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VULCAN900 CLASSIC
VULCAN900 CLASSIC LT
VN900 CLASSIC
Motorcycle
Service Manual

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Table of Contents

   Also See for Kawasaki VULCAN900 CLASSIC LT

   Summary of Contents for Kawasaki VULCAN900 CLASSIC LT

  • Page 1 VULCAN900 CLASSIC VULCAN900 CLASSIC LT VN900 CLASSIC 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) pounds(s) ABDC after bottom dead center meter(s) alternating current minute(s) ATDC after top dead center newton(s) BBDC before bottom dead center pascal(s) bottom dead center horsepower BTDC before top dead center pound(s) per square inch °C degree(s) Celsius revolution direct current...
  • Page 7: Emission Control Information

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

    Be alert for problems and non-scheduled correctly followed, could result in per- maintenance. sonal injury, or loss of life. • Use proper tools and genuine Kawasaki Mo- torcycle parts. Special tools, gauges, and CAUTION testers that are necessary when servicing This caution symbol identifies special...
  • Page 10 NOTE ○ This note symbol indicates points of par- ticular interest for more efficient and con- venient operation. • Indicates a procedural step or work to be done. ○ Indicates a procedural sub-step or how to do the work of the procedural step it follows. It also precedes the text of a NOTE.
  • Page 11 GENERAL INFORMATION 1-1 General Information Table of Contents Before Servicing ........................Model Identification......................... General Specifications......................1-10 Unit Conversion Table ......................1-13...
  • Page 12: Before Servicing

    1-2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly opera- tion on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustra- tions, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary.
  • Page 13 Replacement Parts Replacement parts must be KAWASAKI genuine or recommended by KAWASAKI. Gaskets, O-rings, oil seals, grease seals, circlips or cotter pins must be replaced with new ones whenever disassembled.
  • Page 14: Tightening Torque

    1-4 GENERAL INFORMATION Before Servicing Tightening Sequence Generally, when installing a part with several bolts, nuts, or screws, start them all in their holes and tighten them to a snug fit. Then tighten them according to the specified se- quence to prevent case warpage or deformation which can lead to malfunction.
  • Page 15 GENERAL INFORMATION 1-5 Before Servicing Press For items such as bearings or oil seals that must be pressed into place, apply small amount of oil to the con- tact area. Be sure to maintain proper alignment and use smooth movements when installing. Ball Bearing and Needle Bearing Do not remove pressed ball or needle unless removal is absolutely necessary.
  • Page 16 1-6 GENERAL INFORMATION Before Servicing Lubrication It is important to lubricate rotating or sliding parts during assembly to minimize wear during initial operation. Lubri- cation points are called out throughout this manual, apply the specific oil or grease as specified. Direction of Engine Rotation When rotating the crankshaft by hand, the free play amount of rotating direction will affect the adjustment.
  • Page 17: Model Identification

    GENERAL INFORMATION 1-7 Model Identification VN900B6F (US and Canada) Left Side View: VN900B6F (US and Canada) Right Side View: Frame Number Engine Number [A] Frame Number [A] Engine Number [B] Front Fork (Right side) [B] Right Engine Cover...
  • Page 18: General Information

    1-8 GENERAL INFORMATION Model Identification VN900B6F (Europe and Australia) Left Side View: VN900B6F (Europe and Australia) Right Side View:...
  • Page 19 GENERAL INFORMATION 1-9 Model Identification VN900D6F (US and Canada) Left Side View: VN900D6F (US and Canada) Right Side View:...
  • Page 20: General Specifications

    1-10 GENERAL INFORMATION General Specifications Items VN900B6F/D6F Dimensions Overall Length 2 465 mm (97.05 in.) Overall Width 1 005 mm (39.57 in.), (AU) 980 mm (38.6 in.) Overall Height (VN900B) 1 065 mm (41.93 in.) (VN900D) 1 480 mm (58.27 in.) Wheelbase 1 645 mm (64.76 in.) Road Clearance...
  • Page 21 GENERAL INFORMATION 1-11 General Specifications Items VN900B6F/D6F Valve Timing: Inlet open 40° BTDC close 40° ABDC duration 260° Exhaust Open 55° BBDC Close 25° ATDC Duration 260° Lubrication System Forced lubrication (wet sump) Engine Oil: Type API SE, SF or SG class API SH or SJ class with JASO MA Viscosity SAE10W-40...
  • Page 22 1-12 GENERAL INFORMATION General Specifications Items VN900B6F/D6F Front Suspension: Type Telescopic fork Wheel Travel 150 mm (5.90 in.) Rear Suspension: Type Swingarm (uni-trak) Wheel Travel 103 mm (4.06 in.) Brake Type: Front Single disc Rear Single disc Electrical Equipment Battery: Capacity 12 V 10 Ah Headlight:...
  • Page 23: 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 25: Table Of Contents

    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 26 2-2 PERIODIC MAINTENANCE Electrical System ......................... 2-39 Lights and Switches Operation Inspection................ 2-39 Headlight Aiming Inspection ..................... 2-41 Sidestand Switch Operation Inspection ................2-42 Engine Stop Switch Operation Inspection................. 2-43 Others ..........................2-44 Chassis Parts Lubrication ....................2-44 Bolts, Nuts and Fasteners Tightness Inspection............... 2-45 Evaporative Emission Control SystemInspection (CAL)............
  • Page 27: 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 28: Periodic Maintenance Chart

    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 damage - inspect year 2-32 •...
  • Page 29: 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 # Every 18 000 km (12 000 mile) 2-47 •...
  • Page 30: 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: 2T: Apply 2-stroke oil. L: Apply a non-permanent locking agent to the threads. Lh: Left-hand threads M: Apply molybdenum disulfide grease.
  • Page 31 PERIODIC MAINTENANCE 2-7 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Cylinder Head Cover Bolts 106 in·lb Cylinder Head Outer Cover Bolts 87 in·lb Plug (PT1/4) Plug (PT1/2) Muffler Mounting Bolts Muffler Mounting Nut Muffler Joint Clamp Bolt Exhaust Pipe Cover Clamp Bolts 0.70 61 in·lb...
  • Page 32 2-8 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Rear Shift Lever Clamp Bolt 106 in·lb Shift Pedal Clamp Bolt 106 in·lb Shift Rod Locknut (Front) 87 in·lb Oil Nozzle 0.40 34 in·lb Shift Rod Locknut (Rear) 87 in·lb Rear Shift Pedal Pad Screw 0.70...
  • Page 33 PERIODIC MAINTENANCE 2-9 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Suspension Swingarm Pivot Shaft Nut Rear Shock Absorber Nuts Lower Tie-Rod Nut Upper Tie-Rod Nut 11.0 Rocker Arm Pivot Shaft Nut Upper Front Fork Clamp Bolts Lower Front Fork Clamp Bolts Front Fork Bottom Allen Bolts Front Fork Upper Cover Stopper Bolts 0.43...
  • Page 34 2-10 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Spark Plugs 13 in·lb Sidestand Switch Mounting Bolts 0.90 78 in·lb The table below, relating tightening torque to thread diameter, lists the basic torque for the bolts and nuts.
  • Page 35: 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 1 000 ±50 r/min (rpm) – – – Air Cleaner Element Polyurethane Foam –...
  • Page 36 2-12 PERIODIC MAINTENANCE Specifications Item Standard Service Limit Final Drive Drive Belt Deflection: – – – (45 N, 4.6 kgf, 10 lb fprce) 1.5 ∼ 4.0 mm (0.059 ∼ 0.16 in.) – – – When Installing New Belt 1.5 mm (0.059 in.) –...
  • Page 37: Special Tools

    PERIODIC MAINTENANCE 2-13 Special Tools Inside Circlip Pliers: Oil Filter Wrench: 57001-143 57001-1249 Steering Stem Nut Wrench: Spark Plug Wrench, Hex 16: 57001-1100 57001-1262 Jack: Tension Gauge: 57001-1238 57001-1585...
  • Page 38: 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 39: Idle Speed Inspection

    PERIODIC MAINTENANCE 2-15 Periodic Maintenance Procedures • If necessary, adjust the throttle cable as follows: ○ Loosen the locknuts [A] and screw the adjusters [B] all the way in so as to give the throttle grip plenty of play. ○ Turn out the adjuster of the decelerator cable [D] until there is no play.
  • Page 40: Cooling System

    2-16 PERIODIC MAINTENANCE Periodic Maintenance Procedures Cooling System Coolant Level Inspection NOTE ○ Check the level when the engine is cold (room or ambi- ent temperature). • Check the coolant level in the reserve tank [A] with the motorcycle held upright. If the coolant level is lower than the “L”...
  • Page 41: Air Suction System

    PERIODIC MAINTENANCE 2-17 Periodic Maintenance Procedures Air Suction System Air Suction System Damage Inspection • Pull the air switching valve hose [A] out of the right air cleaner housing. • Start the engine and run it at idle speed. • Plug the air switching valve hose end with your finger and feel vacuum pulsing in the hose.
  • Page 42 2-18 PERIODIC MAINTENANCE Periodic Maintenance Procedures • To select a new shim which brings the valve clearance within the specified range, refer to the Valve Clearance Adjustment Charts. • Remeasure any valve clearance that was adjusted. Readjust if necessary. CAUTION Do not put shim stock under the shim.
  • Page 43 PERIODIC MAINTENANCE 2-19 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 2.60 mm (0.102 in.) Measured clearance is 0.25 mm (0.010 in.)
  • Page 44 2-20 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 2.55 mm (0.100 in.) Measured clearance is 0.50 mm (0.020 in.)
  • Page 45: Clutch

    PERIODIC MAINTENANCE 2-21 Periodic Maintenance Procedures Clutch Clutch Operation Inspection Clutch Lever Free Play Inspection • Pull the clutch lever just enough to take up the free play [A]. • Measure the gap between the lever and the lever holder. If the gap is too wide, the clutch may not release fully.
  • Page 46: Wheels And Tires

    2-22 PERIODIC MAINTENANCE Periodic Maintenance Procedures Wheels and Tires Tire Air Pressure Inspection • Measure the tire air pressure with an air pressure gauge [A] when the tires are cold (that is, when the motorcycle has not been ridden more than a mile during the past 3 hours).
  • Page 47: Wheel Bearing Damage Inspection

    PERIODIC MAINTENANCE 2-23 Periodic Maintenance Procedures • Measure the tread depth at the center of the tread with a depth gauge [A]. Since the tire may wear unevenly, take measurement at several places. If any measurement is less than the service limit, replace the tire.
  • Page 48: Spoke Tightness And Rim Runout Inspection

    2-24 PERIODIC MAINTENANCE Periodic Maintenance Procedures Spoke Tightness and Rim Runout Inspection • Check that all the spokes are tightened evenly. If spoke tightness is uneven or loose, tighten the spoke nipples evenly. Torque - Spoke Nipples: 5.2 N·m (0.53 kgf·m, 46 in·lb) •...
  • Page 49: Drive Train

    PERIODIC MAINTENANCE 2-25 Periodic Maintenance Procedures Drive Train Belt Deflection Inspection NOTE ○ Belt deflection must be checked and adjusted when the belt is cold (at room temperature). ○ Belt deflection also should be checked at first 1000 km ride after belt replacement. •...
  • Page 50 2-26 PERIODIC MAINTENANCE Periodic Maintenance Procedures NOTE ○ Push the belt by the gauge until the top surface [A] of the stopper comes to the 45 N loaded scale [B], marked “45N”. ○ Push up on the center of the belt. An inaccurate reading will occur if the edge of the belt is pushed up.
  • Page 51: Belt Deflection Adjustment

    PERIODIC MAINTENANCE 2-27 Periodic Maintenance Procedures • Decide the belt deflection at the position [C] of one where deflection is large. Drive Belt Deflection (with 45 N, 4.6 kgf, 10 lb force) Standard: 1.5 ∼ 4.0 mm (0.059 ∼ 0.16 in.) Drive Belt Deflection (with 45 N, 4.6 kgf, 10 lb force, when installing new belt or engine remounted) Standard: 1.5 mm (0.059 in.)
  • Page 52: Wheel Alignment Inspection/adjustment

    2-28 PERIODIC MAINTENANCE 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 53 PERIODIC MAINTENANCE 2-29 Periodic Maintenance Procedures • Visually inspect the belt [A] for wear and damage. If the nylon fabric facing of any portion is worn off, and the polyurethane compound is exposed, or belt is damaged, replace the belt immediately with a new one. •...
  • Page 54 2-30 PERIODIC MAINTENANCE Periodic Maintenance Procedures Drive Belt Tooth Wear and Damage Patterns A. Belt Cross Section B. Edge Bevel Wear C. Rub Wear D. Stone...
  • Page 55: Brake System

    PERIODIC MAINTENANCE 2-31 Periodic Maintenance Procedures Drive Belt Wear and Damage Analysis Pattern Condition Required Action O.K. for continued use, but inspect the Internal tooth cracks (slight) belt periodically. O.K. for continued use, but inspect the Scuffing to side of teeth belt periodically.
  • Page 56: Brake Hose Damage And Installation Condition Inspection

    2-32 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Hose Damage and Installation Condition Inspection • Inspect the brake hoses and fittings for deterioration, cracks and signs of leakage. ○ The high pressure inside the brake line can cause fluid to leak [A] or the hose to burst if the line is not properly main- tained.
  • Page 57: Brake Pad Wear Inspection

    PERIODIC MAINTENANCE 2-33 Periodic Maintenance Procedures • Check that the brake fluid level in the rear brake reservoir [A] is above the lower level line [B]. If the fluid level is lower than the lower level line, fill the reservoir to the upper level line [C]. WARNING Change the brake fluid in the brake line completely if the brake fluid must be refilled but the type and...
  • Page 58: Suspensions

    2-34 PERIODIC MAINTENANCE Periodic Maintenance Procedures If it does not, adjust the brake light switch. • While holding the switch body, turn the adjusting nut [A] to adjust the switch. CAUTION To avoid damaging the electrical connections in- side the switch, be sure that the switch body does not turn during adjustment.
  • Page 59: Front Fork Oil Leak Inspection

    PERIODIC MAINTENANCE 2-35 Periodic Maintenance Procedures Front Fork Oil Leak Inspection • Visually inspect the front forks [A] for oil leakage. Replace or repair any defective parts, if necessary. Rear Shock Absorber Oil Leak Inspection • Remove the left side cover (see Left Side Cover Removal in the Frame chapter).
  • Page 60: Uni-trak Linkage Lubrication

    2-36 PERIODIC MAINTENANCE Periodic Maintenance Procedures Uni-trak Linkage Lubrication • Remove: Tie-Rod (see Tie-Rod Removal in the Suspension chap- ter) • Apply grease to the inner surfaces of the needle bearings • For the rocker arm it has grease nipples [A] on the rocker arm for lubrication.
  • Page 61 PERIODIC MAINTENANCE 2-37 Periodic Maintenance Procedures • Straighten the claws [A] of the claw washer. • Remove the steering stem locknut [B] and claw washer [C]. • 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.
  • Page 62: Steering Stem Bearing Lubrication

    2-38 PERIODIC MAINTENANCE Periodic Maintenance Procedures Steering Stem Bearing Lubrication • Remove the steering stem (see Steering Stem Removal in the Steering chapter). • Using a high flash-point solvent, wash the upper and lower ball bearings in the cages, and wipe the upper and lower outer races, which are press-fitted into the frame head pipe, clean off grease and dirt.
  • Page 63: Electrical System

    PERIODIC MAINTENANCE 2-39 Periodic Maintenance Procedures Electrical System Lights and Switches Operation Inspection First Step • Turn on the ignition switch. • The following lights should go on according to below table. Position Lights [A] ( US and Canada goes on Models) City Light [B] (Europe Models) goes on...
  • Page 64 2-40 PERIODIC MAINTENANCE 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 65: Headlight Aiming Inspection

    PERIODIC MAINTENANCE 2-41 Periodic Maintenance Procedures • Set the dimmer switch to high beam position. • The high beam should go on. • The high beam indicator light (LED) [A] 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 66: Sidestand Switch Operation Inspection

    2-42 PERIODIC MAINTENANCE Periodic Maintenance Procedures NOTE ○ For US model, the proper angle is 0.4 degrees below horizontal. This is 50 mm (2 in.) drop at 7.6 m (25 ft.) measured from the center of the headlight with the motorcycle on its wheels and the rider seated.
  • Page 67: Engine Stop Switch Operation Inspection

    PERIODIC MAINTENANCE 2-43 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 68: Others

    2-44 PERIODIC MAINTENANCE 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 69: Bolts, Nuts And Fasteners Tightness Inspection

    PERIODIC MAINTENANCE 2-45 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 70: Evaporative Emission Control Systeminspection (cal)

    2-46 PERIODIC MAINTENANCE Periodic Maintenance Procedures Evaporative Emission Control System Inspection (CAL) Evaporative Emission Control System Inspection • Inspect the canister as follows: ○ Remove: Muffler (see Muffler Removal in the Engine Top End chapter) ○ Remove the bolts [A]. ○...
  • Page 71: Replacement Parts

    Install a new element [A] with the mesh side facing up -ward. CAUTION Use only the recommended air cleaner element (Kawasaki part number 11013-0015). Using another air cleaner element will wear the engine prema- turely or lower the engine performance. Torque - Air Cleaner Element Screw: 4.9 N·m (0.50 kgf·m,...
  • Page 72: Engine Oil Change

    2-48 PERIODIC MAINTENANCE Periodic Maintenance Procedures Engine Oil Change • Situate the motorcycle so that it is vertical after warning up the engine. • Remove: Oil Filler Cap [A] Special Tool - Filler Cap Driver: 57001-1454 • Remove the engine drain plug [A] to drain the oil. ○...
  • Page 73: Oil Filter Replacement

    PERIODIC MAINTENANCE 2-49 Periodic Maintenance Procedures Oil Filter Replacement • Drain the engine oil (see Engine Oil Change). • Remove: Regulator/Rectifier (see Regulator/Rectifier Removal in the Electrical System chapter) Bolts [A] Bracket [B] • Remove the oil filter [A] with the oil filter wrench [B] and discard the oil filter.
  • Page 74 2-50 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Twist the driver to disconnect the joint lock [A]. • Pull [B] the fuel hose joint [C] out of the delivery pipe. WARNING Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately. When the fuel hose is disconnected, fuel spills out from the hose and the pipe.
  • Page 75: Coolant Change

    PERIODIC MAINTENANCE 2-51 Periodic Maintenance Procedures Coolant Change WARNING To avoid burns, do not remove the radiator cap or try to change the coolant when the engine is still hot. Wait until it cools down. Coolant on tires will make them slippery, and can cause an accident and injury.
  • Page 76 2-52 PERIODIC MAINTENANCE Periodic Maintenance Procedures Water and Coolant Mixture Ratio (when recommended) Soft Water Coolant Freezing Point : −35°C (−31°F) Total Amount 2.2 L (2.3 US gt.) • Tighten: Torque - Coolant Drain Bolt: 9.8 N·m (1.0 kgf·m, 87 in·lb) •...
  • Page 77: Radiator Hose And O-ring Replacement

    PERIODIC MAINTENANCE 2-53 Periodic Maintenance Procedures Radiator Hose and O-ring Replacement • Drain the coolant (see Coolant Change). • Remove: Thermostat Bracket [A] (see Thermostat Removal in the Cooling System chapter) • Loosen the radiator hose clamps and remove the hoses [B].
  • Page 78: Brake Fluid Change

    2-54 PERIODIC MAINTENANCE Periodic Maintenance Procedures • When installing the hoses [A], avoid sharp bending, kink- ing, flattening or twisting, and route the hoses according to Cable, Wire and Hose Routing section in the Appendix chapter. • Fill the brake line after installing the brake hose (see Brake Fluid Change).
  • Page 79 PERIODIC MAINTENANCE 2-55 Periodic Maintenance Procedures ○ Repeat this operation until fresh brake fluid comes out from the plastic hose or the color of the fluid changes. Open the bleed valve [A]. Pump the brake lever and hold it [B]. Close the bleed valve [C].
  • Page 80: Master Cylinder Rubber Parts Replacement

    2-56 PERIODIC MAINTENANCE 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 [A], plate [B], and diaphragm [C].
  • Page 81: Caliper Rubber Parts Replacement

    PERIODIC MAINTENANCE 2-57 Periodic Maintenance Procedures Master Cylinder Assembly • Before assembly, clean all parts including the master cylinder with brake fluid or alcohol. CAUTION Except for the disc pads and disc, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol for cleaning brake parts.
  • Page 82 2-58 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Using compressed air, remove the piston. WARNING To avoid serious injury, never place your fingers or palm inside the caliper opening. If you apply com- pressed air into the caliper, the piston may crush your hand or fingers.
  • Page 83 PERIODIC MAINTENANCE 2-59 Periodic Maintenance Procedures • Apply brake fluid to the inside of the cylinders and to the outside of the pistons and push the pistons [A] into the cylinders. • Check the friction boot [B] and dust boot [C] and replace them with new ones if they are damaged.
  • Page 84: Spark Plug Replacement

    2-60 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Remove: Antirattle Spring [A] Dust Seals [B] and Fluid Seals [C] Rubber Friction Boots [D] Bleed Valves [E] and Rubber Caps [F] Rear Caliper Assembly • Tighten the bleed valve. Torque - Rear Caliper Bleed Valves: 7.8 N·m (0.80 kgf·m, 69 in·lb) ○...
  • Page 85 PERIODIC MAINTENANCE 2-61 Periodic Maintenance Procedures CAUTION The insulator [A] of the spark plug may break if when the wrench is inclined during loosening. Inclined Spark Plug Wrench [B] Contact (Spark Plug and Plug Wrench) [C] Bad [D] Vertically Spark Plug Wrench [E] Good [F] •...
  • Page 87 FUEL SYSTEM (DFI) 3-1 Fuel System (DFI) Table of Contents Exploded View........................DFI Parts Location........................Specifications ......................... 3-11 Special Tools and Sealant ...................... 3-13 DFI System..........................3-14 DFI Servicing Precautions ...................... 3-22 DFI Servicing Precautions ....................3-22 Troubleshooting the DFI System .................... 3-24 Outline ..........................
  • Page 88 3-2 FUEL SYSTEM (DFI) Speed Sensor Removal ....................3-63 Speed Sensor Installation ....................3-63 Speed Sensor Inspection....................3-63 Input Voltage Inspection....................3-63 Output Voltage Inspection....................3-64 Vehicle-down Sensor (Service Code 31)................3-66 Vehicle-down Sensor Removal ..................3-66 Vehicle-down Sensor Installation ..................3-66 Vehicle-down Sensor Inspection..................
  • Page 89 FUEL SYSTEM (DFI) 3-3 Audible Inspection......................3-106 Fuel Injector Power Source Voltage Inspection ..............3-106 Output Voltage Inspection....................3-107 Injector Signal Test......................3-108 Injector Resistance Inspection ..................3-108 Injector Unit Test ....................... 3-109 Throttle Grip and Cables ......................3-112 Throttle Grip Free Play Inspection ..................3-112 Throttle Grip Free Play Adjustment...................
  • Page 90: Exploded View

    3-4 FUEL SYSTEM (DFI) Exploded View...
  • Page 91 FUEL SYSTEM (DFI) 3-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Fuel Pump Bolts 87 in·lb Air Cleaner Housing Bolts 87 in·lb Air Cleaner Cover Bolts 0.50 43 in·lb Throttle Body Assy Holder Bolts 87 in·lb Inlet Manifold Bolts 87 in·lb Delivery Joint Bolts 87 in·lb...
  • Page 92 3-6 FUEL SYSTEM (DFI) Exploded View...
  • Page 93 FUEL SYSTEM (DFI) 3-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Fuel Level Sensor Mounting Bolts 0.70 61 in·lb 2. California Model 3. Breather Hose (Other than California Models) L: Apply a non-permanent locking agent. R: Replacement Parts...
  • Page 94: Dfi Parts Location

    3-8 FUEL SYSTEM (DFI) DFI Parts Location 1. Ignition Coil #1 12. Injector #1 2. Fuel Pump 13. Water Temperature Sensor 3. Ignition Coil #2 14. Main Throttle Sensor 4. Main Fuse 30 A 15. Subthrottle Sensor 5. Relay Box 16.
  • Page 95 FUEL SYSTEM (DFI) 3-9 DFI Parts Location...
  • Page 96 3-10 FUEL SYSTEM (DFI) DFI Parts Location...
  • Page 97: Specifications

    FUEL SYSTEM (DFI) 3-11 Specifications Item Standard 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Throttle Grip Free Play Air Cleaner Element Viscous paper element DFI System Make Denso Idle Speed 1 000 ±50 r/min (rpm) Throttle Body Assy: Type × Bore Two barrel type ×...
  • Page 98 3-12 FUEL SYSTEM (DFI) Specifications Item Standard Subthrottle Sensor: Non-adjustable and non-removable 4.75 ∼ 5.25 V DC between BL and BR/BK leads Input Voltage 0.93 ∼ 4.59 V DC between BL/W and BR/BK leads Output Voltage (at idle throttle opening to full throttle opening) 4 ∼...
  • Page 99: Special Tools And Sealant

    Oil Pressure Gauge, 5 kgf/cm²: Needle Adapter Set: 57001-125 57001-1457 Fork Oil Level Gauge: Fuel Pressure Gauge Adapter: 57001-1290 57001-1593 Hand Tester: Fuel Hose: 57001-1394 57001-1607 Peak Voltage Adapter: Speed Sensor Measuring Adapter: 57001-1415 57001-1667 Filler Cap Driver: Kawasaki Bond (Silicone Sealant): 57001-1454 56019-120...
  • Page 100: Dfi System

    3-14 FUEL SYSTEM (DFI) DFI System DFI System...
  • Page 101 FUEL SYSTEM (DFI) 3-15 DFI System 1. Battery 2. ECU 3. Injector 4. Fuel Pump 5. Fuel Tank 6. Subthrottle Valve Actuator 7. Air Cleaner 8. Subthrottle Sensor 9. Main Throttle Sensor 10. Inlet Air Temperature Sensor 11. Water Temperature Sensor 12.
  • Page 102 3-16 FUEL SYSTEM (DFI) DFI System DFI System Wiring Diagram (Other than Europe Models)
  • Page 103 FUEL SYSTEM (DFI) 3-17 DFI System Part Name 1. ECU 2. Diagnosis Connector 3. Self-diagnosis Terminal 4. Fuel Pump 5. Vehicle-down Sensor 6. Frame Ground 7. Battery 8. Main Fuse 30 A 9. Relay Box 10. Fuel Pump Relay 11. ECU Main Relay 12.
  • Page 104 3-18 FUEL SYSTEM (DFI) DFI System DFI System Wiring Diagram (Europe Models)
  • Page 105 FUEL SYSTEM (DFI) 3-19 DFI System Part Name 1. ECU 2. Diagnosis Connector 3. Self-diagnosis Terminal 4. Fuel Pump 5. Vehicle-down Sensor 6. Frame Ground 7. Battery 8. Main Fuse 30 A 9. Relay Box 10. Fuel Pump Relay 11. ECU Main Relay 12.
  • Page 106 3-20 FUEL SYSTEM (DFI) DFI System Other than Europe Models Terminal Names 1. Subthrottle Valve Actuator Drive Signal 2 23. Unused 2. Subthrottle Valve Actuator Drive Signal 1 24. Crankshaft Sensor (–) Signal 3. Water Temperature Warning Light Signal 25. Unused 4.
  • Page 107 FUEL SYSTEM (DFI) 3-21 DFI System Europe Model 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.
  • Page 108: Dfi Servicing Precautions

    3-22 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 109 FUEL SYSTEM (DFI) 3-23 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. Alternator Cover [B] Special Tool - Filler Cap Driver: 57001-1454...
  • Page 110: Troubleshooting The Dfi System

    3-24 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 111 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 Vehicle-down Sensor Connector • Always check battery condition before replacing the DFI parts.
  • Page 112 3-26 FUEL SYSTEM (DFI) Troubleshooting the DFI System • Pull each connector [A] apart and inspect it for corrosion, dirt, and damage. If the connector is corroded or dirty, clean it carefully. If it is damaged, replace it. Connect the connectors securely. •...
  • Page 113 FUEL SYSTEM (DFI) 3-27 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 114: Inquiries To Rider

    3-28 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 115 FUEL SYSTEM (DFI) 3-29 Troubleshooting the DFI System Sample Diagnosis Sheet Rider name Registration No. (license plate No.) Year of initial registration Model Engine No. Frame No. Date problem occurred Mileage Environment when problem occurred. □ □ □ □ □ □...
  • Page 116 3-30 FUEL SYSTEM (DFI) Troubleshooting the DFI System □ engine overheating. □ 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 □...
  • Page 117: Dfi System Troubleshooting Guide

    FUEL SYSTEM (DFI) 3-31 DFI System Troubleshooting Guide NOTE ○ This is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties. ○...
  • Page 118 3-32 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) No spark or spark weak Ignition and engine stop switches not ON Turn both switches ON. Clutch lever not pulled in and gear not in neutral Pull the lever in and shift the gear in neutral.
  • Page 119: Poor Running At Low Speed

    FUEL SYSTEM (DFI) 3-33 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Piston ring bad (worn, weak, broken or sticking) Inspect and replace (see chapter 5). Piston ring/groove clearance excessive Inspect and replace (see chapter 5). Cylinder head gasket damaged Replace (see chapter 5).
  • Page 120 3-34 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Incorrect idle speed Water temperature sensor trouble Inspect (see chapter 3). Throttle sensor trouble Inspect (see chapter 3). Throttle valves or actuator trouble Inspect (see chapter 3). Engine stalls easily Fuel pump trouble Inspect (see chapter 3).
  • Page 121 FUEL SYSTEM (DFI) 3-35 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Delay of ignition timing Inspect crankshaft sensor and IC igniter in ECU (see chapter 16). Poor acceleration Too low fuel pressure Inspect (see chapter 3). Water or foreign matter in fuel Change fuel.
  • Page 122: Poor Running Or No Power At High Speed

    3-36 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Fuel injector trouble Inspect (see chapter 3). Run-on (dieseling) Ignition switch trouble Inspect and replace (see chapter 16). Engine switch trouble Inspect and repair or replace (see chapter 16). Fuel injector trouble Inspect (see chapter 3).
  • Page 123 FUEL SYSTEM (DFI) 3-37 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (detailed reference) Inlet air temperature sensor trouble Inspect (see chapter 3). Throttle sensor malfunction Inspect (see chapter 3). Inlet air pressure sensor trouble Inspect (see chapter 3). Cracked or obstructed inlet air pressure sensor Inspect and repair or replace (see chapter 3) hose...
  • Page 124 3-38 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (detailed reference) Cylinder worn Inspect and replace (see chapter 5). Valve oil seal damaged Replace (see chapter 5). Valve guide worn Replace the guide (see chapter 5). Engine oil level too high Repair (see chapter 7).
  • Page 125: Self-diagnosis

    FUEL SYSTEM (DFI) 3-39 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 126: Service Code Clearing Procedures

    3-40 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 127 FUEL SYSTEM (DFI) 3-41 Self-Diagnosis...
  • Page 128: How To Read Service Codes

    3-42 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 129: Service Code Table

    FUEL SYSTEM (DFI) 3-43 Self-Diagnosis Service Code Table Service Code Table Service FI Indicator Light (LED) 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...
  • Page 130 3-44 FUEL SYSTEM (DFI) Self-Diagnosis Notes: ○ The ECU may be involved in these problems. If all the parts and circuits checked out good, be sure to check the ECU for ground and power supply. If the ground and power supply are checked good, replace the ECU.
  • Page 131: Backups

    FUEL SYSTEM (DFI) 3-45 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 132 3-46 FUEL SYSTEM (DFI) 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 (no signal, wiring short or open), the ECU Ignition Coil #1* signals (output voltage) shuts off the injector #1 to stop fuel to the...
  • Page 133: Main Throttle Sensor (service Code 11)

    FUEL SYSTEM (DFI) 3-47 Main Throttle Sensor (Service Code 11) The main throttle sensor is a rotating variable resistor that change output voltage according to throttle operating. The ECU senses this voltage change and determines fuel injec- tion quantity, and ignition timing according to engine rpm, and throttle opening.
  • Page 134: Output Voltage Inspection

    3-48 FUEL SYSTEM (DFI) Main Throttle Sensor (Service Code 11) Output Voltage Inspection • Measure the output voltage at the ECU in the same way as input voltage inspection. Special Tool - Needle Adapter Set: 57001-1457 Main Throttle Sensor Output Voltage Connections to ECU (Other than Europe Models [A]) Meter (+) →...
  • Page 135: Resistance Inspection

    FUEL SYSTEM (DFI) 3-49 Main Throttle Sensor (Service Code 11) NOTE ○ The standard voltage marked with an asterisk refers to the value when the voltage reading at the Input Voltage Inspection shows 5 V exactly. ○ When the input voltage reading shows other than 5 V, derive a voltage range as follows.
  • Page 136 3-50 FUEL SYSTEM (DFI) Main Throttle Sensor (Service Code 11) Main Throttle Sensor Circuit (Other than Europe Models) Main Throttle Sensor Circuit (Europe Models) 1. ECU 2. Main Throttle Sensor 3. Joint Connector B...
  • Page 137: Inlet Air Pressure Sensor (service Code 12)

    FUEL SYSTEM (DFI) 3-51 Inlet Air Pressure Sensor (Service Code 12) Inlet Air Pressure Sensor Removal CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the part can damage it. • Remove: Fuel Tank (see Fuel Tank Removal) Bolt [A] •...
  • Page 138: Output Voltage Inspection

    3-52 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code 12) If the reading is within the standard range, remove the fuel tank, and check wiring from ECU to the inlet pressure sensor for continuity. If wiring is good, check the output voltage of the inlet air pressure sensor.
  • Page 139 FUEL SYSTEM (DFI) 3-53 Inlet Air Pressure Sensor (Service Code 12) • Remove the inlet air pressure sensor [A] and disconnect the vacuum hose from the sensor. ○ Do not disconnect the sensor connector. • Connect an auxiliary hose [B] to the inlet air pressure sen- sor.
  • Page 140 3-54 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code 12) ID: Idling Ps: Standard Atmospheric Pressure (absolute) Pv: Throttle Vacuum Pressure (absolute) ST: Standard of Sensor Output Voltage (v) TO: Throttle Full Open UR: Usable Range of Sensor Output Voltage (v) Vv: Inlet Air Pressure Sensor Output Voltage (v) (Digital Meter Reading)
  • Page 141 FUEL SYSTEM (DFI) 3-55 Inlet Air Pressure Sensor (Service Code 12) Inlet Air Pressure Sensor Circuit (Other than Europe Models) Inlet Air Pressure Sensor Circuit (Europe Models) 1. ECU 2. Inlet Air Pressure Sensor 3. Joint Connector B...
  • Page 142: Inlet Air Temperature Sensor (service Code 13)

    3-56 FUEL SYSTEM (DFI) Inlet Air Temperature Sensor (Service Code 13) Inlet Air Temperature Sensor Removal/Installation CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. • Remove the air cleaner housing (see Air Cleaner Housing Removal).
  • Page 143: Sensor Resistance Inspection

    FUEL SYSTEM (DFI) 3-57 Inlet Air Temperature Sensor (Service Code 13) Sensor Resistance Inspection • Remove the inlet air temperature sensor (see Inlet Air Temperature Sensor Removal). • Suspend the sensor [A] in a container of machine oil so that the heat-sensitive portion is submerged. •...
  • Page 144 3-58 FUEL SYSTEM (DFI) Inlet Air Temperature Sensor (Service Code 13) Inlet Air Temperature Sensor Circuit (Other than Europe Models) Inlet Air Temperature Sensor Circuit (Europe Models) 1. ECU 2. Inlet Air Temperature Sensor 3. Joint Connector B...
  • Page 145: Water Temperature Sensor (service Code 14)

    FUEL SYSTEM (DFI) 3-59 Water Temperature Sensor (Service Code 14) Removal/Installation CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. • Remove the fuel tank (see Fuel Tank Removal). • Drain the coolant (see Coolant Change in the Periodic Maintenance chapter).
  • Page 146 3-60 FUEL SYSTEM (DFI) Water Temperature Sensor (Service Code 14) Water Temperature Sensor Circuit (Other than Europe Models) Water Temperature Sensor Circuit (Europe Models) 1. ECU 2. Water Temperature Sensor 3. Joint Connector B...
  • Page 147: Crankshaft Sensor (service Code 21)

    FUEL SYSTEM (DFI) 3-61 Crankshaft Sensor (Service Code 21) Start the engine and switch the diagnosis mode to Dealer 1 mode to know all the problem that the DFI system has at the time of self-diagnosis. If the engine cannot be started, the self-diagnosis system does not detect dynamic condi- tion of the crankshaft sensor.
  • Page 148 3-62 FUEL SYSTEM (DFI) Crankshaft Sensor (Service Code 21) Crankshaft Sensor Circuit (Other than Europe Models) Crankshaft Sensor Circuit (Europe Models) 1. ECU 2. Crankshaft Sensor...
  • Page 149: Speed Sensor (service Code 24, 25)

    FUEL SYSTEM (DFI) 3-63 Speed Sensor (Service Code 24, 25) Speed Sensor Removal • Refer to the Speed Sensor Removal in the Electrical Sys- tem chapter. Speed Sensor Installation • Refer to the Speed Sensor Installation in the Electrical System chapter. Speed Sensor Inspection •...
  • Page 150: Output Voltage Inspection

    3-64 FUEL SYSTEM (DFI) Speed Sensor (Service Code 24, 25) Output Voltage Inspection • Before this inspection, inspect the input voltage (see Input Voltage Inspection in the Speed Sensor section). NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch OFF.
  • Page 151 FUEL SYSTEM (DFI) 3-65 Speed Sensor (Service Code 24, 25) Speed Sensor Circuit (Other than Europe Models) Speed Sensor Circuit (Europe Models) 1. ECU 2. Meter Unit 3. Joint Connector B 4. Speed Sensor...
  • Page 152: Vehicle-down Sensor (service Code 31)

    3-66 FUEL SYSTEM (DFI) Vehicle-down Sensor (Service Code 31) Vehicle-down Sensor Removal • Remove: Tool Box (see Tool Box Removal in the Frame chapter) Bolts [A] Vehicle-down Sensor [B] Connector [C] (disconnect) Vehicle-down Sensor Installation • Install the vehicle-down sensor [A] in the original position. The arrow mark [B] on the sensor must be on the rear and point upward.
  • Page 153 • Remove the needle adapters, and apply silicone sealant to the seals of the connector for waterproofing. Silicone Sealant (Kawasaki Bond: 56019-120) - Seals of Vehicle-down Sensor Connector If the output voltage is out of the specified, replace the vehicle-down sensor.
  • Page 154 3-68 FUEL SYSTEM (DFI) Vehicle-down Sensor (Service Code 31) Vehicle-down Sensor Circuit (Other than Europe Models) Vehicle-down Sensor Circuit (Europe Models) 1. ECU 2. Vehicle-down Sensor 3. Joint Connector B...
  • Page 155: Subthrottle Sensor (service Code 32)

    FUEL SYSTEM (DFI) 3-69 Subthrottle Sensor (Service Code 32) The subthrottle sensor is a rotating variable resistor that change output voltage according to throttle operating. The ECU senses this voltage change and determines fuel injec- tion quantity, and ignition timing according to engine rpm, and throttle opening.
  • Page 156: Output Voltage Inspection

    3-70 FUEL SYSTEM (DFI) Subthrottle Sensor (Service Code 32) • Turn the ignition switch OFF. If the reading of input voltage is less than the standard, check the ECU for its ground, power supply and wiring shorted. If the input voltage is within the standard range, remove the fuel tank, and check wiring from ECU to the subthrottle sensor for continuity.
  • Page 157: Resistance Inspection

    FUEL SYSTEM (DFI) 3-71 Subthrottle Sensor (Service Code 32) NOTE ○ The standard voltage marked with an asterisk refers to the value when the voltage reading at the Input Voltage Inspection shows 5 V exactly. ○ When the input voltage reading shows other than 5 V, derive a voltage range as follows.
  • Page 158 3-72 FUEL SYSTEM (DFI) Subthrottle Sensor (Service Code 32) Subthrottle Sensor Circuit (Other than Europe Models) Subthrottle Sensor Circuit (Europe Models) 1. ECU 2. Subthrottle Sensor 3. Joint Connector B...
  • Page 159: Oxygen Sensor-not Activated (#1, #2: Service Code 33, 83)-europe Models

    FUEL SYSTEM (DFI) 3-73 Oxygen Sensor-not activated (#1, #2: Service Code 33, 83)-Europe Models Oxygen Sensor #1: Service Code 33 Oxygen Sensor #2: Service Code 83 Oxygen Sensor Removal/Installation • Refer to Oxygen Sensor Removal and Installation in the Electrical System chapter. Oxygen Sensor Inspection NOTE ○...
  • Page 160 If the reading is without range, replace the oxygen sensor. • Remove the needle adapter set, and apply silicone sealant to the seals of the connector for waterproofing. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 Oxygen Sensor Circuit 1. ECU 2. Oxygen Sensor #1 3.
  • Page 161: Ignition Coils (#1, #2: Service Code 51, 52)

    FUEL SYSTEM (DFI) 3-75 Ignition Coils (#1, #2: Service Code 51, 52) Ignition Coil #1: Ignition Coil for Front Cylinder (Service Code 51) Ignition Coil #2: Ignition Coil for Rear Cylinder (Service Code 52) Ignition Coil Removal/Installation CAUTION Never drop the ignition coils, especially on a hard surface.
  • Page 162 3-76 FUEL SYSTEM (DFI) Ignition Coils (#1, #2: Service Code 51, 52) If the reading is out of the standard, check the ECU for its ground and power supply (see ECU Power Supply In- spection). If the reading is good remove the fuel tank and check the wiring between the ECU and the primary lead terminals at the ignition coils.
  • Page 163: Radiator Fan Relay (service Code 56)

    FUEL SYSTEM (DFI) 3-77 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 164 3-78 FUEL SYSTEM (DFI) Radiator Fan Relay (Service Code 56) Radiator Fan Relay Circuit 1. Ignition Switch 2. Radiator Fan 3. Joint Connector B 4. Water Temperature Sensor 5. ECU 6. Frame Ground 7. Battery 8. Main Fuse 30 A 9.
  • Page 165: Subthrottle Valve Actuator (service Code 62)

    FUEL SYSTEM (DFI) 3-79 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 166: Input Voltage Inspection

    3-80 FUEL SYSTEM (DFI) Subthrottle Valve Actuator (Service Code 62) Input Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch OFF. • Remove the fuel tank (see Fuel Tank Removal). • Connect the peak voltage adapter [A] and a digital meter [B] to the connector (main harness side) [C], using the needle adapter set [D].
  • Page 167 FUEL SYSTEM (DFI) 3-81 Subthrottle Valve Actuator (Service Code 62) Subthrottle Valve Actuator Circuit (Other than Europe Models) Subthrottle Valve Actuator Circuit (Europe Models) 1. ECU 2. Subthrottle Valve Actuator...
  • Page 168: Air Switching Valve (service Code 64)

    3-82 FUEL SYSTEM (DFI) Air Switching Valve (Service Code 64) Air Switching Valve Removal/Installation • See Clean Air System section in the Engine Top End chapter. Air Switching Valve Inspection • See Air Switching Valve Unit Test in the Electrical System chapter.
  • Page 169 FUEL SYSTEM (DFI) 3-83 Air Switching Valve (Service Code 64) Air Switching Valve Circuit (Europe Models) 1. ECU 2. Engine Stop Switch 3. Ignition Switch 4. Ignition Fuse 10 A 5. ECU Fuse 15 A 6. Fuse Box 7. ECU Main Relay 8.
  • Page 170: Oxygen Sensor Heaters (#1, #2: Service Code 67)-europe Models

    3-84 FUEL SYSTEM (DFI) Oxygen Sensor Heaters (#1, #2: Service Code 67)-Europe Models Oxygen Sensor Heater Removal/Installation The oxygen sensor heater is bult in the oxygen sensor. So, the heater itself can not be removed. Remove the oxy- gen sensor (see Switch and Sensors section in the Electri- cal System chapter).
  • Page 171 ECU (see ECU section). • Remove the needle adapter set, and apply silicone sealant to the connector for water proofing. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 Oxygen Sensor Circuit 1. ECU 2. Oxygen Sensor #1 3. Oxygen Sensor #2 4.
  • Page 172: Oxygen Sensors-incorrect Output Voltage (#1, #2: Service Code 94, 95)-europe Models

    3-86 FUEL SYSTEM (DFI) Oxygen Sensors-Incorrect Output Voltage (#1, #2: Service Code 94, 95)-Europe Models Oxygen Sensor #1: Service Code 94 Oxygen Sensor #2: Service Code 95 Oxygen Sensor Removal/Installation • Refer to Oxygen Sensor Removal and Installation in the Electrical System chapter.
  • Page 173 • Remove the needle adapter set, and apply silicone sealant to the seals of the connector for waterproofing. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 Oxygen Sensor Circuit 1. ECU 2. Oxygen Sensor #1 3. Oxygen Sensor #2 4.
  • Page 174: Fi Indicator Led Light

    3-88 FUEL SYSTEM (DFI) FI Indicator LED Light Inspection Flow Chart...
  • Page 175: Led Light Inspection

    FUEL SYSTEM (DFI) 3-89 FI Indicator LED Light LED Light Inspection ○ The FI indicator LED light [A] goes ON when the ignition switch is turned ON and the LED light goes OFF when the engine oil pressure is high enough (the engine is running). This is to ensure that the FI indicator LED light has not burned out and the DFI system and the ignition system function properly.
  • Page 176 3-90 FUEL SYSTEM (DFI) FI Indicator LED Light FI Indicator LED Light Circuit (Other than Europe Models) FI Indicator LED Light Circuit (Europe Models) 1. ECU 2. Ignition Switch 3. Meter Unit 4. FI Indicator LED Light 5. Main Fuse 30 A 6.
  • Page 177: Ecu

    FUEL SYSTEM (DFI) 3-91 ECU Removal CAUTION Never drop the ECU, especially on a hard surface. Such a shock to the ECU can damage it. • Remove: Seat (see Seat Removal in the Frame chapter) Tool Box (see Tool Box Removal in the Frame chapter) •...
  • Page 178 3-92 FUEL SYSTEM (DFI) • Check the ECU power source voltage with a digital meter. ○ Position the terminal in accordance with terminal numbers of ECU connectors in this chapter figure. ECU Power Source Inspection Meter Connections: (Other than Europe Models [A]) Between Terminal 12 (BR/W) and Battery (–) Terminal Between Terminal 27 (W/BK) and Battery (–)
  • Page 179: Fuel Line

    FUEL SYSTEM (DFI) 3-93 Fuel Line Fuel Pressure Inspection NOTE ○ This inspection can determine which trouble the DFI system has, mechanical or electrical trouble. ○ It is preferable to measure the fuel pressure while run- ning the motorcycle when the trouble has occurred in order to know symptom well.
  • Page 180 3-94 FUEL SYSTEM (DFI) Fuel Line • Turn the ignition switch ON. The fuel pump will turn for 3 seconds, and then stop. • Measure the fuel pressure with the engine stopped. Fuel Pressure right after Ignition Switch ON, with pump running: Standard: 304 kPa (3.1 kgf/cm², 44 psi) after 3 seconds from Ignition Switch ON, with pump stopped:...
  • Page 181: Fuel Flow Rate Inspection

    FUEL SYSTEM (DFI) 3-95 Fuel Line • Insert the fuel hose joint [A] straight onto the delivery pipe. • Push [B] the joint lock [C] until the hose joint clicks. • 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 182 3-96 FUEL SYSTEM (DFI) Fuel Line • Prepare a plastic hose of the inside diameter 7.5 mm × L = about 400 mm and a measuring cylinder. • Remove: Seat (see Seat Removal in the Frame chapter) Fuel Tank Bolts •...
  • Page 183: Fuel Pump

    FUEL SYSTEM (DFI) 3-97 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 184: Pump Screen, Fuel Filter Cleaning

    3-98 FUEL SYSTEM (DFI) Fuel Pump • Check that the terminals [A] and band [B] are in place. • Apply a non-permanent locking agent to the threads of the fuel pump bolts. • Tighten the fuel pump bolts [C] to a snug fit. •...
  • Page 185: Operating Voltage Inspection

    FUEL SYSTEM (DFI) 3-99 Fuel Pump Operating Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch OFF. • Remove the ignition coil cover (see Ignition Coil Removal in the Electrical System chapter). • Connect the hand tester (25 V DC) to the fuel pump con- nector [A] with needle adapter set.
  • Page 186: Power Source Voltage Inspection

    3-100 FUEL SYSTEM (DFI) Fuel Pump Power Source Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Remove the ignition coil cover (see Ignition Coil Removal in the Electrical System chapter). • Connect a digital voltmeter [A] to the fuel pump connector [B] (3P), using the needle adapter [C].
  • Page 187 FUEL SYSTEM (DFI) 3-101 Fuel Pump Fuel Pump Circuit (Other than Europe Models) 1. ECU 2. Engine Stop Switch 3. Ignition Switch 4. Ignition Fuse 10 A 5. ECU Fuse 15 A 6. Fuse Box 7. ECU Main Relay 8. Fuel Pump Relay 9.
  • Page 188 3-102 FUEL SYSTEM (DFI) Fuel Pump Fuel Pump Circuit (Europe Models) 1. ECU 2. Engine Stop Switch 3. Ignition Switch 4. Ignition Fuse 10 A 5. ECU Fuse 15 A 6. Fuse Box 7. ECU Main Relay 8. Fuel Pump Relay 9.
  • Page 189: Fuel Injectors

    FUEL SYSTEM (DFI) 3-103 Fuel Injectors CAUTION Never drop the injector, especially on a hard sur- face. Such a shock to the injector can damage it. Injector Removal WARNING Gasoline is extremely flammable and can be ex- plosive under certain conditions. Turn the ignition switch OFF.
  • Page 190: Injector Installation

    3-104 FUEL SYSTEM (DFI) Fuel Injectors • Unscrew the delivery joint bolts [A], and lift up the delivery joint [B] with the injectors [C]. • Remove the injectors from the delivery joint. Injector Installation ○ The front and rear injectors are the same. •...
  • Page 191: Injector Fuel Line Inspection

    FUEL SYSTEM (DFI) 3-105 Fuel Injectors Injector Fuel Line Inspection • Remove: Fuel Tank (see Fuel Tank Removal) Fuel Hose (see Fuel Hose Replacement in the Periodic Maintenance chapter) • Check the injector fuel line for leakage as follows: ○ Connect a commercially available vacuum/pressure pump [A] to the nipple of the delivery pipe [B] with a high-pressure fuel hose [C] (both ends connected with...
  • Page 192: Audible Inspection

    3-106 FUEL SYSTEM (DFI) Fuel Injectors Audible Inspection • Start the engine. • Insert a screwdriver from the engine right side between the fuel tank bottom end and the engine top end. • Apply the tip of a screwdriver [A] to the injector [B]. Put the grip end onto your ear, and listen whether the injector is clicking or not.
  • Page 193: Output Voltage Inspection

    FUEL SYSTEM (DFI) 3-107 Fuel Injectors Output Voltage Inspection • Turn the ignition switch OFF. • Remove the ECU (see ECU Removal). Do not disconnect the ECU connector. • Connect a digital voltmeter to the connector, using the needle adapter set. Special Tool - Needle Adapter Set: 57001-1457 Injector Output Voltage at ECU (Other than Europe Models [A])
  • Page 194: Injector Signal Test

    3-108 FUEL SYSTEM (DFI) Fuel Injectors Injector Signal Test • Prepare two test light sets with male terminals as shown. Rating of Bulb [A]: 12 V × 3 ∼ 3.4 W Terminal Width [B]: 1.8 mm Terminal Thickness [C]: 0.8 mm CAUTION Do not use larger terminals than specified above.
  • Page 195: Injector Unit Test

    FUEL SYSTEM (DFI) 3-109 Fuel Injectors Injector Unit Test • Use two wires [A] and the same test light set [B] as in “Injector Signal Test”. Rating of Bulb [C]: 12 V × (3 ∼ 3.4) W 12 V Battery [D] CAUTION Be sure to connect the bulb in series.
  • Page 196 3-110 FUEL SYSTEM (DFI) Fuel Injectors Fuel Injector Circuit (Other than Europe Models) 1. ECU 2. Engine Stop Switch 3. Ignition Switch 4. Ignition Fuse 10 A 5. ECU Fuse 15 A 6. Fuse Box 7. ECU Main Relay 8. Fuel Pump Relay 9.
  • Page 197 FUEL SYSTEM (DFI) 3-111 Fuel Injectors Fuel Injector Circuit (Other than Europe Models) 1. ECU 2. Engine Stop Switch 3. Ignition Switch 4. Ignition Fuse 10 A 5. ECU Fuse 15 A 6. Fuse Box 7. ECU Main Relay 8. Fuel Pump Relay 9.
  • Page 198: Throttle Grip And Cables

    3-112 FUEL SYSTEM (DFI) 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 • Loosen the locknuts [A] and screw the adjusters [B] all the way in so as to give the throttle grip plenty of play.
  • Page 199: Throttle Body Assy

    FUEL SYSTEM (DFI) 3-113 Throttle Body Assy Idle Speed Inspection • Refer to Idle Speed Inspection in the Periodic Mainte- nance Chapter. Idle Speed Adjustment • Refer to Idle Speed Adjustment in the Periodic Mainte- nance Chapter. Throttle Bore Cleaning •...
  • Page 200 3-114 FUEL SYSTEM (DFI) Throttle Body Assy • Remove the screws and take off the right switch housing. • Remove the accelerator cable end [A] and decelerator cable end [B] at the throttle grip. • Disconnect the injector connectors [A]. •...
  • Page 201: Throttle Body Assy And Intake Manifold Installation

    FUEL SYSTEM (DFI) 3-115 Throttle Body Assy ○ Be careful not to damage (dent, nick, flaw, and crack) the flange mating surface and the plastic parts. ○ Do not drop the throttle body assy, especially on a hard surface. WARNING The throttle body assy should never be allowed to fall.
  • Page 202 3-116 FUEL SYSTEM (DFI) Throttle Body Assy • Before Installation, visually inspect the mating surfaces [A] for any damage, like dent, nick, rust, flaw, and crack. • Nick or rust damage can sometimes be repaired by using emery paper (first No. 200, then 400) to remove sharp edges or raised areas.
  • Page 203 FUEL SYSTEM (DFI) 3-117 Throttle Body Assy • Apply a thin coating of grease to the throttle cable upper ends. • Install the upper ends of the throttle cables in the grip. • Fit the projection [A] of the right switch housing into the hole [B] of the handlebar.
  • Page 204: Air Cleaner

    3-118 FUEL SYSTEM (DFI) Air Cleaner Air Cleaner Element Removal/Installation • Refer to the Air Cleaner Element Replacement in the Pe- riodic Maintenance chapter. Air Cleaner Housing Removal • Remove the air cleaner housing bolts [A]. • Clear the idle speed screw [A] from the recess on the air cleaner housing.
  • Page 205 FUEL SYSTEM (DFI) 3-119 Air Cleaner • Fit the idle speed screw [A] in the recess on the air cleaner housing. • Be sure the dampers [A] and collars [B] are in position. ○ Install the damper [A] into the air cleaner housing [C] as shown.
  • Page 206: Fuel Tank

    3-120 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 207 FUEL SYSTEM (DFI) 3-121 Fuel Tank • Remove: Seat (see Seat Removal in the Frame chapter) Fuel Tank Bolts [A] • Disconnect (California Model): Fuel Return Hose (Red) [A] • Unscrew the screw [A], and pull out the ignition coil cover [B].
  • Page 208 3-122 FUEL SYSTEM (DFI) Fuel Tank • Place a cloth around the fuel hose joint. • Insert a minus screw driver [A] into the slit on the joint lock [B]. • Turn the driver to disconnect the joint lock. • Pull [C] the fuel hose joint [D] out of the outlet pipe.
  • Page 209: Fuel Tank Installation

    FUEL SYSTEM (DFI) 3-123 Fuel Tank Fuel Tank Installation • Read the above WARNING. • Route the hoses correctly (see Cable, Wire and Hose Routing section in the Appendix chapter). • For California model, note the following: ○ To prevent the gasoline from flowing into or out of the canister, hold the separator perpendicular to the ground.
  • Page 210: Fuel Tank And Cap Inspection

    3-124 FUEL SYSTEM (DFI) Fuel Tank Fuel Tank and Cap Inspection • Visually inspect the gasket [A] on the tank cap for any damage. Replace the gasket if it is damaged. • Check to see if the breather pipe [B] in the tank is not clogged.
  • Page 211 FUEL SYSTEM (DFI) 3-125 Fuel Tank • 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 pressure of the spring [B]. NOTE ○...
  • Page 212: Evaporative Emission Control System

    3-126 FUEL SYSTEM (DFI) Evaporative Emission Control System The Evaporative Emission Control System for California Model routes fuel vapors from the fuel system into the run- ning engine or stores the vapors in a canister when the en- gine is stopped. Although no adjustments are required, a thorough visual inspection must be made at the intervals specified by the Periodic Maintenance Chart.
  • Page 213: Separator Operation Test

    FUEL SYSTEM (DFI) 3-127 Evaporative Emission Control System Separator Operation Test WARNING Gasoline is extremely flammable and can be explo- sive under certain conditions. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light.
  • Page 214: Evaporative Emission Control System

    3-128 FUEL SYSTEM (DFI) Evaporative Emission Control System 1. Fuel Tank 2. Throttle Body 3. Canister 4. Separator 5. Breather Check Valve 6. Breather Hose 7. Breather Hose (Blue) 8. Vacuum Hose (White) 9. Fuel Return Hose (Red) 10. Purge Hose (Green) 11.
  • Page 215 COOLING SYSTEM 4-1 Cooling System Table of Contents Exploded View........................Specifications ......................... Special Tools and Sealant ...................... Coolant Flow Chart......................... Coolant ........................... Coolant Deterioration Inspection..................Coolant Level Inspection....................Coolant Draining ....................... Coolant Filling ........................Pressure Testing ....................... Reserve Tank Removal..................... Water Pump..........................
  • Page 216: Exploded View

    4-2 COOLING SYSTEM Exploded View...
  • Page 217 COOLING SYSTEM 4-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Water Pump Impeller Bolt 87 in·lb Water Hose Fitting Bolts 87 in·lb Water (Radiator) Hose Clamp Screws 0.20 18 in·lb Thermostat Housing Cover Bracket Bolts 0.70 61 in·lb Thermostat Housing Cover Bolts 0.50 43 in·lb Radiator Bolts...
  • Page 218: Specifications

    4-4 COOLING SYSTEM Specifications Item Standard Service Limit Coolant Provided When Shipping Type 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% –...
  • Page 219: Special Tools And Sealant

    COOLING SYSTEM 4-5 Special Tools and Sealant Bearing Driver Set: Bearing Remover Head, 10 × 12: 57001-1129 57001-1266 Bearing Remover Shaft, 9: Kawasaki Bond (Silicone Sealant): 57001-1265 56019-120...
  • Page 220: Coolant Flow Chart

    4-6 COOLING SYSTEM Coolant Flow Chart...
  • Page 221 COOLING SYSTEM 4-7 Coolant Flow Chart 1. Thermostat 2. Radiator Cap 3. Cylinder Head Jacket 4. Radiator Fan 5. Radiator 6. Cylinder Jacket 7. Water Pump 8. Reserve Tank 9. Hot Coolant 10. Cold Coolant 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.
  • Page 222: Coolant

    4-8 COOLING SYSTEM Coolant Coolant Deterioration Inspection • Visually inspect the coolant in the reserve tank. If whitish cotton-like wafts are observed, aluminum parts in the cooling system are corroded. If the coolant is brown, iron or steel parts are rusting. In either case, flush the cooling system.
  • Page 223: Reserve Tank Removal

    COOLING SYSTEM 4-9 Coolant Reserve Tank Removal • Remove: Left Side Cover (see Left Side Cover Removal in the Frame chapter) Bolt [A] Reserve Tank Cover [B] • Remove: Bolts [A] Cap [B] • Drain the coolant to the suitable container. •...
  • Page 224: Water Pump

    4-10 COOLING SYSTEM Water Pump Water Pump Impeller Removal • Drain: Engine Oil (see Engine Oil Change in the Periodic Main- tenance chapter) Coolant (see Coolant Change in the Periodic Mainte- nance chapter) • Remove: Right Engine Cover (see Right Engine Cover Removal in the Clutch chapter) Bolt [A] and Washer Impeller [B]...
  • Page 225 COOLING SYSTEM 4-11 Water Pump If the seal and ball bearing are damaged, replace the me- chanical seal, ball bearing, and oil seal by splitting the crankcase. • Split the crankcase (see Crankcase Splitting in the Crank- shaft/Transmission chapter). • Take the bearing [A] out of the right crankcase, using the bearing remover.
  • Page 226: Water Pump Inspection

    4-12 COOLING SYSTEM Water Pump Water Pump Inspection • Check the drainage outlet passage [A] at the bottom of the right crankcase for coolant leaks. If the mechanical seal is damaged, the coolant leaks through the seal and drains through the passage. Re- place the mechanical seal with a new one.
  • Page 227: Radiator, Radiator Fan

    COOLING SYSTEM 4-13 Radiator, Radiator Fan Radiator and Radiator Fan Removal WARNING The radiator fan is connected directly to the bat- tery. The radiator fan may start even if the ignition switch is off. NEVER TOUCH THE RADIATOR FAN UNTIL THE RADIATOR FAN CONNECTOR IS DIS- CONNECTED.
  • Page 228: Radiator Fan Installation

    4-14 COOLING SYSTEM Radiator, Radiator Fan • Remove: Radiator Fan Connector [A] Radiator • Remove: Radiator Fan Mounting Bolts [A] Radiator Fan [B] CAUTION Do not touch the radiator core. This could damage the radiator fins, resulting in loss of cooling effi- ciency.
  • Page 229: Radiator Cap Inspection

    COOLING SYSTEM 4-15 Radiator, Radiator Fan Radiator Cap Inspection • Check the condition of the top [A] and bottom [B] valve seals and valve spring [C]. If any one of them shows visible damage, replace the cap with a new one. •...
  • Page 230: Thermostat

    4-16 COOLING SYSTEM Thermostat Thermostat Removal • Drain: Coolant (about 200 mL) • Remove: Seat (see Seat Removal in the Frame chapter) Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Reserve Tank Hose [A] Radiator Hose Clamp [B] (Loosen) Water Temperature Connector [C] Bolt [D] •...
  • Page 231 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 232: Hose And Pipes

    4-18 COOLING SYSTEM Hose and Pipes Hose Installation • Install the hoses and pipes being careful to follow bend- ing direction or diameter. Avoid sharp bending, kinking, flattening, or twisting. • Install the clamps [A] as near as possible to the hose end to clear the raised rib or the fitting.
  • Page 233: Water Temperature Sensor

    COOLING SYSTEM 4-19 Water Temperature Sensor Water Temperature Sensor Removal/Installation CAUTION The water temperature sensor should never be al- lowed to fall on a hard surface. Such a shock to water temperature sensor can damage it. • Refer to the Water Temperature Sensor Removal/Instal- lation in the Fuel System (DFI) chapter.
  • Page 235 ENGINE TOP END 5-1 Engine Top End Table of Contents Exploded View........................Exploded Veiw ........................Specifications ......................... Special Tools .......................... 5-11 Clean Air System........................5-13 Air Suction Valve Removal....................5-13 Air Suction Valve Installation..................... 5-13 Air Suction Valve Inspection ..................... 5-13 Air Switching Valve Removal ....................
  • Page 236 5-2 ENGINE TOP END Piston Wear ........................5-35 Piston/Cylinder Clearance ....................5-36 Piston Ring, Piston Ring Groove Wear................5-36 Piston Ring Groove Width....................5-36 Piston Ring Thickness ..................... 5-37 Piston Ring End Gap ......................5-37 Muffler............................. 5-38 Muffler Removal........................ 5-38 Muffler Installation......................
  • Page 237 ENGINE TOP END 5-3 Dummy Page...
  • Page 238: Exploded View

    5-4 ENGINE TOP END Exploded View...
  • Page 239 ENGINE TOP END 5-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Cylinder Head nuts(M10)(First) S, MO Cylinder Head nuts(M10)(Final) S, MO Cylinder Head nuts(M8) Camshaft Cap Bolts Cylinder Head Cover Bolts 106 in·lb Cylinder Head Outer Cover Bolts 87 in·lb Plug (PT1/4) Plug (PT1/2) EO: Apply oil.
  • Page 240 5-6 ENGINE TOP END Exploded View...
  • Page 241 ENGINE TOP END 5-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Muffler Mounting Bolts Muffler Mounting Nut Muffler Joint Clamp Bolt Exhaust Pipe Cover Clamp Bolts 0.70 61 in·lb Exhaust Pipe Cover Bolts 0.70 61 in·lb Exhaust Pipe Holder Nuts Camshaft Sprocket Bolts Camshaft Chain Tensioner Cap Bolts Camshaft Chain Guide Bolts...
  • Page 242: Exploded Veiw

    5-8 ENGINE TOP END Exploded Veiw Exhaust System UK: U.K Model FULL: Full Power H: Honeycomb Type Catalyst Silensor [A] without Boss [A] for Oxygen Sensor Silensor with Boss [B] for Oxygen Sensor...
  • Page 243: Specifications

    ENGINE TOP END 5-9 Specifications Item Standard Service Limit Camshafts Cam Height: 35.030 ∼ 35.144 mm (1.3791 ∼ 1.3836 in.) Exhaust 34.93 mm (1.375 in.) 35.302 ∼ 35.416 mm (1.3898 ∼ 1.3943 in.) Inlet 35.20 mm (1.386 in.) 0.028 ∼ 0.071 mm (0.0011 ∼ 0.0028 in.) Camshaft Journal, Camshaft 0.16 mm (0.0063 in.) Cap Clearance...
  • Page 244 5-10 ENGINE TOP END Specifications Item Standard Service Limit Cylinder, Piston 88.000 ∼ 88.012 mm (3.4646 ∼ 3.4650 in.) Cylinder Inside Diameter 88.10 mm (3.468 in.) 87.955 ∼ 87.970 mm (3.4628 ∼ 3.4634 in.) Piston Diameter 87.80 mm (3.457 in.) 0.030 ∼...
  • Page 245: Special Tools

    ENGINE TOP END 5-11 Special Tools 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 Piston Pin Puller Assembly: Valve Seat Cutter, 45° - 30: 57001-910 57001-1187 Valve Seat Cutter, 45°...
  • Page 246 5-12 ENGINE TOP END Special Tools Valve Guide Arbor, 5: Spark Plug Wrench, Hex 16: 57001-1203 57001-1262 Valve Guide Reamer, 5: Compression Gauge Adapter, M10 × 1.0: 57001-1204 57001-1317 Valve Seat Cutter Holder, 5: Valve Seat Cutter, 60° - 33: 57001-1208 57001-1334 NOTE...
  • Page 247: Clean Air System

    ENGINE TOP END 5-13 Clean Air System Air Suction Valve Removal • Remove: Cylinder Head Covers (see Cylinder Head Cover Re- moval) Air Suction Valves [A] Air Suction Valve Installation • Install each air suction valve so that stopper side [A] of the reed faces downward.
  • Page 248: Clean Air System Hose Inspection

    5-14 ENGINE TOP END Clean Air System Clean Air System Hose Inspection • Be certain that all the hoses are routed without being flat- tened or kinked, and are connected correctly to the right air cleaner base, air switching valve, and fittings on the rocker case covers If they are not, correct them.
  • Page 249: Cylinder Head Cover

    ENGINE TOP END 5-15 Cylinder Head Cover Cylinder Head Cover Removal • Remove: Seat (see Seat Removal in the Frame chapter) Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) • Slide [A] the air switching valve [B] forward to clear the clamp.
  • Page 250: Cylinder Head Cover Installation

    5-16 ENGINE TOP END Cylinder Head Cover • Remove: Dampers [A] Cylinder Head Cover Bolts [B] and washers Cylinder Head Cover [C] Cylinder Head Cover Gasket ○ Just move everything that is between the cylinder head cover and the frame out of the may to make room. Then as a lift the cover up, make sure the spark plug pipe [A] stays all the way down in the cylinder head.
  • Page 251: Camshaft Chain Tensioner

    ENGINE TOP END 5-17 Camshaft Chain Tensioner Camshaft Chain Tensioner Removal • Remove: Engine (see Engine Removal/Installation chapter) Camshaft (see Camshaft Removal) Cylinder Head (see Cylinder Head Removal) • Remove the camshaft chain tensioner body from the cylinder. Camshaft Chain Tensioner Installation •...
  • Page 252: Camshaft, Camshaft Chain

    5-18 ENGINE TOP END Camshaft, Camshaft Chain Camshaft Removal • Remove: Cylinder Head Cover (see Cylinder Head Cover Re- moval) Ignition Coil Cover (For Front Cylinder)(see Ignition Coil Removal in the Electrical System chapter) Tensioner Cap Bolt [A], Washer [B] and Spring CAUTION Do not turn over the crankshaft while the tensioner cap bolt is removed, The tensioner body is loose...
  • Page 253: Camshaft Installation

    ENGINE TOP END 5-19 Camshaft, Camshaft Chain Camshaft Installation • Apply engine oil to all cam parts and journals. NOTE ○ The front and rear camshafts are different. The rear camshaft [A] has a groove [B]. • Remove: Alternator Outer Cover (see Alternator Outer Cover Re- moval in the Electrical System chapter) Bolts [A] Timing Inspection Plate [B]...
  • Page 254: Camshaft/camshaft Cap Wear

    5-20 ENGINE TOP END Camshaft, Camshaft Chain NOTE ○ Installing the rear camshaft is the same as for the front camshaft. But noting the following. • Set the rear piston at TDC. ○ Align the rear piston TDC mark [A] and timing mark [B] by turning the crankshaft counterclockwise [C] 305°...
  • Page 255: Camshaft Runout

    ENGINE TOP END 5-21 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 256: Camshaft And Sprocket Assembly

    5-22 ENGINE TOP END Camshaft, Camshaft Chain Camshaft and Sprocket Assembly • Clean the sprocket bolt [A] and threads of the camshaft. • Be sure to install the pin [B]. • Apply a non-permanent locking agent to the threads of the camshaft sprocket bolt, and tighten it.
  • Page 257: Rocker Shaft, Rocker Arm

    ENGINE TOP END 5-23 Rocker Shaft, Rocker Arm Rocker Shaft, Rocker Arm Removal • Remove: Cylinder Head Cover (see Cylinder Head Cover Re- moval) Camshaft Cap (see Camshaft Removal) Rocker Shafts [A] Rocker Arms [B] and Springs [C] Rocker Shaft, Rocker Arm Installation •...
  • Page 258: Cylinder Head

    5-24 ENGINE TOP END Cylinder Head Cylinder Compression Measurement NOTE ○ Use the battery which is fully charged. • Warm up the engine thoroughly. • Stop the engine. • Remove: Seat (see Seat Removal in the Frame chapter) Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Spark Plugs Special Tool - Spark Plug Wrench, Hex 16: 57001-1262...
  • Page 259: Cylinder Head Removal

    ENGINE TOP END 5-25 Cylinder Head Cylinder Head Removal • Remove: Engine (see Engine Removal in the Engine Removal/In- stallation chapter) Camshaft (see Camshaft Removal) • Remove the cylinder head nuts following sequence [1 ∼ • Remove: Cylinder Head Cylinder Head Installation NOTE ○...
  • Page 260: Valves

    5-26 ENGINE TOP END Valves Valve Clearance Inspection • Refer to the Valve Clearance Inspection in the Periodic Maintenance chapter. Valve Clearance Adjustment • Refer to the Valve Clearance Adjustment in the Periodic Maintenance chapter. Valve Removal • Remove the cylinder head (see Cylinder Head Removal). •...
  • Page 261: Valve Guide Installation

    ENGINE TOP END 5-27 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) (see Valve Guide Removal). •...
  • Page 262: Valve Seat Inspection

    5-28 ENGINE TOP END Valves Valve Seat Inspection • Remove the valve (see Valve Removal). • Check the valve seating surface [A] between the valve [B] and valve seat [C]. ○ Measure the outside diameter [D] of the seating pattern on the valve seat.
  • Page 263 ENGINE TOP END 5-29 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 264 5-30 ENGINE TOP END Valves • Measure the outside diameter (O.D.) of the seating sur- face with a vernier caliper. If the outside diameter of the seating surface is too small, repeat the 45° grind [A] until the diameter is within the specified range.
  • Page 265 ENGINE TOP END 5-31 Valves • Lap the valve to the seat, once the seat width and O.D. are within the ranges specified above. ○ Put a little coarse grinding compound on the face of the valve in a number of places around the valve head. ○...
  • Page 266 5-32 ENGINE TOP END Valves...
  • Page 267: Cylinders, Pistons

    ENGINE TOP END 5-33 Cylinders, Pistons Cylinder Removal • Drain the coolant (see Coolant Change in the Periodic Maintenance chapter). • Remove the cylinder head (see Cylinder Head Removal). • Pull out the front camshaft chain guide [A] and oil pipe [B]. •...
  • Page 268 5-34 ENGINE TOP END Cylinders, Pistons • Do not mix up the top ring and second ring. • Install the top ring [A] so that the “R” mark [B] faces up. • Install the second ring [C] so that the “RN” mark [D] faces •...
  • Page 269: Cylinder Wear

    ENGINE TOP END 5-35 Cylinders, Pistons NOTE ○ If a new piston or cylinder is used, check piston to cylin- der clearance (see Piston/Cylinder Clearance), and use new piston ring. • Replace the cylinder base gasket with a new one. •...
  • Page 270: Piston/cylinder Clearance

    5-36 ENGINE TOP END Cylinders, Pistons Piston/Cylinder Clearance • Subtract the piston diameter from the cylinder inside di- ameter to get the piston/cylinder clearance. Piston/Cylinder Clearance 0.030 ∼ 0.057 mm (0.0012 ∼ 0.0022 in.) Standard: If the piston/cylinder clearance is less than the specified range, use a smaller piston or increase the cylinder inside diameter by honing.
  • Page 271: Piston Ring Thickness

    ENGINE TOP END 5-37 Cylinders, Pistons Piston Ring Thickness • Measure the piston ring thickness. ○ Use a micrometer to measure at several points around the ring. Piston Ring Thickness Standard: Top and Second 0.97 ∼ 0.99 mm (0.038 ∼ 0.039 in.) Service Limit: Top and Second 0.90 mm (0.035 in.) If any of the measurements is less than the service limit...
  • Page 272: Muffler

    5-38 ENGINE TOP END Muffler Muffler Removal • Remove: Clamp Screws (Loosen) [A] Bolt [B] Rear Muffler Cover [C] • Remove: Clamp Screws (Loosen) [A] Bolt [B] Front Muffler Cover [C] • Remove: Muffler Mounting Nut [A], Collar and Damper Muffler Mounting Bolt [B] •...
  • Page 273: Muffler Installation

    ENGINE TOP END 5-39 Muffler • Remove: Rear Exhaust Holder Nuts [A] • Remove the upper and lower muffler jointed. Muffler Installation • Joint the upper and lower muffler. • Temporary tighten the muffler joint clamp bolt [A]. • Install the muffler. •...
  • Page 275 CLUTCH 6-1 Clutch Table of Contents Exploded View........................Specifications ......................... Special Tool ..........................Clutch Lever and Cable ......................Clutch Lever Free Play Inspection ..................Clutch Lever Free Play Adjustment .................. Clutch Cable Removal ...................... Clutch Cable Installation ....................Cable Lubrication ......................Clutch Lever Installation....................
  • Page 276: Exploded View

    6-2 CLUTCH Exploded View...
  • Page 277 CLUTCH 6-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Right Engine Cover Bolts 87 in·lb L (1) Clutch Hub Nut 13.2 95.9 Clutch Spring Bolts 87 in·lb CL: Apply cable lubricate. EO: Apply engine oil. G: Apply grease. L: Apply a non-permanent locking agent. MO: Apply molybdenum disulfide oil.
  • Page 278: Specifications

    6-4 CLUTCH Specifications Item Standard Service Limit 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Clutch Lever Free Play Clutch 2.9 ∼ 3.1 mm (0.114 ∼ 0.122 in.) Friction Plate Thickness 2.8 mm (0.110 in.) Friction and Steel Plate Warp 0.2 mm (0.008 in.) or less 0.3 mm (0.01 in.) Clutch Spring Free Length...
  • Page 279: Special Tool

    CLUTCH 6-5 Special Tool Clutch Holder: 57001-1243...
  • Page 280: Clutch Lever And Cable

    6-6 CLUTCH Clutch Lever and Cable Clutch Lever Free Play Inspection • Refer to the Clutch Operation Inspection in the Periodic Maintenance chapter. Clutch Lever Free Play Adjustment • Refer to the Clutch Operation Inspection in the Periodic Maintenance chapter. Clutch Cable Removal •...
  • Page 281: Clutch Lever Installation

    CLUTCH 6-7 Clutch Lever and Cable Clutch Lever Installation • Install the clutch lever so that the mating surface [A] of the lever holder is aligned with the punch mark [B] of the handlebar.
  • Page 282: Right Engine Cover

    6-8 CLUTCH Right Engine Cover Right Engine Cover Removal • Drain: Engine Oil (see Engine Oil Change in the Periodic Main- tenance chapter) Coolant (see Coolant Change in the Periodic Mainte- nance chapter) • Remove: Brake Pedal (see Brake Pedal Removal in the Brakes chapter) Right Footboard (see Footboard Removal/Installation in the Frame chapter)
  • Page 283: Release Shaft Removal

    CLUTCH 6-9 Right Engine 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 right engine cover (see Right Engine Cover Removal).
  • Page 284: Clutch Removal

    6-10 CLUTCH Clutch Clutch Removal • Remove: Right Engine Cover (see Right Engine Cover Removal) Clutch Spring Bolts [A] Clutch Springs Clutch Spring Plate [B] (with thrust bearing and pusher [C]) • Remove: Friction Plates, Steel Plates Clutch Hub Nut [A] •...
  • Page 285: Clutch Plate, Wear, Damage Inspection

    CLUTCH 6-11 Clutch • Install the washer so that the OUTSIDE mark [A] faces outward. • Replace the clutch hub nut with a new one. • Apply molybdenum disulfide oil to seating surface of the hub nut. • Holding the clutch hub, tighten the clutch hub nut. Special Tool - Clutch Holder: 57001-1243 Torque - Clutch Hub Nut: 130 N·m (13.3 kgf·m, 95.9 ft·lb) •...
  • Page 286: Clutch Plate Warp Inspection

    6-12 CLUTCH Clutch Clutch Plate Warp Inspection • Place each friction plate or steel plate on a surface plate and measure the gap between the surface plate [A] and each friction plate or steel plate [B] with a thickness gauge [C].
  • Page 287 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 Change ....................... Oil Screen Cleaning ......................Oil Pressure Relief Valve......................
  • Page 288: Exploded View

    7-2 ENGINE LUBRICATION SYSTEM Exploded View...
  • Page 289 ENGINE LUBRICATION SYSTEM 7-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Engine Oil Drain Plug Oil Pump Cover Bolts 87 in·lb Oil Pump Drive Chain Guide Bolt 87 in·lb Oil Filter Oil Filter Plate Bolts 0.80 69 in·lb Oil Screen Plug Oil Pressure Relief Valve Oil Pressure Switch Oil Pressure Switch Adapter...
  • Page 290: Engine Oil Flow Chart

    7-4 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart 1. Rocker Arm 5. Oil Screen 9. Oil Filter 2. Oil Pipe 6. Oil Pump 10. Oil Pressure Relief Valve 3. Output Shaft 7. Crankshaft 4. Drive Shaft 8. Oil Pressure Switch...
  • Page 291: Specifications

    ENGINE LUBRICATION SYSTEM 7-5 Specifications Item Standard Engine Oil Type API SE, SFor SG API SH, SJ or SL with JASO MA Viscosity SAE 10W-40 Capacity 3.0 L (3.2 us qt) (when filter is not removed) 3.2 L (3.4 us qt) (when filter is removed) 3.7 L (3.9 us qt) (when engine is completely dry) Level (After warm-up or driving) Between upper and lower level lines...
  • Page 292: Special Tools And Sealant

    7-6 ENGINE LUBRICATION SYSTEM Special Tools and Sealant Oil Pressure Gauge, 10 kgf/cm²: Kawasaki Bond (Silicone Sealant): 57001-164 56019-120 Oil Pressure Gauge Adapter, M10 × 1.25: 57001-1182...
  • Page 293: Engine Oil And Oil Filter

    ENGINE LUBRICATION SYSTEM 7-7 Engine Oil and Oil Filter WARNING Motorcycle operation with insufficient, deteri- orated, or contaminated engine oil will cause accelerated wear and may result in engine or trans- mission seizure, accident, and injury. Oil Level Inspection • Check that the engine oil level is between the upper [A] and lower [B] level lines next to the gauge [C].
  • Page 294 7-8 ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter • Pull out the oil screen [A]. • Clean the screen with high flash-point solvent. WARNING Clean the screen in a well-ventilated area, and take care that there is no spark or frame anywhere near the working area.
  • Page 295: Oil Pressure Relief Valve

    ENGINE LUBRICATION SYSTEM 7-9 Oil Pressure Relief Valve Oil Pressure Relief Valve Removal/Installation • Split the crankcase (see Crankcase Splitting in the Crank- shaft/Transmission chapter). • Remove the relief valve [A] from the right crankcase. • Apply a non-permanent locking agent to the threads of the relief valve, and tighten it.
  • Page 296: Oil Pump, Oil Pump Drive Chain

    7-10 ENGINE LUBRICATION SYSTEM Oil Pump, Oil Pump Drive Chain Oil Pump Removal • Split the crankcase (see Crankcase Splitting in the Crank- shaft/Transmission chapter). • Remove: Water Pump Impeller (see Water Pump Impeller Re- moval in the Cooling System chapter) Crankshaft (see Crankshaft Removal in the Crank- shaft/Transmission chapter) Oil Pipes (see Oil Pipe (Crankcase Inside) Removal)
  • Page 297: Oil Pump Drive Chain Guide Installation

    ENGINE LUBRICATION SYSTEM 7-11 Oil Pump, Oil Pump Drive Chain Oil Pump Drive Chain Guide Installation • Install the chain guide [A] to the left crankcase. • Apply a non-permanent locking agent to the threads of the chain guide bolt [B], and tighten it. Torque - Oil Pump Drive Chain Guide Bolt: 9.8 N·m (1.0 kgf·m, 87 in·lb)
  • Page 298: Oil Pressure Measurement

    7-12 ENGINE LUBRICATION SYSTEM Oil Pressure Measurement Oil Pressure Measurement • Remove: • Regulator/Rectifier (see Regulator/Rectifier Removal in the Electrical System chapter) • Remove the oil pressure switch together with the adapter (see Oil Pressure Switch Removal) without draining the engine oil.
  • Page 299: 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 300: Oil Pipe And Oil Hose

    7-14 ENGINE LUBRICATION SYSTEM Oil Pipe and Oil Hose Oil Pipe (Crankcase Outside) Removal • Remove: Alternator Cover (see Alternator Cover Removal in the Electrical System chapter) Oil Pipe Mounting Bolts [A] Oil Pipe [B] Oil Pipe (Crankcase Outside) Installation •...

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Vn900 classic

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