGINE REMOVAL/INSTALLATION 8-1 Engine Removal/Installation Table of Contents Exploded View........................Special Tool ..........................Engine Removal/Installation ....................Engine Removal........................ Engine Installation......................
  • Page 322: Exploded View

    8-2 ENGINE REMOVAL/INSTALLATION Exploded View...
  • Page 323 ENGINE REMOVAL/INSTALLATION 8-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Adjusting Collar Locknut Adjusting Collar 87 in·lb Lower Engine Mounting Nut Middle Engine Mounting Bracket Bolts Middle Engine Mounting Nut Upper Engine Mounting Bolts 7. ZX600P7F S: Follow the specified tightening sequence.
  • Page 324: Special Tool

    8-4 ENGINE REMOVAL/INSTALLATION Special Tool Engine Mount Nut Wrench: 57001-1450...
  • Page 325: Engine Removal/installation

    ENGINE REMOVAL/INSTALLATION 8-5 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 326 8-6 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation ○ Disconnect the connectors from the engine and free the wiring from the clamps. Stick Coil Connectors [A] Cylinder Head Cover Ground Terminal [B] Air Switching Valve Connector [C] Camshaft Position Sensor Connector [D] ○ Disconnect: Alternator Lead Connector [A] Rear Brake Light Switch Connector [B]...
  • Page 327 ENGINE REMOVAL/INSTALLATION 8-7 Engine Removal/Installation • Turn up the rear side of the heat insulation rubber plate [A]. • Loosen the middle engine mounting bracket bolts [B] • Support the engine with a suitable stand [A]. ○ Put a plank [B] onto the suitable stand for engine balance. •...
  • Page 328: Engine Installation

    8-8 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Remove the middle and lower engine mounting nuts. • Turn the lower mounting bolts [A] clockwise to make the gap between the collar and frame. • Pull out the engine mounting bolts from the right side. •...
  • Page 329 ENGINE REMOVAL/INSTALLATION 8-9 Engine Removal/Installation • Install the engine mounting bolts and nuts, following the specified installing sequence. ○ Firth, install the middle engine mounting bracket [A], and tighten the bracket bolts [B] temporally. ○ Second, tighten the following bolts and nuts temporally. [C] Lower Engine Mounting Bolt and Nut [D] Collar [E] Middle Engine Mounting Bolt and Nut...
  • Page 330 8-10 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation ○ Forth, tighten the adjuster collar [A] with the lower engine mounting bolt [B] counterclockwise until the collar touches [C] the frame [D]. Torque - Lower Engine Mounting Bolt: 9.8 N·m (1.0 kgf·m, 87 in·lb) ○...
  • Page 331 ENGINE REMOVAL/INSTALLATION 8-11 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) Clutch Cable (see Clutch Operation Inspection in the Pe- riodic Maintenance chapter)
  • Page 333 CRANKSHAFT/TRANSMISSION 9-1 Crankshaft/Transmission Table of Contents Exploded View........Starter Idle Gear Removal ... 9-31 Specifications ........Starter Idle Gear Installation ..9-31 Special Tools and Sealant ....Starter Clutch Removal....9-33 Crankcase ......... 9-10 Starter Clutch Installation .... 9-33 Crankcase Splitting ...... 9-10 Starter Clutch Disassembly..
  • Page 334: Exploded View

    9-2 CRANKSHAFT/TRANSMISSION Exploded View...
  • Page 335 CRANKSHAFT/TRANSMISSION 9-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Coolant Drain Plug (Cylinder) 87 in·lb Breather Plate Bolts 87 in·lb Oil Passage Plugs (Taper) Oil Passage Plug (Left Side) Oil Pressure Switch Oil Pressure Switch Terminal Bolt – – –...
  • Page 336 9-4 CRANKSHAFT/TRANSMISSION Exploded View...
  • Page 337 CRANKSHAFT/TRANSMISSION 9-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Gear Positioning Lever Bolt 106 in·lb Gear Position Switch Screws 0.30 26 in·lb Shift Drum Cam Holder Bolt 106 in·lb Shift Lever Bolt 0.70 61 in·lb Shift Pedal Mounting Bolt Shift Shaft Return Spring Pin Shift Tie-Rod Locknut 0.70...
  • Page 338: Specifications

    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 ∼ 0.33 mm Connecting Rod Big End Side 0.6 mm (0.0051 ∼...
  • Page 339 CRANKSHAFT/TRANSMISSION 9-7 Specifications Item Standard Service Limit 34.000 ∼ 34.016 mm Crankcase Main Bearing Inside – – – (1.3386 ∼ 1.3392 in.) Diameter: Marking: ○ 34.000 ∼ 34.008 mm – – – (1.3386 ∼ 1.3389 in.) 34.009 ∼ 34.016 mm None –...
  • Page 340 9-8 CRANKSHAFT/TRANSMISSION Specifications Item Standard Service Limit 5.9 ∼ 6.0 mm Shift Fork Guide Pin Diameter 5.8 mm (0.232 ∼ 0.236 in.) (0.228 in.) 6.05 ∼ 6.20 mm Shift Drum Groove Width 6.3 mm (0.238 ∼ 0.244 in.) (0.248 in.) Connecting Rod Big End Bearing Insert Selection Con-rod Big End Bearing Insert...
  • Page 341: Special Tools And Sealant

    Outside Circlip Pliers: Grip: 57001-144 57001-1591 Piston Pin Puller Assembly: Rotor Holder: 57001-910 57001-1666 Piston Ring Compressor Grip: Stopper: 57001-1095 57001-1679 Piston Ring Compressor Belt, 67 ∼ 79: Kawasaki Bond (Silicone Sealant): 57001-1097 92104-0004 Bearing Driver Set: Kawasaki Bond: 57001-1129 92104-1064...
  • Page 342: Crankcase

    9-10 CRANKSHAFT/TRANSMISSION Crankcase Crankcase Splitting • Remove the engine (see Engine Removal in the Engine Removal/Installation chapter). • Set the engine on a clean surface and hold the engine steady while parts are being removed. • Remove: Cylinder Head (see Cylinder Head Removal in the En- gine Top End chapter) Clutch (see Clutch Removal in the Clutch chapter) Starter Motor (see Starter Motor Removal in the Electri-...
  • Page 343: Crankcase Assembly

    CRANKSHAFT/TRANSMISSION 9-11 Crankcase ○ Loosen the M8 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. Crankcase Assembly CAUTION The upper and lower crankcase halves are ma- chined at the factory in the assembled state, so the crankcase halves must be replaced as a set.
  • Page 344 9-12 CRANKSHAFT/TRANSMISSION Crankcase • Press and insert the fitting [A] in the upper crankcase [B] until it is bottomed. Special Tool - Bearing Driver Set: 57001-1129 • Apply a non-permanent locking agent to threads of the breather hose fitting [C] and tighten it. Torque - Breather Hose Fitting: 15 N·m (1.5 kgf·m, 11 ft·lb) •...
  • Page 345 CRANKSHAFT/TRANSMISSION 9-13 Crankcase • Press and insert the new needle bearing [A] for the shift shaft so that its marked side faces outside [B] and its sur- face [C] is flush with the end of the hole. • Install the new oil seal [D] so that its surface [E] is flush with the end of the hole.
  • Page 346 Crankcase • Apply liquid gasket [A] to the mating surface of the lower crankcase half. Sealant - Kawasaki Bond: 92104-1064 • Pile up the liquid gasket to groove [B]. CAUTION Do not apply liquid gasket to the inside of the grooves [C] around the crankshaft main bearing inserts and oil passage.
  • Page 347 CRANKSHAFT/TRANSMISSION 9-15 Crankcase • Following the sequence numbers on the lower crankcase half, tighten M8 bolts [1 ∼ 10] with washers. Torque - Crankcase Bolts (M8) [A]: First: 15 N·m (1.5 kgf·m, 11 ft·lb) Final: 31 N·m (3.2 kgf·m, 23 ft·lb) •...
  • Page 348: Crankshaft And Connecting Rods

    9-16 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods Crankshaft Removal • Split the crankcase (see crankcase splitting). • Remove the connecting rod nuts. • Remove the crankshaft. Crankshaft Installation NOTE ○ If the crankshaft is replaced with a new one, refer to the Connecting Rod Big End Bearing/Crankshaft Main Bearing Insert Selection in the Specifications.
  • Page 349 CRANKSHAFT/TRANSMISSION 9-17 Crankshaft and Connecting Rods • Apply molybdenum disulfide grease [A] to the outside sur- faces of both thrust washers [B]. • Slide [C] one thrust washer into the upper crankcase half. • Move the crankshaft to the left or right and then slide the other washer into the upper crankcase half.
  • Page 350: Connecting Rod Removal

    9-18 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods Connecting Rod Removal • Split the crankcase (see Crankcase Splitting in this chap- ter). • Remove the connecting rod nuts [A] and big end caps [B]. 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 351 CRANKSHAFT/TRANSMISSION 9-19 Crankshaft and Connecting Rods ○ When installing the inserts [A], be careful not to damage the insert surface with the edge of the connecting rod [B] or the cap [C]. One way to install inserts is as follows. Installation [D] to Cap Installation [E] to Connecting Rod Push [F]...
  • Page 352 9-20 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods (1) Bolt Length Measurement Method • Be sure to clean the bolts, nuts, and connecting rods thoroughly with a high-flash point solvent, because the new connecting rods, bolts, and nuts are treated with an anti-rust solution.
  • Page 353 CRANKSHAFT/TRANSMISSION 9-21 Crankshaft and Connecting Rods (2) Rotation Angle Method If you don’t have a point micrometer, you may tighten the nuts using the “Rotation Angle Method”. • Be sure to clean the bolts, nuts and connecting rods thor- oughly with a high-flash point solvent, because the new connecting rods, bolts and nuts are treated with an anti -rust solution.
  • Page 354: Crankshaft/connecting Rod Cleaning

    9-22 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods Crankshaft/Connecting Rod Cleaning • After removing the connecting rods from the crankshaft, clean them with a high-flash point solvent. • Blow the crankshaft oil passages with compressed air to remove any foreign particles or residue that may have accumulated in the passages.
  • Page 355: Connecting Rod Big End Bearing Insert/crankpin Wear

    CRANKSHAFT/TRANSMISSION 9-23 Crankshaft and Connecting Rods Connecting Rod Big End Bearing Insert/Crankpin Wear • Measure the bearing insert/crankpin [B] clearance with plastigage [A]. • Tighten the big end nuts to the specified torque (see Con- necting Rod Installation). NOTE ○ Do not move the connecting rod and crankshaft during clearance measurement.
  • Page 356: Crankshaft Side Clearance

    9-24 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods Connecting Rod Big End Inside Diameter Marks None: 33.000 ∼ 33.008 mm (1.2992 ∼ 1.2995 in.) ○ 33.009 ∼ 33.016 mm (1.2996 ∼ 1.2998 in.) Big End Cap [A] Connecting Rod [B] Weight Mark, Alphabet [C] ○...
  • Page 357: Crankshaft Runout

    CRANKSHAFT/TRANSMISSION 9-25 Crankshaft and Connecting Rods Crankshaft Runout • Measure the crankshaft runout. If the measurement exceeds the service limit, replace the crankshaft. Crankshaft Runout Standard: TIR 0.02 mm (0.0008 in.) or less Service Limit: TIR 0.05 mm (0.0020 in.) Crankshaft Main Bearing Insert/Journal Wear •...
  • Page 358 9-26 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods • Measure the main bearing inside diameter, and mark the upper crankcase half in accordance with the inside diam- eter. ○ [A]: Crankcase Main Bearing Inside Diameter Marks, “ ” mark or no mark. •...
  • Page 359: Pistons

    CRANKSHAFT/TRANSMISSION 9-27 Pistons Piston Removal • Split the crankcase (see Crankcase Splitting). • Remove the connecting rod nuts [A] and big end caps [B]. 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 360: Piston Installation

    9-28 CRANKSHAFT/TRANSMISSION 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 361: Cylinder Wear (upper Crankcase)

    CRANKSHAFT/TRANSMISSION 9-29 Pistons • Apply molybdenum disulfide oil solution to the cylinder bore, piston skirt and piston rings. • Install the piston with its marking hollow [A] facing exhaust side. • Using the piston ring compressor assembly [B] to install the piston from the cylinder head side.
  • Page 362: Piston Ring Groove Width

    9-30 CRANKSHAFT/TRANSMISSION 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: 0.84 ∼ 0.86 mm (0.0331 ∼ 0.0339 in.) Top [A] Second [B] 0.82 ∼...
  • Page 363: Starter Idle Gear And Starter Clutch

    CRANKSHAFT/TRANSMISSION 9-31 Starter Idle Gear and Starter Clutch Starter Idle Gear Removal • Remove: Right Middle Fairing (see Right Middle Fairing Removal in the Frame chapter) Heat Insulation Cover [A] Bolts [B] Idle Gear Cover [C] • Pull out the idle gear (starter motor side) [A] with the shaft [B].
  • Page 364 • Apply silicone sealant to the following portion. Crankshaft Sensor Lead Grommet [B] Crankcase Halves Mating Surfaces [C] Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004 • Install the dowel pins [D] and new gasket. • Apply grease to the O-rings of starter motor.
  • Page 365: Starter Clutch Removal

    CRANKSHAFT/TRANSMISSION 9-33 Starter Idle Gear and Starter Clutch Starter Clutch Removal • Remove: Alternator Cover (see Alternator Cover Removal in the Electrical System chapter) Starter Clutch Cover (see Idle Gear Removal) Idle Gear (Starter Clutch Side, see Idle Gear Removal) •...
  • Page 366: Starter Clutch Assembly

    9-34 CRANKSHAFT/TRANSMISSION Starter Idle Gear and Starter Clutch Starter Clutch Assembly • Install the one-way clutch [A] so that its circlip side [B] faces in. • Install the new snap ring. • Push [A] the starter clutch gear [B] in and turn it counter- clockwise [C] and install it.
  • Page 367 CRANKSHAFT/TRANSMISSION 9-35 Starter Idle Gear and Starter Clutch ○ Examine the starter clutch gear [C] as well. Replace the clutch gear if it is worn or damaged.
  • Page 368: Transmission

    9-36 CRANKSHAFT/TRANSMISSION Transmission Shift Pedal Removal • Remove: Shift Lever Bolt [A] Shift Pedal Mounting Bolt [B] Tie-Rod [C] and Shift Pedal [D] Shift Pedal Installation • Apply grease to the sliding surface [A] on the shift pedal mounting bolt [B]. •...
  • Page 369: External Shift Mechanism Installation

    CRANKSHAFT/TRANSMISSION 9-37 Transmission • Remove: Clutch (see Clutch Removal in the Clutch chapter) • Remove the shift shaft assembly [A] while pulling the shift mechanism arm. • Remove: Gear Positioning Lever Bolt [A] Gear Positioning Lever [B], Collar and Spring External Shift Mechanism Installation •...
  • Page 370: Transmission Assy Removal

    9-38 CRANKSHAFT/TRANSMISSION Transmission • Check the return spring pin [A] is not loose. If it is loose, unscrew it, apply a non-permanent locking agent to the threads, and tighten it. Torque - Shift Shaft Return Spring Pin: 28 N·m (2.9 kgf·m, 21 ft·lb) •...
  • Page 371: Transmission Assy Assembly

    CRANKSHAFT/TRANSMISSION 9-39 Transmission • Remove: Gear Positioning Lever [A] Bearing Holder Screws [B] Bearing Holder [C] Shift Drum Assembly [D] Transmission Assy Assembly • Press and insert the race [A] in the transmission case [B] so that the big stepped side [C] faces to transmission gears side until it is bottomed.
  • Page 372: Transmission Assy Installation

    9-40 CRANKSHAFT/TRANSMISSION Transmission • Install the drive shaft [A] and output shaft [B] as a set in the transmission case [C]. • Install the shift forks as shown in the figure. ○ The shift fork [D] for drive shaft gears has the short ears. ○...
  • Page 373: Transmission Shaft Removal

    CRANKSHAFT/TRANSMISSION 9-41 Transmission • Install the gear positioning lever (see External Shift Mech- anism Installation). • Set the gear positioning lever to the neutral position [A]. • Check that the drive and output shaft turn freely. • Apply grease to the O-ring [A] and install it to its position on the output shaft [B].
  • Page 374: Transmission Shaft Disassembly

    9-42 CRANKSHAFT/TRANSMISSION Transmission Transmission Shaft Disassembly • Remove the transmission shafts (see Transmission Shaft Removal). • Remove the circlips, disassemble the transmission shafts. Special Tool - Outside Circlip Pliers: 57001-144 • The 5th gear [A] on the output shaft has three steel balls assembled into it for the positive neutral finder mecha- nism.
  • Page 375 CRANKSHAFT/TRANSMISSION 9-43 Transmission • The drive shaft gears can be recognized by size: the gear with the smallest diameter is 1st gear, and the largest one is 6th gear. Be sure that all parts are put back in the cor- rect sequence and all circlips and washers are properly in place.
  • Page 376 9-44 CRANKSHAFT/TRANSMISSION Transmission 1. 1st Gear 15. Circlip 2. 2nd Gear 16. Water, 40 mm (1.57 in.) 3. 3rd Gear 17. Bushing 4. 4th Gear 18. Toothed Washer, 40 mm (1.57 in.) 5. 5th Gear 19. Circlip 6. 6th (Top) Gear 20.
  • Page 377: Shift Drum And Fork Removal

    CRANKSHAFT/TRANSMISSION 9-45 Transmission Shift Drum and Fork Removal • Remove the transmission assy (see Transmission Assy Removal). • Remove the shift forks [A] and shift drum [B] (see Trans- mission Assy Disassembly). Shift Drum and Fork Installation • Refer to the Transmission Assy Assembly and Installa- tion.
  • Page 378: Shift Fork/gear Groove Wear

    9-46 CRANKSHAFT/TRANSMISSION Transmission Shift Fork/Gear Groove Wear • Measure the thickness of the shift fork ears [A], and mea- sure the width [B] of the gear grooves. If the thickness of a shift fork ear is less than the service limit, the shift fork must be replaced.
  • Page 379 WHEELS/TIRES 10-1 Wheels/Tires Table of Contents Exploded View........................10-2 Specifications ......................... 10-4 Special Tools .......................... 10-5 Wheels (Rims) ........................10-6 Front Wheel Removal ....................... 10-6 Front Wheel Installation ....................10-6 Rear Wheel Removal......................10-7 Rear Wheel Installation..................... 10-8 Wheel Inspection ......................10-10 Axle Inspection........................
  • Page 380: Exploded View

    10-2 WHEELS/TIRES Exploded View...
  • Page 381 WHEELS/TIRES 10-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Axle Clamp Bolts Front Axle Nut Rear Axle Nut AL: Tighten the two clamp bolts alternately two time to ensure even tightening. G: Apply grease. HG: Apply high-temperature grease. R: Replacement Parts WL: Apply soap and water solution or rubber lubricant.
  • Page 382: Specifications

    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 0.05 mm (0.002 in.) or less 0.2 mm (0.01 in.) Wheel Balance...
  • Page 383: Special Tools

    WHEELS/TIRES 10-5 Special Tools Bearing Driver Set: Bearing Remover Shaft, 13: 57001-1129 57001-1377 Jack: Jack Attachment: 57001-1238 57001-1608 Bearing Remover Head, 25 × 28: 57001-1346...
  • Page 384: Wheels (rims)

    10-6 WHEELS/TIRES Wheels (Rims) Front Wheel Removal • Remove: Brake Caliper Mounting Bolts [A] Front Brake Calipers [B] • Loosen: Axle Clamp Bolts [A] (Left Side) Axle Nut [B] Axle Clamp Bolts (Right Side) • Remove the lower fairings (see Lower Fairing Removal in the Frame chapter).
  • Page 385: Rear Wheel Removal

    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. • Tighten the axle nut [B]. Right Axle Clamp Bolts [C] Left Axle Clamp Bolts [D] Viewed from Rear [E]...
  • Page 386: Rear Wheel Installation

    10-8 WHEELS/TIRES Wheels (Rims) • Remove: Rear Caliper Mounting Bolts [A] Rear Caliper [B] • Remove: Cotter Pin [A] Axle Nut [B] Axle [C] (from Right Side) • Remove the drive chain [A] from the rear sprocket toward the left. •...
  • Page 387 WHEELS/TIRES 10-9 Wheels (Rims) • Engage the drive chain with the rear sprocket. • Install the caliper bracket [A] onto the swingarm stop [B]. ○ Insert the axle from the right side of the wheel, and tighten the axle nut. Torque - Rear Axle Nut: 127 N·m (13 kgf·m, 94 ft·lb) •...
  • Page 388: Wheel Inspection

    10-10 WHEELS/TIRES Wheels (Rims) Wheel Inspection • Raise the front/rear wheel off the ground. Special Tools - Jack: 57001-1238 Jack Attachment: 57001-1608 • Spin the wheel lightly, and check for roughness or binding. If roughness or binding is found, replace the hub bearings (see Hub Bearing Removal/Installation).
  • Page 389: Balance Inspection

    WHEELS/TIRES 10-11 Wheels (Rims) Balance Inspection • Remove the front and rear wheels (see Front/Rear Wheel Removal). • Support the wheel so that it can be spun freely. • Spin the wheel lightly, and mark [A] the wheel at the top when the wheel stops.
  • Page 390 30 g (1.06 oz) NOTE ○ Balance weights are available from Kawasaki dealers in 10, 20, and 30 gram (0.35 oz, 0.71 oz, and 1.06 oz) sizes. An imbalance of less than 10 grams (0.35 oz) will not usually affect running stability.
  • Page 391: Tires

    WHEELS/TIRES 10-13 Tires Air Pressure Inspection/Adjustment • Refer to the Air Pressure Inspection in the Periodic Main- tenance chapter (see Air Pressure Inspection in the Peri- odic Maintenance chapter). Tire Inspection • Refer to the Wheel/Tire Damage Inspection in the Peri- odic Maintenance chapter (see Wheel/Tires Damage In- spection in the Periodic Maintenance chapter).
  • Page 392 10-14 WHEELS/TIRES Tires • Install a new valve in the rim. ○ Remove the valve cap, lubricate the stem seal [A] with a soap and water solution or rubber lubricant, and pull [B] the valve stem through the rim from the inside out until it snaps into place.
  • Page 393: 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 394: Hub Bearing

    10-16 WHEELS/TIRES Hub Bearing Hub Bearing Removal • Remove the wheel (see Front/Rear Wheel Removal), and take out the following. Collars Coupling (Out of rear hub) Grease Seals • Use the bearing remover to remove the hub bearing [A]. CAUTION Do not lay the wheel on the ground with the disc facing down.
  • Page 395: Hub Bearing Lubrication

    WHEELS/TIRES 10-17 Hub Bearing Hub Bearing Lubrication NOTE ○ Since the hub bearings are packed with grease and sealed, lubrication is not required.
  • Page 397 FINAL DRIVE 11-1 Final Drive Table of Contents Exploded View ........................11-2 Specifications ........................11-4 Special Tools .......................... 11-5 Drive Chain..........................11-6 Drive Chain Slack Inspection .................... 11-6 Drive Chain Slack Adjustment ..................11-6 Wheel Alignment Inspection/Adjustment ................11-6 Drive Chain Wear Inspection .................... 11-6 Drive Chain Lubrication.....................
  • Page 398: Exploded View

    11-2 FINAL DRIVE Exploded View...
  • Page 399 FINAL DRIVE 11-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Engine Sprocket Cover Bolts 87 in·lb Chain Guide Bolts (Front) 87 in·lb Engine Sprocket Nut Rear Sprocket Nuts Chain Guide Bolt (Rear) 0.50 43 in·lb G: Apply grease. HG: Apply high-temperature grease. HO: Apply heavy oil.
  • Page 400: Specifications

    11-4 FINAL DRIVE Specifications Item Standard Service Limit Drive Chain 30 ∼ 40 mm (1.2 ∼ 1.6 in.) Drive Chain Slack – – – Drive Chain Wear (20-link Length) 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) 323 mm (12.7 in.) Standard Chain: Make ENUMA...
  • Page 401: Special Tools

    FINAL DRIVE 11-5 Special Tools Inside Circlip Pliers: Bearing Driver Set: 57001-143 57001-1129...
  • Page 402: Drive Chain

    11-6 FINAL DRIVE Drive Chain Drive Chain Slack Inspection • Refer to the Drive Chain Slack Inspection in the Periodic Maintenance chapter (see Drive Chain Slack Inspection in the Periodic Maintenance chapter). Drive Chain Slack Adjustment • Refer to the Drive Chain Slack Adjustment in the Periodic Maintenance chapter (see Drive Chain Slack Adjustment in the Periodic Maintenance chapter).
  • Page 403: Drive Chain Installation

    FINAL DRIVE 11-7 Drive Chain • Grind [A] the pin head to make it flat. • Set the cutting and riveting pin [B] as shown. • Screw the pin holder until it touches chain pin. • Be sure that the cutting pin hits center of chain pin. •...
  • Page 404 11-8 FINAL DRIVE Drive Chain • Set the plate holder (a) [A] and plate holder (b) [B] on the body. • Fit the plate holder (a) to link plate. • Turn the pin holder by hand until plate holder (b) touches the other link plate.
  • Page 405 FINAL DRIVE 11-9 Drive Chain • Turn the wrench clockwise until tip of riveting pin hits of link pin. • Rivet it. • Same work for the other link pin. • After staking, check the staked area of the link pin for cracks.
  • Page 406: Sprocket, Coupling

    11-10 FINAL DRIVE Sprocket, Coupling Engine Sprocket Removal • Remove: Speed Sensor Bolt [A] Speed Sensor [B] Engine Sprocket Cover Bolts [C] Engine Sprocket Cover [D] • Flatten out the bended washer [A]. • Remove the engine sprocket nut [B] and washer. NOTE ○...
  • Page 407: Rear Sprocket Removal

    FINAL DRIVE 11-11 Sprocket, Coupling • Make sure that dowel pins [A] are in piace. • Install the engine sprocket cover. • Install the clamp [B] as shown, and tighten the cover bolts. Torque - Engine Sprocket Cover Bolts: 6.9 N·m (0.70 kgf·m, 61 in·lb) •...
  • Page 408: Coupling Installation

    11-12 FINAL DRIVE Sprocket, Coupling Coupling Installation • Grease the following and install the coupling. Coupling Grease Seal Lips [A] Coupling Internal Surface [B] • Apply grease to the O-ring [A]. • Install the collar [B] Coupling Bearing Removal • Remove: Coupling Grease Seal...
  • Page 409: Coupling Bearing Inspection

    FINAL DRIVE 11-13 Sprocket, Coupling • Replace the grease seal with a new one. • Press in the grease seal so that the seal surface is flush with the end of the hole. ○ Apply high-temperature grease to the grease seal lips. Special Tool - Bearing Driver Set: 57001-1129 Coupling Bearing Inspection Since the coupling bearing is made to extremely close...
  • Page 410: Rear Sprocket Warp Inspection

    11-14 FINAL DRIVE Sprocket, Coupling Rear Sprocket Warp Inspection • Raise the rear wheel off the ground so that it will turn freely. • Set a dial gauge [A] against the rear sprocket [B] near the teeth as shown, and rotate [C] the rear wheel to measure the sprocket runout (warp).
  • Page 411 BRAKES 12-1 Brakes Table of Contents Exploded View ........................12-2 Specifications ........................12-6 Special Tools .......................... 12-7 Brake Lever, Brake Pedal....................... 12-8 Brake Lever Position Adjustment..................12-8 Brake Pedal Position Inspection ..................12-8 Brake Pedal Position Adjustment ..................12-8 Brake Pedal Removal ....................... 12-8 Brake Pedal Installation ....................
  • Page 412: Exploded View

    12-2 BRAKES Exploded View...
  • Page 413 BRAKES 12-3 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 Front Brake Disc Mounting Bolts Front Brake Light Switch Screw 0.12 10 in·lb Front Brake Pad Pins...
  • Page 414 12-4 BRAKES Exploded View...
  • Page 415 BRAKES 12-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Bleed Valve 0.80 69 in·lb Brake Hose Banjo Bolts Brake Pedal Bolt 0.90 78 in·lb Rear Brake Disc Mounting Bolts Rear Caliper Mounting Bolts Rear Master Cylinder Mounting Bolts Rear Master Cylinder Push Rod Locknut B: Apply brake fluid.
  • Page 416: Specifications

    12-6 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 78 mm (3.1 in.) below footpeg top –...
  • Page 417: Special Tools

    BRAKES 12-7 Special Tools Inside Circlip Pliers: Jack Attachment: 57001-143 57001-1608 Jack: 57001-1238...
  • Page 418: Brake Lever, Brake Pedal

    12-8 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 419: Brake Pedal Installation

    BRAKES 12-9 Brake Lever, Brake Pedal • Remove: Cotter Pin [A] Joint Pin [B] Rear Brake Light Switch Spring [C] Return Spring [D] • Remove the mounting bolt [E] and take out the brake pedal. Brake Pedal Installation • Apply grease to the pivot shaft [A] and install the washer [B].
  • Page 420: Calipers

    12-10 BRAKES Calipers Front Caliper Removal • Loosen the banjo bolt [A] at the brake hose lower end, and tighten it loosely. • Unscrew the caliper mounting bolts [B], and detach the caliper [C] from the disc. CAUTION Do not loosen the caliper assembly bolts [D]. Take out only the caliper mounting bolts for caliper re- moval.
  • Page 421: Front Caliper Disassembly

    BRAKES 12-11 Calipers WARNING Do not attempt to drive the motorcycle until a full brake lever or pedal is obtained by pumping the brake lever or pedal and the pads are against the disc. The brakes will not function on the first appli- cation of the lever or pedal if this is not done.
  • Page 422: Rear Caliper Dust Boot And Friction Boot Damage

    12-12 BRAKES Calipers Rear Caliper Dust Boot and Friction Boot Damage • Check that the dust boot [A] and friction boot [B] are not cracked, worn, swollen, or otherwise damaged. If they show any damage, replace it. Caliper Piston and Cylinder Damage •...
  • Page 423: Brake Pads

    BRAKES 12-13 Brake Pads Front Brake Pad Removal • 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. • Install the outside pad [A] and insert the pad pin [B] as shown.
  • Page 424: Rear Brake Pad Installation

    12-14 BRAKES Brake Pads Rear Brake Pad Installation • Push the caliper piston in by hand as far as it will go. • Install the pad spring in place. • Install the piston side pad [A] first, and then another pad. ○...
  • Page 425: Master Cylinder

    BRAKES 12-15 Master Cylinder Front Master Cylinder Removal • Remove the reservoir bracket nut [A]. • Remove the banjo bolt [A] to disconnect the brake hose from the master cylinder (see Brake Hose Removal/In- stallation in this chapter). • 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 426: Rear Master Cylinder Removal

    12-16 BRAKES Master Cylinder Rear Master Cylinder Removal • Unscrew the brake hose banjo bolt [A] and brake hose [B]. • Remove: Cotter Pin [C] Joint Pin [D] Bolts [E] Foot Guard [F] Rear Master Cylinder • Slide out the clamp [G]. •...
  • Page 427: Master Cylinder Assembly

    BRAKES 12-17 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 428: Brake Disc

    12-18 BRAKES Brake Disc Brake Disc Removal • Remove the wheel (see Front/Rear Wheel Removal in the Wheels/Tires chapter). • Unscrew the mounting bolts, and take off the disc. Brake Disc Installation • Install the brake disc on the wheel so that the marked side [B] faces out.
  • Page 429: Brake Fluid

    BRAKES 12-19 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 430 12-20 BRAKES Brake Fluid • Bleed the brake 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 brake lever until it becomes hard, and apply the brake and hold it [A].
  • Page 431 BRAKES 12-21 Brake Fluid • Install: Diaphragm [A] Diaphragm Plate [B] Front Brake Reservoir Cap [C] • Follow the procedure below to install the front/rear brake fluid reservoir cap correctly. ○ First, tighten the brake fluid reservoir cap [B] clockwise [C] by hand until the resistance is felt fully;...
  • Page 432 12-22 BRAKES Brake Fluid WARNING When working with the disc brake, observe the pre- cautions listed below. 1. Never reuse old brake fluid. 2. Do not use fluid from a container that has been left unsealed or that has been open for a long time. 3.
  • Page 433: Brake Hose

    BRAKES 12-23 Brake Hose Brake Hose Removal/Installation • Refer to the Brake Hose and Pipe Replacement in the Periodic Maintenance chapter. Brake Hose Inspection • Refer to the Brake Hose Damage and Installation Condi- tion Inspection in the Periodic Maintenance chapter.
  • Page 435 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 Compression Damping Force Adjustment ................ 13-10 Front Fork Removal (Each Fork Leg) ................13-10 Front Fork Installation .......................
  • Page 436: Exploded View

    13-2 SUSPENSION Exploded View...
  • Page 437 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 438 13-4 SUSPENSION Exploded View...
  • Page 439 SUSPENSION 13-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Rear Shock Absorber Bracket Nut Rear Shock Absorber Nut (Lower) Rear Shock Absorber Nut (Upper) Swingarm Pivot Adjusting Collar Swingarm Pivot Adjusting Collar Locknut Swingarm Pivot Shaft Nut Tie-Rod Nuts Uni-Trak Rocker Arm Nut G: Apply grease.
  • Page 440: Specifications

    13-6 SUSPENSION Specifications Item Standard Front Fork (Per One Unit) Fork Inner Tube Diameter 41 mm (1.6 in.) Air Pressure Atmospheric pressure (non-adjustable) Rebound Damper Setting 1 1/2 turns out from the fully clockwise position (Usable range: 0 ←→ 3 1/2 turns out) Compression Damper Setting 1 1/2 turns out from the fully clockwise position (Usable range: 0 ←→...
  • Page 441: Special Tools

    SUSPENSION 13-7 Special Tools Inside Circlip Pliers: Fork Oil Level Gauge: 57001-143 57001-1290 Oil Seal & Bearing Remover: Fork Piston Rod Puller, M10 × 1.0: 57001-1058 57001-1298 Bearing Driver Set: Fork Spring Stopper: 57001-1129 57001-1374 Jack: Bearing Remover Shaft, 13: 57001-1238 57001-1377 Fork Oil Seal Driver, 41:...
  • Page 442 13-8 SUSPENSION Special Tools Swingarm Pivot Nut Wrench: Spacer, 57001-1597 57001-1636 Jack Attachment: Spacer, 57001-1608 57001-1637 Needle Bearing Driver, 17/ 18: Fork Spring Compressor: 57001-1609 57001-1685 Stem Bearing Driver, 28: 57001-1610...
  • Page 443: Front Fork

    SUSPENSION 13-9 Front Fork Rebound Damping Force Adjustment • To adjust the rebound damping force, turn the rebound damping adjuster [A] on top of the right front fork leg to the desired position. ○ The standard adjuster setting for the average-build rider of 68 kg (150 lb) with no passenger and no accessories is 1 1/2 turns out from the fully clockwise position.
  • Page 444: Compression Damping Force Adjustment

    13-10 SUSPENSION Front Fork Compression Damping Force Adjustment • To adjust the compression damping force, turn the com- pression 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 1 1/2 turn out from the fully clockwise position.
  • Page 445: Front Fork Installation

    SUSPENSION 13-11 Front Fork • Loosen the handlebar bolt, upper fork clamp bolt and lower fork clamp bolts [A]. • With a twisting motion, work the fork leg down and out. Front Fork Installation • Install the fork so that the top end [A] of the outer tube as shown.
  • Page 446 13-12 SUSPENSION Front Fork • While holding up the top plug [A] by one person, push down [B] the fork spring compressor and insert the fork spring stopper [C] between the piston rod nut [D] and the spacer [E]. Special Tool - Fork Spring Stopper: 57001-1374 •...
  • Page 447 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 448 13-14 SUSPENSION Front Fork • Screw the fork piston rod puller [A] onto the end of the piston rod. Special Tool - Fork Piston Rod Puller, M10 × 1.0: 57001 -1298 • Pull the puller upward above the outer tube top. •...
  • Page 449: Front Fork Disassembly

    SUSPENSION 13-15 Front Fork • Replace O-ring on the top plug with a new one. • Apply grease to the O-ring. • Insert the rebound damping adjuster rod [A] into the holes of the piston rod. • Screw in the top plug [B] stopped onto the piston rod. •...
  • Page 450: Front Fork Assembly

    13-16 SUSPENSION Front Fork • Separate the inner tube from the outer tube as follows. ○ Slide up the dust seal [A]. ○ Remove the retaining ring [B] from the outer tube. ○ Holding the inner tube [A] by hand, pull the outer tube [B] several times to pull out the outer tube.
  • Page 451: Inner Tube Inspection

    SUSPENSION 13-17 Front Fork • Insert the inner tube to the outer tube. • Fit the new outer tube guide bushing [A] into the outer tube. NOTE ○ When assembling the new outer tube guide bushing, hold the washer [B] against the new outer tube guide bushing and tap the washer with the fork oil seal driver [C] until it stops.
  • Page 452: Dust Seal Inspection

    13-18 SUSPENSION Front Fork CAUTION If the inner tube is badly bent or creased, replace Excessive bending, followed by subsequent straightening, can weaken the inner tube. • Temporarily assemble the inner and outer tubes, and pump them back and forth manually to check for smooth operation.
  • Page 453: Rear Shock Absorber

    SUSPENSION 13-19 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 19th click from the 1st click of the fully clockwise position.
  • Page 454: Spring Preload Adjustment

    13-20 SUSPENSION Rear Shock Absorber Spring Preload Adjustment • Loosen the locknut and turn out the adjusting nut to free the spring. Special Tool - Hook Wrench T=3.2 R37: 57001-1539 • To adjust the spring preload, turn in the adjusting nut [A] to the desired position and tighten the locknut [B].
  • Page 455: Rear Shock Absorber Removal

    SUSPENSION 13-21 Rear Shock Absorber Rear Shock Absorber Removal • Remove: Lower Fairings (see Lower Fairings Removal in the Frame chapter) Front Exhaust Pipe (see Front Exhaust Removal in the Engine Top End chapter) • Using the jack, raise the rear wheel off the ground. Special Tools - Jack: 57001-1238 Jack Attachment: 57001-1608 •...
  • Page 456: Rear Shock Absorber Scrapping

    13-22 SUSPENSION Rear Shock Absorber Rear Shock Absorber Scrapping WARNING Since the reservoir tank of the rear shock absorber contains nitrogen gas, do not incinerate the reser- voir tank without first releasing the gas or it may explode. • Remove the valve cap [A] and release the nitrogen gas completely from the gas reservoir.
  • Page 457: Swingarm

    SUSPENSION 13-23 Swingarm Swingarm Removal • Remove: Rear Wheel (see Rear Wheel Removal in the Wheels/Tires chapter) Engine Sprocket Cover (see Engine Sprocket Removal in the Final Drive chapter) Bolt [A] Brake Hose Clamp [B] Brake Pedal (see Brake Pedal Removal in the Brakes chapter) Rear Exhaust Pipe (see Rear Exhaust Pipe Removal in the Engine Top End chapter)
  • Page 458: Swingarm Installation

    13-24 SUSPENSION Swingarm Swingarm Installation • Apply plenty of grease to the lip [A] of the grease seals. • Screw the adjusting collar [A] into the frame [B] so that the collar does not project the swingarm mating surface [C]. •...
  • Page 459: Swingarm Bearing Removal

    SUSPENSION 13-25 Swingarm • Tighten the pivot shaft nut [A]. Torque - Swingarm Pivot Shaft Nut: 108 N·m (11 kgf·m, 81 ft·lb) • Install the removed parts (see appropriate chapters). Swingarm Bearing Removal • Remove: Swingarm (see Swingarm Removal) Washer [A] Grease Seals [B] Sleeve [C] Circlip [D] (Right Side)
  • Page 460: Swingarm Bearing, Sleeve Inspection

    13-26 SUSPENSION Swingarm • Install the needle bearings [A], ball bearing [B] and oil seals [C] position as shown. Circlip [D] 32.5 mm (1.28 in.) [E] 0.5 mm (0.02 in.) [F] 1 mm (0.04 in.) [G] 5 mm (0.20 in.) [H] Swingarm Bearing, Sleeve Inspection CAUTION Do not remove the bearings for inspection.
  • Page 461: Tie-rod, Rocker Arm

    SUSPENSION 13-27 Tie-Rod, Rocker Arm Tie-Rod Removal • Remove: Lower Fairings (see Lower Fairing Removal in the Frame chapter) Front Exhaust Pipe (see Front Exhaust Pipe Removal in the Engine Top End chapter) • Squeeze the brake lever slowly and hold it with a band [A].
  • Page 462: Rocker Arm Installation

    13-28 SUSPENSION Tie-Rod, Rocker Arm • Using the jack, raise the rear wheel off the ground. Special Tools - Jack [A]: 57001-1238 Jack Attachment [B]: 57001-1608 • Remove: Lower Rear Shock Absorber Bolt [A] Lower Tie-Rod Bolt [B] Rocker Arm Bolt [C] Rocker Arm [D] Rocker Arm Installation •...
  • Page 463: Tie-rod And Rocker Arm Bearing Removal

    SUSPENSION 13-29 Tie-Rod, Rocker Arm Tie-Rod and Rocker Arm Bearing Removal • Remove: Tie-Rods (see Tie-Rod Removal in this chapter) Rocker Arm (see Rocker Arm Removal in this chapter) Sleeves [A] Grease Seal [B] Swingarm [C] Needle Bearings [D] ○ When remove the needle bearings [A], tap the bearings evenly with the bearing remover shaft [B].
  • Page 464 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 465: Rocker Arm/tie-rod Bearing, Sleeve Inspection

    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 rocker 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 467 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 468: Exploded View

    14-2 STEERING Exploded View...
  • Page 469 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 Position Bolts 87 in·lb Steering Stem Head Nut Steering Stem Nut Switch Housing Screws 0.36 31 in·lb AD: Apply adhesive.
  • Page 470: Special Tools

    14-4 STEERING Special Tools Bearing Puller: Bearing Driver Set: 57001-135 57001-1129 Bearing Puller Adapter: Steering Stem Bearing Driver, 42.5: 57001-136 57001-1344 Head Pipe Outer Race Press Shaft: Steering Stem Bearing Driver Adapter, 41.5: 57001-1075 57001-1345 Steering Stem Nut Wrench: Head Pipe Outer Race Driver, 55: 57001-1100 57001-1446...
  • Page 471: Steering Inspection

    STEERING 14-5 Steering Steering Inspection • Refer to the Steering Play Inspection in the Periodic Main- tenance chapter. Steering Adjustment • Refer to the Steering Play Adjustment in the Periodic Maintenance chapter.
  • Page 472: Steering Stem

    14-6 STEERING Steering Stem Stem, Stem Bearing Removal • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Front Wheel (see Front Wheel Removal in the Wheels/Tires chapter) Front Fork (see Front Fork Removal in the Suspension chapter) Brake Hose Clamp Bolt [A] •...
  • Page 473: Stem, Stem Bearing Installation

    STEERING 14-7 Steering Stem • Remove the lower bearing inner race (with its oil seal) [A] which is pressed onto the steering stem [B] with the bearing puller [C] and adapter [D]. Special Tools - Bearing Puller: 57001-135 Bearing Puller Adapter: 57001-136 Stem, Stem Bearing Installation •...
  • Page 474 14-8 STEERING Steering Stem • Settle the bearings in place as follows. ○ Tighten the steering stem nut with 55 N·m (5.6 kgf·m, 41 ft·lb) of torque first, and loosen it a fraction of a turn until it turns lightly (To tighten the stem nut to the specified torque, hook the wrench on the stem nut, and pull the wrench at the hole by 305 N (31.0 kgf, 69 lb) [B] force in the direction shown.).
  • Page 475: Steering Stem Bearing Lubrication

    STEERING 14-9 Steering Stem NOTE ○ Tighten the upper fork clamp bolts [A] first, next the stem head nut [B], last the lower fork clamp bolts [C] and the handlebar bolts [D]. ○ Tighten the two lower fork clamp bolts alternately two times to ensure even tightening torque.
  • Page 476: Handlebar

    14-10 STEERING Handlebar Handlebar Removal • Loosen: Front Fork Clamp Bolts [A] (Right and Left) Handlebar Bolts [B] (Right and Left) • Remove: Clutch Lever Clamp Bolts [A] Clutch Lever Assembly [B] Left Switch Housing [C] Handlebar Weight [D] • Remove: Front Brake Master Cylinder [A] (see Front Master Cylin- der Removal in the Brakes chapter)
  • Page 477: Handlebar Installation

    STEERING 14-11 Handlebar Handlebar Installation • Apply adhesive cement to the inside of the left handlebar grip. • Apply a non-permanent locking agent to the threads of handlebar position bolts. • Tighten: Torque - Steering Stem Head Nut: 78 N·m (8.0 kgf·m, 58 ft·lb) Handlebar Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb) Handlebar Position Bolts: 9.8 N·m (1.0 kgf·m, 87...
  • Page 479 FRAME 15-1 Frame Table of Contents Exploded View........................15-2 Seats ............................15-8 Rear Seat Removal......................15-8 Rear Seat Installation......................15-8 Front Seat Removal ......................15-8 Front Seat Installation ....................... 15-8 Fairings........................... 15-9 Lower Fairing Removal ..................... 15-9 Lower Fairing Installation ....................15-9 Middle Fairing Removal ....................
  • Page 480: Exploded View

    15-2 FRAME Exploded View...
  • Page 481 FRAME 15-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Footpeg Bracket Bolts Rear Footpeg Bracket Bolts Rear Frame 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 482 15-4 FRAME Exploded View...
  • Page 483 FRAME 15-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Fender Mounting Bolts 0.40 35 in·lb 2. United States and Canada Models...
  • Page 484 15-6 FRAME Exploded View...
  • Page 485 FRAME 15-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Windshield Mounting Bolts 0.04 4 in·lb 2. ZX600P7F...
  • Page 486: Seats

    15-8 FRAME Seats Rear Seat Removal • Insert the ignition switch key [A] into the seat lock, turning the key counterclockwise, pulling the front part of the seat [B] up, and pull the seat forward. Rear Seat Installation • Put the rear seat hook [A] on the rib [B]. •...
  • Page 487: Fairings

    FRAME 15-9 Fairings Lower Fairing Removal • Remove: Bolts [A] with Washers • Clear the hook portion from the slot. • Pull up the core [A] by the thin blade screw driver. • Remove: Quick Rivets [B] • Separate the right lower fairing from the left lower fairing. Lower Fairing Installation •...
  • Page 488 15-10 FRAME Fairings • Remove: Quick Rivets [A] • Remove: Quick Rivets [A] Left Turn Signal Lead Connector Separator Band (California Model) • Remove the left middle fairing with lower inner fairing. Left Middle Fairing Installation • Install the separator band (California Model). •...
  • Page 489: Windshield Removal

    FRAME 15-11 Fairings • Remove: Quick Rivets [A] • Remove: Right Turn Signal Lead Connector [A] Fan Motor Connector [B] Relay Box Connectors [C] Fuse Box [D] • Remove the right middle fairing. Right Middle Fairing Installation • Install the Fuse Box. •...
  • Page 490: Upper Fairing Disassembly

    15-12 FRAME Fairings Upper Fairing Removal • Remove: Lower Fairings (see Lower Fairing Removal) Middle Fairing (see Left Middle Fairing Removal) Windshield (see Windshield Removal) Inner Cover (see Inner Cover Removal) Headlight Lead Connectors [A] Clamps (Open) [B] City Light Connector [C] •...
  • Page 491: Inner Cover Installation

    FRAME 15-13 Fairings Inner Cover Installation • Insert the rear portion of the cover under the middle fair- ing. • Fit the projections [B] of the inner cover on to the holes [A] of the upper fairing. • Tighten the bolt. Center Inner Fairing Removal •...
  • Page 492: Lower Inner Fairing Installation

    15-14 FRAME Fairings Lower Inner Fairing Installation • Tighten: Bolts [A] Quick Rivets [B] • Install the removed parts (see appropriate chapters).
  • Page 493: Side Covers

    FRAME 15-15 Side Covers Left Side Cover Removal • Remove: Bolt [A] Projections [B] • Pull out the side cover [C]. Left Side Cover Installation • Insert the projections [A] into the holes [B]. • Tighten the bolt. Right Side Cover Removal •...
  • Page 494: Seat Cover

    15-16 FRAME Seat Cover Seat Cover Removal • Remove: Seats (see Rear/Front Seat Removal) Bolts [A] with Washer • Remove: Bolts [A] with Washer • Remove: Bolt [A] with Washer Seat Cover [B] (backward) Seat Cover Installation • Install the removed parts.
  • Page 495: Engine Cover

    FRAME 15-17 Engine Cover Heat Insulation Plate Removal • Remove: Lower Fairing (see Lower Fairing Removal) Middle Fairing (see Left Middle Fairing Removal) Radiator Upper Bolts [A] (both side) Radiator Lower Bolt [B] • Move the radiator to the front side. •...
  • Page 496: Heat Insulation Rubber Plate Installation

    15-18 FRAME Engine Cover Heat Insulation Rubber Plate Installation • Install the heat insulation rubber plate [A] in throttle body (#2, #3) [B] so that the white paint face [C] up. • Install: Water Temperature Sensor Lead [D] Alternator Lead [E] Gear Position Sensor Lead [F] Crankshaft Sensor Lead [G] Coolant Hose [H]...
  • Page 497: Fenders

    FRAME 15-19 Fenders Front Fender Removal • Remove: Brake Hose Clamps [A] (Both Side) Bolts [B] (Both Side) • Remove the front fender assy [C]. • Remove: Bolts [A] • Separate the front fender cover [B] and front fender [C]. Front Fender Installation •...
  • Page 498 15-20 FRAME Fenders • Remove: Bolts [A] (Both Side) Turn Signal Lights [B] (Both Side) • Remove: Bolts [A] (Both Side) Bracket [B] (Both Side) • Remove: Bolts [A] (Both Side) Bracket [B] Flap [C] with Tail/Brake Light • Separate the flap and Light. •...
  • Page 499 FRAME 15-21 Fenders • Remove: Connectors [A] Grommet [B] • Remove: Rear Footpeg Bracket Bolts [A] (Both Side) Rear Footpeg Bracket Assy [B] • Remove: Band [A] Cables [B] Battery [C] • Remove: Bolts [A] Battery Case [B] Starter Relay [C] (pull out) •...
  • Page 500 15-22 FRAME Fenders • Remove: Main Harness Clamp [A] • Remove: Quick Rivets [A] (both side) • Remove: Screws [A] Rocks with Bracket [B] • Remove: Bolts [A] Rear Fender [B]...
  • Page 501: Flap And Rear Fender Installation

    FRAME 15-23 Fenders Flap and Rear Fender Installation • Install the removed parts (see appropriate chapters). • Tighten: Torque - Rear Footpeg Bracket Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb) • Note the following procedure for the muffler covers instal- lation.
  • Page 502: Rear Frame Removal

    15-24 FRAME Frame Rear Frame Removal • Remove: Rear Fender (see Rear Fender Removal) Frame Bolts [A] and Nuts Rear Frame Installation • Apply a non-permanent locking agent to the threads of rear frame bolt. • Tighten: Torque - Rear Frame Bolts and Nuts: 59 N·m (6.0 kgf·m, 44 ft·lb) Rear Footpeg Bracket Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb)
  • Page 503: Sidestand

    FRAME 15-25 Sidestand Sidestand Removal • Raise the rear wheel off the ground with the stand. • Remove: Lower Fairings (see Lower Fairing Removal) • Disconnect the sidestand switch lead connector [A]. • Remove: Spring [A] Sidestand Bolt Locknut Sidestand Bolt [B] Sidestand [C] Switch Bracket Bolts [D] Sidestand Bracket Bolts [E]...
  • Page 505 ELECTRICAL SYSTEM 16-1 Electrical System Table of Contents Parts Location........16-3 Stick Coil Installation....16-46 Exploded View........16-4 Stick Coil Inspection..... 16-47 Wiring Diagram (United States and Stick Coil Primary Peak Voltage .. 16-47 Canada) ZX600P7F......16-10 Spark Plug Removal ....16-48 Wiring Diagram (United States and Spark Plug Installation ....
  • Page 506 16-2 ELECTRICAL SYSTEM Fan Motor Inspection ....16-70 Water Temperature Sensor Meter, Gauge, Indicator Unit....16-72 Inspection........16-115 Meter Unit Removal ..... 16-72 Speed Sensor Removal ....16-115 Meter Unit Disassembly ....16-72 Speed Sensor Installation .... 16-116 Electronic Unit (Combination Speed Sensor Inspection.....
  • Page 507: Parts Location

    ELECTRICAL SYSTEM 16-3 Parts Location 1. Immobilizer Amplifier (Equipped Models) 14. Regulator/rectifier 2. Meter Unit 15. ECU (Electric Control Unit) 3. Ignition Switch with Immobilizer Antenna 16. Fuel Pump with Fuel Reserve Switch 4. Starter Lockout Switch 17. Front Brake Light Switch 5.
  • Page 508: Exploded View

    16-4 ELECTRICAL SYSTEM Exploded View...
  • Page 509 ELECTRICAL SYSTEM 16-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Meter Mounting Screws 0.12 10 in·lb Headlight Mounting Screws 0.12 10 in·lb Front Turn Signal Light Mounting Screws 0.12 10 in·lb Rear Turn Signal Light Mounting Screws 0.12 10 in·lb Rear Turn Signal Light Lens Screws 0.10 9 in·lb...
  • Page 510 16-6 ELECTRICAL SYSTEM Exploded View...
  • Page 511 ELECTRICAL SYSTEM 16-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Switch Housing Screws 0.36 31 in·lb Front Brake Light Switch Screw 0.12 10 in·lb Cylinder Head Cover Ground Bolt 87 in·lb Crankshaft Sensor Bolts 0.60 52 in·lb Alternator Lead Holding Plate Bolt 87 in·lb Alternator Cover Bolts 87 in·lb...
  • Page 512 16-8 ELECTRICAL SYSTEM Exploded View...
  • Page 513 ELECTRICAL SYSTEM 16-9 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Spark Plugs 113 in·lb Starter Relay Cable Terminal Bolts 0.41 35 in·lb Camshaft Position Sensor Bolt 87 in·lb Water Temperature Sensor Oxygen Sensors Fuel Pump Bolts 87 in·lb L, S Regulator/Rectifier Bracket Nuts 0.70 61 in·lb...
  • Page 514: Wiring Diagram (united States And Canada) Zx600p7f

    16-10 ELECTRICAL SYSTEM Wiring Diagram (United States and Canada) ZX600P7F...
  • Page 515 ELECTRICAL SYSTEM 16-11 Wiring Diagram (United States and Canada) ZX600P7F...
  • Page 516: Wiring Diagram (united States And Canada) Zx600p8f

    16-12 ELECTRICAL SYSTEM Wiring Diagram (United States and Canada) ZX600P8F...
  • Page 517 ELECTRICAL SYSTEM 16-13 Wiring Diagram (United States and Canada) ZX600P8F...
  • Page 518: Wiring Diagram (other Than United States, Canada, Australia And Malaysia) Zx600p7f

    16-14 ELECTRICAL SYSTEM Wiring Diagram (Other than United States, Canada, Australia and Malaysia) ZX600P7F...
  • Page 519 ELECTRICAL SYSTEM 16-15 Wiring Diagram (Other than United States, Canada, Australia and Malaysia) ZX600P7F...
  • Page 520: Wiring Diagram (other Than United States, Canada, Australia And Malaysia) Zx600p8f

    16-16 ELECTRICAL SYSTEM Wiring Diagram (Other than United States, Canada, Australia and Malaysia) ZX600P8F...
  • Page 521 ELECTRICAL SYSTEM 16-17 Wiring Diagram (Other than United States, Canada, Australia and Malaysia) ZX600P8F...
  • Page 522: Wiring Diagram (australia) Zx600p7f

    16-18 ELECTRICAL SYSTEM Wiring Diagram (Australia) ZX600P7F...
  • Page 523 ELECTRICAL SYSTEM 16-19 Wiring Diagram (Australia) ZX600P7F...
  • Page 524: Wiring Diagram (australia) Zx600p8f

    16-20 ELECTRICAL SYSTEM Wiring Diagram (Australia) ZX600P8F...
  • Page 525 ELECTRICAL SYSTEM 16-21 Wiring Diagram (Australia) ZX600P8F...
  • Page 526: Wiring Diagram (malaysia) Zx600p7f

    16-22 ELECTRICAL SYSTEM Wiring Diagram (Malaysia) ZX600P7F...
  • Page 527 ELECTRICAL SYSTEM 16-23 Wiring Diagram (Malaysia) ZX600P7F...
  • Page 528: Wiring Diagram (malaysia) Zx600p8f

    16-24 ELECTRICAL SYSTEM Wiring Diagram (Malaysia) ZX600P8F...
  • Page 529 ELECTRICAL SYSTEM 16-25 Wiring Diagram (Malaysia) ZX600P8F...
  • Page 530: Specifications

    16-26 ELECTRICAL SYSTEM Specifications Item Standard Battery Type Sealed battery Capacity 12 V 8 Ah Voltage 12.8 V or more Charging System Type Three-phase AC Alternator Output Voltage 42 V or more @4 000 r/min (rpm) 0.1 ∼ 0.3 Ω Stator Coil Resistance 14.2 ∼...
  • Page 531: Special Tools And Sealant

    Special Tools and Sealant Hand Tester: Grip: 57001-1394 57001-1591 Flywheel Puller Assembly, M38 × 1.5/M35 × 1.5: Rotor Holder: 57001-1405 57001-1666 Peak Voltage Adapter: Stopper: 57001-1415 57001-1679 Lead Wire - Peak Voltage Adapter: Kawasaki Bond (Silicone Sealant): 57001-1449 92104-0004 Key Registration Unit: 57001-1582...
  • Page 532: Precautions

    16-28 ELECTRICAL SYSTEM Precautions There are a number of important precautions that are musts when servicing electrical systems. Learn and ob- serve all the rules below. ○ Do not reverse the battery cable connection. This will burn out the diodes on the electrical parts. ○...
  • Page 533: Electrical Wiring

    ELECTRICAL SYSTEM 16-29 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 534: Battery

    16-30 ELECTRICAL SYSTEM Battery Battery Removal • Remove: Side Covers (see Side Cover Removal in the Frame chapter) Front Seat (see Front Seat Removal in the Frame chap- ter) • Slide the caps [A]. • Disconnect the negative (–) cable [B] and then positive (+) cable [C].
  • Page 535 ELECTRICAL SYSTEM 16-31 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 536 Newly activated sealed batteries require an initial charge. Standard Charge: 0.9 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 537: Precautions

    ELECTRICAL SYSTEM 16-33 Battery NOTE ○ To ensure maximum battery life and customer satisfac- tion, it is recommended the battery be load tested at three times its amp-hour rating for 15 seconds. Re-check voltage and if less than 12.8 V repeat the charging cycle and load test.
  • Page 538: Charging Condition Inspection

    16-34 ELECTRICAL SYSTEM Battery Charging Condition Inspection ○ Battery charging condition can be checked by measuring battery terminal voltage with a digital voltmeter [A]. • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Battery Cable Caps (see Battery Removal in this chap- ter) •...
  • Page 539 ELECTRICAL SYSTEM 16-35 Battery Terminal Voltage: 11.5 ∼ less than 12.8 V Standard Charge 0.9 A × 5 ∼ 10 h (see following chart) Quick Charge 4 A × 1 h CAUTION If possible, do not quick charge. If quick charge is done unavoidably, do standard charge later on.
  • Page 540: Charging System

    Apply silicone sealant to the alternator lead grommet and crankcase halves mating surface [A] on the front and rear sides of the cover mount. Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004 • Check that dowel pins [B] are in place on the crankcase.
  • Page 541: Stator Coil 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, and apply a non-permanent locking agent to the threads of the plate bolts and tighten them.
  • Page 542: Alternator Inspection

    16-38 ELECTRICAL SYSTEM Charging System • Check the tightening torque with flywheel puller [A]. Special Tool - Flywheel Puller Assembly, M38 × 1.5/M35 × 1.5: 57001-1405 If the rotor is not pulled out with 20 N·m (2.0 kgf·m, 15 ft·lb) of drawing torque, it is installed correctly. If the rotor is pulled out with under 20 N·m (2.0 kgf·m, 15 ft·lb) of drawing torque, clean off any oil dirt or flaw of the crankshaft and rotor tapered portion, and dry them with...
  • Page 543: Regulator/rectifier Removal

    ELECTRICAL SYSTEM 16-39 Charging System If the output voltage shows the value in the table, the al- ternator operates properly. If the output voltage shows a much higher than the value in the table, the regulator/rectifier is damaged. A much lower reading than that given in the table indicates that the alternator is defective.
  • Page 544: 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 545: Charging Voltage Inspection

    ELECTRICAL SYSTEM 16-41 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: Front Seat (see Front Seat Removal in the Frame chap- ter) Caps [A] •...
  • Page 546 16-42 ELECTRICAL SYSTEM Charging System Charging System Circuit 1. Ignition Switch 2. Load 3. Main Fuse 30 A 4. Starter Relay 5. Battery 12 V 8 Ah 6. Frame Ground 7. Alternator 8. Regulator/rectifier...
  • Page 547: Ignition System

    ELECTRICAL SYSTEM 16-43 Ignition System...
  • Page 548: Crankshaft Sensor Removal

    Torque - Crankshaft Sensor Bolts: 5.9 N·m (0.60 kgf·m, 52 in·lb) • Apply silicone sealant. Crankshaft Sensor Lead Grommet (Around) [A] Crankcase Halves Mating Surfaces [B] Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004 • Install: Clamp Starter Clutch Cover (see Starter Idle Gear Installation in the Crankshaft/Transmission chapter)
  • Page 549: Crankshaft Sensor Inspection

    ELECTRICAL SYSTEM 16-45 Ignition System • Connect: Sensor Lead Connector Oil Pressure Switch Lead (see Oil Pressure Switch In- stallation in the Engine Lubrication System) • Install the removed parts (see appropriate chapters). Crankshaft Sensor Inspection • Remove: Crankshaft Sensor Lead Connector (see Crankshaft Sensor Removal) •...
  • Page 550: Stick Coil Removal

    16-46 ELECTRICAL SYSTEM Ignition System • Pushing the starter button, turn the engine 4 ∼ 5 sec- onds with the transmission gear in neutral to measure the crankshaft sensor peak voltage. • Repeat the measurement 5 or more times. Crankshaft Sensor Peak Voltage Standard: 3.2 V or more Special Tools - Hand Tester: 57001-1394 Peak Voltage Adapter: 57001-1415...
  • Page 551: Stick Coil Inspection

    ELECTRICAL SYSTEM 16-47 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 552: Spark Plug Removal

    16-48 ELECTRICAL SYSTEM Ignition System WARNING To avoid extremely high voltage shocks, do not touch the spark plugs or tester connections. • Turn the ignition switch and the engine stop switch ON. • Pushing the starter button, turn the engine 4 ∼ 5 seconds with the transmission in neutral to measure the primary peak voltage.
  • Page 553: Camshaft Position Sensor Removal

    ELECTRICAL SYSTEM 16-49 Ignition System Camshaft Position Sensor Removal • Remove: Air Cleaner Housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter) Camshaft Position Sensor Connector [A] • Remove: Middle Fairings (see Middle Firing Removal in the Frame chapter) Radiator Mounting Bolts (see Radiator Removal in the Cooling System chapter)
  • Page 554: Camshaft Position Sensor Peak Voltage Inspection

    16-50 ELECTRICAL SYSTEM Ignition System • Set the hand tester to the × 10 Ω range and connect it to the terminals. Special Tool - Hand Tester: 57001-1394 If there is more resistance than the specified value, the sensor coil has an open lead and must be replaced. Much less than this resistance means the sensor coil is shorted, and must be replaced.
  • Page 555: Interlock Operation Inspection

    ELECTRICAL SYSTEM 16-51 Ignition System Interlock Operation Inspection • Using the stand [A], raise the rear wheel off the ground. 1st Check • Start the engine to the following conditions. Condition Transmission Gear → 1st Position Clutch Lever → Release Side Stand →...
  • Page 556: Ic Igniter Inspection

    16-52 ELECTRICAL SYSTEM Ignition System IC Igniter Inspection ○ The IC igniter is built in the ECU [A]. • Refer to the Interlock Operation Inspection, Ignition Sys- tem Troubleshooting chart and Fuel System (DFI) chapter for ECU Power Supply Inspection.
  • Page 557 ELECTRICAL SYSTEM 16-53 Ignition System Ignition System Circuit 1. Ignition Switch 14. Engine Stop Switch 2. Joint Connector C 15. Cylinder Head Cover Ground 3. Starter Lockout Switch 16. Spark plugs 4. Fuse Box 17. Stick Coils 5. ECU Fuse 10 A 18.
  • Page 558: Electric Starter System

    16-54 ELECTRICAL SYSTEM Electric Starter System Starter Motor Removal • Remove: Starter Clutch Cover [A] (see Idle Gear Removal in the Crankshaft/Transmission chapter) • Slide back the rubber cap [B]. • Remove Starter Motor Terminal Bolt [C] Mounting Bolts [D] •...
  • Page 559: Starter Motor Disassembly

    ELECTRICAL SYSTEM 16-55 Electric Starter System Starter Motor Disassembly • Take off the starter motor through bolts [A]. • Remove: Left-hand End Cover [A] Right-hand End Cover [B] Armature [C] Yoke [D] Starter Motor Assembly • Apply a thin coat of grease to the oil seal [A]. •...
  • Page 560: Brush Inspection

    16-56 ELECTRICAL SYSTEM Electric Starter System • Align the groove [A] in the right-hand end cover and the hollow mark [B] on the yoke. • Align the hollow mark [A] on the left-hand end cover and the hollow mark [B] on the yoke. Brush Inspection •...
  • Page 561: Armature Inspection

    ELECTRICAL SYSTEM 16-57 Electric Starter System Armature Inspection • Using the × 1 Ω hand tester range, measure the resis- tance between any two commutator segments [A]. Special Tool - Hand Tester: 57001-1394 If there is a high resistance or no reading (∞) between any two segments, a winding is open and the starter motor must be replaced.
  • Page 562 16-58 ELECTRICAL SYSTEM Electric Starter System • Remove: Connector [A] Battery Cable [B] Starter Cable [C] • Connect the hand tester [A] and 12 V battery [B] to the starter relay [C] as shown. Special Tool - Hand Tester: 57001-1394 If the relay does not work as specified, the relay is defec- tive.
  • Page 563 ELECTRICAL SYSTEM 16-59 Electric Starter System Electric Starter Circuit 1. Engine Stop Switch 11. ECU 2. Starter Button 12. Starter Lockout Switch 3. Fuse Box 13. Starter Circuit Relay 4. Ignition Fuse 10 A 14. Relay Box 5. Ignition Switch 15.
  • Page 564: Lighting System

    16-60 ELECTRICAL SYSTEM Lighting System This motorcycle adopt the daylight system and have a headlight relay in the relay box. The headlight does not go on when the ignition switch and the engine stop switch are first turned on. The headlight comes on after the starter button is released and stays on until the ignition switch is turned off.
  • Page 565: City Light Bulb Replacement

    ELECTRICAL SYSTEM 16-61 Lighting System City Light Bulb Replacement • Remove: Center Inner Fairing (see Center Inner Fairing Removal in the Frame chapter) • Turn the socket [A] counterclockwise and pull out the socket together with the bulb. • Pull the bulb [A] out of the socket [B]. CAUTION Do not turn the bulb.
  • Page 566: Tail/brake Light (led) Installation

    16-62 ELECTRICAL SYSTEM Lighting System • Remove: Left Muffler Side Cover [A] (see Turn Signal Removal) Rear Turn Signal Cover [B] Left Turn Signal Light [C] (see Turn Signal Removal) • Unscrew the mounting bolts [A]. • Remove the tail/brake light (LED) [B]. Tail/Brake Light (LED) Installation •...
  • Page 567: Turn Signal Light Bulb Replacement

    ELECTRICAL SYSTEM 16-63 Lighting System Headlight/Tail Light Circuit 13. Fuse Box 1. Ignition Switch 2. High Beam Indicator Light (LED) 14. Headlight Relay 3. Joint Connector C 15. Relay Box 4. Headlight (Low Beam) 16. Joint Connector B 5. City Light 17.
  • Page 568 16-64 ELECTRICAL SYSTEM Lighting System • Turn the socket [A] counterclockwise and pull out the socket together with the bulb. • Push [A] and turn [B] the bulb [C] counterclockwise 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 569: Turn Signal Light Removal

    ELECTRICAL SYSTEM 16-65 Lighting System • Insert the new bulb [A] by aligning its upper and lower pins [B] with the upper and lower grooves [C] in the socket, ant turn the bulb clockwise. Turn Signal Light Removal For the Front Turn Signal Light •...
  • Page 570: Turn Signal Relay Inspection

    16-66 ELECTRICAL SYSTEM Lighting System • Remove: Quick Rivet [A] Screws [B] Left Turn Signal Light with Cover [C] • Remove: Tail/Brake Light (see Tail/Brake Light Removal) Screws [A] Right Turn Signal Light with Cover [B] • Remove: Screws [A] •...
  • Page 571 ELECTRICAL SYSTEM 16-67 Lighting System United States, Canada and Australia Models • Connect one 12 V battery and turn signal lights as indi- cated in the figure, and count how may times the lights flash for one minute. Turn Signal Relay [A] Turn Signal Lights [B] 12 V Battery [C] If the lights do not flash as specified, replace the turn sig-...
  • Page 572 16-68 ELECTRICAL SYSTEM Lighting System Turn Signal Light Circuit 1. Meter Unit 9. Fuse Box 2. Ignition Switch 10. Cylinder Head Cover Ground 3. Front Right Turn Signal Light 11. Turn Signal Relay 4. Front Left Turn Signal Light 12. Joint Connector B 5.
  • Page 573: Air Switching Valve

    ELECTRICAL SYSTEM 16-69 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 574: Radiator Fan System

    16-70 ELECTRICAL SYSTEM Radiator Fan System Fan Motor Inspection • Remove: Right Inner Cover (see Inner Cover Removal in the Frame chapter) • Disconnect the connector [A]. • Using an auxiliary wires, supply battery power to the fan motor. If the fan does not rotate, the fan motor is defective and must be replaced.
  • Page 575 ELECTRICAL SYSTEM 16-71 Radiator Fan System Radiator Fan Circuit ZX600P8F 1. ECU 10. ECU Fuse 10 A 2. Water Temperature Sensor 11. Ignition Fuse 10 A 3. Radiator Fan 12. Fuse Box 4. Joint Connector C 13. Radiator Fan Relay 5.
  • Page 576: Meter, Gauge, Indicator Unit

    16-72 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit Meter Unit Removal • Remove: Windshield (see Windshield Removal in the Frame chapter) • Pull out the rubber cover [A]. • Disconnect the connector [B]. Bolts [C] • Remove: Nut [A] Bolts [B] Fairing Bracket with Meter [C] •...
  • Page 577: Electronic Unit (combination Meter) Inspection

    ELECTRICAL SYSTEM 16-73 Meter, Gauge, Indicator Unit Electronic Unit (Combination Meter) Inspection • Remove the meter unit [A]. [1] Neutral Indicator Light (LED) Ground (–) [2] Right Turn Signal Indicator Light (LED) (+) [3] High Beam Indicator Light (LED) (+) [4] Water Temperature Sensor [5] Lap Time (+) [6] Stop Watch (+)
  • Page 578 16-74 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit • Connect the terminal [16] and the terminal [17]. • When the terminals are connected, check that following items. ○ The tachometer needle [A] momentarily points it last read- ings and back to the minimum position. ○...
  • Page 579 ELECTRICAL SYSTEM 16-75 Meter, Gauge, Indicator Unit Check 2: Meter Communication Line (Service Code 39) Check • Connect the leads in the same circuit as Check 1. • Wait 10 seconds and the FI [A] in the display and warning light (LED) [B] flash.
  • Page 580 16-76 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit Check 3: MODE BUTTON Operation Check • Connect the leads in the same circuit as Check 1. • Check that the display [A] change to the ODO, TRIP and STOP WATCH displays each time the mode selector but- ton [B] is pressed.
  • Page 581 ELECTRICAL SYSTEM 16-77 Meter, Gauge, Indicator Unit • Set the ODO mode [A] by pushing the MODE button [B]. • During the MODE button pushing, the unit of the distance [C] and temperature [D] change every time the RESET button [E] is pushed within 2 seconds. If the meter function does not work, replace the meter assembly.
  • Page 582 16-78 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit • By pushing the RESET button, check that the hour display decides and minute display [A] starts flashing. • By pushing the MODE button each time, check that the minute display changes. • By pushing the RESET button, check that the hour and minute display start flashing.
  • Page 583 ELECTRICAL SYSTEM 16-79 Meter, Gauge, Indicator Unit Check 7: Speed Sensor Electric Source Check • Connect the leads in the same circuit as Check 1. • Set the hand tester [A] to the DC 25 V range and connect it to the terminals [18] and [19]. Electric Source Voltage Standard: Approximately 11.5 V at Battery...
  • Page 584 16-80 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit • Check that the display of the water temperature meter [A] changes from “– –” to “HI”. If the water temperature meter does not work, replace the meter assembly. • Connect the resister [A] (about 210 Ω) to the terminal [4] and the battery (–) terminal.
  • Page 585 ELECTRICAL SYSTEM 16-81 Meter, Gauge, Indicator Unit • Disconnect the terminal [16]. • Check that the tachometer needle [A] back to the mini- mum (0) position. If the meter unit does not work, replace the meter assem- bly. • If the oscillator is not available, the tachometer can be checked as follows.
  • Page 586 16-82 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit • While count the stop watch, connect the auxiliary lead to the terminal [5] as shown, then indicate the counted time [A] during ten seconds. • Check that the meter moves to the lap display stored memory [A] at leaving the button when pushing the RE- SET button [B] less than 2 seconds while stopping the stop watch.
  • Page 587 ELECTRICAL SYSTEM 16-83 Meter, Gauge, Indicator Unit • Check that the stop watch display has 00’ 00” 00 display [A], And lap No display has water temperature display [B], when connecting [16] to (+) terminal again, after discon- necting it while operating the stop watch. If the display function does not work, replace the meter assembly.
  • Page 588 16-84 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit Check 14: Lights (LED) Inspection • Connect the leads in the same circuit as Check 1. Neutral Indicator Light (LED) [A] Warning Indicator Light (LED) [B] Turn Signal Indicator Light (LED) [C] High Beam Indicator Light (LED) [D] Fuel Level Warning Indicator Light (LED) [E] Shift Up Indicator Light (LED) [F] Oil Symbol [G]...
  • Page 589 ELECTRICAL SYSTEM 16-85 Meter, Gauge, Indicator Unit Check 15: Fuel Level Warning Indicator Light (LED) and Fuel Symbol • Connect the leads in the same circuit as Check 1. ○ The fuel segments flashes in the display. • Connect a variable rheostat [A] to terminal [15] as shown. •...
  • Page 590 16-86 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit • Connect the terminal [16] to the battery (+) terminal. • And then, disconnect the terminal [16]. • Push the MODE and RESET buttons more than 2 second, within 20 seconds after the terminal [9] disconnected. •...
  • Page 591 ELECTRICAL SYSTEM 16-87 Meter, Gauge, Indicator Unit • When changing the pre-set engine speed, push the MODE button [A] and RESET button [B] simultaneously for more than 2 seconds, and engine speed and light mode setting complete after 2 seconds passed, then check to go back to the mode before moving to this setting [C] mode.
  • Page 592 16-88 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit • The speed equivalent to the input frequency is indicated In the oscillator if the square wave (illustrated as shown) would be input into the terminal. • When inputting the signal of the oscillator with more than 1 km/h (mph) or equivalent into the terminal [13] line under setting, check to operate normally.
  • Page 593: Fuel Level Sensor Line Self-diagnosis Mode Inspection

    ELECTRICAL SYSTEM 16-89 Meter, Gauge, Indicator Unit Fuel Level Sensor Line Self-Diagnosis Mode Inspection NOTE ○ Usually when the open or short of the fuel level sensor circuit is detected, it becomes the Fuel Level Sensor Line Self-Diagnosis Mode. ○ The fuel level warning indicator light [A] and FUEL [B] in the display will flash.
  • Page 594 16-90 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit Meter Circuit 1. Ignition Switch 2. Meter Unit 3. Joint Connector C 4. Lap Switch 5. ECU Fuse 10 A 6. Ignition Fuse 10 A 7. Horn Fuse 10 A 8. Fuse Box 9.
  • Page 595: Immobilizer System (equipped Models)

    Cut the key in accordance with the shape of the current user key. • Remove: Front Seat (see Front Seat Removal in the Frame chap- ter) • Disconnect the immobilizer/Kawasaki self-diagnosis sys- tem connector [A]. • Connect the key registration unit [A]. Special Tool - Key Registration Unit: 57001-1582...
  • Page 596 16-92 ELECTRICAL SYSTEM Immobilizer System (Equipped Models) • Insert the master key to the ignition switch and turn it ON. Verified ○ The warning indicator light (LED) [A] blinks to display the registration mode (go to the next step). Not Verified ○...
  • Page 597 ELECTRICAL SYSTEM 16-93 Immobilizer System (Equipped Models) ○ If there is any problem in the registration, the warning indicator light (LED) [A] blinks to display the collation error. Immobilizer Amplifier Failure When Registered User Key is Inserted. User Key Collation Error •...
  • Page 598 16-94 ELECTRICAL SYSTEM Immobilizer System (Equipped Models) • Insert the user key 2 to the ignition switch and turn it ON. ○ If there is any problem in the registration, the warning indicator light (LED) [A] blinks to display the collation error. Immobilizer Amplifier Failure When Registered User Key is Inserted.
  • Page 599 Immobilizer System (Equipped Models) • FI indicator light goes off [A]. • Remove the key registration unit and connect the immo- bilizer/Kawasaki self-diagnostic system connector. NOTE ○ Turn the ignition switch ON with the registered user key. ○ Check that the engine can be started using all regis-...
  • Page 600 16-96 ELECTRICAL SYSTEM Immobilizer System (Equipped Models) Spare User Key Registration Flow Chart...
  • Page 601 Ignition Switch and Immobilizer Antenna (see Immobi- lizer System Parts Replacement) Front Seat (see Front Seat Removal in the Frame chap- ter) • Disconnect the immobilizer/Kawasaki self-diagnostic sys- tem connector. • Connect the key registration unit [A]. Special Tool - Key Registration Unit: 57001-1582 •...
  • Page 602 16-98 ELECTRICAL SYSTEM Immobilizer System (Equipped Models) Not Verified ○ The warning indicator light (LED) [A] blinks to display the collation error. Immobilizer Amplifier Failure Master Key Collation Error • Turn off and remove the new user key 1. • Temporarily place the antenna [A] on the new ignition switch [B].
  • Page 603 ELECTRICAL SYSTEM 16-99 Immobilizer System (Equipped Models) ○ If there is any problem in the registration, the warning indicator light (LED) [A] blinks to display the collation error. Immobilizer Amplifier Failure When Registered User Key is Inserted. User Key Collation Error •...
  • Page 604 16-100 ELECTRICAL SYSTEM Immobilizer System (Equipped Models) ○ If there is any problem in the registration, the warning indicator light (LED) [A] blinks to display the collation error. Immobilizer Amplifier Failure When Registered User Key is Inserted. User Key Collation Error •...
  • Page 605 ELECTRICAL SYSTEM 16-101 Immobilizer System (Equipped Models) • Remove the key registration unit and connect the immo- bilizer/Kawasaki self-diagnostic system connector. NOTE ○ Turn the ignition switch ON with the registered user key. ○ Check that the engine can be started using all regis- tered user keys.
  • Page 606 16-102 ELECTRICAL SYSTEM Immobilizer System (Equipped Models) • The master key is registered in the ECU. ○ The warning indicator light (LED) [A] blinks 1 time and stops for 1 second and the repeats this cycle to indicate successful registration of the master key. •...
  • Page 607 ELECTRICAL SYSTEM 16-103 Immobilizer System (Equipped Models) User Key Collation Error • The user key 1 is registered in the ECU. ○ The warning indicator light (LED) [A] blinks 2 times and stops for 1 second and then repeats this cycle to indicate successful registration of user key.
  • Page 608 16-104 ELECTRICAL SYSTEM Immobilizer System (Equipped Models) When Registered User Key is Inserted. User Key Collation Error • The user key 2 is registered in the ECU. ○ The warning indicator light (LED) [A] blinks 3 times and stops for 1 second and then repeats this cycle to indicate successful registration of user key 2.
  • Page 609 ELECTRICAL SYSTEM 16-105 Immobilizer System (Equipped Models) • Prepare a new ECU [A], new master key [B] and current user keys [C]. NOTE ○ The key registration unit is not required. ○ The key registration process is same as the electric con- trol unit replacement.
  • Page 610 16-106 ELECTRICAL SYSTEM Immobilizer System (Equipped Models) All Keys Initial Registration Flow Chart...
  • Page 611: Immobilizer System Parts Replacement

    ELECTRICAL SYSTEM 16-107 Immobilizer System (Equipped Models) Immobilizer System Parts Replacement Immobilizer Antenna • Remove: Left Inner Cover (see Inner Cover Removal in the Frame chapter) • Disconnect the lead connectors [A] and clamp [B]. • Remove: Clutch Cable Upper End Throttle Cable Upper Ends Steering Stem Head and Handlebar (see Handlebar Re- moval in the Steering chapter)
  • Page 612 16-108 ELECTRICAL SYSTEM Immobilizer System (Equipped Models) • Install the clamp [A]. • Tighten a new Torx bolt [B] until the bolt head [C] is bro- ken. • Run the leads correctly (see Cable, Wire, and Hose Rout- ing section in the Appendix chapter). Immobilizer Amplifier Replacement •...
  • Page 613: Immobilizer System Inspection

    ELECTRICAL SYSTEM 16-109 Immobilizer System (Equipped Models) Immobilizer Relational Parts Replacement Chart Failed or Lost Part Master User Ignition Ampli- Switch tenna fier (Red) (Black) Master • (Red) User • ○ (Black) Ignition • Switch • tenna Ampli- • fier ○...
  • Page 614 9. ECU Fuse 10 A 10. Ignition Fuse 10 A 11. Fuse Box 12. Relay Box 13. ECU Main Relay 14. Frame Ground 15. Main Fuse 30 A 16. Starter Relay 17. Battery 12 V 8 Ah 18. Immobilizer/Kawasaki Self-diagnostic System Connector...
  • Page 615: Switches And Sensors

    ELECTRICAL SYSTEM 16-111 Switches and Sensors Brake Light Timing Inspection • Refer to the Brake Light Switch Operation Inspection in the Periodic Maintenance chapter (see 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 (see Brake Light Switch Operation Inspection in the Periodic Maintenance...
  • Page 616: Gear Position Switch Installation

    16-112 ELECTRICAL SYSTEM Switches and Sensors • Remove the pins [A] and springs from the shift drum. Gear Position Switch Installation • Securely place the springs [A] and pins [B] into the holes [C] of the shift drum. • Apply grease to the new O-ring [A]. •...
  • Page 617: Gear Position Switch Inspection

    ELECTRICAL SYSTEM 16-113 Switches and Sensors Gear Position Switch Inspection NOTE ○ Be sure the transmission mechanism is good condition. • Disconnect the connector [A]. Clamp [B] • Set the hand tester [A] to the 1 kΩ or × 100 Ω range and connect it to the terminals in the oil pressure switch/gear position switch lead connector [B] and ground.
  • Page 618: Switch Inspection

    16-114 ELECTRICAL SYSTEM Switches and Sensors Switch Inspection • Using a hand tester, check to see that only the con- nections shown in the table have continuity (about zero ohms). ○ For the switch housings and the ignition switch, refer to the tables in the Wiring Diagram.
  • Page 619: Water Temperature Sensor Inspection

    ELECTRICAL SYSTEM 16-115 Switches and Sensors Water Temperature Sensor Inspection • Remove the water temperature sensor (see Water Tem- perature Sensor Removal in the Fuel System (DFI) chap- ter). • Suspend the sensor [A] in a container of coolant so that the temperature-sensing projection [E] and threaded por- tion [E] are submerged.
  • Page 620: Speed Sensor Installation

    16-116 ELECTRICAL SYSTEM Switches and Sensors • Disconnect the speed sensor lead connector [A]. • Remove the speed sensor bolt [A]. • Open the clamps [B]. • Remove the speed sensor [C]. Speed Sensor Installation • Install the speed sensor. •...
  • Page 621: Fuel Reserve Switch Inspection

    ELECTRICAL SYSTEM 16-117 Switches and Sensors Fuel Reserve Switch Inspection • Remove: Left Side Cover (see Side Cover Removal in the Frame chapter) Fuel Pump Lead Connector [A] • Fill the fuel tank with fuel. • Close the fuel tank cap surely. •...
  • Page 622: Oxygen Sensor Installation (equipped Models)

    16-118 ELECTRICAL SYSTEM Switches and Sensors Oxygen Sensor Installation (Equipped Models) CAUTION Never drop the oxygen sensor [A], especially on a hard surface. Such a shock to the unit can damage it. Do not touch the sensing part [B] to prevent oil contact.
  • Page 623: Relay Box

    ELECTRICAL SYSTEM 16-119 Relay Box The relay box [A] has relays and diodes. The relays and diodes can not be removed. Relay Box Removal • Remove: Right Inner Cover (see Inner Cover Removal in the Frame chapter) Fuse Box [A] (see Fuse Box Removal) •...
  • Page 624: Diode Circuit Inspection

    16-120 ELECTRICAL SYSTEM Relay Box Relay Circuit Inspection (with the battery disconnected) Tester Connection Tester Reading (Ω) Headlight Relay ∞ ∞ ECU Main Relay Not ∞* ∞ Fuel Pump Relay 9-10 Not ∞* 11-16 ∞ Starter Circuit Relay 11-12 ∞ 17-20 ∞...
  • Page 625 ELECTRICAL SYSTEM 16-121 Relay Box Relay Box Internal Circuit A: Headlight Relay B: ECU Main Relay C: Fuel Pump Relay D: Starter Circuit Relay E: Fan Relay...
  • Page 626: Fuse

    16-122 ELECTRICAL SYSTEM Fuse 30 A Main Fuse Removal • Remove: Front Seat (see Front Seat Removal in the Frame chap- ter) • Pull out the starter relay. • Remove: 30 A Main Fuse Connector [A] • Pull out the main fuse [B] from the starter relay with needle nose pliers.
  • Page 627: Fuse Installation

    ELECTRICAL SYSTEM 16-123 Fuse • Pull the ECU fuse [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 629 APPENDIX 17-1 Appendix Table of Contents Cable, Wire, and Hose Routing ....................17-2 Troubleshooting Guide ......................17-30...
  • Page 630 17-2 APPENDIX Cable, Wire, and Hose Routing...
  • Page 631 APPENDIX 17-3 Cable, Wire, and Hose Routing 1. Throttle Cable (Accelerator) 2. Throttle Cable (Decelerator) 3. Clamp 4. Run the clutch cable through backside of the throttle cables. 5. Clutch Cable 6. Run the clutch cable through front side of the front fork and brake hose. 7.
  • Page 632 17-4 APPENDIX Cable, Wire, and Hose Routing...
  • Page 633 APPENDIX 17-5 Cable, Wire, and Hose Routing 1. Turn Signal Relay 2. Clamp the harness so that they does not touch the turn signal relay. 3. Clamp 4. Fuse Box 5. Clamp 6. Replay Box Clamp 7. Low Beam Headlight Connector 8.
  • Page 634