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Kawasaki CONCOURS 14 ABS Service Manual

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1400GTR
CONCOURS 14 ABS
CONCOURS 14
Motorcycle
Service Manual
http://mototh.com

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Table of Contents

   Summary of Contents for Kawasaki CONCOURS 14 ABS

  • Page 1 1400GTR CONCOURS 14 ABS CONCOURS 14 Motorcycle Service Manual http://mototh.com...
  • Page 2 This product contains the encryption algorithm "MISTY" developed by MITSUBISHI ELECTRIC CORPORATION. http://mototh.com...
  • Page 3 Quick Reference Guide General Information Periodic Maintenance Fuel System (DFI) Cooling System Engine Top End Clutch Engine Lubrication System Engine Removal/Installation Crankshaft/Transmission Wheels/Tires 10 j Final Drive 11 j Brakes 12 j Suspension 13 j Steering 14 j Frame 15 j Electrical System 16 j Appendix...
  • Page 4 http://mototh.com...
  • Page 5 All information contained in this publication is based on the latest product information available at the time of publication. Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts. © 2007 Kawasaki Heavy Industries, Ltd. First Edition (1): June 29, 2007 (M) http://mototh.com...
  • Page 6 LIST OF ABBREVIATIONS ampere(s) pound(s) ABDC after bottom dead center meter(s) alternating current minute(s) ATDC after top dead center newton(s) BBDC before bottom dead center pascal(s) bottom dead center horsepower BTDC before top dead center pound(s) per square inch °C degree(s) Celsius revolution direct current...
  • Page 7: Emission Control Information

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

    Be alert for problems and non-scheduled ticular interest for more efficient and con- maintenance. venient operation. • Use proper tools and genuine Kawasaki Mo- torcycle parts. Special tools, gauges, and • Indicates a procedural step or work to be testers that are necessary when servicing done.
  • Page 10 http://mototh.com...
  • Page 11: Table Of Contents

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

    Replacement Parts Replacement Parts must be KAWASAKI genuine or recommended by KAWASAKI. Gaskets, O-rings, oil seals, grease seals, circlips or cotter pins must be replaced with new ones whenever disassembled.
  • Page 14 1-4 GENERAL INFORMATION Before Servicing Tightening Sequence Generally, when installing a part with several bolts, nuts, or screws, start them all in their holes and tighten them to a snug fit. Then tighten them according to the specified se- quence to prevent case warpage or deformation which can lead to malfunction.
  • Page 15 GENERAL INFORMATION 1-5 Before Servicing Press For items such as bearings or oil seals that must be pressed into place, apply small amount of oil to the con- tact area. Be sure to maintain proper alignment and use smooth movements when installing. Ball Bearing and Needle Bearing Do not remove pressed ball or needle unless removal is absolutely necessary.
  • Page 16 1-6 GENERAL INFORMATION Before Servicing Lubrication It is important to lubricate rotating or sliding parts during assembly to minimize wear during initial operation. Lubri- cation points are called out throughout this manual, apply the specific oil or grease as specified. Direction of Engine Rotation When rotating the crankshaft by hand, the free play amount of rotating direction will affect the adjustment.
  • Page 17: Model Identification

    GENERAL INFORMATION 1-7 Model Identification ZG1400A8F Left Side View ZG1400A8F Right Side View Frame Number Engine Number http://mototh.com...
  • Page 18 1-8 GENERAL INFORMATION Model Identification ZG1400A8F (United States and Canada) Left Side View ZG1400A8F (United States and Canada) Right Side View http://mototh.com...
  • Page 19 GENERAL INFORMATION 1-9 Model Identification ZG1400B8F (United States and Canada) Left Side View ZG1400B8F (United States and Canada) Right Side View http://mototh.com...
  • Page 20: General Specifications

    1-10 GENERAL INFORMATION General Specifications Items ZG1400A8F, ZG1400B8F Dimensions Overall Length 2 270 mm (89.4 in.) Overall Width 1 000 mm (39.4 in.) Overall Height/High Position 1 290 mm (50.8 in.)/1 405 mm (55.3 in.) Wheelbase 1 520 mm (59.8 in.) Road Clearance 125 mm (4.9 in.) Seat Height...
  • Page 21 GENERAL INFORMATION 1-11 General Specifications Items ZG1400A8F, ZG1400B8F Exhaust: Open 52° (BBDC) Close 22° (ATDC) Duration 254° Lubrication System Forced lubrication (wet sump with cooler) Engine Oil: Type API SE, SF or SG API SH, SJ or SL with JASO MA Viscosity SAE10W-40 Capacity...
  • Page 22 1-12 GENERAL INFORMATION General Specifications Items ZG1400A8F, ZG1400B8F Rim Size: Front 17 × 3.50 Rear 17 × 6.00 Front Suspension: Type Telescopic fork (upside-down) Wheel Travel 113 mm (4.4 in.) Rear Suspension: Type Swingarm (uni-trak - tetra lever) Wheel Travel 136 mm (5.3 in.) Brake Type: Front...
  • Page 23: Technical Information-variable Valve Timing

    GENERAL INFORMATION 1-13 Technical Information-Variable Valve Timing Overview The camshafts that are provided in the engine determine the amount of valve overlap, which affects the engine’s characteristics. As a result, some engines are high-speed oriented while others are low -speed oriented. (Generally speaking, engines with a greater valve overlap are high-speed oriented.) Ordinarily, it is difficult for a given engine to deliver both high-speed and low-speed characteristics.
  • Page 24 1-14 GENERAL INFORMATION Technical Information-Variable Valve Timing Components • Variable Valve Timing Actuator • Oil Control Valve Solenoid Valve Oil Flow of Parts • Variable Valve Timing Actuator http://mototh.com...
  • Page 25 GENERAL INFORMATION 1-15 Technical Information-Variable Valve Timing • Oil Control Solenoid Valve Oil Flow during Control • Retard Position • Advance Position http://mototh.com...
  • Page 26 1-16 GENERAL INFORMATION Technical Information-Variable Valve Timing • Neutral Position • Most Retarded Position Lock Mechanism • During idle, the lock mechanism locks the camshaft at the most retarded position. • When the engine is stopped, the force of the spring returns the solenoid valve to its most retarded position, thus placing the camshaft in the most retarded position.
  • Page 27: Technical Information-electrical Windshield

    GENERAL INFORMATION 1-17 Technical Information-Electrical Windshield Overview Wind protection for rider and passenger is based on a supersport-style design philosophy. Aero- dynamically curving wind around the riders reduces buffeting that occurs when wind curls around windshield that simply "block" the wind. This model is equipped with the electrically adjustable windshield.
  • Page 28: Technical Information-kipass (kawasaki's Intelligent Proximity Activation Start System)

    1-18 GENERAL INFORMATION Technical Information-KIPASS (Kawasaki’s Intelligent Proximity Activation Start System) Overview • For better user convenience, a system to wirelessly start the engine is used instead of the conven- tional mechanical key. This frees the rider from handling the ignition key, a helpful feature in the rain or after putting on gloves.
  • Page 29 • The key knob can be turned to the ON position when the key knob symbol appears on the LCD meter. Then, the letters "Kawasaki" will appear for 3 seconds on the LCD screen. ○ When the engine operates normally, the turn signal lights in the meter will flash (answer-back) twice to inform the rider of normal operation.
  • Page 30 1986 to be used as a LAN network linking onboard ECUs (Electric Control Units). *At Kawasaki, this system is already being used on the ZX1400A/B. 1. Uses two communication lines (called bus lines, consisting of high and low voltages) and changes their electric potentials to transmit and receive data.
  • Page 31 GENERAL INFORMATION 1-21 Technical Information-KIPASS (Kawasaki’s Intelligent Proximity Activation Start System) • Communication Method Outputs electric potentials pivoted on 2.5 V to transmit "1" or "0" data to a terminal resistor. *Hi and Low transmission data are transmitted simultaneously. Electric Potential...
  • Page 32 1-22 GENERAL INFORMATION Technical Information-KIPASS (Kawasaki’s Intelligent Proximity Activation Start System) CAN Communication Contents Transmission Reception Date Contents Engine speed, water temperature, gear position, → DFI ECU Meter fuel consumption volume, DFI failure data KIPASS failure and warning data, air pressure →...
  • Page 33 GENERAL INFORMATION 1-23 Technical Information-KIPASS (Kawasaki’s Intelligent Proximity Activation Start System) Registering FOB Keys (Additional Registration) *Registration requires one FOB key that is already registered and the KDS3 version kit. • The KIPASS ECU must be replaced if you lose all the registered FOB keys.
  • Page 34 1-24 GENERAL INFORMATION Technical Information-KIPASS (Kawasaki’s Intelligent Proximity Activation Start System) Replacing KIPASS Parts • Registration status when all parts are new: steering lock unit (hereafter referred to as "SL"), KIPASS ECU, and DFI ECU. *The two FOB keys that come with the KIPASS ECU are already registered.
  • Page 35 GENERAL INFORMATION 1-25 Technical Information-KIPASS (Kawasaki’s Intelligent Proximity Activation Start System) • Registration Errors Replacing KIPASS-Related Parts Individually If a KIPASS part is replaced individually, its smart authentication number must be registered. *Registration of a smart authentication number requires the KDS3 version kit.
  • Page 36 1-26 GENERAL INFORMATION Technical Information-KIPASS (Kawasaki’s Intelligent Proximity Activation Start System) If FOB Key Battery Is Dead If the FOB key battery is dead, authentication is performed by the transponder and not by the KIPASS. Authentication requires approximately 1 to 2 seconds.
  • Page 37 GENERAL INFORMATION 1-27 Technical Information-KIPASS (Kawasaki’s Intelligent Proximity Activation Start System) Tire Air Pressure Sensor Overview While the vehicle is running, this system alerts the rider of a reduction in running stability as a result of a sudden drop in the air pressure in the tires.
  • Page 38 1-28 GENERAL INFORMATION Technical Information-KIPASS (Kawasaki’s Intelligent Proximity Activation Start System) Meter Indication In case of a voltage drop in the internal battery of a tire pressure measurement sensor • The meter will indicate the following alternately (when the voltage is 2.4 V or below).
  • Page 39 GENERAL INFORMATION 1-29 Technical Information-KIPASS (Kawasaki’s Intelligent Proximity Activation Start System) Replacing a Tire Pressure Measurement Sensor • To replace an pressure measurement sensor, it is necessary to use the KDS3 version kit in order to register the ID for activating the sensor.
  • Page 40: Technical Information-tetra Lever Shaft Drive System

    1-30 GENERAL INFORMATION Technical Information-Tetra Lever Shaft Drive System Tetra Lever Shaft Drive System Reason for use: To improve the running feel when the drive force is applied to the rear wheel. Tetra Lever Shaft Drive System When the drive force is applied to the rear wheel, a reaction force is generated as shown in the diagram.
  • Page 41 GENERAL INFORMATION 1-31 Technical Information-Tetra Lever Shaft Drive System Comparison to Conventional Shaft Drive System http://mototh.com...
  • Page 42: Unit Conversion Table

    1-32 GENERAL INFORMATION Unit Conversion Table Prefixes for Units Units of Length × 0.6214 mile Prefix Symbol Power × 3.281 mega × 1 000 000 × 0.03937 kilo × 1 000 centi × 0.01 Units of Torque milli × 0.001 N·m ×...
  • Page 43: Periodic Maintenance

    PERIODIC MAINTENANCE 2-1 Periodic Maintenance Table of Contents Periodic Maintenance Chart ....................Torque and Locking Agent...................... Specifications ......................... 2-13 Special Tools .......................... 2-15 Maintenance Procedure ......................2-16 Fuel System (DFI)........................ 2-16 Throttle Control System Inspection................... 2-16 Engine Vacuum Synchronization Inspection..............2-16 Idle Speed Inspection .......................
  • Page 44 2-2 PERIODIC MAINTENANCE Electrical System ......................... 2-39 Lights and Switches Operation Inspection................ 2-39 Headlight Aiming Inspection ..................... 2-41 Sidestand Switch Operation Inspection ................2-43 Engine Stop Switch Operation Inspection................. 2-44 Others ..........................2-44 Chassis Parts Lubrication ....................2-44 Bolts, Nuts and Fasteners Tightness Inspection............... 2-45 Replacement Parts ......................
  • Page 45: Periodic Maintenance Chart

    PERIODIC MAINTENANCE 2-3 Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition.The initial maintenance is vitally important and must not be neglected. FREQUENCY Whichever * ODOMETER comes READING first ×...
  • Page 46 2-4 PERIODIC MAINTENANCE Periodic Maintenance Chart FREQUENCY Whichever * ODOMETER comes READING first × 1000 km (× 1000 mile) Page 18 24 30 INSPECTION Every (0.6) (4) (7.5) (12) (15) (20) (24) Final Drive • • • Final gear case oil level - inspect 2-32 Brake System Brake fluid leak (brake hose and pipe) -...
  • Page 47 PERIODIC MAINTENANCE 2-5 Periodic Maintenance Chart Periodic Replacement Parts FREQUENCY * ODOMETER Whichever READING come × 1000 km first (× 1000 mile) Page CHANGE/REPLACEMENT Every (0.6) (7.5) (15) (24) (30) Air cleaner element # Every 18 000 km (12 000 mile) 2-48 •...
  • Page 48: Torque And Locking Agent

    2-6 PERIODIC MAINTENANCE Torque and Locking Agent The following tables list the tightening torque for the major fasteners requiring use of a non-permanent locking agent or silicone sealant etc. Letters used in the “Remarks” column mean: AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque. G: Apply grease to the threads.
  • Page 49 PERIODIC MAINTENANCE 2-7 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Coolant Fitting Bolt 0.90 78 in·lb Water Temperature Sensor Reserve Tank Bolts 0.40 35 in·lb Cylinder Fitting Bolts 87 in·lb Radiator Stay Bolt 87 in·lb Radiator Lower Bolt 87 in·lb Radiator Upper Bolt Engine Top End...
  • Page 50 2-8 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Oil Filler Cap – – – Hand -tighten Clutch Reservoir Cap Screws 0.15 13 in·lb Clutch Reservoir Mounting Bolt 0.80 70 in·lb Clutch Reservoir Screw 0.10 8.9 in·lb Starter Lockout Switch Screw 0.07 6.2 in·lb...
  • Page 51 PERIODIC MAINTENANCE 2-9 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Crankcase Bolts (M6, L = 25 mm) 106 in·lb Shift Drum Bearing Holder Screws 0.50 43 in·lb Bearing Position Plate Screws 0.50 43 in·lb Oil Passage Plug ←...
  • Page 52 2-10 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Oil Nozzles 0.30 26 in·lb Pinion Gear Assembly Nut 13.3 95.9 Speed Sensor Bolt 87 in·lb Brakes Bleed Valves 0.80 69 in·lb Brake Caliper Holder Plate Bolt Brake Hose Banjo Bolts Brake Lever Pivot Bolt 0.10...
  • Page 53 PERIODIC MAINTENANCE 2-11 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Torque Rod Nuts Steering Front Fork Clamp Bolts (Lower) Front Fork Clamp Bolts (Upper) Handlebar Bolts Handlebar Holder Bolts Left Switch Housing Screws 0.36 31 in·lb Right Switch Housing Screws 0.36 31 in·lb Steering Stem Head Bolt...
  • Page 54 2-12 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Oil Control Valve Bolts 87 in·lb Oil Pressure Switch Oil Pressure Switch Terminal Bolt 0.15 13 in·lb Oxygen Sensors (Equipped Models) Rear Turn Signal Light Mounting Screws 0.12 11 in·lb Regulator/Rectifier Bolts...
  • Page 55: Specifications

    PERIODIC MAINTENANCE 2-13 Specifications Item Standard Service Limit Fuel System 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Throttle Grip Free Play – – – Idle Speed 1 100 ±50 r/min (rpm) – – – Throttle Body Vacuum 33 ±1.33 kPa (250 ±10 mmHg) at idle speed –...
  • Page 56 2-14 PERIODIC MAINTENANCE Specifications Item Standard Service Limit Final Drive Final Gear Case Oil hypoid gear oil – – – Grade API Service Classification: GL-5 – – – Viscosity When above 5°C (41°F) SAE90 When below 5°C (41°F) SAE80 Oil Level Filler opening top –...
  • Page 57: Special Tools

    PERIODIC MAINTENANCE 2-15 Special Tools Inside Circlip Pliers: Pilot Screw Adjuster, C: 57001-143 57001-1292 Steering Stem Nut Wrench: Vacuum Gauge: 57001-1100 57001-1369 Jack: Pilot Screw Adjuster Adapter, 5: 57001-1238 57001-1372 Oil Filter Wrench: Filler Cap Driver: 57001-1249 57001-1454 http://mototh.com...
  • Page 58: Maintenance Procedure

    2-16 PERIODIC MAINTENANCE Maintenance Procedure Fuel System (DFI) Throttle Control System Inspection • Check the throttle grip free play [A]. If the free play is incorrect, adjust the throttle cables. Throttle Grip Free Play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Standard: •...
  • Page 59 PERIODIC MAINTENANCE 2-17 Maintenance Procedure • Remove: Subframe Bolts [A] with Washer Right Fairing Bracket Bolt (Front Side) • Pull off the rubber caps [A] from the fittings of each throttle body. ○ For the rubber cap #2, remove the air cleaner duct. Front [B] •...
  • Page 60 2-18 PERIODIC MAINTENANCE Maintenance Procedure • Start the engine and warm it up thoroughly. • Check the idle speed, using a highly accurate tachometer [A]. If the idle speed is out of the specified range, adjust it with the adjust screw. CAUTION Do not measure the idle speed by the tachometer of the meter unit.
  • Page 61 PERIODIC MAINTENANCE 2-19 Maintenance Procedure If a value of measured vacuum pressure is out of the specified range after synchronization, adjust the bypass screws [A]. Special Tool - Pilot Screw Adjuster, C: 57001-1292 Pilot Screw Adjuster Adapter, 5: 57001 -1372 •...
  • Page 62: Idle Speed Inspection

    2-20 PERIODIC MAINTENANCE Maintenance Procedure • Back out the same number of turns counted when first turned in. This is to set the screw to its original position. NOTE ○ A throttle body has different “turns out” of the bypass screw for each individual unit.
  • Page 63: Idle Speed Adjustment

    PERIODIC MAINTENANCE 2-21 Maintenance Procedure Idle Speed Adjustment • Start the engine and warm it up thoroughly. • Turn the adjusting screw [A] until the idle speed is correct. ○ Open and close the throttle a few times to make sure that the idle speed is within the specified range.
  • Page 64: Cooling System

    2-22 PERIODIC MAINTENANCE Maintenance Procedure Cooling System Coolant Level Inspection NOTE ○ Check the level when the engine is cold (room or ambi- ent temperature). • Check the coolant level in the reserve tank [A] with the motorcycle held perpendicular (Do not use the sidestand). If the coolant level is lower than the “L”...
  • Page 65: Evaporative Emission Control System (california Model)

    PERIODIC MAINTENANCE 2-23 Maintenance Procedure Evaporative Emission Control System (California Model) Evaporative Emission Control System Inspection • Remove: Rear Right Middle Fairing (see Middle Fairing Removal in the Frame chapter) Band [A] Canister [B] • Disconnect the hoses from the canister. •...
  • Page 66: Engine Top End

    2-24 PERIODIC MAINTENANCE Maintenance Procedure • Start the engine and run it at idle speed. • Plug [A] the air switching valve hose end with your finger and feel vacuum pulsing in the hose. If there is no vacuum pulsation, check the hose line for leak.
  • Page 67: Valve Clearance Adjustment

    PERIODIC MAINTENANCE 2-25 Maintenance Procedure NOTE ○ Thickness gauge is horizontally inserted on the valve lifter. Appropriateness [A] Inadequacy [B] Thickness Gauge [C] Horizontally Inserts [D] Cam [E] Valve Lifter [F] Hits the Valve Lifter Ahead [G] ○ When positioning #1 piston TDC at the end of the compression stroke: Inlet Valve Clearance of #2 and #4 Cylinders Exhaust Valve Clearance of #3 and #4 Cylinders...
  • Page 68 2-26 PERIODIC MAINTENANCE Maintenance Procedure • Clean the shim to remove any dust or oil. • Measure the thickness of the removed shim [A]. • Select a new shim thickness calculation as follows. a + b – c = d [a] Present Shim Thickness [b] Measured Valve Clearance [c] Specified Valve Clearance (Mean Value = 0.125 mm...
  • Page 69: Maintenance Procedure

    PERIODIC MAINTENANCE 2-27 Maintenance Procedure Adjustment Shims Thickness Part Number Mark 1.750 92180-1212 –25 1.775 92180-0221 –23 1.800 92180-1211 –20 1.825 92180-0222 –18 1.850 92180-1210 –15 1.875 92180-0223 –13 1.900 92180-1209 –10 1.925 92180-0224 –8 1.950 92180-1208 –5 1.975 92180-0225 –3 2.000 92025-1870...
  • Page 70: Clutch And Drive Train

    2-28 PERIODIC MAINTENANCE Maintenance Procedure Clutch and Drive Train Clutch Operation Inspection • Start the engine and check that the clutch does not slip and that it releases properly. If the clutch operation is insufficiency, inspect the clutch system. WARNING When inspecting by running the vehicle, note a surrounding traffic situation enough in the place of safety.
  • Page 71: Clutch Hose And Pipe Damage And Installation Condition Inspection

    PERIODIC MAINTENANCE 2-29 Maintenance Procedure Clutch Hose and Pipe Damage and Installation Condition Inspection • Inspect the clutch hoses and fittings for deterioration, cracks, corrosion and signs of leakage. ○ The high pressure inside the clutch line can cause fluid to leak [A] or the hose to burst if the line is not properly maintained.
  • Page 72: Tire Tread Wear Inspection

    2-30 PERIODIC MAINTENANCE Maintenance Procedure Tire Tread Wear Inspection As the tire tread wears down, the tire becomes more sus- ceptible to puncture and failure. An accepted estimate is that 90% of all tire failures occur during the last 10% of tread life (90% worn).
  • Page 73: Final Drive

    PERIODIC MAINTENANCE 2-31 Maintenance Procedure • Raise the rear wheel off the ground with the center stand (see Rear Wheel Removal in the Wheels/Tires chapter). • Spin [A] the rear wheel lightly, and check for smoothly turn, roughness, binding or noise. If roughness, binding or noise is found, remove the rear wheel and inspect the wheel bearing (see Hub Bearing Inspection in the Wheels/Tires chapter) and coupling (see...
  • Page 74: Brake System

    2-32 PERIODIC MAINTENANCE Maintenance Procedure Brake System Brake Fluid Leak (Brake Hose and Pipe) Inspection • Apply the brake lever or pedal and inspect the brake fluid leak from the brake hoses [A], pipes (ABS equipped mod- els) [B] and fittings [C]. If the brake fluid leaked from any position, inspect or re- place the problem part.
  • Page 75: Brake Hose And Pipe Damage And Installation Condition Inspection

    PERIODIC MAINTENANCE 2-33 Maintenance Procedure Brake Hose and Pipe Damage and Installation Condition Inspection • For ABS equipped models; note the following. • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Battery (see Battery Removal in the Electrical System chapter) •...
  • Page 76: Brake Pad Wear Inspection

    2-34 PERIODIC MAINTENANCE Maintenance Procedure • Remove the seat (see Seat Removal in the Frame chap- ter). • Check that the brake fluid level in the rear brake reservoir [A] is above the lower level line [B]. If the fluid level is lower than the lower level line, fill the reservoir to the upper level line [C].
  • Page 77: Suspensions

    PERIODIC MAINTENANCE 2-35 Maintenance Procedure If it does not, adjust the brake light switch. • While holding the switch body, turn the adjusting nut to adjust the switch. Switch Body [A] Adjusting Nut [B] Light sooner as the body rises [C] Light later as the body lowers [D] CAUTION To avoid damaging the electrical connections in-...
  • Page 78: Front Fork Oil Leak Inspection

    2-36 PERIODIC MAINTENANCE Maintenance Procedure Front Fork Oil Leak Inspection • Visually inspect the front forks [A] for oil leakage. Replace or repair any defective parts, if necessary. Rear Shock Absorber Oil Leak Inspection • Visually inspect the shock absorber [A] for oil leakage. If the oil leakage is found on it, replace the shock absorber with a new one.
  • Page 79: Steering System

    PERIODIC MAINTENANCE 2-37 Maintenance Procedure Steering System Steering Play Inspection • Raise the front wheel off the ground with the jack. Special Tools - Jack: 57001-1238 • With the front wheel pointing straight ahead, alternately tap each end of the handlebar. The front wheel should swing fully left and right from the force of gravity until the fork hits the stop.
  • Page 80: Steering Stem Bearing Lubrication

    2-38 PERIODIC MAINTENANCE Maintenance Procedure • Install the claw washer [A] so that its bent side [B] faces upward, and engage the bent claws with the grooves of stem locknut [C]. • Hand tighten the stem locknut until it touches the claw washer.
  • Page 81: Electrical System

    PERIODIC MAINTENANCE 2-39 Maintenance Procedure Electrical System Lights and Switches Operation Inspection First Step • Push and turn the key knob to ON. • The following lights should go on according to below table. City Light [A] goes on Taillight [B] goes on License Plate Light [C] goes on...
  • Page 82 2-40 PERIODIC MAINTENANCE Maintenance Procedure Third Step • Push and turn the key knob to ON. • Turn on the turn signal switch [A] (left or right position). • The left or right turn signal lights [B] (front and rear) ac- cording to the switch position should flash.
  • Page 83: Headlight Aiming Inspection

    PERIODIC MAINTENANCE 2-41 Maintenance Procedure Fourth Step • Set the dimmer switch [A] to low beam position. • Start the engine. • The low beam headlights [B] should go on. If the low beam headlight does not go on, inspect or re- place the following item.
  • Page 84 2-42 PERIODIC MAINTENANCE Maintenance Procedure Headlight Beam Horizontal Adjustment • Turn the horizontal adjuster [A] in both headlights in or out until the beam points straight ahead. If the headlight beam points too low or high, adjust the vertical beam. Headlight Beam Vertical Adjustment •...
  • Page 85: Sidestand Switch Operation Inspection

    PERIODIC MAINTENANCE 2-43 Maintenance Procedure Sidestand Switch Operation Inspection • Inspect the sidestand switch [A] operation accordance to table the below. Sidestand Switch Operation Gear Clutch Engine Engine Sidestand Position Lever Start Continue Neutral Released Starts running Continue Neutral Pulled in Starts running Doesn’t...
  • Page 86: Engine Stop Switch Operation Inspection

    2-44 PERIODIC MAINTENANCE Maintenance Procedure Engine Stop Switch Operation Inspection First Step • Push and turn the key knob to ON. • Set the neutral position. • Turn the engine stop switch to stop position [A]. • Push the starter button. •...
  • Page 87: Bolts, Nuts And Fasteners Tightness Inspection

    PERIODIC MAINTENANCE 2-45 Maintenance Procedure Cables: Lubricate with Rust Inhibitor. Throttle Cables • Lubricate the cables by seeping the oil between the cable and housing. ○ The cable may be lubricated by using a commercially available pressure cable lubricator with an aerosol cable lubricant.
  • Page 88: Replacement Parts

    2-46 PERIODIC MAINTENANCE Maintenance Procedure Bolt, Nut and Fastener to be checked Engine: Clutch Lever Pivot Bolt Locknut Engine Mounting Bolts and Nut Muffler Clamp Bolts Exhaust Pipe Manifold Holder Nuts Muffler Body Mounting Bolts Wheels: Front Axle Clamp Bolts Front Axle Nut Rear Axle Nut Rear Axle Nut Cotter Pin...
  • Page 89 Install a new element [A] so that screen side [B] faces upward. CAUTION Use only the recommended air cleaner element (Kawasaki part number 11013-0014). Using another air cleaner element will wear the engine prema- turely or lower the engine performance. •...
  • Page 90: Fuel Hose Replacement

    2-48 PERIODIC MAINTENANCE Maintenance Procedure Fuel Hose Replacement • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Sub Engine Bracket Breather Hose Drain Hose • Be sure to place a piece of cloth [A] around the fuel hose joint.
  • Page 91: Coolant Change

    PERIODIC MAINTENANCE 2-49 Maintenance Procedure • Insert the fuel hose joint [A] straight onto the delivery pipe until the hose joint clicks. • Push [B] the joint lock [C] until the hose joint clicks. • Push and pull the fuel hose joint [A] back and forth [B] more than two times and make sure it is locked and doesn’t come off.
  • Page 92 2-50 PERIODIC MAINTENANCE Maintenance Procedure • Remove: Left Middle Fairing (see Middle Fairing Removal in the Frame chapter) Left Lower Fairing (see Lower Fairing Removal in the Frame chapter) • Place a containers under the drain plug [A] at the bottom of the water pump cover.
  • Page 93: Radiator Hose And O-ring Replacement

    PERIODIC MAINTENANCE 2-51 Maintenance Procedure • Bleed the air from the cooling system as follows. ○ Start the engine with the radiator cap removed and run it until no more air bubbles [A] can be seen in the coolant. ○ Tap the radiator hoses to force any air bubbles caught inside.
  • Page 94: Engine Oil Change

    2-52 PERIODIC MAINTENANCE Maintenance Procedure Engine Oil Change • Situate the motorcycle so that it is vertical after warming up the engine. • Remove the engine oil drain bolt [A] to drain the oil. ○ The oil in the oil filter can be drained by removing the filter (see Oil Filter Replacement).
  • Page 95: Brake Hose And Pipe Replacement

    PERIODIC MAINTENANCE 2-53 Maintenance Procedure Brake Hose and Pipe Replacement CAUTION Brake fluid quickly ruins painted plastic surfaces; any spilled fluid should be completely washed away immediately. • Remove: Radiator Cover (see Steering Stem Removal in the Steering chapter) Brake Hose Banjo Bolts [A] Brake Hose Joint Bolts [B] Brake Hose [C] Brake Hose Clamp Bolt [D]...
  • Page 96: Brake Fluid Change

    2-54 PERIODIC MAINTENANCE Maintenance Procedure • For ABS equipped models; note the following. • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Battery (see Battery Removal in the Electrical System chapter) Upper Fairing (see Upper Fairing Removal in the Frame chapter) Brake Pipe Joint Nuts [A] Bolts [B]...
  • Page 97 PERIODIC MAINTENANCE 2-55 Maintenance Procedure • Remove the rubber cap from the bleed valve [A] on the caliper. • Attach a clear plastic hose [B] to the bleed valve, and run the other end of the hose into a container. •...
  • Page 98: Master Cylinder Rubber Parts Replacement

    2-56 PERIODIC MAINTENANCE Maintenance Procedure Master Cylinder Rubber Parts Replacement Front Master Cylinder Disassembly • Remove the front master cylinder (see Front Master Cylin- der Removal in the Brakes chapter). • Remove: Screws [A] Cap [B] Diaphragm Plate [C] Diaphragm [D] Float [E] Screw [F] Bolt [G]...
  • Page 99: Caliper Rubber Parts Replacement

    PERIODIC MAINTENANCE 2-57 Maintenance Procedure Master Cylinder Assembly • Before assembly, clean all parts including the master cylinder with brake fluid or alcohol. CAUTION Except for the disc pads and disc, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol for cleaning brake parts.
  • Page 100 2-58 PERIODIC MAINTENANCE Maintenance Procedure • Using compressed air, remove the pistons. One way to remove the pistons is as follows. ○ Install a rubber gasket [A] and a wooden board [B] more than 10 mm (0.4 in.) thick on the caliper half, and fas- ten them together with a suitable bolt and nut as shown.
  • Page 101 PERIODIC MAINTENANCE 2-59 Maintenance Procedure • Replace the fluid seals [A] with new ones. ○ Apply silicone grease to the fluid seals, and install them into the cylinders by hand. • Replace the dust seals [B] with new ones if they are dam- aged.
  • Page 102: Rear Caliper Assembly

    2-60 PERIODIC MAINTENANCE Maintenance Procedure • Remove the right side piston as follows. • Using the rear caliper assembly bolt [A], remove the pis- ton [B] as shown in the figure. • Remove the dust seals [A] and fluid seals [B]. •...
  • Page 103: Clutch Hose And Pipe Replacement

    PERIODIC MAINTENANCE 2-61 Maintenance Procedure • Apply brake fluid to the cylinder bores. • Replace the fluid seals [A] with new ones. ○ Apply silicone grease to the fluid seals, and install them into each cylinder by hand. • Replace the dust seals [B] with new ones. •...
  • Page 104 2-62 PERIODIC MAINTENANCE Maintenance Procedure • Remove: Left Middle Fairing (see Middle Fairing Removal in the Frame chapter) Left Lower Fairing (see Lower Fairing Removal in the Frame chapter) Left Heat Insulation Plate (see Fairing Bracket Removal in the Frame chapter) Banjo Bolts [A] with Washers Fitting Bolt [B] Clamp [C]...
  • Page 105: Rubber Parts Of Clutch Master Cylinder/slave Cylinder Replacement

    PERIODIC MAINTENANCE 2-63 Maintenance Procedure Rubber Parts of Clutch Master Cylinder/Slave Cylinder Replacement Clutch Master Cylinder Cup and Dust Seal Replacement • Remove the clutch master cylinder (see Clutch Master Cylinder Removal in the Clutch chapter). • Remove: Screws [A] Cap [B] Diaphragm Plate [C] Diaphragm [D]...
  • Page 106 2-64 PERIODIC MAINTENANCE Maintenance Procedure Clutch Slave Cylinder Piston Seal Replacement • Remove: Left Lower Fairing (see Lower Fairing Removal in the Frame chapter) • Loosen the banjo bolt [A] at the clutch pipe lower end, and tighten it loosely. •...
  • Page 107: Clutch Fluid Change

    PERIODIC MAINTENANCE 2-65 Maintenance Procedure Clutch Fluid Change • Level the clutch fluid reservoir and remove the reservoir cap. • Remove the rubber cap from the bleed valve on the clutch slave cylinder. • Attach a clear plastic hose [A] to the bleed valve and run the other end of the hose into a container.
  • Page 108: Oil Change

    2-66 PERIODIC MAINTENANCE Maintenance Procedure • Replace the spark plug with a new one. Standard Spark Plug Type: NGK CR9EIA-9 • Insert new spark plug in the plug hole, and finger-tighten it first. • Using the plug wrench [A] vertically, tighten the plug. CAUTION The insulator of the spark plug may break if when the wrench is inclined during tightening.
  • Page 109 PERIODIC MAINTENANCE 2-67 Maintenance Procedure • Fill the final gear case with the specified oil and quantity. ○ The oil level [A] should come to the top of the filler open- ing. Final Gear Case Oil: Amount: about 160 mL (5.41 US oz) Grade: API GL-5 hypoid gear oil Viscosity:...
  • Page 110 http://mototh.com...
  • Page 111 FUEL SYSTEM (DFI) 3-1 Fuel System (DFI) Table of Contents Exploded View........................DFI System..........................3-10 DFI Parts Location........................3-15 Specifications ......................... 3-17 Special Tools and Sealant ...................... 3-19 DFI Servicing Precautions ...................... 3-21 DFI Servicing Precautions ....................3-21 Troubleshooting the DFI System .................... 3-23 Outline ..........................
  • Page 112 3-2 FUEL SYSTEM (DFI) Speed Sensor Input Voltage Inspection................3-68 Speed Sensor Output Voltage Inspection ................. 3-69 Gear Position Switch (Service Code 25) ................3-71 Gear Position Switch Removal/Installation ............... 3-71 Gear Position Switch Inspection ..................3-71 Input Voltage Inspection....................3-71 Vehicle-down Sensor (Service Code 31)................
  • Page 113 FUEL SYSTEM (DFI) 3-3 Light (LED) Inspection ...................... 3-110 Fuel Line..........................3-111 Fuel Pressure Inspection ....................3-111 Fuel Flow Rate Inspection ....................3-113 Fuel Pump ..........................3-115 Fuel Pump Removal ......................3-115 Fuel Pump Installation ...................... 3-115 Fuel Pump Operation Inspection ..................3-116 Operating Voltage Inspection....................
  • Page 114: Exploded View

    3-4 FUEL SYSTEM (DFI) Exploded View http://mototh.com...
  • Page 115 FUEL SYSTEM (DFI) 3-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Resonator Mounting Bolts 0.40 35 in·lb Front Air Inlet Duct Mounting Bolts 0.40 35 in·lb Air Inlet Duct Clamp Bolts 0.30 26 in·lb Rear Air Inlet Duct Mounting Bolts 87 in·lb Air Cleaner Element Holder Screws 0.70...
  • Page 116 3-6 FUEL SYSTEM (DFI) Exploded View http://mototh.com...
  • Page 117 FUEL SYSTEM (DFI) 3-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Speed Sensor Bolt 87 in·lb Crankshaft Sensor Bolts 0.60 52 in·lb Gear Position Switch Screws 0.30 26 in·lb Gear Position Switch Lead Clamp Bolts 87 in·lb Vehicle-down Sensor Bolts 0.60 52 in·lb Camshaft Position Sensor Bolts...
  • Page 118 3-8 FUEL SYSTEM (DFI) Exploded View http://mototh.com...
  • Page 119 FUEL SYSTEM (DFI) 3-9 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Fuel Pump Bolts 87 in·lb L, S Separator Bracket Bolt 87 in·lb Oxygen Sensor (Europe Models) Fuel Level Sensor Bolts 0.70 61 in·lb 5. Canister 6. Separator 7. Fitting 8.
  • Page 120: Dfi System

    3-10 FUEL SYSTEM (DFI) DFI System DFI System http://mototh.com...
  • Page 121 FUEL SYSTEM (DFI) 3-11 DFI System 1. ECU 2. Crankshaft Sensor 3. Inlet Camshaft Position Sensor 4. Exhaust Camshaft Position Sensor 5. Main Throttle Sensor 6. Subthrottle Sensor 7. Subthrottle Valve Actuator 8. Inlet Air Pressure Sensor 9. Atmospheric Pressure Sensor 10.
  • Page 122 3-12 FUEL SYSTEM (DFI) DFI System http://mototh.com...
  • Page 123 FUEL SYSTEM (DFI) 3-13 DFI System Part Name 1. Steering Lock Unit 2. Joint Connector 1 3. Engine Stop Switch 4. Starter Button 5. Inlet Camshaft Position Sensor 6. Exhaust Camshaft Position Sensor 7. Stick Coil #1, #2, #3, #4 8.
  • Page 124 66. Crankshaft Sensor Output Signal (–) 35. Power Supply to ECU (from Battery) 67. Speed Sensor Output Signal 68. CAN Communication Line (High) KDS (Kawasaki Diagnostic System) KDS that runs on Windows personal computer (PC) diagnostic tool for motorcycle with Kawasaki DFI system. http://mototh.com...
  • Page 125: Dfi Parts Location

    Water Temperature Sensor [D] Fuel Injectors #1, #2, #3, #4 [A] Vehicle-down Sensor [A] Relay Box (Fuel Pump Relay) [B] Immobilizer/Kawasaki Diagnostic System Connector [C] DFI ECU [D] Atmospheric Pressure Sensor [E] KIPASS ECU [F] Fuse Box (ECU Fuse 15 A) [G]...
  • Page 126 3-16 FUEL SYSTEM (DFI) DFI Parts Location Exhaust Camshaft Position Sensor [A] Crankshaft Sensor [B] Oil Control Valve Solenoid [C] Oxygen Sensor #1, #2 [D] Speed Sensor [A] Gear Position Switch [B] Key Knob [A] Steering Lock Unit [B] (Immobilizer) Air Switching Valve [A] Subthrottle Valve Actuator [B] Fuel Pump [A]...
  • Page 127: Specifications

    FUEL SYSTEM (DFI) 3-17 Specifications Item Standard Digital Fuel Injection System Idle Speed 1 100 ±50 r/min (rpm) Throttle Assy: Type Four barrel type Bore 40 mm (1.6 in.) Throttle Body Vacuum 33 ±1.33 kPa (250 ±10 mmHg) Bypass Screws –...
  • Page 128 3-18 FUEL SYSTEM (DFI) Specifications Item Standard Vehicle-down sensor: Detection Method Magnetic flux detection method More than 60 ∼ 70° for each bank Detection Angle with sensor arrow mark pointed up: 3.55 ∼ 4.45 V Output Voltage with sensor tilted 60 ∼ 70° or more: 0.65 ∼ 1.35 V Subthrottle Sensor: Non-adjustable and non-removal DC 4.75 ∼...
  • Page 129: Special Tools And Sealant

    FUEL SYSTEM (DFI) 3-19 Special Tools and Sealant Oil Pressure Gauge, 5 kgf/cm²: Peak Voltage Adapter: 57001-125 57001-1415 Fork Oil Level Gauge: Needle Adapter Set: 57001-1290 57001-1457 Vacuum Gauge: Throttle Sensor Setting Adapter: 57001-1369 57001-1538 Hand Tester: Sensor Harness Adapter: 57001-1394 57001-1561 Throttle Sensor Setting Adapter #1:...
  • Page 130 3-20 FUEL SYSTEM (DFI) Special Tools and Sealant Fuel Hose: Kawasaki Bond (Silicone Sealant): 57001-1607 56019-120 http://mototh.com...
  • Page 131: Dfi Servicing Precautions

    FUEL SYSTEM (DFI) 3-21 DFI Servicing Precautions DFI Servicing Precautions There are a number of important precautions that should be followed servicing the DFI system. ○ This DFI system is designed to be used with a 12 V sealed battery as its power source. Do not use any other battery except for a 12 V sealed battery as a power source.
  • Page 132 3-22 FUEL SYSTEM (DFI) DFI Servicing Precautions ○ Replace the fuel hose [A] if it has been sharply bent or kinked. ○ The motorcycle is not properly handled, the high pressure inside the fuel line can cause fuel to leak or the hose to burst.
  • Page 133: Troubleshooting The Dfi System

    FUEL SYSTEM (DFI) 3-23 Troubleshooting the DFI System Outline When a problem occurs with DFI system, the warning in- dicator (LED) [A] goes on and FI warning message [B] and FI warning symbol [C] are displayed alternately on the LCD (Liquid Crystal Display) to alert the rider.
  • Page 134 3-24 FUEL SYSTEM (DFI) Troubleshooting the DFI System With the engine stopped and turned in the self-diagnosis mode, the service code (error code) [A] is displayed on the LCD by the number of two digits. When the service code [A] is displayed, for first ask the rider about the conditions [B] of trouble, and then start to determine the cause [C] of problem.
  • Page 135 LCD. But the service codes stored in memory of the ECU are not erased to preserve the problem history. The problem history can be referred using the KDS (Kawasaki Diagnostic System) when solving unstable problems Much of the DFI system troubleshooting work consists of confirming continuity of the wiring.
  • Page 136 3-26 FUEL SYSTEM (DFI) Troubleshooting the DFI System • Always check battery condition before replacing the DFI parts. A fully charged battery is a must for conducting accurate tests of the DFI system. • Trouble may involve one or in some cases all items. Never replace a defective part without determining what CAUSED the problem.
  • Page 137 FUEL SYSTEM (DFI) 3-27 Troubleshooting the DFI System ○ If both ends of a harness [A] are far apart, ground [B] the one end [C], using a jumper lead [D] and check the con- tinuity between the end [E] and the ground [F]. This en- ables to check a long harness for continuity.
  • Page 138: Inquiries To Rider

    3-28 FUEL SYSTEM (DFI) Troubleshooting the DFI System DFI Diagnosis Flow Chart Inquiries to Rider ○ Each rider reacts to problems in different ways, so it is important to confirm what kind of symptoms the rider has encountered. ○ Try to find out exactly what problem occurred under exactly what conditions by asking the rider; knowing this information may help you reproduce the problem.
  • Page 139 FUEL SYSTEM (DFI) 3-29 Troubleshooting the DFI System Sample Diagnosis Sheet Rider name: Registration No. (license plate No.): Year of initial registration: Model: Engine No.: Frame No.: Date problem occurred: Mileage: Environment when problem occurred. □ □ □ □ □ □...
  • Page 140 3-30 FUEL SYSTEM (DFI) Troubleshooting the DFI System □ □ □ Poor running at low very low idle speed, very high idle speed, rough idle speed. □ speed battery voltage is low (charge the battery). □ spark plug loose (tighten it). □...
  • Page 141: Dfi System Troubleshooting Guide

    FUEL SYSTEM (DFI) 3-31 DFI System Troubleshooting Guide NOTE ○ This is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties in DFI system.
  • Page 142 3-32 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Fuel pressure regulator trouble Inspect fuel pressure and replace fuel pump (see chapter 16). Fuel line clogged Inspect and repair (see chapter 3). Inlet air pressure sensor trouble Inspect (see chapter 3).
  • Page 143 FUEL SYSTEM (DFI) 3-33 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Main throttle sensor trouble Inspect (see chapter 3). Subthrottle sensor trouble Inspect (see chapter 3). Subthrottle valve actuator trouble Inspect (see chapter 3). Inlet air pressure sensor trouble Inspect (see chapter 3).
  • Page 144 3-34 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Inlet air temperature sensor trouble Inspect (see chapter 3). Other: Intermittent any DFI fault and its recovery Check that DFI connectors are clean and tight, and examine leads for signs of burning or fraying (see chapter 3).
  • Page 145 FUEL SYSTEM (DFI) 3-35 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Atmospheric pressure sensor trouble Inspect (see chapter 3). Water temperature sensor trouble Inspect (see chapter 3). Inlet air temperature sensor trouble Inspect (see chapter 3). Miscellaneous: Subthrottle sensor trouble Inspect (see chapter 3).
  • Page 146: Self-diagnosis

    3-36 FUEL SYSTEM (DFI) Self-Diagnosis Self-diagnosis Outline The self-diagnosis system has two modes and can be switched to another mode by operating the meter unit. User Mode The ECU notifies the rider of troubles in DFI system , igni- tion system and KIPASS system by lighting up the warning indicator light (LED) [A] and displaying the warning mes- sage [B] and warning symbol [C] alternately on the LCD (Liquid Crystal Display) when DFI, ignition and KIPASS sys-...
  • Page 147: Self-diagnosis Procedures

    FUEL SYSTEM (DFI) 3-37 Self-Diagnosis Self-diagnosis Procedures ○ When a problem occurs with DFI system and ignition sys- tem, the warning indicator (LED) [A] goes on and FI warn- ing message [B] and FI warning symbol [C] are displayed alternately on the LCD (Liquid Crystal Display) to alert the rider.
  • Page 148 3-38 FUEL SYSTEM (DFI) Self-Diagnosis • Push and turn the key knob to ON. • Push the upper button [A] and lower button [B] for more than two seconds. • The service code [C] is displayed on the LCD by the num- ber of two digits.
  • Page 149 FUEL SYSTEM (DFI) 3-39 Self-Diagnosis Self-Diagnosis Flow Chart http://mototh.com...
  • Page 150: Service Code Reading

    3-40 FUEL SYSTEM (DFI) Self-Diagnosis Service Code Reading ○ The service code(s) is displayed on the LCD by the number of two digits. ○ When there are a number of problems, all the service codes can be stored and the display will begin starting from the lowest number service code in the numerical order.
  • Page 151 FUEL SYSTEM (DFI) 3-41 Self-Diagnosis Service Code Table Service Code Problems Main throttle sensor malfunction, wiring open or short Inlet air pressure sensor malfunction, wiring open or short Inlet air temperature sensor malfunction, wiring open or short Water temperature sensor malfunction, wiring open or short Atmospheric pressure sensor malfunction, wiring open or short Crankshaft sensor malfunction, wiring open or short Camshaft position sensor (EX) malfunction, wiring open or short...
  • Page 152: Backups

    3-42 FUEL SYSTEM (DFI) Self-Diagnosis Backups ○ The ECU takes the following measures to prevent engine damage when the DFI, ignition, KIPASS or immobilizer system parts have troubles. Service Output Signal Usable Parts Backups by ECU Codes Range or Criteria If the main throttle sensor system fails (the Main Throttle Sensor signal is out of the usable range, wiring short...
  • Page 153 FUEL SYSTEM (DFI) 3-43 Self-Diagnosis Service Output Signal Usable Parts Backups by ECU Codes Range or Criteria Steering lock unit send the Steering date to the KIPASS ECU – Lock Unit with CAN communication line. FI ECU send the date to FI ECU the KIPASS ECU with CAN –...
  • Page 154 3-44 FUEL SYSTEM (DFI) Self-Diagnosis Service Output Signal Usable Parts Backups by ECU Codes Range or Criteria Oxygen The oxygen sensor heater If the oxygen sensor heater fails (wiring short Sensor raise temperature of or open), the ECU stops the current to the Heater the sensor for its earlier heater, and it stops the feedback mode of the...
  • Page 155: Main Throttle Sensor (service Code 11)

    FUEL SYSTEM (DFI) 3-45 Main Throttle Sensor (Service Code 11) The main throttle sensor is a rotating variable resistor that change output voltage according to throttle operating. The ECU senses this voltage change and determines fuel injec- tion quantity, and ignition timing according to engine rpm, and throttle opening.
  • Page 156 3-46 FUEL SYSTEM (DFI) Main Throttle Sensor (Service Code 11) • Remove: Right Middle Fairing (see Middle Fairing Removal in the Frame chapter) Right Subframe (see Sub Frame Removal in the Frame chapter) • Disconnect the main throttle sensor connector [A]. •...
  • Page 157: Main Throttle Sensor Output Voltage Inspection

    FUEL SYSTEM (DFI) 3-47 Main Throttle Sensor (Service Code 11) Main Throttle Sensor Output Voltage Inspection • Measure the output voltage at the ECU in the same way as input voltage inspection. Note the following. Digital Meter [A] Connector [B] Special Tool - Needle Adapter Set: 57001-1457 Main Throttle Sensor Output Voltage Connections to ECU Connector...
  • Page 158 3-48 FUEL SYSTEM (DFI) Main Throttle Sensor (Service Code 11) NOTE ○ The standard voltage refers to the value when the volt- age reading at the Input Voltage Inspection shows 5 V exactly. ○ When the input voltage reading shows other than 5 V, derive a voltage range as follows.
  • Page 159: Main Throttle Sensor Resistance Inspection

    FUEL SYSTEM (DFI) 3-49 Main Throttle Sensor (Service Code 11) CAUTION Do not remove or adjust the main throttle sensor. It has been adjusted and set with precision at the factory. Never drop the sensor, especially on a hard surface. A shock to the sensor can damage it.
  • Page 160 3-50 FUEL SYSTEM (DFI) Main Throttle Sensor (Service Code 11) Main Throttle Sensor Circuit 1. ECU 2. Subthrottle Valve Actuator 3. Subthrottle Sensor 4. Main Throttle Sensor 5. Water-proof Joint 2 http://mototh.com...
  • Page 161: Inlet Air Pressure Sensor (service Code 12)

    FUEL SYSTEM (DFI) 3-51 Inlet Air Pressure Sensor (Service Code 12) CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the part can damage it. Inlet Air Pressure Sensor Removal • Remove: Left Subframe (see Subframe Removal in the Frame chapter) Bolts [A] Relay Bracket [B] with Relays [C]...
  • Page 162: Inlet Air Pressure Sensor Input Voltage Inspection

    3-52 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code 12) Inlet Air Pressure Sensor Input Voltage Inspection NOTE ○ Be sure the battery is fully charged. ○ The inspection is the same as “Input Voltage Inspection” of the throttle sensor and the atmospheric pressure sen- sor.
  • Page 163: Output Voltage Inspection

    FUEL SYSTEM (DFI) 3-53 Inlet Air Pressure Sensor (Service Code 12) Output Voltage Inspection • Measure the output voltage at the ECU in the same way as input voltage inspection. Note the following. Digital Meter [A] Connector [B] Special Tool - Needle Adapter Set: 57001-1457 Inlet Air Pressure Sensor Output Voltage Connections to ECU Meter (+) →...
  • Page 164 3-54 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code 12) Inlet Air Pressure Sensor Circuit 1. ECU 2. Inlet Air Pressure Sensor 3. Water-proof Joint 2 If you need to check the inlet air pressure sensor for vac- uum other than 76 cmHg (abs.), check the output voltage as follows.
  • Page 165 FUEL SYSTEM (DFI) 3-55 Inlet Air Pressure Sensor (Service Code 12) • Remove the inlet air pressure sensor [A] and disconnect the vacuum hose from the sensor. • Connect an auxiliary hose [B] to the inlet air pressure sen- sor. •...
  • Page 166 3-56 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code 12) ID: Idling Pv: Throttle Vacuum Pressure (abs.) Ps: Standard Atmospheric Pressure (abs.) ST: Standard of Sensor Output Voltage (v) TO: Throttle Full Open UR: Usable Range of Sensor Output Voltage (v) Vv: Inlet Air Pressure Sensor Output Voltage (V) (Digital Meter Reading) http://mototh.com...
  • Page 167: Inlet Air Temperature Sensor (service Code 13)

    FUEL SYSTEM (DFI) 3-57 Inlet Air Temperature Sensor (Service Code 13) Inlet Air Temperature Sensor Removal CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. • Remove the fuel tank (see Fuel Tank Removal). •...
  • Page 168: Inlet Air Temperature Sensor Resistance Inspection

    3-58 FUEL SYSTEM (DFI) Inlet Air Temperature Sensor (Service Code 13) If the output voltage is out of the specified, check the ECU for its ground, and power supply (see ECU Power Supply Inspection). If the ground and power supply are good, replace the ECU (see ECU section).
  • Page 169 FUEL SYSTEM (DFI) 3-59 Inlet Air Temperature Sensor (Service Code 13) Inlet Air Temperature Sensor Circuit 1. ECU 2. Inlet Air Temperature Sensor 3. Water-proof Joint 2 http://mototh.com...
  • Page 170: Water Temperature Sensor (service Code 14)

    3-60 FUEL SYSTEM (DFI) Water Temperature Sensor (Service Code 14) Water Temperature Sensor Removal/Installation CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. • Drain the coolant (see Coolant Change in the Periodic Maintenance chapter).
  • Page 171: Sensor Resistance Inspection

    FUEL SYSTEM (DFI) 3-61 Water Temperature Sensor (Service Code 14) Sensor Resistance Inspection • Refer to the Water Temperature Sensor Inspection in the Electrical System chapter (see Water Temperature Sen- sor Inspection in the Electrical System chapter). Water Temperature Sensor Circuit 1.
  • Page 172: Atmospheric Pressure Sensor (service Code 15)

    3-62 FUEL SYSTEM (DFI) Atmospheric Pressure Sensor (Service Code 15) CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. Removal • Remove: Left Saddlebag (see Saddlebag Removal in the Frame chapter) Seat (see Seat Removal in the Frame chapter) Atmospheric Pressure Sensor Connector [A]...
  • Page 173: Output Voltage Inspection

    FUEL SYSTEM (DFI) 3-63 Atmospheric Pressure Sensor (Service Code 15) If the reading is within the standard range, remove the seat, and check the input voltage again at the sensor con- nector. • Disconnect the atmospheric pressure sensor connector and connect the harness adapter [A] between the harness connector and atmospheric pressure sensor connector.
  • Page 174 3-64 FUEL SYSTEM (DFI) Atmospheric Pressure Sensor (Service Code 15) If the output voltage is far out of the usable range, check the output voltage at the sensor connector [A] (when the wiring is open, the output voltage is about 1.8 V). •...
  • Page 175 FUEL SYSTEM (DFI) 3-65 Atmospheric Pressure Sensor (Service Code 15) If you know the local atmospheric pressure using a barometer, substitute the atmospheric pressure for throt- tle vacuum pressure in the inlet air pressure sensor chart (see Inlet Air Pressure Sensor section). And get the usable range of the atmospheric pressure sensor output voltage and check if output voltage is within the standard or not in the same way as Output Voltage Inspection of...
  • Page 176: Crankshaft Sensor (service Code 21)

    3-66 FUEL SYSTEM (DFI) Crankshaft Sensor (Service Code 21) Crankshaft Sensor Removal/Installation • Refer to the Crankshaft Sensor Removal/Installation in the Electrical System chapter (see Crankshaft Sensor Re- moval/Installation in the Electrical System chapter). Crankshaft Sensor Inspection ○ The crankshaft have no power source, and when the en- gine stops, the crankshaft generates no signals.
  • Page 177: Camshaft Position Sensor (service Code 23, 26)

    FUEL SYSTEM (DFI) 3-67 Camshaft Position Sensor (Service Code 23, 26) Camshaft Position Sensor Removal/Installation The camshaft position sensor detects the position of the camshaft, and distinguishes the cylinder. • Refer to the Camshaft Position Sensor Removal/Installa- tion in the Electrical System chapter (see Camshaft Posi- tion Sensor Removal/Installation in the Electrical System chapter).
  • Page 178: Speed Sensor (service Code 24)

    3-68 FUEL SYSTEM (DFI) Speed Sensor (Service Code 24) Speed Sensor Removal/Installation • Refer to the Speed Sensor Removal/Installation in the Electrical System chapter (see Speed Sensor Re- moval/Installation in the Electrical System chapter). Speed Sensor Inspection • Refer to the Speed Sensor Inspection in the Electrical System chapter (see Speed Sensor Inspection in the Electrical System chapter).
  • Page 179: Speed Sensor Output Voltage Inspection

    FUEL SYSTEM (DFI) 3-69 Speed Sensor (Service Code 24) Speed Sensor Output Voltage Inspection • Before this inspection, inspect the input voltage (see Speed Sensor Input Voltage Inspection). NOTE ○ Be sure the battery is fully charged. • Turn the key knob to OFF. •...
  • Page 180 3-70 FUEL SYSTEM (DFI) Speed Sensor (Service Code 24) 1. ECU 2. Speed Sensor 3. Joint Connector 8 4. Meter Unit 5. Frame Ground 6. Frame Ground 7. Battery 12 V 14 Ah http://mototh.com...
  • Page 181: Gear Position Switch (service Code 25)

    FUEL SYSTEM (DFI) 3-71 Gear Position Switch (Service Code 25) Gear Position Switch Removal/Installation • Refer to the Gear Position Switch Removal/Installation in the Electrical System chapter (see Gear Position Switch Removal/Installation in the Electrical System chapter). Gear Position Switch Inspection •...
  • Page 182 3-72 FUEL SYSTEM (DFI) Gear Position Switch (Service Code 25) Gear Position Switch Circuit 1. ECU 2. Gear Position Switch 3. Joint Connector 8 4. Frame Ground 5. Frame Ground 6. Battery 12 V 14 Ah http://mototh.com...
  • Page 183: Vehicle-down Sensor (service Code 31)

    FUEL SYSTEM (DFI) 3-73 Vehicle-down Sensor (Service Code 31) This sensor has a weight [A] with two magnets inside, and sends a signal to the ECU. But when the motorcycle banks 60 ∼ 70° or more to either side (in fact falls down), the weight turns and shuts off the signal.
  • Page 184: Vehicle-down Sensor Inspection

    3-74 FUEL SYSTEM (DFI) Vehicle-down Sensor (Service Code 31) Vehicle-down Sensor Inspection NOTE ○ Be sure the battery is fully charged. • Remove the rear fender (see Rear Fender Removal in the Frame chapter). • Connect a digital meter [A] to the connector of the vehicle -down sensor [B], with the needle adapter set [C].
  • Page 185 FUEL SYSTEM (DFI) 3-75 Vehicle-down Sensor (Service Code 31) • Turn the key knob to OFF. • Remove the vehicle-down sensor. ○ Do not disconnect the sensor connector. • Connect a digital meter [A] to the connector, with needle adapter set [B]. Special Tool - Needle Adapter Set: 57001-1457 Vehicle-down sensor Output Voltage Connections to Sensor...
  • Page 186: Subthrottle Sensor (service Code 32)

    3-76 FUEL SYSTEM (DFI) Subthrottle Sensor (Service Code 32) The subthrottle sensor is a rotating variable resistor that change output voltage according to throttle operating. The ECU senses this voltage change and determines fuel injec- tion quantity, and ignition timing according to engine rpm, and throttle opening.
  • Page 187 FUEL SYSTEM (DFI) 3-77 Subthrottle Sensor (Service Code 32) • Remove: Right Middle Fairing (see Middle Fairing Removal in the Frame chapter). Right Subframe • Disconnect the subthrottle sensor connector [A]. • Connect the harness adapter [A] between the harness connector and subthrottle sensor connector.
  • Page 188: Output Voltage Inspection

    3-78 FUEL SYSTEM (DFI) Subthrottle Sensor (Service Code 32) Output Voltage Inspection • Measure the output voltage at the ECU in the same way as input voltage inspection. Note the following. Digital Meter [A] Connector [B] Special Tool - Needle Adapter Set: 57001-1457 Subthrottle Sensor Output Voltage Connections to ECU Connector Meter (+) →...
  • Page 189 FUEL SYSTEM (DFI) 3-79 Subthrottle Sensor (Service Code 32) • Disconnect the subthrottle sensor connector [A] and con- nect the harness adapter [B] between the harness con- nector and subthrottle sensor connector. Special Tool - Throttle Sensor Harness Adapter: 57001 -1538 •...
  • Page 190: Resistance Inspection

    3-80 FUEL SYSTEM (DFI) Subthrottle Sensor (Service Code 32) Resistance Inspection • Turn the key knob to OFF. • Disconnect the subthrottle sensor connector. • Connect a digital meter [A] to the subthrottle sensor con- nector [B]. • Measure the subthrottle sensor resistance. Subthrottle Sensor Resistance Connections: BL lead [C] ←→...
  • Page 191: Oxygen Sensor-not Activated (#1, #2: Service Code 33, 83) - Equipped Models

    FUEL SYSTEM (DFI) 3-81 Oxygen Sensor-not activated (#1, #2: Service Code 33, 83) - Equipped Models Oxygen Sensor #2 Removal/Installation • Refer to the Oxygen Sensor Removal (Equipped Models) in the Electrical System chapter (see Oxygen Sensor Re- moval in the Electrical System chapter). Oxygen Sensor #2 Inspection NOTE ○...
  • Page 192 0.05 ∼ 0.45 V), the oxygen sensor is good. If the reading is without range, replace the oxygen sensor. • Remove the needle adapter set, and apply silicone sealant to the seals of the connector for waterproofing. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 http://mototh.com...
  • Page 193 FUEL SYSTEM (DFI) 3-83 Oxygen Sensor-not activated (#1, #2: Service Code 33, 83) - Equipped Models Oxygen Sensor Circuit 1. ECU 2. Joint Connector 9 3. Oxygen Sensor #2 4. Oxygen Sensor #1 5. Steering Lock Unit 6. Oxygen Sensor Heater Fuse 15 A 7.
  • Page 194: Steering Lock Unit And Ecu Communication Error (service Code 37, 38)

    3-84 FUEL SYSTEM (DFI) Steering Lock Unit and ECU Communication Error (Service Code 37, 38) Steering Lock Unit and ECU Communication Line Inspection ○ When the data is not sent from the steering lock unit and ECU to KIPASS ECU, the service code 37, 38 is dis- played.
  • Page 195: Fuel Pump Relay (service Code 46)

    FUEL SYSTEM (DFI) 3-85 Fuel Pump Relay (Service Code 46) Fuel Pump Relay Removal CAUTION Never drop the relay, especially on a hard surface. Such a shock to the relay can damage it. ○ The fuel pump relay is included in the relay box. •...
  • Page 196 3-86 FUEL SYSTEM (DFI) Fuel Pump Relay (Service Code 46) Fuel Pump Relay Circuit 1. Steering Lock Unit 11. Relay Box 2. Joint Connector 1 12. Joint Connector 2 3. Engine Stop Switch 13. Main Fuse 30 A 4. Water-proof Joint 1 14.
  • Page 197: Stick Coils #1, #2, #3, #4: (service Code 51, 52, 53, 54)

    FUEL SYSTEM (DFI) 3-87 Stick Coils #1, #2, #3, #4: (Service Code 51, 52, 53, 54) Stick Coil #1: Service Code 51 Stick Coil #2: Service Code 52 Stick Coil #3: Service Code 53 Stick Coil #4: Service Code 54 Stick Coil Removal/Installation CAUTION Never drop the stick coils, especially on a hard sur-...
  • Page 198 3-88 FUEL SYSTEM (DFI) Stick Coils #1, #2, #3, #4: (Service Code 51, 52, 53, 54) Stick Coil Circuit 1. ECU 10. Joint Connector 9 2. Stick Coil #4 11. Main Fuse 30 A 3. Stick Coil #3 12. Starter Relay 4.
  • Page 199: Radiator Fan Relay (service Code 56)

    FUEL SYSTEM (DFI) 3-89 Radiator Fan Relay (Service Code 56) Radiator Fan Relay Removal/Installation ○ The radiator fan relay is built in the relay box [A]. • Refer to the Relay Box Removal in the Electrical System chapter. Radiator Fan Relay Inspection •...
  • Page 200: Variable Valve Timing And Oil Control Solenoid Valve (service Code 59, 65)

    Using the KDS3 Kit. NOTE ○ Read the OCV Solenoid Test in the Kawasaki Diagnos- tic Software Version 3 Instruction Manual. If the oil control solenoid valve does not function, check it for any tips interlocked or seizure.
  • Page 201 FUEL SYSTEM (DFI) 3-91 Variable Valve Timing and Oil Control Solenoid Valve (Service Code 59, 65) • Turn the key knob to OFF. If the reading is incorrect, check the following. Battery (see Charging Condition Inspection in the Elec- trical System chapter) Main Fuse 30 A (see Fuse Inspection in the Electrical System chapter) Oxygen Sensor Heater Fuse 15 A (see Fuse Inspection...
  • Page 202: Subthrottle Valve Actuator (service Code 62)

    3-92 FUEL SYSTEM (DFI) Subthrottle Valve Actuator (Service Code 62) Subthrottle Valve Actuator Removal CAUTION Do not remove the subthrottle valve actuator [A] since it has been adjusted and set with precision at the factory. Never drop the actuator , especially on a hard sur- face.
  • Page 203: Input Voltage Inspection

    FUEL SYSTEM (DFI) 3-93 Subthrottle Valve Actuator (Service Code 62) Input Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Push and turn the key knob to OFF. • Connect the peak voltage adapter [A] and a digital meter [B] to the connector [C], using the needle adapter set [D].
  • Page 204 3-94 FUEL SYSTEM (DFI) Subthrottle Valve Actuator (Service Code 62) Subthrottle Valve Actuator Circuit 1. ECU 2. Subthrottle Valve Actuator 3. Subthrottle Sensor 4. Main Throttle Sensor 5. Water-proof Joint 2 http://mototh.com...
  • Page 205: Air Switching Valve (service Code 64)

    FUEL SYSTEM (DFI) 3-95 Air Switching Valve (Service Code 64) Air Switching Valve Removal/Installation • Refer to Clean Air System section in the Engine Top End chapter. Air Switching Valve Inspection • Refer to Air Switching Valve Unit Test in the Electrical Sys- tem chapter.
  • Page 206: Oxygen Sensor Heaters (#1 And/or #2: Service Code 67) - Equipped Models

    3-96 FUEL SYSTEM (DFI) Oxygen Sensor Heaters (#1 and/or #2: Service Code 67) - Equipped Models Oxygen Sensor Heaters Removal/Installation The oxygen sensor heater is built in the oxygen sensor. So, the heater itself can not be removed. Remove the oxy- gen sensors (see Oxygen Sensor Removal in the Electrical System chapter).
  • Page 207 (see ECU Power Supply Inspection). If the ground and power supply are good, replace the ECU (see ECU section). • Remove the needle adapter set, and apply silicone sealant to the connector for water proofing. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 http://mototh.com...
  • Page 208 3-98 FUEL SYSTEM (DFI) Oxygen Sensor Heaters (#1 and/or #2: Service Code 67) - Equipped Models Oxygen Sensor Circuit 1. ECU 2. Joint Connector 9 3. Oxygen Sensor #2 4. Oxygen Sensor #1 5. Steering Lock Unit 6. Oxygen Sensor Heater Fuse 15 A 7.
  • Page 209: Steering Lock Unit (service Code 68)

    FUEL SYSTEM (DFI) 3-99 Steering Lock Unit (Service Code 68) Steering Lock Unit Inspection • Remove : Left Inner Cover (see Inner Cover Removal in the Frame chapter) • Turn the key knob to OFF. • Open the rubber cap [A]. •...
  • Page 210 3-100 FUEL SYSTEM (DFI) Steering Lock Unit (Service Code 68) • Push and turn ON the key knob and check the Voltage. Steering Lock Unit Voltage Connections for Main Harness side Connector Meter (+) → W lead Meter (–) → BK/Y lead Standard Voltage: Battery Voltage Meter (+) →...
  • Page 211: Steering Lock Unit And Dfi Ecu - Identify Authentification Error (service Code 87, 88)

    FUEL SYSTEM (DFI) 3-101 Steering Lock Unit and DFI ECU - Identify Authentification Error (Service Code 87, 88) ○ When the service code 87, 88 is displayed, perform the registration of KIPASS ID by using the KDS 3. • If KIPASS ID can not be registered, replace the ECU or steering lock unit.
  • Page 212: Ecu

    3-102 FUEL SYSTEM (DFI) CAUTION Never drop the ECU, especially on a hard surface. Such a shock to the ECU can damage it. ECU Identification ○ Most countries have their own regulations, so each ECU has different characteristic. So, do not confuse ECU with each other and use only the ECU for your model.
  • Page 213: Ecu Installation

    FUEL SYSTEM (DFI) 3-103 • Remove: Fuse Box [A] Bolts [B] Tool Kit Case [C] • Pull of the connectors [D] • For Europe Models, using a suitable tool cut of the screws [A]. • Remove: Connectors [A] Relay Box [B] •...
  • Page 214: Ecu Power Supply Inspection

    Insert the stopper [C] of the fuse box [D] into the groove of the tool case. • For Europe Models, tighten new screws [A] of the tool kit case use Kawasaki genuine screws of witch treads are coated with locking agent. • Install:...
  • Page 215 FUEL SYSTEM (DFI) 3-105 • With the ECU connectors [B] connected, check the fol- lowing ground lead for continuity with the key knob OFF, using a digital meter [A] and needle adapter set. Special Tool - Needle Adapter Set: 57001-1457 ECU Grounding Inspection ←→...
  • Page 216 3-106 FUEL SYSTEM (DFI) ECU Power Source Circuit 1. ECU 2. Water-proof Joint 1 3. Steering Lock Unit 4. Joint Connector 9 5. Fuse Box 2 6. ECU Fuse 15 A 7. Main Fuse 30 A 8. Starter Relay 9. Battery 12 V 14 Ah 10.
  • Page 217: Can Communication Line Resistance Inspection

    FUEL SYSTEM (DFI) 3-107 CAN Communication Line Resistance Inspection ○ In this model, resistors for CAN communication line are built in the DFI ECU, KIPASS ECU and meter unit. • Turn the key knob to OFF. • Disconnect the DFI ECU connector [A] and KIPASS ECU connector [B].
  • Page 218 3-108 FUEL SYSTEM (DFI) CAN Communication Line Circuit 1. Steering Lock Unit 2. Joint Connector 4 3. Joint Connector 5 4. KIPASS ECU 5. Meter Unit 6. Joint Connector 6 7. Joint Connector 7 8. Kawasaki Diagnostic System Connector 9. ECU http://mototh.com...
  • Page 219: Dfi Power Source

    FUEL SYSTEM (DFI) 3-109 DFI Power Source ECU Fuse Removal • Refer to the ECU Fuse 15 A Removal in the Electrical Sys- tem chapter (see ECU Fuse 15 A Removal in the Electri- cal System chapter). ECU Fuse Installation If a fuse fails during operation, inspect the DFI system to determine the cause, and then replace it with a new fuse of proper amperage.
  • Page 220: Warning Indicator Light (led)

    3-110 FUEL SYSTEM (DFI) Warning Indicator Light (LED) Light (LED) Inspection ○ The warning indicator light (LED) [A] is used for the FI indicator and KIPASS indicator. ○ In this model, the warning indicator light (LED) goes on or blinks by the special signal sent from the ECU. •...
  • Page 221: Fuel Line

    FUEL SYSTEM (DFI) 3-111 Fuel Line Fuel Pressure Inspection NOTE ○ Be sure the battery is fully charged. • Remove the fuel tank bolts [A] (see Fuel Tank Removal). ○ Do not disconnect the fuel pump and fuel level sensor lead connector.
  • Page 222 3-112 FUEL SYSTEM (DFI) Fuel Line WARNING Do not try to start the engine with the fuel hoses disconnected. • Push and turn the key knob to ON. The fuel pump will turn for 3 seconds, and then stop. CAUTION Do not drive the fuel pump 3 seconds or more with- out the fuel in the fuel tank.
  • Page 223: Fuel Flow Rate Inspection

    FUEL SYSTEM (DFI) 3-113 Fuel Line Fuel Flow Rate Inspection NOTE ○ Be sure the battery is fully charged. WARNING Gasoline is extremely flammable and can be explo- sive under certain conditions. Make sure the area is well-ventilated and free from any source of flame or sparks;...
  • Page 224 3-114 FUEL SYSTEM (DFI) Fuel Line WARNING Wipe off spilled out fuel immediately. Be sure to hold the measuring cylinder vertical. • Close the fuel tank cap. • With the engine stopped, turn the ignition switch ON. The fuel pump should operate for 3 seconds, and then should stop.
  • Page 225: Fuel Pump

    FUEL SYSTEM (DFI) 3-115 Fuel Pump Fuel Pump Removal CAUTION Never drop the fuel pump, especially on a hard sur- face. Such a shock to the pump can damage it. WARNING Gasoline is extremely flammable and can be explo- sive under certain conditions. Make sure the area is well-ventilated and free from any source of flame or sparks;...
  • Page 226: Fuel Pump Operation Inspection

    3-116 FUEL SYSTEM (DFI) Fuel Pump • Check that the fuel pump terminals [A], fuel reserve switch terminal [B] and band [C] are in place. Left [D] • Apply a non-permanent locking agent to the threads of the fuel pump bolts. •...
  • Page 227 FUEL SYSTEM (DFI) 3-117 Fuel Pump Fuel Pump Circuit 1. Steering Lock Unit 11. Relay Box 2. Joint Connector 1 12. Joint Connector 2 3. Engine Stop Switch 13. Main Fuse 30 A 4. Water-proof Joint 1 14. Starter Relay 5.
  • Page 228: Fuel Injectors

    3-118 FUEL SYSTEM (DFI) Fuel Injectors Fuel Injector Removal/Installation • Refer to the Throttle Body Assy Disassembly/Assembly (see Throttle Body Assy Disassembly/Assembly). CAUTION Never drop the injector, especially on a hard sur- face. Such a shock to the injector can damage it. Power Source Voltage Inspection NOTE ○...
  • Page 229: Fuel Injector Output Voltage Inspection

    FUEL SYSTEM (DFI) 3-119 Fuel Injectors • Connect a digital meter [A] to the throttle body subharness connector [B], using the needle adapter set [C]. Special Tool - Needle Adapter Set: 57001-1457 Injector Power Source Voltage at Injector Connections to Injector #1, #2, #3, #4 Meter (+) →...
  • Page 230: Audible Inspection

    3-120 FUEL SYSTEM (DFI) Fuel Injectors If the output voltage is out of the standard, check the out- put voltage at the throttle body subharness connector [B] using a digital meter [A] and needle adapter set [C] (when the lead is open, the output voltage is 0 V). Special Tool - Needle Adapter Set: 57001-1457 Injector Output Voltage at Injector Connections to Injector #1...
  • Page 231: Injector Signal Test

    FUEL SYSTEM (DFI) 3-121 Fuel Injectors Injector Signal Test • Prepare two test light sets with male terminals as shown. Rating of Bulb [A]: 12 V × 3 ∼ 3.4 W Terminal Width [B]: 1.8 mm (0.07 in.) Terminal Thickness [C]: 0.8 mm (0.03 in.) CAUTION Do not use larger terminals than specified above.
  • Page 232: Injector Unit Test

    3-122 FUEL SYSTEM (DFI) Fuel Injectors Injector Unit Test • Use two leads [A] and the same test light set [B] as in “Injector Signal Test”. Rating of Bulb [C]: 12 V × (3 ∼ 3.4) W 12 V MF Battery [D] CAUTION Be sure to connect the bulb in series.
  • Page 233 FUEL SYSTEM (DFI) 3-123 Fuel Injectors Fuel Injector Circuit 1. Steering Lock Unit 2. Ignition Fuse 10 A 3. ECU Fuse 15 A 4. Fuse Box 2 5. Joint Connector 9 6. Engine Stop Switch 7. Fuel Injector #1 8. Fuel Injector #2 9.
  • Page 234: Throttle Grip And Cables

    3-124 FUEL SYSTEM (DFI) Throttle Grip and Cables Free Play Inspection • Refer to the Throttle Control System Inspection in the Pe- riodic Maintenance chapter (see Throttle Control System Inspection in the Periodic Maintenance chapter). Free Play Adjustment • Refer to the Throttle Control System Inspection in the Pe- riodic Maintenance chapter (see Throttle Control System Inspection in the Periodic Maintenance chapter).
  • Page 235: Throttle Body Assy

    FUEL SYSTEM (DFI) 3-125 Throttle Body Assy Idle Speed Inspection • Refer to the Idle Speed Inspection in the Periodic Mainte- nance chapter (see Idle Speed Inspection in the Periodic Maintenance chapter). Throttle Bore Cleaning • Check the throttle bore for cleanliness as follows. ○...
  • Page 236 3-126 FUEL SYSTEM (DFI) Throttle Body Assy • Remove: Right Subframe Bolt [A] with Washer Right Fairing Bracket Bolt (Front Side) • Disconnect the throttle body subharness connector [A]. • Remove the connector [A] from the connector bracket. ○ Insert the thin blade screw driver into the connector stop- per portion from the right side of motorcycle.
  • Page 237 FUEL SYSTEM (DFI) 3-127 Throttle Body Assy • Remove: Fuel Tank (see Fuel Tank Removal) Inlet Air Temperature Sensor [A] Bolts [B] Left and Right Air Cleaner Caps [C] ○ Do not disconnect the inlet air temperature sensor lead connector. •...
  • Page 238: Throttle Body Assy Installation

    3-128 FUEL SYSTEM (DFI) Throttle Body Assy • Remove the adjuster screw [A] from the clamp [B]. • Loosen the throttle body assy holder clamp bolts [A] on both sides. • Pull out the throttle body assy [B] from the holder. •...
  • Page 239 FUEL SYSTEM (DFI) 3-129 Throttle Body Assy If the grommet [A] was removed, install it. ○ Install the grommet from the inside of the frame. • Insert the duct [B] to the grommet. ○ Apply a soap and water solution or rubber lubricant to the oblique portion [C] on the duct for easy installation.
  • Page 240: Throttle Body Assy Disassembly

    3-130 FUEL SYSTEM (DFI) Throttle Body Assy Throttle Body Assy Disassembly 1. Subthrottle Valve Actuator 2. Subthrottle Sensor 3. Main Throttle Sensor 4. Throttle Body Assy 5. Injector 6. Delivery Pipe 7. Throttle Body Subharness CAUTION Do not remove, disassemble or adjust the main throttle sensor, subthrottle sensor, subthrottle valve actuator, throttle link mechanism and throttle body assy, because they are adjust or set surely at...
  • Page 241 FUEL SYSTEM (DFI) 3-131 Throttle Body Assy • Disconnect the main throttle sensor [A] and subthrottle sensor [B] connector. • Disconnect: Subthrottle Valve Actuator Lead Connector [A] Inlet Air Pressure Sensor Connector [B] • Remove the inlet air pressure sensor [A] with hose [B]. •...
  • Page 242: Throttle Body Assy Assembly

    3-132 FUEL SYSTEM (DFI) Throttle Body Assy Throttle Body Assy Assembly • Before assembling, blow away dirt or dust from the throttle body and delivery pipe by applying compressed air. • Apply daphne oil or engine oil to the new O-rings [A] of each injector, insert them to the delivery pipe [B] and con- firm whether the injectors turn smoothly or not.
  • Page 243: Air Line

    FUEL SYSTEM (DFI) 3-133 Air Line Element Removal • Refer to the Air Cleaner Element Replacement in the Pe- riodic Maintenance chapter (see Air Cleaner Element Re- placement in the Periodic Maintenance chapter). Element Installation • Refer to the Air Cleaner Element Replacement in the Pe- riodic Maintenance chapter (see Air Cleaner Element Re- placement in the Periodic Maintenance chapter).
  • Page 244: Oil Draining

    3-134 FUEL SYSTEM (DFI) Air Line Oil Draining A drain hose is connected to the bottom of the air cleaner part to drain water or oil accumulated in the cleaner part. • Visually check the catch tank [A] of the drain hose, if the water or oil accumulates in the tank.
  • Page 245: Front Air Inlet Duct Removal

    FUEL SYSTEM (DFI) 3-135 Air Line • Insert the rear air inlet duct [A] until the duct end [B] align the line [C] of middle air inlet duct [D]. • Tighten Torque - Rear Air inlet Duct Mounting Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) •...
  • Page 246: Fuel Tank

    3-136 FUEL SYSTEM (DFI) Fuel Tank Fuel Tank Removal WARNING Gasoline is extremely flammable and can be explo- sive under certain conditions. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light.
  • Page 247 FUEL SYSTEM (DFI) 3-137 Fuel Tank • Disconnect: Fuel Pump Lead Connector [A] Fuel Level Sensor Lead Connector [B] • Open the fuel tank cap [A] to lower the pressure in the tank. ○ During tank removal, keep the tank cap open to release pressure in the tank.
  • Page 248: Fuel Tank Installation

    3-138 FUEL SYSTEM (DFI) Fuel Tank • For the California Model, note the following. CAUTION For the California model, if gasoline, solvent, water or any other liquid enters the canister, the canister’s vapor absorbing capacity is greatly reduced. If the canister does become contaminated, replace it with a new one.
  • Page 249 FUEL SYSTEM (DFI) 3-139 Fuel Tank • Pull the joint lock [A] as shown. • Insert the fuel hose joint [A] straight onto the delivery pipe until the hose joint clicks. • Push the joint lock [B] until the hose joint clicks. •...
  • Page 250: Fuel Tank And Cap Inspection

    3-140 FUEL SYSTEM (DFI) Fuel Tank Fuel Tank and Cap Inspection • Visually inspect the gasket [A] on the tank cap for any damage. Replace the gasket if it is damaged. • Check to see if the water drain pipe [B] and fuel breather pipe [C] (California Model) in the tank are not clogged.
  • Page 251: Evaporative Emission Control System

    FUEL SYSTEM (DFI) 3-141 Evaporative Emission Control System The Evaporative Emission Control System routes fuel va- pors from the fuel system into the running engine or stores the vapors in a canister when the engine is stopped. Al- though no adjustments are required, a thorough visual in- spection must be made at the intervals specified by the Pe- riodic Maintenance Chart.
  • Page 252: Separator Operation Test

    3-142 FUEL SYSTEM (DFI) Evaporative Emission Control System Separator Operation Test WARNING Gasoline is extremely flammable and can be ex- plosive under certain conditions. Turn the ignition switch OFF. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks;...
  • Page 253 COOLING SYSTEM 4-1 Cooling System Table of Contents Exploded View........................Coolant Flow Chart......................... Specifications ......................... Coolant ........................... Coolant Deterioration Inspection..................Coolant Level Inspection....................Coolant Draining ....................... Coolant Filling ........................Pressure Testing ....................... Cooling System Flushing ....................Coolant Reserve Tank Removal/Installation ..............Water Pump..........................
  • Page 254: Exploded View

    4-2 COOLING SYSTEM Exploded View http://mototh.com...
  • Page 255 COOLING SYSTEM 4-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Radiator Hose Clamp Screws 0.20 18 in·lb Coolant Drain Plug 106 in·lb Water Pump Cover Bolts 87 in·lb Oil Cooler Mounting Bolts 106 in·lb Thermostat Housing Cover Bolts 0.60 52 in·lb Thermostat Housing Mounting Bolts 87 in·lb...
  • Page 256: Coolant Flow Chart

    4-4 COOLING SYSTEM Coolant Flow Chart http://mototh.com...
  • Page 257: Cooling System

    COOLING SYSTEM 4-5 Coolant Flow Chart Permanent type antifreeze is used as a coolant to protect the cooling system from rust and corrosion. When the engine starts, the water pump turns and the coolant circulates. The thermostat is a wax pellet type which opens or closes with coolant temperature changes. The thermostat continuously changes its valve opening to keep the coolant temperature at the proper level.
  • Page 258: Specifications

    4-6 COOLING SYSTEM Specifications Item Standard Coolant Provided when Shipping Type (Recommended) Permanent type of antifreeze (soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators) Color Green Mixed Ratio Soft water 50%, coolant 50% Freezing Point –35°C (–31°F) Total Amount...
  • Page 259: Coolant

    COOLING SYSTEM 4-7 Coolant Coolant Deterioration Inspection • Visually inspect the coolant in the reserve tank. If whitish cotton-like wafts are observed, aluminum parts in the cooling system are corroded. If the coolant is brown, iron or steel parts are rusting. In either case, flush the cooling system.
  • Page 260: Cooling System Flushing

    4-8 COOLING SYSTEM Coolant Cooling System Flushing Over a period of time, the cooling system accumulates rust, scale, and lime in the water jacket and radiator. When this accumulation is suspected or observed, flush the cool- ing system. If this accumulation is not removed, it will clog up the water passage and considerable reduce the effi- ciency of the cooling system.
  • Page 261: Water Pump

    COOLING SYSTEM 4-9 Water Pump Water Pump Removal • Drain: Coolant (see Coolant Change in the Periodic Mainte- nance chapter) Engine Oil (see Engine Oil Change in the Periodic Main- tenance chapter) • Remove: Lower Fairing (see Lower Fairing Removal in the Frame chapter) •...
  • Page 262: Water Pump Impeller Inspection

    4-10 COOLING SYSTEM Water Pump • Turn the pump drive gear shaft so that the slot [A] in its shaft fits onto the projection [B] of the impeller shaft. • Install: Radiator Hose • Tighten: Torque - Radiator Hose Clamp Screw: 2.0 N·m (0.20 kgf·m, 18 in·lb) •...
  • Page 263: Radiator

    COOLING SYSTEM 4-11 Radiator Radiator and Radiator Fan Removal • Drain: Coolant (see Coolant Change in the Periodic Mainte- nance chapter) • Remove: Middle Fairings (see Middle Fairing Removal in the Frame chapter) Right Side Radiator Fan Lead Connector [A] Reservoir Tank Hose [B] Air Bleeder Hose [C] for Thermostat Housing Radiator Hose [D]...
  • Page 264: Radiator And Radiator Fan Installation

    4-12 COOLING SYSTEM Radiator Radiator and Radiator Fan Installation • Be sure that the trim seals [A] are in position on the radi- ator as shown. • Install the dampers [B], radiator bracket collars [C] and bolts as shown. Radiator Inspection •...
  • Page 265: Radiator Cap Inspection

    COOLING SYSTEM 4-13 Radiator Radiator Cap Inspection • Remove: Front Right Middle Fairing (see Middle Fairing Removal in the Frame chapter) Radiator Cap [A] • Check the condition of the bottom [A] and top [B] valve seals and valve spring [C]. If any one of them shows visible damage, replace the cap with a new one.
  • Page 266: Thermostat

    4-14 COOLING SYSTEM Thermostat Thermostat Removal • Drain the coolant (see Coolant Change in the Periodic Maintenance chapter). • Remove: Right Rear Middle Fairing (see Middle Fairing Removal in the Frame chapter) Battery Compartment Cover (see Battery Removal in the Electrical System chapter) Crankshaft Sensor Connector (see Crankshaft Sensor Removal in the Electrical System chapter)
  • Page 267 COOLING SYSTEM 4-15 Thermostat • To check valve opening temperature, suspend the ther- mostat [A] in a container of water and raise the tempera- ture of the water. ○ The thermostat must be completely submerged and must not touch the container sides or bottom. Suspend an ac- curate thermometer [B] in the water so that the heat sen- sitive portions [C] are located in almost the same depth.
  • Page 268: Hoses And Pipes

    4-16 COOLING SYSTEM Hoses and Pipes Hose Installation • Install the hoses and pipes, being careful to follow bend- ing direction. Avoid sharp bending, kinking, flattening or twisting. • Run the hoses (see Cable, Wire, and Hose Routing sec- tion in the Appendix chapter). •...
  • Page 269: Water Temperature Sensor

    COOLING SYSTEM 4-17 Water Temperature Sensor CAUTION The water temperature sensor should never be al- lowed to fall on a hard surface. Such a shock to their parts can damage them. Water Temperature Sensor Removal • Refer to the Water Temperature Sensor Removal in the Fuel System (DFI) chapter.
  • Page 270 http://mototh.com...
  • Page 271 ENGINE TOP END 5-1 Engine Top End Table of Contents Exploded View........................Exhaust System........................Specifications ......................... Special Tools and Sealant ...................... Clean Air System........................5-11 Air Suction Valve Removal....................5-11 Air Suction Valve Installation..................... 5-11 Air Suction Valve Inspection ..................... 5-12 Air Switching Valve Removal ....................
  • Page 272: Exploded View

    5-2 ENGINE TOP END Exploded View http://mototh.com...
  • Page 273 M: Apply molybdenum disulfide grease. MO: Apply molybdenum disulfide oil. (mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 : 1) R: Replacement Parts S: Follow the specific tightening sequence. SS: Apply silicone sealant (Kawasaki Bond: 92104-0004). http://mototh.com...
  • Page 274 5-4 ENGINE TOP END Exploded View http://mototh.com...
  • Page 275 ENGINE TOP END 5-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Muffler Body Mounting Bolts Crankshaft Sensor Cover Bolts 87 in·lb L (1) Oxygen Sensor (Europe Models) 4. Muffler Body Clamp Bolt 5. Exhaust Pipe Manifold Holder Nuts 6. Europe Models L: Apply a non-permanent locking agent.
  • Page 276: Exhaust System

    5-6 ENGINE TOP END Exhaust System Full: Full Power H: Honeycomb Type Catalyst 78.2: Hosepower 78.2 kW (106.3 ps) Manifold Mark Position [A] http://mototh.com...
  • Page 277 ENGINE TOP END 5-7 Exhaust System Silencer Mark Position [A] Manifold [A] with Holes [B] for Oxygen Sensors [C]. Honeycomb Type Catalysts [A] http://mototh.com...
  • Page 278: Specifications

    5-8 ENGINE TOP END Specifications Item Standard Service Limit Camshafts Cam Height: 33.642 ∼ 33.756 mm (1.3245 ∼ 1.3290 in.) Exhaust 33.54 mm (1.32 in.) 34.243 ∼ 34.357 mm (1.3481 ∼ 1.3526 in.) Inlet 34.14 mm (1.344 in.) 0.038 ∼ 0.081 mm (0.0015 ∼ 0.0032 in.) Camshaft Journal, Camshaft 0.17 mm (0.0067 in.) Cap Clearance...
  • Page 279: Special Tools And Sealant

    ENGINE TOP END 5-9 Special Tools and Sealant Compression Gauge, 20 kgf/cm²: Valve Seat Cutter, 60° - 30: 57001-221 57001-1123 Valve Spring Compressor Assembly: Valve Seat Cutter Holder Bar: 57001-241 57001-1128 Valve Seat Cutter, 45° - 35: Valve Seat Cutter, 45° - 30: 57001-1116 57001-1187 Valve Seat Cutter, 32°...
  • Page 280 Valve Seat Cutter Holder, 5: Valve Spring Compressor Adapter, 24: 57001-1208 57001-1586 Valve Seat Cutter, 60° - 33: Valve Guide Driver Attachment, E: 57001-1334 57001-1677 Compression Gauge Adapter, M10 × 1.0: Kawasaki Bond (Silicone Sealant): 57001-1486 92104-0004 Valve Guide Driver: 57001-1564 http://mototh.com...
  • Page 281: Clean Air System

    ENGINE TOP END 5-11 Clean Air System Air Suction Valve Removal • Remove: Middle Fairings (see Middle Fairing Removal in the Frame chapter) Subframes Engine Bracket • Remove the air switching valve with the hoses [A] (see air switching valve Removal). •...
  • Page 282: Air Suction Valve Inspection

    5-12 ENGINE TOP END Clean Air System Air Suction Valve Inspection • Remove the air suction valve (see Air Suction Valve Re- moval). • Visually inspect the reeds [A] for cracks, folds, warps, heat damage, or other damage. If there is any doubt as to the condition of the reed, replace the air suction valve as an assembly.
  • Page 283: Air Switching Valve Installation

    ENGINE TOP END 5-13 Clean Air System Air Switching Valve Installation • Install the air switching valve so that the air duct [A] faces left side. • Route the hoses correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). Air Switching Valve Operation Test •...
  • Page 284: Cylinder Head Cover

    Remove the cylinder head cover [A] to the right side of the engine. Cylinder Head Cover Installation • Replace the head cover gasket with a new one. • Apply silicone sealant [A] to the cylinder head as shown. Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004 http://mototh.com...
  • Page 285 ENGINE TOP END 5-15 Cylinder Head Cover • Install: Dowel Pins [A] Plug Hole Gaskets [B] • Apply a soap solution to the upper and lower surfaces [A] to the washer. • Install the washer [B] with the metal side faces [C] upward. •...
  • Page 286: Camshaft Chain Tensioner

    5-16 ENGINE TOP END Camshaft Chain Tensioner Camshaft Chain Tensioner Removal CAUTION Do not turn over the crankshaft while the tensioner is removed. This could upset the camshaft chain timing, and damage the valves. • Remove the right Rear middle fairing (see Middle Fairing Removal in the Frame chapter).
  • Page 287: Camshaft, Camshaft Chain

    ENGINE TOP END 5-17 Camshaft, Camshaft Chain Camshaft Removal • Remove: Cylinder Head Cover (see Cylinder Head Cover Re- moval) • Position the crankshaft at #1, 4 piston TDC. TDC mark [A] for #1, 4 Pistons Timing Mark (crankcase halves mating surface) [B] •...
  • Page 288: Camshaft Installation

    5-18 ENGINE TOP END Camshaft, Camshaft Chain • Remove the variable valve actuator and cam sprocket mounting bolts [A]. • Remove the variable valve actuator and cam sprocket. CAUTION The crankshaft may be turned while the camshafts are removed. Always pull the chain taut while turn- ing the crankshaft.
  • Page 289 ENGINE TOP END 5-19 Camshaft, Camshaft Chain NOTE ○ The exhaust camshaft has the projection [A] for camshaft position sensor. ○ The inlet camshaft has two projections [B] for camshaft position sensor. • Position the crankshaft at #1, 4 piston TDC. •...
  • Page 290 5-20 ENGINE TOP END Camshaft, Camshaft Chain • First install the camshaft cap [A] temporary to fix the po- sition of the camshaft. • Next install the camshaft caps, following the identification No. and/or Name [B] and chain guide [C]. ○...
  • Page 291: Camshaft, Camshaft Cap Wear

    ENGINE TOP END 5-21 Camshaft, Camshaft Chain • Be sure to install the following parts. Plug Hole Gaskets [A] Dowel Pins [B] • Install the Cylinder Head Cover (see Cylinder Head Cover Installation). Camshaft, Camshaft Cap Wear • Remove: Camshaft Chain Guide Camshaft Cap (see Camshaft Removal) •...
  • Page 292: Camshaft Runout

    5-22 ENGINE TOP END Camshaft, Camshaft Chain Camshaft Runout • Remove the camshaft (see Camshaft Removal). • Set the camshaft in a camshaft alignment jig or on V blocks. • Measure runout with a dial gauge at the specified place as shown.
  • Page 293: Camshaft Chain Installation

    ENGINE TOP END 5-23 Camshaft, Camshaft Chain Camshaft Chain Installation • Install the camshaft chain from head side. • Install the crankshaft sprocket [A] on the crankshaft [B] with their teeth [C] aligned. • Install: Camshaft Chain Guides (see Cylinder Head Installation) Timing Rotor (see Timing Rotor Installation in the Elec- trical System chapter) Torque - Front Camshaft Chain Guide Bolt (Upper): 25 N·m...
  • Page 294: Cylinder Head

    5-24 ENGINE TOP END Cylinder Head Cylinder Compression Measurement NOTE ○ Use the battery which is fully charged. • Warm up the engine thoroughly. • Stop the engine. • Remove: Stick Coils (see Stick Coil Removal in the Electrical Sys- tem chapter) Spark Plugs (see Spark Plug Replacement in the Peri- odic Maintenance chapter)
  • Page 295: Cylinder Head Removal

    ENGINE TOP END 5-25 Cylinder Head Cylinder Head Removal • Drain the coolant (see Coolant Change in the Periodic Maintenance chapter). • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Throttle Body Assy (see Throttle Body Assy Removal in the Fuel System (DFI) chapter) Exhaust Pipe (see Exhaust Pipe Removal) Cylinder Head Cover (see Cylinder Head Cover Re-...
  • Page 296: Cylinder Head Installation

    5-26 ENGINE TOP END Cylinder Head Cylinder Head Installation NOTE ○ The camshaft cap is machined with the cylinder head, so if a new cylinder head is installed, use the cap that is supplied with the new head. • Install a new cylinder head gasket [A] and dowel pins [B]. •...
  • Page 297: Cylinder Head Warp

    ENGINE TOP END 5-27 Cylinder Head Cylinder Head Warp • Clean the cylinder head. • Lay a straightedge across the lower surface of the cylinder head at several positions. • Use a thickness gauge [A] to measure the space between the straightedge [B] and the head.
  • Page 298: Valves

    5-28 ENGINE TOP END Valves Valve Clearance Inspection • Refer to the Valve Clearance Inspection in the Periodic Maintenance chapter (see Valve Clearance Inspection the Periodic Maintenance chapter). Valve Removal • Remove the cylinder head (see Cylinder Head Removal). • Remove the valve lifter and shim.
  • Page 299: Valve-to-guide Clearance Measurement (wobble Method)

    ENGINE TOP END 5-29 Valves • Assembly the valve guide driver parts (Holder and attach- ment E). • Insert the rod of the driver into the valve guide bore and hammer the end of the driver until it bottoms. Valve Guide Driver Attachment E [A] Valve Guide Driver (Holder) [B] Valve Guide [C] Cylinder Head [D]...
  • Page 300: Valve Seat Inspection

    5-30 ENGINE TOP END Valves Valve Seat Inspection • Remove the valve (see Valve Removal). • Check the valve seating surface [A] between the valve [B] and valve seat [C]. ○ Measure the outside diameter [D] of the seating pattern on the valve seat.
  • Page 301 ENGINE TOP END 5-31 Valves Seat Cutter Operation Care 1. This valve seat cutter is developed to grind the valve for repair. Therefore the cutter must not be used for other purposes than seat repair. 2. Do not drop or shock the valve seat cutter, or the dia- mond particles may fall off.
  • Page 302 5-32 ENGINE TOP END Valves • Measure the outside diameter of the seating surface with a vernier caliper. If the outside diameter of the seating surface is too small, repeat the 45° grind until the diameter is within the spec- ified range.
  • Page 303 ENGINE TOP END 5-33 Valves If the seat width is too wide, make the 60° [A] grind de- scribed below. If the seat width is within the specified range, lap the valve to the seat as described below. • Grind the seat at a 60° angle until the seat width is within the specified range.
  • Page 304 5-34 ENGINE TOP END Valves http://mototh.com...
  • Page 305: Throttle Body Holder

    ENGINE TOP END 5-35 Throttle Body Holder Throttle Body Holder Installation • Be sure to install the O-rings [A]. • Tighten the holder bolts following the tightening sequence [1 ∼ 3]. Torque - Throttle Body Holder Bolts [C]: 9.8 N·m (1.0 kgf·m, 87 in·lb) Throttle Body Assy Holder Clamp Bolts [D]: 2.0 N·m (0.20 kgf·m, 18 in·lb)
  • Page 306: Muffler

    5-36 ENGINE TOP END Muffler WARNING To avoid a serious burn, do not remove the muffler when the engine is still hot. Wait until the muffler cool down. Muffler Body Removal • Remove: Right Saddlebag (see Saddlebag Removal in the Frame chapter) Muffler Clamp Bolts [A] Muffler Mounting Bolts and Nuts [B]...
  • Page 307: Exhaust Pipe Installation

    ENGINE TOP END 5-37 Muffler • For the oxygen sensor was equipped models as follows. ○ Disconnect the sensor connectors [A]. • Remove the sensor [B]. Exhaust Pipe Installation • Replace the exhaust pipe gaskets [A], muffler gasket with new ones and install them. ○...
  • Page 308 http://mototh.com...
  • Page 309 CLUTCH 6-1 Clutch Table of Contents Exploded View........................Specifications ......................... Special Tools and Sealant ...................... Clutch Master Cylinder ......................Clutch Lever Adjustment....................Clutch Master Cylinder Removal ..................Clutch Master Cylinder Installation .................. Clutch Master Cylinder Disassembly ................Clutch Master Cylinder Assembly ..................Clutch Master Cylinder Inspection ..................
  • Page 310: Exploded View

    6-2 CLUTCH Exploded View http://mototh.com...
  • Page 311 CLUTCH 6-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Clutch Lever Pivot Bolt 0.10 8.9 in·lb Clutch Lever Pivot Bolt Locknut 0.60 52 in·lb Clutch Master Cylinder Bleed Valve 0.80 69 in·lb Clutch Reservoir Cap Screws 0.15 13 in·lb Clutch Reservoir Mounting Bolt 0.80 70 in·lb...
  • Page 312: Specifications

    6-4 CLUTCH Specifications Item Standard Service Limit Clutch Fluid Grade DOT4 – – – Clutch Lever – – – Clutch Lever Position 5-way adjustable (to suit rider) – – – Clutch Lever Free Play Non-adjustable – – – Clutch 2.92 ∼ 3.08 mm (0.115 ∼ 0.121 in.) Friction Plate Thickness 2.7 mm (0.106 in.) (13088-0031)
  • Page 313: Special Tools And Sealant

    CLUTCH 6-5 Special Tools and Sealant Inside Circlip Pliers: Clutch Holder: 57001-143 57001-1243 Clutch Spring Compressor: Kawasaki Bond (Silicone Sealant): 57001-1162 92104-0004 http://mototh.com...
  • Page 314: Clutch Master Cylinder

    6-6 CLUTCH Clutch Master Cylinder Clutch Lever Adjustment ○ The adjuster has 5 positions so that the clutch lever posi- tion can be adjusted to suit the operator’s hand. • Push the lever forward and turn the adjuster [A] to align the number with the triangular mark [B] on the lever holder.
  • Page 315: Clutch Master Cylinder Disassembly

    CLUTCH 6-7 Clutch Master Cylinder Clutch Master Cylinder Disassembly • Refer to the Clutch Master Cylinder Cap and Dust Seal Replacement in the Periodic Maintenance chapter. Clutch Master Cylinder Assembly • Refer to the Clutch Master Cylinder Cap and Dust Seal Replacement in the Periodic Maintenance chapter.
  • Page 316: Clutch Slave Cylinder

    6-8 CLUTCH Clutch Slave Cylinder Clutch Slave Cylinder Removal • Remove: Left Rear Middle Fairing (see Middle Fairing Removal in the Frame chapter) Left Lower Fairing (see Lower Fairing Removal in the Frame chapter) Banjo Bolt [A] Clutch Slave Cylinder Bolts [B] Slave Cylinder [C] CAUTION Immediately wash away any clutch fluid that spills.
  • Page 317: Clutch Slave Cylinder Disassembly

    CLUTCH 6-9 Clutch Slave Cylinder • Apply a non-permanent locking agent to the threads of the slave cylinder bolts [A]. • Finger tighten all the clutch slave cylinder bolts. • Remove the band from the clutch lever and release the clutch lever.
  • Page 318: Clutch Fluid

    6-10 CLUTCH Clutch Fluid Clutch Fluid Level Inspection • Refer to the Clutch Fluid Level Inspection in the Periodic Maintenance chapter (see Clutch Fluid Level Inspection in the Periodic Maintenance chapter). Clutch Fluid Change • Refer to the Clutch Fluid Change in the Periodic Mainte- nance chapter (see Clutch Fluid Change in the Periodic Maintenance chapter).
  • Page 319: Clutch Hose Removal/installation

    CLUTCH 6-11 Clutch Fluid • Bleed the clutch line and the master cylinder. ○ Repeat this operation until no more air can be seen com- ing out into the plastic hose. 1. Pump the clutch lever until it becomes hard, and apply the clutch lever and hold it [C].
  • Page 320: 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): 92104-0004 • Replace the clutch cover gasket with a new one. •...
  • Page 321: Clutch Removal

    CLUTCH 6-13 Clutch Clutch Removal • Remove: Right Lower Fairing (see Lower Fairing Removal in the Frame chapter) Clutch Cover (see Clutch Cover Removal) Clutch Spring Bolts [A] with Spring Holder Clutch Springs Clutch Spring Plate [B] (with thrust bearing and washer [C]) •...
  • Page 322: Clutch Installation

    6-14 CLUTCH Clutch • Pull out the sleeve [B] from the clutch housing [D], and remove the housing. ○ If the sleeve does not pull out easily, insert M4 bolts [A] into the threaded hole of the sleeve, and pull out the sleeve and needle bearing [C].
  • Page 323 CLUTCH 6-15 Clutch • Install the spacer [A] and clutch shaft [B]. ○ Install the clutch shaft so that the tooth side faces [C] in. • If the sub clutch hub bolts was removed, install it. ○ Apply a non-permanent locking agent to the threads of the sub clutch hub bolts, and tighten it.
  • Page 324 6-16 CLUTCH Clutch ○ Install the friction plates (between the first and outer-end friction plate), that has notches [A] among others. ○ Install outer-end friction plate, that has the thin thickness body [A] among others [B]. • Install the last friction plate [A] fitting the tangs in the grooves in the housing as shown.
  • Page 325: Clutch Hub Disassembly

    CLUTCH 6-17 Clutch Clutch Hub Disassembly • Remove the clutch hub (see Clutch Removal). • Using a press [A], and the clutch spring compressor [B], push the damper spring holder [C] to remove the retaining ring [D]. Special Tool - Clutch Spring Compressor: 57001-1162 •...
  • Page 326: Spring Plate Free Play Adjustment

    6-18 CLUTCH Clutch • Engage the clutch hub with the sub clutch hub. • To measure the free play, set a dial gauge [A] against the raised center [B] of the clutch spring plate. • Move the clutch housing gear back and forth [C]. The dif- ference between the highest and lowest gauge readings is the amount of free play.
  • Page 327: Clutch Plate Assembly Length (reference Information)

    CLUTCH 6-19 Clutch Clutch Plate Assembly Length (Reference Information) • Inspect the friction plate thickness (see Clutch Plate, Wear, Damage Inspection). • Assemble: Clutch Hub [A] Friction Plates [B] Steel Plates [C] Sub Clutch Hub [D] Spring Plate [E] Clutch Spring [F] Spring Holder [G] Spring Bolts [H] Clutch Hub Bolts [I]...
  • Page 328: Clutch Spring Free Length Measurement

    6-20 CLUTCH Clutch Clutch Spring Free Length Measurement • Measure the free length of the clutch springs [A]. If any spring is shorter than the service limit, it must be replaced. Clutch Spring Free Length Standard: 65.0 mm (2.56 in.) Service Limit: 62.0 mm (2.44 in.) Damper Cam Inspection •...
  • Page 329 ENGINE LUBRICATION SYSTEM 7-1 Engine Lubrication System Table of Contents Exploded View........................Engine Oil Flow Chart......................Specifications ......................... Special Tools and Sealant ...................... Engine Oil and Oil Filter......................Oil Level Inspection......................Engine Oil Change......................Oil Filter Replacement ...................... Oil Pan............................ 7-10 Oil Pan Removal .......................
  • Page 330: Exploded View

    7-2 ENGINE LUBRICATION SYSTEM Exploded View http://mototh.com...
  • Page 331: Engine Lubrication System

    G: Apply grease. L: Apply a non-permanent locking agent. MO: Apply molybdenum disulfide oil. (mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 : 1) R: Replacement Parts SS: Apply silicone sealant (Kawasaki Bond: 56019-120). http://mototh.com...
  • Page 332: Engine Oil Flow Chart

    7-4 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart http://mototh.com...
  • Page 333 ENGINE LUBRICATION SYSTEM 7-5 Engine Oil Flow Chart http://mototh.com...
  • Page 334 7-6 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart http://mototh.com...
  • Page 335: Specifications

    ENGINE LUBRICATION SYSTEM 7-7 Specifications Item Standard Engine Oil Type API SE, SF or SG API SH, SJ or SL with JASO MA Viscosity SAE 10W-40 Capacity 4.0 L (4.2 US gt) (when filter is not removed) 4.4 L (4.7 US gt) (when filter is removed) 4.7 L (5.0 US gt) (when engine is completely dry) Level Between upper and lower level lines...
  • Page 336: Special Tools And Sealant

    7-8 ENGINE LUBRICATION SYSTEM Special Tools and Sealant Oil Pressure Gauge, 10 kgf/cm²: Oil Filter Wrench: 57001-164 57001-1249 Oil Pressure Gauge Adapter, PT3/8 × 19/in.: Kawasaki Bond (Silicone Sealant): 57001-1233 56019-120 http://mototh.com...
  • Page 337: Engine Oil And Oil Filter

    ENGINE LUBRICATION SYSTEM 7-9 Engine Oil and Oil Filter WARNING Motorcycle operation with insufficient, deteri- orated, or contaminated engine oil will cause accelerated wear and may result in engine or trans- mission seizure, accident, and injury. Oil Level Inspection • Check that the engine oil level is between the upper [A] and lower [B] levels in the gauge.
  • Page 338: Oil Pan

    7-10 ENGINE LUBRICATION SYSTEM Oil Pan Oil Pan Removal • Remove: Engine Oil (Drain, see Engine Oil Change in the Periodic Maintenance chapter) Muffler Bodies (see Muffler Body Removal/Installation in the Engine Top End chapter) Exhaust Pipe (see Exhaust Pipe Removal in the Engine Top End chapter) •...
  • Page 339 ENGINE LUBRICATION SYSTEM 7-11 Oil Pan • Replace the O-rings with new ones. • Apply grease the oil pipe O-rings [A] and install the oil pipes [B]. If the oil pressure relief valve [C] was removed, install it (see Oil Pressure Relief Valve Installation). •...
  • Page 340: Oil Pressure Relief Valve

    7-12 ENGINE LUBRICATION SYSTEM Oil Pressure Relief Valve Oil Pressure Relief Valve Removal • Remove: Oil Pan (see Oil Pan Removal) Oil Pipe (see Oil Pan Removal) • Hold the pipe [A] in a vise [B]. • Remove the oil pressure relief valve [C]. Oil Pressure Relief Valve Installation •...
  • Page 341: Oil Pump

    ENGINE LUBRICATION SYSTEM 7-13 Oil Pump Oil Pump Removal • Drain: Engine Oil (see Engine Oil Change in the Periodic Main- tenance chapter) • Remove: Clutch (see Clutch Removal in the Clutch chapter) Oil Pump Cover Bolts [A] Oil Pump Cover [B] Oil Pump Drive Gear Shaft [C] Outer Rotor Inner Rotor...
  • Page 342 7-14 ENGINE LUBRICATION SYSTEM Oil Pump • After tighten tightening the cover bolts [A], check the fol- lowing. ○ Oil pump drive gear turn freely [B]. Torque - Oil Pump Cover Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) http://mototh.com...
  • Page 343: Oil Cooler

    ENGINE LUBRICATION SYSTEM 7-15 Oil Cooler Oil Cooler Removal • Remove: Left Lower Fairings (see Lower Fairing Removal in the Frame chapter) • Drain: Coolant (see Coolant Change in the Periodic Mainte- nance chapter) Engine Oil (see Engine Oil Change in the Periodic Main- tenance chapter) •...
  • Page 344: Oil Pressure Measurement

    7-16 ENGINE LUBRICATION SYSTEM Oil Pressure Measurement Oil Pressure Measurement • Remove the left lower fairing (see Lower Fairing Removal in the Frame chapter). • Remove the oil passage plug, and attach the adapter [A] and gauge [B] to the plug hole. Special Tools - Oil Pressure Gauge, 10 kgf/cm²: 57001-164 Oil Pressure Gauge Adapter, PT3/8 ×...
  • Page 345: 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 [A] as shown.
  • Page 346: Vvt (variable Valve Taiming)

    7-18 ENGINE LUBRICATION SYSTEM VVT (Variable Valve Taiming) Oil Pipe Removal • Drain the engine oil (see Engine Oil Change in the Peri- odic Maintenance chapter). • Remove: Right Middle Fairings (see Middle Fairing Removal in the Frame chapter) Lower Fairing (see Lower Fairing Removal in the Frame chapter) Bolt [A] •...
  • Page 347: Oil Control Solenoid Valve Installation

    ENGINE LUBRICATION SYSTEM 7-19 VVT (Variable Valve Taiming) Oil Control Solenoid Valve Installation • Install the gasket [A] as shown. Cylinder Head Mating Surface [B] • Tighten the bolts. Torque - Oil Control Solenoid Valve Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) Variable Valve Taiming Actuator Removal/Instal- lation •...
  • Page 348 http://mototh.com...
  • Page 349 ENGINE REMOVAL/INSTALLATION 8-1 Engine Removal/Installation Table of Contents Exploded View........................Engine Removal/Installation ....................Engine Removal........................ Engine Installation......................http://mototh.com...
  • Page 350: Exploded View

    8-2 ENGINE REMOVAL/INSTALLATION Exploded View http://mototh.com...
  • Page 351 ENGINE REMOVAL/INSTALLATION 8-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Engine Mounting Nuts (M12) Adjusting Collars Front Engine Mounting Bolts (M10) S, R Engine Bracket Bolts (M8) S, R Subframe Bolts M: Apply molybdenum sulfide grease. R: Replacement Parts S: Follow the specified tightening sequence.
  • Page 352: Engine Removal/installation

    8-4 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation Engine Removal • Support the rear part of the swingarm with a stand. • Squeeze the brake lever slowly and hold it with a band [A]. WARNING Be sure to hold the front brake when removing the engine, or the motorcycle may fall over.
  • Page 353 ENGINE REMOVAL/INSTALLATION 8-5 Engine Removal/Installation • Remove: Pad [A] Right Heat Insulation Cover [B] (see Fairing Bracket Re- moval in the Frame chapter) Right Subframe [C] (see Subframe Removal in the Frame chapter) Bolts [D] Right Engine Bracket [E] Ground Terminals [F] •...
  • Page 354 8-6 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Disconnect: Fuel Hose [A] on the Delivery Pipe • Remove: Clamp [A] Throttle Cable Lower Ends [B] • Loosen the clamp bolts [C] and pull the ducts [D] upward. • Support the engine with a suitable stand [A]. ○...
  • Page 355: Engine Installation

    ENGINE REMOVAL/INSTALLATION 8-7 Engine Removal/Installation • Remove the starter motor cable terminal nut [A]. • Using the stand, take out the engine. Engine Installation • Support the engine with a suitable stand. ○ Put a plank onto the suitable stand for engine balance. •...
  • Page 356 8-8 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation A: After installation, set the projection in the hole. B: To Water Temperature Sensor C: To Breather Hose D: To Throttle Body Subharness Bracket E: To throttle Body Holder F: To Throttle Pulley G: To Inlet Cam Position Sensor H: To Air Suction Valve and Stick Coils I: Only put the heat insulation rubber plate on the cylinder head cover.
  • Page 357 ENGINE REMOVAL/INSTALLATION 8-9 Engine Removal/Installation • Before installing the engine. Confirm the routing of the water temperature sensor lead [A] and inlet camshaft po- sition sensor lead [B]. ○ Run [C] the water temperature sensor lead of the sub- harness between the #3 and #4 throttle body holders and connect the water temperature sensor body.
  • Page 358 8-10 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation ○ Secondly, insert the mounting bolts [A] until they fit [B] in the adjusting collars [C]. ○ Be sure that the collar [D] is in position. NOTE ○ Replace the following bolts with new bolts pre-coated with locking agent.
  • Page 359 ENGINE REMOVAL/INSTALLATION 8-11 Engine Removal/Installation ○ Fifthly, tighten the left engine bracket bolts [A]. ○ Sixthly, tighten the upper engine mounting nut [B] and then the lower engine mounting nut [C]. ○ Seventhly, install the right engine bracket and tighten the right engine bracket bolts [D] and the right front engine mounting bolt [E].
  • Page 360 8-12 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Run the leads, cable and hoses correctly (see Cable, Wire, and Hose Routing section in the Appendix chap- ter). • Install the removed parts (see appropriate chapters). • Adjust: Throttle Cables (see Throttle Control System Inspection in the Periodic Maintenance chapter) •...
  • Page 361 CRANKSHAFT/TRANSMISSION 9-1 Crankshaft/Transmission Table of Contents Exploded View........Rear Balancer Removal....9-31 Specifications ........Rear Balancer Installation.... 9-32 Special Tools and Sealants ....Balancer Adjustment....9-33 Crankcase Splitting......9-10 Balancer Damper Inspection..9-34 Crankcase Splitting ...... 9-10 Starter Motor Clutch and Torque Crankcase Assembly ....
  • Page 362: Exploded View

    9-2 CRANKSHAFT/TRANSMISSION Exploded View http://mototh.com...
  • Page 363 27. Do not apply any grease or oil. G: Apply grease. L: Apply a non-permanent locking agent. LG: Apply liquid gasket (Kawasaki Bond: 92104-1064). M: Apply molybdenum disulfide grease. MO: Apply molybdenum disulfide oil. (mixture of engine oil and molybdenum disulfide grease in a weight ratio is 10 : 1) R: Replacement Parts S: Follow the specified tightening sequence.
  • Page 364 9-4 CRANKSHAFT/TRANSMISSION Exploded View http://mototh.com...
  • Page 365 CRANKSHAFT/TRANSMISSION 9-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Balancer Shaft Clamp Bolts 87 in·lb Balancer Shaft Clamp Lever Bolts Starter Clutch Shaft Bolt 87 in·lb Starter Clutch Shaft Plate Bolt 87 in·lb Torque Limiter Bolt Shift Drum Cam Holder Bolt 106 in·lb Gear Position Switch Screws 0.30...
  • Page 366: Specifications

    9-6 CRANKSHAFT/TRANSMISSION Specifications Item Standard Service Limit Crankcase, Crankshaft, Connecting Rods Connecting Rod Bend – – – TIR 0.2/100 mm (0.008/3.94 in.) Connecting Rod Twist – – – TIR 0.2/100 mm (0.008/3.94 in.) 0.13 ∼ 0.38 mm Connecting Rod Big End Side 0.58 mm (0.0051 ∼...
  • Page 367 CRANKSHAFT/TRANSMISSION 9-7 Specifications Item Standard Service Limit ○ 41.000 ∼ 41.008 mm Marking – – – (1.6142 ∼ 1.6145 in.) 41.009 ∼ 41.016 mm None – – – (1.6145 ∼ 1.6148 in.) Crankshaft Main Bearing Insert Thickness: 1.490 ∼ 1.494 mm Brown –...
  • Page 368 9-8 CRANKSHAFT/TRANSMISSION Specifications Connecting Rod Big End Bearing Insert Selection Bearing Insert Con-rod Big End Bore Crankpin Diameter Diameter Marking Marking Size Color Part Number ○ None Brown 92139-0131 None None Black 92139-0130 ○ ○ ○ None Blue 92139-0129 Crankshaft Main Bearing Insert Selection Crankcase Main Crankshaft Main Bearing Insert...
  • Page 369: Special Tools And Sealants

    CRANKSHAFT/TRANSMISSION 9-9 Special Tools and Sealants Piston Ring Compressor Belt, 80 ∼ 91: Bearing Puller: 57001-135 57001-1320 Bearing Puller Adapter: Kawasaki Bond (Silicone Sealant): 57001-317 56019-120 Piston Pin Puller Assembly: Kawasaki Bond: 57001-910 92104-1064 Piston Ring Compressor Grip: 57001-1095 http://mototh.com...
  • Page 370: Crankcase Splitting

    9-10 CRANKSHAFT/TRANSMISSION Crankcase Splitting Crankcase Splitting • Remove the engine (see Engine Removal/Installation in the Engine Removal/Installation chapter). • Set the engine on a clean surface and hold the engine steady while parts are being removed. • Remove: Clutch (see Clutch Removal in the Clutch chapter) Starter Motor Clutch (see Starter Motor Clutch Removal) Oil Pump (see Oil Pump Removal in the Engine Lubri- cation System chapter)
  • Page 371: Crankcase Assembly

    CRANKSHAFT/TRANSMISSION 9-11 Crankcase Splitting ○ Next, loosen the M10 Bolts [1 ∼10] (sequence numbers). • Tap lightly around the crankcase mating surface with a plastic mallet, and split the crankcase. Take care not to damage the crankcase. If the crankshaft is to be removed [A], remove the pistons (see Piston Removal).
  • Page 372 9-12 CRANKSHAFT/TRANSMISSION Crankcase Splitting • Install the new drive shaft bearing [A] so that its stepped side [B] faces as shown using a press. • Install the bearing plate [A] with the screws [B]. ○ Install the plate so that the stepped hole side [C] faces outside.
  • Page 373 [A]. • Apply liquid gasket [A] to the mating surface of the lower crankcase half. Sealant - Kawasaki Bond: 92104-1064 NOTE ○ Aster tightening the crankcase bolts, wipe up the liquid gasket seeping out the output shaft bearing hole [D].
  • Page 374 9-14 CRANKSHAFT/TRANSMISSION Crankcase Splitting • Tighten the lower crankcase bolts using the following steps. ○ Following the sequence numbers on the lower crankcase half, tighten the M10 bolts [1 ∼ 10] with washers. Torque - Crankcase Bolts (M10): 47 N·m (4.8 kgf·m, 35 ft·lb) ○...
  • Page 375: Crankshaft And Connecting Rods

    CRANKSHAFT/TRANSMISSION 9-15 Crankshaft and Connecting Rods Crankshaft Removal • Split the crankcase (see Crankcase Splitting). • Remove the crankshaft (see Connecting Rod Removal). Crankshaft Installation CAUTION If the crankshaft, bearing inserts, or crankcase halves are replaced with new ones, select the bear- ing inserts and check clearance with a plastigage (press gauge) before assembling engine to be sure the correct bearing inserts are installed.
  • Page 376: Connecting Rod Removal

    9-16 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods Connecting Rod Removal • Split the crankcase (see Crankcase Splitting). • Remove the connecting rod nuts [A]. • Remove the crankshaft. NOTE ○ Mark and record the locations of the connecting rods and their big end caps so that they can be reassembled in their original positions.
  • Page 377 CRANKSHAFT/TRANSMISSION 9-17 Crankshaft and Connecting Rods • Install the crankshaft (see Crankshaft Installation). • Install each connecting rod on its original crankpin. ○ The connecting rod big end is bolted using the “plastic region fastening method”. ○ This method precisely achieves the needed clamping force without exceeding it unnecessarily, allowing the use of thinner, lighter bolts further decreasing connecting rod weight.
  • Page 378 9-18 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods • Install new bolts in reused connecting rods. • Dent both bolt head and bolt tip with a punch as shown. • Before tightening, use a point micrometer to measure the length of new connecting rod bolts and record the values to find the bolt stretch.
  • Page 379: Crankshaft/connecting Rod Cleaning

    CRANKSHAFT/TRANSMISSION 9-19 Crankshaft and Connecting Rods • Install new bolts in reused connecting rods. • Apply a small amount of molybdenum disulfide oil to the following. Threads [A] of Bolts Seating Surfaces [B] of Nuts on the Connecting Rods • First, tighten the nuts to the specified torque.
  • Page 380: Connecting Rod Twist

    9-20 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods Connecting Rod Twist • With the big-end arbor [A] still on V block [C], hold the connecting rod horizontally and measure the amount that the arbor [B] varies from being paralleled with the surface plate over a 100 mm (3.94 in.) length of the arbor to de- termine the amount of connecting rod twist.
  • Page 381 CRANKSHAFT/TRANSMISSION 9-21 Crankshaft and Connecting Rods If the clearance is within the standard, no bearing replace- ment is required. If the clearance is between 0.087 mm (0.0034 in.) and the service limit (0.12 mm, 0.0047 in.), replace the bear- ing inserts [A] with inserts painted blue [B]. Check in- sert/crankpin clearance with the plastigage.
  • Page 382: Crankshaft Side Clearance

    9-22 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods • Select the proper bearing insert [A] in accordance with the combination of the connecting rod and crankshaft coding. Size Color [B] Con-rod Big Crankpin Bearing Insert End Inside Diameter Diameter Marking Size Color Part Number Marking ○...
  • Page 383: Crankshaft Runout

    CRANKSHAFT/TRANSMISSION 9-23 Crankshaft and Connecting Rods • Measure the crankshaft #3 main journal width [A]. If the measurement exceeds the standard, replace the crankshaft [B]. Crankshaft #3 Main Journal Width 27.45 ∼ 27.50 mm (1.0807 ∼ 1.0827 in.) Standard: Crankshaft Runout •...
  • Page 384 9-24 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods Crankshaft Main Journal Diameter 37.984 ∼ 38.000 mm (1.4954 ∼ 1.4961 in.) Standard: Service Limit: 37.96 mm (1.4945 in.) If any journal has worn past the service limit, replace the crankshaft with a new one. If the measured journal diameters are not less than the service limit, but do not coincide with the original diameter markings on the crankshaft, make new marks on it.
  • Page 385 CRANKSHAFT/TRANSMISSION 9-25 Crankshaft and Connecting Rods Bearing Insert Crankcase Main Bearing Crankshaft Main Journal Inside Diameter Marking Diameter Marking Size Color Part Number Journal Nos. 92139-0134 1, 3, 5 ○ Brown 92139-0137 2, 4 None 92139-0133 1, 3, 5 Black ○...
  • Page 386: Pistons

    9-26 CRANKSHAFT/TRANSMISSION Pistons Piston Removal • Split the crankcase (see Crankcase Splitting). • Remove the connecting rod nuts [A]. • Remove the connecting rod big end caps. • Remove the crankshaft. • Remove the piston [A] with connecting rod to the cylinder head side.
  • Page 387: Piston Installation

    CRANKSHAFT/TRANSMISSION 9-27 Pistons Piston Installation • Apply molybdenum disulfide oil solution to the oil ring ex- pander, and install the oil ring expander [A] in the bottom piston ring groove so the ends [B] butt together. • Apply molybdenum disulfide oil solution to the oil ring steel rails, and install the oil ring steel rails, one above the ex- pander and one below it.
  • Page 388: Cylinder Wear (upper Crankcase)

    9-28 CRANKSHAFT/TRANSMISSION Pistons • Install the piston with its marking IN [A] facing inlet side. • Using the piston ring compressor assy [B] to install the piston from the cylinder head side. Special Tools - Piston Ring Compressor Grip: 57001-1095 80 ∼...
  • Page 389: Piston Ring Groove Width

    CRANKSHAFT/TRANSMISSION 9-29 Pistons Piston Ring Groove Width • Measure the piston ring groove width. ○ Use a vernier caliper at several points around the piston. Piston Ring Groove Width Standard: 0.92 ∼ 0.94 mm (0.0362 ∼ 0.0370 in.) Top [A] 1.01 ∼...
  • Page 390: Balancer

    9-30 CRANKSHAFT/TRANSMISSION Balancer Front Balancer Removal • Remove: Engine (see Engine Removal in the Engine Removal/In- stallation chapter) • Unscrew: Balancer Shaft Clamp Bolt [A] Balancer Shaft Clamp Lever Bolt [B] Balancer Shaft Clamp Lever [C] • Split the crankcase (see Crankcase Splitting). •...
  • Page 391: Rear Balancer Removal

    CRANKSHAFT/TRANSMISSION 9-31 Balancer • Insert the pin [A] as shown. • Set the front balancer on the upper crankcase half. ○ Align the punch mark [B] on the balancer gear [C] with the mark [D] (crankshaft at 2, 3 position TDC) on the balancer drive gear [E] of crankshaft.
  • Page 392: Rear Balancer Installation

    9-32 CRANKSHAFT/TRANSMISSION Balancer • Unscrew the balancer shaft clamp lever bolt [A]. • Pry off the clamp lever [A] until the oil seal [B] removed. • Pull the balancer shaft [C] out of the crankcase. The bal- ancer weight and gear assembly [D] come off with needle bearings and copper washers.
  • Page 393: Balancer Adjustment

    CRANKSHAFT/TRANSMISSION 9-33 Balancer • Position the crankshaft at # 2, 3 position TDC or at # 1, 4 position TDC. • Aligin the mark [A] on the balancer gear [B] with the mat- ing surface [C] of the upper crankcase half. •...
  • Page 394: Balancer Damper Inspection

    9-34 CRANKSHAFT/TRANSMISSION Balancer Balancer Damper Inspection • Remove the balancer and disassemble the weight and gear assembly. • Visually inspect the rubber dampers [A]. If they appear damaged or deteriorated, replace them. http://mototh.com...
  • Page 395: Starter Motor Clutch And Torque Limiter

    CRANKSHAFT/TRANSMISSION 9-35 Starter Motor Clutch and Torque Limiter Starter Motor Clutch Removal • Remove: Engine (see Engine Removal in the Engine Removal/In- stallation chapter) Starter Motor (see Starter Motor Removal in the Electri- cal System chapter) Rear Balancer (see Rear Balancer Removal) •...
  • Page 396: Starter Motor Clutch Assembly

    9-36 CRANKSHAFT/TRANSMISSION Starter Motor Clutch and Torque Limiter • Holding the drive gear [A] with a hand, take off the one -way clutch [B] from the gear by using the screw driver [C]. Starter Motor Clutch Assembly • Be sure to install the one-way clutch [A] so that its arrow [B] faces the side of the flat washer.
  • Page 397: Torque Limiter Installation

    CRANKSHAFT/TRANSMISSION 9-37 Starter Motor Clutch and Torque Limiter • Holding the torque limiter [A], remove the torque limiter shaft [B] and the torque limiter. Torque Limiter Installation • Replace the washer with a new one. • Apply molybdenum disulfide grease to the torque limiter shaft and tooths.
  • Page 398: Transmission

    9-38 CRANKSHAFT/TRANSMISSION Transmission Shift Pedal Removal • Remove: Shift Lever Bolt [A] Shift Lever [B] • Remove: Shift Pedal Mounting Bolt [A] Shift Pedal [B] with Tie-rod [C] Shift Pedal Installation • Tighten: Torque - Shift Pedal Mounting Bolt [A]: 25 N·m (2.5 kgf·m, 18 ft·lb) Footpeg Bracket [B] Shift Pedal [C]...
  • Page 399: External Shift Mechanism Removal

    CRANKSHAFT/TRANSMISSION 9-39 Transmission External Shift Mechanism Removal • Remove: Bolt [A] Shift Lever [B] Snap Ring [C] Washer [D] Clutch (see Clutch Removal in the Clutch chapter) • Remove the shift shaft assembly [A]. • Remove: Gear Positioning Lever Bolt [A] Gear Positioning Lever [B] Collar Spring [C] •...
  • Page 400: External Shift Mechanism Inspection

    9-40 CRANKSHAFT/TRANSMISSION Transmission • Install the gear positioning lever [A] as shown. Spring [B] Collar [C] Bolt [D] • Tighten: Torque - Gear Positioning Lever Bolt: 12 N·m (1.2 kgf·m, 106 in·lb) • Be sure to install the washer [A]. •...
  • Page 401: Transmission Shaft Removal

    CRANKSHAFT/TRANSMISSION 9-41 Transmission Transmission Shaft Removal • Split the crankcase (see Crankcase Splitting). • Remove the output shaft [A]. • Remove the shift forks (see Shift Drum and Fork Re- moval). • Remove the cover bolts [A] and cover [B]. •...
  • Page 402: Transmission Shaft Disassembly

    9-42 CRANKSHAFT/TRANSMISSION Transmission Transmission Shaft Disassembly • Remove the transmission shafts (see Transmission Shaft Removal). • Remove the circlips, disassemble the transmission shafts. • The 5th gear [A] on the output shaft has three steel balls assembled into it for the positive neutral finder mecha- nism.
  • Page 403 CRANKSHAFT/TRANSMISSION 9-43 Transmission • Fit the steel balls into the 5th gear holes in the output shaft, aligning three oil holes [D]. 5th Gear [A] Output Shaft [B] Steel Balls [C] CAUTION Do not apply grease to the balls to hold them in place.
  • Page 404 9-44 CRANKSHAFT/TRANSMISSION Transmission 1. Drive Shaft 15. Output Shaft 2. Circlip, 33 mm (1.30 in.) 16. Needle Bearing 3. 2nd Gear 17. Dumper Cam Nut 4. Toothed Washer, 37 mm (1.46 in.) 18. Dumper Cam 5. Toothed Washer, 40.5 mm (1.59 in.) 19.
  • Page 405: Shift Drum And Fork Removal

    CRANKSHAFT/TRANSMISSION 9-45 Transmission Shift Drum and Fork Removal • Remove: Lower Crankcase Half (see Crankcase Splitting) External Shift Mechanism (see External Shift Mecha- nism Removal) Screws [A] Shift Drum Bearing Holder [B] • Pull out the shift rods [C], and take off the shift forks. •...
  • Page 406: Shift Drum Assembly

    9-46 CRANKSHAFT/TRANSMISSION Transmission Shift Drum Assembly • Be sure to install the dowel pin. • Apply a non-permanent locking agent to the threads of the shift drum cam holder bolt, and tighten it. Torque - Shift Drum Cam Holder Bolt: 12 N·m (1.2 kgf·m, 106 in·lb) Shift Fork Bending •...
  • Page 407: Gear Dog And Gear Dog Hole Damage

    CRANKSHAFT/TRANSMISSION 9-47 Transmission Gear Dog and Gear Dog Hole Damage • Visually inspect the gear dogs [A] and gear dog holes [B]. Replace any damaged gears or gears with excessively worn dogs or dog holes. http://mototh.com...
  • Page 408 http://mototh.com...
  • Page 409 WHEELS/TIRES 10-1 Wheels/Tires Table of Contents Exploded View........................10-2 Specifications ......................... 10-4 Special Tools .......................... 10-5 Wheels (Rims) ........................10-6 Front Wheel Removal ....................... 10-6 Front Wheel Installation ....................10-6 Rear Wheel Removal......................10-7 Rear Wheel Installation..................... 10-8 Wheel Coupling Removal ....................10-10 Wheel Coupling Installation ....................
  • Page 410: Exploded View

    10-2 WHEELS/TIRES Exploded View http://mototh.com...
  • Page 411 WHEELS/TIRES 10-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Axle Clamp Bolts Front Axle Nut 13.0 93.7 Front Tire Pressure Measurement Sensor Bolt 0.46 40 in·lb Rear Axle Nut 13.0 93.7 Rear Tire Pressure Measurement Sensor Bolt 0.46 40 in·lb 6.
  • Page 412: Specifications

    10-4 WHEELS/TIRES Specifications Item Standard Service Limit Wheels (Rims) Rim Runout: Axial TIR 0.5 mm (0.02 in.) or less TIR 1.0 mm (0.04 in.) Radial TIR 0.8 mm (0.03 in.) or less TIR 1.0 mm (0.04 in.) Axle Runout/100 mm (3.94 in.) TIR 0.03 mm (0.0012 in.) or less TIR 0.2 mm (0.01 in.) Wheel Balance 10 g (0.35 oz.) or less...
  • Page 413: 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 Bearing Remover Head, 20 × 22: 57001-1293 http://mototh.com...
  • Page 414: Wheels (rims)

    10-6 WHEELS/TIRES Wheels (Rims) Front Wheel Removal • Remove: Front Caliper Mounting Bolts [A] Front Calipers [B] Front Fender [C] (see Front Fender Removal in the Frame chapter) ○ For the ZG1400A Models, remove the bolts [D] and rota- tion sensor [E]. •...
  • Page 415: Rear Wheel Removal

    WHEELS/TIRES 10-7 Wheels (Rims) • Apply high-temperature grease to the grease seal lip. • Fit the collars [A] on the both sides of the hub. ○ The collars are identical. • Insert the axle from the right side. • Tighten the axle nut [B]. Right Axle Clamp Bolts [C] Left Axle Clamp Bolts [D] Viewed from Rear [E]...
  • Page 416: Rear Wheel Installation

    10-8 WHEELS/TIRES Wheels (Rims) • Remove: Saddlebags (see Rear Caliper Mounting Bolts [A] Rear Caliper [B] Caliper Bracket Bolt [C] • For the ZG1400A Models, remove the bolts [D] and rear wheel rotation sensor [E]. • Remove: Cotter Pin [A] Axle Nut [B] Washer [C] Caliper Bracket [D]...
  • Page 417 WHEELS/TIRES 10-9 Wheels (Rims) • Pull the axle little and install the caliper bracket [A]. • Temporary install the caliper bracket bolt. • Tighten: Torque - Rear Axle Nut: 127 N·m (13.0 kgf·m, 94 ft·lb) Caliper Bracket Bolt: 64 N·m (6.5 kgf·m, 47 ft·lb) •...
  • Page 418: Wheel Coupling Removal

    10-10 WHEELS/TIRES Wheels (Rims) Wheel Coupling Removal • Remove the rear wheel (see Rear Wheel Removal). • Remove the coupling retaining ring [A]. • Remove the wheel coupling [B] with a bearing puller if necessary. Wheel Coupling Installation • Replace the O-ring [A] and the retaining ring [B]. •...
  • Page 419: Axle Inspection

    WHEELS/TIRES 10-11 Wheels (Rims) Axle Inspection • Remove the front and rear axles (see Front/Rear Wheel Removal). • Visually inspect the front and rear axle for damages. If the axle is damaged or bent, replace it. • Place the axle in V blocks that are 100 mm (3.94 in.) [A] apart, and set a dial gauge [B] on the axle at a point halfway between the blocks.
  • Page 420: Balance Weight Removal

    30 g (1.06 oz.) NOTE ○ Balance weights are available from Kawasaki dealers in 10, 20, and 30 grams (0.35 oz., 0.71 oz., and 1.06 oz.) sizes. An imbalance of less than 10 grams (0.35 oz.) will not usually affect running stability.
  • Page 421 WHEELS/TIRES 10-13 Wheels (Rims) • Check that the blade [A] and clip [B] are fully seated on the rim [C] and that the clip is hooked over the rib [D]. Left Side [E] Right Side [F] http://mototh.com...
  • Page 422: Tires

    10-14 WHEELS/TIRES Tires Air Pressure Inspection/Adjustment • Refer to the Air Pressure Inspection in the Periodic Main- tenance chapter. Tire Inspection • Refer to the Wheel/Tire Damage Inspection in the Peri- odic Maintenance chapter. Tire Removal • Remove: Wheel (see Front/Rear Wheel Removal) Valve Core (Let out the air) •...
  • Page 423: Tire Installation

    WHEELS/TIRES 10-15 Tires ○ Pull the opposite bead of the tire [A] upward. ○ Unscrew the bolt [B] and remove the tire pressure mea- surement sensor [C], spring and air valve. ○ Step on the side of the tire opposite the air valve, and start plying the tire off the rim near the air valve with tire iron.
  • Page 424 10-16 WHEELS/TIRES Tires • Lubricate the valve seal with a soap and water solution or rubber lubricant. • Install the air valve [A] and sensor [B]. ○ Install the sensor position parallel to the rim line in either direction. Torque - Tire Pressure Measurement sensor: 4.5 N·m (0.46 kgf·m, 40 in·lb) Replacement Procedure •...
  • Page 425 WHEELS/TIRES 10-17 Tires • Install the tire bead over the rim flange using a suitable commercially available tire changer. ○ Install the beads of the tire onto the rim followings the steps shown. Tire pressure measurement sensor [A] Opposite side of rim (180° from sensor) [B] Push on the first bead following direction shown in steps 1 and 2 Push on the second bead following direction shown in...
  • Page 426: 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 427: Hub Bearing

    WHEELS/TIRES 10-19 Hub Bearing Hub Bearing Removal • Remove the wheel (see Front/Rear Wheel Removal), and take out the following. Collars Coupling (Out of rear hub) Grease Seals • Use the bearing remover to remove the hub bearing [A]. CAUTION Do not lay the wheel on the ground with the disc facing down.
  • Page 428: Hub Bearing Lubrication

    10-20 WHEELS/TIRES Hub Bearing Hub Bearing Lubrication NOTE ○ Since the hub bearings are packed with grease and sealed, lubrication is not required. http://mototh.com...
  • Page 429 FINAL DRIVE 11-1 Final Drive Table of Contents Exploded View........11-2 Front Gear Case Disassembly..11-25 Specifications ........11-6 Front Gear Case Assembly..11-26 Special Tools ........11-7 Driven Gear Disassembly .... 11-27 Final Gear Case and Oil ....11-9 Driven Gear Assembly ....
  • Page 430: Exploded View

    11-2 FINAL DRIVE Exploded View http://mototh.com...
  • Page 431 FINAL DRIVE 11-3 Exploded View Front Gear Case Torque Fastener Remarks N·m kgf·m ft·lb Adjuster Locknut Bearing Retainer 55.1 Bearing Retainer Screw 0.71 62 in·lb Filler Plug 0.20 18 in·lb Final Gear Case Cover Bolts (M10) Final Gear Case Cover Bolts (M8) Final Gear Case Outer Cover Bolts 87 in·lb Gear Case Oil Drain Bolt...
  • Page 432 11-4 FINAL DRIVE Exploded View http://mototh.com...
  • Page 433 FINAL DRIVE 11-5 Exploded View Final Gear Case Torque Fastener Remarks N·m kgf·m ft·lb Bearing Retainer Bolts 0.90 78 in·lb Damper Cam Nut 21.4 MO, R Driven Gear Assy Mounting Bolts Driven Gear Bolt 13.3 95.9 Drive Gear Nut 27.0 MO, S Front Gear Case Bolt (L = 50 mm) Front Gear Case Bolts (L = 95 mm)
  • Page 434: Specifications

    11-6 FINAL DRIVE Specifications Item Standard Final Gear Case Oil Grade API GL-5 hypoid gear oil Viscosity When above 5°C (41°F) SAE90 When below 5°C (41°F) SAE80 Oil level Filler opening top Amount about 160 mL (5.41 US oz.) 0.10 ∼ 0.20 mm (0.0039 ∼ 0.0079 in.) (at gear hub Final Bevel Gear Backlash splines) Preload for Pinion Gear Bearing...
  • Page 435: Special Tools

    FINAL DRIVE 11-7 Special Tools Bearing Puller: Oil Seal & Bearing Remover: 57001-158 57001-1058 Bearing Puller Adapter: Bearing Driver Set: 57001-317 57001-1129 Bearing Driver, Drive Shaft Holder, m1.25: 57001-382 57001-1702 Damper Cam Holder: Retainer Wrench: 57001-1025 57001-1703 Driven Gear Holder, m2: Base Set: 57001-1027 57001-1704...
  • Page 436 11-8 FINAL DRIVE Special Tools Bevel Gear Holder: 57001-1706 http://mototh.com...
  • Page 437: Final Gear Case And Oil

    FINAL DRIVE 11-9 Final Gear Case and Oil Oil Level Inspection • Refer to Final Gear Case Oil Level Inspection in Periodic Maintenance chapter (see Final Gear Case Oil Level In- spection in Periodic Maintenance chapter). Oil Change • Refer to Final Gear Case Oil Change in Periodic Mainte- nance chapter (see Final Gear Case Oil Change in Peri- odic Maintenance chapter).
  • Page 438: Final Gear Case Installation

    11-10 FINAL DRIVE Final Gear Case and Oil • Remove the upper side bolt. • Remove the final gear case [A] by taking off the lower bolts [B]. NOTE ○ If the final gear case is full of oil, place the case so that the breather [A] is on top, and joint portion [B] of the case is upward [C] for pervent the oil leak.
  • Page 439: Final Gear Case Disassembly

    FINAL DRIVE 11-11 Final Gear Case and Oil Final Gear Case Disassembly • Drain the oil (see Oil Change). • Remove the final gear case. • Using the hub assembly [A], remove the pinion gear as- sembly nut. ○ Insert the wooden bar [C] between the spokes. CAUTION Do not lay the wheel down on one of the discs.
  • Page 440 11-12 FINAL DRIVE Final Gear Case and Oil • Remove the sliding joint [A] with washer [B], pinion gear assembly [C] and lock plate. • Remove the lock pin and plug. • Final Gear Case Cover Bolts [A]. • Use three tapped holes [A] to lift the ring gear assy from the gear case.
  • Page 441 FINAL DRIVE 11-13 Final Gear Case and Oil ○ Remove the small ring gear oil seal if damaged. Special Tool - Oil Seal & Bearing Remover [D]: 57001-1058 • Unscrew the bearing retainer bolt [A] and washer [B]. • Pull out the needle bearing [C]. Special Tool - Oil Seal &...
  • Page 442: Final Gear Case Assembly

    11-14 FINAL DRIVE Final Gear Case and Oil Final Gear Case 1. Sliding Joint 13. Ring Gear Shim(s) 2. Pinion Gear Nut 14. Ring Gear 3. Washer 15. Ball Bearing Retainer 4. O-ring 16. Ball Bearing 5. Pin 17. Pinion Gear Shim(s) 6.
  • Page 443 FINAL DRIVE 11-15 Final Gear Case and Oil • Replace the needle bearings [A] with new ones. • Apply a hypoid gear oil to the roller parts of the needle bearings. NOTE ○ Install the bearing so that the marked side faces out. ○...
  • Page 444 11-16 FINAL DRIVE Final Gear Case and Oil • Blow the breather hole [A] in the final gear case clean with compressed air. • Install the shim(s) [A] and final gear case cover [B]. ○ Reinstall the original ring gear shim(s) to keep the gear backlash and the tooth contact unchanged.
  • Page 445: Sliding Joint Inspection

    FINAL DRIVE 11-17 Final Gear Case and Oil • Install the sliding joint [A]. • Using the hub assembly [B], tighten the pinion gear as- sembly nut. ○ Insert the wooden bar [C] between the sporks. Torque - Pinion Gear Assembly Nut: 130 N·m (13.3 kgf·m, 95.9 ft·lb) •...
  • Page 446: Backlash Adjustment

    11-18 FINAL DRIVE Final Gear Case and Oil Pinion Gear Shims for Tooth Contact Ring Gear Shims for Backlash Adjustment Adjustment Thickness (mm) Parts Number Thickness (mm) Parts Number 0.15 (0.0059 in.) 92180-0263 0.10 (0.0039 in.) 92025-1733 0.5 (0.02 in.) 92180-0264 0.15 (0.0059 in.) 92025-1734...
  • Page 447: Tooth Contact Adjustment

    FINAL DRIVE 11-19 Final Gear Case and Oil • Mount a dial gage [A] on a vise so that the tip of the gage is against the splines of the ring gear hub. • To measure the backlash, turn the ring gear hub [B] back and forth [C].
  • Page 448 11-20 FINAL DRIVE Final Gear Case and Oil • Remove the ring gear assy and pinion gear assy to check the couvex side pattern and concave side pattern of the bevel gear teeth. Good contact is achieved when the pat- tern of tooth contact is visible in the inside diameter side and center of the tooth flank.
  • Page 449: Propeller Shaft

    FINAL DRIVE 11-21 Propeller Shaft Propeller Shaft Removal • Remove: Final Gear Case (see Final Gear Case Removal) Bolts [A] • Remove the frame side bracket [B] with the footpeg [C] And shift rod [D]. • Open the clamp portion [A] and remove the band [B]. •...
  • Page 450: Propeller Shaft Installation

    11-22 FINAL DRIVE Propeller Shaft ○ Move back the propeller shaft and slip the propeller shaft off the driven gear joint while pushing on the lockpin. Propeller Shaft [A] Universal Joint [B] Lockpin [C] Spring [D] Driven Gear Joint [E] Propeller Shaft Installation •...
  • Page 451: Propeller Shaft Inspection

    FINAL DRIVE 11-23 Propeller Shaft • Pinch the clamp portion [B] of the band [B]. Propeller Shaft Inspection • Check that the universal joints [A] works smoothly without rattling or sticking. If it does not work smoothly, the needle bearings of the universal joint are damaged.
  • Page 452: Front Bevel Gears

    11-24 FINAL DRIVE Front Bevel Gears Front Gear Case Removal • Drain the coolant (see Coolant Change in the Periodic Maintenance chapter). • Remove: Propeller Shaft (see Propeller Shaft Removal) Clutch Slave Cylinder (see Clutch Slave Cylinder Re- moval in the Clutch chapter) Water Pump (see Water Pump Removal in the Cooling System chapter) •...
  • Page 453: Front Gear Case Disassembly

    FINAL DRIVE 11-25 Front Bevel Gears • Tighten the front gear case bolts to the specified torque. Bolts M8 × 92 [A] Bolts M8 × 95 [B] [F] Bolts M8 × 35 [C] [D] Bolts M8 × 50 [E] Torque - Front Gear Case Bolts: Bolts [A] [B] [E]: 29 N·m (3.0 kgf·m, 22 ft·lb) Bolts [C] [D] [F] : 20 N·m (2.0 kgf·m, 15 ft·lb) ○...
  • Page 454: Front Gear Case Assembly

    11-26 FINAL DRIVE Front Bevel Gears ○ Unscrew the drive gear nut [A] while holding the drive gear shaft with the drive gear holder [B]. Front Gear Case [C] Vise [D] Special Tool - Drive Gear Holder, m1.25: 57001-1702 • Pull off the drive gear shaft [A], the drive gear [B], and shim(s) [C].
  • Page 455: Driven Gear Disassembly

    FINAL DRIVE 11-27 Front Bevel Gears ○ Stake [A] the nut [B] to secure it in place. CAUTION When staking the nut, be careful not to apply shock to the shaft and its bearing. Such a shock could damage the shaft and/or bearing. •...
  • Page 456: Driven Gear Assembly

    11-28 FINAL DRIVE Front Bevel Gears Driven Gear Assembly • Replace the driven gear bolt with a new one. ○ The drive and driven gears are lapped as a set at the fac- tory to get the best tooth contact. They must be replaced as a set.
  • Page 457: Damper Cam Installation

    FINAL DRIVE 11-29 Front Bevel Gears Damper Cam Installation • Replace the damper cam nut with a new one. • Fit the damper cam holder [A] on the damper cam [B] and touch in to the frame. • Apply molybdenum disulfide oil to the threads and the seating surface of the damper cam nut [C].
  • Page 458: Preload Adjustment

    11-30 FINAL DRIVE Front Bevel Gears Front Bevel Gear Adjustment ○ When any of the backlash-related parts are replaced, or the driven gear bolt is loosened; even if the purpose is not to replace the parts, be sure to check and adjust the bearing preload, the bevel gear backlash, and tooth con- tact by replacing shims.
  • Page 459: Preload Measurement With Spring Scale

    FINAL DRIVE 11-31 Front Bevel Gears Preload Measurement with Spring Scale • Hold the bearing housing in a vise so that the gear shaft axis is vertical. • Hook [C] the spring scale [B] on the driven gear holder [A] at a point 200 mm (7.9 in.) [D] apart from the center of the gear shaft.
  • Page 460: Backlash Adjustment

    11-32 FINAL DRIVE Front Bevel Gears Bearing Preloading Mechanism 1. Bearing Housing 3. Spacer 5. Tapered Roller Bearing 2. Tapered Roller Bearing 4. Collar Before Tightening [A] Under No Preload [C] Under Preload [E] After Tightening [B] Initial Clearance [D] No Clearance [F] Backlash Adjustment •...
  • Page 461: Tooth Contact Adjustment

    FINAL DRIVE 11-33 Front Bevel Gears • Install a holder [A] with 6 mm bolts and nuts on the front gear case to mount a dial gage. • Set up a dial gage against a drive gear tooth to check gear backlash.
  • Page 462: Bevel Gear Inspection

    11-34 FINAL DRIVE Front Bevel Gears • Turn the driven gear for 3 or 4 revolutions back and forth, while creating a drag on the drive gear. • Check the couvex side pattern and concave side pattern of the bevel gear teeth. Good contact is achieved when pattern of tooth contact is visible in the inside diameter side and center of the tooth flank.
  • Page 463: Cam Damper Inspection

    FINAL DRIVE 11-35 Front Bevel Gears Cam Damper Inspection • Visually inspect the spring [A], cam follower [B], damper cam [C], and output shaft [D]. Replace the damaged parts. http://mototh.com...
  • Page 464: Bearing And Oil Seal

    11-36 FINAL DRIVE Bearing and Oil Seal Ball or Needle Bearing Replacement • Using the bearing driver set or the oil seal & bearing re- mover, remove the bearings. Special Tools - Oil Seal & Bearing Remover: 57001-1058 Bearing Driver Set: 57001-1129 NOTE ○...
  • Page 465: Tapered Roller Bearing Inspection

    FINAL DRIVE 11-37 Bearing and Oil Seal Tapered Roller Bearing Inspection CAUTION Do not remove the tapered roller bearing for inspec- tion. Removal may damage them. • Visually inspect the bearing in the front for abrasion, color change, or other damage. If there is any doubt as to the condition of the bearing, replace it.
  • Page 466 http://mototh.com...
  • Page 467 BRAKES 12-1 Brakes Table of Contents Exploded View ........................12-3 Specifications ........................12-12 Special Tools .......................... 12-13 Brake Lever, Brake Pedal....................... 12-14 Brake Lever Position Adjustment..................12-14 Brake Pedal Position Inspection ..................12-14 Brake Pedal Position Adjustment ..................12-14 Brake Pedal Removal ....................... 12-14 Brake Pedal Installation ....................
  • Page 468 12-2 BRAKES Inquiries to Rider....................... 12-39 Self-diagnosis Outline ....................... 12-41 Self-diagnosis Procedures ....................12-41 Service Code Clearing Procedures................... 12-42 How to Read Service Codes..................... 12-44 How to Erase Service Codes .................... 12-44 ABS Indicator Light (LED) Inspection ................12-46 ABS Indicator Light (LED) is Unlit (When the Key Knob turned to ON) ......12-46 ABS Indicator Light (LED) Lights (When the Motorcycle is Running, - No Service Code) 12-47...
  • Page 469: Exploded View

    BRAKES 12-3 Exploded View Dummy Page http://mototh.com...
  • Page 470 12-4 BRAKES Exploded View ZG1400A Models http://mototh.com...
  • Page 471 BRAKES 12-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Bleed Valves 0.80 69 in·lb Brake Hose Banjo Bolts Brake Lever Pivot Bolt 0.10 9 in·lb Brake Lever Pivot Bolt Locknut 0.60 52 in·lb Brake Pipe Joint Nuts Brake Reservoir Bolt 0.80 69 in·lb Brake Reservoir Screw...
  • Page 472 12-6 BRAKES Exploded View http://mototh.com...
  • Page 473 BRAKES 12-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Bleed Valves 0.80 69 in·lb Brake Caliper Holder Plate Bolt Brake Hose Banjo Bolts Brake Pedal Bolt 0.90 78 in·lb Brake Pipe Joint Nuts Rear Brake Disc Mounting Bolts Rear Brake Pad Pin 17.2 Rear Caliper Assembly Bolts Rear Caliper Mounting Bolts...
  • Page 474 12-8 BRAKES Exploded View ZG1400B Models http://mototh.com...
  • Page 475 BRAKES 12-9 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Bleed Valves 0.80 69 in·lb Brake Hose Banjo Bolts Brake Lever Pivot Bolt 0.10 9 in·lb Brake Lever Pivot Bolt Locknut 0.60 52 in·lb Brake Reservoir Bolt 0.80 69 in·lb Brake Reservoir Screw 0.13 12 in·lb...
  • Page 476 12-10 BRAKES Exploded View http://mototh.com...
  • Page 477 BRAKES 12-11 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Bleed Valves 0.80 69 in·lb Brake Caliper Holder Plate Bolt Brake Hose Banjo Bolts Brake Pedal Bolt 0.90 78 in·lb Rear Brake Disc Mounting Bolts Rear Brake Pad Pin 17.2 Rear Caliper Assembly Bolts Rear Caliper Mounting Bolts Rear Master Cylinder Mounting Bolts...
  • Page 478: Specifications

    12-12 BRAKES Specifications Item Standard Service Limit Brake Lever, Brake Pedal Brake Lever Position 6-way adjustable (to suit rider) – – – Brake Lever Free Play Non-adjustable – – – Pedal Free Play Non-adjustable – – – Pedal Position About 35 mm (1.38 in.) below footpeg top –...
  • Page 479: Special Tools

    BRAKES 12-13 Special Tools Inside Circlip Pliers: Hand Tester: 57001-143 57001-1394 Jack: 57001-1238 http://mototh.com...
  • Page 480: Brake Lever, Brake Pedal

    12-14 BRAKES Brake Lever, Brake Pedal Brake Lever Position Adjustment The brake lever adjuster has 6 positions so that the brake lever position can be adjusted to suit the operator’s hand. • Push the lever forward and turn the adjuster [A] to align the number with the arrow mark [B] on the lever holder.
  • Page 481: Brake Pedal Installation

    BRAKES 12-15 Brake Lever, Brake Pedal • Remove: Hook Bolt [A] Rear Brake Light Switch Spring [B] Return Spring [C] Cotter Pin [D] Joint Pin [E] • Remove the mounting bolt [F] and take out the brake pedal. Brake Pedal Installation •...
  • Page 482: Calipers

    12-16 BRAKES Calipers Front Caliper Removal • Loosen the banjo bolt [A] at the brake hose lower end, and tighten it loosely. • Unscrew the caliper mounting bolts [B], and detach the caliper [C] from the disc. CAUTION Do not loosen the caliper assembly bolts. Take out only the caliper mounting bolts for caliper removal.
  • Page 483: Caliper Installation

    BRAKES 12-17 Calipers Caliper Installation • Install the caliper and brake hose lower end. ○ Replace the washers on each side of hose fitting with new ones. • Tighten: Torque - Caliper Mounting Bolts Front: 34 N·m (3.5 kgf·m, 25 ft·lb) Rear: 25 N·m (2.5 kgf·m, 18 ft·lb) Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb)
  • Page 484: Caliper Fluid Seal Damage

    12-18 BRAKES Calipers Caliper Fluid Seal Damage The fluid seal (piston seal) [A] is placed around the pis- ton to maintain clearance between the pad and the disc. If the seal is in a poor condition, it could lead the pad to wear excessively or the brake to drag, which may cause the tem- perature of the discs or the brake fluid to increase.
  • Page 485: Caliper Piston And Cylinder Damage

    BRAKES 12-19 Calipers Caliper Piston and Cylinder Damage • Visually inspect the pistons [A] and cylinder surfaces [B]. Replace the caliper if the cylinder and piston are badly scores or rusty. http://mototh.com...
  • Page 486: Brake Pads

    12-20 BRAKES Brake Pads Front Brake Pad Removal • Unscrew the pad pins [A]. • Remove: Pad Pins [A] Pad Springs [B] Brake Pads [C] Front Brake Pad Installation • Push the caliper pistons in by hand as far as they will go. •...
  • Page 487: Rear Brake Pad Removal

    BRAKES 12-21 Brake Pads Rear Brake Pad Removal • Remove: Pad Pin [A] Pad Spring [B] Brake Pads [C] Rear Brake Pad Installation • Push the caliper pistons in by hand as far as they will go. • Install the outside pad [A] and insert the pad pin [B] as shown in the figure.
  • Page 488: Master Cylinder

    12-22 BRAKES Master Cylinder Front Master Cylinder Removal • Remove the banjo bolt [A] to disconnect the brake hose from the master cylinder (see Brake Hose Removal/In- stallation). • Unscrew the clamp bolts [B], and take off the master cylin- der [C] as an assembly with the reservoir, brake lever, and brake switch installed.
  • Page 489: Rear Master Cylinder Removal

    BRAKES 12-23 Master Cylinder Rear Master Cylinder Removal • Unscrew the brake hose banjo bolt [A] and brake hose [B]. • Remove: Bolts [C] Foot Guard [D] Cotter Pin [E] Joint Pin [E] Rear Master Cylinder • Slide out the clamp [G]. •...
  • Page 490 12-24 BRAKES Master Cylinder • Check the dust covers [E] for damage. If they are damaged, replace them. • Check the piston return spring [F] for any damage. If the springs are damaged, replace them. • Check that relief port [G] and supply port [H] are not plugged.
  • Page 491: Brake Disc

    BRAKES 12-25 Brake Disc Brake Disc Removal • Remove the wheels (see Front/Rear Wheel Removal in the Wheels/Tires chapter). • Unscrew the mounting bolts, and take off the disc. ○ Remove the sensor rotor (ZG1400A Models). Brake Disc Installation • Install the brake disc on the wheel so that the marked side [A] faces out.
  • Page 492: Brake Fluid

    12-26 BRAKES Brake Fluid Brake Fluid Level Inspection • Refer to the Brake Fluid Level Inspection in the Periodic Maintenance chapter. Brake Fluid Change • Refer to the Brake Fluid Change in the Periodic Mainte- nance chapter. Brake Line Bleeding The brake fluid has a very low compression coefficient so that almost all the movement of the brake lever or pedal is transmitted directly to the caliper for braking action.
  • Page 493 BRAKES 12-27 Brake Fluid • Remove the rubber cap from the bleed valve [A] on the front master cylinder. • Attach a clear plastic hose [B] to the bleed valve, and run the other end of the hose into a container. •...
  • Page 494 12-28 BRAKES Brake Fluid • Bleed the brake line and the caliper. ○ Repeat this operation until no more air can be seen com- ing out into the plastic hose. 1. Pump the brake lever until it becomes hard, and apply the brake and hold it [A].
  • Page 495 BRAKES 12-29 Brake Fluid WARNING When working with the disc brake, observe the pre- cautions listed below. 1. Never reuse old brake fluid. 2. Do not use fluid from a container that has been left unsealed or that has been open for a long time. 3.