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Kawasaki KLX250 D-Tracker X Service Manual

Kawasaki klx250 d-tracker x motorcycle service manual.
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Table of Contents
KLX250
D-TRACKER X
Motorcycle
Service Manual

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Table of Contents

   Also See for Kawasaki KLX250 D-Tracker X

   Summary of Contents for Kawasaki KLX250 D-Tracker X

  • Page 1 KLX250 D-TRACKER X 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) pound(s) ABDC after bottom dead center meter(s) alternating current minute(s) ATDC after top dead center newton(s) BBDC before bottom dead center pascal(s) bottom dead center horsepower BTDC before top dead center pound(s) per square inch °C degree(s) Celsius revolution direct current...
  • Page 7: How To Use This Manual

    ✁ 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 9: Table Of Contents

    GENERAL INFORMATION 1-1 General Information Table of Contents Before Servicing ........................Model Identification......................... Model Identification......................... General Specifications......................Unit Conversion Table ......................1-15...
  • Page 10: Before Servicing

    1-2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly opera- tion on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustra- tions, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary.
  • Page 11: 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 12 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 13 GENERAL INFORMATION 1-5 Before Servicing Press For items such as bearings or oil seals that must be pressed into place, apply small amount of oil to the con- tact area. Be sure to maintain proper alignment and use smooth movements when installing. Ball Bearing and Needle Bearing Do not remove pressed ball or needle unless removal is absolutely necessary.
  • Page 14 1-6 GENERAL INFORMATION Before Servicing 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 15: Model Identification

    GENERAL INFORMATION 1-7 Model Identification KLX250S9 Left Side View KLX250S9 Right Side View Frame Number Engine Number...
  • Page 16: Model Identification

    1-8 GENERAL INFORMATION Model Identification KLX250V9 Left Side View KLX250V9 Right Side View...
  • Page 17: General Specifications

    GENERAL INFORMATION 1-9 General Specifications Items KLX250S9 Dimensions Overall Length 2 200 mm (86.61 in.) Overall Width 820 mm (32.3 in.) Overall Height (IN, EUR, SEA) 1 205 mm (47.44 in.), (TH) 1 190 mm (46.85 in.) Wheelbase 1 430 mm (56.30 in.) Road Clearance 285 mm (11.2 in.) Seat Height...
  • Page 18 1-10 GENERAL INFORMATION General Specifications Items KLX250S9 Drive Train Primary Reduction System: Type Gear drive Reduction Ratio 2.800 (84/30) Clutch Type Wet multi disc Transmission: Type 6-speed, constant mesh, return shift Gear Ratios: 3.000 (30/10) 2.000 (30/15) 1.500 (27/18) 1.250 (25/20) 1.050 (21/20) 0.952 (20/21) Final Drive System:...
  • Page 19 GENERAL INFORMATION 1-11 General Specifications Items KLX250S9 Headlight: Type Semi-sealed beam Bulb (TH) 12 V 30/30 W × 2 (quartz halogen) (IN, EUR, SEA) 12 V 60/55 W (quartz halogen) Tail/Brake Light 12 V 5/21 W Alternator: Type Three-phase AC Rated Output 17.4 A/14 V @5 000 r/min (rpm) Specifications subject to change without notice, and may not apply to every country.
  • Page 20 1-12 GENERAL INFORMATION General Specifications Items KLX250V9 Dimensions Overall Length 2 130 mm (83.86 in.) Overall Width 795 mm (31.3 in.) Overall Height (MY, TH) 1 125 mm (44.29 in.) (BR, IN) 1 140 mm (44.88 in.) Wheelbase 1 420 mm (55.91 in.) Road Clearance 225 mm (8.86 in.) Seat Height...
  • Page 21 GENERAL INFORMATION 1-13 General Specifications Items KLX250V9 Capacity 1.3 L (1.4 US qt) (when engine is completely dry) Drive Train Primary Reduction System: Type Gear drive Reduction Ratio 2.800 (84/30) Clutch Type Wet multi disc Transmission: Type 6-speed, constant mesh, return shift Gear Ratios: 3.000 (30/10) 2.000 (30/15)
  • Page 22 1-14 GENERAL INFORMATION General Specifications Items KLX250V9 Headlight: Type Semi-sealed beam Bulb (MY, TH) 12 V 30/30 W × 2 (quartz halogen) (BR, IN) 12 V 60/55 W (quartz halogen) Tail/Brake Light 12 V 5/21 W Alternator: Type Three-phase AC Rated Output 17.4 A/14 V @5 000 r/min (rpm)
  • Page 23: 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 25: 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 Throttle Control System Inspection................... 2-15 Idle Speed Inspection .......................
  • Page 26 2-2 PERIODIC MAINTENANCE Steering System ........................2-36 Steering Play Inspection ....................2-36 Steering Play Adjustment....................2-37 Steering Stem Bearing Lubrication ................... 2-37 Electrical System ......................... 2-38 Lights and Switches Operation Inspection................ 2-38 Headlight Aiming Inspection ..................... 2-40 Sidestand Switch Operation Inspection ................2-41 Engine Stop Switch Operation Inspection.................
  • Page 27: Periodic Maintenance Chart

    PERIODIC MAINTENANCE 2-3 Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition.The initial maintenance is vitally important and must not be neglected. Periodic Inspection FREQUENCY Whichever * ODOMETER READING comes ×...
  • Page 28 2-4 PERIODIC MAINTENANCE Periodic Maintenance Chart FREQUENCY Whichever * ODOMETER READING comes × 1 000 km first (× 1 000 mile) Page ITEM Every (0.6) (3.75) (7.5) (11.25) (15) (18.75) (22.5) • • • Drive chain wear - inspect # 2-29 •...
  • Page 29 PERIODIC MAINTENANCE 2-5 Periodic Maintenance Chart *: For higher odometer readings, repeat at the frequency interval established here. Periodic Replacement Parts FREQUENCY Whichever * ODOMETER READING comes × 1 000 km first (× 1 000 mile) Page ITEM Every (0.6) (7.5) (15) (22.5) (30.0) Air cleaner element # - replace 2 years 2-46...
  • Page 30: Torque And Locking Agent

    2-6 PERIODIC MAINTENANCE Torque and Locking Agent The following tables list the tightening torque for the major fasteners requiring use of a non-permanent locking agent or silicone sealant etc. Letters used in the “Remarks” column mean: AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque. G: Apply grease.
  • Page 31 PERIODIC MAINTENANCE 2-7 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Camshaft Chain Tensioner Bolts 87 in·lb Camshaft Chain Sub-tensioner Bolt Camshaft Chain Guide Bolt Camshaft Chain Guide Retaining Plate Bolt 87 in·lb Muffler Body Bolts (Front and Center) Muffler Body Bolt (Rear) 87 in·lb Muffler Body Nut...
  • Page 32 2-8 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Drive Chain Guard Plate Bolts 87 in·lb External Shift Mechanism Cover Nut 87 in·lb Shift Drum Cam Holder Bolt 106 in·lb Neutral Switch 14.7 130 in·lb Wheels/Tires Spoke Nipples 0.41 35 in·lb...
  • Page 33 PERIODIC MAINTENANCE 2-9 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Steering Steering Stem Nut 0.50 43 in·lb Handlebar Clamp Bolts Steering Stem Head Nut Upper Front Fork Clamp Bolts Lower Front Fork Clamp Bolts Left Switch Housing Screws 0.36 31 in·lb Right Switch Housing Screws...
  • Page 34 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 35: 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) – – – Air Cleaner Element Polyurethane Foam –...
  • Page 36 2-12 PERIODIC MAINTENANCE Specifications Item Standard Service Limit Rear: KLX250S Up to 97.5 kg (215 lb) load: – – – 150 kPa (1.5 kgf/cm², 22 psi) 97.5 ∼ 181 kg (215 ∼ 399 lb) load: – – – 175 kPa (1.75 kgf/cm², 25 psi) KLX250V 225 kPa (2.25 kgf/cm², 33 psi) –...
  • Page 37: Special Tools

    PERIODIC MAINTENANCE 2-13 Special Tools Inside Circlip Pliers: Spark Plug Wrench, Hex 16: 57001-143 57001-1262 Steering Stem Nut Wrench: Filler Cap Driver: 57001-1100 57001-1454 Jack: 57001-1238...
  • Page 38: Periodic Maintenance Procedures

    2-14 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel System (DFI) Air Cleaner Element Cleaning NOTE I n dusty areas, the element should be cleaned more ✁ frequently than the recommended interval. A fter riding through rain or on muddily roads, the ele- ✁...
  • Page 39: Throttle Control System Inspection

    PERIODIC MAINTENANCE 2-15 Periodic Maintenance Procedures Throttle Control System Inspection • Check that the throttle grip [A] moves smoothly from full open to close, and the throttle closes quickly and com- pletely by the return spring in all steering positions. If the throttle grip does not return properly, check the throt- tle cable routing, grip free play, and cable damage.
  • Page 40: Idle Speed Adjustment

    2-16 PERIODIC MAINTENANCE Periodic Maintenance Procedures Idle Speed Adjustment • Start the engine and warm it up thoroughly. • Turn the adjusting screw [A] until the idle speed is correct. O pen and close the throttle a few times to make sure that ✁...
  • Page 41: Cooling System

    PERIODIC MAINTENANCE 2-17 Periodic Maintenance Procedures • Check the liquid/vapor separator as follows. D isconnect the hoses from the separator, and remove the ✁ separator [A] from the motorcycle left side. V isually inspect the separator for cracks and other dam- ✁...
  • Page 42: Radiator Hose Inspection (coolant Leak, Damage, Installation Condition)

    2-18 PERIODIC MAINTENANCE Periodic Maintenance Procedures Radiator Hose Inspection (coolant leak, damage, installation condition) T he 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 43: Valve Clearance Adjustment

    PERIODIC MAINTENANCE 2-19 Periodic Maintenance Procedures Valve Clearance Adjustment • Remove the camshaft [A] (see Camshaft Removal in the Engine Top End chapter). • Remove the valve lifter [B] of a valve that requires an adjustment. • Remove the shim [C] on the spring retainer. NOTE M ark the shim and valve lifter so that they can be in- ✁...
  • Page 44 2-20 PERIODIC MAINTENANCE Periodic Maintenance Procedures Valve Clearance Adjustment Charts Inlet 1. Measure the valve clearance (when cold). 2. Check the present shim size. 3. Select an optimum shim based on a measured clearance value (row headings) and the thickness of the shim currently in use (column headings).
  • Page 45 PERIODIC MAINTENANCE 2-21 Periodic Maintenance Procedures Valve Clearance Adjustment Charts Exhaust 1. Measure the valve clearance (when cold). 2. Check the present shim size. 3. Select an optimum shim based on a measured clearance value (row headings) and the thickness of the shim currently in use (column headings).
  • Page 46: Air Suction System Damage Inspection

    2-22 PERIODIC MAINTENANCE Periodic Maintenance Procedures Air Suction System Damage Inspection • Remove the fuel tank (see Fuel Tank Removal in the Fuel System (DFI) chapter). • Separate the air switching valve hose [A] from the air cleaner housing. • Install the fuel tank temporary (see Fuel Tank Installation in the Fuel System (DFI) chapter).
  • Page 47: Wheels/tires

    PERIODIC MAINTENANCE 2-23 Periodic Maintenance Procedures WARNING The engine and exhaust system get extremely hot during normal operation and can cause serious burns. Never touch the engine or exhaust pipe during clutch adjustment. • Slide the dust cover [A] at the clutch cable. •...
  • Page 48: Tire Tread Wear Inspection

    2-24 PERIODIC MAINTENANCE Periodic Maintenance Procedures Tire Tread Wear Inspection As the tire tread wears down, the tire becomes more sus- ceptible to puncture and failure. An accepted estimate is that 90% of all tire failures occur during the last 10% of tread life (90% worn).
  • Page 49: Spoke Tightness And Rim Runout Inspection

    PERIODIC MAINTENANCE 2-25 Periodic Maintenance Procedures • Raise the rear wheel off the ground with jack. Special Tool - Jack: 57001-1238 • Inspect the roughness of the rear wheel bearing by mov- ing the wheel with both hands to both sides. •...
  • Page 50: Drive Train

    2-26 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Raise the front/rear wheel off the ground with jack. Special Tool - Jack: 57001-1238 • Inspect the rim for small cracks, dents, bending, or warp- ing. If there is any damage to the rim, it must be replaced. •...
  • Page 51: Drive Chain Slack Inspection

    PERIODIC MAINTENANCE 2-27 Periodic Maintenance Procedures • Apply oil to the sides of the rollers so that oil will penetrate to the rollers and bushings. Apply the oil to the O-rings so that the O-rings will be coated with oil. •...
  • Page 52: Wheel Alignment Inspection

    2-28 PERIODIC MAINTENANCE Periodic Maintenance Procedures NOTE W hen inserting the cotter pin, if the slots in the nut do ✁ not align with the cotter pin hole in the axle shaft, tighten the nut clockwise [A] up to next alignment. I t should be within 30 degrees.
  • Page 53: Drive Chain Wear Inspection

    PERIODIC MAINTENANCE 2-29 Periodic Maintenance Procedures Drive Chain Wear Inspection • Remove the chain cover (see Drive Chain Removal in the Final Drive chapter). • Rotate the rear wheel to inspect the drive chain for dam- aged rollers, and loose pins and links. If there is any irregularity, replace the drive chain.
  • Page 54: Chain Guide Wear Inspection

    2-30 PERIODIC MAINTENANCE Periodic Maintenance Procedures Chain Guide Wear Inspection • Visually inspect the following parts. Front Chain Guide [A] Rear Chain Guide [B] Chain Slipper [C] Chain Guide Roller [D] If the chain guides, chain slipper and chain guide roller show any signs of abnormal wear or damage, replace them.
  • Page 55: Brake System

    PERIODIC MAINTENANCE 2-31 Periodic Maintenance Procedures Brake System Brake Fluid Leak Inspection • Apply the brake lever or pedal and inspect the brake fluid leak from the brake hoses [A] and fittings [B]. If the brake fluid leaked from any position, inspect or re- place the problem part.
  • Page 56: Brake Hose Damage And Installation Condition Inspection

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

    PERIODIC MAINTENANCE 2-33 Periodic Maintenance Procedures • Check that the brake fluid level in the rear brake reservoir [A] is above the lower level line [B]. If the fluid level is lower than the lower level line, fill the reservoir to the upper level line [C]. WARNING Mixing brands and types of brake fluid can reduce the brake system’s effectiveness and cause an ac-...
  • Page 58: Suspensions

    2-34 PERIODIC MAINTENANCE Periodic Maintenance Procedures If it does not, adjust the brake light switch. • While holding the switch body, turn the adjusting nut 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 59: Front Fork Oil Leak Inspection

    PERIODIC MAINTENANCE 2-35 Periodic Maintenance Procedures Front Fork Oil Leak Inspection • Visually inspect the front forks [A] for oil leakage. Replace or repair any defective parts, if necessary. Rear Shock Absorber Oil Leak Inspection • 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 60: Tie-rod Operation Inspection

    2-36 PERIODIC MAINTENANCE Periodic Maintenance Procedures Tie-Rod Operation Inspection • Pump the tail grip down and up 4 or 5 times, and inspect the smooth stroke. If the tie-rods [A] do not smoothly stroke or noise is found, inspect the fasteners and tie-rod bearings (see Rocker Arm/Tie-Rod Bearing, Sleeve Inspection in the Suspen- sion chapter).
  • Page 61: Steering Play Adjustment

    PERIODIC MAINTENANCE 2-37 Periodic Maintenance Procedures Steering Play Adjustment • Remove: Handlebar (see Handlebar Removal in the Steering chapter) • Loosen: Lower Fork Clamp Bolts (see Front Fork Removal in the Suspension chapter) Steering Stem Head Nut [A] • Adjust the steering stem nut [C], using the steering stem nut wrench [B].
  • Page 62: Electrical System

    2-38 PERIODIC MAINTENANCE Periodic Maintenance Procedures Electrical System Lights and Switches Operation Inspection First Step • Set the gear position in the neutral position. • Set the lighting switch to ON position (IN model). • Turn the ignition switch ON. •...
  • Page 63 PERIODIC MAINTENANCE 2-39 Periodic Maintenance Procedures Second Step • Turn on the turn signal switch [A] (left or right position). • The left or right turn signal lights [B] (front and rear) ac- cording to the switch position should flash. •...
  • Page 64: Headlight Aiming Inspection

    2-40 PERIODIC MAINTENANCE Periodic Maintenance Procedures Forth Step • Set the lighting switch to ON position. • Set the dimmer switch [A] to low beam position. • Turn the ignition switch ON. • The low beam headlight should go on. If the low beam headlight does not go on, inspect or re- place the following item.
  • Page 65: Sidestand Switch Operation Inspection

    PERIODIC MAINTENANCE 2-41 Periodic Maintenance Procedures Headlight Beam Vertical Adjustment • Turn the vertical adjuster [A] on the headlight with the screwdriver in or out to adjust the headlight vertically. IN and Europe Models [B] MY and TH Models [C] NOTE O N high beam, the brightest points should be slightly ✁...
  • Page 66: Engine Stop Switch Operation Inspection

    2-42 PERIODIC MAINTENANCE Periodic Maintenance Procedures If the sidestand switch operation does not work, inspect or replace the following item. Battery (see Battery Condition in the Electrical System chapter) Main Fuse 20 A (see Fuse Inspection in the Electrical System chapter) ECU Fuse 15 A (see Fuse Inspection in the Electrical System chapter) Ignition Fuse 10 A (see Fuse Inspection in the Electrical...
  • Page 67: Others

    PERIODIC MAINTENANCE 2-43 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 W henever the vehicle has been operated under ✁...
  • Page 68 2-44 PERIODIC MAINTENANCE 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 69: Bolts, Nuts And Fasteners Tightness Inspection

    PERIODIC MAINTENANCE 2-45 Periodic Maintenance Procedures Bolts, Nuts and Fasteners Tightness Inspection • Check the tightness of the bolts and nuts listed here. Also, check to see that each cotter pin is in place and in good condition. NOTE F or the engine fasteners, check the tightness of them ✁...
  • Page 70: Replacement Parts

    2-46 PERIODIC MAINTENANCE Periodic Maintenance Procedures Replacement Parts Air Cleaner Element Replacement NOTE I n dusty areas, the element should be replaced more ✁ frequently than the recommended interval. A fter riding through rain or on muddily roads, the ele- ✁...
  • Page 71: Fuel Hose Replacement

    PERIODIC MAINTENANCE 2-47 Periodic Maintenance Procedures • Install the frame into the new element. • Coat the lip of the element with a thick layer of all pur- pose grease [A] to assure a complete seal against the air cleaner element base. Also, coat the base where the lip of the element fits.
  • Page 72 2-48 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Be sure to place a piece of cloth [A] around the fuel outlet hose joint. • Insert a minus screw driver [B] into the slit [C] on the joint lock. • Turn the driver to disconnect the joint lock [D]. •...
  • Page 73: Coolant Change

    PERIODIC MAINTENANCE 2-49 Periodic Maintenance Procedures Coolant Change WARNING Coolant can be extremely hot and cause severe burns, is toxic and very slippery. Do not remove the radiator cap or attempt to change the coolant when the engine is hot; allow it cool completely. Immediately wipe any spilled coolant from tires, frame, engine or other painted parts.
  • Page 74 2-50 PERIODIC MAINTENANCE Periodic Maintenance Procedures • When filling the coolant, choose a suitable mixture ratio by referring to the coolant manufacturer’s directions. NOTICE Soft or distilled water must be used with the an- tifreeze in the cooling system. If hard water is used in the system, it causes scales accumulation in the water passages, and consider- ably reduces the efficiency of the cooling system.
  • Page 75: Radiator Hose And O-ring Replacement

    PERIODIC MAINTENANCE 2-51 Periodic Maintenance Procedures Radiator Hose and O-ring Replacement • Drain the coolant (see Coolant Change). • Remove: Water Hose Fitting [A] Water Pump Impeller [B] (see Water Pump Removal in the Cooling System chapter) O-rings [C] Hoses [D] •...
  • Page 76: Oil Filter Replacement

    2-52 PERIODIC MAINTENANCE Periodic Maintenance Procedures Recommended Engine Oil Type: API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2 Viscosity: SAE 10W-40 Capacity: 1.0 L (1.1 US qt) (when filter is not removed) 1.1 L (1.2 US qt) (when filter is removed) 1.3 L (1.4 US qt) (when engine is completely dry) NOTE D o not add any chemical additive to the oil.
  • Page 77: Brake Hose Replacement

    PERIODIC MAINTENANCE 2-53 Periodic Maintenance Procedures • Replace the O-ring [A] of the filter cap with a new one. • Apply engine oil to the O-ring. • Install the oil filter cap so that the align the oil passage holes [B] of the oil filter cap and right engine cover. •...
  • Page 78: Brake Fluid Change

    2-54 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Fluid Change NOTE T he procedure to change the front brake fluid is as fol- ✁ lows. Changing the rear brake fluid is the same as for the front brake. • Level the brake fluid reservoir. •...
  • Page 79: Master Cylinder Rubber Parts Replacement

    PERIODIC MAINTENANCE 2-55 Periodic Maintenance Procedures Master Cylinder Rubber Parts Replacement Front Master Cylinder Disassembly • Remove the front master cylinder (see Front Master Cylin- der Removal in the Brakes chapter). • Remove the reservoir cap [A] and diaphragm [B], and pour the brake fluid into a container.
  • Page 80 2-56 PERIODIC MAINTENANCE Periodic Maintenance Procedures Master Cylinder Assembly • Before assembly, clean all parts including the master cylinder with brake fluid or alcohol. NOTICE Except for the disc pads and disc, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol for cleaning brake parts.
  • Page 81: Caliper Rubber Parts Replacement

    PERIODIC MAINTENANCE 2-57 Periodic Maintenance Procedures Caliper Rubber Parts Replacement Front Caliper Disassembly • Remove: Front Caliper (see Front Caliper Removal in the Brakes chapter) Brake Pads (see Front Brake Pad Removal in the Brakes chapter) • Using compressed air, remove the pistons. C over the piston area with a clean, thick cloth [A].
  • Page 82 2-58 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Install the anti-rattle spring [A] as shown. • Apply brake fluid to the outside of the pistons, and push them into each cylinder by hand. • Check the shaft rubber friction boot [A] and the dust boot [B] replace them with new ones if they are damaged.
  • Page 83 PERIODIC MAINTENANCE 2-59 Periodic Maintenance Procedures Rear Caliper Assembly • Clean the caliper parts except for the pads. NOTICE For cleaning of the parts, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol. • Install the bleed valve and rubber cap. Torque - Bleed Valve: 7.8 N·m (0.80 kgf·m, 69 in·lb) •...
  • Page 84: Spark Plug Replacement

    2-60 PERIODIC MAINTENANCE Periodic Maintenance Procedures Spark Plug Replacement • Remove the left radiator shroud (see Radiator Shroud Re- moval in the Frame System chapter). • Remove the spark plug cap [A] from the spark plug. • Remove the spark plug using the plug wrench vertically. Special Tool - Spark Plug Wrench, Hex 16: 57001-1262 •...
  • Page 85 FUEL SYSTEM (DFI) 3-1 Fuel System (DFI) Table of Contents Exploded View........................DFI System..........................3-10 DFI Parts Location........................3-16 Specifications ......................... 3-18 Special Tools and Sealant ...................... 3-20 DFI Servicing Precautions ...................... 3-22 DFI Servicing Precautions ....................3-22 Troubleshooting the DFI System .................... 3-24 Outline..........................
  • Page 86 3-2 FUEL SYSTEM (DFI) Subthrottle Sensor (Service Code 32: TH and EUR Models/Service Code 62: IN and MY Models) ..........................3-66 Subthrottle Sensor Removal/Adjustment ................3-66 Subthrottle Sensor Input Voltage Inspection..............3-66 Subthrottle Sensor Output Voltage Inspection ..............3-67 Subthrottle Sensor Resistance Inspection ................ 3-69 Oxygen Sensor - not activated (Service Code 33) ..............
  • Page 87 FUEL SYSTEM (DFI) 3-3 Fuel Pump Operating Voltage Inspection ................. 3-102 Pressure Regulator Removal.................... 3-103 Fuel Filter Cleaning......................3-103 Throttle Grip and Cables ......................3-105 Throttle Grip Free Play Inspection ..................3-105 Throttle Grip Free Play Adjustment................... 3-105 Throttle Cable Remove ..................... 3-105 Throttle Cable Installation ....................
  • Page 88: Exploded View

    3-4 FUEL SYSTEM (DFI) Exploded View...
  • Page 89: Exploded View

    FUEL SYSTEM (DFI) 3-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Air Cleaner Duct Clamp Screw 0.20 18 in·lb ECU Bracket Screws 0.51 44 in·lb Inlet Air Temperature Sensor Mounting Screw 0.12 11 in·lb Throttle Pulley Cover Screws 0.51 44 in·lb 5.
  • Page 90 3-6 FUEL SYSTEM (DFI) Exploded View...
  • Page 91 FUEL SYSTEM (DFI) 3-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Fuel Pump Bolts 87 in·lb Vehicle-down Sensor Mounting Bolts 0.70 61 in·lb Water Temperature Sensor 106 in·lb Oxygen Sensor 5. Fuel Pump Relay 6. Speed Sensor 7. Fuel Pump 8.
  • Page 92 3-8 FUEL SYSTEM (DFI) Exploded View SEA and TH Models...
  • Page 93 FUEL SYSTEM (DFI) 3-9 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Separator Bracket Bolts 87 in·lb 2. Canister 3. Separator 4. Green/White Hose 5. Blue Hose 6. Red Hose 7. White Hose...
  • Page 94: Dfi System

    3-10 FUEL SYSTEM (DFI) DFI System DFI System...
  • Page 95 FUEL SYSTEM (DFI) 3-11 DFI System 1. Battery 12 V 6 Ah 2. ECU 3. Fuel Tank 4. Pressure Regulator 5. Fuel Pump 6. Air Switching Valve 7. Inlet Air Pressure Sensor 8. Fuel Injectors 9. Crankshaft Sensor 10. Water Temperature Sensor 11.
  • Page 96 3-12 FUEL SYSTEM (DFI) DFI System DFI System Wiring Diagram...
  • Page 97 13. ECU 14. Starter Relay 15. Main Fuse 20 A 16. Battery 12 V 6 Ah 17. Frame Ground 18. Kawasaki Diagnostic System Connector 19. Self-diagnosis Terminal 20. Fuse Box 21. Ignition Fuse 10 A 22. ECU Fuse 15 A 23.
  • Page 98 3-14 FUEL SYSTEM (DFI) DFI System Terminal Numbers of ECU Connectors Terminal Names 1. Power Supply to ECU (from Ignition Switch) 2. Vehicle-down Sensor 3. Crankshaft Sensor (+) 4. Unused 5. Main Throttle Sensor 6. Inlet Air Pressure Sensor 7. Oxygen Sensor 8.
  • Page 99 FUEL SYSTEM (DFI) 3-15 DFI System 35. Ground for ECU 36. Ground for ECU *: KDS (Kawasaki Diagnostic System)
  • Page 100: Dfi Parts Location

    3-16 FUEL SYSTEM (DFI) DFI Parts Location ECU [A] Self-diagnosis Terminal [A] Kawasaki Diagnostic System Connector [B] Oxygen Sensor [C] Fuel Pump [A] Fuel Pump Relay [B] Throttle Body Assy [C] Inlet Air Temperature Sensor [A] Main Throttle Sensor [A]...
  • Page 101 FUEL SYSTEM (DFI) 3-17 DFI Parts Location Vehicle-down Sensor [A] Subthrottle Sensor [B] Water Temperature Sensor [C] Subthrottle Valve Actuator [D] Fuel Injector [A] Inlet Air Pressure Sensor [B] Ignition Coil [A] Air Switching Valve [B] Speed Sensor [A] ECU Fuse 15 A [A]...
  • Page 102: Specifications

    3-18 FUEL SYSTEM (DFI) Specifications Item Standard Digital Fuel Injection System Idle Speed 1 300 ±50 r/min (rpm) Throttle Body Assy: Type Single barrel Bore 34 mm (1.34 in.) ECU: Make KEIHIN Type Digital memory type, with built in IC igniter, sealed with resin Fuel Pressure (High Pressure Line) 294 kPa (3.0 kgf/cm², 43 psi) with engine idling Fuel Pump: Type...
  • Page 103 FUEL SYSTEM (DFI) 3-19 Specifications Item Standard DC 0.48 ∼ 0.52 V at subthrottle valve full close position Output Voltage DC 3.8 ∼ 4.0 V at subthrottle valve full open position (for reference) 4 ∼ 6 k Resistance ✂ Subthrottle Valve Actuator: About 5.2 ∼...
  • Page 104: Special Tools And Sealant

    3-20 FUEL SYSTEM (DFI) Special Tools and Sealant Oil Pressure Gauge, 5 kgf/cm²: Needle Adapter Set: 57001-125 57001-1457 Jack: Throttle Sensor Setting Adapter: 57001-1238 57001-1538 Hand Tester: Fuel Pressure Gauge Adapter: 57001-1394 57001-1593 Throttle Sensor Setting Adapter #1: Fuel Hose: 57001-1400 57001-1607 Peak Voltage Adapter:...
  • Page 105 FUEL SYSTEM (DFI) 3-21 Special Tools and Sealant Liquid Gasket, TB1211: 56019-120...
  • Page 106: Dfi Servicing Precautions

    3-22 FUEL SYSTEM (DFI) DFI Servicing Precautions DFI Servicing Precautions There are a number of important precautions that should be followed servicing the DFI system. T his DFI system is designed to be used with a 12 V sealed ✁ battery as its power source.
  • Page 107 FUEL SYSTEM (DFI) 3-23 DFI Servicing Precautions I f 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.
  • Page 108: Troubleshooting The Dfi System

    3-24 FUEL SYSTEM (DFI) Troubleshooting the DFI System Outline When an abnormality in the system occurs, the FI indica- tor LED (Light Emitting Diode) light goes on to alert the rider on the meter panel. In addition, the condition of the problem is stored in the memory of the ECU (Electronic Control Unit).
  • Page 109 FUEL SYSTEM (DFI) 3-25 Troubleshooting the DFI System • When checking the DFI parts, use a digital meter which can be read two decimal place voltage or resistance. T he DFI part connectors [A] have seals [B], including the ✁ ECU.
  • Page 110 3-26 FUEL SYSTEM (DFI) Troubleshooting the DFI System • Pull each connector [A] apart and inspect it for corrosion, dirt, and damage. If the connector is corroded or dirty, clean it carefully. If it is damaged, replace it. Connect the connectors securely. •...