Download  Print this page
   
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
146
147
148
149
150
151
152
153
154
155
156
157
158
159
160
161
162
163
164
165
166
167
168
169
170
171
172
173
174
175
176
177
178
179
180
181
182
183
184
185
186
187
188
189
190
191
192
193
194
195
196
197
198
199
200
201
202
203
204
205
206
207
208
209
210
211
212
213
214
215
216
217
218
219
220
221
222
223
224
225
226
227
228
229
230
231
232
233
234
235
236
237
238
239
240
241
242
243
244
245
246
247
248
249
250
251
252
253
254
255
256
257
258
259
260
261
262
263
264
265
266
267
268
269
270
271
272
273
274
275
276
277
278
279
280
281
282
283
284
285
286
287
288
289
290
291
292
293
294
295
296
297
298
299
300
301
302
303
304
305
306
307
308
309
310
311
312
313
314
315
316
317
318
319
320
321
322
323
324
325
326
327
328
329
330
331
332
333
334
335
336
337
338
339
340
341
342
343
344
345
346
347
348
349
350
351
352
353
354
355
356
357
358
359
360
361
362
363
364
365
366
367
368
369
370
371
372
373
374
375
376
377
378
379
380
381
382
383
384
385
386
387
388
389
390
391
392
393
394
395
396
397
398
399
400
401
402
403
404
405
406
407
408
409
410
411
412
413
414
415
416
417
418
419
420
421
422
423
424
425
426
427
428
429
430
431
432
433
434
435
436
437
438
439
440
441
442
443
444
445
446
447
448
449
450
451
452
453
454
455
456
457
458
459
460
461
462
463
464
465
466
467
468
469
470
471
472
473
474
475
476
477
478
479
480
481
482
483
484
485
486
487
488
489
490
491
492
493
494
495
496
497
498
499
500
501
502
503
504
505
506
507
508
509
510
511
512
513
514
515
516
517
518
519
520
521
522
523
524
525
526
527
528
529
530
531
532
533
534
535
536
537

Advertisement

ER-6n
Motorcycle
Service Manual

Advertisement

Table of Contents

   Also See for Kawasaki ER-6n

   Summary of Contents for Kawasaki ER-6n

  • Page 1 ER-6n Motorcycle Service Manual...
  • Page 3: General Information

    Quick Reference Guide General Information Periodic Maintenance Fuel System (DFI) Cooling System Engine Top End Clutch Engine Lubrication System Engine Removal/Installation Crankshaft/Transmission Wheels/Tires 10 j Final Drive 11 j Brakes 12 j Suspension 13 j Steering 14 j Frame 15 j Electrical System 16 j Appendix...
  • Page 5 All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Quality Division/Consumer Products & Machinery Company/Kawasaki Heavy Industries, Ltd., Japan.
  • Page 6 LIST OF ABBREVIATIONS ampere(s) pound(s) ABDC after bottom dead center meter(s) alternating current minute(s) ATDC after top dead center newton(s) BBDC before bottom dead center pascal(s) bottom dead center horsepower BTDC before top dead center pound(s) per square inch °C degree(s) Celsius revolution direct current...
  • Page 7: How To Use This Manual

    Be alert for problems and non-scheduled correctly followed, could result in per- maintenance. sonal injury, or loss of life. • Use proper tools and genuine Kawasaki Mo- torcycle parts. Special tools, gauges, and CAUTION testers that are necessary when servicing This caution symbol identifies special...
  • Page 8 NOTE ○ This note symbol indicates points of par- ticular interest for more efficient and con- venient operation. • Indicates a procedural step or work to be done. ○ Indicates a procedural sub-step or how to do the work of the procedural step it follows. It also precedes the text of a NOTE.
  • Page 9: Table Of Contents

    GENERAL INFORMATION 1-1 General Information Table of Contents Before Servicing ........................Model Identification......................... General Specifications......................Technical Information - Cassette Type Transmission ............. 1-11 Technical Information - Inlet Air Pressure Sensor ..............1-12 Unit Conversion Table ......................1-13...
  • Page 10: Before Servicing

    1-2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly opera- tion on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustra- tions, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary.
  • Page 11 Replacement Parts Replacement parts must be KAWASAKI genuine or recommended by KAWASAKI. Gaskets, O-rings, oil seals, grease seals, circlips or cotter pins must be replaced with new ones whenever disassembled.
  • Page 12 1-4 GENERAL INFORMATION Before Servicing Tightening Sequence Generally, when installing a part with several bolts, nuts, or screws, start them all in their holes and tighten them to a snug fit. Then tighten them according to the specified se- quence to prevent case warpage or deformation which can lead to malfunction.
  • Page 13 GENERAL INFORMATION 1-5 Before Servicing Press For items such as bearings or oil seals that must be pressed into place, apply small amount of oil to the con- tact area. Be sure to maintain proper alignment and use smooth movements when installing. Ball Bearing and Needle Bearing Do not remove pressed ball or needle unless removal is absolutely necessary.
  • Page 14 1-6 GENERAL INFORMATION Before Servicing Lubrication It is important to lubricate rotating or sliding parts during assembly to minimize wear during initial operation. Lubri- cation points are called out throughout this manual, apply the specific oil or grease as specified. Direction of Engine Rotation When rotating the crankshaft by hand, the free play amount of rotating direction will affect the adjustment.
  • Page 15: Model Identification

    GENERAL INFORMATION 1-7 Model Identification ER650A6F/ER650A6S Left Side View ER650A6F/ER650A6S Right Side View ER650A6F: Australia, Malaysia ER650A6S: Europe...
  • Page 16: General Specifications

    1-8 GENERAL INFORMATION General Specifications Items ER650A6F/ER650A6S Dimensions Overall Length 2 100 mm (82.7 in.) Overall Width 760 mm (29.9 in.) Overall Height 1 095 mm (43.1 in.) Wheelbase 1 405 mm (55.3 in.) Road Clearance 140 mm (5.5 in.) Seat Height 785 mm (30.9 in.) Dry Mass...
  • Page 17 GENERAL INFORMATION 1-9 General Specifications Items ER650A6F/ER650A6S Viscosity SAE 10W-40 Capacity 2.4 L (2.5 US qt) Drive Train Primary Reduction System: Type Gear Reduction Ratio 2.095 (88/42) Clutch Type Wet multi disc Transmission: Type 6-speed, constant mesh, return shift Gear Ratios: 2.438 (39/16) 1.714 (36/21) 1.333 (32/24)
  • Page 18 1-10 GENERAL INFORMATION General Specifications Items ER650A6F/ER650A6S Headlight: Type Semi-sealed beam Bulb 12 V 55 W × 2/55 W (Hi/Lo) Tail/Brake Light 12 V 5/21 W Alternator: Type Three-phase AC Rated Output 24 A/14 V @5 000 r/min (rpm) Specifications are subject to change without notice, and may not apply to every country.
  • Page 19: Technical Information - Cassette Type Transmission

    GENERAL INFORMATION 1-11 Technical Information - Cassette Type Transmission Cassette Type Transmission The transmission of the current model is unable to be removed without disassembling upper and lower crankcase halves. The ER650A enables transmission to be removed from the right side of engine as an assy, without disassembling crankcase halves (see Transmission Assy Removal in the Crankshaft/Transmission chapter).
  • Page 20: Technical Information - Inlet Air Pressure Sensor

    1-12 GENERAL INFORMATION Technical Information - Inlet Air Pressure Sensor Atmospheric pressure sensor and camshaft position sensor are not equipped with the ER650A. As a substitute of these sensors above, the ER650A recognizes atmospheric pressure and intake stroke of #1 by the signal of inlet air pressure sensor. The ECU detects atmospheric pressure when the ignition is switched ON.
  • Page 21: Unit Conversion Table

    GENERAL INFORMATION 1-13 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: Periodic Maintenance

    PERIODIC MAINTENANCE 2-1 Periodic Maintenance Table of Contents Periodic Maintenance Chart ....................Torque and Locking Agent...................... Specifications ......................... 2-11 Special Tools .......................... 2-13 Periodic Maintenance Procedures..................2-14 Fuel System (DFI)........................ 2-14 Fuel Hose Inspection (fuel leak, damage, installation condition) ........2-14 Throttle Control System Inspection...................
  • Page 24 2-2 PERIODIC MAINTENANCE Steering Play Inspection ....................2-35 Steering Play Adjustment....................2-35 Steering Stem Bearing Lubrication ................... 2-36 Electrical System ......................... 2-37 Spark Plug Condition Inspection..................2-37 Lights and Switches Operation Inspection................ 2-38 Headlight Aiming Inspection ..................... 2-40 Sidestand Switch Operation Inspection ................2-41 Engine Stop Switch Operation Inspection.................
  • 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) Page INSPECTION Every (0.6) (4) (7.5) (12) (15) (20) (24) • • • • • • • Brake hose and pipe damage - inspect year 2-31 •...
  • Page 27: Periodic Maintenance Chart

    PERIODIC MAINTENANCE 2-5 Periodic Maintenance Chart Periodic Replacement Parts FREQUENCY Whichever * ODOMETER READING comes × 1 000 km first (× 1 000 mile) Page CHANGE/REPLACE ITEM Every (0.6) (7.5) (15) (24) (30) Air cleaner element # 2 years 2-45 •...
  • 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 liquid gasket. Letters used in the “Remarks” column mean: AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque. EO: Apply engine oil.
  • Page 29 PERIODIC MAINTENANCE 2-7 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Clutch Upper Cap on Clutch Cover 0.40 35 in·lb Lower Cap on Clutch Cover – – – Hand-tighten Oil Filler Plug – – – Hand-tighten Clutch Cover Mounting Bolts 87 in·lb Clutch Spring Bolts 87 in·lb...
  • Page 30 2-8 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Oil Pressure Switch Oil Passage Plug Gear Positioning Lever Bolt 106 in·lb Shift Shaft Return Spring pin Shift Drum Cam Bolt 106 in·lb Neutral Switch Transmission Case Bolts Shift Rod Plate Bolt 87 in·lb Neutral Switch Holder Screw...
  • Page 31 PERIODIC MAINTENANCE 2-9 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Rear Shock Absorber Nut Swingarm Pivot Shaft Nut 11.0 Steering Front Fork Clamp Bolts (Lower) Front Fork Clamp Bolts (Upper) Handlebar Holder Bolts Left Switch Housing Screws 0.36 31 in·lb Right Switch Housing Screws...
  • Page 32 2-10 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Timing Rotor Bolt Water Temperature Sensor 106 in·lb The table below, relating tightening torque to thread diameter, lists the basic torque for the bolts and nuts. Use this table for only the bolts and nuts which do not require a specific torque value. All of the values are for use with dry solvent-cleaned threads.
  • Page 33: Specifications

    PERIODIC MAINTENANCE 2-11 Specifications Item Standard Service Limit Fuel System 2 ∼ 3 mm (0.08 ∼ 0.12 in.) – – – Throttle Grip Free Play Idle Speed 1 300 ±50 r/min (rpm) – – – Bypass Screws (Turn Out) 0 ∼ 3 1/2 (for reference) –...
  • Page 34 2-12 PERIODIC MAINTENANCE 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 35: Special Tools

    PERIODIC MAINTENANCE 2-13 Special Tools Inside Circlip Pliers: Extension Tube: 57001-143 57001-1578 Steering Stem Nut Wrench: Pilot Screw Adjuster, E: 57001-1100 57001-1603 Jack: Jack Attachment: 57001-1238 57001-1608 Oil Filter Wrench: 57001-1249...
  • Page 36: Periodic Maintenance Procedures

    2-14 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel System (DFI) Fuel Hose Inspection (fuel leak, damage, installation condition) ○ The fuel hose is designed to be used throughout the mo- torcycle’s life without any maintenance. However, if the motorcycle is not properly handled, the high pressure in- side the fuel line can cause fuel to leak [A] or the hose to burst.
  • Page 37: Idle Speed Inspection

    PERIODIC MAINTENANCE 2-15 Periodic Maintenance Procedures If necessary, adjust the throttle cable as follows. • Loosen the locknut [A] at the upper end of the accelerator cable. • Turn the adjuster [B] in completely so as to give the throttle grip plenty of play.
  • Page 38: Air Cleaner Element Cleaning

    2-16 PERIODIC MAINTENANCE Periodic Maintenance Procedures Air Cleaner Element Cleaning NOTE ○ In dusty areas, the element should be cleaned more frequently than the recommended interval. ○ After riding through rain or on muddily roads, the ele- ment should be cleaned immediately. WARNING If dirt or dust is allowed to pass through into the throttle assy, the throttle may become stuck, possi-...
  • Page 39: Engine Vacuum Synchronization Inspection

    PERIODIC MAINTENANCE 2-17 Periodic Maintenance Procedures WARNING Clean the element in a well-ventilated area, and make sure that there are no sparks or flame any- where near the working area. Because of the danger of highly flammable liquids, do not use gasoline or a low flash-point solvent to clean the element.
  • Page 40 2-18 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Start the engine and warm it up thoroughly. • Check the idle speed. Tachometer [A] • Open and close the throttle. If the idle speed is out of the specified range, adjust it. CAUTION Do not measure the idle speed by the tachometer of the meter unit.
  • Page 41: Cooling System

    PERIODIC MAINTENANCE 2-19 Periodic Maintenance Procedures • Repeat the same procedure for other bypass screws. • Repeat the synchronization. If the vacuums are correct, check the output voltage of the main throttle sensor (see Main Throttle Sensor Output Voltage Inspection in the Fuel System (DFI) chapter). Main Throttle Sensor Output Voltage Connections to ECU Meter (+) →...
  • Page 42: Radiator Hose And Pipe Inspection (coolant Leak, Damage, Installation Condition)

    2-20 PERIODIC MAINTENANCE Periodic Maintenance Procedures Radiator Hose and Pipe Inspection (coolant leak, damage, installation condition) ○ The high pressure inside the radiator hose and pipe can cause coolant to leak [A] or the hose to burst if the line is not properly maintained.
  • Page 43 PERIODIC MAINTENANCE 2-21 Periodic Maintenance Procedures • Check the valve clearance when the pistons are at TDC. ○ The pistons are numbered beginning with the engine left side. • Using a wrench [A] on the crankshaft rotation bolt, turn the crankshaft clockwise until the "1|T" mark on the timing rotor is aligned with the notch [B] in the edge of the upper hole in the clutch cover for #1 piston and "2|T"...
  • Page 44: Valve Clearance Adjustment

    2-22 PERIODIC MAINTENANCE Periodic Maintenance Procedures Valve Clearance Measuring Position #2 Piston TDC at End of Compression Stroke → Inlet valve clearances of #2 piston, and Exhaust valve clearances of #2 piston If the valve clearance is not with in the specified range, first record the clearance, and adjust it.
  • Page 45: Valve Clearance Adjustment Chart Inlet Valve

    PERIODIC MAINTENANCE 2-23 Periodic Maintenance Procedures VALVE CLEARANCE ADJUSTMENT CHART INLET VALVE 1. Measure the clearance (when engine is cold). 2. Check present shim size. 3. Match clearance in vertical column with present shim size in horizontal column. 4. Install the shim specified where the lines intersect. This shim will give the proper clearance. Example: Present shim is 2.95 mm Measured clearance is 0.45 mm...
  • Page 46 2-24 PERIODIC MAINTENANCE Periodic Maintenance Procedures VALVE CLEARANCE ADJUSTMENT CHART EXHAUST VALVE 1. Measure the clearance (when engine is cold). 2. Check present shim size. 3. Match clearance in vertical column with present shim size in horizontal column. 4. Install the shim specified where the lines intersect. This shim will give the proper clearance. Example: Present shim is 2.95 mm.
  • Page 47: Clutch

    PERIODIC MAINTENANCE 2-25 Periodic Maintenance Procedures Clutch Clutch Operation Inspection • Pull the clutch lever just enough to take up the free play [A]. • Measure the gap between the lever and the lever holder. If the gap is too wide, the clutch may not release fully. If the gap is too narrow, the clutch may not engage fully.
  • Page 48: Wheel/tire Damage Inspection

    2-26 PERIODIC MAINTENANCE Periodic Maintenance Procedures Wheel/Tire Damage Inspection • Remove any imbedded stones [A] or other foreign parti- cles [B] from tread. • Visually inspect the tire for cracks and cuts, and replace the tire if necessary. Swelling or high spots indicate inter- nal damage, requiring tire replacement.
  • Page 49: Wheel Bearing Damage Inspection

    PERIODIC MAINTENANCE 2-27 Periodic Maintenance Procedures Wheel Bearing Damage Inspection • Raise the front wheel off the ground with jack (see Front Wheel Removal in the Wheels/Tires chapter). • Turn the handlebar all the way to the right or left. •...
  • Page 50: Drive Chain Slack Inspection

    2-28 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Apply oil to the sides of the rollers so that oil will penetrate to the rollers and bushings. Apply the oil to the O-rings so that the O-rings will be coated with oil. •...
  • Page 51: Wheel Alignment Inspection

    PERIODIC MAINTENANCE 2-29 Periodic Maintenance Procedures • Insert a new cotter pin [A]. NOTE ○ When inserting the cotter pin, if the slots in the nut do not align with the cotter pin hole in the axle, tighten the nut clockwise [B] up to next alignment. ○...
  • Page 52: Drive Chain Wear Inspection

    2-30 PERIODIC MAINTENANCE Periodic Maintenance Procedures Drive Chain Wear Inspection • Remove: Chain Cover (see Swingarm Removal in the Suspension chapter) • Rotate the rear wheel to inspect the drive chain for dam- aged rollers, and loose pins and links. If there is any irregularity, replace the drive chain.
  • Page 53: Brake System

    PERIODIC MAINTENANCE 2-31 Periodic Maintenance Procedures Brake System Brake Fluid Leak (Brake Hose and Pipe) Inspection • Apply the brake lever or pedal and inspect the brake fluid leak from the brake hoses [A] and fittings [B]. If the brake fluid leaked from any position, inspect or re- place the problem part.
  • Page 54: Brake Fluid Level Inspection

    2-32 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Fluid Level Inspection • Check that the brake fluid level in the front brake reservoir [A] is above the lower level line [B]. NOTE ○ Hold the reservoir horizontal by turning the handlebar when checking brake fluid level.
  • Page 55: Brake Pad Wear Inspection

    PERIODIC MAINTENANCE 2-33 Periodic Maintenance Procedures Brake Pad Wear Inspection • Check the lining thickness [A] of the pads in each caliper. If the lining thickness of either pad is less than the service limit [B], replace both pads in the caliper as a set. Pad Lining Thickness Standard: Front...
  • Page 56: Suspensions

    2-34 PERIODIC MAINTENANCE Periodic Maintenance Procedures Suspensions Front Forks/Rear Shock Absorber Operation Inspection • Pump the forks down and up [A] 4 or 5 times, and inspect the smooth stroke. If the forks do not smoothly or noise is found, inspect the fork oil level or fork clamps (see Front Fork Oil Change in the Suspension chapter).
  • Page 57: Steering System

    PERIODIC MAINTENANCE 2-35 Periodic Maintenance Procedures Steering System Steering Play Inspection • Raise the front wheel off the ground with jack. Special Tools - Jack: 57001-1238 Jack Attachment: 57001-1608 • With the front wheel pointing straight ahead, alternately tap each end of the handlebar. The front wheel should swing fully left and right from the force of gravity until the fork hits the stop.
  • Page 58: Steering Stem Bearing Lubrication

    2-36 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Adjust the steering. Special Tool - Steering Stem Nut Wrench [A]: 57001-1100 If the steering is too tight, loosen the stem nut [B] a fraction of a turn. If the steering is too loose, tighten the stem nut a fraction of a turn.
  • Page 59: Electrical System

    PERIODIC MAINTENANCE 2-37 Periodic Maintenance Procedures Electrical System Spark Plug Condition Inspection • Remove the spark plugs (see Spark Plug Replacement). • Visually inspect the spark plugs. If the spark plug center electrode [A] and/or side elec- trode [B] are corroded or damaged, or if the insulator [C] is cracked, replace the plug.
  • Page 60: Lights And Switches Operation Inspection

    2-38 PERIODIC MAINTENANCE Periodic Maintenance Procedures Lights and Switches Operation Inspection First Step • Turn on the ignition switch. • The following lights should go on according to below table. City Light [A] goes on Taillight [B] goes on goes on License Plate Light [C] Meter Panel LCD [D] goes on...
  • Page 61 PERIODIC MAINTENANCE 2-39 Periodic Maintenance Procedures Third Step • Turn on the turn signal switch [A] (left or right position). • The left or right turn signal lights [B] (front and rear) ac- cording to the switch position should flash. •...
  • Page 62: Headlight Aiming Inspection

    2-40 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Set the dimmer switch to high beam position. • The low beam [A] and high beam [B] headlights should go on. • The high beam indicator light (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: Sidestand Switch Operation Inspection

    PERIODIC MAINTENANCE 2-41 Periodic Maintenance Procedures NOTE ○ ON high beam, the brightest points should be slightly below horizontal with the motorcycle on its wheels and the rider seated. Adjust the headlight to the proper an- gle according to local regulations. Low Beam [A] Height of Headlight Center [B] High Beam [C]...
  • Page 64: Engine Stop Switch Operation Inspection

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

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

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

    PERIODIC MAINTENANCE 2-45 Periodic Maintenance Procedures Replacement Parts Air Cleaner Element Replacement • Refer to the Air Cleaner Element Cleaning. Engine Oil Change • Situate the motorcycle so that it is vertical after warming up the engine. • Unscrew the oil filler plug [A]. •...
  • Page 68: Oil Filter Replacement

    2-46 PERIODIC MAINTENANCE Periodic Maintenance Procedures Oil Filter Replacement • Drain the engine oil (see Engine Oil Change). • Remove the oil filter [A] with the oil filter wrench [B]. Special Tool - Oil Filter Wrench: 57001-1249 • Replace the filter with a new one. •...
  • Page 69: Coolant Change

    PERIODIC MAINTENANCE 2-47 Periodic Maintenance Procedures • Install the new fuel hose. • Insert [A] the fuel hose joint [B] straight onto the delivery pipe until the hose joint clicks. • Push [C] the joint lock [D]. • Push and pull [A] the fuel hose joint [B] back and forth more than two times and make sure it is locked and doesn’t come off.
  • Page 70 2-48 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Put [A] the projection [B] on the reserve tank into the hole [C] on the frame bracket, and place the reserve tank on the right side of frame. • Place a container under the water pump drain bolt [A], then remove the drain bolt.
  • Page 71 PERIODIC MAINTENANCE 2-49 Periodic Maintenance Procedures • When filling the coolant, choose a suitable mixture ratio by referring to the coolant manufacturer’s directions. CAUTION Soft or distilled water must be used with the an- tifreeze in the cooling system. If hard water is used in the system, it causes scales accumulation in the water passages, and consider- ably reduces the efficiency of the cooling system.
  • Page 72: Radiator Hose And O-ring Replacement

    2-50 PERIODIC MAINTENANCE Periodic Maintenance Procedures Radiator Hose and O-ring Replacement • Drain the coolant (see Coolant Change in the Periodic Maintenance chapter). • Remove: Thermostat Housing [A] (see Water Pump Removal in the Cooling System chapter) Water Pump Cover [B] (see Water Pump Removal in the Cooling System chapter) Hoses [C] O-rings [D]...
  • Page 73: Brake Hose And Pipe Replacement

    PERIODIC MAINTENANCE 2-51 Periodic Maintenance Procedures Brake Hose and Pipe Replacement CAUTION Brake fluid quickly ruins painted plastic surfaces; any spilled fluid should be completely washed away immediately. • Remove the banjo bolts [A]. • When removing the brake hose, take care not to spill the brake fluid on the painted or plastic parts.
  • Page 74 2-52 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Level the brake fluid reservoir. • Remove the reservoir cap and diaphragm. • Remove the rubber cap from the bleed valve [A] on the caliper. • Attach a clear plastic hose [B] to the bleed valve, and run the other end of the hose into a container.
  • Page 75: Master Cylinder Rubber Parts Replacement

    PERIODIC MAINTENANCE 2-53 Periodic Maintenance Procedures Master Cylinder Rubber Parts Replacement Front Master Cylinder Disassembly • Remove the front master cylinder (see Front Master Cylin- der Removal in the Brakes chapter). • Remove the reservoir cap and diaphragm, and pour the brake fluid into a container.
  • Page 76: Caliper Rubber Parts Replacement

    2-54 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Apply brake fluid to the new parts and to the inner wall of the cylinder. • Take care not to scratch the piston or the inner wall of the cylinder. • Tighten the brake lever pivot bolt and locknut. •...
  • Page 77 PERIODIC MAINTENANCE 2-55 Periodic Maintenance Procedures • Replace the fluid seals [A] with new ones. ○ Apply brake fluid to the fluid seals, and install them into the cylinders by hand. • Replace the dust seals [B] with new ones if they are dam- aged.
  • Page 78: Spark Plug Replacement

    2-56 PERIODIC MAINTENANCE Periodic Maintenance Procedures Rear Caliper Assembly • Clean the caliper parts except for the pads. CAUTION For cleaning of the parts, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol. • Install the bleed valve and rubber cap. Torque - Bleed Valve: 7.8 N·m (0.80 kgf·m, 69 in·lb) •...
  • Page 79 PERIODIC MAINTENANCE 2-57 Periodic Maintenance Procedures • Insert the spark plug vertically into the plug hole with the spark plug installed in the plug wrench [A]. Owner’s Tool - Spark Plug Wrench, 16 mm: 92110-1132 • Tighten: Torque - Spark Plugs: 15 N·m (1.5 kgf·m, 11 ft·lb) •...
  • Page 81 FUEL SYSTEM (DFI) 3-1 Fuel System (DFI) Table of Contents Exploded View........................DFI System..........................DFI System..........................3-10 DFI Parts Location........................3-13 Specifications ......................... 3-14 Special Tools and Sealant ...................... 3-16 DFI Servicing Precautions ...................... 3-18 DFI Servicing Precautions ....................3-18 Troubleshooting the DFI System ....................
  • Page 82 3-2 FUEL SYSTEM (DFI) Sensor Resistance Inspection ..................3-53 Crankshaft Sensor (Service Code 21)..................3-54 Crankshaft Sensor Removal/Installation................3-54 Crankshaft Sensor Inspection................... 3-54 Speed Sensor (Service Code 24, 25)..................3-55 Speed Sensor Removal/Installation.................. 3-55 Speed Sensor Inspection....................3-55 Speed Sensor Input Voltage Inspection................3-55 Speed Sensor Output Voltage Inspection .................
  • Page 83 FUEL SYSTEM (DFI) 3-3 Pump Screen, Fuel Filter Cleaning ................... 3-86 Fuel Injectors .......................... 3-88 Removal/Installation......................3-88 Audible Inspection......................3-88 Fuel Injector Power Source Voltage Inspection ..............3-88 Fuel Injector Output Voltage Inspection ................3-89 Injector Signal Test......................3-89 Injector Resistance Inspection ..................3-90 Injector Unit Test .......................
  • Page 84: Exploded View

    3-4 FUEL SYSTEM (DFI) Exploded View...
  • Page 85 FUEL SYSTEM (DFI) 3-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Fuel Pump Bolts 87 in·lb L, S 2. FI Indicator LED Light 3. Throttle Cable (Accelerator) 4. Throttle Cable (Decelerator) 5. Throttle Body Assy 6. Injectors CL: Apply cable lubricant. EO: Apply engine oil.
  • Page 86 3-6 FUEL SYSTEM (DFI) Exploded View...
  • Page 87 FUEL SYSTEM (DFI) 3-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Water Temperature Sensor 106 in·lb Speed Sensor Bolt 0.80 66 in·lb Oxygen Sensor (Europe Model) 44.1 4.50 32.5 4. Inlet Air Pressure Sensor 5. Air Switching Valve 6. Inlet Air Temperature Sensor 7.
  • Page 88: Dfi System

    3-8 FUEL SYSTEM (DFI) DFI System DFI System...
  • Page 89 FUEL SYSTEM (DFI) 3-9 DFI System 1. Ignition Switch 2. Starter Lockout Switch 3. Starter Relay 4. Tachometer 5. FI Indicator Light (LED) 6. Inlet Air Pressure Sensor 7. Spark Plug 8. Crankshaft Sensor 9. Injector 10. Main Throttle Sensor 11.
  • Page 90 3-10 FUEL SYSTEM (DFI) DFI System DFI System Wiring Diagram...
  • Page 91 FUEL SYSTEM (DFI) 3-11 DFI System Part Name 1. Oxygen Sensor (Europe Model) 2. Crankshaft Sensor 3. Inlet Air Temperature Sensor 4. Water Temperature Sensor 5. Water-proof Joint E 6. Injectors 7. Vehicle-down Sensor 8. Water-proof Joint D 9. Inlet Air Pressure Sensor 10.
  • Page 92 3-12 FUEL SYSTEM (DFI) DFI System Terminal Names 1. Subthrottle Valve Actuator Drive Signal 2 27. Unused 2. Subthrottle Valve Actuator Drive Signal 1 28. Ground to Sensors 3. Water Temperature Warning Light Signal 29. Oxygen Sensor Heater Signal 4. Unused 30.
  • Page 93: Dfi Parts Location

    FUEL SYSTEM (DFI) 3-13 DFI Parts Location DFI: Digital Fuel Injection Parts 12. Speed Sensor 1. FI Indicator Light LED (DFI) 13. Neutral Switch 2. Ignition Switch 14. Water Temperature Sensor 3. Throttle Body Assy 15. Subthrottle Sensor 4. Inlet Air Temperature Sensor 16.
  • Page 94: Specifications

    3-14 FUEL SYSTEM (DFI) Specifications Item Standard Digital Fuel Injection System Idle Speed 1 300 ±50 r/min (rpm) Throttle Assy: Type Two barrel type Bore 38 mm (1.50 in.) ECU (Electronic Control Unit): Make Denso Type Digital memory type, with built in IC igniter, sealed with resin 100 ∼...
  • Page 95 FUEL SYSTEM (DFI) 3-15 Specifications Item Standard with the sensor tilted 60 ∼ 70° or more: 0.65 ∼ 1.35 V Output Voltage with sensor arrow mark pointed up: 3.55 ∼ 4.45 V Subthrottle Sensor: Non-adjustable and non-removal 4.75 ∼ 5.25 V DC between BL and BR/BK leads Input Voltage 0.4 ∼...
  • Page 96: Special Tools And Sealant

    3-16 FUEL SYSTEM (DFI) Special Tools and Sealant Oil Pressure Gauge, 5 kgf/cm²: Needle Adapter Set: 57001-125 57001-1457 Fork Oil Level Gauge: Throttle Sensor Setting Adapter: 57001-1290 57001-1538 Hand Tester: Sensor Harness Adapter: 57001-1394 57001-1561 Throttle Sensor Setting Adapter #1: Fuel Pressure Gauge Adapter: 57001-1400 57001-1593...
  • Page 97 FUEL SYSTEM (DFI) 3-17 Special Tools and Sealant Kawasaki Bond (Silicone Sealant): 56019-120...
  • Page 98: Dfi Servicing Precautions

    3-18 FUEL SYSTEM (DFI) DFI Servicing Precautions DFI Servicing Precautions There are a number of important precautions that should be followed servicing the DFI system. ○ This DFI system is designed to be used with a 12 V sealed battery as its power source. Do not use any other battery except for a 12 V sealed battery as a power source.
  • Page 99 FUEL SYSTEM (DFI) 3-19 DFI Servicing Precautions ○ To maintain the correct fuel/air mixture (F/A), there must be no inlet air leaks in the DFI system. Be sure to install the oil filler plug [A] after filling the engine oil. Clutch Cover [B] Torque - Oil Filler Plug: Hand-tighten...
  • Page 100: Troubleshooting The Dfi System

    3-20 FUEL SYSTEM (DFI) Troubleshooting the DFI System Outline Outline When an abnormality in the system occurs, the FI indica- tor LED (Light Emitting Diode) light goes on to alert the rider on the meter panel. In addition, the condition of the problem is stored in the memory of the ECU (electronic control unit).
  • Page 101 ○ After measurement, remove the needle adapters and ap- ply silicone sealant to the seals [A] of the connector [B] for waterproofing. Silicone Sealant (Kawasaki Bond: 56019-120) - Seals of Connector • Always check battery condition before replacing the DFI parts.
  • Page 102 3-22 FUEL SYSTEM (DFI) Troubleshooting the DFI System • Pull each connector [A] apart and inspect it for corrosion, dirt, and damage. If the connector is corroded or dirty, clean it carefully. If it is damaged, replace it. Connect the connectors securely. •...
  • Page 103 FUEL SYSTEM (DFI) 3-23 Troubleshooting the DFI System ○ There are two ways to inspect the DFI system. One is voltage Check Method and the other is Resistance Check Method. (Voltage Check Method) ○ This method is conducted by measuring the input voltage [B] to a sensor [A] first, and then the output voltage [C] from the sensor.
  • Page 104: Inquiries To Rider

    3-24 FUEL SYSTEM (DFI) Troubleshooting the DFI System DFI Diagnosis Flow Chart Inquiries to Rider Inquiries to Rider ○ Each rider reacts to problems in different ways, so it is important to confirm what kind of symptoms the rider has encountered. ○...
  • Page 105 FUEL SYSTEM (DFI) 3-25 Troubleshooting the DFI System Sample Diagnosis Sheet Rider name: Registration No. (license plate No.): Year of initial registration: Model: Engine No.: Frame No.: Date problem occurred: Mileage: Environment when problem occurred. □ □ □ □ □ □...
  • Page 106 3-26 FUEL SYSTEM (DFI) Troubleshooting the DFI System □ clutch slipping □ other □ Poor running spark plug loose (tighten it) or no power at □ spark plug dirty, broken, or gap maladjusted (remedy it) high speed □ spark plug incorrect (replace it) □...
  • Page 107: Dfi System Troubleshooting Guide

    FUEL SYSTEM (DFI) 3-27 DFI System Troubleshooting Guide NOTE ○ This is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties. ○...
  • Page 108 3-28 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or possible Causes Actions (chapter) Clutch lever not pulled in and gear not in neutral Pull the lever in and shift the gear in neutral. whether sidestand up or not Though clutch lever pulled in, sidestand up and Sidestand down and clutch lever pulled in gear not in neutral whether gear in neutral or not...
  • Page 109: Poor Running At Low Speed

    FUEL SYSTEM (DFI) 3-29 DFI System Troubleshooting Guide Symptoms or possible Causes Actions (chapter) No valve clearance Adjust (see chapter 2). Valve guide worn Inspect and replace (see chapter 5). Valve spring broken or weak Inspect and replace (see chapter 5). Valve not seating properly (valve bent, worn or Inspect and repair or replace (see chapter 5).
  • Page 110 3-30 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Engine stalls easily: Fuel pump trouble Inspect (see chapter 3). Fuel injector trouble Inspect (see chapter 3). Main throttle sensor trouble Inspect (see chapter 3). Fuel pressure too low or too high Inspect (see chapter 3).
  • Page 111 FUEL SYSTEM (DFI) 3-31 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Loose terminal of battery (–) lead or engine Inspect and repair (see chapter 16). ground lead Delay of ignition timing Inspect crankshaft sensor and IC igniter in ECU (see chapter 16).
  • Page 112: Poor Running Or No Power At High Speed

    3-32 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Inlet air temperature sensor trouble Inspect (see chapter 3). Water temperature sensor trouble Inspect (see chapter 3). Inlet air pressure sensor trouble Inspect (see chapter 3). Fuel injector trouble Inspect (see chapter 3).
  • Page 113 FUEL SYSTEM (DFI) 3-33 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Throttle body assy O-ring damaged Replace (see chapter 3). Fuel tank air vent obstructed Inspect and repair (see chapter 3). Fuel line clogged Inspect and repair (see chapter 3). Fuel pump operates intermittently and often DFI Pump bearings may wear.
  • Page 114 3-34 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Drive train trouble Inspect drive chain (see chapter 2) and sprockets (see chapter 11). Camshaft cam worn Inspect and replace (see chapter 5). Air switching valve trouble Inspect and replace (see chapter 5).
  • Page 115: Self-diagnosis

    FUEL SYSTEM (DFI) 3-35 Self-Diagnosis Self-diagnosis Outline Self-diagnosis Outline The self-diagnosis system has three modes and can be switched to another mode by grounding the self-diagnosis terminal. User Mode The ECU notifies the rider of troubles in DFI system and ignition system by lighting the FI indicator when DFI system and ignition system parts are faulty, and initiates fail-safe function.
  • Page 116: Service Code Clearing Procedures

    3-36 FUEL SYSTEM (DFI) Self-Diagnosis • To enter the self-diagnosis dealer mode 2, open [B] and ground [A] the lead more than five times [F] within 2 sec- onds [C] after the lead is first grounded, and then keep it grounded continuously [D] for more than 2 seconds.
  • Page 117 FUEL SYSTEM (DFI) 3-37 Self-Diagnosis...
  • Page 118: How To Read Service Codes

    3-38 FUEL SYSTEM (DFI) Self-Diagnosis How to Read Service Codes How to Read Service Codes ○ Service codes are shown by a series of long and short blinks of the FI indicator light (LED) as shown below. ○ Read 10th digit and unit digit as the FI indicator light (LED) blinks. ○...
  • Page 119: Service Code Table

    FUEL SYSTEM (DFI) 3-39 Self-Diagnosis Service Code Table Service Code Table Service FI Indicator LED Light Problems Code Main throttle sensor malfunction, wiring open or short Inlet air pressure sensor malfunction, wiring open or short Inlet air temperature sensor malfunction, wiring open or short Water temperature sensor malfunction, wiring open or short Crankshaft sensor malfunction, wiring...
  • Page 120: Backups

    3-40 FUEL SYSTEM (DFI) Self-Diagnosis Backups Backups ○ The ECU takes the following measures to prevent engine damage when the DFI or the ignition system parts have troubles. Service Output Signal Usable Parts Backups by ECU Codes Range or Criteria If the main throttle sensor system fails (the signal is out of the usable range, wiring short or open), the ECU locks ignition timing into the...
  • Page 121 FUEL SYSTEM (DFI) 3-41 Self-Diagnosis Service Output Signal Usable Parts Backups by ECU Codes Range or Criteria The stick coil primary If the ignition primary winding #1 has failures winding must send Stick Coil #1 (no signal, wiring short or open), the ECU signals (output voltage) (Ignition Coil)* shuts off the injector #1 to stop fuel to the...
  • Page 122: Main Throttle Sensor (service Code 11)

    3-42 FUEL SYSTEM (DFI) Main Throttle Sensor (Service Code 11) Main Throttle Sensor Removal/Adjustment CAUTION Do not remove or adjust the main throttle sensor [A] since it has been adjusted and set with precision at the factory. Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it.
  • Page 123: Output Voltage Inspection

    FUEL SYSTEM (DFI) 3-43 Main Throttle Sensor (Service Code 11) Output Voltage Inspection • Measure the output voltage at the main throttle sensor in the same way as input voltage inspection, Note the following. • Disconnect the main throttle sensor connector and con- nect the harness adapter [A] between these connectors.
  • Page 124: Resistance Inspection

    3-44 FUEL SYSTEM (DFI) Main Throttle Sensor (Service Code 11) Resistance Inspection • Turn the ignition switch OFF. • Disconnect the main throttle sensor connector. • Connect a digital meter [A] to the main throttle sensor connector [B]. • Measure the main throttle sensor resistance. Main Throttle Sensor Resistance Connections: BL lead [C] ←→...
  • Page 125: Inlet Air Pressure Sensor (service Code 12)

    FUEL SYSTEM (DFI) 3-45 Inlet Air Pressure Sensor (Service Code 12) CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the part can damage it. Removal • Remove: Left Center Fairing (see Center Fairing Removal in the Frame chapter) •...
  • Page 126: Output Voltage Inspection

    3-46 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code 12) Output Voltage Inspection NOTE ○ The output voltage changes according to the local at- mospheric pressure. • Measure the output voltage at the ECU in the same way as input voltage inspection. Note the following. Inlet Air Pressure Sensor Output Voltage Connections to ECU Meter (+) →...
  • Page 127 FUEL SYSTEM (DFI) 3-47 Inlet Air Pressure Sensor (Service Code 12) then Pv = Pl – Pg For example, suppose the following data is obtained: Pg = 8 cmHg (Vacuum gauge reading) Pl = 70 cmHg (Varometer reading) Vv = 3.2 V (Digital volt meter reading) then Pv = 70 –...
  • Page 128 3-48 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code 12) Pv = 55 ∼ 86 cmHg Vv: Inlet Air Pressure Sensor Output Voltage (V) (Digital Meter Reading) Pv: Throttle Vacuum Pressure (Absolute) Ps: Standard Atmospheric Pressure (Absolute) ID: Idling TO: Throttle Full Open ST: Standard of Sensor Output Voltage (v) UR: Usable Range of Sensor Output Voltage (v)
  • Page 129 FUEL SYSTEM (DFI) 3-49 Inlet Air Pressure Sensor (Service Code 12) Inlet Air Pressure Sensor Circuit 1. ECU 2. Water-proof Joint E 3. Water-proof Joint D 4. Inlet Air Pressure Sensor...
  • Page 130: Inlet Air Temperature Sensor (service Code 13)

    (see ECU Power Supply Inspection). If the wiring is good, check the sensor resistance. • Remove the needle adapter set, and apply silicone sealant to the seals of the connector for waterproofing. Silicone Sealant (Kawasaki Bond: 56019-120) - Seals of ECU Connectors...
  • Page 131: Sensor Resistance Inspection

    FUEL SYSTEM (DFI) 3-51 Inlet Air Temperature Sensor (Service Code 13) Sensor Resistance Inspection • Remove the inlet air temperature sensor. • Suspend the sensor [A] in a container of machine oil so that the heat-sensitive portion is submerged. • Suspend a thermometer [B] with the heat-sensitive por- tion [C] located in almost the same depth with the sensor.
  • Page 132: Water Temperature Sensor (service Code 14)

    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. Silicone Sealant (Kawasaki Bond: 56019-120) - Seals of ECU Connectors...
  • Page 133 FUEL SYSTEM (DFI) 3-53 Water Temperature Sensor (Service Code 14) Water Temperature Sensor Circuit 1. ECU 2. Water Temperature Sensor 3. Water-proof Joint E 4. Meter Unit Sensor Resistance Inspection • Remove the water temperature sensor (see Water Tem- perature Sensor Removal/Installation). •...
  • Page 134: Crankshaft Sensor (service Code 21)

    3-54 FUEL SYSTEM (DFI) Crankshaft Sensor (Service Code 21) Start the engine and switch the diagnosis mode to Dealer 1 mode to know all the problem that the DFI system has at the time of self-diagnosis. If the engine cannot be started, the self-diagnosis system does not detect dynamic condi- tion of the crankshaft sensor.
  • Page 135: Speed Sensor (service Code 24, 25)

    FUEL SYSTEM (DFI) 3-55 Speed Sensor (Service Code 24, 25) Speed Sensor Removal/Installation • See the Switches and Sensors section in the Electrical System chapter. Speed Sensor Inspection • See Speed Sensor Inspection section in the Electrical System chapter. Speed Sensor Input Voltage Inspection NOTE ○...
  • Page 136 3-56 FUEL SYSTEM (DFI) Speed Sensor (Service Code 24, 25) • Disconnect the speed sensor connector and connect the harness adapter [A] between the harness connector and speed sensor connector. • Connect a digital meter to the harness adapter leads. Special Tool - Throttle Sensor Setting Adapter #1: 57001 -1400 •...
  • Page 137: Vehicle-down Sensor (service Code 31)

    FUEL SYSTEM (DFI) 3-57 Vehicle-down Sensor (Service Code 31) Vehicle-down Sensor Removal CAUTION Never drop the down-sensor, especially on a hard surface. Such a shock to the sensor can damage it. • Remove: Bolts [A] Connection and Vehicle-down Sensor [B] Vehicle-down Sensor Installation •...
  • Page 138 • Remove the needle adapter set, and apply silicone sealant to the seals of the connector for waterproofing. Silicone Sealant (Kawasaki Bond: 56019-120) - Seals of Vehicle-down Sensor Connector If the output voltage is normal, the wiring is suspect. Check the wiring.
  • Page 139 FUEL SYSTEM (DFI) 3-59 Vehicle-down Sensor (Service Code 31) Vehicle-down Sensor Circuit 1. ECU 2. Water-proof Joint E 3. Vehicle-down Sensor 4. Water-proof Joint D...
  • Page 140: Subthrottle Sensor (service Code 32)

    3-60 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 sensor, especially on a hard surface. Such a shock to the sensor can damage it.
  • Page 141: Subthrottle Sensor Output Voltage Inspection

    FUEL SYSTEM (DFI) 3-61 Subthrottle Sensor (Service Code 32) Subthrottle Sensor Output Voltage Inspection • Remove the fuel tank (see Fuel Tank Removal). • Measure the output voltage at the subthrottle sensor in the same way as input voltage inspection. Note the fol- lowing.
  • Page 142: Subthrottle Sensor Resistance Inspection

    3-62 FUEL SYSTEM (DFI) Subthrottle Sensor (Service Code 32) Subthrottle Sensor Resistance Inspection • Turn the ignition switch OFF. • Disconnect the subthrottle sensor connector. • Connect a digital meter [A] to the subthrottle sensor con- nector [B]. • Measure the subthrottle sensor resistance. Throttle Sensor Resistance Connections: BL lead [C] ←→...
  • Page 143: Oxygen Sensor-not Activated (service Code 33) - Europe Model

    FUEL SYSTEM (DFI) 3-63 Oxygen Sensor-not activated (Service Code 33) - Europe Model Oxygen Sensor Removal/Installation • Refer to Switches and Sensors section in the Electrical System chapter. Oxygen Sensor Inspection • Warm up the engine thoroughly until the radiator fan starts.
  • Page 144 3-64 FUEL SYSTEM (DFI) Oxygen Sensor-not activated (Service Code 33) - Europe Model • Measure the output voltage of the sensor with the con- nector joined. Oxygen Sensor Output Voltage (without Plugs) Standard: 0.2 V or less If the reading is within range (with plugs: 0.7 V or more, without plugs: 0.2 V or less), the oxygen sensor is good.
  • Page 145: Stick Coils (#1, #2: Service Code 51, 52)

    FUEL SYSTEM (DFI) 3-65 Stick Coils (#1, #2: Service Code 51, 52) Stick Coil #1: Ignition Coil (Service Code 51) Stick Coil #2: Ignition Coil (Service Code 52) Stick Coil Removal/Installation CAUTION Never drop the stick coils, especially on a hard sur- face.
  • Page 146 3-66 FUEL SYSTEM (DFI) Stick Coils (#1, #2: Service Code 51, 52) Stick Coil Circuit 1. ECU 2. Water-proof Joint C 3. Stick Coils 4. Engine Stop Switch 5. Ignition Switch 6. Ignition Fuse 10 A 7. Main Fuse 30 A 8.
  • Page 147: Radiator Fan Relay (service Code 56)

    FUEL SYSTEM (DFI) 3-67 Radiator Fan Relay (Service Code 56) Radiator Fan Relay Removal/Installation • Radiator fan relay is bult in the relay box. • Remove the relay box (see Relay Box Removal in the Electrical System chapter). Radiator Fan Relay Inspection •...
  • Page 148: Subthrottle Valve Actuator (service Code 62)

    3-68 FUEL SYSTEM (DFI) Subthrottle Valve Actuator (Service Code 62) Subthrottle Valve Actuator Removal CAUTION Do not remove the subthrottle valve actuator [A] since it has been adjusted and set with precision at the factory. Never drop the actuator , especially on a hard sur- face.
  • Page 149: Subthrottle Valve Actuator Input Voltage Inspection

    FUEL SYSTEM (DFI) 3-69 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 150: Air Switching Valve (service Code 64)

    3-70 FUEL SYSTEM (DFI) 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 section in the Electrical Sys- tem chapter.
  • Page 151: Oxygen Sensor Heater (service Code 67) - Europe Model

    FUEL SYSTEM (DFI) 3-71 Oxygen Sensor Heater (Service Code 67) - Europe Model 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 152 3-72 FUEL SYSTEM (DFI) Oxygen Sensor Heater (Service Code 67) - Europe Model Oxygen Sensor Circuit 1. ECU 6. Main Fuse 30 A 7. Battery 2. Oxygen Sensor 8. Frame Ground 3. Water-proof Joint E 9. Joint Connector 4. Water-proof Joint D 5.
  • Page 153: Oxygen Sensor-incorrect Output Voltage (service Code 94) - Europe Model

    FUEL SYSTEM (DFI) 3-73 Oxygen Sensor-Incorrect Output Voltage (Service Code 94) - Europe Model Oxygen Sensor Removal/Installation • Refer to Oxygen Sensor Removal/Installation in the Elec- trical System chapter. Oxygen Sensor Inspection • Warm up the engine thoroughly until the radiator fan starts.
  • Page 154 3-74 FUEL SYSTEM (DFI) Oxygen Sensor-Incorrect Output Voltage (Service Code 94) - Europe Model • Measure the output voltage of the sensor with the con- nector joined. Oxygen Sensor Output Voltage (without Plugs) Standard: 0.2 V or less If the reading is within range (with plugs: 0.7 V or more, without plugs: 0.2 V or less), the oxygen sensor is good.
  • Page 155: Fi Indicator Light (led)

    FUEL SYSTEM (DFI) 3-75 FI Indicator Light (LED) Inspection Flow Chart...
  • Page 156: Fi Indicator Light (led) Inspection

    3-76 FUEL SYSTEM (DFI) FI Indicator Light (LED) FI Indicator Light (LED) Inspection • Remove the meter unit (see Meter Unit Removal in the Electrical System chapter). • Using two auxiliary leads, supply battery power to the FI indicator light (LED) [A]. 12 V Battery [B] FI Indicator Light (LED) Check Connector:...
  • Page 157: Ecu

    FUEL SYSTEM (DFI) 3-77 CAUTION Never drop the ECU, especially on a hard surface. Such a shock to the ECU can damage it. ECU Removal • Remove: Seat (see Seat Removal in the Frame chapter) Grab Rails [A] (see Seat Covers Removal in the Frame chapter) Center Seat Cover [B] (see Seat Covers section in the Frame chapter)
  • Page 158: Ecu Power Supply Inspection

    3-78 FUEL SYSTEM (DFI) 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. Replace the main harness if the terminals of the main harness connectors are cracked, bent, or otherwise dam- aged.
  • Page 159 FUEL SYSTEM (DFI) 3-79 ECU Power Source Circuit 7. Relay Box 1. ECU 8. Main Fuse 30 A 2. Water-proof Joint C 3. Ignition Switch 9. Battery 4. Water-proof Joint A 10. Frame Ground 5. ECU Main Fuse 15 A 11.
  • Page 160: Fuel Line

    3-80 FUEL SYSTEM (DFI) Fuel Line Fuel Pressure Inspection NOTE ○ This inspection can determine which trouble the DFI system has, mechanical or electrical trouble. ○ It is preferable to measure the fuel pressure while run- ning the motorcycle just when trouble occurred in order to know symptom well.
  • Page 161 FUEL SYSTEM (DFI) 3-81 Fuel Line • Turn the ignition switch ON. The fuel pump will turn for 3 seconds, and then stop. CAUTION Do not drive the fuel pump without the fuel in the fuel tank. • Measure the fuel pressure with the engine stopped. Fuel Pressure Right after Ignition Switch ON, with pump running: Standard:...
  • Page 162: Fuel Flow Rate Inspection

    3-82 FUEL SYSTEM (DFI) Fuel Line Fuel Flow Rate Inspection NOTE ○ Be sure the battery is fully charged. WARNING Gasoline is extremely flammable and can be explo- sive under certain conditions. Make sure the area is well-ventilated and free from any source of flame or sparks;...
  • Page 163 FUEL SYSTEM (DFI) 3-83 Fuel Line CAUTION Do not drive the fuel pump without the fuel in the fuel tank. • Measure the discharge for 3 seconds with the plastic hose filled with fuel. ○ Repeat this operation several times. Amount of Fuel Flow Standard: 60 mL or more for 3 seconds...
  • Page 164: Fuel Pump

    3-84 FUEL SYSTEM (DFI) Fuel Pump Fuel Pump Removal CAUTION Never drop the fuel pump, especially on a hard sur- face. Such a shock to the pump can damage it. WARNING Gasoline is extremely flammable and can be explo- sive under certain conditions. Make sure the area is well-ventilated and free from any source of flame or sparks;...
  • Page 165: Fuel Pump Operation Inspection

    FUEL SYSTEM (DFI) 3-85 Fuel Pump • Replace the fuel pump gasket [A] with a new one. • Apply a non-permanent locking agent to the threads of the fuel pump bolts. • Tighten the fuel pump bolts to a snug fit, tighten them alternating diagonally.
  • Page 166: Pressure Regulator Removal

    3-86 FUEL SYSTEM (DFI) Fuel Pump • Connect the hand tester (25 V DC) to the fuel pump con- nector [A] with needle adapter set. Special Tools - Hand Tester: 57001-1394 Needle Adapter Set: 57001-1457 ○ Measure the operating voltage with the engine stopped, and with the connector joined.
  • Page 167 FUEL SYSTEM (DFI) 3-87 Fuel Pump Fuel Pump Circuit 6. Fuel Pump Relay 1. ECU 7. Relay Box 2. Water-proof Joint C 3. Engine Stop Switch 8. Main Fuse 30 A 4. Ignition Switch 9. Battery 5. Ignition Fuse 10 A 10.
  • Page 168: Fuel Injectors

    3-88 FUEL SYSTEM (DFI) Fuel Injectors Removal/Installation • Refer to the Throttle Body Assy Disassembly/Assembly. Audible Inspection • Start the engine. • Apply the tip of a screwdriver [A] to the injector [C]. Put the grip end onto your ear, and listen whether the injector is clicking or not.
  • Page 169: Fuel Injector Output Voltage Inspection

    Remove the needle adapter. • Apply silicone sealant to the seals of the ECU connector for waterproofing. Silicone Sealant (Kawasaki Bond: 56019-120) - Seals of ECU Connectors Injector Signal Test • Prepare two test light sets with male terminals as shown.
  • Page 170: Injector Resistance Inspection

    3-90 FUEL SYSTEM (DFI) Fuel Injectors • Remove the fuel tank (see Fuel Tank Removal). • Remove the air cleaner housing (see Air Cleaner Housing Removal) • Remove connectors for injector [A]. • Connect each test light set [B] to the injector sub harness connector [C].
  • Page 171: Injector Unit Test

    FUEL SYSTEM (DFI) 3-91 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 172 3-92 FUEL SYSTEM (DFI) Fuel Injectors Fuel Injector Circuit 1. ECU 7. Fuel Pump Relay (for fuel pump and injec- 2. Fuel Injectors tors) 3. Water-proof Joint C 8. Relay Box 4. Engine Stop Switch 9. Main Fuse 30 A 5.
  • Page 173: Throttle Grip And Cables

    FUEL SYSTEM (DFI) 3-93 Throttle Grip and Cables Throttle Grip Free Play Inspection • Refer to Throttle Control System Inspection in the Peri- odic Maintenance chapter. Throttle Grip Free Play Adjustment • Refer to Throttle Control System Inspection in the Peri- odic Maintenance chapter.
  • Page 174: Throttle Body Assy

    3-94 FUEL SYSTEM (DFI) Throttle Body Assy Idle Speed Inspection • Refer to Idle Speed Inspection in the Periodic Mainte- nance chapter. Engine Vacuum Synchronization Inspection/Adjust- ment • Refer to Engine Vacuum Synchronization Inspection in the Periodic Maintenance chapter. High Altitude Performance Adjustment •...
  • Page 175: Throttle Body Assy Installation

    FUEL SYSTEM (DFI) 3-95 Throttle Body Assy • Loosen the locknut and screw in the throttle cable adjuster fully to give the cables plenty of play. • Remove the right switch housing and take out the acceler- ator cable upper end [A] and the decelerator cable upper end [B].
  • Page 176: Throttle Body Assy Disassembly

    3-96 FUEL SYSTEM (DFI) Throttle Body Assy • Fit the accelerator cable end [A] and the decelerator cable end [B] into the throttle pulley. • Check fuel leakage from the throttle body assy. WARNING Fuel spilled from the carburetors is hazardous. •...
  • Page 177: Throttle Body Assy Assembly

    FUEL SYSTEM (DFI) 3-97 Throttle Body Assy • Remove: Screws [A] Delivery Pipe [B] Fuel Injectors [C] Throttle Body Assy Assembly ○ Replace the O-rings [A] and seals [B] with the new ones. • Before assembling, blow away dirt or dust from the throttle body and delivery pipe by applying compressed air.
  • Page 178: Air Cleaner

    3-98 FUEL SYSTEM (DFI) Air Cleaner Air Cleaner Element Removal/Installation • Refer to Air Cleaner Element Replacement in the Periodic Maintenance chapter. Air Cleaner Element Inspection • Remove the air cleaner element (see Air Cleaner Element Replacement in the Periodic Maintenance chapter). •...
  • Page 179: Air Cleaner Housing Installation

    FUEL SYSTEM (DFI) 3-99 Air Cleaner • Unscrew the bolts [A] and remove the air cleaner housing [B]. Air Cleaner Housing Installation • Install the clamp on the hose [A] so that its pinch heads [B] face the right. • Install the clamp on the breather hose [C] so that its pinch heads [D] face the front.
  • Page 180: Fuel Tank

    3-100 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 181: Fuel Tank Installation

    FUEL SYSTEM (DFI) 3-101 Fuel Tank • Be sure to place a piece of cloth [A] around the fuel hose joint. • Insert a minus screw driver [B] into the slit [C]on the joint lock. • Turn [A] the driver to disconnect the joint lock [B]. •...
  • Page 182: Fuel Tank And Cap Inspection

    3-102 FUEL SYSTEM (DFI) Fuel Tank • Be sure that the trim seal [A] is on the fuel tank. Reverse Side of Fuel Tank [B] Side Cover [C] Approx. 17 mm (0.67 in.) [D] Front [E] • Insert [A] the fuel hose joint [B] straight onto the delivery pipe until the hose joint clicks.
  • Page 183: Fuel Tank Cleaning

    FUEL SYSTEM (DFI) 3-103 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 185 COOLING SYSTEM 4-1 Cooling System Table of Contents Exploded View........................Coolant Flow Chart......................... Specifications ......................... Special Tools .......................... Coolant ........................... Coolant Deterioration Inspection..................Coolant Level Inspection....................Coolant Draining ....................... Coolant Filling ........................Pressure Testing ....................... Cooling System Flushing ....................Coolant Reserve Tank Removal/Installation ..............Water Pump..........................
  • Page 186: Exploded View

    4-2 COOLING SYSTEM Exploded View...
  • Page 187 COOLING SYSTEM 4-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Radiator Hose Clamp Screws 0.20 17 in·lb Water Pump Impeller Bolt 87 in·lb Water Pump Cover Bolts 87 in·lb Water Pump Drain Bolt 0.70 62 in·lb Thermostat Housing Bolts 87 in·lb Water Temperature Sensor 106 in·lb...
  • Page 188: Coolant Flow Chart

    4-4 COOLING SYSTEM Coolant Flow Chart...
  • Page 189 COOLING SYSTEM 4-5 Coolant Flow Chart Permanent type antifreeze is used as a coolant to protect the cooling system from rust and corrosion. When the engine starts, the water pump turns and the coolant circulates. The thermostat is a wax pellet type which opens or closes with coolant temperature changes. The thermostat continuously changes its valve opening to keep the coolant temperature at the proper level.
  • Page 190: Specifications

    4-6 COOLING SYSTEM Specifications Item Standard Coolant Provided when Shipping Type (Recommended) Permanent type of antifreeze (soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators) Color Green Mixed Ratio Soft water 50%, coolant 50% Freezing Point −35°C (−31°F) Total Amount...
  • Page 191: Special Tools

    COOLING SYSTEM 4-7 Special Tools Bearing Driver Set: Oil Seal Driver: 57001-1129 57001-1660...
  • Page 192: Coolant

    4-8 COOLING SYSTEM Coolant Coolant Deterioration Inspection • Remove the right center fairing cover (see Center Fairing Removal in the Frame chapter). • Visually inspect the coolant [A] in the reserve tank. If whitish cotton-like wafts are observed, aluminum parts in the cooling system are corroded.
  • Page 193: Cooling System Flushing

    COOLING SYSTEM 4-9 Coolant Cooling System Flushing Over a period of time, the cooling system accumulates rust, scale, and lime in the water jacket and radiator. When this accumulation is suspected or observed, flush the cool- ing system. If this accumulation is not removed, it will clog up the water passage and considerable reduce the effi- ciency of the cooling system.
  • Page 194: Water Pump

    4-10 COOLING SYSTEM Water Pump Water Pump Removal • Drain the coolant (see Coolant Change in the Periodic Maintenance chapter). • Loosen the clamp and remove the radiator hose [A] from the water pump cover [B]. • Remove the water pump cover bolts [C]. •...
  • Page 195: Mechanical Seal Inspection

    COOLING SYSTEM 4-11 Water Pump • Install the water pump cover, being careful of the two dowel pins [A]. Torque - Water Pump Cover Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) Mechanical Seal Inspection • Visually inspect the mechanical seal. If any one of the parts is damaged, replace the mechani- cal seal as a unit.
  • Page 196: Impeller Assembly

    4-12 COOLING SYSTEM Water Pump Impeller Assembly • Clean the sliding surface of the mechanical seal with a high flash-point solvent, and apply a little coolant to the sliding surface to give the mechanical seal initial lubrica- tion. • Apply coolant to the surfaces of the rubber seal [A] and sealing seat [B], and install the rubber seal and sealing seat into the impeller by pressing them by hand until the seat stops at the bottom of the hole.
  • Page 197: Radiator

    COOLING SYSTEM 4-13 Radiator Radiator and Radiator Fan Removal • Drain the coolant (see Coolant Change in the Periodic Maintenance chapter). • Remove: Left/Right Center Fairing (see Center Fairing in the Frame chapter) Reserve Tank (see Coolant Change in the Periodic Main- tenance chapter) Radiator Fan Motor Connector [A] (Disconnect) Radiator Hose Clamp Screw [B] (Loosen)
  • Page 198: Radiator And Radiator Fan Installation

    4-14 COOLING SYSTEM Radiator Radiator and Radiator Fan Installation • Install the grommet [A] so that its large side faces the front. • Install the radiator [B] to the frame. ○ Align [C] the projection on the radiator with the hole on the frame.
  • Page 199: Radiator Filler Neck Inspection

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

    4-16 COOLING SYSTEM Thermostat Thermostat Removal • Drain the coolant (see Coolant Change in the Periodic Maintenance chapter). • Remove: Left Center Fairing (see Center Fairing Removal in the Frame chapter) Thermostat Hosing Bolts [A] Thermostat Hosing [B] • Pull the thermostat [A] out of the cylinder head. Thermostat Installation •...
  • Page 201 COOLING SYSTEM 4-17 Thermostat • To check valve opening temperature, suspend the ther- mostat [A] in a container of water and raise the tempera- ture of the water. ○ The thermostat must be completely submerged and must not touch the container sides or bottom. Suspend an ac- curate thermometer [B] in the water so that the heat sen- sitive portions [C] are located in almost the same depth.
  • Page 202: Hose And Pipes

    4-18 COOLING SYSTEM Hose and Pipes Hose Installation • Install the hoses and pipes, being careful to follow bend- ing direction. Avoid sharp bending, kinking, flattening or twisting. • Run the hoses (see Cable, Wire, and Hose Routing sec- tion in the Appendix chapter). •...
  • Page 203: Water Temperature Sensor

    COOLING SYSTEM 4-19 Water Temperature Sensor CAUTION The water temperature sensor should never be al- lowed to fall on a hard surface. Such a shock to the water temperature sensor can damage it. Water Temperature Sensor Removal/Installation • Refer to Water Temperature Sensor Removal/Installation in the Fuel System (DFI) chapter.
  • Page 205 ENGINE TOP END 5-1 Engine Top End Table of Contents Exploded View........Cylinder Head Removal ....5-21 Specifications ........Cylinder Head Installation .... 5-22 Special Tools and Sealant ....Cylinder Head Warp..... 5-24 Clean Air System....... 5-11 Valves ..........5-25 Air Suction Valve Removal...
  • Page 206: Exploded View

    5-2 ENGINE TOP END Exploded View...
  • Page 207 ENGINE TOP END 5-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Air Suction Valve Cover Bolts 87 in·lb Cylinder Head Cover Bolts 87 in·lb Camshaft Cap Bolts 106 in·lb Cylinder Head Bolts (M10 New Bolts) MO, S Cylinder Head Bolts (M10 Used Bolts) MO, S Cylinder Head Bolts (M6) 106 in·lb...
  • Page 208 5-4 ENGINE TOP END Exploded View...
  • Page 209 ENGINE TOP END 5-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Cylinder Bolt (M8) 27.5 MO,S Cylinder Nut (M10) MO,S Cylinder Bolts (M6) 106 in·lb Exhaust Pipe Manifold Holder Nuts Muffler Body Mounting Bolt (Front) Muffler Body Mounting Bolt (Rear) 7.
  • Page 210 5-6 ENGINE TOP END Exploded View Silencer [C] with Hole [A] for Oxygen Sensor...
  • Page 211: Specifications

    ENGINE TOP END 5-7 Specifications Item Standard Service Limit Camshafts Cam Height: 35.843 ∼ 35.957 mm (1.4111 ∼ 1.4156 in.) 35.74 mm (1.4071 in.) Exhaust 36.543 ∼ 36.657 mm (1.4387 ∼ 1.4432 Inlet 36.44 mm (1.4346 in.) in.) 0.028 ∼ 0.071 mm (0.0011 ∼ 0.0028 in.) Camshaft Journal, Camshaft 0.16 mm (0.0063 in.) Cap Clearance...
  • Page 212 5-8 ENGINE TOP END Specifications Item Standard Service Limit Valve Spring Free Length: Exhaust 41.91 mm (1.650 in.) 40.3 mm (1.587 in.) Inlet 41.91 mm (1.650 in.) 40.3 mm (1.587 in.) Cylinder, Pistons 82.994 ∼ 83.006 mm (3.2675 ∼ 3.2679 Cylinder Inside Diameter 83.10 mm (3.2716 in.) in.)
  • Page 213: Special Tools And Sealant

    ENGINE TOP END 5-9 Special Tools and Sealant Compression Gauge, 20 kgf/cm²: Valve Seat Cutter, 60° - 30: 57001-221 57001-1123 Valve Spring Compressor Assembly: Valve Seat Cutter Holder Bar: 57001-241 57001-1128 Valve Seat Cutter, 45° - 35: Valve Seat Cutter, 45° - 30: 57001-1116 57001-1187 Valve Seat Cutter, 32°...
  • Page 214 Special Tools and Sealant Compression Gauge Adapter, M10 × 1.0: Piston Pin Puller: 57001-1317 57001-1568 Valve Seat Cutter Holder, 4.5: Piston Pin Puller Adapter C: 57001-1330 57001-1657 Valve Guide Arbor, 4.5: Kawasaki Bond (Silicone Sealant): 57001-1331 92104-0004 Valve Guide Reamer, 4.5: 57001-1333...
  • Page 215: 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) Air Switching Valve with Hoses (see Air Switching Valve Removal) Air Suction Valve Cover Bolts [A] and Clamp Air Suction Valve Cover [B]...
  • Page 216: Air Switching Valve Installation

    5-12 ENGINE TOP END Clean Air System Air Switching Valve Installation • Install the vacuum switch valve so that the vacuum fitting [A] faces left side. • Route the hoses correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). Air Switching Valve Operation Test •...
  • Page 217: Cylinder Head Cover

    Cylinder Head Cover Installation • Replace the head cover gasket [A] with a new one. • Apply silicone sealant [B] to the cylinder head as shown. Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004 • Install: Dowel Pins [C] Plug Hole Gaskets [D] •...
  • Page 218: Camshaft Chain Tensioner

    5-14 ENGINE TOP END Camshaft Chain Tensioner Camshaft Chain Tensioner Removal CAUTION This is a non-return type camshaft chain tensioner. The push rod does not return to its original position once it moves out to take up camshaft chain slack. Observe all the rules listed below: When removing the tensioner, do not take out the mounting bolts only halfway.
  • Page 219: Camshaft, Camshaft Chain

    ENGINE TOP END 5-15 Camshaft, Camshaft Chain Camshaft Removal • Remove: Cylinder Head Cover (see Cylinder Head Cover Re- moval) • Position the crankshaft as follows. ○ Remove the upper [A] and lower [B] caps on the clutch cover. ○ Using a wrench on the crankshaft rotation bolt, turn the crankshaft clockwise until the 2|T mark line [A] on the tim- ing rotor is aligned with the notch [B] in the edge of the...
  • Page 220 5-16 ENGINE TOP END Camshaft, Camshaft Chain • Apply molybdenum disulfide oil solution to all cams [A] journals [B] and thrust blocks [C] with × marks. • If a new camshaft is to be used, apply a thin coat of molyb- denum disulfide grease to the cam surfaces.
  • Page 221 ENGINE TOP END 5-17 Camshaft, Camshaft Chain ○ The timing marks must be aligned with the cylinder head upper surface [C]. EX mark [D] (Between #1 Pin and #2 Pin) IN mark [E] (Between #31 Pin and #32 Pin) #1 Pin [F] #2 Pin [G] #31 Pin [H] #32 Pin [J]...
  • Page 222: Camshaft And Sprocket Assembly

    5-18 ENGINE TOP END Camshaft, Camshaft Chain Camshaft and Sprocket Assembly ○ The inlet and exhaust sprockets are identical. • Install the sprockets so that the marked (“IN” and “EX”) side faces to the right side. CAUTION Inlet sprocket must use “IN” marked bolts holes [A]. Exhaust sprocket must use “EX”...
  • Page 223: Camshaft Runout

    ENGINE TOP END 5-19 Camshaft, Camshaft Chain Camshaft Runout • Remove the camshaft (see Camshaft Removal). • Set the camshaft in a camshaft alignment jig or on V blocks. • Measure runout with a dial gauge at the specified place as shown.
  • Page 224: Cylinder Head

    5-20 ENGINE TOP END Cylinder Head Cylinder Compression Measurement NOTE ○ Use the battery which is fully charged. • Warm up the engine thoroughly. • Stop the engine. • Remove: Seat (see Seat Removal in the Frame chapter) 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 225: Cylinder Head Removal

    ENGINE TOP END 5-21 Cylinder Head The following table should be consulted if the obtainable compression reading is not within the us- able range. Problem Diagnosis Remedy (Action) Cylinder compression Carbon accumulation on piston and in is higher than usable combustion chamber possibly due to Remove the carbon deposits range...
  • Page 226: Cylinder Head Installation

    5-22 ENGINE TOP END Cylinder Head • Firstly remove the M6 cylinder head bolts and M6 cylinder bolts [A]. • Secondly, remove the M8 bolts [B]. • Thirdly, remove the M10 nut [C]. • Fourthly, remove the M10 bolts [D]. Cylinder Head Installation NOTE ○...
  • Page 227 ENGINE TOP END 5-23 Cylinder Head • Apply molybdenum disulfide oil solution [A] to both sides of washers and the threads of bolts and nut. M10 Cylinder Head Bolts [B] M10 Cylinder Nut [C] M8 Cylinder Bolt [D] • Torque the all the bolts and nut following the tightening sequence [1 ∼...
  • Page 228: Cylinder Head Warp

    5-24 ENGINE TOP END Cylinder Head • Tighten the M6 cylinder head bolts and M6 cylinder bolts [A]. Torque - Cylinder Head Bolts (M6): 12 N·m (1.2 kgf·m, 106 in·lb) Cylinder Bolts (M6): 12 N·m (1.2 kgf·m, 106 in·lb) • Install the front camshaft chain guide [A].
  • Page 229: Valves

    ENGINE TOP END 5-25 Valves Valve Clearance Inspection • Refer to Valve Clearance Inspection in the Periodic Main- tenance chapter. Valve Clearance Adjustment • Refer to Valve Clearance Adjustment in the Periodic Maintenance chapter. Valve Removal • Remove cylinder head (see Cylinder Head Removal). •...
  • Page 230: Valve Guide Installation

    5-26 ENGINE TOP END Valves Valve Guide Installation • Apply oil to the valve guide outer surface before installa- tion. • Heat the area around the valve guide hole to about 120 ∼ 150°C (248 ∼ 302°F). • Drive the valve guide in from the top of the head using the valve guide arbor.
  • Page 231: Valve Seat Inspection

    ENGINE TOP END 5-27 Valves Valve Seat Inspection • Remove the valve (see Valve Removal). • Check the valve seating surface [A] between the valve [B] and valve seat [C]. ○ Measure the outside diameter [D] of the seating pattern on the valve seat.
  • Page 232 5-28 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 233 ENGINE TOP END 5-29 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 234 5-30 ENGINE TOP END Valves If the seat width is too wide, make the 60° or 55° [A] grind described below. If the seat width is within the specified range, lap the valve to the seat as described below. • Grind the seat at a 60°...
  • Page 235 ENGINE TOP END 5-31 Valves...
  • Page 236: Cylinder, Pistons

    5-32 ENGINE TOP END Cylinder, Pistons Cylinder Removal • Remove: Cylinder Head (see Cylinder Head Removal) Horn • Remove: Front Engine Mounting Bolts (Both Side) [A] (see Engine Removal in the Engine Removal/Installation chapter) Front Engine Brackets (Both Side) [B] (see Engine Re- moval in the Engine Removal/Installation chapter) Cylinder [C] Cylinder Installation...
  • Page 237: Piston Installation

    ENGINE TOP END 5-33 Cylinder, Pistons • Remove the piston pins. Special Tool - Piston Pin Puller: 57001-1568 [A] Piston Pin Puller Adapter C: 57001-1657 [D] Center Bolt [B] Shall of Piston [C] • Remove the pistons. • Carefully spread the ring opening with your thumbs and then push up on the opposite side of the ring [A] to remove •...
  • Page 238: Cylinder Wear

    5-34 ENGINE TOP END Cylinder, Pistons NOTE ○ If a new piston is used, use new piston ring. • Install the piston with its marking hollow facing forward. • Fit a new piston pin snap ring into the side of the piston so that the ring opening [A] does not coincide with the slit [B] of the piston pin hole.
  • Page 239: Piston Ring, Piston Ring Groove Wear

    ENGINE TOP END 5-35 Cylinder, Pistons Piston Ring, Piston Ring Groove Wear • Check for uneven groove wear by inspecting the ring seat- ing. The rings should fit perfectly parallel to groove surfaces. If not, replace the piston and all the piston rings. •...
  • Page 240: Piston Ring End Gap

    5-36 ENGINE TOP END Cylinder, Pistons Piston Ring End Gap • Place the piston ring [A] inside the cylinder, using the pis- ton to locate the ring squarely in place. Set it close to the bottom of the cylinder, where cylinder wear is low. •...
  • Page 241: Throttle Body Holder

    ENGINE TOP END 5-37 Throttle Body Holder Throttle Body Holder Installation • Be sure to install the O-rings [A]. • Install the clamps [B] as shown and so that their projec- tions fit [C] on the holes of the holders. ○...
  • Page 242: Muffler

    5-38 ENGINE TOP END Muffler WARNING To avoid a serious burn, do not remove the muffler when the engine is still hot. Wait until the muffler cool down. Muffler Body Removal • Remove: Right Frame Cover (see Frame Cover Removal in the Frame chapter) •...
  • Page 243: Muffler Body And Exhaust Pipe Installation

    ENGINE TOP END 5-39 Muffler Muffler Body and Exhaust Pipe Installation • Replace the exhaust pipe gaskets [A] and muffler body connection gasket [B] with new ones and install them. ○ Install the muffler body connection gasket until it is bot- tomed so that the chamfer side [C] feces muffler body [D].
  • Page 245 CLUTCH 6-1 Clutch Table of Contents Exploded View........................Specifications ......................... Special Tool and Sealant ......................Clutch Lever and Cable ......................Clutch Lever Free Play Inspection ..................Clutch Lever Free Play Adjustment .................. Clutch Cable Removal ...................... Clutch Cable Installation ....................Clutch Cable Lubrication....................
  • Page 246: Exploded View

    6-2 CLUTCH Exploded View...
  • Page 247 CLUTCH 6-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Upper Cap on Clutch Cover 0.40 35 in·lb Lower Cap on Clutch Cover – – – Hard-tighten Oil Filler Plug – – – Hard-tighten Clutch Cover Mounting Bolts 87 in·lb Clutch Spring Bolts 87 in·lb Clutch Hub Nut...
  • Page 248: Specifications

    6-4 CLUTCH Specifications Item Standard Service Limit 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Clutch Lever Free Play – – – Clutch 2.92 ∼ 3.08 mm (0.115 ∼ 0.121 in.) Friction Plate Thickness 2.8 mm (0.110 in.) Friction Plate Warp 0.15 mm (0.16 in.) or less 0.3 mm (0.012 in.) Steel Plate Warp...
  • Page 249: Special Tool And Sealant

    CLUTCH 6-5 Special Tool and Sealant Clutch Holder: Kawasaki Bond (Silicone Sealant): 57001-1243 92104-0004...
  • Page 250: Clutch Lever And Cable

    6-6 CLUTCH Clutch Lever and Cable Clutch Lever Free Play Inspection • Refer to Clutch Operation Inspection in the Periodic Main- tenance chapter. Clutch Lever Free Play Adjustment • Refer to Clutch Operation Inspection in the Periodic Main- tenance chapter. Clutch Cable Removal •...
  • Page 251: Clutch Lever Installation

    CLUTCH 6-7 Clutch Lever and Cable Clutch Lever Installation • Install the clutch lever so that the mating surface [B] of the clutch lever clamp is aligned with the punch mark [A]. • Tighten the upper clamp bolt first, and then the lower clamp bolt.
  • Page 252: Clutch Cover

    Apply silicone sealant to the area [A] where the mating surface of the crankcase touches the clutch cover gasket and to the crankshaft sensor lead grommet [B]. Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004 • Be sure that the dowel pins [C] are in position.
  • Page 253: Release Shaft Removal

    CLUTCH 6-9 Clutch Cover Release Shaft Removal CAUTION Do not remove the clutch release lever and shaft assembly unless it is absolutely necessary. If re- moved, the oil seal replacement may be required. • Remove the clutch cover (see Clutch Cover Removal). •...
  • Page 254: Clutch Cover Assembly

    6-10 CLUTCH Clutch Cover • Remove the oil level gauge [A]. 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] position as shown.
  • Page 255: Clutch Removal

    CLUTCH 6-11 Clutch Clutch Removal • Remove: Engine Oil (drain, see Engine Oil Change in the Periodic Maintenance chapter) Clutch Cover (see Clutch Cover Removal) Clutch Spring Bolts [A] Clutch Springs Clutch Spring Plate [B] (with thrust bearing and pusher [C]) •...
  • Page 256 6-12 CLUTCH Clutch • Be sure that the spacer [A] is in position. • Insert the following on the drive shaft. Clutch Housing [A] with Chain [B] and Sprocket [C] Sleeve [D] • Align [E] the hole on the oil pump sprocket with the oil pump shaft.
  • Page 257: Clutch Plate, Wear, Damage Inspection

    CLUTCH 6-13 Clutch • Install the friction plates and steel plates, starting with a friction plate and alternating them. CAUTION If new dry friction plates and steel plates are in- stalled, apply engine oil to the surfaces of each plate to avoid clutch plate seizure. ○...
  • Page 258: Clutch Spring Free Length Measurement

    6-14 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: 33.6 mm (1.32 in.) Service Limit: 32.6 mm (1.28 in.) Clutch Housing Finger Inspection •...
  • Page 259 ENGINE LUBRICATION SYSTEM 7-1 Engine Lubrication System Table of Contents Exploded View........................Engine Oil Flow Chart......................Specifications ......................... Special Tools and Sealant ...................... Engine Oil and Oil Filter......................Oil Level Inspection......................Engine Oil Change......................Oil Filter Replacement ...................... Oil Pan............................ Oil Pan Removal .......................
  • Page 260: Exploded View

    7-2 ENGINE LUBRICATION SYSTEM Exploded View...
  • Page 261 L: Apply a non-permanent locking agent. Lh: Left-hand-threads MO: Apply molybdenum disulfide oil solution. (mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 : 1) R: Replacement Parts SS: Apply silicone sealant (Kawasaki Bond: 56019-120).
  • Page 262: Engine Oil Flow Chart

    7-4 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart...
  • Page 263 ENGINE LUBRICATION SYSTEM 7-5 Engine Oil Flow Chart...
  • Page 264: Specifications

    7-6 ENGINE LUBRICATION SYSTEM Specifications Item Standard Engine Oil Type API SE, SF or SG API SH, SJ or SL with JASO MA Viscosity SAE 10W-40 Capacity: 1.7 L (1.8 US gt) (when filter is not removed) 1.9 L (2.0 US gt) (when filter is removed) 2.4 L (2.5 US gt) (when engine is completely dry) Level Between upper and lower level lines...
  • Page 265: Special Tools And Sealant

    ENGINE LUBRICATION SYSTEM 7-7 Special Tools and Sealant Oil Pressure Gauge, 10 kgf/cm²: Oil Filter Wrench: 57001-164 57001-1249 Oil Pressure Gauge Adapter, PT3/8 × 19/in.: Kawasaki Bond (Silicone Sealant): 57001-1233 56019-120...
  • Page 266: 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 267: Oil Pan

    ENGINE LUBRICATION SYSTEM 7-9 Oil Pan Oil Pan Removal • Remove: Engine Oil (drain, see Engine Oil Change in the Periodic Maintenance chapter) Exhaust Pipe (see Exhaust Pipe Removal in the Engine Top End chapter) Muffler Body (see Muffler Body Removal in the Engine Top End chapter) Oil Pan Bolts [A] Oil Pan [B]...
  • Page 268: Oil Pan Installation

    7-10 ENGINE LUBRICATION SYSTEM Oil Pan Oil Pan Installation • Apply grease to the O-rings on the oil pipes [A]. • Install the oil pipe plate [B] so that its guide portion [C] fits the breather pipe [D] as shown. •...
  • Page 269: Oil Pressure Relief Valve

    ENGINE LUBRICATION SYSTEM 7-11 Oil Pressure Relief Valve Oil Pressure Relief Valve Removal • See Oil Pan Removal. Oil Pressure Relief Valve Installation • See Oil Pan Installation. Oil Pressure Relief Valve Inspection • Check to see if the valve [A] slides smoothly when push- ing it in with a wooden or other soft rod, and see if it comes back to its seat by spring [B] pressure.
  • Page 270: Oil Pump

    7-12 ENGINE LUBRICATION SYSTEM Oil Pump Oil Pump Removal • Drain: Engine Oil (see Engine Oil Change in the Periodic Main- tenance chapter) • Remove: Clutch (see Clutch Removal in the Clutch chapter) Oil Pump Cover Bolts [A] Oil Pump Cover [B] •...
  • Page 271: Oil Pump Installation

    ENGINE LUBRICATION SYSTEM 7-13 Oil Pump Oil Pump Installation • Apply molybdenum disulfide grease to the portion [A] of the oil pump shaft, as shown. • Install: Outer Rotor [B] for Feed Pump Inner Rotor [C] for Feed Pump Oil Pump Shaft [D] and Pin [E] Dowel Pin [F] Oil Pump Body [G] Pin [H] and Inner Rotor [I] for Scavenge Pump...
  • Page 272: Oil Pressure Measurement

    7-14 ENGINE LUBRICATION SYSTEM Oil Pressure Measurement Oil Pressure Measurement • Remove the lower fairing (see Lower Fairing Removal in the Frame chapter). • Remove the oil passage plug, and attach the adapter [A] and gauge [B] to the plug hole. Special Tools - Oil Pressure Gauge, 10 kgf/cm²: 57001-164 Oil Pressure Gauge Adapter, PT3/8 ×...
  • Page 273: Oil Pressure Switch

    Oil Pressure Switch Installation • Apply silicone sealant to the threads of the oil pressure switch and tighten it. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 Torque - Oil Pressure Switch: 15 N·m (1.5 kgf·m, 11 ft·lb) • Tighten the terminal bolt securely.
  • Page 275 ENGINE REMOVAL/INSTALLATION 8-1 Engine Removal/Installation Table of Contents Exploded View........................Engine Removal/Installation ....................Engine Removal........................
  • Page 276 8-2 ENGINE REMOVAL/INSTALLATION Exploded View...
  • Page 277 ENGINE REMOVAL/INSTALLATION 8-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Engine Mounting Bracket Bolts Front Engine Mounting Bolts Rear Engine Mounting Nuts 4. Engine Mounting Brackets 5. Collar...
  • Page 278 8-4 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation Engine Removal • Support the rear part of the swingarm with a stand. • Squeeze the brake lever slowly and hold it with a band [A]. WARNING Be sure to hold the front brake when removing the engine, or the motorcycle may fall over.
  • Page 279 ENGINE REMOVAL/INSTALLATION 8-5 Engine Removal/Installation • Disconnect the crankshaft sensor lead connector [A]. • Remove: Exhaust Pipe (see Exhaust Pipe Removal in the Engine Top End chapter) Muffler Body (see Muffler Body Removal in the Engine Top End chapter) Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Air Switching Valve and Hose (see Air Switching Valve Removal in the Engine Top End chapter)
  • Page 280 8-6 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Remove the engine sprocket cover (see Engine Sprocket Removal in the Final Drive chapter). • Remove the shift pedal [A] (see Shift Pedal Removal in the Crankshaft/Transmission chapter). • Disconnect: Oxygen Sensor Lead Connector [B] Neutral Switch Lead Terminal [C] •...
  • Page 281 ENGINE REMOVAL/INSTALLATION 8-7 Engine Removal/Installation • Tighten: Torque - Rear Engine Mounting Nuts: 44 N·m (4.5 kgf·m, 32 ft·lb) Font Engine Mounting Bolts: 44 N·m (4.5 kgf·m, 32 ft·lb) Engine Mounting Bracket bolts: 25 N·m (2.5 kgf·m, 18 ft·lb) • Install the engine sprocket (see Engine Sprocket Installa- tion in the Final Drive chapter).
  • Page 283 CRANKSHAFT/TRANSMISSION 9-1 Crankshaft/Transmission Table of Contents Exploded View........External Shift Mechanism Specifications ........Removal ........9-29 Special Tools and Sealant ....External Shift Mechanism Crankcase Splitting......9-10 Installation ......... 9-30 Crankcase Splitting ...... 9-10 External Shift Mechanism Crankcase Assembly ....9-11 Inspection........
  • Page 284: Exploded View

    9-2 CRANKSHAFT/TRANSMISSION Exploded View...
  • Page 285 15. Do not apply any grease or oil. G: Apply grease. L: Apply a non-permanent locking agent. LG: Apply liquid gasket (Kawasaki Bond: 92104-1064). M: Apply molybdenum disulfide grease. MO: Apply molybdenum disulfide oil solution. (mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 : 1) R: Replacement Parts S: Follow the specific tightening sequence.
  • Page 286 9-4 CRANKSHAFT/TRANSMISSION Exploded View...
  • Page 287 CRANKSHAFT/TRANSMISSION 9-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Gear Positioning Lever Bolt 106 in·lb Transmission Case Bolts Shift Drum Cam Bolt 106 in·lb Shift Drum Bearing Holder Screw 0.50 43 in·lb Shift Rod Plate Bolt 87 in·lb Neutral Switch Holder Screw 0.50 43 in·lb Neutral Switch...
  • Page 288: Specifications

    9-6 CRANKSHAFT/TRANSMISSION Specifications Item Standard Service Limit Crankshaft, Connecting Rods Connecting Rod Bend – – – TIR 0.2/100 mm (0.008/3.94 in.) Connecting Rod Twist – – – TIR 0.2/100 mm (0.008/3.94 in.) 0.13 ∼ 0.38 mm Connecting Rod Big End Side Clearance 0.58 mm (0.0051 ∼...
  • Page 289 CRANKSHAFT/TRANSMISSION 9-7 Specifications Item Standard Service Limit Crankshaft Runout TIR 0.02 mm (0.0008 in.) TIR 0.05 mm or less (0.0020 in.) Crankshaft Main Bearing Insert/Journal Clearance 0.012 ∼ 0.036 mm 0.07 mm (0.0005 ∼ 0.0014 in.) (0.0028 in.) 37.984 ∼ 38.000 mm Crankshaft Main Journal Diameter: 37.96 mm (1.4954 ∼...
  • Page 290 9-8 CRANKSHAFT/TRANSMISSION Specifications Item Standard Service Limit 31.000 ∼ 31.016 mm Crankcase Bearing Bore Diameter: – – – (1.2205 ∼ 1.2228 in.) Marking: ○ 31.000 ∼ 31.008 mm – – – (1.2205 ∼ 1.2208 in.) 31.009 ∼ 31.016 mm None –...
  • Page 291: Special Tools And Sealant

    CRANKSHAFT/TRANSMISSION 9-9 Special Tools and Sealant Outside Circlip Pliers: Bearing Driver Set: 57001-144 57001-1129 Kawasaki Bond: 92104-1064...
  • Page 292: Crankcase Splitting

    9-10 CRANKSHAFT/TRANSMISSION Crankcase Splitting Crankcase Splitting • Remove: Engine (see Engine Removal in the Engine Removal/In- stallation chapter) Cylinder (see Cylinder Removal in the Engine Top End chapter) Pistons (see Piston Removal in the Engine Top End chapter) Stater Motor (see Starter Motor Removal in the Electrical System chapter) Clutch (see Clutch Removal in the Clutch chapter) Transmission Assy (see Transmission Assy Removal)
  • Page 293: Crankcase Splitting

    CRANKSHAFT/TRANSMISSION 9-11 Crankcase Splitting If the oil pie is to be removed, follow the next procedure. ○ Unscrew the bolts [A] and remove the oil pipe [B]. ○ Prepare a 5 mm rod [B], and insert it to the hole of the upper crankcase half.
  • Page 294 9-12 CRANKSHAFT/TRANSMISSION Crankcase Splitting • Press and insert [A] the new needle bearing [B] for the shift drum until it is bottomed. Special Tool - Bearing Driver Set: 57001-1129 • Press and insert [C] the new needle bearing [D] for the shift shaft so that the bearing surface is flush with the end of the hole.
  • Page 295 CRANKSHAFT/TRANSMISSION 9-13 Crankcase Splitting • Install the crankshaft assembly and the balancer shaft as- sembly on the upper crankcase half. ○ Align [A] the timing mark on the balancer gear [B] with the timing mark on the balancer drive gear [C] of the crank- shaft.
  • Page 296 9-14 CRANKSHAFT/TRANSMISSION Crankcase Splitting • Apply liquid gasket [A] to the mating surface of the lower crankcase half. Sealant - Kawasaki Bond: 92104-1064 NOTE ○ Especially, apply a liquid gasket carefully so that it shall be filled up on the grooves.
  • Page 297 CRANKSHAFT/TRANSMISSION 9-15 Crankcase Splitting • Fit the lower crankcase half to the upper crankcase half. ○ Insert [A] the breather pipe [B] on the upper crankcase half through the hole [C] on the lower crankcase half. NOTE ○ Make the application finish within 20 minutes when the liquid gasket to the mating surface of the lower crankcase half is applied.
  • Page 298 9-16 CRANKSHAFT/TRANSMISSION Crankcase Splitting • Tighten the lower crankcase bolts using the following steps. ○ Following the sequence numbers on the lower crankcase half, tighten the M9 bolts [1, 2] L= 113 mm (4.45 in.) with washers. Torque - Crankcase Bolts (M9): 44 N·m (4.5 kgf·m, 32 ft·lb) ○...
  • Page 299: Crankshaft And Connecting Rods

    CRANKSHAFT/TRANSMISSION 9-17 Crankshaft and Connecting Rods Crankshaft Removal • Split the crankcase (see Crankcase Splitting). • Remove the crankshaft [A]. Crankshaft Installation CAUTION If the crankshaft, bearing inserts, or crankcase halves are replaced with new ones, select the bear- ing inserts and check clearance with a plastigage (press gauge) before assembling engine to be sure the correct bearing inserts are installed.
  • Page 300: Connecting Rod Installation

    9-18 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods Connecting Rod Installation CAUTION To minimize vibration, the connecting rods should have the same weight mark. Big End Cap [A] Connecting Rod [B] Weight Mark, Alphabet [C] ○ Diameter Mark [D]: “ ” or no mark CAUTION If the connecting rods, big end bearing inserts, or crankshaft are replaced with new ones, select the...
  • Page 301 CRANKSHAFT/TRANSMISSION 9-19 Crankshaft and Connecting Rods • Install the crankshaft (see Crankshaft Installation). • Install each connecting rod on its original crankpin. NOTE ○ Install each connecting rod so that its oil jet [A] faces the exhaust side (the front [B]) (see Engine Oil Flow Chart in the Engine Lubrication System chapter).
  • Page 302 9-20 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods • Install new bolts in reused connecting rods. • Dent both bolt head and bolt tip with a punch as shown. • Before tightening, use a point micrometer [A] to measure the length of new connecting rod bolts and record the val- ues to find the bolt stretch.
  • Page 303: Crankshaft/connecting Rod Cleaning

    CRANKSHAFT/TRANSMISSION 9-21 Crankshaft and Connecting Rods • Install new bolts in reused connecting rods. • Apply a small amount of molybdenum disulfide oil to the following: Threads [A] of Nuts and Bolts Seating Surfaces [B] of Nuts and Con-rods • First, tighten the nuts to the specified torque.
  • Page 304: Connecting Rod Twist

    9-22 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods Connecting Rod Twist • With the big-end arbor [A] still on V block [C], hold the connecting rod horizontally and measure the amount that the arbor [B] varies from being paralleled with the surface plate over a 100 mm (3.94 in.) length of the arbor to de- termine the amount of connecting rod twist.
  • Page 305 CRANKSHAFT/TRANSMISSION 9-23 Crankshaft and Connecting Rods If any crankpin has worn past the service limit, replace the crankshaft with a new one. If the measured crankpin diameters are not less than the service limit, but do not coincide with the original diameter markings on the crankshaft, make new marks on it.
  • Page 306: Crankshaft Side Clearance

    9-24 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods Crankshaft Side Clearance • Insert a thickness gauge [A] between the crankcase main bearing and the crank web at the No. 2 journal [B] to determine clearance. If the clearance exceeds the service limit, replace the crankcase halves as a set.
  • Page 307 CRANKSHAFT/TRANSMISSION 9-25 Crankshaft and Connecting Rods Crankshaft Main Journal Diameter 37.984 ∼ 38.000 mm (1.4954 ∼ 1.4961 in.) Standard: Service Limit: 37.96 mm (1.4945 in.) If any journal has worn past the service limit, replace the crankshaft with a new one. If the measured journal diameters are not less than the service limit, but do not coincide with the original diameter markings on the crankshaft, make new marks on it.
  • Page 308 9-26 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods • Install the new inserts in the crankcase halves and check insert/journal clearance with the plastigage.
  • Page 309: Balancer

    CRANKSHAFT/TRANSMISSION 9-27 Balancer Balancer Removal • Split the crankcase (see Crankcase Splitting). • Pull the balancer shaft with the balancer gear out of the crankcase. Balancer Installation • Apply molybdenum disulfide oil solution to the inside of the balancer shaft bearing insert. •...
  • Page 310 9-28 CRANKSHAFT/TRANSMISSION Balancer If either journal has worn past the service limit, replace the balancer shaft with a new one. If the measured journal diameters are not less than the service limit, but do not coincide with the original diameter markings on the balancer shaft, write new marks on it.
  • Page 311: Transmission

    CRANKSHAFT/TRANSMISSION 9-29 Transmission Shift Pedal Removal • Remove: Shift Lever Bolt [A] Shift Lever [B] Shift Pedal Installation • Align the mark [A] on the shift shaft with the slit [B] on the shift lever. • Tighten the shift lever bolt securely. •...
  • Page 312: External Shift Mechanism Installation

    9-30 CRANKSHAFT/TRANSMISSION Transmission • Remove: Clutch (see Clutch Removal in the Clutch chapter) Gear Positioning Lever Bolt [A] Gear Positioning Lever [B], Spacer, Washer and Spring External Shift Mechanism Installation • Install the gear positioning lever [A] as shown. Spring [B] Washer [C] Spacer [D] Bolt [E]...
  • Page 313: External Shift Mechanism Inspection

    CRANKSHAFT/TRANSMISSION 9-31 Transmission • When the new needle bearing [A] is installed in the shift shaft cover [B], press and insert the new needle bearing until it is bottomed. Special Tool - Bearing Driver Set: 57001-1129 • When the new oil seal [C] is installed in the shift cover, press and insert the new oil seal so that its surface is flush with the end of the hole.
  • Page 314: Transmission Assy Removal

    9-32 CRANKSHAFT/TRANSMISSION Transmission • Check the gear positioning lever [A] and its spring for breaks or distortion. If the lever or spring are damaged in any way, replace them. • Visually inspect the shift drum cam [B]. If they are badly worn or if they show any damage, replace Transmission Assy Removal •...
  • Page 315: Transmission Assy Disassembly

    CRANKSHAFT/TRANSMISSION 9-33 Transmission Transmission Assy Disassembly • Remove the transmission assy (see Transmission Assy Removal) • Remove the following from the transmission case [A]. Shift Rods [B] Shift Forks [C] Drive Shaft [D] Output Shaft [E] • Remove: Shift Drum Cam Bolt [A] Shift Drum [B] and Pin Shift Drum [C] Transmission Assy Assembly...
  • Page 316: Transmission Assy Installation

    9-34 CRANKSHAFT/TRANSMISSION Transmission • Install the following on the transmission case [A]. Shift Drum [B] Pin [C] Shift Drum Cam [D] ○ Align the pin with the hole on the shift drum cam. • Apply a non-permanent locking agent to the shift drum cam bolt and torque it.
  • Page 317: Transmission Shaft Removal

    CRANKSHAFT/TRANSMISSION 9-35 Transmission • Install the gear positioning lever (see External Shift Mech- anism Installation). • Install the shift rod plate. Torque - Shift Rod Plate Bolt: 9.8 N·m (1.0 kgf·m, 87 in·lb) • Set the gear positioning lever to the neutral position [A]. •...
  • Page 318: Transmission Shaft Disassembly

    9-36 CRANKSHAFT/TRANSMISSION Transmission • Install the transmission assy on the crankcase (see Trans- mission Assy Installation). • Press in the oil seal [A] onto collar [B] so that the surface of the oil seal is flush with the surface [C] of the crankcase. ○...
  • Page 319 CRANKSHAFT/TRANSMISSION 9-37 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 320 9-38 CRANKSHAFT/TRANSMISSION Transmission 1. 1st Gear 16. Collar 2. 2nd Gear 17. Washer 3. 3rd Gear 18. Nut 4. 4th Gear 19. O-ring 5. 5th Gear 20. Bearing 6. 6th (Top) Gear 21. Spacer, 39 mm (1.54 in.) 7. Ball Bearing 22.
  • Page 321: Shift Drum And Fork Removal

    CRANKSHAFT/TRANSMISSION 9-39 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 Transmission Assy Assembly and Installation. Shift Drum Disassembly •...
  • Page 322: Shift Fork Guide Pin/drum Groove Wear

    9-40 CRANKSHAFT/TRANSMISSION Transmission Shift Fork Guide Pin/Drum Groove Wear • Measure the diameter of each shift fork guide pin [A], and measure the width [B] of each shift drum groove. If the guide pin on any shift fork is less than the service limit, the fork must be replaced.
  • Page 323: Ball Bearing, Needle Bearing, And Oil Seal

    CRANKSHAFT/TRANSMISSION 9-41 Ball Bearing, Needle Bearing, and Oil Seal Ball and Needle Bearing Replacement CAUTION Do not remove the ball or needle bearings unless it is necessary. Removal may damage them. • Using a press or puller, remove the ball bearing and/or needle bearings.
  • Page 325 WHEELS/TIRES 10-1 Wheels/Tires Table of Contents Exploded View........................10-2 Specifications ......................... 10-4 Special Tools .......................... 10-5 Wheels (Rims) ........................10-6 Front Wheel Removal ....................... 10-6 Front Wheel Installation ....................10-6 Rear Wheel Removal......................10-8 Rear Wheel Installation..................... 10-8 Wheel Inspection ......................10-10 Axle Inspection........................
  • Page 326: Exploded View

    10-2 WHEELS/TIRES Exploded View...
  • Page 327 WHEELS/TIRES 10-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Axle 11.0 Front Axle Clamp Bolt Rear Axle Nut 11.0 G: Apply grease. HG: Apply high-temperature grease. R: Replacement Parts WL: Apply soap and water solution or rubber lubricant.
  • Page 328: 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 (3.94 in.) TIR 0.03 mm (0.0012 in.) or less TIR 0.2 mm (0.008 in.) Wheel Balance...
  • Page 329: 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, 20 × 22: 57001-1293...
  • Page 330: Wheels (rims)

    10-6 WHEELS/TIRES Wheels (Rims) Front Wheel Removal • Remove: Brake Caliper Mounting Bolts [A] Front Brake Calipers [B] • Loosen: Axle Clamp Bolt [A] • Remove the front axle [B]. • Remove the lower fairing (see Lower Fairing Removal in the Frame chapter).
  • Page 331 WHEELS/TIRES 10-7 Wheels (Rims) • Apply high-temperature grease to the grease seal lips. • Fit the collars [A] on the both sides of the hub. • Insert the front axle, and tighten the axle. Torque - Front Axle: 108 N·m (11.0 kgf·m, 80 ft·lb) •...
  • Page 332: Rear Wheel Removal

    10-8 WHEELS/TIRES Wheels (Rims) Rear Wheel Removal • Raise the rear wheel off the ground with stand [A]. • Remove: Brake Caliper Mounting Bolts [A] Rear Brake Caliper [B] • Remove: Cotter Pin [A] Axle Nut [B] Washer [C] Axle [D] with Washer •...
  • Page 333 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: 108 N·m (11.0 kgf·m, 80 ft·lb) •...
  • Page 334: Wheel Inspection

    10-10 WHEELS/TIRES Wheels (Rims) Wheel Inspection • Raise the front/rear wheel off the ground with jack. Special Tools - Jack: 57001-1238 Jack Attachment: 57001-1608 • Spin the wheel lightly, and check for roughness or binding. If roughness or binding is found, replace the hub bearings. •...
  • Page 335: 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 336 30 g (1.06 oz.) NOTE ○ Balance weights are available from Kawasaki dealers in 10, 20, and 30 grams (0.35, 0.71, and 1.06 oz.) sizes. An imbalance of less than 10 grams (0.35 oz.) will not usually affect running stability.
  • Page 337: Tires

    WHEELS/TIRES 10-13 Tires Air Pressure Inspection/Adjustment • Refer to the Air Pressure Inspection in the Periodic Main- tenance chapter. Tire Inspection • Refer to the Wheel/Tire Damage Inspection in the Peri- odic Maintenance chapter. Tire Removal • Remove: Wheel (see Front/Rear Wheel Removal) Valve Core (Let out the air) •...
  • Page 338 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 339: 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 340: 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 bearings [A]. CAUTION Do not lay the wheel on the ground with the disc facing down.
  • Page 341: 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 343 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 344: Exploded View

    11-2 FINAL DRIVE Exploded View...
  • Page 345 FINAL DRIVE 11-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Engine Sprocket Nut 12.7 Rear Axle Nut 11.0 Rear Sprocket Nuts Speed Sensor Bolt 0.80 69 in·lb Speed Sensor Bracket Bolts 87 in·lb G: Apply grease. HG: Apply high-temperature grease. HO: Apply heavy oil.
  • Page 346: 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 347: Special Tools

    FINAL DRIVE 11-5 Special Tools Inside Circlip Pliers: Bearing Driver Set: 57001-143 57001-1129...
  • Page 348: Drive Chain

    11-6 FINAL DRIVE Drive Chain Drive Chain Slack Inspection • Refer to the Drive Chain Slack Inspection in the Periodic Maintenance chapter. Drive Chain Slack Adjustment • Refer to the Drive Chain Slack Adjustment in the Periodic Maintenance chapter. Wheel Alignment Inspection/Adjustment •...
  • Page 349: Drive Chain Installation

    FINAL DRIVE 11-7 Drive Chain • Screw the pin holder until it touches chain pin. • Be sure that the cutting pin hits center of chain pin. • Screw the handlebar [A] into body. • Turn the pin holder with wrench [B] clockwise to extract chain pin.
  • Page 350 11-8 FINAL DRIVE Drive Chain • Fit the plate holder (a) to link plate. • Turn the pin holder by hand until plate holder (b) touches the other link plate. • Turn the pin holder by wrench clockwise until two pins of link come into groove of plate holder (a).
  • Page 351 FINAL DRIVE 11-9 Drive Chain • After staking, check the staked area of the link pin for cracks. • Measure the outside diameter [A] of the link pin and link plates width [B]. Link Pin Outside Diameter 5.7 ∼ 6.0 mm (0.22 ∼ 0.24 in.) Standard: Link Plates Outside Width 17.25 ∼...
  • Page 352: Sprocket, Coupling

    11-10 FINAL DRIVE Sprocket, Coupling Engine Sprocket Removal • Remove: Engine Sprocket Cover Bolts [A] Engine Sprocket Cover [B] • Remove: Speed Sensor Bracket Bolts [A] Speed Sensor Bracket [B] • Flatten out the bended washer [A]. • Remove the engine sprocket nut [B] and washer. NOTE ○...
  • Page 353: Engine Sprocket Installation

    FINAL DRIVE 11-11 Sprocket, Coupling Engine Sprocket Installation • Replace the sprocket washer and axle cotter pin. • Install the engine sprocket [A] so that “OUTSIDE” letters face outward. • Apply molybdenum disulfide oil solution to the threads of the output shaft and seating surface of the engine sprocket nut.
  • Page 354: Coupling Installation

    11-12 FINAL DRIVE Sprocket, Coupling Coupling Installation • Apply high-temperature grease to the coupling grease seal lips [A]. • Apply grease to the coupling internal surface [B]. • Grease the following. Wheel Flange Portion [A] O-ring [B] • Install the collar [C]. Coupling Bearing Removal •...
  • Page 355: 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 356: Rear Sprocket Warp Inspection

    11-14 FINAL DRIVE Sprocket, Coupling Rear Sprocket Warp Inspection • Raise the rear wheel off the ground with stand so that it will turn freely. • Set a dial gauge [A] against the rear sprocket [B] near the teeth as shown, and rotate [C] the rear wheel to measure the sprocket runout (warp).
  • Page 357 BRAKES 12-1 Brakes Table of Contents Exploded View........12-2 Rear Brake Pad Removal .... 12-14 Specifications ........12-6 Rear Brake Pad Installation ..12-14 Special Tools ........12-7 Brake Pad Wear Inspection ..12-14 Brake Lever, Brake Pedal....12-8 Master Cylinder ......... 12-15 Brake Lever Position Adjustment.
  • Page 358: Exploded View

    12-2 BRAKES Exploded View...
  • Page 359 BRAKES 12-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Bleed Valve 0.80 69 in·lb Brake Hose Banjo Bolts Brake Lever Pivot Bolt 0.10 9 in·lb Brake Lever Pivot Bolt Locknut 0.60 52 in·lb Front Brake Disc Mounting Bolts Front Brake Light Switch Screw 0.10 9 in·lb Front Brake Reservoir Cap Screws...
  • Page 360 12-4 BRAKES Exploded View...
  • Page 361 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 362: Specifications

    12-6 BRAKES Specifications Item Standard Service Limit Brake Lever, Brake Pedal Brake Lever Position 5-way adjustable (to suit rider) – – – Brake Lever Free Play Non-adjustable – – – Pedal Free Play Non-adjustable – – – Pedal Position About 40 mm (1.6 in.) below top of footpeg –...
  • Page 363: Special Tools

    BRAKES 12-7 Special Tools Inside Circlip Pliers: Jack Attachment: 57001-143 57001-1608 Jack: 57001-1238...
  • Page 364: Brake Lever, Brake Pedal

    12-8 BRAKES Brake Lever, Brake Pedal Brake Lever Position Adjustment The brake lever adjuster has 5 positions so that the brake lever position can be adjusted to suit the operator’s hand. • Push the lever forward and turn the adjuster [A] to align the number with the arrow mark [B] on the lever holder.
  • Page 365: Brake Pedal Removal

    BRAKES 12-9 Brake Lever, Brake Pedal Brake Pedal Removal • Remove: Frame Cover (see Frame Cover Removal in the Frame chapter) Bolts [A] Right Footpeg Stay [B] • Remove: Cotter Pin [A] Joint Pin [B] Rear Brake Light Switch Spring [C] Return Spring [D] •...
  • Page 366 12-10 BRAKES Brake Lever, Brake Pedal • Install the right footpeg stay, and tighten the bolts. Torque - Footpeg Stay Bolts: 34 N·m (3.5 kgf·m, 25 ft·lb) ○ Depress the brake pedal [A] and then align the bolts holes of the master cylinder [B]. Torque - Rear Master Cylinder Mounting Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb) •...
  • Page 367: Calipers

    BRAKES 12-11 Calipers Front Caliper Removal • Loosen the banjo bolt [A] at the brake hose lower end, and tighten it loosely. • Unscrew the caliper mounting bolts [B], and detach the caliper [C] from the disc. • Unscrew the banjo bolt and remove the brake hoses [D] from the caliper (see Brake Hose Removal/Installation).
  • Page 368: Front Caliper Disassembly

    12-12 BRAKES Calipers Front Caliper Disassembly • Refer to the Caliper Rubber Parts Replacement in the Pe- riodic Maintenance chapter. Front Caliper Assembly • Refer to the Caliper Rubber Parts Replacement in the Pe- riodic Maintenance chapter. Rear Caliper Disassembly •...
  • Page 369: Caliper Piston And Cylinder Damage

    BRAKES 12-13 Calipers Caliper Piston and Cylinder Damage • Visually inspect the pistons [A] and cylinder surfaces [B]. Replace the caliper if the cylinder and piston are badly scores or rusty. Rear Caliper Holder Shaft Wear The caliper body must slide smoothly on the caliper holder shafts [A].
  • Page 370: Brake Pads

    12-14 BRAKES Brake Pads Front Brake Pad Removal • Remove the front caliper with the hose installed (see Front Caliper Removal). • Draw out the holder shaft pin [A], and take off the holder shaft [B]. • Remove the pad [C] on the piston side. •...
  • Page 371: Master Cylinder

    BRAKES 12-15 Master Cylinder Front Master Cylinder Removal • Remove the banjo bolt [A] to disconnect the brake hose from the master cylinder [B] (see Brake Hose Removal/In- stallation). • Disconnect the front brake light switch connectors [A]. • Unscrew the clamp bolts [B], and take off the master cylin- der as an assembly with the reservoir, brake lever and brake switch installed.
  • Page 372: Rear Master Cylinder Removal

    12-16 BRAKES Master Cylinder Rear Master Cylinder Removal • Unscrew the brake hose banjo bolt [A] on the master cylin- der (see Brake Hose Removal/Installation). • Unscrew the master cylinder mounting bolts [A]. • Remove the cotter pin [B]. NOTE ○...
  • Page 373: Master Cylinder Inspection

    BRAKES 12-17 Master Cylinder Master Cylinder Inspection • Remove the master cylinders (see Front/Rear Master Cylinder Removal). • Disassemble the front and rear master cylinders. • Check that there are no scratches, rust or pitting on the inner wall [A] of each master cylinder and on the outside of each piston [B].
  • Page 374: 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. • Remove the gaskets. Brake Disc Installation • Replace the gaskets with new ones. •...
  • Page 375: 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 376 12-20 BRAKES Brake Fluid • Bleed the brake line and the caliper. ○ Repeat this operation until no more air can be seen com- ing out into the plastic hose. 1. Pump the brake lever until it becomes hard, and apply the brake and hold it [A].
  • Page 377 BRAKES 12-21 Brake Fluid WARNING When working with the disc brake, observe the pre- cautions listed below. 1. Never reuse old brake fluid. 2. Do not use fluid from a container that has been left unsealed or that has been open for a long time. 3.
  • Page 378: Brake Hose

    12-22 BRAKES Brake Hose Brake Hose Removal/Installation • Refer to the Brake Hose and Pipe Replacement in the Periodic Maintenance chapter. Brake Hose Inspection • Refer to the Brake Hose Damage and Installation Condi- tion Inspection in the Periodic Maintenance chapter.
  • Page 379 SUSPENSION 13-1 Suspension Table of Contents Exploded View........................13-2 Specifications ......................... 13-6 Special Tools .......................... 13-7 Front Fork ..........................13-9 Front Fork Removal ......................13-9 Front Fork Installation ....................... 13-9 Front Fork Oil Change ...................... 13-9 Front Fork Disassembly ....................13-11 Front Fork Assembly......................
  • Page 380: Exploded View

    13-2 SUSPENSION Exploded View...
  • Page 381 SUSPENSION 13-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Axle Clamp Bolt Front Fork Bottom Allen Bolts Front Fork Clamp Bolts (Lower) Front Fork Clamp Bolts (Upper) Front Fork Top Plugs AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque. G: Apply grease.
  • Page 382 13-4 SUSPENSION Exploded View...
  • Page 383 SUSPENSION 13-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Rear Shock Absorber Bolt Rear Shock Absorber Nut Swingarm Pivot Shaft Nut 11.0 G: Apply grease. R: Replacement Parts...
  • Page 384: Specifications

    13-6 SUSPENSION Specifications Item Standard Front Fork (Per One Unit) Fork Inner Tube Outside Diameter 41 mm (1.6 in.) Air Pressure Atmospheric pressure (Non-adjustable) Fork Spring Setting Non-adjustable Damper Setting Non-adjustable Fork Oil: Viscosity KAYABA KHL34-G10 or equivalent Amount approx. 390 mL (13.2 US oz.) (when changing oil) 458 ±4 mL (15.5 ±0.14 US oz.) (after disassembly and completely dry) Fork Oil Level...
  • Page 385: Special Tools

    SUSPENSION 13-7 Special Tools Inside Circlip Pliers: Jack: 57001-143 57001-1238 Fork Cylinder Holder Handle: Fork Oil Seal Driver, 41: 57001-183 57001-1288 Fork Cylinder Holder Adapter: Fork Oil Level Gauge: 57001-1057 57001-1290 Oil Seal & Bearing Remover: Jack Attachment: 57001-1058 57001-1608 Bearing Driver Set: Stem Bearing Driver, 28: 57001-1129...
  • Page 386 13-8 SUSPENSION Special Tools Spacer, 57001-1663...
  • Page 387: Front Fork

    SUSPENSION 13-9 Front Fork Front Fork Removal • Remove: Front Wheel (see Front Wheel Removal in the Wheels/Tires chapter) Front Fender (see Front Fender Removal in the Frame chapter) Loosen the upper fork clamp bolt [A] and fork top plug [B] beforehand if the fork leg is to be disassembled.
  • Page 388 13-10 SUSPENSION Front Fork • Compress [A] the fork [B] upside down to draw out the oil into the suitable container [C]. • Pour in the specified amount of oil. Fork Oil Viscosity: KAYABA KHL34-G10 or equivalent Amount (Per Side): When changing oil: approx.
  • Page 389: Front Fork Disassembly

    SUSPENSION 13-11 Front Fork Front Fork Disassembly • Remove the front fork (see Front Fork Removal). • Remove the top plug [A] with O-ring, take out the collar [B], fork spring seat [C], and fork spring [D]. • Drain the fork oil (see Front Fork Oil Change). •...
  • Page 390: Front Fork Assembly

    13-12 SUSPENSION Front Fork • Remove the following from the inner tube. Inner Guide Bushing [A] Outer Guide Bushing [B] Washer [C] Oil Seal [D] • Remove the cylinder base [A] from the bottom of the outer tube. Front Fork Assembly •...
  • Page 391: Inner Tube Inspection

    SUSPENSION 13-13 Front Fork • Apply non-permanent locking agent to the threads of the bottom Allen bolt [A]. • Hold the front fork horizontally in a vise [B]. • Hold the cylinder unit [C] with the special tools and tighten the bottom Allen bolt to secure the cylinder in place.
  • Page 392: Fork Spring Inspection

    13-14 SUSPENSION Front Fork Fork Spring Inspection • Measure the free length [A] of the fork spring [B]. If the measured length is shorter than the service limit, the spring must be replaced. If the free length of the replace- ment spring and that of the remaining spring vary greatly, the remaining spring should also be replaced in order to keep the fork legs balanced to ensure stability.
  • Page 393: Rear Shock Absorber

    SUSPENSION 13-15 Rear Shock Absorber Spring Preload Adjustment • Using the hook wrench [A], turn the adjusting nut [B] to adjust the spring preload. ○ The standard adjuster setting for average-build rider of 68 kg (150 Ib) with no passenger and no accessories is 3rd position.
  • Page 394: Rear Shock Absorber Installation

    13-16 SUSPENSION Rear Shock Absorber • Remove: Upper Shock Absorber Bolt [A] Lower Shock Absorber Nut and Washer Lower Shock Absorber Bolt [B] • Remove the shock absorber [C] from backward. Rear Shock Absorber Installation • Installation is the reverse of removal. •...
  • Page 395: Swingarm

    SUSPENSION 13-17 Swingarm Swingarm Removal • Remove: Chain Cover Bolts [A] and Cover [B] • Remove: Right Side Cover (see Side Cover Removal in the Frame chapter) Frame Covers (see Frame Cover Removal in the Frame chapter) • Remove the brake hose banjo bolt from the rear caliper, free the brake hose [A] from the clamps [B], and remove the footpeg stay with the rear master cylinder (see Rear Caliper Removal in the Brakes chapter).
  • Page 396: Swingarm Bearing Removal

    13-18 SUSPENSION Swingarm Swingarm Bearing Removal • Remove: Swingarm (see Swingarm Removal) Collar [A] Oil Seals [B] Sleeve [C] Circlip [D] Special Tool - Inside Circlip Pliers: 57001-143 • Remove the ball bearing and needle bearings. Special Tool - Oil Seal & Bearing Remover [A]: 57001-1058 Swingarm Bearing Installation •...
  • Page 397: Swingarm Bearing, Sleeve Inspection

    SUSPENSION 13-19 Swingarm • Install the needle bearings [A], ball bearing [B] and oil seals [C] position as shown. Circlip [D] 25 mm (0.98 in.) [E] 17 mm (0.67 in.) [F] 1 mm (0.04 in.) [G] 0.5 mm (0.02 in.) [H] 1 mm (0.04 in.) [I] 23.5 mm (0.93 in.) [J] 6 mm (0.24 in.) [K]...
  • Page 398: Swingarm Bearing Lubrication

    13-20 SUSPENSION Swingarm • Turn the bearing in the swingarm back and forth [A] while checking for plays, roughness, or binding. If the bearing play, roughness, or binding is found, replace the bearing. • Examine the bearing seal [B] for tears or leakage. If the seal is torn or is leaking, replace the bearing.
  • Page 399 STEERING 14-1 Steering Table of Contents Exploded View........................14-2 Special Tools .......................... 14-4 Steering ..........................14-5 Steering Inspection ......................14-5 Steering Adjustment......................14-5 Steering Stem......................... 14-6 Stem, Stem Bearing Removal................... 14-6 Stem, Stem Bearing Installation..................14-7 Stem Bearing Lubrication....................14-8 Steering Stem Warp......................
  • Page 400: Exploded View

    14-2 STEERING Exploded View...
  • Page 401 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 Holder Bolts Left Switch Housing Screws 0.36 31 in·lb Right Switch Housing Screws 0.36 31 in·lb Steering Stem Head Bolt 11.0 Steering Stem Nut AD: Apply adhesive.
  • Page 402: Special Tools

    14-4 STEERING Special Tools Steering Stem Nut Wrench: Steering Stem Bearing Driver, 42.5: 57001-1100 57001-1344 Bearing Driver Set: Steering Stem Bearing Driver Adapter, 41.5: 57001-1129 57001-1345...
  • Page 403: 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 404: Steering Stem

    14-6 STEERING Steering Stem Stem, Stem Bearing Removal • Remove: Front Wheel (see Front Wheel Removal in the Wheels/Tires chapter) Headlight Assy (see Headlight Removal/Installation in the Electrical System chapter) Handlebar (see Handlebar Removal) Steering Stem Head Bolt Plug [A] Steering Stem Head Bolt [B] and Washer Front Fork Clamp Bolts (Upper) [C] (Loosen) Steering Stem Head [D]...
  • Page 405: Stem, Stem Bearing Installation

    STEERING 14-7 Steering Stem • Remove the lower bearing inner race [A] which is pressed onto the steering stem with a suitable commercially avail- able chisel [B]. Stem, Stem Bearing Installation • Replace the bearing outer races with new ones. •...
  • Page 406: Stem Bearing Lubrication

    14-8 STEERING Steering Stem • Settle the inner races in place as follows. ○ Tighten the steering stem nut with 39 N·m (4.0 kgf·m, 29 ft·lb) of torque first, and loosen it a fraction of a turn until it turns lightly. Afterward tighten it again with specified torque using a stem nut wrench [A] in the direction shown.
  • Page 407: Steering Stem Warp

    STEERING 14-9 Steering Stem Steering Stem Warp • Whenever the steering stem is removed, or if the steering cannot be adjusted for smooth action, check the steering stem for straightness. If the steering stem [A] is bent, replace the steering stem. Stem Cap Deterioration, Damage Replace the stem cap if its oil seal [A] shows damage.
  • Page 408: Handlebar

    14-10 STEERING Handlebar Handlebar Removal • Remove: Clutch Lever Assembly [A] Left Switch Housing [B] Left Handlebar Weight [C] • Remove: Front Brake Master Cylinder [A] (see Front Master Cylin- der Removal in the Brakes chapter) Right Switch Housing [B] Right Handlebar Weight [C] Throttle Grip [D] •...
  • Page 409 STEERING 14-11 Handlebar • Install the clutch lever (see Clutch Lever Installation in the Clutch chapter). • Apply adhesive cement to the inside of the left handlebar grip. • Apply a non-permanent locking agent to the left handlebar weight bolt. •...
  • Page 411 FRAME 15-1 Frame Table of Contents Exploded View........................15-2 Seat ............................15-8 Seat Removal ........................15-8 Seat Installation ........................ 15-8 Fairings........................... 15-9 Lower Fairing Removal ..................... 15-9 Lower Fairing Installation ....................15-9 Center Fairing Removal ....................15-9 Center Fairing Installation ....................15-9 Upper Fairing Removal .....................
  • Page 412: Exploded View

    15-2 FRAME Exploded View...
  • Page 413 FRAME 15-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Footpeg Stay Bolts Sidestand Bolt Sidestand Switch Bolt 0.90 78 in·lb G: Apply grease. L: Apply a non-permanent locking agent. R: Replacement Parts...
  • Page 414 15-4 FRAME Exploded View...
  • Page 415 FRAME 15-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Fender Bolts 0.40 35 in·lb Front Fender Bracket Bolts 0.90 78 in·lb L: Apply a non-permanent locking agent.
  • Page 416 15-6 FRAME Exploded View...
  • Page 417 FRAME 15-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Grab Rail Mounting Bolts Lower Fairing Mounting Bolts 0.90 78 in·lb...
  • Page 418: Seat

    15-8 FRAME Seat Seat Removal • Insert the ignition switch key [A] into the seat lock, turning the key clockwise, pulling up on the rear of the seat [B], and pulling the seat backward. Seat Installation • Slip the seat hook [A] under the brace [B] on the fuel tank bracket.
  • Page 419: Fairings

    FRAME 15-9 Fairings Lower Fairing Removal • Remove the mounting bolts [A] and lower fairing [B]. Lower Fairing Installation • Install the lower fairing, and tighten the mounting bolts. Torque - Lower Fairing, Mounting Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb) Center Fairing Removal •...
  • Page 420: Upper Fairing Removal

    15-10 FRAME Fairings • Connect the turn signal lead connector. • Insert the projections [A] into the holes [B]. • Install the mounting bolts. Upper Fairing Removal • Remove: Headlight Assy (see Headlight Removal/Installation in the Electrical System chapter) Mounting Bolts [A] Upper Fairings Upper Fairing Installation •...
  • Page 421: Inner Fairing Removal

    FRAME 15-11 Fairings Inner Fairing Removal • Remove: Center Fairings (see Center Fairing Removal) Mounting Screws [A] Inner Fairing [B] Inner Fairing Installation • Tighten the mounting screws. • Install the center fairings (see Center Fairing Installation).
  • Page 422: Side Covers

    15-12 FRAME Side Covers Side Cover Removal • Remove the seat (see Seat Removal). • Remove the bolt [A]. • Pull the side cover [B] evenly outward to clear the stop- pers. Side Cover Installation • Insert the tabs [A] into the holes [B]. •...
  • Page 423: Seat Covers

    FRAME 15-13 Seat Covers Seat Cover Removal • Remove: Seat (see Seat Removal) Bolts [A] Grab Rails [B] Screw Rivets [C] • Push the central pin, and then remove the quick rivets [A]. • Pull the front and rear portions of the seat cover outside, and then remove the seat covers.
  • Page 424: Fenders

    15-14 FRAME Fenders Front Fender Removal • Remove: Brake Hose Clamps [A] Bolts [B] with Collar (Both Side) • Remove the front fender [C]. Front Fender Installation • Tighten: Torque - Front Fender Bolts: 3.9 N·m (0.40 kgf·m, 35 in·lb) •...
  • Page 425: Rear Fender Front Removal

    FRAME 15-15 Fenders Rear Fender Front Removal • Remove: Rear Fender Rear (see Flap and Rear Fender Rear Re- moval) Battery (see Battery Removal in the Electrical System chapter) Relay Box (see Relay Box Removal in the Electrical Sys- tem chapter) Starter Relay (see Starter Relay Inspection in the Elec- trical System chapter) •...
  • Page 426: Frame Inspection

    15-16 FRAME Frame Frame Inspection • Visually inspect the frame for cracks, dents, bending or warp. ○ If there is any damage to the frame, replace it. WARNING A repaired frame may fail in use, possibly causing an accident. If the frame is bent, dented, cracked, or warped, replace it.
  • Page 427: Sidestand

    FRAME 15-17 Sidestand Sidestand Removal • Raise the rear wheel off the ground with stand. • Remove: Frame Cover (see Frame Cover Removal) Bolts [A] Footpeg Stay [B] • Remove: Sidestand Switch Bolt [A] with Clamp Sidestand Switch [B] • Remove: Spring [A] Sidestand Nut [B]...
  • Page 428: Frame Cover

    15-18 FRAME Frame Cover Frame Cover Removal • Remove the bolt [A]. • Pull the frame cover [B] outward to clear the stoppers. Frame Cover Installation • Insert the projections [A] into the holes [B]. • Tighten the bolt.
  • Page 429: Rear View Mirrors

    FRAME 15-19 Rear View Mirrors Rear View Mirrors Removal • Loosen the lower hexagonal area [A] for tightening to re- move the rear view mirror from the holder. CAUTION Do not force to tighten and/or loosen the upper hexagonal area (adapter) [B] with a pair of span- ners.
  • Page 431 ELECTRICAL SYSTEM 16-1 Electrical System Table of Contents Exploded View........................16-3 Specifications ......................... 16-10 Special Tools and Sealants ....................16-11 Parts Location......................... 16-12 Wiring Diagram........................16-14 Precautions..........................16-16 Electrical Wiring........................16-18 Wiring Inspection ......................16-18 Battery ............................ 16-19 Battery Removal ....................... 16-19 Battery Installation ......................
  • Page 432 16-2 ELECTRICAL SYSTEM IC Igniter Inspection ......................16-40 Electric Starter System ......................16-43 Starter Motor Removal...................... 16-43 Starter Motor Installation....................16-43 Starter Motor Disassembly....................16-43 Starter Motor Assembly ....................16-44 Brush Inspection ....................... 16-45 Commutator Cleaning and Inspection................16-45 Armature Inspection......................16-45 Brush Lead Inspection ......................
  • Page 433: Exploded View

    ELECTRICAL SYSTEM 16-3 Exploded View Dummy Page...
  • Page 434 16-4 ELECTRICAL SYSTEM Exploded View...
  • Page 435 ELECTRICAL SYSTEM 16-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb License Plate Light Cover Screws 0.90 0.090 8 in·lb License Plate Light Mounting Screws 0.12 11 in·lb Meter Screws 0.12 11 in·lb...
  • Page 436 16-6 ELECTRICAL SYSTEM Exploded View...
  • Page 437 ELECTRICAL SYSTEM 16-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Brake Light Switch Screw 0.12 11 in·lb Left Switch Housing Screws 0.36 31 in·lb Right Switch Housing Screws 0.36 31 in·lb Starter Motor Cable Terminal Nut 0.60 53 in·lb Starter Motor Mounting Bolts 87 in·lb Starter Motor Terminal Locknut...
  • Page 438 16-8 ELECTRICAL SYSTEM Exploded View...
  • Page 439 ELECTRICAL SYSTEM 16-9 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Alternator Cover Bolts 87 in·lb Alternator Lead Holding Plate Bolt 87 in·lb Alternator Rotor Bolt 15.8 Crankshaft Sensor Bolts 0.60 53 in·lb Neutral Switch Oil Pressure Switch Oxygen Sensor 44.1 4.50 32.5...
  • Page 440: Specifications

    16-10 ELECTRICAL SYSTEM Specifications Item Standard Battery Type Sealed Battery Model Name YTX12-BS Capacity 12 V 10 Ah Voltage 12.8 V or more Charging System Type Three-phase AC Alternator Output Voltage 42 V or more at 4 000 r/min (rpm) 0.18 ∼...
  • Page 441: Special Tools And Sealants

    Flywheel Puller Assembly, M38 × 1.5/M35 × 1.5: Flywheel & Pulley Holder: 57001-1405 57001-1605 Peak Voltage Adapter: Rotor Holder: 57001-1415 57001-1658 Lead Wire - Peak Voltage Adapter: Kawasaki Bond (Silicone Sealant): 57001-1449 56019-120 Needle Adapter Set: Kawasaki Bond (Silicone Sealant): 57001-1457 92104-0004...
  • Page 442: Parts Location

    16-12 ELECTRICAL SYSTEM Parts Location 1. Air Switching Valve 13. Rear Brake Light Switch 2. Alternator 14. Regulator/Rectifier 3. Battery 12 V 10 Ah 15. Relay Box 4. Crankshaft Sensor 16. Sidestand Switch 5. ECU (Electric Control Unit) 17. Speed Sensor 6.
  • Page 443 ELECTRICAL SYSTEM 16-13 Parts Location Dummy Page...
  • Page 444: Wiring Diagram

    16-14 ELECTRICAL SYSTEM Wiring Diagram...
  • Page 445 ELECTRICAL SYSTEM 16-15 Wiring Diagram...
  • Page 446: Precautions

    16-16 ELECTRICAL SYSTEM Precautions There are a number of important precautions that are musts when servicing electrical systems. Learn and ob- serve all the rules below. ○ Do not reverse the battery cable connections. This will burn out the diodes on the electrical parts. ○...
  • Page 447 ELECTRICAL SYSTEM 16-17 Precautions Male Connectors [B]...
  • Page 448: Electrical Wiring

    16-18 ELECTRICAL SYSTEM Electrical Wiring Wiring Inspection • Visually inspect the wiring for signs of burning, fraying, etc. If any wiring is poor, replace the damaged wiring. • Pull each connector [A] apart and inspect it for corrosion, dirt, and damage. If the connector is corroded or dirty, clean it carefully.
  • Page 449: Battery

    ELECTRICAL SYSTEM 16-19 Battery Battery Removal • Remove: Seat (see Seat Removal in the Frame chapter) • Disconnect the negative (–) cable [A]. • Slide out the positive (+) terminal cap [B] and then discon- nect the positive (+) cable. CAUTION Be sure to disconnect the negative (–) cable first.
  • Page 450 16-20 ELECTRICAL SYSTEM Battery • Remove the electrolyte container from the vinyl bag. • Detach the strip of caps [A] from the container and set aside, these will be used later to seal the battery. NOTE ○ Do not pierce or otherwise open the sealed cells [B] of the electrolyte container.
  • Page 451 Newly activated sealed batteries require an initial charge. Standard Charge: 1.2 A × 5 ∼ 10 hours If using a recommended battery charger, follow the charger’s instructions for newly activated sealed battery. Kawasaki-recommended chargers Optimate III Yuasa 1.5 Amp Automatic Charger Battery Mate 150-9 If the above chargers are not available, use equivalent one.
  • Page 452: Precautions

    16-22 ELECTRICAL SYSTEM Battery Precautions 1) No need of topping-up No topping-up is necessary in this battery until it ends its life under normal use. Forcibly prying off the seal cap to add water is very dangerous. Never do that. 2) Refreshing charge.
  • Page 453: Charging Condition Inspection

    ELECTRICAL SYSTEM 16-23 Battery Charging Condition Inspection ○ Battery charging condition can be checked by measuring battery terminal voltage with a digital voltmeter [A]. • Remove: Seat (see Seat Removal in the Frame chapter) Battery Cable Cap (see Battery Removal) •...
  • Page 454 16-24 ELECTRICAL SYSTEM Battery Terminal Voltage: 11.5 ∼ less than 12.8 V Standard Charge 1.2 A × 5 ∼ 10 h (see following chart) Quick Charge 5 A × 1 h CAUTION If possible, do not quick charge. If quick charge is done unavoidably, do standard charge later on.
  • Page 455: 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 456: 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 • Install the alternator cover (see Alternator Cover Installa- tion).
  • Page 457 ELECTRICAL SYSTEM 16-27 Charging System • Install the starter gear [A] and washer [B]. • Again, clean the crankshaft tapered portion [C] and dry there. • Install the alternator rotor [A] while turning [B] it counter- clockwise. • Install the washer [A]. NOTE ○...
  • Page 458: Alternator Inspection

    16-28 ELECTRICAL SYSTEM Charging System • Apply a thin coat of molybdenum disulfide grease to the shafts [A], and install them. • Install the torque limiter [B] and starter idle gear [C]. • Install the alternator cover (see Alternator Cover Installa- tion).
  • Page 459: Regulator/rectifier Inspection

    ELECTRICAL SYSTEM 16-29 Charging System If there is more resistance than shown in the table, or no hand tester reading (infinity) for any two leads, the stator has an open lead and must be replaced. Much less than this resistance means the stator is shorted, and must be replaced.
  • Page 460 16-30 ELECTRICAL SYSTEM Charging System Regulator Circuit Check To test the regulator out of circuit, use three 12 V batteries and a test light (12 V 3 ∼ 6 W bulb in a socket with leads). CAUTION The test light works as an indicator and also a cur- rent limiter to protect the regulator/rectifier from ex- cessive current.
  • Page 461: Charging Voltage Inspection

    ELECTRICAL SYSTEM 16-31 Charging System Charging Voltage Inspection • Check the battery condition (see Charging Condition In- spection). • Warm up the engine to obtain actual alternator operating conditions. • Remove the seat (see Seat Removal in the Frame chap- ter).
  • Page 462 16-32 ELECTRICAL SYSTEM Charging System Charging System Circuit 1. Ignition Switch 2. Alternator 3. Regulator/Rectifier 4. Water-proof Joint C 5. Main Fuse 30 A 6. Battery 12 V 10 Ah 7. Load...
  • Page 463: Starter Motor Clutch

    ELECTRICAL SYSTEM 16-33 Starter Motor Clutch Starter Motor Clutch Removal/Installation • Refer to the Alternator Rotor Removal/Installation. Starter Motor Clutch Inspection • Remove: Alternator Cover (see Alternator Cover Removal) Starter Idle Gear and Torque Limiter Shafts • Turn the starter motor clutch gear [A] by hand. The starter motor clutch gear should turn clockwise [B] freely, but should not turn counterclockwise [C].
  • Page 464: Ignition System

    16-34 ELECTRICAL SYSTEM Ignition System WARNING The ignition system produces extremely high volt- age. Do not touch the spark plugs or stick coils while the engine is running, or you could receive a severe electrical shock. CAUTION Do not disconnect the battery cables or any other electrical connections when the ignition switch is on, or while the engine is running.
  • Page 465: Crankshaft Sensor Installation

    Torque - Crankshaft Sensor Bolts: 6.0 N·m (0.60 kgf·m, 53 in·lb) • Apply silicone sealant [A] to the crankshaft sensor lead grommet. Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004 • Install the removed parts (see appropriate chapters). Crankshaft Sensor Inspection •...
  • Page 466: Timing Rotor Removal

    16-36 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: 1.9 V or more Special Tools - Hand Tester: 57001-1394...
  • Page 467: Stick Coil (ignition Coil Together With Spark Plug Cap) Inspection

    ELECTRICAL SYSTEM 16-37 Ignition System Stick Coil (Ignition Coil together with Spark Plug Cap) Inspection • Remove the stick coils (see Stick Coil (Ignition Coil to- gether with Spark Plug Cap) Removal). • Measure the primary winding resistance [A] as follows. ○...
  • Page 468: Spark Plug Removal

    16-38 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 469: Interlock Operation Inspection

    ELECTRICAL SYSTEM 16-39 Ignition System Interlock Operation Inspection • Raise the rear wheel off the ground with stand. 1st Check • Start the engine to the following conditions. Condition Transmission Gear → 1st Position Clutch Lever → Release Sidestand → Down or Up ○...
  • Page 470: Ic Igniter Inspection

    16-40 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 471 ELECTRICAL SYSTEM 16-41 Ignition System...
  • Page 472 16-42 ELECTRICAL SYSTEM Ignition System Ignition System Circuit 1. Ignition Switch 12. Water Temperature Sensor 22. Ignition Fuse 10 A 2. Engine Stop Switch 13. Neutral Switch 23. Fuse Box 3. Spark Plugs 14. Crankshaft Sensor 24. ECU Main Relay 4.
  • Page 473: Electric Starter System

    ELECTRICAL SYSTEM 16-43 Electric Starter System Starter Motor Removal CAUTION Do not tap the starter motor shaft or body. Tapping the shaft or body could damage the motor. • Remove the fuel tank (see Fuel Tank Removal in the Fuel System (DFI) chapter).
  • Page 474: Starter Motor Assembly

    16-44 ELECTRICAL SYSTEM Electric Starter System • Remove: Terminal Locknut and Washers O-ring • Remove the brush plate assy [A] from the yoke [B]. • Remove the brush plate [A] from the plate cover [B]. NOTE ○ Do not remove the negative carbon brushes form the brush plate.
  • Page 475: Brush Inspection

    ELECTRICAL SYSTEM 16-45 Electric Starter System • Align the lines [A] on the yoke with the end cover lines [B]. • Tighten the through bolts. Torque - Starter Motor Through Bolts: 4.9 N·m (0.50 kgf·m, 43 in·lb) Brush Inspection • Measure the length of each brush [A].
  • Page 476: Brush Lead Inspection

    16-46 ELECTRICAL SYSTEM Electric Starter System NOTE ○ Even if the foregoing checks show the armature to be good, it may be defective in some manner not readily detectable with the hand tester. If all other starter motor and starter motor circuit components check good, but the starter motor still does not turn over or only turns over weakly, replace the starter motor with a new one.
  • Page 477 ELECTRICAL SYSTEM 16-47 Electric Starter System • Disconnect the connector [A]. • Disconnect the starter motor cable [B] and battery positive (+) cable [C] from the starter relay [D]. CAUTION The battery positive (+) cable with the rubber cap is connected directly to the battery positive (+) termi- nal even when the ignition switch off, so take care not to short the removed cable to chassis ground.
  • Page 478 16-48 ELECTRICAL SYSTEM Electric Starter System Electric Starter Circuit 1. Ignition Switch 2. Water-proof Joint B 3. Starter Lockout Switch 4. Ignition Fuse 10 A 5. Fuse Box 6. Starter Circuit Relay 7. Relay Box 8. Starter Motor 9. Starter Relay 10.
  • Page 479: Lighting System

    ELECTRICAL SYSTEM 16-49 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 480: City Light Bulb Replacement

    16-50 ELECTRICAL SYSTEM Lighting System • Fit the dust cover [A] with the “Top” mark upward onto the bulb [B] firmly as shown. Good [C] Bad [D] Top Mark [E] • After installation, adjust the headlight aim (see Headlight Aiming Inspection in the Periodic Maintenance chapter). City Light Bulb Replacement •...
  • Page 481: Headlight Removal/installation

    ELECTRICAL SYSTEM 16-51 Lighting System Headlight Removal/Installation • Remove: Mounting Bolts [A] • Disconnect the headlight connectors [A] and city light con- nector [B]. • Remove the headlight assy. • Remove the upper fairings (see Upper Fairing Removal in the Frame chapter). •...
  • Page 482: License Plate Light Bulb Replacement

    16-52 ELECTRICAL SYSTEM Lighting System License Plate Light Bulb Replacement • Remove: Screws [A] License Plate Light Cover [B] • Push and turn the bulb 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 483: Turn Signal Light Bulb Replacement

    ELECTRICAL SYSTEM 16-53 Lighting System Headlight/Tail Light Circuit 12. Main Fuse 30 A 1. Ignition Switch 2. Water-proof Joint A 13. Battery 12 V 10 Ah 3. Water-proof Joint B 14. Frame Ground 4. Position Light 15. Tail/Brake Light 5. Headlight (High Beam) 16.
  • Page 484: Turn Signal Relay Inspection

    16-54 ELECTRICAL SYSTEM Lighting System • Push and turn the bulb [A] counterclockwise and remove • Insert the new bulb [A] by aligning its upper and lower pins [B] with the upper and lower grooves [C] in the socket, and turn the bulb clockwise.
  • Page 485 ELECTRICAL SYSTEM 16-55 Lighting System Turn Signal Light Circuit 1. Meter Unit 2. Water-proof Joint A 3. Water-proof Joint B 4. Front Right Turn Signal Light 5. Front Left Turn Signal Light 6. Turn Signal Relay 7. Hazard Button 8. Turn Signal Switch 9.
  • Page 486: Air Switching Valve

    16-56 ELECTRICAL SYSTEM Air Switching Valve Air Switching Valve Operation Test • Remove the fuel tank (see Fuel Tank Removal in the Fuel System (DFI) chapter). • Pull the air switching valve hose [A] out of the air cleaner base. •...
  • Page 487 ELECTRICAL SYSTEM 16-57 Air Switching Valve • Blow the air to the inlet air duct [A], and make sure does not flow the blown air from the outlet air duct [B]. • Disconnect the 12 V battery. • Blow the air to the inlet air duct [A], and make sure does not flow the blown air from the outlet air duct [B].
  • Page 488: Radiator Fan System

    16-58 ELECTRICAL SYSTEM Radiator Fan System Fan Motor Inspection • Disconnect the connector [A]. • Using an auxiliary leads, supply battery power to the fan motor. If the fan does not rotate, the fan motor is defective and must be replaced. Radiator Fan Circuit 1.
  • Page 489: Meter, Gauge, Indicator Unit

    ELECTRICAL SYSTEM 16-59 Meter, Gauge, Indicator Unit Meter Unit Removal • Remove: Headlight Assy (see Headlight Removal/Installation) Screws [A] and Cover [B] • Slide the dust cover [A] and remove the connector [B]. • Remove the meter unit by taking off the mounting screws [C] with the washers.
  • Page 490: Electronic Combination Meter Unit Inspection

    16-60 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit Electronic Combination Meter Unit Inspection • Remove the meter unit [A] (see Meter Unit Removal). [1] Battery (+) [2] Ignition [3] Ground (–) [4] Unused [5] Speed Sensor Signal [6] Tachometer Signal [7] Water Temperature Sensor (–) [8] Oil Pressure Warning Indicator Light (LED) (–) [9] Fuel Level Warning Indicator Light (LED) (–) [10] Speed Sensor Supply Voltage...
  • Page 491 ELECTRICAL SYSTEM 16-61 Meter, Gauge, Indicator Unit ○ When the terminals are connected, all the LCD segments [A] and LED warning lights [B] appear (FI warning light appear for two seconds). If the LCD segments and LED warning lights will not ap- pear, replace the meter assembly.
  • Page 492 16-62 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit • In the HOUR/MINUTE setting mode, press the RESET button again to effect the HOUR setting mode. ○ The hour display flashes on the display. • Press the MODE button to set the hour. •...
  • Page 493 ELECTRICAL SYSTEM 16-63 Meter, Gauge, Indicator Unit • If the oscillator is not available, the speedometer can be checked as follows. ○ Install the meter unit. ○ Raise the rear wheel off the ground with stand. ○ Turn on the ignition switch. ○...
  • Page 494 16-64 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit • If the oscillator is not available, the tachometer can be checked as follows. ○ Connect the 12 V battery and terminals in the same man- ner as specified in the “Liquid Crystal Display (LCD) Seg- ments Check”.
  • Page 495 ELECTRICAL SYSTEM 16-65 Meter, Gauge, Indicator Unit Fuel Level Warning Indictor Light (LED) Battery Negative (–) Terminal to Terminal [9] High Beam Indicator Light (LED) Battery Positive (+) Terminal to Terminal [11] Neutral Indicator Light (LED) Battery Negative (–) Terminal to Terminal [12] Right and Left Turn Signal Indicator Light (LED) For Right Turn Signal Indicator Light (LED) Battery Positive (+) Terminal to Terminal [14]...
  • Page 496 16-66 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit Meter Circuit 1. Ignition Switch 2. Frame Ground 3. Meter Unit 4. Water-proof Joint B 5. ECU Fuse 15 A 6. Ignition Fuse 10 A 7. Fuse Box 8. Main Fuse 30 A 9.
  • Page 497: Switches And Sensors

    ELECTRICAL SYSTEM 16-67 Switches and Sensors Brake Light Timing Inspection • Refer to the Brake Light Switch Operation Inspection in the Periodic Maintenance chapter. Brake Light Timing Adjustment • Refer to the Brake Light Switch Operation Inspection in the Periodic Maintenance chapter. Switch Inspection •...
  • Page 498: Water Temperature Sensor Inspection

    16-68 ELECTRICAL SYSTEM Switches and Sensors Water Temperature Sensor Inspection • Remove the water temperature sensor (see Removal/In- stallation in the Fuel System (DFI) chapter). • Suspend the sensor [A] in a container of coolant so that the temperature-sensing projection [C] and threaded por- tion [C] are submerged.
  • Page 499: Speed Sensor Inspection

    ELECTRICAL SYSTEM 16-69 Switches and Sensors Speed Sensor Inspection • Remove the speed sensor (see Speed Sensor Removal). • Connect the speed sensor connector [A] with the battery [B], 10 kΩ resistor [C] and hand tester [D] as shown. • Set the tester to the DC 25 V range.
  • Page 500: Oxygen Sensor Inspection (europe Models)

    16-70 ELECTRICAL SYSTEM Switches and Sensors Oxygen Sensor Inspection (Europe Models) • Refer to the Oxygen Sensor Inspection in the Fuel System (DFI) chapter. Fuel Reserve Switch Inspection • Fill the fuel tank with fuel. • Close the fuel tank cap surely. •...
  • Page 501: Relay Box

    ELECTRICAL SYSTEM 16-71 Relay Box The relay box [A] has relays and diodes. The relays and diodes can not be removed. Relay Box Removal • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) • Take out the relay box [A] and disconnect the connectors [B].
  • Page 502: Diode Circuit Inspection

    16-72 ELECTRICAL SYSTEM Relay Box Relay Circuit Inspection (with the battery connected) Battery Tester Tester Connection Connection Reading (Ω) (–) 2-11 ECU Main Relay Fuel Pump Relay 9-10 Fan Relay 18-19 17-20 Battery Tester Tester Connection Connection DC 25 V Range Reading (V) (–) Starter...
  • Page 503 ELECTRICAL SYSTEM 16-73 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 504: Fuse

    16-74 ELECTRICAL SYSTEM Fuse 30 A Main Fuse Removal • Remove: Left Side Cover (see Side Cover Removal in the Frame chapter) Cover (see Starter Relay Inspection) Connector [A] • Pull out the main fuse [B] from the starter relay with needle nose pliers.
  • Page 505: Fuse Installation

    ELECTRICAL SYSTEM 16-75 Fuse 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. • Install the fuse box fuses on the original position as spec- ified on the lid.
  • Page 507 APPENDIX 17-1 Appendix Table of Contents Cable, Wire, and Hose Routing ....................17-2 Troubleshooting Guide ......................17-26...
  • Page 508 17-2 APPENDIX Cable, Wire, and Hose Routing...
  • Page 509 APPENDIX 17-3 Cable, Wire, and Hose Routing 1. Clamp (From the on sequentially, through the left switch housing lead, ignition switch lead and main harness.) 2. Left Switch Housing Lead Connector 3. Clamp (Insert the clamp from air cleaner side.) 4.
  • Page 510 17-4 APPENDIX Cable, Wire, and Hose Routing...
  • Page 511 APPENDIX 17-5 Cable, Wire, and Hose Routing 1. Relay Box 2. Main Harness 3. Clamp (Insert the clamp in the bracket.) 4. Battery Negative Cable 5. Battery Positive Cable 6. ECU Connectors 7. Clamp 8. Clamp 9. Tail Light Connector 10.
  • Page 512 17-6 APPENDIX Cable, Wire, and Hose Routing...
  • Page 513 APPENDIX 17-7 Cable, Wire, and Hose Routing 1. Inlet Pressure Sensor 2. Turn Signal Relay 3. Clamp (Insert the clamp in the frame.) 4. Horn Lead 5. To the Water Temperature Sensor 6. Oxygen Sensor Lead Connector 7. Clamp (Through the sidestand switch lead and oxygen sensor lead in the clamp.) 8.
  • Page 514 17-8 APPENDIX Cable, Wire, and Hose Routing...
  • Page 515 APPENDIX 17-9 Cable, Wire, and Hose Routing 1. Radiator Fan Connector 2. Clamp (Through the main harness and radiator fan lead, and insert the clamp in the frame.) 3. Through the horn lead between water pipe and frame. 4. To Front Left Turn Signal Light 5.
  • Page 516 17-10 APPENDIX Cable, Wire, and Hose Routing...
  • Page 517 APPENDIX 17-11 Cable, Wire, and Hose Routing 1. Clamp (Through the right switch housing lead, and insert the clamp in the frame.) 2. Clutch Cable 3. Throttle Cables 4. Clamp 5. Right Switch Housing Lead 6. Clamp (Insert the clamp in the bracket.) 7.
  • Page 518 17-12 APPENDIX Cable, Wire, and Hose Routing...
  • Page 519 APPENDIX 17-13 Cable, Wire, and Hose Routing 1. Crankshaft Sensor Lead Connector 2. Clamp (Insert the clamp in the bracket.)
  • Page 520 17-14 APPENDIX Cable, Wire, and Hose Routing...
  • Page 521 APPENDIX 17-15 Cable, Wire, and Hose Routing 1. Tail Light Connector 2. License Plate Light Connector 3. Rear Right Turn Signal Light Connector 4. Rear Left Turn Signal Light Connector 5. Clamp (Insert the clamp in the rear fender rear.) 6.
  • Page 522 17-16 APPENDIX Cable, Wire, and Hose Routing...
  • Page 523 APPENDIX 17-17 Cable, Wire, and Hose Routing 1. Right Switch Housing Lead 2. Throttle Cables 3. Headlight (LO) Connector 4. Headlight (HI) Connector 5. Brake Hose 6. Clamp 7. Ignition Switch Lead 8. Main Harness 9. Left Switch Housing Lead 10.
  • Page 524 17-18 APPENDIX Cable, Wire, and Hose Routing...
  • Page 525 APPENDIX 17-19 Cable, Wire, and Hose Routing 1. Clamp 2. Clamp 3. Clamp 4. Clamp (Clamp the main harness, subthrottle sensor lead and subthrottle valve actuator lead to the delivery pipe.) 5. Ground Lead 6. Clamp 7. Subthrottle Sensor Lead Connector 8.
  • Page 526 17-20 APPENDIX Cable, Wire, and Hose Routing...
  • Page 527 APPENDIX 17-21 Cable, Wire, and Hose Routing 1. Regulator/Rectifier Lead 2. Clamp (Insert the clamp in the frame.) 3. Rear Brake Light Switch Lead Connector 4. Through the rear brake light switch lead and vehicle-down sensor lead from the front side of the rear shockabsorber installation part.
  • Page 528 17-22 APPENDIX Cable, Wire, and Hose Routing...
  • Page 529 APPENDIX 17-23 Cable, Wire, and Hose Routing 1. Clamp (Insert the clamp in the front fender.) 2. Brake Hose 3. Clamp...
  • Page 530 17-24 APPENDIX Cable, Wire, and Hose Routing...
  • Page 531 APPENDIX 17-25 Cable, Wire, and Hose Routing 1. Brake Hose 2. Clamp 3. Clamp...
  • Page 532: Troubleshooting Guide

    17-26 APPENDIX Troubleshooting Guide NOTE Spark plug dirty, broken, or gap malad- ○ Refer to the Fuel System chapter for most justed of DFI trouble shooting guide. Stick coil shorted or not in good contact ○ This is not an exhaustive list, giving every Stick coil trouble possible cause for each problem listed.
  • Page 533 APPENDIX 17-27 Troubleshooting Guide Compression low: Cylinder head gasket damaged Spark plug loose Cylinder head warped Cylinder head not sufficiently tightened Valve spring broken or weak down Valve not seating properly (valve bent, No valve clearance worn, or carbon accumulation on the Cylinder, piston worn seating surface) Piston ring bad (worn, weak, broken, or...
  • Page 534: Gear Shifting Faulty

    17-28 APPENDIX Troubleshooting Guide Gear Shifting Faulty: Engine oil viscosity too high Drive train trouble Doesn’t go into gear; shift pedal doesn’t Brake dragging return: Lubrication inadequate: Clutch not disengaging Engine oil level too low Shift fork bent or seized Engine oil poor quality or incorrect Gear stuck on the shaft Gauge incorrect:...
  • Page 535: Exhaust Smokes Excessively

    APPENDIX 17-29 Troubleshooting Guide Engine mount loose O-ring at the oil passage in the crankcase Crankshaft bearing worn damaged Primary gear worn or chipped Exhaust Smokes Excessively: Camshaft chain tensioner trouble Camshaft chain, sprocket, guide worn White smoke: Air suction valve damaged Piston oil ring worn Air switching valve damaged Cylinder worn...
  • Page 536: Battery Trouble

    17-30 APPENDIX Troubleshooting Guide Battery Trouble: Rear shock adjustment too soft Front fork, rear shock absorber spring weak Battery discharged: Rear shock absorber oil leaking Charge insufficient Battery faulty (too low terminal voltage) Brake Doesn’t Hold: Battery lead making poor contact Load excessive (e.g., bulb of excessive Air in the brake line wattage)
  • Page 537 MODEL APPLICATION Year Model Beginning Frame No. □ JKAEREA1 6A000001 2006 ER650A6F ER650A-000001 2006 ER650A6S JKAER650AAA000001 □ :This digit in the frame number changes from one machine to another. Part No.99924-1360-01 Printed in Japan...

Comments to this Manuals

Symbols: 0
Latest comments: