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Z1000
Motorcycle
Service Manual

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Table of Contents

   Also See for Kawasaki Z1000

   Summary of Contents for Kawasaki Z1000

  • Page 1 Z1000 Motorcycle Service Manual...
  • Page 3: General Information

    Quick Reference Guide General Information Periodic Maintenance Fuel System (DFI) Cooling System Engine Top End Clutch Engine Lubrication System Engine Removal/Installation Crankshaft/Transmission Wheels/Tires 10 j Final Drive 11 j Brakes 12 j Suspension 13 j Steering 14 j Frame 15 j Electrical System 16 j Appendix...
  • Page 5 All information contained in this publication is based on the latest product information available at the time of publication. Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts. © 2002 Kawasaki Heavy Industries, Ltd. Third Edition (1) : Aug. 25, 2003 (K)
  • Page 6 LIST OF ABBREVIATIONS ampere(s) pound(s) ABDC after bottom dead center meter(s) alternating current minute(s) ATDC after top dead center newton(s) BBDC before bottom dead center pascal(s) bottom dead center horsepower BTDC before top dead center pound(s) per square inch °C degree(s) Celsius revolution direct current...
  • Page 7: 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 WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL LAW, THE VIOLATION OF WHICH IS PUNISHABLE BY CIVIL PENALTIES NOT EXCEEDING $10,000 PER VIOLATION. 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...
  • 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: Table Of Contents

    Technical Information – Air Inlet System ................1-11 Technical Information – New Ignition Interlock Sidestand ............1-13 Technical Information – Tail/Brake Lights Employing LED ............. 1-14 Technical Information - KLEEN (KAWASAKI LOW EXHAUST EMISSION SYSTEM) ... 1-16 Unit Conversion Table ......................1-17...
  • 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 rec- ommended by KAWASAKI. Gaskets, O rings, Oil seals, Grease seals, circlips or cotter pins must be replaced with new ones whenever disassembled.
  • Page 14 1-4 GENERAL INFORMATION Before Servicing Tightening Sequence Bolts, nuts, or screws must be tightened according to the specified sequence to prevent case warpage or deformation which can lead to malfunction. If the specified tightening sequence is not indicated, tighten the fasteners alternating diagonally.
  • Page 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 Direction of Engine Rotation When rotating the crankshaft by hand, the free play amount of rotating direction will affect the adjustment. Ro- tate the crankshaft to positive direction (clockwise viewed from output side). Electrical Wires A two-color wire is identified first by the primary color and then the stripe color.
  • Page 17: Model Identification

    GENERAL INFORMATION 1-7 Model Identification ZR1000–A1 Left Side View: ZR1000–A1 Right Side View:...
  • Page 18: General Specifications

    1-8 GENERAL INFORMATION General Specifications ZR1000–A1 ∼ Items Dimensions: Overall length 2 080 mm (81.9 in.) Overall width 770 mm (30.3 in.) Overall height 1 055 mm (41.5 in.) Wheelbase 1 420 mm (55.9 in.) Road clearance 145 mm (5.7 in.) Seat height 820 mm (32.3 in.) Dry mass...
  • Page 19 GENERAL INFORMATION 1-9 General Specifications ZR1000–A1 ∼ Items Lubrication system Forced lubrication (wet sump with cooler) Engine oil: Type API SE, SF or SG API SH or SJ with JASO MA Viscosity SAE10W-40 Capacity 3.8 L (4.0 US qt) Drive Train: Primary reduction system: Type Gear...
  • Page 20 1-10 GENERAL INFORMATION General Specifications ZR1000–A1 ∼ Items Tail/brake light 12 V 0.5/3.8 W (LED) (US, CA, Cal) 12 V 0.5/5W (LED) Alternator: Type Three-phase AC Rated output 24 A/ 14 V @5 000 r/min (rpm) Specifications are subject to change without notice, and may not apply to every country. (AU): Australia Model (US): U.S.A.
  • Page 21: Technical Information - Air Inlet System

    GENERAL INFORMATION 1-11 Technical Information – Air Inlet System Subthrottle Control System The ZR1000–A1 ∼ employs large bore throttle bodies to increase power output. However, sudden changes in throttle opening can cause hesitation and jerky throttle response with a single butterfly valve in a large bore.
  • Page 22 1-12 GENERAL INFORMATION Technical Information – Air Inlet System Operation The subthrottle control system consists of the subthrottle valve, subthrottle valve actuator with a stepping motor built in it, ECU, and subthrottle sensor. The subthrottle valve is built in the each throttle body.
  • Page 23: Technical Information - New Ignition Interlock Sidestand

    GENERAL INFORMATION 1-13 Technical Information – New Ignition Interlock Sidestand Outline The New Ignition Interlock Sidestand System applied to ZR1000–A1 models that cannot function if gears are engaged and/or the sidestand is not lifted upward even though clutch lever pulled in, which differs from the traditional one.
  • Page 24: Technical Information - Tail/brake Lights Employing Led

    1-14 GENERAL INFORMATION Technical Information – Tail/Brake Lights Employing LED Outline This model employs a tail/brake light containing 21 Light Emitting Diodes (LED). The LED emits luminous beams over a longer life span than those emitted from a traditional electric heated bulb (more than 5 times longer), uses lower voltage, expends lower wattage (approx.1/5), and is quicker responsing.
  • Page 25 GENERAL INFORMATION 1-15 Technical Information – Tail/Brake Lights Employing LED The emitting color differs according to the materials of semi-conductors. Materials of Semi-Conductor and Emitting Color Materials of Semi-Conductor Emitting Color GaAsP, GaAlAs Green Blue Ga: Gallium As: Arsenic P: Phosphorus N: Nitrogen Al: Aluminum...
  • Page 26: Technical Information - Kleen (kawasaki Low Exhaust Emission System)

    1-16 GENERAL INFORMATION Technical Information - KLEEN (KAWASAKI LOW EXHAUST EMISSION SYSTEM) Since the emission regulations become more severe, Kawasaki has adopted a type of simplified KLEEN, which have no catalyst protection system, according to each regulation of different countries.
  • Page 27: Unit Conversion Table

    GENERAL INFORMATION 1-17 Unit Conversion Table Prefixes for Units: Units of Length: × 0.6214 mile Prefix Symbol Power × 3.281 mega × 1 000 000 × 0.03937 kilo × 1 000 centi × 0.01 milli × 0.001 Units of Torque: micro µ...
  • Page 29 PERIODIC MAINTENANCE 2-1 Periodic Maintenance Table of Contents Periodic Maintenance Chart ....Drive Chain Slack Adjustment ..2-31 Torque and Locking Agent....Wheel Alignment Specifications ........Inspection/Adjustment....2-32 Special Tools ........2-11 Drive Chain Wear Inspection ..2-32 Periodic Maintenance Procedures..2-12 Drive Chain Lubrication....
  • Page 30: Periodic Maintenance Chart

    2-2 PERIODIC MAINTENANCE Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition. The initial maintenance is vitally important and must not be neglected. FREQUENCY Whichever 1 000 km * ODOMETER READING comes...
  • Page 31 PERIODIC MAINTENANCE 2-3 Periodic Maintenance Chart FREQUENCY Whichever 1 000 km * ODOMETER READING comes (600 mile) first 6 000 km → (4 000 mile) ↓ 12 000 km ( 7 500 mile) 18 000 km (12 000 mile) 24 000 km (15 000 mile) 30 000 km (20 000 mile)
  • Page 32: Torque And Locking Agent

    2-4 PERIODIC MAINTENANCE Torque and Locking Agent The following tables list the tightening torque The table on the right lists the basic torque for the major fasteners requiring use of a non for the bolts and nuts, which are determined -permanent locking agent or liquid gasket.
  • Page 33 PERIODIC MAINTENANCE 2-5 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Water pump drain bolt 95 in·lb Water pipe bolts 95 in·lb in/outlet Thermostat housing ground bolt 61 in·lb Thermostat bracket bolt 61 in·lb Radiator upper bolts 61 in·lb Radiator lower bolts 61 in·lb Radiator screen bolt...
  • Page 34 2-6 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Engine Lubrication: Oil filler plug 0.15 13 in·lb Engine drain plug 14.5 Oil filter (cartridge type, P/No.16097–1070) R, EO Oil filter (cartridge type, P/No.16097–0002) R, EO Oil cooler mounting bolt Oil pan bolts 95 in·lb Oil pipe holder bolts...
  • Page 35 PERIODIC MAINTENANCE 2-7 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Wheels/Tires: Front axle clamp bolt Front axle Rear axle nut Final Drive: Engine sprocket nut Engine sprocket cover bolts 87 in·lb Engine sprocket cover damper bolt 61 in·lb Rear sprocket nuts Speed sensor bolt 61 in·lb...
  • Page 36 2-8 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Handlebar lower clamp nuts Handlebar switch housing screws 0.35 30 in·lb Frame: Footpeg holder bolts Muffler mounting bolts Side stand bolt Side stand switch bolt 78 in·lb 0.35 ∼...
  • Page 37: Specifications

    PERIODIC MAINTENANCE 2-9 Specifications Item Standard Service Limit Fuel System: 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Throttle grip free play Idle speed 1 100 ± 50 r/min (rpm) – – – Bypass screws (turn out) 2 ± 1/4 (for reference) Engine vacuum 32.7 ±...
  • Page 38 2-10 PERIODIC MAINTENANCE Specifications Item Standard Service Limit Air pressure: (when cold) – – – Front Up to 180 kg (396 lb) load: 250 kPa (2.5 kgf/cm², 36 psi) Rear Up to 180 kg (396 lb) load: – – – 290 kPa (2.9 kgf/cm², 41 psi) Final Drive: 20 ∼...
  • Page 39: Special Tools

    PERIODIC MAINTENANCE 2-11 Special Tools Steering Stem Nut Wrench: Pilot Screw Adjuster, C: 57001–1100 57001–1292 Jack: Hand Tester: 57001–1238 57001–1394 Oil Filter Wrench: Spark Plug Wrench (Owner’s Tool): 57001–1249 92110–1132...
  • Page 40: Periodic Maintenance Procedures

    2-12 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel System (DFI) Fuel Hose and Connection Inspection ○ The fuel hoses are designed to be used throughout the motorcycle’s life without any maintenance, however, if the motorcycle is not properly handled, the high pressure in- side the fuel line can cause fuel to leak [A] or the hose to burst.
  • Page 41: Throttle Control System Inspection

    PERIODIC MAINTENANCE 2-13 Periodic Maintenance Procedures Throttle Control System Inspection Throttle Grip Play Inspection • Check the throttle grip free play [A]. If the free play is incorrect, adjust the throttle cable (see below). Throttle Grip Free Play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Standard: •...
  • Page 42: Idle Speed Inspection

    2-14 PERIODIC MAINTENANCE Periodic Maintenance Procedures Throttle Bore Cleaning • Check the throttle bore for cleanliness as follows: ○ Remove the throttle body assy (see Fuel System (DFI) chapter). ○ Check the main throttle valves and throttle bores [A] for carbon deposits by opening the main valves.
  • Page 43: Engine Vacuum Synchronization Inspection

    PERIODIC MAINTENANCE 2-15 Periodic Maintenance Procedures Engine Vacuum Synchronization Inspection NOTE ○ These procedures are explained on the assumption that the inlet and exhaust systems of the engine are in good condition. • Situate the motorcycle so that it is vertical. •...
  • Page 44 2-16 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Install the fuel tank (see Fuel System (DFI) chapter). • Start the engine and warm it up thoroughly. • Check the idle speed. Tachometer [A] If the idle speed is out of the specified range, adjust it. CAUTION Do not measure the idle speed by the tachometer of the meter unit.
  • Page 45 PERIODIC MAINTENANCE 2-17 Periodic Maintenance Procedures If any one vacuum measurement is out of the standard measurement after synchronization, adjust the bypass screws [A]. Front [B] Special Tool - Pilot Screw Adjuster, C: 57001-1292 • Adjust the lowest vacuum between #1 and #2 to the high- est of #1 and #2.
  • Page 46 2-18 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Back out the same number of turns counted when first turned in. This is to set the screw to its original position. NOTE ○ A throttle body has different “turns out” of the bypass screw for each individual unit.
  • Page 47: Air Cleaner Element Cleaning

    PERIODIC MAINTENANCE 2-19 Periodic Maintenance Procedures Air Cleaner Element Cleaning NOTE ○ In dusty areas, the element should be cleaned more frequently than the recommended interval. ○ After riding through rain or on muddily roads, the ele- ment should be cleaned immediately. WARNING If dirt or dust is allowed to pass through into the throttle assy, the throttle may become stuck, possi-...
  • Page 48: Evaporative Emission Control System Inspection (cal)

    2-20 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Clean the element by tapping it lightly to loosen dust. • Blow away the remaining dust by applying compressed air [A] from the outside to the inside (from the clean side to the dirty side). •...
  • Page 49: Cooling System

    PERIODIC MAINTENANCE 2-21 Periodic Maintenance Procedures ○ Disconnect the hoses from the separator, and remove the separator [A] from the motorcycle left side. Front [B] ○ Visually inspect the separator for cracks and other dam- age. If the separator has any cracks or damage, replace it with a new one.
  • Page 50 2-22 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Remove the fuel tank (see Fuel System (DFI) chapter). • Remove the radiator cap [A] in two steps. First turn the cap counterclockwise to the first stop. Then push and turn it further in the same direction and remove the cap. ○...
  • Page 51: Engine Top End

    PERIODIC MAINTENANCE 2-23 Periodic Maintenance Procedures • Loosen the air bleeder bolt [A] on the thermostat housing. Front [B] • Replenish the coolant into the radiator until the coolant begins to flow out the air bleeder bolt hole (that is, all the remaining air is forced out).
  • Page 52: Valve Clearance Inspection

    2-24 PERIODIC MAINTENANCE Periodic Maintenance Procedures Valve Clearance Inspection NOTE ○ Valve clearance must be checked and adjusted when the engine is cold (at room temperature). • Remove: Lower Fairings (see Frame chapter) Pickup Coil Cover Cylinder Head Cover (see Cylinder Head Cover Re- moval) •...
  • Page 53: Valve Clearance Adjustment

    PERIODIC MAINTENANCE 2-25 Periodic Maintenance Procedures Valve Clearance Adjustment • To change the valve clearance, remove the camshaft chain tensioner, camshafts and valve lifters. Replace the shim with one of a different thickness. NOTE ○ Mark and record the valve lifter and shim locations so they can be reinstalled in their original positions.
  • Page 54 2-26 PERIODIC MAINTENANCE Periodic Maintenance Procedures VALVE CLEARANCE ADJUSTMENT CHART INLET VALVE 1. Measure the clearance (when engine is cold). 2. Check present shim size. 3. Match clearance in vertical column with present shim size in horizontal column. 4. Install the shim specified where the lines intersect. This shim will give the proper clearance. Example: Present shim is 2.95 mm Measured clearance is 0.45 mm...
  • Page 55 PERIODIC MAINTENANCE 2-27 Periodic Maintenance Procedures VALVE CLEARANCE ADJUSTMENT CHART EXHAUST VALVE 1. Measure the clearance (when engine is cold). 2. Check present shim size. 3. Match clearance in vertical column with present shim size in horizontal column. 4. Install the shim specified where the lines intersect. This shim will give the proper clearance. Example: Present shim is 2.95 mm.
  • Page 56: Clutch

    2-28 PERIODIC MAINTENANCE Periodic Maintenance Procedures Clutch Clutch Adjust Inspection • Pull the clutch lever just enough to take up the free play [A]. • Measure the gap between the lever and the lever holder. If the gap is too wide, the clutch may not release fully. If the gap is too narrow, the clutch may not engage fully.
  • Page 57: Engine Lubrication System

    PERIODIC MAINTENANCE 2-29 Periodic Maintenance Procedures Engine Lubrication System Engine Oil Change • Situate the motorcycle so that it is vertical after warming up the engine. • Remove the engine drain plug [A] to drain the oil. ○ The oil in the oil filter can be drained by removing the filter (see Oil Filter Change).
  • Page 58: Wheels/tires

    2-30 PERIODIC MAINTENANCE Periodic Maintenance Procedures Wheels/Tires Tire Inspection As the tire tread wears down, the tire becomes more sus- ceptible to puncture and failure. An accepted estimate is that 90 % of all tire failures occur during the last 10 % of tread life (90 % worn).
  • Page 59: Air Pressure Inspection/adjustment

    PERIODIC MAINTENANCE 2-31 Periodic Maintenance Procedures Air Pressure Inspection/Adjustment • Remove the air valve cap. • Measure the tire air pressure with an air pressure gauge [A] when the tires are cold (that is, when the motorcycle has not been ridden more than a mile during the past 3 hours).
  • Page 60: Wheel Alignment Inspection/adjustment

    2-32 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Tighten both chain adjuster locknuts securely. • Tighten the axle nut. Torque - Rear Axle Nut: 127 N·m (13 kgf·m, 94 ft·lb) • Turn the wheel, measure the chain slack again at the tight- est position, and readjust if necessary.
  • Page 61: Drive Chain Lubrication

    PERIODIC MAINTENANCE 2-33 Periodic Maintenance Procedures • Rotate the rear wheel to inspect the drive chain for dam- aged rollers, and loose pins and links. If there is any irregularity, replace the drive chain. Lubricate the drive chain if it appears dry. •...
  • Page 62: Brakes

    2-34 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Apply oil to the sides of the rollers so that oil will penetrate to the rollers and bushings. Apply the oil to the O-rings so that the O-rings will be coated with oil. •...
  • Page 63: Caliper Fluid Seal Damage

    PERIODIC MAINTENANCE 2-35 Periodic Maintenance Procedures If it does not, adjust and inspect 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 64: Master Cylinder Inspection (visual Inspection)

    2-36 PERIODIC MAINTENANCE Periodic Maintenance Procedures Master Cylinder Inspection (Visual Inspection) • Disassemble the front and rear master cylinders. • Check that there are no scratches, rust or pitting on the inner wall [A] of each master cylinder and on the outside of each piston [B].
  • Page 65: Level Inspection

    PERIODIC MAINTENANCE 2-37 Periodic Maintenance Procedures Level Inspection • Check that the brake fluid level in the front brake reservoir [A] is above the lower level line [B]. NOTE ○ Hold the reservoir horizontal by turning the handlebar when checking brake fluid level. If the fluid level is lower than the lower level line, fill the reservoir to the upper level line [C] in the reservoir.
  • Page 66 2-38 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Level the brake fluid reservoir. • Remove the reservoir cap and diaphragm. • Remove the rubber cap from the bleed valve [A] on the caliper. • Attach a clear plastic hose [B] to the bleed valve, and run the other end of the hose into a container.
  • Page 67: Brake Line Bleeding

    PERIODIC MAINTENANCE 2-39 Periodic Maintenance Procedures Brake Line Bleeding The brake fluid has a very low compression coefficient so that almost all the movement of the brake lever or pedal is transmitted directly to the caliper for braking action. Air, however, is easily compressed.
  • Page 68 2-40 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Bleed the brake line and the caliper: ○ Repeat this operation until no more air can be seen com- ing out into the plastic hose. 1. Pump the brake lever until it becomes hard, and apply the brake and hold it [A].
  • Page 69: Brake Hoses And Connections Inspection

    PERIODIC MAINTENANCE 2-41 Periodic Maintenance Procedures WARNING When working with the disc brake, observe the pre- cautions listed below. 1. Never reuse old brake fluid. 2. Do not use fluid from a container that has been left unsealed or that has been open for a long time. 3.
  • Page 70: Suspension

    2-42 PERIODIC MAINTENANCE Periodic Maintenance Procedures Suspension Front Fork Oil Leak Check • Visually inspect the front forks [A] for oil leakage, scoring or scratches on the outer surface of the inner tubes. Replace or repair any defective parts, if necessary. Rear Shock Absorber Oil Leak Check •...
  • Page 71: Steering

    PERIODIC MAINTENANCE 2-43 Periodic Maintenance Procedures Steering Steering Inspection • Lift the front wheel off the ground using the jack. Special Tool - Jack: 57001–1238 • With the front wheel pointing straight ahead, alternately tap each end of the handlebar. The front wheel should swing fully left and right from the force of gravity until the fork hits the stop.
  • Page 72: Stem Bearing Lubrication

    2-44 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Adjust the steering. Special Tool - Steering Stem Nut Wrench: 57001–1100 [B] If the steering is too tight, loosen the stem nut [A] a fraction of a turn. If the steering is too loose, tighten the stem nut a fraction of a turn.
  • Page 73 PERIODIC MAINTENANCE 2-45 Periodic Maintenance Procedures • Unscrew the thermostat bracket bolt [A]. ○ If removing the spark plug #2 or #3. • Disconnect: Stick Coil Connectors [A] • Pull out the stick coil #1 [B]. • Take out the camshaft position sensor connector [C] from the bracket.
  • Page 74 2-46 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Clean the spark plug, preferably in a sandblasting device, and then clean off any abrasive particles. The plug may also be cleaned using a high-flash point solvent and a wire brush or other tool. If the spark plug center electrode [A] and/or side elec- trode [B] are corroded or damaged, or if the insulator [C] is cracked, replace the plug.
  • Page 75: General Lubrication

    PERIODIC MAINTENANCE 2-47 Periodic Maintenance Procedures General Lubrication 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 76: Nut, Bolt, And Fastener Tightness

    2-48 PERIODIC MAINTENANCE Periodic Maintenance Procedures Nut, Bolt, and Fastener Tightness Tightness Inspection • Check the tightness of the bolts and nuts listed here. Also, check to see that each cotter pin is in place and in good condition. NOTE ○...
  • Page 77 FUEL SYSTEM (DFI) 3-1 Fuel System (DFI) Table of Contents Exploded View........Crankshaft Sensor (Service Code DFI Parts Location......21)........... 3-55 DFI Wiring Diagram ......3-10 Crankshaft Sensor Specifications ........3-12 Removal/Installation....3-55 Special Tools ........3-14 Crankshaft Sensor Inspection..3-55 DFI Servicing Precautions ....
  • Page 78 3-2 FUEL SYSTEM (DFI) ECU Installation ......3-71 Choke Lever Operation....3-88 ECU Power Supply Inspection..3-72 Choke Lever Play Inspection ..3-88 DFI Power Source ......3-74 Choke Lever Play Adjustment..3-88 ECU Fuse Removal ..... 3-74 Cable Removal/Installation ..3-88 ECU Fuse Installation ....
  • Page 79: Exploded View

    FUEL SYSTEM (DFI) 3-3 Exploded View Clifornia Evaporative Emission Control System 1. Canister 6. Fuel return hose (left, red) 2. Separator 7. Fuel tank breather hose (right, blue) 3. Right fitting of throttle body #2 8. Separator breather hose (blue) 4.
  • Page 80 3-4 FUEL SYSTEM (DFI) Exploded View...
  • Page 81 FUEL SYSTEM (DFI) 3-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Throttle cable plate bolt 52 in·lb Throttle body cover bolts 61 in·lb Throttle assy holder clamp bolts 17 in·lb Choke link holder screws 0.21 18 in·lb Delivery pipe screws 0.35 30 in·lb Bypass screws...
  • Page 82 3-6 FUEL SYSTEM (DFI) Exploded View...
  • Page 83 FUEL SYSTEM (DFI) 3-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Inlet air pressure sensor bolt 104 in·lb Water temperature sensor Vehicle downsensor bolts 17 in·lb Camshaft position sensor bolt 104 in·lb Camshaft position sensor rotor bolt 104 in·lb Air cleaner duct holder screws 0.39 34 in·lb...
  • Page 84: Dfi Parts Location

    3-8 FUEL SYSTEM (DFI) DFI Parts Location DFI: DFI Parts (this chapter) ECU Fuse 15A 19. Turn Signal Relay F: Front ECU (DFI) 20. Subthrottle Sensor (DFI) 1. Water temperature 10. Stick Coils 21. Main Throttle Sensor (DFI) Sensor (DFI) 11.
  • Page 85 FUEL SYSTEM (DFI) 3-9 DFI Parts Location [1], [2], [10], [13], [22] and [24] are not included.
  • Page 86: Dfi Wiring Diagram

    3-10 FUEL SYSTEM (DFI) DFI Wiring Diagram...
  • Page 87: Dfi Wiring Diagram

    FUEL SYSTEM (DFI) 3-11 DFI Wiring Diagram Terminal Names 26. ECU Power Source Circuit Ground to Bat- 1. Power Supply to Sensors (inlet air pres- tery (–) Terminal sure, atmospheric pressure, and throttle 27. Engine Stop Switch Signal sensors) from ECU. 28.
  • Page 88: Specifications

    3-12 FUEL SYSTEM (DFI) Specifications Item Standard Digital Fuel Injection System Idle Speed 1 100 ± 50 r/min (rpm) Throttle Assy: Four barrel type Type Bore 38 mm (1.5 in.) ECU (Electronic Control Unit): Make Denso Type Digital memory type, with built in IC igniter, sealed with resin 100 ∼...
  • Page 89 FUEL SYSTEM (DFI) 3-13 Specifications Item Standard Within 0.5 ∼ 1.0 sec. Detection time with the sensor tilted 60 ∼ 70° or more: 3.7 ∼ 4.4 V Output voltage with sensor arrow mark pointed up: 0.4 ∼ 1.4 V Subthrottle Sensor: Non-adjustable and non-removal 4.75 ∼...
  • Page 90: Special Tools

    57001–125 57001–1417 Carburetor Drain Plug Wrench, Hex 3: Needle Adapter Set: 57001–1269 57001–1457 Fork Oil Level Gauge: Throttle Sensor Setting Adapter: 57001–1290 57001–1538 Hand Tester: Sensor Harness Adapter: 57001–1394 57001–1561 Throttle Sensor Setting Adapter: Kawasaki Bond (Silicone Sealant): 57001–1400 56019–120...
  • Page 91: Dfi Servicing Precautions

    FUEL SYSTEM (DFI) 3-15 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 92 3-16 FUEL SYSTEM (DFI) DFI Servicing Precautions ○ To maintain the correct fuel/air mixture (F/A), there must be no inlet air leaks in the DFI system. Be sure to install the oil filler plug [A] after filling the engine oil. Clutch Cover [B] Front [C] Torque - Oil Filler Plug: 1.5 N·m (0.15 kgf·m, 13 in·lb)
  • Page 93: Troubleshooting The Dfi System

    FUEL SYSTEM (DFI) 3-17 Troubleshooting the DFI System Outline When an abnormality in the system occurs, the FI indica- tor LED (Light Emitting Diode) light goes on to alert the rider on the meter panel. In addition, the condition of the problem is stored in the memory of the ECU (electronic control unit).
  • Page 94 ○ After measurement, remove the needle adapters and ap- ply silicone sealant to the seals [A] of the connector [B] for waterproofing. Silicone Sealant (Kawasaki Bond: 56019–120) - Seals of Connector • Always check battery condition before replacing the DFI parts.
  • Page 95 FUEL SYSTEM (DFI) 3-19 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 96 3-20 FUEL SYSTEM (DFI) 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 97: Inquiries To Rider

    FUEL SYSTEM (DFI) 3-21 Troubleshooting the DFI System DFI Diagnosis Flow Chart Inquiries to Rider ○ Each rider reacts to problems in different ways, so it is important to confirm what kind of symptoms the rider has encountered. ○ Try to find out exactly what problem occurred under exactly what conditions by asking the rider; knowing this information may help you reproduce the problem.
  • Page 98 3-22 FUEL SYSTEM (DFI) Troubleshooting the DFI System Sample Diagnosis Sheet Rider name: Registration No. (license plate No.): Year of initial registration: Model: Engine No.: Frame No.: Date problem occurred: Mileage: Environment when problem occurred. Weather □ fine, □ cloudy, □ rain, □ snow, □ always, □ other: Temperature □...
  • Page 99 FUEL SYSTEM (DFI) 3-23 Troubleshooting the DFI System Poor running □ choke lever pulled out fully (push it in fully) at low speed □ very low choke speed (adjust choke cable) □ very low idle speed, □ very high idle speed, □ rough idle speed □...
  • Page 100: Dfi System Troubleshooting Guide

    3-24 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide NOTE ○ This is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties. ○...
  • Page 101 FUEL SYSTEM (DFI) 3-25 DFI System Troubleshooting Guide Symptoms or possible Causes Actions (chapter) Ignition and engine stop switches not ON Turn both switches ON . Clutch lever not pulled in and gear not in neutral Pull the lever in and shift the gear in neutral. whether sidestand up or not Though clutch lever pulled in, sidestand up and Pull the lever in and shift the gear in neutral.
  • Page 102: Poor Running At Low Speed

    3-26 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or possible Causes Actions (chapter) Piston ring /groove clearance excessive Inspect and replace (see chapter 5). Cylinder head gasket damaged Replace (see chapter 5). Cylinder head warped Inspect and replace (see chapter 5). No valve clearance Adjust (see chapter 2).
  • Page 103 FUEL SYSTEM (DFI) 3-27 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Atmospheric pressure sensor trouble Inspect (see chapter 3). Fuel pressure too low or too high Inspect (see chapter 3). Battery voltage low Inspect and charge (see chapter 16). Incorrect idle speed : Water temperature sensor trouble Inspect (see chapter 3).
  • Page 104 3-28 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Subthrottle sensor trouble Inspect (see chapter 3). Subthrottle valve actuator trouble Inspect (see chapter 3). Water temperature sensor trouble Inspect (see chapter 3). Atmospheric pressure sensor trouble Inspect (see chapter 3).
  • Page 105 FUEL SYSTEM (DFI) 3-29 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Clean spark plugs and adjust plug gap (see Spark plug dirty, broken or gap maladjusted chapter 2). Too low fuel pressure Inspect (see chapter 3). Fuel pump trouble Inspect (see chapter 3).
  • Page 106: Poor Running Or No Power At High Speed

    3-30 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Poor Running or No Power at High Speed: Symptoms or Possible Causes Actions (chapter) Firing incorrect : Clean spark plug and adjust plug gap (see chapter Spark plug dirty, broken or maladjusted Spark plug cap trouble Inspect stick coil (see chapter 16).
  • Page 107 FUEL SYSTEM (DFI) 3-31 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Fuel poor quality or incorrect (Use the gasoline Change fuel (see chapter 3). recommended in the Owner’s Manual) Spark plug incorrect Replace it with the correct plug (see chapter 16). Stick coil trouble Inspect (see chapter 16).
  • Page 108 3-32 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Too low fuel pressure Inspect fuel line and fuel pump (see chapter 3). Water temperature sensor trouble Inspect and replace (see chapter 3). Inlet air temperature sensor trouble Inspect and replace (see chapter 3).
  • Page 109: Self-diagnosis

    FUEL SYSTEM (DFI) 3-33 Self-Diagnosis Self-diagnosis Outline The self-diagnosis system has three modes and can be switched to another mode by grounding the self-diagnosis terminal. 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 110: Service Code Clearing Procedures

    3-34 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 111 FUEL SYSTEM (DFI) 3-35 Self-Diagnosis...
  • Page 112: How To Read Service Codes

    3-36 FUEL SYSTEM (DFI) Self-Diagnosis How to Read Service Codes ○ Service codes are shown by a series of long and short blinks of the FI indicator LED light as shown below. ○ Read 10th digit and unit digit as the FI indicator LED light blinks. ○...
  • Page 113: Service Code Table

    FUEL SYSTEM (DFI) 3-37 Self-Diagnosis Service Code Table Service FI Indicator LED Light Problems Code Main throttle sensor malfunction, wiring open or short Inlet air pressure sensor malfunction, wiring open or short Inlet air temperature sensor malfunction, wiring open or short Water temperature sensor malfunction, wiring open or short Atmospheric pressure sensor malfunction, wiring...
  • Page 114: Backups

    3-38 FUEL SYSTEM (DFI) Self-Diagnosis Backups ○ The ECU takes the following measures to prevent engine damage when the DFI or the ignition system parts have troubles. Service Output Signal Usable Parts Backups by ECU Codes Range or Criteria If the main throttle sensor system fails (the signal is out of the usable range, wiring short or open), the ECU locks ignition timing into the ignition Main...
  • Page 115 FUEL SYSTEM (DFI) 3-39 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 (no Stick Coil winding must send signal, wiring short or open), the ECU shuts off #1 (Ignition signals (output voltage) the injector #1 to stop fuel to the cylinder #1,...
  • Page 116: Main Throttle Sensor (service Code 11)

    3-40 FUEL SYSTEM (DFI) Main Throttle Sensor (Service Code 11) Main Throttle Sensor Removal/Adjustment CAUTION Do not remove or adjust the main throttle sensor [A] since it has been adjusted and set with precision at the factory. Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it.
  • Page 117: Output Voltage Inspection

    FUEL SYSTEM (DFI) 3-41 Main Throttle Sensor (Service Code 11) Output Voltage Inspection • Measure the output voltage at the main throttle sensor in the same way as input voltage inspection, Note the following. • Disconnect the main throttle sensor (gray) [A] and con- nect the harness adapter [B] between these connectors.
  • Page 118: Resistance Inspection

    3-42 FUEL SYSTEM (DFI) Main Throttle Sensor (Service Code 11) Resistance Inspection • Turn the ignition switch OFF. • Disconnect the main throttle sensor connector. • Connect a digital meter [A] to the main throttle sensor connector [B]. • Measure the main throttle sensor resistance. Main Throttle Sensor Resistance Connections: BL lead [C] ←→...
  • Page 119: Inlet Air Pressure Sensor (service Code 12)

    FUEL SYSTEM (DFI) 3-43 Inlet Air Pressure Sensor (Service Code 12) CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the part can damage it. Removal • Remove: Fuel Tank (see Fuel System chapter) Water Temperature Sensor Connector [A] Inlet Air Pressure Sensor Bolt [B] •...
  • Page 120: Output Voltage Inspection

    3-44 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code 12) Output Voltage Inspection NOTE ○ The output voltage changes according to the local at- mospheric pressure. • Measure the output voltage at the ECU in the same way as input voltage inspection. Note the following. Inlet Air Pressure Sensor Output Voltage Connections to ECU Meter (+) →...
  • Page 121 FUEL SYSTEM (DFI) 3-45 Inlet Air Pressure Sensor (Service Code 12) ○ Turn the ignition switch ON. ○ Measure the inlet air pressure sensor output voltage from various vacuum readings, while pulling the handle of the fork oil level gauge. ○...
  • Page 122 3-46 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code 12) Pv = 24 ∼ 55 cmHg...
  • Page 123 FUEL SYSTEM (DFI) 3-47 Inlet Air Pressure Sensor (Service Code 12) Pv = 55 ∼ 86 cmHg Vv: Inlet Air Pressure Sensor Output Volt- ID: Idling age (V) (Digital Meter Reading) TO: Throttle Full Open Pv: Throttle Vacuum Pressure (absolute) ST: Standard of Sensor Output Voltage (v) Ps: Standard Atmospheric Pressure (abso- UR: Usable Range of Sensor Output Voltage (v)
  • Page 124: Inlet Air Temperature Sensor (service Code 13)

    (see ECU section in this chapter). If the wiring is good, check the sensor resistance. • Remove the needle adapter set, and apply silicone sealant to the seals of the connector for waterproofing. Silicone Sealant (Kawasaki Bond: 56019–120) - Seals of ECU Connectors...
  • Page 125: Sensor Resistance Inspection

    FUEL SYSTEM (DFI) 3-49 Inlet Air Temperature Sensor (Service Code 13) Sensor Resistance Inspection • Remove the inlet air temperature sensor (see this sec- tion). • Suspend the sensor [A] in a container of machine oil so that the heat-sensitive portion is submerged. •...
  • Page 126: Code 14)

    4.8 V, the ECU is normal. If the wiring is good, check the water temperature sensor resistance. • Remove the needle adapter set, and apply silicone sealant to the seals of the connector for waterproofing. Silicone Sealant (Kawasaki Bond: 56019–120) - Seals of ECU Connectors...
  • Page 127: Sensor Resistance Inspection

    FUEL SYSTEM (DFI) 3-51 Water Temperature Sensor (Service Code 14) A. ECU D. Water Temperature Sensor V. Coolant Temperature Gauge in Tachometer Sensor Resistance Inspection • Remove the water temperature sensor (see this section). • Refer to the Electrical System chapter for water temper- ature sensor inspection.
  • Page 128: Atmospheric Pressure Sensor (service Code 15)

    3-52 FUEL SYSTEM (DFI) Atmospheric Pressure Sensor (Service Code 15) CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. NOTE ○ The atmospheric pressure sensor is the same part as the inlet air pressure sensor except that the inlet air pressure sensor has the vacuum hose and different wiring.
  • Page 129: Output Voltage Inspection

    FUEL SYSTEM (DFI) 3-53 Atmospheric Pressure Sensor (Service Code 15) Output Voltage Inspection • Measure the output voltage at the ECU in the same way as input voltage inspection. Note the following. Digital Meter [A] ECU Connector [B] Atmospheric Pressure Sensor Output Voltage Connections to ECU Meter (+) →...
  • Page 130 3-54 FUEL SYSTEM (DFI) Atmospheric Pressure Sensor (Service Code 15) Va: Atmospheric Pressure Sensor Output ST: Standard of Sensor Output Voltage (v) Voltage (v) UR: Usable Range of Sensor Output Voltage (v) H: Altitude (m or feet) A. ECU E. Atmospheric Pressure Sensor...
  • Page 131: Crankshaft Sensor (service Code 21)

    FUEL SYSTEM (DFI) 3-55 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 132: Camshaft Position Sensor (service Code 23)

    3-56 FUEL SYSTEM (DFI) Camshaft Position Sensor (Service Code 23) Start the engine and switch the diagnosis mode to Dealer 1 mode to know all the problem that the DFI system has at the time of self-diagnosis. If the engine cannot be started, the self-diagnosis system does not detect dynamic condi- tion of the camshaft position sensor.
  • Page 133: Speed Sensor (service Code 24, 25)

    FUEL SYSTEM (DFI) 3-57 Speed Sensor (Service Code 24, 25) Speed Sensor Removal/Installation • See the Switches and Sensors section in the Electrical System chapter. Speed Sensor Inspection • See the Switches and Sensors section in the Electrical System chapter. Input Voltage Inspection NOTE ○...
  • Page 134 3-58 FUEL SYSTEM (DFI) Speed Sensor (Service Code 24, 25) • Disconnect the speed sensor connector [A] and connect the harness adapter [B] between the harness connector and speed sensor connector. Engine Sprocket Cover [C] • Connect a digital meter to the harness adapter leads. Special Tool - Throttle Sensor Setting...
  • Page 135: Vehicle-down Sensor (service Code 31)

    FUEL SYSTEM (DFI) 3-59 Vehicle-down Sensor (Service Code 31) Removal CAUTION Never drop the down-sensor, especially on a hard surface. Such a shock to the sensor can damage it. • Remove: Connection and Vehicle-down Sensor [A] Bolts and Washers [B] Front [C] Installation •...
  • Page 136 • Remove the needle adapter set, and apply silicone sealant to the seals of the connector for waterproofing. Silicone Sealant (Kawasaki Bond: 56019–120) - Seals of Vehicle-down Sensor Connector If the output voltage is normal, the wiring is suspect. Check the wiring.
  • Page 137 FUEL SYSTEM (DFI) 3-61 Vehicle-down Sensor (Service Code 31) A. ECU a. ECU Fuse 15A f. Sealed Battery S. ECU Main Relay b. Vehicle-down Sensor j. Joint Connector B T. Ignition Switch d. Starter Relay k. Main Fuse 30 A...
  • Page 138: Subthrottle Sensor (service Code 32)

    3-62 FUEL SYSTEM (DFI) Subthrottle Sensor (Service Code 32) Subthrottle Sensor Removal/Adjustment CAUTION Do not remove or adjust the subthrottle sensor [A] since it has been adjusted and set with precision at the factory. Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it.
  • Page 139: Output Voltage Inspection

    FUEL SYSTEM (DFI) 3-63 Subthrottle Sensor (Service Code 32) Output Voltage Inspection • Remove the throttle body assy (see Throttle Body Assy Removal). • Measure the output voltage at the subthrottle sensor in the same way as input voltage inspection. Note the fol- lowing.
  • Page 140: Resistance Inspection

    3-64 FUEL SYSTEM (DFI) Subthrottle Sensor (Service Code 32) Resistance Inspection • Turn the ignition switch OFF. • Disconnect the subthrottle sensor connector. • Connect a digital meter [A] to the subthrottle sensor con- nector [B]. • Measure the subthrottle sensor resistance. Throttle Sensor Resistance Connections: BL lead [C] ←→...
  • Page 141: Stick Coils (#1, #2, #3, #4: Service Code 51, 52, 53, 54)

    FUEL SYSTEM (DFI) 3-65 Stick Coils (#1, #2, #3, #4: Service Code 51, 52, 53, 54) Stick Coil #1: Ignition Coil (Service Code 51) Stick Coil #2: Ignition Coil (Service Code 52) Stick Coil #3: Ignition Coil (Service Code 53) Stick Coil #4: Ignition Coil (Service Code 54) Removal/Installation CAUTION...
  • Page 142 3-66 FUEL SYSTEM (DFI) Stick Coils (#1, #2, #3, #4: Service Code 51, 52, 53, 54) A. ECU X. Ignition Fuse 10 A f. Sealed Battery M. Stick Coils Y. Junction Box k. Main Fuse 30 A N. Engine Stop Switch d.
  • Page 143: Subthrottle Valve Actuator (service Code 62)

    FUEL SYSTEM (DFI) 3-67 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 144: Input Voltage Inspection

    3-68 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 throttle body assy (see Throttle Body Assy Removal). • Connect the peak voltage adapter [A] and a digital meter [B] to the connector [C], using the needle adapter set [D].
  • Page 145: Fi Indicator Led Light

    FUEL SYSTEM (DFI) 3-69 FI Indicator LED Light Inspection Flow Chart...
  • Page 146: Led Light Inspection

    3-70 FUEL SYSTEM (DFI) FI Indicator LED Light LED Light Inspection • Remove the meter unit (see Electrical System chapter). • Using two auxiliary leads, supply battery power to the FI indicator LED light [A]. 12 V Battery [B] FI Indicator LED Light Check Connector: Meter Connector [C] (disconnected) Connection:...
  • Page 147: Ecu

    FUEL SYSTEM (DFI) 3-71 CAUTION Never drop the ECU, especially on a hard surface. Such a shock to the ECU can damage it. ECU Identification ○ Most countries have their own regulations, so each ECU has different characteristic. So, do not confuse ECU’s with each other and use only the ECU’s for your country.
  • Page 148: Ecu Power Supply Inspection

    3-72 FUEL SYSTEM (DFI) If the rubber protector [A] is removed, install it. ECU [B] ECU Power Supply Inspection • Visually inspect the terminals [A] of the ECU connectors. If the connector is clogged with mud or dust, blow it off with compressed air.
  • Page 149 FUEL SYSTEM (DFI) 3-73 • Check the ECU power source voltage with a digital meter [A]. ○ Position the terminal in accordance with terminal numbers of ECU connectors [B] in this chapter figure. Battery [C] ECU Power Source Inspection Meter between Terminal 13 (W/Y) and Connections: Battery (–) Terminal...
  • Page 150: Dfi Power Source

    3-74 FUEL SYSTEM (DFI) DFI Power Source ECU Fuse Removal • Refer to the Electrical System chapter for the ECU fuse removal. ECU Fuse Installation If a fuse fails during operation, inspect the DFI system to determine the cause, and then replace it with a new fuse of proper amperage.
  • Page 151: Fuel Line

    FUEL SYSTEM (DFI) 3-75 Fuel Line Fuel Pressure Inspection NOTE ○ This inspection can determine which trouble the DFI system has, mechanical or electrical trouble. ○ It is preferable to measure the fuel pressure while run- ning the motorcycle just when trouble occurred in order to know symptom well.
  • Page 152: Fuel Flow Rate Inspection

    3-76 FUEL SYSTEM (DFI) Fuel Line • Start the engine, and let it idle. • Measure the fuel pressure with the engine idling. Fuel Pressure (idling) Standard: 310 kPa (3.2 kgf/cm², 46 psi) NOTE ○ The gauge needle will fluctuate. Read the pressure at the average of the maximum and minimum indications.
  • Page 153 FUEL SYSTEM (DFI) 3-77 Fuel Line • Open the fuel tank cap [A] to lower the pressure in the tank. Front [B] • Be sure to place a piece of cloth around the fuel pump outlet hose. • Remove the fuel pump outlet hose [A] from the fuel pump [B] and the delivery pipe [C] (see Fuel Pump Removal).
  • Page 154: Fuel Pump

    3-78 FUEL SYSTEM (DFI) Fuel Pump Fuel Pump Removal CAUTION Never drop the fuel pump, especially on a hard sur- face. Such a shock to the pump can damage it. WARNING Gasoline is extremely flammable and can be explo- sive under certain conditions. Make sure the area is well-ventilated and free from any source of flame or sparks;...
  • Page 155: Operation Inspection

    FUEL SYSTEM (DFI) 3-79 Fuel Pump • Replace the fuel pump gasket [A] with a new one. • Check that the fuel pump (–) terminal [A] and band [B] are in place. Front [C] • Apply a non-permanent locking agent to the threads of the fuel pump bolts.
  • Page 156: Pressure Regulator Removal

    3-80 FUEL SYSTEM (DFI) Fuel Pump • Connect the hand tester (25 V DC) to the fuel pump con- nector [A] with needle adapter set. Front [B] Special Tools - Hand Tester: 57001–1394 Needle Adapter Set: 57001–1457 ○ Measure the operating voltage with the engine stopped, and with the connector joined.
  • Page 157: Fuel Pump Relay Removal

    FUEL SYSTEM (DFI) 3-81 Fuel Pump Fuel Pump Relay Removal CAUTION Never drop the relay, especially on a hard surface. Such a shock to the relay can damage it. • Remove the seat cover (see Frame chapter). • Remove the fuel pump relay [A] from the tongue of the storage compartment.
  • Page 158: Fuel Injectors

    3-82 FUEL SYSTEM (DFI) Fuel Injectors Removal/Installation • Refer to the Throttle Body Assy Disassembly/Assembly. Audible Inspection • Start the engine. • Apply the tip of a screwdriver [A] to the injector [C]. Put the grip end onto your ear, and listen whether the injector is clicking or not.
  • Page 159: Output Voltage Inspection

    FUEL SYSTEM (DFI) 3-83 Fuel Injectors Output Voltage Inspection • Turn the ignition switch OFF. • Remove the ECU (see ECU section). • Connect a digital voltmeter [A] to the ECU connector [B] with the needle adapter set [C]. Special Tool - Needle Adapter Set: 57001–1457 Injector Output Voltage Connections to Injector #1 Meter (+) →...
  • Page 160: Injector Signal Test

    3-84 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 (0.071 in.) Terminal Thickness [C]: 0.8 mm (0.031 in.) CAUTION Do not use larger terminals than specified above.
  • Page 161: Injector Resistance Inspection

    FUEL SYSTEM (DFI) 3-85 Fuel Injectors Injector Resistance Inspection • Remove the fuel tank (see Fuel Tank Removal). • Disconnect the connector from the injector [A] (see Throt- tle Body Assy Disassembly/Assembly). • Measure the injector resistance with the hand tester [B]. Front [C] Special Tool - Hand Tester: 57001–1394 Injector Resistance...
  • Page 162 3-86 FUEL SYSTEM (DFI) Fuel Injectors • 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 the clamps [D]) as shown.
  • Page 163 FUEL SYSTEM (DFI) 3-87 Fuel Injectors A. ECU Y. Junction Box f. Sealed Battery K. Fuel Injectors Z. Fuel Pump Relay (for fuel j. Joint Connector B N. Engine Stop Switch pump an injectors) k. Main Fuse 30 A T. Ignition Switch d.
  • Page 164: Throttle Grip And Cables

    3-88 FUEL SYSTEM (DFI) Throttle Grip and Cables Throttle Grip Play Inspection/Adjustment • Refer to the Throttle Control System Inspection in the Pe- riodic Maintenance chapter. Choke Lever Operation ○ Do not use the choke lever except when the engine has a starting difficulty like in cold weather (10 °C, 50 °F or be- low) or at high altitude.
  • Page 165: Throttle Body Assy

    FUEL SYSTEM (DFI) 3-89 Throttle Body Assy Idle Speed Inspection/Adjustment • Refer to the Idle Speed Inspection in the Periodic Main- tenance chapter . Throttle Bore Cleaning • Refer to the Throttle Control System Inspection in the Pe- riodic Maintenance chapter. Engine Vacuum Synchronization...
  • Page 166 3-90 FUEL SYSTEM (DFI) Throttle Body Assy • Loosen: Throttle Assy Holder Clamp Bolts [A] Air Cleaner Duct Clamp Bolts [B] Special Tool - Carburetor Drain Plug Wrench, Hex 3: 57001–1269 • Remove: Right and Left Side Covers (see Frame chapter) Coolant Reserve Tank (see Coolant Change in the Peri- odic Maintenance chapter) Starter Relay, Junction Box (right)
  • Page 167: Throttle Body Assy Installation

    FUEL SYSTEM (DFI) 3-91 Throttle Body Assy • Remove the bolt [A] and the throttle cable plate [B] from the throttle body front side. • Remove the throttle cable lower ends from the throttle pulley. • Remove: Choke Cable Upper End (From choke lever) Choke Cable Lower End [A] Throttle Body #2 [B] •...
  • Page 168: Throttle Body Assy Disassembly

    3-92 FUEL SYSTEM (DFI) 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 (see Throttle Body Assy Removal). • Fit the projection [A] of the right switch housing into the hole [B] of the handlebar (front view).
  • Page 169: Throttle Body Assy Assembly

    FUEL SYSTEM (DFI) 3-93 Throttle Body Assy CAUTION Never drop the injector, especially on a hard sur- face. Such a shock to the injector can damage it. • Pull out [A] the injectors along with the delivery pipe [B]. If necessary, remove the injectors from the delivery pipe. Replace the O-rigs of the indicators.
  • Page 170: Air Cleaner

    3-94 FUEL SYSTEM (DFI) Air Cleaner Element Removal/Installation • Refer to the Air Cleaner Element Cleaning in the Periodic Maintenance chapter. Air Cleaner Oil Draining A drain hose is connected to the bottom of the air cleaner to drain water or oil accumulated in the cleaner part. •...
  • Page 171: Fuel Tank

    FUEL SYSTEM (DFI) 3-95 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 172 3-96 FUEL SYSTEM (DFI) Fuel Tank • Be sure to place a piece of cloth [A] around the fuel hose pump outlet joint [B]. • While pinching the hose joint locks [C] with fingers, pull the joint out along the delivery pipe. Front [D] WARNING Be prepared for fuel spillage;...
  • Page 173: Fuel Tank Installation

    FUEL SYSTEM (DFI) 3-97 Fuel Tank Fuel Tank Installation • Note the above WARNING (see Fuel Tank Removal). • Route the hoses correctly (see Appendix chapter). • Check that the rubber dampers [A] are on the frame and the fuel tank. Front [B] •...
  • Page 174: Fuel Tank And Cap Inspection

    3-98 FUEL SYSTEM (DFI) Fuel Tank Fuel Tank and Cap Inspection • Visually inspect the gasket [A] on the tank cap for any damage. Replace the gasket if it is damaged. • Check to see if the water drain pipe [B] and fuel breather pipe [C] in the tank are not clogged.
  • Page 175: Evaporative Emission Control System

    FUEL SYSTEM (DFI) 3-99 Evaporative Emission Control System Parts Removal/Installation WARNING Gasoline is extremely flammable and can be ex- plosive under certain conditions. Turn the ignition switch OFF. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks;...
  • Page 176: Separator Operation Test

    3-100 FUEL SYSTEM (DFI) Evaporative Emission Control System Separator Operation Test WARNING Gasoline is extremely flammable and can be ex- plosive under certain conditions. Turn the ignition switch OFF. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks;...
  • Page 177 COOLING SYSTEM 4-1 Cooling System Table of Contents Exploded View........................Coolant Flow Chart......................... Specifications ......................... Special Tool ..........................Coolant ........................... Coolant Deterioration Inspection..................Coolant Level Inspection....................Coolant Draining ....................... Coolant Filling ........................Pressure Testing ....................... Cooling System Flushing ....................Coolant Reserve Tank Removal/Installation ..............Water Pump..........................
  • Page 178: Exploded View

    4-2 COOLING SYSTEM Exploded View...
  • Page 179 COOLING SYSTEM 4-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Radiator hose clamp screws 17 in·lb Thermostat air bleeder bolt 0.80 69 in·lb Radiator fan bolts 0.85 74 in·lb Water pump impeller bolt 87 in·lb Water pump cover bolts 95 in·lb Water pump drain bolt 95 in·lb...
  • Page 180: Coolant Flow Chart

    4-4 COOLING SYSTEM Coolant Flow Chart...
  • Page 181 COOLING SYSTEM 4-5 Coolant Flow Chart 1. Drain Bolt 9. Oil Filter 17. Water Temperature Sen- 2. Water Pump 10. Outlet Hose 3. Cylinder Jacket 11. Inlet Hose 18. Radiator Fan Switch 4. Cylinder Head Jacket 12. Oil Cooler 19. Hot Coolant 5.
  • Page 182: Specifications

    4-6 COOLING SYSTEM Specifications Item Standard Coolant provided when shipping: Type (recommended) Permanent type of antifreeze (soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators) Color Green Mixed ratio Soft water 50%, coolant 50% Freezing point –...
  • Page 183: Special Tool

    COOLING SYSTEM 4-7 Special Tool Bearing Driver Set: Kawasaki Bond (Silicone Sealant): 57001–1129 56019–120 Bearing Driver: 57001–382...
  • Page 184: Coolant

    4-8 COOLING SYSTEM Coolant Coolant Deterioration Inspection • Remove the left side cover (see Frame chapter). • Visually inspect the coolant [A] in the reserve tank. Front [B] 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.
  • Page 185: Pressure Testing

    COOLING SYSTEM 4-9 Coolant Pressure Testing • Remove the fuel tank (see Fuel System (DFI) chapter). • Remove the radiator cap, and install a cooling system pressure tester [A] on the filler neck [B]. NOTE ○ Wet the cap sealing surfaces with water or coolant to prevent pressure leaks.
  • Page 186: Water Pump

    4-10 COOLING SYSTEM Water Pump Water Pump Removal • Refer to Oil Pump Removal in the Engine Lubrication Sys- tem chapter. Water Pump [A] Front [B] Water Pump Installation • Refer to Oil Pump Installation in the Engine Lubrication System chapter. Water Pump Inspection •...
  • Page 187 COOLING SYSTEM 4-11 Water Pump • Be sure to replace the mechanical seal, oil seal, and O -ring with new ones because these parts will be damaged by removal. • Apply plenty of high temperature grease to the oil seal lips.
  • Page 188: Radiator

    4-12 COOLING SYSTEM Radiator Radiator 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 189: Radiator Inspection

    COOLING SYSTEM 4-13 Radiator • If necessary, remove: Radiator Fan Mounting Bolts [A] Radiator Fan [B] Radiator Inspection • Check the radiator core. If there are obstructions to air flow, remove them. If the corrugated fins [A] are deformed, carefully straighten them.
  • Page 190: Radiator Filler Neck Inspection

    4-14 COOLING SYSTEM Radiator • Install the cap [A] on a cooling system pressure tester [B]. NOTE ○ Wet the cap sealing surfaces with water or coolant to prevent pressure leaks. • Watching the pressure gauge, pump the pressure tester to build up the pressure until the relief valve opens: the gauge needle flicks downward.
  • Page 191: Thermostat

    COOLING SYSTEM 4-15 Thermostat Thermostat Removal • Remove: Coolant : Drain about 200 mL Fuel Tank (see Fuel System (DFI) chapter) Thermostat Bracket Bolt [A] Water Temperature Sensor Connector [B] Three Water Hoses [C] • Remove the thermostat housing [D]. Front [E] •...
  • Page 192 4-16 COOLING SYSTEM 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 193: Hose And Pipes

    COOLING SYSTEM 4-17 Hose and Pipes Hose Installation • Install the hoses and pipes, being careful to follow bend- ing direction. Avoid sharp bending, kinking, flattening or twisting. • Run the hoses in accordance with the Cable, Wire, and Hose Routing section in the Appendix chapter. •...
  • Page 194: Radiator Fan Switch, Water Temperature Sensor

    4-18 COOLING SYSTEM Radiator Fan Switch, Water Temperature Sensor CAUTION The fan switch or the water temperature sensor should never be allowed to fall on a hard surface. Such a shock to their parts can damage them. Radiator Fan Switch Removal •...
  • Page 195 ENGINE TOP END 5-1 Engine Top End Table of Contents Exploded View........Cylinder Head Warp..... 5-21 Specifications ........Valves ..........5-22 Special Tools and Sealant ....Valve Clearance Inspection ..5-22 Clean Air System....... 5-10 Valve Clearance Adjustment..5-22 Air Suction Valve Removal... 5-10 Valve Removal ......
  • Page 196: Exploded View

    5-2 ENGINE TOP END Exploded View...
  • Page 197 M: Apply molybdenum disulfide grease. MO: Apply molybdenum disulfide oil. (mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10:1) R: Replacement Parts S: Follow the specific tightening sequence. SS: Apply silicone sealant (Kawasaki Bond: 56019–120). CAL: California model...
  • Page 198 5-4 ENGINE TOP END Exploded View...
  • Page 199 ENGINE TOP END 5-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Coolant Drain Plug (Cylinder) 87 in·lb Exhaust pipe manifold holder nuts Muffler body clamp bolts Muffler body mounting bolts and nuts Crankshaft sensor cover bolts 95 in·lb 6: "R" marked side faces up. 7.
  • Page 200: Specifications

    5-6 ENGINE TOP END Specifications Item Standard Service Limit Clean Air System: Vacuum switch valve closing Open → Close 45 ∼ 53 kPa pressure: - - - (340 ∼ 400 mmHg, 6.5 ∼ 7.7 psi) Camshafts: 36.146 ∼ 36.254 mm Cam height: Exhaust 36.05 mm...
  • Page 201 ENGINE TOP END 5-7 Specifications Item Standard Service Limit Valve/valve guide clearance 0.09 ∼ 0.18 mm (wobble method): Exhaust 0.40 mm (0.0035 ∼ 0.0071 in.) (0.016 in.) 0.03 ∼ 0.12 mm Inlet 0.33 mm (0.0012 ∼ 0.0047 in.) (0.013 in.) Valve seat cutting angle 45°, 32°, 60°...
  • Page 202: Special Tools And Sealant

    5-8 ENGINE TOP END Special Tools and Sealant Compression Gauge: Valve Seat Cutter, 32° - 28: 57001–221 57001–1119 Valve Spring Compressor Assembly: Valve Seat Cutter, 32° - 30: 57001–241 57001–1120 Piston Pin Puller Assembly: Valve Seat Cutter, 60° - 30: 57001–910 57001–1123 Valve Seat Cutter, 45°...
  • Page 203 Spark Plug Wrench, Hex 16: Valve Guide Reamer, 4.5: 57001–1262 57001–1333 Fork Oil Level Gauge: Valve Seat Cutter, 60° - 33: 57001–1290 57001–1334 Compression Gauge Adapter, M10 × 1.0: Kawasaki Bond (Silicone Sealant): 57001–1317 56019–120 Valve Guide Arbor, 4.5: 57001–1331...
  • Page 204: Clean Air System

    5-10 ENGINE TOP END Clean Air System Air Suction Valve Removal • Remove: Fuel Tank (see Fuel System (DFI) chapter) Connector [A] (from Clamp [B]) Air Suction Valve Cover Bolts [C] and Clamp Air Suction Valve Cover [D] Air Suction Valve Air Suction Valve Installation •...
  • Page 205: Vacuum Switch Valve Test

    ENGINE TOP END 5-11 Clean Air System Vacuum Switch Valve Test • Remove: Fuel Tank (see Fuel System (DFI) chapter) Vacuum Switch Valve • Connect a vacuum gauge [A] and syringe [B] or fork oil level gauge to the vacuum hoses as shown. Special Tool - Fork Oil Level Gauge: 57001–1290 Air Flow [C] •...
  • Page 206: Cylinder Head Cover

    • Replace the head cover gasket with a new one if dam- aged. • Apply silicone sealant [A] to the cylinder head as shown. Sealant - Kawasaki Bond (Silicone Sealant): 56019–120 • Install: Dowel Pins [A] Plug Hole Gaskets [B]...
  • Page 207 ENGINE TOP END 5-13 Cylinder Head Cover • Install the washer [A] with the metal side faces upward. • Tighten: Torque - Cylinder Head Cover Bolts [B]: 10 N·m (1.0 kgf·m, 87 in·lb)
  • Page 208: Camshaft Chain Tensioner

    5-14 ENGINE TOP END Camshaft Chain Tensioner Camshaft Chain Tensioner Removal CAUTION This is a non-return type camshaft chain tensioner. The push rod does not return to its original position once it moves out to take up camshaft chain slack. Observe all the rules listed below: When removing the tensioner, do not take out the mounting bolts only halfway.
  • Page 209: Camshaft, Camshaft Chain

    ENGINE TOP END 5-15 Camshaft, Camshaft Chain Camshaft Removal • Remove: Fuel Tank (see Fuel System (DFI) chapter) Stick Coils (see Electrical System) Cylinder Head Cover (see Cylinder Head Cover Re- moval) Pickup Coil Cover • Position the crankshaft at #1, 4 piston TDC. [A] TDC mark for #1, 4 Pistons [B] Timing Mark (crankcase halves mating surface) •...
  • Page 210 5-16 ENGINE TOP END Camshaft, Camshaft Chain • Apply engine oil to all cam parts and journals. • If a new camshaft is to be used, apply a thin coat of molyb- denum disulfide grease to the cam surfaces. NOTE ○...
  • Page 211: Camshaft, Camshaft Cap Wear

    ENGINE TOP END 5-17 Camshaft, Camshaft Chain Camshaft, Camshaft Cap Wear • Remove: Camshaft Chain Guide Camshaft Cap • Cut strips of plastigage to journal width. Place a strip on each journal parallel to the camshaft installed in the correct position. •...
  • Page 212: Camshaft Chain Removal

    5-18 ENGINE TOP END Camshaft, Camshaft Chain Camshaft Chain Removal • Split the crankcase (see Crankshaft/Transmission chap- ter). • Remove the camshaft chain [A] from the crankshaft sprocket.
  • Page 213: Cylinder Head

    ENGINE TOP END 5-19 Cylinder Head Cylinder Compression Measurement NOTE ○ Use the battery which is fully charged. • Warm up the engine thoroughly. • Stop the engine. • Remove: Seats (see Frame chapter) Fuel Tank (see Fuel System (DFI) chapter) Stick Coils Spark Plugs Owners Tool - Spark Plug Wrench, Hex 16...
  • Page 214: Cylinder Head Removal

    5-20 ENGINE TOP END Cylinder Head Cylinder Head Removal • Drain the coolant (see Cooling System chapter). • Remove: Exhaust Pipes (see Exhaust Pipe Removal) Coolant Drain Bolt [A] (cylinder) • Remove: Cylinder Head Cover (see Cylinder Head Cover Re- moval) Camshaft Position Sensor (see Electrical System chap- ter)
  • Page 215: Cylinder Head Warp

    ENGINE TOP END 5-21 Cylinder Head • Install: Front Camshaft Chain Guide [A] O-ring [B] Collar [C] • Tighten: Torque - Front Camshaft Chain Guide Bolt (Upper) [D]: 25 N·m (2.5 kgf·m, 18 ft·lb) Front Camshaft Chain Guide Bolt (Lower) [E]: 12 N·m (1.2 kgf·m, 104 in·lb) •...
  • Page 216: Valves

    5-22 ENGINE TOP END Valves Valve Clearance Inspection • Refer to the Engine Top End in the Periodic Maintenance chapter. Valve Clearance Adjustment • Refer to the Engine Top End in the Periodic Maintenance chapter. Valve Removal • Remove the cylinder head (see Cylinder Head Removal). •...
  • Page 217: Valve Guide Installation

    ENGINE TOP END 5-23 Valves Valve Guide Installation • Apply oil to the valve guide outer surface before installa- tion. • Heat the area around the valve guide hole to about 120 ∼ 150 °C (248 ∼ 302 °F). • Drive the valve guide in from the top of the head using the valve guide arbor.
  • Page 218: Valve Seat Inspection

    5-24 ENGINE TOP END Valves Valve Seat Inspection • Remove the valve (see Valve Removal). • Check the valve seating surface [A] between the valve [B] and valve seat [C]. ○ Measure the outside diameter [D] of the seating pattern on the valve seat.
  • Page 219 ENGINE TOP END 5-25 Valves Seat Cutter Operation Care: 1. This valve seat cutter is developed to grind the valve for repair. Therefore the cutter must not be used for other purposes than seat repair. 2. Do not drop or shock the valve seat cutter, or the dia- mond particles may fall off.
  • Page 220 5-26 ENGINE TOP END Valves • Measure the outside diameter of the seating surface with a vernier caliper. If the outside diameter of the seating surface is too small, repeat the 45° grind until the diameter is within the spec- ified range.
  • Page 221 ENGINE TOP END 5-27 Valves If the seat width is too wide, make the 60° [A] grind de- scribed below. If the seat width is within the specified range, lap the valve to the seat as described below. • Grind the seat at a 60° angle until the seat width is within the specified range.
  • Page 222 5-28 ENGINE TOP END Valves...
  • Page 223: Cylinder, Pistons

    ENGINE TOP END 5-29 Cylinder, Pistons Cylinder Removal • Remove: Cylinder Head (see Cylinder Head Removal) Water Hose [A] • Remove the cylinder [B]. Cylinder Installation NOTE ○ If a new cylinder is used, use new piston ring. • Install the pins [A] and new cylinder gasket [B]. •...
  • Page 224: Piston Installation

    5-30 ENGINE TOP END Cylinder, Pistons • Remove the piston pins. Special Tool - Piston Pin Puller Assembly: 57001–910 [A] • Remove the pistons. • Carefully spread the ring opening with your thumbs and then push up on the opposite side of the ring [A] to remove •...
  • Page 225: Cylinder Wear

    ENGINE TOP END 5-31 Cylinder, Pistons NOTE ○ If a new piston is used, use new piston ring. • Install the piston with its hollow facing forward. • Fit a new piston pin snap ring into the side of the piston so that the ring opening [A] does not coincide with the slit [B] of the piston pin hole.
  • Page 226: Piston Ring Groove Width

    5-32 ENGINE TOP END Cylinder, Pistons Piston Ring Groove Width • Measure the piston ring groove width. ○ Use a vernier caliper at several points around the piston. Piston Ring Groove Width Standard Service Limit 0.83 ∼ 0.85 mm Top [A] 0.93 mm (0.0327 ∼...
  • Page 227: Throttle Body Holder

    ENGINE TOP END 5-33 Throttle Body Holder Throttle Body Holder Installation • Be sure to install the O-rings [A]. • Install the clamps [B] as shown and so that its hole fit on the projection [C] of the holder. • Tighten: Torque - Throttle Body Holder Bolts [D]: 12 N·m (1.2 kgf·m, 104 in·lb)
  • Page 228: Muffler

    5-34 ENGINE TOP END Muffler WARNING To avoid a serious burn, do not remove the mufflers when the engine is still hot. Wait until the mufflers cool down. Muffler Body Removal • Remove: Muffler Body Clamp Bolts [A] Muffler Body Mounting Bolts [B] Muffler Body [C] Exhaust Pipe Removal •...
  • Page 229 ENGINE TOP END 5-35 Muffler ○ Install the muffler body clamp bolts as shown. [L] Upper Side [M] Inside [N] Connection Part Detail • Thoroughly warm up the engine, wait until the engine cools down, and retighten all the bolts and nuts.
  • Page 231 CLUTCH 6-1 Clutch Table of Contents Exploded View........................Specifications ......................... Special Tools and Sealant ...................... Clutch Lever and Cable ......................Clutch Lever Free Play Inspection ..................Clutch Lever Free Play Adjustment .................. Cable Removal ......................... Cable Installation ......................Cable Lubrication ......................Clutch Lever Installation....................
  • Page 232: Exploded View

    6-2 CLUTCH Exploded View...
  • Page 233 CLUTCH 6-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Clutch lever clamp bolts 69 in·lb Clutch cover bolts (L = 32 mm) 95 in·lb Clutch cover bolts (L = 45 mm) 95 in·lb Clutch cover bolts (L = 30 mm) 95 in·lb Clutch cover bolts 95 in·lb...
  • Page 234: Specifications

    6-4 CLUTCH Specifications Item Standard Service Limit 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Clutch Lever Free Play - - - Clutch: 48.4 ∼ 49.0 mm (1.91 ∼ 1.93 in.) Clutch plate assembly - - - 2.72 ∼ 2.88 mm (0.107 ∼ 0.113 in.) Friction plate thickness 2.4 mm (0.094 in.) Friction and steel plate warp...
  • Page 235: Special Tools And Sealant

    CLUTCH 6-5 Special Tools and Sealant Inside Circlip Pliers: Kawasaki Bond (Silicone Sealant): 57001–143 56019–120 Clutch Holder: 57001–1243...
  • Page 236: Clutch Lever And Cable

    6-6 CLUTCH Clutch Lever and Cable Clutch Lever Free Play Inspection • Refer to the Clutch Adjust Inspection in the Periodic Main- tenance chapter. Clutch Lever Free Play Adjustment • Refer to the Clutch Adjust Inspection in the Periodic Main- tenance chapter.
  • Page 237: Clutch Cover

    Clutch Cover Installation • Apply silicone sealant to the area [A] where the mating surface of the crankcase touches the clutch cover gasket. Sealant - Kawasaki Bond (Silicone Sealant): 56019–120 • Replace the cover gasket with a new one. •...
  • Page 238: Clutch Cover Disassembly

    6-8 CLUTCH Clutch Cover • Fit the spring [A] as shown. [B] Viewed from Rear [C] Release Shaft [D] Clutch Cover Clutch Cover Disassembly • Remove: Oil Seal [A] Needle Bearings • Remove: Circlip [A] Special Tool - Inside Circlip Pliers [B]: 57001–143 •...
  • Page 239: Clutch Removal

    CLUTCH 6-9 Clutch Clutch Removal • Remove: Engine Oil (drain, see Engine Oil Change section in the Periodic Maintenance chapter) Clutch Cover (see Clutch Cover Removal) Clutch Spring Bolts [A] Clutch Springs Clutch Spring Plate [B] (with thrust bearing and pusher [C]) •...
  • Page 240 6-10 CLUTCH Clutch ○ Install the spacer [A] so that the tapered side [B] faces inward. ○ Install the washer [A] so that the OUT SIDE mark faces outward. ○ Replace the clutch hub nut with a new one. ○ Holding the clutch hub, tighten the clutch hub nut.
  • Page 241: Clutch Plate Assembly Inspection

    CLUTCH 6-11 Clutch • Apply molybdenum disulfide grease to the pusher ends [A] and install the pusher [B]. • Apply engine oil to the needle bearing [C] and install it. • Install the washer [D]. • Align the mark [A] of the clutch spring plate [B] with the groove [C] of the clutch hub.
  • Page 242: Clutch Plate Assembly Adjustment

    6-12 CLUTCH Clutch Clutch Plate Assembly Adjustment • Inspect the clutch plate assembly length, and then re- place the steel plate(s) which brings the length within the specified range. • Remove: Spring Bolts Spring Holders Springs Spring Plate • Replace the following steel plate(s). Part No.
  • Page 243 ENGINE LUBRICATION SYSTEM 7-1 Engine Lubrication System Table of Contents Exploded View........................Engine Oil Flow Chart......................Specifications ......................... Special Tools and Sealant ...................... Engine Oil and Oil Filter......................Oil Level Inspection......................Engine Oil Change......................Oil Filter Replacement ...................... Oil Pan............................ Oil Pan Removal .......................
  • Page 244: Exploded View

    7-2 ENGINE LUBRICATION SYSTEM Exploded View...
  • Page 245 L: Apply a non-permanent locking agent. MO: Apply molybdenum disulfide oil. (mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 : 1) R: Replacement Parts SS: Apply silicone sealant (Kawasaki Bond: 56019–120). W: Apply water.
  • Page 246: Engine Oil Flow Chart

    7-4 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart...
  • Page 247 ENGINE LUBRICATION SYSTEM 7-5 Engine Oil Flow Chart 1. Camshaft Oil Passage 2. Oil Passage Hole in Alternator Rotor Bolt 3. Starter Clutch Oil Passage Hole 4. Main Oil Passage 5. Crankshaft Oil Passage 6. Oil Filter 7. Oil Cooler 8.
  • Page 248: Specifications

    7-6 ENGINE LUBRICATION SYSTEM Specifications Item Standard Engine Oil: Type API SE, SF or SG API SH or SJ with JASO MA Viscosity SAE 10W-40 Capacity: 3.1 L (3.3 US gt) (when filter is not removed) 3.3 L (3.5 US gt) (when filter is removed) 3.8 L (4.0 US gt) (when engine is completely dry) Level Between upper and lower level lines...
  • Page 249: Special Tools And Sealant

    ENGINE LUBRICATION SYSTEM 7-7 Special Tools and Sealant Oil Pressure Gauge, 10 kgf/cm²: Kawasaki Bond (Silicone Sealant): 57001–164 56019–120 Oil Pressure Gauge Adapter, PT3/8: Oil Filter Wrench: 57001–1233 57001–1249...
  • Page 250: Engine Oil And Oil Filter

    7-8 ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter WARNING Motorcycle operation with insufficient, deteri- orated, or contaminated engine oil will cause accelerated wear and may result in engine or trans- mission seizure, accident, and injury. Oil Level Inspection • Check that the engine oil level is between the upper [A] and lower [B] levels in the gauge.
  • Page 251: Oil Pan

    ENGINE LUBRICATION SYSTEM 7-9 Oil Pan Oil Pan Removal • Remove: Engine Oil (drain, see Periodic Maintenance chapter) Muffler (see Engine Top End chapter) Oil Pan Bolts [A] Oil Pan [B] ○ Remove the oil pipe [A], oil pressure relief valve [B] and oil screen [C] as necessary.
  • Page 252: Oil Pressure Relief Valve

    7-10 ENGINE LUBRICATION SYSTEM Oil Pressure Relief Valve Oil Pressure Relief Valve Removal • See Oil Pan Removal. Oil Pressure Relief Valve Installation • See Oil Pan Installation. Oil Pressure Relief Valve Inspection • Check to see if the valve [A] slides smoothly when push- ing it in with a wooden or other soft rod, and see if it comes back to its seat by spring [B] pressure.
  • Page 253: Oil Pump

    ENGINE LUBRICATION SYSTEM 7-11 Oil Pump Oil Pump Removal • Drain: Coolant (see Periodic Maintenance chapter) Engine Oil (see Periodic Maintenance chapter) • Remove: Water Hose [A] Water Pipe Fitting Bolts [B] Water Pipes [C] • Remove: Water Pump Cover Bolts [A] Clamp [B] Water Pump Cover [C] •...
  • Page 254 7-12 ENGINE LUBRICATION SYSTEM Oil Pump • Fit the pin [A] of the oil pump cover [B] into the hole [C] in the crankcase. • Install: Pins [A] Water Pump Body [B] • Install: Impeller [A] and Bolt [B] • Tighten: Torque - Water Pump Impeller Bolt: 10 N·m (1.0 kgf·m, 87 in·lb)
  • Page 255: Oil Pump Drive Gear Removal

    ENGINE LUBRICATION SYSTEM 7-13 Oil Pump Oil Pump Drive Gear Removal • Remove: Clutch (see Clutch chapter) Oil Pan (see Oil Pan Removal) Circlip [A] and Washer [B] Oil Pump Drive Gear [C] Oil Pump Drive Gear Installation • Apply molybdenum disulfide oil solution to the journal por- tions [A] on the oil pump gear shaft [B].
  • Page 256: Oil Cooler

    7-14 ENGINE LUBRICATION SYSTEM Oil Cooler Oil Cooler Removal • Drain: Coolant (see Periodic Maintenance chapter) Engine Oil (see Periodic Maintenance chapter) • Remove: Oil Filter (see Periodic Maintenance chapter) Water Hose [A] Oil Cooler Mounting Bolt [B] and Washer Oil Cooler [C] and Water Hose Oil Cooler Installation •...
  • Page 257: Oil Pressure Measurement

    ENGINE LUBRICATION SYSTEM 7-15 Oil Pressure Measurement Oil Pressure Measurement • Remove the oil passage plug, and attach the adapter [A] and gauge [B] to the plug hole. Special Tools - Oil Pressure Gauge, 10 kgf/cm²: 57001–164 Oil Pressure Gauge Adapter, PT 3/8: 57001–1233 •...
  • Page 258: Oil Pressure Switch

    • Apply silicone sealant to the threads of the oil pressure switch and tighten it. Sealant - Kawasaki Bond (Silicone Sealant): 56019–120 Torque - Oil Pressure Switch: 15 N·m (1.5 kgf·m, 11 ft·lb) • Install the switch lead direction upward.
  • Page 259 ENGINE REMOVAL/INSTALLATION 8-1 Engine Removal/Installation Table of Contents Exploded View........................Special Tools .......................... Engine Removal/Installation ....................Engine Removal........................ Engine Installation......................
  • Page 260: Exploded View

    8-2 ENGINE REMOVAL/INSTALLATION Exploded View...
  • Page 261 ENGINE REMOVAL/INSTALLATION 8-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Adjusting collar locknut Upper engine mounting bolts Rear engine bracket bolts Front engine bracket bolts Middle engine mounting nut Lower engine mounting nut 7. Adjusting Collar 8. Middle Engine Mounting Bolt 9.
  • Page 262: Special Tools

    8-4 ENGINE REMOVAL/INSTALLATION Special Tools Carburetor Drain Plug Wrench, Hex3: Engine Mount Nut Wrench: 57001–1269 57001–1450...
  • Page 263: Engine Removal/installation

    ENGINE REMOVAL/INSTALLATION 8-5 Engine Removal/Installation Engine Removal • Support the rear part of the swingarm with a stand [A]. • Squeeze the brake lever slowly and hold it with a band [A]. WARNING Be sure to hold the front brake when removing the engine, or the motorcycle may fall over.
  • Page 264 8-6 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Remove: Radiator Hose Clamp [A] (Loosen) Radiator Hose [B] Oil Cooler Water Hose Clamp [C] (Loosen) Oil Cooler Water Hose [D] Radiator Bolt [E] (Loosen) Radiator Bracket Bolt [F] • Disconnect Crankshaft Sensor Lead Connector (see Electrical Sys- tem chapter) Stick Coil Harness Connector [A] •...
  • Page 265 ENGINE REMOVAL/INSTALLATION 8-7 Engine Removal/Installation • Remove: Camshaft Position Sensor Connector [A] Injector Harness Connector [B] Coolant Reserve Tank [A] (see Cooling System chapter) Air Cleaner Housing Bolt [B] Vacuum Switch Valve Hose [C] • Remove: Vacuum Switch Valve Tube [A] Inlet Air Pressure Sensor Tube [B] Throttle Body Assy [C] ○...
  • Page 266 8-8 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Support the engine with a suitable stand [A]. ○ Put a plank [B] onto the suitable stand for engine balance. • Remove: Right and Left Engine Upper Mounting Bolts [A] Front Engine Bracket Bolts [B] Front Engine Bracket [C] •...
  • Page 267: Engine Installation

    ENGINE REMOVAL/INSTALLATION 8-9 Engine Removal/Installation • Using the Hexagon Wrench, turn the adjusting collar [A] counter clockwise to mark the gap between the engine and flame adjusting collar. • Remove the drive chain [A] from the output shaft [B]. • Down the rear portion of the engine a little and remove the engine ground [A].
  • Page 268 8-10 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Install the engine mounting bolts and nuts, following the specified installing sequence. ○ First, hang the drive chain over the output shaft just before moving the engine into its final position in the frame. ○...
  • Page 269 ENGINE REMOVAL/INSTALLATION 8-11 Engine Removal/Installation ○ Ninth, temporarily install: Front Engine Bracket [A] Front Right Engine Mounting Bolt [B] ○ Tenth, tighten the rear bracket bolts. Torque - Rear Engine Bracket Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb) ○ Eleventh, tighten securely: Middle Engine Mounting Nut Lower Engine Mounting Nut Torque - Engine Mounting Nut: 44 N·m (4.5 kgf·m, 32 ft·lb)
  • Page 271 CRANKSHAFT/TRANSMISSION 9-1 Crankshaft/Transmission Table of Contents Exploded View........Starter Motor Clutch Assembly ..9-21 Specifications ........Starter Motor Clutch Inspection ... 9-21 Special Tools and Sealant ....Transmission ........9-22 Crankcase Splitting......Shift Pedal Removal ....9-22 Crankcase Splitting ...... Shift Pedal Installation ....
  • Page 272: Exploded View

    9-2 CRANKSHAFT/TRANSMISSION Exploded View...
  • Page 273 EO: Apply engine oil. G: Apply grease. L: Apply a non-permanent locking agent. LG: Apply liquid gasket (Kawasaki Bond: 92104–1063). M: Apply molybdenum disulfide grease. MO: Apply molybdenum disulfide oil. (mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10:1) R: Replacement Parts S: Tightening the fasteners following the specified sequence.
  • Page 274 9-4 CRANKSHAFT/TRANSMISSION Exploded View...
  • Page 275 CRANKSHAFT/TRANSMISSION 9-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Shift pedal mounting bolt Gear positioning lever bolt 104 in·lb Shift shaft return spring pin Shift drum cam holder bolt 104 in·lb Footpeg bracket bolts Shift lever bolt 61 in·lb Tie-rod locknuts 61 in·lb Neutral switch...
  • Page 276: Specifications

    9-6 CRANKSHAFT/TRANSMISSION Specifications Item Standard Service Limit Crankshaft, Connecting Rods: Connecting rod bend - - - TIR 0.2/100 mm (0.008/3.94 in.) Connecting rod twist - - - TIR 0.2/100 mm (0.008/3.94 in.) 0.13 ∼ 0.38 mm Connecting rod big end side clearance 0.58 mm (0.0051 ∼...
  • Page 277 CRANKSHAFT/TRANSMISSION 9-7 Specifications Item Standard Service Limit Crankshaft runout TIR 0.02 mm (0.0008 in.) or TIR 0.05 mm less (0.0020 in.) Crankshaft main bearing insert/journal clearance 0.020 ∼ 0.044 mm 0.07 mm (0.0008 ∼ 0.0017 in.) (0.0028 in.) 32.984 ∼ 33.000 mm Crankshaft main journal diameter: 32.96 mm (1.2986 ∼...
  • Page 278: Special Tools And Sealant

    9-8 CRANKSHAFT/TRANSMISSION Special Tools and Sealant Bearing Puller: Kawasaki Bond (Silicone Sealant): 57001–135 56019–120 Bearing Puller Adapter: Kawasaki Bond (Silicone Sealant): 57001–317 92104–1063...
  • Page 279: Crankcase Splitting

    CRANKSHAFT/TRANSMISSION 9-9 Crankcase Splitting Crankcase Splitting • Remove the engine (see Engine Removal/Installation chapter). • Set the engine on a clean surface and hold the engine steady while parts are being removed. • Remove: Crankshaft Sensor (see Electrical System chapter) Clutch (see Clutch chapter) External Shift Mechanism (see External Shift Mecha- nism Removal)
  • Page 280 9-10 CRANKSHAFT/TRANSMISSION Crankcase Splitting • Apply liquid gasket to the breather plate mating surface [A] 1 to 1.5 mm (0.04 to 0.06 in.) thick, and then install the breather plate. Sealant - Three Bond: 1207B • Apply a non-permanent locking agent to the threads and tighten the bolts [A].
  • Page 281 Crankcase Splitting • Apply liquid gasket [A] to the mating surface of the lower crankcase half. Sealant - Kawasaki Bond (Silicone Sealant): 92104–1063 CAUTION Do not apply liquid gasket around the crankshaft main bearing inserts, and oil passage holes. •...
  • Page 282: Crankshaft And Connecting Rods

    9-12 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods Crankshaft Removal • Split the crankcase (see Crankcase Splitting). • Remove the crankshaft [A]. Crankshaft Installation CAUTION If the crankshaft, bearing inserts, or crankcase halves are replaced with new ones, select the bear- ing inserts and check clearance with a plastigage (press gauge) before assembling engine to be sure the correct bearing inserts are installed.
  • Page 283 CRANKSHAFT/TRANSMISSION 9-13 Crankshaft and Connecting Rods • Apply molybdenum disulfide grease [A] to the outer sur- face of the upper insert and the inner surface of the con- necting rod big end. • Apply molybdenum disulfide oil [B] to the inner surfaces of upper and lower bearing inserts.
  • Page 284 9-14 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods (1) Bolt Length Measurement Method • Be sure to clean the bolts, nuts, and connecting rods thoroughly with a high-flash point solvent, because the new connecting rods, bolts, and nuts are treated with an anti-rust solution.
  • Page 285: Crankshaft/connecting Rod Cleaning

    CRANKSHAFT/TRANSMISSION 9-15 Crankshaft and Connecting Rods (2) Rotation Angle Method If you don’t have a point micrometer, you may tighten the nuts using the “Rotation Angle Method”. • Be sure to clean the bolts and nuts thoroughly with a high -flash point solvent, because the new bolts and nuts are treated with an anti-rust solution.
  • Page 286: Connecting Rod Bend

    9-16 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods Connecting Rod Bend • Remove the connecting rod big end bearing inserts, and reinstall the connecting rod big end cap. • Select an arbor [A] of the same diameter as the connect- ing rod big end, and insert the arbor through the connect- ing rod big end.
  • Page 287: Connecting Rod Big End Bearing Insert/crankpin Wear

    CRANKSHAFT/TRANSMISSION 9-17 Crankshaft and Connecting Rods Connecting Rod Big End Bearing Insert/Crankpin Wear • Measure the bearing insert/crankpin [B] clearance with plastigage [A]. ○ Tighten the big end nuts to the specified torque (see Con- necting Rod Installation). NOTE ○ Do not move the connecting rod and crankshaft during clearance measurement.
  • Page 288: Crankshaft Side Clearance

    9-18 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods Connecting Rod Big End Inside Diameter Marks 38.000mm ∼ 38.008mm (1.4961 ∼ 1.4964 in.) None 38.009 ∼ 38.016 mm (1.4964 ∼ 1.4967 in.) Big End Cap [A] Connecting Rod [B] Weight Mark, Alphabet [C] Diameter Mark (Around Weight Mark) [D]: “...
  • Page 289: Crankshaft Main Bearing Insert/journal Wear

    CRANKSHAFT/TRANSMISSION 9-19 Crankshaft and Connecting Rods Crankshaft Main Bearing Insert/Journal Wear • Using a plastigage (press gauge) [A], measure the bear- ing insert/journal [B] clearance. NOTE ○ Tighten the crankcase bolts to the specified torque (see Crankcase Assembly). ○ Do not turn the crankshaft during clearance measure- ment.
  • Page 290 9-20 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods • Measure the main bearing inside diameter, and mark the upper crankcase half in accordance with the inside diam- eter. Crankcase Main Bearing Inside Diameter Marks : " " or no mark. • Tighten the crankcase bolts to the specified torque (see Crankcase Assembly).
  • Page 291: Starter Motor Clutch

    CRANKSHAFT/TRANSMISSION 9-21 Starter Motor Clutch Starter Motor Clutch Removal/Installation • Refer to the Alternator Rotor Removal and Installation in the Electrical System chapter. Starter Motor Clutch Assembly • Be sure to install the one-way clutch [A] so that its flange [B] fits in the holder recess [C].
  • Page 292: Transmission

    9-22 CRANKSHAFT/TRANSMISSION Transmission Shift Pedal Removal • Mark [A] the position of the shift lever [B] on the shift shaft so that it can be installed later in the same position. • Remove: Shift Lever Bolt [C] Shift Lever • Remove: Footpeg Bracket Bolts [A] Muffler Mounting Bolt [B]...
  • Page 293: External Shift Mechanism Removal

    CRANKSHAFT/TRANSMISSION 9-23 Transmission • Install the footpeg bracket [A]. • Apply a non-permanent locking agent to the footpeg bracket bolts [B]. • Tighten: Torque - Footpeg bracket Bolts: 34 N·m (3.5 kgf·m, 25 ft·lb) Muffler Mounting Bolt and Nut [C]: 29 N·m (3.0 kgf·m, 22 ft·lb) •...
  • Page 294: External Shift Mechanism Installation

    9-24 CRANKSHAFT/TRANSMISSION Transmission • Remove: Gear Positioning Lever Bolt [A] Gear Positioning Lever [B], Collar and spring External Shift Mechanism Installation • Install the gear positioning lever [A] as shown. Spring [B] Collar [C] Bolt [D] • Tighten: Torque - Gear Positioning Lever Bolt: 12 N·m (1.2 kgf·m, 104 in·lb) •...
  • Page 295: Transmission Shaft Removal

    CRANKSHAFT/TRANSMISSION 9-25 Transmission Transmission Shaft Removal • Split the crankcase (see Crankcase Splitting). • Remove the drive shaft [A] and output shaft [B]. Transmission Shaft Installation • Check to see that the set pins [A] and set rings [B] are in place.
  • Page 296: Transmission Shaft Assembly

    9-26 CRANKSHAFT/TRANSMISSION Transmission • Remove the ball bearing [A] from each shafts. Special Tools - Bearing Puller: 57001–135 [B] Bearing Puller Adapter: 57001–317 [C] • Discard the bearing. Transmission Shaft Assembly • Apply engine oil to the sliding surfaces on the transmis- sion shafts, gears and bushings.
  • Page 297 CRANKSHAFT/TRANSMISSION 9-27 Transmission NOTE ○ When the toothed washers [28] [29] are assembled onto the output shaft, note the following. ○ When the tangs [A] of the toothed washer [29] shall be assembled, they should be installed into the notch [B] of the toothed washer [28].
  • Page 298: Shift Drum And Fork Removal

    9-28 CRANKSHAFT/TRANSMISSION Transmission 1. 1st Gear 11. Bushing 23. Washer 2. 2nd Gear 12. Bushing 24. Toothed Washer 3. 3rd Gear 13. Needle Bearing 25. Oil Seal 4. 4th Gear 14. Needle Bearing 26. Thrust Washer, 31 mm 5. 5th Gear 15.
  • Page 299: Shift Drum And Fork Installation

    CRANKSHAFT/TRANSMISSION 9-29 Transmission Shift Drum and Fork Installation • Install the shift rods [A], noting the groove position. The rods are identical. • Position the one with shortest ears [B] on the drive shaft and place the pin in the center groove in the shift drum [C].
  • Page 300: Shift Fork/gear Groove Wear

    9-30 CRANKSHAFT/TRANSMISSION Transmission Shift Fork/Gear Groove Wear • Measure the thickness of the shift fork ears [A], and mea- sure the width [B] of the gear grooves. If the thickness of a shift fork ear is less than the service limit, the shift fork must be replaced.
  • Page 301 WHEELS/TIRES 10-1 Wheels/Tires Table of Contents Exploded View........................10-2 Specifications ......................... 10-4 Special Tools .......................... 10-5 Wheels (Rims) ........................10-6 Front Wheel Removal ....................... 10-6 Front Wheel Installation ....................10-6 Rear Wheel Removal......................10-7 Rear Wheel Installation..................... 10-8 Wheel Inspection ......................10-9 Axle Inspection........................
  • Page 302: Exploded View

    10-2 WHEELS/TIRES Exploded View...
  • Page 303 WHEELS/TIRES 10-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front axle clamp bolt Front axle Rear axle nut G: Apply grease. R: Replacement Parts WL: Apply soap and water solution or rubber lubricant.
  • Page 304: Specifications

    10-4 WHEELS/TIRES Specifications Item Standard Service Limit Wheels (Rims): Rim runout: Axial - - - TIR 0.5 mm (0.020 in.) Radial - - - TIR 0.8 mm (0.031 in.) Axle runout/100 mm (3.94 TIR 0.05 mm (0.0020 in.) or less TIR 0.2 mm in.) (0.008 in.)
  • Page 305: Special Tools

    WHEELS/TIRES 10-5 Special Tools Bearing Driver Set: Bearing Remover Head, 25 × 28: 57001–1129 57001–1346 Jack: Bearing Remover Shaft, 13: 57001–1238 57001–1377...
  • Page 306: Wheels (rims)

    10-6 WHEELS/TIRES Wheels (Rims) Front Wheel Removal • Remove: Brake Caliper Mounting Bolts [A] • Loosen: Right Side Axle Clamp Bolt [A] Axle [B] • Raise the front wheel off the ground. Special Tool - Jack: 57001–1238 • Pull out the axle to the right and drop the front wheel out of the forks.
  • Page 307: Rear Wheel Removal

    WHEELS/TIRES 10-7 Wheels (Rims) • Tighten the axle. Torque - Front Axle: 127 N·m (13 kgf·m, 94 ft·lb) • Before tightening the clamp bolt on the right front fork leg, pump the front fork up and down 4 or 5 times to allow the right front fork leg to seat on the front axle.
  • Page 308: Rear Wheel Installation

    10-8 WHEELS/TIRES Wheels (Rims) • Remove: Caliper Mounting Bolts [A] Caliper [B] • Remove the drive chain [A] from the rear sprocket toward the left. • Move the rear wheel back and remove the wheel from the rear caliper. • Remove the rear wheel.
  • Page 309: Wheel Inspection

    WHEELS/TIRES 10-9 Wheels (Rims) • Bend the cotter pin [A] over the nut [B]. WARNING If the rear axle nut is not securely tightened or the cotter pin is not installed, an unsafe riding condi- tion may result. • Adjust the drive chain slack after installation (see Final Drive chapter).
  • Page 310: Axle Inspection

    10-10 WHEELS/TIRES Wheels (Rims) Axle Inspection • Visually inspect the front and rear axle for damages. If the axle is damaged or bent, replace it. • Place the axle in V blocks that are 100 mm (3.94 in.) [A] apart, and set a dial gauge [B] on the axle at a point halfway between the blocks.
  • Page 311: Balance Weight Installation

    WHEELS/TIRES 10-11 Wheels (Rims) (b) When the tire is on the rim. • Pry [A] the balance weight off the rim flange using a reg- ular tip screwdriver as shown in the figure. ○ Insert a tip of the screwdriver between the tire bead [B] and weight blade [C] until the end of the tip reaches the end of the weight blade.
  • Page 312 41075–1015 41075–1016 NOTE ○ Balance weights are available from Kawasaki dealers in 10, 20, and 30 grams (0.35, 0.71, and 1.06 US oz). An imbalance of less than 10 grams (0.35 US oz) will not usually affect running stability. ○...
  • Page 313: Tires

    WHEELS/TIRES 10-13 Tires Air Pressure Inspection/Adjustment • Refer to the Air Pressure Inspection/Adjustment in the Pe- riodic Maintenance chapter. Tire Inspection • Refer to the Tire Inspection in the Periodic Maintenance chapter. Tire Removal • Remove: Wheel (see Front Wheel Removal, Rear Wheel Re- moval) Disc (s) Valve Core (let out the air)
  • Page 314 10-14 WHEELS/TIRES Tires • Install a new valve in the rim. ○ Remove the valve cap, lubricate the stem seal with a soap and water solution or rubber lubricant, and pull [B] the valve stem [A] through the rim from the inside out until it snaps into place.
  • Page 315: Tire Repair

    Also, permanent (internal) repairs have the advantage of permitting a thorough examination for secondary damage not visible from external inspection of the tire. For these reasons, Kawasaki does not recommend temporary (exter- nal) repair. Only appropriate permanent (internal) repairs are recommended. Repair methods may vary slightly from make to make.
  • Page 316: Hub Bearing

    10-16 WHEELS/TIRES Hub Bearing Hub Bearing Removal • Remove the wheel, and take out the following. Collars Coupling (out of rear hub) Grease Seals Circlips • Use the bearing remover to remove the hub bearings [A]. CAUTION Do not lay the wheel on the ground with the disc facing down.
  • Page 317 FINAL DRIVE 11-1 Final Drive Table of Contents Exploded View........................11-2 Specifications ......................... 11-4 Special Tools .......................... 11-5 Drive Chain..........................11-6 Drive Chain Slack Inspection .................... 11-6 Drive Chain Slack Adjustment ..................11-6 Wheel Alignment Inspection/Adjustment ................11-6 Drive Chain Wear Inspection .................... 11-6 Drive Chain Lubrication.....................
  • Page 318: Exploded View

    11-2 FINAL DRIVE Exploded View...
  • Page 319 FINAL DRIVE 11-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Engine sprocket cover bolts 87 in·lb Engine sprocket nut Rear sprocket nut Engine sprocket cover damper bolts 61 in·lb Speed sensor bolt 61 in·lb Rear axle nut 7. Drive chain joint (ZR1000–A2 ∼ ) G: Apply grease.
  • Page 320: Specifications

    11-4 FINAL DRIVE Specifications Item Standard Service Limit Drive Chain: 20 ∼ 30 mm (0.8 ∼ 1.2 in.) Chain slack - - - 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) 20-link length 323 mm (12.7 in.) Standard chain Make ENUMA - - - Type...
  • Page 321: Special Tools

    FINAL DRIVE 11-5 Special Tools Bearing Driver Set: Jack: 57001–1129 57001–1238...
  • Page 322: Drive Chain

    11-6 FINAL DRIVE Drive Chain Drive Chain Slack Inspection • Refer to the Drive Chain Slack Inspection in the Periodic Maintenance chapter. Drive Chain Slack Adjustment • Refer to the Drive Chain Slack Adjustment in the Periodic Maintenance chapter. Wheel Alignment Inspection/Adjustment •...
  • Page 323 FINAL DRIVE 11-7 Drive Chain EK JOINT TOOL #50 Body [A] Handlebar [B] Cutting and Riveting Pin [C] For Cutting [D] For Riveting [E] Plate Holder (A) [F] Plate Holder (B) [G] Gauge [H] • Grind [A] pin head to make it flat. •...
  • Page 324 11-8 FINAL DRIVE Drive Chain • Set plate holder (A) [A] and plate holder (B) [B] on the body. • Fit plate holder (A) to link plate. • Turn pin holder by hand until plate holder (B) touches the other link plate. •...
  • Page 325 FINAL DRIVE 11-9 Drive Chain • Turn wrench clockwise until tip of riveting pin hits of link pin. • Rivet it. • Some work for the other link pin. • After staking, check the staked area of the link pin for cracks.
  • Page 326: Sprocket, Coupling

    11-10 FINAL DRIVE Sprocket, Coupling Engine Sprocket Removal • Remove: Speed Sensor [A] Connector Engine Sprocket Cover Bolts [B] Engine Sprocket Cover [C] with Speed Sensor • Flatten out the bended washer [A]. • Remove the engine sprocket nut [B] and washer. NOTE ○...
  • Page 327: Rear Sprocket Removal

    FINAL DRIVE 11-11 Sprocket, Coupling Rear Sprocket Removal • Remove the rear wheel (see Wheels/Tires chapter). CAUTION Do not lay the wheel on the ground with the disc facing down. This can damage or warp the disc. Place blocks under the wheel so that the disc does not touch the ground.
  • Page 328: Coupling Installation

    11-12 FINAL DRIVE Sprocket, Coupling • Replace the grease seal with a new one. • Press in the grease seal so that the seal surface is flush with the end of the hole. ○ Apply high temperature grease to the grease seal lips. Special Tool - Bearing Driver Set : 57001–1129 Coupling Installation •...
  • Page 329: Sprocket Wear Inspection

    FINAL DRIVE 11-13 Sprocket, Coupling Sprocket Wear Inspection • Visually inspect the engine and rear sprocket teeth for wear and damage. If the teeth are worn as illustrated, replace the sprocket, and inspect the drive chain wear (see Drive Chain Wear Inspection).
  • Page 331 BRAKES 12-1 Brakes Table of Contents Exploded View........12-2 Brake Pad Wear Inspection ..12-16 Specifications ........12-6 Master Cylinder ......... 12-17 Special Tool ........12-7 Front Master Cylinder Removal ... 12-17 Brake Lever, Brake Pedal....12-8 Front Master Cylinder Installation 12-17 Brake Lever Position Adjustment.
  • Page 332: Exploded View

    12-2 BRAKES Exploded View...
  • Page 333 BRAKES 12-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front caliper mounting bolts Brake hose banjo bolt Bleed valve 0.80 69 in·lb Front caliper assembly bolts Front brake pad pin bolt Brake lever pivot bolt 0.10 9 in·lb Brake lever pivot bolt locknut 0.60 52 in·lb Brake disc mounting bolts...
  • Page 334 12-4 BRAKES Exploded View...
  • Page 335 BRAKES 12-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Rear master cylinder push lod locknut Rear caliper mounting bolts Brake hose banjo bolts Bleed valve 0.80 69 in·lb Rear master cylinder mounting bolts Brake disc mounting bolts 7. Gasket (Before Frame No. 005854) B: Apply brake fluid.
  • Page 336: Specifications

    12-6 BRAKES Specifications Item Standard Service Limit Brake Lever, Brake Pedal: Brake lever position 5-way adjustable (to suit rider) - - - Brake lever free play Non-adjustable - - - Pedal free play Non-adjustable - - - Pedal position About 47 mm (1.85 in.) below footpeg top - - - Brake Fluid: Grade...
  • Page 337: Special Tool

    BRAKES 12-7 Special Tool Jack: 57001–1238...
  • Page 338: Brake Lever, Brake Pedal

    12-8 BRAKES Brake Lever, Brake Pedal Brake Lever Position Adjustment The brake lever adjuster has 5 positions so that the brake lever position can be adjusted to suit the operator’s hand. • Push the lever forward and turn the adjuster [A] to align the number with the arrow mark [B] on the lever holder.
  • Page 339: Calipers

    BRAKES 12-9 Calipers Front Caliper Removal • Loosen the banjo bolt [A] at the brake hose lower end, and tighten it loosely. • Unscrew the caliper mounting bolts [B], and detach the caliper [C] from the disc. CAUTION Do not loosen the caliper assembly bolts [D]. Take out only the caliper mounting bolts for caliper re- moval.
  • Page 340: Caliper Installation

    12-10 BRAKES Calipers Caliper Installation • Install the caliper and brake hose lower end. ○ Replace the washers on each side of hose fitting with new ones. • Tighten: Torque - Caliper Mounting Bolts (Front): 25 N·m (2.5 kgf·m, 18 ft·lb) Caliper Mounting Bolts (Rear): 25 N·m (2.5 kgf·m, 18 ft·lb) Brake Hose Banjo Bolt: 25 N·m (2.5 kgf·m, 18 ft·lb)
  • Page 341: Front Caliper Assembly

    BRAKES 12-11 Calipers WARNING To avoid serious injury, never place your fingers or palm in front of the piston. If you apply compressed air into the caliper, the piston may crush your hand or fingers. ○ Pull out the pistons by hand. •...
  • Page 342: Rear Caliper Disassembly

    12-12 BRAKES Calipers • Replace the fluid seals [A] with new ones. ○ Apply brake fluid to the fluid seals, and install them into the cylinders by hand. • Replace the dust seals [B] with new ones if they are dam- aged.
  • Page 343: Rear Caliper Assembly

    BRAKES 12-13 Calipers Rear Caliper Assembly • Clean the caliper parts except for the pads. CAUTION For cleaning the parts, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol. • Install the bleed valve and rubber cap. Torque - Bleed Valve: 7.8 N·m (0.80 kgf·m, 69 in·lb) •...
  • Page 344: Caliper Piston And Cylinder Damage

    12-14 BRAKES Calipers Caliper Piston and Cylinder Damage • Visually inspect the piston [A] and cylinder surfaces. Replace the caliper if the cylinder and piston are badly scores or rusty. Front Caliper [B] Rear Caliper [C] Caliper Holder Shaft Wear The caliper body must slide smoothly on the caliper holder shaft [D].
  • Page 345: Brake Pads

    BRAKES 12-15 Brake Pads Front Brake Pad Removal • Remove: Mounting Bolts [A] • Remove: Pad Pin Bolt [A] Pad Spring [B] Brake Pads [C] Front Brake Pad Installation • Push the caliper pistons in by hand as far as they will go. •...
  • Page 346: Rear Brake Pad Installation

    12-16 BRAKES Brake Pads Rear Brake Pad Installation • Push the caliper piston in by hand as far as it will go. • Install: Brake Pads Pad Pin Clip • Install the caliper (see Caliper Installation). WARNING Do not attempt to drive the motorcycle until a full brake pedal is obtained by pumping the brake pedal until the pads are against the disc.
  • Page 347: Master Cylinder

    BRAKES 12-17 Master Cylinder Front Master Cylinder Removal • Disconnect the front brake light switch connectors [A]. • Remove the banjo bolt [B] to disconnect the brake hose from the master cylinder [C] (see Brake Hose Removal/In- stallation). • Remove the rear view mirror (see Steering chapter). •...
  • Page 348: Rear Master Cylinder Removal

    12-18 BRAKES Master Cylinder Rear Master Cylinder Removal • Unscrew the brake hose banjo bolt [A] on the master cylin- der (see Brake Hose Removal/Installation). • Pull off the reservoir hose lower end [B], and drain the brake fluid into a container. •...
  • Page 349: Rear Master Cylinder Disassembly

    BRAKES 12-19 Master Cylinder Rear Master Cylinder Disassembly NOTE ○ Do not remove the push rod clevis for master cylinder disassembly since removal requires brake position ad- justment. • Remove the rear master cylinder (see Rear Master Cylin- der Removal). •...
  • Page 350: Brake Disc

    12-20 BRAKES Brake Disc Brake Disc Removal • Remove the wheel (see Wheels/Tires chapter). • Unscrew the mounting bolts, and take off the disc. Brake Disc Installation • Install the brake disc on the wheel so that the marked side [A] faces out.
  • Page 351: Brake Fluid

    BRAKES 12-21 Brake Fluid Brake Fluid Level Inspection • Refer to the Brake Fluid Level in the Periodic Maintenance chapter. Brake Fluid Change • Refer to the Brake Fluid Change in the Periodic Mainte- nance chapter. Brake Line Bleeding • Refer to the Brake Line Bleeding in the Periodic Mainte- nance chapter.
  • Page 352: Brake Hose

    12-22 BRAKES Brake Hose Brake Hose Removal/Installation CAUTION Brake fluid quickly ruins painted or plastic sur- faces; any spilled fluid should be completely wiped up immediately with wet cloth. • When removing the brake hose, take care not to spill the brake fluid on the painted or plastic parts.
  • Page 353 SUSPENSION 13-1 Suspension Table of Contents Exploded View........................13-2 Specifications ......................... 13-6 Special Tools .......................... 13-7 Front Fork ..........................13-8 Rebound Damping Force Adjustment (Only Right Fork Leg) ........... 13-8 Spring Preload Adjustment ....................13-8 Front Fork Removal (each fork leg) .................. 13-9 Front Fork Installation .......................
  • Page 354: Exploded View

    13-2 SUSPENSION Exploded View...
  • Page 355 SUSPENSION 13-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front fork clamp bolts (Upper) 0.90 78 in·lb Front fork clamp bolts (Upper): ZR1000–A2 ∼ 113 in·lb Front fork clamp bolts (Lower) Front fork clamp bolts (Lower): ZR1000–A2 ∼ Front fork top plugs Piston rod nuts Front fork bottom Allen bolts Front axle clamp bolt...
  • Page 356 13-4 SUSPENSION Exploded View...
  • Page 357 SUSPENSION 13-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Rear shock absorber nuts (upper and lower) Swingarm pivot shaft nut Swingarm pivot shaft locknut Rocker arm nut Tie-rod nuts G: Apply or add grease.
  • Page 358: Specifications

    13-6 SUSPENSION Specifications Item Standard Front Fork (per one unit): Fork inner tube outside diameter 41 mm (1.61 in.) Air Pressure Atmospheric pressure (Non-adjustable) Rebound damper setting 1 turns out from the fully clockwise position (Usable Range: 0 ←→ 1 4/5 ∼ 2 2/5 turns out) (only right fork leg) Fork spring preload setting Adjuster protrusion is 19 mm (0.75 in.)
  • Page 359: Special Tools

    SUSPENSION 13-7 Special Tools Oil Seal and Bearing Remover: Fork Piston Rod Puller, M10 × 1.0: 57001–1058 57001–1298 Bearing Driver Set: Front Fork Spring Compressor: 57001–1129 57001–1338 Jack: Socket Wrench: 57001–1238 57001–1370 Front Fork Oil Seal Driver: Hook Wrench: 57001–1288 57001–1539 Fork Oil Level Gauge: 57001–1290...
  • Page 360: Front Fork

    13-8 SUSPENSION Front Fork Rebound Damping Force Adjustment (Only Right Fork Leg) • To adjust the rebound damping force, turn the rebound damping adjuster [A] on top of the right front fork leg to the desired position. ○ The standard adjuster setting for the average-build rider of 68 kg (150 lb) with no passenger and no accessories is 1 turns out of the fully clockwise position.
  • Page 361: Front Fork Removal (each Fork Leg)

    SUSPENSION 13-9 Front Fork Front Fork Removal (each fork leg) • Remove: Front Wheel (see Wheels/Tires chapter.) Front Fender (see Frame chapter.) Windshield and Bracket (see Frame chapter.) Inner Cover (see Frame chapter.) Fairing and Bracket (see Frame chapter.) Loosen the upper fork clamp bolts [A] and fork top plug [B] before-hand if the fork leg is to be disassembled.
  • Page 362: Fork Oil Change

    13-10 SUSPENSION Front Fork Fork Oil Change • Remove the front fork (see Front Fork Removal). ○ Turn the spring preload adjuster [A] counterclockwise until the fully position. • Unscrew the top plug [B] out of the inner tube. • Avoiding the pins [A], set the front fork spring compressor set [B] on the washer [C].
  • Page 363 SUSPENSION 13-11 Front Fork • Drain the fork oil into a suitable container. • Remove the fork spring [A]. ○ Pump the piston rod [B] up and down at least ten times to expel the oil from the fork. • Hold the fork tube upright, press the inner tube and the piston rod all the way down.
  • Page 364 13-12 SUSPENSION Front Fork Oil Level (fully compressed, without spring) Standard: Right fork leg 62 ± 2 mm (2.44 ± 0.08 in.) Left fork leg 47 ± 2 mm (1.85 ± 0.08 in.) (from the top of the outer tube) NOTE ○...
  • Page 365: Front Fork Disassembly

    SUSPENSION 13-13 Front Fork • Check the O-ring on the top plug and replace it with a new one if damaged. • For the right fork leg, check the distance [C] between the bottom end [A] of the top plug and rebound damping ad- juster [B] with a pair of vernier caliper.
  • Page 366: Front Fork Assembly

    13-14 SUSPENSION Front Fork ○ Holding the inner tube [A] by hand, pull the outer tube [B] several times to pull out the outer tube. • Remove the inner tube guide bushing [A], outer tube guide bushing [B], washer [C], oil seal [D] from the inner tube.
  • Page 367: Inner Tube, Outer Tube Inspection

    SUSPENSION 13-15 Front Fork • Install the cente ring plate on the cylinder unit. • Insert the cente ring plate and cylinder unit as a set into the inner tube. Cylinder Unit [A] and Center Ring Plate [C] for Right Fork Cylinder Unit [B] and Center Ring Plate [C] for Left Fork •...
  • Page 368: Spring Tension

    13-16 SUSPENSION Front Fork Spring Tension • Since a spring becomes shorter as it weakens, check its free length [A] to determine its condition. If the spring of either fork leg is shorter than the service limit, it must be replaced. If the length of a replacement spring and that of the remaining spring vary greatly, the remaining spring should also be replaced in order to keep the fork legs balanced for motorcycle stability.
  • Page 369: Rear Shock Absorber

    SUSPENSION 13-17 Rear Shock Absorber Rebound Damping Force Adjustment • To adjust the rebound damping force, turn the rebound damping adjuster [A] to the desired position. ○ The standard adjuster setting for an average-build rider of 68 kg (150 lb) with no passenger and no accessories 3/4 turns out of the fully clockwise position.
  • Page 370: Rear Shock Absorber Removal

    13-18 SUSPENSION Rear Shock Absorber Special Tools - Hook Wrench: 57001–1539 [A] Spring Adjustment Adjuster Damping Setting Load Road Speed Position Force 193.4 mm Weak Soft Light Good (7.61 in.) ↑ ↑ ↑ ↑ ↑ ↑ ↓ ↓ ↓ ↓ ↓...
  • Page 371: Rear Shock Absorber Installation

    SUSPENSION 13-19 Rear Shock Absorber • Remove the shock absorber [A] from upside. Rear Shock Absorber Installation • Tighten: Torque - Rear Shock Absorber Nuts: 34 N·m (3.5 kgf·m, 25 ft·lb) Rear Shock Absorber Inspection • Remove the rear shock absorber. •...
  • Page 372: Swingarm

    13-20 SUSPENSION Swingarm Swingarm Removal • Remove the muffler bodies (see Engine Top End chapter.) • Raise the rear wheel off the ground with jack. Special Tool - Jack: 57001–1238 • Remove: Rear Wheel (see Wheels/Tires chapter.) Chain Cover (see Final Drive chapter.) Mud Guard (see Frame chapter.) Brake Hose Clamp [A] Lower Shock Absorber Nut and Bolt [A]...
  • Page 373: Swingarm Installation

    SUSPENSION 13-21 Swingarm Swingarm Installation • Apply plenty of grease to the ball bearing, needle bearings and grease seals, and add plenty of grease to the grease nipple. • Install the collars [A]. ○ Place the right collar [A] on the stopper [B] inside the frame [C].
  • Page 374: Swingarm Bearing Installation

    13-22 SUSPENSION Swingarm • Remove the ball bearing and needle bearings. Special Tool - Oil Seal and Bearing Remover: 57001–1058 Swingarm Bearing Installation • Apply plenty of grease to the ball bearing and needle bearings. • Install the needle bearings so that the manufacturer’s marks face in.
  • Page 375: Tie-rod, Rocker Arm

    SUSPENSION 13-23 Tie-Rod, Rocker Arm Tie-Rod Removal • Remove the muffler bodies (see Engine Top End chapter.) • Remove the side stand (see Frame chapter.) • Using the jack, raise the rear wheel off the ground. Special Tool - Jack: 57001–1238 •...
  • Page 376: Rocker Arm Installation

    13-24 SUSPENSION Tie-Rod, Rocker Arm Rocker Arm Installation • Apply grease to the inside of the needle bearings and oil seal lips, and add grease to the grease nipple. • Tighten: Torque - Rocker Arm Bolt: 34 N·m (3.5 kgf·m, 25 ft·lb) Tie-Rod Nut: 59 N·m (6.0 kgf·m, 43 ft·lb) Rear Shock Absorber Nut: 34 N·m (3.5 kgf·m, 25 ft·lb)
  • Page 377 STEERING 14-1 Steering Table of Contents Exploded View........................14-2 Special Tools .......................... 14-4 Steering ..........................14-5 Steering Inspection ......................14-5 Steering Adjustment......................14-5 Steering Stem......................... 14-6 Stem, Stem Bearing Removal................... 14-6 Stem, Stem Bearing Installation..................14-7 Stem Bearing Lubrication....................14-9 Steering Stem Warp......................
  • Page 378: Exploded View

    14-2 STEERING Exploded View...
  • Page 379 STEERING 14-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Steering stem nut 2.75 Steering stem head bolt Front fork clamp bolts (Upper) 0.90 78 in·lb Front fork clamp bolts (Upper): ZR1000–A2 ∼ 113 in·lb Front fork clamp bolts (Lower) Front fork clamp bolts (Lower): ZR1000–A2 ∼...
  • Page 380: Special Tools

    14-4 STEERING Special Tools Steering Stem Nut Wrench: Steering Stem Bearing Driver: 57001–1100 57001–1344 Bearing Driver Set: Steering Stem Bearing Driver Adapter: 57001–1129 57001–1345 Jack: 57001–1238...
  • Page 381: Steering Inspection

    STEERING 14-5 Steering Steering Inspection • Refer to the Steering Inspection in the Periodic Mainte- nance chapter. Steering Adjustment • Refer to the Steering Adjustment in the Periodic Mainte- nance chapter.
  • Page 382: Steering Stem

    14-6 STEERING Steering Stem Stem, Stem Bearing Removal • Remove: Windshield and Bracket (see Frame chapter.) Inner Cover (see Frame chapter.) Fairing and Bracket (see Frame chapter.) Front Wheel (see Wheels/Tires chapter.) Handlebar (see Handlebar Removal.) Steering Stem Head Bolt Plug Steering Stem Head Bolt [A] and Washer Steering Stem Head •...
  • Page 383: Stem, Stem Bearing Installation

    STEERING 14-7 Steering Stem • To remove the bearing outer races [C] pressed into the head pipe [B], insert a bar [A] into the recesses [D] of head pipe, and applying it to both recess alternately hammer it to drive the race out. NOTE ○...
  • Page 384 14-8 STEERING Steering Stem • Apply grease the lower ball bearing [A] and install it onto the stem. • Apply grease to the upper ball bearing [B] and inner race [C]. • Install the stem [A] through the head pipe and install the ball bearing [B] and inner race [C] on it.
  • Page 385: Stem Bearing Lubrication

    STEERING 14-9 Steering Stem NOTE ○ Tighten the fork upper clamp bolts first, next the stem head nut, last the fork lower clamp bolts. Torque - Steering Stem Head Bolt : 108 N·m (11 kgf·m, 80 ft·lb) Front Fork Clamp Bolts (Upper): 8.8 N·m (0.90 kgf·m, 78 in·lb) 13 N·m (1.3 kgf·m, 113 in·lb): ZR1000–A2 ∼...
  • Page 386: Handlebar

    14-10 STEERING Handlebar Handlebar Removal • Remove: Clutch Lever Assembly [A] Left Handlebar Switch Housing [B] Front Brake Master Cylinder [C] Right Handlebar Switch Housing [D] Handlebar Holder Bolts [E] • Remove the handlebar holders [F] and then pull out the handlebar [G].
  • Page 387: Rear View Mirrors Removal

    STEERING 14-11 Handlebar Rear View Mirrors Removal • Loosen the lower hexagonal area [A] for tightening to re- move the rear view mirror from the holder. CAUTION Do not force to tighten and/or loosen the upper hexagonal area (Adapter) [B] with a pair of span- ners.
  • Page 389 FRAME 15-1 Frame Table of Contents Exploded View........................15-2 Seats ............................15-7 Rear Seat Removal......................15-7 Rear Seat Installation......................15-7 Front Seat Removal ......................15-7 Front Seat Installation ....................... 15-7 Side Covers ..........................15-8 Side Cover Removal ......................15-8 Side Cover Installation ...................... 15-8 Fairings...........................
  • Page 390: Exploded View

    15-2 FRAME Exploded View...
  • Page 391 FRAME 15-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb 1 Footpeg holder bolts 2 Muffler mounting nuts 3 Side stand bolt 4 Side stand switch bolt 78 in·lb G: Apply grease.
  • Page 392 15-4 FRAME Exploded View...
  • Page 393 FRAME 15-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb 0.35 ∼ 0.50 0.035 ∼ 0.050 3 ∼4 in·lb Windshield screws Front fender bolts 34.7 in·lb...
  • Page 394 15-6 FRAME Exploded View...
  • Page 395: Seats

    FRAME 15-7 Seats Rear Seat Removal • Insert the ignition switch key into the seat lock [A], turning the key counterclockwise, pulling up on the rear of the seat [B], and pulling the seat backward. WARNING The muffler surface is hot once the engine has been started.
  • Page 396: Side Covers

    15-8 FRAME Side Covers Side Cover Removal • Remove the bolt [A]. • Pull the side cover [B] evenly outward to clear the stop- pers. Side Cover Installation • Insert the tabs [A] into the holes [B]. • Install the bolt.
  • Page 397: Fairings

    FRAME 15-9 Fairings Windshield Removal • Remove: Bolts [A] Windshield [B] Windshield Installation • Windshield Installation is the reverse of removal. Torque - Windshield Screw: 0.35 ∼ 0.50 N·m (0.035 ∼ 0.050 kgf·m, 3 ∼ 4 in·lb) Inner Cover Removal •...
  • Page 398: Fairing Installation

    15-10 FRAME Fairings • Remove: Fairing Mounting Bolts [A] (both side) Headlight Connectors Fairing Installation • Fairing installation is the reverse of removal. Faring Bracket Removal • Remove: Fairing (see Fairing Removal) Turn Signal Lights (see Electrical System chapter) Meter Unit [A] (see Electrical System chapter) Clamp [B] Bolts [C] Firing Bracket [D]...
  • Page 399: Seat Covers

    FRAME 15-11 Seat Covers Seat Cover Removal • Remove: Seats Screws [A] • Push the central pin, and then remove the quick rivets [A]. • Pull the front portions [A] of the seat cover outside [B], and then remove the seat cover backward. Seat Cover Installation •...
  • Page 400: Mud Guard

    15-12 FRAME Mud Guard Mud Guard Removal • Remove: Chain Cover (see Final Drive chapter) Bolt [A] Clamp [B] • Lift up the mud guard [A], and then pull it out backward. Mud Guard Installation • Put the projections [A] into the grommets [B].
  • Page 401: Fenders

    FRAME 15-13 Fenders Front Fender Removal • Remove: Brake Hose Clamps [A] Bolts [B] (both side) • Remove the front fender [C]. Front Fender Installation • Install the brake hose clamps to the front fender holes. Rear Fender Rear Removal •...
  • Page 402: Rear Fender Rear Installation

    15-14 FRAME Fenders • Remove: Quick Rivets [A] Rear Fender Rear [B] Rear Fender Rear Installation • Put the projection [A] into the hole [B]. • Put the projections [A] into the holes [B]. • Installation is reverse of removal.
  • Page 403: Frame Cover

    FRAME 15-15 Frame Cover Frame Cover Removal • Remove: Bolts [A] Frame Cover [B] (both side)
  • Page 404: Battery Case

    15-16 FRAME Battery Case Battery Case Removal • Remove: Seats Seat Cover Rear Fender Assy Side Covers Battery Left Side Screw [A] (with reserver tank) • Pull out the battery case [B] backward [C]. Battery Case Installation • Put the battery case attachments [A] at the projections [B] on the frame.
  • Page 405: Side Stand

    FRAME 15-17 Side Stand Side Stand Removal • Raise the rear wheel off the ground with the stand. • Remove: Muffler (both side) Exhaust pipe Side Stand Switch Bolt [A] Side Stand Switch [B] Spring [C] Side Stand Nut [D] Side Stand Bolt [E] Side Stand [F] Side Stand Installation...
  • Page 406: Frame Inspection

    15-18 FRAME Frame Frame Inspection • Visually inspect the frame for cracks, dents, bending, or warp. ○ If there is any damage to the frame, replace it. WARNING A repaired frame may fail in use, possibly causing an accident. If the frame is bent, dented, cracked, or warped, replace it.
  • Page 407 ELECTRICAL SYSTEM 16-1 Electrical System Table of Contents Parts Location........16-3 Camshaft Position Sensor Peak Exploded View........16-4 Voltage Inspection..... 16-41 Specifications ........16-10 Stick Coil (Ignition Coil together Special Tools and Sealant ....16-11 with Spark Plug Cap) Removal . 16-41 Wiring Diagram (U.S.A.
  • Page 408 16-2 ELECTRICAL SYSTEM Fan Motor Inspection ....16-63 Fuel Reserve Switch Inspection... 16-79 Meter, Gauge, Indicator Unit....16-65 Diode (Rectifier) Inspection..16-80 Meter Unit Removal ..... 16-65 Junction Box ........16-81 Meter, Gauge Disassembly..16-65 Junction Box Fuse Circuit Electronic Combination Meter Inspection........
  • Page 409: Parts Location

    ELECTRICAL SYSTEM 16-3 Parts Location [A] Starter Lockout Switch [I] Water Temperature Sensor [Q] ECU Fuse [B] Camshaft Position Sensor [J] Battery [R] Turn Signal Relay [C] Radiator Fan Switch [K] Junction Box [S] Diode (Rectifier) [D] Starter Motor [L] Front Brake Light Switch [T] ECU [E] Alternator [M] Stick Coils...
  • Page 410: Exploded View

    16-4 ELECTRICAL SYSTEM Exploded View...
  • Page 411 ELECTRICAL SYSTEM 16-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Meter mounting screws 0.12 11 in·lb Tail/brake light mounting screws 0.12 11 in·lb License plate light mounting screws 0.12 11 in·lb Front brake light switch screw 0.12 11 in·lb Starter locknut switch screws Left switch housing screws 0.35...
  • Page 412 16-6 ELECTRICAL SYSTEM Exploded View...
  • Page 413 ELECTRICAL SYSTEM 16-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Water temperature sensor Spark plugs 115 in·lb Alternator lead holding plate bolts 95 in·lb Starter motor mounting bolts 95 in·lb Stator motor coil bolts 95 in·lb Alternator rotor bolt Starter clutch bolts 104 in·lb Alternator cover bolts...
  • Page 414 16-8 ELECTRICAL SYSTEM Exploded View...
  • Page 415 ELECTRICAL SYSTEM 16-9 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Regulator/rectifier bolts 62 in·lb Fuel level sensor bolts 62 in·lb Side stand switch bolt 78 in·lb Neutral switch Speed sensor bolt 62 in·lb Speed sensor cover bolts 62 in·lb Regulator/rectifier bracket bolts 62 in·lb Engine ground cable terminal bolt...
  • Page 416: Specifications

    16-10 ELECTRICAL SYSTEM Specifications Item Standard Battery: Type Sealed Battery Capacity 12 V 8 Ah 12.6 V or more Voltage Charging System: Type Three–phase AC Alternator output voltage 42 V or more 0.3 ∼ 0.4 Ω Stator coil resistance Charging voltage 14.7 ±...
  • Page 417: Special Tools And Sealant

    Rotor Puller, M16/M18/M20/M22 × 1.5: 57001–1394 57001–1216 Flywheel Puller, M38 × 1.5: Flywheel and Pulley Holder: 57001–1405 57001–1343 Rotor Holder: Needle Adapter: 57001–1543 57001–1457 Lead Wire-Peak Voltage Adapter: Spark Plug Wrench (Owner’s Tool): 57001–1449 92110–1132 Kawasaki Bond (Silicone Sealant): Harness Adapter: 56019–120 57001–1542...
  • Page 418 16-12 ELECTRICAL SYSTEM Wiring Diagram (U.S.A. and Canada)
  • Page 419 ELECTRICAL SYSTEM 16-13 Wiring Diagram (U.S.A. and Canada)
  • Page 420: Wiring Diagram (australia)

    16-14 ELECTRICAL SYSTEM Wiring Diagram (Australia)
  • Page 421 ELECTRICAL SYSTEM 16-15 Wiring Diagram (Australia)
  • Page 422: Wiring Diagram (other Than U.s.a., Canada, Australia, And Malaysia)

    16-16 ELECTRICAL SYSTEM Wiring Diagram (Other than U.S.A., Canada, Australia, and Malaysia)
  • Page 423 ELECTRICAL SYSTEM 16-17 Wiring Diagram (Other than U.S.A., Canada, Australia, and Malaysia)
  • Page 424: Wiring Diagram (malaysia)

    16-18 ELECTRICAL SYSTEM Wiring Diagram (Malaysia)
  • Page 425 ELECTRICAL SYSTEM 16-19 Wiring Diagram (Malaysia)
  • Page 426: Precautions

    16-20 ELECTRICAL SYSTEM Precautions There are a number of important precautions that are musts when servicing electrical systems. Learn and ob- serve all the rules below. ○ Do not reverse the battery lead connections. This will burn out the diodes on the electrical parts. ○...
  • Page 427 ELECTRICAL SYSTEM 16-21 Precautions Male Connectors [B]...
  • Page 428: Electrical Wiring

    16-22 ELECTRICAL SYSTEM Electrical Wiring Wiring Inspection • Visually inspect the wiring for signs of burning, fraying, etc. If any wiring is poor, replace the damaged wiring. • Pull each connector [A] apart and inspect it for corrosion, dirt, and damage. If the connector is corroded or dirty, clean it carefully.
  • Page 429: Battery

    ELECTRICAL SYSTEM 16-23 Battery Battery Removal CAUTION Do not disconnect the battery cables or any other electrical connections when the ignition switch is ON, as this could damage the ECU (Electronic Con- trol Unit). Never reverse the connections of the battery, this could damage the ECU.
  • Page 430 16-24 ELECTRICAL SYSTEM Battery CAUTION Do not remove the aluminum seal sheet [A] sealing the filler ports [B] until just before use. • Check to see that there is no peeling, tears or holes in the seal sheet on the top of the battery. •...
  • Page 431: Initial Charge

    ELECTRICAL SYSTEM 16-25 Battery • Fit the seal caps [A] tightly into the filler ports until the seal caps are at the same level as the top of the battery. NOTE ○ Do not hammer. Press down evenly with both hands. CAUTION Once you installed the seal caps after filling the bat- tery, never remove it, nor add any water or elec-...
  • Page 432: Precautions

    16-26 ELECTRICAL SYSTEM Battery Precautions 1) No need of topping–up No topping–up is necessary in this battery until it ends its life under normal use. Forcibly prying off the sealing plug to add water is very dangerous. Never do that. 2) Refreshing charge If an engine will not start, a horn sounds weak, or lamps are dim, it indicates the battery has been dis-...
  • Page 433: Interchange

    ELECTRICAL SYSTEM 16-27 Battery Interchange The sealed battery can fully display its performance only when combined with a proper vehicle electric system. Therefore, replace the sealed battery only on a motorcycle which was originally equipped with the sealed battery. Be careful, if a sealed battery is installed on a motorcycle which had an ordinary battery as original equipment, the sealed battery’s life will be shortened.
  • Page 434 16-28 ELECTRICAL SYSTEM Battery Terminal Voltage: 11.5 ∼ less than 12.6 V Standard Charge 0.9 A × 5 ∼ 10 h Quick Charge 4.0 A × 1.0 h Battery Terminal Voltage (V) [A] Charge Time (h) [B] CAUTION If possible, do not quick charge. If the quick charge is done due to unavoidable circumstances, do stan- dard charge later on.
  • Page 435: Charging System

    Apply silicone sealant to the alternator lead grommet and crankcase halves mating surface [A] on the front and rear sides of the cover mount. Sealant - Kawasaki Bond (Silicone Sealant): 56019– 120 • Check that knock pins [B] are in place on the crankcase.
  • Page 436: Stator Coil Installation

    Apply silicone sealant to the circumference of the alter- nator lead grommet, and fit the grommet into the notch of the cover securely. Sealant - Kawasaki Bond (Silicone Sealant): 56019–120 • Install the alternator cover (see Alternator Cover Installa- tion).
  • Page 437 ELECTRICAL SYSTEM 16-31 Charging System • Install the starter gear [A]. • Again, clean the crankshaft tapered portion [B] and dry there. • Fit the woodruff key [C] securely in the slot in the crank- shaft before installing the alternator rotor. •...
  • Page 438: Alternator Inspection

    16-32 ELECTRICAL SYSTEM Charging System • Apply a thin coat of molybdenum disulfide grease to the shaft [A], and install it and starter idle gear [B]. • Install the alternator cover (see Alternator Cover Installa- tion). Alternator Inspection There are three types of alternator failures: short, open (wire burned out), or loss in rotor magnetism.
  • Page 439: Regulator/rectifier Inspection

    ELECTRICAL SYSTEM 16-33 Charging System If there is more resistance than shown in the table, or no hand tester reading (infinity) for any two leads, the stator has an open lead and must be replaced. Much less than this resistance means the stator is shorted, and must be replaced.
  • Page 440 16-34 ELECTRICAL SYSTEM Charging System • Do the 1st step regulator circuit test: ○ Connect the test light and the 12 V battery to the regula- tor/rectifier as shown. ○ Check BK1, BK2, and BK3 terminal respectively. If the test light turns on, the regulator/rectifier is defective. Replace it.
  • Page 441: Charging Voltage Inspection

    ELECTRICAL SYSTEM 16-35 Charging System Charging Voltage Inspection • Check the battery condition (see Battery section). • Warm up the engine to obtain actual alternator operating conditions. • Remove the seats (see Frame chapter). • Check that the ignition switch is turned off, and connect the hand tester [A] to the battery terminals [B].
  • Page 442 16-36 ELECTRICAL SYSTEM Charging System Charging System Circuit 1. Ignition Switch 4. Regulator/Rectifier 7. Main Fuse 30A 2. To Starter Circuit Relay 5. Joint Connector C 8. Load 3. Alternator 6. Battery 12 V 8 Ah...
  • Page 443: Ignition System

    ELECTRICAL SYSTEM 16-37 Ignition System WARNING The ignition system produces extremely high volt- age. Do not touch the spark plugs or stick coils while the engine is running, or you could receive a severe electrical shock. CAUTION Do not disconnect the battery cables or any other electrical connections when the ignition switch is on, or while the engine is running.
  • Page 444: Crankshaft Sensor Installation

    Apply silicone sealant [A] to the crankshaft sensor lead grommet and crankcase halves mating surface on the front and rear sides of the crankshaft sensor cover mount. Sealant - Kawasaki Bond (Silicone Sealant): 56019–120 • Install the clamps [A] direction as shown.
  • Page 445: Crankshaft Sensor Peak Voltage Inspection

    ELECTRICAL SYSTEM 16-39 Ignition System Crankshaft Sensor Resistance: 375 ∼ 565 Ω • Using the highest resistance range of the tester, measure the resistance between the crankshaft sensor leads and chassis ground. Any tester reading less than infinity (∞) indicates a short, necessitating replacement of the crankshaft sensor as- sembly.
  • Page 446: Camshaft Position Sensor Removal

    16-40 ELECTRICAL SYSTEM Ignition System Camshaft Position Sensor Removal • Remove: Fuel Tank (see Fuel System (DFI) chapter) Camshaft Position Sensor Lead Connector [A] (discon- nect) ○ Push the tongue [B] upside and take out the connector from the bracket. •...
  • Page 447: Camshaft Position Sensor Peak Voltage Inspection

    ELECTRICAL SYSTEM 16-41 Ignition System Camshaft Position Sensor Peak Voltage Inspection • Remove: Fuel Tank (see Fuel System (DFI) chapter) Camshaft Position Sensor Lead Connector [A] (discon- nect) • Set the hand tester [B] to the 10 V DC range. •...
  • Page 448: Stick Coil (ignition Coil Together With Spark Plug Cap) Installation

    16-42 ELECTRICAL SYSTEM Ignition System • Remove the stick coil harness [A] from the bracket. • Remove: Stick Coil Connector #4 [B] (disconnect) Stick Coil #4 [C] Stick Coil Connector #3 [D] (disconnect) • Disconnect: Water Temperature Sensor Connector [A] Left Switch Housing Connector [B] •...
  • Page 449: Stick Coil

    ELECTRICAL SYSTEM 16-43 Ignition System Stick Coil (Ignition Coil together with Spark Plug Cap) Inspection • Remove the stick coils (see this chapter). • Measure the primary winding resistance [A] as follows. ○ Connect the hand tester between the coil terminals. ○...
  • Page 450: Spark Plug Removal

    16-44 ELECTRICAL SYSTEM Ignition System WARNING To avoid extremely high voltage shocks, do not touch the spark plugs or tester connections. • Turn the ignition switch and the engine stop switch ON. • Pushing the starter button, turn the engine 4 ∼ 5 seconds with the transmission in neutral to measure the primary peak voltage.
  • Page 451: Interlock Operation Inspection

    ELECTRICAL SYSTEM 16-45 Ignition System Interlock Operation Inspection • Remove: Seats (see Frame chapter) Junction Box (see this chapter) ○ Do not disconnect the connectors. 1st Check • Measure the terminal voltage of the G/BK lead in the junc- tion box connector [A] in accordance with the following procedure.
  • Page 452: Ic Igniter Inspection

    16-46 ELECTRICAL SYSTEM Ignition System IC Igniter Inspection ○ The IC Igniter is built in the ECU [A]. • Refer to the Interlock Operation Inspection, Ignition System Troubleshooting Chapter and Fuel System (DFI) chapter for ECU Inspection.
  • Page 453 ELECTRICAL SYSTEM 16-47 Ignition System...
  • Page 454 16-48 ELECTRICAL SYSTEM Ignition System Ignition System Circuit 1. Ignition Switch 9. Throttle Sensor 18. Main Fuse 30A 2. Engine Stop Switch 10. Neutral Switch 19. Battery 12 V 8 Ah 3. Starter Button 11. Junction Box 20. ECU 4. Spark Plugs 12.
  • Page 455: Electric Starter System

    ELECTRICAL SYSTEM 16-49 Electric Starter System Starter Motor Removal CAUTION Do not tap the starter motor shaft or body. Tapping the shaft or body could damage the motor. • Remove the mounting bolts [A]. • Pull out the starter motor [B]. •...
  • Page 456: Starter Motor Assembly

    16-50 ELECTRICAL SYSTEM Electric Starter System ○ The brush plate [A] and brushes come off with the right–hand end cover [B]. • Remove the terminal locknut [A] and terminal bolt [B], and then remove the brush with the brush plate [C] from the right–hand end cover.
  • Page 457: Brush Inspection

    ELECTRICAL SYSTEM 16-51 Electric Starter System • Align the line [A] marked on the yoke with the through bolt hole [B]. Brush Inspection • Measure the length [A] of each brush. If any is worn down to the service limit, replace the carbon brush holder assembly [B] and the terminal bolt assembly [C].
  • Page 458: Brush Lead Inspection

    16-52 ELECTRICAL SYSTEM Electric Starter System NOTE ○ Even if the foregoing checks show the armature to be good, it may be defective in some manner not readily detectable with the hand tester. If all other starter motor and starter motor circuit components check good, but the starter motor still does not turn over or only turns over weakly, replace the starter motor with a new one.
  • Page 459 ELECTRICAL SYSTEM 16-53 Electric Starter System • Connect the hand tester [A] and 12 V battery [B] to the starter relay [C] as shown. Special Tool - Hand Tester: 57001–1394 If the relay does not work as specified, the relay is defec- tive.
  • Page 460: Lighting System

    16-54 ELECTRICAL SYSTEM Lighting System This models adopt the daylight system and have a head- light relay in the junction box. In these models, the head- light does not go on when the ignition switch and the engine stop switch are first turned on. The headlight comes on after the starter button is released and stays on until the ignition switch is turned off.
  • Page 461: Headlight Bulb Replacement

    ELECTRICAL SYSTEM 16-55 Lighting System Headlight Bulb Replacement • Remove: Headlight Connector [A] Headlight Bulb Dust Cover [B] • Remove: Hook [A] Headlight Bulb [B] CAUTION When handling the quartz–halogen bulb, never touch the glass portion with bare hands. Always use a clean cloth.
  • Page 462: Headlight Removal/installation

    16-56 ELECTRICAL SYSTEM Lighting System • Fit the dust cover [A] with the arrow mark upward onto the bulb [B] firmly as shown. Good [C] Bad [D] Arrow Mark [E] • After installation, adjust the headlight aim (see this chap- ter).
  • Page 463 ELECTRICAL SYSTEM 16-57 Lighting System • Pull the bulb [A] out of the socket [B]. CAUTION Do not turn the bulb. Pull the bulb out to prevent damage to the bulb. Do not use bulb rated for greater wattage then the specified valve. •...
  • Page 464 16-58 ELECTRICAL SYSTEM Lighting System Headlight/Tail Light Circuit (US, CA, AS) Headlight/Tail Light Circuit (Other than US, CA, AS) US: United States of America 7. Junction Box 14. Dimmer Switch CA: Canada 8. High Beam Indicator 15. Pussing Button AS: Australia Light (LED) 16.
  • Page 465: Turn Signal Light Bulb Replacement

    ELECTRICAL SYSTEM 16-59 Lighting System Turn Signal Light Circuit US: U.S.A. model 10. Turn Signal Switch CA: Canada model 11. Meter Ground MY: Malaysia model 12. Turn Signal Relay 1. Joint Connector D 13. Junction Box 2. Meter Unit 14. Turn Signal Fuse 10A 3.
  • Page 466 16-60 ELECTRICAL SYSTEM Lighting System • Push and turn the bulb [A] counterclockwise and remove • Insert the new bulb [A] by aligning its upper and lower pins [B] with the upper and lower grooves [C] in the socket, and turn the bulb clockwise.
  • Page 467: Turn Signal Relay Inspection

    ELECTRICAL SYSTEM 16-61 Lighting System • Insert the new bulb [A] by aligning its upper and lower pins [B] with the upper and lower grooves [C] in the socket, and turn the bulb clockwise. CAUTION The front turn signal/running position lights use a vibration resistant bulb.
  • Page 468: Tail/brake Light (led) Installation

    16-62 ELECTRICAL SYSTEM Lighting System • Unscrew the bolts [A]. • Loosen the bolts [B]. • Unscrew the mounting screws [A]. • Remove the tail/brake light (LED) [B]. ○ Pull out the mount portion [C]. Tail/Brake Light (LED) Installation • Tighten the tail/brake light mounting screws.
  • Page 469: Radiator Fan System

    ELECTRICAL SYSTEM 16-63 Radiator Fan System Fan System Circuit Inspection • Disconnect the lead connector [A] from the radiator fan switch. • Using an auxiliary wire [A], connect the radiator fan switch leads. If the fan rotates, inspect the fan switch. If the fan does not rotate, inspect the following.
  • Page 470 16-64 ELECTRICAL SYSTEM Radiator Fan System Radiator Fan Circuit 1. Radiator Fan 5. Meter Ground 9. Fan Fuse 10A 2. Radiator Fan Switch 6. Frame Ground 10. Main Fuse 30A 3. Joint Connector A 7. Joint Connector B 11. Battery 12 V 8 Ah 4.
  • Page 471: Meter, Gauge, Indicator Unit

    ELECTRICAL SYSTEM 16-65 Meter, Gauge, Indicator Unit Meter Unit Removal • Remove: Wind Sealed (see Frame chapter) • Slide the dust cover [A] and remove the wiring connector [B]. • Remove the meter unit by taking off the mounting screws [C] with the washers.
  • Page 472: Electronic Combination Meter Unit Inspection

    16-66 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit Electronic Combination Meter Unit Inspection • Remove the meter unit [A]. [1] Ignition [10] Battery (+) [2] Fuel Reserve Switch [11] Oil Pressure Warning [3] Unused Indicator Light (LED) [4] Fuel Level Sensor Ground (–) [5] Neutral Indicator Light [12] Speed Sensor Supply Voltage...
  • Page 473 ELECTRICAL SYSTEM 16-67 Meter, Gauge, Indicator Unit MODE AND RESET BUTTON Operation Check: • Connect the 12 V battery and terminals in the same man- ner as specified in the "Liquid Crystal Display (LCD) Seg- ments Check". • Check that the display change to the ODO, TRIP, and CLOCK displays each time the MODE button [A] is pressed.
  • Page 474 16-68 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit • In the HOUR setting mode, press the RESET button to effect the MINUTE setting mode. ○ The minute display flashes on the display. • Press the MODE button to set the minute. •...
  • Page 475 ELECTRICAL SYSTEM 16-69 Meter, Gauge, Indicator Unit • If the oscillator is not available, the speedometer can be checked as follows. ○ Install the meter unit. ○ Raise the rear wheel off the ground, using the jack. ○ Turn on the ignition switch. ○...
  • Page 476 16-70 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit Water Temperature Meter Check: • Connect the 12 V battery and terminals in the same man- ner as specified in the "Liquid Crystal Display (LCD) Seg- ments Check". • Connect the variable rheostat [A] to the terminal [8] as shown.
  • Page 477 ELECTRICAL SYSTEM 16-71 Meter, Gauge, Indicator Unit Fuel Level Gauge Inspection: • Connect the 12 V battery and terminals in the same man- ner as specified in the “Liquid Crystal Display (LCD) Seg- ments Check”. • Connect a variable rheostat [A] to terminal [4] and [9] as shown.
  • Page 478 16-72 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit • If the oscillator is not available, the tachometer can be checked as follows. ○ Connect the 12 V battery and terminals in the same man- ner as specified in the "Liquid Crystal Display (LCD) Seg- ments Check".
  • Page 479 ELECTRICAL SYSTEM 16-73 Meter, Gauge, Indicator Unit Right and Left Turn Signal Indicator Light (LED): For Right Turn Signal Indicator Light (LED) Battery Positive (+) Terminal to Terminal [13] For Left Turn Signal Indicator Light (LED) Battery Positive (+) Terminal to Terminal [14] High Beam Indicator Light: Battery Positive (+) Terminal to Terminal [15] •...
  • Page 480 16-74 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit Meter Circuit 1. Right Turn Signal Indicator Light (LED) 17. Speed Sensor 2. High Beam Indicator Light (LED) 18. Fuel Reserve Switch 3. Neutral Indicator Light (LED) 19. Fuel Level Sensor 4. Oil Pressure Warning Indicator Light (LED) 20.
  • Page 481: Switches And Sensors

    ELECTRICAL SYSTEM 16-75 Switches and Sensors Brake Light Timing Inspection • Refer to the Brakes in the Periodic Maintenance chapter. Brake Light Timing Adjustment • Refer to the Brakes in the Periodic Maintenance chapter. Switch Inspection • Using a hand tester, check to see that only the con- nections shown in the table have continuity (about zero ohms).
  • Page 482: Water Temperature Sensor Inspection

    16-76 ELECTRICAL SYSTEM Switches and Sensors • Disconnect the connector [A]. • Remove the fan switch [B]. • Suspend the switch [A] in a container of coolant so that the temperature–sensing projection and threaded portion are submerged. • Suspend an accurate thermometer [B] in the coolant so that the sensitive portions are located in almost the same depth.
  • Page 483: Speed Sensor Inspection

    ELECTRICAL SYSTEM 16-77 Switches and Sensors • Suspend the sensor [A] in a container of coolant so that the temperature-sensing projection [E] and threaded por- tion [E] are submerged. • Suspend an accurate thermometer [B] in the coolant. NOTE ○ The sensor and thermometer must not touch the con- tainer side or bottom.
  • Page 484 16-78 ELECTRICAL SYSTEM Switches and Sensors • Remove: Bolts [A] Speed Sensor Cover • Remove: Bolt [A] • Take out the speed sensor [B]. • Connect the speed sensor connector [A] with the battery [B], 10 kΩ resistor [C] and hand tester [D] as shown. •...
  • Page 485: Fuel Level Sensor Inspection

    ELECTRICAL SYSTEM 16-79 Switches and Sensors Fuel Level Sensor Inspection • Remove: Fuel Tank (see Fuel System (DFI) chapter) • Open the clamps [A]. • Remove: Bolts [B] Fuel Level Sensor [C] • Check that the float moves up and down smoothly without binding.
  • Page 486: Diode (rectifier) Inspection

    16-80 ELECTRICAL SYSTEM Switches and Sensors • Connect the test light [A] (12 V 3.4 W bulb a socket with leads) and the 12 V battery [B] to the fuel level sensor connector [C]. Connections: Battery (+) → 12 V 3.4 W Bulb (one side) 12 V 3.4 W Bulb (other side) →...
  • Page 487: Junction Box

    ELECTRICAL SYSTEM 16-81 Junction Box The junction box [A] has fuses [B], relays, and diodes. The relays and diodes can not be removed. Junction Box Fuse Circuit Inspection • Remove the seats (see Frame chapter). • Remove the junction box [A]. •...
  • Page 488: Starter Circuit/headlight Relay Inspection

    16-82 ELECTRICAL SYSTEM Junction Box Starter Circuit/Headlight Relay Inspection • Remove the junction box (see Junction Box Fuse Circuit Inspection). • Check conductivity of the following numbered terminals by connecting the hand tester and one 12 V battery to the junction box as shown.
  • Page 489: Diode Circuit Inspection

    ELECTRICAL SYSTEM 16-83 Junction Box Diode Circuit Inspection • Remove the junction box. • Check conductivity of the following pairs of terminals. Diode Circuit Inspection Tester 13–8, 13–9, 12–11, 12–14, 15–14, 16–14 Connection The resistance should be low in one direction and more than ten times as much in the other direction.
  • Page 490: Fuse

    16-84 ELECTRICAL SYSTEM Fuse 30A Main Fuse Removal • Remove: Right Side Cover (see Frame chapter) 30A Main Fuse Connector [A] • Pull out the main fuse [B] from the starter relay with needle nose pliers. Junction Box Fuse Removal •...
  • Page 491 APPENDIX 17-1 Appendix Table of Contents Cable, Wire, and Hose Routing ....................17-2 Troubleshooting Guide ......................17-20...
  • Page 492 17-2 APPENDIX Cable, Wire, and Hose Routing...
  • Page 493 APPENDIX 17-3 Cable, Wire, and Hose Routing 1. Fixes by the left side clamp of the tank. 2. Tank drain hose passes the side cover installation under the bracket. 3. Air cleaner drain hose 4. Fuel tank drain hose 5. Cooling reserve tank hose 6.
  • Page 494 17-4 APPENDIX Cable, Wire, and Hose Routing...
  • Page 495 APPENDIX 17-5 Cable, Wire, and Hose Routing 1. Clutch cable 37. Neutral Switch 2. Meter ground 38. Speed sensor 3. Clamp (Ignition switch connector) 39. Alternator 4. Ignition switch connector 40. Engine harness 5. Inlet air pressure sensor 41. Water temperature sensor 6.
  • Page 496 17-6 APPENDIX Cable, Wire, and Hose Routing...
  • Page 497 APPENDIX 17-7 Cable, Wire, and Hose Routing 1. Run the main harness through lower and right side of the thermostat. 2. Frame ground (with thermostat bracket) 3. Ignition switch connector 4. Meter ground (with thermostat) 5. Engine harness (Connect the harness on the cross pipe.) 6.
  • Page 498 17-8 APPENDIX Cable, Wire, and Hose Routing...
  • Page 499 APPENDIX 17-9 Cable, Wire, and Hose Routing 1. Tail light 2. Clamp 3. Atmospheric pressure sensor 4. To ECU fuse 5. Junction Box 6. To self-diagnosis indicator terminal 7. Pickup coil and oil pressure switch 8. Fuel pump 9. Fuel level gauge and fuel reserve switch 10.
  • Page 500 17-10 APPENDIX Cable, Wire, and Hose Routing...
  • Page 501 APPENDIX 17-11 Cable, Wire, and Hose Routing 1. Clamp all the wires as shown in the encircled area. 2. Meter 3. Take out the lead of the meter from the right side of the tie lap to connect with the meter. 4.
  • Page 502 17-12 APPENDIX Cable, Wire, and Hose Routing...
  • Page 503 APPENDIX 17-13 Cable, Wire, and Hose Routing 1. Clamp 2. Brake hose 3. Punch mark 4. Run the brake hose through the inside of the frame. 5. Tight the bolt to the specified torque with the stopper (for turning prevention) applied.
  • Page 504 17-14 APPENDIX Cable, Wire, and Hose Routing...
  • Page 505 APPENDIX 17-15 Cable, Wire, and Hose Routing 1. Cam sensor lead (Run the lead between the convex area of cap center and bolt head to secure the coupler.) 2. Radiator fan switch lead (Run the lead through into the water hose.) 3.
  • Page 506 17-16 APPENDIX Cable, Wire, and Hose Routing...
  • Page 507 APPENDIX 17-17 Cable, Wire, and Hose Routing 1. Bend the bracket as shown to secure the lead. 2. Bend the bracket. 3. Run the lead end till it touches the boss of the crankcase. 4. Install the exterior of the lead with staking area facing downward.
  • Page 508 17-18 APPENDIX Cable, Wire, and Hose Routing...
  • Page 509 APPENDIX 17-19 Cable, Wire, and Hose Routing 1. Run the hose (cap – reserve) through upside of the throttle cable. 2. Run the hose (white) through into the throttle cables. 3. Run the throttle body harness throttle upside of the hose (white) and hose (throttle – fitting). 4.
  • Page 510: Troubleshooting Guide

    17-20 APPENDIX Troubleshooting Guide NOTE Spark plug dirty, broken, or gap malad- ○ Refer to the Fuel System chapter for most justed of DFI trouble shooting guide. Stick coil shorted or not in good contact ○ This is not an exhaustive list, giving every Stick coil trouble possible cause for each problem listed.
  • Page 511 APPENDIX 17-21 Troubleshooting Guide Air cleaner duct loose Cylinder, piston worn Compression low: Piston ring bad (worn, weak, broken, or Spark plug loose sticking) Cylinder head not sufficiently tightened Piston ring/groove clearance excessive down Cylinder head gasket damaged No valve clearance Cylinder head warped Cylinder, piston worn Valve spring broken or weak...
  • Page 512: Over Cooling

    17-22 APPENDIX Troubleshooting Guide Over Cooling: Muffler overheating: For KLEEN, do not run the engine even if Gauge incorrect: with only one cylinder misfiring or poor Water temperature gauge broken running (Request the nearest service fa- Water temperature sensor broken cility to correct it) Cooling system component incorrect: For KLEEN, do not push-start with a dead...
  • Page 513: Abnormal Engine Noise

    APPENDIX 17-23 Troubleshooting Guide Abnormal Engine Noise: Engine oil insufficient Knocking: Drive line noise: IC igniter in ECU trouble Drive chain adjusted improperly Carbon built up in combustion chamber Drive chain worn Fuel poor quality or incorrect Rear and/or engine sprocket worn Spark plug incorrect Chain lubrication insufficient Overheating...
  • Page 514: Battery Trouble

    17-24 APPENDIX Troubleshooting Guide Handling and/or Stability Brake Doesn’t Hold: Unsatisfactory: Air in the brake line Handlebar hard to turn: Pad or disc worn Cable routing incorrect Brake fluid leakage Hose routing incorrect Disc warped Wiring routing incorrect Contaminated pad Steering stem nut too tight Brake fluid deteriorated Steering stem bearing damaged...
  • Page 515 MODEL APPLICATION Year Model Beginning Frame No. □ JKAZRCA1 3A000001 2003 ZR1000–A1 ZRT00A–000001 JKAZRT00AAA000001 □ JKAZRCA1 4A015001 2004 ZR1000–A2 JKAZRT00AAA015001 ZRT00A–015001 □ :This digit in the frame number changes from one machine to another. Part No.99924-1310-03 Printed in Japan...

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