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ZZR1400 ABS
Ninja ZX-14R
Ninja ZX-14R ABS
Motorcycle
Service Manual

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Table of Contents

   Summary of Contents for Kawasaki ZZR1400 ABS

  • Page 1 ZZR1400 ABS Ninja ZX-14R Ninja ZX-14R 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: Country And Area Codes

    LIST OF ABBREVIATIONS ampere(s) Kawasaki Diagnostic System ABDC after bottom dead center km/h kilometers per hour alternating current liter(s) ampere hour pound(s) ATDC after top dead center Liquid Crystal Display BBDC before bottom dead center Light Emitting Diode bottom dead center...
  • 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-Evaporative Emission Control System (CAL and SEA B1 Models)..1-12 Unit Conversion Table ......................1-14...
  • Page 12: Before Servicing

    1-2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly opera- tion on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustra- tions, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary.
  • Page 13 Replacement Parts Replacement parts must be KAWASAKI genuine or 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 ZX1400EC Left Side View ZX1400EC Right Side View Frame Number Engine Number...
  • Page 18 1-8 GENERAL INFORMATION Model Identification ZX1400FC Left Side View ZX1400FC Right Side View...
  • Page 19: General Specifications

    GENERAL INFORMATION 1-9 General Specifications Items ZX1400EC, ZX1400FC Dimensions Overall Length 2 170 mm (85.43 in.) Overall Width 770 mm (30.31 in.) Overall Height 1 170 mm (46.06 in.) Wheelbase 1 480 mm (58.27 in.) Road Clearance 125 mm (4.92 in.) Seat Height 800 mm (31.50 in.) Curb Mass:...
  • Page 20 1-10 GENERAL INFORMATION General Specifications Items ZX1400EC, ZX1400FC Exhaust: Open 66° (BBDC) Close 36° (ATDC) Duration 282° Lubrication System Forced lubrication (wet sump with cooler) Engine Oil: Type API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2 Viscosity SAE 10W-40 Capacity...
  • Page 21 GENERAL INFORMATION 1-11 General Specifications Items ZX1400EC, ZX1400FC Rear Suspension: Type Swingarm (uni-trak) Wheel Travel 124 mm (4.88 in.) Brake Type: Front Dual discs Rear Single disc Electrical Equipment Battery 12 V 12 Ah Headlight: Type Semi-sealed beam Bulb: High 12 V 55 W + 65 W (quartz-halogen) ×...
  • Page 22: Technical Information-evaporative Emission Control System (cal And Sea B1 Models)

    1-12 GENERAL INFORMATION Technical Information-Evaporative Emission Control System (CAL and SEA B1 Models) Overview The fuel vapors from the fuel tank contain toxic HC (Hydrocarbons). In the evaporative emission control system, these vapors are kept in the canister temporarily without being released directly into the atmosphere.
  • Page 23: Technical Information-evaporative Emission Control System (cal And Sea B1 Models)

    GENERAL INFORMATION 1-13 Technical Information-Evaporative Emission Control System (CAL and SEA B1 Models) New Evaporative Emission Control System 1. Breather Hose (Blue) 6. Purge Valve 2. Purge Hose (Green) 7. Purge Hose (Green) 3. Breather Hose (Blue) 8. Throttle Body 4.
  • Page 24: Unit Conversion Table

    1-14 GENERAL INFORMATION Unit Conversion Table Prefixes for Units: Units of Length: × 0.6214 mile Prefix Symbol Power × 3.281 mega × 1 000 000 × 0.03937 kilo × 1 000 centi × 0.01 Units of Torque: milli × 0.001 N·m ×...
  • Page 25: Periodic Maintenance

    PERIODIC MAINTENANCE 2-1 Periodic Maintenance Table of Contents Periodic Maintenance Chart ....................Torque and Locking Agent...................... Specifications ......................... 2-13 Special Tools and Sealant ...................... 2-15 Periodic Maintenance Procedures..................2-16 Fuel System (DFI)........................ 2-16 Throttle Control System Inspection................... 2-16 Engine Vacuum Synchronization Inspection..............2-16 Idle Speed Inspection .......................
  • Page 26 2-2 PERIODIC MAINTENANCE Steering Play Inspection ....................2-39 Steering Play Adjustment....................2-39 Steering Stem Bearing Lubrication ................... 2-40 Electrical System ......................... 2-41 Lights and Switches Operation Inspection................ 2-41 Headlight Aiming Inspection ..................... 2-44 Sidestand Switch Operation Inspection ................2-45 Engine Stop Switch Operation Inspection................. 2-46 Others ..........................
  • 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) Clutch hose installation condition • • • • • •...
  • Page 29 PERIODIC MAINTENANCE 2-5 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) • • • Headlight aiming - inspect year 2-44 Sidestand switch operation - •...
  • Page 30 2-6 PERIODIC MAINTENANCE Periodic Maintenance Chart Periodic Replacement Parts FREQUENCY * ODOMETER Whichever READING comes × 1 000 km first (× 1 000 mile) Page ITEM Every (0.6) (7.5) (15) (22.5) (30) Air cleaner element - replace # Every 18 000 km (11 250 mile) 2-48 Fuel hose - replace 5 years...
  • Page 31: Torque And Locking Agent

    PERIODIC MAINTENANCE 2-7 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 32 2-8 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Front Engine Mounting Bolts (M10) R, S Camshaft Chain Tensioner Mounting Bolts 87 in·lb ← ← Cylinder Head Bolts (M11) see the text MO, S Cylinder Head Bolts (M6) 106 in·lb Water Passage Plugs 19.6...
  • Page 33 PERIODIC MAINTENANCE 2-9 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Engine Mounting Nuts (M12) R, S Adjusting Collars Crankshaft/Transmission Breather Cover Bolts (L = 25 mm) 87 in·lb Breather Cover Bolt (L = 35 mm) 87 in·lb Breather Cover Plate Screws 87 in·lb Oil Nozzle Pipe Mounting Bolts...
  • Page 34 2-10 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Chain Guide Bolts 87 in·lb Engine Sprocket Nut 13.0 93.7 Rear Axle Nut 13.0 93.7 Rear Sprocket Nuts Stud Bolts 14.7 10.8 Brakes Front Brake Pad Pins 17.2 1.75 12.7...
  • Page 35 PERIODIC MAINTENANCE 2-11 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Right Switch Housing Screws 0.36 31 in·lb Throttle Case Screws 0.36 31 in·lb Steering Stem Head Nut Front Fork Clamp Bolts (Upper) Steering Stem Nut Left Switch Housing Screws 0.36 31 in·lb Front Fork Clamp Bolts (Lower)
  • Page 36 2-12 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Oil Pressure Switch Terminal Bolt 0.15 13 in·lb Oil Pressure Switch Switch Housing Screws 0.36 31 in·lb Starter Lockout Switch Screw 0.70 0.071 6.2 in·lb Front Brake Light Switch Screw 0.12 11 in·lb Fuel Level Sensor Bolts...
  • Page 37: Specifications

    PERIODIC MAINTENANCE 2-13 Specifications Item Standard Service Limit Fuel System (DFI) 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Throttle Grip Free Play – – – Idle Speed 1 100 ±50 r/min (rpm) – – – Throttle Body Vacuum 36.66 ±1.3 kPa (275.0 ±10 mmHg) at –...
  • Page 38 2-14 PERIODIC MAINTENANCE Specifications Item Standard Service Limit Air Pressure (when Cold): Front – – – Up to 175 kg (385 lb) load: 290 kPa (2.9 kgf/cm², 42 psi) Rear Up to 175 kg (385 lb) load: – – – 290 kPa (2.9 kgf/cm², 42 psi) Final Drive 25 ∼...
  • Page 39: Special Tools And Sealant

    PERIODIC MAINTENANCE 2-15 Special Tools and Sealant Inside Circlip Pliers: Vacuum Gauge: 57001-143 57001-1369 Steering Stem Nut Wrench: Throttle Sensor Setting Adapter: 57001-1100 57001-1538 Jack: Jack Attachment: 57001-1238 57001-1608 Pilot Screw Adjuster, A: Liquid Gasket, TB1211F: 57001-1239 92104-0004 Oil Filter Wrench: 57001-1249...
  • Page 40: Periodic Maintenance Procedures

    2-16 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel System (DFI) Throttle Control System Inspection • Check the throttle grip free play [A]. If the free play is incorrect, adjust the throttle cables. Throttle Grip Free Play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Standard: •...
  • Page 41 PERIODIC MAINTENANCE 2-17 Periodic Maintenance Procedures • Connect a vacuum gauge and hoses [A] (Special Tool: 57001-1369) to the fittings on the throttle body. Special Tool - Vacuum Gauge: 57001-1369 • Tighten the screw [B] without the bracket [C]. • Pull off the air switching valve hose [A] from the frame.
  • Page 42 2-18 PERIODIC MAINTENANCE Periodic Maintenance Procedures If any vacuum is not within specifications, adjust the by- pass screws [A]. View from Rear [B] Special Tool - Pilot Screw Adjuster, A [C]: 57001-1239 • Adjust the each vacuum (#1 ∼ #4) to the standard value. •...
  • Page 43: Idle Speed Inspection

    PERIODIC MAINTENANCE 2-19 Periodic Maintenance Procedures • Back out the same number of turns counted when first turned in. This is to set the screw to its original position. NOTE ○ A throttle body has different “turns out” of the bypass screw for each individual unit.
  • Page 44: Idle Speed Adjustment

    2-20 PERIODIC MAINTENANCE Periodic Maintenance Procedures Idle Speed Adjustment NOTE ○ This motorcycle is equipped with the idle speed control valve. The idle speed is adjusted automatically at the specified value (1 100 r/min (rpm)) by the idle speed control valve system. Therefore, it is not necessary to adjust the idle speed normally.
  • Page 45: Cooling System

    PERIODIC MAINTENANCE 2-21 Periodic Maintenance Procedures ○ Remove: Inner Fairing (see Inner Fairing Remove the Frame chapter) Screws [A] ○ Visually inspect the canister [B] for cracks or other dam- age. If the canister has any cracks or bad damage, replace it with a new one.
  • Page 46: Radiator Hose And Pipe Inspection

    2-22 PERIODIC MAINTENANCE Periodic Maintenance Procedures Radiator 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 47: Valve Clearance Adjustment

    PERIODIC MAINTENANCE 2-23 Periodic Maintenance Procedures NOTE ○ Thickness gauge is horizontally inserted on the valve lifter. Appropriateness [A] Inadequacy [B] Thickness Gauge [C] Horizontally Inserts [D] Cam [E] Valve Lifter [F] Hits the Valve Lifter Ahead [G] ○ When positioning #1 piston TDC at the end of the compression stroke: Intake Valve Clearance of #1 and #3 Cylinders Exhaust Valve Clearance of #1 and #2 Cylinders...
  • Page 48 2-24 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Clean the shim to remove any dust or oil. • Measure the thickness of the removed shim [A]. • Select a new shim thickness calculation as follows. a + b – c = d [a] Present Shim Thickness [b] Measured Valve Clearance [c] Specified Valve Clearance [Mean Value = 0.245 mm...
  • Page 49: Periodic Maintenance Procedures

    PERIODIC MAINTENANCE 2-25 Periodic Maintenance Procedures Adjustment Shims Thickness Part Number Mark 2.000 92025-1870 2.025 92180-0209 2.050 92025-1871 2.075 92180-0210 2.100 92025-1872 2.125 92180-0211 2.150 92025-1873 2.175 92180-0212 2.200 92025-1874 2.225 92180-0213 2.250 92025-1875 2.275 92180-0214 2.300 92025-1876 2.325 92180-0215 2.350 92025-1877 2.375...
  • Page 50: Air Suction System Damage Inspection

    2-26 PERIODIC MAINTENANCE Periodic Maintenance Procedures NOTICE Be sure to remeasure the clearance after selecting a shim. The clearance can be out of the specified range because of the shim tolerance. ○ If there is no valve clearance, use a shim that is a few sizes smaller, and remeasure the valve clearance.
  • Page 51: Clutch Fluid Level Inspection

    PERIODIC MAINTENANCE 2-27 Periodic Maintenance Procedures Clutch Fluid Level Inspection • Hold the clutch fluid reservoir [A] horizontal. • Check that the clutch fluid level of the clutch reservoir is between the lower [B] and the upper [C] level lines. If the fluid level is lower than the lower level line, fill the reservoir to the upper level line in the reservoir.
  • Page 52: Wheels/tires

    2-28 PERIODIC MAINTENANCE Periodic Maintenance Procedures Wheels/Tires Tire 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 53: Wheel Bearing Damage Inspection

    PERIODIC MAINTENANCE 2-29 Periodic Maintenance Procedures WARNING Some replacement tires may adversely affect han- dling and cause an accident resulting in serious in- jury or death. To ensure proper handling and sta- bility, use only the recommended standard tires for replacement, inflated to the standard pressure.
  • Page 54: Final Drive

    2-30 PERIODIC MAINTENANCE 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 55: Drive Chain Slack Adjustment

    PERIODIC MAINTENANCE 2-31 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 right and left chain adjusters [D] evenly.
  • Page 56: Wheel Alignment Inspection

    2-32 PERIODIC MAINTENANCE Periodic Maintenance Procedures Wheel Alignment Inspection • Check that the notch [A] on the right alignment indicator [B] aligns with the same swingarm mark or position [C] that the left alignment indicator notch aligns with. If they do not, adjust the chain slack and align the wheel alignment (see Drive Chain Slack Adjustment).
  • Page 57: Drive Chain Guide Wear Inspection

    PERIODIC MAINTENANCE 2-33 Periodic Maintenance Procedures Drive Chain Guide Wear Inspection • Remove the swingarm (see Swingarm Removal in the Suspension chapter). • Visually inspect the chain guide [A]. Replace the chain guide if it shows any signs of abnormal wear or damage.
  • Page 58: Brake Hose And Pipe Damage And Installation Condition Inspection

    2-34 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Apply the brake lever or pedal and inspect the brake fluid leak from the brake hoses [A], pipes [B] (ABS equipped models) and fittings [C]. If the brake fluid leaked from any position, inspect or re- place the problem part.
  • Page 59: Brake Operation Inspection

    PERIODIC MAINTENANCE 2-35 Periodic Maintenance Procedures • Inspect the brake hoses, pipes and fittings for deteriora- tion, cracks and signs of leakage. ○ The high pressure inside of the brake line can cause fluid to leak [A] or the hose, pipes (ABS equipped models) to burst if the line is not properly maintained.
  • Page 60: Brake Pad Wear Inspection

    2-36 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Remove the seat (see Seat Removal in the Frame chap- ter). • Check that the brake fluid level in the rear brake reservoir [A] is above the lower level line [B]. If the fluid level is lower than the lower level line, fill the reservoir to the upper level line [C].
  • Page 61: Suspension

    PERIODIC MAINTENANCE 2-37 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 62: Front Fork Oil Leak Inspection

    2-38 PERIODIC MAINTENANCE 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 63: Steering

    PERIODIC MAINTENANCE 2-39 Periodic Maintenance Procedures Steering Steering Play Inspection • Raise the front wheel off the ground with the jack (see Front Wheel Removal in the Wheel/Tire chapter). Special Tools - Jack: 57001-1238 Jack Attachment: 57001-1608 • With the front wheel pointing straight ahead, alternately tap each end of the handlebar.
  • Page 64: Steering Stem Bearing Lubrication

    2-40 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Install the claw washer [A] so that its bent side [B] faces upward, and engage the bent claws with the grooves of steering stem locknut [C]. • Hand tighten the steering stem locknut until it touches the claw washer.
  • Page 65: Electrical System

    PERIODIC MAINTENANCE 2-41 Periodic Maintenance Procedures Electrical System Lights and Switches Operation Inspection First Step • Turn the ignition switch to ON. • The following lights should go on according to below table. City Light [A] goes on Taillight [B] goes on License Plate Light [C] goes on...
  • Page 66 2-42 PERIODIC MAINTENANCE Periodic Maintenance Procedures Second Step • Turn the ignition switch to P (Park) position (Other than US and CA models). • The city light, taillight and license plate light should go on. If the light does not go on, inspect or replace the following item.
  • Page 67 PERIODIC MAINTENANCE 2-43 Periodic Maintenance Procedures Fourth Step • Set the dimmer switch [A] to low beam position. • Start the engine. • The low beam headlights [B] should go on. If the low beam headlight does not go on, inspect or re- place the following item.
  • Page 68: Headlight Aiming Inspection

    2-44 PERIODIC MAINTENANCE Periodic Maintenance Procedures Headlight Aiming Inspection • Inspect the headlight beam for aiming. If the headlight beam points to one side rather than straight ahead, adjust the horizontal beam. Headlight Beam Horizontal Adjustment • Remove the inner covers (see Inner Cover Removal in the Frame chapter).
  • Page 69: Sidestand Switch Operation Inspection

    PERIODIC MAINTENANCE 2-45 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 Start Position Lever Continue Neutral Released Starts running Continue Neutral Pulled in Starts running...
  • Page 70: Engine Stop Switch Operation Inspection

    2-46 PERIODIC MAINTENANCE Periodic Maintenance Procedures Engine Stop Switch Operation Inspection First Step • Turn the ignition switch to ON. • Set the neutral position. • Turn the engine stop switch to stop position [A]. • Push the starter button. •...
  • Page 71: Bolts, Nuts And Fasteners Tightness Inspection

    PERIODIC MAINTENANCE 2-47 Periodic Maintenance Procedures Cables: Lubricate with Rust Inhibitor. Throttle Inner Cables • Lubricate the cables by seeping the oil between the cable and housing. ○ The cable may be lubricated by using a commercially available pressure cable lubricator with an aerosol cable lubricant.
  • Page 72: Replacement Parts

    2-48 PERIODIC MAINTENANCE Periodic Maintenance Procedures Bolt, Nut and Fastener to be checked Engine: Clutch Lever Pivot Bolt Locknut Engine Mounting Bolts and Nuts Exhaust Pipe Manifold Holder Nuts Muffler Body Clamp Bolts Muffler Body Mounting Bolts Wheels: Front Axle Clamp Bolts Front Axle Nut Rear Axle Nut Rear Axle Nut Cotter Pin...
  • Page 73: Fuel Hose Replacement

    Install a new element [A] so that screen side [B] faces backward. NOTICE Use only the recommended air cleaner element (Kawasaki part number 11013-0718). Using another air cleaner element will wear the engine prema- turely or lower the engine performance. •...
  • Page 74 2-50 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Pull the joint lock [A] fully as shown in the figure. • Pull the fuel hose [B] out of the delivery pipe. • Remove: Bolts [A] Bracket [B] • Remove the throttle body assy (see Throttle Body Assy Removal in the Fuel System (DFI) chapter).
  • Page 75: Coolant Change

    PERIODIC MAINTENANCE 2-51 Periodic Maintenance Procedures • Push and pull the fuel hose joint [A] back and forth more than two times, and make sure it is locked and doesn’t come off. WARNING Leaking fuel can cause a fire or explosion resulting in severe burns.
  • Page 76 2-52 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Remove: Hoses [A] Bolts [B] Reserve Tank [C] • Remove the cap [D] and pour the coolant into a container. • Install the reserve tank, and reconnect the reserve tank hose and overflow hose correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter).
  • Page 77: Radiator Hose And O-ring Replacement

    PERIODIC MAINTENANCE 2-53 Periodic Maintenance Procedures • Bleed the air from the cooling system as follows. ○ Start the engine with the radiator cap removed and run it until no more air bubbles [A] can be seen in the coolant. ○...
  • Page 78: Clutch Hose Replacement

    2-54 PERIODIC MAINTENANCE Periodic Maintenance Procedures Clutch Hose Replacement NOTICE Clutch fluid quickly ruins painted plastic surfaces; any spilled fluid should be completely washed away immediately. • Remove the left middle fairing (see Middle Fairing Re- moval in the Frame chapter). •...
  • Page 79: Clutch Fluid Change

    PERIODIC MAINTENANCE 2-55 Periodic Maintenance Procedures Clutch Fluid Change • Level the clutch fluid reservoir and remove the reservoir cap. • Free the lower fairing (see Clutch Slave Cylinder Removal in the Clutch chapter) • Remove the rubber cap from the bleed valve on the clutch slave cylinder.
  • Page 80: Rubber Parts Of Clutch Master Cylinder/slave Cylinder Replacement

    2-56 PERIODIC MAINTENANCE Periodic Maintenance Procedures Rubber Parts of Clutch Master Cylinder/Slave Cylinder Replacement Clutch Master Cylinder Cup and Dust Seal Replacement • Remove the clutch master cylinder (see Clutch Master Cylinder Removal in the Clutch chapter). • Remove the seal cover [A], circlip [B], connector [C] and O-ring [D].
  • Page 81: Engine Oil Change

    PERIODIC MAINTENANCE 2-57 Periodic Maintenance Procedures Clutch Slave Cylinder Piston Seal Replacement • Remove: Left Lower Fairing (see Lower Fairing Removal in the Frame chapter) Coolant Reserve Tank (see Coolant Reserve Tank Re- moval/Installation in the Cooling System chapter) • Loosen the banjo bolt [A] at the clutch pipe lower end, and tighten it loosely.
  • Page 82: Oil Filter Replacement

    2-58 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Remove the oil filler plug [A]. • 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:...
  • Page 83: Brake Hose Replacement

    PERIODIC MAINTENANCE 2-59 Periodic Maintenance Procedures • Replace the filter with a new one. • Apply grease to the gasket [A] before installation. • Tighten the filter with the oil filter wrench. Torque - Oil Filter: 17 N·m (1.7 kgf·m, 13 ft·lb) NOTE ○...
  • Page 84 2-60 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Remove the brake hose banjo bolts [A]. • When removing the brake hose, take care not to spill the brake fluid on the painted or plastic parts. • When removing the brake hoses [B], temporarily secure the end of the brake hose to some high place to keep fluid loss to a minimum.
  • Page 85 PERIODIC MAINTENANCE 2-61 Periodic Maintenance Procedures • For ABS equipped models; note the following. • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Battery (see Battery Removal in the Electrical System chapter) Upper Fairing (see Upper Fairing Removal in the Frame chapter) Brake Pipe Joint Nuts [A] (Using the flare nut wrench) Bolts [B]...
  • Page 86: Brake Fluid Change

    2-62 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Fluid Change NOTE ○ The 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 87: Master Cylinder Rubber Parts Replacement

    PERIODIC MAINTENANCE 2-63 Periodic Maintenance Procedures • Follow the procedure below to install the front brake fluid reservoir cap correctly. ○ First, tighten the front/rear brake fluid reservoir cap [B] clockwise [C] by hand until slight resistance is felt indi- cating that the cap is seated on the reservoir body, then tighten the cap an additional 1/6 turn [D] while holding the brake fluid reservoir body [A].
  • Page 88 2-64 PERIODIC MAINTENANCE Periodic Maintenance Procedures Rear Master Cylinder Disassembly • Remove the rear master cylinder (see Rear Master Cylin- der Removal in the Brakes chapter). • Remove the circlip [A], connector [B] and O-ring [C]. Special Tool - Inside Circlip Pliers: 57001-143 •...
  • Page 89: Caliper Rubber Parts Replacement

    PERIODIC MAINTENANCE 2-65 Periodic Maintenance Procedures Caliper Rubber Parts Replacement Front Caliper Disassembly • Loosen the front caliper pad pins [A] and banjo bolt [B] and tighten them loosely. • Remove: Front Caliper [C] (see Front Caliper Removal in the Brakes chapter) Brake Pads (see Front Brake Pad Removal in the brakes chapter)
  • Page 90 2-66 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Replace the fluid seals [A] with new ones. ○ Apply silicone grease to the fluid seals, and install them into the cylinders by hand. • Replace the dust seals [B] with new ones if they are dam- aged.
  • Page 91 PERIODIC MAINTENANCE 2-67 Periodic Maintenance Procedures • Remove the right side piston as follows. • Using the rear caliper assembly bolt [A], remove the pis- ton [B] as shown in the figure. • Remove: Dust Seals [A] Fluid Seals [B] Bleed Valves [C] Rubber Caps [D] NOTE...
  • Page 92: Spark Plug Replacement

    2-68 PERIODIC MAINTENANCE 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 each cylinder by hand. • Replace the dust seals [B] with new ones.
  • Page 93 FUEL SYSTEM (DFI) 3-1 Fuel System (DFI) Table of Contents Exploded View........................DFI System..........................3-12 DFI Parts Location........................3-22 Specifications ......................... 3-25 Special Tools and Sealant ...................... 3-27 DFI Servicing Precautions ...................... 3-29 DFI Servicing Precautions ....................3-29 Troubleshooting the DFI System .................... 3-31 Outline ..........................
  • Page 94 3-2 FUEL SYSTEM (DFI) Gear Position Switch Resistance Inspection ..............3-75 Gear Position Switch Output Voltage Inspection .............. 3-75 Front Wheel Rotation Sensor Signal (Service Code 27) ............3-77 Front Wheel Rotation Sensor Signal Inspection ............... 3-77 Vehicle-down Sensor (Service Code 31)................3-79 Vehicle-down Sensor Removal ..................
  • Page 95 FUEL SYSTEM (DFI) 3-3 ECU ............................3-112 ECU Identification ......................3-112 ECU Removal ........................3-112 ECU Installation ........................ 3-113 ECU Power Supply Inspection..................3-114 CAN Communication Line ...................... 3-117 CAN Communication Line Resistance Inspection ............3-117 DFI Power Source ........................3-119 ECU Fuse Removal ......................
  • Page 96 3-4 FUEL SYSTEM (DFI) Fuel Tank Cleaning ......................3-151 Evaporative Emission Control System (CAL and SEA-B1 Models)........3-152 Parts Removal/Installation ....................3-152 Hose Inspection ........................ 3-152 Purge Valve Inspection ..................... 3-152 Canister Inspection ......................3-152...
  • Page 97: Exploded View

    FUEL SYSTEM (DFI) 3-5 Exploded View This page intentionally left blank.
  • Page 98 3-6 FUEL SYSTEM (DFI) Exploded View...
  • Page 99 FUEL SYSTEM (DFI) 3-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Idle Speed Control Valve Actuator Mounting Bolts 0.85 73 in·lb L: Apply a non-permanent locking agent. R: Replacement Parts WL: Apply soap and water solution or rubber lubricant.
  • Page 100 3-8 FUEL SYSTEM (DFI) Exploded View...
  • Page 101 FUEL SYSTEM (DFI) 3-9 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Delivery Pipe Mounting Screws 0.51 44 in·lb Crankshaft Sensor Bolts 0.60 52 in·lb Gear Position Switch Screws 0.30 26 in·lb Water Temperature Sensor 106 in·lb Throttle Body Assy Holder Bolts 87 in·lb Throttle Body Assy Holder Clamp Bolts 0.20...
  • Page 102 3-10 FUEL SYSTEM (DFI) Exploded View...
  • Page 103 FUEL SYSTEM (DFI) 3-11 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Fuel Level Sensor Bolts 0.70 61 in·lb Fuel Pump Bolts 87 in·lb L, S 3. Canister 4. Purge Valve 5. CAL and SEA-B1 Models 6. ABS Equipped Models 7.
  • Page 104: Dfi System

    3-12 FUEL SYSTEM (DFI) DFI System DFI System...
  • Page 105 FUEL SYSTEM (DFI) 3-13 DFI System 1. ECU 2. Battery 12 V 14 Ah 3. Air Switching Valve 4. Idle Speed Control Valve Actuator 5. Intake Air Pressure Sensor #1 6. Intake Air Pressure Sensor #2 7. Subthrottle Valve Actuator 8.
  • Page 106 3-14 FUEL SYSTEM (DFI) DFI System DFI System Wiring Diagram...
  • Page 107 DFI System Part Names 1. ECU 2. Rear Wheel Rotation Sensor 3. Joint Connector B 4. Immobilizer (Equipped Models)/Kawasaki Diagnostic System Connector 5. Frame Ground 6. Battery 7. Starter Relay 8. Main Fuse 30 A 9. ECU Fuse 15 A 10.
  • Page 108 3-16 FUEL SYSTEM (DFI) DFI System DFI System Wiring Diagram (ABS Equipped Models)
  • Page 109 FUEL SYSTEM (DFI) 3-17 DFI System Part Names 1. ECU 2. Rear Wheel Rotation Sensor 3. Immobilizer (Equipped Models)/Kawasaki Diagnostic System Connector 4. Joint Connector B 5. Frame Ground 6. Battery 7. Starter Relay 8. Main Fuse 30 A 9. ECU Fuse 15 A 10.
  • Page 110 3-18 FUEL SYSTEM (DFI) DFI System ○ Color Codes: BK: Black GY: Gray PU: Purple BL: Blue LB: Light Blue R: Red BR: Brown LG: Light Green V: Violet CH: Chocolate W: White O: Orange DG: Dark Green P: Pink Y: Yellow G: Green...
  • Page 111 FUEL SYSTEM (DFI) 3-19 DFI System This page intentionally left blank.
  • Page 112 3-20 FUEL SYSTEM (DFI) DFI System Terminal Numbers of ECU Connectors Terminal Names 1. Subthrottle Valve Actuator: Y/R 2. Subthrottle Valve Actuator: BK 3. Front Wheel Rotation Sensor Signal (ZX1400F Model): G/Y Unused (ZX1400E Model) 4. Front Wheel Rotation Sensor Signal (ZX1400E Model): BK/W Unused (ZX1400F Model) 5.
  • Page 113 71. Fuel Pump Relay: BR/Y 72. Unused 73. Engine Ground: BK/Y 74. Engine Ground: BK/Y 75. Purge Valve (CAL and SEA-B1 Models): R/W 76. Oxygen Sensor Heater (Equipped Models): R 77. Unused 78. Stick Coil #3: BK/O KDS (Kawasaki Diagnostic System)
  • Page 114: Dfi Parts Location

    Stick Coils #1, #2, #3, #4 [A] Intake Air Pressure Sensor #1 [B] Idle Speed Control Valve Actuator [C] Relay Box (Fuel Pump Relay, ECU Main Relay) [A] Immobilizer (Equipped Models)/Kawasaki Diagnostic System Connector [B] ECU [C] Intake Air Temperature Sensor [A]...
  • Page 115 FUEL SYSTEM (DFI) 3-23 DFI Parts Location Gear Position Switch [A] Immobilizer Amplifier [A] (Equipped Models) Vehicle-down Sensor [B] Ignition (Transponder, Immobilizer System Equipped Models) [A] Ignition Switch [B] Immobilizer Antenna [C] (Equipped Models) Yellow Engine Warning Indicator Light (LED) [D] Intake Air Pressure Sensor #2 [A] Fuel Pump [A]...
  • Page 116 3-24 FUEL SYSTEM (DFI) DFI Parts Location Front Wheel Rotation Sensor [A] Rear Wheel Rotation Sensor [A] Purge Valve [A] (CAL and SEA-B1 Models)
  • Page 117: Specifications

    FUEL SYSTEM (DFI) 3-25 Specifications Item Standard Digital Fuel Injection System Idle Speed 1 100 ±50 r/min (rpm) Throttle Assy: Throttle Valve Dual throttle valve Bore 44 mm (1.7 in.) Throttle Body Vacuum 36.66 ±1.3 kPa (275.0 ±10 mmHg) 0 ∼ 1 1/4 (for reference) Bypass Screws ECU: Make...
  • Page 118 3-26 FUEL SYSTEM (DFI) Specifications Item Standard 4 ∼ 6 kΩ Resistance Subthrottle Valve Actuator: About 6.5 ∼ 8.5 Ω Resistance About DC 9.5 ∼ 11.5 V and then 0 V or Input Voltage About DC 9.5 ∼ 11.5 V Oxygen Sensor (Equipped Models): Output Voltage (Rich) DC 0.8 V or more...
  • Page 119: Special Tools And Sealant

    FUEL SYSTEM (DFI) 3-27 Special Tools and Sealant Oil Pressure Gauge, 5 kgf/cm²: Needle Adapter Set: 57001-125 57001-1457 Fork Oil Level Gauge: Throttle Sensor Setting Adapter: 57001-1290 57001-1538 Vacuum Gauge: Fuel Pressure Gauge Adapter: 57001-1369 57001-1593 Hand Tester: Fuel Hose: 57001-1394 57001-1607 Peak Voltage Adapter:...
  • Page 120 3-28 FUEL SYSTEM (DFI) Special Tools and Sealant Liquid Gasket, TB1211: 56019-120...
  • Page 121: Dfi Servicing Precautions

    FUEL SYSTEM (DFI) 3-29 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 122 3-30 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. Check the fuel hose [A] (see Fuel Hose Inspec- tion (fuel leak, damage, installation condition) in the Peri- odic Maintenance chapter).
  • Page 123: Troubleshooting The Dfi System

    FUEL SYSTEM (DFI) 3-31 Troubleshooting the DFI System Outline When a problem occurs with DFI system, the yellow en- gine warning indicator light (LED) [A] goes on to alert the rider. ○ When a problem occurs with KTRC system, the yellow KTRC warning indicator light (LED) [B] goes on, the KTRC and POWER mode symbols [C] blinking on the LCD.
  • Page 124 3-32 FUEL SYSTEM (DFI) Troubleshooting the DFI System With the engine stopped and turned in the self-diagnosis mode, the service code (error code) [A] is displayed on the LCD by the number of two digits. If the problem is with the following parts, the ECU can not recognize these problem.
  • Page 125 (LED) goes off. But the service codes stored in memory of the ECU are not erased to preserve the prob- lem history. The problem history can be referred using the KDS (Kawasaki Diagnostic System) when solving unstable problems When the motorcycle is down, the vehicle-down sensor operates and the ECU shuts off the fuel pump relay, fuel in- jectors and ignition system.
  • Page 126 3-34 FUEL SYSTEM (DFI) 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 127 FUEL SYSTEM (DFI) 3-35 Troubleshooting the DFI System ○ If both ends of a harness [A] are far apart, ground [B] the one end [C], using a jumper lead [D] and check the con- tinuity between the end [E] and the ground [F]. This en- ables to check a long harness for continuity.
  • Page 128: Inquiries To Rider

    3-36 FUEL SYSTEM (DFI) Troubleshooting the DFI System DFI Diagnosis Flow Chart Inquiries to Rider ○ Each rider reacts to problems in different ways, so it is important to confirm what kind of symptoms the rider has encountered. ○ Try to find out exactly what problem occurred under exactly what conditions by asking the rider; knowing this information may help you reproduce the problem.
  • Page 129 FUEL SYSTEM (DFI) 3-37 Troubleshooting the DFI System Sample Diagnosis Sheet Rider name: Registration No. (license plate No.): Year of initial registration: Model: Engine No.: Frame No.: Date problem occurred: Mileage: Environment when problem occurred. □ □ □ □ □ □...
  • Page 130 3-38 FUEL SYSTEM (DFI) Troubleshooting the DFI System □ □ □ Poor running at low very low idle speed, very high idle speed, rough idle speed. □ speed battery voltage is low (charge the battery). □ spark plug loose (tighten it). □...
  • Page 131: Dfi System Troubleshooting Guide

    FUEL SYSTEM (DFI) 3-39 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 132 3-40 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Fuel filter or pump screen clogged Inspect and replace fuel pump (see chapter 3). Fuel pressure regulator trouble Inspect fuel pressure and replace fuel pump (see chapter 3).
  • Page 133 FUEL SYSTEM (DFI) 3-41 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Fuel pump trouble Inspect (see chapter 3). Fuel injector trouble Inspect (see chapter 3). Main throttle sensor trouble Inspect (see chapter 3). Subthrottle sensor trouble Inspect (see chapter 3). Subthrottle valve actuator trouble Inspect (see chapter 3).
  • Page 134 3-42 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Intake air pressure sensor #2 trouble Inspect (see chapter 3). Water temperature sensor trouble Inspect (see chapter 3). Intake air temperature sensor trouble Inspect (see chapter 3). Other: Intermittent any DFI fault and its recovery Check that DFI connectors are clean and tight,...
  • Page 135 FUEL SYSTEM (DFI) 3-43 DFI System Troubleshooting Guide Symptoms or Possible Causes Actions (chapter) Intake air pressure sensor #1 trouble Inspect (see chapter 3). Intake air pressure sensor #2 trouble Inspect (see chapter 3). Water temperature sensor trouble Inspect (see chapter 3). Intake air temperature sensor trouble Inspect (see chapter 3).
  • Page 136: Self-diagnosis

    3-44 FUEL SYSTEM (DFI) Self-Diagnosis Self-Diagnosis Outline The self-diagnosis system is monitoring the following mechanisms. DFI System and Ignition System KTRC System Immobilizer System (Equipped Models) The following warning indicator lights (LED) are used for symbols of below table. LED Color Warning Indicator Symbols Oil Pressure Battery...
  • Page 137: Self-diagnosis Procedures

    FUEL SYSTEM (DFI) 3-45 Self-Diagnosis Dealer Mode The LCD (Liquid Crystal Display) displays the service code(s) [A] to show the problem(s) which the above system has at the moment of diagnosis. Self-Diagnosis Procedures NOTE ○ Use a fully charged battery when conducting self-diagnosis.
  • Page 138 3-46 FUEL SYSTEM (DFI) Self-Diagnosis ○ When a problem occurs with immobilizer system (equipped models), the red warning indicator light (LED) [A] blinks and immobilizer warning symbol [B] is displayed on the LCD (Liquid Crystal Display). • Push the “SEL” button for more than two seconds. •...
  • Page 139: Self-diagnosis Flow Chart

    FUEL SYSTEM (DFI) 3-47 Self-Diagnosis Self-Diagnosis Flow Chart...
  • Page 140: Service Code Reading

    3-48 FUEL SYSTEM (DFI) Self-Diagnosis Service Code Reading ○ The service code(s) is displayed on the LCD by the number of two digits. ○ When there are a number of problems, all the service codes can be stored and the display will begin starting from the lowest number service code in the numerical order.
  • Page 141 FUEL SYSTEM (DFI) 3-49 Self-Diagnosis Service System Problems Code Front wheel rotation sensor signal abnormal (sensor or rotor missing, FI/KTRC too large clearance, rotor tooth worn or missing, wiring open) Vehicle-down sensor malfunction, wiring open or short Subthrottle sensor malfunction, wiring open or short Oxygen sensor inactivation, wiring open or short (Equipped Models) Immobilizer Immobilizer amplifier malfunction (Equipped Models) Immobilizer Blank key detection (Equipped Models)
  • Page 142: Backups

    3-50 FUEL SYSTEM (DFI) Self-Diagnosis Backups ○ The ECU takes the following measures to prevent engine damage when the DFI, ignition, KTRC or immobilizer system parts have troubles. Service Parts or Output Signal Usable Backups by ECU Codes Function Range or Criteria If the main throttle sensor system fails (the output voltage is out of the usable range, Main Throttle...
  • Page 143 FUEL SYSTEM (DFI) 3-51 Self-Diagnosis Service Parts or Output Signal Usable Backups by ECU Codes Function Range or Criteria The oxygen sensor is Oxygen active and sensor must Sensor If the oxygen sensor is not activated, the ECU send signals (output (Equipped stops the feedback mode of the oxygen sensor.
  • Page 144 3-52 FUEL SYSTEM (DFI) Self-Diagnosis Service Parts or Output Signal Usable Backups by ECU Codes Function Range or Criteria The actuator operates If the ISC actuator fails (the signal is out to the open and close of the ISC Actuator usable range, wiring short or open), the ECU bypass passage by the stops the current to the actuator.
  • Page 145: Main Throttle Sensor (service Code 11)

    FUEL SYSTEM (DFI) 3-53 Main Throttle Sensor (Service Code 11) The main throttle sensor is a rotating variable resistor that change output voltage according to throttle operating. The ECU senses this voltage change and determines fuel injec- tion quantity, and ignition timing according to engine rpm, and throttle opening.
  • Page 146: Main Throttle Sensor Resistance Inspection

    3-54 FUEL SYSTEM (DFI) Main Throttle Sensor (Service Code 11) If the reading is out of the standard, remove the ECU and check the wiring for continuity between harness connec- tors. Special Tool - Hand Tester: 57001-1394 ○ Disconnect the ECU and sensor connectors. Wiring Continuity Inspection ECU Connector [A] ←→...
  • Page 147 FUEL SYSTEM (DFI) 3-55 Main Throttle Sensor (Service Code 11) • Start the engine and warm it up thoroughly. • Check idle speed to ensure the throttle opening is correct (see Idle Speed Inspection in the Periodic Maintenance chapter). Idle Speed Standard: 1 100 ±50 r/min (rpm) •...
  • Page 148 3-56 FUEL SYSTEM (DFI) Main Throttle Sensor (Service Code 11) Main Throttle Sensor Circuit 1. ECU 2. Main Throttle Sensor 3. Subthrottle Sensor...
  • Page 149: Intake Air Pressure Sensor #1 (service Code 12)

    FUEL SYSTEM (DFI) 3-57 Intake Air Pressure Sensor #1 (Service Code 12) Intake Air Pressure Sensor #1 Removal NOTICE Never drop the intake air pressure sensor #1 espe- cially on a hard surface. Such a shock to the sensor can damage it. •...
  • Page 150: Intake Air Pressure Sensor #1 Input Voltage Inspection

    3-58 FUEL SYSTEM (DFI) Intake Air Pressure Sensor #1 (Service Code 12) Intake Air Pressure Sensor #1 Input Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch to OFF. • Remove the throttle body assy (see Throttle Body Assy Removal).
  • Page 151: Intake Air Pressure Sensor #1 Output Voltage Inspection

    FUEL SYSTEM (DFI) 3-59 Intake Air Pressure Sensor #1 (Service Code 12) Intake Air Pressure Sensor #1 Output Voltage Inspection • Measure the output voltage at the intake air pressure sen- sor #1 in the same way as input voltage inspection, note the following.
  • Page 152 3-60 FUEL SYSTEM (DFI) Intake Air Pressure Sensor #1 (Service Code 12) If the wiring is good, check the sensor for various vacuum. • Remove the intake air pressure sensor #1 [A] and discon- nect the vacuum hose from the sensor. •...
  • Page 153 FUEL SYSTEM (DFI) 3-61 Intake Air Pressure Sensor #1 (Service Code 12) 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 #1 Output Voltage (V) (Digital Meter Reading)
  • Page 154 3-62 FUEL SYSTEM (DFI) Intake Air Pressure Sensor #1 (Service Code 12) Intake Air Pressure Sensor #1 Circuit 1. ECU 2. Intake Air Pressure Sensor #1 3. Intake Air Pressure Sensor #2 4. Joint Connector I 5. Joint Connector J...
  • Page 155: Intake Air Temperature Sensor (service Code 13)

    FUEL SYSTEM (DFI) 3-63 Intake Air Temperature Sensor (Service Code 13) Intake Air Temperature Sensor Removal NOTICE Never drop the intake air temperature sensor espe- cially on a hard surface. Such a shock to the sensor can damage it. • Remove: Fuel Tank (see Fuel Tank Removal) Heat Insulation Cover (see Throttle Body Assy Removal)
  • Page 156: Intake Air Temperature Sensor Resistance Inspection

    3-64 FUEL SYSTEM (DFI) Intake Air Temperature Sensor (Service Code 13) • Turn the ignition switch to OFF. If the reading is within the standard, check the ECU for its ground, and power supply (see ECU Power Supply Inspection). If the ground and power supply are good, replace the ECU (see ECU Removal/Installation).
  • Page 157 FUEL SYSTEM (DFI) 3-65 Intake Air Temperature Sensor (Service Code 13) Intake Air Temperature Sensor Circuit 1. ECU 2. Intake Air Temperature Sensor...
  • Page 158: Water Temperature Sensor (service Code 14)

    3-66 FUEL SYSTEM (DFI) 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. • Remove the throttle body assy (see Throttle Body Assy Removal).
  • Page 159: Water Temperature Sensor Resistance Inspection

    FUEL SYSTEM (DFI) 3-67 Water Temperature Sensor (Service Code 14) • Turn the ignition switch to OFF. If the reading is within the standard, check the ECU for its ground, and power supply (see ECU Power Supply Inspection). If the ground and power supply are good, replace the ECU (see ECU Removal/Installation).
  • Page 160: Intake Air Pressure Sensor #2 (service Code 16)

    3-68 FUEL SYSTEM (DFI) Intake Air Pressure Sensor #2 (Service Code 16) Intake Air Pressure Sensor #2 Removal NOTICE Never drop the intake air pressure sensor #2 espe- cially on a hard surface. Such a shock to the sensor can damage it. •...
  • Page 161: Intake Air Pressure Sensor #2 Input Voltage Inspection

    FUEL SYSTEM (DFI) 3-69 Intake Air Pressure Sensor #2 (Service Code 16) Intake Air Pressure Sensor #2 Input Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch to OFF. • Remove the throttle body assy (see Throttle Body Assy Removal).
  • Page 162: Intake Air Pressure Sensor #2 Output Voltage Inspection

    3-70 FUEL SYSTEM (DFI) Intake Air Pressure Sensor #2 (Service Code 16) Intake Air Pressure Sensor #2 Output Voltage Inspection • Measure the output voltage at the intake air pressure sen- sor #2 in the same way as input voltage inspection, note the following.
  • Page 163 FUEL SYSTEM (DFI) 3-71 Intake Air Pressure Sensor #2 (Service Code 16) Intake Air Pressure Sensor #2 Circuit 1. ECU 2. Intake Air Pressure Sensor #1 3. Intake Air Pressure Sensor #2 4. Joint Connector I 5. Joint Connector J...
  • Page 164: Crankshaft Sensor (service Code 21)

    3-72 FUEL SYSTEM (DFI) 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 165: Rear Wheel Rotation Sensor Signal (service Code 24)

    FUEL SYSTEM (DFI) 3-73 Rear Wheel Rotation Sensor Signal (Service Code 24) Rear Wheel Rotation Sensor Signal Inspection ○ The rear wheel rotation sensor sends the signal to the ECU through the ABS hydraulic unit (ABS equipped mod- els). For other than ABS equipped models, the signal is sent directly to the ECU.
  • Page 166 3-74 FUEL SYSTEM (DFI) Rear Wheel Rotation Sensor Signal (Service Code 24) If the wiring is good, check the ECU for its ground and power supply (see ECU Power Supply Inspection). If the ground and power supply are good, replace the ECU (see ECU Removal/Installation).
  • Page 167: Gear Position Switch (service Code 25)

    FUEL SYSTEM (DFI) 3-75 Gear Position Switch (Service Code 25) Gear Position Switch Removal/Installation • Refer to the Gear Position Switch Removal/Installation in the Electrical System chapter. Gear Position Switch Resistance Inspection • Refer to the Gear Position Switch Inspection in the Elec- trical System chapter.
  • Page 168 3-76 FUEL SYSTEM (DFI) Gear Position Switch (Service Code 25) • Turn the ignition switch to OFF. If the reading is out of the standard, check the wiring for continuity, using the wiring diagram in this section. Special Tool - Hand Tester: 57001-1394 If the wiring is good, check the ECU for its ground and power supply (see ECU Power Supply Inspection).
  • Page 169: Front Wheel Rotation Sensor Signal (service Code 27)

    FUEL SYSTEM (DFI) 3-77 Front Wheel Rotation Sensor Signal (Service Code 27) Front Wheel Rotation Sensor Signal Inspection ○ The front wheel rotation sensor sends the signal to the ECU through the ABS hydraulic unit (ABS equipped mod- els). For other than ABS equipped models, the signal is sent directly to the ECU.
  • Page 170 3-78 FUEL SYSTEM (DFI) Front Wheel Rotation Sensor Signal (Service Code 27) If the wiring is good, check the ECU for its ground and power supply (see ECU Power Supply Inspection). If the ground and power supply are good, replace the ECU (see ECU Removal/Installation).
  • Page 171: Vehicle-down Sensor (service Code 31)

    FUEL SYSTEM (DFI) 3-79 Vehicle-down Sensor (Service Code 31) This sensor has a weight [A] with two magnets inside, and sends a signal to the ECU. But when the motorcycle banks 60 ∼ 70° or more to either side (in fact falls down), the weight turns and the signal changes.
  • Page 172: Vehicle-down Sensor Input Voltage Inspection

    3-80 FUEL SYSTEM (DFI) Vehicle-down Sensor (Service Code 31) • The UP mark [A] of the sensor should face upward. WARNING Incorrect installation of the vehicle-down sensor could cause sudden loss of engine power. The rider could lose balance during certain riding situ- ations for an accident resulting in injury or death.
  • Page 173: Vehicle-down Sensor Output Voltage Inspection

    FUEL SYSTEM (DFI) 3-81 Vehicle-down Sensor (Service Code 31) 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 174 3-82 FUEL SYSTEM (DFI) Vehicle-down Sensor (Service Code 31) • Hold the sensor vertically. • Measure the output voltage with the engine stopped, and with the connector joined. • Turn the ignition switch to ON. • Tilt the sensor 60 ∼ 70° or more [A] right or left, then hold the sensor almost vertical with the arrow mark pointed up [B], and measure the output voltage.
  • Page 175 FUEL SYSTEM (DFI) 3-83 Vehicle-down Sensor (Service Code 31) Vehicle-down Sensor Circuit 1. ECU 2. Vehicle-down Sensor...
  • Page 176: Subthrottle Sensor (service Code 32)

    3-84 FUEL SYSTEM (DFI) Subthrottle Sensor (Service Code 32) The subthrottle sensor is a rotating variable resistor that change output voltage according to throttle operating. The ECU senses this voltage change and determines fuel injec- tion quantity, and ignition timing according to engine rpm, and throttle opening.
  • Page 177: Subthrottle Sensor Output Voltage Inspection

    FUEL SYSTEM (DFI) 3-85 Subthrottle Sensor (Service Code 32) If the reading is out of the standard, remove the ECU and check the wiring for continuity between harness connec- tors. Special Tool - Hand Tester: 57001-1394 ○ Disconnect the ECU and sensor connectors. Wiring Continuity Inspection ECU Connector [A] ←→...
  • Page 178 3-86 FUEL SYSTEM (DFI) Subthrottle Sensor (Service Code 32) • Measure the output voltage with the engine stopped with the connector joined. • Turn the ignition switch to ON. • Measure the output voltage when the subthrottle valves are fully opened by hand. Output Voltage DC 4.14 ∼...
  • Page 179: Subthrottle Sensor Resistance Inspection

    FUEL SYSTEM (DFI) 3-87 Subthrottle Sensor (Service Code 32) Subthrottle Sensor Resistance Inspection • Turn the ignition switch to OFF. • Disconnect the subthrottle sensor connector. • Connect a digital meter [A] to the subthrottle sensor con- nector [B]. • Measure the subthrottle sensor resistance.
  • Page 180: Oxygen Sensor - Not Activated (service Code 33, Equipped Models)

    3-88 FUEL SYSTEM (DFI) Oxygen Sensor - not activated (Service Code 33, Equipped Models) Oxygen Sensor Removal/Installation • Refer to the Oxygen Sensor Removal/Installation (Equipped Models) in the Electrical System chapter. Oxygen Sensor Inspection • Remove: Right Middle Fairing (see Middle Fairing Removal in the Frame chapter) Oxygen Sensor Lead Connector [A] •...
  • Page 181 FUEL SYSTEM (DFI) 3-89 Oxygen Sensor - not activated (Service Code 33, Equipped Models) • Install the suitable plugs [A] on the fitting of the air suction valve covers, and shut off the secondary air. • Warm up the engine thoroughly until the radiator fan starts.
  • Page 182 3-90 FUEL SYSTEM (DFI) Oxygen Sensor - not activated (Service Code 33, Equipped Models) Oxygen Sensor Circuit 1. ECU 2. Frame Ground 3. Battery 4. Starter Relay 5. Main Fuse 30 A 6. ECU Fuse 15 A 7. Frame Ground 1 8.
  • Page 183: Immobilizer Amplifier (service Code 35, Equipped Models)

    FUEL SYSTEM (DFI) 3-91 Immobilizer Amplifier (Service Code 35, Equipped Models) Antenna Resistance Inspection • Turn the ignition switch to OFF. • Remove the left inner cover (see Inner Cover Removal in the Frame chapter). • Disconnect the antenna lead connector [A]. •...
  • Page 184: Blank Key Detection (service Code 36, Equipped Models)

    If the service code 36 appears again, the transponder in the key is malfunction, replace it. Immobilizer System Circuit 1. ECU 6. Main Fuse 30 A 13. Water Temperature/Bat- 2. Immobilizer/Kawasaki 7. Frame Ground 2 tery/Immobilizer Warning In- 8. Joint Connector D Diagnostic System dicator Light (LED) Connector 9.
  • Page 185: Ecu Communication Error (service Code 39)

    FUEL SYSTEM (DFI) 3-93 ECU Communication Error (Service Code 39) ECU Communication Line Inspection ○ When the data is not sent from the ECU to the meter unit for more than about 5 seconds, the service code 39 is displayed. ○...
  • Page 186 3-94 FUEL SYSTEM (DFI) ECU Communication Error (Service Code 39) ECU Communication Line Circuit 1. ECU 2. Joint Connector D 3. Joint Connector C 4. Meter Unit 5. Yellow Engine Warning Indicator Light (LED) 6. Yellow KTRC Warning Indicator Light (LED)
  • Page 187: Fuel Pump Relay (service Code 46)

    FUEL SYSTEM (DFI) 3-95 Fuel Pump Relay (Service Code 46) Fuel Pump Relay Removal/Installation ○ The fuel pump relay is built in the relay box [A]. • Refer to the Relay Box Removal in the Electrical System chapter. Fuel Pump Relay Inspection •...
  • Page 188: Stick Coils #1, #2, #3, #4: (service Code 51, 52, 53, 54)

    3-96 FUEL SYSTEM (DFI) Stick Coils #1, #2, #3, #4: (Service Code 51, 52, 53, 54) Stick Coil #1: Service Code 51 Stick Coil #2: Service Code 52 Stick Coil #3: Service Code 53 Stick Coil #4: Service Code 54 Stick Coil Removal/Installation •...
  • Page 189 FUEL SYSTEM (DFI) 3-97 Stick Coils #1, #2, #3, #4: (Service Code 51, 52, 53, 54) • Turn the ignition switch to OFF. If the input voltage is out of the standard, check the wiring for continuity (see Stick Coil Circuit). Special Tool - Hand Tester: 57001-1394 If the wiring is good, check the ECU for its ground and power supply (see ECU Power Supply Inspection).
  • Page 190: Radiator Fan Relay (service Code 56)

    3-98 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 191: Subthrottle Valve Actuator (service Code 62)

    FUEL SYSTEM (DFI) 3-99 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 192: Subthrottle Valve Actuator Input Voltage Inspection

    3-100 FUEL SYSTEM (DFI) Subthrottle Valve Actuator (Service Code 62) Subthrottle Valve Actuator Input Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch to OFF. • Remove the throttle body assy (see Throttle Body Assy Removal).
  • Page 193 FUEL SYSTEM (DFI) 3-101 Subthrottle Valve Actuator (Service Code 62) If the reading is out of the specification, remove the ECU and check the wiring for continuity between harness con- nector. Special Tool - Hand Tester: 57001-1394 ○ Disconnect the ECU and actuator connectors. Wiring Continuity Inspection ECU Connector [A] ←→...
  • Page 194: Air Switching Valve (service Code 64)

    3-102 FUEL SYSTEM (DFI) 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 195: Oxygen Sensor Heater (service Code 67, Equipped Models)

    FUEL SYSTEM (DFI) 3-103 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 (Equipped Mod- els) in the Electrical System chapter).
  • Page 196: Oxygen Sensor Heater Power Source Voltage Inspection

    3-104 FUEL SYSTEM (DFI) Oxygen Sensor Heater (Service Code 67, Equipped Models) Oxygen Sensor Heater Power Source Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch to OFF. • Remove the right middle fairing (see Middle Fairing Re- moval in the Frame chapter).
  • Page 197 FUEL SYSTEM (DFI) 3-105 Oxygen Sensor Heater (Service Code 67, Equipped Models) Oxygen Sensor Circuit 1. ECU 2. Frame Ground 3. Battery 4. Starter Relay 5. Main Fuse 30 A 6. ECU Fuse 15 A 7. Frame Ground 1 8. Relay Box 9.
  • Page 198: Idle Speed Control Valve Actuator (service Code 1c)

    3-106 FUEL SYSTEM (DFI) Idle Speed Control Valve Actuator (Service Code 1C) Idle Speed Control Valve Actuator Removal NOTICE Never drop the idle speed control valve actuator es- pecially on a hard surface. Such a shock to the ac- tuator can damage it. •...
  • Page 199: Idle Speed Control Valve Actuator Input Voltage Inspection

    FUEL SYSTEM (DFI) 3-107 Idle Speed Control Valve Actuator (Service Code 1C) • Connect a digital meter to the idle speed control valve actuator [A]. • Measure the idle speed control valve actuator resistance. Idle Speed Control Valve Actuator Resistance G/Y lead [1] ←→...
  • Page 200 3-108 FUEL SYSTEM (DFI) Idle Speed Control Valve Actuator (Service Code 1C) If the reading is out of the specification, remove the ECU and check the wiring for continuity between main harness connector. Special Tool - Hand Tester: 57001-1394 ○ Disconnect the ECU and actuator connectors.
  • Page 201: Purge Valve (service Code 3a) (cal And Sea-b1 Models)

    FUEL SYSTEM (DFI) 3-109 Purge Valve (Service Code 3A) (CAL and SEA-B1 Models) Purge Valve Removal/Installation • Remove: Right Middle Fairing (see Middle Fairing Removal in the Frame chapter) Purge Valve Connector [A] (Disconnect) Tubes [B] (Disconnect) Bolt [C] Purge Valve [D] •...
  • Page 202 3-110 FUEL SYSTEM (DFI) Purge Valve (Service Code 3A) (CAL and SEA-B1 Models) • 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 203: Warning Indicator Light (led)

    FUEL SYSTEM (DFI) 3-111 Warning Indicator Light (LED) Yellow Engine Warning/Yellow KTRC Warning/Red Warning Indicator Light (LED) Inspection Yellow Engine Warning Indicator Light (LED) [A] Yellow KTRC Warning Indicator Light (LED) [B] Red Warning Indicator Light (LED) [C] ○ In this model, the above mentioned warning indicator lights (LED) go on or blink by the data sent from the ECU.
  • Page 204: Ecu

    3-112 FUEL SYSTEM (DFI) 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 Specification...
  • Page 205: Ecu Installation

    • Pull out the following connectors from the connector holder [A]. Immobilizer (Equipped Models)/Kawasaki Diagnostic System Connector [B] ABS Kawasaki Self-diagnosis System Connector [C] (Equipped Models) • Remove the connector holder. • Remove the relay box [D] from the rubber protector [E].
  • Page 206: Ecu Power Supply Inspection

    3-114 FUEL SYSTEM (DFI) ECU Power Supply Inspection • Remove the tool kit case (see ECU Removal). • Visually inspect the ECU connectors. If the connector is clogged with mud or dust, blow it off with compressed air. • Remove the ECU (see ECU Removal). •...
  • Page 207 FUEL SYSTEM (DFI) 3-115 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 (gray) [B] with the needle adapter set.
  • Page 208 3-116 FUEL SYSTEM (DFI) ECU Power Source Circuit 1. Ignition Switch 2. Joint Connector E 3. ECU 4. Frame Ground 5. Battery 6. Starter Relay 7. Main Fuse 30 A 8. ECU Fuse 15 A 9. Frame Ground 3 10. Frame Ground 2 11.
  • Page 209: Can Communication Line

    FUEL SYSTEM (DFI) 3-117 CAN Communication Line CAN Communication Line Resistance Inspection ○ In this model, resistors for CAN communication line are built in the ECU [A] and meter unit. • Refer to the Meter Unit Inspection in the Electrical System chapter for the resistor in the meter unit.
  • Page 210 3-118 FUEL SYSTEM (DFI) CAN Communication Line CAN Communication Line Circuit 1. Meter Unit 2. Joint Connector C 3. Joint Connector D 4. ECU 5. Immobilizer (Equipped Models)/Kawasaki Diagnostic System Connector...
  • Page 211: Dfi Power Source

    FUEL SYSTEM (DFI) 3-119 DFI Power Source ECU Fuse Removal • Refer to the 30 A Main/15 A ECU Fuse Removal in the Electrical System chapter. ECU Fuse Installation If a fuse fails during operation, inspect the DFI system to determine the cause, and then replace it with a new fuse of proper amperage.
  • Page 212: Fuel Line

    3-120 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 fuel outlet pipe of the fuel pump and the delivery pipe of the throttle body assy.
  • Page 213: Fuel Flow Rate Inspection

    FUEL SYSTEM (DFI) 3-121 Fuel Line • Start the engine, and let it idle. • Measure the fuel pressure with the engine idling. Fuel Pressure (with Engine Idling) Standard: 294 kPa (3.0 kgf/cm², 43 psi) NOTE ○ The gauge needle will fluctuate. Read the pressure at the average of the maximum and minimum indications.
  • Page 214 3-122 FUEL SYSTEM (DFI) Fuel Line • Remove the fuel tank bolts (see Fuel Tank Removal). • Open the fuel tank cap [A] to lower the pressure in the tank. • Remove the fuel hose from the fuel pump (see Fuel Tank Removal).
  • Page 215: Fuel Pump

    FUEL SYSTEM (DFI) 3-123 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 216: Fuel Pump Installation

    3-124 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 with a new one. • Check that the fuel pump terminals [A], fuel reserve switch terminal [B] and band [C] are in place.
  • Page 217: Pressure Regulator Removal

    FUEL SYSTEM (DFI) 3-125 Fuel Pump • Disconnect the fuel pump lead connector and connect the measuring adapter [A] between these connectors as shown in the figure. Main Harness [B] Fuel Pump [C] Special Tool - Measuring Adapter: 57001-1700 • Connect a digital meter [D] to the measuring adapter leads.
  • Page 218: Fuel Filter Cleaning

    3-126 FUEL SYSTEM (DFI) Fuel Pump Fuel Filter Cleaning ○ The fuel filter [A] is built into the fuel pump and can not be cleaned or checked. If the fuel filter is suspected of clogging or being damaged, replace it with the fuel pump as a set. Fuel Pump Circuit 1.
  • Page 219: Fuel Injectors

    FUEL SYSTEM (DFI) 3-127 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 and right middle fairings (see Middle Fair- ing Removal in the Frame chapter).
  • Page 220: Fuel Injector Power Source Voltage Inspection

    3-128 FUEL SYSTEM (DFI) Fuel Injectors Fuel Injector Power Source Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch to OFF. • Remove the throttle body assy (see Throttle Body Assy Removal). • Connect the throttle body subharness connector [A] tem- porarily.
  • Page 221: Fuel Injector Output Voltage Inspection

    FUEL SYSTEM (DFI) 3-129 Fuel Injectors Fuel Injector Output Voltage Inspection NOTE ○ Be sure the battery is fully charged. • Turn the ignition switch to OFF. • Remove the ECU (see ECU Removal). ○ Do not disconnect the ECU connector. •...
  • Page 222: Fuel Injector Fuel Line Inspection

    3-130 FUEL SYSTEM (DFI) Fuel Injectors If the reading is out of the specification, remove the ECU and check the wiring for continuity between harness con- nector. Special Tool - Hand Tester: 57001-1394 ○ Disconnect the ECU and injector connector. Wiring Continuity Inspection ECU Connector (Gray) [A] ←→...
  • Page 223 FUEL SYSTEM (DFI) 3-131 Fuel Injectors Fuel Injector Circuit 1. Ignition Switch 2. Engine Stop Switch 3. Fuel Injector #1 4. Fuel Injector #2 5. Fuel Injector #3 6. Fuel Injector #4 7. Joint Connector H 8. Joint Connector E 9.
  • Page 224: Throttle Grip And Cables

    3-132 FUEL SYSTEM (DFI) 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 225: Throttle Body Assy

    FUEL SYSTEM (DFI) 3-133 Throttle Body Assy Idle Speed Inspection • Refer to the Idle Speed Inspection in the Periodic Main- tenance chapter. Throttle Bore Cleaning • Check the throttle bore for cleanliness as follows. ○ Remove the throttle body assy (see Throttle Body Assy Removal).
  • Page 226 3-134 FUEL SYSTEM (DFI) Throttle Body Assy • Disconnect the throttle body subharness connector [A]. • Remove the connector from the connector bracket. ○ Insert the standard tip screwdriver into the connector stopper portion from the right side of motorcycle. •...
  • Page 227 FUEL SYSTEM (DFI) 3-135 Throttle Body Assy • Remove: Screw [A] Intake Air Temperature Sensor [B] Bolts [C] Air Cleaner Caps [D] ○ Do not disconnect the intake air temperature sensor lead connector. • Remove the duct clamps from the ducts [A], and pull out the ducts upward.
  • Page 228: Throttle Body Assy Installation

    3-136 FUEL SYSTEM (DFI) Throttle Body Assy • Loosen the throttle body assy holder clamp bolt [A] on both sides. • Pull out the throttle body assy [B] from the holder. • Disconnect the fuel hose joint from the delivery pipe of the throttle body assy (see Fuel Hose Replacement in the Periodic Maintenance chapter).
  • Page 229 FUEL SYSTEM (DFI) 3-137 Throttle Body Assy • Install the ducts [A] to the throttle body assy as shown in the figure. Front [B] Rear View [C] • Install the duct clamp bolts [A] in the direction as shown in the figure. Front [B] Upside View [C] •...
  • Page 230 3-138 FUEL SYSTEM (DFI) Throttle Body Assy • Install the removed parts (see appropriate chapters). • Run the leads and hoses correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). • Adjust: Throttle Grip Free Play (see Throttle Control System In- spection in the Periodic Maintenance chapter)
  • Page 231: Throttle Body Assy Disassembly

    FUEL SYSTEM (DFI) 3-139 Throttle Body Assy Throttle Body Assy Disassembly 1. Throttle Body Assy 2. Intake Air Pressure Sensor #2 3. Intake Air Pressure Sensor #1 4. Subthrottle Valve Actuator 5. Main Throttle Sensor 6. Subthrottle Sensor 7. Fuel Injectors 8.
  • Page 232: Throttle Body Assy Assembly

    3-140 FUEL SYSTEM (DFI) Throttle Body Assy • Disconnect the main throttle sensor [A] and subthrottle sensor [B] connectors. • Disconnect: Subthrottle Valve Actuator Lead Connector [A] Intake Air Pressure Sensor Connectors [B] • Cut the clamps [C]. • Cut the clamps [A]. •...
  • Page 233 FUEL SYSTEM (DFI) 3-141 Throttle Body Assy • Replace the dust seals [A] with new ones. • Apply engine oil to the new dust seals. • Install the fuel injectors along with the delivery pipe to the throttle body. • Tighten: Torque - Delivery Pipe Mounting Screws: 5.0 N·m (0.51 kgf·m, 44 in·lb)
  • Page 234: Air Cleaner

    3-142 FUEL SYSTEM (DFI) Air Cleaner Air Cleaner Element Removal • Refer to the Air Cleaner Element Replacement in the Pe- riodic Maintenance chapter. Air Cleaner Element Installation • Refer to the Air Cleaner Element Replacement in the Pe- riodic Maintenance chapter. Air Cleaner Element Inspection •...
  • Page 235: Air Line

    FUEL SYSTEM (DFI) 3-143 Air Line Rear Air Intake Duct Removal Left Rear Air Intake Duct • Remove: Left Inner Cover (see Inner Cover Removal in the Frame chapter) Fuel Tank Cover (see Fuel Tank Removal) • Loosen the clamp bolt [A]. •...
  • Page 236: Front And Middle Air Intake Duct Removal

    3-144 FUEL SYSTEM (DFI) Air Line Front and Middle Air Intake Duct Removal • Remove: Upper Fairing (see Upper Fairing Removal in the Frame chapter) Clamp [A] • Open the clamps [B]. • Remove: Outside Temperature Sensor [A] (see Outside Temper- ature Sensor Removal in the Electrical System chapter) Clamp [B] •...
  • Page 237 FUEL SYSTEM (DFI) 3-145 Air Line • Install the air intake duct clamp bolts in the direction as shown in the figure. Bolt Heads [A] Upper Side [B] Left Clamp [C] Right Clamp [D] About 30° [E] Rear View [F] •...
  • Page 238: Fuel Tank

    3-146 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 239 FUEL SYSTEM (DFI) 3-147 Fuel Tank • Open the fuel tank cap [A] to lower the pressure in the tank. ○ During tank removal, keep the tank cap open to release pressure in the tank. This makes fuel spillage less. •...
  • Page 240: Fuel Tank Installation

    3-148 FUEL SYSTEM (DFI) Fuel Tank • For CAL and SEA-B1 models, note the following. NOTICE For CAL and SEA-B1 models, if gasoline, solvent, water or any other liquid enters the canister, the canister’s vapor absorbing capacity is greatly re- duced.
  • Page 241 FUEL SYSTEM (DFI) 3-149 Fuel Tank • When installing the dampers [A] so that the side of it con- tacts the bracket as shown in the figure. • When installing the trim [B], install it align the corner [C] of the bracket. •...
  • Page 242: Fuel Tank And Cap Inspection

    3-150 FUEL SYSTEM (DFI) Fuel Tank • Insert the fuel hose joint [A] straight onto the fuel outlet pipe until the hose joint clicks. • Push [B] the joint lock [C] until the hose joint clicks. • Push and pull [A] the hose joint [B] back and forth more than two times and make sure it is locked and doesn’t come off.
  • Page 243: Fuel Tank Cleaning

    FUEL SYSTEM (DFI) 3-151 Fuel Tank Fuel Tank Cleaning WARNING Gasoline and low flash-point solvents can be flammable and/or explosive and cause severe burns. Clean the tank in a well-ventilated area, and take care that there are no sparks or flame any- where near the working area.
  • Page 244: Evaporative Emission Control System (cal And Sea-b1 Models)

    3-152 FUEL SYSTEM (DFI) Evaporative Emission Control System (CAL and SEA-B1 Models) The Evaporative Emission Control System routes fuel va- pors from the fuel system into the running engine or stores the vapors in a canister when the engine is stopped. Al- though no adjustments are required, a thorough visual in- spection must be made at the intervals specified by the Pe- riodic Maintenance Chart.
  • Page 245 COOLING SYSTEM 4-1 Cooling System Table of Contents Exploded View........................Coolant Flow Chart......................... Specifications ......................... Sealant ........................... Coolant ........................... Coolant Deterioration Inspection..................Coolant Level Inspection....................Coolant Draining ....................... Coolant Filling ........................Pressure Testing ....................... Cooling System Flushing ....................Coolant Reserve Tank Removal/Installation ..............Water Pump..........................
  • Page 246: Exploded View

    4-2 COOLING SYSTEM Exploded View...
  • Page 247 COOLING SYSTEM 4-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Water Hose Clamp Screws 0.31 27 in·lb Coolant Fitting Bolts 0.90 78 in·lb Thermostat Housing Mounting Bolts 87 in·lb Thermostat Housing Cover Bolts 0.60 52 in·lb Oil Cooler Mounting Bolts 106 in·lb Cylinder Fitting Mounting Bolts 87 in·lb...
  • Page 248: Coolant Flow Chart

    4-4 COOLING SYSTEM Coolant Flow Chart...
  • Page 249: Cooling System

    COOLING SYSTEM 4-5 Coolant Flow Chart 1. Thermostat Housing 2. Cylinder Jacket 3. Air Bleeder Hose for Water Pump 4. Cylinder Head Jacket 5. Air Bleeder Hose for Thermostat Housing 6. Reserve Tank Hose 7. Radiator Cap 8. Radiator 9. Radiator Fan 10.
  • Page 250: 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 251: Sealant

    COOLING SYSTEM 4-7 Sealant Liquid Gasket, TB1211F: 92104-0004...
  • Page 252: Coolant

    4-8 COOLING SYSTEM Coolant Coolant Deterioration Inspection • Visually inspect the coolant in the reserve tank. If whitish cotton-like wafts are observed, aluminum parts in the cooling system are corroded. If the coolant is brown, iron or steel parts are rusting. In either case, flush the cooling system.
  • Page 253: Cooling System Flushing

    COOLING SYSTEM 4-9 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 254: Water Pump

    4-10 COOLING SYSTEM Water Pump Water Pump Removal • Remove: Coolant (Drain, see Coolant Change in the Periodic Maintenance chapter) Engine Oil (Drain, see Engine Oil Change in the Periodic Maintenance chapter) Clutch Slave Cylinder (see Clutch Slave Cylinder Re- moval in the Clutch chapter) Engine Sprocket Cover (see Engine Sprocket Removal in the Final Drive chapter)
  • Page 255: Water Pump Inspection

    COOLING SYSTEM 4-11 Water Pump • Turn the water pump shaft so that the slot [A] in its shaft fits onto the projection [B] of the oil pump drive gear shaft. • Install the water hose [A] and hose clamp [B] as shown in the figure.
  • Page 256: Radiator

    4-12 COOLING SYSTEM Radiator Radiator and Radiator Fan Removal • Remove: Middle Fairings (see Middle Fairing Removal in the Frame chapter) Coolant (Drain, see Coolant Change in the Periodic Maintenance chapter) Right Radiator Fan Motor Lead Connector [A] (Discon- nect) Clamp [B] Quick Rivet [C] •...
  • Page 257: Radiator And Radiator Fan Installation

    COOLING SYSTEM 4-13 Radiator • Remove: Radiator Fan Mounting Bolts [A] Left Side Radiator Fan Assy [B] Right Side Radiator Fan Assy [C] Radiator and Radiator Fan Installation • Run the radiator fan motor lead correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). •...
  • Page 258: Radiator Cap Inspection

    4-14 COOLING SYSTEM Radiator NOTICE When cleaning the radiator with steam cleaner, be careful of the following to prevent radiator damage: Keep the steam gun [A] away more than 0.5 m (1.6 ft) [B] from the radiator core. Hold the steam gun perpendicular [C] (not oblique [D]) to the core surface.
  • Page 259: Radiator Cover Removal

    COOLING SYSTEM 4-15 Radiator Radiator Cover Removal • Remove: Radiator (see Radiator and Radiator Fan Removal) • Clear the inner rubber cover [A] from the hook [B] of the radiator cover [C] (Both Sides). • Remove: Clamp [A] Quick Rivets [B] Radiator Cover [C] Radiator Cover Installation •...
  • Page 260: Thermostat

    4-16 COOLING SYSTEM Thermostat Thermostat Removal • Remove: Coolant (Drain, see Coolant Change in the Periodic Maintenance chapter) Clamp Screw (Loosen) and Water Hose [A] Thermostat Housing Cover Bolts [B] and Clamp [C] Thermostat Housing Cover [D] Thermostat Thermostat Installation •...
  • Page 261 COOLING SYSTEM 4-17 Thermostat • To check valve opening temperature, suspend the ther- mostat [A] in a container of water and raise the tempera- ture of the water. ○ The thermostat must be completely submerged and must not touch the container sides or bottom. Suspend an ac- curate thermometer [B] in the water so that the heat sen- sitive portions [C] are located in almost the same depth.
  • Page 262: Hoses And Pipes

    4-18 COOLING SYSTEM Hoses and Pipes Hose Installation • Apply soap and water solution to the inside of the water hoses before installation. • Install the hoses and pipes, being careful to follow bend- ing direction. Avoid sharp bending, kinking, flattening or twisting.
  • Page 263: Water Temperature Sensor

    COOLING SYSTEM 4-19 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 • Refer to the Water Temperature Sensor Removal/Instal- lation in the Fuel System (DFI) chapter.
  • Page 265 ENGINE TOP END 5-1 Engine Top End Table of Contents Exploded View........................Exhaust System........................Specifications ......................... Special Tools and Sealants ....................Clean Air System........................5-11 Air Suction Valve Removal....................5-11 Air Suction Valve Installation..................... 5-11 Air Suction Valve Inspection ..................... 5-12 Air Switching Valve Removal ....................
  • Page 266: Exploded View

    5-2 ENGINE TOP END Exploded View...
  • Page 267: Engine Top End

    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 Camshaft Sprocket Mounting Bolts Front Camshaft Chain Guide Bolt (Upper) Front Camshaft Chain Guide Bolt (Lower) 106 in·lb Engine Bracket Bolts (M8) R, S...
  • Page 268 5-4 ENGINE TOP END Exploded View...
  • Page 269 ENGINE TOP END 5-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Muffler Body Mounting Bolts R: Replacement Parts S: Follow the specified tightening sequence.
  • Page 270: Exhaust System

    5-6 ENGINE TOP END Exhaust System Exhaust System Manifold Mark Position [A] Muffler Body Mark Position [A]...
  • Page 271 ENGINE TOP END 5-7 Exhaust System Manifold [A] with Hole [B] for Oxygen Sensor [C] Honeycomb Type Catalyst Positions [A] Left Muffler Body [B] Right Muffler Body [C] Manifold [D]...
  • Page 272: Specifications

    5-8 ENGINE TOP END Specifications Item Standard Service Limit Camshafts Cam Height: 35.243 ∼ 35.357 mm (1.3875 ∼ 1.3920 in.) Exhaust 35.14 mm (1.383 in.) 35.243 ∼ 35.357 mm (1.3875 ∼ 1.3920 in.) Intake 35.14 mm (1.383 in.) 0.038 ∼ 0.081 mm (0.0015 ∼ 0.0032 in.) Camshaft Journal, Camshaft 0.17 mm (0.0067 in.) Cap Clearance...
  • Page 273: Special Tools And Sealants

    ENGINE TOP END 5-9 Special Tools and Sealants Compression Gauge, 20 kgf/cm²: Valve Seat Cutter, 60° - 30: 57001-221 57001-1123 Valve Spring Compressor Assembly: Valve Seat Cutter Holder Bar: 57001-241 57001-1128 Valve Seat Cutter, 45° - 35: Valve Seat Cutter, 45° - 30: 57001-1116 57001-1187 Valve Seat Cutter, 32°...
  • Page 274 5-10 ENGINE TOP END Special Tools and Sealants Valve Seat Cutter Holder, 5: L-Shape Hose: 57001-1208 57001-1606 Valve Seat Cutter, 60° - 33: Valve Guide Driver Attachment, E: 57001-1334 57001-1677 Valve Guide Driver: Liquid Gasket, TB1211F: 57001-1564 92104-0004 Valve Spring Compressor Adapter, 24: Liquid Gasket, TB1216B: 57001-1586 92104-1064...
  • Page 275: Clean Air System

    ENGINE TOP END 5-11 Clean Air System Air Suction Valve Removal • Remove: Middle Fairings (see Middle Fairing Removal in the Frame chapter) Air Switching Valve (see Air Switching Valve Removal) Bolt [A] • Remove: Bolts [A] • Remove: Air Suction Valve Cover Bolts [A] Air Suction Valve Covers [B] Air Suction Valves [C] Air Suction Valve Installation...
  • Page 276: Air Suction Valve Inspection

    5-12 ENGINE TOP END Clean Air System Air Suction Valve Inspection • Remove the air suction valve (see Air Suction Valve Re- moval). • Visually inspect the reeds [A] for cracks, folds, warps, heat damage or other damage. If there is any doubt as to the condition of the reeds, re- place the air suction valve as an assembly.
  • Page 277: Air Switching Valve Installation

    ENGINE TOP END 5-13 Clean Air System Air Switching Valve Installation • Install the air switching valve [A] with hoses [B] as shown in the figure. Front [C] Right Side View [D] White Paint [E] • Run the hoses correctly (see Cable, Wire, and Hose Rout- ing section in the Appendix chapter).
  • Page 278: Cylinder Head Cover

    5-14 ENGINE TOP END Cylinder Head Cover Cylinder Head Cover Removal • Remove: Middle Fairings (see Middle Fairing Removal in the Frame chapter) Throttle Body Assy (see Throttle Body Assy Removal in the Fuel System (DFI) chapter) Air Switching Valve (see Air Switching Valve Removal) Radiator Cover (see Radiator Cover Removal in the Cooling System chapter) Stick Coils (see Stick Coil Removal in the Electrical Sys-...
  • Page 279 ENGINE TOP END 5-15 Cylinder Head Cover • Install the cylinder head cover. • Install the rubber washers [A] with the metal side faces upward. • Tighten the cover bolts following the specified tightening sequence. Torque - Cylinder Head Cover Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) •...
  • Page 280: Camshaft Chain Tensioner

    5-16 ENGINE TOP END Camshaft Chain Tensioner Camshaft Chain Tensioner Removal NOTICE Do not turn over the crankshaft while the tensioner is removed. This could upset the camshaft chain timing, and damage the valves. • Remove: Right Middle Fairing (see Middle Fairing Removal in the Frame chapter) Camshaft Chain Tensioner Mounting Bolts [A] Camshaft Chain Tensioner [B]...
  • Page 281 ENGINE TOP END 5-17 Camshaft Chain Tensioner • Replace the gasket [A] with a new one. • Install the tensioner body so that the plug [B] faces up- ward. • Tighten: Torque - Camshaft Chain Tensioner Mounting Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) •...
  • Page 282: Camshaft, Camshaft Chain

    5-18 ENGINE TOP END Camshaft, Camshaft Chain Camshaft Removal • Remove: Cylinder Head Cover (see Cylinder Head Cover Re- moval) Crankshaft Sensor Cover (see Crankshaft Sensor Re- moval in the Electrical System chapter) • Using a wrench on the timing rotor bolt [A], turn the crank- shaft clockwise until the line [B] (TDC mark for #1,4 pis- tons) on the timing rotor [C] is aligned with the mating sur- face [D] of the crankcase.
  • Page 283: Camshaft Installation

    ENGINE TOP END 5-19 Camshaft, Camshaft Chain • Remove: Camshaft Sprocket Bolts [A] Camshaft Sprockets NOTICE The crankshaft may be turned while the camshafts are removed. Always pull the chain taut while turn- ing the crankshaft. This avoids kinking the chain on the lower (crankshaft) sprocket.
  • Page 284 5-20 ENGINE TOP END Camshaft, Camshaft Chain • Pull the tension side (exhaust side) [A] of the chain taut to install the chain. • Engage the camshaft chain with the sprockets so that tim- ing marks on the sprockets are positioned as shown in the figure.
  • Page 285 ENGINE TOP END 5-21 Camshaft, Camshaft Chain • Install the ten dowel pins on the marks [A]. • Install the camshaft cap, following the identification No. [B] and upper camshaft chain guide [C]. • First tighten the all camshaft cap bolts evenly to seat the camshaft in place, then tighten all bolts following the spec- ified tightening sequence.
  • Page 286: Camshaft, Camshaft Cap Wear Inspection

    5-22 ENGINE TOP END Camshaft, Camshaft Chain Camshaft, Camshaft Cap Wear Inspection • Remove: Upper Chain Guide (see Camshaft Removal) Camshaft Caps (see Camshaft Removal) • Cut strips of plastigage (press gauge) to journal width. Place a strip on each journal parallel to the camshaft in- stalled in the correct position.
  • Page 287: Cam Wear Inspection

    ENGINE TOP END 5-23 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: 35.243 ∼...
  • Page 288: Cylinder Head

    5-24 ENGINE TOP END Cylinder Head Cylinder Compression Measurement NOTE ○ Use the battery which is fully charged. • Warm up the engine thoroughly. • Stop the engine. • Remove: Spark Plugs (see Spark Plug Replacement in the Peri- odic Maintenance chapter) •...
  • Page 289: Cylinder Head Installation

    ENGINE TOP END 5-25 Cylinder Head • Remove the air bleeder hoses and water hose from the thermostat housing. • Remove: Front Camshaft Chain Guide Bolt (Upper) [A] • Remove: Front Camshaft Chain Guide Bolt (Lower) [A] Collar Front Camshaft Chain Guide [B] Dowel Pin [C] Rear Camshaft Chain Guide [D] •...
  • Page 290 5-26 ENGINE TOP END Cylinder Head • Tighten the M11 cylinder head bolts following the tighten- ing sequence [1 ∼ 10]. ○ First, tighten the bolts specified torque. New Bolts: One Time Used Bolts: Two Times ○ Next, using a angle torque gauge [A], tighten the bolts specified angle.
  • Page 291: Cylinder Head Warp Inspection

    ENGINE TOP END 5-27 Cylinder Head Cylinder Head Warp Inspection • Clean the cylinder head. • Lay a straightedge across the lower surface of the cylinder head at several positions. • Use a thickness gauge [A] to measure the space between the straightedge [B] and the head.
  • Page 292: Valves

    5-28 ENGINE TOP END 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 NOTE ○...
  • Page 293: Valve Guide Installation

    ENGINE TOP END 5-29 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 294: Valve-to-guide Clearance Measurement (wobble Method)

    5-30 ENGINE TOP END Valves Valve-to-Guide Clearance Measurement (Wobble Method) If a small bore gauge is not available, inspect the valve guide wear by measuring the valve to valve guide clearance with the wobble method as indicated below. • Insert a new valve [A] into the guide [B] and set a dial gauge against the stem perpendicular to it as close as possible to the cylinder head mating surface.
  • Page 295: Valve Seat Inspection

    ENGINE TOP END 5-31 Valves Valve Seat Inspection • Remove the valve (see Valve Removal). • Check the valve seating surface [A] between the valve [B] and valve seat [C]. ○ Measure the outside diameter [D] of the seating pattern on the valve seat.
  • Page 296 5-32 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 297 ENGINE TOP END 5-33 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 298 5-34 ENGINE TOP END Valves If the seat width is too wide, make the 60° [A] grind de- scribed below. If the seat width is within the specified range, lap the valve to the seat as described below. • Grind the seat at a 60° angle until the seat width is within the specified range.
  • Page 299 ENGINE TOP END 5-35 Valves...
  • Page 300: Throttle Body Holder

    5-36 ENGINE TOP END Throttle Body Holder Throttle Body Assy Holder Removal • Remove: Throttle Body Assy (see Throttle Body Assy Removal in the Fuel System (DFI) chapter) Clamp [A] Throttle Body Assy Holder Bolts [B] Throttle Body Assy Holders [C] Throttle Body Assy Holder Installation •...
  • Page 301: Muffler

    ENGINE TOP END 5-37 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: Rear Fairing (see Rear Fairing Removal in the Frame chapter) (Equipped Models) Muffler Body Clamp Bolts [A] (Loosen) Bolt [B]...
  • Page 302 5-38 ENGINE TOP END Muffler • Install the muffler body clamps [A] as shown in the figure. ○ Insert the projections [B] into the slots [C]. • Install the muffler bodies [D]. • Replace the nuts [E] with new ones. •...
  • Page 303: Exhaust Pipe Removal

    ENGINE TOP END 5-39 Muffler ○ Fit the dampers [A] of the muffler cover [B] into the slots [C] of the muffler body [D], and tighten the bolts. Exhaust Pipe Removal • Remove: Oxygen Sensor (Equipped Models) (see Oxygen Sen- sor Removal (Equipped Models) in the Electrical System chapter) Radiator (see Radiator and Radiator Fan Removal in the...
  • Page 305 CLUTCH 6-1 Clutch Table of Contents Exploded View........................Specifications ......................... Special Tools and Sealant ...................... Clutch Master Cylinder ......................Clutch Lever Position Adjustment ..................Clutch Master Cylinder Removal ..................Clutch Master Cylinder Installation .................. Clutch Master Cylinder Disassembly ................Clutch Master Cylinder Assembly ..................Clutch Master Cylinder Inspection ..................
  • Page 306: Exploded View

    6-2 CLUTCH Exploded View...
  • Page 307 CLUTCH 6-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Clutch Cover Bolts 87 in·lb L (1) Oil Filler Plug – – – Hand-tighten Clutch Lever Pivot Bolt 0.10 8.9 in·lb Clutch Hose Banjo Bolts Clutch Lever Pivot Bolt Locknut 0.60 52 in·lb Clutch Master Cylinder Bleed Valve...
  • Page 308: Specifications

    6-4 CLUTCH Specifications Item Standard Service Limit Clutch Lever Clutch Lever Position 5-way adjustable (to suit rider) – – – Clutch Lever Free Play Non-adjustable – – – Clutch Fluid Grade DOT4 – – – Clutch Spring Plate Free Play (Usable Range) –...
  • Page 309: Special Tools And Sealant

    CLUTCH 6-5 Special Tools and Sealant Inside Circlip Pliers: Liquid Gasket, TB1211F: 57001-143 92104-0004 Clutch Holder: 57001-1243...
  • Page 310: Clutch Master Cylinder

    6-6 CLUTCH Clutch Master Cylinder Clutch Lever Position Adjustment The clutch lever adjuster has 5 positions so that the clutch lever position can be adjusted to suit the operator’s hand. • Push the lever forward and turn the adjuster [A] to align the number with the arrow mark [B] on the lever.
  • Page 311: Clutch Master Cylinder Disassembly

    CLUTCH 6-7 Clutch Master Cylinder • Align the punch mark [A] on the handlebar with the mating surface [B] of the master cylinder clamp. • Tighten the upper clamp bolt first, and then the lower clamp bolt. There will be a gap at the lower part of the clamp after tightening.
  • Page 312: Clutch Slave Cylinder

    6-8 CLUTCH Clutch Slave Cylinder Clutch Slave Cylinder Removal • Remove: Quick Rivet [A] Bolts [B] and Washers • Free the lower fairing. • Remove: Banjo Bolt [A] Clutch Slave Cylinder Bolts [B] Slave Cylinder [C] NOTICE Immediately wash away any clutch fluid that spills. It may damage painted surfaces.
  • Page 313: Clutch Slave Cylinder Disassembly

    CLUTCH 6-9 Clutch Slave Cylinder • Apply a non-permanent locking agent to the threads of the slave cylinder bolts [A]. • Finger tighten all the clutch slave cylinder bolts. • Remove the band from the clutch lever and release the clutch lever.
  • Page 314: Clutch Fluid

    6-10 CLUTCH Clutch Fluid Clutch Fluid Level Inspection • Refer to the Clutch Fluid Level Inspection in the Periodic Maintenance chapter. Clutch Fluid Change • Refer to the Clutch Fluid Change in the Periodic Mainte- nance chapter. Bleeding the Clutch Line WARNING Air in the clutch lines diminish clutch performance and can cause an accident resulting in injury or...
  • Page 315 CLUTCH 6-11 Clutch Fluid • Bleed the clutch line and the master cylinder. ○ Repeat this operation until no more air can be seen com- ing out into the plastic hose. 1. Pump the clutch lever until it becomes hard, and apply the clutch lever and hold it [A].
  • Page 316: Clutch Hose Removal/installation

    6-12 CLUTCH Clutch Fluid WARNING Mixing brands and types of hydraulic fluid lowers the fluid’s boiling point, cause rubber part to de- teriorate and can reduce the hydraulic clutch sys- tem’s effectiveness and cause an accident resulting in injury or death. Do not mix two brands of brake fluid.
  • Page 317: Clutch Cover

    CLUTCH 6-13 Clutch Cover Clutch Cover Removal • Remove: Engine Oil (Drain, see Engine Oil Change in the Periodic Maintenance chapter) Right Middle Fairing (see Middle Fairing Removal in the Frame chapter) Clutch Cover Bolts [A] Clutch Cover [B] Clutch Cover Installation •...
  • Page 318: Clutch Removal

    6-14 CLUTCH Clutch Clutch Removal • Remove: Right Middle Fairing (see Middle Fairing Removal in the Frame chapter) Clutch Cover (see Clutch Cover Removal) Clutch Spring Bolts [A] with Spring Holder Clutch Springs Clutch Spring Plate [B] (with Thrust Bearing, Pusher [C] and Washer) •...
  • Page 319: Clutch Installation

    CLUTCH 6-15 Clutch Clutch Installation • Install the thrust washer [A] by facing its chamfered side [B] towards the crankcase. • Engage the clutch housing gear [A] and oil pump drive gear [B] with the crankshaft primary gear [C] and oil pump gear [D].
  • Page 320 6-16 CLUTCH Clutch • Replace the clutch hub nut [A] with a new one. • Hold the sub clutch hub [B] steady with the clutch holder [C], and tighten the clutch hub nut. Special Tool - Clutch Holder: 57001-1243 Torque - Clutch Hub Nut: 135 N·m (13.8 kgf·m, 100 ft·lb) •...
  • Page 321: Spring Plate Free Play Measurement

    CLUTCH 6-17 Clutch • Align the wide projections [A] of the spring plate [B] with the wide grooves [C] of the sub clutch hub [D] to install the spring plate on the sub clutch hub. • Install the clutch springs, spring holders, and tighten the clutch spring bolts.
  • Page 322: Spring Plate Free Play Adjustment

    6-18 CLUTCH Clutch Spring Plate Free Play Adjustment NOTE ○ The free play adjustment is performed by replacing the steel plate(s). • Measure the clutch spring plate free play (see Clutch Spring Plate Free Play Measurement), and then replace the steel plate(s) which brings the free play within the usable range.
  • Page 323: Clutch Plate, Wear, Damage Inspection

    CLUTCH 6-19 Clutch Clutch Plate, Wear, 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 324: Clutch Housing Spline Inspection

    6-20 CLUTCH Clutch Clutch Housing Spline Inspection • Visually inspect where the teeth [A] on the steel plates wear against the sub clutch hub splines [B]. If there are notches worn into the splines, replace the sub clutch hub. Also, replace the steel plates if their teeth are damaged.
  • Page 325 ENGINE LUBRICATION SYSTEM 7-1 Engine Lubrication System Table of Contents Exploded View........................Engine Oil Flow Chart......................Specifications ......................... Special Tools and Sealants ....................Engine Oil and Oil Filter......................7-10 Oil Level Inspection......................7-10 Engine Oil Change......................7-10 Oil Filter Replacement ...................... 7-10 Oil Pan............................
  • Page 326: Exploded View

    7-2 ENGINE LUBRICATION SYSTEM Exploded View...
  • Page 327: Engine Lubrication System

    ENGINE LUBRICATION SYSTEM 7-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Oil Pipe Mounting Bolts 87 in·lb Oil Pipe Bolts 87 in·lb Oil Passage Plug (R1/4) Oil Cooler Mounting Bolts 106 in·lb Oil Pump Cover Bolts 87 in·lb Oil Filter G, R Oil Pan Plate Bolts 87 in·lb...
  • Page 328: Engine Oil Flow Chart

    7-4 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart...
  • Page 329 ENGINE LUBRICATION SYSTEM 7-5 Engine Oil Flow Chart 1. Exhaust Camshaft 2. Intake Camshaft 3. Camshaft Oil Passage 4. Camshaft Chain Tensioner 5. Crankshaft Oil Passage 6. Main Oil Passage 7. Oil Pump 8. Oil Screen 9. Oil Pipe 10. Breather Hose for Return 11.
  • Page 330 7-6 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart 1. Oil Jet 2. Oil Cooler 3. from Oil Filter 4. Oil Pipe...
  • Page 331 ENGINE LUBRICATION SYSTEM 7-7 Engine Oil Flow Chart...
  • Page 332: Specifications

    7-8 ENGINE LUBRICATION SYSTEM Specifications Item Standard Engine Oil Type API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2 Viscosity SAE 10W-40 Capacity 3.8 L (4.0 US qt) (when filter is not removed) 4.2 L (4.4 US qt) (when filter is removed) 4.6 L (4.9 US qt) (when engine is completely dry) Between upper and lower level lines (Wait 2 ∼...
  • Page 333: Special Tools And Sealants

    ENGINE LUBRICATION SYSTEM 7-9 Special Tools and Sealants Oil Pressure Gauge, 10 kgf/cm²: Liquid Gasket, TB1211: 57001-164 56019-120 Oil Pressure Gauge Adapter, PT3/8: 57001-1233...
  • Page 334: Engine Oil And Oil Filter

    7-10 ENGINE LUBRICATION SYSTEM 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 335: Oil Pan

    ENGINE LUBRICATION SYSTEM 7-11 Oil Pan Oil Pan Removal • Remove: Engine Oil (Drain, see Engine Oil Change in the Periodic Maintenance chapter) Muffler Bodies (see Muffler Body Removal/Installation in the Engine Top End chapter) Exhaust Pipe (see Exhaust Pipe Removal in the Engine Top End chapter) Oil Pressure Switch Terminal [A] (Disconnect) Oil Filter [B] (see Oil Filter Replacement in the Periodic...
  • Page 336: Oil Pan Installation

    7-12 ENGINE LUBRICATION SYSTEM Oil Pan Oil Pan Installation • Install the oil pressure relief valve (see Oil Pressure Relief Valve Installation). • Replace the O-ring with a new one. • Clean the oil screen [A]. • Install the oil screen so that the crankcase rib [B] fits the notch [C] of the oil screen.
  • Page 337: Oil Pressure Relief Valve

    ENGINE LUBRICATION SYSTEM 7-13 Oil Pressure Relief Valve Oil Pressure Relief Valve Removal • Remove: Oil Pan (see Oil Pan Removal) Oil Pipe (see Oil Pan Removal) • Hold the pipe [A] in a vise [B]. • Remove the oil pressure relief valve [C]. Oil Pressure Relief Valve Installation •...
  • Page 338: Oil Pump

    7-14 ENGINE LUBRICATION SYSTEM Oil Pump Oil Pump Removal • Remove: Coolant (Drain, see Coolant Change in the Periodic Maintenance chapter) Engine Oil (Drain, see Engine Oil Change in the Periodic Maintenance chapter) Clutch (see Clutch Removal in the Clutch chapter) •...
  • Page 339 ENGINE LUBRICATION SYSTEM 7-15 Oil Pump • Install the oil pump drive gear shaft with inner rotor. ○ Turn the oil pump drive gear shaft so that the projection in its shaft fits onto the slot of the water pump shaft. ○...
  • Page 340: Oil Cooler

    7-16 ENGINE LUBRICATION SYSTEM Oil Cooler Oil Cooler Removal • Remove: Coolant (Drain, see Coolant Change in the Periodic Maintenance chapter) Engine Oil (Drain, see Engine Oil Change in the Periodic Maintenance chapter) Exhaust Pipe (see Exhaust Pipe Removal in the Engine Top End chapter) Oil Pipe Bolt [A] •...
  • Page 341: Oil Pressure Measurement

    ENGINE LUBRICATION SYSTEM 7-17 Oil Pressure Measurement Oil Pressure Measurement • Remove the left middle fairing (see Middle Fairing Re- moval in the Frame chapter). • Remove the oil passage plug, and attach the adapter [A] and gauge [B] to the plug hole. Special Tools - Oil Pressure Gauge, 10 kgf/cm²: 57001-164 Oil Pressure Gauge Adapter, PT3/8: 57001 -1233...
  • Page 342: Oil Pressure Switch

    7-18 ENGINE LUBRICATION SYSTEM Oil Pressure Switch Oil Pressure Switch Removal • Remove: Engine Oil (Drain, see Engine Oil Change in the Periodic Maintenance chapter) Left Middle Fairing (see Middle Fairing Removal in the Frame chapter) Rubber Boot [A] Switch Terminal Bolt [B] Oil Pressure Switch [C] Oil Pressure Switch Installation •...
  • Page 343: Oil Pipe

    ENGINE LUBRICATION SYSTEM 7-19 Oil pipe Oil Pipe Removal • Remove: Engine Oil (Drain, see Engine Oil Change in the Periodic Maintenance chapter) Oil Cooler (see Oil Cooler Removal) Oil Pipe Mounting Bolt [A] with washers [B] Oil Pipe [C] •...
  • Page 345 ENGINE REMOVAL/INSTALLATION 8-1 Engine Removal/Installation Table of Contents Exploded View........................Engine Removal/Installation ....................Engine Removal........................ Engine Installation......................
  • Page 346: Exploded View

    8-2 ENGINE REMOVAL/INSTALLATION Exploded View...
  • Page 347 ENGINE REMOVAL/INSTALLATION 8-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Engine Bracket Bolts (M8) R, S Subframe Bolts Front Engine Mounting Bolts (M10) R, S Engine Mounting Nuts (M12) R, S Adjusting Collars M: Apply molybdenum disulfide grease. R: Replacement Parts S: Follow the specified tightening sequence.
  • Page 348: 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 349 ENGINE REMOVAL/INSTALLATION 8-5 Engine Removal/Installation • Remove: Bolts [A] Bolt [B] Subframe Bracket Bolt [C] Subframe Bolts [D] • Remove the subframe [E] with the clutch pipe [F]. • Remove: Throttle Body Subharness Connector [A] (Disconnect) Breather Hose [B] Fuel Hose [C] on the Delivery Pipe Throttle Cable Lower Ends [D] •...
  • Page 350: Engine Installation

    8-6 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Remove the engine sprocket (see Engine Sprocket Re- moval in the Final Drive chapter). • Support the engine with a suitable stand [A]. ○ Put a plank [B] onto the suitable stand for engine balance. •...
  • Page 351 ENGINE REMOVAL/INSTALLATION 8-7 Engine Removal/Installation • Install the engine mounting bolts and nuts, following the specified installing sequence. ○ Apply molybdenum disulfide grease [A] to the threads of the adjusting collars. ○ First, tighten the adjusting collars fully by hand. Upper Adjusting Collar [B] Upper Crankcase [C] Lower Adjusting Collar [D]...
  • Page 352 8-8 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation ○ Fourth, remove the wrench lever and leave the socket head on the engine mounting bolt [A]. Turn the adjust- ing collar [F] counterclockwise with the socket head to grabbed hands until it becomes hard to turn, eliminating a gap [B].
  • Page 353 ENGINE REMOVAL/INSTALLATION 8-9 Engine Removal/Installation ○ Fifth, tighten the left engine bracket bolts [A] and left front engine mounting bolt [B]. ○ Sixth, put alignment marks [C] on upper and lower engine mounting bolt [D] [E] and frame. ○ Replace the engine mounting nuts (M12) [F] [G] with new ones.
  • Page 354 8-10 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation ○ Seventh, install the right engine bracket and tighten the right engine bracket bolts [H] and the right front engine mounting bolt [I]. ○ Tighten: Torque - Engine Bracket Bolts (M8): 25 N·m (2.5 kgf·m, 18 ft·lb) Front Engine Mounting Bolts (M10): 59 N·m (6.0 kgf·m, 44 ft·lb)
  • Page 355 CRANKSHAFT/TRANSMISSION 9-1 Crankshaft/Transmission Table of Contents Exploded View........Front Balancer Installation ... 9-31 Specifications ........Rear Balancer Removal....9-32 Special Tools and Sealants ....Rear Balancer Installation.... 9-33 Crankcase Splitting......9-10 Balancer Adjustment....9-35 Crankcase Splitting ...... 9-10 Balancer Damper Inspection..9-36 Crankcase Assembly ....
  • Page 356: Exploded View

    9-2 CRANKSHAFT/TRANSMISSION Exploded View...
  • Page 357 CRANKSHAFT/TRANSMISSION 9-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Breather Cover Bolts (L = 25 mm) 87 in·lb Breather Cover Bolt (L = 35 mm) 87 in·lb Breather Cover Plate Screws 87 in·lb Oil Nozzle Pipe Mounting Bolts Oil Passage Plugs (R3/8) Bearing Position Plate Screws 0.50 43 in·lb...
  • Page 358 9-4 CRANKSHAFT/TRANSMISSION Exploded View...
  • Page 359 CRANKSHAFT/TRANSMISSION 9-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Balancer Shaft Clamp Bolts 87 in·lb Balancer Shaft Clamp Lever Bolts Shift Drum Cam Holder Bolt 106 in·lb Shift Shaft Return Spring Pin Gear Position Switch Screws 0.30 26 in·lb Gear Positioning Lever Bolt 106 in·lb Torque Limiter Bolt...
  • Page 360: Specifications

    9-6 CRANKSHAFT/TRANSMISSION Specifications Item Standard Service Limit Crankcase, Crankshaft, Connecting Rods – – – Connecting Rod Bend TIR 0.2/100 mm (0.008/3.94 in.) Connecting Rod Twist – – – TIR 0.2/100 mm (0.008/3.94 in.) 0.13 ∼ 0.38 mm Connecting Rod Big End Side Clearance 0.58 mm (0.0051 ∼...
  • Page 361 CRANKSHAFT/TRANSMISSION 9-7 Specifications Item Standard Service Limit ○ 43.000 ∼ 43.008 mm Marking – – – (1.6929 ∼ 1.6932 in.) 43.009 ∼ 41.016 mm None – – – (1.6933 ∼ 1.6935 in.) Crankshaft Main Bearing Insert Thickness: 1.490 ∼ 1.494 mm Brown –...
  • Page 362 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 92139-0131 None None Black 92139-0130 ○ ○ ○ None Blue 92139-0129 Crankshaft Main Bearing Insert Selection Crankcase Main Crankshaft Main Bearing Insert*...
  • Page 363: Special Tools And Sealants

    CRANKSHAFT/TRANSMISSION 9-9 Special Tools and Sealants Bearing Puller: Piston Ring Compressor Grip: 57001-135 57001-1095 Outside Circlip Pliers: Bearing Driver Set: 57001-144 57001-1129 Piston Ring Compressor Belt, 80 ∼ 91: Bearing Puller Adapter: 57001-317 57001-1320 Piston Pin Puller Assembly: Liquid Gasket, TB1216B: 57001-910 92104-1064...
  • Page 364: Crankcase Splitting

    9-10 CRANKSHAFT/TRANSMISSION Crankcase Splitting 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 Head (see Cylinder Head Removal in the En- gine Top End chapter) Clutch (see Clutch Removal in the Clutch chapter) Timing Rotor (see Timing Rotor Removal in the Electrical...
  • Page 365 CRANKSHAFT/TRANSMISSION 9-11 Crankcase Splitting • Remove the upper crankcase bolts. ○ First loosen the M6 bolts. M6 Bolts [A] M7 Bolt [B] M7 Bolt with Clamp [C] M8 Bolts with Washers [D] • Remove the lower crankcase bolts. ○ First loosen the M7 bolts [A]. ○...
  • Page 366: Crankcase Assembly

    9-12 CRANKSHAFT/TRANSMISSION Crankcase Splitting Crankcase Assembly NOTICE The upper and lower crankcase halves are ma- chined at the factory in the assembled state, so the crankcase halves must be replaced as a set. • With a high flash-point solvent, clean off the mating sur- faces of the crankcase halves and wipe dry.
  • Page 367 CRANKSHAFT/TRANSMISSION 9-13 Crankcase Splitting • When installing the oil passage plugs [A], note the follow- ing. ○ Apply a non-permanent locking agent to the oil passage plugs. ○ Tighten: Torque - Oil Passage Plugs (R3/8): 20 N·m (2.0 kgf·m, 15 ft·lb) •...
  • Page 368 9-14 CRANKSHAFT/TRANSMISSION Crankcase Splitting • Using a high flash-point solvent, clean off any oil or dirt that may be on the liquid gasket, coating area. Dry them with a clean cloth. • Apply liquid gasket [A] to the mating surface of the lower crankcase half as shown in the figure.
  • Page 369 CRANKSHAFT/TRANSMISSION 9-15 Crankcase Splitting ○ Tighten the M7 bolts [A]. Torque - Crankcase Bolts (M7): 20 N·m (2.0 kgf·m, 15 ft·lb) • Tighten the upper crankcase bolts in the order listed. ○ The M8 bolts have washers, replace them with new ones. ○...
  • Page 370: Crankshaft And Connecting Rods

    9-16 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods Crankshaft Removal • Split the crankcase (see Crankcase Splitting). • Remove the crankshaft (see Connecting Rod Removal). Crankshaft Installation NOTICE If the crankshaft, bearing inserts, or crankcase halves are replaced with new ones, select the bear- ing inserts and check clearance with a plastigage (press gauge) before assembling engine to be sure the correct bearing inserts are installed.
  • Page 371: Connecting Rod Removal

    CRANKSHAFT/TRANSMISSION 9-17 Crankshaft and Connecting Rods Connecting Rod Removal • Split the crankcase (see Crankcase Splitting). • Remove: Connecting Rod Nuts [A] Crankshaft NOTE ○ Mark and record the locations of the connecting rods and their big end caps so that they can be reassembled in their original positions.
  • Page 372 9-18 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods ○ When installing the inserts [A], be careful not to damage the insert surface with the edge of the connecting rod [B] or the cap [C]. One way to install inserts is as follows. Installation [D] to Cap Installation [E] to Connecting Rod Push [F]...
  • Page 373 CRANKSHAFT/TRANSMISSION 9-19 Crankshaft and Connecting Rods (1) Bolt Length Measurement Method • Be sure to clean the bolts, nuts, and connecting rods thoroughly with a high flash-point solvent, because the new connecting rods, bolts, and nuts are treated with an anti-rust solution.
  • Page 374 9-20 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods (2) Rotation Angle Method If you don’t have a point micrometer, you may tighten the nuts using the “Rotation Angle Method”. • Be sure to clean the bolts, nuts and connecting rods thor- oughly with a high flash-point solvent, because the new connecting rods, bolts and nuts are treated with an anti -rust solution.
  • Page 375: Crankshaft/connecting Rod Cleaning

    CRANKSHAFT/TRANSMISSION 9-21 Crankshaft and Connecting Rods Crankshaft/Connecting Rod Cleaning • After removing the connecting rods from the crankshaft, clean them with a high flash-point solvent. • Blow the crankshaft oil passages with compressed air to remove any foreign particles or residue that may have accumulated in the passages.
  • Page 376: Connecting Rod Big End Bearing Insert/crankpin Wear Inspection

    9-22 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods Connecting Rod Big End Bearing Insert/Crankpin Wear Inspection • Remove the connecting rod big end (see Connecting Rod Removal). • Cut strips of plastigage (press gauge) to crankpin width. Place a strip on the crankpin parallel to the crankshaft installed in the correct position.
  • Page 377 CRANKSHAFT/TRANSMISSION 9-23 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 378: Crankshaft Side Clearance Inspection

    9-24 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods Crankshaft Side Clearance Inspection • Move [A] the crankshaft to the side of the camshaft chain. • Insert a thickness gauge [B] between the thrust washer [C] and the crank web [D] at the #3 main journal to deter- mine clearance.
  • Page 379: Crankshaft Main Bearing Insert/journal Wear Inspection

    CRANKSHAFT/TRANSMISSION 9-25 Crankshaft and Connecting Rods Crankshaft Main Bearing Insert/Journal Wear Inspection • Split the crankcase (see Crankcase Splitting). • Cut strips of plastigage (press gauge) to journal width. • Place a strip on each journal parallel to the crankshaft installed in the correct position.
  • Page 380 9-26 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods • Measure the main bearing inside diameter, and mark the upper crankcase half in accordance with the inside diam- eter. ○ [A]: Crankcase Main Bearing Inside Diameter Marks, “ ” or no mark. • Tighten the crankcase bolts to the specified torque (see Crankcase Assembly).
  • Page 381: Pistons

    CRANKSHAFT/TRANSMISSION 9-27 Pistons Piston Removal • Split the crankcase (see Crankcase Splitting). • Remove: Connecting Rod Nuts [A] Connecting Rod Big End Caps • Remove the crankshaft. • Remove the piston [A] with connecting rod to the cylinder head side. •...
  • Page 382: Piston Installation

    9-28 CRANKSHAFT/TRANSMISSION Pistons Piston Installation NOTE ○ If a new piston is used, use new piston ring. • Apply molybdenum disulfide oil solution to the oil ring ex- pander, and install the oil ring expander [A] in the bottom piston ring groove so the ends [B] not butt together. •...
  • Page 383: Cylinder Wear (upper Crankcase) Inspection

    CRANKSHAFT/TRANSMISSION 9-29 Pistons • Apply molybdenum disulfide oil solution to the cylinder bore and piston skirt. • Install the piston with its dent mark [A] facing exhaust side. • Using the piston ring compressor assembly [B] to install the piston from the cylinder head side. Special Tools - Piston Ring Compressor Grip: 57001-1095 80 ∼...
  • Page 384: Piston Ring Groove Width Inspection

    9-30 CRANKSHAFT/TRANSMISSION Pistons Piston Ring Groove Width Inspection • Measure the piston ring groove width. ○ Use a vernier caliper at several points around the piston. Piston Ring Groove Width Standard: 0.92 ∼ 0.94 mm (0.0362 ∼ 0.0370 in.) Top [A] 1.01 ∼...
  • Page 385: Balancer

    CRANKSHAFT/TRANSMISSION 9-31 Balancer Front Balancer Removal • Split the crankcase (see Crankcase Splitting). • Remove: Front Balancer [A] Balancer Shaft Oil Seal [B] Front Balancer Installation • Apply molybdenum disulfide oil solution to the ribs [A] of the balancer. • Apply molybdenum disulfide oil solution to the ribs [A] of the balancer gear.
  • Page 386: Rear Balancer Removal

    9-32 CRANKSHAFT/TRANSMISSION Balancer • Position the crankshaft at #2, 3 position TDC. • Insert the pin [A] as shown in the figure. • Set the front balancer on the upper crankcase half. ○ Align the punch mark [B] on the balancer gear [C] with the mark [D] on the balancer drive gear [E] of crankshaft.
  • Page 387: Rear Balancer Installation

    CRANKSHAFT/TRANSMISSION 9-33 Balancer • Remove: Balancer Shaft Clamp Lever Bolt [A] • Pry off the clamp lever [A] until the oil seal [B] removed. • Pull the balancer shaft [C] out of the crankcase. The bal- ancer weight and gear assembly [D] come off with needle bearings and washers.
  • Page 388 9-34 CRANKSHAFT/TRANSMISSION Balancer • Apply molybdenum disulfide oil solution to the needle bearings. Insert the needle bearings. • Fit the washers [A] on both ends of the weight and gear assembly. The projected sides [B] face inward. • Position the crankshaft at # 2, 3 position TDC or at # 1, 4 position TDC.
  • Page 389: Balancer Adjustment

    CRANKSHAFT/TRANSMISSION 9-35 Balancer • When installing the breather cover plate [A], note the fol- lowing. ○ Install the breather cover plate to the breather cover [B] as shown in the figure. ○ Apply a non-permanent locking agent to the threads of the breather cover plate screws [C].
  • Page 390: Balancer Damper Inspection

    9-36 CRANKSHAFT/TRANSMISSION Balancer Balancer Damper Inspection • Remove the balancer and disassemble the weight and gear assembly. • Visually inspect the rubber dampers [A]. If they appear damaged or deteriorated, replace them.
  • Page 391: Starter Motor Clutch And Torque Limiter

    CRANKSHAFT/TRANSMISSION 9-37 Starter Motor Clutch and Torque Limiter Starter Motor Clutch Removal • Remove: Torque Limiter (see Torque Limiter Removal) Starter Clutch Shaft Plate Bolt [A] • Pull the starter clutch shaft bolt [A] with the shaft plate [B] and starter clutch shaft holding the starter clutch [C]. •...
  • Page 392: Starter Motor Clutch Disassembly

    9-38 CRANKSHAFT/TRANSMISSION Starter Motor Clutch and Torque Limiter • Install the starter clutch and starter clutch shaft. • Apply a non-permanent locking agent to the threads of the starter clutch shaft plate bolt, and tighten it. Torque - Starter Clutch Shaft Plate Bolt : 9.8 N·m (1.0 kgf·m, 87 in·lb) Starter Motor Clutch Disassembly •...
  • Page 393: Starter Clutch Inspection

    CRANKSHAFT/TRANSMISSION 9-39 Starter Motor Clutch and Torque Limiter • Turn in the driven gear [A] to the drive gear [B]. Counterclockwise [C] • Install the needle bearing. Starter Clutch Inspection • Remove the rear balancer (see Rear Balancer Removal). • Turn the starter idle gear [A] by hand.
  • Page 394: Transmission

    9-40 CRANKSHAFT/TRANSMISSION Transmission Shift Pedal Removal • Remove: Shift Pedal Bolt [A] Shift Pedal [B] Shift Pedal Installation • Align [A] the punch mark [B] on the shift shaft with the upper surface [C] of shift pedal slit. If the punch mark is misaligned with the slit, the shift pedal is positioned [D] as shown in the figure.
  • Page 395: External Shift Mechanism Inspection

    CRANKSHAFT/TRANSMISSION 9-41 Transmission • Replace the oil seal [A] with a new one. • Apply grease to the lips of the grease seal. • Install: Shift Shaft Assembly [A] and Washer ○ Fit the hole [B] and return spring pin [C]. •...
  • Page 396: Transmission Shaft Removal

    9-42 CRANKSHAFT/TRANSMISSION Transmission Transmission Shaft Removal • Split the crankcase (see Crankcase Splitting). • Remove the output shaft [A]. • Remove: Shift Forks (see Shift Drum and Fork Removal) Cover Bolts [A] Cover [B] • Pull out the drive shaft. Transmission Shaft Installation •...
  • Page 397: Transmission Shaft Disassembly

    CRANKSHAFT/TRANSMISSION 9-43 Transmission If the cover disassembled, install the bearing, bushing and oil seal as shown in the figure. • Press the new bushing [A] into cover [B] so that the sur- face of the bushing is flush with the bottom surface [C] of the cover.
  • Page 398: Transmission Shaft Assembly

    9-44 CRANKSHAFT/TRANSMISSION Transmission Transmission Shaft Assembly • Apply engine oil to the bushings, ball bearing and shafts. • Install the gear bushings [A] on the shaft with their holes [B] aligned. • Replace any circlips removed with new ones. • Install the circlips [A] so that the opening [B] of it is aligned with spline grooves [C].
  • Page 399 CRANKSHAFT/TRANSMISSION 9-45 Transmission 1. Output Shaft 13. 5th Gear 2. Collar 14. Thrust Washer, 35 mm (1.38 in.) 3. Ball Bearing 15. 1st Gear 4. Bushing 16. Needle Bearing 5. 2nd Gear 17. Bearing Outer Race 6. Toothed Washer, 40 mm (1.57 in.) 18.
  • Page 400: Shift Drum And Fork Removal

    9-46 CRANKSHAFT/TRANSMISSION Transmission Shift Drum and Fork Removal • Remove: Lower Crankcase Half (see Crankcase Splitting) Gear Positioning Lever (see External Shift Mechanism Removal) Screws [A] Shift Drum Bearing Holder [B] • Pull out the shift rods [C], and remove the shift forks. •...
  • Page 401: Shift Drum Assembly

    CRANKSHAFT/TRANSMISSION 9-47 Transmission Shift Drum Assembly • Install: Ball Bearing [A] Dowel Pin [B] and Shift Drum Cam [C] ○ Align the pin with the groove in the shift drum cam. • Apply a non-permanent locking agent to the threads of the shift drum cam holder bolt [D], and tighten it.
  • Page 402: Gear Dog And Gear Dog Hole Damage Inspection

    9-48 CRANKSHAFT/TRANSMISSION Transmission Gear Dog and Gear Dog Hole Damage Inspection • Visually inspect the gear dogs [A] and gear dog holes [B]. Replace any damaged gears or gears with excessively worn dogs or dog holes.
  • Page 403 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 404: Exploded View

    10-2 WHEELS/TIRES Exploded View...
  • Page 405 WHEELS/TIRES 10-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Axle Clamp Bolts Front Axle Nut 13.0 93.7 Rear Axle Nut 13.0 93.7 AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque. HG: Apply high-temperature grease. R: Replacement Parts WL: Apply soap and water solution or rubber lubricant.
  • Page 406: Specifications

    10-4 WHEELS/TIRES Specifications Item Standard Service Limit Wheels (Rims) Rim Runout: Axial TIR 0.5 mm (0.02 in.) or less TIR 1.0 mm (0.04 in.) Radial TIR 0.8 mm (0.03 in.) or less TIR 1.0 mm (0.04 in.) Axle Runout/100 mm (3.94 in.) TIR 0.03 mm (0.0012 in.) or less TIR 0.2 mm (0.008 in.) Wheel Balance 10 g (0.35 oz.) or less...
  • Page 407: Special Tools

    WHEELS/TIRES 10-5 Special Tools Bearing Driver Set: Bearing Remover Head, 25 × 28: 57001-1129 57001-1346 Jack: Bearing Remover Shaft, 13: 57001-1238 57001-1377...
  • Page 408: Wheels (rims)

    10-6 WHEELS/TIRES Wheels (Rims) Front Wheel Removal • Remove: Front Caliper Mounting Bolts [A] (Both Sides) Front Calipers [B] (Both Sides) • Loosen: Front Axle Clamp Bolts [A] (Right Side) Front Axle [B] • Raise the front wheel off the ground. Special Tool - Jack: 57001-1238 •...
  • Page 409: Rear Wheel Removal

    WHEELS/TIRES 10-7 Wheels (Rims) • Apply high-temperature grease to the grease seal lips. • Fit the collars [A] on the both sides of the hub. ○ The collars are identical. • Insert the axle from the right side. • Tighten the axle nut [B]. Right Axle Clamp Bolts [C] Left Axle Clamp Bolts [D] Viewed from Rear [E]...
  • Page 410: Rear Wheel Installation

    10-8 WHEELS/TIRES Wheels (Rims) • Remove: Rear Caliper Mounting Bolts [A] Rear Caliper [B] • Remove the rear wheel rotation sensor [C] from the caliper bracket (see Rear Wheel Rotation Sensor Re- moval in the Brakes chapter). • Remove: Cotter Pin [A] Axle Nut [B] Washer [C] Axle [D] (from Left Side)
  • Page 411 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 412: Wheel Inspection

    10-10 WHEELS/TIRES Wheels (Rims) Wheel Inspection • Raise the front/rear wheel off the ground. Special Tool - Jack: 57001-1238 • 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 413: 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 414: Balance Weight Installation

    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 415 WHEELS/TIRES 10-13 Wheels (Rims) • Slip the balance weight [A] on the rib [B], by pushing or lightly hammering [C] the clip [D]. ○ Install the balance weight at the left side of the motorcycle. Left Side [E] Right Side [F] •...
  • Page 416: Tires

    10-14 WHEELS/TIRES Tires Air Pressure Inspection/Adjustment • Refer to the Air Pressure Inspection in the Periodic Main- tenance chapter. Tire Inspection • Refer to the Wheel/Tire Damage Inspection in the Peri- odic Maintenance chapter. Tire Removal • Remove: Wheels (see Front/Rear Wheel Removal) Valve Core (Let out the air) •...
  • Page 417 WHEELS/TIRES 10-15 Tires • Install a new valve in the rim. ○ Remove the valve cap, lubricate the stem seal [A] with a soap and water solution or rubber lubricant, and pull [B] the valve stem through the rim from the inside out until it snaps into place.
  • Page 418: 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 419: Hub Bearing

    WHEELS/TIRES 10-17 Hub Bearing Hub Bearing Removal • Remove the wheels (see Front/Rear Wheel Removal), and take out the following. Collars Coupling (Out of rear hub) Grease Seals • Use the bearing remover to remove the hub bearings [A]. NOTICE Do not lay the wheel on the ground with the disc facing down.
  • Page 420: Hub Bearing Lubrication

    10-18 WHEELS/TIRES Hub Bearing Hub Bearing Lubrication NOTE ○ Since the hub bearings are packed with grease and sealed, lubrication is not required.
  • Page 421 FINAL DRIVE 11-1 Final Drive Table of Contents Exploded View ........................11-2 Specifications ........................11-4 Special Tools .......................... 11-5 Drive Chain..........................11-6 Drive Chain Slack Inspection .................... 11-6 Drive Chain Slack Adjustment ..................11-6 Wheel Alignment Inspection/Adjustment ................11-6 Drive Chain Wear Inspection .................... 11-6 Drive Chain Lubrication.....................
  • Page 422: Exploded View

    11-2 FINAL DRIVE Exploded View...
  • Page 423 FINAL DRIVE 11-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Chain Guide Bolt 106 in·lb Chain Guide Bolts 87 in·lb Engine Sprocket Nut 13.0 93.7 Rear Axle Nut 13.0 93.7 Rear Sprocket Nuts Stud Bolts 14.7 10.8 G: Apply grease. HG: Apply high-temperature grease.
  • Page 424: Specifications

    11-4 FINAL DRIVE Specifications Item Standard Service Limit Drive Chain 25 ∼ 30 mm (1.0 ∼ 1.2 in.) Drive Chain Slack – – – 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) Drive Chain Wear (20-link 319 mm (12.6 in.) Length) Standard Chain: Make...
  • Page 425: Special Tools

    FINAL DRIVE 11-5 Special Tools Inside Circlip Pliers: Bearing Driver Set: 57001-143 57001-1129...
  • Page 426: 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 427 FINAL DRIVE 11-7 Drive Chain Body [A] Handlebar [B] Cutting and Riveting Pin [C] For Cutting [D] For Riveting [E] Plate Holder (A) [F] Plate Holder (B) [G] Gauge [H] • Grind [A] the pin head to make it flat. •...
  • Page 428 11-8 FINAL DRIVE Drive Chain • Set the plate holder (A) [A] and plate holder (B) [B] on the body. • Fit the plate holder (A) to the link plate. • Turn the pin holder by hand until the plate holder (B) touches the other link plate.
  • Page 429 FINAL DRIVE 11-9 Drive Chain • Turn the wrench clockwise until the tip of riveting pin hits of the link pin. • Rivet it. • Same work for the other link pin. • After staking, check the staked area of the link pin for cracks.
  • Page 430: Sprocket, Coupling

    11-10 FINAL DRIVE Sprocket, Coupling Engine Sprocket Removal • Pull up the core of the quick rivet [A] by the thin blade driver, and remove it. • Remove the bolts [B] and washers. • Free the lower fairing. • Remove: Clutch Slave Cylinder [A] (see Clutch Slave Cylinder Re- moval in the Clutch chapter) Engine Sprocket Cover Bolts [B]...
  • Page 431: Engine Sprocket Installation

    FINAL DRIVE 11-11 Sprocket, Coupling Engine Sprocket Installation • Replace the sprocket washer. • Install the engine sprocket onto the output shaft. • Apply a non-permanent locking agent to the threads of the chain guide bolts. • Install the chain guide, and tighten the bolts. Torque - Chain Guide Bolt [A]: 12 N·m (1.2 kgf·m, 106 in·lb) Chain Guide Bolts [B]: 9.8 N·m (1.0 kgf·m, 87 in·lb) •...
  • Page 432: Engine Sprocket Cover Assembly

    11-12 FINAL DRIVE Sprocket, Coupling • Remove the damper [A]. Engine Sprocket Cover Assembly • Assembly is reverse of disassembly. ○ Apply a non-permanent locking agent to the threads of the plate mounting bolts. Rear Sprocket Removal • Remove the rear wheel (see Rear Wheel Removal in the Wheels/Tires chapter).
  • Page 433: Coupling Bearing Removal

    FINAL DRIVE 11-13 Sprocket, Coupling • Install: Collar [A] Coupling Coupling Bearing Removal • Remove: Coupling Grease Seal Circlip [A] Special Tool - Inside Circlip Pliers: 57001-143 • Remove the bearing [A] by tapping from the wheel side. Special Tool - Bearing Driver Set [B]: 57001-1129 Coupling Bearing Installation •...
  • Page 434: Coupling Bearing Inspection

    11-14 FINAL DRIVE Sprocket, Coupling Coupling Bearing Inspection Since the coupling bearing is made to extremely close tolerances, the clearance can not normally be measured. NOTE ○ It is not necessary to remove the coupling bearing for inspection. If the bearing is removed, it will need to be replaced with a new one.
  • Page 435 BRAKES 12-1 Brakes Table of Contents Exploded View ........................12-4 Specifications ........................12-12 Special Tools .......................... 12-13 Brake Lever, Brake Pedal....................... 12-14 Brake Lever Position Adjustment..................12-14 Brake Pedal Position Inspection ..................12-14 Brake Pedal Position Adjustment ..................12-14 Brake Pedal Removal ....................... 12-14 Brake Pedal Installation ....................
  • Page 436 12-2 BRAKES Inquiries to Rider....................... 12-38 Self-diagnosis Outline ....................... 12-40 Self-diagnosis Procedures ....................12-40 Service Code Clearing Procedures................... 12-41 How to Read Service Codes..................... 12-44 How to Erase Service Codes .................... 12-44 Yellow ABS Indicator Light (LED) Inspection ..............12-45 Solenoid Valve Inspection (Service Code 13, 14, 17, 18)..........
  • Page 437 BRAKES 12-3 This page intentionally left blank.
  • Page 438: Exploded View

    12-4 BRAKES Exploded View...
  • Page 439 BRAKES 12-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Brake Pad Pins 17.2 1.75 12.7 Bleed Valves 0.80 69 in·lb Front Caliper Mounting Bolts Front Brake Reservoir Cap Stopper Screw 0.12 11 in·lb Front Caliper Assembly Bolts Brake Lever Pivot Bolt 0.10 8.9 in·lb Front Brake Master Cylinder Bleed Valve...
  • Page 440 12-6 BRAKES Exploded View...
  • Page 441 BRAKES 12-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Brake Hose Banjo Bolts Rear Master Cylinder Mounting Bolts Rear Master Cylinder Push Rod Locknut 17.2 1.75 12.7 Brake Pedal Bolt 0.90 78 in·lb Rear Brake Disc Mounting Bolts Bleed Valves 0.80 69 in·lb Rear Caliper Assembly Bolts...
  • Page 442 12-8 BRAKES Exploded View ABS Equipped Models...
  • Page 443 BRAKES 12-9 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Brake Hose Banjo Bolts Brake Pipe Joint Nuts 3. ABS Hydraulic Unit 4. White Paint Marks 5. Blue Paint Marks R: Replacement Parts...
  • Page 444 12-10 BRAKES Exploded View ABS Equipped Models...
  • Page 445 BRAKES 12-11 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Brake Pipe Joint Nuts Brake Hose Banjo Bolts 3. ABS Hydraulic Unit 4. Blue Paint Marks (2 Points) 5. White Paint Marks 6. White Paint Marks (2 Points) 7. Yellow Paint Marks (2 Points) R: Replacement Parts...
  • Page 446: Specifications

    12-12 BRAKES Specifications Item Standard Service Limit Brake Lever, Brake Pedal Brake Lever Position 6-way adjustable (to suit rider) – – – Brake Lever Free Play Non-adjustable – – – Pedal Position About 45 mm (1.77 in.) below top of footpeg –...
  • Page 447 BRAKES 12-13 Special Tools Jack: Jack Attachment: 57001-1238 57001-1608 Hand Tester: 57001-1394...
  • Page 448: Brake Lever Position Adjustment

    12-14 BRAKES Brake Lever, Brake Pedal Brake Lever Position Adjustment The brake lever adjuster has 6 positions so that the brake lever position can be adjusted to suit the operator’s hand. • Push the lever forward and turn the adjuster [A] to align the number with the arrow mark [B] on the lever.
  • Page 449: Brake Pedal Installation

    BRAKES 12-15 Brake Lever, Brake Pedal • Remove: Cotter Pin [A] Joint Pin [B] Rear Brake Light Switch Spring [C] Return Spring [D] • Remove the brake pedal bolt [E] and take out the brake pedal. Brake Pedal Installation • Apply grease to the pivot shaft [A] and install the washer [B].
  • Page 450: 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 detach the caliper [C] from the disc. NOTICE Do not loosen the caliper assembly bolts. Take out only the caliper mounting bolts for caliper removal.
  • Page 451: Caliper Installation

    BRAKES 12-17 Calipers Caliper Installation • Install the caliper and brake hose lower end. ○ Replace the washers on each side of hose fitting with new ones. • Tighten: Torque - Caliper Mounting Bolts: Front: 34 N·m (3.5 kgf·m, 25 ft·lb) Rear: 25 N·m (2.5 kgf·m, 18 ft·lb) Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb)
  • Page 452: Caliper Fluid Seal Damage Inspection

    12-18 BRAKES Calipers Caliper Fluid Seal Damage Inspection The fluid seal (piston seal) [A] is placed around the pis- ton to maintain clearance between the pad and the disc. If the seal is in a poor condition, it could lead the pad to wear excessively or the brake to drag, which may cause the tem- perature of the discs or the brake fluid to increase.
  • Page 453: Caliper Piston And Cylinder Damage Inspection

    BRAKES 12-19 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.
  • Page 454: Brake Pads

    12-20 BRAKES Brake Pads Front Brake Pad Removal • Loosen the pad pins [A]. • Remove: Pad Pins [A] Pad Springs [B] Brake Pads [C] Front Brake Pad Installation • Push the caliper pistons in by hand as far as they will go. •...
  • Page 455: Rear Brake Pad Removal

    BRAKES 12-21 Brake Pads Rear Brake Pad Removal • Loosen the pad pin [A]. • Remove the caliper mounting bolts [B]. • Remove the caliper with the hose installed. • Remove: Pad Pin [A] Pad Spring [B] Brake Pads [C] Rear Brake Pad Installation •...
  • Page 456: Master Cylinder

    12-22 BRAKES Master Cylinder Front Master Cylinder Removal • Remove the reservoir bracket bolt [A]. • Remove the banjo bolt [B] and remove the brake hose from the master cylinder (see Brake Hose Removal/In- stallation). • Remove the clamp bolts [C], and take off the master cylin- der [D] as an assembly with the reservoir, brake lever, and front brake light switch installed.
  • Page 457: Rear Master Cylinder Installation

    BRAKES 12-23 Master Cylinder Rear Master Cylinder Installation • Replace the cotter pin with a new one. • 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) Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb)
  • Page 458: Brake Disc

    12-24 BRAKES Brake Disc Brake Disc Removal • Remove the wheels (see Front/Rear Wheel Removal in the Wheels/Tires chapter). • Remove the mounting bolts, and take off the disc. ○ Remove the sensor rotor (ABS Equipped Models). • Remove the gaskets. Brake Disc Installation •...
  • Page 459: Brake Fluid

    BRAKES 12-25 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 460 12-26 BRAKES Brake Fluid • Bleed the brake line and the master cylinder. ○ Repeat this operation until no more air can be seen com- ing out into the plastic hose. 1. Pump the brake lever until it becomes hard, and apply the brake and hold it [A].
  • Page 461 BRAKES 12-27 Brake Fluid • Follow the procedure below to install the front/rear brake fluid reservoir cap correctly. ○ First, tighten the brake fluid reservoir cap [B] clockwise [C] by hand until slight resistance is felt indicating that the cap is seated on the reservoir body, then tighten the cap an additional 1/6 turn [D] while holding the brake fluid reservoir body [A].
  • Page 462 12-28 BRAKES Brake Fluid WARNING When working with the disc brake, observe the pre- cautions listed below. 1. Never reuse old brake fluid. 2. Do not use fluid from a container that has been left unsealed or that has been open for a long time. 3.
  • Page 463: Brake Hose

    BRAKES 12-29 Brake Hose Brake Hose and Pipe Removal/Installation • Refer to the Brake Hose and Pipe Replacement in the Periodic Maintenance chapter. Brake Hose and Pipe Inspection • Refer to the Brake Hose and Pipe Damage and Instal- lation Condition Inspection in the Periodic Maintenance chapter.
  • Page 464: Anti-lock Brake System (equipped Models)

    12-30 BRAKES Anti-Lock Brake System (Equipped Models) Parts Location 1. ABS Fuse Box 2. ABS Kawasaki Self-diagnosis System Connector 3. ABS Hydraulic Unit 4. ABS Indicator Light (LED) 5. Front Wheel Rotation Sensor Rotor 6. Front Wheel Rotation Sensor 7. Rear Wheel Rotation Sensor 8.
  • Page 465 14. Frame Ground 5 2. Front Brake Switch 15. ABS Self-diagnosis Terminal 3. Front Wheel Rotation Sensor 16. ABS Kawasaki Self-diagnosis System Connector 4. Joint Connector C 17. ABS Hydraulic Unit 5. Joint Connector D 18. Brake Light/Horn Fuse 10 A 6.
  • Page 466 6. Unused 7. Unused 8. Power Supply to ABS Solenoid Valve Relay 9. Power Supply to ABS Motor Relay 10. ABS Kawasaki Self-diagnosis System Terminal 11. Unused 12. Power Supply to Front Wheel Rotation Sensor 13. ABS Self-diagnosis Terminal 14. Unused 15.
  • Page 467: Abs Servicing Precautions

    BRAKES 12-33 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 468 12-34 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 469: Abs Troubleshooting Outline

    BRAKES 12-35 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 470 12-36 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 471 BRAKES 12-37 Anti-Lock Brake System (Equipped Models) ABS Diagnosis Flow Chart...
  • Page 472: Inquiries To Rider

    12-38 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 473 BRAKES 12-39 Anti-Lock Brake System (Equipped Models) Pre-Diagnosis Inspection 1...
  • Page 474: Self-diagnosis Outline

    12-40 BRAKES Anti-Lock Brake System (Equipped Models) Pre-Diagnosis Inspection 2 Self-diagnosis Outline When the indicator light has blinked or come on, the ABS hydraulic unit memorizes 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 475: Service Code Clearing Procedures

    BRAKES 12-41 Anti-Lock Brake System (Equipped Models) • Remove the seat (see Seat Removal in the Frame chap- ter). • Ground the self-diagnosis terminal [A] (Gray) to the frame ground, using a suitable lead. • Turn the ignition switch to ON. ○...
  • Page 476 12-42 BRAKES Anti-Lock Brake System (Equipped Models)
  • Page 477 BRAKES 12-43 Anti-Lock Brake System (Equipped Models) Self-diagnosis Flow Chart...
  • Page 478: How To Read Service Codes

    12-44 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 479: Yellow Abs Indicator Light (led) Inspection

    BRAKES 12-45 Anti-Lock Brake System (Equipped Models) Service Code Table Service Yellow ABS Indicator Problems Light State Code Light (LED) Rear intake solenoid valve trouble (wiring shorted or open) Rear outlet solenoid valve trouble (wiring shorted or open) Front intake solenoid valve trouble (wiring shorted or open) Front outlet solenoid valve trouble (wiring shorted or open)
  • Page 480: Solenoid Valve Inspection (service Code 13, 14, 17, 18)

    12-46 BRAKES Anti-Lock Brake System (Equipped Models) Solenoid Valve Inspection (Service Code 13, 14, 17, 18) ○ The solenoid valve is built in the ABS Hydraulic Unit [A]. Therefore the solenoid valve cannot be checked directly. • Perform the Pre-Diagnosis Inspection 1 and 2 (see In- quiries to Rider).
  • Page 481: Front Wheel Rotation Sensor Signal Abnormal (service Code 42)

    BRAKES 12-47 Anti-Lock Brake System (Equipped Models) ○ Check the wiring continuity between the positive cable terminal [A] of the battery and R/W lead terminal [B] in the ABS Hydraulic Unit Lead Connector [C]. If the wiring is open, replace or repair the harness (see ABS System Circuit).
  • Page 482: Front Wheel Rotation Sensor Wiring Inspection (service Code 43)

    12-48 BRAKES Anti-Lock Brake System (Equipped Models) Front Wheel Rotation Sensor Wiring Inspection (Service Code 43) • Disconnect the front wheel rotation sensor lead connector [A] (see Front Wheel Rotation Sensor Removal). • Disconnect the ABS hydraulic unit lead connector (see ABS Hydraulic Unit Removal).
  • Page 483: Rear Wheel Rotation Sensor Wiring Inspection (service Code 45)

    BRAKES 12-49 Anti-Lock Brake System (Equipped Models) • Perform the Pre-Diagnosis Inspection 1 and 2 (see In- quiries to Rider). If this service code appears even if all checks are ended, replace the ABS hydraulic unit. If the service code does not appear, the ABS system nor- mal (temporary failure).
  • Page 484: Power Supply Voltage Inspection (over-voltage) (service Code 53)

    12-50 BRAKES Anti-Lock Brake System (Equipped Models) Power Supply Voltage Inspection (Over-Voltage) (Service Code 53) • Check the charging voltage (see Charging Voltage In- spection in the Electrical System chapter). If the charging voltage is good, perform the Pre-Diagnosis Inspection 1 and 2 (see Inquiries to Rider). If this service code appears even if all checks are ended, replace the ABS hydraulic unit.
  • Page 485: Abs Hydraulic Unit Installation

    BRAKES 12-51 Anti-Lock Brake System (Equipped Models) • Remove the brake pipe joint nuts [A] [B] [C] [D] with the flare nut wrench. • Tape the brake line opening to prevent brake fluid leakage or contamination by foreign matter. NOTICE Brake fluid quickly ruins painted plastic surfaces;...
  • Page 486: Abs Hydraulic Unit Inspection

    12-52 BRAKES Anti-Lock Brake System (Equipped Models) • Run the lead correctly, and fix the connector [A] securely. ○ Lock the joint lock [B] as shown in the figure. • Install the brake pipes correctly as shown in the figure. 48°...
  • Page 487: Front Wheel Rotation Sensor Removal

    BRAKES 12-53 Anti-Lock Brake System (Equipped Models) Front Wheel Rotation Sensor Removal NOTICE The wheel rotation sensor should be handled care- fully, never struck sharply with a hammer, or al- lowed to fall on a hard surface since the wheel rota- tion sensor is precision made.
  • Page 488: Rear Wheel Rotation Sensor Installation

    12-54 BRAKES Anti-Lock Brake System (Equipped Models) • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Connector [A] (Disconnect) • Remove the connector from the bracket. • Remove: Bracket Bolts [A] Clamps [B] Bolts [C] Rear Wheel Rotation Sensor [D] Rear Wheel Rotation Sensor Installation •...
  • Page 489: Wheel Rotation Sensor Air Gap Inspection

    BRAKES 12-55 Anti-Lock Brake System (Equipped Models) Wheel Rotation Sensor Air Gap Inspection • Raise the front/rear wheel off the ground (see Front/Rear Wheel Removal in the Wheels/Tires chapter). • Measure the air gap between the sensor and sensor rotor at several points by turning the wheel slowly.
  • Page 490: Abs Solenoid Valve Relay Fuse (20 A) Removal

    12-56 BRAKES Anti-Lock Brake System (Equipped Models) • Visually inspect the wheel rotation sensor rotor. If the rotor is deformed or damaged (chipped teeth [A]), replace the sensor rotor with a new one. If there is iron or other magnetic deposits [B], remove the deposits.
  • Page 491 SUSPENSION 13-1 Suspension Table of Contents Exploded View........................13-2 Specifications ......................... 13-6 Special Tools .......................... 13-7 Front Fork ..........................13-10 Rebound Damping Force Adjustment................13-10 Compression Damping Force Adjustment ................ 13-10 Spring Preload Adjustment ....................13-11 Front Fork Removal (Each Fork Leg) ................13-11 Front Fork Installation .......................
  • Page 492: Exploded View

    13-2 SUSPENSION Exploded View...
  • Page 493 SUSPENSION 13-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Fork Clamp Bolts (Upper) Front Fork Clamp Bolts (Lower) Front Fork Top Plugs Piston Rod Nuts Front Axle Clamp Bolts Front Fork Bottom Allen Bolts AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque. G: Apply grease.
  • Page 494 13-4 SUSPENSION Exploded View...
  • Page 495 SUSPENSION 13-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Rear Shock Absorber Nuts Swingarm Pivot Shaft Swingarm Pivot Shaft Locknut 10.0 Swingarm Pivot Shaft Nut 11.0 79.7 Rocker Arm Nut Tie-Rod Nuts G: Apply grease. R: Replacement Parts...
  • Page 496: Specifications

    13-6 SUSPENSION Specifications Item Standard Front Fork (Per One Unit) Fork Inner Tube Diameter 43 mm (1.7 in.) Air Pressure Atmospheric pressure (Non-adjustable) Rebound Damper Setting 8th click from the 1st click of the fully clockwise position (Usable Range: 0 ←→ 15 clicks) Compression Damper Setting 10th click from the 1st click of the fully clockwise position (Usable Range: 0 ←→...
  • Page 497 SUSPENSION 13-7 Special Tools Inside Circlip Pliers: Fork Piston Rod Puller, M12 × 1.25: 57001-143 57001-1289 Oil Seal & Bearing Remover: Fork Oil Level Gauge: 57001-1058 57001-1290 Bearing Driver Set: Bearing Remover Head, 20 × 22: 57001-1129 57001-1293 Jack: Fork Spring Stopper: 57001-1238 57001-1374 Fork Cylinder Holder:...
  • Page 498: Special Tools

    13-8 SUSPENSION Special Tools Hook Wrench T=3.2 R37: Jack Attachment: 57001-1522 57001-1608 Fork Oil Seal Driver, 43: Needle Bearing Driver, 17/ 18: 57001-1530 57001-1609 Fork Spring Compressor: Needle Bearing Driver, 28: 57001-1540 57001-1610 Fork Spring Compressor: Spacer, 57001-1587 57001-1636 Swingarm Pivot Nut Wrench: Spacer 28: 57001-1597 57001-1663...
  • Page 499 SUSPENSION 13-9 Special Tools Needle Bearing Driver, 20 & Spacer, 28: Fork Spring Compressor: 57001-1678 57001-1771...
  • Page 500: Front Fork

    13-10 SUSPENSION Front Fork Rebound Damping Force Adjustment • To adjust the rebound damping force, turn the rebound damping adjuster [A] until you feel a click. ○ The standard adjuster setting is the 8th click from the 1st click of the fully clockwise position. WARNING If both adjusters are not adjusted equally, handling may be impaired and a hazardous condition may...
  • Page 501: Spring Preload Adjustment

    SUSPENSION 13-11 Front Fork Spring Preload Adjustment • Turn the spring preload adjuster [A] to change spring preload setting. ○ The standard adjuster setting is the 14 mm (0.55 in.) [B] from top as shown in the figure. Adjuster Protrusion (from top) Standard: 14 mm (0.55 in.) 4 ∼...
  • Page 502: Front Fork Installation

    13-12 SUSPENSION Front Fork Loosen the upper front fork clamp bolt [A] and fork top plug [B] beforehand if the fork leg is to be disassembled. NOTE ○ Loosen the top plug after loosening the upper front fork clamp bolt. •...
  • Page 503: Front Fork Oil Change

    SUSPENSION 13-13 Front Fork Front Fork Oil Change • Remove the front fork (see Front Fork Removal). • Hold the inner tube lower end in a vise. • Unscrew the top plug [A] out of the outer tube. • Install the clamps [A] as shown in the figure. NOTE ○...
  • Page 504 13-14 SUSPENSION Front Fork • Set the front fork [A] under the holder [B]. • Lift up the suitable jack, and hold the front fork. • Lift up the suitable jack until the piston rod nut [A] comes out. • Insert the fork spring stopper [B] between the piston rod nut and the holder [C] while holding up the top plug [D].
  • Page 505 SUSPENSION 13-15 Front Fork • Drain the fork oil into a suitable container. ○ Using the piston rod puller [A], pump the piston rod [B] up and down at least ten times to expel the oil from the fork. Special Tool - Fork Piston Rod Puller, M12 × 1.25: 57001 -1289 •...
  • Page 506 13-16 SUSPENSION Front Fork Oil Level (fully compressed, without spring) Standard: 94 ±2 mm (3.70 ±0.08 in.) (from the top of the inner tube) NOTE ○ Fork oil lever may also be measured using the fork oil level gauge. Special Tool - Fork Oil Level Gauge [A]: 57001-1290 ○...
  • Page 507 SUSPENSION 13-17 Front Fork • Install the clamps [A] as shown in the figure. Special Tool - Fork Spring Compressor: 57001-1540 NOTE ○ Set the clamps so that the cutouts [B] do not fit the hole [C] of the washer [D], pull up the outer tube [E] to hold it by the clamps, and then tighten the two bolts [F].
  • Page 508 13-18 SUSPENSION Front Fork • Check the distance between the bottom end [A] of the top plug and rebound damping adjuster [B] with a pair of vernier caliper. 13 mm (0.51 in.) [C] • Replace the O-ring [A] on the top plug [B] with a new one. •...
  • Page 509 SUSPENSION 13-19 Front Fork • Insert the holder bar [A] into the axle hole of the front fork [B]. • Insert the compression shafts [A] and install the nuts [B]. ○ Set the other side compression shaft same process. • Insert the lower end of the compression shaft [A] into the hole [B] of the holder bar.
  • Page 510 13-20 SUSPENSION Front Fork • Insert the fork spring stopper [A] between the piston rod nut [B] and the clamp [C] while holding up the top plug [D]. Special Tool - Fork Spring Stopper: 57001-1374 • Holding the piston rod nut with a wrench [A], remove the top plug [B] from the piston rod.
  • Page 511 SUSPENSION 13-21 Front Fork • Hold the fork tube upright, press the inner tube [A] and the piston rod all the way down. • Pour in the type and amount of fork oil specified. Recommended Oil KAYABA 01 (KHL15-10) or equivalent Amount (Per Side): When changing oil: Approx.
  • Page 512 13-22 SUSPENSION Front Fork • Screw the fork piston rod puller onto the end of the piston rod. Special Tool - Fork Piston Rod Puller, M12 × 1.25: 57001 -1289 • Pull the puller up above the outer tube top. •...
  • Page 513 SUSPENSION 13-23 Front Fork • Insert the fork spring stopper [A] between the piston rod nut [B] and the clamp [C] while holding up the fork piston rod puller [D]. Special Tool - Fork Spring Stopper: 57001-1374 • Remove the fork piston rod puller. •...
  • Page 514: Front Fork Disassembly

    13-24 SUSPENSION Front Fork Front Fork Disassembly • Remove the front fork (see Front Fork Removal). • Drain the fork oil (see Front Fork Oil Change). • Hold the axle portion of the front fork in a vise [A]. • Stop the cylinder [B] from turning by using the fork cylinder holder [C].
  • Page 515: Inner Tube, Outer Tube Inspection

    SUSPENSION 13-25 Front Fork • Apply grease to the oil seal lips. • Install the following parts onto the inner tube [A] temporar- ily. Dust Seal [B] Retaining Ring [C] Oil Seal [D] Washer [E] • Insert the inner tube to the outer tube. •...
  • Page 516: Dust Seal Inspection

    13-26 SUSPENSION Front Fork Dust Seal Inspection • Inspect the dust seal [A] for any signs of deterioration or damage. Replace it if necessary. 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 517: Rear Shock Absorber

    SUSPENSION 13-27 Rear Shock Absorber Rebound Damping Force Adjustment • Remove the rear fairing (see Rear Fairing Removal in the Frame chapter) (Equipped Models). • To adjust the rebound damping force, turn the lower damping adjuster [A]. ○ The standard adjuster setting is the 2 turns out from the fully clockwise position.
  • Page 518: Rear Shock Absorber Removal

    13-28 SUSPENSION Rear Shock Absorber • To adjust the spring preload, turn in the adjusting nut [A] and tighten the locknut [B]. Spring Length [C] Spring Preload Setting Standard: Spring length 175.5 mm (6.909 in.) Spring length 170.0 ∼ 180.5 mm Usable Range: (6.693 ∼...
  • Page 519: Rear Shock Absorber Installation

    SUSPENSION 13-29 Rear Shock Absorber • Squeeze the brake lever slowly and hold it with a band [A]. WARNING Be sure to hold the front brake when removing the shock absorber, or the motorcycle may fall over. It could cause an accident and injury. •...
  • Page 520: Rear Shock Absorber Scrapping

    13-30 SUSPENSION Rear Shock Absorber Rear Shock Absorber Scrapping WARNING Pressurized nitrogen may explode when heated. The rear shock contains nitrogen gas. To avoid an explosion, do not incinerate the shock body without first releasing the nitrogen and removing the shraeder valve. •...
  • Page 521: Swingarm

    SUSPENSION 13-31 Swingarm Swingarm Removal • Remove: Chain Cover (see Drive Chain Removal in the Final Drive chapter) Rear Wheel (see Rear Wheel Removal in the Wheels/Tires chapter) Bolts [A] Clamps [B] • Remove: Upper Tie-Rod Nut and Bolt [A] Rear Shock Absorber [B] (see Rear Shock Absorber Re- moval) •...
  • Page 522: Swingarm Installation

    13-32 SUSPENSION Swingarm Swingarm Installation • Apply plenty of grease to the lip of the oil seals [A]. • Install the collar to the left side of the swingarm. • Place the adjusting collar [A] into the frame [B] as shown in the figure.
  • Page 523: Swingarm Bearing Removal

    SUSPENSION 13-33 Swingarm Swingarm Bearing Removal • Remove: Swingarm (see Swingarm Removal) Collar [A] Oil Seals [B] Sleeves [C] Circlip [D] (Right Side) Special Tool - Inside Circlip Pliers: 57001-143 • Remove the ball bearing and needle bearings. Special Tool - Oil Seal & Bearing Remover [A]: 57001-1058 Swingarm Bearing Installation •...
  • Page 524: Swingarm Bearing, Sleeve Inspection

    13-34 SUSPENSION Swingarm • Install the needle bearings [A], ball bearing [B] and oil seals [C] position as shown in the figure. Circlip [D] 32 mm (1.26 in.) [E] 27.5 mm (1.08 in.) [F] 9.5 mm (0.37 in.) [G] Swingarm Bearing, Sleeve Inspection NOTICE Do not remove the bearings for inspection.
  • Page 525: Swingarm Bearing Lubrication

    SUSPENSION 13-35 Swingarm Swingarm Bearing Lubrication NOTE ○ Since the bearings are packed with grease and sealed, lubrication is not required. Chain Guide Inspection • Refer to the Chain Guide Wear Inspection in the Periodic Maintenance chapter.
  • Page 526: Tie-rod, Rocker Arm

    13-36 SUSPENSION Tie-Rod, Rocker Arm Tie-Rod Removal • Squeeze the brake lever slowly and hold it with a band [A]. • Remove: Center Stand (see Center Stand Removal in the Frame chapter) (Equipped Models) Rear Fairing (see Rear Fairing Removal in the Frame chapter) (Equipped Models) Bracket (see Rear Shock Absorber Removal) (Equipped Models)
  • Page 527: Rocker Arm Removal

    SUSPENSION 13-37 Tie-Rod, Rocker Arm Rocker Arm Removal • Squeeze the brake lever slowly and hold it with a band. • Remove: Center Stand (see Center Stand Removal in the Frame chapter) (Equipped Models) Rear Fairing (see Rear Fairing Removal in the Frame chapter) (Equipped Models) Bracket (see Rear Shock Absorber Removal) (Equipped Models)
  • Page 528: Tie-rod And Rocker Arm Bearing Removal

    13-38 SUSPENSION Tie-Rod, Rocker Arm Tie-Rod and Rocker Arm Bearing Removal • Remove: Tie-Rods (see Tie-Rod Removal) Rocker Arm (see Rocker Arm Removal) Sleeves [A] Oil Seals [B] Swingarm [C] (see Swingarm Removal) • Remove the needle bearings [D], using the bearing re- mover head and bearing remover shaft.
  • Page 529 SUSPENSION 13-39 Tie-Rod, Rocker Arm ○ Screw the needle bearing driver [A] into the driver holder [B]. ○ Insert the needle bearing driver into the needle bearing [C] and press the needle bearing into the housing until the driver contacts the end surface of the housing. Bearing Pressing Depth: 5.5 mm (0.22 in.) [D] 5.0 mm (0.20 in.) [E] NOTE...
  • Page 530: Rocker Arm/tie-rod Bearing, Sleeve Inspection

    13-40 SUSPENSION Tie-Rod, Rocker Arm Rocker Arm/Tie-Rod Bearing, Sleeve Inspection NOTICE Do not remove the bearings for inspection. Re- moval may damage them. • Visually inspect the locker arm, or tie-rod sleeves [A] and needle bearings [B]. • The rollers in a needle bearing normally wear very little, and wear is difficult to measure.
  • Page 531 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 ................... 14-9 Steering Stem Warp Inspection ..................
  • Page 532: Exploded View

    14-2 STEERING Exploded View...
  • Page 533 STEERING 14-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Handlebar Bolts Handlebar Holder Bolts Right Switch Housing Screws 0.36 31 in·lb Throttle Case Screws 0.36 31 in·lb Steering Stem Head Nut Front Fork Clamp Bolts (Upper) Steering Stem Nut Left Switch Housing Screws 0.36 31 in·lb...
  • Page 534: Special Tools

    14-4 STEERING Special Tools Head Pipe Outer Race Press Shaft: Steering Stem Bearing Driver, 42.5: 57001-1075 57001-1344 Steering Stem Nut Wrench: Steering Stem Bearing Driver Adapter, 41.5: 57001-1100 57001-1345 Bearing Driver Set: Head Pipe Outer Race Driver, 55: 57001-1129 57001-1446...
  • Page 535: 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 536: Steering Stem

    14-6 STEERING Steering Stem Stem, Stem Bearing Removal • Remove: Upper Fairing (see Upper Fairing Removal in the Frame chapter) Front Wheel (see Front Wheel Removal in the Wheels/Tires chapter) Handlebars (see Handlebar Removal) Steering Stem Head Nut [A] and Washer [B] Steering Stem Head [C] Front Forks (see Front Fork Removal in the Suspension chapter)
  • Page 537: Stem, Stem Bearing Installation

    STEERING 14-7 Steering Stem • Remove the lower ball bearing inner race (with its oil seal) [A] which is pressed onto the steering stem with a suitable commercially available chisel [B]. Stem, Stem Bearing Installation • Replace the bearing outer races with new ones. •...
  • Page 538 14-8 STEERING Steering Stem • Install the stem [A] through the head pipe and install the ball bearing [B] and inner race [C] on it. • Install: Stem Cap [D] Steering Stem Nut [E] • Settle the bearings in place as follows. ○...
  • Page 539: Steering Stem Bearing Lubrication

    STEERING 14-9 Steering Stem NOTE ○ Tighten the upper front fork clamp bolts first, next the stem head nut, last the lower front fork clamp bolts. ○ Tighten the two lower front fork clamp bolts alternately two times to ensure even tightening torque. Torque - Front Fork Clamp Bolts (Upper): 20 N·m (2.0 kgf·m, 15 ft·lb) Steering Stem Head Nut: 78 N·m (8.0 kgf·m, 58...
  • Page 540: Handlebar

    14-10 STEERING Handlebar Handlebar Removal • Remove: Clutch Lever Clamp Bolts [A] Clutch Lever Assembly [B] Left Switch Housing [C] Handlebar Weight [D] • Remove: Front Master Cylinder [A] (see Front Master Cylinder Re- moval in the Brakes chapter) Right Switch Housing [B] Throttle Case [C] Handlebar Weight [D] Throttle Grip [E]...
  • Page 541 STEERING 14-11 Handlebar • Install the handlebar holder with handlebar on the steering stem head. • Tighten the handlebar holder bolts [A] following the tight- ening sequence [1-2-1]. Torque - Handlebar Holder Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb) • Install the front master cylinder (see Front Master Cylinder Installation in the Brakes chapter).
  • Page 543 FRAME 15-1 Frame Table of Contents Exploded View........15-2 Seat Cover Installation....15-19 Seat ........... 15-10 Seat Cover Disassembly....15-20 Seat Removal ......15-10 Seat Cover Assembly ....15-20 Seat Installation ......15-10 Fenders ..........15-21 Single Seat Cover Removal Front Fender Removal ....
  • Page 544: Exploded View

    15-2 FRAME Exploded View...