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Table of Contents

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Table of Contents

   Summary of Contents for Kawasaki Z750

  • 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 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. © 2003 Kawasaki Heavy Industries, Ltd. First Edition (1) : Sep. 16, 2003 (M)
  • Page 6 LIST OF ABBREVIATIONS ampere(s) pound(s) ABDC after bottom dead center meter(s) alternating current minute(s) ATDC after top dead center newton(s) BBDC before bottom dead center pascal(s) bottom dead center horsepower BTDC before top dead center pound(s) per square inch °C degree(s) Celsius revolution direct current...
  • Page 7: How To Use This Manual

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

    Technical Information – Air Inlet System ................1-10 Technical Information – New Ignition Interlock Sidestand ............1-12 Technical Information – Tail/Brake Lights Employing LED ............. 1-13 Technical Information – KAWASAKI LOW EXHAUST EMISSION SYSTEM ......1-15 Unit Conversion Table ......................1-16...
  • Page 10: Before Servicing

    1-2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly opera- tion on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustra- tions, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary.
  • Page 11 Replacement Parts Replacement parts must be KAWASAKI genuine or recommended by KAWASAKI. Gaskets, O-rings, oil seals, grease seals, circlips or cotter pins must be replaced with new ones whenever disassembled.
  • Page 12 1-4 GENERAL INFORMATION Before Servicing Tightening Sequence Bolts, nuts, or screws must be tightened according to the specified sequence to prevent case warpage or deformation which can lead to malfunction. If the specified tightening sequence is not indicated, tighten the fasteners alternating diagonally.
  • Page 13 GENERAL INFORMATION 1-5 Before Servicing Press For items such as bearings or oil seals that must be pressed into place, apply small amount of oil to the con- tact area. Be sure to maintain proper alignment and use smooth movements when installing. Ball Bearing and Needle Bearing Do not remove pressed ball or needle unless removal is absolutely necessary.
  • Page 14 1-6 GENERAL INFORMATION Before Servicing Direction of Engine Rotation When rotating the crankshaft by hand, the free play amount of rotating direction will affect the adjustment. Ro- tate the crankshaft to positive direction (clockwise viewed from output side). Electrical Wires A two-color wire is identified first by the primary color and then the stripe color.
  • Page 15: Model Identification

    GENERAL INFORMATION 1-7 Model Identification ZR750–J1 Left Side View: ZR750–J1 Right Side View:...
  • Page 16: General Specifications

    1-8 GENERAL INFORMATION General Specifications Items ZR750–J1 Dimensions: Overall length 2 080 mm (81.9 in.) Overall width 780 mm (30.7 in.) Overall height 1 055 mm (41.5 in.) Wheelbase 1 425 mm (56.1 in.) Road clearance 165 mm (6.5 in.) Seat height 815 mm (32.1 in.) Dry mass...
  • Page 17 GENERAL INFORMATION 1-9 General Specifications Items ZR750–J1 Viscosity SAE 10W-40 Capacity 3.8 L (4.0 US qt) Drive Train: Primary reduction system: Type Gear Reduction ratio 1.714 (84/49) Clutch type Wet multi disc Transmission: Type 6-speed, constant mesh, return shift Gear ratios: 2.571 (36/14) 1.941 (33/17) 1.555 (28/18)
  • Page 18: Technical Information - Air Inlet System

    1-10 GENERAL INFORMATION Technical Information – Air Inlet System Subthrottle Control System The ZR750–J1 employs large bore throttle bodies to increase power output. However, sudden changes in throttle opening can cause hesitation and jerky throttle response with a single butterfly valve in a large bore.
  • Page 19 GENERAL INFORMATION 1-11 Technical Information – Air Inlet System Operation The subthrottle control system consists of the subthrottle valve, subthrottle valve actuator with a stepping motor built in it, ECU, and subthrottle sensor. The subthrottle valve is built in the each throttle body.
  • Page 20: Technical Information - New Ignition Interlock Sidestand

    1-12 GENERAL INFORMATION Technical Information – New Ignition Interlock Sidestand Outline The New Ignition Interlock Sidestand System applied to ZR750–J1 models that cannot function if gears are engaged and/or the sidestand is not lifted upward even though clutch lever pulled in, which differs from the traditional one.
  • Page 21: Technical Information - Tail/brake Lights Employing Led

    GENERAL INFORMATION 1-13 Technical Information – Tail/Brake Lights Employing LED Outline This model employs a tail/brake light containing 21 Light Emitting Diodes (LED). The LED emits luminous beams over a longer life span than those emitted from a traditional electric heated bulb (more than 5 times longer), uses lower voltage, expends lower wattage (approx.
  • Page 22 1-14 GENERAL INFORMATION Technical Information – Tail/Brake Lights Employing LED The emitting color differs according to the materials of semi-conductors. Materials of Semi-Conductor and Emitting Color Materials of Semi-Conductor Emitting Color GaAsP, GaAlAs Green Blue Ga: Gallium As: Arsenic P: Phosphorus N: Nitrogen Al: Aluminum...
  • Page 23: Technical Information - Kawasaki Low Exhaust Emission System

    GENERAL INFORMATION 1-15 Technical Information – KAWASAKI LOW EXHAUST EMISSION SYSTEM Since the emission regulations become more severe, Kawasaki has adopted a type of simplified KAWASAKI LOW EXHAUST EMISSION SYSTEM (KLEEN), which have no catalyst protection sys- tem, according to each regulation of different countries.
  • Page 24: Unit Conversion Table

    1-16 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 milli × 0.001 Units of Torque: micro µ...
  • Page 25: Periodic Maintenance

    PERIODIC MAINTENANCE 2-1 Periodic Maintenance Table of Contents Periodic Maintenance Chart ....Drive Chain Wear Inspection ..2-28 Torque and Locking Agent....Drive Chain Lubrication....2-29 Specifications ........2-10 Brakes..........2-29 Special Tools ........2-12 Brake Pad Wear Inspection ..2-29 Periodic Maintenance Procedures..
  • Page 26: Periodic Maintenance Chart

    2-2 PERIODIC MAINTENANCE Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition. The initial maintenance is vitally important and must not be neglected. Periodic Inspection: FREQUENCY Whichever * ODOMETER READING comes km ×...
  • Page 27: Periodic Maintenance

    PERIODIC MAINTENANCE 2-3 Periodic Maintenance Chart FREQUENCY Whichever * ODOMETER READING comes km × 1000 (mile × 1000) first INSPECTION Every (0.6) (4) (7.5) (12) (15) (20) (24) Page • • • Engine stop switch operation year — Fuel system (DFI): •...
  • Page 28 2-4 PERIODIC MAINTENANCE Periodic Maintenance Chart Periodic Replacement Parts: FREQUENCY Whichever * ODOMETER READING comes km × 1000 (mile × 1000) first CHANGE/REPLACE ITEM Every (0.6) (7.5) (15) (24) (30) Page • Brake hoses 4 years 2–36 • • Brake fluid (front and rear) 2 years 2–32 •...
  • Page 29: Torque And Locking Agent

    PERIODIC MAINTENANCE 2-5 Torque and Locking Agent The following tables list the tightening torque The table below, relating tightening torque to for the major fasteners requiring use of a non thread diameter, lists the basic torque for the -permanent locking agent or liquid gasket. bolts and nuts.
  • Page 30 2-6 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Water pump drain bolt 95 in·lb Water pipe bolts 95 in·lb Thermostat housing ground bolt 0.70 61 in·lb Thermostat bracket bolt 0.70 61 in·lb Radiator upper bolts 0.70 61 in·lb Radiator lower bolts...
  • Page 31 PERIODIC MAINTENANCE 2-7 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Engine Lubrication: Oil filler plug 0.15 13 in·lb Engine oil drain bolt Oil filter EO, R Holder mounting bolt Oil pan bolts 95 in·lb Oil pipe holder bolts 113 in·lb Oil pressure relief valve Oil pressure switch...
  • Page 32 2-8 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Tie-rod locknuts 0.70 61 in·lb Neutral switch Wheels/Tires: Front axle clamp bolt Front axle Rear axle nut Final Drive: Engine sprocket nut Engine sprocket cover bolts 87 in·lb Speed sensor cover bolts 0.70 61 in·lb...
  • Page 33 PERIODIC MAINTENANCE 2-9 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Handlebar lower clamp nuts Switch housing screws 0.36 31 in·lb Front fork clamp bolts (Upper) Front fork clamp bolts (Lower) Frame: Footpeg bracket bolts Side stand bolt Side stand switch bolt 0.90 78 in·lb...
  • Page 34: Specifications

    2-10 PERIODIC MAINTENANCE Specifications Item Standard Service Limit Fuel System: 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Throttle grip free play – – – Idle speed 1 100 ±50 r/min (rpm) – – – Bypass screws (turn out) 2 ±1/4 (for reference) –...
  • Page 35 PERIODIC MAINTENANCE 2-11 Specifications Item Standard Service Limit Air pressure: (when cold) Front Up to 180 kg (397 lb) load: – – – 250 kPa (2.5 kgf/cm², 36 psi) Rear Up to 180 kg (397 lb) load: – – – 290 kPa (2.9 kgf/cm², 42 psi) Final Drive: 25 ∼...
  • Page 36: Special Tools

    2-12 PERIODIC MAINTENANCE Special Tools Steering Stem Nut Wrench: Pilot Screw Adjuster, C: 57001–1100 57001–1292 Jack: Hand Tester: 57001–1238 57001–1394 Oil Filter Wrench: Spark Plug Wrench (Owner’s Tool): 57001–1249 92110–1146...
  • Page 37: Periodic Maintenance Procedures

    PERIODIC MAINTENANCE 2-13 Periodic Maintenance Procedures Fuel System (DFI) Fuel Hose and Connection Inspection ○ The fuel hoses are designed to be used throughout the motorcycle’s life without any maintenance, however, if the motorcycle is not properly handled, the high pressure in- side the fuel line can cause fuel to leak [A] or the hose to burst.
  • Page 38: Throttle Control System Inspection

    2-14 PERIODIC MAINTENANCE Periodic Maintenance Procedures Throttle Control System Inspection Throttle Grip Play Inspection • Check the throttle grip free play [A]. If the free play is incorrect, adjust the throttle cable. Throttle Grip Free Play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Standard: •...
  • Page 39: Idle Speed Inspection

    PERIODIC MAINTENANCE 2-15 Periodic Maintenance Procedures Idle Speed Inspection • Start the engine and warm it up thoroughly. • With the engine idling, turn the handlebar to both sides. If handlebar movement changes the idle speed, the throttle cables may be improperly adjusted or incorrectly routed or damaged.
  • Page 40 2-16 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Install the fuel tank (see Fuel System (DFI) chapter). • Start the engine and warm it up thoroughly. • Check the idle speed. Tachometer [A] If the idle speed is out of the specified range, adjust it. CAUTION Do not measure the idle speed by the tachometer of the meter unit.
  • Page 41 PERIODIC MAINTENANCE 2-17 Periodic Maintenance Procedures If any one vacuum measurement is out of the standard measurement after synchronization, adjust the bypass screws [A]. Front [B] Special Tool - Pilot Screw Adjuster, C: 57001–1292 • Adjust the lowest vacuum between #1 and #2 to the high- est of #1 and #2.
  • Page 42: Air Cleaner Element Cleaning

    2-18 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Back out the same number of turns counted when first turned in. This is to set the screw to its original position. NOTE ○ A throttle body has different “turns out” of the bypass screw for each individual unit.
  • Page 43 PERIODIC MAINTENANCE 2-19 Periodic Maintenance Procedures • Remove the fuel tank (see Fuel System (DFI) chapter). • Remove the fuel tank bracket bolts and bracket [A]. • Remove: Air Cleaner Duct Holder Screws [A] • Remove the air cleaner duct holder [B] backward. •...
  • Page 44: Cooling System

    2-20 PERIODIC MAINTENANCE Periodic Maintenance Procedures Cooling System Radiator Hose and Connection Inspection ○ The high pressure inside the radiator hose can cause coolant to leak [A] or the hose to burst if the line is not properly maintained. Visually inspect the hoses for signs of deterioration.
  • Page 45 PERIODIC MAINTENANCE 2-21 Periodic Maintenance Procedures • When filling the coolant, choose a suitable mixture ratio by referring to the coolant manufacturer’s directions. CAUTION Soft or distilled water must be used with the an- tifreeze in the cooling system. If hard water is used in the system, it causes scale accumulation in the water passages, and consider- ably reduces the efficiency of the cooling system.
  • Page 46: Engine Top End

    2-22 PERIODIC MAINTENANCE Periodic Maintenance Procedures Engine Top End Air Suction Valve Inspection • Remove the air suction valve (see Engine Top End chap- ter). • Visually inspect the reeds for cracks, folds, warps, heat damage or other damage. If there is any doubt as to the condition of the reeds [A], replace the air suction valve as an assembly.
  • Page 47: Clutch

    PERIODIC MAINTENANCE 2-23 Periodic Maintenance Procedures ○ When positioning #4 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 Measuring Valve [A] ○ When positioning #1 piston TDC at the end of the compression stroke: Inlet valve clearance of #1 and #3 cylinders Exhaust valve clearance of #1 and #2 cylinders...
  • Page 48: Engine Lubrication System

    2-24 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Slide the dust cover [A] at the clutch cable lower end out of place. • Loosen both adjusting nuts [B] at the clutch cover as far as they will go. • Pull the clutch outer cable [C] tight and tighten the adjust- ing nuts against the cover [D].
  • Page 49: Oil Filter Change

    PERIODIC MAINTENANCE 2-25 Periodic Maintenance Procedures NOTE ○ Although 10W-40 engine oil is the recommended oil for most conditions, the oil viscosity may need to be changed to accommodate atmospheric conditions in your riding area. Oil Filter Change • Drain the engine oil (see Engine Oil Change). •...
  • Page 50: Air Pressure Inspection

    2-26 PERIODIC MAINTENANCE Periodic Maintenance Procedures Tread Depth Front: Standard: 3.4 mm (0.13 in.) Service Limit: 1 mm (0.04 in.) 1.6 mm (0.06 in.) (AT, CH, DE) Rear: Standard: 5.8 mm (0.23 in.) Service Limit: 2 mm (0.08 in.) (Up to 130 km/h (80 mph)) 3 mm (0.12 in.) (Over 130 km/h (80 mph)) WARNING...
  • Page 51: Final Drive

    PERIODIC MAINTENANCE 2-27 Periodic Maintenance Procedures Final Drive Drive Chain Slack Inspection NOTE ○ Check the slack with the motorcycle setting on its side stand. ○ Clean the chain if it is dirty, and lubricate it if it appears dry. •...
  • Page 52: Drive Chain Wear Inspection

    2-28 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Bend the cotter pin [A] over the nut. WARNING If the rear axle nut is not securely tightened or the cotter pin is not installed, an unsafe riding condi- tion may result. Drive Chain Wear Inspection •...
  • Page 53: Drive Chain Lubrication

    PERIODIC MAINTENANCE 2-29 Periodic Maintenance Procedures Drive Chain Lubrication • If a special lubricant is not available, a heavy oil such as SAE 90 is preferred to a lighter oil because it will stay on the chain longer and provide better lubrication. •...
  • Page 54: Caliper Fluid Seal Damage

    2-30 PERIODIC MAINTENANCE Periodic Maintenance Procedures If it does not, adjust and inspect the brake light switch. • While holding the switch body, turn the adjusting nut [A] to adjust the switch. CAUTION To avoid damaging the electrical connections in- side the switch, be sure that the switch body does not turn during adjustment.
  • Page 55: Master Cylinder Inspection (visual Inspection)

    PERIODIC MAINTENANCE 2-31 Periodic Maintenance Procedures Master Cylinder Inspection (Visual Inspection) • Remove the master cylinders (see Brakes chapter). • Disassemble the front and rear master cylinders. • Check that there are no scratches, rust or pitting on the inner wall [A] of each master cylinder and on the outside of each piston [B].
  • Page 56: Brake Fluid Level Inspection

    2-32 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Fluid Level Inspection • Check that the brake fluid level in the front brake reservoir [A] is above the lower level line [B]. NOTE ○ Hold the reservoir horizontal by turning the handlebar when checking brake fluid level.
  • Page 57 PERIODIC MAINTENANCE 2-33 Periodic Maintenance Procedures • Level the brake fluid reservoir. • Remove the reservoir cap and diaphragm. • Remove the rubber cap from the bleed valve [A] on the caliper. • Attach a clear plastic hose [B] to the bleed valve, and run the other end of the hose into a container.
  • Page 58: Brake Line Bleeding

    2-34 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Line Bleeding The brake fluid has a very low compression coefficient so that almost all the movement of the brake lever or pedal is transmitted directly to the caliper for braking action. Air, however, is easily compressed.
  • Page 59 PERIODIC MAINTENANCE 2-35 Periodic Maintenance Procedures • Bleed the brake line and the caliper: ○ Repeat this operation until no more air can be seen com- ing out into the plastic hose. 1. Pump the brake lever until it becomes hard, and apply the brake and hold it [A].
  • Page 60: Brake Hoses And Connections Inspection

    2-36 PERIODIC MAINTENANCE Periodic Maintenance Procedures WARNING When working with the disc brake, observe the pre- cautions listed below. 1. Never reuse old brake fluid. 2. Do not use fluid from a container that has been left unsealed or that has been open for a long time. 3.
  • Page 61: Suspension

    PERIODIC MAINTENANCE 2-37 Periodic Maintenance Procedures Suspension Front Fork Oil Leak Check • Visually inspect the front forks [A] for oil leakage, scoring or scratches on the inner surface of the inner tubes. Replace or repair any defective parts, if necessary. Rear Shock Absorber Oil Leak Check •...
  • Page 62: Steering Stem Bearing Lubrication

    2-38 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Bend the claw washer tabs [A]. • Remove the steering stem locknut [B] and claw washer [C]. • Adjust the steering. Special Tool - Steering Stem Nut Wrench: 57001–1100 [B] If the steering is too tight, loosen the stem nut [A] a fraction of a turn.
  • Page 63: Electrical System

    PERIODIC MAINTENANCE 2-39 Periodic Maintenance Procedures Electrical System Spark Plug Inspection • Remove: Fuel Tank (see Fuel System (DFI) chapter) • Unscrew the thermostat bracket bolt [A]. • Disconnect: Water Temperature Sensor Connector [B] Left Switch Housing Connector [C] ○ If removing the spark plug #2 or #3.
  • Page 64 2-40 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Clean the spark plug, preferably in a sandblasting device, and then clean off any abrasive particles. The plug may also be cleaned using a high-flash point solvent and a wire brush or other suitable tool. If the spark plug center electrode [A] and/or side electrode [B] are corrected or damaged, or if the insulator [C] is cracked, replace the plug.
  • Page 65: General Lubrication

    PERIODIC MAINTENANCE 2-41 Periodic Maintenance Procedures General Lubrication Lubrication • Before lubricating each part, clean off any rusty spots with rust remover and wipe off any grease, oil, dirt, or grime. • Lubricate the points listed below with indicated lubricant. NOTE ○...
  • Page 66: Nut, Bolt, And Fastener Tightness

    2-42 PERIODIC MAINTENANCE Periodic Maintenance Procedures Nut, Bolt, and Fastener Tightness Tightness Inspection • Check the tightness of the bolts and nuts listed here. Also, check to see that each cotter pin is in place and in good condition. NOTE ○...
  • Page 67 FUEL SYSTEM (DFI) 3-1 Fuel System (DFI) Table of Contents Exploded View........................DFI Parts Location........................DFI Wiring Diagram ........................ 3-10 Specifications ......................... 3-12 Special Tools .......................... 3-14 DFI Servicing Precautions ...................... 3-15 DFI Servicing Precautions ....................3-15 Troubleshooting the DFI System .................... 3-17 Outline ..........................
  • Page 68 3-2 FUEL SYSTEM (DFI) Sensor Resistance Inspection ..................3-50 Atmospheric Pressure Sensor (Service Code 15)..............3-51 Removal..........................3-51 Input Voltage Inspection....................3-51 Output Voltage Inspection....................3-52 Crankshaft Sensor (Service Code 21)..................3-54 Crankshaft Sensor Removal/Installation................3-54 Crankshaft Sensor Inspection................... 3-54 Camshaft Position Sensor (Service Code 23) ................
  • Page 69 FUEL SYSTEM (DFI) 3-3 Fuel Pump Relay Removal ....................3-80 Fuel Pump Relay Inspection ..................... 3-80 Fuel Injectors .......................... 3-81 Removal/Installation......................3-81 Audible Inspection......................3-81 Power Source Voltage Inspection ..................3-81 Output Voltage Inspection....................3-82 Injector Signal Test......................3-83 Injector Resistance Inspection ..................3-84 Injector Unit Test .......................
  • Page 70: Exploded View

    3-4 FUEL SYSTEM (DFI) Exploded View...
  • Page 71 FUEL SYSTEM (DFI) 3-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Throttle cable plate bolt 0.60 52 in·lb Throttle body assy holder clamp bolts 0.20 17 in·lb Choke link holder screws 0.21 18 in·lb Delivery pipe screws 0.35 30 in·lb Fuel pump bolts 87 in·lb Fuel level sensor bolts...
  • Page 72 3-6 FUEL SYSTEM (DFI) Exploded View...
  • Page 73 FUEL SYSTEM (DFI) 3-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Inlet air pressure sensor bolt 104 in·lb Water temperature sensor Vehicle down sensor bolts 0.20 17 in·lb Camshaft position sensor bolt 104 in·lb Camshaft position sensor rotor bolt 104 in·lb Air cleaner duct holder screws 0.39...
  • Page 74: Dfi Parts Location

    3-8 FUEL SYSTEM (DFI) DFI Parts Location DFI: DFI Parts (this chapter) 10. Stick Coils 21. Main Throttle Sensor 1. Water temperature Sen- 11. Throttle Body Assy (DFI) sor (DFI) 12. Self-diagnosis Terminal 22. Ignition Switch 2. Inlet Air Pressure Sensor 13.
  • Page 75 FUEL SYSTEM (DFI) 3-9 DFI Parts Location [1], [2], [10], [13], [22] and [24] are not included.
  • Page 76: Dfi Wiring Diagram

    3-10 FUEL SYSTEM (DFI) DFI Wiring Diagram...
  • Page 77 FUEL SYSTEM (DFI) 3-11 DFI Wiring Diagram Terminal Names 27. Engine Stop Switch Signal 1. Power Supply to Sensors 28. Starter Lockout Switch Signal 2. Main Throttle Sensor Signal 29. Electric Starter Button Signal 3. Subthrottle Sensor Signal 30. Fuel Pump Relay Signal 4.
  • Page 78: Specifications

    3-12 FUEL SYSTEM (DFI) Specifications Item Standard Digital Fuel Injection System Idle Speed 1 100 ±50 r/min (rpm) Throttle Assy: Type Four barrel type Bore 34 mm (1.34 in.) ECU (Electronic Control Unit): Make Denso Type Digital memory type, with built in IC igniter, sealed with resin 100 ∼...
  • Page 79 FUEL SYSTEM (DFI) 3-13 Specifications Item Standard Within 0.5 ∼ 1.0 sec. Detection time with the sensor tilted 60 ∼ 70° or more: 3.7 ∼ 4.4 V Output voltage with sensor arrow mark pointed up: 0.4 ∼ 1.4 V Subthrottle Sensor: Non-adjustable and non-removal 4.75 ∼...
  • Page 80: Special Tools

    Oil Pressure Gauge: Needle Adapter Set: 57001–125 57001–1457 Fork Oil Level Gauge: Throttle Sensor Setting Adapter: 57001–1290 57001–1538 Hand Tester: Sensor Harness Adapter: 57001–1394 57001–1561 Throttle Sensor Setting Adapter: Kawasaki Bond (Silicone Sealant): 57001–1400 56019–120 Fuel Pressure Gauge Adapter: 57001–1417...
  • Page 81: Dfi Servicing Precautions

    FUEL SYSTEM (DFI) 3-15 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 82: Dfi Servicing Precautions

    3-16 FUEL SYSTEM (DFI) DFI Servicing Precautions ○ Whenever the DFI electrical connections are to be discon- nected, first turn off the ignition SW (switch), and discon- nect the battery (–) terminal. Do not pull the lead, only the connector. Conversely, make sure that all the DFI elec- trical connections are firmly reconnected before starting the engine.
  • Page 83: Troubleshooting The Dfi System

    FUEL SYSTEM (DFI) 3-17 Troubleshooting the DFI System Outline Outline When an abnormality in the system occurs, the FI indica- tor LED (Light Emitting Diode) light goes on to alert the rider on the meter panel. In addition, the condition of the problem is stored in the memory of the ECU (electronic control unit).
  • Page 84 ○ After measurement, remove the needle adapters and ap- ply silicone sealant to the seals [A] of the connector [B] for waterproofing. Silicone Sealant (Kawasaki Bond: 56019–120) – Seals of Connector • Always check battery condition before replacing the DFI parts.
  • Page 85 FUEL SYSTEM (DFI) 3-19 Troubleshooting the DFI System • Pull each connector [A] apart and inspect it for corrosion, dirt, and damage. If the connector is corroded or dirty, clean it carefully. If it is damaged, replace it. Connect the connectors securely. •...
  • Page 86 3-20 FUEL SYSTEM (DFI) Troubleshooting the DFI System ○ There are two ways to inspect the DFI system. One is voltage Check Method and the other is Resistance Check Method. (Voltage Check Method) ○ This method is conducted by measuring the input voltage [B] to a sensor [A] first, and then the output voltage [C] from the sensor.
  • Page 87: Inquiries To Rider

    FUEL SYSTEM (DFI) 3-21 Troubleshooting the DFI System DFI Diagnosis Flow Chart Inquiries to Rider Inquiries to Rider ○ Each rider reacts to problems in different ways, so it is important to confirm what kind of symptoms the rider has encountered. ○...
  • Page 88 3-22 FUEL SYSTEM (DFI) Troubleshooting the DFI System Sample Diagnosis Sheet Rider name: Registration No. (license plate No.): Year of initial registration: Model: Engine No.: Frame No.: Date problem occurred: Mileage: Environment when problem occurred. Weather □ fine, □ cloudy, □ rain, □ snow, □ always, □ other: Temperature □...
  • Page 89 FUEL SYSTEM (DFI) 3-23 Troubleshooting the DFI System Poor running □ choke lever pulled out fully (push it in fully) at low speed □ very low choke speed (adjust choke cable) □ very low idle speed, □ very high idle speed, □ rough idle speed □...
  • Page 90: Dfi System Troubleshooting Guide

    3-24 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide DFI System Troubleshooting Guide NOTE ○ This is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties. ○...
  • Page 91 FUEL SYSTEM (DFI) 3-25 DFI System Troubleshooting Guide Symptoms or possible Causes Actions (chapter) When flooded, don’t crank engine with throttle Starting technique faulty fully opened. No spark or spark weak : Ignition and engine stop switches not ON Turn both switches ON . Clutch lever not pulled in and gear not in neutral Pull the lever in and shift the gear in neutral.
  • Page 92: Poor Running At Low Speed

    3-26 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or possible Causes Actions (chapter) Cylinder, piston worn Inspect and replace (see chapter 5). Piston ring bad (worn, weak, broken or sticking) Inspect and replace (see chapter 5). Piston ring/groove clearance excessive Inspect and replace (see chapter 5).
  • Page 93 FUEL SYSTEM (DFI) 3-27 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Inlet air temperature sensor trouble Inspect (see chapter 3). Water temperature sensor trouble Inspect (see chapter 3). Atmospheric pressure sensor trouble Inspect (see chapter 3). Fuel pressure too low or too high Inspect (see chapter 3).
  • Page 94 3-28 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Main throttle sensor trouble Inspect (see chapter 3). Subthrottle sensor trouble Inspect (see chapter 3). Subthrottle valve actuator trouble Inspect (see chapter 3). Water temperature sensor trouble Inspect (see chapter 3).
  • Page 95 FUEL SYSTEM (DFI) 3-29 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Clean spark plugs and adjust plug gap (see Spark plug dirty, broken or gap maladjusted chapter 2). Too low fuel pressure Inspect (see chapter 3). Fuel pump trouble Inspect (see chapter 3).
  • Page 96: Poor Running Or No Power At High Speed

    3-30 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Poor Running or No Power at High Speed: Symptoms or Possible Causes Actions (chapter) Firing incorrect : Clean spark plug and adjust plug gap (see chapter Spark plug dirty, broken or maladjusted Spark plug cap trouble Inspect stick coil (see chapter 16).
  • Page 97 FUEL SYSTEM (DFI) 3-31 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Fuel poor quality or incorrect (Use the gasoline Change fuel (see chapter 3). recommended in the Owner’s Manual) Spark plug incorrect Replace it with the correct plug (see chapter 16). Stick coil trouble Inspect (see chapter 16).
  • Page 98 3-32 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Too low fuel pressure Inspect fuel line and fuel pump (see chapter 3). Water temperature sensor trouble Inspect and replace (see chapter 3). Inlet air temperature sensor trouble Inspect and replace (see chapter 3).
  • Page 99: Self-diagnosis

    FUEL SYSTEM (DFI) 3-33 Self-Diagnosis Self-diagnosis Outline Self-diagnosis Outline The self-diagnosis system has three modes and can be switched to another mode by grounding the self-diagnosis terminal. User Mode: The ECU notifies the rider of troubles in DFI system and ignition system by lighting the FI indicator when DFI system and ignition system parts are faulty, and initiates fail-safe function.
  • Page 100: Self-diagnosis Procedures

    3-34 FUEL SYSTEM (DFI) Self-Diagnosis • To enter the self-diagnosis dealer mode 2, open [B] and ground [A] the lead more than five times [F] within 2 sec- onds [C] after the lead is first grounded, and then keep it grounded continuously [D] for more than 2 seconds.
  • Page 101 FUEL SYSTEM (DFI) 3-35 Self-Diagnosis...
  • Page 102: How To Read Service Codes

    3-36 FUEL SYSTEM (DFI) Self-Diagnosis How to Read Service Codes How to Read Service Codes ○ Service codes are shown by a series of long and short blinks of the FI indicator LED light as shown below. ○ Read 10th digit and unit digit as the FI indicator LED light blinks. ○...
  • Page 103: Service Code Table

    FUEL SYSTEM (DFI) 3-37 Self-Diagnosis Service Code Table Service Code Table Service FI Indicator LED Light Problems Code Main throttle sensor malfunction, wiring open or short Inlet air pressure sensor malfunction, wiring open or short Inlet air temperature sensor malfunction, wiring open or short Water temperature sensor malfunction, wiring open or short...
  • Page 104: Backups

    3-38 FUEL SYSTEM (DFI) Self-Diagnosis Backups Backups ○ The ECU takes the following measures to prevent engine damage when the DFI or the ignition system parts have troubles. Service Output Signal Usable Parts Backups by ECU Codes Range or Criteria If the main throttle sensor system fails (the signal is out of the usable range, wiring short or open), the ECU locks ignition timing into the ignition...
  • Page 105 FUEL SYSTEM (DFI) 3-39 Self-Diagnosis Service Output Signal Usable Parts Backups by ECU Codes Range or Criteria If the subthrottle sensor system fails (the signal Subthrottle Sensor Subthrottle is out of the usable range, wiring short or open), Output Voltage sensor the actuator locks sub throttle valve at full open 0.15 ∼...
  • Page 106: Main Throttle Sensor (service Code 11)

    3-40 FUEL SYSTEM (DFI) Main Throttle Sensor (Service Code 11) Main Throttle Sensor Removal/Adjustment CAUTION Do not remove or adjust the main throttle sensor [A] since it has been adjusted and set with precision at the factory. Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it.
  • Page 107: Output Voltage Inspection

    FUEL SYSTEM (DFI) 3-41 Main Throttle Sensor (Service Code 11) Output Voltage Inspection • Measure the output voltage at the main throttle sensor in the same way as input voltage inspection, Note the following. • Disconnect the main throttle sensor (gray) [A] and con- nect the harness adapter [B] between these connectors.
  • Page 108: Resistance Inspection

    3-42 FUEL SYSTEM (DFI) Main Throttle Sensor (Service Code 11) Resistance Inspection • Turn the ignition switch OFF. • Disconnect the main throttle sensor connector. • Connect a digital meter [A] to the main throttle sensor connector [B]. • Measure the main throttle sensor resistance. Main Throttle Sensor Resistance Connections: BL lead [C] ←→...
  • Page 109: Inlet Air Pressure Sensor (service Code 12)

    FUEL SYSTEM (DFI) 3-43 Inlet Air Pressure Sensor (Service Code 12) CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the part can damage it. Removal • Remove: Fuel Tank (see Fuel System chapter) Water Temperature Sensor Connector [A] Inlet Air Pressure Sensor Bolt [B] •...
  • Page 110: Output Voltage Inspection

    3-44 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code 12) Output Voltage Inspection NOTE ○ The output voltage changes according to the local at- mospheric pressure. • Measure the output voltage at the ECU in the same way as input voltage inspection. Note the following. Inlet Air Pressure Sensor Output Voltage Connections to ECU Meter (+) →...
  • Page 111 FUEL SYSTEM (DFI) 3-45 Inlet Air Pressure Sensor (Service Code 12) then Pv = Pl – Pg For example, suppose the following data is obtained: Pg = 8 cmHg (vacuum gauge reading) Pl = 70 cmHg (barometer reading) Vv = 3.2 V (digital volt meter reading) then Pv = 70 –...
  • Page 112 3-46 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code 12) Pv = 55 ∼ 86 cmHg Vv: Inlet Air Pressure Sensor Output Volt- ID: Idling age (V) (Digital Meter Reading) Pv: Throttle Vacuum Pressure (absolute) TO: Throttle Full Open Ps: Standard Atmospheric Pressure (abso- ST: Standard of Sensor Output Voltage (v) lute)
  • Page 113: Inlet Air Temperature Sensor (service Code 13)

    (see ECU section in this chapter). If the wiring is good, check the sensor resistance. • Remove the needle adapter set, and apply silicone sealant to the seals of the connector for waterproofing. Silicone Sealant (Kawasaki Bond: 56019–120) – Seals of ECU Connectors...
  • Page 114: Sensor Resistance Inspection

    3-48 FUEL SYSTEM (DFI) Inlet Air Temperature Sensor (Service Code 13) Sensor Resistance Inspection • Remove the inlet air temperature sensor (see this sec- tion). • Suspend the sensor [A] in a container of machine oil so that the heat-sensitive portion is submerged. •...
  • Page 115: Water Temperature Sensor (service Code 14)

    4.8 V, the ECU is normal. If the wiring is good, check the water temperature sensor resistance. • Remove the needle adapter set, and apply silicone sealant to the seals of the connector for waterproofing. Silicone Sealant (Kawasaki Bond: 56019–120) – Seals of ECU Connectors...
  • Page 116: Sensor Resistance Inspection

    3-50 FUEL SYSTEM (DFI) Water Temperature Sensor (Service Code 14) A. ECU D. Water Temperature Sensor V. Coolant Temperature Gauge in Tachometer Sensor Resistance Inspection • Remove the water temperature sensor (see this section). • Refer to the Electrical System chapter for water temper- ature sensor inspection.
  • Page 117: Atmospheric Pressure Sensor (service Code 15)

    FUEL SYSTEM (DFI) 3-51 Atmospheric Pressure Sensor (Service Code 15) CAUTION Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. NOTE ○ The atmospheric pressure sensor is the same part as the inlet air pressure sensor except that the inlet air pressure sensor has the vacuum hose and different wiring.
  • Page 118: Output Voltage Inspection

    3-52 FUEL SYSTEM (DFI) Atmospheric Pressure Sensor (Service Code 15) Output Voltage Inspection • Measure the output voltage at the ECU in the same way as input voltage inspection. Note the following. Digital Meter [A] ECU Connector [B] Atmospheric Pressure Sensor Output Voltage Connections to ECU Meter (+) →...
  • Page 119 FUEL SYSTEM (DFI) 3-53 Atmospheric Pressure Sensor (Service Code 15) Va: Atmospheric Pressure Sensor Output ST: Standard of Sensor Output Voltage (v) Voltage (v) H: Altitude (m or feet) UR: Usable Range of Sensor Output Voltage (v) A. ECU E. Atmospheric Pressure Sensor...
  • Page 120: Crankshaft Sensor (service Code 21)

    3-54 FUEL SYSTEM (DFI) Crankshaft Sensor (Service Code 21) Start the engine and switch the diagnosis mode to Dealer 1 mode to know all the problem that the DFI system has at the time of self-diagnosis. If the engine cannot be started, the self-diagnosis system does not detect dynamic condi- tion of the crankshaft sensor.
  • Page 121: Camshaft Position Sensor (service Code 23)

    FUEL SYSTEM (DFI) 3-55 Camshaft Position Sensor (Service Code 23) Start the engine and switch the diagnosis mode to Dealer 1 mode to know all the problem that the DFI system has at the time of self-diagnosis. If the engine cannot be started, the self-diagnosis system does not detect dynamic condi- tion of the camshaft position sensor.
  • Page 122: Speed Sensor (service Code 24, 25)

    3-56 FUEL SYSTEM (DFI) Speed Sensor (Service Code 24, 25) Speed Sensor Removal/Installation • See the Switches and Sensors section in the Electrical System chapter. Speed Sensor Inspection • See the Switches and Sensors section in the Electrical System chapter. Input Voltage Inspection NOTE ○...
  • Page 123 FUEL SYSTEM (DFI) 3-57 Speed Sensor (Service Code 24, 25) • Disconnect the speed sensor connector [A] and connect the harness adapter [B] between the harness connector and speed sensor connector. Engine Sprocket Cover [C] • Connect a digital meter to the harness adapter leads. Special Tool - Throttle Sensor Setting Adapter: 57001–1400 •...
  • Page 124: Vehicle-down Sensor (service Code 31)

    3-58 FUEL SYSTEM (DFI) Vehicle-down Sensor (Service Code 31) Removal CAUTION Never drop the down-sensor, especially on a hard surface. Such a shock to the sensor can damage it. • Remove: Connection and Vehicle-down Sensor [A] Bolts [B] Installation • The UP mark [A] of the sensor should face upward.
  • Page 125 • Remove the needle adapter set, and apply silicone sealant to the seals of the connector for waterproofing. Silicone Sealant (Kawasaki Bond: 56019–120) – Seals of Vehicle-down Sensor Connector If the output voltage is normal, the wiring is suspect. Check the wiring.
  • Page 126 3-60 FUEL SYSTEM (DFI) Vehicle-down Sensor (Service Code 31) A. ECU a. ECU Fuse 15 A f. Sealed Battery S. ECU Main Relay b. Vehicle-down Sensor j. Joint Connector B T. Ignition Switch d. Starter Relay k. Main Fuse 30 A...
  • Page 127: Subthrottle Sensor (service Code 32)

    FUEL SYSTEM (DFI) 3-61 Subthrottle Sensor (Service Code 32) Subthrottle Sensor Removal/Adjustment CAUTION Do not remove or adjust the subthrottle sensor [A] since it has been adjusted and set with precision at the factory. Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it.
  • Page 128: Output Voltage Inspection

    3-62 FUEL SYSTEM (DFI) Subthrottle Sensor (Service Code 32) Output Voltage Inspection • Remove the throttle body assy (see Throttle Body Assy Removal). • Measure the output voltage at the subthrottle sensor in the same way as input voltage inspection. Note the fol- lowing.
  • Page 129: Resistance Inspection

    FUEL SYSTEM (DFI) 3-63 Subthrottle Sensor (Service Code 32) Resistance Inspection • Turn the ignition switch OFF. • Disconnect the subthrottle sensor connector. • Connect a digital meter [A] to the subthrottle sensor con- nector [B]. • Measure the subthrottle sensor resistance. Throttle Sensor Resistance Connections: BL lead [C] ←→...
  • Page 130: Stick Coils (#1, #2, #3, #4: Service Code 51, 52, 53, 54)

    3-64 FUEL SYSTEM (DFI) Stick Coils (#1, #2, #3, #4: Service Code 51, 52, 53, 54) Stick Coil #1: Ignition Coil (Service Code 51) Stick Coil #2: Ignition Coil (Service Code 52) Stick Coil #3: Ignition Coil (Service Code 53) Stick Coil #4: Ignition Coil (Service Code 54) Removal/Installation CAUTION...
  • Page 131 FUEL SYSTEM (DFI) 3-65 Stick Coils (#1, #2, #3, #4: Service Code 51, 52, 53, 54) A. ECU X. Ignition Fuse 10 A f. Sealed Battery M. Stick Coils Y. Junction Box k. Main Fuse 30 A N. Engine Stop Switch d.
  • Page 132: Subthrottle Valve Actuator (service Code 62)

    3-66 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 133: Input Voltage Inspection

    FUEL SYSTEM (DFI) 3-67 Subthrottle Valve Actuator (Service Code 62) Input Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch OFF. • Remove the throttle body assy (see Throttle Body Assy Removal). • Connect the peak voltage adapter [A] and a digital meter [B] to the connector [C], using the needle adapter set [D].
  • Page 134: Fi Indicator Led Light

    3-68 FUEL SYSTEM (DFI) FI Indicator LED Light Inspection Flow Chart...
  • Page 135: Led Light Inspection

    FUEL SYSTEM (DFI) 3-69 FI Indicator LED Light LED Light Inspection • Remove the meter unit (see Electrical System chapter). • Using two auxiliary leads, supply battery power to the FI indicator LED light [A]. 12 V Battery [B] FI Indicator LED Light Check Connector: Meter Connector [C] (disconnected) BR/W Lead Terminal [1] of the Meter →...
  • Page 136: Ecu

    3-70 FUEL SYSTEM (DFI) CAUTION Never drop the ECU, especially on a hard surface. Such a shock to the ECU can damage it. ECU Removal • Remove: Seats (see Frame chapter) Junction Box [A] • Take the ECU [A] out along with the harness. •...
  • Page 137 FUEL SYSTEM (DFI) 3-71 • With the ECU connectors [A] connected, check the fol- lowing ground lead for continuity with the ignition switch OFF, using a tester and needle adapter set. ECU Grounding Inspection 26, 50, or 51 (BK/Y) ←→ Battery (–) Terminal: 0 Ω Terminal Engine Ground ←→...
  • Page 138 3-72 FUEL SYSTEM (DFI) ECU Power Source Circuit A. ECU a. ECU Fuse 15 A f. Sealed Battery S. ECU Main Relay d. Starter Relay j. Joint Connector B T. Ignition Switch e. Joint Connector C k. Main Fuse 30 A...
  • Page 139: Dfi Power Source

    FUEL SYSTEM (DFI) 3-73 DFI Power Source ECU Fuse Removal • Refer to the Electrical System chapter for the ECU fuse removal. ECU Fuse Installation If a fuse fails during operation, inspect the DFI system to determine the cause, and then replace it with a new fuse of proper amperage.
  • Page 140: Fuel Line

    3-74 FUEL SYSTEM (DFI) Fuel Line Fuel Pressure Inspection NOTE ○ This inspection can determine which trouble the DFI system has, mechanical or electrical trouble. ○ It is preferable to measure the fuel pressure while run- ning the motorcycle just when trouble occurred in order to know symptom well.
  • Page 141: Fuel Flow Rate Inspection

    FUEL SYSTEM (DFI) 3-75 Fuel Line • Start the engine, and let it idle. • Measure the fuel pressure with the engine idling. Fuel Pressure (idling) Standard: 310 kPa (3.2 kgf/cm², 46 psi) NOTE ○ The gauge needle will fluctuate. Read the pressure at the average of the maximum and minimum indications.
  • Page 142 3-76 FUEL SYSTEM (DFI) Fuel Line • Open the fuel tank cap [A] to lower the pressure in the tank. • Be sure to place a piece of cloth around the fuel pump outlet hose. • Remove the fuel pump outlet hose [A] from the fuel pump [B] and the delivery pipe [C] (see Fuel Pump Removal).
  • Page 143: Fuel Pump

    FUEL SYSTEM (DFI) 3-77 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 144: Operation Inspection

    3-78 FUEL SYSTEM (DFI) Fuel Pump • Replace the fuel pump gasket [A] with a new one. • Check that the fuel pump (–) terminal [A] and band [B] are in place. Front [C] • Apply a non-permanent locking agent to the threads of the fuel pump bolts.
  • Page 145: Pressure Regulator Removal

    FUEL SYSTEM (DFI) 3-79 Fuel Pump • Connect the hand tester (25 V DC) to the fuel pump con- nector [A] with needle adapter set. Special Tools - Hand Tester: 57001–1394 Needle Adapter Set: 57001–1457 ○ Measure the operating voltage with the engine stopped, and with the connector joined.
  • Page 146: Fuel Pump Relay Removal

    3-80 FUEL SYSTEM (DFI) Fuel Pump Fuel Pump Relay Removal CAUTION Never drop the relay, especially on a hard surface. Such a shock to the relay can damage it. • Remove the seat cover (see Frame chapter). • Remove the fuel pump relay [A] from the tongue of the storage compartment.
  • Page 147: Fuel Injectors

    FUEL SYSTEM (DFI) 3-81 Fuel Injectors Removal/Installation • Refer to the Throttle Body Assy Disassembly/Assembly. Audible Inspection • Start the engine. • Apply the tip of a screwdriver [A] to the injector [C]. Put the grip end onto your ear, and listen whether the injector is clicking or not.
  • Page 148: Output Voltage Inspection

    3-82 FUEL SYSTEM (DFI) Fuel Injectors Output Voltage Inspection • Turn the ignition switch OFF. • Remove the ECU (see ECU section). • Connect a digital voltmeter [A] to the ECU connector [B] with the needle adapter set [C]. Special Tool - Needle Adapter Set: 57001-1457 Injector Output Voltage Connections to Injector #1 Meter (+) →...
  • Page 149: Injector Signal Test

    FUEL SYSTEM (DFI) 3-83 Fuel Injectors Injector Signal Test • Prepare two test light sets with male terminals as shown. Rating of Bulb [A]: 12 V × 3 ∼ 3.4 W Terminal Width [B]: 1.8 mm (0.071 in.) Terminal Thickness [C]: 0.8 mm (0.031 in.) CAUTION Do not use larger terminals than specified above.
  • Page 150: Injector Resistance Inspection

    3-84 FUEL SYSTEM (DFI) Fuel Injectors Injector Resistance Inspection • Remove the fuel tank (see Fuel Tank Removal). • Disconnect the connector from the injector [A] (see Throt- tle Body Assy Disassembly/Assembly). • Measure the injector resistance with the hand tester [B]. Special Tool - Hand Tester: 57001–1394 Injector Resistance Connections to Injector...
  • Page 151 FUEL SYSTEM (DFI) 3-85 Fuel Injectors • Check the injector fuel line for leakage as follows: ○ Connect a commercially available vacuum/pressure pump [A] to the nipple of the delivery pipe [B] with a high-pressure fuel hose [C] (both ends connected with the clamps [D]) as shown.
  • Page 152 3-86 FUEL SYSTEM (DFI) Fuel Injectors A. ECU Y. Junction Box f. Sealed Battery K. Fuel Injectors Z. Fuel Pump Relay (for fuel j. Joint Connector B N. Engine Stop Switch pump an injectors) k. Main Fuse 30 A T. Ignition Switch d.
  • Page 153: Throttle Grip And Cables

    FUEL SYSTEM (DFI) 3-87 Throttle Grip and Cables Throttle Grip Play Inspection/Adjustment • Refer to the Throttle Control System Inspection in the Pe- riodic Maintenance chapter. Choke Lever Operation ○ Do not use the choke lever except when the engine has a starting difficulty like in cold weather (10°C, 50°F or below) or at high altitude.
  • Page 154: Throttle Body Assy

    3-88 FUEL SYSTEM (DFI) Throttle Body Assy Idle Speed Inspection • Refer to the Idle Speed Inspection in the Periodic Main- tenance chapter. Engine Vacuum Synchronization Inspection/ Adjustment • Refer to the Engine Vacuum Synchronization Inspection in the Periodic Maintenance chapter. High Altitude Performance Adjustment •...
  • Page 155 FUEL SYSTEM (DFI) 3-89 Throttle Body Assy • Loosen: Throttle Assy Holder Clamp Bolts [A] Air Cleaner Duct Clamp Bolts [B] • Remove: Right and Left Side Covers (see Frame chapter) Coolant Reserve Tank (see Cooling System in the Peri- odic Maintenance chapter) Crankcase Breather Hose Right and Left Air Cleaner Housing Mounting Bolts [A]...
  • Page 156: Throttle Body Assy Installation

    3-90 FUEL SYSTEM (DFI) Throttle Body Assy • Remove the bolt [A] and the throttle cable plate [B] from the throttle body front side. • Remove the throttle cable lower ends from the throttle pulley. • Remove: Choke Cable Upper End (From choke lever) Choke Cable Lower End [A] •...
  • Page 157: Throttle Body Assy Disassembly

    FUEL SYSTEM (DFI) 3-91 Throttle Body Assy • Apply a thin coating of grease to the throttle cable upper ends. • Install the upper ends of the throttle cables in the grip. • Fit the projection [A] of the right switch housing into the hole [B] of the handlebar.
  • Page 158: Throttle Body Assy Assembly

    3-92 FUEL SYSTEM (DFI) Throttle Body Assy CAUTION Never drop the injector, especially on a hard sur- face. Such a shock to the injector can damage it. • Pull out the injectors along with the delivery pipe [A]. If necessary, remove the injectors from the delivery pipe. Replace the O-rigs of the indicators.
  • Page 159: Air Cleaner

    FUEL SYSTEM (DFI) 3-93 Air Cleaner Element Removal/Installation • Refer to the Air Cleaner Element Cleaning in the Periodic Maintenance chapter. Air Cleaner Oil Draining A drain hose is connected to the bottom of the air cleaner to drain water or oil accumulated in the cleaner part. •...
  • Page 160: Fuel Tank

    3-94 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 161: Fuel Tank Installation

    FUEL SYSTEM (DFI) 3-95 Fuel Tank • Be sure to place a piece of cloth [A] around the fuel hose pump outlet joint [B]. • While pinching the hose joint locks [C] with fingers, pull the joint out along the delivery pipe. WARNING Be prepared for fuel spillage;...
  • Page 162: Fuel Tank And Cap Inspection

    3-96 FUEL SYSTEM (DFI) Fuel Tank • Insert the pump outlet hose joint [A] straight onto the de- livery pipe [B] until the hose joint clicks [C]. Front [D] • Push and pull [A] the hose joint [B] back and forth more than two times and make sure it is locked and doesn’t come off.
  • Page 163 COOLING SYSTEM 4-1 Cooling System Table of Contents Exploded View........................Coolant Flow Chart......................... Specifications ......................... Special Tools and Sealant ...................... Coolant ........................... Coolant Deterioration Inspection..................Coolant Level Inspection....................Coolant Draining ....................... Coolant Filling ........................Pressure Testing ....................... Cooling System Flushing ....................Coolant Reserve Tank Removal/Installation ..............
  • Page 164: Exploded View

    4-2 COOLING SYSTEM Exploded View...
  • Page 165 COOLING SYSTEM 4-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Radiator hose clamp screws 0.20 17 in·lb Radiator fan bolts 0.85 74 in·lb Water pump impeller bolt 87 in·lb Water pump cover bolts 95 in·lb Water pump drain bolt 95 in·lb Water pipe bolts 95 in·lb...
  • Page 166: Coolant Flow Chart

    4-4 COOLING SYSTEM Coolant Flow Chart...
  • Page 167 COOLING SYSTEM 4-5 Coolant Flow Chart 1. Drain Bolt 10. Reserve Tank Hose 2. Water Pump 11. Reserve Tank Overflow Hose 3. Cylinder Jacket 12. Radiator Fan 4. Cylinder Head Jacket 13. Water Temperature Sensor 5. Thermostat Housing 14. Radiator Fan Switch 6.
  • Page 168: Specifications

    4-6 COOLING SYSTEM Specifications Item Standard Coolant provided when shipping: Permanent type of antifreeze (soft water and ethylene glycol Type (recommended) 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 169: Special Tools And Sealant

    COOLING SYSTEM 4-7 Special Tools and Sealant Bearing Driver: Kawasaki Bond (Silicone Sealant): 57001–382 56019–120 Bearing Driver Set: 57001–1129...
  • Page 170: Coolant

    4-8 COOLING SYSTEM Coolant Coolant Deterioration Inspection • Remove the left side cover (see Frame chapter). • Visually inspect the coolant [A] in the reserve tank. If whitish cotton-like wafts are observed, aluminum parts in the cooling system are corroded. If the coolant is brown, iron or steel parts are rusting.
  • Page 171: Pressure Testing

    COOLING SYSTEM 4-9 Coolant Pressure Testing • Remove the fuel tank (see Fuel System (DFI) chapter). • Remove the radiator cap, and install a cooling system pressure tester [A] on the filler neck [B]. NOTE ○ Wet the cap sealing surfaces with water or coolant to prevent pressure leaks.
  • Page 172: Water Pump

    4-10 COOLING SYSTEM Water Pump Water Pump Removal • Refer to the Oil Pump Removal in the Engine Lubrication System chapter. Water Pump Installation • Refer to the Oil Pump Installation in the Engine Lubrica- tion System chapter. Water Pump Inspection •...
  • Page 173: Water Pump Housing Assembly

    COOLING SYSTEM 4-11 Water Pump • Take the oil seal [A] out of the housing [B] with a hook [C]. Water Pump Housing Assembly CAUTION Do not reuse the mechanical seal and oil seal. • Apply high temperature grease to the oil seal lips [A]. •...
  • Page 174: Radiator

    4-12 COOLING SYSTEM Radiator Radiator and Radiator Fan Removal WARNING The radiator fan is connected directly to the bat- tery. The radiator fan may start even if the ignition switch is off. NEVER TOUCH THE RADIATOR FAN UNTIL THE RADIATOR FAN CONNECTOR IS DIS- CONNECTED.
  • Page 175: Radiator And Radiator Fan Installation

    COOLING SYSTEM 4-13 Radiator Radiator and Radiator Fan Installation • Installation is the reverse of removal. • Install the radiator bracket collars [A] as shown. Rubber Damper [B] 30 ∼ 40° [C] Radiator [D] Bracket [E] • Tighten: Torque - Radiator Lower Bolts [F]: 7.0 N·m (0.70 kgf·m, 61 in·lb) Radiator Upper Bolts [G]: 7.0 N·m (0.70 kgf·m, 61 in·lb)
  • Page 176: Radiator Filler Neck Inspection

    4-14 COOLING SYSTEM Radiator • Install the cap [A] on a cooling system pressure tester [B]. NOTE ○ Wet the cap sealing surfaces with water or coolant to prevent pressure leaks. • Watching the pressure gauge, pump the pressure tester to build up the pressure until the relief valve opens: the gauge needle flicks downward.
  • Page 177: Thermostat

    COOLING SYSTEM 4-15 Thermostat Thermostat Removal • Drain the coolant (see Cooling System in the Periodic Maintenance chapter). • Remove: Fuel Tank (see Fuel System (DFI) chapter) Thermostat Bracket Bolt [A] Ground Lead [B] Water Temperature Sensor Connector [C] Three Water Hoses [D] •...
  • Page 178 4-16 COOLING SYSTEM Thermostat • To check valve opening temperature, suspend the ther- mostat [A] in a container of water and raise the tempera- ture of the water. ○ The thermostat must be completely submerged and must not touch the container sides or bottom. Suspend an ac- curate thermometer [B] in the water so that the heat sen- sitive portions [C] are located in almost the same depth.
  • Page 179: Hoses And Pipes

    COOLING SYSTEM 4-17 Hoses and Pipes Hose Installation • Install the hoses and pipes, being careful to follow bend- ing direction. Avoid sharp bending, kinking, flattening or twisting. • Run the hoses in accordance with the Cable, Wire, and Hose Routing section in the Appendix chapter. •...
  • Page 180: Radiator Fan Switch, Water Temperature Sensor

    4-18 COOLING SYSTEM Radiator Fan Switch, Water Temperature Sensor CAUTION The fan switch or the water temperature sensor should never be allowed to fall on a hard surface. Such a shock to their parts can damage them. Radiator Fan Switch Removal •...
  • Page 181 ENGINE TOP END 5-1 Engine Top End Table of Contents Exploded View........Cylinder Head Warp..... 5-20 Specifications ........Valves ..........5-21 Special Tools and Sealant ....Valve Clearance Inspection ..5-21 Clean Air System....... 5-10 Valve Removal ......5-21 Air Suction Valve Removal... 5-10 Valve Installation ......
  • Page 182: Exploded View

    5-2 ENGINE TOP END Exploded View...
  • Page 183 M: Apply molybdenum disulfide grease. MO: Apply molybdenum disulfide oil. (mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10:1) R: Replacement Parts S: Follow the specific tightening sequence. SS: Apply silicone sealant (Kawasaki Bond: 56019–120).
  • Page 184 5-4 ENGINE TOP END Exploded View...
  • Page 185 ENGINE TOP END 5-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Coolant drain plug (cylinder) 87 in·lb Exhaust pipe manifold holder nuts Muffler body clamp bolt Muffler body mounting bolt Crankshaft sensor cover bolts 95 in·lb 6. "1T" marked side faces up. 7.
  • Page 186: Specifications

    5-6 ENGINE TOP END Specifications Item Standard Service Limit Clean Air System: Vacuum switch valve closing Open → Close – – – 41 ∼ 49 kPa (310 ∼ 370 mmHg, 6.0 ∼ 7.1 pressure psi) Camshafts: Cam height: Exhaust 36.146 ∼ 36.254 mm (1.4231 ∼ 1.4273 in.) 36.05 mm (1.419 in.) 36.746 ∼...
  • Page 187 ENGINE TOP END 5-7 Specifications Item Standard Service Limit Valve spring free length: Exhaust 40.7 mm (1.602 in.) 38.9 mm (1.531 in.) Inlet 40.7 mm (1.602 in.) 38.9 mm (1.531 in.) Cylinder, Pistons: 68.400 ∼ 68.412 mm (2.6929 ∼ 2.6934 in.) 68.50 mm (2.6969 in.) Cylinder inside diameter: 68.345 ∼...
  • Page 188: Special Tools And Sealant

    5-8 ENGINE TOP END Special Tools and Sealant Compression Gauge: Valve Seat Cutter, 32° - 25: 57001–221 57001–1118 Valve Spring Compressor Assembly: Valve Seat Cutter, 32° - 28: 57001–241 57001–1119 Piston Pin Puller Assembly: Valve Seat Cutter Holder Bar: 57001–910 57001–1128 Valve Seat Cutter, 45°...
  • Page 189 Valve Seat Cutter, 60° - 25: 57001–1274 57001–1328 Valve Seat Cutter Holder, 4: Valve Seat Cutter, 60° - 27: 57001–1275 57001–1409 Fork Oil Level Gauge: Spark Plug Wrench (Owner’s Tool): 57001–1290 92110–1146 Compression Gauge Adapter, M10 × 1.0: Kawasaki Bond (Silicone Sealant): 57001–1317 56019–120...
  • Page 190: Clean Air System

    5-10 ENGINE TOP END Clean Air System Air Suction Valve Removal • Remove: Fuel Tank (see Fuel System (DFI) chapter) Connector [A] (from Clamp [B]) Air Suction Valve Cover Bolts [C] and Clamp Air Suction Valve Cover [D] Air Suction Valve Air Suction Valve Installation •...
  • Page 191: Vacuum Switch Valve Test

    ENGINE TOP END 5-11 Clean Air System Vacuum Switch Valve Test • Remove: Vacuum Switch Valve (see Vacuum Switch Valve Re- moval) • Connect a vacuum gauge [A] and syringe [B] or fork oil level gauge to the vacuum hoses as shown. Special Tool - Fork Oil Level Gauge: 57001–1290 Air Flow [C] •...
  • Page 192: Cylinder Head Cover

    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): 56019-120 • Install: Dowel Pins [A] Plug Hole Gaskets [B] •...
  • Page 193 ENGINE TOP END 5-13 Cylinder Head Cover • Tighten the cover bolts following the specified tightening sequence. Torque - Cylinder Head Cover Bolts [B]: 9.8 N·m (1.0 kgf·m, 87 in·lb) • Install the removed parts (see appropriate chapters).
  • Page 194: Camshaft Chain Tensioner

    5-14 ENGINE TOP END Camshaft Chain Tensioner Camshaft Chain Tensioner Removal CAUTION This is a non-return type camshaft chain tensioner. The push rod does not return to its original position once it moves out to take up camshaft chain slack. Observe all the rules listed below: When removing the tensioner, do not take out the mounting bolts only halfway.
  • Page 195: Camshaft, Camshaft Chain

    ENGINE TOP END 5-15 Camshaft, Camshaft Chain Camshaft Removal • Remove: Cylinder Head Cover (see Cylinder Head Cover Re- moval) Pickup Coil Cover • Position the crankshaft at #1, 4 piston TDC. TDC mark [A] for #1, 4 Pistons Timing Mark (crankcase halves mating surface) [B] •...
  • Page 196: Camshaft, Camshaft Cap Wear

    5-16 ENGINE TOP END Camshaft, Camshaft Chain • Position the crankshaft at #1, 4 piston TDC. • Pull the tension side (exhaust side) [A] of the chain taut to install the chain. • Engage the camshaft chain with the camshaft sprockets so that the timing marks on the sprockets are positioned as shown.
  • Page 197: Camshaft Runout

    ENGINE TOP END 5-17 Camshaft, Camshaft Chain If any clearance exceeds the service limit, measure the diameter of each camshaft journal with a micrometer. Camshaft Journal Diameter 23.950 ∼ 23.972 mm (0.9429 ∼ 0.9438 in.) Standard: Service Limit: 23.92 mm (0.942 in.) If the camshaft journal diameter is less than the service limit, replace the camshaft with a new one and measure the clearance again.
  • Page 198: Cylinder Head

    5-18 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: Seats (see Frame chapter) Fuel Tank (see Fuel System (DFI) chapter) Stick Coils Spark Plugs Owner’s Tool - Spark Plug Wrench, 16 mm: 92110–1146...
  • Page 199: Cylinder Head Removal

    ENGINE TOP END 5-19 Cylinder Head Cylinder Head Removal • Drain the coolant (see Cooling System chapter). • Remove: Exhaust Pipes (see Exhaust Pipe Removal) Coolant Drain Bolt [A] (cylinder) • Remove: Cylinder Head Cover (see Cylinder Head Cover Re- moval) Camshaft Position Sensor (see Electrical System chap- ter)
  • Page 200: Cylinder Head Warp

    5-20 ENGINE TOP END Cylinder Head • Install: Front Camshaft Chain Guide [A] O-ring [B] Collar [C] • Tighten: Torque - Front Camshaft Chain Guide Bolt (Upper) [D]: 25 N·m (2.5 kgf·m, 18 ft·lb) Front Camshaft Chain Guide Bolt (Lower) [E]: 12 N·m (1.2 kgf·m, 104 in·lb) •...
  • Page 201: Valves

    ENGINE TOP END 5-21 Valves Valve Clearance Inspection • Refer to the Engine Top End in the Periodic Maintenance chapter. Valve Removal • Remove the cylinder head (see Cylinder Head Removal). • Remove the valve lifter and shim. ○ Mark and record the valve lifter and shim locations so they can be installed in their original positions.
  • Page 202: Valve Guide Installation

    5-22 ENGINE TOP END Valves Valve Guide Installation • Apply oil to the valve guide outer surface before installa- tion. • Heat the area around the valve guide hole to about 120 ∼ 150°C (248 ∼ 302°F). • Drive the valve guide in from the top of the head using the valve guide arbor.
  • Page 203: Valve Seat Inspection

    ENGINE TOP END 5-23 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 204 5-24 ENGINE TOP END Valves Seat Cutter Operation Care: 1. This valve seat cutter is developed to grind the valve for repair. Therefore the cutter must not be used for other purposes than seat repair. 2. Do not drop or shock the valve seat cutter, or the dia- mond particles may fall off.
  • Page 205 ENGINE TOP END 5-25 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 206 5-26 ENGINE TOP END Valves If the seat width is too wide, make the 60° [A] grind de- scribed below. If the seat width is within the specified range, lap the valve to the seat as described below. • Grind the seat at a 60° angle until the seat width is within the specified range.
  • Page 207 ENGINE TOP END 5-27 Valves...
  • Page 208: Cylinder, Pistons

    5-28 ENGINE TOP END Cylinder, Pistons Cylinder Removal • Remove: Cylinder Head (see Cylinder Head Removal) Water Hose [A] • Remove the cylinder [B]. Cylinder Installation NOTE ○ If a new cylinder is used, use new piston ring. • Install the dowel pins [A] and new cylinder gasket [B]. •...
  • Page 209: Piston Installation

    ENGINE TOP END 5-29 Cylinder, Pistons • Remove the piston pins. Spec