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Ninja 300
Ninja 300 ABS
Motorcycle
Service Manual

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Table of Contents

   Summary of Contents for Kawasaki Ninja 300

  • Page 1 Ninja 300 Ninja 300 ABS Motorcycle Service Manual...
  • 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 rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Quality Assurance Division/Motorcycle & Engine Company/Kawasaki Heavy Industries, Ltd., Japan.
  • Page 6 LIST OF ABBREVIATIONS ampere(s) inch(s) ABDC after bottom dead center km/h kilometers per hour antilock brake system liter(s) alternating current liquid crystal display ampere hour light emitting diode ATDC after top dead center pound(s) BBDC before bottom dead center meter(s) bottom dead center minute(s) BTDC...
  • 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 11: Table Of Contents

    GENERAL INFORMATION 1-1 General Information Table of Contents Before Servicing ........................Model Identification......................... General Specifications......................Technical Information - Assist and Slipper Clutch ..............1-12 Unit Conversion Table ......................1-15...
  • 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, cotter pins or self-locking nuts 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 EX300AD (EUR Models) Left Side View EX300AD (EUR Models) Right Side View...
  • Page 18 1-8 GENERAL INFORMATION Model Identification EX300BD (EUR Models) Left Side View EX300BD (EUR Models) Right Side View Frame Number Engine Number...
  • Page 19: General Specifications

    GENERAL INFORMATION 1-9 General Specifications Items EX300AD/BD Dimensions Overall Length 2 015 mm (79.33 in.) Overall Width 715 mm (28.15 in.) Overall Height 1 110 mm (43.70 in.) Wheelbase 1 405 mm (55.31 in.) Road Clearance 140 mm (5.51 in.) Seat Height 785 mm (30.91 in.) Curb Mass:...
  • Page 20 1-10 GENERAL INFORMATION General Specifications Items EX300AD/BD Exhaust: Open 61° BBDC Close 31° ATDC Duration 272° Lubrication System Forced lubrication (wet sump) Engine Oil: Type API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2 Viscosity SAE 10W-40 Capacity 2.4 L (2.5 US qt) Drive Train...
  • Page 21 GENERAL INFORMATION 1-11 General Specifications Items EX300AD/BD Rear Suspension: Type Swingarm (uni-trak) Wheel Travel 132 mm (5.20 in.) Brake Type: Front Single disc Rear Single disc Electrical Equipment Battery 12 V 8 Ah Headlight: Type Semi-sealed beam Bulb: High 12 V 55 W (quartz-halogen) × 2 12 V 55 W (quartz-halogen) Tail/Brake Light 12 V 5/21 W...
  • Page 22: Technical Information - Assist And Slipper Clutch

    1-12 GENERAL INFORMATION Technical Information - Assist and Slipper Clutch 1) Overview This model has an Assist and Slipper clutch. The new Assist and Slipper clutch was developed without changing the size and number of parts of the conventional clutch. It also decreases the spring load (clutch lever load) and back-torque (during deceleration).
  • Page 23 GENERAL INFORMATION 1-13 Technical Information - Assist and Slipper Clutch A. Clutch Pressure Plate B. Clutch Hub C. Assist Cams (6 points) D. Slipper Cams (6 points)
  • Page 24 1-14 GENERAL INFORMATION Technical Information - Assist and Slipper Clutch 4) Assist Mechanism When the rotating force [A] of the clutch pressure plate [B] surpasses the rotating force [C] of the clutch hub [D] by the torque [E] generated by the crankshaft during acceleration, the assist cams [F] engage [G] and the clutch pressure plate applies force to the clutch plates [H].
  • Page 25: Unit Conversion Table

    GENERAL INFORMATION 1-15 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 27: Periodic Maintenance

    PERIODIC MAINTENANCE 2-1 Periodic Maintenance Table of Contents Periodic Maintenance Chart ....................Torque and Locking Agent...................... Specifications ......................... 2-11 Special Tools .......................... 2-13 Periodic Maintenance Procedures..................2-14 Fuel System (DFI)........................ 2-14 Air Cleaner Element Cleaning................... 2-14 Air Cleaner Element Replacement..................2-15 Idle Speed Inspection .......................
  • Page 28 2-2 PERIODIC MAINTENANCE Suspension System ......................2-48 Lubrication of Rear Suspension..................2-49 Steering ..........................2-50 Steering Play Inspection ....................2-50 Steering Play Adjustment....................2-50 Steering Stem Bearing Lubrication ................... 2-51 Electrical System ......................... 2-52 Lights and Switches Operation Inspection................ 2-52 Headlight Aiming Inspection .....................
  • Page 29: Periodic Inspection

    PERIODIC MAINTENANCE 2-3 Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition.The initial maintenance is vitally important and must not be neglected. Periodic Inspection *A: Service at number of years shown or indicated odometer reading intervals, whichever comes first.
  • Page 30 2-4 PERIODIC MAINTENANCE Periodic Maintenance Chart Odometer Reading (*B) × 1 000 km (× 1 000 mile) year (*A) Page Items (0.6) (3.8) (7.6) (11.4) (15.2) Final Drive Drive chain lubrication condition (*C) 2-34 : every 600 km (400 mile) Drive chain slack (*C) 2-34 : every 1 000 km (600 mile)
  • Page 31: Torque And Locking Agent

    PERIODIC MAINTENANCE 2-5 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: G: Apply grease. HL: Apply a non-permanent locking agent (High Strength). L: Apply a non-permanent locking agent.
  • Page 32 2-6 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Water Hose Fitting Bolts 87 in·lb Water Pump Cover Bolts 87 in·lb Water Pump Impeller 87 in·lb Water Pump Bolts 87 in·lb Coolant Drain Bolt (Water Pump) 87 in·lb Water Pipe Bolt 87 in·lb...
  • Page 33 PERIODIC MAINTENANCE 2-7 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Oil Pump Mounting Bolts 87 in·lb Oil Pressure Switch Terminal Bolt 0.15 13 in·lb Oil Pressure Switch Oil Pipe Banjo Bolt (Inside) 106 in·lb Oil Pressure Relief Valve Oil Pan Bolts 87 in·lb Engine Oil Drain Bolt...
  • Page 34 2-8 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Brake Lever Pivot Bolt Locknut 0.60 52 in·lb Front Master Cylinder Clamp Bolts 0.90 78 in·lb Front Brake Light Switch Screw 0.12 11 in·lb Bleed Valve 0.56 49 in·lb Front Brake Pad Pins 17.2...
  • Page 35 PERIODIC MAINTENANCE 2-9 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Electrical System Front Brake Light Switch Screw 0.12 11 in·lb Switch Housing Screws 0.36 31 in·lb Spark Plugs 115 in·lb Crankshaft Sensor Screws 0.53 46 in·lb Alternator Rotor Bolt 107.8 10.99 79.51...
  • Page 36 2-10 PERIODIC MAINTENANCE Torque and Locking Agent The table below, relating tightening torque to thread diameter, lists the basic torque for the bolts and nuts. Use this table for only the bolts and nuts which do not require a specific torque value. All of the values are for use with dry solvent-cleaned threads.
  • Page 37: Specifications

    PERIODIC MAINTENANCE 2-11 Specifications Item Standard Service Limit Fuel System (DFI) 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Throttle Grip Free Play – – – Idle Speed 1 300 ±50 r/min (rpm) – – – Throttle Body Vacuum 24.7 ±1.33 kPa (185 ±10 mmHg) at idle –...
  • Page 38 2-12 PERIODIC MAINTENANCE Specifications Item Standard Service Limit Air Pressure (when Cold): Front Up to 180 kg (397 lb) load: – – – 200 kPa (2.00 kgf/cm², 28 psi) Rear Up to 180 kg (397 lb) load: – – – 225 kPa (2.25 kgf/cm², 32 psi) Final Drive 20 ∼...
  • Page 39: Special Tools

    PERIODIC MAINTENANCE 2-13 Special Tools Inside Circlip Pliers: Filler Cap Driver: 57001-143 57001-1454 Steering Stem Nut Wrench: Throttle Sensor Setting Adapter: 57001-1100 57001-1538 Jack: Extension Tube: 57001-1238 57001-1578 Oil Filter Wrench: Jack Attachment: 57001-1249 57001-1608 Vacuum Gauge: 57001-1369...
  • Page 40: Periodic Maintenance Procedures

    2-14 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel System (DFI) Air Cleaner Element Cleaning NOTE ○ In dusty areas, the element should be cleaned more frequently than the recommended interval. WARNING If dirt or dust is allowed to pass through into the throttle assy, the throttle may become stuck, pos- sibly causing accident.
  • Page 41: Air Cleaner Element Replacement

    PERIODIC MAINTENANCE 2-15 Periodic Maintenance Procedures Air Cleaner Element Replacement NOTE ○ In dusty areas, the element should be replaced more frequently than the recommended interval. ○ After riding through rain or on muddily roads, the ele- ment should be replaced immediately. WARNING If dirt or dust is allowed to pass through into the throttle assy, the throttle may become stuck, pos-...
  • Page 42: Idle Speed Inspection

    2-16 PERIODIC MAINTENANCE Periodic Maintenance Procedures Idle Speed Inspection • Start the engine and warm it up thoroughly. • With the engine idling, turn the handlebars to both sides [A]. If handlebar movement changes the idle speed, the throttle cables may be improperly adjusted or incorrectly routed or damaged.
  • Page 43: Engine Vacuum Synchronization Inspection

    PERIODIC MAINTENANCE 2-17 Periodic Maintenance Procedures If the throttle grip free play can not be adjusted with the adjuster, use the adjusters in the lower ends of the throttle cables. • Remove: Left Middle Fairing (see Middle Fairing Removal in the Frame chapter) •...
  • Page 44 2-18 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Connect a vacuum gauge (special tool) and hoses [A] to the fittings on the throttle body. Special Tool - Vacuum Gauge: 57001-1369 • Connect a highly accurate tachometer to one of the stick coil primary leads.
  • Page 45 PERIODIC MAINTENANCE 2-19 Periodic Maintenance Procedures • Turn out the bypass screw of the higher vacuum between #1 [A] and #2 [B] to the lower vacuum. • Open and close the throttle valves after each measure- ment and adjust the idle speed as necessary. •...
  • Page 46: Fuel System

    2-20 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel System Fuel Hose Inspection (fuel leak, damage, installation condition) ○ If the motorcycle is not properly handled, the high pres- sure inside the fuel line can cause fuel to leak [A] or the hose to burst.
  • Page 47: Fuel Hose Replacement

    PERIODIC MAINTENANCE 2-21 Periodic Maintenance Procedures Fuel Hose Replacement WARNING Fuel is flammable and explosive under certain con- ditions and can cause severe burns. Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately. When the fuel hose is dis- connected, fuel spills out from the hose and the pipe because of residual pressure.
  • Page 48 2-22 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Pull the fuel hose joint [A] out of the delivery pipe. • Clean the delivery pipe. • Cover the delivery pipe with the vinyl bag to keep it clean. • Remove the vinyl bag on the pipe. •...
  • Page 49: Evaporative Emission Control System Inspection (cal Model)

    PERIODIC MAINTENANCE 2-23 Periodic Maintenance Procedures Evaporative Emission Control System Inspection (CAL Model) • Inspect the canister as follows. ○ Remove: Left Middle Fairing (see Middle Fairing Removal in the Frame chapter) ○ Remove the canister [A], and disconnect the hoses from the canister.
  • Page 50: Cooling System

    2-24 PERIODIC MAINTENANCE Periodic Maintenance Procedures Cooling System Water Hose and Pipe Inspection (coolant leak, damage, installation condition) ○ 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.
  • Page 51 PERIODIC MAINTENANCE 2-25 Periodic Maintenance Procedures • Place a container under the coolant drain bolts [A], then remove the drain bolts. ○ The coolant will drain from the radiator and engine. • Remove the hose [A]. • Pour the coolant into a suitable container. •...
  • Page 52: Water Hose And O-ring Replacement

    2-26 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Fill the radiator up to the filler neck [A] with coolant. NOTE ○ Pour in the coolant slowly so that it can expel the air from the engine and radiator. • Check the cooling system for leaks. •...
  • Page 53: Engine Top End

    PERIODIC MAINTENANCE 2-27 Periodic Maintenance Procedures Engine Top End Valve Clearance Inspection NOTE ○ Valve clearance must be checked and adjusted when the engine is cold (at room temperature). • Remove: Cylinder Head Cover (see Cylinder Head Cover Re- moval in the Engine Top End chapter) Plugs [A] [B] Special Tool - Filler Cap Driver: 57001-1454 •...
  • Page 54: Valve Clearance Adjustment

    2-28 PERIODIC MAINTENANCE Periodic Maintenance Procedures Valve Clearance Measuring Position #2 Piston TDC at End of Compression Stroke: Intake Valve Clearances of #2 Piston Exhaust Valve Clearances of #2 Piston If the valve clearance is not within the specified range, first record the clearance, and then adjust it.
  • Page 55 PERIODIC MAINTENANCE 2-29 Periodic Maintenance Procedures Adjustment Shims Thickness Part Number Mark 2.50 92180-1014 2.55 92180-1016 2.60 92180-1018 2.65 92180-1020 2.70 92180-1022 2.75 92180-1024 2.80 92180-1026 2.85 92180-1028 2.90 92180-1030 2.95 92180-1032 3.00 92180-1034 3.05 92180-1036 3.10 92180-1038 3.15 92180-1040 3.20 92180-1042 3.25...
  • Page 56: Air Suction System Damage Inspection

    2-30 PERIODIC MAINTENANCE Periodic Maintenance Procedures Air Suction System Damage Inspection • Remove: Middle Fairings (see Middle Fairing Removal in the Frame chapter) Fuel Tank Bolts (see Fuel Tank Removal in the Fuel Sys- tem (DFI) chapter) • Remove the air switching valve hose [A] from the air cleaner housing.
  • Page 57: Engine Lubrication System

    PERIODIC MAINTENANCE 2-31 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 cable holder [D].
  • Page 58: Oil Filter Replacement

    2-32 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Pour in the specified type and amount of oil. Recommended Engine Oil Type: API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2 Viscosity: SAE 10W-40 Capacity: 2.0 L (2.1 US qt) (when filter is not removed) 2.2 L (2.3 US qt) (when filter is removed) 2.4 L (2.5 US qt) (when engine is...
  • Page 59: Wheels/tires

    PERIODIC MAINTENANCE 2-33 Periodic Maintenance Procedures Wheels/Tires Air Pressure Inspection • Remove the air valve cap. • Measure the tire air pressure with an air pressure gauge [A] when the tires are cold (that is, when the motorcycle has not been ridden more than a mile during the past 3 hours).
  • Page 60: Wheel Bearing Damage Inspection

    2-34 PERIODIC MAINTENANCE Periodic Maintenance Procedures Tread Depth Standard: Front 4.2 mm (0.17 in.) Rear 6.4 mm (0.25 in.) Service Limit: Front 1 mm (0.04 in.) (AT, CH, DE) 1.6 mm (0.06 in.) Rear 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 61: Final Drive

    PERIODIC MAINTENANCE 2-35 Periodic Maintenance Procedures Final Drive Drive Chain Lubrication Condition Inspection • 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 62: Drive Chain Slack Adjustment

    2-36 PERIODIC MAINTENANCE Periodic Maintenance Procedures Drive Chain Slack Adjustment • Remove the cotter pin [A], and loosen the axle nut [B]. • Loosen the both chain adjuster locknuts [C]. If the chain is too loose, turn out the left and right chain adjusters [D] evenly.
  • Page 63: Wheel Alignment Inspection

    PERIODIC MAINTENANCE 2-37 Periodic Maintenance Procedures Wheel Alignment Inspection • Check that the notch [A] on the left alignment indicator [B] aligns with the same swingarm mark or position [C] that the right alignment indicator notch aligns with. If they do not, adjust the chain slack and align the wheel alignment (see Drive Chain Slack Adjustment).
  • Page 64: Chain Guide Wear Inspection

    2-38 PERIODIC MAINTENANCE Periodic Maintenance Procedures Chain Guide Wear Inspection • Visually inspect the chain guide [A]. If it shows any signs of abnormal wear or damage, replace the chain guide by removing the bolt [B].
  • Page 65: Brakes

    PERIODIC MAINTENANCE 2-39 Periodic Maintenance Procedures Brakes Brake System Brake Fluid Leak (Brake Hose and Pipe) Inspection • For models equipped with an ABS, remove the fuel tank (see Fuel Tank Removal in the Fuel System (DFI) chap- ter). • 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].
  • Page 66: Brake Fluid Level Inspection

    2-40 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Hose and Pipe Damage and Installation Condi- tion Inspection • For models equipped with an ABS, remove the fuel tank (see Fuel Tank Removal in the Fuel System (DFI) chap- ter). • Inspect the brake hoses and fittings for deterioration, cracks and signs of leakage.
  • Page 67: Brake Fluid Change

    PERIODIC MAINTENANCE 2-41 Periodic Maintenance Procedures • Check that the brake fluid level in the rear brake reservoir [A] is above the lower level line [B]. If the fluid level is lower than the lower level line, fill the reservoir to the upper level line [C]. WARNING Mixing brands and types of brake fluid can reduce the brake system’s effectiveness and cause an ac-...
  • Page 68 2-42 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Change the brake fluid. ○ Repeat this operation until fresh brake fluid comes out from the plastic hose or the color of the fluid changes. 1. Open the bleed valve [A]. 2. Apply the brake and hold it [B]. 3.
  • Page 69: Brake Hose And Pipe Replacement

    PERIODIC MAINTENANCE 2-43 Periodic Maintenance Procedures Brake Hose and Pipe Replacement NOTICE Brake fluid quickly ruins painted plastic surfaces; any spilled fluid should be completely washed away immediately. • Remove the brake hose banjo bolts [A]. • Remove the brake hoses [B], noting the following. ○...
  • Page 70: Master Cylinder Rubber Parts Replacement

    2-44 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Install the brake hose, noting the following. ○ Replace the washers [A] on each side of hose fitting [B] with new ones. ○ Avoid sharp bending, kinking, flattening or twisting, and route the hoses according to Cable, Wire, and Hose Rout- ing section in the Appendix chapter.
  • Page 71 PERIODIC MAINTENANCE 2-45 Periodic Maintenance Procedures Rear Master Cylinder Disassembly NOTE ○ Do not remove the push rod clevis for master cylinder disassembly since removal requires brake position ad- justment. • Remove the rear master cylinder (see Rear Master Cylin- der Removal in the Brakes chapter).
  • Page 72: Caliper Rubber Parts Replacement

    2-46 PERIODIC MAINTENANCE Periodic Maintenance Procedures Caliper Rubber Parts Replacement NOTE ○ The procedure to assembly/disassembly the front caliper is as follows. Assembling/disassembling the rear caliper is the same as for the front caliper. Caliper Disassembly • Remove: Front/Rear Caliper (see Front/Rear Caliper Removal in the Brakes chapter) Brake Pads (see Brake Pad Removal in the Brakes chapter)
  • Page 73: Brake Pad Wear Inspection

    PERIODIC MAINTENANCE 2-47 Periodic Maintenance Procedures • 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 the cylinders by hand. • Replace the dust seals [B] with new ones.
  • Page 74: Suspension

    2-48 PERIODIC MAINTENANCE Periodic Maintenance Procedures 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] NOTICE To avoid damaging the electrical connections in-...
  • Page 75: Lubrication Of Rear Suspension

    PERIODIC MAINTENANCE 2-49 Periodic Maintenance Procedures Front Fork Oil Leak Inspection • Visually inspect the front forks [A] for oil leakage. Replace 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 76: Steering

    2-50 PERIODIC MAINTENANCE Periodic Maintenance Procedures Steering Steering Play Inspection • Remove the lower fairings (see Lower Fairing Removal in the Frame chapter). • Raise the front wheel off the ground with the jack. Special Tools - Jack: 57001-1238 Jack Attachment: 57001-1608 •...
  • Page 77: Steering Stem Bearing Lubrication

    PERIODIC MAINTENANCE 2-51 Periodic Maintenance Procedures Steering Stem Bearing Lubrication • Remove the steering stem (see Stem, Stem Bearing Re- moval in the Steering chapter). • Using a high flash-point solvent, wash the upper and lower [A] ball bearings, and wipe the upper and lower outer races, which are press-fitted into the frame head pipe, clean off grease and dirt.
  • Page 78: Electrical System

    2-52 PERIODIC MAINTENANCE Periodic Maintenance Procedures Electrical System Lights and Switches Operation Inspection First Step • Set the gear position in the neutral position. • Turn the ignition switch on. • The following lights should go on according to the table below.
  • Page 79 PERIODIC MAINTENANCE 2-53 Periodic Maintenance Procedures Meter Unit for Blue High Beam Indicator Light (LED) (see Meter Unit Inspection in the Electrical System chapter) ECU (see ECU Power Supply Inspection in the Fuel Sys- tem (DFI) chapter) Ignition Switch (see Switch Inspection in the Electrical System chapter) Neutral Switch (see Switch Inspection in the Electrical System chapter)
  • Page 80: Headlight Aiming Inspection

    2-54 PERIODIC MAINTENANCE Periodic Maintenance Procedures Third Step • Set the dimmer switch [A] to low beam position. • Start the engine. • The low beam headlight should go on. If the low beam headlight does not go on, inspect or re- place the following item.
  • Page 81 PERIODIC MAINTENANCE 2-55 Periodic Maintenance Procedures Headlight Beam Horizontal Adjustment • Turn the horizontal adjuster [A] on the headlight in or out until the beam points straight ahead. If the headlight beam points too low or high, adjust the vertical beam. [B] Viewed from Rear Headlight Beam Vertical Adjustment •...
  • Page 82: Sidestand Switch Operation Inspection

    2-56 PERIODIC MAINTENANCE Periodic Maintenance Procedures Sidestand Switch Operation Inspection • Inspect the sidestand switch [A] operation accordance to the following table. Sidestand Switch Operation Gear Clutch Engine Engine Sidestand Position Lever Start Continue Neutral Released Starts running Continue Neutral Pulled in Starts running...
  • Page 83: Engine Stop Switch Operation Inspection

    PERIODIC MAINTENANCE 2-57 Periodic Maintenance Procedures Engine Stop Switch Operation Inspection First Step • Turn the ignition switch on. • Set the neutral position. • Turn the engine stop switch to stop position [A]. • Push the starter button. • The engine does not start.
  • Page 84: Others

    2-58 PERIODIC MAINTENANCE Periodic Maintenance Procedures Others Chassis Parts Lubrication • Before lubricating each part, clean off any rusty spots with rust remover and wipe off any grease, oil, dirt, or grime. • Lubricate the points listed below with indicated lubricant. NOTE ○...
  • Page 85 PERIODIC MAINTENANCE 2-59 Periodic Maintenance Procedures • With the cable disconnected at both ends, the cable should move freely [A] within the cable housing. If cable movement is not free after lubricating, if the cable is frayed [B], or if the cable housing is kinked [C], replace the cable.
  • Page 86: Condition Of Bolts, Nuts And Fasteners Tightness Inspection

    2-60 PERIODIC MAINTENANCE Periodic Maintenance Procedures Condition of Bolts, Nuts and Fasteners Tightness Inspection • Check the tightness of the bolts and nuts listed here. Also, check to see that each cotter pin is in place and in good condition. NOTE ○...
  • Page 87 FUEL SYSTEM (DFI) 3-1 Fuel System (DFI) Table of Contents Exploded View........................DFI System..........................3-10 DFI Parts Location........................3-16 Specifications ......................... 3-19 Special Tools and Sealant ...................... 3-21 DFI Servicing Precautions ...................... 3-23 DFI Servicing Precautions ....................3-23 Troubleshooting the DFI System .................... 3-25 Outline..........................
  • Page 88 3-2 FUEL SYSTEM (DFI) Subthrottle Sensor Input Voltage Inspection..............3-64 Subthrottle Sensor Output Voltage Inspection ..............3-65 Subthrottle Sensor Resistance Inspection ................ 3-66 Oxygen Sensor - not activated (Service Code 33) (Equipped Models) ........3-67 Oxygen Sensor Removal/Installation................3-67 Oxygen Sensor Inspection....................3-67 Stick Coils #1, #2 (Service Code 51, 52)................
  • Page 89 FUEL SYSTEM (DFI) 3-3 Fuel Injector Removal/Installation..................3-98 Fuel Injector Audible Inspection..................3-98 Fuel Injector Resistance Inspection .................. 3-98 Fuel Injector Power Source Voltage Inspection ..............3-99 Fuel Injector Output Voltage Inspection ................3-100 Fuel Injector Fuel Line Inspection ..................3-101 Throttle Grip and Cables ......................
  • Page 90: Exploded View

    3-4 FUEL SYSTEM (DFI) Exploded View...
  • Page 91: Exploded View

    FUEL SYSTEM (DFI) 3-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Switch Housing Screws 0.36 31 in·lb Throttle Cable Locknuts 0.29 25 in·lb Delivery Pipe Assy Mounting Screws 0.35 30 in·lb Water Temperature Sensor 106 in·lb Thermostat Housing Mounting Bolts 87 in·lb Throttle Body Assy Holder Clamp Screws 0.20...
  • Page 92 3-6 FUEL SYSTEM (DFI) Exploded View...
  • Page 93 FUEL SYSTEM (DFI) 3-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Fuel Pump Bolts 87 in·lb Air Cleaner Housing Cap Screws 0.25 22 in·lb Air Cleaner Housing Screws 1.15 0.117 10 in·lb Air Cleaner Housing Mounting Bolts 0.41 35 in·lb Air Duct Clamp Screws 0.20 18 in·lb...
  • Page 94 3-8 FUEL SYSTEM (DFI) Exploded View CAL Model...
  • Page 95 FUEL SYSTEM (DFI) 3-9 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Purge Valve Mounting Nut 87 in·lb Canister Bracket Bolts 87 in·lb 3. Drain Hose 4. Breather Hose (Blue Mark) 5. Canister 6. Canister Hose (Green Mark) (L = 380 mm, 15.0 in.) 7.
  • Page 96: Dfi System

    3-10 FUEL SYSTEM (DFI) DFI System DFI System...
  • Page 97 FUEL SYSTEM (DFI) 3-11 DFI System 1. ECU 2. Battery 12 V 8 Ah 3. Neutral Switch 4. Intake Air Pressure Sensor 5. Air Switching Valve 6. Water Temperature Sensor 7. Speed Sensor 8. Vehicle-down Sensor 9. Oxygen Sensor (Equipped Models) 10.
  • Page 98 3-12 FUEL SYSTEM (DFI) DFI System DFI System Wiring Diagram...
  • Page 99 FUEL SYSTEM (DFI) 3-13 DFI System Part Names 1. ECU 2. Kawasaki Diagnostic System Connector 3. Water-proof Joint 1 4. Fuel Pump 5. Water-proof Joint 2 6. Frame Ground 7. Engine Ground 8. Battery 12 V 8 Ah 9. Main Fuse 30 A 10.
  • Page 100 3-14 FUEL SYSTEM (DFI) DFI System ○ Color Codes: BK: Black GY: Gray PU: Purple BL: Blue LB: Light Blue R: Red BR: Brown V: Violet LG: Light Green CH: Chocolate O: Orange W: White DG: Dark Green P: Pink Y: Yellow G: Green Terminal Numbers of ECU Connectors...
  • Page 101 FUEL SYSTEM (DFI) 3-15 DFI System 26. Ground for ECU: BK/BL 27. Power Supply to ECU (from Battery): W/BK 28. Engine Stop Switch: R 29. Starter Lockout Switch: R/G 30. Starter Button: BK/R 31. Fuel Pump Relay: BR/Y 32. Air Switching Valve: R/BL 33.
  • Page 102: Dfi Parts Location

    3-16 FUEL SYSTEM (DFI) DFI Parts Location Main Throttle Sensor [A] Subthrottle Sensor [B] Subthrottle Valve Actuator [C] Fuel Injectors #1, #2 [A] Crankshaft Sensor [A] Oxygen Sensor (Equipped Models) [A] Ignition Switch [A] Yellow Engine Warning Indicator Light (LED) [B]...
  • Page 103 FUEL SYSTEM (DFI) 3-17 DFI Parts Location Stick Coils #1, #2 [A] Air Switching Valve [A] Intake Air Pressure Sensor [B] Frame Ground [C] Water Temperature Sensor [A] Vehicle-down Sensor [B] Intake Air Temperature Sensor [A] Relay Box [A] Battery 12 V 8 Ah [B] ECU [C] Fuse Box 1 [D] Fuse Box 2 [E]...
  • Page 104 3-18 FUEL SYSTEM (DFI) DFI Parts Location Kawasaki Diagnostic System Connector [A] Speed Sensor [A] Fuel Pump [A]...
  • Page 105: Specifications

    FUEL SYSTEM (DFI) 3-19 Specifications Item Standard Digital Fuel Injection System Idle Speed 1 300 ±50 r/min (rpm) Throttle Body Assy: Throttle Valve Dual throttle valve Bore 32 mm (1.26 in.) Throttle Body Vacuum 24.7 ±1.33 kPa (185 ±10 mmHg) at idle speed 0 ∼...
  • Page 106 3-20 FUEL SYSTEM (DFI) Specifications Item Standard Subthrottle Sensor: DC 4.75 ∼ 5.25 V Input Voltage DC 0.78 ∼ 0.82 V at subthrottle valve full close Output Voltage position DC 3.9 ∼ 4.5 V at subthrottle valve full open position (for reference) 4 ∼...
  • Page 107: Special Tools And Sealant

    FUEL SYSTEM (DFI) 3-21 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: Fuel Pressure Gauge Adapter: 57001-1394 57001-1593 Throttle Sensor Setting Adapter #1:...
  • Page 108 3-22 FUEL SYSTEM (DFI) Special Tools and Sealant Oxygen Sensor Measuring Adapter: Liquid Gasket, TB1211: 57001-1682 56019-120 Measuring Adapter: 57001-1700...
  • Page 109: Dfi Servicing Precautions

    FUEL SYSTEM (DFI) 3-23 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 110 3-24 FUEL SYSTEM (DFI) DFI Servicing Precautions ○ If the motorcycle is not properly handled, the high pres- sure inside the fuel line can cause fuel to leak or the hose to burst. Remove the fuel tank (see Fuel Tank Removal) and check the fuel hose [A].
  • Page 111: Troubleshooting The Dfi System

    FUEL SYSTEM (DFI) 3-25 Troubleshooting the DFI System Outline When a problem occurs with DFI system, the yellow en- gine warning indicator light (LED) [A] goes on or blinks to alert the rider. In addition, the condition of the problem is stored in the memory of the ECU.
  • Page 112 (LED) goes off. 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 solv- ing unstable problems. When the motorcycle is down, the vehicle-down sensor operates and the ECU shuts off the fuel pump relay, fuel injectors and ignition system.
  • Page 113 FUEL SYSTEM (DFI) 3-27 Troubleshooting the DFI System ○ After measurement, remove the needle adapters and ap- ply silicone sealant to the seals [A] of the connector [B] for waterproofing. Sealant - Liquid Gasket, TB1211: 56019-120 • Always check battery condition before replacing the DFI parts.
  • Page 114 3-28 FUEL SYSTEM (DFI) Troubleshooting the DFI System ○ When checking a harness [A] for short circuit, open one end [B] and check the continuity between the other end [C] and ground [D]. If there is continuity, the harness has a short circuit to ground, and it must be repaired or re- placed.
  • Page 115: Inquiries To Rider

    FUEL SYSTEM (DFI) 3-29 Troubleshooting the DFI System 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 116 3-30 FUEL SYSTEM (DFI) Troubleshooting the DFI System □ □ □ Poor running very low idle speed, very high idle speed, rough idle speed at low speed □ battery voltage is low (charge the battery) □ spark plug loose (tighten it) □...
  • Page 117: Dfi System Troubleshooting Guide

    FUEL SYSTEM (DFI) 3-31 DFI System Troubleshooting Guide NOTE ○ This is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties in DFI system.
  • Page 118 3-32 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions Fuel pressure regulator trouble Inspect fuel pressure and replace fuel pump (see chapter 3). Fuel line clogged Inspect and repair (see chapter 3). Intake air pressure sensor trouble Inspect (see chapter 3).
  • Page 119 FUEL SYSTEM (DFI) 3-33 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions Water temperature sensor trouble Inspect (see chapter 3). Intake air temperature sensor trouble Inspect (see chapter 3). Spark plug dirty, broken or gap maladjusted Inspect and replace (see chapter 2). Stick coil trouble Inspect (see chapter 16).
  • Page 120: Poor Running Or No Power At High Speed

    3-34 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Poor Running or No Power at High Speed Symptoms or Possible Causes Actions Firing incorrect: Stick coil shorted or not in good contact Inspect or Reinstall (see chapter 16). Stick coil trouble Inspect (see chapter 16).
  • Page 121 FUEL SYSTEM (DFI) 3-35 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions Engine overheating - Water temperature sensor, (see Overheating of Troubleshooting Guide in crankshaft sensor or speed sensor trouble chapter 17) Air switching valve trouble Inspect and replace (see chapter 16). Air suction valve trouble Inspect and replace (see chapter 5).
  • Page 122: Self-diagnosis

    3-36 FUEL SYSTEM (DFI) Self-Diagnosis Self-diagnosis Outline The self-diagnosis system has 2 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 and ignition system by lighting the yellow engine warning indi- cator light (LED) [A] when DFI and ignition system parts are faulty, and initiates fail-safe function.
  • Page 123 FUEL SYSTEM (DFI) 3-37 Self-Diagnosis • Press the left button [A] for more than 2 seconds. • The service code [B] is displayed on the LCD by the num- ber of two digits. • Any of the following procedures ends self-diagnosis. ○...
  • Page 124 3-38 FUEL SYSTEM (DFI) Self-Diagnosis...
  • Page 125: Service Code Reading

    Service Code Erasing ○ When repair has been done, the yellow engine warning indicator light (LED) goes off and service code is not displayed. The service codes stored in memory of the ECU can be erased using Kawasaki Diagnostic System (KDS Ver.3).
  • Page 126: Service Code Table

    3-40 FUEL SYSTEM (DFI) Self-Diagnosis Service Code Table Service Code Problems Main throttle sensor malfunction, wiring open or short Intake air pressure sensor malfunction, wiring open or short Intake air temperature sensor malfunction, wiring open or short Water temperature sensor malfunction, wiring open or short Crankshaft sensor malfunction, wiring open or short Speed sensor malfunction, wiring open or short Vehicle-down sensor malfunction, wiring open or short...
  • Page 127: Backups

    FUEL SYSTEM (DFI) 3-41 Self-Diagnosis Backups ○ The ECU takes the following measures to prevent engine damage when the DFI or the ignition system parts have troubles. Service Output Signal Usable Parts Backups by ECU Codes Range or Criteria If the main throttle sensor system fails (the output voltage is out of the usable range, wiring short or open), the ECU locks ignition timing into the ignition timing at closed throttle...
  • Page 128 3-42 FUEL SYSTEM (DFI) Self-Diagnosis Service Output Signal Usable Parts Backups by ECU Codes Range or Criteria The ECU must send If the stick coil #1 primary winding has failures signals continuously to (no signal, wiring short or open), the ECU Stick Coil #1* the stick coil primary shuts off the injector #1 to stop fuel to the...
  • Page 129: Main Throttle Sensor (service Code 11)

    FUEL SYSTEM (DFI) 3-43 Main Throttle Sensor (Service Code 11) Main Throttle Sensor Removal/Adjustment NOTICE 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 throttle body assy especially on a hard surface.
  • Page 130: Main Throttle Sensor Output Voltage Inspection

    3-44 FUEL SYSTEM (DFI) Main Throttle Sensor (Service Code 11) Main Throttle Sensor Output Voltage Inspection • Measure the output voltage at the main throttle sensor in the same way as input voltage inspection. ○ Disconnect the main throttle sensor connector and con- nect the harness adapter [A] between these connectors.
  • Page 131: Main Throttle Sensor Resistance Inspection

    FUEL SYSTEM (DFI) 3-45 Main Throttle Sensor (Service Code 11) If the reading is within the standard, remove the ECU and check the wiring for continuity between main harness con- nectors. Special Tool - Hand Tester: 57001-1394 ○ Disconnect the ECU and sensor connectors. Wiring Continuity Inspection ECU Connector [A] ←→...
  • Page 132: Intake Air Pressure Sensor (service Code 12)

    3-46 FUEL SYSTEM (DFI) Intake Air Pressure Sensor (Service Code 12) Intake Air Pressure Sensor Removal NOTICE Never drop the intake air pressure sensor espe- cially on a hard surface. Such a shock to the sensor can damage it. • Remove the fuel tank (see Fuel Tank Removal).
  • Page 133: Intake Air Pressure Sensor Output Voltage Inspection

    FUEL SYSTEM (DFI) 3-47 Intake Air Pressure Sensor (Service Code 12) If the reading is out of the standard, remove the ECU and check the wiring for continuity between main harness connectors. Special Tool - Hand Tester: 57001-1394 ○ Disconnect the ECU and sensor connectors. Wiring Continuity Inspection ECU Connector [A] ←→...
  • Page 134 3-48 FUEL SYSTEM (DFI) Intake Air Pressure Sensor (Service Code 12) If the wiring is good, check the sensor for various vacuum. • Remove the intake air pressure sensor [A] and disconnect the vacuum hose from the sensor. • Connect an auxiliary hose [B] to the intake air pressure sensor.
  • Page 135 FUEL SYSTEM (DFI) 3-49 Intake Air Pressure Sensor (Service Code 12) Pv = 24 ∼ 55 cmHg...
  • Page 136 3-50 FUEL SYSTEM (DFI) Intake Air Pressure Sensor (Service Code 12) Pv = 55 ∼ 86 cmHg ID: Idling Ps: Standard Atmospheric Pressure (Absolute) Pv: Throttle Vacuum Pressure (Absolute) ST: Standard of Sensor Output Voltage (V) TO: Throttle Full Open UR: Usable Range of Sensor Output Voltage (V) Vv: Intake Air Pressure Sensor Output Voltage (V) (Digital Meter Reading)
  • Page 137 FUEL SYSTEM (DFI) 3-51 Intake Air Pressure Sensor (Service Code 12) Intake Air Pressure Sensor Circuit 1. ECU 2. Water-proof Joint 4 3. Intake Air Pressure Sensor 4. Water-proof Joint 3...
  • Page 138: Intake Air Temperature Sensor (service Code 13)

    3-52 FUEL SYSTEM (DFI) Intake Air Temperature Sensor (Service Code 13) Intake Air Temperature Sensor Removal/Instal- lation NOTICE Never drop the intake air temperature sensor espe- cially on a hard surface. Such a shock to the sensor can damage it. •...
  • Page 139: Intake Air Temperature Sensor Resistance Inspection

    FUEL SYSTEM (DFI) 3-53 Intake Air Temperature Sensor (Service Code 13) • Turn the ignition switch off. If the reading is within the standard, check the ECU for its ground and power supply (see ECU Power Supply In- spection). If the ground and power supply are good, replace the ECU (see ECU Removal/Installation).
  • Page 140 3-54 FUEL SYSTEM (DFI) Intake Air Temperature Sensor (Service Code 13) Intake Air Temperature Sensor Circuit 1. ECU 2. Water-proof Joint 3 3. Intake Air Temperature Sensor...
  • Page 141: Water Temperature Sensor (service Code 14)

    FUEL SYSTEM (DFI) 3-55 Water Temperature Sensor (Service Code 14) Water Temperature Sensor Removal/Installation NOTICE Never drop the water temperature 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 142: Water Temperature Sensor Resistance Inspection

    3-56 FUEL SYSTEM (DFI) Water Temperature Sensor (Service Code 14) If the reading is out of the standard, remove the ECU and check the wiring for continuity between main harness connectors. Special Tool - Hand Tester: 57001-1394 ○ Disconnect the ECU and sensor connectors. Wiring Continuity Inspection ECU Connector [A] ←→...
  • Page 143: Crankshaft Sensor (service Code 21)

    FUEL SYSTEM (DFI) 3-57 Crankshaft Sensor (Service Code 21) The crankshaft sensor has no power source, and when the engine stops, the crankshaft sensor generates no sig- nals. Crankshaft Sensor Removal/Installation • Refer to the Crankshaft Sensor Removal/Installation in the Electrical System chapter. Crankshaft Sensor Resistance Inspection •...
  • Page 144: Speed Sensor (service Code 24)

    3-58 FUEL SYSTEM (DFI) Speed Sensor (Service Code 24) Speed Sensor Removal/Installation • Refer to the Speed Sensor Removal/Installation in the Electrical System chapter. Speed Sensor Inspection • Refer to the Speed Sensor Inspection in the Electrical System chapter. Speed Sensor Input Voltage Inspection NOTE ○...
  • Page 145: Speed Sensor Output Voltage Inspection

    FUEL SYSTEM (DFI) 3-59 Speed Sensor (Service Code 24) Speed Sensor Output Voltage Inspection • Raise the rear wheel off the ground with the stand. • Measure the output voltage at the speed sensor in the same way as input voltage inspection. ○...
  • Page 146 3-60 FUEL SYSTEM (DFI) Speed Sensor (Service Code 24) Speed Sensor Circuit 1. ECU 2. Speed Sensor 3. Water-proof Joint 4 4. Water-proof Joint 3...
  • Page 147: Vehicle-down Sensor (service Code 31)

    FUEL SYSTEM (DFI) 3-61 Vehicle-down Sensor (Service Code 31) Vehicle-down Sensor Removal/Installation NOTICE Never drop the vehicle-down sensor especially on a hard surface. Such a shock to the sensor can damage it. • Remove the fuel tank (see Fuel Tank Removal). •...
  • Page 148 3-62 FUEL SYSTEM (DFI) Vehicle-down Sensor (Service Code 31) • Remove the vehicle-down sensor (see Vehicle-down Sensor Removal/Installation). ○ Do not disconnect the sensor connector. • Using the needle adapter set [A], connect a digital meter [B] to the connector. Special Tool - Needle Adapter Set: 57001-1457 Vehicle-down Sensor Output Voltage Connections to Sensor Connector:...
  • Page 149 FUEL SYSTEM (DFI) 3-63 Vehicle-down Sensor (Service Code 31) Vehicle-down Sensor Circuit 1. ECU 2. Water-proof Joint 4 3. Vehicle-down Sensor 4. Water-proof Joint 3...
  • Page 150: Subthrottle Sensor (service Code 32)

    3-64 FUEL SYSTEM (DFI) Subthrottle Sensor (Service Code 32) Subthrottle Sensor Removal/Adjustment NOTICE Do not remove or adjust the subthrottle sensor [A] since it has been adjusted and set with precision at the factory. Never drop the throttle body assy especially on a hard surface.
  • Page 151: Subthrottle Sensor Output Voltage Inspection

    FUEL SYSTEM (DFI) 3-65 Subthrottle Sensor (Service Code 32) Subthrottle Sensor Output Voltage Inspection • Measure the output voltage at the subthrottle sensor in the same way as input voltage inspection (see Subthrottle Sensor Input Voltage Inspection). ○ Disconnect the subthrottle sensor connector and connect the harness adapter [A] between these connectors.
  • Page 152: Subthrottle Sensor Resistance Inspection

    3-66 FUEL SYSTEM (DFI) Subthrottle Sensor (Service Code 32) If the reading is within the standard, remove the ECU and check the wiring for continuity between main harness con- nectors. Special Tool - Hand Tester: 57001-1394 ○ Disconnect the ECU and sensor connectors. Wiring Continuity Inspection ECU Connector [A] ←→...
  • Page 153: Oxygen Sensor - Not Activated (service Code 33) (equipped Models)

    FUEL SYSTEM (DFI) 3-67 Oxygen Sensor - not activated (Service Code 33) (Equipped Models) Oxygen Sensor Removal/Installation • Refer to the Oxygen Sensor Removal/Installation in the Electrical System chapter. Oxygen Sensor Inspection • Remove the left middle fairing (see Middle Fairing Re- moval in the Frame chapter).
  • Page 154 3-68 FUEL SYSTEM (DFI) Oxygen Sensor - not activated (Service Code 33) (Equipped Models) If the reading is out of the standard (with plug: DC 0.7 V or more, without plug: DC 0.2 V or less), remove the ECU and check the wiring for continuity between main harness connectors.
  • Page 155 FUEL SYSTEM (DFI) 3-69 Oxygen Sensor - not activated (Service Code 33) (Equipped Models) Oxygen Sensor Circuit 1. Oxygen Sensor 2. ECU 3. Water-proof Joint 1 4. Frame Ground 5. Engine Ground 6. Battery 12 V 8 Ah 7. Main Fuse 30 A 8.
  • Page 156: Stick Coils #1, #2 (service Code 51, 52)

    3-70 FUEL SYSTEM (DFI) Stick Coils #1, #2 (Service Code 51, 52) Stick Coil #1: Service Code 51 Stick Coil #2: Service Code 52 Stick Coil Removal/Installation • Refer to the Stick Coil Removal/Installation in the Electri- cal System chapter. Stick Coil Primary Winding Resistance Inspection •...
  • Page 157 FUEL SYSTEM (DFI) 3-71 Stick Coils #1, #2 (Service Code 51, 52) Stick Coil Circuit 1. ECU 2. Water-proof Joint 2 3. Frame Ground 4. Engine Ground 5. Battery 12 V 8 Ah 6. Main Fuse 30 A 7. Starter Relay 8.
  • Page 158: Radiator Fan Relay (service Code 56)

    3-72 FUEL SYSTEM (DFI) 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 159 FUEL SYSTEM (DFI) 3-73 Radiator Fan Relay (Service Code 56) Radiator Fan Relay Circuit 1. ECU 2. Water-proof Joint 2 3. Frame Ground 4. Engine Ground 5. Battery 12 V 8 Ah 6. Main Fuse 30 A 7. Starter Relay 8.
  • Page 160: Subthrottle Valve Actuator (service Code 62)

    3-74 FUEL SYSTEM (DFI) Subthrottle Valve Actuator (Service Code 62) Subthrottle Valve Actuator Removal NOTICE Do not remove the subthrottle valve actuator [A] since it has been adjusted and set with precision at the factory. Never drop the throttle body assy especially on a hard surface.
  • Page 161: Subthrottle Valve Actuator Input Voltage Inspection

    FUEL SYSTEM (DFI) 3-75 Subthrottle Valve Actuator (Service Code 62) Subthrottle Valve Actuator Input Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Remove the fuel tank (see Fuel Tank Removal). • Turn the ignition switch off. •...
  • Page 162 3-76 FUEL SYSTEM (DFI) Subthrottle Valve Actuator (Service Code 62) Subthrottle Valve Actuator Circuit 1. ECU 2. Subthrottle Valve Actuator...
  • Page 163: Air Switching Valve (service Code 64)

    FUEL SYSTEM (DFI) 3-77 Air Switching Valve (Service Code 64) Air Switching Valve Removal/Installation • Refer to the Air Switching Valve Removal/Installation in the Engine Top End chapter. Air Switching Valve Inspection • Refer to the Air Switching Valve Unit Test in the Electrical System chapter.
  • Page 164: Oxygen Sensor Heater (service Code 67) (equipped Models)

    3-78 FUEL SYSTEM (DFI) Oxygen Sensor Heater (Service Code 67) (Equipped Models) Oxygen Sensor Heater Removal/Installation The oxygen sensor heater is built in the oxygen sensor. So, the heater itself can not be removed. Remove the oxy- gen sensor (see Oxygen Sensor Removal in the Electrical System chapter).
  • Page 165 FUEL SYSTEM (DFI) 3-79 Oxygen Sensor Heater (Service Code 67) (Equipped Models) If the fuse and wiring are good, remove the ECU and check the wiring for continuity between main harness con- nectors. Special Tool - Hand Tester: 57001-1394 ○ Disconnect the ECU and sensor connectors.
  • Page 166: Oxygen Sensor - Incorrect Output Voltage (service Code 94) (equipped Models)

    3-80 FUEL SYSTEM (DFI) Oxygen Sensor - Incorrect Output Voltage (Service Code 94) (Equipped Models) Oxygen Sensor Removal/Installation • Refer to the Oxygen Sensor Removal/Installation in the Electrical System chapter. Oxygen Sensor Inspection • Remove the left middle fairing (see Middle Fairing Re- moval in the Frame chapter).
  • Page 167 FUEL SYSTEM (DFI) 3-81 Oxygen Sensor - Incorrect Output Voltage (Service Code 94) (Equipped Models) • Next, remove the plug from the fitting [A] with idling. • Measure the output voltage with the connector joined. Output Voltage (without Plug) Standard: DC 0.2 V or less •...
  • Page 168: Purge Valve (service Code 3a) (cal Model)

    3-82 FUEL SYSTEM (DFI) Purge Valve (Service Code 3A) (CAL Model) Purge Valve Removal/Installation • Remove the left middle fairing (see Middle Fairing Re- moval in the Frame chapter). • Disconnect the purge valve connector [A] and tubes [B]. • Remove the purge valve mounting nut [C] and purge valve [D].
  • Page 169 FUEL SYSTEM (DFI) 3-83 Purge Valve (Service Code 3A) (CAL Model) • Disconnect the 12 V battery. • Blow the air to the intake air duct [A] again, and make sure that the air does not flow from the outlet air duct [B]. If the purge valve dose not operate as described, replace it with a new one.
  • Page 170: Yellow Engine Warning Indicator Light (led)

    3-84 FUEL SYSTEM (DFI) Yellow Engine Warning Indicator Light (LED) Yellow Engine Warning Indicator Light (LED) Inspection ○ In this model, the yellow engine warning indicator light (LED) goes on or blinks by the data sent from the ECU. • Refer to the Meter Unit Inspection in the Electrical System chapter.
  • Page 171: Ecu

    FUEL SYSTEM (DFI) 3-85 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. Other- wise, the motorcycle cannot clear the regulation. ECU Identification Part Number [A] Specification...
  • Page 172: Ecu Installation

    3-86 FUEL SYSTEM (DFI) ECU Installation • Install the ECU [A] into the rubber protector [B]. • Connect the ECU connectors [C]. • Insert the slits of the rubber protector to the projections [D] of the rear fender. • Install the connector/bracket on the ECU and tighten the screw.
  • Page 173 FUEL SYSTEM (DFI) 3-87 If the wiring is good, check the power source voltage of the ECU. NOTE ○ Be sure the battery is fully charged. • Connect the ECU connectors. • Connect a digital meter [A] to the connector [B] with the needle adapter set.
  • Page 174 3-88 FUEL SYSTEM (DFI) ECU Power Source Circuit 1. ECU 2. Water-proof Joint 1 3. Water-proof Joint 2 4. Frame Ground 5. Engine Ground 6. Battery 12 V 8 Ah 7. Main Fuse 30 A 8. Starter Relay 9. Fuse Box 1 10.
  • Page 175: Dfi Power Source

    FUEL SYSTEM (DFI) 3-89 DFI Power Source FI Fuse Removal • Refer to the FI Fuse 15 A Removal in the Electrical Sys- tem chapter. FI 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 176: Fuel Line

    3-90 FUEL SYSTEM (DFI) Fuel Line Fuel Pressure Inspection NOTE ○ Be sure the battery is fully charged. • Remove: Fuel Tank (see Fuel Tank Removal) Fuel Hose (see Fuel Hose Replacement in the Periodic Maintenance chapter) ○ Be sure to place a piece of cloth around the outlet pipes of the fuel pump and the throttle body assy.
  • Page 177: Fuel Flow Rate Inspection

    FUEL SYSTEM (DFI) 3-91 Fuel Line NOTE ○ The gauge needle will fluctuate. Read the pressure at the average of the maximum and minimum indications. • Turn the ignition switch off. If the fuel pressure is much higher than specified, the fuel pressure regulator in the fuel pump have been clogged or stuck.
  • Page 178 3-92 FUEL SYSTEM (DFI) Fuel Line • Open the fuel tank cap [A] to release the pressure in the tank. • Disconnect the fuel hose from the fuel pump (see Fuel Tank Removal). ○ Be sure to place a piece of cloth around the fuel supply pipe of the fuel pump.
  • Page 179: Fuel Pump

    FUEL SYSTEM (DFI) 3-93 Fuel Pump Fuel Pump Removal WARNING Gasoline is extremely flammable and can be ex- plosive under certain conditions, creating the potential for serious burns. Make sure the area is well-ventilated and free from any source of flame or sparks;...
  • Page 180: Fuel Pump Installation

    3-94 FUEL SYSTEM (DFI) Fuel Pump Fuel Pump Installation • Remove dirt or dust from the fuel pump [A] by lightly ap- plying compressed air. • Replace the fuel pump gasket [A] with a new one. • Install the fuel pump [B] into the fuel tank. •...
  • Page 181: Fuel Pump Operating Voltage Inspection

    FUEL SYSTEM (DFI) 3-95 Fuel Pump Fuel Pump Operating Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch off. • Remove the fuel tank bolts (see Fuel Tank Removal). • Disconnect the fuel pump lead connector and connect the harness adapter [A] between these connectors as shown.
  • Page 182: Pressure Regulator Removal

    3-96 FUEL SYSTEM (DFI) Fuel Pump Pressure Regulator Removal ○ The pressure regulator [A] is built into the fuel pump unit [B] and can not be removed. Fuel Filter Cleaning ○ The fuel filter [A] are built into the fuel pump unit and can not be cleaned or checked.
  • Page 183 FUEL SYSTEM (DFI) 3-97 Fuel Pump Fuel Pump Circuit 1. ECU 2. Fuel Pump 3. Water-proof Joint 2 4. Frame Ground 5. Engine Ground 6. Battery 12 V 8 Ah 7. Main Fuse 30 A 8. Starter Relay 9. Fuse Box 1 10.
  • Page 184: Fuel Injectors

    3-98 FUEL SYSTEM (DFI) Fuel Injectors Fuel Injector Removal/Installation • Refer to the Throttle Body Assy Disassembly/Assembly. Fuel Injector Audible Inspection NOTE ○ Be sure the battery is fully charged. • Remove the left middle fairing (see Middle Fairing Re- moval in the Frame chapter).
  • Page 185: Fuel Injector Power Source Voltage Inspection

    FUEL SYSTEM (DFI) 3-99 Fuel Injectors Fuel Injector Power Source Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Remove the fuel tank (see Fuel Tank Removal). • Turn the ignition switch off. • Disconnect the injector connector and connect the har- ness adapter [A] between these connectors as shown.
  • Page 186: Fuel Injector Output Voltage Inspection

    3-100 FUEL SYSTEM (DFI) Fuel Injectors Fuel Injector Output Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch off. • Remove the ECU (see ECU Removal). ○ Do not disconnect the ECU connector. •...
  • Page 187: Fuel Injector Fuel Line Inspection

    FUEL SYSTEM (DFI) 3-101 Fuel Injectors Fuel Injector Fuel Line Inspection • Remove: Fuel Tank (see Fuel Tank Removal) Fuel Hose (see Fuel Hose Replacement in the Periodic Maintenance chapter) ○ Be sure to place a piece of cloth around the delivery pipes of the fuel pump and the throttle body assy.
  • Page 188 3-102 FUEL SYSTEM (DFI) Fuel Injectors Fuel Injector Circuit 1. ECU 2. Water-proof Joint 2 3. Frame Ground 4. Engine Ground 5. Battery 12 V 8 Ah 6. Main Fuse 30 A 7. Starter Relay 8. Fuse Box 1 9. FI Fuse 15 A 10.
  • Page 189: Throttle Grip And Cables

    FUEL SYSTEM (DFI) 3-103 Throttle Grip and Cables Free Play Inspection • Refer to the Throttle Control System Inspection in the Pe- riodic Maintenance chapter. Free Play Adjustment • Refer to the Throttle Control System Inspection in the Pe- riodic Maintenance chapter. Cable Installation •...
  • Page 190: Throttle Body Assy

    3-104 FUEL SYSTEM (DFI) Throttle Body Assy Idle Speed Inspection/Adjustment • Refer to the Idle Speed Inspection/Adjustment in the Pe- riodic Maintenance chapter. Synchronization Inspection/Adjustment • Refer to the Engine Vacuum Synchronization Inspection in the Periodic Maintenance chapter. Throttle Body Assy Removal WARNING Gasoline is extremely flammable and can be ex- plosive under certain conditions, creating the...
  • Page 191 FUEL SYSTEM (DFI) 3-105 Throttle Body Assy • Loosen the nuts [A], and remove the throttle cable lower ends [B]. • Disconnect the vacuum hose [C]. • Remove: Bracket Bolts [A] Upper Air Cleaner Housing Mounting Bolt [B] • Disconnect the air switching valve hose and intake air temperature sensor connector [C] from the air cleaner housing.
  • Page 192: Throttle Body Assy Installation

    3-106 FUEL SYSTEM (DFI) Throttle Body Assy • Loosen the throttle body assy holder clamp screws [A], and pull the throttle body assy [B] backward. • Remove the throttle body assy to left side of motorcycle. • After removing the throttle body assy, stuff pieces of lint- free, clean cloth into the throttle body assy holders.
  • Page 193: Throttle Body Assy Disassembly

    FUEL SYSTEM (DFI) 3-107 Throttle Body Assy Throttle Body Assy Disassembly 1. Delivery Pipe Assy 2. Fuel Injectors 3. Throttle Body Assy 4. Main Throttle Sensor 5. Subthrottle Sensor 6. Subthrottle Valve Actuator 7. For CAL Model NOTICE 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 194: Throttle Body Assy Assembly

    3-108 FUEL SYSTEM (DFI) Throttle Body Assy • Pull out the injectors [A] from the delivery pipe assy [B]. NOTE ○ Do not damage the insertion portions of the injectors when they are pulled out from the delivery pipe assy. NOTICE Never drop the fuel injector especially on a hard surface.
  • Page 195: Air Cleaner

    FUEL SYSTEM (DFI) 3-109 Air Cleaner Air Cleaner Element Removal/Installation • Refer to the Air Cleaner Element Replacement in the Pe- riodic Maintenance chapter. Air Cleaner Element Inspection • Remove the air cleaner element (see Air Cleaner Element Replacement in the Periodic Maintenance chapter). •...
  • Page 196: Air Cleaner Housing Installation

    3-110 FUEL SYSTEM (DFI) Air Cleaner • Move the air cleaner housing [A] backward to pull out the air ducts [B] from the throttle body assy [C]. • Remove the air cleaner housing [A] from the frame as shown. • After removing the air cleaner housing, stuff pieces of lint- free, clean cloth into the throttle body assy.
  • Page 197: Air Cleaner Housing Assembly

    FUEL SYSTEM (DFI) 3-111 Air Cleaner Air Cleaner Housing Assembly • Install the flame arrester [A]. • Be sure the seal ring [B] is in position. • Apply a adhesive cement to the slash portions [A] of the air cleaner housing. •...
  • Page 198: Fuel Tank

    3-112 FUEL SYSTEM (DFI) Fuel Tank Fuel Tank Removal WARNING Gasoline is extremely flammable and can be ex- plosive under certain conditions, creating the potential for serious burns. Make sure the area is well-ventilated and free from any source of flame or sparks;...
  • Page 199 FUEL SYSTEM (DFI) 3-113 Fuel Tank • Open the fuel tank cap [A] to release the pressure in the tank. • Draw the fuel out from the fuel tank with a commercially available pump [A]. ○ Use a soft plastic hose [B] as a pump intake hose in order to insert the hose smoothly.
  • Page 200 3-114 FUEL SYSTEM (DFI) Fuel Tank When removing with standard tip screwdriver • Insert the standard tip screwdriver [A] into slit on the joint lock [B]. • Turn the driver to disconnect the joint lock. When removing with fingers • Open and push up [C] the joint lock with your fingers.
  • Page 201: Fuel Tank Installation

    FUEL SYSTEM (DFI) 3-115 Fuel Tank Fuel Tank Installation • Note the above WARNING (see Fuel Tank Removal). • Run the hoses correctly (see Cable, Wire, and Hose Rout- ing section in the Appendix chapter). • Check that the dampers [A] are in place on the frame and the fuel tank.
  • Page 202: Fuel Tank Inspection

    3-116 FUEL SYSTEM (DFI) Fuel Tank Fuel Tank Inspection • Open the tank cap. • 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 hole [B] in the tank is not clogged.
  • Page 203: Evaporative Emission Control System (cal Model)

    FUEL SYSTEM (DFI) 3-117 Evaporative Emission Control System (CAL Model) The Evaporative Emission Control System routes fuel va- pors from the fuel system into the running engine or stores the vapors in a canister [A] when the engine is stopped. Although no adjustments are required, a thorough visual inspection must be made at the intervals specified by the Periodic Maintenance Chart.
  • Page 205 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 ..................Coolant Reserve Tank Installation ..................
  • Page 206: Exploded View

    4-2 COOLING SYSTEM Exploded View...
  • Page 207 COOLING SYSTEM 4-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Thermostat Housing Mounting Bolts 87 in·lb Reserve Tank Bolts 0.41 35 in·lb Reserve Tank Cap – – – Hand-Tighten Radiator Cap Bracket Bolt 87 in·lb Radiator Bolts 87 in·lb Radiator Fan Assy Mounting Bolts 0.86 74 in·lb...
  • Page 208: Coolant Flow Chart

    4-4 COOLING SYSTEM Coolant Flow Chart...
  • Page 209 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 210: 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 211: Coolant

    COOLING SYSTEM 4-7 Coolant Coolant Deterioration Inspection • Remove the right middle fairing (see Middle Fairing Re- moval in the Frame chapter). • Visually inspect the coolant [A] in the reserve tank. If whitish cotton-like wafts are observed, aluminum parts in the cooling system are corroded.
  • Page 212: 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 213: Water Pump

    COOLING SYSTEM 4-9 Water Pump Water Pump Cover Removal • Drain the coolant (see Coolant Change in the Periodic Maintenance chapter). • Remove: Engine Sprocket Cover (see Engine Sprocket Removal in the Final Drive chapter) Water Pipe Bolt [A] Left Middle Fairing Bracket Bolt [B] Bracket [C] Water Pipes [D] Speed Sensor Bracket [E] (see Engine Sprocket Re-...
  • Page 214: Water Pump Installation

    4-10 COOLING SYSTEM Water Pump Water Pump Installation • Apply grease to a new O-ring [A]. • Install the water pump aligning the slot [B] of the water pump shaft with the oil pump shaft. • Tighten: Torque - Water Pump Bolts [A]: 9.8 N·m (1.0 kgf·m, 87 in·lb) Water Pump Impeller [B]: 9.8 N·m (1.0 kgf·m, 87 in·lb) Water Pump Inspection...
  • Page 215: Mechanical Seal Installation

    COOLING SYSTEM 4-11 Water Pump Mechanical Seal Installation • Using a suitable tool or pipe with the dimension as shown, install the mechanical seal [A] to the water pump housing [B] until the flange [C] on the mechanical seal bottomed to the water pump housing.
  • Page 216: Radiator

    4-12 COOLING SYSTEM Radiator Radiator and Radiator Fan Removal • Drain the coolant (see Coolant Change in the Periodic Maintenance chapter). • Remove: Inner Fairing (see Inner Fairing Removal in the Frame chapter) Coolant Reserve Tank (see Coolant Reserve Tank Re- moval) Radiator Hose Clamp Screw [A] (Loosen) Radiator Bolts [B]...
  • Page 217: Radiator Inspection

    COOLING SYSTEM 4-13 Radiator Radiator Inspection • Check the radiator core. If there are obstructions to air flow, remove them. If the corrugated fins [A] are deformed, carefully straighten them. If the air passages of the radiator core are blocked more than 20% by unremovable obstructions or irreparably de- formed fins, replace the radiator with a new one.
  • Page 218: Radiator Filler Neck Inspection

    4-14 COOLING SYSTEM Radiator Radiator Filler Neck Inspection • Remove: Right Middle Fairing (see Middle Fairing Removal in the Frame chapter) Radiator Cap • Check the radiator filler neck for signs of damage. • Check the condition of the top and bottom sealing seats [A] in the filler neck.
  • Page 219: Thermostat

    COOLING SYSTEM 4-15 Thermostat Thermostat 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) Thermostat Cover Bolts [A] • Move the thermostat cover [A] outwards and remove the thermostat [B].
  • Page 220: Thermostat Inspection

    4-16 COOLING SYSTEM Thermostat Thermostat Inspection • Remove the thermostat (see Thermostat Removal), and inspect the thermostat valve [A] at room temperature. If the valve is open, replace the thermostat with a new one. • To check valve opening temperature, suspend the ther- mostat [A] in a container of water and raise the tempera- ture of the water.
  • Page 221: 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 correctly (see Cable, Wire, and Hose Rout- ing section in the Appendix chapter). •...
  • Page 222: Water Temperature Sensor

    4-18 COOLING SYSTEM Water Temperature Sensor NOTICE The water temperature sensor should never be al- lowed to fall on a hard surface. Such a shock to the water temperature sensor can damage it. Water Temperature Sensor Removal/Installation • Refer to the Water Temperature Sensor Removal/Instal- lation in the Fuel System (DFI) chapter.
  • Page 223 ENGINE TOP END 5-1 Engine Top End Table of Contents Exploded View........Cylinder Head Installation .... 5-25 Exhaust System Identification ... Cylinder Head Warp Inspection ... 5-26 Specifications ........Valves ..........5-27 Special Tools and Sealant ....5-10 Valve Clearance Inspection ..5-27 Clean Air System.......
  • Page 224: Exploded View

    5-2 ENGINE TOP END Exploded View...
  • Page 225 ENGINE TOP END 5-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Air Suction Valve Cover Bolts 87 in·lb Cylinder Head Cover Bolts 87 in·lb Cylinder Head Bolts (M8, L = 146) MO, S Cylinder Head Bolts (M8, L = 115) MO, S Camshaft Cap Bolts 106 in·lb...
  • Page 226 5-4 ENGINE TOP END Exploded View...
  • Page 227 ENGINE TOP END 5-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Muffler Body Mounting Bolt Muffler Cover Bolt 87 in·lb Muffler Body Rear Cover Bolts 0.81 70 in·lb Exhaust Pipe Holder Nuts 106 in·lb Exhaust Pipe Mounting Bolt Muffler Cover Clamp Screw 0.70 61 in·lb Muffler Body Clamp Bolt...
  • Page 228: Exhaust System Identification

    5-6 ENGINE TOP END Exhaust System Identification Exhaust System Manifold Mark Position [A] Muffler Body Mark Position [A]...
  • Page 229 ENGINE TOP END 5-7 Exhaust System Identification Honeycomb Type Catalyst Position [A] Oxygen Sensor [B] Honeycomb Type Catalyst Positions [A] (without Oxygen Sensor)
  • Page 230: Specifications

    5-8 ENGINE TOP END Specifications Item Standard Service Limit Camshafts Cam Height: 32.843 ∼ 32.957 mm (1.2930 ∼ 1.2975 in.) Exhaust 32.74 mm (1.289 in.) 33.843 ∼ 33.957 mm (1.3324 ∼ 1.3369 in.) Intake 33.74 mm (1.328 in.) 0.028 ∼ 0.071 mm (0.0011 ∼ 0.0028 in.) Camshaft Journal, Camshaft 0.16 mm (0.0063 in.) Cap Clearance...
  • Page 231 ENGINE TOP END 5-9 Specifications Item Standard Service Limit Cylinder, Pistons 61.994 ∼ 62.010 mm (2.4407 ∼ 2.4413 in.) 62.09 mm (2.4445 in.) Cylinder Inside Diameter 61.969 ∼ 61.984 mm (2.4397 ∼ 2.4403 in.) 61.82 mm (2.4339 in.) Piston Diameter 0.010 ∼...
  • Page 232: Special Tools And Sealant

    5-10 ENGINE TOP END Special Tools and Sealant Compression Gauge, 20 kgf/cm²: Valve Seat Cutter Holder Bar: 57001-221 57001-1128 Valve Spring Compressor Assembly: Valve Seat Cutter, 32° - 22: 57001-241 57001-1206 Piston Pin Puller Assembly: Valve Seat Cutter, 67.5° - 22: 57001-910 57001-1207 Valve Seat Cutter, 45°...
  • Page 233 ENGINE TOP END 5-11 Special Tools and Sealant Valve Seat Cutter Holder, 4.5: Valve Guide Driver: 57001-1330 57001-1564 Valve Guide Arbor, 4.5: Washer: 57001-1331 57001-1720 Valve Guide Reamer, 4.5: Liquid Gasket, TB1216B: 57001-1333 92104-1064 Filler Cap Driver: 57001-1454...
  • Page 234: Clean Air System

    5-12 ENGINE TOP END Clean Air System Air Suction Valve Removal • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) • Disconnect the hose [A] from the air suction valve cover [B]. • Remove: Air Suction Valve Cover Bolts [C] Air Suction Valve Cover [B] Air Suction Valve Air Suction Valve Installation...
  • Page 235: Air Switching Valve Installation

    ENGINE TOP END 5-13 Clean Air System • Remove the hoses from the air switching valve assembly. • Remove: Intake Air Pressure Sensor [A] Damper [B] Air Switching Valve [C] NOTICE Never drop the air switching valve especially on a hardsurface. Such a shock to the air switching valve can damaged it.
  • Page 236: Cylinder Head Cover

    5-14 ENGINE TOP END Cylinder Head Cover Cylinder Head Cover Removal • Remove: Coolant (Drain, see Coolant Change in the Periodic Maintenance chapter) Air Switching Valve (see Air Switching Valve Removal) Air Suction Valve Cover (see Air Suction Valve Removal) Stick Coils (see Stick Coil Removal in the Electrical Sys- tem chapter) Water Hose [A]...
  • Page 237 ENGINE TOP END 5-15 Cylinder Head Cover • Insert the hook [A] of the water pipe [B] in the groove of the damper [C] as shown. Damper [D] • Install the head cover [E], and tighten the bolts. Torque - Cylinder Head Cover Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) •...
  • Page 238: Camshaft Chain Tensioner

    5-16 ENGINE TOP END Camshaft Chain Tensioner Camshaft Chain Tensioner Removal NOTICE 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.
  • Page 239 ENGINE TOP END 5-17 Camshaft Chain Tensioner • Tighten: Torque - Camshaft Chain Tensioner Mounting Bolts [A]: 9.8 N·m (1.0 kgf·m, 87 in·lb) • Take out the holder plate [B]. • Replace the O-ring with a new one and apply grease to it. •...
  • Page 240: Camshaft, Camshaft Chain

    5-18 ENGINE TOP END Camshaft, Camshaft Chain Camshaft Removal • Remove: Cylinder Head Cover (see Cylinder Head Cover Re- moval) Plugs [A] [B] Special Tool - Filler Cap Driver: 57001-1454 • Position the crankshaft at #2 piston TDC. ○ Using a wrench on the alternator rotor bolt, turn the crank- shaft counterclockwise until the "2T"...
  • Page 241: Camshaft Installation

    ENGINE TOP END 5-19 Camshaft, Camshaft Chain Camshaft Installation • Install the camshaft sprockets as shown. Intake Camshaft Sprocket [A] Exhaust Camshaft Sprocket [B] ○ The exhaust camshaft has the groove [C]. • Apply a non-permanent locking agent to the threads of the camshaft sprocket bolts and tighten them.
  • Page 242 5-20 ENGINE TOP END Camshaft, Camshaft Chain • Install the six dowel pins on the marks [A]. • Install the camshaft caps as shown, noting the “EX” [B] and “IN” [C] marks. NOTICE The camshaft caps are machined with the cylinder head.
  • Page 243: Camshaft, Camshaft Cap Wear Inspection

    ENGINE TOP END 5-21 Camshaft, Camshaft Chain Camshaft, Camshaft Cap Wear Inspection • Remove: Upper Chain Guide (see Camshaft Removal) Camshaft Caps (see Camshaft Removal) • Cut the strips of plastigauge to journal width. Place a strip on each journal parallel to the camshaft installed in the correct position.
  • Page 244: Cam Wear Inspection

    5-22 ENGINE TOP END Camshaft, Camshaft Chain Cam Wear Inspection • Remove the camshafts (see Camshaft Removal). • Measure the height [A] of each cam with a micrometer. If the cams are worn down past the service limit, replace the camshaft. Cam Height Standard: 32.843 ∼...
  • Page 245: Cylinder Head

    ENGINE TOP END 5-23 Cylinder Head Cylinder Compression Measurement NOTE ○ Use the battery which is fully charged. • Warm up the engine thoroughly. • Stop the engine. • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Stick Coils (see Stick Coil Removal in the Electrical Sys- tem chapter)
  • Page 246: Cylinder Head Removal

    5-24 ENGINE TOP END Cylinder Head Cylinder Head Removal • Drain: Coolant (see Coolant Change in the Periodic Mainte- nance chapter) • Remove: Cylinder Head Cover (see Cylinder Head Cover Re- moval) Camshafts (see Camshaft Removal) Radiator (see Radiator and Radiator Fan Removal in the Cooling System chapter) Throttle Body Assy (see Throttle Body Assy Removal in the Fuel System (DFI) chapter)
  • Page 247: Cylinder Head Installation

    ENGINE TOP END 5-25 Cylinder Head • Remove: M6 Cylinder Head Bolt [A] M8 Cylinder Head Bolts [B] 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.
  • Page 248: Cylinder Head Warp Inspection

    5-26 ENGINE TOP END Cylinder Head • Install: Front Camshaft Chain Guide [A] • Replace the O-ring [A] with a new one. • Apply grease to the O-ring. • Install the water pipe [B] and dampers [C] (see Cylinder Head Cover Installation). •...
  • Page 249: Valves

    ENGINE TOP END 5-27 Valves Valve Clearance Inspection • Refer to the Valve Clearance Inspection in the Periodic Maintenance chapter. Valve Clearance Adjustment • Refer to the Valve Clearance Adjustment in the Periodic Maintenance chapter. Valve Removal • Remove: Cylinder Head (see Cylinder Head Removal) Valve Lifter and Shim ○...
  • Page 250: Valve Guide Installation

    5-28 ENGINE TOP END Valves Valve Guide Installation • Apply engine oil to the valve guide outer surface before installation. • Heat the area around the valve guide hole to about 120 ∼ 150°C (248 ∼ 302°F). NOTICE Do not heat the cylinder head with a torch. This will warp the cylinder head.
  • Page 251: Valve Seat Inspection

    ENGINE TOP END 5-29 Valves NOTE ○ The reading is not actual valve/valve guide clearance because the measuring point is above the guide. Valve/Valve Guide Clearance (Wobble Method) Standard: 0.08 ∼ 0.15 mm (0.0031 ∼ 0.0059 in.) Exhaust 0.03 ∼ 0.09 mm (0.0012 ∼ 0.0035 in.) Intake Service Limit: Exhaust...
  • Page 252 5-30 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 253 ENGINE TOP END 5-31 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 254 5-32 ENGINE TOP END Valves If the seat width is too wide, make the 67.5° [A] grind described below. If the seat width is within the specified range, lap the valve to the seat as described below. • Grind the seat at a 67.5° angle until the seat width is within the specified range.
  • Page 255 ENGINE TOP END 5-33 Valves...
  • Page 256: Cylinder, Pistons

    5-34 ENGINE TOP END Cylinder, Pistons Cylinder Removal • Remove: Cylinder Head (see Cylinder Head Removal) Bolt [A] Water Hose Clamp Screw (Loosen) [B] Water Pipe [C] and Hose Cylinder [D] Cylinder Installation NOTE ○ If a new cylinder is used, use a new piston ring. •...
  • Page 257: Piston Installation

    ENGINE TOP END 5-35 Cylinder, Pistons • Remove the piston pins. Special Tool - Piston Pin Puller Assembly [A]: 57001-910 • Remove the pistons. • Carefully spread the ring opening with your thumbs and then push up on the opposite side of the ring [A] to remove •...
  • Page 258: Cylinder Wear Inspection

    5-36 ENGINE TOP END Cylinder, Pistons NOTE ○ If a new piston is used, use new piston ring. • Install the piston with its dent mark facing forward. • Fit a new piston pin snap ring into the side of the piston so that the ring opening [A] does not coincide with the slit [B] of the piston pin hole.
  • Page 259: Piston Ring, Piston Ring Groove Wear Inspection

    ENGINE TOP END 5-37 Cylinder, Pistons Piston Ring, Piston Ring Groove Wear Inspection • Check for uneven groove wear by inspecting the ring seat- ing. The rings should fit perfectly parallel to groove surfaces. If not, replace the piston and all the piston rings. •...
  • Page 260: Piston Ring End Gap Inspection

    5-38 ENGINE TOP END Cylinder, Pistons Piston Ring End Gap Inspection • Place the piston ring [A] inside the cylinder, using the pis- ton to locate the ring squarely in place. Set it close to the bottom of the cylinder, where cylinder wear is low. •...
  • Page 261: Throttle Body Assy Holder

    ENGINE TOP END 5-39 Throttle Body Assy Holder Throttle Body Assy Holder Installation • Fit the groove [A] of the throttle body holder to the projec- tion [B] of the cylinder head. • Install the clamps [C] as shown. • Tighten: Torque - Throttle Body Assy Holder Clamp Screws: 2.0 N·m (0.20 kgf·m, 18 in·lb)
  • Page 262: Muffler

    5-40 ENGINE TOP END Muffler WARNING The muffler can become extremely hot during nor- mal operation and cause severe burns. Do not re- move the muffler while it is hot. Muffler Body Removal • Remove: Lower Fairings (see Lower Fairing Removal in the Frame chapter) Muffler Cover Clamp Screw [A] (Loosen) Muffler Cover Bolts [B]...
  • Page 263 ENGINE TOP END 5-41 Muffler If the pad [A] was removed, attach the pad as follows: • Align the end of slit [B] on the pad with the bending point [C] of the edge line on the muffler cover [D]. •...
  • Page 264: Exhaust Pipe Removal

    5-42 ENGINE TOP END Muffler Exhaust Pipe Removal • Remove: Muffler Body (see Muffler Body Removal) Oxygen Sensor (see Oxygen Sensor Removal in the Electrical System chapter) Mounting Bolt [A] • Remove: Exhaust Pipe Holder Nuts [A] Exhaust Pipe [B] Exhaust Pipe Installation •...
  • Page 265 CLUTCH 6-1 Clutch Table of Contents Exploded View........................Specifications ......................... Special Tool and Sealant ......................Clutch Lever and Cable ......................Clutch Lever Free Play Inspection ..................Clutch Lever Free Play Adjustment .................. Clutch Cable Removal ...................... Clutch Cable Installation ....................Clutch Cable Lubrication....................
  • Page 266: Exploded View

    6-2 CLUTCH Exploded View...
  • Page 267 CLUTCH 6-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Clutch Lever Clamp Bolt 0.90 78 in·lb Clutch Lever Pivot Bolt Locknut 0.16 14 in·lb Clutch Stopper Bolts 8.83 0.900 78.2 in·lb Oil Filler Plug – – – Hand-Tighten Clutch Cover Bolts 87 in·lb Clutch Hub Nut 13.5...
  • Page 268: Specifications

    6-4 CLUTCH Specifications Item Standard Service Limit 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Clutch Lever Free Play – – – Clutch 2.92 ∼ 3.08 mm (0.115 ∼ 0.121 in.) Friction Plate Thickness 2.6 mm (0.10 in.) Friction and Steel Plate Warp 0.15 mm (0.0059 in.) or less 0.3 mm (0.012 in.) Clutch Spring Free Length...
  • Page 269: Special Tool And Sealant

    CLUTCH 6-5 Special Tool and Sealant Clutch Holder: Liquid Gasket, TB1211F: 57001-1243 92104-0004...
  • Page 270: Clutch Lever And Cable

    6-6 CLUTCH Clutch Lever and Cable Clutch Lever Free Play Inspection • Refer to the Clutch Operation Inspection in the Periodic Maintenance chapter. Clutch Lever Free Play Adjustment • Refer to the Clutch Operation Inspection in the Periodic Maintenance chapter. Clutch Cable Removal •...
  • Page 271: Clutch Cover

    CLUTCH 6-7 Clutch Cover Clutch Cover Removal • Drain the engine oil (see Engine Oil Change in the Peri- odic Maintenance chapter). • Remove: Right Lower Fairing (see Lower Fairing Removal in the Frame chapter) Clutch Cable Lower End [A] Clutch Cover Bolts [B] Bolt [C] •...
  • Page 272: Release Shaft Installation

    6-8 CLUTCH Clutch Cover Release Shaft Installation • Apply grease to the oil seal lips on the upper ridge of the clutch cover. • Apply engine oil to the needle bearing in the hole of the clutch cover. • Apply molybdenum disulfide grease to the pusher-holding portion [A] on the release shaft.
  • Page 273: Clutch Removal

    CLUTCH 6-9 Clutch Clutch Removal • Remove: Clutch Cover (see Clutch Cover Removal) Clutch Stopper Bolts [A] ○ Loosen the clutch stopper bolts evenly with little by little to prevent tilting the clutch stopper plate. NOTICE Do not loosen the one or two clutch stopper plate bolt at once to prevent clutch stopper plate warpage by the spring force.
  • Page 274 6-10 CLUTCH Clutch • Install the bushing [A], clutch housing [B], spacer, clutch hub, washer and clutch hub nut. ○ Holding the clutch hub [A], tighten the clutch hub nut [B]. Special Tool - Clutch Holder [C]: 57001-1243 Torque - Clutch Hub Nut: 132 N·m (13.5 kgf·m, 97.4 ft·lb) •...
  • Page 275 CLUTCH 6-11 Clutch • Apply engine oil to the sliding surfaces of the bearing [A]. • Put the friction plate [B] (no cutout) and steel plate [C] (larger inner diameter) on the clutch pressure plate [D], and install them. ○ Align the tangs [A] on the friction plates (no cutout) with hole [B] on the clutch pressure plate [C] to install them into the clutch housing [D].
  • Page 276: Clutch Plate Wear And Damage Inspection

    6-12 CLUTCH Clutch Clutch Plate Wear and Damage Inspection • Visually inspect the friction and steel plates for signs of seizure, overheating (discoloration), or uneven wear. • Measure the thickness of each friction plate [A] at several points. If any plates show signs of damage, or if they have worn past the service limit, replace them with new ones.
  • Page 277: Clutch Housing Spline Inspection

    CLUTCH 6-13 Clutch Clutch Housing Spline Inspection • Visually inspect where the teeth [A] on the steel plates wear against the clutch hub splines [B]. If there are notches worn into the splines, replace the clutch hub. Also, replace the steel plates if their teeth are damaged.
  • Page 279 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 Removal ....................... Oil Pan Installation ......................
  • Page 280: Exploded View

    7-2 ENGINE LUBRICATION SYSTEM Exploded View...
  • Page 281 ENGINE LUBRICATION SYSTEM 7-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Oil Pipe Banjo Bolts (Outside) 19.6 2.00 14.5 Oil Pipe Bolt 87 in·lb Oil Breather Mounting Bolts 87 in·lb Oil Filter 17.5 1.78 12.9 EO, R Crankcase Oil Passage Plugs Spur Gear Mounting Bolt 87 in·lb Oil Pump Mounting Bolts...
  • Page 282: Engine Oil Flow Chart

    7-4 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart...
  • Page 283: Specifications

    ENGINE LUBRICATION SYSTEM 7-5 Specifications Item Standard Engine Oil Type API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2 Viscosity SAE 10W-40 Capacity 2.0 L (2.1 US qt) (when filter is not removed) 2.2 L (2.3 US qt) (when filter is removed) 2.4 L (2.5 US qt) (when engine is completely dry) Between upper and lower level lines (Wait 2 ∼...
  • Page 284: Special Tools And Sealant

    7-6 ENGINE LUBRICATION SYSTEM Special Tools and Sealant Oil Pressure Gauge, 10 kgf/cm²: Clutch Holder 1: 57001-164 57001-1507 Oil Pressure Gauge Adapter, PT3/8: Liquid Gasket, TB1211: 57001-1233 56019-120...
  • Page 285: Engine Oil And Oil Filter

    ENGINE LUBRICATION SYSTEM 7-7 Engine Oil and Oil Filter WARNING Vehicle operation with insufficient, deteriorated, or contaminated engine oil will cause accelerated wear and may result in engine seizure, accident, and injury. Check the oil level before each use and change the oil and filter according to the periodic maintenance chart.
  • Page 286: Oil Pan Removal

    7-8 ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter Oil Pan Removal • Drain the engine oil (see Engine Oil Change in the Peri- odic Maintenance chapter). • Remove: Exhaust Pipe (see Exhaust Pipe Removal in the Engine Top End chapter) Oil Pan Bolts [A] with Bracket Oil Pan [B] Gasket...
  • Page 287: Oil Screen Cleaning

    ENGINE LUBRICATION SYSTEM 7-9 Engine Oil and Oil Filter Oil Screen Cleaning • Remove the oil screen (see Oil Screen Removal). • Clean the oil screen with a high flash-point solvent and remove the particles stuck. • Blow away the particles by applying compressed air [A] from the inside to the outside (from the clean side to the dirty side).
  • Page 288: Oil Pressure Relief Valve

    7-10 ENGINE LUBRICATION SYSTEM Oil Pressure Relief Valve Oil Pressure Relief Valve Removal • Remove: Oil Pan (see Oil Pan Removal) Oil Pressure Relief Valve [A] Oil Pressure Relief Valve Installation • Apply a non-permanent locking agent to the threads of the oil pressure relief valve, and tighten it.
  • Page 289: Oil Pump

    ENGINE LUBRICATION SYSTEM 7-11 Oil Pump Oil Pump Removal • Remove: Clutch (see Clutch Removal in the Clutch chapter) Spur Gear Mounting Bolt [A] Special Tool - Clutch Holder 1 [B]: 57001-1507 • Place a clean cloth under the oil pump cover [A]. •...
  • Page 290 7-12 ENGINE LUBRICATION SYSTEM Oil Pump • Install the oil pump cover [A] so that the dowel pin [B] fits into the hole [C] of the crankcase. • Tighten: Torque - Oil Pump Mounting Bolts [A]: 9.8 N·m (1.0 kgf·m, 87 in·lb) •...
  • Page 291: Oil Pressure Measurement

    ENGINE LUBRICATION SYSTEM 7-13 Oil Pressure Measurement Oil Pressure Measurement • Remove the right lower fairing (see Lower Fairing Re- moval in the Frame chapter). • Remove the crankcase 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: 57001 -1233...
  • Page 292: Oil Pressure Switch

    7-14 ENGINE LUBRICATION SYSTEM Oil Pressure Switch Oil Pressure Switch Removal • Drain: Engine Oil (see Engine Oil Change in the Periodic Main- tenance chapter) • Remove: Right Lower Fairing (see Lower Fairing Removal in the Frame chapter) Switch Cover [A] Switch Terminal Bolt [B] Oil Pressure Switch [C] Oil Pressure Switch Installation...
  • Page 293 ENGINE REMOVAL/INSTALLATION 8-1 Engine Removal/Installation Table of Contents Exploded View........................Engine Removal/Installation ....................Engine Removal........................ Engine Installation......................
  • Page 294: Exploded View

    8-2 ENGINE REMOVAL/INSTALLATION Exploded View...
  • Page 295 ENGINE REMOVAL/INSTALLATION 8-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Upper Engine Mounting Bolts Front Lower Engine Mounting Nut Front Middle Engine Mounting Nut Rear Engine Mounting Nuts...
  • Page 296: 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 Motorcycle may fall over unexpectedly resulting in an accident or injury. Be sure to hold the front brake when removing the engine.
  • Page 297: Engine Installation

    ENGINE REMOVAL/INSTALLATION 8-5 Engine Removal/Installation • Disconnect: Neutral Switch Lead Terminal [A] Crankshaft Sensor Lead Connector [B] Alternator Lead Connector [C] • Remove: Breather Hose [D] Connector Mounting Bracket Bolts [E] • Support the engine with a suitable stand [A]. ○...
  • Page 298 8-6 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Insert the rear lower engine mounting bolt [A] first from left side while supporting the engine. Then insert the rear upper engine mounting bolt [B] from left side, and tighten the nuts temporarily. • Install the following temporarily: Front Middle Engine Mounting Bolt [A] Side Dampers [B]...
  • Page 299 CRANKSHAFT/TRANSMISSION 9-1 Crankshaft/Transmission Table of Contents Exploded View........Starter Motor Clutch Assembly ..9-24 Specifications ........Balancer ..........9-25 Special Tools and Sealant ....Balancer Removal......9-25 Crankcase ........9-10 Balancer Installation..... 9-25 Crankcase Splitting ...... 9-10 Balancer Shaft Bearing Crankcase Assembly ....
  • Page 300: Exploded View

    9-2 CRANKSHAFT/TRANSMISSION Exploded View...
  • Page 301 CRANKSHAFT/TRANSMISSION 9-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Connecting Rod Big End Nuts see the text ← ← MO, R Shift Drum Bearing Holder Screws 0.45 39 in·lb Oil Breather Mounting Bolts 87 in·lb Starter Motor Clutch Bolts 34.3 3.50 25.3...
  • Page 302 9-4 CRANKSHAFT/TRANSMISSION Exploded View...
  • Page 303 CRANKSHAFT/TRANSMISSION 9-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Gear Positioning Lever Bolt 106 in·lb Shift Lever Bolt 106 in·lb Shift Shaft Return Spring Pin 19.6 14.5 Shift Drum Cam Bolt 0.92 80 in·lb Tie-Rod Locknut (Front) 87 in·lb Tie-Rod Locknut (Rear) 87 in·lb Neutral Switch...
  • Page 304: Specifications

    9-6 CRANKSHAFT/TRANSMISSION Specifications Item Standard Service Limit Crankshaft, Connecting Rods Connecting Rod Bend – – – TIR 0.2/100 mm (0.008/3.94 in.) Connecting Rod Twist – – – TIR 0.2/100 mm (0.008/3.94 in.) 0.13 ∼ 0.38 mm Connecting Rod Big End Side Clearance 0.58 mm (0.0051 ∼...
  • Page 305 CRANKSHAFT/TRANSMISSION 9-7 Specifications Item Standard Service Limit Marking ○ 31.000 ∼ 31.008 mm – – – (1.2205 ∼ 1.2208 in.) 31.009 ∼ 31.016 mm None – – – (1.2208 ∼ 1.2211 in.) Crankshaft Main Bearing Insert Thickness: 1.495 ∼ 1.499 mm Black –...
  • Page 306 9-8 CRANKSHAFT/TRANSMISSION Specifications Connecting Rod Big End Bearing Insert Selection Con-rod Big End Bearing Insert Crankpin Diameter Inside Diameter Marking Size Color Part Number Marking ○ None Brown 92139-0784 None None Black 92139-0783 ○ ○ ○ None Blue 92139-0782 Crankshaft Main Bearing Insert Selection Crankcase Main Crankshaft Main Bearing Insert*...
  • Page 307: Special Tools And Sealant

    CRANKSHAFT/TRANSMISSION 9-9 Special Tools and Sealant Bearing Puller: Bearing Puller Adapter: 57001-135 57001-317 Outside Circlip Pliers: Liquid Gasket, TB1216B: 57001-144 92104-1064...
  • Page 308: Crankcase

    9-10 CRANKSHAFT/TRANSMISSION Crankcase Crankcase Splitting • Remove the engine (see Engine Removal in the Engine Removal/Installation chapter). • Set the engine on a clean surface and hold the engine steady while parts are being removed. • Remove: Cylinder (see Cylinder Removal in the Engine Top End chapter) Clutch (see Clutch Removal in the Clutch chapter) External Shift Mechanism (see External Shift Mecha-...
  • Page 309: Crankcase Assembly

    CRANKSHAFT/TRANSMISSION 9-11 Crankcase • Remove: Oil Pan (see Oil Pan Removal in the Engine Lubrication System chapter) Oil Screen (see Oil Pan Removal in the Engine Lubrica- tion System chapter) Oil Pressure Relief Valve (see Oil Pressure Relief Valve Removal in the Engine Lubrication System chapter) •...
  • Page 310 9-12 CRANKSHAFT/TRANSMISSION Crankcase • Apply a non-permanent locking agent to the threads of the breather plate bolts [A] and tighten them. Torque - Breather Plate Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) • Install: Shift Drum (see Shift Drum and Fork Installation) Shift Forks and Shift Rods (see Shift Drum and Fork In- stallation) Crankshaft (see Crankshaft Installation)
  • Page 311 CRANKSHAFT/TRANSMISSION 9-13 Crankcase • Apply molybdenum disulfide oil solution to the seating sur- face [A] and threads [B] of the M8 bolts. • Tighten the lower crankcase bolts using the following steps. • Replace the crankcase bolt [A] (M6, L = 135 mm) with a new one.
  • Page 312: Crankshaft And Connecting Rods

    9-14 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods Crankshaft Removal • Split the crankcase (see Crankcase Splitting). • Remove the crankshaft [A]. Crankshaft Installation • Install the crankshaft. NOTE ○ If the crankshaft is replaced with a new one, refer to the Connecting Rod Big End Bearing Insert Selection in the Specifications.
  • Page 313: Connecting Rod Installation

    CRANKSHAFT/TRANSMISSION 9-15 Crankshaft and Connecting Rods Connecting Rod Installation NOTICE To minimize vibration, the connecting rods should have the same weight mark. Big End Cap [A] Connecting Rod [B] Weight Mark, Alphabet [C] ○ Diameter Mark (Around Weight Mark) [D]: " "...
  • Page 314 9-16 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods • 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 315 CRANKSHAFT/TRANSMISSION 9-17 Crankshaft and Connecting Rods • Install new bolts and nuts in reused connecting rod. If the connecting rod assy was replaced, use the new bolts and nuts attached to the new connecting rod assy. • Apply a small amount of molybdenum disulfide oil solution to the following portions.
  • Page 316: Crankshaft/connecting Rod Cleaning

    9-18 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods • Install new bolts and nuts in reused connecting rod. If the connecting rod assy was replaced, use the new bolts and nuts attached to the new connecting rod assy. • Apply a small amount of molybdenum disulfide oil solution to the following portions.
  • Page 317: Connecting Rod Bend Inspection

    CRANKSHAFT/TRANSMISSION 9-19 Crankshaft and Connecting Rods Connecting Rod Bend Inspection • Remove the connecting rod big end bearing inserts, and reinstall the connecting rod big end cap. • Select an arbor [A] of the same diameter as the connect- ing rod big end, and insert the arbor through the connect- ing rod big end.
  • Page 318: Connecting Rod Big End Bearing Insert/crankpin Wear Inspection

    9-20 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods Connecting Rod Big End Bearing Insert/Crankpin Wear Inspection • Measure the bearing insert/crankpin [A] clearance with plastigage [B]. • Tighten the big end nuts to the specified torque (see Con- necting Rod Installation). NOTE ○...
  • Page 319: Crankshaft Side Clearance Inspection

    CRANKSHAFT/TRANSMISSION 9-21 Crankshaft and Connecting Rods • Measure the connecting rod big end inside diameter, and mark each connecting rod big end in accordance with the inside diameter. • Tighten the connecting rod big end nuts to the specified torque (see Connecting Rod Installation). NOTE ○...
  • Page 320: Crankshaft Runout Inspection

    9-22 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods Crankshaft Runout Inspection • Measure the crankshaft runout. If the measurement exceeds the service limit, replace the crankshaft. Crankshaft Runout Standard: TIR 0.02 mm (0.0008 in.) or less Service Limit: TIR 0.05 mm (0.0020 in.) Crankshaft Main Bearing Insert/Journal Wear Inspection •...
  • Page 321 CRANKSHAFT/TRANSMISSION 9-23 Crankshaft and Connecting Rods • Measure the main bearing inside diameter, and mark the upper crankcase half in accordance with the inside diam- eter. [A]: Crankcase Main Bearing Inside Diameter Marks, ○ " " or no mark. NOTE ○...
  • Page 322: Starter Motor Clutch

    9-24 CRANKSHAFT/TRANSMISSION Starter Motor Clutch Starter Motor Clutch Removal/Installation • Refer to the Alternator Rotor Removal/Installation in the Electrical System chapter. Starter Motor Clutch Inspection • Remove: Alternator Cover (see Alternator Cover Removal in the Electrical System chapter) Starter Idle Gear and shaft •...
  • Page 323: Balancer

    CRANKSHAFT/TRANSMISSION 9-25 Balancer Balancer Removal • Split the crankcase (see Crankcase Splitting). • Remove the balancer shaft [A] with the balancer gear. Balancer Installation • Install the balancer shaft. ○ Align the timing mark [A] on the balancer gear [B] with the timing mark [C] on the balancer drive gear [D].
  • Page 324 9-26 CRANKSHAFT/TRANSMISSION Balancer If any journal has worn past the service limit, replace the balancer shaft with a new one. If the measured journal diameters are not less than the service limit, but do not coincide with the original diameter markings [A] on the balancer shaft, make new marks on Balancer Shaft Journal Diameter Marks None: 25.984 ∼...
  • Page 325: Transmission

    CRANKSHAFT/TRANSMISSION 9-27 Transmission Shift Pedal Removal • Remove: Shift Pedal Mounting Bolt [A] Shift Lever Bolt [B] Shift Pedal [C] with Shift Lever Shift Pedal Installation • Apply grease to the shift pedal [A]. • Install the washers [B] and shift pedal. •...
  • Page 326: External Shift Mechanism Removal

    9-28 CRANKSHAFT/TRANSMISSION Transmission • Be sure the sealing lip of the rubber boots [A] fits into the groove of the ball joint after installing the shift lever link. Correctly Boot Fitting Position [B] Incorrectly Boot Fitting Position [C] External Shift Mechanism Removal •...
  • Page 327: Transmission Shaft Removal

    CRANKSHAFT/TRANSMISSION 9-29 Transmission • Check the return spring pin [A] is not loose. If it is loose, unscrew it, apply a non-permanent locking agent to the threads, and tighten it. Torque - Shift Shaft Return Spring Pin: 19.6 N·m (2.0 kgf·m, 14.5 ft·lb) •...
  • Page 328: Transmission Shaft Disassembly

    9-30 CRANKSHAFT/TRANSMISSION Transmission • Apply engine oil to the bearings. ○ The bearing set pins and rings must match properly with the holes or grooves in the bearing outer races. When they are properly matched, there is no clearance [A] be- tween the crankcase and the bearing outer races.
  • Page 329: Transmission Shaft Assembly

    CRANKSHAFT/TRANSMISSION 9-31 Transmission Transmission Shaft Assembly • Apply engine oil to the bushings, ball bearings and shafts. • Install the ball bearings on the shafts with the groove to- ward the clutch side. • Install the gear bushings [A] on the shaft with their holes [B] aligned.
  • Page 330 9-32 CRANKSHAFT/TRANSMISSION Transmission 1. Circlip, 29 mm (1.14 in.) 15. Ball Bearing 2. Circlip 16. Drive Shaft 3. Thrust Washer, 30 mm (1.18 in.) (Inside Diameter: 17. Nut 25.3 mm (0.996 in.)) 18. Washer 4. Toothed Washer, 30 mm (1.18 in.) 19.
  • Page 331: Shift Drum And Fork Removal

    CRANKSHAFT/TRANSMISSION 9-33 Transmission Shift Drum and Fork Removal • Remove: Lower Crankcase Half (see Crankcase Splitting) Transmission Shafts (see Transmission Shaft Removal) • Remove: Gear Positioning Lever Bolt [A] Spacer [B] Gear Positioning Lever [C] Washer [D] Spring [E] Shift Drum Bearing Holder Screws [F] Shift Drum Bearing Holder [G] Shift Rods [H] Shift Forks...
  • Page 332: Shift Drum Disassembly

    9-34 CRANKSHAFT/TRANSMISSION Transmission • Install the shift drum bearing holder [A]. • Apply a non-permanent locking agent to the threads of the shift drum bearing holder screws [B], and tighten them. Torque - Shift Drum Bearing Holder Screws: 4.4 N·m (0.45 kgf·m, 39 in·lb) Shift Drum Disassembly •...
  • Page 333: Shift Fork/gear Groove Wear Inspection

    CRANKSHAFT/TRANSMISSION 9-35 Transmission Shift Fork/Gear Groove Wear Inspection • Measure the thickness of the shift fork ears [A], and mea- sure the width of the gear grooves [B]. If the thickness of a shift fork ear is less than the service limit, the shift fork must be replaced.
  • Page 335 WHEELS/TIRES 10-1 Wheels/Tires Table of Contents Exploded View........................10-2 Specifications ......................... 10-4 Special Tools ......................... 10-5 Wheels (Rims) ........................10-6 Front Wheel Removal ....................... 10-6 Front Wheel Installation ....................10-6 Rear Wheel Removal......................10-7 Rear Wheel Installation..................... 10-8 Wheel Inspection ......................10-10 Axle Inspection........................
  • Page 336: Exploded View

    10-2 WHEELS/TIRES Exploded View...
  • Page 337 WHEELS/TIRES 10-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Axle Nut Rear Axle Nut 10.0 G: Apply grease. HG: Apply high-temperature grease. R: Replacement Parts WL: Apply soap and water solution or rubber lubricant.
  • Page 338: 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 0.1 mm (0.004 in.) or less TIR 0.2 mm (0.008 in.) Wheel Balance 10 g (0.35 oz.) or less...
  • Page 339 WHEELS/TIRES 10-5 Special Tools Inside Circlip Pliers: Jack: 57001-143 57001-1238 Rim Protector: Bearing Remover Shaft, 9: 57001-1063 57001-1265 Bead Breaker Assembly: Bearing Remover Head, 15 × 17: 57001-1072 57001-1267 Bearing Driver Set: Jack Attachment: 57001-1129 57001-1608...
  • Page 340: Front Wheel Removal

    10-6 WHEELS/TIRES Wheels (Rims) Front Wheel Removal • Remove: Front Caliper (see Front Caliper Removal in the Brakes chapter) Bolt [A] (ABS Equipped Models) Front Wheel Rotation Sensor [B] (ABS Equipped Mod- els) Cotter Pin [C] Axle Nut [D] and Washer Lower Fairings (see Lower Fairing Removal in the Frame chapter) •...
  • Page 341: Rear Wheel Removal

    WHEELS/TIRES 10-7 Wheels (Rims) • Insert a new cotter pin [A]. NOTE ○ When inserting the cotter pin, if the slots in the nut do not align with the cotter pin hole in the axle, tighten the nut clockwise [B] up to next alignment. ○...
  • Page 342: Rear Wheel Installation

    10-8 WHEELS/TIRES Wheels (Rims) • Remove the rear caliper mounting bolts [A]. • Turn the rear caliper [B] rearward to take off from the rear brake disc. • Remove the bolt [A] and rear wheel rotation sensor [B] (ABS Equipped Models). •...
  • Page 343 WHEELS/TIRES 10-9 Wheels (Rims) • Insert a new cotter pin [A]. NOTE ○ When inserting the cotter pin, if the slots in the nut do not align with the cotter pin hole in the axle, tighten the nut clockwise [B] up to next alignment. ○...
  • Page 344: Wheel Inspection

    10-10 WHEELS/TIRES Wheels (Rims) Wheel Inspection • Raise the front/rear wheel off the ground. Special Tools - Jack: 57001-1238 Jack Attachment: 57001-1608 • Spin the wheel lightly, and check for roughness or binding. If roughness or binding is found, replace the hub bearings (see Hub Bearing Removal/Installation).
  • Page 345: Balance Inspection

    WHEELS/TIRES 10-11 Wheels (Rims) Balance Inspection • Remove the front and rear wheels (see Front/Rear Wheel Removal). • Support the wheel so that it can be spun freely. • Spin the wheel lightly, and mark [A] the wheel at the top when the wheel stops.
  • Page 346 30 g (1.06 oz.) NOTE ○ Balance weights are available from Kawasaki dealers in 10, 20, and 30 grams (0.35, 0.71, and 1.06 oz.) sizes. An imbalance of less than 10 grams (0.35 oz.) will not usually affect running stability.
  • Page 347: Tires

    WHEELS/TIRES 10-13 Tires Air Pressure Inspection/Adjustment • Refer to the Air Pressure Inspection in the Periodic Main- tenance chapter. Tire Inspection • Refer to the Wheel/Tire Damage Inspection in the Peri- odic Maintenance chapter. Tire Removal • Remove: Wheels (see Front/Rear Wheel Removal) Valve Core (Let out the air) •...
  • Page 348: Tire Installation

    10-14 WHEELS/TIRES Tires NOTE ○ For easier removal, always position the tire bead oppo- site the valve stem in the rim well, and pry the tire bead a little at a time. NOTICE Be careful not to scratch the inner liner [A] and air sealing surfaces [B] of the rim and tire with the tire irons.
  • Page 349 WHEELS/TIRES 10-15 Tires • Check the tire rotation mark on the front and rear tires and install them on the rim accordingly. Tire Rotation Mark [A] Rotating Direction [B] • Position the tire on the rim so that the air valve [A] align with the tire balance mark [B] (the chalk mark made during removal, or the yellow paint mark on a new tire).
  • Page 350: 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 351: Hub Bearing

    WHEELS/TIRES 10-17 Hub Bearing Hub Bearing Removal • Remove the wheels (see Front/Rear Wheel Removal). • Remove: Collars Coupling (Out of rear hub) Grease Seals [A] Circlip [B] (For Rear Wheel) Special Tool - Inside Circlip Pliers: 57001-143 • Use the bearing remover to remove the hub bearings [A]. NOTICE Do not lay the wheel on the ground with the disc facing down.
  • Page 352: Hub Bearing Inspection

    10-18 WHEELS/TIRES Hub Bearing Hub Bearing Inspection Since the hub bearings are made to extremely close tol- erances, the clearance can not normally be measured. NOTE ○ Do not remove any bearings for inspection. If any bear- ings are removed, they will need to be replaced with new ones.
  • Page 353 FINAL DRIVE 11-1 Final Drive Table of Contents Exploded View........................11-2 Specifications ......................... 11-4 Special Tool ..........................11-5 Drive Chain..........................11-6 Drive Chain Slack Inspection .................... 11-6 Drive Chain Slack Adjustment ..................11-6 Wheel Alignment Inspection/Adjustment ................11-6 Drive Chain Wear Inspection .................... 11-6 Drive Chain Lubrication.....................
  • Page 354: Exploded View

    11-2 FINAL DRIVE Exploded View...
  • Page 355 FINAL DRIVE 11-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Engine Sprocket Cover Bolts 87 in·lb Speed Sensor Bolt 0.80 69 in·lb Speed Sensor Bracket Bolts 87 in·lb Rear Sprocket Nuts Engine Sprocket Nut 13.0 93.7 Rear Axle Nut 10.0 7.
  • Page 356: Specifications

    11-4 FINAL DRIVE Specifications Item Standard Service Limit Drive Chain 20 ∼ 30 mm (0.8 ∼ 1.2 in.) Drive Chain Slack – – – Drive Chain Wear (20-link Length) 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) 319 mm (12.56 in.) Standard Chain: Make ENUMA...
  • Page 357: Special Tool

    FINAL DRIVE 11-5 Special Tool Bearing Driver Set: 57001-1129...
  • Page 358: Drive Chain

    11-6 FINAL DRIVE Drive Chain Drive Chain Slack Inspection • Refer to the Drive Chain Slack Inspection in the Periodic Maintenance chapter. Drive Chain Slack Adjustment • Refer to the Drive Chain Slack Adjustment in the Periodic Maintenance chapter. Wheel Alignment Inspection/Adjustment •...
  • Page 359: Drive Chain Installation

    FINAL DRIVE 11-7 Drive Chain Drive Chain Installation • Install the drive chain to the output shaft. • Install: Swingarm (see Swingarm Installation in the Suspension chapter) Rear Wheel (see Rear Wheel Installation in the Wheels/Tires chapter) Engine Sprocket (see Engine Sprocket Installation) Chain Cover Saree Guard (IN Model) •...
  • Page 360 11-8 FINAL DRIVE Drive Chain • Screw the pin holder until it touches the link pin. • Be sure that the cutting pin hits center of the link pin. • Screw the handlebar [A] into the body. • Turn the pin holder with the wrench [B] clockwise to ex- tract the link pin.
  • Page 361 FINAL DRIVE 11-9 Drive Chain • Turn the pin holder by a wrench clockwise until two pins of link come into groove of the plate holder (A). • Take off the plate holder. • Set the plate holder (B) [A] and cutting and riveting pin [B] as shown.
  • Page 362 11-10 FINAL DRIVE Drive Chain • After staking, check the staked area of the link pin for cracks. • Measure the outside diameter [A] of the link pin and link plates width [B]. Link Pin Outside Diameter 5.3 ∼ 5.7 mm (0.21 ∼ 0.22 in.) Standard: Link Plates Outside Width 17.35 ∼...
  • Page 363: Sprocket, Coupling

    FINAL DRIVE 11-11 Sprocket, Coupling Engine Sprocket Removal • Remove: Shift Lever [A] (see Shift Pedal Removal in the Crank- shaft/Transmission chapter) Engine Sprocket Cover Bolts [B] Engine Sprocket Cover [C] • Remove the speed sensor mounting bracket upper bolts [A] and lower bolt [B].
  • Page 364: Rear Sprocket Removal

    11-12 FINAL DRIVE Sprocket, Coupling • Install the dowel pins [A]. • Install the speed sensor bracket [B] so that the dowel pins fits into the holes [C] of the speed sensor bracket. • Tighten: Torque - Speed Sensor Bracket Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) •...
  • Page 365: Coupling Bearing Removal

    FINAL DRIVE 11-13 Sprocket, Coupling • Replace the O-ring [A] with a new one and apply grease to it. • Install: O-ring Collar [B] Coupling Coupling Bearing Removal • Remove: Coupling Grease Seal • Remove the bearing [A] by tapping from the wheel side. Special Tool - Bearing Driver Set [B]: 57001-1129 Coupling Bearing Installation •...
  • Page 366: Coupling Bearing Lubrication

    11-14 FINAL DRIVE Sprocket, Coupling Coupling Bearing Lubrication • Pack the bearing with grease. Turn the bearing around by hand a few times to make sure the grease is distributed uniformly inside the bearing. Coupling Damper Inspection • Remove the rear wheel coupling, and inspect the rubber dampers [A].
  • Page 367 BRAKES 12-1 Brakes Table of Contents Exploded View ........................12-4 Specifications ........................12-12 Special Tools .......................... 12-13 Brake Pedal ..........................12-14 Brake Pedal Position Inspection ..................12-14 Brake Pedal Position Adjustment ..................12-14 Brake Pedal Removal ....................... 12-14 Brake Pedal Installation ....................12-15 Calipers ..........................
  • Page 368 12-2 BRAKES Inquiries to Rider....................... 12-36 Self-diagnosis Outline ....................... 12-38 Self-diagnosis Procedures ....................12-38 Service Code Clearing Procedures................... 12-39 How to Read Service Codes..................... 12-42 How to Erase Service Codes .................... 12-42 Yellow ABS Indicator Light (LED) Inspection ..............12-44 ABS Unit Solenoid Valve Inspection (Service Code 13, 14, 17, 18) .........
  • Page 369 BRAKES 12-3 This page intentionally left blank.
  • Page 370: Exploded View

    12-4 BRAKES Exploded View EX300A Model...
  • Page 371 BRAKES 12-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Brake Hose Banjo Bolts Front Brake Reservoir Cap Screws 0.15 13 in·lb Brake Lever Pivot Bolt 0.60 52 in·lb Brake Lever Pivot Bolt Locknut 0.60 52 in·lb Front Master Cylinder Clamp Bolts 0.90 78 in·lb Front Brake Light Switch Screw...
  • Page 372 12-6 BRAKES Exploded View EX300A Model...
  • Page 373 BRAKES 12-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Rear Master Cylinder Mounting Bolts Brake Pedal Bolt 0.90 78 in·lb Rear Master Cylinder Push Rod Locknut 17.2 1.75 12.7 Brake Hose Banjo Bolts Rear Brake Pad Pins 17.2 1.75 12.7 Bleed Valve 0.56...
  • Page 374 12-8 BRAKES Exploded View EX300B Model...
  • Page 375 BRAKES 12-9 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Brake Hose Banjo Bolts Front Brake Reservoir Cap Screws 0.15 13 in·lb Brake Lever Pivot Bolt 0.60 52 in·lb Brake Lever Pivot Bolt Locknut 0.60 52 in·lb Front Master Cylinder Clamp Bolts 0.90 78 in·lb Front Brake Light Switch Screw...
  • Page 376 12-10 BRAKES Exploded View EX300B Model...
  • Page 377 BRAKES 12-11 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Rear Master Cylinder Mounting Bolts Brake Pedal Bolt 0.90 78 in·lb Rear Master Cylinder Push Rod Locknut 17.2 1.75 12.7 Brake Pipe Joint Nuts Brake Hose Banjo Bolts Rear Brake Pad Pins 17.2 1.75 12.7...
  • Page 378: Specifications

    12-12 BRAKES Specifications Item Standard Service Limit Brake Lever, Brake Pedal Brake Lever Position Non-adjustable – – – Brake Lever Free Play Non-adjustable – – – Pedal Free Play Non-adjustable – – – Pedal Position About 40 mm (1.57 in.) below top of footpeg –...
  • Page 379: Special Tools

    BRAKES 12-13 Special Tools Jack: Jack Attachment: 57001-1238 57001-1608 Hand Tester: 57001-1394...
  • Page 380: Brake Pedal

    12-14 BRAKES Brake Pedal Brake Pedal Position Inspection • Check that the brake pedal [A] is in the correct position. Footpeg [B] Pedal Position Standard: About 40 mm (1.57 in.) [C] below top of footpeg If it is incorrect, adjust the brake pedal position. Brake Pedal Position Adjustment NOTE ○...
  • Page 381: Brake Pedal Installation

    BRAKES 12-15 Brake Pedal Brake Pedal Installation • Apply grease to the pivot shaft [A] and install the washer [B]. • Install: Brake Pedal [C] Washer [D] • Tighten: Torque - Brake Pedal Bolt [E]: 8.8 N·m (0.90 kgf·m, 78 in·lb) •...
  • Page 382: Calipers

    12-16 BRAKES Calipers Front Caliper Removal • Loosen the banjo bolt [A] at the brake hose lower end, and tighten it loosely. • Remove the caliper mounting bolts [B] and caliper [C]. • Remove the banjo bolt to disconnect the brake hose [D] from the caliper (see Brake Hose Removal/Installation).
  • Page 383: Front Caliper Disassembly

    BRAKES 12-17 Calipers Front Caliper Disassembly • Refer to the Caliper Rubber Parts Replacement in the Pe- riodic Maintenance chapter. Front Caliper Assembly • Refer to the Caliper Rubber Parts Replacement in the Pe- riodic Maintenance chapter. Rear Caliper Disassembly •...
  • Page 384: Caliper Piston And Cylinder Damage Inspection

    12-18 BRAKES Calipers Caliper Piston and Cylinder Damage Inspection • Visually inspect the pistons [A] and cylinder surfaces [B]. Replace the caliper if the cylinder and piston are badly scores or rusty. Caliper Holder Pin Inspection The caliper body must slide smoothly on the caliper holder pins [A].
  • Page 385: Brake Pads

    BRAKES 12-19 Brake Pads Brake Pad Removal NOTE ○ The procedure to remove the front brake pad is as fol- lows. Removing the rear brake pad is the same as for the front brake pad. • Loosen the pad pins [A]. •...
  • Page 386: Master Cylinder

    12-20 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). • Remove the clamp bolts [B] and remove the master cylin- der [C] with the reservoir, brake lever, and brake switch as an assembly.
  • Page 387: Rear Master Cylinder Installation

    BRAKES 12-21 Master Cylinder Rear Master Cylinder Installation • Connect the reservoir hose to the rear master cylinder and hold it with the clamp. • Replace the washers that are on each side of hose fitting with new ones. • Tighten: Torque - Rear Master Cylinder Mounting Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb)
  • Page 388: Master Cylinder Inspection

    12-22 BRAKES Master Cylinder Master Cylinder Inspection • Remove the master cylinders (see Front/Rear Master Cylinder Removal). • Disassemble the front and rear master cylinders (see Master Cylinder Rubber Parts Replacement in the Peri- odic Maintenance chapter). • 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 389: Brake Disc

    BRAKES 12-23 Brake Disc Brake Disc Removal • Remove the wheels (see Front/Rear Wheel Removal in the Wheels/Tires chapter). • Remove the mounting bolts and disc. Brake Disc Installation • Install the brake disc on the wheel so that the marked side [A] faces out.
  • Page 390: Brake Fluid

    12-24 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 391 BRAKES 12-25 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 392 12-26 BRAKES Brake Fluid WARNING When working with the disc brake, observe the pre- cautions listed below. • Never reuse old brake fluid. • Do not use fluid from a container that has been left unsealed or that has been open for a long time. •...
  • Page 393: Brake Hose

    BRAKES 12-27 Brake Hose Brake Hose Removal/Installation • Refer to the Brake Hose and Pipe Replacement in the Periodic Maintenance chapter. Brake Hose Inspection • Refer to the Brake Hose and Pipe Damage and Instal- lation Condition Inspection in the Periodic Maintenance chapter.
  • Page 394: Anti-lock Brake System (equipped Models)

    12-28 BRAKES Anti-Lock Brake System (Equipped Models) Parts Location Front Wheel Rotation Sensor [A] Front Wheel Rotation Sensor Rotor [B] Rear Wheel Rotation Sensor [A] Rear Wheel Rotation Sensor Rotor [B] Yellow ABS Indicator Light (LED) [A] ABS Hydraulic Unit [A] Fuse Box 1 [A] Fuse Box 2 [B]...
  • Page 395 BRAKES 12-29 Anti-Lock Brake System (Equipped Models) ABS Kawasaki Diagnostic System Connector [A] ABS Self-diagnosis Terminal [B] ABS System Wiring Diagram 1. Front Brake Light Switch 12. Fuse Box 2 2. Ignition Switch 13. ABS Hydraulic Unit 14. ABS Self-diagnosis Terminal 3.
  • Page 396 2. Unused 3. Unused 4. Front and Rear Brake Light Switch Signal: BL/R 5. ABS Kawasaki Diagnostic System Terminal: P 6. Power Supply to Rear Wheel Rotation Sensor: W/G 7. Power Supply: BR/W 8. Power Supply to Front Wheel Rotation Sensor: W/BK 9.
  • Page 397: Abs Servicing Precautions

    BRAKES 12-31 Anti-Lock Brake System (Equipped Models) ABS Servicing Precautions There are a number of important precautions that should be followed servicing the ABS system. ○ This ABS 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 398 12-32 BRAKES Anti-Lock Brake System (Equipped Models) WARNING Air in the brake lines diminish braking performance and can cause an accident resulting in injury or death. If any of the brake line fittings, including the ABS hydraulic unit joint nuts, or the bleed valve is opened at any time, the air must be bled completely from the brake line.
  • Page 399: Abs Troubleshooting Outline

    BRAKES 12-33 Anti-Lock Brake System (Equipped Models) ○ The yellow ABS indicator light (LED) may come on if the engine is run with the motorcycle on its stand and the transmission in gear. If the indicator light comes on, just turn the ignition switch off, then clear service code 42, which indicates a “Faulty front wheel rotation sensor”.
  • Page 400 12-34 BRAKES Anti-Lock Brake System (Equipped Models) Even when the ABS is operating normally, the yellow ABS indicator light (LED) may light up under the conditions listed below. Turn the ignition switch off to stop the indicator light. If the motorcycle runs without erasing the service code, the light may light up again.
  • Page 401 BRAKES 12-35 Anti-Lock Brake System (Equipped Models) ABS Diagnosis Flow Chart...
  • Page 402: Inquiries To Rider

    12-36 BRAKES Anti-Lock Brake System (Equipped Models) Inquiries to Rider ○ Each rider reacts to problems in different ways, so it is important to confirm what kind of condition the rider is dissatisfied with. ○ Try to find out exactly what problem occurs under exactly what conditions by asking the rider; know- ing this information may help you reproduce the problem in the shop.
  • Page 403 BRAKES 12-37 Anti-Lock Brake System (Equipped Models) Pre-Diagnosis Inspection 1...
  • Page 404: Self-diagnosis Outline

    12-38 BRAKES Anti-Lock Brake System (Equipped Models) Pre-Diagnosis Inspection 2 Self-diagnosis Outline When the yellow ABS indicator light (LED) has blinked or come on, the ABS hydraulic unit mem- orizes and stores the service code for the service person to troubleshoot easily. The service code memory is powered directly by the battery and cannot be canceled by the ignition switch.
  • Page 405: Service Code Clearing Procedures

    BRAKES 12-39 Anti-Lock Brake System (Equipped Models) • The ABS hydraulic unit can be store the service codes including previous ones. • To read out the current service code, erase the stored service codes once prior reading the service code (see Service Code Clearing Procedures).
  • Page 406 12-40 BRAKES Anti-Lock Brake System (Equipped Models)
  • Page 407 BRAKES 12-41 Anti-Lock Brake System (Equipped Models) Self-diagnosis Flow Chart...
  • Page 408: How To Read Service Codes

    12-42 BRAKES Anti-Lock Brake System (Equipped Models) How to Read Service Codes ○ Service codes are shown by a series of long and short blinks of the yellow ABS indicator light (LED) as shown below. ○ Read 10th digit and unit digit as the yellow ABS indicator light (LED) blinks. ○...
  • Page 409 BRAKES 12-43 Anti-Lock Brake System (Equipped Models) Service Code Table Service Yellow ABS Indicator Problems Light State Code Light (LED) Stays on* (Error function Main harness, meter unit, wheel rotation – after the ignition switch sensor(s) or ABS unit abnormal turned on) Does not go on (When the Main harness, meter unit or ABS unit...
  • Page 410: Yellow Abs Indicator Light (led) Inspection

    12-44 BRAKES Anti-Lock Brake System (Equipped Models) Yellow ABS Indicator Light (LED) Inspection ○ In this model, the yellow ABS indicator light (LED) [A] goes on or blinks by the control of the ABS hydraulic unit. Yellow ABS Indicator Light (LED) Stays ON (Error func- tion after the ignition switch turned on - No Service Code) •...
  • Page 411 BRAKES 12-45 Anti-Lock Brake System (Equipped Models) Step 3-2 • Check for continuity between the terminal 9 (BK/Y) [A] of the ABS hydraulic unit connector and a frame ground [B]. If there is no continuity, repair or replace the main har- ness.
  • Page 412 12-46 BRAKES Anti-Lock Brake System (Equipped Models) Step 2 • Disconnect the ABS hydraulic unit connector [A] and check the yellow ABS indicator light (LED) for function. ○ The yellow ABS indicator light (LED) should goes on when the ignition switch turned on. If the indicator does not goes on, go to next step.
  • Page 413: Abs Unit Solenoid Valve Inspection (service Code 13, 14, 17, 18)

    BRAKES 12-47 Anti-Lock Brake System (Equipped Models) ABS Unit Solenoid Valve Inspection (Service Code 13, 14, 17, 18) ○ These codes indicate there is a problem in the solenoid valves, which integrated into the ABS Hydraulic Unit. Therefore the solenoid valves cannot be checked directly. •...
  • Page 414: Abs Motor Inspection (service Code 35)

    12-48 BRAKES Anti-Lock Brake System (Equipped Models) Step 3 • Measure the front and rear wheel rotation sensor air gaps (see Wheel Rotation Sensor Air Gap Inspection). If the air gap is not within the specification, recheck the hub bearing, sensor, sensor rotor and sensor installation condition.
  • Page 415: Front Or Rear Wheel Rotation Sensor Wiring Inspection (service Code 43)

    BRAKES 12-49 Anti-Lock Brake System (Equipped Models) Step 3 • Check the front and rear tire/wheel conditions for tire pres- sure, tire size/types, abnormal wear and deformations (see Wheels/Tires in the Periodic Maintenance chapter). If the tire and/or wheel are in bad condition, correct them if necessary and recheck.
  • Page 416 12-50 BRAKES Anti-Lock Brake System (Equipped Models) Step 2-1 • Disconnect the rear wheel rotation sensor connector. • Recheck the continuity between the terminal 9 (BK/Y) [A] and terminal 6 (W/G) [B] of the ABS hydraulic unit con- nector. If there is continuity, repair or replace the main harness. If there is no continuity, replace the rear wheel rotation sensor.
  • Page 417: Rear Wheel Rotation Sensor Wiring Inspection (service Code 45)

    BRAKES 12-51 Anti-Lock Brake System (Equipped Models) Step 6 • Connect the front wheel rotation sensor connector. • Connect the 4.5 ∼ 5.0 V DC power (e.g. three AA dry battery in series [A]) between the terminal 17 (BK/W) (–) [B] and terminal 8 (W/BK) (+) [C] of the ABS hydraulic unit connector to measure DC amperage.
  • Page 418 12-52 BRAKES Anti-Lock Brake System (Equipped Models) Step 2 • Check for continuity between the terminal 9 (BK/Y) [A] and terminal 6 (W/G) [B] of the ABS hydraulic unit connector. If there is continuity, go to next step. If there is no continuity, go to step 3. Step 2-1 •...
  • Page 419: Power Supply Voltage Abnormal Inspection (service Code 52: Low Voltage) (service Code 53: High Voltage)

    BRAKES 12-53 Anti-Lock Brake System (Equipped Models) Step 5 • With disconnecting the rear wheel rotation sensor con- nector [A], check for continuity between the terminal 15 (BK/O) [B] of the ABS hydraulic unit connector [C] and terminal 1 (BK/O) [D] of the rear wheel rotation sensor connector (main harness side).
  • Page 420: Abs Hydraulic Unit Internal Error Inspection (service Code 55)

    12-54 BRAKES Anti-Lock Brake System (Equipped Models) Step 3 • Disconnect the ABS hydraulic unit connector. • Check the voltage between the terminal 9 (BK/Y) (–) [A] and terminal 18 (R/W) (+) [B] of the ABS hydraulic unit connector. Special Tool - Hand Tester: 57001-1394 ○...
  • Page 421: Abs Hydraulic Unit Removal

    BRAKES 12-55 Anti-Lock Brake System (Equipped Models) ABS Hydraulic Unit Removal NOTICE The ABS hydraulic unit [A] has been adjusted and set with precision at the factory. Therefore, it should be handled carefully, never struck sharply, as with a hammer, or allowed to fall on a hard surface.
  • Page 422: Abs Hydraulic Unit Installation

    12-56 BRAKES Anti-Lock Brake System (Equipped Models) • Remove: Bolts [A] and Washers Bracket [B] NOTICE The ABS hydraulic unit has been adjusted and set with precision at the factory. Do not try to disas- semble and repair the ABS hydraulic unit. ABS Hydraulic Unit Installation •...
  • Page 423: Front Wheel Rotation Sensor Removal

    BRAKES 12-57 Anti-Lock Brake System (Equipped Models) Front Wheel Rotation Sensor Removal NOTICE The wheel rotation sensor should be handled care- fully, never struck sharply, as with a hammer, or al- lowed to fall on a hard surface since the wheel rota- tion sensor is precision made.
  • Page 424: Rear Wheel Rotation Sensor Removal

    12-58 BRAKES Anti-Lock Brake System (Equipped Models) Rear Wheel Rotation Sensor Removal NOTICE The wheel rotation sensor should be handled care- fully, never struck sharply, as with a hammer, or al- lowed to fall on a hard surface since the wheel rota- tion sensor is precision made.
  • Page 425: Wheel Rotation Sensor Inspection

    BRAKES 12-59 Anti-Lock Brake System (Equipped Models) Wheel Rotation Sensor Inspection • Remove the front wheel rotation sensor [A] from the front fork. • Remove the rear wheel rotation sensor [B] from the caliper bracket. • Visually inspect the wheel rotation sensors. Replace the wheel rotation sensor if it is cracked, bent, or otherwise damaged.
  • Page 426: Fuse Removal

    12-60 BRAKES Anti-Lock Brake System (Equipped Models) • If necessary, replace the sensor rotor as follows. • Remove: Wheels (see Front/Rear Wheel Removal in the Wheels/Tires chapter) Brake Disc Mounting Bolts [A] Sensor Rotor [B] Front Wheel [C] Rear Wheel [D] ○...
  • Page 427 SUSPENSION 13-1 Suspension Table of Contents Exploded View........................13-2 Specifications ......................... 13-6 Special Tools .......................... 13-7 Front Fork ..........................13-8 Front Fork Removal (Each Fork Leg) ................13-8 Front Fork Installation (Each Fork Leg) ................13-8 Front Fork Oil Change ...................... 13-8 Front Fork Disassembly ....................
  • Page 428: Exploded View

    13-2 SUSPENSION Exploded View...
  • Page 429 SUSPENSION 13-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Fork Upper Clamp Bolts Front Fork Lower Clamp Bolts Front Fork Bottom Allen Bolts AD: Apply adhesive. G: Apply grease. R: Replacement Parts...
  • Page 430 13-4 SUSPENSION Exploded View...
  • Page 431 SUSPENSION 13-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Rear Shock Absorber Nuts Swingarm Pivot Shaft Nut 10.0 Rocker Arm Nut Tie-Rod Nuts G: Apply grease. R: Replacement Parts...
  • Page 432: Specifications

    13-6 SUSPENSION Specifications Item Standard Front Fork (Per One Unit) Fork Inner Tube Diameter 37 mm (1.5 in.) Air Pressure Atmospheric pressure (Non-adjustable) Rebound Damper Setting Non-adjustable Fork Spring Preload Setting Non-adjustable Fork Oil: Recommended Oil SHOWA SS-8 or equivalent Amount Approx.
  • Page 433: Special Tools

    SUSPENSION 13-7 Special Tools Fork Cylinder Holder Handle: Front Fork Oil Seal Driver: 57001-183 57001-1219 Fork Cylinder Holder Adapter: Jack: 57001-1057 57001-1238 Oil Seal & Bearing Remover: Fork Oil Level Gauge: 57001-1058 57001-1290 Bearing Driver Set: Jack Attachment: 57001-1129 57001-1608 Fork Outer Tube Weight: 57001-1218...
  • Page 434: Front Fork

    13-8 SUSPENSION Front Fork Front Fork Removal (Each Fork Leg) • Remove: Lower Fairings (see Lower Fairing Removal in the Frame chapter) Front Wheel (see Front Wheel Removal in the Wheels/Tires chapter) Front Fender (see Front Fender Removal in the Frame chapter) Bolts [A] (Both Sides) Bracket [B]...
  • Page 435 SUSPENSION 13-9 Front Fork • Compress [A] the fork [B] upside down to draw out the oil into the suitable container [C]. • Hold the fork tube upright, pour in the type and amount of fork oil specified. Suspension Oil - SHOWA SS-8: 44091-0007 Fork Oil Amount (Per Side): When changing oil:...
  • Page 436: Front Fork Disassembly

    13-10 SUSPENSION Front Fork Front Fork Disassembly • Remove the front fork (see Front Fork Removal). • To remove the top plug [A], remove the snap ring [B] while pushing down the top plug with a suitable tool. • Remove: Top Plug [A] with O-ring [B] Collar [C] Fork Spring Seat [D]...
  • Page 437: Front Fork Assembly

    SUSPENSION 13-11 Front Fork • Remove: Oil Seal Washer Outer Guide Bushing Inner Guide Bushing Cylinder Base Front Fork Assembly • Replace the following parts with new ones. Inner Guide Bushing [A] Oil Seal [B] Outer Guide Bushing [C] Bottom Allen Bolt Gasket [D] •...
  • Page 438: Inner Tube, Outer Tube Inspection

    13-12 SUSPENSION Front Fork • Apply grease to the oil seal lips, and install the washer and the oil seal [A] into the outer tube. Special Tool - Front Fork Oil Seal Driver [B]: 57001-1219 • Install the retaining ring [A] on the outer tube. •...
  • Page 439: Dust Seal Inspection

    SUSPENSION 13-13 Front Fork Dust Seal Inspection • Inspect the dust seal [A] for any signs of deterioration or damage. Replace it if necessary. Fork Spring Tension Inspection • Since a spring becomes shorter as it weakens, check its free length [A] to determine its condition. If the spring of either fork leg is shorter than the service limit, it must be replaced.
  • Page 440: Rear Shock Absorber

    13-14 SUSPENSION Rear Shock Absorber Spring Preload Adjustment • Remove the bolts [A] and chain cover [B]. • Using the wrench [A] from the tool kit, turn the adjusting nut to adjust the spring preload. ○ The standard adjuster setting is 2nd position. Spring Preload Setting Standard Position: 2nd position...
  • Page 441: Rear Shock Absorber Installation

    SUSPENSION 13-15 Rear Shock Absorber • Remove the cap [A] (both sides). • Remove: Tie-Rod Lower Nut [A] and Bolt Rear Shock Absorber Nuts [B] and Bolts • Remove the shock absorber [C] from downside. Rear Shock Absorber Installation • Install the rear shock absorber [A].
  • Page 442: Rear Shock Absorber Scrapping

    13-16 SUSPENSION Rear Shock Absorber Rear Shock Absorber Scrapping WARNING Since the rear shock absorber contains nitrogen gas, do not incinerate the rear shock absorber with- out first releasing the gas or it may explode. Before a rear shock absorber is scrapped, drill a hole at the point [A] shown to release the nitrogen gas completely.
  • Page 443: Swingarm

    SUSPENSION 13-17 Swingarm Swingarm Removal • Remove: Lower Fairings (see Lower Fairing Removal in the Frame chapter) Rear Wheel (see Rear Wheel Removal in the Wheels/Tires chapter) Chain Cover [A] (see Spring Preload Adjustment) • Remove the brake hose [A] from the clamp [B] and guides [C].
  • Page 444: Swingarm Bearing Removal

    13-18 SUSPENSION Swingarm • Replace: Rear Shock Absorber Lower Nut [A] Tie-Rod Upper Nut [B] O-rings • Apply grease to the O-ring. • Tighten: Torque - Swingarm Pivot Shaft Nut [C]: 98 N·m (10.0 kgf·m, 72 ft·lb) Rear Shock Absorber Lower Nut: 59 N·m (6.0 kgf·m, 44 ft·lb) Tie-Rod Upper Nut: 59 N·m (6.0 kgf·m, 44 ft·lb) •...
  • Page 445: Swingarm Bearing, Sleeve Inspection

    SUSPENSION 13-19 Swingarm Swingarm Bearing, Sleeve Inspection NOTICE Do not remove the bearings for inspection. Re- moval may damage them. • Inspect the needle bearings [A] installed in the swingarm. ○ The rollers in a needle bearing normally wear very little, and wear is difficult to measure.
  • Page 446: Tie-rod, Rocker Arm

    13-20 SUSPENSION Tie-Rod, Rocker Arm Tie-Rod Removal • Squeeze the brake lever slowly and hold it with a band [A]. • Remove: Muffler Cover (see Muffler Body Removal in the Engine Top End chapter) Lower Fairings (see Lower Fairing Removal in the Frame chapter) •...
  • Page 447: Rocker Arm Installation

    SUSPENSION 13-21 Tie-Rod, Rocker Arm • Remove: Rear Shock Absorber Lower Nut [A] and Bolt Tie-Rod Lower Nut [B] and Bolt Rocker Arm Nut [C] and Bolt Rocker Arm [D] Rocker Arm Installation • Replace: Rocker Arm Nut Tie-Rod Lower Nut Rear Shock Absorber Lower Nut O-rings •...
  • Page 449 STEERING 14-1 Steering Table of Contents Exploded View........................14-2 Special Tools .......................... 14-4 Steering ..........................14-5 Steering Inspection ......................14-5 Steering Adjustment......................14-5 Steering Stem......................... 14-6 Stem, Stem Bearing Removal................... 14-6 Stem, Stem Bearing Installation..................14-7 Steering Stem Bearing Lubrication ................... 14-8 Steering Stem Warp Inspection ..................
  • Page 450: Exploded View

    14-2 STEERING Exploded View...
  • Page 451 STEERING 14-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Switch Housing Screws 0.36 31 in·lb Handlebar Mounting Bolts Steering Stem Head Bolt Front Fork Upper Clamp Bolts Steering Stem Nut Front Fork Lower Clamp Bolts AD: Apply adhesive. G: Apply grease. L: Apply a non-permanent locking agent.
  • Page 452: Special Tools

    14-4 STEERING Special Tools Steering Stem Bearing Driver: Head Pipe Outer Race Press Shaft: 57001-137 57001-1075 Bearing Puller: Head Pipe Outer Race Driver, 51.5: 57001-158 57001-1076 Bearing Puller Adapter: Steering Stem Nut Wrench: 57001-317 57001-1100 Oil Seal & Bearing Remover: Head Pipe Outer Race Driver, 47: 57001-1058 57001-1447...
  • Page 453: Steering Inspection

    STEERING 14-5 Steering Steering Inspection • Refer to the Steering Play Inspection in the Periodic Main- tenance chapter. Steering Adjustment • Refer to the Steering Play Adjustment in the Periodic Maintenance chapter.
  • Page 454: Steering Stem

    14-6 STEERING Steering Stem Stem, Stem Bearing Removal • Remove: Lower Fairings (see Lower Fairing Removal in the Frame chapter) Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Front Wheel (see Front Wheel Removal in the Wheels/Tires chapter) •...
  • Page 455: Stem, Stem Bearing Installation

    STEERING 14-7 Steering Stem Stem, Stem Bearing Installation • Replace the bearing outer races with new ones. • Drive them into the head pipe at the same time. Special Tools - Head Pipe Outer Race Press Shaft [A]: 57001-1075 Head Pipe Outer Race Driver, 51.5 [B]: 57001-1076 Head Pipe Outer Race Driver, 47 [C]: 57001...
  • Page 456: Steering Stem Bearing Lubrication

    14-8 STEERING Steering Stem • Settle the bearings in place as follows. ○ Tighten the steering stem nut with 35 N·m (3.6 kgf·m, 26 ft·lb) of torque first (Pull the steering stem nut wrench [A] at the hole by 194 N (19.8 kgf) force [B] in the direc- tion shown), and loosen it a fraction of a turn until it turns lightly.
  • Page 457: Steering Stem Warp Inspection

    STEERING 14-9 Steering Stem Steering Stem Warp Inspection • Whenever the steering stem is removed, or if the steering can not be adjusted for smooth action, check the steering stem for straightness [A]. If the steering stem is bent, replace it with a new one. Oil Seal Deterioration, Damage Inspection •...
  • Page 458: Handlebar

    14-10 STEERING Handlebar Handlebar Removal • Remove: Left Switch Housing [A] Handlebar Weight [B] Left Handlebar Grip [C] Clutch Lever Clamp Bolt [D] Clutch Lever Assembly [E] Caps [F] and Bolts Left Handlebar [G] • Remove: Front Master Cylinder [A] (see Front Master Cylinder Re- moval in the Brakes chapter) Right Switch Housing [B] Handlebar Weight [C]...
  • Page 459 FRAME 15-1 Frame Table of Contents Exploded View........................15-2 Seats ............................15-8 Rear Seat Removal......................15-8 Rear Seat Installation......................15-8 Front Seat Removal ......................15-8 Front Seat Installation ....................... 15-8 Fairings........................... 15-9 Lower Fairing Removal ..................... 15-9 Lower Fairing Installation ....................15-9 Inner Fairing Removal.......................
  • Page 460: Exploded View

    15-2 FRAME Exploded View...
  • Page 461 FRAME 15-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Footpeg Bracket Bolts Rear Footpeg Bracket Bolts Sidestand Switch Bolt 0.90 78 in·lb Sidestand Nut G: Apply grease. L: Apply a non-permanent locking agent. R: Replacement Parts...
  • Page 462 15-4 FRAME Exploded View...
  • Page 463 FRAME 15-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Left Middle Fairing Bracket Bolts 87 in·lb 2. US, CAL, CA, AU and CO Models 3. CAL Model HL: Apply a non-permanent locking agent (High Strength).
  • Page 464 15-6 FRAME Exploded View...
  • Page 465 FRAME 15-7 Exploded View 1. US, CAL, CA, AU and CO Models...
  • Page 466: Seats

    15-8 FRAME Seats Rear Seat Removal • Insert the ignition key [A] into the seat lock, turning the key clockwise, pull up the front of seat [B], and remove the rear seat by pushing it to the front. Rear Seat Installation •...
  • Page 467: Fairings

    FRAME 15-9 Fairings Lower Fairing Removal • Remove: Quick Rivets [A] Bolts and Nylon Washers [B] Bolt and Nylon Washer [C] Lower Fairing [D] Lower Fairing Installation • Installation is the reverse of removal. • Insert the tabs [A] on the lower fairing [B] into the slots [C] on the side fairing.
  • Page 468: Tank Side Cover Installation

    15-10 FRAME Fairings Tank Side Cover Installation • Installation is the reverse of removal. • Insert the projections [A] on the tank side cover [B] into the grommets [C] on the middle fairing and fuel tank. Middle Fairing Removal • Remove: Lower Fairing (see Lower Fairing Removal) Inner Fairing (see Inner Fairing Removal)
  • Page 469: Windshield Removal/installation

    FRAME 15-11 Fairings • Tighten the bolts in the following order. 6 mm Bolt [A] and Collar 6 mm Bolt [B] and Washer 5 mm Bolt [C] and Washer 5 mm Bolt [D] Windshield Removal/Installation • Remove: Bolts [A] Rear View Mirrors [B] Windshield [C] •...
  • Page 470: Instrument Cover Removal

    15-12 FRAME Fairings Instrument Cover Removal • Remove the upper fairing (see Upper Fairing Removal). • Slide the connector cover [A] and disconnect the meter connector [B] from the meter unit. • Remove the instrument cover [C] forward. • Remove the meter unit (see Meter Unit Removal/Installa- tion in the Electrical System chapter).
  • Page 471: Side Cover

    FRAME 15-13 Side Cover Side Cover Removal • Remove the bolt and collar [A]. • Pull the side cover [B] outward straight to detach the pro- jections [C] from the grommets. NOTE ○ Be careful not to tilt the side cover when pulling it out to prevent the projections from the breaking.
  • Page 472: Seat Covers

    15-14 FRAME Seat Covers Seat Cover Removal • Remove: Side Covers (see Side Cover Removal) Seats (see Rear/Front Seat Removal) Bolts [A] Bolts [B] • Remove the quick rivets [A]. • Pull the seat covers [B] outward. • Remove the center cover [C]. Seat Cover Installation •...
  • Page 473: Fenders

    FRAME 15-15 Fenders Front Fender Removal • Remove: Bolts [A] with Collars (Both Sides) Front Fender [B] ○ For US, CAL, CA, AU and CO models, remove the reflec- tor before removing the bolts. Front Fender Installation • Installation is the reverse of removal. Flap and Rear Fender Removal •...
  • Page 474: Flap And Rear Fender Installation

    15-16 FRAME Fenders • Remove: Rear Footpeg Bracket Bolts [A] (Both Sides) Screw and Air Cleaner Housing Cap [B] Rear Fender Mounting Bolts [C] Clamp [D] (Right Side only) • Remove: Screw [A] Cover [B] Clamp [C] Rear Fender Mounting Bolts [D] •...
  • Page 475: Frame

    FRAME 15-17 Frame Frame Inspection • Visually inspect the frame for cracks, dents, bending, or warp. If there is any damage to the frame, replace it. WARNING A repaired frame may fail in use, possibly causing an accident resulting in injury or death. If the frame is bent, dented, cracked, or warped, replace it.
  • Page 476: Sidestand

    15-18 FRAME Sidestand Sidestand Removal • Raise the rear wheel off the ground with the stand. • Remove the lower fairing (see Lower Fairing Removal). • Remove: Sidestand Switch Bolt [A] Sidestand Switch [B] Spring [C] Sidestand Nut and Bolt [D] Sidestand [E] Sidestand Installation •...
  • Page 477 ELECTRICAL SYSTEM 16-1 Electrical System Table of Contents Exploded View........................16-4 Specifications ......................... 16-10 Special Tools and Sealant ...................... 16-11 Parts Location......................... 16-12 Wiring Diagram (EX300A without GPS Unit)................16-14 Wiring Diagram (EX300A with GPS Unit)................16-16 Wiring Diagram (EX300B without GPS Unit)................16-18 Wiring Diagram (EX300B with GPS Unit)................
  • Page 478 16-2 ELECTRICAL SYSTEM Armature Inspection......................16-50 Brush Lead Inspection ...................... 16-50 End Cover Inspection......................16-50 Starter Relay Inspection....................16-50 Lighting System ........................16-53 Headlight Beam Horizontal Adjustment ................16-53 Headlight Beam Vertical Adjustment................. 16-53 Headlight Bulb Replacement .................... 16-53 Headlight Removal/Installation ..................16-54 City Light Bulb Replacement.....................
  • Page 479 ELECTRICAL SYSTEM 16-3 This page intentionally left blank.
  • Page 480: Exploded View

    16-4 ELECTRICAL SYSTEM Exploded View...
  • Page 481 ELECTRICAL SYSTEM 16-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Brake Light Switch Screw 0.12 11 in·lb Switch Housing Screws 0.36 31 in·lb...
  • Page 482 16-6 ELECTRICAL SYSTEM Exploded View...
  • Page 483 ELECTRICAL SYSTEM 16-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Spark Plugs 115 in·lb Crankshaft Sensor Screws 0.53 46 in·lb Alternator Rotor Bolt 107.8 10.99 79.51 Stator Coil Bolts 106 in·lb Regulator/rectifier Mounting Bolts 87 in·lb Hand Alternator Cover Plug –...
  • Page 484 16-8 ELECTRICAL SYSTEM Exploded View...
  • Page 485 ELECTRICAL SYSTEM 16-9 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Fuel Pump Bolts 87 in·lb Water Temperature Sensor 106 in·lb Intake Air Temperature Sensor Screw 0.12 11 in·lb Oil Pressure Switch Terminal Bolt 0.15 13 in·lb Oil Pressure Switch Oxygen Sensor 44.1 4.50...
  • Page 486: Specifications

    16-10 ELECTRICAL SYSTEM Specifications Item Standard Battery Type Sealed Battery Model Name FTX9-BS Capacity 12 V 8 Ah Voltage 12.6 V or more Gross Weight 3.0 kg (6.6 lb) Electrolyte Volume 0.41 L (25 cu in.) Charging System Type Three-phase AC Alternator Output Voltage 35 V or more at 4 000 r/min (rpm) 0.05 ∼...
  • Page 487: Special Tools And Sealant

    ELECTRICAL SYSTEM 16-11 Special Tools and Sealant Flywheel Holder: Peak Voltage Adapter: 57001-1313 57001-1415 Hand Tester: Lead Wire - Peak Voltage Adapter: 57001-1394 57001-1449 Flywheel Puller Assembly, M38 × 1.5/M35 × 1.5: Liquid Gasket, TB1211F: 57001-1405 92104-0004...
  • Page 488: Parts Location

    16-12 ELECTRICAL SYSTEM Parts Location...
  • Page 489 ELECTRICAL SYSTEM 16-13 Parts Location 1. Meter Unit 2. Ignition Switch 3. Starter Lockout Switch 4. Air Switching Valve 5. Stick Coils 6. Spark Plugs 7. Neutral Switch 8. Starter Relay 9. Relay Box 10. Fuse Box 11. Turn Signal Relay 12.
  • Page 490: Wiring Diagram (ex300a Without Gps Unit)

    16-14 ELECTRICAL SYSTEM Wiring Diagram (EX300A without GPS Unit)
  • Page 491 ELECTRICAL SYSTEM 16-15 Wiring Diagram (EX300A without GPS Unit)
  • Page 492: Wiring Diagram (ex300a With Gps Unit)

    16-16 ELECTRICAL SYSTEM Wiring Diagram (EX300A with GPS Unit)
  • Page 493 ELECTRICAL SYSTEM 16-17 Wiring Diagram (EX300A with GPS Unit)
  • Page 494: Wiring Diagram (ex300b Without Gps Unit)

    16-18 ELECTRICAL SYSTEM Wiring Diagram (EX300B without GPS Unit)
  • Page 495 ELECTRICAL SYSTEM 16-19 Wiring Diagram (EX300B without GPS Unit)
  • Page 496: Wiring Diagram (ex300b With Gps Unit)

    16-20 ELECTRICAL SYSTEM Wiring Diagram (EX300B with GPS Unit)
  • Page 497 ELECTRICAL SYSTEM 16-21 Wiring Diagram (EX300B with GPS Unit)
  • Page 498: Precautions

    16-22 ELECTRICAL SYSTEM Precautions There are a number of important precautions that are musts when servicing electrical systems. Learn and ob- serve all the rules below. ○ Do not reverse the battery cable connections. This will burn out the diodes on the electrical parts. ○...
  • Page 499: Electrical Wiring

    ELECTRICAL SYSTEM 16-23 Electrical Wiring Main Harness Inspection • Visually inspect the main harness for signs of burning, fraying, etc. If any main harness is poor, replace the damaged main harness. • Pull each connector [A] apart and inspect it for corrosion, dirt, and damage.
  • Page 500: Battery

    16-24 ELECTRICAL SYSTEM Battery Battery Removal • Turn the ignition switch off. • Remove: Front Seat (see Front Seat Removal in the Frame chap- ter) Relay Box (see Relay Box Removal) Screw [A] and Battery Cover [B] • Disconnect the negative (–) cable [A]. NOTICE Be sure to disconnect the negative (–) cable first.
  • Page 501: Battery Activation

    ELECTRICAL SYSTEM 16-25 Battery Battery Activation Electrolyte Filling • Make sure that the model name [A] of the electrolyte con- tainer matches the model name [B] of the battery. These names must be the same. Battery Model Name EX300A/B: FTX9-BS NOTICE Each battery comes with its own specific elec- trolyte container;...
  • Page 502 16-26 ELECTRICAL SYSTEM Battery • Place the electrolyte container upside down with the six sealed cells into the filler ports of the battery. Hold the container level, push down to break the seals of all six cells. You will see air bubbles rising into each cell as the ports fill.
  • Page 503: Precautions

    Newly activated sealed batteries require an initial charge. Standard Charge: 0.9 A × 5 ∼ 10 hours If using a recommended battery charger, follow the charger’s instructions for newly activated sealed battery. Kawasaki-recommended chargers: Battery Mate 150-9 OptiMate PRO 4-S/PRO S/PRO2 Yuasa MB-2040/2060...
  • Page 504: Interchange

    16-28 ELECTRICAL SYSTEM Battery DANGER Batteries produce an explosive gas mixture of hydrogen and oxygen that can cause seri- ous injury and burns if ignited. Keep the battery away from sparks and open flames during charging. When using a battery charger, connect the battery to the charger before turning on the charger.
  • Page 505 ELECTRICAL SYSTEM 16-29 Battery Terminal Voltage: 11.5 ∼ less than 12.6 V Standard Charge 0.9 A × 5 ∼ 10 h (see following chart) Quick Charge 4 A × 1 h NOTICE If possible, do not quick charge. If quick charge is done unavoidably, do standard charge later on.
  • Page 506: Charging System

    16-30 ELECTRICAL SYSTEM Charging System Alternator Cover Removal • Remove: Left Middle Fairing (see Middle Fairing Removal in the Frame chapter) Engine Oil (Drain, see Engine Oil Change in the Periodic Maintenance chapter) Engine Sprocket Cover (see Engine Sprocket Removal in the Final Drive chapter) Coolant (Drain, see Coolant Change in the Periodic Maintenance chapter)
  • Page 507: Stator Coil Removal

    ELECTRICAL SYSTEM 16-31 Charging System • Install the dowel pins [A] and new gasket [B] are in place on the crankcase. • Install the alternator cover [A] and clamp [B]. • Tighten the alternator cover bolts following the specified sequence [1 ∼ 11]. Torque - Alternator Cover Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) •...
  • Page 508: Alternator Rotor Removal

    16-32 ELECTRICAL SYSTEM Charging System Alternator Rotor Removal • Remove: Alternator Cover (see Alternator Cover Removal) Shaft [A] Starter Idle Gear [B] • Hold the alternator rotor steady with the flywheel holder [A]. • Remove the rotor bolt [B] and washer [C]. Special Tool - Flywheel Holder: 57001-1313 NOTICE Do not hold the projections [D].
  • Page 509 ELECTRICAL SYSTEM 16-33 Charging System • Align the woodruff key [A] on the crankshaft with groove [B] on the alternator rotor [C]. • Push the alternator rotor while turning the starter clutch gear [D] clockwise until it engaged into the starter clutch case.
  • Page 510: Charging Voltage Inspection

    16-34 ELECTRICAL SYSTEM Charging System Charging Voltage Inspection NOTE ○ If the Red Battery Voltage Warning Indicator Light (LED) goes on, it indicates the battery voltage is out of the standard range of 11-16 V, therefore it is necessary to inspect the charging system as described below.
  • Page 511 ELECTRICAL SYSTEM 16-35 Charging System • To check the alternator output voltage, do the following procedures. ○ Turn off the ignition switch. ○ Remove the left middle fairing (see Middle Fairing Re- moval in the Frame chapter). ○ Disconnect the alternator lead connector [A]. ○...
  • Page 512: Regulator/rectifier Inspection

    NOTICE Use only Kawasaki Hand Tester 57001-1394 for this test. A tester other than the Kawasaki Hand Tester may show different readings. If a megger or a me- ter with a large capacity battery is used, the regula- tor/rectifier will be damaged.
  • Page 513 ELECTRICAL SYSTEM 16-37 Charging System Charging System Circuit 1. Alternator 2. Engine Ground 3. Battery 12 V 8 Ah 4. Frame Ground 5. Main Fuse 30 A 6. Regulator/Rectifier 7. Ignition Switch 8. Load...
  • Page 514: Ignition System

    16-38 ELECTRICAL SYSTEM Ignition System WARNING The ignition system produces extremely high volt- age. Do not touch the spark plug, stick coil or stick coil lead while the engine is running, or you could receive a severe electrical shock. NOTICE Do not disconnect the battery cables or any other electrical connections when the ignition switch is on, or while the engine is running.
  • Page 515: Crankshaft Sensor Peak Voltage Inspection

    ELECTRICAL SYSTEM 16-39 Ignition System Crankshaft Sensor Peak Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Remove: Left Middle Fairing (see Middle Fairing Removal in the Frame chapter) • Disconnect the crankshaft sensor lead connector [A]. •...
  • Page 516: Stick Coil Installation

    16-40 ELECTRICAL SYSTEM Ignition System Stick Coil Installation • Insert the coil as shown being careful of the coil heads [A] direction. • Be sure the stick coils are installed by pulling up it lightly. • Connect the connectors. NOTICE Do not tap the coil head while installing the coil.
  • Page 517: Spark Plug Removal

    ELECTRICAL SYSTEM 16-41 Ignition System Special Tools - Hand Tester: 57001-1394 Peak Voltage Adapter: 57001-1415 Type: KEK-54-9-B Lead Wire - Peak Voltage Adapter: 57001 -1449 Primary Lead Connection Adapter (R, +) to lead wire-peak voltage adapter (R) Adapter (BK, –) to lead wire-peak voltage adapter (W) WARNING To avoid extremely high voltage shocks, do not touch the spark plugs or tester connections.
  • Page 518: Interlock Operation Inspection

    16-42 ELECTRICAL SYSTEM Ignition System Interlock Operation Inspection • Raise the rear wheel off the ground using the stand (see Rear Wheel Removal in the Wheels/Tires chapter). • Turn the engine stop switch on (run position). 1st Check • Start the engine to the following conditions. Condition: Transmission Gear →...
  • Page 519: Ic Igniter Inspection

    ELECTRICAL SYSTEM 16-43 Ignition System IC Igniter Inspection ○ The IC igniter is built in the ECU [A]. • Refer to the following items. Interlock Operation Inspection (see Interlock Operation Inspection) Ignition System Troubleshooting (see Ignition System section) ECU Power Supply Inspection (see ECU Power Supply Inspection in the Fuel System (DFI) chapter)
  • Page 520 16-44 ELECTRICAL SYSTEM Ignition System...
  • Page 521 ELECTRICAL SYSTEM 16-45 Ignition System Ignition System Circuit 1. ECU 15. Water-proof Joint 7 2. Water-proof Joint 1 16. Ignition Switch 3. Sidestand Switch 17. Engine Stop Switch 4. Frame Ground 18. Spark Plugs 5. Engine Ground 19. Water-proof Joint 5 6.
  • Page 522: Electric Starter System

    16-46 ELECTRICAL SYSTEM Electric Starter System Starter Motor Removal NOTICE Do not tap the starter motor shaft or body. Tapping the shaft or body could damage the motor. • Remove the clutch cable and clutch cable bracket. • Remove the starter motor mounting bolts [A]. •...
  • Page 523: Starter Motor Disassembly

    ELECTRICAL SYSTEM 16-47 Electric Starter System Starter Motor Disassembly • Remove the starter motor (see Starter Motor Removal). • Remove the starter motor through bolts [A]. • Remove the both end covers [A]. • Remove the armature [B] from the yoke [C]. •...
  • Page 524: Starter Motor Assembly

    16-48 ELECTRICAL SYSTEM Electric Starter System Starter Motor Assembly • Install: Brush Holder [A] Negative Brush [B] Brush Holder Screw [C] Positive brush [D] Terminal [E] Brush Springs [F] NOTE ○ Make sure the brush base plates are properly fitted into the grooves on the brush holder.
  • Page 525: Brush Inspection

    ELECTRICAL SYSTEM 16-49 Electric Starter System • Install the yoke [A] over the armature so that the cut-out [B] on the yoke faces commutator side [C]. • Make sure the brush springs and brushes [D] are installed in place. • Align the tab [E] with the cut-out on the yoke to install the right end cover to the yoke.
  • Page 526: Armature Inspection

    16-50 ELECTRICAL SYSTEM Electric Starter System Armature Inspection • Using the × 1 Ω hand tester range, measure the resis- tance between any two commutator segments [A]. Special Tool - Hand Tester: 57001-1394 If there is a high resistance or no reading (∞) between any two segments, a winding is open and the starter motor must be replaced.
  • Page 527 ELECTRICAL SYSTEM 16-51 Electric Starter System • Remove: Cable Terminal Bolts [A] Starter Relay [B] • Connect the hand tester [A] and 12 V battery [B] to the starter relay [C] as shown. Special Tool - Hand Tester: 57001-1394 If the relay does not work as specified, the relay is defec- tive.
  • Page 528 16-52 ELECTRICAL SYSTEM Electric Starter System Electric Starter Circuit 1. Ignition Switch 2. Engine Stop Switch 3. Starter Button 4. Neutral Switch 5. Water-proof Joint 5 6. Water-proof Joint 7 7. Water-proof Joint 1 8. Frame Ground 9. Sidestand Switch 10.
  • Page 529: Lighting System

    ELECTRICAL SYSTEM 16-53 Lighting System This motorcycle adopt the daylight system and have a headlight relay in the relay box. The headlight does not go on when the ignition switch and the engine stop switch are first turned on. The headlight comes on after the starter button is released and stays on until the ignition switch is turned off.
  • Page 530: Headlight Removal/installation

    16-54 ELECTRICAL SYSTEM Lighting System • Install the hook [A] and connect the connector [B] to the headlight bulb. • Fit the dust cover [A] onto the headlight housing with its lead toward downward. • After installation, adjust the headlight aim (see Headlight Aiming Inspection in the Periodic Maintenance chapter).
  • Page 531: Tail/brake Light Bulb Replacement

    ELECTRICAL SYSTEM 16-55 Lighting System Tail/Brake Light Bulb Replacement • Remove the rear seat (see Rear Seat Removal in the Frame chapter). • Turn the socket [A] counterclockwise to remove it. • Push the bulb [A] in the socket, turn it counterclockwise and pull it out.
  • Page 532: License Plate Light Bulb Replacement

    16-56 ELECTRICAL SYSTEM Lighting System License Plate Light Bulb Replacement • Remove: Screws [A] License Plate Light Cover [B] • Pull the bulb [A] out of the socket [B]. NOTICE Do not turn the bulb. Pull the bulb out to prevent damage to the bulb.
  • Page 533: Turn Signal Light Bulb Replacement

    ELECTRICAL SYSTEM 16-57 Lighting System Headlight/Tail Light Circuit 1. Ignition Switch 8. Starter Relay 17. Dimmer Switch 2. Alternator 9. Main Fuse 30 A 18. Left City Light 12 V 5 W 3. License Plate Light 12 10. Fuse Box 1 19.
  • Page 534: Turn Signal Relay Inspection

    16-58 ELECTRICAL SYSTEM Lighting System • Push and turn the bulb [A] counterclockwise and remove • Insert the new bulb [A] by aligning its pins [B] with the grooves [C] in the socket, and turn the bulb clockwise. ○ Turn the bulb about 15°. •...
  • Page 535 ELECTRICAL SYSTEM 16-59 Lighting System • Connect one 12 V battery and turn signal lights as indi- cated in the figure, and count how may times the lights flash for one minute. Turn Signal Relay [A] Turn Signal Lights [B] 12 V Battery [C] If the lights do not flash as specified, replace the turn sig- nal relay.
  • Page 536 16-60 ELECTRICAL SYSTEM Lighting System Turn Signal Light Circuit 1. Ignition Switch 2. Water-proof Joint 1 3. Rear Right Turn Signal Light 12 V 10 W 4. Rear Left Turn Signal Light 12 V 10 W 5. Frame Ground 6. Engine Ground 7.
  • Page 537: Air Switching Valve

    ELECTRICAL SYSTEM 16-61 Air Switching Valve Air Switching Valve Operation Test • Refer to the Air Suction System Damage Inspection in the Periodic Maintenance chapter. Air Switching Valve Unit Test • Remove the air switching valve (see Air Switching Valve Removal in the Engine Top End chapter).
  • Page 538 16-62 ELECTRICAL SYSTEM Air Switching Valve Air Switching Valve Circuit 1. ECU 2. Water-proof Joint 1 3. Water-proof Joint 2 4. Frame Ground 5. Engine Ground 6. Battery 12 V 8 Ah 7. Main Fuse 30 A 8. Starter Relay 9.
  • Page 539: Radiator Fan System

    ELECTRICAL SYSTEM 16-63 Radiator Fan System Fan Motor Inspection • Remove the fuel tank (see Fuel Tank Removal in the Fuel System (DFI) chapter). • Disconnect the connector [A]. • Using an auxiliary leads, supply battery power to the fan motor.
  • Page 540 16-64 ELECTRICAL SYSTEM Radiator Fan System Radiator Fan Circuit 1. ECU 2. Joint Connector 2 3. Frame Ground 4. Engine Ground 5. Battery 12 V 8 Ah 6. Main Fuse 30 A 7. Starter Relay 8. Fuse Box 1 9. Fan Fuse 10 A 10.
  • Page 541: Meter, Gauge, Indicator Unit

    ELECTRICAL SYSTEM 16-65 Meter, Gauge, Indicator Unit Meter Unit Removal/Installation • Remove: Instrument Cover (see Instrument Cover Removal in the Frame chapter) Screws [A] Clamps [B] NOTICE Place the meter unit so that the face is up. If a meter unit is left upside down or sideways for any length of time, it will malfunction.
  • Page 542 16-66 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit Liquid Crystal Display (LCD) Segment Check • Using the auxiliary leads, connect the 12 V battery to the meter unit connector as follows. Battery Positive (+) Terminal to Terminal [6] and [16] Battery Negative (–) Terminal to Terminal [15] ○...
  • Page 543 ELECTRICAL SYSTEM 16-67 Meter, Gauge, Indicator Unit Left and Right Button Operation Check • Connect the 12 V battery and terminals in the same man- ner as specified in the “Liquid Crystal Display (LCD) Seg- ments Check”. • Check that the multifunction meter displays shift as shown when the left button [A] is pressed.
  • Page 544 16-68 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit • In the MINUTE setting mode, press the right button to return the HOUR/MINUTE setting mode. • Press the left button to complete the clock setting process. ○ The clock starts counting the seconds as soon as the left button is pressed.
  • Page 545 ELECTRICAL SYSTEM 16-69 Meter, Gauge, Indicator Unit Odometer Check • Check the odometer with the speedometer in the same way. If the value indicated in the odometer is not added, re- place the meter assembly. NOTE ○ The integrated value of the odometer cannot be reset. ○...
  • Page 546 16-70 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit Fuel Level Sensor Line Self-Diagnosis Mode Inspection NOTE ○ Usually when the open or short of the fuel level sensor circuit is detected, it becomes the Fuel Level Sensor Line Self-Diagnosis Mode. ○ The all segments of the fuel gauge [A] and fuel warning symbol [B] in the display will blink.
  • Page 547 ELECTRICAL SYSTEM 16-71 Meter, Gauge, Indicator Unit • Check that one segment [A] in the fuel gauge starts blink- ing. • Check that the fuel warning symbol [B] blinks. If the multifunction meter display function does not work, replace the meter assembly. Indicator Lights Inspection •...
  • Page 548 16-72 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit Green Left and Right Turn Signal Indicator Light (LED) For Green Left Turn Signal Indicator Light (LED) Battery Positive (+) Terminal to Terminal [1] For Green Right Turn Signal Indicator Light (LED) Battery Positive (+) Terminal to Terminal [2] Green Neutral Indicator Light (LED) Battery Negative (–) Terminal to Terminal [3] Blue High Beam Indicator Light (LED)
  • Page 549 ELECTRICAL SYSTEM 16-73 Meter, Gauge, Indicator Unit Meter Circuit 1. Ignition Switch 12. Engine Ground 2. Speed Sensor 13. Battery 12 V 8 Ah 3. Water-proof Joint 4 14. Main Fuse 30 A 4. Water-proof Joint 3 15. Starter Relay 5.
  • Page 550: Switches And Sensors

    16-74 ELECTRICAL SYSTEM Switches and Sensors Brake Light Timing Inspection • Refer to the Brake Light Switch Operation Inspection in the Periodic Maintenance chapter. Brake Light Timing Adjustment • Refer to the Brake Light Switch Operation Inspection in the Periodic Maintenance chapter. Switch Inspection •...
  • Page 551: Water Temperature Sensor Inspection

    ELECTRICAL SYSTEM 16-75 Switches and Sensors Water Temperature Sensor Inspection • Remove the water temperature sensor (see Water Tem- perature Sensor Removal/Installation in the Fuel System (DFI) chapter). • Suspend the sensor [A] in a container of coolant so that the temperature-sensing projection [C] is submerged.
  • Page 552: Speed Sensor Installation

    16-76 ELECTRICAL SYSTEM Switches and Sensors Speed Sensor Installation • Installation is the reverse of removal. • Run the lead correctly (see Cable, Wire, and Hose Rout- ing section in the Appendix chapter). • Apply a non-permanent locking agent to the threads of the speed sensor bolt, and tighten it.
  • Page 553: Oxygen Sensor Installation (equipped Model)

    ELECTRICAL SYSTEM 16-77 Switches and Sensors Oxygen Sensor Installation (Equipped Model) NOTICE Never drop the oxygen sensor [A] especially on a hard surface. Such a shock to the unit can damage it. Do not touch the sensing part [B] and filter holes [C] of the sensor to prevent oil contact.
  • Page 554: Relay Box

    16-78 ELECTRICAL SYSTEM Relay Box NOTE ○ The relay box [A] has relays and diodes. The relays and diodes can not be removed. Relay Box Removal NOTICE Never drop the relay box especially on a hard sur- face. Such a shock to the relay box can damage it. •...
  • Page 555: Diode Circuit Inspection

    ELECTRICAL SYSTEM 16-79 Relay Box Relay Circuit Inspection (with the battery connected) Battery Tester Tester Connection Connection Reading (Ω) (–) Headlight Circuit 2-11 Relay ECU Main Relay Fuel Pump Relay 9-10 Fan Relay 18-19 17-20 Battery Tester Connection Tester Connection DC 25 V Range Reading (V) (–)
  • Page 556 16-80 ELECTRICAL SYSTEM Relay Box Relay Box Internal Circuit A: Headlight Circuit Relay B: ECU Main Relay C: Fuel Pump Relay D: Starter Circuit Relay E: Fan Relay...
  • Page 557: Fuse

    ELECTRICAL SYSTEM 16-81 Fuse 30 A Main Fuse Removal • Remove: Front Seat (see Front Seat Removal in the Frame chap- ter) 30 A Main Fuse Cover [A] • Pull out the main fuse [A] from the starter relay with a needle nose pliers.
  • Page 558: Fuse Inspection

    16-82 ELECTRICAL SYSTEM Fuse Fuse Inspection • Remove the fuse (see 30 A Main/Fuse Box/Sub Fuse Re- moval). • Inspect the fuse element. If it is blown out, replace the fuse. Before replacing a blown fuse, always check the amperage in the affected circuit.
  • Page 559 APPENDIX 17-1 Appendix Table of Contents Cable, Wire, and Hose Routing ....................17-2 Troubleshooting Guide ......................17-54...
  • Page 560 17-2 APPENDIX Cable, Wire, and Hose Routing Left Side Main Harness...
  • Page 561 27. Wheel Rotation Sensor Lead Connector (ABS Equipped Model) 28. Fuse Box 29. License Plate Light Lead Connector 30. Tail/Brake Light Lead Connector 31. Kawasaki Diagnostic System Connector 32. Sidestand Switch Lead Connector 33. Neutral Switch Lead Connector 34. Clamp...
  • Page 562 17-4 APPENDIX Cable, Wire, and Hose Routing Right Side Main Harness...
  • Page 563 9. Turn Signal Light Relay Lead Connector 10. Rear Brake Light Switch Lead Connector 11. Battery Negative Lead Connector 12. ABS Kawasaki Diagnostic System Connector 13. Subthrottle Sensor Lead Connector 14. Main Throttle Sensor Lead Connector 15. Oil Pressure Switch Lead Connector 16.
  • Page 564 17-6 APPENDIX Cable, Wire, and Hose Routing...
  • Page 565 APPENDIX 17-7 Cable, Wire, and Hose Routing 1. Right Switch Housing Lead 2. Clamp (Hold the right switch housing lead.) 3. Clamp (Hold the left switch housing lead.) 4. Starter Lockout Switch 5. Left Switch Housing Lead 6. Throttle Cable 7.
  • Page 566 17-8 APPENDIX Cable, Wire, and Hose Routing...
  • Page 567 APPENDIX 17-9 Cable, Wire, and Hose Routing 1. Run the brake hose to front of the right switch housing lead. 2. Front Brake Hose 3. Run the front brake hose to front of the throttle cables. 4. Front Brake Hose 5.
  • Page 568 17-10 APPENDIX Cable, Wire, and Hose Routing...
  • Page 569 APPENDIX 17-11 Cable, Wire, and Hose Routing 1. Throttle Cable (Decelerator) 2. Throttle Cable (Accelerator) 3. Guide (Run the throttle cables, right switch housing and ignition switch leads through into the guide.) 4. Clutch Cable 5. Guide (Run the clutch cable and left switch housing lead through into the guide.) 6.
  • Page 570 17-12 APPENDIX Cable, Wire, and Hose Routing...
  • Page 571 APPENDIX 17-13 Cable, Wire, and Hose Routing 1. Guide (Run the horn lead through into the guide.) 2. Horn Lead 3. Guide (Run the throttle cables through into the guide.) 4. Throttle Cable (Decelerator) 5. Throttle Cable (Accelerator) 6. Regulator/Rectifier 7.
  • Page 572 17-14 APPENDIX Cable, Wire, and Hose Routing...
  • Page 573 APPENDIX 17-15 Cable, Wire, and Hose Routing 1. Vehicle-down Sensor Lead 2. Clamp (Hold the right switch housing lead and fix the clamp into the frame.) 3. Ignition Switch Lead 4. Clamp (Hold the ignition switch lead and front right turn signal light lead and fix the clamp into the upper fairing bracket.) 5.
  • Page 574 17-16 APPENDIX Cable, Wire, and Hose Routing...
  • Page 575 APPENDIX 17-17 Cable, Wire, and Hose Routing 1. Guide (Run the sidestand switch lead, neutral switch lead and speed sensor lead through into the guide.) 2. Drain Hose 3. Speed Sensor Lead 4. Neutral Switch Lead 5. Sidestand Switch Lead 6.
  • Page 576 17-18 APPENDIX Cable, Wire, and Hose Routing...
  • Page 577 4. Guide (Run the turn signal relay lead through into the guide.) 5. Turn Signal Relay 6. License Plate Light Lead Connector 7. Tail/Brake Light Lead Connector 8. Kawasaki Diagnostic System Connector 9. Fuel Injector #1 10. Subthrottle Valve Actuator Lead Connector 11. Rear Right Turn Signal Light Lead Connector 12.
  • Page 578 17-20 APPENDIX Cable, Wire, and Hose Routing...
  • Page 579 APPENDIX 17-21 Cable, Wire, and Hose Routing 1. Turn Signal Relay 2. Main Harness 3. Band (Hold the main harness to the frame.) 4. Band (Hold the main harness, battery negative cable and starter motor cable. Do not hold them to the frame.) 5.
  • Page 580 17-22 APPENDIX Cable, Wire, and Hose Routing...
  • Page 581 11. Clamp (Hold the license plate light lead, rear left turn signal light lead, rear right turn signal light lead and tail/brake light lead to the bracket.) 12. Kawasaki Diagnostic System Connector 13. Guide (Run the license plate light lead, rear left turn signal light lead and rear right turn signal light lead through into the guide.)
  • Page 582 17-24 APPENDIX Cable, Wire, and Hose Routing...
  • Page 583 APPENDIX 17-25 Cable, Wire, and Hose Routing 1. Fuel Tank Breather Hose 2. Guide (Run the fuel tank breather hose through into the guide.) 3. Drain Hose 4. Clamp (Hold the fuel tank drain hose with the frame.) 5. Adjusting Screw 6.
  • Page 584 17-26 APPENDIX Cable, Wire, and Hose Routing...
  • Page 585 APPENDIX 17-27 Cable, Wire, and Hose Routing 1. Clamp (Hold the left city light lead and headlight (high) lead and fix the clamp into the upper fairing bracket.) 2. Left City Light Lead 3. Cover 4. Headlight (High) Lead 5. Band (Hold the left city light lead and headlight (high) lead to the upper fairing bracket.) 6.
  • Page 586 17-28 APPENDIX Cable, Wire, and Hose Routing ABS Equipped Models...
  • Page 587 APPENDIX 17-29 Cable, Wire, and Hose Routing 1. ABS Hydraulic Unit 2. Damper (Hold the brake pipes to bracket on frame.) 3. Brake Pipe (ABS Hydraulic Unit ∼ Front Caliper) 4. Brake Pipe (Front Master Cylinder ∼ ABS Hydraulic Unit) 5.
  • Page 588 17-30 APPENDIX Cable, Wire, and Hose Routing ABS Equipped Models...
  • Page 589 9. Run the rear wheel rotation sensor lead and rear brake switch lead into the hole of the rear fender. 10. Damper (Hold the brake pipes to bracket on frame.) 11. ABS Kawasaki Diagnostic System Connector 12. Hold the ABS Kawasaki Diagnostic System Connector to the fuel tank bracket.
  • Page 590 17-32 APPENDIX Cable, Wire, and Hose Routing ABS Equipped Models...
  • Page 591 APPENDIX 17-33 Cable, Wire, and Hose Routing 1. Rear Wheel Rotation Sensor Lead 2. Clamp (Hold the rear wheel rotation sensor lead to the swingarm.) 3. Run the rear wheel rotation sensor lead and rear brake switch lead into the hole of the rear fender.
  • Page 592 17-34 APPENDIX Cable, Wire, and Hose Routing 1. Stick Coil #1 Lead Connector 2. Stick Coil #2 Lead Connector...
  • Page 593 APPENDIX 17-35 Cable, Wire, and Hose Routing CAL Model 1. Purge Valve 2. Main Harness 3. Fuel Tank Drain Hose 4. Guide (Run the hose into the guide.) 5. Guide (Run the hose into the guide.) 6. Canister...
  • Page 594 17-36 APPENDIX Cable, Wire, and Hose Routing GPS Unit Equipped Models...
  • Page 595 APPENDIX 17-37 Cable, Wire, and Hose Routing 1. Right City Light Connector 2. Headlight (Low) Connector 3. Upper Fairing Bracket 4. GPS Unit Lead Connector 5. To Meter 6. Headlight (High) Connector 7. Left City Light Connector 8. GPS Unit 9.
  • Page 596 17-38 APPENDIX Cable, Wire, and Hose Routing GPS Unit Equipped Models...
  • Page 597 APPENDIX 17-39 Cable, Wire, and Hose Routing 1. Band (Hold the main harness to the upper fairing bracket.) 2. Siren 3. Band (Hold the main harness to the frame.) 4. Main Harness...
  • Page 598 17-40 APPENDIX Cable, Wire, and Hose Routing...
  • Page 599 APPENDIX 17-41 Cable, Wire, and Hose Routing 1. Thermostat 2. Radiator Cap 3. Clamp Screw 4. 90° 5. Section B-B 6. Upper 7. 45° 8. Viewed A 9. Align the white paint mark on the hose with the projection mark on the fitting. 10.
  • Page 600 17-42 APPENDIX Cable, Wire, and Hose Routing...
  • Page 601 APPENDIX 17-43 Cable, Wire, and Hose Routing 1. Reserve Tank Overflow Hose 2. Clamps 3. Radiator Cap 4. Align the white paint mark on the hose with the hole of the reserve tank. 5. Reserve Tank Hose 6. Reserve Tank 7.
  • Page 602 17-44 APPENDIX Cable, Wire, and Hose Routing...
  • Page 603 APPENDIX 17-45 Cable, Wire, and Hose Routing 1. Vehicle-down Sensor 2. Intake Air Pressure Sensor 3. Damper 4. Clamps 5. Vacuum Hose 6. Air Switching Valve Hose 7. Air Switching Valve 8. Clamp 9. Install the hose so that its white mark side faces the air switching valve.
  • Page 604 17-46 APPENDIX Cable, Wire, and Hose Routing...
  • Page 605 APPENDIX 17-47 Cable, Wire, and Hose Routing 1. Front Master Cylinder 2. Front Brake Hose 3. Bracket 4. Guide 5. Front Brake Caliper 6. Rear Brake Reservoir Tank 7. Rear Brake Caliper 8. Clamp 9. Clamp 10. Clamp 11. Rear Master Cylinder 12.
  • Page 606 17-48 APPENDIX Cable, Wire, and Hose Routing ABS Equipped Models...
  • Page 607 APPENDIX 17-49 Cable, Wire, and Hose Routing 1. Front Master Cylinder 2. ABS Hydraulic Unit 3. Brake Pipe (ABS Hydraulic Unit ∼ Front Caliper) 4. Clamp (Hold the brake pipes.) 5. Bracket (Hold the brake pipes.) 6. Brake Hose (Front Master Cylinder ∼ ABS Hydraulic Unit) 7.
  • Page 608 17-50 APPENDIX Cable, Wire, and Hose Routing ABS Equipped Models...
  • Page 609 APPENDIX 17-51 Cable, Wire, and Hose Routing 1. Clamp (Hold the rear wheel rotation sensor lead to the brake hose with the clamp at the white mark on the lead.) 2. ABS Hydraulic Unit 3. Bracket (Hold the brake hoses.) 4.
  • Page 610 17-52 APPENDIX Cable, Wire, and Hose Routing CAL Model...
  • Page 611 APPENDIX 17-53 Cable, Wire, and Hose Routing 1. Clamp (Face the tabs of the clamp in direction.) 2. Green Mark 3. Hose (Green) 4. Vacuum Hose 5. Run the hose (Green) over the vacuum hose and throttle cable. 6. Throttle Cable 7.
  • Page 612: Troubleshooting Guide

    17-54 APPENDIX Troubleshooting Guide NOTE Spark plug dirty, broken, or gap malad- ○ Refer to the Fuel System (DFI) chapter for justed most of DFI trouble shooting guide. Stick coil shorted or not in good contact ○ This is not an exhaustive list, giving every Stick coil trouble possible cause for each problem listed.
  • Page 613 APPENDIX 17-55 Troubleshooting Guide Cylinder head not sufficiently tightened Valve spring broken or weak down Valve not seating properly (valve bent, No valve clearance worn, or carbon accumulation on the Cylinder, piston worn seating surface) Piston ring bad (worn, weak, broken, or Knocking: sticking) Carbon built up in combustion chamber...
  • Page 614: Abnormal Engine Noise

    17-56 APPENDIX Troubleshooting Guide Brake dragging Gear stuck on the shaft Lubrication inadequate: Gear positioning lever binding Engine oil level too low Shift return spring weak or broken Engine oil poor quality or incorrect Shift return spring pin loose Water temperature warning indicator light Shift mechanism arm spring broken incorrect: Shift mechanism arm broken...
  • Page 615: Abnormal Drive Train Noise

    APPENDIX 17-57 Troubleshooting Guide Air switching valve damaged Valve oil seal damaged Alternator rotor loose Valve guide worn Catalytic converter melt down due to muffler Engine oil level too high overheating (KLEEN) Black smoke: Air cleaner clogged Abnormal Drive Train Noise: Brown smoke: Air cleaner duct loose Clutch noise:...
  • Page 616: Battery Trouble

    17-58 APPENDIX Troubleshooting Guide Brake fluid leakage Battery cable making poor contact Disc warped Load excessive (e.g., bulb of excessive Contaminated pad wattage) Brake fluid deteriorated Ignition switch trouble Primary or secondary cup damaged in master Alternator trouble cylinder Wiring faulty Master cylinder scratched inside Regulator/rectifier trouble Battery overcharged:...
  • Page 617 MODEL APPLICATION Year Model Beginning Frame No. □ JKAEX8A1 DDA00001 2013 EX300AD JKAEX300AADA00001 □ JKAEX8B1 DDA00001 2013 EX300BD JKAEX300ABDA00001 □ :This digit in the frame number changes from one machine to another. Part No.99924-1460-01 Printed in Japan...

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  • Kyle Mar 11, 2018 08:47:
    On page 3, it stated "All rights reserved. No parts of this publicatio​n may be reproduced​, stored in a retrieval system, or transmitte​d in any form or by any means, electronic mechanical photocopyi​ng, recording or otherwise, without the prior written permission of Quality Assurance Division/M​otorcycle & Engine Company/Ka​wasaki Heavy Industries​, Ltd., Japan.&quo​t;
    Meaning it's illegal to store and download this manual.
  • Claudinei Dec 14, 2016 10:46:
    Boa tarde não tô conseguind​o colocar a ninja 300 no ponto
    Algu​ém tem o manual como colocar no porto
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